okuma ES-L10 Maintenance Manual

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SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

The machine is equipped with safety devices, which serve to protect personnel and machine itself from hazards arising from unforeseen accidents. But operators must not rely exclusively on these safety devices. They must also become fully familiar with the safety guidelines presented below to ensure the accident-free operation.

This instruction manual and the warning signs attached to the machine cover only those hazards which Okuma can predict. Be aware that they do not cover all possible hazards. For safety consideration, the operator must be skilled and has been trained. And every operator must read this manual carefully before operating the machine.

Furthermore, the standard machine cannot incorporate with the ancillary handling device (e.g. robot) and if incorporate the redesign of the safety guarding system is required. Never try to install other devices by yourselves for safety consideration.

1.BEFORE TURNING ON THE POWER

(1)Make sure that the doors to the operation panel and the electric control cabinet are closed.

(2)Make sure that there are no obstacles around the machine.

(3)Turn on the main power disconnect switch before turning on the CONTROL ON switch on the operation panel.

2.CHUCK PRECAUTIONS

(1)Always close the front shield before starting the spindle or cutting operations.

(2)Always observe the spindle speed maximums for the installed chuck. Never run the spindle exceeding the maximum allowable spindle speed.

(3)If a chuck or fixture is unique to your application, check the maximum allowable spindle speed and stay

within the limit. Also, take note of the workpiece gripping force and balance.

(4)The maximum spindle speed can be limited by inputting a G50 command with the spindle speed. The G50 command helps to ensure safety in operation.

(5)If the spindle must be rotated close to the maximum allowable spindle speed, observe the following points:

-Make sure that the workpiece clamped in the chuck is balanced.

-Apply the allowable maximum amount of pressure to grip the workpiece because centrifugal force reduces the chuck gripping force.

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SAFETY PRECAUTIONS

The maximum allowable spindle speed and application pressure is indicated on the nameplate on the front shield and on the chuck body. The allowable maximum speed and the applicable pressure ensure a chucking force that is more than one-third over the original chuck gripping force with the standard soft-top jaw set in line with the periphery of the chuck body.

(6)If special jaws (large than standard soft-top jaws) are used, observe the following points:

-Lower the spindle speed because centrifugal force and lower efficiency reduce the chuck gripping force.

-If the jaw-tightening nut (jaw nut) is outside of the periphery of the chuck, only one tightening bolt is holding the jaws in place. This is a potentially dangerous condition. Jaw nuts must always be within the periphery of the chuck.

-Machine the jaws to the workpiece shape.

(7)Securely tighten the bolts on the chuck body, the jaws, and the black to the specified torque. Use lubrication oil. Make sure that the torque is at least 392 to 490 N [40 to 50kgf (88 to 110 lbf)].

3.GENERAL CHECKS

(1)Check the amount of lubricating oil every day before starting operation.

(2)Always use the specified brand of lubricating oil.

(3)Use the recommended type of type cutting fluid (coolant) when possible.

(4)It is recommended to a water-soluble coolant to prevent fire. Do not attempt unmanned operation if a non-soluble coolant is used.

(5)Change and replenish the lubricating oil and coolant in each reservoir according to the schedules in the manual.

(6)Clean the filters according to the schedules in the manual.

(7)Make sure that each pressure gauge on the air and hydraulic lines display the correct value as described in this manual.

(8)Always turn off the power before beginning any work inside the front shield. In addition, turn off the power before beginning work at the back of the machine that requires an operator to enter the machine-operating zone.

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SAFETY PRECAUTIONS

4.BEFORE STARTING OPERATION

(1)Always follow the instructions in the operation manual.

(2)Never operate the machine without all of protective covers and shields in place.

(3)Always close the front shield before starting operation.

(4)Never attempt to run a new program without checking its operation. Run the program without a workpiece set in the chuck and make sure that there is no interference. After making sure that the program has no bugs, cut a workpiece in the single block mode. If no problems are discovered, automatic operation may be started.

(5)Before attempting the following operations, make sure that they can be accomplished safely.

-Spindle rotation

-Turret indexing

-Axis movement

(6)Never touch chips or the workpiece while the spindle is rotating.

(7)Never attempt to stop a moving object by hand or with a tool.

(8)Check the jaw installation conditions, the hydraulic pressure, and the maximum allowable spindle speed for the power chuck.

(9)Check the installation and arrangement of the tools.

(10)Check the tool offset settings.

(11)Check the zero offset settings.

(12)Make sure that the spindle speed and feedrate override settings are at 100%.

(13)Before feeding the turret, check the software limit setting and the emergency limit LS (limit switch) dog positions for both the X- and Z-axis.

(14)Check the turret index/rotation position.

(15)Check the tailstock body position.

(16)Make sure the cutting operation is within the allowable transmission power and torque ranges.

(17)Make sure that the workpiece securely fitted in the chuck or fixture.

(18)Check the cutting fluid nozzle positions. They must be set to properly supply cutting fluid to the appropriate points.

(19)Check the lamp. The work lamp of 18 W can provide 500 Lux. of lighting and won’t dazzle the operator.

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SAFETY PRECAUTIONS

5.PRECAUTIONS AGAINST FIRE

(1)Use meticulous care to prevent fire especially when performing untended operation.

(2)Use nonflammable coolant.

(3)Do not leave any flammables around the machine.

(4)Do not heap up chips.

(5)Check the tool cutting edge, cutting conditions, and tool life.

6.SET UP

(1)Make sure that setup is complete. Refer to SAFETY PRECAUTION 4. BEFORE STARTING OPERATION.

(2)If the setup is changed, operate the machine step-by-step to make sure that cutting can performed without any problems.

(3)Before changing the chuck and/or chuck jaws, make sure that the chuck fits the intended jog.

(4)If two or more workers must work together, establish signals so that they can communicate (for example, when lifting or setting heavy objects). Each worked should be aware when a new process is about to begin.

(5)Use the crane or equivalent tool to handle heavy objects.

(6)When attempting an unfamiliar setup, recheck the setup before beginning operation.

7.WORKPIECE LOADING AND UNLOADING

(1)Make sure that workpieces are loaded and unloaded securely.

(2)Before loading or unloading a workpiece, retract the turret so that the cutting tools in the turret cannot injure the operator.

(3)Before loading and unloading a workpiece, make sure that the spindle has come to a complete stop.

(4)Before running a new program, rotate the spindle to make sure that the workpiece is securely clamped in the chuck.

(5)Before machining an irregular-shaped workpiece, make sure that it is balanced properly.

(6)When handing heavy workpieces, use the crane, hoist, or other similar tool.

(7)Before loading a workpiece, make sure that the workpiece has a portion that can be used for proper chucking.

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SAFETY PRECAUTIONS

8.AT THE END OF THE DAY

(1)Clean the machine.

(2)Move the turret to the predetermined retraction position.

(3)Turn off the CONTROL ON switch on the operation panel before turning off the main power disconnect switch.

(4)Make sure all power switches are turned off.

9.WHEN A PROBLEM OCCURS

(1)Stop the machine immediately by pressing the EMERGENCY STOP switch on the operation panel.

(2)Consult with the person in charge of maintenance to determine what corrective measures need to be taken.

(3)If two or more workers must work together, establish signals so that they can communicate (for example, when lifting or setting heavy objects). Each worker should be aware when a new process is about to begin.

(4)Only use specified replacement parts and fuses.

10.GENERAL PRECAUTIONS

(1)Wears appropriate clothing.

(2)Keep the machine and the area around it clean and organized.

(3)Never touch the CNC control system or switches with wet hands.

(4)During cleaning the machine, loading and unloading workpiece, an operator must wear safety gloves, goggles and safety shoes. Do not wear gloves when an operator is operating a machine.

(5)During cleaning the machine, an operator must wear safety gloves and use iron-crook.

(6)Dismantle the revolving center of the tailstock before inspecting and maintaining the machine.

(7)The materials such as cast iron ‚carbon steel ‚copper ‚brass ‚bronze and aluminum can be used on this machine. But the flammable materials such as magnesium ‚magnesium alloy ‚carbon bar‚ plastic or wood should be prohibited. Also the low flash point cutting fluid and lubricant is not allowable.

(8)If the workpiece or processing materials are likely to produce the noxious dust, the extraction system should be added.

(9)When the reduced valve of the tailstock is adjusted, it is necessary to adjust the throttle valve of the tailstock to keep the speed of the tailstock center lower than 20 mm/sec for safety consideration.

(10)During a normal operation, the NC PANEL lockable switch should be in the “ lock” position only for authorized persons to operate.

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SAFETY PRECAUTIONS

(11)The disposal of wastes, such as oil, coolant, and chips, must comply the local regulations.

(12)If the buyer wants to change any mechanical or electrical, or electronic/software parts, especially the safety related components, please call our service member or representative for safety considerations. Only after confirming safety and completion of the changing, the machine can be operated.

11.SAFETY DEVICES AND FUNCTIONS

	Contents	Location	Remark
1.	Front shield with safety glass	Machine
2.	Shield open / close interlock	Machine
3.	Chuck interlock	Electric control cabinet
4.	Foot pedal protection cover	Machine
5.	Emergency limit setting LS	Machine
	(Limit switch)
6.	Software limit	Operation panel
7.	Chuck barrier	Operation panel
8.	Turret barrier	Operation panel
9.	Tailstock barrier	Operation panel	Optional
10. Emergency stop button		Operation panel
11.	Slide hold button	Operation panel
12. Alarm display		Operation panel
13. Leakage circuit breaker		Electric control cabinet	Optional
14. Self-locking cylinder for chuck		Machine
15. Cycle start requiring simultaneous		Machine	Optional
	depression of both buttons
16. Turret rotation at low speeds		Machine
	(manual)

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SAFETY PRECAUTIONS

12.SYMBOLS

The following warning indications are used in this manual to draw attention to information of particular importance.

!DANGER

!WARNING

:Indicates an imminent hazard which, if not avoided, will result in death or serious injury.

:Indicates hazards which, if not avoided, could result in death or serious injury.

! CAUTION

NOTICE

:Indicates hazards which, if not avoided, could result in minor injuries or damage to NC unit or other equipment.

:Indicates precautions relating to NC unit operations.

13.FOR SAFE CHUCK WORK

1.Safe the chuck gripping force by ensuring sufficient factor of safety (2 to 3 or over). Run the spindle with the allowable speed range set at this time.

2.Inconstant peripheral speed cutting, calculate the actual machining speed before designating G50 (max. speed limit function).

3.Secure the jaw gripping depth as much as possible.

4.Before machining an unbalanced workpiece, carry out balancing of the workpiece weight by gradually changing the spindle speed.

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SAFETY PRECAUTIONS

5.Never attempt to install jigs using T-nut. Be sure to fix the jigs with bolts.

No chucks prepared by Okuma have T-groove.

6.When inserting a bar material into the hollow chuck, ensure that the bar does not protrude from the rear end of the cylinder.

7.Never use double chucking method.

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SAFETY PRECAUTIONS

14.CAUTION PLATE

-The machine and its components are fitted with various caution plates. Carefully read these plates and follow the instructions described there.

-Do not teat or damage the caution plates. In case a plate has been lost or become illegible, ask us for a new plate, quoting the Tatung-Okuma part number written in this manual.

(1) Caution Plate and Tatung-Okuma Part Number

1)	Tatung-Okuma Part No. 4163-6023-90
			5	4
				3
				2
				5
			1
	1
	2		3
	3	180	3
	4	22	3
	5
				4163-6023-90 E

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SAFETY PRECAUTIONS

2)Tatung-Okuma Part No. 4163-6024-91

3)Tatung-Okuma Part No. 4162-6107-90

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SAFETY PRECAUTIONS

4)Tatung-Okuma Part No. 4162-6108-90

5) Tatung-Okuma Part No. 4162-6157-90

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SAFETY PRECAUTIONS

6)Tatung-Okuma Part No. 4162-6162-90

7)Tatung-Okuma Part No. 4162-6160-90

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SAFETY PRECAUTIONS

15.Others

(1)The machine is designed to cutting iron, aluminum, copper, bronze and cast iron.

For safety consideration, do not cut wood, magnesium ally and other combustible materials.

(2)Be sure to turn off the main power switch before maintaining this machine.

INTRODUCTION

INTRODUCTION

Thank you for choosing a Tatung-Okuma Model L-390 CNC lathe. We are proud to have you among our Tatung-Okuma family of users.

This instruction manual contains concise information on the installation, setup, operation, and maintenance of your Model L-390 CNC lathe. To make the most of its outstanding performance over a long period, the machine must be properly installed and operating and maintenance procedures must be clearly understood and carefully followed. You are encouraged to study this instruction manual carefully before the machine is installed and to keep it on file for future reference.

			P- (i)
			TABLE OF CONTENTS
		TABLE OF CONTENTS
				PAGE
SECTION 1		MACHINE SPECIFICATIONS
			1
1.	SPECIFICATION TABLE..................................................................................................................		1
2.	DIMENSIONAL DRAWINGS ..........................................................................................................		3
SECTION 2....HANDLING AND INSTALLATION OF MACHINE ................................................			4
1.	GUIDE TO SELECT A INSTALLATION SITE ..................................................................................		4
2.	CARE IN HANDLING A PRECISION MACHINE ............................................................................		5
	2-1.	Machine Lifting ......................................................................................................................	5
	2-2.	Precaution for Lifting...............................................................................................................	6
	2-3.	Rolling .....................................................................................................................................	6
3.	FOUNDATION REQUIREMENTS....................................................................................................		6
	3-1. General Precautions for Building a New Foundation .............................................................		6
4.	GENERAL PROCEDURE FOR INSTALLATION .............................................................................		7
	4-1.	Procedure for Installation .......................................................................................................	7
	4-2.	Precautions for Installation.....................................................................................................	7
5.	LEVELING THE MACHINE ..............................................................................................................		8
	5-1.	Leveling Procedure ................................................................................................................	8
6.	FOUNDATION PLAN........................................................................................................................		9
7.	POWER REQUIREMENT ................................................................................................................		10
	7-1. Inspection of Cable Connection .............................................................................................		10
	7-2.	Electrical Work........................................................................................................................	11
SECTION 3		MACHINE OPERATION ......................................................................................	13
1.	BEFORE STARTING OPERATIONS ...............................................................................................		13
	1-1.	NC Operation ..........................................................................................................................	13
	1-2.	Setting Zero Offsets................................................................................................................	29
	1-3.	MC User Parameter................................................................................................................	41
	1-4.	Alarm.......................................................................................................................................	43
	1-5.	Operation of Safety Interlock ..................................................................................................	44
	1-6.	Measures for Operation in Extreme Cold Regions.................................................................	45

			P- (ii)
			TABLE OF CONTENTS
			PAGE
2.	MACHINE OPERATION ................................................................................................................		46
	2-1.	Hydraulic Unit..........................................................................................................................	46
	2-2. Selection of Spindle Motor Speed...........................................................................................		49
	2-3.	Hydraulic Chuck......................................................................................................................	51
	2-4.	Manual Turret Operation.........................................................................................................	60
	2-5. Cutting Soft Top Jaws of Power Chuck ..................................................................................		61
	2-6.	Hydraulic Tailstock Operation.................................................................................................	64
	2-7. Cautions on Operating the Turret ...........................................................................................		67
	2-8.	Interlock Function ...................................................................................................................	67
	2-9.	Safety Door Switch .................................................................................................................	70
	2-10. Manually Operated Chuck .......................................................................................................		72
SECTION 4 INSPECTION AND MAINTENANCE OF MACHINE.............................................			80
1.	LUBRICATION..................................................................................................................................		81
	1-1.	Spindle Lubrication System ....................................................................................................	84
	1-2.	Slide way Lubrication System .................................................................................................	84
2. ADJUSTING CENTRALIZED LUBRICATION UNIT ........................................................................			85
	2-1.	Adjusting Pump Delivery ........................................................................................................	85
	2-2.	Maintenance and Countermeasure ........................................................................................	85
	2-3	Other Remarks ........................................................................................................................	85
3.	CLEANING COOLANT PUMP..........................................................................................................		86
	3-1.	Maintenance ...........................................................................................................................	86
4.	TENSIONING BELTS.......................................................................................................................		87
	4-1.	Spindle Drive Belts..................................................................................................................	87
	4-2 Timing Belt for Z-axis Servo Motor ..........................................................................................		89
	4-3 Timing Belt for X-axis Servo Motor ..........................................................................................		90
5.	OTHER MAINTENANCE ITEMS......................................................................................................		91
	5-1. Adjusting the Turret Rotation Speed.......................................................................................		91
	5-2.	Alignment of Headstock..........................................................................................................	92
	5-3. Adjustment of Tapered Gibs on Saddle Cross-slide...............................................................		93
	5-4.	Cautions on Checking the X-axis Ball Screw and Related Parts............................................	94

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TABLE OF CONTENTS

			PAGE
6.	TROUBLESHOOTING FOR SIMPLE MECHANICAL TROUBLE....................................................		95
	6-1.	Trouble with Headstock ..........................................................................................................	95
	6-2.	Trouble with Turret..................................................................................................................	95
	6-3.	Others .....................................................................................................................................	101
7.	MACHINE RESTARTING.................................................................................................................		102
8.	CHIPS COLLECTION AND REMOVAL............................................................................................		104
9.	TROUBLE OF BLOCKAGE..............................................................................................................		104
SECTION 5 SPARE PARTS LIST.............................................................................................			105
1.	HYDRAULICS...................................................................................................................................		105
2.	ELECTRICALS (ON MACHINE).......................................................................................................		106
3.	CONSUMABLE ITEMS ....................................................................................................................		107
SECTION 6		TECHNICAL DATA ...............................................................................................	108
1.	TOOLING SYSTEM..........................................................................................................................		108
2.	V8 TURRET DIMENSIONS..............................................................................................................		109
3.	V12 TURRET DIMENSIONS............................................................................................................		110
4.	V8 TOOLHOLDER DIMENSIONS....................................................................................................		111
5.	TOOL INTERFERENCE DIAGRAM (V8 TURRET) .........................................................................		113
6.	TOOL INTERFERENCE DIAGRAM (V12 TURRET) .......................................................................		114
7.	WORKING RANGE DIAGRAM (V8 TURRET).................................................................................		115
	7-1. Standard Specification (Without Tailstock).............................................................................		115
	7-2.	Tailstock Specification (With Tailstock) ..................................................................................	117
8.	WORKING RANGE DIAGRAM (V12 TURRET)...............................................................................		119
	8-1. Standard Specification (Without Tailstock).............................................................................		119
	8-2.	Tailstock Specification (With Tailstock) ..................................................................................	121
9.	DIMENSION OF SPINDLE NOSE (JIS A2-8)...................................................................................		123
10.	HYDRAULIC SOLID CHUCK AND CYLINDER................................................................................		124
11.	HYDRAULIC HOLLOW CHUCK AND CYLINDER...........................................................................		125
12.	HYDRAULIC TAILSTOCK ................................................................................................................		126
13.	HYDRAULIC CIRCUIT DIAGRAM....................................................................................................		127
14.	CHIP CONVEYOR (OPTIONAL)......................................................................................................		129
15.	PLC ALARM LIST.............................................................................................................................		131

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SECTION 1 MACHINE SPECIFICATION

SECTION 1 MACHINE SPECIFICATIONS

1.SPECIFICATION TABLE

	Item		Unit		Specifications
CAPACITY:
	No. of controlled axes						2
	Swing over bed		mm (in.)			520 (20.47)
	Swing over carriage		mm (in.)			450 (17.72)
	Swing over cross-slide		mm (in.)			300 (11.81)
	Max. turning diameter		mm (in.)		390 500 (		15.35 19.6) for V8
	x length		x mm (in)		310x 500 (		112.2 19.6) for V12
SPINDLE:
	Spindle diameter		mm (in.)			120 (4.72)
	Spindle nose type					JIS A2-8
	Taper hole		mm (in.)		90 (3.54) 1/10
	Through-spindle hole		mm (in.)				80 (3.15)
	No. of spindle speed ranges			Stepless x Auto 2 steps (Coil changeable)
	Spindle speed		min-1{rpm}		25 to 3,000
CROSS-SLIDE (X-AXIS):
	Axis travel		mm (in.)	220 = 195+25 (8.66 =7.68+0.98) for V8
				220 = 155+65 (8.66 =6.1+2.56) for V12
	Feedrate		mm/rev	0.001 to 1,000.000 (0.00004 to 39.37)
			(ipr)
	Rapid feedrate		mm/min		15,000 (590.55)
			(ipm)
CARRIAGE (Z-AXIS):
	Axis travel		mm (in.)		520 (20.47)
	Feedrate		mm/rev	0.001 to 1, 000.000 (0.00004 to 39.37)
			(ipr)
	Rapid feedrate		mm/min		20,000 (787.40)
			(ipm)
TURRET:
	Type						V
	No. of tools						8 [*12]
	Tool size	OD turning tools	mm (in.)			□ 25 (1)
		ID turning tools	mm (in.)				40 (1.5)
TAILSTOCK*:
	Tailstock spindle diameter		mm (in.)				90 (3.54)
	Tailstock spindle taper hole				MT No.5 (revolving center)

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			SECTION 1 MACHINE SPECIFICATION
	Item	Unit	Specifications
Tailstock spindle travel		mm (in.)	100 (3.94)
MOTOR:
	Spindle drive motor	kW (hp)	VAC 15 / 11 ( 20 / 15 ) ( 30min / cont.)
			VAC 11 / 7.5 ( 15 / 10 ) ( 30min / cont.)
	Carriage feed (Z-axis)	kW (hp)	3	(4)
	Cross-slide feed (X-axis)	kW (hp)	2 (2.7)
	Hydraulic power unit pump	kW (hp)	1.5 (2)
	Guideway lubrication pump	kW (hp)	0.017	(0.023)
	Coolant pump	kW (hp)	0.19	(0.25)
MACHINE HEIGHT		mm (in.)	1,795	(70.67)
FLOOR SPACE REQUIRED		mmxmm	2550 x 1970(100.39 x 77.56)		15/11kW
		(in.x in.)	2280 x 1970(89.76 x 77.56)		11/7.5kW
NET WEIGHT		kg (lb.)	3,800 (8377)

* V12 Turret,Tailstock is optional.

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SECTION 1 MACHINE SPECIFICATION

2.DIMENSIONAL DRAWINGS

15/11kW ONLY

Fig. 1-1 Dimensional Drawing

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SECTION 2 HANDLING AND INSTALLATION OF MACHINE

SECTION 2 HANDLING AND INSTALLATION OF MACHINE

This section outlines the procedures for handling and installing your CNC lathe when it has to be moved to a place area due to any change in your plant layout.

Most precautions noted may also apply to the initial installation of a CNC lathe at your plant.

1.GUIDE TO SELECT A INSTALLATION SITE

In order to ensure high machine accuracy and performance, the following points should be considered with regard to the installation site.

(1)Foundation work is advised for sites where the subsoil is soft, to prevent the machine from titling or sinking after installation.

For details regarding foundations, refer to SECTION 2, 3. Of the Operation Manual.

(2)The installation site should be as far as possible from vibration sources such as roads, stamping/press equipment, or planer machine tools.

If nearby sources of vibration are unavoidable, prepare dampening pits around the foundation to reduce the vibration effects.

(3)NC malfunctions could result from the proximity of high-frequency power generator, electric discharge machines, and electric welding machines, or when power is supplied from the same distributor panel as these machines.

For wiring details, consult our service engineer dispatched to assist with installation.

(4)The ideal operating environment calls for an ambient temperature of 20° C, with humidity between 40 and 75%.

(5)Keeping the ambient temperature at a constant level is an essential factor for accurate machining.

(6)In order to maintain static machine accuracy within guaranteed values, the machine installation site should be air-conditioning is not required, the optimal ambient temperature range is 17° C to 25° C.

(7)To maintain static machine accuracy at levels even higher than the standard guaranteed values:

a)Keep the ambient temperature variance for 24 hours (1 day) within ± 2° C

b)Ambient temperature variances from floor level to a height of about 5 meters should be held within 1° C.

(8)The machine is capable of operating correctly at the altitude up to 1,000 m above mean sea level.

(9)During transportation and storage, the temperature must be within a range of -25° C to 55° C and for a short period not exceeding 24 hr. at up to 70° C.

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SECTION 2 HANDLING AND INSTALLATION OF MACHINE

2.CARE IN HANDING A PRECISION MACHINE

The CNC lathe consists essentially of four major components: the machine, the electric control box, the hydraulic power unit and the CNC unit. Model ES-L10 CNC lathe is built in one unit and it can be easily moved without separating it into consisting units.

Lifting and moving machine:

There are two different methods for moving the entire machine to any desire location; by an overhead crane, using lifting hooks supplied together with the machine and by rolls over which the machine is pushed by manual labor.

2-1. Machine Lifting

Hydraulic unit

Hole

Unit

Hook

Hook

Front cover		Hook

Fig. 2-1 Machine Lifting

Procedure:

(1)Detach the chip bucket and chip conveyor.

(2)Drain the coolant from the tank in leg.

(3)Move the saddle to the right.

(4)Open the front chip cover halfway.

(5)Fix the lifting hooks at the predetermined position.

(6)The crane can be loaded 5ton (or up) for lift lathe.

							P- 6
							SECTION 2 HANDLING AND INSTALLATION OF MACHINE
2-2. Precautions for Lifting
				:		(1)	The cables should have a nominal diameter of 16 mm (0.63in.) or larger.
!		WARNING
						(2)	Change an angle formed by each cable line so that the cables will not contact the
							finished surfaces of the machine. (The cables may not form an angle larger than 40
							degrees to the perpendicular line.)

(3)Check for balance and be very careful when lifting the machine.

(4)Use extra care to lower the machine gently onto the floor; NEVER APPLY SHOCKS TO THE MACHINE WHEN PLACING IT ON FLOOR.

Approximate Weight of Machine

3800 kg(8377lb)

(Machine weight indicated above includes the weight of hydraulic power unit, electrical control box and CNC unit, but not the weight of chip conveyor.)

2-3. Rolling

! WARNING :

Be careful that the machine does not tip over on any side so that the machine base may not strike the ground.

3. FOUNDATION REQUIREMENTS

3-1. General Precautions for Building a New Foundation

NOTICE : In most plants where concrete floors are solid and level, your CNC lathe may be installed without anchoring it to the floor and then used satisfactorily if leveled carefully.

For long-maintained accuracy and where sub-soil or ground under the floor is not strong enough, a new concrete foundation should be set up in accordance with the Foundation Plan attached to this Manual. (See 6.)

(1)Foundation requirements vary depending on the characteristics of the sub-soil. Under any soil conditions, it is important that sub-soil should be well compacted to keep the foundation from unsetting once the machine has been installed.

(2)Where sub-soil is too soft, it is necessary to drive concrete piles into the sub-soil.

(3)The Foundation Plan attached to this Manual is prepared for laying a typical concrete foundation specifically for the machine. The concrete thickness or depth should be determined in terms of the ground condition in each case.

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SECTION 2 HANDLING AND INSTALLATION OF MACHINE

4. GENERAL PROCEDURE FOR INSTALLATION

4-1. Procedure for Installation

(1)Place leveling plates, 150×150×19mm (5.91×5.91×0.75in.) over individual foundation bolt-holes. Refer to the Foundation Plan.

(2)Place foundation washers (furnished together with the machine) on the leveling plates and then place the machine on them.

(3)Pass foundation bolts through the hole in the leveling plate and a center bore through the built-in jack screw assembly.

(4)Use wedge pieces, shims, or leveling blocks under the machine base to level the machine approximately.

(5)Pour mortar into the foundation bolt holes and allow it to set.

(6)After the mixture has become hard enough, remove the shims or leveling blocks from under the machine base, and level the machine within the specified limits.

4-2. Precaution for Installation

(1)Keep the underside of the leveling plates free from any oily substance.

(2)With leveling jack screws resting on foundation washers, the bottom surfaces of the machine base casting should be about 10 to 20mm (0.39 to 0.79in.) above concrete floor level.

(3)Fill the foundation bolt holes with mortar so as to reach the underside of the respective leveling plates. Be sure to compact the mortar thoroughly.

10 to 20mm (0.39 to 0.79in)

The part names shown in are not supplied as standard equipment

Fig. 2-2 Precautions for Installation

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SECTION 2 HANDLING AND INSTALLATION OF MACHINE

5. LEVELING THE MACHINE

The machine must be carefully leveled because the accuracy of the level at the initial installation will greatly affect the working accuracy and the service life of the machine.

	No. of Leveling	Remarks
	Jack Screws
	5	Pass foundation bolts.

5-1. Leveling Procedure

(1)Measure the machine level at both right and left ends of bed ways in the X- and Z-axis directions. Set the feedrate override at about 30%.

Precision level

Turret

Leveling fixture

Fig2-3 Leveling Procedure

(2)Readings are taken on both longitudinal and transverse directions while both the leveling jack screws and the foundation bolt nuts are tightened firmly.

Tolerance : 0.04 mm per 1000 mm (0.0005 in./ ft)

Accuracy of level : 1 div.=0.02 mm per 1000 mm (0.00025 in./ft)

Plan Foundation 4-2 .Fig

Outline of machine Enclosing cover

Concrete range

	.6
Mortar filter port	FOUNDATION
	PLAN

Spindle center

Note1: This foundation plan is typical.

Concrete thickness is determined in accordance with sub-soil conditions. Note2: Customers should have on hand the parts for installation of machine.

1)Foundation bolt M16 …………………5 pcs.

2)Nut and washer for above M16 ……..5 pcs. each

3)Leveling plate 150 x 150 x 19…….…5 pcs.

(5.91 x 5.91 x 0.39in.) These parts are available as options.

Concrete pillar

(for soft subsoil)

Unit: mm (in.)

9 -P MACHINE OF INSTALLATION AND HANDLING 2 SECTION

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SECTION 2 HANDLING AND INSTALLATION OF MACHINE

7. POWER REQUIREMENTS

Fig.2-5 Power Requirements

	3-phase power source	220 / 380V, 50 / 60Hz
	Main motor	15 / 11 kW ( 20 / 15 Hp)
		11 / 7.5 kW ( 15 / 10 Hp)
	Automatic circuit breaker	75 A min for 15 / 11kW
	fusing capacity	60 A min for 11 / 7.5 kW
	Cable size	22 mm² (0.034 in²) for 15 / 11kW
		14 mm² (0.022 in²) for 11 / 7.5 kW

7-1. Inspection of Cable Connection

The operator can check correctness of cable connection by reading the pressure gauge whether it indicates the specified pressure level.

Confirm that the pressure gauge indicates the set pressure {3.9Mpa {40kgf/cm2 (568.8psi)}} When it indicate the specified pressure level, the electrical connection is correct.

				P- 11
				SECTION 2 HANDLING AND INSTALLATION OF MACHINE
7-2.		Electrical Work
!		CAUTION		: (1) Connect the ground to the external protector connection terminal (PE) located inside
				the control box.

(2)Do not connect the power cord and the grounding wire in serial; if attempted, it will give adverse affect to other equipment or cause malfunctioning of the leak breaker, etc.

(3)When a leak breaker is used, select the one meeting the following rating.

-For inverter circuit use

-Sensitive current of 100mA or more

-Middle-sensitivity high-speed inverter type

(4)If more than one machine tool is connected to the same single power source, the value of “inductance of power source” for each machine is obtained by dividing the value in the table by the number of machine tools to be connected.

(5)Wiring inductance in 50m (164.05ft) cable is approximately 12 H when general KIV cable is used.

(6)The momentary voltage variation ratio is calculated in the manner as explained below. If the “excessive voltage variation ratio” warning function which function functions if power source inductance is higher than the allowable limit does not give warning signal and if the momentary voltage variation ratio is lower than the value indicated in the table above, then it is assumed that the power source inductance is lower than the limit.

(7)For further information on the momentary voltage variation ratio and power source induction, please contact your local Okuma service representative.

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SECTION 2 HANDLING AND INSTALLATION OF MACHINE

Calculating momentary voltage variation ratio:

(1)As indicated in the illustration above, connect the AC voltmeter to the power supply terminals at the spindle drive motor controller or the machine.

(2)Measure the voltage while the spindle drive motor is stopped. Take this value as “V0”.

(3)Measure the voltage while the spindle drive motor is decelerating. Take this value as “V1”.

(4)Calculate the momentary voltage variation ratio using the following formula:

Momentary voltage variation ratio = (V1-V0)/V0

Note 1: Since a digital AC voltmeter has slow response, momentary voltage variation ratio obtained using the voltage measured with the digital AC voltmeter is lower than the actual value. To obtain the precise value, it is recommended to use an analog voltmeter.

Note 2: Voltage “V1” cannot be measured accurately if motor decelerating time is short. Therefore, it is recommended start deceleration from as high spindle speed as possible.

Note 3: If the “excessive voltage variation ratio” warning function which functions if power source inductance is higher than the allowable limit gives a warning, output is restricted by the spindle drive motor controller. Therefore, the momentary voltage variation ratio calculated using voltage which has been measured under such situation does is not reliable.