ME12-008-R01a

HORIZONTAL MACHINING CENTER

MB-H Series
OPERATION & MAINTENANCE(1st Edition)Pub No. 5963-E (ME12-008-R1) Mar. 2012
MB-4000HMB-5000HMB-8000H

5963-E P-(i)INTRODUCTION

INTRODUCTION

Thank you very much for your purchase of this machine.This instruction manual contains information on correct machine operation that is essential for maximizing performance and for maintaining machine precision. It also covers essential information on machine inspection and maintenance as well as safety precautions.Please read it carefully and follow the instructions contained.Please also refer to the [Separate volume technical sheet].For information related to the Control Apparatus, please see the separately provided [Control Apparatus Related Manual].

Note

In this manual, all dimensions in the images are in "mm (inch)" unless otherwise specified.

5963-E P-(i)TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION 1 SAFETY GUIDE ....................................................................................1

1-1. General advice .................................................................................................................. 1

1-2. Basic security advice ......................................................................................................... 1

1-2-1. Warning signals and symbols.............................................................................. 1

1-2-2. Electric system .................................................................................................... 4

1-2-3. Strong magnetic fields......................................................................................... 4

1-2-4. Pneumatic, hydraulic and coolant system ........................................................... 5

1-2-5. Laser radiation..................................................................................................... 6

1-3. Personal security ............................................................................................................... 7

1-4. Intended use...................................................................................................................... 7

1-5. Improper use ..................................................................................................................... 8

1-6. What to do in case of emergency ...................................................................................... 9

1-6-1. Emergency stop .................................................................................................. 9

1-6-2. Fire protection ..................................................................................................... 9

1-7. General advice for the user ............................................................................................. 10

1-7-1. Prerequisites for operating the machine............................................................ 10

1-7-2. Caution plates ................................................................................................... 10

1-7-3. Structural alterations to machines and systems................................................ 11

1-7-4. Replacement parts ............................................................................................ 11

1-7-5. Requirements for operators and maintenance staff .......................................... 12

1-7-6. Special applications........................................................................................... 13

1-7-7. Safety at the workplace ..................................................................................... 13

1-8. Tools/tool change ............................................................................................................ 14

SECTION 2 OUTLINE.............................................................................................15

2-1. Features of this machine ................................................................................................. 15

2-1-1. Features of machine components ..................................................................... 16

2-1-2. Features of machine functions .......................................................................... 17

2-2. Parts of the machine........................................................................................................ 19

2-2-1. Main unit............................................................................................................ 19

2-3. Machining range and workpiece dimensions................................................................... 21

2-3-1. Machining range (pallet table) ........................................................................... 21

2-3-2. Max. workpiece dimensions .............................................................................. 25

2-3-3. Precautions related to workpieces and tools..................................................... 29

2-4. Safety functions ............................................................................................................... 30

2-4-1. Interlock and door lock functions....................................................................... 30

2-4-2. Door lock switch positions and types ................................................................ 30

2-4-3. Door lock releasing in emergency ..................................................................... 34

2-4-4. Door interlock function....................................................................................... 35

5963-E P-(ii)TABLE OF CONTENTS

SECTION 3 TRANSPORT AND INSTALLATION....................................................37

3-1. About safety..................................................................................................................... 37

3-2. Site selection guidelines .................................................................................................. 38

3-3. Foundation requirements................................................................................................. 38

3-4. Fixing the machine to the floor with hole-in (chemical) anchors ...................................... 40

3-5. Transporting the machine................................................................................................ 41

3-5-1. Lifting the machine ............................................................................................ 41

3-5-2. Lifting the coolant tank ...................................................................................... 51

3-5-3. Lifting the APC unit............................................................................................ 54

3-5-4. Lifting the ATC magazine for 40/60 tools .......................................................... 54

3-5-5. Cautions for truck transportation ....................................................................... 55

3-5-6. When removing Y-axis motor ............................................................................ 55

3-6. Preparation before delivery ............................................................................................. 55

3-6-1. About fixtures .................................................................................................... 55

3-6-2. Power supply..................................................................................................... 56

3-6-3. Power requirements and fuse capacity ............................................................. 58

3-6-4. Inspection of cable connection .......................................................................... 59

3-6-5. Preparation of air source ................................................................................... 61

3-6-6. Factory water supply ......................................................................................... 62

3-6-7. Oil for trial runs .................................................................................................. 63

3-7. Machine installation ......................................................................................................... 64

3-7-1. Temporary leveling............................................................................................ 64

3-7-2. Assembling the units and parts shipped separately and preparing for operation ........................................................................................................... 64

3-7-3. Leveling the machine ........................................................................................ 65

SECTION 4 PREPARATION FOR OPERATION.....................................................68

4-1. Supplying lubricating oil/hydraulic oil ............................................................................... 68

4-1-1. Lubrication oil charts ......................................................................................... 69

4-1-2. Symbols............................................................................................................. 75

4-1-3. Lubrication oils for machine tools ...................................................................... 76

4-2. Lubrication and inspection method.................................................................................. 77

4-2-1. Supplying oil for the hydraulic power unit.......................................................... 77

4-2-2. Supplying oil for the oil-air lubrication unit......................................................... 80

4-2-3. Supplying oil for the spindlehead cooling unit ................................................... 81

4-2-4. Centralized lubrication unit ................................................................................ 84

4-2-5. Supply to table (pallet) drive gearbox................................................................ 86

4-2-6. Oil filling to lubricator ......................................................................................... 89

4-2-7. Lubricating the toolpot ....................................................................................... 90

4-3. Lubrication warning system - lubrication alarm................................................................ 91

4-4. Automatic centralized lubrication..................................................................................... 92

4-4-1. Confirmation of automatic lubricant supply intervals ......................................... 92

4-4-2. Parameter data setting for the automatic lubrication timer................................ 93

5963-E P-(iii)TABLE OF CONTENTS

4-5. Waste oil .......................................................................................................................... 94

4-5-1. Drain oil tank for X-, Y-, Z-axes guideways ....................................................... 94

4-6. Backlash adjustments for table drive worm gear ............................................................. 96

4-7. Maintenance and inspection of HSK tool clamping unit (optional)................................... 98

4-7-1. Greasing clamping unit...................................................................................... 98

4-7-2. Inspecting the packing used in the clamping unit.............................................. 99

4-8. Coolant .......................................................................................................................... 100

4-8-1. Coolant unit specification ................................................................................ 100

4-8-2. Coolant tank .................................................................................................... 101

4-8-3. Oil-coolant tank ............................................................................................... 105

4-8-4. Coolant precautions ........................................................................................ 107

4-8-5. Recommended coolant ................................................................................... 107

4-8-6. Fire precautions............................................................................................... 109

4-8-7. Other precautions for using non-water-soluble (oil-based) coolant................. 109

4-8-8. Classification of (water-soluble) coolant performance..................................... 110

4-9. Chip pan ........................................................................................................................ 112

4-9-1. Chip pan configuration .................................................................................... 112

4-10. Oil hole holder ............................................................................................................... 113

4-10-1. Specifications .................................................................................................. 113

SECTION 5 OPERATION......................................................................................115

5-1. Operation panels ........................................................................................................... 115

5-2. Before starting operation ............................................................................................... 117

5-2-1. General checks ............................................................................................... 117

5-2-2. Before turning on the power ............................................................................ 117

5-2-3. Precautions during manual operation and continuous operation .................... 118

5-2-4. Spindle precautions......................................................................................... 119

5-2-5. Tool precautions.............................................................................................. 119

5-2-6. Things to remember during set-up and configuration...................................... 120

5-2-7. Workpiece loading and unloading ................................................................... 120

5-2-8. Dry and minimum quantity machining (MQL) .................................................. 121

5-2-9. When a problem occurs .................................................................................. 121

5-3. Manual operation, preparatory operation ...................................................................... 123

5-3-1. Power ON/OFF................................................................................................ 123

5-3-2. Emergency stop .............................................................................................. 126

5-3-3. Spindle rotation in neutral (spindle release) .................................................... 127

5-3-4. Spindle indexing (position stopping of the spindle) ......................................... 128

5-3-5. Clamping and unclamping the tool in spindle.................................................. 131

5-3-6. Reference information on [MOLYKOTE 321] .................................................. 133

5-4. When starting the machine............................................................................................ 135

5-5. Spindle speed selection................................................................................................. 136

5-5-1. Spindle speed selection .................................................................................. 136

5-5-2. Spindle speed - spindle power/torque diagrams ............................................. 140

5963-E P-(iv)TABLE OF CONTENTS

5-6. Spindle CW, CCW, STOP ............................................................................................. 145

5-6-1. Operating conditions ....................................................................................... 145

5-6-2. Operating method............................................................................................ 145

5-7. Feeding the X-, Y-, and Z-axes ..................................................................................... 146


5-7-2. Rapid feed operation procedure...................................................................... 147

5-7-3. Running-in operations ..................................................................................... 148

5-7-4. Manual feed operation..................................................................................... 149

5-7-5. Automatic feed operation ................................................................................ 150

5-8. Manual pulse feed ......................................................................................................... 151



5-9. Coolant unit ................................................................................................................... 155

5-9-1. Coolant nozzle................................................................................................. 155

5-9-2. Coolant operation ............................................................................................ 157

5-10. Chip conveyor (floor type) ............................................................................................. 158

5-10-1. Chip conveyor configuration............................................................................ 158

5-11. Panel light ...................................................................................................................... 160

5-11-1. Panel light location .......................................................................................... 161

5-12. Table indexing operation ............................................................................................... 163

5-13. Oil mist coolant supply system (with air blow circuit)..................................................... 164

5-14. Nozzle chip air blower ................................................................................................... 166

5-14-1. Nozzle location ................................................................................................ 166

5-15. Operation end lamp, buzzer and auto power shutoff lamp (signal tower) ..................... 168

5-15-1. Display lamp location ...................................................................................... 169

SECTION 6 MAINTENANCE, INSPECTION AND ADJUSTMENTS ....................170

6-1. General information ....................................................................................................... 172

6-2. Cleaning agents............................................................................................................. 172

6-3. Periodical inspection schedule ...................................................................................... 173

6-3-1. Precautions for cleaning the safety window .................................................... 173

6-4. Adjustment of hydraulic unit .......................................................................................... 174

6-4-1. Source pressure adjustment and pressure indication ..................................... 174

6-5. Adjustment for regulator, lubricator, and air filter........................................................... 180

6-6. Precautions regarding spindle rotation (15,000 min-1 (No.40), 6,000 min-1/12,000 min-1 (No.50))..................................................................................................... 182

6-6-1. Spindle lubrication (oil-air)............................................................................... 182

6-6-2. Lubricating oil and air supply conditions.......................................................... 184

6-6-3. Lubrication alarms and reset method .............................................................. 184

6-6-4. Spindle bearing life.......................................................................................... 185

6-6-5. Spindle bearing life counter function ............................................................... 186

6-6-6. Replacement of spindle unit ............................................................................ 187

6-7. Adjusting micro mist separator ...................................................................................... 188

5963-E P-(v)TABLE OF CONTENTS

6-8. Cleaning the air filter of the spindlehead cooling unit (cooler) ....................................... 189

6-8-1. Spindlehead cooling unit configuration............................................................ 190

6-9. Changing the work lamp (fluorescent lamp) .................................................................. 193

6-10. Halogen lamp bulb (optional) changing procedure ........................................................ 195

6-11. Cleaning the coolant unit ............................................................................................... 198

6-11-1. Cleaning .......................................................................................................... 198

6-12. Procured parts ............................................................................................................... 201

6-13. Glass window in the operation door .............................................................................. 201

6-13-1. Operation door window glass replacement ..................................................... 202

SECTION 7 ATC....................................................................................................204

7-1. ATC safety precautions ................................................................................................. 204

7-2. ATC magazine door interlock ........................................................................................ 205

7-3. ATC tool dimensions ..................................................................................................... 206

7-3-1. Maximum tool size storable with adjacent tools .............................................. 206

7-3-2. Maximum tool size storable without adjacent tools ......................................... 209

7-3-3. Maximum tool mass moment .......................................................................... 214

7-3-4. ATC operating speed and tool mass moment ................................................. 216

7-3-5. ATC magazine interference diagram............................................................... 220

7-4. Preparing the ATC......................................................................................................... 224

7-4-1. Preparing ATC tools ........................................................................................ 224

7-4-2. Setting tools into the ATC magazine ............................................................... 227

7-4-3. Manual magazine indexing operation.............................................................. 229

7-5. Manual ATC operation................................................................................................... 231

7-5-1. One step advance and one step reverse ........................................................ 231

7-5-2. One cycle start and return cycle start.............................................................. 233

7-5-3. Precautions for manual ATC operation ........................................................... 234

7-5-4. Memory-random ATC specification ................................................................. 234

7-6. ATC continuous operation ............................................................................................. 244

7-6-1. Initial conditions for continuous ATC operation ............................................... 244

7-6-2. ATC operation sequence................................................................................. 245

7-6-3. ATC operation sequence diagram................................................................... 253

7-7. Adjusting ATC................................................................................................................ 255

7-7-1. Adjustment of magazine chain tension............................................................ 255

SECTION 8 APC ...................................................................................................257

8-1. Outline of 2-pallet rotary type APC ................................................................................ 257

8-1-1. Construction .................................................................................................... 257

8-1-2. Specifications .................................................................................................. 257

8-1-3. Limitation on workpiece center of gravity ........................................................ 258

8-2. Operating the two-pallet rotary APC.............................................................................. 261

8-2-1. Safety precautions for APC operation ............................................................. 261

8-2-2. Conditions for automatic pallet changing operation ........................................ 261

5963-E P-(vi)TABLE OF CONTENTS


8-3. Automatic pallet change operation sequences.............................................................. 263

8-3-1. Two-pallet APC operation sequence diagram................................................. 263

8-3-2. APC operation sequence diagram .................................................................. 264

8-4. APC continuous operation............................................................................................. 266

8-4-1. Initial conditions for continuous two-pallet APC rotation operation ................. 266

8-5. Manual APC operations................................................................................................. 268

8-5-1. Safety precautions for manual APC operation ................................................ 268

8-5-2. One step advance and one step reverse ........................................................ 269

8-5-3. One cycle start and return cycle start.............................................................. 270

SECTION 9 HIGH CAPACITY MAGAZINE ...........................................................271

9-1. Matrix magazine (110, 146, 182, 218 tools) (optional for MB-4000H/5000H) ............... 271

9-1-1. Outline ............................................................................................................. 271

9-1-2. Specifications .................................................................................................. 271

9-1-3. Precautions ..................................................................................................... 272

9-1-4. Diagram of tool storage rack ........................................................................... 273

9-1-5. ATC tool dimensions ....................................................................................... 274

9-1-6. Lubricating the magazine ................................................................................ 276

9-2. Matrix magazine (81, 111, 141, 171, 195, 225, 255, 285 tools) (optional for MB-8000H)........................................................................................................................... 277

9-2-1. Outline ............................................................................................................. 277

9-2-2. Specifications .................................................................................................. 277

9-2-3. Precautions ..................................................................................................... 279

9-2-4. Diagram of tool storage rack ........................................................................... 280

9-2-5. ATC tool dimensions ....................................................................................... 282

9-3. Lubricating the magazine .............................................................................................. 286

SECTION 10 MULTI-PALLET APC (6, 10, 12 PALLETS) (OPTIONAL FOR MB-4000H/5000H/8000H) .................................................................287

10-1. Outline ........................................................................................................................... 287

10-2. Specifications ................................................................................................................ 288

10-2-1. Summary by model ......................................................................................... 288

10-3. Precautions.................................................................................................................... 289

10-4. Lubrication oil chart ....................................................................................................... 290

10-5. Cleaning ........................................................................................................................ 291

10-6. Multi-pallet APC operation sequence diagram .............................................................. 294

10-6-1. Operation sequence ........................................................................................ 294

10-6-2. Operation sequence diagram.......................................................................... 295

SECTION 11 OPTIONS ..........................................................................................297

11-1. Through-spindle coolant supply unit [1.5 MPa (217.7 psi)]............................................ 297

11-1-1. Outline ............................................................................................................. 297

5963-E P-(vii)TABLE OF CONTENTS

11-1-2. Circuit diagram of through-spindle coolant system ......................................... 299

11-1-3. Specifications .................................................................................................. 301

11-1-4. Preparation for operation................................................................................. 303

11-1-5. Maintenance and regular inspection ............................................................... 304

11-2. Through-spindle coolant supply unit [7 MPa (1,016 psi)]............................................... 306

11-2-1. Outline ............................................................................................................. 306

11-2-2. Circuit diagram of through-spindle coolant system ......................................... 308

11-2-3. Specifications .................................................................................................. 312

11-2-4. Preparation for operation................................................................................. 314

11-2-5. Maintenance and regular inspection ............................................................... 315

11-2-6. Procedure to change through pin in the pulling shaft ...................................... 318

SECTION 12 PRESERVATION...............................................................................329

12-1. Preservation during transportation and storage ............................................................ 329

12-2. Cleaning before preservation ........................................................................................ 329

12-3. Truck transportation and warehouse storage ................................................................ 329

12-4. Removing preservation.................................................................................................. 329

12-5. Machine transportation .................................................................................................. 329

SECTION 13 DISPOSAL OF THE MACHINE.........................................................330

13-1. Material groups.............................................................................................................. 330

13-2. Operating materials ....................................................................................................... 330

13-3. Disposal of electronic components ................................................................................ 330

13-4. Disposal of the packaging ............................................................................................. 330

5963-E P-1SECTION 1 SAFETY GUIDE

SECTION 1 SAFETY GUIDE

1-1. General advice

Your personal safety is important!

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

Every person responsible for installing, operating, maintaining, repairing and inspecting the machine must have read and understood the following safety regulations.

The machine may only be operated by trained and authorized personnel.

Responsibilities for operating, servicing and maintenance of the machine must be clearly laid down and adhered to.

Note

1-2. Basic security advice

1-2-1. Warning signals and symbols

The following warning indications are used in this manual to draw attention to information of particular importance. Read the instructions marked with these symbols carefully and follow them.

The content will be updated according to the safety regulations when required and without notice.


Danger due to suspended loadsThis symbol warns of lifted or suspended loads.Never step under lifted or suspended loads.Non-observance of these instructions could result in death or serious injury.

Danger due to toppling of the machineThis symbol warns of machines or machine parts that may topple over.Always observe the specifications related to load support and load carrying devices.Non-observance of these instructions could result in death or serious injury.

Danger of being crushedThis symbol warns of risks of hands and upper limbs being crushed.Non-observance of these instructions could result in death or serious injury.

Danger of slippingThis symbol warns of a danger of slipping in the area of use and the work area of the machine.Non-observance of these instructions could result in death or serious injury.

Danger of being cutThis symbol warns of a danger of being cut due to sharp edges and cutting edges of tools.Non-observance of these instructions could result in death or serious injury.

Danger due to laser beamsThis symbol warns of a danger due to laser beams.Non-observance of these instructions could result in death or serious injury.

Danger due to electrical voltageThis symbol warns of a danger due to electrical voltage.Non-observance of these instructions could result in death or serious injury.

Risk of explosionThis symbol warns of a risk of explosion.Non-observance of these instructions could result in death or serious injury.

Fire hazardThis symbol indicates situations which may lead to a fire. Keep open flames and heat sources away and prevent the formation of sparks!Non-observance of these instructions could result in death or serious injury.


Danger due to strong magnetic fieldsDanger of the effect of magnetic forces on ferromagnetic objects! Do not allow these objects to enter the close range of magnets!Non-observance of these instructions could result in death or serious injury.

Danger due to crushing zoneThis symbol warns of an area in which body parts may be crushed and persons may be caught.Non-observance of these instructions could result in death or serious injury.

Danger due to protruding toolsThis symbol warns of protruding tools with sharp edges and cutting edges.Non-observance of these instructions could result in death or serious injury.

Personal protective equipmentThese symbols instruct you to use personal protective equipment when performing certain work on the machine. Depending on the situation, all persons in the operation area of the machine must wear the protective clothing mentioned below.Non-observance of these instructions could result in death or serious injury.

No access for persons with pacemakersAccess is prohibited to persons with cardiac pacemakers.Electromagnetic or magnetic fields may cause malfunctions in these devices.

No access for persons with metallic implantsAccess is prohibited to persons with metallic implants.Electromagnetic or magnetic fields may cause metallic implants to be heated and, therefore, lead to considerable body injuries.

No open flames or heat sourcesOpen flames or heat sources are forbidden. Depending on the type of production, there may be highly inflammable media or substances in the area around the machine.

Do not extinguish with waterSeats of fire must not be extinguished with water.


1-2-2. Electric system

1-2-3. Strong magnetic fields

Danger due to electrical voltageIncorrect handling or failure to follow these instructions may result in electric shock, causing serious injury or death.Do not operate the machine with the switch cabinet doors, terminal boxes, or control panels open.The electrical equipment of the machine must be regularly checked. Immediately rectify any defects, such as loose connections or damaged cables.The connection of the machine to the electrical mains supply and work on the electrical equipment and in the switch cabinet may be performed only by qualified staff. When performing this work, the regulations and guidelines for the installation and operation of electrical systems applicable at the place of installation must be observed.The electric system remains active even after the main switch is turned off.

Danger due to powerful magnetsSome products contain powerful magnets, which could be dangerous if exposed by disassembling the products.Products containing powerful magnets are provided with a caution plate to indicate where such magnets are used.

(1) Get assistance from OKUMA for disassembling or repairing the powerful magnet housing unit.

Strong magnetic force is exposed during and after disassembling these units, causing extreme danger.

Disassembling work requires special knowledge and jigs.

(2) Danger due to powerful magnetsThe following are examples of possible damage caused by being close to powerful magnets.

Medical electronic instruments such as pacemakers could malfunction, resulting in serious bodily injury or loss of life.

Magnetic metal devices implanted in the body (e.g. artificial eyes, brain artery clips) may be attracted by the powerful magnetic force, causing life threatening danger.

Metal clothing accessories may be attracted by the powerful magnetic force, resulting in body injury.

Tools or parts may be attracted by the powerful magnetic force, resulting in body injury.

Precision equipment could malfunction if it is placed near the machine.

Data loss may be caused if any electromagnetic media is placed near the machine.

(3) Contact OKUMA when disassembling a magnet housing unit is necessary to dispose of the machine.


1-2-4. Pneumatic, hydraulic and coolant system

Work on the hydraulic, pneumatic or coolant system may be performed only by qualified staff in compliance with the guidelines and regulations applicable at the place of installation.The system must be depressurised before disconnecting a pipe or disassembling a control or driving unit. Lower or secure the loads, switch off the pumps, and relieve the pressure accumulators. Also with machines with automatic pressure relief, check on the pressure gauge whether the system is really depressurised!Pressure accumulators are equipped with safety valves. The safety valves are leaded, and their setting fixed. Changing the setting of these valves can be life-threatening. Do not change the setting of these valves!Checking and maintenance of pressure accumulators must be performed according to national regulations.If you notice damage to pressure hoses, pressure pipes and screw fittings (e.g. chafe marks or leaks), the machine must be immediately switched off even if there are only minor defects and may be put into operation again only after the defects have been eliminated.There is danger of injuries, explosion and fire due to the discharge of media under high pressure.There is danger of injuries, explosion and fire due to the discharge of hydraulic fluid under high pressure. Therefore, leaks and damage to the piping must be immediately repaired.Check at regular intervals whether pressure hoses, pressure pipes and screw fittings are intact and immediately replace them even if they are only slightly damaged.Regularly replace the pressure hoses according to the applicable regulations. Observe instructions provided by OKUMA.Hydraulic and compressed air pipes should be laid and installed by a specialist.Do not mix up the connections! Fittings and the length and quality of the hoses must meet the requirements.Pipes, hoses and machine parts may be damaged if the hydraulic system is not vented when it is put into operation again after repair or after being moved to a different location.Penetration of oil into the ground must be prevented under all circumstances.Cooling lubricants which attack plastics, rubber or paint, must not be used. These may damage hoses (hydraulic, pneumatic), cables and seals.Cooling lubricants may contain harmful substances.Cooling lubricants pose an environmental hazard. Make sure they are disposed of properly.


1-2-5. Laser radiation

Observe the warnings and the instructions in the operation manual of the device manufacturer!

Danger due to laser beamDanger of severe eye and skin injuries due to invisible or visible laser beams!Do not look into the laser beam directly or with optical devices! Wear suitable protective goggles depending on the laser intensity!Do not allow parts of the body to be exposed to radiation.


1-3. Personal security

Wear tight-fitting clothing in order to avoid accidents.In particular, avoid wearing ties, scarves, rings, and necklaces. There is danger of getting caught in the machine's moving parts. If you have long hair, bundle your hair by wearing a hat or other head wear.Depending on the situation, all persons in the machine working area must wear the following protective clothing:

1-4. Intended use

This machine can be used primarily for turning, milling, drilling, tapping, centering, hob cutting, and boring of metallic materials.The performance details of the machine are specified in the Technical Data in the operating instructions.The machine is designed for machining at ambient temperatures between 10 °C (50 °F) and 40 °C (104 °F). Ambient temperatures under 10 °C (50 °F) and over 40 °C (104 °F) can lead to malfunctions in individual components.Any other use or any use beyond this scope is considered improper use. OKUMA shall not be responsible for any damages resulting from such use. The customer shall be responsible for all associated risk.Proper use also means that the operating instructions must be observed and the prescribed inspection and maintenance intervals must be adhered to.

Protective gogglesBreak proof protective goggles with side shield must be worn during all turning and milling work. Flying metallic chips may cause severe eye injuries or loss of eyesight.Suitable special goggles must be worn when performing any kind of work within the danger zone of active laser devices.

Safety shoesSafety shoes with steel toe caps must be worn for protection against being crushed.

Safety glovesMachining results in high temperatures and sharp edges on the workpiece. Do not touch workpieces, tools or chips with bare hands! Gloves may not be worn if there is danger of them getting caught.

Hearing protectionWear hearing protection if the noise emission at the machine location exceeds the permissible level. Do not remove any noise insulation equipment.

Safety helmetA safety helmet must be worn when performing overhead assembly and disassembly work, working with the crane, or if there is a risk of head injuries, particularly due to falling tools or workpieces.


1-5. Improper use

The machine is not designed for:

machining any flammable material

machining composite material (fiber)

machining carbon material

machining magnesium material

Use of oil-based coolants

Improper use includes, among other things, using the machine in:

explosive environment

residential areas

water protection areas

If the machine is not used according to its intended purpose or not used properly, this may lead to:

danger of life and limb

damage to the machine

damage to other property

Non-observance of this instruction may result in forfeiture of any liability and warranty.


1-6. What to do in case of emergency

1-6-1. Emergency stop

Press EMG. STOP button:

if persons are in danger.

if there is a danger of the machine or the workpiece being damaged.

Important

EMG. STOP button does not completely switch off the machine!When the emergency stop function is triggered, the machine is brought to a standstill as quickly as possible. Damage may occur to workpieces and tools.

Emergency Measures in Door-close and Power-OFF StateWhen fire breaks out inside the machine while the door is closed and the power is OFF, open the door using the door lock switch "release key" and extinguish the fire.

For door interlock switch positions, refer to [SECTION 2, 2-4-2. Door lock switch positions and types].

1-6-2. Fire protection

Please follow general safety regulations for fire protection in your facility.

Take every measure so that you can extinguish the fire immediately by placing a fire extinguisher near the machine and have an operator always watch the machining condition, or by installing an auto extinguisher.

What to do if there is a fire

(1) Immediately leave the interior of the machine and close the protective doors.

(2) Switch off the machine:

Press the EMG. STOP button.

Shut off the main breaker in the control box.

Please check all EMG. STOP button positions (depending on machine model) before using the machine.


1-7. General advice for the user

1-7-1. Prerequisites for operating the machine

Operate the machine only when it is in a safe condition. This particularly requires that the machine should be cleaned and maintained. Changes in the machine that impair its safety must be rectified without any delay.Observe the time limits for periodic tests/inspections.All existing safety devices must be regularly checked at the fixed inspections intervals.Use only virus-free devices and data carriers on the machine.This instruction manual must always be kept close to the machine working area and made available to the operating and maintenance staff. In addition to this instruction manual, generally accepted regulations as well as local and national regulations on accident prevention and environment protection must be provided and their observance regularly checked.Any necessary personal protective equipment must be provided by the operator. It is also the operator's duty to take measures ensuring the proper use of all necessary protective equipment by the staff.When selecting operating oils, auxiliary oils or cleaning agents such as cooling lubricant, lubricant, hydraulic oil, or detergents, abide by requirements on environmental preservation and disposal as well as restrictions imposed on manufacturing sites concerning contained amounts of toxic substances.

1-7-2. Caution plates

The following caution plates are attached to the machine and related equipment. Carefully read and follow the instructions inscribed on the plates.

All safety and caution signs on the machine must be kept in a legible state and must never be removed.

Do not peel or damage the caution plates. If a plate is lost or becomes illegible, place an order with OKUMA for a new plate by referring to the OKUMA part number written on the plate.

For information on Caution Plates, refer to the [Separate volume technical sheet].


1-7-3. Structural alterations to machines and systems

Specification of this machine in its original condition, is stated in the operation manual. Do not modify or reassemble this machine. Do not modify or rebuild the machine and do not attach any fittings to it without written consultation with the OKUMA local representative!Non-observance of this instruction may result in forfeiture of any liability and warranty. The following cases also are subject to the same treatment.

Installation and setting of safety devices and valves.

Welding on load-bearing parts of the machine. Electrical components can be damaged if electric welding is carried out on the machine or to parts connected to it, even when the machine is switched off. OKUMA accepts no liability for damage caused in this way.

Changes in the cooling lubricant (e.g. type, mixing ratio).

As a basic principle, the safety of workers (operator and maintenance/repair personnel) must be taken into consideration when making structural alterations. All rebuilding or attachment measures must be tested and confirmed by authorities.If the following structural alterations are performed, related documentation (applicable operation, maintenance, or cleaning manuals, or other documents related to matters such as risk analyses, declarations of conformity) must be revised by local OKUMA representatives.

Replacing a component with the one with increased performance (e.g. motors, linear axes, etc.).

Replacing or using control units.

Removing, attaching or modifying parts or system components (geometric form). This may lead to another source of danger.

Exchanging of bigger work holding systems, which are not covered by the specific regulation of [Safety of machine tools].

1-7-4. Replacement parts

Spare parts must meet technical requirements specified by OKUMA.All OKUMA specified replacement parts meet these requirements.Use of replacement parts other than those specified by OKUMA may result in personal injury or damage to the machine.


1-7-5. Requirements for operators and maintenance staff

Every person dealing with the setup, installation, test operation, operation and maintenance of the machine must read and understand this instruction manual, particularly [SECTION 1 SAFETY GUIDE], before starting work for the first time.The machine may be operated and maintained only by persons who are specially trained for this kind of work. This is especially important for the electrical, pneumatic, and hydraulic or coolant related equipment of the machine.After completion of installation work, a qualified staff or an authorized representative from OKUMA will provide basic instructions to operators who will engage in the operation and maintenance of the machine, on how to operate the machine.The operator agrees to provide operation and maintenance training to new machine operators and maintenance personnel at the equivalent level of detail and with full consideration across all safety requirements.Staff to be trained or instructed or staff undergoing general training may be allowed to work on the machine only under constant supervision by an experienced person!If more than one person works on the machine, clearly define the job responsibilities of each individual and adhere to those job assignments.With regard to safety, there must not be any ambiguity as to the responsibilities.Persons with health restrictions must find out before working on the machine which additional dangers the machine poses to them. This applies, for example, to persons with implants or a cardiac pacemaker.If there are any malfunctions or safety-relevant modifications in the machine, immediately stop the machine and secure it. Inform the person in charge of the appropriate department about the malfunction and have it rectified immediately!Do not use any methods of operation which may compromise safety!Before switching on or running the machine, make sure that nobody can be put at risk when the machine starts and that there are no persons in the danger zone of the machine!Do not switch off or remove suction and venting devices while the machine is running!During machine operation, there may be no persons in the area around the pressure relief valves.In the event of an explosion in the workplace, hot combustion gases may escape causing a hazard to persons.Do not make any program changes (software) in programmable control systems that may impair the safety of the machine!

Ensure that all safety and danger signs are attached to the machine so they are clearly legible, and adhere to the instructions on them.Do not put anything in the working area. The machine could be seriously damaged.Keep the operator station and the access points free from tools, auxiliary materials and other objects. Ensure that the work place at and around the machine is clean and neatly organized.The safety key to the machine control panel, electrical switch box, terminal box, setup unit (oil pressure, air pressure), and other safety related equipment should be controlled by a person specially trained and approved in the operation of such equipment.Use only virus-free devices and data carriers on the machine.Electrical limit switches, hydraulic solenoid valves and other control or actuating elements included in the controlling process cannot be operated. Non-observance of this instruction may lead to injuries to persons or damage to the machine.

Mobile and Wireless telephones are not allowed.Use of mobile phones, wireless telephones, wireless sets or any other radio frequency devices in close proximity to the open control box is prohibited. It can't be ruled out that they have an interfering effect on the CNC control.


1-7-6. Special applications

Special machining applications in combination with non-standardized machine equipment require careful assessment inspection. Please check with an OKUMA representative for each individual case.Exceptional application cases are:

machining magnesium material

use of oil-based coolants

machining composite material (fiber)

machining carbon material

machining any flammable material

When it is necessary to implement any one of the above exceptions, be sure to consult with an OKUMA representative to obtain expert advice necessary for maintaining machine safety. The OKUMA representatives are ready to offer a special kit for these exceptional requirements.Non-observance of this instruction may result in forfeiture of any liability and warranty.

1-7-7. Safety at the workplace

Caution! Risk of slippingThere is a danger of slipping if oil or coolant spills on the floor. You can be seriously injured if you slip while holding heavy parts or sharp tools.Please follow the listed advice:

Keep the workplace clean and tidy.

Do not place anything on top of the NC controller. Items may fall and cause damage or injury.

Do not leave unnecessary tooling nearby the machinery.

Ensure proper lighting to have clear visual working conditions.


1-8. Tools/tool change

Use sharp tools carefully! Risk of injuryAlways wear protective gloves. Never touch a moving tool.Wear tight-fitting clothing in order to avoid accidents.In particular, avoid wearing ties, scarves, rings, and necklaces. There is a danger of getting caught in moving tools or tool holders. If you have long hair, bundle your hair by wearing a hat or other head wear.

Beware of protruding tools! Risk of injuryTool change can be performed only when the target tool is set at the tool change position.All tools used on this machine may be used only within the limited speed. If the circumferential speed (number of revolutions) is too high, there is a risk of destruction of the tool and, therefore, an increased risk of accident for the operator.During tool change, make sure not to re-start the machine. (If necessary, engage the safety lock to secure the protective door so it does not close inadvertently.) Maintain the balance of all tools in accordance with the specifications from the machine or tool manufacturer. If the specifications differ, comply with the requirements for maintaining the best balance.

5963-E P-15SECTION 2 OUTLINE

SECTION 2 OUTLINE

2-1. Features of this machine

The machine is an NC-controlled, high-speed, high-precision horizontal machining center. The machine has a main milling spindle, an ATC unit and an APC unit with pallets which can be indexed. It can perform multiple machining tasks, including milling, drilling, boring, tapping and grinding, all in a single setup. The machine also can perform free curved plane machining with simultaneous 3-axis control. The machine, designed for high-speed and high-precision machining, can also promote automation and labor saving. With its high productivity and machining accuracy, the machine is suitably used for machining of parts in a wide application range including automobiles, construction equipment, airplanes, hydraulic/pneumatic equipment and molds.

Axis moving directions in the machine coordinate system(The figure shows MB-4000H.)

Spindle

Pallet

ATC

APC

ME12008R0100400010001


2-1-1. Features of machine components

MB-4000H

(1) Spindle

Spindle with No.40 taper, driven by a built-in motor, max. speed of 15,000 min-1 (Optional:

Max. 20,000 min-1)

High-power spindle: 26 kW/18.5 kW (34.7 hp/24.67 hp) (10 min./cont.: 15,000 min-1), 163 N-m (120 lbf-ft)

(2) Table

□400 (□15.75), min. index unit: 0.001°

Optional automatic hydraulic piping supply to jigs.

(3) Chip disposal (conveyor)

The double coil-type conveyor under the APC and the center trough conveyor under the main spindle quickly discharge chips out of the machine.

MB-5000H

(1) Spindle


Max. 20,000 min-1)

High-power spindle: 26 kW/18.5 kW (34.7 hp/24.67 hp) (10 min./cont., 6,000 min-1), 199 N-m (147 lbf-ft)

(2) Table

□500 (□19.69), min. index unit: 1° (Optional: 0.001°)




MB-8000H

(1) Spindle


Max. 12,000 min-1)

High-power spindle: 30 kW/22 kW (40 hp/30 hp) (10 min./cont., 6,000 min-1), 606 N-m (447 lbf-ft)

Optional super heavy spindle: 45 kW/37 kW (60 hp/50 hp) (20 min./cont., 6,000 min-1) Maximum torque: 1,071 N-m (790 lbf-ft)


(2) Table

□800 (□31.50), min. index unit: 1° (Optional: 0.001°)




2-1-2. Features of machine functions

MB-4000H

(1) Hi-speed positioning at a rapid traverse: 60 m/min (197 fpm), high-speed ATC: 1.0 sec. (T-T time)

(2) Positioning accuracy : ± 0.003 mm (0.00012 in.), repeatability: ± 0.0015 mm (0.000059 in.)

(3) Extremely low thermal deformation realized by a unique construction and control of the machine.

(4) ATC storage capacity: max. 326 tools, APC: max. 12 pallets (optional)

(5) A wide variety of options such as coolant unit, chip disposal equipment, automatic gauging unit, tool management, and fixtures are available.

(6) A full-enclosure shielding (w/ ceiling) is provided as a standard equipment to keep the working environment clean.

MB-5000H







MB-8000H









2-2. Parts of the machine

2-2-1. Main unit

MB-4000H/5000H

1 ATC magazine 8 NC operation panel

2 ATC unit 9 Control box

3 Full-enclosure shielding 10 Spindlehead

4 2-pallet rotary-shuttle APC 11 Center Trough Conveyor

5 Air devices 12 Table

6 Lubrication unit 13 Bed

7 Column

(1)

(2)

(3)

(4)

(5) (6) (13) (8)

(12)

(11)

(10)

(9)

(7)

ME12008R0100400090001


MB-8000H

1 Spindle cooling system 9 ATC unit

2 Full-enclosure shielding 10 2-pallet rotary-shuttle APC

3 Hydraulic unit 11 Spindle

4 Control box 12 Column

5 Air devices 13 Oil-air lubrication unit

6 Lubrication unit 14 Bed

7 NC operation panel 15 Pallet

8 Coolant tank 16 Table

(2)

(5)

(4)

(8)(7)

(13)

(6)

(1)(3)

(11)

(12)

(14)

(16)

(10)

(15)

(9)

ME12008R0100400120001


2-3. Machining range and workpiece dimensions

2-3-1. Machining range (pallet table)

MB-4000H

Movement range of the spindle center relative to the pallet center.Determine the movement of each axis during machine operation with consideration given to elements such as tool length, etc.

Avoid the following interference ranges when operating the machine.Part A: Spindlehead interference range. (When B=0°, 90°, 270°, or 360°, the range is 125 mm (4.92 in.) when B is at an angle other than 0°, 90°, 270° or 360° or if the edge locator is attached, the range is extended to 125 mm (4.92 in.) or more.)Part B: If the workpiece has a diameter of Φ500 (19.69) to Φ600 (23.62), it will interfere.

X-axis 560 (22.05) travel

Z-axis 625 (24.61) travel

85 (3.35)

50 (1.97)

Y-axis 560 (22.05) travel

610

(24.

02)

50 (1

.97)

85 (3

.35)

125 (4.92)

B

A

ME12008R0100400130002


[Supplement]

This drawing shows the standard pallet with tapped holes. unit: mm (inch)If the pallet is thicker than the standard one, the dimension (A) should be shorter by excess amount.


MB-5000H

[Supplement]


Avoid the following interference ranges when operating the machine.Part A: Spindlehead interference range. (When B=0°, 90°, 270°, or 360°, the range is 125 mm (4.92 in.) when B is at an angle other than 0°, 90°, 270° or 360° or if the edge locator is attached, the range is extended to 125 mm (4.92 in.) or more.)Part B: If the workpiece has a diameter of Φ630 (24.80) to Φ800 (31.50), it will interfere.

This drawing shows the standard pallet with tapped holes. unit: mm (inch)If the pallet is thicker than the standard one, the dimension (A) should be shorter by the excess amount.



Y-axis 760 (29.92) travel

810

(31.

89)

50 (1

.97)

85 (3

.35)

125 (4.92)

135 (5.31)

85 (3.35)

B

A

ME12008R0100400150002


MB-8000H

[Supplement]


Avoid the following interference ranges when operating the machine.Part A: Spindlehead interference rangePart B: Interference range of Y-telescoping cover with the workpiece having a diameter of Φ1,000 (39.37) to Φ1,300 (51.18)

This drawing shows the standard pallet with tapped holes. unit: mm (inch)If the pallet is thicker than the standard one, the dimension (A) should be shorter and (B) should be longer by the excess amount.

A

A

B

Z-axis 1,250 (49.21) travel

Y-axis 1,100 (43.31) travel

X-axis 1,300 (51.18) travel

Table rotation center

B

A

85 (3

.35)

310 (12.20)

50 (1

.97)

1,15

0 (4

5.28

)

100 (3.94)

150 (5.91)

ME12008R0100400170002


2-3-2. Max. workpiece dimensions

MB-4000H

:The closest the pallet can be to the spindle is 50 mm (1.97 in.), any closer than this and the telescopic cover interferes with the workpiece. The maximum diameter and height of the workpiece will be Φ500 (19.69) x 900 mm (35.43 in.).

The spindle interferes with the pallet if it is located in a position where both Z-axis and Y-axis are at their negative ends.

Φ500 (19.69)

85 (3.35)

660

(25.

98)

50 (1

.97)

Maximum diameter Φ600 (23.62)



Max

imum

hei

ght 9

00 (3

5.43

)

Y-ax

is 56

0 (2

2.05

) tra

vel


ME12008R0100400140001


[Supplement]

This drawing shows the standard pallet with tapped holes. unit: mm (inch)If the pallet is thicker than the standard one, the dimension (A) should be shorter by excess amount.


MB-5000H

*:The closest the pallet can be to the spindle is 85 mm (3.35 in.), any closer than this and the telescopic cover interferes with the workpiece. The maximum diameter and height of the workpiece will be Φ630 (24.80) x 1,000 mm (39.37 in.).

[Supplement]



A

A

135 (5.31)

810

(31.

89)

50 (1

.97)

Max diameter Φ800 (31.50) *

Φ630 (24.80)


X-axis 760 (29.92) travelM

axim

um h

eigh

t 1,0

00 (3

9.37

)


Y-ax

is 76

0 (2

9.92

) tra

vel

ME12008R0100400160001


MB-8000H

*:If there is movement in the Z-axis negative end position, the maximum workpiece diameter should be Φ1,000 (39.37) to avoid interference with the Y-telescoping cover.

[Supplement]



A

A

Z-axis 1,250 (49.21) travel

X-axis 1,300 (51.18) travel

Maximum diameter* Φ1,300 (51.18)

Z-axis negative end maximum diameter Φ1,000 (39.37)

50 (1

.97)

1,15

0 (4

5.28

)

Y-ax

is 1,

100

(43.

31) t

rave

l

100 (3.94)

Max

imum

hei

ght 1

,450

(57.

09)


ME12008R0100400180002


2-3-3. Precautions related to workpieces and tools

(1) Workpiece materialsThe machine can cut ordinary structural steels such as carbon steel, ferrous material such as castings, and non-ferrous material such as aluminum.The machine can also cut non-metallic materials such as ceramics or graphite. These materials, however, require dust preventive measures to protect the human body and the machine. For information on safety measures, contact OKUMA.Additionally, when working on flammable materials, make sure to take every safety precautions.

(2) Maximum workpiece size and massAs for maximum workpiece size, ensure compliance with information provided in [SECTION 2, 2-3. Machining range and workpiece dimensions] and [SECTION 8, 8-1-3. Limitation on workpiece center of gravity]. The maximum workpiece mass this machine can work on is 400 kg (880 lb) (MB-4000H), 500 kg (1,100 lb) (MB-5000H), and 2,000 kg (4,400 lb) (MB-8000H).Please note that if the workpiece is not well balanced, the machine may not perform to specification, even if maximum workpiece size and mass are not exceeded. Always be sure that the workpiece is well balanced and that it is securely fastened to ensure safe machining operation.

(3) Maximum tool size and massFor maximum tool size, be sure to follow the requirements specified in the [Separate volume technical sheet] and [SECTION 7, 7-3. ATC tool dimensions]. The maximum tool mass that can be used on this machine is 10 kg (22 lb) (MB-4000H/5000H) and 25 kg (55 lb) (MB-8000H). Refer to [SECTION 7, 7-3-3. Maximum tool mass moment] even if the max. tool mass has not been exceeded. Tools heavier than the designated mass cannot be used. If the tool is used at a speed exceeding the limit, it could result in tool breakage.


2-4. Safety functions

2-4-1. Interlock and door lock functions

The machine incorporates the automatic lock mechanism and interlock function for the front door in the full enclosure shielding to ensure the safety of machine operators and other workers. These door lock functions are described below.

During automatic operation, the door is automatically locked.

AUTO or MDI cannot be launched while the door is open.

When changing the setup or checking the program, it is possible to disable the door interlock switch and to operate the spindle and feed the axis while the door is left open. For this, however, spindle speed and axis feed rate is limited to within a specified speed.

For detailed specifications on the door lock functions, refer to [SECTION 2, 2-4-4. Door interlock function].

2-4-2. Door lock switch positions and types

Door interlock switch

Never remove or modify the door interlock switch.

If the switch becomes faulty, please contact OKUMA or OKUMA's service representative immediately. It is strictly forbidden to operate the machine with the faulty door interlock switch.

Failure to observe these instructions may lead to getting caught in moving parts or hitting them.It may also result in being caught in rotating tools.

Position Class

Operation door Spring lock

APC door Electromagnetic lock

MG door Electromagnetic lock

The operation door is locked when the power is turned off.Therefore, before you enter the machine, be sure to use a door stopper to prevent the door from locking so you do not get trapped inside the machine.


MB-4000H

When entering the enclosure shielding after unlocking the door lock switch, watch the spindle because it might be coasting. Do not get near the spindle until you confirm that the spindle is stopped.

Do not unlock the door during machine operation. The machine will stop immediately if the door is unlocked.

1 Door lock switch 2 Release key slot

(1)

(2)

Safety door switch

UNLOCK

LOCK

ME12008R0100400210004


MB-5000H




Safety door switch

Door lock switch release key

LOCK

UNLOCK

ME12008R0100400210003


MB-8000H




(1)

(2)

Safety door switch

Door lock switch release key

LOCK

UNLOCK

ME12008R0100400210002


2-4-3. Door lock releasing in emergency

It is possible to open the door when the machine makes an emergency stop. However, when the power is shut off, or when there is a power outage, the door will not open. In such a case, release the door lock through the following procedure:

MB-4000H

Procedure :

1- The door lock switch is mounted on the top right of the operation door. (See figure for location.)

2- Insert Phillips screwdriver in the release keyhole of the door lock switch.

3- Turn the Phillips screwdriver to UNLOCK to release the lock.

4- Open the door.

When restarting the machine, use the Phillips screwdriver to turn from UNLOCK to LOCK.

When the door is in unlock state, the machine does not operate even if the door is closed.

MB-5000H/8000H

Procedure :

1- The door lock switch is mounted on the lower right of the operation door. (See figure for location.)

2- Remove the cap on the release keyhole of the door lock switch, and insert the special release key into the hole.

3- Turn the special release key to UNLOCK to release the lock.

4- Open the door.

When restarting the machine, turn the special release key from UNLOCK to LOCK.

When the door is in unlock state, the machine does not operate even if the door is closed.

Only the person in charge shall keep the special release key.


2-4-4. Door interlock function

For details of the door lock switch, refer to the attached material (Instruction sheet).

Items Door Status of door Spindle NC axis advance

ATC MG

Interlock switch [OFF]

MANUAL Operation door(manual door)

Closed→Open × × × ○

Open Δ Δ ▲ ○

MDI Closed→Open × × × ○

Open Δ Δ × ○

AUTO,SINGLE BLOCK ON


Open Δ Δ × ○

AUTO,SINGLE BLOCK OFF


Open × × × ○

Interlock switch [ON]

MANUAL Closed→Open × × × ○

Open × × × ○

MDI Closed→Open × × × ○

Open × × × ○



Open × × × ○



Open × × × ○

Interlock switch [ON/OFF]

All modes MG door Open ○ ○ MB-4000H/5000H xMB-8000H o

×

2-pallet APC door Open ○ ○ ○ ○

Multi-pallet APC setup ST door

Open ○ ○ ○ ○


Open halfway ○ ○ ○ ○

○: Operation is enabled or can be continued.

Δ: Operation is enabled or can be continued at the limited speed or feedrate described below:

Spindle Max. 800 min-1

Axis feed Axis feed Cutting feed is not allowed. Rapid traverse speed: max. 2 m/min (7 fpm). B-axis rotation: max. 1.4 min-1

If a command exceeding the above limit is specified while the door is open, it triggers an alarm (ALARM-D).However if the specified is within the limit, the spindle or axis feed is permitted.

▲: Continuous operation (one cycle) is impossible and only one-step operation is permitted.

×: Operation cannot be started. If any of these conditions occur during operation, the machine will stop immediately.

Items Door Status of door

Spindle NC axis advance ATC MG

Drive unit stop function Operation door Open D/U: OFF D/U: OFF D/U: OFF motor: ON

MG door Open D/U: ON D/U: ON D/U: ON motor: ON

2-pallet APC door Open D/U: ON D/U: ON D/U: ON motor: ON


Open D/U: ON D/U: ON D/U: ON motor: ON


Open halfway

D/U: ON D/U: ON D/U: ON motor: ON

Operation recovery by pressing the enabling button

Operation door Open D/U: ON D/U: ON D/U: ON motor: ON

Unlock button valid conditions for operator's door

Operation door stop stop stop ―

Unlock button valid conditions for the operator door


― ― ― ―


( ): This indicates automatic door.

Items2-pallet APC

shifter

Multi-pallet APCChip conveyor Cycle start

APC shifter Pallet MG Set-up ST shifter

Interlock switch [OFF]

MANUAL × × ○ ○ × ―

▲ ▲ ○ ○ × ―

MDI × × ○ ○ × ―

× × ○ ○ × Unable (unable)


× × ○ ○ × ―



× × ○ ○ × ―

× × ○ ○ × Unable (able)

Interlock switch [ON]

MANUAL × × ○ ○ × ―

× × ○ ○ × ―

MDI × × ○ ○ × ―



× × ○ ○ × ―



× × ○ ○ × ―


Interlock switch [ON/OFF]

All modes ○ ○ ○ ○ ○ able

× ― ― ― ○ able

― ○ ○ × ○ able

― ○ × × ○ able

○: Operation is enabled or can be continued.

Δ: Operation is enabled or can be continued at the limited speed or feedrate described below:

Spindle Max. 800 min-1

Axis feed Axis feed Cutting feed is not allowed. Rapid traverse speed: max. 2 m/min (7 fpm). B-axis rotation: max. 1.4 min-1

If a command exceeding the above limit is specified while the door is open, it triggers an alarm (ALARM-D).However if the specified is within the limit, the spindle or axis feed is permitted.

▲: Continuous operation (one cycle) is impossible and only one-step operation is permitted.

×: Operation cannot be started. If any of these conditions occur during operation, the machine will stop immediately.

5963-E P-37SECTION 3 TRANSPORT AND INSTALLATION

SECTION 3 TRANSPORT AND INSTALLATION

3-1. About safety

The lifting gear must be theoretically appropriate for the situation and its permissible load bearing capacity must be adequate. The chains, ropes, hooks and swivel eye bolts must also be able to safely support these weights.Assign the job of applying load and instructing crane operators only to qualified staff. The person giving instructions must be in the operator's range of sight or have verbal contact with the operator.Secure lifting rods with adjusting rings! The rope or the machine part must not slip on the rod.Transportation safety devices must not be disassembled during transportation and installation.If the part to be lifted has sharp edges, put pads in order to prevent the rope or the machine from being damaged.Never lift the machine part suddenly or with a jerk with the lifting gear or a crane. Lift slowly.Make sure that the load is well balanced.

Protective clothingMake sure you wear protective gear when performing work.

The machine can cause crush injuriesUse only means of transportation (fork lift, crane, ropes) of sufficient power and size. Do not step under the machine when it is being moved.Maintain a safe distance from the machine.Do not lift the machine higher than necessary. Do not touch the bottom of the machine by hand. Observe the floor loading capacity. The floor must be capable of sustaining the machine load. A stress analyst should be appointed to do the calculations.

The machine can toppleRefer to [SECTION 3, 3-5. Transporting the machine]. This section covers the following content.

Weight

Installation places

Safety ropes

The prescribed lifting gear

These instructions must be strictly observed when transporting the machine and its components. All other methods for transporting the machine or its components are not allowed.


3-2. Site selection guidelines

When installing the machine, the following points should be checked in order to ensure high accuracy and performance.

(1) We recommend that you perform appropriate foundation work if the ground is not hard enough or the land may sink after installation. Refer to [SECTION 3, 3-3. Foundation requirements].

(2) The installation site should be as far as possible from vibration sources, such as roads, stamping/press type equipment, or planer type machine tools. If nearby sources of vibration are unavoidable, dampening pits around the machine foundation, for example, should help lessen vibrations.

(3) If there are high-frequency power generators, electric discharge machines or electric welding machines around or when power is supplied from the same power distributor panel, electrical interference may cause NC malfunctions. Please consult with the OKUMA's on-site engineer who will be dispatched for machine installation.

(4) The ideal operating environment calls for an ambient temperature between 10 °C (50 °F) and 40 °C (104 °F) with humidity between 40 % and 75 % at 20 °C (68 °F).

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

(6) In order to maintain static machine accuracy within guaranteed values, the machine should be installed in an area where it is not affected by airflow. Air conditioning is not essential, but an ambient temperature between 17 °C (63 °F) and 25 °C (77 °F) is recommended.

(7) To maintain static machine accuracy within the Standard Guaranteed Values:

a. Keep ambient temperature variance for a full day or 24 hours within ±2 °C (36 °F).

b. Ambient temperature variances from the floor level to a height of the machine (3 m (10 ft.)) should be held within 1 °C (34 °F).

(8) Usually, no consideration is required on heat insulation against the machine foundation.

(9) Keep the floor level error within 10 mm (0.39 in.).

3-3. Foundation requirements

With solid ground, a concrete floor about 300 mm (11.81 in.) thick and no gaps between ground and floor, foundation work or anchoring is not required. The structural rigidity of the machine permits normal machining. The use of foundation bolts is not required, either.However, under the following circumstances, be sure to carry out foundation work by referring to the attached foundation drawing.

(1) For higher accuracy and performance.

(2) To maintain high accuracy while extending the intervals between periodic maintenance.

(3) When the ground (type of soil) is not strong enough, refer to the provided Foundation Plan and carry out the foundation work.


Note

The NC performs Hi-G control to reduce the positioning time by rapid traverse. However, axis positioning may cause the machine to vibrate depending on the floor conditions of the installation area. In such a case, you can turn on or off the Hi-G control or make override adjustment of the time constant for acceleration/deceleration by parameter setting.Before shipment, the Hi-G control is set at ON and the time constant is set at 50 %. The more you increase the override value within the setting range of 1 % to 100 %, the higher the acceleration or deceleration becomes. Change the parameters according to your installation site. (Note that the machining time has to be a little bit longer if you turn off the Hi-G control or decrease the time constant.)


3-4. Fixing the machine to the floor with hole-in (chemical) anchors

The machine accelerates and decelerates the spindle quickly to enable high-efficiency machining. If a machining cycle includes frequent starts and stops as in the case of die cutting, or if the floor is slippery with a low friction coefficient, the machine may move due to the vibration generated by acceleration and deceleration. To avoid such movement, it is recommended to fix the machine in the floor using the hole-in (chemical) anchors.Fixing the machine with hole-in (chemical) anchors is not effective for soft ground. If the floor is soft, vibration is transmitted to the machine, affecting its machining accuracy. The anchors may not be effective when the concrete is not thick enough. For these reasons, foundation work must be done for the purpose of giving sufficient concrete thickness and strength to the ground.When fixing the machine, refer to the foundation plan.

Make sure the machine bed is secured to a chemical (hole-in) anchor.Without doing so, the machine may move and may result in a life threatening accident.


3-5. Transporting the machine

With the exception of the separately attached units such as the coolant tank and chip pan (kit), in principal, the machine can be moved or transported as a single unit.Optional external devices (matrix magazine, multi pallet APC, etc.) should be transported separately following disassembly. Installation is performed by OKUMA representatives dispatched to the site. After the machine arrives at your facility, remove the packaging material and anti-rust oil, and wait for the OKUMA representative.

3-5-1. Lifting the machine

Moving the machine in a plant for changing the layout, etc.

Lifting the machine to load it on to a truck.

MB-4000H

To lift the machine, follow the steps below:

Procedure :

1- Remove the face cover at the bottom of the operation door and mount the lifting tool.

1 Removable cover, removable APC unit 4 Y-axis fixture (wood)

2 Balance beam 5 Z-axis fixture

3 X-axis fixture 6 Lifting tools

(1) (2)

(6)

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

ME12008R0100500050001


2- Open the MG side door, remove the MG motor cover, the MG bottom oil pan, the two Z-axis piping covers at the lower front side and then attach the lifting tool.

3- Remove the front APC unit (x2).

4- Place the table at the center of saddle. (Locking device mounting position: Z-axis travel end)

5- Remove the rear maintenance cover.

6- Move the column to the specified position at the table side. (Locking device mounting position: Middle of X-axis travel)

7- Place a wood block at the lower inside of the column to stabilize the column.

8- Move the spindlehead to the specified position. (Locking device mounting position: 160 mm (6.30 in.) above the Y-axis negative limit)

9- Fix the table, column, spindlehead, and pallet at the each position using the fixtures.

10- Drain the hydraulic oil tank and the spindle cooling oil tank.

11- Disconnect the coolant hose from the coolant tank.

12- Open the door on the operation side and secure it to prevent it from moving.

13- Tighten Z-axis hoses and pipes to prevent them from being caught by lifting tools.

Perform the above steps (1) to (9) before turning off the power. In each step, carefully operate the machine using the pulse handle. There is danger of injury if caught between moving parts.

After fixing, never attempt to further lower the spindlehead by operating the pulse handle with the fixture being attached. The Y-axis motor may be overloaded and burnt if attempted.

Insert rust prevention sheet between fixture and table, fixture and spindlehead, and fixture and column to prevent damage or rust formation.


Precautions for lifting the machine

1) Use a wire rope that is thick enough to withstand a maximum load of 250 kN (56,250 lbf).Failure to do so may result in dropping the machine leading to death or serious injury.

2) The wire rope should not come into direct contact with any machine parts other than bed or column. Use a wire rope with suitable length so it does not form an excessively wide angle when lifting.

3) Lift the machine carefully while balancing it.

4) When lowering the machine, use care not to hit the machine against the floor.

Machine body Coolant tank

MB-4000H (48 tools) 9,580 kg (21,076 lb) 370 kg (814 lb)


MB-5000H


Procedure :

1- Open the MG side door to remove the upper surface cover, the ATC upper section cover and Z-axis piping cover at the lower front.

2- Place the table at the center of saddle. (Locking device mounting position: Z-axis travel end)


4- Move the column to the specified position at the table side. (Locking device mounting position: Middle of X-axis travel)


6- Move the spindlehead to the specified position. (Locking device mounting position: 160 mm (6.30 in.) above the Y-axis negative limit)

7- Fix the table, column, and spindlehead at the each position using the fixtures.


9- Disconnect the coolant hose from the coolant tank.

10- Remove the door and door guards on the operation side. Then, remove the step on the MG side.

1 Remove cover 4 Lifting tools

2 Z-axis fixture 5 X-axis fixture

3 Balance beam 6 Y-axis fixture (wood)

(5)

(6) (2)

(1)

(4)

(3)

ME12008R0100500080001


11- Tighten Z-axis hoses and pipes to prevent them from being caught by lifting tools.



After fixing, never attempt to further lower the spindlehead by operating the pulse handle with the fixture being attached. The Y-axis motor may be overloaded and burnt if attempted.






Moving or transporting the machine requires working at high places and preparation of lifting equipment. Have the OKUMA representative perform the work.

Machine body Coolant tank

MB-5000H (48 tools) 11,500 kg (25,300 lb)400 kg (880 lb) (Without

coolant)


MB-8000H

When moving the machine, it is necessary to remove the separate accessory units (such as coolant tank), APC unit (including APC cover), and magazine cover. When transporting the machine by truck, it is also necessary to remove the ATC magazine.If the machine is equipped with the optional external units (such as the matrix magazine, multi-magazine or multi-pallet APC), they must be removed as well.

If your machine has an ATC magazine for 40 or 60 tools, you can move the machine without removing the ATC magazine when changing your plant layout.

When lifting the machine to the truck, however, it is necessary to remove the ATC magazine.

Moving or transporting the machine requires working at high places and preparation of lifting equipment. Have the OKUMA representative perform the work.


1 Machine center of gravity 5 Operation panel fixture

2 X-axis fixture 6 Y-axis fixture (wood)

3 Crane height 6,000 mm (236.22 in.) to 6,500 mm (255.91 in.)

7 Z-axis fixture (opposite table pallet)

4 Balance beam

(1)

(3)

(4)

(7)

(2)

(6)

(5)

Top Front

Operation side Back

ME12008R0100500810002



Procedure :

1- Remove the machine cover, lower covers and connection covers of APC cover as well as the magazine cover.

2- Remove the cover for passing the lifting cable located on top of the cover of the machine.

3- Remove the footstep on the operation panel side and the lower cover.

4- Place the table at the fixture mounting position of the center of saddle. (350 mm (13.78 in.) from the Z-axis travel end)


6- Place the column at the locking device mounting position of the center of saddle. (Middle of X-axis travel)


8- Place the spindlehead at the locking device mounting position of the center of saddle. (182.5 mm (7.185 in.) above the Y-axis travel end)

9- Fix the table, column, and spindlehead at the each position using the fixtures.

10- With the operation side door halfway open, secure the specified fixture.

11- Secure the left/right slide direction and the swivel direction of the operation panel, and the specified fixture that you will use.


13- Remove the wiring and piping from the hydraulic oil tank and loosen the jack bolts under the tank. Then separate the tank from the machine.

14- Remove the cables and piping that connect the machine and APC unit and bundle them so that they do not hinder transportation.

15- Remove the APC unit to separate it from the machine. Refer to [SECTION 7, 7-4. Preparing the ATC].

16- Remove the cables and piping that connect the machine and ATC magazine and bundle them so that they do not hinder transportation.

17- Remove the ATC magazine to separate it from the machine. Refer to [SECTION 7, 7-5. Manual ATC operation].

18- Attach the cables on the hooks at the front and back of the bed and lift the APC unit.










Weight

Machine body 20,000 kg (44,000 lb)

APC unit 4,000 kg (8,800 lb)

ATC magazine (40 tools) 3,000 kg (6,600 lb)

Coolant tank 580 kg (1,276 lb)


3-5-2. Lifting the coolant tank

MB-4000H

Loosen the jack screw on the tank bottom face and pull out the tank from the rear of the machine. Hook the wire ropes on the tank sides. Then, lift the coolant tank.

Remove coolant before transportation.

370 kg (814 lb)

ME12008R0100500260002


MB-5000H

Loosen the jack screw on the tank bottom face and pull out the tank from the rear of the machine. Hook the wire ropes on the tank sides. Then, lift the coolant tank.


400 kg (880 lb)

ME12008R0100500270001


MB-8000H

Procedure :

1- Remove the cables and pipes from each pump and conveyor.

2- Loosen the jack bolt on the bottom of the tank and pull it out from the left side of the machine.

3- Attach the wire rope to the hook on the tank side.

4- Then, lift the tank.


580 kg (1,276 lb)

ME12008R0100500280001


3-5-3. Lifting the APC unit

Procedure :

1- Move the table to the Z-axis travel end.

2- Remove the pallets from the table and the APC setup station.

3- Turn off the power. Use the fixture to fix the APC fork at the specified position.

4- Remove the APC fork cover (both left and right) of the APC setup station.

5- With the left and right doors open on the front APC, secure the specified fixture.

6- Mount the special lifting bolts in four positions of the APC frame.

7- Separate the APC unit from the bed by disengaging two connecting parts, and then lift the APC unit. The base at the front of APC unit can be removed.

3-5-4. Lifting the ATC magazine for 40/60 tools

Procedure :

1- Remove the magazine cover and the oil pan.

2- Mount the lifting tools to upper part of the back of magazine frame.

3- Disconnect the bed and the cam box support and lift the ATC magazine.


3-5-5. Cautions for truck transportation

When transporting the machine by a truck, take notice of the following points as well as observation of lifting instructions described above.

(1) Check that the fixtures are firmly fixed.

(2) To protect the disconnected hoses and cables from dirt, fasten them to the machine after wrapping them in cloth or vinyl sheet.

(3) The MB-4000H/5000H can be transported fully covered. The MB-8000H can be transported with the top section and cover frame fully covered.

(4) Observe the laws related with loading capacity and transportation. MB-8000H can be transported only by a low-floor trailer.

3-5-6. When removing Y-axis motor

(1) Since the Y-axis motor is equipped with the brake (brake is ON when power is OFF), removal of the Y-axis motor causes the spindlehead to drop. Always secure the spindlehead by attaching a fixture between the spindlehead and table before removing the Y-axis motor.

(2) When removing the Y-axis motor, do so in a position where its relative position can be reinstated, because changes made to the spindlehead position and the Y-axis detector value can influence pitch error correction.(The position where the distance between the spindle nose end and the table surface is 210 mm (8.27 in.), for example.)

3-6. Preparation before delivery

3-6-1. About fixtures

Before connecting the main power cable to the machine, the fixtures used to secure the machine during transportation must be removed.

The fixtures are red in color. Store the removed fixtures in a safe place.These fixtures will be used to secure the machine when the machine is moved or repositioned in the future.Failure to do so may result in damage to the machine.


3-6-2. Power supply

Power specification

Power requirements are as follows:The values may change depending on the options added.MB-4000H

MB-5000H

MB-8000H

Normal rated voltage : 200 V (380 V/400 V)

Allowable voltage range : 180 Vrms to 220 Vrms (90 Vrms to 110 Vrms)(Includes voltage fluctuation resulting from load.)

Frequency : 50 Hz/60 Hz

Allowed frequency range

: 49 Hz to 61 Hz

Power Source Inductance

: Allowed power source inductance instantaneous voltage fluctuation at maximum power output 15 % or less(However, voltage fluctuation must be within allowable voltage range.)

High power source inductance of input power supply results in longer acceleration/deceleration time of the spindle. Also, operating with power supply with high power supply inductance can trigger the protection circuit in the DC power supply unit.Rated output is guaranteed under normal rated voltage. Fluctuation in input voltage can result in rated output not being met, even if the fluctuation is within the allowable voltage range.

Spindle specifications 15,000 min-1

Voltage AC200 V (380 V/400 V) ± 10 %

Cycle 50 Hz/60 Hz

Volume 43 kVA

Phase Three-phase

Cable thickness□80 (□3.15) (□38 (□1.50)), 4-core (Including ground)

Spindle specifications 15,000 min-1

Voltage AC200 V (380 V/400 V) ± 10 %

Cycle 50 Hz/60 Hz

Volume 45 kVA

Phase Three-phase


Spindle specifications Standard 6,000 min-1 Extended 12,000 min-1

Voltage AC200 V (380 V/400 V) ± 10 % AC200 V (380 V/400 V) ± 10 %

Cycle 50 Hz/60 Hz 50 Hz/60 Hz

Volume 52 kVA 57 kVA

Phase Three-phase Three-phase



□100 (□3.94) (□38 (□1.50)), 4-core (Including ground)

Spindle specifications High torque: 6,000 min-1

Voltage AC200 V (380 V/400 V) ± 10 %

Cycle 50 Hz/60 Hz

Volume 72 kVA

Phase Three-phase


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 series; if attempted, it will adverse affect other equipment or cause malfunctioning of the leak breaker, etc.

3) When a leak breaker is used, select the one meeting the following rating.Ratings of leak breakers, etc.For inverter circuit useSensitive current of 100 mA or moreFast-blow type (0.1 sec.)

4) To furnish the power source into the machine, pull the cable through under the control box where is advantageous for the dust and water prevention. Apply the protection against dust and water to the cable. Protection measures are required also when pulled through over the cabinet.In addition, hold the power supply cable appropriately so that the tension wire will not hang on to the connection part of the main breaker of the power supply line.

Spindle specifications Standard 6,000 min-1 Extended 12,000 min-1


3-6-3. Power requirements and fuse capacity

Connecting power to the electrical equipment of the machine should be performed by a specially trained technician.Failure to observe these instructions may result in death or serious injuries.

1 Automatic circuit breakerBreaker capacity: Refer to next page.

3 Power supply lever switch

2 Cable size: Refer to next page.

L1 L2 L3 PE

(1)

(2)

(3)

NC control box

Power supply: Three-phase

Transformer(Optional)

Ground

200 V/380 V/400 V ± 10%50 Hz/60 Hz

ME12008R0100500160001


Automatic breaker capacity and cable thickness

The values in the table may vary depending on the optional specifications.MB-4000H

MB-5000H

MB-8000H

3-6-4. Inspection of cable connection

Line connections can be checked by checking the pressure level of the hydraulic unit.

Voltage 200 V 380 V/400 V

Spindle speed [min-1] 15,000 15,000

Branching automatic circuit breaker capacity [A]

200 100

Cable thickness [mm2 (in.2)] 80 (0.12) 38 (0.06)

Voltage 200 V 380 V/400 V

Spindle speed [min-1] 15,000 15,000


200 100

Cable thickness [mm2 (in.2)] 80 (0.12) 38 (0.06)

Voltage 200 V

Spindle speed [min-1] 6,000 12,000 High torque: 6,000


225 225 250

Cable thickness [mm2 (in.2)] 100 (0.16) 100 (0.16) 150 (0.23)

Voltage 380 V/400 V

Spindle speed [min-1] 6,000 12,000 High torque: 6,000


125 125 150

Cable thickness [mm2 (in.2)] 38 (0.06) 38 (0.06) 60 (0.09)

Failure to observe the following instructions may result in serious injury or damage to your machine or facilities.

1) Connect the ground wire to the external protective earth terminal (PE) in the control box.

2) Do not connect the power cord and ground cable in series. It may cause adverse effects on other equipment, or cause malfunction of the leak breaker.

3) When using a ground fault circuit interrupter (GFCI), select one that meets the following ratings.

For inverter circuit use

Sensitive current: 100 mA or more

Middle-sensitivity high-speed inverter type


If pressure of the hydraulic unit reaches the set pressure of 6.5 MPa (943.2 psi), lines are properly connected.


3-6-5. Preparation of air source

This machine lubricates its spindle bearings by oil-air lubrication. Insufficient or improper air supply may cause the spindle bearings to seize, or deteriorate other pneumatic equipment.Prepare the air source based on the following conditions.

Flow rate

The table below shows the amount of compressed air required for the machine.

Give additional 10 % to the required air supply to ensure all the pneumatic units are provided with sufficient air supply.If a compressor is shared with the other machine, air gun, or air grinder, the flow rate may become lower than the specified rate. In this case, check the flow rate with the airflow meter to see if the compressor can supply enough air even while the other machine is using the air.

Pressure

(1) Air pressure at the primary side should be set in the range of 0.5 MPa (72.6 psi) to 0.7 MPa (101.6 psi) and kept above 0.5 MPa (72.6 psi).Primary side air pressure of more than 0.5 MPa (72.6 psi) must be maintained even when air is used at the airflow rate in the table below, or when an external device such as an air gun or air grinder is used on the same system.The following table, given for your reference, shows the typical pressure loss generated in the pipe from compressor to the pneumatic unit inlet.

(2) Secondary pressure should be kept constant at 0.5 MPa (72.6 psi) using the pressure regulator on the machine.

Moisture

Use clean and dry air for the compressed.An air filter is mounted to the side of the machine. The air delivered from the compressor is normally hot and moist. Therefore, mount a freeze-dryer or after-cooler between the compressor and the air filter to remove moisture (temperature at machine air inlet is within 5 °C (41 °F) + room temperature).This is because the rust generated in the pipe due to moisture will deteriorate the machine.

Standard spindle model 900 L/min (237.8 gpm) (ANR)

Airflow rate Typical pressure loss in pipe per meter

3/8 1/2 3/4

500 L/min (132.1 gpm) (ANR)

0.0033 MPa (0.4788 psi)

0.0009 MPa (0.1306 psi)

0.0002 MPa (0.029 psi)

700 L/min (184.9 gpm) (ANR)

0.0065 MPa (0.9432 psi)

0.0018 MPa (0.2612 psi)

0.0003 MPa (0.0435 psi)

1,000 L/min (264.2 gpm) (ANR)

0.0133 MPa (1.9299 psi)

0.0036 MPa (0.5224 psi)

0.0006 MPa (0.0871 psi)

1,200 L/min (317 gpm) (ANR)

0.0192 MPa (2.786 psi) 0.0052 MPa (0.7545 psi)

0.0009 MPa (0.1306 psi)

1,400 L/min (369.9 gpm) (ANR)

0.0261 MPa (3.7872 psi)

0.0071 MPa (1.0302 psi)

0.0012 MPa (0.1741 psi)


Piping

The piping ID from the compressor to the pneumatic unit must be 12 mm (1/2 in.) or more.When the water is accumulated in the piping, it may reduce the effective area and cause pressure loss. So locate the drain in the place where the pipe height is the lowest to drain water from the pipe.

Filter drain

If you choose to install a filter drain as a precaution against moisture, we recommend using an auto-drain type filter.Maintenance is necessary even for the auto-draining type, but when you choose any filter other than this type, please pay good attention to maintenance, especially.

Selecting a compressor

(1) Select a model that is rated with discharge pressure that is slightly higher than the required pressure.(We recommend a model with discharge pressure that is higher than the operating pressure by +0.2 MPa (29.0 psi).)

(2) Select a model that is rated with discharge flow rate that is greater than the operating flow rate.(We recommend a rating that is 10 % to 20 % more than required.)

Air quality grade

The quality grade of primary air pressure should meet the following.

Solid particle diameter: 5 µm (200 µin.)

Pressure dew point: 3 °C (37 °F)

Oil concentration: 1.0 mg/m3

Quality grade: Grade 3 in Max. particle diameter; Grade 4 in Min. pressure dew point; Grade 3 in Highest oil concentration; or better.

3-6-6. Factory water supply

Please use drinkable water when diluting the coolant.Water that contains bacteria or salt can damage machine parts.

International standard ISO 8573-1:1991 Quality grade

Japan Industrial Standards JIS B 8392-1:2000 Quality grade

Quality gradeMax. particle

diameter(µm (µin.))

Min. pressure dew point(°C)

Highest oil concentration

(mg/m3)

1 0.1 (4) -70 (-94) 0.01

2 1 (40) -40 (-40) 0.1

3 5 (200) -20 (-4) 1.0

4 15 (600) +3 (37) 5

5 40 (1,600) +7 (45) 25

6 - +10 (50) -


3-6-7. Oil for trial runs

(1) Oils and coolants are drained when the machine is shipped. Please procure them before the machine is installed at your site.

(2) When supplying oils and coolants to the machine, read through the [SECTION 4 PREPARATION FOR OPERATION] and follow the lubricating oil chart and the lubricating oil specifications.

MB-4000H/5000H

MB-8000H

Tank Oil type Reserved amount

Spindle cooling unit AKZ438-CX-GKSFC2 (e.g.: Mobil Velocite Oil No.3)

10 L (2.6 gal)

Lubricator HM32 0.085 L (0.0225 gal)

Hydraulic unit HM32 20 L (5.3 gal)

Oil-air lubrication unitExxonMobil Mobil DTE Oil Light (specified)

2 L (0.5 gal)

Centralized lubrication unit G68 6 L (1.6 gal)

Tank Oil type Reserved amount

Spindle cooling unit

6,000 min-1 (No.50)12,000 min-1 (No.50)

FC2(Ex.Mobil Velocite Oil No.3)

50 L (13.2 gal)

Lubricator HM32 0.085 L (0.0225 gal)

Hydraulic unit HM32 20 L (5.3 gal)

Oil-air lubrication unitExxonMobil Mobil DTE Oil Light (specified)

2 L (0.5 gal)

Centralized lubrication unit G68 20 L (5.3 gal)


3-7. Machine installation

3-7-1. Temporary leveling

(1) Clean the foundation plates free of oily substances.

(2) The distance between the bottom of the foundation seat and the bottom of the bed should be approximately 70 mm (2.76 in.) (MB-4000H), 60 mm (2.36 in.) (MB-5000H) and 30 mm (1.18 in.) (MB-8000H).

(3) If the concrete floor is significantly inclined or uneven, procure an iron sheet and correct the floor (particularly pay attention to inclination and height of coolant tank).

(4) Do not firmly tighten M16 jack screws on the unit table and NC control box.

3-7-2. Assembling the units and parts shipped separately and preparing for operation

(1) To install the units and parts shipped separately, reverse the procedure for removal for transportation.

(2) Fill each tank and reservoir with the specified oil according to lubricating oil chart.

(3) Connect power supply cables and pneumatic pipes.

(4) Clean the machine by removing dirt from each component.

(5) Check the phase of the power source by operating the coolant unit pump motor.

Reverse motion of the motorWhen the motor is rotating in reverse direction and the required pressure is not achieved, turn off the power supply immediately and correct the power cable connection.Continuous rotation of the motor in the reverse direction may cause a problem.


3-7-3. Leveling the machine

Setting the machine in a level position greatly affects both working accuracy and service life. The machine should be carefully leveled during installation.Use a precision level (0.02 mm/m (0.0008 ipm) per division) to measure the machine level.Level the machine as follows:

MB-4000H/5000H

Procedure :

1- Position the spindlehead at the center of vertical travel (Y-axis).

2- Position the spindlehead in the middle of front-back travel range (Z-axis).

3- Position the column (X-axis) at the center of the bed.

4- With the precision level placed near the center of the table (pallet) along the X- and Y-axis directions, slowly move the table over the full range of Z-axis travel and take readings.Then, adjust the jack bolts of the bed so that the measured results fall within the tolerances specified in the accuracy test chart.

5- Adjust the machine level by using the five jack screws (MB-4000H) and three jack screws (MB-5000H) under the bed.

6- After adjustment, lock the jack bolts firmly with the lock nuts.

7- Fix the bed to the floor with hole-in (chemical) anchors.

8- Again, check the machine for levelness.

1 Precision level

(1)

Z

ME12008R0100500840001


Check the machine for levelness at least once a month also after starting the machine operation. If required levelness cannot be obtained, readjust the levelness.

MB-8000H

Procedure :

1- Move the spindlehead, carrier, and table to the middle of their travels, and place levels in X-axis and Z-axis directions on the table. Slowly move the table forward and backward and measure the levelness along the full travel.Then, adjust the jack bolts of the bed so that the measured results fall within the tolerances specified in the accuracy test chart.

2- Next, attach a dial gauge to the spindlehead and apply the gauge to the table upper surface. Move the carrier and measure the levelness of the bed in X-axis direction.

1 Precision level

(1)

ME12008R0100500250001

ME12008R0100500250002


3- Adjust the levelness based on the measuring results. Next, place a reference cylinder on the table and move the spindlehead equipped with a dial gauge vertically to check the perpendicularity in Y-axis direction.

4- By repeating the above measurements, restore the accuracy indicated in the accuracy test chart.

5- Adjust the machine level by using the seven jack screws under the bed.

6- After adjustment, lock the jack bolts firmly with the lock nuts.

7- Fix the bed to the floor with hole-in (chemical) anchors.

8- Again, check the machine for levelness.

Check the machine for levelness at least once a month also after starting the machine operation. If required levelness cannot be obtained, readjust the levelness.

1 Plug tool(Optional)

3 Dial gauge(1 reading: 0.01 mm (0.0004 in.))

2 Magnet stand 4 Reference cylinder

(4)

(1)

(2)

(3)ME12008R0100500250003

5963-E P-68SECTION 4 PREPARATION FOR OPERATION

SECTION 4 PREPARATION FOR OPERATION

4-1. Supplying lubricating oil/hydraulic oil

Machine parts should be lubricated according to [SECTION 4, 4-1-1. Lubrication oil charts] and [SECTION 4, 4-1-3. Lubrication oils for machine tools]. Check oil level and pump operation every day.Prior to shipment, the hydraulic oil tank, the oil-air lubrication oil tank, the spindle cooling oil tank, and the coolant tank are drained. Fill before installation.

(1) Hydraulic fluid for hydraulic unit

(2) Oil-air lubrication oil

(3) Spindle cooling oil

(4) Coolant

(5) Lubrication oil

(6) Lubricator oil

Always use the specified oil or its equivalent. Do not use used oil.

Note

The lubrication oil charts have prepared in accordance with MAS standards. The symbols used in these charts are described in lubrication chart symbols. Lubricating oils for machine tools in this section lists oil types to be used.

Lubricating oil

1) Use of improper lubricating oils may lead to poor performance or malfunction of the machine.

2) Be sure to use new oil for lubrication.

3) Always use an oil strainer when feeding oil.


4-1-1. Lubrication oil charts

MB-4000H

Lubricating management chart from operation side

Note

Lubrication pointsCentralized lubrication

unitLubricator Oil-air lubrication unit Table gearbox

Lube point number 1 2 3 4 5 6 7 8 9

Symbol

Maintenance item

Inspection 8 8 8 8 50

Replenish 50 50 1,000

Cleaning, Replaceme

nt

Replace 2,000

Lubricant name

G68 HM32 Mobil DTE Oil Light G68

Tank capacity (L

(gal))6 (1.6) - 2.0 (0.53) 3.2 (0.85)

Amount added (L

(gal))4 (1.1) 0.05 (0.013) 1.5 (0.40) -

Also refer to the lubrication management chart for the magazine side.

Clean the lubrication point before supplying oil.

Maintenance interval

Drain port

ME12008R0100600020002


Lubricating management chart for the magazine side

Note

Lubrication points Hydraulic unit Spindle cooling unit

Lube point number 1 2 3 4 5 6

Symbol

Maintenance item

Inspection 50 8 50

Replenish

Cleaning, Replacement

2,000

Replace 2,000 2,000

Lubricant name HM32 FC2

Tank capacity (L (gal))

18 (4.8) 10 (2.6)

Amount added (L (gal))

- -

Also refer to the lubrication management chart for the operation side.


Normally use HM32. However, use FC22 (with a viscosity index of 140 or more) at temperatures below 10 °C (50 °F).


Drain port

ME12008R0100600020001


MB-5000H


Note

Lubrication pointsCentralized lubrication

unitLubricator Oil-air lubrication unit Table gearbox

Lube point number 1 2 3 4 5 6 7 8 9

Symbol

Maintenance item

Inspection 8 8 8 8 50


Cleaning, Replaceme

nt

Replace 2,000

Lubricant name

G68 HM32 Mobil DTE Oil Light G68

Tank capacity (L

(gal))6 (1.6) - 2.0 (0.53)

3.4 (0.90)15.2 (1.37)2

Amount added (L

(gal))4 (1.1) 0.05 (0.013) 1.5 (0.40) -



1 1° table

2 0.001° table


Drain port

2 1

ME12008R0100600030003



Note

Lubrication points Hydraulic unit Spindle cooling unit

Lube point number 1 2 3 4 5 6

Symbol

Maintenance item

Inspection 50 8 50

Replenish


2,000

Replace 2,000 2,000

Lubricant name HM32 FC2


20 (5.3) 10 (2.6)


- -





Drain port

ME12008R0100600030002


unit

MB-8000H


Note

Lubrication pointsCentralized

lubrication unitLubricator Oil-air lubrication unit Table gearbox Spindle cooling

Lube point number 1 2 3 4 5 6 7 8 9 10 11

Symbol

Maintenance item

Inspection 8 8 8 8 50 50


Cleaning, Replacem

ent

Replace 2,000 2,000

Lubricant name

G68 HM32 Mobil DTE Oil Light G68 FC2


20 (5.3) - 2.0 (0.53)11.0 (2.91)122.0 (5.81)2

50 (13.2)

Amount added (L

(gal))16 (4.2) 0.05 (0.013) 1.5 (0.40) - -



1 1° table

2 0.001° table


Drain port

ME12008R0100600050001



Note

Lubrication points Hydraulic unit

Lube point number 1 2 3

Symbol

Maintenance item

Inspection 50 8

Replenish


Replace 2,000

Lubricant name HM32

Tank capacity (L (gal)) 18 (4.8)

Amount added (L (gal)) -





Drain port

ME12008R0100600050002


4-1-2. Symbols

Description Symbol Remarks

Oil level

Replenish

Replace

Pressure gauge

Thermometer

Filter

Clean or replace the filter element.

Check condition of filter element.

Flow sight

Check oil flow by visual inspection through window, gear, rotary ring or spout devices.

Oil pump

Operate manual pump with lever or push button.

Separator

Clean the magnetic coolant separator.

Time (operating hours)

Inspection

This symbol is used in combination with other symbols.

ME12008R0100600060001

ME12008R0100600060002

ME12008R0100600060003

ME12008R0100600060004

ME12008R0100600060005

ME12008R0100600060006

ME12008R0100600060007

ME12008R0100600060008

ME12008R0100600060009

ME12008R0100600060010

ME12008R0100600060011


4-1-3. Lubrication oils for machine tools

[Supplement]

Lubricant typeCode

Manufacturer

ExxonMobil Shell BP Japan

Gears lubrication CKB32 Mobil DTE Oil Light Shell Tellus Oil C32 Castrol Hyspin AWS32

CKB68Mobil DTE Oil Heavy

MediumShell Tellus Oil C68 Castrol Hyspin AWS68

CKC150 Mobilgear 600 XP 150 Shell Omala Oil 150 Castrol Hyspin AWS150

Bearing lubrication FC2 Mobil Velocite Oil No.3 Shell Tetra Oil 2 Castrol Magna2

FC10 Mobil Velocite Oil No.6 Shell Tellus Oil C10 Castrol Hyspin AWS10

Slideway lubrication G68 Mobil Vactra Oil No.2 Shell Tonna Oil S68 Castrol Magnaglide D68

G220 Mobil Vactra Oil No.4 Shell Tonna Oil S220 Castrol Magnaglide D220

Hydraulic fluid

HM32 Mobil DTE Excel 32 Shell Tellus Oil S32 Castrol Hyspin AWS32

Grease XBCEA1 Mobilux EP1 Alvania EP Grease 1 Castrol Spheerol EPL1

XBCEA2 Mobilux EP2 Unirex N2 Alvania EP Grease 2 Castrol Spheerol EPL2

1) The table above shows the major brand lubricating oils in reference to the standard JIS B6016-1 (ISO/TR 3498).

2) See the lubricating oil specifications given for each component in this manual for service points, supply amount, and the type of oil.

3) Always use the specified lubricating oil for slideways.

4) For lubrication of optional units (such as chip conveyor, NC rotary table, and robot), refer to the instruction manual for each unit.

5) If the slideway lubricant gets into the coolant and causes undesirable effects, we have oil skimmers (optional) that may resolve the issue. Please contact OKUMA for details.


4-2. Lubrication and inspection method

4-2-1. Supplying oil for the hydraulic power unit

MB-4000H

[Supplement]

1 Pressure adjusting screw 5 Oil filler port

2 Tank 6 Oil level gauge

3 Terminal box 7 Filter

4 Pressure gauge 8 Drain port

Specified oil HM32 (Typical Brand: Mobil DTE Excel 32)Use up to NAS11 grade, clean hydraulic fluid.

Tank capacity 18 L (4.8 gal)After filling up, operate the machine once and then replenish the tank.

Oil change interval 2,000H10 months at 200 hours/month operation4 months at 500 hours/month operation

1) For adjusting operation of the hydraulics unit, refer to [SECTION 6, 6-4. Adjustment of hydraulic unit].For detailed operation procedures, refer to the [HYDRAULIC POWER UNIT INSTRUCTION MANUAL] supplied separately.

2) A warning is issued when the oil level drops, and this is an ALARM-C warning that will disrupt operation. Always check the oil level before beginning work.

3) Normally use HM32. However, use FC22 (with a viscosity index of 140 or over) at a temperature below 10 °C (50 °F).

(1)

(3)

(5)

(6)

(2)

(8)

(4)

(7)

ME12008R0100600080001


MB-5000H

[Supplement]


2 Tank 6 Oil level gauge

3 Terminal box 7 Filter

4 Pressure gauge 8 Drain port







(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)ME12008R0100600040001


MB-8000H

[Supplement]

1 Pressure gauge 5 Oil level gauge


3 Terminal box 7 Tank

4 Drain port 8 Filter







(2)

(7)

(4)

(8)

(5)

(6)

(1)

(3)

ME12008R0100600090001


4-2-2. Supplying oil for the oil-air lubrication unit

[Supplement]

1 Oil-air lubrication unit 3 Oil level gauge

2 Oil filler port

Specified oil Mobil DTE Oil Light

Tank capacity 2 L (0.5 gal)

Replenish When filled to effective tank capacity, the oil should last approximately 5 months. However, this may vary depending on operating conditions.

Filter cleaning interval

The pump filter in the tank should be cleaned every 6 months and replaced once a year.

1) Always use the specified oil. Supply clean and new oil up to the H level. When supplying oil, be careful not to include dust in the oil.

2) Check the oil level every morning when starting operation. If the oil level drops to the L-level, low oil ALARM-C is triggered and the machine stops. Therefore, supply oil before the alarm lamp lights up.

3) For other precautions regarding oil-air lubricants, refer to the precautions provided in [SECTION 6, 6-6-1. Spindle lubrication (oil-air)]. For details on the instrument, refer to the [PURCHASED UNIT INSTRUCTION MANUAL].

(1) (2)

(3)ME12008R0100600100001


4-2-3. Supplying oil for the spindlehead cooling unit

MB-4000H/5000H

No.40: Spindlehead cooling unitAKZ439-C+AKZ9 (DAIKIN)

1 Exhaust 5 Drain port

2 Control panel 6 Tank

3 Air filterSlightly lift to remove.

7 Oil level gauge

4 Oil filler port

Specified oil FC2 (e.g.: Mobil Velocite Oil No.3)



1) If cooling oil other than the specified one is used, cooling efficiency could be lowered.

2) When supplying or replenishing the cooling oil, make sure to cut off the power.

3) The temperature setting volume is basically turned to the machine temperature ±0 °C (32 °F). Do not change the set temperature. (The volume is provided in the cooling system.)

4) Clean the filter at regular intervals (every month). If the filter is clogged, it could cause alarm and stop the machine.

(1)

(2)

(3)

(4)

(6)

(7)(5)

ME12008R0100600110001


MB-8000H

No.50: Spindlehead cooling unit for standard spindle (6,000 min-1) and extended spindle (12,000 min-1)NU-YOK630CNB (PANASONIC ELECTRIC WORKS)

1 Air filterPull out in the direction shown by the arrow.

4 Oil level gauge


3 Oil filler portRemove the cap.








(1)

(5)

(4)

(3)(2)

ME12008R0100600120001


No.50: Spindlehead cooling unit for high torque spindle (6,000 min -1)NU-YOK900CNA03 (PANASONIC ELECTRIC WORKS)


2 Oil filler portRemove the cap.

5 Air filterPull out in the direction shown by the arrow.

3 Oil level gauge








(3)

(5)

(2)

(4)

(1)

ME12008R0100600120002


4-2-4. Centralized lubrication unit

The centralized lubrication unit pressure-feeds lubricating oil at certain intervals after power is turned on in response to the usage of the X-, Y-, and Z-axes, B-axis, ATC and MG-axes. The oil is supplied to the X-, Y-, and Z-axis guideways and driving unit as well as ATC unit and table through the metering distributor.

MB-4000H/5000H

1 Centralized lubrication unit 3 Oil level gauge

2 Oil filler port 4 (Oil-air lubrication unit)

Specified oil G68 (Typical Brand: Mobil Vactra Oil No.2 SLC)


Replenish The lubricating oil might be consumed rapidly depending on timer setting or if the machine is operated for a long time continuously. Check the lubricating oil level and replenish as needed.The reservoir has a float switch which gives a warning signal when the level becomes low.

(3)

(1)

(2)

(4)

ME12008R0100600150001


MB-8000H

1 Centralized lubrication unit 3 Oil filler port

2 (Oil-air lubrication unit) 4 Oil level gauge

Specified oil G68 (Typical Brand: Mobil Vactra Oil No.2 SLC)


Replenish The lubricating oil might be consumed rapidly depending on timer setting or if the machine is operated for a long time continuously. Check the lubricating oil level and replenish as needed.The reservoir has a float switch which gives a warning signal when the level becomes low.

(1)

(4)

(3)

(2)

ME12008R0100600160001


4-2-5. Supply to table (pallet) drive gearbox

MB-4000H

The table or the pallet is driven by the combination of the worm and worm wheel. If they are not lubricated well, the service life will be considerably shortened due to rapid wear of them.

1 Oil filler port 3 Drain port

2 Oil level gauge

0.001° table (NC rotary table)

Specified oilG68

(Ex.Shell Shell Tonna Oil S68)

Tank capacity Approx. 3.2 L (0.85 gal)

Oil change interval2,000H

10 months at 200 hours/month operation4 months at 500 hours/month operation

(3) (1)

(2)

0.001° table

ME12008R0100600190002


MB-5000H


2 Oil level gauge

1° table 0.001° table (NC rotary table)

Specified oilG68

Ex.Japan Energy JOMO Slidus HS68

Tank capacity Approx. 3.4 L (0.9 gal) Approx. 5.2 L (1.37 gal)



(1)

(2)

(3)

1° table 0.001° table

ME12008R0100600200002


MB-8000H


2 Oil level gauge

1° table 0.001° table (NC rotary table)

Specified oilG68

Ex.Japan Energy JOMO Slidus HS68

Tank capacity Approx. 11 L (2.9 gal) Approx. 22 L (5.8 gal)



(1)

(2)

(3)

1° table 0.001° table

ME12008R0100600210001


4-2-6. Oil filling to lubricator

Fill the lubricator of the air filter for the air blower with the specified lubricating oil.If the lubricating oil in the lubricator is not sufficient, it will cause rusting.

Specified oil HM32 (Typical Brand: Mobil DTE Excel 32)

Tank capacity 0.085 L (0.0225 gal)Check the oil level every day and replenish whenever necessary.

Supply the specified lubricating oil from the filler port on the lubricator after releasing the air pressure while the machine is stopped.


4-2-7. Lubricating the toolpot

[Supplement]

Lubrication points Magazine toolpot chain

Symbol

Maintenance item

Replenish 1,000 hours

Lubricant name XBCEA2

Amount added (L (gal)) Adequate amount.

Lubricate the toolpot chain for the ATC magazine once every 1,000 hours by applying grease in the areas indicated with arrows in the above figures. This procedure is not necessary for MB-8000H as it is greased automatically.

ME12008R0100600230001


4-3. Lubrication warning system - lubrication alarm

Poor lubrication affects machine accuracy and causes breakdowns. As a safeguard, the automatic centralized guideway lubrication system is provided with the following warning devices.

(1) Low oil level in tankAn EC alarm is displayed when the level in the tank drops below the lower limit.

(2) Low lubrication pressureA pressure switch is used to detect the pump output pressure. Switch actuation is checked when the pump is set into operation. If pressure does not rise, an EC alarm is displayed.

(3) Excessive lubrication pressureThe above pressure switch is used to detect pump stoppage and whether pump output pressure has dropped to the specified level.If pressure does not drop, an EC alarm is displayed.

(4) Tripping of overload protective relay of the centralized lubrication system pump motor

If an alarm occurs, check the contents of the alarm. Take necessary measures to reset the alarm so that machine accuracy will not be affected and serious trouble may be prevented. Then proceed to the next operation.

Alarm No. Alarm message Alarm release

3703 Axis lube level low Supply the specified oil.

2705Axis lube pressure ON confirmation(insufficient pressure)

Inspect the lubrication unit and normalize the pump output pressure.

2706Axis lube pressure OFF confirmation(excessive pressure)

Inspect the lubrication unit and normalize the pump output pressure.

2704 Axis lube motor overload Reset the tripped overload relay.

About alarmsWhen any of the above four alarms takes place, the alarm message is displayed along with an alarm number on the NC screen.Note that even when an alarm (1) takes place, operation from the programmed commands continues.


4-4. Automatic centralized lubrication

4-4-1. Confirmation of automatic lubricant supply intervals

Automatic lubrication interval is set as a parameter in the NC unit, and is usually set to 10 minutes at factory shipment for this machine. The pump's run time is set to 60 seconds.This automatic lubricant supply interval can be checked on the pendant operation panel screen.

Procedure :

1- Press the PARAMETER key on the NC operation panel to MODE SELECT.

2- Press the function key [F6] (ITEM ↑) or [F7] (ITEM ↓) until the [MC USER PARAMETER] setting screen appears.

3- Hold down the PAGE↑ key or PAGE↓ key until the [No.12 AXIS LUBE] screen appears.

4- The value set at "1. AXIS LUBE CYCLE TIME" on the NC screen shows the lubrication interval.

ME12008R0100600250001


4-4-2. Parameter data setting for the automatic lubrication timer

To change the setting at "1. AXIS LUBE CYCLE TIME", follow the steps below.

Procedure :

1- Follow the procedures in [SECTION 4, 4-4-1. Confirmation of automatic lubricant supply intervals] to check the current automatic lubrication interval.

2- Use the cursor control key to locate the cursor to the data given as "1. AXIS LUBE CYCLE TIME".

3- Press the function key [F1] (SET).

4- Key in the time interval data in units of minutes.

5- Press WRITE.This overrides the "1. AXIS LUBE CYCLE TIME" data and the screen display changes.

Reference: Time setting ranges are as follows:

"1. AXIS LUBE CYCLE TIME" 0 minute to 10 minutes

"2. AXIS LUBE PUMP TIME" 15 seconds to 120 seconds Lubricating oil pump operation time

"3. CROSS RAIL LUBE CYCLE TIME"

0 minute to 120 minutes (Not used)

"4. CROSS RAIL LUBE PUMP TIME"

15 seconds to 60 seconds (Not used)

About lubrication timeWhen the interval of the automatic lubrication cycle is too long, lubricating oil is not supplied sufficiently, causing malfunction of the machine depending on the operating condition.


4-5. Waste oil

4-5-1. Drain oil tank for X-, Y-, Z-axes guideways

Lubricating oil supplied to the X-, Y-, and Z-axes and others from the centralized lubrication unit is collected to the drain oil tanks at a side of the coolant tank through the drain oil passage around the bed.The waste oil tank capacity is approximately 7 L (1.8 gal) (MB-4000H/5000H) and 20 L (5.3 gal) (MB-8000H).When the centralized lubrication unit is replenished, discharge the drained lubricating oil.

MB-4000H

1 Coolant tank 3 Oil-coolant tank

2 Waste oil tank

(1)

(2)

(3)

ME12008R0100600270001


MB-5000H

MB-8000H


2 Waste oil tank


2 Waste oil tank

(1)

(2)

(3)

ME12008R0100600450001

(1)

(2)

(3)

ME12008R0100600460001


4-6. Backlash adjustments for table drive worm gear

Worm gear backlash amount can be adjusted to an optimum value using the dual-lead mechanism.If backlash amount is too large, a play will be generated between the worm gear and the worm wheel, resulting in table indexing error.

Backlash adjusting procedure

Procedure :

1- Disconnect the worm gear from the motor shaft by loosening the bolt at the right of the coupling (1).

2- Remove the cover (2), and loosen the lock bolt from the nut (3). Then, loosen the nut (3) using the wrench (4).

3- Insert a hexagon bar wrench into the 17 mm (0.67 in.)-dia. hole of the lid attached to the housing (5), and turn the wrench clockwise to adjust the backlash.

4- After adjustment, tighten the bolts and covers in the reverse order of the above procedure.

1 Table 6 (1) Coupling

2 Motor 7 Worm gear

3 Worm wheel 8 Worm adjusting direction (to reduce backlash)

4 (4) Special wrench 9 (3) Nut

5 (2) Cover 10 (5) Housing

(8)

(1)

(2)

(6) (7) (9) (10)

(5)

(4)(3)

ME12008R0100600280001


[Supplement]

Backlash adjustment requires removal of the coupling. When the coupling is removed, the worm gear is disengaged from the motor shaft. After adjusting the backlash, therefore, you need to change the relevant data such as zero position and software limits.


4-7. Maintenance and inspection of HSK tool clamping unit (optional)

4-7-1. Greasing clamping unit

Due to the construction, the HSK tool clamping unit operates under friction.Therefore, if friction force that prevents normal operation of the clamping unit parts is generated, tool clamping error will take place.Periodically apply grease to the clamping unit to secure stable operation for a long period of time.

Procedure :

1- Unclamp the clamping unit by manual operation and remove the tool.

2- Set the clamping unit in the clamp state, as illustrated below, and supply grease through the finger to finger gap with the nozzle entered 3 mm (0.12 in.) to 5 mm (0.20 in.) into the gap.

3- Supply one shot of grease in each gap. Use the grease METAFLUX 70-81 that comes with the machine or an equivalent product.

4- Greasing interval 1 - 2 times a month

1 Finger 3 Finger

2 METAFLUX 70-81 (H1104-0000-78)

(2)

(3)(1)

ME12008R0100600290001


4-7-2. Inspecting the packing used in the clamping unit

The coolant supply port to the HSK tool incorporates a U-packing. When this U-packing wears, coolant may leak and deteriorate the spindle functions.To maintain stable spindle operation over a long period, inspect the U-packing at regular intervals. If wear is observed on the packing, replace it as soon as possible.Although the wear developing speed may vary with the machine operating conditions, it is recommended that you inspect the packing 1 - 2 times a month.

Procedure :

1- Unclamp the clamping unit by manual operation and remove the tool.

2- Remove the U-packing using a flathead screwdriver.

3- Attach a new packing by hand.

Note

When placing an order with OKUMA for U-packing, provide the following information:HSK-A63

HSK-A100

Do not reuse the removed packing.Early coolant leak may occur due to scratches.

Part No. : F119-0002-51

Part Name : Oil seal

Model number : Fukuda Corporation C1-1028V3664 VITON for HSK-A63

Part No. : F119-0002-60

Part Name : Oil seal

Model number : Fukuda Corporation C1-1053V3664 VITON for HSK-A100

U-packing

ME12008R0100600300001


4-8. Coolant

4-8-1. Coolant unit specification

[Supplement]

MB-4000H MB-5000H MB-8000H

Coolant tank capacity850 L (224.6 gal) (Effective 550 L

(145.3 gal))

650 L (171.7 gal) (Effective 450 L

(118.9 gal))

1,030 L (272.1 gal) (Effective 500 L

(132.1 gal))

Coolant typeWater-soluble coolant

Low viscosity non-water-soluble (oil-based) coolant

Pump motor200 V 50 Hz/60 Hz,

1.5 kW (2 hp)200 V 50 Hz/60 Hz,

390 W

Maximum output50 Hz/60 Hz

29 L/min/35 L/min (7.7 gpm/9.2 gpm)

50 Hz/60 Hz40 L/min/50 L/min

(10.6 gpm/13.2 gpm)

50 Hz/60 Hz42 L/min/50 L/min

(11.1gpm/13.2 gpm)

No. of coolant nozzles x7 (No.40), x8 (No.50) (angle adjustable)

The machine is coated with two-liquid paint consisting of polyurethane compound base and curing agent. Therefore, use the water-soluble coolant of emulsion type (W type 1).Water-soluble type coolant (W type 2) may damage the coating.


4-8-2. Coolant tank

The coolant tank is located at the backside of the machine.

MB-4000H

chip pan specification

1 Terminal box 9 Waste oil tank

2 Shower coolant pump 10 APC downstream washing pump

3 Internal washing, coolant nozzle, table washer, through-spindle coolant suction pump

11 Oil hole pump

4 Work washing gun pump 12 Float switch

5 Oil level gauge 13 Oil skimmer

6 Filter 14 Internal chip conveyor

7 Chip pan 15 Oil-coolant tank

8 Filter

(2)

(10)

(3)

(1)

(12)

(5)

(6)

(4)

(11)

(14)

(13)

(15)

(7)

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(9)

ME12008R0100600510001


MB-5000H


1 APC downstream washer pump 10 Oil-coolant tank

2 Filter 11 Oil hole pump

3 Table washer 12 Waste oil tank

4 Work washing gun pump 13 Filter

5 Through-spindle coolant suction pump 14 Chip pan

6 Shower coolant pump 15 Filter

7 Coolant nozzle pump 16 Oil level gauge

8 Float switch 17 Terminal box

9 Internal chip conveyor

(1)

(6)

(3)

(4)

(7)

(5)(8)

(17)

(16)

(15)

(14)

(13)

(12)

(10)

(9)

(2)

(11)

ME12008R0100600500001


MB-8000H


1 XY telescoping upper cover washing + internal chip flusher pump

10 Oil-coolant tank

2 Filter 11 Waste oil relay gutter

3 Table washer + X telescoping lower cover washing pump

12 Waste oil tank

4 Work washing gun pump(Optional)

13 Filter

5 Through-spindle coolant suction pump(Optional)

14 Chip pan

6 Shower coolant pump(Optional)

15 Coolant tank


8 Float switch 17 Filter


(8) (9)

(10)

(11)

(17)

(12)

(14)

(15)(13)(16)(5)

(4)

(3)

(6)

(7)

(1) (2)

ME12008R0100600490002


Lift-up chip conveyor specification

1 XY telescoping upper cover washing + internal chip flusher pump

10 Oil-coolant tank

2 Filter 11 Waste oil relay gutter

3 Table washer + X telescoping lower cover washing pump

12 Waste oil tank

4 Work washing gun pump(Optional)

13 Filter

5 Through-spindle coolant suction pump(Optional)

14 Lift up conveyor(Optional)

6 Shower coolant pump(Optional)

15 Coolant tank


8 Float switch 17 Drum filter reverse washing pump(Optional)


(1)

(7)

(6)

(3)

(4)

(5) (16) (17) (13) (15)

(14)

(12)

(11)

(10)

(9)(8)(2)

ME12008R0100600490001


4-8-3. Oil-coolant tank

A waste oil tank and oil-coolant separating tank is provided on the side of the coolant tank. This separating tank is used to separate the lubricating waste oil from the coolant. Periodically empty the waste oil tank.

MB-4000H

MB-5000H

1 Waste oil tank 2 Oil-coolant tank

1 Waste oil tank 2 Oil-coolant tank

(1)

(2)

ME12008R0100600540001

(1)

(2)

ME12008R0100600530001


MB-8000H

The oil-coolant separating tank employs a diaphragm that separates the tank into two compartments. Each compartment has a drain port. By changing the height of the drain ports, coolant flows into the coolant tank and waste oil to the waste oil tank due to the difference in specific gravity between coolant and oil.For efficient separation, coolant must be filled in the separation tank in advance up to the upper limit.

[Supplement]

1 Oil-coolant tank 2 Waste oil tank

1 Before starting, fill with coolant to this level. 5 To waste oil tank

2 Coolant mixed with oil. 6 Coolant(Specific gravity 1.0)

3 Separating plate 7 Oil(Specific gravity 0.88)

4 To coolant tank

The oil-coolant separation rate lowers if the heights of the waste oil port and coolant return port are not correctly set.When installing the oil-water separating tank, ensure that the tank is placed on the level.

(1)

(2)ME12008R0100600520001

(4) (5)

(7)(6)

(1) (2) (3)

ME12008R0100600520002


4-8-4. Coolant precautions

There are various types of plastics, lacquer, resin based materials, and adhesives used on this machine. Each of these materials is selected carefully in consideration of being used with the coolant.

4-8-5. Recommended coolant

The table below shows the recommended coolants:

Do not inhale coolant mist. It may be harmful to your health. Never use coolant which has a 15 % or higher oil content.

Mixing air and oil mist may result in the formation of an explosive compound. Therefore, do not blow pressurized air or oxygen on the machine or on compounds.Also, keep fire away from the machine.

The plant floor may be slippery from the coolant. Please use caution.

Do not use highly corrosive chemicals or additives. It may damage the machine and may cause malfunction.

Before operating the machine, communicate with the coolant supplier to obtain recommendations on compatibility and mixture ratio.

Also take into consideration local conditions such as hardness of the water used for the coolant.

OKUMA does not conduct tests on coolants.

OKUMA assumes no responsibility for any loss or damage that may occur during machining operation that may result from following any recommendations made by coolant suppliers.

When using synthetic coolants, make sure ample precautions are taken to prevent corrosion. Also check that compatibility between any coating material and plastic material and the OKUMA machine is fully guaranteed.

Strictly adhere to mixing ratio instructions from the coolant manufacturer.

Products Maker Type Use

NC-21K Taiyu Soluble Casting, iron, (aluminum)

EX-108M Taiyu Emulsion Iron, aluminum

EX-318 Taiyu Emulsion Iron, aluminum and stainless steel


Use only the water-soluble coolant recommended by OKUMA. Note that the water-soluble coolant of soluble type (W type 2) other than listed above may damage the coating. Also avoid using the chemical solution coolant because it damages not only the coating but also the slideways where chemical reaction with the lubricating oil tends to occur, and the rubber parts such as sealing material may also be damaged.


4-8-6. Fire precautions

From the standpoint of fire prevention, we recommend that you use water-soluble coolant. If you must use non-water-soluble (oil-based) coolants, strictly adhere to the information in [SECTION 1, 1-6-2. Fire protection].

4-8-7. Other precautions for using non-water-soluble (oil-based) coolant

Compared to water-soluble coolants, non-water-soluble (oil-based) coolants are higher in viscosity and lower in specific heat. As such, non-water-soluble (oil-based) coolants are:

less effective for rinsing.

less effective for coolant recycle and pumping rates.

likely to affect machining precision due to coolant temperature rise.

These are some of the effects it can have.Therefore, the following measures should be included in the machine specifications when non-water-soluble (oil-based) coolant is used.

Increasing the suction motor capacity for through-spindle coolant unit

Adjusting the coolant temperature if high machining accuracy is required

Precautions such as those listed above are necessary.

Note that we are not liable for any defects in machine performance, accidents, or damage caused by use of non-water-soluble (oil-based) coolant.

Particularly, avoid using high viscosity non-water-soluble (oil-based) coolant (with a viscosity of 10 cSt at 40 °C (104 °F) or over).


4-8-8. Classification of (water-soluble) coolant performance

Reference material: One-point Lessons on the Machining Process (Taiga Shuppan)

The role of coolant is classified into the primary performance that is directly needed in metal cutting and the secondary performance that is indirectly needed but plays important roles.

Among the above characteristics, determine which characteristics should take priority over the others.

Primary performance

(1) Lowers the temperature at the cutting edge to reduce tool wear.

(2) Prevents melted chips from sticking to the cutting edge or building up on the edge to improve the machined surface roughness and stabilize the dimensional accuracy.

(3) Reduces the cutting resistance and cools down the cutting system to prevent the system from being deformed by thermal deviation.

Secondary performance

(1) Chemically reacts with the cut surface or coated surface to prevent corrosion or discoloration.

(2) Prevents generation of smoke or fire.

(3) Harmless to human body.

(4) Prevents fume generation, prevents the coolant from getting sticky or rotten or deteriorating.

(5) Easy to dispose of.

JIS-specified water-soluble coolant

This coolant has excellent penetration and cooling characteristics, and is frequently used for grinding. One is the emulsion type (W type 1) coolant which is emulsified to a white milk-like liquid when diluted with water. The other is the soluble type (W type 2) coolant that becomes semi-transparent or transparent when diluted with water, and is effective for its penetration and cooling characteristics, making it a popular coolant for grinding.Soluble type includes detergent as a main ingredient and features excellent penetrating, cooling and washing effects and suitable for light cutting and grinding. In addition, resistance against rotting is stronger than the emulsion type. But due to its excellent washing ability, it may dissolve the lubricating oil mixed with the coolant and damage the coating.Select the coolant while keeping it in mind that there is no such coolant that satisfies both primary and secondary performances, for example, the coolant which prolongs tool life in light cutting and heavy cutting, assures accurate machined surface, and can be easily disposed of.

Class Type Main ingredients Application

W1(No.1 to 3)

Emulsion Mineral oil, detergent, corrosion/rust preventive compound, antifoam agent

Cutting or grinding various alloy steels and nonferrous alloy

W2(No.1 to 3)

Soluble Detergent, corrosion/rust preventive compound

Light cutting or grinding


Use only the water-soluble coolant recommended by OKUMA. Note that the water-soluble coolant of soluble type (W type 2) other than listed above may damage the coating. Also avoid using the chemical solution coolant because it damages not only the coating but also the slideways where chemical reaction with the lubricating oil tends to occur, and the rubber parts such as sealing material may also be damaged.


4-9. Chip pan

4-9-1. Chip pan configuration

MB-4000H/5000H/8000H

(The figure shows MB-4000H.)

Chips discharged from the chip conveyor are collected in this chip pan.

(1) The chip pan capacity is about 60 L (15.9 gal).

(2) Perforated sheet metal is built into the bottom of the chip pan so that coolant can be returned to the coolant tank from the bottom of the chip pan.

(3) Normally a cover is provided for this chip pan to prevent coolant from splashing. Remove the cover, inspect, and clean the chip pan whenever necessary.

1 Internal chip conveyor 3 Splash guard

2 Chip pan

(3) (2)

(1)

ME12008R0100600560001


htlb)

.4)

.5)

0.6)

0.3)

0.1)

1.9)

4-10. Oil hole holder

4-10-1.Specifications

MB-4000H/5000H

1 Oil path 5 Oil path

2 Free length b 6 Free length b

3 Set length a 7 Set length a

4 Positioning pin 8 Positioning pin

Model number FigMT. No.

D1 L1 C1 H1 H2 G1 S a b DMax.

speed min-1

Weigkg (

BT40-OMT3-120 1 MT3 23.825 120 82 21 22 - 65 6 0 23.5 - 32 3,000 3.8 (8

BT40-OMT4-120 1 MT4 31.267 120 82 21 34 - 65 6 0 33 - 50 3,000 3.4 (7

BT40-OSL16-150 2 - 16 150 82 25 - M12 P1.5 65 6 0Varies depending on carbide bit maker.

3,000 4.8 (1

BT40-OSL20-150 2 - 20 150 82 25 - M12 P1.5 65 6 0 3,000 4.7 (1

BT40-OSL25-165 2 - 25 165 82 15 20 M16 P1.5 65 6 0 3,000 4.6 (1

BT40-OSL32-165 2 - 32 165 82 15 20 M16 P1.5 65 6 0 3,000 5.4 (1

1) The angle between the positioning pin and the drive key slot should be 35°, as shown above.

2) Positioning and oil delivery blocks are supplied by OKUMA.

3) When making a purchase, specify to the tool manufacturer that the tool is for MB-4000H/5000H.

4) Pull-stud bolt: MAS 407 Type 2.

5) Purchase an oil hole holder of Daishowa Seiki.

H2 H1 D2

D

L1L

MT, NO.

(1)

(4) (8)

h6 h6

H3 H1

C1

G1

DSD

L1L

(5)

35°(2)(3)

(6)

(7)Φ18 (0.71) Φ18 (0.71)

[For Morse Taper type drill] [For Set Screw type drill]

Fig.1 Fig.2

ME12008R0100600430001


htlb)

7.6)

7.2)

6.5)

8.0)

7.6)

2.4)

2.4)

7.6)

MB-8000H

1 Oil path 5 Oil path

2 Free length b 6 Free length b

3 Set length a 7 Set length a

4 Positioning pin 8 Positioning pin

Model number FigMT. No.

D1 L1 C1 H1 H2 G1 S a b DMax.

speed min-1

Weigkg (

BT50-OMT3-115 1 MT3 23.825 115 98 21 22 - 80 6 0 23.5 - 32 3,000 8.0 (1

BT50-OMT4-120 1 MT4 31.267 120 98 21 34 - 80 6 0 33 - 50 3,000 7.8 (1

BT50-OMT5-120 1 MT5 44.399 120 98 28 40 - 80 6 0 50.5 -60 3,000 7.5 (1

BT50-OSL16-165 2 - 16 165 98 25 - M12 P1.5 80 6 0

Varies depending on carbide bit maker.

3,000 8.2 (1

BT50-OSL20-165 2 - 20 165 98 25 - M12 P1.5 80 6 0 3,000 8.0 (1

BT50-OSL25-165 2 - 25 165 98 15 20 M16 P1.5 80 6 0 3,000 10.2 (2

BT50-OSL32-165 2 - 32 165 98 15 20 M16 P1.5 80 6 0 3,000 10.2 (2

BT50-OSL40-165 2 - 40 165 98 15 25 M16 P1.5 80 6 0 3,000 8.0 (1

1) The angle between the positioning pin and the drive key slot should be 60°, as shown above.

2) Positioning and oil delivery blocks are supplied by OKUMA.

3) When making a purchase, specify to the tool manufacturer that the tool is for MB-8000H.

4) Pull-stud bolt: MAS 403 Type 2.

5) Purchase an oil hole holder of Daishowa Seiki.

6) The spring pressure of positioning pin should be 100 N (23 lbf) or lower. (When the positioning pin consists of two springs or more, the total of the springs pressure should be 100 N (23 lbf) or lower.)

H2 H1 D2

D

L1

L

MT, NO.

(1)

(4) (8)

h6 h6

H3 H1

C1

G1

DSD

L1

L

(5)

60°(2)(3)

(6)(7)Φ18 (0.71) Φ18 (0.71)

[For Morse Taper type drill] [For Set Screw type drill]

Fig.1 Fig.2

ME12008R0100600440001

5963-E P-115SECTION 5 OPERATION

SECTION 5 OPERATION

5-1. Operation panels

ME12008R0100700080001


Magazine operation panel

MANUAL INT.

MANUALINT.

DOORINTERLOCK

IO

CONSTANT INDEX

INDEX START

O I

CW

RESTART

EMG. STOP

INDEX STOP

CCW

MG. MANUAL

ME12008R0100700080002


5-2. Before starting operation

5-2-1. General checks

Check the lubricating oil level every day before starting operation.

Always use the OKUMA recommended and specified brands of lubricating oil.

For coolant, use the OKUMA specified coolant.

It is recommended to use a water-soluble coolant to prevent fire. Do not attempt unmanned operation when a non-water-soluble (oil-based) coolant is used.

Change and replenish the lubricating oil and coolant in each reservoir regularly according to the manual.

Clean the filters regularly according to the manual.

Check that each pressure gauge on the air and hydraulic lines displays correct value as described in this manual.

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.

When the front door will be locked in power off condition, the safety door switch will mechanically lock the door. For door open procedures, refer to [SECTION 2, 2-4-2. Door lock switch positions and types].

5-2-2. Before turning on the power

Make sure that the doors to the operation panel and the control box are closed.

Make sure that there are no obstacles around the machine.

Turn on the main switch before turning on the control on the operation panel.

Make sure that no person is inside the machinery.

Make sure that hydraulic and pneumatic piping are connected correctly.


5-2-3. Precautions during manual operation and continuous operation

Always follow the instructions in the operation manual.

Always make sure that all of the protective covers including the front door cover are in place before operating the machine.

Always close the front shield before starting operation.

When processing the first product, check operations and interference between parts thoroughly by performing idling -> cutting of a single block -> continuous operation in order.

Ensure safety before spindle rotation, workpiece clamping and axis movement.

Never touch chips or the workpiece while the spindle is rotating.

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

Check the jig installation conditions, all hydraulic pressures, and the maximum allowable spindle speed.

Check the installation and arrangement of the tools.

Check the tool offset settings.

Check the zero offset settings.

Make sure that SPINDLE OVERRIDE and FEED RATE settings on the NC operation panel are at 100%.

Check the software limit setting positions for the X-, Y-, Z-, and A-axes (in case of MU-type machining center).

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

Make sure that the workpiece and tool are securely fitted in the clamping unit or jig.

Check the cutting fluid nozzle positions.

Bring the machine to a complete stop by turning off the main switch before operations such as setup or adjustments inside the chip guard are carried out. Also turn off the main switch before working inside the machine at the rear side of the machine.


5-2-4. Spindle precautions

When removing chips adhering to the spindle or around the spindle, do not blow air or coolant on the spindle. The scattered chips or dust may enter the spindle and damage the bearings. When cleaning the spindle unit, use a broom or waste cloth.

When cleaning the spindle tapered bore, use the supplied cleaning bar or clean waste cloth.

If the power is turned off, the air supply to the spindle inside is cut off. Dust particles may get in the spindle and cause damage to the bearings. When the internal space of the machine is dusty, air supply to the inside of the spindle may be shut off. This may cause dust to get into the spindle, resulting in damage to the bearings. Therefore, do not turn off the power or implement emergency stop operation unless a true emergency arises.

5-2-5. Tool precautions

When a poorly balanced tool is rotated at speeds exceeding 3,000 min-1, it can create abnormal vibrations to the spindle drive system, leading to potential damage to the bearings. Use of unbalanced tools are also dangerous to the machine operator. Especially when using a big-bore tool or boring bar, ensure that the tool is well-balanced.

For high-speed operation, consult the tool manufacturer to select the appropriate tool.

Never use unbalanced tools. Tool could strike through the front cover.The use of unbalanced tools is highly dangerous, and may result in death or serious injury when tools strike through the front cover or safety glass window.The following precautions must be taken for safe operating.

1) Do not rotate the spindle exceeding the allowable speed of the tool. Otherwise, the tool could be broken with fragments flying out of the machine causing serious injury to operators. Consult the tool manufacturer for the allowable speed of the tool to be used.

2) During high-speed operation, there is a danger that a broken tool could fly out of the machine. Therefore, the full-enclosure shielding cover must always be kept closed during high-speed operation.

3) Do not use a tool that uses replaceable inserts, etc. which could fly out during spindle rotation due to centrifugal force. If a replaceable insert flies out during operation, it could cause serious injury to operators.

4) Use only tools that are dynamically balanced.

5) Use of unbalanced tools is strictly prohibited.

6) Special care must be paid when using big-bore tools and boring bars. If vibration is generated during high-speed spindle rotation, stop the spindle immediately.

Continuous rotation of the spindle can cause breakage of the tool and impact of fragments of the broken tool on the front shield of the machine, resulting in serious injury.

During high-speed cutting, chips or broken tool fragments might fly off the machine.Strictly observe the safety precautions such as "Do not stand in front of rotating parts".


5-2-6. Things to remember during set-up and configuration

Make sure that setup is complete.

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

Before changing the clamping unit or jig, make sure that it fits the intended job.

If two or more workers must work together, establish signals so that they can communicate.

Use the crane or equivalent tool to handle heavy objects.

When attempting an unfamiliar setup, double-check the setup before operation.

5-2-7. Workpiece loading and unloading

Make sure that workpieces are loaded and unloaded securely.

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

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

Before running a new program, rotate the spindle to make sure that the tool is securely clamped in the holder.

Before machining an irregularly-shaped tool, make sure that it is balanced properly.

When handling heavy workpieces, use a crane, hoist, or other similar tool.

Before loading a workpiece, make sure that the workpiece has an area that can be used for proper clamping.


5-2-8. Dry and minimum quantity machining (MQL)

Dry machining is a fire hazard because workpiece, tool, or chips are not cooled. Therefore, never place any flammable objects near the machine and dispose of chips and do not allow them to stack up.

In machines for dry machining, the tools are cooled with oiled air. These machines are designed for machining at the currently standard cutting speeds. There is a possibility of sparks or burning chips being formed during machining.

The air volume exchange is designed for normal operating conditions.

Ensure that no explosive mixtures with air are formed from the machining operation.

Machines designed for dry machining must never be used for machining magnesium materials.

Thoroughly clean the machine and the filter system each time before you change the material to be machined.

Machines that are designed only for dry machining must never be used for machining using cooling lubricants.

5-2-9. When a problem occurs

The following procedure should be performed:

Check the NC program.

Check the Alarm Message which is displayed on top line at the control.

Consult the person in charge of maintenance to determine what corrective measures need to be taken. Make sure to consult any specially trained and skilled personnel who are authorised for this purpose. Clearly assign responsibility of operation, service, and maintenance of the machine to individuals, and follow instructions from the responsible individual.

If two or more workers must work together, establish signals so that they can communicate.

Dry machining can cause fire.Make sure to exercise safety precautions to avoid fire.

Hazards due to gases and vaporsOil mists are harmful to health and may contain cancer-causing substances. Do not inhale oil mist!Operate machines with suction systems only when the suction is working.Harmful gases and vapors may escape when protective devices are opened. Ensure adequate ventilation or exhaust.


Shut off the machine's main switch while servicing the machine. Secure the main breaker against unauthorized activation by locking it.


5-3. Manual operation, preparatory operation

For safe operation, safety devices such as door interlocks are provided as standard equipment.Before operating the machine, refer to [OSP-P200MA OPERATION MANUAL] and [SAFETY DOOR INTERLOCK FUNCTION MANUAL] provided separately.

5-3-1. Power ON/OFF

Procedure :

1- Turn the power switch of the circuit breaker, located on the side of the NC control box, to the right so it is in the ON position in order to supply power to the NC unit.

1) If power is not supplied, check the factory power supply switch.

2) The pumps for the NC cooler, hydraulic unit, and spindlehead lubrication unit start. Check the pressure for each unit.

OFF

(0)

ON(1)

ME12008R0100700100001


2- Press the CONTROL ON push button switch on the NC operation panel.

3- Set the key-lock selection switch on the NC PANEL to the UNLOCK position. The screen and the indicating lights on the panel will be turned ON.

1 CONTROL ON buttonsThe switch lights up.

2 CONTROL OFF buttonsAll operational power is shut off.

If the CONTROL ON push button switch is not illuminated, one of the EMG. STOP push button switches is likely in the hold position. Check and reset it.

ORIENTA-TION RESTART

MACHINELOCK

BLOCKSKIP

OPTIONALSTOP

SINGLEBLOCK

DRYRUN

MID.AUTOMANUAL

PULSEHANDLE

SHIFTSEQUENCERESTART

INTERLOCKRELEASE

RELEASECCWCW STOP

UNLOCKEDITLOCK LOCK

NC PANEL

I ODOOR INTERLOCK

mm/min (inch/min)

(1)

(2)

ME12008R0100700100002


MACHINELOCK

BLOCKSKIP

OPTIONALSTOP

SINGLEBLOCK

DRYRUN

MID.AUTOMANUAL

PULSEHANDLE


INTERLOCKRELEASE

RELEASECCWCW STOP

UNLOCKEDITLOCK LOCK

NC PANEL

I ODOOR INTERLOCK

mm/min (inch/min)

NC PANELEDITLOCK UNLOCK LOCK

ME12008R0100700100003


4- When shutting off the power during normal operation, first press the CONTROL OFF push button switch on the left of the NC operation panel. (For an emergency stop, press the EMG. STOP push button switch.)Then turn the main power switch on the side of the NC control box to the OFF position on the left.

[Supplement]

As described above, each of the machine units is active until the power is shut off with the power supply lever. Use caution as they may move unexpectedly.

After turning the power on, perform routine inspection and adjustments before beginning work. (Refer to [SECTION 6, 6-3. Periodical inspection schedule].)


5-3-2. Emergency stop

To stop the machine immediately during a MANUAL, AUTO or MDI (Manual Data Input) mode, press the red EMG. STOP button. Control power will be shut off and the machine will stop immediately.

To restore power to the control system after an emergency stop, first remove the cause of malfunction, next turn the EMG. STOP push button switch clockwise to reset it, then press the CONTROL ON push button switch.

NC operation panel EMG. STOP buttons

ATC operation panel EMG. STOP buttons

APC operation panel EMG. STOP buttons

1) Pressing an EMG. STOP button only shuts off the control power. Main power to the circuit breaker stays on and the units remain energized.

2) Engaging emergency stop operation while the spindle is rotating may not stop the spindle rotation immediately due to its rotational inertia. To avoid being caught in spinning tools, do not approach them until they come to a full stop.


MACHINELOCK

BLOCKSKIP

OPTIONALSTOP

SINGLEBLOCK

DRYRUN

MID.AUTOMANUAL

PULSEHANDLE


INTERLOCKRELEASE

RELEASECCWCW STOP

UNLOCKEDITLOCK LOCK

NC PANEL

I ODOOR INTERLOCK

mm/min (inch/min)

ME12008R0100700110001


5-3-3. Spindle rotation in neutral (spindle release)

It is often necessary to rotate the spindle slightly while the spindle is at a stand still, for example, for alignment of a cutting tool to the workpiece, manual removal and setting of a cutting tool from and to the spindle, and inspection of cutting bits. For this, press the spindle RELEASE flat key on the NC operation panel. The spindle drive system will be set to neutral, allowing easy hand turning of the spindle.

Operating conditions

Control power is ON.

Spindle is at a stand still.

Tool is clamped in spindle.

Machine is not in the ATC cycle.

MANUAL mode is selected.

[Supplement]

When working with the spindle running idle, take care that no other operator will inadvertently engage the spindle. Failure to observe this instruction may result in being caught in the spindle.

To restart the spindle after it has been running idle, enter a spindle speed command.


MACHINELOCK

BLOCKSKIP

OPTIONALSTOP

SINGLEBLOCK

DRYRUN

MID.AUTOMANUAL

PULSEHANDLE


INTERLOCKRELEASE

RELEASECCWCW STOP

UNLOCKEDITLOCK LOCK

NC PANEL

I ODOOR INTERLOCK

mm/min (inch/min)

RELEASE

ME12008R0100700120001


5-3-4. Spindle indexing (position stopping of the spindle)

Spindle indexing is performed to index and clamp the spindle to a certain position to prepare for tool changes.Spindle rotation is done by the spindle drive motor.



MANUAL mode is selected on the NC operation panel.(In AUTO or MDI mode, spindle orientation is possible using the M19 command.)

Tool is clamped in the spindle.

The ATC tool change arm is not at the spindlehead.


Operating method

(1) Press the spindle ORIENTATION flat key while holding down the INTERLOCK RELEASE flat key at NC operation.

1 The lamp should be ON. 2 The lamp will light.

(1) (2)


MACHINELOCK

BLOCKSKIP

OPTIONALSTOP

SINGLEBLOCK

DRYRUN

MID.AUTOMANUAL

PULSEHANDLE


INTERLOCKRELEASE

RELEASECCWCW STOP

UNLOCKEDITLOCK LOCK

NC PANEL

I ODOOR INTERLOCK

mm/min (inch/min)

ORIENTA-TION INTERLOCK

RELEASE

ME12008R0100700160001


(2) To reset the spindle indexing mode, rotate or idle the spindle.

To rotate the spindle (clockwise or counterclockwise), press either CW or CCW flat key while holding down the INTERLOCK RELEASE flat key at NC operation.

To release the spindle, press the spindle RELEASE flat key.

Never touch the spindle while it is in the spindle indexing mode. Failure to observe this instruction may result in being caught in the machine.

The spindle should be indexed during clockwise rotation. The spindle stops at the first indexed position, basically. However, it might rotate two or three times before stopping.

Never apply a rotating torque to the spindle right after completion of spindle indexing, for example by tightening the milling chuck, because of the following dangers.

Torque may be generated in the opposite direction to return to the indexed position.

An alarm error may occur.

Power may be shut off, causing a free state.

ME12008R0100700160002


5-3-5. Clamping and unclamping the tool in spindle

Tools can be clamped/unclamped by pressing the push button switch in order to manually remove tools attached to the spindle during ATC auto changes or to manually attach/remove tools to/from the spindle which cannot be handled by the ATC magazine.A time-saving pull stud mechanism is used to draw the tool into the spindle. The pull stud, located at the rear of the toolholder, is drawn into the spindle by a collet and a belleville spring housed in the spindle.To remove a tool, a hydraulic cylinder at the top of the spindlehead opens the collet, which is held closed by spring force, and pushes the tool out of the spindle. This tool push-out stroke is about 1 mm (0.04 in.).


Use tools which conform to machine specifications and match the figures shown in the [Separate volume technical sheet].

The MANUAL mode has been selected.

The spindle is at a stand still. The spindlehead may be in any position. Position it closer to the operator.

Operating method

Spindlehead operation panel

Press the MANUAL TOOL CHANGE push button on the manual tool tightening/releasing operation panel.

To prevent accidentally pressing the TOOL UNCLAMP button and dropping the tool from the spindle, the TOOL CLAMP and TOOL UNCLAMP buttons are disabled until they are enabled by expressly pressing the MANUAL TOOL CHANGE button.

MANUAL TOOL CHANGE

TOOL CLAMP

TOOL UNCLAMP

ME12008R0100700190001


Tool removalWhile holding the tool by hand, press the TOOL UNCLAMP button. After three seconds, the tool in the spindle will be unclamped and can then be removed from the spindle. A time-delay of three seconds is built into the tool unclamp operation to allow the operator to hold a heavy tool with both hands after pressing the button.

Tool installationInsert new tool into the spindle, align the drive key, then press the TOOL CLAMP button. The tool will be clamped in the spindle.

When the optional through-spindle coolant configuration is used, the through pin presses down the pull stud by another 10 mm (0.39 in.). (Refer to [SECTION 11, 11-2-6. Procedure to change through pin in the pulling shaft].)

1) Clean the spindle nose and tool shank tapers before setting a tool in the spindle.

2) If a tool has been used for a long time or heavy cutting operation, it may become heated and difficult to remove from the spindle. Care should be taken while handling a hot tool.Continuous heavily vibrating cutting may cause rust to form among the spindle taper hole tools due to fretting corrosion symptoms. Apply a coating of powder lubricant such as aerosol molybdenum disulfide to the taper section. (Refer to [SECTION 5, 5-3-6. Reference information on [MOLYKOTE321]].)However, lubricant oil film is formed within the inner diameter of spindle taper and the tool edge position slightly changes when it is not applied. So, take this into consideration when performing finish machining that requires precise machining accuracy.Also, when lubricant is applied to the 2-flat fixing tools (such as BIG PLUS or HSK), please be aware that the contact pressure between the tool and the spindle end face may be reduced.


5-3-6. Reference information on [MOLYKOTE 321]

Data sheet

MOLYKOTE® D-321R dry coating grease

Grease type Air dry type

Components Binder Inorganic compound

Solid lubricant M0S2 + graphite

Solvent (diluted) Mineral Spirit

Color Dark gray

Optimal application method

Spraying ○

Dipping ○

Tumbling ○

Brushing ○

Set to touch (at 25°C (77°F)) 3 min.

Curing conditions Leaving the grease for 30 minutes at room temperature

Greasing area (10 µm (400 µin.) film) 20 m2/L

Working temperature range -180 °C (-292 °F) to 450 °C (842 °F) (650 °C (1,202 °F) in inactive atmosphere)

Storage life Bulk: 1 year, Aerosol: 2 years

Flash point 23 °C (73 °F)

Falex test1 Abrasion resistance life 75 min.

Withstand load 1,136.4 kg (2,500.1 lb)

LFW-1 test2 Abrasion resistance life 460,000 cycles

Abrasion resistance life against reciprocating movements

250,000 cycles

Adhesive property 3 Good

5 % salt water spray test 4 2 hours

Applicable standards Fourth group, second class petroleum

Features Low friction coefficient

Noncombustible

Radiation resistant

Easy to use

Use Cold forging

Replacement with other dry coating

Preventing nibbling of bolts

Fitting of parts

Volume Aerosol 233 mL

Bulk 1 L (0.3 gal), 4 L (1.1 gal)


Test conditions (test conditions for tests 1 through 4 in the MOLYKOTE 321 datasheet.)

The test pieces are sandblasted and coated with grease sprayed to a thickness of 10 µm (400 µin.).

1

Falex abrasion resistance life(Federal Standard 791-3807)

Load 4,450 N (1,001 lbf)

Speed 290 min-1

Falex withstand load(Federal Standard 791-3812)

Load increasing amount 1,110 N (250 lbf)/min

Speed 290 min-1

2

LFW-1 abrasion resistance life

Load 2,800 N (630 lbf)

Speed 72 min-1

Ring hardness HRC60

Block hardness HRC60

Kinematic friction coefficient for judgment

Time measured until the coefficient reach 0.1

LFW-1 abrasion resistance life against reciprocating movements

Reciprocating cycle 87.5 min-1

Rotary angle 90°

Ring hardness HRC60

Block hardness HRC60

Kinematic friction coefficient for judgment

Time measured until the coefficient reach 0.1

3Adhesive property(Federal Standard 791-3810)

Pressure sensitive tape test

45 % salt water spray test(Federal Standard 791-4001)

5 % salt water

35 °C (95 °F) continuously


Greasing method

Grease can be applied by spraying, dipping, or brushing.Solids in MOLYKOTE® D-321R dry coating grease can deposit over time. Shake well before use. Usually, cover the grease container to prevent the binder from hydrolyzing and the solvent from evaporating.It is best to use undiluted MOLYKOTE® D-321R dry coating grease. However, the solvent can evaporate over time. If you must adjust viscosity, use mineral spirit.

Spraying

Use a general spray gun. When spraying, ventilate the room and use it in the same way as general spraying. At this time, do not forget to stir up the grease sufficiently. By a single stroke of spraying, 5 µm (200 µin.) to 7.6 µm (304 µin.) thick film is formed thereby optimum adhesive property and abrasion resistance life can be obtained.

Dipping

Stir up the grease sufficiently before use because solid material in the grease tends to precipitate. It is recommended to use an automatic stirrer.

Brushing

Apply grease by brushing when there is no other choice. Use a normal brush for painting.

Curing method

MOLYKOTE® D-321R dry coating grease hardens if exposed to air moisture. In the normal state (at 21 °C (70 °F) with relative humidity of 50 %), the grease cures within 30 minutes. The curing time will be shortened with increase in temperature or humidity.

5-4. When starting the machine

Check the air pressure and oil levels. Normally, warm-up is not required for a spindle speed mode of 6,000 min-1. However, in extremely low temperatures (i.e., during winter), warm-up must be performed for 10 minutes when the spindle speed mode is 3,000 min-1.Before operating the high-speed spindle model, conduct the warm-up run according to the table below.

Make sure to read the Material Safety Data Sheet (MSDS) before use.When using MOLYKOTE® D-321R, do so in a well-ventilated area and do not breath its vapor for long periods. Since the vapor stimulates your eyes or mucous membrane, wear protective devices whenever necessary. After greasing, wash your hands. Do not directly apply grease to any hot parts. When storing the grease, do so with it stopped tightly and in a cool dark place.

15,000 min-1 spindle model 12,000 min-1 spindle model

4,000 min-1 10 min. 3,000 min-1 10 min.

9,000 min-1 10 min. 6,000 min-1 10 min.


5-5. Spindle speed selection

5-5-1. Spindle speed selection

(1) The machine is not equipped with controls for manually selecting the spindle speed.

(2) With an AUTO or MDI command, S4-digit direct commands from the NC controller changes the spindle speed automatically.

(3) A graph showing the relationship between spindle speed, torque, and output is provided in [SECTION 5, 5-5-2. Spindle speed - spindle power/torque diagrams].

(4) The table below shows the spindle speed ranges and full-power ranges of each spindle specification.

Machine model MB-4000H

Spindle specifications

Spindle taper No. 40

Spindle specifications 15,000

Speed range(min-1)

50 to 15,000

Spindle outputkW (hp)

26/18.5 (34.7/24.67)(10 min./cont.)

Max. torqueN-m (lbf-ft)

163 (120)

Constant output range(min-1)

4,000 to 15,000




Spindle specifications 15,000

Speed range(min-1)

50 to 15,000


26/18.5 (34.7/24.67)(10 min./cont.)


199 (147)


4,000 to 15,000






Standard 6,000 Extended 12,000 High torque: 6,000

Speed range(min-1)

50 to 6,000 50 to 12,000 50 to 6,000


30/22 (40/30)(10 min./cont.)

37/26 (50/34.7)(10 min./cont.)

45/37 (60/50)(20 min./cont.)


606 (447) 284 (210) 1,071 (790)


950 to 6,000 2,000 to 12,000 1,900 to 4,100


(5) The SPINDLE OVERRIDE(%) dial is used to override the commanded spindle speed in a range from 30 % to 200 %.Changing this override dial setting during spindle rotation is effective. However, the override dial setting is ineffective if the resultant spindle speed exceeds the specified spindle speed range.

1 SLOWER flat keySpindle speed decreases by 10 % every time pressed.

3 FASTER flat keySpindle speed increases by 10 % every time pressed.

2 Spindle override display

If the specified speed command value is lower than the minimum speed or larger than the maximum speed, the spindle remains stopped and an alarm occurs. (However, if such a command is specified during spindle rotation, the spindle keeps rotating.)

(2)

(1) (3)

%

21

ME12008R0100700280001


Do not rotate the spindle exceeding the allowable maximum speed of the mounted tool.The tool may fly out of the machine causing serious injury. For the allowable tool rotation speed, check with the tool maker.

The SPINDLE OVERRIDE dial is always effective. If you set it to a value higher than 100 %, the spindle speed selected by the next speed command is also increased by the dial-selected rate.Make it a rule to return the dial to 100 % or lower rate immediately after a cutting cycle is finished.

Even if power is shut off when the spindle is spinning, it continues to spin due to inertia. To avoid being caught by the spinning spindle, do not approach it until it comes to a complete stop.

Check the allowable spindle speed for a tool to be used. Specify allowable spindle speed for each tool on the tool information setting screen.

Do not set a speed that exceeds the specified allowable spindle speed for a tool. If you do so and a command is issued for a speed over the tool's allowable spindle speed, a tool, a holder, or chips may fly out causing death or serious injury to passers-by.

Do not perform milling under conditions where the speed of the tool tip is 1,000 m/min (3,281 fpm) or faster.This is extremely dangerous as the tool may be broken and its pieces dispersed, causing death or serious injury to passers-by.If such milling conditions are unavoidable, take safety measures such as placing covers around the area.

Do not rotate a gun drill tool without the tool being inserted in a guide hole. This is extremely dangerous as the tool may be broken and its pieces dispersed, causing death or serious injury to passers-by.

Do not operate the machine with the operation door left opened or with an operator standing inside the plastic chain. There is a risk of entanglement in rotating parts or broken tool pieces being dispersed, causing death or serious injury.


5-5-2. Spindle speed - spindle power/torque diagrams

MB-4000H 15,000 min-1 (No.40) specification

When setting the cutting conditions, take into account the following values for spindle torque and output.

Maximum spindle torque : 163 N-m (120 lbf-ft)

Maximum spindle output 26 kW (34.7 hp)/18.5 kW (24.67 hp), 10 min./cont.

The spindle's full-power range is from 4,000 min-1 to 15,000 min-1.

1

10

100

1000

10 100 1000 10000 1000000.1

1

10

100

88050

Spin

dle

torq

ue N

-m (l

bf-ft

)

Mot

or o

utpu

t kW

(hp)

Spindle speed min-1

163 N-m (120 lbf-ft) (5 min.)

15 kW (20 hp) (5 min.)

11 kW (15 hp) (cont.)

120 N-m (89 lbf-ft) (cont.)

26 kW (34.7 hp) (10 min.)

18.5 kW (24.67 hp) (cont.)

15,000

4,000

2,500 8,800

ME12008R0100700290002


MB-5000H 15,000 min-1 (No.40) specification


Maximum spindle torque : 199 N-m (147 lbf-ft)

Maximum spindle output 26 kW (34.7 hp)/18.5 kW (24.67 hp), 10 min./cont.

The spindle's full-power range is from 4,000 min-1 to 15,000 min-1.

300

200

100

60

40

20

50 100 200 400 720 1000 2000 4000 100000

1

2

4

6

10

20

30

10

Spin

dle

torq

ue N

-m (l

bf-ft

)

Mot

or o

utpu

t kW

(hp)

Spindle speed min-1

199 N-m (147 lbf-ft)

146 N-m (108 lbf-ft) 15 kW (20 hp) (10 min.)

11 kW (15 hp) (cont.)

26 kW (34.7 hp) (10 min.)

18.5 kW (24.67 hp) (cont.)

62 N-m (46 lbf-ft)

44 N-m (32 lbf-ft)

16.6 N-m (12.3 lbf-ft)

11.8 N-m (8.7 lbf-ft)

2,50015,000

ME12008R0100700300001


MB-8000H, Standard 6,000 min-1 (No.50) specification


Spindle speed 6,000 min-1

Max. output 30 kW (40 hp)/22 kW (30 hp) (10 min./cont.)

Max. torque 606 N-m (447 lbf-ft)

Spindle taper 7/24 taper No.50, HSK-A100

Bearing lubrication method Oil air

Bearing inside diameter Φ100 (3.94)

Standard spindle: 50 min-1 to 6,000 min-1 30 kW (40 hp)/22 kW (30 hp) (10 min./cont.), 7/24 taper No.50

100 10

1000 100

200 20

500 50

50 5

20 2

50 100 200 500 1000 2000 6000 10000

10 1

410 830 950

Spin

dle

torq

ue N

-m (l

bf-ft

)

Mot

or o

utpu

t kW

(hp)

Spindle speed min-1

606 N-m (447 lbf-ft) (10 min.)

349 N-m (258 lbf-ft) (cont.)30 kW (40 hp) (10 min.)

22 kW (30 hp) (cont.)

26 kW (34.7 hp) (10 min.)

15 kW (20 hp) (cont.)

2,800

ME12008R0100700310001


MB-8000H, Extended 12,000 min-1 (No.50) specification



Max. output 37 kW (50 hp)/26 kW (34.7 hp) (10 min./cont.)

Max. torque 419 N-m (309 lbf-ft)




Extended spindle: 50 min-1 to 12,000 min-1 37 kW (50 hp)/26 kW (34.7 hp) (10 min./cont.), 7/24 taper No.50

5000

1000

100

10

50

500

100 500 1000 10000

100

10

1

50

5

50 2000200

740

Spin

dle

torq

ue N

-m (l

bf-ft

)

Mot

or o

utpu

t kW

(hp)

Spindle speed min-1

284 N-m (210 lbf-ft) (10 min.)

194 N-m (143 lbf-ft) (cont.)

22 kW (30 hp) (10 min.)419 N-m (309 lbf-ft) (2 min.)

37 kW (50 hp) (10 min.)

26 kW (34.7 hp) (cont.)

12,0001,200

32.5 kW (43.33 hp) (2 min.)

15 kW (20 hp) (cont.)

ME12008R0100700320002


MB-8000H, High torque 6,000 min-1 (No.50) specification



Max. output 45 kW (60 hp)/37 kW (50 hp) (20 min./cont.)

Max. torque 1,071 N-m (790 lbf-ft)




High torque spindle: 50 min-1 to 6,000 min-1 45 kW (60 hp)/37 kW (50 hp) (20 min./cont.), 7/24 taper No.50

1000

500

100

50

1050 100 500 1000 6000

100

50

10

5

1

Spin

dle

torq

ue N

-m (l

bf-ft

)

Mot

or o

utpu

t kW

(hp)

Spindle speed min-1

1,071 N-m (790 lbf-ft) (3 min.)

752 N-m (555 lbf-ft) (20 min.)

637 N-m (470 lbf-ft) (cont.)

37 kW (50 hp)

45 kW (60 hp) (20 min.)

37 kW (50 hp) (cont.)

1,130 1,900 3,300 4,100330

ME12008R0100700660001


5-6. Spindle CW, CCW, STOP

This machine has been designed to carry out cutting according to the programmed commands in AUTO mode or the commands entered in MDI mode instead of the manual switch cutting operation. Therefore only CW, CCW, and STOP manual switch flat keys are available for spindle rotation and no switch is prepared for selecting the spindlehead rotation speed.

Spindle speed has to be selected in advance by programmed S 4-digit commands in AUTO mode or by the commands entered in MDI mode. (Refer to [SECTION 5, 5-5. Spindle speed selection].)

5-6-1. Operating conditions


The MANUAL mode has been selected. However, even during AUTO mode, if operation is paused or MANUAL INT. is ON, manual operation is possible.

The tool is clamped in the spindle.

The ATC tool change arm is at the standby position.

An S command has been given to control the spindle speed.If the specified speed command value is the minimum speed or the maximum speed or higher, the spindle remains stopped and an alarm occurs.

5-6-2. Operating method

(1) To rotate the spindle (clockwise or counterclockwise), press either the CW or CCW flat key while holding down the INTERLOCK RELEASE flat key at NC operation.

(2) To stop the spindle, press the spindle STOP flat key.

(3) Pressing the spindle STOP flat key applies the motor brake and stops the spindle.


MACHINELOCK

BLOCKSKIP

OPTIONALSTOP

SINGLEBLOCK

DRYRUN

MID.AUTOMANUAL

PULSEHANDLE


INTERLOCKRELEASE

RELEASECCWCW STOP

UNLOCKEDITLOCK LOCK

NC PANEL

I ODOOR INTERLOCK

mm/min (inch/min)

CCWCW STOP INTERLOCKRELEASE

ME12008R0100700350001


5-7. Feeding the X-, Y-, and Z-axes

The axis nomenclature is indicated below. (Viewed from operator position)


The MANUAL mode has been selected on the NC operation panel.

The flat key of the feed axis to be operated has been selected.

The axis to be controlled is not located at its travel end.

The ATC tool change arm is at the standby position.

1) Switching the NC operation modes does not affect the spindle rotation conditions.

2) Pressing the RESET key on the NC operation panel causes the spindle to stop.

3) If the spindle drive motor load exceeds the motor capacity (150 % is displayed on the CRT as a load in the constant output range), the spindle will stop.

Operation +direction

X-axis Column left and right To the left (MG side)

Y-axis Spindlehead up/down Upward

Z-axis Table front/back Backwards (APC side)

M15'

M16'

Y

Z'

X

ME12008R0100700360001


5-7-2. Rapid feed operation procedure

Procedure :

1- Select the axis to be moved with a flat key.

2- Select the desired rapid feed rate override percentage, from 1, 5, 10, 30, 50, 70, 80, 90, 100 % by adjusting the RAPID OVERRIDE(%) switch.This selection can be changed during operation while an axis is moving.

3- By pressing the RAPID+ or RAPID- flat key, the selected axis moves rapidly in the direction of the flat key pressed for as long as it is pressed, and stops when the key is released.

[Supplement]

1 Check that the lamp is lit.

Rapid traverse of the X-, Y- and Z-axes on this machine operates at 60 m/min (197 fpm) (MB-4000H/5000H) or 50 m/min (164 fpm) (MB-8000H). Be very careful as incorrect operation can result in a collision at this high speed. When the operator is not familiar with machine operations, or to run the machine with extra care, use the RAPID OVERRIDE switch to reduce its speed.


MACHINELOCK

BLOCKSKIP

OPTIONALSTOP

SINGLEBLOCK

DRYRUN

MID.AUTOMANUAL

PULSEHANDLE


INTERLOCKRELEASE

RELEASECCWCW STOP

UNLOCKEDITLOCK LOCK

NC PANEL

I ODOOR INTERLOCK

mm/min (inch/min)

(1)

ME12008R0100700380001


5-7-3. Running-in operations

Follow the steps below to carry out run-in operation for axis feed.

Procedure :

1- When the power is supplied, the LUBE PUMP ON switch automatically comes ON. Set the RAPID OVERRIDE dial to 10 % and move individual axes throughout their travel ranges for 20 minutes to 30 minutes.


5-7-4. Manual feed operation

Procedure :

1- Select the axis to be moved with a flat key.

2- Select a desired feedrate using the JOG SPEED SELECT selector switch. The feedrate setting range is from 1 mm/min (0.04 ipm) to 10,000 mm/min (393.7 ipm). This selection can be changed during operation while an axis is moving.

3- By pressing the JOG+ or JOG- flat key, the axis will move in the direction selected by the flat keys at the selected feedrate.

4- Press the JOG STOP flat key to stop axis feed.

1 Check that the lamp is lit.


MACHINELOCK

BLOCKSKIP

OPTIONALSTOP

SINGLEBLOCK

DRYRUN

MID.AUTOMANUAL

PULSEHANDLE


INTERLOCKRELEASE

RELEASECCWCW STOP

UNLOCKEDITLOCK LOCK

NC PANEL

I ODOOR INTERLOCK

mm/min (inch/min)

(1)

mm/min (inch/min)

ME12008R0100700400001


5-7-5. Automatic feed operation

Automatic axis feed is controlled by a programmed command in the AUTO mode or a command entered in MDI mode. Refer to the [OSP-P200MA PROGRAMMING MANUAL] provided separately.The feedrate specified from the keyboard or tape input can be changed using FEEDRATE. A feedrate switch setting of 100 % will maintain the programmed rate as it is, and the speed is adjustable in 23 stages from 0 % to 200 %.

95 1009080

7060

50

40

30

2010

50 200

180170

160

150

140

130

120110

105

% FEEDRATE

ME12008R0100700410001


5-8. Manual pulse feed

The manual pulse feed operation is effective for feeding an axis a relatively short distance at a low feedrate, for example such as aligning a cutting tool to a workpiece or manually feeding an axis in a trial cut.


The MANUAL mode has been selected on the NC operation panel.

1 Check that the lamp is lit. 2 The lamp will light.


MACHINELOCK

BLOCKSKIP

OPTIONALSTOP

SINGLEBLOCK

DRYRUN

MID.AUTOMANUAL

PULSEHANDLE


INTERLOCKRELEASE

RELEASECCWCW STOP

UNLOCKEDITLOCK LOCK

NC PANEL

I ODOOR INTERLOCK

mm/min (inch/min)

(1)

(2)

ME12008R0100700430001


1 Pulse handle operation is enabled only while both of these buttons are pressed.

0

1020

30

4050

60

7080

90

YX ZX10X1 X50

(1)

Y ZX

60

70

90

80

5040

0

10

3020

ME12008R0100700430002

[Standard pulse handle] [CE-compliant pulse handle]



Procedure :

1- Press the PULSE HANDLE key to turn the lamp on.

2- Set the desired multiple on the PULSE HANDLE MAGNIFICATION switch. This multiplication factor multiplies the travel per pulse by 1, 10, or 50 (100) times.

3- Select the axis to be controlled (X, Y, Z) with the PULSE HANDLE AXIS SELECTION switch.

4- Rotate the pulse handle clockwise to feed the axis in the positive (+) direction; rotate it counterclockwise to feed in the negative (-) direction.One revolution of the pulse handle dial generates 100 pulses.The pulse handle unit is removable from the NC operation panel. This facilitates centering work to be carried out near the workpiece.

Multiplication Factor

1 10 50

Pulse Unit 0.001 0.001 0.01 0.05

1) An alarm will be activated when the given feedrate exceeds the maximum allowable axis feedrate. This may result if the pulse handle dial is turned quickly while a high multiplication factor has been set.

2) If the axis does not move when the pulse handle dial is turned, it may be necessary to adjust the [set backlash amount].

3) To prevent accidental movement from inadvertent operation when pulse feed operation is not in use, turn the function OFF by pressing any other AXIS SELECT flat key.

010

2030

4050

60

7080

90

ME12008R0100700440001

Pulse handle


1 Turns the lamp OFF.

(1)

ME12008R0100700440002


5-9. Coolant unit

5-9-1. Coolant nozzle

MB-4000H/5000H

1 Spindlehead 3 Coolant nozzles (7 locations)Adjust nozzle angles using a Phillips screwdriver.

2 Flowrate adjusting screwAdjust flow rate using a flat-blade screwdriver.

(1)

(3)

(2)

ME12008R0100700450001


MB-8000H

a. Coolant nozzles are equipped with spherical joints, making it easy to set the desired angle.

b. Set each nozzle at a different angle so the coolant is discharged to different locations. This eliminates the need to re-adjust the nozzles each time tools are changed.

[Supplement]

1 Spindlehead 3 Coolant nozzles (8 locations)

2 Flow rate adjustment screwsAdjust flow rate using a flat-blade screwdriver.

M08 Coolant ON

M09 Coolant OFF

For selection of coolant, consult its maker since some types of coolant may damage or abnormally rust packings or wipers.

(3)

(2)

(1)

ME12008R0100700550001


5-9-2. Coolant operation

COOLANT ON/OFFPressing the flat switch turns it ON, and also lights the LED lamp at the top left. Pressing it again switches it OFF and also turns the LED lamp OFF.

(1) In MANUAL ModePress the COOLANT flat key on the operation panel to display the [COOLANT] operation screen.Pressing a function key will start or stop discharge of the coolant.

(2) Program entry command and keyboard entry commandCodes to be used

To use program entry operation, enter the above M code into the program.In keyboard operation, enter the above M-code from the keyboard and press the CYCLE START push button switch.

a. The coolant pump's ON setting is changed to OFF with the following commands.M00, M01, M02, M30, M50, M51

b. The coolant pump is turned on/off by the operation of the flat key or the M codes, whichever given later.For example, if the coolant pump is set to ON due to an M code command, it can be turned off by pressing the flat key. Same is true for the reverse case.

c. Coolant flowrate can be adjusted with an adjusting screw located near each nozzle. Although coolant flow can be shut off by fully closing the adjusting screws while the coolant pump is operating, it could cause coolant temperature to rise and the pump to be damaged. Therefore, they should not be closed completely while the coolant pump is operating.

1 COOLANT flat key

M08 Coolant pump ON

M09 Coolant pump OFF

(1)

ME12008R0100700460001


5-10. Chip conveyor (floor type)

Coil-screw chip conveyor is located on the right and left of the table.Coolant and chips from the table are discharged to the rear of the machine by the conveyor, where chips are collected in the chip pan (lift-up conveyor). The coolant returns to the coolant tank from the bottom of the chip pan (lift-up conveyor).

5-10-1.Chip conveyor configuration

MB-4000H/5000H/8000H

1 Coil-type conveyor 4 Chip pan

2 Chip conveyor 5 Coolant tank

3 Bed

(1) (2) (4)

(3)

(5)

(Front of machine) (Back of machine)

ME12008R0100700470001


The chip conveyor is turned ON and OFF by pressing the CHIP CONVEYOR flat key on the NC operation panel.

1 CHIP CONVEYOR flat key

1) To prevent the system from being clogged with chips, leave coolant flushing continuously to smoothly discharge chips.

2) Opening the full-enclosure shielding will cause the chip conveyor to stop for safety.

3) Long chips generated by drilling and small and long fibrous chips are not suitable for the conveyance. Cut chips short by step feeding or similar operation.

4) When cleaning the inside of the machine, dropping excessive amounts of chips on the chip conveyor at once may result in the chips clogging the conveyor and stopping it. Remove the chips a little at a time.

(1)

ME12008R0100700470002


5-11. Panel light

Cycle [ON] and [OFF] by pressing flat keys on the NC operation panel.

RESTARTINTERLOCKRELEASE


MACHINELOCK

BLOCKSKIP

OPTIONALSTOP

SINGLEBLOCK

DRYRUN

MID.AUTOMANUAL

PULSEHANDLE


INTERLOCKRELEASE

RELEASECCWCW STOP

UNLOCKEDITLOCK LOCK

NC PANEL

I ODOOR INTERLOCK

mm/min (inch/min)

ME12008R0100700480001


5-11-1.Panel light location

MB-4000H/5000H

1 Panel lightSpot lightOKUMA part number: E3525-905-001-1Halogen lamp JW-55S24 V 60 W Nikki Co., Ltd.Rated life: 3,000 hrs

2 Panel light (Optional)Fluorescent lampJF-W18D8100 V 50 Hz/60 Hz 23.5 WFluorescent lamp: FPL18EX-N 18WRated life: 7,500 hrsOKUMA part number: E9919-431-004-3Located behind the operation panel inside the full-enclosure shielding.

(1)

(2)

ME12008R0100700600001


MB-8000H

1 Panel light (Optional)Spot light

2 Panel lightFluorescent lamp

(1)

(2)

ME12008R0100700590001


5-12. Table indexing operation

(1) The machine is not equipped with TABLE INDEXING MANUAL switches.

(2) Table indexing operation is performed by the commands entered through the keyboard or a table.

(3) Minimum input increment (0° ≤ B ≤ 360°)

(4) The direction of the rotation is instructed by either M15 or M16.

Note that the table indexing angular position is fixed. (Absolute value)

(5) Procedure for entering a table indexing command through the keyboard:

a. Set the MODE SELECT to MDI.

b. Press the function key [F1] (DATA INPUT).

c. Press the Address M, Numeric key 15 or 16 and then the index angle in this order.(Make sure there are no errors in the entered data.)

d. Press the WRITE key. (The input data display disappears and the data is displayed in the buffer column for the MDI program display, instead.)

e. Press the CYCLE START button. The table is rotated in accordance with the entered data.

1 degree index type (MB-5000H/8000H) 1°

0.001 degree index type (NC rotary table) 0.001°

M15 : Table Indexing Clockwise Rotation

M16 : Table Indexing Counterclockwise Rotation

M16

M15

90° 270°

0°

180°

ME12008R0100700490001


5-13. Oil mist coolant supply system (with air blow circuit)

(1) Mist spray unit

This oil mist coolant tank is located on the air panel at the back of the machine.

1 Power cord entry (G1/2) 7 Mist oil (Rc1/4)Mist air (Rc1/4)Air blow (Rc1/4)

2 Air source pressure (Rc1/4) 8 Manual mist spray button

3 Drain port (Rc1/4) 9 Pressure adjustment dial

4 Coolant tank (capacity 3 L (0.8 gal)) 10 Pressure gauge (air pressure)

5 Manual air blow button 11 Pressure gauge (tank)

6 Oil filler port 12 Oil level gauge

(2)(7)

(3)

(1)

(4)

(11)

(10)

(12)

(9)

(8)

(6)

(5)

ME12008R0100700500001


(2) Flexible extension nozzle jet

The flexible hose can be bent freely and therefore you can apply coolant mist to any point desired.

(3) The following M codes are used to control the oil mist coolant system:

(4) To replenish the tank with coolant, turn off the machine and the air supply to the machine and remove the filling port.

1 Spindlehead 3 Air adjustment needle

2 Oil adjusting needle 4 Nozzle

The figure shows MB-4000H/5000H.

M07 Oil Mist Coolant System ON

M09 Oil Mist Coolant System OFF

(1)

(2)

(3)

(4)

ME12008R0100700500002


5-14. Nozzle chip air blower

Attach flexible extension nozzle to the spindlehead as shown in the following figure and turn ON/OFF the air blower with M signal.

5-14-1.Nozzle location

MB-4000H/5000H

M12 Chip Air Blower ON

M09 Chip Air Blower OFF

1 Flow rate adjustment valve 2 Flexible nozzle lengthDistance from the end of the spindlehead noseMB-4000H: (Approximately 77 mm (3.03 in.) (approx. 68 mm (2.68 in.) from the end of the spindlehead)MB-5000H: (Approximately 91 mm (3.58 in.) (approx. 82 mm (3.23 in.) from the end of the spindlehead)

(1)

(2)

ME12008R0100700610001


MB-8000H

The flexible nozzle is approximately 78 mm (3.07 in.) long from the end of the spindlehead nose. (Approximately 70 mm (2.76 in.) from the end of the spindlehead.)

1 Flow rate adjustment valve

(1)

ME12008R0100700620001


5-15. Operation end lamp, buzzer and auto power shutoff lamp (signal tower)

(1) Lamps

a. Operation end lamp (yellow)Lights up when M00, M01, M02, M30, or END is executed.Also lights when M60 is specified without depression of APC SETUP COMPLETE push button on the machine with APC.

b. Alarm lamp (red)Lights up when an NC alarm or EC alarm occurs.

c. The operation end lamp or alarm lamp goes out when the RESET push button switch is pressed on the NC operation panel.

(2) Operation end buzzer

a. The buzzer sounds for a preset time under the same conditions as lighting of the operation end lamp.

b. The end buzzer and the end lamp can be actuated together.

(3) Auto power shutoff function

a. The power is shut off when the programmed M02, M30, or END is executed.

b. The power is also shut off when M60 is specified without depression of APC SETUP COMPLETE push button on the machine with APC.

(4) The above function can be switched between valid and invalid using the PARAMETER key.(For details, refer to [OSP-P200MA OPERATION MANUAL] provided separately.)


5-15-1.Display lamp location

MB-4000H/5000H/8000H


1 3-step status indicator lamp (signal tower)PatliteLHE302A-RYG (LED type)Lamp life: Approximately 80,000 hrs(Red, yellow, green from the top.)OKUMA part number: E3509-284-371

(1)

ME12008R0100700630001

5963-E P-170SECTION 6 MAINTENANCE, INSPECTION AND ADJUSTMENTS

SECTION 6 MAINTENANCE, INSPECTION AND ADJUSTMENTS

The machine should only be operated and serviced by personnel trained and authorised for this purpose.Designate a responsible party for operation, service, and maintenance of the machine and follow the instructions given by such responsible party.The following steps should be done:

Clean the machine.

Before entering the machine, remove the M-spindle tool.

Turn off the control switch, before turning off the main power disconnect switch.

Make sure all power switches are turned off.

Shut off the machine's main breaker while servicing the machine.Lock the main breaker to ensure that the power is not inadvertently turned back on.Note the 4 safety rules before the work.

Switch off.

Lock the main breaker to ensure that the power is not inadvertently turned back on.

Even with the main breaker turned off, electrical potential may still be left in the MCS drive unit (for axes and spindle), so no one except a service personnel should touch these units.

Adjacent energized parts should be covered or fenced off. Parts in the switch cabinet can be energized when the main switch is deactivated. These parts are specially marked!

Electricity is flowing through components in the electrical system even if the main switch is turned OFF.When service personnel are inside the machine, the safety door may not be reopened.The safety door can be closed without electricity flowing, but to open it, the machine control switch must be turned ON.Check that the door is not inadvertently closed.

The inside of the machine is slippery with coolant and oil. Be cautious as to where you stand and take precautions such as using a rubber mat.

Be careful with the tool or workpiece attached to the machine. There is a risk of injury.


Maintenance inspection of this machine may be performed only by personnel thoroughly familiar with machine operation and properly trained in maintenance inspection.If maintenance inspection is performed by individuals without such proper skills, they may not be able to properly handle any accidents that may occur during maintenance work, resulting in serious injury or death.Also, improper maintenance work may result in detrimental impact on the machine or its accuracy.OKUMA assumes no responsibility, and extends no product warranty related to accidents or damage to the machine that may occur as a result of not following these instructions.


6-1. General information

Maintenance and repair work may be performed only by persons specially trained for the type of work involved.The setting, maintenance and inspection work and the intervals for replacing operating materials and worn parts specified in these operating instructions must be observed!Inform the operating staff before beginning special work and maintenance. Appoint the supervisory staff!When replacing large subassemblies, carefully fasten them to the lifting gear and make sure they are secure.When performing installation work above head height, use climbing aids and working platforms which are intended for this purpose or designed to ensure safety.Do not use machine parts as climbing aids! When performing maintenance in high places take measures to prevent objects from falling.Keep all handles, treads, railings, pedestals, platforms and ladders free from dirt and lubricants!Secure sufficient work space and protective equipment necessary for maintenance work.After finishing maintenance and repair work, always tighten the loosened screw fittings!If you disassemble the protective cover or safety unit as part of the maintenance work, reassemble them as soon as maintenance and repair work is complete. Upon reassembly of these covers and units, confirm that they are functioning normally.

6-2. Cleaning agents

Do not use any cleaning agents which could damage resin, seals or paint (e.g. agents containing alcohol or solvents). These can damage hoses (hydraulic, pneumatic), cables, seals and other resin parts.Cleaning agents can contain health-damaging substances. Keep in mind instructions from the cleaning agent manufacturer.Do not use compressed air for cleaning.We recommend cleaning the entire machine once a week, or more frequently if it is prone to getting dirty sooner.Never use alcohol-containing cleaning agents for cleaning the polycarbonate window of the front shield.


6-3. Periodical inspection schedule

6-3-1. Precautions for cleaning the safety window

(1) Use a soft cloth for cleaning.Do not use a scourer or hard cloth.

(2) Use cold or warm water when removing dirt. If it is difficult to remove dirt, use a neutral detergent (for example, a kitchen detergent) by diluting it.

(3) Do not use organic solvents, such as thinner and benzene, or strong alkali detergents.

Interval Inspection itemsCheck point

CheckMB-4000H/5000H MB-8000H

Every day (1) Check hydraulic unit pressure (6.5 MPa (943.2 psi)). Left side Left side

(2) Check oil level and oil pressure in the centralized lubrication unit.

Below the air panel Right side

(3) Check air source pressure (0.5 MPa (72.6 psi)). Air panel Air panel

(4) Check and replenish the lubricator. Air panel Air panel

(5) Check and replenish the oil-air lubrication unit. Below the air panel Right side

(6) Check and replenish the coolant oil tank. Coolant tank Coolant tank

(7) Clean the spindle tapered bore. Spindle Spindle

(8) Remove chips and clean. Chip pan in the machine Chip pan in the machine

Weekly (1) Check and replenish the spindlehead cooling unit. Left side Right side

(2) Clean the air filter element. Air panel Air panel

(3) Clean the coolant tank filter. Coolant tank Coolant tank

(4) Inspect and replace the prefilter if through-spindle coolant unit (optional) is provided.

Through-spindle coolant tank


(5) Check oil level in the hydraulic unit. Left side Left side

(6) Check oil level in the table rotation drive gearbox. Table Table

(7) Replenish lubricating oil to the lubricator. Air panel Air panel

(8) Replenish lubricating oil to the lubrication unit. Below the air panel Right side

1 monthOnly for the first month after installation

(1) Check the machine for levelness. Bed Bed

(2) Replace the oil in the hydraulic unit spindle cooling system. Left side Left side and right side

(3) Clean the coolant tank. Coolant tank Coolant tank

3 months (1) Check the machine for levelness. Bed Bed

(2) Clean the coolant tank. Coolant tank Coolant tank

(3) Clean the air filter for the cooler. Left side Right side

6 months (1) Inspect and lubricate the ATC cam box (MB-8000H only) ATC

(2) Clean the filter in the oil air lubrication unit. Below the air panel Right side

(3) Inspect and replace the through pin seal if through-spindle coolant unit (optional) is provided.

Spindle Spindle

(4) Inspect and replenish the through-spindle coolant tank if through-spindle coolant unit (optional) is provided.



(5) Grease the ATC magazine chain (MB-8000H only) ATC

Yearly (1) Adjust the tension of the ATC magazine. ATC

(2) Replace the filter in the oil air lubrication unit. Below the air panel Right side

(3) Change oil in the hydraulic unit and clean or change the oil filter.

Left side Left side

(4) Change oil in the spindle cooling unit and clean or change filters.

Left side Right side

(5) Change oil in the table rotation gearbox. Table Table

Two-years (1) Operation door window glass replacement Operation door Operation door


6-4. Adjustment of hydraulic unit

6-4-1. Source pressure adjustment and pressure indication

MB-4000H

The pressure gauge is located at the front side of the hydraulic unit.

1 Hydraulic pump 7 Terminal box

2 Oil filler port and air breather 8 Motor

3 Pressure adjusting screw 9 Filter

4 Flow regulating screw 10 Drain port

5 Level switch 11 Oil level gauge

6 Pressure gauge

System pressure 6.5 MPa (943.2 psi)

(5)

(3)(6)

(1)

(11)

(9) (10)

(2)

(8)

(7)(4)

ME12008R0100800060001


Note

1) When it is necessary to adjust source pressure, turn the pressure adjustment screw on the vane pump. Clockwise turning → Pressure increases Counterclockwise turning → Pressure decreases

2) When it is necessary to adjust flow rate, turn the flow regulating screw on the vane pump. Clockwise turning → Discharge decreases Counterclockwise turning → Discharge increases

3) For details on the hydraulic unit, refer to the [HYDRAULIC POWER UNIT INSTRUCTION MANUAL] supplied separately.


MB-5000H


Note

1 Hydraulic pump 7 Level switch

2 Oil filler port and air breather 8 Terminal box

3 Oil level gauge 9 Motor

4 Pressure gauge for source pressure 10 Filter

5 Pressure adjusting screw 11 Drain port

6 Flow regulating screw





(7)

(5)

(4)

(1)

(10) (11) (3)

(8)

(2)

(9)(6)

ME12008R0100800070001


Do not change the table clamp pressure. If changed, the table unit may break.


MB-8000H


1 Hydraulic pump 7 Pressure gauge

2 Oil filler port and air breather 8 Terminal box

3 Pressure adjusting screw 9 Drain port

4 Level switch 10 Motor

5 Oil level gauge 11 Filter

6 Flow regulating screw 12 Table clamp and unclamp pressure gauge (0.001° table specification)


Table clamp pressure setting 4 MPa (580 psi)

(4)

(2)

(8)

(10)

(5)

(9)

(6)

(11)

(1)

(7) (12)

(3)

ME12008R0100800080001


Note




Do not change the table clamp pressure. If changed, the table unit may break.


6-5. Adjustment for regulator, lubricator, and air filter

Adjust the air 3-piece set (air filter, regulator, and lubricator) in the air panel at the front of the machine according to the following procedure:

(1) Adjustment of the regulator pressure

= How to adjust pressure =Lightly pull the pressure adjusting knob downwards.

1 Oil drop adjusting knob 5 Pressure adjusting knob

2 Pressure regulator 6 Air filter

3 Pressure gauge 7 Drain outlet

4 Lubricator 8 Air intakeThe factory side pressure should be between 0.5 MPa (72.6 psi) and 1.0 MPa (145.1 psi)


Next, turn the knob: Clockwise turning → Pressure increases

Counterclockwise turning → Pressure decreases

(1) (2)

(5)(4)

(7)

(6)

(8)

(3)

IN

ME12008R0100800090001


(2) Supplying oil to the lubricator and adjustment of oil drip-feed amount= Oil supply =Remove the oil supply plug and supply oil as needed.(Oil can be supplied while the oil inside the bowl is pressurized. However, it is necessary to discharge the residual pressure inside the bowl by turning the plug a couple of times before supplying oil.)

= Oil drip-feed adjustment =The lubricator is provided with a drip-feed adjusting scale. Set the scale to the proper position according to machine operating conditions.

= Oil drip-feed volume =When the system pressure is set at 0.5 MPa (72.6 psi), one drop of oil should be supplied per 5 to 6 times of tool clamp/unclamp operations (one drop in every 2 seconds with OUT side fully opened).

(3) Draining oil from the air filter= Air filter =The air filter removes moisture from the supplied air to prevent corrosion inside the machine.The air temperature for supply should be within the room temperature + 5 °C (41 °F). Note that humidity cannot be removed sufficiently if the air temperature is high.

= Draining =The moisture collected in the air filter bowl is discharged automatically through the drain port by the auto drain system using a float. Manual draining is possible.A water sump is to be prepared by the customer.

Reservoir capacity of the lubricator0.05 L

(0.013 gal) Check the oil volume every day.


6-6. Precautions regarding spindle rotation (15,000 min-1 (No.40), 6,000 min-1/12,000 min-1 (No.50))

6-6-1. Spindle lubrication (oil-air)

The spindle bearings are lubricated not by grease but by oil-air lubrication system.The oil-air lubrication system is configured as shown in the diagram below.

Principle of operation

The oil-air lubrication unit (mounted at the rear left of the machine) sends pulse to the metering piston type distributor (mounted at the right of the spindlehead). On receiving the pulse, the distributor operates at intervals of 8 minutes only while the spindle is rotating. The discharged oil is carried to the bearings by compressed air.

To prevent damage to the bearings, the following interlock is provided: The NC monitors the oil level of lubricating oil tank, oil pressure, and air pressure. On detecting a decrease in oil level, oil pressure, or air pressure, the NC causes an alarm to stop the spindle.

Oil spray volume 0.03 cc/stroke x6

M

Oil-air lubrication unit

Pressure gauge

Pressure switch(Oil-air lubrication unit pressure decrease monitor)Pressure setting: 0.18 MPa (26.12 psi)

Solenoid valve

Oil pump

Air bleed valve

Nozzle

Spindle bearing

Mixing valve

Orifice

Solenoid valve

Filter kit

Drain catch

Micro mist separatorAir 3-piece set

Air source

Float switch(Low oil level monitor)

Line filter30 µm (1,200 µin.)

Pressure switch(Oil-air lubrication unit pressure in-crease monitor)Pressure setting: 1 MPa (145 psi)

Metering piston typeDistributor

Pressure switch(Source pressure monitor)(Clogging monitor)Pressure setting: 0.3 MPa (43.5 psi)

ME12008R0100800100001

Pressure setting: 0.5 MPa (72.6 psi)


Application

A proper amount of oil is fed without fail.

Temperature rise at the bearings is kept low because the oil is cooled by the air and the lubrication system does not use much oil.

The oil mist lubrication requires less oil and therefore causes less contamination of ambient air.

Unlike the grease lubrication, the oil-air lubrication is highly reliable regardless of the lubricating oil life.


6-6-2. Lubricating oil and air supply conditions

(1) Use clean and dry air for the compressed.

(2) Keep the air pressure at 0.5 MPa (72.6 psi) and the air flow rate at 900 L/min (237.8 gpm) (ANR).

(3) Periodically clean the air filer and the micromist separator mounted at the air inlet port, if necessary.

(4) For lubricating oil, use Mobil DTE Oil Light.

(5) Always supply clean and new oil. Never allow intrusion of foreign particle into the oil.

(6) Never disconnect any lubricate piping for between distributors from the piping unit. The distributors will malfunction if air is entrapped in the piping.

6-6-3. Lubrication alarms and reset method

[Supplement]

Alarm display Alarm message Cause of alarm

(1) Oil-air pressure rise error

The pump dischargepressure does not reach the oil pressure switch set value of 1 MPa (145 psi) within 60 seconds from starting the pump.

Oil-air unit pump is faulty.

Air bleed valve is closed.

Pressure rise confirmation PS is faulty.

Line filter is clogged.

Mixing valve is faulty.

Air is mixed into the piping.

(2) Oil-air pressure drop error

The oil pressure does not drop during the 8 minutes interval.

Oil-air unit failed to drop its pressure.

Pressure drop monitoring switch is faulty.

(3) Unit oil level low The tank oil level dropped, which actuated the float switch.

Oil-air unit oil level is low.

(4) Air pressure error The air pressure dropped below 0.3 MPa (43.5 psi) (air pressure switch set value), which opened the pressure switch contact.

Air source pressure has dropped.

Micro mist separator clogged.

Each of the above errors is indicated as an alarm on the NC screen.To release the alarm, clear the cause of the alarm and press the RESET button on the OSP operation panel.For details, see the [Instruction Manual for Centralized Lubrication Unit MR-LUB (issued by Daido Metal Co. Ltd.)].


6-6-4. Spindle bearing life

Spindle bearing life is largely affected by the number of spindle revolution and, therefore, it may be quite difficult to determine the bearing life under the actual operating conditions.This machine is equipped with a [SPINDLE BEARING LIFE COUNTER] function which displays on the NC screen, an indication of the hours of actual operation relative to the life of the spindle bearing. This information should be useful for periodic maintenance.For details on the [SPINDLE BEARING LIFE COUNTER] function, refer to [SECTION 6, 6-6-5. Spindle bearing life counter function].

15,000 min-1 spindle model

The spindle bearing life is designed to last for 20,000 hours as a target on condition that the spindle is rotated continuously at the maximum speed.Since forced lubrication system is used, there is no limit in lubricating oil life.When supplying oil, always use new and clean oil.

6,000 min-1/ 12,000 min-1 specification

The spindle bearing life is designed to last for 20,000 hours as a target on condition that the spindle is rotated continuously at the maximum speed.Since forced lubrication system is used, there is no limit in lubricating oil life.When supplying oil, always use new and clean oil.


6-6-5. Spindle bearing life counter function

Following [SPINDLE BEARING LIFE COUNTER] screen is added to the [PARAMETER] screens.On the [PARAMETER] screen, select [F8] (DISPLAY CHANGE) to display the "DISPLAY CHANGE" screen, then select "2. SPINDLE BEARING LIFE COUNTER".The [SPINDLE BEARING LIFE COUNTER] screen is for display of various counter data only. No data can be set or added on this screen.

"STANDARD SPINDLE BEARING LIFE"Indicates the standard bearing life when the spindle is rotated at the maximum speed.

"SPINDLE BEARING LIFE COUNTER"The NC calculates the spindle life from the actual number of spindle revolution and the rotating time. Then, it converts the calculated value into the total time estimated on assumption that the spindle is rotated at the maximum speed. The life time is always calculated even during machine lock.

"SPINDLE ACCUMULATION TIME"

Indicates the total time for which the spindle is rotated at 5 min-1 or over.Also in this case, the machine lock time is not included in the total time.

"SPINDLE HIGH SPEED TIME"Indicates the cumulative spindle revolution during which the spindle was operated at 50 % of its maximum speed or faster.Also in this case, the machine lock time is not included in the total time.

Note

Each of the above data shows the time in the format of [hours: minutes].The "SPINDLE BEARING LIFE COUNTER", the "SPINDLE ACCUMULATION TIME", and the "SPINDLE HIGH SPEED TIME" are fixed when their counter reaches 99999:59.

ME12008R0100800180001


6-6-6. Replacement of spindle unit

If the spindle generates abnormal heat or vibration, or it does not rotate, the spindle bearings may be damaged. Immediately contact your OKUMA representative.

Never attempt to disassemble or reassemble the spindle. If the necessity arises, request OKUMA to do such work.The spindle units are designed by considering their compatibility.


6-7. Adjusting micro mist separator

A filter set (micromist separator, drain catch, and pressure switch) is mounted in the air panel located at the right side of the machine.Since the oil-air lubrication unit for lubricating the spindle bearings requires pure clean air, inspect and clean the filter whenever necessary.

The drain catch removes moisture in the compressed air.The collected water is automatically drained through the auto drain system.

The micromist separator removes minute oil particle and dust in the compressed air.The collected oil and dust are automatically drained through the auto drain system. When the red indicator reaches the top of indication range, replace the filter element.

The air filter life of each device is two years. Replace the filter elements with new ones if the clogging monitor pressure is triggered (Set pressure: 0.3 MPa (43.5 psi)) or after using the filters for 2 years.

For details regarding [micromist separator], [drain catch], and [electronic pressure switch], refer to their corresponding instruction manuals issued by SMC.

1 Clogging monitor pressure switch 4 N.O. auto-drain

2 Micro mist separator 5 N.O. auto-drain

3 Drain catch

(3)

(4)(5)

(2)

(1)

Φ10 (0.39)IN

OUT

ME12008R0100800200001


6-8. Cleaning the air filter of the spindlehead cooling unit (cooler)

Clean the air filter for the spindlehead cooling unit by the following procedure.

(1) The air filter can be easily removed by pulling it out.

(2) Clean the filter once every two weeks.

(3) To clean the filter, wash it with water or use compressed air.

1) An uncleaned air filter can significantly reduce cooling efficiency and may cause the protection mechanism of the compressor to disrupt normal operation.

2) If the thermal relay of the refrigerator motor is tripped, check the air filter for clogging, ambient temperature (which must not exceed 45 °C (113 °F)), or other reasons that will cause overloading.

3) Do not change the thermal relay setting.

4) The temperature setting volume is basically turned to the machine temperature ±0 °C (32 °F).Do not change the set temperature. (The volume is provided in the cooling system.)


6-8-1. Spindlehead cooling unit configuration

MB-4000H/5000H

(Installation location: left side of the machine)


2 Control panel 6 Tank

3 Air filterSlightly lift to remove.

7 Oil level gauge

4 Oil filler port

(1)

(2)

(3)

(4)

(6)

(7)(5)

ME12008R0100800260001


MB-8000H

No.50: Spindlehead cooling unit for standard spindle (6,000 min-1/12,000 min-1)NU-YOK630CNB (PANASONIC ELECTRIC WORKS)

(Installation location: right side of the machine)

1 Exhaust 2 Air filterPull out in the direction shown by the arrow.

(1)

(2)

ME12008R0100800290001


No.50: Spindlehead cooling unit for high torque spindle (6,000 min -1)NU-YOK900CNA (PANASONIC ELECTRIC WORKS)

(Installation location: left side of the machine, separate attachment)

1 Exhaust 2 Air filterPull out in the direction shown by the arrow.

(1) (2)

ME12008R0100800290002


6-9. Changing the work lamp (fluorescent lamp)

Procedure :

1- Remove the fluorescent lamp unit from the machine.Remove the four fixing screws (1).

2- Remove the round mounting base on the cable side.Loosen the M6 set screw (2) on the base.

3- Remove the six M6 screws (3) from the end plate connected with the cable.Be careful not to lose the nuts.Loosening the ring brackets (4) separates the glass tube from the side bracket.

4- Hold the lamp unit vertically with the cable side at the bottom, then pull the glass tube upward.The tube can be easily removed by giving a little pull to the fluorescent lamp metal sheet (5) inside the tube.

1 M6 retaining screws (2) 6 Socket

2 Mounting screw (1) 7 Aluminum casing

3 Pull out upward 8 (5) Fluorescent lamp plating

4 (6) Fluorescent lamp 9 Glow lamp (7)

5 (4) Ring bracket 10 (3) M6 screw (x6)

(1) (2)

(3) (4)

(5)

(6)

(7)

(8)

(9)

(10)

ME12008R0100800220001


5- Place the fluorescent lamp horizontally and change the fluorescent lamp (6) and the glow lamp (7). When removing the fluorescent lamp, pull out the socket horizontally.When removing the glow lamp, turn it counterclockwise.Replacement parts

Assemble the fluorescent lamp unit in the reverse order of the above steps 1- to 5-.

Note

Florescent lamp FPL18EX-N, 18 W, neutral white, a product common to all makers(Part No. E3532-820-002)

Glow lamp FP-1P 10-30 W

* The florescent lamp and the glow lamp are available in a general electric appliance shop.

When inserting the glass tube, hold it vertically or at an angle.The bracket at the end of the glass tube has a groove (8). Align the metal plate at the tip of the lamp unit with this groove and slide it in to complete the insertion.

1 Glass tube 3 Metal plate

2 Groove for bracket (8)

Before changing the fluorescent lamp, shut off the main power to the machine.Failing to do so can result in electrocution.

(1)(2)

(3)

ME12008R0100800220002


6-10. Halogen lamp bulb (optional) changing procedure

Refer to the halogen lamp drawing on the next page and disassemble and assemble in the following procedure.

Procedure :

1- Remove the six fixing screws.

2- Remove the O-ring.

3- Remove the C-ring. When removing the C-ring, use a flathead screwdriver and hook the blade in the ring opening.

4- Remove the front glass. Handle carefully though it is made of reinforced glass.

5- Pull the reflecting plate forward. Do not pull the plate strongly. The cable might be disconnected.

6- Pinch the lamp-fixing clip in the arrow directions (→←) and pull out the clip. The lamp bulb is unscrewed.

7- Disconnect the lead cable connector extending from the lamp bulb.

8- Pull out the lamp bulb away from the reflecting plate.

9- Connect the new bulb lead cable to the connector, and fix the lamp with the clip.

Then, assemble the lamp unit by following the above steps in reverse order.

Replaceable lamp bulb

The lamp bulb is of H3 type and conforms to the international standard. The bulbs from all the makers are usable if they have a capacity of 24 V, 60 W, and conform to H3 standard.

Model number Nikki OSRAM H3 24 V/60 W

OKUMA Part No. E3528-905-001

Lamp life 3,000 h

1) Use care when handling the glass.

2) To prevent coolant from entering the lamp unit, securely tighten the 6 machine screws for fixing the front glass.

3) Never touch the lamp bulb directly with your hand. If touched, the glass may deteriorate resulting in breakage or short life. When handling, use clean gloves.

4) Before changing the fluorescent lamp, shut off the main power to the machine.

5) Before changing the halogen lamp bulb, ensure that the lamp unit and the lamp bulb are completely cooled down.If you attempt lamp change while they are hot, you may get burned.


Halogen lamp unit

1 Mounting screws x6 7 Lamp bulb

2 Lamp securing clip 8 Connector

3 O-ring 9 For mounting M4 screws x4

4 C-ring 10 Lamp securing clip

5 All glass 11 Lampmounting direction

6 Reflecting plate

(1) (2)(3)

(10)

(11)

(4)

(5)

(6)

(7)

(8)

(9)

105 (4.13)140 (5.51)

85 (3.35)10 (0.39)

120 (4.72) ×Φ130 (5.12)

□60 (□2.36)

□70 (□2.76)

SideSurfaceFront

15 (0.59)

115 (4.53)

32 (1.26)

ME12008R0100800230001


Halogen lamp bulb

max. 11.5 (0.453)

100±5 (3.94±0.20)18

.0±0

.5

(0.7

09±0

.020

)

max

. 32

(1.2

6)m

ax. 1

0.0

(0.3

94)

2.25

±0.5

(0.0

886±

0.02

0)

ME12008R0100800230002


6-11. Cleaning the coolant unit

6-11-1.Cleaning

It is important to maintain the coolant and the coolant tank for continuing safety machining. Supply the coolant and clean the filter periodically. Also, clean the sludge pan and the inside of the tank as needed.

(1) Inside the tank, beneath the chip pan, there is a sludge pan.

(2) Remove the cover on the tank and you will see a handle. Hoist it and take it out.

(3) Remove sludge and chips from the wired pan. Clean the inside of the tank, and check the filter for clogging and clean it periodically.

MB-4000H

1 Cap 5 Cap

2 Cap 6 Cap

3 Filters (x4)Always leave one filter inside and replace it with the other one when cleaning.

7 Pan with wire mesh (x2)(Sludge pan)

4 Filters (x4)

(1)

(2)

(5)

(6)(7)(4)

(3)

ME12008R0100800280001


MB-5000H


5 Filters (x2)

2 Cap 6 Filters (x2)

3 Cap 7 Pan with wire mesh (x2)(Sludge pan)

4 Cap

(3)

(4)(7)

(6)

(5)

(1)

(2)

ME12008R0100800320001


MB-8000H


5 Cap

2 Filters (x2) 6 Cap

3 Filters (x2) 7 Cap

4 Cap 8 Pan with wire mesh (x2)(Sludge pan)

After cleaning the coolant tank, place the filter correctly at the place where it was set before starting an operation.If the tank is not cleaned completely or if the filter is not set correctly, chips will be pumped when the machine is started to cause the blocking of the piping parts, especially the check valves, nozzles, and the pump. If this occurs, coolant is not delivered to the cutting point appropriately and serious accidents such as breakage of tools and fire could occur.

(8)

(1)

(6)

(3)

(2)

(7)

(5)

(4)

ME12008R0100800310001


6-12. Procured parts

6-13. Glass window in the operation door

The glass window in the operation door is made of polycarbonate.Over time, polycarbonate is affected by the coolants and cleaning agents, and may not be able to hold up to being hit by scattered chips. Inspection windows are subject to wear over time.

On this machine, parts not listed on the spare parts list may be used from procured parts.For information on such procured parts, refer to the usage instructions or technical documents provided by the parts suppliers.When using procured parts, follow instructions from OKUMA.

Scattered chips may collide with the window.To prevent irreversible situations such as life-threatening injuries, serious health hazards, or considerable property damage, strictly observe instructions when replacing the window.Old polycarbonate may be penetrated when collided with parts, etc. Operators may be exposed to the danger.


6-13-1.Operation door window glass replacement

How to replace window glass MB-4000H/5000H/8000H


Procedure :

1- Remove the retainer plate inside the operation door. (Mounting bolts: 20 locations)

2- Replace the polycarbonate window with a new one.

3- Remove the grated cover and replace the foam nitrile on either side of it with new foam nitrile.

4- Mount the retainer plate inside the operation door.

5- Check for water leakage.

1 Mounting bolt 4 Foam nitrile(adhesive on one side)

2 Retainer plate 5 Grated cover

3 Polycarbonate window 6 Foam nitrile(adhesive on one side)

Safety window glass performance gradually deteriorates due to cutting fluid corrosion. Accordingly, scattering chips or a rotating tool may fly out breaking the window glass.The safety window glass must be replaced every two years.

(1)

(2)

(3)

(4)

(5)

(6)

ME12008R0100800300001


Turn the power off and apply the stopper to prevent the door from closing when entering the machine.

5963-E P-204SECTION 7 ATC

SECTION 7 ATC

7-1. ATC safety precautions

1) To change tools in manual operation, turn the MANUAL INT. switch on the [MG. MANUAL] panel to ON and firmly insert the tool into the toolpot to prevent it from falling.

2) When indexing the magazine manually, close the magazine door and ensure that magazine indexing does not cause problems.

3) Use the tool pull stud with appropriate dimensions. Poor clamping of the toolpot or the spindle may result in the danger of tools falling out.

4) When the tool change arm extracts the tool from the spindle tapered bore in the tool change cycle, the tool nose moves 115 mm (4.53 in.) (MB-4000H/5000H), 165 mm (6.50 in.) (MB-8000H) from its state when mounted in the spindle. The tool change arm rotates 180° in that position. Therefore, ensure that the tool does not interfere with the workpiece before starting the tool change cycle. There is danger of broken pieces of the tool being dispersed.

5) Clean the magazine and other units to remove dirt, dust and chips to avoid an ATC malfunction. Avoid the use of compressed air, however, because the air could blow chips into the units and could cause any serious problems. Never clean or perform maintenance work on the ATC while it is in operation.

6) Some tools in particular become easily entangled with chips. Be careful that the chips do not disrupt ATC magazine operation.

1) Be careful that the chips do not disrupt ATC magazine operation. Check, before a tool change is made, that there is no interference between the tool and the workpiece. Do not get close to or touch any parts during the ATC cycle. Although the tool clamping mechanism in the magazine and spindle, etc are all designed to handle the tool without slipping, it is possible that a sharp tool could drop due to interference with workpieces or other objects.Do not open the operation door or the magazine door.

2) The SLIDE HOLD button on the operation panel does not stop the ATC cycle. (Press the EMG. STOP button if operation must be stopped immediately.)


7-2. ATC magazine door interlock

The ATC magazine door incorporates a door lock mechanism and an interlock switch.

With this mechanism, this magazine door is always locked while the MANUAL INT. switch is OFF on the ATC [MG. MANUAL]. This means that the door can be opened by turning the MANUAL INT. switch to ON.

When the operation door in the front of the machine is open, the magazine door is locked so that no one can open it. Conversely, the operation door can not be opened when the magazine door is open.

Do not slam the door shut such that it bounces back open. Shut it slowly but firmly.


7-3. ATC tool dimensions

7-3-1. Maximum tool size storable with adjacent tools

MB-4000H/5000H

(1) Maximum tool dimensions storable with adjacent tool in the magazine

Φ44

.45

(1.7

5)

Φ63

(2.4

8)

Φ44

.45

(1.7

5)

Φ44

.45

(1.7

5)

40 (1.57) 40 (1.57)

300 (11.81) 300 (11.81)Φ

70 (2

.76)

Φ70

(2.7

6)

CAT/DIN*MAS

ME12008R0100900030003


(2) For tools like boring bars that have an OD of Φ70 (2.76) or less and the cutting edge being set in the following position, any tools can have cutting edges up to Φ150 (5.91).

1 Cutting edge range 3 Cutting edge range

2 Magazine key position 4 Magazine key position

(1)

(2)

(3)

(4)

MAS

CAT/DIN*

Φ44

.45

(1.7

5)

40 (1.57)

300 (11.81)

Φ70

(2.7

6)

Φ15

0 (5

.91)

Φ63

(2.4

8)

Φ150 (5.91) Φ70 (2

.76)

40 (1.57)

300 (11.81)Φ44

.45

(1.7

5)Φ44

.45

(1.7

5)

Φ70

(2.7

6)

Φ15

0 (5

.91)

Φ150 (5.91) Φ70 (2

.76)

ME12008R0100900030001


MB-8000H

(1) Maximum tool dimensions storable with adjacent tool in the magazine

(2) When a boring bar or a similar tool is Φ140 (5.51) or less in outside diameter and the adjacent tool diameters are both Φ140 (5.51) or less, boring bars with tool tips up to Φ240 (9.45) can be set adjacently.However, the tool storing range is limited by the direction of the tool nose set in the magazine.



CATMAS

Φ69.

85 (2

.75)

Φ10

0 (3

.94)

Φ14

0 (5

.51)

46 (1.81)

600 (23.62)

Φ69

.85

(2.7

5)

Φ68

(2.6

8)

Φ14

0 (5

.51)

46 (1.81)

600 (23.62)

ME12008R0100900050001

CAT

MAS

(1)

(2)

(3)

(4)

30°

30°

Φ69

.85

(2.7

5)

Φ100

(3.9

4)

Φ14

0 (5

.51)

46 (1.81)

600 (23.62)

49 (1.93)

Φ24

0 (9

.45)

Φ240

(9.4

5)

Φ140(5.51)

140 (5.51)

Φ69

.85

(2.7

5)

Φ68

(2.6

8)

Φ14

0 (5

.51)

46 (1.81)

600 (23.62)

49 (1.93)

Φ24

0 (9

.45)

Φ240

(9.4

5)

Φ140(5.51)

140 (5.51)

ME12008R0100900050002


7-3-2. Maximum tool size storable without adjacent tools

MB-4000H/5000H

(1) Maximum tool dimensions that can be stored in the magazine with adjacent tool pots empty

Φ44

.45

(1.7

5)

Φ63

(2.4

8)

Φ44

.45

(1.7

5)

Φ44

.45

(1.7

5)

40 (1.57) 40 (1.57)

300 (11.81) 300 (11.81)

Φ15

0 (5

.91)

Φ15

0 (5

.91)

CAT/DIN*MAS

300 (11.81) 300 (11.81)

40 (1.57) 40 (1.57)

Φ11

0 (4

.33)

Φ11

0 (4

.33)

Φ44

.45

(1.7

5)Φ44

.45

(1.7

5)

Φ63

(2.4

8)

Φ44

.45

(1.7

5)

Medium bore tools (Maximum Tool Size Storable with Adjacent Tools)

Big-bore tool (Maximum Tool Size Storable without Adjacent Tools)

ME12008R0100900060003


(2) With boring bars and similar types of tools, a tool with tool bit swing diameter of up to Φ190 (7.48) can be used by setting it in the direction in which the tool bit does not interfere with the other tools if the bar diameter is less than Φ150 (5.91).

1 Cutting edge range 2 Magazine key position

(1)

(2)

(2)

(1)MAS

Medium bore tools, boring bar, etc.

Φ44

.45

(1.7

5)

Φ63

(2.4

8)

Φ15

0 (5

.91)

Φ19

0 (7

.48)

Φ190

(7.48

)

Φ150 (5.91)

40 (1.57)

300 (11.81)

40 (1.57)

300 (11.81)

Φ44

.45 (

1.75

)

Φ63

(2.4

8)

Φ11

0 (4

.33)

Φ13

5 (5

.31)

Φ110 (4.33) Φ135 (5.31)

Big-bore tools (Maximum Tool Size Storable without Adjacent Tools), boring bar, etc.

ME12008R0100900060001


(3) When storing a tool with a diameter between Φ70 (2.76) and Φ110 (4.33), set the medium bore tool flag (so that adjacent tool pots are designated as dummies).

(4) When storing a tool with a diameter between Φ110 (4.33) and Φ150 (5.91), set the big-bore tool flag (so that adjacent tool pots are designated as dummies) to ensure safety.

1 Cutting edge range 2 Magazine key position

(1)

(1)

(2)

(2)

Medium bore tools, boring bar, etc.

Φ44

.45

(1.7

5)

Φ15

0 (5

.91)

Φ19

0 (7

.48)

Φ190

(7.48

)

Φ150 (5.91)

40 (1.57)

300 (11.81)

Big-bore tools (Maximum Tool Size Storable without Adjacent Tools), boring bar, etc.

Φ44

.45

(1.7

5)

Φ44

.45

(1.7

5)

Φ11

0 (4

.33)

Φ13

5 (5

.31)

Φ110 (4.33) Φ135 (5.31)

40 (1.57)

300 (11.81)

Φ44

.45

(1.7

5)

CAT/DIN*

ME12008R0100900060002


MB-8000H

(1) Maximum tool dimensions that can be stored in the magazine with adjacent tool pots empty

(2) When a boring bar or a similar tool is Φ240 (9.45) or less in outside diameter, a boring bar with tool tip diameter of up to R210 mm (8.27 in.) may be set in a direction that does not interfere with the other tools.However, the tool storing range is limited by the direction of the tool nose set in the magazine.

(3) When storing a tool with diameter greater than Φ140 (5.51), set the big-bore tool flag (designates adjacent toolpots to be dummies) for safety.



CATMAS

30°

30°

Φ69

.85

(2.7

5)

Φ100

(3.9

4)

46 (1.81)

600 (23.62)

49 (1.93)

Φ24

0 (9

.45) Φ

69.8

5 (2

.75)

Φ68

(2.6

8)

46 (1.81)

600 (23.62)

49 (1.93)

Φ24

0 (9

.45)

ME12008R0100900080001

CAT

MAS

30°

30°

(1)

(2)

(3)

(4)

Φ69

.85

(2.7

5)

Φ10

0 (3

.94)

46 (1.81)

600 (23.62)

49 (1.93)

Φ24

0 (9

.45)

50 (1

.97)

50 (1

.97)

50 (1

.97)

50 (1

.97)

R410 (16.14)

R410 (16.14)

R410 (16.14)

R410 (16.14)

R210 (8.27)

Φ69

.85

(2.7

5)

Φ68

(2.6

8)

46 (1.81)

600 (23.62)

49 (1.93)

Φ24

0 (9

.45)

50 (1

.97)

50 (1

.97)

50 (1

.97)

50 (1

.97)

R410 (16.14) R410 (16.14)

R410 (16.14)

286 (11.26) 286 (11.26)

286 (11.26) 286 (11.26)

R410 (16.14)R210 (8.27)

ME12008R0100900080002


(4) If the boring bar is stored with two adjacent toolpots empty and has a diameter of Φ240 (9.45) or less, a boring bar with tool tips within the specified ranges of any of the four corners may be stored.



CAT

MAS

30°

30°

(1)

(2)

(3)

(4)

Φ69

.85

(2.7

5)

Φ10

0 (3

.94)

46 (1.81)

600 (23.62)

49 (1.93)

Φ24

0 (9

.45)

50 (1

.97)

50 (1

.97)

50 (1

.97)

50 (1

.97)

R410 (16.14)

R410 (16.14)

R410 (16.14)

R410 (16.14)

Φ69

.85

(2.7

5)

Φ68

(2

.68)

46 (1.81)

600 (23.62)

49 (1.93)

Φ24

0 (9

.45)

50 (1

.97)

50 (1

.97)

50 (1

.97)

50 (1

.97)

R410 (16.14)

R410 (16.14)

R410 (16.14)

R410 (16.14)

286 (11.26) 286 (11.26)

Φ29

6.6

(11.

677)

Φ29

6.6

(11.

677)

286 (11.26) 286 (11.26)

ME12008R0100900080003


7-3-3. Maximum tool mass moment

MB-4000H/5000H

Max. tool size replaceable with ATC tool

The allowable maximum tool weight, including the tool shank, is 10 kg (22 lb) and the center of gravity must be within 100 mm (3.94 in.) from the datum diameter [Φ44.45 (1.75)] position.

1 98 N (22 lbf) (Mass 10 kg (22 lb))

100 (3.94)10 kg (22 lb) Tool mass moment: 9.8 N-m (7.2 lbf-ft)

10 kg (22 lb) × 9.8 m/s2 (32.15 ft/s2) × 0.1 m (0.3 ft.) = 9.8 N-m (7.2 lbf-ft)

The tools whose tool mass moment is larger than 9.8 N-m (7.2 lbf-ft) cannot be handled by the ATC.

ME12008R0100900090001

(1)

100 (3.94)

Φ44

.45

(1.7

5)

ME12008R0100900090002


MB-8000H

The allowable maximum tool weight, including the tool shank, is 25 kg (55 lb) and the center of gravity must be within 150 mm (5.91 in.) from the datum diameter [Φ69.85 (2.75)] position.Because there are restrictions on ATC operating speed, refer to [SECTION 7, 7-3-4. ATC operating speed and tool mass moment].

1 245 N (55 lbf) (Mass 25 kg (55 lb))

(1)

150 (5.91)

Φ69

.85

(2.7

5)

ME12008R0100900100001


7-3-4. ATC operating speed and tool mass moment

To prevent damage to the ATC mechanism and to ensure safe ATC operation, ATC operates at two different speeds (high and low) depending on the tool mass moment; High (T-T2 sec.) for small mass moment tools, and Low (T-T3 sec.) for large mass moment tools.Tools whose mass moment is greater than 17.6 N-m (13 lbf-ft) and smaller than 36.8 N-m (27.2 lbf-ft). The lower ATC cycle speed is selected by designating [M] with a tool number.

(1) Formula used to calculate approximate tool mass moment

a. Simple shape tools

[Supplement]

b. Stepped tools

c. Tools whose tool mass moment calculated using the formula above is smaller than 36.8 N-m (27.2 lbf-ft) can be handled by the ATC.

This calculation applies to the steel tools.

L1 (cm)

D1

(cm

)

T = × L1 × 7.85 × 10-3 × × 10-2 × 9.8L1

2= 30.2 × 10-3 × D × L (N-m) 2

1

πD4

21

21

ME12008R0100900110001

L (cm)

L1 (cm)L2

(cm)

D2

(cm

)

D1

(cm

)T = × L1 × 7.85 × 10-3 × × 10-2 × 9.8πD

4L1

2

21

πD4

22+ × L2 × 7.85 × 10-3 × × 10-2 × 9.8L2

2( + L1)

= (30.2 × 10-5 × D 21

22

21 × L ) + 60.4 × 10-5 × D L2

2( + L1) (N-m) × L2 ×

ME12008R0100900110002


(2) Maximum tools which can be handled by the ATC at a higher cycle speed

Tool mass moment 17.6 N-m (13 lbf-ft)

(3) Maximum tools which can be handled by the ATC at a lower cycle speed

Tool mass moment 36.8 N-m (27.2 lbf-ft)

The tools whose tool mass moment is larger than 36.8 N-m (27.2 lbf-ft) cannot be handled by the ATC.

Tool mass moment may be calculated roughly. It may also be measured with a spring balance or determined using the chart on the following page.When changing tools whose mass moment exceeds 17.6 N-m (13 lbf-ft), always set the ATC cycle speed to "low". Using these tools at high speed, can lead to the tools flying off or falling off or to shortening the life of the ATC.

120 (4.72)

15 kg (33 lb)

ME12008R0100900110003

150 (5.91)

25 kg (55 lb)

ME12008R0100900110004


(4) Relationship between tool weight moment and ATC cycle speed

300

250

200

150

100

100

150

200

250

300

350

400

450

L (m

m)

D (

mm

)

Note

: Thi

s gr

aph

is fo

r all t

ools

mad

e of

ste

el.

Tool

leng

th L

(mm

(in.

))

Tool diameter D (mm (in.))

ATC

off-l

imit

area

Tool

mas

s m

omen

t17

.6 N

-m (1

3 lb

f-ft)

ATC

low

spee

d

ATC

high

spe

ed

Tool

mas

s m

omen

t36

.8 N

-m (2

7.2

lbf-f

t)

ME12008R0100900110005


(5) Tool mass moment and ATC speed chart

a. How to read the chartDraw a horizontal line corresponding to the tool length and a vertical line corresponding to the tool diameter. Check the point of intersection of these lines to see in which ATC cycle speed zone the point falls.

Relationship between tool weight moment and ATC cycle speed

b. Examples

(1) Tool length 130 mm (5.12 in.) and tool diameter 80 mm (3.15 in.). The point of intersection falls within the high ATC cycle speed zone. Therefore, this tool can be handled at a high ATC speed.

(2) Tool length 230 mm (9.06 in.) and tool diameter 120 mm (4.72 in.). The point of intersection falls within the low ATC cycle speed zone. Therefore, this tool should be handled at a low ATC speed.

(3) Tool length 270 mm (10.63 in.) and tool diameter 170 mm (6.69 in.). The point of intersection falls within the ATC impossible zone. Therefore, this tool cannot be handled by the ATC.

300

250

200

150

100

100 150 200 250 300 350 400 450

D (mm)

L (mm)

ATC off-limit area

ATC low speed

ATC high speed

Tool length L (mm (in.))

Tool

dia

met

er D

(mm

(in.

))

Tool mass moment36.8 N-m (27.2 lbf-ft)

Tool mass moment17.6 N-m (13 lbf-ft)

ME12008R0100900110006


7-3-5. ATC magazine interference diagram

MB-4000H/5000H

(1)

(3)

(4)

(5)

(2)

(7)(6)

Φ190 (7.48)

Φ150 (

5.91)

Φ190 (7.48)

Φ135 (5.31)

Φ110 (4.33) Φ135 (5.31)

Φ150 (5.91)

Φ70 (2.76)

Φ70 (2.76)

Φ70 (2.76)

Φ70 (2.76)

Φ70 (2.76)

Φ110 (4.33)

Φ110 (4.33)

Φ150 (5.91)

Φ190 (7.48)

Φ150 (5.91)

Φ135 (5.31)

ME12008R0100900120002


1 By leaving a pot open between two boring bars, and by setting the pots to big-bore (pots on both sides become dummies), it is possible to use boring bars with tool tip diameter of up to Φ190 (7.48) if the outside diameter of the bar is Φ150 (5.91) or less.However, if the outside diameter of the bar is Φ110 (4.33), it is possible to use a boring bar (medium bore tool) with a tool tip up to Φ135 (5.31).

5 If both adjacent tools are Φ70 (2.76) or less in diameter, and the outside diameter of the bar is Φ70 (2.76) or less, boring bars with tool tip diameter of up to Φ150 (5.91) may be stored in adjacent positions.

2 Magazine key position 6 When storing a tool with a diameter from Φ110 (4.33) or more to Φ150 (5.91), set the big-bore tool flag (so that adjacent toolpots are designated as dummies).A dummy tool cannot be shared among big-bore tools.The dummy tool can be shared in combination with a big-bore tool and medium bore tool.

3 When storing a tool with a diameter between Φ70 (2.76) and Φ110 (4.33), set the medium bore tool flag (so that adjacent tool pots are designated as dummies).As shown in the figure, a boring bar with a tool tip diameter up to Φ135 (5.31) can be used as a medium bore tool.

7 Magazine key position

4 If tool diameter is Φ70 (2.76) or less, it will not interfere with other tools.


MB-8000H

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)(13)

(14)

(15)

(16)

Φ140

(5.51

)140 (5.51)

Φ140 (5.51)

Φ140 (5.51)

Φ140 (5.51)

140 (5.51)

R120 (4.72)

140 (

5.51)

140 (

5.51)

Φ150 (5.91)

Φ140 (5.51)

Φ140 (5.51)

Φ140 (5.51)

145 (

5.71)

145 (

5.71)

Φ240 (9.45)

R410 (16.14)R410 (16.14)

Φ240 (9.45)R410 (16.14)

R210 (8.27)

R410 (16.14)

Φ240 (9.45)

Φ240

(9.45

)

R410 (16.14)

R410 (16.14)

R410 (16.14)

R410 (16.14)

ME12008R0100900130001


1 If a boring bar and its adjacent tools have a diameter smaller than Φ140 (5.51), it is possible to store the boring bar having a cutting edge within Φ240 (9.45) range together with the adjacent tools.

9 Cutting edge range

2 Magazine key position 10 Set the oil hole tool holder (Option) in the orientation shown in this figure.Both adjacent toolpots should be vacant and it should be designated as a big-bore tool.

3 Cutting edge range 11 When a boring bar or a similar tool is Φ240 (9.45) or less in outside diameter, a boring bar with tool tip diameter of up to R210 mm (8.27 in.) may be set in a direction that does not interfere with the other tools.


5 When storing a tool larger than Φ140 (5.51) in diameter, for safety, it should be designated as big-bore and both adjacent toolpots should be left vacant.

13 Cutting edge range


7 Maximum tool space available with tools in adjacent pots.

15 Maximum tool space available without tools in adjacent pots.

8 Magazine key position 16 If the boring bar is stored with two adjacent toolpots empty and has a diameter of Φ240 (9.45) or less, you can use a bar of which cutting edge is within any of the specified four ranges.


7-4. Preparing the ATC

7-4-1. Preparing ATC tools

MB-4000H/5000H

(1) The shank has NT (National Standard Taper) No.40 for milling machines.

(2) [Tool grip] The tool grip is shaped and dimensioned to MAS standards - MAS 403-1982, BT40. Dimension from the trapezoidal groove center to the datum diameter [Φ44.45 (1.75)] of the shank taper should be held to 16.6 mm (0.654 in.) ± 0.1 mm (0.004 in.).(Refer to the [Separate volume technical sheet].)

(3) [Pull stud] Use a pull stud that conforms to MAS Standard; Type 2 MAS 407-1982. With being firmly screwed into the tool, dimensions from the diameter Φ15 (0.59) of the pull stud to the datum diameter [Φ44.45 (1.75)] of the shank taper should be held to 93.4 mm (3.677 in.) -0.3 mm (0.012 in.) + 0.2 mm (0.008 in.). (Refer to the [Separate volume technical sheet].)

(4) [Max. tool length] The maximum length of a cutting tool measured from the datum diameter [Φ44.45 (1.75)] of the shank taper to the cutting tip (edge) should be 300 mm (11.81 in.).(Refer to [SECTION 7, 7-3. ATC tool dimensions].)

(5) [Maximum tool diameter with cutting tools in adjacent tool grippers] The maximum size of a tool in the magazine when there are other tools in adjacent tool grippers on either side is Φ70 (2.76).(Refer to [SECTION 7, 7-3. ATC tool dimensions].)

(6) [Maximum tool diameter when there are no tools in adjacent tool grippers] The maximum tool size, when there are no cutting tools in adjacent tool grippers on either side, is Φ150 (5.91)*. When cutting tools having a diameter larger than the size indicated in (5) is used, the tool grippers for these tools are fixed and they are assigned as a big-bore tool gripper (L).The specification of the code of a big-bore tool automatically sets dummy grippers on both sides, which prevents entry of tool number data for these grippers. An attempt to enter a tool number for them results in an alarm.(Refer to [SECTION 7, 7-3-2. Maximum tool size storable without adjacent tools] and [SECTION 7, 7-3-5. ATC magazine interference diagram].)*However, the size of the tool next to it is Φ135 (5.31).

(7) [Maximum tool mass] The maximum mass of a cutting tool including the tapered shank arbor is 10 kg (22 lb).(Refer to [SECTION 7, 7-3-3. Maximum tool mass moment].)

(8) [Maximum tool mass moment] The above maximum tool mass 10 kg (22 lb) is rated at the center of gravity located up to 100 mm (3.94 in.) from the datum diameter [Φ44.45 (1.75)] of the shank taper. That is, the allowable maximum moment is TM < 9.8 N (2.2 lbf) (10 kg (22 lb)) x 100 mm (3.94 in.) = 9.8 N-m (7.2 lbf-ft) (9,800 N-mm)Therefore, if a tool of 5 kg (11 lb) is used, its center of gravity must be within 200 mm (7.87 in.) from the position of datum diameter.(Refer to [SECTION 7, 7-3-3. Maximum tool mass moment].)

(9) The machine can use milling cutters up to type 6R, Φ150 (5.91) in nominal size. However, note that there are cases when the cutter body is larger than Φ150 (5.91) despite using the milling cutter. Face milling cutters larger than that must be mounted directly onto the spindle.

(10) When boring bars are used, the orientation of the tool bit should be taken into consideration.


(Refer to [SECTION 7, 7-3-1. Maximum tool size storable with adjacent tools] and [SECTION 7, 7-3-5. ATC magazine interference diagram].)Boring bars with diameters up to Φ70 (2.76) and bit swing diameters ranging from Φ70 (2.76) to Φ150 (5.91) can be used with any adjacent tools that do not exceed Φ70 (2.76) in size.

(11) Maximum boring bar diameter without adjacent tools and with the tool bit set in certain angular range, a boring bar with bit swing diameter of up to Φ190 (7.48) can be used.(Refer to [SECTION 7, 7-3-2. Maximum tool size storable without adjacent tools].)

(12) If you store a boring bar in the magazine with its cutting edge 90° apart from the toolpot key, the cutting edge is always directed in X-axis negative direction (over the workpiece) when the bar is inserted into the spindle.

If you selected optional tools other than MAS standard BT40, refer to the standards for those tools and pull stud.

MB-8000H

(1) The shank has NT (National Standard Taper) No.50 for milling machines.

(2) [Tool grip] Use one of the following tool grips that conforms to the standard that meets the spindle specification of this machine.(Refer to the [Separate volume technical sheet].)(1) CAT (MF5311) No.50(2) MAS (403-1982) BT50

(3) [Pull stud] Select a pull stud from nine listed below designed for this machine.

(Refer to the [Separate volume technical sheet].)

(4) [Max. tool length] The maximum length of a cutting tool measured from the datum diameter [Φ69.85 (2.75)] of the shank taper to the cutting tip (edge) should be 600 mm (23.62 in.).

(5) [Maximum tool diameter with cutting tools in adjacent tool grippers] The maximum size of a tool in a magazine when there are other tools in adjacent toolpots on either side is Φ140 (5.51).

(6) [Maximum tool diameter without cutting tools in adjacent tool grippers] The maximum tool size, when there are no cutting tools in adjacent toolpots on either side, is Φ240 (9.45). When cutting tools having a diameter larger than Φ140 (5.51), the toolpots for these tools are assigned as a big-bore toolpot (dummy pots on both sides).

(7) [Maximum tool mass] The maximum mass of a cutting tool including the tapered shank arbor is 25 kg (55 lb).(Refer to [SECTION 7, 7-3-3. Maximum tool mass moment].)

(1) CAT(MF2560) No.50(no through hole)

(2) MAS(403-1982)Type 1 P50T(no through hole)

(3) MAS(403-1982)Type 2 P50T(no through hole)

(4) Special CAT (OKUMA) No.50(no through hole)

(5) CAT (MF5311) No.50(through hole)

(6) JIS(B6339-1992) 50P(through hole)

(7) MAS(403-1982)Type 1 P50T(through hole)

(8) MAS(403-1982)Type 2 P50T(through hole)

(9) Special CAT (OKUMA) No.50(through hole)


(8) [Maximum tool mass moment] The above maximum tool mass 25 kg (55 lb) is rated at the center of gravity located up to 150 mm (5.91 in.) from the datum diameter [Φ69.85 (2.75)] of the shank taper. The ATC speed varies depending on the moment rating of a cutting tool.Refer to [SECTION 7, 7-3-3. Maximum tool mass moment].

(9) The ATC can handle a face mill (full-back cutter) of up to 8R.

(10) If you store a boring bar in the magazine with its cutting edge directed in opposition to the toolpot key, the cutting edge is always directed in Y-axis negative direction (over the workpiece) when the bar is inserted into the spindle. If you store a boring bar with its cutting edge 90° apart from the toolpot key and the bar diameter does not exceed Φ140 (5.51), you can set a bar having an edge rotation diameter over Φ140 (5.51) up to Φ240 (9.45) together with the adjacent tools.

(11) For maximum boring bar diameter, Refer to [SECTION 7, 7-3. ATC tool dimensions].

If you selected optional tools other than MAS standard BT50, refer to the standards for those tools and pull stud.


7-4-2. Setting tools into the ATC magazine

MB-4000H/5000H

(1) The ATC magazine can store up to 48 (64, 110, 146, 182, 218, 254, 290, 326) (optional) tools. Each tool pot is identified with a nameplate marked on the tool pot. Tool selection is a random memory operation.

(2) For efficient setup, preset the tool point using a tool presetting device.

(3) When placing tools in the ATC magazine, make sure they do not interfere with adjacent tools. (Refer to [SECTION 7, 7-3-5. ATC magazine interference diagram]. ) With a random memory operation, the correspondence between the tool number and the tool pot number changes in the progress of machine operation. (For the ATC with 110 or more tools, fixed addressed are used.)

(4) Before loading tools, thoroughly clean the tapered shank of the tools and tool pots.Foreign particles on the tapered shank arbor can lead to poor machining accuracy.

(5) Load the tools specified on the program process sheet into the corresponding tool pots. Make a memo of the correspondence between the tool number and the pot number.By pushing the tool into the tool pot strongly, the tool is held by spring action.When using a big-bore tool, make sure that it does not interfere with the tool next to it.

(6) When setting tools having a retaining pin such as those described below, ensure that the pin comes to the allowable range shown in the tool interference diagram in order for the tool to be mounted in the spindle correctly: Through-the-tool coolant adaptors, high speed spindles, angular attachments, multi-spindle tools, reversible tappers, etc.

(7) Never tighten a tool, for example by tightening the milling chuck, while it is set in a tool pot. Otherwise, the tool pot could be damaged.

(8) Before starting ATC automated operation, enter the ATC tool numbers. (Refer to [SECTION 7, 7-5. Manual ATC operation].)

(9) If you insert tools collectively in a specific part (ex. No.1 to No.24) of the magazine chain and the weight gap exceeds 100 kg (220 lb), the magazine loses its weight balance, which may cause unstable magazine indexing and even affect indexing accuracy.To solve this problem, insert unused tools into empty pots for balancing. When using a heavy tool with a big-bore, determine the other tool positions using care to distribute the weight of the heavy tool all over the magazine.

(10) To remove the tool from the toolpot, insert the provided tool release lever in the gap between the pot face and the tool. Holding the tool with one hand, push the lever and the tool can be easy pulled out.


MB-8000H

(1) The ATC magazine can store up to 40 (60, 81, 111, 141, 171, 195, 225, 255, 320, 400) (optional) tools. Each tool pot is identified with a nameplate marked on the tool pot. Tool selection is a random memory operation.

(2) For efficient setup, preset the tool point using a tool presetting device.

(3) When placing tools in the ATC magazine, make sure they do not interfere with adjacent tools. (Refer to [SECTION 7, 7-3-5. ATC magazine interference diagram]. ) With a random memory operation, the correspondence between the tool number and the tool pot number changes in the progress of machine operation. (For the ATC with 81 or more tools, fixed addressed are used.)

(4) Before loading tools, thoroughly clean the tapered shank of the tools and tool pots.Foreign particles on the tapered shank arbor can lead to poor machining accuracy.

(5) Load the tools specified on the program process sheet into the corresponding tool pots. Make a memo of the correspondence between the tool number and the pot number.By pushing the tool into the tool pot strongly, the tool is held by spring action.When using a big-bore tool, make sure that it does not interfere with the tool next to it.

(6) When setting tools having a retaining pin such as those described below, ensure that the pin comes to the allowable range shown in the tool interference diagram in order for the tool to be mounted in the spindle correctly: Through-the-tool coolant adaptors, high speed spindles, angular attachments, multi-spindle tools, reversible tappers, etc.

(7) Never tighten a tool, for example by tightening the milling chuck, while it is set in a tool pot. Otherwise, the tool pot could be damaged.

(8) Before starting ATC automated operation, enter the ATC tool numbers. (Refer to [SECTION 7, 7-5. Manual ATC operation].)

(9) If you insert tools collectively in a specific part (ex. No.1 to No.15) of the magazine chain and the weight gap exceeds 100 kg (220 lb), the magazine loses its weight balance, which may cause unstable magazine indexing and even affect indexing accuracy.To solve this problem, insert unused tools into empty pots for balancing. When using a heavy tool with a big-bore, determine the other tool positions using care to distribute the weight of the heavy tool all over the magazine.

(10) To remove the tool from the toolpot, insert the provided tool release lever in the gap between the pot face and the tool. Holding the tool with one hand, push the lever and the tool can be easy pulled out.


7-4-3. Manual magazine indexing operation

Magazine indexing can be performed using AUTO or MDI, as well as the [MG. MANUAL] panel on the left side of the ATC door (on the right side of the door for multi-magazine (MB-8000H)).


The magazine door is closed.ATC is not in operation.

[MG. MANUAL] panel

MANUAL INT.

MANUALINT.

DOORINTERLOCK

IO

CONSTANT INDEX

INDEX START

O I

CW

RESTART

EMG. STOP

INDEX STOP

CCW

MG. MANUAL

ME12008R0100900190001


Operating method

(1) Set MODE SELECT on the NC operation panel to MANUAL.

(2) On the [MG. MANUAL] panel, perform the following procedures.

For indexing the magazine to the next pot:

Procedure :

1- Turn the MANUAL INT. ON/OFF switch to ON. Turn the CONSTANT INDEX ON/OFF switch to OFF.

2- Turn the outer ring of INDEX START selector switch to CW or CCW, then press its inner push button switch. The magazine is unclamped and the next pot is indexed.

For indexing the magazine continuously:

Procedure :

1- Turn the MANUAL INT. ON/OFF switch to ON.

2- Turn the outer ring of INDEX START selector switch to CW or CCW, then press its inner push button switch.

3- When the rotation comes one tool before the tool to be indexed, release the selector push button switch. The magazine stops at the next pot and then be clamped.

To perform magazine indexing during AUTO, turning ON the MANUAL INT. ON/OFF switch will make it possible to perform the above indexing procedure. After indexing the magazine manually, be sure to turn this switch off.

[Supplement]

If the magazine is rotated during finish cutting, vibration generated during magazine rotation could leave cutter marks on the surface of workpiece being machined. To avoid such defects, avoid rotating of the magazine during finish cutting by changing the program. During finish cutting, manual magazine index must also be avoided.


7-5. Manual ATC operation

The ATC can be manually operated in addition to the automatic operation in the AUTO or MDI modes by the controls on the NC operation panel.

7-5-1. One step advance and one step reverse

In the "1 STEP ADVANCE" and "1 STEP RETURN" operation, the ATC cycle advances or returns according to its operation sequence.This mode of operation is not used in normal operation, but is necessary when checking operation, or after the EMG. STOP button is pressed during ATC operation, and it becomes necessary to return to ATC initial conditions before resuming operation.

Procedure :

1- Set MODE SELECT on the NC operation panel to MANUAL.

2- Press the ATC flat key.

When operating the ATC manually, make sure to close the front door. The tool change arm and tools swing around at very high speeds, posing extreme danger of pinching your hand or being caught in such moving parts.


ME12008R0100900220001


3- The display changes, enabling "1 STEP ADVANCE" and "1 STEP RETURN" operation using the corresponding function keys.

7-5-2. One cycle start and return cycle start

(1) "1 CYCLE START" initiates a tool change cycle in which the tool picked up from the magazine is mounted on the spindle and the tool currently mounted on the spindle is returned to the magazine.Operation is possible when the CRT screen is in the "START OK" state.

(2) "RETURN CYCLE" starts the return cycle which returns the tool to the magazine, and is used when the ATC cycle is interrupted, for example.

ME12008R0100900220002

ME12008R0100900230001


7-5-3. Precautions for manual ATC operation

(1) When "CYCLE RUN" is displayed on the operation panel, the "1 STEP ADVANCE", "1 CYCLE START", and "RETURN CYCLE" keys are inoperable. Press the RESET push button switch to cancel "CYCLE RUN".

(2) If the EMG. STOP button is pressed while the tool change arm is in operation, the ZHP (Z-axis tool change position) and SHP (spindle indexing completion) signals may be lost and may consequently make the "1 STEP ADVANCE" and "RETURN CYCLE" keys inoperable. In this case, check the next operation, check for safety, then, while pressing and holding the INTERLOCK RELEASE key, press the "1 STEP ADVANCE" key. The APC carries out 1-step advance operation by ignoring the interlock.

(3) When the ATC cycle is interrupted by an emergency stop during operation steps [7], [8], or [9], the machine stops in the "SPINDLE TOOL CLAMP" state, making "1 STEP ADVANCE" or "RETURN CYCLE" inoperable. When this occurs, to return the spindle to the [tool unclamp] state, tool change on the right side of the spindlehead and press the TOOL UNCLAMP push button switch.

(4) ATC Pot No./Tool No. Table (Setting Tools)With a vertical machining center that has a relatively small number of tools in the tool magazine, memory-random method is generally adopted for the ATC operation. For machining centers equipped with a large-capacity tool magazine fixed address method is adopted.This machine adopts memory-random ATC.

7-5-4. Memory-random ATC specification

In the memory-random ATC system, the relationship between the tool number and the pot number constantly changes. This is because the "ACT TOOL" removed from the spindle is returned to the pot from which the "NXT TOOL", to be mounted on the spindle next, was taken. As such, before using the ATC, it is necessary to place the tools in the pots and set the initial relationship between the tool numbers and the pot numbers.In addition, since the use of a big-bore tool may cause interference with adjacent tools, the control must be capable of recognizing a big-bore tool so that the tool pot which accommodates one is placed between the pots having dummy tools or no tool. That is, the big-bore tool must be returned to the tool pot originally stored.A big-bore tool is distinguished from other conventional tools based on tool diameter as shown in the table below.

Tool numbers and pot numbers can be set using the following 2 methods.

Create a table listing the initial relationship between tool numbers and pot numbers. Enter this relationship information from the CRT, and then set the tools in the "RET POT" in the magazine.

Mount each tool on the spindle, then, using the manual tool change cycle, place each tool in a "RET POT" or an automatically selected vacant pot.

MB-4000H/5000H MB-8000H

Small-diameter toolLess than Φ70 (2.76) in

diameterLess than Φ140 (5.51) in

diameter

Big-bore toolShould be over Φ70 (2.76) in

diameterShould be over Φ140 (5.51) in

diameter


Setting from an initial relationship table

MB-4000H/5000H

Procedure :

1- In MODE SELECT, press the TOOL DATA key.

2- Press "ITEM↓" on the displayed screen.Open the [POT NO./TOOL NO. TABLE (MEMORY-RANDOM)] screen.

3- For each "POT NO." to be set, move the cursor on the corresponding "TOOL NO.".

4- Press [F1] (SET) on the displayed screen.

ME12008R0100900070001


5- Select the tool to be set from the displayed screen.

6- Select the "DIAMETER".Place the cursor on the "DIAMETER" shown in the settings pop-up window and press the "NEXT[-+]" on the display screen to select the "DIAMETER".Select from the following "DIAMETER".

"STD. TOOL"Tools with a tool diameter of Φ70 (2.76) or less

"MID. TOOL(J)"Tools with a tool diameter between Φ70 (2.76) and Φ110 (4.33)

"LARGE TOOL(L)"Tools with a tool diameter between Φ110 (4.33) and Φ150 (5.91)

Refer to [SECTION 7, 7-3. ATC tool dimensions].

7- Select the "WEIGHT".Place the cursor on the "WEIGHT" shown in the settings pop-up window and press the "NEXT[-+]" on the display screen to select the "WEIGHT".Select from the following "WEIGHT".

"STD. TOOL"A tool having a tool weight of 10 kg (22 lb) or less and one that is set by the ATC at standard speed.

"HEAVY TOOL(M)"A touch probe, attachment or other tools that are set by the ATC at low speeds.

"LIGHT TOOL(S)"A tool having a tool weight of 4 kg (9 lb) or less and one that is set by the ATC at high speed.

ME12008R0100900070002


[Supplement]

8- Press "OK".This sets the correspondence between the tool number and the pot number.

[Supplement]

ATC operational speeds will function at a speed on the lower side.(Ex.: When the ATC is set to "LIGHT TOOL(S)" and "STD. TOOL", it operates at standard speed.)

When the "WEIGHT" is set to "LIGHT TOOL(S)", always check that the tool weighs 4 kg (9 lb) or less.When the ATC tool is replaced, setting the tool weight more than 4 kg (9 lb) while in "LIGHT TOOL(S)" will damage the ATC unit and significantly shorten its operational life.

The following symbols in the "POT NO." field indicate that the pot is in the following designated positions.→ : Tool changing position with ATC>> : Manual tool change position

Pot numbers can be set from 1 to the total number of magazine pots in the specification, which is 48 tools for standard specification.The tool number is identical to the tool offset number.

A "MID. TOOL(J)" or "LARGE TOOL(L)" can be set to a pot only if both adjacent "TOOL NO." are either set to "NONE" or dummy tool (D). If either of the adjacent pots has a "TOOL NO." assigned, an alarm is triggered.The setting of a "MID. TOOL(J)" and "LARGE TOOL(L)" in a tool pots automatically sets dummy tool (D) at two adjacent tool pots. A dummy tool cannot be shared amongst "LARGE TOOL(L)". The dummy tool can be shared in combination with a "LARGE TOOL(L)" and "MID. TOOL(J)" or with a combination of "MID. TOOL(J)".

An error occurs if any of two tool numbers share the same pot number.

An error occurs if you try to set a tool to any pot which already has any dummy tools.In this case, press the [] button to clear the dummy tool. Note that the dummy tools placed in the tool pots adjacent to the one accommodating a "MID. TOOL(J)" and "LARGE TOOL(L)" should not be cleared.


MB-8000H

Procedure :

1- In MODE SELECT, press the TOOL DATA key.

2- Press "ITEM↓" on the displayed screen.Open the [POT NO./TOOL NO. TABLE (MEMORY-RANDOM)] screen.

3- For each "POT NO." to be set, move the cursor on the corresponding "TOOL NO.".

4- Press [F1] (SET) on the displayed screen.

5- Select the tool to be set from the displayed screen.

6- Press "OK".This sets the correspondence between the tool number and the pot number.

ME12008R0100900260001

ME12008R0100900260002


[Supplement]

Setting method by the manual operation

Procedure :

1- Press the MODE SELECT key of the MANUAL.The upper left MANUAL lamp lights up, and the machine enters MANUAL mode.

2- Press the ATC key on the additional operation panel.The [ATC OPERATION] screen is displayed.

Fig.7-1 [ATC OPERATION] Screen

The following symbols in the "POT NO." field indicate that the pot is in the following designated positions.→ : Tool changing position with ATC>> : Manual tool change position

Pot numbers can be set from 1 to the total number of magazine pots in the specification, which is 30 or 40 tools for standard specification.The tool number is identical to the tool offset number.

A big-bore tool can be set to a pot only if both adjacent "TOOL NO." are either set to "NONE" or dummy tool (D). If either of the adjacent pots has a "TOOL NO." assigned, an alarm is triggered.The setting of a big-bore tool in a tool pots automatically sets dummy tool (D) at two adjacent tool pots.

An error occurs if any of two tool numbers share the same pot number.

An error occurs if you try to set a tool to any pot which already has any dummy tools.In this case, press the [] button to clear the dummy tool. Note that the dummy tools placed in the tool pots adjacent to the one accommodating a big-bore tool should not be cleared. A dummy tool can be shared among big-bore tools.

ME12008R0100900270001

ME12008R0100900270002

ME12008R0100900270003


3- Set the data for "RET POT", "ACT TOOL" and "NXT TOOL".The data to be set for these items are described below.

"RET POT"

Specify the pot number when returning the "ACT TOOL" to the magazine pot.To set a pot number, select [F1] (SET) in the function menu and input the desired pot number.

[Supplement]

"ACT TOOL"

A tool number is marked on the spindle.Move the cursor to the input area of "ACT TOOL" and select [F1] (SET) in the function menu. This displays the [SET] pop-up window.The information on the "ACT TOOL" may be set using this [SET] pop-up window.

Fig.7-2 [SET] Pop-up Window

1) The allowable maximum number is the maximum number of pots.

2) An error occurs if a "TOOL NO." has already been set for the specified "POT NO.".

3) If the "ACT TOOL" is already specified as a "MID. TOOL(J)" or "LARGE TOOL(L)", an error will result unless both adjacent pots to "RET POT" are designated as dummy tool or no tool.

4) If "ACT TOOL" is already specified as a "LARGE TOOL(L)", an error will result unless both adjacent pots to "RET POT" are designated as dummy tool or no tool, or if a "LARGE TOOL(L)" is in place next to this dummy tool (because a dummy tool cannot be shared among big-bore tools).

ME12008R0100900290001


[Supplement]

1) The allowable maximum number is the number of offset pairs (100 for the standard specifications).

2) If the selected tool number is already assigned to another pot number, an error occurs.

3) If the "RET POT" already is an assigned pot, and is subsequently designated as a "MID. TOOL(J)" or "LARGE TOOL(L)", unless vacant pots with adjacent pots of the "RET POT" that are both either dummy tool or no tool are confirmed, an alarm will result.

4) If the "RET POT" is not an assigned pot and, if the "ACT TOOL" is designated as a "LARGE TOOL(L)" or "MID. TOOL(J)", an error will result if there are no vacant pots with adjacent pots that are both either dummy tool or no tool.


"NXT TOOL"

This is the "TOOL NO." of the tool that will be mounted on the spindle next.When setting tools to the pots for the first time, this box should be left blank.Information for the "NXT TOOL" is set in the same manner as for the "ACT TOOL" by using the [SET] pop-up window.

[Supplement]

Storing tools to magazine pots

There are two methods of storing a tool in a magazine pot: specifying a pot, and auto-searching empty pots.The procedure for storing tools to magazine pots is explained below for each of these approaches.For instructions on how to manually set a tool on the spindle, refer to [SECTION 5, 5-3-5. Clamping and unclamping the tool in spindle].

Storing a tool by specifying a pot

Procedure :

1- Move the cursor to "RET POT" using the cursor keys.

2- Input the pot number and press the WRITE key.

3- Set a tool in the spindle.

4- Move the cursor to "ACT TOOL" using the cursor keys.

5- Select [F1] (SET) from the function menu, enter the "ACT TOOL" and press the WRITE key.At this time, "NXT TOOL" must be set to "NONE". If "NXT TOOL" already has a "NXT TOOL" number in it, "NXT TOOL" must be cleared. To clear "NXT TOOL", place the cursor on the "NXT TOOL" to clear, select [F1] (SET) from the function menu to display the [SET] pop-up menu, and place a check mark in "TOOL NO. CLEAR". Next select [F7] (OK) from the function menu, and this will clear the "NXT TOOL" where the cursor is placed.

6- Press "1 CYCLE START".The tool set in the spindle is returned to the specified pot and, at the same time, the correspondence between the tool number and the pot number is established. If a tool is already assigned to the "RET POT" it gives an error and aborts the tool store process.

1) Maximum value is the same as that of the "ACT TOOL".

2) An error occurs if the specified tool number is not assigned to a pot number.

3) Designation of a medium bore tool (J), a big-bore tool (L) and a dummy tool (D) is not allowed.

4) If the "RET POT" already has received a pot assignment, it will result in an error.


Storing a tool by auto-searching empty pots

Procedure :

1- Clear the "RET POT" setting by entering "".

2- Set a tool in the spindle.

3- Enter the "ACT TOOL" number for the "ACT TOOL".At this time, "NXT TOOL" must be set to "NONE".

4- Press "1 CYCLE START".An empty pot closest to the presently indexed pot is automatically selected and the tool is returned to this pot.

[Supplement]

1) When 1 cycle start is performed, it is the same as for a normal tool change operation if a tool number is set for "NXT TOOL".

2) "RET POT" command is automatically cleared after 1 cycle start is performed.

3) "RET POT" commands are for tool storage. Therefore, an error will occur if 1 cycle start is performed when both "NXT TOOL" and "RET POT" commands have been issued.

4) For automatic empty pot selection, choose an empty pot closest to the pot being indexed in a clockwise direction. If there is no empty pot, an alarm occurs and the spindle tool is not returned to a pot.


7-6. ATC continuous operation

7-6-1. Initial conditions for continuous ATC operation

In the AUTO and MDI mode operation, the ATC cycle is carried out when the following commands are given

Tool Number Command: 1 to 3-digit T code

Tool Change Command: M06 (M19 Spindle position stopping included)

However, before pressing the CYCLE START push button switch, it is necessary to confirm that the following initial conditions are met.

(1) "ATC SEQ. NO." should be [1].[1] is the sequence reached when the tool change has completed.If the sequence number is not [1], set it to [1] per ATC manual operation. (Refer to [SECTION 7, 7-5. Manual ATC operation].)

(2) Both the "ACT TOOL NO." and "NXT TOOL NO." should be "NONE".If the "ACT TOOL" and "NXT TOOL" number is not "NONE", set it to [000] through ATC tool number entry.

(3) The MODE SELECT on the NC operation panel should be set to AUTO or MDI .

In addition to the conditions indicated above, other preparatory steps indicated below necessary for starting the AUTO must be performed in advance.

Mounting the workpiece

Adjusting zero point offset

Tool length offset

Reading NC program

1 (1) To be set to [1]. 3 (3) To be set to "NONE".

2 (2) To be set to "NONE".

(1)

(3)

(2)

ME12008R0100900340001


7-6-2. ATC operation sequence

MB-4000H/5000H

By specifying the tool number of Txx (xx is the tool data set number; 01 through 48 is standard) which has already been written in memory, the T command is displayed as the tool number in the next stage and the magazine is to be indexed.With the M06 command programmed next, the spindlehead will locate at the tool changing position and the spindle stops at a fixed position at the same time. The magazine pot will be in a position facing down. The tool changing arm changes the spindle tool and returns the tool removed from the spindle to the magazine. After the tool has been returned to the magazine, the tool number used as the next tool number is shifted to the current tool number and waits for the next T command.In the final machining process, the M63 command is executed if there are no tools in the next process. ATC cycle finishes only after returning the current tool without a new tool being loaded by the magazine.These series of operations are as shown in the diagram. The operation sequence number is displayed on the [ATC STATUS INDICATING] panel. (Refer to [SECTION 7, 7-6-3. ATC operation sequence diagram].)The tool change cycle is described below.[ATC operation according to sequence number]

Note

[Supplement]

No. Operation

1 Next tool writing

2 Continuous

3 Magazine indexing

4 Continuous

5 Magazine pot horizontal

6 Waiting for machine cycle completion

7 Spindle indexing

8 Tool changing position (HP1)

9 ATC door open (shutter open)

10 Tool change arm rotation

11 Magazine pot forward

12 Continuous

13 Magazine indexing

14 Continuous

15 Magazine pot horizontal


17 ATC door close (shutter close)

18 Magazine pot forward

Operations 11 to 16 are for handling a big-bore tool.

When next process tool preparatory operation is attempted during end face finish cutting, there might be cases in which the finished surface is affected. In this case, any measures such as incorporating the dwell is necessary.


The machine / NC unit Operation group No. ATC

(Initial tool cycle)

Cycle start

Instruct initial process tool number → Preparing the initial tool (T01)

(Eg. T01) ↓ (1) Write-in next tool (Tool number 01 is displayed)

↓ ↓ (2) Continuous

Stop tool rotation ↓ (3) Index magazine (T01)

X, Y, Z positioning ↓ (4) Continuous

↓ ↓ (5) Magazine pot horizontal

↓ Mounting the initial tool on the spindle (T01)

Instruct tool change (M06) ← ↓ (6) Waiting for machine cycle completion

↓ ↓ ↓ (7) Spindle indexing

↓ ↓ ↓ (8) Tool exchange position

↓ ↓ ↓ (HP1: ATC home position)

↓ ↓ ↓ (9) ATC door open (shutter open)

↓ ↓ ↓ (10) Operate tool change arm

↓ ↓ ↓ Rotate tool changing arm 90° (Tool grasp position)

↓ ↓ ↓ Tighten retaining cylinder for tool in spindle

↓ ↓ ↓ Remove tool with tool change arm (Current tool removal)

↓ ↓ ↓ Rotate tool changing arm 180°

↓ ↓ ↓ Insert tool with tool change arm (Next tool mounting)


↓ ↓ ↓ Rotate tool changing arm 90° (Change arm escape position)

↓ →→→→→→→→ → ↓ (17) ATC door close (shutter close)

X, Y, Z positioning ← ↓ (NC answer back)

(Begin cutting) ↓ (18) Magazine pot swings to magazine side

↓ ↓

↓ (Small-diameter tool cycle)

↓

Instruct next process tool number → Preparing the next tool (T02)



Stop spindle rotation ↓ (3) Index magazine (T02)


↓ ↓ (5) Magazine pot swings toward the spindle


↓ ↓ Exchanging the next tool and the current tool (T01) ←→ (T02)


↓ ↓ ↓ (8) Tool changing position (HP1)

↓ ↓ ↓ (9) ATC door open


↓ ↓ ↓ ATC door open (shutter open)









↓ ↓ ↓ ATC door close (shutter close)

↓ →→→→→→→→ → (17) Tighten outer retaining cylinder for tool in spindle

X, Y, Z positioning (NC answer back)

(Begin cutting) ← (18) Magazine pot forward

↓

↓ (Big-bore tool cycle)

↓

Instruct next process tool number → Preparing the returning pot

(Eg. T04, L) ↓ (1) Write-in next tool (Tool number 04 is displayed)


Stop spindle rotation ↓ (3) Index magazine (Returning pot)



↓ Returning the current tool (T02)




↓ ↓ ↓ (9) Loosen outer cylinder




↓ ↓ ↓ Tighten inner retaining cylinder for tool in spindle






↓ ↓ ↓ ATC door close (shutter close)

↓ ↓ Preparing the next tool (T04)

↓ ↓ ↓ (11) Magazine pot forward

↓ ↓ ↓ (12) Continuous

↓ ↓ ↓ (13) Index magazine (T04)

↓ ↓ ↓ (14) Continuous

↓ ↓ ↓ (15) Magazine pot horizontal

↓ ↓ Mounting the next tool on the spindle (T04)










↓ →→→→→→→→ → ↓ (17) ATC door close (shutter close)



X, Y, Z positioning ↓ (NC answer back)

(Begin cutting) ← ↓ (18) Magazine pot forward



MB-8000H

By specifying the tool number of Txx (xx is the tool data set number; 01 through 40 is standard) which has already been written in memory, the T command is displayed as the tool number in the next stage and the magazine is to be indexed.With the M06 command programmed next, the spindlehead will locate at the tool changing position and the spindle stops at a fixed position at the same time. The magazine pot will be in a position on the spindle side. The tool changing arm changes the spindle tool and returns the tool removed from the spindle to the magazine. After the tool has been returned to the magazine, the tool number used as the next tool number is shifted to the current tool number and waits for the next T command.In the final machining process, the M63 command is executed if there are no tools in the next process. ATC cycle finishes only after returning the current tool without a new tool being loaded by the magazine.These series of operations are as shown in the diagram. The operation sequence number is displayed on the [ATC STATUS INDICATING] panel. (Refer to [SECTION 7, 7-6-3. ATC operation sequence diagram].)The tool change cycle is described below.[ATC operation according to sequence number]

Note

[Supplement]

No. Operation

1 Next tool writing

2

3 Magazine indexing

4

5 Magazine pot swings toward the spindle

6 Waiting for machine cycle completion

7 Spindle indexing

8 Tool changing position (HP1)

9 ATC door open


11 Magazine pot swings to magazine side

12

13 Magazine indexing

14

15 Magazine pot swings toward the spindle


17 ATC door close

18 Magazine pot swings to magazine side

Operations 11 to 16 are for handling a big-bore tool.

When next process tool preparatory operation is attempted during end face finish cutting, there might be cases in which the finished surface is affected. In this case, any measures such as incorporating the dwell is necessary.



(Initial tool cycle)

Cycle start

Instruct initial process tool number → Preparing the initial tool (T01)


↓ ↓

Stop tool rotation ↓ (3) Index magazine (T01)

X, Y, Z positioning ↓


↓ ↓ (Check availability of magazine tool)

↓ Mounting the initial tool on the spindle (T01)



↓ ↓ ↓ (8) Tool exchange position

↓ ↓ ↓ (HP1: ATC home position)



↓ ↓ ↓ (Check availability of magazine tool)








↓ →→→→→→→→ → ↓ (17) ATC door close

X, Y, Z positioning ← ↓ (NC answer back)

(Begin cutting) ↓ (18) Magazine pot swings to magazine side


↓ (Small-diameter tool cycle)

↓

Instruct next process tool number → Preparing the next tool (T02)


↓ ↓

Stop spindle rotation ↓ (3) Index magazine (T02)





↓ ↓ Exchanging the next tool and the current tool (T01) ←→ (T02)






↓ ↓ ↓ ATC door open









↓ →→→→→→→→ → (17) ATC door close(NC answer back)

X, Y, Z positioning(Begin cutting)

(18) Magazine pot swings to magazine side(Check availability of magazine tool)

↓

↓ (Big-bore tool cycle)

↓

Instruct next process tool number → Preparing the returning pot

(Eg. T04, L) ↓ (1) Write-in next tool (Tool number 04 is displayed)

↓ ↓

Stop spindle rotation ↓ (3) Index magazine (Returning pot)




↓ Returning the current tool (T02)














↓ ↓ Preparing the next tool (T04)

↓ ↓ ↓ (11) Magazine pot swings to magazine side

↓ ↓ ↓

↓ ↓ ↓ (13) Index magazine (T04)

↓ ↓ ↓

↓ ↓ ↓ (15) Magazine pot swings toward the spindle


↓ ↓ Mounting the next tool on the spindle (T04)












↓ →→→→→→→→ → ↓ (17) ATC door close

X, Y, Z positioning ↓ (NC answer back)

(Begin cutting) ← ↓ (18) Magazine pot swings to magazine side

↓ (Check availability of magazine tool)



7-6-3. ATC operation sequence diagram

MB-4000H/5000H

Next tool writing

MG axis drive motor

MG axisSpindlehead

MG

Pot

Tool change armATC door

ATC drive motor

ME12008R0100900370002


MB-8000H

110

16

1016

8

8

7

3

13

5 15

18 11

9

10 16

10 16

1016

1016

16

10

17

ATC axis drive motor

Next tool writing ATC axis

MG

Pot Tool change arm

ATC door

Spindle-head

Tighten

MG axisdrive motor

Spindle toolCylinder Loosen

ME12008R0100900380001


7-7. Adjusting ATC

(1) Adjusting accuracy of ATCMisalignment or defective adjustment of ATC components will result in malfunction of ATC or drop of a tool.Movements of ATC tool change arm and indexing of the magazine are controlled by OSP. The arm unit and the magazine unit can be adjusted with the adjust bolts provided for each unit.However, these adjustments require special skills. Please consult with OKUMA service personnel to make these adjustments.

(2) ATC LIMIT switches and air pressure solenoid valvesSolenoid valves and proximity switches are arranged as shown in the [Separate volume technical sheet].These switch statuses can be checked with the check data display on OSP screen.For details, refer to [OSP-P200MA MAINTENANCE MANUAL].

7-7-1. Adjustment of magazine chain tension

When magazine link chain has become loose after a long time of service, resulting in vibration during magazine rotation, its tension should be adjusted.Loosen the lock nuts, and then turn the adjustment bolts clockwise. Note that excessively high tension causes low magazine rotation speed.

MB-4000H/5000H

Magazine back

1 Lock nut 3 Adjusting bolt

2 Block 4 Lock bolt (x4)

(4)

(1)

(3)

(2)

ME12008R0100900410001


MB-8000H

1 Block 3 Adjusting bolt

2 Lock nut 4 Lock bolts

(1)

(2)

(3)

(4)

ME12008R0100900420001

5963-E P-257SECTION 8 APC

SECTION 8 APC

8-1. Outline of 2-pallet rotary type APC

8-1-1. Construction

The two-pallet rotary APC is installed on the left side of the machine.This APC exchanges the two pallets installed on the machine table and the setup station by holding and rotating them with the servo motor drive fork of the APC main unit. The machine table incorporates a pallet clamper. The splash guard functions in synchronization with the pallet change cycle and separates the processing unit from the setup station after the change.The machine uses four tapered cone-pins to position the pallet with high accuracy. When rotating the pallet, the machine blows compressed air on the cone-pine to remove dust and chips. In addition, the machine checks the pallet seated condition. If chips or dust is found between the cone-pin and the pallet, the machine issues an alarm.

8-1-2. Specifications

For pallet dimensions, refer to separately attached sheet.

MB-4000H MB-5000H MB-8000H

Pallet dimensions□400 mm (□15.75

in.)□500 mm (□19.69

in.)□800 mm (□31.5

in.)

Maximum load 400 kg (880 lb) 500 kg (1,100 lb)2,000 kg (4,400

lb)


8-1-3. Limitation on workpiece center of gravity

When using APC, avoid mounting a workpiece with unbalanced load so that the workpiece does not fall on the pallet.The following drawing shows the center of gravity range of the workpiece with the maximum load.

MB-4000H

: Center of Gravity allowable position (Including area for two-pallet APC)

: Not usable for multi-pallet APC

indicates directions relative to the attitude when loaded into the machining room (B-axis 0°).

1 Setup station side 2 Spindle side

Φ242 (9.53)

Φ180 (7.09)

60 (2.36)

590

(23.

23)

400 (15.75)

200 (7.87) 200 (7.87)

400

(15.

75)

200

(7.8

7)20

0 (7

.87)(1) (2)

ME12008R0101000040001


MB-5000H



Φ242 (9.53)

Φ180 (7.09)

60 (2.36)

590

(23.

23)

500 (19.69)

250 (9.84) 250 (9.84)

500

(19.

69)

250

(9.8

4)25

0 (9

.84)(1) (2)

ME12008R0101000050001


MB-8000H



Φ420 (16.54)

Φ200 (7.87)

900

(35.

43)

800 (31.50)

400 (15.75) 400 (15.75)

800

(31.

50)40

0 (1

5.75

)40

0 (1

5.75

)

(2)(1)

ME12008R0101000070001


8-2. Operating the two-pallet rotary APC

8-2-1. Safety precautions for APC operation

(1) Before carrying out setup operations on a pallet, make sure that the SETUP COMPLETION lamp is off. If the SETUP COMPLETION lamp is on, operation starts with the tape M60 command.

(2) During the automatic pallet change operation, operations of the APC fork and pallet must be carefully attended to. Do not try to touch the APC.

(3) The pallet on the setup station can be manually indexed at every 90°. Pull the lever to rotate the pallet to an approximate position. Push back the lever and then slowly rotate and index the pallet.After indexing, check that the lever has been completely returned.

8-2-2. Conditions for automatic pallet changing operation

a. The magazine door and the APC setup station door are securely closed.

b. A pallet is set on the machine.

c. Another pallet is set on the APC. Note that pallet changing operation always requires two pallets.

d. The pallet on the APC is correctly positioned by the location pin.

e. The SETUP COMPLETION button is pressed. The work setup completion state can be cancelled by turning the APC MANUAL INT. selector switch in the ON position.

f. The MODE SELECT on the NC operation panel should be set to AUTO or MDI.

Never activate the automatic pallet changing function when a person is inside the machine.Failure to observe these instructions will pose immediate danger that, unless rectified, may lead to death or serious injury.



The pallet change cycle called by the M60 tape command is carried out in the following sequence.

a. APC at ready position. The NC checks whether the SETUP COMPLETION button has been pressed or not.

b. Z-axis moves to APC position (pallet A position). Machine table is indexed to 0° position.

c. Pallet unclamped.

d. APC fork rises.

e. APC fork rotates 180° (to pallet B position).

f. APC fork lowers.

g. Pallet clamped.

The cycle above is for changing the pallet on the machine with the pallet at APC ready position.


8-3. Automatic pallet change operation sequences

8-3-1. Two-pallet APC operation sequence diagram

(1) Operating conditions

a. Magazine door and APC setup station door are securely closed.

b. A pallet is set on the machine.

c. Another pallet is set on the APC. (Note that pallet changing operation always requires two pallets.)

d. The pallet on the APC is positioned at the correct position (in-position) by means of the location pin.

e. The SETUP COMPLETION button should be pressed. (To reset the Setup completion operation, turn the MANUAL INT. selector on APC operation panel in the ON position.)

f. The MODE SELECT on the NC operation panel should be set to AUTO or MDI.

(2) Tape command (M Code)

(3) Operation sequence

The cycle above is for changing the pallet on the machine table and the pallet at the escape position.

M60 Automatic Pallet Change Cycle

M60 → (1) APC is at ready position

Confirm completion of workpiece setup

(2) Z-axis moves to APC position (pallet A position).Indexing to table change position ( 0°).

(3) Pallet unclamped.

(4) APC fork rises.

(5) APC fork rotates 180° (to pallet B position).

(6) APC fork lowers.

(7) Pallet clamped.


8-3-2. APC operation sequence diagram

(1) APC preparation(2) Z-axis moves to APC position (pallet A position).(3) Pallet is unclamped.

(4) APC fork rises.

(5) APC fork rotates 180° (to pallet B position).

3

2

B

A

ME12008R0101000120001

4

B

A

ME12008R0101000120002

5 B

A

ME12008R0101000120003


(6) APC fork lowers.

(7) Pallet is clamped.

6

B

A

ME12008R0101000120004

7

B

A

ME12008R0101000120005


8-4. APC continuous operation

8-4-1. Initial conditions for continuous two-pallet APC rotation operation

(1) A pallet is placed on the machine.

(2) Another pallet is set at the APC ready position.Two pallets must always be used. Therefore, even when machining of only one workpiece is required, it is necessary to use two pallets.

(3) The pallet on the APC is positioned at the correct position (in-position) by means of the location pin.

(4) SETUP COMPLETION button has been pressed.By pressing the SETUP COMPLETION button after attaching the new workpiece to a pallet, the lamp on the switch is lit, and the next APC replacement command is enabled. This button is provided to ensure safety of the operator by preventing pallet change cycle start while work setting up is being carried out.

To reset the Setup completion operation, turn the MANUAL INT. selector on APC operation panel in the ON position.

SETUP COMPLETION

SETUP COMPLETION

MANUAL INT.

ME12008R0101000130001


(5) The MODE SELECT on the NC operation panel should be set to AUTO or MDI.

After the above, pressing the CYCLE START button will cause the M60 command to start the automatic pallet change cycle. (Refer to [SECTION 8, 8-3. Automatic pallet change operation sequences].) The CYCLE START button is provided on the APC operation panel in addition to the main operation panel.

1) If, due to interference or other reasons, it is necessary to stop APC operation during an APC sequence, use the EMG. STOP button.

2) Note that the SLIDE HOLD push button switch works for axis feed only, thus it cannot be used to stop APC or ATC operation.

ME12008R0101000130002


8-5. Manual APC operations

In addition to APC automatic operation in AUTO and MDI, manual operation is possible using [ATC OPERATION] on the NC operation panel.

8-5-1. Safety precautions for manual APC operation

(1) While the CYCLE RUN lamp is on, all manual APC control keys - "1 STEP ADVANCE", "1 STEP RETURN", "1 CYCLE START" and "RETURN CYCLE" - are disabled. To manually operate the APC while the RUN lamp is on, press the RESET push button to turn off the run lamp.

(2) Under certain conditions, such as when the EMG. STOP button is pressed while the APC fork is rotating, the shifter retraction position signal may turn off, and the "1 STEP ADVANCE", "1 STEP RETURN", and "RETURN CYCLE" keys may be disabled. In this case, check the next operation, check for safety, then, while pressing and holding the INTERLOCK RELEASE key, press the "1 STEP ADVANCE" key. The APC carries out 1-step advance operation by ignoring the interlock.

If power is shut off during clamping operation, the operation may be resumed when power is reinstated. This can lead to danger of being caught in the clamp.


8-5-2. One step advance and one step reverse

In "1 STEP ADVANCE" and "1 STEP RETURN" operation, operation takes place one step at a time in the same order as the APC sequence.This mode of operation is not used in normal operation, but is necessary when checking APC operation, or after the EMG. STOP button is pressed during APC operation, and it becomes necessary to return to APC initial conditions before resuming operation.

Procedure :

1- Set MODE SELECT on the NC operation panel to MANUAL.

2- Press the APC flat key.

1 APC flat key


MACHINELOCK

BLOCKSKIP

OPTIONALSTOP

SINGLEBLOCK

DRYRUN

MID.AUTOMANUAL

PULSEHANDLE


INTERLOCKRELEASE

RELEASECCWCW STOP

UNLOCKEDITLOCK LOCK

NC PANEL

I ODOOR INTERLOCK

mm/min (inch/min)

(1)

ME12008R0101000160001


3- The display changes, enabling "1 STEP ADVANCE" and "1 STEP RETURN" operation using the corresponding function keys.

8-5-3. One cycle start and return cycle start

(1) The "1 CYCLE START" key is used for starting a series of automatic pallet change cycle in which the pallet on the machine is unloaded to the APC and the pallet on the APC is loaded to the machine.The operation is possible if the CRT monitor displays "START OK".

(2) The "RETURN CYCLE" key is used for carrying out the automatic pallet change cycle in the reverse order up to the pallet change cycle starting sequence, thus returning the pallet to the machine.

ME12008R0101000160002

ME12008R0101000170001

5963-E P-271SECTION 9 HIGH CAPACITY MAGAZINE

SECTION 9 HIGH CAPACITY MAGAZINE

9-1. Matrix magazine (110, 146, 182, 218 tools) (optional for MB-4000H/5000H)

9-1-1. Outline

The matrix magazine stores the tools used in the machine and carries the selected tool to the ATC tool change position. The magazine stores the tools in partitioned racks to save space.


*1 The ranges for the standard tool rack are listed in the table below.

Items

Tool shank type MAS BT40

Pull-stud bolt MAS, CAT

Tool storage capacity

Cabinet Number of toolsStandard tool Φ70 (2.76) or less

Big-bore tool Φ150 (5.91) or less

146 tools110 tools 110 tools 18 tools

146 tools 146 tools 18 tools

218 tools182 tools 182 tools 18 tools


326 tools




Max. tool diameter (standard tool storage area) *1Φ70 (2.76) without condition, R75 mm (2.95 in.) under certain condition

Max. tool diameter (big-bore tool storage area) *2Φ150 (5.91) without condition, R95 mm (3.74 in.) under certain condition

Max. tool length 300 mm (11.81 in.)

Max. tool mass 10 kg (22 lb)

Tool selection Fixed address

Tool transfer motor (Horizontal axis) 2.2 kW (3 hp) AC servomotor

Tool transfer motor (Vertical axis) 3.0 kW (4 hp) AC servomotor

Tool transfer motor (Rotation axis) 1.7 kW (2.27 hp) AC servomotor

Number of magazines Tool rack ranges

110 tools 1 to 146 (39 to 74: non-existent numbers)

146 tools 1 to 146


218 tools 1 to 218



326 tools 1 to 326


*2 The ranges for the big-bore tool rack are listed in the table below.

9-1-3. Precautions

(1) We pay sufficient attention for holding tools such as magazine, sub arm, tool change arm, and spindle, but they rotates sharp edged tools and could accidentally drop. Therefore, never try to touch or stand near them during ATC operation.

(2) Before indexing the magazine manually, be sure to close the safety fence door.

(3) When changing tools manually, insert a tool securely into a toolpot.

(4) Use the tool pull stud with appropriate dimensions.

(5) The tool change arm removes the tool from the spindle tapered bore and rotates 180°. Before the tool change, check that the arm rotation does not cause interference between the tool and the workpiece.

(6) Remove chips from the magazine and the tool change arm whenever necessary, because those chips may cause malfunction of ATC. When removing chips, avoid using the compressed air because the air will blow chips into the ATC unit. Also avoid cleaning or inspection during ATC operation for reasons of safety.

(7) To stop the ATC in emergency, press the EMG. STOP button.

(8) Observe the tool limits listed in the [SECTION 9, 9-1-5. ATC tool dimensions].


110, 146-tool 93 to 110, 129 to 146

182, 218-tool 165 to 182, 201 to 218

254, 290, 326-tool 273 to 290, 309 to 326


9-1-4. Diagram of tool storage rack

The figure below is a 146-tool cabinet. For the 218-tool cabinet, the standard tool storage rack has two columns in-between A-A. (182-tool model has one column, the 218-tool model has two columns.)For the 326-tool cabinet, the standard tool storage rack has five columns in-between A-A. (256-tool model has three columns, the 290-tool model has four columns, the 326-tool model has five columns.)

1 Available big-bore tool storage areas 5 Manual tool exchange positionAdditional NG tool buffer ST(SET/NG1)

2 Standard tool storage area 6 NG tool buffer ST(3 places: NG2 to NG4)

3 Magazine key position 7 Standard tool storage area

4 Next tool ready ST(4 places: RDY 1 to 4)

8 110-tool specification missing rack

(1)

(2)

(3) (4)

(5)

(6)

(7)

(8)

Φ150 (5.91)

Φ190 (7.4

8)Φ1

50 (5

.91)

Φ70 (2.76)

70 (2.76)

ME12008R0101100040001


9-1-5. ATC tool dimensions

Standard toolA standard tool is normally Φ70 (2.76) or less. It can be stored in all areas.

Standard boring bar tool Tool label [R] It can be stored in all areas except for No.1 and No.10. Both pots will be D (Dummy).



Φ44

.45

(1.7

5)

Φ63

(2.4

8)

Φ44

.45

(1.7

5) Φ44

.45

(1.7

5)

Φ70

(2.7

6)

Φ70

(2.7

6)

40 (1.57)

300 (11.81) 300 (11.81)

40 (1.57)

ME12008R0101100050005

(1)

(2)

(3)

(4)

Φ44

.45

(1.7

5)

Φ70

(2.7

6)

Φ15

0 (5

.91)

Φ63

(2.4

8)

300 (11.81)

40 (1.57)

70 (2.76)

Φ70 (2.76)

Φ150

(5.91

)

Φ70 (2.76)

Φ150

(5.91

)

70 (2.76)

Φ70

(2.7

6)

Φ15

0 (5

.91)

Φ44.4

5(1

.75)

300 (11.81)

40 (1.57)

Φ44

.45

(1.7

5)

ME12008R0101100050001


Big-bore tool Tool label [L]A big-bore tool has a diameter of Φ150 (5.91) or less. It can be stored in areas that allow the storage of big-bore tools.Both pots will be D (Dummy).

Maximum tool size storable without adjacent tools

Maximum tool size storable without adjacent tools, boring bar, etc.

Φ44

.45

(1.7

5)

Φ63

(2.4

8)

Φ44

.45

(1.7

5)

Φ44.4

5 (1.7

5)

Φ15

0 (5

.91)

40 (1.57)

300 (11.81) 300 (11.81)

40 (1.57)

Φ15

0 (5

.91)

ME12008R0101100050002

(1)

(3)

(4)

(2)

Φ190

(7.48

)

Φ150 (5.91)

Φ44

.45

(1.7

5)

Φ63

(2.4

8)

Φ15

0 (5

.91)

Φ19

0 (7

.48)

40 (1.57)

300 (11.81)

Φ44

.45

(1.7

5)

Φ44

.45

(1.7

5)

40 (1.57)

300 (11.81)

Φ15

0 (5

.91)

Φ19

0 (7

.48)

Φ190

(7.48

)

Φ150 (5.91)

ME12008R0101100050004


Maximum tool mass momentThe tools whose tool mass moment is larger than 9.8 N-m (7.2 lbf-ft) cannot be handled by the ATC.


* The special diameter tools and tools with positioning pins (oil hole, angular attachments) are not standard, but are options.

9-1-6. Lubricating the magazine

Grease the magazine drive rack every month. For information on greasing points and procedures, refer to the [Matrix Magazine section of the Maintenance Manual] provided separately.Usually the guide will not need grease, but if during your annual inspection, you observe that there's little to no grease on it, lubricate it using standard lithium grease.



98 N (22 lbf) (Mass 10 kg (22 lb))Φ

44.4

5 (1

.75)

100 (3.94)

ME12008R0101100050003


9-2. Matrix magazine (81, 111, 141, 171, 195, 225, 255, 285 tools) (optional for MB-8000H)

9-2-1. Outline

The matrix magazine stores the tools used in the machine and carries the selected tool to the ATC tool change position. The magazine stores the tools in partitioned racks to save space.


Items

Tool shank type MAS, BT50, CAT No.50, DIN No.50, HSK 100A

Pull-stud bolt Type 2 MAS, special CAT, DIN

Tool storage capacity

Cabinet Number of tools

Max. tool diameter and storage

Standard tool Φ105 (4.13) or less

Medium bore tool Φ130 (5.12) or less

Big-bore tool Φ240 (9.45) or less

171 tools

81 tools 81 tools 48 tools 12 tools




285 tools





Max. tool diameter (standard tool storage area) *1Φ105 (4.13) without condition, R100 mm (3.94 in.) under certain condition

Max. tool diameter (medium bore tool storage area) *2

Φ130 (5.12) without condition, R120 mm (4.72 in.) under certain condition

Max. tool diameter (big-bore tool storage area) *3Top/bottom gripper:Φ240 (9.45) with dummy, R210 mm (8.27 in.) under certain condition

Max. tool length 600 mm (23.62 in.)

Max. tool mass 25 kg (55 lb)

Tool selection Fixed address

Tool transfer motor (Horizontal axis) 3.0 kW (4 hp) AC servomotor

Tool transfer motor (Vertical axis) 3.0 kW (4 hp) AC servomotor


*1 The ranges for the standard tool rack are listed in the table below.

*2 The ranges for the medium bore tool rack are listed in the table below.

*3 The ranges for the big-bore tool rack are listed in the table below.





171 tools 1 to 123




285 tools 1 to 213


81, 111-tool141, 171-tool

124 to 135, 148 to 159

195, 225-tool255, 285-tool

214 to 225, 238 to 249262 to 273


81, 111-tool141, 171-tool

136 to 147, 160 to 171

195, 225-tool255, 285-tool

226 to 237, 250 to 261274 to 285


9-2-3. Precautions

(1) We pay sufficient attention for holding tools such as magazine, sub arm, tool change arm, and spindle, but they rotates sharp edged tools and could accidentally drop. Therefore, never try to touch or stand near them during ATC operation.

(2) Before indexing the magazine manually, be sure to close the safety fence door.

(3) When changing tools manually, insert a tool securely into a toolpot.

(4) Use the tool pull stud with appropriate dimensions.

(5) The tool change arm removes the tool from the spindle tapered bore and rotates 180°. Before the tool change, check that the arm rotation does not cause interference between the tool and the workpiece.

(6) Remove chips from the magazine and the tool change arm whenever necessary, because those chips may cause malfunction of ATC. When removing chips, avoid using the compressed air because the air will blow chips into the ATC unit. Also avoid cleaning or inspection during ATC operation for reasons of safety.

(7) To stop the ATC in emergency, press the EMG. STOP button.

(8) Observe the tool limits listed in the [SECTION 9, 9-2-5. ATC tool dimensions].


9-2-4. Diagram of tool storage rack

The figure below is a 111-tool cabinet. For the 171-tool cabinet, the standard tool storage rack has two columns in-between A-A. (141-tool model has one column, the 171-tool model has two columns.)

1 Available big-bore tool storage areas 5 NG tool buffer ST(3 places: NG2 to NG4)

2 Available medium-bore tool storage areas 6 Standard tool storage area



4 Manual tool exchange positionAdditional NG tool buffer ST(SET/NG1)

(2)(3)

(4)

(5)

(6)(7)

(1)

Φ240 (9.45)

R210 (8.27)

130 (5.12) 105 (4.13)

Φ240

(9.45

)Φ1

30 (5

.12)

Φ200

(7.87

)

Φ105 (4.13)

ME12008R0101100100001


The figure below is a 225-tool cabinet. For the 285-tool cabinet, the standard tool storage rack has two columns in-between A-A. (255-tool model has one column, the 285-tool model has two columns.)

1 Available big-bore tool storage areas 5 NG tool buffer ST(3 places: NG2 to NG4)

2 Available medium-bore tool storage areas 6 Standard tool storage area



4 Manual tool exchange positionAdditional NG tool buffer ST(SET/NG1)

(2)

(1)(3)

(4)

(5)

(6)(7)

Φ240 (9.45)

R210 (8.27)

130 (5.12)

Φ240

(9.45

)

105 (4.13)Φ130 (5.12)

Φ130

(5.12

)

Φ105 (4.13)

Φ200

(7.87

)

ME12008R0101100100002


9-2-5. ATC tool dimensions

Standard toolA standard tool is normally Φ105 (4.13) or less. It can be stored in all areas.

Standard boring bar tool (double edge) Tool label [R] A tool with a shank diameter of Φ105 (4.13) or less, and a boring diameter of Φ200 (7.87) or less. It can be assigned to areas besides those off-limit to standard boring bar tools. Both pots will be D (Dummy).


2 Gripper position 4 Gripper position

Φ69

.85

(2.7

5)

46 (1.81)

600 (23.62) 600 (23.62)

Φ10

0 (3

.94)

Φ10

5 (4

.13)

Φ69

.85

(2.7

5)

46 (1.81)

Φ69

.85

(2.7

5)

Φ10

5 (4

.13)

ME12008R0101100110001

Φ69

.85

(2.7

5)

46 (1.81)

Φ10

0 (3

.94)

14 (0.55)

Φ20

0 (7

.87)

Φ10

5 (4

.13)

600 (23.62)105

(4.13)

Φ105 (4.13)

Φ200

(7.8

7)

Φ69

.85

(2.7

5)

46 (1.81)

Φ69

.85

(2.7

5)

14 (0.55)

Φ20

0 (7

.87)

Φ10

5 (4

.13)

600 (23.62)105

(4.13)

Φ105 (4.13)

Φ200

(7.8

7)

ME12008R0101100110002


Medium bore tool Tool label [J]A medium bore tool has a diameter of Φ130 (5.12).It can be assigned to the mountable areas of medium bore, big-bore and oversize bore tools.

Medium boring bar tool (Double edge) Tool label [K] A tool with a shank diameter of Φ130 (5.12) or less and a boring diameter of Φ240 (9.45) or less.It can be assigned to the mountable areas of medium bore, big-bore and oversize bore tools.Both pots will be D (Dummy).



Φ69

.85

(2.7

5)

46 (1.81)

600 (23.62) 600 (23.62)

Φ10

0 (3

.94)

Φ13

0 (5

.12)

Φ69

.85

(2.7

5)

46 (1.81)

Φ69

.85

(2.7

5)

Φ13

0 (5

.12)

ME12008R0101100110003

Φ69

.85

(2.7

5)

46 (1.81)

Φ10

0 (3

.94)

49 (1.93)

Φ24

0 (9

.45)

600 (23.62) 130 (5.12)

Φ130 (5.12)Φ

240

(9.4

5)

Φ13

0 (5

.12)

Φ69

.85

(2.7

5)

46 (1.81)

Φ69

.85

(2.7

5)

49 (1.93)

Φ24

0 (9

.45)

600 (23.62) 130 (5.12)

Φ130 (5.12)

Φ24

0 (9

.45)

Φ13

0 (5

.12)

ME12008R0101100110004


Big-bore tool Tool label [L]A big-bore tool has a diameter of Φ240 (9.45) or less.It can be assigned to the mountable areas of big-bore and oversize-bore tools.Both pots will be D (Dummy).

Φ69

.85

(2.7

5)

46 (1.81)

600 (23.62) 600 (23.62)

Φ10

0 (3

.94)

Φ24

0 (9

.45)

Φ69

.85

(2.7

5)

46 (1.81)

Φ69

.85

(2.7

5)

Φ24

0 (9

.45)

49 (1.93) 49 (1.93)

ME12008R0101100110005


Big-bore boring bar tool (Single edge) Tool label [V] Big-bore boring bar tool (R210 mm (8.27 in.) or less, single edge) It can be assigned to mountable areas of oversize tool only.Both pots will be D (Dummy). This tool cannot be registered to the Next Tool Ready ST. For oversize diameter tools, a special ATC cycle will be performed. (The cycle stops at HP7 in front of the ATC, and then moves to the ATC replacement position after the magazine shutter opens.)



Φ69

.85

(2.7

5)

46 (1.81)

Φ100

(3.9

4)

49 (1.93)

50 (1

.97)

600 (23.62) 286 (11.26)

R410 (16.14)

Φ24

0 (9

.45)

50 (1

.97)

R410 (16.14)

R410 (16.14)

R410 (16.14)

R210 (8.27)

286 (11.26)

50 (1

.97)

50 (1

.97)

Φ69

.85

(2.7

5)

46 (1.81)

Φ69

.85

(2.7

5)

49 (1.93)

50 (1

.97)

600 (23.62) 286 (11.26)

R410 (16.14)

Φ24

0 (9

.45)

50 (1

.97)

R410 (16.14)

R410 (16.14)

R410 (16.14)

R210 (8.27)

286 (11.26)50

(1.9

7)50

(1.9

7)

ME12008R0101100110006


Maximum tool mass momentThe tools whose tool mass moment is larger than 36.75 N-m (27.12 lbf-ft) cannot be handled by the ATC.


* The big-bore boring bar (double edge, Φ420 T (16.54) model), oversize diameter tool (Φ315 (12.4)) and tools with positioning pins (oil hole, angular attachments) are not standard, but are options.

9-3. Lubricating the magazine

Grease the magazine drive rack every month. For information on greasing points and procedures, refer to the [Matrix Magazine section of the Maintenance Manual] provided separately.Usually the guide will not need grease, but if during your annual inspection, you observe that there's little to no grease on it, lubricate it using standard lithium grease.

245 N (55 lbf)(Mass 25 kg (55 lb))

Φ69

.85

(2.7

5)

25 kg (55 lb) ×150 mm (5.91 in.)

150 (5.91)

ME12008R0101100110007

5963-E P-287SECTION 10 MULTI-PALLET APC (6, 10, 12 PALLETS) (OPTIONAL FOR MB-4000H/5000H/8000H)

SECTION 10 MULTI-PALLET APC (6, 10, 12 PALLETS) (OPTIONAL FOR MB-4000H/5000H/8000H)

10-1. Outline

This multi-pallet APC enables unattended operation for long hours when used in combination with the machining center. This APC has the following features;

(1) The standard 2-pallet rotary-shuttle APC is usable without change to construct the multi-pallet APC.

(2) The APC is still faster even though the number of pallets increases.

(3) The APC system has the setup station for safe and easy operation.


10-2. Specifications

10-2-1.Summary by model

ItemsItems

MB-4000H MB-5000H MB-8000H

Type 2-pallet rotary APC + radiated multi-pallet APC

Max. work dimensionsΦ600 (23.62) × 900

mm (35.43 in.)

Φ800 (31.50) × 1,000 mm (39.37

in.)

Φ1,300 (51.18) × 1,450 mm (57.09 in.)

Max. pallet load 400 kg (880 lb) 500 kg (1,100 lb) 2,000 kg (4,400 lb)

Pallet dimensions □400 (□15.75) □500 (□19.69) □800 (□31.50)

Single pallet weight 65 kg (143 lb) 105 kg (231 lb) 420 kg (924 lb)

Pallet selection method Memory random

Swivel base swiveling speed 10 min-1 10 min-1 8 min-1

Swivel base swivel range 275°

Fork travel 850 mm (33.46 in.)1,060 mm (41.73

in.)1,780 mm (70.08 in.)

Fork traveling speed7.3 m/min (24 fpm) 8.5 m/min (27.9

fpm)9.5 m/min (31.2 fpm)

Carrier base travel (10/12 pallets)

10-pallet: 1,400 mm (55.12 in.)

12-pallet: 2,100 mm (82.68 in.)

10-pallet: 1,800 mm (70.87 in.)

12-pallet: 2,700 mm (106.30 in.)

10-pallet: 2,200 mm (86.61 in.)

Carrier base travel speed (10/12 pallets) 30 m/min (98 fpm)

Setup station indexing Manual indexing at every 90°

PPC (Pallet pool line control) operation panel

LCD touch panel


10-3. Precautions

(1) Do not enter the machine working range during machine operation. Whenever cleaning, inspecting, or adjusting the machine in the machine working range, shut off the main power supply to ensure safety.

(2) To remove the pallet at the setup station, remove the two blocks that fix the pallet to the rail.

(3) Ensure that your workpiece meets the following conditions:

To prevent workpieces from falling over during APC operation, refer to [SECTION 8, 8-1-3. Limitation on workpiece center of gravity].

(4) Drive chemical anchors into the floor and secure the carrier rail, swivel base frame, setup station, and pallet base to the anchors with bolts or fixtures.If not securely fixed, the above units will deviates from their normal positions, resulting in deteriorated positioning accuracy of pallets.

(5) Drive hole-in anchors into the floor and secure the APC enclosure shield to the anchors with bolts.

1 Transfer plate 4 Pallet

2 Anti-fall-overhook (MB-4000H/5000H only) 5 Rail

3 Block

ModelMax. workpiece dimensions

[mm (in.)]Max. workpiece mass kg (lb)

MB-4000H Φ600 (23.62) × 900 (35.43) 400 (880)

MB-5000H Φ800 (31.50) × 1,000 (39.37) 500 (1,100)

MB-8000H Φ1,300 (51.18) × 1,450 (57.09) 2,000 (4,400)

(1)

(2)

(3)

(4)

(5)

ME12008R0101200040001


10-4. Lubrication oil chart

Note

Lubrication points Carrier base guide Swivel base guideSwivel base arm

guideSwivel base chain

1Swivel base chain

2

Item number 1 2 3 4 5

Symbol

Maintenance item

Inspection

Replenish 1,000 1,000 1,000 1,000 1,000

Clean / Replace

Replace

Lubricant name XBCEA2 XBCEA2 XBCEA2 XBCEA2 XBCEA2


- - - - -


Adequate amount. Adequate amount. Adequate amount. Adequate amount. Adequate amount.

1) Clean the lubrication point before supplying oil.

2) Always use the specified lubricating oil (grease).

This above figure shows the lubrication points of the multi-pallet APC with a traveling swivel base and, therefore, applies to 10- and 12-pallet APCs.Lubrication points of 6-pallet APC are the same with those of 10- or 12- pallet APC except that the 6-pallet APC has no carrier base guide.


ME12008R0101200050001


10-5. Cleaning

The figure shows a 12 pallet APC, but cleaning should be performed in similar fashion for 6 or 10 pallet APCs also.

1 (1) Connecting gutter to host machine(Feeds to the hosting machine)

4 (5) Swivel base support

2 (4) Pallet table 5 (3) Setup station

3 (2) Collection gutter

[Precautions]

1. Before cleaning the APC, ensure that the machine is stopped.

2. Clean the above units (1) to (5) at regular intervals judged from the machine operating hours. Pallets drop chips while being carried. Accumulation of these chips may disable collection of coolant.

3. When cleaning the setup station (3), pull up and remove the chip ejection port covers in the arrow direction (see the figure below), and rake chips away using a spatula or something.

(1)

(2)

(3)

(5)

(4)

ME12008R0101200060001


Front of multi-pallet APC setup station

1 Chip removal opening (2 locations)

(1)ME12008R0101200060002


Multi-pallet APC overall cover

4. To clean the chip collecting trough (2), the pallet base (4), and the swivel base frame (5), remove the APC safety fence from the floor and put in out of the way. Then, rake away chips accumulated inside the trough or frame using a spatula.At this time, be careful not to move any pallet base.

1 Safety fence

(1)

ME12008R0101200060003


10-6. Multi-pallet APC operation sequence diagram

10-6-1.Operation sequence


Cycle start

Previous pallet machining complete

(Table)

↓

Exchange pallet with two-pallet rotary APC

(Table ←→ ST.1)

↓

Hold ST.1 pallet → Unload pallet: ST.1 → Setup ST.

↓ ↓ (1) Write in next pallet

Start machining ↓ (2) Extend fork

(Table) ↓ (3) Rotate swivel base -5° (hooking position)

↓ ↓ (4) Remove pallet positioning pin for ST.1

↓ ↓ (5) Reduce fork (Pull in pallet)

↓ ↓ (6) Rotate swivel base -90° (load angle for setup station.)

↓ ↓ (7) Extend fork (load pallet to setup ST.)

Machining complete ↓ (8) Insert pallet positioning pin for setup ST.

(Table) ↓ (9) Rotate swivel base 5° (unhooking position)

↓ ↓ (10) Reduce fork

Wait for next pallet to load ↓

(Eg. ST.(n-1)) ↓

↓ Loading pallet: ST.(n-1) → ST.1

↓ ↓ (11) Rotate swivel base (next pallet unload angle)

↓ ↓ (12) Move carrier base (next pallet unload position)

↓ ↓ (11) and (12) are simultaneous operations

↓ ↓ (13) Extend fork

↓ ↓ (14) Rotate swivel base -5° (hooking position)

↓ ↓ (15) Reduce fork (Pull in pallet)

↓ ↓ (16) Rotate swivel base (load angle for ST.1)

↓ ↓ (17) Travel base motion (load angle for ST.1)

↓ ↓ (16) and (17) are simultaneous operations

↓ ↓ (18) Extend fork

↓ ↓ (19) Insert pallet positioning pin for ST.1

Exchange pallet with two-pallet rotary APC ↓ (20) Rotate swivel base 5° (unhooking position)

(Table ←→ ST.1) ← ↓ (21) Reduce fork

↓ ↓

Hold ST.1 pallet → Unload pallet: ST.1 → Setup ST.

↓ ↓ (1) Write in next pallet

Start machining ↓ (2) Extend fork

(Table) ↓ : :

↓ ↓


10-6-2.Operation sequence diagram

Target pallet Pallet present (non-target) No pallet present

The numbers from (1) to (21) are the operation sequence numbers of multi-pallet APC.

Insert pallet positioning pin for setup ST.

Remove pallet positioning pin for ST.1.

Insert pallet positioning pin for setup ST.

ME12008R0101200080001


The above diagrams show the sequences for unloading a pallet from the machine station (ST.1) to the setup station (ST.2) and then loading a new pallet from a pallet base (ST.[n-1]) to the machine setup station.

For the 6-pallet APC, which has no carrier base, ignore the sequence No. (12) and (17).

5963-E P-297SECTION 11 OPTIONS

SECTION 11 OPTIONS

11-1. Through-spindle coolant supply unit [1.5 MPa (217.7 psi)]

11-1-1.Outline

As illustrated below, this unit allows coolant to run through the spindle center and sprays from the drill tip, enabling efficient hole machining.After using the through-spindle coolant, apply compressed air (cleaning air blow ON) to force out the coolant remaining inside the piping completely. Otherwise, the remaining coolant will leak to the spindle tapered surface causing tool mounting accuracy to be lowered.

1 Coolant 4 Oil hole holder(Customer to procure)

2 Oil hole pull stud(Customer to procure)

5 Oil hole drill(Customer to procure)

3 Spindlehead

(1)

(2)(3)(4)

(5)ME12008R0101300010001


Coolant tank diagram (MB-4000H/5000H/8000H)

Note

1 Top cover 6 Drain valve

2 Stop valve 7 Filter element

3 Float switch for low fluid warning 8 Trochoid pump

4 Float switch for clogged filter warning 9 Oil level gauge

5 Overflow tank 10 Tank capacity: 84 L (22.2 gal)

M339 Cleaning air blow ON

M09 Cleaning air blow OFF

M51 Through-the-spindle coolant ON

M09 Through-the-spindle coolant OFF

1) To remove the coolant remaining in the piping completely, air blow must be supplied for at least 15 seconds. Especially, before executing ATC, cleaning air blow must always be turned ON.

2) To use the through-spindle coolant, the special pull-stud bolt supplied by OKUMA must be used. (Refer to the [Separate volume technical sheet].)

3) If non-water-soluble (oil-based) coolant is used, specified pressure and/or discharge may not be obtained. Use water-soluble coolant for the through-spindle coolant system.

(7)

(8)

(9)(10)

(1)

(2)

(3)

(4)

(5)

(6)

ME12008R0101300010002


11-1-2.Circuit diagram of through-spindle coolant system

MB-4000H

No Lubricant type Part number Maker Model number Q'ty

1 Coolant pump F0130-06-000-46 Grundfos SPK8-7/5 1

2 MS filter H0032-0012-77 Yamasei MS70 Embossed 20 µm (800 µin.) filter

4

3 Level switch E3041-592-017 Noken OLV-2A 2

4 Trochoid pump F0101-42-000-07 NOP AMTP-750-208HAVD

1

5 Coolant valve F0001-400-008-61 CKD GCVSE2-B-20A-05-B2HS-3

1

4

1

533

2

FL R

M

M

To rotary coupler

Check valveAir blow ON

Air

Air 3-piece set

Prefilter

Fluid level low

Check valve

84 L (22.2 gal)

Overflow

1.5 kW (2 hp)

Coolant tank

Unit abnormalityFloat switch

0.75 kW (1 hp)

Trochoid pump1.5 MPa (217.7 psi)12 L/min (3.2 gpm)/14.4 L/min (3.8 gpm)(50 Hz/60 Hz)

Medium pressure O.H. tank unit

Coolant valve for suction

Table rotation washing pump

ME12008R0101300340001


MB-5000H/8000H

No Lubricant type Part number Maker Model number Q'ty

1 Coolant pump F0130-03-001-23 Grundfos MTA4-250 1

2 MS filter H0032-0012-77 Yamasei MS70 Embossed 20 µm (800 µin.) filter

4

3 Level switch(MB-5000H/8000H)

E3041-592-017 Noken OLV-2A 2

4 Trochoid pump F0101-42-000-07 NOP AMTP-750-208HAVD

1

43 3

M

1

2

M

L R F 3/8

To rotary couplerCheck valve

Air blow ON

Air

Air 3-piece set

Prefilter

Fluid level low

Check valve

84 L (22.2 gal)

Overflow

0.25 kW (0.333 hp)

Coolant tank

Unit abnormalityFloat switch

0.75 kW (1.0 hp)

Trochoid pump1.5 MPa (217.7 psi)12 L/min (3.2 gpm)/14.4 L/min (3.8 gpm)(50 Hz/60 Hz)

Medium pressure O.H. tank unit

Suction pump20 L/min (5.3 gpm)

ME12008R0101300020001



Trochoid pump (motor) three-phase squired cage induction motor, totally-enclosed fan cool type, class E insulation

Trochoid pump

Coolant pump (suction pump)

MB-4000H/5000H/8000H

Model number FELQ-8T

Output (kW (hp)) 0.75 (1.0)

Number of poles 4

Rating Continuous

Voltage (V) 200

Frequency (Hz) 50/60/60

Number of rotation (min-1) 1,440/1,720/1,740

Current (A) 3.6/3.3/3.2

MB-4000H/5000H/8000H

Model number AMTP-750-208HAVD

50 Hz(1,500 min-1) Theoretical delivery(L/min (gpm))

12.0 (3.17)

60 Hz(1,800 min-1) 14.4 (3.80)

50 Hz(1,500 min-1) Rated pressure(MPa (psi))

1.5 (217.7)

60 Hz(1,800 min-1) 1.5 (217.7)

Motor output (kW (hp)) 0.75 (1.0)

MB-5000H/8000H

Category Suction pump

Model number MTA4-250

Output (kW (hp)) 0.25 (0.333)

Rated voltage (V) 200 to 220 200 to 230

Frequency (Hz) 50 60

Rated current (A) 1.65 1.8

Delivery (L/min (gpm)) 20 (5.3) 20 (5.3)

Total lift (m (ft.)) 9 (30) 12.5 (41)

Standard piping diameter (PS) 3/4


Filter

Operating oil temperature: In continuous operation, the oil temperature must be in the range from 15 °C (59 °F) to 60 °C (140 °F).

Rotary union (at the top of spindle)

[Supplement]

MB-4000H/5000H/8000H

Filtering accuracy Flow rate

MS filter 20 µm (800 µin.) 20 L/min (5.3 gpm)

Do not use the filter in clean water.

Model number Rocky joint ESX20S-9534Y (RIX)

Coolant Water-soluble coolant/air

Max. rotating speed min-1 40,000

Max. working pressure MPa (psi) 12.0 (1,741.2) (coolant) 1.0 (145.1) (air)

Max. flow rate L/min (gpm) 30 (7.9) (coolant)

Recommended filtering accuracy µm (µin.) 25 (1,000)

Refer to the [PURCHASED UNIT INSTRUCTION MANUAL] provided separately.

The flow rate widely varies with the coolant type and viscosity.

Spindle side Coolant unit side

Air

Check valve

Coolant

6.5 (0.217) (stroke)

ME12008R0101300080002


11-1-4.Preparation for operation

Supplying coolant

Open the top cover and fill the tank with the specified fresh coolant to the upper red line on the oil level gauge.

Turning the power ON

Make sure that unit fault warning signal is not output. If the warning signal is output, it indicates clogging of the prefilter or that coolant is filled to the upper limit of the overflow tank.To clean the prefilter, refer to [SECTION 11, 11-1-5. Maintenance and regular inspection].


11-1-5.Maintenance and regular inspection

Cleaning the tank and changing coolant

Inspection frequency: 6 months

Prefilter (changing filter element)

Inspection frequency: once a week or when a warning is issued

(1) Lift the cap on top of the filter to see if each chamber is filled as full as the root of the pipe.

(2) If all chambers are full of coolant, stop flowing dirty coolant into the filter and leave the filter for one night for dehydration.Deposited sludge will be dehydrated to a cake containing 70 % to 85 % water in approximately 8 hours to 24 hours.

(3) In the next morning, when the filter is dried, take the filter out of the arm and set new filter. The opening of the removed filter should be tightened by string and the filter should be disposed or burnt.

(4) After replacing the filter element, discharge the overflow tank by opening the drain valve. Finally, close the valve.

1 Pipe arm 4 Float switch

2 Filter element 20 µm (800 µin.)Part number: H0032-0012-77

5 Overflow tank

3 Overflow tankDrain valve

6 Sediments

(1) (2)

(6)(4)

(3)(5)

ME12008R0101300120001


[Supplement]

Stop valve at the inlet of the prefilter

The valve should be left open during operation. Close the valve only when replacing the filter element.

Water repellency of prefilter in the initial stage of usePrefilter has a light repellency because of its material (polypropylene unwoven cloth).During initial use, this water-repellent characteristic may make it difficult for the coolant to pass through the filter, resulting in a [FILTER CLOGGED] alarm. (This does not mean the filter is defective.)

SolutionTo reduce the adverse effect of repellency, lightly pick up an edge of the prefilter filled with coolant, and then drop it.By giving such light impact, coolant will start flowing and thereafter a required filtering amount can be obtained.

If chips are contained in the coolant, it will shorten pump life. Therefore, cleaning of the inside of the tank and cleaning and changing of filter element must be carried out at regular intervals.

Open

Close

ME12008R0101300120002


11-2. Through-spindle coolant supply unit [7 MPa (1,016 psi)]

11-2-1.Outline

As illustrated below, this unit allows coolant to run through the spindle center and sprays from the drill tip, enabling efficient hole machining.After using the through-spindle coolant, apply compressed air (cleaning air blow ON) to force out the coolant remaining inside the piping completely. Otherwise, the remaining coolant will leak to the spindle tapered surface causing tool mounting accuracy to be lowered.

1 Oil hole drill(Customer to procure)

4 Coolant

2 Oil hole holder(Customer to procure)

5 Oil hole pull stud(Customer to procure)

3 Spindlehead

(4)

(1)

(2)(3) (5)

ME12008R0101300150001


Diagram of coolant tank

Note

1 Stop valve 4 Tank capacity: 150 L (39.6 gal)

2 Prefilter 5 Oil level gauge

3 Piston pump

M339 Cleaning air blow ON

M09 Cleaning air blow OFF

M51 Through-the-spindle coolant ON

M09 Through-the-spindle coolant OFF

1) To remove the coolant remaining in the piping completely, air blow must be supplied for at least 15 seconds. Especially, before executing ATC, cleaning air blow must always be turned ON.

2) To use the through-spindle coolant, the special pull-stud bolt supplied by OKUMA must be used. (Refer to the [Separate volume technical sheet].)

3) If non-water-soluble (oil-based) coolant is used, specified pressure and/or discharge may not be obtained. Use water-soluble coolant for the through-spindle coolant system.

(1)

(2)

(5)

(4)

(3)

ME12008R0101300150002


11-2-2.Circuit diagram of through-spindle coolant system

MB-4000H

Table 1Frequency (Hz) 50 60


No. Q'ty Lubricant type Part number Maker Model number

1 1 Oil pump F0130-06-000-46 Grundfos SPK8-7/5

2 3 MS filter H0032-0012-75 Yamasei MS100 embossed 5 µm (200 µin.)

3 1 Suction filter H0032-0009-22 Masuda MFG. F-VLFE06-100S06T

4 1 Oil pump F0130-07-000-35-4 KISO PK-6 50 Hz/60 Hz 14 L/min (3.7 gpm) 7 MPa (1,016 psi) 2.2 kW (3 hp)

(4') (Adjusting handle) - - -

5 1 Line filter H0032-0011-22-2 Masuda MFG. F-FPME06-20S-036-X-C

Filter element H0032-0011-86 Masuda MFG. A06-020SW-F

6 1 Pressure gauge (SI) T019-400-008-12 Yodogawa Keiki PAGT-R1/4-60x16 MPa (2,322 psi)

1 Pressure gauge (SI, psi) T019-400-008-13 Yodogawa Keiki PAGT-R1/4-60x16 MPa/PSI scale

7 1 Float switch H0090-0003-10 Noken FP-1A

8 1 Level switch E3041-070-037 Willy Vogel WS32-2/340

9 1 Level switch E3041-592-019-1 Noken FS-2S L430

10 1 S solenoid valve F0001-411-000-68 SMC VT317-5DZ-02

11 1 Check valve F0040-982-000-82 IHARA KZU00-005E

12 1 Universal elbow H0016-0003-38 SMC KQZD08-02S

12

4

4,

1

13

10 11

2

2

2

7 8 9 3

56FL R

M

M

To rotary couplerDischarge together with rotary coupler drain.

Air blow ON

Air

Air 3-piece set

Prefilter5 µm (200 µin.)

High-pressure pump7 MPa (1,016 psi)/14 L

(3.7 gal)

Line filter20 µm (800 µin.)

150 L (39.6 gal)Drain

1.5 kW (2 hp)

Coolant tank

for suctionCoolant valve

2.2 kW (3 hp)

Suction line filter100 µm (4,000 µin.)

High pressure (7 MPa (1,016 psi)) coolant tank unit

Table rotation washing pump

Refer to Table 1

ME12008R0101300030001


13 1 Coolant valve F0001-400-008-61 CKD GCVSE2-8-20A-05-B2HS-3



MB-5000H/8000H

Table 1

Table 2




Total lift (m (ft.)) 9 (29) 12.5 (41)


To rotary couplerDischarge together with rotary coupler drain.

Air blow ON

Air

Air 3-piece set

Prefilter5 µm (200 µin.)

High-pressure pump7 MPa (1,016 psi)/14 L

(3.7 gal)

Line filter20 µm (800 µin.)

150 L (39.6 gal)Drain

0.25 kW (0.333 hp)

Coolant tank

Suction pump20 L/min (5.3 gpm)

2.2 kW (3 hp)

Suction line filter100 µm (4,000 µin.)

High pressure (7 MPa (1,016 psi)) coolant tank unit

Refer to Table 1

Refer to Table 2

ME12008R0101300160002



1 1 Oil pump F0130-03-001-23 Grundfos MTA4-250 0.25 kW (0.333 hp) 200 V

2 3 MS filter H0032-0012-75 Yamasei MS100 embossed 5 µm (200 µin.)

3 1 Suction filter H0032-0009-22 Masuda MFG. F-VLFE06-100S06T

4 1 Oil pump F0130-07-000-35-4 KISO PK-6 50 Hz/60 Hz 14 L/min (3.7 gpm) 7 MPa (1,016 psi) 2.2 kW (3 hp)

(4') (Adjusting handle) - - -

5 1 Line filter H0032-0011-22-2 Masuda MFG. F-FPME06-20S-036-X-C

Filter element H0032-0011-86 Masuda MFG. A06-020SW-F

6 1 Pressure gauge (SI) T019-400-008-12 Yodogawa Keiki PAGT-R1/4-60x16 MPa (2,322 psi)

1 Pressure gauge (SI, psi) T019-400-008-13 Yodogawa Keiki PAGT-R1/4-60x16 MPa/PSI scale

7 1 Float switch H0090-0003-10 Noken FP-1A

8 1 Level switch E3041-070-037 Willy Vogel WS32-2/340

9 1 Level switch E3041-592-019-1 Noken FS-2S L430

10 1 S solenoid valve F0001-411-000-68 SMC VT317-5DZ-02

11 1 Check valve F0040-982-000-82 IHARA KZU00-005E

12 1 Universal elbow H0016-0003-38 SMC KQZD08-02S



Piston pump (motor)

Piston pump

Coolant pump (suction pump) MB-5000H/8000H only

Filter

Operating oil temperature: In continuous operation, the oil temperature must be in the range from 15 °C (59 °F) to 60 °C (140 °F).

Model number MLA6107B

Output (kW (hp)) 2.2 (3)

Number of poles 4

Voltage (V) 200

Frequency (Hz) 50/60

Current (A) 9.2/8.5

Model number PK-6-3(RB)

Delivery [L/min (gpm)] 50 Hz 12.0 (3.17)

60 Hz 14.0 (3.70)

Delivery [MPa (psi)] 7 (1,016)

MB-5000H/8000H

Category Suction pump

Model number MTA4-250

Output (kW (hp)) 0.25 (0.333)

Rated voltage (V) 200 200/220


Rated current (A) 1.65 1.8


Total lift (m (ft.)) 9 (30) 12.5 (41)

Standard piping diameter (PS) 3/4

Filtering accuracy Flow rate

MS filter 5 µm (200 µin.) 10 L/min (2.6 gpm)

Do not use the filter in clean water.


Rotary union (at the top of spindle)

[Supplement]

Model number Rocky joint ESX20S-9534Y (RIX)

Coolant Water-soluble coolant/air

Max. rotating speed min-1 40,000

Max. working pressure MPa (psi) 12.0 (1,741.2) (coolant) 1.0 (145.1) (air)

Max. flow rate L/min (gpm) 30 (7.9) (coolant)

Recommended filtering accuracy µm (µin.) 25 (1,000)

Refer to the [PURCHASED UNIT INSTRUCTION MANUAL] provided separately.

The flow rate widely varies with the coolant type and viscosity.

Spindle side Coolant unit side

Air

Check valve

Coolant

6.5 (0.217) (stroke)

ME12008R0101300230001


11-2-4.Preparation for operation

Supplying coolant

Open the top cover and fill the tank with the specified fresh coolant to the upper red line on the oil level gauge.

Turning the power ON

Make sure that unit fault warning signal is not output. If the warning signal is output, it indicates clogging of the prefilter or that coolant is filled to the upper limit of the overflow tank.To clean the prefilter, refer to [SECTION 11, 11-2-5. Maintenance and regular inspection].

Pressure adjustment

Procedure :

1- Mount a through-spindle tool (holes at the tool tip: Φ1.6 (0.063) × 2) to the spindle.

2- Turn the pressure regulation handle (No.4' in the circuit diagram) of the through-spindle cooling unit counterclockwise fully until it stops.

3- Start coolant supply by executing the through-spindle coolant ON command.

4- Turn the pressure regulation handle (No.4' in the circuit diagram) of through-spindle cooling unit clockwise until the pressure gauge indicates 7.0 MPa (1,015.7 psi).

[Supplement]

Coolant discharge varies according to the type and viscosity of coolant.


11-2-5.Maintenance and regular inspection

MB-4000H/5000H/8000H

Cleaning the tank and changing coolant

Inspection frequency: 6 months

Prefilter (changing filter element)

Inspection frequency: once a week or when a warning is issued

(1) Lift the cap on top of the filter to see if each chamber is filled as full as the root of the pipe.

(2) If all chambers are full of coolant, stop flowing dirty coolant into the filter and leave the filter for one night for dehydration.Deposited sludge will be dehydrated to a cake containing 70 % to 85 % water in approximately 8 hours to 24 hours.

(3) In the next morning, when the filter is dried, take the filter out of the arm and set new filter. The opening of the removed filter should be tightened by string and the filter should be disposed or burnt.

(4) After replacing the filter element, discharge the overflow tank by opening the drain valve. Finally, close the valve.

1 Float switch 4 Sediments

2 Pipe arm 5 Overflow tank

3 Filter 5 µm (200 µin.)Part number: H0032-0012-75

6 Overflow tankDrain valve

(1) (2)(3)

(4)

(6)(5)ME12008R0101300280001


[Supplement]

Water repellency of prefilter in the initial stage of usePrefilter has a light repellency because of its material (polypropylene unwoven cloth).During initial use, this water-repellent characteristic may make it difficult for the coolant to pass through the filter, resulting in a [FILTER CLOGGED] alarm. (This does not mean the filter is defective.)

SolutionTo reduce the adverse effect of repellency, lightly pick up an edge of the prefilter filled with coolant, and then drop it.By giving such light impact, coolant will start flowing and thereafter a required filtering amount can be obtained.


Stop valve at the inlet of the prefilter

The valve should be left open during operation. Close the valve only when replacing the filter element.

Replacing the seals in the piston pump for 7 MPa (1,016 psi) through-spindle coolant system

Seals inside the pump have a limited life. For details, refer to the [KISO PK-6 PUMP UNIT INSTRUCTION MANUAL]. Replace the life-expired seals according to [O ring packing exchange procedure manual] in the [PURCHASED UNIT INSTRUCTION MANUAL].

If chips are contained in the coolant, it will shorten pump life. Therefore, cleaning of the inside of the tank and cleaning and changing of filter element must be carried out at regular intervals.

Open

Close

ME12008R0101300280002


11-2-6.Procedure to change through pin in the pulling shaft

Procedure to change through pin in the pulling shaft (No.40)

Part number for through pin

Installation preparation

1) The through pin incorporated in the through-spindle tool pulling shaft is a consumable part. Replace the through pin every 10 months of machine operation (or when ATC operation cycle reaches 180,000 times, whichever is shorter) according to the procedure described below. If the wear develops in the seal attached on the bottom end of the through pin, water will leak, causing a trouble.

2) The seal life varies, depending on machining kind and coolant type.If water leakage is observed before the above specified part change time (or the number of ATC times) is reached, immediately stop using the through-spindle and replace the through pin.

3) Wear safety gears such as safety boots, helmet, and protective goggle to change through pins.

4) Secure sufficient floor space and take safe positions for the through pin changes.For other precautions, refer to [SECTION 1 SAFETY GUIDE]. Make sure you read it in advance.

Specifications OKUMA Part No.

No.40 spindle JIS/DIN U9800-0614-013-01

CAT U9800-0614-014-01

1 Bolts to removeM5 x2

2 Cap

(1)

(2)

ME12008R0101300320001


Installation

1 When placing the spindle operation in a tool-unclamped state, make sure the drive key position is aligned with the keyhole of the stopper.

5 Stopper

2 Stopper securing bolt M5 × 16 L × 2 6 Collet guide lock boltsM4 × 8 L × 4

3 Spindle drive keyhole 7 Attached spanner

4 Collet guide 8 Lever, provided tool

(1)

(2)

(3)

(4)

(5)

(6)

(8)

(7)

ME12008R0101300320002


Installation completed

1 Preparation for removal of drawbar through pin is complete.

(1)

ME12008R0101300320003


Cross-section of spindle

Procedure :

1- Set the spindle to RELEASE.

2- Remove two M5 bolts on the spindle end face cover.

3- Turn the spindle with hand to the position where the spindle drive key aligns with the drive keyhole on the stopper.

1 Coil spring 7 Collet guide

2 Collar 8 Cap

3 Pulling shaft 9 Lever, provided tool

4 Through pin 10 Attached spanner

5 Ring 11 Stopper

6 Collet

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)(10)

(11)

ME12008R0101300320004


Note

4- Mount the collet guide to the stopper and then mount it to the spindle end face.Use 8L-M4 bolts to mount the collet guide. Tighten them only halfway so that it is easier to align the stopper with spindle center.Use 16L-M5 bolts to mount the stopper.

5- Set the spindle to the state where it is not clamping the tool and insert [the attached spanner].

6- Using the [spanner] and [lever], remove the [pulling shaft] unit.

Unclamp: Counterclockwise turning (CCW)

Clamp: Clockwise turning (CW)

[Collet], [ring], [through pin], [coil spring], and [collar] will come off along with the [pulling shaft].

7- Remove the [coil spring] and [through pin] from the [pulling shaft].

8- Then, install a new [through pin] in the [pulling shaft].Grease a new through pin and the O-ring mounted in the through pin. Next, mount the [coil spring] and apply grease to the O-ring section incorporated in to the outer regions of the [pulling shaft] as well as the entire [pulling shaft].

9- Mount the assembled [pulling shaft] and [collar] in the spindle.Use only the [attached spanner and lever] to perfectly tighten. Do not tighten the [attached lever] excessively by inserting a pipe or the like in the lever. Failure to follow the instruction may damage the spindle. Take an extra caution not to damage the O-rings when mounting them.

10- After verifying that the pulling shaft is tighten enough, remove the [stopper].After removing the [stopper], install the two M5 bolts removed from the [cap] of the spindle side.

11- Mount a through spindle tool and run the coolant to verify that no coolant leakage occurs inside the spindle.

The procedure above completes the through pin replacement.

Verify that [spindle indexing] has not been executed.


Procedure to change through pin in the pulling shaft (No.50)

Part numbers for through pins and O-rings (for No.50 spindle taper only)

1 Including optional CAT specifications

2 The part number, U9800-0616-017-01 for through pins comes with S15 O-ring

Installation preparation

1) The through pin incorporated in the through-spindle tool pulling shaft is a consumable part. Replace the through pin every 10 months of machine operation (or when ATC operation cycle reaches 180,000 times, whichever is shorter) according to the procedure described below. If the wear develops in the seal attached on the bottom end of the through pin, water will leak, causing a trouble.

2) The seal life varies, depending on machining kind and coolant type.If water leakage is observed before the above specified part change time (or the number of ATC times) is reached, immediately stop using the through-spindle and replace the through pin.

3) Wear safety gears such as safety boots, helmet, and protective goggle to change through pins.

4) Secure sufficient floor space and take safe positions for the through pin changes.For other precautions, refer to [SECTION 1 SAFETY GUIDE]. Make sure you read it in advance.

Specifications Part number for through pin

No.50 spindle MAS/JIS/DIN/CAT (1) U9800-0616-017-01

Model number Part number for O-ring alone

O-ring (2) S15 JIS4 Type D F109-0004-88

1 Bolts to removeM4 x3

(1)

ME12008R0101300330001


Installation

1 When placing the spindle operation in a tool-unclamped state, make sure the drive key position is aligned with the keyhole of the stopper.

5 Attached spanner

2 Collet guide 6 Stopper securing bolt M4×25L x2

3 Spindle drive keyhole 7 Stopper

4 Collet guide lock boltsM5×12L x2

8 Lever, provided tool

(1)

(2)

(3)

(4)

(5)

(8)

(7)

(6)

ME12008R0101300330002


Installation completed

1 Preparation for removal of drawbar through pin is complete.

(1)

ME12008R0101300330003


Cross-section of spindle

1 Collar 7 Collet

2 O-ring (S15) 8 Stopper

3 Coil spring 9 Attached spanner

4 Pulling shaft 10 Cap

5 Ring 11 Lever, provided tool

6 Through pin

(1)

(2)

(3)

(4)

(6)

(5)

(7)

(8) (10)

(9)

(11)

Through pin

ME12008R0101300330004


Cross-section of pulling shaft

Procedure :

1- Set the spindle to RELEASE.

2- Remove three M4 bolts on the spindle end face cap.

3- Turn the spindle with hand to the position where the spindle drive key aligns with the drive keyhole on the stopper.

Note

4- Mount the collet guide to the stopper and then mount it to the spindle end face.Use 12L-M5 bolts to mount the collet guide. Tighten them only halfway so that it is easier to align the stopper with spindle center.Use 25L-M4 bolts to mount the stopper.

5- Set the spindle to the state where it is not clamping the tool and insert [the attached spanner].

1 O-ring (S15)

Verify that [spindle indexing] has not been executed.

(1)

ME12008R0101300330005


6- Using the [spanner] and [lever], remove the [pulling shaft] unit.

Unclamp: Counterclockwise turning (CCW)

Clamp: Clockwise turning (CW)

[Collet], [ring], [through pin], [coil spring], and [collar] will come off along with the [pulling shaft].

7- Remove the [coil spring] and [through pin] from the [pulling shaft].Before removing the through pin, remove the O-ring that is assembled inside the pulling shaft. When doing so, use a stick with a thin tip.The [through pin] would not come off unless the [O-ring (S15)] is removed.

8- Then, install a new [through pin] in the [pulling shaft].Grease a new through pin and the O-ring mounted in the through pin.After mounting the through pin, mount the O-ring (S15).Choose a soft stick without sharp edge to mount the [O-ring (S15)]. Do not use finger since the inside of the pulling shaft has threads and may cut the finger if inserted.After the [O-ring (S15)] mounting is done, apply grease to the [O-ring (S15)] area.Next, mount the [coil spring] and apply grease to the O-ring section incorporated in to the outer regions of the [pulling shaft] as well as the entire [pulling shaft].

9- Mount the assembled [pulling shaft] and [collar] in the spindle.Use only the [attached spanner and lever] to perfectly tighten. Do not tighten the [attached lever] excessively by inserting a pipe or the like in the lever. Failure to follow the instruction may damage the spindle. Take an extra caution not to damage the O-rings when mounting them.

10- After verifying that the pulling shaft is tighten enough, remove the [stopper].After removing the [stopper], install the three M4 bolts removed from the [cap] of the spindle side.

11- Mount a through spindle tool and run the coolant to verify that no coolant leakage occurs inside the spindle.

The procedure above completes the through pin replacement.

5963-E P-329SECTION 12 PRESERVATION

SECTION 12 PRESERVATION

12-1. Preservation during transportation and storage

The machine can be damaged permanently by corrosion. Rust removal and cleaning are extremely expensive and time consuming. The machine should therefore be protected against corrosion when shut down for long periods (storage) or during transportation.The machine is prepared and protected in the following manner by OKUMA for transportation ex. works.

12-2. Cleaning before preservation

The clamping surface, jig, spindle tube, telescopic covers, guide rails and other machined surfaces are particularly sensitive to corrosion. These parts should be cleaned well prior to preserving.Ensure that coolant lines and hoses are blown out carefully so as to prevent any subsequent emergence of residual coolant.

12-3. Truck transportation and warehouse storage

Machines transported by truck are treated with preservative oil (if transportation and any necessary intermediate storage does not take longer than 4 weeks). For the preservative oil, any oil-based product that is suitable for the purpose can be used. Ensure that all exposed polished and burnished parts and surfaces of the machine are absolutely clean. Residual coolant must be removed with particular care, as oil cannot infiltrate this and it forms stains after a short period of time. Oil must be applied twice, the second application should be 15 to 20 minutes after the first one.

12-4. Removing preservation

The preservation must be removed using any commercially available machine cleaning concentrate in a solution ratio of 10:1.

12-5. Machine transportation

All NC axes of the machine have to be fixed with the transportation fixtures before moving or lifting the machine.

5963-E P-330SECTION 13 DISPOSAL OF THE MACHINE

SECTION 13 DISPOSAL OF THE MACHINE

When disposing of this machine, comply with municipal disposal ordinances and regulations concerning environmental compatibility, health hazards, and disposal.For detailed information, check with your local municipality.

13-1. Material groups

Separate metals, non-metals, composite materials and auxiliary materials by material type and dispose of them in an environmentally friendly manner.

13-2. Operating materials

All operating materials must be disposed of in compliance with applicable waste disposal regulations.

13-3. Disposal of electronic components

Electronic components (primary parts, drive systems, wires, etc.) are to be disposed of properly as electronic scrap.

13-4. Disposal of the packaging

The packaging and packing material used by OKUMA do not contain any problematic substances. They are all recyclable with the exception of wood materials, and should be fundamentally disposed of in the recycling bin. Wood should be disposed of in compliance with local ordinances.

5963-E

This manual may be at variance with the actual product due to specification or design changes.Please also note that specifications are subject to change without notice.If you require clarification or further explanation of any point in this manual, please contact your OKUMA representative.

LIST OF PUBLICATIONS

Publication No. Date Edition

5963-E March 2012 1st

Original Instruction Manual

Documents

ME12-008-R01a