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Introduction
Thank you for purchasing a Takamatsu CNC Precision Lathe. This machine is designed
and manufactured giving first priority to safety precautions according to nationally 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.
Chapter 1 Basic Conditions for Safe Operation
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.
Chapter 1 Basic Conditions for Safe Operation
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
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.
Chapter 2 Preparation for Safe Operation
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.
Chapter 2 Preparation for Safe 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
* The figure shows the machine equipped with Σ loader.
7
Chapter 4 Warning Labels
Fig. 3
Never remove or relocate warning labels.WARNING
Chapter 4 Warning Labels
The machine is equipped with warning labels for safe and correct operation. Read and
understand the cautions printed on the warning labels before starting operation.
If any of the labels become damaged and illegible, contact your local distributor for
replacement.
* The figure shows the machine equipped with Σ loader.
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
Chapter 4 Warning Labels
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
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.
* The figure shows the machine equipped with Σ loader.
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)
Chapter 5 Safety Devices
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
Chapter 6 Hazardous Area
6-1 Machine Movable Area
It is very hazardous inside the machine during automatic operation because of high-speed
spindle (chuck) rotation, X/Z-axis movements and turret rotation. Besides, chips and
coolant splash in a hot and humid space.
Chip discharge port is hazardous.
Inside the front door is hazardous.
* The figure shows the machine equipped with Σ loader.
12
6-2 High-voltage Area
Chapter 6 Hazardous 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
* The figure shows the machine equipped with Σ loader.
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
Chapter 8 Safety Precautions
8-1 Basics
High-voltage mark
EMERGENCYSTOP
EMERGENCYSTOP
15
DANGER
Chapter 8 Safety Precautions
• 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
Chapter 8 Safety Precautions
• 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
Chapter 8 Safety Precautions
• 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
Chapter 8 Safety Precautions
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
Chapter 8 Safety Precautions
• 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
Chapter 8 Safety Precautions
• 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.
Chapter 8 Safety Precautions
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.
Chapter 8 Safety Precautions
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
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
Chapter 1 Machine Appearance
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
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
Chapter 2 Machine Specifications
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
Chapter 3 Controller Specifications
3-1 Standard Specifications
6
Chapter 3 Controller Specifications
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
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
Chapter 4 Major Units
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
Chapter 4 Major Units
Collet chuck
Power chuck
M10, depth 20
ZA5-6-0-05 (Matsumoto)
10
Chapter 4 Major Units
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
5.5 kW 30 min. 50% ED area
3.7 kW cont. area
5.5 kW cont. area
7.5 kW 30 min. 50% ED 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
5.5 kW 30 min. 50% ED area
3.7 kW cont. areaOutput
kW
5.5 kW 30 min. 50% ED area
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
Chapter 4 Major Units
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
Standard specification
Tailstock specification
Standard specification
Tailstock specification
Chapter 4 Major Units
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
Chapter 4 Major Units
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
types and quantities of parts to be replaced, and place an order with Takamatsu.
4-4-1 Assembly Drawing of Hydraulic Pump Unit
Chapter 4 Major Units
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
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-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
21 Pressure gauge (with glycerine) ATR 1/4 × 60 × 5 MPa Asahi Keiki
22 Flow regulator HT-720-03 Hirose
Spindle chuck
Turret clamp
Tailstock
Optional
Chapter 4 Major Units
16
4-4-3 Arrangement of Valves
Fig. 12 Valve layout drawing
Turret clamp valve
Chapter 4 Major Units
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
types and quantities of parts to be replaced, and place an order with Takamatsu.
4-5-1 Lubrication System Diagram
Chapter 4 Major Units
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
Chapter 4 Major Units
4-6 Coolant Unit
This unit is used for cooling and washing workpieces and cutting tools as well as removing
chips during cutting. Priming the pump is not required because an immersion type pump
is used.
Tank capacity : 95 lit.
Discharge : 30~40 lit./min.
4-6-1 Coolant System Diagram
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)
* The figure shows the machine equipped with Σ loader.
*Type and location of the air unit may differ depending on the specifications.
Fig. 15 Air unit
Chapter 4 Major Units
20
Chapter 5 Electrical Drawings
Chapter 5 Electrical Drawings
5-1 Connection Diagram
Fig. 16 Connection diagram
21
Chapter 5 Electrical Drawings
5-2 Electric Circuit Diagrams
Electric circuit diagram 1
Fig. 17 Electric circuit diagram 1
22
Electric circuit diagram 2
Fig. 18 Electric circuit diagram 2
Chapter 5 Electrical Drawings
23
Electric circuit diagram 3
Fig. 19 Electric circuit diagram 3
Chapter 5 Electrical Drawings
24
Electric circuit diagram 4
Fig. 20 Electric circuit diagram 4
Chapter 5 Electrical Drawings
25
Electric circuit diagram 5
Fig. 21 Electric circuit diagram 5
Chapter 5 Electrical Drawings
26
Electric circuit diagram 6
Fig. 22 Electric circuit diagram 6
Chapter 5 Electrical Drawings
27
Electric circuit diagram 7
Fig. 23 Electric circuit diagram 7
Chapter 5 Electrical Drawings
28
Electric circuit diagram 8
Fig. 24 Electric circuit diagram 8
Chapter 5 Electrical Drawings
29
Electric circuit diagram 9
Fig. 25 Electric circuit diagram 9
Chapter 5 Electrical Drawings
30
Electric circuit diagram 10
Fig. 26 Electric circuit diagram 10
Chapter 5 Electrical Drawings
31
Electric circuit diagram 11
Fig. 27 Electric circuit diagram 11
Chapter 5 Electrical Drawings
32
Electric circuit diagram 12
Fig. 28 Electric circuit diagram 12
Chapter 5 Electrical Drawings
33
Electric circuit diagram 13
Fig. 29 Electric circuit diagram 13
Chapter 5 Electrical Drawings
34
Electric circuit diagram 14
Fig. 30 Electric circuit diagram 14
Chapter 5 Electrical Drawings
35
Electric circuit diagram 15
Fig. 31 Electric circuit diagram 15
Chapter 5 Electrical Drawings
36
5-3 Parts Arrangement in Electric Box
Chapter 5 Electrical Drawings
37
5-4 Electric Parts List
* Specifications are subject to change according to the improvement of the machine. Check the
types and quantities of parts to be replaced, and place an order with Takamatsu.
(standard)No. 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
Chapter 5 Electrical Drawings
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
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Chapter 5 Electrical Drawings
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
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
Chapter 1 Safety Precautions for Installation
• 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
Chapter 2 Preparation for Installation
Fig. 1
Chapter 2 Preparation for Installation
2-1 Environment
To ensure machine accuracy and efficiency, check the following items before installation.
• Avoid direct sunlight or heat source which will cause a partial temperature rise.
• Ambient temperature: 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
Chapter 2 Preparation for Installation
2-3 Air Source
Use clean and dry compressed air.
When the air source is shared with other facilities, care should be exercised so that the
pressure does not become low.
Pressure: 0.5 MPa
Discharge amount: 5.82 NL/time
2-4 Electrical Wiring
Prepare the primary power and cables as described below on your side.
• Supply voltage
Within 200/220 V ± 10%, 3-phase, within 50/60 Hz ± 2 Hz
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
Chapter 2 Preparation for Installation
2-5 Installation Space
Installation space should comply with the following:
• There is enough room to open/close the doors.
• There is enough room to supply oil and discharge chips.
• Workpieces can be mounted/removed without hindrance.
Fig. 2
* Required installation space may change slightly according to optional accesso-
ries and/or a destination of the machine.
6
Chapter 3 Transportation
Chapter 3 Transportation
The standard machine weighs about 2,200 kg. Use transportation equipment which is rigid
enough to withstand the machine weight.
DANGER • Crane and fork lift operation and slinging work should be
done only by qualified personnel.
• Never put your body partially or wholly under the lifted
machine.
• 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.
Chapter 3 Transportation
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.
Chapter 5 Power Connection
10
Chapter 5 Power Connection
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
* The figure shows the machine equipped with Σ loader.
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
* The figure shows the machine equipped with Σ loader.
* 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
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
* The figure shows the machine equipped with Σ loader.
Chapter 1 Outline of Machine
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
Chapter 1 Outline of Machine
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
Chapter 1 Outline of Machine
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
Chapter 1 Outline of Machine
• 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
Chapter 1 Outline of Machine
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
Chapter 1 Outline of Machine
(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
Chapter 1 Outline of Machine
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.
Tool path 1 to 4 is assumed as one
cycle. Movement stops after 4 is
finished.
Tool path 1 to 4 is assumed as one
cycle. Movement stops after 4 is
finished.
Tool path 1 to 7 is assumed as one
cycle. Movement stops after 7 is
finished.
G90
G92
G94
G70
G73
Tool path 1 to 6 is assumed as one
cycle. Movement stops after 6 is
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.
Tool path 1 to 10 is assumed as one
cycle. Movement stops after 10 is
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.
Tool path 1 to 4 is assumed as one
cycle. Movement stops after 4 is
finished.
9
Chapter 1 Outline of Machine
(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
Chapter 1 Outline of Machine
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
Chapter 1 Outline of Machine
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
Chapter 1 Outline of Machine
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
Chapter 1 Outline of Machine
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
Chapter 1 Outline of Machine
14
1-2-2 CNC Operation Panel
Fig. 3
* The figure shows the machine equipped with Σ loader.
15
Chapter 1 Outline of Machine
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
Chapter 1 Outline of Machine
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
Chapter 1 Outline of Machine
(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
Chapter 1 Outline of Machine
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
Chapter 2 Preparation for Operation
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.
* The figure shows the machine equipped with Σ loader.
20
2-2 Turning Power ON
Chapter 2 Preparation for Operation
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.
Chapter 2 Preparation for Operation
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)
* The figure shows the machine equipped with Σ loader.
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
NC screen• must not indicate any alarm message.
Machine operation panel• must not have any illuminating alarm lamps.• The cycle end signal light is turned on.• All machine motions are completely stopped.
* The figure shows the machine equipped with Σ loader.
Chapter 2 Preparation for Operation
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.
Chapter 2 Preparation for Operation
24
2-6 Check-ups after Turning Power OFF
After turning the power off, check the following items.
Chapter 2 Preparation for Operation
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
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.
Chapter 3 Manual Operation
EDIT AUTO MDI HAN-DLE
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.
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
1. Press “JOG” of the mode selector switch.
• The lamp in the switch will light up.
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
Chapter 3 Manual Operation
+ X
- Z + ZRAPID
- X
28
3-2-2 Rapid Traverse
1. Press “JOG” of the mode selector switch.
• The lamp in the switch will light up.
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.
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
F0
100%
RAPIDOVERRIDE
100%F0
+ X
- Z + ZRAPID
- X
Chapter 3 Manual Operation
29
3-2-3 Handle Feed
1. Press “HANDLE” of the mode selector switch.
• The lamp in the switch will light up.
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.
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
AXISSELECT
HANDLE
Chapter 3 Manual Operation
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.
EDIT AUTO MDI HAN-DLE
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
Chapter 3 Manual Operation
31
Chapter 3 Manual Operation
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
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
or
CHUCK
CLOSE
Chapter 3 Manual Operation
33
Chapter 3 Manual Operation
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
Chapter 3 Manual Operation
35
Chapter 4 MDI Operation
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
* The figure shows the machine equipped with Σ loader.
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.
Chapter 4 MDI Operation
EDIT AUTO MDI HAN-DLE
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.
FANUC OPERATOR’S MANUAL for details
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)
Chapter 4 MDI Operation
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
Chapter 4 MDI Operation
39
4-3 Turret Indexing (continued from step 2 in 4-1-2)
Chapter 4 MDI Operation
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
“5-7 Program Editing” when a wrong data has been input
1. Press the address/numerical keys [T], [0], [*], [0]
and [0] is sequence.
* Tool number to be indexed
2. Press the EOB key.
3. Press the INSERT key.
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
>_MDI **** *** ***[ PRGRM ] [ MDI ] [ CURRNT ] [ NEXT ] [ (OPRT) ]
4. Press the START button.
• 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.
2. Press the INSERT key.
INSERT
Fig. 17
“5-7 Program Editing” when a wrong data has been input
+ X
- X
+ Z
- Z
Chapter 4 MDI Operation
41
7. Press the EOB key.
8. Press the START button.
• 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.
6. Press the INSERT key.
START
O0020 N0020PROGRAM (MDI)O0000%
G00 G69 G21 G25 G80 G54G97 G99 G40 G22 G67 G18
MTF S
>_MDI **** *** ***[ PRGRM ] [ MDI ] [ CURRNT ] [ NEXT ] [ (OPRT) ]
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 4 MDI Operation
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.
Failure to observe this warning will result in critical bodily
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
Chapter 5 Automatic Operation
In automatic operation, the machine is operated according to the program.
It is very hazardous inside the machine during automatic operation because of high-speed
spindle (chuck) rotation, X-/Z-axis movements, and turret rotation. Besides, chips and
coolant splash in a hot and humid space.
Inside the front door is a hazardous area.
* The figure shows the machine equipped with Σ loader.
43
Chapter 5 Automatic Operation
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
Chapter 5 Automatic Operation
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.
• The lamp in the switch will light up.
(2) Press the PROG key.
(3) Press the RESET key.
• The cursor moves to the top of the program.
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
PROG
RESET
“5-7-2 Calling a Program”
+ X
- Z + ZRAPID
- X
45
Chapter 5 Automatic Operation
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
3. Press “AUTO” of the mode selector switch.
• The lamp in the switch will light up.
CHUCKCLOSE
4. Close the chuck, by stepping on the foot switch.
• The CHUCK CLOSE lamp will light up.
Chapter 5 Automatic Operation
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
Chapter 5 Automatic Operation
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.
Chapter 5 Automatic Operation
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%.
5. Press the START button.
• The CYCLE START lamp will light up.
* The program is executed only by one block each
time the START button is pressed.
START
RAPID
OVERRIDE
100%
F0
100%F0
SINGLEBLOCK
49
Chapter 5 Automatic Operation
5-3 Trial Cutting
If the program check (2) results in success, conduct a trial cutting next. The trial cutting
can be done in the following procedures.
WARNING• Be sure to close the front door tightly and never open any
cover or door during automatic operation.• Noise during cutting may exceed 70 dB, resulting in 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
Chapter 5 Automatic Operation
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
Chapter 5 Automatic Operation
5-5 Manual Operation during Automatic Operation
When performing manual operation during automatic operation, follow the procedures
below.
1. Press the FEED HOLD button or set the SINGLE
BLOCK switch to ON.
• Automatic operation will stop temporarily.
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.
5. Press “AUTO” of the mode selector switch.
• The lamp in the switch will light up.
6. Press the START button.
• Automatic operation will restart.
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
START
POS
[ ABS ] [ REL ] [ ALL ] [ ] [ (OPRT) ]
SINGLEBLOCK
Chapter 5 Automatic Operation
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.
• The lamp in the switch will light up.
• Automatic operation will stop temporarily.
2. Press “MDI” of the mode selector switch.
• The lamp in the switch will light up.
3. Perform MDI operation.
“Chapter 4 MDI Operation”
4. Press “AUTO” of the mode selector switch.
• The lamp in the switch will light up.
5. Press the START button.
• Automatic operation will restart.
*MDI operation is not available in feed hold status.
START
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
SINGLEBLOCK
53
Chapter 5 Automatic Operation
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
FANUC OPERATOR’S MANUAL for details
Chapter 5 Automatic Operation
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.
• The lamp in the switch will light up.
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.
6. Press the INSERT key.
7. Press the EOB key.
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
PROGRAMEDITOFF
ON
PROG
O P
INSERT
EOBE
55
Chapter 5 Automatic Operation
8. Press the INSERT key.
9. Input only a word of program using the data input
keys.
Ex.) N1
10. Press the INSERT key.
11. Repeat steps 9 and 10 to input a block of the
program.
Ex.) N1 G00 S500 M03
12. Press the EOB key.
Ex.) N1 G00 S500 M03;
13. Press the INSERT key.
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
Chapter 5 Automatic Operation
56
5-7-2 Calling a Program
Calling a program can be done in the following procedures.
1. Press “EDIT” of the mode selector switch.
• The lamp in the switch will light up.
2. Press the PROG key.
• The program screen will appear.
3. Press the key [O].
4. Input the program number to be called using the
data input keys.
5. Press the [O SRH] soft key.
* [O SRH] is displayed by pressing the [(OPRT)] soft
key.
PROG
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
PROGRAM O0040 N0012
ADRS. S OT
EDIT
[ PRGRM ] [ CHECK ] [ CURRENT ] [ NEXT ] [ (OPRT) ]
O P
57
Chapter 5 Automatic Operation
5-7-3 Displaying a Program Library
Follow the procedures below when displaying all the program numbers registered in the
memory.
1. Press “EDIT” of the mode selector switch.
• The lamp in the switch will light up.
2. Press the PROG key.
• The program screen will appear.
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)
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
PROG
*Program names can be displayed by the setting at
parameter NAM (No. 3107#0).
Chapter 5 Automatic Operation
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.
1. Press “EDIT” of the mode selector switch.
• The lamp in the switch will light up.EDIT AUTO MDI HAN-
DLEJOG
ZERORE-TURN
2. Turn the PROGRAM EDIT switch to “ON”.
3. Press the PROG key.
4. Press the key [O].
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
Chapter 5 Automatic Operation
5-7-5 Searching
Searching a work or sequence number can be done in the following procedures.
Procedures for calling the program to be edited are omitted in this section.
“5-7-2 Calling a Program”
Example 1 Searching for the sequence No. “N2” from the top of the program
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”.
Chapter 5 Automatic Operation
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
Chapter 5 Automatic Operation
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.
Procedures for calling the program to be edited are omitted in this section.
“5-7-2 Calling a Program”
Example 1 Deleting a word
DELETE
DELETE
1. Search for the word to be deleted.
“5-7-5 Searching”
2. Press the DELETE key.
Chapter 5 Automatic Operation
62
Example 2 Deleting a block
1. Search for the word heading the block to be
deleted.
“5-7-5 Searching”
2. Press the EOB key.
3. Press the DELETE key.
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
Chapter 5 Automatic Operation
5-7-7 Inserting a Word
Follow the procedures below when inserting a word.
Procedures for calling the program to be edited are omitted in this section.
“5-7-2 Calling a Program”
1. Search for the word immediately before the
insertion location.
“5-7-5 Searching”
2. Input the word to be inserted using the data input
keys.
3. Press the INSERT key.
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*
Chapter 5 Automatic Operation
64
5-7-8 Altering a Word
Follow the procedures below when altering a word.
Procedures for calling the program to be edited are omitted in this section.
“5-7-2 Calling a Program”
1. Search for the word to be altered.
“5-7-5 Searching”
2. Input the required word using the data input keys.
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.
Chapter 6 Setting Up
In order to operate the machine in automatic operation, cutting tools and the chuck must be
mounted correctly and the tool offset should be done properly.
6-1 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.
Chapter 6 Setting Up
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:
Tailstock specification
OD nozzle
67
Chapter 6 Setting Up
6-2 Tool Offset
The start point of each cutting tool should be the machine zero point whenever automatic
operation is started.
It is impossible to set all tools equally in length. Accordingly, a distance to the program
zero point from the tool nose located at the machine zero point needs to be input into the
machine. Measure the distance and input it on the tool offset screen in the following
procedures.
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
Chapter 6 Setting Up
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
Chapter 6 Setting Up
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
Chapter 6 Setting Up
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
Chapter 6 Setting Up
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)
Then, press the [MEASUR] soft key.
3) In the case that the end face has been cut exces-
sively by 0.5 mm, input as follows:
Z Y 0*
•/
5 ]
Then, press the [MEASUR] soft key.
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*
— +
Chapter 6 Setting Up
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.
1. Press the OFFSET SETTING key.
2. Press the [OFFSET] soft key and then [WEAR] soft
key.
• Display the OFFSET/WEAR screen.
73
Chapter 6 Setting Up
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.
Failure to observe this warning will result in critical bodily
injuries.
The cover must not be opened by unqualified personnel for
maintenance. Be sure to turn the main power switch OFF
when it is needed to work inside the cover.
WARNING
Chapter 6 Setting Up
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
Chapter 6 Setting Up
6-5 Mounting of Collet Chuck
Follow the procedures below when mounting a collet chuck for the spindle.
When carrying out maintenance work, put a panel or a plate
indicating “MAINTENANCE - KEEP AWAY FROM THE
MACHINE.” around the machine so that the power is not
turned ON or the operation panel is not touched by mistake.
The cover must not be opened by unqualified personnel for
maintenance. Be sure to turn the main power switch OFF
when it is needed to work inside the cover.
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
Chapter 6 Setting Up
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
Chapter 6 Setting Up
6-6 Forming of Soft Jaws
In order to securely clamp or accurately cut workpieces, it is necessary to form soft jaws.
According to the cutting conditions, such as material, shape, size, chuck type, etc., there
are various methods to form soft jaws.
WARNING • Never touch the spindle directly nor indirectly while it is
rotating.
• Dull or unstable cutting tools will cause damage or 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
Chapter 6 Setting Up
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
Chapter 6 Setting Up
6-6-2 Forming of Soft Jaws in Manual Operation
WARNING • Never touch the spindle directly nor indirectly while it is
rotating.
• Dull or unstable cutting tools will cause damage or 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”.
ACTUAL POSITION (RELATIVE)
O0001 N0000
U XXX.XXX
W XXX.XXX
Chapter 6 Setting Up
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”)
ACTUAL POSITION (RELATIVE)
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
Chapter 6 Setting Up
6-6-3 Forming of Soft Jaws in Automatic Operation
* Be sure to check the O.D. runout of the soft jaws. Form them to the desired workpiece diameter
after turning O.D. of the soft jaws. Because of a trivial unbalance, roundness in cutting may
deteriorate.
1. Return both the X and Z axes to their zero points.
* Check that Y axis zero point return is complete.
“3-1 Zero Point Return”
2. Move a cutting tool close to a soft jaw in manual feed.
3. Machine on the I.D. of soft jaw by using a manual pulse generator, and then perform a
tool offset.
Ex.) When the I.D. is 20.5 mm after cutting:
1) Display the OFFSET/GEOMETRY screen, and move the cursor to the offset number of
the cutting tool.
2) Press keys as follows.
Jaw
0*
•/ 5 ]
Then, press the [MEASUR] soft key.
Jaw
φ20.5
4. Apply the cutting tool tip onto the end face of soft jaw.
5. Press the and keys.
Then, press the [MEASUR] soft key.
“6-2 Tool Offset”
2#
XC
Chapter 6 Setting Up
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.
“6-2 Tool Offset”
Jaw
83
Chapter 6 Setting Up
10. Perform finish turning using the program below.
O1000;
G00 S500 M03 T0100;
X35.0 Z50.0 T0101;
Z2.0;
G01 X30.0 Z-0.5 F0.1;
Z-20.0;
X19.0;
G00 Z50.0;
G28 U0 W0;
M30;
11. Perform recessing using a manual pulse generator.
Recessing tool
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
*M46 Spindle orientation (at 5th point) & lock
*M47 Spindle orientation (at 6th 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
(with sensor confirmation)
*M25 Tailstock (quill + base) retract
(with sensor confirmation)
*M26 Tailstock base advance
(with sensor confirmation)
*M27 Tailstock base retract
(with sensor confirmation)
*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
(with sensor confirmation)
*M79 Parts catcher retract
(with sensor confirmation)
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
4-3 Hydraulic Pump Unit ..................................................................................... 12
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 Hydraulic Pump Unit ..................................................................................... 58
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
Chapter 2 Daily Inspection
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
Chapter 2 Daily Inspection
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.
* The figure shows the machine equipped with Σ loader.
4
Unit Inspection Items Remarks
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.
Chapter 2 Daily Inspection
5
Fig. 2
Chapter 2 Daily Inspection
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.
* The figure shows the machine equipped with Σ loader.
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”
Unit Inspection Items Remarks
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
indicating “MAINTENANCE - KEEP AWAY FROM THE
MACHINE.” around the machine so that the power is not
turned on or the operation panel is not touched by mistake.
• Turn the main power switch off during maintenance work.
The primary power in the factory also should be off for
maintenance of the electric cabinet. Never open the door
for several minutes even after the power is turned off, as
remaining voltage could cause critical bodily injuries.
3-1 Weekly Inspection
Chapter 3 Periodical 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.
Unit Inspection Items Remarks
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.
Chapter 3 Periodical Inspection
3-3 Semiannual Inspection
Unit Inspection Items Remarks
“6-2-1”
8
Unit Inspection Items Remarks
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.
Unit Inspection Items Remarks
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”
Chapter 3 Periodical Inspection
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
* The figure shows the machine equipped with Σ loader.
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
* The figure shows the machine equipped with Σ loader.
12
Chapter 4 Oiling
4-3 Hydraulic Pump Unit
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
when it is needed to work inside the cover.
Fig. 5
• Inspection interval Daily
• 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)
1. Turn the main power switch off.
2. Place the can under the drain port.
3. Loosen the drain cock.
• The hydraulic oil will drain.
4. Tighten the drain cock.
5. Replenish the tank with hydraulic oil from the oil filler port.
Oil filler port
Drain
WARNING
* The figure shows the machine equipped with Σ loader.
13
Chapter 4 Oiling
4-4 Coolant Unit
• Inspection interval Daily
• Oiling interval As required
• Oil amount 95 lit. (Tank capacity)
[Required tools] Spanner [14]
Can (for waste oil)
1. Turn the main power switch off.
2. Drain the waste coolant into the can.
3. Replenish the tank with coolant.
Fig. 6
Drain Level gauge
* The figure shows the machine equipped with Σ loader.
When carrying out maintenance work, put a panel or a plate
indicating “MAINTENANCE - KEEP AWAY FROM THE
MACHINE.” around the machine so that the power is not
turned on or the operation panel is not touched by mistake.
Use non-flammable coolant. When using oil-based coolant
inevitably, strictly follow the instructions in “Safety 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
1. Turn the main power switch off.
2. Put grease into the grease nipples using a grease gun.
Fig. 7
Grease nipple
Chapter 4 Oiling
* The figure shows the machine equipped with Σ loader.
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
Chapter 5 Trouble Shooting
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.
Chapter 5 Trouble Shooting
“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.
* The figure shows the machine equipped with Σ loader.
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)
FANUC OPERATOR’S MANUAL for details
HELP
Chapter 5 Trouble Shooting
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
Chapter 5 Trouble Shooting
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
Chapter 5 Trouble Shooting
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
Chapter 5 Trouble Shooting
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”
Chapter 5 Trouble Shooting
22
Phenomenon Cause Remedy
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”
Chapter 5 Trouble Shooting
23
Phenomenon Cause Remedy
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
Chapter 5 Trouble Shooting
24
Check the piping.
Phenomenon Cause Remedy
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.
Chapter 5 Trouble Shooting
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:
1. Press “JOG” of the mode selector switch.
• The lamp in the switch will light up.
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.
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
Chapter 5 Trouble Shooting
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
Chapter 5 Trouble Shooting
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
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
2. Press “HANDLE” of the mode selector switch.
• The lamp in the switch will light up.
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
Chapter 5 Trouble Shooting
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
Chapter 5 Trouble Shooting
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) ]
Chapter 5 Trouble Shooting
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 ] [ ]
1. Press the SYSTEM key.
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
press the [NO. SRH] soft key.
* [NO. SRH] can be displayed by pressing the
[(OPRT)] soft key.
Status of input/output signals
Chapter 5 Trouble Shooting
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
Chapter 5 Trouble Shooting
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.
a) Press the page keys until the required screen is
displayed.
b) Key in the desired parameter number, and then
press the [NO. SRH] soft key.
Chapter 5 Trouble Shooting
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
2. Press the OFFSET SETTING key.
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
Chapter 5 Trouble Shooting
34
The FANUC Operator’s Manual for the status in the
CNC
6. Press the SYSTEM key.
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.
a) Press the page keys until the required screen is
displayed.
b) Key in the desired parameter number, and then
press the [NO. SRH] soft key.
* [NO. SRH] can be displayed by pressing the [(OPRT)]
soft key.
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.
Chapter 5 Trouble Shooting
35
9. Enter the desired value, and press the INPUT key (or
the [INPUT] soft key).
10. Press the OFFSET SETTING 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
Chapter 5 Trouble Shooting
36
Chapter 5 Trouble Shooting
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.
DANGERWhen carrying out maintenance work, put a panel or a plate
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.
The cover should not be opened by unqualified personnel for
maintenance. Turn the main power switch off when it is needed
to work inside the cover.
WARNING
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.
5. Press “JOG” or “HANDLE” of the mode selector
switch.
• The lamp in the switch will light up.
EMERGENCYSTOP
or
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
37
Chapter 5 Trouble Shooting
6. Move the axis of which zero point setting is required
20 mm or more in a single direction using jog or
handle operation.* When this is completed, zero point setting becomes
available. (After turning the power on)
7. Turn the power OFF and back it ON.
8. Press “JOG” or “HANDLE” of the mode selector
switch.
• The lamp in the switch will light up.
9. Move the slide to a safe area.
10. Press “ZERO RETURN” of the mode selector
switch.
• The lamp in the switch will light up.
11. Use the AXIS SELECT switch to select the axis that
you mounted the stopper on.
or
or
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
+ X
- Z + Z
- X
RAPID
EDIT AUTO MDI HAN-DLE
JOGZERORE-TURN
X Z
AXIS
SELECT
The machine may be damaged if you select the wrong axis.
38
Chapter 5 Trouble Shooting
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
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
[Required tools] Spanner [13]
Allen wrench [5]
1. Loosen the lock nut of the chuck valve (reducing valve).
2. Adjust the chuck pressure by turning the pressure adjust knob.
• Turning the knob clockwise increases the pressure.
• Turning the knob counter-clockwise decreases the pressure.
3. Tighten the lock nut firmly.
Fig. 9
WARNING
6-1-1 Adjustment of Chuck Pressure
Lock nutChuck pressure gauge
* The figure shows the machine equipped with Σ loader.
* 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
Chapter 6 Maintenance for Each Unit
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
Chapter 6 Maintenance for Each Unit
6-1-3 Adjustment of Belt
An excessive tension on the belt may reduce the life of the belt or bearings. Also, less
tension may cause abnormal noise or vibration, and the rated horse power cannot be trans-
mitted because the belt slips.
Fig. 10
• Inspection interval Every 6 months
<Adjustment procedures>
[Required tools] Allen wrenches [4], [6], [10]
Spanner [13]
Tension gauge (or spring balance)
1. Turn the main power switch off.
2. Remove the motor cover.* Carefully remove the cover as a pressure gauge is mounted on it.
3. Loosen four motor base mounting bolts.
4. Loosen the lock nuts.
5. Adjust the belt tension so that a flexibility of 10.0 mm can be obtained when a specified
load is applied to the belt.
• To increase the tension, turn the adjust bolt CW.
• To decrease the tension, turn the adjust bolt CCW and press down the belt from both
sides.
6. Re-tighten the four motor base mounting bolts securely.
7. Secure the lock nuts.
8. Re-mounting the motor cover.
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
Chapter 6 Maintenance for Each Unit
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
* The figure shows the machine equipped with Σ loader.
43
Chapter 6 Maintenance for Each Unit
6-1-4 Replacement of Belt
[Required tools] Allen wrenches [4], [6], [10]
Spanner [13]
Screwdriver and Phillips screwdriver
1. Turn the main power switch off.
2. Remove the motor cover.
3. Disconnect the drain hose and the HP hoses from the chucking cylinder.
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)
* The figure shows the machine
equipped with Σ loader.
44
Chapter 6 Maintenance for Each Unit
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
Chapter 6 Maintenance for Each Unit
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
1. Turn the main power switch off.
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
* The figure shows the machine
equipped with Σ loader.
46
Chapter 6 Maintenance for Each Unit
6-2 Slide Unit
DANGER When carrying out maintenance work, put a panel or a plate
indicating “MAINTENANCE - KEEP AWAY FROM THE
MACHINE.” around the machine so that the power is not
turned on or the operation panel is not touched by mistake.
The cover must not be opened by unqualified personnel for
maintenance. Turn the main power switch off when it is
needed to work inside the cover.
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
Chapter 6 Maintenance for Each Unit
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.
3. Turn the main power switch OFF.
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.
2. Turn the main power switch OFF.
3. Shift the Z-axis slide cover to the left.
4. Remove the broken wiper(s).
5. Mount new one(s).
6. Return the Z-axis slide cover to the original position.
Wipers
Wipers
48
Chapter 6 Maintenance for Each Unit
Z-axis right wipers (on the tailstock side)
1. Move the Z-axis slide about 160 mm away from the zero point in the minus direction.
2. Turn the main power switch OFF.
3. Dismount the top and right side covers from the machine.
4. Remove the broken wiper(s).
5. Mount new one(s).
6. Re-mount the top and right side covers on the machine.
Wipers
Fig. 18
49
Chapter 6 Maintenance for Each Unit
• 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
Chapter 6 Maintenance for Each Unit
2. Press “HANDLE” of the mode selector switch.
3. Select the handle magnification “X1” with the “x10/x1” switch.
4. Select the axis to measure a backlash with the AXIS SELECT switch.
5. Rotate the manual pulse generator in the minus direction by 20 pulses.
6. Rotate the manual pulse generator in the plus direction by the same amount (20 pulses)
as in step 5.
7. Read the indicator.
Backlash
“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
Chapter 6 Maintenance for Each Unit
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
Allen wrenches [4], [5]
X axis
1. Turn the main power switch OFF.
2. Open the machine front cover.
3. Remove the X-axis slide cover.
4. Remove wipers (1) and (2).
• Adjustment bolt "A" and gib will appear.
5. Turn adjust bolt "A" counter-clockwise to loosen it.
6. Remove wipers (3) and (4) from the rear of the machine.
• Adjustment bolt "B" and gib will appear.
7. Push the gib using a screwdriver.
8. Turn adjustment bolt "B" clockwise to hold the gib.
9. Turn adjustment bolt "A" clockwise from the machine front to hold the gib.
10. Re-mount wipers (1), (2), (3) and (4).
11. Re-mount the X-axis slide cover.
GibAdjustment
bolt "A"
Gib
Adjustment bolt "B"
Gib
Adjustment bolt
Fig. 22
52
Chapter 6 Maintenance for Each Unit
Z axis
1. Move the Z-axis slide about 100 mm away from the zero point in the minus direction.
2. Turn the main power switch OFF.
3. Remove the right side cover from the machine.
4. Remove wiper (1).
• Adjustment bolt "A" and gib will appear.
5. Turn the adjust bolt "A" counter-clockwise to loosen it.
6. Remove wiper (2).
Adjustment bolt "B" and gib will appear.
7. Push the gib using a screwdriver.
8. Turn adjustment bolt "B" clockwise to hold the gib.
9. Turn adjustment bolt "A" clockwise as well to hold the gib.
10. Re-mount wipers (1) and (2).
11. Re-mount the right side cover on the machine.
53
Chapter 6 Maintenance for Each Unit
Fig. 23
Gib
Gib adjust bolt
GibGib adjust bolt A
Gib
Gib adjust bolt B
Right side cover Remove the wiper.
* The figure shows the machine equipped with Σ loader.
54
Chapter 6 Maintenance for Each Unit
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
Chapter 6 Maintenance for Each Unit
7. Keep the indicator in place while moving the Z-axis slide in the +Z direction, and index
the turret by one station.
8. Move the Z-axis slide in the -Z direction until the indicator makes contact with the
holder mounting surface. Then, read the indicator.
9. Repeat steps 7 and 8, and measure at 8 stations.
10. Attach a boring holder to the holder mounting surface that showed an average reading.
* Clean the mounting surface before mounting a boring holder.
11. Move the X-axis slide until the hole center of the boring holder aligns with the spindle
center.
12. Bring the indicator into contact with the inside of the hole on the boring holder.
13. Turn the spindle by hand, and read the indicator.
14. Move the X-axis slide using the manual pulse generator until the indicator shows the
same value at “a” and “b”. Then, read the indicator at “c” and “d”.
* When the indicator reading is 25 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
CAUTION If any adjustment is required, contact Takamatsu.
56
Chapter 6 Maintenance for Each Unit
6-3-2 Adjustment of Turret Clamp Proximity Switch
When the turret clamp signal is not given even if the turret is indexed at normal position,
adjust the proximity switch used for checking the turret clamping.
[Required tools] Allen wrenches [4] [5]
Spanner [24]
Phillips screwdriver
1. Remove the right side cover from the machine.
2. Remove the relay box.
3. Loosen a lock nut of the proximity switch.
4. Adjust the position of the proximity switch so that the lamp will turn ON when the turret
is clamped (or unclamped)
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.
7. Re-mount the right side cover on the machine.
CAUTION
Turret clamp proximity switchDog
Fig. 26
57
Chapter 6 Maintenance for Each Unit
6-3-3Turret Zero Position Setting (for Mitsubishi Motor)
When the turret has been assembled or aligned, the following zero position setting for the
servo motor is required.
1. Set the TURRET ZERO SET switch to ON in the control box.
2. Turn the breaker ON. If "A.25" is indicated for the turret servo amplifier, turn the
breaker OFF and back it ON.
3. Turn the power ON. Check that the mode selector switches (EDIT, AUTO, MDI,
HANDLE, JOG, ZERO RETURN) are blinking.
4. Press the TURRET switch. The turret is unclamped.
5. Turn the turret by hand until station No. 1 is indexed.
6. Press the TURRET switch again.
• The turret is clamped.
When the turret is clamped, the mode selector switches come on. Five seconds later,
the switches start blinking again, and the TURRET ALM. lamp lights up.
7. Check the turret motion. Turn the power OFF.
8. Set the TURRET ZERO SET switch to OFF in the control box.
9. Turn the power ON again. Check that the turret can index correctly in manual and
automatic operation.
* If the turret cannot be clamped properly in step 6, press the RESET button, and try again from
step 4.
* This zero position setting must be made if the turret motion is awkward or if the servo amplifier
has been replaced.
* When the turret has bumped against anything during rotation or is slanted by an emergency stop,
turn the power OFF, and follow the above steps for resetting. In this case, the TURRET ALM.
lamp lights up when station No. 1 is indexed. Align the position referring to the TURRET ALM.
lamp.
58
Chapter 6 Maintenance for Each Unit
6-4 Hydraulic Pump Unit
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
1. Turn the main power switch off.
2. Remove the cap from the oil filler port by turning it with hand.
3. Pull the cap upward to draw the oil filler filter.
4. Wash the filter in wash oil.
5. Return the filter inside the tank, and secure the cap by turning it with hand.
Oil filler filter
* The figure shows the machine equipped with Σ loader.
* Specifications are subject to change according to the improvement of the machine. Check the
types and quantities of parts to be replaced, and place an order with Takamatsu.
59
Chapter 6 Maintenance for Each Unit
6-4-2 Cleaning of Strainer
Clean the strainer when replacing the hydraulic oil.
• Cleaning interval Yearly
[Required tools] Phillips screwdriver
1. Turn the main power switch off.
2. Remove tank cover mounting bolts (8 pcs).
3. Remove the cover from the tank.
4. Remove the strainer by turning it.
5. Wash the strainer in wash oil.
* Replace the strainer with a new one if it is too dirty.
6. Re-mount the strainer and return in the tank.
7. Re-mount the cover on the tank.
8. Tighten the cover mounting bolts (8 pcs) securely.
Fig. 28
Strainer
Tank cover
Tank cover mounting bolt
* The figure shows the machine equipped with Σ loader.
60
Chapter 6 Maintenance for Each Unit
6-4-3 Cleaning of Hydraulic Tank
Clean inside of the hydraulic tank when renewing the supply of hydraulic oil in it.
• Cleaning interval Yearly
[Required tools] Phillips screwdriver
Can (for waste oil)
1. Turn the main power switch off.
2. Put the can under the drain port.
3. Loosen the drain cock.
• Hydraulic oil will drain from the tank.
4. Remove the tank cover mounting bolts (8 pcs).
5. Remove the cover from the tank.
6. Clean inside of the hydraulic tank with wash oil.
* Clean the magnet separator too.
7. Re-mount the cover on the tank.
8. Tighten the tank cover mounting bolts (8 pcs).
9. Secure the drain cock.
10. Supply hydraulic oil from the oil filler port up to the upper limit of the oil level gauge.
Fig. 29
Tank cover
Magnet separator
Drain
Tank cover mounting bolt
* The figure shows the machine equipped with Σ loader.
61
Chapter 6 Maintenance for Each Unit
6-5 Lubricant Unit
6-5-1 Cleaning of Oil Filler Filter
• Cleaning interval Yearly
[Required tools] Phillips screwdriver
1. Turn the main power switch off.
2. Loosen two set screws.
3. Remove the lubricant tank.
• Slide both fittings located on the right and left sides of the tank and open them.
4. Push down three claws mounted on the back of oil filler filter.
5. Draw the filter out while holding it up.
6. Wash the filter in wash oil.
7. Re-mount the filter while pushing it down.
8. Re-mount the tank.
9. Tighten the two set screws.
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.
* Specifications are subject to change according to the improvement of the machine. Check the
types and quantities of parts to be replaced, and place an order with Takamatsu.
62
Chapter 6 Maintenance for Each Unit
6-5-2 Cleaning of Suction Filter
• Cleaning interval Yearly
[Required tools] Phillips screwdriver
1. Turn the main power switch off.
2. Loosen two set screws.
3. Remove the lubricant tank.
• Slide both fittings on the right and left sides of the tank and open them.
4. Remove the filter stopper.
5. Remove the suction filter by picking it up with finger.
6. Wash the suction filter in wash oil.
* Replace the suction filter with a new one if it is too dirty.
7. Re-mount the suction filter.
8. Re-mount the filter stopper.
9. Re-mount the tank.
10. Tighten the two set screws securely.
Suction filter
Filter stopper
Fig. 31
63
Chapter 6 Maintenance for Each Unit
6-5-3 Cleaning of Lubricant Tank
• Cleaning interval Yearly
[Required tools] Phillips screwdriver
Can (for waste oil)
1. Turn the main power switch off.
2. Loosen two set screws.
3. Remove the lubricant tank.
• Slide both fittings on the right and left sides of the tank and open them.
4. Drain lubricant into the can from the tank.
5. Clean inside the tank with wash oil.
6. Re-mount the tank.
7. Tighten the two set screws.
Fittings
①Set screw
Fitting
Fig. 32
③
②
Oil filler filter
Tank
Tank
64
Chapter 6 Maintenance for Each Unit
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
* Specifications are subject to change according to the improvement of the machine. Check the
types and quantities of parts to be replaced, and place an order with Takamatsu.
65
Chapter 6 Maintenance for Each Unit
3. While the lock button is held down, raise the case slightly and turn it 45° to the left (or
right) until the mark on the case is aligned with the mark on the body.
Body
Alignment mark
Case
4. Remove your thumb from the lock button. Lower the case slowly in a vertical direction.
• The case is disengaged.
O-ring
5. While pushing up the baffle, turn it 15° to the left.
• The baffle and the filter element are disengaged.
6. Attach a new filter element by hand.
7. Align the groove of the valve guide with the projection from the baffle. While pushing
up the baffle, turn it 15° to the right.
Valve guide
Element
Baffle
66
Chapter 6 Maintenance for Each Unit
8. Check that the O-ring on the case is clean. Align the mark on the case with the mark on
the body, and push the case in.* Operating the lock button is not necessary to attach the case.
9. Turn the case in the direction opposite to the direction for disengaging.
• You will feel a click. The arrow is hidden from view.
Alignment mark
10. Check that the case does not turn by trying to turn it slightly in both directions.* If the case turns, perform step 8 and after again.
67
Chapter 6 Maintenance for Each Unit
6-6-2 Replacement of Elements in Mist Separator and Micro Mist Separator
• Before replacing the element, make sure that the pressure is
released from the case.
• Replace the element within two years of use or by the time the
amount of pressure drop reaches 0.1 MPa. Failure to replace
the element within an appropriate period of time may damage
it.
• Replace the element with a new one. Do not wash and reuse
the old element.
• Use an element of the designated type. If any element of a
different type or of a different size is used, malfunction or
damage may occur.
• Replacement interval One year (approximately)
• Element type Check with Takamatsu.
1. Stop the air supply.
2. Hold the case slightly. Slide the lock button down with your thumb.
• An arrow comes into view.
Lock button
Arrow
3. While the lock button is held down, raise the case slightly and turn it 45° to the left (or
right) until the mark on the case is aligned with the mark on the body.
Body
Alignment mark
Case
68
Chapter 6 Maintenance for Each Unit
4. Remove your thumb from the lock button. Lower the case slowly in a vertical direction.
• The case is disengaged.
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
Chapter 6 Maintenance for Each Unit
6-6-3 Adjustment of Lubricator Oil Drop Amount
Drop oil amount from the lubricator (type: AL3000) can be adjusted by the adjustment knob.
Turn the adjustment knob clockwise to decrease the drop amount. To increase the amount,
turn it counter-clockwise.
Adjustment knob
Fig. 33
* The figure shows the machine equipped with Σ loader.
* Type and mounting position of the filter regulator differ depending on the specifications.
70
Chapter 6 Maintenance for Each Unit
6-6-4 Pressure Adjustment of Filter Regulator
The secondary pressure of the air unit is adjusted to 0.5 MPa before delivery.
When re-adjustment is required, follow the procedures below.
1. Pull the adjust handle up by hand to unlock it.
• An orange mark will appear.
2. Adjust the secondary pressure by turning the adjust handle.
• Turning the handle CW increases the pressure.
• Turning the handle CCW decreases the pressure.
3. Push the adjust handle down by hand to lock it.
• The orange mark will disappear.
Fig. 34
* The figure shows the machine equipped with Σ loader.
* Type and mounting position of the filter regulator differ depending on the specifications.
71
Chapter 6 Maintenance for Each Unit
6-7 Coolant Unit
6-7-1 Cleaning of Coolant Tank
• Cleaning interval Every 6 months
[Required tools] Can (for waste oil)
Spanner [14]
1. Turn the main power switch off.
2. Remove filters from the tank.
3. Drain waste coolant into the can.
4. Clean inside the tank.
5. Supply coolant up to the upper limit of the oil level gauge.
6. Re-mount the filters on the tank.
Fig. 35
Filters
Filters
Oil level gaugeDrain
* The figure shows the machine equipped with Σ loader.
* Type and mounting position of the filter regulator differ depending on the specifications.
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.
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
Chapter 6 Maintenance for Each Unit
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
1. Turn the main power switch off.
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
Chapter 6 Maintenance for Each Unit
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
* Specifications are subject to change according to the improvement of the machine. Check the
types and quantities of parts to be replaced, and place an order with Takamatsu.
74
Chapter 6 Maintenance for Each Unit
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.
* The figure shows the machine equipped with Σ loader.
Fig. 38
75
Chapter 6 Maintenance for Each Unit
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.
1. Turn the main power switch OFF.
2. Open the electric box door using the dedicated key.
3. Open the operation window.
4. Attach the battery to the battery holder.
5. Insert the battery connector into CON1 until a click is heard.
6. Close the operation window.
7. Close the electric box door.
See “6-3-3 Turret Zero Position Setting (for Mitsubishi Motor)”
CON1
Operation window
Battery Battery holder
Battery connector
76
Chapter 6 Maintenance for Each Unit
6-8-3 Replacement of Fuse
Be 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.
DANGER
Fuse for power supply module(A06B-6077-K250)
Fig. 40
1. Turn the main power switch off.
2. Shut off the primary power in the factory.
3. Open the electric cabinet’s door with the designated key.
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)
* Specifications are subject to change according to the improvement of the machine. Check the
types and quantities of parts to be replaced, and place an order with Takamatsu.
77
Chapter 6 Maintenance for Each Unit
DANGER
Reset button
6-8-4 Resetting of Thermal Relay
Be 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.
1. Turn the main power switch off.
2. Shut off the primary power in the factory.
3. Open the electric cabinet’s door with the designated key.
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
Chuck Clamp Detector
This is a safety device to check if a workpiece is securely clamped by the chuck.
When this device is installed, adjust it according to chuck open/close motions as described
below.
The device cannot be started unless the proximity switches (A) and (B) are effective.
When carrying out maintenance work, put a panel or a plate
indicating “MAINTENANCE - KEEP AWAY FROM THE MA-
CHINE” around the machine so that the power is not turned on
or the operation panel is not touched by mistake.
The cover should not be opened by unqualified personnel for
maintenance. Turn the main power switch off and lock when it
is needed to work inside the cover.
DANGER
WARNING
[Required tools]
Allen wrench [5]
Spanner [24]
Phillips screwdriver
1. Remove the chuck cover from the machine.
2. Adjust the proximity switch positions correctly.
3. Re-mount the chuck cover on the machine.
O.D. grip (clamping by pulling)
Adjust so that the proximity switch (A) becomes effective (lamp ON) when the chuck
closes to clamp a workpiece.
I.D. grip (clamping by pushing)
Adjust so that the proximity switch (B) becomes effective (lamp ON) when the chuck
opens to clamp a workpiece.
* Adjustment of the proximity switch itself can be done by loosing the lock nut and turning the
switch.
2
Chuck Clamp Detector
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
* The figure shows the machine equipped with Σ loader.
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
Mounting of Chuck (Stroke-Adjustable Cylinder)
Chapter 2 Mounting of Collet Chuck
(φφφφφ26 through)
1. Clean all the mating surfaces of the spindle and the collet chuck before mounting.
2. Close the chuck using the CHUCK CLOSE switch.
3. Loosen the bolt at the stroke, adjustment nut and adjust chucking cylinder stroke. Turn
the stroke adjustment nut until the distance between the cylinder and the stroke 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
Mounting of Chuck (Stroke-Adjustable Cylinder)
(φφφφφ35/φφφφφ42 through)
1. Clean all the mating surfaces of the spindle and the collet chuck before mounting.
2. Close the chuck using the CHUCK CLOSE switch.
3. Loosen the bolt at the stroke, adjustment nut and adjust chucking cylinder stroke. Turn
the stroke adjustment nut until the distance between the cylinder and the stroke 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
Mounting of Chuck (Stroke-Adjustable Cylinder)
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
Tailstock Unit (Manual Type)
Chapter 1 Specifications
Manual type tailstock unit is optionally available in order to cope with shaft workpieces.
1-1 Major Specifications
Slide stroke 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
Tailstock Unit (Manual Type)
Chapter 2 Operation
See For detailed programming and M codes, refer to the separately provided Programming
Manual and “7-2 List of M Codes” in Operation respectively.
2-1 Operation Panel
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
Tailstock Unit (Manual Type)
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
Tailstock Unit (Manual Type)
Chapter 3 Maintenance
3-1 Adjustment of Tailstock Pressure
• Adjustment interval As required
[Required tools] Allen wench [5]
1. Adjust the tailstock pressure by turning the pressure adjust knob.
• Turning the knob CW increases the pressure.
• Turning the knob CCW decreases the pressure.
CAUTION Do not set the tailstock pressure to 2.0 MPa or more.
Tailstock pressure adjust knob
Tailstock pressure gauge
* The figure shows the machine equipped with Σ loader.
5
Tailstock Unit (Manual Type)
3-2 Adjustment of Tailstock Unit’s Position
When carrying out maintenance work, put a panel or a plate
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.
The cover should not be opened by unqualified personnel for
maintenance. Turn the main power switch off and lock when it
is needed to work inside the cover.
WARNING
DANGER
• Adjustment interval As required
[Required tools] Spanner [36]
1. Return both the X and Z axes to respective zero points.
2. Turn the main power switch off and lock.
3. Remove the right side cover from the machine.
4. Loosen two clamping bolts.
5. Move the main unit of tailstock to a designated position.
6. Tighten the two clamping bolts securely.
7. Re-mount the right side cover on the machine.
* To remove the tail center, tap the push rod by a hammer.
Right side cover
Clamping bolt
Push rod
Clamping bolt
* The figure shows the machine equipped with Σ loader.
6
Tailstock Unit (Manual Type)
3-3 Replacement of Wipers
When carrying out maintenance work, put a panel or a plate
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.
The cover should not be opened by unqualified personnel for
maintenance. Turn the power switch off and lock when it is
needed to work inside the cover.
DANGER
WARNING
• Inspection (replacement) interval Semiannually
[Required tools] Phillips screwdriver
1. Turn the main power switch off and lock.
2. Open the front door of the machine.
3. Remove the right side cover from the machine.
4. Remove wipers from the machine.
5. Mount new wipers instead.
6. Close the front door tightly.
7. Re-mount the right side cover on the machine.
Right side cover
Wipers (C)2323118006
Wipers
24330199003
Wipers
24330199003 Wipers (C)2323118006
* The figure shows the machine equipped with Σ loader.
7
Tailstock Unit (Manual Type)
3-4 Alignment if Tail Spindle
When carrying out maintenance work, put a panel or a plate
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.
The cover should not be opened by unqualified personnel for
maintenance. Turn the power switch off and lock when it is
needed to work inside the cover.
DANGER
WARNING
• Inspection (adjustment) interval Yearly
[Required tools] Test piece
Indicator (with magnet stand)
Allen wrenches [6], [8]
Spanner [36]
1. Finish-cut a test piece.
2. Measure a cylindricity of the machined test piece.
* Adjustment is not required if a reading of indicator is below 0.007/150mm and tapers off.
CAUTION If any adjustment is required, contact Takamatsu.
150 mm
Tailstock
Chuck
Large Small