LT-42_52_65

Version: 005 P 0-1

Date of Version: Sep. 2012

MACHINE MANUALLT-42/52/65 SERIES

MACHINE MANUAL

Persons unable to read English must have this manual read and explained to them before

operating or maintaining the machine. Everyone working on the machine must know how to

operate it safely and correctly to avoid possible injury.

WARNING

Version: 005 P 0-2



Version & relative revise record

1) Updated date: April 2007

Version: 002 version date: April 2007

Relative Chapters/Pages Modification context

All Chapters Revised manual version

Ch 7-3, 7-4 Add 7..5 Replacing oil on headstock and 7.6 Aligning

headstock

Ch 8-13, 8-14 8.6 Full splash guard

Ch 8-16, 8-17 8.7 Encoder

Ch 8-18~8-47 Add 8.8~8.22 parts list & drawing into manual

2) Updated date: Jun. 2008

Version: 003 version date: Jun. 2008

Relative Chapters/Pages Modification context

All Chapters Revised manual version

Ch 2.4 Add Power turret

Ch 2.5 Add Spindle rpm(s) & output diagram

Ch 3.8 Add Tooling system & limitation

Ch 3.9 Add Hydraulic unit

3) Updated date: Aug. 2009

Version: 004 version date: Aug. 2009

Relative Chapters Relative Pages Modification context

Ch2.4.2 P2-6 Replace the content

Ch3.3 P3-6~P3-11 Replace the content

Ch3.4 P3-11~P3-25 Replace the content

Ch3.9 P3-20 Replace the content

Ch8.11.1 P8-25 Revise the belt type of No. 7



Ch8.22 P8-46~P8-47 Replace the picture and revise the parts list

Version: 005 P 0-3



First revised Updated date: July. 2010


Ch1.2.1 P1-3 Add environmental requirement

Second revised Updated date: Nov. 2010


Add tool limitation

Third revised Updated date: March. 2011


Ch8 Add C-axis drawing

Forth revised Updated date: March. 2011


Ch1.2.9 The safety instruction of using air gun is added

Fifth revised Updated date: March. 2011


Ch3 Add lubrication system data

Sixth revised Updated date: March. 2011


Ch3 Add CTS data

Seventh revised Updated date: March. 2011


Ch7 Add CTS data

Eighth revised Updated date: Aug. 2011


Ch8.26 Add angle encoder drawing and parts list

Version: 005 P 0-4



Ninth revised Updated date: Sep. 2011


Ch3 Add Bar feeder data

Tenth revised Updated date: July. 2012


Ch3.8 Add LS-200 STD tool system drawing

Eleven revised Updated date: Sep. 2012


Ch8.19.1 P8-41 Revise part no. of item 1 and item 2

4) Updated date: Sep. 2012

Version: 005 version date: Sep. 2012

Modification context Relative Chapters

Ch1~4 Re-construct all sections and add necessary content

First revised Updated date: Jan. 2013


Ch4.1 P4-3~4-4 Add maintenance specification of cover

Second revised Updated date: Jan. 2013


Ch4.3 4-12 Add maintenance specification of cover


Table of Contents

1. SAFETY INSTRUCTIONS

2. SPECIFICATIONS

3. INSTALLATION

4. MAINTENANCE 5. ADDITIONAL & REVISE PAGES


1 SAFETY INSTRUCTIONS

Version: 005 P 1-1



1 SAFETY INSTRUCTIONS ............................................................................. 2

1.1 DEFINITION OF WARNING SIGN ................................................................... 2

1.2 BEFORE OPERATING THE MACHINE ............................................................ 3

1.2.1 Before using the machine .................................................................................. 3

1.2.2 Before operating the machine ........................................................................... 6

1.3 TURNING THE POWER ON .......................................................................... 8

1.3.1 Before turning the power on .............................................................................. 8

1.3.2 After turning the power on ................................................................................. 9

1.4 PRECAUTIONS ON MACHINE INSTALLATION ............................................... 10

1.4.1 Installation site ................................................................................................. 10

1.4.2 Power supply ................................................................................................... 11

1.4.3 Grounding ........................................................................................................ 11

1.4.4 Air supply ......................................................................................................... 13

1.4.5 Lubrication ....................................................................................................... 13

1.4.6 Installation ....................................................................................................... 13

1.4.7 Points to check before turning on the power for the first time ......................... 15

1.4.8 Points to check after turning on the power for the first time ............................ 16

1.5 SAFETY PRACTICES WHEN MOUNTING/REMOVING A CHUCK ...................... 16

1.6 SAFETY PRACTICES WHEN CHUCKING A WORKPIECE ................................ 17

1.7 SAFETY PRACTICES DURING MACHINE OPERATION .................................... 21

1.8 SAFETY PRACTICES DURING MAINTENANCE AND INSPECTION ..................... 23

1.8.1 Daily maintenance ........................................................................................... 23

1.8.2 Precautions when performing maintenance and inspection work ................... 24

1.9 WARNING PLATES ON THE MACHINE .......................................................... 27

1.10 RISK LIST AND SOLUTION ........................................................................ 42

Version: 005 P 1-2



1 SAFETY INSTRUCTIONS

1.1 Definition of Warning Sign

A variety of symbols are used to indicate different types of warning information and advice.

Learn the meanings of these symbols and carefully read the explanation to ensure safe

operation while using this manual.

<Symbols related with warning>

The warning information is classified into three categories, DANGER, WARNING, and

CAUTION. The following symbols are used to indicate the level of danger.

DANGER symbol indicates an imminently hazardous situation which, if not avoided, will

result in death or serious injury. The information described following the DANGER symbol

must be strictly observed.

WARNING symbol indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury. The information described following the WARNING symbol

must be strictly observed.

CAUTION symbol indicates a potentially hazardous situation which, if not avoided, may result

in minor personal injury or mechanical damage. The information described following the

CAUTION symbol must be strictly observed.

<Other symbols>

NOTE symbol gives additional information to the operator about a particular step or procedure.

The information described following the NOTE symbol should be taken into consideration.

NOTE

CAUTION

WARNING

DANGER

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1.2 Before Operating the Machine

This machine is provided with numbers of safety device to protect operator and equipment

from being injured and damaged based on the safety regulation. However, operator should

not rely solely upon these safety devices but should operate the machine after fully

understanding special precautions by reading the following remarks thoroughly. The cautions

listed below must be constantly born in mind when operating the machine.

1.2.1 Before using the machine Items listed below are important cautions that apply to all machine-related work (machine

operation, maintenance, inspection, programming, etc.).

1) Never touch a switch, button, or key with wet hands.

2) Before starting machine operation, ensure there is nobody inside the door or close to

rotating or moving parts of the machine.

3) Never operate the machine if any protective cover removed or other safety devices

ineffective. Check if all safety devices are properly operated.

4) Always lock out the power to the machine before carrying out work inside the machine. In

addition, place “MACHINE UNDER REPAIR” or other similar signs around the machine to

stop anyone from turning on the power.

5) Always turn off the power before carrying out inspection or maintenance work in the

electrical cabinet or on motors and transformers.

6) Cover power supply cables on the floor with rigid insulated plates.

7) Even after the power is turned off, some devices are still power connected. The

temperature of motors and lights inside the machine remain high. Make sure that the

power has been disconnected or the temperature has fallen before carrying out inspection

or maintenance work.

8) Ensure all cables are properly insulated before using the machine.

1) Keep the floor around the machine tidy and clean.

2) Before operating the machine, make sure a proper working area and the machine can be

WARNING

DANGER

Version: 005 P 1-4



operated safely.

3) Before using a switch, button or key, check visually that it is the one you intend to use and

then press or set it decisively.

4) Operate the machine only when the front door is closed.

5) Do not change the parameters without the permission of manufacturer.

6) Do not change the specifications or settings without the permission of manufacturer.

7) Do not install, operate or maintain the machine until reading the operation manual

carefully.

8) Do not soil, scratch or remove the caution plates on the machine. If the caution plates are

missing or become illegible, order another from the manufacturer. The part numbers are

shown at the bottom right side of the plates.

9) Always observe the instruction in the caution plates on the machine. Carefully read the

safety guidelines of the caution labels so that you fully understand them.

10) Never operate or maintain the machine while under the influence of alcohol or drugs.

Personnel with illness, which might cause dizziness or fainting, should never operate this

machine.

11) Machine operators or personnel working inside the machine must put their clothing and

hair in order so that they will not be entangled in the machine.

12) The machine is equipped with interlock functions such as the door interlock and chuck

interlock to ensure the operator’s safety. All the interlock functions must be ON when

operating the machine.

13) If the door interlock is removed, the machine is able to operate with some limitations while

the door is open, exposing you to danger. In daily production operation, the door interlock

function must be set “valid” and the key operating the switch must be removed from the

switch and kept safely. When measuring the tool offset, program check, test cutting or

carrying out other setup work, it may be necessary to open the door. If so, you must

recognize that there are many hazards involved and pay particular attention to safety.

14) The emergency stop buttons are used to stop all operations in the event of an emergency.

Before operating the machine, memorize the locations of the emergency stop buttons so

that you can press one immediately. Use the emergency stop button only in emergencies

to avoid crashing the machine.

15) Adjust the position of the tailstock body so that the workpiece is securely held by the

tailstock spindle center when the tailstock quill is extended. After this adjustment, clamp

the tailstock body to the bed.

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16) Only authorized personnel with sufficient safety training can work on this machine.

17) Because of the inertia of the moving parts, they may not be stopped immediately when the

EMERGENCY STOP button is pressed. Always confirm that all operations have stopped

before going near these parts.

18) Do not operate the machine with articles such as tools and rags left inside the machine.

19) Use appropriate eye and ear protection, safety shoes, helmets or other safety protections

while operating the machine.

20) Tooling should conform to the machine specifications, dimensions and types.

21) Check for damaged parts and tools before operating the machine. Any part or tool that is

damaged should be properly repaired or replaced by authorized personnel before

machining.

22) The machine is designed to be operated by one person. If two or more persons are

involved, they must cooperate carefully and communicate as fully as possible.

23) The functions of the machine make it impossible to eliminate all pinch points. Be

particularly aware of the following pinch points:

- Spindle and chuck rotation

- Indexing of turret and tools

- Carriage and cross-slide movement

- Tailstock movement, both quill and body

24) At the end of the workday, the machine should be placed in either “control off” or “power off”

modes.

25) When restarting a machine after it has been shut down, always assume it has been

tampered with. Recheck all phases of the job as though you were running the first piece.

26) Never extend an unsupported bar out of the rear of the spindle or hydraulic cylinder. A

distance from a concentric support more than 10 times of its diameter is required. When

any bar is extended, a large sign should be placed to warn people to stay away from the

area.

27) If the machine has a bar-feeder, keep yourself and others away from the exit end of the

bar-feeder when operating the machine.

28) When loading or unloading work, move the turret to the right-up side or left-up side to

avoid injuries or interference.

29) When loading or unloading work, spindle must be in a stop position. 30) Reverse the spindle when chucking work for the first time to confirm the tightness of

chuck.

Version: 005 P 1-6



1) User programs stored in the memory, parameters set before shipping and the offset data

input by the user could be destroyed or lost due to incorrect operation or other causes. In

order to protect data against destruction and loss, back it up by using an external I/O

device or other device.

2) Never touch chips or the cutting edges of tools with your bare hands.

3) Take care not to stumble over the footswitch.

4) The machine operator must have normal sensory perception.

5) Ensure that the workplace is adequately lit.

6) Secure adequate space around the machine for working and adequate passageway,

considering both ease of operation and safety.

7) Stack products (workpieces) stably.

8) Keep the area around the machine clean; remove chips and foreign particles near the

machine.

9) Use a working bench strong and stable enough to support the weight of the workpiece and

tools.

10) When mounting tools to the turret head, make sure there is no interference between the

tools/holds and the workpiece or machine, and make sure that the arrangement in the

turret is balanced.

11) Always make a trial run after installing a tool. 12) In the working area, fire extinguisher must be placed in a visible area for emergency use.

1.2.2 Before operating the machine The cautions that must constantly be born in mind when operating the machine.

1) Never stand in front of the spindle or other rotating parts. Never stand in front of the chuck

since the workpiece, cutting tools, or chuck jaws might fly out, particularly during test

cutting.

2) Specify a spindle speed limit that is lower than the highest of the allowable speed limits for

the chuck, fixture, and cylinder. Never operate spindle-mounted accessories over their

rated speed. If the chuck or accessory is not supplied by machine manufacturer, verify the

safe operating speed with the manufacturer.

WARNING

CAUTION

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3) Before starting spindle rotation, ensure the workpiece is securely clamped. Or, if

performing center-work, ensure the tailstock spindle center securely supports the

workpiece. (Applies only to machines equipped with a tailstock.)

4) Before starting the spindle in manual operation, set the spindle speed setting switch to the

lowest setting. After starting the spindle, increase the spindle speed to the required speed

gradually. When stopping the spindle, lower the spindle speed first and then stop it.

5) Never attempt to reach inside the chip conveyor or put your feet in it while it is operating.

You could be caught in the chip conveyor and seriously injured. (Applies only to machines

equipped with a chip conveyor.)

6) Select the appropriate chucking pressure and tailstock spindle thrust force (applies only to

machines equipped with a tailstock) for the workpiece shape and material, and the cutting

condition.

7) Do not wear gloves when operating the machine since it could cause your hands to get

entangled in the rotating parts.

8) Never remove burrs on a workpiece by hand while it is clamped by the chuck or while it is

fixed inside the machine.

9) Keep flammable liquids and materials away from the work area and hot chips.

1) When machining bar stock on the machine with a bar feeder or spindle through-hole, use

straight workpieces only.

2) Always wait some time before touching the lamp illuminating the interior of the machine

after turning the power OFF since it would be very hot and will burn you.

3) When clamping or unclamping the chuck, pay sufficient care so that hand or fingers will

not be caught by the chuck or the chuck jaws.

CAUTION

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1.3 Turning the Power On

1.3.1 Before turning the power on The cautions that must constantly be born in mind before turning the power ON .

1) Check whether all cables, cords or electric wires are insulated well. If the insulations are

damaged, it could lead to current leaks and the machine operator could receive an electric

shock.

1) Always lock the electric cabinet door, operating cover, guarding door before switching on

the machine.

1) Make sure that all bolts are tightened securely.

2) Make sure that all connectors, hydraulic hoses and air pipes are connected securely.

3) If the machine is equipped with any external equipment (bar feeder, hydraulic chuck, etc.),

make sure that the electric cables and hydraulic/pneumatic pipes for these equipments are

connected correctly.

4) Do not turn the machine on while the primary power is not supplied to the main circuit

breaker.

CAUTION

WARNING

DANGER

Version: 005 P 1-9



1.3.2 After turning the power on The cautions that must constantly be born in mind after turning the power ON.

1) To prevent seizure of the chuck and cylinder, repeat the chuck opening and closing

operations several times, ensure the jaws or workpiece holding fixture are securely

mounted.

2) If the machine stops due to a power failure, turn off the main circuit breaker immediately. If

you do not turn off the power, the machine will start operating unexpectedly when power is

restored.

3) The machine cannot operate correctly unless the specified power is supplied. If the power

supply is momentarily cut off during machine operation due to a power failure or lightning,

the machine may operate unexpectedly.

4) Check oil leaks and ensure all gauges read the correct value.

1) After turning the power ON, ensure the fans are operating normally so that the heat inside

the machine will be dissipated.

2) After turning the power ON, ensure the lubrication pump is operating normally. In order to

protect the sliding parts, never feed the axes immediately after turning the power ON;

manually operate the slideway surface first.

3) After turning the power ON, warm up the spindle for about 15 minutes. If you do not warm

up the spindle, the machine’s life and machining accuracy will be adversely affected.

4) When turning the power ON after the machine has been stopped by a power outage,

ensure the program, parameter data, offset data, etc. have not been destroyed.

CAUTION

WARNING

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1.4 Precautions on Machine Installation

1.4.1 Installation site

1) When installing the machine, refer to the installation drawing and other instructions and

provide sufficient maintenance area to allow the chip conveyor (if featured) and coolant

tank to be removed, and the electrical cabinet door to be opened and closed, without

difficulty. Also ensure that the doors of the machine and NC unit will be able to be opened

without interference.

2) Choose an installation site that is as free as possible from dirt, dust, and mist.

3) Install the machine at a site where it will not be reached by chips, water, and oil scattered

from other machine.

4) Install the machine at a site where the ambient temperature remains within the range 0 to

45 and the humidity does not exceed 80% RH (with no condensation).

5) The machine must not be installed at a site subject to excessive vibration.

1) Install the machine at a site where neither it nor the NC unit is subject to direct sunlight.

Direct sunlight will raise the temperature and cause thermal displacement, adversely

affecting machine accuracy.

2) Make sure the floor is strong enough to support the machine. The floor must not be sloped

or irregular in any way. Twisting or other distortion of the machine will adversely affect

machining accuracy.

NOTE

CAUTION

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1.4.2 Power supply

1) Only a qualified electrical technician should perform work involving the power cable

connections.

1) For the power supply, provide isolated wiring directly from the input power supply. If there

is an excessive voltage drop, for example due to insufficient capacity of the factory power supply, the machine may malfunction.

2) Select a primary power cable by accurately calculating the power supply capacity at the

supply side. Using an inappropriate cable could lead to fire, injury, or damage to the

machine.

3) The electrical power must meet the specifications. Attempting to run the machine from any

other source can cause severe damage and will void the warranty.

4) Do not install the machine close to major sources of electrical noise, such as electric

welders and electrical discharge machines. If the voltage supply is not stable, the machine

may malfunction.

1.4.3 Grounding

1) Grounding work is essential. If grounding work is not performed, the machine operator

could receive an electric shock.

2) The ground wire must be as short as possible and have the same diameter as the input

power cable. With regard to grounding resistance, observe the applicable regulations in

the country in which the machine is being used

1) Use a grounding wire with a cross section of more than 14mm² and a resistance less than

100 ohms. This wire size should be greater than AWB (American Wire Gauge) No. 5 or

SWG (British Legal Standard Wire Gauge) No. 6.

WARNING

DANGER

WARNING

DANGER

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2) Generally, the machine should be grounded independently. If the ground wire is not

connected independently, prepare the ground connection as follows:

‐ Connect a single conductor to the grounding terminal. This will avoid possible serious

accidents resulting from grounding currents, which might otherwise flow in the NC

machine.

‐ Be careful when using concrete reinforcing rods as grounding points. These reinforcing

rods are often used to ground equipment because they usually offer a resistance less

than 100 ohms. In doing so, make the connections as follow:

a. Do not use the same grounding-reinforcing rod or grounding terminal for other

devices since the machine could malfunction due to electrical noise from other

machines.

b. Use a grounding terminal which is durable and with an adequate electrical

performance rating.

‐ Use a separate grounding wire, and the length of the wire should be as short as

possible.

‐ Check the resistance to ground by actual measurement. This should measure less

than 100 ohms if the single device is connected to its own grounding rod.

Desirable Independent Grounding:

Earth resistance: Less than 100 ohms

Common grounds:

Resistance to ground = 100 the number of

devices connected to the grounding (Ω)

Never ground equipment as shown in the

left side figure:

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1.4.4 Air supply

1) Use only clean and dry air, 6 kgf/cm².

2) Ensure the air source can supply the specified volume of air.

1.4.5 Lubrication

1) For first operation, press the feed-oil button to supply lubricating oil to the empty pipes.

Never hold down the feed-oil button more than 3 minutes.

2) Ensure that the gauge on the lubrication oil pump indicates the correct values.

3) After turning the power ON, ensure lubricating oil is supplied to the slideway surfaces,

ballscrews and gibs.

4) Use only fresh, uncontaminated lubricating oil of the type specified in the MAINTENANCE

Chapter.

1.4.6 Installation

1) Only a qualified technician should perform machine hoisting work using crane or forklift.

2) Use only wires, shackles and jigs of the dimensions specified in the manual. They must be

strong enough to support the weight of the machine.

3) Ensure the machine is well balanced in both the crosswise and lengthwise directions after

hoisting it a little above the floor.

4) When two or more people are involved in the hoisting work, they must cooperate carefully

and communicate as fully as possible.

5) Before hoisting the machine, ensure no tools, rags, etc., have been left inside it.

6) When moving the machine with a forklift, do not move the forklift while lifting the machine

to a high level.

7) Use a crane or forklift which can bear the weight of the machine.

WARNING

CAUTION

CAUTION

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8) When hoisting the machine, confirm the center of gravity of the machine.

9) Do not attempt to operate the machine before all of the installation instructions have been

completed.

1) If a rust-preventive is applied to the slideway surfaces, it must be removed completely.

2) Some parts of the machine are fixed in place with transit clamps when the machine is

shipped. Also eyebolts are used to hoist the machine. All clamps and eyebolts must be

removed before switching the power ON.

3) Before hoisting the machine, ensure all of its parts are clamped.

4) When moving the machine by using rollers, use only rollers, floor plates, and tread way

that are strong enough, both in material and number, to bear the weight of the machine.

5) When installing the machine, mount the coolant tank and the chip bucket by pushing them

into an appropriate position to prevent coolant from being splashed around the machine.

6) In order to maintain the accuracy and performance of the machine over a long period of

time, perform foundation work carefully and pay attention to machine installation.

7) Protect the NC unit, operating panel, etc. from electric shocks. If the machine receives an

electric shock, it could cause malfunction or damage to the machine.

1) After the machine has been installed, it must be leveled. If the adjustment of level is not

carried out properly, machining accuracy will be adversely affected.

NOTE

CAUTION

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1.4.7 Points to check before turning on the power for the first time

After completing machine installation, check the following points before turning ON the power

for the first time.

1) Check the voltage and sequence of phases L1, L2, and L3(R, S, T) of the input power

supply with a phase rotation indicator.

1) Ensure all bolts are tightened securely.

2) Ensure all connectors, hydraulic hoses and air pipes are connected securely.

3) If the machine is equipped with any optional external equipment (bar feeder, hydraulic

chuck, etc.), make sure that the electric cables and hydraulic/pneumatic pipes for these

equipments are connected correctly.

4) Select handle mode.

CAUTION

WARNING

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1.4.8 Points to check after turning on the power for the first time

1) To prevent seizure of the chuck and cylinder, repeat the chuck opening and closing

operations several times, ensure the jaws or workpiece holding fixture are securely

mounted. 2) Check oil leaks and ensure all gauges read the correct value.

1) Remove any clamps that could not be removed with the power OFF immediately after

turning the power ON and making sure that the “HANDLE” mode is selected and the chuck

is unclamped.

2) After turning the power ON, ensure the lubrication pump is operating normally. In order to

protect the sliding parts, never feed the axes immediately after turning the power ON;

manually operate the slideway surface first.

1.5 Safety Practices When Mounting/Removing a Chuck

1) The socket hole of the hexagonal socket cap bolts used for mounting chuck will become

enlarged over a long period of use. Check these bolts regularly and if a hexagonal wrench

does not fit in the socket hole, replace the bolt with new one.

2) The chuck must be secured to the spindle nose. Never clamp another chuck with the

chuck.

WARNING

CAUTION

WARNING

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1.6 Safety Practices When Chucking a Workpiece

The workpiece gripping capacity of a chuck is lowered as the gripping faces of the chuck jaws

become worn. Furthermore, the workpiece holding capacity of the chuck jaws is greatly

influenced by the nature of the workpiece. 1) Heavy workpieces with a large diameter apply a large force to the chuck jaws and the

force applied to the chuck jaws can exceed their workpiece holding capacity in some cases.

2) As the spindle speed increases, the forces acting on the workpiece to cause it to fly out of

the chuck will increase.

3) Improper maintenance, foreign particles, rusting, and inadequate greasing cause

reduction of the workpiece holding capacity of the chuck.

Finally, the machining method determines the exact force that will be applied to both the

workpiece and the chuck jaws, and whether this force exceeds the workpiece holding capacity

of the chuck jaws.

Therefore, review the workpiece holding capacity of the chuck each time the job changes or at

regular intervals if the same job is carried out continuously.

1) The allowable chucking pressure must be set to a value lower than the cylinder pressure

that generates the cylinder thrust allowance for the chuck, or the allowable cylinder

pressure, whichever is the lower.

2) Use only the specified bolts to mount the chuck and chuck jaws and tighten them to the

specified torque. Ensure the bolts are securely tightened regularly.

3) Take the height of the top jaw into consideration when determining the chucking pressure.

If the height is greater than the standard height, reduce the cylinder thrust.

4) When clamping or unclamping a workpiece in the chuck, ensure that your hands will not be

trapped by the workpiece, jaws, or tailstock (if featured).

5) When machining long workpieces, always hold the free end of the workpiece securely with

the tailstock (if featured) or a steady rest (if featured).

6) Before clamping a workpiece in the chuck, use a pressure gauge to ensure that the correct

hydraulic or pneumatic pressure is supplied to the cylinder which actuates chuck operation.

Low chucking pressures will reduce jaw-gripping force, which may allow the workpiece to

fly out of the chuck. Excessive high chucking pressure can damage the chuck, which could

WARNING

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cause a loss of jaw force.

7) The T-nuts in the chuck must not protrude from the master jaw. Otherwise, the master jaw

or T-nuts may be damaged, and machining accuracy will be impaired.

8) Mount jaws in the chuck in a well-balanced manner.

9) Various types of top jaws are used on chucks for different applications. For the best

holding conditions, using serrated contact surfaces on work gripping surfaces and using

the maximum area of contact between the jaws and the work piece.

10) Do not use top jaws with a serration of a different pitch from that of the master jaws.

Otherwise, the serration may be damaged when the workpiece is clamped in the chuck

due to insufficient length of the areas of engagement.

11) Do not use excessively heavy jaws. If the spindle is rotated with top jaws heavier than the

standard jaws, the loss of chuck gripping force due to centrifugal force will be larger than

the loss seen with standard chuck jaws.

12) Always use the T-nuts specified by the chuck manufacturer. If the bolts used to mount the

top jaws cannot be screwed a sufficient depth into the T-nuts, the T-nuts may break.

Conversely, if the bolts protrude past the bottom faces of the T-nuts, it will not be possible

to secure the top jaws by tightening the bolts.

13) Clamp workpieces at the center of the master jaws’ stroke or within their appropriate stroke

range.

14) Never leave the top jaws or T-nuts in the chuck after they have been loosened.

15) Lubricate the chuck every day with the specified grease. The gripping force of a power

chuck can be diminished as much as 50% because lack of lubrication or lack of periodic

cleaning. Components of the chuck are subject to wear and damage which also can

lessen gripping power. Use only the chuck manufacturer’s recommended lubricant.

16) Accumulation of chips inside the chuck reduces the gripping force and shortens the jaw

stroke. Clean out any chips accumulated inside the chuck.

17) Deburr soft jaws after shaping them. Switch off the power before starting the deburring

work.

18) Do not machine the counter bore depth of the soft jaw mounting bolts. This will weaken the

soft jaws. In addition, the mounting bolts will contact the bottom of the master jaw T groove,

making it impossible to hold the soft jaws securely.

19) After forming soft jaws, close the front door while a workpiece is gripped in the chuck, set

the spindle speed to the lowest setting, rotate the spindle in manual operation, gradually

increase the spindle speed to the maximum speed used in the program, and check

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whether the workpiece gripping conditions are appropriate: ensure the workpiece does not

come out of the chuck and no vibration is generated.

20) A regular inspection of jaw clamping force should be made by a force gauge to insure that

the chuck function well.

21) Use proper equipment to hoist heavy chucks, fixtures and workpieces.

22) The safety instructions applying to power chucks also apply to manual operated chucks.

Furthermore, the following precautions should be taken when using a manual chuck.

‐ Always use spring-loaded, self-ejecting type safety wrenches.

‐ Never put an extension bar on a chuck wrench or hit it with a hammer.

‐ Never run a gear scroll chuck with nothing chucked in the jaws. If the chuck is empty ,

centrifugal force could cause the scroll to unwind and the jaws could come out of the

chuck while the spindle is turning

23) If a workpiece is extended from the chuck a distance of 3 to 4 times its diameter without

being supported by the tailstock, poor cutting conditions will normally occur. Under any

circumstances, do not extend an unsupported work piece more than this amount without

supporting the workpiece with the tailstock. Doing so can cause the workpiece to bend or

break.

24) When using chuck or other clamping tools, do not exceed the maximum RPM or load.

25) In order to control the RPM of main axle, when programming, follow the below settings.

For FAGOR system, apply G50 to set maximum RPM. For safety precaution, set

appropriate maximum RPM before starting main spindle. 26) For processing, when reaching the maximum main spindle RPM, pay attention to the

following:

a. When chucking work, pay attention to leveling the work. To avoid using the maximum

clamping force, keep the work as leveled as possible.

b. Follow the operation manual for allowable maximum RPM and pressure of chuck.

Read and adhere to these rules. 27) Follow the standard for all chuck lubrication or screws. 28) If using larger than standard size chuck, pay attention to the following:

a. When using larger than standard size chuck, the center of gravity will be higher. This will decrease the clamping force, thus affect the main spindle performance. Therefore, the maximum allowable RPM must be below the RPM of using standard chuck.

b. The screws of chuck cannot extend outside of chuck. By using one screw to secure chuck will cause danger.

c. Use suitable chuck for the work.

Version: 005 P 1-20



1) When soft jaws are used, they must be made of a softer material than the workpiece to

prevent the workpiece from being distorted or scratched.

2) Do not modify the chuck unnecessarily since this will adversely affect accuracy and

functions and reduce the chuck service life.

3) When machining is carried out using a bar feeder or bar supporter, close the front door

while a workpiece is gripped in the chuck, set the spindle speed to the lowest setting,

rotate the spindle in manual operation, gradually increase the spindle speed to the

maximum speed used in the program, and check if any vibration is generated. If there is

any vibration, take the following measures to eliminate it.

‐ If bar materials to be machined is bent to an extent that exceeds the allowable range

specified by the bar feeder manufacturer, correct the bend.

‐ Change the maximum spindle speed used in the program to a speed that does not

cause vibration of the machine body or the bar feeder.

‐ Adjust the alignment of the machine and bar feeder.

‐ Ensure appropriate guide bushes are used in the spindle through-hole.

4) Never subject the chuck, chuck jaws, or workpiece to shock by tapping them with a

hammer, etc., since this will adversely affect accuracy and functions and reduce the chuck

service life.

5) When stopping the machine for a long time after switching the power off, always remove

the workpiece from a holding device. Otherwise the weight of workpiece will cause the

jaws of the chuck or fixture to open, or cause the tailstock spindle or body to retract if the

workpiece is held using the tailstock, and the workpiece will fall causing damage to the

machine.

CAUTION

Version: 005 P 1-21



1.7 Safety Practices during Machine Operation

1) Do not insert bar stock into the spindle while the spindle is rotating. The length of the bar

stock must be shorter than the spindle length unless a bar feeder or a rear chuck is used.

2) While the spindle is rotating, never open the front door to remove chips or touch the

workpiece or cutting tools.

3) Do not lean against the machine while it is operating.

4) Put the machine in manual mode and be sure that the last programmed function has been

completed before removing the machined workpiece and setting a new workpiece.

5) Never leave any objects on any moving part of the machine.

6) Some switches have transparent covers to prevent them from being pressed by mistake.

Keep these covers closed except when actually pressing the switches.

7) Always stop the machine before removing chips inside it during operation. Also stop the

machine and coolant supply before adjusting the direction or volume of coolant supply.

8) Before opening the front door to remove chips from inside the machine during machining

operation, make sure that the door interlock function is valid. Otherwise, it will be possible

to open the door while the machine is operating.

9) Be aware that the machine will start automatic operation if the cycle start switch is pressed

by mistake while the conditions required to start automatic operation are satisfied.

10) While the machine is temporarily stopped during machining, for example when checking a

program, performing test cutting, or cleaning chips out of the machine, do not feed the

axes or index the turret head in manual operation. Or, if it is absolutely necessary to do so,

be sure to return the axes and turret to their original positions before starting the program.

11) When leaving the machine temporarily after completing a job, be sure to turn off the power

switch on the operation panel and the main circuit breaker.

12) When moving heavy workpieces, two or more people should always work together and

cooperate carefully.

13) Before machining, be sure that the workpiece are securely gripped so that it can withstand

the centrifugal force from rotation and the cutting force of the tooling.

14) Always stop the machine before installing or removing a tool.

15) Wear a protective mask when machining magnesium alloy workpieces.

WARNING

Version: 005 P 1-22



1) Warm up the machine, especially the spindle and the feed shaft, for 10 to 20 minutes at

about half or one-third the maximum speed in the automatic operation mode. At the same

time, check whether all the machine components operate normally.

2) Be particularly careful to warm up the spindle. If the machine is used for machining

immediately after a long period of idle time, sliding parts could be worn due to lacks of oil

and thermal expansion of the machine components could adversely affect machine

accuracy.

3) Before starting mass production, always check the program and perform test cutting in the

single block mode.

4) When the EMERGENCY STOP button or reset key has been pressed to stop the machine

during a threading operation or a hole machining operation, especially tapping operation,

carefully feed the axes after checking the workpiece and cutting tool. If you feed the axes

without due care, the workpiece and cutting tool may collide or interfere with each other.

5) Return each machine component to its initial condition after completing a job.

6) Keep the chip conveyor (if featured) operating all the time during automatic operation.

7) Ensure no abnormal noise or vibration is generated during machine operation. If there is

any abnormal noise or vibration, determine the cause and take appropriate action.

8) If abnormal vibration or chattering is generated during machining due to improper

combination among jig, cutting tool, workpiece material, etc., change the machining

conditions to proper values.

9) The machine front door cannot be opened under automatic operation. Attempting to force

the door open in this situation could cause damage to the machine. 10) When carrying out heavy-duty machining, carefully prevent chips from being accumulated

since hot chips could lead to fire. 11) Communication must be set when two or more persons operate on the same machine.

CAUTION

Version: 005 P 1-23



1.8 Safety Practices during Maintenance and Inspection

1.8.1 Daily maintenance In order to keep the machine operating safely, it must be maintained and inspected daily.

Observe the following points when carrying out the maintenance and inspection work.

1) Always turn the power OFF before performing maintenance and inspection work. Or, if it is

absolutely necessary to carry out the work with the power ON, exercise due caution since

there is a danger of serious injury: you could receive an electric shock, be entangled by the

rotating parts of the machine, or crushed by its moving parts.

1) After finishing the work, always clean the machine so that abnormalities can be found

easily and inspect each part. If you find an abnormality, take appropriate action

immediately.

2) Always clean the machine after it has been stopped.

3) After dry machining or machining of cast workpieces, clean the machine so that chips do

not accumulate. Do not remove chips with compressed air inside the cutting area.

Otherwise the chips will adhere onto the inside of machine and cause damage.

4) Make sure that the gauges on the oil cooler, lubrication oil pump, hydraulic equipment,

pneumatic equipment, etc., indicate the correct values.

5) Make sure that lubricating oil is supplied to the slideways properly.

6) Drain the air filter. If too much water builds up in the filter, its performance will be impaired,

pneumatic equipment will operate incorrectly, and machine faults may be caused. (Applies

only to machines equipped with pneumatic equipment.)

7) Turret must return to home position after completion of work.

CAUTION

DANGER

Version: 005 P 1-24



1.8.2 Precautions when performing maintenance and inspection work

1) Electrical wiring work should only be done by qualified electrical engineers.

2) Always switch the power OFF before mounting, removing, inspecting, or lubricating the

chuck.

3) Before attempting maintenance and inspection inside the electrical cabinet, be sure to turn

OFF the power at the circuit breaker for the entire plant. Even when the main power switch

on the electrical cabinet is turned OFF, parts of the cabinet may still have potential and

may give an electric shock if accidentally touched. If it is necessary to conduct

maintenance with the power being supplied, confirm the state of power supply by checking

the electric wiring diagram and exercise extreme caution.

4) Those not engaged in the maintenance work should not operate the main circuit breaker or

the power supply switch on the operating panel. For this purpose, “Do not touch the switch,

maintenance operation in progress” or similar signs should be placed on such switches

and at any other appropriate locations. These indications should be secured by a

semi-permanent means in the reading direction.

1) Do not climb on top of the machine. Coolant or oils can make surfaces on the machine

slippery. They can also present an electrical hazard if the machine has power on.

2) Periodically disassemble and clean the chuck. Apply grease to the chuck every day. If

chips or coolant enter the chuck, or if the grease runs out, the chuck gripping force will be

reduced.

3) Periodically clean the fan and filter in the electrical cabinet. If foreign particles adheres to

the fan and filter, it will impair the cooling performance and this will cause machine

malfunctions.

4) Use only genuine parts specified by MACHINE MANUFACTURER as replacement parts.

Using unspecified parts will not only impair the performance of the machine and it will also

make the machine less safe.

5) Bolts used for fixtures should be regularly replaced once a year. If the same bolts are used

without replacement, the bolts could break, causing the workpiece, fixture, or cutting tool

to fly out during machining.

WARNING

DANGER

Version: 005 P 1-25



6) When mounting or removing the chuck, use eye bolts and a lifting belt, and lift the chuck

using a crane. After mounting or removing the chuck, be sure to remove the eye bolts and

lifting belt from the chuck.

7) If it is necessary to carry out work inside the machine for cleaning or maintenance, turn

OFF the power and keep the door open while working. If the operator is in the machine

and the door is closed, the door will be mechanically locked and cannot be manually

opened from inside the machine.

8) Over-travel limit, proximity switches, and interlock mechanisms including functional parts

should not be removed or modified.

9) When working at a high place, use ladders which are maintained daily.

10) Be careful not to get your fingers caught between the belt and the pulley when checking or

adjusting belt tensions.

11) The electric components are protected from normal moisture resulting from using of water

base soluble, such as coolant, etc. Do not, however, use water hose to clean the machine

or the area around it.

12) Do not remove chips with compressed air inside the cutting area. Otherwise the chips will

adhere onto the inside of machine and cause damage.

1) Do not overtighten bolts, since this could distort the machine or break the bolts, cause

damage to the machine.

2) The drain provided in the spindle front cover to keep coolant from entering the spindle

bearings must be kept clean and unblocked by foreign particles. When cleaning the

machine, do not use compressed air. If the drain is allowed to become blocked or if

compressed air is used when cleaning, coolant will enter the spindle bearings.

3) When a hollow chuck is used, a coolant drain is provided in the cylinder portion at the rear

of the spindle. This drain must be periodically cleaned to prevent blockage by chips.

4) The solenoid valves become very hot when the machine is operating. Be careful not to

touch them soon after machine operation has finished since they could burn you.

5) Supply or change hydraulic oil and lubricating oil and clean the filters at the intervals

specified in the MAINTENANCE Chapter.

6) Use only fresh, uncontaminated lubricating oil and hydraulic oil of the types specified in the

MAINTENANCE Chapter.

7) Periodically clean the tanks and filters of all equipment and inspect the equipment and its

CAUTION

Version: 005 P 1-26



piping for damage.

8) Do not open the doors of the electrical cabinet or the operation panel expect for

maintenance and inspection purpose since it will allow dust and moisture to enter. Once

the machine is installed, the control cabinet must be locked and the key available only to

qualified service personnel.

9) Regularly inspect the slide protection seals and oil seals and replace them before their

sealing characteristics are lost.

10) Always wait some time before touching the lamp illuminating the interior of the machine

after turning the power OFF since it would be very hot and will burn you.

11) Carry out daily inspections and regular inspections in according with the Instructions in the

MAINTENANCE Chapter.

12) On completing a job, clean the chuck and the inside of the machine. If chips are allowed to

accumulate in the machine over long periods, it will cause machine faults.

13) Make sure that the draw bar between the chuck and cylinder, and other thread parts, are

tightened securely. If the draw bar is not secure enough it will lead to vibration and strength

defects.

14) Consumable parts (packing, oil seals, O-rings, bearings, oil and grease, etc.) for

replacement should be available in advance.

15) Maintenance and inspection data should be recorded and kept for reference.

16) When cleaning the machine, always use a soft brush or sweeper to remove chips. Do not

use compressed air to clean the machine.

17) The fuses for replacement should have proper current rating.

18) Sent any loose, worn or broken parts to your supervisor. The same action should be taken

if any unusual noise or machine action occurs.

Version: 005 P 1-27



1.9 Warning plates on the machine

Safety-related information shown on warning plate must be strictly observed by operators.

These warning plates are attached to the machine.

WARNING ATTENTION!

Vor dem Oeffnen des Deckels den Hauptschalterausschalten.

WARNINGHigh speed belt and pulley inside.

Do not touch belt or pulley wheel whilstBefore take off the cover,turn off the power.

Failure to follow the warning can result in severe injury.

machine running.

fonctionnement de la machine.Ne pas respecter ces consignes peut entrainer degraves lesions.

ATTENTION!Renferme des poulies et courroies pouvant tourner

Ne pas toucher les poulies et courroies pendant le

Avant l'ouverture, couper le puissance sur la

Nichtbeachtung kann zu ernsthaften.

machine.

a haute vitesse.

Verletzungen fuehren.

Do not extend or exposebarstock form rear of

The extended bar stcker from rear of spindle

Failure to follow the warning may result inwill be swinged to a broadish range.

severe injury.

proper bar feeder.

ATTENZIONE

ACHTUNG

ALL' INTERNO CINGHIE E PULEGGE AD ALTA

TOLTO L'ALIMENTAZIONE ELETTRICA ESTERNA.

Freilaufender Keilriemen und Keilriemenscheibe.

COPERTURA PER EFFETTUARE INTERVENTIVELOCITA'! PRIMA DI TOGLIERE QUESTA

ALLA MACCHINA ASSICURARSI DI AVER

ESTERNA.

La barre depassant a l'arriere de la broche peut

Ne pas respecter ces consignes peut entrainer de fouetter sur un diametre important.

broche sans utiliser un avance barre approprie.Ne pas faire depasser une barre a l'arriere de la

graves lesions.

Ueberstehendes Werkstueck kann zu ernsthaftenStangenvorschub ueberstehen lassen.Spindelrueckseite nicht ohne passenden

ACHTUNG


Werkstueck auf der .

E' SEVERAMENTE VIETATO LAVORARE

AL MANDRINO E NON ADEGUATAMENTE PROTETTE . IL MANCATO RISPETTO DIQUESTO AVVERTIMENTO PUO' CAUSARE

BARRE CHE SPORGANO POSTERIORMENTE

ATTENZIONE

GRAVE PERICOLO.

LE FONCTIONNEMENTFailure to follow a warningcan result in severe injury.

ENTRAINER DE GRAVES LESIONS

NE PAS RESPECTER CET AVERTISSEMENT PEUT

DO NOT put your hand intothe convryor during runing.

WARNING

ACHTUNG

NE PAS INTRODUIRE LA MAINDANS LE CONVOYEUR PENDANT

ATTENTION!

Hande weg vom

Nichtbeachtung kann ernsteVerletzungen verursachen

Laufenden spaneforderer... ..

CONVOGLIATORE DVRANTE IL

CAVSARE GRAVE INFORTUNiOIL NON RISPETTO DELL' INDiCAZiONE PVO

NON METTERE LA MANO NET

ATTEZIONE

FUNZIONAMENTO

..

Programmable Tailstock

HYDRAULIC DIAGRAM

Rteady Rest

Tailstock QuillTurret OrientationTurret Rotating

Chuck

Pneumatic Diagram

WARNING ATTENTION!Please clean chip to avoid unnecessarydamage to machine.

Nettoyer et enlever les copeaux afin d'eviter toutdommage a la machine.

ACHTUNGSchaden an der Maschine zu vermeiden.Bitte immer Spaene entfernen um unnoetigen

per garantire il suo buon funzionamento.Rimuovere regolarmente i trucioli dalla macchina

ATTENZIONE13

14

1

2

3

9

10

11

4

6

5

12

N OTE : Machine w eight can change accor ding to the option required.

CONTENUTO DEL MANUALE DI ISTRUZIONE E DELLE TARGHE DI SICUREZZA.

3.NON TENTARE DI AVVICINARSI AGLI ORGANI IN MOTO PRIMA CHE SI SIANO

6.NON MODIFICARE I PARAMETRI DEL TORNIO SENZA AVER PRIMA CONSULTATO

ADEGUATO, SENZA VESTITI PENDENTI, NE' CATENINE , BRACCIALI ECC. E DEVE

9. NON LAVORARE BARRE CHE SPORGANO POSTERIORMENTE DAL MANDRINO, SE

7.CHI OPERA CON QUESTA MACCHINA DEVE INDOSSARE ABBIGLIAMENTO

ESSERE PROVVISTO DI SCARPE ,GUANTI ED OCCHIALI ANTINFORTUNISTICI.8.LA MANUTENZIONE VA FATTA A MACCHINA SPENTA E SOLO DA PERSONALE QUALIFICATO ED ISTRUITO, IN ACCORDO AL MANUALE DI MANUTENZIONE

5.NON RIMUOVERE O DETERIORARE I DISPOSITIVI E LE PROTEZIONI DI SICUREZZA.

DEL COSTRUTTORE.

QUESTE NON SONO ADEGUATAMENTE PROTETTE.

COMPLETAMENTE FERMATI.

QUALIFICATI ED ADEGUATAMENTE ADDESTRATI.

L'ASSISTENZA TECNICA AUTORIZZATA.

4.NON APRIRE PORTE O SPORTELLI CON LA MACCHINA IN MOTO.

ISTRUZIONI PER LA SICUREZZA1.PRIMA DI OPERARE CON LA MACCHINA, LEGGERE E COMPRENDERE IL

2.QUESTA MACCHINA VA UTILIZZATA ESCLUSIVAMENTE DA OPERATORI

SAFETY INSTRUCTION

utilize the machine.

HzDATE :

KVAPOWER :

VOLTAGE :RATED

PHASES :

NUMBER OF

NOTE: Machine weight can change according to the option required.

SHORT CIRCUIT :

LARGEST LOAD

....+PE

V

KgsCURRENT :

PROTECT

CURRENT :

FULL LOAD

A

KA

A

MODEL :

MANUFACTURING

56.Lane 318, Der Sheng Road, Ta Ya, Taichung County, Taiwan R.O.C.TEL:886−4−25603759 FAX:886−4−25603769

7

8

Version: 005 P 1-28



1)

Item Part no. Description Q'ty Remark

1

L-5106-00231 Warning Signs Plate 1

English Italian Germany French


Spanish Danish Turkish Finnish


Russian Norwegian Czech Portuguese

AL MANDRINO E NON ADEGUATAMENTE


graves lesions.

fouetter sur un diametre important.La barre depassant a l'arriere de la broche peut broche sans utiliser un avance barre approprie.

Ne pas respecter ces consignes peut entrainer de

Ne pas faire depasser une barre a l'arriere de la

ACHTUNGWerkstueck auf der .

Stangenvorschub ueberstehen lassen.Spindelrueckseite nicht ohne passenden

PROTETTE . IL MANCATO RISPETTO DIQUESTO AVVERTIMENTO PUO' CAUSAREGRAVE PERICOLO.

proper bar feeder.

severe injury.

will be swinged to a broadish range.Failure to follow the warning may result in

Do not extend or exposebarstock form rear of

The extended bar stcker from rear of spindle

WARNING

Ueberstehendes Werkstueck kann zu ernsthaften

ATTENTION!

ATTENZIONEE' SEVERAMENTE VIETATO LAVORARE BARRE CHE SPORGANO POSTERIORMENTE

Version: 005 P 1-29



2)


2







ACHTUNG

Avant l'ouverture, couper le puissance sur la

fonctionnement de la machine.

machine.

graves lesions.

a haute vitesse.Renferme des poulies et courroies pouvant tourner

Ne pas toucher les poulies et courroies pendant le


ATTENTION!

Nichtbeachtung kann zu ernsthaften.ausschalten.


Freilaufender Keilriemen und Keilriemenscheibe.Vor dem Oeffnen des Deckels den Hauptschalter

machine running.

severe injury.

High speed belt and pulley inside.

Do not touch belt or pulley wheel whilstBefore take off the cover,turn off the power.

Failure to follow the warning can result in

WARNING

VELOCITA'! PRIMA DI TOGLIERE QUESTA

ALLA MACCHINA ASSICURARSI DI AVER

ESTERNA.

ALL' INTERNO CINGHIE E PULEGGE AD ALTA

TOLTO L'ALIMENTAZIONE ELETTRICA ESTERNA.

COPERTURA PER EFFETTUARE INTERVENTI

ATTENZIONE

Version: 005 P 1-30



3)


3







ATTENTION!dommage a la machine.Nettoyer et enlever les copeaux afin d'eviter tout

damage to machine.Please clean chip to avoid unnecessary

WARNING

ACHTUNG

ATTENZIONE

Schaden an der Maschine zu vermeiden.Bitte immer Spaene entfernen um unnoetigen

per garantire il suo buon funzionamento.Rimuovere regolarmente i trucioli dalla macchina

Version: 005 P 1-31



4)


4

L-5106-00271 Warning Signs Plate 1 English L-5106-00272 Warning Signs Plate 1 Italian L-5106-00273 Warning Signs Plate 1 Germany L-5106-00274 Warning Signs Plate 1 French L-5106-00275 Warning Signs Plate 1 Spanish L-5106-00276 Warning Signs Plate 1 Danish L-5106-00277 Warning Signs Plate 1 Turkish L-5106-00278 Warning Signs Plate 1 Finnish L-5106-00279 Warning Signs Plate 1 Russian L-5106-00280 Warning Signs Plate 1 Norwegian L-5106-00281 Warning Signs Plate 1 Czech L-5106-00282 Warning Signs Plate 1 Portuguese

ONLY FOR TECHNICIAN

WARNING

ELECTRICAPPLIANCE KEEP POWER ON MAINTENANCE KEY

Version: 005 P 1-32



5)


5

L-5106-00291 Warning Signs Plate 1 English L-5106-00292 Warning Signs Plate 1 Italian L-5106-00293 Warning Signs Plate 1 Germany L-5106-00294 Warning Signs Plate 1 French L-5106-00295 Warning Signs Plate 1 Spanish L-5106-00296 Warning Signs Plate 1 Danish L-5106-00297 Warning Signs Plate 1 Turkish L-5106-00298 Warning Signs Plate 1 Finnish L-5106-00299 Warning Signs Plate 1 Russian L-5106-00300 Warning Signs Plate 1 Norwegian L-5106-00301 Warning Signs Plate 1 Czech L-5106-00302 Warning Signs Plate 1 Portuguese

ELECTRICAPPLIANCE POWER ON

Version: 005 P 1-33



6)


6







injury or death.Turn off power before servicing.

Hazardous voltage will cause severe

ACHTUNG

ATTEZIONE

ATTENTION!WARNING

PERSONALE AUTORIZZATO E QUALIFICATO.ED E CONSENTITO ESCLUSIVAMENTE APERMESSO SOLO A MACCHINA SPENTAL'ACCESSO ALL'ARMADIO ELETTRICO EPERICOLO DI FOLGORAZIONE ELETTRICA!

Hochspannung.Vor dem Oeffnen der Tuere hauptschalterausschalten.

Le courant electrique peut entralner degraves lesions ou deces.Couper l'alimentation avant touteintervention.

Version: 005 P 1-34



7)


7

L-5106-00101 Warning Signs Plate 1 English Italian

L-5106-00102 Warning Signs Plate 1 Germany French

L-5106-00103 Warning Signs Plate 1 Spanish Danish

L-5106-00104 Warning Signs Plate 1 Turkish Finnish

L-5106-00105 Warning Signs Plate 1 Russian Norwegian

L-5106-00105 Warning Signs Plate 1 Czech Portuguese

8.LA MANUTENZIONE VA FATTA A MACCHINA SPENTA E SOLO DA PERSONALE

DEL COSTRUTTORE. QUALIFICATO ED ISTRUITO, IN ACCORDO AL MANUALE DI MANUTENZIONE

9. NON LAVORARE BARRE CHE SPORGANO POSTERIORMENTE DAL MANDRINO, SE QUESTE NON SONO ADEGUATAMENTE PROTETTE.

utilize the machine.

L'ASSISTENZA TECNICA AUTORIZZATA.

COMPLETAMENTE FERMATI.

QUALIFICATI ED ADEGUATAMENTE ADDESTRATI.

ISTRUZIONI PER LA SICUREZZA1.PRIMA DI OPERARE CON LA MACCHINA, LEGGERE E COMPRENDERE IL CONTENUTO DEL MANUALE DI ISTRUZIONE E DELLE TARGHE DI SICUREZZA.2.QUESTA MACCHINA VA UTILIZZATA ESCLUSIVAMENTE DA OPERATORI

3.NON TENTARE DI AVVICINARSI AGLI ORGANI IN MOTO PRIMA CHE SI SIANO

4.NON APRIRE PORTE O SPORTELLI CON LA MACCHINA IN MOTO.5.NON RIMUOVERE O DETERIORARE I DISPOSITIVI E LE PROTEZIONI DI SICUREZZA.6.NON MODIFICARE I PARAMETRI DEL TORNIO SENZA AVER PRIMA CONSULTATO

7.CHI OPERA CON QUESTA MACCHINA DEVE INDOSSARE ABBIGLIAMENTO ADEGUATO, SENZA VESTITI PENDENTI, NE' CATENINE , BRACCIALI ECC. E DEVE ESSERE PROVVISTO DI SCARPE ,GUANTI ED OCCHIALI ANTINFORTUNISTICI.

SAFETY INSTRUCTION

Version: 005 P 1-35



8)


8

L-5112-00011 Machine Plate 1 English (Without Microcut logo)

L-5112-00012 Machine Plate 1 English (With Microcut logo)

L-5112-00051 Machine Plate 1

English (Without Microcut / With customer & circuit data)

HzDATE :

KVAPOWER :

VOLTAGE :RATED

PHASES :

NUMBER OF


SHORT CIRCUIT :

LARGEST LOAD

....+PE

V

KgsCURRENT :

PROTECT

CURRENT :

FULL LOAD

A

KA

A

MODEL :

MANUFACTURING

56.Lane 318, Der Sheng Road, Ta Ya, Taichung County, Taiwan R.O.C.TEL:886−4−25603759 FAX:886−4−25603769

56.Lane 318, Der Sheng Road, Ta Ya, Taichung County, Taiwan R.O.C.

TEL:886−4−25603759 FAX:886−4−25603769


POWER :

MODEL :

RATED

PHASES :NUMBER OF

VOLTAGE :V

....+PE

KVA

KgsCURRENT :

PROTECT

LARGEST LOAD

FULL LOAD

SHORT CIRCUIT :

CURRENT :

MANUFACTURING

DATE :

A

KA

A

Hz

Version: 005 P 1-36



9)


9







etre ejectes.

Nichtbeachtung kann zu ernsthaften

GARDER LA PORTE FERMEE pendant les

S"assurer du verrouillage de la porte.

Les pieces, mors de mandrin ou copeaux

operations automatiques ou les rotations broche.


Wekstueck, Spannbacken oder Spaene

TUERE GESCHLOSSEN HALTEN waehrendHauptspindellauf oder automatischem Arbeiten.Verriegelung schliessen.


graves lesions ou deces.

koennen herausfliegen.

provocare grave pericolo.II mancato rispetto di questo avvertimen pvo'il portellone anteriore sia chiuso.Prima di fare operare la macchina,accertarsi che

WARNING

Ensure Door Interlock On.

KEEP DOOR CLOSED during:

injury or death

Work piece, chuck jaw or chip may fly out.

Automatic Operation Or Spindle Rotating.

Failure to follow warning can result in severe

ATTENTION!

ACHTUNG

ATTENZIONE

Version: 005 P 1-37



10)


10







ACHTUNGzu sich bewegenden Teilen halten.

kann zu ernsthaften Verletzungen Nichtbeachtung olicser warnung

MANI O ALTRE PARTI DEL CORPO, ORGANI

PUO' PROVOCARE GRAVE PERICOLO.

IN MOVIMENTO. IL MANCATO RISPETTO DI OUESTO AVVERTIMENTO

Ne pas s'approcher des pieces modiles

Ne pas respecter ces consignes peutentrainer de graves lesions.

pendant leurs deplacements.

NON TENTARE DI RAGGIUNGERE CON LE

Waehrend des Betriebes Abstand

WARNING

fuehren.

can result in severe injury.Failure to follow the warningduring operation.Do not approach moving parts

ATTENTION!

ATTEZIONE

Version: 005 P 1-38



11)


11







le macchine di acqua.

Reinigung des Fensters

2.Nochmals spuelen. Um Wasserflecken zu vermeiden, mit Hilfe eines weichen Tuchs oder saugfaehigem

Reinigungsbenzin oder Isopropanol-Alkohol einreiben und dann abwaschen und spulen. 3.Um nasse Farbe, Silikonrueckstaende oder Fett zu entfernen, leicht mit einem hochwertigen

chiffon doux ou une eponge. NE PAS frotter, ne pas utiliser de brosse ou racloir.

3.Pour retirer de la peinture fraiche, du verni ou de la graisse, frotter legerement avec un bon degre d'huile

2.Rincer a nouveau. Secher avec un chiffon doux ou une eponge humide en cellulose pour eviter les

1.Rincer a l'eau tiede, laver doucement avec du savon ou du detergent doux et eau tiede, en utilisant un

de naphte VP et P ou de l'alcool isopropyl puis laver et rincer. Ne pas utiliser d'essence.

3.Per rimuovere vernice fresca, composti o grasso, grattare leggermene con nafta con un buon grado

1.Abspuelen der Oberflaeche mit handwarmem Wasser und dann sanft, mit milder Seife oder Reinigungsmittel abwaschen. Dabei ein weiches Tuch oder einen Schwamm einsetzen.BITTE NICHT

Nettoyage fenetre

di VM&P o alcohol, dopodiche lavare e risciacquare. NON utilizzare benzina.

Papier trockenreiben.

BITTE KEIN Autobenzin benutzen.

marques d'eau.

scheuern oder Buersten benutzen.

..

1.Rinse sheet with lukewarm water ; wash gently with mild soap or detergent and lukewarm water , using

3.To remove wet paint , glazing compound or grease, rub lightly with a good grade of VM&P naphtha or

1.Sciacquare con aqua tiepida ; lavare con sapone o detergente delicato e acqua utilizzando un panno

2.Risciacquare di nuovo. Asciugare con un panno morbido o una spugna di mista cellulosa per eliminare

PULIZIA FINESTRA

a soft cloth or sponge . DO NOT SCRUB or use brushes or squeegees.

morbido o spugna. NON strofinare, ne utilizzare spazzole o raschiatori .

isopropyl alcohol, then wash and rinse. DO NOT USE GASOLINE.

CLEANING WINDOW2.Rinse again. Dry with soft cloth or moist cellulose sponge to prevent water spotting.

Version: 005 P 1-39



12)


12







NON METTERE LA MANO NET..

Laufenden spaneforderer.

Nichtbeachtung kann ernste

Hande weg vom

ENTRAINER DE GRAVES LESIONS

LE FONCTIONNEMENT

NE PAS INTRODUIRE LA MAINDANS LE CONVOYEUR PENDANT

AVERTISSEMENT PEUTNE PAS RESPECTER CET

FUNZIONAMENTOCONVOGLIATORE DVRANTE IL

CAVSARE GRAVE INFORTUNiOIL NON RISPETTO DELL' INDiCAZiONE PVO

ATTENTION!

Verletzungen verursachen

WARNINGthe convryor during runing.DO NOT put your hand into

can result in severe injury.Failure to follow a warning

..

ACHTUNG..

ATTEZIONE

Version: 005 P 1-40



13)

Item Part no. Description Q'ty Remark 13 E-ARAK-75231-01 Pneumatic diagram plate 1 English

Pneumatic Diagram

Version: 005 P 1-41



14)

Item Part no. Description Q'ty Remark 14 E-ARAK-75241-01 Hydraulic diagram plate 1 English

HYDRAULIC DIAGRAMSauter Turret

Rteady Rest

P T

M

p

T

A

B

a

Programmable Tailstock

Pneumatic Diagram : ARAK-J-0022

Pressure required : 35 kg/cm

p

T

A

B

a

p

T

A

B

a

英E-ARAK-75241-01p

T

A

B

a

Tailstock QuillTurret OrientationTurret Rotating

Chuck C-Axis

OM

Version: 005 P 1-42



1.10 Risk List and Solution

1.10.1 Dangerous Zone of Spindle Transmission Area

Dangerous Item 1 Rolling in When risk happen? The side cover is opened when this area is repaired or

cleaned. Risk conditions: After the machine is repaired, the operator tests running.

When the operator adjusts the belt, his finger or his sleeve with one arm is rolled in due to carelessness, and it causes a wound of cutting off.

Risk Solution 1. Install a magnetic interlock switch on the side door. When the door is opened for repair, the power will be cut off automatically. 2. Stick a warning label inside the door.

Dangerous Item 2 Motor falling down When risk happen? When the spindle motor is out of order, the motor needs to be

lifted up or down for repair. The motor might fall down. Risk conditions: a. When we repair the motor, we need to dismount the motor.

When we install the repaired motor, we need to move the motor into the machine. However, the lifter or the hanger cannot reach the inside. The motor is moved in manually. If the motor is not fastened, it might fall down, and cause the danger of hurting hands or feet.

Risk Solution Clearly describe the moving method of the spindle motor in the operating instructions.

Version: 005 P 1-43



1.10.2 Dangerous Zone of Chuck Area

Dangerous Item 1 Collision When risk happen? During operation or repair Risk conditions: If the work piece is not clamped properly, or the jaws of the

chuck lose tension, the work piece will spring out in the tangent direction when the spindle is turning. If the operator or the cleaning people within the spring-out area, he might be hit.

Risk Solution 1. Install a magnetic interlock switch on the front guard door. During the processing, the front guard door cannot be opened.2. When the front guard door is opened, the spindle will not turn. 3. Install a check valve on the cylinder of the hydraulic chuck so that the jaws of the chuck will not open when the power breaks off. 4. Stick a warning label on the front guard door.

Dangerous Item 2 Cut wound When risk happen? The machine is repaired or cleaned. Risk conditions: The soft jaws have sharp edges after finishing.

The operator might be cut due to carelessness when he install, dismount or clean the chuck.

Risk Solution 1. Install a magnetic interlock switch on the front guard door. The door cannot be opened when the work piece is under processing. 2. Stick a warning label on the front guard door. 3. Add the items to be noticed in the operating instructions.

Dangerous Item 3 Falling down or loose When risk happen? During operation or repair Risk conditions: The sliding type protective guard will become loose or fall

down under outside impact. When the guard is dismounted for repair, it might fall down due to carelessness, and hit people’s foot.

Risk Solution Add the transportation method and the items to be noticed in the operating instructions.

Version: 005 P 1-44



1.10.3 Dangerous Zone of Turret Turning Area

Dangerous Item 1 Crush When risk happen? During operation or repair Risk conditions: 1.When the operator mounts or dismounts the work piece, and

if the turret turns by error operation, the operator’s hands or fingers might be crushed, or even seriously crushed to cause broken bones. 2. When the turret is moving toward the work piece at high speed, if operator’s hands are between them, it will cause crush wound. 3. When the operator measures the work piece, if the turret turns by error operation, the operator’s hands or fingers might be crushed. If it is serious, the bones might be broken.

Risk Solution 1. Add the transportation method and the items to be noticed in the operating & Maintenance Manual.

2.Stick a warning label on the front side of the turret

Version: 005 P 1-45



1.10.4 Dangerous Zone of Tail Stock Area

Dangerous Item 1 Crush When risk happen? During operation or repair Risk conditions: When the operator mounts or dismounts the work piece, if the

tailstock turns by error operation, the hands or the fingers might be crushed. If the situation is serious, the bones might be broken.

Risk Solution 1. Add the items to be noticed in the operating & Maintenance Manual. 2. Stick a warning label on the front side of the hydraulic tailstock.

Dangerous Item 2 Sticking wound When risk happen? During operation or maintenance (cleaning) Risk conditions: If the center is in the tailstock, the operator might be stuck and

cause sticking wound during the operation or repair, because of the carelessness.

Risk Solution 1Add the items to be noticed in the operating & Maintenance Manual. 2. Stick a warning label on the front side of the hydraulic tailstock.

Version: 005 P 1-46



1.10.5 Dangerous Zone of Electric Control Box Area

Dangerous Item 1 Clipping wound When risk happen? During operation or maintenance Risk conditions: During the process of repair, adjustment, cleaning, or

announcement of invalid parts, the door of the electric control box must be opened or closed. If the operator is careless, his hand or finger(s) might be clipped, and is (are) wounded.

Risk Solution Add the items to be noticed in the operating & Maintenance Manual.

Dangerous Item 2 Cut wound When risk happen? During operation or maintenance Risk conditions: 1. There are rhombic edges and sharp edges on the electric

control box and box door. During the process of repair, adjustment, cleaning or the announcement of invalid parts, the hands might be cut due to carelessness. 2. There are rhombic edges and sharp edges on the main circuit and sub circuit. During the process of repair, adjustment or cleaning, the hands might be cut due to carelessness.

Risk Solution Add the items to be noticed in the operating & Maintenance Manual


2 SPECIFICATIONS

Version: 005 P 2-1



2 SPECIFICATION ........................................................................................... 2

2.1. MACHINE DESCRIPTION ............................................................................. 2

2.1.1. Main parts of machine ....................................................................................... 2

2.1.2. Movable part ...................................................................................................... 3

2.1.3. Location of safety devices ................................................................................. 4

2.2. SPECIFICATIONS ........................................................................................ 5

2.2.1. Machine specifications ...................................................................................... 5

2.2.2. Power turret specifications ................................................................................ 7

2.2.3. Hydraulic turret specifications ............................................................................ 8

2.3. SPINDLE POWER & TORQUE DIAGRAM ........................................................ 9

2.4. GENERAL LAYOUT ................................................................................... 14

2.5. OUTLINE OF SYSTEMS ............................................................................. 15

2.5.1. Lubrication system ........................................................................................... 15

2.5.2. Hydraulic system ............................................................................................. 17

2.5.3. Coolant system ................................................................................................ 22

2.5.4. Tooling system ................................................................................................ 22

2.5.5. Pneumatic system ........................................................................................... 49

2.5.6. CTS ................................................................................................................. 51

Version: 005 P 2-2



2 SPECIFICATION

2.1. Machine Description

2.1.1. Main parts of machine

1. Ac Spindle Motor 6. Tail Stock 11. Ac Y Axis Motor

2. Headstock 7. Chip Conveyor 12. Electrical Cabinet

3. Hydraulic Chuck 8. Operation 13. Lube Tank

4. Safety Door 9. Ac X Axis Motor 14. Hydraulic Unit

5. Turret Turning 10. Oiler

Version: 005 P 2-3



2.1.2. Movable part

1. door 4. Turret index 7. Z-axis

2. Chip conveyor (opt.) 5. X-axis 8. Turret

3. Main spindle 6. Tailstock 9. Chuck jaws

Version: 005 P 2-4



2.1.3. Location of safety devices

1. Chuck sensor 4. Safety switch 7. Alarm lamp 10. X-axis limit switch

2. Safety door 5. Emergency stop 8. Z-axis limit switch

3. Interlock switch 6. Chip stop switch (opt.) 9. Spindle encoder

Version: 005 P 2-5



2.2. Specifications

2.2.1. Machine specifications

Description Unit LT-42 LT-52 LT-65 Capacity

Swing over bed mm 500

Swing over cross slide mm 220 Max. turning length (with turret)

mm 460

Max. turning diameter (with turret)

mm 210

Slant bed degree 30 Bar capacity (hyd. chuck cylinder)

mm 42(A2-5) 52(A2-6) 65(A2-6)

Travel

X axis mm 215

Z axis mm 520

Spindle

Transmission belt

Spindle speed rpm 6000 5000 4000

Suitable chuck size (option) mm 169 210 215

Spindle nose A2-5/A2-6

Spindle hole diameter mm 52 62 75

Motor output KW

Fagor: 7.5/11 Fanuc: 11/15

Siemens: 12/16(802D) Siemens: 12/15(828D)

Fagor: 11/15 Fanuc: 11/15

Siemens:12/16(802D)Siemens:12/15(828D)

Feedrate

X axis rapid traverse m/min. 30

Z axis rapid traverse m/min. 30

Accuracy

Positioning mm ±0.005/300

Repeatability mm ±0.005

Feed motors X axis power NM Fagor: 11.6, Fanuc: 11, Siemens: 11 Z axis power NM Fagor: 11.6, Fanuc: 11, Siemens: 11

Ballscrew

X axis ballscrew mm ψ32X P10X C3

X axis transmission direct

Z axis ballscrew mm ψ32X P10X C3

Z axis transmission direct

Version: 005 P 2-6



Guide way

X axis guide way type Box way

Z axis guide way type Box way

Turret (option)

Number of tool stations 12/8

Boring bar dia. mm ψ32 (VDI-30) / ψ40 (VDI-40)

Live tooling (option)

Number of tool stations Mm 12(VDI-30)/8(VDI-40)

Power rating KW 3.75

Maximum speed rpm 4000

Tailstock

Movement Manual

Quill movement Hydraulic

Tailstock travel mm 370

Quill travel mm 50

Quill diameter mm 65

Quill inside taper MT 4

Coolant

Pump capacity L/min. 530(50Hz)/750(60Hz)

Max. pump flow L/min 58(50Hz)/66(60Hz) Max. pump pressure kg/cm² 10 Tank capacity L 140 Lubrication Distributor type Pressure released

Pump motor w 12

Pump capacity cc/min. 130

Pump pressure Kg/cm2 15

Hydraulic

Hyd. pump motor W 1500

Dimension

Weight kg 3200

Length (w/o chip conveyor) mm 2530

Length (with chip conveyor) mm 3330

Width mm 1821

Height mm 1930

Total power consumption KVA Fagor: 20 Fanuc: 25

Siemens: 20

Version: 005 P 2-7



2.2.2. Power turret specifications

TBMA

Turret size 120 160 200 250

Tool holder size Mm 20 30 40 50

Max. power KW 4 5 9 12

Max. torque Nm 15 20 50 55

Max. speed at the spindle rpm 6000 6000 5000 5000

Transmission ratio τ 1:1 1:1 1:1 1:1

Fagor FM7-A037-S1C1-E01

Fanuc α2/10000i α3/10000i

Siemens 802Dsl 1FT6084-1AH71-1DG1

Siemens 810D 1FT6084-8AH71-3AG1

Heidenhain QSY-155 D

<Cutting Capacity (with fit motors)>

＊ Work piece material: 600N/square mm steel

＊ Cutting tool materials: HSS

Twist drilling Slot milling Tapping

d x a

[mm] x [mm/u]

d x p x a

[mm] x [mm] x [mm/min]

d x p

[mm] x [mm]

TBMA-120 8 x 0.15 12 x 8 x 45 M6 x 1

TBMA-160 12 x 0.20 20 x 10 x 40 M8 x 1.25

TBMA-200 20 x 0.20 25 x 14 x 40 M16 x 2

TBMA-250 22 x 0.20 25 x 20 x 40 M18 x 2

Version: 005 P 2-8



2.2.3. Hydraulic turret specifications

Turret size LS-200

Center height mm 100

Number of tools N 8T/12T

Rotating time

(tool-to-tool)

sec 0.3

Rotating time (including locking) sec 0.4

Total indexing time for 180° sec 1.2/1.8

Total indexing time for 180°

(including locking)

sec 1.3/1.9

Rotating a cycle time

(unlocking cycle locking)

rev/min 37/25

Curvic coupling type 24180

Oil hydraulic motor type DANFOSS OMP100

Solenoid operated valve AC110V DC24V

Proximity switch X2F1

Hydraulic working pressure Kgf/cm² (35~40) 35

Flow rate L/min 30

Thrusting force of hyd. cyl. Kgf 3800

Accuracy of repeatability mm 0.003

Net weight (without tool disc) Kg 100

Version: 005 P 2-9



2.3. Spindle Power & Torque Diagram

<LT-42>

1) Fagor FM7-A075_7.5/11KW

2) FANUC aP22_6000i_11/15KW

16.7

Torque / Horsepower Chart Data

Spindle Taper

Spindle Speed

33833500

0

1.5

21001127

700 1400 2800

-6000

ISO-A2-5

Gear RatioPulley Ratio

Spindle MotorMotor Output

SPINDLE (rpm)4511

4200 49006000

5600 63000

700

13

SPINDLE (rpm)

-1:1.33

Fagor FM-7-A0757.5/11 kw

42001127

1400 21003383

2800 3500 56004511

4900 63006000

8.89.8

10412

Continuous rating(S1)

4.5

3

6

7.5

9

1110.5S6-40%

5.66.2

3932.4

26

52

65.765

78

9691

Horsepower Chart

KW N-m

Cont

inuo

us ra

ting

S6-4

0%

Torque Chart


Spindle Speed

Spindle TaperA2-5(42mm)

6000

ISO --

Horsepower Chart

Contin

uous

ratin

gS3-2

5%

8080.6

7000

12.715.7

SPINDLE (rpm)

Pulley Ratio

Motor OutputSpindle Motor

Gear Ratio-

Fanuc β12/7000i11/15 kw1:1.12

17862000

20

0

13391000

60.4

47.1

34.5

40

60

31253000 4000 60005000

Torque Chart

109.9

120

100

140

160

N-m

10

010001339 1786

2000

5

500040003125

3000

SPINDLE (rpm)

6000 7000

7.8

9.4

15min,S3-25%

Continuous rating(S1)11

15

KW

20

Version: 005 P 2-10



3) Siemens 1PH7133-2QD_12/16KW

SPINDLE (rpm)2556

0

2

1600752800 2400 3200



-Spindle Speed 6000

Spindle Taper-

ISO A2-5Gear RatioPulley Ratio

56003459

48004000 64000

SPINDLE (rpm)

30

-1:1.33

12/16 kwSIEMENS 1PH7133-2QD


Horsepower Chart

16

6

4

8

10

12

14S6-40%

KW

Cont

inuo

us ra

ting

240

90

60

6.1

120

152 150

180

210

S6-4

0%

N-m

Torque Chart

6000 25561600

752800 2400 3200 5600

345948004000 6400

6000

33

9.7

203

Version: 005 P 2-11



<LT-52> 1) Fagor_FM7-A075_7.5/11KW

2) FANUC β12_7000i_5000rpm

700


-5000

-A2-6ISO



384649004200 5600

0

SPINDLE (rpm)

1.5

-1:1.56

Fagor FM-7-A0757.5/11kw

21001400 2800 3500 56004200 4900 6300


Horsepower Chart

12

4.5

3

6

7.5

9

10.5S6-40%

KW

Cont

inuou

s rat

ing

12

7.8

4.5

3.8

3

6.3 6

11.4

7.5

9

10.5

S6-4

0%

Kg-m

Torque Chart

5.8

5000

11

1.261.16

1.95

962 2885 50003846SPINDLE (rpm)

Spindle Taper

Spindle Speed

28853500

0

1.5

962700 1400 2100 2800

S3-2

5%

Torque Chart

3000

10 80

5000Spindle Speed

Spindle Taper ISO

14392000

1079

01000

25183000 4000

5



Pulley RatioGear Ratio

A2-6(52mm)--

Fanuc β12/7000i11/15 kw

-1:1.39

SPINDLE (rpm)

60005000

7.6

9.1

20

0

25181079 143920001000

43.240

60

74.5

Horsepower Chart

15min,S3-25%


15

11

20

KW

120

100 100

136 140

160

N-m

Contin

uous

ratin

g

SPINDLE (rpm)

17.8

4000 5000 6000

15

Version: 005 P 2-12



<LT-65> 1) Fagor_FM7-A110_11/15.5KW

2) FANUC β12_7000i_4000rpm


7003500

Spindle Taper

Spindle Speed

0

2

1042700 1400

312528002100

-4000

ISO-A2-6



49004444

4200 560062506300

0

SPINDLE (rpm)

7000

20

7000

SPINDLE (rpm)

-1:1.44

Fagor FM-7-A11011/15.5 kw

21001042

14003125

2800 3500 56004444

4200 4900 63006250

12.2

24.3

16016


6

4

8

11

10

12

14

15.5 S6-40%

60

48.640

7.8 80

100103.5

120

145.9 140

Horsepower Chart

KW N-m

Con

tinuo

us ra

ting

S6-4

0%

Torque Chart

S3-2

5%

2431

Torque Chart

10 80

4000

ISO

4000

Spindle Speed

Spindle Taper

1389

0

10421000 3000

24312000

5



Pulley RatioGear Ratio

A2-6(65mm)-- 1:1.44

Fanuc β12/7000i11/15 kw

-

SPINDLE (rpm)

5000

9.1

20

010001042

20001389

4440

61 60

77.5

Horsepower Chart

15min,S3-25%


15

11

20

KW

10.9

120

100104

141140

N-m

160

Contin

uous

ratin

g

SPINDLE (rpm)

500040003000

26.522.6

Version: 005 P 2-13



3) Siemens 1PH7133-2QD_12/16KW

4) Siemens 1PH8137-1DD_12/27KW

SPINDLE (rpm)2361

0

2

1200694

600 1800 2400



-Spindle Speed 4000

Spindle Taper-

ISO A2-6Gear RatioPulley Ratio

42003194

36003000 4800

SPINDLE (rpm)

-1:1.44

12/16 kwSIEMENS 1PH7133-2QD


Horsepower Chart

16

6

4

8

10

12

14S6-40%

KW

Cont

inuo

us ra

ting

6.9

S6-4

0%

N-m

Torque Chart

17

36.9

40001200600 1800 2400 4200

319436003000 4800

694 2361 4000

0

30

240

90

67 60

120

170

150

180

226

210

Siemens 1PH8133-1DD02-0CA1Spindle MotorA2-6(65mm)Spindle Taper

Spindle Speed-

4000 RPM

ISO - Motor OutputGear RatioPulley Ratio

-1:1.44

12/27KW

30001000500

SPINDLE (rpm)

20001500 2500


40003500

Torque ChartHorsepower Chart

KW

0

100

50

150

350

200

250

300

400

N-m

694 833

372

17.7

3.5

0

7

14

10.5

17.5

24.5

21

2827

12

2083

165

55

7.4


30001000500 20001500 2500 40003500694 833 2083

SPINDLE (rpm)

310


Version: 005 P 2-14



2.4. General Layout

Version: 005 P 2-15



2.5. Outline of Systems

2.5.1. Lubrication system

The lubrication system is used to maintain oil films on the machine’s slideways, bearings, gibs,

and ballscrews to ensure smooth motion and prevent wear.

This system comprises the lubrication pump unit, the distributors, and the piping. A float

switch (level switch) and pressure switch are installed inside the lubrication pump unit.

1) The pump is operated to charge lubricant automatically at the required intervals under the

control of PLC controller.

2) The oil dispensed from the pump enters the distributors, which distribute the correct

volume of oil to each lubrication point. The lubrication system drawings are shown in

Spare Parts Manual.

3) The pressure switch device is set up as 1kg/cm² for checking if the piping works normally.

If the pressure is abnormal, it will have abnormal signal.

4) The float switch can detect the volume of oil. Warning signal will show up automatically

when the oil level is lower than the standard.

5) Overview of the electric lubricator:

Symbol Description Function 1 Pump - Extract oil 2 Tank - Store oil 3 Oil supply port filter - Filter oil poured in 4 Feed oil button (F key) - Feed oil immediately 5 Float switch - Detect oil level

1

5

3

2

4

Version: 005 P 2-16



6) The specifications of the electric lubricator (CESD Type) are listed as following table.

Item Specification

TIMER Act Time

controlled by timing device Interval Time

MOTOR

Voltage/Hz AC 110V/50 or 60Hz Current 1.6A Phase 1ф Power 12W

PUMP Max. Discharge Volume 130 cc/min Max. Discharge Pressure 8 kgf/cm² Discharge Bore 6φ

TANK Material Resin Capacity 2.5L

Oil Viscosity 32-68 cSt@40

7) Oil type

G 68 HL 32 Mobil oil Mobil Vactra oil

NO.2 Mobil DTE oil Lighet

Shell oil Shell Tonna oil T 68

Teresso 32

Esso Standard oil Febis K68

Shell Terrus oil C32

Mitsubishi oil Diamond Slideway 68

Diamond Lube RO32

Nippon oil Uniway 68

FBK oil RO32

Kyodo oil Kyoseki Slidus 68

Kyoseki RIX Turbine 32

Idemitsu oil Daphny Multiway 68C

Daphny Hydraulic Fluid 32

Showa oil Showa A-R68 Showa J-H32

Check all the fittings of lubrication system under normal operation temperature. If oil leaking is found, tighten the fittings. Inspect oil level daily.

CAUTION

Version: 005 P 2-17



2.5.2. Hydraulic system

The hydraulic system comprises the hydraulic unit, the valve units, the hydraulic actuators,

and the piping. When the power is turned on, the motor starts and actuates the pump to draw

hydraulic fluid. The hydraulic fluid flowing from the pump port is supplied to the valve units

through the piping. The valve units direct hydraulic fluid to specific actuators to operate the

chucks, turrets and brakes. The specifications of the hydraulic system are listed below. 1) Oil type：ISO VG32 2) Tank capital：80L(2HP) 3) Period renewing Hydraulic oil：

a. Renewing oil in 3 months after machine start usage. b. Then replace oil every 2 years after 1st renewal.

Version: 005 P 2-18



1) Chuck+ Tailstock+ Turret in/out+ Turret Rotation+ Parts Catcher (Standard)

Version: 005 P 2-19



2) Chuck+ Tailstock+ Turret in/out+ Turret Rotation+ Parts Catcher (for MILL)

Version: 005 P 2-20



3) Chuck+ Tailstock+ Turret in/out+ Turret Rotation (Standard)

Version: 005 P 2-21



4) Chuck+ Tailstock+ Turret in/out+ Turret Rotation (for MILL)

Version: 005 P 2-22



2.5.3. Coolant system

The coolant system consists of the coolant tank, the coolant pump, and the piping. Coolant is

used to cool down or lubricate the cutting point. It is pumped up from coolant tank by coolant

pump, carried through the piping, and discharged from holders and tools of the turret head.

2.5.4. Tooling system

<Tooling system diagram>

Refer to the tooling system diagram when carrying out tooling work (mounting holders and

tools to the turret). The tooling system diagram is shown below. The numbers is the reference

number for placing an order.

Version: 005 P 2-23



1) LS-160_STD_8T (Metric-20mm)

42042-60011

42042-60012

42042-60014(20mm)

42042-60040

42042-60016(32mm)

42042-60018 42042-6001020mm

Version: 005 P 2-24



2) LS-160_STD_8T (I mperial-3/4”)

42042-6001142042-60015

(19.05mm)

42042-60013 42042-60040

42042-60017(31.75mm)

42042-60018 42042-6019.05mm

Version: 005 P 2-25




42042-6001842042-6005025mm

42042-60052 42042-60058

42042-60051

(25mm)42042-60054

(32mm)42042-60056

Version: 005 P 2-26



4) LS-160_STD_8T (I mperial-1”)

42042-6001842042-60070

42042-60051

42042-60053

(25.4mm)42042-60055

(31.75mm)42042-60057

25.4mm

42042-60058

Version: 005 P 2-27




42042-60051

42042-60054(25mm)

42042-60052 42042-60058

42042-60056(32mm)

25mm

42042-6001842042-60710

Version: 005 P 2-28




42042-6001842042-6071025mm

42042-60052

(25mm)

42042-60058

(32mm)42042-60051 42042-60054

42042-60056

Version: 005 P 2-29



7) LS-200_STD_12T (Imperial-1”)

42042-60018-25.4mm

42042-60053

(25.4mm)

42042-60058

(31.75mm)42042-60051 42042-60055

42042-60057

Version: 005 P 2-30



<Working zone>

1) LT-42

a. LS-160A_STD_8T (Rear mounted)

Version: 005 P 2-31



b. LS-200_STD_12T (Rear mounted)

Version: 005 P 2-32



c. LS-160A_VDI-30_12T (Rear mounted)

Version: 005 P 2-33



d. LS-160A_VDI-40_8T (Rear mounted)

Version: 005 P 2-34



e. LS-200_VDI-30_12T (Rear mounted)

Version: 005 P 2-35



f. TBMA-160_VDI-30/R135_12T (Rear mounted)

Version: 005 P 2-36



g. TBMA-160_VDI-40/R135_8T (Rear mounted)

Version: 005 P 2-37



2) LT-52

a. LS-160A_STD_8T (Rear mounted) (A2-5)

Version: 005 P 2-38



b. LS-160A_STD_8T (Rear mounted) (A2-6)

Version: 005 P 2-39



c. LS-160A_STD_12T (Rear mounted) (A2-5)

Version: 005 P 2-40



d. LS-200_STD_8T (Rear mounted) (A2-6)

Version: 005 P 2-41



e. LS-200_STD_12T (Rear mounted) (A2-6)

Version: 005 P 2-42



f. LS-200_VDI-30_12T (Rear mounted) (A2-6)

Version: 005 P 2-43



g. TBMR-160_12T (Rear mounted) (A2-6)

Version: 005 P 2-44



3) LT-65

a. LS-160A_STD_8T (Rear mounted) (A2-6)

Version: 005 P 2-45



b. LS-160A_STD_12T (Rear mounted) (A2-6)

Version: 005 P 2-46



c. LS-200_STD_12T (Rear mounted) (A2-6)

Version: 005 P 2-47



d. LS-200_VDI-30_12T (Rear mounted) (A2-6)

Version: 005 P 2-48



e. LS-200_VDI-30_12T (Rear mounted) +SMW+SLU1(A2-6)

Version: 005 P 2-49



2.5.5. Pneumatic system

The pneumatic system consists of air filter, air regulator, air lubricator, air solenoid valve, and

piping. The compressed air supplied to the air supply port has moisture and dust. The

moisture and dust can be removed from the compressed air through the air filter, which

generates clean and dry air. Next, the air is adjusted to the appropriate pressure by regulator

and lubricated by lubricator. The adjusted and lubricated compressed air is sent to the

pneumatic solenoid valves, which directs air flow to specific actuators to operate the various

pneumatic devices.

Version: 005 P 2-50



The specifications of the air unit are listed as following table.

Port size PT 3/8

Operation pressure range 0~9.9 kgf/cm² (0~0.99 MPa)

Test pressure 15 kgf/cm² (1.5 MPa)

Regulated pressure range 0.5~8.5 kgf/cm² (0.05~0.85 MPa)

Ambient temperature -5 ~60 (No freezing)

Filter element Standard:5μm

Lubricating oil capacity 55 c.c.

Min. air flow for oil drip 60L/min

Recommended lubricating oil Turbine oil ISO-VG32

Weight 724 g

Dimensions Show as following figure

Version: 005 P 2-51



2.5.6. CTS

Coolant through spindle (CTS) device is provided as standard accessory of this machine. A

CTS device includes a rotary jointer (universal union) secured to the rear end of the spindle

for conducting coolant into the spindle. The coolant is conducted through a separate passage

inside the spindle to the nozzles formed on a cutting tool. The coolant sprayed out fully cool

down and lubricate the cutting point, increase machining precision and cutting rate, and

prolong service life of the cutting tools.

The built-in type CTS system with 20 bar high pressure pump and 40μm filter system is

standard. It is combined with the coolant from machine coolant tank. A compact design saves

space.

Symbol Description Specification

1 Cover - 2 Inlet Filter - PF-06-10-130+MF-06-230 3 Outlet Filter - 40CN-2-20Q-E2-C1+930119Q 4 CTS Box - 5 Pressure Gauge - 2.5” x 50kg 6 Motor Pump - 5E-2HP-TK-3020+CE

1 6

2

3

5 4

Version: 005 P 2-52



Recommendation coolant

This system only limits uses in the greasy cutting compound oil “1”, water “4”

1) ELF COUPE MAX FK 13T

2) ELF SPIRIT/442PLUS

Installation

1) When moving it by crane, use Ø10mm steel rope (through the eye bolt). Should take care

of the center of gravity if there is coolant inside the tank, don’t lean it & cause the coolant

flow out.

2) This system can be installed in any place, just on the concrete floor is ok.

3) Make sure the motor rotating by the clock-wise direction after power on.

Built-in type CTS


3 INSTALLATION

Version: 005 P 3-1



3 INSTALLATION ............................................................................................. 3

3.1 ENVIRONMENTAL REQUIREMENTS ............................................................... 3

3.2 EXPLANATION OF IMPORTANT PARTS .......................................................... 4

3.3 CAUTIONS AND HAZARDOUS AREA ............................................................. 5

3.3.1 Cautions while in storage status ........................................................................ 5

3.3.2 Cautions while removing the wooden case ....................................................... 5

3.3.3 Cautions while moving ....................................................................................... 6

3.3.4 Cautions while re-setup ..................................................................................... 6

3.3.5 Machine Hazardous Area Diagram ................................................................... 7

3.3.6 Operation Position ............................................................................................. 8

3.4 FOUNDATION WORK .................................................................................. 9

3.4.1 Foundation layout .............................................................................................. 9

3.5 PREPARATION FOR INSTALLATION ............................................................ 11

3.5.1 Power requirements ........................................................................................ 11

3.5.2 Power cable ..................................................................................................... 11

3.5.3 Grounding cable .............................................................................................. 11

3.5.4 Main breaker for the shop power distribution board ........................................ 12

3.5.5 Compressed air supply .................................................................................... 12

3.5.6 Hoses for supplying compressed air ............................................................... 12

3.6 AFTER RECEIVING THE MACHINE .............................................................. 13

3.6.1 Unpacking ........................................................................................................ 13

3.6.2 Checking for shortage ..................................................................................... 13

3.6.3 Hoisting the machine ....................................................................................... 13

3.6.4 Placing the machine ........................................................................................ 15

3.6.5 Cleaning the machine ...................................................................................... 15

3.7 CONNECTING THE POWER CABLE ............................................................. 16

3.8 CONNECTION OF COMPRESSED AIR SUPPLY HOSE .................................... 16

Version: 005 P 3-2



3.9 MACHINE LEVELING ................................................................................. 16

3.10 LUBRICATION .......................................................................................... 18

3.10.1 Automatic lubrication ....................................................................................... 18

3.10.2 Lubrication in headstock .................................................................................. 18

3.10.3 Lubrication on tailstock .................................................................................... 18

3.11 CHUCKS AND CHUCK MOUNTING .............................................................. 19

3.11.1 Chuck fitting on ASA2-5 / ASA2-6 spindle nose .............................................. 19

3.11.2 Chuck fitting on cam-lock spindle nose ........................................................... 19

3.12 TAILSTOCK CENTER LOADING & UNLOADING ............................................ 21

3.13 COOLANT ............................................................................................... 21

3.14 BAR FEEDER RECOMMENDATION (OPTION) ............................................... 22

Version: 005 P 3-3



3 INSTALLATION

3.1 Environmental Requirements

Consider the following requirements when selecting a site to install the machine. However,

these could change over a period of time or in response to seasonal changes.

<Ambient temperature and humidity>

1) Choose an installation site where the ambient temperature remains with the range 0 to

45 and the humidity does not exceed 80% RH (with no condensation).

2) Install the machine at a site where neither it nor the NC unit is subject to direct sunshine,

heat rays, or rain.

<Vibration>

1) The machine must not be installed at a site subject to excessive vibration (greater than 2

mm/s). Excessive vibration could lead to machine failure and will adversely affect

machining accuracy.

2) Be sure not to install the machine adjacent to planning machine, milling machine, molding

machine, punching machine, press brake or any high frequency control machine center.

<Atmosphere>

1) Install the machine at a site that is as free as possible from dirt, dust, and mist. If dirt and

dust adhere to the cooling fan fitted inside the machine, its cooling capacity will be

impaired.

2) Install the machine at a site where it will not be reached by chips, water, and oil scattered

from other machine.

3) Install the machine at a site that is as free as possible from acid fumes, corrosive gases,

and salt.

<Installation ground>

Make sure the floor is strong enough to support the machine. The floor must not be sloped or

irregular in any way. Twisting or other distortion of the machine will adversely affect machining

accuracy.

Version: 005 P 3-4



<Maintenance>

When installing the machine, a distance of at least 35.4” (900mm) is required from machine to

wall and objects or between machines. Therefore, it can provide sufficient maintenance area

to allow the chip conveyor (if featured) and coolant tank to be removed, and the electrical

cabinet door to be opened and closed without difficulty.

< Noise>

Noise range emitted from all area of machine (distance: 1 m from the machine surface, height:

1.6m from the floor) during use at a typical operator’s position is between 70~85 dB. Take

precautions to prevent hearing damage from machine/machining noise. Wear ear protection,

alter cutting application (tooling, spindle speed, axis feed, fixturing, programmed path) to

reduce noise, and restrict access to machine area during cutting.

3.2 Explanation of Important Parts

1) This machine is a CNC machine. It would perform the required eroding operation mode according to the program written on the base of working condition and program set rules.

2) This is a machining machine, which is made from steel metal and non-iron metal material. This machine can perform the machining program of outer diameter cutting, milling and drilling.

3) The main parts of the machine are main shaft box, turret, foot stock, tool slider, power supply box and guard plate etc.

4) The machine uses high output AC servomotor, which has high torque force output and consistent speed control to match with the conveyer of the high torque belt for the best cutting effect.

5) This main shaft is equipped with high accuracy bearing to make the main shaft with high-speed steel and high main shaft speed.

6) 45°bank machine unit, which makes it easier for cutting, tool installation and unload, could keep stable and high accurate performance.

7) The foot stock arbor controlled by oil pressure could be moved by hand or auto adjustment. Use the pinion gear to make the band pulley move to make sure the stability of drive.

The machine unit is assembled with computer control system and the oil pressure system to

make a complete set. It’s more convenient for moving and takes smaller space. It will be

easier for operation.

Version: 005 P 3-5



3.3 Cautions and Hazardous Area

3.3.1 Cautions while in storage status 1) Turn off all of the outer power. 2) Remove the cutting fluid, hydraulic oil and other fluid. Make sure there is no fluid in the

machine or the fluid reservoir so that there will no fluid overflow while moving. 3) Make the turret back to home position and then fix it to avoid touching the drill chuck. 4) Make the foot stock away from the drill chuck and then tighten it. 5) Make sure to have proper anti-rust process for the parts. Which are easy to get rusted. 6) Make sure if the power specification on the machine on the machine is same as the

specification on the delivery invoice such as: voltage, frequency, current etc. 7) Check if the quantities of the standard and optional accessories are the same as listed on

the delivery invoice. 8) Put the dryer in the machines to avoid humid and use the plastic bag to cover the exterior

of the machine for anti-humidity. 9) Check if wooden plate is strong enough to bear the machine weights and the possible

force occurred during moving. 10) Fix the machine tightly on the wooden plate according to the illustration and check if the

machine is fixed securely on the wooden plate. 11) Check if every kind of mark is marked properly on the wooden case such as CE mark, the

front and back of the machine, weight, up, down, and anti-humidity. 12) Be careful with the environment and should be kept between 5° and 40°C.

3.3.2 Cautions while removing the wooden case 1) While removing the wooden case, the agent should send a representative to inspect the

machine, accessories and relevant document. 2) Remove the wooden case from top first, then the sides and the wooden plates. Remove

the wooden case carefully. The torn wooden plates should be clear up quickly so that the nails and chips will not hurt anyone.

3) Before moving the machine after removing the wooden case, take the accessories, tools box and relevant documents away first.

4) Before moving the machine after removing the wooden case, loosen the fixed base screw bolts and remove the nuts.

Version: 005 P 3-6



3.3.3 Cautions while moving 1) Before using the fork truck, make sure the fork truck has more then 5 tons bearing

capacity. 2) Make enough and proper space for the machine and leave space for operation. 3) Clear all of the possible obstacles on the way. Which the fork truck uses. 4) During moving the machine, make sure the temperature of the surrounding is between 5°C

to 40°C. 5) When using the fork truck to carry the machine, the speed of the fork truck can’t be over 5

km/hr and the height should be kept between 100mm to 1000mm. 6) When using the fork truck to carry the machine, an assistant should be accompanied with

the driver to be in charge of moving and other assorted work. The illustration is the gestures used for conduct.

7) During the way of moving, avoid the curved road and choose the smooth road. 8) After the machine is fixed, connect the oil tubes and wires etc.

3.3.4 Cautions while re-setup 1) Turn off all of the power. 2) Remove the cutting fluid, oil pressure oil and other fluid, Make sure there is no fluid in the

machine or the fluid reservoir so that there will no fluid overflow while moving. 3) Make the turret back to home position and then fix it to avoid touching the drill chuck. 4) Make the foot stock away from the drill chuck and then tighten it. 5) Before moving, make sure the fork truck has more than 5 tons capacity. 6) Make sure to have enough space for machine operation. 7) Remove all of the possible obstacles on the way so that the fork truck can go along the

road smoothly. 8) While moving, the environment temperature should be kept between 5 C and 40 C.∘ ∘ 9) When using the fork truck to carry the machine, the speed of the fork truck can’t be over 5

km/hr and the height should be kept between 100mm t0 1000mm. 10) When using the fork truck to carry the machine, and assistant should be accompanied with

the driver to be in charge of moving and other assorted work, the illustration is the gestures used for conduct.

11) During the way of moving, avoid the curved road and choose the smooth road. 12) After the machine is fixed, connect the oil tubes and wires etc.

Version: 005 P 3-7



3.3.5 Machine Hazardous Area Diagram

1. Spindle Motor 4. Turret Turning 7. Turret Moving

2. Headstock 5. Conveyor Motor

3. Hydraulic Chuck 6. Chip Conveyor Outlet

Version: 005 P 3-8



3.3.6 Operation Position

Version: 005 P 3-9



3.4 Foundation Work

To upgrade the operation efficiency and accuracy of precision machining, a proper foundation

is required.

With special torque-resistant capability at the machine base, this machine requires no

particular foundation. Just provide rubble layer with thickness of 50mm and concrete layer

with thickness of 250mm on the floor and sufficient space for leveling. The strength of

concrete is 3000 psi (28 days after placing concrete).

Do not use wood foundation with nature of unsuitability which may cause the machine to

move gradually.

Install the machine on the first or second floor. Take the stress of ceiling and foundation into

careful consideration to see if machine load can be offset.

3.4.1 Foundation layout

Drill six holes into the concrete foundation for mounting foundation bolts. The positions and

dimensions of the pre-drilled holes are shown in below figure. Place the foundation bolts into

the holes and pour concrete until the surface is flush with the ground surface. After the

concrete has been cured, place the machine on the bolts, adjust the level, and then lock the

nuts.

Version: 005 P 3-10



Styr

ofoa

m

Bar

Fee

der

(Opt

ion)

Version: 005 P 3-11



3.5 Preparation for Installation

3.5.1 Power requirements

The power source must satisfy all of the requirements indicated in following table.

Item Range

Nominal power source voltage fluctuation range

(200/220/400 VAC)

±10%*

Voltage drop Within 15% of normal voltage for 0.5

sec.

Frequency fluctuation range (50/60 Hz) ±2Hz

Momentary power failure Less than 10 msec.

Voltage impulse The peak value is 200% or less of the

effective value (rms value) of the line

voltage with pulse duration of 1.5

msec.

Waveform distortion of AC voltage 7% or less

Imbalance in line voltages 5% or less, or within 10V

* Voltage fluctuation (drop) during spindle or servo system acceleration must be less than 7%.

If voltage drops more than 7% during servo system acceleration or deceleration, actual

acceleration or deceleration time may be elongated than the theoretical time.

3.5.2 Power cable

Prepare a power cable that can supply the total power capacity required by the machine. The

cable type, wire thickness, and other cable specifications vary according to the insulation

class, ambient temperature, temperature correction coefficient, and wire laying conditions. For

advice on cable selection, consult the cable dealer.

3.5.3 Grounding cable

For the grounding cable, consult the cable manufacturer to select the one which is sufficient to

take earth for the machine to be installed. When selecting the grounding cable, observe the

applicable local regulations where the machine is installed.

Version: 005 P 3-12



3.5.4 Main breaker for the shop power distribution board

Use a breaker for an AC inverter as the main breaker on the shop power distribution board. If

another type of breaker is used, it may be actuated by the high-frequency leak current specific

to AC inverters.

3.5.5 Compressed air supply

Select a compressed air supply that can supply the required volume of compressed air at the

required pressure. (Applies to machines with pneumatic devices) For the selection, consult

the compressor manufacturer.

1) Use only clean and dry air, 6kgf/cm². If the supplied air is moist or has a high

concentration of dust, the pneumatic devices could malfunction, causing damage to the

machine.

2) Check that the compressed air supply capacity is at least the specified capacity.

Insufficient capacity could damage the machine. If the compressed air quality is not within

the specified range, use a line filter, dryer, etc. between the machine and the air source.

3) The pressure setting of the compressor should be in the range from 0 to 9.9kgf/cm². If the

setting is higher than 9.9kgf/cm², pneumatic actuators used in the machine could be

damaged.

3.5.6 Hoses for supplying compressed air

Select hoses for supplying compressed air that can comfortably withstand the compressed air

pressure. For advice on the selection, consult the hose manufacturer.

Compressed air supply port size: 3/8”

CAUTION

Version: 005 P 3-13



3.6 After Receiving the Machine

If the machine is not moved to the installation site immediately after its delivery, keep it in a

location not exposed to dust, dirt, mist, or extremely low or high temperature. Leaving the

machine in such conditions could cause troubles in the electrical systems of the NC unit and

peripheral devices and lead to machine faults.

3.6.1 Unpacking

Remove the top cover of the wooden case first and then the plates at four sides. Carefully

take out fittings at first, if necessary. Remove the set screws used for holding the machine on

the base.

Disassemble packing crate and remove skids as carefully as possible to avoid damaging the

machine. If the machine is damaged during transportation, contact your local dealer,

insurance company and the transportation company who delivered your machine

immediately.

3.6.2 Checking for shortage

Be sure to check your machine against the packing list which is shipped with every machine.

In case of shortages, note items not received and contact your local dealer.

3.6.3 Hoisting the machine

Please use Crane to hoist the machine.

1) Make sure that the machine is well balanced in both the crosswise and lengthwise

directions after hoisting it a little above the floor.

2) Place protection material on any part of the machine that might be touched by straps.

3) Hoist the machine in the slowest speed of crane

WARNING

Version: 005 P 3-14



Carry position for lift truck

Version: 005 P 3-15



3.6.4 Placing the machine

Before placing the machine, lock the adjusting screws on the base, make the machine as

close as possible to the floor, and position the leveling pads at the most suitable place, so as

to increase the stability of machine.

3.6.5 Cleaning the machine

All protective coating must be removed before using machine. Do not attempt to move any

ways if the coating still exists. Be cautions while selecting a suitable cleaning agent. Paraffin

applied with a clean brush will soften the protective coating. The protective coating can then

be removed with clean rags.

Some parts of the machine are fixed in place with transit clamps when the machine is shipped.

Also eyebolts are used to hoist the machine. All clamps and eyebolts must be removed before

switching the power ON. The positions of the transit clamps are shown in the following figure.

1) Do not use gasoline or any other flammable solution to clean the machine

2) Clean and lubricate all the exposed trails of the table and saddle. Drive the table and

saddle to one end of travel. Clean and lubricate the trails thoroughly, then drive them to the

other end and do the same procedure as well. Be sure to use a suitable lubricant such as

Sunoco Way-lube #11180 or Mobil Vactra Oil #2.

WARNING

Version: 005 P 3-16



3.7 Connecting the Power Cable

1) Make sure the voltage of power supply is the right type that the machine requires or as

marked on the unit.

2) Connect the power wires per electrical code in your area.

3) Power wires, grounding and over-voltage protector should comply with the local electricity

regulations.

For wiring to other voltages, be sure to rewire the spindle motor, coolant pump, dust suction

device and transformer to correct voltage. The relevant currents, fuses and overload relays

are shown in the electrical manual.

Do not turn on the machine motor unless the specified power is supplied.

3.8 Connection of Compressed Air Supply Hose

Follow the procedure below to connect the compressed air supply hose.

1) Turn off the power.

2) Connect the compressed air supply hose from the air source to the air supply port (3/8”) in

the air panel of the machine.

3) Start the compressor to supply the compressed air to the machine.

4) Make sure that there is no air leak at hose joints and pneumatic actuators.

5) Adjust the compressed air pressure to the specified value with the regulator in the air

panel. For the correct air pressure, refer to Chapter 2.

3.9 Machine Leveling

It is necessary to level the machine before operating the machine.

Prepare the following tools to adjust machine level:

1) Accurate spirit leveling gauge (spec. 0.02mm/1000mm or 0.001in/4ft)

2) Two adjustable wrenches

WARNING

Version: 005 P 3-17



A VIEWFixed block

Leveling gauge 2

Leveling gauge 1

A

<Adjusting procedure>


2) Before adjusting the level of the machine, make sure the tolerance of the accuracy

exceeds 0.04mm/min. perform the steps of level adjustment.

3) Before confirming the accuracy of the level, be sure to adjust the screw bolt first and then

tighten the bolts.

4) The illustration on the top of the right shows the simple way to confirm the accuracy of the

level: Put the leveling gauge on the turret. Then move the left, right, front and back fixed

positions of the turret. Observe the values on the leveling gauge while moving the turret to

get the accuracy values of the level for X and Z-axis of this machine.

5) Standard way of adjusting the level. a) Place a ground parallel block with two-side parallel on the track of the machine unit as

the illustration shown on the bottom of the right. Then put the leveling gauge on it. Move the left, right front and back fixed positions of the parallel block. Observe the values of the leveling gauge while moving to the fixed positions to get the level accuracy of X and Z-axis of this machine.

b) Use the value of the leveling gauge as the standard to get the highest and the lowest position of the machine and record them according to the facts.

c) Use the positions of the record to adjust the screw bolts until they reach the required accuracy of level within 0.04mm/M.

1) For the newly installed machine, check its level once every week. If the foundation is rigid

enough, then you may level the machine once per month.

NOTE

Version: 005 P 3-18



3.10 Lubrication

3.10.1 Automatic lubrication

1) For first operation, press the feed-oil button to supply lubricating oil to the empty pipes.

Never hold down the feed-oil button more than 3 minutes. When the temperature reaches 100, the motor will shut down 5 minutes to protect the motor.

2) Make sure that lubricating oil is supplied to the slideway surfaces, ballscrews and gibs.

3) For the adjustment of the oil discharge volume, release and turn the fixing bolt to adjust to

the desired figure displayed on the scale plate.

3.10.2 Lubrication in headstock

It is not necessary to replace the oil for machine unless you have to change bearing set inside

of this device. Grease has been used as lubricant fitting, you are free to work here. The

bearing set has long life with machining, so it is no common to change it in normal condition.

In case of any damage under warranty period, we will supply the fitting free of charge.

3.10.3 Lubrication on tailstock

There is one oil ball above the tailstock. In order to ensure smooth operation, add 10 drops of

recommended lubricant every day before operating the machine.

1) Check all the fittings of the lubrication system under normal operation temperature. If oil

leaking is found, tighten the fittings.

2) Inspect oil level daily.

NOTE

Version: 005 P 3-19



3.11 Chucks and Chuck Mounting

Use only high-speed chucks which are capable of min. 3500rpm with these machines.

3.11.1 Chuck fitting on ASA2-5 / ASA2-6 spindle nose

When mounting an ASA type chuck, it is necessary to install a back plate first, and then mount

the chuck on the spindle nose. It would be easier to mount chuck when the back plate is

already well-fit on the machine.

3.11.2 Chuck fitting on cam-lock spindle nose

Before mounting cam-lock chucks or face-plates, ensure that the spindle and the chuck tapers

are scrupulously clean and that all cams lock is in the correct positions. When mounting a new

chuck, it may be necessary to re-set the cam-lock studs (see A in the following figure). This is

done by loosening the cap-head locking screw (see B in the following figure) and setting each

stud so that the scribed ring (see C in the following figure) is flush with the rear face of the

chuck and the slots line up with the locking screw holes.

Now, mount the chuck or face-plate on the spindle nose and tighten the six cams in turn.

When the cams are fully tightened, the reference line on each cam should fall between the

two V marks on the spindle nose to ensure that mounting is secured.

Each spindle has two V marks at 3 o’clock and 6 o’clock, when mounting is properly tightened,

the reference line on the cam should be between the two V marks, shown in the following

figure. If the reference line does not fall between “V” marks, remove the chuck or face-plate

and re-adjust the cam-lock studs. If the reference line does not go beyond the V mark at 3

o’clock, turn the stud out one full turn. In addition, turn the stud in if the line goes beyond the V

mark at 6 o’clock. Then tighten the locking screw (B) beside each stud before remounting the

chuck.

A reference mark should be made on each correctly fitted chuck or face-plate to coincide with

the reference mark scribed on the spindle nose. This will assist subsequent remounting. Do

not interchange chucks or face-plates between lathes without checking correct cam lock.

WARNING

Version: 005 P 3-20



1) Take careful note of speed limitations when using face plates.

A: Cam-lock stud

B: Cap-head locking screw

C: Scribed ring

NOTE

Version: 005 P 3-21



3.12 Tailstock Center Loading & Unloading

To unload the center just hold the center and back the tail spindle.

Please wipe the taper part of the center clean before loading it to the tail spindle.

3.13 Coolant

There are a variety of types of coolant available on the market. We does not specify the type

of coolant to be used. Choose a coolant suitable for your applications by consulting the

supplier, taking the following requirements into consideration.

1) Do not use flammable coolant. Heat generated by electrical devices or during cutting might

cause a fire.

1) The coolant must be free of constituents with adverse affects on human beings; for

example constituents with offensive smalls or those that cause skin eruption.

2) The coolant must not corrode the machine.

3) Ensure the constituents of the coolant exclude Sulfur and Chlorine, which may damage

the machine painting.

4) The coolant must not cause hardening or swelling of chemical parts (rubber parts,

synthetic resin parts, etc.), since this will cause damage to the machine.

5) When supplying water-soluble coolant, pour the coolant into the tank after dissolving it in

water. Do not pour water only into the tank since it will cause rusting on the machine.

6) The coolant must always be used at the concentration specified by its supplier. If a coolant

of improper concentration is used, the workability will be degraded and the machine and

workpiece will be rusted, causing damage to the machine and adversely affecting

machining accuracy.

CAUTION

DANGER

Version: 005 P 3-22



B

C

A

3.14 Bar Feeder Recommendation (Option)

On following models, when a bar feeder device is chosen, considering the headstock length,

following dimension is recommended.

Model LT Series

Length from chuck to coolant collector (A) 921

Length of headstock (B) 543

Hydraulic draw tub inner diameter (C) 64

Recommended max. bar diameter X length for bar feeder device

62X980


4 MAINTENANCE

Version: 005 P 4-1



4 MAINTENANCE ............................................................................................. 3

4.1 REGULAR INSPECTION LIST ........................................................................ 3

4.2 OILING CHARTS ......................................................................................... 5

4.3 DAILY MAINTENANCE INSTRUCTION ............................................................ 6

4.3.1 Supplying oil to the lubricating oil tank .............................................................. 6

4.3.2 Supplying coolant to the coolant tank ................................................................ 7

4.3.3 Inspecting lubricating oil level of turret .............................................................. 8

4.3.4 Inspecting the air unit ........................................................................................ 9

4.3.5 Lubricating and cleaning the chuck ................................................................. 11

4.3.6 Cleaning the chip collector .............................................................................. 12

4.3.7 Cleaning front door rail .................................................................................... 12

4.4 REGULAR MAINTENANCE INSTRUCTION ..................................................... 13

4.4.1 Cleaning the air filter of electrical cabinet ........................................................ 13

4.4.2 Cleaning front cover of the spindle .................................................................. 14

4.4.3 Cleaning coolant tank and coolant filter ........................................................... 15

4.4.4 Cleaning lubricating oil tank and oil filters ....................................................... 16

4.4.5 Disassembly and cleaning the chuck .............................................................. 17

4.4.6 Inspection of machine level using leveler ........................................................ 17

4.4.7 Inspection and replacement of slide wiper ...................................................... 18

4.4.8 Inspection of servo motor connectors .............................................................. 19

4.4.9 Inspection of coolant motor connector and chip conveyor motor connector ... 19

4.4.10 Replacing air filter for air actuators .................................................................. 20

4.4.11 Cleaning electrical cabinet ............................................................................... 21

4.4.12 Cleaning fans of electrical cabinet ................................................................... 21

4.4.13 Replacing hydraulic oil ..................................................................................... 22

4.4.14 Cleaning the suction strainer in the hydraulic oil tank ..................................... 23

4.4.15 Replacing the machine light ............................................................................ 24

4.4.16 Replacing the battery ....................................................................................... 26

4.4.17 Replacing oil on headstock .............................................................................. 30

4.4.18 CTS ................................................................................................................. 31

4.4.19 Cleaning and replacing inlet and outlet filters .................................................. 32

Version: 005 P 4-2



4.4.20 Disposal Method for Oil, Water and Material Waste ........................................ 33

4.5 INSTRUCTION OF GEOMETRICAL ACCURACY ADJUSTMENT ......................... 34

4.5.1 Headstock ........................................................................................................ 34

4.6 SIMPLE TROUBLE SHOOTING .................................................................... 35

Version: 005 P 4-3



4 MAINTENANCE

4.1 Regular inspection list

This items that require inspection and maintenance regularly are indicated below. By referring to the machine specification and other reference information, carry out inspection and maintenance work at the specified inspection intervals.

Item Inspection item Inspect interval Reference Chapter

1 Check electrical circuit connection Every time before operation

2 Inspect the oil level in the lubricating oil tank, and supply oil if low oil alarm is given. Daily 4.3.1

3 Inspect the oil level in the turret, and supply oil if oil is scant. Daily 4.3.3

4 Inspect the air unit Daily 4.3.4

5 Grease chuck master jaws Daily 4.3.5

6 Oil and clean the chuck Daily 4.3.5

7 Clean chip drawer Daily

8 Clean the coolant collector in the rear of the cylinder Daily 4.3.6

9 Clean front door rail Daily 4.3.7

10 Supply coolant to the coolant tank Daily inspection 4.3.2

11 Clean air filter of electrical cabinet 50 hours 4.4.1

12 Inspect the clamping force of jaws by force gauge 50 hours

13 Inspect oil leak in pipe joints 50 hours

14 Inspect air pressure(with pressure gauge) 50 hours

15 Clean front cover of the spindle 50 hours 4.4.2

16 Check all fittings of hydraulic, pneumatic, and lubricating system 500 hours

17 Clean coolant tank and coolant filter 500 hours 4.4.3

18 Replace coolant 500 hours 4.4.3

19 Inspect temperature inside the electrical cabinet 500 hours

20 Clean chip conveyor outside machine 500 hours

21 Clean lubricating oil tank and oil filters 500 hours 4.4.4

22 Disassemble and clean the Chuck 1000 hours 4.4.5

23 Inspect machine level using level 1000 hours 4.4.6

24 Inspect and replace the slide wipers 1000 hours 4.4.7

Version: 005 P 4-4



25 Inspect vibration, abnormal noise, and heat generation of

servomotors 1000 hours

26 Inspection of servomotor connectors 1000 hours 4.4.8

27 Inspect vibration, abnormal noise, and heat generation of the spindle

motor 1000 hours

28 Inspect the spindle motor insulation resistance 1000 hours

29 Inspect coolant motor connector and chip conveyor motor connector 1000 hours 4.4.9

30 Dynamic inspection by test cutting 1000 hours

31 Inspect abnormal noise and vibration of ball screw 1000 hours

32 Inspect abnormal noise and vibration during spindle rotation 1000 hours

33 Inspect turret indexing time 1000 hours

34 Inspect turret center height 1000 hours

35 Inspect misalignment of turret 1000 hours

36 Inspect cracked or hardened hoses 1000 hours

37 Inspect cable breakage, damaged shielding 1000 hours

38 Inspect relay terminal screws(tightness inspection and tightening) 1000 hours

39 Disassemble and clean the air solenoid valves 1000 hours

40 Clean inside the electrical cabinet 1000 hours 4.4.11

41 Clean the fans 1000 hours 4.4.12

42 Replace hydraulic oil 1000 hours 4.4.13

43 Clean the suction strainer in the hydraulic oil tank 1000 hours 4.4.14

44 Replace filter element of air actuators 2000 hours 4.4.10

45 Clean the parts catcher traverse rail 2000 hours

46 Clean the hydraulic oil tank 2000 hours

47 Disassemble and clean cylinders 2000 hours

48 Check and adjust the gibs of cross-slide and saddle 2000 hours

49 Replace the machine light

While working area cannot be illuminated satisfactorily

4.4.15

50 Replace the battery While battery alarm displayed 4.4.16

Version: 005 P 4-5



4.2 Oiling charts

The oil points of this machine, and the types and quantities of oil to be used, are indicated

below.

1) Inspect lubrication at all points and replace oil regularly.

2) Use the lubricating oil and hydraulic oil specified in the Oil Charts. Do not use oil

containing impurities or degraded oil.

3) Check all the fittings of lubrication system under normal operation temperature. If oil

leaking exists, tighten the fittings.

4) Inspect oil level of the lubrication system and the hydraulic system daily.

<Oil type>

<Oil pressure>

Code ESSO Shell Mobil

Hydraulic system HL32 Unipower FM32 TETRA 32 DTE oil light

Slide way lube G68,G220 Febis K68, 220TONNA T68,

T220 -

Coolant tank - Cut well 30 DROMUS oil B MET 150

Jaw on chuck Grease - - -

Chip conveyor Grease - - -

Gear box CB32 Unipower FM32 TETRA 32 DTE oil light

Main pressure 25~30 kgf/cm2

Chuck pressure 20~30 kgf/cm2

Tail stock 5~12.5 kgf/cm2

Max flow value 30L/min.

Version: 005 P 4-6



4.3 Daily Maintenance Instruction

4.3.1 Supplying oil to the lubricating oil tank

If the oil level in the lubricating oil tank is lower than the standard, a warning alarm will appear

on the display screen. If this low lubricating oil level alarm appears, supply lubricating oil.

<Procedure>

(Example: Changhua Chen Ying CESD 2.5L)

1) Check the volume of oil in the lubricating oil tank by the oil level gauge.

2) Remove the cap on the oil supply port.

3) Supply the specified lubricating oil by using the oil jug while checking the oil level with the

oil level gauge. For type and volume of the lubricating oil, refer to the Oil Charts in the

Chapter 4.2.

Oil tank

Oil level gauge

Cap on the oil supply port

Version: 005 P 4-7



4.3.2 Supplying coolant to the coolant tank

If the coolant level is lower than the red bold line of the level gauge installed on the coolant

tank, an insufficient amount of coolant is supplied to the cutting tool. If cutting is continued

under such conditions, accuracy will be impaired due to insufficiency of cooling, and tool and

pump service life will be shorted. Supply coolant to the coolant tank if coolant level drops

under the red bold line of the level gauge.

<Procedure>

1) Press the coolant switch off to stop coolant supply.


3) Check the coolant volume with the level gauge.

4) Supply coolant from the top of the coolant tank. For the capacity of the coolant tank, refer

to the Oil Charts in the Chapter 4.2. Be aware of not exceeding the black bold line of the

level gauge.

Coolant level gauge

Version: 005 P 4-8



4.3.3 Inspecting lubricating oil level of turret

The inner of turret is lubricated by oil bath to reduce wear of transmitting gear, coaxial cam

and bearings. Appropriate lubricating also can reduce temperature and noise, and prolong

service life of the turret. Inspect lubricating oil volume daily, and supply oil if the lubricant is

insufficient.

<Procedure>

1) View from the oil indicating window to inspect the lubricating oil volume.

2) If the lubricating is scant, pour oil to the inner turret from the oil inlet.

3) If it is necessary to replace the lubricating oil, discharge old lubricant from the oil outlet and

supply new lubricant from the oil inlet.

Consult the manufacture of lubricating oil for replacing interval advice since it varies with

the type of oil.

NOTE

Oil indicating window

Oil inlet

Version: 005 P 4-9



4.3.4 Inspecting the air unit

<Drain the filter>

Filtration of water and other contaminants in the air line system occurs automatically when

compressed air passes through the filter portion of the air unit. If the water level of the filter

bowl exceeds the maximum limit, the water will come into air pipes and cause damages to

pneumatic devices. Check the water level daily, and drain the filter if necessary. This is done

by pressing the drain outlet on the bottom of the filter with a finger. And the drain outlet will be

closed when the pressing load is released.

Drain outlet

Filter bowl

Version: 005 P 4-10



<Supply oil to the lubricator>

The lubricator of the air unit ensures that the pneumatic devices receive the required

lubrication to maintain peak performance, reduce wear, and prolong service life. Check the

lubricating oil level of the lubricator bowl daily, and supply oil if the oil level drops under the

minimum limit. For supplement of lubricating oil, follow the following steps:


2) Shut off the compressed air and discharge all air from the FRL unit.

3) Remove the lubricator bowl from the air unit. Pay attention not to spill the lubricating oil

when removing the bowl.

4) Supply the specified lubricating oil by using the oil jug while checking the oil level with the

oil level gauge. For type and volume of the lubricating oil, refer to the Oil Charts in the

Chapter 4.2.

5) Assemble the air lubricator by following the disassembly procedure in reverse.

6) Supply compressed air to make sure that there is no air leak.

Lubricator bowl

Version: 005 P 4-11



4.3.5 Lubricating and cleaning the chuck

Coolant splashed on the chuck will wash away the grease of the master jaws. To maintain the

gripping accuracy of the chuck for a long time, it is necessary to lubricate the chuck regularly.

Inadequate lubrication causes malfunction at low hydraulic pressure, reduces gripping force

and affects gripping accuracy, and causes abnormal wear and seizure.

<Procedure>

1) Stop the spindle.


3) Supply grease from the grease nipples of the chuck. As a minimum, all chucks equipped

with grease nipples should be lubricated at least once a week. Lubricants should be a high

quality designed for lubricating high pressure contact surfaces. The lubricant should be

able to resist coolant and other chemicals. To lubricate those chucks without grease

fittings, the jaws must be removed to expose the scroll and apply a light coating of grease

to the scroll and re-assemble the jaws.

1) There are a variety of types of chucks available in the market, and the lubricating method

varies with the types of chucks. Read the instruction manuals provided by the chuck

manufacturer for the procedure of lubricating the chuck.

2) At the end of each day, when operation is completed, clean the chuck body and slideways.

Do not use compressed air to remove dust and foreign particles from the chuck.

WARNING

Version: 005 P 4-12



4.3.6 Cleaning the chip collector

Coolant and chips flow into the chip collector at the rear of the cylinder via the through hole in

the draw bar. The coolant returns to the coolant tank via the drain hose. If chips are

accumulated on the punched-metal sheet of the chip collector, coolant will overflow and spill

to the floor. Coolant will flow into the hydraulic oil tank via the cylinder drain, inhibiting proper

machine operation. Remove chips from the punched-metal sheet every day.

<Procedure>


2) Remove the cover at the left side of the machine.

3) Remove the chips that have accumulated on the punched-metal sheet of the coolant

collector.

4) Mount the cover.

4.3.7 Cleaning front door rail

If chips accumulate on the front door rail, the door can not open/close smoothly. Clean the

front rail daily.

<Procedure>


2) Remove the chips that accumulated on the front door rail.

Version: 005 P 4-13



4.4 Regular Maintenance Instruction

4.4.1 Cleaning the air filter of electrical cabinet

The electrical cabinet is cooled directly or indirectly (option) by ambient air. For the direct way,

outside cool air flows into the cabinet from the lower side fan and mixed with inside hot air.

Then, the mixed air flows out of the cabinet from the top outlet. For the indirect way, the

cabinet is cooled through heat exchanger by exchanging the heat inside with cool air outside.

Therefore, if the air filter at the air suction port is clogged, the heat in the electrical cabinet will

not be cooled efficiently. 1. Air filter of electrical cabinet (directly) 2. Air filter of heat exchanger (indirectly)

<Cleaning interval>

Every 50 hours of operation

If the machine is exposed to the environment with dirt, dust, fine chips or mist, it is

recommended to clean the inside of the air filter more frequently. <Procedure>


2) Remove the filter cover from the electrical cabinet.

3) Clean the filter using neutral detergent and dry the filter with compressed air.

4) Mount the filter cover in the electrical cabinet.

5) Turn on the power.

Version: 005 P 4-14



4.4.2 Cleaning front cover of the spindle

Dust and foreign particle will accumulate in the coolant discharging holes on the front cover of

the spindle. This will allow coolant to enter the bearings and cause the bearings to seize.

Clean the coolant holes in the front cover of the spindle with a clean cloth at least once a

week.

<Cleaning interval>


Do not use compressed air to remove dust and foreign particle from the coolant holes. If

compressed air is used, dust and foreign particle will get into the bearings or bearing surface.

CAUTION

Version: 005 P 4-15



4.4.3 Cleaning coolant tank and coolant filter

If fine chips and other foreign particles accumulate in the coolant tank, the coolant cannot be

supplied properly. In addition, if contaminated coolant is pumped, the service life of the pump

will be shortened.

<Cleaning interval>


When machining cast iron or similar material that generates fine chips, it is recommended to

clean the inside of the tank more frequently.

<Procedure>

1) Press the coolant switch off to stop coolant supply.

2) Turn of the power.

3) Remove the drain plug and discharge the coolant of the coolant tank.

4) Loosen the connector and remove coolant motor pipe and wiring.

5) Pull out the coolant tank and chip drawer.

6) Remove the chip drawer on the coolant tank and clean the chip drawer.

7) Clean the inside of the coolant tank and the coolant filter.

8) Wrap the drain plug thread with sealing tape and fit it to the coolant tank.

9) Mount the coolant tank and the chip drawer to the machine by pushing them to an

appropriate position.

10) Connect the coolant motor pipe and wiring.

11) Supply coolant in the tank. Replace the coolant if necessary. Consult the coolant

manufacturer for recommended replacing interval since it varies with the coolant type and

machining conditions.

Version: 005 P 4-16



4.4.4 Cleaning lubricating oil tank and oil filters

<Cleaning interval>


<Procedure>

(Example: Changhua Chen Ying CESD 2.5L)


2) Remove the lubricating oil tank. Pay attention not to spill the lubricating oil when removing

the tank.

3) Clean the inside of the lubricating oil tank with diesel oil.

4) Remove the suction filter from the suction port.

5) Clean the suction filter with diesel oil.

6) Blow the suction filter with compressed air.

7) Mount the suction filter to the suction port.

8) Remove the filter at the oil supply port.

9) Clean oil supply port filter with diesel oil.

10) Mount the filter at the oil supply port.

11) Mount the lubricating oil tank.

12) Read the oil level gauge and supply lubricating oil in the tank. For name and volume of the

lubricating oil, refer to the Oil Charts in the Chapter 4.2.


14) Press the feed-oil button to supply lubricating oil to the slideways. Never press the feed-oil button more than 3 minutes. When the temperature reaches 100, the motor will shut

down 5 minutes to protect the motor.

15) Make sure that lubricating oil is supplied to the slideway surfaces.

Oil tank Suction filter

Oil supply port filter

Oil level gauge

Feed-oil button

Version: 005 P 4-17



4.4.5 Disassembly and cleaning the chuck

<Cleaning interval>


When machining cast iron or similar material that generates fine chips, it is recommended to

clean the inside of the tank more frequently.

<Procedure>

(Example: manual operated chuck)

1) Remove the chuck jaws out of the T-slots with the chuck wrench. Wipe the jaws with a

clean cloth and cover the jaws with a light film of oil.

2) Clean the scroll and the chuck slots with a clean rag and/or brush. Wipe the scroll and

chuck slots with a clean, lightly oiled rag. Do not use too much oil on the chuck. Excessive

amounts of oil will collect dirt and chips that will eventually clog the chuck jaws and scroll.

3) Install the chuck jaws.

1) A variety of types of chucks is available in the market, and the cleaning method varies with

chuck types. Read the instruction manuals provided by the chuck manufacturer for the

detail procedure of cleaning the chuck.

2) If any part of the chuck are worn or cracked, replace it if required.

4.4.6 Inspection of machine level using leveler

The machine level adversely affects the machine accuracy. If the machine level is not

adjusted correctly, the machine will be tilted. This will result in uneven wear of the bed and

slideway surfaces and machining defects.

<Inspecting interval>


<Procedure>

Refer to Chapter 3.9.

WARNING

Version: 005 P 4-18



4.4.7 Inspection and replacement of slide wiper

Slide wipers are used on each slideway. The slide wipers are used to prevent the entry of

chips. Check the slide wipers periodically. Pay careful attention to abnormal wear on the

scratches or damage due to chips. If the slide wiper is abnormal, chips or foreign particles

could get in the seam over the slideway and the wear-proof material coated on the surface of

slideway could be damaged. This could adversely affect machine accuracy. If a slide wiper is

damaged, replace it immediately.

Be sure to shut off the power before inspecting or replacing the slide wipers.

Before replacing the slide wipers, clean the inside of the machine and remove foreign

particles and chips completely. Chips or foreign particles on the surface of slideway will cause

machine faults



<Procedure>

For the installation positions and order numbers of slide wipers, please refer to Spare parts

Manual.

CAUTION

DANGER

Version: 005 P 4-19



4.4.8 Inspection of servo motor connectors

<Connector position>

Z-axis servomotor and x-axis servo motor



<Procedure>


2) Remove the cover.

3) Make sure that servomotor connector is mounted correctly.

4) Mount the cover.

4.4.9 Inspection of coolant motor connector and chip conveyor motor connector

<Connector position>

1) Left side behind the machine:

If the machine is equipped with a chip conveyor, the connectors of coolant motor are at the

left side of the machine.



<Procedure>


2) Make sure that the connectors are mounted correctly.

Version: 005 P 4-20



4.4.10 Replacing air filter for air actuators

The air filter can screen moisture and dust from the compressed air that is supplied to the

pneumatic devices. If the air filter element is clogged, the air pressure supplied to the

actuators is reduced, causing their operation failure. Therefore, the air filter element should be

inspected regularly.

<Replacing interval>


<Procedure>


2) Shut off the compressed air.

3) Remove the bowl from the air filter.

4) Replace the filter element.

5) Clean the filter bowl using neutral detergent.

6) Assemble the air filter by following the disassembly procedure in reverse.

7) Supply compressed air to ensure no air leak.

Filter element

Filter bowl

Version: 005 P 4-21



4.4.11 Cleaning electrical cabinet

Although the electrical cabinet is constructed to shut off external air, foreign particles such as

dust and dirt may enter the cabinet when the door is open. Accumulation of foreign particles

on the printed circuit boards or other electronic components could cause machine malfunction.

Clean the inside of the electrical cabinet regularly.

<Cleaning interval>


<Procedure>


2) Open the electrical cabinet door.

3) Remove dust inside electrical cabinet with a vacuum cleaner. Do not use compressed air

to clean inside the electrical cabinet. Never touch printed circuit boards or parts around the

connector. Also avoid shock on these parts.

4) Close the electrical cabinet.

4.4.12 Cleaning fans of electrical cabinet

<Cleaning interval>


<Procedure>


2) Remove the fan cover.

3) Wipe the fan with a dry and clean cloth.

4) Mount the fan cover.

Version: 005 P 4-22



4.4.13 Replacing hydraulic oil

Replace the hydraulic oil in the hydraulic unit tank regularly while paying attention to the

following:

1) Maintain the oil level of hydraulic oil in the tank at proper level; make sure that the pump

unit does not suck in air.

2) Keep the hydraulic oil clean.

3) Clean the strainer periodically to avoid clogging which will lower the pump flow rate.



Consult the manufacture of hydraulic oil for recommended replacing interval since it varies

with the type of hydraulic oil.

<Procedure>


2) Remove the cover of the oil supply port.

3) Place the drain oil receiver beneath the drain plug of the hydraulic unit tank.

4) Remove the drain plug.

Drain plug

Oil level gauge

Version: 005 P 4-23



5) After the oil is completely discharged, wrap the drain plug thread with sealing tape and

install the drain plug.

6) Fill the tank with hydraulic oil. Supply the hydraulic oil through the oil filler port while

reading the oil level with the oil level gauge.

7) Check the oil level with the oil level gauge.

8) Fit the cover of the oil supply port.


10) Check the oil pumping sound.

11) Make sure that the chuck opens and closes smoothly.

4.4.14 Cleaning the suction strainer in the hydraulic oil tank

If the suction strainer in the hydraulic oil tank is clogged, cavitation is generated and this could

damage the hydraulic piping and hydraulic pump. Clean the suction strainer in the hydraulic

oil tank regularly.

<Cleaning interval>


<Procedure>


2) Disconnect the pipe from the suction port of the pump.

3) Remove the suction pipe mounting plate.

4) Remove the suction pipe with the suction strainer from

the tank.

5) Remove the suction strainer from the suction pipe.

6) Clean the suction strainer with diesel oil and dry it with

compressed air.

7) Mount the suction strainer to the suction pipe.

8) Mount the suction pipe and suction strainer to the tank.

9) Connect the suction pipe to the pump.

10) Mount the suction pipe mounting plate on the tank.


12) Check the oil pumping sound.

Version: 005 P 4-24



4.4.15 Replacing the machine light

The lamp is a consumable part.


When the light cannot satisfactorily illuminate the working area

<Procedure>


2) Clean the lamp; wipe off coolant and chips.

3) Loosen the cable connecting cap bolt.

4) Remove the screws of the clamp. Hold the lamp so that it does not fall.

5) Remove the lamp unit from the clamp.

6) Loosen the cable connecting cap bolt on the cap of the lamp unit.

7) Remove the screws on the cap.

8) Remove the cap from the glass tube.

9) Pull the lamp mounting plate out of the glass tube.

10) Remove the plastic diffusers from the lamp mounting plate.

Screws on the cap

Cable connecting

cap bolt

Cap

Glass tube

Version: 005 P 4-25



11) Remove the fluorescent lamp by turning it 90°. Be careful that the fluorescent lamp do not

fall into the machine.

12) Mount a new fluorescent lamp.

13) Assemble the lamp by following the disassembly procedure in reverse.


15) Press the machine light switch to turn on the fluorescent lamps.

16) Make sure that the fluorescent lamps light up.

Lamp mounting plate

Plastic diffuser

Fluorescent lamps

Version: 005 P 4-26



4.4.16 Replacing the battery

Two types of batteries are on the machine: one is for memory backup and the other is for

absolute position sensing. If the battery voltage is low, the battery alarm message will be

displayed on the screen. If the alarm indication is given, change the batteries by following the

procedure below.

Since the battery is located in the electrical cabinet, replace the battery very carefully. If live

parts are touched by mistake, the operator could get an electric shock.

Replace batteries while power is being supplied to the NC. If batteries are replaced with the

NC power supply shut off, the data stored in the memory will be lost. To avoid the danger of

lost data, it is recommended to save the memory data to an external I/O device or a memory

card.

<Battery to be used>

Memory Back-up Battery Absolute Position Sensing Battery

Fanuc Lithium battery

A02B-0200-K102*

1) Alkaline battery×4 pcs.

(Size D, products on the market)*

2) Lithium battery

E67028[A06B-6073-K001]*

Heidenhain Lithium battery, type CR 2450N

(Renata), Id. Nr. 315878-01

Estimated life: 3~5 years

Siemens

Fagor 3.5 V lithium battery

(Estimated life: 3 years)

* The number of batteries used varies from different machine model. Check the battery

number on the battery case.

CAUTION

DANGER

Version: 005 P 4-27



(Example: Fanuc)

1) Memory Back-up Battery (Lithium battery)

<Battery position>

The batteries are installed in the rear cover of the operation panel.


Once a year

When the battery alarm message is displayed on the screen

<Procedure>

1) Turn the NC power switch on for about 30 seconds.

2) Turn off the NC power.

3) Disconnect the battery connector. Do not pull the battery cable.

4) Take the battery out of the battery case. The battery case is located at the top right end

of the NC unit.

5) Insert a new battery and connect the battery connector. Always make sure the polarity

of the batteries is correct.

Replacement of battery should be completed within 30 minutes. Do not leave the control

unit without a battery for any longer than 30 minutes, as this will result in memory lost.

CAUTION

Version: 005 P 4-28



2) Absolute Position Sensing Battery (Alkaline battery)

<Battery position>

The batteries are installed in the electrical cabinet door


Once a year


<Procedure>

1) Turn the NC power switch off.


3) Place the electrical cabinet door interlock key-switch in the OFF position.



6) Turn on the NC power.

7) Loosen the screws of the battery case to remove the cover. When the cover is

removed, size D batteries are exposed.

8) Replace the batteries. Note the polarity of the batteries as shown in the figure below.

(orient two batteries one way and the other two in the opposite direction)

9) Mount the cover.

10) Press the NC power switch off.


12) Close the electrical cabinet door.

13) Place the electrical cabinet door interlock key-switch in the ON position.

Version: 005 P 4-29



3) Absolute Position Sensing Battery(Lithium battery)

<Battery position>

The batteries are installed in the servo inserters of individual axes


Once a year


<Procedure>



3) Place the electrical cabinet door interlock key-switch in the OFF position.



6) Press the NC power switch on.

7) Remove the battery case. Hold the battery case at the top and bottom faces and pull it

toward you.

8) Disconnect the battery connector. Do not pull the battery cable.

9) Replace the battery and connect the battery connector.

10) Mount the battery case.



13) Close the electrical cabinet door.

14) Place the electrical cabinet door interlock key-switch in the ON position.

Version: 005 P 4-30



(Example: Heidenhain) 1. Memory Back-up Battery (Lithium battery)

<Battery position>

The batteries are installed in the electrical cabinet door


3~5 years


<Procedure>

1) Check the load status of the capacitor in the Info menu. →Enter the code number

79513 and read U [ACCU]. The voltage must be >= 3 V.

The capacitor (Gold cap) is only loaded when the iTNC is switched on. If the Gold cap

is still not loaded sufficiently, please wait a few seconds and enter the code number

79513 again to read the updated voltage value. If the voltage of the Gold cap does not

reach 3 V or more, the MC must be replaced.

2) Switch off the main switch of the machine.

3) Dismount the MC.

4) Replace the battery. Due to the non-symmetric shape of the battery there is only one

possibility of inserting.

4.4.17 Replacing oil on headstock

It is not necessary to replace the oil for the headstock unless you have to change bearing set

inside the headstock. Grease has been used as lubricant. The bearing set is durable for

machining, so replacement is rarely required under normal conditions. Free replacement will

be supplied if any damage under warranty.

Version: 005 P 4-31



4.4.18 CTS

Coolant-Through-Spindle (CTS) system allows coolant to be pumped deep into the part where

normally coolant does not reach. It improves the heat removing rate from the cutting area,

reducing the expansion of the part material significantly. In addition, there is less heat

transferred through the tool to the spindle, so expansion of the spindle and head is also

significantly reduced, improving Z axis positioning and accuracy. CTS system requires the

following maintenance.

<Daily works>

1) Check coolant level on the system. If the coolant level is lower than the low limit, supply

coolant to the coolant tank.

2) Ensure that the index of pressure switch gauge is normal.

3) After finishing the cutting job, clean the working area.

4) If the machine is out of pressure in a cutting condition, stop the machine immediately and

ensure the inlet and outlet filters are not clogged.

<Weekly works>

1) Ensure the coolant returning tube is not choked.

2) Ensure that the proportion of water to coolant is within the range recommended by the

coolant manufacturer.

<Monthly works>

1) Clean the inlet and outlet filters to obtain good filtering efficiency.

2) Ensure the system is not leaking.

3) Ensure there is no abnormal noise when the motor is running.

<Yearly works>

1) Ensure all switches on the electric box are working normally.

2) Replace the inlet and outlet filters to maintain high quality of coolant.

Version: 005 P 4-32



4.4.19 Cleaning and replacing inlet and outlet filters

Cleaning and replacing inlet and outlet filters

If the filters of CTS are clogged, cavitation is generated and this could damage the piping and

pump. In addition, if contaminated coolant is pumped to the CTS system, fine chips may enter

the pump, generating abnormal noise and shortening the service life of the pump.

<Interval>

Monthly for cleaning filters

Yearly for replacing filters

<Procedure>

The built-in type CTS system which shares the coolant from machine coolant tank. The

procedures described above are for CTS tank. The inlet/outlet filter of built-in type CTS is

shown as below figure. When cleaning or replacing the filter element, loosen the screws on

the filter to take out the filter element.

Inlet filter

(150μm Galvanized

Iron Filter)

Outlet filter

(40μm Copper

Sintered Filter)

Version: 005 P 4-33



4.4.20 Disposal Method for Oil, Water and Material Waste

Oil, water and material waste produced by process should be appropriately handled. Contact

local environment protection agency or qualified waste treatment company for disposal.

Waste can be disposed privately to create pollution.

Version: 005 P 4-34



4.5 Instruction of Geometrical Accuracy Adjustment

If taper appears on turning work piece and convex on rounding, adjust the parallel of

headstock by the following steps.

4.5.1 Headstock

<Aligning headstock>

1) Insert gauge bar in the spindle bore, attach the base of test indicator to the tool post.

Apply the stylus of the indicator to the outer diameter of the bar. Move the saddle along

Z axis and measure the maximal difference.

2) If the pointer of the indicator swings drastically, release the headstock fixing screws and

adjust the adjusting screws to fine the paralleled of spindle and Z axis

3) After adjustment, tighten the fixing screws and move the saddle to observe the pointer of

the indicator.

Version: 005 P 4-35



4.6 Simple trouble shooting

Description Possible cause Repair method

Rails on bed turn black

Automatic lubrication system is

out of lubricant Add lubricant

Inappropriate oil properties Immediately replace the oil

Oil tube clogged Replace tube or clear the

clogged material

Cylindrical machined into

conical shape Spindle head slick Alignment

Inaccurate machining

between

two centers

Poor accuracy on center Alignment

Steps appear on the

spherical

work piece surface

Inaccurate backlash

compensation Check Z-feed unit


5 ADDITIONAL & REVISE PAGES

Version: 005-01 Revised Ch4.1

Date of Version: Jan. 2013 1 of 2

OPERATION MANUALLT-42/52/65 SERIES

4 MAINTENANCE

4.1 Regular inspection list

This items that require inspection and maintenance regularly are indicated below. By referring to the machine specification and other reference information, carry out inspection and maintenance work at the specified inspection intervals.

Item Inspection item Inspect interval Reference Chapter

1 Check electrical circuit connection Every time before operation

2 Inspect the oil level in the lubricating oil tank, and supply oil if low oil alarm is given. Daily 4.3.1

3 Inspect the oil level in the turret, and supply oil if oil is scant. Daily 4.3.3

4 Inspect the air unit Daily 4.3.4

5 Grease chuck master jaws Daily 4.3.5

6 Oil and clean the chuck Daily 4.3.5

7 Clean chip drawer Daily

8 Clean the coolant collector in the rear of the cylinder Daily 4.3.6

9 Clean front door rail Daily 4.3.7

10 Supply coolant to the coolant tank Daily inspection 4.3.2

11 Please make basic cleaning and maintenance to the cover while getting off work or daily duty is done Daily 4.3.8

12 Clean air filter of electrical cabinet 50 hours 4.4.1

13 Inspect the clamping force of jaws by force gauge 50 hours

14 Inspect oil leak in pipe joints 50 hours

15 Inspect air pressure(with pressure gauge) 50 hours

16 Clean front cover of the spindle 50 hours 4.4.2

17 Check all fittings of hydraulic, pneumatic, and lubricating system 500 hours

18 Clean coolant tank and coolant filter 500 hours 4.4.3

19 Replace coolant 500 hours 4.4.3

20 Inspect temperature inside the electrical cabinet 500 hours

21 Clean chip conveyor outside machine 500 hours

22 Clean lubricating oil tank and oil filters 500 hours 4.4.4

23 Disassemble and clean the Chuck 1000 hours 4.4.5

24 Inspect machine level using level 1000 hours 4.4.6

Version: 005-01 Revised Ch4.1



25 Inspect and replace the slide wipers 1000 hours 4.4.7

26 Inspect vibration, abnormal noise, and heat generation of

servomotors 1000 hours

27 Inspection of servomotor connectors 1000 hours 4.4.8

28 Inspect vibration, abnormal noise, and heat generation of the spindle

motor 1000 hours

29 Inspect the spindle motor insulation resistance 1000 hours

30 Inspect coolant motor connector and chip conveyor motor connector 1000 hours 4.4.9

31 Dynamic inspection by test cutting 1000 hours

32 Inspect abnormal noise and vibration of ball screw 1000 hours

33 Inspect abnormal noise and vibration during spindle rotation 1000 hours

34 Inspect turret indexing time 1000 hours

35 Inspect turret center height 1000 hours

36 Inspect misalignment of turret 1000 hours

37 Inspect cracked or hardened hoses 1000 hours

38 Inspect cable breakage, damaged shielding 1000 hours

39 Inspect relay terminal screws(tightness inspection and tightening) 1000 hours

40 Disassemble and clean the air solenoid valves 1000 hours

41 Clean inside the electrical cabinet 1000 hours 4.4.11

42 Clean the fans 1000 hours 4.4.12

43 Replace hydraulic oil 1000 hours 4.4.13

44 Clean the suction strainer in the hydraulic oil tank 1000 hours 4.4.14

45 Replace filter element of air actuators 2000 hours 4.4.10

46 Clean the parts catcher traverse rail 2000 hours

47 Clean the hydraulic oil tank 2000 hours

48 Disassemble and clean cylinders 2000 hours

49 Check and adjust the gibs of cross-slide and saddle 2000 hours

50 Replace the machine light

While working area cannot be illuminated satisfactorily

4.4.15

51 Replace the battery While battery alarm displayed 4.4.16

Version: 005-02 Revise Ch4.3 (P4-12)



4.3.6 Cleaning the chip collector

Coolant and chips flow into the chip collector at the rear of the cylinder via the through hole in

the draw bar. The coolant returns to the coolant tank via the drain hose. If chips are

accumulated on the punched-metal sheet of the chip collector, coolant will overflow and spill

to the floor. Coolant will flow into the hydraulic oil tank via the cylinder drain, inhibiting proper

machine operation. Remove chips from the punched-metal sheet every day.

<Procedure>


2) Remove the cover at the left side of the machine.

3) Remove the chips that have accumulated on the punched-metal sheet of the coolant

collector.

4) Mount the cover.

4.3.7 Cleaning front door rail

If chips accumulate on the front door rail, the door can not open/close smoothly. Clean the

front rail daily.

<Procedure>


2) Remove the chips that accumulated on the front door rail.

4.3.8 Cleaning the cover

1) After the cover is installed, please avoid trampling on it, in case there are damages occur.

2) After the cover is installed, clean all the rust, swear and grease stained on it.

3) During the rainy season and vacation, apply second-class anti-rust treatment to the cover. Use liquid anti-rust oil only.

4) When the cover is stored in a warehouse, keep it from raining, splashing and deforming.

5) To prevent deformation, take and place the cover gently. It is forbidden to throw, smash and press the cover, in case there are damages caused by abnormal movement.

6) Please make basic cleaning and maintenance to the cover while getting off work or daily duty is done.

Version: 005 P 0-1


SPARE PARTS MANUALLT-42/52/65 SERIES

SPARE PARTS MANUAL

Persons unable to read English must have this manual read and explained to them before

operating or maintaining the machine. Everyone working on the machine must know how to

operate it safely and correctly to avoid possible injury.

WARNING

Version: 005 P 0-2



Version & relative revise record

1) Updated date: Sep. 2012

Version: 005 version date: Sep. 2012


All chapter Re-construct all sections and add necessary content


Table of Contents

1. SPARE PARTS LIST OF LT-42/52/65


1 SPARE PARTS LIST OF LT-42/52/65

Version: 005 P 1-1



1 PARTS LIST

1 PARTS LIST ......................................................................................... 1

1.1 HEADSTOCK (LT-42) ............................................................................... 4

1.1.1 Headstock (LT-42) ........................................................................................... 5

1.2 HEADSTOCK (LT-52) ............................................................................... 6

1.2.1 Headstock (LT-52) ........................................................................................... 7

1.3 HEADSTOCK (LT-65) ............................................................................... 8

1.3.1 Headstock (LT-65) ........................................................................................... 9

1.4 C-AXIS (LT-42/52) ................................................................................ 10

1.4.1 C-axis (LT-42/52) ........................................................................................... 11

1.5 C-AXIS (LT-65) ..................................................................................... 12

1.5.1 C-axis (LT-65) ................................................................................................ 13

1.6 CF-AXIS (LT-65) ................................................................................... 14

1.6.1 CF-axis (LT-65) ............................................................................................. 15

1.7 ENCODER ............................................................................................. 16

1.7.1 Encoder ......................................................................................................... 17

1.8 ANGLE ENCODER .................................................................................. 18

1.8.1 Angle Encoder ............................................................................................... 19

1.9 SPINDLE MOTOR PULLEY-INSIDE THE BASE HOUSING (LT-42/65) ............ 20

1.9.1 Spindle Motor Pulley-Inside the Base Housing (LT-42/65) ............................ 21

1.10 SPINDLE MOTOR PULLEY-OUT THE BASE HOUSING (LT-42/52) ............... 22

1.10.1 Spindle Motor Pulley-Out the Base Housing (LT-42/52) ............................... 23

Version: 005 P 1-2



1.11 SPINDLE MOTOR PULLEY-OUT THE BASE HOUSING (LT-65) .................... 24

1.11.1 Spindle Motor Pulley-Out the Base Housing (LT-65) .................................... 25

1.12 CYLINDER ............................................................................................. 26

1.12.1 Cylinder ......................................................................................................... 27

1.13 BASE .................................................................................................... 28

1.13.1 Base .............................................................................................................. 29

1.14 X-AXIS .................................................................................................. 30

1.14.1 X-axis ............................................................................................................. 31

1.15 X-AXIS LINEAR GUIDEWAY ..................................................................... 32

1.15.1 X-axis Linear Guideway ................................................................................. 33

1.16 X-AXIS LUBRICATION SYSTEM ................................................................ 34

1.16.1 X-axis Lubrication System ............................................................................. 35

1.17 Z-AXIS .................................................................................................. 36

1.17.1 Z-axis ............................................................................................................. 37

1.18 Z-AXIS GUIDEWAY ................................................................................. 38

1.18.1 Z-axis Guideway ............................................................................................ 39

1.19 Z-AXIS LUBRICATION SYSTEM ................................................................ 40

1.19.1 Z-axis Lubrication System ............................................................................. 41

1.20 MOTOR ................................................................................................. 42

1.20.1 Motor ............................................................................................................. 43

1.21 TAILSTOCK BODY .................................................................................. 44

1.21.1 Tailstock Body ............................................................................................... 45

1.22 CABLE TRACK & WORK LIGHT ................................................................ 46

1.22.1 Cable track & Work Light ............................................................................... 47

Version: 005 P 1-3



1.23 TOOL SETTER ....................................................................................... 48

1.23.1 Tool Setter ..................................................................................................... 49

1.24 PARTS CATCHER ................................................................................... 50

1.24.1 Parts Catcher ................................................................................................. 51

1.25 FULL SPLASH GUARD ............................................................................ 52

1.25.1 Full Splash Guard .......................................................................................... 53

1.26 CHIP CONVEYOR & COOLANT TANK ....................................................... 55

1.26.1 Chip Conveyor & Coolant Tank ..................................................................... 56

Version: 005 P 1-4



1.1 Headstock (LT-42)

Version: 005 P 1-5



1.1.1 Headstock (LT-42)

Item Part no. Description Q'ty Remark 1 Socket Screw 1 M6XP1.0X16L

2 Drive Key 1 3 Spindle 1 4 Key 1 8X7X60 5 Socket Screw 6 M6XP1.0X20L

6 Cover 1 7 Seal Ring 1 8 Socket Screw 8 M6XP1.0X30L 9 Cover 1

10 O Ring 1 G130 11 Bearing 2 7016

12 Spacer 1 13 Spacer 1 14 Spacer 1

15 Nut 1 YSRM80XP2.0 16 Socket Screw 6 M12XP1.75X45L 17 Sleeve 1 18 42042-00001 Headstock 1 19 Bearing 2 7014 20 Cover 1 21 Socket Screw 6 M6XP1.0X20L 22 Seal Ring 1 23 Cover 1 24 Spacer 1 25 Socket Screw 6 M5XP0.8X25L 26 Timing Belt Pulley 1 27 Pulley 1 28 Nut 1 YSAM70XP2.0

Version: 005 P 1-6




Version: 005 P 1-7




Item Part no. Description Q'ty Remark 1 Socket Screw 1 M8XP1.25X16L

2 Drive Key 1 3 Spindle 1 4 Key 1 12X8X70 5 Socket Screw 4 M6XP1.0X25L

6 Cover 1 7 Seal Ring 1 8 Socket Screw 8 M6XP1.0X35L 9 Cover 1

10 O Ring 1 G155 11 Bearing 2 7020

12 Spacer 1 13 Spacer 1 14 Spacer 1

15 Nut 1 YSRM100XP2.0 16 Socket Screw 6 M12XP1.75X45L 17 Sleeve 1 18 42042-00051 Headstock 1 19 Bearing 2 7018 20 Cover 1 21 Socket Screw 6 M6XP1.0X30L 22 Seal Ring 1 23 Cover 1 24 Spacer 1 25 Socket Screw 6 M5XP0.8X25L 26 Timing Belt Pulley 1 27 Pulley 1 28 Nut 1 YSAM90XP2.0

Version: 005 P 1-8




Version: 005 P 1-9




Item Part no. Description Q'ty Remark 1 Socket Screw 1 M6XP1.0X50L 2 Drive Key 1 3 Spindle 1 4 Key 2 12X8X60 5 O Ring 1 G100 6 Seal Ring 1 7 Socket Screw 6 M6XP1.0X50L 8 Cover 1 9 O Ring 1 G150

10 Bearing 3 7020 11 Spacer 1 12 Socket Screw 6 M8XP1.25 13 Sleeve 1 14 42042-00051 Headstock 1 15 Bearing 2 7020 16 Cover 1 17 Socket Screw 6 M5XP0.8X20L 18 Seal Ring 1 19 Socket Screw 6 M6XP1.0X20L 20 Cover 1 21 Socket Screw 6 M8XP1.25X20L 22 Timing Belt Pulley 1 23 Pulley 1 24 Cover 1 25 Cover 1 26 Cover 1 27 Socket Screw 4 M8XP1.25X40L

Version: 005 P 1-10



1

2

3

4

5

1.4 C-axis (LT-42/52)

Version: 005 P 1-11



1.4.1 C-axis (LT-42/52)


1 42042-03045 Disc 1 LT-42

42042-03075 Disc 1 LT-52

2 51010-101501000A Hex. socket screw 4 M10XP1.5X100L

3 42042-83001 Brake 2 DBF10


5 42042-83004 Bracket 1 LT-42

42042-83003 Bracket 1 LT-52

Version: 005 P 1-12



1

2

3

4

5

1.5 C-axis (LT-65)

Version: 005 P 1-13



1.5.1 C-axis (LT-65)


1 42042-03105 Disc 1


3 42042-83001 Brake 2 DBF10


5 42042-83002 Bracket 1

Version: 005 P 1-14



1.6 CF-axis (LT-65)

Version: 005 P 1-15



1.6.1 CF-axis (LT-65)

Item Part no. Description Q'ty Remark 1 Motor 1 2 42042-06009 Coupling 1 ψ65X85/ψ20Xψ22

3 42042-06002 Gear box 1

4 42042-06003 Fixing seat 2


6 42042-83001 Brake 2 DBF10



9 53030-060042200 Bearing 2 6004ZZ

10 42042-06004 Shaft 1

11 42042-06005 Gear 1

12 51131-000000420 C snap 1 R-42


14 42042-06006 Poke ring 1

15 42042-06007 Fixing rod 1

16 55076-000000450 O ring 1 G-45

17 55070-000000250 Oil seal 2 SKY-25 18 43110-00570 Cylinder 1 19 51010-061000350A Hex. socket screw 4 M6XP1.0X35L 20 55070-000000300 Oil seal 2 SKY-30 21 43110-00571 Piston rod 1 22 42042-06008 Ring 1 23 55076-000000350 O ring 1 G-35 24 55077-000000350 Ring 1 BP-35 25 43110-00572 Cylinder cover 1 26 51010-061000200A Hex. socket screw 6 M6XP1.0X20L 27 43110-00573 Dog 1 28 51010-050800150A Hex. socket screw 2 M5XP0.8X15L 29 Limit switch 2 30 43110-00574 Fixing plate 1 31 51010-121750500A Hex. socket screw 4 M12XP1.75X50L 32 42042-06001 Bracket 1 33 42042-03106 Disc 1

Version: 005 P 1-16



1.7 Encoder

Version: 005 P 1-17



1.7.1 Encoder

Item Part no. Description Q'ty Remark 1 42042-00001 Head Stock 1 LT-42 2 42042-00051 Head Stock 1 LT-52,LT-65 3 42042-01001 Shaft 1 4 42042-01002 Adapter 1 5 42042-01013 Encoder Housing 1 6 42042-01014 Mounting Bracket 1 7 42042-01005 Pulley 1 LT-42,LT-52 8 42042-01006 Belt Guide 2 LT-42,LT-52 9 42042-01010 Pulley 1 LT-65

10 42042-01011 Belt Guide 2 LT-65 11 42042-01007 Key 1 12 Belt(935-5GT10) 1 LT-42,LT-52 13 Belt(960-5GT10) 1 LT-65 A1 Bearing 2 ψ30*ψ50*13

A2 Socket Screw 4 M6*1*20L A3 Socket Screw 4 M8*1.25*35L A4 Socket Screw 4 M8*1.25*40L A5 Washer 4 M8 A6 Cap Screw 8 M5*0.8*10L A7 Spring Washer 8 M5 A8 Washer 8 M5 A9 Clip 1 ψ30(STW)

A10 Socket Screw 1 M5*0.8*12L

Version: 005 P 1-18



10

1

2

3

4

5

67

8

9

1.8 Angle Encoder

Version: 005 P 1-19



1.8.1 Angle Encoder

Item Part no. Description Q'ty Remark 1 Sensor ring 1 αiBZ(A860-2150-t611)

2 Sensor 1 αiBZ(A860-2150-t611)

3 42042-03091-401 Fixing block 1

4 42042-03090-401 Fixing block 1 5 Screw 2 M3XP0.5X20L 6 Hex. socket screw 2 M6XP1.0X22L 7 Washer 2 M6 8 Hex. socket screw 2 M8XP1.25X22L 9 Washer 2 M8

10 Pin 2 ψ3X6L

Version: 005 P 1-20



1.9 Spindle Motor Pulley-Inside the Base Housing (LT-42/65)

Version: 005 P 1-21



1.9.1 Spindle Motor Pulley-Inside the Base Housing (LT-42/65)

Item Part no. Description Q'ty Remark 1 42042-00001 Headstock 1 LT-42 42042-00051 Headstock 1 LT-65 2 42042-03001 Spindle 1 LT-42 42042-03101 Spindle 1 LT-65 3 42042-05003 Spindle Motor Mounting Bracket 1 4 42042-05007 Spindle Motor Pulley 1 LT-42 42042-05010 Spindle Motor Pulley 1 LT-65 5 43210-552014 Clamp Ring 1 LT-42 42042-05011 Clamp Ring 1 LT-65 6 43210-520019 Clamp Ring 2 LT-42 43130-05004 Clamp Ring 2 LT-65

7 V-Belt (LT-42) 1 4R11M2000(2+2)

V-Belt (LT-65) 1 4R11M2120(2+2)

8 3-Jaw Chuck (LT-42) 1 6” 3-Jaw Chuck (LT-65) 1 8” (10”) 9 Spindle Motor 1

A1 Socket Screw (LT-42) 6 M10XP1.5X100L Socket Screw (LT-65) 6 M12XP1.75X100L

A2 Socket Screw 6 M12XP1.75X40L A3 Socket Screw 6 M16XP2.0X65L A4 Spring Washer 6 M16 A5 Socket Screw 6 M8XP1.25X30L A6 Hex. Head Screw 4 M14XP2.0X35L A7 Socket Screw 6 M12XP1.75X60L A8 Spring Washer 6 M12 A9 Flat Washer 6 M12

Version: 005 P 1-22



1.10 Spindle Motor Pulley-Out the Base Housing (LT-42/52)

Version: 005 P 1-23



1.10.1 Spindle Motor Pulley-Out the Base Housing (LT-42/52)


1 42042-00001 Headstock 1 LT-42

42042-00051 Headstock 1 LT-52

2 42042-03001 Spindle 1 LT-42

42042-03051 Spindle 1 LT-52

3 42042-05005 Spindle Motor Mounting Bracket 1 LT-42

42042-05006 Spindle Motor Mounting Bracket 1 LT-52

4 42042-05007 Spindle Motor Pulley (Fagor) 1 LT-42

42042-05009 Spindle Motor Pulley (Fagor) 1 LT-52

5 42042-05008 Spindle Motor Pulley (Fanuc) 1 LT-42

42042-05010 Spindle Motor Pulley (Fanuc) 1 LT-52

6 43210-552014 Clamp Ring 1 LT-42

42042-05011 Clamp Ring 1 LT-52

7 43210-520019 Clamp Ring 2 LT-42

43120-05004 Clamp Ring 2 LT-52

8 V-Belt (LT-42) 1 4R11M2000(2+2)

V-Belt (LT-65) 1 4R11M2120(2+2)

9 3-Jaw Chuck (LT-42) 1 6”

3-Jaw Chuck (LT-52) 1 8”

10 Spindle Motor 1

A1 Socket Screw (LT-42) 6 M10XP1.5X100L

Socket Screw (LT-52) 6 M12XP1.75X100L

A2 Socket Screw 6 M12XP1.75X40L


A4 Spring Washer 6 M16


A6 Hex. Head Screw 4 M14XP2.0X35L



A9 Flat Washer 6 M12

Version: 005 P 1-24



1.11 Spindle Motor Pulley-Out the Base Housing (LT-65)

Version: 005 P 1-25



1.11.1 Spindle Motor Pulley-Out the Base Housing (LT-65)


1 42042-00051 Headstock 1

2 42042-03101 Spindle 1

3 42042-05001 Spindle Motor Mounting Bracket 1

4 42042-05009 Spindle Motor Pulley 1

5 42042-05011 Clamp Ring 1

6 43130-05004 Clamp Ring 2

7 V-Belt 1 4R11M2120(2+2)

8 3-Jaw Chuck 1 8” (10”)

9 Spindle Motor 1






A6 Hex. Head Screw 4 M14XP2.0X35L



A9 Flat Washer 6 M12

Version: 005 P 1-26



1.12 Cylinder

Version: 005 P 1-27



1.12.1 Cylinder

Item Part no. Description Q'ty Remark 1 42042-04002 Draw tube 1 42042-04052 Draw tube 1 42042-04102 Draw tube 1 2 42042-04003 Cylinder 1 6” 42042-04053 Cylinder 1 8” 42042-04103 Cylinder 1 10” 3 42042-04004 Coolant Collector 1 42042-04054 Coolant Collector 1 42042-04104 Coolant Collector 1 4 Cover 1

5 42042-04007 Nut 1 6” 42042-04057 Nut 1 8” 42042-04107 Nut 1 10” 6 Adjusting Plate 2

A1 Screw 8 M5X10L A2 Fitting 2 1”PTX1”L A3 Hyd. Hose 2 3/8R1X2800-90°

A4 Clamper 4

Version: 005 P 1-28



1.13 Base

Version: 005 P 1-29



1.13.1 Base

Item Part no. Description Q'ty Remark 1 42042-40001 Base 1 2 43061-40002 Levelling Bolt 6 M20*P1.5 3 43061-40003 Levelling Block 6 ψ80*27

4 43061-40007 Nut 6 M20*P1.5

Version: 005 P 1-30



1.14 X-axis

Version: 005 P 1-31



1.14.1 X-axis

Item Part no. Description Q'ty Remark 1 42042-20001 Carriage 1 2 42042-51001 Ball Screw & Nut 1 ψ32*669

3 42042-51002 Motor Seat 1 4 42042-51008 Bearing Seat 2 5 43130-52004 Cover 2 6 42042-51005 Collar 4 ψ38*18

7 42042-51007 Lock Nut 2 YSF M25*P1.5*18 8 43061-51006 Stopper 4 9 42042-51009 Coupling 1 FANUC

10 43061-51002 Motor Flange 1 FANUC A1 Bearing 4 NSK 25TAC62B A2 Oil Seal 4 ψ38*ψ50*8

A3 Socket Screw 14 M10*1.5*30L A4 Socket Screw 12 M6*1*20L

A5 Socket Screw 11 M8*1.25*25L

A6 Taper Pin 4 #5

Version: 005 P 1-32



1.15 X-axis Linear Guideway

Version: 005 P 1-33



1.15.1 X-axis Linear Guideway

Item Part no. Description Q'ty Remark 1 42042-20001 Carriage 1 2 42042-51011 Linear Guideway 2 H30LEAB2T3-680 3 42042-51012 Block 14 T2


Version: 005 P 1-34



1.16 X-axis Lubrication System

Version: 005 P 1-35



1.16.1 X-axis Lubrication System

Item Part no. Description Q'ty Remark 1 Distributor 1 2 Meter Valve 4 #3 3 Meter Valve 1 #4 4 Plug 1 5 Fitting 6

Version: 005 P 1-36



1.17 Z-axis

Version: 005 P 1-37



1.17.1 Z-axis

Item Part no. Description Q'ty Remark 1 42042-40001 Base 1 2 42042-53001 Ball Screw & Nut 1 ψ32*974

3 42042-53002 Motor Seat 1 4 42042-53003 Bearing Seat 1 5 43130-52004 Cover 2 6 42042-51005 Collar 4 ψ38*18

7 42042-51007 Lock Nut 2 YEF M25*P1.5*18 8 43061-51006 Stopper 4 9 42042-51009 Coupling 1 FANUC

10 43061-51002 Motor Flange 1 FANUC A1 Bearing 4 NSK 25TAC62B A2 Oil Seal 4 ψ38*ψ50*8

A3 Socket Screw 6 M10*1.5*45L A4 Socket Screw 4 M10*1.5*55L A5 Socket Screw 11 M8*1.25*25L A6 Socket Screw 12 M6*1*20L A7 Taper Pin 4 #5

Version: 005 P 1-38



1.18 Z-axis Guideway

Version: 005 P 1-39



1.18.1 Z-axis Guideway

Item Part no. Description Q'ty Remark 1 42042-40001 Base 1 2 42042-53011 Linear Guideway 2 H35LEAB2T3-1080 3 42042-51012 Block 28 T2


Version: 005 P 1-40



1.19 Z-axis Lubrication System

Version: 005 P 1-41



1.19.1 Z-axis Lubrication System

Item Part no. Description Q'ty Remark 1 Distributor 1 2 Meter Valve 4 #3 3 Meter Valve 1 #4 4 Plug 1 5 Plug 1 6 Fitting 5

Version: 005 P 1-42



1.20 Motor

Version: 005 P 1-43



1.20.1 Motor

Item Part no. Description Q'ty Remark 1 X-motor 1 2 Z-motor 1 3 Spindle-motor 1 4 42042-05004 Adjusting Block 2

A1 Socket Screw 6 M12X60L A2 Spring Washer 6 M12 A3 Flat Washer 6 M12 A4 Hex. Head Screw 2 M8X60L A5 Nut 2 M8 A6 Socket Screw 4 M8X35L A7 Hex. Head Screw 4 M14X35L A8 Socket Screw 8 M8X40L

Version: 005 P 1-44



1.21 Tailstock Body

Version: 005 P 1-45



1.21.1 Tailstock Body

Item Part no. Description Q'ty Remark A 42042-86001 Tailstock Body 1 B 42042-86002 Tailstock Base 1 C 42042-86010 Clamp Pad 1 1 42042-86004 Clamp Plate 1 2 42042-86003 Riser 2 3 42042-86007 Gib 1 4 42042-86005 Adjusting Block 1 5 42042-86006 Clamp Plate 1 6 42042-86008 Adjusting Block 1 7 42042-86009 Adjusting Block 1

S1 Hex. Head Screw 4 M12X75L S2 Flat Washer 4 M12 S3 Screw 3 M8X30L S4 Socket Screw 2 M16X150L S5 Flat Washer 2 M16 S6 Hex. Head Screw 1 M10X30L S7 Socket Screw 2 M8X25L S8 Socket Screw 5 M6X12L

Version: 005 P 1-46



1.22 Cable track & Work Light

Version: 005 P 1-47



1.22.1 Cable track & Work Light

Item Part no. Description Q'ty Remark 1 Cable Track 1 74X39XKR100 2 Work Light 1

A1 Socket Screw 4 M6X12L A2 Socket Screw 4 M6X40L

Version: 005 P 1-48



1.23 Tool Setter

Version: 005 P 1-49



1.23.1 Tool Setter


1 E-AREA-85003-01 Seat 1

2 E-AREA-85002-01 Block 1

3 Tool Setter 1

4 Tool Setter Seat 1

A1 Socket Screw 1 M12X35L


A3 Socket Screw 1 M6XP1X50L

Version: 005 P 1-50



1

A19A2

A4

A6

4

7

6

103

5

A32

8

A4

A5

A5

A4

1.24 Parts Catcher

Version: 005 P 1-51



1.24.1 Parts Catcher

Item Part no. Description Q'ty Remark 1 42042-85010 Block 1 2 Parts catcher assembly 1 3 42042-85019 Arm 1 4 42042-85020 Catcher 1 5 42042-85021 Rod 1 6 42042-85022 Chip Cover 1 7 42042-85023 Cover 1 8 42042-85024 Dog 1 9 42042-85026 Plate 1

10 42042-85031 Dog 1 A1 Socket Screw 2 M12X35L A2 Socket Screw 3 M8XP1.25X12L A3 Socket Screw 4 M8XP1.25X100L A4 Screw 8 M6XP1.0X10L A5 Socket Screw 2 M8XP1.25X16L A6 Socket Screw 2 M8XP1.25X16L

Version: 005 P 1-52



1.25 Full Splash Guard

Version: 005 P 1-53



1.25.1 Full Splash Guard

Item Part no. Description Q'ty Remark 1 42042-70001 Full Guard 1

2A 42042-70005 Control Panel 1 FANUC 2B 42042-70008 Control Panel 1 For Milltronic 2C 42042-70006 Control Panel 1 Fagor 2C1 42042-70007 Control Box 1 Fagor 8040

3 42042-70003 Side Guard-Right Headstock 1 4A 42042-70012 Clamp Plate 1 LT-42 4B 42042-70013 Clamp Plate 1 LT-52 4C 42042-70036 Clamp Plate 1 LT-65 5 42042-70010 Rear Guard 1 6 42042-70011 Rear Cover 1 7 42042-70014 Cover 2 8 42042-70017 Cover 1 9 42042-70018 Cover 1

10 42042-70019 Cover 1 11 42042-70020 Cover 2 12 42042-70021 Front Cover 1 13 42042-70022 Left Cover 1 14 42042-70023 Cover-Spindle Bore 2 15 42042-70024 Slide 1 16 42042-70028 Transfer Box 1 17 42042-70029 Side Cover 1 18 42042-70037 Guard-Base 1 19 42042-70038 Cover 1

20A 42042-70040 Sliding Door 1 20B 42042-70070 Sliding Door 1 For Parts catcher 21 42042-70041 Oil Collector 1 22 42042-70046 Clamper-Wheel 2 23 42042-70047 Clamp Plate 2 24 42042-70048 Clamp Plate 2 25 42042-70055 Roller Bracket 2 26 42042-70058 Right Cover 1 27 42042-70067 Front Cover 1 28 42042-70073 Oil Revisor 1 29 42042-71001 Electric Box 1 30 42042-71002 Door 1 31 42042-71011 Cover plate 2

Version: 005 P 1-54



32 42042-71012 Cover plate 1 33 42042-71014 Cover 1 34 E-ARAK-70024-01 Safety glass 1 535*620 35 Wheel 2 36 Bearing 4 608ZZ

Version: 005 P 1-55



1.26 Chip Conveyor & Coolant Tank

Version: 005 P 1-56



1.26.1 Chip Conveyor & Coolant Tank

Item Part no. Description Q'ty Remark 1 42042-41001 Coolant Tank 1 2 42042-41010 Chip Tank 1 3 42042-41015 Chip Conveyor 1 4 Bucket 1 5 Spacer 1 6 42042-41050 Coolant Pump 1 7 Pipe 1

A1 Socket Screw 9 M10X30L A2 Socket Screw 4 M80X30L A3 Fitting 2 1”PTX3/8”H A4 Check Valve 1 3/4”PT A5 Fitting 1 3/4”PT A6 Clamper 2

LT-42_52_65

Documents

date of version

version date

revised updated date

manual version ch

parts list version

content ch3

content ch8

encoder ch