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Mazak SQT 200 250 Fusion 640 T Maintenace Operation
Mazak SQT 200 250 Fusion 640 T Maintenace Operation
Mazak SQT 200 250 Fusion 640 T Maintenace Operation
Publication # C320MA0010E
1/98
CAUTION
Notes:
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SAFETY PRECAUTIONS
The machine is provided with a number of safety 6) Do not deface, scratch or remove any caution
devices to protect personnel and equipment from plate. Should it become illegible or missing,
injury and damage. Operators should not, order another caution plate from the supplier,
however, rely solely upon these safety devices, specifying the part number shown at the lower
but should operate the machine only after fully right corner of the plate.
understanding what special precautions to take by • BEFORE POWERING UP
reading the following documentation thoroughly.
DANGER:
• BASIC OPERATING PRACTICES
Cables, cords or electric wires whose insulation
DANGER: is damaged can produce current leaks and
1) Some control panels, transformers, motors, electric shocks. Before using, check their
junction boxes and other parts have high condition.
voltage terminals. These should not be touched WARNING:
or a severe electric shock may be sustained. 1) Be sure the instruction manual and the
2) Do not touch any switches with wet hands. programming manual are fully understood
This too, can produce an electric shock. before operating the machine. Every function
WARNING: and operating procedure should be completely
1) The emergency stop pushbutton switch clear.
location should be well known, so that it can be 2) Use approved oil resistant safety shoes, safety
operated at any time without having to look for goggles with side covers, safe clothes, and
it. other safety protection required.
2) Before replacing a fuse, turn off the main 3) Close all NC unit, operating panel, electric
incoming power switch to the machine. control panel doors and covers.
3) Provide sufficient working space to avoid CAUTION:
hazardous falls. 1) The power cable from the factory feeder switch
4) Water or oil can make floors slippery and to the machine main circuit breaker should
hazardous. All floors should be clean and dry have a sufficient sectional area to handle the
to prevent accidents electric power used.
5) Do not operated any switch without a thorough 2) Cables which must be laid on the floor must be
understanding of the actions about to be taken. protected from hot chips, by using rigid or
other approved conduit, so that short-circuits
6) Avoid accidental operation of switches.
will not occur.
7) Work benches near the machine must be
3) Before first time operation of the machine after
strong enough to hold materials placed on
unpacking it or from being idle for a long period
them to prevent accidents. Articles should be
of time (several days or more), each sliding
prevented from slipping off the bench surface.
part must be sufficiently lubricated. To do so,
8) If a job is to be done by two or more persons, push and release the pump button several
coordinating signals should be given at each times until the oil seeps out on the sliding
step of the operation. The next step should not parts. The pump button has a return spring, so
be taken unless a signal is given and do not force it to return.
acknowledged.
4) Oil reservoirs should be filled to indicated
CAUTION: levels. Check and add oil, if needed.
1) In the event of power failure, turn off the main 5) For lubrication points, oil specification and
circuit breaker immediately. appropriate levels, see the various instruction
2) Use the recommended hydraulic oils, lubricants plates.
and grease or acceptable equivalents. 6) Switches and levers should operate smoothly.
3) Replacement fuses should have the proper Check that they do.
current ratings. 7) When powering the machine on, turn on the
4) Protect the NC unit, operating panel, electric switches in the following order: first the factory
control panel, etc. from shocks, since this feeder switch, then the machine main circuit
could cause a failure or malfunction. breaker, and then the control power on switch
5) Do not change parameters or electrical located on the operating panel.
settings. If changes are unavoidable, record 8) Check the coolant level, and add coolant, if
the values prior to the change so that they can needed.
be returned to their original settings, if
necessary.
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CAUTION:
CAUTION: 1) Thoroughly read and understand the safety
1) During automatic operation, never open the precautions in the instruction manual.
machine door. Machines equipped with the 2) Thoroughly read the whole maintenance
door interlock will set the program to single manual and fully understand the principles,
step. construction and precautions involved.
2) When performing heavy-duty machining, • MAINTENANCE OPERATION
carefully prevent chips from being accumulated DANGER:
since hot chips from certain materials can 1) Those not engaged in the maintenance work
cause a fire. should not operate the main circuit breaker or
• TO INTERRUPT MACHINING the control power "ON" switch on the
WARNING: operating panel. For this purpose, "Do not
When leaving the machine temporarily after Touch the Switch, Maintenance Operation in
completing a job, turn off the power switch on Progress!" or similar warning should be
the operation panel, and also the main circuit indicated on such switches and at any other
breaker. appropriate locations. Such indication should
be secured by a semi-permanent means in the
• COMPLETING A JOB reading direction.
CAUTION:
2) With the machine turned on, any maintenance
1) Always clean the machine or equipment. operation can be dangerous. In principle, the
Remove and dispose of chips and clean cover main circuit breaker should be turned off
windows, etc. throughout the maintenance operation.
2) Make sure the machine has stopped running, WARNING:
before cleaning. 1) The electrical maintenance should be done by
3) Return each machine component to its initial a qualified person or by others competent to do
condition. the job. Keep close contact with the
4) Check the wipers for breakage. Replace responsible person. Do not proceed alone.
broken wipers. 2) Overtravel limit and proximity switches and
5) Check the coolant, hydraulic oils and lubricants interlock mechanisms including functional parts
for contamination. Change them if they are should not be removed or modified.
seriously contaminated. 3) When working at a height, use steps or ladders
6) Check the coolant, hydraulic oil and lubricant which are maintained and controlled daily for
levels. Add if necessary. safety.
7) Clean the oil pan filter. 4) Fuses, cables, etc. made by qualified
manufacturers should be employed.
8) Before leaving the machine at the end of the
shift, turn off the power switch on the operating • BEFORE OPERATION & MAINTENANCE BEGINS
panel, machine main circuit breaker and factory WARNING:
feeder switch in that order. 1) Arrange things in order around the section to
• SAFETY DEVICES receive the maintenance, including working
1) Front cover, rear cover and coolant cover. environments. Wipe water and oil off parts and
provide safe working environments.
2) Chuck barrier, tail barrier and tool barrier (NC
software). 2) All parts and waste oils should be removed by
the operator and placed far enough away from
3) Stored stroke limit (NC software). the machine to be safe.
4) Emergency stop pushbutton switch. CAUTION:
• MAINTENANCE OPERATION PREPARATIONS 1) The maintenance person should check that the
1) Do not proceed to do any maintenance machine operates safely.
operation unless instructed to do so by the 2) Maintenance and inspection data should be
foreman. recorded and kept for reference.
2) Replacement parts, consumables (packing, oil
seals, O rings, bearing, oil and grease, etc.)
Should be arranged in advance.
3) Prepare preventive maintenance and record
maintenance programs.
000X717-KY
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! WARNING
a
ALWAYS TURN THE MAIN CIRCUIT BREAKER TO THE “OFF” POSITION & USE AN APPROVED
LOCKOUT DEVICE WHEN COMPLETING MAINTENANCE OR REPAIRS.
LOCKOUT PROCEDURE
1) THE LOCKOUT PROCESS MUST BE PERFORMED BY AUTHORIZED PERSONNEL ONLY.
2) INFORM ALL EFFECTED PERSONNEL OF YOUR INTENT TO LOCKOUT AND SERVICE THE
SPECIFIED MACHINE.
3) SHUT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES.
4) TURN OFF THE MACHINE AND INDIVIDUAL BUILDING CIRCUIT BREAKERS. MAKE SURE ALL
STORED ELECTRICAL ENERGY IS RELIEVED. (EG: SPINDLE & AXIS SERVO CONTROLLERS)
5) CONNECT THE LOCKOUT DEVICE AS SHOWN IN FIGURE 1, AND ATTACH THE APPROPRIATE
TAG AT THE MACHINE CIRCUIT BREAKER. THE TAG MUST IDENTIFY THE PERSON
RESPONSIBLE FOR THE LOCKOUT. THIS WILL ENSURE THAT POWER CANNOT BE
RESTORED BY ANYONE ELSE.
6) TEST THE MACHINE TO VERIFY THAT MACHINE SYSTEMS DO NOT OPERATE IN ANY WAY.
ONCE TESTING IS COMPLETE, MAKE SURE ALL SWITCHES ARE IN THE “OFF” POSITION.
CONFIRM THAT THE LOCKOUT DEVICES REMAIN PROPERLY INSTALLED.
7) COMPLETE THE REQUIRED MAINTENANCE OPERATIONS.
8) MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.
9) REMOVE THE LOCKOUT DEVICE. MAKE SURE ALL PERSONNEL ARE AT A SAFE LOCATION
BEFORE RESTORING MACHINE POWER.
PADLOCK
FIGURE
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INSTALLATION PRECAUTIONS
The following subjects outline the items that 6) In pouring grout, fasten the leveling block
directly affect the machine installation and start- base plates with the collar retaining screws
up. To ensure an efficient and timely installation, to prevent the base plates from dropping.
please follow these recommendations before When the grout has completely hardened,
calling to schedule a service engineer. level the machine properly, and tighten M24
nuts to secure the machine to the
foundation.
• ENVIRONMENTAL REQUIREMENTS
Note:
Avoid the following places for installing the
machine: The machine must be anchored to the
foundation with J-bolts, expansion bolts or
1) Avoid exposure to direct sunlight and/or near a other suitable method.
heat source, etc. Ambient temperature during
operation: 0° thru 45°C (32°F to 113°F). The machine accuracy and alignment
specifications quoted by Mazak can usually
2) Avoid areas where the humidity fluctuates be obtained when the minimum foundation
greatly and/or if high humidity is present; requirements are met. However, production
normally 75% and below in relative humidity. A of close tolerance parts requires the use of an
higher humidity deteriorates insulation and appropriate certified foundation. Foundations
might accelerate the deterioration of parts. that do not meet certified specifications may
3) Avoid areas that are especially dusty and/or require more frequent machine re-leveling and
where acid fumes, corrosive gases and salt are re-alignment, which can not be provided
present. under terms of warranty.
4) Avoid areas of high vibration. If any of these conditions cannot be met,
5) Avoid soft or weak ground (minimum load contact the nearest Mazak service office
bearing capacity of 1025 lbs./ft2) immediately.
• FOUNDATION REQUIREMENTS
For high machining accuracy, the foundation
must be firm and rigid. This is typically
accomplished by securely fastening the
machine to the foundation with anchor bolts. In
addition, the depth of concrete should be as
deep as possible (minimum 6 - 8 inches). Note
the following:
1) There can be no cracks in the foundation
concrete or surrounding area.
2) Vibration proofing material (such as asphalt)
should be put all around the concrete pad.
3) Form a “cone” in the foundation for J-bolt
anchors, or use expansion anchors.
4) With the foundation anchor bolt holes open
pour the primary concrete at a minimum
thickness of 6 - 8 inches. Typically, the
concrete must have a minimum compression
rating of 2500 lbs. @ 250 lbs. compression
and strengthened with reinforcing rods. When
the concrete has cured, rough level the
machine, and install the J-bolts, leveling blocks,
etc., and pour grout into foundation bolt holes.
5) Mix an anti-shrinkage agent such as Denka
CSA with concrete, or use Embeco grout to fill
the foundation bolt holes.
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• WIRING
1) Use only electrical conductors with
performance ratings equivalent or superior.
2) Do not connect any power cables for devices
which can cause line noise to the power Desirable Independent Grounding:
distribution panel, such as arc welders and high
frequency machinery.
3) Arrange for a qualified electrician to connect NC Earth resistance:
the power lines. Machine Less than 100 ohms
4) Incoming supply voltage should not deviate
more than ±10% of specified supply voltage.
5) Source frequency should be±2 Hz of nominal Common Grounds:
frequency.
Resistance to ground
= 100 ÷ the number of
[ CAUTION ] devices connected to
the grounding (ohms)
VERIFY THE ACTUAL MACHINE ELECTRICAL
Note: Never ground equipment as shown below:
POWER REQUIREMENT AND THE MAIN
TRANSFORMER RATING (IF APPLICABLE), AS
• GROUNDING
1) An isolated earth ground with a resistance to
ground of less than 100 ohms is required.
Typically, a 5/8” copper rod, 8 feet long, and
no more than 5 feet from the machine, is
sufficient. Building grounds or multiple
machines grounded to the same ground rod,
are not acceptable.
2) The wire size should be greater than AWG
(American Wire Gauge) No. 5 and SWG
(British Legal Standard Wire Gauge) No. 6.
000X713-KY
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! CAUTION
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MACHINE DOCUMENTATION
CUSTOMER EVALUATION The Other Thoroughbred From Kentucky
Your opinion is important to enable us to issue documentation that will fit your needs.
Thank you for taking the time to supply this information.
Date:
Machine Type: Machine Serial#: NC Type:
Customer: Reported By:
Address: Position:
Telephone#:
Manual Publication #: Excellent Good Adequate Fair Poor
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SF-202Xa
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CONTENTS
Page
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C-2
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C-3
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7. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-1 Headstock ............................................ 7-1
7-2 Chuck ............................................ 7-2
7-3 Turret ............................................ 7-3
7-4 TOOL EYE ............................................ 7-3
7-5 X-axis ............................................ 7-4
7-6 Z-axis ............................................ 7-4
7-7 Tailstock ............................................ 7-4
7-8 Hydraulic Unit ............................................ 7-5
7-9 Lubrication Unit ............................................ 7-6
7-10 Coolant Unit ............................................ 7-6
7-11 Air Unit ............................................ 7-6
7-12 Headstock Cooling Unit ......................................... 7-6
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1. INTRODUCTION
1-1 PURPOSE OF THIS MANUAL
Mazak is committed to the highest levels of customer service and support. If a
machine problem is encountered, contact the nearest service office of the Mazak
customer support network for assistance. Please use the Machine Documentation
Customer Evaluation form supplied at the end of this section with any comments and
suggestions for improvement. Thank you for your interest.
[ NOTE ]
This manual is provided as a quick reference to basic machine and CNC functions. It
should, however, be used in conjunction with the operation and programming manuals
also supplied.
[ NOTE ]
assistance.
1-1
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Mazak machines are engineered with a number of safety devices to protect personnel
and equipment from injury and damage. Operators should not, however, rely solely
upon these safety devices, but should operate the machine only after fully
understanding what special precautions to take by reading the machine documentation
thoroughly.
[ CAUTION ]
1-2 CONFIGURATION
1) Page numbers are given as two numerals joined by a hyphen. The first number
indicates the chapter number and the second indicates the page number within
that chapter.
Example 1: 2-15
In the event an additional page is inserted, the page number is shown by adding
Example 2: 3-16-1
Additional page
2) Figure numbers consist of the word "Fig." followed by two numbers separated by
a hyphen. The first of these numbers is the chapter number; the second is the
number of the figure in that chapter. The figure number is followed by the title of
the figure.
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Chapter
Title
number
The suffix shown here indicates that
Number of figure in chapter there are two figures with this title, as
3) Table numbers consist of the word “Table” followed by two numbers separated by
a hyphen. The first of these numbers is the chapter number; the second is the
number of the table in that chapter. The table number is followed by the title of
the table. The tables are listed in an index at the end of the manual.
Chapter
Title
This suffix is added to the title on the
number
second and subsequent pages if the
Number of table in chapter
table occupies more than one page.
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This chapter describes coordinate axes, components location and functional principles.
1. Main spindle
The main spindle is driven directly by a variable-speed AC inverter motor built into the spindle
body. The spindle is cooled by a water and air cooling system, reducing the effects of heat to
an absolute minimum.
2. Tailstock
The tailstock comprises the tail spindle which is hydraulically driven.
3. Chucks
The chucks are connected with a rotary hydraulic cylinder at the rear of the spindle by a
connecting tube. When the piston in the cylinder moves towards the chuck, the chuck jaws
open; when the piston moves away from the chuck, the chuck jaws close.
4. X-axis, Z-axis
The carriage is moved along the bed in the Z-axis direction by a Z-axis AC servo motor through
a ball screw. The turret mounted on the carriage is moved in the X-axis direction by an X-axis
AC servo motor through a ball screw.
5. Turret (SQT-200/250)
The turret has 12 faces, enabling 12 tools (rotary tools) to be mounted simultaneously.
The tool holders are of the bolt fixing type. When the lathe is performing an automatic operation,
the next command is read and the turret is rotated in the direction of the shorter route from the
position of the tool currently in use to that of the next tool.
When the lathe is in the manual mode, either clockwise rotation or counterclockwise rotation can
be selected. Except when rotating, the turret is clamped hydraulically to the turret base (the
index coupling is engaged).
When an rotating command is received, the index coupling is disengaged, and the turret is
unclamped. The turret is then rotated by the hydraulic motor until the encoder detects that the
turret has reached the position set by the command, after which the turret is clamped.
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The SQT lathe is controlled by MAZATROL CNC, a system featuring interactive programming and
artificial intelligence. An ultra-high-speed 32-bit microprocessor enables all lathe operations - feed
rate acceleration and deceleration, spindle acceleration and deceleration, PLC operations, turret
indexing, etc. - to be performed at high speed, and spindle and servo motor control is fully digitized.
8
4
6
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1
8
4
12
2
13
10
14 9
15
5
3
6
Fig. 2-2 Machine main components (1/2) TR113-01606
11
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8 Chuck
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The coordinate axes used for the machine are defined as follows.
X-axis: This is the turret motion vertical axis.
“+” (plus) indicates the upward direction; “-” (minus) indicates the downward direction.
Z-axis: This is the turret motion transverse axis.
“+” (plus) indicates movement to the right ; “-” (minus) indicates movement to the left
(towards the chuck).
X-axis
Z-axis
–
+
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3 4
38 5 11
15
14
31
8
32
12 13
33
30 29 7 35 36 37 10 9
34
25 17 18 23 19
21
26 27 28
24 22
16
20
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Some of the keys and buttons on the operation panel have a small lamp at their respective top left
corner. The lamp is on when the function is effective and off when the function is ineffective
(except for the power ON button).
1 Power ON button - This button is used to switch on the power to the NC unit.
(POWER I) Several seconds after this button has been pressed, the “READY” lamp will light, indicating
that the lathe is ready for operation.
When the main breaker is switched on, the backlighting of this button will light, indicating that
power is being supplied to the machine.
- When this button is pressed, the backlighting will go off.
2 Power OFF button - This button is used to switch off the power to the NC unit.
(POWER O) When this button is pressed, the backlighting of the power ON button will light.
3 Display selector key - This key is used to select the display on the CRT screen.
When this key is pressed, the display selection menu is displayed.
4 Menu selector key - This key is used to change the menu currently being displayed over to another one.
5 Menu keys - These keys are used to select one of the menu items being displayed.
6 Brightness adjustment - This dial is used to adjust the brightness of the display.
dial (BRIGHT) Turn the dial clockwise to increase the brightness and counterclockwise to reduce the
brightness.
7 Cursor keys - These keys are used to make the cursor appear on the screen and to move the cursor
around the screen.
Ø Press this key to move the cursor down to the line below.
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8 Page keys - These keys are used to call the previous page or the next page of a display which has
multiple pages.
≠≠ Press this key to move the cursor to the beginning of the previous process.
ØØ Press this key to move the cursor to the beginning of the next process.
9 Data cancel key - This key is used to cancel the data displayed in the data display area.
(CAN) When this key is pressed, the data at the position where the cursor is blinking will be deleted.
11 Address/numeric data - These keys are used to set address data (alphabetic characters) and numeric data.
keys See Part 3, Chapter 3, DATA SETTING METHODS, for the usage of the keys.
12 Shift key - This key is used to set the address data displayed at the bottom right of the address keys.
See Part 3, Chapter 3, DATA SETTING METHODS, for the usage of the key.
13 Input key (INPUT) - This key is used to set the data displayed in the data input display area of the display.
Press this key after inputting the data with the numeric data keys.
14 Clear key (CLEAR) - This key is used to cancel the data displayed in the data input area of the display.
Press this key if incorrect data has been input into the data input area.
15 Reset key (RESET) - This key is used to reset the NC unit to its initial status.
If an alarm is displayed, eliminate its cause then press this key to cancel the alarm.
16 Cutting feed/manual - These keys are used to select the cutting feed/manual pulse feed mode.
pulse feed keys Press one of these keys and the appropriate axis movement button to execute axis motion at
the cutting feed rate in the selected axis direction.
Press the appropriate key and turn the manual pulse handle.
An axis motion will occur over the selected distance in the selected axis direction.
If this key is pressed, each graduation on the manual pulse handle will be equivalent
to a movement of 0.001 mm (0.000039 in.) in the direction of the selected axis.
If this key is pressed, each graduation on the manual pulse handle will be equivalent
to a movement of 0.01 mm (0.00039 in.) in the direction of the selected axis.
If this key is pressed, each graduation on the manual pulse handle will be equivalent
to a movement of 0.1 mm (0.0039 in.) in the direction of the selected axis.
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17 Rapid feed key - This key is used to select the rapid feed mode.
Press this key then press the appropriate axis movement button. Motion will take place in the
selected direction along the selected axis at the rapid feed rate.
18 Zero-point return key - This key is used to select the zero-point return mode.
Press this key then press the appropriate axis movement button. The selected axis will return
to its zero-point in the machine coordinates system.
19 Automatic operation - This key is used to select the automatic operation mode.
key Press this key to execute programs registered in the NC unit.
23 Tape run key - This key is used to select the tape run mode.
Press this key to execute programs stored on paper tape, a micro disk or other external
equipment.
* This key is used for EIA/ISO programs only.
25 Coolant automatic - This key is used to select ON/OFF-status of the coolant in the automatic operation mode.
key Press this key to make M08 (coolant ON) valid in the programs for the automatic operation.
Even when M08 is set, the feeding of coolant will not start, unless this key is pressed.
26 Rapid feed override - These keys are used to adjust the rapid feed override rate.
keys The current rate is indicated on the indicator above the keys as a percentage of the maximum
rapid feed rate.
27 Spindle override keys - These keys are used to adjust the spindle rotation speed (peripheral speed).
When the lathe is in the manual mode, the speed indicated on the indicator above the keys is
equal to one-tenth of the value of the current rotation speed.
When the lathe is in the automatic operation mode, the current rotation speed is indicated on
the indicator above the keys as a percentage of the speed set in the program.
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28 Cutting feed override - These keys are used to adjust the cutting feed rate.
keys (FEED) When the lathe is in the manual operation mode, the code corresponding to the feed rate is
indicated on the indicator above the keys.
When the lathe is in the automatic operation mode, the current feed rate is indicated on the
indicator above the keys as a percentage of the feed rate set in the program.
29 VFC key - This key is used to change the cutting condition values (peripheral speed, feed rate) set in
the program to the values set using the override keys.
If this key is pressed after the spindle rotation speed or the cutting feed rate has been
adjusted during automatic operation, the values set in the program will be changed
automatically to the values set using the override keys.
* This key can be used for MAZATROL programs only.
30 TPS key - This key is used to register the tool tip position into the NC when a manual interrupt operation
is performed.
Use this key when interrupting an automatic operation to change tool tip, etc.
31 Overtravel release - This key is used to return an axis which has stopped at the axis stroke end to a movable
key range of the axis.
This key is also used to cancel emergency stops.
32 Display erasure key - This key is used to temporarily erase the display from the CRT screen, with the intention of
extending the life of the CRT screen and saving energy.
If an alarm occurs while the display is off, the alarm only will be displayed.
To make the display reappear, press this key again.
33 Hardcopy key - This key is used to print out the display on the CRT screen.
(COPY) Windows cannot be printed out.
34 Window key - This key is used to display a window on the CRT screen.
35 Auxiliary key - Use this key as an aid key according to the particular machine specifications.
36 Coolant menu key - This key is used to display the coolant menu on the CRT screen.
Pressing this key will display the menu for various coolant functions on the CRT screen.
37 Machine menu key - This key is used to display the menu for various machine-operations on the CRT screen.
Pressing this key will display the menu for various machine-operations on the CRT screen.
38 Arbitrary display - These keys are used to select the following displays whose names are inscribed on the keys:
selector keys
D POSITION display
D PROGRAM display
D SET UP display
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1 11
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20
Fig. 2-5 Optional panel (Indicator lamps) D147S0006
1 Operation ready indicator - This lamp comes on when the lathe is ready to operate.
lamp (READY) This lamp comes on several seconds after the power has been switched on.
2 Program head indicator - This lamp comes on when the program head is called up.
lamp (P.HEAD) This lamp also comes on when the RESET key is pressed when the lathe is
performing an automatic operation.
3 Program stop indicator - This lamp comes on to indicate that program execution has terminated or stopped.
lamp (P.STOP)
4 Turning mode indicator - This lamp comes on when the turning mode is selected.
lamp (SPINDLE)
6 Spindle unclamp indicator - This lamp is on when the spindle is in the unclamp status.
lamp (UNCLAMP)
7 Spindle clamp indicator - This lamp is on when the spindle is in the clamp status.
lamp (CLAMP)
11 X-axis zero-point return - This lamp is on when the X-axis is at the machine zero point.
indicator lamp
12 Z-axis zero-point return - This lamp is on when the Z-axis is at the machine zero point.
indicator lamp
14 4th axis zero-point return - This lamp is on when the 4th axis is at the machine zero point.
indicator lamp
15 5th axis zero-point return - This lamp is on when the 5th axis is at the machine zero point.
indicator lamp
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16, 17 Main spindle chuck - These lamps indicate whether the chuck unit of the main spindle is open or closed.
open/close indicator If unclamping lamp 16 is on, this indicates that the chuck unit is open.
lamps (CHUCK 1st) If clamping lamp 17 is on, this indicates that the chuck unit is closed.
Note: The meaning of lighting of the lamps becomes converse if the chucking
direction selector switch has been set to inner chucking.
20 Measurement indicator - This lamp comes on when the sensor is turned on during workpiece measurement.
lamp (W.MEASURE)
54 53 57 55
46
42 41 40 43
48
47
58 59
49 44
45
50
39
51 52
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Table 2-3 Names and functions of keys, buttons and switches (cont’d)
39 Emergency stop - This button is used to stop the lathe operation in case of emergency.
button If this button is pressed, all of the lathe operations will stop immediately and a “128
(EMERGENCY EMERGENCY STOP” alarm will be displayed.
STOP) To cancel an emergency stop, turn the emergency stop button in the direction of the arrow
and then simultaneously press the reset key and the overtravel release key.
40 Spindle rotation - This button is used to specify the spindle rotation direction when the lathe is in the manual
direction change operation mode.
button (REV) When the backlighting of this button is on, the spindle rotates in the reverse direction.
When the backlighting of this button is off, the spindle rotates in the forward direction.
41 Spindle start button - This button is used to rotate the spindle when the lathe is in the manual operation mode.
(START) The backlighting of this button is on while the spindle is rotating.
42 Spindle stop button - This button is used to stop the spindle when the lathe is in the manual operation mode.
(STOP)
43 Spindle jog button - This button is used to jog the spindle when the lathe is in the manual operation mode.
(JOG) The spindle rotates slowly when the button is being pressed and stops when the button is
released.
44 Tool selector button - This button is used to index a tool on the turret when the lathe is in the manual operation
(TOOL SELECT) mode.
The turret rotates one position towards the operator each time the button is pressed.
45 Axis movement - These buttons are used to move the turret in the X-axis direction and the Z-axis direction
buttons when the lathe is in the manual operation mode.
The turret moves in the selected direction when a button is being pressed and stops when
the button is released.
46 Axis selector switch - This switch is used to select the axis in whose direction the movement occurs when the lathe
(AXIS SELECT) is in the manual pulse feed mode.
47 Manual pulse handle - This handle is used to specify the axis motion direction and distance when the lathe is in the
manual pulse feed mode.
49 Tail spindle operation - This switch is used to move forward/reversely or stop the tail spindle.
switch * Invalid during automatic operation.
51 Feed hold button - This button is used to stop the axis feed when the lathe is in the automatic operation mode.
(red) When the feed is stopped, the LED comes on and the cycle start button LED goes off.
(FEED HOLD)
White LED
52 Cycle start button - This button is used to start the lathe when it is in the automatic operation mode.
(green) The LED is on when the lathe is in the automatic operation.
(CYCLE START) The LED goes off when the automatic operation is interrupted or has been completed.
Green LED
53 Automatic power - This switch is used to cut off the power automatically when the execution of a program has
cutoff switch (option) been completed.
When the switch is set to the top position ( I ), the automatic power cutoff function is effective
and the lamp comes on.
When the switch is set to the bottom position ( O ), the automatic power cutoff function is
ineffective and the lamp goes off.
2-13
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54 Automatic door - This switch is used to open and close the front door.
opening/closing
switch (option) ¨ Æ Set this switch to the top position to open the front door.
(The lamp will light when the door is fully opened.)
Æ ¨ Set this switch to the bottom position to close the front door.
(The lamp will light when the door is fully closed.)
55 Reprogramming - This switch is used to prevent programs or data in the NC unit from being erased
switch (with key) accidentally.
To rewrite a program or data, set this switch to the ENABLE position.
When the switch is set to the LOCK position, rewriting of programs and part of the data is
rendered impossible.
2-14
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Transference of
NC program data
2-15
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3. MACHINE OPERATION
In order to ensure safe operation and good machine maintenance, the following points must be
inspected before starting operation.
1. Check that the voltage of the factory power supply is correct. (Permissible voltage : 200 to 230
V)
2. Check that the doors of the operation panel and electrical control panel are closed.
3. Check that there is nothing abnormal about the safety covers (particularly about the front door).
4. Check that the selector switch for chucking direction is set to the correct direction.
5. Check that the oil level gauges are indicating the correct values.
3-1
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DANGER
- Cables or wires with damaged insulation could cause current leakage or electric shocks.
Always check that the insulation is sound.
- There are high voltage terminals in the electrical control panel, transformers, motors,
junction boxes, etc. Never touch these terminals.
- Do not touch the switches with wet hands.
WARNING
In order to prevent the entry of water, oil, chips, dust, etc. into the electrical control panel
and other machine units, ensure that the doors of the CNC unit and electrical control panel,
and all other doors and covers, are closed.
CAUTION
Follow any instructions on the distributor for the factory power supply (for example,
instructions on a nameplate).
2. Turn the main breaker on the front face of the machine to the ON position.
- The power ON button (POWER I) on the operation panel will light up.
- The spindle cooling water pump, spindle cooling fan and spindle control amplifier/servo
amplifier heat sink fan will be turned on.
3-2
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OFF ON
3 Power ON button
3-3
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3. Check that the pressure gauges in the upper part of the front face of the machine are indicating
the correct values.
- Main pressure: 5 MPa (50 kgf/cm2 (711.5 PSI))
- Chuck pressure: Adjusted in accordance with the workpiece to be machined
- Tailstock thrust power: Adjusted in accordance with the workpiece to be machined
POSITION display
Pressure nameplate
3-4
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WARNING
- Do not press switches while wearing gloves. This could cause machine malfunction.
- In order to prevent machine malfunction, confirm the functions of switches before using
them.
CAUTION
- In the case of the optional absolute position detection specification, the record of the
machine zero point is not lost even if the power is switched off. Accordingly, it is not
necessary to perform an all-axis zero-point return operation after switching the power on.
- If the battery voltage drops the record of the machine zero point may be lost. If the
message ZERO RETURN is displayed on the CRT screen, perform an all-axis zero-point
return operation.
The zero-point return operation is important because it registers the machine zero point in the NC
unit.
When the power is switched off, the record of the machine zero point is lost. Therefore, the first
thing that has to be done after switching on the power is to perform a zero-point return operation.
2. Move the turret and the carriage at least 30 mm (1.18 in.) in the minus direction, away from the
machine zero point by pressing the axis movement buttons.
- When detecting zero-point dog at this axis movement, axis movement direction becomes the
direction for the zero-point return and feed speed changes into “zero-point return speed”.
(Refer to Fig. 3-5.)
For example, if zero-point dog is detected when pressing X-axis movement button for minus
direction at around the X-axis home position, direction of axis movement changes to plus
direction.
3. Hold down one of the axis movement buttons for plus direction.
- Movement will stop when you release the button.
- When becoming zero-point return speed (Refer to Fig. 3-5.) after zero-point dog detecting, the
axis continues zero-point return without stop even if the button is released.
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4. Release the button when the relevant zero-point indicator lamp lights (“X” or “Z”).
Z Z
3-6
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Zero-point
return speed
Movement
The warmup operation is important for maintaining lifelong precision and the long life of the machine.
Make sure to perform the warmup operation daily.
CAUTION
- Warm up the spindle and feed axes. Do this by performing automatic operation at
between 1/2 and 1/3 of the maximum spindle speed and maximum feed rate for between
10 and 20 minutes.
- Write the program for the warmup operation so as to execute the functions of the full
range of machine components.
- If operation is to be performed at maximum spindle speed, pay meticulous attention to the
warmup operation.
* If the machine features the automatic warmup operation function (option), refer to the operating
manual for options.
3-7
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CAUTION
Check that the chuck pressure is correct.
1. When the machine menu key on the operation panel is pressed, the menu will change. Set the
chuck opening and closing directions with the internal gripping menu items which appear after
pressing the CHUCK menu key.
Fig. 3-6 Operation of foot switch (1/2) - Single foot switch - NM210-00463’
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Fig. 3-6 Operation of foot switch (2/2) - Double foot switch - NM210-00464’
3-9
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WARNING
Never touch the spindle while it is rotating.
This function is used for operations such as simple test cutting in manual operation.
D366S0001
3-10
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2. Select the rotational direction using the spindle rotational direction change backlit button (REV).
Fig. 3-7 Pressing the spindle rotational direction change button (REV) NM210-00206
Forward
Reverse
D366S0002
3-11
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Press the spindle stop backlit button (STOP) to stop the rotation of the spindle.
- The value displayed in the override indicator will not change.
- The radiator fan keeps rotating during parameter set time even after spindle stop.
- In automatic operation, the spindle will not stop even if the spindle stop backlit button (STOP) is
pressed.
For jogging the spindle, press the spindle jog button (JOG).
- The spindle keeps rotating while the button is pressed and stops when the button is released.
- If the spindle jog backlit button (JOG) is pressed during spindle rotation, the spindle speed will
change to the jog speed. The spindle will stop when the button is released.
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- It is possible to change the spindle speed while it is rotating by pressing the spindle override keys
(SPINDLE).
- If the spindle rotational direction change backlit button (REV) is pressed while the spindle is
rotating, it will stop rotating.
CAUTION
- Check that there will be no interference before starting axis feed or tailstock operation.
- Interlocks are not effective until the zero-point return has been completed.
X-axis
Interference
3-13
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D366S0011
2. Set the feed rate by pressing the rapid feed override keys
(RAPID).
- 50% and 100% indicate the feed rate as a percentage
value against the maximum rapid feed rate.
- For R0, R1 and R2, the feed rate can be set to the
parameter as a percentage value.
R0: Parameter B149
R1: Parameter B150
R2: Parameter B151 D366S0006
+X direction
X
Z Z
-Z direction +Z direction
X
-X direction
3-14
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D366S0008
2. Set the feed rate using the cutting feed override key
(FEED).
120 37 (1.457)
3-15
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+X direction
X
Z Z
-Z direction +Z direction
X
-X direction
3-16
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NM210-00460
3-17
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CAUTION
Before rotating the turret, always check that there will be no interference between the tools
and the chuck, etc. And also check that the tool is fixed securely.
This procedure is used to rotate the turret to mount tools to the turret, remove tools from the turret,
and index tools.
1. Press one of the manual mode keys to select the
manual mode.
- The key lamp of the key pressed will light.
D366S0001
2. Turn the tool selector button (TOOL SELECT) to select the turret rotational direction.
FWD
TOOL SELECT
FWD REV
REV
Fig. 3-14 Turret rotation by pressing tool selector button (TOOL SELECT) TR113-00159’
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3. Check that the tail spindle thrust power is set to an appropriate value.
(1) Move the tail spindle forward to fix a workpiece or move the spindle right to the stroke end.
* For the operation procedure, refer to the section 4-5-2 “Moving the tail spindle in the
forward and reverse directions”.
(2) Adjust the tail spindle thrust power by using the adjustment knob while referring to the
pressure gauge (the pressure will increase if the knob is turned in the direction of the
arrow).
Name plate
* The setting range for thrust power is 40 to 700 kgf (88 to 1541 lbs).
3-19
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4. Check that the settings for the tail spindle forward end and reverse end are appropriate.
Fig. 3-16 Settings for tail spindle forward and reverse end
After adjusting the tail spindle stroke, do not fail to adjust the proximity switches.
* The proximity switch clearance should be 0.5 to 1 mm (0.02 to 0.039 in.).
3-20
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3-2-5-2 Moving the tail spindle in the forward and reverse directions
Fig. 3-18
3. In case tail sleeve is to be operated with M31 or M32 in automatic operation mode, set the
switch to the center position with the tail spindle positioned at forward end or reverse end.
3-21
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3-2-5-3 Moving the tailstock body in the forward and reverse directions
CAUTION
- Tailstock base must be unclamped before the operation for its movement.
- To connect/release the tailstock with (from) the carriage, turn the connecting lever
securely.
- The movement speed must be 2 m/min (6.56 ft/min) or lower.
Tailstock body
Tail spindle
Connecting pin
Connecting mark
Position mark
Connecting dial
Release mark
Clamping bolts
Fig. 3-19
[1] Loosen the tailstock body clamping bolts (2 pcs.) to unclamp the tailstock body.
[2] Move the carriage manually (JOG/HANDLE) to the tailstock connecting position.
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[3] To connect the tailstock base with the carriage, turn the connecting dial in the front part of
the tailstock base and insert the connecting pin into the connecting block in the lower part of
the carriage.
Connecting block
Connect
Connecting pin
EXT
RET
Release
Connecting dial
[4] Move the tailstock base by using the Z-axis movement button in the manual pulse feed or
JOG mode.
If an unusual force is added to the Z-axis load during movement, the connection will be
released. In this case, release the connecting pin and restart the operation from procedure
2.
[5] Turn the connecting dial, and pull the connecting pin out of the block to release the
connection.
3-23
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Fig. 3-21
[3] Move the carriage by using the JOG button (2 m/min (6.56 ft/min)) and stop it at the
connecting position.
Check that the JOINT POSITION menu item is highlighted on the CRT screen.
Dog
Limit switch
[5] Move the tailstock base by using the Z-axis movement button in the manual pulse feed or
JOG mode.
[6] Cancel the TAILBODY MODE of the menu display when completing the movement.
3-24
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CAUTION
If the tailstock body is advanced while the turret is lowered as indicated in the figure below,
there will be an interference.
X-axis
Interference
CAUTION
The chuck barrier, tailstock barrier and tool barrier are not effective in the manual operation
mode. Due care must therefore be taken to avoid interference with the chuck.
3-25
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Movable range of X- and Z-axes is limited with parameters so that they cannot move to O.T. stroke.
(O.T. is the abbreviation of OVER TRAVEL, and it represents stroke limit.)
If trying to move the axes out of the range, 120 SOFT LIMIT alarm is displayed on the screen.
Interlock is set not to move the axis out of the range.
Press the reset key (RESET) to release the alarm.
CAUTION
- Soft limit (*) becomes effective when, after power ON, zero-point return has been
performed and machine zero point has been set.
Therefore, soft limit never works when NC has lost its zero point by servo alarm.
- Carry out the zero-point return certainly.
+O.T.
A10 A9
A10
– O.T.
Name Name
: Movable range (Both A9 and A10 are set for each axis.)
* A “soft limit” is a point beyond which the NC unit does not monitor axis movement.
3-26
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This is a function whereby the feed axes are mechanically locked. When this function is set, there
is no actual axis movement but the movements corresponding to the specified operations are
depicted on the CRT screen. This function is used to check the program execution condition.
CAUTION
When selecting the menu keys for machine lock, C-axis lock cancel and dry run, use the
auxiliary key MF1 in addition to them as a safety measure.
Highlighted
MACHINE MACHINE
LOCK LOCK
MF1
When pressing the menu key, the auxiliary key MF1 lamp will flicker. Then press the MF1 key. The
menu item will be highlighted and the MF1 lamp will light. Use the MF1 key also to cancel the
function.
WARNING
After the machine lock function has been cancelled, the actual position of the feed axes may
differ from those displayed on the CRT screen. Do not cancel this function during
automatic operation.
3-27
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1. Coolant MANUAL
This hardware-key function allows you to start and stop the supply of coolant during manual
operation.
- When the key lamp is turned on, the coolant will be supplied.
2. WORK LIGHT
This function is used to switch the machine lights on and off.
Highlighted
WORK WORK
LIGHT LIGHT
- When the menu is highlighted, the machine light will be turned on.
3-28
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WARNING
- Use tools which are suitable for the work to be carried out and conform to the machine
specifications.
- Use of badly worn tools can result in injury. Replace worn tools with appropriate new
ones.
- Illuminate the workplace adequately to ensure safety.
- Remove tools and other obstacles in the vicinity of the machine and peripheral devices to
a safe distance so that the operator has sufficient clear floorspace to stand in and walk
around.
CAUTION
Use tools which are no longer than the provided length so as to avoid interference.
(2) Change the injection direction of the coolant, depending on the type of tool to be used and
on whether the tool is lefthanded or righthanded.
- For an O.D. cutting tool, relocate the coolant nozzle and the blank cap, as shown in the
figure below.
Coolant nozzle
Blank cap
3-29
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- For a boring bar 25 mm or more in diameter, adjust the coolant injection direction select
knob so that the coolant is injected from the tool holder. Use a slotted screwdriver to adjust
the knob. After adjustment, mount a blank cap (use an M6 bolt) at the end of the coolant
nozzle located on the side opposite to the adjusted select knob.
Coolant
- For a boring bar 20 mm or less in diameter, U-drill or drill, adjust the coolant injection
direction select knob so that the coolant is injected from the socket. Use a slotted
screwdriver to adjust the knob. For a boring bar, mount a blank cap (use an M6 bolt) at the
end of the coolant nozzle located on the side opposite to the adjusted select knob.
Coolant
Socket
Boring bar
(left-handed)
Blank cap Coolant injection
(M6 bolt) direction select knob
3-30
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Soft jaws are machined using different methods; the method used depends on machining
conditions such as the chuck type of the workpiece. The general method is described here.
WARNING
- Close the door securely while machining.
- Never touch a rotating workpiece or spindle with your bare hands or anything else,
whatever circumstances may occur.
- Do not open or close the chuck while the spindle is rotating.
CAUTION
- Use the most appropriate soft jaws for the shape of the workpiece they are to grip, its
dimensions, material, surface roughness, and the machining conditions.
- Adjust the chuck pressure in accordance with the shape of the workpiece, its dimensions,
material, and surface roughness, and the machining conditions.
- The master jaws must be used at the central part of the optimum jaw stroke range.
- Do not strike the workpiece clamped in the chuck with a hammer or any similar
implement. This will impair machine accuracy and functions and shorten machine life.
- Finish the zD diameter to the same dimension as the part of the workpiece to be gripped
(to approximately H7). During machining, set the same chuck pressure as that used to
grip the workpiece or a little higher.
- Soft jaws are machined by intermittent cutting. Make the spindle speed as low as
possible accordingly. During machining, use an internal cutting tool of small ejection to
prevent chipping or chattering.
3-31
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Pecking
a
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aa
aa
a
a
a
aa
aa
a
a
a
aa
aaaa
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a
a
a
aa
a
a
a
aa
aa
a
a
a
aa
External diameter: zW
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a
a
aa
a
a
a
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a
a
a
aa
a
a
a
aa
a
a
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aa
aa
a
a
a
a
a
a
TR100-00015 The length for gripping should
generally be no less than the
1/3rd of the total length of the
workpiece. (recommended value)
Fig. 3-28 Soft jaw machining (External gripping)
zd
zP
zD
aaa a
a
a a
a a
aaa
a
a
a
3-32
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Pecking
aaa
aa
aa
a
a
a
aaaa
aaaa
aaaa
aa
aaa
a
a
a
a
a
a
a
a
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Internal
diameter: zW
aaa
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a
a
a
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aaa
a
a
a
a
a
a
a
a
a
TR100-00020 The length for gripping should
generally be no less than the
1/3rd of the total length of the
workpiece. (recommended value)
Fig. 3-29 Soft jaw machining (internal gripping)
zd
zP
3-33
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aa
a aa
aa
diameter (zW). (zD e zW)
aaaa
aaaa
zD
aaaaa
a a a aa
CAUTION
Finish the zD section to the same dimension as the part of the workpiece to be gripped (to
approximately H6) and to a surface roughness of no more than 6-S. During machining, set
the same chuck pressure as that used to grip the workpiece or a little higher.
3-34
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4-1 General
1. Inspection and maintenance of the machine at regular intervals is necessary to keep the
machine in optimum operating condition as well as to allow the machine to operate for a
prolonged period. Therefore, regular inspection and maintenance should be given highest
priority.
WARNING
The power is not cut off even when the electrical control cabinet door is opened. During
either inspection or repair inside the control cabinet, lock the power ON/OFF switch in the
“OFF” position using a padlock, as shown in Fig. 4-1.
* The customer supplies the padlock.
Padlock
CAUTION
Keep the door to the electrical control cabinet closed during inspection and maintenance
work, unless it is electrically related. Never use compressed air while cleaning the machine
since fine dust and other foreign matter will enter the bearings and slideways.
4-1
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3. By spending a little time on inspection and maintenance intervals, unexpected problems will be
eliminated. In addition, regular maintenance ensures high productivity of the machine over a
prolonged period and maintains the designed machine performance.
4. Lubrication
CAUTION
Use only the recommended brands of oil listed in this manual. Use of a lubricating oil which
is not recommended could cause machine failure or other problems.
There are number of locations where lubricating oil must be supplied. Never supply too much
lubricating oil. To supply the lubricating oil, follow the steps described in this manual.
5. During regular inspection, checking, oil refilling, machine cleaning and other preventive
maintenance items specified in the regular inspection schedule should be carried out on a daily,
weekly, monthly, semiannually, and annually.
4-2
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4-3
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4
2
3
12 6
5
9
7
13
10
4-4
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Period of inspection
Reference Number of months
No. Inspection point Inspection item
pages Daily Weekly of operation
1 6 12 24
Arranging the machine periphery in order, cleaning the
1 General {
machine and its periphery (especially, the floor)
- Checking the chuck unit and its periphery to scan for 5-1 - 5-8 {
chips 7-1 - 7-2
- Checking for secure mounting of the top jaws {
2 Headstock
- Checking for smooth chucking/unchucking {
- Greasing the chuck unit {
- Removing any chips from the coolant collector {
- Checking for secure mounting of the cutting tools and the 5-9 - 5-12 {
4 Turret and X-axis holder 5-18 - 5-22
- Checking the turrets and the cutting tools to scan for chips 7-3 - 7-4 {
TOOL EYE - Cleaning the sensor section and removing any chips 5-13 - 5-17 {
5 (Japan:option,
{
export: standard) - Checking for sounds of reaction during sensor contact 7-3
15 Foundation - Checking and adjusting the bed level using a level 6-15 {
* Japan: mounted when an optional component is mounted that requires air to operate.
Export: Standard
4-5
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WARNING
When supplying or exchanging coolant, hydraulic oil and lubricating oil, use only oil brands
recommended by MAZAK. Use of another brand of oil will cause machine malfunction and
will damage the machine.
Use the appropriate amount of the recommended brand of oil when adding or changing oil.
9
10
8
7
Fig. 4-3 Lubrication Points (1/2)
4-6
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3
Fig. 4-3 Lubrication Points (2/2) TR113-01591’
Lubricating
No. Part name Q'ty Recommended oil Remarks Reference
point
1 Water filler port Headstock 5i - Distilled water or ion Exchange coolant every 5-53 - 5-56
cooling unit (1.32 gal) exchanged water 50% 2 years.
2 Level gauge
- Long life coolant (Mobil)
50%
3 Strainer Hydraulic 30 i - DTE24 (Mobil) Exchange oil every 6 5-31 - 5-36
unit (7.93 gal) - UNI POWER 32 (Esso) months, then clean the
4 Oil filler port
- TELLUS OIL 32 (Shell) strainer and micro-
5 Drain plug separator.
6 Level gauge
7 Drain plug Lubrication 1.5 i - VACTRA No. 2 (Mobil) Automatic lubrication. 5-37 - 5-44
unit (0.40 gal) - FEBIS K68 (ESSO) Supply occasionally.
8 Suction filter
- TONNA OIL T68 (Shell)
Clean the suction filter
9 Level gauge
every year.
10 Oil filler port
Note:
The replacement period is determined on the basis of eight hours operation a day.
Delayed replacement or use of any product other than recommended oil may damage the machine.
4-7
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After circulating through the Z-axial ball screw, the linear guide, and the X-axial ball screw, the
lubricating oil accumulates in the oil pan located at the rear right of the machine and is then
discharged through a tube. The oil discharged from the tube, therefore, needs receiving using a
waste oil can.
Fig. 4-4
4-8
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5-1 Headstock
1. Spindle
The Spindle is directly driven by the built-in motor without using reduction gears or drive belts.
This built-in motor construction converts the power generated by the AC inverter motor into
machining power without mechanical loss. During manual operation the required spindle speed
(in units of 10 rpm) is input directly to the CNC. During automatic operation, the spindle speed is
controlled by the constant cutting speed (peripheral speed) control mode. The spindle is cooled
with coolant and air.
Built-in motor
Headstock
Speed detector
Spindle
Cylinder
Chuck
2. Chuck
The chuck is connected with a rotary hydraulic cylinder at the rear of the spindle by a
connecting rod. When the piston in the cylinder moves towards the power chuck, the chuck
jaws open; when it moves away from the power chuck, the chuck jaws close.
The collet chuck is clamped by forward movement of the piston or unclamped by backward
movement of the piston.
5-1
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CAUTION
- For the sake of safety and to ensure accuracy and a long chuck life, read the chuck
operation manual thoroughly and follow the instructions precisely.
Cylinder Chuck
Ø Spindle =
Ø
Solid chuck
TR113-00138
Chuck
Cylinder =
Ø Spindle
Ø
Hollow chuck
TR113-00140
Cylinder
Ø Spindle Chuck
=
Ø
Collet chuck
TR113-00139
5-2
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WARNING
Bearings should be packed with the specified amount of grease when reassembling.
Particular care should be taken when packing the main spindle bearings, since overheating
of the main spindle greatly reduces its life. When packing grease, contact your local
MAZAK service representative.
Those sections of the headstock that require greasing are listed in Table 5-1 below.
DANGER
The specified grease must be used.
Insufficient greasing may deteriorate the gripping force of the chuck and thus cause the
workpiece to fly about during machining.
The power must be turned off before greasing.
A. To operate the chuck in its best condition over a long time, it is important to grease the chuck
jaws at the appropriate time. Greasing must be provided correctly and sufficiently.
Otherwise, malfunctions at low oil pressure, insufficient gripping force, decreases in gripping
accuracy, unusual wear, and/or thermal damage may result.
5-3
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B. Grease the chuck jaws from the grease nipples provided on the outer periphery of each
master jaw. Greasing must be executed at least once a week using a grease gun. In cases
where high-speed rotation and a large amount of water-soluble coolant oil are to be used,
increase the frequency of greasing according to the particular operating conditions.
Notes:
1. After working, the chuck body and the jaw sliding surfaces must be completely cleaned using
an air gun.
2. Use corrosion-preventive coolant water. Otherwise, the inside of the chuck body may
corrode and thus result in deterioration of its gripping force.
Grease gun
Grease nipple
5-4
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1. Adjustment of the chuck clamp/unclamp proximity switches (The switches are standard parts for
Europe. For other regions, they are optional parts.)
The proximity switches in the chucking cylinder must be adjusted if the chuck clamp or unclamp
signal is not input although the chuck has been clamped or unclamped.
Two proximity switches are provided to detect clamping and unclamping of the chuck.
B. With the nut for the unclamp detection proximity switch loosened, turn the proximity switch
until its head portion comes into contact with the circumference of the detection plate.
C. Turn the proximity switch in the reverse direction by one turn and then tighten the nut.
The clearance between the proximity switch and the detection plate is set to 0.5 to 1.0 mm
(0.020 to 0.039 in.).
D. Set the chucking cylinder in the clamped status.
F. Make sure that the clamp or unclamp proximity switch lamp is lit when the chucking cylinder
is set in the clamped or unclamped status, respectively.
* For more details, refer to the instruction manual supplied by the chuck maker.
Clamp
proximity switch Unclamp
proximity switch
Lock nut
0.5 to
1.0 mm
(0.020 to
0.039 in.)
Detection
plate
5-5
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CAUTION
Before replacing it, the chuck must be fully secured using hoisting belts or hoisting bolts.
The power must be turned off before replacing the chuck.
A. Loosen the jaw mounting bolts, and remove the soft jaws and the T-nuts.
C. Loosening the chuck mounting bolt, rotate the draw nut using the connecting handle, and
then remove the chuck.
To reassemble the chuck section, apply a sufficient coat of recommended grease and then carry
out a reverse procedure to that of disassembly. Be careful at that time to ensure that the
identification numbers of the chuck body and the master jaws become correct.
2 1
3
4
5 6 7 8
5-6
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5-7
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5-1-4 Cleaning
5-8
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5-2 Turret
B. Turret head
The turret head has 12 faces and each face (position) may be mounted with a cutting tool.
2. The turret head is hydraulically clamped to the turret base while it is not rotating. The index
coupling with which the turret head is engaged ensures accurate indexing of the turret head to
the required tool position.
3. When the turret rotation command becomes active, the turret head is disengaged from the index
coupling and unclamped. The turret head is then rotated by the hydraulic index motor. The
turret head position is detected by the encoder; when the turret head is indexed to the
commanded position, the hydraulic motor stops and the turret head is clamped to the turret
base.
During automatic operation, the turret rotation direction is determined from the currently located
turret head position and the target index position so that it will rotate in the shortest way.
During manual operation, the turret rotation direction is selected as required - FWD (forward,
clockwise viewed from the turret face) and REV (reverse, counterclockwise viewed from the
turret face).
5-9
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2
Fig. 5-8 Construction of Turret [SQT-200/250] D320M0002
2 Encoder
4. Turret rotation
5-10
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D. The relationship between the turret rotation direction and the hydraulic index motor rotation
direction is shown in Fig. 5-9. The table below shows the motor rotation direction needed to
rotate the turret in the forward direction.
Encoder CCW
Hydraulic
(CCW)
Turret index motor
forward
(V type tool) rotation
Encoder
5-11
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5. The turret indexing sequence is explained below. This shows how the T05 command is
executed while the turret is in the T01 position.
A. Flow chart
B. Timing chart
T05 command ON
OFF
Turret head unclamp
clamp
5-12
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The TOOL EYE is used to measure the tool tip position for the tool set measurement function and
automatic tool wear compensation function.
The arm of the TOOL EYE swings into (extending) the measuring position by a torque motor. The
sensor mounted in the arm tip measures the tool tip position by bringing it into contact with the
sensor. After completion of measurement, the arm retracts to the standby position (retracting).
Completion of arm motion is confirmed by proximity switches (SQ-7 for extend and SQ-8 for
retraction).
1 5
2
4
A-view
7
3
A 2
Fig. 5-11 Construction of TOOL EYE (the arrow means meaurement position.)
4 Sensor
5-13
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A. Press the TOOL SET MEASURE menu key to extend the TOOL EYE arm to the measuring
position.
5-14
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C. Pull the joint section from the arm body, and pull that section away by slightly rotating it.
Joint section
5-15
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E. Mount the new TOOL EYE sensor and fix it in place following the above steps in the reverse
order.
(1) Fix the dial indicator or micro dial indicator to the turret and adjust parallelism regarding the
machined face at the center of the sensor as reference.
5-16
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Reference block
Bolt
Dial indicator
5-17
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1. X- and Z-axes
The turret base and the carriage are driven respectively by the X-axis or Z-axis AC servo- motor
via the ball screw to move in the respective direction. The position encoder is located at the
end of the motor and the motor is directly connected to the ball screw by coupling ensuring high
positioning accuracy.
-Z +Z
5
11
Z-axis
7 9
1
10
Fig. 5-14 Construction of Z-axis
1 Coupling 7 Nut
5-18
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+X
2
-X
8
4
1
12
6
5
A. When the zero return key on the operation panel is pressed, the zero return mode signal is
turned on.
B. Using the axis movement switches, move the turret to the zero point of respective axis.
C. When the zero point limit switch is tripped by the dog, the deceleration signal is turned on,
turret motion is decelerated, and the turret moves at the predetermined feedrate.
5-19
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D. After the zero point limit switch is released from the dog, the turret continuously moves to the
point far from the last grid signal by the amount preset in parameter BS12. (This is the
electrical zero point.) The turret further moves from this point by the zero shift amount set in
parameter BS13. This position is stored by the NC as the machine zero point.
Parameter settings for SQT-200/250 are as follows
X-axis BS12 10 (fixed) BS13 Shift amount from the electrical to the machine zero
Z-axis BS12 12 (fixed) BS13 point (variable, machine-specific)
E. The grid signal is always turned on at the fixed position unless the relative position between
the encoder input shaft and the ball screw is not changed. The zero point shift amount is a
fixed amount set with a parameter in the NC.
Zero point
return direction
Push-in
allowance
ON
OFF OFF
Zero point limit switch
Axis feedrate
BS12 BS13
ON
OFF
Grid signal
Machine zero point
Electrical zero point
Fig. 5-16 Principle of X- and Z-axes Machine Zero Point D320M0004
5-20
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5-4-2 Lubrication
The lubrication unit supplies lubricating oil to the linear motion guide blocks, ball screws and ball
screw nuts. Lubricant is automatically supplied every 6 minutes (for 50Hz) or 5 minutes (for 60Hz)
by the electrical intermittent lubrication pump unit at the left front side of the machine.
5-4-3 Adjustment
Backlash compensation
The following factors between the X- or Z-axis position encoder and the turret generate errors
between the axis motion command value and actual turret position.
(a) Feed the turret in the “plus” (+) direction by 50 mm (2.0 in.) in rapid feed.
(b) Set the dial indicator at the “minus” side of the turret and set the reading to “0”.
Set the dial indicator at the headstock as shown in Fig. 5-17 for measuring lost motion.
(c) Feed the turret further in the “plus” direction by 50 mm (2.0 in.) in rapid feed.
(d) Return the turret in the “minus” (-) direction by 50 mm (2.0 in.).
(e) Read the dial indicator.
The value read by the dial indicator shows the amount of “lost motion” which is the total
mechanical system error including backlash.
5-21
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Lost motion
If the relative position between the encoder input shaft and the ball screw has been shifted, for
example if the coupling has been removed and installed again, the zero point position may be
shifted. In such cases, set the machine zero point anew.
* Whether the zero point limit switch is ON or OFF can be checked in I/O MONITOR area on the
DIAGNOSIS (MONITOR) display.
5-22
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5-5 Tailstock
The tailstock consists of the tailstock body and the tailstock spindle.
1. The tailstock body is driven with its driving pin fitted in the connecting block mounted. For a
manual tailstock spindle (standard), the pins can be extended and retracted by rotating the lever,
or for an automatic tailstock spindle (optional), they are driven hydraulically. Also, for a manual
tailstock spindle (standard), the tailstock body can be clamped by bolting it down, or for an
automatic tailstock spindle (optional), the tailstock body is driven hydraulically.
Tailstock spindle
Slideway
5-23
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5-5-3 Lubrication
2. The electrical intermittent lubricating pump unit which is mounted at the left front of the machine
supplies lubricating oil to the above lubricating points in intervals of 6 minutes (for 50Hz) or 5
minutes (for 60Hz).
3. The supply volume of the lubricating oil is adjusted by the flow unit mounted at the end of
lubrication pipe.
5-5-4 Adjustment
A. Move the spindle forward to hold the workpiece or move the spindle to the stroke end.
B. Turn the knob while reading the thrust meter (pressure gauge) indication.
* Turning the knob in the direction indicated with an arrow mark increases the thrust.
Thrust range: 392 to 6860 N (40 to 700 kgf (88.2 to 1543.5 lbs))
Chuck Tailspindle
pressure thrust
5-24
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A. With the tailstock spindle retracted fully, advance the tailstock body to the position where the
tailstock body is to be located to machine a workpiece.
C. Taking the workpiece length variations into account, loosen the socket head screw of the
advance end dog and adjust the dog position so that the advance end proximity switch faces
the dog at its center.
Retract end
proximity switch
Advance end
proximity switch
* Clearance between the proximity switch and the dog should be 0.5 to 1.0 mm (0.02 to
0.039 in.).
5-25
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Adjusting screw A
Rushing bolt
5-26
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A. Hold a test workpiece in the chuck, with the tailstock sleeve in contact with the test workpiece.
5-27
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5-28
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D. Loosen the four bolts and two pushing bolts clamping the tailstock body to the tailstock base.
F. Tighten the bolts clamping the tailstock body to the tailstock base and the pushing bolts.
5-29
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The hydraulic unit consists of the tank, hydraulic pump, strainer, and radiator.
The following units are hydraulically operated.
- Chuck
- Turret
- Clamping the tailstock body
- Parts catcher (option)
2
3
4
Fig. 5-23 Construction of Hydraulic Unit TR113-01591’
4 Strainer
5-30
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Turret
Unclamp Clamp
Joint pin
(option) Tailstock body
(option)
Clamp
Unclamp
45 kgf/cm2
(640.4 PSI)
Hydraulic unit
5-31
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Clamp
Tail sleeve
FWD REV
Sleeve
Mounted on the
side cover of
the headstock
(option) Down
Mounted in the
front on the
left side cover
5-32
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CAUTION
When supplying or changing hydraulic oil in the reserve tank, use only the recommended
oil. Use of another grade of oil will lead to machine malfunction and damage to the
machine.
The hydraulic oil change interval varies according to the machine operating conditions. Change the
hydraulic oil three months after machine installation. After that, change it every six months.
Note:
Always maintain the quantity of hydraulic oil between the 2/3 and FULL levels on the gauge
located on the side of the hydraulic tank.
5-33
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5-6-3 Adjustment
Adjusting pressure
2. Adjust pressure to the specified value 50 kgf/cm2 (711.5 PSI) while reading the indication of the
pressure gauge.
Pressure increases when the pressure adjusting screw is turned clockwise.
5-34
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5-6-4 Cleaning
5-35
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1. The lubrication unit supplies lubricating oil to the linear guides and ball screws of the X- and Z-
axis and to the tailstock slideway.
2. The electrical intermittent lubricating pump unit is mounted at the left front of the machine, and
supplies lubricating oil to the above lubricating points at intervals of 6 minutes (for 50Hz) or 5
minutes (for 60Hz).
3. The supply volume of the lubricating oil is adjusted by the flow unit mounted at the end of the
lubrication pipe.
* The flow unit is a kind of joint used in the lubrication circuit and functions as a valve that
allows lubricating oil to flow only in one direction. If the pump pressure drops, it prevents
lubricating oil from flowing in the reverse direction, thereby protecting the machine from
problems occurring from the reverse flow of lubricating oil.
4. If an error occurs in the lubrication system, the pressure switch in the lubrication piping is
activated, and alarm message 260 SLIDEWAY LUBRICATION ALARM will be displayed on
the CRT screen.
Delivering Delivering
Pressure
(kgf/cm2)
Interval time
Delivering Delivering
Pressure
(kgf/cm2) Pressure
(kgf/cm2)
1.0 1.0
Abnormal
pressure
status
(1) The oil pressure does not drop (2) The oil pressure does not exceed
below 1 kgf/cm2 (14.2 PSI). 1 kgf/cm2 (14.2 PSI).
Fig. 5-29
5-36
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166 (6.54)
2
3
1
124
(4.88)
M6
38
28
(1.50)
(1.10)
213.5
(8.41)
143
9 (5.63)
10 Unit: mm (in.)
Fig. 5-30 Construction of Lubrication Unit D320M0010
5-37
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Tailstock sleeve
4
5
Fig. 5-31 Lubrication Circuit Diagram TR113-01149’’
3 Suction filter
5-38
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CAUTION
- When replenishing lubricating oil, use only the recommended lubricating oil. If lubricating
oil other than the recommended oil is used, it will cause malfunction of the machine.
- Observe the caution items printed on the legend plates.
- Before starting the day's operation, check that the lubricating oil reserve tank is filled with the
specified lubricating oil to the specified level.
- When starting the machine operation after it has been stopped for a long period, press the
machine-menu key, and then select the menu item for forced lubrication on the maintenance
display. (The lubricating pump will then operate for 8 seconds, and the respective alarm display
can be cleared by pressing the clear key.)
1. Oil supply
Lubrication unit
Fig. 5-32 Supplying Lubrication Oil (1/2) D320M0011
5-39
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3. Oil discharge
Remove the lubrication unit from the machine, and then remove drain plug to let the oil out.
5-40
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5-7-3 Cleaning
5-41
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CAUTION
Connect the pipes to the correct port.
5-42
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5-43
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The coolant system consists of the coolant pump and the chip pan where coolant is stored. Two
nozzles are mounted in the turret; one for supplying coolant to cool the cutting tool at the cutting
point and the other for supplying coolant to wash away chips. They are used for cooling and
cleaning tools or workpieces, and removing chips while cutting workpieces.
The coolant inside the chip pan is pumped up by the coolant pump mounted on the right side of the
chip pan, and then injected from the nozzle of the turret.
The injected coolant is passed through the chip receiving plate and then salvaged into the chip pan.
Level gauge
Coolant pump
Chip pan
Drain port
Filter
5-44
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CAUTION
When replenishing coolant to the chip pan, use the recommended coolant. If coolant other
than recommended ones is used, it will cause malfunction of the machine.
Check if coolant is stored in the chip pan to the specified level before starting the day's operation.
If the volume of the coolant supplied from the nozzle becomes low, check the coolant level in the
chip pan if the coolant level is lower than the allowable lower limit.
2. Supplying coolant
Replenish the coolant that has been arranged
to the appropriate density beforehand so that
the suction port is completely immersed in
the coolant.
3. Discharging coolant
If the coolant is heavily contaminated, change the coolant completely. Clean the inside of the
chip pan at the same time. (See Subsection 5-8-3.)
Tools to be used: Oil drain pan
Allen wrench
5-45
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5-8-3 Cleaning
C. Remove chips from the chip pan every day after completing the day's work.
5-46
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A. After the coolant is drained, remove the chip receiving plate and clean the inside of the chip
pan.
5-47
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WARNING
Moisture in the compressed air causes deterioration and damage to the air actuators used in
the machine.
5-48
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TOOL EYE air blast Workpiece measuring Chuck air blast Automatic door
(*) system air blast (option) (option) (option)
Coolant
oil
Panel
33205117530
AVK-400
5-49
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Filter case
D320M0012
Fig. 5-43 Replacing the Filter Element (1/4)
D320M0013
Fig. 5-43 Replacing the Filter Element (2/4)
Baffle
D320M0014
Fig. 5-43 Replacing the Filter Element (3/4)
5-50
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Filter element
D320M0015
Fig. 5-43 Replacing the Filter Element (4/4)
5-51
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The headstock cooling unit is installed in the integrated form with the headstock.
1. Coolant is supplied to the headstock by the centrifugal pump from the headstock cooling unit
tank and the headstock is cooled.
2. The coolant warmed while circulating inside the headstock is cooled by the radiator and the
cooling fan and returned to the tank of the cooling unit.
6
1
5 2
4 Drain
5-52
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Fan cooler
aaa
aa
aaaa
M
aa
aaa
a
a
Tank
Headstock
aaaaaa
aaaaaa
Pressure switch M
Centrifugal pump
Level gauge
Fig. 5-46 Location of the
Level Sight Gauge
WARNING
- When replenishing coolant, use only the recommended coolant. If coolant other than the
recommended ones is used, it will cause malfunction of the machine.
- If the coolant level is lower than the center mark of the level sight gauge, the headstock
cannot be cooled satisfactorily, causing overheating of the headstock and machine
malfunction. Replenish the coolant occasionally so that the coolant level is maintained
correctly.
5-53
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2. Replenishing coolant
Remove the replenishing port cap and
replenish the coolant.
Recommended coolant
Distilled water or ion exchanged water 50%
Long life coolant (Mobil) 50%
Exchange coolant every 2 years. When exchanging the coolant, clean the inside of the reserve
tank at the same time.
3. Discharging coolant
5-54
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(1) After turning off the power, remove all remaining coolant by blowing air through the pipe
using an air compressor.
(2) Sufficiently stir previously diluted coolant (50 % dilution) and fill the tank.
(3) Run the machine for about 10 minutes to circulate coolant throughout the entire cooling
system. Confirm that the coolant has been spread throughout the system sufficiently as
indicated by the lowered level of coolant in the tank. Add cooling water according to the
particular decrease in oil level.
(4) Replacement is complete.
(1) After turning off the power, remove all remaining coolant by blowing air through the pipe
using an air compressor.
(2) Pour distilled water or ion exchanged water into tank and circulate to clean for about 15
minutes.
(3) Drain water for cleaning using the same procedure as in A.
(4) Immediately pour new coolant previously diluted to 50 % density into tank after stirring the
coolant.
(5) Run the machine for about 10 minutes to circulate coolant throughout the entire cooling
system. Confirm that the coolant has been spread throughout the system sufficiently as
indicated by the lowered level of coolant in the tank. Add cooling water according to the
particular decrease in oil level.
(6) Replacement is complete.
C. When headstock coolant gets too low or too discolored, check for the following:
Thorough cleaning is required in this case. After checking the above conditions, contact the
nearest MAZAK distributor.
5-55
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6
4
5
7
AC200/220V 3z
Fig. 5-49 Lathe Control TR113-01233’’
5-56
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1. Control of the CNC unit enables ultra-high-speed control for the following functions: rapid feed
rate acceleration and deceleration, spindle acceleration and deceleration, PLC operations, high
speed rough machining cycle, constant optimum peripheral speed control, automatic setting of
turret indexing positions, and simultaneous operations. Moreover, the spindle motor and all
servo motors are under full digital control.
2. Program patterns simplify the creation of programs such as those for measuring the dimensions
of machined workpieces, measuring tool wear with the TOOL EYE, lapping, and the machining
of soft jaws. There are also automatic setting functions for the chuck barriers.
5-57
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3 1 2
16 15 14
8 9 10 11
4 5 6 7
13
12
3 QF2 Circuit protector of auxiliary units (Hydraulic pump motor, head lube motor,
clamp motor, chip conveyor motor)
4 KM11 Hydraulic pump motor switching
5 KM12 Headstock cooling pump motor switching
5-58
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DANGER
- High voltages are applied to terminals inside the electrical control cabinet, transformer,
motor and relay box. Never touch these terminals.
- After the power supply has been turned off, the electric components inside the electric
control cabinet are still alive with remaining voltage. Before touching these components,
make sure that no voltage is applied using a multimeter or other proper instrument.
- Before attempting any repair or service work in the electrical control cabinet, confirm the
high voltage areas by referring to the electric circuit diagram.
WARNING
- Only authorized personnel can carry out electric maintenance.
- Before carrying out inspection of the electrical control cabinet, turn off the power supply at
the factory power distribution board.
- The power is not cut off when the control cabinet door is opened. During either inspection
or repair inside the control cabinet, lock the power ON/OFF switch in the OFF position
using a padlock.
* The customer supplies the padlock.
- Thermal relay F12 (for spindle cooling water pump motor use) at the bottom of electromagnetic
switch KM12
- Thermal relay F13 (for cutting water pump motor use) at the bottom of electromagnetic switch
KM13
- Thermal relay F14 (for chip conveyor motor use) at the bottom of electromagnetic switch KM14
5-59
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After removing the cause of overloading of the corresponding motor, reset the thermal relays as
shown below.
5-60
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6. INSTALLATION
1. Machine
Avoid the following places when choosing the installation site for the machine:
- Places subject to direct sunlight, near heat sources, or subject to excessive temperature
change
- Humid places
- Dusty places
- Places near vibration generating equipment
- Weak soil
CAUTION
- If the machine is to be installed near vibration generating equipment, a vibration-proof
drain should be provided around the machine foundation.
- If the soil is weak, reinforce it by driving piles into the soil to avoid settlement and
inclination of the soil after machine installation.
2. NC
A. Environmental temperature
Allowable temperature range during machine operation: 0° to 40°C (32° to 104°F)
B. Humidity
Allowable humidity: Less than 75%
CAUTION
As humidity increases, insulation deteriorates causing electrical component parts to
deteriorate quickly. Although no special dehumidifying measures are required, the machine
should not be installed in humid places.
C. Vibration
During operation: Less than 0.5G
During transportation: Less than 3.5G
6-1
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D. Environment
If the machine must be installed in a dusty place or in an environment where organic,
corrosive gas concentration is high, consult Mazak for proper measures.
CAUTION
MAZATROL uses a memory back up battery to maintain important data stored in memory
even after power supply is turned off. However, since the back-up data may be lost due to
expiration of battery life or misoperation or unexpected trouble, to ensure safety of important
data, it is advisable to store the data with external device.
1. Power source
Voltage : 200/220 VAC, 3 phases
Permissible voltage fluctuation : ±10%
Frequency : 50/60 Hz±2 Hz
2. The size of the primary side power cable is calculated under the following conditions.
- Primary incoming cable : 50 mm2 (0.078 in2) or larger for SQT-200
60 mm2 (0.093 in2) or larger for SQT-250
- Environment temperature : Less than 30° C
- Power source : 200 VAC, 3 phases
- Metallic conduit : 3 pieces
- Continuous rating for spindle drive motor
Notes:
1. To connect power supply cables, class 3* grounding or above must be performed.
* Class 3: Grounding resistance 100 ] maximum
2. When an earth leakage breaker is used, select one with a trip current of 200 mA. One with
a trip current of 30 mA cannot be used for this machine equipped with inverters.
6-2
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[ ] : Optional
* 1: The spindle drive motor, and the servo motors are of the batch power supply scheme, the
ratios of the axes were calculated as follows:
Spindle drive motor : 1
X-axis servo motor : 0.2
Z-axis servo motor : 1
Table 6-2 Additional unit for FA
6-3
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An air source with the following specifications is required when an optional part is mounted that
requires air to operate.
1. Air source
Pressure 5 kgf/cm2 (71.2 PSI)
Discharge 100 Ni/min (3.53 ft3/min) (ANR) or larger
(Use a 0.75 kW (1 HP) compressor or equivalent.)
CAUTION
If the air has a high moisture content or if hot air is used, damage to the air actuators and
equipment could result. In such cases, use an air dryer or similar equipment.
2. Selection of compressor
A. The minimum required discharge pressure of a compressor is 5 kgf/cm2 (71.2 PSI). When
selecting a compressor, allow approximately 2 kgf/cm2 (28.5 PSI) margin.
B. Required discharge volume is 100 Ni/min (3.53 ft3/min) (ANR). With this volume, an air gun
can be used at the same time as the air blast.
C. There are three compressor operation types; manual unloader, automatic unloader, and
pressure switch types.
The compressor should be a pressure switch type for this machine model.
D. The compressor should be 1 HP (0.75 kW) in size. For details, contact a compressor maker.
CAUTION
- If the machine is to be installed near vibration generating equipment, a vibration-proof
drain must be provided around the machine foundation.
- If the soil is weak, reinforce it by driving piles into the soil to avoid subsidence and
inclination of the soil after machine installation.
For machine installation, select a flat place; avoid places subject to direct sunlight, humid places,
and places near heat generating equipment. Foundation work will vary according to soil conditions.
Compact the ground well or pour a concrete base to avoid subsidence or inclination of the soil after
machine installation.
6-4
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Foundation parts and their uses are listed in Table 6-3 and Fig. 6-2.
TR000-00021
TR113-00017
” Nut 7 pcs
TR113-00016
6-5
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To deliver the machine, the delivering entrance shown below is required. (Fig. 6-1)
A 1696
(66.77)
1850
(72.83) 1801
(70.91)
Unit: mm (in.)
Bolt
Nut
Plate
6-6
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WARNING
- Two or more workers are necessary to handle heavy objects.
- Only authorized workers should use a forklift or crane, or lift the machine using wire
ropes.
- When operating a forklift or crane, care should be taken not to hit other objects.
- Use wire rope or a sling that can tolerate the weight to be lifted.
- Check the chain block, wire rope or sling, hoist, or other lifting equipment before using
them. Never use defective wire rope/slings or lifting equipment.
CAUTION
- The machine must be lifted properly. Lift the machine slightly from the floor to check if it
is well balanced.
- The angle made by the wire rope or sling must be less than 60°.
- When two or more workers are working together to lift the machine, they should cooperate
carefully using signals.
- When lifting the machine, great care should be taken not to shock the machine, NC unit,
or electrical control cabinet.
- Before lifting the machine, check that each machine unit is fixed in position and that there
are no tools or other objects on the machine.
* The coolant unit will be delivered separately.
A. Fix the turret, the saddle, the tailstock, and the TOOL EYE (Japan: option, export: standard),
with power on.
Fix the turret at a distance of -185 mm (- from the zero point of the X-axis, that is, an
overtravel position in the minus direction of the X-axis).
Fix the saddle at the origin of the Z-axis.
Fix the tailstock at its backward end stop.
Fix the TOOL EYE at its backward end stop (retraction position). Refer to Subsection 6-2-3.
B. Turn off the machine power and the main power of the factory, and disconnect the factory
power - machine power connection cable from the circuit breaker of the machine.
C. Disconnect the cable and hose of the coolant unit (pump) from the machine.
Disconnect the cable by disconnecting the cannon connector from the side of the electrical
control cabinet.
Disconnect the hose from the pump. The residual coolant within the hose flows out. Receive
this coolant using a waste oil can. The total amount of outflow is about two liters.
Completely wipe away any coolant that may have spilled over the floor. Otherwise, workers
may overturn during lifting.
6-7
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D. Drain out the coolant from the coolant tank, then separate the tank from the machine, and
move the tank away to where the machine can be lifted smoothly.
A. Place the wire ropes on the bed hook (1 place) and on the both ends of the pipe that passes
the bed.
Use a wire rope and a pipe described in Fig. 6-4.
Use a crane with a 5 ton (11025 lbs) capacity or larger for lifting the machine.
C. Raise the arm of the crane to such an extent that the wire ropes become taunt, and make
sure that the ropes are firmly hooked on the machine body and at the chain block. If the
ropes are not correctly hooked, slacken and rehook them.
D. After checking that the wire ropes are correctly hooked, operate the crane to lift the machine.
6-8
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z25
89 (z0.98)
R90 Working load: 1.73t (3806 lbs) (3.50)
(R3.54) (Static load) MH-25
z16 (z0.63)
(Rubber protector)
1000 (39.37) 3060 (120.47)
2-Hexaon socket head cap 2-Hexagon socket headcap
screw M20×280 screw M20×220
(continuous thread stud) (continuous thread stud)
z90 Wire A Wire B
(z3.54) 35 (1.38) 65 (2.56)
z130
(z5.12)
8-Hexagon 55 (2.17) 85
(100) nut M20 (3.35)
(3.94) 520 (20.47) 500 (19.69) 330 100 (3.94)
Pipe carbon steel Unit: mm (in.)
1550 (61.02) (12.99)
or equivalent
8-z22 hole
Fig. 6-4 Chain block (8-z0.87) D320M0017
CAUTION
- When removing the rust preventive coating with cleaning oil, great care should be taken
so that the cleaning oil does not enter into the slideway surfaces passing the wiper.
- Used rags should be disposed of at a predetermined place.
1. The machine is shipped with transit clamps so that the machine units will not move during
transportation. After installing the machine, remove all of the transit clamps. Store the clamps,
bolts, etc. in a suitable place to allow for reuse during movement or transport in the future.
2. Install the covers and other parts, which are supplied in separate packages.
3. Cleaning
After having placed the machine on the base, remove the rust preventive coating from the
slideway surfaces and machined surfaces using rags and cleaning oil. Never try to operate any
section of the machine before cleaning since the rust preventive coating is apt to have been
contaminated with dusts and other foreign particles during machine transportation.
After having completely removed the rust preventive coating, apply the specified lubricant to the
slideway surfaces.
6-9
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TOOL EYE
(Japan: option, X-axis
export: standard)
Z-axis
Tailstock
6-10
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Fig. 6-6 Details for Each Transit Clamps Location (1/4) - TOOL EYE - TR113-00406
Fig. 6-6 Details for Each Transit Clamps Location (2/4) - Z-axis -
6-11
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Fig. 6-6 Details for Each Transit Clamps Location (3/4) - X-axis -
Fig. 6-6 Details for Each Transit Clamps Location (4/4) - Automatic tailstock (option) -
6-12
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The machining accuracy is greatly influenced by installation conditions. Install the machine carefully
to the utmost.
A. With the machine lifted, fit the foundation bolts, leveling bolt, nut and foundation plates to the
leveling bolt holes in the machine bed.
B. Lower the machine gently so that the foundation bolts are correctly inserted into the
foundation holes prepared according to the foundation plan.
* During this step, the leveling bolts cannot be used; pull up the machine from the bottom.
C. Adjust the machine level temporarily by driving wedges under the machine.
D. After leveling the machine temporarily, fix the foundation bolts with mortar.
Leveling bolt
25
(0.94")
100×100×t15
(4"×4"×5/8")
Foundation plate 100 140
(3.94") (5.5")
5-M16×320 320
(5>W5/8"×12") 15 (12.0")
Foundation bolt (0.62")
180
(6.5") 320
(12.0")
70
(2.5")
35 170
(1.5") (6.5")
205
(8.0") Unit: mm (in.)
6-13
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2. Checking interconnections
After leveling is finished, check and confirm the following items before turning the power on.
3. Adjust the machine height so that the clearance between the front cover and the chip pan will be
10 mm (0.39 in.) when the clearance between the machine bottom surface and the floor is 10
mm (0.39 in.).
Unit: mm (in.)
Clearance:
10 (0.39)
6-14
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Precision level
Leveling base
6-15
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6-3 Connecting the Power Supply Cable and Air Supply Hose
DANGER
Do not connect the power supply cable to the factory power distribution board until all
installation work has been completed.
2. Turn the breaker handle to the OPEN RESET position and pull the cover.
6-16
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3. Pass the power cable into the main power breaker cover.
T
S
Grounding terminal
R
5. Check for correct connection using a phase tester. Otherwise, damage to the important
sections of the machine may result.
6. Return the cover and breaker handle to their original position by pushing them into place.
6-17
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6-3-2 Grounding
1. All electrical devices must be grounded in order to protect personnel and machines from
electrical hazards. Grounding must be performed after the machine has been installed in
accordance with the standards for electrical equipment.
2. Ideally, the grounding point should be as close as possible to the machine, but depending on the
machine installation site this may not always be possible.
3. The work must be performed by personnel with publicly recognized qualifications. This will
depend on the size of the company, but generally there will be a chief engineer or someone
licensed to perform electrical work who should be asked to carry out the work. The work to be
done is basically class 3 grounding.
Grounding resistance: 100 ] max.
Cross-sectional area of wires: A half or more cross-sectional area of primary incoming cable
(at least 30 mm2 (0.046 in2)).
Measuring equipment: 500 V megger
WARNING
The grounding work must be entrusted to an electrical engineer with publicly recognized
qualifications. If the work is done by an unqualified person, it could result in serious
injury, death, or damage to the machine.
4. The connections between the machines and ground should be made as indicated below.
WARNING
Never perform wiring as shown below.
When the grounding work is performed, no more than one wire should be connected to
any terminal. The reason for this is to prevent a serious accident. For example, if a wiring
plan like the one shown above is used, a faulty connection at one of the terminals could
cause short-circuited current from another terminal to be fed back to the machine,
resulting in serious damage.
6-18
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A. Independent connections
B. Common connection
When an optional component is mounted that requires air to operate, connect the air supply both
correctly and firmly to the air connection port located at the bottom left of the machine.
6-19
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After connecting the power supply cables and air supply hose to the machine, check the following
points before starting trial operation.
1. The machine and machine parts are all free from damages.
3. Each part of the machine is lubricated with the specified lubricating oil.
6-20
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7. TROUBLESHOOTING
7-1 Headstock
If a problem occurs with the spindle, check the LED indication at the spindle unit in the electric
control cabinet and contact your local MAZAK service representative.
Overheating of headstock - The magnetic contactor (KM12) is tripped. - Reset the magnetic contactor (KM12).
(See Section 5-11)
* The alarm message 261 * If the alarm state cannot be cleared after * Contact your local MAZAK service
HEAD LUBRICATION resetting the contactor, the motor is faulty. representative.
ALARM is displayed on
the CRT screen.
Motor does not rotate. - The power switch is off. - Turn ON the power.
- If the power switch is not off, the no-fuse - Change the no-fuse breaker or the
breaker (OF1) or the magnet contactor is magnet contactor.
faulty.
- If the lamp is not lit, the inverter is faulty. - Change the inverter.
The motor hums but does - Heavy load or short acceleration time setting. - Decrease the machine side load, or
not rotate. increase the acceleration time setting.
The motor is overheated. - Check if the motor is overloaded. - Decrease the machine side load.
The motor does not rotate - Check if the motor is overloaded. - Decrease the machine side load.
smoothly.
7-1
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7-2 Chuck
The chuck does not operate. - Chuck component part is damaged. - Disassemble the chuck and replace the
broken parts.
- The rotary hydraulic cylinder does not - Check the hydraulic system.
function.
Master jaw stroke is not - Large volume of chips are accumulated - Disassemble and clean the chuck.
sufficient. inside the chuck.
Workpiece slips in the chuck. - Master jaw stroke is insufficient. - Adjust master jaw stroke.
- Top jaws are not shaped correctly to the - Shape the top jaws correctly.
workpiece diameter.
- Master jaw and other sliding parts are not - Grease them.
lubricated correctly.
Accuracy is not high. - The chuck is shaking. - If the chuck is shaking, retighten the
bolts.
- Foreign matter on serration of master and - Remove the top jaws and clean the
chuck jaws. serration.
- Top jaw clamping bolts are loose. - Tighten the bolts to the specified
torque.
- Top jaws are too high causing deformation, - Lower the top jaws.
or top jaw clamping bolts are loose.
7-2
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7-3 Turret
The turret is not - The clamp control solenoid valve is not - Check the solenoid valve or change it.
clamped/unclamped. operating correctly.
The turret does not rotate - The TURRET UNCLAMP menu is set. - Make the TURRET UNCLAMP menu
although it is unclamped. ineffective.
- The index coupling teeth do not engage - Contact your local MAZAK
correctly. representative.
- The bolts and mechanical connecting - Retighten the bolts and span ring.
element (span ring) fixing the turret are loose.
The turret keeps rotating - The turret position detection encoder is faulty. - Check the position detection encoder
without positioning. or change it.
- The clamp control solenoid valve is not - Check the valve or change it.
operating correctly.
The turret rotates but stops - The index coupling teeth do not engage - Contact your local MAZAK
halfway. correctly. representative.
- The clamp control solenoid valve is faulty. - Check the solenoid valve or change it.
- The turret position detection encoder is faulty. - Check the position detection encoder
or change it.
The turret rotates but does - The index coupling teeth do not engage - Contact your local MAZAK
not index correctly. correctly. representative.
The TOOL EYE does not operate. - The proximity switch (SQ7 or SQ8) is - Adjust or replace the proximity switch
* The following alarm message is faulty. (SQ7, SQ8).
displayed. - Wiring is broken or socket is loose. - Replace the wiring.
“209 INCORRECT TOOL EYE
ARM POSITI”
“231 TOOL EYE POSITION
SENSOR MALF”
7-3
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7-5 X-axis
Positioning is not accurate. - Bolts, taper pins and/or nuts are loose. - Tighten them.
The X-axis zero point is not fixed - Mounting bolt for X-axis zero point limit - Retighten the bolt.
(the variation is less than 10 mm switch is loose.
(0.394 in.)).
The X-axis zero point is not fixed - The X-axis zero point dog is not - Adjust the X-axis zero point dog.
(the variation is more than 10 mm adjusted.
(0.394 in.)).
7-6 Z-axis
Positioning is not accurate. - Bolts, taper pins and/or nuts are loose. - Tighten them.
The Z-axis zero point is not fixed - Mounting bolt for Z-axis zero point limit - Retighten the bolt.
(the variation is less than 12 mm switch is loose.
(0.47 in))
The Z-axis zero point is not fixed - The Z-axis zero point dog position is - Adjust the Z-axis zero point dog
(the variation is more than 12 mm not adjusted. position.
(0.47 in))
7-7 Tailstock
The tail spindle does not move - The tail spindle thrust power is - Adjust the thrust power.
forward and/or backward. excessively high.
- The solenoid valve does not operate - Check the solenoid valve and replace
correctly. it, if necessary.
- The proximity switch does not operate - Adjust the proximity switch and replace
correctly. it, if necessary.
Noise from the rotary center - The tail spindle thrust power is - Adjust the thrust power.
excessively high.
7-4
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Oil is not discharged. - The pump does not rotate. - Check the connection of the power cable.
- The pump is rotating in the reverse - Check the polarity of the power supply.
direction.
- Suction pipe is clogged. - Check the suction pipe.
- Strainer is clogged. - Clean the strainer.
- Leak in suction pipe - Check the suction pipe and its joint.
- Suction filter is not completely immersed - Replenish the hydraulic oil with the same
in oil. grade up to the reference line in the level
sight gauge.
- Discharge volume adjusting sleeve is - Loose the sleeve.
tightened excessively.
- Hydraulic oil viscosity is too high. - Replace the oil entirely with oil of correct
viscosity.
* Warm the oil using a heater as temporary
measures.
Although oil is discharged, - The relief valve is not operating - Disassemble and check the relief valve.
pressure is not built up. correctly.
- Load is not applied in the hydraulic - Check the circuit and apply the load.
circuit.
- Leak in the hydraulic system. - Check the piping and repair the leak.
Oil is not discharged or - Seals inside the pump are broken. - Contact your local Mazak service
volumetric efficiency lowers representative.
when pressure is built up.
- Slide portions are worn abnormally due
to dust and foreign matter.
Noise is excessively large. - Strainer is clogged. - Clean the strainer.
- Air is sucked from the suction pipe or - Check the point where air is sucked by
other portion. applying oil on the suspected portions.
- Bubbles inside the reserve tank. - Check the return pipe and prevent
generation of bubbles.
- Bubbles trapped inside the piping. - Repeat inching of the pump to discharge
the bubbles.
- Low oil level - Replenish the specified grade of the
hydraulic oil up to the reference line in the
level sight gauge.
- Pump mount base is not rigid. - Use rigid base; check loose bolts as well.
- Pump sliding portions exhibit wear. - If the wear is abnormal, check for oil
contamination, water in the oil, oil viscosity,
and oil temperature during pump operation.
Pump generates heat. - Heat generation due to improper - If the pump surface temperature rises
volumetric efficiency. excessively, stop pump operation
immediately.
- Seizure on sliding portions of the pump
7-5
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Lubricating oil pressure drops below - Lubricating oil is insufficient. - Add lubricating oil.
1.0 kgf/cm2 (14.2 PSI).
- Leak from the lubrication pipe. - Retighten the pipe.
The alarm message 260 SLIDEWAY
- Lubrication pipe is clogged. - Clean the pipe.
LUBRICATION ALARM is displayed
on the CRT screen.
Coolant is not supplied. - Filter of the coolnt tank is clogged. - Clean the filter.
Air flow volume decreases due to - Element is clogged. - Change the element.
high air flow resistance.
The alarm message 261 HEAD LUBRICATION ALARM is displayed on the CRT screen if an error
occurs in the headstock cooling unit. Refer to the Alarm List for details.
The alarm message 261 HEAD - Coolant is insufficient. - Replenish the coolant.
LUBRICATION ALARM is
displayed on the CRT screen. - The pressure switch is faulty. - Change the pressure switch.
The centrifugal pump is not - The electromagnetic switch (KM12) is - Reset the electromagnetic switch
operating. tripped. (KM12). (See Section 5-11.)
* When the magnetic switch (KM12) is * If the pump is faulty, contact your local
not tripped, the pump is faulty. MAZAK representative.
7-6
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8. GRAPHIC MAINTENANCE
8-1 Outline
If a PC-related alarm occurs, the source of the alarm will be displayed in reverse form on a layout
diagram of the corresponding section. This display is therefore useful for early machine recovery.
PC: A unit that controls the operation of the movable components of the machine (except axial
operation).
8-2 Operations
1. If a PC-related alarm occurs, the following display will appear on the CRT:
or
X AXIS SERVO MOTOR
AIR KIT
TOOL EYE
SQ8
SQ7 SP3
HYD PUMP MOTOR
COOLANT MOTOR
8-1
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2. Change the display over using the page keys to identify the source of the alarm.
3. When a layout diagram of the corresponding section is displayed, the display status of the
section where the alarm has occurred will reverse in that diagram to identify the source of the
alarm.
TAIL SPINDLE
SLEEVE SLEEVE
FORWORD REVERSE
YV13 YV11
SQ26
VIEW B
aaaaaa
aaaaaa
A B SQ27
8-2
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SOLENOID FOR
CHUCK &
TAIL SPINDLE
AIR KIT
TOOL EYE
SQ8
SQ7 SP3 HYDRAULIC SERVO MOTOR
COOLANT MOTOR
8-3
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TURRET REV.
YV06
TURRET
FOR.
YV02 TURRET UNCLAMP
SQ04
TURRET CLAMP
SQ04 GEAR SHIFT GEAR SHIFT
YV06 TURRET
YV01
VIEW A
TAIL. TAIL.
FOR. REV.
YV13 YV11
SQ26
A B SQ27
VIEW B
8-4
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SQ30
SQ33 SQ34
SQ31
AIR KIT
AIR FILTER
PRESSURE SW.
SP02
8-5
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8-5 Parameter
When the display request turns on, the GRAPHIC MAINTENANCE display will also turn on
automatically.
If E50 (bit 6) = 1:
Even when the display request turns on, the GRAPHIC MAINTENANCE display will not turn on
automatically.
If E50 (bit 6) = 0:
8-6
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SQT-200 SQT-250
Item Description
Distance between spindle end and turret 130 to 665 119 to 654
mm (in.)
end face (5.12 to 26.18) (4.69 to 25.75)
9-1
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(Cont’d)
SQT-200 SQT-250
Item Description
Note:
The figures indicated in the machine plates shall be applied if ones in the manual may differ.
9-2
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SQT-200
30°
7°7'30"
z169 (6.65)
8 40.3
(0.31) 26 (1.59)
(1.02)
Taper 1/20
3-M5 10 (0.39)
854.3 deep holes
(33.63) (equidistant)
814
(32.05)
z69
(2.72)
z61 (2.40)
z77 (3.03)
9-3
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SQT-250
30°
7°7'30"
z165 (6.50)
8 40.3
(0.31) 26 (1.59)
(1.02)
Taper 1/20
864
(34.02)
z84
(3.31)
z76 (2.99)
z92 (3.62)
9-4
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1. SQT-200 (mm)
9-5
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2. SQT-200 (inch)
9-6
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3. SQT-250 (mm)
9-7
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4. SQT-250 (inch)
9-8
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Unit : mm
9-9
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2. SQT-200/250 (inch)
Unit : inch
9-10
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Front view
285 (11.22)
240 (9.45)
*z210 (8.27)
45 (1.77)
*z254 (10.0)
45 (1.77)
164 (6.46)
37 (1.46)
59 (2.32)
207.5 (8.17)
Unit : mm (inch)
9-11
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[ ]: for SQT-250
Face cover
43 (1.69) 322 (12.68) [302 (11.89)]
[63 (2.48)] 139(5.47) [150 (5.91)]
97 (3.82) 42 (1.65)
[104 (4.09)] [46 (1.81)]
34 (1.34)
34 (1.34)
45 (1.77)
80 66
(3.15) (2.60)
z210 (8.27) [z254 (10.0)] 146 (5.75)
285 (11.22)
Unit : mm (inch)
9-12