Takamaz X-10i E F21iTB 002a

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 recog-

nized 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 “Don’ts” to be observed when operating the machine. It

should be considered a “Don’t” 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.

WARNING

CAUTION Failure to follow the instructions may result in less serious

bodily injuries or machine damage.

DANGERFailure to follow the instructions will result in critical bodily inju-

ries.

* 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.

Failure to follow the instructions will result in serious bodily inju-

ries.

About This Manual

This Instruction Manual describes the following model :

Model : X-10iManufacturer : Takamatsu Machinery Co., Ltd.

* Consisting of :

• Safety Guide Safety precautions

• Specifications Machine specifications, drawings

• Installation Machine installation procedures

• Operation Machine operation procedures

• Maintenance Inspection, oiling, trouble shooting, adjust-ment, replacement

• Special Version Instruction to operate the optional equipment

TAKAMATSU MACHINERY Co., Ltd.HEAD OFFICE & PLANT

1-8 ASAHIGAOKA MATTO-CITY ISHIKAWA JAPAN, 924-8558TEL 81-76-274-1403 FAX 81-76-274-8530

EUROPE OFFICEIMMERMANNSTRASSE 65C D-40210 DUSSELDORF GERMANYTEL 49-0211-1677290 FAX 49-0211-8604542

BANGKOK OFFICE3RD FL., RUAM DANU THAI LANG SUAN BLDG., 34/3 SOI LANG SUAN, PLOENCHIT ROAD,LUMPINEE, PATHUMWAN, BANGKOK 10330 THAILANDTEL 66-2-652-1764 FAX 66-2-652-1765

TAKAMATSU MACHINERY USA INC.1320 LANDMEIER ROAD ELK GROVE BILLAGE, IL 60007 USATEL 1-847-981-8577(8559)(8569) FAX 1-847-981-8599

All rights reserved. No part of this document and attached technical materi-

als (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.

If you have any questions or doubts about this instruction manual, feel

free to contact us or your local agent at any time.

Safety Guide

Contents

Chapter 1 Basic Conditions for Safe Operation ....................................................... 1

Chapter 2 Preparation for Safe Operation ............................................................... 3

Chapter 3 Name of Each Component ........................................................................ 6

Chapter 4 Warning Labels ......................................................................................... 7

Chapter 5 Safety Devices ............................................................................................ 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 ..................................................................................... 14

8-1 Basics ............................................................................................................. 14

8-2 Installation ..................................................................................................... 15

8-3 Turning Power ON/OFF ................................................................................ 17

8-4 Warming Up .................................................................................................. 17

8-5 Setting Up ...................................................................................................... 18

8-6 Operation ....................................................................................................... 19

8-7 Finishing Operation ....................................................................................... 21

8-8 Maintenance................................................................................................... 22

1

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 par-

ticular 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 ma-

chine 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.


2

EMERGENCYSTOP

EMERGENCYSTOP

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 emer-

gency 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.


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.

EMERGENCY STOP buttonPressing this button stops all themachine motions immediately.

* The figure shows the machine equipped with Σ loader.

3

Chapter 2 Preparation for Safe Operation


Check the following points to operate the machine safely.

Installationenvironment

• Avoid direct sunlight or heat source which will generate a partialtemperature rise.

Ambient temperature: 0 ~ 45°C (20°C ± 2 is most recommended.)

Change in temperature: Max. 1°C/min.

• Keep apart from other machines which may splash water, oil orchips.

• Keep apart from press machines and forging machines to preventtransmission 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 andrelocation

• Use cranes and fork lifts which have passed in examinationsprescribed in nationally recognized safety standards and legal andgovernmental regulations.

• Lifting unit and wire rope should be of the specified size withoutdamage.

• Handling of cranes, fork lifts as well as slinging work should bedone by qualified persons.

• Lifting and transportation of the machine should be done withoutgiving any vibration or shock.

4

Lubrication • Use designated oil.• Never mix with other maker’s 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.

Machineenvironment

• 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 opera-

tion. 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 ma-chine 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 exhaustingunits to clear away dust or gas (flammable gas). If sufficientventilation is not assured, do not use the machine.

• Designated fire extinguishers should be provided at specifiedplaces 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.

Power sourceand grounding

• Electrical connection should be done by qualified electrical engi-neers.

• Power voltage 3-phase: 200/220 V ±10%Frequency: 50/60 Hz ± 2 HzPower cable: Min. 8 mm2 (in the case of single-wire cables)

• Keep apart from noise sources, such as welding machines, electricdischarge machines, etc.

• Comply with nationally recognized electrical standards and legaland 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 Ω• 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.


5

Operator’sclothing

• Wear a protective helmet, safety shoes and safety goggles thatcomply with the necessary safety regulations.

• Never wear gloves, a ring, a bracelet, a watch, or clothes that arebaggy or loose and may be caught up by the machine.

• Long hair should be tied or covered with a hat to avoid accidentsduring 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 operator’s hands duringsetting up. However, the key and switch operation should be donewith bare hands.

Safety controlsystem

• The instruction manual and safety guidebook should be kept byauthorized personnel at a designated place near the machine sothat they can be accessed at any time.

• Keys attached to the machine should be kept by authorized per-sonnel.

• A supervisor for safety control should be responsible for trainingoperators periodically so that environmental conditions can bechecked at any time for safety operation.


6

Chapter 3 Name of Each Component

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

shipment.

Chapter 3 Name of Each Component

Fig. 2

Front door

SpindleTurret NC screen

CNC operation panel

Machineoperation panel

Air unit

Foot switch

Lubrication unit

Electric cabinet Main power switch

Coolant pump motor

Coolant tankHydraulic pump unit

Hydraulic

pressure gauge

Absolute pulse coder

battery case


7

Chapter 4 Warning Labels

Fig. 3

Never remove or relocate warning labels.WARNING


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.


Standard specification

Σ loader specification

②④ ⑤⑤

A

⑤

③

①

③

⑤

⑤

③③

③

⑥

⑤②④

⑤

⑤

③

A

⑦

③

⑥

①

8


A

Safety Instructions1. 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 recommenda-

tions on the labels attached to the machine and in the manualsprovided.

4. Be sure that all personnel know the location of the EMERGENCYSTOP 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 ormachine damage. If you have any questions or doubt on theseinstructions, contact your supervisor or distributor immediately.

TAKAMATSU MACHINERY CO., LTD.

1

NEVER open door.Only for qualifiedservice 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

WARNINGNEVER open frontdoor during autooperation.

2 DANGER

3

NEVER extend barout of spindle rearside. Bar can bewaved about.NEVER insert barduring spindlerotation.

WARNING

6

WARNINGKeep away frommovable parts, such asspindle or turret, duringoperation.Shut machine off beforereaching movable partsfor servicing.

4 5

WARNINGNEVER open thiscover.Only qualified servicepersonnel can haveaccess. Shut themachine off beforeservicing.

WARNING

7

Crush hazard in loaderwork range duringoperation or servicing.NEVER reach into thecover. Shut power offbefore servicing insidethe cover.

9

Edit key switchProtects programs from being modified bymistake.

Door interlock switchStops the spindle rotation and the slidemotion if the front door is opened duringautomatic operation.

Lubricant alarm lampLights up if lubricant in the tank becomesinsufficient.

Turret alarm lampLights up or blinks if an error has arisen inthe turret.

Sequence alarm lampLights up or blinks if an error has arisen inthe components.

EMERGENCY STOP buttonPressing this button stops all the machinemotions immediately.

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.

• Never remove or modify safety devices, or stop their functionswithout our permission in advance.

• The covers without open/close switch and the doors of theelectrical cabinet should not be opened by unauthorized per-sonnel.

• Before starting operation, check that each safety device canfunction properly. If there is any problem, contact your localdistributor immediately.

DANGER

Fig. 4

WARNING

Front doorReinforced cover to prevent chips,workpieces and jaws from splashing

Chuck ID/OD change-over switch (optional)For changing over ID or OD gripping of chuck. The switchcannot be changed over when the power is turned on.


10

1 Prevents the Z axis from overrunning. A soft limit is also provided besides this.

2 Prevents the X axis from overrunning. A soft limit is also provided besides this.

3 Checks a clamping motion of the turret. Automatic operation cannot be started without a clampconfirmation.

4 Checks a lubricant level. Automatic operation cannot be started without lubricant.

5 Checks if the door is closed. Automatic operation cannot be started if the door is open.

6 Checks if the chuck is opened or closed. Automatic operation and the spindle rotation are notallowed unless the switch is turned on.

7 Checks the hydraulic pressure. Automatic operation cannot be started if the cylinderpressure is low.

8 Checks if a door of electric cabinet is closed. The primary power is shut off if the door is opened.(Optional)

9 Checks the position of the tailstock spindle. Automatic operation cannot be started if the position is notconfirmed.

(Optional)


3. Turret clamp limit switch

Fig. 5

2. X-axis limit switch

5. Door interlock switch

4. Lubricant float switch

1. Z-axis limit switch

6. Chuck clamp detector (optional)

8. Electric cabinet door interlock

(optional)

7. Hydraulic pressure switch (optional)

9. Tailstock limit switch

(optional)

(Optional)

(Optional)

11

Chapter 6 Hazardous Area

• 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.

WARNING

Fig. 6


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.

Chip discharge port is hazardous.

Inside the front door is hazardous.


12

6-2 High-voltage Area


• 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.

DANGER

Fig. 7

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.

DANGERNever touch the area marked with

even if the main power switch isoff, as high-voltage of 200 V is sup-plied up to the main power switchwhen the power in the factory isturned on. Failure to observe thiswarning will result in critical bodilyinjuries.

Hydraulic pump motorpower connector

Coolant pump motorpower connector


13

Chapter 7 Safety Precautions for Fire Prevention

Chapter 7 Safety Precautions for Fire Prevention

WARNINGWhen coolant is used for cutting, there is a possibility of catch-

ing a fire from high-temperature chips, frictional heat at the tool,

sparks during cutting, etc.

Follow the safety precautions described below and take suffi-

cient 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.

To perform machine operation continuously in safety, follow the precautions for fire

prevention described below.

14

DANGER• The electric cabinet, motors, transformers, and relay boxes (con-

nectors) are equipped with high-voltage terminals. Access tothese by unauthorized personnel is strictly prohibited as it is verydangerous.

• Never remove or modify any covers, switches or doors mountedfor safety without our permission.

• Understand the operation switches and relative machine motionsthoroughly before operating them.

• Never use machine in an atmosphere having a possibility of explo-sion.

• Never touch on switches and keys with wet or dirty hand.

• Never operate any switches before you have realized their result-ing 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. Thisshould be understood by all the personnel concerned.

• Stop operating the machine in case of abnormal lightning orrepeated power failure in order to avoid accidents.

• Keep the floor clean and dry. Slippage can easily occur if there isoil or water on the floor.

• Keep flammable materials and liquid away from the working areaas prescribed in nationally recognized safety standards and legaland 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.

Chapter 8 Safety Precautions

WARNING


8-1 Basics

High-voltage mark

EMERGENCYSTOP

EMERGENCYSTOP

15

DANGER


• Oil to use should be new and clean, and as designated in theinstruction manual. Any other oil than specified may result inmachine 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 opera-

tion.

• 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 powerfailure.

• Never give an excessive shock to the machine operation panel orthe 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 evenif it is not a movable section.

• Keep sufficient working area and remove obstacles from aroundthe machine.

• A work table to place cutting tools and workpieces should be rigidenough and so designed to prevent tools and workpieces fromslipping 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 cleaningthe machine.)

CAUTION

8-2 Installation

• Power connection, crane and fork lift operation and slinging workshould 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 byqualified personnel according to “Installation”

• Power cables from the primary terminal in the factory to the mainpower switch should have a rated cross sectional area in order tosupply stable power required for operation.

WARNING

16


• 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 highlevel.

• Never put your fingers between the bed and the floor when locat-ing the machine at a designated place.

• When lifting a machine, use wire rope, shackles and hoisting jigsthat 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 andtransporting.

• When rust preventive oil is applied to the slideways, remove itthoroughly with cleaning oil before starting operation.

• Remove eye bolts used for transportation as well as other fixingjigs 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 beforeturning 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 in-

structed.

• Water and dust on the machine are all wiped off.

• There is no oil leakage around the machine.

WARNING

CAUTION

17

8-3 Turning Power ON/OFF


• Before turning the power on, check that all cables are properlyinsulated. Damaged or disconnected cables should be immedi-ately repaired or replaced by qualified personnel, as they couldcause an electrical shock or leakage later.

• 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.• 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 describedin “Maintenance”.

• After stopping the machine for a long period of time, check thatthe motions, noise and slideway lubrication are free from trouble.If any abnormality is found, turn off the power immediately andinform the person in charge, then take necessary measures.

DANGER

WARNING

CAUTION

8-4 Warming Up

• After turning the power on, perform warm-up operation suffi-ciently.

• 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.

CAUTION

18


8-5 Setting Up

• Operation of crane and fork lifts as well as slinging work shouldbe 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 loca-tion 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 nextstep if there is no response from your partner.

• Never stand or work on the machine. If it is needed to stand onthe machine, wear a protective helmet, leather gloves and otherprotective 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, abnor-

mal 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 shouldbe properly done while keeping your balance so that you may nottouch or fall over hazardous part of the machine.

• Never stand in the rotating direction of the spindle, as aworkpiece, jaws or tools may fall off during setting up or trialrunning 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.

DANGER

WARNING

CAUTION

19


• When handling a heavy item of more than 20 kg, make a team forcooperative work or use proper transporters.

• After mounting cutting tools on the turret, check that they aresecurely fixed without backlash and well balanced.

• Tools used for setting up should be suitable for the machinespecifications. Spanners to use should fit nuts and bolts to avoidaccidental slippage.

CAUTION

DANGER

8-6 Operation

• Never remove a safety cover or safety device partially or wholly.It is strictly prohibited to operate the machine while exposing ahigh-voltage terminal.

• Removing or relocating limit switches, dogs and interlockingmechanism should be strictly prohibited.

• Never touch any switch or button with wet hands.

• High-speed moving sections, turret rotating section, and spindlerotating section should be isolated from operators during auto-matic or manual operation. Access or entry to these areas duringoperation is strictly prohibited. If it is needed to enter such anarea for maintenance and other purposes, turn off the power in thedesignated procedures. Failure to observe this will cause a criticalaccident.

• When machining a bar material without using a bar feeder, the barmaterial should not stick out from the spindle rear as it is hazard-ous when the spindle rotates.

• When chucking a workpiece, apply most suitable pressure to thechuck and the turret according to the workpiece material, grippingamount and machining conditions.

• Check that the chuck rotation speed does not exceed the allowablerange.

• Before starting unattended operation or leaving the machine for along 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.

WARNING

20


• 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 ischucked.

• Before unloading a finished workpiece, check that the spindle isstopped 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 auto-matic operation.

• Before starting operation, check that there is nobody or nothinginside the machine movable section.

• If the machine stops during automatic operation for some reason,check the trouble status and take necessary measures beforeremoving the cause. Restarting before taking proper measuresmust be avoided.

• Noise during machining may exceed 70 dB, resulting in damagingyour hearing ability. Use protective articles (headphones, etc.) asappropriate.

• Never touch any switch or key if not needed. Never lean againstthe machine during automatic operation.

• Never operate the machine while leaving a tool, cutter or measur-ing instrument inside or around the machine.

• When starting automatic operation for the first time, check thatthe program is correctly made and all the switches for automaticoperation (dry run, override, coolant control, etc.) are correctlyset.

• Discharge chips regularly so that they may not remain inside themachine.

• When machining special workpieces, check the characteristics inadvance and wear necessary protective clothes.

WARNING

CAUTION

21

DANGER

• Note the following points so that you will not be caught in themachine 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 machineimmediately and inform the supervisor.

• Modification of parameter setting should not be done without ourpermission.

• When an alarm message is displayed or an alarm indication lampis illuminating, take necessary measures immediately (such asinforming a person in charge).

• Chips should not be removed from the cutting edge with barehands. Always use gloves and a brush.

• Never touch tools or workpieces with hands immediately aftercutting. These can be extremely hot.

• Be sure not to touch the work light as it becomes very hot afterbeing operated for a long time.

• Never touch any switch or button with gloves on, as it could resultin malfunction or damage to the machine.


CAUTION

8-7 Finishing Operation

• After finishing all the operation, check that the primary power inthe factory is completely turned off.

• Before cleaning the machine and peripheral equipment such as achip conveyor, stop all the machine motions, turn off the mainpower switch and the primary power in the factory, and put a tagor a placard saying “Cleaning!”.

• Never use an air gun for cleaning the machine, as it may helpcoolant permeate into the spindle bearing and shorten the bearinglife. Use soft and clean cloth and clean the spindle carefully.

• When finishing operation, check that each section of the machineis 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.

CAUTION

22

• Turn the main power switch off during maintenance work. Theprimary power in the factory also should be off for maintenance ofthe electric cabinet. Never open the door in five minutes afterturning the power off, as residual voltage remains.

• When carrying out maintenance work, put a panel or a plateindicating “MAINTENANCE - KEEP AWAY FROM THEMACHINE.” around the machine so that the power is not turnedon 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 withoutour permission. Failure to observe this warning will result notonly in machine malfunctioning or damage, but also criticalbodily injuries.

• The cover should not be opened by unqualified personnel formaintenance. Turn the main power switch off when it is neededto 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. or-

derly, and remove all the obstacles, water and oil from the floor inorder to restore proper working environment.

• Procedures and methods described in “Maintenance” should bestrictly observed. Contact your local distributor immediatelywhen any question or doubt arises.

• Check each item after finishing maintenance work together with aperson 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 desig-

nated by Takamatsu.


DANGER

8-8 Maintenance

WARNING

CAUTION

Specifications

Contents

Chapter 1 Machine Appearance ................................................................................ 1

1-1 Name of Each Component ............................................................................. 1

1-2 Dimensional Drawing .................................................................................... 2

Chapter 2 Machine Specifications ............................................................................. 3

2-1 Standard Specifications ................................................................................. 3

2-2 Standard and Optional Accessories ............................................................... 4

Chapter 3 Controller Specifications .......................................................................... 5

3-1 Standard Specifications ................................................................................. 5

3-2 Optional Specifications.................................................................................. 6

Chapter 4 Major Units ................................................................................................ 7

4-1 Headstock Unit .............................................................................................. 7

4-1-1 Spindle .............................................................................................. 7

4-1-2 Spindle Nose Drawing ...................................................................... 8

4-1-3 Chuck Mounting Drawing ................................................................ 9

4-1-4 Spindle Motor Characteristic Diagram ............................................. 10

4-2 Turret Unit ..................................................................................................... 11

4-2-1 Tooling System Drawing .................................................................. 11

4-2-2 Turret Interference ............................................................................ 12

4-3 Slide Unit ....................................................................................................... 13

4-4 Hydraulic Pump Unit ..................................................................................... 14

4-4-1 Assembly Drawing of Hydraulic Pump Unit .................................... 14

4-4-2 Hydraulic Circuit Diagram ............................................................... 15

4-4-3 Arrangement of Valves ..................................................................... 16

4-5 Lubricant Unit ................................................................................................ 17

4-5-1 Lubrication System Diagram ............................................................ 17

4-6 Coolant Unit .................................................................................................. 18

4-6-1 Coolant System Diagram .................................................................. 18

4-7 Air Unit (optional) ......................................................................................... 19

Chapter 5 Electrical Drawings ................................................................................... 20

5-1 Connection Diagram ...................................................................................... 20

5-2 Electric Circuit Diagrams .............................................................................. 21

5-3 Parts Arrangement in Electric Box ................................................................ 36

5-4 Electric Parts List (standard) ......................................................................... 37

1

Chapter 1 Machine Appearance


1-1 Name of Each Component

Fig. 1 Machine appearance and name of each component

No. Name No. Name

1 Electric cabinet 13 Lubrication pump

2 Turret clamp valve 14 Saddle

3 Z-axis limit switch (Omron) 15 Slideways

4 X-axis servo motor (αC4i) 16 Coolant pump (250 W)

5 Turret index motor (Mitsubishi) 17 Tailstock (MT-3) optional

6 Turret housing 18 Quill advance/retract valve optional

7 X-axis limit switch (Omron) 19 Z-axis servo motor (α8i)

8 Hydraulic pump (0.75 kW) 20 Chucking cylinder (solid 15st.)

9 Spindle motor (AC 3.7/5.5) 21 Headstock

10 Foot switch 22 6" hydraulic chuck

11 Bed 23 Operation panel

12 8-station turret 24 Chuck valve

2


1-2 Dimensional Drawing

Fig. 2 Dimensional drawing

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

3

Optimum turning dia. mm φ60

Optimum turning length mm 50

Chuck size inch 6 (8)

Maximum swing mm 320

Max. bar dia. mm Solid (φ26, φ35, φ42)

Maximum turning dia. mm φ180

Maximum turning length mm 190

Spindle nose JIS A2 - 5

Spindle bearing I.D. mm φ75 (φ85)

Hole through spindle mm φ46 (φ52)

Max. speed min-1 3,500 (4,500)

Type stations 8

Max. tool size mm 20 sq.

Max. boring holder I.D. mm φ25

Max. stroke X 120 [90]mm

Z 230

Rapid traverse rate X 12m/min

Z 18

Spindle motor kW AC 5.5/3.7 (AC 7.5/5.5)

Feed motor kW X: AC 1.0, Z: AC 1.6

Coolant motor kW AC 0.25

Hydraulic motor kW AC 0.75

L x W x H mm 1,370 × 1,360 × 1,720

Machine weight kg 2,200

Total power capacity kVA 13.1 (For AC 7.5/5.5: 16.3)

Controller TAKAMAZ FANUC 21i-TB

Tur

ret

Cap

acity

Chapter 2 Machine Specifications


2-1 Standard Specifications

* 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.

SpecificationsItem UnitSp

indl

eSi

zeM

otor

4


2-2 Standard and Optional Accessories

Standard accessoriesBoring holders 2 sets

OD nozzle 8 sets

Collet flange 1 pce

Collet chuck (Takamaz standard) 1 pce

Hydraulic cylinder 1 set

Coolant unit 1 set

Work light 1 set

Splash guard 1 set

Tool kit 1 set

Instruction manuals 1 set

Optional accessoriesCollet chuck

Hydraulic chuck

Tailstock

Σ60 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)

(solid)

5

Item TAKAMAZ FANUC 21i-TB

Controlled axis Simultaneous controllable axes: 2

Least input increment 0.001 mm

Least command increment X: 0.0005 mm, Z: 0.001 mm

Auxiliary function M-3 digit

Spindle function S-5 digit

Tool function T-4 digit

Tape code EIA/ISO automatic recognition

Cutting feedrate 1~5,000 mm/min.

Command system Absolute/incremental

Interpolation Linear/circular

Cutting feed override 0~150%

Rapid traverse override F0, 100%

Program number 4 digits

Backlash compensation 0~9999 µm

Part program storage length 40 m

Tool offsets 16 sets

Registered programs 63 pcs

Tool geometry/wear offset Standard

Canned cycle Standard

Radius designation on arc Standard

Direct input of tool offset value measured A Standard

Background editing Standard

Chamfering/corner R Standard

Custom macro B Standard

Nose R compensation Standard

Inch/metric conversion Standard

Programmable offset data input Standard

Clock function Standard

Help function Standard

Alarm history 50

Self-diagnosis function Standard

Sub-program call up to 4 loops

Decimal point input Standard

2nd reference point return Standard

Stored stroke limit check Standard

Input/output interface (RS232C) Standard

Chapter 3 Controller Specifications


3-1 Standard Specifications

6


Item TAKAMAZ FANUC 21i-TB

Constant surface speed control G96, G97

Multiple repetitive cycles G70 - G76

Additional tool offsets 32 sets, 64 sets

Extended part program function

Part program storage length 80 m, 160 m

Run hour/parts count display

Continuous threading G33

Multiple M code in one block

Spindle orientation

Work coordinate system selection G54 - G59

Drilling cycle G83

Tool life management

Automatic zero return

3-2 Optional Specifications

7

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

Hydraulic cylinder

Encoder

Collet chuck

Double-row cylindrical roller bearing

Thrust angular ball bearing

Fig. 3 Structural drawing of headstock

Hydraulic chuck

Double-row cylindricalroller bearing

(solid)

(solid)

8

Fig. 4 Spindle nose drawing


4-1-2 Spindle Nose Drawing

Standard: solid type

φ26 through type

φ35 through type

depth 31

9

4-1-3 Chuck Mounting Drawing

Fig. 5 Chuck mounting drawing


Collet chuck

Power chuck

M10, depth 20

ZA5-6-0-05 (Matsumoto)

10


4-1-4 Spindle Motor Characteristic Diagram

Fig. 6 Spindle motor characteristic diagram

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

5.5 kW 30 min. 50% ED area

3.7 kW cont. area


3.7 kW cont. area

5.5 kW cont. area


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

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

Output

kW

Speed min-1

Output

kW

Output

kW

Speed min-1

Speed min-1 Speed min-1

Speed min-1


3.7 kW cont. areaOutput

kW


3.7 kW cont. areaOutput

kW

5.5/7.5 kW (Max. 4,500 min-1)5.5/7.5 kW (Max. 3,500 min-1)

11

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


Clamp block C

OD/face/grooving tool 20 sq.

ID holder

φ25 Boring holder

Double boring holder

φ25

Tap Tap holder

Boring bar

Center straight drillDrillchuck

Blank

Drill chuck arbor

Blank

Round hole bush

U-drill holder

Fig. 7 Tooling system drawing

Double boring holder φ20

Drill socket

Taper drill Drill Sleeve

U-drill Round hole bush

Boring bar

Center straight drill

Option:

Tailstock specification

OD nozzle

12

Fig. 8 Reference drawing of turret interference

4-2-2 Turret Interference

Distance betweencentersDistance betweencenters

Distance between centers

Distance between centers

Distance betweencenters

Distance betweencenters






13

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.

Fig. 9 Stroke drawing

OD turning range

Z-axis stroke

X-a

xis

stro

ke(t

ails

tock

spe

cific

atio

n)

Tailstock spindle stroke Tailstock slide stroke

ID turning range

Standard

collet

Matusmoto

Nikko

Z-axis stroke

X-a

xis

stro

ke(t

ails

tock

spe

cific

atio

n)

Tailstock spindle stroke Tailstock slide stroke

Standard

collet

Matusmoto

Nikko


14

4-4 Hydraulic Pump Unit

Fig. 10 Hydraulic pump unit

No. Name Type Maker

1 Piston pump P8VMR-10-CB-10 Tokimec

2 Tank filter MSY-04-150M (100 µm) Masuda

3 Tank 10L Tokimec

4 Radiator RA-1-N01 Nakamura Jiko

5 Oil level gauge OLG2-60K-M8 Kinoshita

6 Oil filler port/air breather MSA-V30 Masuda

7 Magnet MG40 Osaka Magnet

8 Pressure gauge (with glycerine) ATR 1/4 × 60 × 7 MPa Asahi Keiki

9 Solenoid valve DG4SM-3-2N-P7-H-52 Tokimec

10 Reducing valve TGMX2-3-PP-BW-G-50 Tokimec

11 Check valve BH40028525 Tokimec

12 Check valve HTIC-03-04-10 Tokimec

13 Direct drive motor 0.75kW4P Toshiba

8. External

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


4-4-1 Assembly Drawing of Hydraulic Pump Unit


A-A section(base notch details)

Oil filler port in the casingRemove the piping jointbefore oiling.

Terminal boxDrain port(Rc 1/4)

Pressure adjustment screw(Pressure increase by turning to the right)

Nut (2-M8)

15

4-4-2 Hydraulic Circuit Diagram

Fig. 11 Hydraulic circuit diagram

No. Name Type Maker

1 Piston pump motor P8NMR-10-CB-10 Tokimec

2 Tank filter MSY-04-150M (100 µm) Masuda

3 Tank 10L (2.6 gal.) Tokimec

4 Radiator RA-1-No1 (1013-201-138) Nakamura Jiko

5 Oil level gauge OLG2-60-M8 Kinoshita

6 Oil filler port air breather MSA-V30 Masuda

7 Magnet MG40 Osaka Magnet


9 Solenoid valve DG4SM-3-2N-P7-H-52 Tokimec

10 Reducing valve TGMX2-3-PP-BW-G50 Tokimec

11 Check valve BH40028525 Tokimec

12 Check valve HTIC-03-04-10 Hirose

13 Direct drive motor 0.75 kW 4P Toshiba

14 Solenoic valve SL-G01-H3X-GR-D2-5195A NACHI

15 Check plate 2755002009 Takamaz

16 Check valve ACC-05-C1 ASK

17 Manifold MBG-1 Kanazawa Kiko

18 Solenoid valve SL-G01-E3X-R-D2-5195A NACHI

19 Reducing valve 0GB-G01-AC-20 NACHI

20 Manifold MBS-1-10 NACHI


22 Flow regulator HT-720-03 Hirose

Spindle chuck

Turret clamp

Tailstock

Optional


16

4-4-3 Arrangement of Valves

Fig. 12 Valve layout drawing

Turret clamp valve


Tailstock valve

(optional)

Chuck clamp valve

17

4-5 Lubricant UnitThis 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


4-5-1 Lubrication System Diagram


Fig. 13 Lubrication system diagram

Nylon 4

Z Wear plate R

Z Slide R

Z Gib

Z Slide F2

Z Slide F1

Z Wear plate F

Oil amount with 3 cc/30 min setting

Unit code

Nylon 4

Nylon 4

Nylon 4

Tailstock

Nylon 4

Nyl

on 4

Takamatsu Showa

Standard 1751001015 161019-050R3

w/ tailstock 1751002013 161019-064R3

Distributor type Oil amount Oil amount Oiling positions

(w/ tailstock) (w/ tailstock)

PSS0 0.125 0.12 10 (10)

PSS1 0.25 0.24 5 (5)

PST0 0.125 0.12 2 (3)

PST1 0.25 0.24 1 (1)

Total 2.05 3.0 18 (19)

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

X Gib

Z Gib

Z Wear plate F

Z Ball screw

Z Slide F1

Z Slide F2

Z Slide R

Z Wear plate R

Nylon 4

Nylon 4

Nylon 4

Nylon 4

Nylon 4

Nylon 4

Nylon 4

Optional

Nylon 4

No. Part Name Type Q’ty1 Semi-cycle pump SMD3301AT 12 Flow distributor PSS0 103 Flow distributor PSS1 54 Flow distributor PST0 35 Flow distributor PST1 16 Tightening plug PA4 317 Distributor nut PAN4 198 Sleeve PB4 449 Nipple PD4 410 Elbow PHD4 1311 Dester-uni DB6D 112 Dester-uni DB8D 113 Dester-uni DB9D 114 Connector PM104 115 Elbow PH4M8T 416 Flexible hose FHC405 117 Flexible hose FHC407 118 Tube insert AL4 4419 Flexible hose FHC408 120 Junction JD3 1

18


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

CAUTIONAlways 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

Turret

Flood coolant

95 lit.

19

4-7 Air Unit (optional)


*Type and location of the air unit may differ depending on the specifications.

Fig. 15 Air unit


20

Chapter 5 Electrical Drawings


5-1 Connection Diagram

Fig. 16 Connection diagram

21


5-2 Electric Circuit Diagrams

Electric circuit diagram 1

Fig. 17 Electric circuit diagram 1

22




23




24




25




26




27




28




29




30




31




32




33




34




35




36

5-3 Parts Arrangement in Electric Box


37

5-4 Electric Parts List

* Specifications are subject to change according to the improvement of the machine. Check the


(standard)No. Part name Maker Type Q’ty Remarks

1 Earth leakage breaker Hitachi EX50B-50A-30 mA 200Vac 1 ELB

2 Magnetic switch Hitachi HJ10-T 100 V RC 3.8 A 1 OM: hydraulic (0.75 kW)

3 Magnetic switch Hitachi HJ10-T 100 V RC 1.4 A 1 CM: coolant (0.25 kW)

4 Electromagnetic contactor Hitachi HJ35 100 Vac 1 MCC1: Power supply power

5 Electromagnetic contactor Hitachi HJ10 100 Vac 1 MCC2: Turret amplifier power

6 Coil surge absorber Hitachi CSJ2-15C 3 OM, CM, MCC2 coil

7 Coil surge absorber Hitachi CSJ5-15C 1 MCC1 coil

8 Diode Hitachi V07E 3 HH52P-R, HH64P-L

9 Bi-power relay Fuji HH64P-L 24 Vdc 1 NON

10 Bi-power relay Fuji HH62P-FL 24 Vdc 1 RDY

11 Latching relay Fuji HH52P-R 24 Vdc 1 CHK

12 Mini-power relay Fuji HH54P-FL 24 Vdc 1 EST

13 Mini-power relay Fuji HH52P-FL 24 Vdc 1 UCL

14 Relay socket Fuji TP614X2 1 for HH64P-L

15 Relay socket Fuji TP68X2 1 for HH62P-FL

16 Relay socket Fuji TP514X1 2 for HH52P-R, HH54P-FL

17 Relay socket Fuji TP58X1 1 for HH52P-FL

18 Terminal relay Fuji RS-4DN 24 Vdc 1 OTX/OTZ/OTY/CLT

19 Circuit protector Fuji CP31FM/5 2 F1, F2 (5A)

20 DIN rail Toyo Giken DAS4 2

21 Fixture Toyo Giken CT-H 4

22 Mark plate Toyo Giken M-1LE 2

23 2-step terminal block Toyo Giken CTW-15S2 42

24 2-step terminal block side plate Toyo Giken CTW-15L2 1

25 Terminal cover Toyo Giken CA-30 1

26 Terminal block Toyo Giken AT-20 2 L1, L2, L3, PE

27 Terminal block side plate Toyo Giken ATL-20 1 L1, L2, L3, PE

28 Relay box terminal block Toyo Giken BOXTC 2 X-, Z-axis LS

29 Fan motor Minebea 3610PS-10T-B30-B00 1 Attached to the operation box

30 Fan guard Minebea PG-36 1 Attached to the operation box

31 Heat exchanger Ohm OC-15 1

32 Cap connector Ohm OA-2 1

33 Spark killer Okaya CR-10201 1

34 Spark killer (3RMS) Okaya 3RMES-12334-B0 1 CM

35 Transformer Yokoyama 200, 220/100 V 500 VA 1 TR

36 24 Vdc power supply Cosel PAA100-24 2 DCP1: for control, DCP2: for SOL

37 Grommet Takigen C-30SG-20A2 1

38 Toggle switch Nippon Kaiheiki M-2012L 1 TZPSW

39 Receptacle Matsushita WK3001 1 Attached to the electric box


38

No. Part Name Maker Type Q'ty Remarks

1 Keyswitch Takigen S-9-90-B-1 (same number) 2 PRGED, DINTK

2 Pushbutton switch Fuji AH30-VR01 1 ESTP

3 Pushbutton switch Fuji AH25-FG10 2 PON, CYST

4 Pushbutton switch Fuji AH25-FR01 2 POF, FHLD

5 Pushbutton switch Fuji AH165-SFG11 1 TURK

6 Dustproof cover Fuji AHX047 (green) 1 CYST

7 Dustproof cover Fuji AHX046 (red) 1 FHLD

8 Dustproof cover Omron A3BA-5060 1 TURK

9 Pushbutton switch Nippon Kaiheiki MB-2011-f8Y 1 OTR

10 Manual pulse generator Tokyo Sokuteiki RE45T 1S M5D1 1

11 Rotary switch Tokyo Sokuteiki DP-P01-0-15G 15° L=16 2 FOV, SOV

12 Switch knob Fujitsu R. antr 60a 2

13 Dust cap with a cord Japan Aviation DB-59-J2 1 RS-232-C connector cover

14 Hole plug Heiko DP-250 1

15

16 Relay board Takamaz TACS-10-5A-18T 1 for 18T, 21T

17

18 NC control unit (7.2" LCD) FANUC A02B-0285-B500 1 21i-TB

19 Separate type MDI unit FANUC A02B-0281-C120#TBR 1

(compact key)

20 Distribution panel I/O module FANUC A03B-0815-C001 1 IOM1

(basic)

21 Distribution panel I/O module FANUC A03B-0815-C003 2 IOM2, IOM3, (OP. IOF4)

(extended B)

22 Machine operation panel I/F unit FANUC A16B-2201-0110 1 OPIFB

23 Power supply module FANUC A06B-6110-H006 1 PSM (PSM-5.5i)

24 Servo amplifier module FANUC A06B-6114-H206 1 SVM (SVM2-20/40i)

25 Spindle amplifier module FANUC A06B-6082-H206#H512 1 SPM (SPMC-5.5)

26 AC reactor FANUC A81L-0001-0155 1 ACL

27 Optical fiber cable FANUC A66L-6001-0026#L5R003 1

(5 m for external cable)

28 MDI signal cable FANUC A02B-0236-K812 1

(compact, horizontal)

29 Battery case FANUC A06B-6050-K060 1

30 Battery FANUC A06B-6050-K061 1

31 DC link short bar (64 mm) FANUC A06B-6078-K803 2

32

33 Servo amplifier module Mitsubishi MR-J2-40D-S28 1 SVMT

34

35

36

37

38

39

40


Installation

Contents

Chapter 1 Safety Precautions for Installation .......................................................... 1

Chapter 2 Preparation for Installation

2-1 Environment .................................................................................................. 3

2-2 Foundation ..................................................................................................... 3

2-3 Air Source ...................................................................................................... 4

2-4 Electrical Wiring............................................................................................ 4

2-5 Installation Space ........................................................................................... 5

Chapter 3 Transportation........................................................................................... 6

Chapter 4 Cleaning of Machine ................................................................................. 8

Chapter 5 Power Connection ..................................................................................... 9

Chapter 6 Grounding Work ....................................................................................... 11

Chapter 7 Air Connection .......................................................................................... 12

Chapter 8 Oiling .......................................................................................................... 13

Chapter 9 Levelling ..................................................................................................... 14

1

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 ma-

chine.• 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 doneby qualified personnel according to “Installation”.

• Power cables from the primary terminal in the factory to themain power switch should have a rated cross sectional area inorder to supply stable power required for operation.

• Check the following points to ensure safety at the installationsite.

• When foundation bolts are buried, mark those points clearly to

protect workers from stumbling over and the machine and car-

riages 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 highlevel.

• Never put your fingers between the bed and the floor whenlocating the machine at a designated place.

• When lifting a machine, use wire rope, shackles and hoistingjigs that are not damaged and rigid enough to withstand themachine 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 duringlifting and transporting.

WARNING

2


• When rust preventive oil is applied to the slideways, remove itthoroughly with wash oil before starting operation.

• Remove eye bolts used for transportation as well as other fixingjigs 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 beforeturning 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

3


Fig. 1


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: 0°C ~ 45°C (20°C ± 2°C is most recommended. Temperature fluctuation

should be within 1°C 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.

4


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

CAUTION If normal voltage is not supplied, the machine may not actu-

ate correctly.

Be sure to measure voltage with a tester. When voltage

fluctuation exceeds ±10%, provide a voltage stabilizer.

• 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 : Below 100 ΩGrounding cable : 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.

5


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.

Fig. 2

* Required installation space may change slightly according to optional accesso-

ries and/or a destination of the machine.

6

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.

• 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 φ10 mm)* The thickness of the above wire rope is for the standard specifications. For

optional specifications, the total machine weight differs for respective specifi-

cations so that the thickness of the wire rope to use may differ as well.

Contact Takamatsu before starting the work.

• When working in a team, choose a leader to give instruc-

tions.

• 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.

WARNING

CAUTION

7

[Required jigs]

Dedicated hoisting jigs

Crane

Wire rope (more than φ10 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.


Fig. 3

* These hoisting jigs are optionally provided.

Dedicated hoisting jig

Dedicated hoisting jigs

8

Chapter 4 Cleaning of Machine

CAUTION • Do not operate the machine before cleaning is finished.

• Never use compressed air, like air gun, for cleaning the

machine.

Chapter 4 Cleaning of Machine

Remove rust preventive oil applied on the slideways and metal surfaces thoroughly with

nonflammable cleaning agent after unpacking.

9

Chapter 5 Power Connection

DANGER • Electric connection should be done only by qualified electric

engineers.

• Turn off the primary power in the factory first. Never con-

nect 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.

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.


10


Fig. 4

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.

Electric cabinet

Cable connection port

ＥＲＴ

Ｓ


11

Chapter 6 Grounding Work

• 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.

Chapter 6 Grounding Work

Comply with the electrical rules and regulations on grounding prescribed in your country.

DANGER

WARNING

12

Chapter 7 Air Connection


* Type and location of the air unit may differ depending on the specifications.

Fig. 5

Air connection port

Chapter 7 Air Connection

Use clean and dry compressed air.

13

Chapter 8 Oiling

“Chapter 4 Oiling” in Maintenance

Chapter 8 Oiling

See

14

Chapter 9 Levelling

DANGER Turn off the main power switch first when maintenance work

should be done inside the cover.

WARNINGCovers of the machine should be opened only by qualified

maintenance personnel.

[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.

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.

15

Chapter 9 Levelling

Fig. 6

Level gauge

Levelling block

Lock nut

Jack bolt

Place the level gauge.

* The diagram above is for tailstock specifications.

Jack bolt position (4 places)

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 ....................................................................... 19

2-1 Check-ups before Turning Power ON ........................................................... 19

2-2 Turning Power ON ........................................................................................ 20

2-3 Check-ups after Turning Power ON .............................................................. 21

2-4 Check-ups before Turning Power OFF ......................................................... 22

2-5 Turning Power OFF ....................................................................................... 23

2-6 Check-ups after Turning Power OFF ............................................................ 24

Chapter 3 Manual Operation ..................................................................................... 25

3-1 Zero Point Return .......................................................................................... 25

3-2 Manual Feed .................................................................................................. 27

3-2-1 JOG Feed .......................................................................................... 27

3-2-2 Rapid Traverse .................................................................................. 28

3-2-3 Handle Feed ...................................................................................... 29

3-3 Turret Indexing .............................................................................................. 30

3-4 Chuck Open/Close ......................................................................................... 31

3-5 Spindle Rotation and Stop ............................................................................. 32

3-6 Coolant Discharge ......................................................................................... 34

Chapter 4 MDI Operation .......................................................................................... 35

4-1 Preparation for MDI Operation ..................................................................... 35

4-1-1 Switches and Keys Used ................................................................... 35

4-1-2 MDI Screen ....................................................................................... 36

4-2 Spindle Rotation and Stop (continued from step 2 in 4-1-2) ......................... 37

4-3 Turret Indexing (continued from step 2 in 4-1-2).......................................... 39

4-4 X-/Z-axis Travel (continued from step 2 in 4-1-2) ........................................ 40

Chapter 5 Automatic Operation ................................................................................ 42

5-1 Preparation for Automatic Operation ............................................................ 43

5-1-1 Process of Starting Automatic Operation ......................................... 43

5-1-2 Conditions for Starting Automatic Operation ................................... 44

5-2 Program Check (Test Running) ..................................................................... 46

5-2-1 Program Check (Test Running) - (1) ................................................ 46

5-2-2 Program Check (Test Running) - (2) ................................................ 48

5-3 Trial Cutting .................................................................................................. 49

5-4 Pause and Restart of Automatic Operation.................................................... 50

5-4-1 Pause of Automatic Operation .......................................................... 50

5-4-2 Restart of Automatic Operation ........................................................ 50

5-5 Manual Operation during Automatic Operation ............................................ 51

5-6 MDI Operation during Automatic Operation ................................................ 52

5-7 Program Editing ............................................................................................. 53

5-7-1 Inputting a Program .......................................................................... 54

5-7-2 Calling a Program ............................................................................. 56

5-7-3 Displaying a Program Library .......................................................... 57

5-7-4 Deleting a Program ........................................................................... 58

5-7-5 Searching .......................................................................................... 59

5-7-6 Deleting a Word or Block ................................................................. 61

5-7-7 Inserting a Word ............................................................................... 63

5-7-8 Altering a Word ................................................................................ 64

Chapter 6 Setting Up ................................................................................................... 65

6-1 Tooling........................................................................................................... 65

6-2 Tool Offset ..................................................................................................... 67

6-3 Tool Wear Offset ........................................................................................... 72

6-4 Mounting of Power Chuck ............................................................................ 73

6-5 Mounting of Collet Chuck ............................................................................. 75

6-6 Forming of Soft Jaws ..................................................................................... 77

6-6-1 Precaution for Forming Soft Jaws .................................................... 77

6-6-2 Forming of Soft Jaws in Manual Operation...................................... 79

6-6-3 Forming of Soft Jaws in Automatic Operation ................................. 81

Chapter 7 Appendix .................................................................................................... 84

7-1 List of G Codes .............................................................................................. 84

7-2 List of M Codes ............................................................................................. 85

7-3 Variable Timers List ...................................................................................... 87

1

Chapter 1 Outline of Machine


1-1 Name and Function of Each Component

Fig. 1

Front door

SpindleTurret NC screen

CNC operation panel

Machineoperation panel

Air unit

Foot switch

Lubrication unit

Electric cabinet Main power switch

Coolant pump motor

Coolant tankHydraulic pump unit

Hydraulic

pressure gauge

Absolute pulse coder

battery case



2

DANGER

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.

1-2-1 Machine Operation Panel

Fig. 2

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

CAUTION

2 1

3

4

6

7

8 9 10 1213 14 15

16 17 18 5 19 20

21

22

23

24

25

26

27

28

11

29

30

31

32

33 34 35

3


ON

Name Function

Turns the NC power on and displays the NCscreen, while the power in the factory and themain power switch are turned on.

(1) POWER ON button

OFF Turns the NC power and the NC screen off.Turn the main power switch off after pressing thisbutton.

(2) POWER OFF button

(3) Manual pulse generatorFeeds 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 onecomplete revolution.

• Rotate the manual pulse generator at a speed under

5 rotations/sec.

TURRET

Rotates the turret in manual operation.When “JOG” or “HANDLE” of mode selectorswitch (5) is selected, the turret is indexed onestep in the CW direction each time this switch ispressed.

(4) TURRET switch


4

EDIT AUTO MDI HAN-DLE

JOGZERORE-TURN

(5) Mode selector switchesSelects operation mode.A lamp of the selected mode switch will light up.

• EDIT switchAllows registering a program into the memory.Altering, inserting and deleting programs can bedone by using keys on the CNC operation panel.

• AUTO switchAllows an execution of programs registered inthe memory.Program number search and sequence numbersearch of programs in the memory can also bedone.

• MDI switchAllows manual data input by using keys on theCNC operation panel.MDI operation can start with the START button(33) on the machine operation panel.

• HANDLE switchAllows a fine feed of each axis by using themanual pulse generator (3).A fine feed can be done by rotating the manualpulse generator (3) after the required axis (X orZ) and feed amount (0.01 mm or 0.001 mm) areselected with the AXIS SELECT switch (6) andthe “x10 / x1” switch (7) respectively.

• JOG switchAllows 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 selecteddirection as long as the switch (8) is pressed.A feedrate can vary with the FEED RATEOVERRIDE switch (29).A rapid traverse becomes effective by pressingthe RAPID switch (9) and any of JOG FEEDswitches (8) at the same time.

5


• ZERO RETURN switchAllows a zero point return in manual operation when the"+X" or "+Z" of JOG FEED switch (8) is pressed untilthe zero return lamp lights up.

"3-1 Zero Point Return"

For the model equipped with Σ loader, be sure to performloader home position return when the power is turned onor when the EMERGENCY STOP button is reset.

"Σ Loader Instruction Manual."

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

(6) AXIS SELECT switch

(7) “x10 / x1” (Handle magnification) switchSelects a feed amount per scale of the manualpulse generator, and is effective when“HANDLE” of mode selector switch (5) is se-lected. The lamp of the selected magnificationwill light up.

x10: Feed amount per scale = 0.01 mmx1: Feed amount per scale = 0.001 mm

X10 X1

X 10

X 1

(8) JOG FEED switches

(9) RAPID switchAllows a rapid traverse of each axis when it ispressed along with any of the JOG FEEDswitches (8), when “JOG” of mode selectorswitch (5) is selected.

Selects the axis and its direction to be movedwhen “JOG” of mode selector switch (5) isselected. JOG feed of each axis is effective aslong as the switch is pressed. In the ZERORETURN mode, only "+X" and "+Z" switchesare effective, and press both switches until theirzero return completion lamps light up accord-ingly.

X Z

AXIS

SELECT

Zero return comple-

tion lamp

+ X

- Z + Z

- X

RAPID

+ X

- Z + Z

- X

RAPID


6

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

(11) COOLANT switch

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.

(13) SPINDLE FOR. switchRotates the spindle in normal direction, and turnsthe lamp on.This switch is effective when “JOG” or“HANDLE” of mode selector switch (5) is se-lected.

Selects either of F0 and 100% for rapid traverse.The lamp of the selected rapid feedrate will lightup. This switch is effective both in manualoperation and automatic operation (G00).The rapid feed rate of each axis is as shownbelow.

F0: 2.5 m/min. (X and Z)100%: 12 m/min. (X)

18 m/min. (Z)

COO-LANT 1

COO-LANT 2

AIR 1

(12) AIR switch

AIR 2

SPI-NDLEFOR.

(14) SPINDLE STOP switchStops the spindle.This switch is effective when “JOG” or“HANDLE” of mode selector switch (5) is se-lected.

SPI-NDLESTOP

F0

100%

RAPIDOVERRIDE

100%F0

Discharges and stops coolant in manual opera-tion.Coolant is discharged from the tops of the slidecover and the chip cover. The lamp will light upduring coolant discharge.

7


(15) SPINDLE REV. switchRotates the spindle in reverse direction, and turnsthe lamp on.This switch is effective when “JOG” or“HANDLE” of mode selector switch (5) is se-lected.

SPI-NDLEREV.

(16) M01 (optional stop) switchStops automatic operation after a block contain-ing M01 is executed. (Effective while the lamplights up.)To restart automatic operation, press the STARTbutton. By setting this switch to OFF (the lampgoes off), automatic operation does not stop evenafter the M01 in the program is read.

M01

(17) SINGLE BLOCK switchExecutes only one block in the program each timethe START button (33) is pressed. (Effectivewhile the lamp lights up.)This function is effective for checking the motionof each block one by one.

SINGLEBLOCK


8

*1 Operation does not stop if the block contains thread cutting, but stops only after the block next tothe 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.

G code Tool path Explanation

Tool path 1 to 4 is assumed as one

cycle. Movement stops after 4 is

finished.



finished.



finished.



finished.

G90

G92

G94

G70

G73



finished.

G76

*5 In the blocks containing “M98 P_” or “M99”, operation does not stop even when the SINGLEBLOCK switch is on.

For details, refer to the separately provided Programming Manual and FANUCOPERATOR’S MANUAL.

Rapid traverse

Cutting feed

G74

G75

* The figure shows the case of G74. G75 is thesame as this.



finished.

* The figure shows the case of G71. G72 is thesame as this.

G71

G72

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.



finished.

9


(18) DRY RUN switchIgnores all commands for the rapid feed and thecutting feed specified by the program. (Effectivewhile the lamp lights up.)The feedrate specified by the FEEDRATEOVERRIDE switch (29) becomes effective at thistime.When the PROGRAM CHECK switch (20) is setto ON (its lamp lights up), this switch also be-comes effective automatically (the lamp lightsup.)

CAUTIONAs this switch becomes effective even during thread cutting,pay careful attention to the actual cutting of workpieces.

Ignores blocks following a slash “/” in the pro-gram. (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 whichhas been read into the buffer, as this codechecked when they are read into the buffer regis-ter.

(20) PROGRAM CHECK switchAllows automatic operation without rotating thespindle in order to check each motion of the Xand Z axes. When this switch is set to ON (thelamp lights up), the DRY RUN switch (18) alsobecomes effective (the lamp lights up).This function is effective to carry out a programcheck safely without mounting a workpiece intothe chuck.

(21) CYCLE END lampComes on when automatic operation is com-pleted, and goes off when automatic operationrestarts.

(19) “/ CODE” (block delete) switch

DRYRUN

/

CODE

CYCLE

END

PRO-GRAMCHECK


10

(22) CHUCK CLOSE lampComes on when the chuck is closed by steppingon the foot switch, and goes off when the chuck isopened by the switch again.The spindle rotation is available while the lamplights up.* The chuck is so controlled not to open during spindle

rotation.

(23) CYCLE START lampComes on when automatic operation starts.The lamp stays on during automatic operation,but goes off when the cycle operation is com-pleted or has paused.* The lamp also lights up when the MDI operation is

started.

(24) FEED HOLD lampComes on when automatic operation has pausedtemporarily, and goes off when automatic opera-tion is restarted.

(25) LUB. ALARM (lubricant alarm) lamp

Comes on when lubricant in the lubricant tankbecomes insufficient.

(26) SEQ. ALARM (sequence alarm) lamp

Comes on when an error has arisen in the electricsystem, for example, when a spindle normal(reverse) rotation command is given during thespindle reverse (normal) rotation without stop-ping the spindle, when an error is occurring in thespindle motor, etc.

(27) TURRET ALM. (Turret alarm) lamp

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

CHUCK

CLOSE

CYCLE

START

FEED

HOLD

LUB. ALARM

SEQ. ALARM

TURRET ALM.

CAUTION If the cause is unknown, contact Takamatsu.

11


SPINDLE

(28) COUNT UP lamp

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

(29) FEED RATE OVERRIDE switchHas two functions according to the mode selectedby the mode selector switch (5).• Feed rate override

In the AUTO or MDI mode, the speed specifiedin the program can be overridden in the range of0 to 150%.

The feedrate override set by this switch is ignored duringthread cutting, that is, the override is always 100% duringthread cutting.

CAUTION

(30) SPINDLE (spindle speed setting) switch

CAUTIONBefore starting the spindle rotation, turn the SPINDLE switchfully to the left once and then return it gradually to the right toset the required speed.

• JOG feedrate settingIn the JOG mode, the feedrate of each axis canbe selected.When the switch is set to 100%, the axis movesat the speed of 126 mm/min.

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

150

10050

0 %

COUNT UP


12

(31) PROGRAM EDIT switch (with key)

• OFFEntering and editing programs cannot be done.

• ONEntering and editing programs can be done.

(33) START buttonStarts machine operation and turns on the CYCLESTART lamp (23), when the AUTO or MDImode 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)

PROGRAMEDITOFF

ON

START

(32) O.T. RELEASE switchIf the axis (X or Z) travels to the mechanical limitbeyond its soft limit, the power to the hydraulicmotor and the servo system is shut off in order toprotect the machine from being damaged.As the power can be restored by pressing thisswitch, move the overtraveled axis in its safe areaby rotating the manual pulse generator (3) whileholding this switch down.

CAUTIONBe sure to check that the axis direction is correct, whenmoving the overtraveled axis from its mechanical limit posi-tion.

O.T.RELEASE

13


EMERGENCYSTOP

EMERGENCYSTOP

(34) FEED HOLD button

Suspends automatic operation, and turns off theCYCLE START lamp (23) and on the FEEDHOLD 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. Ac-

cordingly, 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)

Always be aware of theEMERGENCY STOPbutton’s location and opera-tion so that it can be oper-ated quickly in emergency.This must be understood byall the personnel concerned.

Stops the machine immediately in emergency.Once the emergency stop becomes effective, theservo power shuts off, and each axis feed, thespindle rotation, the turret indexing and thecoolant 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.

WARNING

FEED HOLD


14

1-2-2 CNC Operation Panel

Fig. 3


15


Name Function

Used for displaying the current position of each

axis.

(1) Position key

Used for displaying programs in EDIT mode and

for inputting or displaying data in MDI mode.

(2) Program key

Used for setting a tool offset amount or for

setting and displaying the custom macro variable.

(3) Offset/setting key

(4) System key

Used for setting parameters or for displaying

parameters and diagnosis data.

(5) Message key

Used for displaying alarm numbers and mes-

sages.* When an alarm arises, the alarm contents are

automatically displayed on the NC screen.

(6) Graphic key

With standard specifications, pressing this key

displays nothing.

(7) Address/numeric keys

Used for inputting data composed of the alphabet,

numeric characters and symbols.

POS

PROG

OFFSETSETTING

MESSAGE

SYSTEM

CUSTOMGRAPH


16

(8) Shift keyUsed 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.

(9) Cancellation key

(10) Input key

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 [IN-

PUT] soft key, either key may be used.

(11) Deletion key

Used for deleting the program data.

(12) Insertion key

Used for inserting the program data.

(13) Alteration key

Used for altering the program data.

(14) Help key

Used for accessing the help function regarding

key operation.

Used for deleting the alphabet, numeric charac-

ters, 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

SHIFT

CAN

DELETE

INPUT

ALTER

INSERT

HELP

17


(16) Cursor keys

(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 rota-

tion, coolant, etc.) immediately. Before restarting

automatic operation, return all the axes to their

zero positions and check that the program returns

to its beginning.

Used for moving the cursor. Press a key depend-

ing 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.

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.

(17) Page keys

RESET

PAGE

PAGE


18

Chapter selection(main)

Chapter selection(sub)

Operationselection

Operation guide

(OPRT)

(OPRT)

return(Return menu key)

returncontinued

return

continued(Continuedmenu key)

(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.

* Soft keys consist of ① chapter selection keys, ②operation selection keys, ③ return menu key and ④continued menu key.

① 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.

② 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 opera-

tion selection keys are not available.

③ 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 selec-

tion keys (main).

④ Continued menu key

Pressing the continued menu key displays hidden

keys of the chapter selection keys or operation

selection keys if any.

19

Chapter 2 Preparation for Operation

WARNING

Fig. 4


2-1 Check-ups before Turning Power ON

• 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.

• 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.

DANGER

Front door• must be closed.

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.

EMERGENCY STOP button• must be depressed.

Electric cabinet• door must be closed.

Coolant tank• must be equipped with an

appropriate amount of oil.• must not have build-up chips.

Cable connection port• must not hold any damaged cable.

Lubrication unit• must be equipped with an

appropriate amount ofclean oil.

Hydraulic pump unit• must be equipped with an

appropriate amount of oil.


20

2-2 Turning Power ON


DANGER

WARNING

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

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)

2. Main power switch ON3. POWER ON button

4. Reset the EMERGENCYSTOP button.

Electric cabinet

1. Primary power supply ON

Fig. 5

21

Fig. 6

2-3 Check-ups after Turning Power ON

CAUTIONWhen starting operation after stopping the machine for along period of time, check that the machine motions, noiseand slideway lubrication are free from trouble.If any abnormality, such as abnormal noise, excessive heatgeneration and abnormal motion, is found, turn off the powerimmediately and contact the maintenance personnel to takenecessary measures.

Machine operation panel• must not have any illumi-

nating or blinking alarmlamps.

NC screen• must not indicate any alarm message.

Lubrication unit• must be set to an appropriate

discharge amount.

Spindle motor, X/Z-axis motor• must be free from abnormal noise

or vibration.

Hydraulic pressure gauge• must indicate appropriate chuck pressure.

(Max. 2.0 MPa)(Source pressure: 3.4 MPa)

Coolant pump motor• is working properly.


Turret unit• should not generate any abnormal sound or

excessive vibration during the turret turning.

Air unit• must indicate appropriate air

pump pressure.(0.5 MPa)


22

2-4 Check-ups before Turning Power OFF

CAUTION When finishing operation, check that each section of the

machine is in the initial status.

Fig. 7


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



23

2-5 Turning 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.

DANGER

WARNING

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

Procedures and instructions described in this manual must

strictly be observed when turning the power off.

2. POWER OFF button 3. Main power switch OFF

Electric cabinet

Fig. 8

4. Primary power supply OFF4. Reset the EMERGENCYSTOP button.


24

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.

Check that the covers (the front door, in particular) are not damaged.

Fig. 9

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.

• 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.

* The figure shows the machine

equipped with Σ loader.

25

Chapter 3 Manual Operation


WARNING

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.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.

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.

26

1. Press “ZERO RETURN” of the mode selector

switch.

• The lamp in the switch will light up.

2. Press the JOG FEED switch “+X”.

• Keep pressing until the X-axis zero return

completion lamp lights up.

3. Press the JOG FEED switch “+Z”.

• Keep pressing until the Z-axis zero return

completion lamp lights up.

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.



JOGZERORE-TURN

POS

ACTUAL POSITION(RELATIVE) (ABSOLUTE)

X*.*** X*.***Z*.*** Z*.***

(MACHINE) (DISTANCE TO GO)X0.000 X*.***Z0.000 Z*.***

PART COUNTRUN TIME CYCLE TIMEACT.F

+ X

- Z + ZRAPID

- X

+ X

- Z + ZRAPID

- X

27

FEED RATEOVERRIDE

150

10050

0 %

3-2 Manual Feed

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

CAUTION When the RAPID switch is pressed along with any of the

JOG FEED switches, a rapid traverse becomes effective.


JOGZERORE-TURN

1. Press “JOG” of the mode selector switch.


2. Select a feedrate with the FEED RATE OVER-

RIDE switch.

Ex.) When the switch is set to the 100% posi-

tion, the slide moves at a speed of 126

mm/min.

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.

Fig. 10

3-2-1 JOG Feed

+ X

- X

+ Z

- Z


+ X

- Z + ZRAPID

- X

28

3-2-2 Rapid Traverse



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.


JOGZERORE-TURN

F0

100%

RAPIDOVERRIDE

100%F0

+ X

- Z + ZRAPID

- X


29

3-2-3 Handle Feed

1. Press “HANDLE” of the mode selector switch.


2. Press the AXIS SELECT switch.

• The indication lamp of the selected axis will

light up.

3. Press the magnification switch “x10 / x1”.

• The indication lamp of the selected magnifica-

tion (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.


JOGZERORE-TURN

AXISSELECT

HANDLE


30

or

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.


JOGZERORE-TURN

1. Press “JOG” or “HANDLE ”of the mode selector

switch.• The lamp of the selected switch will light up.

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.

TURRET

Fig.11


31


3-4 Chuck Open/Close

* 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.

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.

Fig. 12

MAIN

Foot switch* The figure shows the machine equipped with Σ loader.

32

3-5 Spindle Rotation and Stop

WARNING Never touch the spindle directly nor indirectly while it is

rotating.

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.

CAUTION

Follow the procedures below when rotating or stopping the spindle.

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

2. Press “JOG” or “HANDLE” of the mode selector

switch.• The lamp in the selected switch will light up.

3. Press the SPINDLE FOR. or SPINDLE REV.

switch.• The lamp in the selected switch will light up,

and the spindle starts to rotate.

or


JOGZERORE-TURN

or

CHUCK

CLOSE


33


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.

SPINDLE

Fig. 13

Normal rotation(M03)

Reverse rotation(M04)

34

3-6 Coolant Discharge

CAUTION Determine the direction of coolant discharged from the cool-

ant hose beforehand.

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 opera-

tion mode.

Fig. 14

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

discharge will stop.

COO-LANT

CloseOpen

Handle cock


35

Chapter 4 MDI Operation


With the MDI operation, a program can be created and executed in the same way as usualprograms 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 OPERATOR’S MANUAL for details

Fig. 15

4-1 Preparation for MDI Operation

4-1-1 Switches and Keys Used


36

4-1-2 MDI Screen

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.



JOGZERORE-TURN

*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.


PROGO0020 N0020PROGRAM (MDI)

O0000%

G00 G69 G21 G25 G80 G54G97 G99 G40 G22 G67 G18

MTF S

>_MDI **** *** ***[ PRGRM ] [ MDI ] [ CURRNT ] [ NEXT ] [ (OPRT) ]

37

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


WARNINGNever touch the spindle directly nor indirectly while it is

rotating.

“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.

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.

Fig. 16

INSERT

Normal rotationM03

Reverse rotationM04

38

4. Press the EOB key.

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

EOBE

PROGRAM O0020 N0020O0000 S1000 M03;%G00 G69 G21 G25 G80 G54G97 G99 G40 G22 G67 G18

MTF S

)_MDI 20 : 50 : 14

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

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

order.

8. Press the EOB key.EOB

E

10. Press the START button.

• The spindle stops rotating.

9. Press the INSERT key.INSERT

START

5. Press the INSERT key.INSERT

Stopping the spindle

START


39

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


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.

WARNING

CAUTION


1. Press the address/numerical keys [T], [0], [*], [0]

and [0] is sequence.

* Tool number to be indexed



Ex.) Indexing the turret at No. 3INSERT

EOBE

O0020 N0020PROGRAM (MDI)O0000%

G00 G69 G21 G25 G80 G54G97 G99 G40 G22 G67 G18

MTF S



• The turret will turn to index the turret No. 3.

START

40

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

Before starting operation, check that there are obstacles inthe axis movable area.Pay careful attention to interference of cutting tools with thechuck or a workpiece.Be sure to perform the coordinate system setting and offsetinput before moving each axis.

CAUTION

“6-2 Tool Offset”

Moving the axes to the position (X50.0, Z30.0)

1. Press the data input keys [G], [0] and [0] in se-quence.


INSERT

Fig. 17


+ X

- X

+ Z

- Z


41



• The X axis and the Z axis move to “50.0” and

“30.0” respectively at rapid traverse.

INSERT

INSERT

EOBE

4. Press the INSERT key again.

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


START

O0020 N0020PROGRAM (MDI)O0000%

G00 G69 G21 G25 G80 G54G97 G99 G40 G22 G67 G18

MTF S


3. Press the data input keys [X], [5], [0] and [.] insequence.* There is a great difference in values with and

without the decimal point.

Program command Meaning

X50. 50 mm

X50 0.05 mm

X1. 1 mm

X1 0.001 mm


Chapter 5 Automatic Operation

42

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 mainte-

nance work while the power is turned on.


injuries.

• Noise during cutting may exceed 70 dB, resulting in damag-

ing your hearing ability. Use protective articles (head-

phones, etc.) as appropriate.

Fig. 18


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.

Inside the front door is a hazardous area.


43


5-1 Preparation for Automatic Operation

5-1-1 Process of Starting Automatic Operation

Input the program into the machine.

Perform the dimensional offset.

Check cutting sections and contents with drawings.

Determine the operation process.

Prepare required tools and workpieces.

Enter a required program in a process sheet.

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

Perform the program check (test running).

Conduct the trial cutting.

Start the productive operation.

process sheet


44

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.

PROGRAM O0001 N1234

O 0001;

N1 G00 G97 S500 M03 T0100;

X... Z... T0100 M08;

Cursor

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

• The zero return completion lamp for each axis

will light up.

2. Move the cursor to the beginning of the program.

(1) Press “EDIT” of the mode selector switch.


(2) Press the PROG key.

(3) Press the RESET key.

• The cursor moves to the top of the program.


JOGZERORE-TURN

PROG

RESET

“5-7-2 Calling a Program”

+ X

- Z + ZRAPID

- X

45



JOGZERORE-TURN

3. Press “AUTO” of the mode selector switch.


CHUCKCLOSE

4. Close the chuck, by stepping on the foot switch.

• The CHUCK CLOSE lamp will light up.


46

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 automaticoperation as described in “5-1-2”.* Do not mount a workpiece in the chuck.

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

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

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

5. Press the START button.• The CYCLE START lamp will light up.

6. Press the [CHECK] soft key until the requiredprogram check screen appears.

PROGRAM CHECK O0010 N0010O0001 ;G00 G97 S500 M03 T0100;G00 X50 Z2 T0101 M08;(RELATIVE) (DISTANCE TO GO) (G)U -134.442 X 0.000 G00 G99 G25W 54.366 Z 0.000 G97 G21 G22

G69 G40SRPM 1000

SSPM 0F S0 10000 SMAX 32767M T SACT 0

ARS. [ ABS ] [ REL ] [ ] [ ] [ (OPRT) ]

FEED RATEOVERRIDE

150

10050

0 %

SINGLEBLOCK

START

PRO-GRAMCHECK

47


FEED RATEOVERRIDE

150

10050

0 %

7. Set the FEED RATE OVERRIDE switch to the

position except 0%.

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 run-

ning) again.


48

FEED RATEOVERRIDE

150

10050

0 %

5-2-2 Program Check (Test Running) - (2)

If the program check (1) results in success, proceed with the program check (2) continu-

ously. 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.

2. Press the SINGLE BLOCK switch.

• A lamp in the switch will light up.

3. Select “F0” with the RAPID OVERRIDE switch.

4. Set the FEED RATE OVERRIDE switch to

100%.


• The CYCLE START lamp will light up.

* The program is executed only by one block each

time the START button is pressed.

START

RAPID

OVERRIDE

100%

F0

100%F0

SINGLEBLOCK

49


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 damag-

ing your hearing ability. Use protective articles (head-phones, etc.) as appropriate.

1. Satisfy the conditions for starting automaticoperation as described in “5-1-2”.In this operation, mount a workpiece in the chuckand then close the chuck.

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.

5. Set the FEED RATE OVERRIDE switch to100%.

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 theconfiguration and dimensions of finishedworkpiece.• If any defect is found in the configuration or

dimensions, perform a tool offset, etc. and thenconduct the trial cutting again.

“6-3 Tool Wear Offset”

RAPID

OVERRIDE

100%

F0

100%F0

FEED RATEOVERRIDE

150

10050

0 %

START

SINGLEBLOCK


50

5-4 Pause and Restart of Automatic Operation

5-4-1 Pause of Automatic Operation

To stop the execution of automatic operation tempo-

rarily, 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.

* 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

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.

FEED HOLD

START

FEEDHOLD

CYCLESTART

FEEDHOLD

CYCLESTART

51


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.

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 123.456Z 32.456

FEED HOLD

or

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.




• Automatic operation will restart.


JOGZERORE-TURN

START

POS

[ ABS ] [ REL ] [ ALL ] [ ] [ (OPRT) ]

SINGLEBLOCK


52

5-6 MDI Operation during Automatic Operation

When performing MDI operation during automatic operation, follow the procedures below.

1. Press the SINGLE BLOCK switch.


• Automatic operation will stop temporarily.

2. Press “MDI” of the mode selector switch.


3. Perform MDI operation.

“Chapter 4 MDI Operation”




• Automatic operation will restart.

*MDI operation is not available in feed hold status.

START


JOGZERORE-TURN


JOGZERORE-TURN

SINGLEBLOCK

53


5-7 Program Editing

This section describes procedures each for inputting, calling, listing, deleting, inserting,

altering and searching the program.

CAUTIONNever operate any switch, key or button while wearing

gloves.

* The following operation methods can be checked on the

NC screen using the help function.PROGHELP

HELP (OPERATION METHOD) 01234 N0001

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 0 T0000

MEM **** *** *** 00:00:00

[ 1. ALAM ] [ 2. OPR ] [ 3. PARA ] [ ] [ (OPRT) ]

OPERATION METHOD menu Screen

HELP (OPERATION METHOD) 01234 N0001

<<1. PROGRAM EDIT>> 1/4

* DELETE ALL PROGRAMS

MODE : EDIT

SCREEN : PROGRAM

OPR : (09999)-<DELETE>

* DELETE ONE PROGRAM

MODE : EDIT

SCREEN : PROGRAM

OPR : (O+PROGRAM NUMBER) - <DELETE>

> S 0 T0000

MEM **** *** *** 00:00:00

[ 1. ALAM ] [ 2. OPR ] [ 3. PARA ] [ ] [ (OPRT) ]

Example of OPERATION METHOD Screens

Each item

Page/maximum page

Operation

Set mode

Operation location

Operation procedure



54

5-7-1 Inputting a Program

When inputting the program in manual operation without using any input equipment,

follow the procedures below.

1. Press “EDIT” of the mode selector switch.


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

3. Press the PROG key.

• The program screen will appear.

4. Press the key [O].

5. Input a required program number using data input

keys.




JOGZERORE-TURN

PROGRAMEDITOFF

ON

PROG

O P

INSERT

EOBE

55



9. Input only a word of program using the data input

keys.

Ex.) N1


11. Repeat steps 9 and 10 to input a block of the

program.

Ex.) N1 G00 S500 M03


Ex.) N1 G00 S500 M03;


14. Repeat steps 9 to 13 to input the required pro-

gram completely.

15. Return the PROGRAM EDIT switch to “OFF”.

separately provided Programming Manual for

details

PROGRAMEDITOFF

ON

INSERT

INSERT

EOBE

INSERT


56

5-7-2 Calling a Program

Calling a program can be done in the following procedures.






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.

PROG


JOGZERORE-TURN

PROGRAM O0040 N0012

ADRS. S OT

EDIT

[ PRGRM ] [ CHECK ] [ CURRENT ] [ NEXT ] [ (OPRT) ]

O P

57


5-7-3 Displaying a Program Library

Follow the procedures below when displaying all the program numbers registered in the

memory.





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.

PROGRAM O2000 N0120SYSTEM EDITION O0400-01PROGRAM NO. : 8 FREE : 55MEMORY AREA USED : 381 FREE : 3714PROGRAM LIBRARYO0001 O2000 O0050 O0040 O0100 O0124

S O T0000>EDIT **** *** *** 10:20:45[ PRGRM ] [ LIB ] [ CURRNT ] [ C. A. P. ] [ (OPRT) ]

The number of programs which can

be registered additionally.

The number of the programs registered

(including the subprograms)

The capacity of the program memory in

which data is registered (indicated by the

number of characters)

The capacity of the program memorywhich can be used additionally (indicatedby the number of characters)


JOGZERORE-TURN

PROG

*Program names can be displayed by the setting at

parameter NAM (No. 3107#0).


58

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.


• The lamp in the switch will light up.EDIT AUTO MDI HAN-

DLEJOG

ZERORE-TURN

2. Turn the PROGRAM EDIT switch to “ON”.



5. Input the program number to be deleted using the

data input keys.

6. Press the DELETE key.

* When deleting all programs registered in the

memory, press the keys as follows in step 5 ;

PROGRAMEDITOFF

ON

(—) (9) (9) (9) (9)

PROG

O P

DELETE

— + 9 D 9 D 9 D 9 D

59


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.


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

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.

N Q

2#

O 0001 ;N1 G00 S3000 M03 T0100 ;

X32.0 Z0 TO101 M08 ;G01 X-1.0 F0.1 ;G00 X30.0 Z2.0 ;G90 X10.5 Z-5.0 F0.2 ;G28 U0 W0 ;M01 ;

N2 G00 S3000 M03 T0200 ;

The cursor moves below “N2”.


60

The cursor moves below “Z0”.

1. Press the key [Z].

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.

Example 2 Searching for the word “Z0” from the top of the program

Z Y

0*

* 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.

O 0001 ;

N1 G00 S3000 M03 T0100 ;X32.0 Z0 T0101 M08 ;

G01 X 1.0

61


O 0001 ;

N1 G00 S3000 M03 T0100 ;

O 0001 ;

N1 G00 M03 T0100 ;

word to be deleted

5-7-6 Deleting a Word or Block

Deleting a word or a block can be done in the following procedures.



Example 1 Deleting a word

DELETE

DELETE

1. Search for the word to be deleted.

“5-7-5 Searching”



62

Example 2 Deleting a block

1. Search for the word heading the block to be

deleted.




O 0001 ;

N1 G00 S3000 M03 T0100 ;

G01 X-1.0 F0.1 ;

O 0001 ;

N1 G00 S3000 M03 T0100 ;

X32.0 Z0 TO101 M08 ;

G01 X-1.0 F0.1 ;Cursor block to be deleted

DELETE

EOBE

EOBE

DELETE

* When a sequence number (N) is specified in step 2, the

blocks from the searched one to the specified one will

be deleted.

63


5-7-7 Inserting a Word

Follow the procedures below when inserting a word.



1. Search for the word immediately before the

insertion location.


2. Input the word to be inserted using the data input

keys.


O 0001 ;

N1 G00 M03 T0100 ;

O 0001 ;

N1 G00 S2000 M03 T0100 ;

Cursor Insert “S2000”.

inserted word

INSERT

INSERT

0*

0*

SK

2#

0*


64

5-7-8 Altering a Word

Follow the procedures below when altering a word.



1. Search for the word to be altered.


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

3. Press the ALTER key.

Ex.) Changing the word “S3000” to “S2500”ALTER

O 0001 ;

N1 G00 S2500 M03 T0101 ;

ALTER

(S) (2) (5) (0) (0)

O 0001 ;

N1 G00 S3000 M03 T0101 ;

Cursor word to be altered

altered word

SK

5 ]2#

0*

0*

65

Chapter 6 Setting Up

[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.


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 ToolingFollow 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.

Fig. 19

OD turning tool

Clamp block

Hex. socket

head cap bolt

Holder

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


66

Fig. 20

Clamp block C

OD/face/grooving tool 20 sq.

ID holder

φ25 Boring holder

Double boring holder

φ25

Tap Tap holder

Boring bar

Center straight drillDrillchuck

Blank

Drill chuck arbor

Blank

Round hole bush

U-drill holder

Double boring holder φ20

Drill socket

Taper drill Drill Sleeve

U-drill Round hole bush

Boring bar

Center straight drill

Option:


OD nozzle

67


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.

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

manual operation.

“3-1 Zero Point Return”

2. Move the cutting tool toward a workpiece in JOG

feed.

“3-2-1 JOG Feed”

3. Rotate the spindle.

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 + ZRAPID

- X

+ X

- Z + Z

- X

RAPID

Zero return

completion

lamps


68

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.

8. Press the [OFFSET] soft key.

9. Press the [GEOM] soft key.

• The OFFSET/GEOMETRY screen is displayed.

10. Measure the diameter of finished workpiece.

In the X-axis direction

4. Cut outer surface (OD) of the workpiece in the

handle mode.

OFFSETSETTING

OFFSET/GEOMETRY O1000 N1000

NO. X Z R TG_01 0.000 0.000 0.000 0G 02 0.000 0.000 0.000 0G 03 0.000 0.000 0.000 0G 04 0.000 0.000 0.000 0G 05 0.000 0.000 0.000 0G 06 0.000 0.000 0.000 0G 07 0.000 0.000 0.000 0G 08 0.000 0.000 0.000 0ACTUAL POSITION (RELATIVE)

[WEAR ] [ GEOM ] [ ] [ ] [(OPRT)]

69


11. Move the cursor up to the required tool offset

number using the cursor keys.

13. Press the [MEASUR] soft key.

• The X-axis shift amount to the program zero point

from the machine zero point will be entered auto-

matically.

Ex.) If OD of the machined workpiece is 20.1 mm,

press;

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

keys and then the [MEASUR] soft key.

XC

(X)

XC

(X) (2) (0) (.) (1)

•/

1 ,0*

2#

measurement


70

In the Z-axis direction

14. Rotate the spindle again.

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

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.

(Z) finishing allowance

measured in step 18

Z Y

Machining allowance

Finish surface

71


TURRET

123456123456123456123456123456123456123456123456123456123456123456123456123456123456123456123456123456123456

1） 3）2）

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.

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:

Z Y 0*

(Z) (0) (.) (5)


3) In the case that the end face has been cut exces-

sively by 0.5 mm, input as follows:

Z Y 0*

•/

5 ]


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

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

Z Y

(Z) (-) (0) (.) (5)

5 ]•

/0*

— +


72

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.

OFFSETSETTING

OFFSET/WEAR O1000 N1000

NO. X Z R TG_01 0.000 0.000 0.000 0G 02 0.000 0.000 0.000 0G 03 0.000 0.000 0.000 0G 04 0.000 0.000 0.000 0G 05 0.000 0.000 0.000 0G 06 0.000 0.000 0.000 0G 07 0.000 0.000 0.000 0G 08 0.000 0.000 0.000 0ACTUAL POSITION (RELATIVE)

[ WEAR ] [ GEOM ] [ ] [ ] [ (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.

(-) (0) (.) (0) (5)

0*

•/ 0

*5 ]— +

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 incremen-

tal command.


2. Press the [OFFSET] soft key and then [WEAR] soft

key.

• Display the OFFSET/WEAR screen.

73


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 (M10×85 (2)).

5. Fix the chuck jaws (4) and T-nuts (3) with bolts (M8×25 (5)).

6. Adjust the stroke of chuck jaws.

“6-6 Forming of Soft Jaws”

6-4 Mounting of Power Chuck

Follow the procedures below when mounting the power chuck.

the instruction manual issued by the chuck maker, because mount-

ing method differs according to the chuck maker, chuck type, etc.

DANGERWhen 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.


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


74

Fig. 21

No. Part name

1 Chuck body

2 Bolt (M10 x 85)

3 T-nut

4 Jaw

5 Bolt (M8 x 25)

75


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



turned ON or the operation panel is not touched by mistake.


maintenance. Be sure to turn the main power switch OFF


WARNING

DANGER

[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 Draw bar A

2 Collet flange

3 Detent pin

4 Bolt M10×100 (6)

5 Collet

Fig. 22


76

Fig. 23

Collet flange

Collet

[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

Collet mounting drawing

Hydraulic chuck

77


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.


rotating.

• Dull or unstable cutting tools will cause damage or acci-

dents. Replace with proper tools in advance.

• Wear a protective helmet, safety goggles and safety shoes.

Fig. 24

JawChuck Jaw

6-6-1 Precaution for Forming Soft Jaws

[[[[[Required tools]

ID boring tool and tip

Spacer for forming jaws (or its equivalent)

Chuck Bolt hole for jaw

Spacer

Chuck jaw former


78

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 form-

ing.

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 mi-

crometer 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.

123456123456123456123456123456123456123456123456123456123456123456123456123456123456

Center

Opened position

When jaws are closed

Forming of soft jaws

Make a recess on the inside corner of soft jaws.

Cutting tool for recessing

Spacer

79


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


rotating.

• Dull or unstable cutting tools will cause damage or acci-

dents. Replace with proper tools in advance.

• Wear a protective helmet, safety goggles and safety shoes.

(position of “U0”)

Spacer

ACTUAL POSITION (RELATIVE)

O0001 N0000

U 0.000

W XXX.XXX

[ ] [ ORIGIN ]

* 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.

POS

1. Display the ACTUAL POSITION (RELATIVE) screen using the POS key and the

[REL] soft key.

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”.


O0001 N0000

U XXX.XXX

W XXX.XXX


80

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”.

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:

Spacer

(position of “W0”)


O0001 N0000

U XXX.XXX

W 0.000

[ ] [ ORIGIN ]

Hardening

Recessing

123123123123123123123123123123123123123123

Spacer

Recess

Finish turning

(to the specified dia.

and depth)

φ30.0

12341234123412341234123412341234123412341234123412341234

Spacer

Turning

(leaving 0.3 mm (in dia.)

and 0.05 mm (in depth)

finishing allowance)

12341234123412341234123412341234123412341234123412341234

12345123451234512345123451234512345

14.95

φ29.7

Spacer

81


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.

Jaw

0*

•/ 5 ]


Jaw

φ20.5

4. Apply the cutting tool tip onto the end face of soft jaw.

5. Press the and keys.



2#

XC


82

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.

O1000;

G00 S500 M03 T0100;

X18.0 Z50.0 T0101;

Z2.0;

G90 X22.0 Z-19.95 F0.15;

X24.0;

X26.0;

X28.0; (Depth of cut in X-axis direction may differ depending on conditions.)

X29.6;

X29.8;

G28 U0. W50.0;

M30;

8. Measure the I.D. of soft jaw precisely.

9. Perform offset against the dia. of 29.8 mm.


Jaw

83


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

84

Chapter 7 Appendix

Chapter 7 Appendix

7-1 List of G Codes

G code Function Group Remarks

G00 Rapid traverse (positioning) Standard

G01 Linear cutting (linear interpolation) 01 Standard

G02 Circular cutting CW (circular interpolation) Standard

G03 Circular cutting CCW (circular interpolation) Standard

G04 Timer (dwell) 00 Standard

G10 Offset amount program input Option

G20 Input in inch 06 Standard

G21 Input in metric Standard

G27 Reference point return check Standard

G28 Reference point return 00 Standard

G30 2nd reference point return Standard

G32 Straight/taper thread cutting 01 Standard

G40 Tool nose radius compensation cancel Standard

G41 Tool nose radius compensation right 07 Standard

G42 Tool nose radius compensation left Standard

G50 Coordinate system setting Standard

G50 Max. spindle speed setting Standard

G70 Finishing cycle (Multiple cycle) Option

G71 Stock removal in turning (Multiple cycle) Option

G72 Stock removal in facing (Multiple cycle) 00 Option

G73 Pattern repeating (Multiple cycle) Option

G74 End face cut-off cycle (Multiple cycle) Option

G75 Outer diameter grooving cycle (Multiple cycle) Option

G76 Thread cutting cycle (Multiple cycle) Option

G90 Stock removal in turning (Canned cycle) Standard

G92 Thread cutting cycle (Canned cycle) 01 Option

G94 Stock removal in facing (Canned cycle) Standard

G96 Constant surface speed control 02 Option

G97 Constant surface speed control cancel Option

G98 Feed per minute 05 Standard

G99 Feed per rotation 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.

Chapter 7 Appendix

85

M code Function

*M40 Spindle orientation (at 1st point, w/o lock)

*M41 Spindle orientation (at 1st point) & lock

*M42 Spindle orientation, electric lock canceled

*M43 Spindle orientation (at 2nd point) & lock

*M44 Spindle orientation (at 3rd point) & lock

*M45 Spindle orientation (at 4th point) & lock



*M48 Low chuck pressure SET

*M49 High chuck pressure SET

*M50 Air 3 ON

*M51 Air 3 OFF

*M52 Coolant 3 ON

*M53 Coolant 3 OFF

*M54 Yellow signal light ON

*M55 Yellow signal light OFF

*M56 Red signal light ON

*M57 Red signal light OFF

*M58 Chucking sensor OFF confirmation

*M59 Chucking sensor ON confirmation

*M60 Parts catcher advance (w/o sensor confirmation)

*M61 Parts catcher retract (w/o sensor confirmation)

*M62 Automatic tool presetter advance (cover open)

*M63 Automatic tool presetter retract (cover close)

*M66 Spindle inching SET

*M67 Spindle inching RESET

*M68 Shutter (auto door) open

(w/o sensor confirmation)

*M69 Shutter (auto door) close

(w/o sensor confirmation)

M70 Cycle time over check 1 (Timer No. 1)

M71 Chuck OPEN

M72 Chuck CLOSE

*M73 Shutter (auto door) open

(with sensor confirmation)

*M74 Shutter (auto door) close (with sensor

confirmation)

*M76 Counter motion

7-2 List of M Codes

TAKAMAZ FANUC

M code Function

M00 Program stop

M01 Optional program stop

M02 End of program (same as M30)

M03 Spindle normal rotation (with S code)

M04 Spindle reverse rotation (with S code)

M05 Spindle stop

*M06 Air 1 ON

*M07 Air 1 OFF

*M08 Coolant 1 ON

*M09 Coolant 1 OFF

*M10 Chuck air SET

*M11 Chuck air RESET

*M12 Spindle non-stop/chuck open-close SET

*M13 Spindle non-stop/chuck open-close RESET

*M14 Air 2 ON

*M15 Air 2 OFF

*M16 Tail quill advance (with sensor check)

*M17 Tail quill retract (with sensor check)

*M18 Coolant 2 ON

*M19 Coolant 2 OFF

*M20 Unloader operation

*M21 Auto loader operation

*M24 Tailstock (quill + base) advance


*M25 Tailstock (quill + base) retract


*M26 Tailstock base advance


*M27 Tailstock base retract


*M28 Spindle index pin advance (lock)

*M29 Spindle index pin retract (free)

M30 End of program (same as M02)

*M31 Spindle brake ON (lock)

*M32 Spindle brake OFF (free)

*M33 Cut-off confirmation

*M34 Bar end check SET

*M35 Bar end check RESET

*M36 Bar feeder retract start (for Taiwan, Hong Kong)

* : Optional

86

Chapter 7 Appendix

M code Function

*M78 Parts catcher advance


*M79 Parts catcher retract


M80 Non-buffering M code

*M81 Bar replacement monitor

*M83 HATEC bar feeder start

*M84 Tail base advance (w/o sensor confirmation)

*M85 Tail base retract (w/o sensor confirmation)

*M86 Tail quill advance (w/o sensor confirmation)

*M87 Tail quill retract (w/o sensor confirmation)

*M88 Dry Run ON

*M89 Dry Run OFF

*M90 / code control mode SET

*M91 / code control mode RESET

*M92 Tool breakage detection: tool check (START)

*M93 Tool breakage detection: sensor check (END)

*M96 End of measurement macro

M98 Call of sub-program (internal memory)

M99 End of sub-program

*M112 Additional universal output 1 ON (w/o FIN signal)

*M113 Additional universal output 1 OFF (w/o FIN signal)

*M114 Additional universal output 2 ON (w/o FIN signal)

*M115 Additional universal output 2 OFF (w/o FIN signal)

*M116 Conveyor motor CW

*M117 Conveyor motor CCW

*M120 / code 1 SET

*M121 / code 1 RESET

*M122 / code 2 SET

*M123 / code 2 RESET

*M124 PMC counter RESET

*M126 Spindle inching CW

*M127 Spindle inching stop

M code Function

M140 Spindle orientation & lock

(every 15°, 24 divisions)

M163

*M198 Sub-program call (from external memory)

M202 Spindle speed attainment check

*M212 Additional universal output 1 ON (without FIN signal)

*M213 Additional universal output 1 OFF (without FIN signal)

*M214 Additional universal output 2 ON (without FIN signal)

*M215 Additional universal output 2 OFF (without FIN signal)

M240 Tool life management restart

M241 Tool life management check

M242 Tool life management skip

M370 Cycle time over check 2 SET (timer No. 2)

M371 Cycle time over check 2 RESET

*M400 B-code spindle orientation (w/o lock)

*M401 B-code spindle orientation (with lock)

*M404 Spindle override SET (% designation by B code)

*M405 Spindle override RESET

(fixed to 100%; as specified by S code)

M406 Feed override cancel SET (100% fixed)

M407 Feed override cancel RESET (0-150%)

M408 Error detect ON

M409 Error detect OFF

M410 Thread chamfering OFF (chamfering 0)

M411 Thread chamfering ON (parameter No. 5130 = 5)

*M412 Manual absolute OFF

*M413 Manual absolute ON

M414 Wait for delivery completion ON

M415 Wait for delivery completion OFF

*M420 1st (X-axis) abnormal load detection ON

*M421 1st (X-axis) abnormal load detection OFF

*M422 2nd (Z-axis) abnormal load detection ON

*M423 2nd (Z-axis) abnormal load detection

Chapter 7 Appendix

87

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 No. Address

01 T00 Cycle time-over alarm 1: Time from M70 to the next M70

02 T02 Cycle time-over alarm 2: Time from M370 to M371

03 T04 Tailstock quill advance (M16) FIN: Time before returning the FIN signal without LS confirmation

04 T06 Tailstock quill retract (M17) FIN: Time before returning the FIN signal without LS confirmation

05 T08

06 T10

07 T12 Shutter open (M68) FIN: Time before returning the FIN signal without LS confirmation

08 T14 Shutter close (M69) FIN: Time before returning the FIN signal without LS confirmation

09 T16 Unloader advance (M60) FIN: Time before returning the FIN signal without LS confirmation

10 T18 Unloader retract (M61) FIN: Time before returning the FIN signal without LS confirmation

11 T20 Chuck air (M10) ON: Time from chuck open to air ON

12 T22 Chuck air (M10) OFF: Time for air ON

13 T24 Chuck seating ON confirmation (M59) alarm: Time from ON confirmation start to triggering an

alarm

14 T26

15 T28

16 T30

17 T32 Chuck seating ON confirmation (M59): Time from ON confirmation start to returning the FIN

signal

18 T34 Out-conveyor normal rotation time (M116): Time from conveyor normal rotation (M116) to

conveyor stop

19 T36 Out-conveyor reverse rotation time (M117): Time from conveyor reverse rotation (M117) to

conveyor stop

20 T38 Out-conveyor normal rotation time: Time from unloader retract (M61, M79) to conveyor stop

21 T40 Coolant discharge alarm: Time from discharge confirmation sensor OFF to triggering an alarm

when the coolant ON command is issued

22 T42

23 T44 Reset & rewind: Time from receiving the loader request signal to executing reset & rewind

24 T46 Automatic power shut-off output: Time from power shut-off condition establishment to output

25 T48 Panel key input delay: Measures against wrong entry on the operation panel

26 T50

27 T52

28 T54

29 T56

30 T58 Turret FIN: Time from turret clamp sensor ON to returning the FIN signal

31 T60 Turret rotation start: Time from turret unclamp to rotation start

32 T62

33 T64

34 T66

35 T68

36 T70

37 T72

38 T74

39 T76

40 T78

Maintenance

Contents

Chapter 1 Safety Precautions for Maintenance........................................................ 1

Chapter 2 Daily Inspection ......................................................................................... 2

2-1 Check Items before Turning Power ON ........................................................ 2

2-2 Check Items after Turning Power ON ........................................................... 4

Chapter 3 Periodical Inspection ................................................................................. 6

3-1 Weekly Inspection ......................................................................................... 6

3-2 Monthly Inspection ........................................................................................ 6

3-3 Semiannual Inspection ................................................................................... 7

3-4 Yearly Inspection ........................................................................................... 8

3-5 Every Three Years Inspection ....................................................................... 8

Chapter 4 Oiling .......................................................................................................... 9

4-1 List of Oils ..................................................................................................... 9

4-2 Lubricant Unit ................................................................................................ 11


4-4 Coolant Unit .................................................................................................. 13

4-5 Chuck ............................................................................................................. 14

Chapter 5 Trouble Shooting ....................................................................................... 15

5-1 Initial Measures ............................................................................................. 15

5-2 Alarm Display................................................................................................ 16

5-2-1 Alarm Display Sections .................................................................... 16

5-2-2 Alarm Message Screen and Help Function....................................... 17

5-3 Check Sheet ................................................................................................... 18

5-4 Resetting of Emergency Stop ........................................................................ 19

5-5 Phenomenon and Remedy of Major Problems .............................................. 20

5-6 Resetting of Overtravel .................................................................................. 25

5-6-1 When Soft Limit is Actuated: ........................................................... 25

5-6-2 When Mechanical Limit is Actuated: ............................................... 27

5-7 Self-diagnosis Procedures.............................................................................. 29

5-7-1 Displaying Diagnosis Screen ............................................................ 29

5-7-2 Reading of Signal Address Table ..................................................... 31

5-8 Parameter Setting and Change ....................................................................... 32

5-8-1 Parameter Reference ......................................................................... 32

5-8-2 Parameter Setting (Change) .............................................................. 33

5-9 Slide Reference Point Setting ........................................................................ 36

Chapter 6 Maintenance for Each Unit ...................................................................... 39

6-1 Headstock ...................................................................................................... 39

6-1-1 Adjustment of Chuck Pressure ......................................................... 39

6-1-2 Chuck Pressure Setting Table for Stroke Adjustable Cylinder ......... 40

6-1-3 Adjustment of Belt ............................................................................ 41

6-1-4 Replacement of Belt .......................................................................... 43

6-1-5 Alignment of Headstock ................................................................... 44

6-1-6 Replacement of Position Coder ........................................................ 45

6-2 Slide Unit ....................................................................................................... 46

6-2-1 Replacement of Wipers ..................................................................... 46

6-2-2 Measurement and Compensation of Backlash .................................. 49

6-2-3 Adjustment of Gib ............................................................................ 51

6-3 Turret Unit ..................................................................................................... 54

6-3-1 Measurement of Turret Parallelism .................................................. 54

6-3-2 Adjustment of Turret Clamp Proximity Switch ................................ 56

6-3-3 Turret Zero Position Setting (for Mitsubishi Motor) ........................ 57


6-4-1 Cleaning of Oil Filler Filter .............................................................. 58

6-4-2 Cleaning of Strainer .......................................................................... 59

6-4-3 Cleaning of Hydraulic Tank ............................................................. 60

6-5 Lubricant Unit ................................................................................................ 61

6-5-1 Cleaning of Oil Filler Filter .............................................................. 61

6-5-2 Cleaning of Suction Filter ................................................................. 62

6-5-3 Cleaning of Lubricant Tank .............................................................. 63

6-6 Air Unit ......................................................................................................... 64

6-6-1 Replacement of Filter Regulator Element ........................................ 64

6-6-2 Replacement of Elements in Mist Separator and

Micro Mist Separator ........................................................................ 67

6-6-3 Adjustment of Lubricator Oil Drop Amount .................................... 69

6-6-4 Pressure Adjustment of Filter Regulator .......................................... 70

6-7 Coolant Unit .................................................................................................. 71

6-7-1 Cleaning of Coolant Tank ................................................................. 71

6-8 Electric Cabinet ............................................................................................. 72

6-8-1 Cleaning of Heat Exchanger ............................................................. 72

6-8-2 Replacement of Battery .................................................................... 73

6-8-3 Replacement of Fuse ......................................................................... 76

6-8-4 Resetting of Thermal Relay .............................................................. 77

1

Chapter 1 Safety Precautions for Maintenance

• Be sure to turn the main power switch off during maintenancework. The primary power in the factory also should be off formaintenance of the electric cabinet. Never open the door in fiveminutes after turning the power off, as residual voltage remains.

• When carrying out maintenance work, put a panel or a plate indi-cating “MAINTENANCE - KEEP AWAY FROM THE MA-CHINE.” around the machine so that the power is not turned on orthe 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 withoutour permission. Failure to observe this warning will result notonly in machine malfunctioning or damage, but also critical bodilyinjuries.

• The cover should not be opened by unqualified personnel formaintenance. Turn the main power switch off when it is needed towork 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. or-

derly, and remove all the obstacles, water and oil from the floor inorder to restore proper working environment.

• Procedures and methods described in “Maintenance” shouldstrictly be observed. Contact your local distributor immediatelywhen any question or doubt arises.

• Replacement parts (electrical and mechanical) should be as desig-nated 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.

DANGER

WARNING

Safety Guide

CAUTION

Chapter 1 Safety Precautions for Maintenance

2

Unit Inspection Items Remarks

Headstock unit No chips should be in/on the collet chuck.

The chuck jaws should not be worn out.

Lubricant unit Lubricant amount should be sufficient.

Hydraulic pump unit Hydraulic oil amount should be sufficient.

Reading of the pressure gauge should be “0”.

Coolant unit Coolant amount should be sufficient.

Chips should not be deposited in the tank excessively.

Turret unit 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.

Electric cabinet The door should be closed completely.

All cables should not be damaged or broken.

Others The front door should be closed completely.

The EMERGENCY STOP button should be pressed.

The machine environment should be tidy.

Chapter 2 Daily Inspection

2-1 Check Items before Turning Power ON


DANGERBefore turning the power on, check that all cables are prop-

erly 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

operation or maintenance work, in/around the machine.

• The floor must be free from water and oil.

WARNING

3

Fig. 1


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.

Front door• must be closed.

EMERGENCY STOP button• must be depressed.

Electric cabinet• door must be closed. Cable connection port

• must not hold any damaged cable.

Lubrication unit• must be equipped with an appropriate

amount of oil.

Coolant tank• must be equipped with an appropri-

ate amount of clean oil.• must not have build-up chips.

Hydraulic pump unit• must be equipped with an appropriate

amount of oil.

Hydraulic pump unit

• The pressure gauge should read "0".

Coolant tank

• Coolant should not be dirty and its level

should be appropriate.

• Chips should not be deposited in the tank.


4


Headstock unit There should be no abnormal noise and excessive vibrationduring 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.

Slide unit There should be no abnormal noise and excessive vibrationgenerated from the X-axis motor and Z-axis motor.

Hydraulic pump unit The pump pressure should be appropriate. (3.4 MPa)The chuck pressure should be appropriate. (Max. 2.0 MPa)

Coolant unit The coolant pump should be working properly.

Air unit Air pressure should be appropriate. (0.5 MPa)Air should be dry.

Lubricant unit Lubricant discharge should be appropriate.

Turret unit There should be no abnormal noise and excessive vibrationduring the turret indexing.

Others No alarm message should be displayed on the NC screen.No alarm lamp should be turned on on the machine operationpanel.

2-2 Check Items after Turning Power ON

CAUTIONWhen starting operation after stopping the machine for a longperiod of time, check that the machine motions, noise andslideway lubrication are free from trouble.If any abnormality, such as abnormal noise, excessive heatgeneration and abnormal motion, is found, turn off the powerimmediately and contact the maintenance personnel to takenecessary measures.After turning the power on, conduct warm-up operation suffi-ciently.

• Mount no workpiece at this time.

• Programs for automatic operation should include each func-

tion of the machine.

• Change the spindle speed from low (500 min-1) to intermedi-

ate (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.


5

Fig. 2


Machine operation panel• must not have any illumi-

nating or blinking alarmlamps.


Lubrication unit• must be set to an appropriate

discharge amount.

Spindle motor, X/Z-axis motor• must be free from abnormal noise

or vibration.

Hydraulic pressure gauge• must indicate appropriate chuck pressure.

(Max. 2.0 MPa)(Source pressure: 3.4 MPa)

Coolant pump motor• is working properly.


Turret unit• must not generate any abnormal sound or

excessive vibration during turret rotation.

Air unit• Air pressure should be appropriate.

(0.5 MPa)

6

Coolant unit Check if the coolant discharge is proper. “4-4”

Headstock unit Replenish the chuck jaws with grease. “4-5”

Lubricant unit Check that oil amount is appropriate. “4-2”


Chapter 3 Periodical Inspection

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



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


Headstock unit Check if there is abnormal noise, excessive vibration

or excessive heat generation from the motor.

Slide unit Check if there is abnormal noise, excessive vibration

or excessive heat generation from the motor.

Electric cabinet Check and clean the cooling fan filter. “6-8-1”

Check and wipe dust off if any.


3-2 Monthly Inspection

“Special Version” for optional equipment

7

Headstock unit Check the tension of the spindle driving belt. “6-1-3”

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.

Slide unit 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.

Lubricant unit Check that there is no oil leakage and that pipings are

not crushed.

Hydraulic pump unit Check that there is no oil leakage and that pipings are

not crushed.

Coolant unit Check that there is no oil leakage.

Electric cabinet Check that connectors, relays and bolts are all securely

tightened.

Others Check that bolts and nuts of the covers are all Installation

securely tightened.

Check the levelling, and adjust it if necessary.


3-3 Semiannual Inspection


“6-2-1”

8


Headstock unit Check the spindle accuracy, adjust it if necessary. “6-1-5”

Slide unit Measure the backlash, and adjust it if necessary. “6-2-2”

Replace the hydraulic oil with new one. “4-3”

Clean the oil inlet filter. “6-4-1”

Clean the strainer. “6-4-2”

Lubricant unit Clean the suction filter, and replace it if necessary. “6-5-2”

Clean the oil inlet filter. “6-5-1”

Turret unit Check the parallelism of the turret, and adjust it if

necessary.

Air unit Replace the filter element.

Electric cabinet Replace the back-up batteries with new ones.* Be sure to replace the batteries while power is sup-

plied to the entire system.


Headstock unit Replace the spindle bearing grease with new one.

3-5 Every Three Years Inspection

“6-6”

3-4 Yearly Inspection

“6-3-1”

Hydraulic pump unit

“6-8-2”


Contact

Takamatsu.

9

Chapter 4 Oiling

Chapter 4 Oiling

4-1 List of Oils

CAUTIONUse new oils specified below to prevent damage to the ma-

chine. 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.

Oiling Point Specified Oil (Maker) Amount Interval Remarks

Lubricant unit Slideway lubricant 1.5 lit. As required See “4-2”.

Febis K68 (ESSO)

Hydraulic pump unit Hydraulic oil 10 lit. Yearly See “4-3”.

Nuto 32 (ESSO)

Coolant unit – 95 lit. As required See “4-4”.

Headstock unit Grease – Every 3 years

Chuck jaws Grease As required Weekly See “4-5”.

ContactTakamatsu.

Name ISO VG68 ISO VG32

Maker Slideway lubricant Hydraulic oil

Mobil Mobil Vactra Oil No. 2 Mobil DTE Oil Lite

Showa Shell Shell Tonna Oil S68 Shell Tellus Oil C32

Esso Febis K68 Nuto 32

Nippon Oil Uniway HP68 FBK Oil RO 32

Japan Energy Slidus HS68 Hydrax 32

Idemitsu Petrochemical Daphne Multiway 68C Daphne Mechanic Oil 32

List of Recommended Oils

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

operating hours.

10

Fig. 3

Headstock

Hydraulic pumpCoolant unit

Lubrication unit

Chapter 4 Oiling

Air unit


11

4-2 Lubricant Unit

• Inspection interval Daily

• Oiling interval As required

• Specified oil Slideway lubricant

Febis K68 (ESSO)

• Oil amount 1.5 lit. (Tank capacity: 2.0 lit.)

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

the machine.

Supply specified oil from the oil filler port.

Chapter 4 Oiling

Fig. 4

Oil filler port


12

Chapter 4 Oiling


DANGER • When carrying out maintenance work, put a panel or aplate indicating “MAINTENANCE - KEEP AWAY FROMTHE MACHINE.” around the machine so that the power isnot turned on or the operation panel is not touched bymistake.

The cover should not be opened by unqualified personnel for

maintenance. Turn the main power switch OFF and lock


Fig. 5


• Oiling (replacing) interval Yearly

• Specified oil Hydraulic oil

Nuto 32 (ESSO)

• Oil amount 10 lit. (tank capacity)

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

operating hours.

[Required tools] Allen wrench [10]

Can (for waste oil)


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.

Oil filler port

Drain

WARNING


13

Chapter 4 Oiling

4-4 Coolant Unit


• Oiling interval As required

• Oil amount 95 lit. (Tank capacity)

[Required tools] Spanner [14]

Can (for waste oil)


2. Drain the waste coolant into the can.

3. Replenish the tank with coolant.

Fig. 6

Drain Level gauge






Use non-flammable coolant. When using oil-based coolant

inevitably, strictly follow the instructions in “Safety Precau-

tions for Fire Prevention”

“Chapter 7 Safety Precautions for Fire Prevention” in Safety Guide

Never handle coolant with bare hands.

DANGER

WARNING

CAUTION

14

4-5 Chuck

• Inspection interval Weekly

• Oiling interval Weekly

• Oil amount As required

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

Takamatsu.

[Required tools] Grease gun


2. Put grease into the grease nipples using a grease gun.

Fig. 7

Grease nipple

Chapter 4 Oiling


15

Chapter 5 Trouble Shooting

WARNINGIf any doubt or question arises, contact Takamatsu for guid-

ance.

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:

Trouble to be reported to Takamatsu to be taken care of by our service engineers.

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

the instructions of Takamatsu.

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


5-1 Initial Measures

16

5-2 Alarm Display

5-2-1 Alarm Display Sections

When any trouble occurs in the machine, it is indicated on the following sections.


“5-5 Phenomenon and Remedy of Major Problems” when any

trouble occurs in the machine

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 OPERATOR’S 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

“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.


Fig. 8

17

5-2-2 Alarm Message Screen and Help Function

Alarm Message Screen

ALARM MESSAGE O0000 N0000

100 PARAMETER WRITE ENABLE

510 OVER TRAVEL: +1

521 OVER TRAVEL: -2

S O T0000

MDM **** *** *** 13:27:30

[ ALARM ] [ ] [ HISTORY ] [ ] [ ]

Indicates the controller status.

Alarm number and message

--EMG--

EDIT STOP MTN FIN ALM 16:52:13

(Soft key display) INPUT

Indicates an emergency

stop status.

Indicates that an alarm is being issued.

BAT Indicates that the battery is low.

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 O T0000

MEN **** *** *** 00:00:00

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

2. Press the [1 ALAM] soft key.

• The details of the alarm currently issued will

be displayed.

Help Function

HELP (ALARM DETAIL) O1234 N0001

NUMBER : 094

M’SAGE : 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 O T0000

MEN **** *** *** 00:00:00

[ 1 ALAM ] [ 2 OPR ] [ 3 PARA ] [ ] [ (OPRT) ]

Alarm number

Normal explanation on alarm (32 characters)

Function classification (30 characters)

Alarm details (216 characters)


HELP


18

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 opera-

tion 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


19

YES

NONO

YES

NO

5-4 Resetting of Emergency Stop

Is the emergency stopbutton pressed?

Is the overtravelproximity switch hit?

Turn the emergency stop button in the arrowdirection of “RESET”.

The spindle control unit may bethe cause of the trouble.

The thermal relay of the hydraulicpump motor might have tripped ormalfunctioned.

The thermal relay of the coolantpump motor might have tripped ormalfunctioned.

Does the message “---EMG---”disappear?

Reset the overtravel status.

“5-6 Resetting of

Overtravel”

Does the message“---EMG---”disappear?

NO

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

Contact Takamatsu.

Instruction manual issued by Fuji Electric. Co.,

Ltd.

“6-8-4 Resetting of Thermal Relay”

“6-8-4 Resetting of Thermal Relay”

YES OK

YES OK


20

The NC display circuit may be

faulty.

5-5 Phenomenon and Remedy of Major Problems

The NC shows incorrectly or

does not light up at all.

Contact Takamatsu.

Cycle start is not available. Operation has not been done

correctly.

Operation

The NC controller may be faulty. Contact Takamatsu.

The breaker is turned off. Faulty motor, valves or a fan has

caused a short-circuit or electric

leakage.

Contact Takamatsu.

A mode cannot be changed

over.

The I/O board or the operation

panel may be faulty.Contact Takamatsu.

The power cannot be turned

on.

The power cord is not connected. Connect the power cord.

Installation

Jog feed is not available. Operation has not been done

correctly.

Operation

The servo amplifier or NC control-

ler may be faulty.

Dimension error in the

longitudinal direction is

abnormal.

Check and adjust backlash.

“6-2-2”

Backlash is faulty.

Positioning accuracy is faulty. Check and adjust the posi-

tioning accuracy. Contact

Takamatsu.

Repeatability is faulty. Check and adjust repeatabil-

ity. Contact Takamatsu.

The servo flex coupling (clamping

bolt) is loosened.

Tighten the servo flex

coupling (clamping bolt)

securely.

Threading or tapping is not

correctly done.

A program is not correctly made. Programming Manual

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.

“6-1-6”

The primary power in the factory is

not on.

Turn on the primary power

in the factory.

Contact Takamatsu.

Phenomenon Cause Remedy

“Special Version” for information on the optional units


21

Phenomenon Cause RemedyDimension error in the radialdirection is abnormal.

Lower the chuck clampingforce.

Chuck jaw mounting bolt is loos-ened.

Tighten the mounting boltsecurely.

Runout on the outer surface or endface of the chuck is faulty.

Measure and adjust therunout.

Chuck clamping force is exces-sively strong.

Turret positioning accuracy is faulty(due to chips in the turret curviccoupling).

Check and adjust the turretpositioning accuracy.

The spindle position coder is faulty. Check and adjust the spindleposition coder.

“6-1-6”

The spindle drive belt is worn outor slipped.

Check the spindle drive beltand replace if required.

“6-1-3” and “6-1-4”

Cutting is not available as itstops halfway.

Gib clearance is faulty. Adjust the gib. “6-2-3”

The servo flex coupling (clampingbolt) is loosened.

Tighten the servo flexcoupling (clamping bolt)securely.

Zero return is not available. Operation has not been done cor-rectly.

Operation

The emergency stop button ispressed.

Reset the emergency stopbutton.

Required hydraulic pressureis not obtained.

The thermal relay might havetripped or be faulty.

“6-8-4”

Hydraulic oil is not dis-charged.

Hydraulic oil is insufficient. Replenish the tank withhydraulic oil.

“4-3”

Hydraulic oil viscosity is too high. Replace hydraulic oil.“4-3”

The strainer is clogged. Wash the strainer andreplace if required.

“6-4-2”

The zero point proximity switch isoff-positioned or out of order.

Contact Takamatsu.

Spindle runout is faulty. Check and adjust spindlerunout.

“6-1-5”


22


The solenoid valvedoes not function.

Foreign objects are caught up inthe spool slideway.

Disassemble and wash it. Ifthe spool does not movesmoothly inside the mainunit, there are burrs in themain unit. Deburr in such acase.

The mounting bolts are too tight,or flatness on the mounting surfaceis insufficient.

Tightening torque should bewithin 4.9 N.

Pressure flow is excessive. Adjust it within the desig-nated value in the specifica-tions, using a throttle valve.

Check the solenoid currentand voltage. If resistance isfaulty, replace the valve.

Contacting is faulty or wiring isdisconnected.

Hydraulic phenomenon occurs. Reduce dust mixed in the oil.Lower the pressure as muchas possible. Change thecycle time and shorten theexciting time.

The solenoid coil isburnt.

Voltage is excessive or insuffi-cient.

Check that voltage is within10% above the rating.

Ambient temperature is abnor-mally high.

Adjust the oil temperatureand ambient temperature tobe below 65°C and 50°Crespectively.

Common wiring is faulty. Carry out wiring correctly.

Both the solenoid coils are turnedON due to malfunction.

Check the electric circuitagain.

External leakage isabnormal.

The rolling is damaged or dropped. Replace with a new one.

Adjust mounting pitch andsurface roughness on themounting surface.

The solenoid valve is worn out dueto hydraulic oil deterioration.

Replace oil.“4-3”

Internal leakage isabnormal.

Hydraulic oil is not appropriate. Abnormal wear occurs due tonon-combustible hydraulicoil.

The mounting surface is faulty.

Solenoidvalve

Discharge pressure is improper. Adjust discharge pressure.“6-4-2”


23


Excessive pressure flow. Liquidthrust exceeds changeover force,and the spool vibrates.

Abnormal noise isgenerated.

The solenoid pull-in section beats.

Solenoidvalve

Regulate difference inpressure by using a throttlevalve.Lower hydraulic pressure asmuch as possible.

Remove foreign objects fromthe pull-in section, if any.Replace the solenoid valve ifit is faulty.

The turret is normallypositioned but the clampsignal is not output.

The proximity switch for turretclamp is off-positioned.

“6-3-2”

The servo amplifier may be faulty.The turret is not correctly

indexed as designated.

The turret stopped while it is

inclined.

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.

Disassemble and clean the

chuck.

NC controller, etc. may be faulty. Contact Takamatsu.

The chuck does not open or

close smoothly.

The solenoid valve is out of order. the previous page

A workpiece slips. Cutting conditions are not properly

set.

Check the cutting condi-

tions.

Stroke of the master jaw is insuffi-

cient.

Adjust the master jaw

stroke.

Form dia. of the chuck jaws is

improper.

Form the jaw again.

Operation

Grease is not sufficient. Replenish with grease.

“4-5”

Clamping force is insufficient. Adjust chuck pressure.

“6-1-1”

“6-3-3”

the previous page


24

Check the piping.


The spindle does not rotate. Contact Takamatsu.Operation error.

The spindle motor is faulty

(abnormal noise or vibra-

tion).

Mounting bolts are loosened. Tighten the bolts securely.

The spindle motor is out of order. Contact Takamatsu.

The spindle motor output

does not increase.

Belt tension is not sufficient. Adjust belt tension.

“6-1-3”

The motor pulley is worn out. Check the motor pulley.

“6-1-3”

The spindle drive belt cuts

off.

The motor pulley groove is dirty or

worn out.

Check the motor pulley.

“6-1-3”

The spindle generates

abnormal noise.

The spindle bearing is abnormal. Contact Takamatsu.

The spindle generates

abnormal temperature.

The spindle bearing is not greased

sufficiently.

Contact Takamatsu.

Lubricant is not discharged

to a certain section.

Piping is broken and oil leaks. Check the piping and

distributor.

Coolant is not discharged. The emergency stop button is

pressed.

Reset the emergency stop

button.

The thermal relay tripped or is

faulty.

“6-8-4”

Coolant is insufficient. Replenish the tank with

coolant.

“4-4”

Piping is broken and oil leaks.

Spindle, the amplifier or NC

controller may be faulty.Contact Takamatsu.

Turret does not rotate. The proximity switch is defective. Replace the proximityswitch with a new one.

A.** is indicated on the servoamplifier.

1. Turn the main powerswitch OFF once and ONagain after 40 sec.

2. Re-connect the connec-tor.

The turret PCB or motor is defec-tive.

Contact Takamatsu.

The unclamp valve is defective. 1. Clean the valve.2. Replace the valve with a

new one.


25

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.

5-6-1 When Soft Limit is Actuated:



ALARM MESSAGE O 0000 N0000

500 OVER TRAVEL : +X

S O T0000MDM **** *** **** 13:27:30[ ALARM ] [ MSG ] [HISTORY ] [ ] [ (OPRT) ]

150

10050

0 %

FEED RATE

OVERRIDE2. Select the required feedrate with the FEED RATE

OVERRIDE switch.


JOGZERORE-TURN


26

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.

CAUTIONRapid feed becomes effective when

the RAPID switch is pressed to-

gether with the JOG FEED switch.

RESET 4. Press the RESET key.

+ X

- Z + Z

- X

RAPID


27

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.

CAUTION Be sure to check that the axis travel

direction is correct.

O.T.

RELEASE


JOGZERORE-TURN



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 nor-

mal range.

- Y


AXISSELECT

HANDLE

28

6. Detach the O.T. RELEASE switch.

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

* Keep an interval of 3 seconds at least before turning the

power ON again.

O.T.

RELEASE


POWER

OFF ON

29

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

1. Press the SYSTEM key.

2. Press the [DGNOS] soft key.

• The diagnosis screen will appear.

Status in the CNC

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 Operator’s Manual for the status in

the CNC

PAGE

PAGE

SYSTEM

DIAGNOSIS O0001 N0001

000 WAITING FOR FIN SIGNAL : 0001 MOTION : 0002 DWELL : 0003 IN-POSITION CHECK : 0004 FEEDRATE OVERRIDE 0% : 0005 INTERLOCK/START-LOCK : 0006 SPINDLE SPEED ARRIVAL CHECK : 0

[ PARAM ] [ DGNOS ] [ PMC ] [ SYSTEM ] [ (OPRT) ]


30

DIAGNOSIS (GENERAL) O0020 N0001000 WAITING FOR FIN SIGNAL : 0001 MOTION : 0002 DWELL : 0003 IN-POSITION CHECK : 0004 FEEDRATE OVERRIDE 0% : 0005 INTERLOCK/START-LOCK : 0006 SPINDLE SPEED ARRIVAL CHECK : 0

)_EDIT **** *** *** 14 :51 : 55

[PARAM] [DGNOS] [ PMC ] [SYSTEM] [(OPRT)]

SYSTEM

PAGE

PAGE

PMC SIGNAL STATUS O0020 N0001ADDRESS 7 6 5 4 3 2 1 0G0000 ** ** ** ** ** ** ** **G0001 ** ** ** ** ** ** ** **G0002 ** ** ** ** ** ** ** **G0003 ** ** ** ** ** ** ** **G0004 ** ** ** ** ** ** ** **G0005 ** ** ** ** ** ** ** **

)_EDIT **** *** *** 14 :51 : 55

[ TITLE ] [ STATUS ] [ ALARM ] [ TRACE ] [ ]


2. Press the [DGNOS] soft key.

• The diagnosis screen is displayed.

3. Press the [PMC] soft key.

4. Press the [PMCDGN] soft key.

5. Press the [STATUS] soft key.

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


* [NO. SRH] can be displayed by pressing the

[(OPRT)] soft key.

Status of input/output signals


31

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.

X9

7 6 5 4 3 2 1 0

5-7-2 Reading of Signal Address Table


32

WARNING

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.

5-8-1 Parameter Reference

PARAMETER O1234 N00010000 SEQ INI ISO TVC0001 FCV

0 0 0 0 0 0 0 00012 MIRX 0 0 0 0 0 0 0 0Z 0 0 0 0 0 0 0 0

0020 I/O CHANNEL0022

)_ S 0 T0000

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

1. Press the SYSTEM key.SYSTEM

PAGE

PAGE

The FANUC Operator’s Manual for the status in the

CNC

* [NO. SRH] can be displayed by pressing the [(OPRT)]

soft key.

2. Press the [PARAM] soft key.

• The parameter screen is displayed.

3. Bring up the desired parameter.


displayed.

b) Key in the desired parameter number, and then



Before changing any parameter, be sure to contact Takamatsu.

33

HELPIf you don’t know the parameter number to be refer-

enced, it can be found by accessing the help function.

The FANUC Operator’s Manual

HELP (PARAMETER TABLE) O1234 N00011/4

*SETTING (NO. 0000 - )* READER/PUNCHER INTERFACE (NO. 0100 - )* AXIS CONTROL/SETTING UNIT (NO. 1000 - )* COORDINATE SYSTEM (NO. 0000 - )* STROKE LIMIT (NO. 0000 - )* FEED RATE (NO. 0000 - )* ACCEL/DECELERATION CTRL (NO. 0000 - )* SERVO RELATED (NO. 0000 - )* DI/DO (NO. 0000 - )

S O T0000MEM **** *** *** 00:00:00[ 1 ALAM ] [ 2 OPR ] [ 3 PARA ] [ ] [ (OPRT) ]

5-8-2 Parameter Setting (Change)

1. Press “MDI” of the mode selector switch.

• The lamp lights up.EDIT AUTO MDI HAN-

DLEJOG

ZERORE-TURN


3. Press the [SETTING] soft key.

• The setting screen is displayed.

SETTING (HANDY) O1234 N0001PWE = (0 : DISABLE 1 : ENABLE)TV CHECK = 0 (0 : OFF 1 : ON)PUNCH CODE = 1 (0 : EIA 1 : ISO)INPUT UNIT = 0 (0 : MM 1 : INCH)I/O CHANNEL = 0 (0-3 : CHANNEL NO.)SEQUENCE NO. = 0 (0 : OFF 1 : ON)TAPE FORMAT = 0 (0 : NO CONVERT 1 : F10/F11)VERIFY STOP = 0 (PROGRAM NO.)VERIFY STOP = 0 (SEQUENCE NO.))_ S 0 T0000MDI *** 00 : 00 : 00

[ OFFSET ] [ SETTING ] [ COORD ] [ ] [ (OPRT) ]

OFFSETSETTING


34

The FANUC Operator’s Manual for the status in the

CNC


7. Press the [PARAM] soft key.

• The parameter screen is displayed.

PARAMETER (SETTING) O1234 N00010000 SEQ INI ISO TVC0001 FCV

0 0 0 0 0 0 0 00012 MIRX 0 0 0 0 0 0 0 0Z 0 0 0 0 0 0 0 0C 0 0 0 0 0 0 0 0Y 0 0 0 0 0 0 0 0A 0 0 0 0 0 0 0 06 0 0 0 0 0 0 0 0

)_ S 0 T0000MDI 15 : 28 : 59

[ ] [PITCH] [SV. PARA] [ ] [(OPRT)]

SYSTEM

PAGE

PAGE

8. Bring up the desired parameter.


displayed.

b) Key in the desired parameter number, and then


* [NO. SRH] can be displayed by pressing the [(OPRT)]

soft key.

4. Press the cursor key until the cursor comes to

“PWE”.

5. Set PWE to “1” (parameter write enable), by press-

ing:

(or press the [INPUT] soft key)

• “P/S100 Alarm” is indicated on the screen.


35

9. Enter the desired value, and press the INPUT key (or

the [INPUT] soft key).


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.

OFFSETSETTING

INPUT

RESET


36


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 refer-

ence 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 param-

eter is automatically reset to “0”.

3. Turn power off.

“2-5 Turning Power OFF” in Operation

5-9 Slide Reference Point Setting

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.


indicating “MAINTENANCE - KEEP AWAY FROM THE MA-

CHINE.” 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.


maintenance. Turn the main power switch off when it is needed

to work inside the cover.

WARNING

4. Press the POWER ON button and reset the EMER-

GENCY STOP button.

“2-2 Turning Power ON” in Operation

• “300 APC ALARM: X (Z) axis zero return re-

quest” is displayed.


switch.


EMERGENCYSTOP

or


JOGZERORE-TURN

37


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.


switch.


9. Move the slide to a safe area.

10. Press “ZERO RETURN” of the mode selector

switch.


11. Use the AXIS SELECT switch to select the axis that

you mounted the stopper on.

or

or


JOGZERORE-TURN

+ X

- Z + Z

- X

RAPID


JOGZERORE-TURN

X Z

AXIS

SELECT

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

38


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

Reference

point setting

stopper

Tool post

Reference

point setting

stopper

Tool post

Reference

point setting

stopper

Tool post

(2) When the axis bumps into the stopper, it retreats approxi-

mately 10 to 40 mm.

(3) The axis moves towards the stopper again.

(4) When the axis bumps into the stopper, it moves to the

reference point position.

(5) When the axis arrives at the reference point position, thereference point is established and reference point setting

is finished. The axis reference point lamp on the opera-tion 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.

Tool post

Machine zero point

START

X-axis stopper

Z-axis stopper

O.T.RELEASE

39

Chapter 6 Maintenance for Each Unit


6-1 Headstock

When carrying out maintenance work, put a panel or a plateindicating “MAINTENANCE - KEEP AWAY FROM THE MA-CHINE.” around the machine so that the power is not turnedon or the operation panel is not touched by mistake.

The cover must not be opened by unqualified personnel formaintenance. Turn the main power switch off when it isneeded to work inside the cover.

DANGER

• Adjustment interval As required


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.

Fig. 9

WARNING

6-1-1 Adjustment of Chuck Pressure

Lock nutChuck pressure gauge


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

Adjust the chuck pressure within the setting range that is

determined by the combination of the chuck and the cylinder

to use.

CAUTION

40


6-1-2 Chuck Pressure Setting Table for Stroke Adjustable Cylinder

Maximum allowable pressure (MPa) by chuck type

*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.

Cyl

inde

r (K

ITA

GA

WA

)M

aker

Cyl

inde

r ty

peP

ull-s

ide

area

Pul

l-sid

e cy

linde

r for

ceC

huck

type

Mar

ker

Col

let

type

Inte

rnal

clam

p ty

pe

Com

mon

Bla

nk, o

vers

ize,

high

-pre

cisi

on ty

pe

KIT

AG

AW

A

Type

B

Type

BT

Type

N

Type

NT

Type

NLT

Cyl

inde

r (N

IKK

O)

Mak

er

Cyl

inde

r ty

peP

ull-s

ide

area

Pul

l-sid

e cy

linde

r for

ceC

huck

type

Mar

ker

Col

let

type

Inte

rnal

clam

p ty

pe

Com

mon

Bla

nk, o

vers

ize,

high

-pre

cisi

on ty

pe

NIK

KO

Type

HF

Type

MO

41


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 trans-

mitted because the belt slips.

Fig. 10

• Inspection interval Every 6 months

<Adjustment procedures>


Spanner [13]

Tension gauge (or spring balance)


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.

Specified load Fδ

Flexibility δ

Ls

Name Type Q'ty Tensile load (N) Re-tensile load (N) Flexibility (δ) Remarks

1 Timing belt 337L050 1 - - - Encoder

2 V belt (Powerace) 3V-670 4 33.8 37.0 10.6 Motor inside: 3,500

3 V belt (Powerace) 3V-670 3 36.4 41.8 10.3 Motor inside: 4,500

4 V belt (Powerace) 3V-630 4 33.8 37.0 9.8 Motor outside: 3,500

5 V belt (Powerace) 3V-630 3 36.4 41.8 9.5 Motor outside: 4,500

6 V birred belt (Ribace) 8PK1750 1 34.0 34.9 10.5 Motor outside: 6,000

Tensile load F (N) at the time of belt replacement is shown.

Flexibility δ (mm) obtained when the tensile load is applied to the center of the span is shown.

(6): For 5.5/7.5 kW motor

42


Fig. 11

Front covers

Motor base mounting bolts

Adjust boltFlexibility

Lock nut

Motor inside mounting Motor outside mounting

1

3 2

1

45

6

Flexibility

Motor base mounting bolts

Adjust bolt

Lock nut


43


6-1-4 Replacement of Belt


Spanner [13]

Screwdriver and Phillips screwdriver


2. Remove the motor cover.

3. Disconnect the drain hose and the HP hoses from the chucking cylinder.

Fig. 12

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.

CAUTION Put match marks on these hoses to prevent misconnection.

Belt

Adjust bolt

Motor base

mounting bolts

Lock nut

HP hose

Drain hose

Timing belt (337L050)



44


6-1-5 Alignment of Headstock

• Inspection interval Yearly

[Required tools] L wrenches [5], [6], [8], [10], [14]

Spanner [13]

Test bar (workpiece)

Dial indicator (with magnet stand, division: 0.002 mm)

CAUTION If any adjustment is required, contact Takamatsu.

Fig. 13

150 mm

0 mm 0.005 mm

150 mm

D0 D1

* If the difference between D0 and D1 is 0.01 mm or less and the workpiece is tapered off,

headstock adjustment is not required.

Z-axis direction

Indicator

Test bar

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

Chuck

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.

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.

Workpiece

D0 - D1 = 0.01 mm

45


6-1-6 Replacement of Position Coder

CAUTION Carefully handle the position coder since it is a precision

equipment.

Never use a hammer to remove or mount it.

Fig. 14

[Require tools] Allen wrench [8]

Snap ring remover


2. Dismount the headstock cover.

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

Key

Snap ring

Canon plug

Position coder



46


6-2 Slide Unit

DANGER When carrying out maintenance work, put a panel or a plate





maintenance. Turn the main power switch off when it is

needed to work inside the cover.

6-2-1 Replacement of Wipers

• Inspection (replacement) interval Every 6 months

[Required tools] 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.

WARNING

Fig. 15

Wiper

47


Fig. 17

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.


4. Remove the rear cover.

5. Remove the broken wiper(s).

6. Mount new one(s).

Fig. 16

Z-axis wipers on the headstock side

1. Return both the Z-axis and X-axis slides to their zero points.


3. Shift the Z-axis slide cover to the left.



6. Return the Z-axis slide cover to the original position.

Wipers

Wipers

48


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.


3. Dismount the top and right side covers from the machine.



6. Re-mount the top and right side covers on the machine.

Wipers

Fig. 18

49


• 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

Fig. 19

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 screw’s 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 im-

proper after use of the machine for a long period of time.

• Inspection interval Yearly

[Required tools] 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”.

50



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

“5-8 Parameter Setting and Change”

As for detailed parameters, refer to “FANUC OPERATOR’S MANUAL”.

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)

Fig. 21

Backlash

51


CAUTION

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


X axis


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.

GibAdjustment

bolt "A"

Gib

Adjustment bolt "B"

Gib

Adjustment bolt

Fig. 22

52


Z axis

1. Move the Z-axis slide about 100 mm away from the zero point in the minus direction.


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.

53


Fig. 23

Gib

Gib adjust bolt

GibGib adjust bolt A

Gib

Gib adjust bolt B

Right side cover Remove the wiper.


54


6-3 Turret Unit

When carrying out maintenance work, put a panel or a plateindicating “MAINTENANCE - KEEP AWAY FROM THEMACHINE.” around the machine so that the power is notturned on or the operation panel is not touched by mistake.

The cover must not be opened by unqualified personal formaintenance. Turn the main power switch off when it isneeded to work inside the cover.

DANGER

WARNING

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 µm or less, no adjustment is required.

If it exceeds 5 µm, 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.

55


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 µm or less, it is acceptable; however, to obtain a higher

center height accuracy, adjust it to 5 µm or less at the position of an average reading.

* If it exceeds 25 µm, 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 µm or less, no adjustment is required.

If the deviation at “a-b” exceeds 25 µm, center alignment must be made by adjusting FANUC

parameter of grid shift amount.

If the deviation at “c-d” exceeds 25 µm, turret curvic coupling alignment must be made.

Fig. 25


56


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]



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)

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

5. Tighten the lock nut of the proximity switch.

6. Attach the relay box.


CAUTION

Turret clamp proximity switchDog

Fig. 26

57


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.

58



When carrying out maintenance work, put a panel or a plateindicating “MAINTENANCE - KEEP AWAY FROM THEMAINTENANCE.” around the machine so that the power isnot turned on or the operation panel is not touched by mis-take.

The cover must not be opened by unqualified personnel formaintenance. Turn the main power switch off when it isneeded to work inside the cover.

DANGER

Fig. 27

WARNING

6-4-1 Cleaning of Oil Filler Filter

• Cleaning interval Yearly


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




59


6-4-2 Cleaning of Strainer

Clean the strainer when replacing the hydraulic oil.




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.

Fig. 28

Strainer

Tank cover

Tank cover mounting bolt


60


6-4-3 Cleaning of Hydraulic Tank

Clean inside of the hydraulic tank when renewing the supply of hydraulic oil in it.



Can (for waste oil)


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.

Fig. 29

Tank cover

Magnet separator

Drain

Tank cover mounting bolt


61


6-5 Lubricant Unit

6-5-1 Cleaning of Oil Filler Filter




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.

DANGERWhen carrying out maintenance work, put a panel or a plateindicating “MAINTENANCE - KEEP AWAY FROM THEMACHINE.” around the machine so that the power is notturned on or the operation panel is not touched by mistake.

FittingFitting

①Set screw

③

②

Oil filler filter

Tank

Tank

Fig. 30

* The figure shows the machine equipped

with Σ loader.



62


6-5-2 Cleaning of Suction Filter






• 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.


10. Tighten the two set screws securely.

Suction filter

Filter stopper

Fig. 31

63


6-5-3 Cleaning of Lubricant Tank



Can (for waste oil)




• 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.


7. Tighten the two set screws.

Fittings

①Set screw

Fitting

Fig. 32

③

②

Oil filler filter

Tank

Tank

64


6-6 Air Unit

When carrying out maintenance work, put a panel or a plateindicating MAINTENANCE - KEEP AWAY FROM THE MA-CHINE. around the machine so that the power is not turned onor the operation panel is not touched by mistake.

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 buttonArrow



65


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

66


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.

67


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

68


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

• The case is disengaged.

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

O-ring

69


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

Fig. 33


* Type and mounting position of the filter regulator differ depending on the specifications.

70


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.

Fig. 34



71


6-7 Coolant Unit

6-7-1 Cleaning of Coolant Tank

• Cleaning interval Every 6 months

[Required tools] Can (for waste oil)

Spanner [14]


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.

Fig. 35

Filters

Filters

Oil level gaugeDrain







Use non-flammable coolant. When using oil-based coolant

inevitably, strictly follow the instructions in “Safety Precau-

tions for Fire Prevention”

“Chapter 7 Safety Precautions for Fire Prevention” in Safety Guide

WARNING

72


6-8 Electric Cabinet

6-8-1 Cleaning of Heat Exchanger

DANGERBe sure to turn the main power switch off during mainte-

nance work.

The primary power in the factory also must be off for mainte-

nance of the electric cabinet. Never open the door in five

minutes after turning the power off, as residual voltage re-

mains.

• Cleaning interval Monthly

[Required tools] Air gun


2. Open the electric cabinet’s door with the designated key.

3. Clean the heat exchanger by blowing dry air with an air gun.

4. Close the electric cabinet’s door tightly.

Fig. 36

→→→→→

Air blowing

73


6-8-2 Replacement of Battery

Fig. 37

Battery for memory back-up

CAUTION

• 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. Other-

wise, data will be deleted from memory.

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.

Batterycase

Connector

Lithium batteryA02B-0200-K102

Operation box

WARNING



74


CAUTION

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.

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.

Battery case

Battery (4 “D” size batteries)

When the door to the power box is

closed, remove the battery case (cap),

and replace the battery.

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.

WARNINGTo avoid the possibility of someone starting the machinemistakenly, the EMERGENCY STOP button should bepressed and remain in the down position while you are per-forming this operation.


Fig. 38

75


Fig. 39

CAUTION

Battery for absolute pulse coder (for turret motor)

WARNING

• Turn the main power switch OFF before replacing the bat-

tery.

• 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.

• Keep away from electrically active parts such as batteryconnector pins, electric parts, etc. when mounting thebattery. Failure to do so may cause electrostatic break-down in the servo amplifier internal circuit.


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)”

CON1

Operation window

Battery Battery holder

Battery connector

76


6-8-3 Replacement of Fuse

Be sure to turn the main power switch off during mainte-

nance work.




mains.

DANGER

Fuse for power supply module(A06B-6077-K250)

Fig. 40




4. Remove the blown fuse.

5. Mount a new fuse instead.

6. Close the electric cabinet’s door securely.

“5-3 Parts Arrangement in Electric Box” in Specifications

Fuse for servo amplifier module3.2 A (A06B-6073-K250)



77


DANGER

Reset button

6-8-4 Resetting of Thermal Relay

Be sure to turn the main power switch off during mainte-

nance work.




mains.




4. Press the reset button of the thermal relay.

5. Close the electric cabinet’s door securely.

“5-3 Parts Arrangement in Electric Box” in Specifications

* Contact Takamatsu when a thermal relay trips repeatedly even after resetting it.

Fig. 41

CNC Precision Lathe

X-10i

Special Version

Read and understand this Manual

thoroughly before operating the

machine.

TAKAMATSU MACHINERY Co., Ltd.

Chuck Clamp Detector

1


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.



CHINE” around the machine so that the power is not turned on

or the operation panel is not touched by mistake.


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]


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.

2


Detail of proximity switch

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)

Proximity switch B

Lock nut

Proximity switchLamp

CAUTION

Proximity switch A


Mounting of Chuck(Stroke-Adjustable Cylinder)

1

Mounting of Chuck (Stroke-Adjustable Cylinder)

Chapter 1 Mounting of Power Chuck (NIKKO)

1. Clean all the mating surfaces of the spindle and the chuck before mounting.

2. Close the chuck using the CHUCK CLOSE switch.

3. Mount chuck adaptor (2) on the spindle.

4. Mount draw bar joint (1) on the sleeve.

5. To adjust the chucking cylinder stroke, turn the stroke adjustment nut.

6. 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. Part name

1 Draw bar joint

2 Chuck adaptor

3 Bolt

4 Chuck

5 Bolt

6 Round nut

7 Nut

8 Set screw

9 Jaw

10 T nut

11 Bolt

2


Chapter 2 Mounting of Collet Chuck

(φφφφφ26 through)

1. Clean all the mating surfaces of the spindle and the collet chuck before mounting.


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 adjust-

ment 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. Part name

1 Collet flange

2 Detent pin

3 Bolt M10 x 90

4 ColletStroke adjustable cylinder specification

Standard collet (φ26 through)

3


(φφφφφ35/φφφφφ42 through)

1. Clean all the mating surfaces of the spindle and the collet chuck before mounting.


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 adjust-

ment 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. Part name

1 Draw bar joint

2 Collet flange

3 Detent pin

4 Bolt

5 ColletStroke adjustable cylinder specification

Standard collet (φ35/φ42 through)

4


Collet adjust nut

Back nut

Stop pin

Stroke adjust nutSleeve

2A-850 collet flange

850 collet

Round nut

Joint

Chuck flangeHydraulic chuck

Adjust nut clamp bolt

[Dimensional mounting drawing]

Most retractedposition for collect

Most advanced positionfor power chuck

2A-850 collet flange850 collet

[Reference drawing]

The following figure shows the hydraulic chuck/collet mounting state on the machine.

[Collet mounting drawing]

[Hydraulic chuck mounting drawing]

Chapter 1 Specifications

1-1 Major Specifications ................................................... 1

1-2 Stroke Drawing ........................................................... 1

Chapter 2 Operation

2-1 Operation Panel ........................................................... 2

2-2 Programming ............................................................... 3

2-2-1 M Codes ............................................................. 3

2-2-2 Command System .............................................. 3

Chapter 3 Maintenance

3-1 Adjustment of Tailstock Pressure ............................... 4

3-2 Adjustment of Tailstock Unit's Position ..................... 5

3-3 Replacement of Wipers ............................................... 6

3-4 Alignment if Tail Spindle ........................................... 7

Tailstock Unit (Manual Type)

1


Chapter 1 Specifications

Manual type tailstock unit is optionally available in order to cope with shaft workpieces.

1-1 Major Specifications

Slide stroke mm 170

Quill stroke mm 80

Tapered bore size MT 3

Quill O.D. mm 56

Max. thrust kN 3.5

1-2 Stroke Drawing

(Z-axis slide)

X-a

xis

slid

e(t

ails

tock

spe

cific

atio

ns)

Matsumoto

Tail quill stroke Tailstock slide stroke

Nikko

2


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

TAILFOR.

(1) (2)

(1) Tail quill forward switch Pressing this switch moves the tail quill forward.

(A lamp of the switch will turn on.)

(2) Tail quill backward switch Pressing this switch moves the tail quill backward.

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.

TAILBACK

CAUTION

LUB. ALARM

SEQ. ALARM

TURRET ALM.

COUNT UP

SPI-NDLEFOR.

+ X

- Z + Z

- X

RAPID

EDIT AUTO MDI HANDLE JOGZERORE-

TURN

M01 SINGLEBLOCK

DRYRUN

／CODE

PRO-GRAMCHECK

HANDLEXZ

AXISSELECT

×10×1

CYCLEEND

F0

100%

RAPIDOVERRIDE AIR 1

AIR 2

COO-LANT 1

100%F0

CHUCKCLOSE

CYCLESTART

FEEDHOLD

×10

×1

SPI-NDLESTOP

SPI-NDLEREV.

COO-LANT 2

TAILFOR.

TAILBACK

3


2-2 Programming

2-2-1 M Codes

M16 Tail quill forward

M17 Tail quill backward

2-2-2 Command System

M16; (Tail quill forward)

Machining program

M17; (Tail quill backward)

G28 X0 Z0; (Zero point return)

* Not available when mounting/dismounting a workpiece manually.

See For details, refer to the separately provided Programming Manual.

4


Chapter 3 Maintenance

3-1 Adjustment of Tailstock Pressure


[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.

CAUTION Do not set the tailstock pressure to 2.0 MPa or more.

Tailstock pressure adjust knob

Tailstock pressure gauge


5


3-2 Adjustment of Tailstock Unit’s Position






maintenance. Turn the main power switch off and lock when it

is needed to work inside the cover.

WARNING

DANGER



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

2. Turn the main power switch off and lock.


4. Loosen two clamping bolts.

5. Move the main unit of tailstock to a designated position.

6. Tighten the two clamping bolts securely.


* To remove the tail center, tap the push rod by a hammer.

Right side cover

Clamping bolt

Push rod

Clamping bolt


6


3-3 Replacement of Wipers






maintenance. Turn the power switch off and lock when it is


DANGER

WARNING

• Inspection (replacement) interval Semiannually


1. Turn the main power switch off and lock.

2. Open the front door of the machine.


4. Remove wipers from the machine.

5. Mount new wipers instead.

6. Close the front door tightly.


Right side cover

Wipers (C)2323118006

Wipers

24330199003

Wipers

24330199003 Wipers (C)2323118006


7


3-4 Alignment if Tail Spindle






maintenance. Turn the power switch off and lock when it is


DANGER

WARNING

• Inspection (adjustment) interval Yearly

[Required tools] Test piece

Indicator (with magnet stand)


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

Tailstock

Chuck

Large Small

Takamaz X-10i E F21iTB 002a

Documents

Transcript of Takamaz X-10i E F21iTB 002a