VERTICAL MACHINING CENTER

SERIES
Professional P

MAINTENANCE MANUAL

WARNING 2009.12
1. Do not operate, maintain, or inspect this machine without carefully reading and understanding this manual.
2. Store this manual in a clearly marked location for easy reference when operating, maintaining, or inspecting
this machine.
3. All right reserved. No part of this document may be reproduced, copied, or modified in any form or any
means without direct permission of Makino Asia Pte. Ltd.
4. All specification and design are subjected to change without prior notification.

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 Maintenance Manual PS-Series

MACHINE MODEL : PS65, PS95

CONTROLLER TYPE : Professional P

COMPANY NAME :

This manual is developed for the use of Makino customers to help and guide in making all
necessary pre-Installation arrangements for PS65 and PS95 machines.

1st Release Date: 12/2009

Revision(s) Date:

Copyright © All Rights Reserved

No part of this manual may be reproduced or transmitted by any means or in any form to
parties other than which it is intended, without the expressed written permission from
Makino.
All specifications and designs may change without notice.
Every attempt was made to ensure that the information in this publication was correct at
the time of printing. As specifications and designs change, Makino is not responsible for
information that becomes incorrect or inaccurate after publication.

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Table of Contents
1. Introduction...................................................................................................................6
1.1 Introduction .......................................................................................................... 6
1.2 Machine General Descriptions ............................................................................. 7
1.2.1 Machine Structure/Components..................................................................... 7
1.2.2 Machine Basic Specifications......................................................................... 9
2. Safety .........................................................................................................................10
2.1 Safety Precautions ............................................................................................. 10
2.1.1 Operator Checks .......................................................................................... 11
2.1.2 Work Environment Checks........................................................................... 11
2.1.3 Machine Condition Checks .......................................................................... 12
2.1.4 Pre-operation Checks .................................................................................. 12
2.1.5 Lockout and Tagout Confirmation (LOTO) ................................................... 13
2.1.6 During-Operation Checks............................................................................. 14
2.2 Warning Labels .................................................................................................. 16
2.3 Utilization of Safety Devices............................................................................... 17
2.3.1 Safety Device Locations............................................................................... 18
2.3.2 Emergency Stop Switch ............................................................................... 19
2.4 Warning List ....................................................................................................... 20
2.4.1 Inside of Machining Chamber....................................................................... 20
2.4.2 Tool Magazine, Tool Loading Station........................................................... 21
2.4.3 Cutting Fluid Supply Unit, Chip Disposal Unit .............................................. 21
2.4.4 Splash Guard ............................................................................................... 22
2.4.5 Oil Temperature Controller, Hydraulic Unit .................................................. 22
2.4.6 Machine Surrounding Area .......................................................................... 22
2.4.7 Electrical System.......................................................................................... 23
2.4.8 Parameters .................................................................................................. 23
2.4.9 Auxiliary Devices.......................................................................................... 23
3. Machine Controller .....................................................................................................24
3.1 Composition ....................................................................................................... 24
3.1.1 General View and Components ................................................................... 24
3.1.2 Professional P .............................................................................................. 26
3.2 Display Screens ................................................................................................. 26
3.2.1 Position Display Screen ............................................................................... 26
3.2.2 Offset/Setting Screen ................................................................................... 28
3.2.3 System Screen............................................................................................. 29
3.2.4 Message Screen .......................................................................................... 35
3.3 Parameter, Program and Data Input/Output Procedure ..................................... 37
3.3.1 Machine Data Input/Output Procedure......................................................... 37
3.3.2 NC Program Input/Output Procedure ........................................................... 43
3.3.3 SRAM Backup.............................................................................................. 46
4. Troubleshooting..........................................................................................................47
4.1 Machine Abnormal Condition ............................................................................. 48
4.1.1 Emergency Stop........................................................................................... 48
4.1.2 Axis Fails to Move ........................................................................................ 58
4.1.3 Program Fails to Start .................................................................................. 59

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4.2 Professional P Troubleshooting ......................................................................... 60
4.2.1 Professional P Does Not Start...................................................................... 60
4.2.2 Professional P Trouble during Start-up ........................................................ 60
4.2.3 Touch Panel Calibration............................................................................... 61
4.3 Spindle Head...................................................................................................... 62
4.3.1 Spindle Start/Stop Malfunction ..................................................................... 62
4.3.2 Abnormal Spindle Speed or Start/Stop Timing............................................. 62
4.3.3 Orientation Malfunction ................................................................................ 63
4.3.4 Tool Clamp/Unclamp Malfunction ................................................................ 63
4.3.5 Abnormal Noise Generated During Spindle Rotation ................................... 64
4.3.6 Oil Leakage .................................................................................................. 64
4.4 Feed Axis ........................................................................................................... 65
4.4.1 Axis Fails To Move In Manual Mode ............................................................ 65
4.4.2 Servo Alarm Is Triggered During Operation ................................................. 66
4.4.3 Feed Axis Runs until Hitting Mechanical Stop.............................................. 66
4.4.4 Positioning Accuracy Not Achieved.............................................................. 67
4.4.5 Abnormal Noise or Vibration Generated During Axis Operation................... 68
4.4.6 Oil Leakage .................................................................................................. 69
4.5 ATC Arm ............................................................................................................ 70
4.5.1 Tool Change Operation Does Not Start ....................................................... 70
4.5.2 Abnormal Noise During Tool Change Operation .......................................... 70
4.5.3 Tool Dropped During Tool Change .............................................................. 71
4.5.4 Abnormal Opening and Closing of Shutter................................................... 71
4.5.5 Inverter Alarms............................................................................................. 72
4.6 Tool Magazine.................................................................................................... 75
4.6.1 Door Lock Released Malfunction (Door Lock Specification) ........................ 75
4.6.2 Door Lock Malfunction (Door Lock Specification) ........................................ 75
4.6.3 Tool Dropped During Operation ................................................................... 75
4.6.4 Tool Search (T) Command Malfunction ....................................................... 75
4.6.5 Servo Alarm Triggered During Operation..................................................... 76
4.6.6 Wrong Tool Called to ATC Position.............................................................. 76
4.6.7 Time-out Alarm Triggered ............................................................................ 77
4.7 Spindle Oil Temperature Controller.................................................................... 78
4.7.1 Troubleshooting with Alarm Displayed ......................................................... 81
4.8 Spindle Lubrication (Oil-Air) Device for Bearing ................................................. 86
4.9 Oil-Mist Supply Unit............................................................................................ 87
4.10 Automatic Grease Supply Unit ........................................................................... 88
4.11 Hydraulic System ............................................................................................... 91
4.12 Pneumatic System ............................................................................................. 93
4.12.1 Pressure Switch Malfunction........................................................................ 93
4.12.2 Filter Malfunction.......................................................................................... 94
4.13 Cutting Fluid ....................................................................................................... 95
4.13.1 Cutting Fluid Supply Unit Malfunction .......................................................... 95
4.13.2 Cutting Fluid Temperature Controller ........................................................... 96
4.13.3 Troubleshooting with Alarm Displayed ......................................................... 99
4.14 Mist Collector ................................................................................................... 104
4.14.1 Motor Not Operating................................................................................... 104
4.14.2 Motor Rotates, But Does Not Collect Mist.................................................. 104
4.14.3 Motor Load is Excessive ............................................................................ 105
4.14.4 Oil is not being Collected ........................................................................... 105

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4.14.5 Abnormal Noise or Vibration Emitted from Motor ....................................... 105

4.14.6 Oil Leaks from Duct Connection Point ....................................................... 105
4.15 Automatic Tool Length Measurement............................................................... 106
4.15.1 Repeatability of Measured Value is not Good ............................................ 106
4.15.2 Measured Results Are Not Correct ............................................................ 106
4.15.3 Emergency Stop status is activated during Positioning.............................. 106
4.15.4 Stylus Cleaning Air is not Supplied ............................................................ 107
4.16 Automatic Workpiece Measuring Unit .............................................................. 107
4.16.1 Emergency Stop status is activated during Positioning.............................. 107
5. Machine Maintenance ..............................................................................................108
5.1 Maintenance Screen ........................................................................................ 108
5.1.1 ATC Maintenance Screen .......................................................................... 110
5.1.2 Confirming Signal Status and Errors .......................................................... 112
5.2 ATC .................................................................................................................. 113
5.2.1 ATC Maintenance Items............................................................................. 113
5.2.2 ATC Operation Outline............................................................................... 113
5.2.3 ATC Restore Procedure............................................................................. 115
5.3 ATC Magazine ................................................................................................. 117
5.3.1 ATC Magazine Maintenance Screen.......................................................... 117
5.3.2 ATC Magazine Operation Outline .............................................................. 118
5.3.3 ATC Magazine Operation Procedure ......................................................... 118
6. Periodic Maintenance...............................................................................................119
6.1 Outline/Precautions .......................................................................................... 119
6.2 Periodic Maintenance Lists .............................................................................. 121
6.2.1 Daily / Pre-Operation Inspection Maintenance ........................................... 121
6.2.2 Post-Operation Maintenance...................................................................... 123
6.2.3 Monthly Maintenance ................................................................................. 124
6.2.4 Biannual Maintenance................................................................................ 124
6.2.5 Annual Maintenance .................................................................................. 124
6.2.6 160-Hour Maintenance............................................................................... 124
6.2.7 500-Hour Maintenance............................................................................... 124
6.2.8 2000-Hour Maintenance............................................................................. 125
6.2.9 6000-Hour Maintenance............................................................................. 125
6.2.10 12000-Hour Maintenance........................................................................... 125
6.2.11 20000-Hour Maintenance........................................................................... 125
6.2.12 Alarm-Related Maintenance....................................................................... 126
6.3 Spindle ............................................................................................................. 127
6.3.1 Spindle Taper Cleaning.............................................................................. 127
6.3.2 Sealing Rod (BT)........................................................................................ 128
6.3.3 O-Ring in Sleeve (HSK) ............................................................................. 131
6.3.4 Collet Lubrication (HSK)............................................................................. 133
6.3.5 Spindle Rotary Union/Rotary Union Support Bearing Replacement........... 134
6.4 Feed Axis ......................................................................................................... 135
6.4.1 Feed Axis Ballscrew/Linear Guide Grease Supply..................................... 135
6.5 ATC Unit........................................................................................................... 136
6.5.1 Cam Box Lubricant Level Check ................................................................ 136
6.5.2 Cam box Lubricant Replenishment ............................................................ 137
6.5.3 Cam box Lubricant Replacement ............................................................... 138

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6.6 Tool Magazine.................................................................................................. 139
6.6.1 Tool Shank Check/Cleaning and Tool Pot Key Check ............................... 139
6.6.2 Grease Application to Drive Gear............................................................... 141
6.6.3 Grease Application of Pot Up/Down Cylinder Rod ..................................... 142
6.6.4 Replacement of Arm Gripper Plunger Spring............................................. 143
6.6.5 Replacement of Tool Pot Sliding Pad......................................................... 144
6.7 Spindle Cooling Oil Temperature Controller..................................................... 145
6.7.1 Checking/Replacing of Cooling Oil............................................................. 145
6.7.2 Cleaning of Air Filter and Condenser Coil .................................................. 146
6.7.3 Line Filter Element Replacement ............................................................... 147
6.8 Spindle Lubrication (Oil Air) Device.................................................................. 148
6.8.1 Checking/Replacement of Lubricant .......................................................... 148
6.8.2 Cleaning/Replacement of Suction and Line Filters..................................... 149
6.8.3 Oil Piping Air Removal ............................................................................... 151
6.9 Hydraulic Unit ................................................................................................... 152
6.9.1 Hydraulic Oil Check/Replacement.............................................................. 152
6.10 Pneumatic Unit................................................................................................. 153
6.10.1 Air Panel Configuration .............................................................................. 153
6.10.2 Air Quality Control ...................................................................................... 154
6.10.3 Main Air Unit Pressure Check/Adjustment ................................................. 154
6.10.4 Main Air Unit Filter Replacement................................................................ 155
6.10.5 Scale Air Unit Pressure Check ................................................................... 156
6.11 Chip Disposal/Cutting Fluid Supply Unit........................................................... 157
6.11.1 Cutting Fluid Level Check/Replacement .................................................... 158
6.11.2 Coolant Tank Cleaning............................................................................... 159
6.11.3 Filter Cleaning ............................................................................................ 160
6.11.4 Pump Mechanical Seal Replacement ........................................................ 161
6.11.5 Through Spindle Coolant 1.5Mpa Filter Maintenance ................................ 162
6.11.6 Maintenance Drawings............................................................................... 163
6.12 Machine Controller ........................................................................................... 164
6.12.1 Absolute Pulse Coder Battery Replacement .............................................. 164
6.12.2 NC Backup Battery Replacement............................................................... 165
6.13 Axes Telescopic Cover..................................................................................... 166
6.14 Splash Guard Front Door Glass ....................................................................... 167
6.15 Optional Specification/Equipment .................................................................... 168
6.15.1 Automatic Grease Cartridge Replacement................................................. 168
6.15.2 Automatic Tool Length Measurement Unit (Touch Probe) ......................... 170
6.15.3 Automatic Workpiece Measuring Unit ........................................................ 171
6.16 Arrangement Product Lists............................................................................... 176
6.16.1 Recommended Grease .............................................................................. 176
6.16.2 Recommended Cooling Oil/Hydraulic Oil/Lubricant ................................... 176
6.16.3 Order Numbers for Replacement Parts...................................................... 177

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1. Introduction
1.1 Introduction
Makino offers two different models along a line of PS-series Vertical Machining Centers
(PS - Series machines here in after): PS65 and PS95.

The PS - Series Machines enable high-precision machining performed in a highly efficient

manner. Various peripheral devices and accessories are also available to meet diverse
machining demands and requirements.

Figure 1.1a: PS-Series Machine General View.

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1.2 Machine General Descriptions

1.2.1 Machine Structure/Components
1.2.1.1 Axis Configuration

• X-axis: Table moving horizontally (left and right)

• Y-axis: Saddle moving horizontally (front and back)
• Z-axis: Spindle moving vertically (up and down)

Spindle

Column

Table

Saddle

Z+
Bed

X+
Z-
X-
Y-

Y+

Figure 1.2.1.1a: Machine Structure and Axis Configuration.

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1.2.1.2 Machine Primary Components

The PS-series machine primarily consists of the spindle head, column, bed, saddle, table,
ATC (Automatic Tool Changer), hydraulic unit, spindle cooling oil temperature controller,
machine controller, NC (Numerical Controller) and cutting chip disposal system.

Spindle Head

The spindle head is mounted at the front of the column. The spindle head moves up and
down the column to form the z-axis. A built-in AC motor drives the spindle. The spindle
bearings are lubricated by the oil-air lubrication method. The spindle head and motor are
jacket-cooled and the generated heat is removed by cooling oil supplied from the spindle
oil temperature controller.

Column

The column is rigidly supporting the spindle head. The z-axis linear motion guide is
mounted on the column.

Bed

The bed is of high-strength structure consisting of multiple ribs. The y-axis linear motion
guides are mounted on the bed. An eight-point support structure is employed to improve
the installation accuracy.

Saddle

The saddle is rigidly supporting the table. The x-axis linear motion guide is mounted on
the saddle. The saddle moves front and back to form the y-axis.

Table

The table is mounted on the saddle. The table moves left and right to form the x-axis.

ATC (Automatic Tool Changer)

The ATC unit consists of the following components:

• Tool Magazine
• ATC arm

Hydraulic Unit

The hydraulic unit supplies hydraulic oil to the spindle clamp/unclamp cylinder.

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 Maintenance Manual PS-Series
Spindle Cooling Oil Temperature Controller

The spindle cooling oil temperature controller circulates cooling oil through the spindle
head outer cylinder and absorbs the generated heat to adjust the temperature of the
spindle to that of the machine bed.

Machine Controller

The machine controller controls overall machine operations and functions including
operations of the ATC unit and management of tool/workpiece data required for
machining.

NC (Numerical Controller)

The NC executes NC programs and controls axes servomotors and spindle drive motor. A
micro computer is used of the control and diagnostic functions.

Cutting Chip Disposal Unit

Cutting chips are flushed from the machining point into the inner conveyor chamber with
cutting fluid discharged from the nozzle and overhead shower coolant units. Cutting chips
flown into the inner conveyor are carried out of the machine with the pushing effect
created by the inner conveyor and discharged into the chip bucket by lift-up chute.

1.2.2 Machine Basic Specifications

PS65 PS95
Travels X, Y, Z Axes 660 x 510 x 460 mm 920x510x460
Spindle Speed Range 50 ~ 12,000 min-1
Spindle
Spindle Taper Hole 7/24 No. 40 Taper
Rapid Traverse (XYZ) 36,000 x 36,000 x 30,000 mm/min
Feed Rate
Cutting Feed Rate 30,000 mm/min
Machine Height 2479 mm
Machine Depth 2390 mm
Machine Size
Machine Width 2552 mm 2762 mm
Machine Weight 6,600 kg 6,800 kg

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2. Safety
2.1 Safety Precautions
This manual is designed to use by experienced personnel only.

• There are many precautions that must be observed depending upon each situation
when operating and maintaining the machine. It is impossible to cover all of these
precautions in this manual. The operator and maintenance personnel must
understand the machine thoroughly and always take care to ensure safety and be
aware of possible dangerous situations.
• This manual does not include precautions and warnings for potentially dangerous
operating conditions for personnel lacking the required mechanical/technical
knowledge (operation, programming and maintenance).
• The operator and maintenance personnel must receive proper training in order to
operate and maintain the machine safely.
• Read this manual carefully and understand thoroughly prior to operating and
maintaining the machine.
• Disregarding the specific instructions or precautions included in this manual may
result in serious injury or death and/or damage to the machine.
• Never modify the machine or components. This may result in the machine moving
unexpectedly and/or a decrease in the level of operational safety.
• Never invalidate or remove any safety devices. If the machine is operated while the
safety devices are disabled, it may result in death or damage to the machine.
• Heed the safety precautions provided in this manual at all times to ensure the
safety of operation and maintenance of the machine.
• In order to keep the machine in optimum operating condition, inspect and maintain
the machine regularly. Do not operate the machine if the machine condition is
abnormal.
• The keys (release key for door lock switch (option), machine controller panel key
etc.) which are not necessary for regular operation and maintenance must be
removed from the machine and kept by supervising personnel.
• The chemical (cutting fluid, lubricant etc.) used with the machine should be secured
and managed by supervising personnel.

About This Manual

• Keep this manual in a clearly marked location for easy reference whenever
necessary.
• Make sure to include this manual when moving or reselling this machine.
• Contact your Makino service representative when this manual is lost or damaged.
• Some contents of this manual including illustrations may differ from the actual
machine due to changes in specifications.

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 Maintenance Manual PS-Series
2.1.1 Operator Checks
• Only qualified personnel who have adequate mechanical and technical knowledge
are allowed to operate/maintain the machine.
• Only qualified electrical engineers may perform electrical work.
• Only qualified personnel may use a crane or forklift.
• Read this manual carefully and understand thoroughly prior to operating and
maintaining the machine.
• Operate and maintain the machine with the suitable clothes.
• Do not operate the machine while wearing a necktie, scarf, accessories or any
other clothes that may become entangled with the moving parts of the machine.
• Persons with long hair should tie it back or contain it under a cap (helmet).
• Wear safety glasses, safety shoes, safety cap (helmet) and safety gloves as the
occasion demands.
• 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.
• Make sure the operator knows the location of the [EMERGENCY] stop switches
prior to operating and maintaining the machine to enable immediate use in an
abnormal or dangerous situation following an accident.
• Read and understand the “DANGER”, “WARNING”, “CAUTION” labels
thoroughly prior to operation and maintenance.
• Contact your Makino service representative when the label becomes illegible due to
smudging or damage.

2.1.2 Work Environment Checks

• Make sure the machine and surrounding area is sufficiently illuminated at all times.
• Make sure the machine and surrounding area is tidy and clean at all times.
• Clean up oil, cutting fluid or chips scattered around the machine.
• When a step ladder or stool is necessary, it should be extremely sturdy, safe and
have anti-slip surfaces.
• Keep all flammable liquid away from the work area.
• Maintain adequate working space.

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2.1.3 Machine Condition Checks

• Machine inspections and maintenance must be performed regularly to maintain
optimum machining accuracy and long term performance.
• Confirm that all safety devices are functioning normally.
• Make sure the operator knows the location of the [EMERGENCY] stop switches to
enable immediate use in an abnormal or dangerous situation following an accident.
• Check for loose, damaged or worn parts on the machine. These are the cause of
abnormal noise or machine damage during machine operation.
• Check for loose or damaged piping or electrical wiring. These are the cause of oil
leakage or electric shocks during machining operation.
• Use the most appropriate cutting tool, tool holder, retention knob, workpiece and
make sure that all are tightened securely. If not, the workpiece may fall or tool may
fly out, resulting in machine damage, serious injury or death.
• Confirm that the tool number is registered properly. If not, the spindle speed may
be faster than the allowable range, the tool will fly out. This may result in machine
damage, serious injury or death.

2.1.4 Pre-operation Checks

• Read and understand the precautions and instructions requiring attention in this
chapter and each unit chapter. Never operate any machinery with an improper
understanding.
• Confirm that clothes are suitable for operation.
• Perform periodic maintenance.
• Confirm that the machine power supply is turned OFF.
• Confirm that nobody is in the machining chamber and the surrounding area.
• Check for loose, damaged or worn parts on the machine. These are the cause of
abnormal noise or machine damage during machine operation.
• Check for loose or damaged piping or electrical wiring. These are the cause of oil
leakage or electric shocks during machining operation.
• Back up the parameters set prior to shipping, the program and offset data input by
the customer periodically. If the program and offset data are damaged or lost,
Makino cannot accept any responsibility for this data.
• Contact your Makino service representative prior to replacing the parts. If the
machine is operated with improper parts, it may result in degrading of the
performance of the machine. It may also make the machine less safe, result in
machine damage or operator injury.
• Prior to entering the machining chamber or tool magazine provided with the door
lock system (option), turn the release key to the “UNLOCK” position and enter the
machining chamber or tool magazine with the key to prevent the possibility of being
locked-in. Turn the key to the “LOCK” position and remove the key when finished.
The release key must be kept by supervising personnel.
• Always perform lockout and tag out prior to performing maintenance on the
machine.

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 Maintenance Manual PS-Series
Operation/Maintenance when the machine power is turned ON:

• Confirm that all safety devices are functioning normally.

• Make sure the operator knows the location of the [EMERGENCY] stop switches to
enable immediate use in an abnormal or dangerous situation following an accident.
• Confirm that machine operation is completely stopped.
• Confirm that all doors and covers are closed.
• Confirm the moving range of the machine and components.

2.1.5 Lockout and Tagout Confirmation (LOTO)

Lockout and Tagout Implementation

Lockout consists of shutting down the power source to the machine or devices to lock it.
Example: Set the main power switch to the OFF position and secure it using a padlock or
cover such as a lock out device.

Tagout consists of placing the signs to prevent anyone from switching ON the power
source.
Example: Place “Do Not Operate” or “Under Maintenance” signs with the operator’s name
and department on the main power switch and main operation panel.

Lockout and Tagout to prevent accidental operation is a minimum requirement to ensure

operator safety.

The operator or maintenance personnel should perform Lockout and Tagout

himself/herself. Perform this procedure prior to work and release the lock and
remove the signs yourself after work. Never release the lock and remove the signs
without confirming with or in the presence of the operator.

Use the Lockout and Tagout policy and procedures defined by your company. Example is
as below.

Lockout and Tagout can prevent accidental operation. However this does not guarantee
operator safety. The operator must read and understand thoroughly the precautions in
this chapter and each until chapter, and be aware of possible dangerous situations.

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2.1.6 During-Operation Checks

• Always turn OFF the power before performing maintenance on the machine unless
it is necessary to have the machine power ON.
• Never get close to the moving parts of the machine.
• Always keep the doors and covers closed during operation.
• If an operator is shut inside the machine, press the [EMERGENCY] stop switch
immediately regardless of whether the machine power is ON or OFF.
• When the machine is stopped by a power failure, turn OFF the machine power
immediately. If the power is not turned OFF, the machine will start operating
unexpectedly when the power is restored and this may result in serious injury,
death or damage to the machine.
• When the machine is stopped by a power failure, check that the parameter,
program and offset data have not been damaged. If the machine is operated using
damaged data, it may result in damage to the machine.
• When approaching the moving parts or working with the cover removed in order to
perform maintenance, take adequate safety precautions. Inadequate attention to
safety may result in serious injury or death.
• Be aware of the movement range of the machine and auxiliary components (each
axis stroke, rotation range) and always keep all body parts clear of moving
components.
• When two or more people are required for maintenance work, make sure to
maintain clear communication at all times to ensure operator safety and be ready to
press the [EMERGENCY] stop switch immediately.
• Make sure to always pay attention to the precautions listed on the Danger, Warning
and Caution labels attached to the machine.
• Do not move the switches or change the circuits except for adjustment purposes.
This may result is serious injury, death or damage to the machine.
• In particular, operating the machine with the interlock(s) or other safety
devices/functions disabled is especially dangerous and may result in serious injury,
death or damage to the machine. If you have to operate or maintain the machine
with the interlock(s) released, enable the [MACHINE LOCK] function and pay extra
attention to safety during operation or maintenance.
• If a circuit needs to be changed for adjustment purposes, make sure to return it to
the original setting after adjustment is completed.
• Make sure to return the parameter to its original setting when a parameter is
changed for maintenance or adjustment purposes. If the setting is not correct, the
machine may operate in an unexpected manner and this may result in serious
injury, death or damage to the machine.
• If the memory clear operation is necessary, contact your Makino service
representative first.
• When an alarm is triggered, eliminate the cause of an alarm with the appropriate
procedure. If the procedure is not clear, contact your Makino service
representative.
• Never step on the covers as their surfaces are slippery and very dangerous. This
may result in the serious injury or deformation of the cover(s).

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 Maintenance Manual PS-Series
• When a stepladder or stool is necessary, it should be extremely sturdy, safe and
have anti-slip surfaces.
• If lubricant, cutting fluid and other oils get into eyes/body or on skin surface, it may
cause damage to the eyes or skin. Wear safety gloves, a mask and safety goggles
as the occasion demands.
• Wear safety gloves when handling chips, tools and workpieces.
• Wear safety gloves when handling tools and be careful not to drop tools.
• Never touch a switch, button or key with wet hands. This may result in an electrical
shock.
• Some devices (motors, lighting devices, valves etc) become vey hot when the
machine is operating and remain hot soon after the power is turned OFF. Be
careful when handling these components to prevent from being burned.
• Avoid accidently bumping into or touching any machine controls, as this may cause
unforeseen machine motion that may result in injury or damage to the machine.
• Use the most appropriate cutting tool, tool holder, retention knob and workpiece
and make sure that they are all tightened securely. If not, the workpiece may fall or
tool may fly out and this may result in damage to the machine, serious injury or
death.
• Do not leave articles such as tools or jigs required for maintenance inside the
machine.
• Do not place tools, workpiece or other parts on an unstable working bench.
• When a lifting sling or attachment is necessary, confirm 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.
• Confirm that the tool numbers are registered correctly. If not, the spindle rotating
speed may be faster than the allowable limit and the tool may fly out. This may
result in death or damage to the machine.
• Never insert hands or feet into the lift-up conveyor or internal conveyor. They may
be pulled in and this may result in serious injury or death.
• Contact your Makino service representative prior to replacing parts. If the machine
is operated with improper parts, it may result in degrading of the performance of the
machine. It may also make the machine less safe, result in machine damage or
operator injury.

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2.2 Warning Labels

Warning labels are attached to the machine to ensure safe operation of the machine and
provide important instructions. Confirm that the operator and maintenance personnel are
familiar with the language on the labels. If not, contact your Makino service representative
to get proper labels.

Operators and maintenance personnel need to be able to read and understand all warning
labels. Always keep the labels clean so that they can be read easily.

Replace the labels when the labels peel off or become illegible. If the parts on which the
warning labels are attached are replaced, new labels must be attached to the new parts.
Contact your Makino service representative.

Possibility of Injury or Machine Damage

Major (Urgent) Medium (Possible) Minor (Hypothetical)

Danger Warning
Death

Caution indicates a
potentially
Danger indicates an Warning indicates an hazardous condition,
*Serious Injury imminently hazardous imminently hazardous which if not avoided,
condition, which if not condition, which if not may result in
avoided, will result in avoided, could result in moderate or minor
death or serious injury. death or serious injury. injury. This is also
Caution used to alert the
operator of unsafe
** Minor Injury,
operating
Material Loss
procedures.

* Serious Injury:
• Injury, loss of eyesight, burn, electrical shock, bone fracture or poisoning etc.
• Injury or condition which has a residual effect or requires hospital treatment or long-
term treatment as an outpatient.

** Minor Injury:
• Injury, burn or electrical shock which does not required hospital treatment or long-
term treatment as an outpatient.

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2.3 Utilization of Safety Devices

Safety devices are installed on the machine in order to protect the operators and
maintenance personnel. However, these devices can not guarantee the safety for
operators. Operator must read and thoroughly understand the precautions described in
this chapter and each unit chapter and be aware of possible dangerous situations. The
main safety devices are described below:

[EMERGENCY] stop switch

• Main Operation Panel

• Portable Manual Pulse Generator (Option)
• Tool Magazine (ATC) Operation Panel

Door Interlock Switch (Standard)/Door Lock Switch (Option/CE Specification)

• Operator Door
• Tool Magazine Door

• Confirm that all safety devices are functioning normally prior to operating and
maintaining the machine.
• Make sure the operators know the locations of all [EMERGENCY] stop switches
prior to operating and maintaining the machine to enable immediate use in an
abnormal or dangerous situation following an accident.
• If adjustment or maintenance is necessary with the door, safety guard or
protective cover open, take adequate safety precautions.
• Never disable or remove any safety device. If the machine is operated while the
safety devices are disabled, this may result in serious injury, death or damage
to the machine.

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2.3.1 Safety Device Locations

Door Interlock / Door Lock (Option)

Switch (Front Operator Door)

[EMERGENCY] Stop Switch

(Main Operation Panel)

[EMERGENCY] Stop Switch

(ATC Panel)
Door Interlock / Door Lock (Option)
Switch (ATC Magazine Side)

Figure 2.3.1a: Safety Devices Location.

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2.3.2 Emergency Stop Switch
[EMERGENCY] stop switch are installed at the following locations:

• Main Operation Panel

• Tool Magazine (ATC) Operation Panel
• Portable Manual Pulse Generator (Option)

The following processes are performed when the [EMERGENCY] stop switch is pressed:

• Feeding of each axis stops immediately.

• Spindle rotation stops if rotating.
• The spindle tool is clamped if unclamped.
• When orientation of the spindle has been performed, orientation is released.
• When an ATC or tool magazine operation is being performed, operation stops
immediately (even in mid-motion)
• The NC is reset.
• All Coolant motors will be OFF if it is switched ON.
• Spindle temperature controller will be OFF.
• Spindle rotation speed setting (S - Command) is reset.
• Tool search (T-Command) is cancelled.
• Hydraulic pressure supply stops.
• All solenoid valves (Pneumatic and Hydraulic) are de-energized.

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2.4 Warning List

The following tables list the examples of possible accidents, incidents and careless
operating/maintenance conditions.
These are many precautions that must be observed depending upon each situation when
operating and maintaining the machine. It is impossible to cover all of these precautions in
this manual. The operator and maintenance personnel must understand the machine
thoroughly and always take care to ensure safety and be aware of possible dangerous
situations. Careless operation may result in serious injury, death or damage to the
machine.

2.4.1 Inside of Machining Chamber

Accident/Incident Potential Injuries/Damage (Examples)
Operator enters machining chamber without Injury or death
turning OFF power.
Operator enters machining chamber without Injury or death
safety devices or functions disabled.
Machine is operated with a tool incorrectly Injury or death, machine damage
clamped.
Work without performing Lockout and Tagout. Injury or death, machine damage

Spindle is rotated with a tool incorrectly Injury or death, machine damage

clamped while operator door is open.
Spindle is rotated prior to cleaning of tapered Injury or death, machine damage
section while operator door is open.
Unbalanced tool is rotated at high speed while Injury or death, machine damage
operator door is open.
Feed axis moves, trapping operator in machine. Injury or death
Operator is struck by ATC arm Injury or death
Operator is struck by Internal conveyor. Body part pulled in, resulting in serious
injury or death
Operator touches rotating spindle. Hand(s) cut off or pulled in, resulting in
serious injury or death
Hand(s) caught when closing operator door. Bone fracture
Operator works on oily floor. Bone fracture, Injury caused by falling
Operator touches bladed tools. Cuts or puncture injuries to hands
Operator lifts heavy tools Strained back, hands trapped
Operator is struck by chips and cutting fluid Damage to eyes or cuts/burns to skin
scattered during machining.
Operator is splashed by cutting fluid dripping Damage to eyes
from ceiling (splash guard)
Compressed air is used for spindle cleaning. Spindle head damage
Operating the machine with abnormal vibration Machine damage
or noise.

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2.4.2 Tool Magazine, Tool Loading Station
Accident/Incident Potential Injuries/Damage (Example)
Operator enters tool magazine with the safety Injury or death
devices and functions disabled.
T-search or tool change is operated when tool Injury or death
blade is mounted incorrectly.
Operator enters tool magazine without turning Injury or death
OFF power.
Manually changing tools inside of tool magazine. Injury or death
Work without performing Lockout and Tagout. Injury or death, machine damage
T-search or tool change is performed when tool Injury or death, machine damage
is incorrectly stored in pot.
Operator inserts hand into tool magazine during Cuts, bone fracture of hands
tool magazine operation.
Operator touches bladed tools. Cuts, Injuries to hands
Operator lifts heavy tools. Strained back, hands trapped
Operator works in elevated locations. Falling, bone fracture
Operator works on oily floor. Bone fracture, Injury caused by falling
Tool number is registered improperly. Machine damage

2.4.3 Cutting Fluid Supply Unit, Chip Disposal Unit

Accident/Incident Potential Injuries/Damage (Examples)
Work without performing Lockout and Tagout. Injury or death, machine damage
Inhaling large quantities of cutting fluid mist. Respiratory organ damage
Inserting hands or feet into conveyor or tank Body part pulled in, resulting in
without turning OFF power. serious Injury, cuts to hand and foot
Operator touches moving parts when chip Body part pulled in, resulting in
discharge outlet cover is removed. serious Injury
Insufficient cutting fluid. Fire, machine damage
Contact with cutting fluid. Skin irritation
Contact with chemical additives. Skin irritation
Contact with chips. Cuts or puncture Injuries to hands
Cleaning machine without wearing protective Cuts or puncture Injuries to hands
gloves.
Replacing the filter without prior cleaning. Cuts or puncture Injuries to hands
Stepping on the tank which is not secured Bone fracture, Injury caused by falling
correctly.
Touch the components soon after the power is Burn
turned OFF.
Mixing oils of different brands/manufacturers. Machine damage.

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2.4.4 Splash Guard

Accident/Incident Potential Injuries/Damage (Examples)
Work without performing Lockout and Tagout. Injury or death, machine damage
Operating machine without covers. Injury or death
Operator enters splashguard without the safety Injury or death
devices and functions disabled.
Operator works in elevated locations. Falling, bone fracture
Operator works on oily floor. Bone fracture, Injury caused by falling

2.4.5 Oil Temperature Controller, Hydraulic Unit

Accident/Incident Potential Injuries/Damage (Examples)
Oil temperature exceeds flashpoint. Fire
Spindle lubricant (Mobil Velocite No.3): 108°C.
Standard hydraulic oil flashpoint: approx. 200°C.
Handling the lubricant or oil without safety Damage to eyes, skin irritation,
gloves, mask and other such as protective gear. accidental ingestion or inhalation
Touching the hot component soon after the Burn
operation.
Mixing oils of different brands/manufacturers. Machine damage

2.4.6 Machine Surrounding Area

Accident/Incident Potential Injuries/Damage (Examples)
Stumble over cables or piping. Falling
Operator works on oily floor. Bone fracture, Injury caused by falling

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2.4.7 Electrical System
Accident/Incident Potential Injuries/Damage (Examples)
Operator without turning OFF machine power. Electric shock, machine malfunction,
abnormal operation, fire
Improper wiring. Machine malfunction, abnormal
operation, fire
Loose screws in terminal block. Machine malfunction, abnormal
operation, fire
Machine controller door or terminal box cover is Electric leakage, machine malfunction,
left open. abnormal operation, fire
Touching switches with wet hands. Electric shock
Damage to cable on floor surrounding machine. Electric leakage, machine malfunction,
abnormal operation, fire
operation or maintenance by non-qualified Machine malfunction
personnel.

Prior to performing maintenance on the servo amplifier, spindle amplifier and inverters,
turn OFF the machine power supply and confirm that the red indicator (charging) for each
device is extinguished.
High voltage current flows through components inside the terminal box.
High voltage current continues to flow on the primary side of the main power switch even
after the switch is turned OFF.
Electrical current continues to flow to lamps (option) and outlets in the machine controller
even after the main power switch is turned OFF.

2.4.8 Parameters
Accident/Incident Potential Injuries/Damage (Examples)
Charging NC/machine parameters not listed in Serious Injury, workpiece or machine
manual. damage
Forgetting to return the parameter to its original Serious Injury, workpiece or machine
value after adjustment. damage

2.4.9 Auxiliary Devices

Accident/Incident Potential Injuries/Damage (Examples)
Operation without turning OFF machine power. Injury or death, electric shock

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3. Machine Controller
3.1 Composition
3.1.1 General View and Components

Machine Controller

Figure 3.1.1a: Machine Controller Location.

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 Maintenance Manual PS-Series

Power Supply Module, Servo Amplifier for

base Axis, Spindle, ATC Magazine, 4th/5th
Axis (option)

A/C reactor

Spindle
Switching

Magnetic
Inverter contactor for
power supply

Circuit Lightning
Protector surge
Protector

I/O Module,
Relay, Fuse Option PCB

Regulator
24V

I/O link for 5-

Axis (option)
Motor Starter
with Thermal
Relay
Transformer
Option PCB for control
power 230V

Figure 3.1.1b: Machine Controller Layout.

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3.1.2 Professional P
The machine controller (Professional P: Pro P) includes a numerical controller (FANUC
Series 0i-MD) and Makino-developed control software.
This unit controls automatic machine operations, electrically controlled components, axis
servomotors and the spindle motor.

3.2 Display Screens

The screens that are frequently used during adjustment and maintenance are outlined in
this section. For details on each screen: Refer to NC user’s manual.

3.2.1 Position Display Screen

The screens below can be displayed on the position display screen. This screen is
displayed by pressing the [POS] function key on MDI keyboard. The selection buttons
(softkeys) that belong to the [POS] function key and the function of each screen are
described below.

No Button Description
1 ABSOLUTE Selects the absolute coordinate display screen.
2 RELATIVE Selects the relative coordinate display screen.
3 ALL Selects the overall coordinate display screen.
4 HANDLE Selects the operation screen for manual handle interruption
operation.
6 MONITOR Selects the screen for displaying the servo axis load meter and
serial spindle load meter.
5,10 (OPRT) Operation selection key.

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Transition sequence after pressing the [POS] function key.

POS
Absolute Coordinate Display

[ABSOLUTE] [(OPRT)] [WRK CD] [ALL AXIS]

(Axis name, 0) -- [EXEC]

[PTSPRE] -- [EXEC]

[RUNPRE] -- [EXEC]

Relative Coordinate Display

[RELATIVE] [(OPRT)] (Axis Name, [PRESET]

Numeral)
[ORIGIN] [ALL AXIS]
(Axis name) – [EXEC]

[PTSPRE] -- [EXEC]
[RUNPRE] -- [EXEC]

Current Coordinate Display

[ALL] [(OPRT)] (Axis Name, [PRESET]

Numeral)
[ORIGIN] [ALL AXIS]

(Axis name) – [EXEC]

[PTSPRE] -- [EXEC]

[RUNPRE] -- [EXEC]

Handle Interruption Display

[HANDLE] [(OPRT)] [PTSPRE] -- [EXEC]

[RUNPRE] -- [EXEC]

+
Monitor Display

[MONITOR] [(OPRT)] [PTSPRE] -- [EXEC]

[RUNPRE] -- [EXEC]

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3.2.2 Offset/Setting Screen

The screens below can be displayed on the Offset/Setting screen. Displaying or setting of
tool compensation values and data can be performed on this screen. This screen is
displayed by pressing the [OFFSET SETTING] function key on MDI keyboard. The
selection buttons (softkeys) that belong to the [OFFSET SETTING] function key and the
function of each screen are described below.

No. Button Description

1 OFFSET Selects the screen tool offset values.
2 SETTING Selects the screen for setting parameters.
3 WORK Selects the screen for setting the workpiece coordinate
system offset.
6 MACRO Selects the screen for setting the macro variables.
8 OPERAT Selects the screen for operating some operating switches
PANEL on the main operation panel as soft keys on the MDI
panel.
9 TOOL Selects the screen for setting the data related to tool
MANAGER(*) management.
12 PR-LV(*) Selects the screen for setting the precision level.
17 LANGUAGE Selects the screen for setting the display language.
18 PROTECT(*) Selects the screen for setting data protection.
19 GUARD Selects the screen for setting wrong operation prevention.
5,10,15,20 (OPRT) Operation selection key

The buttons denoted by (*) may or may not be displayed depending upon the machine
specifications.

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Transition sequence after pressing the [OFFSET SETTING] function key is shown below.

OFFSET SETTING

Setting Screen

[SETTING] [(OPRT)] (Number) [NO.SRH]

[ON: 1]
[OFF: 0]
(Numeral) [+ INPUT]
(Numeral) [INPUT]

3.2.3 System Screen

The screen below can be displayed on the System screen. Information confirmation,
adjustment and setting of the machine control system can be performed on this screen.
This screen is displayed by pressing the [SYSTEM] function key on MDI keyboard.
This section describes the parameter setting/modification procedure and the displaying
procedure for the ladder screen. Refer to “NC User’s Manual” for details on the other
screen on the system screen. The selection buttons that belong to the [SYSTEM] function
key and the function of each screen are described below.

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COLOR MAINTE M-INFO W.DGNS (OPRT)

PS-Series Maintenance Manual

No. Button Description

1 PARAMETER Selects the screen for setting parameters.
2 DIAGNOSIS Selects the screen for displaying the CNC status.
4 SYSTEM Selects the screen for displaying the current system
status.
7 PITCH ERROR Selects the screen for setting pitch error
compensation.
8 SERVO SETTING Selects the screen for setting the servo-related
parameters.
9 SPINDLE SETTING Selects the screen for spindle-related setting.
11 WAVE DIAG Selects the screen for displaying data such as servo
positional deviation values, torque values, machine
signals as graphs.
12 ALL IO Selects the screen for data input to and output from
the memory card.
14 OPERAT HISTRY (*) Selects the screen for displaying the history of
operations performed by the operator and issued
alarms.

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16 PMC MAINTE Selects the screen related to PMC maintenance such
as PMC signal status monitoring and tracing and
PMC parameter display/editing.
17 PMC LADDER Selects the screen related to ladder display/editing.
18 PMC CONFIG Displays the screen for display/editing data other than
ladders that comprise sequence programs and for
setting the PMC function.
19 P.MATE.MGR. Selects the screen for showing Power Mate NC
Manager functions.
21 COLOR Selects the screen for setting colors to be used on the
screen.
22 PERIOD MAINTE Selects the screen for setting maintenance items to
be managed periodically.
23 MAINTE INFO Selects the screen for displaying information about
Maintenance performed.
27 FSSB Selects the screen for making settings related to the
high-speed serial servo bus (FSSB: Fanuc Serial
Servo Bus).
28 PARAM SET Selects the screen for setting parameters necessary
for start-up and tuning.
31 EMBED PORT Selects the screen for making settings related to the
embedded Ethernet (embedded port).
32 PCMCIA LAN Selects the screen for making settings related to the
embedded Ethernet (PCMCIA Ethernet card).
33 ETHNET BOARD Selects the screen for making settings related to the
(*) fast Ethernet/fast data server.
34 PROFI-BUS MST (*) Selects the screen for making setting related to the
Profibus master/slave function.
36 ID-INF Selects the screen for showing NC ID information.
5,10, (OPRT) Operation selection Key.
15,20,25,
30,35,40

The buttons denoted by (*) may or may not be displayed depending upon the machine
specifications.

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Transition sequence after pressing the [SYSTEM] function key is shown below.

System
Parameter Screen

[PARAMETER] [(OPRT)] (Number) [NO.SRH]

[ON: 1]
[OFF: 0]
(Numeral) [+ INPUT]
(Numeral) [INPUT]
[F INPUT] [CAN]
[EXEC]
[F OUTPUT] [ALL] [CAN]
[EXEC]
[NON-0] [CAN]
[EXEC]
[PREV GROUP]
[NEXT GROUP]

[OPTION READ]

Diagnosis Screen

[DIAGNOSIS] [(OPRT)] (Number) [NO.SRH]

System Screen

[SYSTEM] [SYSTEM] [(OPRT)] [F OUTPUT] [CAN]

[EXEC]
[SERVO INFO] [(OPRT)] [F OUTPUT] [CAN]
[EXEC]

Go to (1)

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 Maintenance Manual PS-Series
(1)

Servo Setting Screen

[SERVO SETTING] [SERVO SETTING] [(OPRT)] [SET]
[AXIS]
(Numeral) [INPUT]
[SERVO SETTING] [SERVO TUNE] [(OPRT)] [SET]
[AXIS]
(Numeral) [INPUT]

Spindle Setting Screen

[SPINDL SETTING] [SPINDL SETTING] [(OPRT)] (Numeral) [INPUT]

[SPINDL TUNE]
[SPINDL MONIT.]

System Screen

[PMC LADDER] [LIST] [(OPRT)] [ZOOM]

[SEARCH]
[LADDER]

Waveform Diagnosis Screen

[WAVE DIAG] [WAVE GRAPH] [(OPRT)] [TRACE]

[CANCEL]
[F OUTPUT]
[H-DOBL]
[H-HALF]
[
TIME]
[TIME]

+
[CH 1] [W-DOBL]
[CH 2] [TRACE]
[CH 3] [CH ↑]
[CH 4] [CH ↓]
[SIG↑]
[SIG↓]
[WAVE PARAM] [(OPRT)] (Numeral) [INPUT]

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3.2.3.1 NC Parameter Screen

NC parameter display and editing procedure is shown below.

1) Ensure that the user level has the privilege to edit NC parameters. If necessary,
please log in with password.
• Refer to “User Management” function in the later section of the manual.
• Supervisor & Makino logins are able to edit NC parameters by default.
• To display parameter without editing, no login is required.
2) Parameter writing enable alarm (SW0100) may appear, press both [CAN] and
[RESET] keys on MDI keyboard to reset the alarm.
3) Press [SYSTEM] key on MDI keyboard.
4) Press [PARAMETER] softkey on the screen. If the softkey does not appear, press
[+] softkey until [PARAMETER] is displayed.
5) Display the parameter using either of the following procedures:
• Enter the parameter number and press the [NO.SRH] softkey.
• Move the cursor to the parameter number using the page keys [PAGE↑] [PAGE↓]
and/or the arrow keys [↑] [→] [↓] [←]
6) Enter the setting value using the numeric keys in the MDI mode and press the
[INPUT] key.
7) Log out the user level to disable NC parameter editing.

Figure 3.2.3.1a: NC Parameter Screen.

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3.2.3.2 Ladder Screen

When performing maintenance on the machine, the running status of the ladder program
can be checked on the ladder screen. The procedure to display the ladder is as follows.

1) Press the [SYSTEM] key on MDI keyboard.

2) Press the [+] softkey on the screen until the [PMC LADDER] softkey is displayed.
3) The Ladder screen is displayed by pressing the [PMC LADDER] softkey.

Figure 3.2.3.2a: Ladder Screen.

3.2.4 Message Screen

The screens below can be displayed on the message screen. This screen is displayed by
pressing the [MESSAGE] function key on MDI keyboard. The selection buttons (softkeys)
that belong to the [MESSAGE] function key is described below.

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No. Button Description

1 ALARM Selects the alarm message screen.
2 MESSAGE Selects the warning message screen.
3 Selects the screen for displaying the details of alarms
HISTRY
issued (alarm message history screen).
8 MESSAGE HISTRY (*) Selects the screen displaying warning message history.
11 Selects the screen for displaying error messages related
EMBED LOG
to the embedded Ethernet.
13 Selects the screen for displaying error messages related
BOARD LOG (*)
to the fast Ethernet/fast data server.

The buttons denoted by (*) may or may not be displayed depending upon the machine
specifications.

Transition sequence after pressing the [MESSAGE] function key is shown below.

MESSAGE
Alarm Display Screen

[ALARM]

Message Display Screen

[MESSAGE]

Alarm History Display Screen

[HISTRY]

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3.3 Parameter, Program and Data Input/Output

Procedure
3.3.1 Machine Data Input/Output Procedure
3.3.1.1 NC Parameter

NC parameters can be loaded to the CNC memory from an external device. The input
format is the same as the output format. The loaded parameter replaces the existing
parameter in the CNC memory.

Inputting procedure:

1) Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
2) Ensure the user level privilege is enabled to edit NC parameters.
• You may need to log in.
• Alarm SW0100 may appear. Press [CAN] and [RESET] together to reset the
alarm.
3) Press [SYSTEM] key on MDI keyboard. Select [PARAMETER] softkey on the
screen.
4) Select EDIT mode on the operator panel or press EMERGENCY buttons.
5) Select [(OPRT)] softkey. Press [+] softkey few times until [F INPUT] softkey
appears. Select [F INPUT] softkey.
6) Type the name of the file you want to input.
• If the input file name is omitted, the default name “CNC-PARA.TXT” is assumed.
7) Press [EXEC] softkey.
• This starts reading the parameter and “INPUT” blinks in the lower right part of the
screen. To cancel the input of the parameter, press [CAN] softkey.
8) Power OFF the machine. Then power ON the machine.

Outputting procedure:

• Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
• Press [SYSTEM] key on MDI keyboard. Select [PARAMETER] softkey on the
screen.
• Select EDIT mode on the operator panel or press EMERGENCY buttons.
• Select [(OPRT)] softkey. Press [+] softkey few times until [F OUTPUT] softkey
appears. Select [F OUTPUT] softkey.
• If all parameters are to be output, press [ALL] softkey. If only the parameters with
non-zero values are to be output, press [NON-0] softkey.
• Type the file name that you want to output.
• If the file name is omitted, a default file name “CNC-PARA.TXT” is assumed.
• Press [EXEC] softkey.
• This starts reading the parameter and “OUTPUT” blinks in the lower right part of the
screen. To cancel the input of the parameter, press [CAN] softkey.

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3.3.1.2 Tool Offset Data

Tool offset can be loaded to the CNC memory from an external device. The input format is
the same as the output format. The loaded offset data replaces the existing data in the
CNC memory.

Inputting procedure:

1) Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
2) Ensure the user level privilege is enabled to edit tool offset data.
• You may need to log in.
3) Press [OFFSET SETTING] key on MDI keyboard. Select [OFFSET] softkey on the
screen.
4) Select EDIT mode on the operator panel or press EMERGENCY buttons.
5) Select [(OPRT)] softkey. Press [+] softkey few times until [F INPUT] softkey
appears. Select [F INPUT] softkey.
6) Type the name of the file you want to input.
• If the input file name is omitted, the default name “TOOLOFST.TXT” is assumed.
7) Press [EXEC] softkey.
• This starts reading the parameter and “INPUT” blinks in the lower right part of the
screen. To cancel the input of the parameter, press [CAN] softkey.

Outputting procedure:

1) Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
2) Press [OFFSET SETTING] key on MDI keyboard. Select [OFFSET] softkey on the
screen.
3) Select EDIT mode on the operator panel or press EMERGENCY buttons.
4) Select [(OPRT)] softkey. Press [+] softkey few times until [F OUTPUT] softkey
appears. Select [F OUTPUT] softkey.
5) Type the name of the file you want to input.
• If the input file name is omitted, the default name “TOOLOFST.TXT” is assumed.
6) Press [EXEC] softkey.
• This starts reading the parameter and “OUTPUT” blinks in the lower right part of the
screen. To cancel the input of the parameter, press [CAN] softkey.

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3.3.1.3 Pitch Error Compensation Data

Pitch Error Compensation data can be loaded to the CNC memory from an external
device. The input format is the same as the output format. The loaded data replaces the
existing data in the CNC memory.

Inputting procedure:

1) Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
2) Ensure the user level privilege is enabled to edit pitch error compensation data.
• You may need to log in.
3) Alarm SW0100 may appear. Press [CAN] and [RESET] together to reset the
alarm.
4) Press [SYSTEM] key on MDI keyboard. Press [+] softkey few times until [PITCH
ERROR] softkey appears. Select [PITCH ERROR] softkey.
5) Select EDIT mode on the operator panel or press EMERGENCY buttons.
6) Select [(OPRT)] softkey. Press [+] softkey few times until [F INPUT] softkey
appears. Select [F INPUT] softkey.
7) Type the name of the file you want to input.
• If the input file name is omitted, the default name “PITCH.TXT” is assumed.
8) Press [EXEC] softkey.
• This starts reading the parameter and “INPUT” blinks in the lower right part of the
screen. To cancel the input of data, press [CAN] softkey.
9) Power OFF the machine. Then power ON the machine.

Outputting procedure:

1) Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
2) Press [SYSTEM] key on MDI keyboard. Press [+] softkey few times until [PITCH
ERROR] softkey appears. Select [PITCH ERROR] softkey.
3) Select EDIT mode on the operator panel or press EMERGENCY buttons.
4) Select [(OPRT)] softkey. Press [+] softkey few times until [F OUTPUT] softkey
appears. Select [F OUTPUT] softkey.
5) Type the name of the file you want to input.
• If the input file name is omitted, the default name “PITCH.TXT” is assumed.
6) Press [EXEC] softkey.
• This starts reading the parameter and “OUTPUT” blinks in the lower right part of the
screen. To cancel the input of data, press [CAN] softkey.

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3.3.1.4 Custom Macro Common Variables

Custom Macro Common Variables can be loaded to the CNC memory from an external
device. The input format is the same as the output format. The loaded data replaces the
existing data in the CNC memory.

Inputting procedure:

1) Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
2) Ensure the user level privilege is enabled to edit common macro variables.
• You may need to log in.
3) Press [OFFSET SETTING] key on MDI keyboard. Select [MACRO] softkey on the
screen.
4) Select EDIT mode on the operator panel or press EMERGENCY buttons.
5) Select [(OPRT)] softkey. Press [+] softkey few times until [F INPUT] softkey
appears. Select [F INPUT] softkey.
6) Type the name of the file you want to input.
• If the input file name is omitted, the default name “MACRO.TXT” is assumed.
7) Press [EXEC] softkey.
• This starts reading the parameter and “INPUT” blinks in the lower right part of the
screen. To cancel the input of the data, press [CAN] softkey.

Outputting procedure:

1) Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
2) Press [OFFSET SETTING] key on MDI keyboard. Select [MACRO] softkey on the
screen.
3) Select EDIT mode on the operator panel or press EMERGENCY buttons.
4) Select [(OPRT)] softkey. Press [+] softkey few times until [F OUTPUT] softkey
appears. Select [F OUTPUT] softkey.
5) Type the name of the file you want to input.
• If the input file name is omitted, the default name “MACRO.TXT” is assumed.
6) Press [EXEC] softkey.
• This starts reading the parameter and “OUTPUT” blinks in the lower right part of the
screen. To cancel the input of the data, press [CAN] softkey.

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3.3.1.5 Workpiece Coordinate System

Coordinate system data can be loaded to the CNC memory from an external device. The
output format is the same as the output format. The loaded data replaces the existing data
in the CNC memory.

Inputting procedure:

1) Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
2) Ensure the user level privilege is enabled to edit Workpiece Coordinate System.
• You may need to log in.
3) Press [OFFSET SETTING] key on MDI keyboard. Select [WORK] softkey on the
screen.
4) Select EDIT mode on the operator panel or press EMERGENCY buttons.
5) Select [(OPRT)] softkey. Press [+] softkey few times until [F INPUT] softkey
appears. Select [F INPUT] softkey.
6) Type the name of the file you want to input.
• If the input file name is omitted, the default name “EXT_WKZ.TXT” is assumed.
7) Press [EXEC] softkey.
• This starts reading the parameter and “INPUT” blinks in the lower right part of the
screen. To cancel the input of the data, press [CAN] softkey.

Outputting procedure:

1) Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
2) Press [OFFSET SETTING] key on MDI keyboard. Select [WORK] softkey on the
screen.
3) Select EDIT mode on the operator panel or press EMERGENCY buttons.
4) Select [(OPRT)] softkey. Press [+] softkey few times until [F OUTPUT] softkey
appears. Select [F OUTPUT] softkey.
5) Type the name of the file you want to input.
• If the input file name is omitted, the default name “EXT_WKZ.TXT” is assumed.
6) Press [EXEC] softkey.
• This starts reading the parameter and “OUTPUT” blinks in the lower right part of the
screen. To cancel the input of the data, press [CAN] softkey.

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3.3.1.6 Input/Output Using “ALL IO” Screen

The procedure mentioned in section 3.3.1.1 to 3.3.1.5 can also be done using the ALL IO
screen. However, the ALL IO screen can only be operated if a memory card interface is
selected as an external I/O device. The procedure for inputting/outputting files using the
ALL IO screen is very similar as the ones mentioned in section 3.3.1.1 to 3.3.1.5.

The procedure to display the ALL IO screen is as follows:

1) Press [SYSTEM] key on MDI keyboard.

2) Press [+] softkey few times until [ALL IO] softkey appears. Select [ALL IO] softkey.

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3.3.2 NC Program Input/Output Procedure
This section explains how to input/output a NC program from an external device to
memory of the CNC. There are 2 methods can be used to input/output NC programs.

Method 1: Using Program Editing or Program Folder Screen

Inputting procedure:

1) Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
2) Ensure the user level privilege is enabled to edit NC programs.
• You may need to log in.
3) Press [PROG] key on MDI keyboard.
4) Select EDIT mode on the operator panel or press EMERGENCY buttons.
5) Select [(OPRT)] softkey. Press [+] softkey few times until [F INPUT] softkey
appears. Select [F INPUT] softkey.
6) Type the file name you want to input. Press [F-NAME] softkey.
• To specify the program number to input, type the program number and press [O
SET] softkey. For explanation of the operations to be done if file name or program
number is omitted, please refer to the table below.
7) Press [EXEC] softkey.
• This starts reading the parameter and “INPUT” blinks in the lower right part of the
screen. To cancel the input of the program, press [CAN] softkey.

[F-NAME] [O SET] Input File Name Input Program Input Program

Number
BLANK INPUT File for the program All programs in the Continuous
number specified program specified program numbers
with [O SET] with [O SET] starting at one
specified with [O
SET]
INPUT BLANK File name set with All programs in the File name at the
[F-NAME] program specified time the file is
with [F-NAME] saved
INPUT INPUT File name set with All programs in the Continuous
[F-NAME] program specified program numbers
with [F-NAME] starting at one
specified with [O
SET]

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Outputting procedure:

1) Ensure the NC unit and the external devices are ready for reading/writing.
• Ensure NC I/O channel setting.
2) Press [PROG] key on MDI keyboard.
3) Select EDIT mode on the operator panel or press EMERGENCY buttons.
4) Select [(OPRT)] softkey. Press [+] softkey few times until [F OUTPUT] softkey
appears. Select [F OUTPUT] softkey.
5) Type the program number you want to output. Press [O SET] softkey.
• To specify an output file name, type the file name and press [F-NAME] softkey.
• If no output file name or output program number is specified, the main program or
the program being subjected to background editing is output.
• For explanation of the operations to be done if output file name or output program
number is omitted, please refer to the Table below.
6) Press [EXEC] softkey.
• This starts reading the parameter and “OUTPUT” blinks in the lower right part of the
screen. To cancel the output of the program, press [CAN] softkey.

[F-NAME] [O SET] Output File Name Output Program

BLANK BLANK Main program or program Main program or program being
number being subjected to subjected to background
background editing editing
BLANK -9999 ALL-PROG.TXT All programs in the program
memory that are displayed in
the program list
BLANK INPUT Program number set with [O Program in the NC that is set
SET] with [O SET]
INPUT BLANK File name set with [F-NAME] Main program or program being
subjected to background
editing
INPUT -9999 File name set with [F-NAME] All programs in the program
memory that are displayed in
the program list
INPUT INPUT File name set with [F-NAME] Program in the NC that is set
with [O SET]

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Method 2: Using ALL IO Screen

Inputting procedure:

1) Ensure the NC unit and the Memory card is ready for reading/writing.
• Ensure NC I/O channel is set to 4.
2) Ensure the user level privilege is enabled to edit NC programs.
• You may need to log in.
3) Press [SYSTEM] key on MDI keyboard. Press [+] softkey few times until [ALL IO]
softkey appears. Select [ALL IO] softkey.
4) Press [PROGRAM] on the ALL IO screen.
5) Select EDIT mode on the operator panel or press EMERGENCY buttons.
6) Select [(OPRT)] softkey. Then press [N INPUT] softkey.
7) Set file name you want to input and press [F-NAME] softkey.
• If the input file name is omitted, default name “ALL-PROG.TXT” is assumed.
8) Type a program number to be used after the input and press [O SET] softkey.
• If no program number is specified, the program number in the file is adopted as it
is.
9) Press [EXEC] softkey.
• This starts reading the parameter and “INPUT” blinks in the lower right part of the
screen. To cancel the input of the program, press [CAN] softkey.

Outputting procedure:

1) Ensure the NC unit and the memory card is ready for reading/writing.
• Ensure NC I/O channel is set to 4.
2) Press [SYSTEM] key on MDI keyboard. Press [+] softkey few times until [ALL IO]
softkey appears. Select [ALL IO] softkey.
3) Press [PROGRAM] on the ALL IO screen.
4) Select EDIT mode on the operator panel or press EMERGENCY buttons.
5) Select [(OPRT)] softkey. Then press [F OUTPUT] softkey.
6) Type the program number to output and press [O SET].
• If –9999 is typed, all programs in the memory are output.
7) Type the file name to output and press [F-NAME].
• When no file name is set, the output file name is assumed to be “O” or ”number” if a
single program number is specified. If –9999 is specified, the output file name is
assumed to be “ALL-PROG.TXT”
8) Press [EXEC] softkey.
• This starts reading the parameter and “OUTPUT” blinks in the lower right part of the
screen. To cancel the output of the program, press [CAN] softkey.

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3.3.3 SRAM Backup

SRAM data includes NC parameters, tool offset data, pitch error compensation data,
common macro variables and other data. SRAM data can be used for the following
purpose.

• To restore machine condition after the CNC power (battery) in SRAM is lost.
• When some serious problems occur, it may be necessary to send SRAM data to
Makino service representative to confirm NC internal processing status.

SRAM backup procedure:

1) Power OFF the machine. Insert a memory card to the PCMCIA slot on the operator
panel.
2) Turn ON the main circuit breaker.
3) Turn ON the control power while pressing [6] and [7] keys on the MDI keyboard.
The system boot screen is displayed.
4) Use arrow [↑] and [↓] keys on the MDI keyboard to navigate the menu selection.
Select “7. SRAM DATA UTILITY”.
5) Press [2] or [INPUT] key to enter the selection.
6) Select “1. SRAM BACKUP (CNC  MEMORY CARD)”. Then press [3] or [INPUT]
key to start the back up.
• Press [4] key to cancel the operation.
7) A file with default name “SRAM_BAK.001” is created in the memory card.
• If the data can not be save entirely into a single memory card, “SET MEMORY
CARD NO. 002” message is displayed. With the Power still ON, insert the second
memory card and press [3] or [INPUT] key. Press [4] to cancel the operation.
8) Select “4. END” and then press [2] or [INPUT] key to go back to main system boot
screen.
9) Select “1. END” to end the Operation. NC boots up normally.

SRAM restore procedure:

1) The steps are similar as SRAM backup procedure.

2) On the “SRAM DATA UTILITY” screen select “2. SRAM RESTORE (MEMORY
CARD  CNC)”.
• Ensure the correct “SRAM_BAK.001” file exists in the memory card.

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4. Troubleshooting
This chapter describes troubleshooting procedures for each unit.

Prior to Work

• Read and understand chapter 1 “Safety” prior to troubleshooting to ensure safe

working conditions.
• The machine must be handled by trained personnel.
• Wear appropriate safety equipment.
• Ensure the machine surrounding area is sufficiently illuminated.
• Place “UNDER INSPECTION/MAINTENANCE” warning signs at the appropriate
locations, including the main operation panel to notify personnel that work is in
progress to prevent other personnel from inadvertently operating the machine while
work is being performed.
• Prior to maintenance/servicing work, perform troubleshooting thoroughly and be
aware as much as possible of the condition in which machine operation was
interrupted (machine trouble occurred).
• In the following events, leave the machine as it is and contact your Makino service
representative. Do not attempt to correct the problem yourself.
o When the tool/tool pot is not clamped correctly (tool/tool pot may fall off the
machine).
o When the nature/cause of the machine problem is not apparent.

During Work

Observe all safety precautions and exercise extreme caution, especially when operating
under the following conditions. Careless operation may result in serious injury, death
and/or damage to the machine. Take adequate precautions to ensure the safety of
personnel operating the machine.

• When the power must remain ON.

• When it is necessary to enter the machine/tool Magazine.
• When safety devices such as interlock system must be released.

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4.1 Machine Abnormal Condition

When the machine has stopped or will not start due to an emergency stop, interlock or
feed hold function, these causes can be confirmed on the machine status screen.

4.1.1 Emergency Stop

When the [EMERGENCY] switch is pressed, the machine enters the emergency stop
condition.

The machine also enters the emergency stop condition in the following cases:

• When the feed axis exceeds the stroke limit and the over travel 2 (OT2) limit switch
is activated.
• When an abnormality is detected in the machine controller or servo motor.
• When an abnormality is detected in the hydraulic unit.
• When the power outage detection unit is activated.

Following an emergency stop, all commands are stopped and the following operations are
performed:

• Feeding of each axis stops immediately.

• Spindle rotation stops if rotating.
• The spindle tool is clamped if unclamped.
• When orientation of the spindle has been performed, orientation is released.
• When an ATC or tool magazine operation is being performed, operation stops
immediately (even in mid-motion)
• The NC is reset.
• All Coolant motors will be OFF if it is switched ON.
• Spindle temperature controller will be OFF.
• Spindle rotation speed setting (S - Command) is reset.
• Tool search (T-Command) is cancelled.
• Hydraulic pressure supply stops.
• All solenoid valves (Pneumatic and Hydraulic) are de-energized.

Confirm the cause indicated in the cause of emergency stop display area on the machine
status screen and eliminate the cause.

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 Maintenance Manual PS-Series

Cause of Emergency Stop Display Area

Figure 4.1.1a: Machine Status Screen (Emergency).

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4.1.1.1 Recovery from Emergency Stop

The restore procedure differs according to the condition of the machine when emergency
stop is activated. Prior to releasing the emergency stop condition, confirm the cause of the
emergency stop is corrected and ensure the area surrounding the machine is safe.

Restore machine operation from the emergency stop condition using the following
procedure:

When OT2 is activated for a feed axis:

1) If an NC Alarm is triggered, press the [RESET] key to release the alarm.

• Soft OT1 alarm (OT0500 and OT0501) can not be released by pressing the
[RESET] key.
2) Select Jog Feed mode or Handle Feed mode using “Operation Mode Selection”
switches on the main operation panel.
• If the Jog Feed mode is selected, set the [JOG FEED OVERRIDE] Switch to a
sufficiently slow speed.
3) Select the axis for which the OT2 function is activated using “Axis Selection”
Switches.
• For machine equipped with portable Manual Pulse Generator (MPG), use the “MPG
Axis Selection” on the MPG for Axis selection.
4) Turn the [OT RELEASE] switch until the Servo Amplifier enters READY status
(Refer to NOTE).
5) While holding down the [OT RELEASE] switch, press the [+] / [-] switch to move
the Axis until it is within its stroke range.
• Do not release the [OT RELEASE] switch until the axis has moved within its stroke
range. If the [OT RELEASE] switch is released during the operation, an emergency
stop is activated again despite recovering from the emergency stop condition.
• When the handle mode is selected, the axis is moved by rotating the “MPG” handle
in the CW (+) / CCW (-) direction.

• In the “READY” condition, the cause of the emergency stop indicated on the
machine status screen and the “EMG” Indicator on the right lower side of screen
disappears.
• Do not change operation modes or select an axis while holding down the [OT
RELEASE] switch.

Abnormal condition for controller or servomotor:

For NC alarms: Perform the corrective outlined in the “NC User’s Manual”. For machine
alarms and warnings: Perform the corrective outlined in the “Alarm List Manual”. Machine
alarm’s number is indicated with “EX”. If the cause of the problem can not be determined,
contact your Makino service representative for assistance.

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[EMERGENCY] Switch

NC Mode
Selection
Switch

Axis
Selection
Switch

[+] Switch

[-] Switch

[OT RELEASE] Switch [JOG FEED OVERRIDE] Switch

Figure 4.1.1.1a: Main Operator Panel.

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4.1.1.2 Emergency Stop Switch Pressed During ATC Operation

Restore machine operation from the emergency stop condition using the following
procedure:

• Exercise extreme care when restoring the machine from the emergency stop
condition as serious accidents may occur.
• When working with other personnel, maintain clear communication at all times to
prevent serious Injury.
• Contact your Makino service representative for assistance if serious damage to
the machine has occurred.
• If operation cannot be restored using the manual recovery procedure, do not
attempt to remedy the problem. Contact your Makino service representative for
assistance.

Recovery procedure:

1) Make sure the condition(s) that led to tripping of the [EMERGENCY] switch
activations are eliminated.
2) Release the emergency stop condition.
• Rotate the [EMERGENCY] switch in the direction of arrow to release the lock.
• Press the [CONTROL POWER ON] switch.
3) Restore ATC operation on the maintenance screen with [MAINT MODE] enabled.
The ATC restore operation can not be performed in the following conditions:
• Z-axis not positioned at the 2nd reference position.
• Spindle is not orientated.
• Limit switch signal is in a condition where automatic restore procedure is
impossible and an alarm is triggered.
4) Move the axis to the proper position and then perform the Auto Recovery operation
while pressing [OT RELEASE] switch.
• Select “ATC AUTO RECOVERY” button on the screen.
• Select “SINGLE MODE” or “JOG MODE”.
• Press “ON” to start operation. Press “OFF” to stop operation.

Refer to “ATC Auto Recovery” section in the operation manual for more details.

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Figure 4.1.1.2: ATC Maintenance Screen.

1) Press the [MAINT MODE] button to deactivate maintenance mode.

2) Perform the ATC operation from the beginning.
3) Confirm the pot number on the data maintenance screen. If the pot number
indicated on the data maintenance screen is different from the actual machine
conditions, the unique data needs to be changed.

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4.1.1.3 EMERGENCY STOP SWITCH PRESSED DURING T-SEARCH

The automatic recovery procedure cannot be performed. Restore machine operation from
the emergency stop condition using the following procedure:

• Exercise extreme care when restoring the machine from the emergency stop
condition as serious accidents may occur.
• When working with other personnel, maintain clear communication at all times to
prevent serious Injury.
• Contact your Makino service representative for assistance if serious damage to
the machine has occurred.
• If operation cannot be restored using the manual recovery procedure, do not
attempt to remedy the problem. Contact your Makino service representative for
assistance.

Recovery procedure:

1) Make sure the condition(s) that led to tripping of the [EMERGENCY] switch
activation is eliminated.
2) Release the emergency stop condition.
• Rotate the [EMERGENCY] switch in the direction of arrow to release the lock.
• Press the [CONTROL POWER ON] switch.
3) Confirm the status of the ATC arm and then restore operation manually from the
emergency stop condition on the maintenance screen.
4) Issue T-search command once again.
5) Confirm the pot number on the ATC maintenance screen. If the pot number
indicated on the ATC maintenance screen is different from the actual machine
conditions, the unique data needs to be changed.

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4.1.1.4 SWITCH PRESSED DURING MACHINING (THERE IS NO CONTACT
BETWEEN TOOL AND WORKPIECE)

The automatic recovery procedure can not be performed. Restore machining program
operation from the emergency stop condition using the following procedure:

• Exercise extreme care when restoring the machine from the emergency stop
condition as serious accidents may occur.
• Confirm the “Machine Lock” and “Auxiliary Function Lock” functions may need to
be activated prior to entering the machine. Please exercise extreme caution as
performing the following procedures in this condition is extremely dangerous.
• When working with other personnel, maintain clear communication at all times to
prevent serious injury.
• Contact your Makino service representative for assistance if serious damage to
the machine has occurred or the workpiece is unstable.

Recovery procedure:

1) Make sure the condition(s) that led to [EMERGENCY] switch activation are
eliminated.
2) Release the emergency stop condition.
• Rotate the [EMERGENCY] switch in the direction of arrow to release the lock.
• Press the [CONTROL POWER ON] switch.
3) Select the Reference Position Return mode.
4) Return each axis to its reference position so that the workpiece does not interfere
with the spindle tool.
5) Check the tool and workpiece for damage.
• When the workpiece must be exchanged, start the program from the beginning.
6) Restart the program using the method below:
• Display the Program Edit screen to confirm the modal information is correct.
Serious damage to the machine or workpiece may result if a program including
incorrect modal information is restarted. If the modal information is incorrect,
correct the values in the MDI mode. The modal information may be reset to the
original data when the machine enters the emergency stop condition.
• Move the cursor to the block in which the machine entered the emergency stop
condition.
• Input “Sxxxx” using the MDI mode and then press the [SPINDLE START] switch or
input “Sxxxx M03 (M04)”.
• Press the “Cutting fluid-related Function” Switch on the main operation panel or
turn ON the “Cutting fluid-related Function” on the Function screen. Each cutting
fluid functions can be started by the M-code.
• Select Memory mode and then press the [(Cycle) START] switch.

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4.1.1.5 SWITCH PRESSED DURING MACHINING (WORKPIECE AND TOOL

CONTACT EACH OTHER)

The automatic recovery procedure can not be performed. Restore machining program
operation from the emergency stop condition using the following procedure:

• Exercise extreme care when restoring the machine from the emergency stop
condition as serious accidents may occur.
• Confirm the “Machine Lock” and “Auxiliary Function Lock” functions may need to
be activated prior to entering the machine. Please exercise extreme caution as
performing the following procedures in this condition is extremely dangerous.
• When working with other personnel, maintain clear communication at all times to
prevent serious Injury.
• Contact your Makino service representative for assistance if serious damage to
the machine has occurred or the workpiece is unstable.

Recovery procedure:

1) Make sure the condition(s) that led to [EMERGENCY] switch activation are
eliminated.
2) Release the emergency stop condition.
• Rotate the [EMERGENCY] switch in the direction of arrow to release the lock.
• Press the [CONTROL POWER ON] switch.
3) Select the handle mode.
4) Check the position of the spindle tool and workpiece.
• When the tool and workpiece are in contact but can be separated using the handle
mode, proceed to Step 5.
• When the tool and workpiece are in contact and can not be separated using the
handle mode, proceed to Step 6.
5) Separate the tool from the workpiece using the handle mode.
• When the tool has an edge wider than the tool body (ex. boring bar):
o Confirm the part of the tool that has come into contact with the workpiece.
o Move the tool in the x- or y-axis direction to prevent further interference
between the tool and the workpiece. Move the z-axis in “+” direction until
reaching the reference position.
• When workpiece and tool interference does not occur even when z-axis is moved:
o Move the z-axis in “+” direction until reaching the reference position.
6) Separate the tool trapped in the workpiece from the workpiece.
• Activate the Machine Lock and Auxiliary Function Lock modes.
• Hold the tool firmly and then loose the tool holder.
• Release the Machine Lock and Auxiliary Function lock modes after going out of the
machining chamber.
• Move the z-axis in “+” direction to remove the tool from the holder.
• Remove the tool trapped in the workpiece.
7) If the tool is damaged, replace the tool using the following procedure.
• Move the z-axis to the operator comfortable position and remove the tool holder
from the spindle.

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 Maintenance Manual PS-Series
• Mount the replacement tool onto the tool holder and insert into the spindle.
• Measure the tool length and tool radius.
• Input the tool length and tool radius of the replacement tool on the tool data screen.
8) Select Reference Position Return mode.
9) Return each axis to its reference position in the following order:
• Z→ X or Y
10) Check the tool and workpiece for damage. When the workpiece must be
exchanged, start the program from the beginning.
• Restart the program using the method below:
o Display the Program Edit screen to confirm the modal information is correct.
Serious damage to the machine or workpiece may result if a program
including incorrect modal information is restarted. If the modal information is
incorrect, correct the values in the MDI Mode. The modal information may be
reset to the original data when the machine enters the emergency stop
condition.
o Move the cursor to the block in which the machine entered the emergency
stop condition.
o Input “Sxxxx” using the MDI Mode and then press the [SPINDLE START]
switch or input “Sxxxx M03/(M04)”.
o Press the “Cutting Fluid-Related Function” switch on the main operation
panel or turn ON the “Cutting Fluid-Related Function” on the Function
screen. Each cutting fluid functions can be started by the M-code.
o Select memory mode and then press the [(Cycle) START] switch.

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4.1.2 Axis Fails to Move

When axis interlock function is activated, the axis can not move.

Confirm the cause indicated in the cause of interlock (axis interlock) display area on the
machine condition screen and eliminate the cause.

Cause of Interlock Display Area

Figure 4.1.2a: Machine Status Screen (Interlock).

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4.1.3 Program Fails to Start
When the feed hold function is activated, automatic operation of the program can not be
performed.

Confirm the cause Indicated in the cause of feed hold display area on the machine
condition screen and eliminate the cause.

Cause of Feed Hold Display Area

Figure 4.1.3a: Machine Status Screen (Feed Hold).

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4.2 Professional P Troubleshooting

4.2.1 Professional P Does Not Start
Condition Possible Cause Corrective Measure
The screen has no Machine controller failure. Remove the back cover of the
display although the Main Operator Panel, check the
machine power is turned LED status and contact your
ON. Makino service representative.
Professional P does not Machine controller internal Contact your Makino service
start automatically after data failure. representative.
the screen is turned ON
(the display stops with
black background
display).

4.2.2 Professional P Trouble during Start-up

Condition Possible Cause Corrective Measure
Screen is frozen and Professional P shut down Turn the power supply OFF and
operation is impossible. abnormally. ON again. If the problem
persists, contact your Makino
service representative.

Alarm triggered time is Setting time is not correct. Set the time on the NC setting
not precise. screen. Turn the power supply
OFF and ON to activate the
setting.
The touch panel The touch position is out Recalibrate the touch panel.
response is incorrect. of alignment and response
time is slow.

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4.2.3 Touch Panel Calibration
No calibration is required for the LCD’s touch panel in normal condition.

Calibration is only to be done under the following conditions:

• The LCD unit is replaced

• The touch panel is replaced
• The touch panel’s PCB is replaced
• Memory all clear is performed

Calibration procedure:

1) Enable NC parameter No. 3113 # 5 (DCL) to 1.

2) Press [SYSTEM] on MDI keyboard.
3) Press [+] soft key several times until the [TOUCH PANEL] soft key is displayed.
4) Press the [TOUCH PANEL] soft key then the [(OPRT)] soft key. The [TP CAL] soft
key is displayed.
5) Pressing the [TP CAL] soft key causes a full-screen touch panel calibration to
appear.
6) Click the 9 calibration points with a stylus pen. The marker of a normally clicked
point changes from “+” to “o”. If you fail to click right on a “+” mark, a message
“Your stylus pen is not right on “+” mark. Click again” appears.
7) After clicking all the 9 calibration points, pressing [INPUT] key on MDI keyboard
completes the calibration process. To quit or retry calibration, press [CAN] key on
MDI keyboard. The previous screen appears again. Before finishing clicking the 9
calibration points, pressing [INPUT] key aborts calibration.
8) When calibration ends normally, the message “Calibration ended” appears.
9) After completing calibration, reset NC parameter No, 3113 # 5 to 0 to prevent
Operation mistake.

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4.3 Spindle Head

4.3.1 Spindle Start/Stop Malfunction
If the spindle can not be started by the M03 or M04 functions or the [SPINDLE START]
switch, check the display on the alarm screen and/or the machine status screen.

However, in the following cases, the M03/M04 functions and the [SPINLDE START] and
[SPINLDE STOP] switches are disabled as a control and safety precaution.

1) The [SPINDLE STOP] Switch can not be used in the following situations:
• While an M06 command is being executed.
• During machining process (cycle start lamp is ON).
2) The [SPINDLE START] switch can not be used in the following situations:
• While an M06 command is being executed.
• During rigid tapping.
• When the operator door interlock or door lock (option) function is activated.
• In the emergency stop condition.
3) The M03 and M04 functions can not be used in the following situations:
• When the operator door interlock or door lock (option) function is activated.
• In the emergency stop condition.

4.3.2 Abnormal Spindle Speed or Start/Stop Timing

Stop the spindle completely and rotate the spindle manually. If spindle rotation is inhibited
or impossible, this may indicate a problem with the bearings inside the spindle. Contact
your Makino service representative since spindle disassembly is necessary in this case.

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4.3.3 Orientation Malfunction
Check if a machine alarm or an NC alarm is triggered when spindle orientation is
commanded.

1) If an alarm is triggered, please do the recovery steps based on “Alarm List Manual”
or “NC User’s Manual”. If the problem persists, contact your Makino service
representative for assistance.
2) If an alarm has not been triggered, see table below.

Conditions Causes/Corrective Measures

Spindle can not be Orientation or position gain adjustment is incorrect.
Oriented at position
specified.
Spindle moves after Position gain adjustment is incorrect.
Orientation.

4.3.4 Tool Clamp/Unclamp Malfunction

When tool can not be clamped:

1) Confirm that tool specified is used.

2) Check the hydraulic cylinder if clamping is not performed when commanded. If the
hydraulic cylinder is not activated, check solenoid valve SOL01A (Tool Clamp) and
other hydraulic components.
3) Confirm that the air is discharged completely after replacement of the cylinder and
piping. If the hydraulic cylinder is activated, this Indicates that foreign material is
lodged in the mechanism or a mechanical malfunction. Contact your Makino
service representative for assistance.

When tool can not be unclamped:

1) Tool can not be unclamped, if the spindle orientation is not completed.

2) When the NC operation is set in MDI, memory or tape mode, tool unclamping can
not be performed as a safety precaution even if the [TOOL UNCLAMP] switch is
pressed. To unclamp the tool, select NC operation mode to handle mode. Open the
door and then press the [TOOL UNCLAMP] Switch for longer than a second.
3) Check the hydraulic cylinder, if unclamping is not performed correctly when
commanded properly. If the hydraulic cylinder is not activated, check solenoid valve
SOL01B (tool unclamping) and other hydraulic components. If the hydraulic
cylinder is activated correctly, possible causes of incorrect unclamping include the
following:
• Hydraulic cylinder stroke may be adjusted incorrectly.
• Foreign matter is lodged in the tool clamp/unclamp mechanisms.
• Mechanical malfunction.
Contact your Makino service representative for assistance.

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4.3.5 Abnormal Noise Generated During Spindle Rotation

When the winding changeover is performed by the “S” code, a clicking sound is generated
by the electromagnetic contactor inside the machine controller. This sound is normal.

When abnormal noise is emitted, stop the spindle completely and rotate manually. If
spindle rotation is inhibited or impossible or vibration is significant this indicates a problem
with the bearings inside the spindle or clearance for the seals.

Contact your Makino service representative, as spindle disassembly is necessary.

The following table outlines abnormal conditions, possible causes and the corrective
measures to be performed.

Conditions Causes/Corrective Measures

Abnormal noise is Loose piping or electric wiring at the rear of the spindle head
emitted only during unit may be generating noise due to machine vibration. Check
machining. all piping and electric wiring and tighten if necessary.
Abnormal noise is The tool in the spindle may be unbalanced. If Abnormal noise is
emitted only during emitted with the tool balanced correctly, the balance of the
high speed rotation. Spindle during the tool rotation may be incorrect. Contact your
Makino service representative for assistance.
Abnormal noise is Contact your Makino service representative for assistance.
emitted due to an
electrical problem.

4.3.6 Oil Leakage

Hydraulic oil used for tool clamp/unclamp is leaking. Place white paper under the machine
to determine the exact location of the leakage. Check for loosening of the fittings and hose
damage. If the point of oil leakage is unclear, contact your Makino service representative.

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4.4 Feed Axis

4.4.1 Axis Fails To Move In Manual Mode
Possible Cause Corrective Measure
Jog feed speed and Move the axis after changing the settings for these switches to
rapid feed override a value other than 0.
readings are 0.
Machine lock function The Machine lock function is activated to only have the position
is activated. display change without actually feeding the axes.
Press the [MACHINE LOCK] switch on the function screen to
deactivate the machine lock function.
Interlock function is When the interlock is activated, the axis can not move. Confirm
activated. the cause of the interlock on the machine status screen and
then eliminate the cause.
Operator door is open. Confirm the operator door is closed. When the door is closed,
input signal (DI): LS912 (SG Door Lock: X0009.6) is 1.
When input signal (DI): LS 912 is 0, the interlock function is
activated and the axis can not move, unless the door interlock
release key is set to 1.
If the door is closed and the signal indication is incorrect, door
switch LS 912 is either incorrectly adjusted or malfunctioning.
Adjust the door lock switch LS 912 and replace the switch if
necessary.
ATC arm is not in Confirm the ATC arm is in the reference position range. If the
stand-by condition. ATC arm is not in the reference position range, the interlock
function is activated and the feed axis can not be moved. Move
the ATC arm into the reference position range on the
maintenance screen.

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4.4.2 Servo Alarm Is Triggered During Operation

Possible Cause Corrective Measure
Workpiece and spindle Alarm No. SV0409 (Detect Abnormal Torque)
head come into Spindle head may be damaged. Contact your Makino service
contact. representative for assistance.
Workpiece exceeds Alarm No. SV0411 (Excess Error (Moving))
specifications Use workpiece within specified weight.
(especially
recommended weight).
Cutting overload. Alarm No. SV0409 (Detect Abnormal Torque)
Alarm No. SV0411 (Excess Error (Moving))
Confirm the tool is not damaged and machining condition is
correct.
Servomotor cable is Alarm No. SV0446 (Hard Disconnect Alarm)
damaged. Replace the damaged cable.
Servo System Servomotor, servo amplifier, servomotor encoder or scale units
malfunction. are malfunctioning.
Confirm the alarm contents and replace the damaged parts if
necessary.
When replacing the scale unit, contact your Makino service
representative for assistance.

4.4.3 Feed Axis Runs until Hitting Mechanical Stop

Possible Cause Corrective Measure
Servomotor cable is Alarm No. SV0446 (Hard Disconnect Alarm) is triggered.
damaged. Replace the damaged cable.
Axis moved by inertia Turn ON the power supply and then move the axis within the
due to power failure. stroke limit.
Servo System Servo alarm is triggered. Servomotor, servo amplifier,
malfunction. Servomotor encoder or Scale units are malfunctioning.
Confirm the alarm content and replace the damaged parts if
necessary.
When replacing the Scale unit, contact your Makino service
representative for assistance.

When the feed axis hits the mechanical stopper and stops, the machine accuracy must be
confirmed. Contact your Makino service representative for assistance. In the event the
machine accuracy is not confirmed, the specified level of accuracy will not be achieved.

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4.4.4 Positioning Accuracy Not Achieved
Possible Cause Corrective Measure
Bolts securing Retighten the loose securing bolts with the specified torque.
Servomotor and Ball
screw nut are loose.
Clamping bolts on If a scale unit is installed, confirm the reference position is
Motor coupling are correct after changing the NC parameter setting to a machine
loose. without a Scale unit.
When the reference position is incorrect (when the axis stops
short of the correct reference position), the clamping bolts may
be loose.
Retighten the clamping bolts with the following specified torque.
If the above causes do not apply, the motor coupling may be
worn. Replace the motor coupling.
Axis backlash is If a Scale unit is installed, measure the backlash after changing
excessive. the NC parameter setting to a machine without a Scale unit.
If the axis backlash is excessive, the most likely causes are as
follows:
• Ballscrew nut preloading is insufficient. When grease is
discolored gray, ballscrew nut preloading may be
insufficient. In this case, the ballscrew must be replaced.
Contact your Makino service representative for
assistance.
• Ballscrew has lost pre-tensioning. Reapply pre-tension to
the ball screw.
• Ballscrew or linear motion guide is worn or damaged.
Ballscrew or linear motion guide must be replaced.
Contact your Makino service representative for
assistance.

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4.4.5 Abnormal Noise or Vibration Generated During Axis

Operation
Possible Cause Corrective Measure
Grease shortage Grease supplied to the linear motion guide and ballscrew on the
feed axis or the support bearings is not sufficient. Apply grease
to the problem surfaces.
Telescopic cover or Confirm chips are not accumulated in the telescopic cover or
telescopic cover wiper telescopic wiper. Also confirm the telescopic cover and
is damaged or chips telescopic wipers are not damaged. If the covers or wipers are
have accumulated in damaged, replacement is necessary.
the wiper mechanism.
Securing bolts on Retighten the loose securing bolts with the specified torque.
servomotor and ball
screw nut are loose.
Axis backlash is If a scale unit is installed, measure the backlash after changing
excessive. the NC parameter setting to a machine without a scale unit.
If the axis backlash is excessive, the most likely causes are as
follows:
• Ballscrew nut preloading is insufficient. When grease is
discolored gray, ball screw nut preloading may be
insufficient. In this case, the ball screw must be replaced.
Contact your Makino service representative for
assistance.
• Ballscrew has lost pre-tensioning. Reapply pre-tension to
the ball screw.
• Ballscrew or linear motion guide is worn or damaged.
Ballscrew or linear motion guide must be replaced.
Contact your Makino service representative for
assistance.
Support Bearings are Support bearing must be replaced. Contact your Makino service
worn or damaged. representative for assistance.
Ball screw run-out is Adjust the ball screw run-out.
excessive.
Servo System Servo alarm is triggered. Servomotor, servo amplifier, servo
malfunction. motor encoder or scale units are malfunctioning.
Confirm the alarm content and replace the damaged parts if
necessary.
When replacing the scale unit, Contact your Makino service
representative for assistance.

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4.4.6 Oil Leakage
Possible Cause Corrective Measure
Piping connection is Piping connection from spindle oil temperature controller to
loose or damaged. ballscrew may be loose or damaged. Place white paper under
the machine to determine the exact location of the leakage.
Check for loosening of the fittings and hose damage.
Check the piping and then connect any loose or disconnected
pipes. If the piping is damaged, replace with new piping.
If the point of oil leakage is unclear, contact your Makino
service representative for assistance.
Ball screw rotary seal If the above causes do not apply, the ball screw rotary seal may
is worn or damaged. be worn or damaged. The Rotary seal must be replaced.
Contact your Makino service representative for assistance.

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4.5 ATC Arm

Leave the machine in its current condition and contact your Makino service representative
when the ATC Arm interferes with the parts and stops, because the ATC arm may drop
the tool.

4.5.1 Tool Change Operation Does Not Start

Condition Possible Cause Corrective Measure
Machine controller Operation mode is not MDI or Change operation mode.
does not receive memory mode.
M06 command.
Machine controller Following operations were Wait until the operations
received M06 executed but were not completed: specified to the left are
command but • Indexing of tool magazine completed (ATC starts after
operation not by T-command. the operations).
initiated. • Return of X/Y - Axis to 2nd
reference position.
• Return of Z-Axis to
reference or 2nd reference NOTE:
position. When the machine controller
• Tool Magazine manual receives the M06 command,
Intervention. the [(Cycle) START] Switch
• Spindle orientation. is illuminated in white.
• Warning to stop the If an alarm is triggered during
operation by M06 is the operations specified to
triggered. the left, M06 is not executed.
• Servo ready for 2nd PATH Eliminate the cause of the
is OFF. alarm.

4.5.2 Abnormal Noise During Tool Change Operation

Find the exact location of the noise by using the Maintenance mode to perform the series
of ATC operations step by step.

Possible Cause Corrective Measure

Use of a non-standard tool or tool shank Use standard tool and tool shank.
that results in interference with other
components.
ATC shutter position is not proper. ATC shutter adjustment.

If the trouble can not be attributed to any of the above causes, leave the machine in its
current condition and contact your Makino service representative.

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4.5.3 Tool Dropped During Tool Change
Possible Cause Corrective Measure
Use of a non-standard tool or tool Use standard tool and tool shank.
shank.
Loosening of the retention knob. Tighten the retention knob.
The tool exceeds allowable tool moment Check the tool moment limitations.
limitations.
Gripper motion is not smooth. Check for obstruction by chips or other foreign
matter around the gripper.
Reference position alignment of ATC Contact your Makino service representative.
arm and ATC arm motor is not proper.
Alignment of ATC arm and spindle head Check/adjust the ATC arm position in relation
is not proper. to the Spindle head.
2nd reference position (Z-axis) is not Check/adjust the 2nd reference position.
proper.
Spindle orientation position is not Check/adjust the orientation position.
proper.
Tool pot spring malfunction (this causes Change the tool pot.
dropping of tool on the magazine side
when ATC arm is returned to stand-by
position by ATC arm 90° CCW).
Tool clamping device (Spindle head) Contact your Makino service representative.
malfunction (this causes dropping of
tool on the spindle side when ATC arm
is returned to stand-by position by ATC
90° CCW).
Chips enter/adhere to the ATC arm. Clean the ATC arm.
Wearing of the retention knob. Replace the retention knob.

If the trouble can not be attributed to any of the above causes, leave the machine in its
current condition and contact your Makino service representative.

4.5.4 Abnormal Opening and Closing of Shutter

Condition Possible Cause Corrective Measure
Abnormal noise occurs Shutter drive components do Contact your Makino service
during shutter not connect correctly. Shutter representative.
operation. guide is deformed.
Shutter does not move. Chips accumulate on the Disassemble the shutter guide
shutter guide. components and clean.
Solenoid valve failure. Replace the solenoid valve.
Shutter operation is Speed/cushion adjustment is Adjust the speed/cushion.
slow or not smooth. not proper.

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4.5.5 Inverter Alarms

4.5.5.1 Faults Which Can Not be Reset Automatically

Fault Probable Cause Remedy

bLF Brake release current not • Check the drive/motor connection.
Brake reached. • Check the motor windings.
Sequence Brake engage frequency bEN • Check the lbr setting in the FUn -
- nO (not adjusted) when menu.
brake logic bLC is assigned. • Contact Makino service for
assistance.
CrF Load relay control fault or • Replace the drive.
Capacitor charging resistor damaged.
load circuit
EEF Internal memory fault. • Check the environment
EEPROM (electromagnetic compatibility).
fault • Replace the drive.
InF Short circuit on the 10V • Check the circuits connection to the
Internal power. 10V.
fault Internal fault. • Check the wiring of imputs A11 and
A12 and the connection to the RJ45
connector.
• Check the environment
(electromagnetic compatibility).
• Replace the drive.
OCF Incorrect parameters in the • Check the SEt- and drC-
Over SEt- and drC- menus. parameters.
current Inertia or load too high. • Check the size of the
Mechanical blockage. motor/drive/load.
• Check the state of the mechanism.
SCF Short circuit or earthing at the • Check the cables connecting the
Motor short deive output. drive to the motor, and the motor
circuit Significant earth leakage insulation.
current at the drive output • Reduce the switching frequency.
when several motors are • Connect chokes in series with the
connected in parallel. motor.
SDF Instability or • Check the motor, gain and stability
Over Driving load too high parameters.
speed • Add a braking resistor.
• Check the size of the
motor/drive/load.
tnF Special motor or motor whose • Use the L or the P ratio.
auto power is not suitable for the • Check the presence of the motor
turning drive. during auto turning.
fault Motor not connected to the • If a downstream contactor is being
drive. used, close it during auto turning.

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• Contact Makino service for
assistance.

4.5.5.2 Faults Which can be Reset with the Automatic Restart Function, After the
Cause has Disappeared

Fault Probable Cause Remedy

COF Interruption in communication • Check the communication bus.
CAnopen on the CANopen bus.
fault
EPF According to user. • According to user.
External
fault
LFF Loss of the 4-20mA reference • Check the connection of input AI3.
Loss of 4- on input AI3.
20mA
ObF Braking too sudden or driving • Increase the deceleration time.
Overvoltage load. • Install a braking resistor if
during necessary.
deceleration • Activate the brA function if it is
compatible with the application.
• Contact Makino service for
assistance.
OHF Drive temperature too high. • Check the motor load, the drive
Drive ventilation and the environment.
overheated Wait for the drive to cool down
before restarting.
OLF Triggered by excessive motor • Check the ItH setting (motor thermal
Motor current. protection), check the motor load.
overload Incorrect value of parameter Wait for the drive to cool down
rSC. before restarting.
• Measure rSC again.
• Contact Makino service for
assistance.
OPF Loss of one phase at drive • Check the connections from the
Motor output. drive to the motor.
phase loss Downstream contactor open. • Contact Makino service for
Motor not connected or motor assistance.
power too low.
Instantaneous instability in
the motor current.
OSF Line voltage too high. • Check the line voltage.
Overvoltage Disturbed line supply.
PHF Drive incorrectly supplied or a • Check the power connection and
Line phase fuse blown. the fuses.
failure Failure of one phase. • Reset.
3-phase ATV31 used on a • Use a 3-phase line supply.
single phase line supply. • Disable the faulty by setting IPL-nO.

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Unbalanced load. • Contact Makino service for

This protection only operates assistance.
with the drive on load.
SLF Interruption in communication • Check the communication bus.
Modbus on the Modbus bus. • Check the link with the remote
fault Remote terminal enable and terminal.
terminal disconnected.

4.5.5.3 Faults Which can be Reset As Soon As Their Cause Disappears

Fault Probable Cause Remedy

CFF The current configuration is • Return the factory settings.
Configuration inconsistent. • Contact Makino service for
fault assistance.
CFI Invalid configuration; the • Check the configuration loaded
Configuration configuration loaded in the previously.
fault via drive via serial link is • Load a consistent configuration.
serial link inconsistent. • Contact Makino service for
assistance.
USF Line supply too low. • Check the voltage and the voltage
Under Transient voltage up. parameter.
voltage Damaged load resistor. • Replace the drive.
• Contact Makino service for
assistance.

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4.6 Tool Magazine

Leave the machine in its current condition and contact your Makino service representative
when the tool magazine interferes with the parts and stops because the tool magazine
may drop the tool.

4.6.1 Door Lock Released Malfunction (Door Lock

Specification)
The tool magazine door lock can not be released during an ATC or tool magazine
operation (the door can not be opened).

Door lock release procedure:

• Wait until the ATC or tool magazine operation is completed.

• Press [DOOR UNLOCK] button located near the “ATC OPERATION PANEL”.
• Open the door while pressing the [DOOR UNLOCK] button.

4.6.2 Door Lock Malfunction (Door Lock Specification)

The tool magazine door can not be locked unless it is completely closed.
• If the door can not be locked when the door is completely closed, the door switch
has either failed or it is incorrectly adjusted.
• If door switch is incorrectly adjusted, adjust the door switch position.
• If the door switch failed, contact your Makino service representative for door switch
replacement.

4.6.3 Tool Dropped During Operation

Record in detail the status of the machine when the tool or tool pot was dropped and
contact your Makino service representative.

4.6.4 Tool Search (T) Command Malfunction

Check the built-in lamp on the [(cycle) START] switch on the main operation panel.

Check the [(cycle) START] switch lamp on the main operation panel.

If the [(cycle) START] switch lamp is ON or blinking,

• Close the ATC magazine door.
• De-press the [MANUAL INTERVENTION] switch on “ATC OPERATION PANEL”.
• T-search starts automatically.

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If an alarm occurs,
• Check the alarm and restore operation.
• If a T-command was issued simultaneously with other commands that have failed
to be completed, the tool search operation can not begin. Issue the T-command
independently to determine the cause of the problem.

If the called tool is the next tool (tool at the ATC position) or the spindle tool (tool clamped
in the spindle), tool magazine operation is not performed even if a T-command is issued.

4.6.5 Servo Alarm Triggered During Operation

An alarm may be triggered by the servo system or a mechanical malfunction.

Record the alarm number and the machine operation status to determine the appropriate
corrective measures. If corrective measures are unclear, contact your Makino service
representative.

Alarm No. Possible Cause Corrective Measure

SV300's or Tool magazine drive motor Contact your Makino service
SV401 failure. representative.
SV400 or Electrical current overload Check that the driving unit operates
SV402-SV499 of the motor may be correctly.
generated by the driving
unit.
Tool exceeds limitations. Observe the tool limitations.
Driving unit failure or is Check the driving unit. Remove the
interrupted. obstruction if the driving unit is interrupted.
If it is not clear which corrective measures
are needed, contact your Makino service
representative.

4.6.6 Wrong Tool Called to ATC Position

• Confirm the tool pot number of the commanded tool on the tool data screen and
then confirm the commanded tool is actually set in the correct pot. If the tool has
been registered incorrectly, the wrong tool will be indexed even if the machine is
operating normally.
• When a tool is clamped in the spindle, another tool is commanded and it is standby
at the magazine. Confirm the spindle tool number and the commanded tool number
on the tool data management screen.
• Note that a spare tool, not a wrong tool, may be called when the spare tool
selection function is activated.
If the trouble can not be attributed to any of the above causes, leave the machine in its
current condition and contact your Makino service representative.

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4.6.7 Time-out Alarm Triggered
When a time-out alarm is triggered, the alarm message is shown on the screen.

Record the alarm number, machine conditions when the alarm was triggered and the
location to determine the cause of the alarm. The possible causes and corrective
measures are outlined below:

• Failure of the switch or signal input/output device (DI/DO Card) or an improperly

adjusted switch. If the tool magazine is in one of the following conditions, the cause
of an alarm may be failure of the switch or signal input/output device (DI/DO card)
or an improperly adjusted switch:

o The moving components reach the desired position.

o The signal status of the switch is incorrect (when the signal status is 1 when
it is supposed to be 0 or vice versa). The current signal status may be
different from that at the exact time that the time-out alarm occurred. In this
case, transfer the moving components to the desired position again and
confirm the signal status.

If the trouble can not be attributed to any of the above causes, check the following:

• Failure of the solenoid valves, hydraulic/pneumatic cylinders or signal input/output

device (DI/DO card):

o Move the stopped component using the single mode of the ATC
maintenance mode. If the components can move, the hydraulic/pneumatic
cylinder and solenoid valve are functioning normally. Observe this operation
carefully as some problems may occur intermittently.

Leave the machine in its current condition and contact your Makino service representative
when the tool magazine interferes with other parts and it can not move because the tool
may drop from the ATC magazine pot.

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4.7 Spindle Oil Temperature Controller

Perform the following corrective measures, when a malfunction is occurred.

Condition Possible Cause Corrective Measure

Spindle oil Power is not Measure the voltages among the terminals R,
temperature supplied from the S, T.
controller can not machine or the • Correct wiring connection.
be operated. power cable is not
connected
correctly.
The fuse in the Remove the fuse from the fuse holder to
electrical box has check:
burnt out. • When the fuse has burnt out, replace
with a new one.
• If the new fuse has burnt out even after
replacement, there may be a short
circuit in the electrical circuit. Measure
each wiring with a voltmeter.
Faulty electrical Check wiring for loose connections or damage.
cable connection or Tighten connection or replace wiring if cable
wiring damage. damage has occurred.
The oil temperature Check for hose constriction or filter clogging
controller pump is raising oil pressure in the oil piping system.
overloaded. • Replace the hose or filter if necessary.
Check for mechanical problems such as worn
bearings or a broken fan in the oil pump.
• Replace bearings or fan if necessary.

Compressor is Check for clogging of the refrigerant piping

overloaded. system or air filter and for fan motor stoppage
(if replacement of the refrigerant piping is
necessary, contact your Makino service
representative).
Check for excessive ambient temperatures or
insufficient space between the controller and
the ceiling or wall.
• If above space is insufficient, create
sufficient ceiling/controller spacing.
Check for abnormal wearing in the
Compressor or mechanical friction.
• Replace the compressor if necessary
(contact your Makino service
representative for assistance).

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Overload has Check the following:
caused compressor • Fan motor stoppage.
overheating. • Air filter clogging.
• Excessive ambient temperatures.
• Insufficient spacing between controller
and ceiling or wall.
Remedy for above problem:
• Replace the fan motor if necessary.
• Clean the filter if necessary.
• Lower the room temperature if is too
high.
• If space between the controller and
ceiling is insufficient, create sufficient
spacing.

If the problem can not be eliminated using

procedure above, proceed the following:
Check for clogging of the refrigerant piping
system.
• If clogged, replacement is necessary.
Contact your Makino service
representative for assistance.
Check for abnormal wearing in the compressor
or mechanical friction.
• Replace the compressor if necessary
(contact your Makino service
representative for assistance).
Refrigerant Lower the refrigerant temperature by installing
pressure is an auxiliary fan temporarily.
abnormally high. Check for fan motor stoppage or air filter
clogging.
• Replace fan motor is necessary.
• Clean the air filter if necessary.
Check for excessive ambient temperatures or
insufficient spacing between the spindle oil
temperature controller and the ceiling.
• Lower the room temperature if
necessary.
• If above space is insufficient, create
sufficient spacing.

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Oil temperature has Check for insufficient oil in tank.

become high. • Add oil to the specified level if
necessary.
Check if the compressor, oil pump of fan motor
has stopped.
• If any of the above units is
malfunctioning, contact your Makino
service representative.
Check for excessive ambient temperatures.
• Lower the room temperature if
excessive.
• If space in between the radiator and
ceiling is insufficient, create sufficient
spacing.
Check for gas leakage from the refrigerant
piping system.
• If gas (R407C) is leaking, identify the
faulty component using R407C leak
detector or soapy water applied to each
part of the piping system. To stop a gas
leak, contact your Makino service
representative for assistance.
Temperature can Solenoid valve Contact your Makino service representative for
not be adjusted malfunction. assistance.
though operation Control PCB Check the control PCB.
is possible. (printed circuit Replace the control PCB is necessary.
board) is defective.
Gas or oil leakage. Gas leakage from hoses connected to the
compressor, condenser, capillary and
vaporizer is possible.
• Identify the faulty component using the
R407C leak detector or soapy water
applied to each part of the piping
system. To stop a gas leak, contact
your Makino service representative for
assistance.
Oil leakage from hoses connected to the oil
tank, oil supply piping, machine, oil returning
hose and spindle oil temperature controller.
• Identify the faulty component visually or
wiping each part with a piece of clean
cloth. Repair the oil leak and add oil.

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4.7.1 Troubleshooting with Alarm Displayed
(1) Explanation Oil temperature sensor fault.
Possible • Broken connection of the oil temperature sensor.
Cause • Oil temperature sensor unit.
• Temperature controller failure.
Inspection • Check if the connection of the oil temperature sensor is
broken.
• If the connection is not broken, then there are chances of
temperature controller failure or sensor failure.
Solution • Reconnect the wire connection, or replace the wire if
necessary.
• Replace the failure parts.

(2) Explanation There is a problem with the ambient or machine body

temperature sensor.
Possible • The wire connection of the ambient or machine body
Cause temperature sensor is broken.
• The ambient or machine by temperature sensor failure.
• The temperature controller failure.
Inspection • Check if the wire for ambient or machine body temperature
sensor still connected.
• If there are no problems with the connection, chances are
either the sensor or the temperature controller is faulty.
Solution • Reconnect the wire connection, or replace the wire if
necessary.
• Replace the failure parts.

(3) Explanation Oil temperature is too high for the cooler to process.
Possible • Process load over the limit of the cooler unit's capacity.
Cause • Oil temperature sensor failure.
• Refrigeration system failure.
Inspection • Check if the ambient and oil temperatures are higher than
the limit 45 degree.
• Check if the cooler unit is capable for the process load.
• The copper pipe near the low pressure side of the
compressor is not cold.
• Fins of condenser are not hot.
• The temperature of the dryer is lower than exhaust heat.
Solution • Check if the sensor functions properly.
• Keep the oil temperature below 45 degree.
• Change cooler unit to a larger cooling capacity.
• Replace the oil temperature sensor.
• Contact the refrigeration technician for refrigeration system
failures.

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(4) Explanation Oil/ambient temperature is too low for the cooler to process.
Possible • Oil temperature is too low.
Cause • Ambient temperature is too low.
• Temperature controller failure.
• Oil/ambient temperature sensor fault.
Inspection • Check if the oil temperature and the ambient temperature
are above 5 degree.
• Check if the temperature sensor functions properly.
• If the above seems to be order, then the temperature
controller failed.
Solution • Control the oil temperature above 5 degree, note that the
cooler unit and the machine tools should start
simultaneously.
• Keep the ambient above 5 degree.
• Replace fault parts.

(5) Explanation Surface temperature of the compressor is too high.

Possible • Poor heat dissipation.
Cause • Incorrect power voltage input.
• Faulty compressor.
Inspection • Check if any air vent is cloggy.
• Check the input power if it's correct voltage and phase.
• Check the starting condition of the compressor, measure
the starting voltage.
Solution • Create better heat dissipation environment.
• Reconnect the wires for correct power input.
• Replace faulty compressor.

(6) Explanation Liquid level in the tank is tool low.

Possible • Not enough oil in the oil tank.
Cause • Oil level switch faulty.
Inspection • Check if the oil level in the oil tank is sufficient.
• If the oil within the tank is enough, chances are oil level
switch fails.
Solution • Make sure the oil within the oil circulating system is
sufficient.
• Replace the faulty oil level switch.

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(7) Explanation There is a pressure fault within the refrigeration system.
Possible • Low or over charge of refrigerant.
Cause • Obstruction/leakage occurred in the refrigeration system.
• Condenser/air filter are dirty or cloggy.
• Poor heat dissipation.
• Fan failure.
Inspection • The copper pipe near the low pressure side of the
compressor is not cold.
• Fins of condenser are not hot.
• The temperature of the dryer is lower than exhaust heat.
• Check if cooler unit's internal temperature is too high.
• Check if the air intake or exhaust is cloggy.
• Check if the air filter or the condenser is dirty.
• Check if fan out of order.
Solution • Please contact the refrigeration service technician for
faults within the refrigeration system.
• Clean the air filter and the condenser regularly to improve
the heat dissipation, and remove any obstructers from air
intake or exhaust.
• Replace faulty parts.

(8) Explanation There is a fault within the pump which trip out the overload
protector.
Possible • Trip-out in overload protector.
Cause • Poor insulating or a burn out pump.
• The temperature controller failure.
Inspection • Check if the pump motor still operates.
• Check if the bearing is cloggy.
• Check if the oil pressure is too high to cause the overload
protector to trip-out.
• Check the liquid pipe if the liquid flow is smooth.
Solution • Replace faulty pump.
• Reset the overload protector after unload of the oil
pressure.
• Clean the liquid circulating system, add a filter if
necessary.

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(9) Explanation There is a fault within the compressor which trip out the overload
protector.
Possible • Incorrect power voltage input.
Cause • Compressor has burned out.
• Overload protector trip out.
• Poor heat dissipation.
• Fan failure.
Inspection • Check if the input power voltage is correct.
• Check if the compressor has burned out.
• Check if the overload protector has trip out.
• Check if cooler unit's internal temperature is too high.
• Fan is out of order.
Solution • Input the correct power voltage.
• Replace burned out compressor.
• Reset the overload protector.
• Improve the working environment to lower ambient
temperature and create better ventilation.
• Replace fan.

(10) Explanation There is an oil pressure fault or insufficient oil amount within the
oil circulating system.
Possible • No liquid flow or insufficient oil.
Cause • Oil pressure loss.
• Oil pressure switch or flow rate switch failure.
• Air penetrated into oil circulating system.
• Pump motor failure.
• Oil viscosity is too high.
Inspection • Check if there is enough oil within the oil circulating
system.
• Long, thin and flattened oil hoses will cause oil pressure
loss.
• Please check if the value of oil pressure switch is within
the designed specification.
• If the pump motor fails, there will be no oil flow, sometimes
it's the worn out of key.
• Check if the oil used is within the viscosity range.
• If all the above is alright, there is a chance of failure in oil
pressure switch or the flow switch.
Solution • Supply more oil into the oil tank or the oil circulation
system to the rated level.
• Increase the diameter of the hose or shorten the length of
hose to avoid oil pressure loss.
• Reset the oil pressure switch to designed specification.
• Replace faulty pump motor.
• Use oil with lower viscosity.
• Replace faulty parts.

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(11) Explanation The power phase input has been reversed.
Possible • Reversed phase of main power source.
Cause • Power source is single-phased.
• Reverse phase relay failure.
• Temperature controller failure.
Inspection • Check if the power phase input is correct.
• If the power phase is correct, it is whether the reverse
phase relay or the temperature controller has failed.
Solution • Reconnect the power cable with correct phase.
• There phase cooling unit should be connected to three
phase power source.
• Replace the faulty parts.

(12) Explanation Power phase missing alarm

Possible • The S power phase from 3 phase R, S, T is missing.
Cause
Inspection • Check if the S power phase is connected properly.
• If the phase is connected properly, then the controller has
failed.
Solution • Re-fix the S power phase connection.
• Replace the possible failure controller.

(13) Explanation Fan motor overloaded

Possible • The overload protector of the fan motor have tripped out.
Cause • Fan motor failure.
Inspection • Reset the overload protector to check if this is from
sudden overload.
• Check if the fan motor has failed.
Solution • Reset the overload protector.
• Replace the fan motor.

(14) Explanation Abnormal heater operation.

Possible • The overheating protection of heater activated.
Cause • Fake alarm from overheating protection.
Inspection • Check if there are sufficient cooling liquid within the
system or if there are any liquid flow.
• Check the output contact of the overheating protection.
Solution • Refill the cooling liquid and examine the problem of flow.
• Replace the overheating protector.

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4.8 Spindle Lubrication (Oil-Air) Device for

Bearing
Perform the following corrective measures, when a malfunction is occurred.

Trouble Causes Corrective Measures

Oil not Oil level is low. Add oil to tank.
discharged. Suction filter is clogged. Clean or replace the suction filter.
Oil viscosity is tool high. Replace oil with proper oil viscosity
(in case of replacement, flush the
tank and hose system (piping
system) before regular operation).
Pressure does Hose system trouble (piping 1) Check for air release at the
not rise. system trouble) end of the hose or at the hose
1) Air remains in the hose. joints.
2) Oil leakage from joints 2) Screw the hose joints closed
between hoses. with sufficient force.
3) Hose breakage. 3) Replace the hose.
Pressure setting of relief valve Adjust the set value.
is incorrect.
Pressure valve is 1) Disassemble and clean the
malfunctioning pressure valve.
1) Valve sheet is clogged. 2) Replace the pressure valve.
2) Valve sheet is damaged.
Noise emitted Trapped foreign materials have Disassemble the pump to confirm
from pump. damaged the pump gear. the damage. Contact your Makino
service representative if the damage
has occurred as it is necessary to
replace the pump and flush the tank
and hose system.
No signal from Oil level is too low. Add oil to tank to level "L" or higher.
the float switch. Contact point has burnt out. It is necessary to replace the float
switch. Contact your Makino service
representative. Do not overload the
float switch.
Pump not Wiring is incorrect. Check the Electrical wiring.
operating. Pump malfunction. Repair or replacement of the pump
is necessary. Contact your Makino
service representative.

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4.9 Oil-Mist Supply Unit

Perform the following corrective measures, when a malfunction is occurred.

Trouble Causes Corrective Measures

Oil does not drop. Insufficient air flow rate. Adjust the air flow rate.
Insufficient oil in bowl. Fill with oil.
Adjusting screw for oil Adjust the oil-mist flow rate.
drop quantity is foreign
matter on it.
Air leaks from Gasket has been Remove the bowl and clean/replace the
bowl mounting. scratched or there is gasket.
foreign matter on it. Bowl removal procedure:
1) Turn OFF the machine power
supply.
2) Close the oil adjusting needle.
3) Rotate the fill plug one rotation
and confirm that the residual
pressure is completely
discharged.
4) Remove the fill plug.
5) Press the latch and turn the
clamp ring.
6) Pull the bowl and bowl guard.
Bowl is broken. Replace the bowl.
Alarm is not Float switch malfunction Replace the float switch.
triggered even
when there is no
oil.

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4.10 Automatic Grease Supply Unit

Perform the following corrective measures, when a malfunction is occurred.

Error Item Cause Condition Corrective Measure

Excessive Grease is If grease is abnormally
Internal leaking abnormally overflowing the lubricating
in distributing overflowing the point, replace the element of
valve. lubricating point. the distributing valve.
Grease
consumption rate:
excessively high
Grease is Grease Check the grease leaking
leaking between consumption rate: point and tighten the joints.
the pump and excessively high
the distributing
valve.
Air blocked in Grease Loosen air venting screw of
the pump. consumption rate: the pump until and discharge
normal grease until air along with
grease is totally removed.
Air trapped in the Grease After removing the air in the
grease pipe. consumption rate: piping by which air along with
normal grease may also come, run
the pump to remove the air in
the grease pipe.
Grease in Replace with a new cartridge
cartridge is and carry out air venting in
-
empty. the same procedure as
above.
Less- tight Grease Tighten the cartridge
screwing-down consumption rate: completely by screwing it
of cartridge. normal down.
Seal packing is Grease Replace the seal packing.
damaged. consumption rate:
normal
Inner cover is No grease Remove the inner cover from
mounted on consumption. the cartridge.
cartridge.
Heavy wear of Grease Replace the pump.
pump piston unit. consumption rate:
normal
Pump wiring No grease Check and repair electrical
breakdown. consumption. wiring.
Faulty pressure Grease Check/repair or replace the
switch. consumption rate: pressure switch.
moderately high

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Setting value in Setting value is Set a higher value in machine
machine incorrect. parameter No. 07005
parameter No.
07005 is too low.
Abnormal Distributing valve Grease is not Replace the element of the
pressure release is clogged. supplied. distributing valve.
(pressure switch Grease
LS1698 is still 1 consumption rate:
even after excessively low
pressure Faulty pressure Grease Replace the pressure switch.
release). switch. consumption rate:
moderately low
Alarm No. 1585 Abnormality in Disassemble the pressure
or Operator pressure releasing unit for Inspection
Message No. releasing inbuilt - and cleaning.
1826 is triggered. mechanism of
the pump.
Abnormal Faulty pressure Grease Replace the pressure switch.
detection of switch consumption rate:
pressure switch moderately low
(pressure switch Abnormality in Disassemble the pressure
LS1698 is 1 at pressure releasing unit for inspection
start-up) releasing inbuilt and cleaning.
mechanism of
-
Alarm No. 1584 the pump
or Operator
Message No.
1825 is triggered
Alarm No. 1586 Cartridge is Pump count has Change the value in machine
or Operator replaced prior to reached value set parameter No. 07006 to
Message No alarm or warning in machine match the amount of grease
1827 is triggered, is triggered in parameter No. in the cartridge.
but grease last time. 07006
remains in Cartridge is
cartridge. replaced with
half used
cartridge on
previous
occasion.
Incorrect value is
set after
replacement of
cartridge
Alarm or warning
reset is not
performed after
replacement of
cartridge

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Cartridge empty Grease supply Alarm No. 1586 Replace with a new cartridge.
count has or Operator
reached set limit Message No
1827 is triggered
when cartridge is
empty.
Grease supply Cartridge is Change the value in machine
count has not replaced prior to parameter No. 07006 to
reached set limit Alarm No. 1586 match the amount of grease
or Operator in the cartridge.
Message No
1827 on previous
occasion.
Supply amount of Change the supply amount to
distributing valve original setting.
is charged.
Grease Excessive If Grease is abnormally
consumption internal leak of overflowing the lubricating
-
rate: excessively distributing valve point, replace the distributing
high valve.
Grease leak Check the grease leaking
between pump point and tighten the joints.
-
and distributing
valve
Faulty Pressure Grease Replace the pressure switch.
Switch abnormally
overflowing at all
lubricating points.
Setting value in Setting value is Increase the value set in
machine incorrect. machine parameter No.
parameter No. 07025 (pause time)
07025 is too low.
Grease Distributing valve Grease is not Replace the element of the
consumption is clogged. supplied. distributing valve.
rate: excessively Faulty pressure Replace the pressure switch.
-
low switch
Setting value in Setting value is Reduce the value set in
machine incorrect. machine parameter No.
parameter No. 07025 (pause time)
07025 is too
high.

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4.11 Hydraulic System

Condition Possible Cause Corrective Measure
Pump motor Electric power connection is Correct the electric power connection
is not wrong/disconnected/loose. and connect back any
running. disconnected/loose connection.
Pump motor damaged. Replace the pump unit.

Pump Pump can not draw in oil as oil Replace the oil within the
discharge viscosity is too high. recommended viscosity range.
insufficient/ Pump draws in air as oil level is Add oil to recommended level.
stopped. insufficient.
Suction strainer is clogged. Replace the pump unit.
Pump rotation sliding surfaces Contact your Makino service
(piston assembly, cylinder block, representative for damaged part
port plate) are scorched or worn replacement.
out.
Leaking on the Tighten the joint/connector/hose.
joint/connector/hose.
Abnormal Oil viscosity is too high/low. Replace the oil within the
pump noise. recommended viscosity range.
Pump draws in air as oil level is Add oil to recommended level.
insufficient.
Part is damaged. Contact your Makino service
representative.
Pump Unloading valve is not fully Close the unloading valve.
continuously closed.
ON. Internal leakage due to part worn Contact your Makino service
out/damaged e.g. piston representative for damaged part
(Alarm No. assembly, cylinder block, port replacement.
EX1605 is plate.
triggered). Other hydraulic components in Inspect other components and
circuit leakage. replace if necessary.
Accumulator pre-charge pressure Recharge the accumulator pressure
too low. at 63bar.
Accumulator damaged. Replace the accumulator.
Pressure relief valve setting not Correct pressure relief valve to at
correct. least 5-10 bar above the Pressure
Switch setting.
Pressure switch malfunction. Replace pressure switch.
Pump Check possible root causes on Correct the root cause accordingly or
restarts too ‘Pump continuously ON’. contact Makino service.
often.
Oil leakage O-ring is worn out/damaged. Contact your Makino service
from pump. Gasket is damaged. representative for damaged part
replacement.
Oil level is insufficient. Add oil to recommended level.

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Case drain expanding from Contact your Makino service

excessive wear on pump representative for damaged part
rotation/sliding parts. replacement.
Pump restarts too often. Correct the root causes of ‘Pump
restarts too often’.
Oil leakage Loosening of the fittings. Tighten the fittings.
from fittings. Seal surface is defective. Check the accuracy, warping, foreign
matter on the seal surface and
replace if necessary.
Gasket/seal is damaged or worn. Check the damage/wearing of the
gasket or lip packing and replace if
necessary.
Oil leakage Leakage from the following 1) Determine the point of oil
(any part of piping: leakage (see the left column).
Hydraulic • Hydraulic unit If only a small amount of oil is
piping) • Hose leaking, place a white paper
• Fitting under suspected parts to
• Solenoid valve check or add a trace dye into
• Manifold the hydraulic oil before
Leakage rear of the spindle head. operating the machine.
2) Check the amount of oil
leakage (for example per day).
Inform Makino service representative
of the results of the above checks 1
and 2.
Overload of Pump malfunction Press the [START] switch on the
Pump motor Strainer damage caused by motor breaker after eliminating the
for Hydraulic mixing foreign matter into the cause of the overload or contact
unit pump Makino service.
(Alarm No.
EX1601 is
triggered).

Please note that only qualified personnel are allowed to make the necessary repairs and
replacements!

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4.12 Pneumatic System

If the compressed air supplied to machine does not satisfy the necessary conditions
(Note), it may cause a malfunction of the pneumatic system and contaminated
compressed air will severely damage major components of the machine such as spindle,
ATC and scales.

Clean (replace if necessary) the filter periodically. Use clean compressed air free from
dust, moisture or oil and the grade is ISO 2.5.2 as stipulated in JIS B 8392-1 (ISO 8573-
1).

4.12.1 Pressure Switch Malfunction

Condition Possible Cause Corrective Measure
Switch does not Solenoid valve SOL905 Replace solenoid valve SOL905.
activate at the set malfunction
pressure. Air pressure is not Apply pressure higher than the set
supplied or is insufficient. pressure plus hysteresis.
Electrical wiring damage Repair the wiring or replace pressure
switch.
Switch still activates Pressure gauge Replace the pressure gauge.
although air pressure malfunction
is below set Switch contact has Change the load and wiring length
pressure. melted. then replace the pressure switch.
External magnetic field is Keep magnetic field source away
too strong. from the pressure switch or install the
switch far from the source.

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4.12.2 Filter Malfunction

Condition Possible Cause Corrective Measure
Flow rate is Filter clogging. Stop the compressed air supply and
insufficient. remove the bowl and replace/clean
Excessive pressure the filter.
loss.
Drain does not come Drain port clogging. Stop the compressed air supply and
out from open drain remove the bowl and replace/clean
cock. the bowl.
Auto drain not Auto drain malfunction or Stop the compressed air supply and
operating (auto drain clogging. remove the bowl and clean inside of
specification) the bowl or replace the bowl.
Air leakage from
drain port.
Air leakage at bowl O-ring is defective or Stop the compressed air supply and
connection point. clogged with foreign remove the bowl and clean or replace
matter. the o-ring.
Bowl is defective. Stop the compressed air supply to
remove and replace the bowl.
Unable to regulate Foreign matter has Stop the compressed air supply and
the air pressure. scarred the rubber disassemble the filter regulator and
surface of valve sheet. clean.
Valve stem is clogged
with foreign matter (tar)
along its sliding surface.
Foreign matter has
scarred the sliding
surface of valve sheet
and bottom plug.
Air flow direction Stop the compressed air supply and
incorrect. reconnect the piping so that air is
supplied to the air inlet.
O-ring in valve sliding Stop the compressed air supply and
part is defective. disassemble the filter regulator and
Diaphragm is defective. replace the defective parts.
Rubber of valve sheet is
defective.
Air leakage from Diaphragm is defective. Stop the compressed air supply and
diaphragm. disassemble the filter regulator and
replace the diaphragm.

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4.13 Cutting Fluid

4.13.1 Cutting Fluid Supply Unit Malfunction
Condition Possible Cause Corrective Measure
Cutting fluid is not For safety reasons, cutting Complete individual operation or
discharged (Pump fluid is not discharged for one release the condition.
is not rotating). of the following reasons:
• Operator door is
opened.
• Coolant stop switch is
pressed.
• During tool change.
• M00 or M01 (Program
Stop) is executed.
• Cutting fluid-related
alarm is triggered.
Incorrect wiring, cable or hose Check the wiring, cable and hose
connections for pump. connection.
Thermal relay is tripped. Check the alarm triggered in
machine side.
Cutting fluid is not Coolant valve malfunction. Replace the coolant valve if
discharged (pump necessary. If the coolant valve
is rotating). functions normal, check for the
clogging of the piping.
Cutting fluid is below required Add cutting fluid after the machine
level (check the oil level stops completely.
Indicator).
Clogging of the pump or Check for clogging of the piping,
piping. strainer, filter (Through-Spindle
Coolant) and clean/replace.
Incorrect function Incorrect wiring, cable or hose Check the connections.
is operated. connections for
machine/pump.
Incorrect hose between pump Check the piping.
and the discharge ports of the
cutting fluid

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4.13.2 Cutting Fluid Temperature Controller

Perform the following corrective measures, when a malfunction is occurred.

Condition Possible Cause Corrective Measure

Cutting fluid Power is not Measure the voltages among the terminals R,
temperature supplied from the S, T.
controller can not machine or the Correct wiring connection.
be operated. power cable is not
connected
correctly.
The fuse in the Remove the fuse from the fuse holder to
electrical box has check:
burnt out. When the fuse has burnt out, replace with a
new one.
If the new fuse has burnt out even after
replacement, there may be a short circuit in
the electrical circuit. Measure each wiring with
a voltmeter.
Faulty electrical Check wiring for loose connections or damage.
cable connection or Tighten connection or replace wiring if cable
wiring damage. damage has occurred.
Operation starts The fluid Check for hose construction or filter clogging
then suddenly the temperature raising fluid pressure in the fluid piping system.
operation stops controller pump is Replace the hose or filter if necessary.
overloaded. Check for mechanical problems such as worn
bearings or a broken fan in the pump.
Replace bearings or fan if necessary.

Compressor is Check for clogging of the refrigerant piping

overloaded. system or air filter and for fan motor stoppage
(if replacement of the refrigerant piping is
necessary, contact your Makino service
representative).
Check for excessive ambient temperatures or
insufficient space between the controller and
the ceiling or wall.
If above space is insufficient, create sufficient
ceiling/controller spacing.
Check for abnormal wearing in the compressor
or mechanical friction.
Replace the compressor if necessary (contact
your Makino service representative for
assistance).

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Overload has Check the following:
caused compressor Fan motor stoppage.
overheating. Air filter clogging.
Excessive ambient temperatures.
Insufficient spacing between controller and
ceiling or wall.

Remedy for above problem:

Replace the fan motor if necessary.
Clean the filter if necessary.
Lower the room temperature if is too high.
If space between the controller and ceiling is
insufficient, create sufficient spacing.

If the problem can not be eliminated using

procedure above, proceed the following:
Check for clogging of the refrigerant piping
system.
If clogged, replacement is necessary. Contact
your Makino service representative for
assistance.
Check for abnormal wearing in the compressor
or mechanical friction.
Replace the compressor if necessary (contact
your Makino service representative for
assistance).
Refrigerant Lower the refrigerant temperature by installing
pressure is an auxiliary fan temporarily.
abnormally high. Check for fan motor stoppage or air filter
clogging.
Replace fan motor is necessary.
Clean the air filter if necessary.
Check for excessive ambient temperatures or
insufficient spacing between the spindle oil
temperature controller and the ceiling.
Lower the room temperature if necessary.
If above space is insufficient, create sufficient
spacing.

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Fluid temperature Check for insufficient fluid in tank.

has become high. Check if the compressor, pump of fan motor
has stopped.
If any of the above units is malfunctioning,
contact your Makino service representative.
Check for excessive ambient temperatures.
Lower the room temperature if excessive.
If space in between the radiator and ceiling is
insufficient, create sufficient spacing.
Check for gas leakage from the refrigerant
piping system.
• If gas (R407C) is leaking, identify the
faulty component using R407C leak
detector or soapy water applied to each
part of the piping system. To stop a gas
leak, contact your Makino service
representative for assistance.
Temperature can Solenoid valve Contact your Makino service representative for
not be adjusted malfunction. assistance.
though operation Control PCB Check the control PCB.
is possible. (printed circuit Replace the control PCB is necessary.
board) is defective.
Gas or oil leakage. Gas leakage from hoses connected to the
compressor, condenser, capillary and
vaporizer is possible.
• Identify the faulty component using the
R407C leak detector or soapy water
applied to each part of the piping
system. To stop a gas leak, contact
your Makino service representative for
assistance.
Fluid leakage from hoses connected to the
tank, supply piping, machine, returning hose
and fluid temperature controller.
• Identify the faulty component visually or
wiping each part with a piece of clean
cloth. Repair the fluid leak.

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 Maintenance Manual PS-Series
4.13.3 Troubleshooting with Alarm Displayed
(1) Explanation Fluid temperature sensor fault.
Possible • Broken connection of the fluid temperature sensor.
Cause • Fluid temperature sensor unit.
• Temperature controller failure.
Inspection • Check if the connection of the fluid temperature sensor is
broken.
• If the connection is not broken, then there are chances of
temperature controller failure or sensor failure.
Solution • Reconnect the wire connection, or replace the wire if
necessary.
• Replace the failure parts.

(2) Explanation There is a problem with the ambient or machine body

temperature sensor.
Possible • The wire connection of the ambient or machine body
Cause temperature sensor is broken.
• The ambient or machine by temperature sensor failure.
• The temperature controller failure.
Inspection • Check if the wire for ambient or machine body temperature
sensor still connected.
• If there are no problems with the connection, chances are
either the sensor or the temperature controller is faulty.
Solution • Reconnect the wire connection, or replace the wire if
necessary.
• Replace the failure parts.

(3) Explanation Fluid temperature is too high for the cooler to process.
Possible • Process load over the limit of the cooler unit's capacity.
Cause • Fluid temperature sensor failure.
• Refrigeration system failure.
Inspection • Check if the ambient and oil temperatures are higher than
the limit 45 degree.
• Check if the cooler unit is capable for the process load.
• The copper pipe near the low pressure side of the
compressor is not cold.
• Fins of condenser are not hot.
• The temperature of the dryer is lower than exhaust heat.
Solution • Check if the sensor functions properly.
• Keep the fluid temperature below 45 degree.
• Change cooler unit to a larger cooling capacity.
• Replace the fluid temperature sensor.
• Contact the refrigeration technician for refrigeration system
failures.

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(4) Explanation Fluid/ambient temperature is too low for the cooler to process.
Possible • Fluid temperature is too low.
Cause • Ambient temperature is too low.
• Temperature controller failure.
• Fluid/ambient temperature sensor fault.
Inspection • Check if the fluid temperature and the ambient
temperature are above 5 degree.
• Check if the temperature sensor functions properly.
• If the above seems to be order, then the temperature
controller failed.
Solution • Control the fluid temperature above 5 degree, note that the
cooler unit and the machine tools should start
simultaneously.
• Keep the ambient above 5 degree.
• Replace fault parts.

(5) Explanation Surface temperature of the compressor is too high.

Possible • Poor heat dissipation.
Cause • Incorrect power voltage input.
• Faulty compressor.
Inspection • Check if any air vent is cloggy.
• Check the input power if it's correct voltage and phase.
• Check the starting condition of the compressor, measure
the starting voltage.
Solution • Create better heat dissipation environment.
• Reconnect the wires for correct power input.
• Replace faulty compressor.

(6) Explanation Liquid level in the tank is tool low.

Possible • Not enough fluid in the fluid tank.
Cause • Fluid level switch faulty.
Inspection • Check if the fluid level in the fluid tank is sufficient.
• If the fluid within the tank is enough, chances are fluid
level switch fails.
Solution • Make sure the fluid within the oil circulating system is
sufficient.
• Replace the faulty fluid level switch.

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(7) Explanation There is a pressure fault within the refrigeration system.
Possible • Low or over charge of refrigerant.
Cause • Obstruction/leakage occurred in the refrigeration system.
• Condenser/air filter are dirty or cloggy.
• Poor heat dissipation.
• Fan failure.
Inspection • The copper pipe near the low pressure side of the
compressor is not cold.
• Fins of condenser are not hot.
• The temperature of the dryer is lower than exhaust heat.
• Check if cooler unit's internal temperature is too high.
• Check if the air intake or exhaust is cloggy.
• Check if the air filter or the condenser is dirty.
• Check if fan out of order.
Solution • Please contact the refrigeration service technician for
faults within the refrigeration system.
• Clean the air filter and the condenser regularly to improve
the heat dissipation, and remove any obstructers from air
intake or exhaust.
• Replace faulty parts.

(8) Explanation There is a fault within the pump which trip out the overload
protector.
Possible • Trip-out in overload protector.
Cause • Poor insulating or a burn out pump.
• The temperature controller failure.
Inspection • Check if the pump motor still operates.
• Check if the bearing is cloggy.
• Check if the fluid pressure is too high to cause the
overload protector to trip-out.
• Check the liquid pipe if the liquid flow is smooth.
Solution • Replace faulty pump.
• Reset the overload protector after unload of the fluid
pressure.
• Clean the liquid circulating system, add a filter if
necessary.

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(9) Explanation There is a fault within the compressor which trip out the overload
protector.
Possible • Incorrect power voltage input.
Cause • Compressor has burned out.
• Overload protector trip out.
• Poor heat dissipation.
• Fan failure.
Inspection • Check if the input power voltage is correct.
• Check if the compressor has burned out.
• Check if the overload protector has trip out.
• Check if cooler unit's internal temperature is too high.
• Fan is out of order.
Solution • Input the correct power voltage.
• Replace burned out compressor.
• Reset the overload protector.
• Improve the working environment to lower ambient
temperature and create better ventilation.
• Replace fan.

(10) Explanation There is a fluid pressure fault or insufficient oil amount within the
oil circulating system.
Possible • No liquid flow or insufficient fluid.
Cause • Fluid pressure loss.
• Fluid pressure switch or flow rate switch failure.
• Air penetrated into oil circulating system.
• Pump motor failure.
• Oil viscosity is too high.
Inspection • Check if there is enough fluid within the fluid circulating
system.
• Long, thin and flattened fluid hoses will cause oil pressure
loss.
• Please check if the value of fluid pressure switch is within
the designed specification.
• If the pump motor fails, there will be no fluid flow,
sometimes it's the worn out of key.
• Check if the oil used is within the viscosity range.
• If all the above is alright, there is a chance of failure in fluid
pressure switch or the flow switch.
Solution • Supply more fluid into the fluid tank or the fluid circulation
system to the rated level.
• Increase the diameter of the hose or shorten the length of
hose to avoid fluid pressure loss.
• Reset the fluid pressure switch to designed specification.
• Replace faulty pump motor.
• Use fluid with lower viscosity.
• Replace faulty parts.

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(11) Explanation The power phase input has been reversed.
Possible • Reversed phase of main power source.
Cause • Power source is single-phased.
• Reverse phase relay failure.
• Temperature controller failure.
Inspection • Check if the power phase input is correct.
• If the power phase is correct, it is whether the reverse
phase relay or the temperature controller has failed.
Solution • Reconnect the power cable with correct phase.
• There phase cooling unit should be connected to three
phase power source.
• Replace the faulty parts.

(12) Explanation Power phase missing alarm

Possible • The S power phase from 3 phase R, S, T is missing.
Cause
Inspection • Check if the S power phase is connected properly.
• If the phase is connected properly, then the controller has
failed.
Solution • Re-fix the S power phase connection.
• Replace the possible failure controller.

(13) Explanation Fan motor overloaded

Possible • The overload protector of the fan motor have tripped out.
Cause • Fan motor failure.
Inspection • Reset the overload protector to check if this is from
sudden overload.
• Check if the fan motor has failed.
Solution • Reset the overload protector.
• Replace the fan motor.

(14) Explanation Abnormal heater operation.

Possible • The overheating protection of heater activated.
Cause • Fake alarm from overheating protection.
Inspection • Check if there are sufficient cooling liquid within the
system or if there are any liquid flow.
• Check the output contact of the overheating protection.
Solution • Refill the cooling liquid and examine the problem of flow.
• Replace the overheating protector.

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4.14 Mist Collector

4.14.1 Motor Not Operating
Possible Cause Corrective Measure
Electrical cable connection Check the electrical cable is correctly connected. If the cable
failure or disconnection is broken, replace the cable.
Circuit breaker tripped. Circuit breaker is tripped when the motor load is excessive.
Press the [ON] switch on the motor breaker in the machine
controller after eliminating the cause.
Voltage is low. Check cause of low voltage and adjust to regular voltage.
Loose connection on Check the electromagnetic contactor (MS19) for the mist
electromagnetic contactor collector. If the electromagnetic contactor is damaged,
replacement is necessary. Contact your Makino service
representative for assistance.
Motor is damaged. Motor replacement is necessary. Contact your Makino
service representative for assistance.
Seized up or rusted Motor replacement is necessary. Contact your Makino
bearing. service representative for assistance.

4.14.2 Motor Rotates, But Does Not Collect Mist

Possible Cause Corrective Measure
Motor rotation direction is Connect the wiring to rotate motor counterclockwise.
opposite.
Filter is clogged. Inspect the condition of each filter and clean or replace as
necessary.
Connection point of the Check the connection point of the duct and reconnect the
duct and hose duct is duct and the hose duct correctly.
detached. If the duct is damaged, replacement is necessary. Contact
your Makino service representative for assistance.
Clogged duct piping Check the Inside of the duct pipe and remove the foreign
material from the duct if necessary.
Confirm the duct piping is connected correctly.
Primary filter is under Confirm the drain piping is connected correctly.
negative pressure.

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4.14.3 Motor Load is Excessive
Possible Cause Corrective Measure
Supply voltage is The voltage in the factory is high. Confirm the cause and
excessive. adjust to regular voltage.
Rotating components Contact your Makino service representative for assistance.
contacting with
obstacle(s).
Clogged duct piping or Check the duct piping and the filter.
filter. If there is foreign material inside of the duct piping, remove
it.
If the filter is clogged, replace with a new filter.

4.14.4 Oil is not being Collected

Possible Cause Corrective Measure
Clogged drain piping or Check the drain pipes and then remove the foreign material.
solidified oil.
Drain pipe connection Check the drain pipes and then reconnect the pipes
failure or disconnection. correctly.
If the drain pipes are damaged, replacement is necessary.
Air pockets in the drain Reconnect the drain pipes correctly so that air pockets are
pipes. not created.
Installed collection Install the mist collector unit so that the collection container
container higher than is lower than drain port.
drain port.

4.14.5 Abnormal Noise or Vibration Emitted from Motor

Possible Cause Corrective Measure
Defective installation. Confirm the mist collector is installed in applicable location.
Check the bolts securing the mist collector unit and the
base. If the bolts are loose, retighten.
Damaged bearing. Bearing replacement is necessary. Contact your Makino
service representative for assistance.
Clogged motor. Must remove foreign material from the motor. Contact your
Makino service representative for assistance.
Clogged rotating Must remove foreign material from the rotating components.
components. Contact your Makino service representative for assistance.

4.14.6 Oil Leaks from Duct Connection Point

When the collected oil leaks from duct connection point, connect the duct and hose duct
correctly.

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4.15 Automatic Tool Length Measurement

4.15.1 Repeatability of Measured Value is not Good
Possible Cause Corrective Measure
Mounting bolts on tool Check the mounting bolts on the tool length sensor unit
length sensor unit are loose. and retighten any loose bolts.
Mounting bolts on touch Check the mounting bolts on the touch sensor and
sensor are loose. retighten any loose bolts.
Measuring section is worn Check the measuring section and replace the worn or
or damaged. damaged parts if necessary.
Electrical cable connection Check the electrical cable is correctly connected. If the
failure or disconnection. cable is broken, replace the cable.
Chips adhering to the cover Clean the cover or the tip of the stylus to remove the
or the tip of the stylus. chips.
Low main air pressure. Set the main air pressure to 0.5Mpa.

4.15.2 Measured Results Are Not Correct

Possible Cause Corrective Measure
Electrical cable shield Check the electrical cable shield and repair or replace the
(ground) failure. damaged parts if necessary.
Voltage supply may be Confirm the output voltage on the regulator in the machine
unstable. controller is DC24V ± 10%. If the voltage is not within the
above tolerance range, the regulator may be broken.
Contact your Makino service representative for assistance.
Mounting bolts on tool Check the mounting bolts on the touch sensor and
length sensor unit are loose. retighten the loose bolts.
Mounting bolts on touch Check the mounting bolts on the touch sensor and
sensor are loose. retighten the loose bolts.
Measuring section is worn Check the measuring section and replace the worn or
or damaged. damaged parts if necessary.

4.15.3 Emergency Stop status is activated during

Positioning
Possible Cause Corrective Measure
Manual operation mistake. When the stylus touches an obstacle during measuring
positioning movement, the emergency stop status is
activated.
Tool length data has been Confirm the tool data on the tool data screen.
recorded Incorrectly.

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4.15.4 Stylus Cleaning Air is not Supplied
Possible Cause Corrective Measure
Solenoid valve SOL301 is Check the solenoid valve SOL301 and replace the
malfunctioning. damaged parts if necessary.
Cleaning air piping route is Check the piping route and repair or replace the abnormal
abnormal. part if necessary.
Receiver cleaning air flow Check the receiver cleaning air flow rate is correct.
rate is not adequate.

4.16 Automatic Workpiece Measuring Unit

4.16.1 Emergency Stop status is activated during
Positioning
Possible Cause Corrective Measure
Manual operation mistake. When the stylus touches an obstacle during measuring
positioning movement, the emergency stop status is
activated.

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5. Machine Maintenance
5.1 Maintenance Screen
The maintenance screen is used to modify machine setting, restore operation and perform
adjustments when the machine is stopped due to an abnormal condition. Below is the
maintenance menu available in Professional P controller.

Figure 5.1a: Maintenance Screen.

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Machine operator may need to login the user privilege level before he/she can activate
certain maintenance functions. (Refer to “User Management” section of the operation
manual for the details of the user privilege level).

Maintenance menu Description

Regular Maintenance This menu provides list of predefined maintenance actions
necessary to keep the machine in good conditions. There
are 4 periodic maintenance:
• 24 hours (daily)
• 500 hours
• 2000 hours
• 6000 hours
Custom Regular This menu provides additional list of maintenance actions.
Maintenance Up to 10 customized maintenance actions can be
registered. The maintenance period is also customizable.
ATC Maintenance This menu provides provision to adjust and restore
operation during ATC failure.
Fixture Maintenance This menu is optional. It is available when machine is
equipped with fixture hydraulic option. This menu enables
the manual operations related to the
component/workpiece’s fixture.
User Management Only supervisor and Makino user privilege levels can
access this menu. It is used to manage the privilege levels
of the machine’s users.
Coolant Management This menu provides the status of the cutting fluid and
machine auto grease functions.

Note: auto grease is optional function.

Data Management Only supervisor and Makino user privilege levels can
access this menu. It is used to enable/disable customized
optional functions, obtain machine operation logs and
other machine data.
Machine Parameter This menu is used to modify machine settings.
NC Parameter This menu is a shortcut to the NC Fanuc parameter
screen.

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5.1.1 ATC Maintenance Screen

ATC maintenance screen is provided for each of the following units:

• ATC solenoid maintenance

• ATC magazine solenoid maintenance
• ATC magazine servo maintenance
• ATC arm maintenance

In this manual context, the term “maintenance mode” normally has the same meaning as
“ATC maintenance mode”. Maintenance mode enable can be protected by password in
the “User Management” screen.

Procedure to enable maintenance mode:

1) You may need to login if the maintenance mode is protected with a password.
2) Press [CUSTOM 2] key on MDI keyboard to display “Navigation Menu” screen.
Press [MAINT MENU] softkey, the press [ATC MAINTENANCE] on the screen.
3) On the “ATC MAINTENANCE” screen, press [MAINT MODE] softkey to activate
maintenance mode.
4) If warning EX2040 MACHINE NOT STOP appears, reset the warning and press
[NC RESET] key on MDI keyboard. Then try the above steps again.

1
2

3 4
7

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Item Description
1 Items which maintenance can be performed. These include ATC solenoids
and ATC arm motor.
2 Name and status of related signals.
3 Action mode

Single mode:
Movement is performed to the end point (single step) when [ON] button is
pressed.

Jog mode:
Movement is performed while the [ON] button is pressed. It stops when the
button is released.
4 Action
Press [ON]/[OFF] button to actually perform the maintenance operation.
5 Maintenance advice
It displays error message when the maintenance operation cannot be
performed.
6 ATC magazine servo maintenance items.
7 Information about ATC arm position and ATC magazine.

Operation procedure:

1) Please observe the following conditions before doing ATC maintenance operation.
• Please ensure the ATC arm and the ATC magazine are in stop condition.
• Ensure all the feed axes (X, Y, Z, 4, 5) are in the safe position.
• Press [NC RESET] key on MDI keyboard.
• Release ATC manual intervention mode on the ATC operation panel.
• Release tool call mode on the “Tool Data Management” screen.
• Turn on [MAINT MODE] softkey on the screen.
2) In normal situation, you need to move Z-axis to the 2nd reference position and do
spindle orientation.
3) If step 2 is not established due to the ATC arm position not standby, press [OT
RELEASE] button on the main operator panel while activating the ATC
maintenance item.

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5.1.2 Confirming Signal Status and Errors

5.1.2.1 Confirming Signal Status

ATC signal status can be viewed in the ATC maintenance screen directly.

The first column indicates each item description. The next column displays the
corresponding solenoids/actuators status, symbol and address. The last column displays
the items limit switch status, symbol and address.
The current value of the input and output are represented by the Yellow and Green circles.
When the value is 1, the circle is green, when the value is 0, the circle is Yellow.
When the symbol and addresses are black in color, it indicates that the status is in ATC
Standby/Home condition. When they are red in color, it indicates that the status us not in
ATC Standby/Home condition.

5.1.2.2 Confirming Maintenance Advice

Maintenance advice is displayed on the right side of the ATC maintenance screen. Based
on the operation being performed, the advice will automatically update to inform the
required conditions to activate the selected operation.

When there is maintenance advice visible in the screen above, the operation selected
cannot be activated. It is possible to override this condition by pressing the OT Release
button.

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5.2 ATC
The Automatic Tool Changer (ATC) is an integral part of the machine and needs to be
properly maintained to preserve it in good working condition. The ATC system has been
designed with features and functions to assist the operator in performing these operations
easily and efficiently. The operator should familiarize himself with the maintenance
procedures to minimize the downtime of the machine during maintenance or recovery
operations.

5.2.1 ATC Maintenance Items

The ATC maintenance screen allows the operator to individually control the operation of
the following solenoids/actuators:

1) ATC Shutter Open

2) ATC Shutter Close
3) ATC Magazine Pot Horizontal
4) ATC Magazine Pot Vertical
5) ATC Arm Forward (M6 Direction)
6) ATC Arm Reverse

By controlling the above items, the operator is able to perform any maintenance operation
or recover the ATC from any abnormal stop condition.

5.2.2 ATC Operation Outline

A single Tool change process involves the operation of many mechanisms in a
synchronized sequence. The basic outline of the ATC operation is:

1) Z Axis move to 2nd Reference Position

2) Spindle Orientation
3) Coolant OFF
4) ATC Shutter Open
5) ATC Pot Vertical
6) ATC ARM Forward
7) Spindle Unclamp
8) ATC ARM Forward
9) Spindle Clamp
10) ATC ARM Forward
11) ATC ARM Stop at Standby Position
12) ATC Pot Horizontal
13) ATC Shutter Close

The above sequence is a basic sequence of ATC operation. The actual tool change
sequence on the machine may differ based on the options selected.

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5.2.2.1 ATC Operation Flow Chart

M6 Start

Z Axis Interlock

Shutter Open

Pot Vertical

ATC Arm Forward

Tool Unclamp

Yes
Time Over ATC Arm Stop

No

ATC Arm Forward

Tool Clamp

Yes
Time Over ATC Arm Stop

No

ATC Arm Forward

No
Arm Home

Yes
Arm Motor Stop

M6 NC Finish Pot Horizontal

Shutter Close

M6 Finish

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5.2.3 ATC Restore Procedure
To restore the ATC to standby position manually during an abnormal stoppage requires
understanding of the ATC operation sequence. To facilitate ease of operation, an Auto
Recovery Function is also available for the operator.

Please observe the following conditions before doing ATC maintenance operation.

• Please ensure the ATC arm and the ATC magazine is in stop condition.
• Ensure all the feed axes (X, Y, Z, 4, 5) are in the safe position.
• Press [NC RESET] key on MDI keyboard.
• Release ATC manual intervention mode on the ATC operation panel.
• Release Tool Call mode on the “Tool Data Management” screen.
• Turn on [MAINT MODE] softkey on the ATC Maintenance screen.

Note that tool data is not updated in maintenance mode. After any operation of the ATC in
Maintenance Mode, always check and ensure that the tool data is correct.

5.2.3.1 ATC Manual Restore Procedure

To return the ATC to standby condition requires the following conditions to be established.

• ATC Shutter Close

• ATC Magazine Pot Horizontal
• ATC Arm Home Position

ATC shutter close operation requires the following conditions to be established.

• ATC Magazine Pot Horizontal

• ATC Arm Home Position

ATC magazine pot horizontal operation requires the following conditions to be established.

• ATC Shutter Open

• ATC Arm Home Position

To return the ATC arm to home position requires the following conditions to be
established.

• ATC Shutter Open

• ATC Magazine Pot Vertical
• Spindle Orientation
• Spindle Clamp or Unclamp depending on current ATC Arm Position

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• Select each Item on the ATC maintenance screen and refer to the ATC advice to
recover the ATC to standby position.
• For ATC arm forward and reverse operations refer to the arm angle and zone
display.
• ATC arm speed can be adjusted by pressing the ARM SPD 1 Button
• Press OT RELEASE to bypass the interlock conditions if necessary.
• Take additional care when operating under OT release mode.

5.2.3.2 ATC Auto Recovery Operation

The ATC Auto Recovery function is a one touch function that checks the current positions
of every ATC limit switch and sensor and automatically controls the appropriate
solenoids/actuators to return the ATC to standby position.

Single Mode Operation

• In Single Mode, when the “ON” button is pressed, the ATC will start moving and
stop automatically when the ATC is in Standby Condition.
• While the ATC is in movement, it can be stopped by pressing the “OFF” button.

Jog Mode Operation

• In Jog Mode, when the “ON” button is pressed, the ATC will start moving.
• When the “ON” button is released, the ATC will stop immediately.
• When the ATC reaches Standby condition, it will stop automatically even if the “ON”
button is still pressed.

After the Auto Recovery operation, always check and ensure the tool data is correct.

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5.3 ATC Magazine

5.3.1 ATC Magazine Maintenance Screen
The ATC magazine maintenance items are incorporated together with the ATC actuators
into the ATC maintenance screen.

Figure 5.3.1a: ATC Maintenance Screen.

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5.3.2 ATC Magazine Operation Outline

The ATC magazine is a ring type magazine that can rotate clockwise or counter-
clockwise. As the ATC magazine cannot be viewed when the operator is standing at the
main operator panel, the clockwise (CW) and counter-clockwise (CCW) buttons are
located at the ATC operator panel on the left of the machine. The ATC magazine can
operate in the following modes:

Symbol Description
REF MODE Magazine is referenced to pot 1 position.
INCH MODE Magazine moves a fixed distance each time CW/CCW is pressed.
INDEX MODE Magazine automatically moves to the nearest Pot after CW/CCW
button is released.
JOG MODE Magazine stops immediately when CW/CCW button released.

5.3.3 ATC Magazine Operation Procedure

To operate the ATC magazine, perform the following steps:

1) Enable [MAINT MODE].

2) Enable [ATC OP PANEL].
3) Select “MAGAZINE ROTATION”.
4) Select an operation mode (REF/INCH/INDEX/JOG).
5) Enter an inching amount if in “INCH Mode”.
6) Select a rotation speed.
7) Press the CW or CCW button on the ATC operator panel.

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6. Periodic Maintenance
6.1 Outline/Precautions
• Read “Chapter 2 Safety” in maintenance manual thoroughly and ensure
adequate precautions are taken before performing inspections and
Maintenance.
• Stop the machine, turn the control and Main power supplies OFF and perform
“Lockout/Tagout” before performing inspections and maintenance except for
some inspections that must be performed with power ON.
• When the operator door must remain open to perform maintenance or
inspections, open the door then turn OFF power supply.
• If the machine is equipped with a door lock system (option), turn the release key
to the 'UNLOCK' position and enter the machining chamber/tool magazine with
the key to prevent the possibility of being locked-in. Turn the key to the 'LOCK'
position and remove the key when finished. The release key must be placed in
the hands of supervising personnel.
• Main power is automatically turned OFF following specified time after control
power is turned OFF.
• Press emergency stop switch or turn OFF power before entering the machining
chamber, column room and/or Tool Magazine. Take care to avoid slipping when
performing Maintenance within the machining chamber, column room and/or
tool magazine.
• Periodic inspection of ambient air quality is recommended to ensure optimum
machine operation environment.

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Machine inspections and maintenance must be performed regularly to maintain optimum

machining accuracy and long-term performance.

Periodic maintenance is classified as follows:

1) Periodic Maintenance irrespective of accumulated machine operation time.

• Daily or Pre-Operation Maintenance
• Post-Operation Maintenance
• Monthly Maintenance
• Bi-annual Maintenance
• Annual Maintenance
• 2-Year Maintenance
2) Maintenance based on accumulated machine operation time.
• Maintenance schedule differs when based on accumulated machine operation time.
• Perform Maintenance according to the following time table.

Machine Operation Time/Day

16 hours 24 hours
160 hours 2 weeks 7 days
500 hours 1.5 months 1 month
1000 hours 3 month 2 months
2000 hours 6 months 4 months
6000 hours 1.5 years 1 year
12000 hours 3 years 2 years
20000 hours 5 years 3 years
.

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6.2 Periodic Maintenance Lists

6.2.1 Daily / Pre-Operation Inspection Maintenance
Unit Refer Maintenance Point
Spindle 6.3.1 Clean spindle taper
6.3.2.1 Check sealing rod rubber seal (BT)
6.3.3.1 Check o-rings in sleeve (HSK)
Tool Magazine 6.6.1 Clean tool / pot
Spindle Cooling Oil 6.7.1 Check cooling oil level
Temperature Controller
Spindle Lubrication (Oil Air) 6.8.1 Check lubricant level
Device
Hydraulic Unit 6.9.1 Check hydraulic oil level
Pneumatic Unit 6.10.3 Check main air supply pressure
6.10.5 Check scale air pressure
Chip Disposal/Cutting Fluid 6.11.1 Check cutting fluid level and replenish if
Supply Unit necessary
6.11.5 Check through–spindle coolant line filter
Axes Telescopic Cover 6.13 Check wiper
Splash Guard Front Door 6.14 Check glass and polycarbonate
Glass
Tool Length Sensor Unit 6.15.2 Clean sensor unit
Automatic Workpiece 6.15.3.1 Check and clean the measuring probe/
Measuring Unit receiver

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Spindle Taper Cleaning Scale Air Too/Pot Cleaning

Rubber Seal Inspection (BT) Pressure Check
O-ring Inspection (HSK)

Main Air Cooling Oil

Pressure Level Check
Check

Hydraulic Oil Inner Conveyor

Level Check Drain Holes
(Perforated
Sheet) Cleaning

Lubricant Level Through Spindle Cutting Fluid

Check Coolant Filter Check Level Check

Figure 6.2.1a: Daily Inspection Maintenance.

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6.2.2 Post-Operation Maintenance
Unit Maintenance Point
Machining Chamber Clean machining chamber
ATC Unit Clean ATC unit

• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the 'UNLOCK' position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the “LOCK” position and remove
the key when finished. The Release key must be placed in the hands of
supervising personnel.
• Remove the tool and leave an empty tool holder in the spindle when cleaning the
inside of the machining chamber.
• Do not use compressed air.

Cleaning (post operation):

1) Open the ATC shutter completely in maintenance mode.

2) Open the operator door.
• Door lock specifications (option): insert the release key into the door switch and
turn to “UNLOCK” position before entering the machining chamber.
3) Turn OFF the power supply.
4) Clean the followings:
• Table, x-axis, tool length sensor unit (option)
• Table top surface
• ATC shutter, shutter rails, ATC arm/gripper
• X, Y & Z-axis telescopic cover(s)
• Inner conveyor drain holes (perforated sheet)
5) After cleaning, close the operator door
• Door lock specifications (option): turn the release key to 'LOCK' position and
remove from the door switch.
6) Turn ON the power supply.
7) Close the ATC shutter completely in maintenance mode.

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6.2.3 Monthly Maintenance

Unit Refer Maintenance Point
Chip Disposal/Cutting Fluid 6.11.3 Clean coolant tank filters
Supply Unit

6.2.4 Biannual Maintenance

Unit Refer Maintenance Point
ATC Tool Magazine 6.5.1 Check cam box lubricant level and replenish if
6.5.2 necessary
6.6.2 Supply grease to Magazine drive gear
Automatic Work Measuring 6.15.3.4 Check and replace diaphragm (Renishaw)

6.2.5 Annual Maintenance

Unit Refer Maintenance Point
Chip disposal / Cutting Fluid 6.11.4 Replace pump mechanical seal kit
Supply 6.11.2 Clean coolant tank (clean tank and dirty tank)
Machine Controller 6.12.1 Replace absolute pulse coder battery
Machine Controller 6.12.2 Replace NC backup battery

6.2.6 160-Hour Maintenance

Unit Refer Maintenance Point
Spindle Temperature 6.7.2 Clean air filter mesh
Controller

6.2.7 500-Hour Maintenance

Unit Refer Maintenance Point
Spindle 6.3.4 Supply lubricant to collet (HSK)
Feed Axis 6.4.1 Supply manual grease to all the grease point

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6.2.8 2000-Hour Maintenance
Unit Refer Maintenance Point
6.3.2.2 Replace sealing rod rubber seal (BT)
Spindle
6.3.3.2 Replace o-ring in sleeve (HSK)
6.6.3 Supply grease to pot up/down cylinder guide
ATC Tool Magazine
Check tool pot sliding track
Hydraulic Unit 6.9.1 Replace hydraulic oil
Pneumatic Unit 6.10.4 Replace main air unit filter
6.10.5 Replace scale air filter element
Chip Disposal/Cutting Fluid 6.11.5 Replace line filter for through-spindle coolant
Supply Unit (1.5Mpa)
Spindle Lubrication (Oil Air) 6.8.2.1 Clean suction filter
Device 6.8.2.2 Clean line filter

6.2.9 6000-Hour Maintenance

Unit Refer Maintenance Point
6.6.4 Change ATC arm gripper spring
ATC Tool Magazine
6.6.5 Replace sliding pad
Spindle Temperature 6.7.3 Replace line filter for ballscrew
Controller
Spindle Lubrication (Oil Air) 6.8.2.1 Replace suction filter
Device 6.8.2.2 Replace line filter

6.2.10 12000-Hour Maintenance

Unit Refer Maintenance Point
ATC Tool Magazine 6.5.3 Replace cam box lubricant oil
Spindle Temperature 6.7.1 Replace oil
Controller

6.2.11 20000-Hour Maintenance

Unit Refer Maintenance Point
Spindle 6.3.5 Replace spindle rotary union/rotary union
support bearing

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6.2.12 Alarm-Related Maintenance

Alarm Unit Refer Maintenance Point
No.
EX1090 Spindle Lubrication 6.8.1 Check lubricant level and replenish if
(Oil/Air) Device necessary
EX1535 Chip disposal / Cutting 6.11.5 Clean/replace through-spindle line
fluid supply unit filter
EX1443 6.12.1 Replace absolute pulse coder battery
Machine Controller
6.12.2 Replace NC backup battery
EX1586 Automatic Grease 6.15.1 Replace grease cartridge
Supply
EX1180 Automatic Workpiece 6.15.3.2 Replace probe battery
Measuring 6.15.3.3

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6.3 Spindle
6.3.1 Spindle Taper Cleaning
• Press the [EMERGENCY] stop switch prior to performing the following procedure.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the "UNLOCK" position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the "LOCK" position and remove
the key when finished. The release key must be placed in the hands of supervising
personnel.

Daily cleaning:

1) Return the tool from spindle to the tool magazine.

2) Move the spindle (z-axis) to the operator comfortable down position.
3) Open the operator door.
4) Press the [EMERGENCY] switch to set the machine in the emergency stop
condition.
5) Enter the machining chamber.
6) Clean the spindle taper with white cloth.
• Do not use compressed air inside machining chamber. This is to prevent cutting
chips/fluid entering into the spindle. The spindle seal gets damaged if cutting
chips/fluid enters the spindle.
7) After cleaning, close the operator door and release the emergency stop condition.

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6.3.2 Sealing Rod (BT)

6.3.2.1 Checking Sealing Rod Rubber Seal

• Press the [EMERGENCY] stop switch prior to performing the following procedure.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the "UNLOCK" position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the "LOCK" position and remove
the key when finished. The release key must be placed in the hands of supervising
personnel.

Daily inspection:

1) Return the tool from spindle to the tool magazine.

2) Move the spindle (z-axis) to the operator comfortable down position.
3) Open the operator door.
4) Press the [EMERGENCY] switch to set the machine in the emergency stop
condition.
5) Enter the machining chamber.
6) Visually check for any damages such as cracks or cutting chips adhering to the
rubber seal in the sealing rod.
7) Remove any chips adhering to the sealing rod. Replace the rubber seal/o-ring
immediately if damaged or worn.

Sealing Rod Rubber Seal

Figure 6.3.2.1a: Sealing Rod Rubber Seal Inspection.

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6.3.2.2 Replacing Sealing Rod Rubber Seal

• Press the [EMERGENCY] stop switch prior to performing the following procedure.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the "UNLOCK" position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the "LOCK" position and remove
the key when finished. The release key must be placed in the hands of supervising
personnel.

Replacement part:

Name Type Part No. Qty

Rubber Seal - 13M11G704 1

Replacement (every 2000 hours):

1) Return the tool from the spindle to tool magazine.

2) Turn ON the [MACHINE LOCK] and [AUX. FUNC LOCK] switches on the main
operation panel.
• Tool unclamp function is disable in emergency stop condition. [MACHINE LOCK]
and [AUX. FUNC LOCK] functions enable tool unclamp.
• Tool unclamp is disabled unless the operator door is open.
3) Press the [HANDLE] switch to turn the handle mode ON.
4) Open the operator door.
5) Confirm that the [TOOL UNCLAMP] switch is OFF (the spindle is clamped).
6) Screw the T-wrench into the tapped hole in the end of the Sealing rod.
• T-wrench is supplied with the machine.
7) Push the T-wrench in and rotate 90° CW to release the hook. The sealing rod is
pushed out by the internal spring.
8) Press the [TOOL UNCLAMP] switch to unclamp the spindle, then remove the T-
wrench and sealing rod from the spindle.
9) Replace the rubber seal installed in the sealing rod.
10) Apply a small amount of medium-strength thread-locking adhesive to the Inner
sleeve thread area.
11) Assemble the inner sleeve, sleeve and rubber seal using a T-wrench in the reverse
order (tightening torque: 20Nm).
12) Confirm that the rubber seal projects evenly by 0.7 ± 0.1mm.
13) Press the [TOOL UNCLAMP] switch to clamp the spindle Tool.

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Rubber Seal

Hook

Inner
Sleeve
Sealing
Rod

T-Wrench CW

(Unclamp)

T-Wrench

Figure 6.3.2.2a: Sealing Rod Rubber Seal Replacement.

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6.3.3 O-Ring in Sleeve (HSK)
6.3.3.1 Checking Sleeve O-Ring(s)

• Press the [EMERGENCY] stop switch prior to performing the following procedure.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the "UNLOCK" position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the "LOCK" position and remove
the key when finished. The release key must be placed in the hands of supervising
personnel.

Daily inspection:

1) Return the tool from spindle to the tool magazine.

2) Move the spindle (z-axis) to the operator comfortable down position.
3) Open the operator door.
4) Press the [EMERGENCY] switch to set the machine in the emergency stop
condition.
5) Enter the machining chamber.
6) Visually check for any damages such as cracks or cutting chips adhering to the
rubber seal in the sealing rod.
7) Remove any chips adhering to the sealing rod. Replace the rubber seal/o-ring
immediately if damaged or worn.

Sleeve

O-Ring
O-Ring Backup
Ring

Figure 6.3.3.1a: Sleeve O-Ring Inspection.

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6.3.3.2 Replacing Sleeve O-Rings

• Confirm the "MACHINE LOCK" and "AUXILIARY FUNCTION LOCK" functions

are activated prior to entering the machine.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key
to the "UNLOCK" position and enter the machining chamber with the key to
prevent the possibility of being locked-in. Turn the key to the "LOCK" position
and remove the key when finished. The Release key must be placed in the
hands of supervising personnel.

Replacement part:

Name Type Part No. Qty

O-Ring P12 (FKM) Z261A7101201 1
O-Ring S14 (FKM) Z261P2101402 1
Backup Ring SUN-BP-12 Z269A1301201 1

Replacement (every 2000 hours or when damage noted):

1) Return the tool from the spindle to tool magazine.

2) Turn ON the [MACHINE LOCK] and [AUX. FUNC LOCK] switches on the main
operation panel.
3) Press the [HANDLE] switch to turn the handle mode ON.
4) Open the operator door.
5) Press the [TOOL UNCLAMP] switch to unclamp the spindle.
• Tool unclamp is disabled unless the operator door is open.
6) While holding the sleeve with the spanner wrench, remove the Inner sleeve with a
hexagonal wrench.
7) Remove the two o-rings and backup ring from the inner sleeve.
8) Install the new (P12) o-ring and backup ring inside the inner sleeve and (S14) o-
ring on the Inner sleeve.
9) Apply a small amount of medium-strength anaerobic thread adhesive to the Inner
sleeve thread area and install (tightening torque: 35Nm).
• Care must be taken to prevent the adhesive from adhering to the o-rings.
• Do not turn ON the through-spindle coolant until the adhesive sets (approximately
10minutes).
O-Ring (S14)
Inner
Sleeve

Sleeve
Backup Ring
O-Ring (P12)
Figure 6.3.3.2a: Sleeve O-Ring Replacement.

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6.3.4 Collet Lubrication (HSK)
• Confirm the "MACHINE LOCK" and "AUXILIARY FUNCTION LOCK" functions are
activated prior to entering the machine.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the "UNLOCK" position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the "LOCK" position and remove
the key when finished. The Release key must be placed in the hands of
supervising personnel.

Lubrication (every 500 hours):

1) Return the tool from the spindle to tool magazine.

2) Turn ON the [MACHINE LOCK] and [AUX. FUNC LOCK] switches on the main
operation panel.
3) Press the [HANDLE] switch to turn the handle mode ON.
4) Open the operator door.
5) Press the [TOOL UNCLAMP] switch to unclamp the spindle.
• Tool unclamp is disabled unless the operator door is open.
6) Spray the front and rear ends of the collet with grease.
• Spray type grease: Kluber L801
• Insufficient lubricant may hinder proper tool clamping.

Collet
Grease
Spray

Spray
Nozzle
Sleeve

Figure 6.3.4a: Grease Application of Collet.

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6.3.5 Spindle Rotary Union/Rotary Union Support Bearing

Replacement
Replacement (every 20000 hours):

A seal is installed in the spindle rotary union. This seal wears from rotating and needs to
be replaced. A grease bearing is used for the spindle rotary union. The bearing needs to
be replaced as the grease in the bearing deteriorate.

The above parts must be replaced regularly. For replacement, contact Makino Service
Representatives for assistance. The back up rings and o-rings shown in the figure below
must be replaced together with the spindle rotary union bearing.

Figure 6.3.5a: Spindle Rotary Union and Rotary Union Support Bearing Replacement.

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6.4 Feed Axis

6.4.1 Feed Axis Ballscrew/Linear Guide Grease Supply
Replacement part:

Name Type Part No. Qty

Grease Cartridge (Manual) GKL-2-040 Z192A0200008 1

Manual grease supply (every 500 hours):

The manual grease supply operation is required for machines without automatic grease
supply unit. Move all the axes slowly (5-10m/min) and operate the lever for a minimum of
75 times. Ensure that the cartridge is filled with grease before the start of the greasing
operation.

Grease
Pump
Lever

Figure 6.4.1a: Manual Grease Supply.

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6.5 ATC Unit

6.5.1 Cam Box Lubricant Level Check
• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the "UNLOCK" position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the "LOCK" position and remove
the key when finished. The release key must be placed in the hands of supervising
personnel.

Inspection (bi-annually):

1) Return all axes to reference position.

2) Open left front door and locate the rubber plug at the upper left corner.
3) Open the plug and check the lubricant level on the indicator. When the level is
above the half indicator, it is adequate. If the level is below the half indicator,
replenish lubricant by the following procedure.

Rubber Plug Level Indicator

Figure 6.5.1.1a: ATC Cam box Oil Level Check.

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6.5.2 Cam box Lubricant Replenishment
• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the "UNLOCK" position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the "LOCK" position and remove
the key when finished. The release key must be placed in the hands of supervising
personnel.

Replenishment:

1) Return all axes to reference position.

2) Open the top covers.
3) Replenish the specified lubricant from the oil inlet.
4) Confirm the lubricant level from the level indicator.

Covers Oil inlet

Figure 6.5.1.2a: Cam box Lubricant Replenishment.

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6.5.3 Cam box Lubricant Replacement

• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the "UNLOCK" position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the "LOCK" position and remove
the key when finished. The release key must be placed in the hands of supervising
personnel.

Replacement (every 12000 hours): Oil inlet

1) Return all axes to reference position.
2) Open the covers.
3) Remove the drain plug to drain the lubricant.
4) Install back the drain plug.
5) Fill lubricant from the oil inlet.

Covers

Drain Hole
Figure 6.5.1.3a: Cam box Lubricant Replacement.

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6.6 Tool Magazine

6.6.1 Tool Shank Check/Cleaning and Tool Pot Key Check
Daily inspection or cleaning:

1) Check tools and clean the parts specifically indicated below:

• BT: tool taper, retention knob end surface
• HSK: tool taper, tool clamping area clamping face, lubrication pipe.
2) Confirm the specified o-rings are attached to the tool shanks properly.
3) Check and clean the outer surface of the pot and Inner surface of the tapered
section to remove chips.
4) Check the pot key visually for damage. If any damage is found, contact Makino
service representatives for assistance.

BT Tool Pot Key HSK Tool Pot Key

Figure 6.6.1a: Tool Pot Key.

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• Ensure that lubrication pipes are attached to all tools.

• Attach lubrication pipe to all tools. Spindle is damaged by coolant entering inside if
coolant is discharged without attaching lubrication pipe.

Figure 6.6.1b: Tool Shank Inspection/Cleaning.

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6.6.2 Grease Application to Drive Gear
• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.

Grease supply (bi-annually):

1) Turn OFF the power supply.

2) Open the ATC window and remove the ATC magazine cover.
3) Apply grease to the drive gear with a brush.

Drive Gear

Magazine Cover

Figure 6.6.2a: Grease Application to Drive Gear.

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6.6.3 Grease Application of Pot Up/Down Cylinder Rod

• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.
• Exercise extreme caution as early into the machine is necessary in order to
perform the following procedure.

Grease supply (every 2000 hours):

1) Turn OFF the power supply.

2) Open the ATC window and remove the ATC magazine cover.
3) Apply grease to the pot up/down cylinder rod with a brush.

Cylinder Rod

Magazine Cover

Figure 6.6.3a: Grease Application of Pot Up/Down Cylinder Rod.

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6.6.4 Replacement of Arm Gripper Plunger Spring
• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.
• Exercise extreme caution as early into the machine is necessary in order to
perform the following procedure.

Replacement part:

Name Type Part No. Qty

Spring (push rod) CA766008 - 2

Replacement (every 6000 hours):

1) Turn OFF the power supply.

2) Remove the plunger stopper at the ATC arm gripper.
3) Remove the plunger together with the spring.
4) Replace the spring and apply grease to the spring with a brush.

ATC Arm

Arm Gripper

Plunger Plunger Stopper Spring

Figure 6.6.4a: Replacement of Arm Gripper Plunger Spring.

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6.6.5 Replacement of Tool Pot Sliding Pad

• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the "UNLOCK" position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the "LOCK" position and remove
the key when finished. The release key must be placed in the hands of supervising
personnel.

Replacement part:

Name Type Part No. Qty

Sliding Pad CA402405 - 60

Replacement (every 6000 hours):

1) Turn OFF the power supply.

2) Remove the screw and sliding pad.
3) Replace the sliding pad and apply grease to the sliding pad with a brush.

Sliding Pads

Figure 6.6.5a: Replacement of Tool Pot Sliding Pad.

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6.7 Spindle Cooling Oil Temperature Controller

6.7.1 Checking/Replacing of Cooling Oil
Daily inspection:

1) Check the oil level is between the upper (HIGH) and lower (LOW) limits on the oil
level indicator.
2) If the oil is insufficient, replenish following the procedure below:
3) Turn the power supply OFF.
4) Open the filter cap on the oil inlet.
5) Add cooling oil up to the upper (HIGH) limit on the oil level indicator.

Replacement (every 12000 hours):

1) Turn the power supply OFF.

2) Open the filter cap on the oil inlet.
3) Remove the drain port plug to completely drain the oil.
4) Wrap the threads of the drain plug with sealing tape and install.
• When using sealing tape, leave the first two threads free of tape to prevent
contaminating the oil reservoir.
5) Add oil up to the upper (HIGH) limit on the oil level indicator.
6) Install the filter cap.
• Failure to tighten the filter cap will cause the oil to overflow.
• Tighten the filter cap by hand. Do not over-tighten with a tool.
7) Confirm the oil level with power ON.

Line Filter

Air Filter
Condenser Coil

Oil Inlet High

Filter Cap Low

Oil Level Indicator

Drain Port

Figure 6.7.1a: Checking and Cleaning of Cooling Oil.

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6.7.2 Cleaning of Air Filter and Condenser Coil

Cleaning (every 160 hours):

1) Turn OFF the power supply.

2) Pull upward on the handle to remove the air filter.
• The condenser coil is visible after removing the filter.
3) Clean the condenser coil fins with a brush. If necessary, wash with detergent and
rinse with water to remove dust and foreign particles from the gaps between the
fins.
4) Remove dust from the air filter with a vacuum cleaner. Wash the filter with
detergent and rinse with water if necessary. Allow the filter to dry completely before
reinstallation.
• Do not use benzene or thinner.
5) To reinstall, place the air filter into the upper guide from above and lower into
position.

Lift Up and Remove the Air Filter

Air Filter
(Condenser Coil is Overlapping Behind)

Figure 6.7.2a: Cleaning of Air Filter and Condenser Coil.

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6.7.3 Line Filter Element Replacement
• Turn OFF the power supply and perform “Lockout/Tagout” prior to performing the
following procedure.
• If the filter is changed without reducing the internal pressure, oil overflow,
component damage and serious injury may occur.

Replacement part:

Name Type Part No. Qty

Line Filter Element 0060D010BH4HC - 1

Replacement (every 6000 hours or at alarm):

1) Turn OFF the power supply.

2) Unscrew the nut at the bottom of the filter element.
• Prepare a container to collect the dripping oil from the filter.
3) Replace the filter element.
4) Reverse the above procedure to reassemble the filter element
5) After replacement, turn ON the power supply then allow the spindle oil flow to
check for oil leakage from the filter.

Line Filter

Filter Element
(Inside)

Figure 6.7.3a: Line Filter Element Replacement.

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6.8 Spindle Lubrication (Oil Air) Device

6.8.1 Checking/Replacement of Lubricant
• A low level of lubricant may interrupt machining due to oil circulation abnormalities.
• Take care to prevent contamination when adding or replacing lubricant.

Daily inspection:

1) Check that the lubricant level is between the upper (H) and lower (L) limits on the
oil level indicator.
2) If the lubricant level is below the lower limit (L) or an alarm is triggered, replenish
the oil by following the procedure below.
3) Turn OFF the power supply.
4) Open the filter cap on the oil inlet.
5) Add lubricant up to the upper limit (H) on the oil level indicator.
6) Install the filter cap.
7) Confirm the lubricant level with power ON.

Pressure 'H'
Gauge

Oil Air Device

Oil Inlet

Figure 6.8.1a: Spindle Lubrication (oil Air) Device Check.

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6.8.2 Cleaning/Replacement of Suction and Line Filters
After cleaning or replacing the spindle lubrication device suction and line filters, ensure air
is removed from the oil piping.

6.8.2.1 Suction Filter Cleaning/Replacement

• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.

Replacement part:

Name Type Part No. Qty

Suction Filter SF01 ZDDM02-4 1

Cleaning (every 2000 hour or at alarm):

Replacement (every 6000 hours or at alarm):

1) Turn OFF the power supply.

2) Remove the two screws to remove the cover [1].
3) Remove the four screws on the cover [2] to remove the tank from below.
4) Remove the four screws on the bottom of the suction filter and remove the filter to
clean or replace.
5) Install the filter, tank and covers.
6) Remove air in the oil piping.

Top View

Cover [1]

Screws
Screws
Screws

Cover [2] Screws

Cover [2]
Suction Filter

Figure 6.8.2.1a: Suction filter Cleaning / Replacement.

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6.8.2.2 Line Filter Cleaning/Replacement

• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.

Replacement part:

Name Type Part No. Qty

Line Filter P6003L ZDDM02-3 1

Cleaning (every 2000 hours or at alarm):

Replacement (every 6000 hours or at alarm):

1) Turn OFF the power supply.

2) Remove the four screws on the cover [3] to remove the line filter tank.
3) Remove the line filter to clean or replace.
4) Install the filter, tank and covers.
5) Remove air in the oil piping.

Top View

Screw

Cover [3]

Line Filter

Figure 6.8.2.2a: Line Filter Cleaning/Replacement.

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6.8.3 Oil Piping Air Removal
• Turn OFF the power supply to perform the following procedures.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedures.
• After removing air, confirm that oil air pressure is between 1.1~1.6bar during
operation.

Spindle oil piping air removal procedure:

1) Turn OFF the power supply.

2) Remove the tube from the spindle lubrication (oil air) device.
3) Remove the tube from the spindle mixing valve on top of the spindle.
4) Discharge residual oil in the tube using compressed air and reconnect the tubes.
5) Turn the power supply ON to operate the oil pump (stops automatically after 60
seconds).
6) Loosen the oil plug marked with an “O” to discharge air bubbles.
7) If the 60 seconds pump operation is insufficient to remove the air completely, turn
the power supply ON/OFF to operate the pump again.
8) After the oil becomes clear (air is removed), tighten the oil plug.

Mixing Valve for Spindle

Tube

Pressure Gauge Tube

View A Oil Plug

Figure 6.8.3a: Oil Piping Air Removal.

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6.9 Hydraulic Unit

• Contact Makino service representative immediately should the following
problems occur:
o Oil level decreases excessively: may be an indication of a machine
malfunction.
o Pressure is out of setting range: extremely dangerous operating
conditions. Do NOT attempt to adjust.
• Turn OFF the power supply, perform "Lockout/Tagout" and confirm operation has
completely ceased prior to performing the following procedures.

6.9.1 Hydraulic Oil Check/Replacement

Daily inspection:

1) Turn ON the power supply.

2) Check that the oil level is within limits "A" and "B" on the oil level indicator.
3) If the oil level is below “B”, turn OFF the power supply then add oil specified above
from the oil inlet.
4) Confirm the hydraulic oil level with power ON.

Replacement (every 2000 hours):

1) Turn OFF the power supply and remove the cover.

2) Open the oil inlet cap.
3) Remove the drain port plug to drain the oil completely.
4) Add new hydraulic oil up to upper line “A” on the oil level indicator then close the
cap.
• Take care to prevent contamination during hydraulic oil replacement.
5) Confirm the hydraulic oil level after power ON.

Cover

Inlet Cap

Oil Level
Indicator

Drain Plug

Figure 6.9.1a: Hydraulic Oil Check/Replacement.

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6.10 Pneumatic Unit

6.10.1 Air Panel Configuration

Function
Control Valves Scale Air Unit

ATC Magazine Pot Main Air Unit

Up/Down Valve

Figure 6.10.1a: Air Panel Configuration.

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6.10.2 Air Quality Control

The recommended air qualities are described below. The ambient air should be checked
periodically to maintain the optimum machine operating environment.

Equivalent to the grade ISO 2.5.2 specified by ISO8573-1 (equivalent to JIS B 8392-1)

• Max. particles number / 1m3: Below 10 (diameter: 0.001 < x ≤ 0.005mm)

• Max. particles number / 1m3: Below 1000 (diameter: 0.0005 < x ≤ 0.001mm)
• Max. particles number / 1m3: Below 100000 diameter: 0.0001 < x ≤ 0.0005mm)
• Dew point at max. pressure: Below 7 degrees (absolute pressure: 0.8MPa)
• Max. oil concentration: 0.1mg/m3 or less

6.10.3 Main Air Unit Pressure Check/Adjustment

Daily inspection:

1) Turn ON the power supply.

2) Confirm the main air unit pressure gauge indicator is within the green zone (0.45 ~
0.55Mpa)
3) If not, adjust the pressure by following the procedure below.

Adjustment (when necessary):

1) Pull the adjustment knob on the regulator upward to release the lock.
2) Turn the knob to adjust the pressure.
3) After adjustment, push the adjustment knob down to lock.

Pressure Adjustment Knob

Correct Pressure Range:

Pressure Gauge Green Zone

Figure 6.10.3a: Main Air Unit Pressure Check/Adjustment.

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6.10.4 Main Air Unit Filter Replacement
Replacement part:

Name Type Part No. Qty

Filter 5µm PF4-24-005-01 - 1
Filter 0.3µm PPH4-24A030-01 - 1

Replacement (every 2000 hours):

1) Turn OFF the power supply.

2) Turn the knob on the drain cock to bleed the remaining air pressure inside the bowl.
3) After confirming all the residual air is released, press down on the latch and rotate
the bowl to remove from the unit.
4) Loosen and remove the filter from the bowl.
5) Install a new filter.
6) Push the bowl upward and rotate until the marks meet.

Marks

Latch
Filter

Bowl

Knob (Drain Cock)

Filter 0.3µm Filter 5µm
(Inside the Bowl) (Inside the Bowl)

Figure 6.10.4a: Main Air Unit Filter Replacement.

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6.10.5 Scale Air Unit Pressure Check

Daily check:

1) Turn ON the power supply.

2) Confirm the scale air unit pressure gauge reads 0.06~0.1Mpa.
3) If the pressure gauge reads beyond 0.03Mpa, the filter is clogged. Replacement of
the filter if necessary.

Scale Air Unit Filter Replacement

Replacement part:

Name Type Part No. Qty

Filter 0.01µm PFU3000-005A-6082 - 1

Replacement (every 2000 hours or when necessary):

1) Turn OFF the power supply.

2) Turn the knob on the drain cock to bleed the remaining air pressure inside the bowl.
3) After confirming all the residual air is released, press down on the latch and rotate
the bowl to remove from the unit.
4) Loosen and remove the filter from the bowl.
5) Install a new filter.
6) Push the bowl upward and rotate until the marks match.

Marks

Latch
Filter

Bowl

Knob (Drain Cock)

Filter 0.01µm
(Inside the Bowl)

Figure 6.10.5a: Scale Air Unit Filter Replacement.

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6.11 Chip Disposal/Cutting Fluid Supply Unit

• Use of non-foaming and water soluble cutting fluid is strongly recommended.
Before using any other type of cutting fluid, contact Makino service representatives
for assistance.
• Cutting fluid must be non-corrosive (both to rubber seals and metal).
• Do not use anti-foaming additives unless absolutely necessary to prevent clogging
of the drum filter screens. If it must be used, concentration must be properly
controlled.
• Follow the manufacturer’s instructions on cutting fluid concentration.
• Dilute cutting fluid outside the machine. Do NOT dilute in the tank.
• To dilute, add water to the solution gradually and mix well.

Refer to maintenance drawing for locations of maintenance parts.

Tank Capacity (L)

Tank Type PS65 PS95
Left Discharge Water-Based 310 310

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6.11.1 Cutting Fluid Level Check/Replacement

Daily inspection:

• Confirm that the cutting fluid level is between “HIGH” and “LOW” on the oil level
indicator with the pump OFF.
• When cutting fluid level is close to the “LOW” mark, add cutting fluid following the
procedure below.

Replenishment (when necessary):

1) Remove the two screws to open the maintenance cover.

2) Add cutting fluid to near “HIGH” level when the pump is in OFF condition.
• If cutting fluid is added to “HIGH” level while the pump is operating, overflowing
occurs when the pump is stopped. Do not add the fluid above “HIGH” while the
pump is ON. Avoid spilling cutting fluid over surrounding electrical wirings during
replenishment.

Oil Level Indicator

Maintenance Cover

High

Low

Figure 6.11.1a: Cutting Fluid Check and Replenishment.

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6.11.2 Coolant Tank Cleaning
• Turn OFF the power supply and perform “Lockout/Tagout” prior to performing the
following procedures.
• When removing the coolant tank, work in pairs and signal each other to ensure
safety and not to cause impact on the main machine.

Cleaning (annually):

1) Turn OFF the power supply.

2) Disconnect all the hoses from pumps outlet and coolant tank cable from MTC.
3) Loosen the jack bolts and lower the caster on the floor.
4) Pull the coolant tank out from the left of the machine.
5) Remove the covers and first suck the coolant from clean tank and then dirty tank
using a vacuum.
• If vacuum equipment is not available, drain coolant from the drain ports.
6) Clean inside of the tank.

Removable Covers
(Dirty Tank)

Removable Covers
(Dirty Tank)

Removable Covers
(Clean Tank)
Drain Port

Caster Jack Bolt

Figure 6.11.2a: Coolant Tank Cleaning.

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6.11.3 Filter Cleaning

Cleaning (monthly):

1) Turn OFF the power supply.

2) Remove (lift up) the plate filters from coolant tank.
• The plate filter should be removed one after another. This is to make sure that the
dirty coolant is always blocked from entering the clean tank by filtering through the
plate filter.
3) Clean the filters by using compressed air and brush.
4) Install the filters to same position in coolant tank.
5) Turn ON the power supply.

Box Filter
(Maintenance
Cover Removed)

Plate Filter (x2)

Figure 6.11.3a: Filter Cleaning.

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6.11.4 Pump Mechanical Seal Replacement
• Turn OFF the power supply and perform “Lockout/Tagout” prior to performing the
following procedures.

Replacement (annually or when leakage):

• The following coolant pumps are equipped with mechanical seals and replacement
of the mechanical seal kit is necessary (optional specifications are included as
follows too).
• Refer to the manual supplied with the replacement seal kit for replacement
procedure.

Replacement part (pump mechanical seal kit):

Name Type Part No. Qty

Central Coolant Pump 00435045 Z615Z-0006-51 1
Fixture Coolant Pump 00435045 Z615Z-0006-51 1
Shower Coolant Pump 00435045 Z615Z-0006-51 1
Through Spindle Coolant Pump 1.5MPa 96455085 - 1
Cutting Fluid Temperature Controller Pump 00435045 Z615Z-0006-51 1

Through Spindle Coolant

Pump (1.5MPa)

Shower Coolant
Pump
Central Coolant Pump
Cutting Fluid - Nozzle Coolant
Temperature - Flush Coolant
Controller Pump Fixture Coolant Pump - Coolant Gun
Fixture Coolant Pump

Figure 6.11.4a: Pumps with Mechanical Seal Installed.

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6.11.5 Through Spindle Coolant 1.5Mpa Filter Maintenance

• Turn OFF the power supply and perform “Lockout/Tagout” prior to performing the
following procedures.

Replacement part:

Name Type Part No. Qty

Line Filter Element 63DN040W/HC Z474Z-0009-51 1

Daily inspection:

1) Check the clog detector to confirm the indicator (red) is not raised up.
2) If in raised up condition, switch the handle to the opposite side to allow the removal
of the previous filter element for cleaning or replacement.

Cleaning or replacement (every 2000 hours or at alarm):

1) Turn OFF the power supply.

• This is necessary when the clog detector need to be removed, otherwise it is not
necessary.
2) Loosen the drain plug to release residual cutting fluid remaining in the case.
3) Remove the bowl from the main body.
4) Remove the filter element inside to clean or replace.

Handle

Bowl
(Filter Inside)

Drain Plug

Figure 6.11.5a: Through Spindle Coolant 1.5MPa Line Filter Maintenance.

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6.11.6 Maintenance Drawings

Maintenance Cover Plate Filter Through Spindle

/Box Filter Coolant Pump
1.5MPa

Electrical
Terminal
Picture / drawing Box
for wiring / piping
Oil Level in Coolant Tank
Indicator

Shower Coolant
Pump

Cutting Fluid
Temperature
Controller Pump

Line Filter Fixture Coolant Central Coolant Pump Drain Plug

Pump - Nozzle Coolant
- Flush Coolant
- Coolant Gun

Figure 6.11.7a: Coolant Tank Maintenance Drawing.

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6.12 Machine Controller

6.12.1 Absolute Pulse Coder Battery Replacement
• Ensure that the control power is turned ON during battery replacement. If the
battery is changed with control power OFF, the stored absolute position is lost. If
lost, a manual reference position return must be performed to re-establish the
reference position.

Replacement part:

Name Type Part No. Qty

Lithium Battery A06B-6073-K001 - 2

Replacement (annually or at warning or alarm):

1) Opening the MTC door.

• The machine will be in emergency state.
2) Replace the batteries.
3) Turn OFF the power, then turn it back ON.

Batteries

MTC

Figure 6.12.1a: Absolute Pulse Coder Battery Replacement.

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6.12.2 NC Backup Battery Replacement
• Use only specified battery. Use of other batteries may result in explosion.
• Replacement procedure must be completed within 30 minutes. If battery power is
not provided within this limit, stored memory will be lost.
• If replacement is expected to take more than 30 minutes, save the CMOS memory
on a memory card before replacement.

Replacement part:

Name Type Part No. Qty

Lithium Battery A02B-0309-K102 - 1

Replacement (annually or at alarm):

1) Remove the back cover of the main operator panel.

2) Extract the old battery unit from the lower right of the rear main operator panel.
• Hold the latch of the battery unit, and extract the unit upward while releasing the
claw from then case.
3) Mount the new battery unit and ensure that the latch is engaged securely.
• Push the battery unit in until the claw is latched into the case.
4) Install back the back cover.

Figure 6.12.1a: Absolute Pulse Coder Replacement.

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6.13 Axes Telescopic Cover

• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the "UNLOCK" position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the "LOCK" position and remove
the key when finished. The release key must be placed in the hands of supervising
personnel.

Daily inspection:

1) Check the wiper to confirm the wiper is not torn out from the wiper holder, and the
lip of the wiper is not worn off.
2) If it is torn out or the lip of wiper is worn off, replace the wiper immediately.
• Damage wiper may cause cutting fluid leak and cutting chip goes into the ballscrew
and linear guide area, which may result in serious damage to the machine.
3) Contact Makino service representative for wiper replacement.

Wiper Wiper Holder

Telescopic Cover Section View

Figure 6.13a: Checking and Replacement of Telescopic Cover Wiper.

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6.14 Splash Guard Front Door Glass

• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedures.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with a door lock system (option), turn the release key to
the "UNLOCK" position and enter the machining chamber with the key to prevent
the possibility of being locked-in. Turn the key to the "LOCK" position and remove
the key when finished. The release key must be placed in the hands of supervising
personnel.

Daily inspection:

1) Check the glass (inner side/cutting chamber side) and polycarbonate (outer
side/operator side) to confirm the glass and polycarbonate are not damaged
(cracked, dented, scratched and etc).
2) If the above damage condition is found, replace the glass or wiper or both
immediately.
• Damage glass or polycarbonate or both will increase the risk of fly object (chip,
broken tool and etc) penetrates through the glass and polycarbonate, which may
cause serious injury to the operator.
3) Contact Makino service representative for replacement.

Polycarbonate

Tempered Glass

Figure 6.14a: Checking and Replacement of Splash Guard Front Door Glass.

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6.15 Optional Specification/Equipment

6.15.1 Automatic Grease Cartridge Replacement
When grease cartridge replacement or grease replenishment is necessary, a machine
alarm (warning) is triggered and the “WRN” lamp on the screen turns ON.

Replacement part:

Name Type Part No. Qty

Grease Cartridge GLK-2-100 Z192A0200001 1

Replacement (at warning):

1) Turn OFF the power supply.

2) Remove the cover and replace the grease cartridge.
• For details on the replacement procedure, refer to the Instructions Indicated on the
cartridge box.
3) Remove the air bleed screw and turn ON the power supply.
4) Release the air.
• Display the coolant management screen and press [AUTO GREASE] screen
operation button.
• Press [FORCE FORWARD] screen operation button to force drain air from the
bleed screw with grease.
• Press again [FORCE FORWARD] to stop the pump.
• If air entry occurs during the replacement, machine alarm is triggered.
• Press [COUNT RESET] to reset the cycle count.
5) Reset the alarm.

Figure 6.13.1a: Automatic Grease Cartridge Replacement.

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Figure 6.13.1b: Automatic Grease Screen for Maintenance.

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6.15.2 Automatic Tool Length Measurement Unit (Touch

Probe)
• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedure.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with the door lock system (option), use the release key
to open the operator door (the release key must be placed in the hands of
supervising personnel.

Daily inspection and cleaning:

1) Move the axes to reference position.

2) Turn OFF the power supply.
3) Open the main operator door.
4) Visually check and remove cutting chips and fluid adhering around the probe and
bracket of the tool length measurement unit.

Automatic Tool Length

Measurement Unit
Table

Figure 6.13.2a: Automatic Tool Length Measurement Maintenance.

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6.15.3 Automatic Workpiece Measuring Unit
6.15.3.1 Measuring Probe/Receiver Check/Cleaning

• Turn OFF the power supply and perform "Lockout/Tagout" prior to performing the
following procedure.
• Exercise extreme caution as entry into the machine is necessary in order to
perform the following procedure.
• If the machine is equipped with the door lock system (option), use the release key
to open the operator door (the release key must be placed in the hands of
supervising personnel.

Daily inspection and cleaning for receiver:

1) Turn OFF the power supply.

2) Move the axes to reference position.
3) Enter the machine chamber.
4) Visually check and remove cutting chips and fluid adhering to the receiver cover.

Daily inspection and cleaning for probe:

1) Visually check and remove cutting chips and fluid adhering to the measuring probe.

Location of Receiver
(Inside Cutting Chamber)

Figure 6.13.3.1a: Automatic Workpiece Measuring Unit Maintenance.

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6.15.3.2 Measuring Probe Battery Replacement (Marposs)

When machine alarm is triggered, replace the measuring probe battery immediately.

Replacement part:

Name Type Part No.

Lithium Battery Ni-Cd rechargeable Accu 3771/9
Varta TR 7/8
Zinc Philips 6F22P
Alkaline Duracell MN 1604
Philips 1604
Varta 4022
Lithium Accu TL 5306
Kodak U9VL

Replacement (at alarm):

1) Remove the battery cover.

• Take care not to damage the o-ring.
2) Replace the battery.
3) Install the cover with the o-ring mounted correctly.

Figure 6.13.3.2a: Measuring Probe Battery Replacement (Marposs).

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6.15.3.3 Measuring Probe Battery Replacement (Renishaw)

When machine alarm is triggered, replace the measuring probe battery immediately.

Replacement part:

Name Type Part No.

Battery Alkaline AA type -

Replacement (at alarm):

1) Clean and dry the probe before removing the battery cover.
2) Remove the battery cover and withdraw the battery cassette.
3) Take care to avoid damaging the cover gasket.
4) Replace the battery.
• Do not mix new and used batteries or battery type, as this will result in reduced life
and damage to the batteries.
5) Install the cover.
• Ensure the cover gasket and mating surfaces are clean and free from dirt before
reassembly.

Figure 6.13.3.3a: Measuring Probe Battery Replacement (Reinshaw).

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6.15.3.4 Diaphragm Inspection/Replacement (Renishaw)

Inspection (bi-annually):

1) Remove the stylus.

2) Unscrew three M3 front cover screws and remove the front cover.
3) Remove cutting chips and fluid adhering to the diaphragm.
4) Grip the outer diaphragm in the center and pull upward slowly to inspect visually. If
replacement is necessary, replace in a later procedure.
5) Inspect the inner diaphragm while holding the outer diaphragm in the raised
position. To check the condition of the inner diaphragm, press the stylus holder
inward and then release. If the diaphragm does not return to its original state,
damage has occurred. Contact Makino service representatives for assistance.

Figure 6.13.3.4a: Outer and Inner Diaphragm Inspection.

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 Maintenance Manual PS-Series
Replacement part:

Name Type Part No.

Outer Diaphragm (OMP60) A-4038-0302 -

Replacement (when necessary):

1) Remove the outer diaphragm by slowly pulling upward in the center of the
diaphragm.
2) Apply a thin coat of oil or grease in the hole of the replacement diaphragm and
install the installation tool.
• The installation tool is supplied with the unit.
3) Thread the tool completely into the stylus holder and tighten after positioning in the
center of the stylus holder groove.
4) Press the diaphragm to remove trapped air.
5) Remove the tool.
6) Apply a thin layer of oil or grease to the internal surface of the front cover and
install the front cover.
7) Install the stylus to complete the replacement procedure.

Figure 6.13.3.4b: Outer Diaphragm Replacement.

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6.16 Arrangement Product Lists

6.16.1 Recommended Grease
The following are applied to the machine prior to the machine shipment.

General Lubricant
KYODO YUSHI Kyodo Yushi Unilub DL-2 (or equivalent)
In case for ballscrew and linear guide, this grease is filled in cartridge form by
manufacturer. Refer to 6.4.1 (manual) and 6.13.1 (automatic) for cartridge replacement.
Do NOT refill the cartridge with the above mentioned grease, as improper refilling may
cause air tray inside the cartridge which may cause the centralized greasing system
malfunction.

Cambox Lubricant
CASTROL LUBRICATION Castrol 150 (or equivalent with viscosity 150 CST)

HSK Spindle Collect

KLUBER LUBRICATION Kluber L801 (spray-type grease)

6.16.2 Recommended Cooling Oil/Hydraulic Oil/Lubricant

Spindle Cooling Oil Hydraulic Unit Spindle Lubrication (Oil Air)
Temperature (Hydraulic Oil) Device
Controller or
(Cooling Oil) Oil Mist Supply Unit
(Lubricant)
Lubricant Code ISO VG2 VG32 VG32
3448
IDEMITSU KOSAN DAPHNEY SUPER DAPHNEY MECHANIC OIL DAPHNEY MECHANIC OIL
MULTI 2 32 32
JAPAN ENERGY - JOMO LATHUS 32 JOMO LATHUS 32

COSMO SEKIYU COSMO NEW COSMO HYDRO R032 COSMO HYDRO R032
MIGHTY SUPER 2
SHOWA SHELL MORLINA OIL HS SHELL TELLUS OIL 32 SHELL TELLUS OIL 32
SEKIYU
NIHON MITSUBISHI - FBK OIL R032 FBK OIL R032

FUJI KOSAN - FUKKOL DYNAMIC 32 FUKKOL DYNAMIC 32

EXXON MOBIL VELOCITE OIL No.3 MOBIL DTE 24 MOBIL DTE 24

GROUP
KLUBER - LAMORA HLP32 LAMORA HLP32
LUBRICATION

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6.16.3 Order Numbers for Replacement Parts
Unit Period Name Part No. Type Qty
Spindle (BT) 2000 hrs Rubber Seal 13M11G704 1
Spindle (HSK) 2000 hrs O-Ring Z261A7101201 P12 (FKM) 1
2000 hrs O-Ring Z261P2101402 S14 (FKM) 1
2000 hrs Backup Ring Z269A1301201 SUN-BP-12 1
Spindle Cooling 2000 hrs / Line Filter Element - 0060D010BH4HC 1
Oil Temperature Alarm
Controller
Tool Magazine 6000 hrs Spring (push rod) - CA766008 2
Sliding Pad - CA402405 60
Spindle 6000 hrs Suction Filter Element ZDDM02-4 SF01 1
Lubrication (Oil 6000 hrs Line Filter Element ZDDM02-3 P6003L 1
Air) Device
Pneumatic Unit 2000 hrs Filter 5µm - PF4-24-005-01 1
2000 hrs Filter 0.3µm - PPH4-24A030-01 1
2000 hrs Scale Air Filter 0.01µm - PFU3000-005A-6082 1
Chip Disposal / 1 year Pump Mechanical Seal Kit
Cutting Fluid Central Coolant Pump Z615Z-0006-51 00435045 1
Supply Unit Fixture Coolant Pump Z615Z-0006-51 00435045 1
Shower Coolant Pump Z615Z-0006-51 00435045 1
Through Spindle Coolant Pump 1.5Mpa - 96455085 1
Cutting Fluid Temperature Controller Z615Z-0006-51 00435045 1
When Line Filter Element Z474Z-0009-51 63DN040W/HC 1
Necessary (1.5MPa Through Spindle Coolant)
Machine 1 year Lithium Battery (for Pulse Coder) - A06B-6073-K001 2
Controller Lithium Battery (for NC Backup) - A02B-0309-K102 1
Grease Supply 500 hrs Grease Cartridge (Manual) Z192A0200008 GKL-2-040 1
Unit Alarm Grease Cartridge (Auto) Z192A0200001 GKL-2-100 1
Automatic Alarm Probe Battery (Marposs) - Ni-Cd rechargeable: Accu 3771/9, Varta TR 1
Workpiece 7/8
Measuring Unit - Zinc: Philips 6F22P
- Alkaline: Duracell MN 1604, Philips 1604,
Varta 4022
- Lithium: Accu TL 5306, Kodak U9VL
Probe Battery (Reinshaw) - Alkaline AA type 1
2 years Outer Diaphragm (Reinshaw) - A-4038-0302 1

END

V120I-M1E-XA 177
All queries: contact the following offices
Makino Asia Pte. Ltd. http://www.makino.com.sg

2, Gul Avenue, Singapore 629 649 TEL: +65 6861 5722 FAX: +65 6861 1600

Makino (China) Co., Ltd. http://www.makino.com.cn

No.2, Mu Ye Road, Yushan Town, Kunshan City, Jiangsu Province 215 316,
TEL: +86 512 5777 8000 FAX: +86 512 5777 9900
China

Makino India Private Limited http://makinoindia.co.in

No.11, Export Promotion Industrial Park, Whitefield Road, Bangalore 560

TEL: +91 80 2841 9500 FAX: +91 80 2841 0538
066, India

Makino (Thailand) Co., Ltd.

57/23 Moo 4, Ramintra Road, Km.2, Anusaowaree, Bangkhen, Bangkok 102

TEL: +66 2 971 5750 FAX: +66 2 971 5751
20, Thailand

Indonesia Representative Office

Gading Mediterania Residences, Jl. Boulevard Bukit Gading Raya RK/008/D,

Kel. Kelapa Gading Barat, Kec. Kelapa Gading, Jakarta Utara, Jakarta 142 TEL: +62 21 3004 1022 FAX: +62 21 3004 1023
40, Indonesia

Vietnam Representative Office

9th Fl - Vinaconex Building 47 Dien Bien Phu St - Da Kao Ward Dist 1 -

TEL: +84 8 39104832 FAX: +84 8 39104994
HCMC - VN

Makino Milling Machine Co., Ltd. http://www.makino.co.jp

Head Office 3-19 Nakane 2-chome, Meguro-ku, Tokyo 152-8578, Japan TEL: +81(0)3 3717 1151 FAX: +81(0)3 3725 2105

Makino Inc. http://www.makino.com

7680 Innovation Way, Mason, Ohio, 45040, U.S.A. TEL: +1 513 573 7200 FAX: +1 513 573 7360

Makino Europe GmbH http://www.makino.de

Makino GmbH Business Unit Production Machinery

Essener Bogen 5, 22419 Hamburg, Germany TEL: +49 (40) 298 090 FAX: +49 (40) 298 09 400

Makino GmbH Business Unit Die & Mould

Kruichling 18, 73230 Kirchheim unter Teck, Germany TEL: +49 (7021) 503 0 FAX: +49 (7021) 503 400