ME11 158 R02a

HORIZONTAL MACHINING CENTER
MB-500H
OPERATION & MAINTENANCE
(2nd Edition)
Pub No. 5074-E-R1 (ME11-158-R2) Jan. 2008
5074-E P-(i)
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
The machine is equipped with safety devices which serve to protect personnel and the machine itself from
hazards arising from unforeseen accidents. However, misoperation by the operator may lead to a serious
accident. To prevent such accidents, read through this manual and fully understand the machine functions
before operating the machine.
This instruction manual and the warning signs attached to the machine cover only those hazards which
Okuma can predict. Be aware that they do not cover all possible hazards. Okuma shall not be responsible for
any accidents caused by misuse or abuse of the machine by the operator.
The following are the precautions which must be exercised with extra care in machine operation and
maintenance. Every operator must read these precautions carefully and follow the instructions described
there.
1. Precautions When Installing the Machine

(1) To hoist the machine, only use wires of the specified dimensions and strong enough to support
the weight of the machine. Hoist the machine slowly.
(2) Operate the machine at an ambient temperature between 10 and 40°C (50 and 104°F) and a
relative humidity of 80 % or less for stable machine operation.
To maintain the static machine accuracy within the guaranteed values, the following conditions
must be satisfied:
• Ambient temperature: 17 to 25°C (62.6 to 77°F)
• Humidity: 75 % HR or less (without condensation)
• The machine and the NC unit must not be subject to direct sunlight.
• The machine and the NC unit must not be subject to any excessive vibrations.
• The installation site must be free of dust, acid, corrosive gases, and salt.
(3) Make sure that the floor is strong enough to support the machine.
(4) Secure enough space around the machine so that you can perform maintenance, inspection
and adjustment without any interference.
(5) The machine must be leveled carefully during initial installation;

leveling greatly affects the machining accuracy and the service life of the machine.
(6) Transit clamps are used for machine transportation. These clamps must be removed before
turning ON the power.
(7) Electrical wiring should only be carried out by Okuma"s service technician or authorized
electrical technician.
(8) Do not connect the machine power cable to the same power board as noise generating
equipment, such as an electric welder and electric discharge machine. Doing this will cause the
NC to malfunction.
(9) The machine should be grounded independently of other machines. If the machine must be
grounded with other machines, do not connect the ground cable to the same ground terminal as
noise generating equipment, such as an electric welder or an electric discharge machine.
(10) For details on installation, refer to Section 2.

5074-E P-(ii)
SAFETY PRECAUTIONS
2. Precautions Before Starting Machine Operation

(1) Use the specified lubricating and hydraulic oil or an equivalent.
(2) Do not apply mechanical shocks to the NC, operations panel, or electrical control cabinet.
Shocks applied to this equipment will malfunction or fail.
(3) Close all the doors to the NC, operation panel, and electrical control cabinet to prevent entry of
moisture, chips, and other foreign matter.
(4) Check the cables and wiring for damages. Damaged cables or wiring may cause leakage or an
electric shock.
(5) Always be sure that there are no obstacles or people near the machine"s movable parts before
operating the machine.
(6) Use a water-soluble coolant to prevent fire. When using non-water-soluble coolant for
unavoidable reasons, strictly observe the rules described in "10. Precautions against Fire".
(7) Set a proper value at the automatic lubrication interval according to your machine operating
condition. If the interval is too long, oil may be shorted, resulting in machine trouble.
3. Precautions During Machine Operation

(1) Perform daily inspection on the machine according to the daily inspection items described in
this manual immediately after turning ON the power.
(2) Use the cutting tools which meet the machine specification. Do not use tools having heavily
worn edge. Such tools may be a cause of accidents.
(3) Although the spindle stops momentarily during spindle orientation or rotating direction change,
never touch the spindle or the tool because it starts rotating immediately.
(4) Never apply torque to the spindle after the completion of spindle indexing operation, for
example by tightening the milling chuck. The spindle may rotate, causing serious accidents.
(5) Make sure that the tools and workpieces are tightened securely.
(6) Never touch the workpieces or the tools by bare hand.
(7) Never try to remove chips entangled in cutting tools by hand while the spindle is rotating.
To remove chips, make sure that the spindle has come to a complete stop, and use a brush or
broom.
(8) Never approach the cutting point during cutting. Coolant, chips, and/or broken tools splash.
(9) Never start machine operation without the safety devices in place. Never remove the covers
unless absolutely necessary.
(10) Before loading or unloading a workpiece or tool, make sure that the spindle has come to a
complete stop.
(11) Never touch movable parts or stand near the machine during operation.
(12) Before entering the inside of the enclosure shield, be sure to turn OFF the power supply to
ensure safety. Never enter the inside of the enclosure shield during automatic operation.
5074-E P-(iii)
SAFETY PRECAUTIONS
(13) Never touch any switch with wet hands, which is extremely dangerous.
(14) Visually check the switches on the operation panel before operating them.
4. Precautions on Maintenance and Inspection

(1) Always turn OFF the power supply before performing maintenance and inspection.
(2) It is dangerous to perform maintenance with the power ON. In that case, turn OFF the main
circuit breaker.
(3) Never change the parameter settings without consulting your Okuma representative.
(4) When performing maintenance or inspection which cannot be performed with the power OFF,
bring the spindle to complete stop.
(5) When the machine has stopped unexpectedly and inspection needs to be performed with the
power ON, do not touch the machine directly by hand. It might start suddenly.
(6) Perform maintenance or inspection while bearing possible machine motions in mind.
(7) During maintenance work, post up a notice to inform the other personnel that maintenance work
is being conducted for the prevention of accidental switching by them.
(8) If you should get on the top of the machine, be sure to use a ladder or stepladder and wear a
safety belt to ensure safety.
5. Precautitins on Operating the ATC and APC

(1) Before operating the ATC or APC, close the front door, APC door, and magazine door. Since
the tool change arm moves so quickly, it is very dangerous if you operate the ATC with the front
door open.
(2) The tool clamp mechanisms in the magazine, tool change arm, and spindle are constructed to
hold the tool securely. However, do not touch or stand near the ATC units while the ATC is
operating because the tools in these units might drop due to unexpected causes.
(3) When checking or replacing the tools in the ATC magazine, always select the step mode.
(4) Because chips adhering to the magazine or tool change arm will cause faulty operation of the
ATC, always remove them. However, never use compressed air to remove chips; compressed
air will cause chips to enter the ATC units.
(5) If the ATC or APC has stopped due to unknown reason and if it is necessary to check the ATC
or APC while the power is ON, never touch the units because they might begin moving
suddenly.
5074-E P-(iv)
SAFETY PRECAUTIONS
6. Powerful Magnet inside the Product

Some products contain powerful magnets, which could be dangerous if exposed by disassembling
the products. Those which contain powerful magnets are provided with a caution plate to indicate
where such magnets are used.
(1) Get assistance from Okuma for disassembling or repairing the powerful magnet housing unit.
• It is dangerous as strong magnetic attraction is exposed while/after disassembling the

strong magnetic housing unit.
• Disassembling work requires special knowledge and jigs.
(2) Danger of powerful magnet

Following are the examples of possible damage caused by being close to powerful magnet.
• Medical electronic instruments such as pacemaker produce malfunction, resulting in

serious bodily injury or loss of life.
• Implanted magnetic metal devices such as artificial eye, clip used for artery of the brain,
etc. get attracted by powerful magnet, resulting in loss of life.
• Metal clothing accessories get attracted by powerful magnet, resulting in bodily injury.
• Tools or parts get attracted by powerful magnet, resulting in bodily injury.
• Precision instrument becomes out of order.
• Magnetic memory device causes data loss.
(3) Contact Okuma when disassembling a magnet housing unit is necessary to dispose of the
machine.
7. General Precautions
(1) Always keep things in order around the machine. Wipe the floor immediately if it gets wet.
(2) Wear appropriate clothing while working, and follow the instructions of someone with sufficient
training.
(3) Make sure that your clothes and hair cannot become entangled in the machine. Machine
operators must wear safety equipment such as safety shoes, a helmet, and safety goggles.
(4) Machine operators must read the instruction manual carefully and make sure of the correct
procedure before operating the machine.
(5) Memorize the position of the emergency stop button so that you can press it immediately at any
time and from any position.
(6) Do not access the inside of the control panel, transformer, motor, etc., since they contain high-
voltage terminals and other components which are extremely dangerous.
(7) If two or more persons must work together, establish signals so that they can communicate to
confirm safety before proceeding to each new step.
5074-E P-(v)
SAFETY PRECAUTIONS
8. Symbols Used in This Manual

The following warning indications are used in this manual to draw attention to information of
particular importance. Read the instructions marked with these symbols carefully and follow them.
DANGER
indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING
indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION
indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION
indicates a potentially hazardous situation which, if not avoided, may result in damage to your
property.
SAFETY INSTRUCTIONS
indicates general instructions for safe operation.
9. Caution Plates
• The following caution plates are attached to the machine and related equipment. Carefully read
and follow the instructions inscribed on the plates.
• Do not peel or damage the caution plates. If a plate is lost or becomes illegible, request us to
send a new plate by letting us know the Okuma part number marked on the bottom right of the
plate.
5074-E P-(vi)
SAFETY PRECAUTIONS
9-1. Attachment of Caution Labels

(1) Caution Label Positions
Attach to the
column.
Attach to the
column.
ME11158R0200100100001
5074-E P-(vii)
SAFETY PRECAUTIONS
(2) Part Nos., Positions and Meanings of Caution Labels

No. Part No. Position and Meaning of Label
1 AMN3001AAA In the vicinity of operation panel (general caution)
2 AMN3002AAA In the vicinity of magazine (attention to magazine motion)
4 AMN3004AAB In the vicinity of spindlehead (injury by a cutter)
6 AMN3006AAA In the vicinity of ATC unit (injury caused by ATC motion)
7 AMN3007AAA At the left side of splash guard (injury by moving part)
8 AMN3008AAA At the front, right side or rear of splash guard
(attention to opening/closing door)
11 AMN3011AAA In the vicinity of a large moving body
(entanglement of operator"s body)
16 AMN3016AAA In the vicinity of power switch (high voltage)
17 AMN3017AAA Power outlet (attention to usage of power supply)
20 AMN3020AAA In the vicinity of chip conveyor
(entanglement of operator"s hand)
62 B0Z2000AAC Power supply section (power supply present)
* Specify the part Nos. shown above when ordering caution labels for replacement.
Keep the caution labels clean. Do not contaminate or remove them.
Replace caution labels with new ones when they become illegible due to damage
or wear.
Caution labels are offered in Japanese, English and German. Select the
language that can be understood by operators.
In addition to the caution labels, the precautionary instructions shown in this
manual under the titles listed above should be observed.
5074-E P-(viii)
SAFETY PRECAUTIONS
9-2. Types, Meanings and Locations of Caution Labels

1
ME11158R0200100110001
• Explains the safety-first operations of the overall machine.
• Post near the operation panel.
ME11158R0200100110002
• May cause severe bodily injury when standing close to the tool magazine while the machine is
in operation.
• Keep clear of the tool magazine while the machine is in operation.
• Post near the tool magazine.

5074-E P-(ix)
SAFETY PRECAUTIONS
ME11158R0200100110003
• May cause severe bodily injury when standing close to the rotating tool while the machine is in
operation.
• Keep clear and use caution while the rotating tool and machine are in operation.
• Post near the spindle.
ME11158R0200100110004
• May cause severe bodily injury when standing close to the rotating tool while the machine is in
operation.
• Keep clear and use caution while the rotating tool and machine are in operation.
• Post near the spindle.

5074-E P-(x)
SAFETY PRECAUTIONS
ME11158R0200100110005
• May cause severe bodily injury when standing close to the tool-change arm while the machine
is in operation.
• Keep clear and use caution while the tool-change arm is in operation.
• Post near the tool-changing arm.
ME11158R0200100110006
• May cause severe bodily injury when standing close to the tool-change arm while the machine
is in operation.
• Keep clear and use caution while the tool-change arm is in operation.
• Post near the tool-change arm.

5074-E P-(xi)
SAFETY PRECAUTIONS
ME11158R0200100110007
• May cause bodily injury by touching the moving parts or stepping into the moving range while
operting in AUTO mode.
• Keep clear of the moving parts and moving range while operating the machine in AUTO.
• Post near the moving parts.
ME11158R0200100110008
• May cause bodily injury from flying debris when opening the door of the machine while it is in
AUTO operation.
• Do not open the door while operating in AUTO.
• Post near the door.
10
ME11158R0200100110009
• May cause bodily injury by coming into contact with the lower moving part or stepping into the
moving range of the machine while operating in AUTO.
• Keep away from the lower moving body and moving range while operating in AUTO.
• Post near the lower moving body.

5074-E P-(xii)
SAFETY PRECAUTIONS
11
ME11158R0200100110010
• May cause severe bodily injury if the machine is started while working inside.
• Do not turn on the power while working inside the machine.
• Post inside the machine or on the moving body.
12
ME11158R0200100110011
• May cause head injury by standing up right under the slab top.
• Wear a safety helmet.
• Post under the slab top.

5074-E P-(xiii)
SAFETY PRECAUTIONS
13
ME11158R0200100110012
• May cause bodily injury by slipping on leaking liquid coolant on the floor.
• Wipe up liquid coolant from the floor.
• Post on the tank of the liquid coolant.
14
ME11158R0200100110013
• May cause severe bodily injury when working at an elevated location.
• Take safety precautions to prevent slippery surfaces when working at an elevated location.
• Post at elevated working locations.

5074-E P-(xiv)
SAFETY PRECAUTIONS
15, 16
ME11158R0200100110014
AMN3016BAA
ME11158R0200100110015
• Possibility of electrocution by coming into contact with the high voltage areas.
• Perform maintenance after shutting off the power supply.
• Post outside the electrical control panel.
17
ME11158R0200100110016
• Use as an outlet for the I/O equipment.
• Do not use the outlet for any other purpose.
• Post near the outlet.

5074-E P-(xv)
SAFETY PRECAUTIONS
18
ME11158R0200100110017
• Individuals may get caught between the slides, which may cause severe bodily injury, by
stepping to xlose to the slides during operation.
• Keep your head and body parts away from the slides during operation.
• Post on the slides.
19
ME11158R0200100110018
• May slip and cause severe bodily injury or damage by climbing on the cover.
• Do not climb on the cover.
• Post on the cover.
20
ME11158R0200100110019
• May cause severe bodily injury by putting hands in the chip conveyer while the machine is in
operation.
• Do not put hands in the chip conveyer during operation.
• Post on the chip conveyer.

5074-E P-(xvi)
SAFETY PRECAUTIONS
21
ME11158R0200100110020
• Pallets may be damaged when swung to the swing-prohibited range.
• Use the pallets outside the swing-prohibited range.
• Post on the pallets.
22
ME11158R0200100110021
• May cause bodily injury by getting hands close to the slides during operation.
• Keep hands away from slides during operation.
• Post on the slides.

5074-E P-(xvii)
SAFETY PRECAUTIONS
23
ME11158R0200100110022
• Tools may fall and cause bodily injury if not properly loaded to the spindle.
• Line up the key way to insert the tools.
• Post on the spindle head.
27
ME11158R0200100110023
• Possibility of electrocution by touching the terminals inside the control panel.
• Perform maintenance after turning off the power.
• Post inside the electric control box.

5074-E P-(xviii)
SAFETY PRECAUTIONS
28
ME11158R0200100110024
• May cause death from electrical shock by coming into contact with leak current.
• Perform maintenance after turning off the power.
• Post inside the electric control box.
29
ME11158R0200100110025
• May cause bodily injury by placing hands close to the spinning parts during operation.
• Keep hands away from the spinning parts during operation.
• Post near the spinning part.

5074-E P-(xix)
SAFETY PRECAUTIONS
30
ME11158R0200100110026
• May cause severe bodily injury by performing maintenance without shutting off the power.
• Shut off the power to perform maintenance.
• Post at the opening of the main machine body.
50
ME11158R0200100110027
• Change the lever positions after stopping thru-the-tool coolant.
• Failure to do so may cause coolant splash, resulting in serious injury by slipping on the floor.
• Attach this label near the lever switching unit.

5074-E P-(xx)
SAFETY PRECAUTIONS
60
ME11158R0200100110028
• If you enter the machine during or immediately after blowing of nitrogen, you may be suffocated.
• Do not open the door while nitrogen is used.
• Attach this label to the door.
61
ME11158R0200100110029
• If you enter the machine during or immediately after blowing of nitrogen, you may be suffocated.
• Do not open the door while nitrogen is used.
• Attach this label to the door.

5074-E P-(xxi)
SAFETY PRECAUTIONS
62
BOZ2000AAC
ME11158R0200100110030
• High voltage! Do not touch. Negligence of this warning may cause electrical shock resulting in
death.
• Be sure to turn off the power before starting maintenance service.
• Attach this label on the outside of the electrical control box.
WARNING
• Warm the machine up about 30 minutes before the start of machining to protect the
machine from excessive wear, maintain its accuracy and stabilize the product accuracy.
• After power-up, break the spindle in and perform no-load run of the ATC.
• Slowly increase the spindle speed from a lower level for 10 to 20 minutes’ operation.
(For the high-speed machine, make an automatic run for about an hour.)
• Extreme care should be taken when increasing the spindle speed over 4000 min-1.
• The automatic operation program should include functions of machine components.
CAUTION
• Mount the tool to the holder out of the machine.
• Use a tool with an imbalance not larger than 2g-cm. If the imbalance is not known, slowly
increase the revolving speed from a lower level and, if excessive vibration occurs,
immediately stop the spindle and check the tool imbalance.
• When revolving the spindle without any tool, do not raise the spindle speed over 1000
min-1.
• Do not use compressed air to remove particles and chips from the machine body,
control box, NC unit and surrounding floor.
5074-E P-(xxii)
SAFETY PRECAUTIONS
10. Safety Precautions

(1) Before operating the machine, carefully read and understand the operation manual and all the
safety precautions.
(2) Never enter the machine movable range during automatic operation.
(3) When entering the machine movable range for unavoidable reason, turn off the power or cancel
the automatic operation to ensure safety.
(4) The machine is equipped with various safety devices to protect the operator and the machine.
Never operate the machine without such devices in place.
(5) Securely clamp the workpiece and the tool and select feedrates and spindle speeds suitable for
the machining.
(6) Whenever operating the machine, outfit yourself with appropriate clothes (including shoes,
Helmet, and safety goggles).
(7) Clean or inspect the machine after stopping the machine. Never attempt cleaning or inspection
during machine operation.
(8) If two or more operators work together, they must cooperate and communicate with each other.
(9) Only the qualified personnel should install or repair the machine according to the procedures
described in Okuma maintenance manual. Before repairing the machine, be sure to turn off the
power.
5074-E P-(xxiii)
SAFETY PRECAUTIONS
11. Precautions against Fire

Selecting Coolant
• Use nonflammable coolant.
a. Never use oil coolant because it could catch fire from heated chips, tool’s frictional heat, or
grinding spark.
• When using oil coolant for unavoidable reason, observe the following:
a. Check the tool edge condition, tool life, and set the cutting conditions that never cause fire
before you start machining.
b. Clean the coolant filter at regular intervals to maintain sufficient coolant discharge, and
always check the coolant for normal discharge.
c. Take every measures so that you can extinguish the fire immediately by placing a fire
extinguisher near the machine and have an operator always watch the machining
condition, or installing an auto extinguisher.
d. Do not place any flammable objects near the machine.
e. Dispose of chips not to allow them to stack.
f. Periodically clean the inside and surrounding of the machine while checking that all the
devices are normally operating.
g. Never attempt untended operation.
h. When using oil coolant for grinding, you are requested to install fire-fighting equipment
such as auto extinguisher. In this case, inform us of your intention in the stage of examining
your facility.
Grinding Flammable Materials
• Before grinding any of the flammable solid materials such as resin, rubber, or wood, carefully
study and understand the material characteristics and observe the above precautions to take all
possible measures to prevent fire.
• Use particular care when grinding magnesium, because its chips react to the water-soluble
coolant and generate hydrogen. The hydrogen may catch fire from burnt chips, resulting in
explosive fire.
Performing Dry Machining
• Dry machining is a fire hazard because workpiece, tool, or chips are not cooled. Therefore,
never place any flammable objects near the machine and dispose of chips not to allow them to
stack.
• Take the same safety measures as in the case of using oil coolant described above, such as
checking the tool edge state and tool life, and setting cutting conditions that never cause fire.
Emergency Measures in Door-close and Power-OFF State
• Should fire break out in the machine when the door is closed and the power is OFF, open the
door using the door lock switch release key and extinguish the fire.
(For details, refer to "Safety door switch" in Section 3. Interlock.)
5074-E P-(i)
INTRODUCTION
INTRODUCTION
Thank you very much for purchasing Okuma MB-500H horizontal machining center.
This instruction manual describes MB-500H controlled by OSP-E100M, and covers not only the standard
functions but also various optional functions. When reading this manual, ignore description of the functions
that you did not select.
For the instructions related with the control system, refer to the OSP Operation Manual, Programming
Manual, and Special Functions Manual.
To make the most of the machine"s outstanding performance and accuracy over a long period, thoroughly
read this manual, and operate or maintain your machine in proper manners by following the instructions given
here.
5074-E P-(i)
CONTENTS
CONTENTS
SECTION 1 GENERAL INFORMATION
SECTION 2 HANDLING AND INSTALLATION OF MACHINE
SECTION 3 PREPARATION FOR OPERATION
SECTION 4 OPERATIONS
SECTION 5 INSPECTION, MAINTENANCE AND ADJUSTMENTS
SECTION 6 ATC
SECTION 7 AUTOMATIC PALLET CHANGER (APC)
SECTION 8 APPENDED DIAGRAMS
SECTION 9 SPARE PARTS LIST

5074-E P-(i)
TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION 1 GENERAL INFORMATION ......................................................................1
1. Machine Specifications ............................................................................................................ 1
2. Dimensional Drawings ............................................................................................................. 3
3. Installation Plan ....................................................................................................................... 4
4. Names of Main Components ................................................................................................... 5
5. Standard Accessories.............................................................................................................. 6
6. Precautions When the 15,000 min-1 Specification for Selected ............................................... 6
7. Whole Cover Door Lock........................................................................................................... 7
7-1. Door Lock Function .......................................................................................................... 7
7-2. Door Lock Switch Positions and Types ............................................................................ 7
7-3. Door Lock Releasing in Emergency ................................................................................. 8
7-4. Door Lock Switch.............................................................................................................. 9
8. Coolant .................................................................................................................................. 11
8-1. Recommended Coolant .................................................................................................. 11
8-2. Precautions for Preventing Fire ...................................................................................... 11
8-3. Other Precautions for Using Non-water-soluble (Oil) Coolant ........................................ 11
8-4. Classification of (Water-soluble) Coolant Performance .................................................. 12
SECTION 2 HANDLING AND INSTALLATION OF MACHINE ..................................14

1. Site Selection Guidelines....................................................................................................... 14
2. Foundation Requirements ..................................................................................................... 15
3. Fixing the Machine in Floor with Hole-in (Chemical) Anchors ............................................... 15
4. Foundation Plan..................................................................................................................... 16
5. Handling Jack Screws ........................................................................................................... 17
6. Preparation Before Delivery................................................................................................... 17
6-1. Power Requirements ...................................................................................................... 17
6-2. Compressed Air Supply .................................................................................................. 18
6-3. Lubricating and Hydraulic Oil.......................................................................................... 18
7. Handling Procedures ............................................................................................................. 19
7-1. Lifting the Machine ......................................................................................................... 19
7-2. Relocating the Machine with a Fork Lift.......................................................................... 21
7-3. Relocating the Machine with Hangers ............................................................................ 22
8. Machine Transportation by Truck .......................................................................................... 23
9. Before Removing Y-axis Drive Motor .................................................................................... 23
10.Machine Installation ............................................................................................................... 24
10-1.Temporary Installation ................................................................................................... 24
10-2.Assembling the Units and Parts Shipped Separately .................................................... 24
10-3.Leveling the Machine..................................................................................................... 25
5074-E P-(ii)
TABLE OF CONTENTS
SECTION 3 PREPARATION FOR OPERATION .......................................................26

1. Overview................................................................................................................................ 26
1-1. Lubrication Chart ............................................................................................................ 27
1-2. Lubrication Chart Symbols ............................................................................................. 28
1-3. Lubricating Oil Specifications ......................................................................................... 29
2. Lubrication and Inspection Method........................................................................................ 31
2-1. Supplying Oil to the Hydraulic Power Unit ...................................................................... 31
2-2. Supplying Oil to the Oil-air Lubrication Unit .................................................................... 32
2-3. Spindlehead Cooling Unit ............................................................................................... 33
2-4. Centralized Lubrication Unit ........................................................................................... 35
3. Lubrication Warning System - Lubrication Alarm................................................................... 36
4. Manual Lubrication ................................................................................................................ 37
5. Automatic Centralized Lubrication ......................................................................................... 38
5-1. Pump Off-Time Display .................................................................................................. 38
5-2. Parameter Data Setting for the Automatic Lubrication Timer ......................................... 39
SECTION 4 OPERATIONS........................................................................................40
1. Operation Panels ................................................................................................................... 40
1-1. Operation Panel Layout .................................................................................................. 40
1-2. Operation Panels ............................................................................................................ 41
1-3. NC Operation Panel ....................................................................................................... 42
2. Manual Operations ................................................................................................................ 43
2-1. Power ON/OFF ............................................................................................................... 43
2-2. Emergency Stop ............................................................................................................. 46
2-3. Spindle Rotation in Neutral (Spindle Release) ............................................................... 47
2-4. Spindle Orientation (Orient-stop of the Spindle) ............................................................. 48
2-5. Clamping and Unclamping the Tool in Spindle............................................................... 50
2-6. Reference data ............................................................................................................... 52
2-7. Spindle Speed ................................................................................................................ 55
2-8. Spindle CW, CCW, and Stop.......................................................................................... 57
2-9. Feed Axes X, Y, Z .......................................................................................................... 58
2-10.Manual Pulse Feed........................................................................................................ 63
2-11.Coolant Supply Unit....................................................................................................... 65
2-12.Chip Flusher .................................................................................................................. 68
2-13.Work Light ..................................................................................................................... 69
2-14.Drill Holder for Through-the-tool Coolant....................................................................... 70
2-15.Table Indexing Operation .............................................................................................. 71
2-16.Operation End Lamp, Buzzer and Auto Power Shutoff Lamp (Signal Tower)................ 72
SECTION 5 INSPECTION, MAINTENANCE AND ADJUSTMENTS.........................74

1. Periodical Inspection.............................................................................................................. 74
1-1. Inspection Points ............................................................................................................ 75
1-2. Inspection Items ............................................................................................................. 76
5074-E P-(iii)
TABLE OF CONTENTS
1-3. Procedures ..................................................................................................................... 84

2. Maintenance and Inspection of Peripheral Units ................................................................. 112
2-1. Lubrication of Axis Slideways ....................................................................................... 112
2-2. Refilling the Oil-air Lubricator ....................................................................................... 114
2-3. Refilling the Hydraulic Unit ........................................................................................... 116
2-4. Refilling the Spindle Coolant Tank ............................................................................... 118
2-5. Pneumatic Unit ............................................................................................................. 120
2-6. Other Pneumatic Devices ............................................................................................. 125
2-7. Spindle.......................................................................................................................... 125
2-8. X-, Y- and Z-axes ......................................................................................................... 125
2-9. Automatic Tool Changer (ATC) .................................................................................... 126
2-10.APC Unit...................................................................................................................... 129
2-11.Telescopic Covers for Axes......................................................................................... 131
SECTION 6 ATC ......................................................................................................132

1. Tool Preparation .................................................................................................................. 132
1-1. Preparing Tools ............................................................................................................ 132
2. Dimensions of Tool Shank and Pull Stud (MAS2) ............................................................... 134
2-1. Tool Shank and Pull Stud ............................................................................................. 134
2-2. Tool Shank Dimensions................................................................................................ 135
2-3. Pull Stud Dimentions .................................................................................................... 140
3. Tooling for ATC.................................................................................................................... 141
4. Setting Tools into the ATC Magazine .................................................................................. 142
5. Manual Magazine Indexing Operation ................................................................................. 143
5-1. Conditions for Manual Magazine Indexing ................................................................... 143
5-2. Procedure ..................................................................................................................... 144
6. Manual ATC Operation ........................................................................................................ 145
6-1. One Step Advance and One Step Reverse .................................................................. 145
6-2. One Cycle Start and Return Cycle Start ....................................................................... 146
6-3. Precautions for Manual ATC Operation........................................................................ 146
7. Initial Conditions for Continuous ATC Operation ................................................................. 152
8. Automatic Tool Change Sequence ...................................................................................... 153
8-1. Automatic Tool Change Sequence ............................................................................... 154
9. ATC Operation Sequence Diagram ..................................................................................... 157
10.Safety Precautions for ATC Operation ................................................................................ 158
11.ATC Magazine Door Interlock.............................................................................................. 158
SECTION 7 AUTOMATIC PALLET CHANGER (APC) ............................................159

1. Outline of Rotary Type 2-pallet APC.................................................................................... 159
2. Automatic Pallet Change Operation Sequences ................................................................. 161
2-1. Parallel 2-pallet APC Operation Sequences................................................................. 161
2-2. APC Operation Sequence ............................................................................................ 161
3. Initial Conditions for APC Continuous Operations ............................................................... 163
5074-E P-(iv)
TABLE OF CONTENTS
3-1. Parallel 2-pallet APC Continuous Operation ................................................................ 163

4. Manual APC Operations ...................................................................................................... 165
4-1. One Step Advance and One Step Reverse .................................................................. 165
4-2. 1 Cycle Start and Return Cycle Start............................................................................ 166
4-3. Precautions for Manual APC Operation ....................................................................... 166
5. Pallet Dimensions ................................................................................................................ 167
5-1. Pallet with Tapped Holes (Metric System).................................................................... 167
5-2. Pallet with T-slots (Metric System) ............................................................................... 168
6. Safety Precautions for APC Operation ................................................................................ 168
SECTION 8 APPENDED DIAGRAMS .....................................................................169

1. Spindle Nose Dimensions.................................................................................................... 169
1-1. 15,000 min-1 .................................................................................................................. 169
2. Hydraulic Circuit Diagram .................................................................................................... 170
3. Pneumatic Circuit Diagram .................................................................................................. 172
4. Skeleton Drawing................................................................................................................. 174
4-1. Spindle Drive Mechanism 15,000 min-1 ........................................................................ 174
4-2. X-, Y- and Z-axis Drive Mechanism .............................................................................. 175
5. Machine Device Layout (MB-500H)..................................................................................... 178
SECTION 9 SPARE PARTS LIST ............................................................................185

1. Motor/Pump-related Parts.................................................................................................... 186
2. Solenoid Valve List .............................................................................................................. 187
3. Sensors................................................................................................................................ 189
4. Mechanical Parts ................................................................................................................. 191
5074-E P-1
1. Machine Specifications
Item Specification
A-0 Travel
A-1 X-axis (column right/left) 800 mm (31.50 in.)
A-2 Y-axis (spindlehead up/down) 800 mm (31.50 in.)
A-3 Z-axis (table front/back) 800 mm (31.50 in.)
A-4 Table top face to spindle center 70 to 870 mm (2.76 to 34.25 in.)
A-5 Table centerline to spindle end 150 to 950 mm (5.91 to 37.40 in.)
B-0 Table
B-1 Working surface area 500 × 500 mm (19.69 × 19.69 in.)
B-2 Max. load capacity 500 kg (1,100 lb)
B-3 Shape of top face 24-M16 tap
B-4 Min. index angle 1°
B-5 Height of top face 1,160 mm (45.67 in.)
C-0 Spindle
C-1 Spindle speed 50 to 15,000 min-1
C-2 Number of spindle speed ranges Infinitely variable
C-3 Taper hole 7/24 taper No. 40
C-4 Inside diameter of spindle bearing φ70 mm (2.76 in.)
D-0 Feedrate
D-1 Rapid feedrate 90,000 mm/min (3543.31 in./min)
D-2 Cutting feedrate 1 to 60,000 mm/min
(0.039 to 2362.20 in./min)
E-0 ATC
E-1 Tool shank type MAS BT40
E-2 Pull stud type MAS P40T-II
E-3 Tool magazine capacity 40 tools
E-4 Max. tool diameter φ75 mm (2.95 in.) [φ145 mm (5.71
in.) with no adjacent tools]
E-5 Max. tool length 350 mm (13.78 in.)
E-6 Max. tool weight 8 kg (17.6 lb)
E-7 Tool selection system Memory random
5074-E P-2
Item Specification
F-0 APC
F-1 No. of pallets 2
F-2 Pallet change system Rotary
G-0 Motors
G-1 Spindle motor 26kW (34.67 hp) (10 min)/ 18.5kW
(24.67 hp) (cont)
G-2 X-/Y-/Z-axis feed motor 5.1 kW (6.80 hp)
G-3 Index table drive motor 1.5 kW (2.00 hp)
G-4 Hydraulic unit motor 2.2 kW (2.93 hp)
G-5 Lubrication unit motor (for ball screws and guides) 17W (22.67 hp)
Lubrication unit motor (for spindle) 90W (120.00 hp)
G-6 Coolant motor For coolant nozzle 0.43/0.685 kW (0.57/0.91 hp)
For chip flusher 0.39/0.62 kW (0.52/0.83 hp)
G-7 Spindle cooler motor 0.4 kW (0.53 hp)
G-8 Magazine motor 1.5 kW (2.00 hp)
G-9 ATC arm motor 1.5 kW (2.00 hp)
G-10 Ball screw cooler motor 0.4 kW (0.53 hp)
H-0 Primary power sources

H-1 Power supply AC200/220V±10% 40kVA
50/60Hz±2%
H-2 Pneumatic pressure source 0.5 to 0.8 MPa (72.55 to 116.08 psi)
600 L/min (158.52 gal) (at
atmospheric pressure)
J-0 Machine dimensions

J-1 Machine height 3,012 mm (118.58 in.)
J-2 Floor space requirement (width x depth) 2,800 mm × 4,880 mm
(110.24 in. × 192.13 in.)
J-3 Machine weight (incl. numerical control unit) 11,000 kg (24,200 lb)
5074-E P-3
2. Dimensional Drawings
ME11158R0200300020001
5074-E P-4
3. Installation Plan
ME11158R0200300030001
5074-E P-5
4. Names of Main Components
ME11158R0200300040001
(1) Bed (7) NC unit

(2) Automatic tool changer (ATC) (8) CRT/MDI operation panel
(3) B-axis index table (9) ATC operation panel
(4) 2APC (pallet) (10) ATC operation panel
(5) Spindlehead (11) APC safety door
(6) Column
5074-E P-6
5. Standard Accessories
Operation tool kit
(1) A single-ended wrench (41)
(2) A tool remover lever
(3) A bottle of spray grease
(4) A lubricant bucket
(5) A set of mounting blocks
ME11158R0200300050001
6. Precautions When the 15,000 min-1 Specification for

Selected
WARNING
• Slowly increase the spindle speed from a lower level for 10 to 20 minutes’ operation.
(For the high-speed machine, make an automatic run for about an hour.)
• Extreme care should be taken when increasing the spindle speed over 4000 min-1.
CAUTION
• Mount the tool to the toolholder in outside of the machine.
• Use a tool with an imbalance not larger than 2g-cm. If the imbalance is not known, slowly
increase the revolving speed from a lower level and, if excessive vibration occurs,
immediately stop the spindle and check the tool imbalance.
• When revolving the spindle without any tool, do not raise the spindle speed over 1000
min-1.
5074-E P-7
7. Whole Cover Door Lock
7-1. Door Lock Function

The machine has the automatic lock mechanism and interlock function of the front door in the whole
cover to ensure the safety of machine operators and other persons.
• During automatic operation, the door is locked.
• Automatic operation and MDI operation cannot be started while the door is open.
• For setup or checking a program, it is possible to operate the machine within the specified
limitations on spindle speed and axis feedrates with the door open by turning the door interlock
switch off.
For details of the specifications, refer to the table in the next page.
WARNING
Door interlock switch
Never remove or modify the door interlock switch.
If the switch becomes faulty, please contact Okuma or Okuma"s service representative
immediately. It is strictly forbidden to operate the machine with the faulty door interlock
switch.
7-2. Door Lock Switch Positions and Types
Position Type
Operator door Spring lock
APC door Electromagnetic lock
Magazine door Electromagnetic lock
WARNING
The operator door is locked when the power is turned OFF. Therefore, be sure to use a door
stopper to prevent the door from being locked before you enter the machine.
5074-E P-8
7-3. Door Lock Releasing in Emergency

When the machine stops in an emergency, the door opens. When the power supply is turned off or
interrupted, however, the door does not open. In such a case, release the door lock in the following
procedure:
Procedure :
1- The door lock switch is mounted on the upper right of the operation door. (See figure below.)
2- Remove the cap on the release key hole of the door lock switch, and insert the special
release key into the hole.
3- Turn the special release key to UNLOCK to release the lock.
4- Open the door.
• When restarting the machine, turn the special release key from UNLOCK to LOCK.
• When the door is in unlock state, the machine does not operate even if the door is
closed.
• Only the parson in charge shall keep the special release key.
WARNING
• When entering the enclosure shielding after unlocking the door lock switch,
watch the spindle because it might be coasting. Do not get near the spindle until
you confirm that the spindle is stopped.
• Do not unlock the door during machine operation. The machine will stop
immediately if the door is unlocked.
Door lock switch
ME11158R0200300090001
5074-E P-9
7-4. Door Lock Switch
Items Door Status of Door Spindle NC Axis ATC MG

Advance
DOOR Inter lock ON/OFF Manual operations Operation door Close→Open × × × {
INTERLOCK switch “OFF” (manual door)
Open ▲ ▲ ● {
TYPE-E
MDI operations Close→Open × × × {
Open ▲ ▲ × {
Automatic Close→Open × × × {
operations single
Open ▲ ▲ × {
block ON
operations single
Open × × × {
block ON
Inter lock ON/OFF Manual operations Close→Open × × × {
switch “ON”
Open × × × {
MDI operations Close→Open × × × {
Open × × × {
operations single
Open × × × {
block ON
operations single
Open × × × {
block ON
Inter lock ON/OFF All modes MG door Open { { { ×
switch “ON/OFF”
2-pallet APC Open { { { {
door
Set-up ST door Open { { { {
Set-up ST Door Open halfway { { { {
{: Operation is enabled or can be continued.

▲: Operation is enabled or can be continued at the limited speed or feedrate described below:
• Max spindle speed: 800 min-1
• Cutting feed is impossible. Rapid traverse: max 2 m/min (78.74 ipm). B-axis rotation: max
1.4 min-1
• If the spindle rotation or axis feed command specified with the door open exceeds the
above limit, an alarm D occurs. If not, the command is executed.
●: Continuous operation (one cycle) is impossible and only one-step operation is permitted.
×: Operation is impossible or operation is stopped immediately.
Items Door Status of Spindle NC Axis ATC MG

Door Advance
DOOR INTERLOCK TYPE-E Operation door Open D/U: OFF D/U: OFF D/U: OFF MOTOR: ON
MG door Open D/U: ON D/U: ON D/U: ON MOTOR: OFF
2-pallet APC door Open D/U: ON D/U: ON D/U: ON MOTOR: ON
Set-up ST door Open D/U: ON D/U: ON D/U: ON MOTOR: ON
Set-up ST door D/U: ON D/U: ON D/U: ON MOTOR: ON
Operation recovery objective by ENABLING Operation door Open D/U: ON D/U: ON D/U: ON MOTOR: ON
UNLOCK button valid conditions for operator’s door Operation door Stop Stop Stop -
UNLOCK button valid conditions for setup station door Set-up ST door - - - -
5074-E P-10
Multi-pallet APC
2-pallet Chip
Items Set-up ST Start
APC Shifter APC Shifter Pallet MG Conveyer
Shifter
DOOR Inter lock ON/OFF Manual operations × × { { × -
INTERLOCK switch “OFF”
● ● { { × -
TYPE-E
MDI operations × × { { × -
× × { { × Unable (unable)
Automatic operations × × { { × -
single block ON
single block ON
Inter lock ON/OFF Manual operations × × { { × -
switch “ON”
× × { { × -
MDI operations × × { { × -
single block ON
single block ON
Inter lock ON/OFF All modes { { { { { Able
switch “ON/OFF”
× - - - { Able
- { { × { Able
- { × × { Able
( ): This indicates automatic door.
{: Operation is enabled or can be continued.

▲: Operation is enabled or can be continued at the limited speed or feedrate described below:
• Max spindle speed: 800 min-1
• Cutting feed is impossible. Rapid traverse: max 2 m/min (78.74 ipm). B-axis rotation: max
1.4 min-1
• If the spindle rotation or axis feed command specified with the door open exceeds the
above limit, an alarm D occurs. If not, the command is executed.
●: Continuous operation (one cycle) is impossible and only one-step operation is permitted.
×: Operation is impossible or operation is stopped immediately.
5074-E P-11
8. Coolant
8-1. Recommended Coolant

The table below shows the recommended coolants:
Products Maker Type Applicable materials to be cut

NC-21K TAIYU Soluble Casting, iron, aluminum
EX-106B TAIYU Emulsion Iron, aluminum
EX-366R TAIYU Emulsion Iron, aluminum, stainless steel
CAUTION
Use only the water-soluble coolant recommended by Okuma. Note that the water-soluble
coolant of soluble type (W2 type) other than listed above may damage the coating. Also
avoid using the chemical solution coolant because it damages not only the coating but also
the slideways where chemical reaction with the lubricating oil tends to occur, and the
rubber parts such as sealing material.
8-2. Precautions for Preventing Fire

From the standpoint of fire prevention, we recommend that you use water-soluble coolant. If you use
non-water-soluble (oil) coolant for unavoidable reason, be sure to install an oil mist collector. In this
case, never attempt untended operation. In addition, install a fire detector and auto fire extinguisher
to minimize the damage in case of fire.
8-3. Other Precautions for Using Non-water-soluble (Oil) Coolant

Non-water-soluble (oil) coolant is higher in viscosity and lower in specific heat than the water-soluble
coolant. This gives the non-water-soluble coolant the following characteristics:
• Not so effective in flushing chips.
• Coolant is not effectively collected or pumped up.
• Temperature rise of the coolant may affect machining accuracy.
Therefore, the following measures should be included in the machine specifications when non-
water-soluble coolant is used.
• Incorporating an internal conveyor (in the machine with chip flusher)
• Increasing the pump-up motor capacity for through-spindle coolant unit
• Adjusting the coolant temperature if high machining accuracy is required
Note
• Note that we are not liable for any defects in machine performance, accidents, or damage
caused by use of non-water-soluble (oil) coolant.
• Particularly, avoid using high viscosity (oil) coolant (with a viscosity of 10 cSt at 40°C or
over).
5074-E P-12
8-4. Classification of (Water-soluble) Coolant Performance

The roll of coolant is classified into the primary performance that is directly needed in metal cutting
and the secondary performance that is indirect but plays important rolls.
<Primary performance>
(1) Lowers the temperature at the cutting edge to reduce tool wear.
(2) Prevents melted chips from sticking to the cutting edge or building up on the edge to improve
the machined surface roughness and stabilize the dimensional accuracy.
(3) Reduces the cutting resistance and cools down the cutting system to prevent the system from
being deformed by thermal deviation.
<Secondary performance>
(1) Chemically reacts with the cut surface or coated surface to prevent corrosion or discoloration.
(2) Prevents generation of smoke or fire.
(3) Harmless to human body.
(4) Prevents fume generation, prevents the coolant from getting sticky or rotten or deteriorating.
(5) Easy to dispose of.
Among the above characteristics, determine which characteristics should precede the others.
JIS-specified water-soluble coolant
Class Type Main ingredients Application

W1 (No. 1 to 3) Emersion Mineral oil, detergent, corrosion/ Cutting or grinding various alloy
rust preventive compound steels and nonferrous alloy
W2 (No. 1 to 3) Soluble Detergent, corrosion/rust Light cutting or grinding
preventive compound
There are two types of water-soluble coolant:

Emersion type (W1) is emulsified to a white liquid like milk when diluted with water.
Soluble type (W2) becomes semitransparent or transparent when diluted with water. This coolant
has an excellent effect on penetration and cooling and frequently used for grinding.
Soluble type includes detergent as a main ingredient and features excellent penetrating, cooling and
washing effects and suitable for light cutting and grinding. In addition, resistance against rotting is
stronger than the emersion type. But due to its excellent washing ability, it may dissolve the
lubricating oil mixed with the coolant and damage the coating.
Select the coolant while keeping it in mind that there is no such coolant that satisfies both primary
and secondary performances, for example, the coolant which prolongs tool life in light cutting and
heavy cutting, assures accurate machined surface, and can be easily disposed of.
5074-E P-13
CAUTION
Use only the water-soluble coolant recommended by Okuma. Note that the water-soluble
coolant of soluble type (W2 type) other than listed above may damage the coating. Also
avoid using the chemical solution coolant because it damages not only the coating but also
the slideways where chemical reaction with the lubricating oil tends to occur, and the
rubber parts such as sealing material.
5074-E P-14
SECTION 2 HANDLING AND INSTALLATION OF

MACHINE
1. Site Selection Guidelines

At installation, the following points should be checked in order to ensure high accuracy and
performance.
(1) We recommend appropriate foundation work where the soil is soft or apt to sag after initial
installation.
See “Foundation Requirements” for reference.
(2) The installation site should be kept as far as possible from vibration sources, such as roads,
stamping/ press type equipment, or planer type machine tools. If nearby sources of vibration
are unavoidable, dampening pits around the machine foundation, for example, should help
lessen vibrations.
(3) Where there are high-frequency power generators, electric discharge machines or electric
welding machines around or when power is supplied from the same shop power distributor
panel, electrical interference may cause NC malfunctions. For assurances, consult our service
engineer dispatched for the installation.
(4) Keep the factory temperature between 10°C and 40°C with a humidity of up to 80%.
(5) Keeping ambient temperature at a constant level is an essential factor for accurate machining.
(6) In order to maintain static machine accuracy within guaranteed values, the machine should be
installed in an area where it is not affected by air flow. Air conditioning is not necessary but the
ideal ambient temperature is between 17°C (63°F) and 25°C (77°F) with a humidity of up to
75% (without condensation).
(7) To maintain static machine accuracy within the Standard Guaranteed Values:
a. Keep ambient temperature variance for a full day or 24 hours within ±2°C (36°F).
b. Ambient temperature variances from the floor level to a height of the machine (3 m (10 ft))
should be held within 1°C (34°F).
(8) Keep the floor level error within 10 mm (0.39 in.).

5074-E P-15
2. Foundation Requirements
With a solid ground, a concrete floor about 500 mm (19.69 in.) thick and no gaps between ground
and floor, foundation work or anchoring is not required. The structural rigidity of the machine permits
normal machining. The use of foundation bolts is not required, either.
However:
(1) for higher accuracy and performance,
(2) to maintain high accuracy and prolong intervals between periodical maintenance, and
(3) when the ground (type of soil) is not strong enough, refer to the provided Foundation Plan and
carry out the foundation work.
The foundation should be a smooth, concrete floor.

Use the following figure as a guide although the concrete thickness and floor area should be
determined according to the ground condition.
Determine the concrete thickness according to the subsoil condition.
ME11158R0200400020001
3. Fixing the Machine in Floor with Hole-in (Chemical)

Anchors
The machine accelerates and decelerates the spindle so quickly that it can perform high-efficiency
machining. If a machining cycle includes frequent starts and stops of spindle as in the case of die
cutting and if the floor is slippery with low friction coefficient, the machine may move because of
vibration generated by spindle starts and stops. To avoid such movement, it is recommended to fix
the machine in the floor using the hole-in (chemical) anchors.
Fixing the machine with hole-in (chemical) anchors is not effective for soft ground.
If the floor is soft, vibration is transmitted to the machine, affecting its machining accuracy.
The anchors may not be effective also when the concrete is not thick enough. For these reasons,
foundation work must be done for the purpose of giving sufficient concrete thickness and strength to
the ground.
When fixing the machine, refer to the foundation plan.
4.
Foundation Plan
Note: 1. This plan applies to general standard. Change the concrete thickness according
to the subsoil of the installation site.
2. Avoid machine installation in areas which are excessively dusty, exposed to This drawing shows the foundation work dimensions required for installing the
direct sunlight and subject to excessive temperature variations and vibrations or machine and not a working drawing. Please prepare your own working drawing.
impacts caused by nearby equipment.
3. Levelness of the installation surface shall be kept within 10 mm (0.39 in.).
4. Also refer to the installation drawing and dimensional drawing.
ME11158R0200400040001
5074-E P-16
5074-E P-17
5. Handling Jack Screws

Engage a hexagonal wrench with the leveling bolt and turn it clockwise to raise the machine body or
counterclockwise to lower it.
After leveling, tighten the lock bolt.
Adjustment bolt M55x2
Lock bolt
Mounting block
(3.35)
85
(1.97)
50
Ø200 (7.87)
Unit: mm (in.)
ME11158R0200400050001
6. Preparation Before Delivery
6-1. Power Requirements

The machine is designed and built to Japanese industrial Standard (JIS) specifications.
Power requirements are as follows:
Spindle 15,000 min-1

Voltage 200 VAC ± 10%
Cycle 50/60Hz
Capacity 45kVA
Phase Three-phase
Cable thickness 50 sq. (1.97 in.), 4-core (cables including ground cable)
The values in the table above varies depending on the optional specifications.
CAUTION
1) Connect the ground to the external protector connection terminal (PE) located inside the
control box.
2) Do not connect the power cord and the grounding wire in serial; if attempted, it will give
adverse affect to other equipment or cause malfunctioning of the leak breaker, etc.
3) When a leak breaker is used, select the one meeting the following rating.
• For inverter circuit use
• Sensitive current of 100 mA or more
• Fast-blow type (0.1 sec.)
5074-E P-18
6-2. Compressed Air Supply

The table below shows the specifications for the compressed air source, which are used for oil-air
lubrication for spindle, air blow to the tool shank taper activated during ATC cycle, chip air blower, oil
mist lubrication (optional), pallet seating air blow and confirmation for APC, and clamping NC rotary
table (optional).
Specifications of the compressed air supply are shown below.
Pressure 0.4 MPa (58.04 psi)

Air consumption 600 L/min (158.52 gpm) (ANR)
(1) Air pressure at the primary side should be kept above 0.5 MPa (71 psi).
(2) Compressed air should be supplied as free from moisture as possible even though the machine
is provided with an air filter.
The air jetted from the compressor may be hot and contain a lot of moisture. In this case, install
an after-cooler in the air circuit or use the piping of 12 (1/2) or 19 (3/4) in inside diameter
between the compressor and the air unit and prolong the piping length (for example 15 mm
(0.59 in.) or longer) so that the air temperature drops close to the room temperature.
(Temperature at air inlet: Within room temperature + 5°C (41°F))
When the air is cooled in the piping, however, water may collect in the piping. Since the
collected water reduces the effective area of the piping and causes pressure loss, drain water
by providing a drain cock at the lowest position.
(3) Air pressure at the secondary side should be kept constant at 0.5 MPa (71 psi) using the
pressure regulator on the machine.
6-3. Lubricating and Hydraulic Oil
Equipment Name Oil Type Oiling Amount

Spindle cooling unit (15,000 min-1) FC5 32 L (8.45 gal)
Spindle bearing lubrication unit HL32 2 L (0.53 gal)
Hydraulic unit HL32 20 L (5.28 gal)
Slideway lubrication unit G68 6 L (1.59 gal)
(1) The other oil tanks are filled with their specified oils up to their specified levels before shipment.
Lubricant preparation for these tanks is therefore unnecessary for initial machine operation.
(2) Machines equipped with the optional coolant supply system require coolant that must be
prepared before starting actual cutting tests. For further information concerning the required
amounts of coolant and the recommended types of lubricating oil, refer to SECTION 3, 1-1.
"Lubrication Chart" and 1-2. "Lubrication Chart Symbols".
5074-E P-19
7. Handling Procedures
CAUTION
1) When slinging the machine, follow the general procedure and safety rules and take
extreme care.
2) When suspending the machine, the general balance is important. Check that the
machine is well-balanced before suspending. Also check that no unnecessary object is
left on the machine.
3) When transporting the machine body, take special care not to not to give a shock to the
body, control unit and other components. Fully tighten bolts as well.
7-1. Lifting the Machine
Procedure :
1- Removing Pallets
Pallets may be lifted at the setup position.
After removing pallets out of the machine (on the APC), manually operate the APC to
relocate pallets in the machine to the setup position and remove the two pallets.
As there is no pallet in the machine at this time, the alarm "Pallet Clamp Faulty" is raised and
the Z-axis is interlocked and becomes immovable.
In this case, set the machine user parameter to 1 (in the system check mode). After
relocating the machine and installing the pallets, set the parameter back to 0.
2- Fixing the Sliding Parts

Before transporting the machine, fix the table, column and head with dedicated fixtures so
that they will not move. (See the following figure for fixture locations.)
The axes should be positioned around the mechanical coordinates respectively specified
below.
X-axis → 15
Y-axis → 275
Z-axis → -100
5074-E P-20
Fixture Locations
Check that cable bracket

is correctly positioned.
Door fixture
Y-axis fixture
Z-axis fixture
Column
X-axis fixture
Lifting tool
Bed Right door of the splash guard
Front view Right side view

ME11158R0200400100001
3- Remove the tools from the magazine.

5074-E P-21
7-2. Relocating the Machine with a Fork Lift
CAUTION
If the machined is moved, its X-, Y- and Z-axes moves, which may give damage to the
machine components.
To avoid this, be sure to fix the components before relocating the machine according to (1)
"Machine Transportation Procedure."
WARNING
1) When working with a fork lift, follow the general procedure and safety rules and take
extreme care.
2) When suspending the machine, the general balance is important. Check that the
machine is well-balanced before suspending. Especially, note the maximum carrying
load of the fork lift.
3) When transporting, do not put any unnecessary object on the machine. Take special
care not to give a shock to the body and control unit.
Relocate the machine using the following figure as a guide.
Procedure :
1- Fix sliding parts. See (1) "Machine Transportation Procedure."
2- Insert the fork into the side (or left) of the machine as shown below and raise the machine.
When lifting the machine, take care not to put the machine out of balance.
The machine weighs 11,000kg.
The fork lift capacity should be 15 tons or more.
ME11158R0200400110001
5074-E P-22
7-3. Relocating the Machine with Hangers
CAUTION
1) When relocating the machine with hangers, order dedicated hangers from a specialist
or consult us.
2) When relocating the machine with hangers, follow the operation procedure and safety
rules and take extreme care. Failure to do this may lead to severe injury.
Dedicated
hangers
ME11158R0200400120001
5074-E P-23
8. Machine Transportation by Truck

When transporting the machine by a truck, the following points must be taken into consideration in
addition to the instructions described before.
(1) Check if the fixtures are firmly fixed.
(2) To protect the disconnected hoses and cables from dirt, fasten them to the machine after
wrapping them in cloth or vynil sheet.
(3) The machine transportation is possible without detaching the totally enclosing cover.
9. Before Removing Y-axis Drive Motor

(1) Since the Y-axis drive motor is equipped with the brake, which is activated when the power is
cut off, the removal of the motor causes the spindlehead to drop. Therefore, clamp the
spindlehead to the table by using the transit clamp before removing the Y-axis drive motor.
(2) If the positional relationship between the spindlehead and the Y-axis position encoder is shifted,
the pitch error compensation value to be activated will be changed. Therefore, the Y-axis drive
motor may be removed only at the position where the original position relationship may be
restored. The position where the distance between the spindle nose end and the table surface
is 210 mm (8.27 in.).
5074-E P-24
10. Machine Installation
10-1. Temporary Installation

(1) Clean the foundation plates free of oily substances.
(2) The gap between the lower surface of the machine bed and the lower surface of the foundation
plates should be about 50 mm (1.97 in.).
(3) If concrete floor surface is remarkably irregular or slanted, fill mortar and compact until
adhesion to the bottom of the foundation plate is complete. (Especially for the installation of
coolant tank, etc.)
(4) Do not firmly tighten M16 jack screws on the unit table and NC control cabinet.
10-2. Assembling the Units and Parts Shipped Separately

For details, refer to SECTION 3. "PREPARATION FOR OPERATION" and SECTION 4.
"OPERATIONS".
(1) Follow the steps of disassembling for transportation in the reverse order.
(2) Fill each tank and reservoir with the specified oil.
(3) Connect power supply cables and pneumatic pipes.
(4) Clean the machine by removing dirt from each component.
(5) Check the phase of the power source by operating the coolant unit pump motor.
CAUTION
If the motor is rotating in reverse direction and the required pressure is not achieved, turn
off the power supply immediately and correct the power cable connection.
Continually rotating the motor in reverse will lead to trouble.
5074-E P-25
10-3. Leveling the Machine

Setting the machine in a level position greatly affects both working accuracy and service life. The
machine should be carefully leveled during installation.
Use a precision level (0.02 mm/m per division) to measure the machine level.
Level the machine as follows:
Procedure :
1- Position the spindlehead at the center of vertical travel (Y-axis).
2- Position the spindlehead in the middle of front-back travel range (Z-axis).
3- Position the column (X-axis) at the center of the bed.
4- With the precision level placed near the center of the table (pallet) along the X- and Y-axis
directions, slowly move the table over the full range of Z-axis travel and take readings.
The machine should be leveled to within the permissible limits specified in the Static
Accuracy Test Chart supplied with the machine.
Precision level
ME11158R0200400170001
5- Adjust the machine level by using the three jack screws under the bed.
6- After adjustment, securely fix the jack screws with the lock nuts.
7- Fix the bed to the floor with hole-in (chemical) anchors.
8- Again, check the machine for levelness.
Note
After the machine has been in use, check the level once a month. Should the level be off,
repeat the adjustment procedure.
5074-E P-26
1. Overview
Machine parts should be lubricated according to "Lubrication Chart" and "Lubricating Oil
Specifications".
Check oil level and pump operation every day.
Prior to shipment, the hydraulic oil tank, the oil-air lubrication oil tank, the spindle cooling oil tank,
and the coolant tank are drained. Fill before installation.
Always use the specified oil or its equivalent.
Do not use used oil.
Note
The LUBRICATION CHART has been prepared in accordance with MAS standards. The
symbols used in this chart are described in "Lubrication Chart Symbols". "Lubricating Oil
Specifications" in this section lists oil types to be used.
CAUTION
1) Use of improper lubricating oils may lead to poor performance or malfunction of the
machine.
2) Be sure to use new oil for lubrication.
3) Always supply oil through the oil filter.
5074-E P-27
1-1. Lubrication Chart

Lubrication points, names of the lubricants to be applied at respective points, lubricant exchange
frequency and other control items are shown below. Service and check the machine according to
the following lubrication schedule.
Lubrication Schedule
Control frequency
Drain ports Drain port

A: Molykote Grease (BR2 Plus)
Ball screw cooler Magazine Index APC
Lubrication point Spindle bearing Sliding surfaces sliding ATC unit Hydraulic unit
Spindlehead cooler surface (NC round table) rack
Point No.
Symbol
Control item
Inspection (hrs)
Refill (hrs)
Cleaning and exchange (hrs)
Exchange (hrs)
Lubricant name
Tank capacity (L)
Refill quantity (L) As necessary
ME11158R0200500020001
5074-E P-28
1-2. Lubrication Chart Symbols
Description Symbol Comments
Oil Level
Replenish
Change
Pressure Gauge
Thermometer
• Clean or Change filter element.

Oil Filter • Check condition of filter element.
Check oil flow by visual inspection

through window, gear, rotary ring or
Flow Sight spout devices.
Operate manual pump with lever or

button.
Oil Pump
Clean the magnetic coolant

separator.
Separator
Time (Operating
hours)
This symbol is used in combination

with other symbols.
Inspection
5074-E P-29
1-3. Lubricating Oil Specifications
CAUTION
1) Using an unsuitable or degraded lubricant may result in poor lubrication and/or overheat
and affect the machine performance and accuracy.
2) Do not mix lubricants of different brands even if they belong to the same group. (Special
care is required when adding a lubricant in the middle.)
The lubricant types defined by JIS are shown in the lubrication schedule and trade names used by
respective manufacturers for each type of lubricants shown in the next page. Select and use an
available brand.
Lubricating Oils (This table also includes the lubricants not used for the machine.)
Code
Maker
FC5 HL32s HL32 G68 CKC68 CKC100 CKC150
Esso Spinesso 5 Teresso 32 Unipower MP32 Febis K68 Spartan EP68 Spartan EP100 Spartan 150
Shell Tellus Oil C5 Tellus Oil C32 Tonna Oil S68 Omala Oil 68 Omala Oil 100 Omala Oil 150
Velocite Oil No. DTE24 or DTE
Mobil DTE Oil Light Vactra Oil No. 2 Gear 626 Gear 627 Gear 629
6 Oil Light
Greases
Maker
Code
Shell Dow Coning
Molykote BR2 Plus Grease
A Alvania No. 2
Molykote G Rabbit Spray
Dow Coning Asia

AIG Building, Maru-no-uchi 1-1-3, Chiyoda-ku, Tyokyo 100-0003,
Head Office
(03)3287-1155
Daitokai Building, Mei-eki 3-22-8, Nakamura-ku, Nagoya 450-0002,
Nagoya Sales Branch
(052)582-3061
2nd Yurakau Building, Honmachi 4-1-7, Chuo-ku, Osaka 541-0053,
Osaka Sales Branch
(06)6261-7303
Sumiko Junkatsuzai Co., Ltd.

Head Office 23rd floor, Shinjuku Sumitomo Building, Nishi-shinjuku 2-6-1, Shinjuku-ku, Tokyo
163-0223, (03)3344-6831
5074-E P-30
Lubrication of double fit (HSK) clamp unit (optional)
Lubrication point Lubricant type Maker

HSK clamp finger section Great Metal Spray 70-81 METAFLUX
Enshu P/N : BOZ9901AAA
Offered by Tesco Co., Ltd.

Head Office Chigasaki 3-3-5, Chigasaki, Kanagawa Phone: 0467(87)0967 (representative)
253-0041 Fax: 0467(87)8808
Tokyo Branch 5th floor, CTN Building, Suda-cho 2-2-5, Phone: 03(5256)5791 (representative)
Kanda, Chiyoda-ku, Tokyo 101-0041 Fax: 03(5256)5797
5074-E P-31
2. Lubrication and Inspection Method
2-1. Supplying Oil to the Hydraulic Power Unit
Radiator Pressure gauge
Level switch
(optional)
Oil filler port /air breather
Level gauge
Tank 20L
Drain port
ME11158R0200500050001
Specified Oil HL32

(Example: Mobil DTE Oil Light)
Tank Capacity 20 liter (5.28 US gal)
After filling up, operate the machine once and then replenish the oil.
Oil Change Interval 1,000 hours
[Supplement]
1) For operations of the hydraulic power unit, refer to Section 5, 2. “Hydraulic Pressure
Adjustment”.
For detailed operation procedures, refer to the appended instruction manual for the
hydraulic power unit.
2) When the oil level drops below the specified level, an alarm results. However, if this
alarm occurs, power supply to the machine is cut off, which will then cause probelms
for machine operation. Therefore, check the oil level without fail before starting
operation.
3) Normally use HL32. However, use FC22 (with a viscosity index of 140 or over) at a
temperature below 10°C.
5074-E P-32
2-2. Supplying Oil to the Oil-air Lubrication Unit
Lubrication button
Pressure gauge
Oil filler port
Line filter
Tank 2L
Delivery port
Level switch Drain port

ME11158R0200500060001
Specified Oil Example: Mobil DTE Oil Light

Oil Change Interval Depends on the operating condition.
Normally, the oil lasts 5 months when supplied to the effective tank capacity.
Filter Cleaning Clean the pump filter in the tank every 6 months and change every year.
Interval
[Supplement]
1) Always use the specified oil. Supply clean and new oil up to the H level. When supplying
oil, be careful not to include dust in the oil.
2) Check the oil amount every morning when starting operation. If the oil level drops as low
as L level, an alarm C occurs and the machine stops. Therefore, supply oil a little bit
earlier than lighting of the alarm lamp.
3) For the precautions on oil-air lubrication, refer to Section 1, 7-1. "Spindle Lubrication
(Oil-air)". For details regarding the oil-air lubrication unit, refer to Instruction Manual for
Centralized Lubrication Unit MR-LUB (Daido Metal) compiled in the Purchased Unit
Instruction Manual.
5074-E P-33
2-3. Spindlehead Cooling Unit

(1) Spindle cooler
Air filter
ME11158R0200500070001
5074-E P-34
(2) Spindle coolant tank
Oil filler port
Level gauge
Ball screw axis center cooling pump
Suction filter
Drain port
ME11158R0200500070002
Oil Specification FC5 (Example: Mobil Velocite Oil No.6)

Amount 32 L (8.45 gal)
After filling up, operate the machine once and then replenish the tank.
Oil Change Interval 1,000 hours
CAUTION
1) If cooling oil other than the specified one is used, cooling efficiency could be lowered.
2) When supplying or replenishing the cooling oil, make sure to cut off the power.
3) The temperature setting volume is basically tuned to the machine temperature ±0°C.
Do not change the set temperature. (The volume is provided in the cooling system.)
4) Clean the filter in regular intervals (every month). If the filter is clogged, it could cause
alarm and stop the machine.
5074-E P-35
2-4. Centralized Lubrication Unit

The centralized lubrication unit, mounted at the fore part of the machine left side, feeds lubricating
oil to the X-, Y-, and Z-axis guideways and ATC unit.
After the power is turn on, the lubrication unit pump operates at regular intervals to supply oil to the
guideways through the metering valves mounted on the spindlehead, table, column, and ATC unit.
Pressure gauge
Oil filler port
Delivery port
Tank 6L

ME11158R0200500080001
Specified Oil G68

Typical Brand: Mobil Vactra Oil No. 2 3LC
Oil Change Interval The lubricating oil might be consumed rapidly depending on timer setting or
if the machine is operated of a long time continuously. Check the lubricating
oil level and replenish as needed.
The reservoir has a float switch which gives a warning signal when the level
becomes low.
[Supplement]
1) For alarms concerning lubrication, refer to 3. “Lubrication Warning System - Lubrication

Alarm”.
2) For instructions on lubricating oil filling, refer to 4. “Manual L7ubrication”.
3) For timer setting procedure, refer to 5. “Automatic Centralized Lubrication”.
5074-E P-36
3. Lubrication Warning System - Lubrication Alarm

Poor lubrication affects machine accuracy and causes breakdowns. As a safeguard, the automatic
centralized guideway lubrication system is provided with the following warning devices.
(1) Low Oil Level in Tank

An alarm is displayed when the level in the tank drops below the lower limit.
(2) Low Lubrication Pressure

A pressure switch is used to detect the pump output pressure. Switch actuation is checked
when the pump is set into operation. If pressure does not rise, an alarm is displayed.
(3) Excessive Lubrication Pressure

The above pressure switch is used to detect pump stoppage and whether pump output
pressure has dropped to the specified level. If pressure does not drop, an alarm is displayed.
(4) Tripping of Overload Protective Relay of the Centralized Lubrication System Pump Motor
Alarm No. Alarm Message How to Release the Alarm
3703 Axis lube level low Supply the specified oil.
2705 Axis lube pressure ON confirmation Inspect the lubrication unit and
(insufficient pressure) normalize the pump output pressure.
2706 Axis lube pressure OFF confirmation Inspect the lubrication unit and
(excessive pressure) normalize the pump output pressure.
2704 Axis lube motor overload Reset the tripped overload relay.
If an alarm occurs, check the contents of the alarm. Take necessary measures to reset the alarm so
that machine accuracy will not be affected and serious trouble may be prevented. Then proceed to
the next operation.
CAUTION
When any of the above four alarms takes place, the alarm message is displayed with a
three-digit alarm number on the NC screen. Note that even when an alarm (1) takes place,
operation from the programmed commands continues.
5074-E P-37
4. Manual Lubrication
Since the machine is provided with the automatic lubrication unit, manual lubrication is not usually
required.
Manual mode lubrication is also used before staring operation, in could weather, after long rests or
whenever lubrication seems insufficient. Press the LUB. key; this starts the lubrication unit pump
and feeds the lubricating oil to each lubricating point at the preset timing intervals.
[Supplement]
For the time setting procedure, refer to 5. “Automatic Centralized Lubrication”.
S.T.M ?
i F1 F2 F3 F4 F5 F6 F7 F8
DEL
P
A B C D E F G MacMan
HT
H I J K L M N 7 8 9 BS
O P Q R S T U P P
4 5 6
V W X Y Z 1 2 3
CAPS
LOCK
SHIFT CTRL SP SHIFT BS 0
NC OPERATION ATC OPERATION EMG.STOP

CONTROL ON CONTROL OFF
INTER
BLOCK PROGRAM PROGRAM DISPLAY OPTIONAL SINGLE LOCK
SKIP BRANCH BRANCH OFF STOP BLOCK ATC APC RELEASE
1 2
AXIS MID. PULSE RETURN

CYCLE S.T.M AUTO HANDLE SEQUENCE 1CYCLE 1STEP 1STEP
COM. CYCLE
STOP LOCK CANCEL MANUAL SHIFT RESTART START START ADVANCE REVERSE
AXIS SELECT NC OPERATION

MIRROR MIRROR MIRROR MIRROR CYCLE START
X Y Z IMAGE
X
IMAGE
Y
IMAGE
Z
IMAGE
4 A.B ADAPT LIGHT COOLANT A.B NOZ A.B ADAPT WATER GUN Lights up.
INTER
4 5 PULSE LOCK MACHINE
LOCK
DRY
RUN
HANDLE RELEASE LUB. CHIP CON CHIP CON OIL MIST OIL HOLE CHIP WASH SHOWER
RAPID JOG SLIDE HOLD

% FEEDRATE
ORIENTATION SPINDLE RELEASE 90 95 100
80 105
70 110
60 120
CW STOP CCW 50 130
RAPID (inch/min) JOG 40 140
% OVERRIDE % SPINDLE OVERRIDE (mm/min) SPEED RESET
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
1
0
90
100
80 160
8 200 4000 160
RESTART
0 200
DOOR INTER ROCK NC PANEL
EDIT
LUB.
70 180 4 100 LOCK UNLOCK LOCK
6000 240
50 200 2 50
0.04 1 10000 400
ME11158R0200500100001
5074-E P-38
5. Automatic Centralized Lubrication
5-1. Pump Off-Time Display

The time interval of the automatic lubrication cycle, that is, the duration of "OFF" time, is set as a
parameter in the CNC system. Before shipment, "OFF" time is usually set to 10 minutes and "ON"
time for pump actuation to a fixed 60 seconds.
"OFF" time is displayed on the CRT of the pendant operation panel by the following procedure:
Procedure :
1- Press the PARAMETER key on the operation panel.
2- Press function key [F7] (ITEM) repeatedly until the display as shown below appears.
3- Press the PAGE ↑ key or PAGE ↓ key repeatedly until No. 12 AXIS LUBE SET screen
appears.
4- The value set at 1. AXIS LUBE TIME on the NC screen shows the lubrication interval.
PARAMETER
MC USER PARAMETER
NO. 12 AXIS LUBRICANT
1. AXIS LUBE CYCLE TIME 10 [ min ]
2. AXIS LUBE PUMP TIME 30 [s]
3. CROSS RAIL LUBE CYCLE TIME 0 [ min ]
4. CROSS RAIL PUMP TIME 0 [s]
5.
6.
ME11158R0200500110001
5074-E P-39
5-2. Parameter Data Setting for the Automatic Lubrication Timer

To change the setting at AXIS LUBE TIME, follow the steps below.
Procedure :
1- Check to see the current time interval of the automatic lubrication cycle according to 5-1.
described above.
2- Use the cursor control key to locate the cursor to the data given as the AXIS LUBE TIME.
3- Press the function key [F1] (SET).

Character "S" will be displayed on the 21st line of the CRT.
4- Key in the time interval data in units of minutes.

Keyed in data is displayed following the character "S" on the 21st line.
5- Press the WRITE key.

This renews the AXIS LUBE TIME data.
• Reference: Time setting ranges are as follows:

1. AXIS LUBE CYCLE TIME 0 to 10 minutes
2. AXIS LUBE PUMP TIME 15 to 120 seconds
3. CROSS RAIL LUBE CYCLE TIME 0 to 120 minutes
4. CROSS RAIL PUMP TIME 15 to 60 seconds
CAUTION
When the interval of the automatic lubrication cycle is too long, lubricating oil is not
supplied sufficiently, causing malfunction of the machine depending on the
operating condition.
1.
1-1.
Optional Optional Optional Optional
SECTION 4
HOUR METER OPERATION END MODE
SERIAL h BZ
BUZZER LIGHT
Operation Panels
01234 5
Operation Panel Layout
?
AC100V 2A AUTO POWER
NC RUNNING ERROR LIGHT
OFF
OPERATIONS
01234 5
Optional
Optional Optional Optional
Operation Panel on Control Cabinet Upper Part

Controls marked by are optional (available upon request).
ME11158R0200600010001
5074-E P-40
5074-E P-41
1-2. Operation Panels
MG. MANUAL
MANUAL INT. INDEX START

O I
DOOR INTERLOCK
EMG. STOP
RESTART
ME11158R0200600020001
5074-E P-42
1-3. NC Operation Panel
S.T.M ?
i F1 F2 F3 F4 F5 F6 F7 F8
DEL
P
HT
O P Q R S T U P P
4 5 6
V W X Y Z 1 2 3
CAPS
LOCK

INTER
1 2

COM. CYCLE

X Y Z IMAGE IMAGE IMAGE IMAGE
X Y Z 4 A.B ADAPT LIGHT COOLANT A.B NOZ A.B ADAPT WATER GUN
INTER
LOCK
DRY
RUN

% FEEDRATE
80 105
70 110
60 120
CW STOP CCW 50 130
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
80 160 DOOR INTER ROCK NC PANEL
0 100 RESTART EDIT
6000 240
50 200 2 50
0.04 1 10000 400
NC Operation Panel
ME11158R0200600030001
5074-E P-43
2. Manual Operations
For safety use, safety devices such as door interlock are provided as standard equipment.
Before operating the machine, read the attached operation manual and safety door interlock
function manual.
2-1. Power ON/OFF
Procedure :
1- Main Power Switch

Turn the lever switch of the circuit breaker (main power switch) at a side of the NC control
cabinet to the ON position. This turns on power to the control system.
ON (1)
OFF(0)
ME11158R0200600050001
SAFETY INSTRUCTIONS
1) If power is not supplied, check the shop power board.
2) The pumps for the NC cooler, hydraulic unit, and spindle head lubrication unit
start. Check the pressure for each unit.
5074-E P-44
2- Control Power Supply

Press the [CONTROL ON] pushbutton switch on the NC operation panel.
CONTROL ON
CONTROL ON pushbutton switch

Tums off all the operation power.
INTER
1 2

COM. CYCLE
CONTROL OFF X
AXIS SELECT
Y Z
MIRROR
IMAGE
X
NC OPERATION
MIRROR
IMAGE
Y
MIRROR
IMAGE
Z
MIRROR
IMAGE
4 A.B ADAPT LIGHT COOLANT A.B NOZ A.B ADAPT WATER GUN
CYCLE START
INTER
LOCK
DRY
RUN

% FEEDRATE
80 105
70 110
60 120
CW STOP CCW 50 130
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
0 100 RESTART EDIT
CONTROL OFF pushbutton switch 50 200 2 50

0.04 1 10000 400
6000 240
Lights when pressed.

ME11158R0200600050002
SAFETY INSTRUCTIONS
If the [CONTROL ON] pushbutton switch is not illuminated, one of the [EMERGENCY
STOP] buttons has been activated and is still in a locked position. Check the problem
and reset the [EMERGENCY STOP] button.
3- NC Operation Panel Power

Set the key-lock selection switch on the NC operation panel to the UNLOCK position. The
screen and the indicating lights on the panel will be tuned ON.
NC PANEL
NC OPERATION ATC OPERATION EMG.STOP EDIT
LOCK UNLOCK LOCK
INTER
1 2

COM. CYCLE

INTER
LOCK
DRY
RUN

% FEEDRATE
80 105
70 110
60 120
CW STOP CCW 50 130
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
0 100 RESTART EDIT
6000 240
50 200 2 50
0.04 1 10000 400
ME11158R0200600050003
5074-E P-45
4- Power Supply OFF

Press the [POWER OFF] button at the left side of the NC operation panel to turn off the
power supply. (Press the [EMG. STOP] button if operation must be stopped immediately.)
Then turn the main power switch at a side of the NC control cabinet to the OFF position.
WARNING
As described above, each of the machine units is active until the power lever switch
is turned off.
[Supplement]
Before turning the power supply ON, the daily inspections and adjustments listed in
"Periodical Inspection Schedule" should be performed.
5074-E P-46
2-2. Emergency Stop
EMG.STOP

INTER
SKIP BRANCH BRANCH OFF STOP BLOCK A TC APC RELEASE
1 2

COM. CYCLE

INTER
LOCK
DRY
RUN

% FEEDRATE
80 105
70 110
60 120
CW STOP CCW 50 130
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
0 100 RESTART EDIT
6000 240
50 200 2 50
0.04 1 10000 400
ME11158R0200600060001
NC Operation panel Emergency stop buttons

Magazine operation panel Emergency stop buttons
APC operation panel Emergency stop buttons
To stop the machine immediately during a MANUAL, AUTO or MDI (Manual Date Input) mode,
press the red [EMG. STOP] button. Control power will be shut off and the machine will stop
immediately.
WARNING
1) Pressing an [EMERGENCY STOP] button only shuts off the control power. Main power
to the circuit breaker stays on and the units remain energized.
2) If the spindle is rotating while the [EMERGENCY STOP] button is pressed, the spindle
will keep rotating for a while due to inertia.
To turn the power ON after pressing the [EMERGENCY STOP] button, fix the problem, rest the
button by turning it clockwise and press the [POWER ON] button above the tape reader.
5074-E P-47
2-3. Spindle Rotation in Neutral (Spindle Release)
ORIENTATION SPINDLE RELEASE

INTER
SKIP BRANCH BRANCH OFF STOP BLOCK AT C APC RELEASE
1 2
CW STOP CCW CYCLE

STOP
S.T.M
LOCK
AXIS
COM.
CANCEL
MID.
AUTO
MANUAL
PULSE
HANDLE
SHIFT
SEQUENCE
RESTART
1CYCLE
START
RETURN
CYCLE
START
1STEP 1STEP
ADVANCE REVERSE

INTER
LOCK
DRY
RUN

% FEEDRATE
80 105
70 110
60 120
CW STOP CCW 50 130
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
0 100 RESTART EDIT
6000 240
50 200 2 50
0.04 1 10000 400
ME11158R0200600070001
It is often necessary to rotate the spindle slightly while the spindle is at a stand-still, for example for
alignment of a cutting tool to the workpiece, manual removal and setting of a cutting tool from and to
the spindle, and inspection of cutting bits.
Press the [SPINDLE RELEASE] flat key on the NC operation panel. The spindle driving gears will be
set into neutral, allowing the spindle to be rotated by hand.
Conditions for Operation

• Control power is ON.
• Spindle is at a stand-still.
• Tool is clamped in spindle.
• Machine is not in the automatic tool change (ATC) cycle.
• Manual operation mode is selected.
WARNING
Take care that no operator could inadvertently start the spindle while someone is working
with the spindle in neutral.
[Supplement]
To restart the spindle, enter a spindle speed (S) command.

5074-E P-48
2-4. Spindle Orientation (Orient-stop of the Spindle)

Spindle orientation is performed to clamp the spindle after indexing it to a definite angular position.
Spindle orientation is controlled electrically since rotation of the spindle is done by the spindle drive
motor.

• The MANUAL mode has been selected.

(In automatic or MDI mode, M19 command can be specified to orient-stop the spindle.)
• Tool is clamped in the spindle.
• The ATC tool change arm is not at the spindlehead.
Operation Procedure
Confirm that the
light is ON. Light goes on.
DEL
A B C D E F
HT
G
P
MacMan

H I J K L M N A B 7 8 9 BS
O P Q R S T U P P
4 5 6
V W X Y Z 1 2 3
CAPS
LOCK
CW STOP CCW

INTER
1 2

COM. CYCLE

INTER
LOCK
DRY
RUN

% FEEDRATE
80 105
70 110
INTER RAPID
CW STOP CCW
(inch/min) JOG
60
50
40
120
130
140
LOCK 10
% OVERRIDE
30 50
70 100
% SPINDLE OVERRIDE
110 120 130
140 20 500
(mm/min) SPEED
1000 40
2000 80
30
20
150
160
RESET
RELEASE 5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
0 100 RESTART EDIT
6000 240
50 200 2 50
0.04 1 10000 400
ME11158R0200600110001
(1) Press the spindle [ORIENTATION] flat key while holding down the [INTERLOCK RELEASE] flat
key at NC OPERATION.
(2) To reset the spindle orientation mode, rotate or release the spindle.
• To rotate the spindle (clockwise or counterclockwise), press either [CW] or [CCW] flat key
while holding down the [INTERLOCK RELEASE] flat key at NC OPERATION.
• To release the spindle, press the spindle [RELEASE] flat key.
CAUTION
Never touch the spindle while it is in the spindle orientation mode.
5074-E P-49
SAFETY INSTRUCTIONS
The spindle should stop rotating at the first orientation position. However, it might rotate
two or three times.
WARNING
Never apply a rotating torque to the spindle right after completion of spindle orientation, for
example by tightening the milling chuck, because it is possible that the spindle may rotate.
ME11158R0200600110002
5074-E P-50
2-5. Clamping and Unclamping the Tool in Spindle

This machine has been equipped with manual tool change buttons to manually remove a tool from
the spindle or to manually set a tool, which cannot be handled by the ATC, into the spindle.
A time-saving pull stud mechanism is used to draw the tool into the spindle. The pull stud, located at
the rear of the toolholder, is drawn into the spindle by a collet and a belleville spring housed in the
spindle.
To remove a tool, a hydraulic cylinder at the top of the spindlehead opens the collet, which is held
closed by spring force, and pushes the tool out of the spindle. This tool push-out stroke is about 1
mm (0.039 in.).

• Use the tools which conform to the machine specifications. The taper shank and retention knob
shall conform to the drawing given in Section 6, 2. "Dimensions of Tool Shank and Retention
Knob".
• The spindle is at a stand-still. The spindlehead should be located at a convenient position near
the operator for manual tool changing.
Operation Procedure
MANUAL TOOL CHANGE
TOOL CLAMP
TOOL UNCLAMP
Ram Head Operation Panel

ME11158R0200600140001
Manual tool clamp/unclamp at a side of the spindlehead.

Press the [TOOL CHANGE CYCLE] pushbutton on the MANUAL TOOL CHANGE panel the
machine operation panel.
5074-E P-51
SAFETY INSTRUCTIONS
The [TOOL CHANGE CYCLE] button activates the [TOOL CLAMP] and [TOOL UNCLAMP]
buttons. To assure the safety of the operator, these two buttons are inoperative unless the
[TOOL CHANGE CYCLE] button is pressed. This prevents the tool in the spindle from
dropping even when the [TOOL UNCLAMP] button is accidentally pressed.
• Tool Removal
While holding the tool by hand, press the [TOOL UNCLAMP] button. After three second, the tool
in the spindle will be unclamped and can then be removed from the spindle. A time-delay of
three seconds is built into the tool unclamp operation to allow the operator to hold a heavy tool
with both hands after pressing the button.
• Tool Placement
Insert a new tool into the spindle by aligning the key and the keyway, and press the [TOOL
CLAMP] button. The tool will be secured in the spindle.
CAUTION
1) Clean the spindle nose and tool shank tapers before setting a tool in the spindle.
2) If a tool has been used for a long or heavy cutting operation, it may become heated and
difficult to remove from the spindle. Care should be taken while handling a hot tool.
Apply a coating of powder lubricant such as aerosol molybdenum to the taper section
of the tool shank and to the spindle to ease later removal. (Refer to "Dry Coating Grease
for Spindle Taper".)
5074-E P-52
2-6. Reference data
Grease Data
Dry coating grease: MOLYKOTE® D-321R
Grease type Cold setting

Components Binder Inorganic componud
Solid lubricant M0S2 + graphite
Solvent (diluted) Mineral Spirit
Color Dark gray
Optimal Spraying {
application Dipping {
method
Tumbling {
Brushing {
Set to touch (at 25°C (77°F)) 3 min
Curing conditions Leaving the grease for 30 minutes at room
temperature
Greasing area (10 µm (400 µin.) film) 20(815) m2/ L (ft2/gal)
Working temperature range -180 to 450°C(356 to 842°F)
(650°C(1,202°F) in inactive atmosphere)
Preservation period Bulk: 1 year, Aerosol: 2 years
Flash point 23°C(73.4°F)
*1
Falex test Abrasion resistance life 75 min
Withstand load 1,136.4 kg(2,500 lb)
LFW-1 test *2 Abrasion resistance life 460,000 cycles
Abrasion resistance life against 250,000 cycles
reciprocating movements
Adhesive property *3 Good
*4
5 % salt water spray test 2 hours
Applicable standards Class 4, petroleum of second kind
Features Low friction coefficient
Noncombustible
Radiation resistant
Easy to use
Uses Cold forging
Replacement with other dry coating
Preventing nibbling of bolts
Fitting of parts
Volume Aerosol 223 mL (0.06 US gal)
Bulk 1 L (0.26 US gal), 4 L (1.06 US gal)
5074-E P-53
Test conditions
The test pieces are sandblasted and coated with grease sprayed to a thickness of 10 µm (400 µin.).
Falex abrasion resistance life *1 Load 4,450 N (998 lbf)

(Federal Standard 791-3807) Speed 290 min-1
Falex withstand load *1 Load increasing amount 1,110 N/min (248.9 lbf/min)
(Federal Standard 791-3812) Speed 290 min-1
*2
LFW-1 abrasion resistance life Load 142 N (31.8 lbf)
Speed 72 min-1
Ring hardness HRC60
Block hardness HRC60
Kinematic friction coefficient Time measured until the
for judgment coefficient reach 0.1
LFW-1 abrasion resistance life Reciprocating cycle 87.5 min-1
against reciprocating movements*2 Rotary angle 90°
Ring hardness HRC60
Block hardness HRC60
Kinematic friction coefficient Time measured until the
for judgment coefficient reach 0.1
Adhesive property *3 Pressure sensitive tape test
(Federal Standard 791-3810)
5 % salt water spray test *4 5 % salt water
(Federal Standard 791-4001) 35°C(95°F) continuously
Greasing Method
The grease can be applied in the method of spraying, dipping, or brushing.

Solid material included in MOLYKOTE® D-321R is likely to precipitate. Therefore, stir up the grease
sufficiently before use.
Usually, seal the grease container with the cover to prevent the binder from hydrolyzing and the
solvent from evaporating.
It is desirable to use the grease without dilution. If, however, evaporation of solvent makes it
necessary to adjust the viscosity, mix Mineral Spirit in the grease.
Spraying
Use a general spray gun. When spraying, ventilate the room and follow the general spraying
method. At this time, do not forget to stir up the grease sufficiently. By a single stroke of spraying, 5
to 7.6 µm-thick film is formed; thereby optimum adhesive property and abrasion resistance life can
be obtained.
Dipping
Stir up the grease sufficiently before use because solid material in the grease tends to precipitate. It
is recommended to use an automatic stirrer.
Brushing
Apply grease by brushing when there is no other choice. Use a normal brush for painting.
5074-E P-54
Curing Method
MOLYKOTE® D-321R dry coating grease cures with the moisture in the air. In the normal state (at
21°C(69.8°F) with relative humidity of 50 %), the grease cures within 30 minutes. The curing time
will be shortened with increase in temperature or humidity.
CAUTION
Read the MOLYKOTE® D321R Safety Date Sheet (MSDS) before use.
Use the grease in a well-ventilated area and do not breathe its vapor for a long time. Since
the vapor stimulates your eyes or mucous membrane, wear protective devices whenever
necessary. After greasing, wash your hands. Do not directly apply grease to any high-
temperature parts. When storing the grease, seal the grease container and keep it in a cool
dark place.
5074-E P-55
2-7. Spindle Speed
Spindle Speed Selection

(1) The machine is not equipped with controls for manually selecting the spindle speed.
(2) The spindle speed can be changed by a programmed S 4-digit command in the automatic
mode or by the command entered in the MDI mode.
(3) The diagrams showing the relationship between the spindle speed and the torque or the output
is given on 2-6-2. "Spindle Speed - Torque/Output Diagrams".
(4) The table below shows the spindle speed ranges and full-power ranges of each spindle
specification.
Machine model MB-500H
Spindle taper No. 40
Max speed 15000
Speed range (min-1) 50 - 15000
Spindle Spindle output kW (hp) 26/18.5
specifications (34.7/24.7)
(10 min./cont.)
Max torque Nm 199
-1
Constant output range (min ) 4000 to 15000
(5) The SPINDLE OVERRIDE dial is used to override the commanded spindle speed in a range
from 50 to 200%. Changing this override dial setting during spindle rotation is effective.
However, the override dial setting is ineffective if the resultant spindle speed exceeds the
specified spindle speed range.
% SPINDLE OVERRIDE
110 120 130
100 140
90 150
80 160
70 180
50 200
ME11158R0200600180001
CAUTION
If the specified speed command value is lower than the minimum speed or larger than the
maximum speed, the spindle remains stopped and an alarm occurs. (However, if such a
command is specified during spindle rotation, the spindle keeps rotating).
WARNING
• Do not rotate the spindle exceeding the allowable maximum speed of the mounted tool.
If rotated, the tool may fly out of the machine causing serious injury. For the allowable
tool rotation speed, check with the tool maker.
• The SPINDLE OVERRIDE dial is always effective. If you set it to a value higher than 100%,
the spindle speed selected by the next speed command is also overridden by the dial-
selected rate. Make it a rule to return the dial to100% or lower rate immediately after a
cutting cycle is finished.
5074-E P-56
Spindle Speed - Torque/Output Diagram 15,000 min-1 (No. 40)
When setting the cutting conditions, take into account the following values for spindle torque and
output.
Maximum spindle torque : 199 N-m (147 lbf-ft)
Maximum spindle output : 26/18.5 kW (34.67/24.7 hp), 10 min./cont.
The full-power spindle range is from 4,000 to 15,000 min-1.
15 kW (10 min)
11 kW (cont)
26 kW (10 min)
199 N·m (10 min)
146 N·m (cont) 18.5 kW (cont)
Spindle torque (N·m)
Motor output (kW)

Spindle speed (min-1)
ME11158R0200600190001
5074-E P-57
2-8. Spindle CW, CCW, and Stop

• This machine has been designed to carry out cutting according to the programmed commands
in automatic mode or the commands entered in MDI mode.
• Spindle speed can be selected by programmed S 4-digit commands in automatic mode or by

the commands entered in MDI mode. Refer to 2-7. "Spindle Speed" in this section.


The manual spindle operation is possible even in the automatic mode if the manual interruption
switch is set at ON.
• The tool is clamped in the spindle.
• The ATC tool change arm is at the standby position.
• An S command has been given to control the spindle speed.

If the specified speed command value is lower than the minimum speed or larger than the
maximum speed, the spindle remains stopped and an alarm occurs.
Operation Procedures
INTER
LOCK CONTROL ON CONTROL OFF
RELEASE
INTER
SKIP BRANCH BRANCH OFF STOP BLOCK AT C APC RELEASE
1 2
CYCLE
STOP
S.T.M
LOCK
AXIS
COM.
CANCEL
MID.
AUTO
MANUAL
PULSE
HANDLE
SHIFT
SEQUENCE
RESTART
1CYCLE
START
RETURN
CYCLE
START
1STEP 1STEP
ADVANCE REVERSE
CCW
INTER
LOCK
DRY
RUN

% FEEDRATE
80 105
70 110
60 120
CW STOP CCW 50 130
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
0 100 RESTART EDIT
CW 50 200 2 50
6000 240
0.04 1 10000 400
STOP
ME11158R0200600220001
(1) Press either the [CW] key or the [CCW] key while holding down the [INTERLOCK RELEASE]
key.
(2) The spindle does not start rotation immediately after the switch has been pressed.
(3) Pressing the [SPINDLE STOP] flat key stops the spindle by a brake applied to the spindle drive
motor.
SAFETY INSTRUCTIONS
1) Switching the NC operation mode does not affect the spindle rotation conditions.
2) Pressing the [RESET] key on the NC operation panel causes the spindle to stop.
3) If the spindle drive motor load exceeds the motor capacity (150% is displayed on the
CRT as a load in the constant output range), the spindle will stop.
5074-E P-58
2-9. Feed Axes X, Y, Z
M16
M15
Z
ME11158R0200600230001
The axis nomenclature is indicated below. (Viewed from operator position)
Movement +direction
X-axis Column left/right To the right (MG side)
Y-axis Spindlehead up/down Backwards (APC side)
Z-axis Table front/back Forwards

• An axis has been selected, (X, Y, or Z) using the [AXIS SELECT] flat keys.
• The axis to be controlled is not located at its travel end.
• The ATC tool change arm is at the standby position.

5074-E P-59
Rapid Feed Operation Procedure
Confirm that the

light is ON.
RAPID
DEL
P
HT
O P Q R S T U P P
4 5 6
V W X Y Z 1 2 3
CAPS
LOCK
AXIS SELECT NC OPERATION ATC OPERATION EMG.STOP

CONTROL OFF
CONTROL ON
BLOCK
SKIP
PROGRAM
BRANCH
1
PROGRAM
BRANCH
2
DISPLAY
OFF
OPTIONAL
STOP
SINGLE
BLOCK ATC APC
INTER
LOCK
RELEASE RAPID
X Y Z CYCLE
STOP
S.T.M
LOCK
AXIS
COM.
CANCEL
MID.
AUTO
MANUAL
PULSE
HANDLE
SHIFT
SEQUENCE
RESTART
1CYCLE
START
RETURN
CYCLE
START
1STEP 1STEP
ADVANCE REVERSE % OVERRIDE
X Y Z
MIRROR
IMAGE
MIRROR
IMAGE
MIRROR
IMAGE
MIRROR
IMAGE
CYCLE START
30 50
X
INTER
Y Z 4 A.B ADAPT LIGHT COOLANT A.B NOZ A.B ADAPT WATER GUN
10 70
LOCK
DRY
RUN
5 80
4 5 PULSE
RAPID
JOG
80
% FEEDRATE
90 95 100
105
SLIDE HOLD
HANDLE
CW STOP CCW
60
50
70 110
120
130
1 90
30 150
110 120 130 1000 40
5
10
30 50
70
80
100
90
140
150
20 500 2000 80
20
10
5
0 200
160
170
180
0 100
1 90 8 200 4000 160
0 100 RESTART EDIT
6000 240
50 200 2 50
0.04 1 10000 400
ME11158R0200600250001
Procedure :
1- Select the axis to be moved by pressing an [AXIS SELECT] flat key.
2- Select the desired rapid feedrate override percentage by adjusting the % of the RAPID
OVERRIDE dial switch
This selection can be changed during operation, while an axis is moving.
3- Press either the [RAPID+] or the [RAPID-] flat key. The axis selected will moved in the
selected direction while the flat key is pressed. Releasing the key will stop axis movement.
CAUTION
The axis rapid feedrates are as high as 90 m/min (3,543.31 ipm) for the X-, Y- and Z-axis.
Special care should be taken, when feeding an axis at the rapid feedrate, that the cutting
tool does not strike the workpiece, the fixture, or anything else. It is recommended that for
careful operation or when operators are not familiar with machine operation that a low
override ratio should be used.
Running-in Operations
Follow the steps below to carry out run-in operation for axis feed.
Procedure :
1- When the power is supplied, the [LUBE PUMP ON] switch automatically comes ON. Set the
[RAPID OVERRIDE] dial to 10 % and move individual axes throughout their travel ranges for
20 to 30 minutes.
5074-E P-60
Manual Cutting Feed Operation Procedure (JOG SPEED)
Confirm that the

light is ON.
JOG
DEL
P
HT
O P Q R S T U P P
4 5 6
V W X Y Z 1 2 3
CAPS
LOCK
AXIS SELECT NC OPERATION ATC OPERATION EMG.STOP

CONTROL OFF
CONTROL ON
BLOCK
SKIP
PROGRAM
BRANCH
1
PROGRAM
BRANCH
2
DISPLAY
OFF
OPTIONAL
STOP
SINGLE
BLOCK ATC APC
INTER
LOCK
RELEASE (inch/min) JOG
X Y Z AXIS SELECT
CYCLE
STOP
S.T.M
LOCK
NC OPERATION
AXIS
COM.
CANCEL
MID.
AUTO
MANUAL
PULSE
HANDLE
SHIFT
SEQUENCE
RESTART
1CYCLE
START
RETURN
CYCLE
START
1STEP 1STEP
ADVANCE REVERSE (mm/min) SPEED
X Y Z
MIRROR
IMAGE
X
MIRROR
IMAGE
Y
MIRROR
IMAGE
Z
MIRROR
IMAGE
4
CYCLE START 1000 40
20 500
A.B ADAPT LIGHT COOLANT A.B NOZ A.B ADAPT WATER GUN
4 5 PULSE
HANDLE
INTER
LOCK
RELEASE
MACHINE
LOCK
DRY
RUN LUB.
2000 80
CHIP CON CHIP CON OIL MIST OIL HOLE CHIP WASH SHOWER
4 5 PULSE
RAPID
JOG
80
% FEEDRATE
90 95 100
105
SLIDE HOLD
HANDLE 70 110
RAPID
CW STOP CCW
(inch/min) JOG
60
50
40
120
130
140
8 200 4000 160
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
0 100
70 180 4 100 RESTART EDIT
LOCK UNLOCK LOCK 4 100
50 200 2 50
0.04 1 10000 400
6000 240
6000 240
2 50
0.04 1 10000 400
ME11158R0200600270001
Procedure :
1- Select the axis to be moved with an [AXIS SELECT] flat key.
2- Select a desired feedrate using the [JOG SPEED] selector switch. The feedrate setting range
is from 1 to 10,000 mm/min (0.04 to 393.70 ipm). This selection can be changed during
operation while an axis is moving.
3- Press either the [JOG +] or the [JOG -] flat key. The axis will move in the direction selected by
the flat keys at the selected feedrate.
4- Press the [JOG OFF] flat key to stop axis feed.
Automatic Axis Feed Operation
Automatic axis feed is controlled by a programmed command in the automatic mode or a command
entered in MDI mode.
For details, consult the Programming Manual.
Programmed feedrates can be manually overridden within a range from 0 to 200 % using the %
FEEDRATE dial switch located at the bottom of the pendant operation panel. A feedrate switch
setting of 100 % will maintain the programmed rate as it is.
% FEEDRATE
90 95 100
80 105
70 110
60 120
50 130
40 140
30 150
20 160
10 170
5 180
0 200
ME11158R0200600280001
5074-E P-61
Cutting Range (Pallet Table)

(1) Interference Zone
The machine has an interference zone as shown below.
Put this in mind when creating a program or designing a jig.
Also note that putting a jig on the table shifts the interference zone.
A product with the maximum diameter of 800 mm (31.50 in.), if installed, does not interfere with
the tool with a length of 350 mm (13.78 in.) as operated by the ATC with the table at the origin of
the Z-axis.
Ø145 (5.71)
118 (4.65) 350 (13.78)
Allowance for tool removal Maximum tool length
180 (7.09) 180 (7.09)

C. A-axis
S. G.
APC
rotation center
Xst = 400 (15.75)

)
50
1.
(3
00
Ø8
Xst = 400 (15.75)

525 (20.67)
(R8
55 )
445 (17.52) 10 (0.39)

S. G.
Zst = 800 (31.50) 150 20 (0.79)

225 (8.86)
(5.91)
(7.68)
Ø195
Ø800 (31.50)
ATC origin
Yst = 800 (31.50)
800 (31.50)
Ø720 (28.35)
(3.15)
80
(2.76)
70
Unit: mm (in.)
ME11158R0200600290001
5074-E P-62
(2) Maximum Workpiece Shape and Center of Gravity

Maximum workpiece weight : 500 kg (1,100 lb)
Maximum workpiece diameter : 800 mm (31.50 in.)
Maximum workpiece height : 800 mm (31.50 in.)
Center of gravity of workpiece : Should be inside the hatched portion in the figure. To ensure
a longer index life, install the workpiece in such a manner
that as uniformly distributes its weight over the pallet as
possible.
Ø800 (31.50)
Ø720 (28.35)
Ø200 (7.87)
800 (31.50)
375 (14.76)
Pallet upper face

36 (1.42)
80 (3.15)
Edge locators
500 (19.69)
Unit: mm (in.)
ME11158R0200600290002
5074-E P-63
2-10. Manual Pulse Feed

The manual pulse feed operation is effective for feeding an axis a relatively short distance at a low
feedrate, for example such as aligning a cutting tool to a workpiece or manually feeding an axis in a
trial cut.
The MANUAL mode has been selected on the NC operation panel.
Confirm that the

light is ON.
X Y Z X1 X10 X50
0
DEL 90
A B C D E F G
P
MacMan 10
HT
80
20
A B
O P Q R S T U P P
4 5 6
70
30
V W X Y Z 1 2 3
60
40
CAPS
LOCK
SHIFT CTRL SP SHIFT BS 0 50

INTER
1 2

CYCLE S.T.M SEQUENCE 1CYCLE 1STEP 1STEP
AXIS SELECT
COM. AUTO HANDLE CYCLE

INTER
4 5 PULSE LOCK MACHINE DRY
X Y Z HANDLE RELEASE LOCK RUN LUB. CHIP CON CHIP CON OIL MIST OIL HOLE CHIP WASH SHOWER

% FEEDRATE
80 105
70 110
60 120
CW STOP CCW 50 130
30 150
110 120 130 1000 40
4 5
30 50 20 160
10 70 20 500 2000 80
PULSE 1
5 80
90
100
90
140
150
10
5
0 200
170
180
HANDLE 0 100
80
70
160
8 200
180 4 100
4000 160
RESTART
DOOR INTER ROCK NC PANEL
EDIT
LOCK UNLOCK LOCK
6000 240
50 200 2 50
0.04 1 10000 400
The light comes on.

ME11158R0200600310001
Operation Procedure
Procedure :
1- Press the [PULSE HANDLE] flat key on the pendant operation panel.
2- Select the desired multiplication factor (1/1, 10/1, 50/1) by adjusting the small switch above
the pulse handle. Multiply the multiplication factor by the pulse unit to obtain the actual axis
feed amount per pulse:
Multiplication Factor
1 10 50
Pulse Unit 0.001(0.0001) 0.001(0.0001) 0.01(0.001) 0.05(0.005)
3- Select the axis to be controlled (X, Y, Z) with the axis selector switch above the pulse handle.
5074-E P-64
4- Rotate the pulse handle dial clockwise to feed the axis in the positive (+) direction; rotate
counterclockwise to feed in the negative (-) direction.
One revolution of the pulse handle dial generates 100 pulses.
The pulse handle unit is removable from the pendant operation panel.
This facilities aligning work to be carried out near the workpiece.
Pulse handle
0
90
10
80
20
70
30
60
40
50
ME11158R0200600320001
SAFETY INSTRUCTIONS
1) An alarm will be activated when the given feedrate exceeds the maximum allowable axis
FEEDRATE. This may result if the pulse handle dial is turned quickly while a high
multiplication factor has been set.
2) If the axis does not move when the pulse handle dial is turned, it may be necessary to
adjust the "set backlash amout".
3) When the pulse feed operation is not in use, it is important to turn off the pulse handle
by pressing the [PULSE HANDLE] flat key again in order to prevent the axis from
unexpectantly moving if the pulse handle dial is accidentally touched.
AXIS SELECT
X Y Z
4 5 PULSE
HANDLE
Turn off the lamp.

ME11158R0200600320002
5074-E P-65
2-11. Coolant Supply Unit
Specifications
Coolant type Low viscosity non-soluble or water-soluble*

Pump motor 200 V, 50/60 Hz, 430/685 W
No. of coolant nozzles 6 (angle adjustable)
* For coolant, refer to Section 1-9.
[Supplement]
The machine is coated with two-liquid paint consisting of polyurethane compound base
and curing agent. Therefore, use the water-soluble coolant of emulsion type (W type 1).
Soluble type coolant (W class 2) may damage the coating.
Coolant Nozzle
Spindlehead
Coolant nozzle
ME11158R0200600340001
5074-E P-66
a. Six coolant nozzles are arranged on the spindlehead.
b. The use of a spherical joint permits easy angle-setting.
c. Set the seven nozzles at different angles so that coolant will be supplied at different points. This
also eliminates the need to re-adjust the nozzles each time tools are changed.
M08 Coolant ON
M09 Coolant OFF
[Supplement]
For selection of coolant, consult its maker since some types of coolant may damage or
abnormally rust packings or wipers.
5074-E P-67
Operation Procedure

INTER
SKIP BRANCH BRANCH OFF STOP BLOCK A TC APC RELEASE
1 2
CYCLE
STOP
S.T.M
LOCK
AXIS
COM.
CANCEL
MID.
AUTO
MANUAL
PULSE
HANDLE
SHIFT
SEQUENCE
RESTART
1CYCLE
START
RETURN
CYCLE
START
1STEP 1STEP
ADVANCE REVERSE
COOLANT
INTER
LOCK
DRY
RUN

% FEEDRATE
80 105
70 110
60 120
CW STOP CCW 50 130
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
0 100 RESTART EDIT
6000 240
50 200 2 50
0.04 1 10000 400
Coolant pump ON/OFF Pressing the switch turns the coolant ON

and the LED lamp at the upper left lights.
Pressing the flat switch again turns the
coolant motor OFF and the LED goes off.
ME11158R0200600350001
(1) In MANUAL Mode

Press the [COOLANT] flat key on the operation panel to start the coolant pump motor and to
deliver coolant. Press the [COOLANT] flat key again to stop the coolant flow.
(2) In the AUTO or MDI Mode

The following M code are used to control the coolant pump motor:
M08 Coolant pump ON
M09 Coolant pump OFF
To use the AUTO mode, the codes should be incorporated into the program.
To use the MDI mode, enter the codes through the keyboard and then press the SYSLE START
button.
a. The following codes also stop the operation of the coolant pump motor:
M00, M01, M02, M30, M50, and M51
b. The coolant pump is turned on/off by the operation of the flat key or the M codes,
whichever given later.
For example, if the coolant pump is on by the execution an appropriate M code, it can be
turned off by pressing the flat key. Similarly, the coolant pump started by the pressing of the
flat key can be stopped by executing the code M09. Preference is given whichever
command came last.
c. Coolant flowrate can be adjusted with the two lever cock switches located near the nozzle.
Although coolant flow can be shut off by completely closing these lever cock switches while
the coolant pump is operating, it could cause coolant temperature to rise and the pump to
be damaged. Therefore, they should not be closed completely while the coolant pump is
operating.
5074-E P-68
2-12. Chip Flusher
Chip flusher
Bed
(Rear of machine) (Front of machine)
Coolant tank
ME11158R0200600360001
A chip flusher is provided below the table.

The coolant and chips coming from the table are sent to the rear of the machine by the coolant flow
in the flushing trough and the chips are stored in the coolant tank.
The chip conveyor is turned ON and OFF by pressing the [CHIP FLUSHER] flat key on the pendant
operation panel. The light on the flat key will be illuminated when the chip conveyor is ON.
CAUTION
1) To prevent chips from being deposited in the gutters, flow coolant continuously to
smoothly discharge chips.
2) Long chips generated by drilling and small and long cotton-like chips are not suitable
for the conveyance. Cut chips shortly by step feeding or similar operation.
5074-E P-69
2-13. Work Light
Manufacturer: OSRAM
Model: V518DULUXS (13 W)
Remark: Provided above the access door on the wall outside the machine.
ME11158R0200600370001
The work light is turned on and off using the [LIGHT] key on the pendant operation panel.

INTER
1 2
A.B ADAPT LIGHT CYCLE

STOP
S.T.M
LOCK
AXIS
COM.
CANCEL
MID.
AUTO
MANUAL
PULSE
HANDLE
SHIFT
SEQUENCE
RESTART
1CYCLE
START
RETURN
CYCLE
START
1STEP 1STEP
ADVANCE REVERSE

INTER
LOCK
DRY
RUN

% FEEDRATE
CHIP CON CHIP CON ORIENTATION SPINDLE RELEASE
60
70
80
90 95 100
105
110
120
CW STOP CCW 50 130
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
0 100 RESTART EDIT
6000 240
50 200 2 50
0.04 1 10000 400
ME11158R0200600370002
5074-E P-70
2-14. Drill Holder for Through-the-tool Coolant
Fig.1 Fig.2
L L C1
L1 L1
D2
H2 H1 H3 H1
G1
D
D
MT, NO.
S
D
Oil passage Oil passage
45°
Free length b h6 Free length b h6
Set length a φ18 Set length a φ18
Location pin Location pin
[For Morse Taper Type Drills] [For Side Lock Type Drills]
ME11158R0200600380001
Max.
MT. Weight
Type Fig D1 L1 C1 H1 H2 G1 s a b D speed
No. (kg)
min-1
23.825 120 82 21 22 65 6 23.5 - 32 3.8
BT40-OMT3-120 1 MT3 - 0 3000
(0.938) (4.72) (3.23) (0.83) (0.87) (2.56) (0.236) (0.93 - 1.26) (8.4)
31.267 120 82 21 34 65 6 33 - 50 3.4
BT40-OMT4-120 1 MT4 - 0 3000
(1.231) (4.72) (3.23) (0.83) (1.34) (2.56) (0.236) (1.30 - 1.97) (7.5)
16 150 82 25 65 6 4.8
BT40-OSL16-150 2 - - M12 P1.5 0 3000
(0.63) (5.91) (3.23) (0.98) (2.56) (0.236) (10.6)
20 150 82 25 65 6 Varies 4.7
BT40-OSL20-150 2 - - M12 P1.5 0 3000
(0.79) (5.91) (3.23) (0.98) (2.56) (0.236) depending (10.3)
25 165 82 15 20 65 6 on carbide 4.6
BT40-OSL25-165 2 - M16 P1.5 0 bit maker. 3000
(0.98) (6.50) (3.23) (0.59) (0.79) (2.56) (0.236) (10.1)
32 165 82 15 20 65 6 5.4
BT40-OSL32-165 2 - M16 P1.5 0 3000
(1.26) (6.50) (3.23) (0.59) (0.79) (2.56) (0.236) (11.9)
SAFETY INSTRUCTIONS
1) The angle between location pin direction and drive key slot is 45°.
2) Location and oil delivery blocks are supplied by Okuma.
3) To purchase a drill holder, specify that the drill holder is used for MB-500H.
4) Pull-stud bolt: MAS 407 Type 2.
5) Purchase a through-the-tool coolant holder manufactured by Daishowa Seiki (BIC).
5074-E P-71
2-15. Table Indexing Operation

(1) The machine is not equipped with table indexing manual switches.
(2) Table indexing operation is performed by the commands entered through the keyboard or a
tape.
(3) Minimum input increment (0 ≤ B ≤ 360°)

1° index type 1 deg.
0.001° index type (NC rotary table) 0.001 deg.
(4) Direction of the table index is commanded by a proper M code.

M15 : Table Indexing Clockwise Rotation
M16 : Table Indexing Counterclockwise Rotation
Note that the table indexing angular position is fixed.

In other words, table indexing is made by an absolute value.
0°
M16
90° 270°
M15
180°
ME11158R0200600390001
(5) Procedure for entering a table indexing command through the keyboard:
a. Select the MDI mode by pressing the MDI key.
b. Press the function key [F1] (DATA INPUT).
c. Enter the index rotation direction command, M15 or M16 as desired and then the required
table index angle. Make sure that the data has been correctly entered.
d. Press the WRITE key. The input data display disappears and the data is displayed in the
buffer column, instead.
e. Press the CYCLE START button. The table is indexed in accordance with the entered data.
5074-E P-72
2-16. Operation End Lamp, Buzzer and Auto Power Shutoff Lamp (Sig-
nal Tower)
ME11158R0200600400001
(1) Lamps
a. Operation end lamp (yellow)

Lights when M00, M01, M02, M30, or END is executed.
Also lights when M60 is specified without depression of [SETUP COMPLETE] pushbutton
on the machine with APC.
b. Alarm lamp (red)

Lights when an NC alarm or EC alarm occurs.
c. The operation end lamp or alarm lamp goes out when the reset pushbutton switch is
pressed on the NC operation panel.
(2) Operation end buzzer
a. The buzzer sounds for a preset time on the same conditions as lighting of the operation
end lamp.
b. The end buzzer and the end lamp can be actuated together.
5074-E P-73
(3) Auto power shutoff function
a. The power is shut off when the programmed M02, M03, or END is executed.
b. The power is also shut off when M60 is specified without depression of [SETUP
COMPLETE] pushbutton on the machine with APC.
(4) The above function can be switched between valid and invalid by parameter setting.
(Refer to the OSP Operation Manual.)
5074-E P-74
SECTION 5 INSPECTION, MAINTENANCE AND

ADJUSTMENTS
The utilization rate of machining centers in comparison with conventional machine tools is generally 2 to 3
times higher. Therefore, downtime due to problems would all the more affect and reduce productivity.
In situations where one operator handles more than one machine at a time, the operator is often likely to be
away from the machine. Minor problems might damage workpieces or even develop into major breakdowns.
Thus, routine inspection and maintenance work should be strictly carried out to keep the machine running at
its best.
In addition to periodical inspection and regular maintenance, this section deals with adjustments that may be
required depending on the condition of the machine.
Fur further information and in case of problems, call your Okuma representative.
1. Periodical Inspection
CAUTION
1) To prevent machine disorder/failure and excessive wear of components and maintain
the accuracy at the highest level, it is very important to daily service, check and adjust
the machine and replace components as necessary.
The periodical inspection intervals and items are shown below.
2) The periodical inspection intervals and items shown in the following list should be
adjusted according to the workpiece material and machine operation rate. The
maintenance schedule should be optimized to reflect the factory management.
Interval Inspection item

• Check consumable parts for wear and replace if necessary.
Every day • Remove chips.
• Check instruments and check ATC and axes for correct motion.
• Add grease to ATC.
Monthly
• Check filter for clogging matter and clean if necessary.
• Check the above items and levelness of machine.
Every three months
• Check oil level in ATC unit.
• Check the above and following items.
Every six months • For the machine normally operating at a high speed, check spindle for
runout and bearings for unusual sound and replace if necessary.
• Check the above and following items.
• Replace filter for pneumatic unit.
Yearly • Check and adjust backlash.
• Check consumable parts and replace if necessary.
• Replace battery with a new one.
5074-E P-75
1-1. Inspection Points
CAUTION
1) Remember and check the names and locations of machine components.
2) Correct understanding about the machine is important for accurate maintenance and
inspection.
ME11158R0200700030001
(1) Machine body (10) Index

(2) Automatic tool changer (11) 2APC
(3) Magazine (12) Spindle
(4) Hydraulic unit (13) Column
(5) Oil temperature control unit (14) Y-axis motor
(6) Tank w/oil temperature regulator (15) Numerical control unit
(7) Sliding surface lubrication unit (16) CRT operation panel
(8) Pneumatic unit (17) Coolant unit
(9) Oil-air lubrication unit (18) High-pressure coolant unit (optional)
5074-E P-76
1-2. Inspection Items
ME11158R0200700040001
5074-E P-77
Proce
Code Location Inspection item Check method Criteria Frequency Remark
dure
Visual (especially at fixed
Chips accumulated in
telescoping section and Every 3
machine (especially at moving No chips allowed. A2
wiper section as months
parts)
retracted).
Wear of ball screw coolant Every 3
Visual No coolant leak allowed. None
seal months
Lubrication of direct-driven Lubricant should be coming Every 6
Visual None
guide and ball screw out. months
(1) No loose mounting
bolts allowed.
(2) Cover should be free of
deformation at
mounting screws.
Telescoping cover for each (3) Telescoping cover Every 6
Visual A3
axis should be free of dents months
and scratches.
(4) No crack allowed at
bent sections.
(5) No peeled or protruding
wiper seal allowed.
Machine
A (1) No missing clamp bolts
body
allowed.
Pantograph for telescoping Every 6
Visual (2) Telescoping guide and A4
cover months
rail should be free of
excessive wear.
Motive power of feed axes Motor current (monitor Every 6 Current during
Standard value 20% None
under no load screen) months rapid feed
Unusual sound during rapid No unusual conditions Every 6
Five senses None
feed allowed. months
(1) Hose coverings should
be free of severe
damage.
Failures of hydraulic hoses Visual check and sense (2) Hoses should be Every 6
A5
and cables of touch adequately routed. months
(3) No missing or loose
bands, Insulocks and
set screws allowed.
Backlash of feed axes Dial gauge 0.01 or less Every year A6
Precision level (0.02 mm/
Levelness of machine 0.06 or less Every year A1
m)
Oil level Visual (level gauge). Between H and L Every day None
Unusual sound during table Every
Visual and five senses Not allowed. None
rotation month
Oil sticking to level gauge Every 3
Contamination of lubricant Visual None
should be clean. months
Check oil content in air
No oil should be contained.
spray from tapered cone Every 6
Oil leak from rotary joints Put a piece of paper for 10 B4
during air blow onto months
seconds to check.
B Index pallet.
Every 6
Chips on pallet seating area Visual No chips allowed. A2
months
Drive gear backlash (1 deg
Dial gauge 0.44 (at 265 from pallet center) Every year B1
index)
Worm wheel backlash (0.001 0.030 (at 265 from pallet For NC table
Dial gauge Every year B2
deg index) center) type
Timing belt tension (0.001 Belt should deflect by 3.5 mm For NC table
Push belt center. Every year B3
deg index) when pushed at 30N. type
5074-E P-78
ME11158R0200700040002
5074-E P-79
Proce
dure
Coolant level in spindle
Visual (level gauge) Between H and L Every day C1
coolant tank
Oil leak from spindle cooler
Visual Coolant level in tank Every day C1
system
Air should come out from front Every
Air curtain blower Tactile sense C4
spindle lid. month
Vibration and noise of center- Every 6
Five senses No unusual condition allowed. C2 Optional
through rotary coolant joint months
No continuous leak from drain
Oil leak from center-through Every 6
Visual port allowed during use of C3 Optional
C Spindle rotary coolant joint months
center-through.
Tapered portion of spindle Visual No damage and rust allowed. Every year None
Clamping force of coned disc
Clamping force meter 6500N or more Every year None Note 1
spring
Slowly rotate spindle by hand.
Spindle Rotation of spindle Spindle should not stick. Every year None
Bearing should not chatter.
Spindle run-out Measure with test bar. 0.02/300 or less Every year None Note 2
Greasing of collet for HSK Every 2
Grease using a spray. See HSK operation manual. None Optional
spindle weeks
Cushion should effectively
Visual
D Magazine ATC shutter function. No lose screws and Every year D1
Tighten with wrench.
chips inside cover allowed.
Oil level in ATC unit Visual (level gauge) Between H and L Every day None
2 mm or less in peripheral
Chatter at arm end (at direction
Dial gauge Every year E1
standby position) 1 mm or less in longitudinal
Changer direction
E
arm
Motion of slider pin (at Should smoothly move
Tactile sense Every year E2
standby position) without sticking.
Centering gauge should
Concentricity of ATC Centering jig Every year E3
smoothly go through ATC.
Unusual sound and vibration Every
Visual and sense of touch (Rotation and vertical motion) None
during motion month
F APC
Rotation of door and stability Smoothness and door
Visual (adjust cushion). Every year F1
during rest vibration during rest
Note 1: Buy a clamping force meter or use our (pay) service.

Note 2: Buy a test bar or use our (pay) service.
5074-E P-80
ME11158R0200700040003
5074-E P-81
Proce
dure
Oil level in hydraulic unit Visual (level gauge) Between H and L Every day None
Hydraulic unit pressure Pressure panel 6.5MPa Every day None
Hydraulic unit cooling fan Visual Fan should normally rotate. Every day G1
Every 3
Hydraulic unit radiator Visual No clogging matter allowed. G1
months
Hydraulic
G
pressure Replace if oil has turned Every 6
Contamination of hydraulic oil Visual (level gauge) None
yellow. months
Unusual sound from hydraulic Every 6
Listen. Not allowed. None
pump months
Oil level should not rapidly
Oil leak from pipes Level gauge Every year C1
drop.
Pneumatic unit pressure Visual (pressure gauge) 0.4 MPa Every day H1
Air curtain pressure Visual (pressure gauge) 0.1MPa Every day H1
Oil-air pressure Visual (pressure gauge) 0.2MPa or more Every day H1
Automatic drain of filter mist
Pneumatic Visual Drain should be coming out. Every year H1
H separator and drain catcher
pressure
Elements (mist separator,
Replace elements every year
drain catcher and micromist - Every year H1 See 2.3 (5).
as a guide.
separator)
Color of dew point checker for Replace film module if checker
Visual Every year H1 See 2.3 (5).
air drier is pink, white or brown.
Lubricant level in automatic
Visual (level gauge) Between H and L Every day I1
lubricator
Automatic
I Determine from refill
lubricator
Lubricant consumption rate Visual (level gauge) frequency (24cc per 24 Every day I1
hours).
Lubricant level in oil-air
Visual (level gauge) Between H and L Every day J1
Oil-air lubricator
J
lubricator Determine from refill
Lubricant consumption rate Visual (level gauge) Every day J1
frequency.
Every 3
Filter Visual No contamination allowed. K1
Spindle months
K
cooler Unusual sound and vibration Every 3
Five senses Not allowed. None
of pump months
5074-E P-82
ME11158R0200700040004
5074-E P-83
Proce
dure
Coolant level in spindle
Spindle Visual (level gauge) Between H and L Every day C1
coolant tank
L coolant
tank No unusual sound and Every 3
Bass screw coolant pump Five senses None
vibration allowed. months
Above middle point between H Check with
Coolant level in tank Visual (level gauge) Every day None
and L pump at rest.
Replace
Center-through filter Clogged element warning Is signal issued? Occasionally None
element.
Back flush Y strainer clogging For lift-up
Visual (pressure gauge) 0.08MPa or more Every day None
matter conveyor type
Spindle coolant nozzle Visual No clogging matter allowed. Every month M1
Ceiling shower nozzle Visual No clogging matter allowed. Every month M2 Optional
Replace filter.
Filter in coolant tank Visual No tear allowed. Every month M3 For lift-up
conveyor type.
Coolant Filter cleaning nozzle in clean For lift-up

M Visual No clogging matter allowed. Every month M3
unit fluid tank conveyor type
Chips accumulated in clean Every 3
Tactile sense 20 mm or less None
fluid tank months
Unusual sound and vibration Every 3
Five senses No unusual sound allowed. None
of coolant pump months
Every 3
Vibration of pipes Five senses No unusual condition allowed. None
months
Every 6 For lift-up
Conveyor chain tension Lift by hand. Between 20 mm and 30 mm M3
months conveyor type
Clean.
For manual
Detachable filter Visual No clogging matter allowed. Every day None
scraper coolant
type
Fan should be rotating. No Every 3
Fan Visual N1
contamination allowed. months
Electric
Oil inside electric distributor
N distributor Visual No oil intrusion allowed. Every year None
box
box
Replace every year as a
Memory back-up battery Replace battery. Every year None See 2-3-(12).
guide.
Scratches and contamination Every 3
Visual No unusual condition allowed. None
at tapered portion months
O Tools
Every 6
Loose pull studs Wrench Not allowed. None
months
5074-E P-84
1-3. Procedures
A1. Levelness of machine
Procedure :
1- Position the X-axis at the origin and the Z-axis at 300 (stroke center).
2- Put levels on the pallet as shown below. If this is impossible, put them on the LM guides for
X- and Z-axes.
Note
Take enough care when installing the telescopic cover for Z-axis.
1) Install the telescopic cover as fully retracted.
2) The telescopic cover should not be twisted before installed.
3) Apply a coat of sealer over the mounting surface.
4) After installation, check the telescopic cover motion.
3- Read the scale on each level.
Levels
450 (17.72)
(320 (12.60) + 130 (5.12))
Levels
(when they cannot be put on the pallet)
Unit: mm (in.)
ME11158R0200700050001
5074-E P-85
A2. Chips accumulated in the machine
Check for
accumulated chips.
ME11158R0200700060001
Check for
accumulated chips.
ME11158R0200700060002
5074-E P-86
A3. Telescopic cover bodies for axes
Check for dents and

wire seal protrusions.
ME11158R0200700070001
Check for dents,

top cracks,
missing wiper mounting screws
and wiper seal protrusions.
ME11158R0200700070002
5074-E P-87
A4. Pantograph for telescopic cover
Check for missing

mounting bolts.
ME11158R0200700080001
5074-E P-88
A5. Failures of hydraulic hoses and cables
WARNING
1) When checking hoses in the machine with the access door at the rear of the machine
open, disconnect the power supply from the machine and take upmost care in checking
and working.
2) A sign reading `Now Inspected" should be put at the operation panel so that no third
person will turn the power supply on during inspection.
Check hydraulic hoses

and cables for unusual
conditions.
ME11158R0200700090001
5074-E P-89
A6. Backlash of feed axes
X direction
Y direction
Z direction
ME11158R0200700100001
Procedure :
1- Put a dial gauge onto the spindlehead or pallet table.
2- Feed the axis in the positive direction by about 10 pulses (with 10 magnifications).
3- Set the dial gauge to zero.
4- Move the axis in the positive direction by 10 pulses.
5- Move the axis in the opposite (negative) direction by 10 pulses.
6- Record the change in dial gauge reading as feed axis backlash.

5074-E P-90
B1. Curvic drive gear backlash
265 (10.43)
Unit: mm (in.)
ME11158R0200700110001
Procedure :
1- Put a dial gauge onto the edge locator 265 mm (10.43 in.) away from the pallet center as
shown above.
2- After applying a force about 200N clockwise with the index unclamped (issue an M-coded
command, M21), and read the dial gauge.
3- Apply the same force counterclockwise and read the dial gauge.
4- Record the change in dial gauge reading as drive gear backlash.
5- With an excessive drive gear backlash, the curvic couplings cannot be correctly engaged,
resulting in a poor indexing accuracy.
5074-E P-91
B2. NC rotary (worm wheel) backlash
265 (10.43)
Unit: mm (in.)
ME11158R0200700120001
Procedure :
1- Put a dial gauge onto the edge locator 265 mm (10.43 in.) away from the pallet center as
shown above and read the dial gauge.
2- Select the manual mode, and select the "4th axis" for the pulse handle operation. Then, feed
the axis in the positive direction by generating about 10 pulses with a magnification of ×10.
3- Set the dial gauge to zero.
4- Further, move the axis in the same (positive) direction by generating 10 pulses with the pulse
handle.
5- Then, feed the axes in the negative direction by the same number of pulses (10 pulses) so
that they come back to the original position as shown on the operation panel screen. Read
the dial gauge.
6- Record the change in dial gauge reading as worm wheel backlash.
7- If an excessive backlash may be attributed to a poor indexing accuracy, adjust the worm axis
backlash.
5074-E P-92
B3. Timing belt tension (with NC table)
3.5 (0.14)
30 N
Unit: mm (in.)
ME11158R0200700130001
Procedure :
1- Remove the telescopic cover mounting bolts on the index table at the side opposite from the
spindle (2APC side). Open the telescopic cover.
2- Push the center of the timing belt at the side of the index table with a force of 30N to check
that the belt is deflected by about 3.5 mm (0.14 in.).
3- After checking, install the telescopic cover with enough care.

(1) Install the telescopic cover as fully retracted.
(2) The telescopic cover should not be twisted before installed.
(3) Apply a coat of sealer over the mounting surface.
(4) After installation, check the telescopic cover motion.
B4. Oil leak from rotary joints
Procedure :
1- Move each axis to the APC position (second origin).
2- Select the maintenance/independent operation mode and call the APC independent
operation screen.
3- Move the cursor to `Release Interlock" and press the Function Start button.(Check that the
wording `Releasing" blinks.)
4- Move the cursor to `Unclamp Pallet" and press the Function Start button. The pallet moves
up.
5- Move the cursor to `Hook Up" and press the Function Start button. The APC hook moves up
to raise the pallet.
6- Air is blown from the tapered cone on the table body. Put a dry, white piece of paper over it
for about 10 seconds to check for oil contained in the air.
If oil is leaking, it is spread over the paper. In this case, contact our service personnel.
5074-E P-93
7- After checking, move the hook down and clamp the pallet in the independent operation
mode. After the pallet is clamped, switch back to the original mode.
The interlock is automatically applied again.
A piece of paper
ME11158R0200700140001
5074-E P-94
C1. Leak form the spindle cooler and hydraulic systems
Attach a tape
or such and mark the fluid level.
Hydraulic unit Tank w/oil temperature regulator

ME11158R0200700150001
Procedure :
1- When exchanging or adding the spindle coolant or hydraulic fluid, attach a tape near the level
gauge and mark the fluid level.
2- Before the daily work, check that the actual fluid level is not significantly different from the
marked level.
3- If it is significantly different from the marked level, leak from the piping system is suspected.
Check relevant pipes.
5074-E P-95
C2. Condition of center-through rotary coolant joint
DANGER
1) This needs to be checked at the rear of the machine. The machine may be operated
without notice. Extreme care should be taken when checking.
person will operate the machine during inspection.
Center-through rotary coolant joint

ME11158R0200700160001
5074-E P-96
C3. Oil leak from center-through rotary coolant joint
DANGER
1) This needs to be checked at the rear of the machine. The machine may be operated
without notice. Extreme care should be taken when checking.
Head
Column
Drain port
ME11158R0200700170001
C4. Air curtain blower
Check that air is blown from the drain port at the bottom of the front spindle lid.
Spindle
Drain port
ME11158R0200700180001
5074-E P-97
D1. ATC shutter
WARNING
1) This needs to be checked inside the machine. The machine may be operated without
notice. Extreme care should be taken when checking.
Procedure :
1- Check that the cushion is smoothly moving during the ATC shutter motion.
If any shock is caused by the closing or opening motion, adjust the cylinder cushion.
2- Remove the shutter guide cover. Check the ATC shutter components for loose mounting
screws.
3- Remove chips inside the cover if any.
Check for loose mounting screws.
Cylinder cushion
Cylinder cushion
Shutter guide cover
Spindle
ATC shutter
ME11158R0200700190001
5074-E P-98
E1. Measurement of chatter at the end of changer arm
WARNING
The following tools are required for measurement.

(1) A magnet stand
(2) A dial gauge (5 mm/graduation, 0.01 mm approx.)
(3) A loading bar (a wooden bar, 30 x 80 x 500 mm approx.)
Procedure :
1- Select `Open ATC Door" in the maintenance/independent operation mode.
2- Move the axes using the manual handle.

X-axis: Around +400 position (machine coordinate)
Y-axis: Around +225 position (machine coordinate)
Z-axis: Around +700 position (machine coordinate)
3- Turn the power supply off.
4- Check the rotating direction (see the following figure).

Mount a magnet stand to the spindlehead and put a dial gauge onto part A of the ATC arm.
Then, rotate the opposite end of the ATC arm clockwise and counterclockwise by hand (with
a force about 50N). Record the maximum fluctuation in dial gauge reading.
5- Check the tool removal direction (see the following figure).

Mount a magnet stand to the spindlehead and put a dial gauge onto part B of the ATC arm.
Then, insert a loading bar into part C and push the ATC arm toward the spindle (with a force
about 390N onto the arm axis). Read the maximum fluctuation in dial gauge reading.
6- After checking, turn the power supply on and put the ATC door and axes back in place.
5074-E P-99
ME11158R0200700200001
5074-E P-100
E2. Motion of changer arm/slider pin
WARNING
Push the slider pin with finger at the ATC standby position to check that it smoothly moves without
sticking.
Slider pin
ME11158R0200700210001
5074-E P-101
E3. Concentricity of ATC
DANGER
2) A sign reading ‘Now Inspected’ should be put at the operation panel so that no third
Check the concentricity of the ATC with the spindle.
Procedure :
1- Remove all tools from the pots at the standby positions for the spindle and magazine.
2- Prepare a centering jig (shank, grip and reference pin).
Reference pin Grip Shank
ME11158R0200700220001
3- Move the machine to the second origin.

X-axis: +400 mm from the table center
Y-axis: +645 mm from the machine zero
4- Clamp the shank onto the spindle.
5- Assemble the grip and reference pin into the shank.

5074-E P-102
6- Set the changer arm to the 90 degrees (horizontal) position in the manual or maintenance/
independent operation mode. Position the grip in the longitudinal direction so that the
changer arm will be aligned with the V groove on the grip when the changer arm and grip
come into contact with each other. Also check the orientation using the key way on the grip.
Clearance
2.5 (0.10) ± 0.3 (0.011)
CAT: 1.8 (0.07) ± 0.3 (0.011)
Reference pin
Grip
Changer arm Shank
Unit: mm (in.)
ME11158R0200700220002
7- Check that the reference pin smoothly goes into the holes on the grip and shank.
8- Check that the clearance between the shank and the grip is 2.50.3 (or 1.80.3 for the CAT
type).
9- Repeat the same steps for the arm on the opposite side.
5074-E P-103
Concentricity of the ATC with the pot
Procedure :
1- Put the shank into the pot.
2- Assemble the grip and reference pin into the shank.
3- Set the changer arm to the 90 degrees (horizontal) position in the manual or maintenance/
independent operation mode. Position the grip in the longitudinal direction so that the
changer arm will be aligned with the V groove on the grip when the changer arm and grip
come into contact with each other. Also check the orientation using the key way on the grip.
Magazine pot
Changer arm
Reference pin
Grip
2.5 (0.10) ± 0.3 (0.011)

Shank CAT: 1.8 (0.07) ± 0.3 (0.011)
ME11158R0200700220003
4- Check that the reference pin smoothly goes into the holes on the grip and shank.
5- Check that the clearance between the shank and the grip is 2.50.3 (or 1.80.3 for the CAT
type).
6- Repeat the same steps for the arm on the opposite side.
5074-E P-104
Centering jigs
• Shank
Material: SCM415, a carburized, quenched steel (HRc59)
Ø44.45 (1.75)
A Ref 7/24 tapered
2 M6 screws, 12 (0.47) deep
M16
Ø21 (0.83)
Drill, 16 (0.63) deep
2 (0.08)
30º
º
Ø20 (0.79) H7 30
(Ø44.9 (1.77))
(Ø25.3 (1.00))
Ø19 (0.75)
30 (1.18) 1.5 (0.06)
Ø17 (0.67) H7
Ø18 (0.71)
G G
8
G (0.31)
1.5 (0.06) ± 0.1 (0.0039) 65.4 (2.57) ± 0.2 (0.0078)
25 (0.98) 5 (0.20)
G
G
Ø0.02 (0.00078) A
66.9 (2.63)
Unit: mm (in.)
ME11158R0200700220004
• Grip (BT40)
22.6 (0.89) ± 0.1 (0.0039)

G 60º
A Ref
G
G
G
C1
Ø53 (2.09)
-0.03 (0.0011)
Ø20 (0.79) H7
Ø36 (1.42)
Ø63 (2.48) -0
C1
G C1
22.6 (0.89) ± 0.1 (0.0039)
Ø0.02 (0.00078) A
10 (0.39) +0.1
+0
(0.0039)
16 (0.63) +0.1
+0
(0.0039)
12.6 (0.50) ± 0.1 (0.0039)
23 (0.91)
35 (1.38)
Unit: mm (in.)
ME11158R0200700220005
5074-E P-105
• Grip (CAT40)
32 (1.26)
(0.00082) Ø0.01 (0.00039) A
G
16 (0.63)
Ø20 (0.79) H7 +0.021
Ø0.01 (0.00039) A
+0
7.9 (0.31) ± 0.1 (0.0039)
A C0.5 C0.5 C0.5

C
1
Ø63.5 (2.50) ± 0.05 (0.0019)
Ø72.3 (2.85) ± 0.05 (0.0019)
22.6 (0.89) -0-0.3 (0.011) 25.8 (1.02) -0-0.3 (0.011)

Ø44 (1.73)
Ø56 (2.20)
C
1
C1
G
)
28)
(0. G
(Ø7
G
G
3.84 (0.15) 16.4 (0.65) ± 0.1 (0.0039)
7.05 (0.28)
60º ± 15' Unit: mm (in.)

ME11158R0200700220006
• Reference pin
Material: S45C, a quenched & tempered steel (HRc48)
Ø20 (0.79) g6
G
Ø26 (1.02)
80 (3.15) 60 (2.36)
C1
Unit: mm (in.)
ME11158R0200700220007
5074-E P-106
F1. Rotation of APC and stability during rest
After rotating the APC, check both ends of the rotating door for vibration.
If the door goes down with both ends significantly vibrating, it interferes with the fixed cover, possibly
resulting in damage.
Check for vibration after

rotating the APC.
ME11158R0200700230001
G1. Hydraulic unit
Check the radiator for

clogging matter.
Check that the fan is

normally rotating.
ME11158R0200700240001
5074-E P-107
H1. Pneumatic valve plate
Air pressure for oil-air

lubrication: 0.2MPa or more
Air curtain pressure:

0.1MPa
Pneumatic unit pressure:
0.4MPa
Does drain come out?

(Should not normally
come out)
Elements
Dew point checker
Replace every year
Replace film module if
as a guide.
checker is pink, white or
brown.
Does drain come out?

(Should not normally
come out)
ME11158R0200700250001
I1. Automatic lubricator
Pressure gauge
Filler port
Delivery port
Check that the fluid level is

between H and L.
Tank 6L
ME11158R0200700260001
5074-E P-108
J1. Oil-air lubricator
Refill button
Pressure gauge
Filler port
Check that the fluid level is
between H and L.
Line filter
Tank 2L
Delivery port

ME11158R0200700270001
K1. Spindle cooler (oil temperature regulator)
Check for contamination.

Air filter Clean or replace the filter if heavily
contaminated.
ME11158R0200700280001
5074-E P-109
M1. Coolant nozzles
Spindle nozzles (6)
ME11158R0200700290001
M2. Shower coolant nozzles
Shower coolant nozzles (18)
ME11158R0200700300001
5074-E P-110
M3. Coolant unit
Remove the top lid of the coolant unit. Check the filter inside the coolant unit and the filter flushing
nozzles.
Conveyor chain Filter
Filter flushing nozzle
ME11158R0200700310001
If the filter is too contaminated to check the filter flushing nozzles, check them with the following
procedure.
Procedure :
1- Stop the conveyor (turn the power supply off or switch to the independent operation mode).
2- Remove the top lid from the raised part of the coolant unit.
3- The conveyor filter is divided into four segments. Remove the screws fixing the filter and
remove one of the segments.
4- After removing a segment, check the nozzle condition.
5- Attach the filter segment and fix with screws.

5074-E P-111
6- When attaching the filter segment, take care not to deflect it.
Filter segment
Rubber packing
Filter
ME11158R0200700310002
N1. Electric box fan
Check that the cooling fans are rotating in the electric distributor box. Wipe out the fans with a dry
cloth if heavily contaminated.
Cooling fan
Cooling fans
ME11158R0200700320001
5074-E P-112
2. Maintenance and Inspection of Peripheral Units
2-1. Lubrication of Axis Slideways
CAUTION
1) After leaving the machine inactive for an extended period of time, press the Refill button
several times at intervals of a few seconds before starting machine operation to
lubricate the sliding surfaces until the pressure gauge reads a value between 0.98 and
1.2 MPa.
2) If no lubricant is fed to the sliding surfaces, check the pipes for clogging, the pump for
disorder, and for other failures.
3) Note that the automatic lubricator looks like the oil-air lubricator.
Automatic Lubricator
The lubricator at the left as viewed from the left side of the machine is intended for sliding surfaces
of the axes.
The direct-driven guide and index gear for each axis and part of the ATC are lubricated by the
automatic lubricator illustrated below.
The automatic lubricator delivers about 2.4 cc of lubricant per action.
The effective capacity of the pump is about 4.1 liters. About 375 operating hours after the pump is
filled up (6 liters), the level switch is activated to warn the operator.
Pressure gauge
Filler port
Delivery port
Tank 6L

ME11158R0200700340001
5074-E P-113
Refilling the Tank

(1) Use G68 as lubricant.
(For detail about G68, see 2.2(2) "Lubricating Oil Specifications.")
(2) Refill the tank through the filler port. When draining, remove the drain plug at the bottom. (See
2.3.(1) "Schematic of Automatic Lubricator.")
(3) Do not admit debris and other foreign matter into the tank.
(4) For location, etc. of the lubricator, see 2.2.(1) "Lubrication Control Chart."
Maintenance and Inspection

(1) Before running the machine, check that the lubricant level is between H and L.
(2) As described on the automatic lubricator, the lubricant will be consumed.

Timely add a lubricant of the same brand (every 200 operating hours as a guide).
(3) For check frequency and points, see 2.1 "Periodical Inspection."
5074-E P-114
2-2. Refilling the Oil-air Lubricator
CAUTION
1) After an extended suspension, press the Refill button several times at intervals of a few
seconds before the start of operation to lubricate the sliding surfaces until the pressure
gauge reads a value between 0.98 and 1.2 MPa.
2) If the level switch is not activated about 4950 operating hours after the lubricator is filled
up, check for clogged or faulty pipes and other failures.
3) Note that the oil-air lubricator looks like the automatic (intermittent) lubricator.
Oil-air Lubricator
The lubricator at the right as viewed from the left side of the machine is intended for oil-air
lubrication.
The spindle bearing is lubricated by the oil-air lubricator illustrated below.
The automatic lubricator delivers about 0.07 cc of lubricant per action.
The effective capacity of the pump is about 1.5 liters. About 4950 operating hours after the pump is
filled up (2 liters), the level switch is activated to warn the operator.
Refill button
Pressure gauge
Filler port
Line filter
Tank 2L
Delivery port

ME11158R0200700380001
Refilling the Tank

(1) Use HL32 as lubricant. (For detail about HL32, see 2.2. (2) "Lubricating Oil Specifications.") The
tank capacity is 2 liters.
(2) Refill the tank through the filler port. When draining, remove the drain plug at the bottom. (See
2.3. (2) "Schematic of Oil-air Lubricator.")
5074-E P-115

(1) Before running the machine, check that the lubricant level is between H and L.
(2) As described on the oil-air lubricator, the lubricant will be consumed. Timely add a lubricant of
the same brand (every 1000 operating hours as a guide).
(3) For check frequency and points, see 2.1 "Periodical Inspection."
5074-E P-116
2-3. Refilling the Hydraulic Unit
Hydraulic Unit
The hydraulic unit is used for the following purposes.
• Clamping and unclamping the spindle tool
• Sliding the tool from the magazine to the ATC
• Rotating the APC by 180 degrees and moving the pallet up and down
• Clamping and unclamping the pallet
• Clamping and unclamping the index curvic gear
The hydraulic unit delivery pressure is 6.5 MPa.

The effective capacity of the tank is about 17 liters and the full capacity 20 liters.
Radiator Pressure gauge
Level switch
Filler port or breather
Level gauge
Tank 20L
Drain port
ME11158R0200700410001
Refilling the Tank

(1) Use HL32 as lubricant. (For detail about HL32, see 2.2.(2) "Lubricating Oil Specifications.") The
(2) Refill the tank through the filler port. When draining, remove the drain plug at the bottom.
(4) For location, etc. of the lubricator, see section 4 "Hydraulic Circuit Diagram."
5074-E P-117
Before running the machine, check that the lubricant level is between H and L.
Exchange the lubricant every six months as a guide if heavily contaminated.
Check that the cooling fan is rotating.
Check the hydraulic unit radiator for clogging matter.
Overhaul and clean the radiator if clogged.
For maintenance of the hydraulic unit, see the operation manual issued by Fujikoshi.
5074-E P-118
2-4. Refilling the Spindle Coolant Tank
Spindle Coolant Tank
The spindle cooler is used to cool the ball screw axis center and spindle.
The effective capacity of the tank is about 25 liters and the full capacity 32 liters.
Filler port
Level gauge
Level Ball screw axis center coolant pump
Suction filter
Drain port
ME11158R0200700440001
Refilling the Tank

(1) Use FC5 as lubricant. (For detail about FC5, see 2.2. (2) "Lubricating Oil Specifications.") The
(2) Refill the tank through the filler port. When draining, remove the drain plug at the bottom.
(4) For location, etc. of the lubricator, see section 4 "Cooling Circuit Diagram."

(1) Before running the machine, check that the lubricant level is between H and L. Exchange the
lubricant every six months as a guide if heavily contaminated.
(2) If the flow from the pump has decreased, clean the suction filter in the tank.
(3) For maintenance of the spindle cooler, see the operation manual issued by Daikin.
5074-E P-119
Maintenance and Inspection of the Spindle Cooler

(1) Debris and particles accumulated in the air filter decrease the air flow, affect the performance
and activate the compressor protector to interfere with the cooler operation. For this reason, the
air filter should be kept clean.
(2) Wash the air filter in warm water at 40 deg C or lower if heavily contaminated.
(3) Running the spindle cooler without air filter leads to a failure.
Air filter
ME11158R0200700470001
5074-E P-120
2-5. Pneumatic Unit
CAUTION
Clean air dried by an air drier should be used for the machine.
Layout of Devices on the Valve Plate
Pneumatic devices are concentrated at the rear left of the machine. Service them using the following
figure as a guide.
Air for breeze

ATC shutter opener
Air for oil-air lubrication
Negative pressure protection for index Spindle air curtain pressure

reducing valve
Index air blow
Air pressure sensor for
oil-air lubrication Setting: 0.1 MPa
Settings P1: 0.2
P2: 0.1
Air pressure sensor for Drain catch

pallet blower
Dew point checker
Settings P1: 0.35
P2: 0.29
Air drier
Optional
For setting air blow ring
Setting: 0.4 MPa
Micro mist separator
Filter regulator
Air pressure reducing
Mist separator valve for machine
Setting: 0.4 MPa
ME11158R0200700490001
Adjustment of Air Pressure Settings
The pressure preset for the machine is 0.4 MPa.

Before starting the machine, check the pressure with the pressure gauge.
Rotate the reducing valve knob to adjust the pressure setting.
5074-E P-121
Adjustment of Spindle Air Curtain Pressure Setting
Set an air pressure of 0.1 MPa for the spindle air curtain. Before starting the machine, check the
pressure with the pressure gauge.
Drain port
ME11158R0200700510001
Adjustment of Air Blow Ring Pressure Setting (Optional)
The air blow ring is provided with the HSK or BIG Plus spindle.
The pressure preset for the air blow ring is 0.4 MPa.
Before starting the machine, check the pressure with the pressure gauge.
5074-E P-122
Replacement of Filter Elements
Replace filter elements in the micro mist separator and filter regulator with new ones every year as a
guide, depending on the amount of clogging matter.
For manufacturers and models of the elements, see 2.4. (5) "List of Consumable Parts.
Lock button
Case
Auto drain
Outside View of Filter Regulator

ME11158R0200700530001
Replacement procedure
Procedure :
1- Shut off the air pressure supply.
2- Rotate the case by 45 degrees while pressing the black lock button on the case.
(Rotate until the II marks on the body and case are aligned with each other.)
3- Release the lock button and slowly lower the case (in the vertical direction) to disassemble it.
4- Rotate the filter element counterclockwise to remove it from the body.
5- Install a new filter element in the reverse order of steps (1) to (3).
6- The case clicks when locked. Check that the body and case will not be disengaged.
Lock button
Case
Auto drain
Outside View of Micro Mist Separator

ME11158R0200700530002
5074-E P-123
Replacement of Mist Separator and Drain Cather Elements
The machine uses a mist separator as a pneumatic set.

As the spindle air curtain and spindle cooler circuits require clean air with a lower moisture content,
drain catchers are provided in the spindle air curtain and spindle cooler circuits downstream the
pneumatic set to remove moisture from the air and improve the air quality.
Filter elements in the mist separator and drain catchers should be replaced with new ones every
year as a guide according to the amount of clogging matter.
For manufacturers and models of the elements, see 2.4. (5) "List of Consumable Parts."
Procedure :
2- Remove mounting screws at the top of the body. Rotate the case counterclockwise to
remove it.
3- Rotate the filter element counterclockwise to remove it from the body.
4- Install a new filter element in the reverse order of steps (1) to (3). Also replace the O ring and
gasket with new ones.
Auto drain
Outside View of Mist Separator
and Drain Catcher
ME11158R0200700540001
5074-E P-124
Maintenance and Inspection of Air Drier
The oil-air spindle lubrication circuit requires clean air with low moisture content. Therefore, an air
drier is provided in the air supply circuit to the oil-air lubricator to remove moisture from the air and
improve the air quality.
Determine the condition of the film module in the air drier from the color of the dew point checker at
the top of the air drier.
When the dew point checker is blue, the air drier is normally functioning.
When the dew point checker is pink, white or brown, the air drier performance has been decreased.
It takes about an hour after the start of air flow to change the color of the dew point checker.
If the dew point checker turns pink, white or brown, replace the film module with a new one.
Replace the film module set in the air drier every four years as a guide according to the amount of
clogging matter.
For manufacturers and models of the film module, see 2.4. (5) “List of Consumable Parts”.
Dew point checker

Body
Holder
Case
Outside View of Air Drier

ME11158R0200700550001
Procedure :
2- Loosen the holder.
3- Lower the case in the vertical direction and remove it from the body.
4- Remove the film module set from the case.
5- Check that a new film module set has a packing and spacer.
6- Fully insert the new film module set into the case.
7- Fully insert the packing into the groove on the case.
8- Insert the case vertically into the body.
9- Screw the holder into the body.

(The purge hole on the case may be oriented in any way.)
5074-E P-125
2-6. Other Pneumatic Devices

For locations, etc. of other pneumatic devices, see section 4 "Cooling Circuit Diagram."
2-7. Spindle
Check according to 2.3. (5) "Pneumatic Devices" that the spindle air curtain pressure is as preset.
Measure the spindle run-out every six months according to 2.1 "Periodical Inspection" and using a
test bar.
2-8. X-, Y- and Z-axes

(1) The direct-driven guide, ball screw and index gear for each axis and part of the ATC are
forcedly lubricated. For detail, see section 4 "Lubrication Circuit Diagram."
(2) Therefore, the parts listed above are mostly serviced by checking and servicing the automatic
lubricator.
(3) Check and replenish the lubricant according to 2.2. (1) "Lubrication Control Chart."
(4) Other maintenance work should be performed according to 2.1 "Periodical Inspection."
5074-E P-126
2-9. Automatic Tool Changer (ATC)
Arm Drive Unit
The unit contains an oil bath. Exchange oil every six months. Remove the case cover and apply a
coat of the greases respectively specified below using a brush over the gear, intermediate guide,
etc.
Also apply a coat of the specified grease using a brush over the support bar, etc. of the arm shaft.
Grease those parts every six months.
Apply a coat of Balmac RBG,

Spline guide
Kyodo Yushi.
Centrally lubricated.
Do not grease.
Apply a coat of VG32.

Do not grease.

Kyodo Yushi.
Apply a coat of Balmac BRG,

Kyodo Yushi.

Kyodo Yushi.
ME11158R0200700590001
5074-E P-127
Intermediate Pot Unit
Apply a coat of VG32 over the guide bars.

Grease other guide parts using a brush.
(For the trade name of the grease, see 2.2. (2) "Lubricating Oil Specifications.")
Apply a coat of VG32

over the guide bars.
Grease the guides.
ME11158R0200700600001
5074-E P-128
Magazine Unit (40- or 60-tool)
Grease the drum, sprockets, guides, resin plate and other parts using a brush.
For the trade name of the grease, see 2.2. (2) "Lubricating Oil Specifications."
Grease the drum.

Grease the sprocket.
Crease the resin plate.
Grease the guide.
Grease the guide.
Grease the guide.
ME11158R0200700610001
5074-E P-129
2-10. APC Unit
CAUTION
The following operations need to be performed at a high place. Perform them with enough
care with the machine at rest.
Lubrication
Apply a coat of molybdenum grease using a brush over the rack and metal parts of the APC drive
unit at the top of the APC.
When greasing, remove the cylinder mounting bracket cover with the rotary APC door rotating in the
normal or reverse direction and grease the rack inside or exposed teeth and rear of the rack.
Metal parts
Remove the cover and Grease teeth and

grease teeth and rear rear of the rack.
of the rack inside.
As viewed from the top of the rotary APC cylinder

ME11158R0200700630001
As the hydraulic cylinder extends and retracts, the rack rotates the pinion to turn the APC and
automatically change the pallet. The normal turning angle is 180 degrees.
The APC turning angle may change mostly for either of the following reasons.
• The APC timing changes with the gap between the proximity switch and the dog.
• The cylinder rod extention/retraction stroke changes for some reason.
If the APC does not normally turn, check the following items.
5074-E P-130
Gap between the proximity switch and the dog

Completion of the APC turn is confirmed by the proximity switch sensing the travel of the dog. If the
sensing distance changes, completion of the APC turn is delayed, resulting in an inconvenience.
The standard distance between the proximity switch and the dog is 1.5 mm.
Proximity switch
1.5 (0.06) 1.5 (0.06)
Proximity switch
Dog
Unit: mm (in.)
ME11158R0200700640001
Cylinder rod extension/retraction stroke

The normal stroke is 242 mm. The fully extended position of the hydraulic cylinder rod is determined
by the cylinder stroke end while the fully retracted position of the rod determined by the stopper. A
stroke change may affect the APC stopping position.
The fully extended position of the cylinder rod is adjusted by changing the engagement depth of the
screw at the end of the cylinder rod and the rack.
The fully retracted position of the rod can be adjusted by relocating the stopper.
Stopper
(width between flats: 60)
6-M6×28
M16×P2
Reserve a gap.
3 (0.12)
242 (9.53)
17 (0.67) (Rotates by 180 degrees.)
Unit: mm (in.)
ME11158R0200700640002
5074-E P-131
2-11. Telescopic Covers for Axes
CAUTION
Never stand on the Z-axis telescopic covers or hit any object on it.
Doing this may dent the covers to interfere with the axis motion and affect the enclosing
effect. This may also lead to injury.
(1) Do not hit any object with the telescopic covers for X- and Y- axes as well as for Z-axis.
(2) Remove chips on the telescopic covers (especially for Z-axis) at the end of work. At this time,
check them for dents, etc.
(3) Listen for unusual sound from the telescopic covers while operating. Unusual sound indicates
wear of the machine. Contact us for repair as soon as possible.
Y-axis telescopic cover

X-axis telescopic cover
Z-axis Telescopic cover

at spindle side
Z-axis telescopic cover
at APC side
ME11158R0200700650001
5074-E P-132
SECTION 6 ATC
SECTION 6 ATC
1. Tool Preparation
1-1. Preparing Tools

(1) Tool Shank
The shank has NT (National Standard Taper) No. 40 for milling machines.
(2) Tool Grip (Shank Head)

The tool grip is shaped and dimensioned to MAS standards - MAS 403-1982, BT40.
Dimension from the trapezoidal groove center to the datum diameter [44.45 mm (1.75 in.)] of
the shank taper should be held to 16.6 mm (0.654 in.) ± 0.1 mm (0.004 in.).
Refer to 2-2. "Tool Shank Dimensions".
(3) Pull Stud

Use a pull stud that conforms to MAS Standard; Type 2 MAS 407-1982.
Dimensions from the diameter [15 mm (0.59 in.)] if of the pull stud to the datum diameter [44.45
mm (1.75 in.)] of the shank taper should be held to 93.4 mm (3.677 in.) plus 0.2 mm (0.008 in.),
minus 0.3 mm (0.012 in.).
Refer to 2-1 "Dimensions of Tool Shank and Pull Stud".
(4) Maximum Tool Length

The maximum length of a cutting tool measured from the datum diameter [44.45 mm (1.75 in.)]
of the shank taper to the cutting tip (edge) should be 350 mm (13.78 in.).
[Refer to Section 6, 3-1." ATC Tool Dimensions".]
(5) Maximum Tool Diameter with Cutting Tools in Adjacent Tool Grippers
The maximum size of a tool in the magazine when there are other tools in adjacent tool grippers
on either side is 75 mm (2.95 in.).
[Refer to Section 6, 3-1." ATC Tool Dimensions".]
(6) Maximum Tool Diameter when There are No Tools in Adjacent Tool Grippers
The maximum tool size, when there are no cutting tools in adjacent tool grippers on either side,
is 145 mm (5.71 in.).
When cutting tools having a diameter larger than the size indicated in (5) is used, the tool
grippers for these tools are fixed and they are assigned as a large-diameter tool gripper (L).
The specification of the code of a large-diameter tool automatically sets dummy grippers on
both sides, which prevents entry of tool number data for these grippers. An attempt to enter a
tool number for them results in an alarm.
[Refer to Section 6, 3-2."Maximum Tool Dimensions Storable without Adjacent Tools" and 3-9.
"ATC Magazine Tool Interference Diagram".]
(7) Maximum Tool Weight

The maximum weight of a cutting tool including the tapered shank arbor is [8 kg (17.6 lb)].
[Refer to Section 6, 3-3." Maximum Tool Mass Moment".]
(8) Maximum Moment of Tool Weight

As indicated above, the allowable maximum tool weight is 8 kg (17.6 lb). However, the center
of gravity of such a tool must be within 137.5 mm (5.41 in.) from the datum diameter [44.45 mm
(1.75 in.)] position. That is, the allowable maximum moment is
TM < 80 N (8 kg) × 137.5 mm = 11 N-m
Therefore, if a tool of 8 kg (17.6 lb) is used, its center of gravity must be within 137.5 mm (5.41
in.) from the position of datum diameter.
[Refer to Section 6, 3-3." Maximum Tool Mass Moment".]
5074-E P-133
SECTION 6 ATC
(9) Face Milling Cutters (Full-Back Cutters)

The machine can use milling cutters up to type 5R, φ145 mm (5.71 in.) in nominal size. Face
milling cutters larger than that must be mounted directly onto the spindle.
(10) Boring Bars

When boring bars are used, the orientation of the tool bit should be taken into consideration.
[Refer to Section 6,3-6 "Maximum Tool Dimensions Storable with Adjacent Tools", 3-4."ATC
Magazine Tool Interference Diagram", and 3-5. "ATC Work Interference Diagram".]
Boring bars with diameters up to 100 mm (3.94 in.) and bit swing diameters ranging from 100
mm (3.94) to 150 mm (5.91 in.) can be used with any adjacent tools that do not exceed 100 mm
(3.94 in.) in size.
(11) Maximum Boring Bar Diameter

Without adjacent tools and with the tool bit set in certain angular range, a boring bar with bit
swing diameter of up to 190 mm (7.48 in.) can be used.
Refer to SECTION 6, 3-2. "Maximum Size of Tools Stored in Magazine without Adjacent Tools".
(12) Boring Bars

If you store a boring bar in the magazine with its cutting edge 90° apart from the toolpot key, the
cutting edge is always directed in X-axis negative direction (over the workpiece) when the bar is
inserted into the spindle.
If you selected optional tools other than MAS standard BT40, refer to the standards for these tools
and pull stud.
5074-E P-134
SECTION 6 ATC
2. Dimensions of Tool Shank and Pull Stud (MAS2)
2-1. Tool Shank and Pull Stud
Unit: mm (in.)
(0.890 -0.008 )
22.6 -0.2
0
19 (0.75)
(0.890 -0.008 )
22.6 -0.2
0
16.1H12
(0.634)
φ25.3 (0.996)
φ23 (0.91)
φ15 (0.59)
°
60
60°
(0.12)(0.16)
3 4
(0.28)
7
(0.35 0 ) 28 0 (1.10 0 )
-0.004
0.5
22 (0.87)
35 (1.38)
φ10
(0.39)
93.4 -0.3 (3.677 -0.012 )
3
+0.008
-0.1
M16P2
1
NT No. 40 (Taper 7/24)
(0.16) (0.20) (0.24)

16 (0.63) 4 5 6
H8
φ17 h7
+0.5
+0.020
9 0
(0.67)
65.4±0.2 (2.575±0.008)
+0.2
21 (0.83)
43 (1.69)
φ14
(0.55)
(16° 35.6')
(0.08±0.0016)
φ44.45 (1.75)
2±0.4
21 (0.83)
25 (0.98)
φ63h8 (2.48)
Unit: mm (in.)
ME11158R0200800020001
[Supplement]
1) Tool shank shape and dimensions comply with MAS Standard BT 40 (403-1982).
2) Pull Stud shape and dimensions comply to MAS Standard P40T2 (403-1982).
5074-E P-135
SECTION 6 ATC
2-2. Tool Shank Dimensions
Bottle Grip Taper Shank (MAS 403-1982)

0 0
30 -15 30 -15
Gauge line t t
d 0.02 A
A
0.02 A
D6
D5
D4
d2
d1
b
60
D1
R
v
7/24
4
x 2 w A
x1 y1 3
e 1
y
0.05 A
Unit: mm
Shank Thread Slot on Flange

Nominal 4 t
1 R d2 2 3 b 5
No. D1 d1 0.5 0 W
0.2 (Max.) H8 6H (Min.) (Min.) 0 H12 (Min.) 0.2
BT30 31.75 48.4 0.5 14 12.5 M12 24 34 7.0 16.1 17 16.3 0.12
BT35 38.10 56.4 0.5 14 12.5 M12 24 34 7.0 16.1 20 19.6 0.12
BT40 44.45 65.4 1 19 17 M16 30 43 9.0 16.1 21 22.6 0.12
BT45 57.15 82.8 1 23 21 M20 38 53 11.0 19.3 26 29.1 0.12
BT50 69.85 101.8 1 27 25 M24 45 62 13.0 25.7 31 35.4 0.2
BT55 88.90 126.8 1 33 31 M30 56 76 16.0 25.7 31 45.1 0.2
BT60 107.95 161.8 1 33 31 M30 56 76 16.0 25.7 34 60.1 0.2
Flange Allowance Reference

Nominal of
D5 v x1 y y1 Smaller
No. D4 e x 0.1 0 7/24 Taper end d D6
h8 0.1 0 0.4 0.4 ATD Diameter
BT30 38 46 20 13.6 4 8 2 2 0.0039 17.633 8 56.144

0
BT35 43 53 22 14.6 5 10 2 2 0.0045 21.650 10 65.680

0
BT40 53 63 25 16.6 5 10 2 2 0.0041 25.375 10 75.679

0
BT45 73 85 30 21.2 6 12 3 3 0.0052 33.000 12 100.216

0
BT50 85 100 35 23.2 7 15 3 3 0.0051 40.158 15 119.019

0
BT55 107 125 40 26.2 9 18 3 3 0.0063 51.917 18 147.823

0
135 155 45 28.2 11 20 3 3 0.0065 60.758 20 180.359
BT60 0
ME11158R0200800030001
5074-E P-136
SECTION 6 ATC
[Supplement]
Angular allowance of 7/24 taper shall be plus AT4, minus 0, which is specified in JIS B0614,
class AT4.
Note
1) Allowance shall be middle class stipulated in JIS B0405, unless otherwise specified.
2) A relief may be provided at "d2" portion for finish grinding on mating recess.
0.05 A
0 30° 0 Gauge line

30° -15' -15'
[Supplement]
0.05 A
NT40(taper 7/24)
φ17 H8/h7 (0.67)

M16 P2
“Tooling for ATC”.

MAS-compliant Tool Shank
φ44.45 (1.75)
60°
(0.634)
16.1 H12
φ19 (0.75)
φ53 (2.09)
φ63 h8 (2.48)
φ75.679 (2.97949)
Min. 21
Max
(0.83)
. R1
2 0
-0.4
0 A 0.02 A
(0.08 -0.016 )
5
(0.20)
10 +0.1 0
22.6 -0.2 0
22.6 -0.2
0
0.02 A 0
(0.39 +0.004 ) (0.890 -0.008 ) 0
0 (0.890 -0.008 )
16.6 ±0.1 9 +0.5
0
(0.654 ± 0.004) (0.35 +0.020
0 )
Min. 30
(1.18)
Min. 43
(1.69) Unit: mm (in.)
25 65.4 ±0.2
(0.98) 2 ±0.4 (2.575 ± 0.008)
1) For more information on the tool shank shape, refer to MAS (403-1982) BT 40.
(0.08 ± 0.016)
2) The above drawing is based on MAS Standard. Perpare the ATC tools by referring to 3.
SECTION 6 ATC
ME11158R0200800040001
5074-E P-137
5074-E P-138
SECTION 6 ATC
CAT-compliant Tool Shank
depth 0.15 (0.0059)

Drill 3.75 0.1476) to
.645 ± .010
.985+.000
-.015
.890+.000
-.015
Min.φ.86
0
.06
φ720 ± .010
0 to
A
3
R.0
.002
-.000
φ641
+.150
5/8-11UNC
NT40 (taper 7/24)
.256 ± .010
1.12 ± .04
2.687 ± .010
A
.010
Gauge line
.625 ± .002
.362 ± .005
.579 ± .005
30 ±
R.0
5'
±1
φ1.750 ± .002
˚
60
.750 ± .002
A
.002
3
81
φ.2
1.250 ± .010
.151 ± .005
.440 ± .010
10
± .0
30
R.0
φ1.750 ± .010
φ2.219 ± .010
φ2.5 ± .002
Unit: in.
2.863 ± .002
ME11158R0200800050001
[Supplement]
1) For more information on the tool shank shape, refer to JIS (B6339-1992) BT 40.
2) The above drawing is based on JIS. Perpare the ATC tools by referring to 3. “Tooling for
ATC”.
0.025 A
0.12 A
R
Gauge line
(0.0
0
1
4
0
R1 -0.
[Supplement]
5
(0.0
18.5 -0.3
-0.
-0.0
NT40 (taper 7/24)
0 5
0
4 -0.
0 20)
φ7
0
8) (0.728 -0.012 )
0 20)
(0.2 M16 P2 1.6 (0.063)
R1 0
)
-
“Tooling for ATC”.

.
(0.
20
04 0 0.5
R1
0.0
-
-
0.0
7 0 .5
20
04 2 -0 0
)
(0.
0
0
0
0
1.6 (0.063)
18.5 -0.3
(0.728 -0.012 )
DIN-compliant Tool Shank
φ44.45 (1.75)
(2.5020 -0.004)
(2.2146 -0.020 )
(0.75)
(0.67)
(0.634)
φ17 H7
16.1 H12
0
Max. φ19
Max. φ50 (1.97)
0
φ56.25 -0.5
φ63.55 -0.1
φ72.3 ±0.05 (2.846 ± 0.0020)

0.02 A
30°
0.1 A
60 ° ±1 0
25 -0.4 0
22.8 -0.4
5'
0 0
(0.98 -0.016 ) (0.898 -0.016 )
3.75 +0.15
0
0.02 A
(0.148 +0.006
0 )
3.2 ±0.1 8.2
0.05 A
(0.126 ±0.004) (0.323)
11.1 ±0.1 Min. 32
(0.437 ±0.004) (1.26)
0
19.1 -0.1 Min. 42.5
0 (1.673) Unit: mm (in.)
(0.752 -0.004 )
Min. 35 68.4 ±0.1
(1.38) (2.693 ± 0.004)
1) For more information on the tool shank shape, refer to CAT (MF5311) No. 40.
2) The above drawing is based on CAT Standard. Perpare the ATC tools by referring to 3.
SECTION 6 ATC
ME11158R0200800060001
5074-E P-139
5074-E P-140
SECTION 6 ATC
2-3. Pull Stud Dimentions

(1) MAS-2 BT 40 pull stud
0.01 (0.00039) A
-0.018 (0.00070)
0.01 (0.00039) A
Ø17 (0.67) h7 -0 R R1.2

G
60
R3
º±1
Ø10 (0.39) -0.1 (0.0039)
5'
M16
-0
-0.2 (0.0078)
Ø15 (0.59) -0
-0.1 (0.0039)
G
Ø13 (0.51)
Ø23 (0.91) -0
30º
R1
G
.5
G A
R0
G
R1
.5
C2
1
C0
4 (0.16) 4 (0.16)
16 (0.63) 3 (0.12)
G 19 (0.75) -0-0.35 (0.013)
6 (0.24) -0-0.1 (0.0039) 22 (0.87) 4 (0.16)
-0
20 (0.79) 28 (1.10) -0.1 (0.0039) 7
(0.28)
5 (0.20)
G
3.25 (0.13)
-0
25 (0.98) 35 (1.38) -0.1 (0.0039)
60 (2.36) G
0.01 (0.00039) A
Unit: mm (in.)
ME11158R0200800070001
(2) MAS-2 BT 40 pull stud for through-the-coolant
M16 P=2
0.01
(0.00039) A
Ø17 (0.67)-0-0.018 (0.00070)
-0.1 (0.0039)
Ø4 (0.16)
Ø10 (0.39) -0
75 (2.95)
-0.2 (0.0078)
30º
Ø15 (0.59) -0
-0.1 (0.0039)
Ø23 (0.91) -0
G
G
G G
±1 º
G
60
5'
A
R3 G
G
4 (0.16) -0-0.1 (0.0039) 19 (0.75) -0-0.35 (0.013)
6 (0.24) 0.01
G (0.00039) A
22 (0.87) 3 (0.12)
-0
20 (0.79) 5 28 (1.10) -0.1 (0.0039) 4 (0.16)
(0.20) -0
25 (0.98) 35 (1.38) -0.1 (0.0039)
60 (2.36)
0.01
(0.00039) A Unit: mm (in.)
ME11158R0200800070002
5074-E P-141
SECTION 6 ATC
3. Tooling for ATC

Maximum tool diameter : 75 mm (with adjacent tools) or 145 mm (without adjacent tools)
Maximum tool weight : 8 kg (incl. shank)
Maximum tool moment : M = W x L = 11 N-m = (110 kgf-cm)
350 (13.78)
L
With adjacent tools
38
(1.50)
Ø63 (2.48)
Ø75 (2.95)
350 (13.78)
38
Without adjacent tools (1.50)
(No tool can be mounted at
each side.)
Ø145 (5.71)
Ø63 (2.48)
Unit: mm (in.)
ME11158R0200800080001
Restrictions on tools for 2-speed ATC

Maximum tool diameter : 75 mm (with adjacent tools) or 145 mm (without adjacent tools)
Maximum tool weight : 12 kg (incl. tool shank)
Maximum tool moment : M = W x L = 15 N-m = (150 kgf-cm)
5074-E P-142
SECTION 6 ATC
4. Setting Tools into the ATC Magazine

(1) The ATC magazine can store up to 40 (60, 118) tools. Each tool pot is identified with a
nameplate marked on the tool pot. Tool selection is a random memory operation.
(2) For efficient setup, preset the tool point using a tool presetting device.
(3) With a random memory operation, the correspondence between the tool number and the tool
pot number changes in the progress of machine operation. Therefore, use sufficient care to the
interference with the adjacent tools as shown in 3-4 or 3-9. "Tooling Interference" when loading
a tool in the ATC magazine. (For the ATC with 100 or more tools, fixed addressed are used.)
(4) Before loading tools, thoroughly clean the tapered shank of the tools and tool pots.
(5) Load the tools specified on the program process sheet into the corresponding tool pots: Make
a memo of the correspondence between the tool number and the tool pot number.
Push the tool into the tool pot second to the left of the tool pot at the magazine indexing position
(bottom end), while pulling the pot unclamp lever. The tool will be held in the tool pot by spring
action.
(6) When setting a tool having a retaining pin such as those described below, ensure that the pin
comes to the allowable range shown in the tool interference diagram in order for the tool to be
mounted in the spindle correctly.
Through-the-tool coolant adaptors, high speed spindles, angular attachments, multi-spindle
tools, reversible tappers, etc.
(7) Never tighten a tool while it is set in a tool pot. Otherwise, the tool pot could be damaged.
(8) Before starting ATC automated operation, enter the tool numbers as explained in 6. "Manual
ATC Operation".
(9) If you insert tools collectively in a specific part (ex. No.1 to No.15) of the magazine chain and
the weight gap exceeds 100 kg (220 lb), the magazine loses its weight balance, which may
cause unstable magazine indexing and even affect indexing accuracy.
To solve this problem, insert unused tools into empty pots for balancing. When using a heavy
tool with a large diameter, determine the other tool positions using care to distribute the weight
of the heavy tool all over the magazine.
(10) To remove the tool from the toolpot, insert the provided tool release lever in the gap between
the pot face and the tool. Holding the tool with one hand, push the lever and the tool can easily
be pulled out.
5074-E P-143
SECTION 6 ATC
5. Manual Magazine Indexing Operation

In addition to indexing the magazine by tape commands and manually entered commands (MDI),
manual indexing is possible from the ATC operation panel at the left of ATC door.
5-1. Conditions for Manual Magazine Indexing

The magazine door is closed.
ATC is not in operation.
MG. MANUAL
MANUAL INT. INDEX START

O I
DOOR INTERLOCK
EMG. STOP
RESTART
ME11158R0200800110001
5074-E P-144
SECTION 6 ATC
5-2. Procedure
(1) Press the [MANUAL] key on the NC operation panel.
(2) On the ATC magazine operation panel, carry out the operations below.
For indexing the magazine to the next pot:
Procedure :
1- Turn the [MANUAL INT. ON/OFF] switch to ON.

Turn the [CONSTANT INDEX] selector pushbutton to OFF.
2- Turn the [CONSTANT INDEX] selector pushbutton either to CCW or CW and press it. The
magazine is unclamped and the next pot is indexed.
For indexing the magazine continuously:
Procedure :
1- Turn the [MANUAL INT. ON/OFF] switch to ON.
2- Turn the [CONSTANT INDEX] selector pushbutton either to CCW or CW and keep pressing
it.
3- The magazine starts rotation. When the pot right before the required pot is indexed to the tool
change position, release the [CONSTANT INDEX] selector pushbutton. The magazine will be
clamped after the next pot is indexed.
For indexing the magazine during an automatic mode operation:

Turn the [MANUAL INT. ON/OFF] switch to ON and the above indicated indexing operation
becomes possible. After indexing the magazine manually, be sure to turn this switch off.
CAUTION
If the magazine is rotated during finish cutting, vibration generated during magazine
rotation could leave cutter marks on the surface of workpiece being machined. To avoid
such defects, avoid rotating of the magazine during finish cutting by changing the program.
During finish cutting, manual magazine index must also be avoided.
5074-E P-145
SECTION 6 ATC
6. Manual ATC Operation

The automatic tool changer can be manually operated in addition to the automatic operation in the
AUTO or MDI modes by the controls on the NC operation panel.
6-1. One Step Advance and One Step Reverse
F6
S.T.M ?
i F1 F2 F3 F4 F5 F6 F7 F8
DEL
P
HT
O P Q R S T U P P
4 5 6
V W X Y Z 1 2 3
CAPS
LOCK

INTER
1 2

COM. CYCLE

CYCLE START
ATC OPERATION
MIRROR MIRROR MIRROR MIRROR
INTER
LOCK
DRY
RUN

% FEEDRATE
60
50
70
80
90 95 100
105
110
120
130
INTER
LOCK
CW STOP CCW
1
5
10
% OVERRIDE
30 50
70
80
90
100
90
% SPINDLE OVERRIDE
110 120 130
140
150
8 200
20 500
(mm/min) SPEED
1000 40
2000 80
30
20
10
5
0 200
170
180
150
160
RESET
AT C APC RELEASE
80 4000 160
160 DOOR INTER ROCK NC PANEL
0 100 RESTART EDIT
6000 240
50 200 2 50
0.04 1 10000 400
1CYCLE RETURN 1STEP 1STEP

CYCLE
START START ADVANCE REVERSE
ME11158R0200800140001
In the one step advance and one step reverse operation, the automatic tool change cycle advances
or reverses according to its operation sequence.
This type of operation is not carried out during normal machine operation. However, such operation
becomes necessary for checking the ATC operation or in locating the ATC at a sequence. This
allows the return to initial conditions for the automatic tool changing cycle after the [EMG. STOP]
button has been pressed.
WARNING
When operating the ATC manually, make sure to close the front door. The tool change arm
and the cutting tool rotate at a high speed, which is very dangerous.
Procedure :
1- Press the [MANUAL] key on the NC operation panel.
2- Press function key [F6] (ATC/APC) to display the status of ATC.
3- Press the [ATC] key.
4- Press either the [1 STEP ADVANCE] or the [1 STEP REVERSE] key.

5074-E P-146
SECTION 6 ATC
6-2. One Cycle Start and Return Cycle Start

(1) The [1 CYCLE START] flat key initiates a series of tool change cycle in which the tool picked up
from the magazine is set in the spindle and the tool that was set in the spindle is returned to the
magazine.
The operation is possible when the READY lamp is ON.
Confirm that the light is ON.
1CYCLE
START
ME11158R0200800150001
(2) The [RETURN CYCLE START] flat key is used for carrying our the remaining steps if the
automatic tool change cycle has been interrupted.
6-3. Precautions for Manual ATC Operation

(1) When the RUN is displayed on the screen, ATC operation keys such as [1 CYCLE START],
[RETURN CYCLE START], [1 STEP ADVANCE] and [1 STEP REVERSE] are inoperative.
Press the [RESET] button to clear the RUN on the screen.
(2) If the [EMG. STOP] button is pressed while the tool change arm is operating, the signals ZHP
(Z-axis tool change position) and SHP (spindle orientation completion ) are turned off. In this
case, the [1 STEP ADVANCE] and [RETURN CYCLE START] flat keys sometimes become
inoperative. If this occurs, make sure that the next ATC operation does not cause problems,
then press the [1 STEP ADVANCE] flat key while pressing the [INTERLOCK RELEASE] flat
key, and the tool change sequence advances to the next.
(3) The tool in the spindle will be clamped when the automatic tool change cycle is interrupted by
the activation of the [EMG. STOP] button when the ATC sequence number is 7, 8, or 9. This
causes the [1 STEP ADVANCE] and [RETURN CYCLE START] flat keys to be inoperative. In
this case, place the spindle in the unclamp state by pressing the [TOOL UNCLAMP] button at
the right side of the spindlehead.
(4) ATC Pot No./Tool No. Table (Setting Tools)

With a vertical machining center that has a relatively small number of tools in the tool magazine,
memory-random method is generally adopted for the ATC operation. For machining centers
equipped with a tool magazine to large capacity, fixed address method is adopted.
This machine adopts memory-random ATC.
5074-E P-147
SECTION 6 ATC
Memory-random ATC Specification
In the memory-random ATC system, the tool set in the spindle is returned to the magazine tool pot of
the tool to be set in the spindle next. Therefore, the correspondence between the tool number and
the pot number will change each time the tool change cycle is carried out. This requires the initial
correspondence between the tool number and the magazine pot number to be stored in the control
memory after setting all the tools in the magazine.
In addition, since the use of a large-diameter tool will cause an interference with adjacent tools, the
control must be capable of recognizing a large-diameter tool so that the tool pot which
accommodates one is placed between the pots having dummy tools or no tool. That is, the large-
diameter tool must be returned to the tool pot originally stored.
A large-diameter tool is distinguished from other conventional tools based on tool diameter as
shown in the table below.
MB-500H
Small-diameter tool Less than 75 mm (2.95 in.) in diameter
Large-diameter tool 75 mm (2.95 in.) or over in diameter
(Large-diameter tools indicated with "L" are always regarded as heavy tools.)
Follow either manner to set tool numbers for tool pot numbers.
• The table listing the original correspondence between the tool numbers and tool pot numbers
should be made beforehand on the CRT. After that, the tools are set in the tool pots in
accordance with the correspondence table data.
• Tools are set in the spindle and they are returned to the magazine in the manual tool change
operations. In this case, the tool pot where the tool in the spindle is to be returned may be
specified or the one automatically selected may be used, as required.
Setting method by table listing the original
TOOL DATA SET N 1

97/07/15 14:10:00
ATC TOOL SET (POT REF)
POT TOOL POT TOOL POT TOOL POT TOOL

No. No. No. No. No. No. No. No.
1 001 11 011 21 NA :SPCY POT NA
2 002 12 012 22 022 :ACT TOOL 020
3 003 13 013 23 023 :NXT TOOL 007
4 004 14 014 24 024
5 005 15 015 25 025 :MAGAZINE 10
6 006 16 016 26 026
7 007 17 017 27 027
8 008 18 018 28 028
9 009 19 019 29 029
10 021 20 NA 30 030
SET SEARCH ITEM ITEM [EXTEND]
F1 F2 F3 F4 F5 F6 F7 F8
ME11158R0200800180001
Procedure :
1- Press the [TOOL DATA] key.

5074-E P-148
SECTION 6 ATC
2- Press function key [F7]

The screen will display the page of " ATC TOOL SET (POT REF) ".
3- Locate the cursor at TOOL NO. position of the POT NO. for which the tool number is to be
set.
4- Press function key [F1] (SET)

"S_" will be displayed on the console line. ("_" indicates the space.)
5- Key in the desired tool number through the keyboard.
Conventional tool S_1

Large-diameter tool S _7,L
Heavy tool S _8,M
Dummy tool S_D
For clearing tool number S_
Planer tool (optional) S_6,P
6- Press the [WRITE] key.

This sets the correspondence between the tool number and the tool pot number.
CAUTION
• The symbols "→" and ">>" appearing in the Pot NO. column indicate the position of the
corresponding tool pot.
→ : Tool change position with ATC
>> : Manual tool change position
• The range of tool pot numbers which can be set is from "1" to the magazine capacity (the
number of tools accommodated in the magazine).
Standard model: 30-tool ATC
The usabel number of tool numbers is identical to the programmable number of tool
offset numbers.
• For a large-diameter, setting is allowed only when the two adjacent tool pots are
assigned with no tool number of dummy tool code, "D". An alarm occurs if either of two
adjacent tool pots is assigned with an actual tool number.
The setting of a large-diameter tool in a tool pots automatically sets dummy tool code,
"D", at two adjacent tool pots.
• In case the tool number already used is again entered for a new tool pots, an alarm
occurs.
• Any attempt to set a tool number for a tool pots which has a dummy tool in it causes an
error.
In this case, cancel the dummy tool code by entering "" code. Note that the dummy
tools placed in the adjacent tool pots for the one accommodating a large-diameter tool
should not be cleared. A dummy tool may be placed between two large-diameter tools
as a common dummy tool.
5074-E P-149
SECTION 6 ATC
Setting method by the manual operation
Procedure :
1- Switch the mode to "manual" by pressing the [MANUAL] key.

The display is possible in the automatic and MDI modes also. However, the setting is
effective only in the manual mode.
2- Press function key [F8] (EXTEND) to change function key guide message.
3- Then press function key [F2] (TOOL SET).
4- The " ATC TOOL SET (POT REF) " page is displayed.
AUTO OPERATION N 1
97/07/15 14:10:00
ATC TOOL SET (POT REF)
POT TOOL POT TOOL POT TOOL POT TOOL

No. No. No. No. No. No. No. No.
1 001 11 011 :SPCY POT NA
2 002 12 012 :ACT TOOL 020
3 003 13 013 :NXT TOOL 007
4 004 14 014
5 005 15 015 :MAGAZINE 10
6 006 16 016
7 007 17 017
8 008 18 018
9 009 19 019
10 010 20 NA
POT TOOL
SET SEARCH SEARCH QUIT
F1 F2 F3 F4 F5 F6 F7 F8
ME11158R0200800190001
Note that the POT NO. and TOOL NO. displayed at the left side are only for display and
cannot be used for setting.
Symbols on Screen
Symbols on the display pages are as follows
(1) ATC TOOL SET (POT REF)

→ : Indicates the next tool.
>> : Indicates the tool pot number which is located at the position where a tool can be manually
removed from or inserted into the tool pot.
(2) ATC TOOL SET (TOOL REF)

→ : Indicates the next tool.
: Indicates the active tool.
5074-E P-150
SECTION 6 ATC
Data to be Set
The data to be set is indicated below.
(1) SPCY POT

This is used for specifying the tool pot to which the active tool is to be returned, if necessary.
CAUTION
• The maximum number is the number of tool pots in the magazine.
• If another tool number has already been assigned to the specified tool pot number, an
error occurs.
• When specifying a tool pot number for returning a large-diameter tool, the adjacent tool
pots should have dummy tools or they should be left empty. Otherwise, an alarm occurs.
(2) ACT TOOL

This indicates the tool number of the tool set in the spindle.
CAUTION
• The maximum tool number is the same as the number of tool offsets. (50 in standard)
• In case the set tool number has already been assigned to another tool pot number, an
error occurs.
• Setting of a large-diameter tool (L) is possible but the setting of a dummy tool (D) is
impossible.
• In case a large-diameter tool is specified with pot number entered in the SPCY POT, an
error will occur if no tool or a dummy tool (D) is not assigned with the pots prior/next to
the SPCY POT.
• In case a large-diameter tool is specified with no pot number entered in the SPCY POT
data location, an error will occur if there are no three empty pots arranged in succession
or no two empty pots in succession next to the pot assigned with a dummy tool (D).
(3) NEXT TOOL

This indicates the tool number to be set in the spindle next.
No data is entered for the first tool returning cycle.
CAUTION
• The maximum number is the same as the active tool.
• In case there is a mismatch between the tool number specified and the tool pot number,
an error occurs.
• Setting of a large-diameter tool (,L) and dummy tool (D) is impossible.
• An error will occur when pot number is specified in the SPCY POT data location.
5074-E P-151
SECTION 6 ATC
Returning a tool to the magazine

When returning a tool to the magazine pot, there are two methods such as (1) specifying the tool pot
number; and (2) returning the tool to an empty pot automatically. These two methods are detailed
below. For the procedure to set a tool on the spindle manually, refer to the section covering the
manual tool change procedure. (See Section 4 "Operations", 2-5. "Clamping and Unclamping the
Tool in Spindle".)
(1) Tool return cycle with pot number specified:
a. Position the cursor on the SPCY POT data location.

Key in the return pot number and press the [WRITE] key.
b. Set a tool in the spindle.
c. Position the cursor on the ATC TOOL data location.

After keying in the active tool number, press the [WRITE] key.
In this case, the data of NXT TOOL should be NA. If a tool number has been entered, key
in "" after locating the cursor on NXT TOOL, to clear the data.
d. Press the [1 CYCLE START] key.

The tool in the spindle is returned to the specified pot and the correspondence between the
tool pot number and the tool number is set and stored.
If this operation is intended for the pot which is assigned with another tool number, and
error occurs and tool return cycle is not started.
(2) Tool return cycle without pot number specified:
a. Clear the data of the SPCY POT by entering as asterisk ().
b. Set a tool in the spindle.
c. Enter the active tool number for ACT TOOL.

In this data entry, the NXT TOOL data must be NA.
d. Press the [1 CYCLE START] flat key.

The empty pot located nearest to the presently indexed pot is automatically selected and
the tool return cycle is started.
CAUTION
• Pressing the [1 CYCLE START] flat key with the next tool number specified, initiates the
normal tool change cycle.
• The SPCY POT data is automatically cleared after the execution of "1 cycle start"
command.
• The SPCY POT data is only for tool return cycle. Therefore, if this data and the NXT TOOL
data have both been entered when the [1 CYCLE START] flat key is pressed, an error
occurs.
• In the automatic empty pot selection, the empty pot is looked for in the magazine
counterclockwise direction rotation. If there is no empty pot, an error occurs and no
return cycle is carried out.
• When entering a large-diameter tool, enter ",L" following the tool number.
5074-E P-152
SECTION 6 ATC
7. Initial Conditions for Continuous ATC Operation

In the AUTO and MDI mode operation, the automatic tool change cycle is carried out when the
following commands are given:
• Tool Number Command : 2-digit T code (No. of tool data sets: 50 (standard))
• Tool Change Command : M06 (M19 Spindle orientation included)
However, it will be necessary to confirm that the following initial conditions have been met before
pressing the [CYCLE START] button.
(1) ATC sequence number should be "001".

This is the sequence reached when the tool change arm has completed the tool return cycle.
If the sequence number is not "001", set the tool change unit position to "001" in the 1 step
operation explained in refer to "SECTION 6 6”. Manual ATC Operation".
(2) Both the active and next tool numbers should be "000".
If not, set them to "000".
AUTO OPERATION N 1
97/07/15 14:10:00
ATC / APC ATC DATA
ACTIVE NEXT ACT.POS. SEQ.NO.

ATC 000 000 020 001
RUN
1 This must indicate 001.
2 Both of them must be 000.

X Y Z B
ACT POSIT(WORK) 200.000 100.000 0.000 0.0000
PROGRAM ACTUAL PART BLOCK CHECK

SELECT POSIT. PROGRAM DATA SEARCH ATC/APC DATA [EXTEND]
F1 F2 F3 F4 F5 F6 F7 F8
ME11158R0200800200001
(3) The mode selected should be either AUTO or MDI.
In addition to the conditions indicated above, other preparatory steps indicated below necessary for
starting the automatic operation must be performed in advance.
• Mounting the workpiece
• Adjusting zero point offset
• Tool length offset
• Reading NC program
5074-E P-153
SECTION 6 ATC
8. Automatic Tool Change Sequence

When the tool number of Txx (xx is the tool data set number; 01 through 30 in standard) which has
already been written and stored in memory, the T command is displayed as the next tool number
and the magazine is indexed.
With the M06 command programmed next, the spindlehead is positioned at the tool change position
and the spindle orientation is executed at the same time. The magazine pot faces down, the tool
change arm changes the spindle tool and returns the tool removed from the spindle to the
magazine. After the tool has been returned to the magazine, the tool number used as the next tool
number is shifted to the active tool number and the control is placed in the condition that it waits for
the next T command.
In the final machining process, program only the M63 without a T command since there is no tool to
be newly set in the spindle. The M63 executes only the tool return cycle and no tool loading cycle
occurs.
A series of tool change cycle is explained in detail on the following pages. The operation sequence
number is displayed on the ATC status indicating panel.
The tool change cycle is described below.
[Sequence number for ATC operation]
Sequence Operation
No.
1 Next tool command
2 Rotating the magazine
3 Clamping the tool pot in magazine
4 Pot slide on spindle side
5 Waiting for machine cycle completion
6 Spindle orientation
7 Tool change position (HP1)
8 Opening ATC shutter
9 Rotating tool change arm
10 Pot slide on magazine side
11 Unclamping the tool pot in magazine
12 Rotating the magazine
13 Clamping the tool pot in magazine
14 Pot slide pot on spindle side
15 Rotating the tool change arm
16 Closing the ATC shutter
17 Pot slide on magazine side
18 Unclamping the tool pot in magazine
Note
* Operations 10 to 15 are for handling a large diameter tool.
[Supplement]
When next process tool preparatory operation is attempted during end face finish cutting,
there might be cases in which the finished surface is affected. In such cases, designate the
dwell command.
5074-E P-154
SECTION 6 ATC
8-1. Automatic Tool Change Sequence
Sequence
Machine, NC unit Task ATC operation
No.
(Initial tool cycle)

Cycle start
Initial tool number Preparing [1] Writing next tool No. (Tool No. 01 appears)
command (ex. T01) initial tool
(T01)
[2] Magazine indexing (T01)
Spindle stop
(Positioning of X-, Y-, [3] Clamping toolpot in magazine
Z-axes)
[4] Pot slide on spindle side
Tool change [5] Waiting for machine cycle completion

command (M06)
[6] Spindle orientation
[7] Tool change position (HP1: ATC home position)
[8] ATC door opens
Mounting
[9] Tool change arm movements
initial tool
to the spindle
(T01) - Tool change arm rotates 90
(to tool grip position)
- Spindle tool retention cylinder unclamp
- Tool change arm extracts tools (removal of active tool)
- Tool change arm rotates 180°

- Tool change arm inserts tools (insertion of next tool)
- Spindle tool retention cylinder clamp
- Tool change arm rotates 90 (to standby position)

[16] ATC door closes
Positioning X-, Y-,
(NC answer back)
Z-axes (to start cutting)
[17] Pot slide on magazine side
[18] Unclamping toolpot in magazine

Continued
ME11158R0200800220001
5074-E P-155
SECTION 6 ATC
Sequence
No.
(Small diameter tool cycle)
Next tool number Preparing [1] Writing next tool No. (Tool No. 02 appears)
command (ex. T02) next tool
(T02)
[2] Magazine indexing (T02)
Spindle stop [3] Clamping the toolpot in magazine

(Positioning of X-, Y-, [4] Pot slide on spindle side
Z-axes)
Tool change command [5] Waiting for machine cycle completion

(M06)
Changing [7] Tool change position (HP1)
active tool
[8] ATC door opens
with the
next tool [9] Tool change arm movements
(T02) - ATC door opens

- Tool change arm rotates 90 (to tool grip position)
- Spindle tool retention inside cylinder unclamp
- Tool change arm rotates 180
- Tool change arm inserts tools (returning active tool)
- Spindle tool retention inside cylinder clamp
Positioning of X-, Y-,

Z-axes [18] Unclamping the toolpot in magazine
(Machining starts)
(Large diameter tool cycle)

[1] Writing next tool No. (Tool No. 04 appears)
Next tool number Preparing pot
command (ex. T04, L) to which active
[2] Magazine indexing
tool is returned
Spindle stop [3] Clamping the toolpot in magazine
(Positioning of X-, Y-,
Z-axes)
Continued
ME11158R0200800220002
5074-E P-156
SECTION 6 ATC
Sequence
No.
[5] Waiting for machine cycle completion

Tool change command Returning
(M06) [7] Tool change position (HP1)
active tool
(T02) [8] ATC door open
[9] Tool change arm movements

- Tool change arm inserts tools (returning active tool)
Preparing
next tool [11] Unclamping the toolpot in magazine
(T04) [12] Magazine indexing (T02)
[13] Clamping the toolpot in magazine
Inserting
next tool to [15] Tool change arm movements
the spindle
(T04)
- Tool change arm extracts tools (removal of next tool)

- Tool change arm inserts tools (mounting the next tool)

Positioning of X-, Y-
Z-axes (NC answer back)
(Machining starts)
ME11158R0200800220003
5074-E P-157
SECTION 6 ATC
9. ATC Operation Sequence Diagram
1 Next tool command

7
Magazine
Spindlehead 7
2 12 9
15 6
15
9
15 9 9 15
13
4 10 9 15 ATC door
Toolpot 14 17 Tool change arm
8
16
ME11158R0200800230001
5074-E P-158
SECTION 6 ATC
10. Safety Precautions for ATC Operation
CAUTION
1) To change tools in manual operation, turn the [MANUAL INT. ON/OFF] switch on the ATC
magazine operation panel to ON and securely insert the tool into the tool pot.
2) When indexing the magazine manually, close the magazine door and ensure that
magazine indexing does not cause problems.
3) Check that the tool pull stud is of the proper dimensions.
4) When the tool change arm extracts the tool from the spindle tapered bore in the tool
change cycle, the tool nose moves 115 mm (4.53 in.) from the state being mounted in the
spindle. The tool change arm rotates 180° in that position. Therefore, ensure that the tool
does not interfere with the workpiece before starting the tool change cycle.
5) Clean the magazine end other units of dirt, dust and chips to aboid an ATC malfunction.
Avoid the use of compressed air, however, since the air could blow chips into the units
and cause major problems. Never clean or perform maintenance work on the ATC while
it is in operation.
6) Some tools in particular become easily entangled with chips and care should be taken
that the chips do not disrupt ATC operation.
WARNING
1) Check, before a tool change is made, that there will be no interference between the tool
and the workpiece. Do not get close to or touch any parts during the ATC cycle.
Although the tool clamping mechanism in the magazine and spindle, etc are all designed
to handle the tool without slipping, it is possible that a sharp tool could drop due to
interference with workpieces or other objects.
Do not open the operator door or the magazine door.
2) Press the [EMG. STOP] button to interrupt the ATC operation. The [SLIDE HOLD] button
on the operation panel does not stop the ATC cycle.
11. ATC Magazine Door Interlock

• The ATC magazine door incorporates a door lock mechanism and an interlock switch.
• With this mechanism, this magazine door is always locked while the manual interrupt switch is
OFF on the ATC magazine operation panel. This means that the door can be opened by turning
the manual interrupt switch to ON.
5074-E P-159
1. Outline of Rotary Type 2-pallet APC

(1) Construction
The APC is installed in the front of the machine. The APC main unit holds and rotates the
pallets with a fork driven by a servomotor. The machine table incorporates a pallet clamper.
The splash guard rotates its door in synchronization with the pallet change cycle.
The machine uses four tapered cone-pins to position the pallet with high accuracy. When
rotating the pallet, the machine applies compressed air to the cone-pine to remove dust and
chips.
In addition, the machine checks the pallet seated condition. If chips or dust is between the
cone-pin and the pallet, the machine generates an alarm.
(2) Specifications
For pallet dimensions, refer to separately attached sheet.
MB-500H
Pallet Dimensions 500 mm sq. (19.69 in.)
Maximum Load 500 kg (1,100 lb)
(3) Maximum Workpiece Dimensions and Center of Gravity

Maximum workpiece weight : 500 kg (1,100 lb)
Maximum workpiece diameter : 800 mm (31.50 in.)
Maximum workpiece height : 800 mm (31.50 in.)
Center of gravity of workpiece : Should be inside the hatched portion in the figure.
To ensure a longer index life, install the workpiece in
such a manner that as uniformly distributes its weight
over the pallet as possible.
5074-E P-160
Ø800 (31.50)
375 (14.76)
Ø720 (28.35)
Ø200 (7.87) 800 (31.50)
375 (14.76)
Top face of pallet

36 (1.42)
80 (3.15)
Edge locators
500 (19.69)
Unit: mm (in.)
ME11158R0200900010001
5074-E P-161
2. Automatic Pallet Change Operation Sequences
2-1. Parallel 2-pallet APC Operation Sequences

(1) Conditions for Automatic Pallet Change Operations
a. Magazine door and APC setup station door are securely closed.
b. A pallet is set on the machine.
c. Another pallet is set on the APC. Note that pallet change operation always requires two
pallets.
d. The pallet on the APC is positioned at the correct position (in position) by means of the
location pin.
e. The SETUP COMPLETION button is pressed.

The work setup completion state can be canceled by turning the APC MANUAL INT.
selector switch in the ON position.
f. NC operation mode is either automatic or MDI.
(2) Tape command (M Code)

M60 Automatic Pallet Change Cycle
(3) Operation Sequence

The pallet change cycle called by the M60 command is carried out in the following sequence.
M60 → (1) APC at ready position
The NC checks whether the SETUP COMPLETION button has been
pressed or not.
(2) Z-axis moves to APC position (pallet position A).
Machine table is indexed to 0° position
(3) Pallet is unclamped.
(4) APC fork rises.
(5) APC fork rotates 180° (to pallet position B).
(6) APC fork lowers.
(7) Pallet is ungriped.
The cycle above assumes to change the pallet on the machine with the pallet at APC ready
position.
2-2. APC Operation Sequence

(1) APC at ready position
(2) Z-axis moves to APC position.
(3) Pallet is unclamped.
(4) APC fork rises.
(5) Fork rotates by 180°.
(6) APC fork lowers.
(7) Pallet is clamped.
5074-E P-162
Initial APC position

Spindle
Outside of machine Inside of machine
Pallet B Pallet A
Pallet unclamped
Figure A
Pallet A
Pallet B
APC arm up
Figure B
Pallet B Pallet A
ME11158R0200900030001
5074-E P-163
3. Initial Conditions for APC Continuous Operations
3-1. Parallel 2-pallet APC Continuous Operation

(1) A pallet is placed on the machine.
(2) Another pallet is set at the APC ready position.

The automatic operation using the automatic pallet changer always requires two pallets.
Therefore, even when machining of only one workpiece is required, it is necessary to use two
pallets.
(3) The pallet on the APC is positioned at the correct position (in-position) by means of the location
pin.
(4) SETUP COMPLETION button has been pressed.

After the completion of setting up on the pallet, this button should be pressed.
The indicating lamp above the button comes on, enabling the next APC command. This button
is provided to assure safety of the operator by preventing pallet change cycle start while work
setting up is being carried out.
APC
MANUAL INT.
O I
RESTART
APC POSITION
W. LOAD FINISHED
EMG. STOP
ME11158R0200900040001
If the work setup completion status established by pressing the SETUP COMPLETION button is
required to be canceled, turn the MANUAL INT. selector in the ON ( | ) position.
5074-E P-164
(5) The operation mode selected should be either AUTO or MDI.
DEL
P
HT
O P Q R S T U P P
4 5 6
V W X Y Z 1 2 3
CAPS
LOCK

INTER
1 2

COM. CYCLE

INTER
LOCK
DRY
RUN

% FEEDRATE
80 105
70 110
60 120
CW STOP CCW 50 130
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
0 100 RESTART EDIT
6000 240
50 200 2 50
0.04 1 10000 400
ME11158R0200900040002
Under the conditions indicated above, the automatic pallet change cycle can be started in
response to the M60 command when the CYCLE START button is pressed. The CYCLE
START button is provided on the APC operation panel in addition to the main operation panel.
SAFETY INSTRUCTIONS
1) If it is required to stop the automatic pallet change cycle during its execution, press the
EMG. STOP button.
2) Note that the SLIDE HOLD button is provided for disabling axis movements and,
therefore, it is not effective to interrupt the automatic tool and pallet change cycles.
5074-E P-165
4. Manual APC Operations

The automatic pallet changer can be manually operated using switches on the main operation panel
in addition to automatic pallet change cycle called by the M60 command.
4-1. One Step Advance and One Step Reverse

In the one step advance and one step reverse operation, the automatic pallet change cycle
advances or reverses according to its operation sequence. This type of operation is not carried out
during normal machine operation. However, such operation becomes necessary for checking the
APC operation or in locating the APC at a sequence. This allows the return to initial conditions for
the automatic pallet changing cycle after the EMG. STOP button has been pressed.
Procedure :
1- Press the MANUAL key.
2- Press the APC switch at ATC operation section on the main operation panel.
3- Press either the 1 STEP ADVANCE or the 1 STEP REVERSE key.
DEL
P
HT
O P Q R S T U P P
4 5 6
V W X Y Z 1 2 3
CAPS
LOCK

INTER
1 2

COM. CYCLE

INTER
LOCK
DRY
RUN

% FEEDRATE
80 105
70 110
60 120
CW STOP CCW 50 130
30 150
30 50 110 120 130 1000 40
10 70 20 500 20 160
100 140 2000 80
5 80 10 170
90 150 5 180
0 200
1 90 8 200 4000 160
0 100 RESTART EDIT
6000 240
50 200 2 50
0.04 1 10000 400
ATC OPERATION
INTER
A TC APC LOCK
RELEASE
1CYCLE RETURN 1STEP 1STEP

CYCLE
START START ADVANCE REVERSE
ME11158R0200900060001
5074-E P-166
4-2. 1 Cycle Start and Return Cycle Start

The 1 CYCLE START key is used for starting a series of automatic pallet change cycle in which the
pallet on the machine is unloaded to the APC and the pallet on the APC is loaded to the machine.
The operation is possible when the READY lamp is ON.
4-3. Precautions for Manual APC Operation

(1) While the RUN lamp is on, all manual APC control keys - 1 STEP ADVANCE, 1 STEP
RETURN, 1 CYCLE START and RETURN CYCLE START - are ineffective. To manually
operate the APC while the RUN lamp is on, press the RESET pushbutton to turn off the RUN
lamp.
(2) If the EMG. STOP pushbutton is pressed while the APC fork is rotating, shifter retraction
position signal is turned off, which, in turn, might disable 1 STEP ADVANCE, 1 STEP RETURN
and RETURN CYCLE START keys. In this case, press the 1 STEP ADVANCE key while
pressing the INTERLOCK RELEASE key. This advances the automatic pallet change cycle one
step independent of interlock conditions.
5074-E P-167
5. Pallet Dimensions
5-1. Pallet with Tapped Holes (Metric System)
500 mm square pallet

Ø18 through
Ø26 counterbore, 14.5 deep
100 (3.94)
36 18
(1.42) (0.71)
18 (0.71)
100 (3.94)
APC rotary axis side
(1.57)
80 (3.15)
40
(1.81)
500 (19.69)
46
2 (0.08)
100 (3.94)
275 (10.83)
100 (3.94)
(1.97)
50
C
60
(0.98)
25
118º
100 (3.94) 100 (3.94) 100 (3.94) 100 (3.94) Ø20
50
(0.79)
(1.97)
40 500 (19.69) 25
0.5 (0.019)
30 (1.18)
(1.57) (0.98)
40 (1.57)
150 (5.91) 175 (6.89)
2-Ø18 through M16
Ø26 counterbore, 14.5 deep 75 (2.95)
24 places
5/8-11UNC
24 places
For machines
exported to U.S. Detail of a tapped hole on the pallet
145 (5.71)
S=1/1
Edge locator is optional.
Unit: mm (in.)
ME11158R0200900090001
5074-E P-168
5-2. Pallet with T-slots (Metric System)
36 (1.42)
80 80 80 80
(3.15) (3.15) (3.15) (3.15) 18 (0.71)
60
C
(2.95)
250 (9.84)
150 (5.91)
75
500 (19.69)
250 (9.84)
15 (0.59)
25 (0.98)
Ø18 (0.71)
250 (9.84) Ø26 (1.02)
40 (1.57) 500 (19.69)
120 (4.72)
25 (0.98)
Ø26 (1.02)
Ø18 (0.71)
36 (1.42)
16 (0.63)
15 (0.59) 18
30 (1.18)
(0.71)
12 (0.47)
(1.18)
30
30 (1.18)
Unit: mm (in.)
ME11158R0200900100001
6. Safety Precautions for APC Operation

(1) Before carrying out setup operations on a pallet, make sure that the SETUP COMPLETION
lamp is off. If it is on, the automatic pallet change cycle will start when programmed M60
command is read.
(2) During the automatic pallet change operation, operations of the APC fork and pallet must be
carefully attended to. Do not try to touch the APC.
(3) The pallet on the setup station can be manually indexed at every 90°. Pull the lever to rotate the
pallet to an approximate position. Push back the lever and then slowly rotate and index the
pallet. After indexing, check that the lever has been completely returned.
5074-E P-169
1. Spindle Nose Dimensions
1-1. 15,000 min-1
ME11158R0201000010001
5074-E P-170
2. Hydraulic Circuit Diagram
ME11158R0201000020001
5074-E P-171
No. Qty DS Part name Manufacturer Model

51 1 Pressure switch Yuken Kogyo JT-02-100-10
52 1 Port A reducing valve Daikin MGB-02A-03-55
53 2 Reducing valve Daikin MG-02P-1-50
54 2 Solenoid valve Daikin LS-G02-4CP-30-N
55 5 Solenoid valve Daikin LS-G02-2DP-30-N
56 1 Solenoid valve Daikin LS-G02-4CA-30-EN (AC100V)
57 5 Pilot check valve Daikin MC-02P-05-50
58 5 Flow regulating valve w/ Daikin MT-02W-50
check valve
59 2 Orifice Daikin HKF3H-P-Q1-40-025B
60 1 Hydraulic unit NACHI NSP-20-22V1A4-2303K
61 1 Manifold Daikin BT-502
62 1 Manifold Yamazaki Denki BT-202
Sangyo
63 1 Manifold Yamazaki Denki BT-102
Sangyo
64 1 Pressure intake block Daikin BG-02AB
65 1 Closing plate Daikin BS-02-50 For 40-tool MG only
66 4 Hydraulic oil hose Yokohama SF21-9-3140
67 2 Hydraulic oil hose Tokai Gomu SRX140LG-500
68 1 Hydraulic oil hose Bridgestone PF1404-600
73 1 Level switch ASK LSN-80-B-11
101 8 Hexagonal socket head cap M5*45
screw
screw
screw
screw
3.
270NL
Optional
Spindle air blower 380NL
225NL Out-of-spindle air blower Optional Optional Optional
Oil-air lubricator Optional Ring air blower Automatic tool checker blower Automatic tool checker cover opener
Optional 225NL Standard 225NL 90NL Rotary joint for φ6 Out-of-spindle
Negative pressure
center-through Center-through evacuation pressure Coolant BIG+Tooling 225NL
air blower 25B 12R 30ST
Pallet air blower/close contact sensor Pallet air blower protection for index P/N HMP6101CSB HSK Tooling
Coolant BBK6291AFA
50NL
Mixing valve Pressure switch n4 n4 LS77
Air cooler Urethane tube Urethane tube Open
φ10 6.5 φ10 6.5 62 CC-8-CP2-VI-1
(130NL) NC contacts LS73
Cable bearing (SUS) Cable bearing
1.2MPa:OFF VT317-
0.8MPa:ON VT317- 1/2
54-1 Urethane tube 62 CC-8-CP2-VI-1 58 5DZ-02 5DZ-02
φ10 6.5 A Urethane tube
Pallet in close contact 50NL (SUS)
sensing air φ10 6.5
Pallet in close contact sensor Blow air to spindle 58
Set pressure ON SOL117 Pallet seated in close From oil-air Spindle air curtain
0.1MPa contact sensor lubricator P 1/4 ON SOL80 1/4
P R Urethane tube
PS93
71 Urethane tube φ6 4
Secondary supply Yokohama Hidex φ6 4
54-2 M5 threaded VT317- R 58 P R
Settings pressure P 71 WS18-04
0.01MPa portion 5DZ-02 Urethane tube 66
0.08mm(OK) 1/4 hose
Sensor φ6 4 2
0.10mm(NG) Urethane tube AN202-02 71
φ10 6.5 1/4 VX2330 AS2201F-
-02-5DZ-B 02-06
Urethane tube φ10 6.5 Release center-through Release center-through
1/4 1/4 residual pressure residual pressure
54-4 59 1/4
57
54-5 Closed up ON SOL91 ON SOL93
φ10 tube Urethane tube Urethane tube Head bracket
φ10 6.5 φ10 6.5 VQ4200-5-02
φ10 tube P
53 52 Yokohama Hidex Yokohama Hidex 3/8 Yokohama Hidex
A φ10 tube P φ10 tube
A WS18-04 WS18-04 WS18-06
R
R
Yokohama Hidex
WS18-06 AN203-02
Pallet air blower Seating/air blow switch Air pressure sensor for
54-3 54-3 INO-8085 oil-air lubrication
ON SOL81 ON SOL116 Blow air to sensor head Automatic tool length cover 73
SMC Set 0.2MPa(ON) Duct support Open Close
Pallet clamp sensor PS40 ON SOL85 SOL124 SOL125 2
Air catch sensor pressures 0.1MPa(OFF) Urethane tube
54 1/8 1/4 1/4 3/8 3/8
panel unit Set 0.35MPa(ON) PS83 φ10 6.5
Urethane
pressures 0.29MPa(OFF) tube
Urethane Urethane tube
tube
52 53 φ8 6
φ10 6.5
68
φ8 6
80NL
Pallet clamp sensor 67 AFD4000-02D IDG50-02 69 78 ATC door opener Optional
Front automatic APC
LS24
LS25
AS2211F Breezing air output door opener
Set -02-10 AS2201F Open
65 -02-10
pressures 0.35MPa(ON) 0.1MPa BBK6202FFD
PS40 0.29MPa(OFF) (Completely close up.) (Rotate 7 turns.) 3/8
32B x 12R x 530ST LS4M-L LS4M-R
60 AMG250-03BC AR3000-03BG 3/8 3/8
53 4
BBK*******
Pneumatic Circuit Diagram
1/4 1/4 1/4 Close

25B ST Open Open
Close 25B ST
79 AS3000F-12
φ10 tube 1/4 1/4 1/4 1/4
Install in meter-in circuit.
VVX232-04
VX2331
Urethane tube 64 AS2200-02
-00-5DZ φ12 8 2
AN101-01
3/8 Urethane tube
φ12 8 63 63
Pallet air blower Negative pressure Air sensor for Air for breeze
75 55 2 2
protection for index oil-air lubrication Urethane tube
ON SOL81 ON SOL84 ON SOL111 ON SOL110 PE Standardized φ8 steel pipe
φ6 4
into PE A B
(Close completely.) Oil pan manifold
φ10 tube Optional Scale air pressure 3/8
51 76 Close
3 0.03MPa 59 Open P VQ4200-5-B03
Scale air purge Urethane tube
AN202-02 56
65 AS2211F φ10 6.5
-02-10 X Axis 10NL n0.8 Yokohama Hidex
Urethane tube WS18-04 1/4 VX2330 3/8 A B
Y Axis 10NL Air blow ring 71
φ12 8 n0.8 AR2500-02BG-1 -02-5DZ-B ATC door
ON SOL92 Open Close 2
Z Axis 10NL SOL100 SOL101 VQ4400-5-03
n0.8
P AN303-03
Ring air blow pressure
0.4MPa
71 74
Optional 2
Front automatic APC door
Urethane tube 3/8 3/8 Open Close
φ12 8 Filter regulator SOL87 SOL86
80 AW3000-03B-DG Urethane tube
R A 1/4" φ12 x 8
1/4" P
Optional 52 53
58
61 PS56 Urethane tube
72 Pressure switch φ12 8
Optional Air pressure confirm Air source pressure valve
77 Set 0.2 MPa(OFF)
70 pressures ON SOL114
30PM 1/8
3/8 3/8
3/8 3/8
AN302-03 Mist separator Regulator

AM350-03BD AR4000-03BG
VHS400-03
(air)
M/C supply air pressure
Normally open
0.4MPa
ME11158R0201000030001
5074-E P-172
5074-E P-173
NO Qty DS Part name Manufacturer Model P/N

51 3 Fixed throttle SMC CJ-5H-6 BAF3196BE
53 3 Pressure switch SMC ISE40-01-30L-M(NPN) BBK3222EAB
54 1 Air catch sensor panel unit SMC INO-**** BBK3222IAC
55 1 Solenoid valve SMC VQ4200-5-B03 BBK4222KWC
56 1 Solenoid valve SMC VQ4400-5-03 BBK4222KWD
57 1 Solenoid valve SMC VQ4200-5-02 BBK4222KWE
58 4 Solenoid valve SMC VT317-5DZ-02 BBK4222TAA
59 2 Solenoid valve SMC VX2330-02-5DZ-B BBK4222WAD
60 4 Solenoid valve SMC VX2331-00-5DZ BBK4222WAF
61 1 Manual 3-way valve SMC VHS400-03 BBK4322EAA
62 2 Check valve Atsugi Valve SS-8-CP2-VI-1 BBK4417DCD
63 4 Speed controller SMC AS2200-02 BBK5522HAD
64 2 Speed controller SMC AS3000F-12 BBK5522TE
65 1 Speed controller SMC AS2211F-02-10 BBK5522WCD
66 2 Speed controller SMC AS2201F-02-06 BBK5522YCB
67 1 Speed controller SMC AS2201F-02-10 BBK5522ZCD
68 1 Air dryer set SMC AFD4000-02D+IDG50-02 BBK8202ECE
69 1 Drain catcher SMC AMG250-03BC BBK8202GBA
70 1 Mist separator SMC AM350-03BD BBK8204EHA
71 6 Silencer SMC AN202-02 BBK8210DAB
72 1 Silencer SMC AN302-03 BBK8210DAC
73 2 Silencer SMC AN203-02 BBK8210DAF
74 2 Silencer SMC AN303-03 BBK8210DAG
75 1 Silencer SMC AN101-01 BBK8210DBA
76 1 Regulator SMC AR2500-02BG-1 BBK8230ECN
77 1 Regulator SMC AR4000-03BG BBK8230ECP
78 1 Regulator SMC AR3000-03BG-1 BBK8230ECR
79 1 Manifold SMC VVX232-04 BBK8232EKC
80 1 Filter regulator SMC AW3000-03B-DG BBK8302BCE
Components of Air Catch Sensor Panel Unit (Optional)
NO Qty DS Part name Manufacturer Model P/N

54-1 1 Air catch sensor SMC ISA2-HE1(NPN) -
54-2 1 Filter regulator SMC AW20-02E-1 -
54-3 2 Solenoid valve SMC VT317-5DZ-02 BBK4222TAA
54-4 1 Solenoid valve SMC VCA27A-5DLS-4-02 -
54-5 1 Silencer SMC AN203-02 BBK8210DAF
5074-E P-174
4. Skeleton Drawing
4-1. Spindle Drive Mechanism 15,000 min-1
SQ4
(Spindle cylinder retract YV23
confirmation) YV23
SQ5
(Spindle cylinder advance
confirmation)
SQ2
(Clamping with tool
absent)
SQ3
(Clamping with tool
present)
PG
(Spindle rotary position
detection)
M1
(Integral motor/spindle)
ME11158R0201000040001
5074-E P-175
4-2. X-, Y- and Z-axis Drive Mechanism

(1) X-axis Drive Mechanism
X-axis rapid traverse

60 m/min (2362.20 ipm) [90 m/min (3543.31 ipm)]
MX (X-axis feed motor)

Okuma
BL-MP300J-30S
Rapid traverse: 2,000 min-1 (3,000 min-1)
X
Coupling
X-axis ball screw

φ45 (1.77 in.), 30 mm (1.18 in.) lead,
Column right-hand helix
ME11158R0201000050001
5074-E P-176
(2) Y-axis Drive Mechanism
Y-axis rapid traverse

60 m/min (2362.20 ipm) [90 m/min (3543.31 ipm)]
MYM (Y-axis feed motor)

Okuma
BL-MP300J-30SB
Coupling
Y Spindlehead
Magazine side Operator side
Y-axis ball screw

φ45 (1.77 in.),
30 mm (1.18 in.) lead,
right-hand helix
Column
ME11158R0201000050002
Z
Table
(3) Z-axis Drive Mechanism
MZ (Z-axis feed motor)

Okuma
BL-MP300J-30S
Z-axis rapid traverse

60 m/min (2362.20 ipm)
[90 m/min (3543.31 ipm)]
Z-axis ball screw

Coupling
φ45 (1.77 in.), 30 mm (1.18 in.) lead,
right-hand helix
ME11158R0201000050003
5074-E P-177
5074-E P-178
5. Machine Device Layout (MB-500H)

Machine front view
SQ3P
SQ4P
SQ5P
SQ6P
SQ29A/YV29A
SQ29B/YV29B
YV4P
YV3P
YV2P
YV1P
ME11158R0201000060001
5074-E P-179
Machine right side view
SQ9/YV9
ME11158R0201000060002
Device No. Device Name

SQ3P APC fork UP
SQ4P APC fork DOWN
SQ5P Pallet normal rotation
SQ6P Pallet reverse rotation
YV1P APC fork DOWN
YV2P APC fork UP
YV3P Pallet normal rotation
YV4P Pallet reverse rotation
SQ9/YV9 Operation door interlock
SQ29A/YV29A APC right door interlock
SQ29B/YV29B APC left door interlock
5074-E P-180
Machine left side view
YV133 YV72
YV95 YV71
YV98
YV39
SP10A
Details of backplate
SP21
SP2L
SL1
Details of
manifold block SL3L SQ19/YV19
YV8P YV7P
YV6P YV5P
YV19P YV18P
YV18 YV19
YV42B YV41B
ME11158R0201000060003
5074-E P-181

SP10A Oil air pressure normal
SP2L Coolant pressure
SP21 Flow volume of ball screw cooling; normal
SL1 Hydraulic unit oil level normal
SL3L Coolant level lower limit
YV5P Pallet clamp
YV6P Pallet unclamp
YV7P B-axis clamp
YV8P B-axis unclamp
YV9B Curvic air blow
YV18 Tool pot magazine side
YV19 Tool pot spindle side
YV18P Magazine pot clamp
YV19P Magazine pot unclamp
YV39 Pallet seating air blow
YV41B Interlock pin spindle side
YV42B Interlock pin MG side
YV71 ATC door close
YV72 ATC door open
YV95 Oil air lubrication activated
YV133 Low-pressure circuit air
SQ19/YV19 MG door interlock
5074-E P-182
Cross section of Machine
SQ26 SQ27 YV23D
SP13 YV23C
YV4
YV137
SQ2
SQ3
SQ5
SQ4
SQ144
SQ2P
SQ143
SQBELT
SQ7P
ME11158R0201000060004
5074-E P-183
Drawing of Magazine and its vicinity parts
SQ14A
SQ16A
SQ17A
SQ13B
SQ13A
SQ14B
SQ12A
Backside
ME11158R0201000060005
5074-E P-184

SQ2 No spindle tool
SQ2P Setup pallet in home position
SQ3 Inner cylinder retract confirmation
SQ4 Spindle tool unclamp
SQ5 Spindle tool clamp
SQ7P Pallet unclamp
SQ12A ATC change arm in home position
SQ13A Tool pot MG side
SQ13B Interlock pin MG side
SQ14A Tool pot spindle side
SQ14B Interlock pin spindle side
SQ16A Magazine pot clamp
SQ17A Magazine pot unclamp
SQ26 ATC door open
SQ27 ATC door close
SQ143 B-axis clamp
SQ144 B-axis unclamp
SQBELT Break detection of B-axis belt
SP13 Oil air pressure rise detection
YV4 Spindle air blow
YV23D Spindle tool clamp
YV23C Spindle tool unclamp
YV137 Through-spindle coolant
5074-E P-185

<Classification of listed parts>
(1) Motor/Pump-related Parts
(2) Solenoid Valve List
(3) Sensors
(4) Mechanical Parts
<Rank>
A: Standard accessories
C: Consumable parts that should be replaced after operation for 8000 hours or three
years.
D: Consumable parts that should be stocked at the overseas distributors and dealers for
maintenance of the exported machines
<When ordering parts>
- Please let us know the number and the delivery date of your machine for our easy
identification because the machines are always remodeled for improvement.
- Also refer to the attached parts book.
5074-E P-186
1. Motor/Pump-related Parts
Standard equipment
Part name Used for Part type Maker Part No. Qty. Rank Remarks
3-phase induction motor Spindle (rotor) UAASID-11COK11/ Yaskawa E1005-892-208 1 D
37HOK31
3-phase induction motor Spindle (stator) UAASID-11COK11 Yaskawa E1005-892-122 1 D
Servomotor X-axis BL-MP300J-30S/JF U4088-0005-002- 1 D
00
Servomotor Y-axis MP300J-30SB U4188-0005-002- 1 D
00
Servomotor Z-axis MP300J-30SN U4088-0005-002- 1 D
00
Servomotor B-axis (index) MC50J-30TN U4262-0005-002- 1 D
00
Servomotor Magazine rotation MC50J-30TB U4362-0005-002- 1 D
00
Servomotor ATC unit drive MC50J-30TN U4262-0005-002- 1 D
00
Lubrication unit Lubricating oil pump (CE- LCB4-8678E Showa BAP0115AAT 1 D
compliant)
Lubrication unit Oil-air lubrication unit MRJ010211A Daido Metal BAP6008BAA 1 D
Cooling unit Spindle cooling unit (CE- AKZ328-C Daikin BBK9001BEB 1 D
compliant)
Pump Trochoid pump for ball TOP-2MY400-210HBM NOP BMA1605ACB 1 D
screw cooling
Hydraulic unit Hydraulic unit (6.5 MPa) NSP-20-22V1A4-2303K NACHI BBK7061BBA 1 D
Pump Coolant nozzles MTH2-60/4 Grundfos BMA0173AED 1 D
Pump Chip flusher MTH4-40/2 Grundfos BMA0173BCC 1 D
Optional equipment
Hydraulic unit Hydraulic unit for jig (3.5 NSP-10-15V1A3-2329K NACHI BBK7061BCA 1 D
MPa)
Pump Shower coolant system MTH4-40/4 Grundfos BMA0173BCD 1 D
Pump Back-wash pump MTH2-60/3 Grundfos - 1 D
Pump Thru-center (1.8 MPa) CRK2-220-50 Grundfos BMA0172DAI 1 D
50Hz
Motor Mayflan’s lift-up conveyor YTFO-K Hitachi 1 D
(for MT10), CE-compliant
Motor Mayflan’s lift-up conveyor YTFO-K Hitachi 1 D
(for CS1), CE-compliant
Motor Internal chip conveyor 1 G3FM-18-40-T010A Nissei Kogyo VYG7000AAA 1 D
(Tokyo Seimitsu)
Motor Internal chip conveyor 2 G3FM-18-40-T010A Nissei Kogyo VYG7001AAA 1 D
(Tokyo Seimitsu Hatsujo)
5074-E P-187
2. Solenoid Valve List

Hydraulic system
Solenoid valve Spindle tool unclamp 1 D
LS-G02-4CA-30-EN Daikin BBK4213LCC
Solenoid valve Spindle tool clamp 1 D
Solenoid valve Pallet clamp 1 D
LS-G02-2DP-30-N Daikin BBK4213LAI
Solenoid valve Pallet unclamp 1 D
Solenoid valve Index clamp 1 D
Solenoid valve Index clamp 1 D
Solenoid valve APC arm lift up 1 D
Solenoid valve APC arm lift down 1 D
Solenoid valve APC 180° CW 1 D
LS-G02-4CP-30-N Daikin BBK4213LAC
Solenoid valve APC 180° CCW 1 D
Solenoid valve Pot slide magazine side 1 D
Solenoid valve Pot slide spindle side 1 D
Solenoid valve Pot clamp 1 D
Solenoid valve Pot unclamp 1 D
Solenoid valve Magazine clamp 1 D 60-tool
Solenoid valve Magazine unclamp 1 D magazine
Solenoid valve A-pallet jig No. 1 clamp 1 D Optional

specification
Solenoid valve A-pallet jig No. 1 unclamp 1 D Optional
specification
Solenoid valve A-pallet jig No. 2 clamp 1 D Optional
specification
Solenoid valve A-pallet jig No. 2 unclamp 1 D Optional
specification
Solenoid valve B-pallet jig No. 1 clamp 1 D Optional
specification
Solenoid valve B-pallet jig No. 1 unclamp 1 D Optional
specification
Solenoid valve B-pallet jig No. 2 clamp 1 D Optional
specification
Solenoid valve B-pallet jig No. 2 unclamp 1 D Optional
specification
5074-E P-188
Pneumatic system
Solenoid valve Spindle air blow VT317-5DZ-02 SMC BBK4222TAA 1 D
Solenoid valve Tool length measuring unit 1 D
cover open Optional
VQ4200-5-02 SMC BBK4222KWE
Solenoid valve Tool length measuring unit 1 D specification
cover close
Solenoid valve Air blow to tool breakage 1 D Optional
VX2330-02-5DZ-B SMC BBK4222WAD
detection head specification
Solenoid valve ATC door open 1 D
VQ4200-5-B03 SMC BBK4222KWC
Solenoid valve ATC door close 1 D
Solenoid valve Pallet air blow VX2331-00-5DZ SMC BBK4222WAF 1 D
Solenoid valve Air supply to spindle oil-air 1 D
VX2331-00-5DZ SMC BBK4222WAF
lubrication unit
Solenoid valve Breeze circuit air (for air 1 D
VX2331-00-5DZ SMC BBK4222WAF
curtain, cooling, etc.)
Solenoid valve Air blow ring 1 D BIG+/HSK
VX2330-02-5DZ-B SMC BBK4222WAD
tooling
Solenoid valve Thru-center residual 1 D Optional
VT317-5DZ-02 SMC BBK4222TAA
pressure release specification
Solenoid valve A-pallet jig air blow 1 D Optional
VXD2130-03-5DZ-B SMC BBK4222SFF
specification
Solenoid valve B-pallet jig air blow 1 D Optional
VXD2130-03-5DZ-B SMC BBK4222SFF
specification
Coolant system
Solenoid valve Thru-center coolant CVS31-15A-35-B2HSB- CKD BBK4234XHB 1 D For medium
3 pressure (1.8
MPa)
Electrical equipment
Door lock switch Operation panel side door D4BL-2DRA Omron BAK9007AAE 1 D Mecha-lock
close end and release
by solenoid
Door lock switch Magazine door close end D4NL-1DFG-B Omron BAK9009BBA 1 D Solenoid lock
Door lock switch Front door close end (left D4NL-1DFG-B Omron BAK9009BBA 1 D Solenoid lock
side)
Door lock switch Front door close end (right D4NL-1DFG-B Omron BAK9009BBA 1 D Solenoid lock
side)
5074-E P-189
3. Sensors
Proximity switch Tool clamp confirmation FL7M-2J6HD-L5 Yamatake BJA0003JBN 1 C
Proximity switch Tool unclamp confirmation FL7M-2J6HD-L5 Yamatake BJA0003JBN 1 C
Proximity switch Tool clamp error detection FL7M-2J6HD-L5 Yamatake BJA0003JBN 1 C
Proximity switch No-tool detection FL7M-2J6HD-L5 Yamatake BJA0003JBN 1 C
Proximity switch Pot slide MG side FL7M-3J6HD-L5 Yamatake BJA0003JBO 1 C
Limit switch Pot slide spindle side 14CE8-3JKE5 Yamatake BMF1120AAC 1 D
Proximity switch Pot clamp end FL7M-3J6HD-L5 Yamatake BJA0003JBO 1 C
Proximity switch Pot unclamp end FL7M-3J6HD-L5 Yamatake BJA0003JBO 1 C
Auto switch Magazine clamp Type 1 Horiuchi Kikai BBK6353AAA 1 C 60-tool
magazine
Auto switch Magazine unclamp Type 1 Horiuchi Kikai BBK6353AAA 1 C 60-tool
magazine
Proximity switch ATC arm home position FL7M-3J6HD-L5 Yamatake BJA0003JBO 1 C
Proximity switch ATC door open end FL7M-4J6AD-CN03 Yamatake BJA0003JSA 1 C
(aluminum)
Proximity switch ATC door close end FL7M-4J6AD-CN03 Yamatake BJA0003JSA 1 C
(aluminum)
Limit switch APC pallet home position D4C-5302 Omron BMF0120AAC 1 D
Proximity switch APC arm lift upper end FL7M-7J6HD-L5 Yamatake BJA0003JBP 1 C
Proximity switch APC arm lift lower end FL7M-7J6HD-L5 Yamatake BJA0003JBP 1 C
Proximity switch APC 180° CW confirmation FL7M-3J6HD-L5 Yamatake BJA0003JBO 1 C
Proximity switch APC 180° CCW FL7M-3J6HD-L5 Yamatake BJA0003JBO 1 C
confirmation
Pressure sensor Pallet clamp confirmation ISE40-01-30L-M (NPN) SMC BBK3222EAB 1 D
Proximity switch Pallet unclamp end FL7M-3J6HD-L5 Yamatake BJA0003JBO 1 C
Proximity switch Index clamp end FL7M-3J6HD-L5 Yamatake BJA0003JBO 1 C
Proximity switch Index unclamp end FL7M-3J6HD-L5 Yamatake BJA0003JBO 1 C
Pressure sensor B-axis clamp confirmation JT-02-100-10 Yuken Kogyo BBK3218AAB 1 D NC rotary
table
Photoelectrical switch Belt breakage detection HPF-D030+HPX-NT1 Yamatake BJA0008XNB 1 C NC rotary
table (OSP)
Touch sensor In-process tool length MP4/R Renishaw MYN6010XAA 1 D Optional
gauging (breakage specification
detection) unit
Auto switch Tool length gauging unit D-F7BAL SMC BBK6311NAA 1 C Optional
cover open end specification
Auto switch Tool length gauging unit D-F7BAL SMC BBK6311NAA 1 C Optional
cover close end specification
Touch sensor Tool breakage detection (in TP11DM-DBH-5P1 Metrol BMF6500AAH 1 D Optional
machine) specification
Proximity switch Tool breakage detection (in FL7M-3J6HD-L5 Yamatake BJA0003JBO 1 D Optional
magazine) specification
Touch sensor Auto centering unit MP10+OMM (2) Renishaw MYN6004XEH 1 D Optional
specification
Flow sensor Cooling oil tank flow meter IFW510-06-10 SMC BBK9204AAH 1 C
Level switch Hydraulic unit oil level lower LSN-80L-B-11 (DC24V) ASK BJA9006AAB 1 C
limit detection
Pressure sensor Air source pressure ISE40-01-30L-M (NPN) SMC BBK3222EAB 1 C Optional
confirmation specification
Pressure sensor Oil pressure detection for PS1208-R1M Daido Metal BAP6311AAA 1 C
spindle oil air lubrication
unit
Pressure sensor Air pressure detection for ISE40-01-30L-M (NPN) SMC BBK3222EAB 1 C
spindle oil air lubrication
unit
Level switch Oil level detection for Assembled in the unit Daido Metal - 1 -
spindle oil-air lubrication
unit
Pressure sensor Oil pressure detection for Assembled in the unit Showa - 1 -
slideway lubrication unit
5074-E P-190
Level switch Oil level detection for Assembled in the unit Showa - 1 -
slideway lubrication unit
Differential pressure Filter clogging 1 CB-49H SMC BBK8110LAD 1 D Optional
switch specification
Differential pressure Filter clogging 2 CB-49H SMC BBK8110LAD 1 D Optional
switch specification
Pressure sensor Thru-center pressure PN0022 (NPN) Effector BBK3229HAB 1 D Optional
Proximity switch Post-process chip E2E-X7D1-MIG Omron BJA0003RAC 1 D Optional
conveyor overload specification
detection-1
Proximity switch Post-process chip E2E-X7D1-MIG Omron BJA0003RAC 1 D Optional
conveyor overload specification
detection-2
Level sensor Coolant tank overflow FP-1A Nhoken - 1 D Optional
detection specification
Level switch Primary clean tank lower D-Z73-100 SMC DTL7286AZZ 1 D Optional
limit specification
Safety switch Back door close end D4DS-1AFS Omron BAK9005ABA 1 D Optional
specification
Scale Scale (X-axis) Omron 1 D Optional
specification
Scale Scale (Y-axis) Omron 1 D Optional
specification
Scale Scale (Z-axis) Omron 1 D Optional
specification
Pressure sensor A-pallet jig clamp No. 1 HW1-3T1-02-DC-L Toyooki BBK3216BBA 1 D Optional
Pressure switch A-pallet jig clamp No. 2 HW1-3T1-02-DC-L Toyooki BBK3216BBA 1 D Optional
Pressure switch B-pallet jig clamp No. 1 HW1-3T1-02-DC-L Toyooki BBK3216BBA 1 D Optional
Pressure switch B-pallet jig clamp No. 2 HW1-3T1-02-DC-L Toyooki BBK3216BBA 1 D Optional
5074-E P-191
4. Mechanical Parts
Ball screw cooling joint Ball screw cooling joint ES50-8227 Rix HMP6101DSD 1 D
O-ring O-ring P18 NOK DO10180M 3 C
O-ring O-ring S24 NOK BBJ6518A3 3 C
Backup ring Backup ring T2-P16 (bias cut) NOK BBJ6856AAP 3 C
O-ring O-ring G105 NOK DO20105M 6 C
Support bearing Support bearing 35TAC72BSUG250PN7 NSK BAA9035USS 19 D
B
Coupling Coupling SFC-090SA-T01 Miki Pulley BAK5400GAB 3 D
Ball screw Ball screw (X-axis) W4511-240DTX-C5Z30 NSK BBS6917MGA 1 D
Ball screw Ball screw (Y-axis) W4509-388ZTX-C5Z30 NSK BBS6916KTA 1 D
Ball screw Ball screw (Z-axis) W4511-341DTX-C5Z30 NSK BBS6917MJA 1 D
Oil seal Oil seal VB 38 × 58 × 8 (NOK) NOK DV02239M 1 C
Oil seal Oil seal VB45 × 60 × 6 (NOK) NOK DV02640M 3 C
O-ring O-ring G105 NOK DO20105M 6 C Axis feed
system
LM guide X-axis guide, front SRG55LRSSC0E+1780L THK BBT1780HVB 1 D
PS-II
LM guide X-axis guide, rear SRG55RSSC0E+1520L THK BBT1520HVB 1 D
PS-II
LM guide Y-axis guide SRG45LR2SSC0E+1410 THK BBT1410GVB 2 D
LPS-II
LM guide Z-axis guide SNS55R2SSC0+1500LH THK BBT1500HKB 2 D
-II
Telescoping cover X-axis telescoping cover 1011-21 Tokyo Seimitsu HXN1050AAA 1 D
Hatsujo
Telescoping cover Y-axis telescoping cover 1011-31 Tokyo Seimitsu HXN1050ABA 1 D
Hatsujo
Telescoping cover Z-axis telescoping cover 3A263G1 Hatakeyama HXN1052C 1 D
(APC side)
Telescoping cover Z-axis telescoping cover 3A262G1 Hatakeyama HXN1053B 1 D
(spindle side)
Mist separator Mist separator AM350-03BD SMC BBK8204EHA 1 D
Mist separator element Mist separator element AM-EL350 SMC BBK8204EWC 1 D
Regulator Regulator AR4000-03BG SMC BBK8230ECP 1 D
Regulator Regulator AR3000-03BG-1 SMC BBK8230ECR 1 D
Drain catch Drain catch AMG250-03BC SMC BBK8202GBA 1 D
Drain catch element Drain catch element AMG-EL250 SMC BBK8202GZB 1 D
Air pressure
Membrane air dryer set Membrane air dryer set AFD4000-02DIDG50-02 SMC BBK8202ECE 1 D system
Micromist separator Micromist separator 63094 SMC BBK8204EVC 1 D
element element
Film module set for air Film module set for air dryer IDG-EL50 SMC BBK8202EYE 1 D
dryer
Filter regulator Filter regulator AW3000-03B-DG SMC BBK8302BCE 1 D
Filter regulator element Filter regulator element 111585 SMC BBK8201EZF 1 D
Spindle unit assy Spindle unit assy 15000 oil air: BT40 - XN 0451B 1 set D
15000 oil air: HSK-A63 - XN 0461A 1 set D
Spindle unit
Spiral Belleville spring Spiral Belleville spring F1149a/92a Takeda Shoji HXL3043C 1 D
Oil air distributor Oil-air distributor BFA0203BBBBA Daido Metal BAP6302AAA
Spring Tool change arm spring (for WH16-40 Misumi BAS1421BDA 2 D
slider pin) Tool change
Spring Tool change arm spring (for WH22-50 Misumi BAS1928BJA 2 D arm
interlock pin)
Magazine pot Magazine pot (BT40) 5B-837-1 Fudo HXN4000AAA 40 D
Magazine pot Magazine pot (HSK-A63) 5B-879 Fudo HXN4003AAA 40 D
Magazine leaf spring Magazine lead spring 24-610 Fudo HXA4009AAE 40 D Magazine
(BT40) system
Magazine leaf spring Magazine lead spring 24-607 Fudo HXA4009AAD 40 D

(HSK-A63)
5074-E P-192
Air cylinder ATC shutter air cylinder RHCF32-S9018-530 SMC BBK6202FFD 1 D ATC shutter
Air cylinder (with SW) Air cylinder (with SW) MDUB25-30DM-F7BAL SMC BBK6291AFA 1 D Auto tool
length offset
Hydraulic pressure Hydraulic cylinder for pot FA32S35B155ADB Horiuchi Kikai BBK6102BKD 1 D
slide
Hydraulic cylinder (with Hydraulic cylinder for MR70-1ST25 × 25E-SB1 Horiuchi Kikai BBK6191AEC 1 D
SW) magazine (with SW)
Hydraulic pressure Hydraulic cylinder for 2APC 70C-81FA63CB245-BA- Taiyo Tekko BBK6105CIC 1 D
L-X
Timing belt Timing belt 250S8M680 Bando ADV7352AEB 1 D NC rotary
table
Rotary joint Rotary joint ESX20-7885 (Rix) Rix HMP6101CSB 1 D
Coolant valve (mecha- Coolant valve (mecha- CV2-10A-70-B (Rc3/8) CKD BBK4234LAA 1 D Thru-center
valve) valve) coolant
Check valve Check valve B-8-CP2-VI-1 Atsugi Valve BBK4417DAD D system
Line filter element Line filter element EM140-040W SMC BBK8110LAB D

Fluorescent lamp Fluorescent lamp SLCE118 Waldmann 1 C S/G system
Level tower (with SW) Level tower (with SW) CLT-1-B1-00-90-60-C Koike E&S 1 D Coolant
system
LIST OF PUBLICATIONS
Publication No. Date Edition
5074-E February 2004 1st
5074-E-R1 January 2008 2nd
This manual may be at variance with the actual product due to

specification or design changes.
Please also note that specifications are subject to change without notice.
If you require clarification or further explanation of any point in this manual,
please contact your OKUMA representative.

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HORIZONTAL MACHINING CENTER

1. Precautions When Installing the Machine

• Ambient temperature: 17 to 25°C (62.6 to 77°F)

• Humidity: 75 % HR or less (without condensation)

(5) The machine must be leveled carefully during initial installation;

(10) For details on installation, refer to Section 2.

2. Precautions Before Starting Machine Operation

3. Precautions During Machine Operation

(6) Never touch the workpieces or the tools by bare hand.

4. Precautions on Maintenance and Inspection

5. Precautitins on Operating the ATC and APC

6. Powerful Magnet inside the Product

• It is dangerous as strong magnetic attraction is exposed while/after disassembling the

• Disassembling work requires special knowledge and jigs.

(2) Danger of powerful magnet

• Medical electronic instruments such as pacemaker produce malfunction, resulting in

• Tools or parts get attracted by powerful magnet, resulting in bodily injury.

• Precision instrument becomes out of order.

• Magnetic memory device causes data loss.

8. Symbols Used in This Manual

9-1. Attachment of Caution Labels

(2) Part Nos., Positions and Meanings of Caution Labels

62 B0Z2000AAC Power supply section (power supply present)

9-2. Types, Meanings and Locations of Caution Labels

• Explains the safety-first operations of the overall machine.

• Post near the operation panel.

• Keep clear of the tool magazine while the machine is in operation.

• Post near the tool magazine.

• Post near the spindle.

• Post near the spindle.

• Post near the tool-changing arm.

• Post near the tool-change arm.

• Post near the moving parts.

• Do not open the door while operating in AUTO.

• Post near the door.

• Post near the lower moving body.

• Do not turn on the power while working inside the machine.

• Post inside the machine or on the moving body.

• Wear a safety helmet.

• Post under the slab top.

• Wipe up liquid coolant from the floor.

• Post on the tank of the liquid coolant.

• May cause severe bodily injury when working at an elevated location.

• Post at elevated working locations.

• Perform maintenance after shutting off the power supply.

• Post outside the electrical control panel.

• Use as an outlet for the I/O equipment.

• Do not use the outlet for any other purpose.

• Post near the outlet.

• Post on the slides.

• Do not climb on the cover.

• Post on the cover.

• Do not put hands in the chip conveyer during operation.

• Post on the chip conveyer.

• Pallets may be damaged when swung to the swing-prohibited range.

• Use the pallets outside the swing-prohibited range.

• Post on the pallets.