JYOTI

STATIC TURRET

Contents TCCH0000001B Page 0.1.1 of 4

 Copyright:

This documentation is intended for the operating, maintenance and

installation personnel. Passing on as well as copying of this
document in full or part is not permitted, nor its use and notification of
its contents. Exceptions must be expressively agreed to 'Jyoti
Automation Ltd.' reserves all rights in the event of a patent granted or
rights for utility model. Infringement will be liable to damages and can
have legal repercussions.

List of contents

1. Safety notes

1.1 Use within specification……………………………….… 1.1.1

1.2 Required skills …………………………………………... 1.1.1
1.3 Notes on product-specific risks…………………………. 1.1.1
1.4 Disposal …………………………………………………... 1.1.2

2. Product description

2.1 Technical data…………………………………………… 2.1.1

3. Assembly and installation

3.1 Hydraulic system …………………...……………………. 3.1.1

3.2 Basic setting…………… ……………………………….... 3.1.2

4. Operation

4.1 Overview ……………………………….……………...….. 4.1.1

Contents TCCH0000001B Page 0.1.2 of 4

 4.2 Tools …………………………………………………..….... 4.1.1
4.3 Tool holders and spindle unit ………………………….… 4.1.2
4.4 Possible faults and remedies ……………………….....… 4.1.3
.

5. Maintenance

5.1 Overview ………………………………….. 5.1.1

5.2 Service life………………………………… 5.1.1
5.3 Service Interval……………….……………… 5.1.1
5.4 Maintenance work ………………………………………. 5.1.2
5.4 Proximity switch SQ4, SQ5 ……………………………… 5.1.2

6. Replacement parts

Contents TCCH0000001B Page 0.1.3 of 4

1 Safety notes
The turret corresponds to the state of the art and the recognized technical safety
rules. Nevertheless hazards and risks can occur.

1.1 Use within specifications

 Install and operate turret only in machines complying with the relevant
regulations for workspace protection.
 Operate turret only in perfect condition and in compliance with the operating
Instructions.

1.2 Required skills

 Work may only be performed on the turret by qualified staff. These are person
who are able to identify risks and to prevent possible hazards on the basis of
their special training and their experience.
 All work on the electrical system is to be carried out by a qualified electrical
engineer only.
 Only trained and competent personnel may work on the turret; these
personnel must have been instructed in accordance with the Operating
Instructions and directly on the turret.

1.3 Notes on product-specific risks

Setting tasks required a 24 V DC power supply.

Clearing required prior to any work:

 Switch the machine off.
 De pressurize turret.

WARNING
Injury hazard.
On startup, unexpected rotation of the tool disk is possible.
 Following installation of the turret, line A must be pressurized first.

WARNING
Injury hazard.
In the event of a fault or a collision, unexpected rotation of the tool disk is
possible.
 Perform any work on the turret, in particular in swiveling range of the tools,
only, if the turret has been de-energized.

Safety notes TCCH0100100A Page-1.1.1 of 2

 WARNING
Risk of Injury posed by moving machinery components.
If power supply and hydraulic or pneumatic circuits are turned on for adjustment
operations:
 Secure workplace with warning sign.
 Prevent actuation by other persons; secure control panel.
 Do not stay close to moving machinery components, especially within the
swiveling rang of the tools.

CAUTION
Functional faults may be caused by ingress of chips and contamination.
 Close open tool locations and cooling lubricant bores by means of suitable
closing plugs.

CAUTION
Do not attempt any further switching operations, If the turret is damaged, as
otherwise considerable consequential damaged may be caused.
 Call JYOTI Service.

1.4 Disposal
 Comply with all national and regional disposal regulations and laws.

Safety notes TCCH0100100A Page-1.1.2 of 2

 2 Product description

Hydraulic operated functions

 Lock and unlock turret tool disc

2.1 Technical data

Turret

Number of indexing position 12 8

Permissible tangential load 3000 3000

(turret locked) Nm
Permissible mass moment of 2.583 2.799
inertia of tool disk,tool holder and
tool kg-m2
Permissible unbalanced 26.798 69.49
(load moment) caused by tool
holders and tools Nm
Permissible indexing frequency 6 min-1 6 min-1
(median switching angle
Hydraulic operating pressure 50 50
bar
Absorption volume lock and unlock 58.28 cm3 (locked) 58.28 cm3 (locked)
turret 13.38 cm3 (unlocked) 13.38 cm3 (unlocked)
Max. Operating pressure for 10 10
cooling lubricant
bar
Turret mass 130 130
(without tool disk, without motor)
kg
Max. mass of tool disk and tooling 105 90
kg
Permissible ambient temperature +10……+40 +10……+40
°C

Product description TCCH0200100B Page-2.1.1 of 6

 Turret drive

SIEMENS FANUC
Number of indexing positions 12 or 8 12 or 8
Nominal speed 3000 3000
rpm
Permissible drive torque 2.6 3.5
Nm
Gear ratio 64 64

1) The data stated here may differ on special versions.

2) The drive motor torque must be limited to the permissible values mentioned for
turret and tool drive.

2.1 Technical data (FOR BMT 45)

Turret

Number of indexing position 12

Permissible tangential load (turret locked) 3000

Nm
Permissible mass moment of inertia of tool 3.661
disk, tool holder and tool kg-m2

Permissible unbalanced (load moment) 44.14

caused by tool holders and tools Nm

Permissible indexing frequency 6 min-1

(median switching angle
Hydraulic operating pressure bar 50

Absorption volume lock and unlock turret 58.28 cm3 (locked)

13.38 cm3 (unlocked)
Max. Operating pressure for cooling 10
lubricant bar

Product description TCCH0200100B Page-2.1.2 of 6

 Turret mass (without tool disk, without 165
motor) kg
Max. mass of tool disk and tooling kg 122

Permissible ambient temperature +10……+40

°C

3) The data stated here may differ on special versions.

4) The drive motor torque must be limited to the permissible values mentioned for
turret and tool drive.

2.1 Technical data (FOR VDI-30)

Turret

Number of indexing position 12

Permissible tangential load (turret locked) 3000

Nm
Permissible mass moment of inertia of tool 2.583
disk, tool holder and tool kg-m2

Permissible unbalanced (load moment) 42.33

caused by tool holders and tools Nm

Permissible indexing frequency 6 min-1

(median switching angle
Hydraulic operating pressure bar 50

Absorption volume lock and unlock turret 58.28 cm3 (locked)

13.38 cm3 (unlocked)
Max. Operating pressure for cooling 10
lubricant bar

Turret mass (without tool disk, without 165

motor) kg
Max. mass of tool disk and tooling kg 23 (TOOL WEIGHT--------)

Permissible ambient temperature +10……+40

°C

Product description TCCH0200100B Page-2.1.3 of 6

Product description TCCH0200100B Page-2.1.4 of 6
Product description TCCH0200100B Page-2.1.5 of 6
Product description TCCH0200100B Page-2.1.6 of 6
 3 Assembly and installation

3.1 Hydraulic system

 The cylinders of the turret are filled with hydraulic oil.

 Both Hydraulic connections are closed.
 The turret is vented.

IMPORTANT

It must be possible to pressurize the hydraulic lines of the turret for locking and
unlocking operations, even if the machine is stopped.

Air penetrates into the hydraulic system of turret during installation and connection to
the hydraulic circuit of the machine.

Air inside the hydraulic system poses a risk to trouble-free turret operation.

After installation and connection:

 Perform the electrical installation of turret.

 Switch on turret motor.
 Switch hydraulic supply on.

WARNING

Risk of injury posed by moving machinery components.

 Secure workplace with warning sign.

 Prevent actuation by other persons; secure control panel.

Assembly and Installation TCCH0300100B Page-3.1.1 of 4

  Do not stay close to moving machinery components, especially within the
swiveling rang of the tools.

IMPORTANT:

 Start with hydraulic line, e.g. Line A. Adjusting pressure for hydraulic line A: max.
60 bar.

WARNING:

Risk of injury by high pressure inside the hydraulic system.

 Do not unscrew venting screw.

 Losses venting screw with a maximum of 2 revolutions, allow the oil to escape
and close the venting screw again.
 Lock and unlock the turret several times over.
 Repeat the whole process several times over.
 For complete venting, the hydraulic line must be vented successively by means
of all venting bores installed.

3.2 Basic setting:

Clearing required prior to any work:

 De-energize turret work.

IMPORTANT

It has to be possible to pressurize the hydraulic line A of turret, even if the machine has
been switched off.

Preparation

 Install turret hydraulic system.

 Reduce hydraulic pressure down to 10 bar.
 Install turret electrically.
 Unlock turret. Proximity switch (1): LED on.

Determining position 1:

Assembly and Installation TCCH0300100B Page-3.1.2 of 4

  Lock turret. Proximity switch (2) LED on. The tool disk performs a slight
rotational aligning movement.
 Unlock turret. Proximity switch (1) LED on.

 Screw knurled screw (2) from the park thread located laterally on the
motor into piston (3).
 Lock turret. Proximity switch (1) LED on.

Assembly and Installation TCCH0300100B Page-3.1.3 of 4

 • LAYOUT DRAWING

SEE ATTACH DOCUMENT

TC0101900

Assembly and Installation TCCH0300100B Page-3.1.4 of 4

 A B C D E F G H

DECLAMP CONNECTION CLAMP CONNECTION

MOTOR

6 6

Proxy for Clamp Proxy for Declamp

5 5

472 for SIEMENS Motor

464 for FANUC Motor

9.5 47 298

2 Holes; 14 H7(+0.018
0 ) X 15 DEEP
ON 158 P.C.D.
FOR TOOL DISC ALIGNMENT
COOLANT CONNECTOR

4 4
M10x1.5 ISO - H TAP 20.000
8.5 DRILL ( 8.500 ) 22.000 -( 12 ) HOLE
WITH C'SINK 12.000 x 90.0
ON P.C.D 158

311
FOR TOOL DISC MOUNTING
190-0.01
-0.02
0
15
CENTER HEIGHT
30
115 0.1

10 No.S
M12 BOLT SIZE
ACCORDING TO DIN 912

10
20 g6(-0.007
-0.020)
3 SCALE 0.250 3

0 34 74 104 134 174

252

140 140

2 2

TITLE: 05
04
03
-: NOTE ASM JST100 LAYOUT 02
IF IN DOUBT PLEASE ASK *
1 ALL DIMENSIONS ARE IN MM * 01 1
DO NOT SCALE THE DRAWING * MODEL: TC12000_ASM_JST100 No. ALTERATION AREA SIGN DATE
ALL SHARP EDGES SHOULD BE REMOVED *
UNSPECIFIED TOLERANCES AS PER IS:2102-1969 * DRAWING: TC0101900_JST100_LAYOUT DESIGN HARDIK C 08-Mar-18
SCALE 0.250 WEIGHT Kg. MATERIAL MODEL NAME CHECKED ATUL V 08-Mar-18
DEVIATION FOR DIMENSION
119.684 --- JST100 APPD. VIJAY Z 08-Mar-18
OVER 0.5 3 6 30 120 315 1000 SCALE SHEET VERSION DRAWING No.
UP TO 3 6 30 120 315 1000 2000
0.1 0.1 0.2 0.3 0.5 0.8 1.2
- 01 OF 01 00 TC0101900 G-506, GIDC-LODHIKA, METODA-RAJKOT (INDIA)
A B C D E F G H
4 Operation

4.1 Overview

 Changing Tools and Tool holders

 Fault Elimination

4.2 Tools

CAUTION

Risk of the machine damage due to changing a driven tool incorrectly:

Impact on the tool holding fixture can damage the turret drive train.

Therefore, always change driven tools as follows:

 When loosening/clamping the tool holding fixture, always support it

with a second spanner.

Or

 Remove spindle unit, change tool and refit spindle unit.

CAUTION

Functional faults may be caused by ingress of chips and contamination.

 Close open tool locations and cooling lubricant bores by means of

suitable closing plugs.

CAUTION

Functional faults may be caused by an ingress of chips and contamination.

 Close open tool locations and cooling lubricant bores by means of

suitable closing plugs.

Operation TCCH0400100B Page-4.1.1 of 4

4.3 Tool holders and Spindle units

CAUTION

Risk of material damage.

 Use exclusively tool holder/spindle units with cylinder shank and O-ring
seals according to DIN ISO 10889 (formerly DIN 69 880)
 Seal all unoccupied tool holding fixtures:

Preparation

 Unlock turret.
 Rotate the tool disk until the position to be tipped is placed in horizontal
position.
 Lock turret.
 De-energize turret motor.
 Loosen set-bolt.
 Remove closing plug or tool holder /spindle unit.
 Check O-ring seals and keep the plugs in a safe place.

Clean

 Clean the contact surfaces of tool disk and tool holder/spindle unit.
 Do not clean with compressed air!
 Only use cloth to clean.

Checking

 Check O-ring seals on tool holder/spindle unit and replace, if

necessary.
 Check the coupling profile of the spindle unit,
 Check that the spindle locking system on the spindle unit has snapped
on.
 If necessary, rotate tool holding fixture until the spindle locking system
snaps on.

Operation TCCH0400100B Page-4.1.2 of 4

 Assembling

 Insert tool holder/spindle unit.

 Use 20% of maximum tightening torque TA of the set-bolt to tighten the
set-bolt.

Shank diameter (ISO 10889) d1 [mm] Max. tightening torque TA [Nm]

16 6
20 10
25 10
30 25
40 50
50 50
60 86

 Use the adjusting screw to align the tool holder/ angled spindle unit to
the center of rotation.
 Tighten set-bolt observing tightening torque TA.
 Seal all unoccupied tool holding fixtures:

4.4 Possible faults and remedies

Clearing required prior to any work:

 Switch the machine off.

 Depressurize turret.

Fault Cause Remedy

Incorrect center height, Collision when turret Turn back tool disk in
tool disk offset relative to is locked annular groove and align
locating disk
Tool disk does not rotate Gear wheels are Replaced Defective parts
defective
Turret motor or See Operating Instruction
control unit of the machine
defective

Operation TCCH0400100B Page-4.1.3 of 4

 Fault Cause Remedy
Turret does not lock Axis has rotated out Align axis to the locating
of position relative disk
to the locating disk
Proximity switch Check proximity switch
does not work set or replace if
necessary
Turret disk rotates in one Turret motor or See Operating Instruction
directional only control unit of the machine
defective
Tool disk does not stop in Turret motor or
the selected position into control unit
place with strong impact defective
Leakage oil escapes Seals are defective Replace defective parts

Cooling lubrication is not Cooling lubrication Replace defective parts

being transferred valve is defective
Cooling lubricant Blow cooling lubricant
valve/line is blocked valve/line clear
Cooling lubricant escapes Cooling lubricant Replace defective parts
between tool disk turret valve is defective

Preset torque Engage ratcheting clutch

Ratcheting clutch exceeded Adjust current limiter at
disengaged the motor
Tool is not driven Gearwheels are Replaced defective parts
defective

Motor defective Replace motor

• All Types fault must be done by qualified and trained person.

Operation TCCH0400100B Page-4.1.4 of 4

5 Maintenance

5.1 Overview

 Planned preventive maintenance

 Repairs after fault conditions

5.2 Service life

The Service life of turret is approx. 8 million switching’s or approx. 5 years.

The service life of turret of the tool drive unit is approx. 8000 operating hours.

These values apply to

 Collision-free operation,
 Compliance with the specified operation conditions and the permissible
loads,
 Connection to the central lubrication system of the machine.

5.3 Service intervals

IMPORTANT

 Maintenance interval must be adapted to the operating conditions involved.

After 500 operating hours of machine Check tool holders on tool disk for
and/or every month respectively proper seating. Check sealing rings
on tool holders and replaced if
necessary
After 2000 operating hours of the Make sure no cooling lubricant
machine respectively penetrated the gears.
After 4000 operating hours of the Checking cooling lubricant valve for
machine respectively wear and leakage. Replace any
defective part.
After 2.5 years respectively Check all electrical and hydraulic
lines and connection for mechanical
damage .Replace any defective
parts.

Maintenance TCCH0500100B Page-5.1.1 of 3

5.4 Maintenance work

Clearing required prior to any work:

 Switch off the machine.

5.5 Proximity switch SQ4, SQ5

IMPORTANT

Setting task require a 24 V DC power supply.

1 2

1.6

Replacing

 Loosen proxy mounting strip (2).

 Take out proximity switch (1)
 Insert new proximity switch.
 Connect proximity switch electrically.

Adjusting

 Adjust switching space to 1.6mm

 Tighten proxy mounting strip

Maintenance TCCH0500100B Page-5.1.2 of 3

Function check

 Lock turret. Proximity switch SQ4: LED on, SQ5: LED off
 Unlock turret. Proximity switch SQ4: LED off, SQ5: LED on.
 Check this switch process several times.

Maintenance TCCH0500100B Page-5.1.3 of 3

 6 Replacement parts

SEE ATTACH DOCUMENT

TC0102000

Replacement part TCCH0600100B Page-6.1.1 of 3

Designation Description Connection Specification Type. No. Supplier
Proximity
M5x25MML PNP
SQ4 Switch (Turret Direct H1CE022539 JYOTI
NO-3M Cable
DE Clamp FB)
Proximity
M5x25MML PNP
SQ5 Switch (Turret Direct H1CE022539 JYOTI
NO-3M Cable
Clamp FB)
Servo motor Cable Entry 50NM, 3000RPM, 1FT6105-
T MOTOR SIEMENS
(Live Tool) Plate Brake 8AF71-3DH1
Servo Motor Cable Entry 12NM, 3000RPM, 1FT7066-
TI MOTOR SIEMENS
(Indexing) Plate Non-brake 5AF71-1CG2

Replacement part TCCH0600100B Page-6.1.2 of 3

 Ya A B
Yb

~10-12L/MIN.

P=50bar

Hydraulic oprating pressure 50bar

oil viscosity 32-46 mm²/s

Operating temprature of the

25-55°C
hydraulic oil

Recomended nominal diamete of the line between distributing valve and turret

Table of funcation Ya Yb
VDI-25 VDI-30 VDI-40 VDI-50 VDI-60
Lock 0 0
Turret UnLock 1 1
<4 6 - - - -
Engage 1 1
Turret drive Disengage 0 0 8
4-6 8 10 12 12
Engage 0 0
Tool drive Disengage 1 1
>6 10 10 12 15 15
Recommended rated quantiti of
6 6 6 10 10
valve

Replacement part TCCH0600100B Page-6.1.3 of 3

 A B C D E F G H
No. DRAWING No. PART'S NAME QTY. MATERIAL REMARKS
9 1 B60101821000 O-RING ( ID190 X SEC. Ø3) 1 -
13
2 C00500600000 O-RING S 2X85 1 -
17
3 C50302321000 O-RING S3.0 X ID130 2 -
4 E42003521000 O-RING S2 x ID137 1 BOUGHT OUT
6 5 H10103221000 O-RING S3XID254 1 - 6
6 H15603421000 O RING S2 X 150 ID 1 NBR BOUGHT OUT
7 K80200900000 O-RING S2.5 X ID105 1 -
8 T10109321000 O-RING S2 x ID12 1 - BOUGHT OUT
9 T61700321000 O-RING S3 X ID152 'ECONOMOS' 1 ECOPUR
10 T80101300000 COOLANT VALVE 1 BRASS
11 TC0103500000 ROD SEAL S09-D ID 150 X OD 165_1 X 6_3 1 - REMARKS
12 TC0103600000 ROD SEAL S09-D ID 160 X OD 175_1 X 6_3 1 MATERIAL REMARKS
13 TC0103700000 ROD SEAL S09-D ID 110 X OD 125_1 X 6_3 1 -
8 14 TC0105000000 COOLANT STOP VALVE 1 BRASS
5
10 15 TC0105100000 SPRING A-45 OD14.6 X 20.6L X WIRE D 2 1 stainless-steel
16 TC0105500000 KEY 16X10X31 1 EN-8
5 SECTION TOP-TOP 5
17 TC0106000000 ROTARY SEAL R09-FØ190XØ201X4.2L 1 -
18 V80103821000 O-RING 50 X 2 PRESSURE FLANGE 1 NITRILE
15 14 12

LUB-1

FR
32.5
2
6 7 4 18 3

4 4

TOP
TOP

FR
LUB-1 SECTION FR-FR
3 SCALE 0.250
3
1 11

16

SCALE 0.250
2 2

TITLE: 05
04
03
SECTION LUB-1-LUB-1 REPLACEMENT PART 02
1 SCALE 0.250 01 1
MODEL: TC12000_ASM_JST100 No. ALTERATION AREA SIGN DATE
DRAWING: TC0101900_JST100_LAYOUT DESIGN HARDIK C 09-Mar-18
WEIGHT Kg. MATERIAL MODEL NAME CHECKED ATUL V 09-Mar-18
119.684 --- JST100 APPD. VIJAY Z 09-Mar-18
-: NOTE
SCALE SHEET VERSION DRAWING No.
IF IN DOUBT PLEASE ASK *
ALL DIMENSIONS ARE IN MM *
DO NOT SCALE THE DRAWING *
- 01 OF 01 00 TC0102000 G-506, GIDC-LODHIKA, METODA-RAJKOT (INDIA)
A B C D E F G H