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Maintenance & Operation


for
SQT-200/250 Series

Publication # C320MA0010E
1/98

CAUTION

This Manual is published to assist experienced personnel on the


operation, maintenance and/or programming of Mazak machine
tools.

All Mazak machine tools are engineered with a number of safety


devices to protect personnel and equipment from injury or damage.
Operators should not, however, rely solely upon these safety de-
vices, but should operate the machine only after fully understanding
what special precautions to take by reading the following documen-
tation thoroughly.

Do not attempt to operate or perform maintenance / repair on the


machine without a thorough understanding of the actions about to
be taken. If any question exists, contact the nearest Mazak service
center for assistance.

Certain covers, doors or safety guards may be open or removed to


more clearly show machine components. These items must be in
place before operating the machine. Failure to comply with this
instruction may result in serious personal injury or damage to the
machine tool.

This manual was considered complete and accurate at the time of


publication, however, due to our desire to constantly improve the
quality and specification of all Mazak products, it is subject to
change or modification.
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Notes:
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SAFETY PRECAUTIONS
The machine is provided with a number of safety 6) Do not deface, scratch or remove any caution
devices to protect personnel and equipment from plate. Should it become illegible or missing,
injury and damage. Operators should not, order another caution plate from the supplier,
however, rely solely upon these safety devices, specifying the part number shown at the lower
but should operate the machine only after fully right corner of the plate.
understanding what special precautions to take by • BEFORE POWERING UP
reading the following documentation thoroughly.
DANGER:
• BASIC OPERATING PRACTICES
Cables, cords or electric wires whose insulation
DANGER: is damaged can produce current leaks and
1) Some control panels, transformers, motors, electric shocks. Before using, check their
junction boxes and other parts have high condition.
voltage terminals. These should not be touched WARNING:
or a severe electric shock may be sustained. 1) Be sure the instruction manual and the
2) Do not touch any switches with wet hands. programming manual are fully understood
This too, can produce an electric shock. before operating the machine. Every function
WARNING: and operating procedure should be completely
1) The emergency stop pushbutton switch clear.
location should be well known, so that it can be 2) Use approved oil resistant safety shoes, safety
operated at any time without having to look for goggles with side covers, safe clothes, and
it. other safety protection required.
2) Before replacing a fuse, turn off the main 3) Close all NC unit, operating panel, electric
incoming power switch to the machine. control panel doors and covers.
3) Provide sufficient working space to avoid CAUTION:
hazardous falls. 1) The power cable from the factory feeder switch
4) Water or oil can make floors slippery and to the machine main circuit breaker should
hazardous. All floors should be clean and dry have a sufficient sectional area to handle the
to prevent accidents electric power used.
5) Do not operated any switch without a thorough 2) Cables which must be laid on the floor must be
understanding of the actions about to be taken. protected from hot chips, by using rigid or
other approved conduit, so that short-circuits
6) Avoid accidental operation of switches.
will not occur.
7) Work benches near the machine must be
3) Before first time operation of the machine after
strong enough to hold materials placed on
unpacking it or from being idle for a long period
them to prevent accidents. Articles should be
of time (several days or more), each sliding
prevented from slipping off the bench surface.
part must be sufficiently lubricated. To do so,
8) If a job is to be done by two or more persons, push and release the pump button several
coordinating signals should be given at each times until the oil seeps out on the sliding
step of the operation. The next step should not parts. The pump button has a return spring, so
be taken unless a signal is given and do not force it to return.
acknowledged.
4) Oil reservoirs should be filled to indicated
CAUTION: levels. Check and add oil, if needed.
1) In the event of power failure, turn off the main 5) For lubrication points, oil specification and
circuit breaker immediately. appropriate levels, see the various instruction
2) Use the recommended hydraulic oils, lubricants plates.
and grease or acceptable equivalents. 6) Switches and levers should operate smoothly.
3) Replacement fuses should have the proper Check that they do.
current ratings. 7) When powering the machine on, turn on the
4) Protect the NC unit, operating panel, electric switches in the following order: first the factory
control panel, etc. from shocks, since this feeder switch, then the machine main circuit
could cause a failure or malfunction. breaker, and then the control power on switch
5) Do not change parameters or electrical located on the operating panel.
settings. If changes are unavoidable, record 8) Check the coolant level, and add coolant, if
the values prior to the change so that they can needed.
be returned to their original settings, if
necessary.

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• AFTER CONTROL POWER IS TURNED ON


CAUTION:
When the control power “ON” switch on the 4) Tools and other items around the machine or
operating panel is on, the "READY" lamp on equipment should be stored to ensure good
the operating panel should also be on (check to footing and clear aisles.
see that it is). 5) Do not place tools or any other items on the
• ROUTINE INSPECTIONS headstock, turret, covers and similar places
WARNING: (For T/M).
When checking belt tensions, do not get your CAUTION:
fingers caught between the belt and pulley. 1) Tool lengths should be within specified
CAUTION: tolerances to prevent interference.
1) Check pressure gages for proper readings. 2) After installing a tool, make a trial run.
2) Check motors, gear boxes and other parts for • OPERATION
abnormal noises. WARNING:
3) Check the motor lubrication, and sliding parts 1) Do not work with long hair that can be caught
for evidence of proper lubrication. by the machine. Tie it back, out of the way.
4) Check safety covers and safety devices for 2) Do not operate switches with gloves on. This
proper operation. could cause mis-operation.
5) Check belt tensions. Replace any set of belts 3) Whenever a heavy workpiece must be moved,
that have become stretched with a fresh if there is any risk involved, two or more people
matching set. should work together.
• WARM UP 4) Only trained, qualified workers should operate
CAUTION: forklift trucks, cranes or similar equipment and
apply slings.
1) Warm up the machine, especially the spindle
and feed shaft, by running the machine for 10 5) Whenever operating a forklift truck, crane or
to 20 minutes at about one-half or one-third the similar equipment, special care should be taken
maximum speed in the automatic operation to prevent collisions and damage to the
mode. surroundings.
2) The automatic operation program should cause 6) Wire ropes or slings should be strong enough
each machine component to operate. At the to handle the loads to be lifted and should
same time, check their operations. conform to the mandatory provisions.
3) Be particularly careful to warm up the spindle 7) Grip workpieces securely.
which can turn above 4000 rpm. 8) Stop the machine before adjusting the coolant
If the machine is used for actual machining nozzle at the tip.
immediately after being started up following a 9) Never touch a turning workpiece in the spindle
long idle period, the sliding parts may be worn with bare hands, or in any other way.
due to the lack of oil. Also, thermal expansion 10) To remove a workpiece from the machine other
of the machine components can jeopardize than by a pallet changer, stop the tool and
machining accuracy. To prevent this condition, provide plenty of distance between the
always make sure that the machine is warmed workpiece and the tool (for M/C).
up.
11) While a workpiece or tool is turning, do not
• PREPARATIONS wipe it off or remove chips with a cloth or by
WARNING: hand. Always stop the machine first and then
1) Tooling should conform to the machine use a brush and a sweeper.
specifications, dimensions and types. 12) Do not operate the machine with the chuck and
2) Replace all seriously worn tools with new ones front safety covers removed (For T/M).
to prevent injuries. 13) Use a brush to remove chips from the tool tip,
3) The work area should be adequately lighted to do not use bare hands .
facilitate safety checks. 14) Stop the machine whenever installing or
removing a tool.
15) Whenever machining magnesium alloy parts,
wear a protective mask.

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CAUTION:
CAUTION: 1) Thoroughly read and understand the safety
1) During automatic operation, never open the precautions in the instruction manual.
machine door. Machines equipped with the 2) Thoroughly read the whole maintenance
door interlock will set the program to single manual and fully understand the principles,
step. construction and precautions involved.
2) When performing heavy-duty machining, • MAINTENANCE OPERATION
carefully prevent chips from being accumulated DANGER:
since hot chips from certain materials can 1) Those not engaged in the maintenance work
cause a fire. should not operate the main circuit breaker or
• TO INTERRUPT MACHINING the control power "ON" switch on the
WARNING: operating panel. For this purpose, "Do not
When leaving the machine temporarily after Touch the Switch, Maintenance Operation in
completing a job, turn off the power switch on Progress!" or similar warning should be
the operation panel, and also the main circuit indicated on such switches and at any other
breaker. appropriate locations. Such indication should
be secured by a semi-permanent means in the
• COMPLETING A JOB reading direction.
CAUTION:
2) With the machine turned on, any maintenance
1) Always clean the machine or equipment. operation can be dangerous. In principle, the
Remove and dispose of chips and clean cover main circuit breaker should be turned off
windows, etc. throughout the maintenance operation.
2) Make sure the machine has stopped running, WARNING:
before cleaning. 1) The electrical maintenance should be done by
3) Return each machine component to its initial a qualified person or by others competent to do
condition. the job. Keep close contact with the
4) Check the wipers for breakage. Replace responsible person. Do not proceed alone.
broken wipers. 2) Overtravel limit and proximity switches and
5) Check the coolant, hydraulic oils and lubricants interlock mechanisms including functional parts
for contamination. Change them if they are should not be removed or modified.
seriously contaminated. 3) When working at a height, use steps or ladders
6) Check the coolant, hydraulic oil and lubricant which are maintained and controlled daily for
levels. Add if necessary. safety.
7) Clean the oil pan filter. 4) Fuses, cables, etc. made by qualified
manufacturers should be employed.
8) Before leaving the machine at the end of the
shift, turn off the power switch on the operating • BEFORE OPERATION & MAINTENANCE BEGINS
panel, machine main circuit breaker and factory WARNING:
feeder switch in that order. 1) Arrange things in order around the section to
• SAFETY DEVICES receive the maintenance, including working
1) Front cover, rear cover and coolant cover. environments. Wipe water and oil off parts and
provide safe working environments.
2) Chuck barrier, tail barrier and tool barrier (NC
software). 2) All parts and waste oils should be removed by
the operator and placed far enough away from
3) Stored stroke limit (NC software). the machine to be safe.
4) Emergency stop pushbutton switch. CAUTION:
• MAINTENANCE OPERATION PREPARATIONS 1) The maintenance person should check that the
1) Do not proceed to do any maintenance machine operates safely.
operation unless instructed to do so by the 2) Maintenance and inspection data should be
foreman. recorded and kept for reference.
2) Replacement parts, consumables (packing, oil
seals, O rings, bearing, oil and grease, etc.)
Should be arranged in advance.
3) Prepare preventive maintenance and record
maintenance programs.
000X717-KY

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! WARNING

a
ALWAYS TURN THE MAIN CIRCUIT BREAKER TO THE “OFF” POSITION & USE AN APPROVED
LOCKOUT DEVICE WHEN COMPLETING MAINTENANCE OR REPAIRS.

THE LOCKOUT PROCEDURE THAT FOLLOWS IS INTENDED TO SAFEGUARD PERSONNEL &


EQUIPMENT DURING MAINTENANCE OPERATIONS, AND, REPRESENTS THE MINIMUM
REQUIREMENTS. ANY ACTION SHOULD BE PRECEDED BY A “HAZARD ANALYSIS” TO DETERMINE
ANY ADDITIONAL SAFETY PRECAUTIONS THAT MAY BE NECESSARY TO ENSURE THE SAFETY OF
PERSONNEL AND EQUIPMENT.

NOTE: USE OF THE FOLLOWING LOCKOUT PROCEDURE IS MANDATORY WHEN COMPLETING


MAINTENANCE OR REPAIRS.

LOCKOUT PROCEDURE
1) THE LOCKOUT PROCESS MUST BE PERFORMED BY AUTHORIZED PERSONNEL ONLY.
2) INFORM ALL EFFECTED PERSONNEL OF YOUR INTENT TO LOCKOUT AND SERVICE THE
SPECIFIED MACHINE.
3) SHUT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES.
4) TURN OFF THE MACHINE AND INDIVIDUAL BUILDING CIRCUIT BREAKERS. MAKE SURE ALL
STORED ELECTRICAL ENERGY IS RELIEVED. (EG: SPINDLE & AXIS SERVO CONTROLLERS)
5) CONNECT THE LOCKOUT DEVICE AS SHOWN IN FIGURE 1, AND ATTACH THE APPROPRIATE
TAG AT THE MACHINE CIRCUIT BREAKER. THE TAG MUST IDENTIFY THE PERSON
RESPONSIBLE FOR THE LOCKOUT. THIS WILL ENSURE THAT POWER CANNOT BE
RESTORED BY ANYONE ELSE.
6) TEST THE MACHINE TO VERIFY THAT MACHINE SYSTEMS DO NOT OPERATE IN ANY WAY.
ONCE TESTING IS COMPLETE, MAKE SURE ALL SWITCHES ARE IN THE “OFF” POSITION.
CONFIRM THAT THE LOCKOUT DEVICES REMAIN PROPERLY INSTALLED.
7) COMPLETE THE REQUIRED MAINTENANCE OPERATIONS.
8) MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.
9) REMOVE THE LOCKOUT DEVICE. MAKE SURE ALL PERSONNEL ARE AT A SAFE LOCATION
BEFORE RESTORING MACHINE POWER.

PADLOCK

FIGURE

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INSTALLATION PRECAUTIONS
The following subjects outline the items that 6) In pouring grout, fasten the leveling block
directly affect the machine installation and start- base plates with the collar retaining screws
up. To ensure an efficient and timely installation, to prevent the base plates from dropping.
please follow these recommendations before When the grout has completely hardened,
calling to schedule a service engineer. level the machine properly, and tighten M24
nuts to secure the machine to the
foundation.
• ENVIRONMENTAL REQUIREMENTS
Note:
Avoid the following places for installing the
machine: The machine must be anchored to the
foundation with J-bolts, expansion bolts or
1) Avoid exposure to direct sunlight and/or near a other suitable method.
heat source, etc. Ambient temperature during
operation: 0° thru 45°C (32°F to 113°F). The machine accuracy and alignment
specifications quoted by Mazak can usually
2) Avoid areas where the humidity fluctuates be obtained when the minimum foundation
greatly and/or if high humidity is present; requirements are met. However, production
normally 75% and below in relative humidity. A of close tolerance parts requires the use of an
higher humidity deteriorates insulation and appropriate certified foundation. Foundations
might accelerate the deterioration of parts. that do not meet certified specifications may
3) Avoid areas that are especially dusty and/or require more frequent machine re-leveling and
where acid fumes, corrosive gases and salt are re-alignment, which can not be provided
present. under terms of warranty.
4) Avoid areas of high vibration. If any of these conditions cannot be met,
5) Avoid soft or weak ground (minimum load contact the nearest Mazak service office
bearing capacity of 1025 lbs./ft2) immediately.

• FOUNDATION REQUIREMENTS
For high machining accuracy, the foundation
must be firm and rigid. This is typically
accomplished by securely fastening the
machine to the foundation with anchor bolts. In
addition, the depth of concrete should be as
deep as possible (minimum 6 - 8 inches). Note
the following:
1) There can be no cracks in the foundation
concrete or surrounding area.
2) Vibration proofing material (such as asphalt)
should be put all around the concrete pad.
3) Form a “cone” in the foundation for J-bolt
anchors, or use expansion anchors.
4) With the foundation anchor bolt holes open
pour the primary concrete at a minimum
thickness of 6 - 8 inches. Typically, the
concrete must have a minimum compression
rating of 2500 lbs. @ 250 lbs. compression
and strengthened with reinforcing rods. When
the concrete has cured, rough level the
machine, and install the J-bolts, leveling blocks,
etc., and pour grout into foundation bolt holes.
5) Mix an anti-shrinkage agent such as Denka
CSA with concrete, or use Embeco grout to fill
the foundation bolt holes.

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• WIRING
1) Use only electrical conductors with
performance ratings equivalent or superior.
2) Do not connect any power cables for devices
which can cause line noise to the power Desirable Independent Grounding:
distribution panel, such as arc welders and high
frequency machinery.
3) Arrange for a qualified electrician to connect NC Earth resistance:
the power lines. Machine Less than 100 ohms
4) Incoming supply voltage should not deviate
more than ±10% of specified supply voltage.
5) Source frequency should be±2 Hz of nominal Common Grounds:
frequency.

Resistance to ground
= 100 ÷ the number of
[ CAUTION ] devices connected to
the grounding (ohms)
VERIFY THE ACTUAL MACHINE ELECTRICAL
Note: Never ground equipment as shown below:
POWER REQUIREMENT AND THE MAIN
TRANSFORMER RATING (IF APPLICABLE), AS

WELL AS THE LOCAL ELECTRICAL CODE


BEFORE SIZING AND INSTALLING THE

INCOMING POWER WIRING.

PLEASE SEE THE ADDITIONAL CAUTIONS ON


THE FOLLOWING PAGE.

• GROUNDING
1) An isolated earth ground with a resistance to
ground of less than 100 ohms is required.
Typically, a 5/8” copper rod, 8 feet long, and
no more than 5 feet from the machine, is
sufficient. Building grounds or multiple
machines grounded to the same ground rod,
are not acceptable.
2) The wire size should be greater than AWG
(American Wire Gauge) No. 5 and SWG
(British Legal Standard Wire Gauge) No. 6.

000X713-KY

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! CAUTION

A step-down transformer is optional on some machine models. Be certain to


verify the transformer Kva rating (where applicable), as well as local electrical
code requirements before sizing and installing the incoming power wiring.
Machines not equipped with a main transformer are wired for 230 VAC, 3 phase.
The end user must supply a step-down transformer where factory electrical
power varies more than ± 10% of the 230 VAC rating.
NOTE:
Step-down or voltage regulating transformers are external (peripheral) to the
machine tool and are considered the primary input line (source) for the machine.
Local electrical code or practice may require a circuit breaker or other switching
device for the isolation of electrical power when this type of transformer is used.
In such cases, the machine tool end user is required to supply the necessary
circuit breaker or switching device.
FAILURE TO COMPLY CAN RESULT IN PERSONAL INJURY AND DAMAGE TO THE
MACHINE. IF ANY QUESTION EXISTS, CONTACT THE NEAREST MAZAK SERVICE
CENTER FOR ASSISTANCE.

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MACHINE DOCUMENTATION
CUSTOMER EVALUATION The Other Thoroughbred From Kentucky

Your opinion is important to enable us to issue documentation that will fit your needs.
Thank you for taking the time to supply this information.
Date:
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Customer: Reported By:
Address: Position:
Telephone#:
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RETURN TO: MAZAK Corporation


Technical Publication Dept.
8025 Production Drive
Florence, Kentucky 41042
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SF-202Xa
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CONTENTS

Page

2. OUTLINE OF THE SQT LATHE ................................... 2-1


2-1 Functional Principle ............................................ 2-1
2-2 Lathe Control ............................................ 2-2
2-3 Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-4 Coordinate Axes ............................................ 2-5
2-5 Functions of Operation Panel and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-5-1 Operation Panel ............................................ 2-6
2-5-1-1 Disposition of switches and indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-5-1-2 Names and functions of keys, buttons and switches . . . . . . . . . . . . . . . . . . . . . 2-7
2-5-1-3 Names and functions of indicator lamps ............................. 2-11
2-5-2 Auxiliary Operation Panel ....................................... 2-12
2-5-3 Data I/O Panel ........................................... 2-15

3. MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1


3-1 Preparation for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-1-1 Inspection at the Start of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-1-2 Procedure for Switching the Power on ............................... 3-2
3-1-3 Inspection after Switching the Power on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-1-4 Zero-Point Return ............................................ 3-5
3-1-5 Warmup Operation ............................................ 3-7
3-1-6 Opening/Closing of Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-2 Manual Operation ........................................... 3-10
3-2-1 Manual Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-2-2 Spindle Operation ........................................... 3-10
3-2-2-1 Spindle start ........................................... 3-10
3-2-2-2 Spindle stop ........................................... 3-12
3-2-2-3 Spindle jog ........................................... 3-12
3-2-2-4 Spindle rotational direction change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-2-3 X- and Z-Axes Feed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-2-3-1 X- and Z-axes rapid feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-2-3-2 X- and Z-axes cutting feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-2-3-3 X- and Z-axes manual pulse feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-2-3-4 Barrier cancel ........................................... 3-17
3-2-4 Tool Selection ........................................... 3-18
3-2-5 Tailstock Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-2-5-1Checking before tailstock operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-2-5-2 Moving the tail spindle in the forward and reverse directions .............. 3-21
3-2-5-3 Moving the tailstock body in the forward and reverse directions ............ 3-22
3-2-5-4 Feed operations ........................................... 3-25

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3-2-6 Other Manual Operations ....................................... 3-26


3-2-6-1 Soft limit and its release ........................................ 3-26
3-2-6-2 Machine lock ........................................... 3-27
3-2-6-3 Coolant MANUAL and WORK LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-3 Preparation for Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-3-1 Mounting of Tools ........................................... 3-29
3-3-1-1 Mounting/removal of tool holder and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-3-2 Preparation for Gripping Workpiece (Soft Jaw Machining) . . . . . . . . . . . . . . . . 3-31
3-3-2-1 In the case of workpiece external gripping . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-3-2-2 In the case of workpiece internal gripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

4. INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1


4-1 General ............................................ 4-1
4-2 MAINTENANCE CHECK Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-3 Regular Maintenance Inspection .................................. 4-4
4-4 Supplying Oil and Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-5 Handling the Lubricating Oil Retrieval Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

5. MAINTENANCE OF MAJOR MACHINE UNITS . . . . . . . . . . . . . . . . . . . . . . . . . 5-1


5-1 Headstock ............................................ 5-1
5-1-1 Construction and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1-2 Greasing and lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-1-3 Checking, adjustment and replacement of the chuck . . . . . . . . . . . . . . . . . . . . . 5-5
5-1-4 Cleaning ............................................ 5-8
5-2 Turret ............................................ 5-9
5-2-1 Construction and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-3 TOOL EYE ........................................... 5-13
5-3-1 Construction and operation ..................................... 5-13
5-3-2 Checking and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-4 X- and Z-axes ........................................... 5-18
5-4-1 Construction and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-4-2 Lubrication ........................................... 5-21
5-4-3 Adjustment ........................................... 5-21
5-5 Tailstock ........................................... 5-23
5-5-1 Construction and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-5-2 Removing center ........................................... 5-23
5-5-3 Lubrication ........................................... 5-24
5-5-4 Adjustment ........................................... 5-24

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5-6 Hydraulic Unit and Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30


5-6-1 Construction and operation ..................................... 5-30
5-6-2 Supplying and changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-6-3 Adjustment ........................................... 5-34
5-6-4 Cleaning ........................................... 5-35
5-7 Lubrication Unit and Lubrication Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5-7-1 Construction and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5-7-2 Replenishing lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5-7-3 Cleaning ........................................... 5-41
5-8 Coolant System ........................................... 5-44
5-8-1 Construction and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5-8-2 Supplying coolant ........................................... 5-45
5-8-3 Cleaning ........................................... 5-46
5-9 Air Unit ........................................... 5-48
5-9-1 Construction and operation ..................................... 5-48
5-9-2 Replacement and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-10 Headstock Cooling Unit and Headstock Cooling System . . . . . . . . . . . . . . . . . 5-52
5-10-1 Construction and operation ..................................... 5-52
5-10-2 Replenishing and replacement of coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
5-11 CNC Unit and Electrical Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
5-11-1 CNC unit ........................................... 5-56
5-11-2 Electrical control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

6. INSTALLATION ............................................ 6-1


6-1 Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-1-1 Environmental requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-1-2 Power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-1-3 Air source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-1-4 Foundation work ............................................ 6-4
6-1-5 Foundation parts ............................................ 6-5
6-1-6 Delivering the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-2 Machine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-2-1 Precautions for machine installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-2-2 Unpacking, inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-2-3 Location of transit clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-2-4 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-3 Connecting the Power Supply Cable and Air Supply Hose . . . . . . . . . . . . . . . . 6-16
6-3-1 Connecting the power supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-3-2 Grounding ........................................... 6-18
6-3-3 Connecting the air hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6-4 Trial Operation ........................................... 6-20

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7. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-1 Headstock ............................................ 7-1
7-2 Chuck ............................................ 7-2
7-3 Turret ............................................ 7-3
7-4 TOOL EYE ............................................ 7-3
7-5 X-axis ............................................ 7-4
7-6 Z-axis ............................................ 7-4
7-7 Tailstock ............................................ 7-4
7-8 Hydraulic Unit ............................................ 7-5
7-9 Lubrication Unit ............................................ 7-6
7-10 Coolant Unit ............................................ 7-6
7-11 Air Unit ............................................ 7-6
7-12 Headstock Cooling Unit ......................................... 7-6

8. GRAPHIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1


8-1 Outline ............................................ 8-1
8-2 Operations ............................................ 8-1
8-3 Page Keys and ALL DATA DISPLAY Menu Item . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-4 Types of Layout Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8-5 Parameter ............................................ 8-6

9. STANDARD SPECIFICATION OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . 9-1


9-1 Principle Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-2 Spindle Nose Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9-3 Stroke Diagram ............................................ 9-5
9-4 Tooling Interference Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9-5 Relation Diagram between Chuck and TOOL EYE . . . . . . . . . . . . . . . . . . . . . . 9-11

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1. INTRODUCTION
1-1 PURPOSE OF THIS MANUAL
Mazak is committed to the highest levels of customer service and support. If a

machine problem is encountered, contact the nearest service office of the Mazak
customer support network for assistance. Please use the Machine Documentation

Customer Evaluation form supplied at the end of this section with any comments and
suggestions for improvement. Thank you for your interest.

[ NOTE ]

Level 1 and level 2 (advanced) maintenance classes

covering Mazak machines and Mazatrol CNC control systems


are available at the Technical Training Center in Florence,

Kentucky. These classes provide in-depth troubleshooting


procedures not shown in this manual, that can be carried out

only by qualified personnel.


Contact the nearest Mazak service center or the national training

center for additional information.

This manual is provided as a quick reference to basic machine and CNC functions. It

should, however, be used in conjunction with the operation and programming manuals
also supplied.

[ NOTE ]

Please take the time to review the machine documentation

supplied before attempting any machine operations. If any


questions exist, contact the nearest Mazak service center for

assistance.

1-1
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Mazak machines are engineered with a number of safety devices to protect personnel

and equipment from injury and damage. Operators should not, however, rely solely

upon these safety devices, but should operate the machine only after fully
understanding what special precautions to take by reading the machine documentation

thoroughly.

[ CAUTION ]

Do not attempt to operate or perform maintenance / repair on


the machine without a thorough understanding of the actions

about to be taken. If any questions exist, contact the nearest


Mazak service center for assistance.

1-2 CONFIGURATION
1) Page numbers are given as two numerals joined by a hyphen. The first number
indicates the chapter number and the second indicates the page number within

that chapter.

Example 1: 2-15

Chapter number Page number

In the event an additional page is inserted, the page number is shown by adding

sub-page numbers as follows:

Example 2: 3-16-1

Additional page

2) Figure numbers consist of the word "Fig." followed by two numbers separated by
a hyphen. The first of these numbers is the chapter number; the second is the

number of the figure in that chapter. The figure number is followed by the title of
the figure.

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Example: Fig. 3 - 1 Main Machine Components (1/2)

Chapter
Title
number
The suffix shown here indicates that

Number of figure in chapter there are two figures with this title, as

indicated by the denominator, and that

this is the first of those figures, as

indicated by the numerator.

Note: Some figures in this manual are not numbered.

3) Table numbers consist of the word “Table” followed by two numbers separated by

a hyphen. The first of these numbers is the chapter number; the second is the
number of the table in that chapter. The table number is followed by the title of

the table. The tables are listed in an index at the end of the manual.

Example: Table 2 - 1 Safety Nameplate Details (cont’d)

Chapter
Title
This suffix is added to the title on the
number
second and subsequent pages if the
Number of table in chapter
table occupies more than one page.

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1-3 OPTIMUM CUSTOMER SERVICE & SUPPORT NETWORK

1. North Central Technical Center (Florence, Ky.) ............................ (606) 342-1775

Technical Training Center (Florence, Ky.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (606) 342-1482

2. Midwest Technical Center (Chicago, Il.) ................................. (847) 885-8311

3. Canada Service Center (Mississauga, Ont.) .............................. (905) 670-0201

4. East Technical Center (Hartford, CT.) .................................. (860) 528-9511

5. Southeast Technical Center (Atlanta, Ga.) ............................... (770) 996-1030

6. Southwest Technical Center (Houston, Tx.) .............................. (713) 931-7770

7. West Technical Center (Los Angeles, Ca.) ............................... (310) 327-7172

MAZAK After Hours Customer Support Hotline . . . . . . . . . . . . . . . . . . . . . . . (800) 231-1456

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2. OUTLINE OF THE SQT LATHE

This chapter describes coordinate axes, components location and functional principles.

2-1 Functional Principle

1. Main spindle
The main spindle is driven directly by a variable-speed AC inverter motor built into the spindle
body. The spindle is cooled by a water and air cooling system, reducing the effects of heat to
an absolute minimum.

2. Tailstock
The tailstock comprises the tail spindle which is hydraulically driven.

3. Chucks
The chucks are connected with a rotary hydraulic cylinder at the rear of the spindle by a
connecting tube. When the piston in the cylinder moves towards the chuck, the chuck jaws
open; when the piston moves away from the chuck, the chuck jaws close.

4. X-axis, Z-axis
The carriage is moved along the bed in the Z-axis direction by a Z-axis AC servo motor through
a ball screw. The turret mounted on the carriage is moved in the X-axis direction by an X-axis
AC servo motor through a ball screw.

5. Turret (SQT-200/250)
The turret has 12 faces, enabling 12 tools (rotary tools) to be mounted simultaneously.
The tool holders are of the bolt fixing type. When the lathe is performing an automatic operation,
the next command is read and the turret is rotated in the direction of the shorter route from the
position of the tool currently in use to that of the next tool.
When the lathe is in the manual mode, either clockwise rotation or counterclockwise rotation can
be selected. Except when rotating, the turret is clamped hydraulically to the turret base (the
index coupling is engaged).
When an rotating command is received, the index coupling is disengaged, and the turret is
unclamped. The turret is then rotated by the hydraulic motor until the encoder detects that the
turret has reached the position set by the command, after which the turret is clamped.

6. TOOL EYE (option for Japan and standard for export)


The TOOL EYE is a sensor mounted on the end of an arm which automatically measures the
position of the tool tip when the tool tip is brought into contact with TOOL EYE.

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2-2 Lathe Control

The SQT lathe is controlled by MAZATROL CNC, a system featuring interactive programming and
artificial intelligence. An ultra-high-speed 32-bit microprocessor enables all lathe operations - feed
rate acceleration and deceleration, spindle acceleration and deceleration, PLC operations, turret
indexing, etc. - to be performed at high speed, and spindle and servo motor control is fully digitized.

8
4
6

Fig. 2-1 Lathe control

No. Name No. Name

1 X-axis servomotor 5 Headstock (motor)

2 Z-axis servomotor 6 CNC control unit

3 X-axis, Z-axis servo control unit 7 External data I/O unit

4 Spindle control unit 8 Operation panel

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2-3 Components Location

1
8
4

12
2
13
10
14 9
15
5
3
6
Fig. 2-2 Machine main components (1/2) TR113-01606

11

Fig. 2-2 Machine main components (2/2) TR113-01607

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No. Name No. Name

1 Turret 9 Chip pan

2 Main breaker 10 Tailstock

3 Lubrication unit 11 Coolant pump

4 Spindle 12 Data I/O panel (micro disc interface)

5 Spindle cooling unit 13 Operation panel

6 Pressure nameplate (Main pressure, Chuck 14 Air unit


pressure, Tailstock thrust power)

7 Hydraulic unit 15 TOOL EYE

8 Chuck

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2-4 Coordinate Axes

The coordinate axes used for the machine are defined as follows.
X-axis: This is the turret motion vertical axis.
“+” (plus) indicates the upward direction; “-” (minus) indicates the downward direction.
Z-axis: This is the turret motion transverse axis.
“+” (plus) indicates movement to the right ; “-” (minus) indicates movement to the left
(towards the chuck).

X-axis
Z-axis


+

Fig. 2-3 Coordinate axes D320S0001

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2-5 FUNCTIONS OF OPERATION PANEL AND SWITCHES

2-5-1 Operation Panel

2-5-1-1 Disposition of switches and indicator lamps

3 4
38 5 11

15
14

31

8
32
12 13

33

30 29 7 35 36 37 10 9
34

25 17 18 23 19

21
26 27 28

24 22
16
20

Fig. 2-4 Operation panel NM211-00377’

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2-5-1-2 Names and functions of keys, buttons and switches

Some of the keys and buttons on the operation panel have a small lamp at their respective top left
corner. The lamp is on when the function is effective and off when the function is ineffective
(except for the power ON button).

Example: Lamp on Lamp off


RAPI D RAPI D Function
Function
effective ∞ ineffective
~ ~
* The numbers in Table 2-1 correspond to those in Fig. 2-1.

Table 2-1 Names and functions of keys, buttons and switches

No. Name Function

1 Power ON button - This button is used to switch on the power to the NC unit.
(POWER I) Several seconds after this button has been pressed, the “READY” lamp will light, indicating
that the lathe is ready for operation.
When the main breaker is switched on, the backlighting of this button will light, indicating that
power is being supplied to the machine.
- When this button is pressed, the backlighting will go off.

2 Power OFF button - This button is used to switch off the power to the NC unit.
(POWER O) When this button is pressed, the backlighting of the power ON button will light.

3 Display selector key - This key is used to select the display on the CRT screen.
When this key is pressed, the display selection menu is displayed.

4 Menu selector key - This key is used to change the menu currently being displayed over to another one.

5 Menu keys - These keys are used to select one of the menu items being displayed.

6 Brightness adjustment - This dial is used to adjust the brightness of the display.
dial (BRIGHT) Turn the dial clockwise to increase the brightness and counterclockwise to reduce the
brightness.

7 Cursor keys - These keys are used to make the cursor appear on the screen and to move the cursor
around the screen.

Press this key to move the cursor to the left.


¨ If this key is pressed when the cursor is at the left end, the cursor will move to the
right end of the line above.

Press this key to move the cursor to the right.


Æ If this key is pressed when the cursor is at the right end, the cursor will move to the
left end of the line below.

≠ Press this key to move the cursor up to the line above.

Ø Press this key to move the cursor down to the line below.

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No. Name Function

8 Page keys - These keys are used to call the previous page or the next page of a display which has
multiple pages.

≠≠ Press this key to call the previous page.

ØØ Press this key to call the next page.

- When a PROGRAM display is selected:

≠≠ Press this key to move the cursor to the beginning of the previous process.

ØØ Press this key to move the cursor to the beginning of the next process.

9 Data cancel key - This key is used to cancel the data displayed in the data display area.
(CAN) When this key is pressed, the data at the position where the cursor is blinking will be deleted.

10 EOB key - This key is used to set an end-of-block code in data.

11 Address/numeric data - These keys are used to set address data (alphabetic characters) and numeric data.
keys See Part 3, Chapter 3, DATA SETTING METHODS, for the usage of the keys.

12 Shift key - This key is used to set the address data displayed at the bottom right of the address keys.
See Part 3, Chapter 3, DATA SETTING METHODS, for the usage of the key.

13 Input key (INPUT) - This key is used to set the data displayed in the data input display area of the display.
Press this key after inputting the data with the numeric data keys.

14 Clear key (CLEAR) - This key is used to cancel the data displayed in the data input area of the display.
Press this key if incorrect data has been input into the data input area.

15 Reset key (RESET) - This key is used to reset the NC unit to its initial status.
If an alarm is displayed, eliminate its cause then press this key to cancel the alarm.

16 Cutting feed/manual - These keys are used to select the cutting feed/manual pulse feed mode.
pulse feed keys Press one of these keys and the appropriate axis movement button to execute axis motion at
the cutting feed rate in the selected axis direction.
Press the appropriate key and turn the manual pulse handle.
An axis motion will occur over the selected distance in the selected axis direction.
If this key is pressed, each graduation on the manual pulse handle will be equivalent
to a movement of 0.001 mm (0.000039 in.) in the direction of the selected axis.
If this key is pressed, each graduation on the manual pulse handle will be equivalent
to a movement of 0.01 mm (0.00039 in.) in the direction of the selected axis.
If this key is pressed, each graduation on the manual pulse handle will be equivalent
to a movement of 0.1 mm (0.0039 in.) in the direction of the selected axis.

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No. Name Function

17 Rapid feed key - This key is used to select the rapid feed mode.
Press this key then press the appropriate axis movement button. Motion will take place in the
selected direction along the selected axis at the rapid feed rate.

18 Zero-point return key - This key is used to select the zero-point return mode.
Press this key then press the appropriate axis movement button. The selected axis will return
to its zero-point in the machine coordinates system.

19 Automatic operation - This key is used to select the automatic operation mode.
key Press this key to execute programs registered in the NC unit.

20 Single-process key - This key is used to select the single-process mode.


Press this key to execute a specific process within the program currently being executed.
* This key is used for MAZATROL programs only.

21 Single-block key - This key specifies the single-block mode.


Press the key to execute block by block within the program when you want to check the
machine operation or machining state.

22 MDI key - This key specifies the MDI mode.


Press the key to execute the operation automatically using data that has been manually set.

23 Tape run key - This key is used to select the tape run mode.
Press this key to execute programs stored on paper tape, a micro disk or other external
equipment.
* This key is used for EIA/ISO programs only.

24 Coolant manual key - This key is used to feed the coolant.


This key is valid only in the manual operation mode.

25 Coolant automatic - This key is used to select ON/OFF-status of the coolant in the automatic operation mode.
key Press this key to make M08 (coolant ON) valid in the programs for the automatic operation.
Even when M08 is set, the feeding of coolant will not start, unless this key is pressed.

26 Rapid feed override - These keys are used to adjust the rapid feed override rate.
keys The current rate is indicated on the indicator above the keys as a percentage of the maximum
rapid feed rate.

Press this key to increase the rapid feed override.

Press this key to reduce the rapid feed override.

27 Spindle override keys - These keys are used to adjust the spindle rotation speed (peripheral speed).
When the lathe is in the manual mode, the speed indicated on the indicator above the keys is
equal to one-tenth of the value of the current rotation speed.
When the lathe is in the automatic operation mode, the current rotation speed is indicated on
the indicator above the keys as a percentage of the speed set in the program.

Press this key to increase the speed.

Press this key to reduce the speed.

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No. Name Function

28 Cutting feed override - These keys are used to adjust the cutting feed rate.
keys (FEED) When the lathe is in the manual operation mode, the code corresponding to the feed rate is
indicated on the indicator above the keys.
When the lathe is in the automatic operation mode, the current feed rate is indicated on the
indicator above the keys as a percentage of the feed rate set in the program.

Press this key to increase the feed rate.

Press this key to reduce the feed rate.

29 VFC key - This key is used to change the cutting condition values (peripheral speed, feed rate) set in
the program to the values set using the override keys.
If this key is pressed after the spindle rotation speed or the cutting feed rate has been
adjusted during automatic operation, the values set in the program will be changed
automatically to the values set using the override keys.
* This key can be used for MAZATROL programs only.

30 TPS key - This key is used to register the tool tip position into the NC when a manual interrupt operation
is performed.
Use this key when interrupting an automatic operation to change tool tip, etc.

31 Overtravel release - This key is used to return an axis which has stopped at the axis stroke end to a movable
key range of the axis.
This key is also used to cancel emergency stops.

32 Display erasure key - This key is used to temporarily erase the display from the CRT screen, with the intention of
extending the life of the CRT screen and saving energy.
If an alarm occurs while the display is off, the alarm only will be displayed.
To make the display reappear, press this key again.

33 Hardcopy key - This key is used to print out the display on the CRT screen.
(COPY) Windows cannot be printed out.

34 Window key - This key is used to display a window on the CRT screen.

35 Auxiliary key - Use this key as an aid key according to the particular machine specifications.

36 Coolant menu key - This key is used to display the coolant menu on the CRT screen.
Pressing this key will display the menu for various coolant functions on the CRT screen.

37 Machine menu key - This key is used to display the menu for various machine-operations on the CRT screen.
Pressing this key will display the menu for various machine-operations on the CRT screen.

38 Arbitrary display - These keys are used to select the following displays whose names are inscribed on the keys:
selector keys

D POSITION display

D PROGRAM display

D TOOL DATA (1) display

D SET UP display

D USER PARAMETER display

D DATA I/O display

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2-5-1-3 Names and functions of indicator lamps

1 11
2 12
3 13
4 14

5 15
6 16
7 17
8 18

9 19
10 20
Fig. 2-5 Optional panel (Indicator lamps) D147S0006

Table 2-2 Names and functions of the indicator lamps

No. Name Function

1 Operation ready indicator - This lamp comes on when the lathe is ready to operate.
lamp (READY) This lamp comes on several seconds after the power has been switched on.

2 Program head indicator - This lamp comes on when the program head is called up.
lamp (P.HEAD) This lamp also comes on when the RESET key is pressed when the lathe is
performing an automatic operation.

3 Program stop indicator - This lamp comes on to indicate that program execution has terminated or stopped.
lamp (P.STOP)

4 Turning mode indicator - This lamp comes on when the turning mode is selected.
lamp (SPINDLE)

6 Spindle unclamp indicator - This lamp is on when the spindle is in the unclamp status.
lamp (UNCLAMP)

7 Spindle clamp indicator - This lamp is on when the spindle is in the clamp status.
lamp (CLAMP)

8 Spindle brake indicator - This lamp is on when the spindle is braked.


lamp (BRAKE)

10 Alarm indicator lamp - This lamp comes on if an alarm occurs.


(ALARM)

11 X-axis zero-point return - This lamp is on when the X-axis is at the machine zero point.
indicator lamp

12 Z-axis zero-point return - This lamp is on when the Z-axis is at the machine zero point.
indicator lamp

14 4th axis zero-point return - This lamp is on when the 4th axis is at the machine zero point.
indicator lamp

15 5th axis zero-point return - This lamp is on when the 5th axis is at the machine zero point.
indicator lamp

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No. Name Function

16, 17 Main spindle chuck - These lamps indicate whether the chuck unit of the main spindle is open or closed.
open/close indicator If unclamping lamp 16 is on, this indicates that the chuck unit is open.
lamps (CHUCK 1st) If clamping lamp 17 is on, this indicates that the chuck unit is closed.

Note: The meaning of lighting of the lamps becomes converse if the chucking
direction selector switch has been set to inner chucking.

20 Measurement indicator - This lamp comes on when the sensor is turned on during workpiece measurement.
lamp (W.MEASURE)

2-5-2 Auxiliary Operation Panel

54 53 57 55
46

42 41 40 43

48
47

58 59
49 44
45

50
39
51 52

Fig. 2-6 Auxiliary operation panel

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Table 2-3 Names and functions of keys, buttons and switches (cont’d)

No. Name Function

39 Emergency stop - This button is used to stop the lathe operation in case of emergency.
button If this button is pressed, all of the lathe operations will stop immediately and a “128
(EMERGENCY EMERGENCY STOP” alarm will be displayed.
STOP) To cancel an emergency stop, turn the emergency stop button in the direction of the arrow
and then simultaneously press the reset key and the overtravel release key.

40 Spindle rotation - This button is used to specify the spindle rotation direction when the lathe is in the manual
direction change operation mode.
button (REV) When the backlighting of this button is on, the spindle rotates in the reverse direction.
When the backlighting of this button is off, the spindle rotates in the forward direction.

41 Spindle start button - This button is used to rotate the spindle when the lathe is in the manual operation mode.
(START) The backlighting of this button is on while the spindle is rotating.

42 Spindle stop button - This button is used to stop the spindle when the lathe is in the manual operation mode.
(STOP)

43 Spindle jog button - This button is used to jog the spindle when the lathe is in the manual operation mode.
(JOG) The spindle rotates slowly when the button is being pressed and stops when the button is
released.

44 Tool selector button - This button is used to index a tool on the turret when the lathe is in the manual operation
(TOOL SELECT) mode.
The turret rotates one position towards the operator each time the button is pressed.

45 Axis movement - These buttons are used to move the turret in the X-axis direction and the Z-axis direction
buttons when the lathe is in the manual operation mode.
The turret moves in the selected direction when a button is being pressed and stops when
the button is released.

46 Axis selector switch - This switch is used to select the axis in whose direction the movement occurs when the lathe
(AXIS SELECT) is in the manual pulse feed mode.

47 Manual pulse handle - This handle is used to specify the axis motion direction and distance when the lathe is in the
manual pulse feed mode.

49 Tail spindle operation - This switch is used to move forward/reversely or stop the tail spindle.
switch * Invalid during automatic operation.

50 Tailstock body motion


buttons

51 Feed hold button - This button is used to stop the axis feed when the lathe is in the automatic operation mode.
(red) When the feed is stopped, the LED comes on and the cycle start button LED goes off.
(FEED HOLD)
White LED

52 Cycle start button - This button is used to start the lathe when it is in the automatic operation mode.
(green) The LED is on when the lathe is in the automatic operation.
(CYCLE START) The LED goes off when the automatic operation is interrupted or has been completed.
Green LED

53 Automatic power - This switch is used to cut off the power automatically when the execution of a program has
cutoff switch (option) been completed.
When the switch is set to the top position ( I ), the automatic power cutoff function is effective
and the lamp comes on.
When the switch is set to the bottom position ( O ), the automatic power cutoff function is
ineffective and the lamp goes off.

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No. Name Function

54 Automatic door - This switch is used to open and close the front door.
opening/closing
switch (option) ¨ Æ Set this switch to the top position to open the front door.
(The lamp will light when the door is fully opened.)

Æ ¨ Set this switch to the bottom position to close the front door.
(The lamp will light when the door is fully closed.)

55 Reprogramming - This switch is used to prevent programs or data in the NC unit from being erased
switch (with key) accidentally.
To rewrite a program or data, set this switch to the ENABLE position.
When the switch is set to the LOCK position, rewriting of programs and part of the data is
rendered impossible.

57 Chip-conveyor start - This button is used to start the chip-conveyor.


button Pressing this button will start the chip-conveyor operation.
Pressing this button once again will stop it.

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2-5-3 Data I/O Panel

Transference of
NC program data

No fuse breaker switch

100 V AC power source

Fig. 2-7 Data I/O panel (SQT-200/250)

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3. MACHINE OPERATION

3-1 Preparation for Operation

3-1-1 Inspection at the Start of Operation

In order to ensure safe operation and good machine maintenance, the following points must be
inspected before starting operation.

1. Check that the voltage of the factory power supply is correct. (Permissible voltage : 200 to 230
V)
2. Check that the doors of the operation panel and electrical control panel are closed.
3. Check that there is nothing abnormal about the safety covers (particularly about the front door).
4. Check that the selector switch for chucking direction is set to the correct direction.
5. Check that the oil level gauges are indicating the correct values.

Headstock cooling unit


(LLC tank) Hydraulic unit

Lubrication unit Coolant unit

Fig. 3-1 Locations of oil level gauges TR113-01219’

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3-1-2 Procedure for Switching the Power On

DANGER
- Cables or wires with damaged insulation could cause current leakage or electric shocks.
Always check that the insulation is sound.
- There are high voltage terminals in the electrical control panel, transformers, motors,
junction boxes, etc. Never touch these terminals.
- Do not touch the switches with wet hands.

WARNING
In order to prevent the entry of water, oil, chips, dust, etc. into the electrical control panel
and other machine units, ensure that the doors of the CNC unit and electrical control panel,
and all other doors and covers, are closed.

CAUTION
Follow any instructions on the distributor for the factory power supply (for example,
instructions on a nameplate).

1. Switch on the factory power supply.

2. Turn the main breaker on the front face of the machine to the ON position.
- The power ON button (POWER I) on the operation panel will light up.
- The spindle cooling water pump, spindle cooling fan and spindle control amplifier/servo
amplifier heat sink fan will be turned on.

3. Press the power ON button (POWER I) on the operation panel.


- The light in the power ON button (POWER I) will go out.
- The “READY” lamp, which indicates that the machine is ready for operation, will light.
- The POSITION display will be displayed on the CRT screen.
- The zero-point return key (HOME) will light up and the message ZERO RETURN will be
displayed on the CRT screen.
- If the machine features the absolute position detect function (option), the automatic operation
mode key (AUTO) will light up.
- The hydraulic unit pump and lubrication unit pump will start.

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2 Main breaker 1 Factory power supply

OFF ON

3 Power ON button

Operation ready indicator lamp

Fig. 3-2 Procedure for switching the power on TR113-00166’

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3-1-3 Inspection after Switching the Power On

1. Check that the “READY” lamp is on.

2. Check that the POSITION display is displayed on the CRT screen.

3. Check that the pressure gauges in the upper part of the front face of the machine are indicating
the correct values.
- Main pressure: 5 MPa (50 kgf/cm2 (711.5 PSI))
- Chuck pressure: Adjusted in accordance with the workpiece to be machined
- Tailstock thrust power: Adjusted in accordance with the workpiece to be machined

POSITION display

Operation ready indicator lamp

Pressure nameplate

Chuck Tail spindle


pressure thrust power

Fig. 3-3 Check points after switching the power on TR113-00164’

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3-1-4 Zero-Point Return

WARNING
- Do not press switches while wearing gloves. This could cause machine malfunction.
- In order to prevent machine malfunction, confirm the functions of switches before using
them.

CAUTION
- In the case of the optional absolute position detection specification, the record of the
machine zero point is not lost even if the power is switched off. Accordingly, it is not
necessary to perform an all-axis zero-point return operation after switching the power on.
- If the battery voltage drops the record of the machine zero point may be lost. If the
message ZERO RETURN is displayed on the CRT screen, perform an all-axis zero-point
return operation.

The zero-point return operation is important because it registers the machine zero point in the NC
unit.
When the power is switched off, the record of the machine zero point is lost. Therefore, the first
thing that has to be done after switching on the power is to perform a zero-point return operation.

1. Press the zero-point return key (HOME).

2. Move the turret and the carriage at least 30 mm (1.18 in.) in the minus direction, away from the
machine zero point by pressing the axis movement buttons.
- When detecting zero-point dog at this axis movement, axis movement direction becomes the
direction for the zero-point return and feed speed changes into “zero-point return speed”.
(Refer to Fig. 3-5.)
For example, if zero-point dog is detected when pressing X-axis movement button for minus
direction at around the X-axis home position, direction of axis movement changes to plus
direction.

3. Hold down one of the axis movement buttons for plus direction.
- Movement will stop when you release the button.
- When becoming zero-point return speed (Refer to Fig. 3-5.) after zero-point dog detecting, the
axis continues zero-point return without stop even if the button is released.

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4. Release the button when the relevant zero-point indicator lamp lights (“X” or “Z”).

Zero-point indicator lamps

Zero-point return key

Axis movement buttons


X

Z Z

Fig. 3-4 Procedure for zero-point return TR113-01220’’’

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<Zero-point return speed>


In the first operation after turning on the power, deceleration is given to a rapid feed at about 30 mm
(1.18 in.) before zero point stop, and the machine reaches at its zero point at a constant zero-point
return speed and stops. Unless the power is turned off, in the second and subsequent zero-point
return operation the machine returns to the zero point with rapid feed without deceleration.

In case the record of machine zero point at


turning on the power is lost.
Feed rate

Rapid feed rate at turning on the power is limited by setting


value of parameter A3. (Standard setting value: 5 m/min)

Zero-point
return speed

Movement

Zero point dog Machine zero point


Fig. 3-5 Zero-point return speed NM210-00456

3-1-5 Warmup Operation

The warmup operation is important for maintaining lifelong precision and the long life of the machine.
Make sure to perform the warmup operation daily.

CAUTION
- Warm up the spindle and feed axes. Do this by performing automatic operation at
between 1/2 and 1/3 of the maximum spindle speed and maximum feed rate for between
10 and 20 minutes.
- Write the program for the warmup operation so as to execute the functions of the full
range of machine components.
- If operation is to be performed at maximum spindle speed, pay meticulous attention to the
warmup operation.

* If the machine features the automatic warmup operation function (option), refer to the operating
manual for options.

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3-1-6 Opening/Closing of Chuck

CAUTION
Check that the chuck pressure is correct.

The chucks are opened and closed using foot switches.

OPTION MAIN 2nd. CHUCK AXIS MAINTE-


SPINDLE SPINDLE NANCE

MAIN SP. MAIN SP. 2nd.SP. 2nd.SP.


CHK-EXT. CHK-INT. CHK-EXT. CHK-INT.

1. When the machine menu key on the operation panel is pressed, the menu will change. Set the
chuck opening and closing directions with the internal gripping menu items which appear after
pressing the CHUCK menu key.

2. Operate the foot switches to open and close the chuck.

A. Single foot switch


Stepping on the pedal opens the chuck and releasing the pedal closes the chuck.

Jaw motion Jaw motion

Foot switch ON Foot switch OFF


MAIN SP. MAIN SP. 2nd.SP. 2nd.SP.
CHK-EXT. CHK-INT. CHK-EXT. CHK-INT.
Mount
workpiece
MAIN SP. MAIN SP. 2nd.SP. 2nd.SP.
CHK-EXT. CHK-INT. CHK-EXT. CHK-INT.

Fig. 3-6 Operation of foot switch (1/2) - Single foot switch - NM210-00463’

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B. Double foot switch


Stepping on the left pedal opens the chuck and stepping on the right pedal closes the chuck.

* The chuck cannot be opened or closed while the spindle is rotating.

Jaw motion Jaw motion

Foot switch ON Foot switch ON


MAIN SP. MAIN SP. 2nd.SP. 2nd.SP.
CHK-EXT. CHK-INT. CHK-EXT. CHK-INT.
Mount
workpiece
MAIN SP. MAIN SP. 2nd.SP. 2nd.SP.
CHK-EXT. CHK-INT. CHK-EXT. CHK-INT.

Fig. 3-6 Operation of foot switch (2/2) - Double foot switch - NM210-00464’

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3-2 MANUAL OPERATION

3-2-1 Manual Operation Mode

WARNING
Never touch the spindle while it is rotating.

This function is used for operations such as simple test cutting in manual operation.

1. Selection of manual operation mode

Select one of the manual mode keys.


- The key lamp of the pressed key will light.

D366S0001

3-2-2 Spindle Operation

3-2-2-1 Spindle start

1. Select the manual operation mode. (See the section 3-2-1.)

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2. Select the rotational direction using the spindle rotational direction change backlit button (REV).

Lamp ON: Reverse


Lamp OFF: Forward

Fig. 3-7 Pressing the spindle rotational direction change button (REV) NM210-00206

Forward

Reverse

Fig. 3-8 Spindle rotational direction

3. Set the spindle speed using the spindle override keys


(SPINDLE).

D366S0002

The spindle speed is increased by 10 increments each time is pressed.

The spindle speed is decreased by 10 increments each time is pressed.

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4. Press the spindle start backlit button (START).


- The spindle will start rotating.
- The spindle cooling water radiator fan will start rotating.

Fig. 3-9 Pressing the spindle start button (START)

3-2-2-2 Spindle stop

Press the spindle stop backlit button (STOP) to stop the rotation of the spindle.
- The value displayed in the override indicator will not change.
- The radiator fan keeps rotating during parameter set time even after spindle stop.
- In automatic operation, the spindle will not stop even if the spindle stop backlit button (STOP) is
pressed.

3-2-2-3 Spindle jog

For jogging the spindle, press the spindle jog button (JOG).
- The spindle keeps rotating while the button is pressed and stops when the button is released.
- If the spindle jog backlit button (JOG) is pressed during spindle rotation, the spindle speed will
change to the jog speed. The spindle will stop when the button is released.

Fig. 3-10 Pressing the spindle jog button (JOG)

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3-2-2-4 Spindle rotational direction change

- It is possible to change the spindle speed while it is rotating by pressing the spindle override keys
(SPINDLE).
- If the spindle rotational direction change backlit button (REV) is pressed while the spindle is
rotating, it will stop rotating.

3-2-3 X- and Z-Axes Feed Operation

CAUTION
- Check that there will be no interference before starting axis feed or tailstock operation.
- Interlocks are not effective until the zero-point return has been completed.

X-axis

Interference

Tailstock forward movement

Fig. 3-11 Interference between turret and tailstock body

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3-2-3-1 X- and Z-axes rapid feed

1. Press the rapid feed key (RAPID).

- The key lamp will light.

D366S0011

2. Set the feed rate by pressing the rapid feed override keys
(RAPID).
- 50% and 100% indicate the feed rate as a percentage
value against the maximum rapid feed rate.
- For R0, R1 and R2, the feed rate can be set to the
parameter as a percentage value.
R0: Parameter B149
R1: Parameter B150
R2: Parameter B151 D366S0006

3. Press the appropriate axis movement backlit button.


- Axis feed will continue while the button is held down and it will stop when the button is
released.
- It is possible to alter the feed rate while axis feed is in progress by using the rapid feed
override keys (RAPID).

+X direction
X

Z Z

-Z direction +Z direction

X
-X direction

Fig. 3-12 X- and Z-Axes movement D366S0012’’

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3-2-3-2 X- and Z-axes cutting feed

1. Press any one of the cutting feed keys (JOG/HANDLE).


- The key lamp will light.

D366S0008

2. Set the feed rate using the cutting feed override key
(FEED).

When the key is pressed the feed rate is increased


one step.
When the key is pressed the feed rate is de-
creased one step.
- The indicated feed rate value is different from the actual
feed rate. D366S0013

Cutting feed rates

Feed rate Feed rate


Display Display
(mm (in.)/min) (mm (in.)/min)

0 0 (0.00) 130 52 (2.047)

10 1.0 (0.039) 140 72 (2.835)

20 1.4 (0.055) 150 100 (3.937)

30 2.0 (0.079) 160 140 (5.512)

40 2.7 (0.106) 170 200 (7.874)

50 3.7 (0.146) 180 270 (10.630)

60 5.2 (0.205) 190 370 (14.567)

70 7.2 (0.283) 200 520 (20.472)

80 10 (0.394) 210 720 (28.346)

90 14 (0.551) 220 1000 (39.37)

100 20 (0.787) 230 1400 (55.118)

110 27 (1.063) 240 2000 (78.74)

120 37 (1.457)

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3. Press the appropriate axis movement backlit button.


- Axis feed will continue while the button is held down and it will stop when the button is
released.
- It is possible to alter the feed rate while axis feed is in progress by using the cutting feed
override keys.

+X direction
X

Z Z

-Z direction +Z direction

X
-X direction

Fig. 3-13 X- and Z-Axes movement D366S0012’’

3-2-3-3 X- and Z-axes manual pulse feed

1. Press one of the manual pulse feed keys (JOG/HANDLE).

X1 (key lamp ON) 0.001 mm (0.000039 in.) per pulse

X10 (key lamp ON) 0.01 mm (0.00039 in.) per pulse

X100 (key lamp ON) 0.1 mm (0.0039 in.) per pulse

* 1 pulse of the X-axis corresponds to the diameter value.

2. Select the feed axis by using the axis selector switch


(AXIS SELECT).

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3. Turn the manual pulse handle in the direction corres-


ponding to the required axis movement.
- The axis will be moved by the increment selected in
step 1 above each time the pulse handle is turned
through one graduation.

3-2-3-4 Barrier cancel

This function is used to cancel tool, chuck or tail


barriers. Highlighted
- When the menu is highlighted, the barriers will
be cancelled.
BARRIER BARRIER
* The same function is available in automatic CANCEL CANCEL
operation. Effective Ineffective

NM210-00460

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3-2-4 Tool Selection

CAUTION
Before rotating the turret, always check that there will be no interference between the tools
and the chuck, etc. And also check that the tool is fixed securely.

This procedure is used to rotate the turret to mount tools to the turret, remove tools from the turret,
and index tools.
1. Press one of the manual mode keys to select the
manual mode.
- The key lamp of the key pressed will light.

D366S0001

2. Turn the tool selector button (TOOL SELECT) to select the turret rotational direction.

3. Press the tool selector button (TOOL SELECT).


- Each time the tool selector button (TOOL SELECT) is pressed, the turret will be rotated one
position.
- If the tool selector button (TOOL SELECT) is held down, the turret will rotate continuously.
Turret rotation will stop when the button is released.

FWD
TOOL SELECT

FWD REV

REV

Fig. 3-14 Turret rotation by pressing tool selector button (TOOL SELECT) TR113-00159’

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3-2-5 Tailstock Operation

3-2-5-1 Checking before tailstock operation

1. Check that the tailstock body is clamped.

2. Check that the tail connecting pin is unlocked.

3. Check that the tail spindle thrust power is set to an appropriate value.

(1) Move the tail spindle forward to fix a workpiece or move the spindle right to the stroke end.
* For the operation procedure, refer to the section 4-5-2 “Moving the tail spindle in the
forward and reverse directions”.

(2) Adjust the tail spindle thrust power by using the adjustment knob while referring to the
pressure gauge (the pressure will increase if the knob is turned in the direction of the
arrow).

Name plate

Chuck pressure Tail spindle


thrust power

Fig. 3-15 Adjustment of tail spindle thrust power

* The setting range for thrust power is 40 to 700 kgf (88 to 1541 lbs).

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4. Check that the settings for the tail spindle forward end and reverse end are appropriate.

Proximity switch for Proximity


forward end switch for
reverse end

Fig. 3-16 Settings for tail spindle forward and reverse end

After adjusting the tail spindle stroke, do not fail to adjust the proximity switches.
* The proximity switch clearance should be 0.5 to 1 mm (0.02 to 0.039 in.).

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3-2-5-2 Moving the tail spindle in the forward and reverse directions

1. Press one of the manual mode keys.


- The key lamp of the pressed key will light.

Fig. 3-17 Selection of manual operation mode D366S0001

2. Turn the tail spindle switch (TAIL SPINDLE) to the left


or the right to move the tail spindle in the forward or
reverse direction.

Fig. 3-18

3. In case tail sleeve is to be operated with M31 or M32 in automatic operation mode, set the
switch to the center position with the tail spindle positioned at forward end or reverse end.

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3-2-5-3 Moving the tailstock body in the forward and reverse directions

1. For manual tailstock

CAUTION

Precautions for manual tailstock operation:

- Tailstock base must be unclamped before the operation for its movement.
- To connect/release the tailstock with (from) the carriage, turn the connecting lever
securely.
- The movement speed must be 2 m/min (6.56 ft/min) or lower.

Tailstock body

Tail spindle

Connecting pin

Connecting mark
Position mark

Connecting dial

Release mark

Clamping bolts

Fig. 3-19

[1] Loosen the tailstock body clamping bolts (2 pcs.) to unclamp the tailstock body.

[2] Move the carriage manually (JOG/HANDLE) to the tailstock connecting position.

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[3] To connect the tailstock base with the carriage, turn the connecting dial in the front part of
the tailstock base and insert the connecting pin into the connecting block in the lower part of
the carriage.

Connecting block

Connect
Connecting pin

EXT

RET
Release
Connecting dial

Fig. 3-20 Connecting operation for manual tailstock TR113-01246’

[4] Move the tailstock base by using the Z-axis movement button in the manual pulse feed or
JOG mode.
If an unusual force is added to the Z-axis load during movement, the connection will be
released. In this case, release the connecting pin and restart the operation from procedure
2.

[5] Turn the connecting dial, and pull the connecting pin out of the block to release the
connection.

[6] Clamp the tailstock body.

2. For full automatic tailstock

[1] Select the manual mode.

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[2] Select the TAILBODY MODE (menu display).

OPTION MAIN 2nd. CHUCK AXIS MAINTE-


SPINDLE SPINDLE NANCE

PARTS-C. PARTS-C. BAR TAILBODY TAILBODY JOINT JOINT


EXTEND RETRACT FEEDER UNCLAMP MODE START POSITION

Fig. 3-21

[3] Move the carriage by using the JOG button (2 m/min (6.56 ft/min)) and stop it at the
connecting position.
Check that the JOINT POSITION menu item is highlighted on the CRT screen.

[4] Press the JOINT START menu key.

Dog

Limit switch

Fig. 3-22 Forward/reverse movement of tailstock body TR113-00300’

[5] Move the tailstock base by using the Z-axis movement button in the manual pulse feed or
JOG mode.

[6] Cancel the TAILBODY MODE of the menu display when completing the movement.

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3-2-5-4 Feed operations

CAUTION
If the tailstock body is advanced while the turret is lowered as indicated in the figure below,
there will be an interference.

X-axis

Interference

Forward movement of tailstock

Fig. 3-23 Interference between turret and tailstock body

CAUTION
The chuck barrier, tailstock barrier and tool barrier are not effective in the manual operation
mode. Due care must therefore be taken to avoid interference with the chuck.

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3-2-6 Other Manual Operations

3-2-6-1 Soft limit and its release

Movable range of X- and Z-axes is limited with parameters so that they cannot move to O.T. stroke.
(O.T. is the abbreviation of OVER TRAVEL, and it represents stroke limit.)
If trying to move the axes out of the range, 120 SOFT LIMIT alarm is displayed on the screen.
Interlock is set not to move the axis out of the range.
Press the reset key (RESET) to release the alarm.

CAUTION
- Soft limit (*) becomes effective when, after power ON, zero-point return has been
performed and machine zero point has been set.
Therefore, soft limit never works when NC has lost its zero point by servo alarm.
- Carry out the zero-point return certainly.

+O.T.

– O.T. Machine A9 +O.T.


zero point

A10 A9

A10

– O.T.

Fig. 3-24 Soft limit

Name Name

: Machine zero point Parameter A9 : Upper soft limit

O.T. : Stroke limit Parameter A10 : Lower soft limit

: Movable range (Both A9 and A10 are set for each axis.)

* A “soft limit” is a point beyond which the NC unit does not monitor axis movement.

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3-2-6-2 Machine lock

This is a function whereby the feed axes are mechanically locked. When this function is set, there
is no actual axis movement but the movements corresponding to the specified operations are
depicted on the CRT screen. This function is used to check the program execution condition.

CAUTION
When selecting the menu keys for machine lock, C-axis lock cancel and dry run, use the
auxiliary key MF1 in addition to them as a safety measure.

Highlighted

MACHINE MACHINE
LOCK LOCK

Machine lock effective Machine lock ineffective

MF1

When pressing the menu key, the auxiliary key MF1 lamp will flicker. Then press the MF1 key. The
menu item will be highlighted and the MF1 lamp will light. Use the MF1 key also to cancel the
function.

WARNING
After the machine lock function has been cancelled, the actual position of the feed axes may
differ from those displayed on the CRT screen. Do not cancel this function during
automatic operation.

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3-2-6-3 Coolant MANUAL and WORK LIGHT

1. Coolant MANUAL
This hardware-key function allows you to start and stop the supply of coolant during manual
operation.

Coolant supplied Coolant not supplied

- When the key lamp is turned on, the coolant will be supplied.

2. WORK LIGHT
This function is used to switch the machine lights on and off.

Highlighted

WORK WORK
LIGHT LIGHT

Light is ON Light is OFF

- When the menu is highlighted, the machine light will be turned on.

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3-3 PREPARATION FOR MACHINING

3-3-1 Mounting of Tools

3-3-1-1 Mounting/removal of tool holder and tools

WARNING
- Use tools which are suitable for the work to be carried out and conform to the machine
specifications.
- Use of badly worn tools can result in injury. Replace worn tools with appropriate new
ones.
- Illuminate the workplace adequately to ensure safety.
- Remove tools and other obstacles in the vicinity of the machine and peripheral devices to
a safe distance so that the operator has sufficient clear floorspace to stand in and walk
around.

CAUTION
Use tools which are no longer than the provided length so as to avoid interference.

1. Tool mounting procedure


(1) Tighten the clamping bolts with a hexagon wrench or a wrench.

(2) Change the injection direction of the coolant, depending on the type of tool to be used and
on whether the tool is lefthanded or righthanded.
- For an O.D. cutting tool, relocate the coolant nozzle and the blank cap, as shown in the
figure below.

O.D. cutting tool (right-handed) O.D. cutting tool (left-handed)


Blank cap
Coolant nozzle
O.D. cutting tool
(right-handed) O.D. cutting tool
(left-handed)

Coolant nozzle

Blank cap

Fig. 3-25 Injection direction change of the coolant (1/3) 2337MA00120-1

3-29
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- For a boring bar 25 mm or more in diameter, adjust the coolant injection direction select
knob so that the coolant is injected from the tool holder. Use a slotted screwdriver to adjust
the knob. After adjustment, mount a blank cap (use an M6 bolt) at the end of the coolant
nozzle located on the side opposite to the adjusted select knob.

Boring bar (right-handed) Boring bar (left-handed)

Coolant injection Blank cap


direction select knob (M6 bolt)

Coolant

Boring bar Coolant


Boring bar
(right-handed)
(left-handed)
Blank cap
(M6 bolt) Coolant injection
direction select knob

Fig. 3-26 Injection direction change of the coolant (2/3) 2337MA00120-2

- For a boring bar 20 mm or less in diameter, U-drill or drill, adjust the coolant injection
direction select knob so that the coolant is injected from the socket. Use a slotted
screwdriver to adjust the knob. For a boring bar, mount a blank cap (use an M6 bolt) at the
end of the coolant nozzle located on the side opposite to the adjusted select knob.

Boring bar (right-handed) Boring bar (left-handed)


Coolant injection Blank cap
direction select knob (M6 bolt)
Boring bar
Coolant Socket
(right-handed)

Coolant
Socket
Boring bar
(left-handed)
Blank cap Coolant injection
(M6 bolt) direction select knob

Fig. 3-27 Injection direction change of the coolant (3/3) 2337MA00120-3

2. Tool removal procedure

(1) Loosen the clamping bolts with a hexagon wrench or a wrench.

(2) Remove the tool or tool holder from the turret.

3-30
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3-3-2 Preparation for Gripping Workpiece (Soft Jaw Machining)

Soft jaws are machined using different methods; the method used depends on machining
conditions such as the chuck type of the workpiece. The general method is described here.

WARNING
- Close the door securely while machining.
- Never touch a rotating workpiece or spindle with your bare hands or anything else,
whatever circumstances may occur.
- Do not open or close the chuck while the spindle is rotating.

CAUTION
- Use the most appropriate soft jaws for the shape of the workpiece they are to grip, its
dimensions, material, surface roughness, and the machining conditions.
- Adjust the chuck pressure in accordance with the shape of the workpiece, its dimensions,
material, and surface roughness, and the machining conditions.
- The master jaws must be used at the central part of the optimum jaw stroke range.
- Do not strike the workpiece clamped in the chuck with a hammer or any similar
implement. This will impair machine accuracy and functions and shorten machine life.
- Finish the zD diameter to the same dimension as the part of the workpiece to be gripped
(to approximately H7). During machining, set the same chuck pressure as that used to
grip the workpiece or a little higher.
- Soft jaws are machined by intermittent cutting. Make the spindle speed as low as
possible accordingly. During machining, use an internal cutting tool of small ejection to
prevent chipping or chattering.

3-31
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3-3-2-1 In the case of workpiece external gripping

Pecking

a
aaa
aaaaaaaaaaaa a
aaaaaaaaaaaa a
a
aa
aaaaaaaaaaaa a
aaaaaaaaaaaaa
aa
aa
a
a
a
aa
aa
a
a
a
aa
aaaa
aaa
a
a
a
aa
a
a
a
aa
aa
a
a
a
aa
External diameter: zW

aaaaaaaaaaaa
aaaaaa
a
a
a
aa
a
a
a
aa
a
a
a
aa
a
a
a
aa
a
a
aaa
aa
aa
aa
aa
a
a
a
a
a
a
TR100-00015 The length for gripping should
generally be no less than the
1/3rd of the total length of the
workpiece. (recommended value)
Fig. 3-28 Soft jaw machining (External gripping)

1. Measure the jaw stroke (radius value) and


the jaw stroke minimum diameter (zd).
Jaw stroke
(radius value)

zd

2. Clamp the appropriate plug in the chuck jaw


so that the plug diameter (zP) may be
Plug
equivalent to the value of “zd+jaw stroke
(radius value)”.
aaaaaaaa
aaaaaaaa

zP

3. The jaw should be machined so that the


diameter of gripping section (zD) may be
equal to or smaller than the workpiece
aaaaaaaa
aaaaaa
aa
a

external diameter (zW). (zD e zW)


aa
aa aa
aa
aaaa
aaaa
aaaaa a

zD
aaa a
a
a a
a a
aaa
a
a
a

3-32
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3-3-2-2 In the case of workpiece internal gripping

Pecking

aaa
aa
aa
a
a
a
aaaa
aaaa
aaaa
aa
aaa
a
a
a
a
a
a
a
a
a
Internal
diameter: zW

aaa
aa
aa
a
a
a
aaaa
aaaa
aaaa
aa
aaa
a
a
a
a
a
a
a
a
a
TR100-00020 The length for gripping should
generally be no less than the
1/3rd of the total length of the
workpiece. (recommended value)
Fig. 3-29 Soft jaw machining (internal gripping)

1. Measure the jaw stroke (radius value) and the


jaw stroke minimum diameter (zd).
Jaw stroke
(radius value)

zd

2. Clamp the appropriate plug in the chuck jaw so


that the plug diameter (zP) may be equal to
Plug
the value of “zd+jaw stroke (radius value)”.
aaaaa
aaaa

zP

3-33
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3. The jaw should be machined so that the


diameter of gripping section (zD) may be

aaaaa aaaa aaaaa


aa
a
equal to or smaller than the workpiece internal

aa
a aa
aa
diameter (zW). (zD e zW)

aaaa
aaaa
zD

aaaaa
a a a aa
CAUTION
Finish the zD section to the same dimension as the part of the workpiece to be gripped (to
approximately H6) and to a surface roughness of no more than 6-S. During machining, set
the same chuck pressure as that used to grip the workpiece or a little higher.

3-34
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4. INSPECTION AND MAINTENANCE

4-1 General

1. Inspection and maintenance of the machine at regular intervals is necessary to keep the
machine in optimum operating condition as well as to allow the machine to operate for a
prolonged period. Therefore, regular inspection and maintenance should be given highest
priority.

WARNING
The power is not cut off even when the electrical control cabinet door is opened. During
either inspection or repair inside the control cabinet, lock the power ON/OFF switch in the
“OFF” position using a padlock, as shown in Fig. 4-1.
* The customer supplies the padlock.

Padlock

Fig. 4-1 Main Breaker Switch D320M0001

CAUTION
Keep the door to the electrical control cabinet closed during inspection and maintenance
work, unless it is electrically related. Never use compressed air while cleaning the machine
since fine dust and other foreign matter will enter the bearings and slideways.

4-1
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2. Preparing the machine operation record and inspection/maintenance record


To operate the machine according to schedule, a machine operation record is necessary. To
record inspection/maintenance work, use either a machine operation record or prepare a special
record for this purpose.

3. By spending a little time on inspection and maintenance intervals, unexpected problems will be
eliminated. In addition, regular maintenance ensures high productivity of the machine over a
prolonged period and maintains the designed machine performance.

4. Lubrication

CAUTION
Use only the recommended brands of oil listed in this manual. Use of a lubricating oil which
is not recommended could cause machine failure or other problems.

There are number of locations where lubricating oil must be supplied. Never supply too much
lubricating oil. To supply the lubricating oil, follow the steps described in this manual.

5. During regular inspection, checking, oil refilling, machine cleaning and other preventive
maintenance items specified in the regular inspection schedule should be carried out on a daily,
weekly, monthly, semiannually, and annually.

4-2
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4-2 MAINTENANCE CHECK Display

A MAINTENANCE CHECK display is provided to aid in checking items 1 to 5 listed above.


The MAINTENANCE display is intended to notify the operator of the time to replace coolants,
lubricating oils, and other fluids. Thus, the operator can correctly check the time of fluid
replacement before an alarm occurs.

MAINTENANCE CHECK Display

No. MAINTENANCE CHECK DATA TIME (H)


1500
MAINTENANCE CHECK 1500 HOURS [ 29]
3000
MAINTENANCE CHECK 3000 HOURS [ 29]
250
1 Removal Coolant Collector Chips [ 29]
6000
2 Change Head Cooling Fluid [ 29]
30
3 Fill Lube Tank [ 29]
50
4 Clean Chip Conveyor [ 29]
0
5 [ 29]
0
6 [ 29]

[MAINTENANCE CHECK] [MAINTENANCE CHECK]

MAINTENANCE CHECK 1500 HOURS MAINTENANCE CHECK 3000 HOURS


No. No.
1 Change the Hydraulic Oil 1 Check Machine Level
2 Clean the Hyd. Filter & Separator 2 Check Mach. Axis Backlash
3 Check/Replace Way Cover Wipers 3 Clean the Lube System Tanks
4 Overhaul/Clean Chuck 4 Clean Headstk System Filters
5 Clean All Fans and Air Filters 5 Clean Headstk System Radiator
6 6 Check All Hyd. System Hoses
7 7 Check System Wiring
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16

4-3
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4-3 Regular Maintenance Inspection

4
2

3
12 6
5

9
7

Fig. 4-2 Machine Major Components (1/2) TR113-01606’

13

10

Fig. 4-2 Machine Major Components (2/2) TR113-01607’

4-4
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Table 4-1 Inspection Item List

Period of inspection
Reference Number of months
No. Inspection point Inspection item
pages Daily Weekly of operation
1 6 12 24
Arranging the machine periphery in order, cleaning the
1 General {
machine and its periphery (especially, the floor)

- Checking the chuck unit and its periphery to scan for 5-1 - 5-8 {
chips 7-1 - 7-2
- Checking for secure mounting of the top jaws {
2 Headstock
- Checking for smooth chucking/unchucking {
- Greasing the chuck unit {
- Removing any chips from the coolant collector {

- Checking the tailstock spindle to scan for chips 5-23 - 5-29 {


3 Tailstock - Checking the tailstock body and tailstock spindle for 7-4 {
smooth forward/backward movement

- Checking for secure mounting of the cutting tools and the 5-9 - 5-12 {
4 Turret and X-axis holder 5-18 - 5-22
- Checking the turrets and the cutting tools to scan for chips 7-3 - 7-4 {

TOOL EYE - Cleaning the sensor section and removing any chips 5-13 - 5-17 {
5 (Japan:option,
{
export: standard) - Checking for sounds of reaction during sensor contact 7-3

- Checking the wipers for abnormalities such as damage {


Slideway and
6 - Checking for unusual operating sounds during tailstock {
covers
movement

- Checking the oil levels, and if necessary, refilling 4-6 - 4-8 {


7 Lubrication unit - Cleaning the oiling filters 5-37 - 5-44 {
- Checking for oil leakage and for damaged piping 7-6 {

- Checking for appropriate pressure 4-7 {


- Checking the oil levels, and if necessary, refilling 5-31 - 5-36 {
{
8 Hydraulic unit - Cleaning the strainers 7-5
{
- Replacing the hydraulic oil
{
- Checking for oil leakage and for damaged piping

- Checking the coolant levels, and if necessary, refilling 4-6 - 4-7 {


Headstock
9 - Cleaning the radiator 5-53 - 5-56 {
cooling unit
- Replacing the coolant 7-6 {

- Checking the coolant levels, and if necessary, refilling {


- Checking the degree of dirtiness of the filters and cleaning 5-45 - 5-48 {
10 Coolant unit
- Checking the degree of dirtiness of the coolant and if 7-6 {
necessary, replacing

- Checking the element and if necessary, replacing 5-49 - 5-52 {


12 Air unit*
7-6

- Checking if the door is fully closed 5-57 - 5-61 {


Electrical control
13 - Checking the electrical components for dirt and {
cabinet
discoloration and checking for loose terminal screws

14 Connectors - Checking for loose connector/terminals between units 6-16 {

15 Foundation - Checking and adjusting the bed level using a level 6-15 {

Grounding - Checking for a grounding resistance of 100 ohms or less 6-2


16 {
resistance (use a 500 V megger) 6-18 - 6-19

* Japan: mounted when an optional component is mounted that requires air to operate.
Export: Standard

4-5
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4-4 Supplying Oil and Coolant

WARNING
When supplying or exchanging coolant, hydraulic oil and lubricating oil, use only oil brands
recommended by MAZAK. Use of another brand of oil will cause machine malfunction and
will damage the machine.

Use the appropriate amount of the recommended brand of oil when adding or changing oil.

9
10
8
7
Fig. 4-3 Lubrication Points (1/2)

4-6
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3
Fig. 4-3 Lubrication Points (2/2) TR113-01591’

Table 4-2 Oil and Water Supply

Lubricating
No. Part name Q'ty Recommended oil Remarks Reference
point

1 Water filler port Headstock 5i - Distilled water or ion Exchange coolant every 5-53 - 5-56
cooling unit (1.32 gal) exchanged water 50% 2 years.
2 Level gauge
- Long life coolant (Mobil)
50%
3 Strainer Hydraulic 30 i - DTE24 (Mobil) Exchange oil every 6 5-31 - 5-36
unit (7.93 gal) - UNI POWER 32 (Esso) months, then clean the
4 Oil filler port
- TELLUS OIL 32 (Shell) strainer and micro-
5 Drain plug separator.

6 Level gauge

7 Drain plug Lubrication 1.5 i - VACTRA No. 2 (Mobil) Automatic lubrication. 5-37 - 5-44
unit (0.40 gal) - FEBIS K68 (ESSO) Supply occasionally.
8 Suction filter
- TONNA OIL T68 (Shell)
Clean the suction filter
9 Level gauge
every year.
10 Oil filler port

Note:
The replacement period is determined on the basis of eight hours operation a day.
Delayed replacement or use of any product other than recommended oil may damage the machine.

4-7
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4-5 Handling the Lubricating Oil Retrieval Tube

After circulating through the Z-axial ball screw, the linear guide, and the X-axial ball screw, the
lubricating oil accumulates in the oil pan located at the rear right of the machine and is then
discharged through a tube. The oil discharged from the tube, therefore, needs receiving using a
waste oil can.

Waste oil can


(to be prepared by the customer) Waste oil retrieval tube

Fig. 4-4

4-8
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5. MAINTENANCE OF MAJOR MACHINE UNITS

5-1 Headstock

5-1-1 Construction and operation

1. Spindle
The Spindle is directly driven by the built-in motor without using reduction gears or drive belts.
This built-in motor construction converts the power generated by the AC inverter motor into
machining power without mechanical loss. During manual operation the required spindle speed
(in units of 10 rpm) is input directly to the CNC. During automatic operation, the spindle speed is
controlled by the constant cutting speed (peripheral speed) control mode. The spindle is cooled
with coolant and air.

Built-in motor

Headstock
Speed detector
Spindle

Cylinder

Chuck

Fig. 5-1 Construction of Headstock

2. Chuck
The chuck is connected with a rotary hydraulic cylinder at the rear of the spindle by a
connecting rod. When the piston in the cylinder moves towards the power chuck, the chuck
jaws open; when it moves away from the power chuck, the chuck jaws close.
The collet chuck is clamped by forward movement of the piston or unclamped by backward
movement of the piston.

5-1
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CAUTION
- For the sake of safety and to ensure accuracy and a long chuck life, read the chuck
operation manual thoroughly and follow the instructions precisely.

Cylinder Chuck
Ø Spindle =
Ø

Solid chuck
TR113-00138
Chuck
Cylinder =
Ø Spindle
Ø

Hollow chuck
TR113-00140

Cylinder
Ø Spindle Chuck
=
Ø

Collet chuck

TR113-00139

Fig. 5-2 Chuck

5-2
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5-1-2 Greasing and lubrication

1. Greasing for the headstock

WARNING
Bearings should be packed with the specified amount of grease when reassembling.
Particular care should be taken when packing the main spindle bearings, since overheating
of the main spindle greatly reduces its life. When packing grease, contact your local
MAZAK service representative.

Those sections of the headstock that require greasing are listed in Table 5-1 below.

Table 5-1 Greasing for the Headstock

Greasing section Recommended grease Amount of grease

Spindle front bearing ISO FLEX NBU-15


18 cm3 (1.10 in.3)
NN3020KC9NAFWP4U00B (KOYO) (NOK KLUBER)

SQT Spindle front bearing ISO FLEX NBU-15


17 cm3 (1.04 in.3)
series 200 100BA10XTYDBLP4AYU17 (NSK) (NOK KLUBER)
Spindle rear bearing STABULADAGUS
7 cm3 (0.43 in.3)
N1016-1KCONAFGP5U00B (KOYO) NBUBEP

Spindle front bearing ISO FLEX NBU-15


23 cm3 (1.40 in.3)
NN3024KCONAFWP4U00B (KOYO) (NOK KLUBER)
SQT Spindle front bearing ISO FLEX NBU-15
22 cm3 (1.34 in.3)
series 250 120BA10XTYDBCP0P4AYU17 (NSK) (NOK KLUBER)

Spindle rear bearing STABULADAGUS


14 cm3 (0.85 in.3)
N1019-1KCONAFYP5U00B (KOYO) NBUBEP

2. Greasing for the chuck jaws

DANGER
The specified grease must be used.
Insufficient greasing may deteriorate the gripping force of the chuck and thus cause the
workpiece to fly about during machining.
The power must be turned off before greasing.

A. To operate the chuck in its best condition over a long time, it is important to grease the chuck
jaws at the appropriate time. Greasing must be provided correctly and sufficiently.
Otherwise, malfunctions at low oil pressure, insufficient gripping force, decreases in gripping
accuracy, unusual wear, and/or thermal damage may result.

5-3
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B. Grease the chuck jaws from the grease nipples provided on the outer periphery of each
master jaw. Greasing must be executed at least once a week using a grease gun. In cases
where high-speed rotation and a large amount of water-soluble coolant oil are to be used,
increase the frequency of greasing according to the particular operating conditions.

* Recommended grease: Grease for Kitagawa chucks


Molycoat EP Grease (manufactured by Dow Coning)

Notes:
1. After working, the chuck body and the jaw sliding surfaces must be completely cleaned using
an air gun.
2. Use corrosion-preventive coolant water. Otherwise, the inside of the chuck body may
corrode and thus result in deterioration of its gripping force.

Grease gun

Grease nipple

Fig. 5-3 Greasing the Chuck Jaws D366M0002

5-4
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5-1-3 Checking, adjustment and replacement of the chuck

1. Adjustment of the chuck clamp/unclamp proximity switches (The switches are standard parts for
Europe. For other regions, they are optional parts.)

The proximity switches in the chucking cylinder must be adjusted if the chuck clamp or unclamp
signal is not input although the chuck has been clamped or unclamped.
Two proximity switches are provided to detect clamping and unclamping of the chuck.

Tool to be used: Wrench

A. Set the chucking cylinder in the unclamped status.

B. With the nut for the unclamp detection proximity switch loosened, turn the proximity switch
until its head portion comes into contact with the circumference of the detection plate.
C. Turn the proximity switch in the reverse direction by one turn and then tighten the nut.
The clearance between the proximity switch and the detection plate is set to 0.5 to 1.0 mm
(0.020 to 0.039 in.).
D. Set the chucking cylinder in the clamped status.

E. Repeat steps B and C above.

F. Make sure that the clamp or unclamp proximity switch lamp is lit when the chucking cylinder
is set in the clamped or unclamped status, respectively.
* For more details, refer to the instruction manual supplied by the chuck maker.

Clamp
proximity switch Unclamp
proximity switch

Lock nut

0.5 to
1.0 mm
(0.020 to
0.039 in.)

Detection
plate

Fig. 5-4 Chuck Clamp/Unclamp Proximity Switches

5-5
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2. Replacement of the chuck

CAUTION
Before replacing it, the chuck must be fully secured using hoisting belts or hoisting bolts.
The power must be turned off before replacing the chuck.

A. Loosen the jaw mounting bolts, and remove the soft jaws and the T-nuts.

B. Remove the cover.

C. Loosening the chuck mounting bolt, rotate the draw nut using the connecting handle, and
then remove the chuck.

D. Mount new chuck.

To reassemble the chuck section, apply a sufficient coat of recommended grease and then carry
out a reverse procedure to that of disassembly. Be careful at that time to ensure that the
identification numbers of the chuck body and the master jaws become correct.

2 1
3
4

5 6 7 8

Fig. 5-5 Replacement of the Chuck

No. Name No. Name No. Name

1 Jaw mounting bolt 4 Cover 7 Soft jaw

2 T-nut 5 Draw nut 8 Connecting handle

3 Master jaw 6 Chuck mounting bolt

5-6
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3. Checking the headstock for disturbed accuracy in the event of collision

A. Prepare the following test workpiece.


Carry out OD turning of the portion from B to A.

z100 mm (3.94 in.)


A B

i/3 or less i=200 mm (7.87 in.)

Fig. 5-6 Test Workpiece TR113-01202

B. Measure the cylindricity of the cut test workpiece using a micrometer.


Measure portions A and B in Fig. 5-6.
At that time, if the cylindricity stays within its tolerance of ±0.01 mm, the headstock is free from
misalignment. If the cylindricity oversteps the tolerance, please contact your nearest MAZAK
service representative.

4. Checking the headstock for abnormalities occurring after collision


During the misalignment check described above, also check for unusual operating sounds from
the headstock. If they are occurring, please contact your nearest MAZAK service
representative.

5-7
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5-1-4 Cleaning

Cleaning the chucking cylinder


If coolant overflows from the coolant collector, it will enter the hydraulic unit reserve tank through the
drain port. Particular care should be taken to prevent clogging the coolant collector with chips
because it causes the overflow of coolant.

Tool to be used: Allen wrench

1. Remove the three bolts 1.

2. Pull up the plate 2. Chips can now be removed easily.

Fig. 5-7 Cleaning the Chucking Cylinder

No. Name No. Name No. Name

1 Bolt 3 Accumulated chips 5 Drain port

2 Plate 4 Coolant collector 6 Coolant

5-8
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5-2 Turret

5-2-1 Construction and operation (See Fig. 5-8)

1. The turret consists of the following component parts.

A. Turret base unit


The base unit of the turret is where the turret component parts are mounted. It is fixed to the
X-axis linear motion guide.

B. Turret head
The turret head has 12 faces and each face (position) may be mounted with a cutting tool.

C. Hydraulic index motor


The index motor drives the turret head hydraulically.

2. The turret head is hydraulically clamped to the turret base while it is not rotating. The index
coupling with which the turret head is engaged ensures accurate indexing of the turret head to
the required tool position.

3. When the turret rotation command becomes active, the turret head is disengaged from the index
coupling and unclamped. The turret head is then rotated by the hydraulic index motor. The
turret head position is detected by the encoder; when the turret head is indexed to the
commanded position, the hydraulic motor stops and the turret head is clamped to the turret
base.
During automatic operation, the turret rotation direction is determined from the currently located
turret head position and the target index position so that it will rotate in the shortest way.
During manual operation, the turret rotation direction is selected as required - FWD (forward,
clockwise viewed from the turret face) and REV (reverse, counterclockwise viewed from the
turret face).

5-9
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2
Fig. 5-8 Construction of Turret [SQT-200/250] D320M0002

No. Name No. Name

1 Turret head 3 Hydraulic index motor

2 Encoder

4. Turret rotation

A. Turret head rotation method


The turret head is rotated by the hydraulic index motor, and it makes a shortcut turn toward
the next tool in the automatic mode. The speed reduction rate to the motor is set to 1: 6. The
designed maximum motor speed is 180 rpm and set hydraulic pressure is 50 kgf/cm2 (711.5
PSI).
The peripheral speeds at 180 rpm motor operation are:
Turret 30.2 m/min (99.07 ft/min)
Max. swing tool 62.2 m/min (204.03 ft/min)
Max. OD turning tool 58.4 m/min (191.57 ft/min)

5-10
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B. Turret position detection


Turret position is detected by the optical absolute position encoder which has 12 strobe
signals (per rotation) and odd parity signal.

C. Turret rotation direction


Forward (FWD): The turret rotates clockwise when viewed from the turret face.

D. The relationship between the turret rotation direction and the hydraulic index motor rotation
direction is shown in Fig. 5-9. The table below shows the motor rotation direction needed to
rotate the turret in the forward direction.

When the turret head rotates in CW direction

Hydraulic index motor CCW

Encoder CCW

Hydraulic
(CCW)
Turret index motor
forward
(V type tool) rotation
Encoder

Fig. 5-9 Rotation Direction of Turret Head TR113-00596’

5-11
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5. The turret indexing sequence is explained below. This shows how the T05 command is
executed while the turret is in the T01 position.

A. Flow chart

T05 command * Addresses on the DIAGNOSIS (MONITOR) display are


given in parentheses.

YV-1: ON Hydraulic oil flowing for unclamp (Y02)

SQ-4: OFF Turret clamp confirmation signal OFF (X06)

Timer T01 Turret unclamp confirmed (T01)

YV-2: ON Turret rotation start (Y00)

One position before the encoder match signal (T04): ON OFF

Hydraulic oil flowing for unclamp stop (Y02)


YV-1: OFF
(Deceleration)

Encoder match signal (T05): ON

SQ-4: ON Clamp confirmation signal ON (X06)

YV-2: OFF Turret rotation stop (Y00)

Turret rotation completed

B. Timing chart

Start T01 T02 T03 T04 T05 Complete

T05 command ON
OFF
Turret head unclamp
clamp

Turret head rotating


stop
YV-2 motor ONOFF
YV-1 ON
(Turret head unclampled) OFF
SQ-4 ON
(Clamp confirmation) OFF
Encoder ON
INDLS OFF
Fig. 5-10 Timing Chart

5-12
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5-3 TOOL EYE (Motor Drive Type)

5-3-1 Construction and operation

The TOOL EYE is used to measure the tool tip position for the tool set measurement function and
automatic tool wear compensation function.
The arm of the TOOL EYE swings into (extending) the measuring position by a torque motor. The
sensor mounted in the arm tip measures the tool tip position by bringing it into contact with the
sensor. After completion of measurement, the arm retracts to the standby position (retracting).
Completion of arm motion is confirmed by proximity switches (SQ-7 for extend and SQ-8 for
retraction).

1 5
2
4
A-view

7
3
A 2

Fig. 5-11 Construction of TOOL EYE (the arrow means meaurement position.)

No. Name No. Name

1 Proximity switch (SQ-8) 5 Tool

2 Proximity switch (SQ-7) 6 Turret

3 Arm 7 Torque motor

4 Sensor

5-13
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5-3-2 Checking and adjustment

1. Checking the TOOL EYE for extending/retracting


To check the TOOL EYE for extending/retracting, use the following address displayed on the
DIAGNOSIS (MONITOR) display.

TOOL EYE extending: Address XB (bit B of X0000)


TOOL EYE retracting: Address XC (bit C of X0000)

2. Replacement of the TOOL EYE sensor


Tools to be used: Allen wrench
Dial indicator (Micro dial indicator)
Wrench

A. Press the TOOL SET MEASURE menu key to extend the TOOL EYE arm to the measuring
position.

Fig. 5-12 Replacement of the TOOL EYE Sensor (1/4)

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B. Remove the four bolts.

Fig. 5-12 Replacement of the TOOL EYE Sensor (2/4)

C. Pull the joint section from the arm body, and pull that section away by slightly rotating it.

Joint section

Fig. 5-12 Replacement of the TOOL EYE Sensor (3/4)

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D. Remove the bolts and then the TOOL EYE sensor.

Fig. 5-12 Replacement of the TOOL EYE Sensor (4/4)

E. Mount the new TOOL EYE sensor and fix it in place following the above steps in the reverse
order.

F. Adjust the alignment after changing the sensor.

(1) Fix the dial indicator or micro dial indicator to the turret and adjust parallelism regarding the
machined face at the center of the sensor as reference.

(2) Allowable parallelism to the X-axis is within 0.002 mm (0.000079 in.).

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G. Tighten the four bolts.

Reference block
Bolt

Dial indicator

Fig. 5-13 Adjustment of the Sensor Section

5-17
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5-4 X- and Z-axes

5-4-1 Construction and operation

1. X- and Z-axes
The turret base and the carriage are driven respectively by the X-axis or Z-axis AC servo- motor
via the ball screw to move in the respective direction. The position encoder is located at the
end of the motor and the motor is directly connected to the ball screw by coupling ensuring high
positioning accuracy.

-Z +Z

5
11

Z-axis

7 9
1

10
Fig. 5-14 Construction of Z-axis

No. Name No. Name

1 Coupling 7 Nut

2 Turret base 8 Angular bearing

3 X-axis zero point limit switch 9 Tack bearing

4 X-axis AC servomotor 10 Z-axis zero point limit switch

5 Carriage 11 Z-axis AC servomotor

6 X-axis ball screw 12 Brake

5-18
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+X

2
-X
8

4
1
12
6
5

Fig. 5-15 Construction of X-axis

2. Principle of zero return


The reference point of the turret, called “machine zero point”, is located within the turret travel
range. The NC unit establishes the machine coordinate system in which the machine zero point
is taken as the origin of the coordinate system. Turret position is controlled in reference to the
origin of the machine coordinate system. Just after the power supply has been turned on, the
NC unit has no data of the machine zero point. To establish the zero point, perform the zero
return operation before starting automatic operation.
By performing the zero return operation, a predetermined point is established as the machine
zero point in the following manner.

A. When the zero return key on the operation panel is pressed, the zero return mode signal is
turned on.

B. Using the axis movement switches, move the turret to the zero point of respective axis.

C. When the zero point limit switch is tripped by the dog, the deceleration signal is turned on,
turret motion is decelerated, and the turret moves at the predetermined feedrate.

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D. After the zero point limit switch is released from the dog, the turret continuously moves to the
point far from the last grid signal by the amount preset in parameter BS12. (This is the
electrical zero point.) The turret further moves from this point by the zero shift amount set in
parameter BS13. This position is stored by the NC as the machine zero point.
Parameter settings for SQT-200/250 are as follows

Axis Parameter Setting Parameter Setting

X-axis BS12 10 (fixed) BS13 Shift amount from the electrical to the machine zero
Z-axis BS12 12 (fixed) BS13 point (variable, machine-specific)

E. The grid signal is always turned on at the fixed position unless the relative position between
the encoder input shaft and the ball screw is not changed. The zero point shift amount is a
fixed amount set with a parameter in the NC.

Zero point
return direction

Push-in
allowance

ON
OFF OFF
Zero point limit switch

Axis feedrate

Zero return feedrate

BS12 BS13
ON

OFF
Grid signal
Machine zero point
Electrical zero point
Fig. 5-16 Principle of X- and Z-axes Machine Zero Point D320M0004

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5-4-2 Lubrication

The lubrication unit supplies lubricating oil to the linear motion guide blocks, ball screws and ball
screw nuts. Lubricant is automatically supplied every 6 minutes (for 50Hz) or 5 minutes (for 60Hz)
by the electrical intermittent lubrication pump unit at the left front side of the machine.

5-4-3 Adjustment

Backlash compensation

The following factors between the X- or Z-axis position encoder and the turret generate errors
between the axis motion command value and actual turret position.

- Backlash in bearings and ball screws


- Ball screw pitch deviation
Backlash in the mechanical power transmission system is an unavoidable factor.
A too small backlash imposes overload on bearings, gears and other mechanical parts causing
noise and shortening their life.
The NC has the ability to compensate electronically for errors generated in the mechanical system.
This is called the backlash compensation function.
The backlash compensation function is factory-set to the optimum condition and will not need
further adjustment after installation of the machine. However, if this does not compensate for
backlash-caused error during a long period of use, the backlash compensation data can be set
again.
The backlash compensation data can be set by changing the parameter data stored in the NC.
Tool to be used: Dial indicator

(a) Feed the turret in the “plus” (+) direction by 50 mm (2.0 in.) in rapid feed.
(b) Set the dial indicator at the “minus” side of the turret and set the reading to “0”.
Set the dial indicator at the headstock as shown in Fig. 5-17 for measuring lost motion.
(c) Feed the turret further in the “plus” direction by 50 mm (2.0 in.) in rapid feed.
(d) Return the turret in the “minus” (-) direction by 50 mm (2.0 in.).
(e) Read the dial indicator.
The value read by the dial indicator shows the amount of “lost motion” which is the total
mechanical system error including backlash.

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(f) Change the parameter settings.


Parameter BS14: Rapid feed backlash
Parameter BS15: Cutting feed backlash

(a) (b) (c) (d)

Lost motion

Fig. 5-17 Measuring Lost Motion in the Z-axis

Setting machine zero point

If the relative position between the encoder input shaft and the ball screw has been shifted, for
example if the coupling has been removed and installed again, the zero point position may be
shifted. In such cases, set the machine zero point anew.
* Whether the zero point limit switch is ON or OFF can be checked in I/O MONITOR area on the
DIAGNOSIS (MONITOR) display.

- X-axis zero point limit switch ON : X10 bit 8 = 0


OFF : =1
- Z-axis zero point limit switch ON : X10 bit 9 = 0
OFF : =1

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5-5 Tailstock

5-5-1 Construction and operation

The tailstock consists of the tailstock body and the tailstock spindle.

1. The tailstock body is driven with its driving pin fitted in the connecting block mounted. For a
manual tailstock spindle (standard), the pins can be extended and retracted by rotating the lever,
or for an automatic tailstock spindle (optional), they are driven hydraulically. Also, for a manual
tailstock spindle (standard), the tailstock body can be clamped by bolting it down, or for an
automatic tailstock spindle (optional), the tailstock body is driven hydraulically.

2. Tailstock spindle motion is controlled hydraulically.

Tailstock spindle

Slideway

Fig. 5-18 Construction of Tailstock

5-5-2 Removing center

Tools to be used: Plastic hammer


Fixture for removal

1. Insert the fixture for removal.

2. Tap the fixture for removal with a plastic hammer.

3. Remove the tailstock spindle.

5-23
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5-5-3 Lubrication

1. The slideway and the tailstock spindle are lubricated.

2. The electrical intermittent lubricating pump unit which is mounted at the left front of the machine
supplies lubricating oil to the above lubricating points in intervals of 6 minutes (for 50Hz) or 5
minutes (for 60Hz).

3. The supply volume of the lubricating oil is adjusted by the flow unit mounted at the end of
lubrication pipe.

5-5-4 Adjustment

1. Adjusting tailstock spindle thrust


Adjust the tailstock spindle thrust with the spindle thrust adjusting knob (reducing valve).

A. Move the spindle forward to hold the workpiece or move the spindle to the stroke end.

B. Turn the knob while reading the thrust meter (pressure gauge) indication.
* Turning the knob in the direction indicated with an arrow mark increases the thrust.
Thrust range: 392 to 6860 N (40 to 700 kgf (88.2 to 1543.5 lbs))

Chuck Tailspindle
pressure thrust

Fig. 5-19 Adjusting Tailstock Spindle Thrust D320M0005

5-24
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2. Adjusting dog and sensor position (automatic tailstock/option)


Tools to be used: Allen wrench
Wrench

A. With the tailstock spindle retracted fully, advance the tailstock body to the position where the
tailstock body is to be located to machine a workpiece.

B. Move the tailstock spindle forward to hold the workpiece.

C. Taking the workpiece length variations into account, loosen the socket head screw of the
advance end dog and adjust the dog position so that the advance end proximity switch faces
the dog at its center.

D. Tighten the dog clamping socket head screws securely.


* The proximity switch indicator light is red when the switch turns on, changes to green in the
stable range, and goes off when it is off.

Advance end dog

Retract end dog

Retract end
proximity switch
Advance end
proximity switch

Fig. 5-20 Adjusting Dog and Proximity Switch Position

* Clearance between the proximity switch and the dog should be 0.5 to 1.0 mm (0.02 to
0.039 in.).

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3. Adjusting tailstock spindle alignment


If a taper is generated on a workpiece, adjust the tailstock spindle alignment.
Tools to be used: Test workpiece
Micrometer
Dial indicator
Allen wrench

Adjusting screw A

Clamp bolt Adjusting screw B


(4 pcs.)

Rushing bolt

Fig. 5-21 Adjusting Tailstock Spindle Alignment

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A. Hold a test workpiece in the chuck, with the tailstock sleeve in contact with the test workpiece.

Fig. 5-22 Adjusting Procedure of Tailstock Spindle Alignment (1/5)

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B. Finish the test workpiece.

Fig. 5-22 Adjusting Procedure of Tailstock Spindle Alignment (2/5)

C. Measure the cylindricity using a micrometer.

Fig. 5-22 Adjusting Procedure of Tailstock Spindle Alignment (3/5)

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D. Loosen the four bolts and two pushing bolts clamping the tailstock body to the tailstock base.

E. Turn the adjusting screw.


If the test workpiece is thick at the end, loosen the adjusting screw B. Then turn the adjusting
screw A clockwise. If the test workpiece is thin at the end, loosen the adjusting screw A. Then
turn the adjusting screw B clockwise. (See Fig. 5-22.)
* At this time, adjustment should be made while observing the indicator of the dial gauge.
After one adjusting screw has been pushed, always tighten the other adjusting screw.
Tighten the adjusting bolts A and B with equal force

If the test workpiece is thin at the end

Fig. 5-22 Adjusting Procedure of Tailstock Spindle Alignment (4/5)

If the test workpiece is thick at the end

Fig. 5-22 Adjusting Procedure of Tailstock Spindle Alignment (5/5)

F. Tighten the bolts clamping the tailstock body to the tailstock base and the pushing bolts.

G. Carry out OD turning again and measure the cylindricity.


* If a taper is still generated, repeat the above indicated steps from A to G.

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5-6 Hydraulic Unit and Hydraulic Circuit

5-6-1 Construction and operation

The hydraulic unit consists of the tank, hydraulic pump, strainer, and radiator.
The following units are hydraulically operated.
- Chuck
- Turret
- Clamping the tailstock body
- Parts catcher (option)

* See the next page for the hydraulic circuit diagram.

2
3

4
Fig. 5-23 Construction of Hydraulic Unit TR113-01591’

No. Name No. Name

1 Fan cooler 5 Oil filler port

2 Level gauge 6 Tank

3 Drain port 7 Hydraulic pump

4 Strainer

5-30
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Turret
Unclamp Clamp

Joint pin
(option) Tailstock body
(option)

Clamp

Unclamp

45 kgf/cm2
(640.4 PSI)

Hydraulic unit

Fig. 5-24 Hydraulic Circuit Diagram

5-31
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Hydraulic chuck for HD1

Clamp

Tail sleeve
FWD REV

Sleeve

Mounted on the
side cover of
the headstock

Auto parts catcher Up

(option) Down

Mounted in the
front on the
left side cover

No. Parts No. Parts name Maker Q’ty Remarks


1 G49FH007272 Hydraulic unit NACHI 1 TS-4000000
2 G11FH001180 Reducing valve NACHI 1 OG-G01-PC-K-20
3 G16FH002800 Solenoid valve NACHI 1 SLD-G01-C5-C1-11
4 G11FH002080 Reducing valve NACHI 1 OG-G01-A1-K-20
5 G16FH002810 Solenoid valve NACHI 1 SLD-G01-C5-C1-11
6 41415220220 Pressure gauge ASAHI 1 Chuck pressure
7 33415235750 Pressure gauge ASAHI 1 Tail stock thrust
8 13205117450 Manifold 1 Main pressure
9 G10FH002350 Index motor NACHI 1 P1-CB-B7-2GS0L1-8579A
10 G16FH004410 Solenoid valve NACHI (2) SA-G01-A3X-C1-20
11 G14FH001420 Check valve NACHI (1) OC-G01-P1-20
12 23205117470 Manifold (2) Tail clamp, Auto parts catcher
13 G11FH001340 Reducing valve NACHI (1) OG-G01-PC-20
14 41616024300 Pressure gauge (1)
15 G23AM001530 Pressure switch ASIA KOGYO (1) 176-114-500-N1
16 43205117491 Plug GOSEI 1 Hole dia. 1.5
17 41419813330 Plug (1) Hole dia. 1.5
18 G14FH001540 Check valve NACHI (1) OCP-G01-A1-20

5-32
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5-6-2 Supplying and changing oil

CAUTION
When supplying or changing hydraulic oil in the reserve tank, use only the recommended
oil. Use of another grade of oil will lead to machine malfunction and damage to the
machine.

The hydraulic oil change interval varies according to the machine operating conditions. Change the
hydraulic oil three months after machine installation. After that, change it every six months.

Tools to be used: Allen wrench


Oil drain pan

1. Set the oil drain pan under the drain port.

2. Loosen the cap with the wrench.


The hydraulic oil is drained.

Fig. 5-25 Draining Hydraulic Oil

3. Tighten the cap securely.

4. Supply hydraulic oil through the oil filler port.

Note:
Always maintain the quantity of hydraulic oil between the 2/3 and FULL levels on the gauge
located on the side of the hydraulic tank.

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For oil recommendation, refer to Table 4-2.

Fig. 5-26 Supplying Hydraulic Oil D320M0006

5. Fully close the cap of the oiling port.


Failure to close the cap causes oil leakage and/or entry of dirt. Entry of dirt may cause actuator
malfunctioning.

5-6-3 Adjustment

Tools to be used: Wrench


Allen wrench

Adjusting pressure

1. Loosen the locknut of the pressure adjusting screw.

2. Adjust pressure to the specified value 50 kgf/cm2 (711.5 PSI) while reading the indication of the
pressure gauge.
Pressure increases when the pressure adjusting screw is turned clockwise.

3. Tighten the locknut securely.

Fig. 5-27 Adjusting Hydraulic Pressure

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5-6-4 Cleaning

1. Cleaning the strainer


When changing the hydraulic oil, check and clean the strainer at the same time.

A. Disconnect the suction piping.

B. Remove the bolts from the suction port


cover, and remove the cover.

Fig. 5-28 Cleaning the Strainer (1/3) D320M0007

C. Remove the strainer.

Fig. 5-28 Cleaning the Strainer (2/3) D320M0008

D. Clean the strainer with an air gun.

Fig. 5-28 Cleaning the Strainer (3/3)

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5-7 Lubrication Unit and Lubrication Circuit

5-7-1 Construction and operation

1. The lubrication unit supplies lubricating oil to the linear guides and ball screws of the X- and Z-
axis and to the tailstock slideway.

2. The electrical intermittent lubricating pump unit is mounted at the left front of the machine, and
supplies lubricating oil to the above lubricating points at intervals of 6 minutes (for 50Hz) or 5
minutes (for 60Hz).

3. The supply volume of the lubricating oil is adjusted by the flow unit mounted at the end of the
lubrication pipe.
* The flow unit is a kind of joint used in the lubrication circuit and functions as a valve that
allows lubricating oil to flow only in one direction. If the pump pressure drops, it prevents
lubricating oil from flowing in the reverse direction, thereby protecting the machine from
problems occurring from the reverse flow of lubricating oil.

4. If an error occurs in the lubrication system, the pressure switch in the lubrication piping is
activated, and alarm message 260 SLIDEWAY LUBRICATION ALARM will be displayed on
the CRT screen.

Delivering Delivering
Pressure
(kgf/cm2)

1.0 The oil pressure is 1 kgf/cm2 (14.2 PSI) or


more when delivering lubricant.
In the interval time, it drops below 1 kgf/cm2
Normal (14.2 PSI).
pressure
status

Interval time

Delivering Delivering
Pressure
(kgf/cm2) Pressure
(kgf/cm2)

1.0 1.0

Abnormal
pressure
status

Interval time Interval time

(1) The oil pressure does not drop (2) The oil pressure does not exceed
below 1 kgf/cm2 (14.2 PSI). 1 kgf/cm2 (14.2 PSI).
Fig. 5-29

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166 (6.54)

2
3
1
124
(4.88)

72.5 (2.85) 6 72.5 (2.85)


11
5 7

M6
38
28
(1.50)
(1.10)

213.5
(8.41)

143
9 (5.63)

10 Unit: mm (in.)
Fig. 5-30 Construction of Lubrication Unit D320M0010

No. Name No. Name

1 Delivering port (M8×1) 7 Pump motor

2 Earth terminal (MS) 8 Oil filler port filter

3 Earth mark 9 Suction filter

4 Cable outlet 10 Drain plug

5 Oil filler port 11 Terminal cover (cover M)

6 Delivering amount adjusting volume

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Z-axis ball screw


X-axis ball screw

Z-axis linear guide

X-axis linear guide


1
Tailstock slideway

Tailstock sleeve

4
5
Fig. 5-31 Lubrication Circuit Diagram TR113-01149’’

No. Name No. Name

1 Pressure switch 4 Oil tank

2 Piston pump 5 Lubrication unit

3 Suction filter

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5-7-2 Replenishing lubricating oil

CAUTION
- When replenishing lubricating oil, use only the recommended lubricating oil. If lubricating
oil other than the recommended oil is used, it will cause malfunction of the machine.
- Observe the caution items printed on the legend plates.

- Before starting the day's operation, check that the lubricating oil reserve tank is filled with the
specified lubricating oil to the specified level.
- When starting the machine operation after it has been stopped for a long period, press the
machine-menu key, and then select the menu item for forced lubrication on the maintenance
display. (The lubricating pump will then operate for 8 seconds, and the respective alarm display
can be cleared by pressing the clear key.)

* For the lubricating oil recommendation, see Table 4-2.

1. Oil supply

Lubrication unit
Fig. 5-32 Supplying Lubrication Oil (1/2) D320M0011

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2. Add lubricating oil from the oil filler port.

Fig. 5-32 Supplying Lubrication Oil (2/2)

3. Oil discharge
Remove the lubrication unit from the machine, and then remove drain plug to let the oil out.

Fig. 5-33 Lubrication Oil Discharge

* For removal of the lubrication unit, see Subsection 5-7-3.

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5-7-3 Cleaning

Tools to be used: Wrench


Phillips screwdriver
Allen wrench

1. Cleaning the suction filter


The suction filter in the lubricating oil reserve tank should be cleaned at least once a year.

A. Remove the pipes in the lubrication unit.

B. Remove the clamp bolt (2 places).

Fig. 5-34 Cleaning the Suction Filter (1/6)

C. Pull out the lubrication unit.

Fig. 5-34 Cleaning the Suction Filter (2/6)

D. Remove the screws on the lubrication unit


(4 places).

Fig. 5-34 Cleaning the Suction Filter (3/6)

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E. Remove the pump from the tank.


The suction filter can be seen.

Fig. 5-34 Cleaning the Suction Filter (4/6)

F. Remove the clamp.

Fig. 5-34 Cleaning the Suction Filter (5/6)

G. Clean the suction filter.


Clean the inside of the lubricating oil
reserve tank at the same time.

Fig. 5-34 Cleaning the Suction Filter (6/6)

H. Mount the clamp.

J. Mount the pump to the reserve tank.

K. Mount the screws on the lubrication unit.

L. Refit the lubricating oil pipes in the lubrication unit.

CAUTION
Connect the pipes to the correct port.

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2. Cleaning the filter on the oil filler port


Remove the filter and clean it using an air gun.

Fig. 5-35 Cleaning the Oil Filler Port Filter

5-43
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5-8 Coolant System

5-8-1 Construction and operation

The coolant system consists of the coolant pump and the chip pan where coolant is stored. Two
nozzles are mounted in the turret; one for supplying coolant to cool the cutting tool at the cutting
point and the other for supplying coolant to wash away chips. They are used for cooling and
cleaning tools or workpieces, and removing chips while cutting workpieces.
The coolant inside the chip pan is pumped up by the coolant pump mounted on the right side of the
chip pan, and then injected from the nozzle of the turret.
The injected coolant is passed through the chip receiving plate and then salvaged into the chip pan.

Chip receiving plate

Level gauge

Coolant pump

Chip pan

Drain port
Filter

Fig. 5-36 Construction of Coolant System

5-44
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5-8-2 Supplying coolant

CAUTION
When replenishing coolant to the chip pan, use the recommended coolant. If coolant other
than recommended ones is used, it will cause malfunction of the machine.

Check if coolant is stored in the chip pan to the specified level before starting the day's operation.
If the volume of the coolant supplied from the nozzle becomes low, check the coolant level in the
chip pan if the coolant level is lower than the allowable lower limit.

* Tank capacity : Standard tank 160 L (42.3 gal)

: Optional tank 200 L (53.8 gal)

* Recommended coolant : SOLVAC 1535G (Mobil)


TRIMSOLE (Master chemical)

1. Pull out the chip pan.

Fig. 5-37 Supplying Coolant (1/2)

2. Supplying coolant
Replenish the coolant that has been arranged
to the appropriate density beforehand so that
the suction port is completely immersed in
the coolant.

Fig. 5-37 Supplying Coolant (2/2)

3. Discharging coolant
If the coolant is heavily contaminated, change the coolant completely. Clean the inside of the
chip pan at the same time. (See Subsection 5-8-3.)
Tools to be used: Oil drain pan
Allen wrench

A. Place the oil drain pan under the drain port.

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B. Loosen the drain port cap.


The coolant is drained.

Fig. 5-38 Discharging Coolant

5-8-3 Cleaning

1. Cleaning the filter

A. The filter separates the pump chamber


from the chip pan. It can be removed
easily for cleaning. Clean the filter
occasionally.

Fig. 5-39 Cleaning the Filter (1/2)

B. Clean the filter using an air gun.

Fig. 5-39 Cleaning the Filter (2/2)

C. Remove chips from the chip pan every day after completing the day's work.

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2. Cleaning the chip pan

A. After the coolant is drained, remove the chip receiving plate and clean the inside of the chip
pan.

Fig. 5-40 Cleaning the Chip Pan (1/2)

B. Clean the inside of the chip pan with a rag.

Fig. 5-40 Cleaning the Chip Pan (2/2)

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5-9 Air Unit

5-9-1 Construction and operation

The air unit consists of a filter.


The filter removes moisture from the compressed air.

WARNING
Moisture in the compressed air causes deterioration and damage to the air actuators used in
the machine.

Fig. 5-41 Location of the Air Unit

5-48
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The following units are operated pneumatically.

1. TOOL EYE air blast (Japan: option, export: standard)

2. Workpiece measurement (option)

3. Chuck air blast (option)

4. Automatic door (option)

TOOL EYE air blast Workpiece measuring Chuck air blast Automatic door
(*) system air blast (option) (option) (option)

Coolant
oil

Panel
33205117530

AVK-400

5 kgf/cm2 (71.2 PSI)

(*) Optional parts for Japan


Standard parts for export

No. Part No. Part name Material Qt’y Remarks


1 G48SV001980 Air filter (SMC) 1 AF3000-02DB
2 G50SV006120 Solenoid valve (SMC) 1 VX2120-021D
3 H14SV004650 Manifold (SMC) (1) (Option) KM11-08-12-6
4 G50SV002600 Solenoid valve (SMC) (2) (Option) VX-2230-02-1D-B
5 G54SV001360 Needle valve (SMC) (1) (Option) AS2200F-02-10
6 G14SV000680 Check valve (SMC) (1) (Option) XT0674-03
7 G45SV000670 Regulator (SMC) (1) (Option) AR2000-02BG
8 G50SV008240 Solenoid valve (SMC) (1) (Option) VFS2420-1D-02
9 G51SV000340 Silencer (SMC) (1) (Option) AN110-01
10 G54SV001690 Needle valve (SMC) (1) (Option) AS3201F-03-08

Fig. 5-42 Air Circuit Diagram TR113-01653

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5-9-2 Replacement and adjustment

1. Replacing the filter element


Replace the filter element at least once a year.

Tool to be used: Allen wrench

A. Remove the filter case.


Turn the filter case counterclockwise.

Filter case

D320M0012
Fig. 5-43 Replacing the Filter Element (1/4)

B. Replace the socket head screw.

Socket head screw

D320M0013
Fig. 5-43 Replacing the Filter Element (2/4)

C. Pull out the baffle.


The filter element can be removed.

Baffle

D320M0014
Fig. 5-43 Replacing the Filter Element (3/4)

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D. Replace the filter element.


The filter element can be removed.

Filter element

D320M0015
Fig. 5-43 Replacing the Filter Element (4/4)

E. Fix the baffle.

F. Tighten the socket head screw.

G. Fix the filter case.


Turn the filter case clockwise.

5-51
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5-10 Headstock Cooling Unit and Headstock Cooling System

5-10-1 Construction and operation

The headstock cooling unit is installed in the integrated form with the headstock.

1. Coolant is supplied to the headstock by the centrifugal pump from the headstock cooling unit
tank and the headstock is cooled.
2. The coolant warmed while circulating inside the headstock is cooled by the radiator and the
cooling fan and returned to the tank of the cooling unit.

6
1

5 2

Fig. 5-44 Construction of Headstock Cooling Unit

No. Name No. Name

1 Replenishing port 5 Centrifugal pump motor

2 Level gauge 6 Pressure switch

3 Cooling water tank 7 Radiator

4 Drain

5-52
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Fan cooler

aaa
aa
aaaa
M

aa
aaa
a
a
Tank

Headstock

aaaaaa
aaaaaa
Pressure switch M

Centrifugal pump

Fig. 5-45 Headstock Cooling System D320M016

5-10-2 Replenishing and replacement of coolant

The oil level sections can be checked at the


level gauge located on the left side cover.
Center to upper limit: Proper
Lower than center level: Replenish coolant
immediately.
Tank

Level gauge
Fig. 5-46 Location of the
Level Sight Gauge

WARNING
- When replenishing coolant, use only the recommended coolant. If coolant other than the
recommended ones is used, it will cause malfunction of the machine.
- If the coolant level is lower than the center mark of the level sight gauge, the headstock
cannot be cooled satisfactorily, causing overheating of the headstock and machine
malfunction. Replenish the coolant occasionally so that the coolant level is maintained
correctly.

5-53
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Tools to be used: Allen wrench


Oil drain pan

1. Remove the left side cover of the machine.

2. Replenishing coolant
Remove the replenishing port cap and
replenish the coolant.

Fig. 5-47 Replenishing the


Coolant

Recommended coolant
Distilled water or ion exchanged water 50%
Long life coolant (Mobil) 50%
Exchange coolant every 2 years. When exchanging the coolant, clean the inside of the reserve
tank at the same time.

3. Discharging coolant

A. Remove the left side cover.

B. Place the oil drain pan under the drain port.

C. Loosen the drain port cap.


Coolant is drained.

Fig. 5-48 Discharging Coolant

5-54
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4. Changing the coolant


Headstock coolant must be replaced quickly without interruption. If the headstock is left drained
of coolant or becomes filled with distilled water, corrosion may occur. Waste coolant must be
disposed of legally.
Replace headstock coolant in accordance with the following procedure, depending on coolant
consumption rate (discoloration)

A. When headstock coolant is not low or discolored

(1) After turning off the power, remove all remaining coolant by blowing air through the pipe
using an air compressor.
(2) Sufficiently stir previously diluted coolant (50 % dilution) and fill the tank.
(3) Run the machine for about 10 minutes to circulate coolant throughout the entire cooling
system. Confirm that the coolant has been spread throughout the system sufficiently as
indicated by the lowered level of coolant in the tank. Add cooling water according to the
particular decrease in oil level.
(4) Replacement is complete.

B. When headstock coolant is low or discolored

(1) After turning off the power, remove all remaining coolant by blowing air through the pipe
using an air compressor.
(2) Pour distilled water or ion exchanged water into tank and circulate to clean for about 15
minutes.
(3) Drain water for cleaning using the same procedure as in A.
(4) Immediately pour new coolant previously diluted to 50 % density into tank after stirring the
coolant.
(5) Run the machine for about 10 minutes to circulate coolant throughout the entire cooling
system. Confirm that the coolant has been spread throughout the system sufficiently as
indicated by the lowered level of coolant in the tank. Add cooling water according to the
particular decrease in oil level.
(6) Replacement is complete.

C. When headstock coolant gets too low or too discolored, check for the following:

(1) Check that recommended coolant was used.


(2) Check that distilled or ion-exchanged water was used to dilute coolant.
(3) Check that the used coolant density was 50 %.
(4) Check if oil or foreign matter was mixed into coolant in the headstock coolant tank.

Thorough cleaning is required in this case. After checking the above conditions, contact the
nearest MAZAK distributor.

5-55
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5-11 CNC Unit and Electrical Control Cabinet

5-11-1 CNC unit

6
4

5
7

AC200/220V 3z
Fig. 5-49 Lathe Control TR113-01233’’

No. Name No. Name

1 X-axis servomotor 5 Spindle motor

2 Z-axis servomotor 6 CNC control unit

3 X-, Z-axes servo unit 7 External data I/O unit

4 Spindle unit 8 NC operation panel

5-56
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1. Control of the CNC unit enables ultra-high-speed control for the following functions: rapid feed
rate acceleration and deceleration, spindle acceleration and deceleration, PLC operations, high
speed rough machining cycle, constant optimum peripheral speed control, automatic setting of
turret indexing positions, and simultaneous operations. Moreover, the spindle motor and all
servo motors are under full digital control.

2. Program patterns simplify the creation of programs such as those for measuring the dimensions
of machined workpieces, measuring tool wear with the TOOL EYE, lapping, and the machining
of soft jaws. There are also automatic setting functions for the chuck barriers.

5-57
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5-11-2 Electrical control cabinet

3 1 2
16 15 14

8 9 10 11

4 5 6 7
13

12

Fig. 5-50 Arrangement of Switches inside Electrical Control Cabinet

No. Name Function

1 KM1 Main spindle coil switching


2 KM2 Main spindle coil switching

3 QF2 Circuit protector of auxiliary units (Hydraulic pump motor, head lube motor,
clamp motor, chip conveyor motor)
4 KM11 Hydraulic pump motor switching
5 KM12 Headstock cooling pump motor switching

6 KM13 Coolant pump motor switching


7 KM14 Chip conveyor motor switching

8 QF11 Circuit protector for DC power supply


9 QF12 Circuit protector for AC-PCB

10 QF13 Circuit protector for work light (20W)


11 QF14 Circuit protector for NC unit power supply
12 A01 NC unit

13 L1 AC reactor for spindle/servo power supply line


14 A26 Spindle/servo power source unit

15 A11 Main spindle drive unit


16 A21 X-, Z-axes servo drive unit

5-58
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1. Checking the electrical control cabinet

A. All terminal screws of electric parts are tightened securely.

B. Soldered portions have proper strength.


Lightly pull the solder parts by hand to check them.

C. The cap of the cartridge fuse is tightened securely.

D. The spark extinguisher case is not discolored.


If discolored, it is necessary to change the extinguisher.

DANGER
- High voltages are applied to terminals inside the electrical control cabinet, transformer,
motor and relay box. Never touch these terminals.
- After the power supply has been turned off, the electric components inside the electric
control cabinet are still alive with remaining voltage. Before touching these components,
make sure that no voltage is applied using a multimeter or other proper instrument.
- Before attempting any repair or service work in the electrical control cabinet, confirm the
high voltage areas by referring to the electric circuit diagram.

WARNING
- Only authorized personnel can carry out electric maintenance.
- Before carrying out inspection of the electrical control cabinet, turn off the power supply at
the factory power distribution board.
- The power is not cut off when the control cabinet door is opened. During either inspection
or repair inside the control cabinet, lock the power ON/OFF switch in the OFF position
using a padlock.
* The customer supplies the padlock.

2. Resetting the thermal relays


If the alarm 264 THERMAL TRIP (SINGLE BLOCK) is displayed, this indicates that one or
more of the thermal relays listed below have tripped. Overloading of the corresponding motor is
the likely cause of tripping of the relays.

- Thermal relay F12 (for spindle cooling water pump motor use) at the bottom of electromagnetic
switch KM12
- Thermal relay F13 (for cutting water pump motor use) at the bottom of electromagnetic switch
KM13
- Thermal relay F14 (for chip conveyor motor use) at the bottom of electromagnetic switch KM14

5-59
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After removing the cause of overloading of the corresponding motor, reset the thermal relays as
shown below.

KM11 KM12 KM13 KM14

Fig. 5-51 Thermal Relay Reset

5-60
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6. INSTALLATION

6-1 Preparation for Installation

6-1-1 Environmental requirements

1. Machine
Avoid the following places when choosing the installation site for the machine:
- Places subject to direct sunlight, near heat sources, or subject to excessive temperature
change
- Humid places
- Dusty places
- Places near vibration generating equipment
- Weak soil

CAUTION
- If the machine is to be installed near vibration generating equipment, a vibration-proof
drain should be provided around the machine foundation.
- If the soil is weak, reinforce it by driving piles into the soil to avoid settlement and
inclination of the soil after machine installation.

2. NC

A. Environmental temperature
Allowable temperature range during machine operation: 0° to 40°C (32° to 104°F)

B. Humidity
Allowable humidity: Less than 75%

CAUTION
As humidity increases, insulation deteriorates causing electrical component parts to
deteriorate quickly. Although no special dehumidifying measures are required, the machine
should not be installed in humid places.

C. Vibration
During operation: Less than 0.5G
During transportation: Less than 3.5G

6-1
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D. Environment
If the machine must be installed in a dusty place or in an environment where organic,
corrosive gas concentration is high, consult Mazak for proper measures.

CAUTION
MAZATROL uses a memory back up battery to maintain important data stored in memory
even after power supply is turned off. However, since the back-up data may be lost due to
expiration of battery life or misoperation or unexpected trouble, to ensure safety of important
data, it is advisable to store the data with external device.

6-1-2 Power requirements

1. Power source
Voltage : 200/220 VAC, 3 phases
Permissible voltage fluctuation : ±10%
Frequency : 50/60 Hz±2 Hz

2. The size of the primary side power cable is calculated under the following conditions.
- Primary incoming cable : 50 mm2 (0.078 in2) or larger for SQT-200
60 mm2 (0.093 in2) or larger for SQT-250
- Environment temperature : Less than 30° C
- Power source : 200 VAC, 3 phases
- Metallic conduit : 3 pieces
- Continuous rating for spindle drive motor

Notes:
1. To connect power supply cables, class 3* grounding or above must be performed.
* Class 3: Grounding resistance 100 ] maximum
2. When an earth leakage breaker is used, select one with a trip current of 200 mA. One with
a trip current of 30 mA cannot be used for this machine equipped with inverters.

6-2
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3. Total power requirements

Table 6-1 Power Requirement Table

Machine Model SQT-200 (Export)


SQT-200 (Japan)
Item SQT-250
Total power requirement 22.96 kVA 27.44 kVA

Spindle drive motor


20.28 kVA 24.76 kVA
X-axis servomotor
[26.34 kVA] [29.74 kVA]
Z-axis servomotor (*1)

Hydraulic unit 1.0 kVA

Coolant supply pump 0.24 kVA

Radiator fan motor for headstock cooling 0.12 kVA

NC unit 0.32 kVA

Control transformer 1.0 kVA

22.96 kVA: Continuous rating 27.44 kVA: Continuous rating


Total
[29.02 kVA: 30-min. rating] [32.42 kVA: 30-min. rating]

[ ] : Optional

* 1: The spindle drive motor, and the servo motors are of the batch power supply scheme, the
ratios of the axes were calculated as follows:
Spindle drive motor : 1
X-axis servo motor : 0.2
Z-axis servo motor : 1
Table 6-2 Additional unit for FA

Chip conveyor (0.1 kW) 0.131 kVA

Coolant chiller MAC4S 0.693 kVA

6-3
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6-1-3 Air source requirements

An air source with the following specifications is required when an optional part is mounted that
requires air to operate.

1. Air source
Pressure 5 kgf/cm2 (71.2 PSI)
Discharge 100 Ni/min (3.53 ft3/min) (ANR) or larger
(Use a 0.75 kW (1 HP) compressor or equivalent.)

CAUTION
If the air has a high moisture content or if hot air is used, damage to the air actuators and
equipment could result. In such cases, use an air dryer or similar equipment.

2. Selection of compressor

A. The minimum required discharge pressure of a compressor is 5 kgf/cm2 (71.2 PSI). When
selecting a compressor, allow approximately 2 kgf/cm2 (28.5 PSI) margin.

B. Required discharge volume is 100 Ni/min (3.53 ft3/min) (ANR). With this volume, an air gun
can be used at the same time as the air blast.

C. There are three compressor operation types; manual unloader, automatic unloader, and
pressure switch types.
The compressor should be a pressure switch type for this machine model.

D. The compressor should be 1 HP (0.75 kW) in size. For details, contact a compressor maker.

6-1-4 Foundation work

CAUTION
- If the machine is to be installed near vibration generating equipment, a vibration-proof
drain must be provided around the machine foundation.
- If the soil is weak, reinforce it by driving piles into the soil to avoid subsidence and
inclination of the soil after machine installation.

For machine installation, select a flat place; avoid places subject to direct sunlight, humid places,
and places near heat generating equipment. Foundation work will vary according to soil conditions.
Compact the ground well or pour a concrete base to avoid subsidence or inclination of the soil after
machine installation.

6-4
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6-1-5 Foundation parts

Foundation parts and their uses are listed in Table 6-3 and Fig. 6-2.

Table 6-3 List of Foundation Parts

No. Name Illustration For machine

— Foundation plate 7 pcs

TR000-00021

“ Foundation bolt 7 pcs

TR113-00017

” Nut 7 pcs

TR113-00016

6-5
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6-1-6 Delivering the machine

To deliver the machine, the delivering entrance shown below is required. (Fig. 6-1)

A 1696
(66.77)

1850
(72.83) 1801
(70.91)

Fig. 6-1 Delivering the Machine

Unit: mm (in.)

SQT-200 SQT-200 SQT-250 SQT-250


with solid chuck with hollow chuck wiht solid chuck with hollow chuck
(Japan: Standard) (Japan: option, (Japan: standard) (Japan: option,
export: standard) export: standard)

2700 2803 2775 2860


A
(106.30) (110.35) (109.25) (112.60)

Bolt

Nut

Plate

Fig. 6-2 Foundation Parts TR113-00018

6-6
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6-2 Machine Installation

6-2-1 Precautions for machine installation

WARNING
- Two or more workers are necessary to handle heavy objects.
- Only authorized workers should use a forklift or crane, or lift the machine using wire
ropes.
- When operating a forklift or crane, care should be taken not to hit other objects.
- Use wire rope or a sling that can tolerate the weight to be lifted.
- Check the chain block, wire rope or sling, hoist, or other lifting equipment before using
them. Never use defective wire rope/slings or lifting equipment.

CAUTION
- The machine must be lifted properly. Lift the machine slightly from the floor to check if it
is well balanced.
- The angle made by the wire rope or sling must be less than 60°.
- When two or more workers are working together to lift the machine, they should cooperate
carefully using signals.
- When lifting the machine, great care should be taken not to shock the machine, NC unit,
or electrical control cabinet.
- Before lifting the machine, check that each machine unit is fixed in position and that there
are no tools or other objects on the machine.
* The coolant unit will be delivered separately.

1. Preparation for lifting

A. Fix the turret, the saddle, the tailstock, and the TOOL EYE (Japan: option, export: standard),
with power on.
Fix the turret at a distance of -185 mm (- from the zero point of the X-axis, that is, an
overtravel position in the minus direction of the X-axis).
Fix the saddle at the origin of the Z-axis.
Fix the tailstock at its backward end stop.
Fix the TOOL EYE at its backward end stop (retraction position). Refer to Subsection 6-2-3.

B. Turn off the machine power and the main power of the factory, and disconnect the factory
power - machine power connection cable from the circuit breaker of the machine.

C. Disconnect the cable and hose of the coolant unit (pump) from the machine.
Disconnect the cable by disconnecting the cannon connector from the side of the electrical
control cabinet.
Disconnect the hose from the pump. The residual coolant within the hose flows out. Receive
this coolant using a waste oil can. The total amount of outflow is about two liters.
Completely wipe away any coolant that may have spilled over the floor. Otherwise, workers
may overturn during lifting.

6-7
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D. Drain out the coolant from the coolant tank, then separate the tank from the machine, and
move the tank away to where the machine can be lifted smoothly.

E. Remove the anchor bolts from the machine.

2. Procedure to lift the machine (See Fig. 6-3)

A. Place the wire ropes on the bed hook (1 place) and on the both ends of the pipe that passes
the bed.
Use a wire rope and a pipe described in Fig. 6-4.
Use a crane with a 5 ton (11025 lbs) capacity or larger for lifting the machine.

B. Place the wire ropes on the crane hook.


Place wood blocks or pads between the machine and wire ropes so that the machine will not
be damaged.

Fig. 6-3 Lifting the Machine

C. Raise the arm of the crane to such an extent that the wire ropes become taunt, and make
sure that the ropes are firmly hooked on the machine body and at the chain block. If the
ropes are not correctly hooked, slacken and rehook them.

D. After checking that the wire ropes are correctly hooked, operate the crane to lift the machine.

6-8
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Working load: 1.75t (3850 lbs)


(Static load)

2730 (107.48) 178 (7.01)

Working load: 1.05t (2310 lbs)


(Static load)

z25
89 (z0.98)
R90 Working load: 1.73t (3806 lbs) (3.50)
(R3.54) (Static load) MH-25
z16 (z0.63)

(Rubber protector)
1000 (39.37) 3060 (120.47)
2-Hexaon socket head cap 2-Hexagon socket headcap
screw M20×280 screw M20×220
(continuous thread stud) (continuous thread stud)
z90 Wire A Wire B
(z3.54) 35 (1.38) 65 (2.56)
z130
(z5.12)

8-Hexagon 55 (2.17) 85
(100) nut M20 (3.35)
(3.94) 520 (20.47) 500 (19.69) 330 100 (3.94)
Pipe carbon steel Unit: mm (in.)
1550 (61.02) (12.99)
or equivalent
8-z22 hole
Fig. 6-4 Chain block (8-z0.87) D320M0017

6-2-2 Unpacking, inspection and cleaning

CAUTION
- When removing the rust preventive coating with cleaning oil, great care should be taken
so that the cleaning oil does not enter into the slideway surfaces passing the wiper.
- Used rags should be disposed of at a predetermined place.

1. The machine is shipped with transit clamps so that the machine units will not move during
transportation. After installing the machine, remove all of the transit clamps. Store the clamps,
bolts, etc. in a suitable place to allow for reuse during movement or transport in the future.

2. Install the covers and other parts, which are supplied in separate packages.

3. Cleaning
After having placed the machine on the base, remove the rust preventive coating from the
slideway surfaces and machined surfaces using rags and cleaning oil. Never try to operate any
section of the machine before cleaning since the rust preventive coating is apt to have been
contaminated with dusts and other foreign particles during machine transportation.
After having completely removed the rust preventive coating, apply the specified lubricant to the
slideway surfaces.

6-9
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6-2-3 Location of transit clamps

TOOL EYE
(Japan: option, X-axis
export: standard)

Z-axis

Tailstock

Fig. 6-5 Location of Transit Clamps

6-10
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1. Details for each transit clamps location

Fig. 6-6 Details for Each Transit Clamps Location (1/4) - TOOL EYE - TR113-00406

Fig. 6-6 Details for Each Transit Clamps Location (2/4) - Z-axis -

6-11
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Fig. 6-6 Details for Each Transit Clamps Location (3/4) - X-axis -

Fig. 6-6 Details for Each Transit Clamps Location (4/4) - Automatic tailstock (option) -

6-12
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6-2-4 Installation procedure

The machining accuracy is greatly influenced by installation conditions. Install the machine carefully
to the utmost.

1. Temporary leveling adjustments

A. With the machine lifted, fit the foundation bolts, leveling bolt, nut and foundation plates to the
leveling bolt holes in the machine bed.

B. Lower the machine gently so that the foundation bolts are correctly inserted into the
foundation holes prepared according to the foundation plan.
* During this step, the leveling bolts cannot be used; pull up the machine from the bottom.

C. Adjust the machine level temporarily by driving wedges under the machine.

D. After leveling the machine temporarily, fix the foundation bolts with mortar.

Leveling bolt
25
(0.94")

100×100×t15
(4"×4"×5/8")
Foundation plate 100 140
(3.94") (5.5")

5-M16×320 320
(5>W5/8"×12") 15 (12.0")
Foundation bolt (0.62")
180
(6.5") 320
(12.0")

70
(2.5")
35 170
(1.5") (6.5")

205
(8.0") Unit: mm (in.)

Fig. 6-7 Foundation Bolt

6-13
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2. Checking interconnections
After leveling is finished, check and confirm the following items before turning the power on.

A. Grounding (grounding resistance 100 ] maximum)

B. Screws at terminals (must be tight)

C. Connections of cannon connectors and other connectors (must be tight)

D. Relays and timers (must be fitted and connected correctly)

E. Timer and thermal relay settings (must be set correctly)

3. Adjust the machine height so that the clearance between the front cover and the chip pan will be
10 mm (0.39 in.) when the clearance between the machine bottom surface and the floor is 10
mm (0.39 in.).

Unit: mm (in.)

Clearance:
10 (0.39)

Clearance: Oil pan: 15 (0.59)


10 (0.39)

Fig. 6-8 Machine Height Adjustment TR113-00320

6-14
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4. Final level adjustment


After the mortar has cured, adjust the machine level using leveling bolts. Place precision levels
as illustrated in Fig. 6-9.
For details on the procedure to adjust the machine level and allowable leveling error, refer to the
attached accuracy table.
After tightening the leveling nuts and foundation bolts, check the machine level again. Use
precision levels having an accuracy of 0.02 mm (0.00079 in.) division.

Precision level

Leveling base

Fig. 6-9 Final Level Adjustment

6-15
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6-3 Connecting the Power Supply Cable and Air Supply Hose

6-3-1 Connecting the power supply cable

DANGER
Do not connect the power supply cable to the factory power distribution board until all
installation work has been completed.

Fig. 6-10 Connecting the Power Supply Cable (1/4)

1. Remove the screw fixing the cover.

2. Turn the breaker handle to the OPEN RESET position and pull the cover.

Fig. 6-10 Connecting the Power Supply Cable (2/4)

6-16
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3. Pass the power cable into the main power breaker cover.

4. Connect the cable to the NFB (no fuse breaker).


Make sure connections to the R, S and T terminals and grounding terminal.

T
S
Grounding terminal
R

Fig. 6-10 Connecting the Power Supply Cable (3/4)

5. Check for correct connection using a phase tester. Otherwise, damage to the important
sections of the machine may result.

Fig. 6-10 Connecting the Power Supply Cable (4/4) TR113-00706

6. Return the cover and breaker handle to their original position by pushing them into place.

7. Tighten the screws securely to fix the cover.

6-17
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6-3-2 Grounding

1. All electrical devices must be grounded in order to protect personnel and machines from
electrical hazards. Grounding must be performed after the machine has been installed in
accordance with the standards for electrical equipment.

2. Ideally, the grounding point should be as close as possible to the machine, but depending on the
machine installation site this may not always be possible.

3. The work must be performed by personnel with publicly recognized qualifications. This will
depend on the size of the company, but generally there will be a chief engineer or someone
licensed to perform electrical work who should be asked to carry out the work. The work to be
done is basically class 3 grounding.
Grounding resistance: 100 ] max.
Cross-sectional area of wires: A half or more cross-sectional area of primary incoming cable
(at least 30 mm2 (0.046 in2)).
Measuring equipment: 500 V megger

WARNING
The grounding work must be entrusted to an electrical engineer with publicly recognized
qualifications. If the work is done by an unqualified person, it could result in serious
injury, death, or damage to the machine.

4. The connections between the machines and ground should be made as indicated below.

WARNING
Never perform wiring as shown below.

When the grounding work is performed, no more than one wire should be connected to
any terminal. The reason for this is to prevent a serious accident. For example, if a wiring
plan like the one shown above is used, a faulty connection at one of the terminals could
cause short-circuited current from another terminal to be fed back to the machine,
resulting in serious damage.

6-18
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A. Independent connections

Each grounding resistance = 100 ] max.

B. Common connection

* The wires from the grounding terminal should


be directly connected to each of the
machines.
100
Grounding resistance= ]
Number of machines

6-3-3 Connecting the air hose

When an optional component is mounted that requires air to operate, connect the air supply both
correctly and firmly to the air connection port located at the bottom left of the machine.

Fig. 6-11 Connecting the Air Hose

6-19
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6-4 Trial Operation

After connecting the power supply cables and air supply hose to the machine, check the following
points before starting trial operation.

1. The machine and machine parts are all free from damages.

2. There are no missing parts and accessories.

3. Each part of the machine is lubricated with the specified lubricating oil.

4. The hydraulic pipes and hoses are securely connected.

6-20
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7. TROUBLESHOOTING

7-1 Headstock

If a problem occurs with the spindle, check the LED indication at the spindle unit in the electric
control cabinet and contact your local MAZAK service representative.

* See Section 5-11 and the electrical diagrams.


Tools/devices to be used: Tester and multimeter

Trouble Cause Remedy

Overheating of headstock - The magnetic contactor (KM12) is tripped. - Reset the magnetic contactor (KM12).
(See Section 5-11)
* The alarm message 261 * If the alarm state cannot be cleared after * Contact your local MAZAK service
HEAD LUBRICATION resetting the contactor, the motor is faulty. representative.
ALARM is displayed on
the CRT screen.
Motor does not rotate. - The power switch is off. - Turn ON the power.
- If the power switch is not off, the no-fuse - Change the no-fuse breaker or the
breaker (OF1) or the magnet contactor is magnet contactor.
faulty.

- If the lamp is not lit, the inverter is faulty. - Change the inverter.
The motor hums but does - Heavy load or short acceleration time setting. - Decrease the machine side load, or
not rotate. increase the acceleration time setting.
The motor is overheated. - Check if the motor is overloaded. - Decrease the machine side load.

- Check if motor cooling is obstructed. - Remove the obstacles.


* If not obstructed, the motor is faulty. * Change the motor.

The motor does not rotate - Check if the motor is overloaded. - Decrease the machine side load.
smoothly.

7-1
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7-2 Chuck

* Refer to the instruction manual supplied by the chuck maker.

Trouble Cause Remedy

The chuck does not operate. - Chuck component part is damaged. - Disassemble the chuck and replace the
broken parts.

- The rotary hydraulic cylinder does not - Check the hydraulic system.
function.

- The sliding portion is seized. - Disassemble the chuck and remove or


correct the seized portion. If necessary
replace.

Master jaw stroke is not - Large volume of chips are accumulated - Disassemble and clean the chuck.
sufficient. inside the chuck.

- Draw pipe is loosened. - Remove and clean the draw pipe.

Workpiece slips in the chuck. - Master jaw stroke is insufficient. - Adjust master jaw stroke.

- Chuck clamping force is insufficient. - Set the hydraulic pressure correctly.

- Top jaws are not shaped correctly to the - Shape the top jaws correctly.
workpiece diameter.

- Cutting force is too high. - Calculate cutting force; change cutting


conditions.

- Master jaw and other sliding parts are not - Grease them.
lubricated correctly.

- Spindle speed is too high. - Lower the spindle speed.

Accuracy is not high. - The chuck is shaking. - If the chuck is shaking, retighten the
bolts.

- Foreign matter on serration of master and - Remove the top jaws and clean the
chuck jaws. serration.

- Top jaw clamping bolts are loose. - Tighten the bolts to the specified
torque.

- Soft jaws are not shaped correctly. - Shape them correctly.

- Top jaws are too high causing deformation, - Lower the top jaws.
or top jaw clamping bolts are loose.

- The workpiece is deformed due to - Lower the gripping force.


excessively high gripping force.

7-2
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7-3 Turret

Trouble Cause Remedy

The turret is not - The clamp control solenoid valve is not - Check the solenoid valve or change it.
clamped/unclamped. operating correctly.

The turret does not rotate - The TURRET UNCLAMP menu is set. - Make the TURRET UNCLAMP menu
although it is unclamped. ineffective.

- The index coupling teeth do not engage - Contact your local MAZAK
correctly. representative.

- The bolts and mechanical connecting - Retighten the bolts and span ring.
element (span ring) fixing the turret are loose.

- Hydraulic piping is incorrect. - Check the hydraulic piping.

The turret keeps rotating - The turret position detection encoder is faulty. - Check the position detection encoder
without positioning. or change it.

- The clamp control solenoid valve is not - Check the valve or change it.
operating correctly.

- The valve is clogged. - Clean the valve or change it.

The turret rotates but stops - The index coupling teeth do not engage - Contact your local MAZAK
halfway. correctly. representative.

- The clamp control solenoid valve is faulty. - Check the solenoid valve or change it.

- The turret position detection encoder is faulty. - Check the position detection encoder
or change it.

The turret rotates but does - The index coupling teeth do not engage - Contact your local MAZAK
not index correctly. correctly. representative.

- The turret is not mounted correctly.

- The encoder is not mounted correctly.

- Tooling is not balanced. - Balance the tooling.

- Play in drive mechanism is excessive. - Contact your local MAZAK


representative.

- The mechanical connecting element (span - Retighten the span ring.


ring) is loose.

7-4 TOOL EYE

Trouble Cause Remedy

The TOOL EYE does not operate. - The proximity switch (SQ7 or SQ8) is - Adjust or replace the proximity switch
* The following alarm message is faulty. (SQ7, SQ8).
displayed. - Wiring is broken or socket is loose. - Replace the wiring.
“209 INCORRECT TOOL EYE
ARM POSITI”
“231 TOOL EYE POSITION
SENSOR MALF”

7-3
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7-5 X-axis

Trouble Cause Remedy

Positioning is not accurate. - Bolts, taper pins and/or nuts are loose. - Tighten them.

- Coupling is loose. - Retighten the coupling.

The X-axis zero point is not fixed - Mounting bolt for X-axis zero point limit - Retighten the bolt.
(the variation is less than 10 mm switch is loose.
(0.394 in.)).

The X-axis zero point is not fixed - The X-axis zero point dog is not - Adjust the X-axis zero point dog.
(the variation is more than 10 mm adjusted.
(0.394 in.)).

7-6 Z-axis

Trouble Cause Remedy

Positioning is not accurate. - Bolts, taper pins and/or nuts are loose. - Tighten them.

- Coupling is loose. - Retighten the coupling.

The Z-axis zero point is not fixed - Mounting bolt for Z-axis zero point limit - Retighten the bolt.
(the variation is less than 12 mm switch is loose.
(0.47 in))

The Z-axis zero point is not fixed - The Z-axis zero point dog position is - Adjust the Z-axis zero point dog
(the variation is more than 12 mm not adjusted. position.
(0.47 in))

7-7 Tailstock

Trouble Cause Remedy

The tail spindle does not move - The tail spindle thrust power is - Adjust the thrust power.
forward and/or backward. excessively high.

- The solenoid valve does not operate - Check the solenoid valve and replace
correctly. it, if necessary.

- The proximity switch does not operate - Adjust the proximity switch and replace
correctly. it, if necessary.

Noise from the rotary center - The tail spindle thrust power is - Adjust the thrust power.
excessively high.

- The internal bearing is seized or - Replace the bearing.


broken.

7-4
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7-8 Hydraulic Unit

Trouble Cause Remedy

Oil is not discharged. - The pump does not rotate. - Check the connection of the power cable.
- The pump is rotating in the reverse - Check the polarity of the power supply.
direction.
- Suction pipe is clogged. - Check the suction pipe.
- Strainer is clogged. - Clean the strainer.
- Leak in suction pipe - Check the suction pipe and its joint.
- Suction filter is not completely immersed - Replenish the hydraulic oil with the same
in oil. grade up to the reference line in the level
sight gauge.
- Discharge volume adjusting sleeve is - Loose the sleeve.
tightened excessively.
- Hydraulic oil viscosity is too high. - Replace the oil entirely with oil of correct
viscosity.
* Warm the oil using a heater as temporary
measures.

Although oil is discharged, - The relief valve is not operating - Disassemble and check the relief valve.
pressure is not built up. correctly.
- Load is not applied in the hydraulic - Check the circuit and apply the load.
circuit.
- Leak in the hydraulic system. - Check the piping and repair the leak.

Oil is not discharged or - Seals inside the pump are broken. - Contact your local Mazak service
volumetric efficiency lowers representative.
when pressure is built up.
- Slide portions are worn abnormally due
to dust and foreign matter.
Noise is excessively large. - Strainer is clogged. - Clean the strainer.
- Air is sucked from the suction pipe or - Check the point where air is sucked by
other portion. applying oil on the suspected portions.
- Bubbles inside the reserve tank. - Check the return pipe and prevent
generation of bubbles.
- Bubbles trapped inside the piping. - Repeat inching of the pump to discharge
the bubbles.
- Low oil level - Replenish the specified grade of the
hydraulic oil up to the reference line in the
level sight gauge.
- Pump mount base is not rigid. - Use rigid base; check loose bolts as well.
- Pump sliding portions exhibit wear. - If the wear is abnormal, check for oil
contamination, water in the oil, oil viscosity,
and oil temperature during pump operation.
Pump generates heat. - Heat generation due to improper - If the pump surface temperature rises
volumetric efficiency. excessively, stop pump operation
immediately.
- Seizure on sliding portions of the pump

7-5
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7-9 Lubrication Unit

Trouble Cause Remedy

Lubricating oil pressure drops below - Lubricating oil is insufficient. - Add lubricating oil.
1.0 kgf/cm2 (14.2 PSI).
- Leak from the lubrication pipe. - Retighten the pipe.
The alarm message 260 SLIDEWAY
- Lubrication pipe is clogged. - Clean the pipe.
LUBRICATION ALARM is displayed
on the CRT screen.

7-10 Coolant Unit

Trouble Cause Remedy

Coolant is not supplied. - Filter of the coolnt tank is clogged. - Clean the filter.

- Coolant is insufficient. - Refill the coolant.

- The electromagnetic switch (KM13) is - Reset the electromagnetic switch


tripped. (KM13). (See Section 5-11.)
* If the electromagnetic switch (KM13) is * When the coolant pump fails, contact
not tripped, the coolant pump is faulty. your local MAZAK service center.

7-11 Air Unit

Trouble Cause Remedy

Air flow volume decreases due to - Element is clogged. - Change the element.
high air flow resistance.

An excessive volume of water is - Water has accumulated. - Discharge the water.


found in the pipe down-stream from
the element.

7-12 Headstock Cooling Unit

The alarm message 261 HEAD LUBRICATION ALARM is displayed on the CRT screen if an error
occurs in the headstock cooling unit. Refer to the Alarm List for details.

Trouble Cause Remedy

The alarm message 261 HEAD - Coolant is insufficient. - Replenish the coolant.
LUBRICATION ALARM is
displayed on the CRT screen. - The pressure switch is faulty. - Change the pressure switch.

The centrifugal pump is not - The electromagnetic switch (KM12) is - Reset the electromagnetic switch
operating. tripped. (KM12). (See Section 5-11.)
* When the magnetic switch (KM12) is * If the pump is faulty, contact your local
not tripped, the pump is faulty. MAZAK representative.

7-6
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8. GRAPHIC MAINTENANCE
8-1 Outline

If a PC-related alarm occurs, the source of the alarm will be displayed in reverse form on a layout
diagram of the corresponding section. This display is therefore useful for early machine recovery.
PC: A unit that controls the operation of the movable components of the machine (except axial
operation).

8-2 Operations

1. If a PC-related alarm occurs, the following display will appear on the CRT:

Reverse display TURRET TAIL SPINDLE


of the source of SPINDLE
the alarm

CHUCK TAIL SOLENOID

SLIDE WAY LUBE


Z AXIS SERVO MOTOR

DIAGNOS ALL DATA


DISPLAY

or
X AXIS SERVO MOTOR

AIR KIT

TOOL EYE

SQ8
SQ7 SP3
HYD PUMP MOTOR

COOLANT MOTOR

8-1
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2. Change the display over using the page keys to identify the source of the alarm.

3. When a layout diagram of the corresponding section is displayed, the display status of the
section where the alarm has occurred will reverse in that diagram to identify the source of the
alarm.

TAIL SPINDLE

CHUCK CHUCK CONTROL BOX


Reverse display
CLAMP UNCLAMP of the source of
YV03 YV04 SQ52 the alarm
SQ53
SP4
VIEW A

SLEEVE SLEEVE
FORWORD REVERSE
YV13 YV11
SQ26
VIEW B
aaaaaa

aaaaaa
A B SQ27

DIAGNOS ALL DATA


DISPLAY

8-3 Page Keys and ALL DATA DISPLAY Menu Item

<When ALL DATA DISPLAY is reversed>


By using the PAGE keys, all the layout diagrams can be displayed in succession.

<When ALL DATA DISPLAY is not reversed>


By using the PAGE keys, all the layout diagrams where the alarm has occurred can be displayed.

8-2
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8-4 Types of Layout Diagrams

Following 6 types of layout diagrams are available.

TURRET TAIL SPINDLE


SPINDLE

SOLENOID FOR
CHUCK &
TAIL SPINDLE

SLIDEWAY Z-AXIS SERVO


LUBRICATION UNIT MOTOR

X-AXIS SERVO MOTOR

AIR KIT

TOOL EYE

SQ8
SQ7 SP3 HYDRAULIC SERVO MOTOR

COOLANT MOTOR

8-3
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2-AXIS TURRET SERVO TURRET

GEAR SHIFT TURRET


SQ37
TURRET POS. ENCODER TURRET UNC.
B10 YV02
INDEX MOTOR TURRET UNC. GEAR SHIFT MILL TURRET
YV01 SQ38 CLAMP
A TURRET POS.
MILL SERVO MOT. YV07
ENCODER B10
VIEW A

TURRET REV.
YV06
TURRET
FOR.
YV02 TURRET UNCLAMP
SQ04
TURRET CLAMP
SQ04 GEAR SHIFT GEAR SHIFT
YV06 TURRET
YV01

CHUCK CHUCK CONTROL PANEL


CLAMP UNCL.
YV03 YV04
SQ53 SQ52
SP4

VIEW A

TAIL. TAIL.
FOR. REV.
YV13 YV11

SQ26
A B SQ27

VIEW B

8-4
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AUTO TAIL SPINDLE

SQ30

SQ33 SQ34

SQ31

AIR KIT

TURRET MILL JOINT


SILENCER YV05

TURRET MILL JOINT REGULATOR

AIR FILTER

TOOL EYE AIR


YV35

PRESSURE SW.
SP02

8-5
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8-5 Parameter

Parameters regarding to this display are as follows:

When the display request turns on, the GRAPHIC MAINTENANCE display will also turn on
automatically.
If E50 (bit 6) = 1:
Even when the display request turns on, the GRAPHIC MAINTENANCE display will not turn on
automatically.
If E50 (bit 6) = 0:

8-6
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9. STANDARD SPECIFICATION OF THE MACHINE


9-1 Principle Specification

SQT-200 SQT-250
Item Description

Capacity Chuck size inch 8 10


Maximum swing mm (in.) z525 (z20.67)

Standard machining diameter mm (in.) z264 (z10.39)

Maximum machining diameter mm (in.) z350 (z14)

Bar work capability mm (in.) z51 (z2) z64 (z2.5)

Distance between spindle end and turret 130 to 665 119 to 654
mm (in.)
end face (5.12 to 26.18) (4.69 to 25.75)

100 (220) [Chuck work]


Maximum support weight (*) kgf (lbs)
150 (330) [Shaft work]
Main spindle Rotating speed min-1 35 to 5000 [For export] 35 to 4000 [For export]
35 to 4500 [For Japan] 35 to 3500 [For Japan]

Acceleration and deceleration time sec 2.5

Bore mm (in.) z61 (z2.40) z76 (z2.99)

Motor output (30 min rating) 18.5 (25) [For export]


kW (HP) 18.5 (25)
15 (20) [For Japan]

Maximum torque 34 (245.8) [For export]


kgf.m (ft.lbs) 34 (245.8)
25 (180.8) [For Japan]

Tailstock Center MT No. 5


Movement stroke (body/sleeve) mm (in.) 400/150 (15.75/5.91)

Maximum thrust power kgf (lbs) 700 (1540)


Turret Number of tools pcs. 12

Tool size OD turning 25 ( 1)


ID turning z40 (z1.5)
mm (in.)

Indexing time One position/full turn sec 0.25/1.2

Feed axes Rapid feed rate X/Z m/min 30/30


(IPM) (1181/1181)

Rapid feed time


X/Z msec 120/120
constant

Axis strokes X 190 (7.48) [185+5 (7.28+0.20)]


mm (in.)
Z 535 (21.06) [530+5 (20.87+0.20)]

* : These values include chuck weight. (Continues)

9-1
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(Cont’d)
SQT-200 SQT-250
Item Description

Other Coolant tank capacity L (gal) 160 (42.27)


[For export]
27.44 (Continuous)
32.42 (30 min) 27.44 (Continuous)
Electrical requirement kVA 32.42 (30 min)
[For Japan]
22.96 (Continuous)
29.02 (30 min)
Overall dimensions Size Spindle center height 1020 (40.16)
2803 (110.35) [For export] 2860 (112.60) [For export]
Overall length mm (in.) 2700 (106.30) [For Japan] 2775 (109.25) [For Japan]

Overall width 1697 (66.81)

Overall height (*) 1942 (76.46)


4.76 (51.24) [For export] 4.85 (52.20) [For export]
Floor space requirement m2 (ft2)
4.58 (49.30) [For Japan] 4.7 (50.59) [For Japan]
kgf
Machine weight 4500 (9920.7) 4600 (10141.2)
(lbs)

* The overall height during transfer is 1850 mm (72.83 inch).

Note:
The figures indicated in the machine plates shall be applied if ones in the manual may differ.

9-2
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9-2 Spindle Nose Diagram

SQT-200

30°

11-M12 through holes


M8 through- (C1 chamfer at mouth)
hole

z133.35 z106 (4.17)


(5.25)

7°7'30"

z169 (6.65)

z19 (0.75) z70 (2.76) 14.3


(0.56)

8 40.3
(0.31) 26 (1.59)
(1.02)

Taper 1/20

3-M5 10 (0.39)
854.3 deep holes
(33.63) (equidistant)

814
(32.05)

z69
(2.72)

z61 (2.40)
z77 (3.03)

M80 × P2 Unit : mm (in.)

Fig. 9-1 Spindle nose diagram

9-3
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SQT-250

30°

11-M12 through holes


M8 through- (C1 chamfer at mouth)
hole

z133.35 z106 (4.17)


(5.25)

7°7'30"

z165 (6.50)

z19 (0.75) z85 (3.35) 14.3


(0.56)

8 40.3
(0.31) 26 (1.59)
(1.02)

Taper 1/20

60° 6-M5 10 (0.39)


904.3 deep holes
(35.60) (equidistant)

864
(34.02)

z84
(3.31)

z76 (2.99)
z92 (3.62)

M95 × P2 Unit : mm (in.)

Fig. 9-2 Spindle nose diagram

9-4
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9-3 Stroke Diagram

1. SQT-200 (mm)

Fig. 9-3 Stroke diagram of SQT-200 (1/2) - mm - Unit : mm

9-5
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2. SQT-200 (inch)

Fig. 9-3 Stroke diagram of SQT-200 (2/2) - inch - Unit : inch

9-6
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3. SQT-250 (mm)

Fig. 9-4 Stroke diagram of SQT-250 (1/2) - mm - Unit : mm

9-7
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4. SQT-250 (inch)

Fig. 9-4 Stroke diagram of SQT-250 (2/2) - inch - Unit : inch

9-8
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9-4 Tooling Interference Diagram (SQT-200/250)


1. SQT-200/250 (mm)

Unit : mm

Fig. 9-5 Tooling interference diagram of SQT-200/250 (1/2) - mm -

9-9
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2. SQT-200/250 (inch)

Unit : inch

Fig. 9-5 Tooling interference diagram of SQT-200/250 (2/2) - inch -

9-10
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9-5 Relation Diagram between Chuck and TOOL EYE

Front view

* z210 (8.27) for SQT-200


z254 (10.0) for SQT-250

285 (11.22)

240 (9.45)

*z210 (8.27)

45 (1.77)

*z254 (10.0)

45 (1.77)

164 (6.46)
37 (1.46)
59 (2.32)

207.5 (8.17)

Unit : mm (inch)

Fig. 9-6 Front view D320S0003

9-11
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Side view (with tailstock)

[ ]: for SQT-250
Face cover
43 (1.69) 322 (12.68) [302 (11.89)]
[63 (2.48)] 139(5.47) [150 (5.91)]

97 (3.82) 42 (1.65)
[104 (4.09)] [46 (1.81)]

34 (1.34)

34 (1.34)

45 (1.77)

80 66
(3.15) (2.60)
z210 (8.27) [z254 (10.0)] 146 (5.75)

285 (11.22)

Unit : mm (inch)

Fig. 9-7 Side view D320S0004

9-12