Baruffaldi TOEM 120 Guide

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ASSEMBLY DRAWING
(section view)
18
733
705 717
718
722
709
744
M
716
704
720
728
727
720a
728
743
722
742
740
741
Y

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700
707 712 707
for TOEM
120 - 160
S
714
709
713
707
711
714
708
730
706
701
702
710 731
709
for TOEM
200 - 250
X
E
731
707a
( __ __ )
715
745
703
710
L
ASSEMBLY DRAWING
(section view)

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- Set out the turret in open position (unlocked)
- Remove the screws 714 and 715
- Remove all the support ( S ) complete of gear 712, (to facilitate the removing of this last, hit the ends ( E )
with a plastic hammer).
- Remove the supplementary motor ( M )
- Take off the toolholders disk
- Disassemble the flange 716
- Extract the pin 717 and the idle gear 718
- Take off the dowels 719 and the screws 720 & 720a
- Extract the plate unit 721 and the counterplate 722
- Take off the dowels 723 and the screws 724
- Separate the plate 721 from the counterplate 722
- Remove the central gear 705 complete of bearing 727 and thrust blocks 728
- If the disassembly of the components inserted in the support ( S ) is required:
extract the lock pin 713, remove the gear 712 complete of coupling 708, reel 706, lead nut 730 and pins 707
or 707a
- To disassemble the rack 711 the cover 731, and the levers 709 & 710 must be removed.
WHENREASSEMBLINGEVERYTHING
Oil all the retaining rings (O-Rings etc.) with grease, brake all the screws with "Loctite" and lubricate all the
mechanical components; beside it, for what the assembly of the elements belonging to the support unit ( S ) is
concerned, follow the following instructions:
- Insert the rack 711 complete of springs and containers 701 in the seat L; by using a small pin (as on table page
21) and with a suitable manual press compress the spring 702 with value (C) (see page 21); in this condition it must
be inserted the unit ( I ), composed by the gear 712, by the reel 706, by the lead nut 730 and by the pins 707, in the
seat in such a way that the tooth ( D ) of the reel 706 fit the space ( V ) of the rack 711 and that the slot ( A ) is in
correspondence with the hole ( F ).
Insert the lock pin 713 in the seat ( A ).
Eliminate the press action.
Push the gear 712 towards the bottom of the seat ( Z ) in such a way that the lead nut 730 goes in the ledge.
In this condition, the extremity (E) of the coupling 708 must be on line with the extremity ( E ) of the gear 712; if this
does not happen, the reason is caused by the insertion of the tooth ( D ) of the reel 706 in the wrong space of the
rack 711; in this case the assembly of these elements must be made again .
Reassemble the lever 710 on the pin 733, with the marks ( __ __ ) aligned, (see picture page 19)
During the assembly phase of the support ( S ) on the turret, the screws 714 and 715 must be alternately screwed
in such a way to determine the support on the 2 tables (X) & (Y) (see picture on page 18).
TURRET DISASSEMBLY
(Related to the toolholders
rotation)

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B
702
F
Surfaces on contact
GROUP ( I )
Turret
size
TOEM 120
TOEM 160
TOEM 200
TOEM 250
C
(mm)
V
Assembly group ( I ) before
inserting in support ( S )
S
D
Press action
Z
706
21
B
(mm)
711
L
24
24
24
24
3,5
3,5
4
4
Extremity (E)
clutch (708)
and
extremity (E)
gear (712)
on line
Slot ( A ) for
locking pino
(on line with
hole F)
TURRET DISASSEMBLY
(Related to the toolholders
rotation)
C

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Whenever the turret is disassembled, check the state of the following elements which will have to be replaced in
case of a negative result:
- 308 main gasket
- all retaining rings type (O-ring)
- 032 cushion pads
And the following elements (only when the central body has been completely disassembled):
- cam surfaces
- rollers
- HIRTH couplings
- all gears
- support plate of the 003 ring gear with the 002 one.
FROM THE TOP SIDE
Take off the 044 top cover, remove the screws 300, extract the 042 proximity support complete of proximity 301;
take off the 049 support complete of proximity 313, remove the 046a washers, extract the 200 electromagnet, extract
the 017 lock with related 047 spring.
Remove the 019 cover from the two sides, extract the 018 shock absorbing pins complete of 032 pads.
FROMTHE REARSIDE
Take off the 011 cover, remove the screws 302 and remove the 043 encoder support complete of 160 encoder, take
of the 303 seeger, remove the 030 thrust block and the 304 bearing.
FROMTHE FRONT SIDE
Take off the toolholder disk, remove the screws 305, take off the dowels 306. Move the push rod 700 towards outside
(Ú), extract the entire central body composed by 003 mobile ring gear, 005 indexing head, 006 roller carrier set,
007 spider set, 020 ring nut, 307 belleville washers, 025 - 026 spacers.
If dismounting this set too were necessary, unscrew the ring nut with a particular tool and extract all the other
components.
Turret
size
Diameter
R (mm)
44
44
56
56
TOEM 120
TOEM 160
TOEM 200
TOEM 250
8,25
8,25
8,25
8,25
Diameter
S (mm)
R
S n°4
018
032
019
TURRET DISASSEMBLY
(Related to the indexing
components)

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Turret
size
TOEM 120
TOEM 160
TOEM 200
TOEM 250
1,8
2,1
1,7
2
23
025
U
Assemble the parts as shown, then check that the value of U is between the ranges in the table below.
If it is not then grind a new distance piece 025 to it so that U falls within the ranges specified in the table.
Rollers on the high central
part of the cams
If any of the parts composing the central sub-assembly (except the satellite carrier 007), has to be substituted it
is necessary on reassemble to check and reset the distances T and U which determine the correct loading of the
spring.
Reassemble the parts, as shown in the figure, with the HIRTH teeth in contact and the rollers sitting on the raised
parts of the cams, check that the value of T is inside of the range indicated (0,2 - 0,25 mm).
If it is not then grind new races 023 to bring the value of T within the prescribed tolerance.
T = 0,2 - 0,25 mm
protrusion of the gear
Races 023
TURRET DISASSEMBLY
(Related to the indexing
components)
Dimension
U(mm)

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HINTS FOR
REASSEMBLE
DURINGCOMPLETEREASSEMBLE
- Insert the keys 309 into their corresponding key-ways (with identical marks) keeping the threaded holes turned
towards the ring nut 020 and in contact with the bottoms of the key-ways.
- Check that pinion 008 has a good sliding fit. If it does not, take it off and assemble it the other way with respect
to the keys.
- Check that the ring nut is thoroughly tightened. To make sure of this follow these instructions:
Before final assembly temporarily set aside parts 026 - 307 - 025, screw down the ring nut till it touches
its seating, measure the distance between the end of the divider 005 and the top surface of the ring, mark
the position of the ring nut in respect to the divider.
Lubricate O-ring 318 with heavy grease or vaseline.
018
402 0,05 0,05
After assembling all the parts add right amount of the correct type of lubricant to the carcase through the oil
hole (see page 25).
Ring nut in contact
Mark here
Rollers on the high level of the cams
90°
Dimension to measure
Then unscrew the ring nut, assemble the parts 026 - 307 - 025, screw on the ring nut, check that it reaches the same
position as before. Make this check by measuring the distance and observing that the marks coincide. Before
inserting the central sub-assembly into the carcase, rotate the satellite carrier 007 until the sealing of the latch is
in perpendicular position towards the coolant interception holes of the crown 002; insert the latch 017, rotate the
satellite carrier 007 by hand until the HIRTH teeth engage (rollers on the level parts of the cams). Release the latch.
Latch socket

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The mechanical moving parts of the turret are permanently lubricated.
The lubricant must be renewed only after eventual complete dismantling of the turret.
The lubricant, with viscosity 80 SW 90, must be compatible with rubber & teflon.
The following table indicates the quantities to be used.
LUBRICATION OF THE ROTATING TOOLS MECHANISM
The mechanism of the rotating tools is lubricated with oil 80 SW 90. The oil must be changed every new re-assemble.
For this reason on the top of the 722 counterplate is located the hole for the filling.
Take off the airtight plug or the feeding pipe connector of the coolant, take off the spiral spring; then extract the bush
033 complete of O-Ring 322 by using a suitable thread X.
Clean the seating from any eventual incrustation, grease the outside part of the new bushes complete of O-ring, then
insert them in their seating and check the sliding.
TOEM 120 0,150
TOEM 160 0,200
TOEM 200 0,300
TOEM 250 0,400
Airtight plug
033
X
SUBSTITUTION OF THE COOLANT BUSHING
Quantity
of
lubricant
Kg
LUBRICATION &
SUBSTITUTION OF THE
COOLANT BUSHING
Turret size Quantity of oil
Kg
0,500
0,700
1,500
2,000
TOEM 120
TOEM 160
TOEM 200
TOEM 250
Turret size

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SUBSTITUTION OF THE PRE-INDEXING ELECTROMAGNET
SUBSTITUTION OF THE BRAKE MAGNET
AND ADJUSTEMENT OF THE AIR GAP
Remove the rear cover 011, disconnect the leads connecting terminal block to the motor, the brake and the thermal
probes (heat sensor). Unscrew screws 311, extract the motor unit 150. Disassemble the gear 015 and remount it
on the new motor unit. Mount the motor unit in the carcase and reconnect the electric wiring to the terminal block.
To check that the phases are properly connected, perform a tool change by calling up the nearest station ... if the
phases are properly connected, the change of station will take place by the shortest route, if the disk goes the long
way round then interchange two motor supply wires at the terminal block (phase rotation).
Replace the rear cover.
TOEM 120 - 160 - 200 - 250
090
Remove the rear cover 011, extract the motor unit 150 and the gear 015.
Disconnect the brake leads. Remove the defective brake magnet and substitute it with the new one.
Adjust the air gap (0,2 - 0,3 mm to be checked in a vertical position and acting on the distance pieces 090).
Reassemble the whole by following the above sequence in reverse.
Remove the top cover 044, remove the support 042, remove the washers 046a, extract the electromagnet 200.
Remove the rear cover 011 and disconnect the electromagnet supply leads.
Mount the new electromagnet in the carcase and fix it down with the two washers.
Replace the support complete with its proximity switch 301 and reset it (see page 28).
Connect the electromagnet lead wires to the terminal block (see electrical connection schemes page 11).
Replace top and rear cover.
0,2 --- 0,3
:
SUBSTITUTION
OF MOTOR UNIT

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SUBSTITUTION AND
ADJUSTEMENT OF THE
ANGULAR ENCODER
067
043
302
310 311
Marks on the encoder support Mark on the encoder
Remove the rear cover 011, disconnect the encoder leads from the terminal block 310, remove the stirrups 067 and
extract the encoder. Remove the driving hub 035 and mount it on the new encoder.
Remount the encoder following the above instructions in reverse and connect it to the terminal blocks. Before finally
fixing the encoder set it as follows:
Lock the turret in any position, rotate the encoder slowly until the STROBE signal disappears (this can be checked
on the control system or with a voltmeter).
Mark the encoder and make a corresponding mark on its support. Slowly turn the encoder in opposite direction until
the STROBE signal again disappears, and mark the new position on the support.
This defines the region in which there is a STROBE signal. Slowly turn the encoder until the mark on the shaft is half
way between the two marks on the support.
Tighten the stirrups 067 and replace the rear cover.

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TOEM 120
TOEM 160
TOEM 200
TOEM 250
18,3
18,3
18,3
18,3
X
Luminous indicator
Remove the top cover 044, remove the support 042 together with the proximity switch 301. Remove the rear cover
011, disconnect the proximity switch leads from the terminal block 310, and remove the proximity switch. Screw
the new proximity switch into the support until it projects by the correct amount "X".
Assemble the support fixing it with the screw 300a in such a way that the LED (luminous indicator) on the end of
the proximity switch is visible. Insert a 0,8 mm thickness gauge (see figure) and bring the proximity switch into
contact with the thickness gauge.
Tighten the screws 300 - 300a with a torque of 3 Nm and block them with LOCTITE.
Connect the leads to the terminal block, and check that the proximity switch operates correctly when live, as follows:
- With a turret closed (locked) on lowering the end of the electromagnet by an amount between 1,8 and 2,5 mm the
luminous "red" indicator on the back part of the proximity switch should light up.
Replace the rear cover and the top cover.
300 a 300
0,8
SUBSTITUTION &
ADJUSTEMENT OF THE
PRE-INDEXING PROXIMITY SW.
X
(mm)
Turret size

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Remove the top cover 044, unscrew screw 314, extract the support 049, take off the rear cover 011, disconnect the
leads of proximity switch 313 from the terminal block. Unscrew the ring nut 048, unscrew and remove the wire clip
058, and remove the proximity switch.
Screw the new proximity switch into the support by amount needed to make dimension "Z" equal to figures in the
table below.
The dimension given for "Z" in the table are however only indicative, and correct setting of the operating distance
"P" may require departure from those values.
The amount of the operating distance is obtained by difference:
( P ) 0,8 mm = V - Z
where "V" and "Z" are actual measured values.
To measure "V" the closing sector (i) of the roller ring 006 must be against the proximity switch, that is to say with
the turret in the locked condition.
If it is not in this state the carry out the closing operation manually (see page 15).
After adjusting the value of the operating distance "P" screw down the ring nut (tightening torque 3 Nm).
Peen over the edges of the ring nut, thread the wire clip 058 on the proximity switch leads.
Replace and screw on the support 049.
Connect the proximity switch leads on the terminal block (see wiring scheme).
With the proximity switch live the red luminous indicator on the end of the proximity switch should be visible through
the upper hole "n" in the support 049.
When this indicator is lit the turret is in the locked condition.
Replace the wire clip, the rear cover and the top cover.
Luminous indicator
TOEM 120
TOEM 160
TOEM 200
TOEM 250
P = 0,8
Z
V
Closing sector ( i )
006
P
60,7
59,7
60,7
75,7
058
Hole ( n )
SUBSTITUTION &
ADJUSTEMENT OF THE
LOCKING PROXIMITY SWITCH
Indicative value of
Z (mm)
Turret size

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Size of spanner CH (mm)
TOEM 120
TOEM 160
TOEM 200
TOEM 250
Turret size
5
5
5
5
OPERATIONS TO BE CARRIED OUT
IN CASE THE POSITIONING CYCLE
HAS NOT BEEN COMPLETED
an emergency or accidental stop occurred
Call up from the console a "tool change" (the nearest one) keeping to the same direction of rotation that the turret
(the toolholder disk) had when it stopped. If this is not known and the "change" called for does not go through to
completion (namely not locking or bringing about the operation of the heat sensor), proceed as follows:
- Noted the direction of the disk rotated during the attempted (unsuccessfully) "tool change"; call up from the console
the nearest station which can be reached by rotating the disk from its present position in the opposite direction to
that of the previous attempt.
If the control refuses to accept a "tool change" starting from the condition of "turret unlocked", then carry out the
necessary operations manually as follows:
- Remove the rear cover 011 and the top cover 044, unscrew and partially extract the wire clip 058, disconnect the
motor and the brake leads from the terminal block 310 (still keeping the proximity switches connected; please note
the order of the motor wires, in order to avoid wrong connection at the end of operations).
Using a hexagonal spanner (see table) turn the motor shaft 012 by hand so that the toolholder disk rotates in the
same direction as it did when it stopped and at the same time push the core 073 of the electromagnet 200 until the
latch 017 enters a recess in the divider 005.
Keeping the core pushed reverse the rotation of motor shaft until the red indicator of proximity switch 313 lights
up and can be seen from above through the hole (n).
Make the shaft rotate for another turn but working so that the indicator still remain lit.
If the direction in which the disk was rotating when it stopped is not known and a mechanical block is encountered
after the reversal and the turret will not lock, the shaft must be made to rotate in the same sense as that proceeding
the reversal.
Screw on the wire clip, reconnect the leads to the terminal block (care the phases of the motor leads), replace top
and rear covers.

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032
033
150
160
175
200
301
308
313
315
316
317
318
319
320
321
322
323
324
325
326
327
328
740
741
742
743
Pads (2 off)
Fluid coolant valvle
Motor unit
Encoder unit
Brake magnet
Electromagnet
Pre-indexing proximity switch
Wiping seal
Locking proximity switch
O - ring
O - ring
O - ring
O - ring
O - ring
O - ring
O - ring
O - ring
O - ring
O - ring
O - ring
O - ring
O - ring
O - ring
Rotating seal ( MIM )
O - ring
O - ring
O - ring
RECCOMENDED
SPARE PARTS

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TECHNICALDATA
6000
15
4
kW
g/min
RPM
Nm 20
5
Nm
kW
g/min
RPM
TECHNICALDATA
32
TOEM 120 TOEM 160
6000
TABLE OF DATA
ROTATING TOOLHOLDERS
POWER TAKE-OFF
TOEM 250
TOEM 200
60
1,315
1
80
1
1,520
912
4000 4000
Ratio (RPM motor / RPM take power)
Max. speed at the take power
Max. power
Max. torque at the take power
11
--- ---
Ratio (RPM motor / RPM take power)
Max. speed at the take power
Max. power
Max. torque at the take power

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TOEM 160
TOEM 120
TOEM 160/../1
TOEM 200/../0 TOEM 200/../1 TOEM 250/../0 TOEM 250/../1
7,53,0 4,5
6040
750 750
4,5
TABLE OF DATA
TURRETS
TOEM 120/../1
TOEM 120/../0
TURRETSIZE
Code number of transmission
ratio
Moment of inertia of trans-
portable masses (Kgm)
Tangential couple
applicable with turret locked
(Nm)
Unbalanced couple
with horizontal axis
(Nm)
Repetition accuracy
(grad)°
N° of movement / hour
0,65 0,50
800 1850
1510
1,3 0,8 0,5
TOEM 160/../0 TOEM 160/../2
+ 2" + 2"
750 750
TURRETSIZE
Code number of transmission
ratio
Moment of inertia of trans-
portable masses (Kgm)
Tangential couple
applicable with turret locked
(Nm)
Unbalanced couple
with horizontal axis
(Nm)
Repetition accuracy
(grad)°
N° of movement / hour
TOEM 200 TOEM 250
3500 6900
+ 2" + 2"

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20000
10000
7000
5000
4000
3000
2000
1000
700
500
400
300
200
100
a (mm)
(
daN)
F
- F1
20000
10000
7000
5000
4000
3000
2000
1000
700
500
400
300
200
100
a (mm)
(
daN)
20000
10000
7000
5000
4000
3000
2000
1000
700
500
400
300
200
100
a (mm)
(daN)
F3 F2
100 200 300 400 500 600
100 200 300 400 500 600 100 200 300 400 500 600
TOEM 250
TOEM 200
TOEM 160
TOEM 120
TOEM 250
TOEM 200
TOEM 160
TOEM 120
TOEM 250
TOEM 200
TOEM 160
TOEM 120
34
As a function of the
tangential thrust F &
F1
As a function of the
pressing axial force
F2
As a function of the
lifting axial force F3
F1
F3
F2
F
a
PERFORMANCE
DIAGRAMS
After having selected the size of turret according to the above criteria, check that the moment of inertia to be
applied is below the maximum values given in the table of Technical Data.

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PROBLEMS REMEDY
No power at motor
Motor defective
Heat sensor in operation
Turret does not start
35
PROBLEMS & REMEDIES
CAUSE
Get power to the motor
Substitute the motor unit
(see page 26 )
See next point
Turret does not complete its
indexing cycle either because the
heat sensor operates or an incom-
plete cycle is indicated.
Number of movement / hour above
the maximum permissible
With the turret free in the position
required and with current supplied to
the motor there is no signal from the
pre-indexing proximity switch 301
Pre-indexing proximity switch in
defective
Pre-indexing proximity switch not
correctly set
With the turret in the required position
and with current supplied to the motor
there is no signal from the locking
proximity switch 313
Locking proximity switch is defective
Locking proximity switch out of
adjustment
Restart after an emergency or
accidental stop, but in opposite
direction to that most convenient
Blockage of the electromagnet's core
Reduce the number of movements
(see technical data page 33)
Substitute the pre-indexing proximity
(see page 28)
Adjust the pre-indexing proximity sw.
(see page 28)
Substitute the locking proximity sw.
(see page 29)
Adjust the locking proximity switch
(see page 29)
See page 30
See page 30
Overhaul the control apparatus
Electromagnet exited lateThe turret overrun the pre-
indexing station required

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CAUSEPROBLEMS REMEDY
PROBLEMS & REMEDIES
Overhaul the control apparatus
Substitute the brake magnet
(see page 26)
Readjust the air gap in the brake
(see page 26)
Substitute the angular encoder
(see page 27)
Substitute the electromagnet
(see page 26)
Bring power supply up to specified
value
Eliminate the interruption
Delay in switching off the motor and
in the braking
Brake defective
Brake wear excessive
Angular encoder defective
Electromagnet defective
Power does not reach electromagnet
or voltage is below that specified
Break in the electrical leads
Turret does not stay locked
The turret continues to rotate
without stopping at the required
station
Correct the connection of the phases
(see page 30)
Inverted phases in the power supply
of the motor
Substitute the buffer pads
Bring the moment of inertia of the
masses in use down to a
permissible figure (see page 33)
Bring the moment of unbalance of the
masses in use down to a
permissible figure (see page 33)
Excessive travel of the buffer pads
Moment of inertia of the masses in
use is above the permissible maxi-
mum
Moment of unbalance of the masses
in use is above the permissible
maximum
The turret approaches the required
station by the longer path
Excessive shock in pre-indexing
Bring the moment of unbalance of the
masses in use down to a permitted
value (see page 33)
Moment of unbalance above the
permitted
Disk rotates in jerks