Classic MC IM-03 20-Jun-06 PDF

ACE CNC LATHE
INSTRUCTION MANUAL
MACHINE : ACE CNC LATHE

MODEL : LT-20 CLASSIC MC
CONTROL SYSTEM : FANUC Oi-TC
IMPORTANT
Before operating the ACE CNC LATHE LT-20 CLASSIC MC this instruction
manual should be read carefully.
This instruction manual should be kept in a safe place where it is always easily
accessible during operation of ACE CNC LATHE.
While this manual has been compiled to give the general description and usage
of the machine, there may be changes owing to continuous design and develop-
ment. Also some options that have been custom built for your company may not
be included in this manual. Such options will be separately given as a supplement.
Suggestions for improvement are always welcome.
96-104 MC / IM-03 June 06

ACE CNC LATHE
INSTRUCTION MANUAL
MACHINE : ACE CNC LATHE

MODEL : LT-20 CLASSIC MC
CONTROL SYSTEM : FANUC Oi-TC
IMPORTANT
Before operating the ACE CNC LATHE LT-20 CLASSIC MC this instruction
manual should be read carefully.
This instruction manual should be kept in a safe place where it is always easily
accessible during operation of ACE CNC LATHE.
While this manual has been compiled to give the general description and usage
of the machine, there may be changes owing to continuous design and develop-
ment. Also some options that have been custom built for your company may not
be included in this manual. Such options will be separately given as a supplement.
Suggestions for improvement are always welcome.
96-104 MC / IM-03 June 06

Contents Page No.
INTRODUCTION
1. Preface 1.1
2. Notes on safety 1.1
3. Basic points of safety 1.2
4. Clothing and personal safety 1.3
5. Safety aspects related to workpiece and tooling 1.5
6. Safety aspects related to maintenance 1.6
7. Safety aspects related to workplace 1.7
8. Safety equipment 1.7
PREPARATION
1. Preparation to be done by the customer 2.1
2. Foundation drawing for installation 2.2
3. Environmental conditions 2.3
4. Power source intake 2.4
INSTALLATION AND STARTUP

1. Lifting method using ropes 3.1
2. Installation check points 3.2
3. Grounding 3.3
4. Cautionary details concerning installation 3.3
5. Power on / power off check points 3.5
6. Manual operation check points 3.5
7. Manual / automatic operation check points 3.6
8. Automatic operation check points 3.8
9. Levelling 3.9
10. Installation and maintenance of inter-machine connection 3.10
MACHINE SPECIFICATION
1. Machine overall views 4.1
2. Machine specification 4.2
3. Power capacity chart 4.4
Contents Page No.
4. Bed 4.5
5. Head stock 4.5
6. Spindle brake assembly 4.6
7. Spindle encoder assembly 4.7
8. Spindle speed characteristics : Alpha P22i, 50 - 3500 rpm 4.7
9. Spindle speed characteristics : Alpha P22i, 50 - 4000 rpm 4.8
10. Work holding 4.8
11. Z-axis assembly 4.9
12. X-axis assembly 4.10
13. Turret 4.10
14. Tailstock assembly 4.11
15. Hydraulic system 4.13
16. Lubrication system 4.14
17. Coolant system 4.14
WORK HOLDING
1. Standard chucks and cylinders 5.1
2. Chuck installation - Standard chuck 5.1
3. Chuck installation - Hollow chuck 5.2
4. Standard chucking cylinder 5.3
5. Operation and adjustment of hydraulic chuck unit 5.4
6. Soft jaw boring 5.5
7. Spindle speed and chucking force 5.6
8. Sample drawing 5.7
9. Spindle details 5.8
APPLICATION - 12 STATION TURRET

1. Machine movable range 6.1
2. Interference diagram 6.7
Contents Page No.
CONTROL SYSTEM
1. Fanuc Oi-TC specifications 7.1
2. G Code list 7.7
3. M Code list 7.10
4. Operator messages 7.11
MACHINE CONTROL PANEL

1. Operator control panel-1 diagram 8.1
Operator control panel-1 details 8.2
Description of operator control panel-1 8.3
2. Operator control panel-2 diagram 8.7
Operator control panel-2 details 8.8
Description of operator control panel-2 8.9
MAINTENANCE
1. Daily maintenance 9.1
2. Periodic inspection 9.2
3. Lubrication 9.3
4. Head stock realignment 9.7
1. PREFACE :
Proper operational techniques and safety procedures will be explained in detail by our
technical staff. The general principles for safe operation of Ace CNC lathe are outlined in
this manual.
All Ace lathes have been engineered for operational safety. You will note, for example, that
all rotating parts are protected by specially designed covers and shields. The entire machine
is covered to eliminate damage by metal chips and cuttings and to prevent an insecurely
clamped workpiece from being thrown out during cutting operations. If the Ace lathe is
operated in accordance with the manufacturers instructions, it will provide you with reliable
service. However, with machines of this nature, serious accidents may occur owing to
improper or careless operation. Do not attempt to operate this equipment without having first
read and thoroughly understood the contents of this instruction manual. Not every example
of improper operation or unauthorized usage which may lead to malfunction or an accident
can be anticipated. If a particular operation is not documented in the manual as authorized
usage of the equipment, it should be assumed that this is an unauthorized or improper usage
with potential danger and should be avoided.
2. NOTES ON SAFETY :
1. This machine is provided with various safety devices to protect the operator and the machine.
However, these cannot cover all aspects of safety, therefore the operator must thoroughly
read and understand this chapter before operating the machine. The operator should also take
into consideration other aspects of safety related to particular environmental conditions and
materials.
2. Three categories of safety guidelines have been used throughout this manual :
DANGER, WARNING and CAUTION.
Their meanings are as follows :
DANGER : Failure to observe these instructions could result in loss of life.
WARNING : Failure to observe these instructions could result in serious injury or substantial
damage to the machine.
CAUTION : Failure to observe these instructions could result in damage to the machine or
minor injuries.
1.1
3. Always observe the safety instructions inscribed on the safety nameplates fixed onto the
machine. Do not remove or damage these name plates.
4. Do not attempt to operate the machine until you have read the manuals supplied with the
machine and have understood each of the functions and operating methods.
3. BASIC POINTS OF SAFETY :

1. DANGER
There are high voltage terminals on the electrical control panel, transformer, motors, junction
boxes and other equipment.
DO NOT touch any of them under any circumstances, when the power supply is ON.
Make sure that all doors and safety covers are fitted before switching on the power. If any
door or safety cover is to be removed, first switch off the main circuit breaker.
2. WARNING
Memorize the position of the EMERGENCY STOP button so that you can press it immedi-
ately from any position.
Take care not to touch any of the switches accidentally while the machine is in operation.
Take care not to catch your fingers in the chuck .
Under no circumstances touch a rotating workpiece or the tool with your hands or any other
object.
To prevent incorrect operation of the machine, carefully check the position of the switches
before operation.
If in the slightest doubt about a procedure, ask the person in charge.
Always switch off the main circuit breaker before leaving the machine.
If more than one person is operating the machine, do not proceed to the next step without
indicating to the other operator(s) that you are about to do so.
Do not modify the machine in any way that will affect its safety.
1.2
3. CAUTION
Do not subject the CNC unit, the operator panel, or the electrical control panel to strong voltage
fluctuations.
Do not change the parameter values, volume values, or other electrical setting values without
good reason. If it becomes necessary to change a value, first check that it is safe to do so,
then make a note of the original value so that it can be reset if necessary.
Do not paint, soil, damage, modify, or remove any of the safety nameplates. If the details
become illegible or if the name plate is lost, obtain a replacement from Ace and mount it in
the original position.
Do not open any doors or safety covers while the machine is in automatic operation.
Stop all machine operations before cleaning the machine or any of the peripheral equipment.
After a job has been completed, set up each part of the machine so that it is ready to be used
for the next series of operation.
4. CLOTHING AND PERSONAL SAFETY :

1. DANGER
Tie back long hair which could become entangled in drive mechanisms.
Wear safety equipment (helmet, goggles, safety shoes, etc.) whenever possible.
Always wear a helmet if there are any overhead obstacles in the work area.
Always wear a protective mask when machining magnesium alloys.
Always use safety shoes with steel toecaps and oil-resistant soles.
Never wear loose or baggy clothes.
Always completely fasten buttons and hooks on the arms of clothing to avoid the danger of
entanglement in drive mechanisms.
Do not operate the machine while under the influence of drugs with powerful effects,
unprescribed drugs or alcohol.
Do not operate the machine if you suffer from dizziness or fainting spells.
Always use gloves when loading or unloading workpieces or tools and when removing chips
from the work area to protect your hands from sharp edges and heat generated during
machining.
1.3
2. WARNING
Close all doors and covers of the CNC unit, operation panel, electrical control panel and
junction boxes to prevent damage from water, chips and oil.
Check all electrical cables for damage to prevent accidents due to current leakage or electric
shock.
Do not handle coolant with bare hands since it is likely to cause irritation.
Operators with allergies should take special precautions.
Do not operate the machine during violent thunderstorms.
Check the safety covers regularly to make sure that they are properly fitted and that they are
not damaged. Repair or replace any damaged covers immediately.
Always obtain assistance in handling loads beyond your capacity.
Do not operate fork lifts or cranes or carry out slinging work unless you have undergone
officially approved training.
When using fork lifts or cranes, make sure that there are no obstructions in the vicinity of
these machines.
Always use wire rope or slings as per standards, suitable for the load to be supported.
Do not adjust the coolant nozzles while the machine is in operation.
Do not remove or otherwise interfere with safety devices such as actuating dogs, limit switches
or interlocks in order to increase axis travel.
When loading workpiece blank onto or unloading the finished product from the machine,
make sure that the tools are as far away as possible from the work area and the spindle is not
rotating.
Do not wipe the workpiece or clear away chips with your hand or with a rag while the spindle
is rotating. Always stop the machine and use a brush.
Do not operate the machine with any of the safety covers removed.
Always wear gloves and use a brush to clean chips off the tool tip. Never use bare hands.
Stop the machine before mounting or removing a tool.
Check slings, chains, hoists and other lifting gear for defects before use. Repair or replace
defective gear immediately.
1.4
3. CAUTION
Do not allow chips to accumulate during heavy-duty cutting since they will be hot and could
start a fire.
Check that the belts have the correct tension before operating the machine.
Warm up the spindle and the axis motion mechanisms before operation.
Write the program for the warming-up operation so as to execute the functions of the full
range of the machine components.
Do not operate the operation panel switches while wearing gloves as this could lead to
incorrect operation or other mistakes.
Follow the sequence for switching off, press emergency switch off the power switch on the
CNC operation panel, switch off the machine circuit breaker, then switch off the factory power
supply.
5. SAFETY ASPECTS RELATED TO WORKPIECE

AND TOOLING :
1. WARNING
Always use tools suitable for the work and which conform to the machine specifications.
Replace the worn tools immediately, since badly worn tools are a cause of accidents or
damage.
Do not operate the spindle above the rated speed of the accessories mounted on it. Before
starting the spindle, check that any parts which are clamped onto it are properly secured.
If the centre hole on larger workpieces held between centres is too small, the work piece could
come off when cutting load is applied. Make sure that the hole is big enough and that is at
the correct angle.
Take care not to catch your fingers in the chuck.
Always use the correct lifting gear for heavy chucks and workpieces.
2. CAUTION
Make sure that the tool length is such that the tool will not interfere with fixtures or other
objects. Perform a test operation after mounting the tool.
After machining soft jaws, check if they grip the workpiece correctly and that the chuck
pressure is correct.
1.5
6.SAFETY ASPECTS RELATED TO MAINTENANCE:
1. DANGER
Always switch off the main circuit breaker before carrying out any maintenance work. This
will eliminate the possibility of the machinery being started inadvertently by someone else.
After the power has been switched off for a short while, check the voltage with a multimeter
or similar instrument to make sure that there is no residual voltage.
2. WARNING
Always switch off the main circuit breaker before replacing bulbs or other electrical equipment
and use products with the same specifications as the original.
Maintenance of electrical equipment must be carried out by qualified licensed electrical
engineers only.
Do not remove or modify overtravel limit switches, interlock limit switches, proximity
switches, or other safety devices.
When carrying out maintenance in high places, always use a suitable ladder or a service
platform and always wear a helmet.
Keep your fingers clear of belts and pulleys.
Do not start the machine until all the covers removed for maintenance have been refitted.
Wipe up any water or oil spills immediately and keep the maintenance area and the workplace
clean and tidy at all times.
3. CAUTION
Maintenance work should be carried out by qualified personnel in accordance with the
instructions of the person in charge.
Keep a stock of replacement parts.
Do not use compressed air to clean the machine or to remove chips.
Always use gloves when clearing away chips; never touch chips with bare hands.
Use only the specified grades of hydraulic oil, lubricating oil and grease or their equivalents.
When changing a fuse, check that the new fuse has the correct rating. (Using a fuse with too
high a rating could result in damage to the equipment).
Check the results of the maintenance work in the presence of the person in charge.
If one of the belts in a set has stretched beyond the prescribed limit, change the entire set.
Stop all machine operation before cleaning the machine or the surrounding area.
1.6
7. SAFETY ASPECTS RELATED TO THE WORK
PLACE:
1. WARNING
Immediately remove all water and oil spills from the floor and dry the floor to prevent
accidents.
Use strong service platforms only and make sure that nothing can slip off them. Keep
combustible materials well away from the work area or any other place where there are hot
chips.
Always provide sufficient working space and clear access to the machine and peripheral
equipment and store tools and other potential obstacles in a prescribed place away from the
machine.
Never place tools or other potentially dangerous objects on top of the headstock, turret or
covers.
Make sure that the nominal cross-sectional area of the power supply cable between the factory
power supply switch and the machine main circuit breaker is sufficient to enable a stable
supply for operation at the maximum output.
Protect all cables which will run along the floor from being damaged by chips, since this could
cause short-circuiting.
8. SAFETY EQUIPMENT :
This machine is provided with various safety devices to protect the operator and the machine.
The safety devices include interlock devices and emergency stop switches as well as doors
and covers. However it is absolutely necessary that the operator familiarises himself with the
instruction manual of the machine. It is essential that all operations be carried out in
accordance with these instructions. The manufacturer emphasises that it is the sole respon-
sibility of the operator to ensure that all operations using the Ace CNC lathe are carried out
in complete safety.
Neither the manufacturer nor his representatives or dealers can assume responsibility
for any mishaps, damage or personal injury which may occur as a result of improper
operation or from failure to observe the safety precautions mentioned in this manual.
1.7
PREPARATION TO BE DONE BY THE CUSTOMER
PRIOR TO INSTALLATION OF THE MACHINE :
1.Environment (Machine side)
While installing the machine tool, avoid installing the machine in such places as mentioned
below.
a. Places exposed to direct sunshine, close to heat sources and where temperature fluctuation is
considerable.
b. Places where it is extremely humid.
c. Places which are very dusty.
d. Places close to sources of vibration.
e. Places where the floor is not firm.
While installing the machine tool, the foundation should be firm and stable in order to maintain
the machining accuracy of the machine in the best condition. One of the recommended examples
of installation is shown on next page. However, as the foundation construction much depends
upon the condition of soil stratum supporting the floor of your shop, general counter measures for
the foundation of the machine tool should be taken.
When the floor of your shop is made of reinforced concrete having thickness of 300mm, it is
considered that the floor is firm enough to install this machine. The installing position should be
determined, considering the space around the machine so that the operator can remove the cover
for the maintenance of the machine, open and close the machine door and travel the carriage to
take out the cutting chips without contacting with other machines or bumping walls or the line.
Keep the environment around the machine clean at all times and do not install the machine where
it may be exposed to direct sunlight or heat source (heater).
FOUNDATION PROCEDURE FOR ISOLATING THE MACHINE

FROM SURROUNDING VIBRATIONS
In the case where the machine tool is installed out of necessity at a place close to vibration
sources, like hammers and presses, it is recommended to provide an isolated machine
foundation.
Please contact Ace Designers for further details.

2.1
2. FOUNDATION DRAWING FOR INSTALLATION
2.2
MACHINE INSTALLATION
1. Place the machine on 25 mm thick M.S. pads positioned so as to have the anchoring bolt holes
over the grouting pockets.
2. Place the 150 x 150 x 20 mm plates in position and insert the anchor bolt into the pocket
through the gap of the opening of pocket beyond the plate. Assemble the jack bolt, levelling
pad and the anchor bolt.
3. Prepare the grout and pour into the pockets
4. After the specified time finish the floor around the pockets and remove the pads. (25 mm
thick M.S)
5. Level the machine
In case machine is to be installed at a place where the ground is not firm, reinforce it by piling
work to prevent the installation from settling.
3. ENVIRONMENTAL CONDITIONS (NC SIDE)

a. Ambient temperature :
During operation 00 to 450 C (320 to 1130 F)
b. Humidity :
Relative humidity in normal cases, 75% or below. High humidity will cause deterioration of
insulation, leading to accelerated parts deterioration. There is no particular necessity for
dehumidification. However, avoid installing NC equipment in a humid place.
c. Vibration
During operation: 0.5 G or less
During transportation: 3.5 G or less
2.3
4. POWER SOURCE INTAKE : (in INDIA)
Total Power capacity : 27.11 KVA (For Alpha P22i Spindle motor)
Voltage : AC 415 V, +10%, -15%, 3 phase
Frequency : 50 Hz
Current : 42 A
Power cable connection : 10 mm2
POWER SOURCE INTAKE : (Export Machines)

Voltage : AC 380V, +10%, -15%, 3 phase
Frequency : 60 Hz
Current : 46 A

Frequency : 60 Hz
Current : 36 A

Frequency : 60 Hz
Current : 79 A
2.4
1. LIFTING METHOD USING ROPES
The lifting arrangement of the machine is as shown in the figure. Remove the relevant covers
to sling the machine. Use a crane with capacity of at least 5 tons to lift the machine.
While lifting up, carefully check that the wire ropes do not touch the machine and provide
the portions where the ropes may touch with waste cloth or wooden pieces to prevent the
ropes from damaging the machine body.
NOTE : When lifting the machine, it is important to see that it is well balanced backwards
and forwards as well as to the right and left. Lift the machine a little above the floor and make
sure that it is well balanced before final lifting.
In case of lifting the machine by a group, proper co-ordination between the members of the
group has to be ensured.
3.1
2. INSTALLATION - CHECK POINTS
INSTALLATION SITE
The CNC machine should be properly installed in a location not exposed to direct sunlight. Care
should be taken to locate the installation site such that any chips, water, oil, or vibrations from
other equipments do not affect the lathe. Failure to observe these installation precautions may
result in serious malfunction of the machine. Improper installation can cause both numerical
control (CNC) error and loss of precision in machining operations.
Proper ambient temperature : 00 - 450 C.
Proper humidity : Below 75% Relative Humidity.
POWER SOURCE
The power source to the lathe should be free from any electrical noise produced by other equipment
such as electric welders or electrical discharging machines. Voltage drops and insufficient input
current can result in improper functioning of the CNC. An independent power source should be
provided if possible.
ELECTRICAL WIRING
a. Connect the power line to the input terminals which are provided in the electrical cabinet of
the machine.
b. The power source should be AC 415V, +10%, -15%, 50 Hz, 3 phase supply.(In India)
c. Minimum gauge of the cable, from power source to the machine should be 10 mm2 . Separate
neutral and earth wires of 10 mm2 size are to be brought in.
Note : The machine should be earthed with an independent earth cable. We strongly insist
on the use of a 3 unbalanced voltage stabilizer at the incoming line.
3.2
3. GROUNDING
To prevent personal injury due to any abnormal current surges which may result from electrical
malfunction in other equipments, it is absolutely essential that all Ace CNC Lathes be grounded
independent of other equipment. If welding machines, electrical discharging machines, or the
like, are grounded to the steel framework of the building at the installation site, in no case should
any Ace CNC Lathe be grounded to the same steel framework. Malfunctions in electrical
equipment grounded in common with the Ace CNC Lathe may have adverse effects on the CNCs
performance. Grounding wires should be as short and as thick as possible (use a grounding wire
of at least 10 mm2).
4. CAUTIONARY DETAILS CONCERNING

INSTALLATION
Provide a proper maintenance area.
1. Make sure that all doors and panel coverings open and close freely without obstruction. Refer
to the appropriate installation diagram(s) in the manual provided with the Ace CNC Lathe.
2. Make sure that the installation foundation is of sufficient strength and sturdiness. Refer to
the appropriate installation foundation diagram(s) in the manual.
3. Ensure that the chip conveyor can be installed properly while accommodating the mainte-
nance space. Refer to the appropriate installation diagram in the manual.
4. All rust protective coatings on slideways which were applied for shipping should be
completely removed before beginning operations. Failure to do this can result in the actuation
of the servo-alarm when power is switched on.
5. Before turning on the power, be sure to remove all fasteners and stoppers attached to the
carriage and the cross-slide during shipping.
6. A number of internal cooling fans are fitted to each Ace CNC Lathe. It is imperative that the
installation site be located so as to prevent these fans from being clogged by dust or by mist
or spray from other equipment.
7. When lifting the lathe, be sure to use only properly-rated cables, shackles and pipes. Refer
to the appropriate hoisting diagrams in the manual.
3.3
8. After the lathe has been properly installed, use the Accuracy Test Results Chart shipped with
the equipment to ensure that it has been accurately levelled and adjusted so as to function at
a level of accuracy specified as being within the proper operating tolerances. Failure to do
so will result in serious loss of precision in machining operations.
Check the following before switching the power ON for the first time :
1. Make sure that all bolts are properly tightened.
2. Make sure that all high-pressure feed hosing and piping are securely fastened.
All Ace CNC Lathes are inspected and tested at the factory before being shipped to our
customers. However, possible mishandling or carelessness during shipment to the installation
site may result in misalignment or damage to the equipment. If left unchecked, this could
result in serious malfunctions later, such as vibration, CNC error, or oil leaks. To prevent the
possibility of this, it is essential to make a complete pre-operation inspection of the Ace CNC
Lathe.
3. Power source:
Switch the power ON only after these points have been confirmed. At this time, once again,
check to make sure that all fastening and stoppers attached for shipping have been removed.
Do not begin operations immediately after switching the power ON. First operate the lub
pump manually to lubricate the slideways. Failure to provide proper lubrication can result in
seizing of the slideways.
After switching the power ON for the first time, check the following:
1. Inspect for oil leaks. Make sure that all meters and gauges are functioning properly. Confirm
that the main pressure gauge is reading normally.
2. Run the spindle, gradually increasing the RPM from low speed to maximum speed. This
should be separated into approximately five stages, operating at intermediate speeds at each
of the five stages for at least 20 minutes before eventually reaching the maximum allowable
RPM.
3.4
5. POWER ON / POWER OFF - CHECKPOINTS
The following checkpoints should be observed at all times during daily operations :
When switching the power ON, make a careful inspection of all the moving parts of the machine,
ensure that no one is standing close and that there are no obstructions. After switching ON the
power, check to make sure that the pressure gauges, lube pump, cooling fans, and other auxiliary
equipments are functioning properly. After the power is switched ON, do not begin operations
immediately. First operate the lube pump manually to lubricate the slideways and ballscrews.
Then activate each of the axes. Run the spindle for a period of approximately 15 minutes.
When turning OFF the power, observe the following order of operations:
1) Push the Emergency Stop Button
2) Turn OFF CNC
3) Shut OFF the machine power.
Do not leave the machine unattended with the power ON.
6. MANUAL OPERATIONS - CHECKPOINTS

The equipment should be operated only by one person at a time. It should never be operated by
anyone other than a trained operator who is familiar with the CNC Lathe.
If for example, one person is at the control panel operating the machine while another is replacing
the chuck jaws, the latter is liable to serious personal injury should the person at the control panel
inadvertently hit the wrong switch. If special circumstances make it unavoidable for two or more
persons to run the equipment, special care must be taken in co-ordinating activities to prevent
accidents.
Confirm that cutting tools and tool holders are securely fastened to the turret disc. Make sure that
these are fitted so as to be properly balanced and not to cause any interference or obstruction with
other parts of the equipment. Improper balance can have adverse effects on indexing cycle.
When performing set-up operations, be sure that the power is OFF. If it is absolutely necessary
to perform set-up operations with the power ON, take care before hand to set each switch located
on the control panel so as to prevent any accidents.
3.5
When using a scroll chuck, be sure to remove the chuck handle after using it to tighten the jaws.
Even if the spindle is stopped, the spindle will rotate slightly. This movement is more pronounced
on larger equipment. Be prepared for this rotation.
Always start rotating the spindle from minimum speed.
If any axis has moved beyond software overtravel, move the axis in the opposite direction and
then press the System Reset key. If any axis movement has actuated the Emergency limit, the
power to the drives will be shut off. Then keeping the Emergency over ride push button switch
pressed, jog the axis in the opposite direction till the emergency limit switch is released. Then
the emergency over ride push button can be released.
Optimum spindle speed should be calculated with due consideration to the specifications of the
particular chuck and chucking cylinder being used for the operation, and to the specific cutting
conditions.
7. MANUAL / AUTOMATIC OPERATIONS -

CHECK POINTS
Do not remove the protective covers or shields. Never attempt to insert a bar into the bore through
the spindle while it is rotating. This is an extremely dangerous practice with a high likelihood of
personal injury should the operator or portions of his clothing come into contact with the moving
parts of equipment and be drawn into the lathe.
When machining a bar, be sure to use the bar feeder and the guide bush. When a short bar is to
be machined, it must be of such length as to not protrude beyond the end of the spindle and the
guide bush must be used without fail. If the bar is longer than the spindle, it will be whipped
around violently with severe vibration.
3.6
Do not open the front guard or door while the spindle is rotating. Never open the front guard or
door to remove chips or cuttings or to gain access to the workpiece or the cutting tools while the
spindle is rotating.
Make sure that all rotating parts have come to a complete standstill before attempting to touch
them.
Never operate any Ace CNC Lathe with any of the safety devices removed. Be extremely careful
not to let loose clothing or hair get entangled in the moving parts of the machine. Be sure to wear
safety shoes or boots.
Be sure to keep the workpiece and cutting tools securely clamped at all times. Always begin
cutting operations at slow speeds and moderate cutting depths, gradually increase the feed and
depth of cut.
The operator should never stand in front of the spindle or other rotating parts. Particular care
should be taken during set-up operations or trial machining not to stand in front of the chuck since
there may be danger of the workpiece jumping out of the chuck jaws as a result of improper
clamping, and the cutting tool jumping out of the turret disc as a result of improper set-up.
During cutting operations, do not remove the chips by hand. Also, never attempt to touch the
chips directly with bare hands.
Never touch any of the switches or buttons with wet hands. This can cause short circuits or other
electrical malfunctions.
To prevent operational errors, operators should familiarize themselves thoroughly with the exact
positions of all the switches and push buttons.
3.7
8. AUTOMATIC OPERATIONS - CHECKPOINTS
When initiating operations for the first time under a new program, do not attempt to begin
continuous automatic operations at once. Keep the equipment in Single Block Operation (SBL)
mode and use other manual backup devices as appropriate to stop operations in progress as
necessary to check the effects of the program and to eliminate any bugs or undesirable machining
conditions found during trial runs.
Before replacing the workpiece with a new one, check that the Program-End lamp has turned ON
(indicating that the cutting cycle has been completed), and machining operations are actually
completed.
Be careful not to touch any of the push buttons or switches unnecessarily during automatic
operation.
3.8
9. LEVELLING
Before levelling, the machine base should rest on the levelling pads.
Fix the levelling bracket to the turret disc, as shown in the figure and place a spirit level on
the bracket.
Do a level check with the levelling bolts and foundation bolts tightened.
Level used
1 scale division = 0.02 mm per meter.
Face size = 150 x 55 mm
Keep the spirit level on the bracket.
Now, jog the Z-axis slide in both directions and adjust the levelling bolts so that the machine
is levelled both across and along the spindle axis. For levelling the machine across the spindle
axis keep the spirit level square to the spindle axis and repeat the same for different positions
of Z.
The bed should be levelled to get a reading within 2 divisions of the spirit level over the entire
axis length.
The level changes gradually depending on the condition of foundation, machine, etc. If the
above mentioned requirements are not satisfied the machining accuracy will be affected. So,
be sure to readjust the level atleast once every 6 months.
3.9
10. INSTALLATION AND MAINTENANCE OF
INTER-MACHINE CONNECTION
In order to maintain precision of machine for a long period of time and to operate it always
in the best condition, it is necessary to properly maintain the machine. Giving careful attention
to the operating state, conducting periodic inspection and replacing worn-out parts in their
early stage will prevent unexpected accident from happening.
1. Maintenance immediately after installation

In the initial stage when the machine is installed, the machine is largely subject to change in
the bed level due to change in the foundation ground as well as to unstable solidification of
the ground, all of which have a serious influence on machine accuracy and at the same time
the machine itself undergoes initial wear and other changes. These changes possibly could
eventually affect the machine adversely.
While operating the machine, therefore, it is necessary to pay particular attention. Mentioned
below are points of caution as to the initial maintenance.
i) Running in
After installation and when operating the machine for the first time, it is necessary to pay
particular attention to the machine before running in. Allow approximately 100 hours for the
running in. Avoid loading the machine heavily during the running in.
ii) Initial inspection of bed level

Check the bed level and the foundation for changes atleast once a month for a period of six
months after installation and, ensure correction of any disorder and always maintain the bed
level properly. After the six months, gradually extend the period between check as appropriate
depending on the changes observed, then carry out the check once or twice a year as it
stabilises.
3.10
2. Inspection of inter-machine connection
Inspection of the state of electrical connections among respective units of the NC equipment,
the machine proper, the hydraulic unit, the control panel, etc.
i) Loosened connectors
Check each connecting portion for loosening and tighten if so.
ii) Loosened screws at each terminal
Check electrical terminals of machine relay regions and each operation panel for loosened
screws, and tighten them as required.
iii) Check terminal screws and mounting screws of micro-switches for loosening and tighten
them.
3. Inspection of electrical control panel

When inspecting the electrical control panel, be sure to turn off the main circuit breaker before
performing each check.
i) Terminal screws and soldered portions
Check terminal screws of each electrical component for loosening and tighten them if
loosened. Lightly pull soldered portions of relay panel to check soldering strength.
ii) Cleaning
Dust and chips in the electrical control panel will lead to accidents. So vacuum clean them
with care.
3.11
1. ACE LT-20 CLASSIC MC - OVERALL VIEWS
4.1
2. MACHINE SPECIFICATIONS
Description Standard Optional
Swing over bed 550 mm
Swing over carriage 290 mm
Capacity Distance between centres 650 mm
Maximum machining diameter 250 mm
Maximum longitudinal travel (Z) 600 mm
Maximum transverse travel (X) 193 mm
Maximum power requirement 27 KVA
Approximate weight 4500 Kg
Spindle centre height from floor 1050 mm
Spindle nose A2 - 6 A2-8
Bore through spindle 63 mm 86 mm
Maximum bar capacity 51 mm 75 mm
Spindle Front bearing I.D. 100 mm 120 mm
Spindle speed 50 - 4000 rpm 3500 rpm
Spindle motor (A.C. Motor)cont./30min Fanuc Alpha P22i, 11/15 kW
Tailstock quill diameter 80 mm
Tailstock taper in quill MT - 4
Tailstock Tailstock quill stroke 120 mm
Tailstock base travel 425 mm
Thrust (Maximum recommended) 500 kg @ 20 kg/cm2
Cross slide inclination 300
Number of turret stations 12
X&Z Standard cutting tools 25 x 25 mm
Axes Ball screw diameter X-axis 32 mm; Pitch=10 mm
Ball screw diameter Z-axis 40 mm; Pitch=10 mm
Feed motor X-axis Fanuc AC12Bi, 12 Nm
Feed motor Z-axis Fanuc AC12Bi, 12 Nm 4.2
TURNMILL SPECIFICATIONS
Turret specification : Duplomatic BSVN-200

Driven tool System : ODTN 20
Type of Tooling : VDI 40
Rotary tool motor power cont. / 30 min : 3.7 kW / 5.5 kW
Motor Specification : Fanuc Alpha 3i
4.3
3. MACHINE POWER CAPACITY CHART
MACHINE : LT-20 CLASSIC MC
CNC System : FANUC 0i-TC

CNC Package : Alpha C12Bi (Feed motor - 2 Nos.), Alpha P22i (Spindle) with PSM26i.
Elements used Power required (KVA)

Spindle & Servo drives 22.42
Electrical control unit 1.00
Hydraulic pump motor 1.40
Coolant pump motor 0.94
Lubricant pump motor 0.15
Chip conveyor 0.20
Cooling unit 1.00
Total 27.11 KVA
4.4
4. BED :
The Bed is of box type construction made of cast iron grade 25. It is designed for high
rigidity with suitable cross section and ribs. The bed undergoes natural seasoning and stress
relieving before assembly.
5. HEAD STOCK ASSEMBLY (A2-8) :
The head stock aasembly features cartridge type construction. The spindle assembly consists
of three angular contact ball bearings of P4 class accuracyin the front of 2TB construction
and double row cylindrical roller bearing with taper bore NN30K (Super precision class) in
the rear. The bearings are grease lubricated for life. The spindle drive is thro a set of SPA
series wedge belts.
4.5
6. SPINDLE BRAKE ASSEMBLY :
The spindle brake mounting assembly is as shown in figure. The brake is actuated hydraulically
and it locks the spindle in the oriented position.
4.6
7. SPINDLE ENCODER ASSEMBLY :
The spindle speed feed back is through an incremental rotary optical encoder which is driven
by a timing belt.
8. SPINDLE SPEED CHARACTERSTICS :
4.7
9. SPINDLE SPEED CHARACTERSTICS :
10. WORK HOLDING :

The work holding mounted on the spindle front end and the chucking cylinder at the rear are
connected by a drawbar. The clamping and declamping is achieved by the actuation of the
draw bar.
Any standard work holding and chucking cylinder can be mounted on the spindle with suitable
adaptors.
4.8
11. Z-AXIS ASSEMBLY :
The Z-axis slide moves over a pair of hardened & ground guide strips. The sliding surfaces
are lined with Turcite for anti stick slip properties. An AC servo motor drives the ball screw
through a timing belt. The pretensioned ball screw arrangement takes care of the expansion
effect due to temperature variation.
The axis system is provided with overload safety clutch to protect the machine against
application of excessive motor torque on to the elements in case of accidents.
The feedback for the Z-axis motion is through the encoder built into the motor.
For setting the machine co-ordinates in the Z-axis a set of actuating dogs and limit switches
are provided. Machine reference and emergency positions can be set with these limit switches.
4.9
12. X-AXIS ASSEMBLY :
The X-axis slide moves over a pair of hardened & ground guide strips. The sliding surfaces
are lined with Turcite for anti stick slip properties. An AC servo motor drives the ball screw
through a timing belt. The pretensioned ball screw arrangement takes care of the expansion
effect due to temperature variation.
The axis system is provided with overload safety clutch to protect the machine against
application of excessive motor torque on to the elements in case of accidents. An electro-
magnetic brake is provided on the axis for added safety. The feedback for the X-axis motion
is through the encoder built into the motor.
For setting the machine co-ordinates in the X-axis a set of actuating dogs and limit switches
are provided. Machine reference and emergency positions can be set with these limit switches.
13. TURRET
Refer to Duplomatic Rotary Tool Turret Manuals.
4.10
14. TAILSTOCK ASSEMBLY :
The tailstock assembly consists of hardened quill sliding in a honed cast iron housing. The
housing which is adjustable crosswise is mounted on a cast iron base which moves on V and
flat guide ways. The tail stock quill can be advanced and retracted hydraulically using the
foot switch. The whole tailstock body can be moved after loosening the clamp bolts. The
bullet can be removed from the centre assembly by a wedge.
The quill is provided with MT-4 taper in the front to facilitate mounting of add-on revolving
centre, with MT-2 bullet.
The tailstock is also offered with built-in revolving centre with MT-2 bullet as an option. 4.11
Tailstock revolving centre - Load diagram
Example : Admissible load of centre at 1000 rpm

Axial load = 480 Kgf and Radial load = 320 Kg workpiece
4.12
15. HYDRAULIC SYSTEM :
The power pack is mounted at the rear side of the bed. A variable displacement vane pump
supplies oil to the manifold block mounted at the front of the machine. The various control
elements are mounted on the manifold block and the settings of these can be done from the
front of the machine. A gauge isolator with pressure gauge is provided to read the different
pressure settings. From the manifold blocks A & B lines of the actuators are connected
through flexible hoses. The leakage line from the chucking cylinder is connected back to the
power pack through a PVC wire braided hose. Pressure switches provided in the circuit enable
interlocking features to ensure clamping. The spindle locking in oriented position is achieved
by a hydraulic actuated brake.
4.13
16. LUBRICATION SYSTEM
1. Pump 7. Float switch

2. Motor 8. Oil filler cum breather
3. Relief valve 9. Suction strainer
4. Pressure gauge dampner 10. Pressure reducing valve
5. Pressure gauge 11. Feed valve
6. Pressure switch 12. Reservoir
The machine is built with an automatic centralized lubrication system which supplies a
metered quantity of lubricant at a set regular interval to the guide ways and the ball screw
nuts. The quantity of the lubricant is regulated by metering cartridges and the time interval
through a PLC timer. The lubrication system monitors the build up of pressure and oil level
and gives suitable signals to the operator. An oil collector collects the spent lubricant which
is to be disposed off at regular intervals. For lubricant system details refer to the annexure.
17. COOLANT SYSTEM :

The machine has got a coolant tank of 130 litres capacity. The coolant pump mounted on the
tank delivers the coolant to the tool tip through each of the turret station and tool disc assembly.
The coolant which flows out through the turret, drains back to the tank. The machine guarding
is designed to protect the drive elements from coolant splash and chips and to facilitate easy
maintenance. A sight glass with safety grill is provided for viewing the machining
operation with the front doors closed. 4.14
1. STANDARD CHUCKS AND CYLINDERS
Standard 3 jaw / 2 jaw chucks (GMT)
Hollow 3 jaw / 2 jaw chucks (GMT)
Standard chucking cylinders (PRAGATI)
2. STANDARD CHUCK
DISMOUNTING AND INSTALLING PROCEDURE
If the machine is supplied with a standard chuck (GMT 3B/2B x 200), follow the procedure
given below to dismount the chuck.
a. Put the chuck in clamping condition.
b. Remove the jaws.
c. Remove the centre piece.
d. Remove the chuck mounting screw.
e. Actuate the draw bar in out position. The chuck slides out from mounting flange.
f. Hold the chuck firmly.
g. Use the special Allen (or box spanner) supplied along with the chuck to loosen the draw bolt
completely. The chuck will slide out. Avoid hammer blows on the Allen key.
While following the above procedure it is suggested that the hydraulics be put OFF.
HOLLOW CHUCK : Insert a suitable rod inside the draw bar and unscrew the draw nut of
the chuck
FOR REINSTALLING FOLLOW THE STEPS GIVEN BELOW:

a. Clean the chuck mounting surfaces with lint free cloth.
b. If the chuck to be installed is a new one, it has to be dismantled, cleaned and greased as per
the recommended instructions of the manufacturer. Then the chuck assembly without the
hard/soft jaws and centre piece is to be mounted on the face plate.
c. It is assumed that the relevant chucking cylinder and the corresponding drawbar is already
installed on the machine. If it is not done, the appropriate chucking cylinder flange and the
drawbar are to be fitted on to the chucking cylinder after cleaning the mounting surfaces.
5.1
Provisions for mounting the chucking cylinder flange exists on the face of the pulley on the
spindle. Clean the surface well and mount the chucking cylinder together with the flange
and the drawbar onto this surface. Check the alignment of mounting by dialling the reference
surface at the rear of the chucking cylinder. The total indicated reading (TIR) should be
preferably less than 0.04 mm to keep the spindle vibrations to the minimum.
Connect hoses to the input lines. The drain line should be directed downward and held in
that position to avoid tilting, thereby preventing overflow of oil from the drain chamber.
d. Switch on the hydraulics and actuate the chuck clamp, the draw bar will be drawn in. Mount
the chuck in this condition. Engage the draw bar bolt into the draw bar and rotate the draw
bolt till the chuck is seated on the face plate. Insert the mounting bolts and tighten them
uniformly.
To set the clamping stroke, operate the foot pedal to release the chuck. Loosen the draw bar
till it just meets the resistance. This is the fully opened position of the jaws. Now tighten
the draw bolt by half a turn. Now the full stroke of the master jaws is available for clamping.
Operate the clamp/declamp switch/foot pedal to ensure the above. Then insert the centre
piece and fix it. Mount the hard/soft jaws suitably.
3. HOLLOW CHUCK INSTALLING PROCEDURE

This is almost similar to the mounting and dismounting of a standard chuck.
Following are the differences:
The draw bar is hollow and threaded to the piston of the chucking cylinder, and is prevented
from loosening by applying suitable thread locking compounds, which also prevents coolant
seeping through the threads.
The chuck being hollow, a draw nut is provided in it to fasten the draw bar. The draw nut
needs a special tool to rotate it (supplied by chuck manufacturer).
The chucking cylinder is provided at the rear with a coolant collector, (connected to the
housing) and a face seal is provided to seal coolant entry in to the chucking cylinder.
The chuck flange is not the same as that of a standard solid chuck.
5.2
4. STANDARD CHUCKING CYLINDERS(PRAGATI)
The hydraulic cylinders are suitable for operation of power chucks or collets. The cylinder
is mounted on the rear of the lathe spindle, and operates the job holding device through a
draw bar.
These cylinders have been designed with a hole through the entire assembly. The through
hole can be used to supply air or coolant to the work holding fixture. It is also possible to
use a length stop rod fitted from the rear of the cylinder to provide axial location for the
workpiece. This rod rotates with the spindle, but always remains axially stationary with
respect to the spindle, thus providing a positive reference point for job location.
The cylinders incorporate a non-contacting type of rotary joint, which is virtually free from
maintenance problems. This type of rotary joint gives a certain amount of leakage. The
leakage return tube should be of generous size and should be connected directly to the tank.
Cylinders should be mounted in the HORIZONTAL position, with leakage oil connection
pointing downward.
5.3
5. OPERATION AND ADJUSTMENT OF
HYDRAULIC CHUCK UNIT
The hydraulic chuck is opened by depressing the foot pedal and closed by depressing it again.
a. If reduced jaw opening is desired then the draw bolt has to be adjusted after removing the
centre piece. The centre piece should be put back again after adjustment. For large
adjustments, the jaws have to be shifted on the serration on the master jaw.
b. Jaw change :
For jaw change, clean the serration of the master jaw and jaws, and the jaw nut fitting part
carefully, and then install with the same serration engagement as at the time of jaw
boring/turning.
c. Adjustment of the clamping force :
Adjustment is done with the pressure reducing valve on the hydraulic power pack. Adjust
while observing the pressure gauge. After the adjustment, it must be locked with the lock
nut. The chuck pressure adjustment range is from 5 to 30 kg/cm2.
d. Change between Chuck Clamp / Declamp (by M codes).
To be used in MDI mode only and spindle should be OFF.
1. Select MDI mode
2. Enter M11 for chuck clamping
3. Enter M10 for chuck declamping
4. Press cycle start. The selected mode will be retained even after power OFF.
NOTE :
1. For execution of M03 and M04 ensure that chuck is clamped properly before starting the
cycle.
2. Change over from internal to external clamping should be done through I.D./O.D. selection
M codes i.e M16 for I.D. and M18 for O.D.
5.4
6. SOFT JAW BORING SEQUENCE FOR
EXTERNAL CLAMPING
1. Install the soft jaws on the chuck.
2. Set the hydraulic chuck internal clamping by parameter (M11).
3. Use an inner diameter cutting tool to cut a hole (d) about 8 mm smaller than the workpiece
clamping diameter (D) into the soft jaws installed in the chuck.
4. Set the hydraulic chuck external clamping by parameter (M10).
5. Clamp a blank (outer diameter d-1 mm, length about 6 mm) in the hole (d) of the machined
soft jaws.
6. Bore the soft jaws according to the clamping diameter (D) of the workpiece and remove the
blank after boring.
7. Remove burrs.
NOTE : For detailed explanations regarding the hydraulic chuck, refer to the instructions
issued by the chuck manufacturer. 5.5
7. SPINDLE SPEED AND CHUCKING FORCE
1) Maximum chuck operating force :
The chucking force of the chuck may be decreased by the influence of centrifugal force in
proportion to the spindle speed in case of O.D. chucking. However, in general, the maximum
speed is defined as that speed at which the dynamic chucking force becomes a half of the
static chucking force when the standard jaw is used under ordinary condition and chucked
with a suitable cylinder.
2) Spindle speed and chucking force :
The decrease of chucking force against operational speed is shown in figure. The top jaw
is the standard jaw and at the maximum operating position. This value is, however, the
normal case and care must be taken because it generally varies depending on the adjusting
position of top jaws, size of jaw and cutting conditions.
5.6
8. SAMPLE DRAWING Drg. No. 97-108 / 74-0-3
5.7
9. SPINDLE DETAILS (A2-8) Drg. No. 96-104 / 0165-0
5.8
1. MACHINING RANGE 96-104 / M371
6.1
6.2
6.3
6.4
6.5
6.6
7. INTERFERENCE DIAGRAM 96-104 / M36
6.7
1. FANUC Oi-TC SPECIFICATIONS
ITEM SPECIFICATIONS Oi-TC
CONTROLLED AXIS
Controlled path 1 path @
controlled axes
2 axes @
Controlled axis
4 axes (Including Cs axis) #
Simultaneous controlled axes Max. 4 axes @
Machine
Max. simultaneous 4 axes,

Axis control by PMC @
(Not available on Cs axis)
Cs contouring control 1 axis @
In case of G code system A, basic 2
axes are X and Z, Additional axes are @
optional from Y, A, B, and C.
Axis name In case of G code system B/C, basic
2 axes are X and Z, Additional axes
@
are optional from Y, U, V, W, A, B,
and C.
Spindle 2 units @
Simple synchronous control @
Least input increment 0.001mm, 0.001deg, 0.0001inch @
0.0001mm, 0.0001deg,
Increment system 1/10 @
0.00001inch
Flexible feed gear Optional DMR @
Fine Acc & Dec control @
Servo HRV control HRV3 @
Inch / Metric conversion @
All axes / each axis / each direction /
Interlock @
block start / cutting block start.
Machine lock All axes / each axis @
Emergency stop @
Overtravel @
Stored stroke check 1 @
Stored stroke check 2, 3 @
Chuck & Tailstock barrier @
Mirror image Each axis @
Follow-up @
Servo off @
Chamfering on/off @
Backlash compensation @
Backlash compensation for each rapid traverse and
cutting feed
@
Stored pitch error compensation @
Position switch @
Unexpected disturbance torque detection function @
7.1
' @ ' = Standard, ' # ' = Optional
OPERATION
Automatic operation (memory) @
DNC operation Reader/puncher interface is required @
MDI operation @
Schedule function @
Program number search @
Sequence number search @
Sequence number comparison and stop @
Program restart @
Manual intervention and return @
Buffer register @
Dry run @
Single block @
JOG feed @
Manual reference position return @
Reference position setting without DOG @
Reference position setting with mechanical stopper @
1 unit / each path @
Manual handle feed
2 units @
x 1, x 10, x m, x n,
Manual handle feed rate @
m: 0~127, n: 0~1000
Manual handle interruption @
Incremental feed x 1, x 10, x 100, x 1000 @
Jog and handle simultaneous mode @
INTERPOLATION FUNCTIONS
G00 (Linear interpolation type
Positioning @
positioning is possible)
Linear interpolation G01 @
Circular interpolation G02 / G03 (Multi-quadrant) @
Dwell G04 @
Polar coordinate interpolation @
Cylindrical interpolation @
Threading, synchronous cutting @
Multiple threading @
Threading retract @
Continuous threading @
Variable lead threading @
Polygon turning @
Skip G31 @
High-speed skip @
Torque limit skip @
Reference position return G28 @
Reference position return check G27 @
2nd reference position return G30 @
3rd / 4th reference position return @
7.2
FEED FUNCTION
Max. 240 m/min (1 m) @
Rapid traverse rate
Max. 100 m/min (0.1 m) @
Rapid traverse override F0, 25, 50, 100% @
Feed per minute @
Feed per revolution @
Tangential speed constant control @
Cutting feedrate clamp @
Rapid traverse, linear cutting feed,
Automatic acceleration/deceleration @
exponential.
Rapid traverse bell-shaped acceleration /
@
deceleration
Linear acceleration/deceleration after cutting feed
@
interpolation
Feedrate override 0 ~ 150% @
Jog override 0 ~ 150% @
Override cancel @
Manual per revolution feed @
Error detection @
Rapid traverse block overlap @
External deceleration @
PROGRAM INPUT
Tape code EIA RS244 / ISO840 @
Label skip @
Parity check Horizontal and Vertical parity @
Control in / out @
Optional block skip 9 @
Max. programmable dimension 8 digit @
Program number O4 digit @
External memory & sub program calling function @
Sequence number N5 digit @
Absolute / incremental programming Combined use in the same block. @
Decimal point programming / pocket calculator type
@
decimal point programming
Input unit 10 time multiply @
Diameter / radius programming (X-axis) @
Plane selection G17, G18, G19 @
Rotary axis designation @
Rotary axis roll-over @
Coordinate system setting @
Automatic coordinate system setting @
Coordinate system shift @
Direct input of coordinate system shift @
Workpiece coordinate system G52 ~ G59 @
Workpiece coordinate system preset @
Direct input of workpiece origin offset value
@
measured
Manual absolute on and off @
Direct drawing dimension programming @
G code system A/B/C @
Chamfering / corner R @
Programmable data input G10 @
Sub program call 4 folds nested @
Custom macro B @
Addition of custom macro common variables #100 ~ #199, #500 ~ #999 @
Pattern data input @
Interruption type custom macro @
Canned cycles @
Multiple repetitive cycle @
Multiple repetitive cycle II Pocket profile @
Canned cycles for drilling @
Circular interpolation by R programming @
Tape format for FANUC series 10/11 @
Conversational programming with graphic function Graphic display circuit is required. #
Macro executor 512 KB / 2MB / 4MB #
AUXILLIARY / SPINDLE SPEED FUNCTION

Auxilliary function M8 digit @
2nd auxilliary function B8 digit @
Auxilliary function lock @
High speed M / S / T / B interface @
Multiple command of auxilliary function 3 #
Spindle speed function S5 digit, binary output @
Spindle serial output S5 digit, serial output (1st & 2nd) $
spindle analog output S5 digit, analog output $
Constant surface speed control @
Spindle override 0 ~ 120% @
Actual spindle speed output @
Spindle speed fluctuation detection @
1st spindle orientation #
1st spindle output switching function #
2nd spindle orientation #
2nd spindle output switching function #
Spindle synchronous control #
Multi spindle control #
Spindle positioning #
Rigid tapping #
TOOL FUNCTION / TOOL COMPENSATION

Tool function T7 + 1/T6 + 2 digits @
Tool offset pairs 6 digit, 64 pairs @
Tool offset @
Y-axis offset @
Tool nose radius compensation @
Tool geometry/wear compensation @
Tool life management @
Tool offset value couunter input @
Automatic tool offset @
Direct input of tool offset value measured @
Direct input of tool offset value measured B @
EDITING OPERATION
320 m (equivalent to 128KB) *1 @
Part program storage length
640 m (equivalent to 256KB) *1 @
Number of registerable programs 400 @
Part program editing @
Program protect @
Background editing @
Extended part program editing @
Password function @
Playback @
SETTING AND DISPLAY
Status display @
Clock function @
Current position display @
Program display Program name 31 characters @
Parameter setting and display @
Self-diagnosis function @
Alarm display @
Alarm history display @
Operator message history display @
Operator history display @
Machine remote diagnosis package &
Remote diagnostic #
Ethernet card are required.
Operation history display @
Help function @
Run hour and parts count display @
Actual cutting feedrate display @
Display of spindle speed and T code at all screens @
Directory display of floppy cassette @
Graphic function Display unit with graphic is required @
Servo setting screen @
Spindle setting screen Only for serial interface @
Servo waveform display #
Display of hardware and software configuration @
Software operator's panel @
Software operator's panel general purpose switch @
English @
Japanese (Chinese character) #
Chinese (Traditional Chinese) #
Multi-language display
German / French / Italian / Polish #
Spanish / Korean / Portuguese #
Swedish / Czech / Hungarian #
Data protection key 4 types @
Erase CRT screen display @
DATA INPUT/OUTPUT
Reader / puncher (Ch. 1) @
Reader/puncher interface
Reader / puncher (Ch. 2) @
Data server #
External I/O device control @
DNC2 control #
External tool offset @
External message @
External machine zero point shift @
External data input Including above 3 items @
External key input @
External program input @
External workpiece number search 9999 @
External program number search 1 ~ 9999 @
Memory card input/output For maintenance @
Power mate CNC manager @
INTERFACE FUNCTION
Ethernet Ethernet board is required #
Profibus DP Master / slave #
Device Net Master / slave #
OTHERS
NC ready, servo ready, automatic
operation, automatic operation start
lamp, feed hold, reset, NC alarm,
Status output signal @
distribution end, rewinding, inch input,
cutting, in-position, thread cutting,
tapping , etc.
7.2" monochrome LCD/MDI
Control unit incorporated display unit Horizontal type. @
2 slots, 400(W)x200(H)x120(D) mm.
Basic instruction: 5 sec/step Max.
PMC-SA1 $
PMC step number ladder: 5000
SYSTEM Basic instruction: 0.033 sec/step
PMC-SB7 @
Max. step number ladder: 24000
I/O card DI / DO : 96 / 64 @
I/O Link @
Machine operator's panel #
Operator's panel I/O module DI / DO : 48 / 32 points #
Manual pulse generator #
Alpha 2/5000i, 4/5000i, 8/3000i,
Connectable servo motor 12/3000i, 22/3000i, Alpha C4/3000i, @
C8/2000i, C12/2000i, C22/2000i.
Connectable servo amp. Alpha is series (SVM) @
Pulse coder/optical scale (2 phase
Position detector interface (for full-closed control) pulse interface) @
Alpha 3i, 6i, 8i, 12i, Alpha C2i, C3i,
Connectable spindle motor C6i, C8i, C12i, Alpha P8i, P12i, #
P15i, P18i, P22i, P30i, P40i.
Connectable spindle amp. Alpha is series (SPM) #
Input power supply DC 24V 10% @
At operating : 0C ~ 58C
Ambient temperature of unit @
At non-operating : -20C ~ 60C
Normally : 75% RH or less Short term
Ambient relative humidity (within one month) : 95% RH or less @
(No dew, nor frost allowed).
At operating : 0.5G or less
Vibration @
At non-operating : 1G or less
' @ ' = Standard, ' # ' = Optional 7.6
*
' $ ' = Standard alternative, ' ' = Function included in other option
*1 The value might change according to the registered number of programs and the program sizes.
2. G CODES
M-code list for Classic MC
M00 Program stop M50
M01 Optional stop M51
M02 End of program M52 Turret Zero cycle ON
M03 Spindle rotation CW M53
M04 Spindle rotation CCW M54 T.S. quill override ON
M05 Spindle stop M55 Chuck signal override ON
M06 M56 T.S. quill interlock ON
M07 Coolant ON M57 T.S. quill interlock OFF
M08 M58
M09 Coolant OFF M59
M10 Chuck declamp M60
M11 Chuck clamp M61
M12 M62
M13 Live tool rotation cw M63 Cs contour mode ON
M14 Live tool rotation ccw M64 Cs contour mode OFF
M15 Live tool stop M65
M16 Chuck clamp on I.D. M66 Spindle brake ON
M17 M67
M18 Chuck clamp on O.D. M68
M19 M69
M20 M70
M21 M71
M22 M72
M23 M73
M24 M74
M25 M75
M26 M76
M27 M77
M28 M78
M29 M79
M30 End of main program M80
M31 M81
M32 T.S. quill forward M82 T.S. body forward
M33 T.S. quill retract M83 T.S. body retract
M34 Parts catcher fwd M84 T.P. arm forward
M35 Parts catcher ret M85 T.P. arm retract
M36 M86
M37 M87
M38 M88
M39 M89
M40 M90
M41 M91
M42 M92
M43 M93
M44 M94
M45 M95
M46 M96
M47 M97
M48 M98 Sub program call
M49 M99 Sub program end
7.9
M-code list for Classic MC
M00 Program stop M50
M01 Optional stop M51
M02 End of program M52 Turret Zero cycle ON
M03 Spindle rotation CW M53
M04 Spindle rotation CCW M54 T.S. quill override ON
M05 Spindle stop M55 Chuck signal override ON
M06 M56 T.S. quill interlock ON
M07 Coolant ON M57 T.S. quill interlock OFF
M08 M58
M09 Coolant OFF M59
M10 Chuck declamp M60
M11 Chuck clamp M61
M12 M62
M13 Live tool rotation cw M63 Cs contour mode ON
M14 Live tool rotation ccw M64 Cs contour mode OFF
M15 Live tool stop M65
M16 Chuck clamp on I.D. M66 Spindle brake ON
M17 M67
M18 Chuck clamp on O.D. M68
M19 M69
M20 M70
M21 M71
M22 M72
M23 M73
M24 M74
M25 M75
M26 M76
M27 M77
M28 M78
M29 M79
M30 End of main program M80
M31 M81
M32 T.S. quill forward M82 T.S. body forward
M33 T.S. quill retract M83 T.S. body retract
M34 Parts catcher fwd M84 T.P. arm forward
M35 Parts catcher ret M85 T.P. arm retract
M36 M86
M37 M87
M38 M88
M39 M89
M40 M90
M41 M91
M42 M92
M43 M93
M44 M94
M45 M95
M46 M96
M47 M97
M48 M98 Sub program call
M49 M99 Sub program end
7.9
[qtmc-01]
4. OPERATOR MESSAGES 1
NO. ADDRESS MESSAGE

0001 A000.0 1000 LOW LUB OIL LEVEL, CYCLE INTERRUPT
0002 A000.1 1001 LOW LUB PRESSURE, CYCLE INTERRUPT
0003 A000.2 1002 CHUCK ACTUATION FAILURE
0004 A000.3 1003 T.S. BODY UNCLAMP FAULT
0005 A000.4 1004 T.S. BODY ACTUATION FAILURE
0006 A000.5 1005 T.S. QUILL NOT IN POSITION, CYCLE INTERRUPT
0007 A000.6 1006 SPINDLE POSITIONING ABORTED
0008 A000.7 1007 PRG CNTL SW OPRTD, RST & HOME X & Z AXES
0009 A001.0 1008 TURRET CLAMP SIGNAL FAULTY
0010 A001.1 1009 T.S. QUILL POSITION LOST, SET DOGS & RESET
0011 A001.2 1010 T.S. QUILL ACTUATION FAIL
0012 A001.3 1011 SPN O/L, CHK TOOL TIP, DEPTH OF CUT & F/R
0013 A001.4 1012 X-AXIS CLUTCH TRIPPED, REFER MANUAL
0014 A001.5 1013 Z-AXIS CLUTCH TRIPPED, REFER MANUAL
0015 A001.6 1014 TOOL WORNOUT, REPLACE THE INSERT
0016 A001.7 1015 TURRET INDEX ABORTED
0017 A002.0 1016 TURRET NOT IN SAFE ZONE, GO X-HOME
0018 A002.1 1017 TURRET MOTOR OVER HEATED
0019 A002.2 1018 TOOL NUMBER HIGH
0020 A002.3 1019 TURRET UNCLAMPED, FEED OFF
0021 A002.4 1020 PARTS CATCHER ACTUATION FAILURE
0022 A002.5 1021 DOOR ACTUATION FAILURE
0023 A002.6 1022 SPINDLE ORIENTATION ABORTED
0024 A002.7 1023 AIR PRESSURE LOW
0025 A003.0 1024 T.P ACTUATION FAILURE
0026 A003.1 1025 LUB MOTOR/PR SW CONTINUOUSLY ON
0027 A003.2 1026 HOMING FAILURE
0028 A003.3 1027 CANCEL CSS BEFORE T-COMMAND
0029 A003.4 1028 SPINDLE BRAKE ACTUATION FAIL
0030 A003.5 1029 RUN ZERO CYCLE AND THEN INDEX
0031 A003.6
0032 A003.7 1031 BAR FEEDER NOT READY
0033 A004.0 1032 CHIP CONVEYOR TH TRIP/LS OPEN
0034 A004.1 1033 PARTS MACHINED = PARTS SET
0035 A004.2
0064 A007.7
0065 A008.0 1064 TOOL 1 WORNOUT, CHANGE INSERT
[qtmc-01]
OPERATOR MESSAGES 2
NO. ADDRESS MESSAGE

0077 A009.4
0078 A009.5
0079 A009.6
0080 A009.7
0081 A010.0 2009 COOLANT CONTACTOR NOT ON
0082 A010.1 2001 CHUCK POSITION FAULT
0083 A010.2 2015 CHUCK NOT CLAMPED, SPINDLE INHIBIT
0084 A010.3 2000 TOOL IS WEARING OUT
0085 A010.4 2100 CHUCK CLAMPED ON O. D.
0086 A010.5 2101 CHUCK CLAMPED ON I.D.
0087 A010.6 2002 CHUCK IN EXTREME END POSITION
0088 A010.7 2003 AXES NOT REFERENCED, HOME X & Z
0089 A011.0 2004 HOME X BEFORE Z
0090 A011.1 2005 HOME Z BEFORE X
0091 A011.2 2006 CLAMP CHUCK BEFORE SPINDLE START
0092 A011.3 2007 DOOR NOT CLOSED, CLOSE BEFORE CY START
0093 A011.4 2008
0094 A011.5 2010 TOOL PROBING INCOMPLETE,PROBE OTHER AXIS
0095 A011.6
0104 A012.7
0105 A013.0 2021 TOOL 1 GETTING WORNOUT
1. OPERATOR CONTROL PANEL
The above operator panel is only for the user reference. For exact description of operator
panel for the machine supplied refer to the relevant operator panel drawing supplied with
the machine interface manual.
8.1
OPERATOR CONTROL PANEL-1 DETAILS
1. Emergency stop push button
2. CNC OFF/ON push button
3. Emergency override push button
4. +X jog push button
5. -X jog push button
6. +Z jog push button
7. -Z jog push button
8. Rapid override push button
9. Cycle start push button
10. Feed hold push button
11. Spindle CW/CCW push button
12. Spindle stop push button
13. Feed override rotary switch
14. Rapid override rotary switch
15. Handle/Step feed rotary switch
16. Mode selection rotary switch
17. Spindle speed override rotary switch
18. Optional stop switch
19. Block delete switch
20. Dry run switch
21. Machine lock switch
22. Program check switch
23. Program protect OFF/ON key switch
24. RS 232C port
8.2
DESCRIPTION OF OPERATOR CONTROL PANEL-1
1. EMERGENCY STOP PUSH BUTTON

Machine will be in emergency state if this push button is pressed. After pressing the CNC
ON push button, if the emergency push button is released hydraulic gets ON and machine
will reset, automatically. In emergency state, power to the drives and hydraulics are
removed and not ready message is displayed on the screen.
2. CNC ON/OFF PUSH BUTTON

After the main supply is switched ON, CNC system can be switched ON by pressing CNC
ON push button. After a few seconds delay the CRT display will come ON showing
software version number and PMC number. The CNC can be switched OFF by pressing
CNC OFF push button.
3. EMERGENCY OVERRIDE PUSH BUTTON

During machine operation if any slide actuates the end limit switch, the machine will come
to emergency stop state. Jog keys become ineffective unless the emergency override push
button is pressed. Keeping emergency override push button pressed jog the axis in opposite
direction till the end limit switch is released. Then emergency override push button should
be released. After this jog switches will remain effective.
4. +X JOG PUSH BUTTON

If this key is pressed in jog mode then X-slide will move in positive direction at a feed rate
depending upon the feed override selected. When in reference mode, this key can be used
for X-axis homing.
5. -X JOG PUSH BUTTON

If this key is pressed, in jog mode then X-slide will move in negative direction at a feed
rate depending upon the feed override selected.
8.3
6. +Z JOG PUSH BUTTON
If this key is pressed in jog mode then Z-slide will move in positive direction at a feed rate
depending upon the feed override selected. When in reference mode and X-axis reference
is completed then with this key Z-axis homing is possible.
7. -Z JOG PUSH BUTTON

If this key is pressed in jog mode then Z-slide will move in negative direction at a feed rate
depending upon the feed override selected.
8. RAPID OVERRIDE PUSH BUTTON

When this push button is pressed along with any of the jog push buttons, the respective
slide moves in rapid rate set for that slide. This push button is effective only after axes are
referenced. Rapid rate can be set using the rapid override rotary switch.
9. CYCLE START PUSH BUTTON
This push button is effective in Auto single and MDI modes of operation
10. FEED HOLD PUSH BUTTON

Auto cycle is interrupted when this push button is pressed.
11. SPINDLE CW/CCW PUSH BUTTON

In jog mode spindle direction of rotation can be selected using these two push buttons.
The spindle speed can be selected using S command in MDI mode.
12. SPINDLE STOP PUSH BUTTON

In jog mode spindle is disabled using this push button.
13. FEED OVERRIDE ROTARY SWITCH

Feed can be varied from 0-150% of the set feed rate.
14. RAPID OVERRIDE ROTARY SWITCH

Rapid rate can be varied from 0-100% in steps of 25%.
8.4
15. HANDLE/STEP FEED ROTARY SWITCH
In handle/step mode without MPG option, this rotary switch can be used to move the slides
to a distance ranging from one micron to one millimeter using X or Z keys. With MPG
option in handle/step mode, with every incremental rotation of the MPG, slides can be
moved to a distance ranging one micron to 100 microns depending upon the position of
handle/step rotary switch.
16. MODE SELECTION ROTARY SWITCH

Modes of operations such as EDIT, AUTO-SINGLE, AUTO CONT, MDI, HAN-
DLE/STEP, JOG, ZRN can be selected using this switch.
17. SPINDLE SPEED OVERRIDE ROTARY SWITCH

Spindle speed can be varied from 50% to 120% of set speed in turns of 10% step.
18. OPTIONAL STOP SWITCH

For M01 code to be effective, this switch is to be pre selected.
19. BLOCK DELETE SWITCH

For skipping the part program blocks this switch is to be pre-selected. / mark has to be
inserted before the block. If this switch is selected during the execution of auto cycle in
single block then system indicates the error alarm "PRGM CONT SW OPRATD, RST &
HOME".
20. DRY RUN SWITCH

This switch can be used to enable DRN signal. When the DRN signal turns ON, the feed
rate command commanded in Auto or MDI mode is ignored and the machine operates at
the feed determined by the feed override dial. Dry run for rapid traverse can be enabled
or disabled by parameter setting.
8.5
21. MACHINE LOCK SWITCH
The slide movement will only be effective with this switch OFF. This switch is not
effective with auto cycle ON in auto continuous mode. If this switch is selected during
the execution of auto cycle in single block then system indicates the error alarm "PRGM
CONT SW OPERATED, RST & HOME".
22. PROGRAM CHECK SWITCH

Program check switch in combination with the machine lock switch can be used to check
the part program using graphic option. (Graphic simulation)
23. PROGRAM PROTECT OFF/ON KEY SWITCH

Program protection is possible only when this switch is in ON position. In order to edit
the part program in edit mode this switch must be in OFF position.
24. RS 232C PORT

This port can be used to upload or download the PLC program, part program or machine
parameters from CNC system to the computer or other Fanuc system compatible peripheral
devices.
8.6
2. OPERATOR CONTROL PANEL-2
The above operator panel is only for the user reference. For exact description of operator
panel for the machine supplied refer to the relevant operator panel drawing supplied with
the machine interface manual.
8.7
OPERATOR CONTROL PANEL-2 DETAILS
1. Cycle start push button

2. Coolant on/off selector switch
3. Turret index on push button
4. Turret unclamp override push button
5. Machine reset push button
6. Lub inch push button
7. Conveyor forward/reverse spring return selector switch
8. Door open/close push button
9. Turret tool station display unit
10. Spindle load meter
11. LED indicators

a. X-reference LED
b. Z-reference LED
c. Turret clamp LED
d. Tailstock quill forward LED
e. Tailstock quill home LED
f. Chuck clamp LED
g. Chuck declamp LED
h. Lub. ON LED
i. Lub. fault LED
8.8
DESCRIPTION OF OPERATOR CONTROL PANEL-2
1. CYCLE START PUSH BUTTON
This push button is effective in Auto continuous/Auto single and MDI modes of operation
2. COOLANT ON/OFF SELECTOR SWITCH

Coolant can be switched ON and OFF using coolant ON and OFF selector switch in jog
mode. In auto mode, for coolant ON, M07 to be commanded along with coolant ON
selection. Coolant can be made OFF by M09 or machine reset or coolant OFF selection.
3. TURRET INDEX ON PUSH BUTTON

In the jog mode the turret can be indexed forward direction by pressing this push button
provided turret is in safe zone and turret clamp signal is present.
4. TURRET UNCLAMP OVERRIDE PUSH BUTTON

If the turret is unclamped the axes cant be moved. This can be overridden by pressing
this switch.
5. MACHINE RESET PUSH BUTTON

This push button can be used to reset M, S or T functions when in execution. This push
button can also be used to reset PLC messages and spindle alarm.
6. LUB INCH PUSH BUTTON

Once this push button is inched lub motor will be ON for three seconds. Lubrication
inching is possible only when the machine is not under emergency and sufficient oil is
present in the lubrication tank.
7. CHIP CONVEYOR FORWARD/REVERSE SPRING RETURN

SELECTOR SWITCH
In jog mode chip conveyor can be run forward/reverse, by using spring return selector
switch. In auto mode chip conveyor works in forward direction.
8.9
8. MACHINE DOOR OPEN/CLOSE PUSH BUTTON
This push button can be used to open or close the door in Jog, MDI or Auto mode, when
the auto cycle is not ON.
9. TURRET TOOL STATION DISPLAY UNIT

This can be used to indicate the turret station number of the tool being used.
10. SPINDLE LOAD METER

This meter indicates the load conditions of the spindle motor as a percentage of full load
(0 to 120%). This indication is independent of the direction of rotation of the spindle.
Continuous load should be within 100% irrespective of spindle speed.
8.10
1. DAILY MAINTENANCE
1. Lubrication system Check for oil level, pressure At the start of the work
(Alarm signal) build up & film on sliding
surfaces
2. Chuck Greasing the master jaws At the start of the work
through grease nipples.
Tighten the jaws
3. Cutting tools Tighten the tool blocks, At the start of the work
tools and inserts
4. Hydraulic oil level Check for level Replenish if needed
5. Pressure gauge Check system pressure 30 Kg/cm2
Check for chuck pressure As per requirement
6. Coolant level Check for level Replenish if needed
7. Tubing and machine Check for leakage and
surroundings cleanliness
8. External wiring and Check for disconnections and
cables damage to sheath
9. Cleaning Clean the work holding, turret At the end of the work
and sliding guards to remove
chips and coolant
9.1
2. PERIODIC INSPECTION
Coolant Check for condition Replace as required
Hydraulic system Return line filter replacement 6 months
Check condition of oil and replace 1 year
Clean power pack and surroundings 1 year
Clean suction strainer 1 year
Check proper working of 6 months
accumulator
Lubricating system Check for proper working 1 month
Check for oil lubrication lines 1 month
V belts and timing belts Check for condition and tension 1 month
Motors Check for rigid (proper) mounting 6 months
Chuck Overhaul the chuck 1 month
Chucking cylinder Check for leakage across the piston 3 months
Electrical cabinet Vacuum clean the CNC and the 3 months
electrical cabinets
Electrical contacts Check for discolouration in the 3 months
contacts
Electrical elements Check for proper working of push 3 months
button switches
Limit switches Check for proper signals 3 months
Axes backlash Check and compensate 6 months
Foundation Check for level and relevel 6 months
Headstock Clean labrynth holes 1 month
Turret Check for alignment and correct As required
9.2
3. LUBRICATION
Lubrication is very important for machine tools since it greatly affects machine life. Use
only recommended lubrication oils which can clean and free foreign matter. Periodically
clean the tank and filter, inspect equipment or piping for damages to ensure optimum machine
operation.
a. SPINDLE
The headstock houses the spindle in bearings which are lubricated for life with high grade
grease (KLUBER ISOFLEX NBU-15). This grease can withstand low and high tempera-
tures (-60o C to +130o C).
Spindle should be warmed up for approximately one hour when the machine has been
stopped for a long period (e.g. five days or more on account of holidays etc.).
See Cautionary details concerning Installation
b. TAILSTOCK
The tailstock quill is connected to the central lubrication system. If the tailstock contains a
built-in live centre, then it is lubricated for life with KLUBER ISOFLEX NBU-15 grease.
It needs to be changed when the bearings are to be changed. If the machine is with add-on
revolving centre there is no lubrication required.
3.1 COOLANT
A tank serving both as a coolant tank and a chip tray (or optional chip conveyor) is installed
in the front side of the bed. It can be removed from the front side of the machine. Therefore,
it is easy to clean the inner part of the tank and to dispose chips. (Capacity 130 litres)
9.3
3.2 CHUCK
Selection of grease depends on the chuck used. Never fail to supply grease once a day to
the slideway of master jaw.
For GMT Chucks, it is recommended to lubricate the chuck once every shift. Use DOW
CORNING GN PLUS, MOSIL BRB 100, MOLYKOYTE BR 2 GREASES.
DO NOT USE OIL FOR LUBRICATION.
3.3 CENTRALISED LUBRICATION

The X & Z slideways, ballscrews and the tailstock quill are lubricated by automatic
centralised lubrication. Each point of lubrication is connected through a metering cartridge
of 0.25cc capacity/stroke. The provision for manual or automatic selection of lubrication is
provided on the control panel, and the lubrication interval is usually set at once for three
seconds for every 30 minutes.
It is recommended to supply enough number of lubrication shots by manual means before
starting a machine which has been shut down for a long time. The number of shots required
to fill the drained out lubrication lines after the lubrication metering cartridge depends upon
the distance from the metering cartridge to the lubrication point.
For further details see annexure - Centralised Lubrication.
3.4 DAILY INSPECTION

By opening the rear door the lubrication oil distributor mounted beside the X-axis feed motor
is monitored. Visual inspection of the distributor is not sufficient, so check oil at places
where oil is distributed (such as slideways). (e.g. Touch the slideways to check for an oil
film.)
Especially when the machine has been stopped for an extended period, the distributing pipe
gets drained. There are cases when the oil does not flow even though the pipe is filled with
oil. In such a case, check for oil flow by disconnecting the pipe.
If the machine is operated without supplying the lubricating oil to the sliding surfaces, it will
cause seizure of the sliding surface. Be sure to perform the above mentioned inspection
every day.
9.4
3.5 OIL GUIDE TABLE
Lubrication point Lubrication system Recomm. oil grade Quantity

Head stock Grease KLUBER ISOFLEX NBU-15
Ball screws,
Guideways, Centralised lubrication ISO VG-68 3 Litres
Tailstock
Hydraulic ISO VG-68 45 Litres
Coolant 130 Litres
NOTE : Do not use oil other than the above mentioned.

Also, do not use the mixture of oils of different makes.
9.5
3.6 STARTING CHECK TABLE
Check item
1. Lubrication oil level

Check
a. Centralised lubrication unit tank
2. Grease injection
a. Check master jaw (Once every day)
3. Oil flow
Check
a. Slideway
4. Oil leak from each part

a. Hydraulic unit
b. Chucking cylinder
c. Peripheral area of machine
5. Abnormal noise from spindle drive system

a. Head stock
b. Motors
6. Electrical system
a. Check for each indication
b. Check for each switch function
9.6
4. HEAD STOCK REALIGNMENT
In case of axis misalignment of the spindle with respect to the Z-axis, follow the method given
below for resetting:
1. Remove the chuck, chucking cylinder etc.
2. Mount the inspection mandrel.
3. Open the left hand guard covering the head stock.
4. Loosen the mounting bolts of the head stock slightly and use the screws provided to align
the axis with respect to the Z-axis.
5. Tighten the clamping bolts and recheck the alignment in both primary and secondary planes
of the Z-axis.
6. Shift the tailstock also if necessary in the appropriate direction (use a mandrel between
centres for this task).
7. Refix the covers.
9.7
REVISION RECORD
ACE CNC LATHE CLASSIC MC - INSTRUCTION MANUAL
Revision Date Contents
96-104 MC / IM-01 Apr. 02
96-104 MC / IM-02 July 03 Fanuc Oi-TB System

Updated pages 4.2, 4.3, 4.4
Fanuc Oi-TB specifications, G-Code,
M-code, Operator Messages.
96-104 MC / IM-03 June 06 Fanuc Oi-TC System

System Specifications, G-Code

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ACE CNC LATHE

MACHINE : ACE CNC LATHE

Suggestions for improvement are always welcome.

96-104 MC / IM-03 June 06

MACHINE : ACE CNC LATHE

Suggestions for improvement are always welcome.

96-104 MC / IM-03 June 06

INSTALLATION AND STARTUP

APPLICATION - 12 STATION TURRET

MACHINE CONTROL PANEL

3. BASIC POINTS OF SAFETY :

4. CLOTHING AND PERSONAL SAFETY :

5. SAFETY ASPECTS RELATED TO WORKPIECE

FOUNDATION PROCEDURE FOR ISOLATING THE MACHINE

Please contact Ace Designers for further details.

3. ENVIRONMENTAL CONDITIONS (NC SIDE)

POWER SOURCE INTAKE : (Export Machines)

POWER SOURCE INTAKE : (Export Machines)

POWER SOURCE INTAKE : (Export Machines)

4. CAUTIONARY DETAILS CONCERNING

6. MANUAL OPERATIONS - CHECKPOINTS

Always start rotating the spindle from minimum speed.

7. MANUAL / AUTOMATIC OPERATIONS -

1. Maintenance immediately after installation

ii) Initial inspection of bed level

3. Inspection of electrical control panel

Turret specification : Duplomatic BSVN-200

CNC System : FANUC 0i-TC

Elements used Power required (KVA)

5. HEAD STOCK ASSEMBLY (A2-8) :

8. SPINDLE SPEED CHARACTERSTICS :

10. WORK HOLDING :

Example : Admissible load of centre at 1000 rpm

1. Pump 7. Float switch

17. COOLANT SYSTEM :

FOR REINSTALLING FOLLOW THE STEPS GIVEN BELOW:

3. HOLLOW CHUCK INSTALLING PROCEDURE

ITEM SPECIFICATIONS Oi-TC

Max. simultaneous 4 axes,

AUXILLIARY / SPINDLE SPEED FUNCTION

TOOL FUNCTION / TOOL COMPENSATION

NO. ADDRESS MESSAGE

NO. ADDRESS MESSAGE

1. EMERGENCY STOP PUSH BUTTON

2. CNC ON/OFF PUSH BUTTON

3. EMERGENCY OVERRIDE PUSH BUTTON

4. +X JOG PUSH BUTTON

5. -X JOG PUSH BUTTON

7. -Z JOG PUSH BUTTON

8. RAPID OVERRIDE PUSH BUTTON

10. FEED HOLD PUSH BUTTON

11. SPINDLE CW/CCW PUSH BUTTON

12. SPINDLE STOP PUSH BUTTON

13. FEED OVERRIDE ROTARY SWITCH

14. RAPID OVERRIDE ROTARY SWITCH

16. MODE SELECTION ROTARY SWITCH

17. SPINDLE SPEED OVERRIDE ROTARY SWITCH

18. OPTIONAL STOP SWITCH

19. BLOCK DELETE SWITCH

20. DRY RUN SWITCH

22. PROGRAM CHECK SWITCH

23. PROGRAM PROTECT OFF/ON KEY SWITCH

24. RS 232C PORT