MAINTENANCE MANUAL

for

VTM-65
TURNING CENTER OH-FANUC-L (F-18T)

OKUMA & HOWA MACHINERY LTD.

6SK8-H024

Correct handling of the machine ensures safe and efficient operation. Carefully read through this manual before operating the machine.

This manual describes the correct operating and maintenance procedures to use the machine efficiently. Additionally, the manual describes preparations necessary for operators.

CAUTIONS AND SAFETY ALERT SAFETY OPERATION

The machine is equipped with such functions as described below for protecting the operator and the machine from being injured or damaged accidentally.
Door with window safe guard Door open/close interlock Chuck interlock Chuck and tailstock pedal protection cover X-/Z-stroke end limit switches
Soft limit function NC parameter

Machine main unit Machine main unit PMC software Machine main unit Machine main unit Optional

Chuck self-lock cylinder Machine main unit Optional Emergency stop button Operation panel

Feedhold button Operation panel

Emergency alarm lamp Operation panel Optional Earth leakage breaker

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CAUTIONS AND SAFETY ALERT

Optional Besides the above safety devices, operation should be strictly in con formity with instructions in this Manual in order to prevent accidents. Use this machine only after reading and understanding this manual fully. Interpret as impossible any features/operations which this manual does not describe as possible, and never attempt them. Read and understand this Manual carefully before starting operation. Functions and operations, if not stated in this Manual, should be basically considered "Don'ts".

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II

CAUTIONS AND SAFETY ALERT

The machine is equipped with the following warning labels (sign plates) containing signal words to indicate seriousness of warning, detailed warning messages, or pictographs to indicate details of seriousness. Signal words and pictographs used on the warning labels are as shown below. Strictly observe Dos and Donts as stated on the warning labels. Signal words: DANGER Failure to follow the instruction will result in critical bodily injuries or death. WARNING Failure to follow the instruction could result in serious bodily injuries or death. CAUTION Failure to follow the instruction may result in less serious bodily injuries or machine damages.

Pictographs: There is a possibility that the chuck jaws and a workpiece may flip up.

There is a possibility that your fingers or hands may be pinched by the chuck jaws and a workpiec e. There is a possibility that your body or hands may be caught by a machine moving section (doors, tool post, etc.).

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III

CAUTIONS AND SAFETY ALERT

There is a possibility that your body, either partially or wholly, may be caught by a rotating section (chuck, spindle drive pulley, etc.). There is a possibility of electric shock.

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IV

CAUTIONS AND SAFETY ALERT

WARNING LABELS

GROSS MAS WIRE ROPE D

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CAUTIONS AND SAFETY ALERT

[12] Warning lavel for ATC

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VI

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[6] Warning label for door (Only for the machine with automatic door) [5] Warning label for chuck jaw hazard [4] Warning label for spindle hazard [7] Warning label for moving part hazard [11] Warning label for lifting machine haz ar

[2] For spindle Operation

WARNING LABELS POSTING POSITIONS

CAUTIONS AND SAFETY ALERT

VII
[10] Machine number plate with manufacturers name [3] Warning label for workpiece spin-out hazard [9] Warning label for [8] Warning label for rotating part hazard

[1] General caution label

CAUTIONS AND SAFETY ALERT

CONTENTS

CHAPTER 1

MAINTENANCE AND INSPECTION ..................................1-1

1.1 Lubrication Unit ...........................................................................................................1-1 1.2 Hydraulic Oil................................................................................................................1-3 1.3 Coolant........................................................................................................................1-6

CHAPTER 2

CLEANING ......................................................................2-1

2.1 Slide Cover and Wiper................................................................................................2-1 2.2 Limit Switch................................................................................................................2-5

CHAPTER 3

ADJUSTMENT AND REPLACEMENT ...............................3-1

3.1 Pressure Units............................................................................................................3-1 3.2 Tapered Jib for Slideway ............................................................................................3-2 3.3 V-belt...........................................................................................................................3-4
3.3.1 Belt tension adjustment ......................................................................................... 3-5 3.3.2 Replacement of V-belt................................ ................................ ............................ 3-6

3.4 Leaf Chain...................................................................................................................3-7 3.5 CNC Memory Backup B attery .................................................................................. 3-10 3.6 Absolute Pulse Coder B attery .................................................................................. 3-11

CHAPTER 4 CHAPTER 5

PERIODICAL INSPECTION ..............................................4-1 SPARE PARTS LIST (AT ADDITIONAL COST).........................5-1

5.1 Mechanical Parts ........................................................................................................5-1 5.2 Hydraulic Unit/Pneumatic Unit....................................................................................5-4 5.3 Electrical Parts ...........................................................................................................5-5 5.4 Special Specifications ................................................................................................5-6

CHAPTER 6

APPENDIX.......................................................................6-1

CHAPTER 1

MAINTENANCE AND INSPECTION

Lubricant, hydraulic oil and coolant should be properly maintained according to the lubrication control chart (page 1-8) and list of lubricants (page 1-9). Proper lubrication is very important for extending the service life and maintaining the accuracy of the machine. Note: Before lubrication and replenishment, clean around the oil supply port in case dust is taken in. 1.1 Lubrication Unit Oil in the tank decreases gradually as the machine is used. It is necessary to add oil when the alarm buzzer sounds and a warning is displayed on the CRT display when the oil level drops below the specified level. Note: A special long-life grease is sealed in the headstock. Therefore, lubrication of the headstock is generally not needed. The application interval is controlled by the timer and set at approximately 15 minutes to forcibly lubricate the slideway, gear box, and leaf chain (for tool slide balancing) with the automatic intermittent lubrication pump. Maintenance item 1 2 3 4

Symbol

Inspection (hr.) Replenishment (hr.) Cleaning/replacement (hr.) Replenishment amount (lit.) Type of oil Remarks Add if necessary. 200

1000 4.3 (1.14 gal.) Mobil Vactra Oil No.2 (Mobil Oil) Add if low lubricant level alarm occurs. Check pressure (0.5 - 1.6 MPa) Replace suction filter.

1-1
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LUBRICATION UNIT Cleaning/replacement (hr.) Maintenance item

Oil

Maintenance content Replenishment of lubricant [4.3 lit. (1.1 gal.)] ?

200

Mobil Vactra oil No. 2 (Mobil Oil)

Mobil Vactra oil No. 2 (Mobil Oil)

Add if low lubricant level alarm occurs. (Remaining amount: 1.7 lit. (0.45 gal.)) Confirmation of oil level ? Add if oil level is low. Confirmation of pressure 0.5 - 1.6 0.1 MPa Replacement of suction filter Replace suction filter SFC/ZP-20 (Willy Hogel) with new one.

1000

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1-3
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1.2

Hydraulic Oil Hydraulic oil in the hydraulic unit should be replaced periodically. Add oil through the oil supply port while checking the oil level on the level gauge. A suction filter and a cartridge filter are provided to protect the pumps and hydraulic equipment. Since the performance of the suction filter cartridge deteriorates over time, clean or replace it every 3 months.

Maintenance item Symbol Inspection (hr.) Replenishment (hr.) Cleaning/replacement (hr.) Replenishment amount (lit.) Type of oil Remarks

8 1000

1000 60 (15.87 gal.) HM32 Check pressure (4.9 Mpa) Replace after Add if specified necessaty. time period. Replace suction filler.

1000

Replace cartridge filter.

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HYDRAULIC UNIT Cleaning/replacement(hr.) 8 Maintenance item 5 Oil Maintenance content Confirmation of pressure ? 4.9 MPa Replenishment of lubricant [60 lit. (15.87 gal.)] 1000 2 HM 32 or equivalent HM 32 or equivalent ? Replace oil after specified time period. Confirmation of oil level ? If oil level is below L, add oil.

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HYDRAULIC UNIT Cleaning/replacement (hr.) Maintenance item Oil Maintenance content Replacement of suction filter 1000 8 ? Replace suction filter (SFT-06-150W made by Taisei Kogyo) with new ones. Replacement of cartridge filter ? Replace cartridge filter 1000 9 (F-913-1 made by Taisei Kogyo) with new ones.

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1.3

Coolant A water soluble emulsion (emulsifier oil) is recommended. Using other types of water soluble coolant may cause the electrical insulation resistance to lower or non-iron metals (especially zinc) to rust. Therefore, careful consideration is needed when selecting the coolant. During the summer, a large amount of water will evaporate. Water should be added periodically to control the concentration of the coolant. When adding only water, always turn ON the coolant pump switch to agitate sufficiently.

Maintenance item

10

11

12

Symbol

Inspection (hr.) Replenishment (hr.) Cleaning/replacement (hr.) Replenishment amount (lit.)

50

50 400 (105.68 gal.) Clean if cutting chips clogged or Consult sales Add water or coolant have solidified. Replace if representative for depending on coolant wire netting is replacement period. density. damaged or its mesh is damaged.

Remarks

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COOLANT TANK Cleaning/replacement (hr.) Maintenance item Oil Maintenance content Confirmation of coolant level ? If coolant is not at H level while machine is not operating, add water or coolant according to coolant density. Cleaning or replacement of filter ? If the filter clogged with chips, clean the filter (once a week.) Replace if wire netting is damaged or its mesh is deformed.

50

11

Emulsion type

50

12

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Recommended Oil & Grease

No. 1 2 3

Part to be lubricated Lubrication unit Hydraulic unit Coolant tank

Name ESSO Shell Mobile oil Vactra Oil No. 2 Unipower SQ32 Tetora Oil 32 DTE 24

Remarks

Consult sales representative for appropriate coolant Emulsion-type since coolant differs depending on workpiece material coolant is and tool used for machining. recommended. Tetora Oil 68 Turbine Oil 32 DTE Oil Heavy medium

4 5

Lubrication unit (Special Unipower MP68 specification) Pneumatic unit Stanol 43N

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OH-9708-W-015 Part to be lubricated Number Symbol Control item Inspection (hr.) Replenishment (hr.) Cleaning/replacement (hr.) Change (hr.) Tank capacity [lit. (gal.)] Quantity [lit. (gal.)] Lubricant type 6 (1.58) 4.3 (1.13) No.1 No.2 200 1000 1000 60 (15.87) 1000 1000 8 8 8 8 1 Lubrication unit 2 3 4 5 6 Hydraulic unit 7 8 9

LUBRICATION CONTROL CHART

Coolant 10 11 12

50

Note 1: Supply oil while the machine is stopped. Note 2: Clean the lubricating parts befor e oiling. Note 3: Refer to the list of lubricants on the next page for lubricant types.

50 (1000) 400 (105.68)

1-9

No.3

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1-9

CHAPTER 2

CLEANING

2.1

Slide Cover and Wiper Slide seal and wiper are equipped on each slideway to prevent cutting chips from entering the machine. They should be removed every six months for periodical cleaning. If no coolant is going to be used, clean off all chips and apply lubricant before loading the workpiece. Disassembly procedure: First, remove all cutting chips adhering to the machine and clean the area around the machine. Then perform the following procedures. X-axis wiper: 1. 2. 3. 4. Start the machine by turning on the power to the NFB, and control unit, and by pressing the operation preparation button. Move the turret to the +X stroke end and to approx. 100 mm before the +Z stroke end. Turn off the power to the control unit and NFB in that order. Remove the cover on the left side of the tool slide.

Cover

Left side of tool slide

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5. 6. 7. 8.

Remove the wiper on the left side of the tool slide. Remove the slide cover on the right side of the tool slide. Remove the wiper on the right side of the tool slide. Remove cutting chips sticking to the wiper with compressed air and wipe it with cleaning oil. Apply lubricant to the wiper seals and reassemble it. Confirm that the slide cover moves smoothly and wiper works properly after reassembly.

9. 10.

Note: If the seal on the wiper is cracked or damaged, replace the wiper with a new one.
Wiper

Left side of tool slide

Slide cover

Wiper

Right side of tool slide

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Z-axis side cover: 1. 2. 3. 4. 5. 6. 7. Start the machine by turning on the power to the NFB, and control unit, and then pressing the operation preparation button. Move the tool slide to the farthest position away from the spindle on both the X- and Z-axes. Turn off the power to the control unit and NFB in that order. Remove the side cover under the tool slide. Remove cutting chips sticking to the slide cover with compressed air and wipe it with cleaning oil. Apply lubricant to the wiper seals and reassemble it.

Confirm that the slide cover moves smoothly and the wiper works properly after reassembly. Note: If the wiper seal is cracked or damaged, replace the wiper with a new one.

Slide cover

Under tool slide

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Z-axis wiper: 1. 2. 3. 4. 5. Use the same procedures 1 - 4 for the slide cover. Remove the wiper. Remove cutting chips sticking to the wiper with compressed air and wipe it with cleaning oil. Apply lubricant to the wiper seals and reassemble it. Confirm that the wiper moves smoothly and properly after reassembly.

Note: If the wiper seal is cracked or damaged, replace the wiper with a new one.

Wiper

Under tool slide

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2.2

Limit Switch Limit switches are installed to check the open/close status of the door or to confirm the X - and Z -axes overrun to maintain operational safety. Clean the limit switches every 6 months.

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CHAPTER 3

ADJUSTMENT AND REPLACEMENT

3.1

Pressure Units The gripping force of hydraulic chuck is adjusted by the reducing valves located at the lower right of the machine. Turning the knob clockwise will increase the pressure. Adjust the pressure to the required setting while checking it on the pressure gauge. When a pressure switch (speed specification) is provided to detect a chucking pressure drop, be sure to set the pressure switch, as well after adjustment of the reducing valve. Pressure adjustment range: Pressure reducing valve knob: 0.5 - 3.4 MPa Clockwise to increase pressure Counterclockwise to decrease pressure

Lower part of machine front panel

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3.2

Tapered Jib for Slideway The optimum gap is provided in the tapered jib on each slideway of the machine. However, the gap may increase over a long period of use. In that case, perform the following procedures to adjust the gap.

Adjustment method: There is a screw (dot marked) provided for tapered jib adjustment when the wiper is removed (Refer to chapter 2, Cleaning, 2.1, Slide Cover and Wiper for removal of wiper on each axis.)

Left side of tool slide

Front

Under tool slide

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1. Axis X Z

Tighten the screw 2 completely. Tightening torque 3.9 23.5 Applicable tools Ball driver Ball driver + flat ratchet (L = 120)

2.

Loosen the screw 2 until it comes into contact with the taper jib. Then turn the screw 2 back by the amount specified in the table on the previous page. Axes X Z Upper/Middle Lower Screw return angle 0 90 90

3.

Tighten screw 1 to secure the tapered jib.

4.

Move the turret using the AXIS FEED switch, while checking that the load monitor of the feed axis motor shows the following values on the screen. If the value is greatly different from the list, consider the return amount and make adjustment again. X-axis can be finely adjusted with the upper and lower tapered jibs on the left side of the R-spindle tool slide, shown in the figure on the previous page. Axis X Y Feed rate override (%) 100 200 100 200 Load value 50 35 70 (up), -30 (down) 50 (up), -15 (down)

Note:

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3.3

V-belt The spindle AC motor and spindle are connected by a V-belt. If the V-belt is loose or when replacing the V-belt, adjust the belt tension as shown below. Periodic adjustment of the V-belt tension will extend its service life. Note: V-belt wears out quickly if it slips during operation. Always check the belt tension before use. Belt type 14R-3V-1400 Number of belts 3 bundles 2 belts 4 bundles 2 belts X(tension) 16mm(0.63")

Specifications 20-2000min-1 AC 22/30kW

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3.3.1 1. 2. 3. 4. 5. 6. 7.

Belt tension adjustment Remove the pulley cover. Loosen the two adjustment bolts. Loosen the four tightening bolts. Push in the direction indicated by the arrow to slacken the belt. After the belt is loose, tighten the adjustment bolts until the slack is removed, and mark that position. Tighten the adjustment bolts further and secure them when the bolts have been tightened 16 mm (0.63") past the marked position. Lock the adjustment bolts and reattach the pulley cover.

Motor bracket Tightening bolts (4 bolts)

Adjustment bolts (2 bolts)

Spindle motor at the back of the machine

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3.3.2 1. 2.

Replacement of V-belt Perform steps 1 - 4 of item 3.3.1, Belt tension adjustment. Disconnect the hydraulic hoses (for chuck clamping and drain) and insert a hard ball and plug into the end of the hydraulic hose so that no oil flows out or air enters.

3. 4. 5. 6.

Replace the belt. Tighten the adjustment bolts (mentioned on the previous page) and mark the position where the slack disappears. Perform steps 6 and 7 of item 3.3.1 Belt tension adjustment. Reconnect the hydraulic hose.

V-belt Hydraulic hose (for chuck clamping)

Hydraulic hose (for drain)

Hydraulic cylinder at front of machine

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3.4

Leaf Chain The leaf chain elongates due to wearing of the pins and bushings. First, check the elongation of the chain. If the chain length is more than the permissible length, replace the leaf chain. (Refer to the table below.) Criteria for replacement of leaf chain 6-link chain 10-link chain 117.72 mm (4.63") 196.21 mm (7.72")

Permissible length

Measuring points

Note: Since the leaf chain is located above the column, watch your step when measuring. Make sure the NFB is turned off during measurement.

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Replacement methods Perform the following procedures when replacing the leaf chain. 1. 2. 3. 4. 5. 6. Remove the cover on the far right side of the machine. Turn on the power to the NFB, control unit and OPERATION PREPERATION BUTTON. Move the tool slide to right before the stroke end in the positive direction along the X-axis (farthest from the spindle). Move the tool slide along the Z -axis so that the position of the hole on the balance weight and the hole on the column are aligned. Secure the balance weight with the weight support bar (round bar) through the column. Move the tool slide at low speed and make sure the leaf chain which suspends the balance weight is not tightened. (We recommend placement of a wedge between the base and the tool slide for safety.)

Weight support bar insertion hole

Far right side of machine (R-spindle)

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7. 8. 9.

Turn off the power. (As soon as the power is turned off, the brake on the Z-axis motor activates.) Replace the old leaf chain with a new one. Install the new leaf chain in the reverse order of steps 1 - 7 above.

How to remove the leaf chain: While referring to the figure below, remove the split pin, pin and metal fitting of the external link.

77

Notes: 1. If any part of the leaf chain link is disconnected, use a new split pin when reconnecting. 2. The end of the split pins should be bent after they are inserted.

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3.5

CNC Memory Backup Battery l About memory backup battery The control unit CMOS memory stores part programs, offset data, and system parameters. Since the control unit stores a lithium battery for memory backup, the data in CMOS memory can be retained after the main power is turned off. The battery is set in the control unit before shipment. The memory backup period ranges up to one year. When the voltage of the battery has dropped, the alarm message "BAT" flashes on CRT (LCD). (Or, a PMC alarm message is given, depending on the model.) When the alarm occurs, replace the battery as soon as possible within one or two weeks. How long the battery will be available depends on the system configuration. When the voltage of the battery has dropped further, backup will be disabled, and thus memory will be deleted and a system alarm (SRAM parity alarm) will occur. In such a case, data in memory should be cleared completely and input again after battery replacement. Replace the battery once a year, irrespective of the occurrence of the battery alarm. l Battery replacement procedures Use a lithium battery. (Choose a battery type appropriate for the NC model, referring to Table 1.) Keep the control unit ON for 30 seconds or more. Turn OFF the control unit. Disconnect the connector from the battery. (When a battery case is provided, remove the case.)

Replace the battery. Reconnect the connector. (When a battery case is provided, attach the case to its position.) Note: Finish steps through within 30 minutes. If the control unit has no battery for a long time, data in memory will be deleted. Table 1 NC FS-15, 16, 18, 15i, 16i, 18i, 20i, 21i FS-20, 21 POWER MATE Battery type A02B-0200-K102 A02B-0177-K106 A02B-0188-K111 (When placing an order for batteries, contact FANUC.)

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3.6

Absolute Pulse Coder Battery

l About absolute pulse coder battery For a feed axis servo equipped with the absolute value detection function, the servo module CMOS memory stores machine coordinates on feed axes. Since the servo module stores a lithium battery for data backup, the data in CMOS memory can be retained even after the main power is turned off. The battery is set in the servo module before shipment. The memory backup period ranges up to one year. When the voltage of the battery has dropped, the following alarm message appears on CRT (LCD). (Or, a PMC alarm message is given, depending on the model.) "307 APC ALARM: n AXIS BATTERY DOWN 1"------------ FS-16/18/21 series When the alarm occurs, replace the battery as soon as possible within one or two weeks. How long the battery will be available depends on the system configuration, such as the number of feed axes. When the voltage of the battery has dropped further, backup will be disabled, and thus memory will be deleted and the following alarm will occur. "306 APC ALARM: n AXIS BATTERY ZERO"---------------- FS-16/18/21 series In such a case, origin point return for feed axes is required after battery replacement. Replace the battery once a year, irrespective of the occurrence of the battery alarm. l Battery replacement procedures Use a lithium battery. (Choose a battery type appropriate for the NC model, referring to Table 1.) Keep the control unit ON for 30 seconds or more. Turn OFF the control unit. Disconnect the connector from the battery. (When a battery case is provided, remove the case.) Replace the battery. Reconnect the connector. (When a battery case is provided, attach the case to its position.)

Note: Finish steps through within 30 minutes. If the control unit has n o battery for a long time, data in memory will be deleted. Table 1 NC FS-15, 16, 18, 15i, 16i, 18i, 20i, 21i, 20, 21 POWER MATE Battery type A06B-6073-K001 A02B-0168-K111

(When placing an order for batteries, contact FANUC.)

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(Supplemental remarks) Fig. 1 Backup battery for FS-16/18i series

Fig. 2

Battery for FS-16/18i series

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Fig. 3

Backup battery for FS-20/21 series

Fig. 4 Backup battery for absolute pulse coder

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CHAPTER 4

PERIODICAL INSPECTION

Inspection and maintenance After installation Regular inspection Every 12 months Cleaning and replacement (H) Every 6 months

Before starting operation

Inspection Item

Remarks

Main unit

Levelness of main unit Leaf chain (tool slide, balance weight) Starting torque for drive unit

12 months

3 months

6 months

Check levelness with a level. Replace if length of 6 links exceeds 116.01 mm (4.59).

0.49 1.47 Nm Stretches 16 mm (0.62) when no stack is present.

Spindle

Belt tension (motor - spindle) Bolt tightness Position coder timing belt tension

Headstock (12 places), motor main unit, and motor base Stretch so that there is slight elasticity. Adjust if exceeds 0.020 mm (0.001). Adjust if exceeds 0.050 mm (0.001). Tool slide, turret Check for cracks and damage. Refer to section 3.2, Tapered Jib for Slideway. X-axis: OD of tool slide Measure end face of tool slide 0.020 mm (0.001)

Tool slide

Inclination (parallelism) Difference of center height bolt tightness Slideway Cleaning of slide seal and wiper

Axis feed unit

Adjustment of tapered jib

Ball screw backlash

Z-axis

Allowable valve:

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Inspection and maintenance Before starting operation After installation Regular inspection Every 12 months Cleaning and replacement (H)

Inspection Item

Every 6 months

Remarks

Pressure gauge scale Lubricant tank

12 months

3 months

6 months

0.5 1.6 0.1 MPa Type: Mobil Vactra No.2 or equivalent If low lubricant level alarm occurs, it indicates that 1.7 lit. (0.45 gal.) of lubricant remain in tank.) Type: SFC/ZP -20 (Willy Hogel)

Lubricant amount Main unit

200

Filter replacement

1000

Oil leaking or oozing from piping Pressure gauge scale Hydraulic unit Amount of hydraulic oil Filter replacement Replacement of hydraulic oil Oil leaking or oozing from piping Amount of coolant Axis feed unit Cleaning and replacement of filter Coolant replacement

4.9 MPa Add oil level is below L. (Type: HM32 or equivalent) If level is below H while machine is stopped, add water or coolant depending on the concentration. If chips clog or stick, remove them. If filter mesh is damaged or uneven, replace it. Oil amount: 400 lit. (105.68 gal.) Consult coolant manufacturer for replacement frequency.
1000 1000

Type: SFT-06-150W (Taisei) Type: F-913-1 (Taisei) Type: HM32 or equivalent Oil amount: 60 lit. (15.87 gal.)

50

50

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Inspection and maintenance Before starting operation After installation Regular inspection Every 12 months Cleaning and replacement (H)

Inspection Item

Every 6 months

Remarks

Pneumatic units

Lubricant amount for automatic door, machine base with chuck air blower (optional)

12 months

3 months

6 months

Add the specified lubricant.

High voltage panel

Filter replacement

Electrical component

Cleaning of limit switch roller and dog

If roller has hardened or there is uneven wear on roller, replace it. Places where roller and dog are used: Door open/close confirmation switches and overtravel detection switches on X- and Z-axes Gap amount; 0.5 - 1 mm (0.02 - 0.04) Places where proximity switch and dog are used; Clamp/unclamp confirmation of tool slide, chuck open/close confirmation (optional) When workpiece is changed, always adjust positions of proximity switches.

Adjustment of gap between proximity switch and dog

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CHAPTER 5

SPARE PARTS LIST (AT ADDITIONAL COST)

5.1

Mechanical Parts

Machine base, column and cover Name 1 2 3 4 5 6 7 8 9 10 11 12 Leaf chain Polycarbonate Window glass Window packing A Window packing B Rubber plate Liner cover Ball bearing Ball bearing Cam follower Oil gauge Caster Type XE 11105 XA 11145A XA 11146 XA 11147 XA 11148 XA 18210(1) LR 11454(1) #6204-ZZ #6208-ZZ CF10-1UUR KL-120 NJW75 THK KYOWA Okamoto koki Manufacturer TSUBAKIMOTO Okuma Howa Okuma Howa Okuma Howa Okuma Howa Okuma Howa Okuma Howa Qty 2 1 1 2 1 1 1 2 8 2 1 4 Remarks BL634-91 links Polycarbonate (t = 12) Reinforced glass (t = 6) Black oil resistance rubber (t = 1) Black oil resistance rubber (t = 2) Black oil resistance rubber (t = 3) Acrylic plate K206-204-200-000 K206-208-200-000 K217-110-612-580 K392-100-034-090 For chip pan

Headstock Name 1 2 3 4 Round belt Round belt Round belt Round belt Type XC 12121 XC 12122 XC 12123 XF 12106 Manufacturer Okuma Howa Okuma Howa Okuma Howa Okuma Howa Qty 1 1 1 1 Remarks 271 321 352 477

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Spindle drive (1250 min-1 , AC 22/30 kW) Name 1 V-belt Type 5VX-1700(7 ) Manufacturer MITSUBOSHI Qty 1 set Remarks K157-900-111-040

Spindle brake Name 1 2 3 Feed Name 1 2 3 4 5 6 Slide seal XA Slide seal XB Slide seal ZA Slide seal ZB Oil seal (for Needle bearing) Oil seal Type 6CK1-3102 6CK1-3103 6DK1-3102 6DK1-3103 OS 40504 SC 50689 Manufacturer NITTA NITTA NITTA NITTA IKO NOK Qty 1 set 1 set 1 set 1 set 4 4 K218-140-504-010 K382-200-050-110 (XE13121) Remarks Caliper Pad shoe Disc Type 62K1-2101 LV12142 XF12111 Manufacturer SUMITOMO SUMITOMO Okuma Howa Qty 2
1 set

Remarks Additional machining required for LV12143

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Tool slide Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Round belt Spring* Spring* Roller bearing Angular bearing Rotally joint* Belleville spring Collet Quad ring Precision belleville spring Dust Seal U-packing U-packing O-ring O-ring O-ring* O-ring* O-ring* O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring Type XE 14116 XE 14509 MC 50342(1) N1011BTCG5P4 7018ATYDBBC8 P4 532,3,0,5733E MC-K-40 BT50-MAS-2 4446-366Y Xsel TS-50 DSI 28406 USH 283555 USH 45556 P7 P 12 P 14 P 16 P 26 P 34 P 35 P 36 P 110 P 225 G 40 G 60 G 115 G 200 G 210 G 230 G 280 Manufacturer Okuwa Howa Okuwa Howa Okuwa Howa NSK NSK Willy hogel Tokai bane RIKEN Captain Industries Tokusyu Seiko NOK NOK NOK NOK NOK NOK NOK NOK NOK NOK NOK NOK NOK NOK NOK NOK NOK NOK NOK NOK Qty 1 1 2 1 1 1 1 1 2 16 1 1 1 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 12K2-0307 50K2-2132 12K1-2302-2 19K1-4339 15K1-0302 K380-600-215-190 ZL3-050-000-99 ZX4-0280-00-99 ZX6-0280-00-99 ZX6-0450-00-99 YC4-100-07 YC4-100-012 YC4-100-014 YC4-100-016 YC4-100-026 YC4-100-034 YC4-100-035 YC4-100-036 YC4-100-110 YC4-100-225 YC4-200-040 YC4-200-060 YC4-200-115 YC4-200-200 YC4-200-210 YC4-200-230 YC4-200-280 Remarks

*:Spindle through specification

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Filter Name 1 2 3 4 Filter A Filter B Filter C Suction filter Type XA 18254 XB 18205 XB 18206 SFC/ZP-20 Manufacturer Okuma Howa Okuma Howa Okuma Howa WILLEY HOGEL Qty 1 1 1 1 Remarks for coolant tank for coolant tank for coolant tank for lubrication tank

5.2

Hydraulic Unit/Pneumatic Unit

Hydraulic unit Name 1 2 3 4 5 6 7 8 9 10 11 Strainer Check valve Return filter Air breather Reducing valve Module type 2-pressure reducing valve Flow regulator Solenoid valve Solenoid valve Reducing valve Solenoid valve Type SFT-06-150W CN-T03-1-10 CF-06-10 FA-50 OG-G01-P1-20 OGS-G01-P1C-K-D2 -21 OCY-G01-A-Y-20 SA-G01-E3X-D2-10 SA-G01-A3X-D2-10 OG-G01-PB-K5544A SA-G01-E3X-D2-10 Manufacturer TAISEI NACHI TAISEI TAISEI NACHI NACHI NACHI NACHI NACHI NACHI NACHI Qty 1 1 1 1 1 1 1 1 3 1 1 Standard hydraulic chuck Standard chuck hydraulic
Cartridge type: F-913-1

Remarks

Pneumatic unit Name 1 2 3 4 5 6 7 8 9 FR unit FR unit Exhaust cleaner Solenoid valve Solenoid valve Coolant valve Check valve Lubricator Gap sensor Type AW3000-03BDG AF4000-04D AMC320-03BD VS7-6-FJG-D-3Z VP544-5DZ-A AB41-03-5B2HB-DC 24V 2232B3SS AL4000-04B 616JX2-LDC Manufacturer SMC SMC SMC SMC SMC CKD Japan Controls SMC ASAHI Qty 1 1 1 1 2 1 1 1 1 Remarks

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5.3

Electrical Parts

Fuses for AI of NC power supply (A02B-0120-K102)

Name 1 2 3 4 Fuse (7.5 A) Fuse (3.2 A) Fuse (5.0 A) Fuse (0.3 A) Type A60L-0001-0245 # GP75 A60L-0001-0075 # 3.2 A60L-0001-0046 # 5.0 A60L-0001-0290 # LM03 Qty 4 2 2 2 F1,2 F3 F4 F5 Remarks

Fuses for power supply module (A06B-6077-K250)

Name 1 2 Fuse (2.0 A) Fuse (5.0 A) Type A60L-0001-0245 # 2.0 A60L-0001-0359 Qty 2 2 Remarks Short-circuit protection of 200 Vac for cooling fan Short-circuit protection of 200 Vac for control power

Fuse for servo amplifier module (A06B-6073-K250)

Name 1 Fuse (3.2 A) Type A60L-0001-0290- # LM32C Qty 2 Remarks Short-circuit protection of 200 Vdc for control power

Feed axes
Name 1 2 Limit switch Limit switch Type SL1-A (X axis) SL1-D (Z axis) Manufacturer Honeywell Honeywell Qty 2 2 Remarks 4 years (8 hrs./day) 4 years (8 hrs./day)

Turret
Name 1 Proximity switch Type E2E-X3D1-N Manufacturer OMRON Qty 2 Remarks 4 years (8 hrs./day)

Work light
Name 1 Type AC100V 20W,50/60 Hz Qty 2 Remarks 1 year (8 hrs./day)

Fluorescent light

Control panel
Name 1 2 3 4 5 Type LY2N G2A -432A -N G2R-1-S DC24V DC24V Qty 3 2 1 1 2 Remarks 1 year (8 hrs./day) 1 year (8 hrs./day) 1 year (8 hrs./day) 1 year (8 hrs./day) 1 year (8 hrs./day)

Relay Relay Relay Relay Power printed circuit board

DC24V
DC24V

C2A-232A
PC6/PC13902

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5.4

Special Specifications

Chuck high / low pressure changeover Name 1 2 Module type 2- pressure reducing valve Solenoid valve Type OGS-G01-PCC-K -D2-21 SA-G01-E3X-D210 Manufacturer NACHI NACHI Qty 1 1 Remarks

Auto door (pneumatic) Name 1 Solenoid valve Type VS7-6-FJG-D-3Z Manufacturer SMC Qty 1 Remarks

Chuck air blower Name 1 Solenoid valve Type VP544-5DZ-A Manufacturer SMC Qty 1 Remarks

APC pallet clamp (hydraulic) Name 1 Solenoid valve Type SA-G01-E3X-D210 Manufacturer NACHI Qty 1 Remarks

APC pallet clamp (pneumatic) Name 1 2 3 Solenoid valve Pressure switch Air regulator Type VP544-5DZ-A ISE4B-01-65 AR2000-02BG Manufacturer SMC SMC SMC Qty 1 1 1 Remarks

APC shutter (pneumatic) Name 1 Solenoid valve Type VS7-6-FJG-D-3Z Manufacturer SMC Qty 1 Remarks

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ATS (Pneumatic) Name 1 2 3 Solenoid valve Solenoid valve Silencer Type VS7-6-FJG-D-3N VS7-6-FPG-D-3N AN300-03 Manufacturer SMC SMC SMC Qty 1 1 2 Remarks K437-005-008-040 K437-005-010-040 K408-300-001-040

* Excluding automatic door type ATS Name 1 2 3 4 5 6 7 Stopper bolt Slide seal Ball spline Shock killer Linear bush LM guide Hex. socket head set screw Type LP29134 XA19219 6DK1-3205 SCK-00-06 LM16UU HSR30R2UUC-1840LH-2 Manufacturer Okuma Howa Okuma Howa Okuma Howa CKD THK THK IKO Qty 1 1 1 2 2 1 set 1 K195-020-006-090 K293-516-837-080 K296-984-084-480 YT6-012-050 Additional machining to SH-8(NITTA) Remarks

5-7
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CHAPTER 6

APPENDIX

X-AND Z-AXES GEARING DIAGRAM X-axis

Rapid traverse rate: 18 m/min. (708.7 in./min.)

AC servo motor Model 22

Ball screw 40 (1.57") lead 12 mm (0.47") (12 mm/motor revolution)

Z-axis

Rapid traverse rate: 20 m/min. (787.4 in./min.)

AC servo motor Model 22B

Ball screw 50 (1.97") lead 16 mm (0.63") (16 mm/motor revolution)

6-1
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6-2
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19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1-8 1-7 1-6 1-5 1-4 1-3 1-2 1-1 1 No. Oil level gauge Oiling port & air breather Pressure gauge Return filter Check valve Uni pump Strainer Oil tank Hydraulic unit Name KLA-100A FA-50 GV50-173-100K (10Mpa) CF06-10 CN-T03-1-10 UVD-11A-A3-A3-2.2-4-22 SFT-06-150W OH Standard 60lit. 6FK3-6102-1 Type 1 1 1 1 1 1 1 1 1 set Qty Kyowa Taisei Kogyo Nagano Keiki Taisei Kogyo Nachi Nachi Taisei Kogyo Maker Nachi Manufacturer Flow regulator Solenoid valve Solenoid valve Pressure gauge Reducing valve Base OCY-G01-A-Y-20 SA-G01-A3X-D2-10 SA-G01-E3X-D2-10 OPG-D-PT1/4-39x70 OG-G01-P1-20 MOB-01Y-W2-10 1 1 1 1 1 1 Nachi Nachi Nachi ASK Corporation Nachi Nachi Solenoid valve Sub plate SA-G01-E3X-D2-10 MSA-01Y-10 1 1 Nachi Nachi Pressure gauge Pressure switch Solenoid valve Module 2-pressure reducing valve Base GV55-323-5MK-TM Herion 0882100 SA-G01-A3X-D2-10 OGS-G01-P1C-K-D2-2 1 MOB-01X-B2-10 1 1 2 1 1 Nachi Taiyo Nachi Nachi Nachi

6-3
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6-4
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PNEUMATIC CIRCUIT DIAGRAM (3) ATS (special specifications)

ATS Shutter ATS

YV[SOL]-45 YV[SOL]-44 YV[SOL]-33 YV[SOL]-32 5 4 3 2 1 No. Speed controller Solenoid valve Solenoid valve Silencer Manifold Name

ATS shutter OPEN ATS shutter CLOSE ATS backward ATS forward 4 1 1 1 1 Qty Model SMC SMC SMC SMC SMC Manufacturer

AS2201F-01-06S VS7-6-FPG-D-3Z VS7-6-FJG-D-3Z AN300-03 VV712-02R-03D

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6-7
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6-8
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6-9
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1250min-1 , AC22/30 kW

5VX-1500 (7)

6-10
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6-11
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6-12
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6-13
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6-14
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6-15
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6-16
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6-17
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6-18
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6-19
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6-20
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6-23
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OH-9708-W-015
Pressure setting Pressure setting

HYDRAURIC CIRCUIT DIAGRAM

Spindle brake Lower Spindle brake Spindle brake Pallet clamp Tool slide lift Tool slide Tool clamp

Pressure setting

ATC Magazine

Brake ON Spindle brake ON 2 Spindle half brake ON Spindle brake ON

Hydraulic unit

Pallet unclamp Pallet clamp

Pressuresetting

6-2
150-mesh Oil tank [60 lit. (15.87)]

Tool unclamp Tool slide lift

OH-9708-W-015

PNEUMATIC CIRCUIT DIAGRAM (1)

ATC Shutter Auto door APC shutter (Special Specifications) (Special Specifications)
SP(PS)-11 YV(SPL)-27 YV(SPL)-26 YV(SPL)-14 YV(SPL)-13 YV(SPL)-229 YV(SPL)-228 YV(SPL)-96 Source air pressure shutter OPEN shutter CLOSE door OPEN door CLOSE ATC shutter OPEN ATC shutter CLOSE C-axis auxiliary

Pneumatic circuit diagram (3)

ATC Magazine
10 9 8 7 6 5 4 3 2 1 NO. Pressure switch Exhaust cleaner Manifold FR unit Handle cock Name IS300-02L5 AMC320-03B VV714-03R-03B AW3000-03BDG TN400-3/8 Type 1 1 1 1 1 Qty SMC SMC SMC SMC KITAZAWA Manufacture Speed controller Solenoid valve AS2211-F-02-10S VS7-6-FJG-D-3Z 2 1 SMC SMC 17 16 15 14 13 12 11 NO. Speed controller Solenoid valve Name AS2211-F-02-10S VS7-6-FJG-D-3Z Type 2 1 Qty SMC SMC Manufacture Speed controller Solenoid valve AS2211-F-02-10S VS7-6-FJG-D-3Z 2 1 SMC SMC

6-4

OH-9708-W-015 9 8 7 6 5 4 3 2 1

Turret Chuck air blow (Special Specifications) Pallet clamp (Special Specifications) Turning holder seating check Turret high -pressure

Tool air blow

Motor cooling

PNEUMATIC CIRCUIT DIAGRAM (2)

12 11 10 Gap sensor Air regulator Speed controller Solenoid valve Solenoid valve Manifold FR unit Handle cock Name 616J2-LDC AR2000-02BG AS3211-F-03-06S VS544-5DZ -A VP544-5DZ-A VV3P5-41-041-03 AF4000-04BD TN400-1/2 Type 1 1 3 1 1 1 1 1 QTY ASAHI SMC SMC SMC SMC SMC SMC KITAZAWA Manufacture

19 18 17 16 15 14 13 NO.

Gap sensor Solenoid valve Solenoid valve Check valve Coolant valve Name

616J2-LDC VP544-5DZ -A 2 VP544-5DZ -A 2232B-3SS AB41-03-5B2HB-DC24V TYPE 1 2 1 Qty

ASAHI SMC SMC JAPAN Controlls CKD Manufacture

6-5

(Special Specifications)

NO.

SP(PS)-26

Pallet clamp

OH9706-W-013
2-RC/4(With bushing 1/4 -3/4) Drain port

50 Hz 200 V 220 V 8.8 A

60 Hz 8.4 A 8.0 A

Specifications Pressure Power Hydraulic oil Noise Carting Oil temperature 50kg/cm 2 (pressure gauge should be indicated in green.) AC-200 V 50/60 Hz ISO VG32 (90 turbine or equivalent ) Below 70dB Urethane inside the tank, Lacquer primer outside Room temperature below + 30 C (Target: below 25 C )

Pump performance data

Hydraulic circuit diagram

12 11 10 9 8 7 6 5 4 3 2 1 Elbo Take-out block Radiator Bushing Oil level gauge Check valve Pressure gauge Uni pump Return filter Air breather Strainer Oil tank SLC03-000J PT3/8, PT3/4 C013 -200-138 BUT3/4 1/4 KL-100A C N-T03-1-10 GV50-173-100K-1500P.S.I 11VD -1A-A3-15-4-22 C F-0610 FA-50 SFT-06 150W 60 lit. 3 1 2 1 1 1 1 1 1 1 1 1 Fujikoshi Taisei Taisei Taisei Tokiwa Kyowa Taisei Kyowa

6-11

OH-9708-W-015

Indication of Type

Filter type : SFT- 06 150

SFT

Diameter

Filtration accuracy

Symbol 02 03 04 06 08 10 12 16 20 24

Diameter PT (RC) 1/4 PT (RC) 3/8 PT (RC) 1/2 PT (RC) 3/4 PT (RC) 1 PT (RC)1 1 / 4 PT (RC)1 1 / 2 PT (RC) 2 PT (RC) 2 1 / 2 PT (RC) 3

Symbol 60W 100W 150W 200W

Fitration accuracy 60 mesh 100 mesh 150 mesh 200 mesh

Material Wire mesh (SUS)

1. The suction filter Type SFT is built in a tank and used for ordinary hydraulic oil. 2. The filter is a stainless wire mesh type. 3. Filtration accuracy : 60, 100, 150, 200 (standard)
n Parts list
5 4 3 2 1 No. Metal mesh Inner tube End plate (lower) End plate (upper) Connector Name SUS SECC SECC SECC SS material 1 1 1 1 1 Q'ty

Indication example :

SFT- 03 - 150W

Table of Flow ISO VG32 Viscosity : 32cst (40C)

R emarks

n Dimensions and standard flow rate

Model Symbol SFT - 0 2 SFT - 0 3 SFT - 0 4 SFT - 0 6 SFT - 0 8 SFT - 1 0 SFT - 1 2 SFT - 1 6 SFT - 2 0 SFT- 24 Diameter (d) P T (RC) 1/ 2 P T (RC) 1/4 P T (RC) 1/2 P T (RC)1/4 P T (RC) 1 P T (RC) 1 1/2 P T (RC) 1 1/2 PT (RC) 2 PT (RC) 2 1/2 PT (RC) 3 D B 19 22 27 32 41 50 55 70 85 100 L 45 46 71 72 85 87 97.5 130 150 152 t1 36 59 71 71 81.5 110 128 tl 9 10 12 13 14 16 20 22 24 Weight (kgf) 0.065 0.07 0.095 0.1 0.19 0.3 0.39 0.56 0.78 0.96 Standard flow r a t e (lit/min) 10 18 30 45 90 150 205 320 550 730

63

82 104 124 147

6-13

HL35/35L/9710/W-031

6-5