1.2Important Information ................................................................................................................................... 1-3
1.3Manuals and How to Use Them ................................................................................................................. 1-4
2.1.3Precautions for Potential Fire Hazards .................................................................................................... 2-2
2.1.4Confirmation of Machine Status ................................................................................................................ 2-2
2.1.6Implementing Lock-out and Tag-out ....................................................................................................... 2-4
2.1.7During Work ...................................................................................................................................................... 2-5
2.1.8Handling of Hazardous and Toxic Materials ......................................................................................... 2-7
2.2.1Signal Word Definitions ................................................................................................................................ 2-7
2.2.3Information Contained in Warning Labels ............................................................................................. 2-8
2.2.3.1Warning Labels with Warning Text ........................................................................................................... 2-8
2.2.3.2Warning Labels with Warning Marks Only ............................................................................................ 2-9
2.2.4.1Area around Operator Door ...................................................................................................................... 2-10
2.2.4.2Area around Tool Magazine ...................................................................................................................... 2-11
2.4.2Electrical System ............................................................................................................................................. 2-17
2.4.8Hydraulic Unit ................................................................................................................................................. 2-21
2.4.9Pneumatic Unit ............................................................................................................................................... 2-21
2.5.4Disposal of Waste Products ...................................................................................................................... 2-24
2.5.4.1Disposal of Waste Oil, Waste Fluids, and Waste Materials ........................................................... 2-24
2.5.4.2Disposal of This Machine ........................................................................................................................... 2-24
3.4Operation Unit and Display Unit ................................................................................................................ 3-5
6.1Turning Power ON/OFF ................................................................................................................................. 6-1
6.1.1Switches to Turn Power ON/OFF ............................................................................................................... 6-1
6.1.2Turning Power ON ........................................................................................................................................... 6-1
6.1.3Execution of Spindle Running Program .................................................................................................. 6-2
6.1.4Turning Power OFF ......................................................................................................................................... 6-3
6.1.4.1Manually Turning OFF the Power .............................................................................................................. 6-3
6.1.4.2Using the POWER OUT Function to Automatically turn OFF the power .................................... 6-3
6.2Opening and Closing Doors ........................................................................................................................ 6-3
6.2.1Opening and Closing the Operator Door .............................................................................................. 6-3
6.2.2Opening and Closing the Tool Magazine Door ................................................................................... 6-4
6.2.2.1Opening and Closing the Tool Magazine Door ................................................................................... 6-4
6.2.2.2Opening and Closing the Large Capacity Tool Magazine Door (When the Machine Is
Equipped with a Large Capacity Tool Magazine) ................................................................................ 6-5
6.7Cutting Fluid Supply and Chip Disposal ............................................................................................... 6-24
6.7.1Cutting Fluid Supply and Cleaning Air (other than Graphite Specifications) ......................... 6-24
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VIIITable of contents
6.7.2Chip Disposal and Cleaning Air (Graphite Specifications) ............................................................ 6-28
6.7.3Operation of Workpiece Cleaning Gun ................................................................................................ 6-28
6.7.4Through spindle coolant pressure switching function ................................................................... 6-29
6.7.4.1Set the pressure for each tool .................................................................................................................. 6-29
6.7.4.2Switching pressure during processing .................................................................................................. 6-30
6.9.1.3Starting at Specified Date and Time ...................................................................................................... 6-34
6.9.1.4Starting on Specified Day of the Week ................................................................................................. 6-35
6.9.1.5Selecting a Program ..................................................................................................................................... 6-37
6.9.2Switching to Standby Mode ...................................................................................................................... 6-38
7.1.2Precautions when Creating a Program .................................................................................................... 7-1
7.1.3Starting a Program .......................................................................................................................................... 7-1
7.1.4Pausing and Restarting a Program ............................................................................................................ 7-2
7.1.4.1Pausing and Restarting a Program by Stop Commands (Program) ............................................. 7-2
7.1.4.1.1Stopping by Program Stop M0 ................................................................................................................... 7-2
7.1.4.1.2Stopping by Optional Stop M1 ................................................................................................................... 7-2
7.1.4.1.3Restarting a Program that was Already Started ................................................................................... 7-2
7.1.4.1.4Restarting a Program from the Start (Program Rewinding) ............................................................ 7-2
7.1.4.2Pausing and Restarting a Program by Switches ................................................................................... 7-3
7.1.4.2.1Stopping by [FEED HOLD] Switch .............................................................................................................. 7-3
7.1.4.2.2Stopping by [SINGLE BLOCK] Switch ........................................................................................................ 7-3
7.1.4.2.3Restarting a Program that was Already Started ................................................................................... 7-3
7.1.4.2.4Restarting a Program from the Start (Program Rewinding) ............................................................ 7-4
7.1.5Ending a Program ............................................................................................................................................ 7-4
7.2.2Tool Change Program ..................................................................................................................................... 7-5
7.2.2.3Tool Change Program ..................................................................................................................................... 7-7
8.1Overview of Problems .................................................................................................................................... 8-1
8.2.1Recovery from Emergency Stop Status .................................................................................................... 8-2
8.2.1.1[Emergency Stop] Switch Was Pressed During Tool Change Operation .................................... 8-2
29F-21E-2006 (en)MAKINO
Table of contentsIX
8.2.1.2[Emergency Stop] Switch Was Pressed during Machining
(No Workpiece and Tool Contact) ............................................................................................................. 8-3
8.2.1.3[Emergency Stop] Switch Was Pressed during Machining
(Workpiece and Tool Contact) .................................................................................................................... 8-4
8.2.1.4Power Turned ON While Door Was Open ............................................................................................. 8-6
8.2.1.5Abnormal Condition in Machine Controller (MTC) or Servomotor .............................................. 8-6
8.2.2Overtravel 1 (OT1) Was Detected .............................................................................................................. 8-6
8.2.2.1Feed Axis Overtravel 1 (OT1) Was Detected ......................................................................................... 8-7
8.2.3Axis Fails to Move ............................................................................................................................................ 8-7
8.2.4Program Fails to Start ..................................................................................................................................... 8-7
8.2.5Programs Are Executed in Single Block Only ....................................................................................... 8-7
8.2.6Operator Door Fails to Open ...................................................................................................................... 8-8
8.2.7Operator Door Lock Malfunction .............................................................................................................. 8-8
8.2.8Alarm Occurred and Machine Operation Stopped ............................................................................ 8-8
8.2.8.1Switch Is Either Incorrectly Adjusted or Malfunctioning, or Signal Input/Output Device (I/O
Module) Is Malfunctioning ......................................................................................................................... 8-10
8.2.8.2Inspection of the Hydraulic/Air Cylinder or Solenoid Valve .......................................................... 8-10
8.3Spindle Head ................................................................................................................................................... 8-10
8.3.1Spindle Does Not Start ................................................................................................................................ 8-10
8.3.2Spindle Does Not Stop ................................................................................................................................ 8-11
8.3.3Abnormal Spindle Speed or Start/Stop Timing ................................................................................. 8-11
8.3.4.1Alarm Occurs When Orientation Is Performed .................................................................................. 8-12
8.3.4.2Orientation Position Is Shifted .................................................................................................................. 8-12
8.3.4.3Overshoot Occurs or Spindle Moves ..................................................................................................... 8-12
8.5.1C-axis/B-axis Fails to Rotate in Manual Mode .................................................................................... 8-15
8.5.2B-Axis Runs Until Hitting Mechanical Stopper ................................................................................... 8-16
8.5.3Positioning Accuracy Is Not Achieved ................................................................................................... 8-16
8.5.4Abnormal Noises During Axis Operation ............................................................................................. 8-16
8.5.5Machine Operation Stopped During Program Execution .............................................................. 8-17
8.5.6Strong Clamp and Unclamp Operation for Rotating Axis (C-axis)/Inclined Axis (B-axis) Cannot
be Performed .................................................................................................................................................. 8-17
8.8.1Excessively High Cooling Oil Consumption Rate .............................................................................. 8-30
8.9Oil Air Supply Device ................................................................................................................................... 8-30
8.9.1Lubricant Is Not Discharged (Pump Is Not Running) ...................................................................... 8-30
8.9.2Lubricant Is Not Discharged (Pump Is Running) ............................................................................... 8-30
8.9.3Pump Pressure Does Not Rise ................................................................................................................. 8-31
8.9.4No Signal from Float Switch ..................................................................................................................... 8-31
8.9.5Air Bubbles in Oil Piping ............................................................................................................................ 8-31
8.10Hydraulic Unit ................................................................................................................................................. 8-32
8.10.1Excessively High Hydraulic Oil Consumption Rate .......................................................................... 8-32
8.10.2Accumulator Pressure Does Not Rise ................................................................................................... 8-32
8.11Pneumatic Unit ............................................................................................................................................... 8-32
8.11.1Supply Air Pressure Does Not Rise ........................................................................................................ 8-32
8.12.1.1Chip Sludge Accumulates in Coolant Tank ......................................................................................... 8-34
8.12.1.2Large Amounts of Chips Accumulate in Clean Tank ........................................................................ 8-34
8.12.1.3Filter Is Clogged ............................................................................................................................................. 8-35
8.12.1.4Conveyor Is Running in Reverse Rotation ........................................................................................... 8-35
8.12.1.5Geared Motor Does Not Run ................................................................................................................... 8-36
8.12.1.6Geared Motor Generated Excessive Heat ............................................................................................ 8-36
8.12.1.7Abnormal Noise Emitted from Geared Motor ................................................................................... 8-37
8.12.2Cutting Fluid Supply Unit ........................................................................................................................... 8-37
8.12.2.1Cutting Fluid Is Not Discharged (Pump Is Not Running) .............................................................. 8-37
8.12.2.2Cutting Fluid Is Not Discharged (Pump Is Running) ....................................................................... 8-37
8.12.2.3Cutting Fluid Is Leaking from Pump ...................................................................................................... 8-38
8.12.2.4Line Filter, Suction Filter or Y-Strainer Is Clogged ..................................................................
8.12.2.5Through-spindle Coolant Pump Is Not Pressurized ........................................................................ 8-38
8.12.2.6Incorrect Coolant Unit Was Activated ................................................................................................... 8-39
8.15.9Work Measurement Function ................................................................................................................... 8-51
8.15.10Non-Contact Type Tool Measurement Function (Fixed laser type) ............................................ 8-53
8.15.11Special User Input/Output Interface ...................................................................................................... 8-55
8.15.12Auxiliary Control Unit (ACU) ...................................................................................................................... 8-56
9.2Allocation of Installation Area .................................................................................................................... 9-1
9.3Requirements for Carry-in Route .............................................................................................................. 9-8
9.5Recommended Foundation Conditions ................................................................................................ 9-13
9.6Air and Power Sources ................................................................................................................................. 9-15
9.7Preparation of Equipment for Transfer/Installation .......................................................................... 9-18
11REVISION HISTORY ................................................................................................................................... 11-1
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XIITable of contents
29F-21E-2006 (en)MAKINO
GENERAL SAFETY INSTRUCTIONS0-1
0GENERAL SAFETY INSTRUCTIONS
The hazards involved in operating the machine are identified by the following means:
- In this manual, warning notices serve to indicate aspects which are relevant to safety.
- On the machine, warning signs point out aspects which are relevant to safety.
0.1Indicator words and their meaning
The indicator words use for warning notices are divided into the categories listed below, according to the
accepted degree of risk involved.
Consciously ignoring these warning notices can result in accidents, serious injuries or death.
Furthermore, serious damage may be caused to the machine and its auxiliary units. The warning notices
below must there be followed without fail!
DANGER!
Indicator word used to denote an immediately hazardous situation which, if not avoided,
will result in serious injury or death.
WARNING!
Indicator word used to denote a potentially hazardous situation which, if not avoided,
could result in serious injury or death.
CAUTION!
Indicator word used to denote a potentially hazardous situation which, if not avoided,
could result in slight to moderate injuries.
NOTICE!Indicator word used to denote a potentially hazardous situation which, if not avoided,
could result in damage to property.
REMARKIndicator word used to point out important or useful information.
MAKINO29F-21E-2006 (en)
0-2GENERAL SAFETY INSTRUCTIONS
29F-21E-2006 (en)MAKINO
PREFACE1-1
1PREFACE
REMARKDo not operate, maintain, or inspect this machine without carefully reading and under-
standing this manual.
Store this manual in a clearly marked location for easy reference.
All rights reserved. No part of this document may be reproduced, copied, or modified in
any form or any means without direct permission of Makino Milling Machine Co., Ltd.
This machine, including technical data and software, may be subjected to the Japanese Foreign Exchange
and Foreign Trade Law. Prior to any re-sell, re-transfer, or re-export of controlled items, please contact
Makino to obtain any required authorization or approval.
MAKINO29F-21E-2006 (en)
1-2PREFACE
Signal lamp
Refer to chap. “6 BASIC
OPERATION”
Operation modes
Refer to chap. “6 BASIC OPERATION”
Tool magazine
operation panel
Refer to chap. “4 OPERATION
PAN EL”
Screen types
Refer to chap. “5 SCREENS”
Manual pulse generator
Refer to chap. “4 OPERATION
PAN EL”
Main operation panel
switches
Refer to chap. “4 OPERATION
PAN EL ”
Opening and
closing doors
Refer to chap. “6 BASIC
OPERATION”
Manual axis feed
Refer to chap. “7 AUTOMATIC
OPERATION”
Tur ning p ower
ON/OFF
Refer to chap. “6 BASIC
OPERATION”
Tool preparations
Refer to chap. “6 BASIC
OPERATION”
Automatic tool
change
Refer to chap. “7 AUTOMATIC OPERATION”
Workpiece preparations
Refer to chap. “6 BASIC
OPERATION”
1.1Operation Route Map
Fig. 1-1:
29F-21E-2006 (en)MAKINO
PREFACE1-3
Lift-up chip conveyor operation panel
Refer to chap. “4 OPERATION PANEL”
Cutting fluid supply
Refer to chap. “6 BASIC OPERATION”
1.2Important Information
General
- Do not attempt to modify the machine.
- Operation, maintenance, and inspection of this machine must be performed by staff who have received
technical training for the machine, training in machine hazards and their prevention, and safety training.
- Observe the laws, regulations, and other rules of the relevant national and local administrative agencies.
- This machine, including technical data and software, may be subject to the Japanese Foreign Exchange
and Foreign Trade Law.
Prior to any resale, transfer or re-export of controlled items, contact Makino to obtain any required authorization or approval.
- The specifications and design are subject to change without prior notice.
This Manual
- This manual is prepared for usage by experienced operators. For this reason, it does not include safety
precautions for operators who do not have mechanical or technical knowledge of machine operation,
programming, and maintenance.
- If the machine is operated by persons who are not native speakers of the language in this manual, the
customer must ensure that the operators receive complete safety training. Also, warning labels must be
affixed in a language that the operators can understand.
- The copyright for the entire content of this manual belongs to Makino Milling Machine Co., Ltd. The
copying, reproduction, or transfer of this manual, in whole or in part, without the express written permission of Makino Milling Machine Co., Ltd., is strictly prohibited.
MAKINO29F-21E-2006 (en)
Fig. 1-2:
1-4PREFACE
- Illustrations and other details may differ from the actual machine due to the selected options, modified
specifications, or other reasons.
- Store the manuals needed for operation, maintenance, and inspection of this machine in a location
where they can be easily accessed by the operator.
- Be sure to perform periodic inspection and maintenance of the machine according to the periodic
maintenance manual or the legend plate to prevent breakdown of the machine.
Important Points for Work Safety
- Familiarize yourself with the safety precautions and functions before attempting to operate, maintain,
or inspect the machine.
- The points that the operator must observe when performing machine operation and maintenance vary
depending on the situation. All possible points cannot be covered in the content of this manual. Be sure
to fully understand the machine, and remain constantly aware of safety and the potential hazards while
doing work.
- If the safety devices or protective devices do not operate properly, stop operation of the machine and
notify the supervisor or manager. The supervisor or manager must immediately notify your authorized
Makino dealer or Makino service representative.
- When the machine is stopped due to an unknown cause, immediately contact the supervisor or manager, and wait for permission before restarting operation.
Keeping Machining Accuracy
- After installing the machine, to keep machining accuracy, conduct periodic inspection such as performing level adjustment. If the level of the machine changes, high-accuracy machining cannot be performed. In addition, normal machining cannot be performed if the machine vibrates.
- Especially, for approximately six months after installation, the level of the machine might change significantly until the foundation becomes stable.
- Depending on the condition of the foundation or the machine usage frequency, conduct inspection and
adjustment approximately every six months or every year.
1.3Manuals and How to Use Them
Manuals Belonging to This Machine
NameDescription
Instruction ManualThis manual includes the basic information (overview, specifications)
needed for operation, practical operating procedures (operation),
and troubleshooting procedures.
Periodic Maintenance ManualThis manual explains the intervals for periodic maintenance and
work that is required for maintaining optimum performance of this
machine.
Peripheral Device ManualThis manual describes the operating procedures for the peripheral
devices connected to the machine body.
Parts ManualThis manual provides the machine component part names and their
order numbers.
Professional 6 Operation ManualThis manual describes the operating procedures and various func-
tions of the controller (Professional 6).
Professional 6 M Code ListThis manual describes the M codes of Professional 6.
Table 1-1: (1 / 2)
29F-21E-2006 (en)MAKINO
PREFACE1-5
NameDescription
FANUC
Set of NC Manuals
Maintenance Manual (option)This manual describes the mechanisms of the machine and how to
Installation Manual (option)This manual describes the preparation, carry-in, and installation pro-
Other manuals for optionsThese manuals describe the operating procedures for the optional
Notation Used in This Manual
See chapter “0 GENERAL SAFETY INSTRUCTIONS” for the description of used warning symbols.
These manuals describe the operating procedures for FANUC equipment.
perform the maintenance and adjustment work.
cedures for setup of the machine.
devices.
Table 1-1: (2 / 2)
1.4General Contents
Chap. “2 SAFETY”
This chapter describes the safety devices and warning labels, work and operating precautions, and other
information for ensuring safety operation of the machine. Be sure to read this chapter before using the
machine.
Chap. “3 SPECIFICATIONS”
This chapter describes the basic configuration and specifications of the machine.
Chap. “4 OPERATION PANEL”
This chapter describes the main operation panel, manual pulse generator, and other details about the operation panels used in this machine.
Chap. “5 SCREENS”
This chapter provides an overview of the screens used in this machine.
Chap. “6 BASIC OPERATION”
This chapter describes machine power ON/OFF, door open/close, tool and workpiece preparation, manual
axis feed, and other manual operations required before machining.
Chap. “7 AUTOMATIC OPERATION”
This chapter describes the execution of automatic operation, automatic tool change operation, and similar
operations.
Chap. “8 TROUBLESHOOTING”
This chapter provides the basic troubleshooting information when the machine does not operate properly.
Chap. “9 INSTALLATION PREPARATION”
This chapter includes the dimensions required for machine carry-in and other operations.
MAKINO29F-21E-2006 (en)
1-6PREFACE
29F-21E-2006 (en)MAKINO
SAFETY2-1
2SAFETY
2.1Safety Precautions
- Disregarding the specific instructions or precautions included in this manual may result in serious injury
or death to the operators or surrounding workers, or damage to the machine.
- Never disable or remove any safety device. Operating the machine while the safety devices are disabled
may result in serious injury, death, or damage to the machine.
- Observe the safety precautions provided in this manual at all times and fully implement safety measures.
- Inspect and maintain the machine regularly to keep it in optimum operating condition. Do not run the
machine if it shows any signs of abnormal operation.
- The keys (release key for door switch, machine controller panel key, etc.) which are not necessary for
regular operation and maintenance must be removed from the machine and managed by supervising
personnel.
- The lubricating oil, cutting fluid, and other chemical substances used with the machine must be managed by supervising personnel.
- Workpiece materials such as magnesium and titanium may cause a fire if mishandled, so be particularly
careful when machining workpieces and handling cutting chips made from these types of materials.
2.1.1Operator Checks
- Only qualified personnel who have adequate mechanical and technical knowledge are allowed to operate and maintain the machine.
- Only qualified electrical engineers may perform electrical work.
- Only qualified personnel may use a crane or forklift.
- Wear suitable work clothes whenever operating or maintaining the machine. Do not operate the machine while wearing loose-fitting clothes, a necktie, jewelry, or any other clothing or objects which may
become entangled with the moving parts of the machine.
- Tie up long hair, and wear a cap.
- Wear safety glasses, safety shoes, safety cap (including safety helmet), and safety gloves as needed.
Fig. 2-1:
- Protective gear should be worn to protect hearing when excessive noise may be generated during operation or maintenance.
- Never operate any machinery while under the influence of alcohol or drugs.
- The operator should be in proper physical condition. If the operator suffers from a condition that impairs judgment, it may result in serious injury or death.
2.1.2Work Environment Checks
- Make sure the machine and surrounding area are fully lighted.
MAKINO29F-21E-2006 (en)
2-2SAFETY
- Make sure the machine and surrounding area are tidy and clean at all times.
- Clean up any oil, cutting fluid, or chips scattered around the machine.
- When performing work at high locations, use a stable footstool or stepladder.
- Keep all flammable substances away from the work area.
- Maintain adequate working space.
2.1.3Precautions for Potential Fire Hazards
Use the machine by following the precautions below to protect the machine equipment, plant, and surrounding environment from the danger of fire and to ensure the safety of operators.
When using cutting fluid, be sure to use a water-soluble cutting fluid (type A1).
There is no fire hazard when using water-soluble cutting fluids (except when using them with special materials).
Oil-based cutting fluids present a potential fire hazard.
- If an oil-based cutting fluid must be used due to unavoidable circumstances, be sure to observe the
precautions below.
- Do not run the machine in an unmanned operation mode.
- Install the proper fire-extinguishing equipment near the machine.
- Provide alarm devices to detect a fire, automatic fire-extinguishing devices, and other equipment to the
greatest extent possible.
- Do not create situations which may potentially start a fire.
• Machine under the proper cutting conditions.
• Perform proper tool management to prevent the occurrence of abnormal frictional heat and sparks.
• Do not allow chips to accumulate in the machining chamber.
• Check that a constant and full supply of cutting fluid is provided.
• Always clean up and organize the area around the machine, and do not place flammable objects in the
area.
Precautions for machining of flammable solids, resins, wood, and other flammable materials.
When machining flammable solids or other special materials, be sure to fully implement safety measures
after gaining a thorough understanding of the material properties. Be sure to also pay careful attention to
safety when machining resins, wood, and other materials.
When machining materials that generate dust and powder, be sure to provide equipment that takes into
account the danger of a dust explosion for certain material types.
Precautions for machining while blowing air.
Because air blowing has weak cooling performance, the chips that spray and fly out in the surrounding
area are extremely hot. Do not place flammable objects in the machining chamber or in the area surrounding the machine.
2.1.4Confirmation of Machine Status
- Machine inspections and maintenance must be performed regularly to maintain optimum machining
accuracy and long-term performance, and increase machine operating efficiency.
- Confirm that all safety devices are functioning normally.
- Make sure the operator knows the location of the [Emergency Stop] switches to enable easy access in
the event of an abnormal or dangerous situation (refer to “2.3.1 [Emergency Stop] Switch”).
29F-21E-2006 (en)MAKINO
SAFETY2-3
- Check for any loose, damaged, or worn parts on the machine. Operating the machine in a condition in
which any of the parts has an abnormality may cause abnormal noises or damage to the machine.
- Check for any damaged piping or wiring. Operating the machine with the piping or wiring left damaged
may cause oil leakage, electrical shock, or fire.
- Use the most appropriate cutting tool, tool holder, retention knob, and workpiece, and make sure that
they are all secured firmly in place. Otherwise, the workpiece may fall or the tool may fly out, and this
may result in damage to the machine, serious injury, or death.
- Check that the tool numbers are registered correctly. Otherwise, the spindle may rotate at a speed outside the allowable range, the tool may fly out, and this may result in damage to the machine, serious injury, or death.
2.1.5Pre-operation Checks
- Be sure that you fully understand the work procedures and precautions before operating and maintaining the machine. Never operate any machinery if you are unsure about any points.
- Check that the clothes you are wearing are suitable for operation.
- Perform periodic maintenance.
- Confirm that all safety devices are functioning properly before operating and maintaining the machine.
- Periodically back up the parameters when the machine was shipped and the program and offset data
that have been prepared by the customer. Makino is not liable for any program or offset data that is
corrupted or lost.
- Makino does not accept responsibility for any trouble caused by apparatus or programs prepared by
the customers, such as damage to workpieces or the machine.
- For details about replacement parts, contact your Makino service representative. Use of improper parts
may result in reduced machine performance or safety, damage to the machine, or operator injuries.
- Before entering inside the machine to perform work, be sure to confirm the escape procedure in the
event that you inadvertently become shut inside the machine.
- Perform the lock-out and tag-out procedures.
- Make sure the operator knows the location of the [Emergency Stop] switches for each device so that
they can be easily operated in the event of an abnormal or dangerous situation.
- Be sure to observe the information on the warning labels. Contact your Makino service representative if
a warning label comes off or becomes illegible.
- When handling a hazardous or toxic material (oils, cutting fluids, and other chemical substances), obtain
the safety data sheet (SDS), and follow the instructions. The safety data sheet (SDS) contains information about the safe handling of hazardous and toxic materials, and emergency measures.
- For the graphite specifications, do not let the dust collector collect anything other than graphite dust.
Failure to observe this precaution may result in a dust explosion. Also, it may damage the filter or cause
other malfunctions.
- For the graphite specifications, observe the following precautions to prevent health problems related to
the inhalation of graphite dust.
• After machining the workpieces, wait for the dust collector to remove airborne dust particles before
opening the operator door. If you open the operator door immediately after machining, the airborne
dust will disperse throughout the machining room.
• Wear a high-performance dust-proof mask when doing the following (particle collection efficiency of
99.9% or more is recommended).
- Opening and closing the operator door
- Performing an operation with the operator door open
- Replacing a tool in the tool magazine
- Handling dust
• Do not remove the dust car and chip bucket while the dust collector is operating. Otherwise, dust will
disperse in the surrounding area.
MAKINO29F-21E-2006 (en)
2-4SAFETY
DANGER
Under Maintenance/
Inspection
Operator’s Name: xxxxx
Department: xxxxx
D
A
N
G
E
R
2.1.6Implementing Lock-out and Tag-out
Lock-out consists of shutting down the power source to the machine or devices and locking it.
Example: .................... Set the main power switch to the “OFF” position and secure it using a padlock or a
lockout device such as a cover.
Tag-out consists of placing a warning tag to prevent anyone from turning ON the power.
Example: .................... Place a “Do Not Operate” or “Under Maintenance” sign with the operator’s name and
department and indicating that machine operation is prohibited on the main power
switch and main operation panel.
Lock-out/tag-out should be performed to prevent inadvertent operation and ensure operator safety.
- Performing lock-out/tag-out alone does not completely ensure operator safety. The operator must read
and thoroughly understand the work procedures and safety precautions, and always be aware of potential hazards.
Each operator should perform lock-out or tag-out by himself or herself. Perform this procedure before
starting the work, and release the lock and remove warning tag yourself after finishing work. Never release a lock and remove a sign without confirming with the operator or without the presence of the operator himself or herself.
Be sure to clearly define and implement the lock-out and tag-out procedures of your company.
Fig. 2-2: Implementing Lock-out and Tag-out
29F-21E-2006 (en)MAKINO
SAFETY2-5
2.1.7During Work
- Turn OFF the power before performing maintenance of the machine. When work must be performed
with the machine power ON, confirm that all machine operations are completely stopped. Check that
any residual energy in the machine is completely discharged.
- Never go near the moving parts of the machine. If you must approach moving parts to perform maintenance, be sure to take adequate safety precautions. Inadequate attention to safety may result in death
or another serious accident.
- Always keep the doors and covers closed during operation. If you must work with the doors and covers
open, be sure to take ade quate safety precautions. Inadequate attention to safety ma y result in death or
another serious accident.
- If an operator gets trapped inside the machine, press the [Emergency Stop] switch regardless of whether the machine power is ON or OFF.
- If the machine is stopped by a power failure or power supply fault, turn OFF the machine power. If the
power is not turned OFF, the machine may start operating unexpectedly when the power is restored,
and this may result in serious injury, death, or damage to the machine.
- If the machine is stopped by a power failure or power supply fault, check that the parameter, program,
and offset data have not been corrupted. The machine may be damaged if it is operated using corrupted data.
- Be aware of the movement range of the machine and auxiliary components (each axis stroke, rotation
range, etc.), and keep all body parts clear of moving components.
- When two or more people are required for maintenance work, be sure to maintain clear communication
at all times to ensure operator safety. When performing work, be ready to press the [Emergency Stop]
switch at any time.
- Be sure to always pay attention to the safety precautions listed on the warning labels affixed to the machine (refer to “2.2 Warning Labels”).
- Do not operate the switches or change the circuits except for adjustment purposes. In particular, operating the machine with the interlock(s) or other safety devices or functions disabled is extremely dangerous and may result in death or damage to the machine.
- If a circuit or other component needs to be changed for adjustment purposes, be sure to return it to the
original setting after adjustment is completed.
- The optimum values for the NC parameters and machine parameters are set when the machine is
shipped. Do not change any parameter setting unless it is described in the manual. Also, be sure that
you fully understand the function of a parameter before attempting to change the parameter setting,
and return the parameter to its original setting after the work is completed. If you try to operate the
machine without the proper settings, the machine may operate unexpectedly, and this may result in serious injury, death, or damage to the machine.
- If the memory clear operation needs to be performed, be sure to contact your Makino service representative beforehand.
- If an alarm is triggered, eliminate the cause of the alarm using the appropriate procedure. If the remedy
procedure is unclear, contact your Makino service representative.
MAKINO29F-21E-2006 (en)
2-6SAFETY
- Never climb onto the covers. This may deform the covers or result in injury.
- When using a stepladder or stool, it should be sturdy, safe, and have anti-slip surfaces.
- If any oils or cutting fluids get into your eyes, body, or on your skin surface, they may cause severe
health problems. Wear safety gloves, mask, safety glasses, and other safety equipment.
- Wear safety gloves whenever handling chips, tools, and workpieces.
- Protective gear should be worn to protect hearing when excessive noise may be generated during operation or maintenance.
- If lubricating oil, grease, cutting fluid, or other substances are spilled on the floor, it may result in slippage, causing injury. Wipe up any spilled fluids as soon as possible.
- Never touch a switch, button, or key while your hands are wet. Failure to observe this precaution may
result in electric shock.
- Some devices (motors, lighting equipment, valves, etc.) may become very hot while the machine is operating and remain hot soon after the power is turned OFF, so be careful to avoid burns.
- Do not subject the machine to sudden impact or jolts. This may cause the machine to perform an unexpected motion or result in damage to the machine.
- Do not use the machine for operation outside the specifications or exceeding the performance range.
This may cause the machine to perform an unexpected motion or result in serious injury, death, or damage to the machine.
- Use the most appropriate cutting tool, tool holder, retention knob, and workpiece, and make sure that
they are all secured firmly in place. Otherwise, the workpiece may fall or the tool may fly out, and this
may result in damage to the machine, serious injury, or death.
- Be careful that you do not leave objects such as tools or jigs inside the machine.
- Do not place the tools, workpiece, or other parts on an unstable location.
- When a lifting sling or attachment is necessary, verify that it is strong enough to support the weight of
the parts. Confirm that no one is close to the machine and the parts are well balanced, and be careful
not to hit to the machine.
- Never go under a load that is being lifted. While transferring the hoisted load, constantly pay careful attention to the hoisted load during the operation.
- Check that the tool numbers are registered correctly. Otherwise, the spindle may rotate at a speed outside the allowable range, the tool may fly out, and this may result in damage to the machine, serious injury, or death.
- Never insert hands or feet into the chip conveyor. They may be pulled in, and this may result in death or
another serious accident.
- For the graphite specifications, observe the following precautions to prevent health problems related to
the inhalation of graphite dust.
• After machining the workpieces, wait for the dust collector to remove airborne dust particles before
opening the operator door. If you open the operator door immediately after machining, the airborne
29F-21E-2006 (en)MAKINO
SAFETY2-7
dust will disperse throughout the machining room.
• Wear a high-performance dust-proof mask when doing the following (particle collection efficiency of
99.9% or more is recommended).
- Opening and closing the operator door
- Performing an operation with the operator door open
- Replacing a tool in the tool magazine
- Handling dust
• Do not remove the dust car and chip bucket while the dust collector is operating. Otherwise, dust will
disperse in the surrounding area.
2.1.8Handling of Hazardous and Toxic Materials
Handlers of hazardous and toxic materials (such as oils and cutting fluid) must receive information, education, and training in accordance with the stipulations in JIS Z 7253 (revised March 2012)/ISO 11014: 2009.
Particular attention must be paid to the following points.
- Be sure that there is adequate ventilation in areas where hazardous and toxic materials are used.
- Hazardous and toxic materials must be handled and stored based on the handling procedures recommended by the manufacturer.
- Identify hazardous and toxic materials by affixing labels to their containers.
- Assign a person in charge to handle the hazardous and toxic materials, and provide education and
training in emergency response procedures and handling procedures.
- Before handling any hazardous or toxic material, be sure to check the safety data sheet (SDS). The safety
data sheet (SDS) contains detailed information on health and safety hazards, safe handling procedures,
and responses to emergency situations.
2.2Warning Labels
Warning labels are affixed to machine parts that are potentially hazardous to warn operators about the
hazard and its level of danger and ensure the safety of operators.
The warning labels include symbols to indicate the source of the danger, signal words to indicate the level
of danger, and warning text to describe how to prevent the danger. When working at a location where a
warning label is affixed, make sure that you fully understand the warning label information and definitions
and follow the warning text that is provided. Failure to observe the information in the warning labels may
result in death or another serious accident or damage to the machine.
2.2.1Signal Word Definitions
Signal words are divided into four classes based on the degree of expected risk.
See chapter “0 GENERAL SAFETY INSTRUCTIONS” for the description of used warning symbols.
MAKINO29F-21E-2006 (en)
2-8SAFETY
2.2.2Using Warning Labels
- Do not cover up or peel off the warning labels.
- Confirm that the operators and maintenance personnel are familiar with the language on the labels. If
labels in other languages are required, contact your Makino service representative.
- Check that all the information in the warning label is legible. If any portion of the warning text or symbol is not visible, clean by wiping with a soft cloth dipped in water or household cleanser. Do not use organic solvents or gasoline. These may damage the surface of the warning label.
- Replace the warning label if the information in the warning label is no longer visible. To obtain new
warning labels, contact your Makino service representative.
- If a part is replaced where a warning label was affixed, obtain a new warning label and affix it at the
same position as before on the new part. To obtain new warning labels, contact your Makino service
representative.
2.2.3Information Contained in Warning Labels
The two types of warning labels are shown below.
- Labels with warning text and a warning mark
- Labels with a warning mark only
2.2.3.1Warning Labels with Warning Text
Signal WordSymbolDescription
DANGER
DANGER
CAUTION
This warning label is affixed to areas where entry is
prohibited.
This warning label is affixed to places where serious
injury, death, or another accident occurs by being
crushed, entangled, or pierced, or by falling.
Maximum output 1 mW, semiconductor laser
Class 2 laser product
Do not stare into the beam.
Table 2-1:
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