Instruction Manual

Safety Guide

Specifications

Installation

Operation

Maintenance

Special Version
 Introduction

Thank you for purchasing a Takamatsu CNC Precision Lathe. This machine is designed and
manufactured giving first priority to safety precautions according to nationally recognized
standards, so that it can be operated safely.
However, safe operation cannot always be ensured if an operator misuses the machine or ignores
safety regulations. Failure to comply with these instructions will damage the machine and products
as well as result in critical bodily injuries.
Read the attached manuals thoroughly and understand the correct procedures for
operation so that the machine can be operated efficiently and safely.
Ignoring the safety precautions in this Manual will result in bodily injuries. Aside from these
precautions, there are many "Don'ts" to be observed when operating the machine. It should be
considered a "Don't" if not stated in this Manual.

In this Manual, safety instructions are classified into three levels of seriousness regarding personal
injury or machine damage, as indicated by the following marks. Pay particular attention to the
safety instructions regarding situations that are extremely dangerous.

DANGER Failure to follow the instructions will result in critical bodily injuries.

Failure to follow the instructions will result in serious bodily injuries or

WARNING
machine damage.

Failure to follow the instructions may result in less serious bodily injuries or
CAUTION
machine damage.

* The word "qualified" used in this Manual refers to persons who are qualified to perform operation and
maintenance of this machine as authorized by a safety control supervisor.

* Outline drawings, dimensions, and types and quantities of parts described in this manual are subject to
change according to modifications made to this machine. Check the types and quantities of parts to be
replaced, and place an order with Takamatsu.

This machine is subject to the export control laws and regulations of Japan.
When exporting the machine, follow all necessary procedures stipulated by applicable laws and
regulations under the Foreign Exchange and Foreign Trade Act.
Be sure to contact the machine supplier in advance of relocation that includes a change of address
or a transfer of ownership (or a change in the name of the owner).

1
 About This Manual
This Instruction Manual describes the following model :

Model GSL-10H
Manufacturer Takamatsu Machinery Co., Ltd.

About This Manual

Safety Guide Safety precautions
Specifications Machine specifications, drawings
Installation Machine installation procedures
Operation Machine operation procedures
Maintenance Inspection, oiling, trouble-shooting, adjustment, replacement
Special Version Instruction to operate the optional equipment

If you have any questions or doubts about this instruction manual, feel free to
contact us or your local agent at any time.

All rights reserved. No part of this document and attached technical materials (including
drawings and technical information disclosed through drawings) may not be disclosed to
any third party, nor reproduced in any form or any language without permission from
Takamatsu Machinery Co., Ltd.

2
 Contents

Contents

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

Chapter 2 Outline of Machine ................................................................................................. 3

Chapter 3 Disposal of the Machine and Oil ........................................................................... 4

Chapter 4 Preparation for Safe Operation ............................................................................ 5

Chapter 5 Name of Each Component ..................................................................................... 8

Chapter 6 Warning Labels ...................................................................................................... 9

Chapter 7 Safety Devices ....................................................................................................... 11

7-1 Functions of Safety Devices ................................................................................... 11
7-2 Door Interlock Function ......................................................................................... 13
7-2-1 Standard Specification ............................................................................. 13
7-2-2 US Specification ...................................................................................... 14

Chapter 8 Hazardous Area .................................................................................................... 15

8-1 Machine Movable Area .......................................................................................... 15
8-2 High-voltage Area .................................................................................................. 16

Chapter 9 Safety Precautions for Fire Prevention .............................................................. 17

9-1 Around the Machine ............................................................................................... 17
9-2 Coolant ................................................................................................................... 17
9-3 Flammable Material Cutting .................................................................................. 18
9-4 Dry Cutting ............................................................................................................. 18
9-5 Preventive Measures for Tracking Phenomenon ................................................... 18
9-6 Measures and Action to Take against Fire ............................................................. 19

Chapter 10 Notes on Coolant Selection .................................................................................. 20

Contents

Chapter 11 Safety Precautions ................................................................................................ 21

11-1 Basics ..................................................................................................................... 21
11-2 Installation .............................................................................................................. 22
11-3 Turning Power ON/OFF ........................................................................................ 24
11-4 Warming Up ........................................................................................................... 24
11-5 Setting Up ............................................................................................................... 25
11-6 Operation ................................................................................................................ 26
11-7 Finishing Operation ................................................................................................ 29
11-8 Maintenance ........................................................................................................... 30
 Contents

Specifications
Chapter 1 Machine Appearance ............................................................................................. 1
1-1 Name of Each Component ....................................................................................... 1
1-2 Dimensional Drawing .............................................................................................. 2

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

2-1 Standard Specifications ............................................................................................ 3
2-2 Standard Accessories and Optional Attachments .................................................... 4

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

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

Chapter 4 Major Unit .............................................................................................................. 7

4-1 Headstock Unit ......................................................................................................... 7
4-1-1 Spindle ....................................................................................................... 7
4-1-2 Spindle Nose Drawing ............................................................................... 8
4-1-3 Chuck Mounting Drawing ......................................................................... 9
4-1-4 Spindle Motor Characteristic Diagram .................................................... 10
4-2 Turret Unit .............................................................................................................. 11
4-2-1 Tooling System Drawing ......................................................................... 11
4-2-2 Turret Interference ................................................................................... 12
4-3 Slide Unit ............................................................................................................... 13
4-3-1 Stroke Diagram ........................................................................................ 13
4-4 Hydraulic Pump Unit ............................................................................................. 14
4-4-1 Assembly Drawing of Hydraulic Pump Unit ........................................... 14
4-4-2 Hydraulic Circuit Diagram ...................................................................... 15
4-4-3 Arrangement of Valves ............................................................................ 16
4-5 Lubrication Unit ..................................................................................................... 17
4-5-1 Lubrication System Diagram ................................................................... 17
4-6 Coolant Unit ........................................................................................................... 18
4-6-1 Coolant System Diagram ......................................................................... 18

Chapter 5 Electrical Drawings .............................................................................................. 19

5-1 Electrical Circuit Diagram List .............................................................................. 19
5-2 Parts Arrangement in Electric Box ........................................................................ 20
5-3 Parts Arrangement in Operation Box ..................................................................... 21
5-4 Connection Diagram .............................................................................................. 22
5-5 Electric Circuit Diagrams ....................................................................................... 23
5-6 Electric Parts List ................................................................................................... 44
Contents

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

Chapter 2 Installation Procedure ........................................................................................... 3

Chapter 3 Preparation for Installation .................................................................................. 4

3-1 Environment ............................................................................................................. 4
3-2 Foundation ................................................................................................................ 4
3-3 Electrical Wiring ...................................................................................................... 5
3-4 Grounding Work ...................................................................................................... 6
3-5 Installation Space ..................................................................................................... 7

Chapter 4 Transportation ........................................................................................................ 8

Chapter 5 Cleaning of Machine ............................................................................................ 10

Chapter 6 Removing Slide Fixture ....................................................................................... 11

Chapter 7 Levelling ................................................................................................................ 12

Chapter 8 Checking the Amount of Oil ................................................................................ 14

Chapter 9 Power Connection ................................................................................................ 15

 Contents

Operation
Chapter 1 Outline of Machine ................................................................................................. 1
1-1 Name of Each Component ....................................................................................... 1
1-2 Structure of Operation Panel .................................................................................... 2
1-2-1 Machine Operation Panel .......................................................................... 2
1-2-2 CNC Operation Panel .............................................................................. 13

Chapter 2 Preparation for Operation .................................................................................. 19

2-1 Check Items before Turning Power ON ................................................................. 19
2-2 Turning Power ON ................................................................................................. 21
2-3 Check Items after Turning Power ON ................................................................... 22
2-4 Check-ups before Turning Power OFF .................................................................. 24
2-5 Turning Power OFF ............................................................................................... 25
2-6 Check-ups after Turning Power OFF ..................................................................... 26

Chapter 3 Manual Operation ................................................................................................ 27

3-1 Zero Point Return ................................................................................................... 27
3-2 Manual Feed ........................................................................................................... 29
3-2-1 Jog Feed ................................................................................................... 29
3-2-2 Rapid Traverse ......................................................................................... 30
3-2-3 Handle Feed ............................................................................................. 31
3-3 Turret Indexing ....................................................................................................... 32
3-4 Chuck Open/Close ................................................................................................. 33
3-4-1 Changing the Chuck Gripping Direction ................................................. 33
3-5 Spindle Rotation and Stop ...................................................................................... 34
3-6 Coolant Discharge .................................................................................................. 36

Chapter 4 MDI Operation ..................................................................................................... 37

4-1 Preparation for MDI Operation .............................................................................. 37
4-1-1 Switches and Keys Used .......................................................................... 37
4-1-2 MDI Screen .............................................................................................. 38
4-2 Spindle Rotation and Stop (continued from step 2 in 4-1-2) ................................. 39
4-3 Turret Indexing (continued from step 2 in 4-1-2) .................................................. 41
4-4 X-/Z-axis Travel (continued from step 2 in 4-1-2) ................................................ 42

Chapter 5 Automatic Operation ........................................................................................... 44

5-1 Preparation for Automatic Operation ..................................................................... 45
5-1-1 Process of Starting Automatic Operation ................................................ 45
5-1-2 Conditions for Starting Automatic Operation .......................................... 46
Contents

5-2 Program Check ....................................................................................................... 48

5-2-1 Test Running ............................................................................................ 48
5-3 Trial Cutting ........................................................................................................... 49
5-4 Pause and Restart of Automatic Operation ............................................................ 50
5-4-1 Pause of Automatic Operation ................................................................. 50
5-4-2 Restart of Automatic Operation ............................................................... 50
5-5 Manual Operation during Automatic Operation .................................................... 51
5-6 MDI Operation during Automatic Operation ......................................................... 52
5-7 Program Editing ..................................................................................................... 53
5-7-1 Inputting a Program ................................................................................. 54
5-7-2 Calling a Program .................................................................................... 57
5-7-3 Displaying a Program Library ................................................................. 58
5-7-4 Deleting a Program .................................................................................. 59
5-7-5 Searching ................................................................................................. 61
5-7-6 Deleting a Word or Block ........................................................................ 63
5-7-7 Inserting a Word ...................................................................................... 65
5-7-8 Altering a Word ....................................................................................... 66
5-7-9 Inserting a Comment ................................................................................ 67

Chapter 6 Setting Up .............................................................................................................. 70

6-1 Tooling ................................................................................................................... 70
6-2 Tool Offset ............................................................................................................. 72
6-3 Tool Wear Offset .................................................................................................... 77
6-4 Mounting the Power Chuck (Part Order) ............................................................... 78
6-5 Mounting the Collet Chuck (Part Order) ............................................................... 80
6-6 Forming Soft Jaws .................................................................................................. 82
6-6-1 Precaution for Forming Soft Jaws ........................................................... 82
6-6-2 Forming Soft Jaws in Manual Operation ................................................. 84
6-6-3 Forming Soft Jaws in Automatic Operation ............................................ 86

Chapter 7 Appendix ............................................................................................................... 89

7-1 List of G Codes ...................................................................................................... 89
7-2 List of M Codes ...................................................................................................... 91
7-3 Variable Timer List ................................................................................................ 93
 Contents

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

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

2-1 Check Items before Turning Power ON ................................................................... 2
2-2 Check Items after Turning Power ON ..................................................................... 4

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

3-1 Weekly Inspection .................................................................................................... 6
3-2 Monthly Inspection .................................................................................................. 6
3-3 Every Two Months Inspection ................................................................................. 7
3-4 Semiannual Inspection ............................................................................................. 7
3-5 Yearly Inspection ..................................................................................................... 8
3-6 Every Three Years Inspection .................................................................................. 8

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

4-1 List of Oils ................................................................................................................ 9
4-2 Lubrication Unit ..................................................................................................... 12
4-3 Hydraulic Pump Unit ............................................................................................. 13
4-4 Coolant Unit ........................................................................................................... 14
4-5 Chuck (Part Order) ................................................................................................. 16

Chapter 5 Troubleshooting .................................................................................................... 17

5-1 Initial Measures ...................................................................................................... 17
5-2 Alarm Display ........................................................................................................ 18
5-2-1 Alarm Display Sections ........................................................................... 18
5-2-2 Alarm Message Screen and Help Function ............................................. 19
5-3 Check Sheet ............................................................................................................ 20
5-4 Resetting Emergency Stop ..................................................................................... 21
5-5 Phenomenon and Remedy of Major Problems ....................................................... 22
5-6 Resetting Overtravel ............................................................................................... 27
5-6-1 When Soft Limit is Actuated: .................................................................. 27
5-7 Self-diagnosis Procedures ...................................................................................... 28
5-7-1 Displaying Diagnosis Screen ................................................................... 28
5-7-2 Reading the Signal Address Table ........................................................... 30
5-8 Parameter Setting and Change ............................................................................... 31
5-8-1 Parameter Reference ................................................................................ 31
5-8-2 Parameter Setting (Change) ..................................................................... 33
Contents

Chapter 6 Maintenance for Each Unit ................................................................................. 35

6-1 Headstock ............................................................................................................... 35
6-1-1 Adjusting Chuck Pressure ........................................................................ 35
6-1-2 Chuck Pressure Setting Table for Cylinder ............................................. 36
6-1-3 Adjusting the Belt .................................................................................... 37
6-1-4 Replacing the Belt .................................................................................... 39
6-1-5 Aligning the Headstock ........................................................................... 41
6-1-6 Replacing the Position Coder .................................................................. 43
6-2 Slide Unit ............................................................................................................... 44
6-2-1 Replacing Wipers ..................................................................................... 44
6-2-2 Measuring and Compensating Backlash .................................................. 46
6-2-3 Slide Reference Point Setting .................................................................. 48
6-2-4 Settings for Collision Detection Function ............................................... 51
6-3 Turret Unit .............................................................................................................. 52
6-3-1 Measuring Turret Parallelism .................................................................. 52
6-3-2 Adjusting the Turret Clamp Proximity Switch ........................................ 54
6-3-3 Returning the Turret to the Origin Point .................................................. 55
6-3-4 Setting the Turret Zero Point ................................................................... 56
6-4 Hydraulic Pump Unit ............................................................................................. 58
6-4-1 Cleaning the Oil Filler Filter .................................................................... 58
6-4-2 Cleaning the Strainer ............................................................................... 59
6-4-3 Cleaning the Hydraulic Tank ................................................................... 60
6-4-4 Adjusting Discharge Pressure .................................................................. 61
6-5 Lubrication Unit ..................................................................................................... 62
6-5-1 Cleaning the Oil Filler Filter .................................................................... 62
6-5-2 Cleaning the Suction Filter ...................................................................... 63
6-5-3 Cleaning the Lubricant Tank ................................................................... 64
6-6 Coolant Unit ........................................................................................................... 65
6-6-1 Cleaning the Coolant Tank ...................................................................... 65
6-7 Electric Cabinet ...................................................................................................... 67
6-7-1 Replacing the Battery .............................................................................. 67
6-7-2 Replacing the Fuse ................................................................................... 69
6-7-3 Resetting the Thermal Relay ................................................................... 71
6-8 CNC Control Unit .................................................................................................. 72
6-8-1 CNC Screen Auto-Off Function .............................................................. 72
 Contents

Special Version

A. Chuck Clamp Detector

B. Chip Conveyor

C. TAKAMAZ Custom Functions

Chapter 1 Screen Configuration and Functions .................................................................... 1
1-1 Starting Condition Screen ........................................................................................ 1
1-2 Maintenance Function Screen .................................................................................. 2

Chapter 2 Details of Starting Condition Screens .................................................................. 3

2-1 START CONDITION CHECK Screen ................................................................... 3
2-2 START CONDITION SETTING Screen ................................................................ 5

Chapter 3 Details of Maintenance Function Screens ............................................................ 7

3-1 MAINTENANCE MENU Screen ............................................................................ 7
3-2 PERIODICAL INSPECTION Screen ...................................................................... 8
3-2-1 STATE Screen ........................................................................................... 8
3-2-2 SETTING Screen ....................................................................................... 9
3-2-3 DETAIL Screen ....................................................................................... 10
3-2-4 List of Inspection Items ........................................................................... 11
3-3 SIGNAL OUTPUT Screen .................................................................................... 12
3-4 COLLATION Screen ............................................................................................. 13
3-4-1 CNC PARA COLL Screen ...................................................................... 14
3-4-2 PMC PARA COLL Screen ...................................................................... 16
3-5 SAVE/LOAD Screen ............................................................................................. 18
3-5-1 SAVE Screen ........................................................................................... 19
3-5-2 LOAD Screen .......................................................................................... 20
3-5-3 Loading File Name Selection Screen ...................................................... 21
Safety Guide
Safety Guide Contents

Contents

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

Chapter 2 Outline of Machine ................................................................................................. 3

Chapter 3 Disposal of the Machine and Oil ........................................................................... 4

Chapter 4 Preparation for Safe Operation ............................................................................ 5

Chapter 5 Name of Each Component ..................................................................................... 8

Chapter 6 Warning Labels ...................................................................................................... 9

Chapter 7 Safety Devices ....................................................................................................... 11

7-1 Functions of Safety Devices ................................................................................... 11
7-2 Door Interlock Function ......................................................................................... 13
7-2-1 Standard Specification ............................................................................. 13
7-2-2 US Specification ...................................................................................... 14

Chapter 8 Hazardous Area .................................................................................................... 15

8-1 Machine Movable Area .......................................................................................... 15
8-2 High-voltage Area .................................................................................................. 16

Chapter 9 Safety Precautions for Fire Prevention .............................................................. 17

9-1 Around the Machine ............................................................................................... 17
9-2 Coolant ................................................................................................................... 17
9-3 Flammable Material Cutting .................................................................................. 18
9-4 Dry Cutting ............................................................................................................. 18
9-5 Preventive Measures for Tracking Phenomenon ................................................... 18
9-6 Measures and Action to Take against Fire ............................................................. 19

Chapter 10 Notes on Coolant Selection .................................................................................. 20

Chapter 11 Safety Precautions ................................................................................................ 21

11-1 Basics ..................................................................................................................... 21
11-2 Installation .............................................................................................................. 22
11-3 Turning Power ON/OFF ........................................................................................ 24
11-4 Warming Up ........................................................................................................... 24
11-5 Setting Up ............................................................................................................... 25
11-6 Operation ................................................................................................................ 26
11-7 Finishing Operation ................................................................................................ 29
11-8 Maintenance ........................................................................................................... 30
Safety Guide Chapter 1 Basic Conditions for Safe Operation

Chapter 1 Basic Conditions for Safe Operation

The following are the basic conditions that must be strictly observed.

Only qualified personnel should do the handling of the machine.

Those who can operate and maintain the machine should be furnished with the necessary training,
be knowledgeable about safe operation, and be qualified by an authorized person in safety
maintenance.
Establish in-shop regulations for qualification standards. Electrical maintenance in particular
should be carried out by qualified personnel as stated in nationally recognized safety standards and
legal and governmental regulations.
Our company shall not be responsible for any incidental or consequential damages to the machine,
or bodily injuries resulting from any abuse, misuse, misapplication or improper operation by
unqualified personnel.

Read the instruction manual carefully and understand the contents thoroughly.

The machine is equipped with various manuals for safe operation. These manuals cover all the right
procedures and prohibited items concerning machine operation, program creation and maintenance.
These should be read carefully before starting operation. Our company shall not be responsible for
any incidental or consequential damages to the machine or bodily injuries resulting from any abuse,
misuse, misapplication or improper operation by an unknowledgeable operator.

Always keep the attached manuals besides the machine.

Assign someone to keep the manuals at a designated place beside the machine so that they can be
used by anybody anytime. If any of the manuals become illegible or lost, contact your local
distributor for replacement. Inform us of the machine model and serial number so that the correct
manual can be sent to you at your cost.

1
Chapter 1 Basic Conditions for Safe Operation Safety Guide

All the persons in charge of machine operation should be aware of the emergency stop
button locations, functions and operation.

Procedures for communication and necessary measures should be discussed in case of emergency,
and stated in the in-shop regulations.

Emergency stop button

Pressing this button stops all the
machine motions immediately.

Fig. 1

* If you have any questions or doubts about the safety instructions described in this instruction manual, feel
free to contact your local distributor at any time.

2
Safety Guide Chapter 2 Outline of Machine

Chapter 2 Outline of Machine

This machine is a machine tool which is called an "NC lathe".

The machine rotates the workpiece mounted on the spindle while applying a tool to the workpiece to
perform turning operation.
Workpiece positions and motions are expressed numerically to instruct and control (NC: numerical
control) the machine.

WARNING Do not use the machine for any purpose other than as stated above.

Fig. 2

3
Chapter 3 Disposal of the Machine and Oil Safety Guide

Chapter 3 Disposal of the Machine and Oil

When disposing of the machine, follow governmental rules and regulations. Hydraulic oil and
coolant disposal is also obliged by statute to follow the rules and regulations. If you have any
questions, please feed free to contact Takamatsu.

4
Safety Guide Chapter 4 Preparation for Safe Operation

Chapter 4 Preparation for Safe Operation

Check the following points to operate the machine safely.

Installation • Avoid direct sunlight or heat source which will generate a partial
environment temperature rise.
- Ambient temperature: 0 - 45°C (20°C ± 2 is most recommended.)
- Change in temperature: Max. 1°C/min.
- When using the machine in the ambient temperature of 40°C or higher,
lighten the load (cutting conditions, etc.) applied to the machine to avoid
overheating of motors.
• Keep apart from other machines which may splash water, oil or chips.
• Keep apart from press machines and forging machines to prevent
transmission of vibration.
- Installation site should be below 0.5 G. Take anti-vibration measures if
necessary.
• Humidity should be below 75% without dew condensation.
• Install the machine at an altitude lower than 1000 m.
• Installation site should be free from dust, mist, salt, corrosive gas and
other hazardous elements.
• The foundation of the machine should have sufficient strength without
inclination or unevenness.
• If this machine is used in the residential environment, it may adversely
affect other products. To avoid disturbing radio or television broadcast
airwaves, take action to reduce electromagnetic emission or refrain from
using the machine in such an environment.

Installation • Use cranes and forklifts which have passed in examinations prescribed in
and relocation nationally recognized safety standards and legal and governmental
regulations.
• Lifting unit and wire rope should be of the specified size without damage.
• Handling of cranes, forklifts as well as slinging work should be done by
qualified persons.
• Lifting and transportation of the machine should be done without giving
any vibration or shock.
• Avoid direct sunlight or heat source which may cause a local temperature
rise during transportation or storage.
- Ambient temperature: −10 to 50°C
• Humidity should be below 75% without dew condensation during
transportation and storage.
• Transport or store the machine at an altitude lower than 10000 m.

5
Chapter 4 Preparation for Safe Operation Safety Guide

Power source • Electrical connection should be done by qualified electrical engineers.

and grounding • Power voltage: 3-phase 200/220 V ±10%
Frequency: 50/60 Hz ± 2 Hz
The power cable must satisfy the following conditions:
Power cable Terminal screw Total power
(Single wire) size capacity

8 mm2 or greater M5 12 kVA 34 A

• Keep apart from noise sources, such as welding machines, electric

discharge machines, etc.
• Comply with nationally recognized electrical standards and legal and
governmental regulations on grounding.
- Never use a grounding electrode together with a machine which may
generate noise.
- Independently ground the machine to an electrode.
- The grounding resistance must be 100 Ω or smaller.
- The grounding cable must satisfy the following conditions:
Grounding cable Terminal screw
(Single wire) size

8 mm2 or greater M5

* For the optional specifications, the electric cables (power cable and grounding
cable) to use may be different in thickness. Contact Takamatsu before
connecting the electric cables.

Lubrication • Use designated oil.

• Never mix oils of different manufacturers.
• Never use deteriorated oil or oil mixed with foreign objects.

Compressed • Use clean and dry compressed air.

air • Amount of air to supply should be over the designated level.

6
Safety Guide Chapter 4 Preparation for Safe Operation

Machine • The floor should be free from obstacles to machine operation.

environment • The floor should be free from water and oil.
• The working area should be bright enough to ensure safe operation.
If not sufficient, use a work light.
• When connecting external equipment, provide a cover or safety enclosure
around the machine movable area to protect operators from touching the
machine.
• Installation site should be equipped with devices for air ventilation,
deodorization and exhaust.
• Provide the work place with appropriate ventilators or exhausting units to
clear away dust or gas (flammable gas). If sufficient ventilation is not
assured, do not use the machine.
• Designated fire extinguishers should be provided at specified places near
the machine.
• Prepare a first aid kit at a designated place near the machine.
• Keep sufficient maintenance area around the machine so that:
- opening/closing of the doors can be done easily.
- loading/unloading of workpieces can be done easily.
- oiling, chip disposal and chip conveyor operation can be done easily.

Operator's • Wear a protective helmet, safety shoes and safety goggles that comply
clothing with the necessary safety regulations.
• Never wear gloves, a ring, a bracelet, a watch, or clothes that are baggy or
loose and may be caught up by the machine.
• Long hair should be tied or covered with a hat to avoid accidents during
operation.
• Those who feel dizzy and cannot judge properly due to drinking,
medication or sickness should not operate the machine.
• Use leather gloves or the like to protect operator's hands during setting
up. However, the key and switch operation should be done with bare
hands.

Safety control • The instruction manual and the safety guide should be kept by authorized
system personnel at a designated place near the machine so that they can be
accessed at any time.
• A supervisor for safety control should be responsible for training
operators periodically so that environmental conditions can be checked at
any time for safety operation.

7
Chapter 5 Name of Each Component Safety Guide

Chapter 5 Name of Each Component

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

NC screen
CNC operation panel Machine operation panel

Front door

Turret

Spindle

Lubrication unit

Foot switch
Operator's position

Electric cabinet

Main power switch

* The shape may differ
depending on the
specifications.

Coolant pump motor

Coolant tank Hydraulic pump unit Absolute pulse coder

battery case

Fig. 3

8
Safety Guide Chapter 6 Warning Labels

Chapter 6 Warning Labels

The machine is equipped with warning labels for safe and correct operation. Read and understand
the cautions printed on the warning labels before starting operation.
If any of the labels become damaged and illegible, contact your local distributor for
replacement.

WARNING Never remove or relocate warning labels.

(4)

(5)

(5)

(A)

(6)

(4)
(2)

(3) (4)
(1)
(4) (5)
(4)

(5)
(5)

(4)

(6)

Fig. 4

9
Chapter 6 Warning Labels Safety Guide

(A) (1)

3151900500

3128913800

(2)

3151900400

(3) (5)

WARNING
(4) NEVER open this cover.
Only qualified service
personnel can have
access. Shut the
machine off before
servicing.
3105107200
2216001012
2669507002

(6)

6147104001

10
Safety Guide Chapter 7 Safety Devices

Chapter 7 Safety Devices

7-1 Functions of Safety Devices

The machine is equipped with various safety devices as shown below to protect both an operator and
the machine from injuries and damage.
Check and understand the location of each safety device and its functions before starting operation.

• Never remove or modify safety devices, or stop their functions

DANGER
without our permission in advance.
• The covers without open/close switch and the doors of the electric
cabinet should not be opened by unauthorized personnel.
• Before starting operation, check that each safety device can function
WARNING
properly. If there is any problem, contact your local distributor
immediately.

Program edit switch

Protects programs from being modified by
mistake.

Door interlock switch

Stops the spindle rotation and the slide
motion if the front door is opened during
automatic operation.
Operation switch (with key)
(US specification) MC ALARM lamp
Protects programs from being modified Lights up if an error has arisen in the
by mistake. It also protects the program components.
even when the operation panel is
accidentally touched. MC WARNING lamp
Lights up when lubricant in the tank
becomes insufficient.
Door interlock release switch
(US specification)
Disables you to open the front door
unless this switch is held down.
During automatic operation or spindle
rotation, the front door cannot be opened
even if the this switch is held down.

Emergency stop button

Stops all the machine
motions immediately.

Front door
Reinforced cover to prevent chips,
workpieces and jaws from splashing

Fig. 5

11
Chapter 7 Safety Devices Safety Guide

5. Hydraulic pressure switch

(US specification)
1. Turret clamp limit
switch

4. Chuck clamp detector

(US specification)

3. Door close confirmation

sensor

2. Lubrication float
switch

DANGER Never disable the door interlock switch.

Checks a clamping motion of the turret. Automatic operation cannot be started without a clamp
1
confirmation.

Checks the presence or absence of the Automatic operation cannot be started without lubricant.
2
lubricant.

3 Checks if the door is closed. Automatic operation cannot be started if the door is opened.

Checks if the chuck is opened or closed. Automatic operation and spindle rotation are not allowed
4
(US specification) unless the switch is turned on.

Checks the hydraulic pressure. Automatic operation cannot be started if the cylinder
5
(US specification) pressure is low.

Fig. 6

12
Safety Guide Chapter 7 Safety Devices

7-2 Door Interlock Function

7-2-1 Standard Specification

The door interlock function restricts machine operation that can be performed the front door open.
* In this manual, explanations on machine operating procedures are given on the assumption that the door
interlock switch is set to "ON". However, the front door open/close condition is not specified explicitly in
the explanations. Refer to the following restrictions before operation.
* The door interlock function is enabled or disabled by the setting at [DR ITLK] on the software operator's
panel screen. By operating the door interlock switch, some restrictions on machine operation, imposed by
the door interlock function, can be canceled.
* When the door interlock switch is set to "OFF", the message "CAUTION. DOOR INTERLOCK SWITCH IS
OFF." is displayed and the MC WARNING lamp starts blinking.

For details about the software operator's panel screen, refer to FANUC OPERATOR'S MANUAL.

Door interlock switch

Enables (ON) or disables (OFF) the door

interlock function.

When performing manual operation with the front door open, exert added
WARNING
care for your own safety.

Door interlock switch

Operations with the Front Door Open
ON OFF

Automatic operation Disabled Enabled

MDI operation Disabled Enabled

Manual operation Spindle rotation Disabled Enabled

Axis travel (X/Z) Disabled Enabled

Rapid traverse (X/Z) Disabled Enabled

(low speed)

Turret rotation Disabled Enabled

(low speed)

Coolant discharge Disabled Enabled

Air blow (optional) Disabled Enabled

Chip conveyor operation (optional) Disabled Enabled

13
Chapter 7 Safety Devices Safety Guide

7-2-2 US Specification

The door interlock function restricts machine operation that can be performed the front door open.
When the DOOR ITLK RELEASE (door interlock release) switch is pressed, door interlock is
released (door open state).
* In this manual, explanations on machine operating procedures are given on the assumption that the
DOOR ITLK RELEASE (door interlock release) switch is set in the “OFF” position. However, the front door
open/close condition is not mentioned explicitly in the explanations. Refer to the following restrictions
before operation.
* Some restrictions on machine operation by the door interlock function can be canceled by operating the
DOOR ITLK MCATM/SETM (machine operation mode) switch and the DOOR ITLK RELEASE (door
interlock release) switch on the operation panel.

When performing manual operation with the front door open, exert added
WARNING
care for your own safety.

Machine operation mode selector switch

DOOR ITLK RELEASE (door

interlock release) switch

Machine operation mode +

DOOR ITLK RELEASE
Operations with the front door open Cutting (MCATM) + Setting (SETM) + ON
ON (with the switch (with the switch held
held down) down)
Automatic operation Disabled Disabled

MDI operation Disabled Disabled

Manual operation Spindle rotation Disabled Enabled *1

Axis travel (X/Z) Disabled Enabled

Rapid traverse (X/Z) Disabled Enabled (low speed)

Turret rotation Disabled Enabled (low speed)

Coolant discharge Disabled Enabled

Air blow (optional) Disabled Enabled

Chip conveyor operation (optional) Disabled Enabled *2

*1: Inching operation (at 50 min−1 or less)

*2: Inching operation

14
Safety Guide Chapter 8 Hazardous Area

Chapter 8 Hazardous Area

8-1 Machine Movable Area

It is very hazardous inside the machine during automatic operation because of high-speed spindle
(chuck) rotation, X/Z-axis movements and turret rotation. Besides, chips and coolant splash in a hot
and humid space.

Never open any cover or door mounted on the machine during automatic
WARNING
operation and spindle rotation. Even in any status other than automatic
operation, utmost care should be taken if it is needed to enter such a
hazardous area or touch movable sections for setting up or maintenance
work while the power is turned on.

Inside the front door is hazardous.

Fig. 7

15
Chapter 8 Hazardous Area Safety Guide

8-2 High-voltage Area

The electric cabinet, motors, and relay boxes (connectors) have high-
DANGER
voltage terminals. Maintenance of these units should be done only by the
authorized personnel for electrical construction.

Never put a part of your body below the electric cabinet door when
CAUTION
removing the door. The electric cabinet door may come off, resulting in
injury.

Inside the electric cabinet is hazardous.

• A tool (screwdriver) is necessary to
remove the door.

Coolant pump motor

power connector

(Inside the electric cabinet)

Hydraulic pump motor
power connector Never touch the area marked with even
if the main power switch is off, as high-
voltage of 200 V is supplied up to the main
power switch when the power in the factory
is turned on. Failure to observe this
warning will result in critical bodily injuries.

* The shape of the main power switch may differ depending

on the specifications.

Fig. 8

16
Safety Guide Chapter 9 Safety Precautions for Fire Prevention

Chapter 9 Safety Precautions for Fire Prevention

To perform machine operation continuously in safety, follow the precautions for fire prevention
described below.

9-1 Around the Machine

The following precautions must be observed to prevent a fire.

1. Do not smoke around the machine.
2. Do not conduct work that causes sparks, such as welding, around the machine.

9-2 Coolant

When coolant is used for cutting, there is a possibility of catching a fire

WARNING
from high-temperature chips, frictional heat at the tool, sparks during
cutting, etc.
Follow the safety precautions described below and take sufficient
measures to prevent fire.

1. Use non-flammable coolant.

Even if non-flammable coolant is used, lubricant may be mixed into coolant. Follow item 3.
and take sufficient measures for safety.
2. Examine coolant properties (ignition point, viscosity, etc.), and select appropriate cutting
conditions to prevent ignition.
3. If oil-based coolant must be used unavoidably:
1) Check the tool edge condition as well as possible tool life, and select cutting conditions
under which no ignition will occur.
2) An insufficient amount of coolant could cause fire. Always check the amount of coolant.
3) To assure a sufficient amount of coolant at the point of cutting, clean the coolant filter at
regular intervals, and check that coolant is sufficiently discharged from time to time.
4) Provide a fire extinguisher nearby, and always stay alert to fire. Also, take additional
precautions against fire by installing an automatic fire extinguisher, etc.
5) Do not place any flammable things around the machine.
6) Do not allow chips to accumulate.
7) Clean the inside and surrounding of the machine at regular intervals, and check that every
equipment is working in good order.
8) Do not perform unattended operation.
9) Install an automatic fire extinguisher.

17
Chapter 9 Safety Precautions for Fire Prevention Safety Guide

9-3 Flammable Material Cutting

When cutting flammable material (solid), resin, rubber or wooden material, understand properties of
the material and take appropriate measures against fire.

9-4 Dry Cutting

Do not allow chips to accumulate during dry cutting.

Follow item 3. described in 9-2 and take sufficient measures for safety.

9-5 Preventive Measures for Tracking Phenomenon

When dust accumulates on connectors of an electric device (outlet or connecting terminal) under
humid circumstances, a tiny electrical current flows between terminals causing sparks.
If this situation occurs repeatedly, a carbonized route, i.e., a track, is formed on the connector
resulting in a fire. This phenomenon is called a "tracking phenomenon".

Electric device Connecting terminal

Carbonized route (track)

Dust, moisture

To prevent a fire caused by a tracking phenomenon, be sure to take measures described below.

Safety measures against tracking phenomena

1. Remove accumulated dust from connectors of electric devices every two months.
* Excessive humidity may cause a tracking phenomenon.

See "Chapter 3 Periodical Inspection" in "Maintenance".

2. Do not take any action that might cause breakage of electric cables.
1) Do not damage electric cables.
2) Do not make any modification to electric cables.
3) Keep electric cables away from heat sources.
4) Do not bend electric cables forcibly.
5) Do not place a heavy item on electric cables.
3. Do not touch any electric cables with wet hands.

18
Safety Guide Chapter 9 Safety Precautions for Fire Prevention

9-6 Measures and Action to Take against Fire

1. If you suspect a risk of fire or find an inadequacy in fire prevention measures, immediately stop
the machine and contact your local distributor.
2. If a fire occurs during attended operation, secure your own safety, and take action to extinguish
a fire as soon as possible, such as using a fire extinguisher or manually activating an automatic
fire extinguisher according to the situation.

19
Chapter 10 Notes on Coolant Selection Safety Guide

Chapter 10 Notes on Coolant Selection

When selecting coolant to use with this machine, be sure to note the following points.

Using any type of coolant described below may cause corrosion,

WARNING
deterioration or failure of parts in the units (NC unit, motor, amplifier,
spindle, slide, turret, splash guard, etc.) of the machine.
* Any machine faults that stem from the use of the following coolant types are not
covered by warranty.
* Corrosion, deterioration, or failure of parts may occur even if protective measures
are taken against direct contact of coolant.

1. Coolant that contains highly active sulfur or chlorine

Coolant may chemically react with the material of the unit, such as resin, causing corrosion or
deterioration.
2. Synthetic coolant that contains a component such as PAG (polyalkylene glycol) with
high permeability
Even if the unit is tightly sealed, coolant may permeate into the unit, causing insulation
deterioration or failure of parts.
3. Strong-alkaline water-soluble coolant (pH 10 or higher)
If coolant contacts the unit or enters inside the unit, it may chemically react with the material of
the unit, such as resin, causing corrosion or deterioration.
* Some coolant may have a pH of 10 or higher (strong alkaline) at a normal dilution ratio if
alkanolamine is used to increase a pH.

20
Safety Guide Chapter 11 Safety Precautions

Chapter 11 Safety Precautions

11-1 Basics

• The electric cabinet, motors, and relay boxes (connectors) have high-
DANGER
voltage terminals. Access to these by unauthorized personnel is strictly
prohibited as it is very dangerous.
• Never remove or modify any covers, switches or doors mounted for
safety without our permission.
• Understand the operation switches and relative machine motions
thoroughly before operating them.
High-voltage mark
• Never use machine in an atmosphere having a possibility of explosion.
• Never touch on switches and keys with wet or dirty hand.

• Never operate any switches before you have realized their resulting
WARNING
motions.
• Check each switch and key before using them.
• Never touch any key or switch if not needed, or lean against the machine
unconsciously.
• Always be aware of the emergency stop button locations and operation so
that they can be operated quickly in emergency. This should be
understood by all the personnel concerned.
Emergency stop
button • Stop operating the machine in case of abnormal lightning or repeated
power failure in order to avoid accidents.
• Keep the floor clean and dry. Slippage can easily occur if there is oil or
water on the floor.
• Keep flammable materials and liquid away from the working area as
prescribed in nationally recognized safety standards and legal and
governmental regulations.
• The machine should be operated only by one qualified operator.
• Those who feel dizzy or cannot judge properly due to drinking,
medication or sickness should not operate the machine.

21
Chapter 11 Safety Precautions Safety Guide

• Oil to use should be new and clean, and as designated in the instruction
CAUTION
manual. Any oil other than specified may result in machine trouble.
• Replacement parts should be as designated by Takamatsu.
• Wear proper clothes for operation.
- Never wear a ring, a bracelet, a necklace or a watch during operation.
- Always wear a protective helmet, safety goggles and safety shoes.
- Never wear baggy or loose clothes.
• Turn off the main power switch immediately in case of power failure.
• Do not apply any load exceeding the load capacity of the machine cover
or safety device.
• Never give an excessive shock to the machine operation panel or the
electric cabinet.
• Keep the tools and workpieces orderly in the following ways.
- Keep them so that they may not fall.
- When placing tools and parts upright or resting against something, take
necessary measures to prevent them from falling.
- When piling parts and workpieces up, take necessary measures to prevent
them from falling off.
• Never place tools and workpieces anywhere on the machine even if it is
not a movable section.
• Keep sufficient working area and remove obstacles from around the
machine.
• A work table to place cutting tools and workpieces should be rigid
enough and so designed to prevent tools and workpieces from slipping or
falling.
• Coolant has irritating properties and is harmful to humans. Avoid direct
contact with coolant. In particular, potentially allergic operators must not
handle coolant.
• Never operate the machine while wearing gloves.
(Use gloves when handling cutting tools, workpieces, chips and when
cleaning the machine.)

11-2 Installation

• Power connection, crane and forklift operation and slinging work should
DANGER
be done only by qualified personnel.
• Never put your body partially or wholly under the lifted machine.
• When placing electric cables over the floor, use rigid covers to protect
them from being damaged by chips and workers.

22
Safety Guide Chapter 11 Safety Precautions

• Transportation and installation of the machine should be done by

WARNING
qualified personnel according to "Installation".
• Power cables from the primary terminal in the factory to the main power
switch should have a rated cross sectional area in order to supply stable
power required for operation.
• Check the following points to ensure safety at the installation site.
- When foundation bolts are buried, mark these points clearly to protect
workers from stumbling over and to protect the machine and carriages from
bumping.
- When a pit is provided for waste oil, chips and piping, mount a tentative
cover to protect workers from falling down.
- The floor should be clean and dry, and free from obstacles, oil and waste oil
in order to protect workers from slipping or falling.
• Use a stable step or platform when it is needed to reach a high level.
• Never put your fingers between the bed and the floor when locating the
machine at a designated place.
• When lifting a machine, use wire rope, shackles and hoisting jigs that are
rigid enough to withstand the machine weight.
• When working in a team, choose a leader to give instructions.
- Give signals with one another to check other workers' safety before going to
the next step.
- Follow the procedures step by step.
• Never give excessive shock to the machine during lifting and
transporting.

• When rust preventive oil is applied to the slideways, remove it

CAUTION
thoroughly with cleaning oil before starting operation.
• Remove eye bolts used for transportation as well as other fixing jigs and
wood used as shipping brackets.
• Levelling of the machine should be accurate.
(Adjust levelling referring to the attached inspection sheet.)
• When installation is finished, check the following points before turning
the power on.
- All the bolts and connectors are securely tightened.
- Hydraulic hose, air hose and other piping are securely connected and fixed.
- New grease and oil are properly supplied to each section as instructed.
- Water and dust on the machine are all wiped off.
- There is no oil leakage around the machine.

23
Chapter 11 Safety Precautions Safety Guide

11-3 Turning Power ON/OFF

• Check connectors of electric devices (e.g. work light) before turning the
DANGER
power on, and remove dust from them if required. (Periodically check
every two months.)
• Before turning the power on, check that all cables are properly insulated.
Damaged or disconnected cables should be immediately repaired or
replaced by qualified personnel, as they could cause an electrical shock or
leakage later.

• Turn the power on/off as described in "Operation".

WARNING
• Check that all the safety devices are properly functioning.
• Check that all the covers are free from damage and securely closed.
• Check that all the cables installed on the floor have protective covers or
other means to protect them from being damaged.

• Check the following items after turning the power on.

CAUTION
- Check that there is no alarm display on the NC screen.
- Check that hydraulic pressure and air pressure are correctly set.
- Check that there is no abnormal noise generated from the motors or gears.
- Check that the spindle and slideways are properly lubricated.
• Check all the items for starting operation one by one as described in
"Maintenance".
• After stopping the machine for a long period of time, check that the
motions, noise and slideway lubrication are free from trouble. If any
abnormality is found, turn off the power immediately and inform the
person in charge, then take necessary measures.

11-4 Warming Up

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

CAUTION
- Mount no workpiece at this time.
- Programs for automatic operation should include each function of the
machine.
- Change the spindle speed from low (500 min-1) to intermediate (2500 min-1),
and warm up for about 10 minutes at each speed.
- Before rotating the spindle with a chuck on it, check that the chuck and jaws
are securely fixed.

24
Safety Guide Chapter 11 Safety Precautions

11-5 Setting Up

• Operation of crane and forklifts as well as slinging work should be done

DANGER
only by qualified personnel.
• Setting up should be done after turning the main power switch off. If the
main power switch should remain on, be aware of the location of an
emergency stop button to press at any time.

• Always wear a protective helmet during setting up and cleaning.

WARNING
• When working at a high level, use a stable platform, steps or ladders.
• When working in a team, give signals with one another and check given
signals before going to the next step. Do not go to the next step if there is
no response from your partner.
• Never stand or work on the machine. If it is needed to stand on the
machine, wear a protective helmet, leather gloves and other protective
clothes.
• Use proper hoisting devices to handle heavy items.
• Wire ropes and slings are rigid enough for a designated weight.
• Check that the wire rope to use is free from disconnection, abnormal
deformation, corrosion, kink, etc.
• Pay attention to the chuck when stepping on the foot switch so that a part
of your body may not be caught in it.
• Dull or unstable cutting tools will cause damage or accidents. Replace
with proper tools in advance.
• When mounting a workpiece, check that it is securely fixed by a chuck
and a jig. Tightening and loosening of jigs and bolts should be properly
done while keeping your balance so that you may not touch or fall over
hazardous part of the machine.
• Never stand in the rotating direction of the spindle, as the workpiece,
jaws or tools may fall off during setting up or trial running and cause
bodily injuries.

• Always wear leather gloves during setting up and cleaning.

CAUTION
• The length and diameter of the cutting tools should be appropriate so that
each cutting tool cannot interfere with the chuck, turret, cover, etc.
• Never touch cutting tools with bare hands.
• After finishing setting up, keep used tools and equipment in the
designated place.

25
Chapter 11 Safety Precautions Safety Guide

• When handling a heavy item of more than 20 kg, make a team for
CAUTION
cooperative work or use proper transporters.
• After mounting cutting tools on the turret, check that they are securely
fixed without backlash and well balanced.
• Tools used for setting up should be suitable for the machine
specifications. Spanners to use should fit nuts and bolts to avoid
accidental slippage

11-6 Operation

• Never remove a safety cover or safety device partially or wholly. It is

DANGER
strictly prohibited to operate the machine while exposing a high-voltage
terminal.
• Removing or relocating limit switches, dogs and interlocking mechanism
should be strictly prohibited.
• Never touch any switch or button with wet hands.

• High-speed moving sections, turret rotating section, and spindle rotating

WARNING
section should be isolated from operators during automatic or manual
operation. Access or entry to these areas during operation is strictly
prohibited. If it is needed to enter such an area for maintenance and other
purposes, turn off the power in the designated procedures.
• When machining a bar material without using a bar feeder, the bar
material should not stick out from the spindle rear as it is hazardous when
the spindle rotates.
• When chucking a workpiece, apply most suitable pressure to the chuck
and the turret according to the workpiece material, gripping amount and
machining conditions.
• When attaching a workpiece to the chuck, be careful not to get your
finger caught in the chuck.
• Check that the chuck rotation speed does not exceed the allowable range.
• Select cutting conditions (spindle speed or other conditions) carefully,
especially when cutting an unbalanced workpiece.
• After mounting a workpiece, ensure that it is securely clamped in the
chuck. In addition, carefully select cutting conditions. If the workpiece
comes off the chuck during cutting, it will collide with the protection
cover, causing damage to the protection cover.

26
Safety Guide Chapter 11 Safety Precautions

• Before starting unattended operation or leaving the machine for a long

WARNING
time, check the following points to prevent fire.
- Check that used coolant is nonflammable.
- Check that the amount of lubricant and coolant is sufficient, and its operation
is properly done.
- Check the tool cutting edge status, cutting conditions, cutting time and tool
life.
- Check there is no wood, paper, cloth and other flammables around the
machine.
- Check that the chip conveyor is properly operating and chips are smoothly
disposed of.
- Do not smoke around the machine.
- Do not conduct work that causes sparks, such as welding, around the
machine.

"Chapter 9 Safety Precautions for Fire Prevention"

• The following are strictly prohibited during machine operation. Stop the
machine first if any of the following is needed.
- Never adjust the coolant nozzle direction or coolant flow during spindle
rotation.
- Never remove chips around a tool during spindle rotation.
- Never replace or tighten a cutting tool on the turret during machine
operation.
- Never remove chips or clean the machine during operation.
- Never change the chuck pressure during machine operation.
• Never change the chuck gripping direction while a workpiece is chucked.
• Before unloading a finished workpiece, check that the spindle is stopped
and that automatic operation is finished.
• Never enter the chip conveyor working area during operation.
• Turn the main power switch off when suspending operation and leaving
the machine for a while.
• Close the front door tightly before starting automatic operation. Keep the
doors and covers on the machine closed during automatic operation.
• Before starting operation, check that there is nobody or nothing inside the
machine movable section.
• If the machine stops during automatic operation for some reason, check
the trouble status and take necessary measures before removing the
cause. Restarting before taking proper measures must be avoided.
• Noise during machining may exceed 70 dB, resulting in damaging your
hearing ability. Use protective articles (ear muffs, etc) as appropriate.
• Never touch any switch or key if not needed. Never lean against the
machine during automatic operation.

27
Chapter 11 Safety Precautions Safety Guide

• Never operate the machine while leaving a tool, cutter or measuring

CAUTION
instrument inside or around the machine.
• When starting automatic operation for the first time, check that the
program is correctly made and all the switches for automatic operation
(dry run, override, coolant control, etc.) are correctly set.
• Discharge chips regularly so that they may not remain inside the
machine.
• When machining special workpieces, check the characteristics in advance
and wear necessary protective clothes.
• Wear a smoke mask if smoke (oily smoke) may be generated.
• Note the following points so that you will not be caught in the machine
movable section.
- Long hair should be tied or covered with a helmet.
- Tie the hem of loose and baggy pants.
- Button up your clothes.
• If any abnormality is found during operation, stop the machine
immediately and inform the supervisor.
• Modification of parameter setting should not be done without our
permission.
• When an alarm message is displayed or an alarm indication lamp is
illuminating, take necessary measures immediately (such as informing a
person in charge).
• Chips should not be removed from the cutting edge with bare hands.
Always use gloves and a brush.
• Never touch tools or workpieces with hands immediately after cutting.
These can be extremely hot.
• Be sure not to touch the work light as it becomes very hot after operation
for a long time.
• Never touch any switch or button with gloves on, as it could result in
malfunction or damage to the machine.

28
Safety Guide Chapter 11 Safety Precautions

11-7 Finishing Operation

• After finishing all the operation, check that the primary power in the
DANGER
factory is completely turned off.
• Before cleaning the machine and peripheral equipment, such as a chip
conveyor, stop all the machine motions, turn off the main power switch
and the primary power in the factory, and put a tag or a placard saying
"Cleaning!".

• Never use an air gun for cleaning the machine, as it may allow coolant to
CAUTION
permeate into the spindle bearing and shorten the bearing life. Use soft
and clean cloth and clean the spindle carefully.
• When finishing operation, check that each section of the machine is in the
initial status.
• Wear gloves when removing chips and workpieces.
• Handle the solenoid valve carefully as it remains hot for a while even
after the power is turned off.
• When stopping the machine for a long period of time, apply rust
preventive oil slightly to ground surfaces.

29
Chapter 11 Safety Precautions Safety Guide

11-8 Maintenance

• Turn the main power switch off during maintenance work. The primary
DANGER
power in the factory should also be off for maintenance of the electric
cabinet. Never remove the electric cabinet door for five minutes, as
residual voltage remains.
• When carrying out maintenance work, put a panel or a plate indicating
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake.
• Never modify or remove safety devices such as limit switches, proximity
switches and dogs for interlock without our permission.

• The cover should not be opened by unqualified personnel for

WARNING
maintenance. Turn the main power switch off when it is needed to work
inside the cover.
• Wear a protective helmet during maintenance work.
• Use stable ladders, platform, etc., when working at a high level.
• Maintenance work should be done only by qualified personnel.
• Mount the covers on the initial positions correctly after finishing
maintenance work, and lock the doors with a key securely.
• After finishing maintenance work, keep the used tools, etc. orderly, and
remove all the obstacles, water and oil from the floor in order to restore
proper working environment.
• Procedures and methods described in "Maintenance" should be strictly
observed. Contact your local distributor immediately when any question
or doubt arises.
• If any maintenance work not described in this manual is required, contact
Takamatsu.

• Check each item after finishing maintenance work together with a person
CAUTION
in charge.
• Observe periodical check-ups as described in "Maintenance".
• Keep a maintenance record, and report it to a person in charge for
approval and examination.
• Keep the maintenance record for 10 years.
• Replacement parts (electrical and mechanical) should be as designated by
Takamatsu.

30
Specifications
Specifications Contents

Contents

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

1-1 Name of Each Component ....................................................................................... 1
1-2 Dimensional Drawing .............................................................................................. 2

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

2-1 Standard Specifications ............................................................................................ 3
2-2 Standard Accessories and Optional Attachments .................................................... 4

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

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

Chapter 4 Major Unit .............................................................................................................. 7

4-1 Headstock Unit ......................................................................................................... 7
4-1-1 Spindle ....................................................................................................... 7
4-1-2 Spindle Nose Drawing ............................................................................... 8
4-1-3 Chuck Mounting Drawing ......................................................................... 9
4-1-4 Spindle Motor Characteristic Diagram .................................................... 10
4-2 Turret Unit .............................................................................................................. 11
4-2-1 Tooling System Drawing ......................................................................... 11
4-2-2 Turret Interference ................................................................................... 12
4-3 Slide Unit ............................................................................................................... 13
4-3-1 Stroke Diagram ........................................................................................ 13
4-4 Hydraulic Pump Unit ............................................................................................. 14
4-4-1 Assembly Drawing of Hydraulic Pump Unit ........................................... 14
4-4-2 Hydraulic Circuit Diagram ...................................................................... 15
4-4-3 Arrangement of Valves ............................................................................ 16
4-5 Lubrication Unit ..................................................................................................... 17
4-5-1 Lubrication System Diagram ................................................................... 17
4-6 Coolant Unit ........................................................................................................... 18
4-6-1 Coolant System Diagram ......................................................................... 18
Contents Specifications

Chapter 5 Electrical Drawings .............................................................................................. 19

5-1 Electrical Circuit Diagram List .............................................................................. 19
5-2 Parts Arrangement in Electric Box ........................................................................ 20
5-3 Parts Arrangement in Operation Box ..................................................................... 21
5-4 Connection Diagram .............................................................................................. 22
5-5 Electric Circuit Diagrams ....................................................................................... 23
5-6 Electric Parts List ................................................................................................... 44
Specifications Chapter 1 Machine Appearance

Chapter 1 Machine Appearance

1-1 Name of Each Component

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

NC screen
CNC operation panel Machine operation panel

Front door

Turret

Spindle

Lubrication unit

Foot switch
Operator's position

Electric cabinet

Main power switch

* The shape may differ
depending on the
specifications.

Coolant pump motor

Coolant tank Hydraulic pump unit Absolute pulse coder

battery case

Fig. 1 Machine appearance and name of each component

1
Chapter 1 Machine Appearance Specifications

1-2 Dimensional Drawing

removing the chip conveyor

Space for installing/

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

Fig. 2 Dimensional drawing

2
Specifications Chapter 2 Machine Specifications

Chapter 2 Machine Specifications

2-1 Standard Specifications

Item Unit Specifications

Capacity Max. turning diameter mm φ180

Max. turning length mm 190

Max. bar diameter mm φ26 (hollow)

Chuck size inch 6

Spindle Spindle nose JIS Α2−5

Hole through spindle mm φ46

Spindle bearing I.D. mm φ75

Max. rotating speed min−1 Max. 4,500

Spindle motor kW AC5.5/3.7

Tool post Type Station 8

Max. tool size mm 20 sq.

Max. boring bar diameter mm φ25

Slide Max. stroke mm X: 120 Z: 230

Rapid traverse rate m/min X: 12 Z: 18

Feed motor kW X: AC0.75 Z: AC1.2

Size L×W×H mm 1,400 (1,610) × 1,390 × 1,585

Center height mm 960

Machine weight kg 1,620

Motors Coolant pump motor kW AC0.25

Hydraulic pump motor kW AC0.75

Turret drive motor kW AC0.5

Total power capacity KVA 12

Noise level dB (A) 69

Controller TAKAMAZ FANUC 0i Mate-TD

* The machine weight differs depending on the specifications.

* The total power capacity differs depending on the specifications.
* The dimension in the parentheses indicates the length including the cylinder cover.

Refer to "Special Version" for details of optional equipment.

3
Chapter 2 Machine Specifications Specifications

2-2 Standard Accessories and Optional Attachments

Standard accessories
Clamp block........................................................ 8 pcs
Boring holder ...................................................... 2 pcs
Hydraulic chucking cylinder (hollow)................ 1 set
Hydraulic unit ..................................................... 1 set
Thread cutting unit.............................................. 1 set
Coolant unit ........................................................ 1 set
Work light ........................................................... 1 set
Signal light.......................................................... 1 set
TAKAMAZ instruction manual.......................... 1 set

Optional attachments
Tool holders
Front air blower
Chip conveyor (rear side) (spiral type)
Collet chuck
Automatic door
Hydraulic power chuck (hollow)

4
Specifications Chapter 3 Controller Specifications

Chapter 3 Controller Specifications

3-1 Standard Specifications

Item TAKAMAZ FANUC 0i Mate-TD

Controlled axes 2 axes (X, Z)

Simultaneously controllable axes Simultaneous 2 axes

Least input increment 0.001 mm (X in diameter)

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

Auxiliary function M-3 digit

Spindle function S-4 digit

Tool function T-4 digit

Tape code EIA (RS232C) / ISO (840) automatic recognition

Cutting feedrate 1 - 5000 mm/min

Command system Incremental/Absolute

Linear interpolation G01

Circular interpolation G02, G03

Cutting feedrate override 0 - 150%

Rapid traverse override F0, 100%

Program number 4 digits

Backlash compensation 0-9999 μm

Part program storage size 512 kbytes (equivalent to 1,280 m in tape length)

Tool offsets 64 sets

Registered programs 400 pcs.

Tool geometry/wear offset Standard

Canned cycle G90, G92, G94

Radius designation on arc Standard

Tool offset measurement input Standard

Background editing Standard

Direct drawing dimension programming Standard

Custom macro Standard

Additional custom macro common variables #100 - #199, #500 - #999

Pattern data input Standard

Nose R compensation G40, G41, G42

Inch/metric conversion G20/G21

Programmable data input G10

5
Chapter 3 Controller Specifications Specifications

Item TAKAMAZ FANUC 0i Mate-TD

Run hour/parts count display Standard

Extended part program editing Standard

Multiple repetitive cycle G70 - G76

Canned cycle for drilling Standard

Constant surface speed control G96, G97

Contnuous thread cutting G32

Variable lead thread cutting G34

Thread cutting retract Standard

Clock function Standard

Help function Standard

Alarm history display 50 pcs.

Self-diagnosis function Standard

Sub-program call up to 10 loops

Decimal point input Standard

2nd reference point return G30

Work coordinate system G50, G54 - G59

Stored stroke check 1 Standard

Stored stroke check 2, 3 Standard

Input/output interface USB flash drive, memory card, Ethernet

Alarm message Standard

Graphic display Standard

Conversational programming with graphic function Standard

Abnormal load detection Standard

Starting condition check function Standard

TAKAMAZ maintenance function Standard

FANUC instruction manuals CD-ROM

6
Specifications Chapter 4 Major Unit

Chapter 4 Major Unit

4-1 Headstock Unit

The headstock unit consists of the spindle, hydraulic cylinder, etc.

The spindle is driven by an AC spindle motor. The spindle bearing is grease-lubricated, and needs
to be replaced every three years. Contact us when replacing the spindle bearing.

Spindle speed Max. 4,500 min−1

4-1-1 Spindle

Encoder

Hydraulic chucking cylinder Thrust angular ball bearing

Double-row cylindrical Double-row cylindrical

roller bearing roller bearing

Fig. 3 Structural drawing of headstock

7
Chapter 4 Major Unit Specifications

4-1-2 Spindle Nose Drawing

JIS A2 -5
Standard, hollow type

Chucking cylinder: SS1236-102 (Kitagawa)

Fig. 4 Spindle nose drawing

8
Specifications Chapter 4 Major Unit

4-1-3 Chuck Mounting Drawing

Power chuck
Hollow type (JIS A2-5)
Power chuck: B206 (Kitagawa)
Chucking cylinder: SS1236-102 (Kitagawa)

Collet chuck
Hollow type (JIS A2-5)
Collet chuck: TSC-D26-ST (T850)
Chucking cylinder: SS1236-102 (Kitagawa)

Fig. 5 Power chuck mounting drawing

9
Chapter 4 Major Unit Specifications

4-1-4 Spindle Motor Characteristic Diagram

5.5/3.7 kW (Max. 4,500 min−1)

5.5 kW 15 min. operation area

Output 3.7 kW cont. operation area

(kW)
60 min. operation area

Spindle speed (min−1)

Cont. operation area: The motor can be operated continuously.

60 min. operation area: The motor can be operated continuously for 60 minutes after it
was started in the ambient temperature.
15 min. operation area: The motor can be operated continuously for 15 minutes after it
was started in the ambient temperature.

Fig. 6 Spindle motor characteristic diagram

10
Specifications Chapter 4 Major Unit

4-2 Turret Unit

The turret has 8 stations to mount turning or rotating tools.

Clamping and unclamping motions of the turret are hydraulically controlled.
Indexing is driven by a servo motor, and high-speed indexing is assured due to a random selection
system.

4-2-1 Tooling System Drawing

OD/face/grooving tool 20 sq.

2758021022
Clamp block C

Tap Tap holder

3128801400
Round hole bush ID holder
φ20 (2333075006)
φ16 (2333076004)
Boring bar φ12 (2333077002)
Max. φ25 φ10 (2333078000)
φ8 (2333080006)
Blank (2333079008) 2758201020
φ25 boring holder
Assy 8163800400

Drill Drill chuck arbor

Center straight drill chuck JT1-φ25
JT2-φ25
2758210021
φ25 double boring holder
Drill socket
MT-2
2758016006
Taper drill Drill sleeve OD nozzle
MT-1 *MT-2

U-drill Round hole bush

Max. φ25 φ20 (2333075014)

2758208058
U-drill holder

Do not use an ID holder (2758204024) provided for X-100 (X-10i

CAUTION
or X-10). This holder will interfere with the cover when the turret
turns.

Fig. 7 Tooling system drawing

11
Chapter 4 Major Unit Specifications

4-2-2 Turret Interference

Distance between centers: 160 mm

ing 0
urn φ18
. t r
ax te
M me
dia

Spindle center

Distance between centers: 200 mm Distance between centers: 134 mm

Do not use an ID holder (2758204024) provided for X-100 (X-10i

CAUTION
or X-10). It interferes with the cover when the turret turns.

Fig. 8 Reference drawing of turret interference

12
Specifications Chapter 4 Major Unit

4-3 Slide Unit

The X and Z axes are driven by an AC servo motor through the ball screws, thus moving on the
linear guide.
Max. rapid traverse rate: In the X-axis direction 12 m/min.
In the Z-axis direction 18 m/min.

4-3-1 Stroke Diagram

Collet

Z-axis stroke

Kitagawa

Fig. 9 Stroke diagram

13
Chapter 4 Major Unit Specifications

4-4 Hydraulic Pump Unit

The hydraulic pump is used to drive the spindle chucking cylinder (for clamping and unclamping
motions) and the turret (for clamping and unclamping motions).
Tank capacity: 18 lit.
Source pressure: 3.4 MPa (set upon shipment)
* Specifications are subject to change according to the improvement of the machine. Check the types and
quantities of parts to be replaced, and place an order with Takamatsu.

4-4-1 Assembly Drawing of Hydraulic Pump Unit

No. Part name Model Manufacturer

1 Hydraulic tank (18 L) 3151600600 Takamatsu
2 Magnet separator 30 × 30 × 10T Ferrite Osaka Magnet
3 Packing 3133500601 Takamatsu
4 Hydraulic tank cover 3151500500 Takamatsu
5 Oil filler port/air breather FA-35 Taisei
6 Oil level gauge VA-HL Koho
7 Drain pipe 3128501700 Takamatsu
8 Pipe L150 3125502300 Takamatsu
9 Suction filter SFT-06-150W Taisei
10 Rubber bush C-30-SG-34A Takigen
11 Hydraulic pump UVN-1A-0A2-0.7-4-12 NACHI
12 Anti-vibration rubber 3125502400 Takamatsu
13 Oil cooler 1013-201-138 NAJICO
14 Pressure gauge GV50-173 × 5MPa Nagano Keiki
15 Solenoid valve SE-G01-E3X-GR-D2-5453A NACHI
16 Reducing valve OG-G01-PC-21 NACHI
17 Manifold MB-01 Kanazawa Kiko

Fig. 10 Assembly drawing of hydraulic pump unit

14
Specifications Chapter 4 Major Unit

4-4-2 Hydraulic Circuit Diagram

Turret clamp

Spindle chuck

No. Part name Model Manufacturer

1 Hydraulic pump UVN-1A-0A2-0.7-4-12 NACHI
2 Suction filter SFT-06-150W Taisei
3 Tank 3151600600 (18L) Takamatsu
4 Oil cooler 1013-201-138 NAJICO
5 Oil level gauge VA-HL Koho
6 Oil filler port/air breather FA-35 Taisei
7 Magnet separator 30 × 30 × 10T Ferrite Osaka Magnet
8 Pressure gauge (with glycerine) GV50-173 × 5 MPa Nagano Keiki
9 Solenoid valve SE-G01-E3X-GR-D2-5453A NACHI
10 Reducing valve OG-G01-PC-21 NACHI
11 Manifold MB-01 Kanazawa Kiko
12 Solenoid valve SE-G01-H3X-GR-D2-5453A NACHI
13 Manifold MBG-1C Kanazawa Kiko

Fig. 11 Hydraulic circuit diagram

15
Chapter 4 Major Unit Specifications

4-4-3 Arrangement of Valves

Chuck clamp valve Turret clamp valve

Fig. 12 Arrangement of valves

16
Specifications Chapter 4 Major Unit

4-5 Lubrication Unit

This unit is used for lubricating slideways and ball screws forcibly at intervals of 30 minutes.
Effective tank capacity: 2.0 lit.
* Specifications are subject to change according to the improvement of the machine. Check the types and
quantities of parts to be replaced, and place an order with Takamatsu.

4-5-1 Lubrication System Diagram

X linear right-rear
X linear left-front
X linear left-rear

X ball screw

Nylon tube φ4
Nylon tube φ4

Nylon tube φ4

Nylon tube φ4

Nylon tube φ4

Float switch lower limit OFF

X ball screw
Nylon tube φ4

Z linear left-rear
Nylon tube φ4
Z ball screw
Nylon tube φ4
Z linear left-front Nylon tube φ4
Z linear right-rear
Nylon tube φ4

Z linear right-front
Nylon tube φ4

Parts Unit code

No. Name Type Standard Takamatsu Showa

Standard 3151100200 161019-1283
1 Semi-cycle pump SMD3-8537 1
2 Distributor unit PSS0 10
3 Nipple PD4 8
4 Elbow PHD4 2
Amount of oiling: 3 cc/30 min
5 Distributor nut PAN4 10
Distributor Oil amount Q'ty
6 Junction JD2 1
PSS0 0.3 /cy 10
7 Dester-uni DB7D 1 Total 3.00 /cy 10
8 Dester-uni DB6D 1
9 Tube insert AL4 22
10 Sleeve PB4 26
11 Tightening plug PA4 16
12 Flexible hose FHC406 1
13 Flexible hose FHC407.5 1
14 Elbow PH4-M8T 1

Fig. 13 Lubrication system diagram

17
Chapter 4 Major Unit Specifications

4-6 Coolant Unit

This unit is used for cooling and washing workpieces and cutting tools as well as removing chips
during cutting. Priming the pump is not required because an immersion type pump is used.

Tank capacity: 125 lit.

Discharge: 30 - 40 lit./min.

4-6-1 Coolant System Diagram

Turret

Shower coolant

125 lit.

Always fill the tank with coolant up to at least 80% (100 lit.) of the
CAUTION
tank capacity. It is recommended to replenish the coolant during a
break or after finishing work rather than in the middle of operation.

Fig. 14 Coolant system diagram

18
Specifications Chapter 5 Electrical Drawings

Chapter 5 Electrical Drawings

5-1 Electrical Circuit Diagram List

19
Chapter 5 Electrical Drawings Specifications

5-2 Parts Arrangement in Electric Box

20
Specifications Chapter 5 Electrical Drawings

5-3 Parts Arrangement in Operation Box

21
Chapter 5 Electrical Drawings Specifications

5-4 Connection Diagram

22
Specifications Chapter 5 Electrical Drawings

5-5 Electric Circuit Diagrams

Electric circuit diagram 1

23
Chapter 5 Electrical Drawings Specifications

Electric circuit diagram 2

24
Specifications Chapter 5 Electrical Drawings

Electric circuit diagram 3

25
Chapter 5 Electrical Drawings Specifications

Electric circuit diagram 4

26
Specifications Chapter 5 Electrical Drawings

Electric circuit diagram 5

27
Chapter 5 Electrical Drawings Specifications

Electric circuit diagram 6

28
Specifications Chapter 5 Electrical Drawings

Electric circuit diagram 7

29
Chapter 5 Electrical Drawings Specifications

Electric circuit diagram 8

30
Specifications Chapter 5 Electrical Drawings

Electric circuit diagram 9

31
Chapter 5 Electrical Drawings Specifications

Electric circuit diagram 10

32
Specifications Chapter 5 Electrical Drawings

Electric circuit diagram 11

33
Chapter 5 Electrical Drawings Specifications

Electric circuit diagram 12

34
Specifications Chapter 5 Electrical Drawings

Electric circuit diagram 13

35
Chapter 5 Electrical Drawings Specifications

Electric circuit diagram 14

36
Specifications Chapter 5 Electrical Drawings

Electric circuit diagram 15

37
Chapter 5 Electrical Drawings Specifications

Electric circuit diagram 16

38
Specifications Chapter 5 Electrical Drawings

Electric circuit diagram 17

39
Chapter 5 Electrical Drawings Specifications

Electric circuit diagram 18

40
Specifications Chapter 5 Electrical Drawings

Electric circuit diagram 19

41
Chapter 5 Electrical Drawings Specifications

Electric circuit diagram 20

42
Specifications Chapter 5 Electrical Drawings

Electric circuit diagram 21

43
Chapter 5 Electrical Drawings Specifications

5-6 Electric Parts List

* Specifications are subject to change according to the improvement of the machine. Check the types and
quantities of parts to be replaced, and place an order with Takamatsu.

44
Installation
Installation Contents

Contents

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

Chapter 2 Installation Procedure ........................................................................................... 3

Chapter 3 Preparation for Installation .................................................................................. 4

3-1 Environment ............................................................................................................. 4
3-2 Foundation ................................................................................................................ 4
3-3 Electrical Wiring ...................................................................................................... 5
3-4 Grounding Work ...................................................................................................... 6
3-5 Installation Space ..................................................................................................... 7

Chapter 4 Transportation ........................................................................................................ 8

Chapter 5 Cleaning of Machine ............................................................................................ 10

Chapter 6 Removing Slide Fixture ....................................................................................... 11

Chapter 7 Levelling ................................................................................................................ 12

Chapter 8 Checking the Amount of Oil ................................................................................ 14

Chapter 9 Power Connection ................................................................................................ 15

Installation Chapter 1 Safety Precautions for Installation

Chapter 1 Safety Precautions for Installation

• Power connection, crane and forklift operation and slinging work should
DANGER
be done only by qualified personnel.
• Never put your body partially or wholly under the lifted machine.
• When placing electric cables over the floor, use rigid covers to protect
them from being damaged by chips and workers.

• Transportation and installation of the machine should be done by

WARNING
qualified personnel according to "Installation".
• Power cables from the primary terminal in the factory to the main power
switch should have a rated cross sectional area in order to supply stable
power required for operation.
• Check the following points to ensure safety at the installation site.
- When foundation bolts are buried, mark these points clearly to protect
workers from stumbling over and to protect the machine and carriages from
bumping.
- When a pit is provided for waste oil, chips and piping, mount a tentative
cover to protect workers from falling down.
- The floor should be clean and dry, and free from obstacles, oil and waste oil
in order to protect workers from slipping or falling.
• Use a stable step or platform when it is needed to reach a high level.
• Never put your fingers between the bed and the floor when locating the
machine at a designated place.
• When lifting a machine, use wire rope, shackles and hoisting jigs that are
rigid enough to withstand the machine weight.
• When working in a team, choose a leader to give instructions.
- Give signals with one another to check other workers' safety before going to
the next step.
- Follow the procedures step by step.
• Never give excessive shock to the machine during lifting and
transporting.

1
Chapter 1 Safety Precautions for Installation Installation

• When rust preventive oil is applied to the slideways, remove it

CAUTION
thoroughly with cleaning oil before starting operation.
• Remove eye bolts used for transportation as well as other fixing jigs and
wood used as shipping brackets.
• Levelling of the machine should be done accurately.
(Adjust levelling referring to the attached inspection sheet.)
• When installation is finished, check the following points before turning
the power on.
- All the bolts and connectors are securely tightened.
- Hydraulic hose, air hose and other piping are securely connected and fixed.
- New grease and oil are properly supplied to each section as instructed.
- Water and dust on the machine are all wiped off.
- There is no oil leakage around the machine.

2
Installation Chapter 2 Installation Procedure

Chapter 2 Installation Procedure

Follow the procedure described below when installing the machine.

Be sure to check the amount of oil before turning the power on when the
WARNING
machine has been installed. Turning the power on without a sufficient
amount of oil may cause damage to the machine.

Preparation for installation

See "Chapter 3 Preparation for Installation".
• Perform foundation work at the installation
site.
• Prepare power source and air source.
• Perform grounding work.

Transportation
See "Chapter 4 Transportation".
• Transport the machine to the installation site.

Cleaning
See "Chapter 5 Cleaning of Machine".
• Remove rust preventive oil and rust
preventive sheet from the machine.

Removing fixtures
See "Chapter 6 Removing Slide Fixture".
• Remove fixtures from axes.

Levelling
See "Chapter 7 Levelling".
• Perform levelling of the machine.

Checking the amount of oil

See "Chapter 8 Checking the Amount of Oil".
• Check the amount of oil.

Connecting power source

See "Chapter 9 Power Connection".
• Connect power source to the machine.

3
Chapter 3 Preparation for Installation Installation

Chapter 3 Preparation for Installation

3-1 Environment

To ensure machine accuracy and efficiency, check the following items before installation.

• Avoid direct sunlight or heat source which will generate a partial temperature rise.
* Ambient temperature: 0 - 45°C (20°C ± 2 is most recommended.)
* Change in temperature: Max. 1°C/min.
* When using the machine in the ambient temperature of 40°C or higher, lighten the load (cutting
conditions, etc.) applied to the machine to avoid overheating of motors.
• Keep apart from other machines which may splash water, oil or chips.
• Keep apart from press machines and forging machines to prevent transmission of vibration.
* Installation site should be below 0.5 G. Take anti-vibration measures if necessary.
• Humidity should be below 75% without dew condensation.
• Install the machine at an altitude lower than 1000 m.
• Avoid a location of a bad atmosphere with dust, mist, salt, corrosive gas, etc.
• The foundation of the machine should have sufficient strength without inclination or
unevenness.

3-2 Foundation

The machine should be installed on concrete of more than 300 mm in thickness.

The machine is so designed that foundation work is not particularly necessary if the ground is solid
enough. However, it is necessary in the following cases.

• Ground is not solid enough and depression or inclination may occur after the machine is
installed.
• High accuracy and efficiency are required in operation.

Fig. 1

4
Installation Chapter 3 Preparation for Installation

3-3 Electrical Wiring

Prepare the primary power and cables as described below on your side.
• Supply voltage
Within 200/220 V ± 10%, 3-phase, within 50/60 Hz ± 2 Hz

If normal voltage is not supplied, the machine may not actuate correctly.
CAUTION
Be sure to measure voltage with a tester. When voltage fluctuation
exceeds ±10%, provide a voltage stabilizer.

• Cables (to the main power switch from the primary power source in the factory)

Power cable Terminal screw Total power

(Single wire) size capacity

8 mm2 or greater M5 12 kVA 34 A

• Grounding
Comply with the electrical rules and regulations on grounding prescribed in your country.
Grounding resistance: Below 100 Ω
The grounding cable must satisfy the following conditions:

Grounding cable Terminal screw

(Single wire) size

8 mm2 or greater M5

* For the optional specifications, the electric cables (power cable and grounding cable) to use may be
different in thickness. Contact Takamatsu before connecting the electric cables.

5
Chapter 3 Preparation for Installation Installation

3-4 Grounding Work

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

Each grounding terminal should be connected to power cable individually.

DANGER
Wiring as shown below will result in a critical accident.

Grounding work should be done only by officially qualified electric

WARNING
engineers.

6
Installation Chapter 3 Preparation for Installation

3-5 Installation Space

Installation space should comply with the following:

• There is enough room to open/close the doors.
• There is enough room to supply oil and discharge chips.
• Workpieces can be mounted/removed without hindrance.

removing the chip conveyor

Space for installing/

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

Fig. 2

7
Chapter 4 Transportation Installation

Chapter 4 Transportation

The standard machine weighs about 1,620 kg. Use transportation equipment which is rigid enough
to withstand the machine weight. The environment for transportation must satisfy the following
conditions.
• Avoid direct sunlight or heat source which will generate a partial temperature rise.
* Ambient temperature: −10 to 50°C
• Humidity should be below 75% without dew condensation.
• Transport the machine at an altitude lower than 10000 m.

• Crane and forklift operation and slinging work should be done only by
DANGER
qualified personnel.
• Never put your body partially or wholly under the lifted machine.

• When lifting a machine, use wire ropes, shackles and hoisting jigs
WARNING
that are not damaged and rigid enough to withstand the machine
weight.
(Wire rope: More than φ10 mm (safe working load: 3 tons minimum))
* The thickness of the above wire rope is for the standard specifications. For
optional specifications, the total machine weight differs for respective
specifications so that the thickness of the wire rope to use may differ as well.
Contact Takamatsu before starting the work.

• When working in a team, choose a leader to give instructions.

CAUTION
- Give signals with one another to check other workers' safety before going to the
next step.
- Follow the procedures step by step by giving signals.
• Use waste cloth, etc. to protect the machine from being damaged by
wire ropes.
• Never give excessive vibration or shock to the machine during lifting
and transporting.

8
Installation Chapter 4 Transportation

[Required jigs]
Dedicated hoisting jigs
Crane
Wire rope: More than φ10 mm (safe working load: 3 tons minimum)
* The thickness of the above wire rope is for the standard specifications. For optional specifications, the
total machine weight differs for respective specifications so that the thickness of the wire rope to use may
differ as well. Contact Takamatsu before starting the work.

1. Clean the installation site.

2. Check that the Z-axis slide is at its zero position.
* The center of gravity of the machine comes around the spindle nose.
3. Set the dedicated hoisting jigs.
4. Hang wire ropes on the dedicated hoisting jigs.
5. Lift the machine slightly once to check the balance.
6. Transport the machine to the installation site.

* The hoisting jig is not provided as standard.

Dedicated hoisting jig

Dedicated hoisting jig

Fig. 3

9
Chapter 5 Cleaning of Machine Installation

Chapter 5 Cleaning of Machine

When rust inhibiting paper is used inside the machine, remove it from the machine after unpacking.
Remove rust preventive oil from slideways and metal surfaces thoroughly using a nonflammable
cleaning agent.

Do not turn the power on without removing the rust inhibiting paper.
CAUTION
Never use compressed air, like an air gun, for cleaning the machine.

10
Installation Chapter 6 Removing Slide Fixture

Chapter 6 Removing Slide Fixture

The X and Z axes are secured with the X- and Z-axis slide fixtures at the time of shipment. When
the machine has been installed, remove these fixtures before turning the power on.
* Before relocating the machine, secure the X- and Z-axis slides using slide fixtures.
* The fixture is painted in yellow.

DANGER Turn the main power switch off when it is needed to work inside the cover

Covers of the machine should be opened only by qualified maintenance

WARNING
personnel.

[Required tools]
Allen wrenches [4], [5], [9]

1. Check that the main power switch is turned off.

2. Remove the side cover from the machine.
3. Remove the fixtures.
X-axis fixture (M10)
Z-axis fixture (M6)

Side cover

Fixture

Fig. 4

11
Chapter 7 Levelling Installation

Chapter 7 Levelling

Levelling of the machine should be accurate, because it affects not only cutting accuracy but also
machine life.

* If the machine has been left unpacked or in improper status for a long period of time, levelling cannot be
stabilized at once. Level the machine once and adjust it again in three or four weeks.

DANGER Turn the main power switch off when it is needed to work inside the cover.

Covers of the machine should be opened only by qualified maintenance

WARNING
personnel.

[Required tools]
Levels (0.02 mm/m)
Spanner [30]

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

2. Place the level gauge on the top surface of the Z-axis slide.
* Always keep the Z-axis slide surface clean so that no dust may enter between the level gauge and
the surface.
3. Adjust the machine level with four jack bolts at each corner so that the reading of the level
gauge will be within 0.02 mm in both the X- and Z-axis directions.
4. Tighten the lock nuts securely.
5. Check the machine level again with the level gauge.
* If the reading of the gauge is not within 0.02 mm, adjust the machine level again.

12
Installation Chapter 7 Levelling

Jack bolt

Lock nut

Leveling plate

Spirit level

Place the spirit level.

Jack bolt position (4 positions)

φ17-mm hole position (4 positions)

Fig. 5

13
Chapter 8 Checking the Amount of Oil Installation

Chapter 8 Checking the Amount of Oil

Check that the amount of oil is appropriate.

* Oil may not be filled for transportation. Be sure to check the amount of oil to be supplied.

See "Chapter 4 Oiling" in "Maintenance".

Be sure to check the amount of oil before turning the power on. Turning
WARNING
the power on without a sufficient amount of oil may cause damage to the
machine.

Use new oil specified in the instruction manual. Using any oil other than
CAUTION
specified may result in machine trouble.

14
Installation Chapter 9 Power Connection

Chapter 9 Power Connection

• Electric connection should be done only by qualified electric

DANGER
engineers.
• Turn off the primary power in the factory first. Never connect to the
primary power until after connection work and grounding work are
completed.
• When carrying out connection work, put the "KEEP POWER OFF"
panel so that power is not turned on by mistake.
• Check that cable sheathing is not damaged, as defective sheating
may cause a short circuit or an electric shock.

[Required tool]
Phillips screwdriver
Allen wrenches [2], [4]

1. Remove the cover for the main power switch.

2. Remove the electric cabinet door.
3. Put a power cable through the cable connection port.
4. Connect the power cable to the main power switch.
* Connection of the R, S and T terminals as well as earth should be correctly done.
5. Attach the cover to the main power switch.
6. Mount the electric cabinet door.

Phase check
After installation work is finished, check that the phase is correct.

1. Check that the switches on the NC control unit and the control box are all turned to "OFF" or
"STOP".
2. Mount a phase detector on the R, S, and T terminals on the power breaker input side, and detect
the phase.
• If the phase is wrong, turn off the power once and interchange "R" and "T" of the incoming
phase cable.
Turn on the power again and check that the hydraulic pump rotates in the normal direction
and the pressure gauge pointer moves accordingly.

15
Chapter 9 Power Connection Installation

Cable connection port

Electric cabinet door

Electric cabinet

Main power switch

* The shape may differ
depending on the
specifications.

T S

E (Earth)
R

Even if the main power switch is off, high-voltage of 200 V is

DANGER
supplied up to the main power switch when the power in the factory
is turned on. Never touch the part marked with in the above
figure.
Failure to observe this warning will result in critical bodily injuries.

Fig. 6

16
Operation
Operation Contents

Contents

Chapter 1 Outline of Machine ................................................................................................. 1

1-1 Name of Each Component ....................................................................................... 1
1-2 Structure of Operation Panel .................................................................................... 2
1-2-1 Machine Operation Panel .......................................................................... 2
1-2-2 CNC Operation Panel .............................................................................. 13

Chapter 2 Preparation for Operation .................................................................................. 19

2-1 Check Items before Turning Power ON ................................................................. 19
2-2 Turning Power ON ................................................................................................. 21
2-3 Check Items after Turning Power ON ................................................................... 22
2-4 Check-ups before Turning Power OFF .................................................................. 24
2-5 Turning Power OFF ............................................................................................... 25
2-6 Check-ups after Turning Power OFF ..................................................................... 26

Chapter 3 Manual Operation ................................................................................................ 27

3-1 Zero Point Return ................................................................................................... 27
3-2 Manual Feed ........................................................................................................... 29
3-2-1 Jog Feed ................................................................................................... 29
3-2-2 Rapid Traverse ......................................................................................... 30
3-2-3 Handle Feed ............................................................................................. 31
3-3 Turret Indexing ....................................................................................................... 32
3-4 Chuck Open/Close ................................................................................................. 33
3-4-1 Changing the Chuck Gripping Direction ................................................. 33
3-5 Spindle Rotation and Stop ...................................................................................... 34
3-6 Coolant Discharge .................................................................................................. 36

Chapter 4 MDI Operation ..................................................................................................... 37

4-1 Preparation for MDI Operation .............................................................................. 37
4-1-1 Switches and Keys Used .......................................................................... 37
4-1-2 MDI Screen .............................................................................................. 38
4-2 Spindle Rotation and Stop (continued from step 2 in 4-1-2) ................................. 39
4-3 Turret Indexing (continued from step 2 in 4-1-2) .................................................. 41
4-4 X-/Z-axis Travel (continued from step 2 in 4-1-2) ................................................ 42
Contents Operation

Chapter 5 Automatic Operation ........................................................................................... 44

5-1 Preparation for Automatic Operation ..................................................................... 45
5-1-1 Process of Starting Automatic Operation ................................................ 45
5-1-2 Conditions for Starting Automatic Operation .......................................... 46
5-2 Program Check ....................................................................................................... 48
5-2-1 Test Running ............................................................................................ 48
5-3 Trial Cutting ........................................................................................................... 49
5-4 Pause and Restart of Automatic Operation ............................................................ 50
5-4-1 Pause of Automatic Operation ................................................................. 50
5-4-2 Restart of Automatic Operation ............................................................... 50
5-5 Manual Operation during Automatic Operation .................................................... 51
5-6 MDI Operation during Automatic Operation ......................................................... 52
5-7 Program Editing ..................................................................................................... 53
5-7-1 Inputting a Program ................................................................................. 54
5-7-2 Calling a Program .................................................................................... 57
5-7-3 Displaying a Program Library ................................................................. 58
5-7-4 Deleting a Program .................................................................................. 59
5-7-5 Searching ................................................................................................. 61
5-7-6 Deleting a Word or Block ........................................................................ 63
5-7-7 Inserting a Word ...................................................................................... 65
5-7-8 Altering a Word ....................................................................................... 66
5-7-9 Inserting a Comment ................................................................................ 67

Chapter 6 Setting Up .............................................................................................................. 70

6-1 Tooling ................................................................................................................... 70
6-2 Tool Offset ............................................................................................................. 72
6-3 Tool Wear Offset .................................................................................................... 77
6-4 Mounting the Power Chuck (Part Order) ............................................................... 78
6-5 Mounting the Collet Chuck (Part Order) ............................................................... 80
6-6 Forming Soft Jaws .................................................................................................. 82
6-6-1 Precaution for Forming Soft Jaws ........................................................... 82
6-6-2 Forming Soft Jaws in Manual Operation ................................................. 84
6-6-3 Forming Soft Jaws in Automatic Operation ............................................ 86

Chapter 7 Appendix ............................................................................................................... 89

7-1 List of G Codes ...................................................................................................... 89
7-2 List of M Codes ...................................................................................................... 91
7-3 Variable Timer List ................................................................................................ 93
Operation Chapter 1 Outline of Machine

Chapter 1 Outline of Machine

1-1 Name of Each Component

NC screen
CNC operation panel Machine operation panel

Front door

Turret

Spindle

Lubrication unit

Foot switch
Operator's position

Electric cabinet

Main power switch

* The shape may differ
depending on the
specifications.

Coolant pump motor

Coolant tank Hydraulic pump unit Absolute pulse coder

battery case

Fig. 1

1
Chapter 1 Outline of Machine Operation

1-2 Structure of Operation Panel

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

Never operate any switch, key or button on the operation panels while
CAUTION
wearing gloves.

1-2-1 Machine Operation Panel

(5) (18)

(10) (1)
(2)
(4)
(14) (15) (16) (17)

(6)
(9) (8)

(7) (11) (12)

(3)
(24)
(25)

(26)

(20) (13)
(19)

(Only for the US specification)

(21) (22)
(23)

(27) (28)

(29)

Fig. 2

"Special Version" for details of optional equipment.

2
Operation Chapter 1 Outline of Machine

Name Function
(1) Power on button
Turns the NC power on and displays the NC screen, after the
power in the factory and the main power switch are turned
on.

(2) Power off button

Turns the NC power and the NC screen off.
Turn the main power switch off after pressing this button.

(3) Manual pulse generator

Feeds each axis in the required direction after;
• the HANDLE mode is selected with the mode selector
switch (5).
• the required axis is selected with the HNDL X/Z switch
(6).
• the feed per scale is selected with the handle
magnification switch "×10 / ×1" (7).
This generator is graduated into 100 in one complete
revolution.

(4) TURT switches

Rotates the turret clockwise or counterclockwise in manual
operation. When "JOG" or "HNDL" of the mode selector
switches (5) is selected, the turret is indexed one step in the
selected direction each time this switch is pressed.
REV
The turret turns counterclockwise.
FOR
The turret turns clockwise.
* When the front door is closed, the turret turns at the maximum
speed. When the front door is opened, it turns at a low speed
(10% or less of the maximum speed).

For details on manual operation of the turret, see "3-3 Turret

Indexing".

3
Chapter 1 Outline of Machine Operation

(5) Mode selector switches

Selects operation mode.
A lamp of the selected mode switch will turn ON.
EDIT MDI JOG • EDIT switch
AUTO HNDL REF Allows registering a program into the memory.
Altering, inserting and deleting programs can also be
done by using keys on the CNC operation panel.
• AUTO switch
Allows an execution of programs registered in the
memory.
Program number search and sequence number search of
programs in the memory can also be done.
• MDI switch
Allows manual data input by using keys on the CNC
operation panel.
MDI operation can start with the cycle start button (21)
on the CNC operation panel.
• HNDL switch
Allows a fine-feed of each axis by using the manual
pulse generator (3).
A fine-feed can be done by rotating the manual pulse
generator (3) after the required axis (X or Z) and feed
amount (0.01 mm or 0.001 mm) are selected with the
HNDL X/Z switch (6) and the "×10 / ×1" switch (7)
respectively.
• JOG switch
Allows a jog feed in manual operation.
Select the required axis (X or Z) and direction (plus or
minus) with the jog feed switch (8), and the selected axis
will move in the selected direction as long as the switch
(8) is pressed.
A feedrate can vary with the feedrate override switch
(19).
A rapid traverse becomes effective by pressing the RPD
switch (9) and any of jog feed switches (8) at the same
time.
• REF switch
Allows a zero point return in manual operation when
"+X" or "+Z" of the jog feed switch (8) is pressed until
the zero point lamp turns ON.

4
Operation Chapter 1 Outline of Machine

(6) HNDL X/Z switch

Selects the axis to be moved when the HNDL switch of the

mode selector switches (5) is selected.
The lamp of the selected axis will turn on.

(7) Handle magnification switch

Selects a feed amount per scale of the manual pulse

generator, and is effective when the HNDL switch of the
mode selector switches (5) is selected. The lamp of the
selected magnification will turn on.
×10: Feed amount per scale = 0.01 mm
×1: Feed amount per scale = 0.001 mm

(8) Jog feed switches

Zero point lamp

Selects the axis and its direction to be moved when the JOG
or REF RETURN of the mode selector switches (5) is
selected. Jog feed of each axis is effective as long as the
switch is pressed. In the REF RETURN mode, only "+X"
and "+Z" switches are effective, and press both switches until
their zero point lamps turn on accordingly.

(9) RPD switch

Allows a rapid traverse of each axis when it is pressed along
with any of the jog feed switches (8), when the JOG switch of
the mode selector switches (5) is selected.
* The RPD switch is enabled for any of the jog feed switches
"+X", "−X", "+Z", and "−Z".

(10) RPD F0/100% switch

Selects either of F0 and 100% for rapid traverse. The lamp of

the selected rapid feedrate will turn on. This switch is
effective in automatic operation (G00).
F0 is set to achieve 1.2 m/min for the X axis and 1.8 m/min
for the Z axis. Setting to 100% achieves 12 m/min for the X
axis and 18 m/min for the Z axis.
* If 100% is selected in manual operation, the X and Z axes
move at a speed of 2.0 m/min.

5
Chapter 1 Outline of Machine Operation

(11) CLT switches

Discharges and stops coolant in manual operation.

Coolant is discharged from the tops of the slide cover and the
chip cover. The switches lamp will turn on during coolant
discharge.

(12) AIR switches (optional)

Starts and stops blowing air in manual operation when the

machine is equipped with an air blower. The lamp will turn
on during air blowing.

(13) SPDL switches

FOR
This switch is effective when the JOG, REF RETURN or
HNDL switch of the mode selector switches (5) is selected.
Pressing this switch lights up the lamp and rotates the spindle
in the normal direction.

STOP
This switch is effective when the JOG, REF RETURN or
HNDL switch of the mode selector switches (5) is selected.
Pressing this switch stops the spindle.

REV
This switch is effective when the JOG, REF RETURN or
HNDL switch of the mode selector switches (5) is selected.
Pressing this switch lights up the lamp and rotates the spindle
in the reverse direction.

(14) M01 switch

Stops automatic operation after a block containing M01 is

executed. (Effective while the lamp turns on.)
To restart automatic operation, press the cycle start button.
By setting this switch to off (the lamp turns off), automatic
operation does not stop even after the M01 in the program is
read.

(15) SBK switch

Executes only one block in the program each time the cycle
start button (21) is pressed. (Effective while the lamp turns
on.)
This function is effective for checking the motion of each
block one by one.

6
Operation Chapter 1 Outline of Machine

*1: Operation does not stop if the block contains thread cutting, but stops only after the block next to the block
of thread cutting is executed.
*2: Operation also stops even at the intermediate point when G28 or G30 is commanded.
*3: When the SBK switch is set to on during automatic operation, operation stops after completing the current
block being executed.
*4: When the SBK switch is on during canned cycles (G90, G92, G94 and G70 - G76), the actual executions
are as shown below. Rapid traverse
Cutting feed

G code Tool path Explanation

Tool path 1 to 4 is assumed as one cycle.
G90 Movement stops after 4 is finished.

Tool path 1 to 4 is assumed as one cycle.

G92 Movement stops after 4 is finished.

Tool path 1 to 4 is assumed as one cycle.

G94 Movement stops after 4 is finished.

Tool path 1 to 7 is assumed as one cycle.

G70 Movement stops after 7 is finished.

Each of tool paths 1 to 4, 5 to 8, 9 to 12,

13 to 16 and 17 to 20 are assumed as one
G71 cycle. Movement stops after each cycle
G72 is finished.

* The figure shows the case of G71. G72 is

the same as this.

Tool path 1 to 6 is assumed as one cycle.

Movement stops after a cycle is finished.
G73

Tool path 1 to 10 is assumed as one

G74 cycle. Movement stops after a cycle is
G75 finished.
* The figure shows the case of G74. G75 is
the same as this.

Tool path 1 to 4 is assumed as one cycle.

G76 Movement stops after a cycle is finished.

*5: In the blocks containing "M98 P_" or "M99", operation does not stop even when the SBK switch is on.
For details, refer to the separately provided "Programming" and FANUC OPERATOR'S MANUAL.

7
Chapter 1 Outline of Machine Operation

(16) DRN switch

Ignores all commands for the rapid feed and the cutting feed
specified by the program. (Effective while the lamp turns
on.)
The override specified by the feedrate override switch (19) is
applied to the feedrate and turret rotation speed.

• As this switch becomes effective even during thread cutting, pay

CAUTION
careful attention to the actual cutting workpieces.
• The override specified by the feedrate override switch (20) is also
applied to the turret rotation speed. Since the rotation speed may
different from the specified speed, care must be taken when turning
the turret.

(17) / CODE switch

Ignores blocks following a slash "/" in the program.

(Effective while the lamp turns on.)
By setting the switch off (the lamp turns off), blocks
containing a slash "/" become effective.
This function is not effective for the block which has been
already read into the buffer, since blocks are checked when
they are read into the buffer register.

(18) Status indication lamps

• CYC STRT lamp
Turns on when automatic operation starts.
The lamp stays on during automatic operation, but turns
off when the cycle operation is completed or paused.
* The lamp also turns on when the MDI operation is started.
• FEED HLD lamp
Turns on when automatic operation is paused
temporarily, and turns off when automatic operation is
restarted.
• MC ALARM lamp
Turns on when any alarm occurs to the machine.
* See the message screen for the cause of the alarm.

8
Operation Chapter 1 Outline of Machine

• MC WARNING lamp
Turns on in the following cases:
• when lubricant in the lubricant tank becomes
insufficient.
• when the finished product count reaches the preset
value in program operation.
* See the message screen for the cause of the alarm.

CAUTION If the cause is unknown, contact Takamatsu.

• DR CL lamp
Turns on when the machine door is closed.
• CHK OP lamp
Turns on when the foot switch is stepped on and the
chuck is opened.
• CHK CL lamp
Turns on when the foot switch is stepped on and the
chuck is closed.

(19) Feedrate override switch

Has two functions according to the mode selected by the
mode selector switch (5).
• Feedrate override
In the AUTO or MDI mode, the speed specified in the
program can be overridden in the range of 0 to 150%.

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

• Jog feedrate setting

In the JOG mode, the feedrate of each axis can be
selected in the range of 0 to 826 mm/min.
When the switch is set to 100%, the axis moves at the
speed of 126 mm/min.

9
Chapter 1 Outline of Machine Operation

(20) SPDL SPD switches

Used to change the spindle speed in manual operation.
[+]
Increases the spindle speed.
[−]
Decreases the spindle speed.
* When spindle rotation is started, the spindle rotates at a low
speed. Set the required speed with the SPDL SPD switches.
* The spindle speed at the start of rotation varies depending on
the specification.

(21) Cycle start button

Starts machine operation and turns on the CYC STRT lamp,
when the AUTO or MDI mode is selected with the mode
selector switch (5).
* This button is ineffective in any of the following cases:
1. The emergency stop button is pressed.
2. The reset signal is given.
3. The wrong mode is selected.
4. The sequence number is being searched.
5. The machine is in the alarm status.
6. The automatic operation is being executed without a feed
hold.
7. The NC is not ready for the operation. (Not in the READY
status)

(22) Feed hold button

Suspends automatic operation, and turns off the CYC STRT
lamp and on the FEED HLD lamp.

If this button is pressed;

• all the axes being moved are stopped.
• a dwell operation being executed is suspended.
• M or T function being actuated is stopped upon its
execution.
* Operation stops upon completion of retraction if the feed hold
status becomes effective during thread cutting operation.
* When the axis is moved in manual operation, although it is
available even in the feed hold status, pay attention to its
coordinate value. Accordingly, to restart automatic operation,
be sure to return the moved axis to its original position before it
was moved manually.

10
Operation Chapter 1 Outline of Machine

(23) Emergency stop button (with a lock mechanism)

Always be aware of the emergency
WARNING
stop button's locations and operation
so that they can be operated quickly in
emergency. This should be
understood by all the personnel
concerned.

Stops the machine immediately in emergency.

Once an emergency stop becomes effective, the servo power
shuts off, and each axis feed, the spindle rotation, the turret
indexing and the coolant supply stop.
Use (press) this button also to turn the power off.
As the button becomes locked once it is pressed, turn it CW
for resetting.
* Be sure to remove the cause of the trouble before resetting the
emergency stop status.
* All the commands for axis feed or spindle rotation specified
before the emergency stop button is pressed become
ineffective.

(24) CHIP switches (optional)

AUT
When this switch is on (the lamp turns on), the chip conveyor
rotates in the normal direction during automatic operation.

FOR
Pressing this switch in the manual mode rotates the chip
conveyor in the normal direction. Pressing this switch again
during normal rotation stops the chip conveyor.

REV
The chip conveyor is rotated in the reverse direction while
this switch is held down in the manual mode.
"Special Version" as for details of the chip conveyor

(25) ATDR OP switch (optional)

Opens the automatic door.

(26) ATDR CL switch (optional)

Closes the automatic door.

11
Chapter 1 Outline of Machine Operation

(27) OPRT (operation) switch (with key) (only for the US specification)
• PRG. EDIT
Enables program edit/storage and machine operation.
• UNLOCK
Enables machine operation.
* Program edit/storage is not available.
• LOCK
Disables program edit/storage and machine operation.
(The key cannot be removed.)

(28) Machine operation mode selector switch (only for the US specification)
Used to select the machine operation mode.
• Cutting mode (MCATM)
Select this mode for automatic operation.
• Setting mode (SETM)
Select this mode for manual operation.
* When the machine operation mode is changed from cutting
mode (MCATM) to setting mode (SETM) during automatic
operation, the machine will stop temporarily.

For restrictions on machine operation with the front door

open and the DOOR ITLK MCATM/SETM (machine
operation mode) switch operation, see "7-2-2 US
Specification" in Safety Guide.

(29) DOOR ITLK RELEASE (door interlock release) switch (only for the US specification)
Allows you to open the front door when this switch is held
down. During automatic operation or spindle rotation, the
front door cannot be opened even if the this switch is held
down.
If it is necessary to perform manual operation with the front
door open, hold down this switch during operation.
For restrictions on machine operation with the front door
open and the DOOR ITLK RELEASE (door interlock release)
switch operation, see "7-2-2 US Specification" in Safety
Guide.

12
Operation Chapter 1 Outline of Machine

1-2-2 CNC Operation Panel

Fig. 3

13
Chapter 1 Outline of Machine Operation

Name Function
(1) Position key
Used for displaying the current position of each axis.

(2) Program key

Used for displaying programs in the EDIT mode and for
inputting or displaying data in the MDI mode.

(3) Offset/setting key

Used for setting a tool offset amount or for setting and
displaying a custom macro variable or the software operator's
panel screen.

(4) System key

Used for setting parameters or for displaying parameters and
diagnosis data.

(5) Message key

Used for displaying alarm numbers and messages.

14
Operation Chapter 1 Outline of Machine

(6) Custom/graphic key

Used for displaying the custom screens (START
CONDITION CHECK, MAINTENANCE MENU and
GRAPHIC PARAMETER screens).
* Each time this key is pressed, the screen display is changed
over.

START CONDITION CHECK screen

Refer to "C. TAKAMAZ Custom Functions" in "Special

Version".
MAINTENANCE MENU screen
Refer to "C. TAKAMAZ Custom Functions" in "Special
Version".
GRAPHIC PARAMETER screen
Refer to the FANUC OPERATOR’S MANUAL for
details.

(7) Address/numeric keys

Used for inputting data composed of the alphabet, numeric
characters and symbols.

(8) Shift key

Used for entering characters indicated at the lower right on
the address keys. " " is indicated while this key is held
down, showing that the lower right characters can be entered.

15
Chapter 1 Outline of Machine Operation

(9) Cancellation key

Used for deleting the alphabet, numeric characters, symbols,
etc. displayed on the NC screen.
Ex.) When "N001X100Z" is displayed in the key input
buffer line:
Pressing the CAN key deletes "Z", and shows as
below:
N001X100

(10) Input key

Used for entering data, which is displayed on the NC screen
using the data input keys, into the NC.
As the function of this key is equal to the [INPUT] soft key,
either key may be used.

(11) Deletion key

Used for deleting the program data.

(12) Insertion key

Used for inserting the program data.

(13) Alteration key

Used for altering the program data.

(14) Help key

Used for accessing the help function regarding key operation.

(15) Reset key

Used for resetting the NC or the alarm status when it occurs.
Pressing this key during automatic operation stops all the
machine motions (axis feed, spindle rotation, coolant, etc.)
immediately.
Before restarting automatic operation, return all the axes to
their zero positions and check that the program returns to its
beginning.

16
Operation Chapter 1 Outline of Machine

(16) Cursor keys

Used for moving the cursor. Press a key depending on the
direction to move the cursor.
<→>: Moves the cursor to the right, or in the forward
direction in small units.
<←>: Moves the cursor to the left, or in the backward
direction in small units.
<↓>: Moves down the cursor, or in the forward direction
in large units.
<↑>: Moves up the cursor, or in the backward direction in
large units.

(17) Page keys

Used for changing over the page displayed on the NC screen.
Press either key depending on the direction to scroll the page.
<↓>: Scrolls the page in the forward direction.
<↑>: Scrolls the page in the backward direction.

17
Chapter 1 Outline of Machine Operation

(18) Soft keys

Soft keys can work differently depending on the
circumstances. The soft key functions currently in effect are
indicated at the bottom on the screen.
* Soft keys consist of (1) chapter selection soft keys, (2)
operation selection soft keys, (3) auxiliary menu keys, (4)
return menu key and (5) continued menu key.
(1) Chapter selection soft keys
When a screen display is switched using a function key,
the corresponding chapter selection soft keys are
displayed. If one chapter has several sub-chapters,
selection keys for those chapters are displayed by
pressing the continued menu key.
(2) Operation selection soft keys
Operation selection soft keys are displayed when the
[(OPRT)] soft key is pressed. They are displayed in some
cases when data is entered using address/numeric keys.
(3) Auxiliary menu keys
Auxiliary menu keys are displayed when an operation is
made on the screen while operation selection soft keys are
displayed.
Press the key according to the purpose of operation to be
performed.
(4) Return menu key
The return menu key is used to display the chapter
selection soft keys again.
(5) Continued menu key
The continued menu key is used to display the hidden
chapter selection keys (1) if any.
* The shape of the soft key varies according to the function
selected.

Chapter selection soft keys [(OPRT)] soft key

(OPRT)

Continued menu key

Operation selection soft keys

Return menu key

Auxiliary menu keys

Return menu key

18
Operation Chapter 2 Preparation for Operation

Chapter 2 Preparation for Operation

2-1 Check Items before Turning Power ON

• Before turning the power on, check that all cables are properly
DANGER
insulated. Damaged or disconnected cables must be immediately
repaired or replaced by qualified personnel, as they could cause an
electrical shock or leakage later.

• There must be no obstacles, which may interrupt machine operation

WARNING
or maintenance work, in/around the machine.
• The floor should be free from water and oil.

Unit Inspection Items Remarks

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

The chuck jaws should not be worn out.

Lubrication unit Lubricant amount should be sufficient.

Hydraulic pump unit Hydraulic oil amount should be sufficient.

Reading of the pressure gauge should be "0".

Coolant unit Coolant amount should be sufficient.

Chips should not be deposited in the tank excessively.

Turret unit Cutting tools should not be damaged or worn out.

There should be no chips on the cutting tools.
Cutting tools and holders should be mounted securely.

Electric cabinet The door should be mounted properly.

All cables should not be damaged or broken.

Others The front door should be closed completely.

The window pane of the front door should have no flaws or
fouling.
The emergency stop button should be pressed.
The machine environment should be tidy.

19
Chapter 2 Preparation for Operation Operation

Turret
• must not have any broken or wear-out tools.
• must be free from chips around the tools.
• must securely be equipped with tools and holders.

Emergency stop button

• must be depressed.
Front door
• must be closed.
• window pane must be free
from flaws or fouling.

Lubrication unit
• must be equipped with an
appropriate amount of oil.

Electric cabinet Cable connection port

• door must be attached. • must not hold any damaged cable.

Coolant tank Hydraulic pump unit

• must be equipped with an appropriate • must be equipped with an appropriate
amount of clean oil. amount of oil.
• must not have build-up chips. • pressure gauge must indicate "0".

Fig. 4

20
Operation Chapter 2 Preparation for Operation

2-2 Turning Power ON

DANGER Never touch any switch or button with wet hands.

Procedures and instructions described in this manual must strictly be

WARNING
observed when turning the power ON.

Turn the power on in the following procedures.

* Check that the emergency stop button is depressed before turning the power ON.
1. Turn on the primary power in the factory.
2. Turn the main power switch ON.
• A cooling fan will start to rotate in the electric cabinet.
3. Press the power on button.
• The NC screen lights up, and "-- EMG --" is displayed.
• A work light (optional) will light up.
4. Reset the emergency stop button.
(Perform this step after the NC screen is displayed.)
• The current position screen will appear on the NC instead of the message
"--EMG--".
• The hydraulic pump will start. (The pressure increases up to the setting value: 3.4 MPa)

1. Primary power supply on

3. Power on button

2. Main power switch on

4. Reset the emergency

stop button.

Fig. 5

21
Chapter 2 Preparation for Operation Operation

2-3 Check Items after Turning Power ON

• When starting operation after stopping the machine for a long period
CAUTION
of time, check that the machine motions, noise and slideway
lubrication are free from trouble.
If any abnormality, such as abnormal noise, excessive heat
generation and abnormal motion, is found, turn the power off
immediately and contact the maintenance personnel to take
necessary measures.
• After turning the power on, perform warm-up operation sufficiently.
- Mount no workpiece at this time.
- Programs for automatic operation should include each function of the machine.
- Change the spindle speed from low (500 min−1) to intermediate (2500 min−1),
and warm up for about 10 minutes at each speed.
- Before rotating the spindle with a chuck on it, check that the chuck and jaws are
securely fixed.

Unit Inspection Items Remarks

Headstock unit There should be no abnormal noise and excessive vibration

during the spindle motor rotation.
The chuck pressure should be appropriate.
* The chuck pressure depends on the combination of the
chuck and the cylinder to use.

Slide unit There should be no abnormal noise and excessive vibration

generated from the X-axis motor and Z-axis motor.

Hydraulic pump unit There should be no oil leaks.

The pump pressure should be appropriate.

Coolant unit The pump should be working properly.

Lubrication unit There should be no oil leaks.

The pump should be working properly.

Turret unit There should be no abnormal noise and excessive vibration

during the turret indexing.

Others No alarm message should be displayed on the NC screen.

No alarm lamp should be illuminated the machine operation
panel.

22
Operation Chapter 2 Preparation for Operation

Spindle motor, X/Z-axis motor

• must not generate abnormal noise or NC screen
excessive vibration. • must not indicate any alarm message.

Machine operation panel

• must not have any
illuminating or blinking
alarm lamps.

Turret unit
• must not generate any
abnormal noise and
excessive vibration during
the turret rotation.

Lubrication unit
• has no oil leaks.
• pump is working properly.

Coolant unit
Hydraulic pump unit
• pump is working properly.
• has no oil leaks.
• pump is working properly.

Fig. 6

23
Chapter 2 Preparation for Operation Operation

2-4 Check-ups before Turning Power OFF

When finishing operation, check that each section of the machine is in the
CAUTION
initial status.

NC screen Machine operation panel

• must not indicate any alarm message. • must not have any illuminating alarm lamps.
• Indicates that cycle operation is finished.

Machine units
• must be stopped
completely.

Fig. 7

24
Operation Chapter 2 Preparation for Operation

2-5 Turning Power OFF

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

Procedures and instructions described in this manual must strictly be

WARNING
observed when turning the power OFF.

Turn the power off in the following procedures.

1. Press the emergency stop button.

• The hydraulic pump will stop.
• The message "-- EMG --" will blink on the NC screen.
2. Press the power off button.
• The NC screen will turn OFF.
• The work light (optional) will turn OFF.
3. Turn the main power switch OFF.
• The cooling fan will stop in the electric cabinet.
4. Shut off the primary power in the factory.

2. Power off button

3. Main power switch off

1. Press the emergency

stop button.

4. Primary power supply off

Fig. 8

25
Chapter 2 Preparation for Operation Operation

2-6 Check-ups after Turning Power OFF

After turning the power OFF, check the following items.

Before cleaning the machine and peripheral equipment, such as a chip

DANGER
conveyor, stop all the machine motions, turn OFF the main power switch
and the primary power in the factory, and put a tag or a placard saying
"Cleaning!" in a prominent place.
Be sure to wear gloves when removing chips.
CAUTION
Never use an air gun for cleaning the machine, as it may cause a
machine trouble.

• All covers should have no damage.

• The machine and peripheral equipment (chip conveyor, etc.) should be clean.
• No chips should be deposited inside the machine.
• When stopping the machine for a long period of time, apply rust preventive oil slightly to
ground surfaces (slideways, etc.).
• Cutting tools should not be worn out or broken.
• The machine and its peripheral should be tidy.

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

Turret
• must not have any broken or wear-out tools.
• must be free from chips around the tools.
• must securely be equipped with tools and holders.

Fig. 9

26
Operation Chapter 3 Manual Operation

Chapter 3 Manual Operation

DANGER Never touch any switch or button with wet hands.

Before starting operation, check that there is nobody or nothing inside the
WARNING
machine movable section.

Never operate any switch, key or button on the operation panels while
CAUTION
wearing gloves.

* For the standard specification, manual operation can be performed with the front door open when the door
interlock switch is turned off.
* For the US specification, manual operation can be performed with the front door open when the door
interlock switch is held down in the setting mode (SETM) selected with the machine operation mode
selector switch.

For restrictions on machine operation with the front door open and the door interlock switch operation,
refer to "7-2 Door Interlock Function" in "Safety Guide".

3-1 Zero Point Return

Manual zero point return is required in the following cases. (X and Z axes)
• After turning the power on
• After resetting the emergency stop status
Perform the zero point return manually in the following procedures.

Particular care should be paid to the zero point return when cutting tools
CAUTION
or workpieces are mounted on the machine so that they are free from
interference.

27
Chapter 3 Manual Operation Operation

1. Press the REF switch of the mode selector switches.

• The lamp in the switch will light up.

2. Press the jog feed switch "+X".

• Keep pressing until the X-axis zero point lamp
X-axis zero point
lights up.
lamp * When the zero point return has been completed, the
buzzer sounds. The buzzer stops when the switch is
released.

3. Press the jog feed switch "+Z".

• Keep pressing until the Z-axis zero point lamp lights
Z-axis zero point
up.
lamp * When the zero point return has been completed, the
buzzer sounds. The buzzer stops when the switch is
released.

4. Press the POS key and the [ALL] soft key to check that
the machine coordinate value is "0.000".
* The zero point lamp will go off when;
• the axis moves from its zero point.
• The machine is put in an emergency stop status.

28
Operation Chapter 3 Manual Operation

3-2 Manual Feed

Three types of manual feed (jog feed, rapid traverse and handle feed) are available.

Fig. 10

3-2-1 Jog Feed

1. Press the JOG switch of the mode selector switches.

• The lamp in the switch will light up.

2. Select a feedrate with the feedrate override switch.

Ex.) When the switch is set to the 100% position, the
slide moves at a speed of 126 mm/min.

3. Press the jog feed switch of a required axis and direction.

• The slide moves in the selected direction at a speed
specified in step 2. as long as the switch is pressed.

When the RPD switch is pressed along with any of the jog feed switches,
CAUTION
a rapid traverse becomes effective.

29
Chapter 3 Manual Operation Operation

3-2-2 Rapid Traverse

1. Press the JOG switch of the mode selector switches.

• The lamp in the switch will light up.

2. Press the jog feed switch of a required axis and direction

along with the RPD switch.
• The slide moves in the selected direction at a rapid
traverse rate as long as the switches are pressed.
* The X and Z axes are moved at a speed of 2.0 m/min.

30
Operation Chapter 3 Manual Operation

3-2-3 Handle Feed

1. Press the HNDL switch of the mode selector switches.

• The lamp in the switch will light up.

2. Press the HNDL X/Z switch.

• The indication lamp of the selected axis will light
up.

3. Press the handle magnification switch "×10 / ×1".

• The indication lamp of the selected magnification
(×10 or ×1) will light up.
• Relation between the magnification and travel is as
shown below.
×10: Travel per scale 0.01 mm
×1: Travel per scale 0.001 mm

4. Rotate the manual pulse generator

• The axis selected in step 2. moves by the amount per
scale specified in step 3.

31
Chapter 3 Manual Operation Operation

3-3 Turret Indexing

WARNING Never touch the turret directly nor indirectly while it is turning.

• Pay careful attention to interference of cutting tools with the chuck or

CAUTION
a workpiece.
• When the DRN switch is selected, the override specified by the
feedrate override switch is also applied to the turret rotation speed.
Since the rotation speed may different from the specified speed, care
must be taken when turning the turret.
Follow the procedures below when turning the turret.

1. Press the JOG or HNDL switch of the mode selector

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

2. Press the TURT switch.

• The turret is indexed by one step in the selected
direction.
FOR
The turret turns clockwise.
REV
The turret turns counterclockwise.
* This switch is not effective to turn the turret while an axis
is moving in any mode other than HANDLE mode.
* When the front door is closed, the turret turns at the
maximum speed. When the front door is opened, it turns
at a low speed (10% or less of the maximum speed).
* When the DRN switch is ON, the override set by the
feedrate override switch is applied to the turret rotation
speed.

Reverse rotation

Normal rotation

Fig. 11

32
Operation Chapter 3 Manual Operation

3-4 Chuck Open/Close

The foot switch is provided at the bottom center of the machine front.
Each time this foot switch is stepped on, the chuck opens and closes alternately.
The CHK OP lamp lights up while the chuck is opened, and the CHK CL lamp lights up while the
chuck is closed.

3-4-1 Changing the Chuck Gripping Direction

1. Display the software operator's panel screen.

Refer to the FANUC OPERATOR'S MANUAL.

2. Select [CHK CHNG] (spindle chuck ON/OFF switch)

on the screen using the cursor keys.

3. Select "ON" or "OFF" using the cursor keys.

ON:

OFF:

* This switching operation must be performed in the

HANDLE, JOG, or REF RETURN mode with the spindle
stopped.

33
Chapter 3 Manual Operation Operation

3-5 Spindle Rotation and Stop

WARNING Never touch the spindle directly nor indirectly while it is rotating.

Follow the procedures below when rotating or stopping the spindle.

1. Close the chuck with the foot switch.
• The CHK CL lamp will light up.

2. Press JOG or HANDLE of the mode selector switch.

• The lamp in the switch will light up.

or

3. Press the SPDL FOR or SPDL REV switch.

• The spindle starts to rotate. When the SPDL FOR
or the SPDL REV switch is pressed, the lamp in the
selected switch will light up.

Normal rotation (M03) Reverse rotation (M04)

Fig. 12

34
Operation Chapter 3 Manual Operation

4. Press the SPDL SPEED switch.

+: Increases the spindle speed.
−: Decreases the spindle speed.
* When the spindle is started, the spindle rotates at a low
speed.
* The spindle speed at the start of rotation varies depending
on the specification.
5. Press the SPDL STOP switch.
• The spindle stops rotating.

35
Chapter 3 Manual Operation Operation

3-6 Coolant Discharge

Point the coolant hose tip correctly beforehand to avoid splashing coolant
CAUTION
to the operator.

1. Press the CLNT switch.

• The lamp in the switch will light up, and coolant
will be discharged.
* Coolant can be discharged regardless of the operation
mode.

2. Turn the handle cock.

• The discharge amount can be adjusted.

Open Close

Handle cock

Fig. 13

3. Press the CLNT switch again.

• The lamp in the switch will go off, and coolant
discharge will stop.

36
Operation Chapter 4 MDI Operation

Chapter 4 MDI Operation

With the MDI operation, a program can be created and executed in the same way as registered
programs.

* Operation for the registered programs cannot be done in the MDI mode.
* The length of a program for MDI operation is limited to one page of the NC screen.
* Nose R compensation cannot be done in the MDI mode.

FANUC OPERATOR'S MANUAL for details

4-1 Preparation for MDI Operation

4-1-1 Switches and Keys Used

Fig. 14

37
Chapter 4 MDI Operation Operation

4-1-2 MDI Screen

1. Press the MDI switch of the mode selector switches.

• The lamp in the switch will light up.

2. Press the PROG key.

• The MDI screen will appear.

* The program No. "O0000" is automatically inserted.

3. Input a program.
* To delete all programs stored in memory, press the O key
and then the DELETE key.
All programs can be deleted by pressing the RESET key.

FANUC OPERATOR'S MANUAL for details

38
Operation Chapter 4 MDI Operation

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

WARNING Never touch the spindle directly nor indirectly while it is rotating.

"5-7 Program Editing" when a wrong data has been input

Rotating the spindle at 1000 min−1 in normal (reverse)

direction

1. Press the data input keys [S], [1], [0], [0] and [0] in
order.
* When the power is turned on, G97 (constant surface
speed control cancel) mode becomes effective. It is
recommended that G97 is input in the program head on
the safe side.

2. Press the INSERT key.

3. Press the data input keys [M], [0] and [3] (or [M], [0]
and [4]) in order.
• M03 is a command for the spindle normal rotation
and M04 is for the spindle reverse rotation.

Normal rotation (M03) Reverse rotation (M04)

Fig. 15

39
Chapter 4 MDI Operation Operation

4. Press the EOB key.

5. Press the INSERT key.

6. Press the cycle start button.

• The spindle starts rotating at 1000 min−1.

Stopping the spindle

7. Press the data input keys [M], [0], and [5] in order.

8. Press the EOB key.

9. Press the INSERT key.

10. Press the cycle start button.

• The spindle stops rotating.

40
Operation Chapter 4 MDI Operation

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

WARNING Never touch the turret directly nor indirectly while it is turning.

• Pay careful attention to interference of cutting tools with the chuck or

CAUTION
a workpiece.
• When the DRN switch is selected, the override specified by the
feedrate override switch is also applied to the turret rotation speed.
Since the rotation speed may different from the specified speed, care
must be taken when turning the turret.

"5-7 Program Editing" when a wrong data has been input

1. Press the address/numerical keys [T], [∗], [∗], [0] and [0]
in order.
"*": Tool number (01 - 10) to be indexed

2. Press the EOB key.

3. Press the INSERT key.

Ex.) Indexing the turret at No. 3

4. Press the cycle start button.

• The turret will turn and index the turret No. 3.
* When the DRN switch is ON, the override set by the
feedrate override switch is applied to the turret rotation
speed.

41
Chapter 4 MDI Operation Operation

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

Before starting operation, check that there are no obstacles in the axis
CAUTION
movable area.
Pay careful attention to interference of cutting tools with the chuck or a
workpiece.
Be sure to perform the coordinate system setting and offset input before
moving each axis.

"6-2 Tool Offset"

Fig. 16

"5-7 Program Editing" when a wrong data has been input

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

1. Press the data input keys [G], [0], and [0] in order.

2. Press the INSERT key.

42
Operation Chapter 4 MDI Operation

3. Press the data input keys [X], [5], [0], and [.] in order.
* There is a great difference in values with and without the
decimal point.

Program command Meaning

X50. 50 mm

X50 0.05 mm

X1. 1 mm

X1 0.001 mm

According to the setting of parameter No. 3401#0, the

command of "X1" can be changed to 1 mm from
0.001 mm.
4. Press the INSERT key.

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

6. Press the INSERT key.

7. Press the EOB key.

8. Press the cycle start button.

• The X axis and the Z axis move to "50.0" and "30.0"
respectively at a rapid traverse rate.

43
Chapter 5 Automatic Operation Operation

Chapter 5 Automatic Operation

In automatic operation, the machine is operated according to the program.

It is very hazardous inside the machine during automatic operation because of high-speed spindle
(chuck) rotation, X/Z-axis movements and turret rotation. Besides, chips and coolant splash in a hot
and humid space.

• Never open any cover or door mounted on the machine during

WARNING
automatic operation and spindle rotation. Even in any status other
than automatic operation, utmost care should be taken if it is needed
to enter such a hazardous area or touch movable sections for setting
up or maintenance work while the power is turned on.
Failure to observe this warning will result in critical bodily injuries.
• Noise during machining may exceed 70 dB, resulting in damaging
your hearing ability. Use protective gear (ear muffs, etc) as
appropriate.

Inside the front door is a hazardous area.

Fig. 17

44
Operation Chapter 5 Automatic Operation

5-1 Preparation for Automatic Operation

5-1-1 Process of Starting Automatic Operation

Check cutting sections and contents with drawings.

Determine operation processes.

Prepare required tools and workpieces.

Enter a required program in a process sheet.

process sheet

Input the program into the machine.

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

Perform program check (test running).

Conduct trial cutting.

Perform dimensional offset.

Start productive operation.

45
Chapter 5 Automatic Operation Operation

5-1-2 Conditions for Starting Automatic Operation

The conditions for starting automatic operation are described below.

* Automatic operation cannot be started in the following conditions:
• The feed hold button is pressed.
• The emergency stop button is pressed.
• The reset signal is given.
• An operation mode other than AUTO is selected.
• A sequence number is being searched for.
• An alarm is occurring.
• The NC unit is not ready.
• Automatic operation is being executed, and is not in a feed hold.
• The front door is open.
• The door interlock switch is turned on (for the standard specification).
• The setting mode (SETM) is selected with the machine operation mode selector switch (for the US
specification).

1. Select the cutting mode (MCATM) with the machine

operation mode selector switch.
* This step is necessary for the US specification.

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

• The zero point lamp for each axis will light up.

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

1) Press the EDIT switch of the mode selector
switches.
• The lamp in the switch will light up.
2) Press the PROG key.
• The PROGRAM screen will appear.

46
Operation Chapter 5 Automatic Operation

3) Press the RESET key.

• The cursor moves to the top of the program.

"5-7-2 Calling a Program"

4. Press the AUTO switch of the mode selector switches.

• The lamp in the switch will light up.

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

• The CHK CL lamp will light up.

47
Chapter 5 Automatic Operation Operation

5-2 Program Check

5-2-1 Test Running

Before starting automatic operation, check that the program is input correctly and the chuck does not
interfere with any of cutting tools.
A program check (test running) can be done in the following procedures.

1. Satisfy the conditions for starting automatic operation as

described in "5-1-2".
* Do not mount a workpiece in the chuck.

2. Press the SBK switch.

• The lamp in the switch will light up.

3. Select "F0" with the RPD F0/100% switch.

4. Set the feedrate override switch to 100%.

5. Press the cycle start button.

• The CYC STRT lamp will light up.
* The program is executed only by one block each time the
cycle start button is pressed.

48
Operation Chapter 5 Automatic Operation

5-3 Trial Cutting

If the program check results in success, conduct trial cutting next.

Trial cutting can be done in the following procedures.

• Be sure to close the front door tightly and never open any cover or
WARNING
door during automatic operation.
• Noise during machining may exceed 70 dB, resulting in damaging
your hearing ability. Use protective gear (ear muffs, etc) as
appropriate.

1. Satisfy the conditions for starting automatic operation as

described in "5-1-2".
In this operation, mount a workpiece in the chuck and
then close the chuck.

2. Close the front door.

3. Press the SBK switch.

• The lamp in the switch will light up.

4. Set the "F0" with RPD F0/100% switch.

5. Set the feedrate override switch to 100%.

6. Press the cycle start button.

• The CYC STRT lamp will light up.
* The program is executed only by one block each time the
cycle start button is pressed.

7. After completing the trial cutting, inspect the shape and

dimensions of finished workpiece.
• If any defect is found in the shape or dimensions,
perform a tool offset, etc. and then conduct trial
cutting again.
"6-3 Tool Wear Offset"

49
Chapter 5 Automatic Operation Operation

5-4 Pause and Restart of Automatic Operation

5-4-1 Pause of Automatic Operation

To stop the execution of automatic operation temporarily,

press the feed hold button. By pressing the feed hold button,
the slide stops immediately except during thread cutting. As
the same time, the CYC STRT lamp turns off and the FEED
HLD lamp turns on.
* The machine stops in the following status after the feed hold
button is pressed.
• A dwell is suspended if the feed hold status becomes
effective while a dwell is being executed.
• Operation stops upon completion of a motion if the feed
hold status becomes effective while the M code, S code or
the T code command is being executed.
• Operation stops upon completion of retraction if the feed
hold status becomes effective during thread cutting
operation.

5-4-2 Restart of Automatic Operation

In order to restart automatic operation from the feed hold

status, press the cycle start button. By pressing the cycle start
button, the slide starts to move, the FEED HLD lamp turns
off and the CYC STRT lamp turns on.

50
Operation Chapter 5 Automatic Operation

5-5 Manual Operation during Automatic Operation

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

1. Press the feed hold button or set the SBK switch to on.
• Automatic operation will stop temporarily.
or

2. Press the POS key to display the actual position screen,

and record the coordinate value of the stop position from
the screen.

3. Perform manual operation.

"Chapter 3 Manual Operation"

4. Return each axis to the recorded coordinate value

referring to the current position display on the screen.

5. Press the AUTO switch of the mode selector switches.

• The lamp in the switch will light up.

6. Press the cycle start button.

• Automatic operation will restart.

51
Chapter 5 Automatic Operation Operation

5-6 MDI Operation during Automatic Operation

When performing MDI operation during automatic operation, follow the procedures below.
* MDI operation is not available in the feed hold status.

1. Press the SBK switch.

• The lamp in the switch will light up.
• Automatic operation will stop temporarily.

2. Press the MDI switch of the mode selector switches.

• The lamp in the switch will light up.

3. Perform MDI operation.

"Chapter 4 MDI Operation"

4. Press the AUTO switch of the mode selector switches.

• The lamp in the switch will light up.

5. Press the cycle start button.

• Automatic operation will restart.

52
Operation Chapter 5 Automatic Operation

5-7 Program Editing

This section describes procedures each for inputting, calling, listing, deleting, inserting, altering and
searching the program.

CAUTION Never operate any switch, key or button while wearing gloves.

* The following operation methods can be checked on the NC

screen using the help function.

OPERATION METHOD menu screen

Page/maximum page
Operation
Set mode
Operation location
Operation procedure

Example of OPERATION METHOD screens

FANUC OPERATOR'S MANUAL for details.

53
Chapter 5 Automatic Operation Operation

5-7-1 Inputting a Program

When inputting the program in manual operation without using any input equipment, follow the
procedures below.

1. Select the program editing mode.

[For the standard specification]
1) Display the software operator's panel screen.
Refer to the FANUC OPERATOR'S MANUAL.

2) Select "ON" for [EDIT] (program edit switch).

[For the US specification]
1) Set the OPRT switch to "PRG. EDIT".

2. Press the EDIT switch of the mode selector switches.

• The lamp in the switch will light up.

3. Press the PROG key.

• The program screen will appear.

4. Press the key [O].

5. Input a required program number using data input keys.

54
Operation Chapter 5 Automatic Operation

6. Press the INSERT key.

7. Press the EOB key.

8. Press the INSERT key.

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

Ex.) N1

10. Press the INSERT key.

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

Ex.) N1 G00 S500 M03

12. Press the EOB key.

Ex.) N1 G00 S500 M03;

13. Press the INSERT key.

14. Repeat steps 9. to 13. to input the required program

completely.

55
Chapter 5 Automatic Operation Operation

15. Cancel the program editing mode.

[For the standard specification]
1) Select "OFF" for [EDIT] (program edit switch).
[For the US specification]
1) Set the OPRT switch to "LOCK".

separately provided Programming Manual for details

56
Operation Chapter 5 Automatic Operation

5-7-2 Calling a Program

Calling a program can be done in the following procedures.

1. Press the EDIT switch of the mode selector switches.

• The lamp in the switch will light up.

2. Press the PROG key.

• The program screen will appear.

3. Press the key [O].

4. Input the program number to be called using the data

input keys.

5. Press the [O SRH] soft key.

* [O SRH] is displayed by pressing the [(OPRT)] soft key.

57
Chapter 5 Automatic Operation Operation

5-7-3 Displaying a Program Library

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

1. Press the EDIT switch of the mode selector switches.

• The lamp in the switch will light up.

2. Press the PROG key.

• The program screen will appear.

3. Press the [DIR] soft key.

• Number of registered programs, free area, used and
free memory area and program library will be
displayed on the screen.

The capacity of the program memory in which data

is registered (indicated by the number of bytes)

The number of the programs registered

(including the subprograms)
The capacity of the program memory
in which data is registered

The capacity of the program memory which

can be used additionally (indicated by the
number of bytes)

58
Operation Chapter 5 Automatic Operation

5-7-4 Deleting a Program

Be sure to check the content of the program before deleting it. It is

CAUTION
recommended that the backup copy should be stored on an external
memory device, etc.

Program deleting can be done in the following procedures.

1. Select the program editing mode.

[For the standard specification]
1) Display the software operator's panel screen.
Refer to the FANUC OPERATOR'S MANUAL.

2) Select "ON" for [EDIT] (program edit switch).

[For the US specification]

1) Set the OPRT switch to "PRG. EDIT".

2. Press the EDIT switch of the mode selector switches.

• The lamp in the switch will light up.

3. Press the PROG key.

4. Press the key [O].

59
Chapter 5 Automatic Operation Operation

5. Input a required program number to be deleted using

data input keys.
6. Press the DELETE key.
* When deleting all programs registered in the memory, press
the keys in step 5.;

(−) (9) (9) (9) (9)

7. Cancel the program editing mode.

[For the standard specification]
1) Select "OFF" for [EDIT] (program edit switch).
[For the US specification]
1) Set the OPRT switch to "LOCK".

60
Operation Chapter 5 Automatic Operation

5-7-5 Searching

Searching a word or sequence number can be done in the following procedures.

Procedures for calling the program to be edited are omitted in this section.

"5-7-2 Calling a Program"

Ex. 1) Searching for the sequence No. "N2" from the top of the program
1. Press the key [N].

2. Press the key [2].

3. Press the [N SRH] soft key.

* [N SRH] can be displayed by pressing the [(OPRT)] soft
key.

O 0001 ;
N1 G00 S3000 M03 T0100 ;
X32.0 Z0 TO101 M08 ;
G01 X−1.0 F0.1 ;
G00 X30.0 Z2.0 ;
G90 X10.5 Z−5.0 F0.2 ;
G28 U0 W0 ;
M01 ;
N2 G00 S3000 M03 T0200 ;
The cursor moves below "N2".

61
Chapter 5 Automatic Operation Operation

Ex. 2) Searching for the word "Z0" from the top of the program
1. Press the key [Z].

2. Press the key [0 (zero)].

3. Press the [SRH↓] or [SRH↑] soft key.

* [SRH↓] and [SRH↑] can be displayed by pressing the
[(OPRT)] soft key.
* Pressing the [SRH ↑] soft key starts searching from the
current cursor position toward the top of the program.

O 0001 ;
N1 G00 S3000 M03 T0100 ;
X32.0 Z0 TO101 M08 ;
G01 X−1.0 The cursor moves below "Z0".

* The search starts from the current cursor position, and the
cursor moves to the sequence number, word and address
which are programmed first. To start the search from the
head of the program, return the cursor to the program top
by pressing the RESET key.
* When the sequence number, word, or address specified
for searching could not be found, the alarm "Characters
not found." will appear.

62
Operation Chapter 5 Automatic Operation

5-7-6 Deleting a Word or Block

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

Procedures for calling the program to be edited are omitted in this section.

"5-7-2 Calling a Program"

Ex.1) Deleting a word or block

1. Search for the word to be deleted.
"5-7-5 Searching"

2. Press the DELETE key.

O 0001 ;
N1 G00 S3000 M03 T0100 ;

↓ Word to be deleted

↓
O 0001 ;
N1 G00 M03 T0100 ;

63
Chapter 5 Automatic Operation Operation

Ex.2) Deleting a block

1. Search for the first word in the block to be deleted.
"5-7-5 Searching"

2. Press the EOB key.

3. Press the DELETE key.

O 0001 ;
N1 G00 S3000 M03 T0100 ;
X32.0 Z0 T0101 M08 ;
G01 X−1.0 F0.1 ;
Cursor ↓ Block to be deleted

↓
O 0001 ;
N1 G00 S3000 M03 T0100 ;
G01 X−1.0 F0.1 ;

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

blocks from the searched one to the specified one will be
deleted.

64
Operation Chapter 5 Automatic Operation

5-7-7 Inserting a Word

Follow the procedures below when inserting a word.

Procedures for calling the program to be edited are omitted in this section.

"5-7-2 Calling a Program"

1. Search for the word immediately before the insertion

location.
"5-7-5 Searching"

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

3. Press the INSERT key.

O 0001;
N1 G00 M03 T0100 ;

Insert "S2000".
Cursor

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

↓

↓
O 0001;
N1 G00 S2000 M03 T0100 ;

Inserted word

65
Chapter 5 Automatic Operation Operation

5-7-8 Altering a Word

Follow the procedures below when altering a word.

Procedures for calling the program to be edited are omitted in this section.

"5-7-2 Calling a Program"

1. Search for the word to be altered.

"5-7-5 Searching"

2. Input the word to be altered using the data input keys.

3. Press the ALTER key.

Ex.) Changing the word "S3000" to "S2500"

O 0001 ;
N1 G00 S3000 M03 T0101 ;

Word to be altered
Cursor

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

↓

↓
O 0001 ;
N1 G00 S2500 M03 T0101 ;

Altered word

66
Operation Chapter 5 Automatic Operation

5-7-9 Inserting a Comment

It is possible to insert a comment in the program using parentheses. (A maximum of 31 characters

can be entered.)
Ex.) O0001 (MAIN) ;
N10 (GAIKEI) ;
M06 (AIR1 ON) ;
* When a comment is inserted following the O number, it is displayed on the PROGRAM DIRECTORY
screen.

"5-7-3 Displaying a Program Library"

Follow the procedures below when inserting a comment.

Procedures for calling the program to be edited are omitted in this section.

"5-7-2 Calling a Program"

1. Search for the word immediately before the insertion

location.
"5-7-5 Searching"

[(OPRT)] soft key

2. Press the [(OPRT)] soft key.

67
Chapter 5 Automatic Operation Operation

3. Press the continued menu key several times.

• The [CHA-EXT] soft key will appear.

Continued menu key

[CHA-EXT] soft key

4. Press the [CHA-EXT] soft key.

• [(], [)], [?], [*] and [&] will be displayed on the
respective soft keys.
* The soft key display is changed over (such as [@]) as
shown below each time the continued menu key is
pressed.

Continued menu key

5. Input a comment using the data input keys and soft keys.

68
Operation Chapter 5 Automatic Operation

6. Press the INSERT key.

O0001 ;

Cursor Insert "(MAIN)".

(( ) (M) (A) (I) (N) ( ))

↓
O0001 (MAIN) ;

Inserted comment

69
Chapter 6 Setting Up Operation

Chapter 6 Setting Up

In order to operate the machine in automatic operation, cutting tools and the chuck must be mounted
correctly and the tool offset should be done properly.

6-1 Tooling

Follow the procedures below when mounting the cutting tools.

The numbers of cutting tools to be used in the program must conform to ones to be actually
mounted.

• Cutting tools should be mounted securely and well-balanced.

CAUTION
• Tool temperatures will not drop soon after the machine stops. Check
that tools have cooled off before touching them. Do not touch tools
(especially power tools) immediately after operation.

[Required tools]
Allen wrenches [5], [8]
Spanner [17]

1. Turn the turret to index a plane on which a cutting tool is mounted.

"3-3 Turret Indexing"

2. Mount tool holders on the turret. (Securely attach the holder with hexagon socket head cap
bolts.)
* The OD tool should be mounted on the turret directly.
3. Mount cutting tools on the tool holders.
* It is convenient to mount all cutting tools so that their protruding length will be uniform.
4. Repeat steps 1. through 3.

* Fit the holder's bottom projection to the

mounting surface on the turret.

OD tool Hexagon socket head cap bolt

Clamp block

Holder

Fig. 18

70
Operation Chapter 6 Setting Up

OD/face/grooving tool 20 sq.

2758021022
Clamp block C

Tap Tap holder

3128801400
Round hole bush ID holder
φ20 (2333075006)
φ16 (2333076004)
Boring bar φ12 (2333077002)
Max. φ25 φ10 (2333078000)
φ8 (2333080006)
Blank (2333079008) 2758201020
φ25 boring holder
Assy 8163800400

Drill Drill chuck arbor

Center straight drill chuck JT1-φ25
JT2-φ25
2758210021
φ25 double boring holder
Drill socket
MT-2
2758016006
Taper drill Drill sleeve OD nozzle
MT-1 *MT-2

U-drill Round hole bush

Max. φ25 φ20 (2333075014)

2758208058
U-drill holder

Do not use an ID holder (2758204024) provided for X-100 (X-10i

CAUTION
or X-10). This holder will interfere with the cover when the turret
turns.

Fig. 19

71
Chapter 6 Setting Up Operation

6-2 Tool Offset

The start point of each cutting tool should be the machine zero point whenever automatic operation
is started.
However, it is impossible to set all tools equally in length. Therefore, a distance to the program zero
point from the tool nose located at the machine zero point needs to be input into the machine.
Measure the distance and input it on the tool offset screen in the following procedures.

• Never touch the spindle directly nor indirectly while it is rotating.

WARNING
• Do not remove chips on/around cutting tools during spindle rotation.
• Be sure to wear safety goggles.

CAUTION • Be sure to record the value input into the tool offset.

Zero point lamp

1. Return both the X and Z axes to their zero points in
manual operation.
"3-1 Zero Point Return"

2. Move the cutting tool toward a workpiece in jog feed.

"3-2-1 Jog Feed"

3. Rotate the spindle.

72
Operation Chapter 6 Setting Up

In the X-axis direction

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

5. Move only the Z axis in the plus direction.

* Never move the X axis at this time.

6. Stop the spindle

7. Press the OFS/SET key.

8. Press the [OFFSET] soft key.

9. Press the [GEOM] soft key.

• The OFFSET/GEOMETRY screen is displayed.

10. Measure the diameter of finished workpiece.

73
Chapter 6 Setting Up Operation

11. Move the cursor up to the required tool offset number

using the cursor keys.

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

(X)
Measurement

13. Press the [MEASUR] soft key.

• The X-axis shift amount to the program zero point
from the machine zero point will be entered
automatically.
Ex.) If OD of the machined workpiece is 20.1 mm,
press;

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

keys and then the [MEASUR] soft key.

74
Operation Chapter 6 Setting Up

In the Z-axis direction

14. Rotate the spindle again.

15. Cut the end face of the workpiece in the HANDLE

mode.

Finishing allowance

Finish surface

16. Move only the X axis in the plus direction.

* Never move the Z axis at this time.

17. Stop the spindle.

18. Measure the finishing allowance from the actually cut

end face to the finish end face.

19. Check that the cursor is located below the tool offset
number to be input.

20. Use the address/numeric keys and input;

(Z)
Finishing allowance on the end face

75
Chapter 6 Setting Up Operation

21. Press the [MEASUR] soft key.

• The Z-axis shift amount to the program zero point
from the machine zero point will be entered
automatically.
1) 2) 3)

1) In the case that the measured finishing allowance is

0 mm, input as follows:

(Z) (0)

Then, press the [MEASUR] soft key.

2) In the case that the measured finishing allowance is
0.5 mm, input as follows:

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

Then, press the [MEASUR] soft key.

3) In the case that the end face has been cut
excessively by 0.5 mm, input as follows:

(Z) (−) (0) (.) (5)

Then, press the [MEASUR] soft key.

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

"3-3 Turret Indexing"

23. Repeat steps 1. through 22. for all cutting tools.

76
Operation Chapter 6 Setting Up

6-3 Tool Wear Offset

When a dimensional accuracy specified in the drawings cannot be assured due to tool abrasion, the
tool wear can be compensated only by inputting the error.
1. Press the OFS/SET key.

2. Press the [OFFSET] soft key and then [WEAR] soft key.
• The OFFSET/WEAR screen is displayed.

Ex.) When a diameter of the workpiece cut by the cutting

tool T1 has become 0.05 mm larger than the specified
in the drawing:

3. Move the cursor to "W001".

4. Press the keys as follows:

(−) (0) (.) (0) (5)

Then, press the [+INPUT] soft key.

* For the tool wear offset in the Z-axis direction, move the
cursor to Z data, enter the appropriate value, and then
press the [+INPUT] soft key.
* The above offset value should be entered by an
incremental command.

77
Chapter 6 Setting Up Operation

6-4 Mounting the Power Chuck (Part Order)

Follow the procedures below when mounting the power chuck.

Instruction manual issued by the chuck maker, because mounting method differs according to the chuck
maker, chuck type, etc.

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

DANGER
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake. Failure to observe this warning will result in critical
bodily injuries.
The cover should not be opened by unqualified personnel for
WARNING
maintenance. Be sure to turn the main power switch OFF when it is
needed to work inside the cover.

Kitagawa B206 (φ26 through type)

[Required tools]
Allen wrench [8]
Soft hammer
Dial gauge (Division: 0.002 mm)

1. Clean all the mating surfaces of the spindle and the chuck before mounting.
2. Step on the foot switch to bring the machine in the chuck open state.
3. Loosen the stroke adjusting nut clamp bolt to adjust the chucking cylinder stroke.
4. Turn the stroke adjusting nut and adjust the distance between the cylinder and the stroke
adjusting nut according to the chuck stroke. Then tighten the stroke adjusting nut.
5. Loosen the collet adjusting nut clamp bolt.
6. Adjust the distance between the rear end face of the sleeve and that of the collet adjusting nut to
36.5 mm (reference).
7. Tighten the collet adjusting nut clamp bolt.
8. Attach chuck flange (2) to the spindle nose and fasten it with bolts (M10 × 25) (3).
9. Insert joint (1) into the sleeve.
10. Insert chuck body (4) into the joint.
11. Align the phase of chuck body (4) with that of the spindle, and fasten the chuck body with bolts
(M10 × 80) (5).
* Use the special tool supplied with the machine.
* Measure and adjust the runout of the chuck body at its outer surface (O.D.) to 0.01 mm or less.
12. Attach chuck jaws (6) using bolts (M10 × 20) (8) and T-nuts (7).
13. Adjust the stroke of chuck jaws (6).

78
Operation Chapter 6 Setting Up

(2)
(3)

(1)
(4)
(7)
(6)
(8)

(5)

No. Part name Q'ty No. Part name Q'ty

1 Joint 1 5 Bolt (M10 × 80) 6

2 Chuck flange 1 6 Jaw 3

3 Bolt (M10 × 25) 3 7 T-nut 3

4 Chuck body 1 8 Bolt (M10 × 20) 6

Sleeve Chuck flange

Hydraulic chuck
Collet adjusting nut Stroke adjusting nut

Joint
Collet adjusting nut Stroke adjusting nut
clamp bolt clamp bolt

Fig. 20

79
Chapter 6 Setting Up Operation

6-5 Mounting the Collet Chuck (Part Order)

Follow the procedures below when mounting a collet chuck for the spindle.

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

DANGER
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake.
The cover should not be opened by unqualified personnel for
WARNING
maintenance. Be sure to turn the main power switch OFF when it is
needed to work inside the cover.

TSC-D26-ST (T850) (φ26 through type)

[Required tools]
Allen wrenches [6], [8]

1. Clean all the mating surfaces of the spindle and the chuck before mounting.
2. Step on the foot switch to bring the machine in the chuck closed state.
3. Loosen the stroke adjusting nut clamp bolt to adjust the chucking cylinder stroke.
4. Turn the stroke adjusting nut until the distance between the cylinder and the stroke adjusting nut
becomes 3 mm, and tighten the stroke adjusting nut.
* When using a collet chuck, the distance must be no longer than 3 mm. A longer stroke may cause
the collet to break or vibrate.
5. Loosen the collet adjusting nut clamp bolt.
6. Adjust the distance between the rear end face of the sleeve and that of the collet adjusting nut to
21.5 mm (reference).
7. Attach collet flange (1) and fasten it with bolts (M10 × 95) (3).
8. Loosen collet detent pin (2), and insert collet (4) into the collet flange.
9. Align the collet detent pin (2) on the collet flange with the keyway on collet (4). Turn the collet
adjusting nut to the right until the collet is connected to the sleeve.
* There are three positions available for inserting collet detent pin (2) into collet flange (1). Align one of
these positions with the keyway on collet (4).
To the other two positions, regular hexagon socket head cap bolts are attached. When changing the
collet detent pin (2) position, be sure to attach the hexagon socket head cap bolts to these other
positions. Otherwise, the collet may be imbalanced, resulting in poor cutting accuracy.
10. Insert collet detent pin (2) into collet flange (1).
11. Turn the collet adjusting nut until the collet's tapered section comes into contact with the collet
flange.
12. Adjust the fitting clearance of collet (4) by turning the collet adjusting nut.
13. Tighten the collet adjusting nut clamp bolt.

80
Operation Chapter 6 Setting Up

(2)

(1)

(3)

(4)

No. Part name Q'ty

1 Collet flange 1

2 Detent pin 1

3 Bolt (M10 × 95) 6

4 TSC-D26-ST (T850) collet 1

Sleeve TSC-D26-ST collet

Collet adjusting nut Stroke adjusting nut

Collet flange

Collet adjusting nut Stroke adjusting nut

clamp bolt clamp bolt

Fig. 21

81
Chapter 6 Setting Up Operation

6-6 Forming Soft Jaws

In order to securely clamp or accurately cut workpieces, it is necessary to form soft jaws.
According to the cutting conditions, such as material, shape, size, chuck type, etc., there are various
methods to form soft jaws.

• Never touch the turret directly nor indirectly while it is rotating.

WARNING
• Dull or unstable cutting tools will cause damage or accidents.
Replace with proper tools in advance.
• Always wear a protective helmet, safety goggles and safety shoes.

6-6-1 Precaution for Forming Soft Jaws

[Required tools]
ID boring tool and insert
Spacer or jaw lock for forming jaws

Chuck Jaw Chuck Jaw Bolt hole for jaw

Spacer

Jaw lock

Fig. 22

82
Operation Chapter 6 Setting Up

Adjusting the chuck stroke

The chuck jaws should be adjusted so that they can grip a workpiece at the center of chuck stroke. It
is recommended that several spacers of different sizes be prepared for forming.

Opened position

Center

When jaws are closed without workpiece.

Spacer

Forming soft jaws

Make a recess on the inside corner of soft jaws.

Cutting tool for recessing

Other precautions
• Securely mount soft jaws and the chuck in serration while taking notice so that soft jaws do not
stick out from the chuck.
• Chuck pressure for forming soft jaws and for chucking a workpiece should be equal.
• Put marks (ex. 1, 2, 3...) on soft jaws according to the master jaw in order to record their
positions.
• It is recommended that soft jaws be milled beforehand if they have to be cut in a great quantity.
• When forming three-way jaws, it is recommended that a three-point contact type micrometer be
used for measuring the inside diameter accurately.
• As soft jaws should be formed in interrupted cutting, pay attention to the cutting tools because
they may be broken.

83
Chapter 6 Setting Up Operation

6-6-2 Forming Soft Jaws in Manual Operation

• Never touch the spindle directly nor indirectly while it is rotating.

WARNING
• Dull or unstable cutting tools will cause damage or accidents.
Replace with proper tools in advance.
• Always wear a protective helmet, safety goggles and safety shoes.

* Be sure to check the OD runout of the soft jaws. Form them to the desired workpiece diameter after
turning OD of the soft jaws. With slight imbalance, roundness in cutting may deteriorate.

1. Display the ACTUAL POSITION (RELATIVE) screen using the POS key and the [REL] soft
key.

2. Clamp a spacer with the foot switch.

• The CHK CL lamp will turn ON.
3. Move the cutting tool close to a soft jaw in manual feed.
4. Apply the cutting tool tip onto the I.D. of the soft jaw by using the manual pulse generator.

84
Operation Chapter 6 Setting Up

5. Press the key and the [ORIGIN] soft key.

• The value of "U" on the screen will become "0.000"

(Position of "U0")

Spacer

6. Apply the cutting tool onto the end face of the soft jaw by using the manual pulse generator.

7. Press the key and the [ORIGIN] soft key.

• The value of "W" on the screen will become "0.000"

Jaw

(Position of "W0")

Spacer

8. Form the soft jaw with reference to "U0" and "W0".

Ex.) Forming a soft jaw to 30 mm in diameter and 15 mm in depth:

Turning (leaving 0.3 mm (in diameter) and Finish turning (to the specified
Recessing
0.05 mm (in depth) finishing allowance) diameter and depth)

14.95
Recess

Hardening

φ29.7 φ30.0

Spacer Spacer Spacer

85
Chapter 6 Setting Up Operation

6-6-3 Forming Soft Jaws in Automatic Operation

* Be sure to check the OD runout of the soft jaws. Form them to the desired workpiece diameter after
turning OD of the soft jaws. With slight imbalance, roundness in cutting may deteriorate.

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

"3-1 Zero Point Return"

2. Move the cutting tool close to a soft jaw in manual feed.

3. Machine on the I.D. of soft jaw by using the manual pulse generator, and then perform a tool
offset.
Ex.) When the I.D. is 20.5 mm after cutting:
a. Display the OFFSET/GEOMETRY screen, and move the cursor to the offset number
of the cutting tool.
b. Press keys as follows.

Then, press the [MEASUR] soft key.

Jaw

4. Apply the cutting tool onto the end face of the soft jaw by using the manual pulse generator.

5. Press and keys. Then, press the [MEASUR] soft key.

"6-2 Tool Offset"

Jaw

86
Operation Chapter 6 Setting Up

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

7. Roughly machine the soft jaw using the program below.
Ex.) Forming a soft jaw to 30 mm in diameter and 20 mm in depth
Roughly cut the soft jaw to 29.8 mm in diameter and 19.95 mm in depth.

Jaw

O 1000 ;
G00 S500 M03 T0100 ;
X18.0 Z50.0 T0101 ;
Z2.0 ;
G90 X22.0 Z−19.95 F0.15 ;
X24.0 ;
X26.0 ;
X28.0 ; (Depth of cut in X-axis direction may differ depending on conditions.)
X29.6 ;
X29.8 ;
G28 U0. W50.0 ;
M30 ;

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

9. Perform offset against the diameter of 29.8 mm.

"6-2 Tool Offset"

87
Chapter 6 Setting Up Operation

10. Perform finish turning using the program below.

O 1000 ;
G00 S500 M03 T0100 ;
X35.0 Z50.0 T0101 ;
Z2.0 ;
G01 X30.0 Z−0.5 F0.1 ;
Z−20.0 ;
X19.0 ;
G00 Z50.0 ;
G28 U0 W0 ;
M30 ;

11. Perform recessing using the manual pulse generator.

Recessing tool

88
Operation Chapter 7 Appendix

Chapter 7 Appendix

7-1 List of G Codes

G code Function Group Remarks

G00 Positioning (Rapid traverse) Standard
G01 Linear interpolation (Cutting feed) Standard
01
G02 Circular interpolation (Clockwise) Standard
G03 Circular interpolation (Counter-clockwise) Standard
G04 Dwell Standard
G10 Programmable data input 00 Standard
G11 Programmable data input mode cancel Standard
G20 Data input in inch Standard
06
G21 Data input in metric Standard
G22 Stored stroke check ON Standard
09
G23 Stored stroke check OFF Standard
G25 Spindle speed fluctuation detection OFF Optional
08
G26 Spindle speed fluctuation detection ON Optional
G27 Reference point return check Standard
G28 Return to reference point Standard
00
G30 2nd/3rd/4th reference point return Standard
G31 Skip function Optional
G32 Thread cutting Standard
G34 Variable-lead thread cutting Standard
01
G36 Automatic tool offset X Optional
G37 Automatic tool offset Z Optional
G40 Nose R compensation cancel Standard
G41 Nose R compensation left 07 Standard
G42 Nose R compensation right Standard
G50 Coordinate system setting or max. spindle
Standard
speed setting 00
G50.3 Work coordinate system preset Standard
G52 Local coordinate system setting Standard
00
G53 Machine coordinate system selection Standard
G54 Work coordinate system 1 selection Standard
G55 Work coordinate system 2 selection Standard
G56 Work coordinate system 3 selection Standard
14
G57 Work coordinate system 4 selection Standard
G58 Work coordinate system 5 selection Standard
G59 Work coordinate system 6 selection Standard
G65 Macro call 00 Standard
G66 Macro modal call Standard
12
G67 Macro modal call cancel Standard

89
Chapter 7 Appendix Operation

G code Function Group Remarks

G70 Finishing cycle Standard
G71 OD/ID turning cycle Standard
G72 Stock removal in facing Standard
G73 Pattern repeating 00 Standard
G74 End face cut-off cycle Standard
G75 OD/ID cut-off cycle Standard
G76 Multiple threading cycle Standard
G80 Drilling canned cycle cancel Standard
G83 Face drilling cycle Standard
10
G84 Face tapping cycle Standard
G85 Face boring cycle Standard
G90 OD/ID turning cycle Standard
G92 Threading cycle 01 Standard
G94 Facing cycle Standard
G96 Constant surface speed control Standard
02
G97 Constant surface speed control cancel Standard
G98 Feed per minute Standard
05
G99 Feed per rotation Standard

*1: G codes marked with are initial G codes when turning power on.
*2: G codes of group 00 are not modal. They are only effective in the block in which they are specified. Other
G codes are effective until another G code in the same group is commanded.
*3: A number of G codes can be specified in the same block.
When more than one G code of the same group is specified, the G code specified later is effective.
*4: If a G code not listed on the table is inputted, or any optional G code not provided in the system is
commanded, an alarm (010 P/S ALARM) is displayed.

90
Operation Chapter 7 Appendix

7-2 List of M Codes

*: Optional

M code Function

M00 Program stop

M01 Optional program stop

M02 End of program (same as M30)

M03 Spindle normal rotation (with S code)

M04 Spindle reverse rotation (with S code)

M05 Spindle stop

* M06 Air 1 ON

* M07 Air 1 OFF

M08 Coolant 1 ON

M09 Coolant 1 OFF

* M10 Chuck air SET

* M11 Chuck air RESET

M30 End of program (same as M02)

M56 Signal light ON

M57 Signal light OFF

* M68 Shutter (auto door) open (w/o sensor check)

* M69 Shutter (auto door) close (w/o sensor check) (*1)

M71 Chuck open

M72 Chuck close

* M73 Shutter (auto door) open (with sensor check)

* M74 Shutter (auto door) close (with sensor check) (*1)

M76 Counter operation (external counter)

M80 Non-buffering M code

M98 Sub-program call (internal memory)

M99 Sub-program end

M126 Main spindle inching turn

91
Chapter 7 Appendix Operation

M code Function

M127 Main spindle inching stop

* M200 Chip conveyor ON (setting required)

* M201 Chip conveyor OFF (setting required)

M202 Spindle speed reached check

M390 Spindle stop (w/o stop signal check)

M406 Feed override cancel SET (fixed to 100%)

M407 Feed override cancel RESET (0 - 150%)

*1: For the automatic door specification, specify either M code in the same block as the O number (program
number).

92
Operation Chapter 7 Appendix

7-3 Variable Timer List

No. 01 to 08: 48-ms increments (0 to 1572800 ms), No. 09 to 80: 8-ms increments (0 to 262100 ms)
* Timer No. Address Description
01 T00

02 T02

03 T04

04 T06

05 T08

06 T10

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

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

09 T16

10 T18

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

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

13 T24

14 T26

15 T28 Auto door close (door interlock) check delay: Time from auto door close to door interlock
start (to prevent the door from bouncing back)

16 T30

17 T32

18 T34

19 T36

20 T38

21 T40

22 T42

23 T44

24 T46

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

26 T50

27 T52

28 T54

29 T56

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

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

32 T62

33 T64

93
Chapter 7 Appendix Operation

* Timer No. Address Description

34 T66

35 T68

36 T70

37 T72

38 T74

39 T76

40 T78

41 T80

42 T82

43 T84

44 T86

45 T88

46 T90

47 T92

48 T94

49 T96

50 T98

51 T100

52 T102

53 T104

54 T106

55 T108

56 T110

57 T112

58 T114

59 T116

60 T118

61 T120

62 T122

63 T124

64 T126

65 T128

66 T130

67 T132

68 T134

69 T136

94
Operation Chapter 7 Appendix

* Timer No. Address Description

70 T138

71 T140

72 T142

73 T144

74 T146

75 T148

76 T150

77 T152

78 T154

79 T156

80 T158

The "*" column indicates software versions. Setting is enabled with the software of the indicated version or
later.

95
Maintenance
Maintenance Contents

Contents

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

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

2-1 Check Items before Turning Power ON ................................................................... 2
2-2 Check Items after Turning Power ON ..................................................................... 4

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

3-1 Weekly Inspection .................................................................................................... 6
3-2 Monthly Inspection .................................................................................................. 6
3-3 Every Two Months Inspection ................................................................................. 7
3-4 Semiannual Inspection ............................................................................................. 7
3-5 Yearly Inspection ..................................................................................................... 8
3-6 Every Three Years Inspection .................................................................................. 8

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

4-1 List of Oils ................................................................................................................ 9
4-2 Lubrication Unit ..................................................................................................... 12
4-3 Hydraulic Pump Unit ............................................................................................. 13
4-4 Coolant Unit ........................................................................................................... 14
4-5 Chuck (Part Order) ................................................................................................. 16

Chapter 5 Troubleshooting .................................................................................................... 17

5-1 Initial Measures ...................................................................................................... 17
5-2 Alarm Display ........................................................................................................ 18
5-2-1 Alarm Display Sections ........................................................................... 18
5-2-2 Alarm Message Screen and Help Function ............................................. 19
5-3 Check Sheet ............................................................................................................ 20
5-4 Resetting Emergency Stop ..................................................................................... 21
5-5 Phenomenon and Remedy of Major Problems ....................................................... 22
5-6 Resetting Overtravel ............................................................................................... 27
5-6-1 When Soft Limit is Actuated: .................................................................. 27
5-7 Self-diagnosis Procedures ...................................................................................... 28
5-7-1 Displaying Diagnosis Screen ................................................................... 28
5-7-2 Reading the Signal Address Table ........................................................... 30
Contents Maintenance

5-8 Parameter Setting and Change ............................................................................... 31

5-8-1 Parameter Reference ................................................................................ 31
5-8-2 Parameter Setting (Change) ..................................................................... 33

Chapter 6 Maintenance for Each Unit ................................................................................. 35

6-1 Headstock ............................................................................................................... 35
6-1-1 Adjusting Chuck Pressure ........................................................................ 35
6-1-2 Chuck Pressure Setting Table for Cylinder ............................................. 36
6-1-3 Adjusting the Belt .................................................................................... 37
6-1-4 Replacing the Belt .................................................................................... 39
6-1-5 Aligning the Headstock ........................................................................... 41
6-1-6 Replacing the Position Coder .................................................................. 43
6-2 Slide Unit ............................................................................................................... 44
6-2-1 Replacing Wipers ..................................................................................... 44
6-2-2 Measuring and Compensating Backlash .................................................. 46
6-2-3 Slide Reference Point Setting .................................................................. 48
6-2-4 Settings for Collision Detection Function ............................................... 51
6-3 Turret Unit .............................................................................................................. 52
6-3-1 Measuring Turret Parallelism .................................................................. 52
6-3-2 Adjusting the Turret Clamp Proximity Switch ........................................ 54
6-3-3 Returning the Turret to the Origin Point .................................................. 55
6-3-4 Setting the Turret Zero Point ................................................................... 56
6-4 Hydraulic Pump Unit ............................................................................................. 58
6-4-1 Cleaning the Oil Filler Filter .................................................................... 58
6-4-2 Cleaning the Strainer ............................................................................... 59
6-4-3 Cleaning the Hydraulic Tank ................................................................... 60
6-4-4 Adjusting Discharge Pressure .................................................................. 61
6-5 Lubrication Unit ..................................................................................................... 62
6-5-1 Cleaning the Oil Filler Filter .................................................................... 62
6-5-2 Cleaning the Suction Filter ...................................................................... 63
6-5-3 Cleaning the Lubricant Tank ................................................................... 64
6-6 Coolant Unit ........................................................................................................... 65
6-6-1 Cleaning the Coolant Tank ...................................................................... 65
6-7 Electric Cabinet ...................................................................................................... 67
6-7-1 Replacing the Battery .............................................................................. 67
6-7-2 Replacing the Fuse ................................................................................... 69
6-7-3 Resetting the Thermal Relay ................................................................... 71
Maintenance Contents

6-8 CNC Control Unit .................................................................................................. 72

6-8-1 CNC Screen Auto-Off Function .............................................................. 72
Maintenance Chapter 1 Safety Precautions for Maintenance

Chapter 1 Safety Precautions for Maintenance

• Be sure to turn the main power switch off during maintenance work.
DANGER
The primary power in the factory should also be off for maintenance of
the electric cabinet. Never remove the electric cabinet door for five
minutes, as residual voltage remains.
• When carrying out maintenance work, put a panel or a plate indicating
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake.
• Never modify or remove safety devices such as limit switches, proximity
switches and dogs for interlock without our permission.

• The cover should not be opened by unqualified personnel for

WARNING
maintenance. Turn the main power switch off when it is needed to work
inside the cover.
• Wear a protective helmet during maintenance work.
• Use stable ladders, platform, etc., when working at a high level.
• Maintenance work should be done only by qualified personnel.
• Mount the covers on the initial positions correctly after finishing
maintenance work, and lock the doors with a key securely.
• After finishing maintenance work, keep the used tools, etc. orderly, and
remove all the obstacles, water and oil from the floor in order to restore
proper working environment.
• Procedures and methods described in "Maintenance" should be strictly
observed. Contact your local distributor immediately when any question
or doubt arises.
• If any maintenance work not described in this manual is required, contact
Takamatsu.

• Replacement parts (electrical and mechanical) should be as designated by

CAUTION
Takamatsu.
• Observe periodical check-ups as described in "Maintenance".
• Check each item after finishing maintenance work together with a person
in charge.
• Keep a maintenance record, and report it to a person in charge for
approval and examination.
• Keep the maintenance record for 10 years.

"Safety Guide"

1
Chapter 2 Daily Inspection Maintenance

Chapter 2 Daily Inspection

2-1 Check Items before Turning Power ON

• Before turning the power on, check that all cables are properly
DANGER
insulated. Damaged or disconnected cables must be immediately
repaired or replaced by qualified personnel, as they could cause an
electrical shock or leakage later.

• There must be no obstacles, which may interrupt machine operation

WARNING
or maintenance work, in/around the machine.
• The floor should be free from water and oil.

Unit Inspection Items Remarks

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

The chuck jaws should not be worn out.

Lubrication unit Lubricant amount should be sufficient.

Hydraulic pump unit Hydraulic oil amount should be sufficient.

Reading of the pressure gauge should be "0".

Coolant unit Coolant amount should be sufficient.

Chips should not be deposited in the tank excessively.

Turret unit Cutting tools should not be damaged or worn out.

There should be no chips on the cutting tools.
Cutting tools and holders should be mounted securely.

Electric cabinet The door should be mounted properly.

All cables should not be damaged or broken.

Others The front door should be closed completely.

The window pane of the front door should have no flaws or
fouling.
The emergency stop button should be pressed.
The machine environment should be tidy.

2
Maintenance Chapter 2 Daily Inspection

Turret
• must not have any broken or wear-out tools.
• must be free from chips around the tools.
• must securely be equipped with tools and holders.

Emergency stop button

• must be depressed.
Front door
• must be closed.
• window pane must be free
from flaws or fouling.

Lubrication unit
• must be equipped with an
appropriate amount of oil.

Electric cabinet Cable connection port

• door must be attached. • must not hold any damaged cable.

Coolant tank Hydraulic pump unit

• must be equipped with an appropriate • must be equipped with an appropriate
amount of clean oil. amount of oil.
• must not have build-up chips. • pressure gauge must indicate "0".

Fig. 1

3
Chapter 2 Daily Inspection Maintenance

2-2 Check Items after Turning Power ON

• When starting operation after stopping the machine for a long period
CAUTION
of time, check that the machine motions, noise and slideway
lubrication are free from trouble.
If any abnormality, such as abnormal noise, excessive heat
generation and abnormal motion, is found, turn the power off
immediately and contact the maintenance personnel to take
necessary measures.
• After turning the power on, perform warm-up operation sufficiently.
- Mount no workpiece at this time.
- Programs for automatic operation should include each function of the machine.
- Change the spindle speed from low (500 min−1) to intermediate (2500 min−1),
and warm up for about 10 minutes at each speed.
- Before rotating the spindle with a chuck on it, check that the chuck and jaws are
securely fixed.

Unit Inspection Items Remarks

Headstock unit There should be no abnormal noise and excessive vibration

during the spindle motor rotation.
The chuck pressure should be appropriate.
* The chuck pressure depends on the combination of the
chuck and the cylinder to use.

Slide unit There should be no abnormal noise and excessive vibration

generated from the X-axis motor and Z-axis motor.

Hydraulic pump unit There should be no oil leaks.

The pump pressure should be appropriate.

Coolant unit The pump should be working properly.

Lubrication unit There should be no oil leaks.

The pump should be working properly.

Turret unit There should be no abnormal noise and excessive vibration

during the turret indexing.

Others No alarm message should be displayed on the NC screen.

No alarm lamp should be illuminated the machine operation
panel.

4
Maintenance Chapter 2 Daily Inspection

Spindle motor, X/Z-axis motor

• must not generate abnormal noise or NC screen
excessive vibration. • must not indicate any alarm message.

Machine operation panel

• must not have any
illuminating or blinking
alarm lamps.

Turret unit
• must not generate any
abnormal noise and
excessive vibration during
the turret rotation.

Lubrication unit
• has no oil leaks.
• pump is working properly.

Coolant unit
Hydraulic pump unit
• pump is working properly.
• has no oil leaks.
• pump is working properly.

Fig. 2

5
Chapter 3 Periodical Inspection Maintenance

Chapter 3 Periodical Inspection

"Special Version" for optional equipment

• Inspect the following items periodically to maintain the high

DANGER
machining accuracy for a long period of time.
• When carrying out maintenance work, put a panel or a plate
indicating "MAINTENANCE - KEEP AWAY FROM THE MACHINE."
around the machine so that the power is not turned on or the
operation panel is not touched by mistake.
• Turn the main power switch off during maintenance work. The
primary power in the factory should also be off for maintenance of the
electric cabinet. Never remove the electric cabinet door for five
minutes, as residual voltage remains.

3-1 Weekly Inspection

Unit Inspection Items Remarks

Coolant unit Check if the amount of coolant and the coolant discharge are "4-4"
proper.

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

Lubrication unit Check that oil amount is appropriate. "4-2"

3-2 Monthly Inspection

Unit Inspection Items Remarks

Headstock unit Check if there is abnormal noise, excessive vibration or

excessive heat generation from the motor.

Slide unit Check if there is abnormal noise, excessive vibration or

excessive heat generation from the motor.

Hydraulic pump unit Check that oil amount is appropriate. "4-3"

Check if the hydraulic oil is contaminated.
• Recommended oil cleanliness:
17/15/13 (ISO4406/JISB9933)

6
Maintenance Chapter 3 Periodical Inspection

3-3 Every Two Months Inspection

Unit Inspection Items Remarks

Work light Clean connectors for electric cables. "9-5 Preventive

* Remove dust from connectors for electric cables. Measures for
Tracking
Phenomenon" in
"Safety Guide"

Electric cabinet Check the cooling fan filter.

Check and wipe dust off if any.

3-4 Semiannual Inspection

Unit Inspection Items Remarks

Headstock unit Check the tension of the spindle drive belt. "6-1-3"
Check the wear-out on the spindle drive belt.
Check the tension of the timing belt.
Check the wear-out on the timing belt.
Check if the motor pulley is clean.
Check if the timing pulley is clean.
Check if the spindle pulley is clean.

Slide unit Check the wear-out on the wipers, and replace it if "6-2-1"
necessary.

Lubrication unit Check that there is no oil leakage and that pipings are
not crushed.

Hydraulic pump unit Check that there is no oil leakage and that pipings are
not crushed.

Coolant unit Check that there is no oil leakage.

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

Others Check that bolts and nuts of the covers are all securely "Installation"
tightened.
Check the levelling, and adjust it if necessary.

7
Chapter 3 Periodical Inspection Maintenance

3-5 Yearly Inspection

Unit Inspection Items Remarks

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

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

Hydraulic pump unit Replace the hydraulic oil with new one. "4-3"
(every year or every 2000 hours of operation) "6-4-1"
Clean the oil inlet filter.
"6-4-2"
Clean the strainer.

Lubrication unit Clean the suction filter, and replace it if necessary. "6-5-2"
Clean the oil inlet filter. "6-5-1"

Turret unit Check the indexing accuracy, and adjust it if necessary. "6-3-1"

Electric cabinet Replace the back-up batteries with new ones. "6-7-1"
* Be sure to replace the batteries while power is supplied
to the entire system.

3-6 Every Three Years Inspection

Unit Inspection Items Remarks

Headstock unit Replace the spindle bearing grease with new one. Contact
Takamatsu.

8
Maintenance Chapter 4 Oiling

Chapter 4 Oiling

4-1 List of Oils

• Use new oil specified in the instruction manual. Any oil other than
CAUTION
specified may result in machine trouble.
• Slideway lubricant is effective in protecting slideways from coolant
due to the effect of adherence promoter. Do not use multi-purpose oil
which can be used as coolant and hydraulic oil for slideway
lubrication because this type of oil has no such effect.
• If multi-purpose oil is used, part corrosion, oil turbidity, or lubrication
depletion may occur, resulting in damage to the slideways or ball
screws.
• We have verified the following of slides and the separation from
coolant by using the specified lubricant. We shall bear no
responsibility for any trouble caused by using any oil other than the
specified one.
• Using coolant with high permeability may cause insulation
deterioration or part failure.

Specified Oil
Oiling Point Type (Supplied upon Maker Amount Interval Remarks
Shipment)

Lubrication unit ISO VG68 Mobil Vactra Oil No. 2 ExxonMobil 1.5 lit. As required “4-2”
Slideway lubricant SLC

Hydraulic pump unit ISO VG32 Mobil DTE24 ExxonMobil 18 lit. Replenish every “4-3”
Hydraulic oil month or every 200
hours of operation.
Replace every year or
every 2000 hours of
operation.
* For the first time,
replace the oil
when 3 months or
600 operating
hours have
elapsed.

Coolant unit ⎯ ⎯ ⎯ 125 lit. As required “4-4”

Headstock unit Contact Takamatsu. Grease ⎯ ⎯ Every 3 years Contact Takamatsu.

Chuck jaw See the Grease ⎯ As required Weekly “4-5”

(part order) manufacturer’s
instruction manual.

* The oiling interval is given only for reference. Replacement may be required earlier depending on the machine
operating status or the level of oil contamination.

9
Chapter 4 Oiling Maintenance

List of Recommended Oils

Slideway lubricant

Maker Name ISO

ExxonMobil Mobil Vactra Oil No. 2 SLC VG68

Mobil Vacuoline 1409

Showa Shell Shell Tonna S3 M68

JXTG Nippon Oil & Energy Uniway XS68

Uniway EV68

Idemitsu Kosan Daphne Multiway 68MT

Hydraulic oil

Maker Name ISO

ExxonMobil Mobil DTE 24 VG32

Mobil DTE 10 Excel 32

Showa Shell Shell Tellus S2 M32

JXTG Nippon Oil & Energy Super Hyrando 32

Super Hyrando SE32

Idemitsu Kosan Daphne Super Hydro 32A

* If any problem occurs when the oil has been changed from the one supplied upon shipment to another
designated oil, be sure to measure and adjust a backlash of the machine. The backlash may vary
depending on the oil type.

Refer to "6-2-2 Measuring and Compensating Backlash".

10
Maintenance Chapter 4 Oiling

Headstock unit

Lubrication unit Turret unit

Coolant unit Hydraulic pump unit

Fig. 3

11
Chapter 4 Oiling Maintenance

4-2 Lubrication Unit

Inspection interval Daily

Oiling interval As required
Specified oil Slideway lubricant
Mobil Vactra Oil NO. 2 SLC (ExxonMobil)
Oil amount 1.5 lit. (Tank capacity: 2.0 lit.)
* The tank capacity is subject to change according to the specifications or improvements made to the
machine.

Supply specified oil from the oil filler port.

* Supply oil up to the upper limit line indicated on the level gauge.

Oil filler port

Fig. 4

12
Maintenance Chapter 4 Oiling

4-3 Hydraulic Pump Unit

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

DANGER
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake.
The cover should not be opened by unqualified personnel for
WARNING
maintenance. Turn the main power switch off when it is needed to work
inside the cover.

Inspection interval Monthly

Replacement interval Yearly or every 2000 hours of operation
* 3 months or 600 hours of operation for the first time only
Specified oil Hydraulic oil
Mobil DTE 24 (ExxonMobil)
Oil amount 18 lit. (tank capacity)
* The oiling interval is given only for reference. Replacement may be required earlier depending on the
machine operating status or the level of oil contamination.

[Required tools]
Allen wrench [10]
Oil pan (for collecting hydraulic oil)

1. Turn the main power switch OFF.

2. Place the oil pan under the drain port.
3. Loosen the drain cock.
• The hydraulic oil will drain.
4. Tighten the drain cock.
5. Replenish the tank with hydraulic oil from the oil filler port.
* Supply oil up to the upper limit line indicated on the level gauge.

Oil filler port

Oil gauge

Drain

Fig. 5

13
Chapter 4 Oiling Maintenance

4-4 Coolant Unit

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

DANGER
indicating "MAINTENANCE - KEEP AWAY FROM THE MACHINE."
around the machine so that the power is not turned on or the
operation panel is not touched by mistake.
• Use non-flammable coolant. When using oil-based coolant
WARNING
inevitably, strictly follow the instructions in "Safety Precautions for
Fire Prevention".

"Chapter 9 Safety Precautions for Fire Prevention" in "Safety Guide"

• Depending on the coolant to use, corrosion, deterioration or failure of

parts in the unit may occur.
"Chapter 10 Notes on Coolant Selection" in "Safety Guide"

• Coolant has irritating properties and is harmful to humans. Avoid

CAUTION
direct contact with coolant. In particular, potentially allergic operators
must not handle coolant.

Inspection interval Daily

Oiling interval As required
Oil amount 125 lit. (tank capacity)
[Required tools]
Allen wrench [14]
Oil pan (for collecting coolant)

1. Turn the main power switch OFF.

2. Drain the waste coolant into the oil pan.

14
Maintenance Chapter 4 Oiling

3. Replenish the tank with coolant.

* Supply oil up to the upper limit line indicated on the level gauge.

Oil gauge

Coolant tank Drain

Fig. 6

15
Chapter 4 Oiling Maintenance

4-5 Chuck (Part Order)

The workpiece and the chuck are hot and do not cool off soon after the
CAUTION
machine stops. Check that they have cooled off before touching. Do not
touch the workpiece or the chuck (especially the workpiece) immediately
after operation.

Inspection interval Weekly

Greasing interval Weekly
Oil amount As required
* The oiling interval is only for your reference. It depends on the type of chucks to use. Contact Takamatsu.

[Required tool]
Grease gun

1. Turn the main power switch OFF.

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

Grease nipple

Fig. 7

16
Maintenance Chapter 5 Troubleshooting

Chapter 5 Troubleshooting

5-1 Initial Measures

WARNING If any doubt or question arises, contact Takamatsu for guidance.

If the machine does not operate normally or an alarm is displayed, check the cause of the trouble and
take necessary measures immediately.

Troubles can be classified roughly into 3 groups as shown below:

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

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

instructions of Takamatsu.

Trouble to be taken care of by the customer according to the instructions described in this
Manual.
"5-3 Check Sheet" when informing us of the trouble status

17
Chapter 5 Troubleshooting Maintenance

5-2 Alarm Display

5-2-1 Alarm Display Sections

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

NC screen

• Is any alarm message displayed on the screen?

• When the message "ALM" flickers in the lower left on the
screen;
"5-6 Resetting Overtravel" if any of overtravel alarms
(OT0500, 0501, 0502, 0503, 0504, 0505) are indicated
FANUC OPERATOR'S MANUAL if other alarms than
the above are indicated

• When the message "--EMG--" flickers in the lower left on the

screen;

"5-4 Resetting Emergency Stop"

• When the message "BAT" or "APC" flickers in the lower left

on the screen;

"6-7-1 Replacing the Battery"

* "BAT" indicates a voltage drop of the memory

backup battery.
* "APC" indicates a voltage drop of the absolute
pulse coder battery.

Alarm lamps

MC ALARM lamp
Lights up when an error is occurring in the machine.
Check the cause on the message screen.

MC WARNING lamp
• Lights up when the lubricant in the tank becomes insufficient.
• Lights up when the number of products has reached the desig-
nated value during programmed operation.
Check the cause on the message screen.

"5-5 Phenomenon and Remedy of Major Problems" when any trouble occurs in the machine

18
Maintenance Chapter 5 Troubleshooting

5-2-2 Alarm Message Screen and Help Function

Alarm Message Screen

Position for indicating the emergency

stop status
• EMG: Indicates the emergency
stop status (flickering).

Position for indicating the alarm status

• ALM: Indicates that an alarm is occurring (flicker-
ing).
• BAT: Indicates a voltage drop of the memory
backup battery (flickering).
• APC: Indicates a voltage drop of the absolute
pulse coder battery (flickering).
Indicates the controller status.
• FAN: Indicates a decrease in fan rotation speed
Alarm number and message (flickering).

Help Function
1. Press the HELP key.
• The screen below will appear.

2. Press the [ALARM] soft key.

• The details of the alarm currently issued will
displayed.
Alarm number
Normal explanation on alarm

Alarm details

FANUC OPERATOR'S MANUAL for details

19
Chapter 5 Troubleshooting Maintenance

5-3 Check Sheet

Inform Takamatsu of the following points in case of any problem.

How is the current status?

How did the trouble occur?

What is the mode selector switch set to?

How was the machine status before the trouble

occurred?

Did the trouble occur suddenly or did it

become worse little by little?
(When did the phenomenon start?)

What is displayed on the screen?

* Inform us of details of messages and alarm
numbers.

Is any alarm lamp on the machine operation

panel illuminating?

Is operation of the machine available now?

What have you checked already?

* When the diagnosis or the parameter screen
has been checked, inform us of the values.

Other remarks

20
Maintenance Chapter 5 Troubleshooting

5-4 Resetting Emergency Stop

Is the emergency stop Turn the emergency stop button in the arrow
YES
button pressed? direction of "RESET".

NO

Does the message

NO "---EMG---" disappear? YES OK

The spindle control unit may be the FANUC OPERATOR'S MANUAL separately provided
cause of the trouble.

The thermal relay of the hydraulic

pump motor might have tripped or "6-7-3 Resetting the Thermal Relay"
malfunctioned.

The thermal relay of the coolant

pump motor might have tripped or "6-7-3 Resetting the Thermal Relay"
malfunctioned.

21
Chapter 5 Troubleshooting Maintenance

5-5 Phenomenon and Remedy of Major Problems

"Special Version" for optional equipment

Phenomenon Cause Remedy

The NC shows incorrectly or The NC display circuit may be Contact Takamatsu.
does not light up at all. faulty.
Cycle start is not available. Operation has not been done "Operation"
correctly.
The NC controller may be faulty. Contact Takamatsu.
The breaker is turned off. The motor, valves or fan may be Contact Takamatsu.
faulty.
The mode cannot be changed The I/O board or the operation Contact Takamatsu.
over. panel may be faulty.
The power cannot be turned on. The power cord is not connected. Connect the power cord.
"Installation"

The primary power in the factory Turn on the primary power in the
is not on. factory.
Jog feed is not available. Operation has not been done "Operation"
correctly.
The servo amplifier or NC Contact Takamatsu.
controller may be faulty.
Dimension error in the Backlash is faulty. Check and adjust backlash.
longitudinal direction is
"6-2-2"
abnormal.
Positioning accuracy is faulty. Check and adjust the positioning
accuracy. Contact Takamatsu.
Repeatability is faulty. Check and adjust repeatability.
Contact Takamatsu.
The servo flex coupling Tighten the servo flex coupling
(clamping bolt) is loosened. (clamping bolt) securely.
Threading or tapping is not A program is not correctly made. "Programming"
correctly done.
Backlash is faulty. Check and adjust backlash.
"6-2-2"

The spindle position coder is Check and adjust the spindle

faulty. position coder.
"6-1-6"

The timing pulley groove is dirty "6-1-6"

or worn out.

22
Maintenance Chapter 5 Troubleshooting

Phenomenon Cause Remedy

Dimension error in the radial Chuck clamping force is Lower the chuck clamping force.
direction is abnormal. excessively strong.
Chuck jaw mounting bolt is Tighten the mounting bolt
loosened. securely.
Runout on the outer surface or Measure and adjust the runout.
end face of the chuck is faulty.
Headstock alignment is faulty. "6-1-5"

Turret positioning accuracy is Check and adjust the turret

faulty (due to chips in the turret positioning accuracy.
curvic coupling).
Gib clearance is faulty. Adjust the gib.
"6-2-3"

The servo flex coupling Tighten the servo flex coupling

(clamping bolt) is loosened. (clamping bolt) securely.
Zero return is not available. Operation has not been done "Operation"
correctly.
Cutting is not available as it The spindle position coder is Check and adjust the spindle
stops halfway. faulty. position coder.
"6-1-6"

The spindle drive belt is worn out Check the spindle drive belt or
or slipped. replace if required.
"6-1-3" and "6-1-4"

Required hydraulic pressure is The emergency stop button is Reset the emergency stop button.
not obtained. pressed.
The thermal relay may have "6-7-3"
tripped or be faulty.
Hydraulic oil is not discharged. Hydraulic oil is insufficient. Replenish the tank with hydraulic
oil.
"4-3"

Hydraulic oil viscosity is too high. Replace the hydraulic oil.

"4-3"

The strainer is clogged. Wash the strainer or replace if

required.
"6-4-2"

Discharge pressure is not Adjust discharge pressure.

appropriate.

23
Chapter 5 Troubleshooting Maintenance

Phenomenon Cause Remedy

The solenoid valve does Foreign objects are caught up in Disassemble and wash it. If the
not function. the spool slideway. spool does not move smoothly
inside the main unit, there are
burrs in the main unit. Deburr in
such a case.
The mounting bolts are too tight, Tightening torque should be
or flatness on the mounting within 4.9 N.
surface is insufficient.
Pressure or flow is excessive. Adjust it within the designated
value in the specifications, using a
throttle valve.
Contacting is faulty or wiring is Check the solenoid current and
disconnected. voltage. If resistance is faulty,
replace the valve.
Hydraulic phenomenon occurs. Reduce dust in the oil. Lower the
pressure as much as possible.
Change the cycle time and shorten
the exciting time.
The solenoid coil is burnt. Voltage is excessive or Check that voltage is within ±10%
insufficient. above the rating.
Solenoid valve

Ambient temperature is Adjust the oil temperature and

abnormally high. ambient temperature to below
65°C and 50°C, respectively.
Common wiring is faulty. Carry out wiring correctly.
Both the solenoid coils are turned Check the electric circuit again.
ON due to malfunction.
External leakage is An O-ring is damaged or dropped. Replace with a new one.
occuring.
The mounting surface is faulty. Adjust mounting pitch and
surface roughness on the
mounting surface.
Internal leakage is The solenoid valve is worn out Replace oil.
abnormally much. due to hydraulic oil deterioration.
"4-3"

Hydraulic oil is not appropriate. Abnormal wear occurs due to

non-combustible hydraulic oil.
Abnormal noise is Pressure or flow is excessive. Regulate difference in pressure by
generated. Liquid thrust exceeds changeover using a throttle valve. Lower
force and causes the spool vibrate. hydraulic pressure as much as
possible.
The solenoid pull-in section beats. Remove foreign objects from the
pull-in section, if any. Replace
the solenoid valve if it is faulty.

24
Maintenance Chapter 5 Troubleshooting

Phenomenon Cause Remedy

The turret is normally The proximity switch for turret "6-3-2"
positioned but the clamp signal clamp is off-positioned.
is not output.
The turret is not correctly The servo amplifier may be faulty.
indexed as designated.
The turret is stopped while it is A cutting tool is protruding too
inclined. much.
The tool change position is not
appropriate.
The chuck does not open or The solenoid valve is out of order. Previous page
close at all.
Chips or dust are stuck in the Disassemble and clean the chuck.
chuck.
A PCB may be faulty. Contact Takamatsu.
The chuck does not open or The solenoid valve is out of order. Previous page
close smoothly.
The workpiece slips. Cutting conditions are not Check the cutting conditions.
properly set.
Stroke of the master jaw is Adjust the master jaw stroke.
insufficient.
Form diameter of the chuck jaws Form the jaw again.
is not appropriate.
"Operation"

Grease is not sufficient. Replenish with grease.

"4-5"

Clamping force is insufficient. Adjust chuck pressure.

"6-1-1"

The spindle does not rotate. Operation has not been done Contact Takamatsu.
correctly.
The spindle, amplifier or NC Contact Takamatsu.
controller may be faulty.
A motor has abnormal noise or Mounting bolts are loosened. Tighten the bolts securely.
vibration.
The motor is out of order. Contact Takamatsu.
The motor output does not Belt tension is not sufficient. Adjust belt tension.
increase.
"6-1-3"

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

"6-1-3"

The spindle drive belt cuts off. The motor pulley groove is dirty Check the motor pulley.
or worn out.
"6-1-3"

The spindle generates abnormal The spindle bearing is faulty. Contact Takamatsu.
noise.

25
Chapter 5 Troubleshooting Maintenance

Phenomenon Cause Remedy

Spindle temperature abnormally The spindle bearing is not greased Contact Takamatsu.
rises. sufficiently.
Lubricant is not discharged to a Piping is damaged and oil leaks Check the piping and distributors.
certain section. from the piping.
Coolant is not discharged. The emergency stop button is Reset the emergency stop button.
pressed.
The thermal relay tripped or is "6-7-3"
faulty.
Coolant is insufficient. Replenish the tank with coolant.
"4-4"

Piping is damaged and oil leaks Check the piping.

from the piping.
Turret does not rotate. The proximity switch is defective. Replace the proximity switch with
a new one.
Operation has not been done "Operation"
correctly.
The servo amplifier or NC Contact Takamatsu.
controller may be faulty.
The turret PCB or motor is Contact Takamatsu.
defective
The unclamp valve is defective. 1. Clean the valve.
2. Replace the valve with a new
one.

26
Maintenance Chapter 5 Troubleshooting

5-6 Resetting Overtravel

This alarm will occur when the axis travels beyond its allowable range set in the machine.

An alarm message (OT0500, OT0501, OT0502, OT0503, OT0504, OT0505) below will appear on
the NC screen in this case.

5-6-1 When Soft Limit is Actuated:

1. Press the JOG switch of the mode selector switches.

• The lamp in the switch will light up.

2. Select a feedrate with the feedrate override switch.

3. Press the jog feed switch of the required direction to

move the overtraveled axis to the normal range.
• The slide moves in the selected direction at the
speed specified in step 2. as long as the switch is
pressed.

When the RPD switch is pressed

CAUTION
along with any of the jog feed
switches, a rapid traverse becomes
effective.
4. Press the RESET key.

27
Chapter 5 Troubleshooting Maintenance

5-7 Self-diagnosis Procedures

The NC has a function to display the status if switches on the operation panel function normally or if
the controller gives signals or not.
Signal addresses are shown in the electric diagrams in "Specifications".

5-7-1 Displaying Diagnosis Screen

Status in the CNC

1. Press the SYSTEM key.

2. Press the [DGNOS] soft key.

• The diagnosis screen will appear.

3. Display the desired diagnosis number.

1) Press the PAGE keys until the required screen is
displayed.

2) Key in the desired diagnosis number and then press

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

FANUC Operator's Manual for the status in the CNC unit

28
Maintenance Chapter 5 Troubleshooting

Status of input/output signals

1. Press the SYSTEM key.

2. Press the continued menu key several times.

Continued menu key

3. Press the [PMCMNT] soft key.

4. Press the [STATUS] soft key.

• The PMC SIGNAL STATUS screen will appear.

5. Display the desired diagnosis number.

1) Press the PAGE keys until the desired screen is
displayed.

2) Key in the desired diagnosis number, and then press

the [SEARCH] soft key.
* The [SEARCH] soft key is displayed when the [(OPRT)]
soft key is pressed.

29
Chapter 5 Troubleshooting Maintenance

5-7-2 Reading the Signal Address Table

7 6 5 4 3 2 1 0
X9

Each numeral (0 - 7) shown in the above example is called a bit.

A bit is the minimum unit of information. An address table is generally expressed with 8 bits. Bits
are used for indicating an address of a certain signal. The rightmost is bit 0 and the leftmost is bit 7.
(Take note that bits are numbered starting with "0".)
It is normal when bit changes either to 0 or 1 after a motion is executed.

30
Maintenance Chapter 5 Troubleshooting

5-8 Parameter Setting and Change

Parameters determine various setting conditions for the machine, and must be set correctly in order
to operate the machine properly.

WARNING Before changing any parameter, be sure to contact Takamatsu.

5-8-1 Parameter Reference

1. Press the SYSTEM key.

2. Press the [PARAM] soft key.

• The parameter screen is displayed.

3. Bring up the desired parameter.

1) Press the PAGE keys until the required screen is
displayed.

2) Key in the desired parameter number, and then press

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

FANUC OPERATOR'S MANUAL for the status in the CNC

unit

31
Chapter 5 Troubleshooting Maintenance

If you do not know the parameter number to be referenced, it

can be found by accessing the help function.
FANUC OPERATOR'S MANUAL separately provided

Parameter contents screen

32
Maintenance Chapter 5 Troubleshooting

5-8-2 Parameter Setting (Change)

1. Press the MDI switch of the mode selector switches.

• The lamp in the switch will light up.

2. Press the OFS/SET key.

3. Press the [SETTING] soft key.

• The setting screen is displayed.

4. Press the cursor key until the cursor comes to

"PARAMETER WRITE".

5. Set "PARAMETER WRITE" to "1" (parameter write

enable), by pressing:

(or press the [INPUT] soft key.)

• "P/S100 Alarm" is indicated on the screen.

6. Press the SYSTEM key.

33
Chapter 5 Troubleshooting Maintenance

7. Press the [PARAM] soft key.

• The parameter screen is displayed.

8. Bring up the desired parameter.

1) Press the PAGE keys until the required screen is
displayed.

2) Key in the desired parameter number, and then press

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

FANUC OPERATOR'S MANUAL for the status in the CNC

unit

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

(or press the [INPUT] soft key.)

10. Press the OFS/SET key.

11. Press the [SETTING] soft key.

• The setting screen is displayed.

12. Set "PARAMETER WRITE" to "0" (parameter write

disable), by pressing:

(or press the [INPUT] soft key.)

13. Press the RESET key.

• "P/S100 Alarm" disappears from the screen.

34
Maintenance Chapter 6 Maintenance for Each Unit

Chapter 6 Maintenance for Each Unit

6-1 Headstock

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

DANGER
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake.
The cover should not be opened by unqualified personnel for
WARNING
maintenance. Turn the main power switch off when it is needed to work
inside the cover.

6-1-1 Adjusting Chuck Pressure

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

Adjust the chuck pressure within the setting range that is determined by
CAUTION
the combination of the chuck and the cylinder to use.

Adjustment interval As required

[Required tools]
Spanner [13]
Allen wrench [5]

1. Loosen the lock nut.

2. Adjust the chuck pressure by turning the pressure adjusting bolt.
• Turning the knob CW increases the pressure.
• Turning the knob CCW decreases the pressure.

35
Chapter 6 Maintenance for Each Unit Maintenance

3. Tighten the lock nut.

Lock nut

Chuck pressure gauge Pressure adjusting bolt

Fig. 8

6-1-2 Chuck Pressure Setting Table for Cylinder

Maximum allowable pressure (MPa) by chuck type

Hollow type: Kitagawa SS1236-102
Chuck: Kitagawa B206

Pull-side pressure
Type Pull force (kN) Allowable pressure (MPa)
receiving area (cm2)

Kitagawa SS1236-102 22.0 77.1 3.1

*1: If you use a chuck not listed above, carefully consider the allowable pressure (thrust).
*2: If the pressure is 1 MPa or less, chucking operation may become unstable depending on the use
condition, such as ambient temperature.

36
Maintenance Chapter 6 Maintenance for Each Unit

6-1-3 Adjusting the Belt

An excessive tension on the belt may reduce the life of the belt or bearings. Also, less tension may
cause abnormal noise or vibration, and the rated horse power cannot be transmitted because the belt
slips.

Specified load F
Flexibility
Belt name Belt type Q'ty Remarks
Tensile Re-tensile δ (mm)
load (N) load (N)

Wedge belt Motor, 4500 min−1

3V-630 3 12.3 10.8 9
(V belt) 5.5/3.7 kW

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

* The tensile loads indicated above are to be applied to one belt.
* Flexibility δ (mm) obtained when the tensile load is applied to the center of the span is shown.

Specified load F
Flexibility δ

For the specifications (motor output, rotating speed, etc.) not listed above, consult your distributor.

Fig. 9

Inspection interval Every 6 months

[Required tools]
Allen wrenches [4], [10]
Spanner [17]
Tension gauge (or spring balance)

37
Chapter 6 Maintenance for Each Unit Maintenance

Adjustment procedure
1. Turn the main power switch off.
2. Remove the side cover from the machine.
3. Loosen four motor base mounting bolts.
4. Loosen the lock nuts.
5. Adjust the belt tension so that the specified flexibility δ can be obtained when the specified load
F (tensile load or re-tensile load) is applied to the belt.
• To increase the tension, turn the adjusting bolt CW.
• To decrease the tension, turn the adjusting bolt CCW and press down the belt from both
sides.
6. Re-tighten the four motor base mounting bolts securely.
7. Tighten the lock nuts.
8. Mount the side cover on the machine again.

Side covers

Adjusting bolt

Lock nut

Motor base mounting bolt

Fig. 10

38
Maintenance Chapter 6 Maintenance for Each Unit

6-1-4 Replacing the Belt

[Required tools]
Allen wrenches [4], [10]
Spanner [17]
Tension gauge (or spring balance)
Screwdriver

1. Turn the main power switch OFF.

2. Remove the side cover from the machine.
3. Disconnect the drain hose and the hydraulic hose from the chucking cylinder.

CAUTION Put match marks on these hoses to prevent misconnection.

4. Carry out steps 3. and 4. in the adjustment procedure of the belt.

5. Lift the motor base.
6. Remove the belt.
7. Mount a new belt instead.
8. Carry out steps 5. to 7. in the adjustment procedure of the belt.
9. Connect the drain hose and the hydraulic hose to the chucking cylinder again.
10. Mount the side cover on the machine again.

39
Chapter 6 Maintenance for Each Unit Maintenance

Side covers

Adjusting bolt

Lock nut

Motor base mounting bolt

Fig. 11

40
Maintenance Chapter 6 Maintenance for Each Unit

6-1-5 Aligning the Headstock

CAUTION If any adjustment is required, contact Takamatsu.

Inspection interval Yearly

[Required tools]
Allen wrenches [5], [6], [8], [10], [14]
Spanner [13]
Test bar
Dial indicator (with magnet stand, division: 0.002 mm)

Measuring method using a test bar

1. Mount a test bar on the spindle.
2. Attach a magnet stand on the turret, and apply a dial indicator to the test bar.
3. Move the Z axis to measure a dislocation amount of the headstock as shown below.

Indicator

0 mm 0.005 mm
Z-axis
direction

150 mm Test bar

* If the reading of the indicator is 0.005 mm/150 mm, headstock adjustment is not required.

Fig. 12

41
Chapter 6 Maintenance for Each Unit Maintenance

Measuring method by turning a workpiece

1. Mount a long workpiece (test bar) in the chuck.
2. Cut the workpiece to obtain the finish O.D.
3. Remove the workpiece from the chuck and measure the workpiece diameter.

D0 - D1 = 0.01 mm

D0 D1
Chuck Workpiece

150 mm

* If the difference between D0 and D1 is 0.01 mm or less and the workpiece is tapered off, headstock
adjustment is not required.
Fig. 13

42
Maintenance Chapter 6 Maintenance for Each Unit

6-1-6 Replacing the Position Coder

Carefully handle the position coder since it is precision equipment. Never

CAUTION
use a hammer to remove or mount it.

[Required tools]
Allen wrenches [3], [4], [8]

1. Turn the main power switch OFF.

2. Remove the side cover from the machine.
3. Turn the canon plug with hand until it is removed.
4. Loosen four span ring tightening bolts.
5. Remove four position coder mounting bolts.
6. Draw the position coder out of the bracket until it is removed.
7. Fit the new position coder to the bracket.
8. Tighten four position coder mounting bolts.
9. Tighten four span ring tightening bolts.
10. Re-mount the canon plug by turning it with hand.
11. Mount the side cover on the machine again.

Position coder (3133200901)

Side cover

Belt

Span ring Position coder mounting bolt

Span ring mounting bolt

Position coder

* Adjust the tension of the position coder

belt so that the flexibility of 3 mm will be
Canon plug
obtained when the load of 5 N is applied
to the center of the span.
Position coder belt
Type: 337L 050

Fig. 14

43
Chapter 6 Maintenance for Each Unit Maintenance

6-2 Slide Unit

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

DANGER
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake.
The cover should not be opened by unqualified personnel for
WARNING
maintenance. Turn the main power switch off when it is needed to work
inside the cover.

6-2-1 Replacing Wipers

Inspection interval Every 6 months (replace if damaged)

[Required tools]
Phillips screwdriver
Allen wrench [4]

Wipers in front of the X axis

1. Turn the main power switch OFF.

2. Open the front door.
3. Remove the X-axis slide cover.

X-axis slide cover

Fig. 15

44
Maintenance Chapter 6 Maintenance for Each Unit

4. Remove the wipers.

3151301100 (X-axis slide wiper)

3151301700 (wiper) 3151101700 (wiper)

Fig. 16
5. Mount new wiper(s) instead.
6. Re-mount the X-axis slide cover.

45
Chapter 6 Maintenance for Each Unit Maintenance

6-2-2 Measuring and Compensating Backlash

Backlash (lost motion) may occur to each axis feed mechanism due to the following causes, which
makes a difference between the specified value and the actual axial travel.
• Lost motion caused by the rigidity in the axial direction of the ball screw
• Lost motion caused by the rigidity of the ball screw's thrust bearing
Such backlash can be offset by the backlash compensation function provided in the NC unit.
Offset amount of backlash is correctly set before delivery, however, it may become out of
adjustment after use of the machine for a long period of time.

Inspection interval Yearly

[Required tools]
Dial indicator (with magnet stand, division: 0.002 mm)

1. Attach the magnet stand to the spindle nose, and apply the indicator to the turret.
• When measuring a backlash in the Z-axis direction, apply the indicator to the end plane of
the turret as shown below, and reset its reading to "0".

Fig. 17

• When measuring a backlash in the X-axis direction, apply the indicator to a holder
mounting plane on the turret as shown below, and reset its reading to "0".

Fig. 18

46
Maintenance Chapter 6 Maintenance for Each Unit

2. Press HANDLE of the mode selector switch.

3. Press the magnification switch "×1".
4. Select the axis to measure backlash with the HNDL X/Z switch.
5. Rotate the manual pulse generator in the minus (−) direction by 20 pulses.
6. Rotate the manual pulse generator in the plus direction by the same amount (20 pulses) as in
step 5.
7. Read the indicator.

Backlash Backlash

Fig. 19

8. Set an offset amount.

• When the reading is below "0":
Offset amount = Current offset amount + reading
• When the reading exceeds "0":
Offset amount = Current offset amount − reading
* Parameter No. 1851 (for cutting feed)

"5-8 Parameter Setting and Change"

As for detailed parameters, refer to FANUC MAINTENANCE MANUAL.

47
Chapter 6 Maintenance for Each Unit Maintenance

6-2-3 Slide Reference Point Setting

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

DANGER
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake.
The cover should not be opened by unqualified personnel for
WARNING
maintenance. Turn the main power switch off when it is needed to work
inside the cover.

This machine uses absolute pulse encoders for the servo motors of the X and Z axes. Thus, zero
point setting is not required for ordinary operation; however, if any backup battery for the absolute
pulse coder attached in the electric cabinet is dead or if any signal cable for the servo motor is
disconnected during servo amplifier or motor replacement, the zero point setting must be performed.
Also, the zero point setting is required when the grid shift parameter setting (No. 1850) is changed.

1. Display the parameter setting screen.

"5-8 Parameter Setting and Change"

2. Reset parameter No. 1815 for the axis, of which zero

point setting is to be made, to "00100000".
• The alarm message "PW0000 POWER MUST BE
OFF" is displayed.
* When the battery is dead or when the servo motor signal
cable is disconnected, this parameter is automatically
reset to "00100000".

3. Turn the power off.

"2-5 Turning Power OFF" in Operation

4. Press the power on button and reset the emergency stop

button.
"2-2 Turning Power ON" in Operation

• The alarm message "DS0300 (X) APC ALARM:

NEED REF RETURN" is displayed.
* The axis for which zero point setting is required is
indicated in parentheses ( ).
X: X axis
Z: Z axis

48
Maintenance Chapter 6 Maintenance for Each Unit

5. Press JOG or HANDLE of the mode selector switch.

• The lamp in the switch will light up.

or
6. Move the axis for which zero point setting is required
20 mm or more in a single direction (equivalent to one
turn of the motor shaft) using jog or handle operation.
* When this is completed, zero point setting becomes
available. (After turning the power on)
7. Turn the power OFF and back it ON.
8. Press "JOG" or "HANDLE" of the mode selector switch.
• The lamp in the switch will light up.

or

9. Move the slide to a safe area.

* For zero point setting, the slides move automatically.
Select the JOG or HANDLE mode, and move the slides to
the position where they will not interfere with a tool, the
chuck, etc.

or

10. Press "REF RETURN" of the mode selector switch.

• The lamp in the switch will light up.

11. Use the HNDL X/Z switch to select the axis that you
mounted the stopper on

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

49
Chapter 6 Maintenance for Each Unit Maintenance

12. Press the cycle start button.

* Reference point setting begins automatically.
* Pressing the emergency stop button or the RESET key
suspends the zero point setting.
(1) The axis moves at a fixed speed towards the stopper.

Reference point
setting stopper

Tool post

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

approximately 10 to 40 mm.

Reference point
setting stopper

Tool post

(3) The axis moves towards the stopper again.

Reference point
setting stopper

Tool post

(4) When the axis bumps into the stopper, it moves to the
reference point position.

Reference point
Machine zero point setting stopper

Tool post

(5) When the axis arrives at the reference point position,

the reference point is established and reference point
setting is finished. The axis reference point lamp on
the operation panel lights up.
13. Press the RESET key.
• The alarm will disappear from the screen.
* If the alarm does not disappear or the alarm "DS0309
APC ALARM: ( ) REF RETURN IMPOSSIBLE" appears,
follow steps from 6.
* The axis for which zero point setting is required is
indicated in parentheses ( ).
X: X axis
Z: Z axis
14. When setting the zero point of another axis, follow the
same steps from step 6.

50
Maintenance Chapter 6 Maintenance for Each Unit

6-2-4 Settings for Collision Detection Function

This machine is equipped with a function that monitors the torque of the slide-axis (X and Z) servo
motor. When an abnormal load is applied to the slide-axis servo motor, an alarm occurs and the
machine stops.
This function can reduce damage to the machine at the time of collision.
* Note that this function only reduces the damage that might be given to the machine, and is not intended to
avoid damage to the machine completely.
* When an alarm occurs, the following message is displayed.
"SV0409 ( ) DETECT ABNORMAL TORQUE"
* The alarm is cleared when the RESET key is pressed.

Settings for Collision Detection Function

Set the following parameters for the collision detection function.
For details on the parameter setting procedure, see "5-8-2 Parameter Setting (Change)".

Parameter Bit Function Setting

Used to set whether to enable or disable the colli-

sion detection function.
0: Disabled
No. 2016 0 (ABNT) When "1" is set, the collision detection function for
1: Enabled
the servo motor is enabled.
The default setting is "1".

Used to set the retraction distance (mm).

When a collision is detected, the slide axis retracts
the specified distance and stops.
The default setting is "0".
No. 2103 ⎯ * As a guide, set 3 mm for the retraction 0 - 32767
distance.
* Pay careful attention to interference of the
cutting tool with the chuck or workpiece.
* Set the value for each axis.

Used to set the collision detection level.

* The default setting is 100% of the servo motor
load value.
* When "0" or a value greater than "7283" is set,
the collision detection function is disabled.
* Set the value for each axis.
No. 2104 ⎯ 0 - 7282
* If the alarm "SV0409" occurs frequently during
normal cutting operation, adjust the collision
detection level. The collision detection level
must be adjusted in increments of +50.
Perform test cutting each time the value is
changed.

51
Chapter 6 Maintenance for Each Unit Maintenance

6-3 Turret Unit

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

DANGER
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake.
The cover should not be opened by unqualified personnel for
WARNING
maintenance. Turn the main power switch off when it is needed to work
inside the cover.
Tool temperatures will not drop soon after the machine stops. Check that
CAUTION
tools have cooled off before touching them. Do not touch tools
immediately after operation.

6-3-1 Measuring Turret Parallelism

[Required tools]
Dial indicator (Division: 0.002 mm)
Allen wrench [8]
Round bar

Measurement procedure
1. Remove all holders from the turret.
2. Mount the dial indicator on the magnet stand, and attach it to the chuck.
3. Move the slides until the indicator makes contact with the holder mounting surface of the turret.
4. Move the Z-axis slide using the manual pulse generator, and read the indicator.

Z
Z

Fig. 20
* Measure the above for the entire width of the holder mounting surface.
* Make this measurement for one holder mounting surface.
* If the indicator reading is 20 μm or less, no adjustment is required.
If it exceeds 20 μm, turret alignment must be made.
5. Bring the indicator into contact with a side of the holder mounting groove on the turret.
6. Move the Z-axis slide using the manual pulse generator, and read the indicator.

52
Maintenance Chapter 6 Maintenance for Each Unit

7. Keep the indicator in place while moving the Z-axis slide in the +Z direction, and index the
turret by one station.
8. Move the Z-axis slide in the −Z direction until the indicator makes contact with the holder
mounting surface.
9. Repeat steps 7. and 8., and measure at 8 stations
10. Attach a boring holder to the holder mounting surface that showed an average reading.
* Clean the mounting surface before mounting a boring holder.
11. Move the X-axis slide until the hole center of the boring holder aligns with the spindle center.
12. Bring the indicator into contact with the inside of the hole on the boring holder.
13. Turn the spindle by hand, and read the indicator.
14. Move the X-axis slide using the manual pulse generator until the indicator shows the same
value at "a" and "b". Then, read the indicator at "c" and "d".
* When the indicator reading is 25 μm or less, it is acceptable; however, to obtain a higher center
height accuracy, adjust it to 5 μm or less at the position of an average reading.
* If it exceeds 25 μm, turret curvic coupling alignment must be made.
15. Keep the indicator in place while moving the Z-axis slide in the +Z direction, and index the
turret by one station. A boring holder must be attached to the station in advance.
16. Move the Z-axis slide in the −Z direction until the indicator makes contact with the holder
mounting surface.
17. Turn the spindle by hand, and read the indicator.
* Read the deviation at "a-b" and "c-d".
If the indicator reading is 25 μm or less, no adjustment is required.
If the deviation at "a-b" exceeds 25 μm, center alignment must be made by adjusting grid shift
amount in the FANUC parameters.
If the deviation at "c-d" exceeds 25 μm, turret curvic coupling alignment must be made.

Fig. 21
18. Repeat steps 15. to 17., and measure at all stations.

CAUTION If any adjustment is required, contact Takamatsu.

53
Chapter 6 Maintenance for Each Unit Maintenance

6-3-2 Adjusting the Turret Clamp Proximity Switch

When the turret clamp signal is not given even if the turret is indexed in the normal position, adjust
the proximity switch used for checking turret clamping.

[Required tools]
Allen wrenches [4], [5]
Spanner [24]

1. Remove the rear cover from the machine.

2. Loosen the lock nut of the proximity switch.
3. Adjust the proximity switch position so that the switch will light up when the turret is clamped
or unclamped.

The proximity switch must be adjusted to the position where its lamp
CAUTION
barely lights up (keeping a clearance of 4.5 mm between the proximity
switch and the dog).

4. Tighten the lock nut of the proximity switch.

Turret clamp check switch

Dog

Rear cover

Fig. 22
5. Mount the rear cover again.

54
Maintenance Chapter 6 Maintenance for Each Unit

6-3-3 Returning the Turret to the Origin Point

If the turret stops rotating between stations due to an emergency stop or a power failure, follow the
procedure below and return the turret to its origin point.
* When you have replaced the turret servo motor, servo amplifier or battery, or disconnected turret motor
signal cables during replacement of these components, make a turret origin point setting referring to
"6-3-4 Setting the Turret Zero Point".
1. Check that the turret stops and that the following message is displayed on the screen.
• "EX0018 TURRET CLAMP POSITION ALARM"
"CANCEL TURRET ALARM, AND PLEASE PUSH THE TURRET SWITCH WITH
REF RETURN MODE. INDEX THE NO. 1 BY TAKING A SHORT CUT."
2. Reset the emergency stop button.

3. Press REF RETURN of the mode selector switch.

• The lamp in the switch will light up.

4. Check the inside of the machine and confirm that the turret will not interfere with the chuck
during rotation.
5. Press the RESET key.
• The alarm will disappear from the screen.

6. Check that the front door is closed, and then press the TURRET switch.
• The turret will turn at a low speed to the station No. 1. The lamp in REF RETURN of the
mode selector switch will blink.

7. Check that the turret is indexed normally in the manual and automatic modes.
• When no abnormality is found, the procedure is completed.
* If the turret is not clamped normally in step 7., make a turret origin point setting.

"6-3-4 Setting the Turret Zero Point"

55
Chapter 6 Maintenance for Each Unit Maintenance

6-3-4 Setting the Turret Zero Point

When you have mounted the turret, replaced the turret servo motor or servo amplifier, or
disconnected motor signal cables for replacement of these components, make a turret zero point
setting. This setting is also required when the turret operates abnormally or the backup battery for
the absolute pulse coder has expired.
* When the servo motor has been replaced, be sure to index the turret by one step (equivalent to one turn of
the motor shaft) and turn the power off and on before performing step 3. When this is completed, zero
point setting becomes available.

Adjusting the turret position and setting the turret zero point
1. Set "0" for bit 4 (APZ) for "3"-rd axis in parameter No.
1815.

2. Set bit 0 of PMC parameter K14 (keep relay) to "1".

• The lamps on the mode selector switches flash
alternately.

3. Press the TURT switch.

• The turret is unclamped.
* The turret is clamped and unclamped each time the TURT
switch is pressed.
* When the clamp check sensor is in the ON state, the "X"
and "Z" lamps on the HNDL X/Z switch are lit. When the
clamp check sensor is in the OFF state, the "X" and "Z"
lamps on the HNDL X/Z switch are not lit.
* When fine-adjusting the clamp check sensor, turn the
turret until mechanical clamp becomes impossible. Adjust
the clamp check sensor so that its lamp will not light up at
this time. Check that the clamp check sensor lamp lights
up when the turret is clamped again after adjustment is
finished. If the adjustment is not made correctly, trouble
such as turret interference with the curvic coupling during
rotation occurs.

56
Maintenance Chapter 6 Maintenance for Each Unit

4. Manually turn the turret to the position to be set as a zero

point.
* The clamp check sensor must be turned on to complete
the zero point setting.
* Turn the turret while the turret is unclamped.
5. Press the TURT switch.
• The turret is clamped.
* The turret is clamped and unclamped each time the TURT
switch is pressed.
6. Set "1" for bit 4 (APZ) for "3"-rd axis in parameter
No. 1815.

* The alarm message "PW0000 POWER MUST BE OFF" is

displayed.
7. Turn the power off.
* When the power is turned on again, the set position
becomes the turret zero point as well as turret station
No. 1.
8. Press the power on button and reset the emergency stop
button.
* The zero point setting is completed unless the alarm
message "DS0300 (3) APC ALARM: NEED REF
RETURN" is displayed.

See "2-2 Turning Power ON" in Operation.

9. Set bit 0 of PMC parameter K14 (keep relay) to "0".

• The lamps on the mode selector switches (flashing
alternately) are turned off.
10. Check that the turret is indexed correctly in the manual
and automatic modes.
• This step completes the setting when no
abnormality is noted.

57
Chapter 6 Maintenance for Each Unit Maintenance

6-4 Hydraulic Pump Unit

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

DANGER
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake.
The cover should not be opened by unqualified personnel for
WARNING
maintenance. Turn the main power switch off when it is needed to work
inside the cover.
* Specifications are subject to change according to the improvement of the machine. Check the types and
quantities of parts to be replaced, and place an order with Takamatsu.

6-4-1 Cleaning the Oil Filler Filter

Cleaning interval Yearly

1. Turn the main power switch OFF.

2. Remove the cap from the oil filler port by turning it with hand.
3. Pull the cap upward to draw the oil filler filter.
4. Wash the filter in wash oil.
5. Return the filter inside the tank, and secure the cap by turning it with hand.

Cap

Cap

Oil filler filter

Fig. 23

58
Maintenance Chapter 6 Maintenance for Each Unit

6-4-2 Cleaning the Strainer

Clean the strainer when replacing the hydraulic oil.

Cleaning interval Yearly

[Required tool]
Phillips screwdriver

1. Turn the main power switch off.

2. Place the oil pan under the drain port.
3. Loosen the drain cock.
• The hydraulic oil will drain.
4. Remove the left side cover.
5. Remove tank cover mounting bolt.
6. Remove the cover from the tank.
7. Remove the strainer by turning it.
8. Wash the strainer in wash oil.
* Replace the strainer with a new one if it is too dirty.
9. Re-mount the strainer.
10. Re-mount the cover on the tank.
11. Tighten the tank cover mounting bolt securely.
12. Re-mount the left side cover on the machine.
13. Supply hydraulic oil from the oil filler port up to the upper limit of the oil level gauge.

Tank cover
mounting bolt Oil filler port

Tank cover

Strainer

Fig. 24

59
Chapter 6 Maintenance for Each Unit Maintenance

6-4-3 Cleaning the Hydraulic Tank

Clean inside of the hydraulic tank when renewing the supply of hydraulic oil in it.

Cleaning interval Yearly

[Required tools]
Phillips screwdriver
Oil pan (for collecting hydraulic oil)

1. Turn the main power switch off.

2. Place the oil pan under the drain port.
3. Loosen the drain cock.
• The hydraulic oil will drain.
4. Remove the left side cover.
5. Remove tank cover mounting bolt.
6. Remove the cover from the tank.
7. Clean the inside of the tank with wash oil.
* Clean the magnet separator too.
8. Re-mount the cover on the tank.
9. Tighten the tank cover mounting bolt securely.
10. Secure the drain cock.
11. Re-mount the left side cover on the machine.
12. Supply hydraulic oil from the oil filler port up to the upper limit of the oil level gauge.

Tank cover
mounting bolt Oil filler port

Tank cover

Magnet separator Drain

Fig. 25

60
Maintenance Chapter 6 Maintenance for Each Unit

6-4-4 Adjusting Discharge Pressure

Adjust the discharge pressure when the chucking cylinder is most

WARNING
advanced with the chuck (collet) open. Otherwise, the chucking cylinder
or chuck may be damaged.

The source pressure of the hydraulic pump is set to 3.4 MPa upon delivery.
If re-adjustment is required, follow the procedures below.
* Check the discharge pressure on the chuck pressure gauge with the chuck reducing valve fully open
(pressure not reduced). When the discharge pressure has been adjusted, the chuck pressure must also
be adjusted.

For details on adjustment of the chuck pressure, see "6-1-1 Adjusting Chuck Pressure".

[Required tools]
Spanneres [13], [19]
Allen wrench [5]

1. Loosen the lock nut.

2. Adjust the discharge pressure by turning the discharge pressure adjusting bolt.
• Turning the bolt CW increases the pressure.
• Turning the bolt CCW decreases the pressure.
3. Tighten the lock nut.

Discharge pressure Lock nut Lock nut

adjusting bolt
Chuck pressure gauge
Chuck pressure adjusting bolt

Fig. 26

61
Chapter 6 Maintenance for Each Unit Maintenance

6-5 Lubrication Unit

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

DANGER
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake.
* Specifications are subject to change according to the improvement of the machine. Check the types and
quantities of parts to be replaced, and place an order with Takamatsu.

6-5-1 Cleaning the Oil Filler Filter

Cleaning interval Yearly

[Required tool]
Phillips screwdriver

1. Turn the main power switch OFF.

2. Loosen two set screws.
3. Remove the lubricant tank.
• Slide both fittings located on the right and left sides of the tank and open them.
4. Push down three claws mounted on the back of oil filler filter.
5. Draw the filter out while holding it up.
6. Wash the filter in wash oil.
7. Re-mount the filter while pushing it down.
8. Re-mount the tank.
9. Tighten two set screws.

Oil filler filter

(1) (2)
Set screw

(3)
Fitting
Tank Fittings
Tank

Fig. 27

62
Maintenance Chapter 6 Maintenance for Each Unit

6-5-2 Cleaning the Suction Filter

Cleaning interval Yearly

[Required tool]
Phillips screwdriver

1. Turn the main power switch OFF.

2. Loosen two set screws.
3. Remove the lubricant tank.
• Slide both fittings located on the right and left sides of the tank and open them.
4. Remove the filter stopper.
5. Remove the suction filter by picking it up with finger.
6. Wash the suction filter in wash oil.
• Replace the suction filter with a new one if it is too dirty.
7. Re-mount the suction filter.
8. Re-mount the filter stopper.
9. Re-mount the tank.
10. Tighten two set screws.

Suction filter

Filter stopper

Fig. 28

63
Chapter 6 Maintenance for Each Unit Maintenance

6-5-3 Cleaning the Lubricant Tank

Cleaning interval Yearly

[Required tools]
Phillips screwdriver
Oil pan (for collecting lubricant)

1. Turn the main power switch OFF.

2. Loosen two set screws.
3. Remove the lubricant tank.
• Slide both fittings located on the right and left sides of the tank and open them.
4. Drain lubricant into the oil pan from the tank.
5. Clean inside of the hydraulic tank with wash oil.
6. Re-mount the tank.
7. Tighten two set screws.

Oil filler filter

(2)
(1) Set screw

(3)

Fitting

Tank Fittings

Tank

Fig. 29

64
Maintenance Chapter 6 Maintenance for Each Unit

6-6 Coolant Unit

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

DANGER
indicating "MAINTENANCE - KEEP AWAY FROM THE MACHINE."
around the machine so that the power is not turned on or the
operation panel is not touched by mistake.
• Use non-flammable coolant. When using oil-based coolant
WARNING
inevitably, strictly follow the instructions in "Safety Precautions for
Fire Prevention".

"Chapter 9 Safety Precautions for Fire Prevention" in "Safety Guide"

• Depending on the coolant to use, corrosion, deterioration or failure of

parts in the unit may occur.
"Chapter 10 Notes on Coolant Selection" in "Safety Guide"

6-6-1 Cleaning the Coolant Tank

Cleaning interval Every 6 month

[Required tools]
Spanner [14]
Allen wrench [4]
Air vacuum cleaner
Oil pan (for collecting coolant)

1. Turn the main power switch off.

2. Remove the oil pan cover.
3. Remove the tank oil pan and cover.
4. Remove the filters.
5. Remove the bed tank cover.
6. Vacuum the coolant out of the tank using an air vacuum cleaner.
7. Loosen the drain cocks at the front and rear of the machine to drain remaining coolant out of the
tank.
8. Clean the inside of the tank.
9. Tighten the drain cocks at the front and rear of the machine.
10. Supply coolant into the coolant tank.
* Supply coolant up to the upper limit line of the oil gauge.
11. Attach the bed tank cover.
12. Mount the filters.
13. Attach the tank oil pan and cover.
14. Attach the oil pan cover.

65
Chapter 6 Maintenance for Each Unit Maintenance

Filters
Oil pan cover

Bed tank cover

Cover Tank oil pan Level gauge Drain (machine rear)

Drain (machine front) Drain (machine rear)

Fig. 30

66
Maintenance Chapter 6 Maintenance for Each Unit

6-7 Electric Cabinet

6-7-1 Replacing the Battery

* Specifications are subject to change according to the improvement of the machine. Check the types and
quantities of parts to be replaced, and place an order with Takamatsu.

Battery for memory back-up (for the NC Controller)

Improper battery replacement may trigger an explosion.

WARNING
Only use the specified type of battery (A02B-0323-K102).

Be sure to replace the battery within 30 minutes. Otherwise, data will be

CAUTION
deleted from memory.

1. Turn the power on for 30 seconds. (Display the NC screen.)

2. Turn the power OFF.
3. Remove the operation box left side cover from the machine.
4. Pull the battery unit toward you while holding the claw.
5. Insert a new battery unit.
* Check that the claw is securely locked.
6. Mount the operation box left side cover.

Operation box Left side cover

(Rear of the operation box) Battery unit

(A02B-0323-K102)

Display unit (rear)

Fig. 31

67
Chapter 6 Maintenance for Each Unit Maintenance

Battery for absolute pulse coder (for servo motor)

Be sure to keep the NC power on when replacing a battery.

CAUTION
Otherwise stored data (absolute positions) will be deleted from the
memory.
If this occurs, it will be necessary to reestablish the reference point.
If reference point setting is required, contact Takamatsu.

A battery is provided because the servo motors for the X, Z axes and turret indexing use absolute
pulse encoders. When battery voltage becomes low, an alarm will occur.
Replace the battery as soon as possible.
* It is necessary to make a reference point setting in the following cases: The servo motor signal line is
removed when changing the servo amplifier or motor.
The grid shift parameter is changed.

To avoid the possibility of someone starting the machine mistakenly, the

WARNING
emergency stop button should be pressed and remain in the down
position while you are performing this operation.

1. Turn the main power switch ON. (Display the NC screen.)

2. Remove the battery cover.
3. Replace the battery with a new one.
4. Put the battery cover back.
5. Turn power to the machine OFF.

Electric cabinet door

Battery cover
Battery (Alkaline battery size D × 4 pcs)

Remove the battery cover (cap), and

replace the battery with a new one while
the electric cabinet door is mounted.

Fig. 32

68
Maintenance Chapter 6 Maintenance for Each Unit

6-7-2 Replacing the Fuse

Be sure to turn the main power switch off during maintenance work.
DANGER
The primary power in the factory should also be off for maintenance of
the electric cabinet. Never remove the electric cabinet door for five
minutes, as residual voltage remains.

Never put a part of your body below the electric cabinet door when
CAUTION
removing it. The electric cabinet door may come off, resulting in injury.

* Specifications are subject to change according to the improvement of the machine. Check the types and
quantities of parts to be replaced, and place an order with Takamatsu.

1. Turn the main power switch off.

2. Shut off the primary power in the factory.
3. Remove the electric cabinet door.
4. Hold the fixing hooks and pull the PCB out of the servo amplifier (SVSP).
5. Remove the blown fuse.
6. Mount a new fuse instead.
7. Mount the PCB.
8. Mount the electric cabinet door.
* When a fuse is burnt, there is some fault in the control circuit in most cases. In such a case, the situation
may not be improved even if the fuse is replaced. Replace the module entirely.
* The fuse is mounted on the control PCB of the module, and it cannot be replaced from outside. Remove
the control PCB first, then replace the fuse.

See "5-2 Parts Arrangement in Electric Box" in Specifications.

69
Chapter 6 Maintenance for Each Unit Maintenance

Main power switch

Electric cabinet door

Electric cabinet

(Side view of SVSP)

Fuse (A06B-6073-K250) Fixing hook

(Front view of the inside of the electric cabinet)
SVSP

Pull out toward

you.

Fixing hook

PCB Fixing hook

Fig. 33

70
Maintenance Chapter 6 Maintenance for Each Unit

6-7-3 Resetting the Thermal Relay

Be sure to turn the main power switch off during maintenance work.
DANGER
The primary power in the factory should also be off for maintenance of
the electric cabinet. Never open the door for five minutes even after the
power is turned off, as residual voltage remains.

Never put a part of your body below the electric cabinet door when
CAUTION
removing it. The electric cabinet door may come off, resulting in injury.

1. Turn the main power switch OFF.

2. Shut off the primary power in the factory.
3. Remove the electric cabinet door.
4. Press the reset button of the thermal relay.
5. Mount the electric cabinet door.
"5-2 Parts Arrangement in Electric Box" in "Specifications"

* Contact Takamatsu when a thermal relay trips repeatedly even after resetting it.

Main power switch (Front view of the inside of the electric cabinet)

Electric cabinet
door

Reset button

Electric cabinet

Thermal relay

Fig. 34

71
Chapter 6 Maintenance for Each Unit Maintenance

6-8 CNC Control Unit

6-8-1 CNC Screen Auto-Off Function

This machine is equipped with a function that turns off the CNC screen automatically when no
operation is made using soft keys or MDI keys for the predetermined time. Turning off the CNC
screen automatically prolongs the service life of the LCD and enhances the power-saving effect.
* When a soft key or MDI key is pressed while the CNC screen is OFF, the CNC screen will light up.
* When an alarm occurs (an alarm message displayed) while the CNC screen is OFF, the CNC screen will
light up. The CNC screen remains ON until the alarm message is cleared.

Settings for the CNC Screen Auto-Off Function

Set the following parameter for the CNC screen auto-off function.
For details on the parameter setting procedure, see "5-8-2 Parameter Setting (Change)".

Parameter Function Setting

Used to set the waiting time for turning off the CNC screen
automatically.
When no key operation is made for the waiting time set here, the
No. 3123 CNC screen will be turned off. 0 - 127
The default setting is "0".
* When "0" is set, the CNC screen auto-off function is disabled.

Manual-Off of the CNC Screen

The CNC screen can be turned off manually. To turn off the CNC screen, press any of the function
keys together with the CAN key.
* When the CNC screen auto-off function is enabled, it cannot be turned off manually.

CAN key

Function keys

Fig. 35

72
Special Version
Special Version Contents

Contents

Special Version

A. Chuck Clamp Detector

B. Chip Conveyor

C. TAKAMAZ Custom Functions

Chapter 1 Screen Configuration and Functions .................................................................... 1
1-1 Starting Condition Screen ........................................................................................ 1
1-2 Maintenance Function Screen .................................................................................. 2

Chapter 2 Details of Starting Condition Screens .................................................................. 3

2-1 START CONDITION CHECK Screen ................................................................... 3
2-2 START CONDITION SETTING Screen ................................................................ 5

Chapter 3 Details of Maintenance Function Screens ............................................................ 7

3-1 MAINTENANCE MENU Screen ............................................................................ 7
3-2 PERIODICAL INSPECTION Screen ...................................................................... 8
3-2-1 STATE Screen ........................................................................................... 8
3-2-2 SETTING Screen ....................................................................................... 9
3-2-3 DETAIL Screen ....................................................................................... 10
3-2-4 List of Inspection Items ........................................................................... 11
3-3 SIGNAL OUTPUT Screen .................................................................................... 12
3-4 COLLATION Screen ............................................................................................. 13
3-4-1 CNC PARA COLL Screen ...................................................................... 14
3-4-2 PMC PARA COLL Screen ...................................................................... 16
3-5 SAVE/LOAD Screen ............................................................................................. 18
3-5-1 SAVE Screen ........................................................................................... 19
3-5-2 LOAD Screen .......................................................................................... 20
3-5-3 Loading File Name Selection Screen ...................................................... 21
A. Chuck Clamp Detector
Special Version A. Chuck Clamp Detector

This is a safety device to check if a workpiece is securely clamped by the chuck.

When this device is installed, adjust it according to chuck open/close motions as described below.
The device cannot be started unless the proximity switches (A) and (B) are effective.

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

DANGER
"MAINTENANCE - KEEP AWAY FROM THE MACHINE." around the
machine so that the power is not turned on or the operation panel is not
touched by mistake. Failure to observe this warning will result in critical
bodily injuries.
The cover should not be opened by unqualified personnel for
WARNING
maintenance. Turn the main power switch off and lock it using a positive
means, such as a padlock, when working inside the cover.

[Required tools]
Allen wrench [5]
Spanners [13] [24]
Phillips screwdriver

1. Remove the cylinder cover.

2. Remove the chuck cover.
3. Adjust the proximity switch positions.
4. Mount the chuck cover.
5. Mount the cylinder cover.

OD grip (clamping by pulling)

Adjust so that the proximity switch (A) becomes effective (lamp ON) when the chuck closes to
clamp a workpiece.

ID grip (clamping by pushing)

Adjust so that the proximity switch (B) becomes effective (lamp ON) when the chuck opens to
clamp a workpiece.
* Adjustment of the proximity switch itself can be done by loosening the lock nut and turning the switch.

1
A. Chuck Clamp Detector Special Version

Chuck cover

Cylinder cover

Proximity switch A

Proximity switch B

Detail of proximity switch

Proximity sensor

Lock nuts

Lamp

Sensor I/O connector

The proximity switch should be set so that it may not be hit too strongly,
CAUTION
but may barely manage to turn on the lamp. (Clearance: 0.5 - 1.0 mm)

2
B. Chip Conveyor
Special Version B. Chip Conveyor

Use the CHIP switches on the machine operation panel to operate the chip conveyor.

[1] Manual operation

Pressing the FOR switch in the manual mode rotates the chip conveyor in the normal direction
and illuminates the lamp.
Pressing the switch again stops the chip conveyor and turns the lamp off.
While the REV switch is held down in the manual mode, the chip conveyor rotates in the
reverse direction.
* These switches are not available while the AUT lamp is lit.

[2] Automatic operation

When the AUT switch is on (the lamp is lit), the chip conveyor is operated linked to machine
automatic operation.
When the machine starts automatic operation, the chip conveyor rotates in the normal direction
automatically.
When the machine completes automatic operation, the conveyor stops (according to the
standard setting).
* When a setting is made for chip conveyor automatic intermittent operation, the chip conveyor rotates
at a time interval as specified on the optional setting screen during automatic operation.
* When the following M codes are input, the chip conveyor operates according to these codes during
automatic operation. Intermittent operation setting is therefore disabled.
* M200: Chip conveyor normal rotation M201: Chip conveyor reverse rotation

[3] Parameter settings

"0" is specified for each parameter as default.

#7 #6 #5 #4 #3 #2 #1 #0
D314 CFSWSL
CFSWSL: The FOR switch works in such a manner that:
0: the chip conveyor is rotated and stopped alternately each time the switch is pressed.
1: the chip conveyor is rotated only while the switch is held down (inching operation).

#7 #6 #5 #4 #3 #2 #1 #0

D315 CCATSL
CCATSL: Chip conveyor automatic operation is:
0: carried out following an automatic operation signal from the machine.
1: carried out by M200 for normal rotation and M201 for reverse rotation.

1
B. Chip Conveyor Special Version

[4] Intermittent operation timer setting

"0" is specified for each parameter as default.

Set the following time data for "D904" and "D906" in the data table.
D904: Chip conveyor normal turn time (sec)
D906: Chip conveyor stop time (sec)

* Setting range: 1 to 32,767 seconds

* When "0" is set for either "D904" or "D906", continuous operation is performed.

2
C. TAKAMAZ Custom Functions
Special Version C. TAKAMAZ Custom Functions

Chapter 1 Screen Configuration and Functions

The TAKAMAZ custom screen consists of the starting condition screen and maintenance function
screen.

1-1 Starting Condition Screen

The starting condition screen is used for setting and checking conditions (starting conditions)
required for starting automatic operation. Automatic operation can only be started when the set
conditions are satisfied.
The starting condition screen consists of the START CONDITION SETTING screen (for setting
starting conditions) and the START CONDITION CHECK screen (for checking whether or not the
starting conditions are satisfied).
* Starting conditions are not checked in the MDI mode.
* Starting conditions are not checked before restarting automatic operation from the feed hold status.

1
C. TAKAMAZ Custom Functions Special Version

1-2 Maintenance Function Screen

The maintenance function screens (custom screens) include the following screens to display.

MAINTENANCE MENU screen (1) PERIODICAL INSPECTION

screen

(2) SIGNAL OUTPUT screen

(3) COLLATION screen

(4) SAVE/LOAD screen

(5) MOVEMENT
ENVIRONMENT screen

<Screen Function>
(1) PERIODICAL INSPECTION screen
Notification of the time to inspect the machine and equipment is set on this screen.
The operator is notified when the preset time to inspect comes.

(2) SIGNAL OUTPUT screen

A status of the PMC signal of the control unit is output to the memory card inserted in the NC
controller.
The PMC signal status at the time of output can be checked.

(3) COLLATION screen

Collation of the data file saved in the memory card and data in the NC is done for any
discrepancy in data. There are two types of collation - CNC parameter collation and PMC
parameter collation.

(4) SAVE/LOAD screen

Data set on the OPTION FUNCTION MENU screen is saved or loaded. All data set on the
custom screen can be initialized as well.

(5) MOVEMENT ENVIRONMENT screen

Not used

2
Special Version C. TAKAMAZ Custom Functions

Chapter 2 Details of Starting Condition Screens

2-1 START CONDITION CHECK Screen

This screen is used for checking whether or not the starting

conditions required for starting automatic operation are
satisfied.
When the cycle start button is pressed without satisfying any
of the starting conditions, this screen appears with the
message "CONDITIONS NOT SATISFIED. CANNOT
START.". In this state, automatic operation cannot be started.
Check the starting conditions and take appropriate action.
* The START CONDITION CHECK screen can be displayed by
pressing the CSTM/GRPH key.
* The START CONDITION CHECK screen will be switched to
the PROGRAM (CHECK) screen when automatic operation is
started.

Starting condition status display

Message display

3
C. TAKAMAZ Custom Functions Special Version

Display Items

Display items Contents

Starting condition status Displays the statuses of starting conditions.

display • When the condition is satisfied:
Displayed in black.
• When the condition is not satisfied:
Highlighted in yellow with the text blinking.
* If any mode other than AUTO is selected, "AUTO MODE" is
highlighted in red with the text blinking.
* When an alarm is occurring, "ALARM" is highlighted in red with the
text blinking.

Message display • When all starting conditions are satisfied:

The message "OPERATION POSSIBLE" is displayed.
In this case, automatic operation can be started by pressing the cycle start
button.
• When any of the starting conditions is not satisfied:
The message "CONDITIONS NOT SATISFIED. CANNOT START." is
displayed.
In this case, automatic operation cannot be started even if the cycle start
button is pressed.

Soft Keys

No. Menu Contents

1 SETING Changes over to the START CONDITION SETTING screen.

See "2-2 START CONDITION SETTING Screen".

* When "1" is set for "159.0" in the data table, soft key operation is disabled.

2 SKIP - Temporarily disables starting condition check. When this key is

pressed, automatic operation can be started even if any of the
conditions are not satisfied.
* Before using this function, set "1" for "D159.0" in the data table to enable
this soft key.
After automatic operation is finished, be sure to set it to "0" to disable the
soft key.
* Conditions "AUTO MODE", "ALARM", "CHUCK CLAMP", and "FRONT
DOOR CLOSE" cannot be skipped even if this soft key is pressed.
* When this key is selected, the message "OPERATION POSSIBLE BY
SKIPPING" is displayed.
* Once automatic operation starts, starting condition check becomes
enabled. (This setting remains valid until the cycle start button is pressed.)

4
Special Version C. TAKAMAZ Custom Functions

2-2 START CONDITION SETTING Screen

This screen is used for setting starting conditions (check or skip).

Display Items

Display items Contents Setting range

Starting conditions Select either "check" or "skip" for each starting condition. Selected (check)
Move the cursor to the desired condition and press the [ON/ Deselected (skip)
OFF] soft key to select or deselect each condition.
* Conditions "AUTO MODE" and "ALARM" cannot be set
to "skip".

Soft Keys

No. Menu Contents

1 RETURN Changes over to the START CONDITION CHECK screen.

2 INPUT When the cursor is placed on "MAIN PROGRAM NUM.", a main program
number can be input. After inputting, press this soft key to set the program
number to "check".
* This soft key can be used when the cursor is placed on "MAIN PROGRAM
NUM.".
* This key has the same function as the INPUT key on the MDI panel.

3 ON/OFF Sets each starting condition of the cursor position to "check" or "skip".
* Each time this key is pressed, the condition is selected or deselected
(check or skip).

5
C. TAKAMAZ Custom Functions Special Version

Function

No. Function Setting value Contents

1 MAIN PROGRAM ON, 1 - 9999 Check the main program number.

NUM.

2 RAPID OV. (100%) ON Check whether or not 100% is selected with the
RPD F0/100% switch.

3 FEED RATE OV. ON Check whether or not 100% is selected with the
(100%) feedrate override switch.

4 M01 ON Check whether or not the M01 (optional stop)

switch is turned on.

5 SINGLE BLOCK ON Check whether or not the SBK (single block)

switch is turned on.

6 DRY RUN ON Check whether or not the DRN (dry run) switch is
turned on.

7 / CODE ON Check whether or not the / CODE (block delete)

switch is turned on.

8 CHIP CON. AUTO ON Check whether or not the CHIP AUT (chip
conveyor automatic) switch is turned on.

9 PROGRAM REWIND ON Check whether or not the program starts from the
top block (rewound to the beginning).

10 AXIS ZERO POINT ON Check whether or not all axes are located in their
zero points.

11 CHUCK CLAMP ON Check whether or not the chuck is closed.

12 FRONT DOOR CLOSE ON Check whether or not the DR ITLK (door

interlock) switch is turned on.

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Special Version C. TAKAMAZ Custom Functions

Chapter 3 Details of Maintenance Function Screens

3-1 MAINTENANCE MENU Screen

Pressing the CSTM/GR key displays the MAINTENANCE

MENU screen.
* Pressing this key for the second time and afterwards displays a
previously selected screen.

Soft Keys

No. Menu Contents Remarks

1 INSPEC Displays the PERIODICAL INSPECTION "3-2 PERIODICAL

screen. INSPECTION Screen"

2 SIGNAL Displays the SIGNAL OUTPUT screen. "3-3 SIGNAL OUTPUT

Screen"

3 COLLAT Displays the COLLATION screen. "3-4 COLLATION Screen"

4 SV/LD Displays the SAVE/LOAD screen. "3-5 SAVE/LOAD Screen"

5 MV ENV Not used

* After inputting the number on the left side of each display item,
press the INPUT key to display a relevant menu.

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C. TAKAMAZ Custom Functions Special Version

3-2 PERIODICAL INSPECTION Screen

This screen is used for indicating items when relevant inspection timing, if preset, expires.

3-2-1 STATE Screen

This screen is used for displaying a state of periodical inspection. An item which inspection timing
is expired is highlighted. Locate a position to inspect and press the [RESET] soft key for setting the
timing once again and resetting a highlighted item.

Display Items

Display item Contents Setting range

ITEM Displays sections to be inspected periodically. −
Items only set to ON on the SETTING screen are displayed.
REMAIN Displays the number of remaining days before inspection. 0 - 731 days
The display is highlighted when it becomes zero (0).
LAST INSPECTION Indicates the last inspection date of the cursor located item. −
NEXT INSPECTION Indicates the next inspection date of the cursor located item. −

Soft Keys

No. Menu Contents Remarks

1 SETING Displays the SETTING screen. "3-2-2 SETTING Screen"

2 DETAIL Displays detailed contents of each item to

inspect.

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Special Version C. TAKAMAZ Custom Functions

3-2-2 SETTING Screen

This screen is used for setting inspection items and periods.

Display Items

Display item Contents Setting range

ITEM Displays items to be inspected periodically. −

Items only related to the machine are displayed.

PERIOD Displays and sets a period from the starting date to the 1 - 24 months
inspection timing.

REMAIN Displays the number of remaining days before inspection. 0 - 731 days

CHECK Displays and sets whether to periodically inspect (ON) ON/OFF

applicable items or not (OFF).

LAST TIME Indicates the last inspection date of the cursor located item. −

NEXT TIME Indicates the next inspection date of the cursor located item. −

Soft Keys

No. Menu Contents Remarks

1 STATE Changes over to the SETTING screen. "3-2-1 STATE Screen"

2 DETAIL Displays detailed contents of each item to

inspect.

3 INIT Sets a period of an item at the cursor position

to an initial value.

4 RESET Sets the starting date to the current day.

5 ON/OFF Specifies an item to inspect. ON: Inspect

OFF: Does not inspect

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C. TAKAMAZ Custom Functions Special Version

3-2-3 DETAIL Screen

This screen is used for displaying the contents of inspection items.

Soft Keys

No. Menu Contents

1 RETURN Displays the STATE screen or SETTING screen.

2 PREV Displays detailed information about the item with an effective previous number.

3 NEXT Displays detailed information about the item with an effective next number.

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Special Version C. TAKAMAZ Custom Functions

3-2-4 List of Inspection Items

Unit Inspection item Details Setting value

Main unit Electric cabinet Check and clean the cooling fan filter. Monthly
Check if dust or dirt is on it, and clean if required.

Turret unit Supply grease (oil) to the gear. Monthly

Hydraulic pump Replace hydraulic oil. Yearly

unit Clean the oiling port filter.
Clean the strainer.

Lubrication unit Clean the suction filter and replace if required. Yearly
Clean the oiling port filter.

Air unit Replace the filter element. Yearly

Battery Replace the memory backup battery or absolute pulse Yearly

coder battery with a new one.

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C. TAKAMAZ Custom Functions Special Version

3-3 SIGNAL OUTPUT Screen

This screen is used for outputting a status of the control unit PMC signals into the memory card all
at once.

Soft Keys

No. Menu Contents

1 EXEC Pressing this soft key after inserting a memory card into the card interface starts
outputting data. After all data is output, Complestion is displayed.
The following signals can be output.
G, F, X, Y, A, R, T, K, C, D
Output file name: SOUTnn.txt (nn: 01 - 99)

2 STOP This key is displayed during data saving. Pressing this key stops outputting data.

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Special Version C. TAKAMAZ Custom Functions

3-4 COLLATION Screen

This screen is used for collating data files saved in the memory card and data in the NC. Select a file
to collate from a related list of files in the memory card and collate accordingly.

<COLLATION screen>

<Example of displaying a list of files in the memory card>

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C. TAKAMAZ Custom Functions Special Version

3-4-1 CNC PARA COLL Screen

This screen is used for displaying a result of collating CNC parameter files and data in the NC.

Display Items

Display item Contents Setting range

File name Displays the name of the selected file in the memory card in the −
center of the first line.

NO. Displays the address of a parameter if the data is inconsistent as a 0 - 99999

result of collation.

AXIS Displays the number of an axis, if axis data. −

CARD DATA Displays file data in the card different from data in the CNC unit. −

CNC DATA Displays present data in the NC different from file data in the −
card.

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Special Version C. TAKAMAZ Custom Functions

Soft Keys

No. Menu Contents

1 RETURN Returns to display a list of files in the memory card.

2 OUTPUT Displays the output confirmation screen, and outputs the result of collation in the
text format into the memory card.
To output the result of collation, set a product number and press the [EXEC] soft
key.

3 OK Ends the CNC parameter collation and displays the COLLATION screen.

4 STOP Displayed during collation.

Select to stop collation.

5 EXEC Displayed on the output confirmation screen.

Pressing this key starts outputting data into the memory card. The name of a file
to output is created as below:
• When the product number is not set:
CNCCOLnn.TXT (nn: automatically created within the range of 01 - 99)
• When the product number is set:
xxxxxxxx.CNn (xxxxxxxx: PRODUCT NO., n: automatically created within the
range of 1 - 9)
After execution is finished, a created file name is displayed.

6 CANCEL Displayed on the output confirmation screen.

Cancels outputting data.
* Collation is to compare the address of a file in the memory card with the address in the NC. Addresses not
allocated to the file in the memory card are not compared.

<Output confirmation screen>

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C. TAKAMAZ Custom Functions Special Version

3-4-2 PMC PARA COLL Screen

This screen is used for displaying a result of collation of a PMC parameter file and NC data.

Display Item

Display item Contents Setting range

File name Displays the name of the selected file in the memory card in −
the center of the first line.

NO. Displays the number of an address. (Only for the timer and −
counter)

ADDRESS Displays types of different data and their addresses. 0000 - 9999
Types: T (timer), C (counter), K (keep relay), D (data table)
As for the counter, PRE (preset) or CUR (current) is
displayed.

CARD DATA Displays data in the card different from data in the NC unit. −

CNC DATA Displays present data in the NC different from data in the −
card.

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Special Version C. TAKAMAZ Custom Functions

Soft Keys

No. Menu Contents

1 RETURN Returns to display a list of files in the memory card.

2 OUTPUT Displays the output confirmation screen, and outputs the result of collation in the
text format into the memory card.
To output the result of collation, set a product number and press the [EXEC] soft
key.

3 OK Ends the CNC parameter collation and displays the COLLATION screen.

4 STOP Displayed during collation.

Select to stop collation.

5 EXEC Displayed on the output confirmation screen

Pressing this key starts outputting data into the memory card. The name of a file
to output is created as below:
• When the product number is not set:
PMCCOLnn.TXT (nn: automatically created within the range of 01 - 99)
• When the product number is set:
xxxxxxxx.PMn (xxxxxxxx: PRODUCT NO., n: automatically created within
the range of 1 - 9)
After execution is finished, a created file name is displayed.

6 CANCEL Displayed on the output confirmation screen.

Cancels outputting data.

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C. TAKAMAZ Custom Functions Special Version

3-5 SAVE/LOAD Screen

This screen is used for saving and loading data set on the option function screen. All data set on the
custom function screen can be initialized as well.

Soft Keys

No. Menu Contents

1 SAVE Displays the saving screen.

2 LOAD Displays the loading screen.

3 INIT A The work area (P-CODE variables) of the custom function is initialized entirely.
* Note that all parameters set by the custom function are deleted.
* After initialization is finished, turn on the power again.

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Special Version C. TAKAMAZ Custom Functions

3-5-1 SAVE Screen

This screen is used for saving data on the option functions.

Soft Keys

No. Menu Contents

1 EXEC Outputs data to be saved into the memory card.

* The output file name is fixed to "TKCSPRM0.TXT".
* If the same file name already exists, a confirmation message for replacing
such a name is displayed.

Contents of Saved Data

No. Function Contents

1 Work counter

2 Tool counter

3 Tool wear offset control

Not used
4 Fixed wear offset

5 Torque setting for each tool

6 Optional setting

7 Periodical inspection Check (ON/OFF), starting year/month/date, cycle and check time

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C. TAKAMAZ Custom Functions Special Version

3-5-2 LOAD Screen

This screen is used for loading data on the option functions.

Display Items

Display item Contents Setting range

LOAD ITEM Displays a list of information to load from the saving data. 7 types

RESULT Displays a result of loading. OK, NG, −

"−" is displayed when loading is set to OFF, "OK" is
displayed when loading is normally done, and "NG" is
displayed if loading is abnormally done.

SEL. Sets whether to load (ON) or not (OFF). ON/OFF

Items to be loaded (ON) only are displayed.

FILE NAME Displays names of files to load. −

This key is usable to change the contents.

Soft Keys

No. Menu Contents

1 F NAME Selects the name of a file to load.

Select a file to save from the list.

2 EXEC Starts data loading.

3 ON/OFF Changes over the item selected by cursor between ON and OFF

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Special Version C. TAKAMAZ Custom Functions

3-5-3 Loading File Name Selection Screen

This screen is used for displaying a list of files in the memory card with an extension "TXT".
A maximum of 20 files can be displayed. Select an applicable file and press the [SELECT] soft key.

Soft Keys

No. Menu Contents

1 RETURN Displays the LOAD screen.

2 SELECT Selects a file at the cursor position.

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 TAKAMATSU MACHINERY CO.,LTD.
HEAD OFFICE & PLANT
1-8 ASAHIGAOKA HAKUSAN-CITY ISHIKAWA JAPAN 924-8558
TEL +81-(0)76-274-1403 FAX +81-(0)76-274-8530

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