4) manrenance OF MAOR MACHINE UNITS 4-3 [ Never forget to switch off the main power before inspection and adjustment for the milling / § \ head WARNING Ay [ Use a crane, or carry out the job with an assistant, to remove the cover of the milling heed. CAUTION 4-3-1 Mill spindle clamp unit inspection procedure (collet and coned disc spring) (HSK specification only) It is recommended to check the spindle clamp unit in regular intervals (every $0000 times of tool clamp operation). Check the following items. 4. Checking the center cone and finger of the collet for the existence of damages and/or crack Center coneA | wastENAnce OF MAJOR MACHINE UNTS 8 4, Checking the clamp unit lock nut for looseness: If the lock nut holding the clamp unit is loosened and it becomes necessary to tighten it again, refer to Fig. 4-10. ‘After adjusting the tool clamp stroke to 0.45 to 0.66 mm (0.018 to 0.022 in), tighten the lock nut at 18N-m (13.3 ftlbf)._ Make sure to apply Loctite No. 221 to the screw. 0.45 -0.58 mm (0018 - 0022 in) Apply Loctite No. 221 tothe screw. Tighten the lock nut at 18 Nim (13.3 818 [10.5 mm (0.41 in) Fig. 410 Tool clamp Checking the run-out accuracy Ifa test bar is available, check the run-out of the spindle using the test bar. Allowable run-out amount: At mouth: 3 um max. At free end (300 mm (11.81 in) from the mouth): 8 um max. eum 3am Fig. 4-11. Checking the run-out accuracyMAINTENANCE OF MAJOR MACHINE UNITS |4 4-3-2 Checking the tool clamping force It is recommended to check the check valve every 250 hours (1 month). Check the following items, Ifthe special clamping force checking device is available, check the tool clamping force. Allowable clamping force HSK: 22 kN (4946 Ibf) min CAPTO: 20 kN (4496 Ibf) min KM 26 KN (5845 Ibf) min, For the HSK specification, lubricate the collet by referring to 4-3-4 “Lubricating the HSK collect ‘chuck in regular intervals (HSK specification only)" since clamping force will be lowered if the collet is not lubricated properly. Table 41 Recommended clamping force checking device Manufacturer | OTTIAKOB Spanntechnik | Kelch (Germany) ‘Contact the nearest Mazak GmbH & Co. (Germany)" Technical Center or Gauge type | 10-75KN os ectnctony Geates (2248-16061 Io) ‘Adaptertype | HSK6395.600.073.9.2(For | - CE-LC10-S (Sensor Ban) HSK-A63) = CXLC10-E82 Reading Unit) "1 OTT-JAKOB Spanntechnik GmbH & Co. IndustriestraBe 3-7 D - 87663 Lengenwang, Germany Intemet:_http:/Awmw.ottjakob.de *2. For inquires or information, please contact your local SANDVIK Coromant distributor. 4444 | waiwrenance OF MAJOR MACHINE UNITS 4-3-3 Through-spindle coolant system inspection procedure (rotary joint and check valve) Itis recommended to check the check valve every 1500 hours (6 months). Check the following iterns. 4. Cleaning the check valve © Since @ check valve is used to discharge water and oil accumulated in the machine, the spindle will be damaged if the machine is continuously operated although the check valve is clogged. Maintenance interval: Every 1600 hours (6 months) and also when large amount of chips adhered to the machine. ‘After cleaning @ check valve, make sure to remount it as before. if the machine is operated without re-mounting the check vaive, oil and water enter inside of the mill spindle to cause the mill spindle to break. CAUTION A. Type M14 check vaive < Procedure > (1) Remove six check valves (Fig. 4-12) from the mill spindle. Carefully clean the mouth of check valve mounting holes with clean cloth. (Do not direct compressed air to the hole to clean the mouth of mounting holes since it will ‘cause chips to enter into the mill spindle.) ‘After cleaning the mounting holes, cover them with clean cloth or other means until maintenance work completes so that foreign matter will not enter into the mill spindle. (2) Clean the inside of the check valves with compressed air or other appropriate means. (A spring is mounted in a check valve. Pay attention so that the spring will not come off during cleaning. If the spring comes off, fit the spring to the seat by hooking it externally.) (3) Wind seal tape around the check valves, and screw them fully at the previously mounted positions,MAINTENANCE OF MAJOR MACHINE UNITS |4 B. Type M36 check valve < Procedure > (1) At the rear of the mill spindle, two check valve protective covers are mounted (at the place shown in Fig, 4-12 and at the opposite side). Remove the MS screws (two screws for each cover) with an Allen wrench and detach the covers. (2) Clean the covers entirely, the cover mounting face, the side face and the areas around the check valves with compressed air. Carefully wipe the inside of the check valve with clean cloth, (Do not supply compressed air toward the inside of a check valve since it will cause chips to enter into the mill spindle.) (3) Mount the covers as before. Check valves (Type M14) (Check valves (Type M36) Normal state ‘Abnormal state = When the balls pushed, "= When the ball is pushed, it returns tothe orginally does not return to the located postion. ‘originally located positon. Fig. 4-12 Gieaning the check valve 2. Checking the through-spindle coolant supplying state Tum on the through-spindle coolant system and check if coolant leaks through the check valve. IF coolant keeps leaking even if the amount is slight, the rotary joint will be faulty.4) wantenance oF MAJOR MACHINE UNITS 4-3-4 Lubricating the HSK collect chuck in regular intervals (HSK specification only) Lubricate the collet by spraying lubricating oil every 36000 times of tool clamp operation, Lubricant: GLEITMETALL SPRAY 70-81 (METAFLUX) (MAZAK part No.:_ M20FG013900) © Ifthe collet is not lubricated in regular intervals, tool clamping force will be lowered to cause injury of operators, severe damage of the machine and faulty machining due to falling of a tool or improper too! holding, © Before mounting a tool in the spindle, make sure that the packing at the entry of the mil spindle hole is free of damages such as scratches and cuts. If you do not check the Packing before mounting a too! in the spindle, the spindle could be damaged due to coolant. leakage. CAUTION < Maintenance procedure - supplying lubricating oil > (1) Call the tool (2) Select the manual mode (handle, jog, rapid or home), unciamp the tool by operating the tool tunclamp switch after holding the tool by hand and the tool can be removed from the spindle. In this state, the center cone and the finger are visible from the spindle front side as shown below. Set the nozzle to a gap in the finger and spray the coolant for approximately 1 second, Repeat this forall finger gaps (7 gaps). Make sure so that too much amount of lubricant will not be sprayed. Finger (7 parts) Mil spince in unciamped state Fig. 4-13 Lubricating the spindle c'amp unit (3) Mount a tool in the spindle and set the tool unclamp switch in the clamp position, ‘When mounting a tool in the spindle, make sure to set it in the correct direction.wwsreuner or uncon nice vere] < Cleaning the tool tapered face and the area around the spindle tapered bore > ‘To prevent tool clamping error and to keep tool clamping accuracy, clean the tool tapered face and the area around the spindle tapered bore from time to time. ‘Although the through-spindle air blow and the spindle nose air blow are provided to blow off chips from the tool and the spindle, chips cannot be removed completely. Especially, chips wet with oil are sticky and cannot be removed easily. Therefore, the areas indicated in Fig. 4-14 must be cleaned with clean rag CCeaning the tool tapered face, end face and internal face Cleaning the spindle tapered face and nose Fig 4-14 Cleaning the ool tapered face and the eres around the spindle tapered bore4 | swintenance oF MAJOR MACHINE UNITS 4-3-5 Oil level inspec ion and oil replacement for the B-axi ‘The miling head is indexed by roller gear cam, and the cam follower section is lubricated by oil- | bath method to maintain oil film. The amount and quality of lubricating oil must therefore be controlled carefully to prevent the cam follower, shaft support bearing and other components from being damaged. Oil filer por cover Drain pot Drain port cover Inspection glass Fig. 4-15 Oil level inspection and ol replacement for the B-axis| 4. Inspection of oil level < Procedure > (1) Once a week remove the maintenance cover and check by the inspection glass if the oil level is not lower than “L" (2) Check the drain plug for looseness if there is no oil visible through the glass. Tighten the loosened plug and replace cil If the loss of oll should have been caused otherwise than by a looseness of the drain plug, please contact the nearest Mazak Technical Center or Technology Center. 2. Replacement of oil Never fail to replace the lubricating oil for the milling head every year. Recommended lubricant: SHC 629 (Mobil)MAINTENANCE OF MAJOR MACHINE UNITS |4 4-4 Tailstock 4-4-1 Configuration and operation ‘The machine is equipped with the numerically controlled motor driven tailstock. The tailstock consists of the tallstock body and the tailstook drive unit Tailstock spindle Tailstock body Fig 4-16 Configuration ofthe talistock The tailstock body is moved by the rotation of the servomotor of the tailstock drive unit. 44-2 Removing the built-in center ‘The center has a threaded part used for removal. To remove the center, put a nut on the threaded part and tum it inthe tightening direction. Then, the center can be removed. Nut Fig. 417 Removing the bultsin canter 4a74] smvrenance OF MAJOR MACHINE UNITS 4-4-3 Adjusting the If the workpiece is tapered in straight tuming, with the workpiece held by the center, adjust the tailstock spindle alignment by following the procedure below. tock center alignment 18 t0 20mm (0.58 t0.079 in) 1133/0007 Fig. 418 Tallstock pindle alignment (on te horizontal pane) < Procedure > (1) Chuck a round workpiece and hold its end face with the tailstock center. The chucking length should be 15 to 20 mm (0.59 to 0.79 in). (2) Finish-turn the workpiece. (3) Measure the cylindrcity using 2 micrometer. (Measure portions A and B in the figure above.) (4) Apply the dial indi tor to the workpiece at the tailstock side and set the pointer to zero, MB hex socket View head bot Scale pk (positons) == Center corrector clamp bolt Viewa (Cenier corector) Fig. 4-19 Tallstock center corrector (5) Loosen the hex. socket head bolts (2 pes) of the center corrector. (6) Loosen the MB hex. socket head bolts (4 pcs) at the front of the tallstock. (7) Tum the center corrector while observing the indication of the dial indicator (the sleeve is of the eocentric type). ‘A half of a division on the scale plate corresponds to correction amount of approximately 0.013 mm (0.0008 in).AINTENANCE OF MAJOR MACHINE UNITS [4 (8) Tighten hex. socket head bolts. (8) Carry out OD turning again and measure the cylindricity (10) If taper is still generated, repeat the above indicated steps (4) to (8) 44-4 Greasing If any breaks in the oil fim are observed on the rail surface of the linear guide, it is necessary to replenish grease. To replenish grease, remove the side cover of the tallstock and supply {grease through the grease nipples (3 places) provided on the linear guide biock using a grease hand pump. ‘Recommended grease - CITRAX EP No. 1 (Kyodo Yushi) < Replenishing interval > Every 6 months Maintenance cover (MB x 7 places) Fig. 420 Talstock greasing points (10000) 419| sanenance oF MALOR MACHINE UNITS Maintenance cover (MB x 4 places) Fig. 421 Talistock greasing points (1500U)MAINTENANCE OF MAJOR MACHINE Units |4 45 Turret Head of the Lower Turret (with Milling Function) 1, The turret head of the lower turret is driven and indexed by a lower turret mill spindle motor. ‘The controller performs positioning based on the current position stored in the memory and the target index position. Ifan index error should occur, set the current position anew by the following procedure to clear the alarm. Resetting the current position < Procedure > (1) Select the lower turret using the turret selector switch on the auxiliary operating panel. (2) Press the machine menu key to call up the machine menu. (3) Press the display selector key (4) Press the [LOWER-TR MODE] menu key. =} ser up| oprzow Fig. 422 Setting the 2970 point for lower ture incexing - Check the status of the menu display enclosed by [Jin Fig. 4-22. (11 Precaed to Step (6) vrs oF oy aaa ta Peas 5190 = sa [9) Procees to Step (7) Normal = oven-28 Sa [4 Contact the nearest Mazak ONCLANE ween | Teennieal Center or s-azoe |urt-szoe| carene ‘Teennology Center Reversed Normal Reversed Reversed or normal 421| wancrenance oF MALOR MACHINE UNITS (5) Check that the indexed face of the turret is parallel to the edge of HD1 or HD2. If it is not Parallel, follow the instructions given in Step (7) below at first and tum the turret head by hand to make the indexed face parallel to the spindle edge. If turret head cannot be turned by hand, contact the nearest Mazak Technical Center or Technology Center. iQ = l a} Fig. 423 Indexed face adjustment in elation to HDt (6) Press the [LOWER-TR UNCLAMP] menu key in manual operation mode to clamp the turret, (Reverse display of menu item is then cleared.) (7) Press the emergency stop button on the auxiliary operating panel and tum it in the direction indicated by the arrow symbols to reset the button. Then, press the RESET key to clear the emergency stop alarm (8) Make sure that the currently indexed position is displayed at the tool No. item on the POSITION screen itt! {ex position and indicated tool No. coincide, current position is now reset correctly If a different No. is indicated, contact the nearest Mazak Technical Center or Technology Center.MAINTENANCE OF MAJOR MACHINE UNrTs [4 2, Releasing alarms according to the machine menu status When one of the following alarms occurs, follow the steps described below: 4205 TURRET CLAMP SENSOR MALFUNCTION 41204 TURRET INDEX TIME OVER etc. ~ Check the status of the menu display enclosed by [Tin Fig. 4-22. ein | cean 11] Stan rom Step (5) in tem 1 Reversed Reversed Tawencra | voweR-T 12] Press the LOWER-TR GEAR MILSIDE] mens scene | EAR ay Nemal Blinking Towraae [3] Folow the instruction in Step (7) in tem 1. Then mone press the (LOWER-TR GEAR MIL-SIDE] menu key. When the alam occurs anew, contact he Normal nearest Mazak Techical Center or Technology Conte. eta 14] Fotow the instructions in Ste (7) in item 1. When cua the alarm occurs anew, contact he neeest a Mazak Technical Center or Technology Cente. Torenae [5] Press the [LOWER-TR GEAR TR-SIDE] mens coca | ean | en | ae key. When the alarm occurs anew, press he : same menu key and then {LOWERTR Nommal Normal Blinking Reverted or UNCLAMP] menu key. Then proceed to Sten (5) initem 1. ‘Yormaczn | cowen-rn | owsa-zm [zone {6} Contact the nearest Mazak Technical Geter or neuane a, Technology Cente. Other status than those mentioned above, 3. Adjusting the orient shift amount for turret gear connection set in the parameter If the lower turret mill spindle motor has been replaced, the parameter related to the orient shift amount for turret gear connection must be adjusted. The orient shift amount is factory-set to the optimum value. Avoid readjusting the parameter value unnecessarily. If replacement of the lower turret mill spindle motor is required, contact the nearest Mazak Technical Center or Technology Center. 423MAINTENANCE OF MAJOR MACHINE UNITS 4 Restoring the operation after interruption during turret indexing due to emergency stop or power failure (1) Check that the indexed face of the turret is parallel to the edge of HD1 or HD2. Ifthe indexed face is not parallel to the edge of HD1 or HD2. turn the turret head by hand to make the index face parallel to the edge of HD1 or HD2. If turret head cannot be tured by hand, contact the nearest Mazak Technical Center or Technology Center. Hoi oz p>-—— Parallel Fig. 424 Indexed face adjustment in relation to HO’ (2) Select the lower turret using the turret selector switch on the auxiliary operating panel (3) Press the machine menu key to call up the machine menu (4) Press the display selector key (5) Press the [ATC SHIFTER MAGAZINE] menu key. (6). Press the [ATC INT-LOCK CANCEL] menu key. lexox24g| lezzrze [sezxous| cRNCE,MAINTENANCE OF MAYOR MACHINE UNrTs |4 (7) Select the lower turret using the turret selector switch on the auxiliary operating panel. (8) Press the machine menu key to call up the machine menu (9) Press the display selector key MEME. (10) Press the [LOWER-TR MODE] menu key. + Fig. 4.26 Setting the 2070 point for lower turret indexing (11) Press the [LOWER-TR UNCLAMP] menu key in manual operation mode to clamp the turret, (Reverse display of menu item is then cleared.) (12) Press the emergency stop button on the auxiliary operating panel and turn it in the direction indicated by the arrow symbols to reset the button. Then, press the RESET key to clear the emergency stop alarm, (13) Make sure that the currently indexed position is displayed at the tool No. item on the POSITION screen. If the index position and indicated tool No. coincide, current position is now reset correctly. If a different No. is indicated, contact the nearest Mazak Technical Center or Technology Center. (14) Follow steps (2) to (6) above to disable the ATC interlock cancel function, 4-25| screnance OF MALOR MAGHINE UNITS 4-6 Home Position Adjustment ‘The machine origin is the reference point for machining by the NC equipment (MAZATROL). ‘The zero-point retum position, therefore, must be accurately determined. ‘Our machines are shipped after factory adjustment of zero-point return. No further adjustment is required after delivery. Readjustment of the home position becomes necessary only when the ball screw is changed, couplings are disconnected, encoder is dismounted or the home position data is lost due to low voltage of the servo amplifier battery. If the home position data is lost due to low battery voltage, readjust the home position after replacing the servo amplifier battery, 4-6-1 Determining zero point 4. Xteaxis Mount a test piece (round bar) in the chuck and tum outside diameter. Measure the diameter accurately after cutting. Let the diameter be D. Unis mm Zero pont 170 68) 490 1929) u na Ff L: Distance tom the gavee Ine = = fore nove J 40) a orsswor25 Fig. 427. Xt-axis zero-point return ‘The X1-axis zero point (with respect to the turret center) is 490 mm (18.29 in) distant from the spindle center. Therefore, move the X1-axis by 480 mm (19.29 in) ~ [170 mm (6.69 in) +L + D/2] while observing the counter reading. The point reached is the X1-axis zero point Note: In turning mode, since the X1-axis counter only provides @ reading of diameter, multiply the above value by a factor of 2 and confirm the counter value. In milling mode, since the X1-axis counter only provides a reading of radius, confirm the above value on the counter. Refer to PART 2, 4 "MANUAL OPERATION’ in the Operating Manual for turning mode/milling mode selection.2. Zt-axis Mount a test piece in the chuck and perform face turning. Measure the length from the spindle ose to the test piece edge. Let the measurement be L. Unit: mm in) [A: Distance from the spindle nose tothe 21-axie zaro point (rl spindle center) INTEGREX 1-200: 706 (27.80) = INTEGREX 1-300: 720 (28.38) INTEGREX \-400: 752 (29.61) 7 B Distance from the mil spindle ‘center fo the tp nose. See oo orvswoas Fig 428 Zt-axs zero-oint return The Z1-axis zero point is A mm distant from the spindle nose, Therefore move the Z1-axis by (A (B + L)] mm (in) while observing the counter reading and the reached position is the zero point of the Z1-axis. The point reached is the Z1-avis zero point If the Z1-axis zero point is re-set, ATC position must also be adjusted. For this adjustment, contact the nearest Mazak Technical Center or Technology Center. 3. Y-axis Dial gauge sig b13swor27 Fig. 429 Y-axis zeropoint return Index the mill spindle to the H position (horizontal). Attach the test bar to the miling head Attach the dial gauge fixture jg to the turning spindle and set the dial gauge, AAs the Y-axis zero point is located at the position where the mill spindle center coincides with the tuming spindle center, move the mill spindle to a position where the test bar center almost coincides with the turning spindle center. (The X-axis must have been positioned at 490 mm (18.28 in) from the zero point.) ‘Next apply the dial gauge to the end of the test bar, and slowly turn the spindle, and adjust the X-axis and Y-axis until the deflection of dial gauge disappears to obtain the Y-axis zero point. 427MAINTENANCE OF MAJOR MACHINE UNITS W-axis (Tailstock) ‘The tailstock is driven by the servomotor and the absolute position detection system is used for positioning control, The controller retains the factory-set zero position. However, the absolute position dat lost if battery voltage is lowered or the controller is replaced, Ifthe zero point data is lost, set it again by following the procedure explained below. (1) (2) Press the [f=] (machine menu) key on the NC operating panel to display the machine menu Press the display selector key to display the menu shown below. x sat al i vcs frowe ger] HOME onciame| oot | Ser (4) (5) (6) 7 @) @) Press the [TAIL HOME SET MODE] menu key together with the [1] + [8] (MF1 and MF2) keys to highlight the menu item in reverse display. Move the tallstock to the zero point position using the tailstock spindle movement switch. (The zero point position of the tailstock is the position where the distance between the spindle nose and the tailstock end face is as indicate in the figure below.) Unit: mm (in) Wo (Note) (Distance between the spindle nose ‘and the talstock end face) Fig. 420 Weaxls zero-point return Press the [TAIL HOME SET] menu key. The menu item is highlighted and the zero point position is established, Press the [TAIL HOME SET MODE] menu key to return the menu item dispiay to normal display. (Press the menu key together with the [1] + [] (MF1 and MF2) keys.) Press the [TAIL HOME SET] menu key to return the menu item display to normal display. Press the poser off button and then repeat turning off and on of the main power disconnect switch twice. Press the power on button to turn the power on. This completes the operation.iusrcusecor ac Note: The Wo dimension in the above figure depends upon the spindle and center distance expression of the particular model as follows: INTEGREX i-200 [1000U]: 1270 mm (60.00 in) INTEGREX §-300 [1000U]: 1284 mm (60.55 in) INTEGREX i-300 [1500UJ: 1820 mm (71.65 in) INTEGREX |-400 [1000U: 1316 mm (61.81 in) INTEGREX [-400 [1500U]: 1852 mm (72.91 in) 5. W-axis (spindle 2) Wo (Note) Gauge line ofthe turing spindle 1 i Gauge line ofthe turing spindle 2 Zero point ofthe tutring spindle 2 037380032 Fig 4-31 Weaxis zero-point retun ‘As shown in the above figure, the W-axis zero point is located at a distance of Wo between the gauge lines of the tuning spindles 1 and 2. Perform the following operations to move the turning spindle 2 to the W-axis zero point First, mount the standard raw jaws of the manufacturer in the chucks of the tuning spindles * and 2. Next, manually move the turning spindle 2 to the turning spindle 1 and when the chuck jaws of the spindle 2 touch the chuck of the spindle 1, reset the counter of the W-axis to zero. Refer to the assembly drawing of the mounted chuck and confirm the distance from the gauge line to the edge of the jaws. Take this distance as A. Finally, move the turning spindle 2 through the distance of [Wo — 2 x A] in the direction of its zero point. ‘The zero point of the W-axis can be obtained by these operations. Note: The Wo dimension in the above figure depends upon the spindle as follows: INTEGREX 1-200 [1000U}: 1345 mm (52.95 in) INTEGREX (-300 [1500U]: 1881 mm (74.06 in) INTEGREX |-400 [1500U]: 1913 mm (75.31 in) 4.29MAINTENANCE OF MAJOR MACHINE UNITS: x2-axi ‘Mount a test piece (round bar) in the chuck and tum outside diameter. Measure the diameter ‘accurately after cutting. Let the diameter be D. Unt: mm in) 2D 250(9.84) Disswor2s Fig. 4.32 The X2-axis zero point is 250 mm (9.84 in) distant from the spindle center. X2-axis by [250 mm (8.84 in) — (Y + D/2)] while observing the counter reading. The position the X2-axis zero-point return X2-axis reached is the X2-axis zero point. Note: In turning mode, since the X2-axis counter only provides a reading of diameter, multiply the above value by a factor of 2 and confirm the counter value. In miling mode, since the X2-axis counter only provides a reading of radius, confirm the above value on the counter. Refer to Chapter 4 “MANUAL OPERATION” in PART 2 of the Operating Manual for turning mode/miling mode selection Z2-axis Mount a test piece in the chuck and perform face turning. Measure the length from the spindle nose to the test piece edge. Let the measurement be L. }__A___, 530) i, Unit: mm (in) ‘A: Distance trom the spinale nose to the Z2-axls zero point INTEGREX 200" 705 (27.80) INTEGREX -300: 720 (28 35) INTEGREX -400: 752 (28.61) @ Zev point D136wo125 Fig. €33, 22-axis zero-point return ‘The Z2-axis zero point is A mm distant from the spindle nose. Therefore move the Z2-axis by [A= (137 mm (5.39 in) + L)] while observing the counter reading, The position the Z2-axis reached is the Z2-axis zero point, Therefore, move theMAINTENANCE OF MALOR MACHINE UNITS [4 8. Turret head of the lower turret ‘The turret head of the lower turret is driven and indexed by a servomotor on the basis of an absolute positioning system. The controller has the factory-set reference position stored in its memory to perform absolute positioning, If the stored data should be lost due to a drop of the battery voltage or of the controller itself has been replaced, set and store the reference position ‘anew by the following procedure: < Procedure > (1). Select the lower turret using the turret selector switch on the auxiliary operating panel, (2) Press the machine menu key [Til] on the NC operating panel and then press the menu selector key. (3) Select the [LOWER-TR MODE] menu item from the resulting machine menu. (4). Select the [LOWER-TR UNCLAMP] menu item to unciamp the lower turret > The menu item will be highlighted. (8) Select the [LOWER-TR HOME SET MODE] menu item while holding down the auxiliary keys [2] + [3] to highlight it > The menu item will be highlighted Fg 434 (8) Using the lower turret tool selector button, rotate the turret so as to direct the face of tool No. 1 to the axis of revolution of the turning spindle. (This indexing position is the reference one.) (7). Select the [LOWER-TR HOME SET MODE] menu item again to clear its highlighting.A | snivtenance oF MAJOR MACHINE UNITS (8) Select the [LOWER-TR UNCLAMP] menu item again to clamp the lower turret. (9) Select the [LOWER-TR UNCLAMP] menu item anew to unclamp the lower turret. (10) Select the [LOWER-TR HOME SET MODE] menu item anew (by the aid of the auxiliary keys [81] + [2] tohightight its display. (11) Blink the display of the [LOWER-TR HOME SET] menu item by pressing the menu key and operate the lower turret tool selector button to index the turret in the forward direction. > The turret will slightly tum to stop at the nearest grid point The reference position for absolute positioning has now been established and the [LOWER-TR HOME SET] menu item will be highlighted, [Eowen-rafuown | lsowe. sea] nome ‘MODE hy (12) Using the lower turret tool selector button, rotate the turret so as to direct the face of tool No. 1 to the axis of revolution of the turning spindle, (13) Select the [LOWER-TR HOME SET MODE] menu item once again to clear its highlighting (14) Select the [LOWER-TR UNCLAMP] menu item once again to clamp the lower turret, (15) Press the power-off button and then repeat main power disconnect switch offion operations twice. Finally, turn power back on by pressing the power-on button LoweR-73] The procedure is now complete.sunrevseroruncn wre vrs [4] 4-6-2 Zero point position setting by zero-point return To inexperienced persons, zero-point positioning by command entry is not an easy operation It is suggested that before performing the following procedure, the operator should seek advice from the nearest Mazak Technical Center or Technology Center. < Procedure > (1). Set the distance between the proximity sensor and the dog to 0.5 mm (0.02 in). (2). Set the B-axis at zero-point as described in the preceding section (3). Set the parameter for zero-point shift amount (M16) to 0, and set the position counter to 0. For the X-axis, attach the dial gauge fixture jig to the carriage and apply the dial gauge to the upper turret base. For the Z-, Y- and W-axis, attach the dial gauge fixture jig to the bed and apply the dial gauge to the carriage. (4) Move the X-, Y-, Z-, W-, X2+ and Z2-axis 10 mm (0.39 in) to the front side, namely in the negative (-) direction, and adjust the position of the dog so that the proximity sensor turns from on to off at that position. ‘Turning from on to off of the proximity sensor can be confirmed by checking the bit status of the corresponding input address on the DIAGNOSIS screen. (6) Move all axes in the negative (-) direction by about 50 mm (1.97 in). (6) Turn power on and then tum it back on. (7) Perform the zero-point return (with parameter M16 = 0), (8) Enter the distance from the position obtained to the home position into parameter M16. (@) Move the X-, Y-, Z-, We, X2- and Z2-axis by the distance one half of the grid interval of the respective axes to the front side, namely in the negative (~) direction, and adjust the position of the dog so that the proximity sensor tums from on to off at that position. ‘Turning from on to off of the proximity sensor can be confirmed by checking the bit status of the corresponding input address on the DIAGNOSIS screen. Note: When a proximity sensor tums from on to off, the corresponding signal (address) on the DIAGNOSIS screen changes from "1" to 0" (10) After turning power off again, tuming it back on and perform the zero-point retum once again. The axis will be returned to its zero-point position. (11) Confirm that the dial gauge reading is the same as in step (3) above. _< Grid interval of individual axis > X-axis: X2B0 X-axis: 8 mm (0.31 in) Y-axis) X281 Y-axis: 5 mm (0.20 in) Zaxis| X2B2 Z-axis, 8mm (0.31 in) Weaxis: X40 Weaxis: 8 mm (0.24 in) X-axis: X50 X2-axis: 6 mm (0.24 in) Z2-axis: X51 Z2-axis: 8 mm (0.31 in) Note 1: The W-axis is available only on machines equipped with @ spindle No. 2. Note 2: X2 and Z2 axes are available only on machines equipped with the lower turret, 4-334} wantenance OF MAJOR MAGHINE UNITS 4-7 ATC 4-7-1 Zero point adjustment and center alignment for the ATC, the magazine and the shifter If abnormal noise is generated or @ tool is fallen while a too! is transported from the magazine to the mill spindle, the ATC unit must be adjusted andlor parameter setting must be corrected by the Mazak's service technician. If a problem as stated above takes place, contact the nearest Mazak Technical Center or Technology Center. 4. 36+tool magazine specification Fig. 4.35 36-001 magazine specification No Part Name + [ att spincie 3_| Tool shiner ATC arm, 4 | Magazine 434MAINTENANCE OF MAJOR MACHINE UNITs [4 Mil spindle 2_[ ATC arn Too! shifer Magazine 1 5_| Megezine 2 Tool carer 435A | saivrenance oF wAJOR MACHINE UNITS 3. 110-tool magazine specification Part Name Magazine 1 ATC arm Magazine 2 Tool shiter Too! carrierMAINTENANCE OF MAJOR MACHINE UNiTs [4 4-7-2 ATC cover adjustment If a problem arises in the ATC cover operation such that the ATC cover opening/closing operation is not completed, itis necessary to adjust the air cylinder and the guide. If a problem as stated above takes place, contact the nearest Mazak Technical Center or Technology Center. 4-7-3 Checking the magazine chain tension ‘© Place the main power disconnect switch to the “OFF” position before checking the chain, otherwise you could sustain serious injury. WARNING. Although the magazine chain tension is adjusted after initial elongation of the chain before shipping, the magazine chain will be elongated during use of the magazine over a long time. Indexing of tools is carried out by the rotation of sprockets and slight slackness of the magazine chain causes no problems with indexing accuracy. However, if the siackness of the magazine chain is apparent to the touch, it wll cause overloading of the drive motor. Therefore, the chain tension must be adjusted using the tension adjusting bolts. 437A | wanvrenance oF wALOR MACHINE UNITS < Adjusting the magazine chain tension (36-172-tool magazine specification) > (1) Remove all tools from the magazine. (2) Shut off the power to the machine. (3) Open the magazine door and loosen the bolts (4-M12) that clamp the magazine sprocket. (Keep in mind that the bolts should only be loosened and must not be removed.) (Fig. 4-38) (4) Loosen the nut clamping the magazine chain tension adjusting bolt and then tighten the adjusting bolt to 9 N-m (66 fbf) torque with a torque wrench. (Fig. 4-38) (5) Lock the adjusting bolt with the nut and then tighten the sprocket clamping bolt. (6) Tum the power on and check the magazine operation. Note: When tightening the adjusting bol, always use a torque wrench. Ifa torque wrench is not available, contact the nearest Mazak Technical Center or Technology Center. Nut Tension adjusting bolt Sprocket clamping bolt (4-M12) Fig. 439 Adjusting the magazine chain tension (3672-to0l magazine specification)MAINTENANCE OF MAJOR MACHINE UNITS |4 < Adjusting the magazine chain tension (110-tool magazine specification) > a @ @ 4) ©) ©) Remove al tools from the magazine. ‘Shut off the power to the machine, (Open the magazine door and loosen the bolts (2 x 4-M12) that clamp the magazine sprocket. (Keep in mind that the bolts should only be loosened and must not be removed.) (Fig. 4-40) Loosen the nut clamping the magazine chain tension adjusting bolt and then tighten the adjusting bolt to 4.7 Nim (3.5 ftbf) torque with a torque wrench. (Fig. 4-40) Lock the adjusting bolt with the nut and then tighten the sprocket clamping bolt. Turn the power on and check the magazine operation Note: When tightening the adjusting bolt, always use a torque wrench. Ifa torque wrench is not available, contact the nearest Mazak Technical Center or Technology Center. Nut Tension adjusting bolt Nut Sprocket clamping bot (4-M12) Fig. 4-40 Adjusting the magazine chain tension (110-1001 magazine specification) 439A] saivtenance oF MAJOR MACHINE UNTS 4-7-4 Lubrication 4. Checking the level of and changing the ATC unit lubricating oil ‘The roller gear cam is used to index the ATC unit and it is lubricated in the oil bath method so that oil fm is always formed at the area where the cam follower contacts. If lubricating oil is insufficient or not changed for a long time, the cam follower and the shaft support bearings could be damaged. Oi iter por Drain plug Inspection glass Fig. 4-41 Supplying lubricating oll tothe ATC unit ‘A. Inspection < Procedure > (1) Once a week, check the lubricating oil level at the inspection glass by removing the cover at the left side of the machine, The lubricating oil level must be above the "L” indication, (2) Check the drain plug for looseness if there is no oil visible through the glass. Ifthe drain plug has been loosened, change the lubricating oil according to the lubricating oil changing procedure. If the loss of lubricating oil is caused otherwise than by the loose drain plug, contact the nearest Mazak Technical Center or Technology Center. B. Changing the lubricating oll Change the lubricating oil every year. < Procedure > (1) Remove the plug from the oil filler port and the drain port, and drain the lubricating oil (2). Securely tighten the drain plug and fill the lubricating oil (about 5.8 L (0.20 ft)) through the oil filler port. (3) Check the lubricating oil level at the inspection glass. After confirming that the level Is above the ‘L’ indication, tighten the oil filer port plug.NAINTENANGE OF MAJOR MACHINE Units [4 47-5 Cleaning 4. Cleaning the periphery of the ATC unit ‘An oil pan is provided to prevent scattering of chips and coolant from the tools during automatic tool change operation, Clean the oll pan once a week or every 60 hours. Fig. 442 Clearing the perihery of the ATC unt < Procedure > (1). After opening the ATC cover, (refer to PART 2, 4-9-3 "Manual operations on each section” in the Operating Manual) place the main power disconnect switch to the "OFF" position. ‘After that remove chips and other dirt from the oil pan with a rag. Be careful not to allow ‘accumulated chips and other dirt to fall from the oil pan 441MAINTENANCE OF MAJOR MACHINE UNITS 2 Cleaning the oil pan under the magazine Check the oil pan under the magazine about once a week. If chips and coolant are stored in the «il pan, clean it following the procedure described below. Maintenanes’cover 1 Maintenance cover 2 ‘< 36-tool magazine specication > ‘< 721104001 magazine specication > Maintenance cover + Fig. 4-43 Clearing the ol pan under the magazine (lpan drain port “The magazine oll pan is designed so that the fd int flows onto the bed ‘When cleaning the oll pan, clean the drain port as well, Magazine oll pan Fluid fow (View withthe cover removes) Fig, 4-44 Cleaning the ol pan drain port under the magazine (110-100| magazine specification) 442MAINTENANCE OF MAJOR MACHINE UNrTs [4 < Procedure > (1) Place the main power disconnect switch to the “OFF" position. (2) Remove maintenance cover 1 and maintenance cover 2 (Note). (3) Remove chips accumulated in the magazine oil pan with a rag (4) Check the drain port to see ifit is blocked with chips. If blocked with chips, remove them. Note: Maintenance cover 2 is provided only for the 72-/110-tool magazine specification, 4-7-6 Replacing a tool pocket Gripper Cylinder Direction of removal ofthe tool pocket (Gripper operation) iO Press (Detail ofthe too! pocket atthe standby too! postion) o When the [MAGAZINE POCKET UNCLAMP] uit i highlighted, the cylinder presses the griaper to open i Fig. 4-45 Detail ofthe tool pocket at the standby tool postion © Do not touch the cylinder or the opening/closing part of the gripper when cclamping/unclamping the pocket, otherwise you could sustain serious injury. WARNING 443A | snnrenance OF WAJOR MACHINE UNITS 36-tool magazine specification Magazine side maintenance cover Too) poeket to be replaced Fig. 446 Replacing a tool pocket (96-1001 magazine specication) < Procedure > (1) Remove a tool from the tool pocket to be replaced. (2) Confirm that the tool shifter is at the ATC position. (3) Rotate the magazine to bring the tool pocket to be replaced to the stand-by tool position. (4) Remove the maintenance cover. (8) Display the machine menu by pressing the [je] (machine menu) key on the NC operating panel and then press the display selector key to display the following menu. 72ND-POS Hioxe: ser warwrE- RETURN NANCE ‘MOoE (6)_Press the [ATC SHIFTER MAGAZINE] menu key to display the following menu ARH] ATC ARE BASE | SWING TARE] ATC ARM] ATC ARK] ATC ARE Joc |” g0G) Home En)» How are | ARC cover |rvt-tock posttion|e0st 104] cw | cow | Moor nose | cawces (7) Release the interlocks by pressing [4] + [4] (MF1 + MF2) keys while holding down the IATC INT-LOCK CANCEL] menu key. characteristics and operation of each section and operate it with extra care, '@ When the interlocks are released, collisions or interference could result according to the particular position andlor status of the mechanical section. Thoroughly understand the WARNING.MAINTENANCE OF MAJOR MACHINE UNrT | 4 (8)_Press the menu selector key to display the following menu. ‘MAGAZING] SHIFTER pacazrne)ancazine)iacnan pocker | pocket | surrrer|suretzn| seaxe [uoME SET] HOME vovczau | ovczame [wac. StDE|aTc SIDE] RELEASE Ser (9) Press the [MAGAZINE POCKET UNCLAMP] menu key ‘When clamp/unciamp operation starts, the menu will blink in reverse display mode, and ‘when the operation is completed, the menu will light up (unciamp) or turn off (clamp). (10) After replacing the tool pocket, press the [MAGAZINE POCKET UNCLAMP] menu key to clamp the tool pocket 72-1110-tool magazine specification (magazine 1 side) Tool pocket tobe replaced Fig 4-47 Replacing a tool pocket (72-101 magazine specication (magazine 1 si)| wancrenance oF MAJOR MACHINE UNITS Magazine side maintenance cover Teo! pocket to be replaced Fig 448 Replacing a tol pocket (110-001 magazine spectiction (magazine 1 sie)) < Procedure > (1) Remove a tool from the tool pocket to be replaced. (2) Confirm that the tool shifter is at the ATC position. (3). Rotate the magazine to bring the tool pocket to be replaced to the stand-by tool position. (4) Remove the maintenance cover. (5) Display the machine menu by pressing the [[=]] (machine menu) key on the NC operating panel and then press the display selector key to display the following menu. 72/0 ‘Took kone sen] wacwre- (6)_Press the [ATC SHIFTER MAGAZINE] menu key to display the following menu, ‘ATC ARM] ATC ARM]ATC ARMTATC ARH 308 ‘os cw nome | COVER sez | open nfposztrox|po: (7) Release the interiocks by pressing [=] + [A] (MF1 + MF2) keys while holding down the [ATC INT-LOCK CANCEL] menu key. ‘© When the interlocks are released, collisions or interference could result according to the articular position and/or status of the mechanical section. Thoroughly understand the characteristics and operation of each section and operate it with extra care. WARNINGMAINTENANCE OF MALOR MACHINE unrts [4 (8)_Then press the display selector key to display the following menu. are] 12/110, Bub=POs sezeter| Toot vagazinepsncaztne| (9). Press the [72/110 TOOL MAGAZINE] menu key to display the following menu. whG.2 | WAG.i | SAIFTER CARRIER | CARRIER, rocker | rocker | pocke: lcosrrros}eosrtrox| sizezea | serrrea onczaste | osctame | ovcuamp 2 1 ac. srpefanc. sz3e| (10) Press the [MAG.1 POCKET UNCLAMP] menu key. When clamplunclamp operation starts, the menu will blink in reverse display mode, and when the operation is completed, the menu will light up (unclamp) or turn off (clamp). (11) After replacing the tool pocket, press the [MAG.1 POCKET UNCLAMP] menu key to clamp the tool pocket. 3. 72-tool magazine specification (magazine 2 side) “Too! packet to be replaced View A Fig 4-49 Replacing a tool pocket (72-tol magazine specication (megezine 2 sée)) < Procedure > (1) Remove all tools from the tool pockets on the magazine 1 side. f (2) Remove a tool from the tool pocket to be replaced (3) Confirm that the tool shifter is at the ATC position. (4) Rotate the magazine to bring the tool pocket to be replaced to the stand-by tool position. (5) Remove the magazine cover.A | wawreNance OF MAIOR MACHINE UNITS A WARNING (6) Display the machine menu by pressing the menu) key on the NC operating panel and then press the display selector key to display the following menu, are] 72/i10 2ND-FOS suzeten| ‘Toot frour sez] uacere= RETORN macaz NE |yacaztxe| NANCE ODE (2)_Press the [ATC SHIFTER MAGAZINE] menu key to display the following menu. ‘REO ABH] ‘Are ams] atc ARM]ATC ARM[ATC ARM]ATC ARN] ATC | ATC ‘BASE tua | soc | goa [owe nome | coves | cover jrwr~: posrrrox|eosrrzoxfpositiom] cw | cow | mot ser | opex | ctose | canceL (@)_Release the itertocks by pressing [57] + [.] (MF1 + MF2) keys while holding down the [ATC INT-LOCK CANCEL] menu key. [ When the interlocks are released, colisions or interference could result according to the Particular position and/or status of the mechanical section. Thoroughly understand the characteristics and operation of each section and operate it with extra care. (®)_Then press the display selector key to display the following menu. are] 72/110 2ab-FOS sateter| TOOL leone. 522] warkTE- RETURN sagazimepuncazmne| ‘NANCE ‘MODE (10) Press the [72/110 TOOL MAGAZINE] menu key to display the following menu. MAG.2 | ¥AG.1 [SHIFTER CARRIER | CARRIER pocker | rocker | pocker Jroszrroxlposzrzon| ‘UNCLAM® | oncza | UNCLANP 2 a SHIFTER, (11) Press the [MAG.2 POCKET UNCLAMP] menu key When ciamp/unciamp operation starts, the menu will blink in reverse display mode, and When the operation is completed, the menu wil light up (unclamp) or tum off (clamp). (12) After replacing the tool pocket, press the [MAG.2 POCKET UNCLAMP] menu key to clamp the tool pocket.MAINTENANCE OF MAJOR MACHINE UNrts [4 110-tool magazine specification (magazine 2 side) Too! pocket to be replaced > Magazine cover (View withthe cover removed) Fig. 4550 Replacing a ool pocket (110-400! magazine specication (magazine 2 sGe)) < Procedure > (1) Remove tools in the tool pocket to be replaced and the adjacent pockets. (2) Confirm that the tool shifter is at the ATC position, Ifitis not at the ATC position, sett at the ATC position by following the procedure below. < Procedure > (1) Display the machine menu by pressing the ([=}] (machine menu) key on the NC operating panel and then press the display selector key to display the following menu. ‘are_] 727110 ‘2ND=FOS surrten| Tool lkous sx] sare ‘RETURN MAGAZINE MRGAZIN NANCE ‘MODE (2)_Press the [72/110 TOOL MAGAZINE] menu key to display the following menu wc.2 | ¥AG.1 [SHIFTER ‘CARRIER [ CARRIER | rocker | rocker | rocker lposi7zexposzzz0s| SaIETER onciame | uczame | uncLaMP a a peas. sxozfarc. sz03| (3) Press the [SHIFTER ATC. SIDE] menu key. Check that the [SHIFTER ATC. SIDE] menu item is highlighted (4), Check that the tool carrier is at carrier position 1. Ifit is not at carrier position 1, perform the following procedure. < Procedure > (1). Display the machine menu by pressing the a (machine menu) key on the NC operating panel and then press the display selector key to display the following menu. wee] 72/210 2ab-FOs sureter| Toon Jrowe 29] RETURN NODE magna }uacazixe| (2) Press the [72/110 TOOL MAGAZINE] menu key to display the following menu. vAG.2 | wAG.1 [SHIETER| CARRIER poceer | rocker lposzzzox) surerea | serrTER cwcuane | vicLaMe a fac. szoefarc. sre] 4494) nncrenance oF MALOR MACHINE UNITS (3) (4) (5) 6) Press the [CARRIER POSITION 4] menu key. Check that the [CARRIER POSITION 1] menu item is highlighted. Rotate the magazine to bring the tool pooket to be replaced to the stand-by too! position Remove the magazine cover. Release the ATC interlock by following the procedure below. < Procedure > a) Display the machine menu by pressing the [F=j] (machine menu) key on the NC operating panel and then press the display selector key to display the following menu. (2) 72/320 BND-POS ‘T0oL leone 522) MAINTE ‘RETURN jeacazins| NANCE MODE Press the [ATC SHIFTER MAGAZINE] menu key to display the following menu. (3) WARNING 4 Bic ARM[ATG ARN [ATC ARE]ATe ARN]ATC ARM[ATC AR] Ave] ATC ] ATC ‘i : soe | sos (sew sex) soz | cover | cover |rrt-roce Jposs ce | ecw | more | ser | omen | cuose | cawces poss: Release the interiocks by pressing [51] + [J] (MF1 + MF2) keys while holding down the [ATC INT-LOCK CANCEL] menu key. particular position andior status of the mechanical section. Thoroughly understand the A [© When the interlocks are released, collisions or interference could result according to the characteristics and operation of each section and operate it with extra care. ‘Then, unctamp the tool pocket and change it by following the procedure below. < Procedure > (1)_ Press the display selector key to display the following menu. aac] 72/430 ‘Took soe se2| varnre- fuacazze| ANCE Press the [72/110 TOOL MAGAZINE] menu key to display the following menu. (4) (5) SHIFTER CARRIER, ‘POCKET leoszrro ‘UCLANE 2 7 SHIFTER 70. SIDB| Press the [MAG.2 POCKET UNCLAMP] menu key When clamp/unciamp operation starts, the menu will blink in reverse display mode, and when the operation is completed, the menu will ight up (unclamp) or turn off (clamp). Pull the pocket out and replace it with a new one. Press the [MAG.2 POCKET UNCLAMP] menu key to clamp the tool pocket.MAINTENANCE OF MALOR MACHINE UNITS |4 48 48-4 Hydraulic Unit Construction and specifications The hydraulic unit employs the motor and hydraulic oil pump of one unit construction, thereby not only eliminating noises and damage of bearing and oil seal caused by misalignment of pump and motor but also providing easiness in maintenance. Since pressure compensation unit is incorporated, the pump delivers hydraulic oil meeting actually required amount. ‘This reduces power loss and prevents the oil temperature rise. Fig. 451 Hydraulic unit composition No. Ne Type. ay Maker Remake + | tank 30 (1.06 1 IKEYAMA 2_| Oifiter porvar breather FASS 1 TAISE! 3 | Oilevelgavae KLABOA (M10) f KYOWA 4 | Strainer SFT-06-150W 1 TAISE! 5 | Adjustable vane type of UVN-1A-2A4-228-4.61628 1 FUSKOSHI unipume 6 | Drain hose N51-3/8-CINLIN 4_|_NITTA MOORE 7_| Radiator 382-001-1050 1_| TOYO RADIATOR 8 _| Piping biock zi 1 TKEYAMA 9 | Rubber vibration isolator AZH-8755C-3118312 4 FUJIKOSHI 10 [Oirain : 1 FUJIKOSHI 454| wancTeNance OF MAJOR MACHINE UNITS 4-8-2 Checkups before starting hydraulic unit Before starting the hydraulic unit, check the hydraulic oil level. If the hydraulic cil level is below the correct level, supply oil before turning the power on, 1. Specified level ‘The upper limit level line of the cil level gage indicates the specified level. 2. Allowable lowest level The center level of the specified level indicates the allowable lowest level of the hydraulic oil i= the tank. Never operate the hydraulic unit while the oil level is lower than that. If the unit is operated, the following troubles will result: 4. The air is apt to be mixed in the hydraulic oll causing various types of malfunctions of the pump such as seizing of the pump, noises, faulty valve operation, and unstable pressu= variance during operation. 2. Vibration of the piping runs, which in turn causes oil leakage. The hydraulic oil will be deteriorated rapidly. Other troubles of the hydraulic unit 4-8-3 Inspection when starting hydraulic unit 1. Pump rotation direction ‘With the motor started, the pump starts rotation. Check to be sure that the pump as indicated on the legend plates of the motor and pump. Fig 452 Check the correctness of pump rotation direction by putting a sheet of paper near the Confirm the direction of air low; it must be in the suction direction (direction indicates arrow symbol in the figure). If the airflow direction is opposite, exchange connections of the three cables. 2. Pressure Check that the pressure is set to 6 MPa (900 psi) by the pressure gauge. 4-52MANTENANGE OF MasoR MACHINE UNTs [4 48-4 Inspection and maintenance of hydraulic unit ‘© When replenishing the hydraulic unit with oil, use only the recommended oll. If hydraulic. oll other than the recommended oil is used, it will eause malfunction of the machine CAUTION 4, Replenishment Replenish the hydraulic oil when the oil evel gauge float is below the center. < Procedure > (1) Remove the cap on the supply port ofthe oil tank (2). Replenish the hydraulic oil through the supply port up to the yellow line of the oll level gauge. (3) Fasten the supply port cap securely. 2. Replacing the hydraulic oil and cleaning the strainer Hydraulic oil replacing interval varies depending on machine operation conditions and ambient conditions: As a guide, it must be repiaced every six months. © Hydraulic oil may be warmed up to high temperature after the continuous operation, Care should be taken not to be get burt CAUTION < Procedure > (1) Place @ container with a capacity of 40 L (1.41 ft) or so underneath the drain port and discharge hydraulic oil through the drain port, (2) When hydraulic oil has been discharged completely, disengage the connecting part. (@) Remove the hexagon head boits, pull out the maintenance plate in the oblique direction and remove the strainer. Clean the strainer (4) Using a rag, carefully wipe away the dirt and other sediment which have accumulated inside the tank Note: Under no circumstances must any metal or other such articles be used to clean inside the tank since they will damage the paint. (6) Attach the suction strainer and the maintenance plate. ‘At this point, do not wrap sealing tape around the suction strainer. (6) Tighten the pipe to the motor securely, Wrap sealing tape around the connecting part. (7) Clean the drain plug, wrap new sealing tape around it, and fi it back securely into the drain port as far as it will o. (8) Pour 30 L (1.06 ft) of fresh hydraulic oll through the supply port (2) inspect the oil level gauge and drain port, tighten the supply port cap, and finally attach the machine's cover. 453MAINTENANCE OF MAJOR MACHINE UNITS 4 Maintenance piste To loosen Totighten up CConneeting part Pipe Remove the strainer and ean it Oil drain port Dazewoors Fig. 4-53 Cleaning the tank and strainerMAINTENANCE OF MAJOR MACHINE UNrTS | 4 4-9 Spindle Cooling Unit (Chiller Unit) 4-9-1 Replacing and replenishing oil 4. Replacing oils of the chiller unit and cleaning suction filters © Be absolutely certain to power off the machine before starting the maintenance work. © To replenish oil, always use an oil recommended by Mazak. Otherwise, machine trouble WARNING ff of other adverse effects will result. © If the temperature setting is too low, the spindle outer casing is overcooled to generate excessively large temperature difference between the inner and outer races of the spindle bearings, which can cause seizure. Therefore, do not tamper with the temperature setting unnecessarily. ‘Operating panel Level gauge Fig. 454 Replacing the spindle cooling ll and the hydraulic oll ‘+ Repiacing the spindle cooling oil ‘The frequency of replacing the spindle cooling oil of the chiller unit depends on operating conditions. It is suggested, however, that both oils be fully replaced, initially at the sixth month from purchase, and thereafter, at least once a year. ‘See 3-4 "Supplying Oil” for the brands of the recommended oils. 49-2. Cleaning the filter Clean the air fiters every month. (For the cleaning procedure, refer to the Chiller Unit Operating Manual provided by HABOR PRECISE INDUSTRIES Co., LTD.)4 wancrenance oF maton MACHINE UNITS 4-8-3 Processing of refrigerant HFCs (hydrochlorofluorocarbons: alternatives to chlorofluorocarbons) are used as refrigera chiller units. HFCs must be collected and disposed of in accordance with the appli national regulations. Therefore, when disposing of a chiller unt, contact @ waste collection disposal service company and ask for appropriate processing of the HFCs. Note: If you have no contact with an appropriate waste collection and disposal company, please contact the nearest Mazak Technical Center or Technology C: We will respond to your request at your expense. 4-9-4 Line filter in the hydraulic cylinder circuit ‘The machine is equipped with the hydraulic line fiter as the standard feature to prevent se of the hydraulic chuck cylinder due to entry of foreign matter in the hydraulic circuit Fig. 4-65 Line fitrin the hyat ieoylinder circut 4. Replacing the line filter element in the hydraulic cylinder circuit Although replacement interval of the line fiter element differs depending on the machine operating status, replace the element at least every six months or every 1500 hours of operation. Replace the filter element by following the procedure indicated below. (1) Loosen the filter case by turning the hexagonal section at the bottom of the fiter case with = spanner. Note: When the filter case is loosened, oil will drip. Place an oil pan or other appropriate: item under the fiter case to collet the oil (2) Remove the case and take off the filter element from the boss of the head by pulling it (3) Clean the case. (4)_ Insert the new fiter element onto the boss of the head. (5) Replace the O-ring in the case with a new one.MAINTENANCE OF MAJOR MACHINE UNITS (6) Screw the case into the head. Note: Filter case tightening torque 25 to 35 Nim (18.4 to 25.8 fbf) (Screw size: M60 x 2.0) Head o-ring Fiter element o-ring Fig. 455 457[A mresvecer osorweraesnre 4-10 Lubrication Unit 4-10-1 Lubrication of slideway linear guide and ball screw Lubrication of the slideway linear guides and ball screws of all feed axes are coll controlled by the automatic lubricator. For grease lubrication, use only the recom: grease. IF the pressure drops below 3.0 MPa (440 psi) due to a trouble in the lubrication system. lubricating grease runs short, the pressure switch is activated and the alarm mes Gisplayed on the NC screen. At the same time, the machine enters the single block mode Arbleeding plug Cover / Grease discharge port Fig. 4-57 Electic arease pure 4-58MAINTENANCE OF MAJOR MACHINE UNrTs | 4 1. Inspecting the electric grease pump of the slideway section and replenishing grease ‘A. Inspecting the grease amount Before starting the machine, check the grease amount in the grease cartridge of the electric ‘grease pump every day. If the grease amount is not sufficient, repiace the grease cartridge with anewone. Never refil the grease cartridge since the cartridge may be broken B. Replacing the grease cartridge < Procedure > (1), Turn the cover by hand in the counterclockwise direction to remove it from the pump. (2) Remove the empty cartridge by turning it in the counterclockwise direction. (3) While holding a new cartridge by hands, push it by hands to extract grease about 1m (0.39 in). This can minimize the entry of air into the pump suction port (4) Mount the cartridge by tum the cartridge in the clockwise direction while putting the extracted grease into the cartridge mounting hole. (8) Fit the cover by turing it in the clockwise direction by hand unt it stops. After that operate the pump to confirm that it operates correctly. If a warning is output, air could have entered, C. Bleeding ‘Always bleed the air ifthe air is trapped in the pump. Loosen the air bleed plug in the pump (turn the valve counterclockwise by 1 turn) and keep the Pump operating until air does not come out any more but only grease is discharged. After ‘completing air bleeding work, tighten the air bleed plug, 4694) unnenance OF MAJOR MACHINE UNITS 4-10-2 Milling head lubrication (oil and air lubrication) (20000 min” specification) Lubrication of the bearings of the milling head are collectively controlled by the lubricator. Air is supplied from the air unit and then mixed with the lubricating oil by = valve. If the pressure drops below 0.8 MPa (130 psi) due to a trouble in the lubrication s pressure switch is activated. If lubricating oil runs shor, the float switch is activated. case, an alarm message will be displayed on the screen. And the machine will enter single block operation mode Gear lubrication Mill spindle Suction fer Fig, 458 Lubrication unit composition 1. Inspecting the lubrication unit of the milling head and replenishing lubricating oil ‘A. Inspecting the lubricating oil amount Before starting the machine every day, check that the lubricating oil reserve tank is filed wt specified lubricating oil to the specified level. If the oil level is lower than the center of upper/lower level line of the level gauge at the tank side, supply the same brand of lubri from the oil iter port on the upper part of the lubrication unit so that the oil level do not ex the upper limit level line. Cleaning and changing the filter The suction fiter in the automatic intermittent lubricating pump can be removed by taking o% screws of the upper part of the pump. The filter on the oil filing port can be removed in the same manner. Clean the fiters once. year. ©. Checking lubricating status Before starting the day's operation, check every lubricating status of the lubricating ps Shortage of oil in the lubricating parts causes clogging of the flow unit and cil leakage from piping route. Entry of foreign particles like chips into the flow unit causes clogging malfunction of the flow unit. In such a case, replace the flow unit.MAINTENANCE OF MAJOR MACHINE uNrTs |4 4-10-3 Lubrication of the gears (B-axis) and ATC ‘The gears (B-axis) and the ATC are lubricated by the automatic lubricator in the same manner as mmlling head lubrication. For the method for inspecting and replenishing lubricating oil of the automatic lubricator, refer to 4-10-2 "Milling head lubrication (oil and air lubrication) (20000 min’ specification)”. 481A | wancrenance OF MAJOR MACHINE UNTS 4-11 Coolant 4-14-1 Inspection Check if coolant is stored in the coolant tank to the specified level before starting the day's operation. If the volume of the coolant supplied from the nozzle becomes low, check if the coolant level is lower than the allowable lower limit. 411-2. Supplying coolant © Use coolant with antirust effect. Otherwise, corrosion may occur and cause malfunction of the machine. CAUTION 1. Coolant tank capacity ‘Model with chip conveyor 2. Supplying coolant (1) Pull out the coolant tank from the machine and remove chips. (2) Replenish the coolant that has been arranged to the appropriate density through the chip- filtering plate into the coolant tank until the amount reaches the upper limit level line of the level gauge. Note: If coolant is replenished exceeding the upper limit level line, coolant can overfiow due to coolant retumed from the machine when the coolant pump stops,MAINTENANCE OF MAJOR MACHINE Units |4 LH TH) [ veper it ev or coca Conf that the coolant level is within ‘when the coolant pump is ata this range (H -L) while the coolant pump ‘stop (machine stopped) Is ata stop (machine stopped) Ithe coolant levels owerthan the lower | | limit level (L), supply coolant so thatthe Coolant level within this range (HL) L |b (eee | Confer tat the coolant level is within when the coolant pump i at a this range (L- Lt) while the coolant puma stop (machine stopped) Is operating (machine is operating) We coolant eves ower than the lower | 1 Lf [tever tive orcoaae lit evel(L4) while the ealant pump is te Pcie (machine is operating). sop operating (machine operat the coclant pump (ie. machine seats ties eceeneel operation) and supply coolant so that he coolant levels wih his range (HL). ifthe coolant eves ower than Lt while the pump is operating, causes problems suchas low coolant lscharge amount ad coolant pump damage Fig. 459 411-3 Changing coolant Change the coolant in the coolant tank every six months or if coolant is contaminated heavily Note: Concerning the coolant tank to be used with the chip conveyor, itis not necessary to change the coolant in the chip conveyor. < Procedure > (1) Place the oil drain pan under the drain port. (2) Pull out the fiter from the coolant tank and drain the coolant by loosening the drain plug, After emptying the coolant tank, remove the drain plug. (3) Remove chips from the coolant tank. (4). Clean the thread of the drain port and the drain plug. ‘Wind a new sealing tape around the drain plug and then tighten it up to the end of the drain Port. (6) Fillthe coolant tank up to the top of the drain port and check for leakage from the port. (@) Replenish the coolant that has been arranged to the appropriate density beforehand until the amount reaches the upper limit level line ofthe oil level gauge. (For the machine equipped with the ConSep type conveyor, replenish the coolant on top of the conveyor ) Note: For the selection of coolant, see PART 2, 5-6 “Preparing Coolant" in the Operating Manual. 4634] ancrenance OF MAJOR MACHINE UNTTS 4-11-4 Cleaning Remove chips from the coolant tank every day after completing the day's work. Cleaning the filter ‘ConSep2000II specification Fig. 460. Clearing the iter (with chip conveyor ConSep20001I WS) < Procedure > (1) Pull out the filter carefully from the coolant tank. (2) Clean the fiter using @ hand held air nozzle. ‘When using the hand held air nozzle, wear goggles to protect eyes from flying substances (3) Retum the fiter carefully in the coolant tank. < Inspection time > ‘© Atthe inspection after completing @ day's work + Atthe reguler interval inspection (every 6 months or 1500 hours)MAINTENANCE OF MAJOR MACHINE UNITS |4 2. Cleaning the line filter of the through-spindle cooling system Clean the line filter every week or every 60 hours. Check the indicator and if @ half of the indicator is red, remove the bolts and clean the element of the line fiter. Indicator Fig 451 Clearing the line filer ofthe trough-spindle cooling system 4.65MAINTENANCE OF MAJOR MACHINE UNITS. 3. Maintenance of the line filter for through-spindle coolant (option) A. Line filter specification Type’ G-UL-12A-50,.W-DV (Mazak part No.: G30TP002581) Maker: Talsei Max. operating pressure: 3.5 MPa (510 psi) Filtering accuracy: 50m B. Checking and cleaning the line filter The line fiter has the visual inspection/electric contact type indicator. If the NC screen shows message DIRTY COOLANT FILTER ALARM in yellow letters, clean the element. Stop through-spindle coolant system when cleaning the element. Ifthe through-spindlle coolant system is continuously used for 3 hours after the display of Cl COOLANT SYSTEM WRONG. ‘Since the indicator allows visual inspection, check the transparent cover section visually ang the entire part of the cover is red clean the element disregarding the machine operating time ‘Transparent cover. ———+] Fig 462 Transparent cover of the indicator The indicator is the automatic recovery type Type E indicator (visual inspection/electric type). Indicated pressure difference: Green (indicator starts changing from green to red) 0.2 MPa (30 psi) Red (entire area changed red), alarm signal output 0.3 MPa (48 psi) Note that since the dust-proof cover is plastic, keep it away from solvent (thinner, etc.). Since the wire mesh type element (type P-G-UL-12A-50uW (Taise)) is use, it can be r after cleaning, However, if a break is found replace the element with a new one immediately.MANTENANCE OF MAJOR MACHINE UNrts [4 C. Construction of the line filter [81 Drain plug [4 Element Fig. 464 Removing the drain plug (let), the state after the elements removes (right)MAINTENANCE OF MAJOR MACHINE UNITS Table 42. Table of component parts 1 | Boay : z 2 [cover " Si '3__| Suction port : 4 | Element P.G-UL-T2A-SOAW (G2orPoczse8: 5 __| Retetvave = : 6 | Spring : z 7__| Spring noiser 2 5 8 | rain slug - = ® | Hexagon sockethead bot |= - o1__| Washer 10 [Owing 6-100 For cover 12600670000 12__ [Oring G55 For out 12600605500 13 [Oving G28 For element 32600602500 18 [ving P14 For drain pug 260001400 16 [Oring P18 Forindicator “32600P01800 17 | Oring P14 For indicator s2600°01400 23—_| Type E indicator Visual inspectonelectie ‘G30TPO0269A contact type 21 | setscrew o 23.2 | Switch cover 233 | Clamp screw 234 | Teminal bio 23:5 | Ground packing 236 | cabie outet 1/2 female thread Note: When ordering an element, indicator and O-rings, please specify the part No. indicates in the right column,MAINTENANCE OF MAJOR MACHINE UNITS [4 D. Replacing and cleaning the element < Procedure > (1) Stop the through-spindle coolant and after confirming that coolant does not flow, remove the drain plug [8] to completely empty the filter by draining cootant, (2) Remove the hexagon socket head bolt [9] that fixes the cover [2], and take it out upward while turning to the right and left. The suction port [3] and the element [4] are also taken out. (3) Pull the element [4] downward and itis separated from the suction por (3. (4) Clean the element [4], or replace it with a new one. (5) Replace the O-rings [10], [11], [12] and [13] with new parts. Note that O-ring [11] is easily fallen. Securely put it in the groove when reassembling the filter. (6) Insert the cleaned or new element [4] into the suction port [3], and reassemble the fiter in the reverse order of disassembling When reassembling the fitter, make sure that the O-ring [12] is set in the element [4] and that the coolant flow direction indicated on the cover [2] matches the actual direction of Coolant flow. Tighten the hexagon socket head bolt [9] at the specified torque (80 to 80 Nm (44.3 to 59.0 fbf) (7) Tighten the drain plug [8] securely at the specified torque (50 N-m (36.9 ft bf). E. Cleaning the element Clean the element using light oil or kerosene in the manner shown below. (1) Immerse the element in light oil and shake it up and down, and right and left. (2) Brush the element along the pleats to get the dirt out of the element, (3) Ata place away from the machine, clean the element with compressed air using a hand held air nozzle. (4) Rinse the element well and dry it using a hand held air nozzle. 44-5 Maintenance of chip conveyor © Before carrying out the maintenance work, set the main power disconnect switch to the “OFF” position and lock it in that position with a padlock. Failure to observe the instruction Mme ff could cause serious injury to operators, For the maintenance of the chip conveyor, refer to the relevant manuals indicated below. © ConSep specification’ (ConSep200011 Instruction Manual * Chip conveyor {hinge type) specification: C20 instruction Manual 4-69A} anrenance OF MAJOR MACHINE UNITS 4-12 Air Unit 4-121 Composition and operation ‘The air unit consists of a mist separator and a regulator. The mist separator removes moisture from the compressed air and the regulator adjusts © pressure Note: Moisture in the compressed air causes deterioration and damage to the air actu Used in the machine. Inspection glass \ External air source: (coupler sizeof 1/2") Fig 465 Arun No. Pan Name [= + | mist separator 3 | Regulator ‘Auto drain for suppiag ai pressure adjustment 2 | Manometer 7 | Pressure ewten Preset pressure. 0.5 MP2 (70 ps) Preset pressure 0.25 MPa (36 28 4-12-2 Inspection 1. Confirm that the manometer (No. 2 in the Fig. 4-65) indicates the preset value (70 psi. 2. _In the inspection to be carried out after completing a day's work, check the ins in Fig. 4-65 for the entry of coolant, etc. in it, If coolant exists in the inspecson indicates that the check valve in the pneumatic circuit is possibly damaged. In contact the nearest Mazak Technical Center or Technology Center. 4-70MAINTENANCE OF MAJOR MACHINE UnrTs [4 412-3 Replacing the mist separator element Replace the fier element at least once a year or every 3000 hours, (a) (2) ) (4) Remove the drain tube from the filter case, ‘Take off the screw of the mist separator and remove the filter case. Replace the filter element. ‘Mount the mist separator element in the reverse order of the dismounting carefully not to hurt the filter case and the seal of the element. Fier element Fter as D13swo136 412-4 Adjusting the air pressure Fig. 4-68 Replacing he mist separator The air pressure can be increased by pulling the pressure adjust knob of the regulator upward and then rotating the knob clockwise. Preset supply air pressure: 0.5 MPa (70 psi) TRit3.00282 Fig. 487 Adjusting the alr pressure 4744 | mavteNance OF MAJOR MACHINE UNITS 4-13 Water Removal Filter (20000 min” Specification) 4-13-1 Composition and operation ‘The water removal filter to be installed in the pneumatic circult removes water and oil-mist inthe air to keep the pneumatic circuit clean. Table 4-3 shows the water removal filter. Table 43 Water removal iter PartNo, Pat Name, Type, Maker (G483v000670 Water removal iter (SUN-DRAIN) | __YS01-PT3/6 Weter removal iter (SUN-DRAIN) Automatic dain aay | Fig. 468 Water removal fiter installation position ‘Cooling chamber Stainless mesh screen —] | Hard aluminum fier Casing seine / ‘Automatic crain Fig, 409 Sectional view ofthe water removal fiterMAINTENANCE OF MAJOR MACHINE UNITS. 4-13-2 Inspection Weter and oil-mist collected by the water removal fiter is automatically discharged outside the machine by the automatic drain function. However, if the automatic drain function fails as indicated below, it will cause malfunction of the machine such as backflow of drain. To prevent this, check the drain of the water removal fiter everyday. 4. Airis always leaking through the drain port. tt leaks, the water removal fiter must be replaced. 2. Drain is not bowl. ischarged but accumulated up to the uppor limit line in the automatic drain Clean the drain port with neutral detergent to remove contaminants blocking the drain port. If rain is not discharged even after the drain port is cleaned, it is necessary to replace the automatic drain. 443-3 Cleaning the filter ‘The water removal fiter uses a stainless mesh screen and, generally, replacement of the fiter is not necessary. Cleaning intervals vary depending on the operating conditions of the filter. Under normal state, clean the fiter every six months using kerosene or thinner. Ifthe filter gets a hole, however, replace the fiter with a new one immediately. ‘© Before cleaning the fitter, set the main power disconnect switch to the “OFF” position and disconnect the external air source from the machine to remove the air pressure from the ic circuit. CAUTION {| Pneumatic circu < Procedure > (1) Remove the water removal fier maintenance cover. (2) Detach the automatic drain by turning it at the joint. (3) Tum the casing counterclockwise and detach it. (4) To take out the hard aluminum fiter and the stainless mesh screen, first detach the hard aluminum filter by turning it counterclockwise and take it out together with the cooling chamber. (6) Detach the cooling chamber by turning it counterclockwise. (6) Clean the following items with kerosene or thinner; hard aluminum fier, stainless mesh screen, and cooling chamber. Note: The hard aluminum filter and the stainless mesh screen cannot be separated. (7). Blow off kerosene or thinner using a hand held air nozzle at a place away from the machine. (8) Mount the cooling chamber, the hard aluminum fier, the stainless mesh screen, the casing and the automatic drain in order. (9) Mount the water removal fiter maintenance cover. 4734 MAINTENANCE OF MAJOR MACHINE UNITS: 4-14 Other Components 414-1 Procedure for repla Proximity sensor Nuts Washer Bracket 100.39) Nut Watendog 05-1.0 (0.02-0.04) Unit: mm cn) Mc1it-01217" Fig. 4-70 Replacing the proximity sensor < Procedure > a) (2) (3) Remove nuts A and B and remove the sensor. Insert @ new sensor into the hole of the bracket. Hand-tighten nuts A and B. The tightening torque is shown below. Tighten the nuts so that the permissible torque not exceeded, Overtightening causes damage. Tightening torque: 30 Nim (22.1 felbf) (4) Use a feeler gauge to measure the clearance. 6 of the sensor and the watchdog. ‘Measure the clearance between the front end of the sensor and the watchdog, Perform adjustments for a clearance of 0.5 - 1.0 mm (0.02 - 0.04 in) between the front eng Since the thread of the sensor is pitched at 1 mm (0.04 in), rotation of the nut through one: tum moves the sensor through 1 mm (0.04 in). ‘A. To move the sensor forward through 1 mm (0.04 in) ~ Rotate (loosen) nut 8 through one counterclockwise tum. ~ Rotate (tighten) nut A through one clockwise turn, B. To move the sensor backward through 1 mm (0.04 in) Rotate (loosen) nut A through one counterclockwise tum, - Rotate (tighten) nut B through one clockwise turn (6) Retighten the nuts (be sure to tighten nut A). (7) on and off Note: ‘Sensor on/off can also be checked on the DIAGNOSIS screen, After adjustment, operate the machine and check that the LED of the sensor correctly tums: Refer to the relevant electrical drawings and the PART 3 “OPERATING NC UNIT AND PREPARATION FOR AUTOMATIC OPERATION’ of the Operating Manual. 474MAINTENANCE OF MAJOR MACHINE UNITS |4 414-2 Replacing the batteries of the amplifiers 1 Replacing cell batteries aro, MR-J28-1000T4 Magazine Lower turet WRJ25-50074 MR-28-100074 X and Z-axis Weaxis DHNZ-8080 ayy OHIO DH-V2-8080 Fig. 4-71 Replacing he batteries of he amplifiers When alarm 12 ABSOLUTE POSITION WARNING is displayed, it indicates thet the voltage of the battery used in the absolute position detection system is low. If this alarm message is displayed, replace the battery for all axis amplifiers by following the procedure below. Note: Keep the power to the machine on for at least 30 minutes before replacing the battery Battery replacement must be completed within an hour. Battery type Manufacturer: Mitsubishi Electric Corporation Manufacturer's type: ER6V-C119B Mazak part No, D80MA016250| nanerenance oF MAIOR MACHINE UNTS B. Battery replacement procedure (1). Tum off the input power breaker and confirm that the power to the drive unit for which the battery is to be replaced is turned off. (2) Open the cover of the battery holder on the upper part of the front of the drive unit. (3)_Disconnect the battery cable connector from the drive unit and take out the battery Disconnect the battery connector. ‘Open the cover toward you while pushing the battory older tab downward Fig 472 (4) Connect the cable connector of the new battery to the same connector position where the battery cable connector was disconnected in step (3). (5) Put the battery in the battery holder and close the cover. ‘Connect the cable connector ofthe naw battery tothe connector where the battery connector was disconnected. al] Put the battery into the battery holder. MDS.DH= EREV-C1198 a oy Fig. 473 Nene.MAINTENANCE OF MAJOR MACHINE UNrTs |4 C. Battery for the auxiliary equipment servo amplifiers For the motors (ATC rotation, magazine rotation, and lower turret rotation), the type MR-J2 amplifier of Mitsubishi Electric is used and the amplifiers are housed in the electrical control cabinet. Each amplifier retains the absolute home position data even after the machine has been powered off with a builtin battery. The retained home position data, however, will be lost if the builtin battery runs down, In this case, it is necessary to replace the amplifier's battery ‘and reset the home position. Mount a battery to the servo drive unit using the procedure below. (1) Open the window at the operating section. (For MRJ2S-350C74, also remove the front cover.) (2) Seta battery in the battery holder. (3). Insert the battery connector to CON1 until it clicks. The term of battery storage is about five years. Fig. 4-74 Name Type (Maker) PartNo, + [Amotier (MR (tisubishi = 2_| Mos amoiier battery ‘ABBAT (Mitsubishi) ‘bsoMmao08481 3 [Batory connector = = 477MAINTENANCE OF MAJOR MACHINE UNITS. Replacing battery units When alarm 12 SERVO BATTERY WARNING is displayed, it indicates that the voltage of the battery used in the absolute position detection system is low. If this alarm message is displayed, replace all the batteries shown in Fig. 4-76 by following the procedure described in A. “Procedure {or replacing the batteries of the battery unit’ To identify the battery whose voltage is low, check the axis number (Fig. 4-75) indicated in the alarm on the NC screen. The locations of the battery units and their axis numbers are indicated in Fig. 4-76. Four size D alkaline batteries are used in each battery unit, Note: Even if the alarm does not appear, replace the batteries once a year. 012 SERVO BATTERY WARNING (&00000001 ,'&0003, i) ‘Axis number Fig. 4-75 Axis number inthe detalie alarm code Batory unt 1 Battery unit 2 Corresponding axis number: <80005> CCortesponcing axis number, Fig. 6-76 Locations of battery units and thelr axis numbers 478WAINTENANCE OF MAJOR MACHINE UNS [4 Battery unt 3 ‘Coftesponding axis number; Fig. 477 Locations of battery urits and their axis numbers (only for the 110-00] magazine specification) ‘A. Procedure for replacing the batteries of the battery unit Note 1: Replace batteries with the main power disconnect switch in the “ON” position or while the NC power is ON. Note 2: Do not use manganese batteries. Note 3: Use size D alkaline batteries. Use of the following battery is recommended. [Name Type vate of Recommended Batiery Mazak Part No Sie D akaline batery LRZORS(2S)/EE ‘D50F5007730 Note 4: When replacing the size D alkaline batteries in a battery uni, all four ofthe replacement batteries need to be new and of the same type. Note §: Do not use rechargeable batteries. (1) Remove the cover ofthe battery unit. ‘The cover can be taken off ater removing the four screws. Fig. 478 Battery unt cover 4794 | wanrensnce oF mason MAcHNe UNTs (2) Replace the four batteries, ‘Take care to set the batteries with the correct polarities. Minus. terminal atthe ‘near sice Pius terminal atthe e terminal atthe Thea sik Alkaline battery Fig 4-79 Battery arrangement in the battery unit (3) Tighten the screws in diagonal sequence while pressing on the cover. Checks after replacing batteries Check if the batteries have been replaced correctly by following the procedure below. Before starting the checking procedure, the main power disconnect switch needs to temporarily placed in the “OFF” position. Note: If the batteries are not correctly replaced and 10 hours has elapsed with the Power disconnect switch in the "OFF" position, the zero point data of the axes will lost. < Procedure > (1) After replacing the batteries, tum the NC power OFF ifit is ON. (2) Place the main power disconnect switch in the “OFF" position. (3) Place the main power disconnect switch in the “ON" position (4) The NC power comes ON. (6) After the NC unit has started up, check that alarm 12 SERVO BATTERY WARNING is displayed If alarm 12 SERVO BATTERY WARNING remains even after completing the above pr contact the nearest Mazak Technical Center or Technology Center.MAINTENANCE OF MAJOR MACHINE UNrTs [4 414-3 Cleaning the air filters (ampli cabinet cooling air intake port) of the electrical control An air filter is provided at the amplifier cooling air intake port in the electrical control cabinet. Fier (43737208330) Fig. 480 Cleaning the aicfites (ampitfer cooling arintake pon) ofthe electrical control cabinet © After cleaning the fiter, drying it well naturally before remounting ‘© Operate the machine with fiters mounted. Although interval for cleaning the filters varies CAUTION |, depending on the environmental conditions, itis necessary to clean them once a month 4. Cleaning the air filter ‘When the air filter (43737206330) is dirty, remove it and wash it lightly in clean water. ‘The procedure is as follows: < Procedure > (1) Remove the fiter only after tuming off the main power supply to the machine. (The filter can be pulled out to the front by pinching it) (2) Wash the fiter in water. (3). Let the fiter dry well and then remount it. Note: One set of spare air fiters is provided in the toolbox in addition to the filters mounted to the machine. Keep the spare filters in the pocket in the electrical control cabinet or other appropriate places. 2. Airfilter replacing interval Every 2 hours or 6000 hours4-14-4 Way cover and wiper The wipers located on each way cover prevent chips from entering the sliding surfaces and maintain @ uniform oil membrane. Therefore, always watch out for unusual wear on the lips of the wipers and for wiper damage due to chips. Replace wom-out or damaged wipers. (Please refer to the relevant Parts List and place an order to the nearest Mazak Technical Center or Technology Center.) Table of way covers ATC shutter Fig. 481 Way covers and wipers (10000)MAINTENANCE OF MAJOR MACHINE UNITS ie ‘Specification 41000 mm (38.37 in) between centers Part Ni Interval 1 | Xeaxls way cover ‘sAtz480270" ‘satz4s0t40r Z years (6000 nours) 2 | Zaxis way cover (left side) ‘5A12450280" 5A12450130" years (8000 hours) Zeaxis way cover (ight side) 5a12450280" = = ‘Weaxis way cover (ied cover) 5A12450160" ‘SA12480110 2 years (6000 hours) | Weaxis way cover (movable sA12450180" = = over) 6 | Zexis way cover wiper (ight = 3A12470148" 2 years side) (2pcs used) (6000 hours) 7 | Face cover wiper = 72012470618" years (IL specification) 4at2470888° (6000 hours) 4a1247086e" 8 | Face cover wiper = 2012470885" 2 years (SS specification) aatarzo0ss (6000 hours) 4012470859" 9 | ATC shutterwiper (OAT2451176"| = 2 years (6000 hours) Note: Since the length of life of wipers varies depending on the use conditions, from time to time and replace if necessary. ‘The wiper replacement interval gives only reference. Concerning values in years and hours, replace the wiper at the timing whichever reaches earlier. However, since the intervals of replacement vary depending on the use conditions and frequency of use, indicated intervals should only be used for reference. 483 check then4 | wanrenance oF MAIOR MACHINE UNITS Fig. 482 Way covers and wipers (1500U) N Specification 7600 mm (68,06 in) between centers | Wier Replacernent Part Name Paris No. ‘Wiper Kit Unit No Inter 7 | Xeans way cover ‘aIz46027" sAr2450140" 2 years (6000 hours) 2 | Zeaxis way cover (ef side) sarzaso23" 5A1245025", 2 years (6000 hours) 3 | Z-axis way cover (ight side) BRIAR ‘BAI245025 2 years (6000 hours) 4 | Waaxs way cover BAT245051" BaTe5036 2 yeas (1500U, without work rest, HOt (6000 hours) to TUSS) 3 | Weaxis way cover ai268032" ‘BA245040" 2 years (1500U, TUS tort i (6000 hours) 6 | wees way cover sarzas038™ eRTDAEONE™ 2 years (1800U, SS cover (6000 hours) 7 [ATC shuter wer onizaeti74" = 2 years Lo cobra Note: Since the length of life of wipers varies depending on the use conditions, check them from time to time and replace if necessary. The wiper replacement interval gives only reference. Concerning values in years ans hours, replace the wiper at the timing whichever reaches earlier. However, since the intervals of replacement vary depending on the se conditions and frequency of use indicated intervals should only be used for reference. 4-84