hitachi seiki VS50, VS 60 Maintenance Manual

MACHINING CENTER

VS50/60

INSTRUCTION MANUAL

MAINTENANCE

SEIKI-SEICOS Σ 16M/18M

Version 1.01

BM-2782-1-0221-E-1-01

1

Introduction

Thank you for your having purchased the machine, favoring our product lines for your use.

This manual contains fundamental information on the maintenace. Please read and fully understand the contents for your safe machine operation.

In particular, the contents of the items concerning safety in this manual and the descriptions on the “caution plates” attached to the machine are important. Please follow the instructions contained and keep them always in mind to ensure safe operation.

The reference record papers on adjusting setting values such as a parameter list are attached to the machine unit and enclosed in the packing. These are necessary for maintenance and adjustment of the machine later on. Please keep them safely not to be mislaid.

The design and specifications of this machine may be changed to meet any future improvement. As the result, there may arise some cases where explanations in this manual could become partly inconsistent with the actual machine. Please note this point in advance.

In this manual, items on the standard and optional specifications are handled indiscriminately. Please refer to the “delivery note” for the detailed specification of your machine confirmation.

1

CONTENTS

1. INSTALLATION ....................................................................................	1 - 1
1-1 Machine Installation ...........................................................................................................	1 - 1
1-1-1 Environment of the Machine ......................................................................................	1 - 1
1-2 Foundation and Layout Drawing ........................................................................................	1 - 3
1-3 Transportation of Machine .................................................................................................	1 - 5
1-3-1 Precautions for Lifting Work ......................................................................................	1 - 5
1-3-2 Precautions When Using the Forklift .........................................................................	1 - 5
1-4 Electric Wiring ...................................................................................................................	1 - 8
1-5 Air Supply .........................................................................................................................	1 - 10
1-6 Oil Supply ........................................................................................................................	1 - 11
1-7 Mounting Procedure ........................................................................................................	1 - 12
2. INSPECTION AND MAINTENANCE ...................................................	2 - 1
2-1 Daily Check and Periodic Check Items .............................................................................	2 - 1
2-1-1 Daily Checking Items .................................................................................................	2 - 1
2-1-2 Periodic Check Items ................................................................................................	2 - 5
2-2 Lubrication, Oil Supply and Coolant .................................................................................	2 - 10
2-2-1 List of Lubrication and Oil Supply ............................................................................	2 - 11
2-2-2 Handling of Coolant Unit ..........................................................................................	2 - 12
2-3 When the Call Light (Yellow Warning Lamp) is Lit Up......................................................	2 - 17
2-3-1 Kinds of Alarms and Study and Measure of Causes of Obstacles ..........................	2 - 17
2-3-2 Replacing Method of Battery ....................................................................................	2 - 18
2-3-3 Alarm List .................................................................................................................	2 - 21
2-4 Parameters .....................................................................................................................	2 - 32
2-4-1 Kinds and Main Contents of Parameter ...................................................................	2 - 32
2-4-2 About a Management of Parameter .........................................................................	2 - 32
2-4-3 Altering the PC Parameter Setting ...........................................................................	2 - 33
2-5 List of SOL/LS Functions and Uses
(See the SOL/LS Layout for the Location of Equipment.) ...............................................	2 - 34
2-6 ATC Maintenance and Adjustment ...................................................................................	2 - 37
2-6-1 Drive Mechanism General .......................................................................................	2 - 37
2-6-2 Explanation of Actions ATC ......................................................................................	2 - 39
2-6-3 ATC (Automatic Tool Changer) Maintenance, Adjustment and Operation ................	2 - 42
2-6-4 Method of Manual Tool Unclamping .........................................................................	2 - 45
2-6-5 Procedure for Bleeding Air in the Tool Locking System ...........................................	2 - 46
2-6-6 Adjusting a Tool Push Allowance ..............................................................................	2 - 48
2-7 Each Axis Stroke and Zero Point Adjustment ...................................................................	2 - 50
2-8 Countermeasures against shift of follow-up coordinate
(shift of memory software OT) ........................................................................................	2 - 54

i

2-9 Adjustment of Synchro Belt Tension for Z-axis Feed .......................................................	2 - 55
2-10 Instructions for Motor/Inverter for ATC Twin Arm Rotation .............................................	2 - 56
2-10-1 Setting and Changing the Parameters ...................................................................	2	- 56
2-10-2 Initializing the Parameters .....................................................................................	2	- 57
2-10-3 Monitoring ..............................................................................................................	2	- 59
2-10-4 Errors ....................................................................................................................	2	- 60
2-10-5 Resetting the Inverter .............................................................................................	2	- 63
2-10-6 Inspection and Maintenance ..................................................................................	2	- 64
2-10-7 Troubleshooting .....................................................................................................	2	- 67
2-11 Handling and Maintenance of Spindle Oil Air Lubricating Unit (Option) ..........................	2 - 70
2-11-1 Oil Air Lubrication Circuit ........................................................................................	2	- 70
2-11-2 Pump Unit ..............................................................................................................	2	- 71
2-11-3 Mixing Valve ............................................................................................................	2	- 73
2-11-4 Daily maintenance .................................................................................................	2	- 74
2-12 Related to Coolant .........................................................................................................	2 - 76
2-13 Related to Air Pressure..................................................................................................	2 - 80
2-14 Chip Conveyor (For the Inside of Standard Machine) ....................................................	2 - 84
2-15 Spindle Cooling Circuit Diagram ....................................................................................	2 - 85
2-16 Servo Unit ......................................................................................................................	2 - 86
2-16-1 Alarm Concerning Power Supply Unit
(Source Power of Spindle/Servo Amplifier) .............................................................	2	- 86
2-16-2 Spindle Amplifier Status Display .............................................................................	2	- 89
2-16-3 Spindle Amplifier Alarm ..........................................................................................	2	- 90
2-16-4 Detail of Spindle Amplifier Alarm Contents .............................................................	2	- 95
2-17 List of Supply Items .....................................................................................................	2 - 102

ii

1. INSTALLATION

1-1 Machine Installation

When installing NC machine, solid foundation is essential. It is also most important for maintaining the best condition of cutting accuracy of the machine. The nature of the ground condition of the factory site, for example, rock base or reclaimed land, makes a big difference. It is, therefore, difficult to give any definite rules generally applicable to the installation of this machine. (Refer to the foundation and arrangement drawings.)

The followings are the concrete items to be carefully attended when installing this machine.

1)The bearing capacity of soil should be 5 ton/m2 or larger and thickness of the foundation should be 300mm or thicker.

2)The area of the foundation should be extend to at least 300mm outer circumference of the machine bed.

3)When digging vibration proof drains, they should be dug along the circumference of the foundation.

4)Placing separate concrete blocks underneath each machine leg instead of a real foundation is often seen, which is just not adequate. Such is no value as proper foundation,

As this machine yields large volumes of chip during machining, carts are often used for chip disposal. The traffic of carts and detaching covers in maintenance work need free space so that the operators can move around without touching other machines. This factor should be considered when selecting the installing position of the machine.

1-1-1 Environment of the Machine

Pay full attention to a room temperature, dust, vibrations, etc. in order to make use of the primary performance of the machine. High accuracy cannot be obtained in the environment where the room temperature greatly changes. Just a slight change of the room temperature partly affects the machine. Be fully careful of effects heat transfer from the direct sunshine, vent, heating unit, and so on.

Under the environment where the air is polluted so much by dust, etc., the sliding sections and electric devices of the machine are greatly effected in their service lives.

Particularly, electronic devices related to controls are susceptible to dust and humidity. Install the machine in the environment as clean as possible.

1. Installation Environment of NC Machine

In case that electric machines and appliances generating high frequency noise are installed or newly erected near by NC machines, keep to the following precautions.

1)Example of the electric machines and appliances generating high frequency noise.

[1]Arc welding machine

[2]Resistance welding machine

1 - 1

[3]High frequency drying machine

[4]Electric discharge machine

[5]Others

2)Installation form of NC machine

[1]Power supply line

The power supply line (AC200V) of NC machine must be separated line with that for electric machines and appliances.

If impossible, connect the line at the point more than 20m apart from the point where the power supply for electric machines and appliances is connected.

[2]Installation place of NC machine

NC machine must be installed more than 20m apart from electric machines and appliances.

[3]Earth of NC machine

The earth of NC machine must be grounded within 5m from NC machine separating from the ground of electric machines and appliances, and make a ground work with not more than 100Ω or comply with the laws and regulations of the country.

Or the earth wire size must be not less than 8mm2.

3)Example of earth of NC machine

The earth state of NC machine and electric machines and appliances illustrated as under.

Power receiving equipment

1 - 2

1-2 Foundation and Layout Drawing

Note) 1. Ground bearing force should be 5ton/m2 (1000 lbs/ft2) or more. And foundation thickness should be at least 300mm. (12”)

2.The area of foundations is to be 300mm (12”) or more of the circumference of the machine bed.

3.Install the tremor insulating groove along the outer periphery of the foundation.

1 - 3

Foundation and Layout Drawing

Note) 1. Ground bearing force should be 5ton/m2 (1000 lbs/ft2) or more. And foundation thickness should be at least 300mm. (12”)

2.The area of foundations is to be 300mm (12”) or more of the circumference of the machine bed.

3.Install the tremor insulating groove along the outer periphery of the foundation.

1 - 4

1-3 Transportation of Machine

Since this machine has an integrated structure mechanically and electrically, it can be

transported only by detaching its power cord. To fix its moving parts and pass wire ropes

around the machine, refer to Fig.1-1.

1-3-1 Precautions for Lifting Work

Pay proper attention to lifting work, because it is one of important steps when transporting

the machine.

! WARNING

Since the lifting work for machine transportation is carried out with a crane or chain block, its precautions are listed below:

(1)Use a wire rope whose diameter is 14 mm (0.55 inch) or more.

(2)Apply a pad to an acute-angle part to protect the wire rope and machine.

(3)Pass the rope so that the center of gravity of a load will come over the center line of a lifting angle.

(4)Do not use a rusted wire rope, one which has been untwisted, or one whose core wire is broken.

(5)Lift the machine gradually. Stop it once when the wire rope become strained, and check a lifting conditions. When the machine is lifted up from the floor, check again that there are no abnormalities with the lifting rope, and proceed with the lifting rope. When lowering the machine, it is necessary to be careful that it is lowered down slowly. Stop lowering the machine immediately before it reaches the floor to check.

Then, lower it down completely.

1-3-2 Precautions When Using the Forklift

! WARNING

Since the lifting work for machine transportation is carried out with a forklift, its precautions are listed below:

1 - 5

(1)Select a fork lift which has a sufficient capability to handle and endure a machine weight.

(2)In order not to damage the outer projected parts of the machine, it is necessary to carry out this work in cooperation with a watchman.

(3)When inserting the fork under the machine, use the right and left cast grooves provided for fork insertion under the base of the machine proper.

(4)When lifting the machine, be sure to carry out temporary lifting so that you can lift it with the center of gravity of the machine set at the stablest positions in both longitudinal and crosswise directions.

1 - 6

1 - 7

1-4 Electric Wiring

Wires between the machine proper and accessories will be connected by Hitachi Seiki. Wiring from the power supply source to the electric cabinet should be prepared in advance by the customer.

For this purpose, use wires of thickness specified in the following table, depending on the distance from the power supply to the electric cabinet.

Power supply

: 200/220V (50/60 Hz) ± 10%

Source Power Capacity

The electric capacity required for the machine varies depending on the specification of the spindle and the type of option attachments. To calculate the capacity of the machine being installed, add the capacity of option specification on to that of the standard machine.

Machine Electric Capacity = Standard Machine Electric Capacity

+ Total Electric Capacity of Option Attachments

Power Capacity of Standard Machine

Spindle Specification		Power Capacity
4500 min-1		25 kVA
10000 min-1		40 kVA
12000 min-1	Standard	18 kVA
12000 min-1	High output	36 kVA
20000 min-1		31 kVA

Option Attachment requiring Additional Power Capacity

Option Attachment	Additional Power Capacity
Oilhole Coolant 0.5MPA	1.3 kVA
Oilhole Coolant 1.5MPA	1.4 kVA
Oilhole Coolant 7.0MPA	3.7 kVA
Through Coolant 0.5MPA	1.3 kVA
Through Coolant 1.5MPA	1.4 kVA
Through Coolant 7.0MPA	3.7 kVA
Jet Coolant	1.0 kVA
Gun Coolant	0.4 kVA
Mist Collector	1.1 kVA
Hydraulic Power Source	1.3 kVA

1 - 8

Thickness of Wire

The source power wire thickness varies depending on the specification ofthe spindle. Use the wire of the following thickness to meet the specification.

Spindle Specification		Source Power Wire Minimum	Grounding Wire Minimum
		Thickness	Thickness
4500 min-1		38 mm2	8 mm2
10000 min-1		60 mm2	8 mm2
12000 min-1 Standard		22 mm2	8 mm2
12000 min-1	High output	50 mm2	8 mm2
20000 min-1		50 mm2	8 mm2

*The thicknesses of the source power wire in the above table are calculated on the assumption

that three 600V vinyl coated wires are set in a conduit pipe at the ambient temperature is 30° C.

1 - 9

1-5 Air Supply

This machine uses clean air to clean the spindle hole and the tool, for Z axis sliding face and automatic door, or for oil mist unit. The air supply should be prepared by the customer.

Its joint of the machine is of PT1/4, female.

Air pressure : 0.5MPa {5 kgf/cm2} (72 PSI) or more

Flow	: 100 •/min. (ANR) (Standard Specification)

*It is recommended to install an air tank having a capacity of 40• or larger, as there are cases when supply of a large volume of air is needed instantaneously.

The machine proper is provided with an air filter and regulator to remove dust and supersaturated moisture from air. When the temperature of the air from the air supply is higher than that of the machine proper, air gets cooled at the machine proper and tends to form water drops.

Jetting air containing water is prone to cause rust on the spindle hole and tool shank, which may affect machining accuracy and cutting surfaces. Therefore, the temperature of the air from the air supply should below. (Water and dust accumulating in the air filter is automatically drained. To manually drain them, see the descriptions on mechanical drain operation.) In case there is a large difference in temperature, install an air drier between the air supply and the machine.

Flow rete

The flow rate to be set varies depending on the option specification. Therefore, the flow rate applicable to the actual machine should be determined by the flow rate for the standard specification machine added by the total required flow rate for the option specification.

Flow rate for the machine = Standard flow rate + flow rate for option specification

Standard specification

Machine specification	Flow rate
#40-12000min-1	100 /min (ANR)

1 - 10

Additional flow rate required by optional specifications

	Optional specification				Flow rate
	Tool nose air blow				300	/min (ANR)
	Center-through air blow				300	/min (ANR)
	Pulscale X, Y				60	/min (ANR)
	Oil mist/Needle 1 shot				60	/min (ANR)
	Semi-dry processing unit				300	/min (ANR)
In case with APC (essential)
Air pressure:		0.5MPa (5kg/cm2) or higher
Flow rate:		100	/min (ANR)
Air tank capacity:		40	or larger

1-6 Oil Supply

When adding lubricating oil, take care of the following:

1.Add the specified amount of the designated oil. Do not use different oils, and do not add to much of oil.

2.Clean the oil supply port in advance. See that dust, etc. do not enter.

3.When adding oil, set a filter on the oil supply port, so that dust and other foreign substance will not enter. In case a filter is not available, use a wire netting of 150 mesh or more.

4.Always use new oil. Do not use a mixture of new and old oil.

5.Even when using new oil, do not use all the oil from the can. Always leave some oil in the can. This is necessary to avoid sediments in the can being used.

For the oil supply positions, intervals, oil amount and quality, see “5-2 Lubrication and Oil

1 - 11

Supply”.

1-7 Mounting Procedure

(1)Dismounting fixtures for shipment and transportation

Upon installing the machine at a fixed place, be sure to dismount the fixtures for shipment/transportations .

• Remove the fixed plate for the table, column and head.

(2)Installation

A leveling method is one of the factors which determine machine accuracy. Proper leveling of the machine is most fundamental.

Carry it out carefully, because it affects not only machining accuracy, but also machine’s service life.

First, put leveling pads at installation points on the floor.

Install the machine so that the leveling adjust bolts attached to the machine legs will be placed on them.

Use precision levels whose sensitivity per graduation is’ about 0.02 mm/m (0.00025 in./ ft.) and length is about 200 mm (8 in.).

Levels used for woodworking/engineering are not recommendable. Place the levels with the same end in the same direction.

Keep level-placing surfaces clean at any time lest dust, etc. should be caught under the levels.

Outline of Installation Work

[1]Confirming a foam in a level

Adjust so that a foam does not get too long and set it at the center on the table. By turning it by 180° , while holding the position, and observing a foam in memory of the

same direction, level has been obtained.

[2]Adjusting the absolute level

As shown in Fig.5-5, place levels on the table in parallel with the X and Y directions, and measure the level of the machine at 3 places in the X and Y directions, respectively.

1 - 12

Adjust the level of the machine with the leveling bolts so that each difference in reading of the levels may be settled within 0.04 mm/m (0.0005 in./ft.) in both X and Y directions.

[3]Adjusting the table operating level

Place the levels at the center of the table and move the X axis almost over its full stroke. Make adjustment in such a way that each difference in reading of the levels at this time will meet within the following target values:

•For the level put in the X-axis direction: 0.02 mm/m (0.00025 in./ft.)

•For the level put in the Y-axis direction: 0.04 mm/m (0.0005 in./ft.)

[4]Reconfirm the above-mentioned steps [1] through [3] and make fine adjustment, if necessary.

[5]When the stable operating levels in [3] cannot be obtained, it is likely that the condition of the floor, where the machine is installed, is improper. Check and improve it, referring to the foundation drawing.

1 - 13

VS50

Fig.1-2

Fig.1-3

1 - 14

VS60

1 - 15

2. INSPECTION AND MAINTENANCE

2-1 Daily Check and Periodic Check Items

2-1-1 Daily Checking Items

The following are maintenance items to be checked by operators. These maintenance items are important to prevent machine trouble and to perform efficient operation. Perform maintenance according to the following daily check list.

2 - 1

Daily check list

	Checking part	Check item		Details of checks
1.	Main cooling unit	a) Check main cooling unit for	Check for sound of fan running
		operation.
		b) Check cooling unit for sufficient		Oil level check
		quantity of oil. (Checks before
		starting work)
		c) Check that air filter is thoroughly	Checks for clogging and
		cleaned.		cleaning
		d) Check for oil leakage.	Check for oil leakage
2.	Pneumatic unit	a) Check for normal set pressure.	Normal value: 5 kgf/cm2
		b) Check pneumatic unit for faults	Check for air leakage
		such as air leakage.
3.	Coolant unit	a) Check coolant unit and piping for	Checks for coolant leakage and
		faults.		abnormal noise
		b) Check coolant unit for sufficient		Oil level check
		quantity of coolant.
		c) Check that air filter is thoroughly	Checks for clogging and
		cleaned.		cleaning
		d) Check for discharge.		Visual check
		e) Check for oil leakage.	Check for oil leakage
4.	Operation panel	a) Check that alarm is not displayed	Visually check it to determine
	and control panel	on the screen. (Battery alarm,		the cause for corrective action.
		etc.)
		b) Check that cooling fan is running.	Visually check it to determine
				the cause for corrective action.
5.	Spindle head	a) Check that running-in performed.	Run in the spindle according to
				“Spindle warm-up” section of
				the operation manual.
		b) Check for abnormal noise.	Check for abnormal noise
		(M/C, NCL)		during spindle running
		c) Check spindle gear lubricating	Check that spindle head
		float. (TG) (Checks before		ascends when spindle runs and t
		starting work)		hat it descends when spindle
				comes to a stop.
		d) Check that spindle tapered	Check for removal of dust,
		portion is cleaned. (M/C)		fouling and foreign matter such
				as chips
		e) Check spindle for start, stop and	Check that spindle start and
		faults. (NCL, spindle)		stop do not spend time too
				much.
6.	ATC magazine	a) Check that tool pots and tapered	Check for removal of dust,
		portion are cleaned.		fouling and foreign matter such
				as chips
		b) Check that ATC grip portion is	Check for removal of dust,
		cleaned.		fouling and foreign matter such
				as chips
		c) Check pull stud for tool for	Check pull stud for tightness
		looseness.		when changing tools.

2 - 2

	Checking part	Check item		Details of checks
7.	Table unit	a) Check that telescopic cover is	Check for removal of foreign
		cleaned.		matter including chips and chips
				on wiper portion
		b) Check the quantity of table		Oil level check
		indexing gear lubricating oil.
8.	Feed unit	a) Check for abnormal noise.	Check for abnormal noise when
				operating feed unit
9.	Covers	a) Check that covers are not	Check that covers are not
		detached.		detached. If any cover is
				detached, attach it.
		b) Check that window is cleaned.		Check for cleaning
		c) Check that nameplate and		Check for cleaning
		caution plate are cleaned.
10.	Interlocking	a) Check door interlocking function.	Check that spindle does not run
	device			when opening door.
11.	Hydraulic unit	a) Check for normal set pressure.	Normal value: 35 kgf/cm2, 45
	(Option)			kgf/cm2 and 70 kgf/cm2 (It
				depends on the model.)
		b) Check hydraulic unit for faults.	Checks for abnormal noise and
				oil leakage.
		c) Check hydraulic unit for sufficient		Oil level check
		quantity of oil.
		d) Check that oil temperature is	Oil temperature check: Proper
		60° C or less.		temperature is 60° C or less.
		e) Check for oil leakage.	Check for oil leakage
12.	Lubricating unit	a) Check for proper consumption.	1 liter/10 hours as a guide
	(When equipped	b) Check lubricating unit for		Oil level check
	with a high-	sufficient quantity of oil.
	speed spindle.)
		c) Check that air filter is cleaned.	Checks for clogging and
				cleaning.
		d) Check for oil leakage.	Check for oil leakage (Shorten
				checking intervals depending on
				working environment.)
13.	High-pressure	a) Check high-pressure unit and	Checks for coolant leakage,
	coolant	piping for faults.		abnormal noise and abnormal
	(Option)			vibration.
		b) Check for discharge.		Visual check
		c) Check pump for discharge	Normal value: 35 kgf/cm2 or 70
		pressure. (Pressure gage)		kgf/cm2 (It depends on the
				specifications.)
		d) Check that air filter is thoroughly	Checks for clogging and
		cleaned.		cleaning
		e) Check high-pressure pump for	Oil level (cap oil filling) check
		sufficient quantity of oil.		and replenishment
		f) Check for high-pressure pump oil	Checks for oil degradation and
		fouling.		oil color
		g)Check for sufficient quantity of	Check through main tank
		coolant.

2 - 3

	Checking part	Check item		Details of checks
14.	APC	a) Check that pallet seating surface	Check for removal of foreign
	(Option)	is cleaned.		matter including chips
		b) Check that pallets and cover	Check for removal of foreign
		portion are cleaned.		matter including chips
15.	Chip conveyor	a) Check for obstructions on the	Check for removal of
	(Option)	conveyor.		obstructions such as workpiece,
				tool and square bar
		b) Check the quantity of chips in the	Check the quantity of chips and
		chip box and that of coolant.		that of coolant, and dispose of
				them as necessary.
		c) Check that a large quantity of	Prevent a large quantity of chips
		chips collect on the chip		from collecting on the conveyor.
		conveyor. (Inclusive of screw		Check that conveyor operates
		conveyor)		to discharge chips.
		d) Check for abnormal noise.	Check for abnormal noise when
				operating chip conveyor
16.	Mist collector	a) Check that mist does not remain		Visual check Provide angular
	(Option)	in the hose.		hose route.
		b) Check that filter is thoroughly	Checks for clogging and
		cleaned.		cleaning
		c) Check that oil is properly drained.	Visual check for proper oil
				drainage
		d) Check mist for leakage.		Visual check

2 - 4

2-1-2 Periodic Check Items

Periodic checks by maintenance personnel are essential for assuring continued machine accuracy. Perform maintenance at regular intervals according to the following periodic check list.

2 - 5

Periodic check list

	Checking part		Check item	Checking interval					Details of checks
				1	3	6	12
1.	Main cooling		a) Check piping for			O		Check for oil leakage,
	unit		faults.						and tighten connector
									securely if necessary.
			b) Change hydraulic			O		Clean the inside of tank
			fluid.						and strainer, and
									change hydraulic fluid
									as necessary.
2.	Pneumatic unit		a) Check piping for			O		Check for oil leakage,
			faults.						and tighten connector
									securely if necessary.
			b) Check that filter is			O		Checks for clogging and
			thoroughly cleaned.						cleaning (Shorten
									checking intervals
									depending on working
									environment.)
3.	Coolant unit		a) Check for	O				Refer to Coolant section
			conspicuously dirty						in the instruction
			coolant unit.						manual. (NCL)
			b) Check for foul smell.	O
			c) Check piping for			O		Check for oil leakage,
			faults.						and tighten connector
									securely if necessary.
4.	Operation		a) Check for			O			Visual check and
	panel and		conspicuously dirty						cleaning
	control panel		operation panel and
			control panel.
			(Cleaning)
			b) Check for foreign			O			Removal of foreign
			matter in the control						matter
			panel.
			c) Check that air filter is			O		Checks for clogging and
			thoroughly cleaned.						cleaning (Shorten
									checking intervals
									depending on working
									environment.)
			d) Check that cooling fan	O				Check for dirty cooling
			is cleaned.						fan
			e) Check power supply			O			Check that secondary
			and voltage.						voltage of main breaker
									is set within + - 10% of
									the specified value.
5.	Table unit		a) Check bolts on the		O				Check bolts for
			telescopic cover for						tightness, and tighten
			looseness.						them if necessary.
6.	Feed unit		a) Check ball screw and			O		Visually check oil film.
			guide for lubrication
			(oil and grease).

2 - 6

	Checking part	Check item		Checking		interval				Details of checks
				1	3	6	12
7.	Belt, Timing	a) Check belt for				O				Check deflection
	belt (Z axes,)	deflection.								amount with tension
										meter. (Normal value:
										8mm 5.7/kg)
		b) Check surface for				O				Visual checks and
		damage and heights								degreasing
		for deterioration.
8.	Level	a) Check the level of bed			O					Level check and
		and table with level								adjustment with level
		vial.								vial
9.	LS and SOL	a) Check that LS and			O				Determine the cause to
		SOL are not								take corrective action.
		moistened with oil.
		b) Check for oil fouling.			O					Cleaning
10.	Cover	a) Check mounting bolts			O					Check cover clamping
		for looseness.								bolts for tightness, and
										tighten securely if
										necessary.
11.	Wiper and	a) Check wiper and			O					Visual checks
	brush	brush for deterioration
		and damage.
		b) Check for jamming of			O					Visual checks
		chips and foreign
		matter.
12.	Interlocking	a) Check spindle speed				O				Check spindle speed
	device	limiting interlocking								limiting interlocking set
		function.								value (parameter) when
										using special chuck and
										jig.
13.	Cable	a) Check for damaged		O						Visual checks Replace
		appearance (tears,								if there is something
		crushes, stripped								wrong.
		conductor, etc.).
		b) Check connector for		O						Visual check Tighten
		looseness.								securely if necessary.
		c) Check for caught		O						Visual check. Return to
		cable.								normal. Appearance
										check. Replace if there
										is something wrong.
		d) Check that cable is not		O						Visual check and
		moistened.								cleaning. Determine
										the cause.
14.	OT (Over-	a) Check LS for		O					Operate the machine to
	travel)	actuation.								check function.
15.	Earth leakage	a) Check breaker for			O				Press test button to
	breaker	operation.								check breaker for
										operation.

2 - 7

	Checking part			Check item	Checking interval					Details of checks
					1	3	6	12
16.	ATC cam unit		a) Check for proper					O		Check oil level gage of
				quantity of oil.						cam unit. Supply oil
										when insufficient.
17.	Hydraulic unit		a) Check piping for				O			Check for oil leakage,
	(Option)			faults.						and tighten connector
										securely if necessary.
			b) Change hydraulic				O			Clean the inside of tank
				fluid.						and strainer, and
										change hydraulic fluid
										as necessary.
			c) Check that strainer is				O			Checks for clogging
				thoroughly cleaned.						and cleaning (Shorten
										checking intervals
										depending on working
										environment.)
			d) Check oil for				O			Check oil color with oil
				discoloration (fouling).						gage. When color is
										getting brown, change
										oil.
18.	Lubricating		a) Check piping for				O			Check for oil leakage,
	unit			faults.						and tighten connector
	(When									securely if necessary.
	equipped with a
			b) Change hydraulic				O			Clean the inside of tank
	high-speed			fluid.						and strainer, and
	spindle.)									change hydraulic fluid
										as necessary.
			c) Check that strainer is					O		Checks for clogging
				thoroughly cleaned.						and cleaning
19.	High-pressure		a) Check piping for				O			Check for oil leakage,
	coolant			faults.						and tighten connector
	(Option)									securely if necessary.
			b) Check that filter is		O					Checks for clogging
				thoroughly cleaned.						and cleaning
			c)	Check high-pressure	O				Oil level (cap oil filling)
				pump for sufficient						check and
				quantity of oil.						replenishment
			d) Check for high-		O					Checks for oil
				pressure pump oil						degradation and oil
				fouling.						color
			e) Check high-pressure					O		Replace if damage or
				pump suction and						wear is found.
				discharge valves for
				damage or wear.
			f)	Check for damaged				O		Replace or clean if
				or dirty high-pressure						necessary.
				pump diaphragm.

2 - 8

	Checking part	Check item		Checking interval					Details of checks
			1		3	6	12
19.	High-pressure	g) Check gas charging					O		Recharge if charging
	coolant	pressure of							pressure is dropped.
	(Option)	accumulator.							(Charging pressure: 50
									K)
20.	Chip conveyor	a) Check that chip				O			Apply grease to
	(Option)	conveyor is oiled.							sprocket area as
									necessary.

2 - 9

2-2 Lubrication, Oil Supply and Coolant

When supplying oil, be fully aware of the following:

1.Supply specified oil by specified amount. Do not supply a different type of oil or over the specified amount.

Otherwise, the machine may malfunction.

2.Clean an oil inlet port in advance lest dust, etc. should enter inside.

3.When supplying the oil, use a filter to prevent foreign substances from entering inside the tank.

When the filter is not available, use a wire net of 150 mesh or more.

4.Whenever you supply the oil, use new one. Do not mix with reproduced or old oil.

5.Even when opening a new oil can, do not use all oil in it, but leave some unused. This is necessary to eliminate moisture and deposits.

See the lubrication chart for lubricating points, lubrication frequency, oil quantity and oil types.

2 - 10

11 - 2

	Sopt to be	Lubricating	Lubricating	Oil	Nisseki	Idemitsu Kosan	Shell	Mobile	Mitsubishi Oil	ESSO	ISO
	lubricated	method	period	quantity							symbol
			Replace every 6		Super	Daphne Super	Tetra Oil	Mobile Velocity	Diamond Lub	Unipower
1	Spindle cooling	Trochoid pump	months; add	17•	Mulpus 10	Multi Oil 10	10SP	Oil No.3	RO10 (N)	MP10	FC10
			when necessary
	Lub. oil tank				Super	Daphne Super		Mobile DTE Oil	Diamond	Unipower
2	(Spindle oil air)	Gear pump	As necessary	2•	Mulpus 32	Multi Oil 32	Tetra Oil 32	Light	Tetrad 32	MP32	FC32
	#50 - 10,000
	Lub. oil tank				Super	Daphne Super		Mobile Velocity	Diamond	Unipower
3	(Spindle oil air)	Gear pump	As necessary	2•	Mulpus 22	Multi Oil 22	Tetra Oil 22	Oil No.10	Tetrad 22	MP22	FC22
	#40 - 20,000
	ATC cam		Every		Bonnock
4	unit		exchange the		M68
			cam unit

Supply Oil and Lubrication of List 1-2-2