201803AEN00iD0

January. 2010

VX400 (FANUC 0i-MD) VERTICAL MACHINING CENTER VERSION No. 2.1

Contents
1. Safety Articles
2. Installation Manual
3. Operating Manual
4. Maintenance Manual
5. Parts List
6. Electric Diagram
 Caution

Please observe the cautions specified by the User’s Manual and warnings
on the machine. These are very important for your safety. If these are not
observed, the user and machine can be significantly damaged. HYUNDAI-
KIA MACHINE is not responsible for damages or accidents due to user’s
own modification on the machine.
 Preface

Thank you for using VX400 Machining center.

This User’s Manual contains information about install and operation method, routine
maintenance and check-up for safe and proper use to ensure the best performance of
this machine. Please read and fully understand this guide prior to installation and test
operation.

The caution on these manual and warning panels on the machine should be observed.
For user’s easy and comprehensive understanding, following booklets are prepared.

1. Safety Articles
2. Installation Manual
3. Operating Manual
4. Maintenance Manual
5. Parts List
6. Electric Diagram

The adjustment and setting up record such as parameter table attached on this machine
is necessary for later maintenance and modification. Please keep them. The design of
this machine is subject to be changed without prior notice. Thus, in some cases, the
contents of this User’s Manual may not be in accordance with the machine.

January. 2010

■ The contents of this manual can be modified without any notice for improving the performance
and in accordance with a design change.

PRINTED IN HYUNDAI-KIA MACHINE

 Publication Record

Simple description for this version and previously version are as following.
Status of each publication is displayed with code as follows.

A … Original Edition
B … Revision by design Change
C … Change part No. and Revision by series development

Issue Manual No. Remarks

November.07 201803AEN00iC0 A
February.08 201803AEN00iC1 B
January.10 201803AEN00iD0 C

■ Publisher ---------------------------------------------------------------------------------------------------------
HYUNDAI-KIA MACHINE http://wiamachine.co.kr
2018EN00iDSA0

Safety Articles
Chapter 1 Safety Articles
1.1 Introduction ............................................................................................ 1-1-3
1.2 Signal Word Introduction ............................................................ 1-1-4
1.3 Caution ...................................................................................................... 1-1-5
1.4 Safety Device ................................................................................... 1-1-30
1.5 Mechanical Safety ........................................................................ 1-1-35
1.6 Electrical Safety .............................................................................. 1-1-38
1.7 Industrial Accident ......................................................................... 1-1-41
1.8 Industrial Safety and Countermeasures .................... 1-1-42
Chapter 1
Safety Articles
1.1 Introduction ................................................................................................................1-1-3

1.2 Signal Word Introduction ................................................................................1-1-4

1.3 Caution ..........................................................................................................................1-1-5

1.3.1 Basic Caution .....................................................................................1-1-5

1.3.2 Caution for Emergency Stop .................................................1-1-8

1.3.3 Caution before Power Supply ..............................................1-1-9

1.3.4 Caution after Power Supply ................................................1-1-11

1.3.5 Warming up ..................................................................................... 1-1-12

1.3.6 Caution before Handling the Machine ...................... 1-1-13

1.3.7 Caution for Handling the Machine ................................ 1-1-14

1.3.8 Caution during Machine Operation ................................ 1-1-15

1.3.9 Caution for automatic operation ..................................... 1-1-16

1.3.10 Precaution during work is stopped ............................... 1-1-17

1.3.11 Precaution during work is finished ................................ 1-1-17

1.3.12 Caution for maintenance and Checkup ................... 1-1-18

1.3.13 Caution for Handling Electronics ................................... 1-1-20

1.3.14 Caution for Supplying Lubrication ................................. 1-1-21

1.3.15 Caution for Handling Coolant ........................................... 1-1-22

1.3.16 Caution for the Machine Setup ....................................... 1-1-24

1.3.17 Tool Setting (Lathe) ................................................................... 1-1-25

 1.3.18 Work Chucking (Lathe) .......................................................... 1-1-26
1.3.19 Related Safety Information for Chip Conveyor .. 1-1-27
1.3.20 Other Caution ................................................................................. 1-1-27

1.3.21 Precaution for Fire Prevention ......................................... 1-1-28

1.4 Safety Device ...................................................................................................... 1-1-30

1.4.1 Safety Nameplate Type ......................................................... 1-1-30

1.4.2 Attachment Position of NamePlate .............................. 1-1-33

1.4.3 Safety Device ................................................................................. 1-1-34

1.5 Mechanical Safety ........................................................................................... 1-1-35

1.5.1 Safety Generals ........................................................................... 1-1-35

1.5.2 Safety Requirement for Hand Tools ............................ 1-1-35

1.5.3 Safety Requirement for Major Machine Works . 1-1-36

1.6 Electrical Safety ................................................................................................. 1-1-38

1.6.1 Safety for Electrical Equipment ....................................... 1-1-38

1.6.2 Electrical Hazard and its Precautions ........................ 1-1-38

1.6.3 Over-current Relay .................................................................... 1-1-39

1.6.4 Failure Diagnosis and Control of

Various Switches ........................................................................ 1-1-40
1.7 Industrial Accident ............................................................................................ 1-1-41

1.7.1 Causes of Industrial Accident .......................................... 1-1-41

1.8 Industrial Safety and Countermeasures ....................................... 1-1-42

1.8.1 Safety Signs and Colors ...................................................... 1-1-42

1.8.2 Fire and Explosion .................................................................... 1-1-43
1.8.3 First-aid ............................................................................................... 1-1-44
1.8.4 Regulations for Mechanical Safety ............................. 1-1-45
 Safety Articles

1.1 Introduction
This chapter explains how to use this machine and contains cautions to ensure
user's safety and prevent machine's damage while operating this machine.
Operators should read and observe the following to prevent accident or damage.

• Operation of this machine should be restricted to the person who attended certain
operation training.
• An operator who have attended a certain training should conduct set up, operation,
maintenance, check up, modification, oil supply and cleaning after cutting power
and air pressure and confirming everything in accordance with specified work order.
• HYUNDAI-KIA MACHINE is not responsible for the accidents due to user's failure
of observing this guide or user's own modification or dismantling.

• Please read and observe this User's Manual and warnings on the
machine.
• Please do not move or damage the warning panels attached on the
machine.

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1.2 Signal Word Introduction

The purpose of safety related items are to prevent unforeseen accidents to
operators and machine. "Danger" / "Warning" / "Caution" are three different words
meaning different degrees of safety. These words reflect the degree and possibility
of danger. Please read the following meanings of each words before using this
machine.

Table 1-1-1. Signal Words and their Meanings

Section Signal Word Meanings

When a certain item is not observed, operator's

DANGER
death or similar danger may occur.

When a certain item is not observed, there is

WARNING
potential of operator's death or severe injury.

When a certain item is not observed, operator's

CAUTION
minor injury or machine's damage may occur.

NOTICE It shows reference or advice for operators.

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1.3 Caution
This machine is provided with a number of safety devices to protect personnel and equipment
from injury and damage. Operators should not, however, rely solely upon these safety devices
but should operate the machine after fully understanding what special precautions to take by
reading the following remarks thoroughly.

1.3.1 Basic Caution

(1) In the area of power supply board/controller/current transformer/motor /inside

of terminal box/operation panel and other area with warning sign of electric
shock, the possibility of electric shock and other electricity related accidents is
high. Check whether it is safe or not before operation.

(2) Do not touch the machine with wet hand. It is result to electrical shock.

(1) You have to know where the emergency stop button is so that you can
unconsciously hit the button if necessary.

(2) Operate it after verifying the position.

(3) Completely understand the machine specification and function and perform the
operation by specified method.

(4) Do not disassembly/adjust the unit and the cover for safety arbitrarily.

(5) Keep your hands away from rotating material or equipment during operation.

(6) Wipe to remove water or oil on the floor to prevent workers from slipping.

(7) Do not get in the machine except for maintenance.

(8) Designate the required person for each work and perform appropriate work by
designated person only. When two or more workers are working, they should
exchange signals at each stage before proceeding to next.

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(9) Do not place tools, equipment or other material on the machine.

(10) Extreme care should be taken to prevent fire when handling combustible
materials such as wood, plastic, magnesium, etc. (Continuous observation by
operator shall be required during handling.)

(11) Modification of the machine shall be implemented after consulting responsible

personnel of HYUNDAI-KIA MACHINE.

(12) Cut power supply before changing fuses.

(13) Enough work space shall be ensured to avoid falling object.

(14) Inside of the machine is very dangerous due to rotating material, transferring
equipment, scattering oil and chips with high temperature. Close the door
during operation.

(1) Examine the machine every quarter to prevent machine error or malfunction.

(2) Turn off the main power in case of power failure.

(3) Signs on the machine shall not be detached or moved. If any of the signs
damaged, you can get new ones upon inquiry to HYUNDAI-KIA MACHINE with
product number on the lower right side of the sign or on the parts list.

(4) Wear protective device that can operates safety shoes, protective glass, work
cloths etc, safely.

(5) Operator shall wear comfortably and properly. Do not operate with wearing gloves.

(6) Worktables around the machine shall be strong enough and their surface shall
not be slippery.

(7) It has to be bright, dry and clean around the machine.

(8) When installing the machine, remove dust or chips near the power supply
controller and other equipment. The use of compressed air for cleaning shall
be avoided if possible.

(9) Do not shock on the controlling panel and power supply control board. (It
causes to mis-operate, break. )

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(10) Do not change a Parameters and set point, etc. If necessary, take proper
measures so that it can be restored before change it.

(11) Use designated items or equivalent or above product for hydraulic fluid,
lubrication oil.

(12) Use rated current for fuse. If it is not appropriate, it influences NC instruments,
etc.

(13) Do not operate the machine when you are under medication or effect of drinking.

(14) Do not operate the machine when you are in physically bad condition or sleepy.

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1.3.2 Caution for Emergency Stop

When you notice danger to stable circumstances during operation, push the Emergency
Stop switch on the switch operation panel so that all the operation of the equipment can
be stopped. Emergency Stop switch stops the operation of motor temporarily. Once it is
stopped, it maintains the status, so if you want to start the machine again, you should
turn the switch to the direction of the arrow. You should know where the Emergency
Switch is so that you can unconsciously push it if necessary.

Figure1-1-1. Emergency Stop Switch Panel

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1.3.3 Caution before Power Supply

Read and understand the following before supplying power to prevent any
malfunction of the machine and injury of the operator.

(1) As damaged cable, wire can exist short circuit, electric shock, please check it.

(1) Read the description, program description. Operate and understand the
function and usage method of each instrument before operating it.

(2) Close the door tightly to prevent water, dust or chips into the NC Machine,
power supply board and controlling panel.

(3) Do not connect to other equipment while grounding. It can cause electrical
overload that may lead to fire.

(4) The voltage of the plant shall be measured before operating NFB1 of the
power supply board.

(5) Wear protective device that can operates safety shoes, protective glass, work
cloths etc, safely.

(1) An authorized size of wire shall be used for the power supply line of the circuit
breaker of the machine's main power supply.

(2) For the power supply switch of plant side, cable for main switch power of the
machine side in the power supply, use standard cable which can supply the
required power safely.

(3) If an wire lays on the bottom surface, it can damage by chip or foreign material
etc or protect it from shorting.

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(4) When the machine is used for the first time or after long period of time since its
last operation, operate the pump first until oil is smeared out to the wiper unit of
counter face to prevent scorching and unusual abrasion. It varies according to
the type of machine. Please consult with the service personnel of HYUNDAI-
KIA MACHINE.

(5) Check the amount of oil in each tank meet the requirement.

(6) Observe the instruction on the sign for the amount of oil supply, kind of oil and
process of oil supply.

(7) Check whether the switches and levers are operated properly.

(8) Power shall be supplied in the following order: Turn on the distributing board of
the plant → Turn on the main power supply of the machine → Turn on the
machine → deactivate Emergency Stop Switch → Reset.

(9) Check the order of terminal R.S.T using phase gauge. If it is reversed, modify
the order by changing 2 sets among 3 sets of the power sources.

(10) Use 15 mm or above thickness, 1m or above length of the grounded bar.

Grounding poll shall be buried at least 1 m below ground, when there is no
grounding unit buried.

(11) The third type of grounding is necessary. (grounding resistance: 100 ohm)

(12) Grounding shall not be buried near water pipe or other buried objects.

(13) Check whether the bolt is firmly fixed. Loosely fixed bolt may cause machine
malfunction.

(14) Confirm whether all the connectors are properly connected. Loosely connected
connectors cause machine malfunction.

(15) Confirm the connection of oil and air pressure hoses and pipes. Any problems on
the connection cause the leakage of oil and air that leads to machine malfunction.

(16) When the main power of the plant is not supplied, do not turn on the main
switch of the machine. Otherwise, the main switch may be damaged when
power is abruptly supplied.

(17) Add it if required after verifying the cutting oil level.

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1.3.4 Caution after Power Supply

(1) When the power is supplied, verify that the Power ON lamp is switched on in
the operation panel.

(1) After supplying the power, do not touch the operation button of operation panel
before alarm message is displayed on the monitor. As POWER ON switch is
connected to other buttons of operation panel for the purpose of maintenance or
check, if you can touch the operation button unconsciously, the mis-operation of
machine results in machine fault and person’s injury.
(2) Confirm whether oil or compressed air is leaking. Confirm all the gauges (if the
gauge is not correct or oil/compressed air is leaking, the machine can be
severely damaged.
(3) Check the tension of belt, Pay attention to not enter the foreign material
between the belt and the pulley.

(1) Confirm the operation of the fan after power supply. If the machine is operated
while the fan is not properly working, the machine can be damaged due to the
heat inside of the machine.

(2) When the machine's lubrication system has manual 'automatic lubrication
button', confirm slide way lubrication pump is working properly after power
supply. Otherwise, the machine can be damaged.

(3) To protect the slide surface, do not move each axis right after power supply.
Operate lubrication pump manually so that oil can be supplied on the slide
surface. If the axis is operated without oil supply, slide surface and ball screw
can be wore, which can lead to machine malfunction.

(4) Verify the reading value of pressure indicator correctly.

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(5) Verify that the noise of motor, pulley, other parts occurs.

(6) Verify that the head, moving section is properly lubricated.

(7) Check safety cover, safety device.

(8) Check the belt tension and replace it if exceeding the limited value. (Lathe)

1.3.5 Warming up

(1) Perform warming-up of main shat and feed shaft. At this time, Automatically operate it to

1/2–1/4 of maximum speed for 10-20 minutes. For initial RPM of main axis, perform base

RPM or below of RPM.

(2) In the automatic operation, check the motion and function of machine’s section

simultaneously.

(3) If you immediately operate after remaining for long term, faulty wear occurs in the wet

moving section, as machining can occur in the instability due to heat expansion of

machine section, warm-up should be performed. If you increase the RPM of main axis

suddenly with machine lubrication is not smoothly operated, RPM should be slowly

increased because of bearing sticking.

(4) Make warm-up program running all functions of machine.

(5) Pay attention to warm up to maximize the axis speed.

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1.3.6 Caution before Handling the Machine

(1) Keep away flammable materials from all the switches, power supply board,
main controlling board and distributing box.

(1) Tooling should conform to the machine specifications, dimensions and types.

(2) Seriously worn tools can cause injuries. Replace all such tools with new ones
beforehand.

(3) The work area should be adequately lighted to facilitate safety checks.

(4) Tools and other items around the machine or equipment should be stored to
ensure good footing and clear aisles.

(5) Tools or any items must not be placed on the headstock, turret, cover and
similar places.
(6) For heavy bar type of material, pay attention to the size and angle of center
hole. (lathe)

(1) Rotating and backlash shall not be continued within 5 seconds.

(2) The direct ray of light and heaters may distort the machine. The precision of
the machine may be obstructed.

(3) Do not shock when workpiece engages in the axis spindle. (lathe)

(4) Be cautious not to drop chips on the bed sliding surface. If the machine is
damaged due to the chips, remove with the oil whetstone and move the saddle.

(5) Check the motor lubrication, and sliding parts for evidence of proper lubrication.

(6) Make the length within specified value to prevent the interference of tool.

(7) Verify that the blots of each section are completely engaged.

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(8) Verify that the blots of each section are completely engaged.

1.3.7 Caution for Handling the Machine

(1) Operate it after understanding the function and usage of each instrument
before operating.

(2) Close the door of the power supply board to prevent the damage from water,
chip and oil.

(3) Check the tension of the belt. Do not let your hands or fingers get between the
belt and pully.

(4) Clamp the material and equipment precisely. Start cutting from the shallow
cutting off and small amount of transfer.

(5) Do not adjust the position of the coolant nozzle during operating. Adjust the
position after stopping the machine of cutting oil nozzle.

(1) Do not touch the switches with wet hands.

(2) Do not operate switches with gloves on. This could cause malfunctions, etc.

(3) During heavy cutting, chips with high temperature may be burned. Remove
chips not to be piled up.

(4) Confirm the unusual noise of motors or other parts during operation.

(5) For the machine with special parts, proper handling method is required
according to the specification.

(6) Visually check the switch on the Operating Panel and then operate it correctly.

(7) Check the pressure gage indicates correctly.

(8) For handling of heavy material, work it according with safety rules.

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(9) Only trained, qualified workers should operate forklift trucks, cranes or similar
equipment and slings.

(10) Wire ropes or slings should be strong enough to handle the loads to be lifted
and should conform to the mandatory provisions.

(11) Check the fixation & chucking correctly.

(12) Secure your hair and sleeves and then d are secured, and operate to not wind
the it in the machine.

(13) Do not touch rotating workpiece, tool with your hand or do not touch it with
others.

(14) Do not remove the safety cover.

(15) Remove the brush with the chip of tool end.

(16) The attachment & removal of tool to the M/C should be done after stopping the
M/C.

(17) Use the normal masker for safety when processing the material, which will be
harmful to the body.

1.3.8 Caution during Machine Operation

(1) Do not let workers body (including clothes) and other objects contact with the
moving machine.

(2) When the system shows abnormality, understand the situation first. If
necessary, cut off the power before taking care of the problem.

(3) When the equipment's performance is not as usual, push the Emergency Stop
button to stop the machine. If necessary, cut off the power.

(4) No one can get into the operation area except the operator. Do not touch the
rotating and moving unit during operation.

(5) When you disassemble the workpiece without pallet changer section, the
distance between tool and it leaves space as possible, stop the tool rotation
simultaneously. (M/C)

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(1) If you dispose the chip that is attached in the tool or fallen on the table, as you
push out it with your hand, to dispose the chip, stop the machine and then
wear the glove, dispose it with blush.

1.3.9 Caution for automatic operation.

(1) Do not lean on the machine during automatic operation.

(2) Close all doors before starting the operation.
(3) Do not touch it when some parts are operating. Before touching it, verify that
operation is completely stopped.
(4) During operating the machine, do not open all door and cover.

(1) Caution that other switches are operated. Check the switch of operation panel
with eye and verify it when switch is operated.
(2) Before performing the operation such as rotation of main axis, tool change, axis
moving, verify that these operation is performed safely.
(3) When new program is run, verify the program. After verifying that any bug is not
existed in the program, machine the workpiece with single block mode. If it is
not resulted in problem, start the automatic operation.
(4) During the automatic operation, caution to not touch other switches.
(5) Do not open the door during automatic operating.

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1.3.10 Precaution during work is stopped.

(1) When leaving the machine temporary after completing a job, turn off the power
switch on the operation panel, and the main circuit breaker.

(2) Perform following procedures to switch off it.

① Verify that warning or abnormal condition occurs.

② Press emergency stop switch.

③ Switch Off the power switch of operation panel.

④ Switch Off main switch.

If you switch off the power without following ready to step, machine will
intentionally operate.

1.3.11 Precaution during work is finished.

(1) Always clean the machine or equipment. (Remove and dispose of chips and
clean cover windows, etc.)

(2) Do not clean the machine or equipment, before it has stopped.

(3) Return each machine component to its initial condition.

(4) Check wipers for breakage. Replace broken wipers.

(5) Check coolants, hydraulic oils and lubricants for contamination. Change them if
they are seriously contaminated.

(6) Clean the oil pan filter.

(7) Before leaving the machine at the end of the shift, turn off the emergency
switch on the operating panel, the machine main circuit breaker, and the
factory feeder switch in that order.

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(8) Switch off the power according with procedure after ending the work, clean the
machine and apply rust preventive oil in the each machine section such as
each slide surface. Specially, for cutting oil usage, caution and apply it.

(9) If machining is completed, clean the machine interior and arrange the machine
around. After lubricating required place, position the table on the center.

(10) If rain and humidity is increased, apply the rust preventive oil after completing
the work and caution to not rust.

1.3.12 Caution for maintenance and Checkup

(1) Confirm whether the main power is turned off before maintenance.

(2) Even after the main power has been turned off, electricity may remain on the
power supply board and electronic equipment. Confirm it before maintenance.

(3) All the doors and covers shall be closed except for the modification. Doors of
NC equipment and power supply control board need special attention.
(4) To prevent the operation of control power ON switch on the main power switch
and operation panel by persons that is not related to the work, Mark the
warning “Do not touch the switch with your hand due to maintaining”.
(5) Do not remove or modify the instrument or electrical circuit that is installed for
purpose of each type of safety such as dog and limit switch for limiting the
stroke of transfer indicator, limit switch for interlocking.

(1) Operator and maintenance personnel should read and observe the warning
signs on the machine. Do not damage or remove the signs.

(2) Only the people who have gotten through required training should maintain,
inspect, modify, supply oil and clean the machine. All the required instruction
shall be observed and the power shall be cut off for those works.

(3) Do not operate the machine while the cover is opened for repair or maintenance.

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(4) Do not use compressed air for the machine maintenance and cleaning. Dust,
small foreign material can be entered in the bearing, slide section.

(5) The floor shall not be wet by water or oil during the machine maintenance and
cleaning.

(6) Use proper support or ladder and wear safety hat when the maintenance has
to be done at an elevated place.

(7) Use specified value of fuse, wire.

(8) Arrange maintenance part, work environment, and make the environment that
can operate it normally.

(9) For unnecessary part, disposed oil, dispose it according with procedure.

(1) For maintenance work, check work, record the result, and then arrange and
store so that it can be referred in future. Verify it under responsible person
session for work result.

(2) Designated products of lubrication oil and grease shall be used only.

(3) Confirm whether the lubrication oil is well supplied on the counter face.

(4) Oil supply and exchange for each part shall be regularly implemented
according to this guide.

(5) After maintenance, rust preventive oil shall be supplied on each part of the
machine.

(6) Specified tools such as spanners and wrenches shall be used for modification
and repair.

(7) Keep enough parts in stock for repairing and replacing.

(8) The person who responsible for maintenance should obey the instructions on
the machine.

(9) Clean the machine after a completion of daily work to make it easier to find out
anything wrong. Cleaning of the machine is important condition of preventive
measurement. Dust, humidity, other foreign material promotes the rust of
electrical unit and machine part and it may be not operated due to fault.

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(10) Check each gage indicates its normal value.

(11) When cleaning the chip, always wear gloves.

Instructions in this guide shall be strictly observed to prevent accidents

and damage during operation and maintenance.

1.3.13 Caution for Handling Electronics

(1) Do not shock on the power supply control board.

(2) Initial wiring of the machine shall be done with the required wires and
unnecessarily long wires shall be avoided. When the initial wiring has to lay on
the floor, protect them form the damage by the chip.

(3) In case of test operation, check the parameter of NC device is set properly with our
instructor attended. Also, do not change any parameters except one for backlash.

(1) Power supply control board is sealed tightly. It shall not be exposed to air.
Direct ray of light or flash light into the power supply control board may
damage the parts. Do not open the control board door for a long time during
power input.

(2) Equipment in the power supply control board shall be used designated
standard products.

(3) When repairing the electric instrument, switch OFF the power of the Operating
Panel. Also switch OFF the Electric Control Panel and then the Power Supply
at factory. Do not move it with power shut off or mark warning such as
nameplate/label, mark usage prohibition in the operation button of machine
and do not operate it but related person.

(4) Do not change the current set point of relay in the control board or the set point

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of volumes. Do not open the door of the control board if possible to prevent
foreign objects and moist.

(1) Special care should be taken in handling the electric instrument of the body.

(2) Clean the fan and filter in the Electric Control Panel regularly.

(3) Check the no. of program on the screen of the Operating Panel.

1.3.14 Caution for Supplying Lubrication

Lubrication oil is important for endurance and accuracy of the machine, so

maintenance for the whole oil supply equipment shall be implemented thoroughly.

(1) Confirm the bottom of oil supply pot so that there is no dust, moist or chips on
the bottom of it. Oil pot should be managed with the greatest possible care. It
has to be distinguished by color and its location has to be carefully decided to
prevent being confused with other oil pots.

(2) User shall inspect the machine regularly. Clean inside of the tank and
exchange the oil when there is foreign object. Do not use the whole amount of
new oil to avoid moist and a deposit.

(1) Use designated kind and amount of oil only.

(2) Oil supply channel shall be cleaned so that dust, moist and chip can not get
into the tank.

(3) When the amount of oil reduction is unusually large, inspect the outlet.

(4) Filters on the pump and within the pipe circuit shall be exchanged with new
ones at least once a year.

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1.3.15 Caution for Handling Coolant

Watersoluble coolant can cause deterioration of rust prevention and cutting

capability due to mixing and increase of microorganism. In case of using
watersoluble coolant, the following shall be observed.

(1) Watersoluble coolant is alkaline so may cause skin trouble since it removes fat
and grease. Operator has to be careful.

(1) Watersoluble coolant can cause deterioration of rust prevention and cutting
capability due to mixing and increase of microorganism. Accordingly
watersoluble cutting oil become putrid and replace it immediately.

(2) Before and after operation, the operator shall not only remove the chips to be
cut but also wipe off watersoluble coolant on each counter face, rotating unit,
saddle and column and apply a thin layer of lubrication.

(1) Watersoluble coolant has the ingredient of removing rust. When the product is
wet, there is no problem but once it dries, it can get rusty. Apply rust prevention
oil after operation.

(2) The method of diluting the watersoluble coolant and the kind of diluents
depend on the kind of watersoluble coolant. Instructions of coolant maker shall
be observed.

(3) Industrial water may contain a lot of microorganism. It has to be checked

before being used as a diluents or supplementary water. Tap water is
recommended.

(4) The following diagram shows the impact of using different oils altogether.

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Necessary management shall be considered according to the decomposition of

the coolant.

(5) By removing the cover per 6 months, it is recommended to clean ball screw,
respective Limit Switch, transmit motor of each joint section, X, Y, Z axis.

(6) Do not use chemical solution type of soluble cutting oil. It has a bad effect the
paint exfoliation, sealing, resin material.

(7) The effect for inlet usage of different oil is as follows. According with cutting oil
status, maintenance must be sufficiently considered.

In case of different oil

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1.3.16 Caution for the Machine Setup

production. Program set up, material line up, offset amount measuring for equipment,
programmed inspection and test production will be included to the machine setup.

(1) This machine is designed to be operated by one trained operator. If two or

more operators are needed, operators have to take care of and communicate
with other operators. If an operator push buttons on the control board or move
the machine while other operators are working on material, material fixing
equipment or cutting equipment, operator himself and other nearby operators
may be severely injured.

(2) Confirm whether the maximum velocity of spindle is set to be below the
maximum velocity of each equipment and holder. Otherwise, material or
equipment can be bounced out of the machine which can harm the operators
or the machine.

(3) Fix the material and cutting equipment properly. During the test process, set
the depth of cut and transferring speed in consideration of the safety.
Otherwise, material or equipment can be bounced out of the machine which
can harm the operators or the machine.

(4) Select the most appropriate equipment, holder and processing method for the
quality and the shape of the material. Conform whether there is any problem
for the processing. Otherwise, material or equipment can be bounced out of
the machine which can harm the operators or the machine. In addition that, It
may deteriorate the precision of the material.

(5) Confirm whether the cutting equipment, holder, material fixing unit and the
material itself are safely fixed or not. Material or equipment can be bounced
out of the machine which can harm the operator or the machine.

(6) Before operating the spindle, confirm whether the equipment has been
precisely fixed and the spindle speed has been properly set. If the equipment
has been fixed unstably or the spindle speed is improper, equipment can be
bounced out of the machine which can harm the operator or the machine.

(7) For handling heavy material or removing or moving equipment, use proper
equipment such as crane or hoist. Otherwise, operator or the machine can be

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harmed due to heavy weight.

(8) Do not touch the light inside of the machine. In case of the machine with
halogen lamps or glow lamps, those lamps are extremely hot to cause a burn.
The lamp will be hot for a while even the machine has been turned off.

(9) For the machine set up, keep the light on for the safety reason. If it is not bright
enough, it is hard to check the circumstances inside of the machine and to
conduct test operation; it can cause the damage on the machine and the
operator can be injured.

(10) In case that the toner oil button is on the toner oil system of the slide surface,
the oil layer can be disappear if the machine has been stopped more than a
day. If the machine is operated under the circumstances, slide surface or ball
screw can be worn off.

(11) In case that the toner oil button is on the toner oil system of the slide surface,
do not push the manual toner oil button for more than a minute for the
protection of the toner oil pump motor. Otherwise, the motor of toner oil pump
can be damaged.

1.3.17 Tool Setting (Lathe)

(1) For tool setting, after stopping the main axis, stop the feed of each axis and
implement it.

(2) Tool should be installed within specified length and diameter. If it is installed
over specified dimension, when turret is indexed, the cover, body is interfered.
If tool of instrument is installed in the holder, rotation tool main shaft can be
rotated. When tool is installed in the holder, set out of instrument or perform it
after converting Mill Spindle to lathe mode.

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1.3.18 Work Chucking (Lathe)

(1) When the work is installed in the chuck, take attention to balance of the work
and do not rotate the spindle with it unbalance.

(2) Jaw uses the standard soft jaw, please install the jaw so that chuck cannot
outer diameter cannot.

(3) For the setting pressure of chuck cylinder, see and determine the chuck
pressure-attaching pressure diagram. For high speed rotation, note that
chuck’s attaching pressure is suddenly reduced by chuck’s attaching pressure.

(4) For soft jaw’s molding, note that molded ring’s securing position and mold
configuration is sufficient. After cutting the jaw, make sure that jaw is corrected
hold the work and chuck’s pressure is properly maintained.

(5) If center work is chucking and centered, please attention the work weight and
center hole, configuration or center propulsion. When heavy object is centered
in the small hole, if it is pressured. it breaks the center end and result to spring
out the work.

(6) Before rotating the main axis, verify that workpiece is securely chucked and
preventive dust hole is correctly fitted.

(7) If you support a long bar material with tailstock, and perform the machining, the
center size of material should be endured it’s load and the contact of center
should be become correct angle.

(8) Please pay attention to not hold his finger in the jaw during chucking the
workpieces.

(9) Do not use the double chuck ingmethod.

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1.3.19 Related Safety Information for Chip Conveyor

(1) When chip conveyor is maintained and cleaned, switch off the power and then
perform it after completely stopping.

(2) During operating the chip conveyor, do not contact your hand or body with
conveyor. As chip conveyor can be operated with switched on. Do not it at
any case.

(3) Do not put your feet and hand in the conveyor during discharging the chip
from chip conveyor.

1.3.20 Other Caution

(1) When there is a problem on the system, grasp the situation and take
measures.

(2) Do not let your body (part of your body or your clothe) within the operation
range of dangerous machine.

(3) In case of earthquake, storm, flood and fire, stop the equipment immediately
and cut off the power.

(4) If correct power supply is not performed, the machine can not be operated
correctly. If power supply is suddenly shut off due to interruption of electrical
power, thunderbolt etc during operating the machine, it can cause the
intentional operation and serious fault including the machine damage. If
voltage of supplied power is abnormal, shut off the main power switch
immediately.

(5) If you switch on after stopping the machine due to interruption of electrical
power, verify that program and parameter, offset data is damaged. If you
operate the machine with above data is damaged, it causes to machine fault.

(6) Take a measurement for the noise prevention of surrounding facility so that
equipment can not mis-operate.

(7) When the workpiece, machine, part is lifted, use sufficient size of rope or strap
so that shock load can endure. For equipment weight and operation/installation

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method, refer to operation description.

(8) Verify the existence and nonexistence of problem before using forklift, crane,
hoist, wirerope, strap, and repair or replace uncompleted part immediately.

(9) For switch key related to safety, manage it by responsible person. (safety door,
lock release key, electrical panel key, etc).

(10) Replace the entire during replacing the belt.

(11) In replacing the battery for backing up memory, perform it with machine
CONTROL ON. If you replace it without marking of the screen, program and
parameter should be deleted.

(12) As interior lighting becomes hot condition, do not touch it immediately after
shutting off.

(13) Perform routine check, regular check according with operation description.

1.3.21 Precaution for Fire Prevention

1. Before using a Machine Tool

(1) Do not place the flammable material and equipment around machine tool
where firing can occurs. (welder, stove, heater, flammable material, etc)

(2) Verify that cutting oil is full and is not contaminated. (Do not use cutting oil
except for specified cutting oil.)

(3) Against fire, stock fire extinguisher in the work area..

2. During using a Machine Tool

(1) Do not smoke around when machine tool operates.

(2) When flammable material such as wood, plastic, magnesium etc processes,
take a caution that fire is not occurred. (Operator should observe it during

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processing)

(3) As spark is occurred in the surface of tool and material can spark,
successive observe it during using the non-soluble cutting oil.

(4) If cutting fluid containing water is used when processing the magnesium, as
firing can occur due to H2 gas discharged with reaction of chip and water,
use the anhydrous oil. However, Water-soluble cutting oil including restraint
that can reduce H2 gas, can be used.

(5) If processing, do not inject other material except for specified cutting oil to
processing object. (light oil or other flammable material).

(6) If processing, verify that cutting oil is injected to processing object.

(7) If processing, do not perform the welding work or work that firing can occur
around machine tool.

3. After using a Machine Tool

(1) Verify that machine tool switches off completely.

(2) Verify that machine tool around is not firing dangerous.

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1.4 Safety Device

1.4.1 Safety Nameplate Type

Safety nameplate has role to safety device that announce dangerous elements resulted
during operator uses machine. Also, it describes the dangerous elements that should be
cautioned during using the machine and accidents type and disaster that can result in
danger.
Use the machine safely after understanding following safety nameplate type and
danger/accident type.

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1.4.2 Attachment Position of NamePlate

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1.4.3 Safety Device

No. Name Function

If the door opened while operating the

1 Door Lock System
machine, it may be in Feed Hold state.

If you press emergency stop switch, all

2 Emergency Stop Switch
operation section is stop.

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1.5 Mechanical Safety

1.5.1 Safety Generals

(1) Working Clothes

a. The working clothes, which are light and well fitted, shall be selected
and its shirttail or trailing end of trousers shall be tied up to prevent from
getting jammed if necessary.
b. Any opened seams shall be darned immediately.

(2) Working cap

a. When working nearby the machine, cap must be put on.
b. For women or long-haired person, hair shall be covered with cap or
towel completely.

(3) Shoes
a. Wearing safety shoes is desirable.

(4) Safety Outfits

a. Proper outfits for work shall be chosen and their usage shall be familiar
with.
b. Any necessary outfit must be worn. (ex: Safety goggle, safety helmet)

1.5.2 Safety Requirement for Hand Tools

(1) General Requirements

a. Any stains on the hands such as oil and water shall be wiped off.
(Using of oil we tool is dangerous due to slipping)
b. Working place shall be kept tidy.
c. The hand tools shall not be used for other than their original purpose.
d. Acceptable quality of tools shall be used.
e. The tools shall be used to match their usage.

(2) Hand Tools Safety Requirements

a. Spanner and wrench works

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① Spanner or wrench shall not be used for substitute use of hammer.

② Proper size of spanner and wrench well fitted with the nuts shall be
used.
③ Tooling works shall be conducted slowly.
④ Tooling works shall be made in a safe manner keeping from hurt or
falling down when removed.
⑤ Monkey wrench too large for small bolts shall not be used.
⑥ Spanner shall not be strained by using pipe or hammered.
⑦ Straining shall be made to the frontward direction.
⑧ Use of steel plate between spanner and nut for improving contact
shall not be made.
b. Screwdriver works
① Proper size of screwdriver, which is fitted with the size and shape of
groove, shall be used.
② Chipped screwdriver shall not be used. (The edge of screwdriver
shall be flat and free of chips.)
③ Screwdriver works shall be made in a safe manner so that the
screwdriver not to be removed.
④ Insulated screwdriver shall be used during electrical works and
electroscopic screwdriver shall be used during electroscopic works.

1.5.3 Safety Requirement for Major Machine Works

(1) Safety Requirements for Machine Tools

a. Tools or materials shall not be placed on the machine.
b. Machine shall not be stopped while feeding is turned on.
c. Machine shall not be stopped by hand or tools while the machine is on
running.
d. Material and cutting tools shall be installed perfectly.
e. Cutting tools shall be installed reduced and replaced soon if the cutting
capability is not satisfactory.
f. Safety goggle shall be used in order to prevent chips from scattering.
g. When removing chips, brush or chip cleaner shall be used and shall not
be treated with bare hand.

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h. Care shall be taken so that the hands are not to be touched to the
cutting edge.
i. Measurement of material shall not be made during cutting or rotating.

(2) Drilling Works

a. Hand, head or rag shall be away from the rotating shaft or drill.
b. Good quality of drill shall be used. Any drill with crack shall not be used.
c. If the cuttability is not satisfactory when drilling, drill shall be grinded
before use.
d. Fixing or unfixing of drill shall be done after the main shaft is completely
stopped.
e. Small items shall be fixed with vice or cleat and shall not be hold with
hand.
f. Drilling of thin items shall be made on the hard plate such as wooden
plate for drilling.
g. When the drill end is pierced out, feed speed shall be reduced to
prevent the rotation of material.
h. When the drill is staged in the material, machine shall be stopped and
drill pulled by hand.
i. When unplug drill socket puller shall be used instead of tampering with
hammer.
j. When pulling drill or chuck, the gap between main shaft and table shall
be reduced and put the wood stuffs on the table to place them.

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1.6 Electrical Safety

1.6.1 Safety for Electrical Equipment

(1) Use of explosion-proof structure

Spark shall not be occurred when operating the equipment in where there is
potential explosion due to gases, flammable materials, dusts, etc. Therefore,
switches and others shall be made with explosion-proof structure.
Explosion-proof structure can be classified into pressure explosion-proof
type, Liquid explosion-proof type and special explosion-proof type.

(2) Checkup of electrical facilities

a. The safety of insulated wires, insulated covers and fences of wiring,
cables, switches and electrical machines and equipment shall be
checked and repaired as necessary.
b. Grounding of equipment or breaking of wire shall be checked out.
c. Fuse box and various safety systems shall be checked whether they
are in normal operation or not.

(3) Protection from electrostatic hazard

a. Spark may lead to explosion when there is electric discharge due to
electrostatics in where there are dusts, explosive materials and
flammable gases.
b. Electrostatics is easily occurred when transporting gasoline, flour, etc.
or milling of solid, and printing work.
c. In order to reduce electrostatics, friction shall be reduced, flow
maintained and grounding made as possible.
d. Damping agent or ionization of air shall be used to neutralize
electrostatics as necessary.

1.6.2 Electrical Hazard and its Precautions

(1) Resistance and electric shock of human body

There is higher possibility of electric shock when human body is electrified.

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The danger of high voltage is even greater. Some may think that he will be
safe at about 100 V of voltage but there is a case that someone died at the
low voltage of 35 V.
Human body is quite resistant against the current to reduce current flow in
the body. However, even the lowest voltage may give great impact on
human body. The currents and degrees of electric shock are as follows:

Table 1-1-2. Current and Degree of Feeling

Current Degree of Feeling Current Degree of Feeling

Danger, potential
Bellow 1 [mA] Weak feeling of current Above 50 [mA]
electrocution
Bellow 5 [mA] Significant pain Above 100 [mA] Fatal death
Muscular contraction,
10~20[mA]
loss of command

1.6.3 Over-current Relay

The over-current relay is designed to block current to protect circuit in case of

voltage above rated current. It can be classified into electronic type, thermal type
and induction type. Among these, thermal type is most frequently used. Thermal
type over-current relay is made using bimetal. In case of current over designed
current in the circuit, bimetal is heated up and contact opened to cutoff electric
current.

Type Description
Sensitive to the movement as it is designed to send electric
Direct heating type current directly to the bimetal but have loss of current due
to resistance.
Bimetal is covered by asbestos for insulation and coiled
with heat element (nichrome wire). One end of heat
Semi-indirect type
element (nichrome wire) is connected to the bimetal to
send electric current.
Electric current is not sent to the bimetal and sent only to
Heat release type
the heat element (nichrome wire), resulting slow reactive.

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1.6.4 Failure Diagnosis and Control of Various Switches

(1) Control and switching disabled

a. Deposition due to short circuit
b. Insufficient capacity of switch
c. Longer operation hours of motor
d. Negative phase damping
e. Large remanence
f. Deposition due to vibration of contact resulting from low-voltage
g. Section of iron core is too big or inside of bobbing is too small
h. Sticky oil on the surface of core

(2) Abnormal reduction of electric current at the contact

a. Developing of arc due to the above a.~e. reasons
b. Frequent operation
c. Developing of arc due to bad or dirty contact

(3) Loose contact and its countermeasures

a. Parallel connection of contacts
b. Removal of foreign substances at the contact

(4) Failure of thermal type over-voltage relay

a. Burnt out of heater
b. Failure of operating characteristic

(5) Phase short circuit

a. Phase short circuit due to dust and moisture
b. Phase short circuit due to arc heating

(6) Cause of coil burn out

a. Short circuit
b. Over-voltage (more than 110 % of rated voltage)
c. Low-voltage (less than 85 % of rated voltage)
d. Deterioration due to passive cutting fluid
e. Failure of Movable contact
f. Excessively frequent switching

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(7) Cause of electromagnetic vibration

a. Low-voltage
b. Foreign substance at contact
c. Rusty electrode
d. Short of shading coil

1.7 Industrial Accident

1.7.1 Causes of Industrial Accident

(1) Human factors

a. Psychological factor : overwork, mistake, lack of proficiency, violence,
excitation, inadvertency, willfulness, etc.
b. Physiological factor : adverse effect on physical strength, physical
defect, illness, drinking, lack of sleep, fatigue, etc.
c. Others : clothes, factory works, etc.

(2) Physical factors

a. Building (Environment) : insufficient ventilation, insufficient lighting,
narrow workplace and narrow corridor.
b. Facilities : Bad safety system, broken machine, bad tools and
inadequate facilities.

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1.8 Industrial Safety and Countermeasures

1.8.1 Safety Signs and Colors

(1) Working Environment

a. Lighting and illumination: Daylight of sunray (4500 lux) shall be used as
possible.
b. Ventilation: The most desirable temperature, humidity and airflow in
Korea are as follows :

Summer 25~27 ℃

Winter 15~23 ℃

Relative Humidity 50~60 %

Airflow 1 m/s (current of air)

Table 1-1-3. Intensity of Illumination

Factory Office
Super precision
1500~700 Precise desk work 1500~700
work
Precision work 700~300 Normal desk work 700~300
Reception room,
Coarse work 155~70 300~150
den

c. Noise
Noise means a sound causing unpleasant feeling to the listener in
general. The tolerance of noise level is different depending on the
researcher but is within the range of 85~95dB.
※ dB: unit of sound pressure

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1.8.2 Fire and Explosion

(1) Preventive measures against fire and explosion

a. The source of fire shall be controlled so that there is no dangerous
source of fire nearby.
b. Necessary measures against power failure shall be provided including
redundant power supply since the power failure during work may cause
perplexity and even fire.
c. Pipes and equipment shall be checked thoroughly whether there is any
a flammable gas or steam leaked or not.
d. In order to prevent malfunction of machines and mechanical appliances,
it is necessary to provide auto control system, rearrange valves so as
not cause confusion, and indicate switching status clearly.
e. Adequate distance from shall be maintained in order to prevent burning
out from fire.
f. Necessary firefighting facilities shall be provided in proper locations to
take on fire.

(2) Fire in the workplace

a. extinguishing measures
① Fire extinguisher shall be provided in the location easily identified
and in the location easily accessible in where there is high
possibility of ignition.
② In case of outdoor fire extinguisher, it shall be kept incased.
③ Any dangerous or flammable material shall be avoided nearby.
④ Regular monitoring shall be made for the fire extinguisher so as to
use it whenever necessary.

Table 1-1-4. Type and use of Fire Extinguishers

Use
Type Normal Fire Oil Fire Electrical Fire

Foam fire extinguisher Fair Fair Poor

Powder fire extinguisher Good Good Good

CO2 fire extinguisher Good Good Fair

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1.8.3 First-aid

(1) First-aid items need to be provided

01. Gusset 02. Bandage 03. Gauze 04. Plaster

05. Wadding 06. Cotton (If bending, 07. Scissors 08. Tweezers
for fix the block)
09. Styptic rubber 10. Splint 11. Tourniquet 12. Alcohol
strap
13. Iodine tincture 14. Mercurochrome 15. Boric acid 16. Ammonia
solution solution
(2) First-aid
a. Cut (stab, wound and scratch)
① Wound shall not be touched with dirty paper or gusset.
② Wound shall be exposed so as not to be irritated.
③ Mercurochrome shall be applied on the wound and a bandage
applied to it.
④ Surrounding of wound shall be cleansed.
⑤ Dirt or soils stuck to the wound shall not be removed forcedly.
b. Bruise and sprain
① Iodine tincture shall be applied on the bruised or sprained area. (it
shall not be used together with the Mercurochrome)
② A cold pack shall be applied to the bruised or sprained area.
③ Hear, chest or abdomen shall be treated by doctor.
c. Bleeding
Blood accounts for 7.7 % of weight of human body. It is dangerous if
more than 30 % of blood is shed and lead to fatal death if more than
50 % of blood is shed.
① In case of vein hemorrhage (dark red blood), blooding area shall be
pressed by using the sterile surgical compresses or by hand with
gauze and held to the higher position.
② In case of artery hemorrhage (cardinal blood), treatment by doctor
is necessary and blood shall be stanched by using the sterile
surgical compresses, acupressure and emergency haemostatic.
③ In case of hypodermic bleeding, hot pack shall be applied followed
by cold pack.

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d. Burn
① In case of first-degree burn (red and sore skin), cold pack or boric
acid solution pack shall be applied on the target skin.
② In case of second-degree burn (red and blistered skin), similar
treatment shall be made as in the case of first-degree burn but
blister shall not be broken.
③ In case of third-degree burn (necrosis of subcutaneous tissue),
similar treatment shall be made as in the case of second-degree
burn as a first aid and treatment by doctor shall be made
immediately.
④ If the burnt area reaches over 30 % of the whole body, even the
first-degree burn may endanger and fatal and care shall be taken in
treatment.

1.8.4 Regulations for Mechanical Safety

(1) Regulations for safety management in workplace

a. Compulsive installation of safety devices for the dangerous machines :
dangerous machine or device shall not be disposed, leased or installed
without safety device provided.
b. Dangerous machines :
proper size and capacity of safety devices shall be provided for
dangerous machines including grinding machine, press, cutter, saw,
plane and roller welder.
c. Type of safety devices :
following safety devices are used to secure safety from dangerous work.
① Two-hand control safety device
② Magnet safety device
③ Sweep-guard safety device
④ Gate type safety device
⑤ Cut-off safety device
⑥ Pull-out safety de-vice
⑦ Photo electric safety device
⑧ Voltage reducing de-vice

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d. Prevention of hazard
① The owner shall provide safety device for the facilities dangerous or
hazardous.
② The worker shall perform works conforming to the safety requirements.
e. Dangerous works
① Machine or device requiring dangerous work cannot be manufactured,
installed and modified without approval of the Ministry of Health and
Welfare in advance.
② Any machine or device, which is specified under the presidential
decree and without performance test of the Ministry of Health and
Welfare shall not be used.
f. Limitation in working at the dangerous workplace
① The owner shall not make the unskilled workers to perform
dangerous work.
② Dangerous works requiring limitation are specified by the
presidential decree.
g. Interruption of power
① Proper power interruption device shall be provided for each
powered machines.
② Emergency stop shall be provided for the device such as roller.

(2) Provisions for safety management in workplace

a. Safety device
① Approval of manufacture for the welding machines : approval of
Ministry of Labor Affairs
② Approval of installation and modification for machines : approval of
Ministry of Labor Affairs
b. Performance test (validity period)
① Engine: 1 year
② Crane: 2 years
③ Oxyacetylene welding machine: 3 years
④ Pressure vessel: 1 year
c. Companies need to employ safety manager
① All companies with more than 50 workers and the companies with
less than 50 workers and specified by the Ministry of Labor Affairs
shall employ the safety manager.

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 Safety Articles

② The safety manager means the traffic safety manager as prescribed

by the Article 7, Traffic Safety Law.
③ The responsibility of safety manager is as follows :
1) Taking emergency and preventive measures against the hazard
due to working in the building, facility, workplace or work
method.
2) Procuring and checking the performance of safety devices and
safety outfits.
3) Conducting regular checkup and maintenance of safety devices,
safety outfits, fire fighting facilities and other hazard preventive
facility.
4) Providing training on the safety of work.
5) Investigating the causes of accident and preparing their
countermeasure.
6) Agreeing to the placement of workers requiring agreement by
safety manager.
7) Supervising safety assistant.
8) Providing comment and recommendation on the workers
violated safety regulation.
9) Documenting and recording major safety items.
10) Other safety related.
11) For the work requiring special safety measure, assistant safety
manager shall be positioned to assist the safety manager.
d. Corridor and workplace
① The area within 2 m from the corridor wall shall be cleared not to
have any obstacle.
② The width of corridor between machines shall be at least 80 cm.
③ Emergency exit: at least 2 emergency exits shall be secured.
1) At the indoor workplace in where explosive or flammable
materials are used.
2) And at the outdoor workplace with more than 50 permanent
employees.
④ Stairs
1) The stairwells shall be provided in 5 m intervals for the stairs
with more than 5 m of height.

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2) Handrail shall be provided at least on one side of stairs.

⑤ Emergency stairs: at least 2 emergency stairs to the outdoor shall
be provided for the underground workplace or second floor or
higher with more than 20 workers.
⑥ Structure of temporary access
1) The slope of ramps shall be lower than 35° and proper anti-
sleep shall be provided for the ramp with more than 15° of
slope except proper footstep or handrail with lower than 2m of
height is installed.
2) In the place with potential falling hazard, solid handrail with
more than 75 cm of height shall be installed.
3) If the length of temporary access in the shaft is longer than 15 m,
stepping fences shall be provided for every 10 m.
4) For the temporary landing stages with higher than 8 m of height,
redundant shall be provided for every 7 m.

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Installation Manual
Chapter 1 Acceptance, Transportation
and Installation
1.1 Preparation for Acceptance ...................................................... 2-1-3
1.2 Introduction ........................................................................................... 2-1-5
1.3 Specification of NC device ..................................................... 2-1-6
1.4 Shipment ................................................................................................ 2-1-9
1.5 Machine Transportation ......................................................... 2-1-13
1.6 Conditions and Environment for Installation ....... 2-1-18
1.7 Level Modification ........................................................................ 2-1-23
1.8 Shipment, Disassembling and Cleaning of
The Fixed Unit ................................................................................ 2-1-30
1.9 Re-Installation of other Equipment .............................. 2-1-31
Chapter 1
Introduction
1.1 PREPARATION FOR ACCEPTANCE ........................................... 2-1-3
1.1.1 Checklist for the Machining Center Acceptance
Preparation ........................................................................................ 2-1-3
1.1.2 Registration and Inquiry for NC Classes .................. 2-1-4
1.2 INTRODUCTION .............................................................................................. 2-1-5
1.3 Specification of NC device ......................................................................... 2-1-6
1.4 SHIPMENT ............................................................................................................ 2-1-9
1.4.1 Items to be Prepared for Witness Inspection ....... 2-1-9
1.4.2 Inspection of driving instruction during the
machine delivery. ...................................................................... 2-1-11
1.4.3 Items to be Prepared before the Machine’s
Delivery ............................................................................................. 2-1-12
1.5 MACHINE TRANSPORTATION ....................................................... 2-1-13
1.5.1 Transportation by Crane ..................................................... 2-1-13
1.5.2 Transportation by Forklift .................................................... 2-1-16
1.6 CONDITIONS AND ENVIRONMENT FOR
INSTALLATION ............................................................................................... 2-1-18
1.6.1 Process of Machine Installation .................................... 2-1-18
1.6.2 Conditions and Environment for Installation ....... 2-1-19
1.6.3 Items to be Prepared before Installation ................ 2-1-20
1.6.4 Basic Arrangement Plan ..................................................... 2-1-21
1.6.5 Basic Arrangement Drawing ........................................... 2-1-22
1.7 LEVEL MODIFICATION ........................................................................... 2-1-23
1.7.1 Level Modification ..................................................................... 2-1-23
1.7.2 Grounding ....................................................................................... 2-1-25
1.7.3 Connecting Main Power ..................................................... 2-1-27
1.8 SHIPMENT, DISASSEMBLING AND CLEANING OF
THE FIXED UNIT .......................................................................................... 2-1-30
1.9 RE-INSTALLATION OF OTHER EQUIPMENT .................. 2-1-31
 Acceptance, Transportation and Installation

1.1 PREPARATION FOR ACCEPTANCE

1.1.1 Checklist for the Machining Center Acceptance Preparation

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1.1.2 Registration and Inquiry for NC Classes

N/C classes for the Machining Center are held regularly once every other month. For
registration, call use with the information of your desirable date and the number of
participants.

Schedule

6 day training (maximum size of a class : 15)

From 9:00 A.M to 5:30 P.M

Day 1 Orientation, Introduction to WIA Corporation, Basic NC

Day 2 Basic Program, Introduction to Program
Day 3 Exercise Program
Day 4 Exercise Program, Introduction to Control Method
Day 5 Exercise Control Method
Day 6 Evaluation, Q&A, Completion

If you have any special inquiry, call us prior to the training.

Note 1) The machine for training may be different from the one shipped.
Note 2) Some of these are subject to be changed

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1.2 INTRODUCTION
• This is a single bodied machine. Only power codes can be transported.
• This machine is composed of three main units of the main body, power supply control
board and coolant tank. Each unit is connected by wires or hoses. For transportation
of this machine, the main body and the coolant tank shall be separated.
• This machine can be transported both by a crane or a forklift.
• For the desirable machine performance, all the installation process in this guide shall
be observed.

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1.3 Specification of NC device

Table 3-1-1. Standard Specifications

No Item Spec. Remark

1 Control Axis X, Y, Z three Axis
Number of Concurrent
2 Concurrent three Axis Parameter Change
Control Axis
Straight Line and Arc
3 Interpolation Function G90/G91
Interpolation
4 Set Unit 0.01 / 0.001 mm
5 Method of Command Absolute/Incremental
6 Tape Code EIA RS-244 A/ISO 840
7 Preparation Function G2 Digit
8 Auxiliary Function M3 Digit
9 Main Spindle Function S4/S5 Digit Override 0~150 %
10 Tool Function T2 Digit
11 Feed Rate Designation F4 Digit Direct Input
Manual Button
12 Automatic Origin Returning
G27, G28, G29
13 2nd Automatic Origin Returning G30
14 Automatic Coordinate Setting
15 INCH/METRIC Conversion G20/21
16 Tool Length Offset G43, G44, G49
17 Tool Offset G45~G48
18 Character Display 8.4 inch Color TFT LCD/MDI
19 Backlash Offset 0~255 Pulse
20 Mirror Image(external)
JOG Feed, Manual 0~5000 mm/min
21 Continuous Manual Feed
Rapid Feed (24 Step)
22 Fixed Cycle B G73, G74, G76, G80~G89
23 Manual Pulse Generator Remote MPG X1, X10, X100
24 Tape Memory 1280 m
25 Rapid Feed Override F0, 25, 50, 100 %

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No Item Spec. Remark

26 Stored Stroke Limit-1 Parameter Change
27 Stored Stroke Limit-2 Parameter Change
Memory Type Pitch Error
28 ± 0~7 μ (128 Positions)
Offset
29 Manual Absolute ON Compensation
30 Tool Offset C G40~G42, G39
31 Coordinate System Setting G92
32 Exact Stop Check G09
33 Exact stop check Mode G61
34 Continuous Cutting Mode G64
35 Rigid Tapping M29/M28 BUILT-IN SENSOR
36 NC Self-Diagnosis Function
37 Point Input
38 Auxiliary Function Lock
39 Z-axis Command Cancel
40 Program Number Search By MDI command
41 Dwell G04
42 Override Cancel By M function
43 Automatic Acc/dec
44 Work Coordinate System G54~59
45 POSITION SWITCH
46 Buffer Register 256 Byte
47 Helical interpolation
48 Programmable Data Input G10
49 Custom Macro B #100~#199, #500~#999
50 Addition of Common Variable
51 Tool Offset C
52 Tool Length Offset
53 Program Restart 400 ea
54 Playback
55 Watch Function
56 Alarm History Display
57 Servo setting screen

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No Item Spec. Remark

58 Main spindle setting screen
Addition of work
59 48 ea
coordinates
60 coordinates rotation
61 Cylinder interpolation
3nd, 4nd Automatic Origin
62
Returning
63 Scalling
64 2nd Auxiliary Function
65 Background Editing
66 Operation History Display
67 Input of outer data
68 Tool Offset 6 Digit, 400 ea
Label Skip, Single Block, Dry Run, Optional block Skip, Interlock, Machine Lock, Retardation Outdoors

Table 3-1-2. Option Specifications

No Item Spec. Remark

Heat displacement
1
compensation unit
Both direction of pitch
2
compensation
3 Manual guide 0i
4 4-Axis Function
5 Manual guide i
6 Dynamic graphic display

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1.4 SHIPMENT

1.4.1 Items to be Prepared for Witness Inspection

1. In case of standard witness inspection

Standard witness inspection checklist that HYUNDAI-KIA MACHINE prepared
will be used.
2. In case of designated material inspection
In case that the customer prepares inspection instead of HYUNDAI-KIA
MACHINE, the following shall be prepared.
1) Processing plan of the designated material
Only one material shall be designated(HYUNDAI-KIA MACHINE does not
inspect for two or more material).
2) Processing plan
Enter the previous program, standard surface and production location onto
plan before sending out. (Indicated in red)
3) Equipment list
(The table woth both the area to be processed and equipment holder/bite
shall be attached.)

Table 2-1-3 Example Tooling Summary

NO. Operation Content Tool Holder Type Adapter Amount Maker

1 Surface Cutting BT40-FMC22-90 SK-5.0 1 NIKKEN

2 M6 inner diameter BT40-SK6-195 1 NIKKEN

12 M12 Tap BT40-TP3A-1-140 WES1B-M12 NT

NO. Type of Bite Number Manufacturer Remarks

1 63 X 521 1 SECO
2 DRILL 1 K.H

12 M12 X 1.75 1 O.S.G

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4) Assembly Diagram
<Material Fixture> diagram of table at the state of fixture part shall be
submitted.
Evaluation sheet with the number of installation shall be submitted.
5) The date of designated witness inspection
The material of the customer shall be sent to HYUNDAI-KIA MACHINE
2weeks before the inspection date.
① One processed designated material and some of material
② Equipment holder and bite(including equipment list)
③ A set of Fixture(including the diagram and evaluation sheet)
④ Inspection criteria for the material(if there are its own tools, they shall be
provided)
6) Others
Any specification such as the use of coolant, processing order, criteria for
tape or specified cycle time shall be provided.

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1.4.2 Inspection of driving instruction during the machine delivery.

1) Shipment and Acceptance

The date of machine shipment and acceptance will be fixed during standard
witness inspection or designated witness inspection. If no change has made on
the machine specification, the machine will be shipped within few days from the
witness inspection.

2) Preparation for Machine Acceptance

See "1.3.3 Items to be prepared before the Machine's delivery" for preparation.
User's guide also explains the detailed of preparation. If it is necessary to make
things clear, explain them during witness inspection. Operation
diagram(processing drwaing), fixture, equipment, bite and tape, etc. shall be
prepared when there is the material for designated cutting after machine delivery.

3) Machine Installation
The location of installation shall be specified to the professional shipping
company. HYUNDAI-KIA MACHINE is responsible for the machine installation,
and it will take 3~4 days. N/C equipment will be leveled within this period of time.

4) Operation Training
Different personnel will take care of installation and training. Training will take
3~4 days. Program explanation and cutting training will be performed for only
one material. Specify whether operation training is necessary or not.

5) Metage
Metage will be conducted with Work confirmation document after machine
installation or operation training.

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1.4.3 Items to be Prepared before the Machine's Delivery

Table 2-1-2 Items to be prepared before the Machine's delivery

NO. Item Detail Spec.

1 Coolant Capacity 400 ℓ

Capacity 2ℓ
2 Lubrication oil
Kind G68, ML0371H

Pressure 5 Kgf/㎠

3 Air supply Capacity 250 ℓ/min

Size of inlet PT 1/4 inches

Ampere 25 kVA

Voltage AC220 V±10 %, 3-phase

Frequency 60 Hz±1 %
4 Power Supply Grounding Better than type 3 of electronics, less than 100 Ω
Power circuit
100 A
breaker
Minimum thicker than 5 ㎟
thickness (for grounding, thicker than 14 ㎟)

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1.5 MACHINE TRANSPORTATION

• This machine can be transported by a crane or a forklift.
• Pay special attention for lifting and transportation this machine.

1. The machine may collide to nearby obstacles. Pay special attention while
transporting the machine.
2. Do not pass by or stand below the machine when it is lifted.

1. Confirm whether the machine's each part is fixed before transporting it.
2. Lift the machine gradually considering overall balance.
3. Do not shock the main body, power supply control board and other electric
equipment.
4. Coolant tank shall be separated before transporting the machine.

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1.5.1 Transportation by Crane

1) The machine shall be kept horizontal in any circumstances.

2) The machine shall be firmly fixed to the transportation equipment so that it will
not move.
3) Wire rope may damage the hook area of upper part of the machine. Protect that
area with cloth(protection cloth) for transportation.
4) Wire rope shall be thicker than Ø30 ㎜.
5) The machine shall be lifted slowly. As soon as the machine is lifted from the
ground, stop and check the balance of the wire rope and the machine.
6) See the following illustration. The wire rope shall be fixed on the hook of the
upper part of the machine for transportation.

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1. This machine is heavy. Required lifting fixture shall be used only for lifting and
transporting the machine with the crane.
2. Check the balance of right and left, front and rare when the machine is lifted slightly.
Check whether the rope, cover or other parts are get touched.
3. Then two or more people are involved to the lifting, everybody has to communicated
with each other.
4. For lifting up the machine, wind it up slowly until the wire rope is flat. Stop and check
the location of Fixture before moving the machine up to necessary height.
5. Pull down the machine slowly and check the location before putting the machine on
the ground.
6. People with experience shall operate the crane.

7) Confirm the following for transportation.

① The center of the machine weight shall be on the lifting part of lifting
fixture. Modify the center of the machine weight moving saddle and
table. The fixture center of the machine weight shall be as low as
possible; Spindle head shall be lowered.
② Capacity of the wire rope and the crane shall be as following.
▶ Wire rope thicker than 30 ㎜
▶ Crane more than 30 ton of allowed weight
③ Location of the wire rope
▶ Fixture of right, left, front and rare side of the bed.
▶ Fixture of the upper column

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1.5.2 Transportation by Forklift

1) The machine shall be keep horizontal in any circumstances.

2) The machine shall be firmly fixed to the transportation equipment so that it will
not move.
3) The forklift to be used shall be checked the following;
whether the loading surface is proper for the machine transportation
whether the loading surface can bear the weight of the machine
whether the loading surface is flat.
4) When you use a fork-lift truck, do not have the lug touch and lift the auxiliary bed,
but lift the main bed.
5) The forklift shall not move while loading the machine.
6) As the following illustration, the machine shall be lifted after being located to the
LUG spot.

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1. The people who have operating license of the folklift shall operate the folklift.
2. Other than the operator of the folklift, one more personnel shall monitor the process
so that the projected parts are not damaged.
3. The machine shall be put on the ground slowly to prevent shock.
4. The machine shall be lifted using a wood material between the folk of the folklift and
the machine.

1. It there are no lifting mark or 'handle with care' sticker, call HYUNDAI-KIA MACHINE
to get them before transportation.
2. The folklift with enough capacity to bear the weight of the machine and its wooden
case shall be used. For the long distance transportation of the machine, a safe
vehicle shall be used for safety reasons.
3. The folk shall be put into the groove on the bed side of the lower part of the machine.
4. For changing direction of the machine and lifting, do not have the lug apply a force to
the auxiliary bed part, but work with the main bed.

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1.6 CONDITIONS AND ENVIRONMENT FOR INSTALLATION

This chapter explains each step from the machine location, conditions and environment
of the machine installation to the final level modification. These are all necessary
information for users to prevent machine error and malfunction due to wrong installation.
Users shall understand and observe the following conditions, environment and method
of the machine installation.

1.6.1 Process of Machine Installation

The following process shall be observed.
1) Move the machine to the location to be installed.
2) Remove all the wrapping material covering the machine.
3) Assemble additional parts to the main body.
4) Connect the power cable.
5) Turn on the main power switch on the right side of Control box.
6) Turn right the Emergency Stop switch to release. It is on the control panel on the
machine front.
7) Turn the Operate/Stop switch to toward operate. It is on the control panel.
8) The preparation process of the machine operation has been finished.

Table 2-1-3 Process of Machine Installation

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1.6.2 Conditions and Environment for Installation

1. Installation Environment
The following shall be avoided.
1) The place with direct ray of light, near heating elements, with too much
temperature change
2) The place with excessive dust and moist
3) The place near vibrating machines
4) The place with weak ground
5) The place with uneven or slide ground

2. The following places are favorable to install the machine.

1) The place without condensing and dewiness due to the temperature change
2) The place with an even and resistant surface
3) The place with stable utility supply and maintenance
4) The place where the machine can be easily relocated
5) The place without the danger of fire or explosion

Table 2-1-4 Installation Conditions

Classification Contents

Temperature 0℃~45 ℃ Celsius shall be maintained

Humidity 10 %~75 % RH

Additional space at least of 600 mm around the machine for

Space
maintenance and repair

Light lighting facility of at least 300 Lux

Purity Better than Class 100

Noise Lower than 70 dB(A)

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1. All the warnings and cautions shall be understood by users before machine
installation.
2. Remove all the moist and oil on the floor to prevent the operator from slipping during
installation.
3. Check whether the location is appropriate for machine installation.

1. When there has to be a vibrating machine nearby, some kind of a vibration absorber
shall be placed around the machine.
2. If special options are attached on the machine, the space for maintenance shall be
insured.
1.5.3 Items to be Prepared before Installation

1.6.3 Items to be Prepared before Installation

This chapter explains necessary equipment and minimum personnel to be required.
See the following requirement.

Table 2-1-5 Items to be prepared before machine installation

Equipment Number of the equipment

Horizontal Gauge(leveler) 2

Spanner(width of 32 mm) X 32 1

Tape measurer(500 mm) 1

Required personnel 2

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1.6.4 Basic Arrangement Plan

Due to the characteristics, the machine shall be installed on a support with the
capacity of pressure-resistance and the thickness of more than 600 ㎜. When the
plant's floor is covered with concrete, additional support work may not be
necessary. However, the concrete floor's intensity and pressure resistance shall be
checked.

This machine shall be installed by the personnel qualified by HYUNDAI-KIA

MACHINE. HYUNDAI-KIA MACHINE is not responsible for any problems cause by
unqualified personnel or failure to observe this instructions.

1. Pay special attention to the basic support work. Poor basic support work may lead
deterioration of the machine's precision.
2. The machine shall be installed on strong and resistant ground. When the ground is
made of wood or shock absorbing material, excessive vibration may be expected
during machine operation.

1. Basic Installation
1) For the machine installation, concrete ground with the thickness of at least
600 ㎜ is required. Lay leveling sheet beneath the leveling bolt.
2) To maintain the machine's precision for a long time, put a new concrete
ground as shown on the Basic Arrangement Plan, if the thickness of concrete
ground is less than 600 ㎜.
3) Lay leveling sheet on the location specified by the Basic plan.
4) After putting leveling bolt on the machine, place the machine on the
leveling sheet so that the machine is lifted about 20 ㎜ from the ground.
5) Modify leveling bolt to level the machine. Tighten the fixing nut.
6) Confirm the leveling bolt at the lower part of the machine.
7) Keep in mind that the use of leveling bolt will enhance the safety of the
machine.

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1.6.5 Basic Arrangement Drawing

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1.7 LEVEL MODIFICATION

Leveling is one of the factors to decide the machine's precision. Leveling is the most
basic process and related to the machine's performance as well as the durability.

1.7.1 Level Modification

1. The following process shall be observed.
1) Install the machine as the instruction of 1.5.1 Process of Machine Installation
on the location to be installed.
2) Install the leveling equipment on the center of the table as illustrated below.
3) The leveling equipment shall be precise with the sensitivity of 0.02 ㎜ for a
graduation of 1m.
4) Make sure that each end of the leveler lies in the same direction.
5) Modify the leveling equipment so that the deviance of the right and left, front
and rare readings are within 0.04 ㎜/m.

Leveling equipment
수준기

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1. The surface for the leveling equipment shall be always clean. Do not let dust stick
onto the bottom of the leveling equipment.
2. If the machine's level is not modified, the machine may be tilted to lead bed and
counter face wearing out.

2. After finalizing the leveling, the basic bolt and level modifying nut shall be
firmly fixed.

3. The term of level management after machine installation is as following.

Table 2-1-6 Term of level management

Time Term

2~3 days after machine installation everyday

For the 6 months since machine installation every 1 month

After the 6 month from machine installation every 3 months

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1.7.2 Grounding
Earth connections standards are set out in local electrical codes (based on Class 3
Grounding, Article 18 from Korean Electrical Codes). This machinery uses
independent earth connection, in special circumstances where earth connection is
not possible, earth connection conditions should be carefully thought out before
connection works begins.

1. Grounding conditions and methods

Table 2-1-7 Type 3 Grounding

Category Condition

Grounding Resistanc Less than 100Ω

Grounding wire Section sid More than 5.5 ㎟

1.5 times of the thickness of the power supply wire

Thickness of wir
(minimum 14 ㎟)

Measure 500V MEGGER

1) One wire shall be used for a terminal to prevent severe accident due to inflow of
leaked electric current from other damaged equipment in case of contact failure
of the grounding terminal.
2) When the steel frame of a building is used for grounding, the grounding
resistance will be less than 100 Ω. In this case, the following shall be considered.
This method shall be selected when it is connected to the regular terminal.
3) Grounding cable shall be as short as possible.
4) Confirm grounding resistance. When an equipment has been connected to one
grounding polar, the grounding resistance has to be less than 100 Ω.
5) All electric equipment shall be grounded after installation according to
specification in order to prevent human and machine damage.
6) Designated a grounding point near the machine and ground independently.
7) Grounding shall be performed by an experienced personnel. Type 3 grounding is
required.

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Grounding shall be performed by an experienced electricity expert. Otherwise, severe

injury, death or machine malfunction can be occurred.

2. Ideal grounding method

3. Inappropriate method

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1.7.3 Connecting Main Power

For power supply to this machine, the plant's power shall be wired to the machine's
power supply control board.
Power inlet is located on the lower part inside the control box.

1. Power Switch
Power Switch shall be installed separately at the place where it is easy to open
and close the machine switch. For fuse capacity, refer to the following table.

Table 2-1-8 Allowance of Power

Power Capacity Used wire(㎟)

Fuse(A)
(KVA)
R.S.T Grounding Line

25 14 22 100

2. Exchange of Electric machinery according to voltage and frequency

The configuration of electric machinery needs to be modified in accordance with
the voltage of the plant's power and the frequency. Confirm the voltage and
frequency before modification.

• Voltage 200/200 V ± 10 %
• Frequency 50/60 Hz ± 1 Hz

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If the voltage fluctuates too much, it can lead machine's error and malfunction of
electric/electronic parts. The voltage shall fluctuate within +10 % range.

1) Tap change of control transformer

Open the door of power supply control board and separate the plastic cover from
the transformer. Change the wiring according to the table below.

Table 2-1-9 Voltage

Main Power Voltage R2 T2

191~210V 200V 0V

211~240V 220V 0V

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2) Separated Transformer
In case of 380 V or 440 V voltage, the transformer with 25 KVA that
HYUNDAI-KIA MACHINE has been provided shall be used.

<Power supply switch> <Separated Transformer> <Power supply control Box>

Electric equipment generating high frequency noise(Welding machine, high frequency

dryer, anti-electric processor) shall use a separated distributing board or install another
distributing board to be apart more than 20 m.

When the voltage exceeds the allowance(see Table 2-1-8) or fluctuate too much, a
constant voltage equipment is required. If equipment like welding machine is to be
contacted to the power line, excessive noise may be generated and cause machine
malfunction. Separated those equipment from machine power line.

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1.8 SHIPMENT, DISASSEMBLING AND CLEANING OF

THE FIXED UNIT
• At the time of shipment, each axis and balance weight have been firmly tightened for
the safety reasons. Do not operate the machine without releasing them.
• When the machine is manually operated, rust-proof dye can be spoiled by soil or dust.
Before machine cleaning, do not move table or saddle.
• Shipment fixed unit shall be released before machine cleaning. When there is no
special comment from HYUNDAI-KIA MACHINE, clean the rust prevention oil with
light oil or cleaning oil and apply lubrication oil to the cleaned area.
• Remove moist from all the machine surface. Remove all moisture on machinery.

1. Avoid compressed air for cleaning. Alien substances may be held between narrow
space, which can cause damage on the surface.
2. Oil or chemicals that may damage the coating of the main body shall be avoided
when cleaning. Avoid fire.

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1.9 RE-INSTALLATION OF OTHER EQUIPMENT

After finishing dismantling the shipment fixing unit, equipment to be dismantled for
damage prevention or convenience of transportation shall be re-assembled.

1. Assembly of Splash Guard

For smooth operation of the machine, you should reassemble the splash guard that
was disassembled before shipment.

2. Fixing Operating Panel with Mounting Bolt

Fix the operating panel, mounted inside the machine for convenient transportation
of the machine, to a place where no interference with the splash guard occurs when
you rotate the operating panel.

3. Connector assembling
Connector to connect each equipment shall be connected to the power supply
control board on the right direction of the machine.
1) Wire connector for standard coolant equipment
2) Pipe connector for standard coolant equipment

4. Coolant Tank and Chip Box Installation

1) After you put the chip box (chip conv.) on the cutting oil tank, push the tank in
while watching out the position of the outlet of the right and left splash guards in
front of the machine. If it does not fit, it may cause cutting oil leakage.
2) Connect pump wire and pipe connector. If there is penetrated coolant equipment
attached, connect it.
3) Connect the wiring connector for the oil skimmer to the pump of the auxiliary tank
for collecting lubricant.

5. Option installation
Confirm the location and condition of them, if option equipment has been attached.

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Operating Manual
Chapter 1 Machine Specification
1.1 Machinery Usage .......................................................................... 3-1-3
Chapter 1
Machine Specification
1.1 Machinery Usage .............................................................................................. 3-1-3
1.1.1 NC operating panel description ....................................... 3-1-3
1.1.2 DOOR INTERLOCK operation by Key
switch change ................................................................................ 3-1-5
1.1.3 Explanation of Key Board ..................................................... 3-1-7
1.1.4 Machine Operation Sequence ...................................... 3-1-23
1.1.5 Manual Operation ..................................................................... 3-1-24
1.1.6 Automatic Operation .............................................................. 3-1-28
1.1.7 Rigid Tap operation ................................................................. 3-1-30
1.1.8 NC Command Value .............................................................. 3-1-33
1.1.9 ATC Operation ............................................................................ 3-1-40
 Machine Specification

1.1 Machinery Usage

1.1.1 NC operating panel description

NAME USE

Select one mode of EDIT(program edition), MDI, Tape,

MODE selection switch
Jog, Rapid, area return and handle.

Start automatic operation by tape and operation by MDI

and MEMORY.
PROGRAM START Program start lamp will get on when the push button is
pressed.(Illuminate the lamp with PROGRAM START
starting.)

This is used for stopping the automatic operation by tape

or memory during program running.
PROGRAM FEED
When this push button is pressed, program start lamp will
HOLD
be out and axis be stopped.
Accordingly, the feed hold lamp will also be out.
Automatic operating group

Feed speed rate is designated on the auto mode

(Command speed 0~200%)
FEEDRATE(%)
Manual feed speed is designated on the JOG mode
(Command speed 0~5000mm/min)
To automatic and manual rapid feed rate, override can be
RAPID OVERRIDE(%)
applied by 4 steps as F0, 25, 50, 100 %.

Only Z-axis come into machine lock state when this

CANCEL Z AXIS switch is put on. The checking for the contact is tape is
SWITCH convenient by pen.
Use this switch only during feeding and block stop.
When this switch is switched on, block which “ / ” is
BLOCK SKIP SWITCH
included will be ignored and operation be going on.

If this switch is put on, operation will be stopped after

OPTIONAL STOP
command to the block is run in case of M01 command.
SWITCH
At this time M01 is read and lamp is lit up.

SINGLE BLOCK Program is run block by this switch.

SWITCH (It can be run continuously in ATC cycle and fixed cycle.)

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NAME USE
If you turn on this switch, NC tape will ignore the given
DRY RUN SWITCH
speed, and is commended as Passive movement speed

FEEDRATE SELECT Manual feed speed is selected by this switch.(Feed speed

SWITCH is divided into 24 steps from 0~5000 mm/min.)

FEED DIRECTION
Direction of feed as + or – is determined by this switch.
SELECT SWITCH

This handle is used to move each axis manually.

1 scale is corresponding to 1 pulse and 1 turn to 100
HANDLE pulses.
Accordingly feed of 0.001, 0.01, 0.1 mm is made in
accordance with magnification.
Automatic operating group

When this button is switched on, feed pulse command is

MACHINE LOCK not given to machine, so machine, so machine does not
SWITCH operate.
(Both manual or automatic mode is possible.)
Its operation supplies ON/OFF coolant.
COOLANT SWITCH
(Both manual or automatic mode is possible.)
EMERGENCY STOP All operation of machine is to be stopped.
SWITCH Control device is reset since servo motor, etc. is stopped.
It is operated for clamping or unclamping tool. If tool is at
TOOL CLAMP,
sate off unclamp, the lamp lights up and main spindle
UNCLAMP SWITCH
does not turn.
Pressing start button starts the motor and stop button
SPINDLE START/STOP
stops it.

CALL LIGHT OFF Call light(rotating lamp) will be out when pressing CALL
SWITCH LIGHT OFF push button.

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1.1.2 DOOR INTERLOCK operation by Key switch change

AUTO MODE & DOOR STATE Remarks

LOCK PROGRAM WRITE
ON ON
■ DATA INPUT Disable
PROGRAM - Setting Data input
- Program registration, edit
SPINDLE - PMD DATA input
However, offset should be input.
■ Sheet key Switch Operation Disable
AXIS However, following switches is enable.
- Cycle start
- Feed hold
TURRET
- Standby
- Rapid Transfer/Feed Transfer
ATC ARM Override
- Work Lamp
- Chip conveyor
MAGAZINE - Coolant type button
(eneral, Penetration, Gun...)
(If Auto/manual is separated, only use ■ DATA INPUT Enalbe
APC Auto)
- Air blow type button ■ Sheet key Switch operation
(General, Tool air blow...) enalbe
COOLANT - Single Block button
- Auto power cut off ■ Automatic operation
- Tailstock Button
AIRBLOW ■ The buttons that are attached to exterior, ■ Door Lock
such as, fixture, footplate switche type,
are separated with above key.
■ Operation after initial power approving
1. Incremental Type
1) JOG or Reference mode is turned so
that zero return can be performed.
INSIDE 2) Memory mode is automaticaaly
CHIP CONV turned after the zero point return
completing.
-> Following operation is operated
according with lock condition.
2. Absolute Type
1) Memory mode is automatically
turned after operation ready completing.
OUTSIDE
-> Following operation is operated
CHIP CONV according with lock condition.

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AUTO MODE & DOOR STATE MANUAL MODE Remarks

SET UP DOOR DOOR
ON CLOSE OPEN

PROGRAM ■ DATA INPUT Enable

■ Sheet key Switch Operation Enable
■ Door Unlock Status Stop
SPINDLE ○ Below50 rpm
<< Several type of operation during unlocking >>
Hold to run
1) Coolant type and Chip conveyor
AXIS Peripheral device, such as Air blow ○ Feed 2 m/min
- Stop

2) During Spindle operation Two hand

TURRET - Door open enable ○ Control
- Door open eable after stopping (Speed Down)

3) During automatic opration

ATC ARM - FeedHold ○ Stop

4) Cycle Start disable

- Cycle start after converting the mode
MAGAZINE ○ Stop
※Machining Center
AL.occurs "G01 COMMAND
ERROR" for G01 execution
APC ○ Stop
=> Procedeed the SP manual after rotating

5) Rigid Tap
COOLANT - Feedhold+Door open Eable after ending ○ Stop
6) Fixed Cycle
- After procedding the designated section
AIRBLOW - After Main spindle stop + Feedhold ○ Stop
Door open Enable

INSIDE 7) ATC ARM

- Stop after 1 Cycle completing. ○ Stop
CHIP CONV
8) Magazine
- Stop

OUTSIDE 9) Turret
○ Stop
CHIP CONV - Stop after transfer completing and
clamping.

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1.1.3 Explanation of Key Board

1. Explanation of Operation Panel of CRT/MDI

1) LCD Type CNC UNIT

Figure 3-1-1. 8.4"(10.4") Color TFT LCD/MDI

Address/Numerical
Value Key
Shift Key
Cancel Key
Input Key

Function Key

Cursor Key Edit Key

Help Key

Page change Keys Reset Key

Figure 3-1-2. Key Setting

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2) MDI Keyboard

NO. NAME EXPLANATION

Reset(RESET) key
1 Press this key to reset the CNC, to cancel an alarm, etc.
RESET

Help(HELP) key Press this button to use the help function when uncertain
2
HELP about the operation of an MDI key(help function).
The soft keys have various functions, according to the
3 SOFT keys Applications. The soft key functions are displayed at the
bottom of the screen.
Address/number keys
Press these keys to input alphabetic, numeric, and other
4 N
( 4← characters.
…
Some keys have two characters on their keytop. Pressing
the <SHIFT> key switches the characters. Special
SHIFT key
5 characters E is displayed on the screen when a characters
SHIFT
indicated at the bottom right corner on the keytop can be
entered.
When an address or a numerical key is pressed, the data
is input t the buffer, and it is displayed on the screen. To
INPUT key copy the data in the key input buffer to the offset register,
6
INPUT etc., press the INPUT key.
This key is equivalent to the [INPUT] key of the soft keys,
and either can be pressed to produce the same result.

Press this key to delete the last character or symbol input

Cancel key to the key input buffer. When the key input buffer displays.
7
CAN >N001X100Z-and the cancel CAN Key is pressed, Z is
canceled and >N001X100– Is displayed.

Program edit keys

8 ALTER INSERT Press these keys when editing the program.
DELETE

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NO. NAME EXPLANATION

ALTER Alteration
INSERT Insertion
DELETE Deletion

Function key Press these keys to switch display screen for each
9
POS PROG … function.

Cursor keys
↑
10 These are four different cursor move keys.
← →
↓
→ This key is used to move the cursor to the right
or in the forward direction. The cursor is moved
in short units in the forward direction.
← This key is used to move the cursor to the left or
in the reverse direction. The cursor is moved in
short units in the reverse direction.
↓ This key is used to move the cursor in a
downward or forward direction. The cursor is
moved in large units in the forward direction.
↑ This key is used to move the cursor in an
upward or reverse direction. The cursor is
moved in large units in the reverse direction.
Page change keys Two kinds of page change keys are describe below.
↑
↑ This key is used to change over the
PAGE
PAGE page on the screen in the forward
11 PAGE
direction.
↓
PAGE This key is used to change over the
↓ page on the screen in the reverse
direction.

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2. Function Key and SOFT Key

Function Key is used to select the type of screen (function) to be displayed. By
pressing the soft key (soft key for selecting the page) connected to the function
key, screen (page) of each function can be selected

1) Display Sequence of General Screen

① By pressing the function key on the
MDI Panel, the soft key for selecting
the page on the function, is displayed
② By pressing the soft key for selecting
the page, screen of the page is
displayed, If the soft key of screen to
be displayed is not displayed, press FUNCTION KEY
the menu key continuously, several
pages in the pages can be selected
③ If the screen of page to be displayed is
displayed, operation selection key is
pressed and the contents to be
operated is displayed
④ If the soft key for selecting the page is SOFT KEY For
Selecting PAGE
returned, press the menu key.
Following is display sequence of
general screen.
Display sequence is different from
respective screen. Return Continuous
MENU KEY MENU KEY
For detailed operation, refer to respective
operation description

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2) Function Keys

Function Keys are provide to select the type of screen to be displayed.

The following function keys are provided on the MDI panel ;

POS : Press this key to display the position screen.

PROS : Press this key to display the program screen.

OFFSET
SETTING : Press this key to display the offset/setting screen.

SYSTEM : Press this key to display the system screen.

MESSAGE : Press this key to display the message screen.

GRAPH : Press this key to display the graphics screen.

: Press this key to display the custom screen.

CUSTOM
(conversational macro screen)

3) Soft Key

To display a more detailed screen, press a function key followed by a soft key. Soft keys are
also used for actual operations.

The following illustrates how soft key displays are changed by pressing each function key.

The symbol in the following figures mean as shown below :

: Indicates screens.
: Indicates a screen that can be displayed by pressing a function key(*1).
[ ] : Indicates a soft key(*2)
( ) : Indicates input from the MDI Panel.
〔 〕 : Indicates a soft key displayed in green.
▷ : Indicates the continuous menu key(rightmcst soft key)(*3)

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*1. Press function keys to switch between screens that are used frequently.

*2. Some soft keys are not displayed depending on the option configuration.

*3. In some cases, the continuous menu key is omitted when the 12 soft keys display
units is used.

• Screen when function KEY POS is pressed.

Absolute Relative Integration Handling

Position display Position Position Manual

in work display in work display in work Handle
coordinate coordinate coordinate Intercept

Actual Actual Actual

Speed Mark Speed Mark Speed Mark

Operating time Operating time Operating time

and part and part and part
quantity mark quantity mark quantity mark

Monitor

Operating
Monitor
display

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• Screen when function KEY PROG is pressed.

If MEM/RMT Mode

Program Check Current Next Handling

Check Display Display

Edit of
screen of screen of screen of
Program Program Program
Program

Restart List (Handling)

Program List Display of

Restart Program

If MDI Mode

Program Current Next (Handling)

Program Display Display screen

Edit of
screen for MDI screen of of Next block
Program
driving Current block

Restart List (Handling)

Program List Display

Restart of Program

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If EDIT/TJOG/THND Mode

Program List Interactive (Handling)

Edit of List Display Input screen

Program of Program of dialogue

If JOG/HND/REF Mode

Program Current Next (Handling)

Display Display screen

Edit of screen of of Next block
Program Current block

Restart List (Handling)

Program List Display

Restart of Program

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Offset Setting Coordinate (Handling)

Mark and Mark and Mark and

setting of tool setting of setting of
offset Setting date work zero
quantity offset

Macro Menu Operation TL life (Handling)

panel

Mark and Mark and Mark and Mark and

setting of setting of setting of setting of
custom Macro pattern date software pattern date
parameter input operator’s panel input

Program Current Next (Handling)

Setting of
Y axis work
offset coordinate
shift

Degree
(Handling)
Level

Selection of
Degree Level

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Language protection Mis -

handling (Handling)

Mark and B Level Date Mis handling

conversion of protection prevention
mark language function

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• Screen when function KEY SYTEM is pressed.

Diagnosis (Handling)

Mark and Verification of System

setting of diagnosis configuration
parameter mark screen

SV setting SP setting (Handling)

Display and
setting of pitch Servo
error compen Setting
sation date

W. Handling
Diagnosis History

History Function
Display of Input and output Intruction
Waveform handling on the
Diagnosis All/o screen

Diagnosis Configuration Power Mate

Monitor and of PMC
and edit screen of CNC Manager
maintenance Date setting function
ladder Screen
of PMC

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Coloring Regular Maintenance (Handling)

Maintenance Information

Screen of Regular Maintenance

coloring maintenance information
setting screen screen

PRM setting (Handling)

Display and Setting

setting screen support
screen of
of FSSB Date parameter

(Handling)

Embed Embed Setting data

Ethernet Ethernet server
function function function

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Remote Machining
(Handling)
Diagnosis Adjusting

Machine Machining
remote Parameter adjustment
diagnosis

ID information Memory (Handling)

Display of Memory

(Handling)

PROFIBUS-DP PROFIBUS-DP
Master function Slave function

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3. Key input and Input Buffer

If Address Key and number key is pressed, the character corresponding
with the key that is entered in the key input buffer.
The contents of key input buffer is displayed in the bottom of LCD screen.
the final part of the data entered in the key, 「-」is displayed, input
position of following character is indicated.

Key input and Input Buffer

Figure 3-1-3 Display of Key input Buffer

If key is stamped on the top and bottom, 2 stages, press the SHIFT Key
first to enter the character, and then press the character key on the bottom.
If SHIFT Key is pressed, 「-」indicating the input position of following
character, turns to 「∧」 and bottom character can be input. This status
is called to SHIFT status.
On the SHIFT status, if you input 1 character, Shift status is released.
Additionally, if SHIFT Key is pressed on the Shift status, Shift status is
released.
Key Input Buffer that can be up to 32 characters at once.
If you want to delete the character or symbol entered in the key input buffer,
press the CAN Key.

If display of Key input buffer is above >N001X100Z,

Ex)
If CAN Key is pressed, Z is deleted, and then became >N001X100_.

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4. Warning Message
Character or Number on the MDI panel, is entered, and then if you press INPUT
Key or Soft Key, data is checked.
If data is input with error or operation is not suitable, warning message is
illuminated or displayed on the status display row.

Key input and Input Buffer

Status Sign EEIT MODE is incorrect

Warning
Message Sign

Figure 3-1-4 Display of warning message

Warning Message Contents

Format error
Format incorrect.
Format incorrect.
Write protect By data protection key, key input become
invalidity, or parameter writing function is
Write prohibit
not operated.
Data is out of range
Input value exceeds allowable value.
Data out of scope
Tool Many Digits Value to be entered exceeds allowable
Position No. tool many. value.
Wrong mode Except for MDI mode, parameter cannot
Mode incorrect. be input.
Edit Rejected On current CNC status, edit is not
Can not be edited. functioned.

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1.1.4 Machine Operation Sequence

1. If starting.

1) Switch on the power switch.

2) Switch On power switch of control panel.

3) Press Power On push button of NC unit that installed in top and

left of main operation panel.

The NC unit is housed in the closed structure and exterior air should be mixed directly.
Thus if power applied, please open each door for long time, including the door of
control box. Moving of fan motor should be verified in the display of screen and control
box.

4) Set each axis to zero point.

2. If completing
1) Clean the machine.

2) Move each axis to stop position.

•X axis ………………… Center of stroke
•Y axis ………………… Center of stroke

•Z axis ………………… Top and middle level of head

3) Verify that PROGRAM-START display lamp of main operation panel is
switched Off.
4) Press EMERGENCY STOP pushbutton on the main operation panel.
5) Switch off control power by pressing the POWER OFF pushbutton on the
main operation panel.
6) Switch off power of the control panel.
7) Shut off power.

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1.1.5 Manual Operation

1. Transfer of each axis

(1) For manual transfer
A. Select the MODE selection switch to “JOG”.
B. Fix “FEEDRATE” switch to proper feed speed.
Move the machine to desired direction by manual feed direction switch of
axis to be moved.
If it comes to desired position, release it. (When switch On only, move it)
(Example of Usage)
• If trial runs
• If near to machine zero point
• If manual cutting

(2) For handle feed

A. Select MODE selection Switch to “HANDLE”.
B. Select the axis to axis selection Switch.
C. 0.001 mm per 1 scales by manual handle (If X1 is selected)
Can move by 0.01 mm(If X10 is selectedX10), 0.1 mm(If X100 is selected).
(Example of Usage)
• For attaching structure or fitting, If slightly moving, when determining the
zero point

(3) For MDI

A. Press MDI Switch in the Mode selection Switch.
B. When appear the Program by press the PROG in the function key of MDI
Panel, following screen is displayed.

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C. Apply the program that executes by handling, such common program edit.
Position the M99 to final block, after driving over, return to front of program.
Insertion, change, search of Word, Program rewind is effective for writing
program by MDI.
D. Once the program written by MDI, is cleared, perform as follows.
① Input the Address O to press DELET Key in the edit key of MDI panel.
② Or, press RESET Key(For this case, set 1 to Parameter MCL (NO3203).
E. When executing the program, set the cursor to front of program. (starting possible).
Press the Cycle Start Button of machine operation panel. Written program is run
by it. If Program•End(M02, M30) or ER(%) is executed, written program is
automatically cleared and operation is over.
If M99 is executed, return to front of written program.

F. If you want to stop or end during MDI operating, perform as follows.

① Stop of MDI drive
When Feed Hold Switch is pressed on the machine operation panel, Feed
Hold (LED) is illuminated and Cycle Start (LED) is shut off. And perform as
follows.
• When machine is moving operated, feed is reduced and stopped.
• During performing dwell, dwell is paused.
• After performing it, operating of the M, S, T is stopped.
When Cycle Start Switch is pressed on the machine operation panel,
machine operation is re-executed.
② MDI Driving Over
If you press RESET Key on the MDI Panel, automatic operation is ended and
reset it. If it is reset during moving, reduction speed is stopped.

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2. Determination of main spindle position

1) Select the MODE selection switch to “MDI”.
2) When you press PROG KEY, change the PROGRAM screen.
3) Press M of ADDRESS KEY.
4) DATA KEY 1 , 9
5) Press DATA KEY EOB
6) Press INSERT KEY, and then if you press PROGRAM- START button, main
spindle is rotated at a low speed and it is stopped.

3. Tool Clamp/Unclamp
1) Move the spindle to some area.
2) Select one of the manual modes, which are『JOG』,『RAPID』,『HANDLE』
and『ZERO RETURN』mode.
3) Hold a tool in the spindle securely, turn the push button switch, which could be
switched to “CLAMP” or “UNCLAMP”, to the “UNCLAMP”. In case of existing of
clamping tool, if pressing it, the edge of draw bar push the tool shank out of the
spindle. (Hold a tool securely not to be drop it) Red LED at the upper-left of
push button is lit up during unclamping of tool.
4) To clamp a tool, remove a dust completely on the taper surface of tool shank.
And also clean inside surface of the spindle by prepared cleaner.
5) Insert a tool shank into the spindle hole, turn the switching type push button to
the “CLAMP” and press it. Tool is clamped automatically and lamp is lit off.

4. Main spindle transmission, rotation

1) Select the MODE selection switch to “MDI”.
2) When you press PROG KEY, PROGRAM screen is changed.
3) Enter M code of main spindle rotation or reverse rotation by same method
(Example: M03 or M04)
4) Press the S of ADDRESS key.
5) Enter the DATA key RPM.
6) Press EOB of ADDRESS KEY.
7) Pres INSERT KEY.
8) Enter M code of main spindle rotation or reverse rotation by same method
(Example: M03 or M04)
9) Press PROGRAM START push button.

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10) When you want to stop it if you command the M05, main spindle is stopped.

5. Rapid Feed
1) Select the MODE selection switch to “RAPID”.
2) Set the spindle switch to be rapid fed to desired direction.
(When it switched to ON only, it is fed rapidly.)
For rapid feed speed 3600 mm/min (X, Y axis) 30000 mm/min (Z axis), it is
overridden by P0/ 25/50/100 %.

6. Procedure of Returning to the Origin Position

It has to be done returning to origin position manually to set the basic machine
coordinate up after power up.

1) Select the『ZERO RETURN』mode.

2) Turn the toggle switch that is going to return to origin position to the mark of
zero return ( ).
3) Returning to origin position with rapid traverse speed.
Returning is stop at the origin position and the lamp for confirmation of axis’s
origin is lit up.
4) Off your hand from the toggle switch when lamp is lit up. These are all
procedure for returning to origin position.

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1.1.6 Automatic Operation

1. In Case of Machining the First Work with Checking of Newly Written Program
1) Cursor is positioned on the new writed program.
2) Switch of single block is positioned "ON".
(At this time, rapid feed override is safe that it is set to 25%.)
3) Press the CYCLE START button.
4) Check one block worth of operation. Again, press the CYCLE START button
and proceed with the program sequentially.

2. Memory Operation of Program

1) Check that the ALARM lamp on the main operation panel is not lit up.
2) Check and correct tool length and tool diameter compensation data.
3) Select the mode selector switch MEMORY. At this time, turn of the DRY RUN,
OPTIONAL STOP, MACHINE LOCK, BLOCK SKIP and SINGLE BLOCK
switches, and set the FEEDRATE OVERRIDE, SPINDLE OVERRIDE and
RAPID OVERRIDE switches to 100 %, in case of regular operation.
4) Press the RESET button on the setting operation panel.
5) Set X, Y and Z position display values to 0 with the ORIGIN button on the
display panel. When setting to a numerical value other than 0, set a desired
value through the machine lock function. (Return to the AUTO mode again
after MDI or manual operation.)
6) When temporarily stopping machine operation halfway, press the PROGRAM
FEEDHOLDE button or turn on the SINGLE BOLCK switch. When an
unexpected condition occurred, stop the machine immediately by pressing the
EMERGENCY STOP button on the operation panel.

3. In Case of Manual Operation during Memory Operation

1) Press the PROGRAM FEED HOLD push button switch (while program
operation is suspended, a red lamp is lit up) or turn on the SINGLE BLOCK
switch to suspend program operation.
2) Select the operation mode selector push button switch either ‘HANDLE’ or
‘JOG’, and perform manual operation.
3) After completing manual operation, return the operation mode to ‘MEMORY’.
4) Press the PROGRAM START button to restart the program.

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Even when the PROGRAM FEED HOLD button is pressed, the M, S and T
functions continue until their actions are completed. Manual operation is
available only after these actions are completed.

4. f it is driven by MDI during automatic driving

1) Set the single block switch of operation panel to ON」.
2) If operation is stopped on the single block, set mode selection switch to
「MDI」.
3) Press PROG on the function key of MDI Panel to select the program screen.
4) Enter necessity operation as “ADDRESS” Key and value Key, press
INSERT button.
5) Verify input data and press PROGRAM START button.
6) When your re-execute automatic driving, set the mode selection switch to
MEMORY position and set single block switch to 「OFF」.
7) Press the PROGRAM START button of main operation panel.

If auto operation is continuously performed after converting the mode in the MDI,
as buffer contents is replaced and entered with non-executing MDI buffer
contents, operation excluding expectation occurs. Pay attention to it due to it’s
risk.

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1.1.7 Rigid Tap operation

1) Advantages of tapping operation

a. Since standard collect is used than extensile tapper, cost of tool can be
reduced.
b. Precision of thread is enhanced since feed speed matches with that of
spindle.
c. Tapping for small hole diameter which is difficult for machining up to now is
possible.
d. Depth of tap can be machined evenly.
2) Position of attachment Encoder for rigid tapping is built in spindle motor.
3) Purpose : It is used to synchronize rotation of main spindle and feed in Z-axis,
so the machining is capable only with the floating tapper which usually used,
drill chuck and collect chuck. It’s also a kind of option for machine frame that
the high speed and high precision tapping at rate of 2000 ~ 3000 rpm is
possible.
There are two kinds of tapping as high speed tapping and direct tapping those
are identified by mark.
4) Function : In case of rigid tapping, position of rotating spindle is controlled, and
rotation of spindle and Z-axis feed is controlled by means of linear
compensation for two axes. Therefore, the requirements of deceleration at end,
Z-axis feed per turn at acceleration and thread pitch are all satisfied.
5) Programming : Command G84(right-handed thread)/G74(left-handed thread)
on NC FANUC-0i-MD. In case of command in per turn model[G95], feed
speed[F] can be set just as tapping pitch. If the machine needs spindle speed
changing, in case G84 and [S] is commanded in separate block for high and
low speed gear shifting, high speed gear is always selected regardless of
rotation number.

Rigid tapping machining is also capable with conventional floating taper.

6) Rigid tapping programming G84(right hand screw)/ G74(left hand screw)

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a. Purpose
By the method of synchronizing rotation of spindle and feed of Z-axis, high
speed and precision tapping is achieved. Conventional tapper is necessary.

M29 RIGID TAP MODE

M28 RIGID TAP MODE CANCEL
X Coordinate of tap hole position
Y Coordinate of tap hole position
Z Position of end of hole
R Start point of machining
(P) Dwell time for returning to hole end and R point.
F Feed speed/Pitch
S Spindle rate
L Repeating times

b. Method of command
**In case of per minute command
G94 *
M29 S ― * ― change to rigid tap mode(M03 command is impossible)
G84 X ― Y ― Z ― R ― P ― F ― L ― *
X―Y―*
Feed speed
X―Y―*
M28 Spindle start(rotation) and stop
G80 at R point.

** In case of per turn command

G95 *
M29 S ― * ― change to rigid tap mode(M03 command is impossible.)
G84 X ― Y ― Z ― R ― P ― F ― L ― *
X―Y―*
Tap pitch
X―Y―*
M28 Spindle start(rotation) and stop
G80 at R point.
G94

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c. Actual programming(in case of aluminium M6×P1.0 tap)

** In case of per minute command
G54 G90 C00 X50.0 Y100.0 T05 *
G43 Z30.0 H04 *
G94 *
M29 S1000 *RIGID TAP MODE Command
(including spindle start)
G98 G84 Z-20.0 R5.0 F1000 *
X75.0 Y150.0 *
X100.0 Y200.0 *
M28 *CANCEL(RIGID MODE)
G80 * CANCEL(TAP MODE)

** In case of command per turn

G54 G90 C00 X50.0 Y100.0 T05 *

G43 Z30.0 H04 *
G95 *
M29 S1000 * RIGID TAP MODE Command
(including spindle start)
G98 G84 Z-20.0 R5.0 F1.0 *
X75.0 Y150.0 *
X100.0 Y200.0 *
M28 *CANCEL(RIGID MODE)
G80 *CANCEL(TAP MODE)
G94

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1.1.8 NC Command Value

Next table shows the range capable for inputting in this machine.

1. Basic address and range of command Value

Function Address Rage of command value

Number of program O 1~9999

Number of sequence N 1~9999
X, Y, Z, U, V, W, A,
Dimension word ± 99999.999
B, C, I, J, K, R, Q

Feed speed X, Y/Z 36000 mm/min / 30000 mm/min

Rapid feed(X, Z/Y) F
Cutting feed speed 1~10000
Tool function T 0~24
Spindle function S 35~6000
Auxiliary function M 0~99
2nd Auxiliary function B 0~359
Number of offset D, H 0~99(OP : 200)
Dwell P, X 0~99999.999 sec
Repeating function L 0~9999

2. No. Sequence

N5 digit : N1~N9999

3. Preparatory functions G code followed by two digits

G code Group Function

★ G 00 Positioning (Rapid Feed)
★ G 01 Linear interpolation (Cutting Feed)
01
G 02 Circular interpolation / Helical interpolation CW
G 03 Circular interpolation / Helical interpolation CCW

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G code Group Function

G 04 Dwell
G 05 High speed Remote Buffer
G 07.1(G107) Cylindrical interpolation
G 08 00 Advanced preview control
G 09 Exact stop
G 10 Programmable data input
G 11 Programmable data input Mode cancel
★ G 15 Polar coordinates command cancel
17
★ G 16 Polar coordinates command
★ G 17 Xp Yp plane selection Xp : X axis or its parallel axis
★ G 18 02 Zp Xp plane selection Yp : Y axis or its parallel axis
★ G 19 Yp Zp plane selection Zp : Z axis or its parallel axis
G 20 Input in inch
06
G 21 Input in mm
★ G 22 Stored stroke check function on
04
G 23 Stored stroke check function off
G 25 Spindle speed fluctuation detection off
24
G 26 Spindle speed fluctuation detection on
G 27 Reference position return check
G 28 Return to reference position
G 29 00 Return from reference position
G 30 2nd reference position return
G 31 Skip function
G 33 01 Thread cutting
★ G 37 00 Automatic tool length measurement
G 40 Cutter compensation cancel
G 41 07 Cutter compensation left
G 42 Cutter compensation right

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G code Group Function

G 40.1(G150) Cutter compensation cancel mode
G 41.1(G151) 19 Cutter compensation left side on
G 42.1(G152) Cutter compensation right side off
G43 Tool length compensation + direction
08
G44 Tool length compensation - direction
G 45 Tool offset increase
G 46 Tool offset decrease
00
G 47 Tool offset double increase
G 48 Tool offset double decrease
★ G 49 08 Tool length compensation cancel
★ G 50 Scaling Cancel
11
G 51 Scaling
★ G 50.1 Programmable Mirror Image Cancel
22
G 51.1 Programmable Mirror Image
G 52 Local coordinate system selection
00
G 53 Machine coordinate system selection
★ G 54 Workpiece coordinate system selection
G 54.1 Additional workpiece coordinate system selection
G 55 Workpiece coordinate system 2 selection
G 56 14 Workpiece coordinate system 3 selection
G 57 Workpiece coordinate system 4 selection
G 58 Workpiece coordinate system 5 selection
G 59 Workpiece coordinate system 6 selection
G 60 00/01 Single direction positioning
G 61 Exact Stop Mode
G 62 Automatic Corner Override
15
G 63 Tapping Mode
★ G 64 Cutting Mode

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G code Group Function

G 65 00 Macro Call
G 66 Macro Modal Call
12
★ G 67 Macro Modal Call Cancel
G 68 Coordinate rotation
16
★ G 69 Coordinate rotation Cancel
G 73 Peck Drilling Cycle
G 74 Counter Tapping Cycle
G 76 Fine Boring Cycle
Canned cycle cancel / external operation function
★ G 80
cancel
Drill Cycle, Spot Boring Cycle or external operation
G 81
function
G 82 09 Drilling Cycle or Counter Boring Cycle
G 83 Peck Drill Cycle
G 84 Tapping Cycle
G 85 Boring Cycle
G 86 Boring Cycle
G 87 Back Boring Cycle
G 88 Boring Cycle
G 89 Boring Cycle
★ G 90 Absolute command
03
★ G 91 Incremental command
Setting for work coordinate system or clamp at
G 92
00 maximum spindle speed
G 92.1 Workpiece coordinate system preset
★ G 94 Feed per minute
05
G 95 Feed per rotation
G 96 Constant surface speed control
13
★ G 97 Constant surface speed control Cancel

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G code Group Function

★ G 98 Return to initial point in canned cycle
10
G 99 Return to R point in canned cycle

※ Remarks
1. G Code with the ★ symbol are the default G-Code when power is on.
2. 00 Group G-Codes represents G-Code that are not Modal and are only effective to the
instructed block.
3. If the G-Code in the same block are called upon for more than 2 times, the lastest command is
in effect.
4. When G-Code in 01 group is called among fixed cycle, the fixed cycle is cancelled automatically
and becomes G80 state.

4. Dimension word

X, Y, Z, I, J, K, Q, P
Max. command value : 99999.999 mm

5. Feed capability

Rapid feed(G00 location)

36000 m/min(X, Y axis), 30000 m/min(Z-axis)
Cutting feed F function 4 digits F1~F5000

6. Dwell : 04

G04 P.X
Stopping is made at designated time being up by this command.
Address can be designated by X besides P. When address is X, decimal input is
possible.
Maximum designated time period : 99999.999
Set unit : 0.001 second.

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7. M Code list

M CODE FUNCTION REMARKS

M00 PROGRAM STOP
M01 OPTIONAL STOP
M02 PROGRAM END
M03 SPINDLE CW
M04 SPINDLE CCW
M05 SPINDLE STOP
M06 AUTO TOOL CHANGE
M07 OIL MIST COOLANT ON OPTION
M08 COOLANT ON
M09 COOLANT OFF
M10 4TH CLAMP OPTION
M11 4TH UNCLAMP OPTION
M12 WORK COUNT OPTION
M13 M03 & M08
M14 M04 & M08
M15 M05 & M09
M16 MEASURE. AIR BLOW ON OPTION
M17 MEASURE. AIR BLOW OFF OPTION
M18 SPINDLE 2 ORIENTATION OPTION
M19 SPINDLE ORIENTATION
M20 FIXTURE CLAMP OPTION
M21 FIXTURE UNCLAMP OPTION
M28 RIGID TAPPIND CANCEL
M29 RIGID TAPPING CYCLE
M30 PROGRAM END&REWIND
M31 MAN. ATC MODE ON
M32 MAN. ATC MODE OFF

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M CODE FUNCTION REMARKS

M35 MAN. ATC MODE ORT.
M36 SCREW CHIP CONV. ON OPTION
M37 SCREW CHIP CONV. OFF OPTION
M40 TOOL DETECTOR AIR ON OPTION
M41 TOOL DETECTOR AIR OFF OPTION
M43 TOOL BROKEN CHECK OPTION
M46 BED FLUSHING ON
M47 JET COONAT ON OPTION
M48 OVERRIDE CANCEL RELEASE
M49 OVERRIDE CANCEL
M50 OIL HOLE COOLANT ON OPTION
M53 Y MIRROR OFF
M54 Y MIRROR ON
M55 X MIRROR OFF
M56 X MIRROR ON
M70 EXTERNAL M-CODE OUT OPTION
M71 EXTERNAL M-CODE OUT OPTION
M72 EXTERNAL M-CODE OUT OPTION
M73 EXTERNAL M-CODE OUT OPTION
M79 ATC DOOR OPEN (M) NOT USE
M80 ATC DOOR CLOSE (M) NOT USE
M90 AUTO DOOR OPEN NOT USE
M91 AUTO DOOR CLOSE NOT USE
M98 SUB PROGRAM CALL
M99 SUB PROGRAM END

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1.1.9 ATC Operation

1. ATC single operation

Name Use

Lamp is lit on when mode selection switch on main operating panel is in

Manual mode set manual operating mode (Handle, jog, Rapid and Zero return).
And operation on this operating panel Is possible

Magazine forward While SELECT SWITCH is pressed with pressing MAGAZINE INDEX
rotation FORWARD, MAGAZINE is rotated with C.W.

2. Description of ATC operation

ATC cycle run in the procedure as below.

Procedure Operation Diagram of stat of operation Remark

1 POT-DOWN M31, M35 Command

Use Y-axis(+) Jog

Feed Switch
2 SPINDLE ORIENTATION
(Normal state:
POT-DOWN)

Use X-axis(+) Jog

3 ARM 52° ROTATION
Feed Switch

Use Z-axis(-) Jog

4 TOOL UNCLAMP
Feed Switch

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Procedure Operation Diagram of stat of operation Remark

Use X-axis(+)(-) Jog

5 ARM DOWN
Feed Switch

ARM 180° ROTATION Use X-axis(+) Jog

6
(clockwise) Feed Switch

Use X-axis(+) Jog

7 ARM UP
Feed Switch

Use Z-axis(+) Jog

8 TOOL CLAMP
Feed Switch

ARM 70° ROTATION Use X-axis(+) Jog

9
(counter clockwise) Feed Switch

Use Y-axis(-) Jog

Feed Switch
10 POT-UP
(Normal state:
POT-DOWN)

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3. Tool clamp and unclamp

Tool clamping and unclamping is possible at any position on magazine.
So pay a full attention to safety.

※ Nose key direction

When blade of tool such as boring bar is set in direction of pot key and the Tool is clamped
into spindle, the blade of tool will face to the right.
Magazine rotation can be started by magazine rotation change push button On operating
panel. When performing inching operation it move only by 1 pitch.

※ Notes for oil hole tool

When using oil hole tool, there occur trouble in determination of position if Chip, attached to
oil hole block, is inserted into pilot plunger block of same tool.
Therefore, if oil tool is set on main spindle manually or automatically, Tool should be changed
after block is cleaned by coolant switch or M30 Command.

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4. Limit of Tool Length & Weight

Maximum
Item Symbol Unit Remarks
Value
Tool For more than maximum value, not capable
L mm 300
Length of tool change.

Capable of holding if there is no tool in the

90
Tool adjacent part.
D mm
Diameter
Capable of holding if there is no tool in the
150
adjacent part.

Tool For more than maximum value, not capable

W Kgf 8
Weight of tool change.

Tool For more than maximum value, not capable

W·S kgf·cm 80
Moment of holding in the tool magazine.

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5. Details and method of operation (ATC)

1) Single or continuous operation can be obtained by ATC command.
Separate single operation can be operated as the procedure below when
Separate single operation test(MDI, Maintenance Mode) and adjustment,
Etc. is necessary.
① Set each axis and ATC arm to “ ATC origin.”
② Put maintenance on by M31 in MDI mode.
③ M code used for separate operation is as below.
④ Maintenance off by M32

Operation M code Manual aid Remark

1 Magazine Tool Pot Down M31 Y-axis Jog Switch
2 Orientation M35
3 ATC arm operation - X-axis Jog switch
4 Spindle Tool Clamp X - Z-axis Jog switch
5 ATC arm operation - X-axis Jog switch
6 Spindle Tool Unclamp - Z-axis Jog Switch
7 Magazine Tool Pot Up M35 Y-axis Jog switch
8 Magazine Rotation - Manual Push Button

The door of high voltage control panel must be closed for safety.

2) Rotation of Tool Hanging Magazine (Single Mode)

Magazine is rotated while pressing SELECT and FORWARD / REVERSE in the
operating panel.
If the push button switch is released when desired pot No. is approached to the
appointed place, magazine is rotated slowly and stopped.

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6. Running ATC program

1) Activating block by program (in automatic mode)
T△△ : Call Tool No. △△ out of magazine for standby position.
M 06 : Exchanges tool on spindle for that waiting in standby position.
M 06: Returns tool on main spindle to magazine.
T□□ : Call tool No. □□ out of magazine for standby position.
Definition of ATC T ,M

a. T△△…………
① When no tool is at standby position, move △△ tool from magazine to
standby position.
② If a tool except △△ tool is at standby position, magazine rotates and △△
tool is called out from the magazine.
③ When △△ tool is at standby position, the motion will not be started but it
will be ended.
④ After above operation is completed, if a tool is there no main spindle, the
pot of the tool number will be indexed.
b. T△△M 06……
① If △△ tool is present on main spindle, the motion will not be started but
immediately ended.
② If △△ tool is at standby position, tool will get attached on main spindle by
M06 function.
③ If △△ tool is not present at standby position, magazine will rotate to call
△△ too out to the standby position and after that M06 will be operated to
attach the △△ tool to main spindle.

7. State confirmation when ATC is started

Current tool NO. can be checked by tool No. selector switch on main operating panel.
• When setting the switch to WAIT. TOOL, standby tool No. at MAG. Side can be
checked.
• When setting switch at SP.TOOL, standby tool No. at SP. Side can be checked.

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Maintenance Manual
Chapter 1 General Check-Up And Repair
1.1 General Check-up and Repair ........................................... 4-1-3
1.2 Check-up with Detector Switches ................................. 4-1-13
1.3 Checking Solenoid Valves ................................................... 4-1-22
1.4 Coolant and Lubrication ........................................................ 4-1-24
1.5 Comparative Oil Table .......................................................... 4-1-38
1.6 Air Pressure Device ............................................................... 4-1-40
1.7 The Troubles and Measures for Spindle ................. 4-1-44
1.8 Feed Axis ............................................................................................. 4-1-50
1.9 Twin Arm Type 24 Tools (Standard),
30 Tools (Option) ATC ............................................................. 4-1-64

Chapter 2 Error Code And Trouble Shooting

2.1 Error Codes and Electric Matters .................................... 4-2-3
2018EN00iDMA0

Chapter 3 References
3.1 Oil Cooler .............................................................................................. 4-3-3
3.2 Coolant Pump ................................................................................ 4-3-13

Chapter 4 Troubleshooting
Chapter 1
General Check-up and Repair
1.1 GENERAL CHECK-UP AND REPAIR ........................................... 4-1-3
1.1.1 The Importance of Repair Work ...................................... 4-1-3
1.1.2 General Guidelines .................................................................... 4-1-3
1.1.3 Regular Check-up ....................................................................... 4-1-5
1.1.4 General Check-up .................................................................... 4-1-10
1.2 CHECK-UP WITH DETECTOR SWITCHES ....................... 4-1-13
1.2.1 Stroke Control Switch ............................................................ 4-1-15
1.2.2 Spindle Tool Clamp/Unclamp Switch ....................... 4-1-16
1.2.3 Tool Number Searching Switch .................................... 4-1-17
1.2.4 Tool Pot Up/Down Search Switch :
24/30 Tools ATC ......................................................................... 4-1-19
1.2.5 Twin Arm Origin/Escalation Search Switch ......... 4-1-20
1.2.6 Lubricator Switch ....................................................................... 4-1-21
1.3 CHECKING SOLENOID VALVES .................................................. 4-1-22
1.4 COOLANT AND LUBRICATION ...................................................... 4-1-24
1.4.1 Coolant .............................................................................................. 4-1-24
1.4.2 Coolant Device ........................................................................... 4-1-27
1.4.3 Lubricator ......................................................................................... 4-1-31
1.4.4 Supplying Lubricator .............................................................. 4-1-33
1.4.5 Discharging Lubricator ......................................................... 4-1-36
1.4.6 Drawing for Lubricator Pipes Laying ......................... 4-1-37
1.5 Comparative Oil Table ................................................................................ 4-1-38
1.6 AIR PRESSURE DEVICE ..................................................................... 4-1-40
1.6.1 Places to be Used ......................................................................................... 4-1-40
1.6.2 Functions ......................................................................................... 4-1-40
1.6.3 Controls of Oil Supplying .................................................... 4-1-41
1.6.4 Oil Supply into Oiler ................................................................ 4-1-41
1.6.5 Drawing for Air Pressure Circuit ................................... 4-1-42
1.6.6 Air Pressure Piping .................................................................. 4-1-43
1.7 THE TROUBLES AND MEASURES FOR SPINDLE ... 4-1-44
1.7.1 Introduction .................................................................................... 4-1-44
1.7.2 Spindle Air Pressure Circuit Drawing ....................... 4-1-45
1.7.3 Spindle Operation ..................................................................... 4-1-46
1.8 FEED AXIS .......................................................................................................... 4-1-50
1.8.1 Introduction .................................................................................... 4-1-50
1.8.2 Feed Operation Device ....................................................... 4-1-53
1.8.3 Axis Feed Range ...................................................................... 4-1-54
1.8.4 Each Axis Zero Return Switch Location ................ 4-1-56
1.8.5 Zero Return Control ................................................................ 4-1-59
1.9 TWIN ARM TYPE 24 TOOLS (STANDARD),
30 TOOLS (OPTION) ATC .................................................................... 4-1-64
1.9.1 Introduction .................................................................................... 4-1-64
1.9.2 ATC Limit Switch ....................................................................... 4-1-65
1.9.3 ATC System Control .............................................................. 4-1-66
1.9.4 ATC Motor Control ................................................................... 4-1-68
1.9.5 Tool Pot and Twin Arm Control ...................................... 4-1-73
1.9.6 ATC Operation ............................................................................ 4-1-74
1.9.7 Empty Pot ........................................................................................ 4-1-75
1.9.8 Magazine Indexing .................................................................. 4-1-75
1.9.9 ATC Function Review ........................................................... 4-1-77
1.9.10 ATC Return .................................................................................... 4-1-79
1.9.11 Maintenance Operation of ATC .................................... 4-1-81
1-13
 General Check-up and Repair

1.1 GENERAL CHECK-UP AND REPAIR

This chapter describes general instructions for critical parts and VX400 which
adjustments and repairs are needed for safe and secure use.

1.1.1 The Importance of Repair Work

As the machine is produced by the ample quality control, the adequate operation
and regular checkups by repair worker can guarantee the longer use of the machine.
When repair and restore work is needed, the maintenance worker’s opinion should
be taken. This manual is prepared in order for the machine to be quickly restored
from trouble. If it is determined that restoring be not possible by a restore worker, call
to the personnel who is in charge of customer service of the company.
Prior understanding is required since this manual is subject to the production
conditions, which part of the machine may be changed according to design change.

1.1.2 General Guidelines

1. Checkups prior to repair work

1) Listen to the worker in charge and fully understand about the conditions of the
machine.
2) Plan the repair work and work order.
3) Make full understanding of specifications, structures and functions of the repair
work required.
4) Discuss and confer with related departments or co-workers for coordination
before starting repair work.

2. Cautions for electrician

1) The restore and repair work related to electricity must be done by the eligible
worker designated as an electrician by the shop.
2) An electrician must be fitted with proper outfit for the work.
3) Make clear notice as “Under repair work” at the surrounding area.

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4) Make sure to shut down the power and put a warning notice, “Don’t Power On”
at the surrounding of main power switch.
5) Do not touch or operate electricity lines, equipments or power sockets with wet
hands.
6) Do not change parameter values set for the machine without approval.
7) In case of co-operation, make sure to recognize each worker by signaling.
8) In case of the exchange of the electric parts, legitimate products must be used.
9) When a work in the machine is required, the worker must cut off the main
switch and put up a warning board, “Power is not allowed” at the surrounding
of the main power switch.

3. Cautions for the machine restore worker

1) A worker must be fitted with proper outfit for the work.
2) Make clear notice as “Under repair work” at the surrounding area.
3) Tools and instruments should be selected for its proper usage.
4) Do not put or place tools or parts directly on the moving area or line ring bearing.
5) In case of co-operation, make sure to recognize each worker by signaling.
Then, move on to the next step.
6) A ladder must be used for the work required up in high places.
7) When handling heavy things, more than two workers are required or use a
crane.
8) Proper wire rope or crane which is designated for weight must be used.
9) When a work in the machine is required, the worker must cut off the main switch
and put up a warning board, “Power is not allowed” at the surrounding of the
main power switch.

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1.1.3 Regular Check-Up

1. Checkup after installation of the machine

The following instructions must be observed until complete setting of the
machine(approximately a month).
1) Check the status of terminals
2) Do enough warm-ups.
3) Check any thermostatic escalation or abnormal sound.

2. Daily checkups prior to work

The followings must be done daily.
1) Mover axis lubrication: the volume of oil and discharge pressure
2) Coolant device : the volume of oil and discharge pressure, filter
3) [Emergency Stop] button: confirm its operation
4) Air pressure device : the volume of oil in the oiler, pressure and filter status
5) Cleansing of the machine:
• Check the cleaning status and wear/tear of Spindle taper and ATC arm clamp
bar area
• Cleaning the taper area of ATC tools shed pot
• Cleaning of chips in the upper ATC magazine
6) Check for Spindle lubricator oil level
Confirm the oil level be on the center of the gauge
(Since the oil level goes down when the Spindle is moving, check at
the stop.)
7) Clearing of chip on the cover of the slide side or cleaning inside the
machine.
8) Clearing chips inside the machine.
9) Get rid of each slide cover chip
10) Clearing chip wagon chip
11) Check coolant

Make sure Power Off before cleaning inside the machine.

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Any coolant, oil or water on the floor must be instantly cleared by floorcloth or paper.
Slippery floor can cause harm.

1. Do not use pressured air when cleaning the inside of machine. It causes a
breakdown.
2. Gather chips in the machine in the chip box.
3. Use coolant when cleaning the inside of the machine.
4. Chips not cleared can cause a breakdown of the machine.

3. Weekly Checkups
1) Cleaning of coolant filter
2) Confirm of control panel
3) Check the status of bolts

1. Do not touch coolant. The coolant is hazardous for skin.

2. Always wear safety glasses when cleaning by using pressured air.

4. Monthly Checkups
1) Check filters
2) Clean or exchange the following dirty filters
•NC Device Filter
•Air filter
3) Check the power and voltage:
Measure the second voltage of the main breaker within the panel while the
machine is working to confirm the electric pressure stays within ±10%.
4) Refer to CNC Manual when checking Spindle and mover AC motor.
5) Cleaning of electric box.

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5. Bi-annual Checkups (1000 hours)

The following items also need to be checked daily.
1) The origin of the machine
2) Filter exchange: for oil pressure, lubricator, and air pressure
3) Supply grease oil: ATC magazine gear
4) Cleaning of the front cover of Spindle
5) Cleaning of fluorescent lamp
6) Moving hose
7) Exchange of coolant
8) Check of tool clamp bar
Check the operation and wear/tear
Rocking status of the tools when they are fixed

6. Annual Checkups (2000 hours)

1) Check and correct the level of the machine body
2) Wash or exchange of dirty filter in the oil pressure tank
3) Check the precision
① Straightness of X, Y, Z axis
② Right angle of XZ, XY, YZ
③ Feeding level of X, Y axis
4) Check if the number of rotation of the Spindle is within the range of ±10%.
5) Wear/tear status
① The key and taper area of the Spindle
② Guide way wiper
③ ATC arm (clamp bar and spring)
6) Check the status of positioning: refer to the separate checklist.
7) Check the relay and loosening of the attached terminal
8) Check with the emergency stop limit switch for each axis by hand

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Table 4-1-1 Check List

No. Check Area Daily Weekly Monthly Biannually Annually

1 Eradicate inside chips O

Eradicate chips on the tool

2 O
table
Eradicate chips on each
3 O
slide cover

4 Eradicate chip O

5 Clean Coolant Tank O

6 Coolant Filter O
7 Check oil quantity O

8 Check lubricator O

9 Check Coolant O

10 Work oil pressure 35kgf/㎝ O

11 Check supplying coolant O

12 Work oil strainer O

13 Lubricator pump filter O

14 Oil leaking O

15 Loosening bolt O

16 Check operating panel O

17 Relay in the electric box O

18 The level of machine O

19 Air Filter O

20 Clean Fan O

21 Clean the electrical box O

22 Operation of E.S O

Noise, vibration, hike of

23 O
temperature
24 Operation of safety device O

25 NC device filter O

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No. Check Area Daily Weekly Monthly Biannually Annually

26 Cover of axis’bellows O
27 Operation of X, Y, Z axis wiper O

Clean inside of coolant

28 O
tank exchange of coolant

29 Movable hoses O

30 Clean fluorescent lamp O

31 Check with machine origin O

32 Supply Grease O

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1.1.4 General Check-up

1. General checkups and maintenance
1) General checkups and maintenance are necessary for longer use of the
machine in secure state. General checkups and maintenance must be on the
first priority.

1. For general checkups and maintenance, open the cover or doors and keep the
electric box door shut.
2. Do not use pressured air. It may cause the penetration of alien substances into
Spindle bearing or the inside.

Before starting with general checkups and maintenance, keep off the main switch at
the electric box.

2) The operation and `checkups/repairs must be recorded.

Keep the records of the operation is necessary for the operation of the machine.
The records of checkups/repairs are kept separated from the operation of the
machine.
3) Supply oil

1. The use of other oils not designated may harm the machine.
2. The lubricators are required in many areas for the machine.
The first thing in lubrication is not overly supply lubricator.

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4) Eradicate chips

1. Take the chips out of the machine and put in the chip box.
2. Clean the inside of the machine by using coolant
3. Negligent chips are the cause of troubling.

5) Pressure

The pressure set beyond the design is the cause of breakdown of the machine.

6) In case of watersoluble coolant

Table 4-1-2 Cautions for handling coolant

No. Caution
1 Select coolant considering anti-rustiness, safety, and cooling
2 No harmful substances such as stink or getting sore on human skin
3 No deterioration in quality during keeping
4 No causing rusty on machine or deteriorating on paint
5 No rubber-soluble substance
6 No deterioration in processed substance
Put a little rust-preventing oil with cooling water and water soluble coolant. Or it
7
gets rusty with coolant dries.
Mob clean on the surface where coolant was. Coat with rust-proof oil after
8
cleaning.
Take extra caution not to contact coolant. Practice the handling guide lines of
9
coolant for safety.
The mixing method of coolant with water varies depending on types of
10
coolant. Follow the guidelines of the manufacturer.

No guarantee on troubles caused by coolant. Take cautions.

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7) Supply oil (when necessary)

Replenish beside the machine: Take out the coolant tank and supply oil.

1. Do not touch coolant with bare hands.

2. Coolant injures human skin.

8) Clean the exterior of the machine

① Clean the exterior of the machine.
Mob out oil and eradicate coolant and chips.
Rub the CRT screen and control panel with soft cloth and cleaning material.
② Check if there is a leak of oil from the machine.

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1.2 CHECK-UP WITH DETECTOR SWITCHES

The detector switches are to confirm the start and end of each move during the machine
operation. Prompt repair is required in case of unusual operation of the switches, which
may cause a serious trouble. Refer to the followings for regular checkups of switches.

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Table 4-1-3 Limit Switch and Proximity Switch Table (24/30 tools Twin Arm type ATC)

L/S Number Usage Type Maker Position

SQ96 X axis +Over Travel

SQ97 X axis -Over Travel
LDV5312 YAMATAKE SADDLE
X axis Zero return
SQ90
Decelerate
SQ100 Y axis +Over Travel
SQ101 Y axis -Over Travel
LDV5312 YAMATAKE SADDLE
Y axis Zero return
SQ91
Decelerate
SQ102 Z axis +Over Travel
SQ103 Z axis -Over Travel
LDV5412 YAMATAKE COLUMN
Z axis Zero return
SQ92
Decelerate
SQ80 Check Twin Arm Origin 24 TOOLS
Check Twin Arm 30 TOOLS
SQ81
Escalation ATC

SQ35 Magazine Tool Count(A)

SQ36 Magazine Tool Count(B) OMRON
SQ37 Magazine Tool Count(C)
SQ86 Tool Pot Up
SQ87 Tool Pot Down
Camp Axis Unclamp
SQ82
Lotation
Camp Axis Clamp
SQ83
Lotation
SQ32 Check Tool Clamp
SL-1A YAMATAKE HEAD
SQ33 Check Tool Unclamp

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1.2.1 Stroke Control Switch

For the control of strokes of each axis are used limit switches.
1) Position
① X axis: at the center down of the saddle front
② Y axis: at the right down of the saddle front
③ Z axis: at the right side of the column

2) Functions
① Zero return switch
The switch is to control each axis to decelerate the moving to the origin
by the status of “ON” at the distance of 60mm away from the origin, then to
decide the position of origin by the stop signature with “OFF”.
Position of zero point is correctly determined by shift of grid signal.
② Over Travel Detector Switch
Over Travel (Emergency Stop) switch is set at the 6㎜ distance out of
the both ends of the stroke.
If the machine gets away from the region of stroke, press the switch to
start the state of Emergency Stop. Then, CRT shows the message as
“Over Travel”.

SOFT OVER TRAVEL is the measure for double safety and the built-in stroke limit of
NC function. The position of OT is set at the distance of 0.5㎜ from mover stroke. If
the machine goes beyond the region, a message is shown on CRT screen and axis
moving promptly stops.
In order to release, After push the [STABD-BY] button, move [JOG] or [HANDLE] to
the opposite direction, get rid of the axis and press [ALRAM RESET] on the MDI/CRT.

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1.2.2 Spindle Tool Clamp/Unclamp Switch

1) Location : in the upper cover of the Spindle

2) Function :
① Switch for Clamp : for the final confirmation of the execution of the Head
Stock tool clamp
② Switch for Unclamp : for the final confirmation of the execution of the
Spindle tool unclamp

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1.2.3 Tool Number Searching Switch

1) Location : in the cover of the magazine

2) Function
① Switch to search for reference POT
When NC and tool magazine are lost recognition each other just after
power on or emergency stop, press this switch to be “ON” by rotating
the tool magazine, which results in the return to the recognition of the
reference POT. When this switch is “ON” the waiting POT becomes 24
POT (in case of 30 magazine, 30 POT).

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② Tool Pot Count Switch

Whenever this switch is “ON” by the search DOG attached to the side of
the magazine motor, NC increases or decreases the pot number which is
in the status of waiting.

STANDARD : ARMLESS 24 TOOLS ATC(OPTION : 30 TOOLS ATC)

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1.2.4 Tool Pot Up/Down Search Switch: 24/30 Tools ATC

1) Location : in the cover of magazine

2) Function
Turn 90° the tool pot in order to change the tools stored in the
magazine into the spindle. The magazine can turn at the time of POT up.

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1.2.5 Twin Arm Origin/Escalation Search Switch

1) Location
① Confirm Origin : in the magazine cover
② Confirm Escalation : in the magazine cover (upper frame)
2) Function
① Confirm Origin : This is to check that the twin arm does correctly the tool
change or it is to stop at the designated location to change the next tool.
② Confirm Escalation: This is to check if the twin arm shaft is up.

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1.2.6 Lubricator Switch

1) Location : Built-in the lubricator device

2) Function
① Low level of oil Switch(Level Switch : check the level of the lubricator
② Discharge Stress Switch : this is to check if the air infiltrates in the pipes or if
there is any oil leakage by checking the discharge stress of the lubricator.

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1.3 CHECKING SOLENOID VALVES

Solenoid Valve controls the flow of oil. Since the faulting of a solenoid valve results in a
fault movement of the machine, regular checkups are indispensable. When checking on
a solenoid valve, a check on the related search switch is required.

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1) Solenoid valve for the spindle tool unclamp (auto/manual)

This is to move the air pressure cylinder used for unclamp by the signal of the spindle
tool clamp/unclamp.
2) Solenoid value for tool magazine pot Up/Down(24 tools, 30 tools ATC)
This is to make tool pot turn by 90°.
3) Solenoid value for emitting the spindle taper air
This moves at the time of the spindle tool unclamp and cleanse foreign objects
around the spindle taper by air.

Table 4-1-4 Solenoid Valve Table

L/s Number Purpose Type Maker Location

YV44A Tool Clamp

4KA420-15-BS-DC24V CKD Upper Head
(*YV44B) Tool Unclamp

YV21 Spindle Air blow AB31015-02G-DC24V CKD Upper Head

YV46B Tool Pot Down ATC

4KA210-06-LS-DC24V CKD
(24 Tools, 30 Tools)
YV46A Tool Pot Up

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1.4 COOLANT AND LUBRICATION

1.4.1 Coolant

Cutting and shearing between the processed side and tools of working causes
escalation of the temperature to bad effects.
Coolant prevents those bad effects.

1) Works and Qualities of Coolant

Works of Coolant Qualities of Coolant

a) Cooling : prevents rise of temperature of a) Easy to separate chips, which

cutting tools and work piece have to be taken back.
b) Lubrication : decrease friction between b) It should be rust-prevented on the machine.
chips on upper side of tools
c) Cleanse : wash chips c) It must be harmless.

2) Advantages of Coolant
① It lessens the cutting resists and lengthens the usage of tools.
② It prevents scratches on the trimmed side.
③ It prevents heat inflation of work piece, which will improve the precision of
dimensions for the processed.
④ Because of better chip flow, the cutting work becomes easier.

3) Types of Coolant

Division Types Description

Surface active agent and mineral oil are main ingredients. Becomes
Type W 1 white turbid liquid in water. 1~3.
Common name : Emulsion type watersoluble coolant
Water- Surface active agent is the main ingredient. Becomes transparent
soluble Type W 2 or half-transparent. 1~3.
Coolant Common name : Soluble type insoluble coolant

Inorganic dyes is the main ingredient. Becomes white turbid liquid

Type W 3 in water. 1~2
Common name : Solution type insoluble coolant

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Division Types Description

Mineral oil or mineral oil and fatty oil are main ingredients. Doesn’t
Type 1 contain ultimate stress additives. 1~6.
Common name : oil
Water- Surface active agent is the main ingredient. Becomes transparent
soluble Type 2 or half-transparent. 1~3.
Coolant Common name : Soluble type insoluble coolant

Inorganic dyes is the main ingredient. Becomes white turbid liquid

Type 3 in water. 1~8
Common name : Solution type insoluble coolant

① Alkaline aqueous solution: This is the solution composed of water which is good for cooling and
alkaline additive for anti-rust effect. This makes easy for cooling down and flow of chips and is
mainly used for grinding work.
② Mineral oil: machine oil, spindle oil, and light oil are included. Since this is good for lubrication
but lacks cooling effect, this is used for light cutting.
③ Animal/plant oil: lard, whale oil, olive oil, bean oil, cottonseed oil. This kind of oil have better
viscosity but bad cooling effect. This oil is used for medium coolant.
④ Mineral oil+animal/plant oil (mixed oil): mixing ratio becomes different in accordance with work.
This can be made separately according to the purpose of cooling and lubrication.
⑤ Extreme pressure oil: this is used for lubrication when the cutting tools have frictions at the state
of high temperature and high stress. As extreme stress additives for the mineral or mixed oil
includes S, CL, Pb, and P.
⑥ Emulsified oil : This is good for cooling and lubrication and widely used for cutting work by
mixing with water. For cutting, 10~30 times of water and for grinding 50~100 times of water is to
be mixed. It is cream-colored just like mineral oil soaked in soap water.
⑦ Chloridation oil: this is chlorine combinated with paraffin or fat oil and then diluted with mineral
oil. This creates a solid cover of iron chloride between cutted part and tools under the state of
high temperature and high stress.
As temperature is approximately 400℃, gear cutting machining or cutting of nonferrous metal is
proper.
⑧ Emulsified chloridation oil: This has two types: the mixed oil of emulsified oil together with
chloridation oil or chlorides sulfur combined with fat oil and then diluted with mineral oil.
Most of coolant products are emulsified chloridation oil.

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4) Selection of coolant : coolant should be selected in consideration of the quality of

work piece, the speed of cutting, the quantity of move, the depth and width of move,
if the cutted chip are eradicated or not, and other cutting conditions. The lower the
viscosity of coolant is, the better it is for high speed cutting.
Coolant should be kept in the cool area and from dust and foreign objects.

Table 4-1-5 Selection of Coolant

Cut
Angular Taper
Rough cut Threading Sawing Boring Knurling Reamer
Cut Grind
Material
Mineral oil ,
Emulsified Mineral
Soft steel Mineral oil Mineral oil emulsified Mineral oil Mineral oil Mineral oil
oil oil
oil
Mineral oil,
Emulsified Mineral
Hard steel Mineral oil Mineral oil emulsified Mineral oil Mineral oil Mineral oil
oil oil
oil
Mineral
Cast iron No used No used No used No used No used No used No used oil (light
oil)
Only Only Only Only Only Only Only
Brass mineral
Emulsified Emulsified Emulsified Emulsified Emulsified Emulsified Emulsified
Bronze oil
oil oil oil oil oil oil oil

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1.4.2 Coolant Device

1. Coolant device
The coolant escalated by the pump of coolant from the tank is discharged
through pipes and the nozzle for the purpose of cooling down and lubrication of
things.

2. Specification of the motor pump for the coolant

Table 4-1-6 Specifications of the Motor Pump for the Coolant

Types Submersion(ACP-400F)
Power (kW) 0.4
Number of phases Ø3, 2P
Voltage(V) 200 220
Max. allowable current (A) 2.4 2.7
Wave(㎐) 50 60
Temp.(℃) -50 ~ +40
Discharge Q’ty 50Hz 140
(ℓ/min) 60Hz 200
Total stroke(m) 5
Usable viscosity limit
75
(cST)

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3. Specification of the motor pump for Bed Flushing

Table 4-1-7 Specifications of the Motor Pump for Bed Flushing

Types Submersion(ACP-900MF)
Power (kW) 0.9
Number of phases Ø3, 2P
Voltage(V) 200 220
Max. allowable current (A) 4.3 5.2
Wave(㎐) 50 60
Discharge Q’ty (ℓ/min) 200(50 ~ 250)
Total stroke(m) 6.5 10
Usable viscosity limit (cST) 75

The volume of the discharge in the above table is based on the “○”of back pressure,
that is the oil amount of pump discharger. The actual discharge amount from the nozzle
is different depending on the size of the nozzle, the pipe resistance, the height difference
between nozzle and pump, and the viscosity of coolant.

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4. Cleaning of the motor pump for the7 coolant

Table 4-1-8 Order of Cleaning

Types Description

1 Stop the discharge of coolant

2 Unwise the cover of discharge of the tank and extract the coolant reside in the tank.

3 Separate the cover plate on the tank

4 Separate the filter of side tank

5 Clean the cover plate and filter.

6 Supply coolant into the tank (345ℓx 2 = 690ℓ: Standard).

7 Put together in the reorder of separation.

Tools Tool(5, 6. 7mm), screwl driver, rag, container for extracted coolant

The oil spilled on the floor while cleaning coolant tank must be mobbed by cloth. Or the
slippery floor may cause accident.

Only used the coolant product is designated by the company.

The use of unauthorized coolant without permit of the company will cause a trouble.

The dregs on the cover plate on the tank and chip box must be periodically gotten rid of.

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5. Checkup and repair

In daily operation, any detection of shaking of coolant pump, noise or unusual
discharge amount requires immediate stop of oil discharge and repair in accordance
with the following table.

Table 4-1-9 Checkup and Repair

Symptoms Causes Measures

Cutted line Repair or change

Broken fuse Change and identify the cause
Bad switch contact function Examine contact area
Not working Low voltage Contact power company
motor Break-down the motor Change
Foreign object in the fan Disassembly and repair
Wear/tear line ring bearing Disassembly and repair
Rust on shaft Disassembly and repair
Down the speed of rotation Examine rotation part
Motor working
Foreign object in the pipe Clean the pipe
but not Up
coolant Unsoaked pump in coolant Supply coolant and clean the tank
Unsubmerged fan Unwise the air cover and let out the air
Foreign object plugging fan and
Separate and repair
Up coolant case
but could not
Fan wear Separate, then repair or change
meet the
Leaking discharge pipe Examine and repair
designed
amount Lessen the number of rotation Examine the rotation area
Stopping the pipe Examine and clean the pipes
High gravity and viscosity Examine coolant
Too much Rotation area contact Change
load on motor Over discharge Lessen
Low voltage Contact power company
Lost balance by stopping fan by
Separate and examine
Shaking or foreign object
noise of pump Tear on bearing or the machine Change
Cavitation Consult with the maker

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The power must be OFF before any activities to examine and repair coolant.
Safety is first.

1.4.3 Lubricator
1) Lubrication: lubricating is to change solid friction to liquid friction to lessen the loss
of power at which lubricator is used. There are liquid (mineral, animal/plant oil),
semi-solid(grease, etc.), and solid (graphite, talc, mica, etc.) lubricator.

2) Qualities of lubricator
① Good flow and low carbonation.
② Low corrosiveness for metals.
③ Good thermal conductive and high anti-load.
④ Strong against heat and acid.
⑤ Cost effective and appropriate cohesiveness
⑥ Little change in viscosity according to the difference of temperature.

3) Purpose of lubricator
① Lubrication: it creates oil film at the surface where the movement of two metals
makes friction and prevents friction, wear, or deposition of the metals.
② Cooling effect: absorb the friction heat at the friction surface
③ Airtight effect: it keeps from dust, grease, etc. The oil film between piston ring
and cylinder works as sealing from leak of gas.
④ Cleaning: lubricator cleanse solid object on the friction surface and prevents
rust.

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4) Lubrication method
① Complete lubrication: also called as liquid lubrication. In this case, there are
enough lubricator so that the metals are separated from each other.
② Incomplete lubrication: also called as dangerous lubrication with very thin oil
film. The friction between two objects makes less comparative speed and
viscosity. But a shock makes oil film to be broken.
③ Solid lubrication: heat, deposition of metals due to friction are created. This
must not be allowed.

5) Types of lubricators
① Liquid: mineral oil or animal/plant oil. Animal/plant oils are good at the flow,
viscosity and ignition. Mineral oil is good at preventing degeneration in quality
at the high temperature and anti-rust of metals.
② Extreme pressure oil which adds special lubricators (P, S, etc.) and anti-
freezing machine oil whose solidification point is -35°C~-50°C, silicon oil
which is good for cold-resistant and heat resistant, and coolant in order to
lessen the cooling and friction at the time of cutting (there are watersoluble
coolant and non-soluble coolant).
Liquid lubricators are classified by the SAE(Society of Automotive Engineers in
USA).
•For winter: 5W, 10W, 20W
•For summer: 20W, 30W, 40W, 50W
③ Solid lubricators: graphite, talc, soap stone, mica, etc. Grease is semi solid oil.

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1.4.4 Supplying Lubricator

1. Supply only the designed amount of the designated oil. Either the different type of oil
or over amount of oil may have adverse effect on the durability of the machine.
2. Clean the supply tap and take extra care to keep dust out.
3. When supplying oil, use filter in order to prevent foreign object such as dust from
infiltrating into the tank.
4. New oil only. Regenerated oil or old oil or mixed oil should not be used.
5. When supplying new oil, don’t use it all but remain a little, which should be used later
in order to eradicate moisture or sediments.

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Table 4-1-10 Lubricators Table

NO.
1 2
Item
Oil Supplying
Lubricator Tank ATC Cam
P o i n t
Method Gear Pump Grease Gun(Manual Oil Supplying)
Every six months,
Period When necessary
when necessary
Amount 1.8ℓ Appropriate amount
NISSEKI UNIWA Y 68
IDEMITSU DAPHINE SUPER MULTI WAY 68C
SHELL OIL TONNA T68 ALVANIA EP2
MOBIL OIL VACTRA NO.2 MOBILUX EP2
MITSUBISH OIL DIAMOND SLIDE WAY 68
ISO CODE G68 XBCEB2

1. Places to be lubricated
1) 7 places including X axis lm guide block, ball screws
2) 7 places including Y axis lm guide block, ball screws
3) 7 places including Z axis lm guide block, ball screws

2. Lubricator oil pump, motor specification

1) Pump

Table 4-1-11 Pump Specification

Items Specifications

Amount of discharge 150cc/min, 50/60Hz

Max. discharging stress 17kgf/㎠

Voltage AC 220V

Frequency 50/60Hz

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2) Motor

Table 4-1-12 Motor Specification

Items Specifications

Power 46W

Voltage 200/220V

Frequency 50/60Hz

Authorized current 0.55A

3. Cleaning Lubrication Unit

Table 4-1-13 Cleaning Lubrication Unit

No. Description
1 Power OFF
2 Unwise bolt and separate unit
3 Disassemble the tank with + type driver.
4 Clean the inner of the tank
5 Eradicate the filter of the inlet point
6 Cleanse the filter with kerosene
7 Get rid of foreign objects in the filter with compressed air
8 Attach filter
9 Attach tank
10 Attach unit
11 Supply lubricator
12 Power ON
13 Check if lubricator is supplying into line ring bearing
Tools Wrench(5㎜), + type driver

Any oil on the floor must be instantly cleared by floorcloth. Slippery floor can cause harm.

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1.4.5 Discharging Lubricator

1. Discharging period of lubricator

① The discharging time is set as 15 ~ 20 seconds. (Timer No.11)

② The stopping of discharging is set as 15 minutes. (Timer No.1)

1. Do not change without permit the period of discharging lubricator, which has effects on
the machine.
2. The working time of valve is required for the operation of quantitative valve. Longer
time does not have effect on the amount of lubricator.

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1.4.6 Drawing for Lubricator Pipes Laying

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1.5 Comparative Oil Table

OIL TYPE SHELL OIL MOBIL OIL CASTROL OIL BP OIL CALTEX OIL

VELOCITE Hyspin BP ENERGOL SPINDURA

FC 10 Morlina 10
NO. 6 VG 10 HP10 OIL 10

Hyspin ENERGOL RANDO

FD 22 TELLUS 22 DTE 22
AWS 22 HLP-HM 22 HDZ 22

VELOCITE Hyspin BP ENERGOL RANDO OIL

FC 32 TELLUS 32
NO. 10 AWS 22 HLP-HM 22 HD 32
BP
DTE 24, Hyspin RANDO OIL
HM 32 TELLUS 32 ENERGOL
Nuto H 32 AWS 32 HD 32
HLP-HM 32
WAY
VACUOLINE Magna BP ENERGOL
HG 32 TONNA T 32 LUBRICANT
1405 GC 32 GHL 32
32
DTE 25, Hyspin BP ENERGOL RANDO OIL
HM 46 TELLUS 46
Nuto H 46 AWS 46 HLP-HM 46 HD 46

DTE 26, Hyspin BP ENERGOL RANDO OIL

HM 68 TELLUS 68
Nuto H 68 AWS 68 HLP-HM 68 HD 68
WAY
VACUOLINE Magna BP ENERGOL
HG 68 TONNA T 68 LUBRICANT
1409 BD 68 GHL 68
68
WAY
Magna BP ENERGOL
G 68 TONNA T 68 VACTRA NO. 2 LUBRICANT
BD 68 GHL 68
68
VACUOLINE 528
Alpha BP ENERGOL RANDO OIL
CKB 150 Morlina 150 (DTE OIL
SP 150 GRXP 150 150
EXTRA HEAVY)
WAY
Magna BP ENERGOL
G 220 TONNA T 220 VACTRA NO. 4 LUBRICANT
CF 220 GHL 220
220
MOBILGEAR MEROPA
Alpha BP ENERGOL
CKC 320 OMALA 320 600XP 320, LUBRICANT
SP 320 GRXP 320
Spartan EP 320 320
BP
Alvania Spheerol MULTIFAK
XBCEB 2 MOBILUX EP2 ENERGREASE
EP(LF) #2 EPL 2 EP 2
LS-EP 2
BP
Alvania Spheerol MULTFAK
XBCEB 0 MOBILUX EP0 ENERGREASE
EP(LF) #0 EPL 0 EP 0
LS-EP 0

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Oil type are same as symbol and viscosity grades specified by ISO.

Do not mix two type of oil. It decreases the machine performance and causes
the accident.

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1.6 AIR PRESSURE DEVICE

1.6.1 Places to Be Used

1) Cleaning Spindle taper area

2) Air Purge on Spindle Nose
3) ATC tools Up/Down operation (24 tools, 30 tools ATC)

1.6.2 Functions

1) Filter : Eradicate the moisture in the air and foreign objects

2) Oiler : Supply oil to inhibit corrosion of machine by moisture
3) Amount of supply : Approx. 50cc

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1.6.3 Controls of Oil Supplying

The control bolt is attached on the upper part of oiler. The amount of oil should be
controlled 5 drops in a minute.

1. Too little amount of oil makes air pressure line and machines corrosive and too much
amount of oil becomes the cause of machine error. Care is required for the control.
2. If the air in the factory contains lots of moisture, an air driver must be used.

1.6.4 Oil Supply into Oiler

The oil supply should follow the order below.

1) Shut the air pressure
2) Open the supplying point and supply until the “H” line.
3) Close the supplying point

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1.6.5 Drawing for Air Pressure Circuit

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1.6.6 Air Pressure Piping

The machine uses clean air for cleaning of Spindle taper, tool unclamp, ATC
magazine cylinder. Be prepared with air pressure.

• Pressure 5kg/㎠, oil amount 250ℓ/min

This original air should be clean from dust and over-saturated moisture in the air.

The higher the air temperature of the air pressure origin is than that of the machine
body, the easier water drops are created on the machine body because of the nature
of air. The moisture contained in the air develops rust on the Spindle hole or tool
shank and has adverse effects on the processing or cutting surface. So, the lower
the air temperature of the air pressure origin is, the better. If there is big difference in
temperature, set up an air drier between air pressure origin and the machine. The
following drawing is hose joint to let in the air.

(Manufacture the pipes to fit your factory.)

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1.7 THE TROUBLES AND MEASURES FOR SPINDLE

1.7.1 Introduction

The nose-key of the spindle is supported by angular contact ball bearing and the rear
side of the spindle by cylindrical roller bearing, and that is moved by 11/15㎾ spindle
motor.
The oil conditioner lubricates and cools down bearings in the Spindle. The
deformation of Spindle by the heat generated during high speeding rotation has
adverse effects on the durability of the bearings and processing. To counter this kind
of heat deformation, this machine has been set up a oil conditioner so as to
guarantee the durability of the machine and processing.
The orientation device of the Spindle can decide the position with the proximity switch.
So, it can decide the high speed location without stopping Spindle.
Tool lock device makes automatic movement of tool clamp and unclamp by the tool
unclamp cylinder which is working by the squared coil spring and air pressure.

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1.7.2 Spindle Air Pressure Circuit Drawing

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1.7.3 Spindle Operation

1. Spindle operation
The spindle is operated by the AC motor and motor is transmitted by voltage
control and relay control, spindle’s speed of 8000 rpm (Option : 12000 rpm) can be
reached.
Spindle output is 15 kW (rated for 15 minutes), the machining with 11 kw load can
be continuously operated. Also, if load time exceeds, it is protected by operation
the thermal relay in the motor control unit and transferring spindle is stopped.

2. Spindle device
There are angular contact ball bearing (4 of 1 set) at the front of the Spindle and is
cylindrical roller bearing at the rear of the Spindle.
The inner wheel of the cylindrical roller bearing and angular contact ball bearing is
supported by collar, tightened by nut and fixed by piece.
The outside wheel of the angular contact bearing is given a pre-stress by front
cover so that the optimum gap in the axis direction and the forced circulation of oil
through oil way in the sleeve of the outer bearing makes the heat deformation
generated by bearing heat to be minimum even in the high gear.
The grease for bearing lubrication is protected from the Spindle lubricator by the
ideal form of labyrinth.

Since any abnormal situation happens in the Spindle cannot be solved without skilled
hands, seek an expert through Customer Service.

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3. Tool clamp, unclamp device

The tool holder can be mounted on the Spindle by getting the taper side of the tool
holder close to the Spindle hole taper by pulling the full stud bolt with collet inserted
in the Spindle and rod.
Clamp power can be earned by square shaped coil spring which is inserted in the
rod. This machine is designed as 1024 ㎏ of clamp power.
Unclamp can be done by pressing rod by tool unclamp cylinder that makes square
coil spring to be shrunk and the tool holder to be separated from collet.
To keep dust out from the taper area, air (5 ㎏/㎠) is blown at the state of unclamp.
However, this function works only during ATC operation and its related movement
(under the automatic movement), tool clamp and unclamp movement by manual
operation does not involve air.

4. Control of tool unclamp stroke

The changes of parts in the Spindle such as collet or draw bar, part changes due to
damages of tool unclamp cylinder, or oil changes require the control of stroke
under the tool unclamp. The following instructions show the order of the control
work.
1) Adjust the gap between the cover of tool unclamp cylinder side and nut to be
about 20 ㎜. Do not too tighten the set screw in order to be adjusted.

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2) Measure with deep gauge the length from the spindle hem to the draw bar hem
by automatic tool unclamp.

100.9

3) The length from the hem of spindle to draw bar should be 100.9 including 0.5
㎜ of tool thrust depth at the state of complete unclamp.

It is possible to be a little difference in the length from the hem of spindle

to end of full study of tool because of spindle processing and the
tolerance of tool side. Adjust the connector of cylinder so that the tool
thrust depth becomes 0.5 mm after measuring the correct size with
JIG(or a real tool).

4) When nut is adjusted, press the manual unclamp button, check the tool thrust
depth and tighten the set screw so as not to loosen the nut.
5) After completion of adjustment, examine the movement with naked eyes by
using tool.
6) Adjust the Z-axis origin so that the gauge line of spindle is 0.5 ㎜ higher than
the gauge line of ATC pot.
7) Confirm the ATC movement and ATC origin position a couple of times at the
automatic state.

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5. Spindle drive unit (AC motor)

1) Power on
Before power on, measure the voltage with AC power voltage to be AC 200V ~
AC230V. Note R, S, T.
Use the power enough to supply steady power so as not to have low voltage even
high loading.
2) Maintenance (Spindle AC servo motor)
For stable use of motor regular maintenance is necessary.
The status of motor can be detected by diagnostic observance with vibration, noise,
and temperature. Daily checkups and regular maintenance will help earlier
detection of unusual movement of motor. Treat troubles in accordance with causes.

Table 4-1-14 Checkup Items

Daily Checkups Regular Maintenance

Vibration and sound of bearing Loosened bolts
Temperature of bearing Clean dusts and oil

3) Vibration and noise of bearings

① Vibration
In daily checkup, decide with hands on the bearing.
Too much vibration is the cause of trouble in bearing and coils. If the
vibration range is over 1750rpm ~ 50μ with naked eye, find out the cause and
clear the problem.
② Sound
The cause of sound is difficult to determine. However, unusual noise
must be found out. If there is a sound around bearing, put grease. The noise
stops with grease, it would be no problem.

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1.8 FEED AXIS

1.8.1 Introduction

The bed of this machine has a stable structure in terms of precision and high-strength.
For the X axis, the saddle is placed on the bed and the table moves right and left on
the top. For the Y axis, the saddled on the bed moves back and forth, and for the Z
axis, the head moves up and down on the surface of the column, having sufficient
strength.
The linear motion guide, enabling the high-precision position determination due to the
low friction resistance of the X, Y and Z axes, is selected, and the high-precision ball
screw is used as the feed screw.

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1. Axis feeding sequence

1) Axis feeding sequence(high gear feeding, feeding, return origin, handle)

<Figure 4-1-1 Axis feeding Sequence>

Input/output can be known by NC relational signal with NC magnetic

diagnosis.(PMCDGN)

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2) Axis feeding sequence (Tape, memory, MDI)

Tapes, memory, MDI chosen

Not set to 0%

<Figure 4-1-2 Axis feeding Sequence>

Input/output can be known by NC relational signal with NC magnetic

diagnosis (PMCDGN).

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1.8.2 Feed Operation Device

<Fig. 4-1-3> illustrates axis feed operation device and the structures of all axis are
the same.

<Figure 4-1-3 Feed Operation Device>

The rotation of servo motor can move each axis with the rotation power of ball screw
through crook-resistant and less inertia coupling.
The transfer of power from ball screw and motor axis has no back rash since it is
done by the cone push of wedge-shaped coupling.
The both ends of ball screw are fixed with angular bearing given with pre-load and
ball bearing.
In consideration with heat deformation(heat swelling) by load, cutting and speed
move, each axis is given tension by nut. Bearings, ball screws, and nuts are
lubricated by automatic central lubrication system and can keep the high precision for
long hour operation.

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1.8.3 Axis Feed Range

Table 4-1-15 Axis Feed Range

Left/right Table moving direction

X-axis +direction: table moves toward left
-direction: table moves toward right
Front and rear saddle moving direction
Y-axis +direction: saddle moves toward front
-direction: saddle moves toward rear
Up and down Spindle moving direction
Z-axis +direction: Spindle feeds upward
-direction: Spindle feeds downward

This moving direction is on the reference that a worker stands at the front of the
machine.

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1.8.4 Each Axis Zero Return Switch Location

1. Axis stroke

X-AXIS : 800mm
Y-AXIS : 460mm
Z-AXIS : 520mm

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2. Axis limit switch

1) X-axis

2) Y-axis

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3) Z-axis

3. Parameter number for stroke control

쪾Parameter number for stroke control

·Back rash amount (set value : -9999 ~ +9999, unit : 1/1000mm)
No. 1851(X, Y, Z)
·Reference zero return (set value : -9999999999 ~ 999999999, unit : 1/1000mm)
No. 1850(X, Y, Z)
·SOFT O.T (set value : -9999999999 ~ 999999999, unit : 1/1000mm)
No. 1320 : + direction Soft limit (X, Y, Z)
No. 1321 : - direction soft limit (X, Y, Z)

Each axis must be given parameters.

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1.8.5 Zero Return Control

1. Zero return method

The zero return of a machine is the reference point of machine coordinates and
required regular checkups.
The zero returns of X, Y is set as reference of table center. That is, the center of
Spindle is aligned with the table center and the coordinates is set as X=400.00,
Y=230.00, from which the zero return of the machine is set.
The zero return of Z-axis is set as 650 ㎜ on the table.
For NC machine, the zero return of axis is accurately decided by the signal of grid
which is output from the position detector. The relation between grid signal and
machine stop position at the time of zero return is illustrated as the drawing below.
The machine decelerates as it receives zero return deceleration signal. When the
signal is off, the first grid signal stops the machine.
The final zero return position can be minutely adjusted by shifting this grid signal
by change of parameter. In this case, the parameter number is No. 1850(X, Y, Z).

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2. Zero return adjustment

The zero return of the machine

• Input appropriate amount of back rash into each

• Set the zero return parameter (No. 1850) of each axis to be “0”.

1) Set the zero return position

Set the zero return position as following drawings.

① Establish block gauge at the end of table with using magnet or other methods
as the drawing A.
② Set the dial gauge (or lever type dial test indicator) fixed on the spindle
as“0”.
③ Move the block gauge to the opposite end of table as drawing B.
④ Move table until the dial gauge (or lever type dial test indicator) is aligned with
the number gotten from A.
⑤ Move to the center of table and set again the current position as 0.

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1. Use only authentic dial gauge (or lever type dial test indicator) since a dial gauge
must measure approximately 0.01 ㎜ of a zero return. Use only good state of
stand and the stand should be short enough to resist any shock while rotation.
2. The adjustment of zero return (decision of reference point and parameter setting)
can be done once for each axis.

Y-axis reference point is the center of T home on the table center.

① Fix the lever type dial indicator to spindle and place in the center of the two center
homes.
② Set the current position Y-axis of the table center as 0.

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The reference point of Z-axis is determined by the relations of ATC and Spindle.

① As illustrated in the drawing, ATC position becomes a reference and the zero
return of the machine coordinates becomes the second reference point for Z-axis.
Set the optimum ATC position as in the order of “1.9.5 Adjustment of Tool Pot
and Twin Arm Part”. The position of Z-axis on the CRT screen should be “0”.
② Move Z-axis to manual mode, get 150 ㎜ block gauge close to the between table
and Spindle section, move 1pulse(1/1000 ㎜) with manual pulse generator and
find the point where the block gauge is aligned accurately with in-between table
and Spindle section.
③ From the above position, move Z-axis to 635 ㎜ MDI operation, and its position
becomes the second reference point (zero return of machine coordinates).

2) Control of origin DOG

① Do the zero return.
② Control DOG so as for the positions of all axis to show on the screen as follows:
•X-axis : 1th Zero Point
•Y-axis : 1th Zero Point
•Z-axis : to be followed to ATC control

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3) Calculation of position error

① After controlling of DOG position, do the zero return again.
② Take the note of the current position.
③ Calculate the difference between the return position and actual origin. (that is, the
position not yet controlled)

4) Input parameter data

• Set value: -99999999 ~ 9999999(unit : 1/1000 ㎜)
• Parameter No.1850 (X, Y, Z)
• Set +(-) value when reference point(zero return) moves +(-) position.

5) Control of SOFT OT
Input the value as determined for parameter.

Parameter No. Axis Direction Set Value

X: +direction soft limit 1000
1320 Y: +direction soft limit 1000
Z: +direction soft limit 2000
X: -direction soft limit -801000
1321 Y: -direction soft limit -461000
Z: -direction soft limit -521000

6) Adjustment of Hard OT
① Return to the origin.
② Move about 1 ㎜ to have the SOFT OT to operate, then move 5 ㎜ more and
adjust DOG position to have the HARD OT to operate.

7) OT Release
① SOFT OT Release
If any axis moves to the end of stroke by false movement or false function, it
causes OT Alarm, which returns the axis. Release by pressing Reset.
② HARD OT Release
If the SOFT OT does not move, HARD OT stops the feed.
When HARD OT switch operates, ALARM message shows on the screen and the
power to the speed control unit becomes off, which stops all axis.
With pressing the SPINDLE STOP SWITCH and HANDLE or JOG, the HARD OT
is transferred to released to the opposite direction of OT.

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1.9 TWIN ARM TYPE 24 TOOLS(STANDARD), 30

TOOLS(OPTION) ATC

1.9.1 Introduction
ATC(Automatic Tool Change) device is composed of Twin Arm which moves tools
between Spindle and magazine and the Magazine part to keep tool. The body of ATC
is installed on the side of Column.
Twin Arm has tool gripper at its both ends and performs Arm 52° rotation, Arm 180°
rotation, Arm up and down. Tool gripper has a tool drop-prevention device to keep
tool from dropping during Arm moving.

While Twin arm is rotating 55°, it performs up and down of tool pot on the magazine
side, arm down as well as tool drop prevention device at the same time so as to save
the tool change time.
Magazine has 24 Tool pots for National Taper No.40 (Option: 30 sets) and realized
the speed operation by geared motor. And the selection of tool has adopted random
method which enables to optionally call for the necessary tool.

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1.9.2 ATC Limit Switch

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1.9.3 ATC System Control

Table 4-1-16 ATC DATA TABLE

No. Address Data Function

000 D130 - MAX. TOOL POT NO.(AUTO SETTING)
001 D132 - PRESENT TOOL POT NO.(AUTO SETTING)
002 D134 - -
003 D136 - -
004 D138 - -
005 D140 - WAITING TOOL NO.
006 D142 - T-CODE BCD DATA CHANGE
007 D144 25(31) SPINDLE TOOL NO.(AT TOOL POT 30)
008 D146 1 TOOL NO. OF POT NO.1
009 D148 2 TOOL NO. OF POT NO.2
010 D150 3 TOOL NO. OF POT NO.3
011 D152 4 TOOL NO. OF POT NO.4
012 D154 5 TOOL NO. OF POT NO.5
013 D156 6 TOOL NO. OF POT NO.6
014 D158 7 TOOL NO. OF POT NO.7
015 D160 8 TOOL NO. OF POT NO.8
016 D162 9 TOOL NO. OF POT NO.9
017 D164 10 TOOL NO. OF POT NO.10
018 D166 11 TOOL NO. OF POT NO.11
019 D168 12 TOOL NO. OF POT NO.12
020 D170 13 TOOL NO. OF POT NO.13
021 D172 14 TOOL NO. OF POT NO.14
022 D174 15 TOOL NO. OF POT NO.15
023 D176 16 TOOL NO. OF POT NO.16
024 D178 17 TOOL NO. OF POT NO.17
025 D180 18 TOOL NO. OF POT NO.18
026 D182 19 TOOL NO. OF POT NO.19
027 D184 20 TOOL NO. OF POT NO.20
028 D186 21 TOOL NO. OF POT NO.21
029 D188 22 TOOL NO. OF POT NO.22
030 D190 23 TOOL NO. OF POT NO.23
031 D192 24 TOOL NO. OF POT NO.24

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No. Address Data Function

032 D194 25 TOOL NO. OF POT NO.25 (OPTION 30EA)
033 D196 26 TOOL NO. OF POT NO.26 (OPTION 30EA)
034 D198 27 TOOL NO. OF POT NO.27 (OPTION 30EA)
035 D200 28 TOOL NO. OF POT NO.28 (OPTION 30EA)
036 D202 29 TOOL NO. OF POT NO.29 (OPTION 30EA)
037 D204 30 TOOL NO. OF POT NO.30 (OPTION 30EA)

Table 4-1-17 COUNTER

NO. ADDRESS RESET CURRENT REMARK

ATC POSITION TOOL ATC COUNTER
01 C00 24(30)
POT NO. (AT 30 POT)
02 C04 -
03 C08 -
04 C12 -
05 C16 -
06 C20 -
07 C24 -
08 C28 -
09 C32 -
10 C36 -
11 C40 -
12 C44 -
13 C48 -
14 C52 -
15 C56 -
16 C60 -
17 C64 -
18 C68 -
19 C72 -
20 C76 -

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1.9.4 ATC Motor Control

Both ATC twin arm and magazine are generated by AC motor and use DC type brake.

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No. Message PCDGN

KM3F ATC Forward Y0.1

KM3R ATC Reserve Y0.2

KMB ATC Braking Y0.3

KM4 Magazine Motor Drive Y0.6

KM5 Arm Motor Drive Y0.7

Ex.) MAGAZINE RESERVE ------------------------ KM3R, KM4 ON

MAGAZINE BRACKING ------------------------ KMB ON, KM4 OFF
ARM FORWARD---------------------------------- KM3F, KM5 ON
ARM BRAKING ----------------------------------- KMB ON, KM5 OFF

1. Arm motor control

① Get rid of tool which is hang on spindle
② Perform M31 at MDI mode, move the Y-axis Jog mover Toggle switch to +Y, then
pot will be down. (move it toward -Y, then pot will be up.)
③ Perform M35. (check main-axis orientation)
④ Confirm the following by X-axis Jog switch.
(It only rotates while pressing the button, if the first rotation completes, it stops
even with the switch being pressed.)
(+X: Twin arm forward, -X: Twin arm reverse)
⑤ Take off the magazine cover and confirm the switch for Arm origin checking(SQ14).
If the switch is placed on the upper DOG, the control is complete.
⑥ Adjust the brake by changing D19 (right revolution) and D18 (reverse revolution)
values of the PC parameter timer if the SQ14 is out of the upper part of the dog.

2. Checking Magazine Motor Control

1) Select Manual Mode.
2) Press Magazine Index button for a second and release it.
3) Check the magazine position. The correct position of tool pot is at the center of the
bracket(post down) for supporting pot.
4) Check if the magazine position detection(SQ11) of the down barrel cam shaft in
the center of magazine is out of the DOG.

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5) If the tool pot is out of the center of positing, adjust with the data table
D18(Forward), D19(Reverse).
6) After forward and adjust the magazine brake timer, do the same to adjust reverse
brake timer.

Determine the time from releasing magazine rotation power to braking while
D18
rotating magazine forward
D16
Determine the time from releasing Arm rotation power to braking
D17
Determine the time from releasing magazine rotation power to braking while
D19
rotating magazine reverse

3. Adjust motor brake gap

Due to long hours of work, the gap of motor brake is widened, which causes error of
stop position or slippage of brake. The gap shall be appropriately adjusted.

MAGAZINE MOTOR

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TWIN ARM MOTOR

4. After completion of twin arm adjustment, align the finger with tools and tighten
the span ring and fix Arm to Arm shaft.

When squeezing the span ring, there will not be enough room for the rectangular
wrench. Instead, use three rectangular bolt for the time being. When the arm comes
down, change the rectangular bolt to cap bolt.

5. Check if the length that the draw bar pushes a tool full stud bolt is 0.5 ㎜. (Use
deep gauge)

6. The abnormal length of tool push causes the break-down of twin arm and finger.
Correct the tool push by adjusting tool unclamp cylinder nut attached to head.

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7. Check the followings so that ATC can operate by moving fan of geared motor.
1) Smooth working of tool rock pin and tool clamp bar without interfering.
2) Whether the tool is clamp when the arm is down or not.
3) Whether the tool is completely taken when the arm is down or not.
4) The status of close adherence of arm finger and tool V home.
5) When the tool is clamp/unclamp to spindle, whether Spindle key is obstacles by full
stud bolt.

8. Practice ATC operation after the installation of ATC operation motor.

Check if ATC returns to home position again.

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1.9.5 Tool Pot and Twin Arm Control

1) Adjust the nut in the hook so that the gap

between cylinder and roller becomes about 2
㎜ at the state of upside pot.

2) Define the range of movement for pot up-

down and check if all pots move smoothly
in the pot bracket.

3) Insert tool into pot and down the pot.

4) Open the brake of geared motor (arm-operating motor)

① Insert tool into Spindle, align spindle side home of twin arm and V home of pot
side to the center of V home of tool. Adjust Z-axis origin so that spindle goes up
0.5 ㎜. (because of 0.5 ㎜, the length that draw bar pushes full stud bolt of tool)
② Use care that finger is not harmed by tool while aligning tools with finger.

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1.9.6 ATC Operation

1. Tool Data Setting

1) Process for tool data setting
① Press SYSTEM, then press soft keys, [PMCPRM], [DATA] to choose PC
parameter screen.
② Place the curser on D144
③ Input data to be the same as ATC initial setting list.
④ Limitation of the registration of data
A) Tool data cannot be registered while ATC or magazine is moving.
B) Data setting is possible only when the tool is set on magazine or there is
tool in the spindle. The data for empty pot and data the next tool are to be
instructed.
C) Set tool data onto D144 for spindle tool.

2. Spindle tool data setting

Change the spindle tool as follows:
① Select manual mode (Handle, Jog, Rapid or Zero Return)
② Out of spindle tool manual change switch, turn to tool unclamp and press the
button and change tool and press button after turning next clamp position. If
the number of spindle tool is aligned with the number of the previous tool
before change, the setting is over.
③ Select MDI mode. Place Key Switch of the operation panel to Write.
④ Set the tool number as「1. Tool Data Setting」.
⑤ Check if it is possible for the spindle tool to return to the empty pot of the
number shown on the tool setting screen.

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1.9.7 Empty Pot

Empty Pot is the pot which tool at the spindle returns. Tool can be changed when
there is no tool in spindle but in the waiting pot. Pot number is set as empty pot.
As long as the same tool is changed, the empty pot number remains the same.

When a tool with different diameter (neighboring pot and interfered longer tool) is
changed, take good care of programming so as not to interfere with tool of
neighboring pot at the time when the spindle tool returns to the empty pot.

1.9.8 Magazine indexing

The position of magazine indexing is detected by the ring counter which is using the
origin(pot 24) as standard. After initial start or when magazine indexing stops,
counter becomes to initialize. In this case, magazine has to do zero return. Or,
counting does not start.

1. Magazine zero return process

1) T command
Magazine zero return does automatically by the command of T code and the
wanted tool is indexed. The circuit drawing is illustrated as follows :

Tool Command

Magazine Forward

Pot 24 Indexing

After passing the first pot, magazine rotates

forward to the designated location for indexing.

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Magazine receives the tool indexing command when the power is on, it indexes
the Pot 24 first, then indexes the pot that receives command.
2) Manual indexing
In the manual mode, while pressing Magazine Index button on the control panel,
the magazine rotates forward and when releasing the button, it stops rotation. In
this case as previously stated, a zero return performs automatically when the
magazine completes 1st round even though the zero return does not complete.
Magazine zero return does not require any special operation but is performed
automatically.

1. Bear in mind that tool change is impossible when magazine zero return does not
complete.
2. Give T command before tool change.

2. Current Magazine Positioning

The current magazine position is set on the PC screen as following processes.
1) Press SYSTEM → PMC → PMCPRM keys to go PC screen.
2) Put the curser to D0130 on the DATA TABLE GROUP screen and select
[G.DATA].
3) Push in the order D , 1 , 3 , 2 then the curser goes to D132. (D132
means the current tool pot number.)

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1.9.9 ATC Function Review

1. ATC Cycle
ATC Cycle works in the following order.

Order Activity Activity Drawing

1 Spindle Orientation

2 Pot Down

Arm 52° Rotation

3
(Counter clockwise)

4 Tool Unclamp

5 Arm Down

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Order Activity Activity Drawing

Arm 180° Rotation

6
(Counter clockwise)

7 Arm Up

8 Tool Clamp

Arm 52° Rotation

9
(Clockwise)

10 Pot Up

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1.9.10 ATC Return

If ATC movement is interfered by Emergency Stop, return it as the following order.

1.Operational Key on Operating Panel

2. ATC Single Operation

1) Press RESERT button.
2) Carry out M31, EOB, M35, EOB and INSERT in sequence and press the
CYCLE START button in the MDI mode. (The feed hold lamp will be on, and
then off after around one second.)
※ If the CYCLE START is not executed, press the CYCLE START button and
the SELECT button at the same time.
3) If the pot is down, execute the clause 7), and execute clause 4) if the pot is up.
4) Select the empty pot by pressing the MAGAZINE INDEX button in the handle
mode.
5) Place the Z axis at the reference point.
Ex) Carry out G91, G28, Z0, EOB and INSERT in sequence, and press the
CYCLE START button.
6) Check the followings by pressing the Y axis jog feed switch.

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In case of pressing +Y : Pot Down Operation

In case of Pressing –Y : Pot Up Operation
7) Check the followings by pressing the X axis jog feed switch.
In case of pressing +X : Arm CW Cycle Operation
In case of Pressing –X : Arm CCW Cycle Operation
8) Check the followings by pressing the Z axis jog feed switch
In case of pressing +Z : Tool Clamping Operation
In case of Pressing –Z : Tool Unclamping Operation
9) Have the pot up by pressing the Y axis jog feed switch.
10) Carry out M32, EOB and INSERT in sequence, and press the CYCLE START
button.
11) Press RESERT button.

M6 COMMAND
M6(Tool Change) command releases interlock when the following requirements are
satisfied:
① Z-axis shall be on the position of Zero Return.
② When pressing Magazine Index button at the manual mode, magazine shall
rotate.
③ Twin arm shall be on Home Position.
(Check the ATC home position with lighting of the lamp.)
④ Alarm lamp shall be off.

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1.9.11 Maintenance Operation of ATC

Start

ATC Origin Position(G91 G28 Z0)

※ If the CYCLE START is not

MDI, M31 COMMAND executed, press the CYCLE
START button and the
MAG. SELECT button at the
MDI, M35 COMMAND
same time.
(SPINDLE ORIENTATION Confirm)

- Y-Axis JOG Siwtch ON : POT DOWN

+ X-Axis JOG Siwtch ON : ARM CW CYCLE

(TOOL UNCLAMP START LS ON Confirm)

- Z-Axis JOG Siwtch ON : TOOL UNCLAMP

+ X-Axis JOG Siwtch ON : ARM CW CYCLE

(TOOL UNCLAMP START LS ON Confirm)

+ Z-Axis JOG Siwtch ON : TOOL CLAMP

+ X-Axis JOG Siwtch ON : ARM CW CYCLE

(ARM HOME POSITION LS ON Confirm)

+ Y-Axis JOG Siwtch ON : POT UP

MDI, M32 COMMAND

End

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Chapter 2
Error Code and
Trouble Shooting
2.1 Error Codes and Electric Matters ......................................................... 4-2-3
2.1.1 NC Alarm and Trouble Shootings .................................. 4-2-3
2.1.2 Parameter Setting ....................................................................... 4-2-7
2.1.3 Check on Main Power r ....................................................... 4-2-10
2.1.4 Thermal Relay ............................................................................. 4-2-11
2.1.5 Circuit Protector .......................................................................... 4-2-12
2.1.6 Control Relay ................................................................................ 4-2-13
2.1.7 Ladder Diagram ......................................................................... 4-2-14
2.1.8 PC Timer & DAT ........................................................................ 4-2-16
 Error Code and Trouble Shooting

2.1 Error Codes and Electric Matters

This chapter describes error codes and trouble shootings by classifying the codes in
the table. Users shall refer to the descriptions of errors to solve them.

2.1.1 NC Alarm and Trouble Shootings

This describes troubles or abnormal states of the machine during the operation and
their countermeasures. Even though the descriptions stipulated in this chapter are
brief, for more details to the NC alarm shall refer to the Repair Manual for NC or ask
for customer service to the company.
In some cases, the troubles of NC device look as if the machine body has troubles.
Then, look up this User’s Manual and NC Repair Manual for the cause.

1. In case of lighting Warning Lamp(call light, yellow revolving light)

Call light is on the following conditions:
1) Machine stops due to program failure, program stop codes(M00, M01, M02,
M30, etc.) during the program operation.
2) When the alarm lamp of the operating panel is on, the machine becomes “Stop
Operation” to show the cause of any obstacles.
2. Types of alarms and causes of trouble
1) CRT shows alarm number and alarms messages. Look for the cause of the
alarm from the NC Alarm Message List and clear of the trouble.
2) Alarms for machine and PC control (Machine alarm)
A. CRT on the side of the operating panel
B. Press ALARM key of the operating panel to see the function menus on the
CRT, which shows the description and number of the alarm.
C. Find out and clear the cause of the trouble in relation with the alarm number
by using self diagnosis function (PMCDGN) of PC.

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 Error Code and Trouble Shooting

3. Alarm List

Table 4-2-1 PC Alarm List

ADDRESS MESSAGE REMARKS

A0.0 AIR PRESSURE ARARM
THROUGH(SIDE HOLE)COOLANT
A0.1
OVERLOAD
A0.2 LUB.PRESSURE ALARM
A0.3 LUB.OIL LACK ALARM
A0.4 LUB. MOTOR OVERLOAD
A0.5 ATC MOTOR OVERLOAD
A0.6
A0.7 AC 100V TRIP
A1.0 SPINDLE COOLING ALARM
A1.1 GEAR CHANGE TOOL CLAMP ALARM
A1.2 GEAR CHANGE ARM ORIGIN ALARM
A1.3 GEAR CHANGE TIME OVER ALARM
A1.4 ORT. TOOL CLAMP ALARM
A1.5 ORT. ARM ORIGIN ALARM
A1.6 DOOR CLOSE STATUS ALARM
A1.7 HYD. MOTOR OVERLOAD ERROR
A2.0

A2.1 NO S-CODE SP.START ALARM

A2.2 NO POT DOWN ERROR

A2.3 TOOL CLAMP SP.ROTATING ERROR

A2.4 ARM ORIGIN SP.ROTATING ERROR

A2.5 TOOL CLAMP SP.ROTATING ERROR

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ADDRESS MESSAGE REMARKS

A2.6 SPINDLE DATA OVER ERROR

A2.7 TOOL UNCLAMP START L/S ERROR

A3.0 TOOL CLAMP START L/S ERROR

A3.1 SPINDLE UNIT ALARM

A3.2 COOLANT MOTOR O/L
A3.3 JET COOLANT MOTOR O/L
A3.4 GUN COOLANT MOTOR O/L
A3.5 CHIP CONVEYOR MOTOR O/L
A3.6 TOOL BROKEN ALARM

A3.7 SP. OVERLOAD STOP ALARM

A4.0 ARM HOME POSITION ERROR

A4.1 DOOR CLOSE TIME OVER

A4.2 SPINDLE ROTATION AT M31

A4.3 M06 POT NOT UP ERROR

A4.4 MAGAZINE NOT ZERO RETURN

A4.5 M31 NOT CANCEL

A4.6 Z AXIS NOT AT ATC POSITION

A4.7 M06 AT NO TOOL CLAMP

A5.0 ATC CYCLE NOT END

A5.1 M31, M35 AT NOT MDI MODE

A5.2 M31, M35 DURING SPINDLE ON

A5.3 M31 NOT COMMAND

A5.4 ATC ALARM NOT CANCEL

A5.5 POT UP L/S NOT ON

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ADDRESS MESSAGE REMARKS

A5.6 POT DOWN L/S NOT OFF

ATC UNCLAMP/CLAMP TIME
A5.7
ERROR
A6.0 POT UP L/S NOT OFF
A6.1 POT NOT UP
A6.2 TOOL LIFE END

A6.3 ARM UP/DOWN TIME OVER

A6.4 ARM NOT UP

A6.5 ARM NOT HOME POSITION

A6.6 ATC TIME OVER

A6.7 ARM UP L/S ERROR

A7.0 MAGAZINE B-PHASE NOT ON

A7.1 MAGAZINE A-PHASE NOT ON

A7.2 MAGAZINE INDEX TIME OVER

A7.3 POT UP CONDITION LOST

A7.4 MAG.POSITION ERROR

A7.5 MAGAZINE A,B-PHASE BOTH ON

A7.6 SP.THRU COOLANT FILTER NOT ON

A7.7 SP.THRU COOLANT PRESS NOT ON
A8.0 +X O.T(HARD)
A8.1 -X O.T(HARD)
A8.2 +Y O.T(HARD)
A8.3 -Y O.T(HARD)
A8.4 +Z O.T(HARD)
A8.5 -Z O.T(HARD)
A8.6 COUNT FINISH
A8.7 NC ALARM

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 Error Code and Trouble Shooting

2.1.2 Parameter Setting

Parameters are very important since they determine the characters and functions of
the machine. They are the determinants for standard specifications and option
specifications, specific selections of specifications or functions, and capabilities of
relevant function or processing order.

1. Types of parameters
1) NC parameters
Refer to NC Parameter List
2) PC parameters

2. Adjustment of parameters
The parameter data has been set by the manufacturer of the machine. In most
cases users don’t need to adjust or set the data. (except user’s macro range,
backrash/correction of pitch errors)
The NC, PC parameter data list are enclosed together with the machine at the
release of the machine from the factory. Keep this list for maintenance or repair.

3. In case of power failure (Emergency Stop during machine operation)

In case of power failure during the operation, NC device and machine operating
panel turn OFF and the commands memorized in the NC device and electric
commands generated by manual operating buttons are all erased, and the
machine stops.
Even after returning to normal conditions, the machine does not resume its
operation until the user pushes POWER ON button on the NC device.
Take good care of pushing POWER ON button makes the cylinders related to oil
pressure circuits to complete the motion that was doing just before the power
failure.

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 Error Code and Trouble Shooting

Motion or state after ON of Acts to be needed after power

Motion or state before pw.failure
control circuit on

Spindle rotating Stop

Spindle stops Stop
Spindle change gear Stop Command S5 at MDI
Spindle orientating Stop Command M19 at MDI
Stop at the state before power
Tool clamp
failure
Stop at the state before power
Tool unclamp
failure
Stop at the state before power
X, Y, Z-axis
failure
Coolant discharging Stop
Mist discharging Stop

Chip conveyer moving Stop

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4. Motor List
*: Options
Type Output
No. of
Purpose Polar Voltage Wave Current Position
Maker Cont. %(ED) rotation

Β12/8000i
Spindle 11㎾ 15㎾ ~8000 Head
FANUC
X-axis β12/3000i
1.8㎾ 3000 Saddle
Feed FANUC
Y-axis β22/2000i
2.5㎾ 2000 Bed
Feed FANUC
Z-axis β22/2000i
2.5㎾ 2000 Column
Feed FANUC
*Outside SHIN Outside
0.2㎾ 4P 220 50/60
Chip con. MYUNG machine

For WILLY
0.5㎾ 4P “ “ 0.2 Lub. Tank
Lub.Tank VOGEL
For
ACP-400F Coolant
Standard 0.4㎾ 3P “ “ 1.4/1.5
A-RYUNG Tank
Coolant
*For Oil TOP-2MY-400-
Coolant
Hole 204HAM-VB- 0.4㎾ 3P “ “ 2.20
Tank
Coolant 15-NOP
*For Gun ACP-250F Coolant
0.25㎾ 3P “ “ 1.5
Coolant A-RYUNG Tank
For Bed
ACP-900F Coolant
Flushing 0.9㎾ 3P “ “ 2.5
A-RYUNG Tank
Coolant

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 Error Code and Trouble Shooting

2.1.3 Check on Main Power

1. Magnet Switch

Magnet switch is used to start and stop induction motor.

1) When magnet switch does not work:
• Spring holder is side by side with the switch body.
2) When magnet switch is working:
• The switch holder is approx. 4 ㎜ inside than the body of switch

It is possible that the spring holder goes inside the body when the magnet switch
does not move due to dust or any other cause.
Check the voltage between terminal a and b with multi-tester for any possible causes.

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2.1.4 Thermal Relay

This thermal relay is used to protect motor overload and breakdown.

1) Amp. Range setting dial
• Do not touch this dial as this is set at the release time by the manufacturer.
2) Reset button
• Push this Reset button after waiting 2 or 3 minutes when the Reset button is
projected due to the power overload to the thermal relay.

Frequent use of thermal relay causes damages on motor and overload on the
machine.

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2.1.5 Circuit Protector

Circuit Protector is similar to fuse. Fuse has to be changed when cut, however, the
CP can be reset by pressing “ON” button.

1) Normal State:

When pushing “ON” electric circuit shows the normal state.

2) Abnormal State:
“ON” button on circuit is projected to protect circuit. Solve the problem
and press the “ON” button.

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2.1.6 Control Relay

The state of Control Relay can be checked by its contact.

1. No move of relay

When there is electric current in the coil relay, the contact of relay changes.
At this time the movable contact is contacted with the upper side by the spring.
The contact with electric current without moving relay is called ‘B contact’.

2. Moving relay
When the coil contacts the lower side due to electric current, this means the
current flows to the other circuit.
In this case the contact that relay moves is called ‘A contact’
When ‘A contact’ happens, ‘B contact’ opens and shut the current.

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2.1.7 Ladder Diagram

1. Ladder Diagram
The mechanical control is controlled by PC and PC program is composed of I/O
interface, address, and PC function commands.

2. I/O Interface
1) Input interface

Input interface means the control signal is sent from the machine to PC.
RV illustrates the input terminal as follow:

If an address is ‘1’ the address with the same voltage with 24V is input.

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2) Read Address Diagram

① Address Number
The address number composed of letters and numbers shows on PC DGN
screen.
The meaning of the letters used is described as:

• X : Input
• Y : Output
• F : Signal sent from NC to PC
• G : from PC to NC
• R : PC inner relay

The number down the decimal point shows bit.

For example, X00.7 means the 7th bit of address X00.

② Connecter Number
Connecter number shows the connecter number of I/O module and the Pin
number.

CMA 44

DI/DO connector no. PIN no.

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2.1.8 PC Timer & DATE

1. Setting
The timer shall be decimally set from T1 through T150.

Setting Unit
• T1~T8 : 48 msec
• T9~T150 : 8 msec

2. Variable Timer (ATC 24ea/30ea)

TMR OUTPUT FUNCTION
REMARK
NO ADDRESS UNIT : msec
LUBRICATION PAUSE TIME
1 R726.3
300,000

GUN COOLANT OFF DELAY

4 R773.1
120,000
SPINDLE STOP CHECK
5 R760.0
0
AUTO DOOR CLOSE DELAY TIME
6 R833.0
0
MAGAZINE ARM MOTOR FREE TIME
7 R843.5
144
ARM/MAG MOTOR BRAKE TIME
8 R843.4
288
INITIAL SET TIME
9 R725.3
3,000
ORIENTATION FINISH TIME
10 R757.2
496
LUBRICATION ON TIME
11 R726.2
20,000
LUB. PRESSURE HIGH CHECK TIME
12 R728.7
20,000
LUB. PRESSURE LOW CHECK TIME
13 R729.0
10,000
GEAR CHANGE TIME
14 R755.4
10,000

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 Error Code and Trouble Shooting

TMR OUTPUT FUNCTION

REMARK
NO ADDRESS UNIT : msec
15

16
CYCLE DELAY TIME
17 R765.7
3,000
M FUNCTION DELAY TIME
18 R766.5
96
AUTO POWER OFF TIME
19 R769.7
5,000
ARM NOT UP
20 D236.4
2,000
MANUAL ATC TIME LIMIT
21 R880.3
25,000
MAGAZINE INDEX TIME LIMIT
22 D237.2
50,000
TOOL UNCLAMP START L/S TOUCH LIMIT
23 R744.4
496
TOOL CLAMP START L/S TOUCH LIMIT
24 R744.5
2,000
GEAR CHANGE DELAY TIME
25 R807.5
1,000
MANUAL ATC INDEX TIME LIMIT
26 R857.2
1,000
POT UP/DOWN TIME LIMIT
27 R879.0
5,000
ARM UP/DOWN TIME LIMIT
28 D236.3
2,000
29
EMERGENCY DELAY (RAPID)
30 R720.0
1,000
THROUGH COOLANT AIR BLOW ON TIME
31 R773.6
5,000
THROUGH COOLANT AIR BLOW OFF DELAY
32 R773.7
0
SP. THROUGH COOLANT FILTER NOT ON
33 D237.6
2,000
SP. THROUGH COOLANT PRESS SW NOT ON
34 D237.7
4,000

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 Error Code and Trouble Shooting

TMR OUTPUT FUNCTION

REMARK
NO ADDRESS UNIT : msec
SPINDLE DRAIN SOL ON TIME
35 R774.6
4,000
INITIAL SPINDLE AIR BLOW
36 R777.6
3,000
4-AXIS CLAMP L/S CHECK TIME
37 R796.4
1,000
4-AXIS DETACH
38 R704.6
496
4-AXIS HANDLE DELAY TIME
39 R707.5
1,000
4-AXIS UNCLAMP DELAY TIME
40 R796.7
496
TOOL UNCLAMP START DELAY TIME
41 R120.0
1,200
GIN COOLANT OFF DELAY
50 R773.1
15,000

3. Fixed TIMER(ATC 24EA/30EA)

TMR OUTPUT FUNCTION
REMARK
NO ADDRESS UNIT : msec
FLICKER ON TIME
1 R723.0
500
FLICKER OFF TIME
2 R723.1
500
LUBRICATION LACK CHECK TIME
3 R726.7
3,000
TOOL CLAMP CHECK TIME
4 R855.4
1,152
CYCLE START TIME
5 R765.4
50
ORIENTATION OFF TIME
6 R854.6
1,000
RIGID TAPPING ON TIME
7 R786.7
300
MACHINE READY TIME
8 R900.3
250
TOOL UNCLAMP DELAY TIME
9 R855.3
48
BUZZER OFF SUB
10 R76.3
150
AIR PRESS DELAY
11 R725.5
1,500

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 Error Code and Trouble Shooting

TMR OUTPUT FUNCTION

REMARK
NO ADDRESS UNIT : msec

12
SPINDLE COOLING RUN CHECK
13 R705.5
1,000
AXIS MOVE CHECK DELAY TIME
14 R730.2
1,000
MDI DELAY
15 R444.0
96
CHIP CONVEYOR ALARM DELAY TIME
16 R706.0
500
ALARM AUTO DOOR OPEN COAMMAND
17 R833.1
3,000
LUB.NO ACT 20 MIN
18 R727.1
1,200,000
LUB.NO ACT 1 HOUR
19 R727.0
3,600,000
20

21

LARGE TOOL MAGAZINE ALARM

22 R1615.1
500
23

24

25
MANUAL FEED
26 R730.6
100
TOOL UNCLAMP START SIG. KEEP
27 R859.1
120
TOOL CLAMP START SIG. KEEP
28 R859.5
208
SPINDLE ROTATION TOOL CLAMP ALARM
29 D232.5
700

30
MAGAZINE INDEX S/W DELAY
31 R716.0
250

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 Error Code and Trouble Shooting

4.DATA GROUP TABLE COUNT = 9

NO. ADDRESS PARAMETER TYPE NO. OF DATA REMARK

001 D0042 0000 0000 1 9

002 D0060 0000 0010 1 22 FEEDRATE

003 D0104 0000 0001 1 1 VDE SP.RPM

004 D0106 0000 0000 0 24 DATA TABLE

005 D0130 0000 0001 1 7 ATC DATA

006 D0144 0000 0001 1 31 ATC DATA

007 D0230 0000 0000 0 20 ALARM

008 D0250 0000 0000 1 21 TEMP.COMP.

009 D0310 0000 0000 2 1 LARGE TOOL

5.DATA GROUP TABLE NO. 001

NO. ADDRESS DATA FUNCTION

000 D42 -

001 D44 24 FEEDRATE STEP NUMBER

002 D46 -

003 D48 -

004 D50 -

005 D52 -

006 D54 -

007 D56 - M-CODE B.C.D DATA CHANGE

008 D58 -

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 Error Code and Trouble Shooting

6. DATA GROUP TABLE NO. 002 (MANUAL FEED DATA)

NO. ADDRESS DATA NO. ADDRESS DATA

000 D60 0 012 D84 370

001 D62 5 013 D86 520

002 D64 10 014 D88 720

003 D66 14 015 D90 1000

004 D68 20 016 D92 1400

005 D70 37 017 D94 2000

006 D72 52 018 D96 2700

007 D74 72 019 D98 3700

008 D76 100 020 D100 5000

009 D78 140 021 D102 0

010 D80 200

011 D82 270

7. DATA GROUP TABLE NO. 003 (VDE SP.RPM)

NO. ADDRESS DATA NO. ADDRESS DATA

000 D0104 19(S8000) ☞ 15(S10000)

8.DATA GROUP TABLE NO. 004 (DATA TABLE)

NO. ADDRESS DATA NO. ADDRESS DATA

000 D106 - 006 D112 -

001 D107 - 007 D113 -

002 D108 - 008 D114 -

003 D109 - 009 D115 -

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 Error Code and Trouble Shooting

NO. ADDRESS DATA NO. ADDRESS DATA

004 D110 - 010 D116 -

005 D111 - 011 D117 -

012 D118 018 D124

013 D119 019 D125

014 D120 020 D126

015 D121 021 D127

016 D122 022 D128

017 D123 023 D129

9. DATA GROUP TABLE NO. 005 (ATC DATA)

NO. ADDRESS DATA FUNCTION

000 D130 24(30) MAX TOOL POT NO. (AUTO SETTING)

001 D132 - PRESENT TOOL POT NO. (AUTO SETTING)

002 D134 -

003 D136 -

004 D138 -

005 D140 - WAITTING TOOL NO.

006 D142 - T-CODE BCD DATA CHANGE

10. DATA GROUP TABLE NO. 006 (ATC DATA)

NO. ADDRESS DATA FUNCTION

000 D144 25(31) SPINDLE TOOL NO. (AT TOOL POT 30)

001 D146 1 TOOL NO. OF POT NO. 1

002 D148 2 TOOL NO. OF POT NO. 2

003 D150 3 TOOL NO. OF POT NO. 3

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 Error Code and Trouble Shooting

NO. ADDRESS DATA FUNCTION

004 D152 4 TOOL NO. OF POT NO. 4

005 D154 5 TOOL NO. OF POT NO. 5

006 D156 6 TOOL NO. OF POT NO. 6

007 D158 7 TOOL NO. OF POT NO. 7

008 D160 8 TOOL NO. OF POT NO. 8

009 D162 9 TOOL NO. OF POT NO. 9

010 D164 10 TOOL NO. OF POT NO. 10

011 D166 11 TOOL NO. OF POT NO. 11

012 D168 12 TOOL NO. OF POT NO. 12

013 D170 13 TOOL NO. OF POT NO. 13

014 D172 14 TOOL NO. OF POT NO. 14

015 D174 15 TOOL NO. OF POT NO. 15

016 D176 16 TOOL NO. OF POT NO. 16

017 D178 17 TOOL NO. OF POT NO. 17

018 D180 18

019 D182 19

020 D184 20

021 D186 21

022 D188 22

023 D190 23

024 D192 24

025 D194 25

026 D196 26

027 D198 27

028 D200 28

029 D202 29

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 Error Code and Trouble Shooting

NO. ADDRESS DATA FUNCTION

030 D204 30

11. DATA GROUP TABLE NO. 007 (ALARM)

NO. ADDRESS DATA NO. ADDRESS DATA

000 D230 - 010 D240 -

001 D231 - 011 D241 -

002 D232 - 012 D242 -

003 D233 - 013 D243 -

004 D234 - 014 D244 -

005 D235 - 015 D245 -

006 D236 016 D246

007 D237 017 D247

008 D238 018 D248

009 D239 019 D249

12. DATA GROUP TABLE NO. 008 (TEMP.COMPENSATION)

NO. ADDRESS DATA FUNCTION

000 D250 - NOT USE

001 D252 - NOT USE

13. DATA GROUP TABLE NO. 009 (LARGE TOOL)

NO. ADDRESS DATA FUNCTION

SET TOOL BORE TO TOOL OFFSET

000 D310 90000
(90000 MORE)

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 Error Code and Trouble Shooting

14.COUNTER

NO. ADDRESS RESET CURRENT REMARK

ATC COUNTER
01 C00 24(30) ATC POSITION TOOL POT NO.
(AT 30 POT)
02 C04 -
03 C08 -
04 C12 -
05 C16 -
06 C20 -
07 C24 -
08 C28 -
09 C32 -
10 C36 -
11 C40 -
12 C44 -
13 C48 -
14 C52 -
15 C56 -
16 C60 -
17 C64 -
18 C68 -
19 C72 -
20 C76 -

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Chapter 3
References
3.1 OIL COOLER (8000rpm; Standard / 12000rpm; Option) 4-3-3
3.1.1 General Requirements ............................................................ 4-3-3
3.1.2 Installation Requirements ..................................................... 4-3-4
3.1.3 Electrical Wiring Works ........................................................... 4-3-5
3.1.4 Operation Requirements ....................................................... 4-3-7
3.1.5 Part Name, Function and Operation in
Control Panel .................................................................................. 4-3-8
3.1.6 Maintenance .................................................................................... 4-3-9
3.1.7 Failures Controls ....................................................................... 4-3-11
3.2 Coolant Pump ................................................................................................... 4-3-13
3.2.1 Flood Coolant Pum ................................................................. 4-3-13
3.2.2 Bed Flushing Coolant Pump ........................................... 4-3-15
3.2.3 Gun Coolant Pump - Option ............................................ 4-3-17
3.2.4 Cool Jet Coolant Pump-Option ..................................... 4-3-19
 References

3.1 OIL COOLER (8000rpm; Standard / 12000rpm; Option)

3.1.1 General Requirements

1. Allowable Temperature Range

Oil Cooler shall be used within the following allowable temperature range.

2. Prohibited Oils
As the oil coolant requires hydraulic fluid (mineral oil), it is not allowed to use the
following fluids:
1) Flame-retardants
• Phosphate esters
• Chlorinated hydrocarbons
• Water+cryolite
• W/O, O/W emulsions
2) Water and water soluble solutions
3) Medicated fluid and edible fluid
4) Cutting and grinding fluids
5) Fuels including kerosene and gasoline

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 References

3.1.2 Installation Requirements

1. Location of Installation
Oil coolant shall be located at the following places.
1) Flat and solid floor
2) Place not exposed to the direct sunlight of heat.
3) Place with well ventilation and low humidity
4) Place where the intake and exhaust is separated
5) Place with easy wiring and ventilation
6) Place with less dirt, dust and oil mist
Any material obstructing ventilation shall not be placed within 500 ㎜
distance from inlets and outlets.

2. Exhaust Pipe
1) Inlet pressure -------------- 200 ~ 0 ㎜Hg
Outlet pressure ------------ 3.5 kgf/㎠
2) Use of valve shall be avoided for pipe connection as possible. Use of valve
leads to significant loss of pressure.
3) Connection of pipe shall be sealed by seal tape so as to prevent mixing of
fluid with air and leakage of fluid.

3. Intake filter (line filter)

Pipes and tubes shall be cleaned by using the filter with less pressure loss and
superior efficiency (100 ~ 150 mesh filter) during preparation for start-up as the
dusts accumulated inside of oil cooler may lead to deteriorated capacity and
trouble of compressor or oil pump. Maintenance of filter shall be made on a
regular basis.

4. Oil Tank
Oil tank shall be designed so as to mix hot oil from machine homogeneously with
cold oil from oil cone considering the compartment and pipe arrangement. In
order to avoid mixing of oil with air, the lowest level of oil in the oil tank must be
kept higher than the oil outlet.
Tank capacity : 60 ℓ

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 References

3.1.3 Electrical Wiring Works

• Wiring diagram attached on the back of switch panel shall be referred to for
wiring works.
• When rearranging the wiring inside of oil cone or contactors and switches,
wiring works shall not be made by hand.

1. Power capacity
Power : 200/220V(50/60㎐) ± 10%
Capacity : 1.6 KVA

2. Molded case circuit breaker

As the over-current circuit breaker is not provided with the oil cooler, molded
case circuit breaker with 12A of rated current must be installed.

3. Grounding and Power Connection

1) Top cover and switch box cover shall be removed.
2) Power and grounding connections (600V vinyl insulated wire [IV] with more
than 2 ㎟ of diameter) shall be encased in the switch box through the holes
(Ø27) in the left and right plate.
3) Grounding and Connection

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 References

4) R.S.T wires of power connection shall be connected to the corresponding

R.S.T (TeS) locations.
Reverse wiring : Connection of R. T wires shall be made as follows in case
of reverse wiring. (Alarm LED is lit on the control panel when reverse wired)

4. Wiring diagram

Power connection holes(both sides)

(Ø27 Hole)

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 References

5. Connection of Alarm contact

No.11 and 12 of TES shall be used for alarm contact.

Operation Switch OFF ON

Power
Mode of Operation STOP Operation Error Operation Operation
failure

ON
BETWEEN (11)~(12)
OFF

3.1.4 Operation Requirements

1) Operation without plenty of fluid shall be avoided. (It may cause failure of oil pump
and others)
2) Mixing of air with fluid in the system shall be avoided. (It may cause noise problem)
3) In case of adhesive fluid is used or loss of pressure in the pipe (except oil cone
body) is excessive, pipe shall be replaced into proper size of one to reduce pressure
loss. Use of improper size of pipes may lead to noise or failure.
4) Repeated running of cooler with short intervals (within 30 seconds) by using
temperature control Vr or ON/OFF switch shall be avoided as it may lead to failure.
5) Temperature controller shall be used to control the temperature of fluid at the oil
cone inlet.
6) External temperature sensor is provided fixed at the side of oil cone as a factory
option. Fixation tap shall be installed at the back of the column during installation of
oil cooler.

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 References

3.1.5 Part Name, Function and Operation in Control Panel

No Name Description

ON/OFF switch of main.

Auto : available remote controlling by terminal 6 ~ 8 of TES
① Selection Switch
OFF : cut-off power
ON : start operation of pump and fan

② Temperature controller Controls temperature of oil cooler and is fixed mounted.

③ White LED (power-White) White LED is lit when power on.

④ White LED (Driving-Green) Green LED is lit when oil cooler is in operation.

Red LED is lit when error occurred.

⑤ White LED (More-Red)
Please refer to the troubleshooting for details.

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 References

3.1.6 Maintenance

1. Safety Precautions for Maintenance

Though the oil cone is produced under the strict quality control, maintenance is
required (including replacement of parts) and special care shall be taken to the
followings.
1) Oil cooler shall be switched off and main power disconnected.
2) If the fire is used for maintenance, oil cone shall be away from the machine
and the fluid in the oil cone shall be removed completely. Work shall be made
in the place with well ventilation so as to prevent any potential suffocation due
to the flammable and coolant gases.

2. Disassembling of case
1) The surface of case shall be cleaned with dry rag.
Work shall not be conducted at the location directly exposed to the water to
prevent potential short or fire.
2) “Brush”, “lapping agent”, “acid”, “solvent including benzene” and “hot water”
shall not be used to prevent from removal of painting

3. Oil tank and intake filter

Adequate level of oil shall be maintained in the oil tank to prevent incoming of air
into the oil. The oil shall be kept in clean always. Filter shall be cleaned on a
regular basis to prevent lowering of fluid level in the pump due to dust.

4. Air Filter
1) Air filter must be cleaned every two weeks with not higher than 40℃ of hot
water. (Dusts or foreign substances may lead to deterioration of quality due to
the reduced air blow and prevent smooth operation due to the activation of
compressor.)
2) Operation of air cooler without air filter may lead to failure.
3) If the condenser is contaminated heavily, it shall be cleaned with brush, air gun,
etc.

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 References

5. In case of longer downtime

Cover shall be place on the cooler to prevent contamination of dust, foreign
substance, water and others into the oil cone.
Oil cooler must be switched off and main power disconnected.

6. In case of activation of safety system

Section 3.1.7 (Failure Controls) shall be referred to for details of activation of
safety system including causes and troubleshooting.

7. Checking of pressure
For checking of outlet pressure at the oil cone, pressure gauge port PT 1/8
(hexagonal plug) shall be used.

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 References

3.1.7 Failures Controls

If the condition of oil cone is not satisfactory, following shall be checked. And if the
problem still remains, please contact to our service center with product name,
manufacturing No. and description of problem.

Table 4-3-1 Troubleshooting

No. Condition Cause Solution

Power led is not lit when main ① Power LED is broken. ·Replace power LED.
1 power connected. ② Fuse short
·Replace fuse.
No oil runs while pump is on ① Inlet pipe is loosened. ·Check whether the inlet pipe
running. is fastened and tighten it if
Insufficient circulation of oil, necessary.
mixing of air or noise in the ② Inlet filter is clogged. ·Clean the filter.
pump. ·Replace the dirty oil in the oil
tank into new
2 ③ Level of oil is ·Check and refill oils in the
insufficient in the oil oil tank.
tank.
④ pressure loss in the ·Replace pipe into larger
pipe is excessive, relief diameter and reduce the
valve activated or length of pipe.
cavitations occur.
Cooler is not in operation ① Cooler stopped due to ·Change temperature
while pump is on running. the high temperature setting of temperature
setting in the controller to check
temperature whether the oil cooler is
controller. operating or not.
·Oil cooler does not work if
3
the oil temperature is
extremely low.
·Wait until the temperature of
oil raised.
② Temperature ·Replace the temperature
controller is broken. controller.
Oil cooler stopped without ① No power supply ·Check power supply.
4
error LED on.

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 References

No. Condition Cause Solution

Error LED lit while oil cooler ① Reverse phase wiring ·Change wiring from three-
is in operation. phase into two-phase.
(1) Reverse phase circuit
breaker is activated.
(2) Error in thermostat. ② Thermostat is broken. ·Replace the thermostat and
③ Short or loose wiring of correct the connection of
thermostat wiring.
(3) Protective thermo ④ Air filter is clogged. ·Clean the air filter.
(49℃) for compressor is
activated.
(4) Over-current ⑤ There is obstacle ·Remove obstacle.
relay for compressor nearby.
5 motor is activated. ⑥ Exterior temperature ·Use cooler within the
(5) High pressure switch (room temperature) is tolerable temperature
(63H) is activated. too high. range. Heat source nearby
(6) Over-current relay (50P) shall be removed as
for fan, pump motor is necessary.
activated.
⑦ Oil temperature is too ·Use oil with tolerable range
(7) Error occurred in the
high. of temperature.
control panel (ECI).
⑧ Compressor is ·Replace compressor.
not running.
⑨ Adhesive fluid is ·Replace oil into of low
in use. viscosity.
⑩ Same as f or 2-④. ·Same as for 2-④.
⑪ Control panel is broken. ·Replace control panel.
Oil is not hot while pump, cooler ① Same as for 5-④, ⑤, ·Same as for 5-④, ⑤, ⑥, ⑦.
and fan is on running. ⑥, ⑦.
② Same as for 3. ·Same as for 2
③ Overload ·Find and remove the reason
of overload.
6
④ Temperature setting in ·Change temperature
the oil temperature setting.
controller is too high.
⑤ Coolant gas is ·Refill coolant gas.
insufficient.

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 References

3.2 Coolant Pump

3.2.1 Flood Coolant Pump

ACP-400F

Type øD L1 L2 L3 L4 L5 L6 LK PK KC
ACP-400F 158 30 27 210 280 59 191 75 100 130
Type PE øLA øLB øLC LG M øR1 øR2 TL LZ-LN
ACP-400F PS1" 180 - 210 10 180 152 146 530 2-ø10

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 References

Table 4-3-2 ACP-400F Specification

Type of pump ACP-400F

Outlet amount(ℓ/min) 140 200

Total Dynamic Head(m) 5

Water soluble coolant, cleaning agent

Fluid
(weak alkali solution)
Pump
Rotor
Degree of filtration (glass wool tempered polyamide resin)
Material Intermediate casing, impeller guide
(mineral tempered polyamide resin)

Phase 3

Poles 2

Power(㎾) 0.4

Voltage (V) 200~230/380~415 220~240/380~440

Max. allowable current(A) 4.3~3.8/2.4~2.1 5.2~4.8/3.0~2.6

Frequency(㎐) 50 60

Synchronization RPM(rpm) 2870 3450

Motor
Class of insulation E

Exterior temperature(℃) -50~+40

Temperature raising(deg) Below 75

Rating Continuous

Motor type Totally enclosed type for indoor use

Loading 6204ZZ
Bearing
Anti-loading 6203ZZ

Weight(kgf) 18.5

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 References

3.2.2 Bed Flushing Coolant Pump

ACP-900MF

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Maintenance Manual
 References

Table 4-3-3 ACP-900MF Specification

Pump Type ACP-900MF

Output Rate (ℓ/min) 20(10~80) 20(10~90)

Total Dynamic Head (m) 20 30

Water soluble coolant, cleaning agent

Fluid
Pump (weak alkali solution)

Rotor (glass wool tempered polyamide resin)

Degree of filtration
Intermediate casing, impeller guide
Material
(mineral tempered polyamide resin)

Phase 3

Poles 2

Power (Kw) 0.9

Voltage (V) 200~230 /380~415 220 ~240/380~440

Max. allowable current(A) 4.3~3.8/2.4~2.1 5.2~4.8/3.0~2.6

Frequency (Hz) 50 60

Motor Class of insulation E

Exterior temperature(℃) -50~+40

Temperature raising(deg) Below 75

Rating Continuous

Motor type Totally enclosed type for indoor use

Loading 6204ZZ
Bearing
Anti-loading 6203ZZ

Weight(kgf) 32.0

Note : Please contact us if you want to use highly adhesive fluid (with more than 75cSt
of viscosity).

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 References

3.2.3 Gun Coolant Pump - Option

ACP-250F

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Maintenance Manual
 References

Table 4-3-4 ACP-250F Specification

Pump Type ACP-250F

Diameter(mm) 19

Output Rate (ℓ/min) 125 150

Total Dynamic Head (m) 3

Pump Allowable viscosity(cSt) 75

Medium
Degree of filtration
(max. length of chip filterable in the pump 2.5㎜)

Material Impeller, casing, outlet casing : GC

phase 3

Poles 2

Power (Kw) 0.25

Voltage (V) 200 220/380

Max. allowable current(A) 1.4 1.5/0.87

Frequency (Hz) 50 60

Revolution of motor(rpm) 2870 3450

Motor
Class of insulation E

Exterior temperature(℃) -50~40

Temperature raising(deg) Below 75

Rating Continuous

Motor type Totally enclosed type for indoor use

Loading 6204ZZ
Bearing
Anti-loading 6203ZZ

Weight(kgf) 13

Note) Please contact us if you want to use highly adhesive fluid (with more than 75cSt of
viscosity).

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 References

3.2.4 Cool Jet Coolant Pump-Option

ACP-900MF

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Maintenance Manual
 References

Table 4-3-5 ACP-900MF Specification

Pump Type ACP-900MF

Output Rate (ℓ/min) 20(10~80) 20(10~90)

Total Dynamic Head (m) 20 30

Water soluble coolant, cleaning agent

Fluid
(weak alkali solution)
Pump
Rotor
Degree of filtration (glass wool tempered polyamide resin)
Material Intermediate casing, impeller guide
(mineral tempered polyamide resin)

Phase 3

Poles 2

Power (Kw) 0.9

Voltage (V) 200~230/380~415 220~240/380~440

Max. allowable current(A) 4.3~3.8/2.4~2.1 5.2~4.8/3.0~2.6

Frequency (Hz) 50 60

Motor Class of insulation E

Exterior temperature(℃) -50~+40

Temperature raising(deg) Below 75

Rating Continuous

Motor type Totally enclosed type for indoor use

Loading 6204ZZ
Bearing
Anti-loading 6203ZZ

Weight(kgf) 32.0

Note : Please contact us if you want to use highly adhesive fluid(with more than 75cSt of
viscosity).

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Maintenance Manual
Chapter 4
Troubleshooting
 Troubleshooting

2000 AIR PRESSURE ALARM

Cause:
- In case that the air pressure level is under the standard level.
- Malfunction of the pressure switch.
- Fault in the wiring.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
- Supply air pressure. Alarm is released if air pressure level is normal.
- Adjust air pressure level tuning air pressure switch.
- Although pressure is set to specific value and the contact of X6.1(AIR PRESSURE CHECK)
is not on, check the wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X6 => Search
7 6 5 4 3 2 1 0
X06
1
If input signal X6.1 is 1, it is normal state.

- Confirming the electric Diagram

Check the signal X6.1 and switch SP61.

VX400(FANUC 0i-MD) 4-4-3 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

If air pressure verified signal x6.1 is not on during 1.5 sec (setting in TIMER No.11), it turn alarm
status.

VX400(FANUC 0i-MD) 4-4-4 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2001 THROUGH (SIDE HOLE) COOLANT OVERLOAD

Cause:
- In case that OCR (FT8) is tripped because of over-current in the SIDE HOLE (THR.)
COOLANT motor.
- Malfunction of the THERMAL RELAY.
- Shortage of 3 phase power and fault wiring.

Condition
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
Warning
1. After main power turn off, check the electric wiring .
2. If thermal relay is tripped continuously, motor is possible to damage. You
should operate machine after cause of over-current is removed according to
follow method.

- FT8 is switched ON in the control box and if resistance between terminals of FT8 is
checked using tester and it is not continuity, please change the THERMAL RELAY or servo
contact UNIT.
- Check 3 phase(r, s, t) of motor.
- If it is not normal after check above cases, Check input address X5.2.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X5 => Search
7 6 5 4 3 2 1 0
X05
1
If input signal X5.2 is 1, it is normal state.

VX400(FANUC 0i-MD) 4-4-5 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

Check capability of magnet switch and motor state.

- Confirming the PMC

In machine ready status if input signal X5.2 (THROUGH COOLANT OVERLOAD) is not on during 3
sec (setting in TIMER No. 9), it turn to alarm status.

VX400(FANUC 0i-MD) 4-4-6 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2002 LUB. PRESSURE ALARM

Cause:
- In case that pressure of lubrication pump is set below regular value.
- Fault in the wiring.
- Fault in setting DATA TABLE.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
- If lubrication pump is operated, turn the pressure adjusting bolt of lubrication pump to adjust
the specific value.
- Although pressure is set to specific value and the contact of X6.3 is not 1, check the wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X6 => Search
7 6 5 4 3 2 1 0
X06
1
If input signal X6.3is 1, it is normal state.

- Confirming the electric Diagram

VX400(FANUC 0i-MD) 4-4-7 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

If it is verified (X6.3) after operating the lubrication pump, it is alarmed.

VX400(FANUC 0i-MD) 4-4-8 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2003 LUB. OIL LACK ALARM

Cause:
- Lack of lubrication oil.
- Fault in FLOAT SWITCH.
- Fault in the wiring.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- If Z axis is positioned to zero point during auto operation in the alarm, Feed hold
status will be remain.
Actions:/Procedures:
- When the oil is added to lubrication pump, alarm will be released.
- If the contact of X6.2 is not 1 after adding the oil, check the wiring and change the unit.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X6 => Search
7 6 5 4 3 2 1 0
X06
1
If X6.2 is 1, it is normal

- Confirming the electric Diagram

VX400(FANUC 0i-MD) 4-4-9 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

When LUB. OIL LACK signal is switched OFF, it is alarmed.

VX400(FANUC 0i-MD) 4-4-10 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2004 LUB. OVERLOAD ALARM

Cause:
- In case that OCR is tripped because of over-current in the lubrication pump motor.
- THERMAL RELAY SETTING value (0.23A) is fault.
- Shortage of 3 phase power and fault of contact wiring.

Condition:
- Alarm Lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
Warning
1. After main power turn off, check the electric wiring.
2. If thermal relay is tripped continuously, motor is possible to damage. You
should operate machine after cause of over-current is removed according to
follow method.

- FT2 is switched ON in the control box and if resistance between terminals of FT2 is
checked using tester and it is not continuity, please change the THERMAL RELAY or servo
contact UNIT.
- Check R, S, T phase of lubrication motor.
- If fault is found after above checking, check the contact of input signal X4.1(NORMAL ON).
- Check DATA TABLE setting value.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X4 => Search
7 6 5 4 3 2 1 0
X04
1
If input signal X4.1 is 1, it is normal state.

VX400(FANUC 0i-MD) 4-4-11 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

- Confirming the PMC

Due to over load of lubrication pump motor after M/C READY, when OCR (FT2) is tripped (X4.1 is
switched OFF), it will be alarmed.

VX400(FANUC 0i-MD) 4-4-12 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2005 ATC MOTOR OVERLOAD

Causes:
- Due to over load of MAGAZINE motor or ARM motor, over current is flown to motor
and OCR had been tripped.
- Malfunction of the THERMAL RELAY.
- Shortage of 3 phase power and fault of wiring.

Conditions:
- Alarm Lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
Warning
1. After main power turn off, check the electric wiring.
2. If thermal relay is tripped continuously, motor is possible to damage. You
should operate machine after cause of over-current is removed according to
follow method

- FT4, FT5 is switched ON in the control box and if resistance between terminals of FT4, FT5
is checked using tester and it is not continuity, please change the THERMAL RELAY or
servo contact UNIT.
- Check R, S, T phase of ATC motor.
- If fault is found after above checking, check the contact of input signal X4.3,X4.4.

Measures
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X4 => Search
7 6 5 4 3 2 1 0
X04
1 1
If input signal X4.3 is 1, it is normal state.

VX400(FANUC 0i-MD) 4-4-13 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

Check setting value and wiring error of OCR (FT4, FT5) in the MAGAZINE and ARM MOTOR and
check the wiring of X4.3, X4.4.

- Confirming the PMC

Due to over load of motor, If X4.3, X4.4 signal is switched OFF, it will be alarmed. alarm status.

VX400(FANUC 0i-MD) 4-4-14 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2007 AC110V TRIP

Causes:
- In case that CP(FC1, FC3,RC4) is tripped because of over-current in AC 100V line or
28V line.
- Malfunction of the CP (circuit protector).
- Fault in the wiring.

Conditions:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
Warning
Check the wiring, after make it sure to shut the power source off in any case.

- After shut off the power source, check circuit with tester.
- After shut off the power source, check the malfunction of CP.
- If you have trouble after following above referred inspection, check the contact point of input
signal X6.0.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X6 => Search
7 6 5 4 3 2 1 0
X06
1
If input signal, X6.0 becomes 1(ON), this means normal state.

VX400(FANUC 0i-MD) 4-4-15 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

- Confirming the PMC

If CP has been tripped, ADDRESS X6.0 signal becomes off and alarm occurs.

VX400(FANUC 0i-MD) 4-4-16 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2010 SPINDLE COOLING ALARM

Cause:
- In case that Power is not supplied to SPINDLE COOLING UNIT normally.
- ALARM occurs due to SPINDLE COOLING UNIT’S problem.
- Fault in the wiring.

Condition:
- Alarm Lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- CYCLE START Driving Prohibit State.

Actions:/Procedures:
Warning
You should turn off power and check the wiring.

- With main power is applied, check that 3 phases between cooling units is 220V.
- Verify setting value (D117.5 is 1) of DATA TABLE.
- If it is not normal after check above point, Check input address X7.1.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X7 => Search
7 6 5 4 3 2 1 0
X07
1
If input signal X7.1 is 1, it is normal state.

- Confirming the electric Diagram

VX400(FANUC 0i-MD) 4-4-17 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

If X7.1 signal is switched OFF by fault of cooling unit, is continued for 1 or more seconds, it will be
alarmed.

VX400(FANUC 0i-MD) 4-4-18 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2011 GEAR CHANGE TOOL CLAMP ALARM

Cause:
- In case that Spindle rotation is commanded when tool clamp is not tool unclamp.
- Malfunction and incorrect position of TOOL CLAMP and UNCLAMP limit switch.
- Fault in the wiring.

Condition:
- ALARM MESSAGE is displayed in the LCD screen.

Actions:/Procedures:
- Press RESET button to release ALARM. Check TOOL CLAMP state in manual mode.
- Check TOOL CLAMP and TOOL UNCLAMP limit switch and contact point X3.2, X3.3.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X3 => Search
7 6 5 4 3 2 1 0
X03
0 1
Verify that input signal X3.2 is 1 and X3.3 is 0.

- Confirming the electric Diagram

Check limit switch and the input signal of TOOL CLAMP (X3.2), TOOL UNCLAMP (X3.3).

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

ALARM occurs if R755.1 (GEAR CHANGE COMMAND) related to spindle rotation is on except
TOOL CALMP state.

VX400(FANUC 0i-MD) 4-4-20 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2012 GEAR CHANGE ARM ORIGIN ALARM

Cause:
- In case that Spindle rotation is commanded when ATC ARM is not in position.
- Malfunction of the ARM UP and ARM HOME limit switch.
- Fault in the wiring.

Condition:
- ALARM MESSAGE is displayed in the LCD screen.

Actions:/Procedures:
- Press RESET button to release ALARM. And place ARM HOME, ARM UP in position
- Check the malfunction of ARM UP/ARM HOME limit switch and contact point X8.0, X8.1.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X08
1 1
If input signal X8.0 and X8.1 is 1, it is normal state.

- Confirming the electric Diagram

Check the input signal X8.0, X8.1 and limit switch SQ80, SQ81.

VX400(FANUC 0i-MD) 4-4-21 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

In the normal position of ATC ARM, ARM HOME (X8.0) and ARM UP(X8.1) remain On.
If alarm occurs, verify the signal of two sensors.

VX400(FANUC 0i-MD) 4-4-22 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2013 GEAR CHANGE TIME OVER ALARM

Cause:
- In case that GEAR CHANGE is not finished within 10 sec when spindle rotation is
commanded.

Condition:
- ALARM MESSAGE is displayed in the LCD screen.

Actions:/Procedures:
- Press RESET button to release ALARM. Command the spindle rotation again.

Solution:
- Confirming the PMC

If main spindle conversion, it is necessary to verify that SSTA (F45.1) of SPINDLE STOP SIGNAL is
switches ON. If signal is output, check the parameter.
Verify that Low and high gear conversion area set to parameter is correctly set.
If it is unit that not converted to the gear, this alarm is not relative.

VX400(FANUC 0i-MD) 4-4-23 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2014 ORT. TOOL CLAMP ALARM

Cause:
- In case that ORT (M19) or ATC command (M06) is executed when tool is not clamp.
- Malfunction of the TOOL CLAMP L/S and TOOL UNCLAMP limit switch.
- Fault in the wiring.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
- Press RESET button to release ALARM. And clamp the tool with TOOL CLAMP switch in
manual mode. Then execute ORT command or ATC command.
- Check the malfunction and signal of L/S for TOOL CLAMP and UNCLAMP and
Check the signal ON/OFF of TOOL CLAMP (X3.2) & TOOL UNCLAMP (X3.3).

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X3 => Search
7 6 5 4 3 2 1 0
X03
0 1
Verify that TOOL CLAMP input signal X3.2 is 1 and X3.3 is 0.

- Confirming the electric Diagram

Check input signals X3.2, X3.3 and L/S SQ32, SQ33.

VX400(FANUC 0i-MD) 4-4-24 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

In case of TOOL CLAMP signal (X3.2) becomes OFF; namely, in TOOL UNCLAMP state,
ALARM occurs when ORT command such as M19&M06 has been used.
Therefore, it needs to check TOOL CLAMP (X3.2) state.

VX400(FANUC 0i-MD) 4-4-25 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2015 ORT. ARM ORIGIN ALARM

Cause:
- In case that ORT command (M19) or ATC command (M06) is executed in the position
where ATC ARM or ARM UP SENSOR is not in position.
- Malfunction of ARM UP L/S or ARM HOME L/S.
- Fault in the wiring.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
- Release the alarm by reset button to position ARM and ARM UP SENSOR to normal
position on the MAINTENANCE mode and command the orientation (M19).
- Check the Malfunction of ARM UP L/S, ARM HOME L/S and contact point X8.0, X8.1.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X08
1 1
When operation is normal state, input signal X8.0 and X8.1 is 1.

- Confirming the electric Diagram

Check input signal X8.0, X8.1 and access switch SQ80, SQ81.

VX400(FANUC 0i-MD) 4-4-26 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

If command related to ORT is (Orientation) is performed with ARM HOME(X8.0) & ARM UP(X8.1)
SENSOR switching Off, it will be alarmed.

VX400(FANUC 0i-MD) 4-4-27 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2016 DOOR CLOSE STATUS ALARM

Causes:
- Front door is opened when program is running.
- Malfunction of DOOR LOCK UNIT.
- Fault in the wiring.

Actions:/Procedures:
- Press RESET button to release ALARM. Close the DOOR and operate it again.
- If the door closes, verify that DOOR CLOSE check signal X10.6 is ON (1).

Measures:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X10 => Search
7 6 5 4 3 2 1 0
X10
1
It is normal when X10.6 is 1 during door closing.

- Confirming the electric Diagram

Check the DOOR CLOSE CHECK signal and contact point X10.6 in DOOR LOCKING UNIT.

VX400(FANUC 0i-MD) 4-4-28 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

Program is not executed during door opening according with domestic PL relation safety
specification.
As alarm occurs during door opening, close the door during execution of program. Door is not
opened during execution of auto program.

VX400(FANUC 0i-MD) 4-4-29 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2017 HYD. MOTOR OVERLOAD ERROR

Cause:
- In case that OCR is tripped because of over-current in the hydraulic pump Motor.
- Malfunction of THERMAL RELAY or Fault in the wiring.
- DATA TABLE setting value error.
- Shortage of 3 phase power.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
Warning
1. After main power turn off, check the electric wiring
2. If thermal relay is tripped continuously, motor is possible to damage. You
should operate machine after cause of over-current is removed according to
follow method.
- KM1 is switched ON in the control box and if resistance between terminals of FT1 is
checked using tester and it is not continuity, please change the THERMAL RELAY or servo
contact UNIT.
- Check R, S, T phase of hydraulic motor.
- If fault is found after above checking, check the contact of input address X4.0.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X4 => Search
7 6 5 4 3 2 1 0
X04
1
If input signal X4.0 is 1, it is normal state.

VX400(FANUC 0i-MD) 4-4-30 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

- Confirming the PMC

When overload of hydraulic pump happen, X4.0 is off, ALARM occurs.

VX400(FANUC 0i-MD) 4-4-31 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2021 NO S-CODE SP. START ERROR

Cause:
- When spindle rotation command is executed in auto-mode, spindle doesn’t rotate
because of the strobe signal SF being not output.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
- Check spindle motor and spindle motor AMP.
- Check G4.3 (FIN) signal in PMC.
- Check strobe signal SF (F7.2) and distribution end signal DEN (F1.3). If signals are not
output, check ST (G7.2) and *SP signals.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>F07 => Search
7 6 5 4 3 2 1 0
F07
1
When rotating command is ordered, if F7.2 is 1, it is normal state.

VX400(FANUC 0i-MD) 4-4-32 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

With spindle rotating command is ordered in the auto mode, if F7.2 signal is switched OFF, it will be
alarmed.

VX400(FANUC 0i-MD) 4-4-33 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2022 NO POT DOWN ERROR

Cause:
- If POT UP L/S is not switched OFF, with POT DOWN SOL switching ON.
- Position error and fault of POT UP L/S or POT DOWN L/S.
- Faults in the wiring.

Condition:
- Alarm Lamp in operation panel illuminated
- Feed Hold in operation panel illuminated
- CALL LIGHT and BUZZER illuminated

Actions:/Procedures:
- On the M31, M35 mode (ATC MAINTENANCE MODE), by pressing +Y, -Y button to
repeatedly implement the POT UP-DOWN operation and verify the interference and
operation state of limit switch.
- If X8.6 and X8.7 state is correctly operated in the above item, adjust the switch location or
check the wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8 1 0
If POT DOWN, X8.7signal 1 is normal state.

- Confirming the electric Diagram

VX400(FANUC 0i-MD) 4-4-34 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

If POT UP signal R851.4 signal switches ON with POT DOWN output SOL switching ON, it is
alarmed.
.

VX400(FANUC 0i-MD) 4-4-35 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2023 TOOL CLAMP SP. START ERROR

Cause:
- In case that Spindle rotation command be executed in auto-mode when TOOL
CLAMP state.
- Malfunction of TOOL CLAMP limit switch and TOOL UNCLAMP limit switch.
- Fault in the wiring.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
- Press RESET button to release ALARM. Rotate spindle after check TOOL CLAMP state.
- Check TOOL CLAMP limit switch and TOOL UNCLAMP limit switch. And check the TOOL
CLAMP (X8.6) signal.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X3 => Search
7 6 5 4 3 2 1 0
X03
1 0
If Spindle commanding, when input signal X3.2 is 1 and X3.3 is 0, it is normal state.

- Confirming the electric Diagram

Check address the Input signal, X3.2 and X3.3. If both signals are ON or OFF state at the same
time, inspect the limit switch.

VX400(FANUC 0i-MD) 4-4-36 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

With TOOL CLAMP signal X3.2 switching OFF, if spindle rotating is commanded to auto mode (M03,
M04) ALARM will occur.

VX400(FANUC 0i-MD) 4-4-37 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2024 ARM ORIGIN SP. ROTATING ERROR

Cause:
- ATC ARM is not in position and ARM HOME sensor (SQ80) is off when spindle motor
is rotating.
- Malfunction of ARM HOME POSITION (X8.0) limit switch.
- Fault in the wiring.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
- If ATC ARM is out of normal range, rotate the spindle after returning the ARM to HOME
position by commanding the M31, M35 (MAN. ATC MODE ON).
- Check ARM HOME POSITION limit switch and contact point of X8.0.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X08
1
If input signal X8.0 is 1, it is normal state.

- Confirming the electric Diagram

Check input signal X8.0 and proximity switch, SQ80.

VX400(FANUC 0i-MD) 4-4-38 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

If ARM HOME POSITION check signal, X8.0 is off in rotating spindle, Alarm occurs.

VX400(FANUC 0i-MD) 4-4-39 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2025 TOOL CLAMP SP. ROTATING ERROR

Cause:
- In case that tool becomes unclamp when spindle motor is rotating.
- Malfunction of TOOL CLAMP, UNCLAMP proximity switch.
- Fault in the wiring.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
- Press RESET button to release ALARM. And command spindle rotating in TOOL CLAMP
state.
- On the manual mode and automatic mode, check the malfunction for TOOL CLAMP, TOOL
UNCLAMP access switch and the contact of X3.2, X3.3.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X3 => Search
7 6 5 4 3 2 1 0
X03
0 1
When input signal X3.2 is 1 and X3.3 is 0, it is normal state.

- Confirming the electric Diagram

VX400(FANUC 0i-MD) 4-4-40 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the PMC

With TOOL CLAMP signal X3.2 switching OFF, spindle rotating command had been performed. Or,
if access sensor for tool clamp is switched OFF during rotation, alarm can occur. On the manual
mode, execute the TOOL CLAMP and UNCLAMP to execute the automatic mode after checking the
normal state.

VX400(FANUC 0i-MD) 4-4-41 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2026 SPINDLE DATA OVER ERROR

Cause:
- Data related to spindle override is fault entered in the PMC ladder or the length of
operation designation data is exceeded.
- Data is not correctly entered in the Spindle override rotary switch.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
- In PMC you should modify the data type related to spindle override to right data type.
- Check the spindle override rotary switch and wiring.
Solution:
- Confirming the PMC

VX400(FANUC 0i-MD) 4-4-42 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

In the SPINDLE OVERRIDE operation process, if R133.0 or R133.1 is switched ON by generating

fault in the operation, it will be alarmed.

VX400(FANUC 0i-MD) 4-4-43 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2027 TOOL UNCLAMP START L/S ERROR

Cause:
- If M06 commanding, the ARM is not stopped in the position unclamped to TOOL
UNCLAMP and ATC operation had been stopped by over-run.
- TOOL UNCLAMP START limit switch position error.
- Fault in the wiring.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Release the alarm by reset button to check that limit switch for ARM stop is operated in the
ATC MAINTENANCE MODE.
- After checking the malfunction of TOOL UNCLAMP START sensor, signal for ARM stop
and DOG, execute the M06 ATC CYCLE.

Solution:
- Confirming the electric Diagram

Check input signal X8.2, X8.3 and access switch SQ82, SQ83.

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Maintenance Manual
 Troubleshooting

- Information for confirming the PMC

During M06 commanding, if TOOL UNCLAMP START signal is not received in the 0.2 seconds, set
to TIMER NO.23.

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Maintenance Manual
 Troubleshooting

2030 TOOL CLAMP START L/S ERROR

Cause:
- If M06 commanding, check signal of TOOL CLAMP START is not switched ON for
specific time, ATC had been stopped.
- Malfunction of TOOL CLAMP START, TOOL UNCLAMP START limit switch
- Fault in the wiring.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Press RESET button to release ALARM. And In ATC MAINTENANCE MODE, check TOOL
CLAMP START limit switch operates normally.
- After checking the malfunction of TOOL UNCLAMP START limit switch,
contact for X7.0,X7.1, execute the M06 ATC CYCLE.

Solution:
- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

During M06 commanding, if time clamped to spindle is exceeded to setting timer during change of
waiting tool and spindle tool, it will be alarmed.

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Maintenance Manual
 Troubleshooting

2031 SPINDLE UNIT ALARM

Cause:
- Spindle is stopped because spindle motor or spindle AMP is ALARM state.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.
- It turn to Feed hold status in operation mode.

Actions:/Procedures:
- After check message displayed in LCD monitor, you should solve problem by FANUC
MAINTENANCE MANUAL.
- Remove cause of spindle unit ALARM and press RESET button to release ALARM.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>F45 => Search
7 6 5 4 3 2 1 0
F45
0
If input signal F45.0 is 0, it is normal state.

- Confirming the PMC

If SPINDLE ALARM signal F45.0 is OFF, ALARM occurs.

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Maintenance Manual
 Troubleshooting

2032 COOLANT MOTOR OVERLOAD

Cause:
- In case that OCR (FT9) is tripped because of over-current in the coolant pump motor.
- Malfunction of the THERMAL RELAY.
- Shortage of 3phase power and fault of wiring.
- Error of current setting value.

Conditions:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
Warning
1. After main power turn off, check the electric wiring .
2. If thermal relay is tripped continuously, motor is possible to damage. You
should operate machine after cause of over-current is removed according to
follow method.

- FT6 is switched on in the control box and if resistance between terminals of FT6 is checked
using tester and it is not continuity, please change the THERMAL RELAY or servo contact
UNIT.
- Check R, S, T phase of hydraulic motor.
- If fault is found after above checking, check the contact of input address X5.0.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X5 => Search
7 6 5 4 3 2 1 0
X05
1
If input signal X5.0 is 1, it is normal state.

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Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

- Confirming the PMC

If OCR (FT6) is tripped with magnet for COOLANT MOTROR switching ON, check setting value and
re-execute it after resetting.

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Maintenance Manual
 Troubleshooting

2033 JET COOLANT MOTOR O/L

Cause:
- In case that OCR (FT9) is tripped because of over-current in the jet coolant pump
motor.
- Malfunction of the THERMAL RELAY.
- Shortage of 3 phase power and fault of wiring.
- Error of current setting value and error of DATA TABLE D116.3 setting.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
Warning
1. After main power turn off, check the electric wiring.
2. If thermal relay is tripped continuously, motor is possible to damage. You
should operate machine after cause of over-current is removed according to
follow method.

- FT9 is switched ON in the control box and if resistance between terminals of FT9 is
checked using tester and it is not continuity, please change the THERMAL RELAY or servo
contact UNIT.
- Check R, S, T phase of hydraulic motor.
- If fault is found after above checking, check the contact of input address X5.3.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X5 => Search
7 6 5 4 3 2 1 0
X05
1
If input signal X5.3 is 1, it is normal state

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Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

- Confirming the PMC

In machine ready status if input signal X5.3 (jet coolant motor overload) is not on, it turns to alarm
status. Check DATA TABLE setting value, D116.3

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Maintenance Manual
 Troubleshooting

2034 GUN COOLANT MOTOR O/L

Cause:
- In case that OCR (FT10) is tripped because of over-current in the gun coolant pump
motor.
- Malfunction of the THERMAL RELAY.
- Shortage of 3 phase power and fault of wiring.
- Error of current setting value and error of DATA TABLE D116.5 setting.

Condition:
- Alarm in operation panel on.
- CALL LIGHT and BUZZER are on.
- CYCLE START Driving disable.

Actions:/Procedures:
Warning
1. After main power turn off, check the electric wiring.
2. If thermal relay is tripped continuously, motor is possible to damage. You
should operate machine after cause of over-current is removed according to
follow method.

- QM8 is switched ON in the control box and if resistance between terminals of FT10 is
checked using tester and it is not continuity, please change the THERMAL RELAY or servo
contact UNIT.
- Check R, S, T phase of hydraulic motor.
- If fault is found after above checking, check the contact of input address X5.4.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X5 => Search
7 6 5 4 3 2 1 0
X05
1
If input signal X5.4 is 1, it is normal state.

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Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

- Confirming the PMC

If input signal X5.4 (gun coolant motor overload) is not on, it turns to alarm status.
Check DATA TABLE setting value, D116.5.

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 Troubleshooting

2035 CHIP CONVEYOR MOTOR O/L

Cause:
- In case that OCR (FT12,FT12A,FT12B) is tripped because of over-current in the inner
chip conveyor motor.
- Malfunction of the THERMAL RELAY.
- Shortage of 3 phase power and fault of wiring.
- Error of current setting value and error of DATA TABLE D116.6, D121.7 setting.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
Warning
1. After main power turn off, check the electric wiring.
2. If thermal relay is tripped continuously, motor is possible to damage. You
should operate machine after cause of over-current is removed according to
follow method.

- FT12 (FT12A, FT12B) is switched ON in the control box and if resistance between terminals
of QM11 is checked using tester and it is not continuity, please change the THERMAL
RELAY or servo contact UNIT.
- Check R, S, T phase of hydraulic motor.
- If fault is found after above checking, check the contact of input address X5.6.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X5 => Search
7 6 5 4 3 2 1 0
X05
1
If input signal X5.6 is 1, it is normal state.

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Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

- Confirming the PMC

If input signal X5.6 (chip conveyor motor overload) is not on, it turns to alarm status.
Check DATA TABLE setting value, D116.6, D121.7.

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Maintenance Manual
 Troubleshooting

2036 TOOL BROKEN ALARM

Cause:
- In case that tool is broken when command M43 to check tool broken in auto-mode.
- Malfunction of TOOL BROKEN CHECK limit switch.
- Fault in the wiring.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Check the tool is broken or not.
- If tool is broken, change new TOOL.
- Check the program.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X4 => Search
7 6 5 4 3 2 1 0
X4
1
During M43 commanding, if TOUCH PROBE is achieved, when input signal X4.2 is 1, it
is normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

During M code M43 commanding for TOOL BROKEN CHECK, if tool is switched OFF in the
TOUCH PROBE, it will be alarmed. Length and setting error of tool can cause. Please check it.

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Maintenance Manual
 Troubleshooting

2037 SPINDLE OVERLOAD STOP ALARM

Cause:
- In case that Spindle stops in cutting operation.
- During cut machining, over load can cause.
- Parameter setting error

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on
- CALL LIGHT and BUZZER are on
- It turn to Feed hold status in operation mode

Actions:/Procedures:
- Verify that Y-delta output conversion of spindle motor is correctly converted.
- Check the parameter setting value (NO.4026, NO.4027, NO.4024)

Solution:
- Confirming the PMC

G70.4: Spindle reverse rotation signal (CCW)

G70.5: Spindle forward rotation signal (CW)
F2.6: This signal is on in cutting process

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Maintenance Manual
 Troubleshooting

F45.1: This signal is on when spindle is zero speed level.

F45.4, F45.5: This signal is on when spindle is overload state.
During spindle rotating, if setting load is or more in the cut machining and spindle is stopped during
cut, when the state is more 1seconds, it will be alarmed.

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Maintenance Manual
 Troubleshooting

2040 ARM HOME POSITION ERROR

Cause:
- In case that ATC ARM is not in ARM Home position when spindle rotation command
(M03, M04) is executed in auto mode.
- ATC ARM Home position signal (X8.0) is not ON in normal state.
- Malfunction of proximity switch.
- Fault in the wiring.

Condition:
- Alarm Lamp operation panel on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- If sensor for ARM HOME verification is switched OFF, implement the MAINTENACE MODE
(M31, M35) and adjust the ARM HOME POSITION position.
- Check ARM HOME POSITION proximity switch and contact point of X8.0.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8
1
If input signal X8.0 is 1, it is normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

If access sensor for ARM HOME POSITION verification is switched OFF, when SPINDLE rotating
command (M03, M04) is ordered, it will be alarmed. Always during execution of program, ARM
HOME POSITION verification signal (X8.0) should be switched ON.

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Maintenance Manual
 Troubleshooting

2041 DOOR CLOSE TIME OVER

Cause:
- If auto door is applied, the door close(M91) is not operated after designated time .
- Fault of AUTO DOOR cylinder.
- Wiring fault.

Condition:
- Release the alarm by using RESET button, verify output SOL (Y2.6, Y2.7) state.
- If the DOOR CLOSE, verify OPEN input signal ( X10.6, X10.7).

Actions:/Procedures:
- DGN contact information
SYSTEM =>PMCMNT => < => STATUS => X10 => Search
7 6 5 4 3 2 1 0
X10
1 1
If DOOR CLOSE when X10.6 is 1, it is normal state, If DOOR OPEN when X10.7 is 1, it is
normal state.

- Confirming the electric Diagram

Verify X10.6, X10.7 signal of AUTO DOOR state verifying signal.

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

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Maintenance Manual
 Troubleshooting

2042 SPINDLE ROTATION AT M31

Cause:
- Spindle rotation(M03,M04) command is executed in ATC MAINTENANCE MODE (M31).

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Press RESET key to release ALARM.
- After final verify that ATC operation is completed, spindle rotation is commanded after
execution of M32 (MAINTENANCE MODE over).
- Check ARM HOME POSITION (X8.0), POT UP (X8.6) and ARM UP (X8.1) sensors.

Solution:
- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

During execution of MAINTENANCE MODE, if SPINDLE rotating command (M03, M04) is ordered,
it will be alarmed.

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Maintenance Manual
 Troubleshooting

2043 M06 POT NOT UP ERROR

Cause:
- M 06 had been commanded with POT UP state is not.
- Position fault of POT UP L/S or POT DOWN L/S and wiring fault.
- Fault in the wiring.

Condition:
- Alarm Lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- On the M31, M35 mode (MAINTENANCE MODE), by pressing +Y, -Y button to repeatedly
implement the POT UP operation and verify the interference and operation state of limit
switch.
- If X8.6 and X8.7 state is correctly operated in the above item, adjust the switch location or
check the wiring.
Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8
0 1
In case of pop up position, X8.6 signal becomes 1 in normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

During execution of M06, operation execution is processed by alarm with it is not POT UP.
Confirm that POT UP has been completed before executing ATC Change.

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Maintenance Manual
 Troubleshooting

2044 MAGAZINE NOT ZERO RETURN

Cause:
- To acknowledge the magazine number during power on, max. MAX TOOL is not
executed and M06 (ATC CHANGE) CYCLE had been commanded.
Conditions
- Alarm Lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- acknowledge the TOOL NO during initial POWER ON, MAX TOOL had been called.
As method to prevent the TOOL NO error, during execution of program, if T_ _MAX NO. is
not executed, it will cause.

Solution:
- Confirming the PMC

There is sensor, called to MAGAZINE C PHASE on the electrical circuit diagram, the sensor
remembers the MAX. TOOL as sensor for MAX TOOL recognizing.
If execution of ATC TOOL CHANGE, please call the MAX. TOOL of TOOL.

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Maintenance Manual
 Troubleshooting

2045 M31 NOT CANCEL

Cause:
- M06, ATC CHANGE had been called, with ATC MAINTENANCE MODE (M31) is
executing on the MDI mode.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Press RESET key to release ALARM.
- By commanding M32 on the MDI mode to release the MAINTENANCE mode and execute
M06 (ATC CHANGE).

Solution:
- Confirming the PMC

If M06 CYCLE executing during ATC MAINTENACE MODE, it will be alarmed. Command the M32
to release the MAINTENACE MODE.

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Maintenance Manual
 Troubleshooting

2046 Z-AXIS NOT AT ATC POSITION

Cause:
- M06 command is issued when Z-axis is not in reference position.

Actions:/Procedures:
- Press RESET key to release ALARM.
- after Z axis is reference position, M06 is commanded.
- check ATC macro program.

Solution:
- Confirming the PMC

If M06 is commanded with it is not ATC CHANGE POSITION, it will be alarmed. If execution of ATC
automatic MACRO PROGRAM, auto ATC CHANGE is enable at any position.

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Maintenance Manual
 Troubleshooting

2047 M06 AT NO TOOL CLAMP

Cause:
- If execution of M06, TOOL CLAMP access sensor is switched OFF or it is not M06
initial state.
- Malfunction of TOOL CLAMP/TOOL UNCLAMP proximity switch.
- Fault in the wiring.

Condition:
- Alarm Lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Press RESET key to release ALARM and command M06 in TOOL CLAMP state.
- Check the malfunction of TOOL CLAMP, UNCLAMP proximity switch and contact point of
X3.2, X3.3.
- During ATC CHANGE, TOOL CLAMP sensor is switched OFF or initially switched OFF,
implement the TOOL CLAMP/UNCLAMP on the manual mode to verify the operation.

Measures:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X3 => Search
7 6 5 4 3 2 1 0
X03
1 0
Verify that input signal X3.2 is 1 and X3.3 is 0.

- Confirming the electric Diagram

Check the input signal X3.2, X3.3 and proximity switch SQ32, SQ33.

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

Verify TOOL CLAMP/UNCLAMP signal state, command the M06 after executing the TOOL CLAMP
state. It is necessary to correctly check, as fault of access sensor or operation of signal can be
incorrect.

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Maintenance Manual
 Troubleshooting

2050 ATC CYCLE NOT END

Cause:
- In case that M06 ATC CHANGE CYCLE is not finished.
- Malfunction or incorrect position of a proximity switch.

Condition:
- Alarm Lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- If it is not condition of stop state in the stop state, implement the MAINTENANCE MODE to
return to normal state and execute the M06.
- When ATC ARM and POT is positioned in the normal position, if access switch is not
switched ON, adjust the position of access switch and check the wiring.
- Normal state is ARM UP SENSOR ON, ARM HOME POSITION ON, POT UP ON, ATC
POSITION ON in the stop state.

Solution:
- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

When M06 CYCLE is not completed, alarm causes. It is necessary to verify that ATC operation is
correct. Refer to R856.4 part on the ATC operation relative to SOFT R854.5.

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Maintenance Manual
 Troubleshooting

2051 M31, M35 AT NOT MDI MODE

Cause:
- In case that M31 or M35 is commanded when is not MDI mode.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Press RESET key to release alarm.
- Command M31/M35 in MDI mode.
- ATC MAINTENANCE MODE should be executed at only MDI mode.

Solution:
- Confirming the PMC

ATC MAINTENANCE MODE (M31,M35) can be executed at only MDI mode.

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 Troubleshooting

2052 M31, M35 DURING SPINDLE ON

Cause:
- In M31 or M35 is commanded during spindle rotating or M31, M35 had been
commanded during orientation executing.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- M31/M35 is executed only at spindle stop.

Solution:
- Confirming the PMC

When during spindle rotating or orientation executing, if M31, M35, ATC MAINTENANCE MODE is
executed, alarm causes and if spindle stopping, execute the M31, M35.

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Maintenance Manual
 Troubleshooting

2053 M31 NOT COMMAND

Cause:
- In case that M35 is commanded when M31(MAINTENANCE MODE ON) is not
executed.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Press RESET key to release alarm.
- Command M35 when M31 is executed.

Solution:
- Confirming the PMC

With MAINTENANCE MODE is not switched ON, M35 command is not executed. Please order M35
command after M31 order.

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 Troubleshooting

2054 ATC ALARM NOT CANCEL

Cause:
- In case that T-code is commanded when ATC cycle is not finished.
- Malfunction and incorrect position of proximity switch.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- On the ATC MAINTENANCE mode, command T-CODE after completely replacing the ATC
ARM according with ATC return procedure.
- When ATC ARM is positioned to normal position, if access switch is not switched ON,
adjust the position of access switch and check the wiring.

Measures:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X08
1
If input signal X8.0 is 1, it is normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

With ATC operation signal K0.4 is switching On, when TF signal F7.3 is switched ON, ALARM
causes.

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Maintenance Manual
 Troubleshooting

2055 POT UP L/S NOT ON

Cause:
- Although pot up sol is on, both pot up limit switch and pot down limit switch are not
on during 5sec.
- Incorrect position of pot up and down switch.
- Fault in the wiring.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- On the M31, M35 mode (ATC MAINTENANCE MODE), by pressing +Y, -Y button to
repeatedly implement the POT UP operation and verify the interference and operation state
of limit switch.
- If X8.6 and X8.7 state is correctly operated in the above item, adjust the switch location or
check the wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8
0 1
If Pot up, when X8.6 signal is 1 and X8.7 is 0, it is normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

During POT UP SOL operation, if POT UP L/S and POT DOWN L/S is switched ON for more 5
seconds set to TIMER NO.27, ALARM causes. Check the SOL operation and AIR duct.

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 Troubleshooting

2056 POT DOWN L/S NOT OFF

Cause:
- Despite of the SOL for POT UP is operating, POT UP L/S and POT DOWN L/S remain
on for 5 seconds simultaneously.
- Fault of POT UP L/S or POT DOWN L/S and wiring fault.

Condition:
- Alarm Lamp in operation panel illuminated.
- Feed Hold in operation panel illuminated.
- CALL LIGHT and BUZZER illuminated.

Actions:/Procedures:
- On the M31, M35 mode (ATC MAINTENANCE MODE), by pressing +Y, -Y button to
repeatedly implement the POT UP operation and verify the interference and operation state
of limit switch.
- If X8.6 and X8.7 state is correctly operated in the above item, adjust the switch location or
check the wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8 0 1
If POT UP, when X8.7signal is 0 and X8.6 is 1, it is normal state.

- Confirming the electric Diagram

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 Troubleshooting

- Confirming the PMC

If POT UP L/S(SQ86) and POT DOWN L/S(SQ87) is continuously switched ON for 5 seconds with
SOL for pot up operating, it is alarmed.

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 Troubleshooting

2060 POT UP L/S NOT OFF

Cause:
- Despite of operation of SOL for POT DOWN, POT UP L/S and POT DOWN L/S is
continuously switched On for 5 seconds.
- Malfunction of POT UP L/S or POT DOWN L/S and wiring fault.

Condition:
- Alarm Lamp in operation panel illuminated.
- Feed Hold in operation panel illuminated.
- CALL LIGHT and BUZZER illuminated.

Actions:/Procedures:
- On the M31, M35 mode (ATC MAINTENANCE MODE), by pressing +Y, -Y button to
repeatedly implement the POT UP-DOWN operation and verify the interference and
operation state of limit switch.
- If X8.6 and X8.7 state is correctly operated in the above item, adjust the switch location or
check the wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8 1 0
If POT DOWN, when X8.7 signal is 1 and X8.6 is 0, it is normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

With SOL(Y4.7) for POT DOWN operating, when POT UP L/S(X8.6) and POT DOWN L/S(X8.7) is
switched On for 5 seconds set to TIMER NO.27, it will be alarmed.

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Maintenance Manual
 Troubleshooting

2061 POT NOT UP

Cause:
- SOL for POT UP is maintain the POT DOWN L/S in the operation for 5 seconds.
- Position error and fault of POT UP L/S or POT DOWN L/S.
- Faults in the wiring.

Condition:
- Alarm Lamp in operation panel illuminated.
- Feed Hold in operation panel illuminated.
- CALL LIGHT and BUZZER illuminated.

Actions:/Procedures:
- On the M31, M35 mode (ATC MAINTENANCE MODE), by pressing +Y, -Y button to
repeatedly implement the POT UP-DOWN operation and verify the interference and
operation state of limit switch.
- If X8.6 and X8.7 state is correctly operated in the above item, adjust the switch location or
check the wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8 0 1
If POT UP, when X8.6 signal is 1, it is normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

If POT DOWN L/S(X8.7) is continuously maintained for 5 seconds despite of operation of POT UP
SOL(Y4.6), it will be alarmed.

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Maintenance Manual
 Troubleshooting

2062 TOOL LIFE END

Cause:
- To achieve the tool life (usage number or usage time), alarm when following tool is
set.
- DATA TABLE D107.3 Setting Error.

Condition:
- Alarm Lamp in operation panel illuminated.
- Feed Hold in operation panel illuminated.
- CALL LIGHT and BUZZER illuminated.

Actions:/Procedures:
- By reset usage number and usage time to replace new tool after clearing.

Solution :
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>F64 => Search
7 6 5 4 3 2 1 0
F64
0
If the tool life is achieving, F64.0 signal become 1.

- Confirming the PMC

For machining center, it is mostly limited to usage number. In this case it is up counted by “+1” for
count. If set count value is achieving when F64.0 of tool change signal is output, it is alarmed. In
this case, by reset the count, release the alarm.

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Maintenance Manual
 Troubleshooting

2063 ARM UP/DOWN TIME OVER

Cause:
- If ARM is caught during ARM in the ATC operation, ARM is not smoothly operated.
- During ARM rotation, Fault of ARM UP sensor (X8.1) can occur.
- Malfunction of POT DOWN (X8.7) and ARM UP(X8.1) access switch and wiring fault.

Condition:
- Alarm Lamp in operation panel illuminated.
- Feed Hold in operation panel illuminated.
- CALL LIGHT and BUZZER illuminated.

Actions:/Procedures:
- If ARM is stopped or positioned out of normal state, implement ATC MAINTENANCE
MODE and position the ARM normally.
- On the MAINTENANCE MODE, implement ATC operation C step and verify that it is normal.
Specially, verify sensor for POT UP/DOWN and ARM UP/ARM HOME POSITION.
- Check access switch malfunction and wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8
1 1
If ARM HOME is positioned, when X8.0 signal is 1, it is normal state and if ARM UP is
normal operated, when X8.1 signal is 0, it is normal state.

- Confirming the electric Diagram

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 Troubleshooting

- Confirming the PMC

With POT DOWN during ATC operation, if ARM is not rotated for 2 seconds and if value set to
TIMER NO. 28 is not normally rotated, it will be alarmed.

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 Troubleshooting

2064 ARM NOT UP

Cause:
- If ATC starting, ARM UP sensor (SQ81) was not switched on.
- Malfunction of access switch and wiring fault.

Condition:
- Alarm Lamp in operation panel illuminated.
- Feed Hold in operation panel illuminated.
- CALL LIGHT and BUZZER illuminated.

Actions:/Procedures:
- When ARM is not placed on the normal position, command the ATC MAINTENANCE mode
and ARM should be placed in the normal position.
- Check the malfunction for ARM UP access switch and contact of X8.1.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8
1
If ARM UP SENSOR (X8.1) is placed on normal position, 1 is normal state.

- Confirming the electric Diagram

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 Troubleshooting

- Confirming the PMC

If initially executing the ATC CHANGE, the position of ARM UP SENSOR(X8.1) is not correct or
signal is detected by fault, it is alarmed.

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 Troubleshooting

2065 ARM NOT HOME POSITION

Cause:
- After replace and complete the tool of waiting pot and tool of spindle, arm is not
placed on the normal state of home position.
- Malfunction of access switch (X8.0) for ARM HOME POSITION and wiring fault.

Condition:
- Alarm Lamp in operation panel illuminated.
- Feed Hold in operation panel illuminated.
- CALL LIGHT and BUZZER illuminated.

Actions:/Procedures:
- If arm is not normal position, command the MAINTENANCE mode, adjust so that the arm
can position in the normal position.
- Check malfunction for ARM HOME POSITION access switch and the contact of X8.0.
- It is necessary to check that position of DOG is constantly stopped.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8
1
If ARM HOME position, when X8.0 signal is 1, it is normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

After replacing and completing the ATC tool, if ARM is not positioned in the normal position, it is
alarmed.
Verify that access sensor for ARM HOME POSITION is normal state and check location of DOG.

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Maintenance Manual
 Troubleshooting

2066 ATC TIME OVER

Cause:
- In ATC MAINTENANCE MODE, returning step of ATC ARM or POT is not finished
within 25sec.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- The alarm by reset button to perform the ATC return operation.

Solution:
- Confirming the PMC

If returning step of ATC ARM or POT is not finished within 25 sec In ATC MAINTENANCE MODE.
Alarm occurs.

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Maintenance Manual
 Troubleshooting

2067 ARM UP L/S ERROR

Cause:
- When ARM HOME POSITION SENSOR is positioned on the normal position, if ARM
UP SENSOR is positioned on the normal position, it will be cause.
- Malfunction of access switch and wiring fault.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- On the M31, M35 mode (ATC MAINTENANCE MODE), by pressing +Y, -Y button to
repeatedly implement the ARM rotating operation and verify the interference and operation
state of ARM UP and ARM HOME SENSOR.
- If X8.0 and X8.1 state is correctly operated in the above item, adjust the sensor location or
check the wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8
1 1
X8.0 and X8.1 contact points should be displayed as ‘1’ at ARM home position.

- Confirming the electric Diagram

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 Troubleshooting

- Confirming the PMC

With ARM HOME access sensor signal X8.0 is switching ON, when ARM UP access sensor is
switched OFF, alarm causes.

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Maintenance Manual
 Troubleshooting

2070 MAGAZINE B-PH NOT ON

Cause:
- During one pot rotating of magazine, B phase was switched On after A phase
switching ON.
- Malfunction or position error of Magazine A or B phase proximity switch unit.
- Fault in the wiring.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- On the manual mode, rotate the magazine to verify access switch during operation and stop.
During rotation, X3.5 is switched On and then Off, if completion of stop, X3.6 should be
switched ON.
- If it doesn’t operate normally, adjust position of the limit switch or check the wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X3 => Search
7 6 5 4 3 2 1 0
X3
1 0
If MAGAZINE stopping, when X3.5 is 0, X3.6 is 1, it is normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

When magazine is one rotated in the pot, if A phase is switched ON and then B phase is not
switched On, alarm causes.
Verify operation of sensor and verify that it is positioned on the normal position.

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Maintenance Manual
 Troubleshooting

2071 MAGAZINE A-PH NOT ON

Cause:
- When magazine is one rotated in the pot, if MAGAZINE B is switched ON and then
sensor of A phase was not switched On.
- Malfunction or position error of Magazine A or B phase limit switch unit.
- Malfunction of access switch and signal wiring fault.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- On the manual mode, rotate the magazine to verify access switch during operation and
stop. During rotation, X3.5 (MAGAZINE A) is switched On and then Off, if completion of
stop, X3.6(MAGAZINE B) should be switched ON.
- If it doesn’t operate normally, adjust position of the limit switch or check the wiring.
.
Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X3 => Search
7 6 5 4 3 2 1 0
X3
1 0
When MAGAZINE is rotating, when X3.6 is 1, X3.5 is 0, it is normal state.

- Confirming the electric Diagram

- Confirming the PMC

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 Troubleshooting

If MAGAZINE is rotated one pot, B phase is stopped after switching ON, but if sensor of A phase is not
switched to ON, it is alarmed.
Verify the wiring and switch of access sensor on the A phase.

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Maintenance Manual
 Troubleshooting

2072 MAGAZINE INDEX TIME OVER

Cause:
- When T code is commanded and magazine rotation is executed on the auto mode,
command tool will be not returned within 50 seconds for finding of command tool.
- Malfunction or position error of Magazine A, B phase limit switch.

Condition:
- Alarm Lamp in operation panel on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- On the manual mode, rotate the MAGAZINE to verify the proximity switch during operation
and stop. When magazine is one rotated in the pot, verify that signal switch ON/OFF of
X3.5 and X3.6 is normal state.
- If operation is normal on the manual mode, verify that count is normally COUNT UP/DOWN
during pot rotating.
- If it is not normal state during operation, adjust the position of proximity switch or check the
wiring.
- According with above condition, check the area of ATC DATA TABLE.

Solution:
- Information about contact point of DGN
SYSTEM =>PMCMNT => < => STATUS =>X3 => Search
7 6 5 4 3 2 1 0
X3
1 0
When MAGAZINE stops, when X3.5 is 0, X3.6 is 1, it is normal state.

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 Troubleshooting

- Confirming the electric Diagram

- Confirming the PMC

If T-code calling, tool data is searched and magazine is rotated.

If Tool is returned within 50 seconds, it will be alarm.

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Maintenance Manual
 Troubleshooting

2073 POT UP CONDITION LOST

Cause:
- If T-CODE call command or manual magazine rotating command is executed, it is not
pot up.
- Incorrect position and malfunction of the proximity switch for pot up.
- Fault in the wiring.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- On the M31, M35 mode (ATC MAINTENANCE MODE), by pressing +Y, -Y button to
repeatedly implement the POT UP-DOWN operation and verify the interference and
operation state of limit switch.
- If X8.6 and X8.7 state is correctly operated in the above item, adjust the switch location or
check the wiring.

Solution::
- Confirmation information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X8 => Search
7 6 5 4 3 2 1 0
X8
0 1
If POT UP, when X8.6 is 1, it is normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

Although magazine rotating signal R882.0 is switched ON and POT UP signal Y4.6 is switched On,
when POT DOWN signal X8.7 is switched On for more 5 seconds, alarm causes.

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Maintenance Manual
 Troubleshooting

2074 MAGAZINE POSITION ERROR

Cause:
- If MAGAZINE is rotated or stopped, MAGAZINE B phase is not switched On.
- Fault of MAGAZINE A phase, B phase access switch
- Faults in the wiring.

Condition:
- Alarm Lamp in operation panel illuminated
- CALL LIGHT and BUZZER illuminated

Actions:/Procedures:
- After releasing the alarm by reset button, by rotate the magazine on the manual to verify
that access switch is operated during operation and stop.
In case of sensor fault or wiring fault, it is mostly.
- If it is not normal state during operation, adjust the position of access switch and check the
wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS => X3 => Search
7 6 5 4 3 2 1 0
X3 1 0
If MAGAZINE is stopped, when X3.5 is 0 and X3.6 is 1, it is normal state.

- Confirming the electric Diagram

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 Troubleshooting

- Confirming the PMC

If B phase is not switched ON on the magazine stop position, it is alarmed, verify that the access
sensor is normal.

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 Troubleshooting

2075 MAGAZINE A, B PHASE BOTH ON

Cause:
- In case that both magazine a phase and magazine b phase are on in when magazine
is rotating.
- Malfunction of the proximity switch for magazine A and B Phase.
- Fault in the wiring.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- After releasing the alarm by reset button, rotate the magazine on the manual mode to verify
that access switch is operated during operation and stop. In this case, there is most of
sensor malfunction and wiring fault.
- If it doesn’t operate normally, adjust position of the limit switch or check the wiring.

Solution::
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X3 => Search
7 6 5 4 3 2 1 0
X3
1 0
If MAGAZINE stopping, when X3.5 is 0, X3.6 is 1, it is normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

When MAGAZINE rotation is commanded and MAGAZINE A phase and B phase is switched ON,
alarm will be caused. Verify that access sensor is normal state.

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 Troubleshooting

2076 SP. THRU COOLANT FILTER NOT ON

Cause:
- A filter for cool jet unit isn’t activated when coolant motor operates.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Check the COOL JET UNIT and wiring.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X6 => Search
7 6 5 4 3 2 1 0
X6
0
If X6.4 is 0 it is normal states.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

A filter for cool jet unit isn’t activated in 2 seconds when coolant motor operates. In this case, alarm
occurs.

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Maintenance Manual
 Troubleshooting

2077 SP. THRU COOLANT PRESS NOT ON

Cause:
- Pressure of the COOL JET UNIT isn’t activated when COOLANT MOTOR operates
- Malfunction of SPINDLE THROUGHT COOLANT pressure switch.
- Fault in the wiring.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Check the press switch of cool jet unit.
- Check the pressure switch.

Solution:
-Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X6 => Search
7 6 5 4 3 2 1 0
X6
0
X6.5 is displayed as ‘0’ in normal condition.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

A press for cool jet unit isn’t activated in 4 seconds when coolant motor operates. In this case,
alarm occurs.

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 Troubleshooting

2080 +X O.T (HARD)

Cause:
- Plus +X axis Hard O.T switch is touched while X axis moves.
- Malfunction of Limit switch
- Fault in the wiring

Condition:
- Machine becomes emergency stop state and each of axis have been not transferred.
- CALL LIGHT and BUZZER are on

Actions:/Procedures:
- After pressing the STANDBY switch and moving the axis from manual mode to 0.T opposite
direction, release the alarm by reset. Reset after O.T area is completely turned away from.
- Check the limit switch or wiring when alarm is still displayed with above listed measure

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X10 => Search
7 6 5 4 3 2 1 0
X10
1 1 1 1
When input signal X9.6 ~ X10.3 is all 1, it is alarmed.

- Confirming the electric Diagram

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 Troubleshooting

- Confirming the PMC

When +X axis O.T signal X9.6 is switched OFF, it will be alarmed.

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Maintenance Manual
 Troubleshooting

2081 -X O.T (HARD)

Cause:
- Minus X axis Hard O.T switch is touched while X axis moves.
- Malfunction of Limit switch.
- Fault in the wiring.

Condition:
- Machine becomes emergency stop state and each of axis have been not transferred.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- After pressing the STANDBY switch and moving the axis from manual mode to 0.T opposite
direction, release the alarm by reset. Reset after O.T area is completely turned away from.
- Check the limit switch or wiring when Alarm is still displayed with above listed measure.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X10 => Search
7 6 5 4 3 2 1 0
X10
1 1 1 1
Input signal X9.6~X10.3 is 1 in normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

When +X axis 0.T signal X9.6 is switched to ON and -X axis 0.T signal X.9.7 is switched to OFF, it
is alarmed.

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Maintenance Manual
 Troubleshooting

2082 + Y O.T (HARD)

Cause:
- Plus Y axis Hard O.T switch is touched while Y axis moves.
- Malfunction of Limit switch.
- Fault in the wiring.

Condition:
- Machine becomes emergency stop state and each of axis have been not transferred.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- After pressing the STANDBY switch and moving the axis from manual mode to 0.T opposite
direction, release the alarm by reset. Reset after O.T area is completely turned away from.
- Check the limit switch or wiring when Alarm is still displayed with above listed measure.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X10 => Search
7 6 5 4 3 2 1 0
X10
1 1 1 1
Input signal X9.6~X10.3 becomes 1 in normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

When +X axis 0.T signal X9.7 is switched to ON and -Y axis 0.T signal X.10.0 is switched to OFF, it
is alarmed.

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Maintenance Manual
 Troubleshooting

2083 -Y O.T (HARD)

Cause:
- Minus Y axis Hard O.T switch is touched during Y axis movement.
- Malfunction of Limit switch
- Fault in the wiring

Condition:
- becomes emergency stop state and each of axis have been not transferred.
- CALL LIGHT and BUZZER are on

Actions:/Procedures:
- After pressing the STANDBY switch and moving the axis from manual mode to 0.T opposite
direction, release the alarm by reset. Reset after O.T area is completely turned away from.
- Check the limit switch or wiring when Alarm is still displayed with above listed measure

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X10 => Search
7 6 5 4 3 2 1 0
X10
1 1 1 1
Input signal X9.6~10.3 is 1 in normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

When +Y axis O.T signal X10.0 is switched ON and -Y axis signal X10.1 is switched OFF, it will be
alarmed.

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 Troubleshooting

2084 + Z O.T (HARD)

Cause:
- Plus Z axis Hard O.T switch is touched during Z axis movement.
- Malfunction of Limit switch
- Fault in the wiring

Condition:
- Machine becomes emergency stop state and each of axis have been not transferred.
- CALL LIGHT and BUZZER are on

Actions:/Procedures:
- After pressing the STANDBY switch and moving the axis from manual mode to 0.T opposite
direction, release the alarm by reset. Reset after O.T area is completely turned away from.
- Check the limit switch or wiring when Alarm is still displayed with above listed measure

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X10 => Search
7 6 5 4 3 2 1 0
X10
1 1 1 1
Input signal X9.6~X10.3 becomes 1 in normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

When -Y axis O.T signal X10.1 is switched ON and +Z axis signal X10.2 is switched OFF, it will be
alarmed.

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 Troubleshooting

2085 - Z O.T (HARD)

Cause:
- Minus Z axis Hard O.T switch is touched during Z axis movement.
- Malfunction of Limit switch.
- Fault in the wiring.

Condition:
- Machine becomes emergency stop state and each of axis have been not transferred.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- After pressing the STANDBY switch and moving the axis from manual mode to 0.T opposite
direction, release the alarm by reset. Reset after O.T area is completely turned away from.
- Check the limit switch or wiring when Alarm is still displayed with above listed measure

Solution:
- Information of DGN
SYSTEM =>PMCMNT => > => STATUS =>X10 => Search
7 6 5 4 3 2 1 0
X10
1 1 1 1
Input signal X9.6~X10.3 becomes 1 in normal state.

- Confirming the electric Diagram

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Maintenance Manual
 Troubleshooting

- Confirming the PMC

When +Z axis O.T signal X10.2 is switched ON and -Z axis O.T signal X10.3 is switched OFF, it
will be alarmed.

VX400(FANUC 0i-MD) 4-4-126 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2086 COUNT FINISH

Cause:
- Count reaches limitation of setting value.

Conditions:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Cancel alarm with reset button placed on Work count unit, and reset the setting value of
count.
- For processing in the NC, reset the count.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS =>X7 => Search
7 6 5 4 3 2 1 0
X7
1
When X7.4 is 1, it is alarmed.

- Confirming the electric Diagram

- Confirming the PMC

Alarm occurs when count reaches limited setting value.

VX400(FANUC 0i-MD) 4-4-127 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2087 NC ALARM

Cause:
- In case of that CNC is alarm state. Follow case is possibility to occur.
.TH ALARM
.TV ALARM
.P/S ALARM
.OVERTRAVEL ALARM
.OVERHEAT ALARM
.SERVO ALARM etc.

Condition:
- Alarm Lamp and feed hold lamp in operation panel are on.
- CALL LIGHT and BUZZER are on.

Actions:/Procedures:
- Check the displayed alarm message on CRT and follow the instruction of FANUC
maintenance manual.

Solution:
- Confirming the PMC

If ALARM detect signal F1.0 is outputted from NC, Alarm occurs.

VX400(FANUC 0i-MD) 4-4-128 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2104 MAGAZINE TOOL NO. ERROR

Cause:
- Commanded tool No. data had not been searched.
- 0 is commanded as TOOL NO. value.

Condition:
- Alarm Lamp in operation panel illuminated.
- CALL LIGHT and BUZZER illuminated.

Actions:/Procedures:
- By tracking the alarm contact of PMC sequence, verify that Tool No. data and commanded
tool No. is not 0.

Solution:
- Confirming the PMC

VX400(FANUC 0i-MD) 4-4-129 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2105 FLUSHING COOLANT MOTOR OVERLOAD

Cause:
- Due to overheating of FLUSHING COOLANT pump motor, over current is flown to the
motor and OCR(FT7) had been tripped.
- THERMAL RELAY Fault.
- Fault of three phases and wiring fault.
- Current setting value error.

Condition:
- Alarm Lamp in operation panel illuminated.
- Feed Hold in operation panel illuminated.
- CALL LIGHT and BUZZER illuminated.

Actions:/Procedures:
Caution
1. After main power turn off, check the electric wiring.
2. If thermal relay is tripped continuously, motor is possible to damage. You should
operate machine after cause of over-current is removed according to follow
method.

- FT7 is switched On in the control box and if it is not continued by checking the resistance
between terminals of FT7 using the Tester, replace THERMAL RELAY or contact unit
- Check the current and wiring among, R, S and T of motor.
- If it is not normal after check above cases, check the wiring of input signal X5.1 contact.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS => X5 => Search
7 6 5 4 3 2 1 0
X05 1
If input signal 5.1 is 1, It is normal state.

VX400(FANUC 0i-MD) 4-4-130 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

- Confirming the PMC

If the magnet for FLUSHING COOLANT MOTROR is switched ON and OCR(FT7) is tripped, re-
perform the reset after verifying the setting value.

VX400(FANUC 0i-MD) 4-4-131 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2106 SPINDLE NO ROTATE G01 COM ERROR

Cause:
- G01 command had been performed without spindle rotation command.

Condition:
- Alarm Lamp and Feed Hold lamp in operation panel illuminated
- CALL LIGHT and BUZZER illuminated
- During operation, the state become FEED HOLD.

Actions:/Procedures:
- After checking the spindle rotating state, command the G01.

Solution:
- Confirming the PMC

F2.6: Signal is switched On when cut machining is performing..

F45.1: Within zero speed LEVEL, signal is switched On.
F1.5, F76.3 : When TAP and RIGID TAP mode, alarm is not occurred.

VX400(FANUC 0i-MD) 4-4-132 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2107 OPERATION SET UP STATE !

Cause:
- With key switch remains in the SET UP mode, command the cycle start on the
automatic mode.

Condition:
- Alarm Lamp and Feed Hold lamp in operation panel illuminated.
- CALL LIGHT and BUZZER illuminated.
- During operation, the state become FEED HOLD.

Actions:/Procedures:
- Change key switch mode to lock position.

Solution:
- Confirming the PMC

VX400(FANUC 0i-MD) 4-4-133 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2111 SPINDLE FAN MOTOR OVERLOAD

Cause:
- Due to overheating of SPINDLE FAN MOTOR, over current is flown to the motor and
OCR (FTF) had been tripped.
- THERMAL RELAY Fault.
- Fault of three phases and wiring fault.
- Current setting value error.

Condition:
- Alarm Lamp in operation panel illuminated.
- Feed Hold in operation panel illuminated.
- CALL LIGHT and BUZZER illuminated.

Actions:/Procedures:
Caution
1. After main power turn off, check the electric wiring.
2. If thermal relay is tripped continuously, motor is possible to damage. You should
operate machine after cause of over-current is removed according to follow
method

- FTF is switched On in the control box and if it is not continued by checking the resistance
between terminals of FT F using the Tester, replace THERMAL RELAY or contact unit.
- Check the current and wiring among, R, S and T of motor.
- If it is not normal after check above cases, check the wiring of input signal X4.5 contact.

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS => X4 => Search
7 6 5 4 3 2 1 0
X04 1
If input signal X4.5 is 1, It is normal state.

VX400(FANUC 0i-MD) 4-4-134 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

- Confirming the PMC

If the magnet for SPINDLE FAN MOTROR is switched ON and OCR (FTF) is tripped, re-perform
the reset after verifying the setting value.

VX400(FANUC 0i-MD) 4-4-135 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

2112 OIL SKIMMER MOTOR O/L

Cause:
- Due to overheating of OIL SKIMMER MOTOR, over current is flown to the motor and
OCR(FT11) had been tripped.
- THERMAL RELAY Fault
- Fault of three phases and wiring fault.
- Current setting value error

Condition:
- Alarm Lamp in operation panel illuminated
- Feed Hold in operation panel illuminated
- CALL LIGHT and BUZZER illuminated

Actions:/Procedures:
Caution
1. After main power turn off, check the electric wiring.
2. If thermal relay is tripped continuously, motor is possible to damage. You should
operate machine after cause of over-current is removed according to follow
method.

- FT11 is switched On in the control box and if it is not continued by checking the resistance
between terminals of FT11, replace THERMAL RELAY or contact unit.
- Check the current and wiring among, R, S and T of motor.
- If it is not normal after check above cases, check the wiring of input signal X5.5 contact

Solution:
- Information of DGN
SYSTEM =>PMCMNT => < => STATUS => X5 => Search
7 6 5 4 3 2 1 0
X05 1
If input signal X5.5 is 1, It is normal state.

VX400(FANUC 0i-MD) 4-4-136 2018EN00iDMA0

Maintenance Manual
 Troubleshooting

- Confirming the electric Diagram

- Confirming the PMC

If the magnet for OIL SKIMMER MOTROR is switched ON and OCR(FT11) is tripped, re-perform
the reset after verifying the setting value.

VX400(FANUC 0i-MD) 4-4-137 2018EN00iDMA0

Maintenance Manual