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Introduction

Thank you for purchasing a Takamatsu CNC Precision Lathe. This machine is designed and manufactured giving first priority to safety precautions according to nationally recognized standards, so that it can be operated safely. However, safe operation cannot always be ensured if an operator misuses the machine or ignores safety regulations. Failure to comply with these instructions will damage the machine and products as well as result in critical bodily injuries. Read the attached manuals thoroughly and understand the correct procedures for operation so that the machine can be operated efficiently and safely. Ignoring the safety precautions in this Manual will result in bodily injuries. Aside from these precautions, there are many Donts to be observed when operating the machine. It should be considered a Dont if not stated in this Manual. In this Manual, safety instructions are classified into three levels of seriousness regarding personal injury or machine damage, as indicated by the following marks. Pay particular attention to the safety instructions regarding situations that are extremely dangerous.

DANGER

Failure to follow the instructions will result in critical bodily injuries. Failure to follow the instructions will result in serious bodily injuries.

WARNING

CAUTION

Failure to follow the instructions may result in less serious bodily injuries or machine damage.

* The word qualified used in this Manual refers to persons who are qualified to perform operation and maintenance of this machine as authorized by a safety control supervisor. * Outline drawings, dimensions, and types and quantities of parts described in this manual are subject to change according to modifications made to this machine. Check the types and quantities of parts to be replaced, and place an order with Takamatsu.

About This Manual


This Instruction Manual describes the following model : Model : Manufacturer : * Consisting of : Safety Guide Specifications Installation Operation Maintenance Special Version Safety precautions Machine specifications, drawings Machine installation procedures Machine operation procedures Inspection, oiling, trouble shooting, adjustment, replacement Instruction to operate the optional equipment X-10i Takamatsu Machinery Co., Ltd.

If you have any questions or doubts about this instruction manual, feel free to contact us or your local agent at any time.

All rights reserved. No part of this document and attached technical materials (including drawings and technical information disclosed through drawings) may not be disclosed to any third party, nor reproduced in any form or any language without permission from Takamatsu Machinery Co., Ltd.

TAKAMATSU MACHINERY Co., Ltd.


HEAD OFFICE & PLANT 1-8 ASAHIGAOKA MATTO-CITY ISHIKAWA JAPAN, 924-8558 TEL 81-76-274-1403 FAX 81-76-274-8530 EUROPE OFFICE IMMERMANNSTRASSE 65C D-40210 DUSSELDORF GERMANY TEL 49-0211-1677290 FAX 49-0211-8604542 BANGKOK OFFICE 3RD FL., RUAM DANU THAI LANG SUAN BLDG., 34/3 SOI LANG SUAN, PLOENCHIT ROAD, LUMPINEE, PATHUMWAN, BANGKOK 10330 THAILAND TEL 66-2-652-1764 FAX 66-2-652-1765 TAKAMATSU MACHINERY USA INC. 1320 LANDMEIER ROAD ELK GROVE BILLAGE, IL 60007 USA TEL 1-847-981-8577(8559)(8569) FAX 1-847-981-8599

Safety Guide

Contents
Chapter 1 Basic Conditions for Safe Operation ....................................................... Chapter 2 Preparation for Safe Operation ............................................................... Chapter 3 Name of Each Component ........................................................................ Chapter 4 Warning Labels ......................................................................................... Chapter 5 Safety Devices ............................................................................................ 1 3 6 7 9

Chapter 6 Hazardous Area ......................................................................................... 11 6-1 Machine Movable Area ................................................................................. 11 6-2 High-voltage Area ......................................................................................... 12 Chapter 7 Safety Precautions for Fire Prevention ................................................... 13 Chapter 8 Safety Precautions ..................................................................................... 8-1 Basics ............................................................................................................. 8-2 Installation ..................................................................................................... 8-3 Turning Power ON/OFF ................................................................................ 8-4 Warming Up .................................................................................................. 8-5 Setting Up ...................................................................................................... 8-6 Operation ....................................................................................................... 8-7 Finishing Operation ....................................................................................... 8-8 Maintenance................................................................................................... 14 14 15 17 17 18 19 21 22

Chapter 1 Basic Conditions for Safe Operation

Chapter 1 Basic Conditions for Safe Operation


The following are the basic conditions that must be strictly observed.

Only qualified personnel should do the handling of the machine. Those who can operate and maintain the machine should be furnished with the necessary training, be knowledgeable about safe operation, and be qualified by an authorized person in safety maintenance. Establish in-shop regulations for qualification standards. Electrical maintenance in particular should be carried out by qualified personnel as stated in nationally recognized safety standards and legal and governmental regulations. Our company shall not be responsible for any incidental or consequential damages to the machine, or bodily injuries resulting from any abuse, misuse, misapplication or improper operation by unqualified personnel.

Read the instruction manual carefully and understand the contents thoroughly. The machine is equipped with various manuals for safe operation. These manuals cover all the right procedures and prohibited items concerning machine operation, program creation and maintenance. These should be read carefully before starting operation. The machine should not be operated in any other way than the way described in the manuals. Our company shall not be responsible for any incidental or consequential damages to the machine or bodily injuries resulting from any abuse, misuse, misapplication or improper operation by an unknowledgeable operator.

Always keep the attached manuals besides the machine. Assign someone to keep the manuals at a designated place beside the machine so that they can be used by anybody anytime. If any of the manuals become illegible or lost, contact your local distributor for replacement. Inform us of the machine model and serial number so that the correct manual can be sent to you at your cost.

Chapter 1 Basic Conditions for Safe Operation

The keys should be kept securely by an authorized person. This machine is equipped with keys as safety devices. For safe operation and maintenance, put someone who is knowledgeable about machine operation and safety regulations in charge of the keys. All the persons in charge of machine operation should be aware of the emergency stop button locations, functions and operation. Procedures for communication and necessary measures should be discussed in case of emergency, and stated in the in-shop regulations.

EMERGENCY STOP button Pressing this button stops all the machine motions immediately.
EMERGENCY STOP

* The figure shows the machine equipped with loader.

Fig. 1

* If you have any questions or doubts about the safety instructions described in this guidebook and instruction manuals, feel free to contact your local distributor at any time.

Chapter 2 Preparation for Safe Operation

Chapter 2 Preparation for Safe Operation


Check the following points to operate the machine safely. Installation environment Avoid direct sunlight or heat source which will generate a partial temperature rise.
Ambient temperature: 0 ~ 45C (20C 2 is most recommended.) Change in temperature: Max. 1C/min.

Keep apart from other machines which may splash water, oil or chips. Keep apart from press machines and forging machines to prevent transmission of vibration.
Installation site should be below 0.5G. Take anti-vibration measures if necessary.

Humidity should be below 75% without dew condensation. Installation site should be free from dust, mist, salt, corrosive gas and other hazardous elements. The foundation of the machine should have sufficient strength without inclination or unevenness. Installation and Use cranes and fork lifts which have passed in examinations relocation prescribed in nationally recognized safety standards and legal and governmental regulations. Lifting unit and wire rope should be of the specified size without damage. Handling of cranes, fork lifts as well as slinging work should be done by qualified persons. Lifting and transportation of the machine should be done without giving any vibration or shock.

Chapter 2 Preparation for Safe Operation

Power source and grounding

Electrical connection should be done by qualified electrical engineers. Power voltage 3-phase: 200/220 V 10% Frequency: 50/60 Hz 2 Hz Power cable: Min. 8 mm2 (in the case of single-wire cables) Keep apart from noise sources, such as welding machines, electric discharge machines, etc. Comply with nationally recognized electrical standards and legal and governmental regulations on grounding.
Never use a grounding electrode together with a machine which may generate noise. Independently ground the machine to an electrode. Grounding resistance: Below 100 Grounding cable: Min. 8 mm2 (in the case of single-wire cables)

* For the optional specifications, the electric cables (power cable and
grounding cable) to use may be different in thickness. Contact Takamatsu before connecting the electric cables.

Lubrication

Use designated oil. Never mix with other makers oil. Never use deteriorated oil or oil mixed with foreign objects.

Compressed air Use clean and dry compressed air. Amount of air to supply should be over the designated level. Machine environment The floor should be free from obstacles to machine operation. The floor should be free from water and oil. The working area should be bright enough to ensure safe operation. If not sufficient, use a work light. When connecting the machine with other equipment such as robots and loaders, provide a cover or safety enclosure around the machine movable area to protect operators from touching the machine. Installation site should be equipped with devices for air ventilation, deodorization and exhaust. Provide the work place with appropriate ventilators or exhausting units to clear away dust or gas (flammable gas). If sufficient ventilation is not assured, do not use the machine. Designated fire extinguishers should be provided at specified places near the machine. Prepare a first aid kit at a designated place near the machine. Keep sufficient maintenance area around the machine so that:
1) opening/closing of the doors can be done easily. 2) loading/unloading of workpieces can be easily done. 3) oiling, chip disposal and chip conveyor operation can be done easily.

Chapter 2 Preparation for Safe Operation

Operators clothing

Wear a protective helmet, safety shoes and safety goggles that comply with the necessary safety regulations. Never wear gloves, a ring, a bracelet, a watch, or clothes that are baggy or loose and may be caught up by the machine. Long hair should be tied or covered with a hat to avoid accidents during operation. Those who feel dizzy and cannot judge properly due to drinking, medication or sickness should not operate the machine. Use leather gloves or the like to protect operators hands during setting up. However, the key and switch operation should be done with bare hands. The instruction manual and safety guidebook should be kept by authorized personnel at a designated place near the machine so that they can be accessed at any time. Keys attached to the machine should be kept by authorized personnel. A supervisor for safety control should be responsible for training operators periodically so that environmental conditions can be checked at any time for safety operation.

Safety control system

Chapter 3 Name of Each Component

Chapter 3 Name of Each Component


* Location of components may differ slightly according to optional equipment and destination of shipment.

Spindle

Turret

NC screen

Front door

CNC operation panel

Machine operation panel

Hydraulic pressure gauge

Air unit Lubrication unit Foot switch Electric cabinet Main power switch

Absolute pulse coder battery case

Coolant pump motor Hydraulic pump unit

Coolant tank

* The figure shows the machine equipped with loader.

Fig. 2 6

Chapter 4 Warning Labels

Chapter 4 Warning Labels


The machine is equipped with warning labels for safe and correct operation. Read and understand the cautions printed on the warning labels before starting operation. If any of the labels become damaged and illegible, contact your local distributor for replacement.

WARNING

Never remove or relocate warning labels.

Standard specification

loader specification

* The figure shows the machine equipped with loader.

Fig. 3 7

Chapter 4 Warning Labels

Safety Instructions
1. NEVER allow anyone to operate and service this machine except qualified personnel trained for it. 2. NEVER operate this machine in any way until you have read the manuals provided with the machine. 3. ALWAYS understand and obey all instructions and recommendations on the labels attached to the machine and in the manuals provided. 4. Be sure that all personnel know the location of the EMERGENCY STOP BUTTON and how to use it properly. 5. ALWAYS shut off the machine before servicing. 6. NEVER remove warning plates. Keep them clean all times. Failure to follow these instructions can result in personal injury or machine damage. If you have any questions or doubt on these instructions, contact your supervisor or distributor immediately. TAKAMATSU MACHINERY CO., LTD.

DANGER
NEVER open door. Only for qualified service personnel.
Shut machine off before opening the door. NEVER touch inside soon after shut-off due to lethal voltage. NEVER touch inside parts with wet hands.

DANGER WARNING
NEVER open front door during auto operation.

WARNING
Keep away from movable parts, such as spindle or turret, during operation. Shut machine off before reaching movable parts for servicing.

WARNING
NEVER open this cover. Only qualified service personnel can have access. Shut the machine off before servicing.

WARNING
NEVER extend bar out of spindle rear side. Bar can be waved about. NEVER insert bar during spindle rotation.

WARNING
Crush hazard in loader work range during operation or servicing. NEVER reach into the cover. Shut power off before servicing inside the cover.

Chapter 5 Safety Devices

Chapter 5 Safety Devices


The machine is equipped with various safety devices as shown below to protect both an operator and the machine from injuries and damage. Check and understand the location of each safety device and its functions before starting operation.

DANGER

Never remove or modify safety devices, or stop their functions without our permission in advance. The covers without open/close switch and the doors of the electrical cabinet should not be opened by unauthorized personnel. Before starting operation, check that each safety device can function properly. If there is any problem, contact your local distributor immediately.

WARNING

Front door Reinforced cover to prevent chips, workpieces and jaws from splashing

Edit key switch Protects programs from being modified by mistake. Door interlock switch Stops the spindle rotation and the slide motion if the front door is opened during automatic operation. Lubricant alarm lamp Lights up if lubricant in the tank becomes insufficient. Turret alarm lamp Lights up or blinks if an error has arisen in the turret. Sequence alarm lamp Lights up or blinks if an error has arisen in the components. EMERGENCY STOP button Pressing this button stops all the machine motions immediately.

Chuck ID/OD change-over switch (optional) For changing over ID or OD gripping of chuck. The switch cannot be changed over when the power is turned on. * The figure shows the machine equipped with loader.

Fig. 4 9

Chapter 5 Safety Devices

8. Electric cabinet door interlock (optional) 1. Z-axis limit switch

3. Turret clamp limit switch

2. X-axis limit switch

6. Chuck clamp detector (optional) 7. Hydraulic pressure switch (optional) 5. Door interlock switch

9. Tailstock limit switch (optional) 4. Lubricant float switch

1 2 3 4 5 6 7 8 9

Prevents the Z axis from overrunning. Prevents the X axis from overrunning. Checks a clamping motion of the turret. Checks a lubricant level. Checks if the door is closed. Checks if the chuck is opened or closed. (Optional) Checks the hydraulic pressure. (Optional)

A soft limit is also provided besides this. A soft limit is also provided besides this. Automatic operation cannot be started without a clamp confirmation. Automatic operation cannot be started without lubricant. Automatic operation cannot be started if the door is open. Automatic operation and the spindle rotation are not allowed unless the switch is turned on. Automatic operation cannot be started if the cylinder pressure is low.

Checks if a door of electric cabinet is closed. The primary power is shut off if the door is opened. (Optional) Checks the position of the tailstock spindle. (Optional) Automatic operation cannot be started if the position is not confirmed.

Fig. 5

10

Chapter 6 Hazardous Area

Chapter 6 Hazardous Area


6-1 Machine Movable Area
It is very hazardous inside the machine during automatic operation because of high-speed spindle (chuck) rotation, X/Z-axis movements and turret rotation. Besides, chips and coolant splash in a hot and humid space.

WARNING

Never open any cover or door mounted on the machine during automatic operation and spindle rotation. Even in any other status than automatic operation, utmost care should be taken if it is needed to enter such a hazardous area or touch movable sections for setting up or maintenance work while the power is turned on.

Inside the front door is hazardous.

Chip discharge port is hazardous.

* The figure shows the machine equipped with loader.

Fig. 6

11

Chapter 6 Hazardous Area

6-2 High-voltage Area


DANGER

The electric cabinet, motors, transformers, and relay boxes (connectors) have high-voltage terminals. Maintenance of these units should be done only by the authorized personnel for electrical construction.

Inside the electric cabinet is hazardous. The door cannot be opened/closed without a key. The key should be kept by a person in charge.

Hydraulic pump motor power connector

Coolant pump motor power connector

* The figure shows the machine equipped with loader.

DANGER

Never touch the area marked with even if the main power switch is off, as high-voltage of 200 V is supplied up to the main power switch when the power in the factory is turned on. Failure to observe this warning will result in critical bodily injuries.

Fig. 7

12

Chapter 7 Safety Precautions for Fire Prevention

Chapter 7 Safety Precautions for Fire Prevention


To perform machine operation continuously in safety, follow the precautions for fire prevention described below. WARNING When coolant is used for cutting, there is a possibility of catching a fire from high-temperature chips, frictional heat at the tool, sparks during cutting, etc. Follow the safety precautions described below and take sufficient measures to prevent fire.

(1) Coolant 1. Use non-flammable coolant. Even if non-flammable coolant is used, lubricant may be mixed into coolant. Follow item 2. and take sufficient measures for safety. 2. If oil-based coolant must be used unavoidably: 1) Check the tool edge condition as well as possible tool life, and select cutting conditions under which no ignition will occur. 2) An insufficient amount of coolant could cause fire. Always check the amount of coolant. 3) To assure a sufficient amount of coolant at the point of cutting, clean the coolant filter at regular intervals, and check that coolant is sufficiently discharged from time to time. 4) Provide a fire extinguisher nearby, and always stay alert to fire. Also, take additional precautions against fire by installing an automatic fire extinguisher, etc. 5) Do not place any flammable things around the machine. 6) Do not allow chips to accumulate. 7) Clean the inside and surrounding of the machine at regular intervals, and check that every equipment is working in good order. 8) Do not perform unattended operation. 9) Install an automatic fire extinguisher. (2) Flammable Material Cutting When cutting flammable material (solid), resin, rubber or wooden material, understand properties of the material and take appropriate measures against fire. (3) Dry Cutting Do not allow chips to accumulate during dry cutting. Follow item 2. above and take sufficient measures for safety.
13

Chapter 8 Safety Precautions

Chapter 8 Safety Precautions


8-1 Basics
DANGER

High-voltage mark

The electric cabinet, motors, transformers, and relay boxes (connectors) are equipped with high-voltage terminals. Access to these by unauthorized personnel is strictly prohibited as it is very dangerous. Never remove or modify any covers, switches or doors mounted for safety without our permission. Understand the operation switches and relative machine motions thoroughly before operating them. Never use machine in an atmosphere having a possibility of explosion. Never touch on switches and keys with wet or dirty hand. Never operate any switches before you have realized their resulting motions. Check each switch and key before using them. Never touch any key or switch if not needed, or lean against the machine unconsciously. Always be aware of the emergency stop button locations and operation so that they can be operated quickly in emergency. This should be understood by all the personnel concerned. Stop operating the machine in case of abnormal lightning or repeated power failure in order to avoid accidents. Keep the floor clean and dry. Slippage can easily occur if there is oil or water on the floor. Keep flammable materials and liquid away from the working area as prescribed in nationally recognized safety standards and legal and governmental regulations. The machine should be operated only by one qualified operator. Those who feel dizzy or cannot judge properly due to drinking, medication or sickness should not operate the machine.

WARNING
EMERGENCY STOP

14

Chapter 8 Safety Precautions

CAUTION

Oil to use should be new and clean, and as designated in the instruction manual. Any other oil than specified may result in machine trouble. Replacement parts should be as designated by Takamatsu. Wear proper clothes for operation.
Never wear a ring, a bracelet, a necklace or a watch during operation. Always wear a protective helmet, safety goggles and safety shoes. Never wear baggy or loose clothes.

Turn off the main power switch immediately in case of power failure. Never give an excessive shock to the machine operation panel or the electrical cabinet. Keep the tools and workpieces orderly in the following ways.
Keep them so that they may not fall. When placing tools and parts upright or resting against something, take necessary measures to prevent them from falling. When piling parts and workpieces up, take necessary measures to prevent them from falling off.

Never place tools and workpieces anywhere on the machine even if it is not a movable section. Keep sufficient working area and remove obstacles from around the machine. A work table to place cutting tools and workpieces should be rigid enough and so designed to prevent tools and workpieces from slipping or falling. Coolant should not be handled with bare hands. Never operate the machine while wearing gloves. (Use gloves when handling cutting tools, workpieces, chips and when cleaning the machine.)

8-2 Installation
DANGER

Power connection, crane and fork lift operation and slinging work should be done only by qualified personnel. Never put your body partially or wholly under the lifted machine. When placing electric cables over the floor, use rigid covers to protect them from being damaged by chips and workers. Transportation and installation of the machine should be done by qualified personnel according to Installation Power cables from the primary terminal in the factory to the main power switch should have a rated cross sectional area in order to supply stable power required for operation.

WARNING

15

Chapter 8 Safety Precautions

WARNING

Check the following points to ensure safety at the installation site.


When foundation bolts are buried, mark these points clearly to protect workers from stumbling over and the machine and carriages from bumping. When a pit is provided for waste oil, chips and piping, mount a tentative cover to protect workers from falling down. The floor should be clean and dry, and free from obstacles, oil and waste oil in order to protect workers from slipping or falling.

Use a stable step or platform when it is needed to reach a high level. Never put your fingers between the bed and the floor when locating the machine at a designated place. When lifting a machine, use wire rope, shackles and hoisting jigs that are rigid enough to withstand the machine weight. When working in a team, choose a leader to give instructions.
Give signals with one another to check other workers safety before going to the next step. Follow the procedures step by step.

Never give excessive shock to the machine during lifting and transporting. When rust preventive oil is applied to the slideways, remove it thoroughly with cleaning oil before starting operation. Remove eye bolts used for transportation as well as other fixing jigs and wood used as shipping brackets. Levelling of the machine should be accurate. (Adjust levelling referring to the attached inspection sheet.) When installation is finished, check the following points before turning on the power.
All the bolts and connectors are securely tightened. Hydraulic hose, air hose and other piping are securely connected and fixed. New grease and oil are properly supplied to each section as instructed. Water and dust on the machine are all wiped off. There is no oil leakage around the machine.

CAUTION

16

Chapter 8 Safety Precautions

8-3 Turning Power ON/OFF


DANGER

Before turning the power on, check that all cables are properly insulated. Damaged or disconnected cables should be immediately repaired or replaced by qualified personnel, as they could cause an electrical shock or leakage later.

WARNING

Turn the power on/off as described in Operation. Check that all the safety devices are properly functioning. Check that all the covers are free from damage and securely closed. Check that all the cables installed on the floor have protective covers or other means to protect them from being damaged. Check the following items after turning the power on.

CAUTION

Check that there is no alarm display on the NC screen. Check that the hydraulic pressure and air pressure are correctly set. Check that there is no abnormal noise generated from the motors or gears. Check that the spindle and slideways are properly lubricated.

Check all the items for starting operation one by one as described in Maintenance. After stopping the machine for a long period of time, check that the motions, noise and slideway lubrication are free from trouble. If any abnormality is found, turn off the power immediately and inform the person in charge, then take necessary measures.

8-4 Warming Up
CAUTION

After turning the power on, perform warm-up operation sufficiently.


Mount no workpiece at this time. Programs for automatic operation should include each function of the machine. Change the spindle speed from low (500 min-1) to intermediate (2500 min-1), and warm up for about 10 minutes at each speed. Before rotating the spindle with a chuck on it, check that the chuck and jaws are securely fixed.

17

Chapter 8 Safety Precautions

8-5 Setting Up
DANGER
Operation of crane and fork lifts as well as slinging work should be done only by qualified personnel. Setting up should be done after turning the main power switch off. If the main power switch should remain on, be aware of the location of an emergency stop button to press at any time. Always wear a protective helmet during setting up and cleaning. When working at a high level, use a stable platform, steps or ladders. When working in a team, give signals with one another and check given signals before going to the next step. Do not go to the next step if there is no response from your partner. Never stand or work on the machine. If it is needed to stand on the machine, wear a protective helmet, leather gloves and other protective clothes. Use proper hoisting devices to handle heavy items. Wire ropes and slings are rigid enough for a designated weight. Check that the wire rope to use is free from disconnection, abnormal deformation, corrosion, kink, etc. Pay attention to the chuck when stepping on the foot switch so that a part of your body may not be caught in it. Dull or unstable cutting tools will cause damage or accidents. Replace with proper tools in advance. When mounting a workpiece, check that it is securely fixed by a chuck and a jig. Tightening and loosening of jigs and bolts should be properly done while keeping your balance so that you may not touch or fall over hazardous part of the machine. Never stand in the rotating direction of the spindle, as a workpiece, jaws or tools may fall off during setting up or trial running and cause bodily injuries. Always wear leather gloves during setting up and cleaning. The length and diameter of the cutting tools should be proper so that each cutting tool cannot interfere with the chuck, turret, cover, etc. Never touch cutting tools with bare hands. After finishing setting up, keep used tools and equipment in the designated place.

WARNING

CAUTION

18

Chapter 8 Safety Precautions

CAUTION

When handling a heavy item of more than 20 kg, make a team for cooperative work or use proper transporters. After mounting cutting tools on the turret, check that they are securely fixed without backlash and well balanced. Tools used for setting up should be suitable for the machine specifications. Spanners to use should fit nuts and bolts to avoid accidental slippage.

8-6 Operation
DANGER

Never remove a safety cover or safety device partially or wholly. It is strictly prohibited to operate the machine while exposing a high-voltage terminal. Removing or relocating limit switches, dogs and interlocking mechanism should be strictly prohibited. Never touch any switch or button with wet hands.

WARNING

High-speed moving sections, turret rotating section, and spindle rotating section should be isolated from operators during automatic or manual operation. Access or entry to these areas during operation is strictly prohibited. If it is needed to enter such an area for maintenance and other purposes, turn off the power in the designated procedures. Failure to observe this will cause a critical accident. When machining a bar material without using a bar feeder, the bar material should not stick out from the spindle rear as it is hazardous when the spindle rotates. When chucking a workpiece, apply most suitable pressure to the chuck and the turret according to the workpiece material, gripping amount and machining conditions. Check that the chuck rotation speed does not exceed the allowable range. Before starting unattended operation or leaving the machine for a long time, check the following points to prevent fire.
Check that used coolant is nonflammable. Check that the amount of lubricant and coolant is sufficient, and its operation is properly done. Check the tool cutting edge status, cutting conditions, cutting time and tool life. Check there is no wood, paper, cloth and other flammables around the machine.

19

Chapter 8 Safety Precautions

WARNING

Check that the chip conveyor is properly operating and chips are smoothly disposed of. Chapter 7 Safety Precautions for Fire Prevention

The following are strictly prohibited during machine operation. Stop the machine first if any of the following is needed.
Never adjust the coolant nozzle direction or coolant flow during spindle rotation. Never remove chips around a tool during spindle rotation. Never replace or tighten a cutting tool on the turret during machine operation. Never remove chips or clean the machine during operation. Never change the chuck pressure during machine operation.

Never change the chuck gripping direction while a workpiece is chucked. Before unloading a finished workpiece, check that the spindle is stopped and automatic operation is finished. Never enter the chip conveyor working area during operation. Turn the main power switch off when suspending operation and leaving the machine for a while. Close the front door tightly before starting automatic operation. Keep the doors and covers on the machine closed during automatic operation. Before starting operation, check that there is nobody or nothing inside the machine movable section. If the machine stops during automatic operation for some reason, check the trouble status and take necessary measures before removing the cause. Restarting before taking proper measures must be avoided. Noise during machining may exceed 70 dB, resulting in damaging your hearing ability. Use protective articles (headphones, etc.) as appropriate. Never touch any switch or key if not needed. Never lean against the machine during automatic operation. Never operate the machine while leaving a tool, cutter or measuring instrument inside or around the machine. When starting automatic operation for the first time, check that the program is correctly made and all the switches for automatic operation (dry run, override, coolant control, etc.) are correctly set. Discharge chips regularly so that they may not remain inside the machine. When machining special workpieces, check the characteristics in advance and wear necessary protective clothes.

CAUTION

20

Chapter 8 Safety Precautions

CAUTION

Note the following points so that you will not be caught in the machine movable section.
Long hair should be tied or covered with a helmet. Tie the hem of loose and baggy pants. Button up your clothes.

If any abnormality is found during operation, stop the machine immediately and inform the supervisor. Modification of parameter setting should not be done without our permission. When an alarm message is displayed or an alarm indication lamp is illuminating, take necessary measures immediately (such as informing a person in charge). Chips should not be removed from the cutting edge with bare hands. Always use gloves and a brush. Never touch tools or workpieces with hands immediately after cutting. These can be extremely hot. Be sure not to touch the work light as it becomes very hot after being operated for a long time. Never touch any switch or button with gloves on, as it could result in malfunction or damage to the machine.

8-7 Finishing Operation


After finishing all the operation, check that the primary power in the factory is completely turned off. Before cleaning the machine and peripheral equipment such as a chip conveyor, stop all the machine motions, turn off the main power switch and the primary power in the factory, and put a tag or a placard saying Cleaning!. Never use an air gun for cleaning the machine, as it may help coolant permeate into the spindle bearing and shorten the bearing life. Use soft and clean cloth and clean the spindle carefully. When finishing operation, check that each section of the machine is in the initial status. Wear gloves when removing chips and workpieces. Handle the solenoid valve carefully as it remains hot for a while even after the power is turned off. When stopping the machine for a long period of time, apply rust preventive oil slightly to ground surfaces.

DANGER

CAUTION

21

Chapter 8 Safety Precautions

8-8 Maintenance
Turn the main power switch off during maintenance work. The primary power in the factory also should be off for maintenance of the electric cabinet. Never open the door in five minutes after turning the power off, as residual voltage remains. When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake. Never modify or remove safety devices such as limit switches, proximity switches and dogs for overtravel and interlock without our permission. Failure to observe this warning will result not only in machine malfunctioning or damage, but also critical bodily injuries. The cover should not be opened by unqualified personnel for maintenance. Turn the main power switch off when it is needed to work inside the cover. Wear a protective helmet during maintenance work. Use stable ladders, platform, etc., when working at a high level. Maintenance work should be done only by qualified personnel. Mount the covers on the initial positions correctly after finishing maintenance work, and lock the doors with a key securely. After finishing maintenance work, keep the used tools, etc. orderly, and remove all the obstacles, water and oil from the floor in order to restore proper working environment. Procedures and methods described in Maintenance should be strictly observed. Contact your local distributor immediately when any question or doubt arises. Check each item after finishing maintenance work together with a person in charge. Observe periodical check-ups as described in Maintenance. Keep a maintenance record, and report it to a person in charge for approval and examination. Keep the maintenance record for 10 years. Replacement parts (electrical and mechanical) should be as designated by Takamatsu.

DANGER

WARNING

CAUTION

22

Specifications

Contents
Chapter 1 Machine Appearance ................................................................................ 1-1 Name of Each Component ............................................................................. 1-2 Dimensional Drawing .................................................................................... Chapter 2 Machine Specifications ............................................................................. 2-1 Standard Specifications ................................................................................. 2-2 Standard and Optional Accessories ............................................................... Chapter 3 Controller Specifications .......................................................................... 3-1 Standard Specifications ................................................................................. 3-2 Optional Specifications.................................................................................. Chapter 4 Major Units ................................................................................................ 4-1 Headstock Unit .............................................................................................. 4-1-1 Spindle .............................................................................................. 4-1-2 Spindle Nose Drawing ...................................................................... 4-1-3 Chuck Mounting Drawing ................................................................ 4-1-4 Spindle Motor Characteristic Diagram ............................................. 4-2 Turret Unit ..................................................................................................... 4-2-1 Tooling System Drawing .................................................................. 4-2-2 Turret Interference ............................................................................ 4-3 Slide Unit ....................................................................................................... 4-4 Hydraulic Pump Unit ..................................................................................... 4-4-1 Assembly Drawing of Hydraulic Pump Unit .................................... 4-4-2 Hydraulic Circuit Diagram ............................................................... 4-4-3 Arrangement of Valves ..................................................................... 4-5 Lubricant Unit................................................................................................ 4-5-1 Lubrication System Diagram ............................................................ 4-6 Coolant Unit .................................................................................................. 4-6-1 Coolant System Diagram .................................................................. 4-7 Air Unit (optional) ......................................................................................... 1 1 2 3 3 4 5 5 6 7 7 7 8 9 10 11 11 12 13 14 14 15 16 17 17 18 18 19

Chapter 5 Electrical Drawings ................................................................................... 5-1 Connection Diagram ...................................................................................... 5-2 Electric Circuit Diagrams .............................................................................. 5-3 Parts Arrangement in Electric Box ................................................................ 5-4 Electric Parts List (standard) .........................................................................

20 20 21 36 37

Chapter 1 Machine Appearance

Chapter 1 Machine Appearance


1-1 Name of Each Component

No. 1 2 3 4 5 6 7 8 9 10 11 12

Name Electric cabinet Turret clamp valve Z-axis limit switch (Omron) X-axis servo motor (C4i) Turret index motor (Mitsubishi) Turret housing X-axis limit switch (Omron) Hydraulic pump (0.75 kW) Spindle motor (AC 3.7/5.5) Foot switch Bed 8-station turret

No. 13 14 15 16 17 18 19 20 21 22 23 24 Saddle Slideways

Name Lubrication pump

Coolant pump (250 W) Tailstock (MT-3) optional Quill advance/retract valve optional Z-axis servo motor (8i) Chucking cylinder (solid 15st.) Headstock 6" hydraulic chuck Operation panel Chuck valve

Fig. 1 Machine appearance and name of each component


1

Chapter 1 Machine Appearance

1-2 Dimensional Drawing

*Dimensions may differ depending on optional accessories and/or the specifications.

Fig. 2 Dimensional drawing

Chapter 2 Machine Specifications

Chapter 2 Machine Specifications


2-1 Standard Specifications
Item Optimum turning dia. Optimum turning length Chuck size Maximum swing Max. bar dia. Maximum turning dia. Maximum turning length Spindle nose Spindle bearing I.D. Hole through spindle Max. speed Type Max. tool size Max. boring holder I.D. Max. stroke Rapid traverse rate Spindle motor Feed motor Coolant motor Hydraulic motor LxWxH Machine weight Total power capacity Controller Unit mm mm inch mm mm mm mm JIS mm mm min-1 stations mm mm mm m/min kW kW kW kW mm kg kVA X Z X Z Specifications 60 50 6 (8) 320 Solid (26, 35, 42) 180 190 A2 - 5 75 (85) 46 (52) 3,500 (4,500) 8 20 sq. 25 120 [90] 230 12 18 AC 5.5/3.7 (AC 7.5/5.5) X: AC 1.0, Z: AC 1.6 AC 0.25 AC 0.75 1,370 1,360 1,720 2,200 13.1 (For AC 7.5/5.5: 16.3) TAKAMAZ FANUC 21i-TB

* The figure in parentheses is that for optional features. * [ ]: For the tailstock specification * The machine weight differs depending on the specifications. * The total power capacity differs depending on the specifications.

Special Version as for details of optional equipment such as a tailstock unit, etc.

Size

Motor

Turret

Spindle

Capacity

Chapter 2 Machine Specifications

2-2 Standard and Optional Accessories


Standard accessories
Boring holders OD nozzle Collet flange Collet chuck (Takamaz standard) Hydraulic cylinder (solid) Coolant unit Work light Splash guard Tool kit Instruction manuals 2 sets 8 sets 1 pce 1 pce 1 set 1 set 1 set 1 set 1 set 1 set

Optional accessories
Collet chuck Hydraulic chuck Tailstock 60 Compact loader CR60 Compact loader Thread cutting device Special spindle speed (4500 min-1) Bar feeder system Boring holder Turning holder Double-tool holder (with or without tailstock) Chip conveyor (Chip disposal to the right/rear) Air blower Signal light Auto. door Electro-magnetic counter Hydraulic cylinder (Kitagawa SS1236-102, Nikko 46FS-Ta, SMW)

Chapter 3 Controller Specifications

Chapter 3 Controller Specifications


3-1 Standard Specifications
Item Controlled axis Least input increment Least command increment Auxiliary function Spindle function Tool function Tape code Cutting feedrate Command system Interpolation Cutting feed override Rapid traverse override Program number Backlash compensation Part program storage length Tool offsets Registered programs Tool geometry/wear offset Canned cycle Radius designation on arc Direct input of tool offset value measured A Background editing Chamfering/corner R Custom macro B Nose R compensation Inch/metric conversion Programmable offset data input Clock function Help function Alarm history Self-diagnosis function Sub-program call Decimal point input 2nd reference point return Stored stroke limit check Input/output interface (RS232C) TAKAMAZ FANUC 21i-TB Simultaneous controllable axes: 2 0.001 mm X: 0.0005 mm, Z: 0.001 mm M-3 digit S-5 digit T-4 digit EIA/ISO automatic recognition 1~5,000 mm/min. Absolute/incremental Linear/circular 0~150% F0, 100% 4 digits 0~9999 m 40 m 16 sets 63 pcs Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard 50 Standard up to 4 loops Standard Standard Standard Standard

Chapter 3 Controller Specifications

3-2 Optional Specifications


Item Constant surface speed control Multiple repetitive cycles Additional tool offsets Extended part program function Part program storage length Run hour/parts count display Continuous threading Multiple M code in one block Spindle orientation Work coordinate system selection Drilling cycle Tool life management Automatic zero return TAKAMAZ FANUC 21i-TB G96, G97 G70 - G76 32 sets, 64 sets 80 m, 160 m G33

G54 - G59 G83

Chapter 4 Major Units

Chapter 4 Major Units


4-1 Headstock Unit
The headstock unit consists of the spindle, hydraulic cylinder, etc. A solid hydraulic cylinder is used as standard, thus increasing rigidity of the spindle within a limited space. The spindle is driven by an AC spindle motor. The spindle bearing is grease-lubricated, and needs to be replaced every three years. Contact us when replacing the spindle bearing. Spindle speed Max. 3,500 min-1 Max. 4,500 min-1 (optional)

4-1-1 Spindle

Encoder Double-row cylindrical roller bearing Hydraulic cylinder Thrust angular ball bearing Hydraulic chuck (solid)

Collet chuck (solid) Double-row cylindrical roller bearing

Fig. 3 Structural drawing of headstock


7

Chapter 4 Major Units

4-1-2 Spindle Nose Drawing

Standard: solid type

depth 31

26 through type

35 through type

Fig. 4 Spindle nose drawing 8

Chapter 4 Major Units

4-1-3 Chuck Mounting Drawing

Collet chuck

M10, depth 20

Power chuck

ZA5-6-0-05 (Matsumoto)

Fig. 5 Chuck mounting drawing

Chapter 4 Major Units

4-1-4 Spindle Motor Characteristic Diagram

3.7/5.5 kW (Max. 3,500 min-1)


5.5 kW 30 min. 50% ED area

3.7/5.5 kW (Max. 4,500 min-1)


5.5 kW 30 min. 50% ED area

Output kW

3.7 kW cont. area

Output kW

3.7 kW cont. area

Speed min-1

Speed min-1

5.5/7.5 kW (Max. 3,500 min-1)


5.5 kW 30 min. 50% ED area

5.5/7.5 kW (Max. 4,500 min-1)


5.5 kW 30 min. 50% ED area

Output kW

3.7 kW cont. area

Output kW

3.7 kW cont. area

Speed min-1

Speed min-1

5.5/7.5 kW (Max. 6,000 min-1)

7.5 kW 30 min. 50% ED area

Output kW

5.5 kW cont. area

Speed min-1

Fig. 6 Spindle motor characteristic diagram

10

Chapter 4 Major Units

4-2 Turret Unit


The turret has 8 stations to mount turning or rotating tools. Clamping and unclamping motions of the turret are hydraulically controlled. Indexing is driven by a servo motor, and high-speed indexing is assured due to a random selection system. 4-2-1 Tooling System Drawing
OD/face/grooving tool 20 sq.

Clamp block C

Tap

Tap holder

Round hole bush

ID holder

Boring bar

Blank 25 Boring holder

Center straight drill

Drill chuck

Drill chuck arbor

Drill socket

Double boring holder 25

Taper drill

Drill Sleeve

OD nozzle

U-drill

Round hole bush

U-drill holder Option: Tailstock specification

Boring bar

Center straight drill Blank

Double boring holder 20

Fig. 7 Tooling system drawing


11

Chapter 4 Major Units

4-2-2 Turret Interference

Distance between centers

Distance between centers Distance between centers

Standard specification

Standard specification Distance between centers

Distance between centers Distance between centers Tailstock specification

Tailstock specification

Fig. 8 Reference drawing of turret interference

12

Chapter 4 Major Units

4-3 Slide Unit


The X and Z axes are driven by AC servo motors via ball screws, thus moving on the square slideways. Max. rapid traverse rate: In the X-axis direction 12 m/min. In the Z-axis direction 18 m/min.
OD turning range

Z-axis stroke

Standard collet
Matusmoto

Nikko

Tailstock spindle stroke

Tailstock slide stroke

ID turning range

Z-axis stroke

Standard collet
Matusmoto

Nikko

Tailstock spindle stroke Tailstock slide stroke

Fig. 9 Stroke drawing


13

X-axis stroke (tailstock specification)

X-axis stroke (tailstock specification)

Chapter 4 Major Units

4-4 Hydraulic Pump Unit


The hydraulic pump is used to drive the spindle chucking cylinder (for clamping and unclamping motions) and the turret (for clamping and unclamping motions). Tank capacity: 10 lit.
* Specifications are subject to change according to the improvement of the machine. Check the types and quantities of parts to be replaced, and place an order with Takamatsu.

4-4-1 Assembly Drawing of Hydraulic Pump Unit

8. External
Nut (2-M8)

A-A section (base notch details) Oil filler port in the casing Remove the piping joint before oiling.

Drain port (Rc 1/4) Pressure adjustment screw (Pressure increase by turning to the right)

Terminal box

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Name Piston pump Tank filter Tank Radiator Oil level gauge Oil filler port/air breather Magnet Pressure gauge (with glycerine) Solenoid valve Reducing valve Check valve Check valve Direct drive motor

Type P8VMR-10-CB-10 MSY-04-150M (100 m) 10L RA-1-N01 OLG2-60K-M8 MSA-V30 MG40 ATR 1/4 60 7 MPa DG4SM-3-2N-P7-H-52 TGMX2-3-PP-BW-G-50 BH40028525 HTIC-03-04-10 0.75kW4P

Maker Tokimec Masuda Tokimec Nakamura Jiko Kinoshita Masuda Osaka Magnet Asahi Keiki Tokimec Tokimec Tokimec Tokimec Toshiba

Fig. 10 Hydraulic pump unit 14

Chapter 4 Major Units

4-4-2 Hydraulic Circuit Diagram

Turret clamp

Spindle chuck
Tailstock

Optional

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Tank filter Tank Radiator

Name Piston pump motor

Type P8NMR-10-CB-10 MSY-04-150M (100 m) 10L (2.6 gal.) RA-1-No1 (1013-201-138) OLG2-60-M8 MSA-V30 MG40 ATR 1/4 60 7 MPa DG4SM-3-2N-P7-H-52 TGMX2-3-PP-BW-G50 BH40028525 HTIC-03-04-10 0.75 kW 4P SL-G01-H3X-GR-D2-5195A 2755002009 ACC-05-C1 MBG-1 SL-G01-E3X-R-D2-5195A 0GB-G01-AC-20 MBS-1-10 ATR 1/4 60 5 MPa HT-720-03

Maker Tokimec Masuda Tokimec Nakamura Jiko Kinoshita Masuda Osaka Magnet Asahi Keiki Tokimec Tokimec Tokimec Hirose Toshiba NACHI Takamaz ASK Kanazawa Kiko NACHI NACHI NACHI Asahi Keiki Hirose

Oil level gauge Oil filler port air breather Magnet Pressure gauge (with glycerine) Solenoid valve Reducing valve Check valve Check valve Direct drive motor Solenoic valve Check plate Check valve Manifold Solenoid valve Reducing valve Manifold Pressure gauge (with glycerine) Flow regulator

Fig. 11 Hydraulic circuit diagram

15

Chapter 4 Major Units

4-4-3 Arrangement of Valves

Turret clamp valve Tailstock valve (optional)

Chuck clamp valve

Fig. 12 Valve layout drawing

16

Chapter 4 Major Units

4-5 Lubricant Unit


This unit is used for lubricating slideways and ball screws forcibly at intervals of 30 min. If lubricating oil decreases quickly, a tube or flow distributor may be damaged. Effective tank capacity: 1.5 lit. (Tank capacity : 2 lit.)
* Specifications are subject to change according to the improvement of the machine. Check the types and quantities of parts to be replaced, and place an order with Takamatsu.

4-5-1 Lubrication System Diagram

Z Wear plate R Z Slide R Z Gib Z Slide F2 Z Slide F1 Z Wear plate F


Nylon 4 Nylon 4 Nylon 4 Nylon 4 Nylon 4 Nylon 4 Nylon 4 Nylon 4

Nylon 4 Nylon 4 Nylon 4 Nylon 4

X Slide F1 X Slide F2 X Ball screw X Slide R


Nylon 4

X Gib
Nylon 4 Nylon 4 Nylon 4 Nylon 4

Z Gib Z Wear plate F Z Ball screw Z Slide F1


Nylon 4
Nylon 4 Nylon 4

Z Slide F2 Z Slide R

Nylon 4 Nylon 4

Z Wear plate R

Optional
Nylon 4 Nylon 4

Nylon 4

Tailstock

Unit code
Standard w/ tailstock Takamatsu 1751001015 1751002013 Showa 161019-050R3 161019-064R3

Oil amount with 3 cc/30 min setting


Distributor type PSS0 PSS1 PST0 PST1 Total Oil amount 0.125 0.25 0.125 0.25 2.05 Oil amount (w/ tailstock) 0.12 0.24 0.12 0.24 3.0 Oiling positions (w/ tailstock) 10 (10) 5 (5) 2 (3) 1 (1) 18 (19)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Part Name Semi-cycle pump Flow distributor Flow distributor Flow distributor Flow distributor Tightening plug Distributor nut Sleeve Nipple Elbow Dester-uni Dester-uni Dester-uni Connector Elbow Flexible hose Flexible hose Tube insert Flexible hose Junction

Type SMD3301AT PSS0 PSS1 PST0 PST1 PA4 PAN4 PB4 PD4 PHD4 DB6D DB8D DB9D PM104 PH4M8T FHC405 FHC407 AL4 FHC408 JD3

Qty 1 10 5 3 1 31 19 44 4 13 1 1 1 1 4 1 1 44 1 1

Fig. 13 Lubrication system diagram


17

Chapter 4 Major Units

4-6 Coolant Unit


This unit is used for cooling and washing workpieces and cutting tools as well as removing chips during cutting. Priming the pump is not required because an immersion type pump is used. Tank capacity : 95 lit. Discharge : 30~40 lit./min.

4-6-1 Coolant System Diagram

Turret

Flood coolant

95 lit.

CAUTION

Always fill the tank with coolant to at least 80% (76 lit.) of the tank capacity. It is recommended to replenish the coolant supply during a break or after finishing work rather than in the middle of operation.
Fig. 14 Coolant system diagram

18

Chapter 4 Major Units

4-7 Air Unit (optional)

* The figure shows the machine equipped with loader. *Type and location of the air unit may differ depending on the specifications.

Fig. 15 Air unit

19

Chapter 5 Electrical Drawings

Chapter 5 Electrical Drawings


5-1 Connection Diagram

Fig. 16 Connection diagram 20

Chapter 5 Electrical Drawings

5-2 Electric Circuit Diagrams


Electric circuit diagram 1

Fig. 17 Electric circuit diagram 1

21

Chapter 5 Electrical Drawings

Electric circuit diagram 2

Fig. 18 Electric circuit diagram 2

22

Chapter 5 Electrical Drawings

Electric circuit diagram 3

Fig. 19 Electric circuit diagram 3

23

Chapter 5 Electrical Drawings

Electric circuit diagram 4

Fig. 20 Electric circuit diagram 4

24

Chapter 5 Electrical Drawings

Electric circuit diagram 5

Fig. 21 Electric circuit diagram 5

25

Chapter 5 Electrical Drawings

Electric circuit diagram 6

Fig. 22 Electric circuit diagram 6

26

Chapter 5 Electrical Drawings

Electric circuit diagram 7

Fig. 23 Electric circuit diagram 7

27

Chapter 5 Electrical Drawings

Electric circuit diagram 8

Fig. 24 Electric circuit diagram 8

28

Chapter 5 Electrical Drawings

Electric circuit diagram 9

Fig. 25 Electric circuit diagram 9

29

Chapter 5 Electrical Drawings

Electric circuit diagram 10

Fig. 26 Electric circuit diagram 10

30

Chapter 5 Electrical Drawings

Electric circuit diagram 11

Fig. 27 Electric circuit diagram 11

31

Chapter 5 Electrical Drawings

Electric circuit diagram 12

Fig. 28 Electric circuit diagram 12

32

Chapter 5 Electrical Drawings

Electric circuit diagram 13

Fig. 29 Electric circuit diagram 13

33

Chapter 5 Electrical Drawings

Electric circuit diagram 14

Fig. 30 Electric circuit diagram 14

34

Chapter 5 Electrical Drawings

Electric circuit diagram 15

Fig. 31 Electric circuit diagram 15

35

Chapter 5 Electrical Drawings

5-3 Parts Arrangement in Electric Box

36

Chapter 5 Electrical Drawings

5-4 Electric Parts List


* Specifications are subject to change according to the improvement of the machine. Check the types and quantities of parts to be replaced, and place an order with Takamatsu.

(standard)
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Part name Earth leakage breaker Magnetic switch Magnetic switch Electromagnetic contactor Electromagnetic contactor Coil surge absorber Coil surge absorber Diode Bi-power relay Bi-power relay Latching relay Mini-power relay Mini-power relay Relay socket Relay socket Relay socket Relay socket Terminal relay Circuit protector DIN rail Fixture Mark plate 2-step terminal block Terminal cover Terminal block Terminal block side plate Relay box terminal block Fan motor Fan guard Heat exchanger Cap connector Spark killer Spark killer (3RMS) Transformer 24 Vdc power supply Grommet Toggle switch Receptacle Maker Hitachi Hitachi Hitachi Hitachi Hitachi Hitachi Hitachi Hitachi Fuji Fuji Fuji Fuji Fuji Fuji Fuji Fuji Fuji Fuji Fuji Toyo Giken Toyo Giken Toyo Giken Toyo Giken Toyo Giken Toyo Giken Toyo Giken Toyo Giken Minebea Minebea Ohm Ohm Okaya Okaya Yokoyama Cosel Takigen Matsushita Type EX50B-50A-30 mA 200Vac HJ10-T 100 V RC 3.8 A HJ10-T 100 V RC 1.4 A HJ35 100 Vac HJ10 100 Vac CSJ2-15C CSJ5-15C V07E HH64P-L 24 Vdc HH62P-FL 24 Vdc HH52P-R 24 Vdc HH54P-FL 24 Vdc HH52P-FL 24 Vdc TP614X2 TP68X2 TP514X1 TP58X1 RS-4DN 24 Vdc CP31FM/5 DAS4 CT-H M-1LE CTW-15S2 CTW-15L2 CA-30 AT-20 ATL-20 BOXTC 3610PS-10T-B30-B00 PG-36 OC-15 OA-2 CR-10201 3RMES-12334-B0 200, 220/100 V 500 VA PAA100-24 C-30SG-20A2 WK3001 Qty 1 1 1 1 1 3 1 3 1 1 1 1 1 1 1 2 1 1 2 2 4 2 42 1 1 2 1 2 1 1 1 1 1 1 1 2 1 1 1 TZPSW Attached to the electric box CM TR DCP1: for control, DCP2: for SOL L1, L2, L3, PE L1, L2, L3, PE X-, Z-axis LS Attached to the operation box Attached to the operation box ELB OM: hydraulic (0.75 kW) CM: coolant (0.25 kW) MCC1: Power supply power MCC2: Turret amplifier power OM, CM, MCC2 coil MCC1 coil HH52P-R, HH64P-L NON RDY CHK EST UCL for HH64P-L for HH62P-FL for HH52P-R, HH54P-FL for HH52P-FL OTX/OTZ/OTY/CLT F1, F2 (5A) Remarks

2-step terminal block side plate Toyo Giken

Nippon Kaiheiki M-2012L

37

Chapter 5 Electrical Drawings

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Keyswitch

Part Name Pushbutton switch Pushbutton switch Pushbutton switch Pushbutton switch Dustproof cover Dustproof cover Dustproof cover Pushbutton switch Manual pulse generator Rotary switch Switch knob Dust cap with a cord Hole plug Relay board NC control unit (7.2" LCD) Separate type MDI unit (compact key) Distribution panel I/O module (basic) Distribution panel I/O module (extended B) Machine operation panel I/F unit Power supply module Servo amplifier module Spindle amplifier module AC reactor Optical fiber cable (5 m for external cable) MDI signal cable (compact, horizontal) Battery case Battery DC link short bar (64 mm) Servo amplifier module Fuji Fuji Fuji Fuji Fuji Fuji

Maker Takigen

Type S-9-90-B-1 (same number) AH30-VR01 AH25-FG10 AH25-FR01 AH165-SFG11 AHX047 (green) AHX046 (red) A3BA-5060 MB-2011-f8Y RE45T 1S M5D1 DP-P01-0-15G 15 L=16 R. antr 60a DB-59-J2 DP-250 TACS-10-5A-18T A02B-0285-B500 A02B-0281-C120#TBR A03B-0815-C001 A03B-0815-C003 A16B-2201-0110 A06B-6110-H006 A06B-6114-H206 A06B-6082-H206#H512 A81L-0001-0155 A66L-6001-0026#L5R003 A02B-0236-K812 A06B-6050-K060 A06B-6050-K061 A06B-6078-K803 MR-J2-40D-S28

Q'ty 2 1 2 2 1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 SVMT IOM1 ESTP

Remarks PRGED, DINTK PON, CYST POF, FHLD TURK CYST FHLD TURK OTR FOV, SOV RS-232-C connector cover

Omron Nippon Kaiheiki Tokyo Sokuteiki Tokyo Sokuteiki Fujitsu Japan Aviation Heiko Takamaz FANUC FANUC FANUC FANUC FANUC FANUC FANUC FANUC FANUC FANUC FANUC FANUC FANUC FANUC Mitsubishi

for 18T, 21T 21i-TB

IOM2, IOM3, (OP. IOF4) OPIFB PSM (PSM-5.5i) SVM (SVM2-20/40i) SPM (SPMC-5.5) ACL

38

Installation

Contents
Chapter 1 Safety Precautions for Installation .......................................................... Chapter 2 Preparation for Installation 2-1 Environment .................................................................................................. 2-2 Foundation ..................................................................................................... 2-3 Air Source ...................................................................................................... 2-4 Electrical Wiring ............................................................................................ 2-5 Installation Space ........................................................................................... Chapter 3 Transportation........................................................................................... Chapter 4 Cleaning of Machine ................................................................................. Chapter 5 Power Connection ..................................................................................... 1

3 3 4 4 5 6 8 9

Chapter 6 Grounding Work ....................................................................................... 11 Chapter 7 Air Connection .......................................................................................... 12 Chapter 8 Oiling .......................................................................................................... 13 Chapter 9 Levelling ..................................................................................................... 14

Chapter 1 Safety Precautions for Installation

Chapter 1 Safety Precautions for Installation


DANGER
Power connection, crane and fork lift operation and slinging work should be done only by qualified personnel. Never put your body partially or wholly under the lifted machine. When placing electric cables over the floor, use rigid covers to protect them from being damaged by chips and workers. Transportation and installation of the machine should be done by qualified personnel according to Installation. Power cables from the primary terminal in the factory to the main power switch should have a rated cross sectional area in order to supply stable power required for operation. Check the following points to ensure safety at the installation site.
When foundation bolts are buried, mark those points clearly to protect workers from stumbling over and the machine and carriages from bumping. When a pit is provided for waste oil, chips and piping, mount a tentative cover to protect workers from falling down. The floor should be clean and dry, and free from obstacles, oil and waste oil in order to protect workers from slipping or falling.

WARNING

Use a stable step or platform when it is needed to reach a high level. Never put your fingers between the bed and the floor when locating the machine at a designated place. When lifting a machine, use wire rope, shackles and hoisting jigs that are not damaged and rigid enough to withstand the machine weight. When working in a team, choose a leader to give instructions.
Give signals with one another to check other workers status before going to the next step. Follow the procedures step by step.

Never give excessive vibration or shock to the machine during lifting and transporting.

Chapter 1 Safety Precautions for Installation

CAUTION

When rust preventive oil is applied to the slideways, remove it thoroughly with wash oil before starting operation. Remove eye bolts used for transportation as well as other fixing jigs and wood used as shipping brackets. Levelling of the machine should be done accurately. (Adjust levelling referring to the attached inspection sheet.) When installation is finished, check the following points before turning on the power.
All the bolts and connectors are securely tightened. Hydraulic hose, air hose and other piping are securely connected and fixed. New grease and oil are properly supplied to each section as instructed. Water and dust on the machine are all wiped off. There is no oil leakage around the machine.

Chapter 2 Preparation for Installation

Chapter 2 Preparation for Installation


2-1 Environment
To ensure machine accuracy and efficiency, check the following items before installation. Avoid direct sunlight or heat source which will cause a partial temperature rise.
Ambient temperature: 0C ~ 45C (20C 2C is most recommended. Temperature fluctuation should be within 1C in one minute.)

Keep apart from other machines which may splash water, oil or chips. Keep apart from press machines or forging machines to prevent transmission of vibration.
The site should be below 0.5G. Take anti-vibration measures if necessary.

Humidity should be below 75% without dew condensation. Avoid a location of a bad atmosphere with dust, mist, salt, corrosive gas, etc. The foundation of the machine should have sufficient strength without inclination or unevenness.

2-2 Foundation
The machine should be installed on concrete of more than 300 mm in thickness. The machine is so designed that foundation work is not particularly necessary if the ground is solid enough. However, it is necessary in the following cases. Ground is not solid enough and depression or inclination may occur after the machine is installed. High accuracy and efficiency are required in operation.

Fig. 1

Chapter 2 Preparation for Installation

2-3 Air Source


Use clean and dry compressed air. When the air source is shared with other facilities, care should be exercised so that the pressure does not become low. Pressure: 0.5 MPa Discharge amount: 5.82 NL/time

2-4 Electrical Wiring


Prepare the primary power and cables as described below on your side. Supply voltage Within 200/220 V 10%, 3-phase, within 50/60 Hz 2 Hz
If normal voltage is not supplied, the machine may not actuate correctly. Be sure to measure voltage with a tester. When voltage fluctuation exceeds 10%, provide a voltage stabilizer.

CAUTION

Cables (to the main power switch from the primary power source in the factory) Cable thickness : More than 8 mm2 (in the case of single-wire cables) AC 5.5/3.7 kW : 13.1 kVA, 38 A AC 7.5/5.5 kW 16.3 kVA, 47 A Grounding Grounding resistance Grounding cable

: Below 100 : More than 8 mm2 (in the case of single-wire cables)

* For the optional specifications, the electric cables (power cable and grounding cable) to use may be different in thickness. Contact Takamatsu before connecting the electric cables.

Chapter 2 Preparation for Installation

2-5 Installation Space


Installation space should comply with the following: There is enough room to open/close the doors. There is enough room to supply oil and discharge chips. Workpieces can be mounted/removed without hindrance.

* Required installation space may change slightly according to optional accessories and/or a destination of the machine. Fig. 2 5

Chapter 3 Transportation

Chapter 3 Transportation
The standard machine weighs about 2,200 kg. Use transportation equipment which is rigid enough to withstand the machine weight.

DANGER

Crane and fork lift operation and slinging work should be done only by qualified personnel. Never put your body partially or wholly under the lifted machine.

WARNING

When lifting the machine, use wire rope, shackles and hoisting jigs that are not damaged and rigid enough to withstand the machine weight. (Wire rope: More than 10 mm)
* The thickness of the above wire rope is for the standard specifications. For
optional specifications, the total machine weight differs for respective specifications so that the thickness of the wire rope to use may differ as well. Contact Takamatsu before starting the work.

CAUTION

When working in a team, choose a leader to give instructions.


Give signals with one another to check other workers safety before going to the next step. Follow the procedures step by step by giving signals.

Use waste cloth, etc. to protect the machine from being damaged by wire ropes. Never give excessive vibration or shock to the machine during lifting and transporting.

Chapter 3 Transportation

[Required jigs] Dedicated hoisting jigs Crane Wire rope (more than 10 mm)
* The thickness of the above wire rope is for the standard specifications. For optional specifications, the
total machine weight differs for respective specifications so that the thickness of the wire rope to use may differ as well. Contact Takamatsu before starting the work.

1. Clean the installation site. 2. Check that the Z-axis slide is at its zero position.
* The center of gravity of the machine comes around the spindle nose.

3. Set the dedicated hoisting jigs. 4. Hang wire ropes on the dedicated hoisting jigs. 5. Lift the machine slightly once to check the balance. 6. Transport the machine to the installation site.
* These hoisting jigs are optionally provided. Dedicated hoisting jig

Dedicated hoisting jigs

Fig. 3 7

Chapter 4 Cleaning of Machine

Chapter 4 Cleaning of Machine


Remove rust preventive oil applied on the slideways and metal surfaces thoroughly with nonflammable cleaning agent after unpacking.

CAUTION

Do not operate the machine before cleaning is finished. Never use compressed air, like air gun, for cleaning the machine.

Chapter 5 Power Connection

Chapter 5 Power Connection


Electric connection should be done only by qualified electric engineers. Turn off the primary power in the factory first. Never connect to the primary power until after connection work and grounding work are completed. When carrying out connection work, put the KEEP POWER OFF panel so that power is not turned on by mistake. Check that cable coating is not damaged, as defective coating may cause a short circuit or an electric shock. [Required tools] Phillips screwdriver 1. Remove the cover for the main power switch. 2. Open the electric cabinet door. 3. Put a power cable through the cable connection port. 4. Connect the power cable to the main power switch.
* Connection of the R, S and T terminals as well as earth should be correctly done.

DANGER

5. Attach the cover to the main power switch. 6. Close the electric cabinet door. * Phase check After installation work is finished, check that the phase is correct. 1. Check that the switches on the NC control unit and the control box are all turned to OFF or STOP. 2. Mount a phase detector on the R, S, and T terminals on the power breaker input side, and detect the phase. If the phase is wrong, turn off the power once and interchange R and T of the incoming phase cable. Turn on the power again and check that the hydraulic pump rotates in the normal direction and the pressure gauge pointer moves accordingly.

Chapter 5 Power Connection

Electric cabinet

Cable connection port

* The figure shows the machine equipped with loader.

DANGER

Even if the main power switch is off, high-voltage of 200 V is supplied up to the main power switch when the power in the factory is turned on. Never touch the part marked with in the above figure. Failure to observe this warning will result in critical bodily injuries.

Fig. 4 10

Chapter 6 Grounding Work

Chapter 6 Grounding Work


Comply with the electrical rules and regulations on grounding prescribed in your country. Each grounding terminal should be connected to power cable individually. Wiring as shown below will result in a critical accident. Grounding work should be done only by officially qualified electric engineers.

DANGER

WARNING

11

Chapter 7 Air Connection

Chapter 7 Air Connection


Use clean and dry compressed air.

Air connection port

* The figure shows the machine equipped with loader. * Type and location of the air unit may differ depending on the specifications.

Fig. 5

12

Chapter 8 Oiling

Chapter 8 Oiling
See Chapter 4 Oiling in Maintenance

13

Chapter 9 Levelling

Chapter 9 Levelling
Levelling of the machine should be accurate, as it affects not only cutting accuracy but also machine life.
* If the machine has been left unpacked or in improper status for a long period of time, levelling cannot be stabilized at once. Level the machine once and adjust it again in three or four weeks.

DANGER

Turn off the main power switch first when maintenance work should be done inside the cover. Covers of the machine should be opened only by qualified maintenance personnel.

WARNING

[Required tools] Levels (0.02 mm/m) Spanner [30] 1. Return both the X and Z axes to the respective zero points. 2. Place the level gauge on the top surface of the Z-axis slide.
* Always keep the surface to set a level gauge clean so that no dust may permeate between the level gauge and the mounting surface.

3. Adjust the machine level with four jack bolts at each corner so that the reading of the level gauge is to be within 0.02 mm in both the X- and Z-axis directions. 4. Tighten the lock nuts securely. 5. Check the machine level again with the level gauge.
* If the reading of the gauge is not within 0.02 mm, adjust the machine level again.

14

Chapter 9 Levelling

Jack bolt Lock nut Levelling block

Level gauge

Place the level gauge.

Jack bolt position (4 places)

* The diagram above is for tailstock specifications. Fig. 6

15

Operation

Contents
Chapter 1 Outline of Machine .................................................................................... 1 1-1 Name and Function of Each Component ....................................................... 1 1-2 Structure of Operation Panel ......................................................................... 2 1-2-1 Machine Operation Panel.................................................................. 2 1-2-2 CNC Operation Panel ....................................................................... 14 Chapter 2 Preparation for Operation ....................................................................... 2-1 Check-ups before Turning Power ON ........................................................... 2-2 Turning Power ON ........................................................................................ 2-3 Check-ups after Turning Power ON .............................................................. 2-4 Check-ups before Turning Power OFF ......................................................... 2-5 Turning Power OFF ....................................................................................... 2-6 Check-ups after Turning Power OFF ............................................................ Chapter 3 Manual Operation ..................................................................................... 3-1 Zero Point Return .......................................................................................... 3-2 Manual Feed .................................................................................................. 3-2-1 JOG Feed .......................................................................................... 3-2-2 Rapid Traverse .................................................................................. 3-2-3 Handle Feed ...................................................................................... 3-3 Turret Indexing .............................................................................................. 3-4 Chuck Open/Close ......................................................................................... 3-5 Spindle Rotation and Stop ............................................................................. 3-6 Coolant Discharge ......................................................................................... Chapter 4 MDI Operation .......................................................................................... 4-1 Preparation for MDI Operation ..................................................................... 4-1-1 Switches and Keys Used ................................................................... 4-1-2 MDI Screen ....................................................................................... 4-2 Spindle Rotation and Stop (continued from step 2 in 4-1-2) ......................... 4-3 Turret Indexing (continued from step 2 in 4-1-2).......................................... 4-4 X-/Z-axis Travel (continued from step 2 in 4-1-2) ........................................ 19 19 20 21 22 23 24 25 25 27 27 28 29 30 31 32 34 35 35 35 36 37 39 40

Chapter 5 Automatic Operation ................................................................................ 5-1 Preparation for Automatic Operation ............................................................ 5-1-1 Process of Starting Automatic Operation ......................................... 5-1-2 Conditions for Starting Automatic Operation ................................... 5-2 Program Check (Test Running) ..................................................................... 5-2-1 Program Check (Test Running) - (1) ................................................ 5-2-2 Program Check (Test Running) - (2) ................................................ 5-3 Trial Cutting .................................................................................................. 5-4 Pause and Restart of Automatic Operation .................................................... 5-4-1 Pause of Automatic Operation .......................................................... 5-4-2 Restart of Automatic Operation ........................................................ 5-5 Manual Operation during Automatic Operation ............................................ 5-6 MDI Operation during Automatic Operation ................................................ 5-7 Program Editing ............................................................................................. 5-7-1 Inputting a Program .......................................................................... 5-7-2 Calling a Program ............................................................................. 5-7-3 Displaying a Program Library .......................................................... 5-7-4 Deleting a Program ........................................................................... 5-7-5 Searching .......................................................................................... 5-7-6 Deleting a Word or Block ................................................................. 5-7-7 Inserting a Word ............................................................................... 5-7-8 Altering a Word ................................................................................ Chapter 6 Setting Up ................................................................................................... 6-1 Tooling........................................................................................................... 6-2 Tool Offset ..................................................................................................... 6-3 Tool Wear Offset ........................................................................................... 6-4 Mounting of Power Chuck ............................................................................ 6-5 Mounting of Collet Chuck ............................................................................. 6-6 Forming of Soft Jaws ..................................................................................... 6-6-1 Precaution for Forming Soft Jaws .................................................... 6-6-2 Forming of Soft Jaws in Manual Operation ...................................... 6-6-3 Forming of Soft Jaws in Automatic Operation ................................. Chapter 7 Appendix .................................................................................................... 7-1 List of G Codes .............................................................................................. 7-2 List of M Codes ............................................................................................. 7-3 Variable Timers List ......................................................................................

42 43 43 44 46 46 48 49 50 50 50 51 52 53 54 56 57 58 59 61 63 64 65 65 67 72 73 75 77 77 79 81 84 84 85 87

Chapter 1 Outline of Machine

Chapter 1 Outline of Machine


1-1 Name and Function of Each Component

Spindle

Turret

NC screen

Front door

CNC operation panel

Machine operation panel

Hydraulic pressure gauge

Air unit Lubrication unit Foot switch Electric cabinet Main power switch

Absolute pulse coder battery case

Coolant pump motor Hydraulic pump unit

Coolant tank

* The figure shows the machine equipped with loader.

Fig. 1 1

Chapter 1 Outline of Machine

1-2 Structure of Operation Panel


Never touch any switch, key or button with wet hands. Never operate any switch, key or button on the operation panels while wearing gloves.

DANGER
CAUTION

1-2-1 Machine Operation Panel

31

16

17

18

19

20 29 25

6 7 21 22 23

26 27 28

30

32

24

10

13 11 14

15 12

33

34

35

"Special Version" for more information on operations of optional equipment. Fig. 2 2

Chapter 1 Outline of Machine

Name (1) POWER ON button


ON

Function

Turns the NC power on and displays the NC screen, while the power in the factory and the main power switch are turned on.

(2) POWER OFF button


OFF

Turns the NC power and the NC screen off. Turn the main power switch off after pressing this button.

(3) Manual pulse generator Feeds each axis in the required direction after; the HANDLE mode is selected with the mode selector switch (5). the required axis is selected with the AXIS SELECT switch (6). the feed per scale is selected with the handle magnification switch x10 / x1 (7). This generator is graduated into 100 in one complete revolution.
Rotate the manual pulse generator at a speed under 5 rotations/sec.

(4) TURRET switch


TURRET

Rotates the turret in manual operation. When JOG or HANDLE of mode selector switch (5) is selected, the turret is indexed one step in the CW direction each time this switch is pressed.

Chapter 1 Outline of Machine

(5) Mode selector switches


EDIT AUTO

MDI

HANDLE

JOG

ZERO RETURN

Selects operation mode. A lamp of the selected mode switch will light up. EDIT switch Allows registering a program into the memory. Altering, inserting and deleting programs can be done by using keys on the CNC operation panel. AUTO switch Allows an execution of programs registered in the memory. Program number search and sequence number search of programs in the memory can also be done. MDI switch Allows manual data input by using keys on the CNC operation panel. MDI operation can start with the START button (33) on the machine operation panel. HANDLE switch Allows a fine feed of each axis by using the manual pulse generator (3). A fine feed can be done by rotating the manual pulse generator (3) after the required axis (X or Z) and feed amount (0.01 mm or 0.001 mm) are selected with the AXIS SELECT switch (6) and the x10 / x1 switch (7) respectively. JOG switch Allows a JOG feed in manual operation. Select the required axis (X or Z) and direction (plus or minus) with the JOG FEED switch (8), and the selected axis will move in the selected direction as long as the switch (8) is pressed. A feedrate can vary with the FEED RATE OVERRIDE switch (29). A rapid traverse becomes effective by pressing the RAPID switch (9) and any of JOG FEED switches (8) at the same time.

Chapter 1 Outline of Machine

ZERO RETURN switch Allows a zero point return in manual operation when the "+X" or "+Z" of JOG FEED switch (8) is pressed until the zero return lamp lights up.
"3-1 Zero Point Return"

For the model equipped with loader, be sure to perform loader home position return when the power is turned on or when the EMERGENCY STOP button is reset.
" Loader Instruction Manual."

(6) AXIS SELECT switch


X Z
AXIS SELECT

Selects the axis to be moved when HANDLE of mode selector switch (5) is selected. The lamp of the selected axis will light up.

(7) x10 / x1 (Handle magnification) switch Selects a feed amount per scale of the manual pulse generator, and is effective when X10 HANDLE of mode selector switch (5) is se X1 lected. The lamp of the selected magnification X 10 will light up. X1 x10: Feed amount per scale = 0.01 mm x1: Feed amount per scale = 0.001 mm (8) JOG FEED switches
+X -Z +Z
Zero return completion lamp

RAPID

-X

Selects the axis and its direction to be moved when JOG of mode selector switch (5) is selected. JOG feed of each axis is effective as long as the switch is pressed. In the ZERO RETURN mode, only "+X" and "+Z" switches are effective, and press both switches until their zero return completion lamps light up accordingly.

(9) RAPID switch


+X -Z +Z

RAPID

Allows a rapid traverse of each axis when it is pressed along with any of the JOG FEED switches (8), when JOG of mode selector switch (5) is selected.

-X 5

Chapter 1 Outline of Machine

(10) F0 / 100% (rapid feedrate) switch


RAPID OVERRIDE 100% F0 F0 100%

Selects either of F0 and 100% for rapid traverse. The lamp of the selected rapid feedrate will light up. This switch is effective both in manual operation and automatic operation (G00). The rapid feed rate of each axis is as shown below. F0: 2.5 m/min. (X and Z) 100%: 12 m/min. (X) 18 m/min. (Z)

(11) COOLANT switch


COOLANT 1

Discharges and stops coolant in manual operation. Coolant is discharged from the tops of the slide cover and the chip cover. The lamp will light up during coolant discharge.

COOLANT 2

(12) AIR switch

AIR 1

Starts and stops blowing air in manual operation, when the machine is equipped with an air blower. The lamp will light up during air blowing.

AIR 2

(13) SPINDLE FOR. switch


SPINDLE FOR.

Rotates the spindle in normal direction, and turns the lamp on. This switch is effective when JOG or HANDLE of mode selector switch (5) is selected.

(14) SPINDLE STOP switch


SPINDLE STOP

Stops the spindle. This switch is effective when JOG or HANDLE of mode selector switch (5) is selected.

Chapter 1 Outline of Machine

(15) SPINDLE REV. switch


SPINDLE REV.

Rotates the spindle in reverse direction, and turns the lamp on. This switch is effective when JOG or HANDLE of mode selector switch (5) is selected.

(16) M01 (optional stop) switch Stops automatic operation after a block containing M01 is executed. (Effective while the lamp lights up.) To restart automatic operation, press the START button. By setting this switch to OFF (the lamp goes off), automatic operation does not stop even after the M01 in the program is read.

M01

(17) SINGLE BLOCK switch Executes only one block in the program each time the START button (33) is pressed. (Effective while the lamp lights up.) This function is effective for checking the motion of each block one by one.

SINGLE BLOCK

Chapter 1 Outline of Machine

*1 Operation does not stop if the block contains thread cutting, but stops only after the block next to the block of thread cutting is executed. *2 Operation also stops even at the intermediate point when G28 or G30 is commanded. *3 When the SINGLE BLOCK switch is set to ON during automatic operation, operation stops after completing the current block being executed. *4 When the SINGLE BLOCK switch is on during canned cycles (G90, G92, G94 and G70~G76), the actual executions are as shown below. Rapid traverse Cutting feed G code Tool path Explanation Tool path 1 to 4 is assumed as one cycle. Movement stops after 4 is finished. Tool path 1 to 4 is assumed as one cycle. Movement stops after 4 is finished. Tool path 1 to 4 is assumed as one cycle. Movement stops after 4 is finished. Tool path 1 to 7 is assumed as one cycle. Movement stops after 7 is finished. Each of tool paths 1 to 4, 5 to 8, 9 to 12, 13 to 16, 17 to 20 are assumed as one cycle. Movement stops after each cycle is finished.
* The figure shows the case of G71. G72 is the same as this.

G90

G92

G94

G70

G71 G72

G73

Tool path 1 to 6 is assumed as one cycle. Movement stops after 6 is finished. Tool path 1 to 10 is assumed as one cycle. Movement stops after 10 is finished.
* The figure shows the case of G74. G75 is the same as this.

G74 G75

G76

Tool path 1 to 4 is assumed as one cycle. Movement stops after 4 is finished.

*5 In the blocks containing M98 P_ or M99, operation does not stop even when the SINGLE BLOCK switch is on. For details, refer to the separately provided Programming Manual and FANUC OPERATORS MANUAL. 8

Chapter 1 Outline of Machine

(18) DRY RUN switch


DRY RUN

Ignores all commands for the rapid feed and the cutting feed specified by the program. (Effective while the lamp lights up.) The feedrate specified by the FEEDRATE OVERRIDE switch (29) becomes effective at this time. When the PROGRAM CHECK switch (20) is set to ON (its lamp lights up), this switch also becomes effective automatically (the lamp lights up.)
As this switch becomes effective even during thread cutting, pay careful attention to the actual cutting of workpieces.

CAUTION

(19) / CODE (block delete) switch


/ CODE

Ignores blocks following a slash / in the program. (Effective while the lamp lights up.) By setting the switch to OFF (the lamp goes off), blocks containing a slash / become effective. This function is not effective for the block which has been read into the buffer, as this code checked when they are read into the buffer register.

(20) PROGRAM CHECK switch


PROGRAM CHECK

Allows automatic operation without rotating the spindle in order to check each motion of the X and Z axes. When this switch is set to ON (the lamp lights up), the DRY RUN switch (18) also becomes effective (the lamp lights up). This function is effective to carry out a program check safely without mounting a workpiece into the chuck.

(21) CYCLE END lamp


CYCLE END

Comes on when automatic operation is completed, and goes off when automatic operation restarts.

Chapter 1 Outline of Machine

(22) CHUCK CLOSE lamp


CHUCK CLOSE

Comes on when the chuck is closed by stepping on the foot switch, and goes off when the chuck is opened by the switch again. The spindle rotation is available while the lamp lights up.
* The chuck is so controlled not to open during spindle rotation.

(23) CYCLE START lamp


CYCLE START

Comes on when automatic operation starts. The lamp stays on during automatic operation, but goes off when the cycle operation is completed or has paused.
* The lamp also lights up when the MDI operation is started.

(24) FEED HOLD lamp


FEED HOLD

Comes on when automatic operation has paused temporarily, and goes off when automatic operation is restarted.

(25) LUB. ALARM (lubricant alarm) lamp


LUB. ALARM

Comes on when lubricant in the lubricant tank becomes insufficient.

(26) SEQ. ALARM (sequence alarm) lamp


SEQ. ALARM

Comes on when an error has arisen in the electric system, for example, when a spindle normal (reverse) rotation command is given during the spindle reverse (normal) rotation without stopping the spindle, when an error is occurring in the spindle motor, etc.

CAUTION

If the cause is unknown, contact Takamatsu.

(27) TURRET ALM. (Turret alarm) lamp


TURRET ALM.

Comes on when the turret has an indexing fault. Turn the power off and back it on. The alarm may be cleared.

10

Chapter 1 Outline of Machine

(28) COUNT UP lamp


COUNT UP

Blinks when the number of completed products has reached preset value in automatic operation. The machine stops upon illumination of the lamp.

(29) FEED RATE OVERRIDE switch


50 100

0%

150

Has two functions according to the mode selected by the mode selector switch (5). Feed rate override In the AUTO or MDI mode, the speed specified in the program can be overridden in the range of 0 to 150%.

CAUTION

The feedrate override set by this switch is ignored during thread cutting, that is, the override is always 100% during thread cutting.
JOG feedrate setting In the JOG mode, the feedrate of each axis can be selected. When the switch is set to 100%, the axis moves at the speed of 126 mm/min.

(30) SPINDLE (spindle speed setting) switch


Varies the spindle speed in manual operation. Turning the switch CW increases the spindle speed, and turning it CCW decreases the spindle speed.

SPINDLE

CAUTION

Before starting the spindle rotation, turn the SPINDLE switch fully to the left once and then return it gradually to the right to set the required speed.

11

Chapter 1 Outline of Machine

(31) PROGRAM EDIT switch (with key)


PROGRAM EDIT OFF ON

OFF Entering and editing programs cannot be done. ON Entering and editing programs can be done.

(32) O.T. RELEASE switch


O.T. RELEASE

If the axis (X or Z) travels to the mechanical limit beyond its soft limit, the power to the hydraulic motor and the servo system is shut off in order to protect the machine from being damaged. As the power can be restored by pressing this switch, move the overtraveled axis in its safe area by rotating the manual pulse generator (3) while holding this switch down.

CAUTION

Be sure to check that the axis direction is correct, when moving the overtraveled axis from its mechanical limit position.

(33) START button


START

Starts machine operation and turns on the CYCLE START lamp (23), when the AUTO or MDI mode is selected with the mode selector switch (5).
* This button is ineffective in any of the following cases: 1. The EMERGENCY STOP button is pressed. 2. The reset signal is given. 3. A wrong mode is selected. 4. The sequence number is being searched for. 5. The machine is in the alarm status. 6. The automatic operation is being executed and is not in a feed hold. 7. The NC is not ready for the operation. (Not in the READY status)

12

Chapter 1 Outline of Machine

(34) FEED HOLD button


FEED HOLD

Suspends automatic operation, and turns off the CYCLE START lamp (23) and on the FEED HOLD lamp (24). If this button is pressed; all the axes being moved are stopped. a dwell operation being executed is suspended. M or T function being actuated is stopped upon its execution.
* Thread cutting is not suspended even by pressing this button, but stops after the block next to the block containing the thread cutting is executed. * When the axis is moved in manual operation, although it is available even in the FEED HOLD status, pay attention to its coordinate value. Accordingly, to restart automatic operation, be sure to return the moved axis to its original position before it was moved manually.

(35) EMERGENCY STOP button (with a lock mechanism)


EMERGENCY STOP

WARNING

Always be aware of the EMERGENCY STOP buttons location and operation so that it can be operated quickly in emergency. This must be understood by all the personnel concerned.

Stops the machine immediately in emergency. Once the emergency stop becomes effective, the servo power shuts off, and each axis feed, the spindle rotation, the turret indexing and the coolant supply stop. Use (press) this button also to turn the power off. As the button becomes locked once it is pressed, turn it CW for resetting.
* Be sure to remove the cause of the trouble before resetting the emergency stop status. * All the commands for axis feed or spindle rotation specified before the EMERGENCY STOP button is pressed become ineffective.

13

Chapter 1 Outline of Machine

1-2-2 CNC Operation Panel

* The figure shows the machine equipped with loader.

Fig. 3

14

Chapter 1 Outline of Machine

Name (1) Position key


POS

Function

Used for displaying the current position of each axis.

(2) Program key


PROG

Used for displaying programs in EDIT mode and for inputting or displaying data in MDI mode.

(3) Offset/setting key


OFFSET SETTING

Used for setting a tool offset amount or for setting and displaying the custom macro variable.

(4) System key


SYSTEM

Used for setting parameters or for displaying parameters and diagnosis data.

(5) Message key Used for displaying alarm numbers and mesMESSAGE

sages.
* When an alarm arises, the alarm contents are automatically displayed on the NC screen.

(6) Graphic key


CUSTOM GRAPH

With standard specifications, pressing this key displays nothing.

(7) Address/numeric keys Used for inputting data composed of the alphabet, numeric characters and symbols.

15

Chapter 1 Outline of Machine

(8) Shift key Used for entering characters indicated at the lower right on the address keys. is indicated while this key is held down, showing that the lower right characters can be entered.

SHIFT

(9) Cancellation key


CAN

Used for deleting the alphabet, numeric characters, symbols, etc. displayed on the NC screen. Ex.) When N001X100Z is displayed in the key input buffer line: Pressing the CAN key deletes Z, and shows as below: N001X100

(10) Input key


INPUT

Used for entering data, which is displayed on the NC screen using the data input keys, into the NC. As the function of this key is equal to the [INPUT] soft key, either key may be used.

(11) Deletion key Used for deleting the program data.


DELETE

(12) Insertion key Used for inserting the program data.


INSERT

(13) Alteration key Used for altering the program data.


ALTER

(14) Help key Used for accessing the help function regarding key operation.

HELP

16

Chapter 1 Outline of Machine

(15) Reset key Used for resetting the NC and alarm status when it occurs. Pressing this key during automatic operation stops all the machine motions (axis feed, spindle rotation, coolant, etc.) immediately. Before restarting automatic operation, return all the axes to their zero positions and check that the program returns to its beginning.

RESET

(16) Cursor keys Used for moving the cursor. Press a key depending on the direction to move the cursor. <>: Moves the cursor to the right, or in the forward direction in small units. <>: Moves the cursor to the left, or in the backward direction in small units. <>: Moves down the cursor, or in the forward direction in large units. <>: Moves up the cursor, or in the backward direction in large units.

(17) Page keys Used for changing over the page displayed on the NC screen. Press either key depending on the direction to scroll the page. []: Scrolls the page in the forward direction. []: Scrolls the page in the backward direction.

PAGE PAGE

17

Chapter 1 Outline of Machine

(18) Soft keys Soft keys can work differently depending on the circumstances. The soft key functions currently in effect are indicated at the bottom on the screen.
Chapter selection (main) (OPRT) continued (Continued menu key) Chapter selection (sub) return (Return menu key) (OPRT)

* Soft keys consist of chapter selection keys, operation selection keys, return menu key and continued menu key. Chapter selection keys When a screen display is switched by a function key, the corresponding chapter selection keys (main) are displayed. If one chapter has several sub-chapters, the corresponding chapter selection keys (sub) can be displayed. Operation selection keys These keys are displayed by pressing the (OPRT) soft key (included in the chapter selection keys) or by entering data through the MDI panel. The (OPRT) soft key will not be displayed when operation selection keys are not available. Return menu key Pressing the return menu key returns the soft key indication from the operation selection keys or the chapter selection keys (sub) to the chapter selection keys (main). Continued menu key Pressing the continued menu key displays hidden keys of the chapter selection keys or operation selection keys if any.

Operation selection continued return Operation guide

return

18

Chapter 2 Preparation for Operation

Chapter 2 Preparation for Operation


2-1 Check-ups before Turning Power ON
DANGER

Before turning the power on, check that all cables are properly insulated. Damaged or disconnected cables must be immediately repaired or replaced by qualified personnel, as they could cause an electrical shock or leakage later.

WARNING

There must be no obstacles, which may interrupt machine operation or maintenance work, in/around the machine. The floor must be free from water and oil.

Front door must be closed.

* The figure shows the machine equipped with loader.


EMERGENCY STOP button must be depressed.

Turret must not have any broken or wear-out tools. must be free from chips around the tools. must securely be equipped with tools and holders.

Lubrication unit must be equipped with an appropriate amount of clean oil.

Electric cabinet door must be closed.

Cable connection port must not hold any damaged cable.

Coolant tank must be equipped with an appropriate amount of oil. must not have build-up chips.

Hydraulic pump unit must be equipped with an appropriate amount of oil.

Fig. 4

19

Chapter 2 Preparation for Operation

2-2 Turning Power ON


Never touch any switch, key or button with wet hands.

DANGER

WARNING

Procedures and instructions described in this manual must strictly be observed when turning the power on.

Turn the power on in the following procedures.


* Check that the EMERGENCY STOP button is depressed before turning the power ON.

1. Turn on the primary power in the factory. 2. Turn the main power switch on. A work light will light up. A cooling fan will start to rotate in the electric cabinet. 3. Press the POWER ON button. The NC screen lights up, and NOT READY is displayed. 4. Reset the EMERGENCY STOP button in 3~4 sec. after step 3. The current position screen will appear on the NC instead of the message NOT READY . The hydraulic pump will start. (The pressure increases up to the setting value: 3.4 MPa)

3. POWER ON button

2. Main power switch ON

Electric cabinet

4. Reset the EMERGENCY STOP button.

1. Primary power supply ON

Fig. 5

20

Chapter 2 Preparation for Operation

2-3 Check-ups after Turning Power ON


CAUTION
When starting operation after stopping the machine for a long period of time, check that the machine motions, noise and slideway lubrication are free from trouble. If any abnormality, such as abnormal noise, excessive heat generation and abnormal motion, is found, turn off the power immediately and contact the maintenance personnel to take necessary measures.
NC screen must not indicate any alarm message.

Turret unit should not generate any abnormal sound or excessive vibration during the turret turning.

Spindle motor, X/Z-axis motor must be free from abnormal noise or vibration.

Machine operation panel must not have any illuminating or blinking alarm lamps.

Hydraulic pressure gauge must indicate appropriate chuck pressure. (Max. 2.0 MPa) (Source pressure: 3.4 MPa) Air unit must indicate appropriate air pump pressure. (0.5 MPa)

Lubrication unit must be set to an appropriate discharge amount.

Coolant pump motor is working properly.

* The figure shows the machine equipped with loader.

Fig. 6 21

Chapter 2 Preparation for Operation

2-4 Check-ups before Turning Power OFF


When finishing operation, check that each section of the machine is in the initial status.

CAUTION

NC screen must not indicate any alarm message.

Machine operation panel must not have any illuminating alarm lamps. The cycle end signal light is turned on. All machine motions are completely stopped.

* The figure shows the machine equipped with loader.

Fig. 7

22

Chapter 2 Preparation for Operation

2-5 Turning Power OFF


Never touch any switch, key or button with wet hands.

DANGER

WARNING

Procedures and instructions described in this manual must strictly be observed when turning the power off.

Turn the power off in the following procedures. 1. Press the EMERGENCY STOP button. The hydraulic pump will stop. The message -- EMG -- will blink on the NC screen. 2. Press the POWER OFF button. The NC screen will be turned off. 3. Turn the main power switch off. The work light will be turned off. The cooling fan will stop in the electric cabinet. 4. Shut off the primary power in the factory.

2. POWER OFF button

3. Main power switch OFF

Electric cabinet

4. Reset the EMERGENCY STOP button.

4. Primary power supply OFF

Fig. 8

23

Chapter 2 Preparation for Operation

2-6 Check-ups after Turning Power OFF


After turning the power off, check the following items.

DANGER

Before cleaning the machine and peripheral equipment such as a chip conveyor, stop all the machine motions, turn off the main power switch and the primary power in the factory, and put a tag or a placard saying Cleaning in a prominent place.

CAUTION

Be sure to wear gloves when removing chips. Never use an air gun for cleaning the machine, as it may cause a machine trouble.

All covers should have no damage. The machine and peripheral equipment (chip conveyor, etc.) should be clean. No chips should be deposited inside the machine. When stopping the machine for a long period of time, apply rust preventive oil slightly to ground surfaces (slideways, etc.). Cutting tools should not be worn out or broken. The machine and its peripheral should be tidy.
Check that the covers (the front door, in particular) are not damaged.

Turret must not have any broken or wear-out tools. must be free from chips around the tools. must securely be equipped with tools and holders.

* The figure shows the machine equipped with loader.

Fig. 9
24

Chapter 3 Manual Operation

Chapter 3 Manual Operation


DANGER
Never touch any switch, key or button with wet hands. Before starting operation, check that there is nobody or nothing inside the machine movable area. Never operate any switch, key or button while wearing gloves.

WARNING

CAUTION

3-1 Zero Point Return


Manual zero point return is required in the following cases. (X and Z axes) After turning the power on After resetting the emergency stop status Perform the zero point return manually in the following procedures.
CAUTION

Particular care should be paid to the zero point return when cutting tools or a workpiece are/is mounted on the machine so that they are free from interference.

25

Chapter 3 Manual Operation

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

1. Press ZERO RETURN of the mode selector switch. The lamp in the switch will light up.

+X -Z +Z

RAPID

2. Press the JOG FEED switch +X. Keep pressing until the X-axis zero return completion lamp lights up.

-X

+X -Z +Z

RAPID

3. Press the JOG FEED switch +Z. Keep pressing until the Z-axis zero return completion lamp lights up.

-X

POS

4. Press the POS key and the [ALL] soft key to check that the machine coordinate value is 0.000.
* The zero point lamp will go off when; the axis moves from its zero point. the machine is put in an emergency stop status.
ACTUAL POSITION (RELATIVE) X*.*** Z*.*** (MACHINE) X0.000 Z0.000

(ABSOLUTE) X*.*** Z*.*** (DISTANCE TO GO) X*.*** Z*.*** PART COUNT CYCLE TIME

RUN TIME ACT.F

26

Chapter 3 Manual Operation

3-2 Manual Feed


Three types of manual feed JOG feed, rapid traverse and handle feed are available.

+X -Z

+Z -X

Fig. 10

3-2-1 JOG Feed


ZERO RETURN

EDIT

AUTO

MDI

HANDLE

JOG

1. Press JOG of the mode selector switch. The lamp in the switch will light up.

FEED RATE OVERRIDE


50 100

2. Select a feedrate with the FEED RATE OVERRIDE switch. Ex.) When the switch is set to the 100% position, the slide moves at a speed of 126 mm/min.

0%

150

+X -Z +Z

RAPID

-X

3. Press the JOG FEED switch of a required axis and direction. The slide moves in the selected direction at a speed specified in step 2 as long as the switch is pressed.

CAUTION

When the RAPID switch is pressed along with any of the JOG FEED switches, a rapid traverse becomes effective.
27

Chapter 3 Manual Operation

3-2-2 Rapid Traverse 1. Press JOG of the mode selector switch. The lamp in the switch will light up.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

RAPID OVERRIDE 100% F0 F0 100%

2. Press the RAPID OVERRIDE switch F0 / 100%. The indication lamp of the selected speed (F0 or 100%) will light up. The rapid traverse rate of each axis is as shown below. F0: 2.5 m/min. (X and Z) 100%: 12 m/min. (X) 18 m/min. (Z) 3. Press the JOG FEED switch of a required axis and direction along with the RAPID switch. The slide moves in the selected direction at a rapid traverse rate specified in step 2 as long as the switches are pressed.

+X -Z +Z

RAPID

-X

28

Chapter 3 Manual Operation

3-2-3 Handle Feed


EDIT AUTO

MDI

HANDLE

JOG

ZERO RETURN

1. Press HANDLE of the mode selector switch. The lamp in the switch will light up.

HANDLE

2. Press the AXIS SELECT switch. The indication lamp of the selected axis will light up.

AXIS SELECT

3. Press the magnification switch x10 / x1. The indication lamp of the selected magnification (x10 or x1) will light up. Relation between the magnification and travel is as shown below. x10: Travel per scale 0.01 mm x1: Travel per scale 0.001 mm 4. Rotate the manual pulse generator. The axis selected in step 2 moves by the amount per scale specified in step 3.
* Rotate the manual pulse generator at a speed under 5 rotations/sec.

29

Chapter 3 Manual Operation

3-3 Turret Indexing


WARNING

Never touch the turret directly nor indirectly while it is turning. Pay careful attention to interference of cutting tools with the chuck or a workpiece.

CAUTION

Follow the procedures below when turning the turret.


1. Press JOG or HANDLE of the mode selector switch. The lamp of the selected switch will light up.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

or

TURRET

2. Press the TURRET switch. The turret will be indexed by one step in the CW direction each time the switch is pressed.
* This switch is ineffective and the turret cannot be indexed while each axis is moving in other modes than HANDLE mode.

Fig.11

30

Chapter 3 Manual Operation

3-4 Chuck Open/Close


The foot switch is provided at the bottom center of the machine front face. Each time this foot switch is stepped on, the chuck opens and closes alternately. The CHUCK CLOSE lamp will light up while the chuck is closed.
* The chuck can be opened or closed regardless of the operation mode. However, it cannot be opened or closed by the foot switch during automatic operation and spindle rotation.

MAIN

Foot switch

* The figure shows the machine equipped with loader.

Fig. 12 * The chuck gripping direction can be changed over by the chuck changeover switch. (optional) This switch cannot be changed over while the power is turned off, or while the spindle is stopped in the manual mode.

31

Chapter 3 Manual Operation

3-5 Spindle Rotation and Stop


WARNING

Never touch the spindle directly nor indirectly while it is rotating.

CAUTION

It is hazardous to start rotating the spindle at a high speed. Turn the SPINDLE switch fully to the left and start the spindle, then gradually turn it to the right to set the speed.

Follow the procedures below when rotating or stopping the spindle.


CHUCK CLOSE

1. Close the chuck with the foot switch. The CHUCK CLOSE lamp will light up.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

2. Press JOG or HANDLE of the mode selector switch. The lamp in the selected switch will light up.

or

or

3. Press the SPINDLE FOR. or SPINDLE REV. switch. The lamp in the selected switch will light up, and the spindle starts to rotate.

32

Chapter 3 Manual Operation

SPINDLE

4. Turn the SPINDLE switch. The spindle speed will increase by turning it CW and decrease by turning it CCW.

5. Press the SPINDLE STOP switch. The spindle will stop rotating.

Normal rotation (M03)

Reverse rotation (M04)

Fig. 13

33

Chapter 3 Manual Operation

3-6 Coolant Discharge


Determine the direction of coolant discharged from the coolant hose beforehand.

CAUTION

COOLANT

1. Press the COOLANT switch. The lamp in the switch will light up, and coolant will be discharged. 2. Turn the handle cock to adjust the discharge.
* Coolant can be discharged regardless of the operation mode.

Open

Close

Handle cock

Fig. 14

3. Press the COOLANT switch again. The lamp in the switch will go off, and coolant discharge will stop.

34

Chapter 4 MDI Operation

Chapter 4 MDI Operation


With the MDI operation, a program can be created and executed in the same way as usual programs registered.
"Special Version" for more information on operations of optional equipment. * Operation for the registered programs cannot be done in the MDI mode. * The length of a program for MDI operation is limited to one page of the NC screen. * Tool nose radius compensation cannot be done in the MDI mode. FANUC OPERATORS MANUAL for details

4-1 Preparation for MDI Operation


4-1-1 Switches and Keys Used

* The figure shows the machine equipped with loader. Fig. 15

35

Chapter 4 MDI Operation

4-1-2 MDI Screen


HANDLE

EDIT

AUTO

MDI

JOG

ZERO RETURN

1. Press MDI of the mode selector switch. The lamp in the switch will light up.

2. Press the PROG key. The MDI screen will appear.


PROG
PROGRAM (MDI) O0000 % G00 G97 G69 G99 T F >_ MDI **** *** *** [ PRGRM ] [ MDI ] [ CURRNT ] G21 G40 G25 G22 G80 G67 O0020 N0020

G54 G18 M

[ NEXT ] [ (OPRT) ]

*The program No. "O0000" is automatically inserted.

3. Input a program.
* To delete all programs stored in memory, press the O key and then the DELETE key. All programs can be deleted by pressing the RESET key. FANUC OPERATORS MANUAL for details

36

Chapter 4 MDI Operation

4-2 Spindle Rotation and Stop (continued from step 2 in 4-1-2)


Never touch the spindle directly nor indirectly while it is rotating.

WARNING

5-7 Program Editing when a wrong data has been input

Rotating the spindle at 1000 min-1 in normal (reverse) direction 1. Press the data input keys [S], [1], [0], [0] and [0] in sequence.
* When the power is turned on, G97 (constant surface speed control cancel) mode becomes effective. It is recommended that the G97 is input in the program head on the basis of safety.

2. Press the INSERT key.


INSERT

3. Press the data input keys [M], [0] and [3] (or [M], [0] and [4]) in sequence. M03 is a command for the spindle normal rotation and M04 is for the spindle reverse rotation.

Normal rotation M03

Reverse rotation M04

Fig. 16

37

Chapter 4 MDI Operation

4. Press the EOB key.


EOB E

5. Press the INSERT key.


INSERT

PROGRAM O0020 O0000 S1000 M03; % G00 G69 G21 G97 G99 G40 M T F S )_ MDI 20 : 50 : 14

N0020

G25 G22

G80 G67

G54 G18

[ PRGRM ] [ MDI ] [ CURRNT ] [ NEXT ] [ (OPRT) ]

START

6. Press the START button. The spindle starts rotating at 1000 min-1.

Stopping the spindle

7. Press the address/numeric keys [M], [0] and [5] in order.

8. Press the EOB key.


EOB E

9. Press the INSERT key.


INSERT

START

10. Press the START button. The spindle stops rotating.

38

Chapter 4 MDI Operation

4-3 Turret Indexing (continued from step 2 in 4-1-2)


WARNING

Never touch the turret directly nor indirectly while it is turning. Pay careful attention to interference of cutting tools with the chuck or a workpiece.

CAUTION

5-7 Program Editing when a wrong data has been input

1. Press the address/numerical keys [T], [0], [*], [0] and [0] is sequence.
* Tool number to be indexed

EOB E

2. Press the EOB key. 3. Press the INSERT key. Ex.) Indexing the turret at No. 3
PROGRAM (MDI) O0000 % G00 G97 G69 G99 T F G21 G40 G25 G22 G80 G67 O0020 N0020

INSERT

G54 G18 M

S >_ MDI **** *** *** [ PRGRM ] [ MDI ] [ CURRNT ] [ NEXT ] [ (OPRT) ]

START

4. Press the START button. The turret will turn to index the turret No. 3.

39

Chapter 4 MDI Operation

4-4 X-/Z-axis Travel (continued from step 2 in 4-1-2)


Before starting operation, check that there are obstacles in the axis movable area. Pay careful attention to interference of cutting tools with the chuck or a workpiece. Be sure to perform the coordinate system setting and offset input before moving each axis.
6-2 Tool Offset

CAUTION

+X -Z

+Z -X

Fig. 17 5-7 Program Editing when a wrong data has been input

Moving the axes to the position (X50.0, Z30.0) 1. Press the data input keys [G], [0] and [0] in sequence. 2. Press the INSERT key.

INSERT

40

Chapter 4 MDI Operation

3. Press the data input keys [X], [5], [0] and [.] in sequence.
* There is a great difference in values with and without the decimal point.
Program command X50. X50 X1. X1 Meaning 50 mm 0.05 mm 1 mm 0.001 mm

4. Press the INSERT key again.


INSERT

5. Press the data input keys [Z], [3], [0] and [.] in sequence.

6. Press the INSERT key.


INSERT

7. Press the EOB key.


EOB E
PROGRAM (MDI) O0000 % G00 G97 G69 G99 T F G21 G40 G25 G22 G80 G67 O0020 N0020

G54 G18 M

S >_ MDI **** *** *** [ PRGRM ] [ MDI ] [ CURRNT ] [ NEXT ] [ (OPRT) ]

START

8. Press the START button. The X axis and the Z axis move to 50.0 and 30.0 respectively at rapid traverse.

41

Chapter 5 Automatic Operation

Chapter 5 Automatic Operation


In automatic operation, the machine is operated according to the program. It is very hazardous inside the machine during automatic operation because of high-speed spindle (chuck) rotation, X-/Z-axis movements, and turret rotation. Besides, chips and coolant splash in a hot and humid space.

WARNING

Never open any cover or door mounted on the machine during automatic operation and spindle rotation. Even in any other status than automatic operation, utmost care should be taken if it is needed to enter such a hazardous area or touch movable sections for setting up or maintenance work while the power is turned on. Failure to observe this warning will result in critical bodily injuries. Noise during cutting may exceed 70 dB, resulting in damaging your hearing ability. Use protective articles (headphones, etc.) as appropriate.

Inside the front door is a hazardous area.

* The figure shows the machine equipped with loader. Fig. 18

42

Chapter 5 Automatic Operation

5-1 Preparation for Automatic Operation


5-1-1 Process of Starting Automatic Operation
Check cutting sections and contents with drawings.

Determine the operation process.

Prepare required tools and workpieces.

Enter a required program in a process sheet.


process sheet

Input the program into the machine.

Carry out the setting up (mounting of workpiece and cutting tools, tool offset, etc.)

Perform the program check (test running).

Conduct the trial cutting.

Perform the dimensional offset.

Start the productive operation.


43

Chapter 5 Automatic Operation

5-1-2 Conditions for Starting Automatic Operation


* Automatic operation cannot be started in the following conditions:

The FEED HOLD button is pressed. The EMERGENCY STOP button is pressed. The reset signal is given. An operation mode other than AUTO is selected. A sequence number is being searched for. An alarm is occurring. The NC unit is not ready. Automatic operation is being executed, and is not in a feed hold. The machine door is open when the DOOR INTERLOCK switch is turned on.

+X -Z +Z

RAPID

1. Return the X and Z axes to their zero points. The zero return completion lamp for each axis will light up.

-X

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

2. Move the cursor to the beginning of the program. (1) Press EDIT of the mode selector switch. The lamp in the switch will light up. (2) Press the PROG key.

PROG

(3) Press the RESET key. The cursor moves to the top of the program.
RESET
PROGRAM O 0001; N1 G00 G97 S500 M03 T0100; X... Z... T0100 M08; O0001 N1234

Cursor

5-7-2 Calling a Program

44

Chapter 5 Automatic Operation

3. Press AUTO of the mode selector switch.


EDIT AUTO

MDI

HANDLE

JOG

ZERO RETURN

The lamp in the switch will light up.

CHUCK CLOSE

4. Close the chuck, by stepping on the foot switch. The CHUCK CLOSE lamp will light up.

45

Chapter 5 Automatic Operation

5-2 Program Check (Test Running)


Before starting automatic operation, check that the program is input correctly and the chuck does not interfere with any of cutting tools. A program check (test running) can be done in the following procedures. 5-2-1 Program Check (Test Running) - (1) In this checking method, the spindle does not rotate. 1. Satisfy the conditions for starting automatic operation as described in 5-1-2.
* Do not mount a workpiece in the chuck.

PROGRAM CHECK

2. Press the PROGRAM CHECK switch. The lamp in the switch will light up.

SINGLE BLOCK

3. Press the SINGLE BLOCK switch. The lamp in the switch will light up.

FEED RATE OVERRIDE


50 100

4. Set the FEED RATE OVERRIDE switch to 0%.

0%

150

START

5. Press the START button. The CYCLE START lamp will light up. 6. Press the [CHECK] soft key until the required program check screen appears.
PROGRAM CHECK O0010 N0010 O0001 ; G00 G97 S500 M03 T0100; G00 X50 Z2 T0101 M08; (RELATIVE) (DISTANCE TO GO) (G) U -134.442 X 0.000 G00 G99 G25 W 54.366 Z 0.000 G97 G21 G22 G69 G40 SRPM 1000 SSPM 0 F S0 10000 SMAX 32767 M T SACT 0 ARS. [ ABS ] [ REL ] [ ] [ ] [ (OPRT) ]

46

Chapter 5 Automatic Operation


FEED RATE OVERRIDE
50 100

7. Set the FEED RATE OVERRIDE switch to the position except 0%.

0%

150

8. Repeat steps 4 to 7.

* If any defect is found in the checked program, press the FEED HOLD button and then the RESET key to reset automatic operation. Perform the zero point return, correct the program and conduct the program check (test running) again.

47

Chapter 5 Automatic Operation

5-2-2 Program Check (Test Running) - (2) If the program check (1) results in success, proceed with the program check (2) continuously. In this checking, the spindle rotates according to the program. 1. Satisfy the conditions for starting automatic operation as described in 5-1-2.
* Do not mount a workpiece in the chuck.

SINGLE BLOCK

2. Press the SINGLE BLOCK switch. A lamp in the switch will light up.

RAPID OVERRIDE

3. Select F0 with the RAPID OVERRIDE switch.

100% F0 F0 100%

FEED RATE OVERRIDE


50 100

4. Set the FEED RATE OVERRIDE switch to 100%.

0%

150

START

5. Press the START button. The CYCLE START lamp will light up.
* The program is executed only by one block each time the START button is pressed.

48

Chapter 5 Automatic Operation

5-3 Trial Cutting


If the program check (2) results in success, conduct a trial cutting next. The trial cutting can be done in the following procedures.
WARNING

Be sure to close the front door tightly and never open any cover or door during automatic operation. Noise during cutting may exceed 70 dB, resulting in damaging your hearing ability. Use protective articles (headphones, etc.) as appropriate. 1. Satisfy the conditions for starting automatic operation as described in 5-1-2. In this operation, mount a workpiece in the chuck and then close the chuck.

SINGLE BLOCK

2. Close the front door. 3. Press the SINGLE BLOCK switch. The lamp in the switch will light up. 4. Select F0 with the RAPID OVERRIDE switch.

RAPID OVERRIDE

100% F0 F0 100%

FEED RATE OVERRIDE


50 100

5. Set the FEED RATE OVERRIDE switch to 100%.

0%

150

START

6. Press the START button. The CYCLE START lamp will light up.
* The program is executed only by one block each time the START button is pressed.

7. After completing the trial cutting, inspect the configuration and dimensions of finished workpiece. If any defect is found in the configuration or dimensions, perform a tool offset, etc. and then conduct the trial cutting again.
6-3 Tool Wear Offset

49

Chapter 5 Automatic Operation

5-4 Pause and Restart of Automatic Operation


5-4-1 Pause of Automatic Operation
FEED HOLD

To stop the execution of automatic operation temporarily, press the FEED HOLD button. By pressing the FEED HOLD button, the slide stops immediately except during thread cutting. As the same time, the CYCLE START lamp is turned off and the FEED HOLD lamp is turned on.
FEED HOLD

CYCLE START

* The machine stops in the following status after the FEED HOLD button is pressed. A dwell is suspended if the feed hold status becomes effective while a dwell is being executed. Operation stops upon completion of a motion if the feed hold status becomes effective while the M code or the T code command is being executed. Operation stops upon completion of thread cutting if the feed hold status becomes effective during thread cutting operation.

5-4-2 Restart of Automatic Operation


START

In order to restart automatic operation from the feed hold status, press the START button. By pressing the START button, the slide starts to move, the FEED HOLD lamp is turned off and the CYCLE START lamp is turned on.

CYCLE START

FEED HOLD

50

Chapter 5 Automatic Operation

5-5 Manual Operation during Automatic Operation


When performing manual operation during automatic operation, follow the procedures below. 1. Press the FEED HOLD button or set the SINGLE BLOCK switch to ON. Automatic operation will stop temporarily.

FEED HOLD
SINGLE BLOCK

or

POS

2. Press the POS key to display the actual position screen, and record the coordinate value of the stop position from the screen.
ACTUAL POSITION (ABSOLUTE) X Z 123.456 32.456

ABS

] [

REL

] [

ALL

] [

] [ (OPRT) ]

3. Perform manual operation.


Chapter 3 Manual Operation

4. Return each axis to the recorded coordinate value referring to the current position display on the screen. 5. Press AUTO of the mode selector switch. The lamp in the switch will light up.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

START

6. Press the START button. Automatic operation will restart.

51

Chapter 5 Automatic Operation

5-6 MDI Operation during Automatic Operation


When performing MDI operation during automatic operation, follow the procedures below. *MDI operation is not available in feed hold status.

SINGLE BLOCK

1. Press the SINGLE BLOCK switch. The lamp in the switch will light up. Automatic operation will stop temporarily.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

2. Press MDI of the mode selector switch. The lamp in the switch will light up.

3. Perform MDI operation.


Chapter 4 MDI Operation
EDIT AUTO

MDI

HANDLE

JOG

ZERO RETURN

4. Press AUTO of the mode selector switch. The lamp in the switch will light up.

START

5. Press the START button. Automatic operation will restart.

52

Chapter 5 Automatic Operation

5-7 Program Editing


This section describes procedures each for inputting, calling, listing, deleting, inserting, altering and searching the program.
Never operate any switch, key or button while wearing gloves.
* The following operation methods can be checked on the
PROG HELP

CAUTION

NC screen using the help function.

HELP (OPERATION METHOD) 1. PROGRAM EDIT 2. SEARCH 3. RESET 4. DATA INPUT WITH MDI 5. DATA INPUT WITH TAPE 6. OUTPUT 7. INPUT WITH FANUC CASSETTE 8. OUTPUT WITH FANUC CASSETTE 9. MEMORY CLEAR S

01234 N0001

0 T0000

MEM **** *** *** 00:00:00 [ 1. ALAM ] [ 2. OPR ] [ 3. PARA ] [ ] [ (OPRT) ]

OPERATION METHOD menu Screen


HELP (OPERATION METHOD) <<1. PROGRAM EDIT>> * DELETE ALL PROGRAMS MODE : EDIT SCREEN : PROGRAM OPR : (09999)-<DELETE> * DELETE ONE PROGRAM MODE : EDIT SCREEN : PROGRAM OPR : (O+PROGRAM NUMBER) - <DELETE> S 00:00:00 0 T0000 ] [ (OPRT) ] 01234 N0001 1/4 Each item Page/maximum page Operation Set mode Operation location Operation procedure

> MEM **** *** *** [ 1. ALAM ] [ 2. OPR ] [ 3. PARA ] [

Example of OPERATION METHOD Screens

FANUC OPERATORS MANUAL for details

53

Chapter 5 Automatic Operation

5-7-1 Inputting a Program When inputting the program in manual operation without using any input equipment, follow the procedures below.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

1. Press EDIT of the mode selector switch. The lamp in the switch will light up.

PROGRAM EDIT OFF ON

2. Turn the PROGRAM EDIT switch to "ON".

PROG

3. Press the PROG key. The program screen will appear.

4. Press the key [O].

OP
5. Input a required program number using data input keys. 6. Press the INSERT key.
INSERT

EOB E

7. Press the EOB key.

54

Chapter 5 Automatic Operation

8. Press the INSERT key.


INSERT

9. Input only a word of program using the data input keys. Ex.) N1

10. Press the INSERT key.


INSERT

11. Repeat steps 9 and 10 to input a block of the program. Ex.) N1 G00 S500 M03 12. Press the EOB key. Ex.) N1 G00 S500 M03;

EOB E

13. Press the INSERT key.


INSERT

14. Repeat steps 9 to 13 to input the required program completely.


PROGRAM EDIT OFF ON

15. Return the PROGRAM EDIT switch to OFF.


separately provided Programming Manual for details

55

Chapter 5 Automatic Operation

5-7-2 Calling a Program Calling a program can be done in the following procedures.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

1. Press EDIT of the mode selector switch. The lamp in the switch will light up.

PROG

2. Press the PROG key. The program screen will appear.


PROGRAM O0040 N0012

ADRS.

S OT EDIT [ PRGRM ] [ CHECK ] [ CURRENT ] [ NEXT ] [ (OPRT) ]

OP

3. Press the key [O].

4. Input the program number to be called using the data input keys. 5. Press the [O SRH] soft key.
* [O SRH] is displayed by pressing the [(OPRT)] soft key.

56

Chapter 5 Automatic Operation

5-7-3 Displaying a Program Library Follow the procedures below when displaying all the program numbers registered in the memory.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

1. Press EDIT of the mode selector switch. The lamp in the switch will light up.

2. Press the PROG key. The program screen will appear.


PROG

3. Press the [LIB] soft key. Number of registered programs, free area, used and free memory area and program library will be displayed on the screen.
The number of programs which can be registered additionally. The number of the programs registered (including the subprograms) PROGRAM O2000 N0120 SYSTEM EDITION O0400-01 PROGRAM NO. : 8 FREE : 55 MEMORY AREA USED : 381 FREE : 3714 PROGRAM LIBRARY O0001 O2000 O0050 O0040 O0100 O0124

The capacity of the program memory in which data is registered (indicated by the number of characters) The capacity of the program memory which can be used additionally (indicated by the number of characters)

S > EDIT **** *** *** [ PRGRM ] [ LIB

O T0000

10:20:45 ] [ CURRNT ] [ C. A. P. ] [ (OPRT) ]

*Program names can be displayed by the setting at parameter NAM (No. 3107#0).

57

Chapter 5 Automatic Operation

5-7-4 Deleting a Program

CAUTION

Be sure to check the content of the program before deleting it. It is recommended that the data should be stored on a tape, etc.

Program deleting can be done in the following procedures.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

1. Press EDIT of the mode selector switch. The lamp in the switch will light up.

PROGRAM EDIT OFF ON

2. Turn the PROGRAM EDIT switch to ON.

3. Press the PROG key.


PROG

4. Press the key [O].

OP

5. Input the program number to be deleted using the data input keys. 6. Press the DELETE key.
DELETE

* When deleting all programs registered in the memory, press the keys as follows in step 5 ;

+
()

9D
(9)

9D
(9)

9D
(9)

9D
(9)

58

Chapter 5 Automatic Operation

5-7-5 Searching Searching a work or sequence number can be done in the following procedures. Procedures for calling the program to be edited are omitted in this section.
5-7-2 Calling a Program

Example 1 Searching for the sequence No. N2 from the top of the program

NQ

1. Press the key [N].

2. Press the key [2].

3. Press the [N SRH] soft key.


* [N SRH] can be displayed by pressing the [(OPRT)] soft key.

O 0001 ; N1 G00 X32.0 G01 G00 G90 G28 M01 ; N2 G00

S3000 M03 T0100 ; Z0 TO101 M08 ; X-1.0 F0.1 ; X30.0 Z2.0 ; X10.5 Z-5.0 F0.2 ; U0 W0 ; S3000 M03 T0200 ;

The cursor moves below N2.

59

Chapter 5 Automatic Operation

Example 2 Searching for the word Z0 from the top of the program 1. Press the key [Z].
Y

2. Press the key [0 (zero)].

3. Press the [SRH] or [SRH] soft key.


* [SRH] and [SRH] can be displayed by pressing the [(OPRT)] soft key. * Pressing the [SRH ] soft key starts searching from the current cursor position toward the top of the program.

O 0001 ; N1 G00 S3000 M03 T0100 ; X32.0 Z0 T0101 M08 ; G01 X 1.0
The cursor moves below Z0.

* The search starts from the current cursor position, and the cursor moves to the sequence number, word and address which are programmed first. To start the search from the head of the program, return the cursor to the program head by pressing the RESET key. * When the sequence number, word, or address specified for searching could not be found, the alarm P/S 71 ALARM will appear.

60

Chapter 5 Automatic Operation

5-7-6 Deleting a Word or Block Deleting a word or a block can be done in the following procedures. Procedures for calling the program to be edited are omitted in this section.
5-7-2 Calling a Program

Example 1 Deleting a word 1. Search for the word to be deleted.


5-7-5 Searching

2. Press the DELETE key.


DELETE

O 0001 ; N1 G00 S3000

M03

T0100 ;

word to be deleted

DELETE

O 0001 ; N1 G00 M03

T0100 ;

61

Chapter 5 Automatic Operation

Example 2 Deleting a block 1. Search for the word heading the block to be deleted.
5-7-5 Searching

2. Press the EOB key.


EOB E

3. Press the DELETE key.


DELETE

O 0001 ; N1 G00 S3000 M03 T0100 ; X32.0 Z0 TO101 M08 ; G01 X-1.0 F0.1 ;
Cursor block to be deleted

EOB E

DELETE

O 0001 ; N1 G00 G01

S3000 M03 X-1.0 F0.1 ;

T0100 ;

* When a sequence number (N) is specified in step 2, the blocks from the searched one to the specified one will be deleted.

62

Chapter 5 Automatic Operation

5-7-7 Inserting a Word Follow the procedures below when inserting a word. Procedures for calling the program to be edited are omitted in this section.
5-7-2 Calling a Program

1. Search for the word immediately before the insertion location.


5-7-5 Searching

2. Input the word to be inserted using the data input keys. 3. Press the INSERT key.
INSERT

O 0001 ; N1 G00
Cursor

M03

T0100 ;
Insert S2000.

INSERT

O 0001 ; N1 G00

S2000

M03

T0100 ;

inserted word

63

Chapter 5 Automatic Operation

5-7-8 Altering a Word Follow the procedures below when altering a word. Procedures for calling the program to be edited are omitted in this section.
5-7-2 Calling a Program

1. Search for the word to be altered.


5-7-5 Searching

2. Input the required word using the data input keys.

ALTER

3. Press the ALTER key. Ex.) Changing the word S3000 to S2500

O 0001 ; N1 G00 S3000


Cursor

M03

T0101 ;

word to be altered

5]
(5)

(S)

(2)

(0)

(0)

ALTER

O 0001 ; N1 G00 S2500

M03

T0101 ;

altered word

64

Chapter 6 Setting Up

Chapter 6 Setting Up
In order to operate the machine in automatic operation, cutting tools and the chuck must be mounted correctly and the tool offset should be done properly.

6-1 Tooling
Follow the procedures below when mounting the cutting tools. The numbers of cutting tools to be used in the program must conform to ones to be actually mounted.
CAUTION

Cutting tools should be mounted securely and well-balanced.

[Required tools]

Allen wrenches [5], [8] Spanner [17]

1. Turn the turret to index a plane on which a cutting tool is mounted.


3-3 Turret Indexing

2. Mount tool holders on the turret.


*OD turning tools can be mounted directly on the turret using clamp blocks.

3. Mount cutting tools on the tool holders.


* It is better to mount all cutting tools so that their protruding length become even.

4. Repeat steps 1 through 3.

OD turning tool Clamp block

Hex. socket head cap bolt

Holder

* Insert the holder's key into the keyway on the turret mounting surface. Fig. 19

65

Chapter 6 Setting Up

OD/face/grooving tool 20 sq.

Clamp block C

Tap

Tap holder

Round hole bush

ID holder

Boring bar

Blank 25 Boring holder

Center straight drill

Drill chuck

Drill chuck arbor

Drill socket

Double boring holder 25

Taper drill

Drill Sleeve

OD nozzle

U-drill

Round hole bush

U-drill holder Option: Tailstock specification

Boring bar

Center straight drill Blank

Double boring holder 20

Fig. 20

66

Chapter 6 Setting Up

6-2 Tool Offset


The start point of each cutting tool should be the machine zero point whenever automatic operation is started. It is impossible to set all tools equally in length. Accordingly, a distance to the program zero point from the tool nose located at the machine zero point needs to be input into the machine. Measure the distance and input it on the tool offset screen in the following procedures.

WARNING

Never touch the spindle directly nor indirectly while it is rotating. Do not remove chips on/around cutting tools during spindle rotation. Be sure to wear safety goggles. Be sure to record the value input into the tool offset.

CAUTION

+X -Z +Z

Zero return completion lamps

1. Return both the X and Z axes to their zero points in manual operation.
3-1 Zero Point Return

RAPID

-X

+X -Z +Z

2. Move the cutting tool toward a workpiece in JOG feed.


3-2-1 JOG Feed

RAPID

-X

3. Rotate the spindle.

67

Chapter 6 Setting Up

In the X-axis direction 4. Cut outer surface (OD) of the workpiece in the handle mode.

5. Move only the Z axis in the plus direction.


* Never move the X axis at this time.

6. Stop the spindle.

7. Press the OFFSET SETTING key.


OFFSET SETTING

8. Press the [OFFSET] soft key. 9. Press the [GEOM] soft key. The OFFSET/GEOMETRY screen is displayed.
OFFSET/GEOMETRY NO. X Z G_01 0.000 0.000 G 02 0.000 0.000 G 03 0.000 0.000 G 04 0.000 0.000 G 05 0.000 0.000 G 06 0.000 0.000 G 07 0.000 0.000 G 08 0.000 0.000 ACTUAL POSITION (RELATIVE) [WEAR ] [ GEOM ] [ ] [ O1000 N1000 R 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 T 0 0 0 0 0 0 0 0

[(OPRT)]

10. Measure the diameter of finished workpiece.

68

Chapter 6 Setting Up

11. Move the cursor up to the required tool offset number using the cursor keys.

12. Input as follows using the address/numeric keys.

C
measurement

(X)

13. Press the [MEASUR] soft key. The X-axis shift amount to the program zero point from the machine zero point will be entered automatically. Ex.) If OD of the machined workpiece is 20.1 mm, press;

0
(0)

(.)

1
(1)

(X)

(2)

keys and then the [MEASUR] soft key.

69

Chapter 6 Setting Up

In the Z-axis direction 14. Rotate the spindle again.

15. Cut the end face of the workpiece in handle mode.

Machining allowance Finish surface

16. Move only the X axis in the plus direction.


* Never move the Z axis at this time.

17. Stop the spindle.

18. Measure the finishing allowance from the actually cut end face to the finish end face. 19. Check that the cursor is located blow the tool offset number to be input. 20. Input as follows using the address/numeric keys.

Y
finishing allowance measured in step 18

(Z)

70

Chapter 6 Setting Up

21. Press the [MEASUR] soft key.


The Z-axis shift amount from the machine zero point to the program zero point will automatically be entered.

2 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456

1) In the case that the measured finishing allowance is 0 mm, input as follows:

(Z)

(0)

Then, press the [MEASUR] soft key. 2) In the case that the measured finishing allowance is 0.5 mm, input as follows:

(.)

5]
(5)

(Z)

(0)

Then, press the [MEASUR] soft key. 3) In the case that the end face has been cut excessively by 0.5 mm, input as follows:

+
(-)

5]
(5)

(Z)

(0)

(.)

Then, press the [MEASUR] soft key.


TURRET

22. Move the turret to index the next cutting tool.

23. Repeat steps 1 through 21 for all cutting tools.

71

Chapter 6 Setting Up

6-3 Tool Wear Offset


When a dimensional accuracy specified in the drawings cannot be assured due to tool abrasion, the tool nose wear can be compensated only by inputting the error.
1. Press the OFFSET SETTING key.
OFFSET SETTING

2. Press the [OFFSET] soft key and then [WEAR] soft key. Display the OFFSET/WEAR screen.
OFFSET/WEAR NO. X Z G_01 0.000 0.000 G 02 0.000 0.000 G 03 0.000 0.000 G 04 0.000 0.000 G 05 0.000 0.000 G 06 0.000 0.000 G 07 0.000 0.000 G 08 0.000 0.000 ACTUAL POSITION (RELATIVE) [ WEAR ] [ GEOM ] [ ] [ O1000 N1000 R 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 T 0 0 0 0 0 0 0 0

] [ (OPRT) ]

Ex.) When a diameter of the workpiece cut by the cutting tool T1 has become 0.05 mm larger than the specified in the drawing: 3. Move the cursor to W01. 4. Press the keys as follows.

+
(-)

5]
(5)

(0)

(.)

(0)

Then, press the [+INPUT] soft key.


* For the tool wear offset in the Z-axis direction, move the cursor to Z data, enter the appropriate value, and then press the [+INPUT] soft key. * The above offset value should be entered by an incremental command.

72

Chapter 6 Setting Up

6-4 Mounting of Power Chuck


Follow the procedures below when mounting the power chuck.
the instruction manual issued by the chuck maker, because mounting method differs according to the chuck maker, chuck type, etc.

DANGER

When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned ON or the operation panel is not touched by mistake. Failure to observe this warning will result in critical bodily injuries. The cover must not be opened by unqualified personnel for maintenance. Be sure to turn the main power switch OFF when it is needed to work inside the cover.

WARNING

Matsumoto ZA-5 [Required tools] Allen wrenches [6], [8], [17] Dial gauge (Division : 0.002 mm) 1. Clean off all the mounting surfaces of the spindle and the chuck. 2. Step on the foot switch to close the chuck. The CHUCK CLOSE lamp will turn ON. 3. Mount the chuck body (1).
* Insert an L wrench from the front side of the chuck while holding the chuck body, ad connect the chuck with the sleeve by turning a mounting bolt (M20).

4. Fix the chuck body (1) with bolts (M1085 (2)). 5. Fix the chuck jaws (4) and T-nuts (3) with bolts (M825 (5)). 6. Adjust the stroke of chuck jaws.
6-6 Forming of Soft Jaws

73

Chapter 6 Setting Up

No. 1 2 3 4 5

Part name Chuck body Bolt (M10 x 85) T-nut Jaw Bolt (M8 x 25)

Fig. 21 74

Chapter 6 Setting Up

6-5 Mounting of Collet Chuck


Follow the procedures below when mounting a collet chuck for the spindle. When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned ON or the operation panel is not touched by mistake. The cover must not be opened by unqualified personnel for maintenance. Be sure to turn the main power switch OFF when it is needed to work inside the cover.

DANGER

WARNING

[Required tools]

Allen wrenches [6], [8]

1. Clean off all the mounting surfaces of the spindle and the collet chuck. 2. Step on the foot switch to open the chuck. 3. Attach the draw bar A (1) to the sleeve. The cylinder stroke 15 mm is shortened to 3 mm. 4. Attach the collet flange (2) using six socket head cap bolts (4) (M10 x 100). 5. Loosen the collet detent pins (3), and attach the collet. 6. There are three collet detent pin positions on the collet flange (2). By changing the collet detent pin position, tightening allowance can be adjusted.
* In other two places, regular socket head cap bolts should be attached. Do not leave these positions empty. Doing so may impair the cutting accuracy because of balance.

1 2 3 4 5

Draw bar A Collet flange Detent pin Bolt M10100 (6) Collet

Fig. 22

75

Chapter 6 Setting Up

[Reference drawing]

The following figure shows the chuck/collet mounting state on the machine equipped with a solid cylinder.

Hydraulic chuck mounting drawing

Draw bar

Hydraulic chuck

Collet Collet flange

Collet mounting drawing

Fig. 23

76

Chapter 6 Setting Up

6-6 Forming of Soft Jaws


In order to securely clamp or accurately cut workpieces, it is necessary to form soft jaws. According to the cutting conditions, such as material, shape, size, chuck type, etc., there are various methods to form soft jaws.

WARNING

Never touch the spindle directly nor indirectly while it is rotating. Dull or unstable cutting tools will cause damage or accidents. Replace with proper tools in advance. Wear a protective helmet, safety goggles and safety shoes.

6-6-1 Precaution for Forming Soft Jaws [ Required tools] ID boring tool and tip Spacer for forming jaws (or its equivalent)

Chuck

Jaw

Chuck

Jaw

Bolt hole for jaw

Spacer

Chuck jaw former

Fig. 24

77

Chapter 6 Setting Up

Adjustment of chuck stroke The chuck jaws should be adjusted so that they can grip a workpiece at the center of chuck stroke. It is recommended that several spacers of different sizes be prepared for the forming.

Opened position
123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456 123456

Center

When jaws are closed

Spacer

Forming of soft jaws Make a recess on the inside corner of soft jaws.

Cutting tool for recessing

Other precautions Securely mount soft jaws and the chuck in serration while taking notice so that soft jaws do not stick out from the chuck. Chuck pressure for forming soft jaws and for chucking a workpiece should be equal. Put marks (ex. 1, 2, 3...) on soft jaws according to the master jaw in order to record their positions. It is recommended that soft jaws be milled beforehand if they have to be largely cut. For forming of three-way jaw, it is recommended that a three-point contact type micrometer be used for measuring the inside diameter accurately. As soft jaws should be formed in continuous operation, cutting tools have to receive sufficient attention because they may be broken.
78

Chapter 6 Setting Up

6-6-2 Forming of Soft Jaws in Manual Operation

WARNING

Never touch the spindle directly nor indirectly while it is rotating. Dull or unstable cutting tools will cause damage or accidents. Replace with proper tools in advance. Wear a protective helmet, safety goggles and safety shoes.

* Be sure to check the OD runout of the soft jaws. Form them to the desired workpiece diameter after turning OD of the soft jaws. Because of a trivial unbalance, roundness in cutting may deteriorate.

1. Display the ACTUAL POSITION (RELATIVE) screen using the POS key and the [REL] soft key.
POS

ACTUAL POSITION (RELATIVE) O0001 N0000 U XXX.XXX W XXX.XXX

2. Clamp a spacer with the foot switch. The CHUCK CLOSE lamp will light up. 3. Move a cutting tool close to a soft jaw in manual feed. 4. Apply the cutting tool tip onto the I.D. of the soft jaw by using a manual pulse generator. 5. Press the and the [ORIGIN] soft key.

The value of U on the screen will become 0.000.

ACTUAL POSITION (RELATIVE) O0001 N0000 U 0.000 W XXX.XXX [ Spacer ] [ ORIGIN ]

(position of U0)

79

Chapter 6 Setting Up

6. Apply the cutting tool tip onto the end face of the soft jaw by using a manual pulse generator. 7. Press the and the [ORIGIN] soft key.

The value of W on the screen will become 0.000.

ACTUAL POSITION (RELATIVE) O0001 N0000 (position of W0) U W [ Spacer XXX.XXX 0.000 ] [ ORIGIN ]

8. Form the soft jaw by making each surface of U0 and W0 as standard.


Ex.) Forming a soft jaw to 30 mm in dia. and 15 mm in depth:

Turning (leaving 0.3 mm (in dia.) and 0.05 mm (in depth) finishing allowance)

Recessing

Finish turning (to the specified dia. and depth)

14.95

Recess

12345 12345 12345 12345 12345 12345 1234 12345 1234

1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234

29.7

123 123 123 123 123 123 123 123 123 123 123 123 123 123

Hardening

1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234

30.0

Spacer

Spacer

Spacer

80

Chapter 6 Setting Up

6-6-3 Forming of Soft Jaws in Automatic Operation


* Be sure to check the O.D. runout of the soft jaws. Form them to the desired workpiece diameter after turning O.D. of the soft jaws. Because of a trivial unbalance, roundness in cutting may deteriorate.

1. Return both the X and Z axes to their zero points.


* Check that Y axis zero point return is complete. 3-1 Zero Point Return

2. Move a cutting tool close to a soft jaw in manual feed. 3. Machine on the I.D. of soft jaw by using a manual pulse generator, and then perform a tool offset.
Ex.) When the I.D. is 20.5 mm after cutting: 1) Display the OFFSET/GEOMETRY screen, and move the cursor to the offset number of the cutting tool. 2) Press keys as follows.

5]

Then, press the [MEASUR] soft key.

Jaw

4. Apply the cutting tool tip onto the end face of soft jaw. 5. Press the and keys.

Then, press the [MEASUR] soft key.


6-2 Tool Offset

Jaw

20.5

81

Chapter 6 Setting Up

6. Return both the X and Z axes to their zero points. 7. Roughly machine the soft jaw using the program below.
Ex.) Forming a soft jaw to 30 mm in dia. and 20 mm in depth Roughly cut the soft jaw to 29.8 mm in dia. and 19.95 mm in depth.

Jaw

O1000; G00

S500 X18.0 X22.0 X24.0; X26.0; X28.0; X29.6; X29.8; U0.

G90

M03 Z50.0 Z2.0; Z-19.95

T0100; T0101; F0.15;

(Depth of cut in X-axis direction may differ depending on conditions.)

G28 M30;

W50.0;

8. Measure the I.D. of soft jaw precisely. 9. Perform offset against the dia. of 29.8 mm.
6-2 Tool Offset

82

Chapter 6 Setting Up

10. Perform finish turning using the program below. O1000; G00 S500 M03 T0100; X35.0 Z50.0 T0101; Z2.0; G01 X30.0 Z-0.5 F0.1; Z-20.0; X19.0; G00 Z50.0; G28 U0 W0; M30; 11. Perform recessing using a manual pulse generator.

Recessing tool

83

Chapter 7 Appendix

Chapter 7 Appendix
7-1 List of G Codes
G code G00 G01 G02 G03 G04 G10 G20 G21 G27 G28 G30 G32 G40 G41 G42 G50 G50 G70 G71 G72 G73 G74 G75 G76 G90 G92 G94 G96 G97 G98 G99 Function Rapid traverse (positioning) Linear cutting (linear interpolation) Circular cutting CW (circular interpolation) Circular cutting CCW (circular interpolation) Timer (dwell) Offset amount program input Input in inch Input in metric Reference point return check Reference point return 2nd reference point return Straight/taper thread cutting Tool nose radius compensation cancel Tool nose radius compensation right Tool nose radius compensation left Coordinate system setting Max. spindle speed setting Finishing cycle Stock removal in turning Stock removal in facing Pattern repeating End face cut-off cycle Outer diameter grooving cycle Thread cutting cycle Stock removal in turning Thread cutting cycle Stock removal in facing Constant surface speed control Constant surface speed control cancel Feed per minute Feed per rotation 05 (Multiple cycle) (Multiple cycle) (Multiple cycle) (Multiple cycle) (Multiple cycle) (Multiple cycle) (Multiple cycle) (Canned cycle) (Canned cycle) (Canned cycle) 02 01 00 07 01 00 06 00 01 Group Remarks Standard Standard Standard Standard Standard Option Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Option Option Option Option Option Option Option Standard Option Standard Option Option Standard Option

*1 G codes marked with are initial G codes when turning power ON. *2 G codes of group 00 are not modal. They are only effective in the block in which they are specified. Other G codes are effective until another G code in the same group is commanded. *3 A number of G codes can be specified in the same block. When more than one G code of the same group is specified, the G code specified later is effective. *4 If a G code not listed on the table is inputted, or any optional G code not provided in the system is commanded, an alarm (010 P/S ALARM) is displayed.

84

Chapter 7 Appendix

7-2 List of M Codes


TAKAMAZ FANUC
M code * : Optional

Function Program stop Optional program stop End of program (same as M30) Spindle normal rotation (with S code) Spindle reverse rotation (with S code) Spindle stop Air 1 ON Air 1 OFF Coolant 1 ON Coolant 1 OFF Chuck air SET Chuck air RESET Spindle non-stop/chuck open-close SET Spindle non-stop/chuck open-close RESET Air 2 ON Air 2 OFF Tail quill advance (with sensor check) Tail quill retract (with sensor check) Coolant 2 ON Coolant 2 OFF Unloader operation Auto loader operation Tailstock (quill + base) advance (with sensor confirmation) Tailstock (quill + base) retract (with sensor confirmation) Tailstock base advance (with sensor confirmation) Tailstock base retract (with sensor confirmation) Spindle index pin advance (lock) Spindle index pin retract (free) End of program (same as M02) Spindle brake ON (lock) Spindle brake OFF (free) Cut-off confirmation Bar end check SET Bar end check RESET
Bar feeder retract start (for Taiwan, Hong Kong)

M code

Function Spindle orientation (at 1st point, w/o lock) Spindle orientation (at 1st point) & lock Spindle orientation, electric lock canceled Spindle orientation (at 2nd point) & lock Spindle orientation (at 3rd point) & lock Spindle orientation (at 4th point) & lock Spindle orientation (at 5th point) & lock Spindle orientation (at 6th point) & lock Low chuck pressure SET High chuck pressure SET Air 3 ON Air 3 OFF Coolant 3 ON Coolant 3 OFF Yellow signal light ON Yellow signal light OFF Red signal light ON Red signal light OFF Chucking sensor OFF confirmation Chucking sensor ON confirmation
Parts catcher advance (w/o sensor confirmation) Parts catcher retract (w/o sensor confirmation) Automatic tool presetter advance (cover open)

M00 M01 M02 M03 M04 M05 *M06 *M07 *M08 *M09 *M10 *M11 *M12 *M13 *M14 *M15 *M16 *M17 *M18 *M19 *M20 *M21 *M24 *M25 *M26 *M27 *M28 *M29 M30 *M31 *M32 *M33 *M34 *M35 *M36

*M40 *M41 *M42 *M43 *M44 *M45 *M46 *M47 *M48 *M49 *M50 *M51 *M52 *M53 *M54 *M55 *M56 *M57 *M58 *M59 *M60 *M61 *M62 *M63 *M66 *M67 *M68 *M69 M70 M71 M72 *M73 *M74

Automatic tool presetter retract (cover close) Spindle inching SET Spindle inching RESET Shutter (auto door) open (w/o sensor confirmation) Shutter (auto door) close (w/o sensor confirmation) Cycle time over check 1 (Timer No. 1) Chuck OPEN Chuck CLOSE Shutter (auto door) open (with sensor confirmation) Shutter (auto door) close (with sensor confirmation)

*M76 85

Counter motion

Chapter 7 Appendix

M code

Function Parts catcher advance (with sensor confirmation) Parts catcher retract (with sensor confirmation) Non-buffering M code Bar replacement monitor

M code

Function Spindle orientation & lock (every 15, 24 divisions)

*M78 *M79 M80 *M81 *M83 *M84 *M85 *M86 *M87 *M88 *M89 *M90 *M91 *M92 *M93 *M96 M98 M99 *M112 *M113 *M114 *M115 *M116 *M117 *M120 *M121 *M122 *M123 *M124 *M126 *M127

M140 M163 *M198 M202


{Sub-program call (from external memory)} Spindle speed attainment check


Additional universal output 1 ON (without FIN signal) Additional universal output 1 OFF (without FIN signal) Additional universal output 2 ON (without FIN signal) Additional universal output 2 OFF (without FIN signal)

HATEC bar feeder start Tail base advance (w/o sensor confirmation) Tail base retract (w/o sensor confirmation) Tail quill advance (w/o sensor confirmation) Tail quill retract (w/o sensor confirmation) Dry Run ON Dry Run OFF / code control mode SET / code control mode RESET
Tool breakage detection: tool check (START)

*M212 *M213 *M214 *M215 M240 M241 M242 M370 M371

Tool life management restart Tool life management check Tool life management skip Cycle time over check 2 SET (timer No. 2) Cycle time over check 2 RESET B-code spindle orientation (w/o lock) B-code spindle orientation (with lock)
Spindle override SET (% designation by B code)

Tool breakage detection: sensor check (END) End of measurement macro

*M400 Call of sub-program (internal memory) End of sub-program *M404


Additional universal output 1 ON (w/o FIN signal) Additional universal output 1 OFF (w/o FIN signal) Additional universal output 2 ON (w/o FIN signal) Additional universal output 2 OFF (w/o FIN signal)

*M401

*M405 M406 M407 M408 M409 M410 M411 *M412 *M413 M414 M415 *M420 *M421 *M422 *M423

Spindle override RESET (fixed to 100%; as specified by S code) Feed override cancel SET (100% fixed) Feed override cancel RESET (0-150%) Error detect ON Error detect OFF Thread chamfering OFF (chamfering 0)
Thread chamfering ON (parameter No. 5130 = 5)

Conveyor motor CW
Conveyor motor CCW

/ code 1 SET / code 1 RESET / code 2 SET / code 2 RESET PMC counter RESET Spindle inching CW Spindle inching stop

Manual absolute OFF Manual absolute ON Wait for delivery completion ON Wait for delivery completion OFF 1st (X-axis) abnormal load detection ON 1st (X-axis) abnormal load detection OFF 2nd (Z-axis) abnormal load detection ON 2nd (Z-axis) abnormal load detection

86

Chapter 7 Appendix

7-3 Variable Timers List


No. 01 to 08: 48-ms increments (0 to 1572800 ms), No. 09 to 40: 8-ms increments (0 to 262100 ms)
Timer 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 No. T00 T02 T04 T06 T08 T10 T12 T14 T16 T18 T20 T22 T24 T26 T28 T30 T32 T34 T36 T38 T40 T42 T44 T46 T48 T50 T52 T54 T56 T58 T60 T62 T64 T66 T68 T70 T72 T74 T76 T78 Turret FIN: Time from turret clamp sensor ON to returning the FIN signal Turret rotation start: Time from turret unclamp to rotation start Chuck seating ON confirmation (M59): Time from ON confirmation start to returning the FIN signal Out-conveyor normal rotation time (M116): Time from conveyor normal rotation (M116) to conveyor stop Out-conveyor reverse rotation time (M117): Time from conveyor reverse rotation (M117) to conveyor stop Out-conveyor normal rotation time: Time from unloader retract (M61, M79) to conveyor stop Coolant discharge alarm: Time from discharge confirmation sensor OFF to triggering an alarm when the coolant ON command is issued Reset & rewind: Time from receiving the loader request signal to executing reset & rewind Automatic power shut-off output: Time from power shut-off condition establishment to output Panel key input delay: Measures against wrong entry on the operation panel Shutter open (M68) FIN: Time before returning the FIN signal without LS confirmation Shutter close (M69) FIN: Time before returning the FIN signal without LS confirmation Unloader advance (M60) FIN: Time before returning the FIN signal without LS confirmation Unloader retract (M61) FIN: Time before returning the FIN signal without LS confirmation Chuck air (M10) ON: Time from chuck open to air ON Chuck air (M10) OFF: Time for air ON Chuck seating ON confirmation (M59) alarm: Time from ON confirmation start to triggering an alarm Address Cycle time-over alarm 1: Time from M70 to the next M70 Cycle time-over alarm 2: Time from M370 to M371 Tailstock quill advance (M16) FIN: Time before returning the FIN signal without LS confirmation Tailstock quill retract (M17) FIN: Time before returning the FIN signal without LS confirmation

87

Maintenance

Contents
Chapter 1 Safety Precautions for Maintenance........................................................ Chapter 2 Daily Inspection ......................................................................................... 2-1 Check Items before Turning Power ON ........................................................ 2-2 Check Items after Turning Power ON ........................................................... Chapter 3 Periodical Inspection ................................................................................. 3-1 Weekly Inspection ......................................................................................... 3-2 Monthly Inspection ........................................................................................ 3-3 Semiannual Inspection ................................................................................... 3-4 Yearly Inspection ........................................................................................... 3-5 Every Three Years Inspection ....................................................................... Chapter 4 Oiling .......................................................................................................... 4-1 List of Oils ..................................................................................................... 4-2 Lubricant Unit................................................................................................ 4-3 Hydraulic Pump Unit ..................................................................................... 4-4 Coolant Unit .................................................................................................. 4-5 Chuck ............................................................................................................. Chapter 5 Trouble Shooting ....................................................................................... 5-1 Initial Measures ............................................................................................. 5-2 Alarm Display................................................................................................ 5-2-1 Alarm Display Sections .................................................................... 5-2-2 Alarm Message Screen and Help Function....................................... 5-3 Check Sheet ................................................................................................... 5-4 Resetting of Emergency Stop ........................................................................ 5-5 Phenomenon and Remedy of Major Problems .............................................. 5-6 Resetting of Overtravel .................................................................................. 5-6-1 When Soft Limit is Actuated: ........................................................... 5-6-2 When Mechanical Limit is Actuated: ............................................... 5-7 Self-diagnosis Procedures.............................................................................. 5-7-1 Displaying Diagnosis Screen ............................................................ 5-7-2 Reading of Signal Address Table ..................................................... 1 2 2 4 6 6 6 7 8 8 9 9 11 12 13 14 15 15 16 16 17 18 19 20 25 25 27 29 29 31

5-8 Parameter Setting and Change ....................................................................... 5-8-1 Parameter Reference ......................................................................... 5-8-2 Parameter Setting (Change) .............................................................. 5-9 Slide Reference Point Setting ........................................................................ Chapter 6 Maintenance for Each Unit ...................................................................... 6-1 Headstock ...................................................................................................... 6-1-1 Adjustment of Chuck Pressure ......................................................... 6-1-2 Chuck Pressure Setting Table for Stroke Adjustable Cylinder ......... 6-1-3 Adjustment of Belt ............................................................................ 6-1-4 Replacement of Belt .......................................................................... 6-1-5 Alignment of Headstock ................................................................... 6-1-6 Replacement of Position Coder ........................................................ 6-2 Slide Unit ....................................................................................................... 6-2-1 Replacement of Wipers ..................................................................... 6-2-2 Measurement and Compensation of Backlash .................................. 6-2-3 Adjustment of Gib ............................................................................ 6-3 Turret Unit ..................................................................................................... 6-3-1 Measurement of Turret Parallelism .................................................. 6-3-2 Adjustment of Turret Clamp Proximity Switch ................................ 6-3-3 Turret Zero Position Setting (for Mitsubishi Motor) ........................ 6-4 Hydraulic Pump Unit ..................................................................................... 6-4-1 Cleaning of Oil Filler Filter .............................................................. 6-4-2 Cleaning of Strainer .......................................................................... 6-4-3 Cleaning of Hydraulic Tank ............................................................. 6-5 Lubricant Unit................................................................................................ 6-5-1 Cleaning of Oil Filler Filter .............................................................. 6-5-2 Cleaning of Suction Filter ................................................................. 6-5-3 Cleaning of Lubricant Tank .............................................................. 6-6 Air Unit ......................................................................................................... 6-6-1 Replacement of Filter Regulator Element ........................................ 6-6-2 Replacement of Elements in Mist Separator and Micro Mist Separator ........................................................................ 6-6-3 Adjustment of Lubricator Oil Drop Amount .................................... 6-6-4 Pressure Adjustment of Filter Regulator .......................................... 6-7 Coolant Unit .................................................................................................. 6-7-1 Cleaning of Coolant Tank .................................................................

32 32 33 36 39 39 39 40 41 43 44 45 46 46 49 51 54 54 56 57 58 58 59 60 61 61 62 63 64 64 67 69 70 71 71

6-8 Electric Cabinet ............................................................................................. 6-8-1 Cleaning of Heat Exchanger ............................................................. 6-8-2 Replacement of Battery .................................................................... 6-8-3 Replacement of Fuse ......................................................................... 6-8-4 Resetting of Thermal Relay ..............................................................

72 72 73 76 77

Chapter 1 Safety Precautions for Maintenance

Chapter 1 Safety Precautions for Maintenance


DANGER

Be sure to turn the main power switch off during maintenance work. The primary power in the factory also should be off for maintenance of the electric cabinet. Never open the door in five minutes after turning the power off, as residual voltage remains. When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake. Never modify or remove safety devices such as limit switches, proximity switches and dogs for overtravel and interlock without our permission. Failure to observe this warning will result not only in machine malfunctioning or damage, but also critical bodily injuries. The cover should not be opened by unqualified personnel for maintenance. Turn the main power switch off when it is needed to work inside the cover. Wear a protective helmet during maintenance work. Use stable ladders, platform, etc. when working at a high level. Maintenance work should be done only by qualified personnel. Mount the covers on the initial positions correctly after finishing maintenance work, and lock the doors with a key securely. After finishing maintenance work, keep the used tools, etc. orderly, and remove all the obstacles, water and oil from the floor in order to restore proper working environment. Procedures and methods described in Maintenance should strictly be observed. Contact your local distributor immediately when any question or doubt arises. Replacement parts (electrical and mechanical) should be as designated by Takamatsu. Observe periodical check-ups as described in Maintenance. Check each item after finishing maintenance work together with a person in charge. Keep a maintenance record, and report it to a person in charge for approval and examination. Keep the maintenance record for 10 years.

WARNING

CAUTION

Safety Guide

Chapter 2 Daily Inspection

Chapter 2 Daily Inspection


2-1 Check Items before Turning Power ON
DANGER

Before turning the power on, check that all cables are properly insulated. Damaged or disconnected cables must be repaired or replaced immediately by qualified personnel, as they could cause an electrical shock or leakage later.

There must be no obstacles, which may interrupt machine


WARNING

operation or maintenance work, in/around the machine. The floor must be free from water and oil.

Unit Headstock unit

Inspection Items No chips should be in/on the collet chuck. The chuck jaws should not be worn out. Lubricant amount should be sufficient. Hydraulic oil amount should be sufficient. Reading of the pressure gauge should be 0. Coolant amount should be sufficient. Chips should not be deposited in the tank excessively. Cutting tools should not be damaged or worn out. There should be no chips on the cutting tools. Cutting tools and holders should be mounted securely. The door should be closed completely. All cables should not be damaged or broken. The front door should be closed completely. The EMERGENCY STOP button should be pressed. The machine environment should be tidy.

Remarks

Lubricant unit Hydraulic pump unit

Coolant unit

Turret unit

Electric cabinet

Others

Chapter 2 Daily Inspection

Front door must be closed.

Turret must not have any broken or wearout tools. must be free from chips around the tools. must securely be equipped with tools and holders.

Hydraulic pump unit The pressure gauge should read "0". EMERGENCY STOP button must be depressed. Coolant tank Coolant should not be dirty and its level should be appropriate.

Electric cabinet door must be closed.

Chips should not be deposited in the tank. Lubrication unit must be equipped with an appropriate amount of oil. Cable connection port must not hold any damaged cable.

Coolant tank must be equipped with an appropriate amount of clean oil. must not have build-up chips.

Hydraulic pump unit must be equipped with an appropriate amount of oil.

* The figure shows the machine equipped with loader. Fig. 1

Chapter 2 Daily Inspection

2-2 Check Items after Turning Power ON


CAUTION

When starting operation after stopping the machine for a long period of time, check that the machine motions, noise and slideway lubrication are free from trouble. If any abnormality, such as abnormal noise, excessive heat generation and abnormal motion, is found, turn off the power immediately and contact the maintenance personnel to take necessary measures. After turning the power on, conduct warm-up operation sufficiently.
Mount no workpiece at this time. Programs for automatic operation should include each function of the machine. Change the spindle speed from low (500 min-1) to intermediate (2,500 min-1), and warm up for about 10 minutes at each speed. Before rotating the spindle with a chuck on it, check that the chuck and jaws are securely fixed.

Unit Headstock unit

Inspection Items There should be no abnormal noise and excessive vibration during the spindle motor rotation. The chuck pressure should be appropriate.
* The chuck pressure depends on the combination of the chuck and the cylinder to use.

Remarks

Slide unit Hydraulic pump unit Coolant unit Air unit Lubricant unit Turret unit Others

There should be no abnormal noise and excessive vibration generated from the X-axis motor and Z-axis motor. The pump pressure should be appropriate. (3.4 MPa) The chuck pressure should be appropriate. (Max. 2.0 MPa) The coolant pump should be working properly. Air pressure should be appropriate. (0.5 MPa) Air should be dry. Lubricant discharge should be appropriate. There should be no abnormal noise and excessive vibration during the turret indexing. No alarm message should be displayed on the NC screen. No alarm lamp should be turned on on the machine operation panel.

Chapter 2 Daily Inspection

Turret unit must not generate any abnormal sound or excessive vibration during turret rotation.

NC screen must not indicate any alarm message.

Spindle motor, X/Z-axis motor must be free from abnormal noise or vibration.

Machine operation panel must not have any illuminating or blinking alarm lamps.

Hydraulic pressure gauge must indicate appropriate chuck pressure. (Max. 2.0 MPa) (Source pressure: 3.4 MPa) Air unit Air pressure should be appropriate. (0.5 MPa)

Lubrication unit must be set to an appropriate discharge amount.

Coolant pump motor is working properly.

* The figure shows the machine equipped with loader. Fig. 2

Chapter 3 Periodical Inspection

Chapter 3 Periodical Inspection


Special Version for optional equipment

DANGER

Inspect the following items periodically to maintain the high machining accuracy for a long period of time. When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake. Turn the main power switch off during maintenance work. The primary power in the factory also should be off for maintenance of the electric cabinet. Never open the door for several minutes even after the power is turned off, as remaining voltage could cause critical bodily injuries.

3-1 Weekly Inspection


Unit Coolant unit Headstock unit Lubricant unit Inspection Items Check if the coolant discharge is proper. Replenish the chuck jaws with grease. Check that oil amount is appropriate. Remarks
4-4 4-5 4-2

3-2 Monthly Inspection


Unit Headstock unit Inspection Items Check if there is abnormal noise, excessive vibration or excessive heat generation from the motor. Check if there is abnormal noise, excessive vibration or excessive heat generation from the motor. Check and clean the cooling fan filter. Check and wipe dust off if any.
6-8-1

Remarks

Slide unit

Electric cabinet

Chapter 3 Periodical Inspection

3-3 Semiannual Inspection


Unit Headstock unit Inspection Items Check the tension of the spindle driving belt. Check the wear-out on the spindle driving belt. Check the tension of the timing belt. Check the wear-out on the timing belt. Check if the motor pulley is clean. Check if the timing pulley is clean. Check that the spindle pulley is clean. Check the wear-out on the wipers, and replace it if necessary. Check that mounting bolts for the proximity switches and dogs are securely tightened. Check that there is no oil leakage and that pipings are not crushed. Remarks
6-1-3

Slide unit

6-2-1

Lubricant unit

Hydraulic pump unit Check that there is no oil leakage and that pipings are not crushed. Coolant unit Electric cabinet Check that there is no oil leakage. Check that connectors, relays and bolts are all securely tightened. Check that bolts and nuts of the covers are all securely tightened. Check the levelling, and adjust it if necessary.
Installation

Others

Chapter 3 Periodical Inspection

3-4 Yearly Inspection


Unit Headstock unit Slide unit Hydraulic pump unit Inspection Items Check the spindle accuracy, adjust it if necessary. Measure the backlash, and adjust it if necessary. Replace the hydraulic oil with new one. Clean the oil inlet filter. Clean the strainer. Clean the suction filter, and replace it if necessary. Clean the oil inlet filter. Check the parallelism of the turret, and adjust it if necessary. Replace the filter element. Replace the back-up batteries with new ones.
* Be sure to replace the batteries while power is supplied to the entire system.

Remarks
6-1-5 6-2-2 4-3 6-4-1 6-4-2 6-5-2 6-5-1 6-3-1

Lubricant unit

Turret unit

Air unit Electric cabinet

6-6 6-8-2

3-5 Every Three Years Inspection


Unit Headstock unit Inspection Items Replace the spindle bearing grease with new one. Remarks
Contact Takamatsu.

Chapter 4 Oiling

Chapter 4 Oiling
4-1 List of Oils
Use new oils specified below to prevent damage to the machine. If an unspecified oil must be used, be sure to check that it has the same viscosity and rust preventive property as the specified oil.

CAUTION

Oiling Point Lubricant unit

Specified Oil (Maker) Slideway lubricant Febis K68 (ESSO)

Amount 1.5 lit.

Interval As required

Remarks
See

4-2.

Hydraulic pump unit Hydraulic oil Nuto 32 (ESSO) Coolant unit Headstock unit Chuck jaws Grease Grease

10 lit.

Yearly

See

4-3.

95 lit. As required

As required Every 3 years Weekly

See

4-4.

Contact Takamatsu.
See

4-5.

* The oiling interval is only for your reference. It may become shorter depending on the machine operating hours.

List of Recommended Oils Name Maker Mobil Showa Shell Esso Nippon Oil Japan Energy ISO VG68 Slideway lubricant Mobil Vactra Oil No. 2 Shell Tonna Oil S68 Febis K68 Uniway HP68 Slidus HS68 ISO VG32 Hydraulic oil Mobil DTE Oil Lite Shell Tellus Oil C32 Nuto 32 FBK Oil RO 32 Hydrax 32 Daphne Mechanic Oil 32

Idemitsu Petrochemical Daphne Multiway 68C

Chapter 4 Oiling

Headstock

Air unit Lubrication unit

Coolant unit

Hydraulic pump

* The figure shows the machine equipped with loader. Fig. 3

10

Chapter 4 Oiling

4-2 Lubricant Unit


Inspection interval Oiling interval Specified oil Oil amount
the machine.

Daily As required Slideway lubricant Febis K68 (ESSO) 1.5 lit. (Tank capacity: 2.0 lit.)

* The tank capacity is subject to change according to the specifications or improvements made to

Supply specified oil from the oil filler port.

Oil filler port

* The figure shows the machine equipped with loader.

Fig. 4 11

Chapter 4 Oiling

4-3 Hydraulic Pump Unit


DANGER

When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake. The cover should not be opened by unqualified personnel for maintenance. Turn the main power switch OFF and lock when it is needed to work inside the cover. Daily Yearly Hydraulic oil Nuto 32 (ESSO) 10 lit. (tank capacity)

WARNING

Inspection interval Oiling (replacing) interval Specified oil Oil amount


operating hours.

* The oiling interval is only for your reference. It may become shorter depending on the machine

Allen wrench [10] Can (for waste oil) 1. Turn the main power switch off. 2. Place the can under the drain port. 3. Loosen the drain cock. The hydraulic oil will drain. 4. Tighten the drain cock. 5. Replenish the tank with hydraulic oil from the oil filler port. [Required tools]
Oil filler port

Drain

* The figure shows the machine equipped with loader. Fig. 5 12

Chapter 4 Oiling

4-4 Coolant Unit


DANGER

When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake. Use non-flammable coolant. When using oil-based coolant inevitably, strictly follow the instructions in Safety Precautions for Fire Prevention Chapter 7 Safety Precautions for Fire Prevention in Safety Guide Never handle coolant with bare hands.

WARNING

CAUTION

Inspection interval Daily Oiling interval As required Oil amount 95 lit. (Tank capacity) [Required tools] Spanner [14] Can (for waste oil) 1. Turn the main power switch off. 2. Drain the waste coolant into the can. 3. Replenish the tank with coolant.
* The figure shows the machine equipped with loader.

Drain

Level gauge

Fig. 6 13

Chapter 4 Oiling

4-5 Chuck
Inspection interval Oiling interval Oil amount
Takamatsu.

Weekly Weekly As required

* The oiling interval is only for your reference. It depends on the type of chucks to use. Contact

[Required tools]

Grease gun

1. Turn the main power switch off. 2. Put grease into the grease nipples using a grease gun.

Grease nipple

* The figure shows the machine equipped with loader. Fig. 7

14

Chapter 5 Trouble Shooting

Chapter 5 Trouble Shooting


5-1 Initial Measures
WARNING

If any doubt or question arises, contact Takamatsu for guidance.

If the machine does not operate normally or an alarm is displayed, check the cause of the trouble and take necessary measures immediately. Troubles can be classified roughly into 3 groups as shown below: I Trouble to be reported to Takamatsu to be taken care of by our service engineers.

I Trouble to be reported to Takamatsu to be taken care of by the customer according to the instructions of Takamatsu.

I Trouble to be taken care of by the customer according to the instructions described in this Manual.
5-3 Check Sheet when informing us of the trouble status

15

Chapter 5 Trouble Shooting

5-2 Alarm Display


5-2-1 Alarm Display Sections When any trouble occurs in the machine, it is indicated on the following sections.
NC Screen Is any alarm message displayed on the screen? When the message ALM flickers in the lower left on the screen; 5-6 Resetting of Overtravel if any of overtravel alarms (No. 500 or 501) are indicated FANUC OPERATORS MANUAL if other alarms than the above are indicated When the message --EMG-- flickers in the lower left on the screen; 5-4 Resetting of Emergency Stop When the message BAT flickers in the lower left on the screen; 6-8-2 Replacement of Battery

Alarm lamps

Fig. 8 * The figure shows the machine equipped with loader.

LUB. ALARM lamp Lights up when the lubricant in the tank becomes insufficient. SEQ. ALARM lamp Lights up when an error is occurring in the electric system. TURRET ALM. lamp Lights up or brinks when a turret-related error is occurring.

5-5 Phenomenon and Remedy of Major Problems when any trouble occurs in the machine

16

Chapter 5 Trouble Shooting

5-2-2 Alarm Message Screen and Help Function


Alarm Message Screen
ALARM MESSAGE O0000 100 510 521 N0000

PARAMETER WRITE ENABLE OVER TRAVEL: +1 OVER TRAVEL: -2

Indicates an emergency stop status.

MDM **** *** *** [ ALARM ] [

S O 13:27:30 ] [ HISTORY ] [

T0000 ][ ]

--EMG-EDIT STOP MTN FIN ALM 16:52:13 (Soft key display) INPUT

Indicates the controller status. Alarm number and message Indicates that an alarm is being issued. BAT Indicates that the battery is low.

Help Function

HELP

1. Press the HELP key. The screen below will appear.


HELP (INITIAL MENU) O1234 N0001 ***** HELP ***** 1. ALARM DETAIL 2. OPERATION METHOD 3. PARAMETER TABLE S MEN **** *** *** O 00:00:00 ] [ T0000

[ 1 ALAM ] [ 2 OPR ] [ 3 PARA ] [

2. Press the [1 ALAM] soft key. The details of the alarm currently issued will be displayed.
HELP (ALARM DETAIL) Alarm number Normal explanation on alarm (32 characters) Function classification (30 characters) NUMBER : 094 MSAGE : P TYPE NOT ALLOWED (COORD CHG) FUNCTION : RESTART PROGRAM ALARM WHEN COORDINATE SYSTEM SETTING IS CONDUCTED AFTER HOLDING AUTOMATIC OPERATION. P-TYPE (WHEN TOOL IS DAMAGED) PROGRAM RESTART CANNOT BE EXECUTED. S MEN **** *** [ 1 ALAM ] [ 2 OPR ] [ *** 3 PARA ] [ O 00:00:00 ] [ T0000 (OPRT) ] O1234 N0001

Alarm details (216 characters)

FANUC OPERATORS MANUAL for details

17

Chapter 5 Trouble Shooting

5-3 Check Sheet


Inform Takamatsu of the following points in case of any problem. How is the current status?

How did the trouble occur?

What is the mode selector switch set to?

How was the machine status before the trouble occurred?

Did the trouble occur suddenly or did it become worse little by little? (When did the phenomenon start?) What is displayed on the screen?
* Inform us of details of messages and alarm numbers.

Is any alarm lamp on the machine operation panel illuminating?

Is operation of the machine available now?

What have you checked already?


* When the diagnosis or the parameter screen has been checked, inform us of the values.

Other remarks

18

Chapter 5 Trouble Shooting

5-4 Resetting of Emergency Stop

Is the emergency stop button pressed?

YES

Turn the emergency stop button in the arrow direction of RESET.

NO

NO

Does the message ---EMG--- disappear?

YES

OK

Is the overtravel proximity switch hit?

YES

Reset the overtravel status. 5-6 Resetting of Overtravel

NO Does the message ---EMG--- disappear?

YES

OK

NO

The overtravel proximity switch may be faulty. The emergency stop button may be faulty.

Contact Takamatsu.

The spindle control unit may be the cause of the trouble. The thermal relay of the hydraulic pump motor might have tripped or malfunctioned. The thermal relay of the coolant pump motor might have tripped or malfunctioned.

Instruction manual issued by Fuji Electric. Co., Ltd. 6-8-4 Resetting of Thermal Relay

6-8-4 Resetting of Thermal Relay

19

Chapter 5 Trouble Shooting

5-5 Phenomenon and Remedy of Major Problems


Special Version for information on the optional units

Phenomenon The NC shows incorrectly or does not light up at all. Cycle start is not available.

Cause The NC display circuit may be faulty. Operation has not been done correctly. The NC controller may be faulty.

Remedy Contact Takamatsu.


Operation

Contact Takamatsu. Contact Takamatsu.

The breaker is turned off.

Faulty motor, valves or a fan has caused a short-circuit or electric leakage. The I/O board or the operation panel may be faulty. The power cord is not connected. The primary power in the factory is not on.

A mode cannot be changed over. The power cannot be turned on.

Contact Takamatsu. Connect the power cord.


Installation

Turn on the primary power in the factory.


Operation

Jog feed is not available.

Operation has not been done correctly. The servo amplifier or NC controller may be faulty.

Contact Takamatsu. Check and adjust backlash.


6-2-2

Dimension error in the longitudinal direction is abnormal.

Backlash is faulty. Positioning accuracy is faulty.

Check and adjust the positioning accuracy. Contact Takamatsu. Check and adjust repeatability. Contact Takamatsu. Tighten the servo flex coupling (clamping bolt) securely.
Programming Manual

Repeatability is faulty.

The servo flex coupling (clamping bolt) is loosened. Threading or tapping is not correctly done. A program is not correctly made. Backlash is faulty.

Check and adjust backlash.


6-2-2

The spindle position coder is faulty.

Check and adjust the spindle position coder.


6-1-6

The timing pulley groove is dirty or worn out.


20

6-1-6

Chapter 5 Trouble Shooting

Phenomenon Dimension error in the radial direction is abnormal.

Cause Chuck clamping force is excessively strong. Chuck jaw mounting bolt is loosened. Runout on the outer surface or end face of the chuck is faulty. Spindle runout is faulty.

Remedy Lower the chuck clamping force. Tighten the mounting bolt securely. Measure and adjust the runout. Check and adjust spindle runout.
6-1-5

Turret positioning accuracy is faulty (due to chips in the turret curvic coupling). Gib clearance is faulty. The servo flex coupling (clamping bolt) is loosened. Zero return is not available. Operation has not been done correctly. The zero point proximity switch is off-positioned or out of order. Cutting is not available as it stops halfway. The spindle position coder is faulty.

Check and adjust the turret positioning accuracy. Adjust the gib.
6-2-3

Tighten the servo flex coupling (clamping bolt) securely.


Operation

Contact Takamatsu. Check and adjust the spindle position coder.


6-1-6

The spindle drive belt is worn out or slipped. Required hydraulic pressure is not obtained. The emergency stop button is pressed. The thermal relay might have tripped or be faulty. Hydraulic oil is not discharged. Hydraulic oil is insufficient.

Check the spindle drive belt and replace if required.


6-1-3 and 6-1-4

Reset the emergency stop button.


6-8-4

Replenish the tank with hydraulic oil.


4-3

Hydraulic oil viscosity is too high. The strainer is clogged.

Replace hydraulic oil.


4-3

Wash the strainer and replace if required.


6-4-2

21

Chapter 5 Trouble Shooting

Phenomenon

Cause Discharge pressure is improper.

Remedy Adjust discharge pressure.


6-4-2

Solenoid The solenoid valve does not function. valve

Foreign objects are caught up in the spool slideway.

Disassemble and wash it. If the spool does not move smoothly inside the main unit, there are burrs in the main unit. Deburr in such a case. Tightening torque should be within 4.9 N. Adjust it within the designated value in the specifications, using a throttle valve. Check the solenoid current and voltage. If resistance is faulty, replace the valve. Reduce dust mixed in the oil. Lower the pressure as much as possible. Change the cycle time and shorten the exciting time. Check that voltage is within 10% above the rating. Adjust the oil temperature and ambient temperature to be below 65C and 50C respectively. Carry out wiring correctly. Check the electric circuit again. Replace with a new one. Adjust mounting pitch and surface roughness on the mounting surface. Replace oil.
4-3

The mounting bolts are too tight, or flatness on the mounting surface is insufficient. Pressure flow is excessive.

Contacting is faulty or wiring is disconnected.

Hydraulic phenomenon occurs.

The solenoid coil is burnt.

Voltage is excessive or insufficient. Ambient temperature is abnormally high.

Common wiring is faulty. Both the solenoid coils are turned ON due to malfunction. External leakage is abnormal. The rolling is damaged or dropped. The mounting surface is faulty.

Internal leakage is abnormal.

The solenoid valve is worn out due to hydraulic oil deterioration. Hydraulic oil is not appropriate.

Abnormal wear occurs due to non-combustible hydraulic oil.

22

Chapter 5 Trouble Shooting

Phenomenon Solenoid Abnormal noise is generated. valve

Cause Excessive pressure flow. Liquid thrust exceeds changeover force, and the spool vibrates.

Remedy Regulate difference in pressure by using a throttle valve. Lower hydraulic pressure as much as possible. Remove foreign objects from the pull-in section, if any. Replace the solenoid valve if it is faulty.
6-3-2

The solenoid pull-in section beats.

The turret is normally positioned but the clamp signal is not output. The turret is not correctly indexed as designated. The turret stopped while it is inclined.

The proximity switch for turret clamp is off-positioned. The servo amplifier may be faulty.

6-3-3

A cutting tool is protruding too much. A tool change position is not appropriate.

The chuck does not open or close at all.

The solenoid valve is out of order. Chips or dust are/is stuck in the chuck. NC controller, etc. may be faulty.

the previous page

Disassemble and clean the chuck. Contact Takamatsu.


the previous page

The chuck does not open or close smoothly. A workpiece slips.

The solenoid valve is out of order. Cutting conditions are not properly set. Stroke of the master jaw is insufficient. Form dia. of the chuck jaws is improper. Grease is not sufficient. Clamping force is insufficient.

Check the cutting conditions. Adjust the master jaw stroke. Form the jaw again.
Operation

Replenish with grease.


4-5

Adjust chuck pressure.


6-1-1

23

Chapter 5 Trouble Shooting

Phenomenon The spindle does not rotate.

Cause Operation error. Spindle, the amplifier or NC controller may be faulty.

Remedy Contact Takamatsu. Contact Takamatsu.

The spindle motor is faulty (abnormal noise or vibration). The spindle motor output does not increase.

Mounting bolts are loosened. The spindle motor is out of order. Belt tension is not sufficient. The motor pulley is worn out.

Tighten the bolts securely. Contact Takamatsu. Adjust belt tension.


6-1-3

Check the motor pulley.


6-1-3

The spindle drive belt cuts off. The spindle generates abnormal noise. The spindle generates abnormal temperature. Lubricant is not discharged to a certain section. Coolant is not discharged.

The motor pulley groove is dirty or worn out. The spindle bearing is abnormal. The spindle bearing is not greased sufficiently. Piping is broken and oil leaks. The emergency stop button is pressed. The thermal relay tripped or is faulty. Coolant is insufficient.

Check the motor pulley.


6-1-3

Contact Takamatsu. Contact Takamatsu.

Check the piping and distributor. Reset the emergency stop button.
6-8-4

Replenish the tank with coolant.


4-4

Piping is broken and oil leaks. Turret does not rotate. The proximity switch is defective.

Check the piping. Replace the proximity switch with a new one. 1. Turn the main power switch OFF once and ON again after 40 sec. 2. Re-connect the connector. Contact Takamatsu.

A.** is indicated on the servo amplifier.

The turret PCB or motor is defective. The unclamp valve is defective.

1. Clean the valve. 2. Replace the valve with a new one.

24

Chapter 5 Trouble Shooting

5-6 Resetting of Overtravel


This alarm will occur when the axis travels beyond its allowable range set in the machine. An alarm message (No. 500, No. 501) below will appear on the NC screen in this case.

ALARM MESSAGE 500 OVER TRAVEL : +X

O 0000

N0000

S MDM **** *** **** [ ALARM ] [ MSG ] [HISTORY ] [

O T0000 13:27:30 ] [ (OPRT) ]

5-6-1 When Soft Limit is Actuated: 1. Press JOG of the mode selector switch. The lamp in the switch will light up.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

FEED RATE OVERRIDE


50 100

2. Select the required feedrate with the FEED RATE OVERRIDE switch.

0%

150

25

Chapter 5 Trouble Shooting

+X -Z +Z

3. Press the JOG FEED switch of the required direction to move the overtraveled axis to the normal range. The slide moves in the selected direction as a speed specified in step 2 as long as the JOG FEED switch is pressed.

RAPID

-X

CAUTION

Rapid feed becomes effective when the RAPID switch is pressed together with the JOG FEED switch.

RESET

4. Press the RESET key.

26

Chapter 5 Trouble Shooting

5-6-2 When Mechanical Limit is Actuated: When the mechanical limit switch is actuated, the message ---EMG--- will appear on the NC screen. 1. Press the O.T. RELEASE switch.
* Keep pressing the O.T. RELEASE switch until step 6.

O.T. RELEASE

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

2. Press HANDLE of the mode selector switch. The lamp in the switch will light up.

HANDLE

3. Select the overtraveled axis with the AXIS SELECT switch. The lamp of the selected axis (X or Z) will light up. 4. Press the magnification switch x10 / x1. The lamp of the selected magnification (x10 or x1) will light up. 5. Rotate the manual pulse generator in the appropriate direction to return the overtraveled axis to the normal range.

AXIS SELECT

CAUTION

Be sure to check that the axis travel direction is correct.

-Y

27

Chapter 5 Trouble Shooting O.T. RELEASE

6. Detach the O.T. RELEASE switch.

POWER OFF ON

7. Turn the power OFF once and then ON again.


* Keep an interval of 3 seconds at least before turning the power ON again.

28

Chapter 5 Trouble Shooting

5-7 Self-diagnosis Procedures


The NC has a function to display the status if switches on the operation panel function normally or if the controller gives signals or not.
Signal addresses are shown in the electric diagrams in Specifications.

5-7-1 Displaying Diagnosis Screen


Status in the CNC

SYSTEM

1. Press the SYSTEM key. 2. Press the [DGNOS] soft key. The diagnosis screen will appear.

DIAGNOSIS 000 001 002 003 004 005 006 WAITING FOR FIN SIGNAL MOTION DWELL IN-POSITION CHECK FEEDRATE OVERRIDE 0% INTERLOCK/START-LOCK SPINDLE SPEED ARRIVAL CHECK

O0001 :0 :0 :0 :0 :0 :0 :0

N0001

[ PARAM ]

[ DGNOS ]

[ PMC ]

[ SYSTEM ]

[ (OPRT) ]

PAGE PAGE

3. Display the desired diagnosis number. a) Press the page keys until the required screen is displayed.

b) Key in the desired diagnosis number and then press the [NO. SRH] soft key.
* [NO. SRH] key can be displayed by pressing the [(OPRT)] soft key.

The FANUC Operators Manual for the status in the CNC

29

Chapter 5 Trouble Shooting

Status of input/output signals

1. Press the SYSTEM key.


SYSTEM

2. Press the [DGNOS] soft key. The diagnosis screen is displayed.

DIAGNOSIS (GENERAL) O0020 N0001 000 WAITING FOR FIN SIGNAL :0 001 MOTION :0 002 DWELL :0 003 IN-POSITION CHECK :0 004 FEEDRATE OVERRIDE 0% :0 005 INTERLOCK/START-LOCK :0 006 SPINDLE SPEED ARRIVAL CHECK :0 )_ EDIT **** *** *** [PARAM] [DGNOS] [ PMC ] [SYSTEM]

14 :51 : 55 [(OPRT)]

3. Press the [PMC] soft key.

4. Press the [PMCDGN] soft key.

5. Press the [STATUS] soft key.


PMC SIGNAL STATUS ADDRESS 7 6 G0000 ** ** G0001 ** ** G0002 ** ** G0003 ** ** G0004 ** ** G0005 ** ** )_ EDIT **** *** *** [ TITLE ] [ STATUS ] O0020 N0001 2 1 0 ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** **

5 ** ** ** ** ** **

4 ** ** ** ** ** **

3 ** ** ** ** ** **

14 :51 : 55 [ ALARM ] [ TRACE ] [ ]

PAGE PAGE

6. Display the desired diagnosis number. a) Press the page keys until the desired screen is displayed. b) Key in the desired diagnosis number, and then press the [NO. SRH] soft key.
* [NO. SRH] can be displayed by pressing the [(OPRT)] soft key.

30

Chapter 5 Trouble Shooting

5-7-2 Reading of Signal Address Table

7 X9

Each numeral (0~7) shown in the above example is called a bit. A bit is the minimum unit of information and used for indicating an address of a certain signal. An address table is generally expressed with 8 bits. The rightmost is bit 0 and the leftmost is bit 7. (Take notice that bits are numbered starting with 0.) It is normal when bit changes either to 0 or 1 after a motion is executed.

31

Chapter 5 Trouble Shooting

5-8 Parameter Setting and Change


Parameters determine various setting conditions for the machine, and must be set correctly in order to operate the machine properly.
WARNING

Before changing any parameter, be sure to contact Takamatsu.

5-8-1 Parameter Reference 1. Press the SYSTEM key.


SYSTEM

2. Press the [PARAM] soft key. The parameter screen is displayed.


PARAMETER O1234 N0001 0000 SEQ INI ISO TVC 0001 FCV 0 0 0 0 0012 X 0 0 0 0 Z 0 0 0 0 0020 I/O CHANNEL 0022 )_ S 0 T0000

0 MIR 0 0

0 0 0

0 0 0

0 0 0

MDI **** *** *** [

15 : 28 : 59 ] [ PITCH ] [SV. PARA] [ ] [(OPRT)]

PAGE PAGE

3. Bring up the desired parameter. a) Press the page keys until the required screen is displayed. b) Key in the desired parameter number, and then press the [NO. SRH] soft key.
* [NO. SRH] can be displayed by pressing the [(OPRT)] soft key.

The FANUC Operators Manual for the status in the CNC

32

Chapter 5 Trouble Shooting

HELP

If you dont know the parameter number to be referenced, it can be found by accessing the help function.
The FANUC Operators Manual

HELP (PARAMETER TABLE)

O1234

N0001 1/4

*SETTING * READER/PUNCHER INTERFACE * AXIS CONTROL/SETTING UNIT * COORDINATE SYSTEM * STROKE LIMIT * FEED RATE * ACCEL/DECELERATION CTRL * SERVO RELATED * DI/DO S MEM **** *** *** [ 1 ALAM ] [ 2 OPR ] [ 3 PARA ] [

(NO. 0000 - ) (NO. 0100 - ) (NO. 1000 - ) (NO. 0000 - ) (NO. 0000 - ) (NO. 0000 - ) (NO. 0000 - ) (NO. 0000 - ) (NO. 0000 - ) O T0000 00:00:00 ] [ (OPRT) ]

5-8-2 Parameter Setting (Change)

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

1. Press MDI of the mode selector switch. The lamp lights up.

OFFSET SETTING

2. Press the OFFSET SETTING key. 3. Press the [SETTING] soft key. The setting screen is displayed.
SETTING (HANDY) PWE TV CHECK PUNCH CODE INPUT UNIT I/O CHANNEL SEQUENCE NO. TAPE FORMAT VERIFY STOP VERIFY STOP )_ S MDI O1234 = =0 =1 =0 =0 =0 =0 =0 =0 0 N0001 (0 : DISABLE 1 : ENABLE) (0 : OFF 1 : ON) (0 : EIA 1 : ISO) (0 : MM 1 : INCH) (0-3 : CHANNEL NO.) (0 : OFF 1 : ON) (0 : NO CONVERT 1 : F10/F11) (PROGRAM NO.) (SEQUENCE NO.) T0000 *** 00 : 00 : 00 ] [ (OPRT) ]

[ OFFSET ] [ SETTING ] [ COORD ] [

33

Chapter 5 Trouble Shooting

4. Press the cursor key until the cursor comes to PWE.

5. Set PWE to 1 (parameter write enable), by pressing:

(or press the [INPUT] soft key) P/S100 Alarm is indicated on the screen.

6. Press the SYSTEM key.


SYSTEM

7. Press the [PARAM] soft key. The parameter screen is displayed.


PARAMETER (SETTING) 0000 0001 0 0 0012 X 0 0 Z 0 0 C 0 0 Y 0 0 A 0 0 6 0 0 )_ S 0 MDI 15 : 28 : 59 [ ] [PITCH] O1234 SEQ 0 0 0 0 0 0 0 T0000 0 0 0 0 0 0 0 0 0 0 0 0 0 N0001 INI 0 0 0 0 0 0 0 0 ISO TVC FCV 0 0 MIR 0 0 0 0 0 0 0 0 0 0 0 0

[SV. PARA]

[(OPRT)]

PAGE PAGE

8. Bring up the desired parameter. a) Press the page keys until the required screen is displayed. b) Key in the desired parameter number, and then press the [NO. SRH] soft key.
* [NO. SRH] can be displayed by pressing the [(OPRT)] soft key.

The FANUC Operators Manual for the status in the CNC

34

Chapter 5 Trouble Shooting

INPUT

9. Enter the desired value, and press the INPUT key (or the [INPUT] soft key). 10. Press the OFFSET SETTING key.

OFFSET SETTING

11. Press the [SETTING] soft key. The setting screen is displayed. 12. Set PWE to 0 (parameter write disable), by pressing: (or press the [INPUT] soft key) 13. Press the RESET key. P/S100 Alarm disappears from the screen.

RESET

35

Chapter 5 Trouble Shooting

5-9 Slide Reference Point Setting


DANGER

When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake. Failure to observe this warning will result in critical bodily injuries. The cover should not be opened by unqualified personnel for maintenance. Turn the main power switch off when it is needed to work inside the cover.

WARNING

This machine uses absolute pulse encoders for the servo motors of the X and Z axes. Thus, it is generally unnecessary to make a reference point setting. However, it is necessary to make a reference point setting in the following cases: - The absolute pulse encoder battery attached to the electric cabinet door becomes depleted. - The servo motor signal line is removed when changing the servo amplifier or motor. - The grid shift parameter (No. 1850) is changed. 1. Display the parameter setting screen.
5-8 Parameter Setting and Change

2. Under the parameter No. 1815: bit 4 (APZ), set the axis that you wish to make a reference point setting for to 0. 000 Shut power off is displayed.
* When the battery is dead or when the servo motor signal cable is disconnected, this parameter is automatically reset to 0.

3. Turn power off.


2-5 Turning Power OFF in Operation
EMERGENCY STOP

4. Press the POWER ON button and reset the EMERGENCY STOP button.
2-2 Turning Power ON in Operation

300 APC ALARM: X (Z) axis zero return request is displayed.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

5. Press JOG or HANDLE of the mode selector switch. The lamp in the switch will light up.

or

36

Chapter 5 Trouble Shooting

6. Move the axis of which zero point setting is required 20 mm or more in a single direction using jog or handle operation.
* When this is completed, zero point setting becomes available. (After turning the power on)

7. Turn the power OFF and back it ON. 8. Press JOG or HANDLE of the mode selector switch. The lamp in the switch will light up.

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

or

+X -Z +Z

9. Move the slide to a safe area.

RAPID

-X
or

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN

10. Press ZERO RETURN of the mode selector switch. The lamp in the switch will light up.

X Z
AXIS SELECT

11. Use the AXIS SELECT switch to select the axis that you mounted the stopper on.

The machine may be damaged if you select the wrong axis.

37

Chapter 5 Trouble Shooting


O.T. RELEASE

START

12. Hold down the O.T. RELEASE switch and press the START button.
* Be sure to hold down the O.T. RELEASE switch until zero point setting is completed. * Reference point setting begins automatically. * Pressing the EMERGENCY STOP button or the RESET key suspends the zero point setting.
(1) The axis moves at a fixed speed towards the stopper.
Reference point setting stopper Tool post

(2) When the axis bumps into the stopper, it retreats approximately 10 to 40 mm.
Reference point setting stopper Tool post

X-axis stopper

(3) The axis moves towards the stopper again.

Z-axis stopper

Reference point setting stopper Tool post

(4) When the axis bumps into the stopper, it moves to the reference point position.
Reference point setting stopper Tool post

Machine zero point

(5) When the axis arrives at the reference point position, the reference point is established and reference point setting is finished. The axis reference point lamp on the operation panel lights up. (6) 000 Shut power off is displayed.

* If 309 APC ALARM: X (Z) axis zero return impossible is displayed, follow steps from 6.

13. Turn the power OFF and back it ON. The set reference point is validated. 14. When setting the zero point of another axis, follow the same steps from step 6.

38

Chapter 6 Maintenance for Each Unit

Chapter 6 Maintenance for Each Unit


6-1 Headstock
DANGER
When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake. The cover must not be opened by unqualified personnel for maintenance. Turn the main power switch off when it is needed to work inside the cover.

WARNING

6-1-1 Adjustment of Chuck Pressure


* The chuck pressure depends on the combination of the chuck and the cylinder to use.

CAUTION

Adjust the chuck pressure within the setting range that is determined by the combination of the chuck and the cylinder to use.

Adjustment interval As required [Required tools] Spanner [13] Allen wrench [5] 1. Loosen the lock nut of the chuck valve (reducing valve). 2. Adjust the chuck pressure by turning the pressure adjust knob. Turning the knob clockwise increases the pressure. Turning the knob counter-clockwise decreases the pressure. 3. Tighten the lock nut firmly.
Chuck pressure gauge Lock nut

* The figure shows the machine equipped with loader. Fig. 9

39

Chapter 6 Maintenance for Each Unit

6-1-2 Chuck Pressure Setting Table for Stroke Adjustable Cylinder Maximum allowable pressure (MPa) by chuck type

Cylinder (KITAGAWA)
Cylinder type Pull -sid e cy Pullside lind er fo area rce Chuck type

Maker

Blank, oversize, high-precision type

Internal clamp type

Cylinder (NIKKO)

Cylinder type Pull -sid e cy Pullside lind er fo area rce Chuck type

Maker

Internal clamp type

Blank, oversize, high-precision type

KITAGAWA

Marker

Collet

type

Common

Marker

*1: Note that all the listed combinations of chuck and cylinder do not fit the machine. *2: If you use a chuck not listed above, carefully consider the allowable pressure (trust). *3: If the pressure is 1 MPa or less, chucking operation may become unstable depending on the use condition, such as ambient temperature. 40

NIKKO

Collet

type

Type MO

Type HF

Type NLT

Common

Type NT

Type BT

Type N

Type B

Chapter 6 Maintenance for Each Unit

6-1-3 Adjustment of Belt An excessive tension on the belt may reduce the life of the belt or bearings. Also, less tension may cause abnormal noise or vibration, and the rated horse power cannot be transmitted because the belt slips.
Specified load F Flexibility

Ls
Name Timing belt V belt (Powerace) V belt (Powerace) V belt (Powerace) V belt (Powerace) V birred belt (Ribace) Type 337L050 3V-670 3V-670 3V-630 3V-630 8PK1750 Q'ty 1 4 3 4 3 1 Tensile load (N) Re-tensile load (N) Flexibility () 33.8 37.0 10.6 36.4 41.8 10.3 33.8 37.0 9.8 36.4 41.8 9.5 34.0 34.9 10.5 Remarks Encoder Motor inside: 3,500 Motor inside: 4,500 Motor outside: 3,500 Motor outside: 4,500 Motor outside: 6,000

1 2 3 4 5 6

Tensile load F (N) at the time of belt replacement is shown. Flexibility (mm) obtained when the tensile load is applied to the center of the span is shown. (6): For 5.5/7.5 kW motor

Fig. 10

Inspection interval

Every 6 months

<Adjustment procedures> [Required tools] Allen wrenches [4], [6], [10] Spanner [13] Tension gauge (or spring balance) 1. Turn the main power switch off. 2. Remove the motor cover.
* Carefully remove the cover as a pressure gauge is mounted on it.

3. Loosen four motor base mounting bolts. 4. Loosen the lock nuts. 5. Adjust the belt tension so that a flexibility of 10.0 mm can be obtained when a specified load is applied to the belt. To increase the tension, turn the adjust bolt CW. To decrease the tension, turn the adjust bolt CCW and press down the belt from both sides. 6. Re-tighten the four motor base mounting bolts securely. 7. Secure the lock nuts. 8. Re-mounting the motor cover.
41

Chapter 6 Maintenance for Each Unit

Front covers

Motor inside mounting


1 1

Motor outside mounting

3 2 Adjust bolt Adjust bolt Lock nut Flexibility Lock nut Flexibility

4 5 6

Motor base mounting bolts

Motor base mounting bolts

* The figure shows the machine equipped with loader. Fig. 11

42

Chapter 6 Maintenance for Each Unit

6-1-4 Replacement of Belt [Required tools] Allen wrenches [4], [6], [10] Spanner [13] Screwdriver and Phillips screwdriver

1. Turn the main power switch off. 2. Remove the motor cover. 3. Disconnect the drain hose and the HP hoses from the chucking cylinder.
CAUTION

Put match marks on these hoses to prevent misconnection.

4. Carry out steps 3 and 4 in the adjustment procedures of the belt. 5. Turn the adjust bolt CCW. 6. Lift the motor base. 7. Remove the belt. 8. Mount a new belt.
* Turn the belt with hand and check that it turns smoothly without problem.

9. Carry out steps 5 through 8 in the adjustment procedures of the belt. 10. Connect the drain hose and the HP hoses to the chucking cylinder again. 11. Re-mount the motor cover.

Timing belt (337L050)

Adjust bolt Lock nut Belt Drain hose HP hose

Motor base mounting bolts

* The figure shows the machine equipped with loader.

Fig. 12 43

Chapter 6 Maintenance for Each Unit

6-1-5 Alignment of Headstock Inspection interval [Required tools] Yearly L wrenches [5], [6], [8], [10], [14] Spanner [13] Test bar (workpiece) Dial indicator (with magnet stand, division: 0.002 mm)

Measuring method using a test bar 1. Mount a test bar on the spindle. 2. Attach a magnet stand on the turret, and apply the test bar to the workpiece. 3. Move the Z axis to measure a dislocation amount of the headstock as shown below.
0 mm Indicator Z-axis direction 0.005 mm

Test bar 150 mm * If the amount of deviation is 0.005 mm/150 mm, headstock adjustment is not required.

Fig. 13

Measuring method by turning a workpiece 1. Mount a long workpiece (test bar) in the chuck. 2. Cut the workpiece to obtain the finish O.D. 3. Remove the workpiece from the chuck and measure the workpiece diameter.
D0 - D1 = 0.01 mm

Chuck

Workpiece

D0

D1

150 mm * If the difference between D0 and D1 is 0.01 mm or less and the workpiece is tapered off, headstock adjustment is not required.

CAUTION

If any adjustment is required, contact Takamatsu.

44

Chapter 6 Maintenance for Each Unit

6-1-6 Replacement of Position Coder


Carefully handle the position coder since it is a precision equipment. Never use a hammer to remove or mount it. [Require tools] Allen wrench [8] Snap ring remover 1. Turn the main power switch off.
2. Dismount the headstock cover.

CAUTION

3. Turn the canon plug with hand to remove it. 4. Remove the snap ring. 5. Remove four position coder mounting bolts. 6. Draw the position coder out of the bracket to remove it. 7. Set the key on a new position coder. 8. Fit the new position coder to the bracket. 9. Re-tighten the four position coder mounting bolts securely. 10. Set the snap ring again. 11. Re-mount the canon plug by turning it with hand. 12. Re-mount the headstock cover.

4628600613 Position coder

Key

Snap ring

* The figure shows the machine equipped with loader.

Canon plug

Fig. 14

45

Chapter 6 Maintenance for Each Unit

6-2 Slide Unit


DANGER

When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake. The cover must not be opened by unqualified personnel for maintenance. Turn the main power switch off when it is needed to work inside the cover.

WARNING

6-2-1 Replacement of Wipers Inspection (replacement) interval [Required tools] Every 6 months Phillips screwdriver Allen wrenches [4], [5]

X-axis lower wiper 1. Turn the main power switch OFF. 2. Open the machine front door. 3. Remove the slide cover (oil-resistant rubber). 4. Remove the broken wiper. 5. Mount a new one.

Wiper

Fig. 15

46

Chapter 6 Maintenance for Each Unit

X-axis wipers on the motor side 1. Return the X-axis slide to the zero point. 2. Move the Z-axis slide about 100 mm away from the zero point in the plus direction. 3. Turn the main power switch OFF. 4. Remove the rear cover. 5. Remove the broken wiper(s). 6. Mount new one(s).

Wipers

Fig. 16

Z-axis wipers on the headstock side 1. Return both the Z-axis and X-axis slides to their zero points. 2. Turn the main power switch OFF. 3. Shift the Z-axis slide cover to the left. 4. Remove the broken wiper(s). 5. Mount new one(s). 6. Return the Z-axis slide cover to the original position.
Wipers

Fig. 17 47

Chapter 6 Maintenance for Each Unit

Z-axis right wipers (on the tailstock side) 1. Move the Z-axis slide about 160 mm away from the zero point in the minus direction. 2. Turn the main power switch OFF. 3. Dismount the top and right side covers from the machine. 4. Remove the broken wiper(s). 5. Mount new one(s). 6. Re-mount the top and right side covers on the machine.

Wipers

Fig. 18

48

Chapter 6 Maintenance for Each Unit

6-2-2 Measurement and Compensation of Backlash Backlash may occur to each axis feed mechanism due to the following causes, which makes a difference between the commanded value and the actual axial travel. A clearance in the axial direction of the ball screw A clearance between the ball screws thrust bearing and its mounting plane Those backlash can be offset by the backlash compensation function provided in the NC unit. Offset amount of backlash is correctly set before delivery, however, it may become improper after use of the machine for a long period of time. Inspection interval [Required tools] Yearly Dial indicator (with magnet stand, division: 0.002 mm)

1. Attach the magnet stand to the spindle nose, and apply the indicator to the turret. For measuring a backlash in the Z-axis direction, apply the indicator to the end plane of the turret as shown below, and set its reading to 0.

Fig. 19

For measuring a backlash in the X-axis direction, apply the indicator to a holder mounting plane on the turret as shown below, and set its reading to 0.

Fig. 20 49

Chapter 6 Maintenance for Each Unit

2. Press HANDLE of the mode selector switch. 3. Select the handle magnification X1 with the x10/x1 switch. 4. Select the axis to measure a backlash with the AXIS SELECT switch. 5. Rotate the manual pulse generator in the minus direction by 20 pulses. 6. Rotate the manual pulse generator in the plus direction by the same amount (20 pulses) as in step 5. 7. Read the indicator.

Backlash

Backlash

Fig. 21

8. Set an offset amount. When the reading is below 0: Offset amount = Current offset amount + reading When the reading exceeds 0: Offset amount = Current offset amount - reading
* Parameter No. 1851 (for cutting feed)

5-8 Parameter Setting and Change As for detailed parameters, refer to FANUC OPERATORS MANUAL.

50

Chapter 6 Maintenance for Each Unit

6-2-3 Adjustment of Gib Be sure to contact TAKAMATSU before gib adjustment and follow the instructions. Do not tighten the gib adjust bolt excessively for pressing the gib. [Required tools] Screwdriver and Phillips screwdriver Allen wrenches [4], [5]

CAUTION

X axis 1. Turn the main power switch OFF. 2. Open the machine front cover. 3. Remove the X-axis slide cover. 4. Remove wipers (1) and (2). Adjustment bolt "A" and gib will appear. 5. Turn adjust bolt "A" counter-clockwise to loosen it. 6. Remove wipers (3) and (4) from the rear of the machine. Adjustment bolt "B" and gib will appear. 7. Push the gib using a screwdriver. 8. Turn adjustment bolt "B" clockwise to hold the gib. 9. Turn adjustment bolt "A" clockwise from the machine front to hold the gib. 10. Re-mount wipers (1), (2), (3) and (4). 11. Re-mount the X-axis slide cover.

Gib

Adjustment bolt "A"

Gib

Gib Adjustment bolt "B" Adjustment bolt

Fig. 22

51

Chapter 6 Maintenance for Each Unit

Z axis 1. Move the Z-axis slide about 100 mm away from the zero point in the minus direction. 2. Turn the main power switch OFF. 3. Remove the right side cover from the machine. 4. Remove wiper (1). Adjustment bolt "A" and gib will appear. 5. Turn the adjust bolt "A" counter-clockwise to loosen it. 6. Remove wiper (2). Adjustment bolt "B" and gib will appear. 7. Push the gib using a screwdriver. 8. Turn adjustment bolt "B" clockwise to hold the gib. 9. Turn adjustment bolt "A" clockwise as well to hold the gib. 10. Re-mount wipers (1) and (2). 11. Re-mount the right side cover on the machine.

52

Chapter 6 Maintenance for Each Unit

Gib Gib adjust bolt A

Gib Gib adjust bolt B

Right side cover

Remove the wiper.

Gib

Gib adjust bolt

* The figure shows the machine equipped with loader.

Fig. 23

53

Chapter 6 Maintenance for Each Unit

6-3 Turret Unit


DANGER
When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake.

WARNING

The cover must not be opened by unqualified personal for maintenance. Turn the main power switch off when it is needed to work inside the cover.

6-3-1 Measurement of Turret Parallelism [Required tools] Dial indicator (Division: 0.002 mm) Allen wrench [8] Round bar
<Procedure>

1. Remove all holders from the turret. 2. Mount the dial indicator on the magnet stand, and attach it to the chuck. 3. Move the slides until the indicator makes contact with the holder mounting surface of the turret. 4. Move the Z-axis slide using the manual pulse generator, and read the indicator.

Fig. 24 * Measure for the overall width of the holder mounting surface. * Make this measurement for one holder mounting surface. * If the indicator reading is 5 m or less, no adjustment is required. If it exceeds 5 m, turret alignment must be made.

5. Bring the indicator into contact with a side of the holder mounting groove on the turret. 6. Move the Z-axis slide using the manual pulse generator, and read the indicator.
54

Chapter 6 Maintenance for Each Unit

7. Keep the indicator in place while moving the Z-axis slide in the +Z direction, and index the turret by one station. 8. Move the Z-axis slide in the -Z direction until the indicator makes contact with the holder mounting surface. Then, read the indicator. 9. Repeat steps 7 and 8, and measure at 8 stations. 10. Attach a boring holder to the holder mounting surface that showed an average reading.
* Clean the mounting surface before mounting a boring holder.

11. Move the X-axis slide until the hole center of the boring holder aligns with the spindle center. 12. Bring the indicator into contact with the inside of the hole on the boring holder. 13. Turn the spindle by hand, and read the indicator. 14. Move the X-axis slide using the manual pulse generator until the indicator shows the same value at a and b. Then, read the indicator at c and d.
* When the indicator reading is 25 m or less, it is acceptable; however, to obtain a higher center height accuracy, adjust it to 5 m or less at the position of an average reading. * If it exceeds 25 m, turret curvic coupling alignment must be made.

15. Keep the indicator in place while moving the Z-axis slide in the +Z direction, and index the turret by one station. A boring holder must be attached to the station in advance. 16. Move the Z-axis slide in the -Z direction until the indicator makes contact with the holder mounting surface. 17. Turn the spindle by hand, and read the indicator.
* Read the deviation at a-b and c-d. When the indicator reading is 25 m or less, no adjustment is required. If the deviation at a-b exceeds 25 m, center alignment must be made by adjusting FANUC parameter of grid shift amount. If the deviation at c-d exceeds 25 m, turret curvic coupling alignment must be made.

Fig. 25

CAUTION

If any adjustment is required, contact Takamatsu.

55

Chapter 6 Maintenance for Each Unit

6-3-2 Adjustment of Turret Clamp Proximity Switch When the turret clamp signal is not given even if the turret is indexed at normal position, adjust the proximity switch used for checking the turret clamping. [Required tools] Allen wrenches [4] [5] Spanner [24] Phillips screwdriver

1. Remove the right side cover from the machine. 2. Remove the relay box. 3. Loosen a lock nut of the proximity switch. 4. Adjust the position of the proximity switch so that the lamp will turn ON when the turret is clamped (or unclamped)

CAUTION

Keep a clearance of approx. 4.5 mm between the dog and the turret clamp proximity switch where the lamp has just come ON.

5. Tighten the lock nut of the proximity switch. 6. Attach the relay box. 7. Re-mount the right side cover on the machine.

Turret clamp proximity switch Dog

Fig. 26

56

Chapter 6 Maintenance for Each Unit

6-3-3Turret Zero Position Setting (for Mitsubishi Motor) When the turret has been assembled or aligned, the following zero position setting for the servo motor is required. 1. Set the TURRET ZERO SET switch to ON in the control box. 2. Turn the breaker ON. If "A.25" is indicated for the turret servo amplifier, turn the breaker OFF and back it ON. 3. Turn the power ON. Check that the mode selector switches (EDIT, AUTO, MDI, HANDLE, JOG, ZERO RETURN) are blinking. 4. Press the TURRET switch. The turret is unclamped. 5. Turn the turret by hand until station No. 1 is indexed. 6. Press the TURRET switch again. The turret is clamped. When the turret is clamped, the mode selector switches come on. Five seconds later, the switches start blinking again, and the TURRET ALM. lamp lights up. 7. Check the turret motion. Turn the power OFF. 8. Set the TURRET ZERO SET switch to OFF in the control box. 9. Turn the power ON again. Check that the turret can index correctly in manual and automatic operation.
* If the turret cannot be clamped properly in step 6, press the RESET button, and try again from step 4. * This zero position setting must be made if the turret motion is awkward or if the servo amplifier has been replaced. * When the turret has bumped against anything during rotation or is slanted by an emergency stop, turn the power OFF, and follow the above steps for resetting. In this case, the TURRET ALM. lamp lights up when station No. 1 is indexed. Align the position referring to the TURRET ALM. lamp.

57

Chapter 6 Maintenance for Each Unit

6-4 Hydraulic Pump Unit


DANGER
When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MAINTENANCE. around the machine so that the power is not turned on or the operation panel is not touched by mistake. The cover must not be opened by unqualified personnel for maintenance. Turn the main power switch off when it is needed to work inside the cover.

WARNING

* Specifications are subject to change according to the improvement of the machine. Check the types and quantities of parts to be replaced, and place an order with Takamatsu.

6-4-1 Cleaning of Oil Filler Filter Cleaning interval Yearly

1. Turn the main power switch off. 2. Remove the cap from the oil filler port by turning it with hand. 3. Pull the cap upward to draw the oil filler filter. 4. Wash the filter in wash oil. 5. Return the filter inside the tank, and secure the cap by turning it with hand.

Oil filler filter

* The figure shows the machine equipped with loader. Fig. 27

58

Chapter 6 Maintenance for Each Unit

6-4-2 Cleaning of Strainer Clean the strainer when replacing the hydraulic oil. Cleaning interval [Required tools] Yearly Phillips screwdriver

1. Turn the main power switch off. 2. Remove tank cover mounting bolts (8 pcs). 3. Remove the cover from the tank. 4. Remove the strainer by turning it. 5. Wash the strainer in wash oil.
* Replace the strainer with a new one if it is too dirty.

6. Re-mount the strainer and return in the tank. 7. Re-mount the cover on the tank. 8. Tighten the cover mounting bolts (8 pcs) securely.

Tank cover

Tank cover mounting bolt

Strainer

* The figure shows the machine equipped with loader.


Fig. 28

59

Chapter 6 Maintenance for Each Unit

6-4-3 Cleaning of Hydraulic Tank Clean inside of the hydraulic tank when renewing the supply of hydraulic oil in it. Cleaning interval [Required tools] Yearly Phillips screwdriver Can (for waste oil)

1. Turn the main power switch off. 2. Put the can under the drain port. 3. Loosen the drain cock. Hydraulic oil will drain from the tank. 4. Remove the tank cover mounting bolts (8 pcs). 5. Remove the cover from the tank. 6. Clean inside of the hydraulic tank with wash oil.
* Clean the magnet separator too.

7. Re-mount the cover on the tank. 8. Tighten the tank cover mounting bolts (8 pcs). 9. Secure the drain cock. 10. Supply hydraulic oil from the oil filler port up to the upper limit of the oil level gauge.

Magnet separator Tank cover

Tank cover mounting bolt

Drain

* The figure shows the machine equipped with loader. Fig. 29 60

Chapter 6 Maintenance for Each Unit

6-5 Lubricant Unit


DANGER

When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake.

* Specifications are subject to change according to the improvement of the machine. Check the types and quantities of parts to be replaced, and place an order with Takamatsu.

6-5-1 Cleaning of Oil Filler Filter Cleaning interval [Required tools] Yearly Phillips screwdriver

1. Turn the main power switch off. 2. Loosen two set screws. 3. Remove the lubricant tank. Slide both fittings located on the right and left sides of the tank and open them. 4. Push down three claws mounted on the back of oil filler filter. 5. Draw the filter out while holding it up. 6. Wash the filter in wash oil. 7. Re-mount the filter while pushing it down. 8. Re-mount the tank. 9. Tighten the two set screws.
* The figure shows the machine equipped with loader.

Oil filler filter

Set screw

Fitting

Fitting
Tank

Tank

Fig. 30

61

Chapter 6 Maintenance for Each Unit

6-5-2 Cleaning of Suction Filter Cleaning interval [Required tools] Yearly Phillips screwdriver

1. Turn the main power switch off. 2. Loosen two set screws. 3. Remove the lubricant tank. Slide both fittings on the right and left sides of the tank and open them. 4. Remove the filter stopper. 5. Remove the suction filter by picking it up with finger. 6. Wash the suction filter in wash oil.
* Replace the suction filter with a new one if it is too dirty.

7. Re-mount the suction filter. 8. Re-mount the filter stopper. 9. Re-mount the tank. 10. Tighten the two set screws securely.

Suction filter Filter stopper

Fig. 31

62

Chapter 6 Maintenance for Each Unit

6-5-3 Cleaning of Lubricant Tank Cleaning interval [Required tools] Yearly Phillips screwdriver Can (for waste oil)

1. Turn the main power switch off. 2. Loosen two set screws. 3. Remove the lubricant tank. Slide both fittings on the right and left sides of the tank and open them. 4. Drain lubricant into the can from the tank. 5. Clean inside the tank with wash oil. 6. Re-mount the tank. 7. Tighten the two set screws.

Oil filler filter

Set screw

Fitting

Fittings
Tank

Tank

Fig. 32

63

Chapter 6 Maintenance for Each Unit

6-6 Air Unit


When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake.
* Specifications are subject to change according to the improvement of the machine. Check the types and quantities of parts to be replaced, and place an order with Takamatsu.

6-6-1 Replacement of Filter Regulator Element Before replacing the element, make sure that the pressure is released from the case. Replace the element within two years of use or by the time the amount of pressure drop reaches 0.1 MPa. Failure to replace the element within an appropriate period of time may damage it. Replace the element with a new one. Do not wash and reuse the old element. Use an element of the designated type. If any element of a different type or of a different size is used, malfunction or damage may occur. Replacement interval One year (approximately) Element type Check with Takamatsu. 1. Stop the air supply. 2. Hold the case slightly. Slide the lock button down with your thumb. An arrow comes into view.

Lock button Arrow

64

Chapter 6 Maintenance for Each Unit

3. While the lock button is held down, raise the case slightly and turn it 45 to the left (or right) until the mark on the case is aligned with the mark on the body.
Body

Alignment mark Case

4. Remove your thumb from the lock button. Lower the case slowly in a vertical direction. The case is disengaged.

O-ring

5. While pushing up the baffle, turn it 15 to the left. The baffle and the filter element are disengaged. 6. Attach a new filter element by hand. 7. Align the groove of the valve guide with the projection from the baffle. While pushing up the baffle, turn it 15 to the right.

Valve guide

Element

Baffle

65

Chapter 6 Maintenance for Each Unit

8. Check that the O-ring on the case is clean. Align the mark on the case with the mark on the body, and push the case in.
* Operating the lock button is not necessary to attach the case.

9. Turn the case in the direction opposite to the direction for disengaging. You will feel a click. The arrow is hidden from view.

Alignment mark

10. Check that the case does not turn by trying to turn it slightly in both directions.
* If the case turns, perform step 8 and after again.

66

Chapter 6 Maintenance for Each Unit

6-6-2 Replacement of Elements in Mist Separator and Micro Mist Separator Before replacing the element, make sure that the pressure is released from the case. Replace the element within two years of use or by the time the amount of pressure drop reaches 0.1 MPa. Failure to replace the element within an appropriate period of time may damage it. Replace the element with a new one. Do not wash and reuse the old element. Use an element of the designated type. If any element of a different type or of a different size is used, malfunction or damage may occur. Replacement interval One year (approximately) Element type Check with Takamatsu. 1. Stop the air supply. 2. Hold the case slightly. Slide the lock button down with your thumb. An arrow comes into view.

Lock button Arrow

3. While the lock button is held down, raise the case slightly and turn it 45 to the left (or right) until the mark on the case is aligned with the mark on the body.
Body

Alignment mark Case

67

Chapter 6 Maintenance for Each Unit

4. Remove your thumb from the lock button. Lower the case slowly in a vertical direction. The case is disengaged.

O-ring

5. Turn the element counterclockwise several turns by hand. The element is disengaged.

Element

6. Attach a new element by hand.


* In order to avoid damaging the element, do not tighten it too firmly.

7. Check that the O-ring on the case is clean. Align the mark on the case with the mark on the body, and push the case in.
* Operating the lock button is not necessary to attach the case.

8. Turn the case in the direction opposite to the direction for disengaging. You will feel a click. The arrow is hidden from view. 9. Check that the case does not turn by trying to turn it slightly in both directions.
* If the case turns, perform step 7 and after again.

Alignment mark

68

Chapter 6 Maintenance for Each Unit

6-6-3 Adjustment of Lubricator Oil Drop Amount Drop oil amount from the lubricator (type: AL3000) can be adjusted by the adjustment knob. Turn the adjustment knob clockwise to decrease the drop amount. To increase the amount, turn it counter-clockwise.

Adjustment knob

* The figure shows the machine equipped with loader. * Type and mounting position of the filter regulator differ depending on the specifications.

Fig. 33

69

Chapter 6 Maintenance for Each Unit

6-6-4 Pressure Adjustment of Filter Regulator The secondary pressure of the air unit is adjusted to 0.5 MPa before delivery. When re-adjustment is required, follow the procedures below. 1. Pull the adjust handle up by hand to unlock it. An orange mark will appear. 2. Adjust the secondary pressure by turning the adjust handle. Turning the handle CW increases the pressure. Turning the handle CCW decreases the pressure. 3. Push the adjust handle down by hand to lock it. The orange mark will disappear.

* The figure shows the machine equipped with loader. * Type and mounting position of the filter regulator differ depending on the specifications. Fig. 34

70

Chapter 6 Maintenance for Each Unit

6-7 Coolant Unit


DANGER

When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake.

WARNING

Use non-flammable coolant. When using oil-based coolant inevitably, strictly follow the instructions in Safety Precautions for Fire Prevention Chapter 7 Safety Precautions for Fire Prevention in Safety Guide

6-7-1 Cleaning of Coolant Tank Cleaning interval [Required tools] Every 6 months

Can (for waste oil) Spanner [14] 1. Turn the main power switch off. 2. Remove filters from the tank. 3. Drain waste coolant into the can. 4. Clean inside the tank. 5. Supply coolant up to the upper limit of the oil level gauge. 6. Re-mount the filters on the tank.

Filters Filters

Drain

Oil level gauge

* The figure shows the machine equipped with loader. * Type and mounting position of the filter regulator differ depending on the specifications. Fig. 35

71

Chapter 6 Maintenance for Each Unit

6-8 Electric Cabinet


6-8-1 Cleaning of Heat Exchanger
DANGER

Be sure to turn the main power switch off during maintenance work. The primary power in the factory also must be off for maintenance of the electric cabinet. Never open the door in five minutes after turning the power off, as residual voltage remains.

Cleaning interval [Required tools]

Monthly Air gun

1. Turn the main power switch off. 2. Open the electric cabinets door with the designated key. 3. Clean the heat exchanger by blowing dry air with an air gun. 4. Close the electric cabinets door tightly.

72

Air blowing

Fig. 36

Chapter 6 Maintenance for Each Unit

6-8-2 Replacement of Battery


* Specifications are subject to change according to the improvement of the machine. Check the types and quantities of parts to be replaced, and place an order with Takamatsu.

Battery for memory back-up


Improper battery replacement may trigger an explosion. Only use the specified type of battery (A02B-0200-K102). Be sure to replace the battery within 30 minutes. Otherwise, data will be deleted from memory.

WARNING

CAUTION

1. Turn the power on for 30 seconds (to display the NC screen). 2. Turn the power off. 3. Open the operation box. 4. Remove the connector. 5. Remove the battery (lithium battery) from the battery case. 6. Mount a new battery, and connect the connector.

Battery case Connector

Lithium battery A02B-0200-K102

Operation box

Fig. 37 73

Chapter 6 Maintenance for Each Unit

Battery for absolute pulse coder (for servo motor) Be sure to keep the NC power on when replacing a battery, otherwise stored data (absolute positions) will be deleted from the memory. If this occurs, it will be necessary to reestablish the reference point. If reference point setting is required, contact Takamatsu. A battery is provided because the servo motors for the X, Z axes and turret indexing use absolute pulse encoders. When battery voltage becomes low, an alarm will occur. Replace the battery as soon as possible,
* It is necessary to make a reference point setting in the following cases: The servo motor signal line is removed when changing the servo amplifier or motor. The grid shift parameter is changed.

CAUTION

WARNING

To avoid the possibility of someone starting the machine mistakenly, the EMERGENCY STOP button should be pressed and remain in the down position while you are performing this operation.

1. Turn the main power switch on (to display the NC screen). 2. Remove the battery case. 3. Replace the battery with a new one. 4. Put the battery case back. 5. Turn power to the machine off.

When the door to the power box is closed, remove the battery case (cap), and replace the battery.

Battery case Battery (4 D size batteries)

* The figure shows the machine equipped with loader. Fig. 38

74

Chapter 6 Maintenance for Each Unit

Battery for absolute pulse coder (for turret motor) Turn the main power switch OFF before replacing the battery. In particular, the primary power in the factory should also be shut off when performing maintenance inside the control box. Never open the door for five minutes even after the power is turned off because residual voltage is present. Never touch any parts except batteries.
WARNING

CAUTION

Keep away from electrically active parts such as battery connector pins, electric parts, etc. when mounting the battery. Failure to do so may cause electrostatic breakdown in the servo amplifier internal circuit.

1. Turn the main power switch OFF. 2. Open the electric box door using the dedicated key. 3. Open the operation window. 4. Attach the battery to the battery holder. 5. Insert the battery connector into CON1 until a click is heard. 6. Close the operation window. 7. Close the electric box door.
See 6-3-3 Turret Zero Position Setting (for Mitsubishi Motor)

Operation window

Battery connector

CON1

Battery

Battery holder

Fig. 39

75

Chapter 6 Maintenance for Each Unit

6-8-3 Replacement of Fuse Be sure to turn the main power switch off during maintenance work. The primary power in the factory also must be off for maintenance of the electric cabinet. Never open the door in five minutes after turning the power off, as residual voltage remains.

DANGER

* Specifications are subject to change according to the improvement of the machine. Check the types and quantities of parts to be replaced, and place an order with Takamatsu.

1. Turn the main power switch off. 2. Shut off the primary power in the factory. 3. Open the electric cabinets door with the designated key. 4. Remove the blown fuse. 5. Mount a new fuse instead. 6. Close the electric cabinets door securely.
5-3 Parts Arrangement in Electric Box in Specifications

Fuse for servo amplifier module 3.2 A (A06B-6073-K250)

Fuse for power supply module (A06B-6077-K250)

Fig. 40

76

Chapter 6 Maintenance for Each Unit

6-8-4 Resetting of Thermal Relay Be sure to turn the main power switch off during maintenance work. The primary power in the factory also must be off for maintenance of the electric cabinet. Never open the door in five minutes after turning the power off, as residual voltage remains.

DANGER

1. Turn the main power switch off. 2. Shut off the primary power in the factory. 3. Open the electric cabinets door with the designated key. 4. Press the reset button of the thermal relay. 5. Close the electric cabinets door securely.
5-3 Parts Arrangement in Electric Box in Specifications

* Contact Takamatsu when a thermal relay trips repeatedly even after resetting it.

Reset button

Fig. 41

77

CNC Precision Lathe

X-10i

Special Version

Read and understand this Manual thoroughly before operating the machine.

TAKAMATSU MACHINERY Co., Ltd.

Chuck Clamp Detector

Chuck Clamp Detector

This is a safety device to check if a workpiece is securely clamped by the chuck. When this device is installed, adjust it according to chuck open/close motions as described below. The device cannot be started unless the proximity switches (A) and (B) are effective. When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE around the machine so that the power is not turned on or the operation panel is not touched by mistake. The cover should not be opened by unqualified personnel for maintenance. Turn the main power switch off and lock when it is needed to work inside the cover.

DANGER

WARNING

[Required tools] Allen wrench [5] Spanner [24] Phillips screwdriver 1. Remove the chuck cover from the machine. 2. Adjust the proximity switch positions correctly. 3. Re-mount the chuck cover on the machine. O.D. grip (clamping by pulling) Adjust so that the proximity switch (A) becomes effective (lamp ON) when the chuck closes to clamp a workpiece. I.D. grip (clamping by pushing) Adjust so that the proximity switch (B) becomes effective (lamp ON) when the chuck opens to clamp a workpiece.
* Adjustment of the proximity switch itself can be done by loosing the lock nut and turning the switch.

Chuck Clamp Detector

* The figure shows the machine equipped with loader.

Proximity switch B
Proximity switch A

Detail of proximity switch

Lock nut

Lamp

Proximity switch

CAUTION

The proximity switch should be so set that it may not be hit too strongly, but may barely manage to turn on the lamp. (Clearance: 0.5 ~ 1.0 mm)
2

Mounting of Chuck
(Stroke-Adjustable Cylinder)

Mounting of Chuck (Stroke-Adjustable Cylinder)

Chapter 1 Mounting of Power Chuck (NIKKO)


1. 2. 3. 4. 5. 6. Clean all the mating surfaces of the spindle and the chuck before mounting. Close the chuck using the CHUCK CLOSE switch. Mount chuck adaptor (2) on the spindle. Mount draw bar joint (1) on the sleeve. To adjust the chucking cylinder stroke, turn the stroke adjustment nut. Mount chuck (4) on chuck adaptor (2). Apply a dial gauge to the chuck outer diameter and make sure that runouts are within 0.01 mm. 7. Mount round nut (6) on the chuck. 8. Mount nut (7), that is supplied with the chuck, and secure it with the set screw. 9. Mount the cap on the chuck and adjust the jaw stroke. Mount the chip cover and set jaws (9).

No. 1 2 3 4 5 6 7 8 9 10 11

Part name Draw bar joint Chuck adaptor Bolt Chuck Bolt Round nut Nut Set screw Jaw T nut Bolt

Mounting of Chuck (Stroke-Adjustable Cylinder)

Chapter 2 Mounting of Collet Chuck


(26 through) 1. Clean all the mating surfaces of the spindle and the collet chuck before mounting. 2. Close the chuck using the CHUCK CLOSE switch. 3. Loosen the bolt at the stroke, adjustment nut and adjust chucking cylinder stroke. Turn the stroke adjustment nut until the distance between the cylinder and the stroke adjustment nut becomes 3 mm. Secure the stroke adjustment nut with the bolt.
* In the case of collets, the distance must be 3 mm or less. Too long clearance may cause collet breakage or runouts.

4. Remove two stop pins from the back nut and disconnect the sleeve from the spindle. 5. Mount collet flange (1) on the spindle nose. Runouts of the collet flange must be 0.01 mm or less. 6. Align the position of the pin located in the collet flange with that of the keyway on collet chuck (4). Slightly press the collet chuck while turning the collet adjustment nut to the right until the collet and the sleeve are connected. 7. Turn the stroke adjustment nut (the sleeve is turned at the same time) until the taper section of the collet makes contact with the flange section. From this point, align the notch position on the sleeve with the stop pin at the nearest point. 8. Set the stop pin to the back nut. 9. Adjust the tightening allowance of the collet using the adjustment nut. 10. Tighten the bolts on the adjustment nut.

No. 1 2 3 4

Part name Collet flange Detent pin Bolt M10 x 90 Collet

Stroke adjustable cylinder specification Standard collet (26 through)

Mounting of Chuck (Stroke-Adjustable Cylinder)

(35/42 through) 1. Clean all the mating surfaces of the spindle and the collet chuck before mounting. 2. Close the chuck using the CHUCK CLOSE switch. 3. Loosen the bolt at the stroke, adjustment nut and adjust chucking cylinder stroke. Turn the stroke adjustment nut until the distance between the cylinder and the stroke adjustment nut becomes 3 mm. Secure the stroke adjustment nut with the bolt.
* In the case of collets, the distance must be 3 mm or less. Too long clearance may cause collet breakage or runouts.

4. Remove two stop pins from the back nut and disconnect the sleeve from the spindle. 5. Mount joint (1) on the sleeve. 6. Mount collet flange (2) on the spindle nose. Runouts of the collet flange must be 0.01 mm or less. 7. Align the position of the pin located in the collet flange with that of the keyway on collet chuck (5). Slightly press the collet chuck while turning the collet adjustment nut to the right until the collet and the sleeve are connected. 8. Turn the stroke adjustment nut (the sleeve is turned at the same time) until the taper section of the collet makes contact with the flange section. From this point, align the notch position on the sleeve with the stop pin at the nearest point. 9. Set the stop pin to the back nut. 10. Adjust the tightening allowance of the collet using the adjustment nut. 11. Tighten the bolts on the adjustment nut.

No. 1 2 3 4 5

Part name Draw bar joint Collet flange Detent pin Bolt Collet

Stroke adjustable cylinder specification Standard collet (35/42 through)

Mounting of Chuck (Stroke-Adjustable Cylinder)

[Reference drawing]

The following figure shows the hydraulic chuck/collet mounting state on the machine.
[Collet mounting drawing] Back nut Stop pin Collet adjust nut Stroke adjust nut Sleeve 2A-850 collet flange 850 collet

Round nut Joint Adjust nut clamp bolt Chuck flange Hydraulic chuck [Hydraulic chuck mounting drawing]

[Dimensional mounting drawing]

Most retracted position for collect

2A-850 collet flange 850 collet

Most advanced position for power chuck

Tailstock Unit
(Manual Type)

Chapter 1 Specifications 1-1 Major Specifications ................................................... 1-2 Stroke Drawing ........................................................... Chapter 2 Operation 2-1 Operation Panel ........................................................... 2-2 Programming ............................................................... 2-2-1 M Codes ............................................................. 2-2-2 Command System .............................................. Chapter 3 Maintenance 3-1 Adjustment of Tailstock Pressure ............................... 3-2 Adjustment of Tailstock Unit's Position ..................... 3-3 Replacement of Wipers ............................................... 3-4 Alignment if Tail Spindle ...........................................

1 1

2 3 3 3

4 5 6 7

Tailstock Unit (Manual Type)

Chapter 1 Specifications
Manual type tailstock unit is optionally available in order to cope with shaft workpieces.

1-1 Major Specifications


Slide stroke Quill stroke Tapered bore size Quill O.D. Max. thrust mm mm MT mm kN 170 80 3 56 3.5

1-2 Stroke Drawing

(Z-axis slide)

Matsumoto

Nikko

Tail quill stroke Tailstock slide stroke

X-axis slide (tailstock specifications)

Tailstock Unit (Manual Type)

Chapter 2 Operation
See

For detailed programming and M codes, refer to the separately provided Programming Manual and 7-2 List of M Codes in Operation respectively.

2-1 Operation Panel

HANDLE X Z

EDIT

AUTO

MDI

HANDLE

JOG

ZERO RETURN LUB. ALARM SEQ. ALARM TURRET ALM. COUNT UP

AXIS SELECT

M01

SINGLE BLOCK

DRY RUN

CODE

PROGRAM CHECK

10 1 10 1

+X -Z
RAPID

+Z

CYCLE END CHUCK CLOSE

RAPID OVERRIDE 100% F0 F0 100%

COOLANT 1

AIR 1

-X

COOLANT 2

AIR 2

CYCLE START

FEED HOLD

TAIL FOR.

TAIL BACK

SPINDLE FOR.

SPINDLE STOP

SPINDLE REV.

(1)

(2)

(1) Tail quill forward switch


TAIL FOR.

Pressing this switch moves the tail quill forward. (A lamp of the switch will turn on.)

(2) Tail quill backward switch


TAIL BACK

Pressing this switch moves the tail quill backward.

CAUTION

Pay careful attention to interference of tail quill with the turret or cutting tools. Never operate any switch while wearing gloves. Never touch any switch with wet hand.

Tailstock Unit (Manual Type)

2-2 Programming
2-2-1 M Codes M16 M17 Tail quill forward Tail quill backward

2-2-2 Command System M16;


(Tail quill forward) Machining program (Tail quill backward) (Zero point return)

M17; G28 X0 Z0;

* Not available when mounting/dismounting a workpiece manually.

See For details, refer to the separately provided Programming Manual.

Tailstock Unit (Manual Type)

Chapter 3 Maintenance
3-1 Adjustment of Tailstock Pressure
CAUTION

Do not set the tailstock pressure to 2.0 MPa or more.

Adjustment interval As required [Required tools] Allen wench [5] 1. Adjust the tailstock pressure by turning the pressure adjust knob. Turning the knob CW increases the pressure. Turning the knob CCW decreases the pressure.

Tailstock pressure gauge

Tailstock pressure adjust knob

* The figure shows the machine equipped with loader.

Tailstock Unit (Manual Type)

3-2 Adjustment of Tailstock Units Position


DANGER

When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake. The cover should not be opened by unqualified personnel for maintenance. Turn the main power switch off and lock when it is needed to work inside the cover.

WARNING

Adjustment interval As required [Required tools] Spanner [36] 1. Return both the X and Z axes to respective zero points. 2. Turn the main power switch off and lock. 3. Remove the right side cover from the machine. 4. Loosen two clamping bolts. 5. Move the main unit of tailstock to a designated position. 6. Tighten the two clamping bolts securely. 7. Re-mount the right side cover on the machine.
* To remove the tail center, tap the push rod by a hammer.

Right side cover

Clamping bolt

Clamping bolt

Push rod

* The figure shows the machine equipped with loader.

Tailstock Unit (Manual Type)

3-3 Replacement of Wipers


DANGER

When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake. The cover should not be opened by unqualified personnel for maintenance. Turn the power switch off and lock when it is needed to work inside the cover.

WARNING

Inspection (replacement) interval Semiannually [Required tools] Phillips screwdriver 1. Turn the main power switch off and lock. 2. Open the front door of the machine. 3. Remove the right side cover from the machine. 4. Remove wipers from the machine. 5. Mount new wipers instead. 6. Close the front door tightly. 7. Re-mount the right side cover on the machine.

Right side cover

Wipers (C) 2323118006

Wipers 24330199003 Wipers 24330199003 Wipers (C) 2323118006

* The figure shows the machine equipped with loader. 6

Tailstock Unit (Manual Type)

3-4 Alignment if Tail Spindle


DANGER

When carrying out maintenance work, put a panel or a plate indicating MAINTENANCE - KEEP AWAY FROM THE MACHINE. around the machine so that the power is not turned on or the operation panel is not touched by mistake.

WARNING

The cover should not be opened by unqualified personnel for maintenance. Turn the power switch off and lock when it is needed to work inside the cover.
Yearly

Inspection (adjustment) interval [Required tools] Test piece

Indicator (with magnet stand) Allen wrenches [6], [8] Spanner [36] 1. Finish-cut a test piece. 2. Measure a cylindricity of the machined test piece.
* Adjustment is not required if a reading of indicator is below 0.007/150mm and tapers off.

150 mm Large Small

Tailstock

Chuck

CAUTION

If any adjustment is required, contact Takamatsu.