Mpaaf4001e Manual Aa65 Fanuc 0imf.31imb

Original
Instructions
VERTICAL MACHINING CENTER
Operation and Maintenance Manual
AA965/1165/1365/1565
Controller : FANUC 0iMF / 31iMB
Manual No. : MPAAF4001E
Date : January, 2015
技術管制文件
Preface

Preface
The content of this manual is the latest edition. However, we are constantly improving the design of
our machine tools so that the illustrations and descriptions may vary from the machine you received.
This means that the machine you received is the latest improved model to better fulfill your
requirements. Your WELE machine is designed and built for maximum ease and safety of
operation. However, some previously accepted shop practices may not reflect current safety
regulations and procedures, and should be re-examined to insure compliance with the current safety
and health standards.
We recommend that all shop supervisors, maintenance personnel, machine and tool operators be
advised of the importance of safety maintenance, setup and operation of WELE built equipment.
There are lots of descriptions in the manual about what ought or not to do, but it still can't cover all
the details. When you think about the possibility of some operations, please refer to the instructions
or informations described in the instruction manuals enclosed with the machine, they are:
1) Operation and Maintenance Manual

2) Mechanism Assembly Drawing And Part List
3) Paramter list, LADDER (export only), DRAWING, CD
4) Operator's Manual (operation & programming, supplied by the manufacturer of the CNC
controller.)
5) Maintenance Manual (supplied by the manufacturer of the CNC controller )
Besides, in the next chapter of this manual, there are safety related descriptions for attention. These
matters for attention contain the essential informations to the operators while operating, and
maintaining. Fail to follow these instructions may result in great damage on the machine or the
operator.
Content i

Content
1. Safety Instruction
1.1 Safety Instructions ........................................................................................................................... 1-2
1.2 Illustration of Hazard Region .......................................................................................................... 1-5
1.3 Illustration of Safety Device Position .............................................................................................. 1-6
1.4 The Position of Warning and Sign ................................................................................................... 1-7
1.4.1 Carousel type magazine ....................................................................................................... 1-7
1.4.2 Arm type magazine ............................................................................................................ 1-11
1.5 Marking of the Oil Replenishing Point of this Machine ................................................................ 1-15
1.5.1 Chain & drum type tool magazine ..................................................................................... 1-15
1.5.2 Carousel type tool magazine .............................................................................................. 1-16
2. Outline of Machine
2.1 Descriptions of mechanical design and construction ....................................................................... 2-1
2.2 Construction features of the machine .............................................................................................. 2-2
2.3 Operation Condition ........................................................................................................................ 2-2
2.4 The Expected life of the machine .................................................................................................... 2-3
2.5 Storage condition ............................................................................................................................. 2-3
2.6 Installation condition ....................................................................................................................... 2-3
2.7 Noise measuring .............................................................................................................................. 2-4
2.8 Coordination .................................................................................................................................... 2-5
2.9 Main part name ................................................................................................................................ 2-6
2.10 Maximum floor space .................................................................................................................... 2-7
2.11 Working range .............................................................................................................................. 2-11
2.12 Table & T-slot size ....................................................................................................................... 2-12
3. Installation
3.1 Space Required ................................................................................................................................ 3-1
3.1.1 Machine size ........................................................................................................................ 3-1
3.1.2 Installation environment....................................................................................................... 3-2
3.1.3 Foundation ........................................................................................................................... 3-2
3.2 The Requirement of Power Sources ................................................................................................ 3-8
3.2.1 Power and grounding ........................................................................................................... 3-8
3.2.2 Compressed air ..................................................................................................................... 3-9
4. Transportation and Installation
4.1 Crane and Hoist Transportation ....................................................................................................... 4-1
4.1.1 Precaution on hoist ............................................................................................................... 4-1
4.1.2 Machine Weight ................................................................................................................... 4-1
4.1.3 Hoisting diagram .................................................................................................................. 4-2
4.1.4 Forklift Truck Transportation ............................................................................................... 4-3

ii

4.2 Axes Locking and Machine Packaging ............................................................................................ 4-5
4.2.1 Axes locking off ................................................................................................................... 4-5
4.2.2 Wooden packaging for transportation .................................................................................. 4-6
4.3 Precaution after Opening Package ................................................................................................... 4-7
4.4 Storage Condition ............................................................................................................................ 4-7
4.5 Precaution on Installation ................................................................................................................ 4-7
4.6 Leveling Adjustment ........................................................................................................................ 4-8
5. Preparation before Trial Run
5.1 Cleaning ........................................................................................................................................... 5-1
5.2 Removing Protection Attachment .................................................................................................... 5-2
5.3 Replenishing Lubricant .................................................................................................................... 5-3
5.4 Air Supply ........................................................................................................................................ 5-4
5.5 Coolant Supply ................................................................................................................................ 5-4
5.6 Electricity Connection and Grounding Method ............................................................................... 5-4
5.7 Safety Inspection.............................................................................................................................. 5-4
5.7.1 Inspection before power on .................................................................................................. 5-4
5.7.2 Inspection after power on ..................................................................................................... 5-5
5.7.3 Manual operate inspection ................................................................................................... 5-5
5.8 Warm-up Description ....................................................................................................................... 5-6
6. Setting and Adjusting
6.1 Structural Setting and Adjusting ...................................................................................................... 6-1
6.1.1 Adjusting of gibs .................................................................................................................. 6-1
6.1.2 Leveling ajusting .................................................................................................................. 6-5
6.1.3 Adjusting of pull stud kick-out amount ................................................................................ 6-5
6.1.4 Adjusting of tool changing point (carousel type) ................................................................. 6-7
6.1.5 Adjusting of tool changing point (arm type) ........................................................................ 6-7
6.1.6 The Adjustment of the CAM-ATC mechanism .................................................................... 6-8
6.1.7 Mounting and adjustment of the couplings of the feed system .......................................... 6-12
6.1.8 Tool information................................................................................................................. 6-12
6.2 Adjusting and Setting of Pressure .................................................................................................. 6-13
6.2.1 Pneumatic system ............................................................................................................... 6-13
6.2.2 Circuit control .................................................................................................................... 6-15
6.2.3 Adjusting and setting of lubrication ................................................................................... 6-17
6.3 Geometric Precision Adjusting ...................................................................................................... 6-18
7. Maintenance
7.1 Preventive Maintenance ................................................................................................................... 7-1
7.1.1 Inspection before starting, after starting and end of daily operation .................................... 7-2
7.1.2 Weekly, monthly, semiannual, and annual inspection .......................................................... 7-3
7.2 Lubrication Maintenance Method .................................................................................................... 7-9

Content iii

7.2.1 Note and maintenance of the ratio distribution controller.................................................... 7-9
7.2.2 Lubrication verification on sliding surface .......................................................................... 7-9
7.2.3 Manual lubrication method .................................................................................................. 7-9
7.2.4 Lubricant replenishing method of headstock (gear drive).................................................. 7-10
7.2.5 Troubleshooting ................................................................................................................. 7-11
7.3 Cleaning and Replacement Method ............................................................................................... 7-13
7.3.1 The cleaning method of the lubrication oil reservoir ......................................................... 7-13
7.3.2 Air condition unit ............................................................................................................... 7-17
7.3.3 Coolant tank ....................................................................................................................... 7-21
7.4 Maintenance of Windows .............................................................................................................. 7-27
7.4.1 Window dimension............................................................................................................. 7-27
7.4.2 The Replacement method of the PC windows ................................................................... 7-28
7.5 Waste Disposal ............................................................................................................................... 7-29
7.6 Personal Protective Equipment ...................................................................................................... 7-29
7.7 Fire Extinguisher............................................................................................................................ 7-29
8. Operator Panel
8.1 LCD & MDI Panel........................................................................................................................... 8-1
8.2 Machine Operator Panel .................................................................................................................. 8-4
8.3 Magazine Operator Panel............................................................................................................... 8-17
8.4 Electrical Components in Cabinet ................................................................................................. 8-19
9. Power On and Power Off
9.1 Inspection before Power On ............................................................................................................ 9-1
9.1.1 Power on .............................................................................................................................. 9-2
9.1.2 Checking after power on ...................................................................................................... 9-3
9.2 Normal Shutdown ............................................................................................................................ 9-3
9.3 Inspection after Power Off ............................................................................................................... 9-4
9.4 Manipulation for Stopping Operation .............................................................................................. 9-4
9.4.1 Emergent stop....................................................................................................................... 9-4
9.4.2 Other stops ........................................................................................................................... 9-4
9.5 Disposal during Power Failure ........................................................................................................ 9-7
9.6 Power On Procedure List ................................................................................................................. 9-8
9.7 Power Off Procedure List ................................................................................................................ 9-9
10. Operation Instruction
10.1 M Code Function List .................................................................................................................. 10-1
10.2 Mode Selection ............................................................................................................................ 10-4
10.3 Manual Operation ........................................................................................................................ 10-6
10.3.1 Reference point return operation ...................................................................................... 10-6
10.3.2 Jog feed operation ............................................................................................................ 10-7
10.3.3 Handwheel operation ....................................................................................................... 10-8

iv

10.3.4 Spindle manual operation ................................................................................................. 10-9
10.3.5 Spindle clamping and unclamping operations ............................................................... 10-10
10.3.6 Chip conveyor operation ................................................................................................ 10-11
10.3.7 Cutting fluid / coolant .................................................................................................... 10-12
10.3.8 Magazine tool loading and unloading ............................................................................ 10-13
10.4 MDI Operation........................................................................................................................... 10-14
10.4.1 MDI function.................................................................................................................. 10-14
10.4.2 Tool number input and modification .............................................................................. 10-17
10.4.3 Automatic tool changer .................................................................................................. 10-18
10.5 Automatic Operation .................................................................................................................. 10-19
10.5.1 Automatic execution program ........................................................................................ 10-19
10.5.2 Block skip ...................................................................................................................... 10-20
10.5.3 Manual absolute value.................................................................................................... 10-21
10.5.4 Program restart ............................................................................................................... 10-26
10.6 Program Performance Test Operation ........................................................................................ 10-29
10.6.1 Machine lock .................................................................................................................. 10-29
10.6.2 Z Axis lock ..................................................................................................................... 10-29
10.6.3 M, S, and T codes lock ................................................................................................... 10-29
10.6.4 Dry run ........................................................................................................................... 10-30
10.6.5 Rapid override ................................................................................................................ 10-30
10.6.6 Feed override.................................................................................................................. 10-30
10.6.7 Jog override .................................................................................................................... 10-31
10.6.8 Spindle override ............................................................................................................. 10-31
10.7 Magazine Operation ................................................................................................................... 10-32
10.8 PMC PRM DATA ...................................................................................................................... 10-33
10.8.1 PMC PRM DATA for arm type ...................................................................................... 10-33
11. Troubleshooting Guide
11.1 Alarm List .................................................................................................................................... 11-2
11.2 Operation Messages and Disposal ............................................................................................... 11-4
11.3 Trouble Shooting .......................................................................................................................... 11-6
11.4 The Remedies of Automatic Tool Change Error ........................................................................ 11-20
11.4.1 Arm type ......................................................................................................................... 11-20
12. Revision History

1. Safety Instruction 1-1

1. Safety Instruction
THESE SAFETY RECOMMENDATIONS FOR THIS WELE MACHINES HAVE BEEN
PREPARED TO ASSIST THE OPERATOR AND MAINTENANCE PERSONNEL IN
PRACTICING GOOD SHOP SAFETY PROCEDURE.
MACHINE OPERATORS ARE REFERRED AS “OPERATORS” WITHIN THE
MANUAL. THE “OPERATOR” SHALL NOT CONDUCT THE MAINTENANCE
WORK. ONLY PROFESSIONALLY TRAINED SERVICE OR MAINTENANCE
PERSONNEL AUTHORIZED BY WELE COMPANY CAN PERFORM
MAINTENANCE WORK ON THIS MACHINE.
THE OPERATOR AND MAINTENANCE PERSONNEL MUST READ AND
UNDERSTAND THESE PRE-CAUTIONS COMPLETELY BEFORE OPERATING,
SETTING UP, RUNNING OR PERFORMING MAINTENANCE ON THE MACHINE.
THERE ARE THREE WARNING LABELS ATTACHED TO THE MACHINE. NEVER
REMOVE OR DISFIGURE ANY LABELS OR INSTRUCTION PLATES FROM THE
MACHINE.

 INDICATES FAILURE TO DO SO WILL RESULT
IN SERIOUS INJURY OR DEATH.
 INDICATES FAILURE TO DO SO COULD RESULT
IN SERIOUS INJURY OR DEATH.
 INDICATES FAILURE TO DO SO MAY RESULT IN
SERIOUS INJURY OR DEATH.

 Shows to follow safety instructions.

 Indicates points to be followed.

 (same as above)



1.(Indicates: refer to the points below)
2.________________________________________
3.________________________________________
 (Indicates manuals, chapters or sections to

be searched for)

1-2

1.1 Safety Instructions

READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE OPERATING
MACHINE
When this instruction manual was printed, the information given was current. However, since
we are constantly improving the design of our machines, it is possible that the illustrations and
descriptions may vary from the machine you received. This means that the machine you had is
the latest improved model to better fulfill your requirements.
Your WELE machine is designed and built for maximum ease and safety of operation. However,
some previously accepted shop practices may not reflect current safety regulations and
procedures, and should be re-examined to insure compliance with the current safety and health
standards.
We recommend that all shop supervisors, maintenance personnel, machine and the operators are
advised of the importance of safety maintenance, setup and operation of WELE built equipment.
Our recommendations are described below.
PLEASE READ THESE SAFETY RECOMMENDATIONS BEFORE PROCEEDING

ANY FURTHER. (“※” indicated: safety item, “◎” indicated environment protection items)

※ ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing
electrical equipment.
※ READ APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation or
maintenance of machine. Make sure you do understand all instructions.
※ CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job.
※ DO NOT OPERATE EQUIPMENT unless proper maintenance has been regularly
performed and the equipment is known to be in good working order.
※ BEFORE OPERATING THE MACHINE check that all protective components and
interlocks work properly. If not, immediately contact your local distributor.
◎ DO NOT CUT THE FLAMMABLE MATERIAL (like: Magnesium base, wooden,
graphite, plastic, etc.) by operating of the machine to avoid any possibility of fire.
◎ The machine can cut the material like cast iron, steel, copper, aluminum, doing the milling,
drilling and tapping etc. jobs.
※ MAKE SURE MACHINE IS PROPERLY GROUNDED. CONSULT NATIONAL
ELECTRIC CODE EN 60204-1 and all local code.
※ KEEP AREA AROUND MACHINE well light and dry.
※ KNOW WHERE ALL stop push buttons are located in case of an emergency.
※ DO NOT REMOVE ANY WARNING or INSTRUCTION TAGS from machine.
◎ DO NOT USE a toxic or flammable substance as a solvent cleaner or coolant.
◎ KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating
equipment.
※ DO NOT ATTEMPT to brake or slow the machine with hands or any makeshift device.
※ DO NOT ALTER THE MACHINE to bypass any interlock, overload, disconnect or other
safety device.


※ REMOVE ANY LOOSE PARTS OR TOOLS left on machine or in the work area before
operating machine. Always check machine and work area for loose tools and parts especially
after work has been done by maintenance personnel.
※ CHECK LUBE LEVEL and status of indicator lights before operating machine.
※ CHECK THE HYDRAULIC OIL LEVEL , pressure and indicate light are in normal
condition after power ON
※ CHECK the air pressure is enough and indicates light is in normal condition.
※ ZERO RETURN BEFORE machine operation to avoid any of over travel.
※ MAKE SURE all functions are in normal condition to ensure the machining quality.
※ ALWAYS to record all operating process while machine is in trouble shooting.
◎ WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. When
necessary, wear respirator, helmet, gloves and ear muffs or plugs.
◎ USE CAUTION around exposed mechanisms and tooling especially when setting up. Be
careful of sharp edges on tools.
◎ DO NOT CLEAN machine with an air hose. DO NOT REMOVE CHIPS with hands.
Use a hook or similar device and make certain that all machine movements have ceased.
※ MAKE SURE fixture plates and all other spindle-mounted tool holding devices are
properly mounted and secured before starting machine.
※ BEFORE PRESSING CYCLE START PUSH-BUTTON, make certain that proper
functions are programmed and that all controls are set in desired modes.
※ DRY CYCLE a new setup to check for programming errors.
◎ MAKE SURE PROPER GUARDING is in place and all doors are closed and secured.
◎ DO NOT OPEN GUARD DOORS while any machine component is in motion.
※ DO NOT REMOVE OR LOAD workpieces while any part of the machine is in motion.
※ USE LIGHTER THAN NORMAL feedrates and depth of cut when machining a
workpiece size that is larger than the WORKING CAPACITY.
◎ DO NOT OPERATE MACHINE if unusual or excessive noise or vibration occurs.
Report any excessive or unusual vibration, sounds, smoke, or heat as well as any
damaged parts.
※ CHECK SETUP, TOOLING AND SECURITY OF WORKPIECE if machine has been
off for any length of time.
※ DISCONNECT MAIN ELECTRICAL POWER before attempting repair or
maintenance.
※ DO NOT USE worn or defective hand tools. Use proper size and type for job being
performed.
※ * USE ONLY a soft-faced hammer on tools and fixtures.
※ REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished.
◎ RECYCLING all replaced parts and chips to save the resources.
◎ MAKE SURE that the waste is well disposed to conform to the environmental protection
regulations. (such as wasted oil, coolant etc.)
◎ DO NOT LEAVE the leaking oil unattended, recycling the leaking oil by wooden chip.
◎ IT IS RECOMMENDED to remove or recycle all useable parts from the machine which
to be junked.
◎ If the workpieces or tools are heavier than 10kg; please use certain equipments to help
carrying on working.

1-4

◎ The noise level of the machines, AA and AQ series are about 71dB(A), VG series is about
78dB(A). If the operator cannot stand the noise, please wear proper ear defender.
※ PLEASE REPLACE THE BATTERY EVERY FOUR YEARS, if machine uses absolute
encoder. The axes will lose the position of origin when the battery has run down, so
please reset the absolute origin after replacing the battery.
※ DO NOT OPERATE machine by wearing gloves or the clothes which is possibly
entangled in by the machine.
The expected life of the machine is counted as:
8 hrs x 5.5 days x 45 weeks x 10 years = 19800 hrs which to be under normal operation
and well maintenance. It is not necessary to replace many components except those are
consumable.
The machine is packed in wooden case before shipment. It can be stored for longer
under dry and ventilated environment. It is necessary for the machine to be clean and
prevent dust while the wooden case is broken or opened.
The suitable environment conditions for the storage are as below:
a. Ambient temperature: -25℃~55℃, and up to +70℃ for short periods less than 24 hrs.
b. Relative humidity: 30%~95% RH
c. Atmosphere: Free from excessive dust, acid fume, corrosive gases and salt.
The machine is designed for not using at the potentially explosive environment.
Generally, the machine should be installed under the following conditions:
a. Supply voltage: 0.9~1.1 nominal supply voltage
b. Source frequency: 0.99~1.01 nominal frequency
c. Ambient temperature: 5℃~40℃ and up to +70℃ for short periods less than 24 hrs.
d. Relative humidity: 30%~90% RH
e. Electrical equipment is capable of operating correctly at altitudes up to 1000 m above
mean sea level.
f. Atmosphere: Free from excessive dust, acid fume, corrosive gases and salt.
g. Avoid exposing to direct sunlight or heat rays, which can change the environmental
temperature.
h. Avoid exposing to abnormal vibration.
i. Ground earth connection is a must.
Colors indicated light meaning on the operator’s panel:

Color Meaning Explanation Action by Operator
Red Emergency Hazard condition Immediately action
Yellow Abnormal Abnormal (critical) condition Monitoring or intervention
Green Normal Normal condition Optional
White Normal Other condition Monitoring
Colors indicated light meaning on the operation cycle finish and alarm light:
Color Meaning Explanation
Red Emergency The red light will be flashed by 0.5 seconds when the
machine alert.
Yellow Program end The yellow light will be flashed by 0.5 seconds when
the program is ended.
Green Normal The green light will be shining when machine is on
normal operation.


1.2 Illustration of Hazard Region

Arrows show the directions of movement in the danger area.

Item Name Item Name
1 Rectangle flexible tube 5 Tool magazine
2 Side door (fixed guard) 6 Front door (movable guard)
3 Transformer 7 The exit of chip conveyor
The area between the magazine and
4
machine head

1-6

1.3 Illustration of Safety Device Position

Item Name Item Name
Power switch on Electric cabinet door: 4 Safety door lock switch(movable guard):
Switch on-Power is supplied, and Machine can’t be started if door is opened.
1 machine will be in a controlled condition. 5 Side door handle (fixed guard):
Switch off-Power is not supplied, and Door can’t be opened without using tools.
machine will stop at once. 6 X axis Origin index
2 Lubrication oil level switch: 7 Y axis Origin index
Show the warning in monitor 8 Emergency stop button
3 Z axis Origin index 9 The exit of chip conveyer

1.4.1 Carousel type magazine

1.4 The Position of Warning and Sign

S AF ETY INS TR UCTIONS
Alway s follow the ins tructions on this label.

Never rem ove, cover, or damage this l abel.

1-8

崴立機電股份有限公司
高速主軸溫機程序表
主軸轉速 (rpm)
分類加工中斷時間檢查項目
(最高轉速N) 時間(分)
Nx20% 10 1.溫升低於15°C
I 停機8至24小時 Nx60% 10
2.振動
Nx20% 10 3.噪音
II 停機24至72小時 Nx40% 10
Nx60% 10 4.需等到溫度穩定後
Nx20% 10 再開始加工
Nx40% 10
停機超過72 小時以上
III Nx60% 10
(含新機安裝)
Nx80% 10
Nx100% 10
1.主軸未裝刀把前請勿運轉 .
2.刀把需達到G2.5級(或更佳 )動平衡.
3.停機時間若超過4小時,開機後請先確認
注意事項主軸潤滑油氣已抵達主軸後才能啟動.
4.主軸溫升超過15°C時 ,請將轉速降至1000rpm,
安全注意事項
請時常留意本標籤提醒事項
請勿移除遮蓋或破壞本標籤

1-10


1.4.2 Arm type magazine
安全注意事項

1-12

安全注意事項

1-14


1.5 Marking of the Oil Replenishing Point of this Machine

1.5.1 Chain & drum type tool magazine

Replenishing Oiling Period Oiling Method
1 Spindle oil cooler Check everyday *Oiling fill to the middle of oil gauge.
2 Oil lubricator When alarm buzzer sounds
3 Air regulator
Check everyday Oiling fill to upper limit of oil gauge.
4 Coolant tank
5 Booster cylinder Check every 3 months
6 Gear box (gear drive) *Oiling fill to the middle of oil gauge.
Check everyday
7 Cam ATC Mechanism (Change every 6 months to one year.)

1-16

1.5.2 Carousel type tool magazine

Replenishing Oiling Period Oiling Method
1 Spindle oil cooler Check everyday *Oiling fill to the middle of oil gauge.
2 Oil lubricator When alarm buzzer sounds
3 Air regulator
Check everyday Oiling fill to upper limit of oil gauge.
4 Coolant tank
5 Booster cylinder Check every 3 months
*Oiling fill to the middle of oil gauge.
6 Gear box (gear drive) Check everyday
(Change every 6 months to one year.)

2. Outline of Machine 2-1
2. Outline of Machine
2.1 Descriptions of mechanical design and construction

The machine consists of column, machine bed, saddle, magazine and the ATC system, spindle
head, and table. Every part is designed for the high precision of long-term and durable cutting
performances. The following are the descriptions of the parts:
A. Column
The column is made of one piece. The thick walls and reinforcement ribs give the
machining unsurpassed rigidity and prevent any bending or twisting that may affect
machining accuracy. The rigid column construction supports the cutting load
symmetrically; thus bending movement and thermal deflection is minimized
B. Machine bed
The machine bed is the foundation of the machining center structure. In addition to
providing rigidity and support for the sliding members, machine alignment is maintained
through the precision leveling of this structure.
C. Saddle
The saddle supports the table movement on the guideways, it is the foundation of the
straight precision of X-direction. Its one piece structure strengthens the rigidity of
guideways and maintains the straightness.
D. Magazine and the ATC system

A Standard magazine can store tools. The ATC time, tool to tool is 8 seconds.
E. Spindle head
The spindle head for rigidity reason, a square-shaped cross section headstock was
designed. The front bearing to assure efficient power transmission to the spindle nose
and to enable heavy duty machining supports the spindle to maintain sensitivity and
accuracy to the cutting area.
F. Table
The table size not only allows for the machining of large parts but also increases the
productivity of small to medium sized parts as they can be set up and processed at one
time.

2-2

2.2 Construction features of the machine

a. The machine is simultaneously control for 3 axes.
b. Fully-enclosed type splash guard for totally protection processing area.
c. Each accessories and machine are passed inspection of coordinate measuring system or laser
measuring system.
d. Each machine has high precision spindle and powerful spindle motor to suit every kind of
processing condition.
e. To guarantee the accurate centre line of spindle, the spindle has automatic temperature
adjusting device.
f. High precision and angular contact ball bearing with locknut and flexibility coupling guarantee
reliable position accuracy and repeatability.

2.3 Operation Condition

a. The machine is a CNC machining center. It is perfectly designed for complete machining
including milling, drilling, tapping, boring, and can optionally install the rotary table for 3D
milling.
b. In order to avoid any possibility of fire, please do not machine the flammable material
(magnesium base, wooden, graphite, plastic etc). Neither stone nor carbon is permitted to cut.
c. The machine must be installed on a level and stable foundation. The following locations are
not allowed to install the machine.
(1) Place subject to external vibration.
(2) Place exposed to excessive humidity.
(3) Place exposed to direct sunshine.
(4) Place near the heat source.
d. There are several kinds of warning plates and labels on the machine, as illustrated in Chapter 1.
They are designed to warn operators to pay attention to the essential information while in use.
e. For safety consideration, only the well trained or authorized person is allowed to do operation
work.
f. The lighting standard for the workplace is 500 lux.
g. Please clean up the chips at all times.
h. Please turn off the power or make machine in manual mode when setting or adjusting the
machine.

2.4 The Expected life of the machine

The expected life of the machine is counted as follow:
8hrs x 5.5days x 45weeks x 10years: 19800 hrs. This expected period is measured under normal
operation and well maintenance. It is not necessary to replace many parts and components except
those are the consumable ones.
2.5 Storage condition

The machine is packed in wooden case before shipment. It can be stored for longer under dry and
ventilated environment. It is necessary for the machine to be clean and prevent dust while the
wooden case is broken or opened. The suitable environment conditions for the storage are as
below:
a. Peripheral temperature: -25℃ ~55℃, and up to +70℃ for short periods less than 24 hrs.
b. Relative humidity: 30%~95% RH
c. Atmosphere: free from excessive dust, acid fume, corrosive gases and salt.

2.6 Installation condition

The machine is designed for not using at the potentially explosive environment. Generally, the
machine should be installed under the following conditions:
a. Supply voltage: 0.9~1.1 supply voltage
b. Source frequency: 0.99~1.01 nominal frequency
c. Peripheral temperature: 5℃~40℃, and up to +70℃ for short periods less than 24 hrs.
d. Relative humidity: 30%~90% RH
e. Atmosphere: free from excessive dust, acid fume, corrosive gases and salt.
f. Electrical equipment is capable of operating correctly at altitures up to 1000 m above mean sea
level.
g. Please avoid exposing to heat rays or direct sunlight that can change the temperature of the
environment.
h. Please avoid exposing to abnormal vibration.
i. The machine needs ground earth connection.

2-4

2.7 Noise measuring

The sound pressure level is under 78 dBA at the position of the operation according to ISO/DIN
230-5.
PA: OPERATOR’S CONTROL PANNEL POSITION

PB: CHIP CONVEYER OPERATE POSITION
1. DISTANCE FROM POINT 1 TO WALL IS: 3000 mm

2. DISTANCE FROM POINT 2 TO MACHINE IS: 2000 mm

2.8 Coordination
The machining center, with the right handed coordinate system, determines the relationship of the
axes that is in accordance with E.I.A. RS-267-A and I.S.O. R841 Axis and Motion Nomenclature.
The following table and figure demonstrate the positive and negative movements of three axes of
AA Series machining directions:
The axis Description

(1) Table travels left in positive movement.
X axis
(2) Table travels right in negative movement.
(1) Saddle travels forward in positive movement.
Y axis
(2) Saddle travels backward in negative movement.
(1) Spindle head travels up in positive movement.
Z axis
(2) Spindle head travels down in negative movement.

2-6

2.9 Main part name

2.10 Maximum floor space

a. AA965

2-8

b. AA1165

c. AA1365

2-10

d. AA1565

2.11 Working range

Model Travel: X-Y-Z A B C D E F G H J

AA 965 900x650x600 1100 450 450 650 325 140 595 130 125~725
AA1165 1100x650x600 1300 550 380 650 325 140 595 130 125~725
AA1365 1300x650x600 1450 650 420 650 325 140 595 130 125~725
AA1565 1500x650x600 1650 750 460 650 325 140 595 130 125~725

2-12

2.12 Table & T-slot size

3. Installation 3-1

3. Installation
3.1 Space Required

3.1.1 Machine size
* We recommend a separate seat be set for over 1 hour operation. The position should be
located about "Q"mm away from the machine.

3-2

3.1.2 Installation environment
The following are installation environment conditions:
a. Avoid exposing the machine to direct sunlight or outdoor.
b. Avoid exposing the machine to the frequent abnormal vibrations.
c. Ambient temperature: 5℃ to 40℃. Avoid exposing the machine to near other heat sources.
d. Free from the atmosphere conditions of excessive dust, acid fume, corrosive gases and salt.
e. Relative humidity: 30%~90% RH
f. Solid foundation is needed: Reinforced concrete is recommended as the most suitable
foundation material.
g. Electrical ground connection is a must for the machine.

3.1.3 Foundation
The solid foundation is for keeping long lasting precision of the machine, please build the
foundation according to the foundation drawings and pay attention to the following items:
a. The foundation area should be built according to the machine size.
b. If the factors of geological structure variability are too large to load the machine weight, try to
search possible depth of the loading demand of the machine or the correlative range of the
adjusting bolts. For example, a shallow foundation design: The possible depth is about 4 times
the width of the anchor bolt. The soil variability will be the indicator of the needed depth.
c. Foundation concrete depends on the soil quality at the site, so build the foundation to assure
sufficient endurance of machine weight and to keep the machine stable and level.
d. If the soil condition is poor, please consult civil specialists for the construction of foundation.
e. Generally, the thickness of foundation concrete should be above 500mm (19.7").
f. The machine is equipped with level bolts and support pads. If the foundation is even and stable,
the machine can be set up only by the support of level bolts and support pads.
g. If it is very important to keep the machine solidly installed, please refer to item h: A reference
method of constructing anchor bolts.
h. The construction of the foundation reinforcement: Please refer to Table3-1.
(1) The reinforcement bars are set from foundation bolt boxes, and then extended outwards.
(2) The distance between two reinforcement bars is about 250mm. If the distance is less than
250mm, there is no need to set bars.
(3) The foundation is about 600mm in depth. Set three rows of reinforcement bars within
foundation. The distance between two rows is about 250mm.
(4) The diameter of reinforcement bars should be between 13mm to 19mm.
(5) The space, under and around the foundation, should be paved with rubble to prevent the
foundation from slipping or sinking of the slack soil.

3. Installation 3-3

The following are foundation drawings and anchor bolt diagram (Table3-1) of AA series.
a. AA965

3-4

b. AA1165

3. Installation 3-5

c. AA1365

3-6

d. AA1565

3. Installation 3-7

Table 3-1 Anchor bolt diagram
Series Unit A B C D E F G H I
AA mm 20 50 200 340 120 300 400 600 800

3-8

3.2 The Requirement of Power Sources

3.2.1 Power and grounding
a. AC line Voltage: 3 phases AC 220V +/- 10% (AC 380V, 400V etc. must through transformer)
b. Frequency: 50 or 60 Hz +/- 1%
c. Power capacity of AA965/AA1165/AA1365/AA1565
SPINDLE TYPE:
α8 : 30KVA
α12: 30KVA
α15: 35KVA
α22: 50KVA
d. Main circuit breaker:
Model Voltage SPINDLE TYPE Current capacity Main breaker
α8
AA965 220V 100A 100A
α12
AA1165 400V 100A 100A
α15
AA1365
220V 125A 125A
AA1565 α22
400V 100A 100A
e. The cross-section area of Power line cable

SPINDLE TYPE:
α8 : 16 mm2
α12: 16 mm2
α15: 25 mm2
α22: 25 mm2
f. The colors of power line cables should be assigned by CE regulations.
g. The outside terminal of power line cables should be protected by fuse or breaker.
h. The power line cables should NOT be connected with other machines, but be connected
independently.
i. The cross-section area specification of grounding wire refers to power line cable; the grounding
resistor should be less than 50 Ω. The color of grounding wire must be yellow-green.
j. The grounding method of multiple machines is shown as Figure 3-1.
Figure 3-1 The grounding method of multiple machines

3. Installation 3-9

3.2.2 Compressed air
a. Compressed air must be filtered to keep it clean and dry (dew point, below 7kgf/cm2; 10℃).
b. The required pressure of compressed air is 4 to 7.0kgf/cm2. Make sure the supply of
compressed air satisfy the capacity requirement. (One-hp air compressor could provide 90
L/min air flow rate, and it is approximately enough.) Furthermore, air compressor should not
branch the use ends excessively, or the instantaneous pressure varieties will cause the
insufficient machine pressure alarm.
c. The size of quick couplings at the air inlet is 3/8".

4. Transportation and Installation 4-1

4. Transportation and Installation
4.1 Crane and Hoist Transportation

4.1.1 Precaution on hoist
Please read the following precautions completely before operating crane and hoist, and
operate as the figures, diagrams, or tables shown as below:
a. Crane and Hoist license required: A licensed operator who is certified to operate the type of
equipment.
b. Please ensure hoist hook is located in gravity center line of the machine.
c. The strength of lifting devices should be able to load machine weight, such as Crane, Hoist,
lifting fixture, hoist block, shackles, etc.
d. Before the lifting operation, please remove the front cover of Y axis and then fix it in the front
side.
e. During the lifting operation, the steel cable must be pulled tightly. Use a blanket to avoid
contact scrapes between steel cable and machine.
f. Avoid the dangers of collision: Please remove the obstacles around the lifting area and operate
all control switches carefully.
g. When the machine is lifted up, please check if any pipes are dropped out.
h. The operator should not operate crane and hoist under the area of the hoisted machine.

4.1.2 Machine Weight

Model AA965 AA1165 AA1365 AA1565
Weight (kg.) 6,800 7,000 7,400 7,600

4-2

4.1.3 Hoisting diagram
Figure 4-1 Hoisting diagram for AA965/AA1165

Figure 4-2 Hoisting diagram for AA1365/AA1565


4.1.4 Forklift Truck Transportation
Please pay attention to transport and lift this high precision machine for avoiding any strong
extrusions or collisions. The lifting capacity of forklift truck must be sufficient for the machine.
Figure 4-4 shows the suggested forklift truck capacity.
Figure 4-3 Lifting diagram of forklift truck (AA965/1165/1365/1565)

4-4

Item
T (ton) H (mm) L (mm) W (mm) P (mm)
Model
AA 965
AA1165 2700
15 120 260 1400
AA1365
AA1565 2800
Figure 4-4 The forklift truck capacity


4.2 Axes Locking and Machine Packaging

4.2.1 Axes locking off
To reduce the vibration caused in transportation and to ensure the axes load in safe range, as the
following table and figure show, the machine has several fixtures to fix axes, front door and
control panel.
Code Description Quantity

A Front door fixture 2
B X axis fixture 1
C Control panel fixture 1
D Z axis fixture 1
E Y axis fixture 2

4-6

4.2.2 Wooden packaging for transportation
Machines to export are packed in specialized wooden box. Iron frames as the support base, full
enclosure box, and Styrofoam or foam rubber filled the remaining space ensure machines safe
when they are shipped.
There are some cautionary markings on the outside of the wooden box as shown below. Please
follow the items’ special care in transportation.

mark indication
Keep Dry
Fragile
This Side Up
Center of Gravity

Packaging and positioning layout:


4.3 Precaution after Opening Package

a. Check over the machine if there is damage.
b. Check over the accessories enclosed with the machine, such as auxiliary tools, document,
manuals, etc.
c. After wooden box is unpacked, the timber and the rest of the package should be properly
disposed or on-site personnel might be hurt by the nails or other sharp-edged objects.
d. Look over the machine if there is rust or peeling painted surface.
e. Make sure the machine can be installed on the site steadily.
f. Make sure all the piping connection and electrical connection are securely held.
g. Make sure if the screws of guards are securely fastened.
h. Check the whole machine according to the specifications listed in manuals or catalogue.
After the customer has checked the machine, if there is any fault, damage, or the specification out
of accord with manuals or catalogue, please contact WELE company or local authorized agent
for further services.

4.4 Storage Condition

This machine has processed through the antirust treatment before packing up, and the storage
period could be maintained for 3 three months under dry and drafty circumstance. Please keep the
following storage conditions of circumstance:
a. Ambient temperature: -25℃ ~55℃, and up to +70℃ for short periods less than 24 hrs.
b. Relative humidity: 30% to 95% (without condensation phenomenon.)
c. Free from the atmosphere conditions of excessive dust, acid fume, corrosive gases and salt.
d. Avoid exposing the machine to outdoor or direct sunlight.
f. Avoid exposing the machine to the frequent abnormal vibrations.

4.5 Precaution on Installation

a. The integral lighting source must be sufficient and suitable during the machine installation.
b. Reserve the open spaces of chip tank, electrical box door, and side door.
c. Do not place the machine on the easy-vibrating site, such as the area near punching machines.
The installation site should be free from abnormal vibration.
d. The ground surface of installation site must be smooth and stable for benefiting the leveling
adjustment.
e. The installation site should be free from the direct sunlight exposure for avoiding the thermal
deformation.
f. The installation site should be refrained from the chips, coolant, dust, oil spray, and any other
dangerous material.

4-8

4.6 Leveling Adjustment

After machine is located onto the installation site, it should be adjusted by the level gage. The
leveling adjustment here is to eliminate the torsion, bend, sag, or any deformations of base.
While the leveling adjustment is completed, the foundation bolts should bear the machine weight
averagely.
a. Initial leveling
Move the table to the stroke center of machine, and place a level gage on X axis and Y axis
each. Then, adjust the gage to 1 division: about 0.02 mm/m.
b. Precision Leveling
Place the gage with magnetic stand on spindle, and rotate 360 degrees to measure the surface
of table. Then, adjust the level for keeping the perpendicularity between spindle and table
within 0.01mm. (Shown as Figure 4-5)
Figure 4-5 The perpendicularity between spindle and table

5. Preparation before Trial Run 5-1

5. Preparation before Trial Run
5.1 Cleaning
Before the shipment of the machine, there was the anti-rust process. The movable parts are
protected by grease, and others are protected by anti-rust oil. Please remove the grease or
anti-rust oil by soft cloth with kerosene; after removing them, please protect those parts with
lubrication oil. While removing the grease and anti-rust oil, make sure that the cleaner will never
go into the wipers or spindle.

5-2

5.2 Removing Protection Attachment

To keep the moving parts being fixed during the shipment, there are fixtures to fix the moving
parts. Please remove the fixtures before the trial run. There are the fixtures as being listed below:
Figure 5-1 Location of the fixtures for AA Series


5.3 Replenishing Lubricant

Please refer to Chap.1.5 for the locations of lubricant replenishment.
Please refer to the following table for the recommended lubricants.
Before the shipment of the machine, there is not any spindle coolant in gear box (gear drive).
Please replenish it before the trial run. The amount for AA965/1165/1365/1565 is 9L. Check the
other replenishing points listed in Chapter 1.5 and replenish it if necessary.

5-4

5.4 Air Supply

1. The required pneumatic air pressure is 4~7kgf/cm2, the pneumatic air must be dehumidified to
ensure the lifetime of related components.
2. Use 3/8” quick coupling to connect the air source and the air RFL device.
3. Please ensure that the flow rate of the air-compressor is sufficient.
5.5 Coolant Supply

1. Fill the coolant tank with the coolant; note that the level of the coolant must be lower than the
upper limit of the level gauge.
2. Connect the hoses between the machine and the coolant tank.
3. Start the pumps, and check whether the pumps work normally.
4. The volume of the coolant tank of AA965/AA1165/AA1365/AA1565 is about 430L.

5.6 Electricity Connection and Grounding Method

1. In according to Chap 3.2, connect the power source. A transformer is required while the power
source is not 3-phase 220V.
2. Connect the cables of the spindle oil cooler.
3. In according to the wiring table, connect the cables which are disconnected before the
shipment.
4. Refer to Chap 3, firmly ground the machine.
5. Check whether the 3-phase motors of the machine are reversed rotating.
6. Check each servo unit and component.

5.7 Safety Inspection

5.7.1 Inspection before power on
No. Items Checking procedure
1. Check whether there is lot of water in the dehumidifier.
Pneumatic
1 2. Check whether the lubricator has sufficient oil.
devices
3. Check whether the pneumatic air pressure is 6.5kgf/cm2.
1. Check whether the oil level is ok.
2 Spindle oil cooler
2. Check whether the hoses are secured.
1. Check whether the tank is leveled.
Tank, 2. Check whether the coolant is sufficient.
3
chip conveyor 3. Check whether the hoses are secured.
4. Check whether the cables are secured.
4 Spindle 1. Check the cleanness of spindle taper.
5 Table 1. Check the cleanness of table surface.
1. Check whether the cables are firmly connected to their terminals.
6 Electric cabinet
2. Check whether the door of the electric cabinet is closed and locked.


5.7.2 Inspection after power on
There are several labels on the machine for electric hazard warning. After connecting the power
line, never open the door or remove the cover of the electric cabinet to prevent electric hazard.
No. Item Checking procedure

1. Check whether there is any noise or abnormally high
1 Motors
temperature.
1. Check whether the pneumatic air pressure is 6.5kg/cm2.
2 Air RFL unit
2. Check whether there is any leakage.
3 Spindle oil cooler 1. Check whether the setting of the temperature is ok.
4 Controller monitor 1. Check whether there is any alarm message.
5 Chip conveyor 1. Check whether it works normally.
6 Door interlock 1. Check whether it works normally.
1. Check whether the pumps work normally.
7 Tank and pumps
2. Check whether there is any leakage.

5.7.3 Manual operate inspection
Item Result
1 Movement of each axis □OK □NG
2 Over-travel protection □OK □NG
3 Zero return □OK □NG
Spindle rotation/reverse □OK □NG
4 clamping/unclamping
Tool magazine/tool changer □OK □NG
5 functions
6 CE door interlock □OK □NG

5-6

5.8 Warm-up Description

Warm-up before the machining job is very helpful in lubricate the machine and increase the
stability, thus a better machining job will be achieved. Usually this procedure is to move the axes
in full strokes and also to start the spindle, from lower feed rate and low spindle speed, gradually
increasing the feed rate and spindle speed. Please refer to the following table for the
recommended warm-up procedure:
Item
Operation
Spindle Feed Time(min) Checking items
Situation
Speed(rpm) rate(mm/min)
500 1000 10 1.Temperature
Daily
2000 2000 10 2.Vibration
operation
4000 2500 10 3.Noise
500 1000 15
Stop for 1.Temperature
1500 1500 more than
15 2.Vibration
3000 2000 48 hours 15 3.Noise
4500 2500 15
Note: If there is spindle tool, or work piece and jigs on the table, please modify the strokes to
prevent collision.

Table 5-1 Procedure of warm-up for high-speed spindles

6. Setting and Adjusting 6-1

6. Setting and Adjusting
6.1 Structural Setting and Adjusting

6.1.1 Adjusting of gibs
The surface of the guideway is machined, hardened and ground so that the smoothness and
geometric accuracy is excellent; Turcite B is attached to the surface of sliding part, automatic
lubrication is applied to the sliding surface to reduce the friction and worn-out. Moreover, to
ensure the sliding surface being contacted properly with the guideway, we apply a rigid-type
fixing of the gibs. If the gib is too tight that makes friction too large, it will cause the poor
lubrication and worn-out of the sliding surface. To ensure the required dynamic accuracy, the
tightness of gib needs some adjustment. Please refer to the following procedure to adjust it.

6-2

a. Adjustment of X-axis gibs (Table)
Step 1. Move the table to the middle of X-axis stroke in handle mode.
Step 2. Remove the bolts of the X-axis telescopic covers, push covers to shortest length.
Step 3. Remove the sheet covers in front and back of the table.
Step 4. Remove the wipers for the slide ways of the table.
Step 5. Remove the fixing block, adjust the tightness of gibs into the tolerance.
Step 6. Secure the fixing block, move-in the screw until it touches the gib’s end surface.
Step 7. Remove the fixing block, measure the length what the screw exceeds surface A.
Step 8. Mill the surface B, the depth is identical to the length measured in previous step.
Step 9. Secure the block again, and secure the screws on the block.
Step 10. Recover the wipers and covers.


b. Adjustment of Y-axis gibs (Saddle)
Step 1. Move the saddle to the middle of Y-axis stroke in handle mode.
Step 2. Remove the bolts of the Y-axis telescopic covers, push covers to shortest length.
Step 3. Remove the wipers for the slide ways of the saddle.

6-4

c. Adjustment of Z-axis gibs (Spindle head)
Step 1. Move the head to the upper limit of Z-axis stroke in handle mode.
Step 2. Remove the bolts of the Z-axis telescopic cover, push cover to shortest length.
Step 3. Remove the sheet covers of the head.
Step 4. Remove the wipers for the slide ways of the head.


6.1.2 Leveling ajusting
When the machine is settled on its foundation, it’s necessary to level it precisely. The good
leveling of the machine can keep the machine’s geometric accuracy, eliminate the twist of the bed,
and keep the straightness of the slide ways. Bad leveling will cause poor work piece surface,
vibration, and even the breakdown of the machine. The procedure of leveling:
a. Move the table and saddle to the middle of their strokes.
b. Put the level on the center of the table. Then perform the leveling.
c. Adjust the perpendicularity between the table surface and the spindle center line.
d. Make sure the leveling bolts are firmly supported on their foundations.
e. Check the level again in six months after installation.

6.1.3 Adjusting of pull stud kick-out amount
There is a 5mm gap between the top of pull stud and the collet cap, and it is required to have a
0.8mm kick-out amount to ensure the completely unclamping. The following is the procedure to
adjust the gap:
a. Tool is not completely unclamped (please refer to Figure 6-1)
(1) The most possible reason is that the collet cap does not hit the pull stud during the
unclamping. Adjust the bolt on the bottom of the piston-rod of the unclamping cylinder to
shift its position.
(2) After the adjustment, secure the locking nut of the mentioned bolt, and check whether the
limit switches of the unclamping cylinder can be activated normally.
(3) In handle mode, check the unclamping function several times, make sure this function is
ok. Then it is allowed to perform the automatic tool changing.
(4) If the ambient temperature is very low, the oil of the unclamping system may become
much viscous and then cause a slower response. In this case, please manually unclamp the
tool several times to rise the oil temperature.
Figure 6-1 Tool is not completely unclamped

6-6

b. Adjust the amount of kick-out (please refer to Figure 6-2)
(1) While without spindle tool, adjust the bolt on the bottom of the piston-rod of the
unclamping cylinder to get the 5mm gap between this bolt and the top of the drawbar.
(2) Mount the tool holder, which has no tool, in the spindle. Apply an indicator and set the
probe to touch the tool holder. Manually push the tool holder upwards and unclamp the
tool holder. If the kick-out amount is not 08.mm, please adjust the mentioned bolt again
until ok.
(3) Secure the locking nut of the mentioned bolt after the adjustment.
Figure 6-2 Adjust the amount of kick-out


6.1.4 Adjusting of tool changing point (carousel type)
(1) If the stroke limit of tool changer is not correct
Release the fixing bolts of tool changer, use the block to adjust the stroke. In this case the
limit switches don’t need any adjustment.
(2) If the tool changer in not aligned in the Y direction
Release the fixing bolts of the support bracket, use the block to adjust it.

6.1.5 Adjusting of tool changing point (arm type)
(1) If the tool changer is not aligned in the X direction
Release the fixing bolts of tool changer, use the block to adjust its position.
(2) If the tool changer is not aligned in the Y direction
Release the fixing bolts of the support bracket, use the block to adjust its position.

6-8

6.1.6 The Adjustment of the CAM-ATC mechanism
(1) CAM-ATC mechanism
Item 1 2 3 4 5 6 7
Name Oil inlet Eccentric Oil drain Air breezer Sensors Sensor of Level sight
plate of counter in-position
and brake


(2) ATC Sequence of tool changing
Step Movement
After spindle
orientation, tool
1 socket tilts down.
The arm rotates 60° to

position A, the
2 grasper holds the
tools, and spindle
tool is released.
The arm goes down
to pull out the tools.
3
After pulling out the

tools, the arm rotates
4 180° to exchange the
tools.
The arm goes up,

tools are sent into the
spindle and the
5
stand-by socket.
Then the spindle tool
is clamped.
After clamping, the
arm rotates back to
6 original position.
The socket moves

back, the whole cycle
7 is completed.

6-10

(3) ATC Time chart


(4) Recover the position of the arm
If there is some interruption during the tool changing so that the arm is stopped in abnormal
position, please follow the procedures to recover it:
a. Press the emergency-stop button to ensure safety.
b. Turn the brake lever to release the brake of the cam motor.
c. Use a wrench to rotate the shaft of the motor. It will cause the moving of the arm.
d. If there is the tool gripped on the arm, please move down the arm, push the pin on the top
surface of the arm to release the gripper, then remove the tool.
e. Move the arm back to its original position, then release the brake lever.
f. Please check the tool management to ensure the correct tool registration.

6-12

6.1.7 Mounting and adjustment of the couplings of the feed system
a. The tolerance in mounting

The tolerance of run-out is 0.02mm. Before secure the bolts on the coupling, please check
whether the coupling can smoothly move along the shaft.
b. To secure the bolts on the coupling, please apply a torque wrench.
The recommended torque of those bolts is:
M6 bolts: 14Nm
M8 bolts: 30Nm

6.1.8 Tool information
#40
#50


6.2 Adjusting and Setting of Pressure

6.2.1 Pneumatic system
a. gear type spindle with chain type ATC system

6-14

b. gear type spindle with disk type ATC system


6.2.2 Circuit control
a. Air condition unit
Fluid to be handled Air

Tubing connection diameters 3/8 Pt
Filtering grade 0.4 µm
Range of pressure setting 5.5~7 Kgf/cm² 550~700 kpal
Max. service pressure 7 Kgf/cm² 700 kpal
Range of service temperature -10~60 ℃
Drain holding capacity of air filter 60 c.c.
Lubricator oil storing capacity 90 c.c.
Recommendable lubricants Turbine oil class 1 (ISO VG 32) or equivalent

6-16

b. Pressure scale
1) Maker: Danfuss
2) Commission: CENEURO ENTERPRISE CO., LTD.
3) TEL : 886-4-2463-3409 / FAX : 886-4-2463-3410
Specification KP35
Pressure setting 6 Bar
Active difference range 0.7~4 Bar
Action range 0.2~7.5Bar
Allowance pressure 22 Bar
Connector size 1/4” PT
Fluid Air
Pressure adjustor


6.2.3 Adjusting and setting of lubrication
1) Lubricator Type : MTE-502FWB-T4A
2) Maker: YEONG-DIEN CO., LTD.
3) TEL : 886-4-25237529 / FAX : 886-4-25248039
TYPE MTE-502FWB-T4A
DISCHARGE VOLUMN 340 cc/min
PUMP DISCHARGE PRESSURE 10 kgf/cm2
POWER 75 W
CAPACITY 4.2L
TANK
VISCOSITY 61.2-74.8 cSt (ISO VG 68)
4) Layout diagram

6-18

6.3 Geometric Precision Adjusting
WELE Mechatronic Co., Ltd. File No.
Name Final Inspection Sheet Version A Page 1
Geometry Inspection Unit: mm
No Item Description Sketch Tolerance Reading
Straightness
of
Set table in middle 0.040
X-directional
of Y-stroke, put / /
movement of m m
precise level on table,
the table
move the table along
(X-Z plane)
X-direction and take
the readings in both
Straightness ends and middle. The
of max. difference in
X-directional 0.040
each direction is the
/ /
movement of straightness in X and m m
the table Y axis.
(Y-Z plane)
1
Set table in middle of

Y-stroke, put the
Straightness straight gauge on
of table and set the 0.007
X-directional indicator, move the
/ /
movement of table along
the table X-direction and take 500 500
(X-Y plane) the readings. The
max. difference is the
straightness.


WELE Mechatronic Co.,Ltd. File No.
Straightness
of Set table in middle of 0.040
Y-directional X-stroke, put precise / /
movement of level on table, move
the table (X-Z m m
the table along
plane) Y-direction and take
the readings in both
ends and middle. The
Straightness
max. difference in
of 0.040
each direction is the
Y-directional
straightness in X and / /
movement of
Y axis. m m
the table (Y-Z
plane)
2
Set table in middle of

X-stroke, put the
Straightness straight gauge on
of table and set the 0.007
Y-directional indicator, move the
/ /
movement of table along
the table Y-direction and take 500 500
(X-Y plane) the readings. The
max. difference is the
straightness.

6-20

Put straight gauge

on table and
indicator on L-plate,
Straightness of 0.007
move the L-plate to
the table (X-Z / /
measure the straight
plane) 500 500
gauge. The max
difference is the
3 straightness. The
straight gauge
should be located in
edges and middle, in
Straightness of 0.007
X and Y directions.
the table (Y-Z / /
This item can also
plane) 500 500
be done by a level in
chain measuring.
Stroke
Attach indicator on 500~1000
head and calibrate 0.025
Parallelism
zero to the straight
between
gauge, move the
4 X-directional
table along
movement and
X-direction. The
table surface
max. difference is Stroke
the parallelism.
1000~2000
0.030


Attach indicator on
head and calibrate
Parallelism
zero to straight
between
gauge on the table,
5 Y-directional 0.020
move the table
movement and
along Y-direction.
table surface
The max. difference
is the parallelism.
Attach side surface

of L-slide to side Stroke
surface of basic 500~1000
Parallelism
T-slot, attach
between 0.020
indicator on head
X-directional
and calibrate zero
6 movement and
to L-slide side
the side surface
surface, move the
of the basic
table along Stroke
T-slot.
X-direction. The
1000~2000
max. difference is
the parallelism.
0.030

6-22

Set table and saddle

in middle of both X
& Y strokes, put
perpendicular
gauge on table
surface, attach
Perpen- indicator on head 0.010
Dicularity and measure the
/ /
between axes side surface of the
(X-Y axis) gauge. Adjust the 300 300
gauge to be parallel
to the X-axis, then
take the reading of
max. difference in
Y-directional
movement.
7

in middle of both X
& Y strokes, put
perpendicular
gauge on table
surface, attach
Perpen- indicator on head 0.015
dicularity and measure the
/ /
(X-Z axis) gauge. Adjust the 300 300
to the X-axis, then
take the reading of
max. difference in
Z-directional
movement.



in middle of both X
& Y strokes, put
perpendicular
gauge on table
Perpen- surface, attach 0.015
dicularity indicator on head
7 and measure the / /
(Y-Z axis) gauge. Adjust the 300 300
to the Y-axis, then
take the reading of
max. difference in
Z-axis movement.
Straightness of
Z-directional in middle of both X
0.005
movement of and Y strokes, put / /
the head (X-Z perpendicular
gauge vertically on 300 300
plane) table surface, attach
indicator on head
8 and measure the
surface of the
gauge. Then take
Straightness of the reading of max.
Z-directional difference in 0.005
Z-directional
movement of movement in both / /
the head (Y-Z XZ and YZ planes. 300 300
plane)

6-24

Perpen-
dicularity 0.015
between spindle Set table and saddle
in middle of both X / /
center line and
table surface and Y strokes, attach 300 300
(X-Z plane) indicator on spindle
and measure the
9 surface of the table.
Then rotate the
Perpen- spindle and take the
dicularity reading of max. 0.015
between spindle difference in both XZ
/ /
center line and and YZ planes.
table surface 300 300
(Y-Z plane)
Clamp the arbor in Arbor

the spindle, use
Root:
indicator to measure
the surface of arbor 0.005
Runout of the in the root and the
10 spindle taper end. Then rotate the
spindle and take the Arbor
reading of max.
300mm
difference in both /
sites.
end:
300
0.015


Parallelism
between spindle 0.015
center line &
/ /
Z-direction
movement (X-Z 300 300
plane) Clamp the arbor in
the spindle, probe
of indicator
contact with the
root of arbor,
rotate the arbor to
11 find the center of
run-out. Then
move the head
along Z-direction
Parallelism , take the reading
between spindle of max.
0.015
center line & difference.
/ /
Z-direction
movement (Y-Z 300 300
plane)

6-26

Clamp the tool

holder with steel
ball on the bottom
in the spindle, use
Runout of the indicator to
12 spindle in measure the 0.002
Z-direction surface of the steel
ball. Then rotate
the spindle and
take the reading of
max. difference.
Use indicator to
measure the end
surface of the
Runout of the spindle, the probe
13 spindle end should be near the 0.005
surface rim. Then rotate
the spindle and
take the reading of
max. difference.


Positioning Accuracy Unit: mm
A. Move the specified

axis along one
direction and stop at X
a reference position.
Then move this axis
in identical direction
and in 50% rapid JIS
traverse, with
intervals shown in Standard:
Y
the table. Measure
the difference ±0.003
between command
and physical
movement, the max.
Linear difference within
movement the reference length Z
positionin is the positioning
14 accuracy.
g accuracy
of each
B. Move the specified
axis axis along one
direction and stop at a
reference position. X
Then move this axis in
identical direction and VDI3441
in 50% rapid traverse, (P)
with intervals shown
in the table. Measure Standard:
the difference between
command and physical 0.015 Y
movement, repeat 5
times, the max.
difference within the
reference length is the
positioning accuracy. Z

6-28

Positioning Accuracy Unit: mm

Select an arbitrary
reference position,
move this axis in 50% X
rapid traverse in single
direction and unique
conditions, repeat 7
JIS
times, then measure the
Standard:
difference from original
±0.002
reference position.
Repeat those Y
procedures in both ends
and middle of the
Linear stroke, the repeatibility
movement is plus-minus half of the
15 Z
repeatability max. difference.
of each axis
Select an arbitrary
reference position, X
move this axis in 50%
rapid traverse in single
VDI3441
direction and unique
(Ps mean)
conditions, repeat 5
Standard: Y
times, then measure the
0.006
difference from original
reference position. The
repeatibility is the mean
difference. Z


Circularity Unit: mm
Attach the ballbar on X

the center of the table,
Y
move the ballbar
JIS Standard:
clockwise with 150mm
Circularity XY 0.015 X
radius and
16 of each
3000mm/min feed rate. XZ 0.020 Z
plane
The circularity is the
YZ 0.020
difference between the
Y
max. and the min.
diameter. Z

7. Maintenance 7-1

7. Maintenance
7.1 Preventive Maintenance
To press the emergency stop button or turn off the main

power before to start the maintenance work.

It is a very important factor in maintenance to keep the machine clean. Humidity, mist, oil and
dust will accelerate corrosion on the electrical contact parts that operate intermitted. In order to
execute the maintenance plan effectively, make a schedule for maintenance and observe it
strictly is important even if the scheduled maintenance time interferes with production schedule.
This can lengthen the lives of machine and control system service. It is important to keep the
maintenance record of the control system. It will help you make stock plan and estimated
service lines of the component parts. Preventive maintenance can be held in daily, weekly,
monthly, every 6 months and Yearly maintenance. All of them can be followed the list below.
Checking each item listed below, correcting any abnormal condition and recording all data
properly are the responsibilities of maintenance. Make sure the E-stop button has been
depressed and the main power switch has been turned off before taking care of the following
maintenance. For safety reason, we recommend you to restore all of the data that has been
provided or setting in the controller. Keep all maintenance data in several copies. For your
reference, please follow our data format.

7-2

7.1.1 Inspection before starting, after starting and end of daily operation
a. Inspection before starting
1. Check over the oil level of the oil cooler, air machine, coolant pump, and lubricant pump,
etc.
2. Exhaust the water accumulated in the air conditioning unit.
3. The operator should dress up himself and put on protection devices.
4. Please check over the connection condition of the power source.
5. Please check over the piping connections of coolant and air circuits.
6. The working area around the machine should be free from obstructions.
7. All doors should be kept close right before the starting of the machine.
8. All screws should be securely held, including the clamping status of jigs and fixture.
9. Make sure all the safety devices are in place and functioning.
10. Before being engaged in machining, check the vibration of the tool and spindle and make
sure that there are no unusual phenomena.
b. Inspection after starting

1. Please check over the lubrication condition of all the slide surfaces.
2. Please check whether the lighting device is working normally or not.
3. Please check the readings on the coolant pump gauge, oil cooler, air machine and
lubricant pump whether they are in the specified working range or not.
4. Please check the whole machine whether there are any abnormal sound or condition or
not.
5. Please make sure the supply condition of electricity is normal.
6. Please check whether there is any rupture on the piping element or not.
7. Please check whether there is any leakage between the guards or not.
8. Please check the machine whether there is any abnormal vibration on the moving axes or
not.
9. Please make sure all the machining precision is under the tolerance.
c. Inspection at the end of daily operation

1. The cleaning of the machine must be complete and thorough after finishing the daily
operation. Try to find out the unusual condition of the machine. (Though the air
compressor may be helpful to clean the chips, the operator still should be careful when
operating it.)
2. The dust on the fans of the filters in the enclosure should be cleaned regularly.
3. Turn the power off after operation. The procedure are shown as follows:
1) Push the “EMERGENCY STOP” button on the operation panel.

7. Maintenance 7-3

2) Push the “POWER OFF” switch on the operation panel.
3) Turn off the main switch breaker in the enclosure.
4. Clean the chips up in the chip tank.
5. Because the relays or other electrical elements may be still in high temperature after
turning the power, please do not touch them.
6. If the remaining is under lower limit, replenish the specified oil into tanks. Replace the oil
with new one immediately if the quality of the oil deteriorated.
7. It is necessary to make a review about the machine at the end of operation in order to
maintain the optimum condition of the machine.
8. Please sweep the chips in the interior of the machine into the chip tank.

7.1.2 Weekly, monthly, semiannual, and annual inspection
a. Annual Maintenance Planning
S/N Install Date
Period Est. wk. hrs. Est. Date Act. Date Act. hrs Checked by
(01)Monthly Main.
(02) Monthly Main
(03) Monthly Main
(04) Monthly Main
(05) Monthly Main
(06) Semiannual
Maintenance
(07) Monthly Main
(08) Monthly Main
(09) Monthly Main
(10) Monthly Main
(11) Monthly Main
Annual Maintenance

7-4

b. Maintenance Schedule Table
Machine Preventive Maintenance Schedule
Maintenance Items Daily Weekly Monthly Semiannual Annual Remark
Spindle oil fill-up D W M S A
Spindle taper clean D W M S A
Remove chip from machine D W M S A
Remove chip from table D W M S A
Remove chip from X cover D W M S A
Remove chip from Y cover D W M S A
Wipe off coolant from table - W M S A
Wipe off coolant from covers D W M S A
Check pull stud etc. D W M S A

Remove chip from tools D W M S A
Clean the tools D W M S A
Remove chip from ways D W M S A

Clean the ways - W M S A
Clean up the X,Y ways - - M S A
Check the X,Y ways - - M S A
Adjust the Z way gibs - - - S A
Check if the ways abnormal - - - S A
Remove chip from magazine - W M S A
Remove chip from tool magazine - - M S A

Tool index greased - - M S A
Check tool magazine condition - - - S A
Remove chip from tool pocket - W M S A

Tool pocket clean - - M S A
Check if pocket abnormal - - - S A
Remove chip from ball screws - - M S A

Check the ball screws surface - - M S A
Check if ball screws abnormal - - - S A
Remove chips from level bolt - - M S A

Clean level bolt - - M S A
Check the leveling condition - - - S A
Remove chip from cable carrier - - M S A

Check if cables abnormal - - M S A
Check if cable carrier abnormal - - - S A
Drain X,Y way oil - W M S A

7. Maintenance 7-5

Machine Preventive Maintenance Schedule
Maintenance Items Daily Weekly Monthly Semiannual Annual Remark
Coolant system
Check coolant, refill D W M S A
Remove chip from bucket D W M S A
Clean coolant filter - W M S A
Clean coolant tank - - M S A
Clean pump filter - - M S A
Remove chip from conveyor - - M S A
Remove chip from auger - - M S A
Replace coolant - - M S A
Electric cabinet
Clean filter for exchanger - W M S A
Clean the electric cabinet - - M S A
Clean the electric parts - - M S A
Check elec. components - - M S A
Operator panel
Check illuminate lamps D W M S A
Check push buttons D W M S A
Pneumatic system
Check air pressure D W M S A
Check lub. oil, refill? D W M S A
Drain water from air combi. D W M S A
Check air combin. pressure - - M S A
Adjust air combin. oil value - - M S A
Check solenoid valves - - M S A
Check air cylinders - - M S A
Spindle oil cooler
Check temperature control D W M S A
Check cooling oil, refill? D W M S A
Clean fan filter - W M S A
Check temp. setting - W M S A
Replace cooling oil - - (M)* S A (new M/C)*
Filter replace - - - S A

7-6

c. Maintenance Checking List
Maintenance Inspection List
Period □ D: Daily □ W: Weekly □ M: Monthly □ S: Semiannual □ A: Annual
Machine S/N: Date: Page: 1 / 2
No. Maintenance Items Period Inspection Record
1 Spindle oil fill-up D W M S A □ Done □ None : □ Redo
2 Spindle taper clean D W M S A □ Done □ None : □ Redo
3 Remove chip from machine D W M S A □ Done □ None : □ Redo
4 Remove chip from table D W M S A □ Done □ None : □ Redo
5 Remove chip from X,Y covers D W M S A □ Done □ None : □ Redo
6 Remove chip from machine D W M S A □ Done □ None : □ Redo
7 Check pull stud etc. D W M S A □ Done □ None : □ Redo
8 Remove chip from tools D W M S A □ Done □ None : □ Redo
9 Remove chip from Z way D W M S A □ Done □ None : □ Redo
10 Check if lamps illuminate D W M S A □ Norm. □ Failed : □ Done
11 Check if panel push buttons work D W M S A □ Norm. □ Failed : □ Done
12 Check coolant, refill? D W M S A □ Done □ None : □ Redo
13 Remove chip from bucket D W M S A □ Done □ None : □ Redo
14 Check temperature control D W M S A □ Norm. □ Failed : □ Done
15 Cooling oil, refill? D W M S A □ Done □ None : □ Redo
16 Check air pressure D W M S A □ Norm. □ Failed : □ Done
17 Check lubricating oil D W M S A □ Norm. □ Failed : □ Done
18 Drain water from air comb. D W M S A □ Done □ None : □ Redo
19 Check weight balancer D W M S A □ Done □ None : □ Redo
20 Check hydraulic oil level D W M S A □ Norm. □ Failed : □ Done
21 Clean up table - W M S A □ Done □ None : □ Redo
22 Clean X cover - W M S A □ Done □ None : □ Redo
23 Remove chip from magazine - W M S A □ Done □ None : □ Redo
24 Remove chip from pocket - W M S A □ Done □ None : □ Redo
25 Clean tools - W M S A □ Done □ None : □ Redo
26 Clean tool holders - W M S A □ Done □ None : □ Redo
27 Clean Z ways - W M S A □ Done □ None : □ Redo
28 Drain X,Y way oil - W M S A □ Done □ None : □ Redo
29 Clean exchanger filter - W M S A □ Done □ None : □ Redo
30 Clean up coolant filter - W M S A □ Done □ None : □ Redo
31 Clean fan filter - W M S A □ Done □ None : □ Redo
32 Check temperature setting - - M S A □ Done □ None : □ Redo
33 Replace cooling oil - - M S A □ Done □ None : □ Redo
34 Remove chip from magazine - - M S A □ Done □ None : □ Redo
35 Remove chip from X,Y ways - - M S A □ Done □ None : □ Redo
36 Greasing X,Y ways - - M S A □ Done □ None : □ Redo
37 Remove chip from screws - - M S A □ Done □ None : □ Redo
Approved Checked Inspected

7. Maintenance 7-7

Maintenance Inspection List
Period □ D: Daily □ W: Weekly □ M: Monthly □ S: Semiannual □ A: Annual
Machine S/N: Date: Page: 2 / 2
No. Maintenance Items Period Inspection Record
38 Clean X,Y screws --MSA □ Done □ None : □ Redo
39 Remove chip from level bolt - - M S A □ Done □ None : □ Redo
40 Clean level bolts - - M S A □ Done □ None : □ Redo
41 Remove chip from carrier - - M S A □ Done □ None : □ Redo
42 Remove chip from cable - - M S A □ Done □ None : □ Redo
43 Remove chip from column - - M S A □ Done □ None : □ Redo
44 Clean elect. cabinet - - M S A □ Done □ None : □ Redo
45 Clean elect. parts - - M S A □ Done □ None : □ Redo
46 Check elect. components - - M S A □ Done □ None : □ Redo
47 Clean coolant tank - - M S A □ Done □ None : □ Redo
48 Clean pump filter - - M S A □ Done □ None : □ Redo
49 Remove chip from conveyor - - M S A □ Done □ None : □ Redo
50 Remove chip from auger - - M S A □ Done □ None : □ Redo
51 Check air combin. pressure - - M S A □ Norm. □ Failed : □Done
52 Check air combin. oil value - - M S A □ Norm. □ Failed : □Done
53 Check Hyd. solenoid valve - - M S A □ Norm. □ Failed : □Done
54 Check Pneu. solenoid valve - - M S A □ Norm. □ Failed : □Done
55 Check Hyd. pressure setting - - M S A □ Norm. □ Failed : □Done
56 Check oil pipe leaking? - - M S A □ Norm. □ Failed : □Done
57 Check Hyd. cylinders? - - M S A □ Norm. □ Failed : □Done
58 Check tool index fail? - - - S A □ Norm. □ Failed : □Done
59 Check tool pocket fail? - - - S A □ Norm. □ Failed : □Done
60 Adjust Z gibs - - - S A □ Done □ None : □ Redo
61 Check ways fail? - - - S A □ Norm. □ Failed : □Done
62 Check screws fail? - - - S A □ Norm. □ Failed : □Done
63 Check level bolts fail? - - - S A □ Norm. □ Failed : □Done
64 Check if cable carrier fail? - - - S A □ Norm. □ Failed : □Done
65 Replace coolant - - - S A □ Done □ None : □ Redo
66 Replace Hyd. filter - - - S A □ Done □ None : □ Redo
67 Replace Hyd. oil - - - - A □ Done □ None : □ Redo
Approved Checked Inspected

7-8

a. Weekly inspection
1. Check over the remaining level of oil cooler, coolant tank and lubrication tank.
2. Check the air or lubricating piping whether the elements are securely held or not.
3. Check over the lubrication condition of all the sliding surfaces.
4. Check over the connection of electric circuits.
5. Remove the chips stuck on the surface of the chip tank.
6. Check the moving parts of the machine whether they are in normal condition or not.
7. Exhaust the water accumulated in the air conditioning unit.
8. Check over the temperature of the oil cooler for the spindle cooling.
b. Monthly inspection
1. Check the coolant whether the water content is proper or not.
2. Check over the oil level of the tool unclamping cylinder.
3. Clean the filter of the oil cooler for the spindle cooling.
4. Check over the assembly condition of switches.
5. Check over the supply condition of the hydraulic, pneumatic or electrical devices.
6. Check if there is any leakage on the splash guards.
7. The linkage condition of the chain drive of the counterbalance should be checked. The set
screw and the guard cover outside of weight block should also be checked, and can't detach
the set screw arbitrarily.
c. Quarterly inspection
1. Check over all the screws, bolts, nuts and joints for firmness.
2. Make sure the coolant has not been deteriorated.
3. Check over the seals or packing whether there is leakage or breakage or not.
4. Make sure the clearance between the ends of the push rod and draw bar is proper.
(including the check of elastic force of the disc spring.)
5. Check the lubrication condition on the slide ways whether there are the situations of
becoming rusty and lubrication breakage.
6. Check over the air and lubricant inlets for the leakage.
d. Annual inspection
1. Check over the strainer for cleaning or replacement.
2. Check over the micro separator for cleaning or replacement.
3. Check over the return filter for cleaning or replacement.
4. Check over the air breather for cleaning or replacement.
5. Check over the tanks for cleaning or replacement.
Note: See the procedures in section 3 of this chapter, which describes how to execute the
above maintenance.

7. Maintenance 7-9

7.2 Lubrication Maintenance Method

7.2.1 Note and maintenance of the ratio distribution controller
1. Input power source should be same as pump indication power.
2. Please be sure ground connected for safety.
3. When refill the oil, please be sure it through the net.
4. When the net was impurities, please be sure to clean it.
5. Control circuit in the pump can’t be soaked by oil or water or other things to avoid breakdown.
6. Please follow the instruction when refill the oil.

7.2.2 Lubrication verification on sliding surface
1. Make sure that the surfaces are covered by the oil film. Touch the sliding surfaces with
fingers directly.
2. By way of visual observation, maybe there is oil in the piping line, but there is no oil
running out. Please take apart the piping fittings and check over the flow condition if this
situation happens.

7.2.3 Manual lubrication method
The lubrication oil film may be broken if the machine has not been operated for a long time. In
this case the ball screws and the sliding surfaces may wear and even get burned out. So it will be
better to force the lubricating pump running manually in order to make surfaces lubricated
properly when the machine having been suspended for a long time.
Procedure 1
i-on
1. Turn on the power.

i-on
o-off
2. Check the lubrication oil level of lubricator.

3. Please increase oil first if the oil level is under
red line.
Procedure 2
1. Push down the manual button for 40 seconds.
2. Release the button and check if there is any oil
out from the lubrication point.
Please do not push the button continuously over
1 minute in order to protect the pumping motor.
3. If there is no oil flowing out, repeat the step 1
until the oil is flowing.

7-10

7.2.4 Lubricant replenishing method of headstock (gear drive)
Check the oil level at the level glass in front of headstock periodically. Replenish specified oil if
the remaining is under lower limit. Replenishing method is shown as follows.
1. Before oiling, be sure to turn off the power of the machine tool.
2. Unplug the plug which is on the left side of headstock with a wrench.
3. Add oil up to the middle level of oil level glass from this oiling port. Excess oil will
overflow from the oil spill block.
4. Plug the plug back and turn on the power of the machine tool. Watch through the sight
glass and check whether the oil sprays. If oil doesn’t spray, the copper tube might be
clogged.
5. It is necessary to replace oil when oil quality deteriorates. Take the drain cover away to
drain the whole deteriorated oil out before oiling.

7. Maintenance 7-11

7.2.5 Troubleshooting

(1)
The capacity of oil reservoir is 4.2 L. When
the oil is decreased to a low level where the
float switch is actuated, and an alarm
message will be issued.
(2)
When the system does not run automatically,
please check the following items:
-Is the oil enough in the reservoir?
-Is there any air getting in the piping lines?
-Is there any breakage in the piping lines?
-Is there any breakdown of the float switch?
(3)
It has to take apart the seal plugs at the
distributor in the ending lubrication in order
to get rid of the air in the pipe.
(4)
1. Push down the manual lubricating button
in order to remove the air in the main
pipe.
2. Repeat the procedure until there is no air
in pipe.

7-12

(5)
After the air has expelled, fasten and restore
the seal plug.
(6)
Take fittings apart in the branch pipes.
(7)
1. Push down the manual lubrication button
to remove the air in the branch pipes.
2. Fasten and restore the fittings after the air
has been expelled.

7. Maintenance 7-13

7.3 Cleaning and Replacement Method

Please refer to Chap.5.3 for the recommended lubricants.
7.3.1 The cleaning method of the lubrication oil reservoir

a. Normal cleaning
(1)
1. Turn cap on of lubricator.
2. Take out the filter.
(2)
1. Clean the filter by cleaner.
2. Dry the filter by clean rag.
b. Oil reservoir cleaning

(1)
1. Turn off the power.
i-on
i-on
o-off

7-14

(2)
1. Loose the screws 2 of the lubricator.
2. Loose the screws 1 of reservoir to take down the reservoir.
(3)
1. Use the cleaner to clean the dirt in reservoir.
2. Use the clean rag to dry the reservoir.
*Do NOT remain any cleaner fluid in the reservoir.

7. Maintenance 7-15

(4)
1. Please restore the reservoir and fasten the screws 2.
2. Please restore the reservoir and fasten the screws 1.
(5)
1. Please open the cap of the lubricator.
2. Please fill the specified lubrication oil into the reservoir.
3. Please keep an eye on the level of the oil and don’t let the oil spill out.

7-16

(6)
1. Please restore the cap of lubricator and fasten it.
2. Turn on the power of machine.
(7)
1. Please push down the manual button.
2. Let the lubrication oil flow into the sliding surfaces.
3. Check the all the sliding surfaces, and make sure all the surfaces are covered by the oil.

7. Maintenance 7-17

7.3.2 Air condition unit
a. Maintenance of air filter
(1)
1. Please set the machine in the manual mode and stop all the movement.
2. Refer to Chap 6 and check the pressure switch of air condition.
3. If the pressure doesn’t descend, you won’t need to maintain this unit.
(2)
1. Please dismantle the quick joint from air source and connect it after one minute if
the pressure descend.
2. Check the pressure again.
3. If the pressure is not normal, please contact with our service person, air condition
maker or salesman.

7-18

(3)
1. The air condition unit is fit with auto drain system in low pressure.
2. When the pressure is lower than the drain pressure, the system will automatically
drain.
3. If the air condition can not drain automatically, please contact with our service
person, air condition maker or salesman.

7. Maintenance 7-19

b. Compressed air system for linear scale
Optical scales with a slight overpressure could get a better degree of protection against
contamination. The compressed air introduced onto scales must be cleaned by a filtration
system and must comply with specific quality classes. So please do the maintenance work for
compressed air system and replace the filter elements periodically to ensure filtration
performance.
There are two kinds of SMC filtration system explained in this section. Please follow the
instruction to do the maintenance work.
Type A.
In order to extend the lives of filtration system, please execute the maintenance work for
compressed air system periodically.
Dew point detector
Inlet Outlet
(to encoders)
AR20-02E
G36-P4-01-X30
AFD20-02C
IDG5-02-S
AFM20-02C
AF20-02C
VX2120-02-5DZ1
Figure 7-1 SMC filtration system (Type A)
Table 7-1 shows the specification and replacement conditions of consumables for filter
components. Please check them periodically and exchange if necessary.
Table 7-1 Consumable Spec. and replacement condition

Vender Component Consumable Spec. Part Replacement condition
AF20-02C AF20P-060S filter elements
1. using after 2 years
AFM20-02C AFM20P-060AS filter elements
2. when pressure below 0.1MPa
AFD20-02C AFD20P-060AS filter elements
SMC
The detector becomes white or
IDG-EL5 filter elements pink. (Blue is normal.)
IDG5-02-S
dew point 1. using after 2 years
IDG-DP01 detector 2. The detector becomes brown.
1 bar = 0.1 MPa

7-20

Type B.
Make sure there is an additional air drier to be preceded the filtration system, and the input
pressure’s dew point is below +3℃. In order to extend the lives of filtration system, please
execute the maintenance work for compressed air system periodically.
Inlet: pressure dew Outlet

point +3℃ (to encoders)
AR20-02E
G36-P4-01-X30
AFD20-02C
AFM20-02C
AF20-02C
AMG250C-03BD
VX2120-02-5DZ1
Figure 7-2 SMC filtration System (Type B)
Make sure the water strainer (AMG150) is functioning well. Refer to Figure 7-3. Turn the
valve switch under the strainer to “S”. If want to drain manually, turn the switch to “O”.
Open Close
Figure 7-3 AMG automatic drain valve
Table 7-2 shows the specification and replacement conditions of consumables for filter
components. Please check them periodically and exchange if necessary.
Table 7-2 Consumable Spec. and replacement condition

Venter Component Consumable Spec. Part Replacement condition
AF20-02C AF20P-060S filter elements 1. using after 2 years
AFM20-02C AFM20P-060AS filter elements
SMC 2. when pressure below
AFD20-02C AFD20P-060AS filter elements
AMG150-02D AMG-EL150 filter elements 0.1MPa
1 bar = 0.1 MPa

7. Maintenance 7-21

7.3.3 Coolant tank
Use safety protective equipment. Wear gloves, eye or face protection, and safety-toe shoes can
help avoid injury.
a. The replacement of the coolant
1. The coolant volume should be kept constantly, and do not let any foreign substance mix
with it.
2. The coolant should be usually kept clean.
3. Please periodically clean the strainer. The flow rate of the pump will decrease if the strainer
gets clogged up.
4. The coolant’s replacement period depends on the cutting material and coolant fluid.
5. Please replace the coolant immediately if it turns turbid.
(1)
1. Please turn the power off.
(2)
1. Please take the chip bucket out.

7-22

(3)
1. Please pump the waste water which is in the tank to waste water bucket.
(4)
1. Please replenish new coolant into the coolant tank.
2. Observe the coolant level and do not let the coolant spill out.
3. Please restore the chip bucket after replenishing.

7. Maintenance 7-23

(5)
1. Please turn on the power, and set the machine in the “manual mode”.
2. Please start the pump and listen to the coolant’s suction voice.
3. Identify the function of the pumping system.
4. Make sure that the coolant flows out of the spraying pipes.
b. The cleaning of the coolant tank

1. The cleaning period of the coolant tank is about 1800 operation hours.
2. The cleaning period of the chip bucket is once per day at least.
(1)
1. Please turn off the power.
2. Dismantle all the coolant pipe and electrical cable.
3. Take the chip bucket out and purge the chip.
4. Clean the filter on the bucket by air gun.

7-24

(2)
1. Please pump the water in the tank to the waste water bucket.
2. Please dismantle the pump.
(3)
1. Please pull out the coolant tank from the machine.

7. Maintenance 7-25

(4)
1. Please dismantle the motor seat and cover.
2. Please clean the interior of the coolant tank.
3. Restore the motor seat and cover.
(5)
1. Please restore the coolant tank.
2. Please restore the pumps.

7-26

(6)
1. Please replenish the new coolant into the coolant tank.
2. Observe the coolant level and do not let the coolant spill out.
3. Please restore the chip bucket after replenishing.
4. Please restore the chip bucket and all the coolant pipe and electrical cable.
(7)
1. Please turn on the power and set the machine in the “manual mode”.
2. Please start the pump and listen to the suction voice of coolant, then identify the
function of the pumping system.
3. Please make sure that the coolant flows out of the spraying pipes.

7. Maintenance 7-27

7.4 Maintenance of Windows

7.4.1 Window dimension

7-28

7.4.2 The Replacement method of the PC windows
1. Replacement period: 1 year
2. The replacement procedure are shown as follows:
(1)
1. Turn off the power.
(2)
1. Please loosen the screws on press
plate of windows.
2. The sequence of press plate’s
dismantling: (1>2>3>4)
3. 1, 2, 3 and 4 are the press plates.
(3)
1. Please clean the surface between
the guard and window.
2. Restore the new PC window.
3. Please turn on the power.
4. The sequence of press plates
installation: (4>3>2>1)
5. 1, 2, 3 and 4 are the press plates.

7. Maintenance 7-29

7.5 Waste Disposal

a. The waste oil and water disposals
(1) Please observe the local law to dispose the industrial wastes. Do NOT abandon the waste
water, oil at will.
(2) The possible way to cope with waste water and oil is to gather them into a storage container,
and then entrust it to professional factory.
(3) The waste water and oil may be toxic. Please do NOT reuse them again. It may cause
damage to the components of the machine.
b. The waste material disposals:

(1) The disposal of the waste material is to gather it into a container firstly. Then depend on the
local law to retreat.
(2) Entrust the waste collector to properly dispose of the waste material.
(3) Please do NOT abandon or dump the waste materials at will.

7.6 Personal Protective Equipment

Personal protective equipment is used to provide a protective barrier between the personnel and
the hazards in the workplace. Personal protective equipment includes equipments such as
chemical resistant gloves, gowns, aprons, safety shoes, hard hats, safety glasses, face shields
and respirators. The personnel should properly wear the personal protective equipment during
operation.

7.7 Fire Extinguisher

Fire safety is tremendous important. Each workplace must have a full complement of the proper
type of fire extinguisher for the fire hazard presences. All workplace ignition sources such as
smoking, welding, burning etc., must be properly controlled. DO NOT CUT THE
FLAMMABLE MATERIAL (like: Magnesium base, wooden, graphite, plastic, etc.) by
operating of the machine to avoid any possibility of fire.

8. Operator Panel 8-1

8. Operator Panel
8.1 LCD & MDI Panel

RETURN

GO FORWARD
BACK

FUNCTION KEY

A. Program Editing Keys
Press this key to display the position screen: indicating the current
position of the slides.
Press this key to display the system screen: the setting of the
System Diagnostic data and System parameter data.
Press this key to display the program screen.

In [EDIT] mode, the cursor can be moved any needed command
by using the cursor Forward or Reverse. In [MDI] mode, the
cursor can be input the data to the buffer memory. In [AUTO]
mode, the cursor can be displayed current commands.
Press this key to display the message screen.
Press this key to display the offset/setting screen. Repeatedly

pressing this pushbutton will alternately display on chapter or the
other.

8-2

Press this key to display the graphics screen.
HELP key:
Display the operation instruction of an MDI key, and detail texts
of alarm messages.
This edit key is used to replace words during program editing.
This key is to edit mode to insert data words, an entire block or

several blocks of data, into an enabled part program stored in
memory. It is also used when entering a part program into
memory from the MDI keyboard.
Deletion: Press this key when editing mode to delete a data word,
an entire block, or several blocks of data, from an enabled part
program stored in memory. It is also used to delete a complete
part program from the program Directory.
This key is used when entering data from the MDI keyboard.
When an address or numerical key is pressed, the alphabet or the
numeral is input once to the key input buffer, and it is displayed
on the CRT screen. To set the data input to the key input buffer in
the offset register, 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.
Cancel key: This key is to erase incorrect data entered on the MDI
keyboard before [INSERT] key is pressed.
Press this key to delete the last character or symbol input to the
key input buffer. Characters are erased singularly each time the
key is pressed starting with the last character entered. That means
when the address key or the numerical key is pressed, the position
where the alphabet or the numeral is inserted next is indicated by
an underscore ( _ ). When the cancel key is pressed, the character,
in front of the underscore, will be canceled immediately
Semicolon(;) key
Press this key to reset the CNC, to cancel an alarm, operation,

function etc.
Display the custom screen 1.


Reserved function key

Uppercase/lowercase switch key:

Switch between uppercase and lowercase when entering
alphabetic characters.

PC function key:
These keys are used with computer function of 300i/300is,
320i/310is, and 320i/320is.

Address/numeric keys:
Input alphabetical, numeric, or special character.

B. Cursor shift keys
Cursor shift keys:

Shift the cursor in upward, downward, left, or right direction.
C. Page change keys
Press the page button down, then the following picture will be
displayed.

8-4
MDI HANDLE
80 90 DNC 25 50 100
JOG
70 100 F0 100
AUTO
RAPID
60 110 50 150
EDIT ZRN
50 120
TOOL CLAMP
0 200
8.2 Machine Operator Panel
CUTTING/JOG TOOL UNCLAMP

SPINDLE (%) MODE RAPID (%) FEEDRATE(%)
CCW CW MLK ZLK APO
SBK BDT H.INT
ASSIST OPEN M01 DRY O.T.


The following are the descriptions of machine operator panel:
A. Emergency stop
If you press this red button in emergency, the machine
movement will stop immediately and mechanical reference
point will disappear. Spindle stops rotating automatically. The
button will be locked when pressed. The button can be
unlocked by twisting or pull it.
B. Rotary switches
1. Cutting Feedrate Override:
100 (1) With this dial, it could override the feedrate designated by
the program. The control range is from 0 to 200 % divide
to 21 scales, this switch provides to the feedrate of G01,
50 150 G02, G03 and other G code which may using this
feedrate for cutting.
(2) Jog Feedrate Override: With this dial, it could override

0 200 the feedrate designated by the program. The control range
is from 0 to 3700 mm/min. divide to 21 scales, this switch
provides to the JOG or Dry RUN feedrate switch.
2. Rapid Feedrate Override:

25 50 The Rapid Override switch provides four scales: 100%,
F0 100 50%, 25% and F0. When the rapid traverse rate is 20
m/min, and this dial is set to 50%, actual rate becomes 10
m/min. F0 is a constant value specified by the parameter.
Rapid override is effective by the following functions:
(1) G00
(2) during canned cycle
(3) in G27 and G28
(4) Manual rapid traverse

8-6

3. MODE selector:
MDI HANDLE It is used when editing a part program stored in
DNC JOG memory, to add data to memory, to delete data from
EDIT memory and to modify data in memory. To use this
AUTO
RAPID mode, Program Protect switch must in [OFF]
position.
EDIT ZRN Press the cycle start pushbutton of the operating
panel. The program in the AUTO operation memory
AUTO will be executed. When the cycle start pushbutton is
pressed, automatically operation will run and cycle
start lamp will light up.
Machine can be direct transfer the program while
DNC machine in auto operation.
The common of the multiple blocks can be input
from the CRT/MDI panel to the MDI operation
buffer memory. The program in the MDI operation
buffer memory can be edited in the same method as
MDI that for the program registered in the memory. Press
the START key of the operating panels the program
in the MDI operation buffers memory will be
executed.
This button can be used to move all axes manually.
Select the axis to be moved by the axial selector, the
HANDLE selected axis can be moved by Manual Pulse
Generator. Handle Multiplication can be set by
actuating one of the three scales X1, X10, X100.
Operation can be moved selected axis and moves in
its directions (X+, X-, Y+, Y-, Z+, Z-), feedrate can
be set by Jog feedrate override switch. Actuate and
JOG hold the corresponding axis key, the machine axis
moves continuously at the set traversing rate.
Release the axis key held so far, the traverse
movement will stop.
Operation can be moved selected axis and moves in
its directions, feedrate can be set by Rapid feedrate
override switch. Actuate and hold the corresponding
RAPID axis key, the machine axis moves continuously at the
set traversing rate. Release the axis key held so far,
the traverse movement will stop.
Set to the Home position, and press the selected axis
to be the reference point. The machine stops at the
reference point return, lighting the Axes Home
ZRN position LED. If 3 axes are selected simultaneously
by three switches, three axes moves are allowed
simultaneously.
80 90 4. Spindle Speed Override:
70 100
The spindle speed override switch allows the operator to
60 110 modify programmed spindle speeds in steps of 10% from
50 120 50% to 120%. The actual spindle speed what you
commended can be seen on the CRT and displays current
block [S].
The switch is active in AUTO, MDI or Dry Run modes.


C. Key switches
Program Protect switch:
The key can be removed when the Program Protect switch
is turned to the [PROTECT ON] position (ccw. turn) for
disabling any program editing works. Programs can be
deleted from memory or modified in any way when switch
is turned to the [PROTECT OFF] position (cw. turn). With
this protection of key, it can be operated by following
process:
1) The program registered in memory and modified.
2) Re-setting the coordinate system.
3) Keying in machine parameter by manual.
4) Setting the PC parameter and timer parameter.
Setting mode switch:

The key can be removed when the [SETTING MODE]
switch is turned to [OFF] position (ccw. turn). When the
machine main door is opened, the power will be cut off
and there will be not axial movements. Use key to turn the
[SETTING MODE] switch to [ON] position (cw. turn).
The machine main door could be opened and with power
supply. Please operate by following steps:
1) Use the [ASSIST] and +/- X, Y, and Z pushbuttons to
operate axial movements.
2) Rotate the MODE selector to [HANDLE] mode.
3) Rotate the assigned axial movement of handwheel.
4) Press the buttons in both side of handwheel.
5) Rotate the manual pulse generator to move the axial
position.
D. Lever switch
This switch is to control the background light condition:
(1) Shifting this switch to [ON] position for turning on the
background light.
(2) Shifting this switch to [OFF] position for turning off the
background light.
E. Pushbuttons
MANUAL Tool Assist pushbutton:
Open the machine main door and press this pushbutton to
load or unload tools manually. (pushbutton illuminated)
When the machine main door is closed, the light of this
pushbutton will be extinguished.

8-8

CYCLE START pushbutton:
The Cycle Start pushbutton is used to initiate programs in
AUTO, MDI, Dry Run, and Machine Lock modes. It will
be lighted up when a data block is being executed. When
control condition is in an End of Block, Feedhold or MDI
mode, the button will not be illuminated. If Feedhold
pushbutton is pressed during execution of a part program,
Cycle Start light will be turned [OFF].
Feed Hold pushbutton:
When this button is pressed during automatic operation,
the pilot lamp light up, the servo motor stops, and the
operation of the machine axes is stopped at the same time.
When the cycle button is pressed again, operation is
resumed, and the lamp goes out.
Cycle Stop pushbutton:
The pushbutton allows the operator to stop all axial motion
during execution of an enabled part program. It is active in
memory AUTO, MDI (Block by Block), Dry Run and
Machine Lock modes. It is illuminated when active. It has
no effect on active spindle speed. At M.S.T. operation
continues up to the end of the block. Cycle Start light and
Spindle CW or CCW button light will turn [OFF] when
feedhold is activated. Normal operation maybe resumed by
pressing Cycle Start push-button.
Work light pushbutton:
Using this pushbutton to turn the work lights ON; to press
the button again, the lamp will be turned off.
Control ON pushbutton:
After pressing Power ON pushbutton and waiting for the
machine standby confirmation from hardware circuit;
pressing Control ON pushbutton, the POWER ON
procedure will be completed.
Power ON pushbutton:
Using this pushbutton to turn the controller ON.
Power OFF pushbutton:

Using this pushbutton to turn the controller OFF.


Spindle CW pushbutton:
The spindle CW pushbutton is an illuminating and
momentary type pushbutton. The light must be turned
[OFF] for spindle CCW mode operation. Effective by
mode selected in Handle position (pushbutton illuminated).
Spindle rotates in clockwise direction.
Note: After machine is turned [ON], spindle speed must be
input the memory by MDI mode, then this button is
effective for pressing.
Spindle CCW pushbutton:
The spindle CCW pushbutton is an illuminating,
momentary type, pushbutton. The light must be [OFF] for
spindle CW mode operation. Effective by mode selected in
Handle position (pushbutton illuminated). Spindle rotates
in counterclockwise direction.
Note: After machine is turned [ON], spindle speed must be
input in the memory by MDI mode, then this button will be
effective for pressing.
(1) Spindle Stop pushbutton: (red lamp will be flashed)
In the HANDLE mode, press this button will stop the
spindle rotation.
(2) Spindle Orientation pushbutton:
In the ZRN mode, press this button for spindle
orientation.
Spindle orientation pushbutton:
Return the spindle to zero degree. The function is the same
as M19 code.
Coolant Auto pushbutton:

The push-button is an illuminating push-button. Press the
button, coolant will be distributed in accordance with
M08, M13, M14, M28, M51 command in Automatic
operation. When coolant is being distributed in Automatic
operation, pressing this button again will stop coolant
flow.
Coolant Manual pushbutton:
Press the button, the coolant will be distributed. Press the
button again, the coolant will be stopped.
Air blower pushbutton:

The air blower function will be active (button is
illuminated) when this button is depressed.

8-10

Chip Screw ON pushbutton:
Using this pushbutton to activate the chip screw, to stop it
by press this button again.
Message Reset pushbutton:

Using this pushbutton to reset the message of PLC.
Water Jet pushbutton:

Using this pushbutton to clean the chip at the bottom of the
machine.
Chip Conveyor forward/CW. pushbutton:

The chip conveyor [ON] is active when the push-button is
illuminated. When the push-button pressed a second time,
the chip conveyor is always [OFF] regardless of operating
mode.
Chip Conveyor Reverse/CCW. pushbutton:
The chip conveyor reverse [ON] is active when the
push-button is illuminated. When the push-button pressed
a second time, the chip conveyor is always [OFF]
regardless of operating mode.
X + pushbutton:
The X+ pushbutton is momentary type switch that allows
the operator to jog the X axis in plus X direction. It is
enabled when mode is selected in JOG position. Press the
pushbutton to return to the reference point by mode
selector in [HOME] position.
X – pushbutton:
The X- pushbutton is momentary type switch that allows
the operator to jog the X axis in minus X direction. It is
enabled when mode is selected in JOG position.
Y + pushbutton:
The Y+ pushbutton is momentary type switch that allows
the operator to jog the Y axis in plus Y direction. It is
Y – pushbutton:
The Y- pushbutton is momentary type switch that allows
the operator to jog the Y axis in minus Y direction. It is


Z + pushbutton:
The Z+ pushbutton is momentary type switch that allows
the operator to jog the Z axis in plus Z direction. It is
Z – pushbutton:
The Z- pushbutton is momentary type switch that allows
the operator to jog the Z axis in minus Z direction. It is
4th + pushbutton:
The 4th + pushbutton is momentary type switch that allows
the operator to jog the 4th axis in CW direction. It is
enabled when mode is selected in JOG/RAPID position.
Press this button to return to the reference point by mode
4th – pushbutton:
The 4th - pushbutton is momentary type switch that allows
the operator to jog the 4th axis in CCW direction. It is
5th + pushbutton:
The 5th + pushbutton is momentary type switch that allows
the operator to jog the 5th axis in CW direction. It is
enabled when mode is selected in JOG/RAPID position.
Press this button to return to the reference point by mode
5th – pushbutton:
The 5th - pushbutton is momentary type switch that allows
the operator to jog the 5th axis in CCW direction. It is
GUIDE pushbutton:
Under EDIT mode, press GUIDE pushbutton to start
MANUAL GUIDE or MANUAL GUIDE i.
Single Block pushbutton:

The Single Block push-button is an illuminating, latch type
switch pushbutton used to initiate AUTO, MDI, Dry Run
SBK and Machine Lock modes. It is illuminated while the
push-button is being pressed. One block of the program is
executed, and then the execution is stopped. If the cycle
start button is pressed, the next block is executed and then
the execution is stopped again. The Single Block
pushbutton must be pressed a second time to be
de-activated.

8-12

Block Skip pushbutton:
The Block-Skip push-button is an illuminating, latching
type that causes the control to ignore any block containing
a Slash code ( / ). The function is active when the
pushbutton is illuminated. When the pushbutton is not
BDT illuminated, the data block is executed. If the slash code is
the first character in the block, all data to the EOB
character will be ignored when the pushbutton is active. If
the slash code is placed in the middle of a block, only data
from the slash code to the EOB character will be ignored;
while data proceeding the slash code will be executed. To
exit from Block Skip, press push-button a second time.
The pushbutton is active in Dry Run and Machine Lock.
Auto power Off pushbutton:
The pushbutton is an illuminating, latching type
pushbutton. M30 function will be active after this button
has been depressed (pushbutton illuminated).
Handle Interruption pushbutton:

H.INT Press the button, the axis can be moved by means of
handwheel.
Optional Stop pushbutton:

The Optional Stop push-button is an illuminated, latch type
switch that causes the control to stop execution of a part
program after completing a block containing an M01 code.
The function is active when the pushbutton is illuminated.
M01
An M01 code is ignored when the push-button is not
illuminated. The pushbutton can be activated before or
during a block containing an M01 code. When a block
containing an activated M01 is completed, all slide motion
and spindle rotation ceases, coolant pump turns OFF, Feed
Hold pushbutton is illuminated and Optional Stop
pushbutton flashes. The pushbutton is active in Dry Run
and Machine Lock modes.
Dry Run pushbutton:
DRY The Dry Run pushbutton is an illuminated, latch type
switch that causes the control to execute of a program and
running with feedrate of JOG OVERRIDE.
Water gun pushbutton:

While the door is open, take the water gun and press this
pushbutton to supply water. Repress this pushbutton again
to stop water supply.


Door open pushbutton:
OPEN The pushbutton is an illuminating momentary type
pushbutton. Press this button while the machine is
stationary, the door will be opened.
Enabling ASSIST pushbutton:

A. Press the pushbutton and spindle CW pushbutton or
spindle CCW pushbutton at the same time to start the
spindle rotation. Spindle speed will limit in 50 rpm. If
ASSIST the operator releases one of the two buttons, the spindle
movement will be stopped immediately.
B. Press the pushbutton and manual feed axis direction
selection pushbutton at the same time to initiate the axis
movement. Axis speed will not exceed 2m/min. If the
operator releases one of the two buttons, the axis
movement will be stopped immediately.
Overtravel Release pushbutton:
When the axes overtravel, set the mode selector in Handle
position, press Overtravel pushbutton, in the mean time,
release the axes by Manual Handwheel.
Caution: Machine may cause machine damage due to axis
move to wrong direction while pressed the button and
protection sensor bypass is active.
Program Restart pushbutton:
When Program Restart pushbutton is pressed, the lamp of
this pushbutton will be lighted up and the function of this
key will be enabled. (Please refer to 8.1 LCD & MDI
Panel). Re-pressing this pushbutton, and the lamp
illumination and function will be released.
Z axis Lock pushbutton:
Press the pushbutton, Z axis will be interlocked (light is
illuminated).
Machine Lock pushbutton:

The pushbutton is an illuminating, latching type
pushbutton. The light must be OFF for normal machine
operation. When Machine Lock mode is active (pushbutton
illuminated), all axes motion is inhibited. To exit from
Machine Lock mode, press the push-button again.
Tool Magazine Index CW pushbutton:
Press this pushbutton, magazine will be CW rotated.
CW (pushbutton is illuminated)

8-14

Tool Magazine Index CCW pushbutton:
Press this pushbutton, magazine will be CCW rotated.
CCW (pushbutton lamp is illuminated)
Ignoring 4th axis pushbutton:

Two conditions of this pushbutton are described below:
(1) Press this pushbutton to enable the 4th axis to be
effectively used and light this pushbutton lamp up.
(2) Press this pushbutton to disable the 4th axis utility and
extinguish this pushbutton lamp.
Locking and Unlocking 4th axis pushbutton:

Two conditions of this pushbutton are described below:
(1) Press this pushbutton to unlock 4th axis and illuminate
pushbutton lamp.
(2) Press this pushbutton to lock the 4th axis and extinguish
this pushbutton lamp.
F. LED display & lamp
Spindle Tool Number Display:
This seven-segment display is to show the spindle tool
number.
Magazine Standby tool number display:

This seven-segment display is to show the standby loading
or unloading tool number of magazine.
High Gear LED lamp:

This LED lamp indicates spindle speed is high gear.
Low Gear:
This LED lamp indicates spindle speed is low gear.
Tool Clamp:
This LED lamp indicates spindle is clamping a tool.
Tool Unclamp:
This LED lamp indicates spindle is unclamping a tool.


X Home:
The X axis Home LED lamp will be flashed whenever the
X axis move to the reference points, and lighted up when
the X axis returned to the HOME position.
Y Home:
The Y axis Home LED lamp will be flashed whenever the
Y axis move to the reference points, and lighted up when
the Y axis returned to the HOME position.
Z Home:
The Z axis Home LED lamp will be flashed whenever the
Z axis move to the reference points, and lighted up when
the Z axis returned to the HOME position.
4 Home:
The 4th axis Home LED lamp will be flashed whenever
the 4th axis move to the reference points, and lighted up
when the 4th axis returned to the HOME position.
5 Home:
The 5th axis Home LED lamp will be flashed whenever
the 5th axis move to the reference points, and lighted up
when the 5th axis returned to the HOME position.
ATC. READY:
This ATC READY LED lamp indicates the automatic tool
change system is ready.
LOW AIR PRESSURE:
This LOW AIR PRESSURE LED lamp indicates the air
pressure is too low. The lamp will be flashed until the air
pressure becomes normal.
LOW HYDRAULIC PRESSURE:
This LOW HYDRAULIC PRESSURE LED lamp
indicates the hydraulic pressure is too low. The lamp will
be flashed until the hydraulic pressure becomes normal.
LOW COOLANT LEVEL:
This LOW COOLANT LEVEL LED lamp indicates the
coolant level is too low. The lamp will be flashed until the
coolant level becomes normal.
CHIP CONVEYOR:
This CHIP CONVEYOR LED lamp indicates failure
signal of chip conveyor.
LOW LEVEL / PRESSURE LUBRICANT:
This LOW LEVEL / PRESSURE LUBRICANT LED
lamp indicates the lubricant level or pressure is too low.
The lamp will be flashed until lubricant level or pressure
becomes normal.
I/O BYPASS:
When the software functions, ATC JOG and CCW, are set
to ON condition, the I/O BYPASS LED lamp will be
illuminated for indicating the alarm.

8-16

G. Manual Pulse Generator (MPG)
1 Manual Pulse When the MODE selector is rotated to [HANDLE] position, the
Generator feedrate can be adjusted precisely by using the Manual Pulse
Generator. Every scale is 0.001 mm. The value of each handwheel
increment depends on the setting of Handle Multiplication selector
and the axis to be jogged depends on the setting of Axial Movement
Selector.
2 Axial Movement Select the axis you want to move. (X, Y, Z, or 4th axis)
selector
3 Handle X1: 0.001mm
MultiplicationX10: 0.010mm
Selector X100: 0.100mm

4 Manual Pulse There are two confirm buttons on the both sides of Manual Pulse
Generator Generator. All axial movements have to be operated by pressing
(MPG) Confirm these 2 buttons at same time.
Button
H. Machining condition and alarm light

Red lamp (R) It will flash once per 0.5 second when machine
alerts.
Yellow lamp (Y) It will flash once per 0.5 second when program
is finished.
Green lamp (G) It will flash when machine is in normal
operation.


8.3 Magazine Operator Panel
F1
F2
LOCK MANUAL
The following are the descriptions of magazine operator panel:

If you press the Emergency Stop button on the magazine operator
panel, the machine movement stops, machine reference point will
be reset. Spindle stops rotating automatically. The button is locked
when pressed. The button can be released by twisting it.
Tool Magazine Index CW pushbutton:

(Rotate the key switch to [LOCK] position and close the safety door
of magazine.)
1. Press this button once; then magazine chain will be rotated
cw. and the lamp of this button will be lighted up. The lamp
will be extinguished by releasing the button and magazine
chain will be stopped.
2. If pressing this button continuously, the magazine chain will be
also rotated cw continuously. and the lamp of this button will be
lighted up. The lamp will be extinguished by releasing the button
and magazine chain will be stopped.

8-18

Tool Magazine Index CCW pushbutton:
(Rotate the key switch to [LOCK] position and close the safety door
of magazine.)
1. Press this button once; then magazine chain will be rotated
ccw. and the lamp of this button will be lighted up. The lamp
will be extinguished by releasing the button and magazine
chain will be stopped.
2. If pressing this button continuously, the magazine chain will be
also rotated ccw continuously. and the lamp of this button will be
lighted up. The lamp will be extinguished by releasing the button
and magazine chain will be stopped.
Reserved pushbutton
F1
Reserved pushbutton
F2
When this key switch is rotated to [LOCK] position, the key could
be removed. The door will be locked. If the key switch is rotated to
[MANUAL] position, the door can be opened. Operator could
manually load or unload tools at this time. After the tool load or
unload is finished, the safety door must be closed and the key
switch must be rotated to [LOCK] position.
This seven-segment display is to show the stand-by tool number of
magazine.


8.4 Electrical Components in Cabinet
1.NC power supply (N1) 13.Circuit Breaker (NFB4)

2.Spindle servo amp module (N3) 14.Motor Protective Circuit Breaker (MCP1~MCP13)
3.XY servo amp module (N4) 15.Magnetic Contactor (MC1~MC21)
4.Z servo amp module (N5) 16.Terminal connector (TB11)
5.4TH servo amp module (N6) 17.FILTER (FILTER1)
6.CNC control unit (N7) 18.Magnetic Contactor (MCC1)
7.Relay board 19.AC Reactor (ACR1)
8.Transfer board 20.DC Power supply (G1,G2)
9.Circuit Breaker (NFB3) 21.OFF Delay Timer (TOF1)
10.Magnetic Contactor (MC18,MC19) 22.Safety Relay Module (SSK1,SSK2)
11.Terminal connector (TB1~TB3) 23.Relay (FOR CE K100~K112,K40~K54)
12.FUSE (F1,F2,F3,F4,F5,F6,F7) 24.Transformer (TR2)

9. Power On and Power Off 9-1

9. Power On and Power Off

This chapter is to introduce the pre-operation checking lists of machine.
9.1 Inspection before Power On

The electric box, motor, transformer and relay boxes with a

high-voltage mark present the fatal voltage terminals. Only
electrical experts with official certificate are authorized to open
their covers and doors. Cable and wire with damaged film can
cause electric leakage or shock. Double check if there is any
damage on cable and wire. Failure to follow this warning will
result in serious and fatal injuries or death from electric shock.

Checking unit Checking item Method Remark
Air filter unit 1. Drain the water from reservoir? Check visually
2. Any lub. oil in reservoir? Check visually
3. Air pressure 4~7 kg/cm2? Check visually
Spindle Oil Cooler 1. Temperature setting value? Check visually
2. Oil sufficient? Check visually
3. Any leakage? Check visually
Chip conveyor 1. Chips removed? Check visually
Coolant Tank 1. Chips removed? Check visually
2. Coolant sufficient? Check visually
3. Any leakage? Check visually
Chip collectors 1. Chips removed? Check visually
2. Anything other than chips? Check visually
Slide cover 1. Any chips accumulated? Check visually
Magazine door 1. Any chips accumulated? Check visually
Table 1. Any chips accumulated? Check visually
Spindle 1. Spindle taper clean? Check visually
Electric cabinet 1. Door closed? Check visually
2. No damage or disconnection on Check visually
external wiring or cables?
3. Earth grounded? Check visually
General 1. Machine environment well Check visually
sorted out?
2. No looseness of bolts on cover, Check visually
etc.?

9-2

9.1.1 Power on
 DO NOT touch any switches or buttons when hands are wet.
 CHECK if the machine environment is clean for operation
convenience.
 CHECK if coolant, cooler oil and pneumatic pressure are
sufficient to work.
 WARM UP the machine for about 15 minutes after turning

the power ON.
 PLEASE pay the highest attention to set the spindle speed,
especially over 3000 rpm.

Power ON procedure is the systematic method of safely turning on the control and the prepared
machine for operation. The following are the descriptions of the 3 axes procedure:
1. Turn “ON” MAIN SWITCH and AIR SWITCH.

2. Press POWER ON pushbutton.
When buzzer has beeped, that indicates that the control is in an EMERGENCY STOP
condition. Press EMERGENCY STOP push-button in clockwise direction to make
certain it is released; beep will be disappeared. Machine is ready for operation.
3. To Zero return axes:
(3.1) Set Mode Selector at HOME position.
(3.2) Set Rapid Override Switch at 50%.
(3.3) Press Home position return push-button (push-button light will come on). Z
axis will move to the Home position (positive direction). After Z axis Home
position L.E.D. lights up showing the Z axis is at the reference zero position,
then Y axis will follow up the Z axis procedure, and move to the Home
position automatically until all axes
Home position L.E.D. light up indicated that all axes are at their reference
zero position.
(3.4) Procedure (c) can be operated by the manual push-button of each axes.
(3.5) Press and release X+ push-button, X axis will move to the positive side of
Home position.
(3.6) After X+ push-button light is out and X Home position L.E.D. lights up
indicating that the X axis is at its reference zero position, press the Y+ and
Z+ push-buttons. When the slides arrive at their reference zero position, Y+
and Z+ push-button lights will be out and Home position L.E.D. Y and Z will
light up.
(3.7) Turn Rapid Override Switch to 100% and try (e) procedure again, to be sure
this function is O.K.


9.1.2 Checking after power on
Checking Point Checking item Method Remark
‧Motor 1. No abnormal sound or heat? Check visually
2
‧Air unit 1. Air pressure (4-7kg/cm )? Check visually
2. Hose leakage? Check visually
‧Coolant unit 1. Pump running perfect? Check visually
‧CRT screen 1. No alarm displayed? Check visually
‧Operator panel 1. Warning lamp lights? Check visually

9.2 Normal Shutdown

 All personnel must know the locations of Emergency Stop
buttons and how to use them in case of emergency situations.
 Main Switch should be always locked for protecting
unauthorized personnel.
 DO NOT leave keys on the switches or lockers after machine is
turned off.
To prevent damage the controller, machine tool or drives during shutdown, follow the Power-Off
procedure listed below:
1. Establish a condition which ensures that the machine tool will not be damaged when
control is shutdown. Ideally, establish an end-of-program condition with all axes at
Home position. If this can not be accomplished, a cycle stop is adequate. But try to
position the axes clear of the workpieces.
2. Press Emergency Stop push-button. If spindle is rotating, it will dynamically brake to a
stop. Any axis motion will be also ceased. Power is removed from axes drive motors
and spindle drive motor, thus disabling axes and spindle.
3. Press Power OFF push-button.
4. Turn OFF main switch and turn Air value OFF.
Note: The machine is placed in E-Stop before the control is turned OFF is to remove
power in two distinct steps; first from the drive motor, then from the drives.
Removing all power at once could damage the machine.

9-4

9.3 Inspection after Power Off

Checking point Checking item Method Remark
‧Motor Check if the motor is stop. Check visually
‧Air unit Check if the air unit is turned off. Check visually
‧Main power Check if the main power is turned off. Check visually

9.4 Manipulation for Stopping Operation

 All personnel must know the locations of Emergency Stop
buttons and how to use them in case of emergency situations.

9.4.1 Emergent stop
In case of any emergency cases, press the button which is nearest button as soon as possible.
Machine will be stopped immediately. CRT screen will display the alarm message “Not ready”.
After the emergency situation has solved, twist the switch clockwise to release the pushbutton.

9.4.2 Other stops
There are several methods to stop machine during machine in AUTO or MDI operation. The
descriptions are as below:
9.4.2.1 Program Stop (M00)

Stops program, stops spindle, turns coolant OFF, "Tool release" push-button is activated.
[Feedhold] light flashes intermittently.
Cycle operation is stopped after a block containing M00 is executed. When the program is
stopped, all existing modal information remains unchanged as in single block operation. The
cycle operation can be restarted by specifying a CNC start. It is the programmer's
responsibility to program an M03, M04, M13, or M14 to restart spindle and turn coolant on
when restarting the program after an M00 program stop.

9.4.2.2 Optional Stop (M01)
Performs the same function as M00 but will not stop the cycle unless [Optional Stop]
push-button is activated (illuminated) before the block containing the M01 is read by the
control. If “Optional Stop” is not activated, the cycle will continue without stopping. When
active, the “Cycle Start” light goes out, “Optional Stop” lights up and [Feed Hold] light is


illuminated. This function is useful when it is necessary to gauge the workpiece during setup.
Pushing “Cycle Start” push-button allows program to continue. It is the programmer's
responsibility to program an M03, M04, M08, M13 or M14 to restart spindle and turn
coolant on when restarting program after an M01 Optional Stop.
ON: Press the button, button lamp will light up.
M01
Machine will be stopped after the block containing the M01 is read by the
control. Machine will be restarted after release the Optional Stop
push-button.
OFF: Release the button, button lamp will go out.
Machine will continue without stopping after the block containing the M01
is read by the control.

9.4.2.3 End of Program (M02, M30)
The M02 or M30 is used at the end of the program. It is usually the last block programmed.
It stops the spindle and turns coolant off. [Cycle Start] light goes out and Feedhold light
flashes intermittently. When entering a program in memory from MDI keyboard, placing
M30 at end of program will cause program to automatically return to stop when M30 is
encountered in the enabled program.

9.4.2.4 Feedhold button
The axial movement will be feedhold temporary when this push button has
been depressed while machine is in operation at the mode of AUTO or MDI
selection. But spindle and coolant will be active continuously.
The light will be light up when Feedhold button has been depressed.
．The feed will be decelerated when machine axis is moving.
．Dwell will be cancelled when program is in G04 status.
M, S, T or B action will be executed till end of single block.
Note 1: If mode selector turns to Handle mode while program is executing, the
NC will be shift to machine block status.
Note 2: NC will be alert while program is executing, then NC will be shift to
machine lock status.
If machine is operating continuously, then push the Cycle start button once
again.

9-6

9.4.2.5 Spindle stop
The spindle can be stopped during machine in AUTO operation. Press Feed
Hold button, and machine will be stopped. Then push Spindle stop button,
the push-button will be illuminated. The spindle will be restarted after
pressing Cycle Start button. All axes movement will be executed 1.5 sec.
later on.
The Spindle stop push-button can also be used to manually release the tool
holder from the spindle. Once press the button, the button light will flash.
Then push the footswitch for tool unclamping which is located in front of
the operator‘s door. The drawbar will stay in the open position as long as the
button is held depressed. The button light will flash in 30 seconds valid for
tool unclamping from Spindle. The spindle unclamping function will be
invalid once light flashing stopped. This push-button is available only when
spindle rotation is stopped and machine is out of cycle.
9.4.2.6 Reset
The Reset push-button is active anytime after the control is ON. It cancels
active spindle speed and slide motions, resets G and M codes to start-up
conditions, and cancels active offsets. If Tool Change is progressing when
[Reset] is pressed, ATC will progress continuously until “Reset” is held
depressed. “Reset” is also used to clear an alarm state after fault has been
corrected. To return a program in memory to the beginning, press
“Program” push-button.


9.5 Disposal during Power Failure

When the control loses power, either because of a power failure or because the Power Off
pushbutton has been pressed, the control system disables all outputs, including the machine
power permission control relay. If the control power is lost during any data entry operation, the
correctness of the data being entered cannot be guaranteed and should be verified. All
information previously entered into the system is retained; active information such as an operator
entered MDI block is lost. There are some mechanical safety devices on the machine that can
protect the operator or third party. A list is as below:
Safety Items Power ON Power Lost

Spindle Tool Power Drawbar Clamp Clamp
Spindle Tool Power Drawbar Unclamp Clamp
Spindle Motor Rotating Stop
All Axes Movement Moving Stop
Z Axial Brake Unclamp Clamp
Tool index for searching tool Indexing Stop
Power Switch On Off
Controller Power Unit On Off

Reset procedure after power loss:
1. Turn the main power OFF.
2. Release the Emergency Stop button on the operator panel.
3. Replace the tools or workpiece if necessary due to bad quality caused by the
power lost.

After power returning back, power up by the procedure mentioned above. Returning all cutting
conditions before power lost, then cycle start continuously.

9-8

9.6 Power On Procedure List

 DO NOT touch any switches or buttons when hands are wet.
 CHECK the machine environment is clean so that convenient
for operation.
 CHECK cooler oil, coolant and pneumatic pressure are
sufficient to work.
 WARM UP the machine for approx. 15 minutes after turning

the power ON.
 WHEN setting the spindle speed over 3000 rpm, pay the closest
attention.
1. The main power switch is on the electric box, in the back of

machine.
2. Rotate the main power switch to On position.
3. The POWER ON pushbutton is on the machine operator panel.

4 Press the POWER ON pushbutton.
5 Screen will display “1001 Emergency Stop”.
6. The Emergency Stop pushbutton is on the machine operator panel.
7 Release the Emergency Stop pushbutton.
8. The CONTROL ON pushbutton is on the machine operator panel.

9. Press the CONTROL ON pushbutton.
MDI HANDLE
10. The MODE selector is on the machine operator panel.
11. Rotate the mode selector to ZRN position.
DNC JOG
AUTO
RAPID
EDIT ZRN
12. The CYCLE START pushbutton is on the machine operator panel.

13. Press the CYCLE START pushbutton.
14. All axes will be returned to home position at this time, and the
lamps of STATUS area will be lighted up.


9.7 Power Off Procedure List

 ALWAYS lock the Main Switch by locker to protect
unauthorized personnel.
 DO NOT leave keys on the switches or lockers after machine is
turned off.

MDI HANDLE
1. The MODE selector is on the machine operator panel.
2. Rotate the mode selector to ZRN position.
DNC JOG
AUTO
RAPID
EDIT ZRN
3. The CYCLE START pushbutton is on the machine operator panel.

4. Press the CYCLE START pushbutton.
5. All axes will be returned to home position at this time, and the
lamps of STATUS area will be lighted up.
6. The Emergency Stop pushbutton is on the machine operator panel.

7. Press the Emergency Stop pushbutton
8. The POWER OFF pushbutton is on the machine operator panel.

9. Press the POWER OFF pushbutton.
10. The main power switch is on the electric box, in the back of
machine.
11. Rotate the main power switch to OFF position.

10. Operation Instruction 10-1

10. Operation Instruction
10.1 M Code Function List

M Code Definition Remark
M00 PROGRAM STOP
M01 OPTIONAL STOP
M02 PROGRAM END
M03 SPINDLE CW
M04 SPINDLE CCW
M05 SPINDLE STOP
M06 AUTO TOOL CHANGE
M07 AIR BLOW CHIP ON
M08 COOLANT ON
M09 COOLANT & AIR OFF
M10 4 TH AXIS UNCLAMP
M11 4 TH AXIS CLAMP
M12
M13 COOLANT ON & SPINDLE CW
M14 COOLANT ON & SPINDLE CCW
M15 ATC DOOR OPEN (reservation)
M16 ATC DOOR CLOSE (reservation)
M17
M18
M19 SPINDLE ORIENTATION
M20 SPINDLE ORIENTATION THE ANGLE
(FOR ATLM Tool Length Measurement)
M21 MAGAZINE POCKET DOWN
M22
M23 TOOL UNCALMP (reservation)
M24
M25 TOOL CLAMP (reservation)
M26
M27 MAGAZINE POCKET UP
M28 COOLANT THROUGH TOOL
M29 RIGID TAPPING
M30 PROGRAM END
M31

10-2

M32
M33 ATLM AIR BLOW ON
M34 ATLM AIR BLOW OFF
M35 SMOKE EXHAUST UNIT ON
M36 SMOKE EXHAUST UNIT OFF
M37
M38 TOOL TABLE REGISTER INITIALIZE
M39
M40
M41
M42
M43 TABLE CLAMP
M44 TABLE UNCLAMP
M45 5 AXIS UNCLAMP
M46 5 AXIS CLAMP
M47
M48
M49
M50 FLUSH FLOOR COOLANT ON
M51 COOLANT THROUGH SPINDLE (CTS)
M52
M53 AIR THROUGH SPINDLE ON
M54 AIR THROUGH SPINDLE OFF
M55 OIL MIST CONTROL ON
M56 OIL MIST CONTROL OFF
M57
M58
M59
M60 AUTO APC CHANGE
M61 APC A TABLE IN
M62 APC B TABLE IN
M63 CONVEYOR ON
M64 CONVEYOR OFF
M65
M66
M67


M68
M69
M70 MIRROR CANCEL (reservation)
M71 TS27R ENABLE (ATLM)
M72 OMP60 ENABLE
M73 CANCEL OMP60 AND TS27R (ATLM)
M74 RESERVATION
M75
M76
M77
M78 X AXIS MIRROR
M79 Y AXIS MIRROR
M80 MIRROR CANCEL (FOR X, Y)
M81 8M FUNCTION-1
M82 RESERVATION
M83 8M FUNCTION-2
M84 8M FUNCTION-3
M85 8M FUNCTION-4
M86 8M FUNCTION-5
M87 8M FUNCTION-6
M88 8M FUNCTION-7
M89 8M FUNCTION-8
M90 RESERVATION
M91 RESERVATION
M92 RESERVATION
M93
M94
M95
M96 RESERVATION
M97 RESERVATION
M98 SUBPROGRAM CALL
M99 SUBPROGRAM CALL

10-4

10.2 Mode Selection

For safety considerations and according to the safety instruction: Whenever mode selection, all
movements must be stopped. If mode is switched between AUTO / MDI and HANDLE / JOG /
HOME modes, all axial movements will be stopped.
 Press the CYCLE Start button to returning to the AUTO mode, and machine will be
started.
 Returning to the HANDLE mode, the program execution must be started from the
beginning.
 Returning to Auto mode for executing the program, and then

spindle rotating will be remain the same as previous RPM &
direction.
 Switch AUTO mode to HANDLE mode during executing
program, if each of axis displacement has been determined.
It will affect the machine dimension when the program is
executing continually.
Whenever cancel or temporarily stop to execute the program in AUTO mode, please follow the
regular procedure to avoid any mode exchange.
1. Cancel program execution
(1) Press the Emergency stop button.
(2) Press the Reset button.
2. Stop program execution temporarily
2-1 Feedhold
(1) Press FEED HOLD button.
(2) Press CYCLE START button to returning back program execution.
2-2 Feedhold; spindle stop

(1) Press FEED HOLD button, and axial movements will be stopped. Then press the Spindle
stop button, the spindle will be stopped. If the spindle stop button is not pressed after the
axial movement has been completely stopped, then spindle will not be stopped.
(2) Press the CYCLE STOP button to stop axial movement, and the spindle will be stopped
automatically.
(3) Press the CYCLE STOP button to returning back to the previous status, and then spindle
will return to rotate and axial movement will remain the same as before.


 The normal programming edit at the end of the program will be

M02 or M30 which means program is to be ended and deleted
all information in the temporarily storage.
 If programming edit of M02 or M30 at the end of program was
missing, then it is necessary to press the RESET button after
program execution ending. Or press the RESET button before
doing any operation on the machine.
 If machine did not follow mentioned above regulation, and then
following condition will happen:
At MDI mode:
1. Input the sample program as presented in left column:

O0000; (1) Press the CYCLE START button and then spindle will be
M03 S300 ; rotating in 300 rpm in CW and then program M03 S300 will
% be disappeared.
(2) Switch the mode to HANDLE, spindle will be stopped.
(3) Switch mode selector back to MDI, and press the CYCLE
START button. Then spindle rotation will be ineffective.
(4) Press the RESET button to end all procedure.
2. Input the sample program as presented in left column:
O0000; (1) Press the CYCLE START button, then spindle will be rotating
M03 S500 in 300 rpm in CW, all axes will be moving normally.
X500.; (2) Change the mode to HANDLE, the axis movement will be
Z-300.; stopped first, spindle will be stopped few second later, the CRT
X-500.; will keep the same.
Z300.; (3) Switch mode selector back to MDI, and press the CYCLE
% START button; then spindle rotation will be kept in the same
500 rpm. Also, axial movement will be remained the same
condition as before. The program execution will be
disappeared, but spindle will be rotating in 500 rpm because of
there is neither M05 nor M02; M30 in the program.
(4) Press the RESET button to ending all actions.

10-6

10.3 Manual Operation

 It is necessary to move each axis 200mm away from Home
position by manual Handle mode before reference point
return.

10.3.1 Reference point return operation
DNC
MDI HANDLE
JOG
1. Switch the mode selector in HOME ZRN position.
AUTO
RAPID
Home mode is selected, if X, Y, Z, or 4th are simultaneously
EDIT ZRN
selected by three or four pushbuttons (X+ or X- , Y+, Z+, or 4th
+), three or four axes movements are followed at the same time.
2. Press the CYCLE START button to make all axes return to
home position.
3. If press X- button or Z axis will move to its home position. After

Z axis is at its home position, Z axis position will be reset in "0".
There are three possibilities to interrupt the home return
function:
(1) Press the Reset push-button on CRT/MDI panel.
(2) Turn the mode selector away from HOME position.
(3) Press the Emergency Stop button.
4. After Z axis is at its home position, Y axis will follow the Z axis
procedure, and then the X axis 4th axis.
5. When axes are returned to home position, the lamps will be

lighted up.
6. Each selected axis will be moving to its HOME position with

Rapid feedrate to the set deceleration position, then move to the
HOME position with 200 mm/min feedrate. The Rapid override
switch can be adjusted while the axis is moving.


10.3.2 Jog feed operation
1. Switch the mode selector to “JOG” position.
JOG mode is selected, X axis can be moved by pressing
X+ momentary pushbutton (button is illuminated) that
MDI HANDLE
allows the operator to jog the X axis in the plus X
DNC JOG
direction with its Jog Override Feedrate. Axial movement

AUTO
RAPID
will stopped by released the push-button. Depress X-
EDIT ZRN
pushbutton (button is illuminated) that allows the operator
to jog the X axis in the minus X direction with its Jog
Override Feedrate. Y, Z, 4th axes are the same as X axis
procedure.
2. Select JOG feedrate override switch.

With this dial, it is possible to override the feedrate
designated by the program. An override of 0 to 3700
mm/min. divide to 16 step, this switch provides to the
JOG feedrate switch. Tolerance will be ±3%.
3. Select the axis which you want to move.

Select JOG or RAPID mode, and all axes can be moved
by pressing one of momentary pushbuttons (X+, X- or Y+,
Y-, etc.: button is illuminated) that allows the operator to
jog the X axis in the plus or minus X direction with its Jog
Override Feedrate. Axial movement will be stopped by
releasing the pushbutton.

10-8

10.3.3 Handwheel operation

MDI HANDLE
Set the mode selector in HANDLE position.
DNC JOG Select the axis to be moved by the axes selector, the selected
AUTO
RAPID axis can be moved by Manual Pulse Generator (M.P.G.).
EDIT ZRN Handle Multiplication can be set by actuating one of the
three scales X1, X10, X100.
Set the Axis select mode.

The axis to be moved is selected by setting of Axis select
mode. The Handle wheel allows the operator to move a slide
in increments when Mode Select Switch is in X, Y, Z or 4th
position.
Set the Handle Multiplication Switch.

The value of each hand wheel increment depends on the
setting of Handle multiplication switch and the axis to be
jogged depends on the setting of Axis select Mode. A list of
movement amount per degree is as below:
Input system X1 X 10 X 100
Metric input (mm) 0.001 0.010 0.100
Inch input (inch) 0.0001 0.0010 0.0100
Handle wheel
To rotate the wheel in one turn (360°), it will create 100
pulse. Turn in CW direction, the axis will be moving in "＋"
direction, Turn in CCW direction, the axis will be moving in
"－" direction.
Note 1: If the Handle is rotated in excess of 5 turns /sec, there is a difference between the
Handle rotation
Note 2: Rotating the Handle too fast when X100 is selected, moves the tool or table at a
rate as fast as the rapid traverse rate. A sudden stop gives the machine tool a shock.
amount and the machine movement distance.


10.3.4 Spindle manual operation
 Do not approach the spindle while it’s running.
 Stop the spindle before maintain the spindle.
 Be sure the tool clamping is secured before spindle running.

The spindle can be rotated by 4 push buttons when the mode at

Manual mode selection (including Handle, Rapid, Jog).
When the spindle is running, mode shift to Auto mode position,

then the spindle will be stopped.

Spindle CW push button:
The spindle CW push-button is an illuminating,
momentary type push-button. The light must be OFF for
spindle CCW mode operation. Effective by mode
selected in Handle position, press the CW push-button.
Spindle rotates in clockwise direction.
Spindle Stop push-button:

Spindle can be stopped by the following methods:
(1) Press the Reset button in Handle mode, spindle will be
stopped immediately. The push-button will be
illuminated whenever spindle is not in running.
(2) Commanded M05 when mode selector is in AUTO
position.
(3) Press the push-button on the programmer's panel or
Emergency stop button. The CW & CCW push-buttons
will light out when spindle is stopped.
Spindle Counter Clockwise (CCW) push-button:

The spindle CCW push-button is an illuminating,
momentary type push-button. The light must be OFF for
spindle CW mode operation. Effective by mode selected in
Handle position, press the CCW push-button. Spindle
rotates in counter clockwise direction.

10-10

10.3.5 Spindle clamping and unclamping operations
 DO NOT approach the running spindle.
 BE SURE that the power has been turned off before
servicing the spindle unit.
 CHECK AND ASSURE that the spindle is stopped while
cleaning the spindle taper.
 MUST STOP the axial movement while in spindle tool
loading and unloading.
 MAKE SURE that there is no tool in the tool pocket of the
magazine of whatever number is occupied on the spindle.
 IF the spindle has been occupied by a tool, DO NOT
modify the spindle tool number at the value of "0".
 The tool must be performed by dimension check, clean
and tightened pull stud before spindle loading.
 The tool to be mounted must meet the specified
specifications as showed in 6.1.8 Tool information.
Spindle tool holder releasing function switches:
1. Press the Spindle Stop pushbutton.
MANUAL
TOOL ASSIST 2. Press the MANUAL TOOL ASSIST pushbutton on the panel.
3. Press the door open pushbutton to open door and change tool.


10.3.6 Chip conveyor operation
A. Operation
Press this button on the operator panel, and then the chips
shall be coming out from the conveyor. Users could stop the
conveyor by re-pressing this button.

 DO NOT use bare hand to remove chips in order to avoid
any injury.

B. Remove the chip from the table

(1) Use brush or water gun to clean the chips to screw conveyor.
(2) Turn the chip conveyor ON to remove the chip from screw conveyor.
C. Trouble shooting
(1) Use hook to remove the chips from the conveyor.
(2) Operation the following procedures to check the conveyor condition.
Press this button once to run chip conveyor CW.
Press this button once to run chip conveyor CCW.
(3) If chip conveyor still does not move that means the motor might be damaged. Please contact
with your local agency.

10-12

10.3.7 Cutting fluid / coolant
A. Manual operation
(1) The ball valve must be turned on first.
(2) Press this button to light up the indicator and spray
coolant from spindle side.
(3) Re-press this button, and the indicator will be

blacked out and the coolant will be stopped.

B. Command
The following commands will be executive by pressing
Coolant Auto pushbutton.
M08: Coolant ON

M09: Coolant OFF

C. Water gun
(1) The ball valve must be turned OFF.
(2) Press this button.
(3) The water gun will be enabled, when the light
illuminates.
(4) Re-press this button, and the water gun will be
stopped.


10.3.8 Magazine tool loading and unloading
 MAKE SURE all items as mentioned below before tool

loading at magazine.
(1) Before your requested tools are put into the magazine,
pre-check tool tips are in good condition and tighten and
clean the tool holder.
(2) The tool to be mounted should meet the specified
specifications.
(3) During mounting of your requested tools in the magazine,
Make sure that your expected tool pocket numbers are
assigned by the controller.
Manual loading tool steps

Step 1: Set the mode selector in the Handle position, then turn the tool magazine mode selector
switch to Manual position.
Step 2: Move the tool holder.
Step 3: Put the tool in the tool holder.
Step 4: After close the door, turn the tool magazine mode selector switch to Auto position, then the
tool magazine can be executed automatically.
Manual unloading tool steps

Step 1: Set the mode selector in the Handle position, then turn the tool magazine mode selector
switch to Manual position.
Step 2: Move the tool holder.
Step 3: Take out the tool by both hands.
Step 4: After close the door, turn the tool magazine mode selector switch to Auto position, then the
tool magazine can be executed automatically.

10-14

10.4 MDI Operation

10.4.1 MDI function
The MDI mode provides the operator with the means to manually enter and execute program
information one block of information at a time. MDI blocks are executed independent of the
Active NC program. Each MDI block is completely executed before the next MDI block can be
entered.
The MDI mode is terminated by depressing one of the other mode keys. If an MDI block is
displayed in the MDI Block entry area when the MDI mode is terminated, the block is erased.
The control state which was active when the MDI mode was entered is retained when the MDI
mode is terminated, unless the state is changed from end of block to end of program while in the
MDI mode, in which case the end of program state is retained.
Note: The MDI mode can not be terminated if the cycle of an MDI block has been started
and has not been completed (in cycle or suspended in the middle of the block).
Programming
Set the mode selector in MDI position. Press the
MDI HANDLE
DNC JOG
PRGRM push-button, the CRT screen will display as
AUTO
below.
RAPID
ZRN
EDIT


‧ The program No. O0000 will be inserted automatically. To program in MDI mode is
the same as program editing.
‧ The length of a program which can be prepared is limited to one page of a CRT
screen. In the above case, the longest program is 6 lines with specification of the
parameter, if the mode is switched to that of no modal information display, up to 10
lines of program can be prepared. If the number of lines of program exceeds the
limit, % will disappear and insertion and modification operation will become
impossible.
‧ To delete a program by press the RESET push-button (when parameter no. 057 is set
as MBCLR=1) or O「DELETE」.

 About program editing, please refer to FANUC operation
manual.
Program Execution

Set the cursor on the head of the program. (Start from an intermediate
point is possible) Press the START push-button on the FANUC Panel
or Cycle Start push-button on the Control Panel. Machine will start to
run. When the program end (M02, M30) or % is executed, the
program will be erased automatically and the operation is end. By
command of M99, return to the head of the program is performed.

10-16

Cautions and Notes
1. Programs registered in the program memory can be called as subprogram. In
this case, the nest of subprogram is up to 2-loops combined with automatic
operation (AUTO) program. (If a caution macro option is provided, up to
4-loops combined is possible.)
2. If the custom macro option is provided, even in the MDI mode, custom
macro program preparation and execution is possible. However, when a
macro program which call another macro program, macro call is not
possible.
3. A program to be prepared in the MDI mode uses program memory vacant

area. If there is no vacancy in the program memory, program preparation in
the MDI mode is not possible.
4. Program prepared in the MDI mode will be erased in the following cases:
a. In MDI operation, if M02, M30 or % is executed.
b. In AUTO mode, if memory operation is performed.
c. In EDIT mode, if any editing is performed.
d. Background editing is performed.
5. The editing operation during the stop of MDI operation will start from the
cursor position which makes start, but not from the current cursor position.


10.4.2 Tool number input and modification
 MAKE SURE ALL FOLLOWING ITEMS MUST BE

MODIFIED BEFORE CHANGING TOOL NUMBER.
 BE SURE that the tool number in the spindle and Magazine
are relative to each other.
 MAKE SURE that there is no tool in the tool pocket of the
magazine of hatever number is occupied on the spindle.
 IF the spindle has been occupied by a tool, DO NOT modify
the spindle tool number at the value of "0".
 The tool must be performed by dimension check, clean and
tightened pull stud before spindle loading.
 The tool to be mounted must meet the specified specifications
as showed in 6.1.8 Tool information.

 Tool loading number must be met the required T# executed
while tool table initial.
 Following procedure is prohibited while tool initial:
 Tool number initial no bigger than the tool number the
machine has.
 After tool initial/modified, all process must be reconfirmed.
 The spindle tool number must be at the pocket where is
empty in order to be sure that the tool returning back will
not be damaged the tool magazine.

Procedure is as below:
1. Put Mode selector at HANDLE position, press the Magazine CW button, indexing the T#1
pocket at the ready position.
2. Remove the tool from T#1 pocket, insert the tool in the spindle.
3. Put the mode selector at MDI, key in M06T1 to process auto tool change.
4. Set the screen at Register display, make sure the spindle tool Number has been set on T1 and
tool pocket tool number 1 is at “0”.

10-18

Tool table register initialization:
 Make sure spindle does not hold any tool first; then initialize
tool table.

MDI HANDLE 1. Rotate the mode selector to MDI position.
DNC JOG
AUTO
RAPID
EDIT ZRN
2. Press the PROG pushbutton

3. Key in “M38.”
4. Press CYCLE START pushbutton to execute the command of

program.
5. Spindle will be assigned as the “NO. 0” tool.
6. The first tool of magazine will be assigned as NO.1, the
second tool will be assigned as NO.2, and so on.

10.4.3 Automatic tool changer
MDI HANDLE
DNC JOG
AUTO
RAPID 1. Rotate the mode selector to MDI or AUTO position.
EDIT ZRN
2. Press the PROG pushbutton

3. During editing program, key the command in the following
examples:
3.1 M6 T**
3.2 T**
:
M6
3.3 M6


10.5 Automatic Operation

10.5.1 Automatic execution program
The program which stored in memory can be executed in AUTO mode. There is only one
program can be performed at the same time. The following steps are to search and enable the
program number:
MDI HANDLE
1. Rotate the mode selector to EDIT position. When once an
DNC JOG
expected program is selected, loading the program by pressing
the RESET pushbutton on the FANUC operator panel.
AUTO
RAPID
EDIT ZRN 2. Rotate the mode selector in AUTO position.
3. Press the softkey under the mode selection of MONITOR, the

programming O number will be showing up.
1. Call the needed program.

2. Press the CYCLE START pushbutton, the button light will be
illuminated.
The following will be executed after starting automatic operation:
(1) A one-block command is read from the specified program.

(2) The block command is decoded.
(3) The command execution is started.
(4) The command in the next block is read.
(5) Buffering is executed. That is, the command is decoded to allow immediate execution.
(6) Immediately after the previous block is executed, the execution of the next block can be
started because buffering has been executed.
(7) Then, automatic operation can be executed by repeating the steps (4) to (6).

10-20

10.5.2 Block skip
ON:
Press the pushbutton, and the button light will be turned ON.
The function is active when the pushbutton is illuminated. The
control will ignore any block containing a Slash code,” /,” when
mode selector is in AUTO or MDI position.
OFF:
Release the pushbutton, and the button light will be turned off.
When the pushbutton is not illuminated, the data block is executed,
even any block containing a Slash code ( / ).
For example:
N1 G54;
N2 G90 G81 X50 .Z-20. R3 .F100;
/ N3 X30.; ( “/: Slash code is in front of the block” )
N4 X10.;
N5 G80;
M30;
※ Please refer to the FANUC Programming Manual for related details.


10.5.3 Manual absolute value
This ON/OFF soft-key selects whether the amount of manual movement is to be added to the
absolute value.
OPERATOR'S PANEL O0000 N0000
： ■ OFF ON
ATC JOG ： ■ OFF ON
ATC CCW ： ■ OFF ON
： ■ OFF ON
MAN ABS ： OFF ■ ON
OVC ： ■ OFF ON
AFL ： ■ OFF ON
TEHIN ： ■ OFF ON
For example:
N001 G01 G90 X100.0 Y100.0 F1000;
N002 X200.0 Y150.0;
N003 X300.0 Y200.0;
(1) When block N002 has been executed after manual operation (X axis + 20.0, Y axis
+100.0) at the end of movement of block N001.
( 220, 250 )
Manual Absolute is OFF

( 120, 200 )
( 200, 150 )
Manual
Operation
( 100, 100 )
Manual Absolue is ON

10-22

(2) When the Feed Hold button is pressed while block N002 is being executed, manual
operation (Y axis +75.0) is performed, and the cycle start button is pressed and
released.

Y
(300, 275)
(200, 225) Manual Absolute is ON
(150, 200 ) (300, 200)

Manual Operation
(200, 150)
(150, 125)
(100, 100)
(3) When the Feed Hold button is pressed while block N002 is being executed, manual
operation (X axis +75.0) is performed, the control unit is reset with RESET button,
and block N002 is read again.
( 300, 275 )
( 200, 225 ) Manual Absolute is ON
( 150, 200 ) ( 300, 200 )

Manual Operation
( 200, 150 )
( 100, 100 )


(4) When there is only one axis in the following command, only the commanded axis
returns.
N1 G01 G90 X100.0 F500 ;

N2 X200.0 ;
N3 Y150.0;
Manual absolute is ON
Manual
Operation
(5) When the following commands are incremental commands, operation is the same
as when the MANUAL ABSOLUTE push-button is OFF.
NOTE: The following conditions will be happened when manual operation is

performed during cutter radius compensation.
A. The MANUAL ABSOLUTE push-button is OFF and cutter compensation

is being performed.
After manual operation is performed with the Manual Absolute push-button in
OFF position during cutter compensation, automatic operation is restarted then the
tool moves parallel to the movement that would have been performed. if manual
movement had not been performed. The amount of separation equals to the amount
that was performed manually.
Manual Absolute is OFF - Tool Path
Tool Path
Program Path
Manual
Operation

10-24

B. The MANUAL ABSOLUTE push-button is ON and cutter radius
compensation is being performed.
Machine operation upon return to automatic operation after manual intervention
with the manual absolute push-button in ON position during execution with an
absolute command program in the cutter radius mode will be described. The
vector, the remaining part of the current block and the beginning of the next block
is shifted in parallel the amount of manual movement performed is included in the
calculations of the vectors of the two blocks subsequent to the current block. This
also applies when manual operation is performed during cornering.
a. During block execution

Example 1:
Program path
(Absolute command)
Tool Path
(before manual operation)
Manual Operation
Assume that the Feed Hold was applied at point PH while moving from PA to PB
of programmed path PA, PB, and PC and that the tool was manually moved to PH'.
The block end point PB moves to the point PB' by the amount of manual
movement, and vectors VB1 and VB2 at PB also move to VB1' and VB2'. Vectors
VC1 and VC2 between the next two blocks PB - PC and PC - PD are discarded
and new vectors VC1' and VC2' (VC2' = VC2 in the example above) are produced
from the relation between PB' - PC and PC - PD. However, since VB2' is not a
newly calculated vector, correct offset is not performed at block PB' - PC. Offset is
correctly performed after PC.


Example 2:
Program Path
(Absolute Command)
Manual Operation
Tool Path
VA1'
This is an example when manual operation is performed during cutter radius

cornering. VA2', VB1', and VB2' are vectors moved in parallel with VA2, VB1 and
VB2 by the amount of manual movement. The new vectors are calculated from
VC1 and VC2. Then correct cutter radius is performed for the blocks following
PC.
b. Manual operation was performed when execution of a block was
terminated by single block stop.
Manual
Operation
Program Path
(Absolute Command)
Tool Path
Vectors VB1 and VB2 are shifted by the amount of manual operation.
Sub-sequence processing is the same as case (a) described above.
An MDI operation can also be intervened as well as manual operation. The
movement is the same as that by manual operation.

10-26

10.5.4 Program restart
This function specifies Sequence No. of a block to be restarted when a tool is broken down or
when it is desired to restart machining operation after a day off, and restart the machining
operation from that block. It can also be used as a high speed tape check function.
When a tool is damaged (P type)

a. Press Feed Hold to escape the tool, and replace it with a new one. Modify the
offset amount if it varies.
b. Press PRGRM to display the present program.
c. Turn the Mode selector in “Handle” or “Rapid” position in order to move Z, Y,
or X axis to change the tool.
d. Depressed the Program Restart push-button on the machine control panel. The
button light will come on.
e. Find the program head, press RESET push-button during memory operation.
Selected AUTO mode position and press O and ↑.
f. Press P Sequence No. ↓, and search the block with Sequence No. to be restarted.
When the same sequence No. appears many times, for example, when the
subprogram is accessed several times in searching Sequence No. in the
subprogram, specify the frequency of a block with its sequence No. in upper 4
digits, and specify Sequence No. in lower 4 digits as illuminated below.
P 1 2 3 4 0 1 2 3 【↓】
└───┘└───┘
Frequency Sequence No.
When the block is the first time, the upper 4 digits can be omitted. Further, the
leading zero can be omitted expect Sequence No. when the frequency is
specified.
g. After completion of block search, the CRT screen is changed to the program
restart screen. Please refer to the screen as below.
(DESTINATION) shows the position where the machining operation is

restarted.
(DISTANCE TO GO) shows the distance between the current tool position and
the machining restart position. The figure at the left side of the axis name shows
the order (parameter setting) described later when the tool moves to the restart
position.
M: Shows M code commanded recently 35 times in the past.
T: Shows T code commanded recently 2 times in the past.


S: Shows S code command in the last.
B: Shows B code command in the last.
Display the most previously commanded code in the head. Each code is cleared
with the program restart command and the cycle start command in reset
conditions.
h. Released Program Restart pushbutton, button light will be extingushed. At this
time, the figure at the left side of axis name (DISTANCE TO GO) flickers as
well as Restart message at the right side.
i. Check the screen, and if M, S, T or B code should be output, select the MDI
mode and output M, S, T or B code from MDI. Each code in this case is not
displayed on the program restart screen.
Selected “Handle” mode, push Spindle CW button to rotate which speed will be
following the spindle speed executed by last block.
j. During memory operation, select AUTO mode and check that the distance of
DISTANCE TO GO is correct, and the tool does not hit the workpiece or others.
If it is about to collide with an obstacle, move the tool manually to the location
where it does not collide, then press CYCLE START button. At this time, the
tool moves to the machining restart position in the Dry Run mode by one axis in
the order set to the parameters No. 0124 to 0127, thus restarting machining
operation in succession.
Manual Absolute button must be depressed all the time.

10-28

When restarting machining operation after the following cases (Q type)
1. When power is turned OFF once
2. When the emergency stop button is depressed once.
3. When the coordinate system is changed after automatic operation is previously
stopped.
For example:
(a) When G92 was set from MDI.
(b) When the coordinate system was shifted.
(c) When the automatic coordinate system was set by the reference point return.
(d) When the coordinate system was modified by "RESET".
a. When power is turned ON or emergency stop is released, perform all necessary

operations at that time, including the reference point return.
b. Move the tool manually to the program starting point (machining start point), and
keep the modal data and coordinate system in the same conditions as at the
machining start.
c. If necessary, set and modify the offset amount.
d. Pressed the Program Restart push-button on the machine operator's panel. Button
light will come ON.
e. Press PRGRM to display the program. When it is not the specified one, search the
specified program.
f. Find the program head block. Press RESET During memory operation, select
AUTO mode, and press O ↑.
g. Press Q "sequence NO." ↓ and search a block with Sequence No. to be re-started.
When the same sequence No. appears many times, specify the frequency of a block
with its sequence No. in upper 4 digits, and specify Sequence No. in lower 4 digits.
h. Upon complete of block searching, the display on the CRT screen is changed to the
Program Restart screen.
i. Release the Program Restart push-button, this function will be ineffective. At this
time, the figure at the left side of axis name (DISTANCE TO GO) blinks.
j. Check the screen, and select the MDI mode if there are M, S, T or B codes to be
specified, and output M, S, T or B codes from MDI, In this case, each code is not
displayed on the program restart screen.
k. During memory operation, return the operation mode to “AUTO” mode, check that
the distance (DISTANCE TO GO) is corrected, and that the tool does nor hit
against a work and others when moving to the machining restart position. If it is
likely to hit against an obstacle, move the tool manually to the position where it
does not collide, then press the CYCLE START button, At this time, the tool
moves to the machining re-start position in the DRY RUN mode by one axis in the
order preset to the parameters (No.0124 to 0127).


10.6 Program Performance Test Operation

10.6.1 Machine lock
This function is used to check a program.
When Machine Lock mode is active (pushbutton is illuminated),

move command pulses are inhibited. Consequently the position
display is updated as specified by the program, but the tool does
not move. The M, S, and T are executed.
Note: When a G27, G28 or G30 command is specified, the tool

does not go to the reference point and the reference point return
completion led does not go on.

10.6.2 Z Axis lock
When the PLC switch # 11 setting up at ON position, the Z axis will
not be moved while machine at Manual/Auto operation.
When the Z axis Cancel push-button is pressed, button is

illuminated, an Z axis command can be ignored during Manual or
AUTO operation. Position display updates as if the axis were
moving. To exit Z axis cancel, press push-button a second time,
button lamp will lights out.

10.6.3 M, S, and T codes lock
When PLC soft-key #7 setting up at “ON”, the M, S, T & B code
will be locked.
(1) When “ON” is selected.

M00, M01, M02, M30, M98 and M99 are executed, even if the
Soft key is ON.
(2) When “OFF” is selected.
All M, S, T code can be executed normally.

10-30

10.6.4 Dry run
When the Dry Run pushbutton is pressed (button is lighted up)
during in MDI or AUTO position, the Feedrate specified by the
program is ignored. G00 will kept the same as Rapid Feedrate,
G01 will becomes as Max. Jog Feedrate by JOG Feedrate
override switch control (P1410). To exit this function, re-press the
pushbutton, and the button lamp will be blacked out.

10.6.5 Rapid override
This Rapid Override switch provides four scales: 100%, 50%,

25% and F0. When the rapid traverse rate is 18 m/min. and a G 00
is commanded in MDI or AUTO mode, this dial is set to 50%,
actual rate becomes 9 m/min. F 0 is a constant value specified by
the parameter.
Rapid override will be effective by the following functions:
(1) By G00.
(2) During canned cycle.
(3) In G27 and G28.
(4) Manual rapid traverse.
(5) Rapid traverse in manual reference point return.

10.6.6 Feed override
With this dial switch, it is possible to override the Feedrate

designated by the program in MDI or AUTO mode. An override of
0 to 200 % can be applied to override all axes in G01 command.
M48, M49 or Rigid Tapping function are always override 100 %,
this dial is not available.


10.6.7 Jog override
When JOG mode is selected, X axis can be moved by pressing +X

momentary pushbutton (button is illuminated) that allows the
operator to jog the X axis in the + X movement with its Jog
Override Feedrate. Axial movement will stopped by released the
push-button. Depress -X pushbutton (button is illuminated) that
allows the operator to jog the X axis in the – X movement with its
Jog Override Feedrate. Y, Z, and 4th axes are the same as X axis
procedure.

10.6.8 Spindle override
The operator could use this switch to modify programmed spindle
speeds in steps of 10% from 50% to 120% during machine is in
the MDI, AUTO or Dry Run mode. The actual spindle speed what
you commanded can be seen on the CRT screen and shows
current spindle speed at Spindle Speed meter. If commanded
spindle speed is 2000 RPM, set the Spindle Speed Override at
50%, the actual Spindle speed will be 1000 RPM.

10-32

10.7 Magazine Operation

 Door must be closed during operation.

MDI HANDLE
DNC JOG
AUTO
RAPID 1. Rotate the mode selector to HANDLE or JOG position.
EDIT ZRN
2. Find the tool magazine index CW pushbutton on the panel.

3. Open the cover of the tool magazine index CW pushbutton.
4. Press this button once; then a pocket will be rotated cw and
the lamp of this button will be lighted up. The lamp will be
extinguished by releasing the button.
5. If pressing this button continuously, the successive pockets
will be also rotated cw. and the lamp of this button will be
lighted up. The lamp will be extinguished by releasing the
button.
6. Find the tool magazine index CCW pushbutton on the panel.
7. Open the cover of the tool magazine index CCW
pushbutton.
8. Press this button once; then a pocket will be rotated ccw. and
the lamp of this button will be lighted up. The lamp will be
extinguished by releasing the button.
9. If pressing this button continuously, the successive pockets
will be also rotated ccw. and the lamp of this button will be
lighted up. The lamp will be extinguished by releasing the
button.


10.8 PMC PRM DATA

10.8.1 PMC PRM DATA for arm type

NO. ADDRESS PRESET CURRENT
01 C00 40 ＊
02 C04 0 0
03 C08 0 0
04 C12 0 0
05 C16 0 0
06 C20 0 0
07 C24 0 0
08 C28 40 ＊
NO.01＊=POCKET NO. OF CURRENT
NO.08＊= TOOL NO. OF SPINDLE
NO. ADDRESS DATA

0001 D0002 1
0002 D0004 2
0003 D0006 3
0004 D0008 4
0005 D0010 5
0006 D0012 6
0007 D0014 7
0008 D0016 8
0009 D0018 9
0010 D0020 10
0011 D0022 11
0012 D0024 12
0013 D0026 13
0014 D0028 14
0015 D0030 15
0006 D0032 16
0017 D0034 17
0018 D0016 18
0019 D0038 19
0020 D0040 20
0021 D0042 21
0022 D0044 22
0023 D0046 23
0024 D0048 24
0025 D0050 25
0026 D0052 26

10-34

NO. ADDRESS DATA
0027 D0054 27
0028 D0056 28
0029 D0058 29
0030 D0060 30
0031 D0062 31
0032 D0064 32
0033 D0066 33
0034 D0068 34
0035 D0070 35
0036 D0072 36
0037 D0074 37
0038 D0076 38
0039 D0078 39
0040 D0080 40
POCKET TOOL
NO. NO.
(NO) 0001~ 0040 0040=POCKET NUMBE

(DATA) 1~ 40 0040=TOOL NUMBER (RANDOM)

11. Troubleshooting Guide 11-1

11. Troubleshooting Guide

This chapter is to guide operator and service personnel in discovering and resolving the errors
or malfunctions emerging from the Programmable Machine Controller (PMC), and the other
alarms from NC or Servo system may be described in the relevant controller manuals supplied
by the controller manufacturer, such as FANUC, MITSUBISHI, SIMENS, HEIDENHAIN, etc.
It depends on the controller attached on your machine. If the following content still can not
help your machine function normally, please check the items described as followed: (1)
Conditions of your machine (as much detailed as possible), (2) Machine Model, (3) Serial No.
(These are all on the machine nameplate), and then contact our Representative or our office in
your territory.
In case of any short circuit or thermal break will be generated by any mechanical overloaded or
mistaken operation, while the electrical malfunction occurs, a prior knowledge of the
components governing the various machine functions can be very useful in segregating the
error of specific area from the control circuit.
As long as the error area has been diagnosed, the electrical components controlling that
function should be checked for proper operation. The coils of any of the electrically held
control devices included within the error area should be checked to inspect if they are in the
proper condition; energized or de-energized as specified in the electrical diagrams. This can be
accomplished by checking the condition of the indicating mechanism on the control device. If
a coil is found to be in the abnormal condition; then the components and related circuitry
controlling the condition of that component must be checked using a volt-ohm meter or similar
checking device. First checks must be certain that 220 Volt supply is being delivered to the
error area. The circuit components will generally operate within a range of 198 to 240 volts. If
the supply voltage is lower than the minimum value, it may be inadequate to energize the
circuit components. In this case, check the transformer output to check if it is within the
prescribed range (220 Volt +/-10%). If not, check the power source to see if line voltage is
being delivered to the electrical system. If the power source and transformer outputs appear to
be adequate, but the voltage being delivered to the error area is low; there is probably a “short”
somewhere in system between the transformer and the error area. The error of malfunction
component will be indicted by checking across each of the circuit components with the proper
voltage being supplied to the error area: the loss of voltage will be detected.
It is quite possible that the coil of the electrically held control device is in the proper condition,
but a system malfunction still exists. In this case, the related circuit components controlling the
condition of that coil would appear to be functioning properly and electrically, thereby
indicting that it is unnecessary to check out the circuit as previously described. In this situation,
the contacts should be inspected for mechanical binding, corrosion, dirt, dust, welded contacts
or similar abnormality.
If the components formerly checked appear to be functioning properly and an error still exists,
check the electrical circuit for such abnormalities as the defective motor, broken or loose
wiring, stuck solenoid, short circuit, etc.
The ordinary component problems and their possible or conceivable factors and reference
remedies are described in this chapter.

11-2

11.1 Alarm List

The following list is for FANUC 0iMD/31iMB controllers.
Address No. Alarm No. Description
A0.0 1000 SPINDLE DRIVER UNIT ALARM
A0.1 1001 EMERGENCY STOP
A0.2 1002 SPINDLE OIL COOLER ALARM
A0.3 1003 OIL/ARI UNIT ALARM
A0.4 1004 SPINDLE OVERHEAT
A2.1 1021 3 AXIS NEED ZERO RETURN

A2.2 1022 Z AXIS IS NOT IN ATC POSITION
A2.3 1023 LOW AIR PRESSURE
A2.4 1024 ATC NOT READY
COOLANT/COOLER MOTOR OVERLOAD
A2.5 1025
(MCP1/MCP2/MCP14/MCP15/MCP16/MCP17)
A2.6 1026 4 TH AXIS CLAMPED
A2.7 1027
A3.0 1030 LOW LUBRICATION PRESSURE
A3.1 1031 LOW LUVTICATION LEVEL
A3.2 1032 GEAR SHIFT FAULT
A3.3 1033 GEAR POSITION ALARM
A3.4 1034 C.T.S TANK OVERFLOW
A3.5 1035 C.T.S FILTER DIRTY
A3.6 1036 C.T.S TANK LOW LEVEL
A3.7 1037 COOLANT TANK LOW OVERFLOW
A4.0 1040 MAGAZINE DOOR OPEN FAULT
A4.1 1041 MAGAZINE DOOR CLOSE FAULT
A4.2 1042 MAGAZINE ROTATION FAULT
A4.3 1043 TOOL UNCLAMP FAULT
A4.4 1044 TOOL CLAMP FAULT
A4.5 1045 MAGAZINE MANUAL MODE


Address No. Alarm No. Description
A4.6 1046 ATLM LIMIT FAULT
A4.7 1047 ALREADY TOOL IN POT
A5.0 1050 TEMPERATURE COMPENSATION UNIT ALARM
A5.1 1051 LOW COOLANT LEVEL
A5.2 1052 TOOL UNCLAMP FAILED DURING M6
A5.3 1053 5 AXIS CLAMP
A5.4 1054
ATC/MAGAZINE MOTOR OVERLOAD
A5.5 1055
(MCP3/MCP5/MCP7/MCP22)
CHIP CONVEYOR MOTOR OVERLOAD
A5.6 1056
(MCP10/MCP12)
A5.7 1057 MCP TURN OFF
A6.0 1060
A6.1 1061
A6.2 1062 T NO. IS NOT REGISTERED
A6.3 1063 T COMMAND > 9998
A6.4 1064 TOOL NO. DUPLICATED
A6.5 1065 POT IS OCCUPIED BY LARGE TOOL
A6.6 1066
A6.7 1067
A7.0 1070 BOTH SIDE OF LARGE TOOL HAVE TOOLS
A7.1 1071
A7.2 1072 ARM MOTOR DRY RUN
A7.3 1073 MAGAZINE POT IS NOT IN POSITION
A7.4 1074
A7.5 1075 TOOL LIFE OVER
A7.6 1076
A7.7 1077

11-4

11.2 Operation Messages and Disposal
Address No. Message No. Disposal
A20.0 2000 DOOR INTERLOCK
A20.1 2001
A20.2 2002
A20.3 2003 HANDLE INTERRUPT
A20.4 2004
A20.5 2005
A20.6 2006
A20.7 2007 SPINDLE LIMIT FAULT
SPINDLE UNCLAMPED CANNOT
A21.0 2010
ORIENTATE/ROTATE
A21.1 2011 M,S,T AND B-FUNCTION ARE LOCKED
PMC K4#2 AND K4#3 CANNOT BE SET1 IN THE
A21.2 2012
SAME TIME
A21.3 2013 SET PMC K0#6=1
SOFT KEY #ATC JOG ON (CHECK SPINDLE ZERO
A21.4 2014
POSITION)
A21.5 2015 SETTING MODE ON
A21.6 2016
NO ROTATING SPINDLE WHILE SPINDLE
A21.7 2017
CLAMPED WITHOUT TOOL
A22.0 2020 X AXIS OVERTRAVEL
A22.1 2021 Y AXIS OVERTRAVEL
A22.2 2022 Z AXIS OVERTRAVEL
A22.3 2023 SET PMC K2#2=1
PMC K0#0 AND K0#1 CANNOT BE SET 1 IN THE
A22.4 2024
SAME TIME
A22.5 2025 SOFT KEY ATC JOG CCW ON
A22.6 2026
A22.7 2027
A23.0 2030 PMM MAGAZINE ALARM


Address No. Message No. Disposal
A23.1 2031
A23.2 2032
A23.3 2033
A23.4 2034
A23.5 2035 AXES INTERLOCK BECAUSE CYCLE STOP
A23.6 2036 AXES INTERLOCK BECAUSE SPINDLE STOP
A23.7 2037
A24.0 2040
A24.1 2041
A24.2 2042
A24.3 2043
A24.4 2044
A24.5 2045
A24.6 2046
A24.7 2047

11-6

11.3 Trouble Shooting

 ONLY the authorized personnel are qualified to service the
following alarms, or the failure could cause serious injury,
fatality, or equipment damage.

1000 SPINDLE DRIVER UNIT ALARM:
Cause Normal Condition Correction
01 Spindle driver fault. PMC signal F45#0=0 -Check spindle driver LED alarm
number.
-Refer FANUC maintenance
manual.
-Replace Spindle driver.
1001 EMERGENCY STOP:

01 Emergency status. PMC signal X8#4=1 -Release E-stop button.
-Check EMG circuit.
02 Operator door is opened. -Operator door must be -Close operator door.

closed during machine -Check door interlock switch.
operation.
03 E-stop button depressed. -E-stop button must be -Release ALL E-stop buttons.
E-stop button on operator released. -Check EMG circuit.
panel, magazine or chip -PMC signal X8#4=1 -Check or replace the wiring.
conveyor side has been -All E-stop buttons are -Check E-stop button is fault.
pressed. normal closed. (normal is closed/push is open)
04 Axes over travel: -All axes in the correct -Push O.T release button than use
X axis hard limit over travel. position MPG move axis to correct
Y axis hard limit over travel. position.
Z axis hard limit over travel.
05 Safety switch is defective. -Switch is in normal closed -Replace the switch.

(SG1/SG2/SG3) during door closed. -Check door interlock circuit.
(X10.0 &X10.1=1)


06 Safety relay is defective. -When normal safety -Check all door is closed and all
(SSK1/SSK2) relay(SSK1 & SSK2) E-stop is release.
contact(S11&S12) -Check door interlock and E-stop
(S21&S22) is closed. circuit.
-Replace safety relay.
1002 SPINDLE OIL COOLER ALARM:

01 Low pressure. -Pressure no less 4 kg/cm^2 -Check the pressure valve and
PMC X5.1=1 Piping.
02 Require oil. -Oil level no less than -Refill the oil.

lower line.
03 Hydraulic motor not start. -Check PMC Y0.0=1 -Clean the filter.
-Check NFB4 ON. -NFB4 on, Has 3Φ-AC220V power.
-Check relay (K8=ON). -Replace the solenoid.
-Check MC1 active.
-No load X10.4=0
04 Electric circuit problem. -PMC X5.1=1 -Check wiring no. 309
05 Motor failed. Motor break. -Check the motor, Replace the

Motor.
1003 OIL/AIR UNIT ALARM: (option function)

01 Oil/Air unit low pressure -Pressure no less -Check Oil and Air piping is ok or
4kg/cm^2. break.
-Check Oil is enough.
1004 SPINDLE OVERHEAT: (option function)

01 Spindle bearing is overheat. -Spindle bearing -Check OIL/AIR unit.
temperature is less 40℃ -Check OIL/AIR piping.
During spindle rotation. -Check spindle oil cooler unit.
-Replace bearing.

11-8

1021 3 AXIS NEED ZERO RETURN:
01 3 axes need home returned -After power on all axes -Select home mode then push cycle
correctly. need home return. start.
-After release E-stop
button all axes need
home return again.
1022 Z AXIS IS NOT IN ATC POSITION:

01 ATC arm active but Z axis not -During ATC change Z -execute CNC program:
in second reference position. axis must be in second G91 G30 Z0 M19;
reference position.
1023 LOW AIR PRESSURE:

01 Air pressure low. -Air pressure need -Check Air source is more
4kg/cm^2~7kg/cm^2 4kg/cm^2.
-Check Air piping is ok or break.
-Check Air master valve.
1024 ATC NOT READY:

01 ATC ARM not in correct -PMC X7#3=0, X7#4=1, -Release the brake which is at the
position. X7#5=0 end of the arm motor.
-Use the wrench to turn the axle
center of the motor until the arm
goes back to the home position.
-Make sure the three sensors of the
arm are normal.
1025 COOLANT/COOLER MOTOR OVERLOAD: (MCP1/MCP2/MCP14/MCP15/MCP16/MCP17)

01 One of the coolant motor is -All MCP switch on. -Reset the overload protector
Overload, So MCP shut off. MCP1/MCP2/MCP14/MCP15/M
CP16/MCP17
-Solve the motor problem and
Reset.


1026 4TH AXIS CLAMPED:
01 On the manual mode -On the manual mode press
4th Axis is clamped. 4th axis unclamp button.
-Select auto mode then execute
M11 code, then turn to manual
mode.
1027
01
1030 LOW LUBRICATION PRESSURE:

01 Lubrication starts with -Way lubrication oil motor -Check Way lubrication piping is ok
incorrect pressure not running X5#2=0. or break.
-Way lubrication oil motor -Check timer no.3 set value is
Running less TIMER correct.
no.3 set value the PMC -Check lubrication pressure switch
X5#2=1 is ok.
02 Oil level low. -Oil level no less than -Refill the oil.
lower level line.
1031 LOW LUBRICATION LEVEL:

01 Low oil level for guide way -PMC X5#3=1 -Oil refill.
Lubrication. -Check oil level switch is ok.
1032 GEAR SHIFT FAULT:

01 Gear shift fault , gear shift -Low gear PMC X4#5=1 -Check gear position sensor.
active more than timer no.33 -High gear PMC X4#6=1 -Check air pressure.
Set value. -Check gear is ok or break.

11-10

1033 GEAR POSITION ALARM:
01 Gear position sensor fault. -Low gear PMC X4#5=1 -Check gear position sensor.
-High gear PMC X4#6=1 -Check air pressure.
1034 C.T.S TANK OVERFLOW: (option function)

01 C.T.S tank coolant overflow. -PMC X8#2=1 -Reducing the coolant from the
-C.T.S tank coolant level Tank.
On the middle. -Check C.T.S tank float switch.
-Check C.T.S tank high level
sensor.
1035 C.T.S FILTER DIRTY:

01 Coolant filter is dirty. -PMC X8#3=1 -Check filter pressure switch.
-Clean the filter of the coolant tank.
1036 C.T.S TANK LOW LEVEL: (option function)

01 C.T.S tank coolant low level. -PMC X8#1=1 -Refill the coolant.
-C.T.S tank coolant level -Check C.T.S tank float switch.
On the middle. -Check C.T.S tank low level sensor.
1037 COOLANT TANK OVERFLOW:

01 Coolant tank coolant high -PMC X8#6=1 -Reducing the coolant from the
level. -Coolant level is middle. coolant tank.
-Check coolant tank float switch.
-Check coolant tank high level
sensor.
1040 MAGAZINE DOOR OPEN FAULT: (option function)

01 ATC operator door open -PMC X18#0=1, when -Resetting.
signal fault. ATC door is open. -Re-adjust the sensor position.
-Adjust the AIR pressure.
-Check the door open sensor.


1041 MAGAZINE DOOR CLOSE FAULT: (option function)
01 ATC operator door close -PMC X18#1=1, when -Resetting.
signal fault. ATC door is closed. -Re-adjust the sensor position.
-Adjust the AIR pressure.
-Check the door close sensor.
1042 MAGAZINE ROTATION FAULT:

01 Magazine rotation more than -Magazine select tool -Check magazine counter sensor.
3 minutes. rotation less 1 minutes -Check magazine tool number.
1043 TOOL UNCLAMP FAULT:

01 Executor tool unclamp Y2#2 -When executor tool -Check tool clamp & unclamp
But X4#2=0 or X4#1=1. unclampY2#2=1, sensor.
X4#2=1 and X4#1=0 -Check sensor wirings.
1044 TOOL CLAMP FAULT:

01 No executor unclamp Y2#2, -When no executor tool -Check tool clamp & unclamp
But X4#1=0 or X4#2=1 unclamp Y2#2=0, sensor.
X4#1=1 and X4#2=0 -Check sensor wirings.
1045 MAGAZINE MANUAL MODE: (option function)

01 Execute M6 or T command -Magazine operator panel -Turn the Magazine operator panel
but Magazine operator panel Mode on the auto mode to auto mode.
In manual mode. position.
1046 ATLM LIMIT FAULT:

01 ATLM limit fault. -No Emergency stop. -Check the electric circuit of the
-Skip signal X4#7=1 ATLM is in good condition.
-Check the activity of the ATLM
is corrected.

11-12

1047 ALREADY TOOL IN POT: (option function)
01 ATC DRUM type alarm: -Just spindle have a tool. -Check magazine counter sensor.
When ATC, spindle have a
tool. And magazine pot have a
tool in the same time.
1050 TEMPERATURE COMPENSATION UNIT ALARM: (option function)

01 Temperature compensation - -Check PLC program.
Unit fault. -Check PMC temperature
compensation card.
-Check temperature sensor.
1051 LOW COOLANT LEVEL:

01 Coolant level low. -PMC X8#5=1 -Refill the coolant.
-Coolant level is middle. -Clean the filter.
-Check float switch.
1052 TOOL UNCLAMP FAILED DURING M6:

01 Execute ATC but spindle tool -Tool unclamp Y2#2=1 -Check tool clamp & unclamp
unclamp can not active. X4#2=1. sensor.
-Check sensor wirings.
1053 5 AXIS CLAMP: (option function)

01 On the manual mode -Select auto mode then execute
5 Axis is clamped. M11 code, then turn to manual
mode.
1054
01


1055 ATC/MAGAZINE MOTOR OVERLOAD (MCP3/MCP5/MCP7/MCP22):
01 ATC / Magazine motor is -MCP3 / MCP5 / MCP7 -Check ATC /Magazine motor.
overload. / MCP22 turn on. -Check MCP set value.
-Check motor power wiring.
1056 CHIP CONVEYOR MOTOR OVERLOAD (MCP10/MCP12):

01 Chip conveyor motor -MCP10 / MCP12 -Check chip conveyor motor.
overload. Turn on -Check MCP set value.
-Check motor power wiring.
1057 MCP TURN OFF:

01 One of the MCP is turn off. -All MCP are turn on. -After maintenance turn ALL MCP
to on.
1060
01
1061
01
1062 T NO. IS NOT REGISTERED:

01 T code number error -All tool number on the -T code number is not in the tool
tool table table, please correct it.
(PMC D00~D400)
1063 T COMMAND > 9998:

01 T command exceeded -T command range is -Corrected the T command.
permitted range. 0~9998

11-14

1064 TOOL NO. DUPLICATED:
01 Tool number already -Spindle tool number -Check tool table.
registered in the tool table already registered in tool -Check spindle tool number.
When designating new tool. table.
1065 POT IS OCCUPIED BY LARGE TOOL:

01 No zero tool in the magazine. -If spindle is large tool -Check tool table.
magazine must be have a
zero tool.
1066
01
1067
01
1070 BOTH SIDE OF LARGE TOOL HAVE TOOLS:

01 Both side of large tool pocket -Both side of large tool -Check the tool table.
Have registered tool no. must be set 9999
1071
01
1072 ARM MOTOR DRY RUN:

01 ATC arm active more than 50 -ATC arm finish tool -Check ARM motor.
sec. change less 50 sec. -Check ARM.


1073 MAGAZINE POT IS NOT IN POSITION:
01 Magazine pot is not in the -IF magazine pot in the -Check magazine counter sensor.
correct position. correct position. -Check magazine position sensor.
1074
01
1075 TOOL LIFE OVER: (option function)

01 Tool life is over. -Tool life is normal. -Change a new tool.
1076
01
1077
01
2000 DOOR INTERLOCK:

01 Operator open while machine -Close the operator door -Close the operator door , then
in operation. PMC X10#0=1 Run the machine.
2001
01
2002
01

11-16

2003 HANDLE INTERRUPT:
01 Operator push Handle -AUTO mode machine -Push handle interrupt button again.
interrupt button. can not use MPG.
Machine is in HANDLE But in handle interrupt
INTERRUPT mode. mode can use MPG
interrupt.
2004
01
2005
01
2006
01
2007 SPINDLE LIMIT FAULT:

01 Spindle clamp and unclamp -Spindle clamp(X4#1) and -Check tool clamp and unclamp
Signal together on. unclamp(X4#2) only one Limit.
signal is on. -Check limit wiring.
2010 SPINDLE UNCLAMPED CANNOT ORIENTATE/ROTATE:

01 Spindle run or orientate while -Spindle run or orientate -Clamp spindle tool, Then run
Spindle unclamping. in spindle clamp status. spindle.
2011 M, S, T AND B-FUNCTION ARE LOCKED:

01 PLC soft key [AFL] on. -PLC soft key [AFL] is -Turn off the PLC soft key[AFL].
M, S, T function are locked. off.


2012 PMC K4#2 AND K4#3 CANNOT BE SET1 IN THE SAME TIME:
01 PMC K4#2 AND K4#3 set 1 -Only one bit set 1. -Check machine type, then set bit.
Together.
2013 SET PMC K0#6=1:

01 CE type machine but PMC -CE type machine PMC -Set PMC K0#6=1
K0#6 set 0. K0#6 set 1.
2014 SOFT KEY #ATC JOG ON (CHECK SPINDLE ZERO POSITION):

01 PLC soft key #ATC JOG is on -Soft key [ATC JOG] is -Turn off the soft key [ATC JOG]
Execute ATC maintenance off.
Status.
2015 SETTING MODE ON:

01 Setting mode key turn on. -Setting mode key turn -Setting mode key turn off.
off.
2016
01
2017 NO ROTATING SPINDLE WHILE SPINDLE CLAMPED WITHOUT TOOL: (option function)
01 High speed spindle rotating -Spindle need clamp tool -Make spindle clamp a tool.
without tool. Then run.
2020 X AXIS OVERTRAVEL: (increment type)

01 X axis over travel. -Push [O.T] release button.
Then move X axis to correct
Position.

11-18

2021 Y AXIS OVERTRAVEL: (increment type)
01 Y axis over travel. -Push [O.T] release button.
Then move Y axis to correct
Position.
2022 Z AXIS OVERTRAVEL: (increment type)

01 Z axis over travel. -Push [O.T] release button.
Then move Z axis to correct
Position.
2023 SET PMC K2#2=1:

01 C.T.S function need set PMC -PMC K2#2=1 when use -Set PMC K2#2=1
K2#2=1 C.T.S function.
2024 PMC K0#0 AND K0#1 CANNOT BE SET 1 IN THE SAME TIME:
01 PMC K0#0 AND K0#1 SET 1 -Only one bit set 1 -Check machine type then set
In the same time. PMC bit.
2025 SOFT KEY ATC JOG CCW ON:

01 PLC soft key -PMC soft key -Turn off the PLC soft key
[ATC JOG CCW] turn on. [ATC JOG CCW] is off. [ATC JOG CCW].
2026
01
2027
01


2030 PMM MAGAZINE ALARM: (option function)
01 PMM magazine alarm. -Check servo magazine motor.
-Check servo magazine wiring.
2031
01
2032
01
2033
01
2034
01
2035 AXES INTERLOCK BECAUSE CYCLE STOP:

01 AXES interlock because -Push CYCLE START.
operator execute CYCLE
STOP.
2036 AXES INTERLOCK BECAUSE SPINDLE STOP:

01 AXES interlock because -Run spindle then push CYCLE
Spindle stop. START.
2037 / 2040 / 2041 / 2042 / 2043

01

11-20

11.4 The Remedies of Automatic Tool Change Error

11.4.1 Arm type
The tool change interruption solution procedures are as follows: Operation A or Operation B.
11.4.1.1 Operation A
Step 1: Press the emergency-stop button to ensure safety, and then release it.
Step 2: Keeps the Z axis at the second reference point if arm is at zero position.
Step 3: Press the buttons on the CRT/MDI panel.
【OFFSET SETTING】Pages 【OPR】 ATC JOG “ON”.

Step 4: Set the mode selector in JOG position.
Step 5: Keep pressing the Cycle Start button on the machine operator’s panel until the tool
arm move to spindle.
Step 6: Press door open button, then open the door.
Step 7: Press [manual tool assist] button.
Step 8: Push tool unclamp button, spindle will keep unclamp tool.
Step 9: Close door, then press door open button to close door.
Step10: Keep pressing Cycle start button, ARM will go down then rote 180 degree. Then go
up to spindle.
Step11: Press door open button, then open the door.
Step12: Push tool unclamp button, spindle will clamp tool.
Step13: Press [manual tool assist] button.
Step14: Press door open button to close door.
Step15: Keep pressing the Cycle Start button on the machine operator’s panel until the tool
arm move to its home position.
Step16: Press the buttons on the CRT/MDI panel.
【OFFSET SETTING】Pages 【OPR】 ATC JOG “OFF”.

Step17: After the tool arm move to its home position, please check the spindle tool number,
current tool pocket number, and current tool number in the pocket.
Step18: Reference Point Return operation is performed.
11.4.1.2 Operation B
Step 1: Press the emergency-stop button to ensure safety.
Step 2: Turn the brake lever to release the brake of the cam motor.
Step 3: Use a wrench to rotate the shaft of the motor. It will cause the moving of the arm.


Step 4: If there is the tool gripped on the arm, please move down the arm, push the pin on
the top surface of the arm to release the gripper, then remove the tool.
Step 5: Move the arm back to its original position, then release the brake lever.
Step 6: Please check the tool management to ensure the correct tool registration.



# Manual No. Date Contents
1 MPAAF1000E Jan., 2008 First edition.
‧ Updated corresponding drawings of sheet metal.
‧ Added new section: 4.2 Axes Locking and Machine Packaging.
‧ Corrected the figure of air pressure to 4~7kgf/cm2 in 5.4 and 9.1.
2 MPAAF1001E Dec., 2009
‧ Updated specification of lubricator in 6.2.3.
‧ Added maintenance information for linear scale in 7.3.2.
‧ Corrected the content of alarm no. 1072 in 11.3.
‧ Corrected the content of 1.4.1 and 1.5.
‧ Added item C. Saddle in 2.1.
‧ Updated the content of 6.1.2 Leveling adjusting.
3 MPAAF1002E Dec., 2010 ‧ Modified the diagram in 6.2.1 and 6.2.2.
‧ Corrected the capacity of oil reservoir to 4.2L in 7.2.4.
‧ Updated M code function list in 10.1.
‧ Updated the content of chapter 12.
‧ Updated the conditions for storage and installation.
‧ Updated foundation drawings and anchor bolt diagram in 3.1.3.
‧ Added a statement regarding headstock coolant replenishment
(gear drive) before trial run and updated the recommended
lubricant table in 5.3.
‧ Updated tool information in 6.1.8
4 MPAAF4000E March, 2014 ‧ Added a maintenance statement regarding headstock lubrication
(gear drive) in 7.2.4.
‧ Replaced FANUC 18i information with FANUC 31i ones in 8.1.
‧ Updated electrical component layout of cabinet in 8.4.
‧ Updated the operation concerning ATC error correction in 11.4.
‧ Removed chapter 12.
‧ Updated the specification data of power source in 3.2.1.
5 MPAAF4001E Jan., 2015
‧ Removed Appendix.

崴立機電股份有限公司
303 新竹縣湖口鄉新興路 458 號
No.458, Sinsing Rd., Hukou Township, Hsinchu County 303, Taiwan (R.O.C)
TEL: +886‐3‐696‐0360 FAX: +886‐3‐696‐0370
421 台中市后里區三豐路 356 號
No.356, Sanfeng Rd., Houli Dist., Taichung City 421, Taiwan (R.O.C.)
TEL: +886‐4‐2558‐0762 FAX: +886‐4‐2558‐0430

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1) Operation and Maintenance Manual

12. Revision History

 Indicates points to be followed.

 (Indicates manuals, chapters or sections to

1.1 Safety Instructions

PLEASE READ THESE SAFETY RECOMMENDATIONS BEFORE PROCEEDING

Colors indicated light meaning on the operator’s panel:

1.2 Illustration of Hazard Region

1.3 Illustration of Safety Device Position

1.4.1 Carousel type magazine

Alway s follow the ins tructions on this label.

1.5 Marking of the Oil Replenishing Point of this Machine

2.1 Descriptions of mechanical design and construction

D. Magazine and the ATC system

2.2 Construction features of the machine

2.3 Operation Condition

2.4 The Expected life of the machine

2.5 Storage condition

2.6 Installation condition

2.7 Noise measuring

PA: OPERATOR’S CONTROL PANNEL POSITION

1. DISTANCE FROM POINT 1 TO WALL IS: 3000 mm

The axis Description

2.9 Main part name

2.10 Maximum floor space

2.11 Working range

Model Travel: X-Y-Z A B C D E F G H J

2.12 Table & T-slot size

3.1 Space Required

AA mm 20 50 200 340 120 300 400 600 800

3.2 The Requirement of Power Sources

e. The cross-section area of Power line cable

Figure 3-1 The grounding method of multiple machines

4. Transportation and Installation

4.1 Crane and Hoist Transportation

Figure 4-1 Hoisting diagram for AA965/AA1165

Figure 4-3 Lifting diagram of forklift truck (AA965/1165/1365/1565)

Figure 4-4 The forklift truck capacity

4.2 Axes Locking and Machine Packaging

Code Description Quantity

4.3 Precaution after Opening Package

4.4 Storage Condition

4.5 Precaution on Installation

4.6 Leveling Adjustment

Figure 4-5 The perpendicularity between spindle and table

5. Preparation before Trial Run

5.2 Removing Protection Attachment

Figure 5-1 Location of the fixtures for AA Series

5.3 Replenishing Lubricant

5.4 Air Supply

5.5 Coolant Supply

5.6 Electricity Connection and Grounding Method

5.7 Safety Inspection

No. Item Checking procedure

5.8 Warm-up Description

6. Setting and Adjusting

6.1 Structural Setting and Adjusting

Figure 6-1 Tool is not completely unclamped