MODEL TG- 610 TOOL GRINDE FOR R TURRE PUNCT PRESH … · 2016-04-25 · Unit Index No. Drawing No. Parts Name Type Q'ty Class Note 1 GX233-18 Knob 1 3 2 GX233-17 Handle 1 3 3 Grinding

MODEL TG-1 6 0

TOOL GRINDER FOR TURRET PUNCH PRESS TOOLING

operator's manual

o MADA

CONTENTS

SECTION 1 - INSTALLATION Page

1. Placement 2 2. Handling 2 3. Cleaning 2 4. Electrical Connection 2 5. Cutting Fluid Supply 4 6. Installation of Grinding Wheel 5

SECTION 3 - MAINTENANCE

1. Minor Troubleshooting

SECTION 2 - OPERATION

1. General Operation 6 2. Grinding of Punch or Die with

Shear Angle 10 3. Grinding Wheel Dresser 10

1) Diamond dresser 10 2) Garbon brick dresser 11

4. Grinding Precaution 12

LEVER

ON/OFF SWITCH BOX

— I —

SECTION 1 - INSTALLATION

1. Placement

The foundation should be constructed of concrete, and must be flat and level.

2. Handling

Handle your machine carefully, and use a crane or forklift to position.

3. Cleaning

After the machine has been set in position, thoroughly remove the rust preventive coating with a suitable cleaning solvent.

4. Electrical Connection

Remove the screws in the ON/OFF switch box and remove cover. Check connection of power supply cable. If the power line voltage is changed, is different than desired, simple connection changes are required.

Changing wiring connections at motor terminals.

R S T

h 7 r \ \ U V W x | Y z

2 3 0 V , 5 0 / 6 0 H z

R S T

n n U V W X Y z

m

4 0 0 V , 5 0 H z

4 6 0 V , 6 0 H z

After making the necessary wiring connection press on Button. Check that the main motor and cutting fluid motor are rotating in the direction indicated by the arrow.

ARROW

Window for inspection of direction of rotation of cutting fluid motor

TRANSPARENT CAP

• s X J

RUBBER PACKING

SHAFT

ON/OFF SWITCH BOX

Note: 1) The direction of rotation of the motor is indicated by an arrow. The forward rotation of the motor is clockwise when viewed from its fan side.

2) The pushbutton switch used in the ON/OFF switch box is a direct "ON" start switch with an overload protective device.

5. Cutting Fluid Supply

1) Connect the hydraulic hose

COUPLER (MALE)

2) Fill the cutting fluid tank with the proper cutting fluid mixture. If Amada cutting fluidîs used the ratio of fluid to water is approximately 1:8 check

I /JO' % o \ u t C <S ' • o • ^ the fluid in the tank Max. tank capacity is 302

4

6. Installation of Grinding Wheel

1) Remove the clamping plate from the shaft.

2) Install the Grinding wheel on the shaft.

3) Finger tighten the built-in nut of the clamping plate.

4) Securely tighten the nut of the clamping plate, using a specially designed installation tool.

Note: Make sure power supply is "OFF" before installing Grinding wheel.

GRINDING WHEEL

— 5 —


1. General Operation

1) Position the Tool to the ground in the chuck. Open or close the chuck according to the outside diameter of the Tool using the handle supplied.

Note: The chuck table can be lowered to ease tooling installation.

CHUCK HANDLE

CHUCK TABLE

6

2) After tooling has been installed in the chuck, the chuck table can be raised up toward the Grinding wheel and locked in position. The grinding wheel should be positioned at the front of the machine, so it can be moved to the right and left during grinding.

GRINDING TOOL WHEEL CHUCK

3) Lower the grinding wheel close to tool by turning the handle.

HANDLE

GRINDIN

TOOL LEVER TOOL GRINDING WHEEL

Note: Bring the grinding wheel close to the tooling (within about 2 mm).

4) Start the cutting fluid pump motor and open the cutting fluid valve. Adjust the opening of the stop valve so that a small amount of the cutting fluid sprays onto the side of the grinding wheel. Move the lever and make sure that it swings smoothly to the right and left.

GRINDING WHEEL

5) Turn the handle and bring the Grinding wheel close to the tool. When a spark is produced, set the indicator scale at zero. Raise the grinding wheel about 0.2 mm.

HANDLE

8

6) Gently move the lever right and left and make sure that the grinding wheel and tool are not in contact with each other. Shift the lever to the right and move the grinding wheel away from the tool. Turn the handle 0.05 mm, lower the grinding wheel and repeat the grinding operation.

TOOL GRINDING WHEEL

Note: a) Never remove more than 0.01 mm per grinding pass, b) Always start grinding from the right.

— 9 —

2. Grinding of Punches with Shear Angles

1) Loosen the chuck attaching bolts on the table.

2) Put the two pins supplied into the V-grooves of the table and chuck bottom (tilt the chuck).

3) Tighten the chuck attaching bolts with an alien wrench.

ALLEN WRENCH

3. Grinding Wheel Dresser

1) Diamond dresser

Hold the supplied diamond dresser in the chuck. Then follow the same procedure as described for tool grinding. The diamond dresser can dress only the bottom surface of the grinding wheel.

Note: When dressing remove at least 0.01 mm.

10

2) Carbon brick dresser

After turning on the grinding wheel, position the carbon brick against the tapered inside surface of the grinding wheel and narrow to 4 to 7 mm. A grinding face of about 4 to 7 mm ensures high speed grinding accuracy.

GRINDING WHEEL

CARBON BRICK

Note: Use extreme caution when using carbon brick.

4. Grinding Precautions

1) When metallic sound occurred or the die surface changes in color during grinding, dress the bottom surface and tapered inside surface of the grinding wheel with the diamond dresser and carbon brick, respectively.

2) Keep the metal removal rate at 0.01 mm per pass. Also, keep in mind that if material removal is excessive, the grinding wheel could break or burning of the die could occur.

3) Never run the grinding wheel motor in reverse with the grinding wheel installed. After the power supply cable is connected to the ON/OFF switch box, the direction of motor rotation should be checked before installation of the grinding wheel. If the rotation is incorrect the wheel will come off creating a hazard.

— 12


MINOR TROUBLESHOOTING

Symptom Probable Cause Corrective Action

1. Grinding wheel motor and cutting fluid pump motor do not run.

a. Power supply cable is discon-nected.

b. Terminal screws are loosened.

c. Thermal relay is overloaded.

d. Voltage is too low.

e. One or more input phases and open and motor is noisy.

f. Stator coil winding is broken.

• Connect.

• Retighten.

• Find out cause of overload and reset thermal relay.

• Check supply voltage and lower voltage.

• Check terminal, pushbutton, etc., and make sure that three phase voltages are all supplied to motor.

• Replace motor assembly or rewind coil.

2. Motor power drops. a. Phase voltages are unbalanced. • Inspect power supply circuit and make three phase voltages bal-anced.

3. Motor overheats. a. Voltage is too high or low. • Correct power supply voltage.

4. Motor vibrates. a. Bearing is defective. • Replace bearing or motor assem-bly.

5. Cutting fluid is not delivered.

a. Air is introduced.

b. Suction pipe is exposed above liquid level.

c. Pump seal is worn and leaking.

d. Impeller clearance is increased.

e. Pump runs in reverse direction.

• Inspect piping for air leakage.

• Add cutting fluid.

• Replace seal.

• Adjust clearance.

• Of three terminals, rewire two.

— 13 —

AMADA METRECS CO.,LTD. 120, MAEKAWA ODAWARA-SHI, KANAGAWA, JAPAN TELEPHONE: (0465)47- 8820 TELEX 3882-311 Answer Bock C o d e A M A D A J TELEFACSIM (0465)47-8897

Printed in Japan Dec. 1985 100 ®

S.MANABE

PARTS LIST MODEL TG-160

TOOL GRINDER FOR TURRET PUNCHPRESS TOOLING

ORDERING INSTRUCTIONS When ordering parts, specify Machine Model, Serial No., Unit No., Index No., Drawing No., Parts Name, Type and Quantity.

O MADA

PARTS CLASSIFICATION

1. Expendable parts

2. Parts requiring periodic replacement to ensure optimum machine performance.

3. Parts requiring replacement due to damage caused by Incorrect operation or maintenance

CONTENTS

Unit— 1

Unit

Index No. Drawing No. Parts Name Type Q'ty Class Note

1 GX233-18 Knob 1 3

2 GX233-17 Handle 1 3

3 Grinding wheel motor 0.75 kw, 3E, 2P 1

4 Bearing nut AN06 1

5 Bolt M10 x 45 4

6 Bearing No. 6006ZZ \l 2

7 GX233-22 Motor plate 1

8 GX233-15 Grinding collar 1 | 9 GX233-16 Grinding nut 1 j

10 Grinding wheel 180 x 7 5 x 3 1 . 7 5 32A46J or N5A46J 1 1


12 Set screw M10 x 12 1

13 Dust seal FD3270A0 2

14 GX233-11 Handle collar 1

15 GX233-12 Dial collar 1 3

16 Cap screw M 6 x 20 1

17 Handle ER-18 1 3

18 Bearing No. 6204ZZ 1

19 GX233-13 Knob

20 GX233-10 Bearing collar ! 1

21 GX233-14 Feed screw j 1

22 GX233-8 Motor base

23 GX233-9 Nut : 1

24 GX233-7 Copper piece 4

25 Set screw M 6 x 10 2

26 Knob KR-10 x 30 2 3

J " •j

— 2 —

Unit — 2

— 3 —

U n i t - 2


1 Chuck SC-6 1

2 Cap screw M10 x 35 2

3 GX233-4 Chuck plate 1

4 GX233-3 Table 1

5 T-nut 12.2 x 1 7 . 5 x 2 2 . 5 2

6 Chuck pawl 3 2

7 Washer M10 2

8 GX233-2 Guide pipe 1

9 Dust seal FD3720A0 2 2

10 GX233-6 Lock piece i 2

11 Knob KR-10 x 30 2

12 Coolant pump YFPC, 3E, 2P 1


14 GX233-5 Guide cap 2 ! i

I i

; 1

j

i ;

i i

i i i i

i i

. .

t .

|

_ 4 —

Unit— 24

U n i t - 3

index No. Drawing No. Parts Name Type Q'ty Class Note

1 ON/OFF switch box ANP50-2CB 2

2 Electric box AB-3 1 | 3 Hydraulic hose 11 x 6 x 1000£ 1 2 I 4 Nipple PT 1/8"

5 Cutting fluid BT-103A 1 1 KURE Industry

6 10201 Filter 1 2

7 Stop valve 3 /8" 1

8 Bushing 1 / 4 x 1 / 8 1

9 Coupler (Mail) Hi-30PM 1

10 Coupler (Femail) GI-30SM 1

11 Pin 10^ x 50c

12 Grinding wheel 1 8 0 x 7 5 x 3 1 . 7 5 1 i 1

13 Chuck pawl 3 ! 2

14 Corbon brick 1 2 5 x 2 5 x 2 5 1 1

15 Diamond dresser 1 1 * x 1 0 0 e x 1 / 2 1 1

16 Arlench set <

17 Chuck handle

18 GX233-19 Specially designed installation tool ' 1

I i i I

i

I

| I

!

I

i

| !

! i

j

| I i ; I ;

; i

J J I

i I I T | I

— 6 —

AMADA METRECS CO.,LTD. 120, MAEKAWA ODAWARA-SHI. KANAGAWA, JAPAN TELEPHONE: (0465)47-8820 TELEX 3882 311 Answer Bock Code A M A D A J TElEFACSIM <0465)47-8897

Printed in Japan Dec. 1985 100 ® S.MANABE

/

M O D E L T E G - I 6 0 E


CONTENTS

Page SECTION 3 - MAINTENANCE

2 1. Minor Troubleshooting 2 2 2 4 5


1. General Operation 6 2. Grinding of Punch or Die with

Shear Angle 10 3. Grinding Wheel Dresser 10

1) Diamond dresser 10 2) Carbon brick dresser 11

4. Grinding Precaution 12


1. Placement 2. Handling 3. Cleaning 4. Electrical Connection 5. Cutting Fluid Supply 6. Installation of Grinding Wheel


1. Placement

The machine n.ust be placed on a level and concrete foundation.

2. Handling

Handle your machine carefully, and s e t i t by crane or f o l k l i f t .

3. Cleaning

After the machine has been set in position, thoroughly remove the rust preventive coating

with a suitable cleaning solvent.


Remove the ON/OFF switch cover(A). A three-phase cable with a capacity of at least 0.85KW must be used. Connect it to the input side terminals of ON/OFF switch.

Motor terminal is located in the next to ON/OFF switches.

R S T

230V. 50/60 Hz

R S T

n n u V W x| Y Z

400V. 50 Hz 460V. 60 Hz

After check the connection.If the main motor and cutting fluid motor rotate in the reverse direction,interchange any two phase connections of the power cable at ON/OFF switches.

CWTClOn-.To protect personal against injury and machine damage, ensure that all electrical work is done by a qualified electric ian.

Cutting Fluid Supply


COUPLER (MALE)

2) Fill the cutting fluid i n the tank with the proper cutting fluid mixture.

Amada cutting fluid ratio to water is approximately 1:8.

Max. tank capacity is 302.

4

6. Installation of Grinding Wheel

1) Remove thee nine r y nvi t from the shaft.


3) Tighten the built-in emmery nut with hand.

4) Securely tighten the e m m e r y n u t using a specially designed installation tool.

5 ) T i g h t e n t h e s u p p o r t washer w i t h t h e r e v e r s e cap s c r e w .

NOTE:M6x30 cap screw i s r e v e r s e s c r e w .

Note: Make sure power supply is " O F F " before installing Grinding wheel.

SPECIALLY DESIGNED INSTALLATION TOOL

GRINDING WHEEL

GRINDING WHEEL Cap screw EMMKRY NUT

SUPPORT WASHER

5



) 1) Position the tool to the bottom in the chuck. Open or close the chuck according to the outside diameter of the Tool using the handle

supplied.


2) After t o o l i n s t a l l s in the chuck, the chuck table can be raised up toward

the Grinding wheel and locked in position.

The grinding wheel should be positioned at the front of the machine, so it can be moved

to the right and left during grinding.

3) Lower the grinding wheel close to tool by turning the handle.

Note: Lower the grinding wheel close to the tooling (within about 2 mm).

7

4) Start the cutting fluid pump motor and open the cutting fluid valve.

Adjust the opening of the stop valve so that a small amount of the cutting fluid sprays

onto the side of the grinding wheel.

Move the lever and make sure that it swings smoothly to the right and left.

5) Turn the handle and lower the G r i n d i n g wheel to the tool. When a spark is produced, set the indicator scale at zero.

Raise the grinding wheel about 0.2 mm.

IND ICATOR

6) Gently move the lever right and left and make sure that the grinding wheel and tool

are not in contact wi th each other. Shift the lever to the right and move the grinding

wheel away from the tool. Turn the handle 0 .05 mm, lower the grinding wheel and repeat the grinding operation.

Note: a) Never remove more than 0 .01 m m per grinding pass, b) Always start grinding from the right.

9 -

Grinding of Punches with Shear Angles


2) Put the two pins supplied into the V-grooves of the table and chuck bot tom (tilt the

chuck).

3) Tighten the chuck attaching bolts wi th an alien wrench.

Grinding Wheel Dresser

1) Diamond dresser

Hold the supplied diamond dresser in the chuck. Then follow the same procedure as

described for tool grinding. The diamond dresser can dress only the bottom surface of the grinding wheel.


After turning on the grinding wheel, position the carbon brick against the tapered inside

surface of the grinding wheel and narrow to 3 to 4 mm A grinding face of about 3 to 4 mm ensures high speed grinding accuracy.

G R I N D I N G WHEEL

CARBON BRICK

Note: Use extremecaut ion when using carbon brick.

Grinding Precautions

1) When metallic sound occurred or the die surface changes in color during grinding, dress the bottom surface and tapered inside surface of the grinding wheel with the diamond dresser and carbon brick respectively.

2} Keep the metal removal rate at 0.01 mm per pass. Also, keep in mind that if material removal is excessive, the grinding wheel could break or burning of the die could occur.












• Connect.

• Retighten.
















• Replace seal.



— 13 —

PARTS LIST M O D E L T E G - I 6 0 E


ORDERING INSTRUCTIONS When ordering parts, specify Machine Model, Serial No.. Uni t No.. Index No.. Drawing No.

Parts Name, Type and Quanti ty.

o M A D A

CONTENTS

Unit


1 GX233-18 Knob 1 3

2 GX233-17**" Handle 1 3



5 Bolt M10 x 45 4

6 Bearing No. 6006ZZ / 2


8 GX233-15 Grinding collar i 1

9 GX233-16 a EMMERY NUT 1

10 Grinding wheel 1 8 0 x 7 5 x 3 1 . 7 5 1 1


12 Set screw M l O x 12 1

13 Oust seal FD3270A0 2




17 Handle ER-18 1 3

18 Bearing No. 6204Z2 1

19 GX233-13 Knob 1

20 GX233-10 Bearing collar 1

21 GX233-14 Feed screw 1

22 GX233-8 a ' Motor base 1

23 GX233-9 Nut 1

24 GX233-35 RUBBER PLATE / 25 Set screw M 6 x 10 2

26 Knob KR- lOx 30 2 3

27 Bearing HR32006J(NSK) | 1 2

28 GX233—39 SUPPORT WASHER 1

29 s Cap screw, (REVERSE) M 6 X 3 0 1

3 0 Cap screw M 5 X 1 5 3

3 1 G X 2 3 3 - 3 1 GRINDING COVER 1

3 2 CAP SCREW M4 X 8 3

UI III — i—

Index No. Orawing No. Parts Name Type Q'ty Class Note

1 Chuck SC-6 1



4 GX233-3 Table 1

5 T-nut 12.2 x 17 .5x22 .5 2

6 Chuck pawl 3 2

7 Washer M10 2


9 Oust seal FD3720A0 2 2

10 GX233-6 Lock piece 2

11 Knob KR-10 x 30 2

12 Coolant pump 3E, 2P 1


14 GX233-5 Guide cap 2

15 G X 2 3 3 - 3 7 I HOSE BRACKET 1

16 CAP SCREW M5 X 15 2

17 LOCK L I N E HOSE 404131 1

-

•

U§ i^r

/ \

\ \

<k

n J o 3 y • H o z>J

2. — r O

Index No. Drawing No. Parts Name Type y Q'ty Class Note

1 ON/OFF switch ANP50-2CB ^ 1 2

2 ON/OFF switch ANP-2CB 1

3 Electric box AB-3 1

4 Hydraulic hose 11 x 6 x 1000® | 1 j 2

5 Nipple P T 1 / 8 " | 1 | -

6 Bushing 1/4 x 1/8 | 1 T 7 Cutting fluid BT-103A , 1 | 1 KURE Industry

8 10201 Filter • 1 2

9 Stop valve 3 /8" 1

10 Coupler (Mail) Hi-30PM 1 |

11 Coupler (Femail) GI-3PSM 1

12 Grinding wheel 1 8 0 x 7 5 x 3 1 . 7 5 1 13 Chuck handle 1 14 Arlench set ! 1

—..

15 Pin 10* x 50*

16 Diamond dresser 11^x100® x 1/2 t

17 Chuck pawl 3

18 Specially designed installation tool i

19 Corbon brick 1 2 5 x 2 5 x 2 5 J

20 G X 2 3 3 - 3 2 ' ACRYLIC PLATE L-TYPE 1

21 G X 2 3 3 - 3 3 ACRYLIC PLATE FLAT TYPE 1

22 CAP SCREW M4 X . 8 8

23 G X 2 3 3 - 2 0 COVER(A) ' 1

24 HANDLE A - 4 2 B - 7 2

25 G X 2 3 3 - 2 1 COVER(B) / •

«

i I i j | i : 1 i 1 ; :

d f

M O D E L T E G - 1 6 0 E S TOOL GRINDER FOR TURRET PUNCHPRESS TOOLING

F O R S A P E T " V O P E R A T I O N

1 - D O ]NT O T O P E N T H E D O O R

W H I E t M E G R I N I D I N G

W H E E L ^ i S R U N N I N G .

G R I N E > I N G W H E E L ^ W O U I ^ I D

N O T S T O P i i v r i v i E I D I A T E L ^ Y

E V E 1ST I P T H E D O O R I S

O P E N E O .

. D O INT O T L _ O W E R T H E E

G R I N r > I 1ST G W M E E L M O R E

T H E N O . O 5 W L W L I N A . O N O E

A T G R I 1ST 3 D I N G «

3 . A P P L . Y O T j r T T I N G F L U I D

W H E I E G R I N I D I N G -

. C O N F I R I V T T H A T T H E

G R I N D i n G W H E E I S

P I R I V E " V T I G H T E N E I D

B " V E M M E R " V N U T A N I D

S U P P O R T W A S I - I E R .

< r v

C O N T E N T S

S E C T I O N 1 - I N S T A L L A T I O N Page

1 . Placement 2 2 . H a n d l i n g 2

3 . Cleaning 2 4 . Electrical Connection 2 5 . Cutting Fluid Supply 4 6 . Instal lation of Grinding Wheel 5

S E C T I O N 3 - M A I N T E N A N C E

1 . Minor Troubleshooting 13 ELECTRIC CIRCUIT DIAGRAM 14 CAUTION 15 OPTION 15

') S E C T I O N 2 - O P E R A T I O N

1 . General Operation 6 2 . Grinding of Punch or Die with

Shear Angle 10 3 . Grinding Wheel Dresser 10

1) Diamond Dresser 10 2) Carbon BricK Dresser 11

4 . Grinding Precaution 12

/

GRINDING WHEEL MO.T.OR

AOJUSJABliE.HANDLE LEVER

ELECTRICAL BOX


1. Placement

The machine must be placed on a level and concrete foundation.

2. Handling

Handle your machine carefully, and se t i t by crane or : f o l k l i f t .

3. Cleaning

After the machine has been set in position, thoroughly remove the rust preventive coating with a suitable cleaning solvent.


CI) TRAMS FORMER CONNECTION

1 6 <! \ o o o

com 20o 230 4 o o 460

AiTe £ THE TAP otJ 7HE

PRIMARY SI-DE

— z —

cr> MQToZ s e c t i o n

S T R S T

230V, 50/60 Hz

R S T R S T

400V, 50 Hz 460V. 60 Hz

n n

T f GRINDING WHEEL

MOTOR CUTTING FLUID MOTOR

After check the connection.If the main.?motor and cutting fluid motor rotate in the reverse direction,interchange any two phase connections of the. terminal R 5 T TAPS.

CAUTION:To protect personal against injury and machine damage, ensure that all electrical v/ork is done by a qualified electrician.



COUPLER (FEMALE)

COUPLER (MALE!

STOP VALVE THIS VALVE IS LOCATING AT THE REAR SIOE

2) Fill the cutting fluid i n t h e tank with the proper cutting fluid mixture.

Amada c u t t i n g f l u i d r a t i o t o w a t e r i s a p p r o x i m a t e l y 1 : 8 .

Max. tank capacity, is 308.

6. Installation of Grinding Wheel.

1) Remove the em me r y n u t f r o m the shaft.


3) Tighten the built-in enunery nut with hand.

4) Securely tighten theemmery|nut.using a specially designed installation tool.

5 ) T i g h t e n the support washer w i t h the r e v e r s e cap screw.

NOTE:M6X30 cap screw is reverse screw.

Note: Make sure power supply is " O F F " before installing Grinding wheel.

SPECIALLY DESIGNED INSTALLATION TOOL

GRINOING WHEEL

- 5 -



1) Position the t o o l t o t h e b o t t o m i n t h e ' . c h u c k .

Open or close the chuck according to the outside diameter of the Tool using the handle supplied.


CHUCK

— 6 —

2) After t o o l i n s t a l l s in the chuck, the chuck table can be raised up toward

the Grinding wheel and locked in position. The grinding wheel should be positioned at the front of the machine, so it can be moved to the right and left during grinding.

Note: Lower the grinding wheel close to the tooling (within about 2 mm).

— 7 —

4) Start the cutting fluid pump motor and open the cutting fluid valve. Adjust the opening of the stop valve so that a small amount of the cutting fluid sprays onto the side of the grinding wheel. Move the lever and make sure that it swings smoothly to the right and left.

5) Turn the handle and lower the:Grinding wheel to the tool. When a spark is produced, set the indicator scale at zero. Raise the grinding wheel about 0.2 mm.

6) Gently move the lever right and left and make sure that the grinding wheel and tool are not in contact with each other. Shift the lever to the right and move the grinding wheel away from the tool. Turn the handle 0.05 mm, lower the grinding wheel and repeat the grinding operation.

Note: a) Never remove more than 0.01 mm per grinding pass, b) Always start grinding from the right.

2. Grinding of Punches with Shear Angles


2) Put the two pins supplied into the V-grooves of the table and chuck bottom (tilt the chuck).

3) Tighten the chuck attaching bolts with an alien wrench.

CHUCK TABLE

3. Grinding Wheel Dresser

1) Diamond dresser

Hold the supplied diamond dresser in the chuck. Then follow the same procedure as described for tool grinding. The diamond dresser can dress only the bottom surface of the grinding wheel.


After turning on the grinding wheel, position the carbon brick against the tapered inside surface of the grinding wheel and narrow to 3 t o 4 mm A grinding face of about 3 t o 4 mm ensures high speed grinding accuracy.

GRINOING WHEEL

CARBON BRICK

4 1 3~4

Note: Use extreme caution when using carbon brick.

4. Grinding Precautions

1) When metallic sound occurred or the die surface changes in color during grinding, dress the bottom surface and tapered inside surface of the grinding wheel with the diamond dresser and carbon brick respectively.

2} Keep the metal removal rate at 0.01 mm per pass. Also, keep in mind that if material removal is excessive, the grinding wheel could break or burning of the die could occur.


_ | 2 __











® Connect.

• Retighten.


® Check supply voltage and lower voltage.














• Replace seal.



E L E C T R I C C I R C U I T DIAGRAM

TERMINAL

— —

C A U T I O N

-Caution-When this cover is been opened Grinding wheel motor and Fuel motor do not work. While motor is running even if this door is opened Motor HILL NOT stop immediately.

PARTS LIST MODEL T E G - 1 6 0 E S

TOOL GRINDER FOR TURRET" PUNCHPRESS TOOLING

ORDERING INSTRUCTIONS When ordering parts, specify Machine Model, Serial No., Unit No., Index No., Drawing No., Parts Name, Type and Quantity.

CONTENTS

)

Unit —2


1 GX233-18 Knob 1 3

2 GX233-17a Handle 1 3



5 Bolt M10 x 45 4

6 Bearing No. 6006ZZ / 2


8 GX233-15 Grinding collar 1

9 GX233-16 a EMMERY NUT 1

10 Grinding wheel 180 x 7 5 x 3 1 . 7 5 1 1


12 Set screw M 1 0 x 12 1

13 Oust seal FD3270A0 2




17 Handle ER-18 1 3

18 Bearing No. 6204ZZ 1

19 GX233-13 Knob 1

20 GX233-10 Bearing collar 1

21 GX233-14 Feed screw 1

22 GX233-8a ' Motor base 1

23 GX233-9 Nut 1

24 GX233-35 RUBBER PLA1E / 25 Set screw M6 x 10 2

26 Knob KR-10 x 30 2 3

27 Bearing HR32006J(NSK) 1 2

28 GX233-39 SUPPORT WASHER 1

29 Cap screw (REVERSE)' M 6 X 3 0 1

30 Cap screw M 5 X 1 5 3

3 1 GX233-31* GRINDING COVER 1

32 CAP SCREW M4 X Q 3

„

— 2 —

Unit — 2


1 Chuck SC-6 1



4 GX233-3 Table 1

5 T-nut 12.2 x 17.5x22.5 2

6 Chuck pawl 3 2

7 Washer M10 2


9 Dust seal FD3720A0 2 2

10 GX233-6 Lock piece 2

11 Knob KR-10 x 30 2

12 Coolant pump 3E, 2P 1


14 GX233-5 Guide cap 2

15 GX233-37 HOSE BRACKET 1

16 CAP SCREW M5 X 15 2

17 LOCK LINE HOSE 4 0 4 1 3 1

18 Stop valve 3 /8" I

19 Nipple PT 1/8" 1

2 0 Bushing 1/4 x 1/8 1

•

*•

— 4 —

©

Unit — 3


1 OK switch AH ZZ-Grf(f\0 I 2 OFF switch ANZZ - I 3

4 Hydraulic'hose 11 x 6 x 1000* 1 2

5 -

6 L I M I T SUJlTCH -D4--0-2I31 1

7 Cutting fluid BT-103A 1 1 KURE Industry

8 10201 Filter 1 2

9

10 Coupler (Mail) Hi-30PM 1

11 Coupler (Femail) GI-30SM 1

12 Grinding wheel 1 8 0 x 7 5 x 3 1 . 7 5 i 13 Chuck handle I 14 Arlench set 1

15 Pin 1 0 * x 5 0 * z 16 Oiamond dresser 11* x 1002x 1/2 t 17 Chuck pawl 3 18 Specially designed

installation tool 1 19 Corbon brick 1 2 5 x 2 5 x 2 5 I 20 GX233-32 ACRYLIC PLATE L-TYPE / 21 GX233-33 . ACRYLIC PLATE FLAT TYPE • / 22 CAP SCREW M4 X .8 8 23 GX233-20 COVER(A) / 24 HANDLE A-42B-7 2 25 GX233-21 COVER(B) / Zb TRAN5 FORMER. TSK-OOlOQ /

11 CIRCUIT PROTECTOR. CP 3 2 / I 2

ZQ FUSE. I / 2 A 2

Z<? relay SVJ-03HC-Z4 2 •

30 THERMAL- (TNI AC200T^ TR-OrtH 4-.2A I « CTH I AC,40OT) "TR-ONH 2.2A i

3) (.TH'Z ACZOO?) TR -ONH 0.3b A 1 • (.TH2. AC400 V) TR-OMH 0.24A I

i i •

. I i I

MODEL ATG-450

TOOL GRINDER FOR TURRET PUNCH PRESS TOOLING

OPERATOR'S MANUAL

WW w

AMADA ENGINEERING & SERVICE CO. INC. 14921 E. Northam St. La Mirada, Ca. 90638

November 1 9 9 7

FOREWORD

This manual has been prepared to acquaint you with the installation, operation and maintenance procedures of your Amada Tool Grinder. We urge that you read this manual carefully for a thorough understanding of the equipment and for trouble-free operation of the machine. In addition to this manual, you may also refer to the Tooling Manual of the punch press.

As Amada's policy .is one of continuous development of each type of machine, this manual, though completely up to date when issued, is subject to change without notice.

SERIAL NUMBER

Please enter the serial number of your machine in the space above. When con-sulting with Amada, be sure to provide the machine model and serial number.

FOR SAFETY OPERATION

1.) DO NOT OPEN THE DOOR WHILE THE GRINDING WHEEL IS RUNNING. THE GRINDING WHEEL WILL NOT STOP IMMEDIATELY EVEN IF THE DOOR IS OPEN.

2.) DO NOT LOWER THE GRINDING WHEEL MORE THEN .0005" AT EACH GRINDING PASS.

3.) APPLY CUTTING FLUID WHILE GRINDING.

4.) CONFIRM THAT THE GRINDING WHEEL IS FIRMLY TIGHTENED.

CONTENTS

SECTION 1 - MACHINE DESCRIPTION

1. TOOL GRINDER -M


1. PLACEMENT 2-1

2. HANDLING 2-1

3. CLEANING • - 2-1

4. ELECTRICAL CONNECTION 2-2

5. ELECTRICAL CIRCUIT DIAGRAM 2-3

6. CUTTING FLUID SUPPLY - 2-4

7. GRINDING WHEEL INSTALLATION 2-5


1. GENERAL OPERATION 3-1

2. TOOL CHUCK • - 3-2

3. GRINDING 3.4

4. GRINDING OF PUNCH OR DIE WITH SHEAR ANGLE 3-5

5. GRINDING WHEEL DRESSER • • • 3-5

6. DIAMOND DRESSER 3-5

7. GRINDING PRECAUTIONS 3-6


1. MINOR TROUBLESHOOTING • • • 4-1

SECTION 1 MACHINE DECRIPTION

1-1


1. Placement

The machine must be placed on a level and firm foundation. For maximum convenience, place on top of a sturdy table approximately 36" high. Install the grinding wheel (Refer to Section 6) and grind the chuck table parallel to the grinding head (flatness .0005") before installing the chuck. To check flatness, install a dial indicator on the spindle shaft (remove the grinding wheel) and swing the motor bracket along the table. Continue this grinding process until you have achieved the required flatness.

2. Handling

Handle the machine carefully, and set it with a crane or forklift. DO NOT attempt to lift the grinder using the motor or table.

3. Cleaning

After the machine has been set in position, thoroughly remove the rust preventative coating with a suitable cleaning solvent.


1) Open the electrical enclosure door (A) 2) A three-phase cable with a capacity of at least 1.5 HP must be used. 3) Connect it to the input side terminals of the terminal block (B)

4) Check the connections. The grinding motor and coolant pump motor must rotate clockwise. If either the main motor and/or the coolant pump motor rotate in the reverse direction, interchange any two phase connections of the power cable at the terminal taps.

2-1

' 1

ELECTRICAL DIAGRAM

L I

460V 30 O 60Hz

L 2

O-L 3

L I 230 V

L 2

H2 H3

j 1 — o r o o n o

X I 1E0VAC X2

(LI)

1FU

LPCC-2A

His

(L2)

2FU

H2 H3

LPCC-2A

Ml 1DL H I —

H l — > 0 0 -

H I — O O AB 100M05ND3

M2 2DL

H I — 0 0

i l — - O O

H I — - O O —

AB 100M05ND3

4 LSI O yO-

3 F U l -n n

H E V I DUTY E105E3PB

MICRO SWITCH 914CEI-3 T AGC 1.5A ( X D 120VAC ' < X 2 )

1DL 6 <95) , . <96)

O O

3PB STQP

-OJ_D-

1M (13) , , (14)

^ H r <Al)

8

4PB START

o l o -O O— 2M

<13) , , <14)

AB 193A1E1 1.6 - 5.0 A

20L 9 < 9 5 ) | <96)

T k AB 193A1A1 .1 - .32 A

e <A2)

10 <A1)

e <A2)

2 -2

1T1

1T2

1T3 - (^MTR^

2T1

2T2

2 T 3

GRINBING WHEEL MOTOR

1.5 HP 3420 RPM

2 3 0 / 4 6 0 V 4.0/2.0 A

CD0LANT PUMP MOTOR

1 / 8 HP

2 3 0 / 4 6 0 V 0.3/0.19 A

WIRING DIAGRAM

© © ® ® © ©

© i i (D L,

HIGH VOLTAGE CONNECTION


Loosen 2 screws and remove ring and screen in the bottom of the grinder. Fill the cutting fluid tank with the proper cutting fluid mixture. The cutting fluid supplied with the ATG-450 should be mixed with the water in ratio 1:30. Hence 1 part of the cutting fluid plus 29 parts of the water will give you the correct mixture. It is strongly recommended in the future using a cutting fluid with a rust inhibitor.

Max. Tank capacity is 8 Ga.

Coolant Pump

Coolant On/Off Valve

2-4

7. Grinding Wheel Installation 1) Loosen the gear nut

2) Remove the washer from the shaft.

3) Install the grinding wheel on the shaft 4) Install the washer on the shaft. 5) Insert the gear handle into the hole in the washer. 6) Tighten the gear nut with the gear handle counterclockwise.

NOTE: Make sure power supply is "OFF" before installing the grinding wheel.

Grinding wheel

- , «• . - * •'*; r - vr t, • • • . - „ .

,.• ;

Gear nut Gear handle

Washer

2-5



• Place the tool in the chuck. Open or close the chuck according to the outside

diameter of the Tool using the handle supplied.

• Note: The chuck table can be lowered for ease of tooling installation

2-1

2) Tool Chuck

1. The tool chuck comes with two sets of chuck jaws. Each piece of the chuck jaw set is numbered eitherl, 2, or 3. To install, so that the grinding surface is centered, engage the helical spiral, which turns while rotating the chuck key in sequence (1) first, then (2) and finally (3). To remove a set of jaws turn chuck key counter clockwise until all chuck jaws

are free to be slid out.

2. It is recommended to use one set of jaws when grinding punch bodies. You will have

good support close to the surface being ground. Use another set for grinding all dies.

When using die's set, always make sure the surface the tool resting on is clean and free

of any dirt, thus assuring the tool will be ground square.

3. After tool is installed in the chuck, the chuck table can be raised up toward the grinding

wheel and locked in position. The grinding wheel should be positioned at the front of the

machine, so it can be moved to the right and left during grinding.

4. Adjust chuck height. In order to avoid having to disassemble the spring off the 1/2" and 1 V* tools, raise the table to a height that allows easy insertion of the

punch assembly from the bottom. Lock the table knob, close the chuck jaws

until it is just clear of the tool diameter. Insert the tool and tighten the chuck

jaws around the tool.

5. Turn on the coolant pump. Lower the grinding wheel, with the motor off, until it just

makes contact with the tool.

6. Turn the coolant pump on, by pushing "Motor Pump On" push button. Direct the coolant spray to cover the surface being ground as much as possible. For example, when grinding a rectangular die, always place the die slot parallel to the cutting fluid flow. If the slot is perpendicular, the coolant will flow through the open slot and the backside of the die will overheat. Open the cutting fluid valve. Adjust the opening of the stop valve so that* a small amount of cutting fluid sprays onto the side of the grinding wheel.

2-3

Grinding Motor On

Pump Motor Off

Grinding Motor Off

Pump Motor On

2.1) Grinding

Turn the grinding wheel on by pushing the green button "Grinding Motor". Always begin

the grinding swing from the right of the tool. Move the hand lever to make sure that it swings

freely right and left. Gently lower the grinding wheel toward the work piece until the wheel

touches the tool surface and you see spark. When a spark is produced, set the indicator dial oS

scale at zero. Move the lever back and forth, all the way across the work surface the rate of approximately 60 cycles/minute, until you barely get a spark. If you oscillate the grinder too slowly, excess heat will build up. With the wheel away from the work, lower 1 to 1 Yz marks on the calibrated dial. Each mark at the dial equals .0005". Continue grinding until you have a clean new cutting edge.

Note:

a) Never remove more than .0005" per grinding pass.

b) Always start grinding from the right.

2-4

2.2) Grinding of Punches with Shear Angles (Roof - Top).

1) Loosen bolts holding the chuck to the table. 2) Tilt the chuck back and insert the two supplied pins (10 mm diameter) into the V-

grooves of the table and chuck bottom (tilt the chuck).

3) Retighten the chuck bolts.

3) Grinding Wheel Dresser

3.1) Diamond Dresser

1) With use, the bottom (3/8" wide) surface of the grinding wheel will become radiused, thus diminishing the cutting speed. When this is the case insert the diamond dresser securely in the chuck and tighten the jaws. Then follow the same procedure as described for the tool grinding. Oscillate the wheel until a new square surface is acquired.

Note: a) The diamond dresser can only dress the bottom surface of the grinding wheel

b) There are three holes bracket on the rear of the grinder cabinet to store the pins when they are not in use.

2-5

Diamond dresser

3.2) Carbon Brick

We suggest using the carbon brick dresser to narrow the edge width on the grinding wheel to about 3/8". This will speed up the grinding process and minimize tool overheating. Another reason to use carbon brick is to clean up the grinding wheel surface of fine particles of grinding dust that loads the wheel. To clean the wheel, hold the carbon brick squarely and gently against the bottom surface of the wheel for just a few seconds.

4) Grinding precautions

1) When metallic sound occurs or the die surface changes in color during grinding, dress the bottom surface and taper the inside surfaces of the grinding wheel with the diamond dresser or carbon brick respectively.

2) Keep the wheel guard in the lower position to avoid injury from airborne debris if the grinding wheel breaks.

3) Keep the metal removal rate at .0005" per pass. Also, keep in mind that if the material removal is excessive, tool burning will occur and it could cause the wheel to break.

2-6

4) Never run the grinding wheel motor in reverse with the grinding wheel installed The wheel could fly off and cause injury. After the power supply cable is connected, check and confirm proper rotation direction before installing the grinding wheel.

5) Clean the bottom of the grinder regularly, especially around the drain screen. If the drain screen is damaged or lost,replace it immediately

CAUTION When this door is open, the grinding wheel motor and the coolant pump motor do not work. When you open the door while the motor is running, the motor WILL NOT stop immediately.



Symptom Probable Cause Corrective Action 1. Grinding wheel motor and pump motor do not run.

a. Power supply cable is disconnected. b. Terminal screws are loose.



e. One or more input phases are open and motor is noisy.


• Connect.

• Retighten.

• Find out the cause of the overload and reset thermal relay.


• Check the terminal, pushbuttons, etc., and make sure that three-phase voltage are all supplied to the motor.

• Replace motor or rewind the coil.

2. Motor power drops. a. Phase voltages are unbalanced.

• Inspect the power supply circuit and make three phase voltages balanced.

3. Motor overhears. a. Voltage is too high or low. • Correct powers supply voltage--® 4. Motor vibrates a. Bearings are defective. • Replace bearings or motor

assembly. 5. Cutting fluid is not delivered.

a. Air is introduced. b. Suction pipe is exposed above the liquid level. c. Pump seal is worn and leaking. d. Impeller clearance is increased. E. Pump runs in reverse direction.

• Inspect piping for air leakage. • Add cutting fluid.

• Replace the seal. • Adjust clearance.

• Of three terminals, rewire two

4-1

3

P A R T S L I S T MODEL ATG-450


AMADA ENGINEERING & SERVICE CO. INC. 14921 E. Northam St. La Mirada, Ca. 90638

November 1 9 9 7

PARTS CLASSIFICATION

1. Expendable parts

2." Parts requiring periodic replacement to ensure optimum machine performance.

3. Parts requiring replacement due to damage caused by incorrect operation or maintenance

ORDERING INSTRUCTIONS

When ordering parts please specify Machine Model, Serial No., Unit No., Line No., Drawing No., Parts Name, Type and Quantity.

2

CONTENTS

3

I H Z D

UNIT-3 No Drawing No. Part Name Part No. QTY Class Description 1 Cap Screw 2 M6x1.0x16 2 Lock Washer 2 For 6mm bolt 3 ATG450-001 Knob 1 3 4 ATG450-002 Handle 1 3 5 Hex Jam Nut 1 M10x1.5 6 El. Motor LM02568 1 1.5HP, 3600RPM 7 Hex Bolt 4 3/8-16x1.25 8 Lock Washer 4 For 3/8 bolt 9 Handle 33604 1 3 10 Cap Screw 1 M6x1x20 11 Lock Washer 1 For 6mm bolt 12 ATG450-021 Washer 1 13 ATG450—004 Handle Collar 1 14 Oversize Key 1 3/16x3/16x.75 15 Bearing 6204ZZ 1 2 16 Set Screw 1 M5x.8x6 17 ATG450-005 Dial 1 18 Cap Screw 3 M6x1x20 19 Lock Washer 3 For 6mm bolt 20 ATG450-022 Bearing Cap 1 21 Cap Screw 3 M4x.7x12 22 Lock Washer 3 For M4 bolt 23 ATG450-010 Bearing Retainer 1 24 ATG450-006 Lead Screw 1 25 Cap Screw 3 M5x.8x16 26 Lock Washer 3 For 5mm bolt 27 Lock Handle 34333 1 3 28 Cap Screw 3 M5x.8x12 29 Lock Washer 3 For 5mm bolt 30 ATG450-018 Lock Cap 1 31 ATG450-017 Lock Plug 1 32 ATG450-007 Motor Bracket 1 33 Retaining Ring 5100-81 1 34 ATG450-012 Washer 1 35 Dust Seal 29850 1 2 HM14 Type 36 ATG450-023 Guard Rubber 1 37 Cap Screw 3 M6x1.0x12 38 ATG450-024 Bar 1 39 Gear Nut GGA1-1-1/4-16RH 1 40 ATG450-003 Spindle •

1 41 Grinding Wheel 1 1 42 ATG450-020 Guard 1 43 Finished Washer 98370A027 5 44 Cap Screw 5 M5x.8x16 45 Bearing 6306ZZ 2 46 Bearing Washer PW05 1 47 Bearing Nut PN05 1 48 ATG450-025 Shaft Key 1 49 Coupling M24 501-024100-0000

601-024202-0006 601-024202-0011

1 1 1

Nylon Sleeve 5/8" Hub 7/8" Hub

50 Button Bolt 1 M5x.8x12 51 ATG450-026 Cover Plate 1 52 ATG450-027 Shaft Key 1 53 ATG450-008 Lead Nut 1

5

UNIT-2

UNIT-3

No Drawing No. Part Name Part No. Q.ty Class Description 1 ATG450-028 Coolant Tank 1 2 ATG450-015 Table 1 3 ATG450-014 Chuck Mount 1 4 Chuck 810-0600 1 5 ATG450-016 Guide Post 1 6 Dust Seal 29850 1 2 HM14 Type 7 ATG-450-017 Lock Plug 1 8 Cap Screw 3 M5x.8x12 9 Lock Washer , 3 For 5mm bolt 10 ATG450-018 Lock Cap 1 11 Lock Handle 34333 1 12 Coolant Pump IMV08-F 1 3 13 Cap Screw 4 M6x1.0x10 14 Lock Washer For 6mm bolt 15 Cap Screw 4 M10x1.5x25 16 Lock Washer 4 For 10mm bolt 17 Column Mounting

Flange No. 1695 1

18 Column Collar No.1615 1 19 Va Lock Line Hose 1 3 20 ATG450-019 Hose Bracket 1 21 Cap Screw 2 M5x15 22 Hose Nipple 5350K41 1 23 Hose Clamp 54175K18 1 24 Plastic Tubing 52375K14 1 3 25 Brass Elbow 1 26 Brass Ball Valve 33325K22 1 27 ATG450-009 Holder 2 28 Cap Screw 4 M5x15 29 ATG450-013 Flange 1 30 ATG450-011 Ring 1 31 ATG450-029 Mesh Disk 1 1

8

UNIT-2

UNIT-2

UNIT-3

No Drawing No. Part Name Part No. Q.ty Class Description 1 ATG450-031 Acrylic Plate 1 2 Cap Screw 3 M4x8 3 ATG450-030 Door 1 4 El. Switch 914CE1-3 1 5 Cap Screw 2 M4x15 6 ATG450-028 Coolant Tank 1 7 ATG450-032 Acrylic Plate 1 8 Cap Screw 4 M4x8 9 ATG450-033 Enclosure 1 10 Cap Screw 10 M5x15 11 El. Enclosure A1412CH 1 12 Cutting Fluid .25 Ga 13 Grinding Tool

Installation Tool 1

14 Pin 2 10x50 15 Grinding Wheel 1 1 16 Chuck Handle 1 17 Chuck Pawl 3 18 Diamond Dresser 1 19 Contactor 100MOSNKD3 2 3 20 Overload Relay 193A1A1 1 3 21 Overload Relay 193A1E1 1 3 22 Control

Transformer E105E3PB 1 3

23 Push Button (green)

800EMF3 2

24 Push Button (red) 800EMF4 2

11

c AUTOMATIC TOOL GRINDING MACHINE

T O G U - m

US EXP.

OPERATOR'S MANUAL

Q M A D A June 15, 2000 ASEI

P R E F A C E This operator's manual applies to the auto-matic tool grinding machines TOGU-IH US and EXP. Read this manual carefully so that you can operate the machine safely and correctly. Keep the manual at hand and refer to it whenever you are not sure of how to operate the machine. The dimensions given in this manual are basically in milli-meters. Inch equivalents are enclosed in parentheses. Except for some values, the inch dimensions are rounded off to three decimal places. Example: 30 mm (1.181")

Operator's Manual: Automatic Tool Grinding Machine TOGU-m US EXP. © 1999 by AMADA METRECS CO., LTD. No part of this publication may be photocopied or otherwise reproduced with-out the prior written permission of AMADA METRECS CO., LTD.

CONTENTS

Safety Safe operation n Locations of warning plates /V Safety rules vi Safety functions vii

Part I Description Identification of main machine parts 1-2 Explanation of main machine parts 1-3 Specifications 1-5 Operating environment 1-6 Accessories 1-7 Difference between US and EXP. machines 1-8

Part II Installation Lifting 11-2 Packaged condition at shipment 11-3 Machine dimensions and installation spaces 11-4 Installing and leveling 11-6 Supplying compressed air 11-8 Supplying electric power 11-9

Part III Controls Control panel ///-2 Names and functions of controls HI-3 Signal indication M-8

Part IV Operation Preparing for operation IV-2 Test operation IV-5 Operating procedures IV-7 Automatic operation chart IV-15 Operation check flowchart IV-16

(Continued on next page.)

Part V Types & Usage of Jigs Methods and jigs for grinding dies V-2 Methods and jigs for grinding punch bodies V-4 Method and jigs for dressing grinding wheel V-9

Part VI Maintenance Changing grinding wheel W-2 Lubricating with grease VI-4 Changing and disposing of coolant VI-5 Changing acrylic sheet of front door W-6

Part VII Alarm Indication & Troubleshooting Alarm indication VII-2 Troubleshooting VII-4

Part VIII Appendix Material safety data sheet W//-2 Mechanical parts list VIII-7 Electric circuit diagram VI11-10 Electric parts list VIII-16

Safe operation // Locations of warning plates iv Safety rules vi Safety functions vii

i

SAFE OPERATION

Warning plates

When operating the machine, be sure to follow the safe operating procedures described in the manual.

The following types of warning plates are attached to the machine. Check the content of these plates to ensure safe operation with the machine. Never remove them from the machine.

Warning plate on electrical box and filter box

o 9 ADANGER

High voltage. fiW ^ Turn mai n power off W before any servicing.

o i

The warning plate shown above consists of an electrical shock mark and a high voltage danger plate.

A D A N G E R • Never open the covers of the electrical box and the filter box when electric power is supplied to the machine. Otherwise you may get an electrical shock in a very dangerous manner.

Warning plate on machine proper The warning plate shown at right specifies the materials that can be ground on the machine. Be sure to observe this warning.

AWARNING Only NCT TOOL INS or compatible metall ic material to NCT TOOLING can be grinded.

A WARNING Grinding any material not specified on the above warning plate causes the failure of the machine. We are unable to warrant the machine against such a failure. Never grind such materials on the machine.

ii

The warning plate shown at right indicates an operating procedure to ensure safety.

E WARNING * Strictly observe the operating precaution described on the above warning plate. If the front door of the machine is forced open when it is fastened with an electromagnetic lock, the lock may be broken.

Definitions of warning instructions Strictly observe the procedures described in the manual when operating, lubricating, or maintaining the machine. The alert symbols used in the manual are classified into the following three types according to the degree of risk involved. Operate and maintain the machine by keeping these warning instructions in mind.

Potential risk is likely to cause death of operator.

Precaution against risk for operator or machine. Operator's injury or machine's damage is involved.

Precaution or advice with respect to operator or machine operation. No risk (hazard or accident) is involved.

For the locations of the above warning plates, refer to the following pages.

A D A N G E R

^ WARNING

A CAUTION

iii

LOCATIONS OF WARNING PLATES Front of machine

Warning plate limiting types of materials that can be ground on machine

Caution plate indicating operational precaution

FRONT DOCR can not bs opened unt i l I tha OEUY TWER toss off a f t e r the autoost ic operation is f in i shed or cancel led or an enercency stop is ac t iva ted

f

iv

Side of machine (electrical box)

Electrical shock mark

This mark is attached to electrical box and filter box

High voltage danger plate

ADANGER High voltage.

j p > Turn rain pwmt »ff

- V k«f«rt anf Mfvlalm.

This plate is attached to electrical box.

v

SAFETY RULES In addition to the instructions described on the warning plates, be sure to observe the following safety rules to ensure the safe operation of the machine.

When installing machine

A CAUTION The machine uses electric sparks of DC 24 V for positioning. Be sure to ground its primary power supply side.

When operating machine

WARNING

A C A U T I O N

A CAUTION

A WARNING

O Grinding wheels other than the CBN grinding wheel installed as standard accessory on the machine cannot be used.

When grinding many high-speed tool steel (SKH) tools — especially type D (3-1/2") and E (4-1/2") dies, dress the grinding wheel as required to prevent its loading. Dress the grinding wheel every three grindings.

When the front door of the machine is open, the ONE CYCLE AUTO START button is disabled, but the GRINDING WHEEL UP button is enabled. Keep this point in mind.

O When the machine is not in use, keep its front door open as much as possible, in order to remove moisture and to protect the jig, chuck and other parts against rusting.

When maintaining machine

A D A N G E R

^ D A N G E R

Before changing the grinding wheel, be sure to turn off the main power circuit breaker switch of the machine.

Before opening the door of the electrical box, be sure to cut off the shop power supply and to attach to the shop circuit breaker a tag indicating that the machine is under maintenance.

vi

SAFETY FUNCTIONS The machine is equipped with the following safety functions in addition to the emergency stop function.

Safety functions for operator protection 1. Door open interlock mechanism The machine is interlocked so that it cannot be automatically started when its front door is open.

2. Safety door lock mechanism This mechanism consists of the front door of the machine and a safety door switch that locks the front door. It electromagnetically locks the front door so that the front door cannot be opened after the start of automatic operation. (The front door cannot be opened until the electromagnetic lock is released.)

Safety functions for machine protection 1. Motor overload protection function When an electric current exceeding the specified limit flows to all of the spindle motor, table motor, and coolant pump motor, this function interrupts the electric power to the motors and protects them.

2. Servo system overload protection function When an electric current exceeding the specified limit flows to the servo system or-when the servo system is overheated, this function interrupts the electric power to the servo system and protects it This condition is indicated as a servo alarm by the signal tower (rotating beacon light tower).

3. Spindle upper overtravel limit switch mechanism The position of the spindle is detected by a limit switch so that the spindle does not overtravel upward during manual operation. When the spindle rises to the specified position, the limit switch automatically stops the spindle. When the limit switch has failed, the spindle is stopped by a mechanical stopper.

vii

Identification of main machine parts /-2 Explanation of main machine parts 1-3 Specifications 1-5 Operating environment 1-6 Accessories .../-7 Difference between US and EXP. machines 1-8

I-l

IDENTIFICATION OF MAIN MACHINE PARTS

DC SERVO MOTOR

I - 2

EXPLANATION OF MAIN MACHINE PARTS DC servo motor Feeds the spindle in the vertical direction. Controlled by a controller, the DC servo motor feeds the spindle for accurate grinding.

Ball screw and LM guides Transfer the rotation of the DC servo motor to the spindle, and guide the spindle sliding in the vertical direction.

Spindle motor and grinding wheel head The spindle motor, spindle, and grinding wheel are installed in the grinding wheel head. Along the column, the spindle is moved up and down by the DC servo motor. The grinding wheel is rotated at high speed by the spindle motor.

CBN grinding wheel An electrically conductive grinding wheel dedicated to the machine and used to determine the grinding start position.

Gas springs Support the grinding wheel head and prevent the grinding wheel from falling under its own weight when the power of the machine is turned off or stopped in an emergency.

Scroll chuck and table The scroll chuck to fix a tool is mounted on the table and driven by the geared motor secured to the frame.

Coolant tank and pump The coolant unit consists of the coolant tank, hose, and coolant pump. It starts and supplies the coolant after the depression of the ONE CYCLE AUTO START button and the completion of positioning, and just before the start of grinding.

Spindle upper overtravel limit switch Limits the vertical movement of the spindle.. When this switch has failed, the spindle is stopped by a mechanical stopper.

Signal tower Indicates the condition of the machine by a red, yellow, or green rotating beacon light.

Electrical box Houses a sequencer and other parts to control the operation of the machine.

1-3

Centralized lubrication manifold Centralized lubrication ports to lubricate the sliding and rotating parts of the machine.

Safety door switch and key A safety mechanism provided for operator protection. After the start of automatic operation, the front door of the machine is electromagnetically locked by the key attached to the front door and the safety door switch mounted on the machine proper. This mechanism prevents the front door from being opened during the rotation of the grinding wheel.

Filter box A box that contains the noise filter to cut noise entering from the main power line.

Air blow mechanism Starts as soon as the ONE CYCLE AUTO START button is pressed, blows the chips and water off the grinding wheel for accurately detecting the position of the tool being ground, and stops as soon as the position of the tool is detected. When the amount of air discharged from the air blow mechanism becomes extremely small, the tool position detection is adversely affected. The air blow mechanism is interlocked so that a pressure switch detects any drop of the air pressure below the specified level and deactivates the machine accordingly.

SPECIFICATIONS Control Sequencer circuit

Maximum grinding amount 0.99 mm (0.099")

Maximum tool diameter 160 mm (6.299") (Type E (4-1/2") die)

Maximum tool height 150 mm (5.906°) (when Type E (4-1/2") shear-angled punch body jig is used)

Minimum tool height Chuck jaw height

Standard grinding wheel Made of CBN and 135 mm (5.315") in diameter (conductive)

Spindle motor 1.5 kW, 2P

Spindle rotating speed 2810/3000 min"1 (rpm) at 50/60 Hz

Vertical travel distance 240 mm (9.449")

Vertical feed motor 40 W, DC servo motor with 1/10 gear head

Rapid feed speed 600 mm (23.622")/min

Positioning speed 60 mm (2.3622")/min

Grinding speed 0.06 mm (0.0023622")/min

Table motor 0.1 kW, 4P, 1/30 geared motor

Table rotating speed 60/72 min"1 (rpm) at 50/60 Hz

Coolant tank capacity 18 L (4.76 US gal)

Coolant pump motor 0.06 kW, 2P

Coolant pump capacity 20/25 L (5.28/6.61 US gal)/min at 50/60 Hz

Air consumption 1700 L (60 ft^/min at 0.5 MPa (5 kgf/cm2 or 72 psi)

Supply voltage 3-phase, 200/220 V at 50/60 Hz

Electric power consumption 2.5 kVA

Machine mass 480 kg (1059 lb) (excluding transformer mass)

Machine dimensions 813 x 858 x 1930'mm.(32.008 x 33.780 x 75.984")

1-17

OPERATING ENVIRONMENT Operate or store the machine under the following environmental conditions.

Ambient temperature 5 to 40°C (41 to KMT)

Maximum relative humidity

75% (without dew condensation)

Levelness Level to 0.05 mm (0.002")/m as specified for general machine tools

Vibration 0.59 m/s2 (0.06 G) or less

Storage temperature 5 to 40°C (41 to 104°F) (without freezing)

E CAUTION If subjected to vibration greater than that specified above, the machine may produce unevenly ground surfaces. In such a case, mount the machine on a vibration-Isolating mat

A WARNING * T h ' s automatic tool grinding machine is designed for grinding the cutting edges of punches, the receiving surfaces of dies, and the like used on CNC turret punch presses. Never use it in any other application. Particularly when used to grind nonmetallic materials, it may break.

ACCESSORIES Standard accessories

The machine is supplied with the following standard accessories.

Part Type or drawing No. (manufacturer)

Quantity

Scroll chuck 5103577 (Taiwa) 1

Chuck handle 5103578 (Taiwa) 1

CBN grinding wheel 5130604 (Taiwa) 1

Air gun AG-45 (Kurita) 1

Dresser 5103662 (Taiwa) 1

Coolant TOGU GRINDING OIL (Amada) 1 (4 Lor 1.05 US gal)

Coupler plug 20PM (Nitto) 1

Coupler socket 30SH (Nitto) 1

Warranty, inspection performance sheet, operator's manual, and service book

1 set

Optional accessories (jigs) The following optional jigs are separately required as optional accessories, depending on the types of tools to be ground. Check the types of tools to see if these optional jigs are necessary.

Type of tool Long Short

Type A (1/2") and B (1-1/4°) die jig Common

Type C (2") shear-angled punch body sleeve

Common

Type D' (3-1/2°) shear-angled punch body sleeve

Common

Type E (4-1/2°) shear-angled punch body jig

Common

Short, small-diameter punch body spacer

Dedicated to short tools

Jigs not listed in the above table must be separately ordered as special jigs.

A table filter is provided as optional accessory, although it is not a jig.

Part Drawing No. (manufacturer) Quantity

Table filter 5103672 (Taiwa) 1

11-7

DIFFERENCE BETWEEN US AND EXP. MACHINES

The TOGU-III US machine appears the same as the TOGU-III EXP. machine. They differ only in the following point. The grinding amount is set in 0.001-inch increments for the US machine and in 0.01-mm increments for the EXP. machine. Since they cannot be visually distinguished, they are made distinguishable by their serial number plates as shown below.

AUTOMATIC) GRINDING MACHINE

MODEL

POWER REQUIRED

MASS

SERIAL No.

OATE MANUFACTURE) | * » / 1 9 " *

MANUFACTURED By

A M A D A METREC5<JCVLm 90S, TAKAMQRI, ISEHARA-SHI. KANAGA1A. JAPAN

MA0£ I N JAPAN

o o

AUTOMATIC) GRINDING MACHINE

MODEL

POWER REQUIRED

MASS

SERIAL No.

0 DATE MANIFACTURH) | * * / 1 8 « *

MANUFACTURED By

A M A D A METRECS C X X L m 806 . TAKAMORI. ISBJARA-SHI, KANAGA8A, JAPAN

MADE I N JAPAN

As shown above, the US logo is marked on the serial number plate of the US machine, while the EXP. logo is marked on the serial number plate of the EXP. machine.

1-8

Lifting 11-2 Packaged condition at shipment 11-3 Machine dimensions and installation spaces 11-4 Installing and leveling 11-6 Supplying compressed air 11-8 Supplying electric power 11-9

II-l

When installing the machine, lift it with a wire rope sling applied to the position as shown below.

AWARNING * When lifted, the machine tilts forward. It is dangerous if you stand before the machine when it is lifted. When lifting the machine, be sure to work alongside the machine.

PACKAGED CONDITION AT SHIPMENT The machine is shipped from our factory as packaged as shown below. Refer to the drawing when assembling the machine for use at your factory. The following transformer is supplied together with the machine. The specifications of the transformer are subject to change without notice. Transformer specifications: Made by Fukuda Denki Seisakusho

3-phase, 5.5 kVA, 50/60 Hz, 14.4 A, with shielded case

Transformer mass: 60 kg (133 lb)

Machine has air gun and handle brackets removed. After installation of machine at site, install air gun and handle brackets in place. Install air gun bracket with M6 bolts and nuts using two 6.5-mm diameter holes at bottom of electrical box. Install handle bracket by using machine side cover fixing screws. Secure handle bracket by aligning its screw holes with cover screw holes and tightening screws.

Standard and optional accessories are packed in cardboard box and fixed together with coolant tank by band to column.

TOGUI

D J B

11-3

MACHINE DIMENSIONS AND INSTALLATION SPACES

Determine the place to install the machine by referring to the machine dimensions and maintenance spaces shown below. The dimensions of the transformer are those of the standard transformer.

Front view INSTALLATION WIDTH

11-4

Side view

INSTALLING AND LEVELING Install the machine on a flat floor where it is isolated from vibration. After its installation, be sure to level the machine to 0.05 mm (0.002")/m as described below.

Setting spirit level

Use spirit level to measure level of machine. Set spirit level on scroll chuck mounted on table of machine, and read its scale.

Leveling machine

1

2

1 1

s Level machine after checking that mass of machine is applied to all of four level bolts shown at left. Where level bolt extremely separates from floor surface, place steel plate or like below level bolt.

CAUTION If the machine is not installed level, it has poor grinding accuracy. Properly level the machine. Take particular care so that the mass of the machine is applied to all of the four level bolts.

11-6

Install the machine where it is subject to as little vibration as possible. If the machine must be installed where it may be exposed to vibration, place a vibration-isolating mat below the level bolts as shown below.

ACAUTION * When the machine is subjected to vibration while it is grinding a tool, the grinding wheel and tool also vibrate, and the tool is ground unevenly and with poor surface finish. If the machine is installed where it may be exposed to vibration greater than the installation criterion of 0.59 m/s2 (0.06 G), be sure to take the vibration-isolating measure shown above.

II-7

SUPPLYING COMPRESSED AIR Supply compressed air to the machine as described below.

Connecting compressed air Connect a coupler socket of the shop's dry air line to the air supply opening of the filter regulator shown below.

ACAUTION * B e s u r e t 0 s e t t h e a i r P r e s s u r e a t t h e

specified level. When the air pressure drops below the specified level, an interlock deactivates the machine. The machine consumes compressed air at a rate of 1700 L (60 tfj/min. Check that the shop's air compressor capacity is large enough to supply compressed air to the machine as well as other pieces of pneumatic equipment installed at the shop.

11-8

SUPPLYING ELECTRIC POWER Supply electric power to the machine as described below.

Power cable Prepare a power cable with four conductors each measuring 2.0 mm2

(AWG #14) or more in size to supply electric power to the machine. The main power cable inlet of the filter box is fitted with a cable clamp. Be sure to pull the cable through the cable ciamp. Note that the maximum outside diameter of the cable that can be pulled through the cable clamp is 19 mm (0.748").

Making electrical connections at shop's power supply Be sure to install a dedicated circuit breaker for the machine at the shop's power supply and to connect the power of the shop to the machine through an independent line from the circuit breaker. Never connect any other machine to the circuit breaker as shown beiow. Since the machine uses DC 24 V electric sparks for positioning, be sure to ground it.

11-9

Making electrical connections at machine (AC 200/220 V) Run the power cable through the cable clamp of the filter box installed in the lower section of the machine frame into the filter box, as shown below. Connect the conductors of the power cable to the line terminals at the input terminal block of the noise filter and the ground terminal in the filter box. Match the phases of the R, S, and T conductors connected to the noise filter output terminals with the corresponding phases of the power cable. When the electrical connections are completed, tighten the cable clamp to securely fix the cable and to prevent the cable conductors from being disconnected.

Maximum outside diameter of cable that can be pulled through cable clamp is 19 mm (0.748").

DANGER Before making necessary electrical connections at the machine, be sure to check that the shop power supply is cut off. Attach to the shop circuit breaker a tag indicating that the electrical work is under way.

11-10

Making electrical connections at machine (voltage other than AC 200/220 V)

Connect the power cable 1 from the shop circuit breaker to the input terminals of the transformer, as shown below. Run the power cable 2 from the output terminals of the transformer through the cable clamp of the filter box into the filter box. Connect the conductors of the power cable 2 to the line terminals at the input terminal block of the noise filter and the ground terminal in the filter box. Match the phases of the R, S, and T conductors connected to the noise filter output terminals with the corresponding phases of the power cable 2. When the electrical connections are completed, tighten the cable clamp to securely fix the cable and to prevent the cable conductors from being disconnected.

FILTER BOX

i tr 1® 6f®

a ©

0 o

® e

J O

TO SHOP CIRCUIT BREAKER

POWER CABLE 1

TERMINAL BLOCK

n n n

CABLE CLAMP* POWER CABLE 2

"Maximum outside diameter of cable that can be pulled through cable clamp is 19 mm (0.748°).

DANGER * Before making necessary electrical connections at the machine, be sure to check that the shop power supply is cut off. Attach to the shop circuit breaker a tag indicating that the electrical work is under way.

11-11

Control panel 111-2 Names and functions of controls 111-3 Signal indication 111-8

III-i

CONTROL PANEL The control panel of the machine is illustrated below.

VIII-2 -1

NAMES AND FUNCTIONS OF CONTROLS The names and functions of the controls used for the operation of the machine are described below.

Main power circuit breaker switch The main power circuit breaker is located in the lower part of the electrical box, and its switch is shown at right. It has a ground fault detection function. When a ground fault occurs, the trip coil trips to automatically interrupt the power to the machine. Turn the knob of the circuit breaker switch to turn on and off the power of the machine. The knob can be padlocked.

N

CI [J @

IN POSITION buzzer The pictograph shown at right means the completion of positioning. The buzzer sounds to notify the completion of tool position detection or the completion of determination of the grinding start position. The grinding start position is detected the instant the grinding wheel contacts the tool after the start of automatic operation. As soon as the buzzer sounds, the red LED comes on.

I IN ¥ POSITION •

GRINDING DATA SET digital switches The pictograph shown at right means the manual setup of the grinding amount. These switches are used to set the required grinding amount. Before pressing the ONE CYCLE AUTO START button, enter the grinding amount in 1/1000° increments for the US machine and in 1/100-mm increments for the EXP. machine. The value set with the two digital switches and multiplied by the setup unit is the actual grinding amount In the example shown at right, the actual grinding amount is 0.005° for the US machine and 0.05 mm for the EXP. machine.

w 0>

\ GRIDING DATA SET

0 CJl

A CAUTION * B e s u r e t o s e t t h e 9 r i n d l n9 amount before the start of automatic operation. Note that any change made to the grinding amount after the start of automatic operation is not effective.

VIII-3 -1

Relationship between grinding amount and time The grinding time with respect to each preset grinding amount is as shown in the table below. The term "spark-out" refers to finish grinding. The actual operating time during automatic operation is the grinding time and spark-out time plus the positioning time, approach time, and reset time.

Grinding amount Grinding time Spark-out time 0.05 mm 50 sec 30 sec 0.1 mm 100 sec 30 sec 0.002" 51 sec 30 sec 0.004" 100 sec 30 sec

GRINDING WHEEL DOWN button (white) The pictograph shown at right means the manual operation to lower the grinding wheel. The button is pressed and held to lower the grinding wheel head at high speed. The grinding wheel continues to lower as long as the button is pressed and held, and stops when the button is released. The button is used to bring the grinding wheel close to the tool before the start of automatic operation.

GRIIDIKG VHEEL DON vm f GRIIDIKG VHEEL DON

AWARNING * T h e 9 r i n d j n9 wheel lowers as long as the button is pressed and held, except when the machine is stopped in an emergency, has its front door opened, or is in automatic operation. Pay attention to the grinding wheel while you hold the button. Otherwise the grinding wheel may strike against the tool and break.

GRINDING WHEEL UP button (white) The pictograph shown below means the manual operation to raise the grinding wheel. The button is pressed and held to raise the grinding wheel head at high speed. The grinding wheel continues to rise as long as the button is pressed and held, and stops when the button is released or the grinding wheel reaches the upper limit The button is used to bring the grinding wheel apart from the tool if the tool is likely to interfere with the grinding wheel when installing or removing the tool.

GRiniNG VHEEL IP

GRiniNG VHEEL IP

AWARNING * T h e 9 r i n d j n9 wheel rises as long as the button is pressed and held, except when the machine is stopped in an emergency or is in automatic operation. Pay attention to the grinding wheel that rises even when the front door of the machine is open.

VIII-4 -1

ONE CYCLE AUTO START button (with cover and white light) The pictograph shown at right means the start of one cycle of automatic operation. The button is pressed to start one cycle of automatic operation. The button is enabled only when the front door of the machine is closed. One cycle of automatic operation involves positioning, grinding, spark-out, rise and reset, and automatic stop. The light of the button comes on to indicate that the machine is in automatic operation.

a < t > ONE-CYCLE AUTO START

ACAUTION 9 T h e 0 N E C Y C L E A U T 0 START button is enabled only when the front door of the machine is closed. The safety door switch attached to the machine proper monitors this condition. Unless the front door is properly closed, the machine cannot start its automatic operation.

Safety functions during automatic operation As soon as automatic operation is started, the machine has the front door electromagnetically locked by the safety door switch shown below. The safety door switch is interlocked with the opening and closing of the front door, and electromagnetically locks the front door after the start of automatic operation. The safety door switch keeps the front door locked as long as the grinding wheel is rotating under inertia after automatic operation is completed, interrupted, or stopped in emergency. The front door can be opened when the electromagnetic lock is released. (The LED of the safety door switch goes out to indicate the released condition.)

VIII-5 -1

A WARNING The safety door switch electromagnetically locks the front door of the machine usually when the grinding wheel is rotating. The electromagnetic lock is released when an electric power failure has occurred or the shop circuit breaker or the main power circuit breaker switch has tripped. In such a case, never open the front door if the grinding wheel is rotating.

STOP AND GRINDING WHEEL UP button (black) The pictograph shown at right means the interruption of one cycle of automatic operation and the rise of the grinding wheel head. The button is pressed to interrupt one cycle of automatic operation. When the button is pressed after the start of automatic operation, the grinding operation is interrupted, the grinding wheel head rises about 50 mm (1.969"), and machine stops all of its motions.

STOP AND GRINDING VHEEL UP

EMERGENCY STOP button (red on yellow background and with key)

This button is marked EMERGENCY STOP on a yellow plate and is pressed to instantaneously cut all power to the machine. When the button is pressed, the machine immediately stops all of its motions without raising the grinding wheel head, unlike when the STOP AND GRINDING WHEEL UP button is pressed. Since the grinding wheel continues to rotate under inertia, the front door of the machine is locked by the safety door switch.

A CAUTION The EMERGENCY STOP button has a key. Once locked, the button cannot be unlocked without the key. Take care not to lose the key.

VIII-6 -1

Load factor check ammeter The pictograph shown at right means an ammeter. The ammeter indicates the load applied to the spindle during grinding. When the spindle load increases to cause the spindle motor current to continuously exceed 6.0 A, the spindle motor is stopped by a motor protection function. The pointer does not swing so much when the grinding area is small or the tool is 2 in. or less in size.

When the spindle starts running, the pointer momentarily swing to a great extend due to the starting current. This is not a trouble. The current that flows during the idle rotation of the spindle (no grinding performed) is approximately 3.5 A.

VIII-7 -1

SIGNAL INDICATION The machine Indicates each operating condition and alarm by the color lights of the signal tower installed on the top of the electrical box. The operating conditions indicated by each color light are described below.

r

RD (red)

YE (yellow)

GL (green)

ON:

OFF:

ON:

1. Power of machine is turned on, and front door of machine is opened

2. Machine is stopped in emergency 3. Air-procouro hao dropped Water level is low

1. Ail other conditions

1. Power of machine Is turned on 2. Automatic operation is completed 3. Automatic operation is Interrupted,

or machine Is stopped in emergency

BLINKING: 1. Automatic operation is interrupted, and grinding wheel head is rising

OFF: 1. Machine is in automatic operation 2. Power of machine is turned off

ON: 1. Machine is In automatic operation 2. Grinding wheel head is rising after

grinding operation

BLINKING: 1. Spark-out Is underway

OFF: 1. All other conditions

TOP OF ELECTRICAL BOX

VIII-8 -1

Part

Operation •HILIIli.ui mi ^ P . i i J i ^ ^ u i ^ j ^ ^ j U A ^ i ^ u j ^ ^ L . ^ ^ ^ a j ^

Preparing for operation IV-2 Test operation IV-5 Operating procedures IV-7 Automatic operation chart IV-15 Operation check flowchart IV-16

rv-i

PREPARING FOR OPERATION Checking air discharge

Check that compressed air is discharged from the accessory air gun. At the same time, check the air pressure at the pressure gauge of the filter regulator. The compressed air is absolutely necessary for accurately determining the grinding start position. If no air is discharged from the air gun or the air pressure is lower than specified, the machine cannot be started. Solve the problem, and use the machine.

Preparing coolant Add water into the coolant tank to about 90% of the height so that the coolant is diluted 30 to 50 times. (The full capacity of the coolant tank is 18 L (<1,76 US gal) ). 34L (8.98US gal) Be sure to check the coolant level before starting the operation of the machine. With the machine stopped, open the lower door, and check that the coolant is filled above the lower cooling water level marked on the coolant tank. If the coolant level is below the lower cooling water level, immediately add the coolant Perform this coolant level check as one of the daily check items.

AWARNING * A , a c k o f c o o , a n t burns the grinding wheel and a tool. The air introduced through the drain hose Is drawn by the coolant supply hose into the coolant pump where it collects. The collected air

I interferes with the discharge of the coolant Pay attention to this phenomenon.

Checking rotational directions of grinding wheel and table Turn on the main power circuit breaker switch of the machine, start the machine, and check the rotational directions of the grinding wheel and table as described below.

1 When you have confirmed that the power of the machine is turned on, close the front door of the machine. If the front door is open, the grinding wheel and table cannot rotate'.

2 Press the ONE CYCLE AUTO START button. The grinding wheel and table instantaneously start rotating.

3 After 1 to 2 sec, press the STOP AND GRINDING WHEEL UP button to stop the machine.

4 Since the table stops immediately, check its rotational direction. Its rotational direction is normal if the table rotates counterclockwise when viewed from above.

5 Next, check the operational direction of the grinding wheel rotating under inertia by looking at the arrow label. Its rotational direction is normal if the grinding wheel rotates in the direction of the arrow (or counterclockwise when viewed from below).

6 If the grinding wheel or table rotates in the reverse direction, interchange two of the three conductors of the power cable connected to the shop power supply.

VIII-3 -1

A DANGER Be sure to turn off the shop circuit breaker to cut off the shop power supply before interchanging two of the three conductors of the power cable. Be sure to interchange the power supply phases at the shop circuit breaker. If the power cable conductors are interchanged at the terminal block in the electrical box of the machine, the other motors run in* the reverse direction. The grinding wheel and table must rotate in the direction opposite to each other.

Checking rotational direction of coolant pump The coolant pump has a transparent cap installed on the head. The transparent cap can be removed. By looking at the arrow marked on the head, check the rotational direction of the coolant pump. The coolant pump does not run unless the machine actually performs grinding. Test-operate the machine to check the rotational direction of the coolant pump. Its rotational direction is normal if the coolant unit discharges the coolant during the grinding motion in the test operation.

Arrow indicating rotational direction is marked on head of coolant pump.

A WARNING O Check the rotational direction of the coolant pump as one item of the test operation described in the next section. When a tool is ground without checking the rotational direction, the grinding wheel and tool are burned unless the coolant is discharged.

rv-4

TEST OPERATION Test operation procedure

Be sure to use the accessory dresser for the test operation of the machine. Test-operate the machine as described below.

1 Install the dresser in the scroll chuck. Mount the dresser in the dresser holder, and fix it with the set screw.

2 Set the grinding amount at 0.02 mm or 0.002". Set the GRINDING DATA SET digital switches at "02°.

DRESS STICK

DRESSER HOLDER 2

SCROLL CHUCK \

3 Close the front door of the machine, and press and hold the GRINDING WHEEL DOWN button until the grinding wheel moves down to about 15 mm (0.5") above the dresser. Then press the ONE CYCLE AUTO START button.

4 The grinding wheel starts rotating and lowering while discharging compressed air.

5 Check that the IN POSITION buzzer sounds when the grinding wheel contacts the dresser.' When the positioning motion is completed, the grinding wheel rises by 0.2 mm (0.008").

6 Check that the coolant is discharged as soon as the compressed air is turned off. The grinding wheel resumes the lowering motion and starts the grinding motion after the completion of the approach.

7 The coolant may not be discharged immediately after the start of the grinding motion, but there is no problem if the coolant is discharged until the spark-out is completed.

CAUTION The dresser can be used dry. If the coolant Is not discharged until the end of automatic operation, prime the coolant pump. The coolant pump in the machine is shipped empty. It must be primed before use.

VII-5

Priming coolant pump Prime the coolant pump as described below.

1 Remove from the coolant tank the end of the hose leading from the coolant pump to the coolant tank.

2 Raise the end of the hose as high as possible, and pour water into the hose using a funnel or the like.

3 Add the water until it comes close to the end of the hose.

4 Close the end of the hose with a finger, and return the hose back into the coolant tank.

5 The coolant starts flowing out of the coolant unit when the automatic operation of the machine is resumed.

OPERATING PROCEDURES Operate the machine as described below.

Turning on power of machine Check the compressed air supply condition and the coolant level, turn on the shop circuit breaker, and turn on the main power circuit breaker switch of the machine shown at right. The instant the power is supplied to the machine, some sound may come from the motors. This is not a trouble. With the power supplied to the machine, check that the signal tower on the top of the electrical box indicates the following conditions:

RD (Red) light On: Front door of machine is open Off: Front door of machine is closed

YE (Yellow) light On: Power of machine is turned on

If the signal tower indicates any other condition when the power of the machine is turned on, there is some problem. Check the condition, and contact us.

r

r—v

\

^ ®

(0 if ©

j

RD (red)

YE (yellow)

GL (green)

Setting tool It is basic practice to set a tool in the scroll chuck for grinding. If chips or other foreign matter is deposited on the jaws of the scroll chuck, the tool cannot be properly ground in the horizontal direction. Be sure to blow off the chips or the like with compressed air and to wipe the chuck jaws with waste cloth. Similarly clean the tool. Special jigs are required for some types of tools. For detailed types and usage of jigs, refer to Part V.

A CAUTION Be sure that no foreign matter is deposited on the jaws of the scroll chuck and the surface portions of the tool that come into contact with the chuck jaws. If there is any such foreign matter, the tool cannot be properly ground in the horizontal direction.

VIII-7 -1

Setting grounding amount Inspect the tool to be ground for wear, and check that the tool is properly mounted in the scroll chuck. Set the grinding amount with the GRINDING DATA SET digital switches shown at right. Be sure to set the grinding amount before the start of automatic operation. As described in Part III, Controls, the two-digit value set here is the grinding amount. If the digital switches are set at u05" as shown at right, the grinding amount is 0.005" for the US machine and 0.05 mm for the EXP. machine.

Y <5>

\ / GRIIDING DATA SET

0 cn

Preparing for automatic operation Once the grinding amount is set, close the front door of the machine in order to lower the spindle. Close the front door by gently inserting the door switch key attached to the front door into the safety door switch attached to the table cover.

Close front door by gently inserting door switch key into keyhole of safety door switch while taking care not to strike key against safety door switch.

The safety door switch monitors whether or not the front door is open, and is interlocked with the front door. Unless the door switch key is properly inserted, the automatic operation of the machine cannot be started.

A WARNING If the front door is violently closed, the safety door switch may strike the door switch key, and bend or break it. Note that if the key is broken, the machine cannot be used any more.

VIII-8 -1

When the front door is properly closed, the signal tower indicates the following conditions:

RD (Red) light Off: Front door is closed

YE (Yellow) light On

If the red light of the signal tower does not go out even though the front door is properly closed, there is some trouble. Close and open the front door several times. If the condition does not change, contact us. If the red light of the signal tower goes out, press and hold the GRINDING WHEEL DOWN button shown below until the spindle (grinding wheel) lowers at high speed and the grinding wheel comes close to the tool. Do not lower the grinding wheel less than 10 mm (0.5") close to the tool. If the grinding wheel is brought too close to the tool, the air blow time is shortened, the water deposited on the tool and grinding wheel cannot be properly removed, and the grinding start position cannot be accurately determined.

AWARNING * When lowering the spindle (grinding wheel) at high speed, keep your eyes on the grinding wheel. The grinding wheel lowers as long as the GRINDING WHEEL DOWN button is held pressed. The grinding wheel may strike the tool and break.

Starting automatic operation When the grinding wheel is brought close enough to the tool, press the ONE CYCLE AUTO START button shown below. The respective steps of the automatic operation of the machine are described below.

1 As soon as the ONE CYCLE AUTO START button is pressed, its white light comes on. At the same time, the safety door switch electromagnetically locks the front door of the machine, and its orange LED comes on.

2 The grinding wheel head and table rotate. The grinding wheel head then lowers at medium speed while discharging compressed air.

RD (red)

YE (yellow)

GL (green)

GRIND H Q VHEEL

V//A f DOVI

ONE CTOLE AVTD START

V s LIGHTED

VIII-9 -1

The air blows water off the grinding wheel and tool, so that the grinding start position can be accurately detected.

The IN POSITION buzzer sounds, and the grinding wheel head rises by 0.2 mm (0.008") at medium speed.

LIGHTED

It* 5 The air blow is stopped, the coolant discharge is started, and the

grinding wheel head lowers at medium speed to approach the tool.

6 When the grinding wheel head reaches the grinding start position, it changes to the grinding motion. It lowers at low speed and grinds the tool by the specified amount.

7 When the grinding of the tool by the specified amount is completed, the grinding wheel head stops lowering and changes to finish grinding (spark-out). The spark-out continues for 30 sec.

8 After the spark-out, the grinding wheel head rises by 50 mm (1.969") at high sp'eed, stops, and completes the automatic operation.

9 After the end of the automatic operation, the safety door switch electromagnetically locks the front door as long as the grinding wheel rotates under inertia. The electromagnetic lock is released about 3 to 5 sec after the complete stop of the grinding wheel. When the electromagnetic lock is released, the orange LED of the safety door switch goes out Check this condition, and open the front door.

During the automatic operation, the signal tower indicates the following conditions:

RD (Red) light Off:Automatic operation is underway On: Automatic operation is underway,

and front door is open Yellow (YE) light

Off:Automatic operation is underway On: Automatic operation is stopped or

completed GL (Green) light

On:Automatic operation is underway Blinking: Spark-out is under way Off: Automatic operation is stopped or

completed

RD (red)

YE (yellow)

GL (green)

Interrupting automatic operation

STOP AND ( \ /Jb^J? GRIWING

WHEEL UP

Press the STOP AND GRINDING WHEEL UP button to interrupt the automatic operation of the machine due to an improper setup of the grinding amount, for example. The interrupt function is effective in all motion areas after the start of automatic operation. (The grinding operation can also be interrupted.) As soon as the button is pressed, the automatic operation command is canceled, and the grinding wheel head starts rising at high speed. The grinding wheel head stops after a rise of 50 mm (1.969") from the position where the button was pressed. Since the grinding wheel is still rotating under inertia, the safety door switch electromagnetically locks the front door of the machine. When the automatic operation is interrupted, the front door cannot be opened until 3 to 5 sec after the complete stop of the grinding wheel. Usually, press the STOP AND GRINDING WHEEL UP button, not the EMERGENCY STOP button, to interrupt the automatic operation. When the automatic operation is interrupted, the signal tower indicates the following conditions:

YE (Yellow) light Blinking: Grinding wheel head is rising

after interruption of automatic operation

On: Grinding wheel head has completed rising

GL (Green) light Off

RD (red)

YE (yellow)

GL (green)

VII-11

Pressing EMERGENCY STOP button When such an emergency occurs that makes it unavoidable to interrupt the automatic operation of the machine, the EMERGENCY STOP button shown at right is pressed to stop the machine. Unlike the interruption of automatic operation, the depression of the button instantaneously stops all power to the machine, so that the grinding wheel head does not rise either. Since the grinding wheel head is supported by the gas springs so that it does not fall under its own weight, it may sometimes rise slightly. Since the grinding wheel continues to rotate under inertia, the safety door switch electromagnetically locks the front door of the machine. The front door cannot be opened until 3 to 5 sec after the complete stop of the grinding wheel. The EMERGENCY STOP button is also used to clear an alarm that occurs in the servo system. For details, refer to Part VII. When the machine is stopped in an emergency, the signal tower indicates the following conditions:

RD (Red) light: On

YE (Yellow) light: On

GL (Green) light: Off

RD (red)

YE (yellow)

GL (green)

VII-12

Check items and precautions during automatic operation Checking grinding wheel When the automatic operation of the machine is started, the pointer of the ammeter indicating the load factor of the spindle starts to swing. The ammeter reads approximately 3.5 A when the spindle is idling. If the tool is 2 in. or less in size, the spindle motor current does not increase much when the grinding wheel starts grinding the tool. When the tool is more than 3-1/2 in. in size and made of high-speed tool steel (SKH), the pointer of the ammeter swings to a greater extent. The current increases with decreasing sharpness of the grinding wheel. When the current increases to 6.0 or 6.5 A, the spindle motor is stopped by its protection function. Check the ammeter in daily use, and dress the grinding wheel when the ammeter indicates a current value close to 6-.0 A.

® MHETER

CAUTION ® Unless the grinding wheel is dressed, the motor protection function frequently actuates, and a servo alarm occurs. If the machine operates without enabling the motor protection function, there occurs the surface polishing phenomenon (mirror condition) that no grinding is actually performed on the tool.

Precautions for safe operation

AWARNING ® Never remove from the machine the safety door switch that monitors whether or not the front door of the machine is open and locks the front door during the automatic operation of the machine, although you may feel some inconvenience with it The removal of the safety door switch not only causes the loss of the safety function, but disables the automatic operation.

• The front door is locked electromagnetically by a timer as long as the grinding wheel rotates under inertia after the completion or interruption of automatic operation, or the emergency stop of the machine. Never adjust the time preset with the timer without our permission.

• The electromagnetic lock of the safety door switch (front door) is released when the shop circuit breaker or the main power circuit breaker switch has tripped or the electric power has failed. Open the front door after checking that the grinding wheel has completely stopped.

VIII-13 -1

Removing tool and ending grinding operation When the grinding of the tool is completed, the grinding wheel head rises by 50 mm (1.969") from the grinding start position and stops. If the tool is likely to interfere with the grinding wheel when removing the tool or installing another tool, press and hold the GRINDING WHEEL .UP button to raise the grinding wheel head. If the grinding wheel is allowed to interfere with the tool, it may chip or break. Particularly when changing from the grinding of a die to that of a Type A (1/2") or B (1-1/4") punch, the grinding wheel interferes in that position. Raise the grinding wheel head beforehand.

Before ending the grinding operation, blow the water and chips off the scroll chuck and surrounding parts with compressed air, wipe them with waste cloth, and spray rust-preventive oil to them.

CAUTION * T h e scro11 c h u c k easily rusts if left to stand contaminated with the coolant for a long period of time. This rust prevents the chuck jaws from properly opening and closing.

VIII-14 -1

AUTOMATIC OPERATION CHART v _ J

(mm)

I V - 1 5

OPERATION CHECK FLOWCHART Start (power turned on) )

Check that signal tower lights Yellow: Always on Red: On when front door is open and off when it is closed

Check emergency si op function, check that air pressure is properly regulated, and contact us

Check that grinding wheel head moves up and down

With front door closed, press GRINDING WHEEL UP and DOWN buttons to check that grinding wheel head moves up and down

Open front door, and check that grinding wheel head fails only to move down

Check emergency stop function

Press EMERGENCY STOP button while grinding wheel head is moving up or down, and check that grinding wheel head stops and red light of signal tower comes on

Does grinding wheel head stop and does red

fight come on?

Yes Contact us

Reset EMERGENCY STOP button with key

When check of manual operation is completed, perform check of automatic operation

Set tool in scroll chuck, and set grinding amount

I

VII-16

Close front door, and check that red light of signal tower goes out

Press GRINDIN< DOWN button to wheel 11 to 15 rc close (but not cic

3 WHEEL bring grinding

lm (0.4 to 0.5") >ser) to tool

Press to light ONE CYCLE AUTO START button

Check that grind table rotate and wheel moves do blowing air

ing wheel and that grinding mi while

To see that safety door switch electromagnetically looks front door, check that LED of switch is turned on

Check motions fi grinding start pos grinding operatic

*om detection of sition to end of n

When grinding s detected, buzzer grinding wheel ri (0.008")

tart position is sounds and

ses 0.2 mm

Air blow is stopped, coolant discharge is started, and grinding wheel lowers again to approach tool

Grinding wheel head changes to grinding motion, grinds tool by preset amount, finish-grinds tool 30 sec, rises 50 mm (1.S69N), and ends automatic operation

Check that safety door switch electromagnetically locks front door

Electromagnetic lock should be held for 3 to 5 sec after complete stop of grinding wheel and then released

VIII-18 -1

Part Types &

Methods and jigs for grinding dies V-2 Methods and jigs for grinding punch bodies V~4 Method and jigs for dressing grinding wheel V-9

V-l

METHODS AND JIGS FOR GRINDING DIES The methods and jigs for grinding specific sizes of dies to be used on the machine are described below.

Type A (1/2") and B (1-1/4") dies [Long and short dies] The 1/2" and 1-1/4" dies are ground using the optional jig shown below. The jig is commonly used for grinding both of the 1/2" and 1-1/4" dies. It is turned over for use on either size of die.

Common jig

SIDE FOR 1/2° DIE

SIDE FOR 1-1/4° DIE

1/2" DIE 1-1/4" DIE

Set each size of shaped die with the die key aligned with the keyway of the jig. Set each size of round die directly in the jig, and lightly fix it with the set screw.

CAUTION O Take care not to overtighten the set screw for fixing the round die. If the set screw is overtightened, the die may tilt, making it impossible to keep the top and bottom surfaces parallel.

Fix the jig holding the die in the scroll chuck mounted as standard accessory on the table as shown at right Before fixing the jig with the scroll chuck, be sure to clean the jig contact surfaces of the chuck jaws and the bottom surface of the jig.

I — I I

0

@ SCROLL CHUCK

V-2

Type C (2"), D (3-1/2"), and E (4-1/2") dies [Long and short dies] The scroll chuck supplied as standard accessory and mounted on the table as shown below is used for grinding the 2", 3-1/2", and 4-1/2" dies without special jigs. The 2" die is fixed in the lower stage of the scroll chuck, and the 3-1/2" and 4-1/2" dies are fixed in the upper stage of the scroll chuck. Be sure to clean the die contact surfaces of the chuck jaws and the bottom surface of the die.

When grinding a large-diameter die, some portions of the die top surface may be left unground, despite the cleaning of the chuck jaws and die. In such a case, the die may be bowed. Grind the bottom surface of the die. Grind the entire bottom surface of the die, check that no portions are left unground, and grind the top surface of the die. The top and bottom surfaces of the die can be thus ground parallel.

VIII-3 -1

METHODS AND JIGS FOR GRINDING PUNCH BODIES

The methods and jigs for grinding the punch bodies to be used on the machine are described below.

Type A (1/2") and B (1-1/4") punches [Long punches] Remove the guide from the punch, and fix the punch with the spring in the scroll chuck as shown below. The punch body alone can be fixed for grinding, of course. There is no special jig. Be sure to remove the slug ejector.

ACAUTION * After grinding a punch body with a spring, blow off all water from the spring, and apply rust-preventive oil to the spring.

VIII-4 -1

Type A (1/2") and B (1-1/4") punches [Short punches] Fix the punch using the optional spacer jig as shown below. The jig is used for both 1/2" and 1-1/4" punches. It is turned over for use on either size of punch. Remove the guide from the punch, install the punch with the spring in the jig, fix the punch with the set screws, and fix the assembly with the scroll chuck. When fixing the punch body alone, screw its end into the hole of the jig, and install the assembly in the scroll chuck. Be sure to remove the slug ejector.

Short punch body spacer

A CAUTION ® A f t e r 9 r i n d i n9 a punch body with a spring, blow off all water from the spring, and apply rust-preventive oil to the spring.

VIII-5 -1

Type C (2"), D (3-1/2"), and E (4-1/2") punches without shear angle [Long and short punches]

Remove the punch body from the guide, and fix it with the scroll chuck as shown below. Be sure to remove the slug ejector.

VIII-6 -1

Type C (2"), D (3-1/2"), and E (4-1/2") punches with shear angle [Long and short punches]

When the punch body is 2" or larger in diameter and has a standard shear angle of 2°, it requires the optional shear angle jig shown below. The body of the jig is designed for the 4-1/2" punch. For the 3-1/2" and 2" punches, a sleeve is installed on the jig, and the punch body is set in the sleeve. The jig is fixed with the scroll chuck.

Shear angle jig assembly

1 The key bolt is installed in the base plate of the jig and marked with a double circle. Set the jig in the scroll chuck so that the key bolt faces the front of the machine.

2 Align the key of the punch body with the key bolt, slightly tilt the punch body, and gently set the punch body in the jig. Never hammer down the punch body into the jig. Once the punch body is set in the jig, lightly turn it. Since the key is located at 90° with respect to the cutting edge in the longitudinal direction, the shear angle can be seen from the front of the machine. The jig has an angle of 2°. Check that the side of the cutting edge to be ground naturally becomes horizontal.

VIII-7 -1

3 Lightly tighten the set screw at the circumference of the ring to fix the punch body.

4 The base plate and taper plate are provided with match marks. Holes are drilled in the match mark position and in the 180° opposite position for inserting and screwing the locate pin. Align the match marks of the base plate and taper plate, and screw in the locate pin for positioning the punch.

5 Grind one side of the cutting edge in that condition.

6 Remove the locate pin, turn the base plate through 180°, and screw in the locate pin. Check that the match mark size of the base plate is different from that of the taper plate.

7 Check that the other side of the cutting edge is horizontal, and grind it

Shear angle jig assembly

ACAUTION 9 When grinding a punch with a shear angle, never change the preset grinding amount of each side during the grinding operation. Otherwise two sides of the cutting edge will be ground to different lengths.

When grinding a 2" or 3-1/2" punch body with a shear angle, install a sleeve for each size in the jig shown above. Set the sleeve in the ring of the jig, and fix it with the set screw. Set the punch body in the sleeve, fix it with the set screw, and grind it in the same way as described for the 4-1/2° punch body.

A CAUTION * whatever grinding method to be used, be sure to clean the jig and punch of any foreign matter before setting the punch in the jig. Otherwise the cutting edge of the punch may not become horizontal or the grinding wheel may be chipped during the grinding operation. After its use, be sure to clean the jig, apply rust-preventive oil to it, and store it.

V-8

METHOD AND JIGS FOR DRESSING GRINDING WHEEL

The method and jigs for dressing the grinding wheel are described below. Dress the grinding wheel with the accessory dresser by the same procedure as described for test operation. Dress the grinding wheel as soon as it grinds tools not in the grinding mark condition but in the mirror condition or the spindle motor current continues to be in the vicinity of 6.0 A during the grinding operation. When the grinding wheel is frequently used for grinding Type D (3-1/2") or E (4-1/2") dies, it is likely to be loaded. Check the grinding wheel for loading as often as possible. When these large-diameter dies are made of high-speed tool steel (SKH), be sure to dress the grinding wheel every three grindings. Otherwise the machine may be frequently stopped by the spindle motor 9verload protection function. Dress the grinding wheel as described below.

1 Set the dress stick in the dresser holder, lightly fix it with the accessory set bolt, and fix the dresser holder with the scroll chuck.

2 Set the GRINDING DATA SET digital switches at "08" for the US machine and at "20" for the EXR machine, and press the ONE CYCLE AUTO START button. The dressing of the grinding wheel is completed when the automatic operation is completed.

AWARNING * T h e d r e s s s t i c k l s mad6 of special conductive material. If a dresser not specified by us is used, the machine cannot position the grinding wheel at the start of automatic operation, resulting in the breakage of the dresser and grinding wheel. Never use such a dresser.

VIII-9 -1

jSPfev Part V I

Changing grinding wheel Vf-2 Lubricating with grease VI-4 Changing and disposing of coolant VI-5 Changing acrylic sheet of front door VI-6

VI-l

CHANGING GRINDING WHEEL The timing and procedure for changing the grinding wheel are described below.

Timing for changing grinding wheel The grinding wheel is about 5.0 mm (0.197") thick. Since there is a 0.5-mm (0.020") thick adhesive layer between the abrasive grains and wheel, the actual thickness through which the grinding wheel can be used is about 4.5 mm (0.177"). The life of the grinding wheel changes with the grinding conditions. The grinding wheel is worn by about 0.001 mm (0.00004") and 0.03 mm (0.0012"), respectively, when it grinds a Type B (1-1/4") die and a Type E (4-1/2") die by 0.1 mm (0.004") each. The abrasive grains cannot be reapplied to the grinding wheel.

Procedure for changing grinding wheel Change the grinding wheel as described below.

1 Be sure to turn off the main power circuit breaker switch of the machine.

2 Wipe off water from the grinding wheel with waste cloth.

3 Remove the four M6 bolts securing the grinding wheel to the grinding wheel head. Cover the holes of the scroll chuck with waste cloth or the like so that the bolts are not dropped into the scroll chuck.

4 Remove the grinding wheel from the grinding wheel head.

5 Install the new grinding wheel in the grinding wheel head by reversing the above procedure.

VI-2

GRINDING WHEEL HEAD

CBN GRINDING WHEEL

Place waste cloth or like to prevent dropping of bolts into scroll chuck.

A WARNING The specified conductive grinding wheel alone can be used. Never use commercial grinding wheels. Use of such a grinding wheel breaks the machine. The grinding wheel has air and coolant nozzles at its rear surface. Wear protective gloves so that you do not get your hands hurt.

VIII-3 -1

LUBRICATING WITH GREASE Periodically lubricate the following parts of the machine with grease.

Lubrication methods: Lubrication with grease gun from centralized grease lubrication manifold and grease nipples

Manual lubrication interval: One month Recommended lubricant No. 1 grease

BALL NUT

SLIDING PART CENTRALIZED GREASE LUBRICATION MANIFOLD

Ball screw and LM guides are lubricated from centralized grease lubrication manifold to which grease is added every month.

SPINDLE

VIII-4 -1

CHANGING AND DISPOSING OF COOLANT Change and dispose of the coolant as described below. A lack of the coolant causes air to be drawn into the coolant pump. The resultant low discharge rate of the coolant bums the grinding wheel and a tool. When the coolant is contaminated with a large amount of grinding chips, the tool is ground with poor finish. To prevent these phenomena, properly change the coolant as described below.

Changing coolant Changing timing Be sure to change the coolant every month, irrespective of the operating frequency of the machine. Be sure to check the coolant for level and contamination before the start of work every day. When the coolant is low in level or dirty, change it immediately, regardless of the interval specified first Do not add a fresh coolant to the one already present in the coolant tank. When the coolant tank is dirty, clean it as well.

Changing procedure A label indicating the low mark is affixed to the coolant tank. Add water to the coolant so that the coolant is diluted 30 to 50 times and in a sufficient amount to rise above the low mark.

Specified coolant As coolant use the TOGU GRINDING OIL (Amada).

Prepare the coolant so that it is diluted 30 to 50 times and in a sufficient amount to rise above the low mark. After removing the coolant tank to change the coolant, replace it by positioning it against the stopper bolts in the machine frame.

AWARNING * Never add a fresh coolant to the one already in the coolant tank. Unless the entire coolant is changed at a time, some of the grinding chips and other foreign matter remain and continue to contaminate the coolant. Such a dirty coolant has a serious effect on the finish of ground tools and causes the failure of the coolant pump.

VI-6

Disposing of coolant It is prohibited to dump the used coolant It must be incinerated and landfilled as prescribed by applicable law. If you cannot take this route, ask an authorized contractor to dispose of the used coolant. The material safety data sheet of the coolant used on the machine is attached in Part VIII. For the detailed precautions on the disposal of the coolant, refer to the material safety data sheet

CHANGING ACRYLIC SHEET OF FRONT DOOR

The front door of the machine uses an acrylic sheet so that the grinding condition can be seen. Change the acrylic sheet when it is cracked or otherwise damaged. The acrylic sheet is screwed to the frame of the front door. Be sure to change it for the specified repair part If the specified repair part is not available in an emergency, use a commercial acrylic sheet of 6.0 mm (0.236°) or more in thickness.

AWARNING * When you must use a commercial product in an emergency, be sure to use an acrylic sheet of the thickness specified in the manual. When a thinner acrylic sheet or sheet of different material Is used, pieces of the tool, if broken during grinding, may break through the sheet in a dangerous manner.

VIII-6 -1

Alarm indication W" 2

Troubleshooting VU'4

VII-1

ALARM INDICATION

Each alarm is described in detail below together with its clearing method.

When the machine develops an operating trouble, it is indicated as an alarm by one of the rotating beacon lights in the signal tower. The alarms that can be indicated by the signal tower are described below. RD (Red) light ^ s

On: Servo alarm flir pressure rlrnp

Low coolant water level

YE (Yellow) light Blinking: Battery alarm <T , * ^ (yellow)

RD (red)

GL (green)

Servo alarms Servo alarms refer to servo system troubles and are classified into the following main types: Overload: This alarm occurs when the servo motor used to move the spindle meets the greater than specified resistance. Motor overheat: This alarm occurs when the heat generated in the servo motor exceeds the preset level. It is likely to occur especially when the grinding wheel is used as loaded for a long period of time. Pulse overflow: This alarm occurs when the actual number of motor rotation pulses is different from the commanded number of motor rotation pulses. Remedy: Each alarm can be cleared by pressing the EMERGENCY STOP button and canceling the servo command. After clearing the motor overheat alarm, allow 1 to 2 min before restarting the servo motor.

Low coolant water level

Check water level.

Clean the filter ( I f it Water level get low doing grinding )

VII-2

This alarm occurs when the program backup battery installed in the sequencer has run down. Remedy: Change the battery. The battery lasts about four years when the machine is used every day. Type of battery: AFB8801 (Matsushita)

VIII-3 -1

TROUBLESHOOTING

VIII-4 -1

No Is motor trying to run?

VIII-5 -1

( ® Automatic operation cannot be started)

Check that serve alarm is

or machine front door interlock is activated

Check that red li tower is illuminal

ght of signal ed

Return to normal condition

Press ONE CYC START button

LEAUTO

Check input of si port X09

squencer input

Yes Push button switch is faulty or power is disconnected

If red light of signal tower comes on momentarily after activation of air blow mechanism and goes out after end of automatic operation, air pressure is low. If air pressure can be raised, make necessary adjustment

If spindle moves up but not down, refer to trouble ©

Does grinding wheel rotate?

VTI-6

Machine cannot position grinding wheef)

Check that posit becomes effectiv automatic operal

oning circuit re as soon as Jon is started

Check output of output port YOD

sequencer

Yes Sequencer is faulty

Check that positioning enable relay KAD turns on

Yes Check power supply. If it is normal, KAD is faulty

Check that signal line is fixed to spindle

Check signal line at terminal block in electrical box

Check input of positioning complete signal to sequencer

Check input of sequencer input port X06

Yes Recheck conductivity of tool, grinding wheel, and signal line

Check output of positioning complete signal from sequencer

Check output of sequencer output port Y03

If output is not available, sequencer is faulty

VIII-7 -1

VIII-8 -1

(I Coolant pump does not rotate

If coolant pump rotates after start of grinding, but coolant is not discharged, coolant is insufficient. If pump stops rotating, motor overload protection thermal relay is tripped

Check operation of magnetic contactor KM2 operating at output of KA1

Remove cause of overload, and reset thermal relay

If coolant pump does not rotate even though thermal relay is not tripped, check output of coolant pump rotation signal from sequencer

Check output of sequencer output port Y01

Check operation of relay KA1 receiving sequencer output

Check power supply. If it is normal, KM2 is faulty

If power line is normal, coolant pump is faulty

Sequencer is faulty

Check power supply. If it is normal, KA1 is faulty

VIII-9 -1

VII-10

VII-11

Part VIII I

Material safety data sheet VIII-2 Mechanical parts list VIII-7 Electric circuit diagram VIII-10 Electric parts list VI11-16

VII-1

MATERIAL SAFETY DATA SHEET Manufacturer information

Manufacturer's name: Amada Co., Ltd. Address: Ishida 200, Isehara, Kanagawa Prefecture, Japan Phone: 0463-96-3456 or 048-281-7767 Fax: 0463-96-3228 or 048-281-7768

Prepared or established: April 1st, 1998

Product name Product name: TOGU GRINDING OIL

Product identification Single product or mixture: Mixture Chemical names: Organic rust inhibitor, alkali agent, water-soluble special lubricant, fatty acid derivative, biocide, other additives, water Ingredients and contents (characteristic values):

Organic rust inhibitor 22% Alkali agent 48% Water-soluble special lubricant 10% Fatty acid derivative 19% Biocide and other additives 1 %

Chemical or structural formula: Not identifiable UN classification and UN number Not applicable

Dissolve these ingredients in soft water, and adjust their concentrations as required.

Hazard and toxicity classification Classification: Not classified as flammable Hazard: Nonhazardous material under normal use Toxicity: Alkaline and causes dermatitis after prolonged or repeated skin contact Environmental impact: No useful information is available.

First aid measures Eye contact: Flush eyes with clean water for at least 15 minutes, and call a physician. Skin contact: Immediately wash with plenty of water and soap water, and apply skin adjustment cream to skin. Inhalation: Move to fresh air, cover with blanket or the like, keep warm and still, and consult a physician if necessary. Ingestion: Immediately induce vomiting, and consult a physician. If mouth is contaminated, wash it with plenty of water.

VI11-2

Fire fighting measures Fire fighting instructions: Usually difficult to ignite. Combustible if water evaporates. Extinguish a peripheral fire developed in such a case as described below.

1. Remove the ignition source. 2. Use powder or carbon dioxide extinguishing medium on the initial

fire. 3. Blocking supply of air with foam extinguishing agent is effective

against large fire. Water expands the fire and is dangerous. 4. Shower water on surrounding equipment. 5. Fight the fire from upwind. Be sure to wear protective equipment. 6. Prohibit unauthorized personnel from entering the area around the

fire.

Extinguishing media: Powder, carbon dioxide, foam, and strong foggy liquid are effective. Never use water in jet form.

Accidental release measures Remove all ignition sources. Large spill: Prohibit entry into the area of the spill by roping off the area. Be sure to wear protective equipment. Block flow of the spilled product with sand, guide it into a safe place, and recover it with a container as much as possible. Prevent the run-off of the spilled product to sewers, streams, or other bodies of water. Small spill: Absorb the spilled product on sand, waste cloth, or sawdust, and transfer it into a container. Spill on sea: When the spilled product floats on the water surface, spread an oil fence to prevent the expansion of the spill, and absorb the spilled product with absorbent mat or the like.

Handling and storage Handling: 1. When the product enters the eyes, it may cause inflammation.

When handling the product, avoid contact with the eyes by wearing protective goggles or the like.

2. When the product gets on the skin, it may cause inflammation. When handling the product, avoid contact with the skin by wearing protective gloves.

3. Do not ingest. (Ingestion may cause diarrhea or vomit) 4. Inhalation of mist or vapor may cause discomfort. When handling

the product, use a breathing apparatus or the like, in order to avoid inhalation of mist or vapor.

5. Place the product where it cannot be reached by children. 6. When using the product, refer to its catalog, check the dilution ratio,

and dilute to the specified ratio with water. 7. Do not apply pressure to an empty container. Otherwise the

container may break. 8. Do not weld, heat, drill, or cut the container. The product residues

in the container may ignite and explode.

VIII-3 -1

9. Avoid contact with flames, sparks, or hot materials. 10. When repairing mechanical equipment where the product remains,

move the equipment to a safe place, and remove the product from the equipment

11. Never siphon off the product with the mouth.

Storage: 1. After use, tightly close the container to prevent contamination with

dirt, dust, moisture, or the like. 2. Keep the container in a dark place to avoid exposure to direct

sunlight 3. Prevent the container from freezing.

Exposure controls/personal protection Engineering controls: Totally enclose the source of the mist or provide ventilation. Personal protective equipment

Respiratory protection: Not usually required. Wear an organic gas mask if necessary. Eye protection: Wear goggles where the product splashes. Skin protection: Wear oil-resistant protective gloves for prolonged or repeated contact with the product Protective clothing: Wear oil-resistant long-sleeved working clothing. As soon as clothing is wetted by the product, remove it, completely clean it, and rewear it

Physical and chemical properties Appearance, etc.: Dark blue and transparent liquid Boiling point: No data Vapor pressure: No data Volatility: None (at room temperature) Melting* point: Not applicable Specific gravity: 1.072 g/cm3 (1.051 kdyn/cm3) at 15/4°C Initial boiling point: No data Solubility in water: Homogeneous solution in water @ 15°C Pour point: -15.0°C or less Others:

Hazard information (stability and reactivity) Flash point Not applicable Ignition point Not applicable Explosion limit: Not applicable Combustibility: None, except when moisture evaporates Ignition: None (spontaneous ignition and reactivity with water)

VIII-4 -1

Oxidizing: None Self-reaction and explosion: None Dust explosion: None Stability: Stable Incompatibility: Avoid contact with strong oxidizing agents. Others: No useful information is available.

Toxicological information (including case and epidemiological information)

Skin cauterization: No data Skin and eye irritation: Prolonged or repeated contact may cause irritation. Skin sensitization: No data Acute toxicity (including lethal dose 50%): No data Subacute toxicity: No data Chronic toxicity: No data Carcinogenicity: No data Mutagenicity (microbial or chromosomal abnormality): No data Reproductive toxicity: No data Teratogenicity: No data Others: No useful information is available (including generation of toxic gas by reaction with water).

Ecological information Degradation: No data Accumulation: No data Aquatic toxicity: No data Others: No useful information is available.

Disposal considerations Waste disposal: Recycle or dispose of in accordance with prevailing regulations, preferably to a recognized collector or contractor. The competence of the contractor or deal satisfactorily with this type of product should be established beforehand. Container disposal: Metal containers should be emptied and returned to the supplier or sent to a container reconditioner without removing or defacing markings or labels. Non-reusable small metal and plastic containers should be recycled where possible, or disposed of as domestic refuse.

VIII-5 -1

Transportation information Check that the product has not spilled from the container or is not likely to spill from the container. Transport so that the container is not excessively abraded or swayed. Not dangerous for conveyance under UN, IMO, ADR/RID and IATA/ICAO codes.

Regulatory information EC CLASSIFICATION: Not classified as dangerous under EC criteria ElNECS (EC): All components listed or polymer exempt TSCA (USA): All components listed MITI (JAPAN): All components listed

Other information Contact: Refer to "Manufacturer information" in this section. This material safety data sheet is furnished to users who handle the product as reference information to ensure safe handling. The users should refer to the material safety data sheet and use the product with the understanding that they must handle the product by appropriate methods under their own responsibility. The material safety data sheet is not to be taken as a safety warranty.

VIII-6 -1

MECHANICAL PARTS LIST



See next Page

Vlll-7

< SPINDLE UNIT >

VIII-7 -1

No. Item No. Part Name Type 1 Drawing No. Maker Qty

1 74081101 COUPLING ASJU35-12/ASJU26-8 ASA DENSHI 1set

2 74081102 SUPPORT UNIT SUP 15K/7002DF/GMP5 HIWIN 1set

3 BALL SCREW COLLAR 5103538-2 TAIWA 1

4 74081103 BALL SCREW R20-5B1 -SSV-470-560-0.05 HIWIN 1set

5 74081105 LM GUIDE LGH20-CA-L640-Z1 -C HIWIN 2sets

6 BALL NUT SPACER 5103539 TAIWA 1

7 OT US DOG 5103544 TAIWA 1

8 74081104 SUPPORT UNIT SUP15-S/6002ZZ HIWIN 1set

9 74081106 COUPLING A 5109594 TAIWA 1

10 74081107 COUPLING B 5109595 TAIWA 1

11 74081108 SPINDLE 5109599 TAIWA 1

12 74081109 BEARING 7012-5DBLP5 KOYO 1set

13 74081110 PLASTIC SPACER 5109596 TAIWA 2

14 74081111 SPACER 5109601 TAIWA 1

15 74081112 BEARING UNIT 5109600 TAIWA 1

16 74081113 HOUSING 5109597 TAIWA 1

17 SPINDLE COVER 5109602 TAIWA . 1

18 74081115 NUT WASHER 5109603 TAIWA 1

19 CBN GRINDING WHEEL 5109604 TAIWA 1

20 74081116 SCROLL CHUCK 5103577 f & S o V Z TAIWA 1

21 |CHUCK PLATE 5103562 - T & S C J Z * > TAIWA 1

22 {TOP PLATE 5103563 TAIWA 1

23 j WATER DEFLECTOR RING 5103571 ^ TAIWA 1

24 | BEARING RETAINER 5103569 TAIWA 1

25 | COLLAR 5103565 -f6 TAIWA 1

26 I OUTER CASING 5103570 TAIWA 1 27 j BEARING HOLDOR (OUTER) 5103567 gO TAIWA 1 28 ! BEARING HOLDOR (INNER) 5 1 0 3 5 6 8 - ^ Ôtt TAIWA 1 29 74081126 | BEARING 32020JR T& KOYO 2 30 | SPACER 5103573 7TP 'SOS? TAIWA 1 31 j BEARING NUTWASER 5103574 S ^ S t o TAIWA 1 32 BEARING 5103564 T & S ^ S V TAIWA 1 33 LUBRICATION MANIFOLD 5109605 fCr TAIWA 1 34 74081130 GAS SPRING GS075-3036C/GS068-3016C TOKIKO 2sets 35 74081131 DOOR SWITCH KEY D4DS-K3 OMRON 1 36 PULLEY BUSHING SPZ90-21610-019 NBR 1

VIII - 8

No. Item No. Part Name Type / Drawing No. Maker Qty 37 74081133 V-BELT 3VX265 BANDO 2

38 O-RING ISO C-1650G NOK 1

39 O-RING G-140 NOK 2

40 BELLOWS 5103610 TAIWA 1

41 AIR FILTER REGULATOR AW3002-02BG-Q SMC 1

42 COOLANT TANK G-34 MITSUBISHI 1

43 FILTER CASE 5103642-2 TAIWA 1

44 FILTER 5103642-3 TAIWA 1set

45 ELECTRODE BRACKET 5103642-5 TAIWA 1

46 BRACKET COVER 5103642-4 TAIWA 1

47 CONNECTOR OAW-1609 OHM 1

48 ELECTRODE HOLDER BF1 OMRON 2

49 ELECTRODE 7 6SUS L=150,180 SMC 1set

50 LEVELING BOLT DC-1M12 x 65 IZUMI 4

51 1/2,1-1/4 inch die Jig 5103670 TAIWA —

52 2 inch roof top punch body sleeve 5108442 TAIWA —

53 3-1/2 inch rooftop punch body sleeve 5108441 TAIWA —

54 J 4-1/2 inch roof top punch body sleeve 5108360 TAIWA —

55 : 4-1/2 inch Jig taper plate 5108361 TAIWA _

56 14-1/2 inch Jig base plate 5108.632 TAIWA —

57 14-1/2 inch Jig ring 5108363 TAIWA

58 i4-1/2 inch Jig Die locating pin 5108364 TAIWA —

59 •4-1/2 inch Jig Die locating pin 5547795 TAIWA —

60 14-1/2 inch Jig Shaft 5108365 TAIWA —

61 14-1/2 inch Jig locating pin 5106367 TAIWA —

62 | Roof top punch body sleeve (3°) 5108361-B TAIWA - -

63 Roof top punch body sleeve (4°) 5108362-C TAIWA | —

64 | Roof top punch body sleeve (5°) 5108363-D TAIWA —

65 jl/2 inch Rooftop punch body sleeve 5103671 TAIWA —

66 1-1/4 inch Rooftop punch body sleeve 5103661 TAIWA —

67 Spacer for Thin type punch body 5103662 TAIWA —

68 74081150 DRESSER 5103661 TAIWA —

69 DRESSER HOLDER 5103662 —

70 74081151 GRINDING OIL FOR TOGUIII (020443) 4L AMADA —

71 74081152 j FILTER 5103672 —

72 74081132 SPINDLE ASSEMBLY TG3056 TAIWA —

VIII - 9

imMSSMIffl

AC 200 V

" K f f l

<-o-

NOTE 1 Schaflner noise filter is used only CE machine. NOTE 2 Installed only on CE machine.

UL.10GD-I40.0m0 VSGN >6GN

mi

(5-C)

eiH

GRINDING WHEEL & TURN TABI.e MOTOR ON

KM2

(5-B

12

Zt ED-— 3 > GOOLtNQ IVrt TSR PUMP MOTOR ON

MODEL APPROVED CHECKED DESIGNED

KWA '99.08.28

TOGLH3

SAKAGAMI '99.08.27

YCKDYAMA '99.08.26

UNIT BBJIHC

DRAWN MacriAMA '99.08.26

SCALE

A t m m t m

NAME

DWG. No.

MAIN PCJ/yffVMOTOR CONTOL CIRCUIT

FAGB/6

5'5!4'8!6!l!9l !

KD

o ~

vin-io

RK1-R COOLING WATER 1ANK

NOTE 1 Installed on machines other than CE machina

nam/ DC34V

r ?

i GROUK3 "IHWINAL

RK1-F)

AC200V/ 0C5V

R A GROIN) mONAL

GE

HOTE1 LVS1

J C

MACMNg I 1 I W I

r0n HU

I

CQQLINQ hm res iFVPt nnwu

(4-0

SERVO AMP POWFR

AR351I

MICFD SBX104Cff(C32T)

•j •24V

OPERA TION POWER

I N PUT OUTPUT POWFR

SFRVO I/O POWER

MODEL APPROVED CHECKED

'99.08.28

TOGU-3

SAKAGAMI 'S9.0a27

DESIGNED YDKOVAMA '99.08.26

UNIT BHJTHC

DRAWN VCKDYAMA '99.08.26

SCALE NAME

& i i m m n m m m ©s iLm DWG. No.

CONTFDLFOAeR CIRCUIT

FAGE2/6

sisflsjeft'o

KD

CD 0

VIII-11 -1

R24 N24

KAE

o-n

C37TUNIT

AI2

PUTRJTCQNNgiTCfl JEFM3 CFFOUT B5 RUSE CUT DIRCCW COUNTS? FEEET

Qy AZA3

B4 A4

INRJTCQNNffiTCF B13 A13

QV

SBM? MP CN1

K+24V)

2<GND)

CNS 2(+5V) l ( G N D )

3(S-CfF) 4(RS 5CDIR

«CO

70NPO) 8CALM)

CN2

> >

(GN0)1 <HW>2 (HV)3 (HU)4

(+1W5 (TH36

(Ll)a (1239

(L3310

CN5 (GND)1 (+SV)2

( A ) 3

(04

(Z)5 troa

IN POSITION

HFM) ALAfM

MACHINE

sakQMaie 1

M-4 JOfl 2.SA

SERVO S PEC I Fl C A TIP £L BALL SCREW P = 5 mm Direction of PULSE MOTOR j.0 0 O.P/R e e d speed high 3 0 0 m m / m in (10kHz)

middle 3 0 m m / m i n (1kHz) , „ „ e low 0 . 0 6 m m / m i n ( 2 H z )

MODEL APPROVED

K3WA '99.08.28

TOGU-3 CHECKED SAKAGAMl '99.08.27

DESIGNED YCKOYAMA '99.08.26

U N I T ELB3TRC DRAWN

YCKOYAMA '99.08.26

SCALE

M A / h m mimess rnîm V I I I - 1 2 -1

NAME

DWG. No.

SEFMD CONTROL CIRCUIT

FAGE3/6

5548621

K£>

CD

"o"

NOTE 1 Normally opened. Short-circuited only on C£ machine. NOTE 2 0.001 arid 0.01 are applied in piace of 0.01 and 0. I.respectivery.ordy to US machine.

camiwrrrNan-CHS

(A) 9

(BIO

CALM) 3

XX) B13

Ml AI3

B11

LVS1 KAE

0-R

XH

TOOL r L

GRNOKQ rthffi. UL1QQ7-1B(OL75ITTOEE (5-D)

MIA EMI

U

MB

X£

X 507

f j 1 SB3CWTH CUATO)

X X)A

SAfOY DOOR LOCK SW

SQ1

UL2<84TA- 20- <X(X 5nn) —O X30

XO

U12WR-20-2(O.W 9Q2

All

BIO

Bt2

AIO

08

AS

A3

B&7

SCNAINAME XX)

XF

X)7

XX)

• CF

PULSE IN PUT PULSE INPUT

'JL PH A SE B PHASF•

f U f H f l f H f l y S T O P INPUT spnvn ai abu

GQNOUGTtON of g L f e rw> c ; r y

NOTE? GRINDING DATA SFT uPfo ni) i GRINDING data sft tlt>< a o i V-> GRINDING OL SET UP( 0 0 I A TA JUL GRINDING SET UP(0Z * TA GRINDING 0. SFT llPtd II A TA GRINDING a SFT UP(0 I )

L A TA UL

GRI NOING a. SFT UPfO t ) A TA QRtNQt SET UP jul a ULLLL ASA. LJL

GRINDING whffi LLE.

down WHEEL

ONE r.vr.iF AiiTn , START STOP AND GRINDING WHEEL LLR PRONT DOOR CLOSE "

FBONT go p R CLOSE * GRINDING whffi UPPER LIU I T

MODEL APPROVED

WNA 'S9.08.28

T0GLH3 CHECKED SAKAGAMI •99.08.27

UNIT DESIGNED YCW3YAMA '99.08.26

EBDTHC DRAWN

YOKOHAMA '99.08.26

SCALE NAME

DWG. No.

SEQUENCE CIR3UIT (INRJD

FAGE4/6

5|5|4]8|6| 2I

KD

CD 0

VIII-13

NOTE 1 a001 and <L0t are applied tn place of 0.01 and 0.1, respectively,only to US machine.

fittTlIKrr OUTPUT N24 RZ4

SQNALNAME

n s r

V04

VCO

BIS

I 1 A1S r ^ n — > >

814

A14

B13

A13 W5 | »

BI2

At 2

A7

AS

1 M XF I »

82 83

\00 KM

Y)1 KA1

— - — 01 V2

VQ2 HUCWD

£83

HA1

V04 KM

KT1

SIGNAL

W

ya

M2A

VOB

VOC

(USSBWDAMP

SGNALTCVfR

SIGNAL IDAfit

\oa oswi(aoi)

toe oswi(ai)

MX: ssiuoaFamjT

ICO

\ce

w

DIR DtR CCW

a. couNVtfsr

BIOW

POOLING WATFR PUMP MOTOR ON

•*TA ITT LAMP ( WHITF)

UL POSITION BUZ7FR

GRINDING WHEEL S TURN TABLF MOTOR ON FRONT tiOOR I N TERt.OG ft timfr

SIGNAL TOWFR < RFH >

pulsf OUTPUT

PULSF OUTPUT

SIGNAL towfr ( YFt LOW)

SIGNAL TOWER ( ORFFN> NOTEt

GRINDING DATA NOTE!

GRINDING DATA SFT UPf O I )

CONDUCT! ON OF ELEO TRIO I TY QJL

• • •

MODEL APPROVED

KIWA '99.08.28

T0GU-3 CHECKED SAKAGAM] •9aoa27

DESIGNED VDMOVAMA •99.0a 26

UNIT ELB3TRC DRAWN

YOKOHAMA '99.08.26

SCALE NAME

DWG. No.

SEQUBMCE CIRCUIT (OUTRJT1/2)

FfcGB/6

5|5!4!8|6|2!3

KD

CD 0

VIII-14 -1

NOTE 1 On machines other than CE machine.

R4

KM W1 UL2WR-2t>-3(Q.5rm)

O (5-ED

KTI

r GROUND TffMJNAL

(5-D)

f~ cMmnruD

Yfl UL2434TA- 20- 6(0.5m0 O

(S-O)

(5-0

(5-F5

J

m F-3

MACHIWP

WI

SAfBYOOORUXK SW

YV2

SQNALWB IHXRJ)

IHJ OS

<8H

US (GN)

N24

1 ^ |

AIR R LOW

PROMT POOR IN TERI.OOK

ON: FRONT DOOR OPEN SERVO A I ARU emergengy stop LOW COOLINO WA res ^ ^ tsmi

ON; POWER. ON EMERGENCY stop in OPERA TtON BLINKING; ba ttery a larv S T OP. and grinding WHEEL UP

ON; ONE cycle auto STA RT RUN KINO-SPARK OUT

+ >4V

MODEL TOGU-3

APPROVED CHECKED '99.08.28

SAKAGAMl '99.08.27

UNIT arn iHc

DESIGNED YGKOYAMA

'99.08.26

DRAWN YOKDYAMA

'99.08.26

SCALE NAME

DWG. No.

SEQUENCE CIRCUIT (OUTFUT2/2)

FAGB5/6

5I5I4I8I6I2I4

KD

CD 0

VIII-15 -1

No. Symboljtem Location Part Name Type I Drawing No. Maker Qty

1 FL1 1-A •1 NIOSE FILTER (CE) FN258-16-29 SCHAFFNER 1

2 FL1 1-A *2 NIOSE FILTER (EXP) 3SUP-HL30-ER-6B OKAYA DENKI 1

3 1-B *1 FEERITE CORE (CE) MSFC13KEX OKAYA DENKI 1

4 QF1 1-C CIRCUIT BREAKER EG33B/20-30MA FUJI 1

5 QF1 1-C CIRCUIT BREAKER HANDLE BZ-V20C-E FUJI 1

6 PA1 (74081006) 1-D AMMETER FS-45 (10A) FUJI 1

7 Z1 1-D SURGE ABSOBER SZ-ZM2 FUJI. 1

8 M-1 (74081008) 1-D GRINDING WHEEL MOTOR VTFO-5 (1.5KW2P) HITACHI 1

9 M-2 (74081009) 1-E TURN TABLE MOTOR CA19-010-30 (0.1 KW) HITACHI 1

10 Z2 1-E SURGE ABSOBER SZ-ZM2 FUJI 1

11 M-3 (74081011) 1-E COOLING WATER PUMP NPJ-60 (60W) MITSUBISHI 1

12 QF2 1-F CIRCUIT PROTECTOR CP32T/5-S (5A) FUJI 1

13 KAE 1-F RELAY MY2N-CR OMRON 1

14 KAE 1-F RELAY SOCKET PYF08A OMRON j 1

15 SB5 1-G PUSH BUTTON SWITCH AH22-VJR02 FUJI 1

16 KM1 1-H MAGNET CONTACTOR SW-03 AC200V FUJI 1

17 FR1 1-H THERMAL RELAY TK-ON (5-8A) FUJI 1

18 Z3 1-H SURGE ABSOBER SZ-Z5 FUJI 1

19 KM2 1-1 MAGNET CONTACTOR SW-03 AC200V FUJI | 1

20 FR2 1-1 THERMAL RELAY TK-ON (0.48-0.72A) FUJI | 1 21 Z4 1-1 SURGE ABSOBER SZ-Z5 FUJI | 1 22 LVS1 2-B LEVEL SWITCH 61F-GP-N AC200V OMRON ; 1

23 LVS1 2-B LEVEL SWITCH SOCKET PF113A OMRON | 1 24 HL1 2-C LAMP 5103622-3 (25W) TAIWA | 1 25 AVR1 (74081024)| 2-D SWITCHING POWER SUPPLY S82J-15024 B2 (6.5A) OMRON 1 26 (74081025) 2-E SEQUENCER C32T(l/0-16/16) MATSUSHITA 1

27 AVR2 (74081026) 2-G SWITCHING POWER SUPPLY S82J-2105 (2A) OMRON 1 28 (74081027) 3-A AMPLIFIER DA402-051TW SOFTRONICS 1

29 M-4 (74081028) 3-A SERVO MOTOR DLM6402-051-G (40W) SOFTRONICS ' 1

30 DSW1 (74081029) 4-D DIGITAL SWITCH A7PH-207-1 OMRON | 1 31 DSW1 4-D SWITCH FIXED PANEL A7P-M-1 OMRON 1 1 32 DSW1 4-D CONNECTOR NRT-C OMRON j 1 33 DSW1 4-D DIODE DC24V FUJI | 8 34 4-D EEP-ROM M27C 256B012F1 FUJI [ 1 35 SB1 4-F PUSH BUTTON SWITCH AH22-SFW10 FUJI j 1

*1 This parts is applied to CE machine

*2 This parts is applied to US machine

VIII-16

No. Symbol Jtem Location Part Name Type / Drawing No. Maker Qty 36 SB2 4-G PUSH BUTTON SWITCH AH22-SFW10 FUJI 1 37 SB3 4-G PUSH BUTTON SWITCH AH22-SFLW10E3 FUJI 1 38 SB3 4-G SWITCH GUARD AHX760 FUJI 1 39 SB4 4-G PUSH BUTTON SWITCH AH22-SFB10 FUJI 1

40 SQ1 (74081039) 4-H SAFETY DOOR SWITCH D4DL-2CFG-B OMRON 1

41 SQ2 4-I LIMIT SWITCH D2VW-5L3-1M OMRON

42 KAO 5-B THERMAL RELAY G6B-4BND DC24V OMRON 1

43 KA1 5-B THERMAL RELAY G6B-4BND DC24V OMRON 1

44 HA1 5-C BUZZER AH22-XBE DC24V FUJI 1

45 KA4 5-C THERMAL RELAY G6B-4BND DC24V OMRON 1

46 KT1 5-D TIMER H3CR-HBL-M DC24V OMRON 1

47 KT1 5-D TIMER SOCKET P2CF-08 OMRON 1

48 V5 5-D DIODE DC24V FUJI 1

49 KAD 5-H THERMAL RELAY G6B-4BND DC24V OMRON 1

50 W1 (74081049) 6-B SOLENOID VALVE VXZ2230-02-5DS-B-Q SMC 1

51 6-D SIGNAL TOWER L0GS-24-3 RROW DENSH 1

52 F-1 6-G FUSE DC24V 1.0A FUJI 1

VIII -17

Documents

MODEL TG- 610 TOOL GRINDE FOR R TURRE PUNCT PRESH … · 2016-04-25 · Unit Index No. Drawing No. Parts Name Type Q'ty Class Note 1 GX233-18 Knob 1 3 2 GX233-17 Handle 1 3 3 Grinding