(9145)

OPERATING/PROGRAMMING SUPPLEMENT
for CINCINNATI HAWK TURNING CENTER Model 150 / 200 / 250 (ERD) with FANUC SERIES 21i CNC CONTROL PUBLICATION NO. 91203597B001
IMPORTANT
Carefully read the instructions and safety precautions given in this manual. Do not attempt to operate this machine until you have thoroughly read and understood the material contained in this manual and all other applicable manuals. At the time of writing, the book was completely up-to-date. However, due to continual improvements in design, it is possible that descriptions contained herein may vary to a slight extent from the system delivered to you. This merely implies that the system has been improved to better fulfill your requirements. You are encouraged to contact the nearest Cincinnati Machine representative for clarification. Patents Notice The machine and attachments and parts thereof illustrated and described in this book are manufactured under and protected by issued and pending British and Foreign Patents and copyright is reserved in any original design feature thereof and in the contents of this book and every part thereof.
IMPORTANT
Cincinnati Machine U.K. Limited P.O. Box 505, Kingsbury Road, Birmingham, B24 0QU
1998 Cincinnati Machine, a Division of UNOVA Industrial Automation Systems, Inc. Cincinnati Machine, CINCINNATI, DART, ARROW, SABRE, LANCER and HAWK are trademarks of Cincinnati Machine, a division of UNOVA Industrial Automation Systems, Inc. ACRAMATIC is a trademark of Vickers E.S.D., Inc. Printed in England - EDITION 1 - June 1999
FOREWORD WARNING 1
In order to clearly show details of this machine, some covers, shields, guards, barriers, devices or doors have either been removed or shown in an open position. All such protective components must be installed in position before operating this machine. Failure to follow this instruction may result in personal injury. The purpose of this manual is to provide the necessary information to enable suitably experienced personnel, to operate the CINCINNATI HAWK 150/200/250 Turning Centers equipped with Fanuc 21i control system. Information contained in this manual is not warranted and is subject to change without notice. The manual has not been prepared to enable inexperienced personnel to operate the machine without further training. The owner/user is responsible for the training of inexperienced personnel and for providing the background necessary for experienced personnel to safely operate these machines. It is intended to cover the control of the MTB (Machine Tool Builders) dependant functions as applicatble to the HAWK TURNING MACHINE with Fanuc control. It does not include general part programming or control maintenance information. These are covered in the appropriate GE FANUC Operators and maintenance manuals, as supplied with the machine. The chapter on general safety precautions should be observed at all times during machine operation and maintenance. Read this chapter before reading the remaining chapters in this manual and operating the machine.
Any questions pertaining to the operation of the machine should be directed to:
WARNING 2
CUTTING FLUIDS When soluble coolants are used, it is important to ensure that recommended concentration levels are maintained. Failure to follow this instruction can cause corrosion of safety critical parts, resulting in machine damage and/or serious personal injury.
Field Service Department Cincinnati Machine U.K. Ltd, P.O. Box 505, Kingsbury Road, Birmingham, B24 0QU England Tel: 0121-351-3821 Fax: 0121-313-1184
Cincinnati Machine Marketing Company, Cincinnati, Ohio 45209-9988, USA. Main Tel: (513) 841-8100 Service Tel: (513) 841 3000 Service Fax: (513) 841 8871
DANGER HIGH VOLTAGE

Lethal voltages are present in the magnetics and electrical control cabinets when the MACHINE MAIN DISCONNECT is ON. Current and voltage measurements should be attempted only by qualified electrical maintenance personnel. Before working on any electrical circuits, turn the machine Main Disconnect Device OFF and lock It. Capacitors in the Servo Drives require up to 20 minutes to completely discharge. Always verify that discharge is complete using a known working and calibrated voltmeter before commencing work on these units. Unless expressly stated in applicable Cincinnati Machine documentation or by the appropriate Cincinnati Machine Field Service Representative, do NOT work with electrical power ON. If such express statement of advice exists, working with electrical power ON should be performed by a Cincinnati Machine Field Service Representative. The customer and subsequent transferees must determine that any other person performing work with electrical power ON is trained and technically qualified. Failure To Follow This Instruction May Result In Death Or Serious Personal Shock Injury.
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Table of Contents
Chapter 1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . .
Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Safety Instructions And Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting And Carrying Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation And Relocation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup And Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Materials Used With This Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFTING DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EYEBOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOIST RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPREADER BARS AND LIFTING BEAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE SLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SYNTHETIC MATERIAL SLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P TYPE HOOKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S HOOKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U TYPE HOOKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL SAFETY LIFTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . Fluids Used With Machine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sources Of Information - USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Usage Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting Fluids - Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Cautions 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Too Soft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Too Hard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning The Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifespan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tramp Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printed Circuit Board Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Handling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perimeter Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Sliding Door(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1 1-2 1-2 1-2 1-3 1-3 1-4 1-4 1-5 1-6 1-7 1-7 1-7 1-9 1-10 1-10 1-12 1-13 1-14 1-14 1-16 1-17 1-18 1-18 1-18 1-18 1-18 1-19 1-20 1-20 1-20 1-20 1-20 1-20 1-21 1-21 1-21 1-21 1-22 1-22 1-22 1-23 1-23 1-23
Table of Contents
Feed Hold Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Stop Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Isolation Device (Main Disconnect Switch) . . . . . . . . . . . . . . . . . . . . . Air Supply Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metric Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Related Safety And Usage Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis Overtravel Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Operation Of Lathe Chucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Holding Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lithium Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 1-24 1-24 1-24 1-24 1-25 1-25 1-25 1-25 1-26 1-27 1-27
Chapter 2 System Information . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guard Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fumes And Coolant Misting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Location - See Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMC Directive Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hawk Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine And Range Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MACHINE ALIGNMENT AND PROGRAM POINTS . . . . . . . . . . . . . . . . . . . . . . Machine Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-1 2-2 2-3 2-4 2-4 2-4 2-4 2-5 2-5 2-6 2-7 2-9 2-25 2-27 2-27
Chapter 3 Functional Description of Controls . . . . . . . . . .

Introduction - GE FANUC 21i-TA CNC System . . . . . . . . . . . . . . . . . . . . . . . . OPERATOR PANEL - PUSHBUTTON DESCRIPTIONS . . . . . . . . . . . . . . . . . AUTOMATIC OPERATION - PROGRAMME SOURCE . . . . . . . . . . . . . . . . . . . . MEMORY OPERATION - (Push button with LED) (A1) . . . . . . . . . . . . . . . . . EDIT MODE - (Push button with LED) (A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . MDI OPERATION - (Push button with LED) (A3) . . . . . . . . . . . . . . . . . . . . . . EXECUTION PUSHBUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYCLE START (Push button with LED) (F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . CYCLE STOP (Push button with LED) (F2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROGRAMME STOP (Push button with LED) (F3) . . . . . . . . . . . . . . . . . . . . . SPINDLE CONTROL BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPINDLE STOP (Push button with LED) (F5) . . . . . . . . . . . . . . . . . . . . . . . . . . SPINDLE CLOCKWISE (CW) (Push Button with LED) (F4) . . . . . . . . . . . . . .
3-1
3-1 3-2 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-4 3-4 3-4 3-4
Table of Contents
SPINDLE COUNTER CLOCKWISE (CCW) (Push button with LED) (F6) . . . SPINDLE 100% (Push button with LED) (D5) . . . . . . . . . . . . . . . . . . . . . . . . . . SPINDLE SPEED INCREMENT (Push button with LED) (D6) . . . . . . . . . . . . SPINDLE SPEED DECREMENT (Push button with LED) (D4) . . . . . . . . . . . . OPERATION BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALIGN MACHINE - (Push Button with LED) (A4) . . . . . . . . . . . . . . . . . . . . . MPG MODE (HANDWHEEL) & INCREMENT SELECTION PUSHBUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPG MODE - 0.001mm (Push Button with LED) (B4) . . . . . . . . . . . . . . . . . . . MPG MODE - 0.010mm (Push Button with LED) (B5) . . . . . . . . . . . . . . . . . . . MPG MODE - 0.100mm (Push Button with LED) (B6) . . . . . . . . . . . . . . . . . . . JOG MODE - (Push Button with LED) (A5) . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION SELECT - PUSHBUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINGLE BLOCK - (Push Button with LED) (B1) . . . . . . . . . . . . . . . . . . . . . . . BLOCK DELETE - (Push Button with LED) (B2) . . . . . . . . . . . . . . . . . . . . . . . OPTIONAL STOP - (Push Button with LED) (B3) . . . . . . . . . . . . . . . . . . . . . . DRY RUN - (Push Button with LED) (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROGRAMME TEST - (Push Button with LED) (C2) . . . . . . . . . . . . . . . . . . . AXES INHIBIT - (Push Button with LED) (C3) . . . . . . . . . . . . . . . . . . . . . . . . AXIS/DIRECTION SELECTION PUSHBUTTONS . . . . . . . . . . . . . . . . . . . . . . . . X+ AXIS (Push Button with LED) (B9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X- AXIS (Push Button with LED) (D9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z+ AXIS (Push Button with LED) (C10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z- AXIS (Push Button with LED) (C8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAPID TRAVERSE (Push Button with LED) (C9) . . . . . . . . . . . . . . . . . . . . . . PARTS CATCHER DOWN (Push Button with LED) (A6) . . . . . . . . . . . . . . . . . PARTS CATCHER UP (Push Button with LED) (A7) . . . . . . . . . . . . . . . . . . . . TURRET JOG + (INCREMENT) (Push Button with LED) (C4) . . . . . . . . . . . . TURRET JOG - (DECREMENT) (Push Button with LED) (C5) . . . . . . . . . . . . CHUCK - ID GRIP (Push Button with LED) (A8) . . . . . . . . . . . . . . . . . . . . . . . CHUCK - OD GRIP (Push Button with LED) (A9) . . . . . . . . . . . . . . . . . . . . . . OFFSET MEASURE (Push Button with LED) (A10) . . . . . . . . . . . . . . . . . . . . . TOOL SETTING ARM DOWN (Push Button with LED) (D2) . . . . . . . . . . . . . TOOL SETTING ARM UP (Push Button with LED) (D3) . . . . . . . . . . . . . . . . . PROGRAM RESTART (Push Button with LED) (D1) . . . . . . . . . . . . . . . . . . . . AUX 1 - Auxillary Push Button (Push Button with LED) (C6) . . . . . . . . . . . . . COOLANT BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT OFF (Push Button with LED) (F9) . . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT ON (Push Button with LED) (F8) . . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT AUTO (Push Button with LED) (F10) . . . . . . . . . . . . . . . . . . . . . . . MISCELLANEOUS CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEMORY PROTECTION - Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS 232 SERIAL DATA PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEED/RAPID/JOG OVERRIDE - Selector Switch . . . . . . . . . . . . . . . . . . . . . . EMERGENCY STOP (red mushroom pushbutton with latch) . . . . . . . . . . . . . . MTB OPERATORS CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Load Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-7 3-7 3-7 3-7 3-7 3-7 3-7 3-8 3-8 3-8 3-8 3-8 3-8 3-8 3-8 3-9 3-9 3-9 3-9 3-9 3-9 3-9 3-9 3-10 3-10 3-10 3-10 3-10 3-11 3-11
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0 to 100% Range (Continuous rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 110 to 150% Range - Yellow Band (30 minutes 50% rating) . . . . . . . . . . . . . . . 3-12 151 to 180% Range - Red Band (1 minute overload capacity) . . . . . . . . . . . . . . 3-12 MASTER START - Illuminated push button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 CYCLE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 HANDWHEEL (MPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 CHUCK UNCLAMP push button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 CHUCK CLAMP push button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 TAILSTOCK QUILL ADVANCE/STEP ADVANCE push button . . . . . . . . . . . 3-14 TAILSTOCK QUILL RETRACT push button . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Machine Pressure - Tailstock Thrust - Chuck Drawbar Force - Chuck Brake (Dampener) Control . . 3-15 MAIN POWER DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Optional Operating Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Swarf Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Wash Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 GENERAL CHUCK SAFETY GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 CHUCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 CHUCKING SYSTEM TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 CHUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 CENTRIFUGAL FORCE AND SPEED LIMITATIONS . . . . . . . . . . . . . . . . . . 3-20 CHUCK LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 TOP JAW RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Chapter 4 Machine Start Up and Alignment Procedure . .

Machine Start Up and Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Up and Shut Down Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine/Control Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turret Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Tool Machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1 4-1 4-1 4-1 4-1 4-2 4-2 4-2
Chapter 5 Software and Hardware Axis Overtravel . . . . . .

Software Axis Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CANCELLING SOFTWARE RANGE CHECKING . . . . . . . . . . . . . . . . . . . . . Hardware Axis Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1 5-1 5-1
Chapter 6 G codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
Chapter 7 M codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-1
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M codes supported on Cincinnati Turning Centres . . . . . . . . . . . . . . . . . . . . . . . 7-1 Function Description of M Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 M00 PROGRAMME STOP (STOPS SPINDLE) . . . . . . . . . . . . . . . . . . . . . . . 7-2 M01 OPTIONAL PROGRAMME STOP (STOPS SPINDLE) . . . . . . . . . . . . . 7-2 M02 END OF PROGRAMME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 M03 START SPINDLE CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 M04 START SPINDLE CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 M05 SPINDLE STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 M08 FLOOD COOLANT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 M09 COOLANT OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 M13 START SPINDLE COUNTER CLOCKWISE WITH COOLANT . . . . . . 7-3 M14 START SPINDLE CLOCKWISE WITH COOLANT . . . . . . . . . . . . . . . . 7-3 M19 ORIENTED SPINDLE STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 M30 END OF PROGRAM AND REWIND . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 M34 PARTS CATCHER ADVANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 M35 PARTS CATCHER RETRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 M44 RENISHAW TOOL SETTING ARM (TSA) UP . . . . . . . . . . . . . . . . . . . . 7-4 M45 RENISHAW TOOL SETTING ARM (TSA) DOWN . . . . . . . . . . . . . . . . . 7-4 M46 FEEDRATE OVERRIDE DISABLE (100%) . . . . . . . . . . . . . . . . . . . . . . . 7-4 M47 FEEDRATE OVERRIDE ENABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 M48 SPINDLE SPEED OVERRIDE DISABLE (100%) . . . . . . . . . . . . . . . . . . 7-4 M49 SPINDLE SPEED OVERRIDE ENABLE . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 M50 C-AXIS MODE OFF (Driven Tool Machines only) . . . . . . . . . . . . . . . . . 7-5 M51 C-AXIS MODE ON (Driven Tool Machines only) . . . . . . . . . . . . . . . . . . 7-5 M52 C-AXIS BRAKE ON (In-Position Mode, Driven Tool FeatureDriven tool machines only) 7-5 M53 C-AXIS BRAKE ON- (Interpolation Mode, Driven Tool Feature)Half pressure - contouring (Driven tool machines only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 M54 C-AXIS BRAKE OFF (Driven Tool Machines only) . . . . . . . . . . . . . . . . 7-6 M61 BARFEED MACRO CALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 M68 ADVANCE TAILSTOCK QUILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 M69 RETRACT TAILSTOCK QUILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 M70 TO M73 CUSTOMER OUTPUTS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . 7-6 M74 COLLET CHUCK MODE DISABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 M75 COLLET CHUCK MODE ENABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 M76 FORCE TURRET ROTATION CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 M77 FORCE TURRET ROTATION CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 M78 CHUCK OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 M79 CHUCK CLOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 M80 BARFEED EJECT/RELOAD NEW BAR . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 M86 BARFEED PRESSURE ON (HYDRAFEED AND FEEDMASTER ONLY) . . . . . . . . . . . . . . . . . . . . . . . 7-7 M87 BARFEED PRESSURE OFF (HYDRAFEED AND FEEDMASTER ONLY) . . . . . . . . . . . . . . . . . . . . . . . 7-7 M90 BARFEED MODE ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 M91 BARFEED MODE OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 M92 BARFEED ROTATION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
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M93 BARFEED ROTATION OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M94 INCREMENT PARTS COUNTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M98 SUBROUTINE CALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M99 END OF SUBROUTINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 7-8 7-8 7-8
Chapter 8 Spindle Functions . . . . . . . . . . . . . . . . . . . . . . . . .

Spindle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driven Tool Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-1 8-1 8-2
Chapter 9 Tooling Functions . . . . . . . . . . . . . . . . . . . . . . . . . .

Tool Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turret Indexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driven Tool Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Force Turret CW and CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Life Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1 9-1 9-1 9-2 9-2 9-2
Chapter 10 Driven Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-Axis Mode Enable/Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-Axis Initialisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-Axis Positioning Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-Axis Interpolation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10-1 10-1 10-1 10-2 10-5 10-5
Chapter 11 Toolsetter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Macro Probing Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Tool Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Tool Setting - TSA only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator and Programming Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Setting Arm Activation - TSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M44 TSA Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M45 TSA Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Setting Arm Down Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Setting Arm Up Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HPA - Manual Toolsetting Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 11-1 11-2 11-2 11-2 11-3 11-3 11-3 11-3 11-3 11-4 11-4 11-4 11-4
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Removing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TSA/HPA Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stylus Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stylus Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stylus Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Calibration Data - Base Number 522 . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Software Back Off Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Macro Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Nose Vector Hh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Calibration - Macro O9011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Macro Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Tool Setting - Macro O9011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Macro Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set a Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Broken Tool Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Tool Setting - Macro O9012 - TSA Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Macro Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 11-4 11-5 11-5 11-5 11-5 11-5 11-6 11-6 11-8 11-9 11-9 11-9 11-9 11-9 11-9 11-9 11-10 11-11 11-11 11-11 11-11 11-11 11-11 11-11 11-12 11-15 11-15 11-15 11-15 11-15
Chapter 12 Parts Catcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M34 Parts Catcher Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M35 Parts Catcher Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Catcher Advance Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Catcher Retract Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator and Programming Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 12-1 12-1 12-1 12-2 12-2 12-2 12-2
Chapter 13 Barfeeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Table of Contents
Bar Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Barfeed Sequence for Multifeed Unit:- ......................... Standard Barfeed Sequence for Hydrafeed and Feedmaster . . . . . . . . . . . . . . . . . Barfeed Spindle Rotation Speed Bits - Keep Relay K Bits . . . . . . . . . . . . . . . . . . . . 13-1 13-1 13-2 13-3 13-4
Chapter 14 Reserved Macro Routines . . . . . . . . . . . . . . . . . . 14-1

Used Macro Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Chapter 15 Connection to Data Input/Output Devices . . . . 15-1

Connection to Data Input and Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input/Output Device and Code Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 15-2
Chapter 16 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

PMC Input Address Reference List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PMC Output Address Reference List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FANUC Operators Panel Connection Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FANUC Operator Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Diagnostic Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Display LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FANUC Operator Station Key/LED - Diagnostic Address Table . . . . . . . . . . . . . . . Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2 16-3 16-4 16-5 16-5 16-5 16-5 16-6 16-7 16-73
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Fig. 1 Preferred Inch Lifting Eyebolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2 Preferred Metric Lifting Eyebolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 3 Eyebolt Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 4 Eyebolt I.D. Plates - Inch and Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 5 Instruction Plate - Inch (Part Number 3375984) . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 6 Instruction Plate - Metric (Part Number 3375983) . . . . . . . . . . . . . . . . . . . . . . . Fig. 7 Hoist Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 8 Hoist Ring Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 9 Spreader Bar - Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 10 Steel Alloy Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 11 Wire Rope Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 12 Sling Load Angle Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 13 P Type Lifting Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 14 P Type Lifting Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 15 S Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 16 S Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 17 U Type Lifting Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 18 U Lifting Hook Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 19 Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................................... Fig. 20 Driven Head Tool Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 21 Hawk Turning Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 22 Axis Orientation - Hawk Turning Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 23 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 24 Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 25 Turning Capacity Chart - Hawk 150 (VDI Tooling) . . . . . . . . . . . . . . . . . . . . . . Fig. 26 Turning Capacity Chart - Hawk 200 Machines (VDI Tooling) . . . . . . . . . . . . . . 1-7 1-8 1-8 1-8 1-8 1-8 1-9 1-9 1-10 1-11 1-12 1-13 1-14 1-14 1-15 1-15 1-16 1-16 1-17 1-26 1-26 2-1 2-6 2-9 2-10 2-11 2-12
Table of Contents
Fig. 27 Turning Capacity Chart - Hawk 250 Machines (VDI Tooling) . . . . . . . . . . . . . . Fig. 28 Data Sheets - Hawk 150 (VDI Tooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 29 Stroke - Hawk 200 Machines (VDI Tooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 30 Stroke - Hawk 250 Machines (VDI Tooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 31 Optional Standard Tooling Package - Hawk 150 (VDI Tooling) . . . . . . . . . . . . . Fig. 32 Optional Standard Tooling Package - Hawk 200/250 Machines (VDI Tooling) . Fig. 33 Work Holding Options - Hawk 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 34 Work Holding Options - Hawk 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 35 Work Holding Options - Hawk 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 36 Work Holding Options - Hawk 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 37 Work Holding Options - Hawk 250 (Continued| . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 38 Bar Feed Options - Hawk 150 machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 39 Hawk 150 - Spindle Power Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 40 Hawk 200 - Spindle Power Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 41 Hawk 250 - Spindle Power Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 42 Machine Alignment And Program Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 43 Control Station Layout for: - Hawk Turning centres with fanuc 21i TA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 44 Operators Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 45 MTB Operators Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 46 Spindle Load Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 47 Main Spindle Chuck & Tailstock Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 48 Chuck Brake Pressure (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 49 Swarf Conveyor Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 49 12 Position Turret - showing Rotation Directions . . . . . . . . . . . . . . . . . . . . . . . . Fig. 51 Driven Tool Setup - Positioning Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 52 C-Axis Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 2-24 2-25 2-25 2-26 2-27 3-1 3-2 3-11 3-11 3-15 3-15 3-17 9-1 10-2 10-2
Table of Contents
Fig. 53 Canned Cycle - Front Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 54 Canned Cycle - Side Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 55 Driven Tool Setup - Interpolation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 56 C-Axis Position Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 57 Polar Co-ordinate Interpolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 58 Cylindrical Interpolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 58 Probe Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 59 Probe Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 60 Parts Catcher fitted to Operator Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 61 Operators Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 10-4 10-5 10-6 10-7 10-8 11-1 11-2 12-1 16-6
Chapter 1 Safety Precautions

Important WARNING
Read related safety precautions before operating this machine. Failure to follow safety instructions may result in serious personal injury. These safety precautions for this CINCINNATI machine have been prepared to assist the operator, programmer and maintenance personnel in practicing good shop safety procedures. Operator and maintenance personnel must read and understand these precautions completely before operating, setting up, running, or performing maintenance on the machine. These precautions are to be used as a guide to supplement safety precautions and warnings in the following: a. All other manuals pertaining to the machine. Local, plant, and shop safety rules and codes. National safety laws and regulations.
WARNING
In order to clearly show details of this machine, some covers, shields, guards, barriers, devices, or doors have either been removed or shown in an open position. All such protective components must be installed in position before operating this machine. Failure to follow this instruction may result in serious personal injury.
b. c.
Cincinnati Machine 91203597B001
Page 1-1
General Safety Instructions And Considerations

Personal Safety Machine owners, operators, setup men, maintenance, and service personnel must be aware of the fact that constant day-to-day safety procedures are a vital part of their job. Accident prevention must be one of the principal objectives of the job regardless of what activity is involved.
WARNING
Failure to follow instructions on this page may result in serious personal injury.
Know and respect your machinery. Read and practice the prescribed safety and checking procedures. Make sure that everyone who works for, with, or near you fully understands and - more importantly - complies with the following safety precautions and procedures when operating this machine. Sudden movements, loud noises, horseplay, etc., must be avoided. These distractions may result in unsafe conditions for those working near the machinery. Observe and follow safety instructions such as NO SMOKING, High Voltage, DANGER, etc., in your working area. Accidents can occur that result in serious personal injury to yourself or others due to clothing and other articles becoming entangled in cutters, hand wheels, levers, or moving machine elements. The following suggestions, if followed, will help you to avoid such accidents: Neckties, scarfs, gloves (except as worn for protection when handling sharp edged cutting tools or rough, sharp or hot parts, see TOOL SAFETY) loose hanging clothing, and jewelry such as watches, rings, or necklaces must not be worn around moving machinery. Restrain long hair with a cap or net. Wear gloves only when handling rough, sharp, or hot parts. Use safety protective equipment. Wear clean approved eye or face protection. Safety-toe shoes with slip-proof soles can help you avoid injury. Keep your protective equipment in good condition. Never operate or service this equipment if affected by alcohol, drugs or other substances or conditions which decrease alertness or judgment. Work Area Safety Always keep your work area clean. Dirty work areas with such hazards as oil, debris, or water on the floor may cause someone to fall to the floor, into the machine, or onto other objects resulting in serious personal injury. Make sure your work area is free of hazardous obstructions and be aware of protruding machine members. Return tools and similar equipment to their proper storage place immediately after use. Keep work benches neat, orderly, and clean. Report unsafe working conditions to your supervisor or safety department. Items such as: worn or broken flooring, ladders, and handrails, unstable or slippery platforms, or scaffolds must be reported and repaired before use. Do not use skids, work pieces, stock, machines, tote pans, and boxes as makeshift climbing aides.
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Tool Safety
WARNING
Sharp edged cutting tools must be handled with gloves or a shop cloth. Inspect cutting tools before use and reject defective tools. See WARNING 1. Remove hand tooling such as wrenches, measuring equipment, hammers, and other miscellaneous parts from the machine immediately after usage. Lifting And Carrying Safety Contact supervision if you have any questions or are not sure about the proper procedures for lifting and carrying. Before lifting or carrying an object, determine the weight and size by referring to such things as tags, shipping data, labels, marked information, or manuals. Use power hoists or other mechanical lifting and carrying equipment for heavy, bulky, or hard to handle objects. Use hookup methods recommended by your safety department and know the signals for safely directing a crane operator. Never place any part of your body under a suspended load or move a suspended load over any part of another persons body. Before lifting, be certain that you have a safe spot for depositing the load. Never work on a component while it is hanging from a crane or other lifting mechanism. If in doubt as to the size or type of lifting equipment, method, and procedures for lifting, contact Cincinnati Machine before proceeding to lift the machine or its components. Always inspect slings, chains, hoists, and other lifting devices prior to use. Do not use lifting devices found to be defective or questionable. Never exceed the safety rated capacity of cranes, hoists, slings, eyebolts, and other lifting equipment. Follow, National and local, standards and instructions applicable to any lifting equipment you use. Before inserting an eyebolt, be certain that both the eyebolt and the hole have the same size and type threads. To attain safe working loads, at least 90% of the threaded portion of a standard forged eyebolt must be engaged.
WARNING 1 CUTTING TOOLS

Use adequate hand protection at all times when handling sharp edged cutting tools. Failure to follow this instruction may result in serious personal injury.
Page 1-3
Installation And Relocation Safety
WARNING
Before lifting the machine, consult the machine manual or Cincinnati Machine for proper methods and procedures. An electrician must read and understand the electrical schematics prior to connecting the machine to the power source. After connecting the machine, test all aspects of the electrical system for proper functioning. Always make sure the machine is grounded properly. Place all selector switches in their OFF or neutral (disengaged) position. The doors of the main electrical cabinet must be closed and the main disconnect switch must be in the OFF position after the power source connection is complete. Always lock the main disconnect device in the OFF position if the machine is left unattended, unless machine is part of an unmanned manufacturing system and in a production cycle. When the machine is installed, be sure that the motors rotate in the proper indicated direction. Setup And Operation Safety Read and understand all the safety instructions before setting up, operating, or servicing this machine. Assign only qualified personnel, instructed in safety and all machine functions, to operate or service this machine. Operators and maintenance personnel must carefully read, understand, and fully comply with all machine mounted warning and instruction plates. Do not paint over, alter, or deface these plates or remove them from the machine. Replace all plates which become illegible. Replacement plates can be purchased from Cincinnati Machine. Safety guards, shields, barriers, covers, and protective devices must be connected or in place before operating the machine. All safety features, disengagements, and interlocks must be in place and functioning correctly prior to operation of this equipment. Never bypass or wire around any safety device. When setting up or adjusting a workpiece or fixture, be certain it is a safe distance away from the cutting tool. Always retract the workpiece a safe distance from the cutting tool when loading and unloading. The spindle must be stopped before adjusting the coolant discharge nozzle. Never brake or slow down moving machinery with your hand or with some makeshift device. Never use machine power to remove a nut from any shaft. The spindle and slides must be stopped when measuring work pieces, changing tools, or removing chips and grit. Remove chips and grit with a chip rake or brush, not with your hands.
Page 1-4
Keep all parts of your body off the machine table, table edge, out of the path of moving units, trip dogs, trip plungers, and out of the machining area during machining operations. Never lean on a machine or reach over or through a machine - you can become entangled in tooling and other moving elements or you may accidentally activate start buttons, feed controls, rapid traverse controls, power work holding control, or similar devices. During operation, be attentive to the machining process. Excessive vibration, unusual sounds, etc., can indicate problems requiring your immediate attention. Watch for conditions such as packed chips or grit which can cause breakage of tooling or machine elements. Shut off power to the machine when leaving the operating area or at the end of your work period. Never leave the machine running unattended, unless it has been designed to do so. Turn the master disconnect device to the OFF position before cleaning the machine at the end of the working day or when guards or covers are removed that expose hazardous areas. Maintenance Safety
WARNING
See DANGER notice. Do not attempt to perform maintenance on this machine until you read and understand all the safety instructions. Assign only qualified service or maintenance personnel trained by Cincinnati Machine, to perform maintenance and repair work on this machine. They should consult the service manual before attempting any service or repair work and when in doubt contact Cincinnati Machine. Use only Cincinnati Machine replacement parts; others may impair the safety of the machine. Before performing maintenance or service work, Warning or Danger signs must be placed conspicuously about the machine. Before detaching counterweights or driving mechanisms, vertical sliding members must be blocked properly. See the Service Manual for proper dismantling procedures. Before removing or opening any electrical enclosure, cover, plate, or door, be sure that the Main Disconnect Switch is in the OFF position. If any tool is required to remove a guard, cover, bracket, or any basic part of this machine, place the Main Disconnect Switch in the OFF position, lock it in the OFF position. If possible, post a sign at the disconnect switch indicating that maintenance is being performed. Whenever maintenance is to be performed in an area away from the disconnect and the disconnect is not locked, tag all start button stations with a DO NOT START tag. Adequate precautions, such as locks on circuit breakers, warning notices, or other equally effective means must be taken to prevent electrical equipment from being electrically activated when maintenance work is being performed. Before attempting to adjust, repair, or perform maintenance on electrical circuits connected with yellow wires, first find the source of power, turn it off, and lock it in the OFF position. Machine tool interlock control circuits connected with yellow wires are powered from a source away from the machine and carry voltage even when the machines main disconnect device is turned to the OFF position. When removing electrical equipment, place number or labeled tags on those wires not marked. If wiring, is replaced, be sure it is of the same type, length, size, and has the same current carrying capacity.
Page 1-5
Close and securely fasten all guards, shields, covers, plates, or doors before power is reconnected. An electrical technician must analyze the electrical system to determine the possible use of power retaining devices such as capacitors. Such power retaining devices must be disconnected, discharged, or made safe before maintenance is performed.
WARNING
Working space around electrical equipment must be clear of obstructions. Provide adequate illumination to allow for proper operation and maintenance.
DANGER
HIGH VOLTAGE Lethal voltages are present in the magnetics and electrical control cabinets when the MACHINE MAIN DISCONNECT is ON. Current and voltage measurements should be attempted only by qualified electrical maintenance personnel. Before working on any electrical circuits, turn the machine Main Disconnect Device OFF and lock It. Capacitors in the Servo Drives require up to 20 minutes to completely discharge. Always verify that discharge is complete using a known working and calibrated voltmeter before commencing work on these units. Unless expressly stated in applicable Cincinnati Machine documentation or by the appropriate Cincinnati Machine Field Service Representative, do NOT work with electrical power ON. If such express statement of advice exists, working with electrical power ON should be performed by a Cincinnati Machine Field Service Representative. The customer and subsequent transferees must determine that any other person performing work with electrical power ON is trained and technically qualified. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN DEATH OR SERIOUS PERSONAL SHOCK INJURY. Materials Used With This Product Various materials may be used with this product. Before using/mixing/diluting materials with this product, contact the manufacturer/authorized supplier of the material to determine that the material is suitable for the intended application and request a Material Safety Data Sheet (MSDS) from the material manufacturer.
Page 1-6
NOTE The information and tables contained in this article relate to Cincinnati Machine methods and standards. Consult National, Local and Plant Laws and Regulations regarding lifting practices.
LIFTING DEVICES
GENERAL The use of lifting devices is subject to certain hazards that cannot be met by mechanical means but only by the exercise of intelligence, care, and common sense. It is, therefore, essential to have competent and careful operators, physically and mentally fit, thoroughly trained to the safe operation of the equipment and the handling of the loads. Serious hazards are overloading, dropping or slipping of the load caused by improper hitching or slinging, standing or crawling under a load, swinging loads, obstruction to the free passage of the load, using equipment for a purpose or a manner for which it was not intended or designed.. EYEBOLTS A straight lift is preferred when using eyebolts. An angular lift places additional stresses on an eyebolt, above that of the load to be hoisted. If the situation necessitates an angular lift, the safe working load for angular lifts shown in Fig. 1 and Fig. 2 should be used. When multiple eyebolt provisions are designed into a lift, it is recommended (in most applications) that a spreader bar be used. (See Fig. 9 which illustrates a typical spreader bar arrangement.) No greater stress should be allowed than that given under Safe Working Load in Fig. 1 and Fig. 2. To obtain greatest strength from an eyebolt, it must fit reasonably tight in the hole with at least 90% of the threaded length engaged. Eyebolts should never be welded or subjected to heat in excess of 900F [480 C]. Eyebolts should never be painted or otherwise coated when used for lifting, as such coating will very likely cover up flaws. Eyebolts should be routinely inspected for defects and if any defects are found, they should be destroyed by melting, crushing, or cutting clear across the eye.
STRAIGHT SHANK INCH (ANSI/ASME B18.15) 60 90
WARNING
Before inserting an eyebolt, check to be certain that both the eyebolt and the hole have the same size and type threads. For example: M12 with M12 or .375-16 with .375-16. To attend safe working loads, at least 90% of the threaded portion of a standard forged eyebolt must be engaged. Failure to follow this instruction may result in serious injury.
THREAD SAFE WORKING LOAD 90 DEGREES 60 DEGREES 30 DEGREES
.375- 16
.500- 13 LBS. [KG]
.625- 11
1.000-8 30
1000 [453] 375 [170] 200 [90] 3449
1840 [834] 805 [365] 470 [213] 870
2940 [1333] 1340 [607] 805 [365] 21312
7880 [3573] 3670 [1664] 2390 [1083] 19489
PART NUMBER IDENTIFICATION PLATE NUMBER
3338325
3338326
3338327
3338328
STRAIGHT SHANK INCH
Fig. 1 Preferred Inch Lifting Eyebolts
Page 1-7
SHOULDER METRIC (ISO 3266- 1984) THREAD SPOT DIAMETER M12 32 mm 1.25 in. M16 37 mm 1.50 in. M20 42 mm 1.65 in. M30 67 mm 2.63 in. 45
90
SAFE WORKING LOAD 90 DEGREES 45 DEGREES
[KILOGRAMS] LBS. [400] 882 [100] 220 6014453-3 3338329 [630] 1389 [160] 352 6014453-4 3338330 [1000] 2205 [250] 551 6014453-5 3338331 [2500] 5512 [625] 1378 6014453-8 3338332
PART NUMBER IDENTIFICATION PLATE NUMBER
SHOULDER METRIC
Fig. 2 Preferred Metric Lifting Eyebolts
5 MAX. NO LOAD LOAD YES
30 MIN. 3338325
3338329
YES NO
INCH
ISO METRIC M12
.375- 16 UNC
Fig. 3 Eyebolt Loading

6.00 THIS MACHINE HAS BEEN MANUFACTURED TO UTILIZE INCH THREAD LIFTING DEVICES. ANY EXCEPTION TO THIS WILL BE LABELED ADJACENT TO THE LIFT POINT. .109 DIA.THRU 4 PLACES .08
Fig. 4 Eyebolt I.D. Plates - Inch and Metric
150
THIS MACHINE HAS BEEN MANUFACTURED TO UTILIZE METRIC THREAD LIFTING DEVICES. ANY EXCEPTION TO THIS WILL BE LABELED ADJACENT TO THE LIFT POINT.
3.00
.25
75
6.3
3375984 .12 R
3375983
.12 .12 TYP.
3 TYP.
1.4 THRU-4 3 TYP. PLACES
3R
NO 21 (.032) GAGE ALUMINUM.- NO. AL 5052 ALLOY. ETCHED AREAS TO BE BLACK BAKED ENAMEL. ETCHED DEPTH TO BE .003 TO .005 INCHES --- OR --- NO. 21 (.032) GAGE ALUMINUM WITH METALPHOTO PROCESS. ALL LETTERING TO BE HELVETICA MEDIUM.
NO 21 (.032) GAGE ALUMINUM.- NO. AL 5052 ALLOY. ETCHED AREAS TO BE BLACK BAKED ENAMEL. ETCHED DEPTH TO BE .003 to .005 INCHES --- OR --- NO. 21 (.032) GAGE ALUMINUM WITH METALPHOTO PROCESS. ALL LETTERING TO BE HELVETICA MEDIUM. SURFACE GRAIN TO RUN PARALLEL TO LETTERING WITH SATIN FINISH.
Fig. 5 Instruction Plate - Inch (Part Number 3375984)
Fig. 6 Instruction Plate - Metric (Part Number 3375983)
Page 1-8
HOIST RINGS Hoist Rings are superior to eyebolts for angular lifting. Be certain the thread projection is in accordance with the manufacturers recommendation. Do not recut any damaged threads on hoist rings. To obtain the safe working load, torque to the recommended values shown in the table below.
Fig. 7 Hoist Ring
Observe all other safety precautions normally practiced on eyebolts.

F THREAD TORQUE 90 _ W W MAX. WT EACH RING Ft- Lb N-m 16.3 38 81.3 312 36.6 80 136 310 Lb 1000 2500 4000 10000 2204 3857 4736 9257 F kg 450 1130 1810 4500 991 1736 2132 4166 F 90 _ W W MAX. WT EACH RING Ft- Lb N-m 16.3 38 81.3 312 36 80 136 310 Lb 1000 2500 4000 10000 2204 3857 4736 9257 kg 450 1130 1810 4500 991 1736 2132 4166 F F F 60 _ W W MAX. WT EACH RING Lb 866 2165 3464 8660 1908 3340 4103 8016 F 90 W W MAX. WT EACH RING Lb 1000 2500 4000 10000 2204 3857 4736 9257 kg 450 1130 1810 4500 991 1736 2132 4166 kg 390 975 1559 3897 859 1503 1846 3607 F F 45 _ W W MAX. WT EACH RING Lb 707 1767 2828 7071 1558 2726 3349 6544 F 90 W W MAX. WT EACH RING Lb 1000 2500 4000 10000 2204 3857 4736 9257 kg 450 1130 1810 4500 991 1736 2132 4166 Ft- Lb N-m .xxx- xx kg 318 795 1273 3182 701 1227 1507 2945 F F F 30 _ W W MAX. WT EACH RING Lb 500 1250 2000 5000 1102 1928 2369 4628 kg 225 562 900 2250 496 868 1066 2083 5013055 001 5013055 002 5013055 003 5013055 004 5013055 006 5013055 007 5013055 008 5013055 009 F .xxx- xx
CM HOIST RING PART NO.
THREAD SIZE
CM IDENT. PLATE PART. NO.
3346225 3346225 3346225 3346225 3346225 3346225 3346225 3346225
1 2 3 4 6 7 8 9
.375- 16 .500- 13 .625- 11 1.000-8 M12X1.75 M16X2 M20X2.5 M30X3.5
12.0 28.0 60.0 230.0 27.0 59.0 100.0 229.0
CM HOIST RING PART NO.
THREAD SIZE
THREAD TORQUE
CM IDENT. PLATE PART. NO. 5013055 001 5013055 002 5013055 003 5013055 004 5013055 006 5013055 007 5013055 008 5013055 009
3346225 3346225 3346225 3346225 3346225 3346225 3346225 3346225
1 2 3 4 6 7 8 9
.375- 16 .500- 13 .625- 11 1.000-8 M12X1.75 M16X2 M20X2.5 M30X3.5
12.0 28.0 60.0 230.0 27.0 59.0 100.0 229.0
Fig. 8 Hoist Ring Table
NOTE F=FORCE W=WEIGHT
Page 1-9
SPREADER BARS AND LIFTING BEAMS
SPREADER
TO LOAD Fig. 9 Spreader Bar - Typical
TO LOAD
Spreader bars are used when multiple eyebolts are designed into a lift. Always observe the following safety precautions when using a spreader bar or lifting beam Do not exceed the safe working load. Use the spreader or beam to handle parts or components only for which it was designed. Inspect it before each use. Do not alter or weld anything to bar or beam. Store properly to avoid damage. CHAIN Select a chain with the suitable characteristics and capacity for the load. See above. Always observe the following safety precautions. Do not shorten chains with knots, bolts, or any non-approved method. Never use damaged chain. Hitch chain securely to the load. Pad sharp corners with material of sufficient strength to withstand load and protect chain.
Page 1-10
SIZE OF CHAIN
SINGLE CHAIN 90 lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. 3 250 1 475 6 600 2 995 11 250 5 100 16 500 7 480 23 000 10 430 28 750 13 040 38 750 17 580 57 500 26 080 80 000 36 290 100 000 45 360 130 000 26 750
DOUBLE SLING CHAINS TYPE D 60 45 30
TRIPLE SLING CHAINS TYPE T 60 45 30
QUAD SLING CHAINS TYPE Q 60 45 30
9/32 in. .7.2 mm 3/8 in. 9.5 mm 1/2 in. 712.7 mm 5/8 in. 15.9 mm 3/4 in. 19.1 mm 7/8 in. 22.6 mm 1 in. 25.4 mm 1 1/4 in. 31.8 mm 1 1/2 in. 38.1 mm 1 3/4 in. 44.5 mm 2 in. 50.8 mm Fig. 10 Steel Alloy Chains
5 625 2 550 11 400 5 170 19 700 8 845 28 600 12 970 39 800 18 050 49 800 22 590 67 100 30 440 99 600 45 180 138 500 62 820 73 200 78 560 225 000 102 060
4 600 2 085 9 300 4 220 15 900 7 210 23 300 10 570 32 500 14 740 40 700 18 460 54 800 24 860 81 300 36 880 113 000 51 260 41 000 63 960 183 000 83 000
3 250 1 475 6 600 2 995 11 250 5 100 16 500 7 480 23 000 10 430 28 750 13 040 38 750 17 580 57 500 26 080 80 000 36 290 100 000 45 360 130 000 26 750
8 400 3 810 17 100 7 750 29 250 13 270 42 900 19 460 59 700 27 080 74 700 33 880 100 650 45 650 149 400 67 770
6 900 3 130 13 950 6 330 23 850 10 820 34 950 15 850 48 750 22 110 61 050 27 690 82 200 37 290 121 950 55 320
4 875 2 210 9 900 4 490 16 875 7650 24 750 11 230 34 500 15 650 43 125 19 560 58 125 26 260 86 250 39 120
8400 3 810 17 100 7750 29 250 13 270 42 900 19 460 59 700 27 080 74 700 33 880 100 660 45 650 149 400 67 770
6900 3 130 13 950 6 330 23 850 10 820 34 950 15 850 48 700 22 110 61 050 27 690 82 200 37 290 121 950 55 320
4 875 2 210 9 900 4 490 16 875 7650 24 750 11 230 34 500 15 650 43 125 19 560 58 125 26 260 86 250 39 120
Keep hands and fingers from between the chain and load. Avoid shock loading - particularly when working at temperatures below 40 F [4 C]. Never pull chain from under load when load is resting on chain. Correct kinks and twisting in chain before lifting. Lift from center of hooks. Avoid lifting from the point. Assure that load is free to move before lifting. Keep clear of all obstructions. When using a basket hitch, balance load and assure that chain legs contain or support load from the sides above the center of gravity. Store chains in an area where they will not be subject to mechanical damage or corrosive action.
Page 1-11
CABLE SLINGS Select the appropriate size wire rope and hitch. See Table below.
CABLE SIZE ESTIMATED RATING CAPACITY (For Exact Rating Check Sling Tag) lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. VERTICAL CHOKER HITCH BASKET HITCH
60
45
30
1/4 in. 6.4 mm 1/2 in. 712.7 mm 3/4 in. 19.1 mm 1 in. 25.4 mm 1 1/4 in. 31.8 mm 1 1/2 in. 38.1 mm 1 3/4 in. 44.5 mm 2 in. 50.8 mm Fig. 11 Wire Rope Slings
980 445 3600 1630 7800 3450 13400 6080 19600 8890 28000 12700 38000 17240 50000 22680
740 335 2800 1270 5800 2630 1000 4540 14800 6710 20000 9070 28000 12700 36000 16330
1400 635 5200 2360 11100 5035 18800 8530 28000 12700 40000 18140 54000 24490 70000 31750
1700 770 6400 2900 13600 6170 22000 9980 34000 15420 48000 21770 66000 29940 86000 39000
1400 635 5200 2360 11100 5035 18800 8530 28000 12700 40000 18140 54000 24490 70000 31750
980 445 3600 1630 7800 3450 13400 6080 19600 6710 28000 12700 38000 17240 50000 22680
Guide loads with a tag line when practical. When using multiple leg sling, select longest one possible. Examine for damaged or worn area. Attach securely to load. Pad sharp corners to protect wire rope. Center load in the base (bowl) of the hook to prevent hook point loading. Do not kink, twist, or loop legs. Keep hands and fingers from between wire rope and load. Stand clear of attached load. Start lift slowly to avoid shock injury. Do not pull wire rope from under a load when the load is resting on it. Do not shorten sling by knotting, by wire rope clips, or by any other means. Do not inspect wire rope by passing bare hands over the body. Broken wire, if present, may puncture the hands. Keep wire rope well-lubricated to prevent corrosion. Use gloves at all times when handling.
Page 1-12
SYNTHETIC MATERIAL SLINGS Select the sling with the suitable characteristics and capability for the load and environment. See Fig. 12.
AS THE SLING TO LOAD ANGLE DECREASES, SO DOES THE RATED CAPACITY OF A SLING. SLING-TO-LOAD ANGLE IS ALWAYS THE ANGLE BETWEEN THE SLING LEG AND THE HORIZONTAL SURFACE. RATED SLING CAPACITY- ONE LEG USE THIS CHART FOR ALL TYPE SLINGS; ROPE, CHAIN, OR NYLON. SLING LIFTING EFFICIENCY If Sling Capacity at 90 is... (LB. [KG]) 1000 [454 ] 1000 [454 ] 1000 [454 ] 1000 [454 ] 1000 [454 ] Then Actual Sling Capacity is ... (LB. [KG]) 1000 [454 ] 968 [439 ] 866 [390 ] 707 [320 ] 500 [225 ]
90 75 60
SLING TO LOAD ANGLE
100.0 %
96.6 % 86.6 % 70.7 % 50.0 %
45 30
Fig. 12 Sling Load Angle Chart
When using a choker hitch, the sling shall be long enough to assure that the choking action is on the webbing. Slings used in a basket hitch shall have the load balanced. Do not drag slings over the floor or any abrasive surface. Do not twist or tie knots in slings. Never pull sling from load when the load is resting on it. Protect sling from sharp corners and abrasive surfaces. Do not drop slings. Store slings in an area where they will not be subject to mechanical or chemical damage. Do not use where acid conditions exist. Do not use polyester and polypropylene slings where caustic conditions exist. Do not use polyester and nylon slings at temperatures in excess of 180 F nor polypropylene slings at temperatures in excess of 200 F. Do not use aluminum fittings where caustic conditions exist.
Page 1-13
P TYPE HOOKS P type hooks are a proprietary design and should be considered for heavy (machine and unit) lifts. Fig. 14 gives dimensional data, safe working loads and screw torque values for P type hooks. The use of these hooks must be shown on the assembly drawing, listed in the Bill of Material and shown in the lifting section of the Service Manual.
D C
F E A
Fig. 13 P Type Lifting Hooks LIFTING PART NO. 402517 296513 296514 402335 296515 CAPACITY LBS. [KG] 1800 [818] 2500 [1136] 3500 [1590] 5000 [2273] 8000 [3636] A INCH 2.00 1.75 2.00 2.25 2.25 B INCH 9.75 10.63 12.25 12.25 15.75 C INCH D INCH E INCH 2.50 4.00 2.50 5.00 4.00 F INCH ----5.00 --7.88 2415 2415 2415 180139 180139 2 2 3 2 3 SCREW NO. QTY. SCREW TORQUE LB./FT. 160 160 160 370 370 SCREW TORQUE N-m 217 217 217 502 502
4.50 3.00 4.00 2.50 4.50 3.00 4.50 3.00 4.50 3.00
WHEN DESIGNING METRIC SIZES SEE THE CURRENT LIFTING MANUAL Fig. 14 P Type Lifting Hooks
S HOOKS The use of S hooks in conjunction with some of the other lifting devices dictates additional safety rules which must always be practiced. Never use more than one S hook in a single chain link or hook. Inspect the S hook before each use and if damaged destroy by cutting into two pieces. Never exceed the safe working load which should be stamped on each hook. Do not paint, weld, or expose an S hook to high heat.
Page 1-14
Do not use when either or both S hooks are opened more than 15% of the normal throat opening or twisted more than 10 from the plane of the unbent hook.
B
STAMP TO INDICATE ALLOY
A C R (REF.) C
STAMP WORKING LOAD LIMIT WITH LOW STRESS CHARACTERS PER NUCLEAR AMERICAN SOCIETY OF MECHANICAL ENGINEERS CODE -3766.6 (2) SECTION III, DIV. 1, PARAGRAPH NA-
STAMP MFGR. NAME OR TRADEMARK FOR IDENTIFICATION
Fig. 15 S Hooks MAX. WORKING LOAD MANUFACTURER AND PART NO. 3590535-5 LBS. 650 KG 294 CODE NUMBER CM Chain 562250 Amer. Chain & Cable 5933-00800 3590535-7 1 015 460 CM Chain 562262 Amer. Chain & Cable 5933-01000 3590535-8 1 465 664 CM Chain 562275 Amer. Chain & Cable 5933-01200 3590535-9 1 990 902 CM Chain 562287 Amer. Chain & Cable 5933-01400 3590535-10 2 600 1179 CM Chain 562300 Amer. Chain & Cable 5933-01600 3590535-12 3 290 1492 CM Chain 562310-B Amer. Chain & Cable 5933-01800 3590535-14 4 065 1843 CM Chain 562325-B Amer. Chain & Cable 5933-02000 3590535-15 4 915 2229 CM Chain 562337-B Amer. Chain & Cable 5933-02200 3590535-16 5 850 2653 CM Chain 562350-B Amer. Chain & Cable 5933-02400 3590535-18 3590535-20 3590535-25 Fig. 16 S Hooks 9 500 12 500 19 000 4309 5669 8618 Amer. Chain & Cable 5933-02800 Amer. Chain & Cable 5933-03200 Amer. Chain & Cable 5933-04000 A 0.500 0.500 0.625 0.625 0.750 0.750 0.875 0.875 1.000 1.000 1.125 1.125 1.250 1.250 1.375 1.375 1.500 1.500 1.750 2.000 2.500 ALL DIMENSIONS IN INCHES (See Fig 16.) B 7.50 5.50 9.00 7.00 10.50 8.25 12.00 9.62 13.00 11.00 15.00 12.12 16.00 13.75 17.00 14.88 18.00 16.50 19.25 22.00 27.50 C 2.00 1.50 2.50 1.88 3.00 2.25 3.50 2.62 4.00 3.00 4.50 3.38 5.00 3.75 5.50 4.12 6.00 4.50 5.25 6.00 7.50 R 1.00 0.75 1.25 0.94 1.50 1.12 1.75 1.31 2.00 1.50 2.25 1.69 2.50 1.88 2.75 2.06 3.00 2.25 2.62 6.00 9.75 S- HOOK WEIGHT LBS. 0.80 0.63 1.60 1.30 2.60 2.10 4.20 3.40 6.00 5.10 8.70 7.00 11.70 10.00 15.40 13.00 19.50 17.50 28.00 41.00 79.00
Page 1-15
U TYPE HOOKS U type hooks are a proprietary design and should be considered for heavy (machine and unit) lifts. Fig. 17 and Fig. 18 give dimensional data, safe working loads and screw torque values for U type hooks. The use of these hooks must be shown on the assembly drawing, listed in the Bill of Material and shown in the lifting section of the Service Manual.
B D A
Fig. 17 U Type Lifting Hooks LIFTING PART NO. LB. 303427 303429 301269 301270 301271 301272 311105 1 500 3 500 6 000 8 000 12 000 16 000 25 000 LB. 990819 3988405 3990821 5024235 5025776 5026032 Fig. 18 U Lifting Hook Table 1 500 3 000 6 000 8 000 14 000 22 500 CAPACITY [KG] [680} [1587] [2720] [3600} [5442] [7256] [11 337] [KG] [680] [1360] [2720] [3600] [6500] [10 200] A in 2.75 3.25 4.00 5.00 6.00 7.00 7.00 mm 75 90 105 130 170 300/180 B in 4.00 4.50 6.00 6.50 8.00 9.50 14.25 mm 107 120 155 180 250 380 C in 2.25 2.50 3.75 3.88 4.50 5.30 6.00 mm 60 65 95 103 133 159 D in 1.25 1.50 2.00 2.25 2.50 3.00 3.50 mm 32.0 38.0 50.0 57.2 76.2 88.9 SCREW NO. 3248 2400 2415 180139 308196---3 308197---4 308197---4 SCREW NO. 1234074 1234100 1400264 1400400 6010088-3 6010088-3 QTY. 2 2 2 2 2 2 2 QTY. 2 2 2 2 2 4 SCREW TORQUE LB./FT. 45 90 160 570 735 1290 1290 N-m 41 108 230 407 1356 1356 SCREW TORQUE N-m 61 122 217 502 997 1749 1749 LB./FT. 30 80 170 300 1000 1000
Page 1-16
GENERAL SAFETY LIFTING INFORMATION All hooks or cranes or any other type lifting device should be equipped with a safety latch (see Fig. 19) similar to the one manufactured by the Harrington Co., Plymouth Meeting, Pennsylvania.
Fig. 19 Safety Latch
Illustrations or descriptions of any special lifting devices or techniques required for servicing components of a specific machine are found in the section dealing with the particular component. Always contact the nearest Cincinnati Machine representative if there are any questions regarding the lifting of any machine components.
Page 1-17
Fluids Used With Machine Tools

General Considerations Various fluid products, such as cutting fluids, lubricants, etc., are used with this machine tool. The correct type and quantity is identified by instruction plates on the machine and/or written instructions in the supplied manual(s). Before using fluids or related products not specifically approved or recommended with this machine tool, the owner/user should contact the authorized supplier, closest Cincinnati Machine regional field office for assistance in determining if the product is suitable for the particular application. Lubricants Only those lubricants (oils and greases) tested and approved by Cincinnati Machine, should be used in Cincinnati machine tools. For information concerning latest lubricants manual, contact Cincinnati Machine service department. Cutting Fluids
WARNING CUTTING FLUIDS

When soluble coolants are used, it is important to ensure that recommended concentration levels are maintained. Failure to follow this Instruction can cause corrosion of safety critical parts, resulting in machine damage and/or personal injury. Before filling the machine, ensure that the product is suitable for the application. Frequently, check for storage, tank unit or hose leaks. Water mixed fluids that contain emulsifiers must be protected from freezing. Cutting fluid products should be tailored to each machine tool application and workpiece requirement for maximum efficiency. See WARNING. For assistance in determining the correct cutting fluid, contact nearest Cincinnati Machine Service Department. Sources Of Information - USA Before using any fluid product with this machine tool, the owner/user should request a Technical Data Product Safety Sheet (for example: OSHA Form 20 or a similar technical data information sheet) from the product manufacturer. This data should include the following: Fire and Explosion Hazard Data Spill or Leak Procedures Special Protective Information Special Precautions Chemical and Trade Name Acute Toxicity Properties Hazardous Ingredients Physical Data Recommended Dilutions
Page 1-18
Listed below are some other sources which can be contacted to obtain additional up-to-date information concerning the safe use, handling, storage and disposal of products, materials, chemicals or substances. Occupational Safety and Health Act (OSHA) Public Law Department of Transportation (DOT) Hazard Classification The Transportation Safety Act Product Safety Data Sheet Toxic Substances Control Act (TSCA) Public Law Federal Insecticide, Fungicide and Rodenticide Act (FIFRA) Public Law Environmental Protection Agency Resource Conservation and Recovery Act (RCRA) Public Law National Institute for Occupational Safety and Health (NIOSH) Cincinnati Machine P.O. Box 9013 Cincinnati, Ohio 45209 American National Standards Institute, Inc. (ANSI) American Conference of Governmental Industrial Hygienists, Threshold Limit Values Clean Water Act After receiving the data, analyze and perform the necessary procedures to assure the safe handling, storage, use and disposal of the product. Emergency/First Aid procedures and training should be readily available to personnel handling or using products which may be hazardous (flammable), harmful (toxic) and/or reactive (unstable) The owner/user should become familiar with and keep informed on all regulated materials or substances. Copies of the latest regulated material may be obtained from agencies, such as NIOSH, Registry of Toxic Effects for Chemical Substances, U.S. Department of Health Education and Welfare, Public Health Service, Center for Disease Control, and the National Institute for Occupational Safety and Health. Usage Information Products must not be mixed with other products unless permission and/or instructions have been granted by the manufacturer(s). Product concentrates must be mixed and diluted exactly as instructed by the manufacturer for a particular approved application. All product CAUTION, WARNING and DANGER labels, tags and printed instructions accompanying the products must be read and followed This instruction shall remain with the product at all times. Additional product instruction labels, signs, etc., should be acquired and displayed with concentrates that are purchased in bulk and then dispensed in small or diluted quantities
Federal Hazardous Substances Act
Page 1-19
Cutting Fluids - Preventative Maintenance

See Cautions 1 and 2 CAUTION 1 COOLANTS It is not recommended that neat mineral oils be used as a cutting fluid for this machine. Failure to heed this warning could seriously impair the efficiency of both the coolant and swarf removal systems. Cutting fluids are designed to cool and lubricate the tool tip while in a cut. There are many types of cutting fluids, some of which may cause various problems on a machining center tool, such as corrosion, bacteria build-up, solid formations of chips and cutting debris, etc. if incorrectly applied. The user should be aware of these potential problems, and guard against them. Two types of cutting fluids can be used on this machine, semi-synthetics, and emulsions. Each has its own advantages and disadvantages and the user should consider all of them when making a product selection. Water Quality Water is the major ingredient in a water-based cutting fluid. Its importance in product performance cannot be ignored. Corrosion, residue, scum, rancidity, foam, excess concentrate use, in fact almost any cutting fluid performance problem may be caused by the quality of the water used in making the mix. CAUTION 2 COOLANTS It is not recommended that coolants having a high demulsification factor, be used with this machine. Such coolants must be checked for compatability with the oils and greases recommended for use with this machine. Failure to follow this instruction can lead to lubrication problems, resulting in damage to the machine. Too Soft When the mix water has a total hardness of less that 75ppm, the cutting fluid may foam - especially in applications where there is agitation. Foam causes problems when it overflows the reservoir, the machining center, the return trenches, etc. Foam may also interfere with settling type separators, obscure the workpiece, and diminish the cooling capacity of a water-based cutting fluid. Generally, all products foam more readily in soft water. Too Hard Hard water, when combined with some water-based cutting fluids, promotes the formation of insoluble soaps. The dissolved minerals in the water combine with anionic emulsifiers in the cutting fluid concentrate to form these insoluble compounds that appear as a scum in the mix. Such scum coats the sides of the reservoir, clogs the pipes and filters, covers machining centers with a sticky residue, and may cause sticking gauges, pushbuttons, selector switches, and other similar devices. Hard water can promote corrosion of machine components and should always be eliminated. De-ionized water will help deal with the problem of hard water, provided advice has been sought. Cleaning The Coolant Reservoir The system requires periodic attention and servicing. The reservoir should be drained and cleaned periodically to remove sediments and prevent conditions that lead to deterioration of the coolant. The reservoir can be cleaned by removing the used fluid before adding and circulating a commercial cleaner or as required by adding a suitable cleaner to the used coolant in the machining center during a shut-down period while the machine is cycling. Specific cleaning procedures should be supplied on the label of each cleaning product.
Page 1-20
Lifespan The lifespan of cutting fluids varies widely and depends on many factors. The basic type of coolant, the hardness of the water, the types of metal in the coolant tank, the cleanliness of the system, and the amount of tramp oil in the fluid, all are factors that affect lifespan. Tramp Oil Tramp oils need to be controlled. Tramp oils in the coolant mix cause a varying degree of degradation of the coolant quality. Minimize the leakage of oils into the system through proper maintenance of seals and lubricant systems. If excess quantities of oils leak into the system, the metalworking fluid performance can be reduced. Lubricating and hydraulic oils contain food for bacteria. They may also blanket the fluid, excluding air, and thereby provide ideal conditions for the growth of odor producing bacteria. If allowed to build up, extraneous oil causes smoking and increases residue around the machining center area. The elimination of tramp oils is even more important if chemical cutting fluids are used. Hydraulic oil is a contaminant that must be kept out of the cutting fluid. Hydraulic oils, and particularly some of the additives formulated into them, can cause serious damage to the machine tool and cutting fluid when mixed with water. If tramp oil build-up should become a problem, various commercial devices are available to remove it. Filtering The cleanliness of the coolant is very important in regards to the reliability of the various coolant valves, tubing, etc. This Machining Center is equipped with a coolant filter system. It is good practice to ensure that any filters are kept in good operating condition. Rust Prevention When a machining center tool is sitting idle for a period, the possibility of corrosion increases. There are certain precautions that the user must take to prevent damage to the precision ground surfaces on this machine tool. Under certain conditions, damage can occur within as little time as a day or two; therefore, it is important that proper precautions be carried out. If the machining center is going to sit idle for a period, it is important to wipe all the coolant off the slideways and then protect them with a good rust-preventive. On the horizontal axes of the machining center, it may be necessary to run the slides back and forth a number of times, wiping the ways each time, until no coolant is seen originating from under the slide. After the coolant is clear from under the slide, spray the rust-preventive on the ways and move the slide again, taking the rust-preventive back under the slide.
Page 1-21
WARNING 1
Do not expose PC Boards to electro-static discharge, as intermittent board failures may occur and cause erratic machine operation. Failure to follow this instruction may result in personal injury.
Printed Circuit Board Handling Instructions

General All integrated circuits are susceptible to electro-static discharge damage. Because of this condition, special procedures must be used when handling circuit boards containing integrated circuits, even though there is no completely foolproof system of protecting integrated circuits. Metal oxide semi-conductor (MOS) assemblies manufactured byVickers Electronic Systems Division Incorporated are supplied with a caution sticker. Refer to the sticker and the information concerning cautions and warnings in the supplied literature. NOTE: It is important to emphasize that electro-static discharge to a PC Board may not completely destroy an assembly component, but severely de-grade this component to a point where intermittent failures may occur. If static discharge occurs at sufficient magnitude (2kV or greater) damage or degradation will usually occur if recommended handling procedures are not used. Personnel handling equipment in a low humidity environment can generate static potentials in excess of 10kV. Do not touch any integrated circuit assemblies at the pins, leads or edge connectors, since most damage is done at these points. See WARNING 1. Recommended Handling Procedure Before removing or replacing any PC Board, a qualified technician must disconnect all electrical power, including battery back-up devices. Refer to the machine dedicated electrical diagrams. See WARNING 2. A recommended procedure before handling printed circuit boards is as follows: 1. Attach a grounded wrist strap in contact with the skin. This strap should have a resistor value of 1 megohm (1/2 watt) in series with the person and grounded to leak off electro-static discharge. When working with static control devices (for example: a bag or pad), touch the device with your grounded hand. This action will place you and the static control device assembly at the same electro-static potential.
WARNING 2
Qualified electrical personnel must disconnect all electrical power before printed circuit boards are replaced. Failure to follow this instruction may result in personal injury.
WARNING 3
Do not set PC Boards in styrofoam, waxed, rubber, plastic or other high rated non-conductive (dielectric) materials. Failure to follow this instruction may result in personal injury.
2.
Store and transport the printed circuit boards in static control bags. Use shorting bars or conductive foam materials. Do not use a suspected static damaged printed circuit board. See WARNING 3. Below are examples of electro-static caution symbols which may appear in areas of concern (for example: packing, shipping or receiving). These symbols signify that the Recommended Handling Procedures must be used and/or follow any special supplied instruction.
Page 1-22
Safety Features WARNING 1

PERIMETER GUARDING It is imperative that this guarding is kept intact and in place at all times during normal operation of the machine. In such cases where the part of the guarding has to be removed for maintenance purposes, the guarding MUST be replaced before the machine is allowed to go back into normal operation. Failure to follow this instruction may result in serious personal injury. Perimeter Guarding A complete set of perimeter guards is supplied and fitted to this machine. See WARNING 1. OPERATOR ACCESS TO THE MACHINE is gained at the following point(s):1. Operator Door - for loading and unloading components and for setting up purposes.
Operator Sliding Door(s) See WARNING 2. With the door(s) closed and machine power on, a safety switch is actuated that allows automatic machine movements to be executed.
WARNING 2
OPERATOR DOOR POWER LOSS If machine power is lost while the door is in its closed position, it will remain latched in that position until power is re-applied. The door can be opened from the inside using the special key attached to the underside of the SHOT BOLT body. Do not attempt to operate the machine with this door open. Failure to follow this instruction may result in serious personal injury.
It is not possible to open the operator door/s while the machine is in automatic cycle, due to the latching mechanism of the switch. With the door(s) open and machine power on, the following conditions apply: With the door(s) open and machine power on, the following functions are available under HOLD TO RUN control. S S Spindle rotation is inhibited. Power feed of the X and Z axes are limited to 2m/min maximum.
The following functions are also available for selection. 1. 2. 3. Coolant Start. Tailstock quill movement. Spindle chuck open/close.
Page 1-23
Feed Hold Push Button CAUTION Emergency Stop Actuating this button with the machine in a cutting cycle may damage cutting tools and work pieces. Failure to follow this instruction may result in damage to equipment. Provides logical and safe interruption of the active machine cycle when actuated. Emergency Stop Push Button See CAUTION. Provides fastest practical elimination of machine movements (spindle, axes and mechanisms, etc.). Electrical Isolation Device (Main Disconnect Switch) A lockable isolation switch is provided on the main electrical cabinet. See DANGER. It should also be noted that it may take up to 20 minutes to discharge completely the capacitors mounted in the servo drives. Air Supply Isolation Valve A pneumatic isolation valve is required to be provided by the customer to allow for the removal of air power from the machine. Metric Lifting Points This machine has been manufactured to utilise METRIC thread lifting devices. Any exception to this will be labelled adjacent to the lift point.
DANGER
The ELECTRICAL ISOLATION switch does NOT isolate the incoming supply to the electrical cabinet or the supply to the transformer unit. Use extreme care when working near the power input leads. Severe shock injury can result if the leads are touched. Failure to follow this instruction may result in death or serious personal injury.
Page 1-24
Machine Related Safety And Usage Notes WARNING 1

Failure to follow instructions on this page may result in serious personal injury. Axis Overtravel Condition Care should be taken when power feeding an axis out of axis overtravel condition, to ensure that the direction selected brings the axis away from the overtravel condition. If the wrong direction is selected it is possible to drive the axis further into overtravel which could result in damage to the machine. Safe Operation Of Lathe Chucks Ensure the chuck is of good condition as damage may impede its safe function especialy at high speeds. Maximum operating speeds for chucks are for guidance only and attention should be made to the size and shape of the workpiece and tooling. The influence of centrifugal force may result in the work piece becoming insucurely gripped under certain conditions. As the factors vary widely with each particular application we are unable to provide specific figures for general use, but the following should be observed; 1. 2. 3. 4. 5. 6. 7. Speed for an application Weight and type of jaws if non-standard Radius at which jaws are operating Condition of chuck State of balance Magnitude of the cutting forces Clamping force applied to the work-piece
When a manual chuck or fixture is used, remove the clamping handle from the chuck or fixture after tightening and before operating/rotating the spindle or moving the axes. Work Holding Devices Always support the work-piece using the correct work holding device, eg. chucks, steadrests and centres. Care should be taken to support work-piece when clamping/unclamping.
WARNING 2
Inadequately supported bar-stock protruding from the headstock may cause whipping. Ensure the material is correctly supported at all times. Failure to follow this instruction may result in serious personal injury.
Safe maximum speed of rotation should be observed, as determined by the work holding device manufacturer. Bar stock protruding from the end of the headstock should be adequately supported at all times. See Warning 2.
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General Operation
WARNING
Loosen tool holder/cutting tool bolts gradually. Keep stable footing and do not overtighten these bolts. Check with the manufacture for proper re-torquing values. Securely tighten all tool holders, tools chuck jaws. Balancing of these items may be necessary. Check with the manufacture for proper re-torquing values. Always use two spanners to lock cutting tools into a Driven Head tool holder. One spanner is located on the rotating spindle unit within the head whilst the other locates on the spindle locknut, see Fig. 20.
Fig. 20 Driven Head Tool Holder
CAUTION Attempting to lock or unlock a tool in a Driven Head tool holder whilst it is mounted in a turret station may cause excessive torsional strain in the spindle drive mechanism. Failure to follow this instruction could result in serious damage to the drive tang on the Driven Head tool holder and drive mechanism.
Never attempt to lock or unlock a tool in a Driven Head when the head is mounted in a tool station on the turret. See CAUTION. Always use a bench mounted propriety Tightening Fixture to lock and unlock a tool from a Driven Head tool holder. For details, see manufacturers catalogue. A tool holder or a plastic blanking plug should be present in each of the turret tool stations. Blanking plugs (shown in Figure 32) are recommended to occupy turret stations not in use to prevent the ingress swarf and coolant, etc. See manufacturers catalogue. Lower the spindle speed when changing the speed range while the spindle is rotating. Do not insert bar stock into a rotating spindle. The bar stock length should be shorter than the spindles length. Bar stock must be straight in order to prevent vibration. Do not attempt to remove chips if the spindle, turret or any machine component is in motion.
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Check that the cycle is complete (Cycle Start indicator is not illuminated) and the machine is in a Feedhold condition before attempting to unload/load a workpiece. Before starting the machine operation (machining), check hydraulic pressures, lubricating oil pressures, compressed air pressure-if present, and chuck pressure to make sure all gauges indicate proper values. Battery Replacement The battery installed in the control unit will provide backup for the memory content for approximately 12 months. If an alarm message is displayed on the screen replace the battery as soon as possible. For the correct battery replacement procedure refer to the control manufacturers operating manual. FANUC alarm message BAT.
WARNING
Improper handling of lithium batteries may cause the batteries to explode, spraying caustic metal, and causing severe chemical burns. Failure to follow this instruction may result in serious personal injury.
Lithium Batteries Lithium batteries contain the hazardous chemical lithium -an extremely active chemical requiring special handling and disposal. The following guidelines should be observed when handling lithium batteries:
Lithium batteries are not rechargeable. Do not allow lithium batteries to be heated above 212 degrees F (100 degrees C). Do not incinerate lithium batteries. Do not expose lithium batteries to water. Water may cause a violent reaction. Do not try to disassemble lithium batteries. Direct contact with the metal causes severe chemical burns.
Because of the hazardous nature of lithium, disposal must be made according to applicable federal, state, and local regulations.
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Chapter 2 System Information
Fig. 21 Hawk Turning Center
Introduction WARNING
MISUSE OF THE MACHINE The machine must not be adapted to carry out any form of MILLING or GRINDING operations, as its design and construction does not allow for these to be performed safely. Failure to heed this warning could result in serious personal injury if not death. The CINCINNATI HAWK range of Turning Centers is a general purpose cold metal turning machine, which use non-rotating tools with an indexing turret. The machine has two sliding axes and tool turret indexing capability all under numerical control. The turning center has been designed to automatically index tools in order to carry out turning, drilling, threading, boring and reaming operations. All functions of the machine may be controlled by the NC program, with the minimum of operator attention being required. The perimeter guarding provided, ensures the safety of personnel against moving parts, coolant, swarf and broken tooling, when the above operations are being undertaken. See WARNING. See also GUARD STRENGTH.
Page 2-1
Guard Strength
The guards of this machine are designed to prevent access to hazardous moving parts and to contain the ejection of tool or work-piece fragments up to a calculated maximum energy level.
WARNING 1
GUARD STRENGTH For safe use of this machine the guards must be in place and properly maintained. Care must be taken to ensure that cutters are applied within their designed safe speed and that any separate component parts of cutters are securely clamped prior to application. Failure to follow this instruction may result in serious personal injury.
For Hawk 150 machines the maximum energy level is 2480 Joules. This is equivalent to a mass of 1.25 kg ejected from the work area and having an impact speed of 63 m/s. For Hawk 200/250 machines the maximum energy level is 8000 Joules. This is equivalent to a mass of 2.5 kg ejected from the work area and having an impact speed of 80 m/s. See WARNING 1.
Page 2-2
Noise Noise level for this machine is within a maximum of 80 dB(A). The operating conditions used to determine this figure were as follows: 1. 2. Machine correctly installed, clear of all nearby reflecting surfaces with all guards fitted and closed. Noise Measurement positions 1.6m high at operators work-station and at six equi-spaced positions along a peripheral path 1.0 from the outer surface of the machine. Noise levels measured using an integrating sound level meter. Machine warmed prior to testing by running for at least 30 minutes at a spindle speed of 66% of max RPM. A-weighted time-averaged emission sound pressure levels measured at each position under the following conditions: 5.1 Machine stopped (hydraulics off) to get background pressure level. Levels recorded in dB(A) using slow setting. 5.2 Spindle running at maximum speed with chuck jaws gripping a dummy workpiece. Emission pressure levels, Lp eq recorded in dB(A) using slow setting. 5.3 Machine performing turning operation as detailed in clause 6.2 below, with time-averaged emission pressure levels being recorded, Lp eq. 6. Operating conditions: 6.1 Mode 1: Running Light Test Spindle Speed: Workpiece: Workpiece holding: 5500rpm (Hawk 150) 34mm diameter (dummy) 3 jaw chuck
3. 4. 5.
6.2 Mode 2: Prescribed Turning Test Workpiece: Workpiece dimensions: Workpiece holding: Tooling type: Tooling geometry: Spindle speed: Feedrate: Depth of cut: Metal removal rate: Length of cut: Duration: EN 302 155mm long, 70mm diameter 3 jaw chuck Indexable insert, sintered carbide, rhomboidal Nose radius: 0.8 mm; Back rake: +9 Cutting edge angle: 95 1000 rpm 250 mm/min 2.0 mm 110 cm3/min 113 mm 27s
Page 2-3
7. 8.
All noise emission values corrected for background level. Noise declaration DECLARED SINGLE-NUMBER NOISE EMISSION VALUES in accordance with ISO 4871, Lp Ad Maximum A-weighted emission sousnd pressure level Lp Ad, (ref. 20Pa) at the operators position or any peripheral position, in decibels: Mode 1: Running light at max. spindle speed: Mode 2: Under prescribed operating conditions: 80 77
WARNING
NOISE LEVEL Running the machine at high speeds with chuck jaws wide open, could generate noise of a level deemed to be injurious to the hearing of operators or bystanders. Under such circumstances the use of hearing protection is required. Failure to heed this warning could result in serious personal injury.
9.
The operating conditions described herein are considered to be adequately representative of the product, and reflect prevailing usage. Noise levels, under different operating conditions, may, however, exceed the limits quoted, and could under extreme conditions necessitate the use of ear protection equipment. See WARNING.
Fumes And Coolant Misting Extraction equipment can be fitted to the machine. When machining materials which might produce fumes or result in coolant misting, note should be taken of local health and safety regulations. Fire Hazard The machine has not been designed to cater for materials which, as a result of the machining application, could combust. It is the owners/users responsibility in these circumstances to conform with local safety regulations for handling and machining such materials. Should further advice be required on any of the above items the request should be forwarded to one of the offices detailed at the front of this manual.
CAUTION Avoid locating the machine near welding , electrical, or magnetic generating equipment. Possible generating electrical noise may result in machine control interference. Failure to follow this instruction may result in damage to equipment.
Machine Location - See Caution EMC Directive Requirements This machine satisfies the EMC Directive by conforming to generic emissions and immunity standards for the INDUSTRIAL ENVIRONMENT ONLY. Install the machine in a clean, well lighted area. Ambient temperatures should remain relatively constant to maintain accurate alignment between components, and there should be enough air space around the machine to dissipate heat built up during operation. Avoid particularly a location near shipping doors, etc. where air temperatures in winter can fluctuate widely. Ensure there will be enough room around the machine to access its components for maintenance and operation. Suitable lifting devices will be required for assembly, servicing , and loading/unloading of workpieces.
Page 2-4
NC Control The machine operating station is mounted and positioned at the front of the machine guarding, Protect the control from dust and extremes of temperature and humidity.
WARNING
In order to clearly show details of this machine, some covers, shields, doors or guards have either been removed or shown in an open position. All such protective devices shall be installed in position before operating this machine. Failure to follow this instruction may result in damage to machine components and/or personal injury
Machine Information
The machine and control are integrated to comprise an efficient manufacturing system. Thus, machining cycles can be completely automatic, including tool selection, tool positioning, selection of spindle speeds and cutting feeds, coolant control with other related auxiliary functions and/or combinations of control. The machine and controls are completely compatible, each taking advantage of the capabilities of the other. The basic machine consists of the following units: Fixed base Fixed headstock/spindle Sliding saddle (Z axis) Sliding turret (X axis) Multi-station indexing turret Hydraulic chuck and cylinder Hydraulic tailstock Computer Numerical Control Station Electrical Cabinet Chip/Coolant Tray Perimeter Guards
Bed/Base Unit . . . . . . . . . . . . . . . . . . . The bed/base unit is the main structure of the Turning Center. In addition to providing rigidity and support for the sliding members, machine alignment is maintained through the strength of this structure. The unit houses the following; Spindle drive motor Hydraulic tank and pump unit - bolted to the Left Hand end of the Bed/Base unit. Electrical Cabinet Headstock Spindle Unit . . . . . . . . . . . . The headstock spindle unit contains the necessary components to drive the spindle through range of speeds in one (1) RPM increments. The spindle is powered by a motor whose speed selection is accomplished via CNC. Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . The sliding saddle provides the Z axis travel. Turret . . . . . . . . . . . . . . . . . . . . . . . . . . The turret is located on the saddle. The turret provides the X axis travel and also carries the multi-station indexing turret. Chip / coolant tray . . . . . . . . . . . . . . . . The chip tray is positioned under the base at the front of the machine. Coolant tank . . . . . . . . . . . . . . . . . . . . . L shaped, lying across the front and Right hand end of the machine. The unit houses the coolant pump.
Page 2-5
Axis Orientation
+X
+C
-Z
+Z
-X
Fig. 22 Axis Orientation - Hawk Turning Centre
The axis orientation photograph enables the operator to affix in his mind the conventional slide directions of movement for the turning center. The photograph is for axis orientation only and does not represent the mechanical zero reference points for these axes.
Page 2-6
Hawk Specification Units

Chuck Turn length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max Jaw chuck diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max swing over bed . . . . . . . . . . . . . . . . . . . . . . . . . max turn diameter (STD tooling) Bar chuck capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis Travel Ranges Turret slide (X axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saddle (Z axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle AC Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . continuous rated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . duty rated Spindle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing size - Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Axis Feedrates and Thrust Feedrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................................. Rapid rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................................. Axis thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................................. Accuracies - Uni-directional Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................................. Axis repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................................. Z X Z X Z X Z X Z X mm mm mm mm mm mm mm kW kW rpm. . . mm. m/min m/min m/min m/min kN kN mm mm mm mm
150
440 210 400 240 51 215 440 5.5 7.5 5500 A2-5 A/C 90 24 16 24 16 5.6 4.0 0.004 0.002 0.001 0.0005 12 0.2 V.D.I.30 65 101 4.5 4 M.T
200
540 254 530 300 65 245 540 11 15 4500 A2-6 A/C 110
250
690 304 530 350 77 270 690 15 18.5 3300 A2-8 A/C 130
Tooling Turret positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index time per station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tooling type (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailstock Quill diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quill stoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quill thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quill taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 0.3 V.D.I.40 95 127 7.8 5M.T
12 0.3 V.D.I.40 95 127 7.8 5M.T
mm mm kN
Page 2-7
Hawk Specification
CNC System Model and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of contouring axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication System Axes ballscrew nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . grease X,Y,Z axis way bearings . . . . . . . . . . . . . . . . . . . . . . . . . . grease Spindle bearing lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant System Coolant delivery system - Low Pressure at 0.9 Bar . . . . . . . . . . Coolant delivery system - High Pressure at 5.2 Bar . . . . . . . . . . Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . without conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with conveyor Hydraulic System Oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Requirement Air supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ANR Electrical Power Requirement Spindle drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis motors X, Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turret Indexing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant pump motor - Low Pressure . . . . . . . . . . . . . . . . . . . . . Coolant pump motor - Low Pressure . . . . . . . . . . . . . . . . . . . . . Control gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Weight/Floor Space Machine net weight approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall machine height (max) . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine length without swarf conveyor Machine length with swarf conveyor
Units
150
200
250
FANUC 21i G.E. FANUC ONE (X Axis) P64 P64 pre-greased sealed l/min l/min m l l 20 20 5 135 155 P38 45 6 1 5 9 3 1.5 3 650 3.5 750 4000 1.62 1.5 2.4 3.2 25 3 1.5 3 650 3.5 750 4500 1.8 1.9 3.0 3.9 37 3 1.5 3 650 3.5 750 5000 1.8 1.9 3.46 4.3
177 205
190 218
l bar dm3/s kVA kVA kVA kVA VA kVA VA kg m m m m
All illustrations and specifications contained in this literature are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice in prices, materials, equipment, specifications, and models and to discontinue models. In addition, all dimensions are nominal and can vary with machine model change.
Page 2-8
Fig. 23 Front View Z AXIS TRAVEL
CNC CONTROL STATION
A
A A
SWARF CONVEYOR
25
B
QUILL TRAVEL
DISCHARGE HEIGHT
25
FLOOR LEVEL
Machine And Range Drawings
O/L LENGTH WITHOUT CONVEYOR
C D
O/L LENGTH WITH CONVEYOR
This section provides machine and range drawings for the Hawk range of turning centers.
The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine
HAWK A B C D E
150 440 100 2.4 3.2 804
200 540 125 3.0 3.9 1075
250 690 125 3.45 4.3 1075
Page 2-9
X AXIS TRAVEL
HEIGHT OF MACHINE
FLOOR MACHINE WIDTH
HAWK A B C
Fig. 24 Left Side View
150 215 1.6 1.5
200 245 1.8 1.9
250 270 1.8 1.9
Page 2-10
A LONG TOOLHOLDER ADJACENT TO A SHORT TOOLHOLDER (ON EITHER SIDE) PRESENTS VIRTUALLY NO INTERFERENCE 187 R.TOOLING ENVELOPE. EVEN WHEN FACING DOWN TO THE CENTRE- LINE. THE TURNING TOOL.. CENTRE. PARTING TOOL IS CLOSER TO DISC THAN LY NO INTERFERENCE EVEN WHEN FACING DOWN TO TOOLHOLDER (ON EITHER SIDE) PRESENTS VIRTUAL-
A PART OFF TOLHOLDER ADJACENT TO A SHORT
218 R.TOOLING ENVELOPE.

203 MAX.TURNING TO SPEC. MAX.TURNING BY SPEC 203 203 270 MAX.TURNED FACE (OUTSIDE SPEC.) 126. LARGEST DIA. BLANK IN CHUCK WHICH CAN BE PARTED; WITH A TURNING TOOLHOLDER IN THE NEXT ADJACENT POSITION 210 CHUCK 170 CHUCK 203 THEORETICAL MAX TO SPECN 50.8 (2) MAX. BAR. DRAW TUBE BORE 52MM 215 XAXIS TOTAL WORKING STROKE 202 R.PARTING- TOOL ENVELOPE APPROX. MAX BORING BAR - 32 TURNING TOOL- 20 X 20 DISC VDI.30. DISC P.C.D. - 270 DISC O/DIA - 340 CHUCK STD- 170 CHUCK SPCL - 210
210 MAX TURNING.
LONG TOOLHOLDER.
(OUTSIDE SPEC.)
203 MAX TURNING BY SPEC.
Fig. 25 Turning Capacity Chart - Hawk 150 (VDI Tooling) The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine
27.4
323 DISTANCE TO SPINDLE
270 VDI.30,PCD
30 VDI
340 DISC.
109.5,LARGEST COMPONENT SWING BETWEEN BORING- BARS ON AD-
JACENT TURRET POSNS.
BORING BARS OF SIMILAR LENGTH ARE NOT RECOMMENDED TO BE PUT
INTO ADJACENT DISC POSITIONS; BUT SHOULD FOLLOW THE GENERAL
RULE OF BEING LOADED INTO THE DIAGONALLY OPPOSED STATIONS.
Page 2-11
Page 2-12
A LONG TOOLHOLDER ADJACENT TO A SHORT TOOLHOLDER (ON EITHER SIDE) PRESENTS VIRTUALLY NO INTERFERENCE EVEN WHEN FACING DOWN TO THE CENTRE LINE 306.5 MAX. TURNED FACE (OUTSIDE SPEC) R267.7 TOOLING ENVELOPE R234.5 TOOLING ENVELOPE A PART OFF TOOLHOLDER ADJACENT TO A SHORT TOOLHOLDER (ON EITHER SIDE) PRESENTS VIRTUALLY NO INTERFERENCE EVEN WHEN FACING DOWN TO CENTRE. PARTING TOOL IS CLOSER TO DISK THAN THE TURNING TOOL 254 MAX. TURNING BY SPEC. 254 MAX. TURNING BY SPEC. 166.5 LARGEST DIA BLANK IN CHUCK WHICH CAN BE PARTED, WITH A TURNING TOOL HOLDER IN THE NEXT ADJACENT POCKET 254 THEORETICAL MAX. TO SPECIFICATION 66 DRAWTUBE BORE R262.5 PARTING TOOL ENVELOPE APPROX. 254 CHUCK 200 CHUCK 245 X AXIS TOTAL WORKING STROKE
240 MAX TURNING (LONG TOOLHOLDER) OUTSIDE SPEC
Fig. 26 Turning Capacity Chart - Hawk 200 Machines (VDI Tooling) The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine
254 MAX TURNING BY SPEC
R388 DISTANCE TO SPINDLE CENTRE LINE
340 P.C.D.
40 VDI
410 DISK
130.5 LARGEST COMPONENT SWING BETWEEN BORING BARS ON ADJACENT TURRET POSITIONS
BORING BARS OF SIMILAR LENGTH ARE NOT RECOMMENDED TO BE PUT INTO ADJACENT DISK POSITIONS, BUT SHOULD FOLLOW THE GENERAL RULE OF BEING LOADED INTO THE DIAGONALLY OPPOSED STATIONS.
TURNING CAPACITY CHART
290.6 MAX TURNING (LONG
TOOLHLDER) OUTSIDE SPEC

305 MAX. TURNIING BY SPEC. R297.7 TOOLING ENVELOPE R264.7 TOOLING ENVELOPE 356.61 MAX TURNED FACE (OUTSIDE SPEC)
Cincinnati Machine 91203597B001 A LONG TOOLHOLDER ADJACENT TO A SHORT TOOLHOLDER (ON EITHER SIDE) PRESENTS VITUALLY NO INTERFERENCE EVEN WHEN PARTING DOWN TO THE CENTRE LINE.
40 V.D.I 305 MAX. TURNIING BY SPEC. 400 P.C.D 470 DISK 196.5 LARGEST DIA BLANK IN CHUCK WHICH CAN BE PARTED WITH A TURNING TOOLHOLDER IN THE NEXT ADJACENT POCKET. 305 MAX. TURNIING BY SPEC. R292.5 PART TOOL ENVELOPE 270 X AXIS STROKE. TOTAL WORKING 78 DRAWTUBE BORE 162.3 LARGEST COMPONENT SWIN G BETWEEN BORING BARS ON ADJACENT TURRET POSITIONS 315 CHUCK. 250 CHUCK. BORING BARS OF SIMILAR LENGTH ARE NOT RECOMMENDED TO BE PUT INTO ADJACENT DISK POSITIONS BUT SHOULD FOLLOW THE GENERAL RULE OF BEING LOADED INTO THE DIAGONALLY OPPOSED STATIONS.
Fig. 27 Turning Capacity Chart - Hawk 250 Machines (VDI Tooling)
A PART OFF TOOLHOLDER ADJACENT TO A SHORT TOOLHOLDER (ON EITHER SIDE) PREENTS VIRTUALLY NO INTERFERENCE EVEN WHEN FACING DOWN TO CENTRE. PARTING TOOL IS CLOSER TO DISK THAN THE TURNING TOOL.
Page 2-13
TURNING CAPACITY CHART
HEADSTOCK FRONT FACE
BULKHEAD FRONT FACE
Fig. 28 Data Sheets - Hawk 150 (VDI Tooling)
Page 2-14
438 190
75
8 320 SLIDE WIDTH 32 52

22
189 68 22
56
43
22
63 DUPLOMATIC INDEXER BSA 150
105
135 ,RAD. TYP PCLNL 2020K12.
47 25 25
25 22
50
30
OVERTRAVEL 438 MAX WORKING STROKE 35

35 10
10
27.4 8
27.4
123 8 O/TRAVEL
91
418 STROKE TO HARD JAWS ON KITAGAWA 170 CHUCK 402 STROKE TO HARD JAWS ON S.M.W. 170 CHUCK 454 ABSOLUTE STROKE
KITAGAWA 170-52
215 MAX STROKE
16
101.6 QUILL STROKE 173.7 O/HANG
173.7
TAILSTOCK FULLY BACK
99
99
SMW-169.
101.6 QUILL STROKE
475.8 TAILSTOCK ADJUSTMENT
139
The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine.
19
223
190 190 65.1 90 100
BULKHEAD FRONT FACE
Cincinnati Machine 91203597B001 83 40
Fig. 29 Stroke - Hawk 200 Machines (VDI Tooling) The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine.
267.7 LONG TOOLHOLDER 127.00 QUILL STROKE 10 O/TRAVEL 245 MAX STROKE 540 MAX. WORKING STROKE 560 ABSOLUTE STROKE 540 TO KITAGAWA BB08--66 CHUCK FACE 539 TO SMW BHM210--A6 CHUCK FACE
24
388 FROM OF DISK TO OF SPINDLE
10 O/TRAVEL
104 SMALL SMW
177.91
255.6
SMW HARD JAWS 12082121
4 SERRATIONS 103 SMALL KITAGAWA
358.6
665.50 TAILSTOCK TRAVEL
1250 TO CLEAR X TRAVEL
57
Page 2-15
BULKHEAD FRONT FACE
Page 2-16
190 100
64.6
54 90 83 40
190
Fig. 30 Stroke - Hawk 250 Machines (VDI Tooling) C L

297.7 LONG TOOLHOLDER
443 FROM C L OF DISK TO OF SPINDLE
10 O/TRAVEL 70 ABSOLUTE STROKE 690 MAX. WORKING STROKE 690 TO KATAGAWA B210-A8 CHUCK FACE 690 TO SMW BBM250-A8 CHUCK FACE 32 10 O/TRAVEL 270 MAX. STROKE 177.91 127.00 QUILL STROKE 97.7 56 234.09 27
SMW HARD JAWS 12082621
119 SMALL SMW
179
4 SERRATIONS
113 SMALL KITAGAWA
56
173
(347.09) 897 TAILSTOCK TRAVEL
1530.62
40 22 B1;30/20:212-100-150. RECTANGULAR TRANSVERSE TOOLHOLDER,R.H.SHORT.
35TYP.
35
25
27.4,TYP. 47 20 SQ.
B3;30/20:212-105-150. RECTANGULAR TRANSVERSE INVERTED TOOLHOLDER, RIGHT-HAND;SHORT.
B7;30/20:222-105-150. RECTANGULAR TRANSVERSE INVERSE TOOLHOLDER, RIGHT-HAND:LONG.
65 82.4
55
190 MAX.- IF USING FULL STROKE. 71 59 E1;30/25:222-052-150 TOOLHOLDER WITH:INTERNAL COOLANT SUPPLY. 17 45 . 68 . E1;30/32:222-055-150 TOOLHOLDER WITH:INTERNAL COOLANT SUPPLY. 68 52. 32 H6. 25 H6 22
61 30. E2;30/30:212-015-156 BORING BAR HOLDER.
63 75 61
10H6.
12H6.
16H6.
20H6.
25H6. 68. 75 30H6.
ONE SET OF FIVE LINER BUSHES.
OPTIONAL STANDARD TOOLING PACKAGE. 001270504000001.
Fig. 31 Optional Standard Tooling Package - Hawk 150 (VDI Tooling)
Page 2-17
Page 2-18
74 52 32 22 75 DRILL HOLDER - VDI 40 Dia 32 (WITH INTERNAL COOLAND SUPPLY) FORM E1 27.4032 DIN 69880
BORING BAR HOLDER - VDI 40 Dia 40 FORM E1 27.4032 DIN 69880
83 40
76
90
COLLET CHUCK - VDI 40 ER32 TYPE FORM E4 30.4032 DIN 69880
PARTING O FF BLADE HOLDER - VSI 40 RIGHT HAND 32.SH32 32.4032
ONE SET OF FOUR LINER BUSHES TURNING TOOL - VDI 40 - RIGHT HAND LONG FORM B5 11.4025/20 DIN 69880 PART 3
Fig. 32 Optional Standard Tooling Package - Hawk 200/250 Machines (VDI Tooling)
BORING BAR SLEEVE 20 28.4020 BORING BAR SLEEVE 25 28.4025
BORING BAR SLEEVE 12 28.4012
BORING BAR SLEEVE 16 28.4016
40
OPTIONAL STANDARD TOOLING PACKAGE 1946177

20 H6 25 H6
78
12 H6
16 H6
TURNING TOOL - VDI 40 - RIGHT HAND SHORT OVERHEAD FORM B3 6.4025/20 DIN 69880 PART 3
PLASTIC PLUG - VDI 40 FORM Z2 29.40K DIN 69880 TURNING TOOL - VDI 40 - RIGHT HAND SHORT FORM B1 5.4025/20 DIN 69880
139
139 156.9
156.9 150
160 24 24 20
99
99
24
24
10.5
20
4 21
24 10.5
SMW.KSZ,MB60. COLLET CHUCK.
4 21
OF JAW SERRATIONS.
24
10 SMW.210,BHD.
HEADSTOCK FRONT FACE.
BULKHEAD FRONT FACE
Cincinnati Machine 91203597B001 10

SMW.HARD JAW 12081621.CM#:1270485000001
22 21 23 82 37
SMW - 170- 52
21
20 67 23 20 CBORE CBORE FOR M12. 19 49,MIN. 72,MAX. FOR M10.
SMW.HARD JAW 1282030.CM#:1270486000001
Fig. 33 Work Holding Options - Hawk 150

45 67
45 46.5,MIN. 210 52. 45 63.5,MAX.
M10
49 MIN 72 MAX 60 130 185

60. 130. 185.
52.
52
14
46.5 MIN 63.5 MAX 210 52 45
170
170. M12 M12
108.9
98
92 111
138.9
108.9 138.9
111 156
156
123
123 24
24
12
165
165
91
91
12 22
12
HARD JAWS HB,06B1.CM#:1270572000001 KITAGAWA B208,A5.
22 12
HARD JAWS HB,08A1.CM#:1270575000001

22
22
15
13 25
15
KITAGAWA CRL60. COLLET CHUCK.
KITAGAWA 170-52
20 CBORE 25 FOR M10. 20 67.5
M10
67.5
8.5
M10 CBORE FOR M10. 18 45.5 ,MIN. 68.7,MAX.
13.75
52
52.
3.7
STROKE
45.5 MIN 68.7 MAX

PER JAW.
60 138 150
60. 138. 190.
52
52.
48,MIN. 60,MAX.
170
170. M10
20
210 M10
91
91
148
148
108
108
Page 2-19
50
50
KITAGAWA CHUCKING SYSTEM
CRS66--A6
150 65 165
17
140
57
B210--A6
75 254
100 25 57 66 200 86 17 103 57 BULKHEAD FRONT FACE HEADSTOCK FRONT FACE BULKHEAD FRONT FACE HEADSTOCK FRONT FACE
BB08--66
Page 2-20
21
21
120
21 BULKHEAD FRONT FACE HEADSTOCK FRONT FACE
SMW CHUCKING SYSTEM
BHM--250--A6
75
250
105 24 57 66 210 92 17 57 BULKHEAD FRONT FACE HEADSTOCK FRONT FACE BULKHEAD FRONT FACE HEADSTOCK FRONT FACE
BBM--210--A6
Page 2-21
21
104
21
124
KITAGAWA CHUCKING SYSTEM
220
11mm STROKE
CDC80A2 (1273393)
30
200
20
159
170
77
B212--A8
91 304
110 18 77 75 254 100 77 18 HEADSTOCK FRONT FACE BULKHEAD FRONT FACE HEADSTOCK FRONT FACE BULKHEAD FRONT FACE
B210--A8
Page 2-22
71
113
71
122
71
BULKHEAD FRONT FACE
SMW CHUCKING SYSTEM
BHM 315-AB
95
315
111 77 30 77 250 105 77 19

HEADSTOCK - FRONT FACE BULKHEAD - FRONT FACE HEADSTOCK - FRONT FACE BULKHEAD - FRONT FACE
BBM 250-A8
Fig. 37 Work Holding Options - Hawk 250 (Continued|
71
119
3
71
136
Page 2-23
CLEARANCE REQUIRED 5500 MIN BEHIND MACHINE 1520 APPROX 3210 APPROX 450 APPROX
350 APPROX
5180 3000 BAR CAPACITY
CLEARANCE REQUIRED 4900 MIN BEHIND MACHINE 2700 720
4800 OVERALL LENGTH 3000 BAR CAPACITY
1150 REF
1770 1064 BASE
MULTIFEED 3 - 76 SHORT MAGAZINE BAR FEED OPTION
1150 1670 PLAN VIEW OF BASE 1975 BASE
BAR FEED SHOWN ROTATED THROUGH 90 AND 135
The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine Fig. 38 Bar Feed Options - Hawk 150 machines
91203090A
Page 2-24
Motor Rating
The MTD (Machine Tool Duty) rating of the motor is based upon the amount of power delivered in a given amount of time. The following chart shows spindle motor MTD ratings. Machine Hawk Model 150 Hawk Model 200 Hawk Model 250 MTD Rating 7.5 15 18.5 Continuous Use 5.5 11 15
7.5 kW MTDR 5.5 kW POWER 5.0 kW 4.5 kW Continuous
30
750
3,500 SPEED RPM
5,500
Fig. 39 Hawk 150 - Spindle Power Characteristics
15 kW MTDR 11 kW POWER Continuous
30
750 SPEED RPM
4,500
Page 2-25
15 kW MTDR 11 kW Continuous POWER
30
575
SPEED RPM
3,300
Page 2-26
MACHINE ALIGNMENT AND PROGRAM POINTS

On Turning Centers, the Z axis travels parallel to the spindle centerline and the X axis travels perpendicular to the spindle centerline. Several real and imaginary points are used to describe the relationship between the machine elements, the tool point, and the workpiece. There are many references to these points throughout the manual. This section defines the machine setup and alignment points. Refer to Machine Range drawings.
X+
Z+
SPINDLE FACE
Z*
CHUCK SPINDLE CENTERLINE
X*
OD COMMON TOOL POINT AT GRID ALIGN POSITION
MACHINE ZERO
Fig. 42 Machine Alignment And Program Points
Machine Zero Machine zero in the X axis is located on the spindle centerline. Machine zero is established only once each time the machine is started and aligned. The control calculates all automatic range checking and interference parameters from machine zero. NOTE: When coordinate reset is active and the machine is aligned, program zero is also located at this point.
Page 2-27
Chapter 3 Functional Description of Controls

Introduction - GE FANUC 21i-TA CNC System The GE Fanuc 21i-TA CNC system control consist of a Control mounted behind flat screen with soft keys, MDI keypad, Operators Control Panel, and an MTB panel (Machine Tool Builders panel). For full description on using the PCMIA slot and softkeys on the control/flat screen unit and also the MDI keypad unit reference should be made to GE Fanuc Operators manual (21i-TA B-63084EN) supplied with this machine. The Hawk Turning centre is arranged with GE Fanuc 21i-TA Computer Numerical Control System comprising an operator control station with a 9.5 high resolution monochrome flatscreen display. See Fig. 43.
Control/Flat Screen/Softkeys MDI Keypad
PC MIA Slot (SRAM) Card
x F 3 1
-
+X
+Z
X
-X
0 + 0
-Z
Operators Control MTB Panel
RS 232 Serial Data Port Fig. 43 Control Station Layout for: - Hawk Turning centres with fanuc 21i TA
Page 3-1
1 A
10
X
B C D
RS 232
x X1 1
X10
A 1 + X100 U
AUX 1 -Z
+ X +X X
-X +Z
X
+
100%
E F
Fig. 44 Operators Control Panel
OPERATOR PANEL - PUSHBUTTON DESCRIPTIONS

REF A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B8 B9 B10 C1 C2 C3 C4 DESCRIPTION REF C5 C6 C8 C9 C10 D1 D2 D3 D4 D5 D6 D8 D9 D10 F1 F2 F3 DESCRIPTION
Memory Operation EDIT mode MDI Operation Align Machine Jog mode Parts catcher down Parts catcher up Chuck - ID Grip Chuck - OD Grip Offset measure Single block Block delete Optional stop MPG mode x 1 MPG mode x 10 MPG mode x 100 +X axis JOG/MPG axis selection Dry run Program test Axes inhibit Turret Jog + (increment)
Turret Jog - (decrement) AUX 1 - spare membrane key -Z axis JOG/MPG axis selection Rapid traverse +Z axis JOG/MPG axis selection Program restart Tool Setting Arm Down (active) Tool Setting Arm Up (stowed) Spindle speed decrement Spindle 100% Spindle speed increment -X axis JOG/MPG axis selection Cycle start Cycle stop Program stop Spindle clockwise (CW) Spindle stop Spindle counterclockwise (CCW) Coolant On Coolant Off Coolant Auto
F4 F5 F6 F8 F9 F10
Page 3-2
AUTOMATIC OPERATION - PROGRAMME SOURCE

MEMORY OPERATION - (Push button with LED) (A1) This mode is selected to run a part programme registered in the active programme memory. (See GE Fanuc Operators Manual - III Operation chapters 1.2 and 4.1). EDIT MODE - (Push button with LED) (A2) This mode is selected to edit part programmes registered in the active programme memory. (See GE Fanuc Operators Manual - III Operation chapters 9). MDI OPERATION - (Push button with LED) (A3) This mode selection enables a programme of up to 10 blocks to be created and processed from the MDI buffer memory. (See GE Fanuc Operators Manual - III Operation chapters 1.2 and 4.2).
EXECUTION PUSHBUTTONS
CYCLE START (Push button with LED) (F1) This push button causes the active NC programme to start, providing that the following conditions are met:1) 2) 3) 4) 5) All axes have been aligned. The turret is aligned, i.e. ALIGN MACHINE key is illuminated No NC or Machine faults are active AUTO or MDI mode has been selected Operator door/s is/are closed
CYCLE STOP (Push button with LED) (F2) Cycle stop is used to stop all feed motors and to suspend the NC cycle. The LED in this button is illuminated whenever the CYCLE STOP is active. It is cancelled when restarting the NC cycle using the CYCLE START push button. NOTE: Any active programme dwell will also be stopped by using this push button. If CYCLE STOP is depressed during a Tapping Cycle the NC cycle will continue until the spindle has reversed and the axis retracted.
Page 3-3
PROGRAMME STOP (Push button with LED) (F3) Pressing this push button during NC part programmed execution causes the active cycle to be held at the end of the current programme block. To restart the active part programme, the CYCLE START push button must be depressed. It is permitted to stop the spindle whilst in a programme stop condition. The NC cycle however cannot be resumed until the spindle has been restarted. PROGRAMME STOP push button is active in both AUTO & MDI modes but only whilst the machine is in cycle. The LED in this push button is illuminated when programme stop is active and remains illuminated until the cycle is restarted or the control system is reset.
SPINDLE CONTROL BUTTONS

SPINDLE STOP (Push button with LED) (F5) This push button causes an immediate spindle stop and is active at all times. If the machine is in cycle, a cycle stop is also generated. The LED in this button is illuminated if the spindle is stopped during an Auto Cycle interrupt condition and acts as a reminder that the spindle must be restarted before the cycle can be resumed. SPINDLE CLOCKWISE (CW) (Push Button with LED) (F4) This push button can be used to restart the spindle, once it has been stopped during an Auto Cycle Interrupt. In C-Axis Mode OFF (M50 active), this button can also be used to jog the spindle in the clockwise direction providing the control is not in cycle or in a cycle interrupt condition, and only when the operator door is closed. See CAUTION. In C-Axis Mode ON (M51 active), this button, in conjunction with the control set in JOG mode, can be used to jog the spindle in the clockwise direction. The operator door is latched shut at all times when M51 is the active M-code. See CAUTION. Also, see HANDWHEEL (MPG) for alternative spindle jog facility. SPINDLE COUNTER CLOCKWISE (CCW) (Push button with LED) (F6) This push button can be used to restart the spindle, once it has been stopped during an Auto Cycle interrupt. In C-Axis Mode OFF (M50 active), this button can also be used to jog the spindle in the CCW direction providing the control is not in cycle or in a cycle interrupt condition, and only when the operator door is closed. See CAUTION. In C-Axis Mode ON (M51 active), this button, in conjunction with the control set in JOG mode, can be used to jog the spindle in the CCW direction. The operator door is latched shut at all times when M51 is the
Page 3-4
active M-code. See CAUTION. Also, see HANDWHEEL (MPG) for alternative spindle jog facility.
CAUTION Spindle Jog

The Spindle/Chuck must be in an interference free position before pressing the SPINDLE CW/CCW pushbutton. Failure to follow this instruction may result in damage to the machine, workpiece and tooling. SPINDLE 100% (Push button with LED) (D5)
100%
This push button is used to return the actual spindle speed to 100% of the last programmed value and to remove any active spindle speed override imposed by means of the spindle speed increment and decrement buttons. The LED in this push button is illuminated all the time that the 100% spindle speed override is active SPINDLE SPEED INCREMENT (Push button with LED) (D6)
This push button is used to override the programmed spindle speed. The actual spindle speed is increase by 10% each time this button is depressed, up to a maximum of 120% of the programmed value or the the maximum spindle speed if this occurs sooner. The LED in this push button is illuminated once the 120% override is active. NOTE: Spindle override is ignored whilst M48 is active SPINDLE SPEED DECREMENT (Push button with LED) (D4)
--
This push button is used to override the programmed spindle speed. The actual spindle speed is decreased by 10% each time this button is depressed, down to a minimum of 50% of the programmed value or the the minimum spindle speed if this occurs sooner. The LED in this push button is illuminated once the 50% override is active. NOTE: Spindle override is ignored whilst M48 is active
OPERATION BUTTONS
ALIGN MACHINE - (Push Button with LED) (A4) This pushbutton is used for referencing the machine axes and turret to the control system. (See chapter 4 of this manual for machine and mechanism alignment procedure). MPG MODE (HANDWHEEL) & INCREMENT SELECTION PUSHBUTTONS MPG MODE - 0.001mm (Push Button with LED) (B4) This pushbutton selects MPG Mode with 0.001mm distance move per increment of the handwheel.
X1
Page 3-5
MPG MODE - 0.010mm (Push Button with LED) (B5) This pushbutton selects MPG Mode with 0.010mm distance move per increment of the handwheel. MPG MODE - 0.100mm (Push Button with LED) (B6) This pushbutton selects MPG Mode with 0.100mm distance move per increment of the handwheel. JOG MODE - (Push Button with LED) (A5) This button accesses the axis and direction push button selections to provide continuous move axis jogs. (See push button references B9, D9, C8 and C10 in this manual, and GE Fanuc Operators Manual - III Operation chapter 3.2). In C-Axis Mode ON (M51 active), manual rotation of the spindle/chuck using the Handwheel (MPG) control is possible proivided JOG mode is selected ON.
X10
X100
OPERATION SELECT - PUSHBUTTONS

SINGLE BLOCK - (Push Button with LED) (B1) This push button allows an active part programme to be processed one block at a time. When this feature is active each block must be started using the CYCLE START push button. The single block push button is enabled in AUTO & MDI mode. The LED is illuminated when SINGLE BLOCK is active. NOTE: It is permitted to use this push button to interrupt an active cycle. For affect of single block on canned cycles refer to GE Fanuc operators manual. BLOCK DELETE - (Push Button with LED) (B2) When BLOCK DELETE is active all programme blocks preceded by the BLOCK DELETE character (/) are skipped during an NC cycle This push button is enabled only in AUTO & MDI mode. The LED is illuminated when BLOCK DELETE is active. OPTIONAL STOP - (Push Button with LED) (B3) This push button enables the OPTIONAL PROGRAMME STOP feature. When optional stop is active the NC cycle will stop on reading an M01 code and can only be restarted by pressing the CYCLE START push button, all existing modal programme information is unaffected by this function. This push button is enabled in AUTO & MDI mode only. The LED is illuminated when OPTIONAL STOP is activate. DRY RUN - (Push Button with LED) (C1) When the DRY RUN feature is active, coolant flow is inhibited and the feedrate specified by the NC programme is ignored. The OVERRIDE SELECTOR switch is used to modify the DRY RUN feedrate from 0.1M/min. to 10 M/min.
Page 3-6
Rapid motions are conducted as normal and can also be overridden by the OVERRIDE SELECTOR. This push button is enabled in AUTO & MDI mode. The LED is illuminated when DRY RUN is active. Dry run can only be selected when the machine is not in cycle. To start the cycle in dry run requires a double press of the CYCLE START push button. On the first press an operator prompt message DRY RUN ACTIVE REPRESS CYCLE START appears on the CRT as a warning that DRY RUN is active. PROGRAMME TEST - (Push Button with LED) (C2) When the programme test feature is active, all T and S codes and all of the M codes with the exception of:M00, M01, M02, M30, M98 and M99 are not processed. This push button is enabled in AUTO & MDI mode. The LED is illuminated when programme test is active. PROGRAM TEST is used during programme checking and may also be used in conjunction with AXES INHIBIT. AXES INHIBIT - (Push Button with LED) (C3) X Z Axes inhibit suppresses all axis moves. The CRT display however is updated as if the axis were not inhibited. This push button is only enabled in AUTO & MDI mode whilst not in cycle. The LED is illuminated when AXIS INHIBIT is active. Axes inhibit is used during programme checking and may also be used in conjunction with PROGRAM TEST.
AXIS/DIRECTION SELECTION PUSHBUTTONS
*
+X
X+ AXIS (Push Button with LED) (B9) This push button is used for continuous axis jogging in the X+ direction. It is also used in the MPG mode for HANDWHEEL X axis selection where upon both X+ and X- push buttons are illuminated. X- AXIS (Push Button with LED) (D9)
--X
This push button is used for continuous axis jogging in the X- direction. It is also used in the MPG mode for HANDWHEEL X axis selection where upon both X+ and X- push buttons are illuminated. Z+ AXIS (Push Button with LED) (C10)
*
+Z
This push button is used for continuous axis jogging in the Z+ direction. It is also used in the MPG mode for HANDWHEEL Z axis selection where upon both Z+ and Z- push buttons are illuminated. Z- AXIS (Push Button with LED) (C8)
--Z
This push button is used for continuous axis jogging in the Z- direction. It is also used in the MPG mode for HANDWHEEL z axis selection where upon both Z+ and Z- push buttons are illuminated.
Page 3-7
NOTE: X+, and Z+ pushbuttons also illuminate; in Auto or MDI mode when the corresponding machine axes are sent to their alignment position using G28 and during the machine axes alignment sequence. RAPID TRAVERSE (Push Button with LED) (C9) This push button can be operated simultaneously with any power feed push button to produce rapid axis jogging motion as long as the operator door is closed. PARTS CATCHER DOWN (Push Button with LED) (A6) (only active when the parts catcher option is fitted) This push button is used to jog the parts catcher down. It is only active when not in cycle and with the operator door closed. PARTS CATCHER UP (Push Button with LED) (A7) (only active when the parts catcher option is fitted) This push button is used to jog the parts catcher up. It is only active when not in cycle and with the operator door closed. TURRET JOG + (INCREMENT) (Push Button with LED) (C4) This push button is used to jog the turret in the clockwise (CW) incrementing count direction. (CW as viewed from spindle to turret). It is only active when not in cycle, operator door closed, spindle is stationary and the AUX 1 push button is pressed. TURRET JOG - (DECREMENT) (Push Button with LED) (C5) This push button is used to jog the turret in the counter clockwise (CCW) decrementing count direction. (CCW as viewed from spindle to turret). It is only active when not in cycle, operator door closed, spindle is stationary and the AUX 1 push button is pressed. CHUCK - ID GRIP (Push Button with LED) (A8) This push button is used to select ID gripping of the chuck. It is only active when not in cycle and the spindle is stationary. CHUCK - OD GRIP (Push Button with LED) (A9) This push button is used to select OD gripping of the chuck. It is only active when not in cycle and the spindle is stationary. OFFSET MEASURE (Push Button with LED) (A10) This push button is used to set offsets on the machine. Refer to Fanuc manual for a full description of its use. It is only active when not in cycle and the spindle is stationary.
Page 3-8
TOOL SETTING ARM DOWN (Push Button with LED) (D2) This push button is used to jog the Renishaw Tool Setting Arm (TSA) to its down position - Active position. It is only active when not in cycle, operator door closed and the spindle is stationary. TOOL SETTING ARM UP (Push Button with LED) (D3) This push button is used to jog the Renishaw Tool Setting Arm (TSA) to its up position - Stowed position. It is only active when not in cycle, operator door closed and the spindle is stationary. PROGRAM RESTART (Push Button with LED) (D1) This push button is currently not used.
AUX 1 - Auxillary Push Button (Push Button with LED) (C6)

AUX 1
Used in conjunction with the Turret Jog + and Turret Jog - push buttons.
COOLANT BUTTONS
COOLANT OFF (Push Button with LED) (F9) This push button is used to manually turn the coolant flow off. It is functional in all modes. When selected during AUTO or MDI mode, M08 coolant on, is ignored. COOLANT ON (Push Button with LED) (F8) This push button is used to manually start the coolant flow and is active in all modes, provided that the operator access door is closed. When selected during AUTO or MDI modes M09 coolant off is ignored. NOTE: Even if COOLANT ON is selected, the coolant flow is inhibited during an automatic turret index but will restart on completion of the turret index.
COOLANT AUTO (Push Button with LED) (F10) This push button enables the coolant system to be controlled via coolant M codes. It is only selectable in AUTO or MDI modes. NOTE: The COOLANT ON and COOLANT OFF push buttons can be used during auto cycle, if COOLANT AUTO is to be overridden. COOLANT AUTO is the default status when first selecting the AUTO or MDI modes and assumed at the end of every programme.
Page 3-9
The coolant flow is automatically turned off by: M00, M01, M02, M06, M09 and M30 codes, providing AUTO COOLANT is selected.
MISCELLANEOUS CONTROLS
MEMORY PROTECTION - Keyswitch This keyswitch is used to prevent part programs, offset values, parameters and setting data from being registered, modified or deleted accidentally. This switch is enabled in all operating modes. The named functions are LOCKED OFF when the MEMORY PROTECTION KEYSWITCH is in the ON position. RS 232 SERIAL DATA PORT The port can be used to interface any RS 232 serial data input / output device via the machine mounted 25 pin D-type female socket. See chapter 10 of this manual for set-up and operational description of this facility.
50 100
FEED/RAPID/JOG OVERRIDE - Selector Switch This selector switch is used to override:

150
1.
Programmed Feedrate (Outer Scale 0-150%) in AUTO & MDI mode. If an override could result in a feedrate greater than the maximum programmable feedrate, then the feedrate is clamped to that maximum value. Rapid Traverse (Inner Scale 0-100%) in AUTO/MDI/JOG modes. Jog rate (Inner Scale 0-100%) in JOG mode only.
2. 3.
Selecting the 0% graduation causes a feedhold condition except during a tapping cycle. NOTE: Feed override is not possible whilst M46, G63 or Tapping cycles are active. EMERGENCY STOP (red mushroom pushbutton with latch) Pressing this pushbutton causes an immediate slide and spindle stop, followed by the removal of drive power. The pushbutton remains depressed (latched) when actuated. Twisting the pushbutton in a counterclockwise direction releases the Emergency Stop button. CAUTION Actuating this button with the machine in a cutting cycle may damage cutting tools and work pieces. Failure to follow this instruction may result in damage to equipment. The pushbutton is active at all times. See CAUTION.
Page 3-10
MTB OPERATORS CONTROL PANEL
Spindle Loadmeter
% SPINDLE LOAD
Master Start
25 50 75 100
150 180
Cycle Start (duplicated) Chuck P.B. Unclamp Chuck P.B. Clamp
Tailstock Retract Tailstock Advance/ Step Advance

0
FANUC
Fig. 45 MTB Operators Control Panel
Spindle Load Meter
% SPINDLE LOAD 0 25 50 75 100 150 180
Yellow Band 100 -150% Fig. 46 Spindle Load Meter
The load meter is graduated in percentage load of the maximum output of the spindle motor. 0 to 100% Range (Continuous rating) Providing the spindle load remains at 100% or less the machine spindle can be run continuously.
50
Red Band 150 -180%
Page 3-11
110 to 150% Range - Yellow Band (30 minutes 50% rating) For every minute or part of a minute up to a maximum of 30 minutes, that the spindle load is in the 101 to 150% to range, there must either be an equivalent time period immediately following this overload when the spindle is in a NO LOAD condition, or a proportionally longer period of time when the load remains within the continuous operating range. 151 to 180% Range - Red Band (1 minute overload capacity) For any period of time up to a maximum of 1 minute the spindle load can enter the 151 - 180% overload range. Immediately after this period however the spindle must, for an equal period of time, be in a NO LOAD condition, or for a proportionally longer period of time, must stay within the continuous operating range. NOTE: The above conditions are theoretical definitions and should only be used as a guide. In practice the spindle load is continuously varying and can therefore be difficult to estimate. As a general rule the spindle load should be kept as much as possible within the CONTINUOUS operating range with only occasional loadings being used within the 101 to 150% YELLOW BAND range. CAUTION: The machine cycle should not take the spindle load into the 151 - 180% RED BAND range whilst cutting is being carried out. Only during acceleration of the spindle should the load meter go to the full scale deflection (RED BAND).
MASTER START - Illuminated push button This push button is used to power up the control and axis/spindle drives in a controlled sequence. Depressing the master start push button will bring the CNC control power on in a control EMG condition. Repressing MASTER START - on receipt of successful control power on, will apply power to the spindle and axis drives, where upon the control removes the EMG status indicator. The control will report an EMG ALM condition, if the Emergency Stop push button is depressed or if axes go into a hard OVERTRAVEL, or if any other alarm is active which results in the removal of servo control. The MASTER START push button is also used in the event of a hardware axis overtravel, as it overrides the overtravel limit switches, whilst held depressed. The axis drive power is thus reinstated, enabling the axis to be jogged back, to within its normal operating range. CYCLE START This duplicated push button has the identical function to that of the CYCLE START push button (F1) on the operators control panel. See Page 3-4.
Page 3-12
HANDWHEEL (MPG)
0
When MPG mode is selected, clockwise rotation of the handwheel will result in Positive axis motion and counterclockwise rotation will give Negative axis motion. Axis selection is performed by using the relevant control panel push buttons.
FANUC
50
MPG mode and the distance per increment are selectable from the control panel push buttons. Increments are: 0.001mm - MPG x 1 pushbutton 0.010mm - MPG x 10 pushbutton 0.100mm - MPG x 100 pushbutton Handwheel control of the machine axes (as described above) is possible when C-Axis Mode OFF (M50) is active. In this mode, the operator door may be open or closed whilst an axis is in motion. In C-Axis Mode ON (M51 active), the handwheel may be used to control rotation of the spindle/chuck. Handwheel mode is selected by pressing one of the MPG Mode - Distance/Increment push buttons on the operator panel. The Spindle CW or Spindle CCW push button must be pressed to engage the spindle/chuck; both CW and CCW button LEDs illuminate. Clockwise rotation of the Handwheel produces a clockwise rotation of the spindle/chuck as viewed from the +Z (tailstock) end of the machine. CHUCK UNCLAMP push button This push button unclamps the chuck. It is only active when not in cycle and with the operator door open. See NOTE 1 below. CHUCK CLAMP push button This push button clamps the chuck. It is only active when not in cycle and with the operator door open. See NOTE 1 below. NOTE 1: The clamping/unclamping of the workpiece is determined by the selection of ID/OD Grip.
WARNING Chuck Operation

Do not operate the chuck at speeds (rpm) greater than its maximum rated speed or at pressures greater than its maximum rated pressure. Refer to machine mounted plate or chuck manufacturer. Reduce chuck speed (rpm) when using special top jaw tooling. Top jaws must not extend beyond the chuck diameter. Never place your hands or any part of your body near the chuck when jogging the spindle, adjusting thrust or pressure. Lubricate the chuck according to the manufacturers specifications. Use jaw serrations as noted on machine mounted plate or specified by chuck manufacturer. Failure to follow this instruction may result in serious personal injury.
Page 3-13
TAILSTOCK QUILL ADVANCE/STEP ADVANCE push button This push button is used to advance the tailstock quill. It has two modes of operation:a) Operator door open - Step advance - Quill stops advancing when pushbutton is released. Quill is not held fully forward, i.e. Operator door must be closed and pushbutton pressed to lock the tailstock fully forward. Operator door closed - full advance - Quill is held fully forward. See WARNING.
b)
TAILSTOCK QUILL RETRACT push button This push button is used to retract the tailstock quill. Operator door must be open for the tailstock to retract.
WARNING Tailstock Quill Step

Tailstock Quill Step Advance must only be used for set-up purposes as pressure is not maintained in its static position. Failure to follow this instruction may result in serious personal injury.
Page 3-14
Machine Pressure - Tailstock Thrust - Chuck Drawbar Force - Chuck Brake (Dampener) Control
This control panel is located on the front of the machine to the left of the headstock and includes: main machine pressure gauge, tailstock thrust gauge and pressure control knob, chuck drawbar force gauge and pressure control knob. A further pressure gauge and control knob is also supplied to adjust a chuck brake (dampener) when the C-Axis mode feature is present. Machine Pressure - The machine system operating pressure of 35 Bar is indicated on the uppermost gauge. This pressure is set by a regulating screw mounted on the top of the hydraulic system pump.
Machine Pressure Gauge
Tailstock Thrust - The centrally located tailstock thrust gauge monitors settings of the adjacent pressure regulating valve control knob. The maximum thrust is 7.86kN @ 35 Bar. When setting the tailstock quill pressure, advance the quill until the tailstock center is engaged with the part, then adjust the valve until the desired pressure setting is obtained.
Tailstock Pressure Knob
When setting a lower pressure, adjust the valve until the lower setting is obtained. Retract the quill then advance it again to check for the correct lower setting. If the pressure falls below 3 Bar before starting a cycle or during a cycle, the machine will stop and display the appropriate alert. Chuck Drawbar Force - The lower chuck drawbar force gauge monitors settings of the adjacent pressure regulating valve control knob. Chuck jaw grip force must be checked a every 200 hours (minimum) of operation. The main spindle chuck pressure regulating valve controls the gripping force of the main spindle power chuck. Use the maximum pressure setting unless the maximum pressure setting distorts the part.
Tailstock Pressure Gauge
Chuck Pressure Knob
Chuck Pressure Gauge Fig. 47 Main Spindle Chuck & Tailstock Pressure
The maximum force is 56.5kN @ 35Bar. Do not exceed the maximum pressure stamped on this plate. If higher pressure is selected, high stress forces are created within the chuck resulting in possible damage to the chuck. Check the chuck manufacturers sprcifications for maximum chucking pressures, maximum rpm and lubrication before using this control. Check the clamping force with a Static Grip Clamping Force Gauge (force per jaw with spindle not running) and a Dynamic Grip Clamping Force Gauge (force per jaw measured with the spindle running). NOTE: Use the maximum manufacturer approved chuck clampimg force pressure that will result in minimum part distortion. Chuck Brake (Dampener): C-Axis Interpolation Mode - The purpose of this brake is to offer a degree of dampening to the cutting action when the spindle chuck is in C-Axis interpolation mode and miscellaneous code M53 is programmed. The minimum setting for the brake is 2 Bar.
CHUCK BRAKE PRESSURE GAUGE Fig. 48 Chuck Brake Pressure (Option)
The amount of dampening is adjustable by the user and will depend on the severity of the cutting process. Brake adjustment is via a regulating screw along side the pressure gauge.
Page 3-15
MAIN POWER DISCONNECT SWITCH
WARNING
Place the MAIN POWER DISCONNECT switch in the OFF position, lock it and tag it with a DO NOT STARTsign before servicing the machine or control. Note: This switch does not isolate the incoming supply to the electrical cabinet or the supply to the Transformer Unit. Failure to follow this instruction can result in machine damage and personal injury.
See WARNING This switch is used to supply power to the machines main electrical cabinet and is located on the rear door of the electrical cabinet. When the switch is in the ON position: power is supplied to the machine electrical cabinet. Before servicing the machine or control, always place this switch in the off position. Lock and tag this switch with a do not start sign. It is also important to wait for the condensers in the servo drives to be completely discharged. A red LED is fitted to each servo drive power circuit PCB. The LED will remain illuminated whilst any charge remains in the condensers.
or
l 0
Page 3-16
Optional Operating Devices

Swarf Conveyor The swarf conveyor unit is positioned across the front of the machine with the outlet hood on the right side of the machine.
Fig. 49 Swarf Conveyor Control Panel
1.
Conveyor Control AUTO/ ON MAN/OFF - Selector Switch In AUTO selection, the chip conveyor will rotate continuously in its normal clockwise direction when the operator door is closed and the machine is set in-cycle by pressing the CYCLE START push button. NOTE: The conveyor will stop if, 6) 7) 8) The EMERGENCY STOP push button is pressed. The Operator Door is opened. The MAN/AUTO selector switch is set to MANUAL.
In MAN (manual) selection, the swarf conveyor will remain stationary unless the conveyor direction selector switch is set to Forward or Reverse.
Page 3-17
2.
CONVEYOR DIRECTION -Selector Switch (spring centered) This switch is a jog facility operative only when the conveyor MAN/AUTO selector switch is set to MANUAL. With the conveyor direction switch held in the FWD (forward) position, the conveyor will rotate in its normal clockwise direction; when held in the REV (reverse) position the conveyor will rotate in a counter-clockwise direction. When released, the switch will spring back to the OFF (center) position.
3.
EMERGENCY STOP - Push Button (Red Mushroom)
This push button is pressed to immediately stop machine cycle and operation in the event of an emergency. When this push button is pressed machine power drops, stopping the feed of all axes and spindle. Control power will remain on and a message is displayed on the control CRT, MACHINE OFF E-STOP. The EMERGENCY STOP must be released before the machine can be restarted. To release the button it must be twisted counter-clockwise. If EMERGENCY STOP is pressed while the axes are not in motion an automatic realignment is possible when the button is released. Wash Gun The Wash Gun (if supplied) is used by the operator to flush swarf into the machine swarf collection tray, or swarf conveyor system (if supplied). The wash gun facility may be used when, - The machine is not in-cycle. - The operator door is open. - The Coolant ON push button is pressed ON. The wash gun is active for a period of 30 seconds after which the Coolant ON push button must be pressed to restore the coolant supply to the wash gun.
Page 3-18
GENERAL CHUCK SAFETY GUIDELINES Observe these guidelines in the daily operation of the turning center. See CAUTION. 1. 2. Always lubricate the chuck according to the instructions given in this manual or the chuck manufacturers instructions. Clamp all work fixtures securely before starting the machine. When using work fixtures mounted in the chuck, use the chuck jaws to center the fixture only. Clamp the fixture to the chuck face using the tapped holes and T-slots in the chuck face once the chuck jaws are secured about the fixture. If appropriate, remove the chuck and mount the fixture directly to the spindle.
CAUTION Always observe the general chuck safety guidelines in the daily operation of the machine. Failure to follow this instruction may result in damage to the machine.
NOTE: Do NOT place a chuck within a chuck already mounted to the spindle. 3. 4. 5. 6. 7. Inspect the top jaws before starting any operation. In the event of a wreck, always replace the top jaw hold down bolts. Always replace the T-nuts, which clamp the top jaws to the master jaws, at the first sign of wear. Never use top jaws with worn or broken jaw serrations. On the first operation, always ensure that the jaw serrations penetrate the part. Load the part in the chuck with one jaw in the 6 oclock position. Never place your hands or any portion of the body, near the chuck when jogging the spindle. See WARNING.
WARNING
Never place your hands or any part of the body near the chuck when jogging the spindle. Failure to follow this instruction may result in serious personal injury.
Page 3-19
WARNING Chuck Operation:

Do not operate the chuck at speeds (rpm) greater than its maximum rated speed or at pressures greater than its maximum rated pressure. Reduce chuck speed (rpm) when using special top jaw tooling. Top jaws must not extend beyond the chuck diameter. Never place your hands or any part of your body near the chuck when jogging the spindle, adjusting thrust or pressure. Lubricate the chuck according to the manufacturers specifications. Failure to follow this instruction may result in serious personal injury.
CHUCKS
Since a variety of chucks may be mounted on the machine, the following information describes the general types of chucking systems that can be applied to the machine, top tooling recommendations, a general discussion of chuck jaw pressure, lubrication of chuck systems and some general chuck safety guidelines.
CHUCKING SYSTEM TYPES These four types of chucks are recommended for use on these machines. Self-centering - simultaneously moves all chuck jaws equally to center the workpiece in the chuck. Self-compensating - used where there is a need to locate the workpiece from center holes, or other locating devices. Combination - combine both self-centering and self-compensating features in one chuck. Collet type - ideal for bar stock, they are compatible with square, hexagonal, and round shapes.
CHUCK
CENTRIFUGAL FORCE AND SPEED LIMITATIONS
CAUTION 1 Do not operate the spindle at speeds greater than the maximum rated speed for the chuck. Failure to follow this instruction may result in damage to the chuck and machine.
Centrifugal force increases as the rpm increases and tends to throw the chuck jaws outward. This decreases the part gripping force. Centrifugal force increases as the jaws are moved farther from the centerline of the chuck, or are made heavier. Exceeding a chucks rated speed results in high internal stresses and loss of clamping force. This can cause jaw and/or chuck component breakage resulting in the release of the jaw and part. See CAUTION 1. Top jaws should never extend beyond the diameter of the chuck.
CAUTION 2 Always reduce spindle speed when using special top jaw tooling. Failure to follow this instruction may result in damage to the machine.
Always reduce the spindle speed when using special top jaw tooling configurations. See CAUTION 2. CHUCK LUBRICATION All chucking systems require some type of lubrication. Chucks may be selflubricating, or require manual lubrication. If manual lubrication is required, follow the instructions in this section for standard chucks installed by the factory. For other chucks, follow the chuck manufacturers specifications for frequency and lubrication type. Inadequate lubrication or use of the wrong type of lubricant will greatly reduce the chuck jaws grip force and allow the workpiece to slip or be thrown from the chuck. If in doubt about the lubrication requirements for the chuck, contact your local Cincinnati Machine Field Service Representative. See CAUTION 3. Factory installed standard chucks that require manual lubrication should be lubricated once during every eight hours of operation.
CAUTION 3 Always lubricate the chuck in accordance with these instructions or follow the chuck manufacturers specifications. Failure to follow this instruction may result in damage to the chuck and machine.
Page 3-20
TOP JAW RECOMMENDATIONS The following illustrations list general guidelines for designing and setting chuck top jaws.
1 1. The length of the top jaws should not exceed the height, and the height of the top jaw should not exceed the length of the master jaw. Do not exceed a 1:1 ratio.
CORRECT
INCORRECT
2. The gripping diameter should be equal to, or greater than, the diameter to be machined. When this is not possible, reduce the feed rate and the depth of cut.
CORRECT
INCORRECT
3. Grip the workpiece as close to the face of the chuck as possible.
CORRECT
INCORRECT
4. Use special jaws with a longer grip on large, long, or heavier workpiece.
5. Jaws should be designed so the diameter fully contracts the workpiece. Standard stepping top jaws seldom achieve this goal. CORRECT INCORRECT INCORRECT
Page 3-21
6.
Use pin type jaws to penetrate forging, casting and irregular surfaces.
3.2 mm (.125) 60_ 7. Use sharp 3.2 mm (.125 inch) pitch 60 degrees serrations on jaws for first operations. 60_
8.
The back of chuck jaws must be ground after hardening.
PIN (IN JAW BOLT HOLE)
9.
Bore soft jaws with a chucking slug or ring under, or in front of, the top jaw. Do not bore with the slug or ring under the master jaws. The slug or ring should be as far as possible from the face of the chuck. SLUG
RING
10. Check the top jaws for bell mouthing. This can cause the workpiece to move slightly under a heavy cut and cause the cutting tool to dig in. This can result in the workpiece being scrapped or the workpiece coming out of the chuck.
76 mm (3.0 )
11. Reduce the chucking pressure approximately 10% for each inch exceeding 76 mm (3 inches) of jaws height to prevent breaking master jaws, levers, or wedges.
76 mm (3.0 )
Page 3-22
12. On second operation jaws, use chrome- moly steel such as 4140 or 4150. To strengthen these jaws and resist chipping, heat treat to 28- 30 Rc. When necessary, they can be true bored.
13. On rough surfaces, use 8615 steel jaws to obtain greater core strength and to resist fracturing under heavy gripping pressure.
CHUCK
14. Use rocking jaws on rough castings or forgings. ROUGH WORKPIECE
WRAP AROUND JAW 15. Use wrap- around jaws on fragile parts to distribute pressure over a larger area and to minimize distortion.
FRAGILE PART
16. On wedge chucks, grip the workpiece 1.6 mm (.06) from the start of jaw travel for best engagement of wedge with the master jaw.
17. On lever chucks, grip the workpiece past the middle of jaw travel for best gripping conditions.
18. Do not grip another chuck in the jaws of the chuck mounted to the spindle.
19. Although fixtures may be gripped in the jaws of chuck for center location, the jaws must be not be the sole mounting means. Bolt the fixture to the chuck.
Page 3-23
Chapter 4 Machine Start Up and Alignment Procedure

Machine Start Up and Alignment Procedure General This section describes the operations required to start the machine and align the control to the machine. Start Up and Shut Down Procedures Start Up 1. 2. 3. 4. Ensure that the machine air supply is turned on and is up to pressure. Ensure sufficient hydraulic oil is in the hydraulic tank. Turn the main disconnect switch to the ON position. Press the MASTER START push button on the MTB operator control panel. This will apply power to the CNC and initiate a power start of the control. After a few seconds, on successful control power up condition, the CRT will flash the EMG condition indicator. 5. Re-press the MASTER START pushbutton. This will initiate a power-up sequence of the axes and spindle drives and apply power to the hydraulic unit. The EMG condition indicator is removed from the display. Care must be taken at this time, if the axes are moved under power feed control, as there is no software range checking until the machine has been aligned. See CAUTION.
CAUTION Until the machine has been aligned it is possible to feed the axes beyond the authorized software feed limits. This may result in the removal of power to the axis drives.
If the EMERGENCY STOP push button is latched down when the MASTER START push button is pressed in step 3 the CRT will display EMG ALM 1002 EMERGENCY STOP alarm. Release the EMERGENCY STOP push button to clear the alarm. If an AXIS OVERTRAVEL condition exists at the time of power-up use the axis power feed controls whilst holding the MASTER START push button depressed, the move all axes within their normal operaating range - see Chapter 5. Shut Down The normal safe shut down sequence is as follows: 1. 2. Depress EMERGENCY STOP to ensure a controlled stop sequence of the axis drives and to turn off the hydraulic motor. Set the main machine power disconnect switch to the OFF position.
Page 4-1
Machine/Control Alignment Procedure The operator must perform a machine/control alignment, each time the control is turned on. The slides and turret are aligned by using the ALIGN push button (A4) on the operators panel. The automatic alignment procedure first moves each axis to its reference position, after which the linear axes are aligned to the control system by moving each axis a small distance to search for the axis motor encoder reference marker. The axes are automatically moved to their reference position in a Z,X sequence. As each axis is aligned to the control system the corresponding axis powerfeed push button is illuminated. Once all active axes are aligned, the ALIGN push button can be released.
AXIS ALIGNMENT SEQUENCE Z X AXES ALIGNMENT COMPLETE INDICATION Z+ PUSHBUTTON ILLUMINATES X+ PUSHBUTTON ILLUMINATES
Turret Alignment On completion of the machine axes alignment, the turret has to be aligned. This is achieved by repressing the ALIGN push button in response to the operator message: PRESS ALIGN P.B. TO REF TURRET. This will cause the turret to rotate to position 1. Drive Tool Machines only The operator message: DRIVEN TOOL SPINDLE NOT ORIENTATED PRESS HOME PB TO ORIENTATE SPINDLE REFERENCE TURRET. Pressing the home push button will cause the driven tool spindle to orientate and the turret will then rotate to position 1. Turret alignment must be completed with the X and Z axes at their extreme positive axis positions. See WARNING.
WARNING
Turret alignment can only take place with X and Z axes at their positive limits. The operator must ensure that, at this position, turret rotation will not cause a collision with tooling or workpiece.
On successful completion of axes and turret alignment, the ALIGN push button will illuminate and remain illuminated until the machine is switched off or an alert is posted which could result in the loss of alignment.
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Chapter 5 Software and Hardware Axis Overtravel

Software Axis Overtravel A software axis overtravel conditon occurs if an axis is commanded to go beyond its normal operating range, indicated by the following alarms: 500 501 500 501 OVER TRAVEL: +X OVER TRAVEL: -X OVER TRAVEL: +Z OVER TRAVEL: -Z
During a software overtravel conditon, the control only permits the axis to move back from the software overtravel condition. CANCELLING SOFTWARE RANGE CHECKING It may sometimes be necessary to temporarily cancel the software range checking feature, to enable the axes to be powerfed back to within their normal operating ranges. To cancel software range checking: 1. 2. 3. 4. 5. 6. Turn the main power disconnect switch to the OFF position. After a few seconds set the main power disconnect switch to the on position. Depress and hold down both P and CAN keys on the MDI keypad. Depress MASTER START to initiate a control power start. Once control is powered up release P and CAN keys on the MDI keypad. The software range checking is now ineffective and therefore it is possible to drive an axis beyond its software range limits.
Hardware Axis Overtravel Prior to completion of machine alignment, it is possible to feed the axes beyond the authorised software limits. This action may result in a servo fail alarm. It will be necessary to use the following procedure to move the overtravelled axis back to within its normal operating range. 1. Try to establish the reason why the overtravel condition occurred. If the overtravel occurred for no apparent reason check the general condition of the axis motor electrical connectors and cables. If the condion of these is good proceed with caution. Power down control, isolator off. Power back up control.
2. 3.
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4. 5.
Select MPG mode. Using the MPG (handwheel) move the axes back within their normal operating range. The axis jog mode is disabled when the axes are not aligned. It may be necessary to supress the axis softwarelimits in order to move the axes back into their normal operating range.
Note:
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Chapter 6 G codes
G codes The following G codes are supported on the Cincinnati Machine range of lathes. G-code of group 00 except G10 and G11 are single-shot G-codes. P/S alarm (no. 010) is displayed when a G-code not listed in the G-Code list is specified or a G-code without a corresponding option is specified.
G code System A is set as standard.

G-code systems B and C are purchased options - contact Cincinnati Machine if option is required. Refer to FANUC Manual B-63084 EN/01 for a complete description of the G Codes. G CODE A G00 G01 G02 G03 G04 G05 G07 G07.1 (G107) G10 G11 G12.1 (G112) G13.1 (G113) G17 G18 G19 G20 G21 G22 G23 B G00 G01 G02 G03 G04 G05 G07 G07.1 (G107) G10 G11 G12.1 (G112) G13.1 (G113) G17 G18 G19 G20 G21 G22 G23 C G00 G01 G02 G03 G04 G05 G07 G07.1 (G107) G10 G11 G12.1 (G112) G13.1 (G113) G17 G18 G19 G70 G71 G22 G23 09 06 16 00 00 01 GROUP FUNCTION Positioning (Rapid Traverse) Linear Interpolation (cutting feed) Circular Interpolation CW or Helical interpolation CW Circular Interpolation CCW or Helical interpolation CCW Dwell High speed cycle cutting Hypothetical axis interpolation Cylindrical interpolation 00 Programmable data input Programmable data input cancel Polar coordinate interpolation mode 21 Polar coordinate interpolation cancel mode XpYp plane selection ZpXp plane selection YpZp plane selection Input in inch Input in mm Stored stroke check function on Stored stroke check function off
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G CODE A G25 G26 G27 G28 G30 G31 G32 G34 G36 G37 G40 G41 G42 G50 G50.3 G50.2 (G250) G51.2 (G251) G52 G53 G54 G55 G56 G57 G58 G59 G65 G66 G67 G68 G69 G70 G71 G72 G73 G74 G75 G76 B G25 G26 G27 G28 G30 G31 G33 G34 G36 G37 G40 G41 G42 G92 G92.1 G50.2 (G250) G51.2 (G251) G52 G53 G54 G55 G56 G57 G58 G59 G65 G66 G67 G68 G69 G70 G71 G72 G73 G74 G75 G76 C G25 G26 G27 G28 G30 G31 G33 G34 G36 G37 G40 G41 G42 G92 G92.1 G50.2 (G250) G51.2 (G251) G52 G53 G54 G55 G56 G57 G58 G59 G65 G66 G67 G68 G69 G72 G73 G74 G75 G76 G77 G78
GROUP 08
FUNCTION Spindle speed fluctuation detection off Spindle speed fluctuation detection on Reference position return check Return to reference position 2nd, 3rd and 4th reference position return Skip function Thread cutting Variable--lead thread cutting Automatic tool compensation X Automatic tool compensation Z Tool nose radius compensation cancel Tool nose radius compensation left Tool nose radius compensation right Coordinate system setting or max. spindle speed setting Workpiece coordinate system preset Polygonal turning cancel
00
01 00
07
00
20 Polygonal turning 00 Local coordinate system setting Machine coordinate system setting Workpiece coordinate system 1 selection Workpiece coordinate system 2 selection 14 Workpiece coordinate system 3 selection Workpiece coordinate system 4 selection Workpiece coordinate system 5 selection Workpiece coordinate system 6 selection 00 12 04 Macro calling Macro modal call Macro modal call cancel Mirror image for double turrets ON or balance cut mode
Mirror image for double turrets OFF or balance cut mode cancel
Finishing cycle Stock removal in turning Stock removal in facing 00 Pattern repeating End face peck drilling Outer diameter/internal diameter drilling Multiple threading cycle
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G CODE A G80 G83 G84 G86 G87 G88 G89 G90 G92 G94 G96 G97 G98 G99 ----B G80 G83 G84 G86 G87 G88 G89 G77 G78 G79 G96 G97 G94 G95 G90 G91 G98 G99 C G80 G83 G84 G86 G87 G88 G89 G20 G21 G24 G96 G97 G94 G95 G90 G91 G98 G99
GROUP
FUNCTION Canned cycle for drilling cancel Cycle for face drilling Cycle for face tapping
10
Cycle for face boring Cycle for side drilling Cycle for side tapping Cycle for side boring Outer diameter/internal diameter cutting cycle
01
Thread cutting cycle Endface turning cycle Constant surface speed control Constant surface speed control cancel Per minute feed Per revolution feed Absolute programming Incremental programming Return to initial level (See Explanations 6) Return to R point level (See Explanations 6)
02 05 03 11
Assumed at Control Power ON.
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Chapter 7 M codes
M codes Miscellaneous codes are programmed using a maximum of one M code per block with a value range of 0 to 99. These codes are used to control a variety of machine related functions, including spindle, coolant and tool change. M codes supported on Cincinnati Turning Centres M codes marked thus * are available as options or are necessary to support optional machine configurations, eg: Parts Catcher, Barfeed, etc. M codes marked thus * support the Driven Tool option, if fitted.
EFFECTIVE AT END OF SPAN ASSUMED AT CONTROL POWER ON EFFECT1VE START OF SPAN M CODE
FUNCTION
00 01 02 03 04 05 08 09 13 14 19 30 34 * 35 * 44 * 45 * 46 47 48 49 50 ** 51 ** 52 ** 53 ** 54 **
PROGRAM STOP OPTIONAL PROGRAM STOP END OF PROGRAM START SPINDLE CCW START SPINDLE CW SPINDLE STOP COOLANT START COOLANT STOP SPINDLE START CCW WITH COOLANT SPINDLE START CW WITH COOLANT ORIENTED SPINDLE STOP END PROGRAMME & RETURN TO START PARTS CATCHER ADVANCE PARTS CATCHER RETRACT RENISHAW TOOL SETTING ARM (TSA) UP RENISHAW TOOL SETTING ARM (TSA) DOWN FEEDRATE OVERRIDE DISABLE (100%) FEEDRATE OVERRIDE ENABLE SPINDLE OVERRIDE DISABLE (100%) SPINDLE OVERRIDE ENABLE C--AXIS MODE OFF C--AXIS MODE ON C--AXIS BRAKE ON (IN--POSITION MODE) C--AXIS BRAKE ON (INTERPOLATION MODE) C--AXIS BRAKE OFF
n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n
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EFFECTIVE AT END OF SPAN
61 * 68 * 69 * 70 * 71 * 72 * 73 * 74 75 76 77 78 79 80 * 86 * 87 * 90 * 91 * 92 * 93 * 94 * 98 99
BARFEED MACRO CALL ADVANCE TAILSTOCK QUILL RETRACT TAILSTOCK QUILL M70 CUSTOMER OUTPUT M71 CUSTOMER OUTPUT M72 CUSTOMER OUTPUT M73 CUSTOMER OUTPUT COLLET CHUCK MODE DISABLE COLLET CHUCK MODE ENABLE FORCE TURRET ROTATION CW FORCE TURRET ROTATION CCW RELEASE CHUCK JAWS GRIP CHUCK JAWS BARFEED EJECT/RELOAD NEW BAR BARFEED PRESSURE ON (HYDRAFEED AND FEEDMASTER ONLY) BARFEED PRESSURE OFF (HYDRAFEED AND FEEDMASTER ONLY) BARFEED MODE ON BARFEED MODE OFF BARFEED ROTATION ON BARFEED ROTATION OFF INCREMENT PARTS COUNTER (Parameter 6710 = 94) SUBROUTINE CALL END SUBROUTINE
n n n n n n n n n n n n n n n n n n n n n n n n n n
Function Description of M Codes

M00 PROGRAMME STOP (STOPS SPINDLE) M00 stops the machine cycle at the END of the block in which it is programmed. The spindle and coolant are stopped and the machine put out of cycle. Pressing CYCLE START will cause the NC cycle to continue from the next block, restarting the spindle and coolant if previously actioned. M01 OPTIONAL PROGRAMME STOP (STOPS SPINDLE) M01 has the same function as M00 except it is only actioned if the operator has selected the OPTIONAL STOP feature to be active. If the feature is not active the programme continues without actioning the M01. M02 END OF PROGRAMME M02 causes the active programme to terminate and the spindle and coolant to stop.
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ASSUMED AT CONTROL POWER ON
EFFECT1VE START OF SPAN
M CODE
FUNCTION
M03 START SPINDLE CCW Note: CCW as viewed from Tailstock to Headstock M03 is used to start the spindle rotation in a counter clockwise direction. The spindle will rotate at the last programmed S word value. If the code is programmed in a block containing a none rapid traverse axis motion, then motion is inhibited until the spindle is up to speed. If the current block is a rapid traverse block the motion will continue until a none rapid block is read with the spindle not yet at the programmed speed. M04 START SPINDLE CW Note: CW as viewed from Tailstock to Headstock M04 is used to start the spindle rotation in a clockwise direction. The spindle will rotate at the last programmed S word value. If the code is programmed in a block containing a none rapid traverse axis motion, then motion is inhibited until the spindle is up to speed. If the current block is a rapid traverse block the motion will continue until a none rapid block is read with the spindle not yet at the programmed speed. M05 SPINDLE STOP M05 is used to stop the spindle. It causes further processing of axis moves or other blocks to be inhibited, until the spindle is stopped. M08 FLOOD COOLANT START M08 is used to tun on the flood coolant flow. There is no interlocking between the code and block processing, the programmer must allow sufficient feed stoke to assure adequate coolant flow before cutting starts. If dry run is active then this code is inhibited. M09 COOLANT OFF M09 is used to turn the coolant off. M13 START SPINDLE COUNTER CLOCKWISE WITH COOLANT M13 is used turn on the flood coolant flow and start the spindle in the CCW direction simultaneously. M14 START SPINDLE CLOCKWISE WITH COOLANT M14 is used turn on the flood coolant flow and start the spindle in the CW direction simultaneously. M19 ORIENTED SPINDLE STOP This code stops the spindle/chuck and turns off the coolant. The code forces the spindle to stop at a preset orient position and inhibits further block processing until orientation is complete. M19 is operable when C-Axis Mode OFF (M50) is active. In certain instances, the oriented spindle stop may facilitate the loading and unloading of workpieces. M30 END OF PROGRAM AND REWIND M30 terminates the active programme, stops the spindle and coolant flow, and returns the cursor back to the start of the programme.
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M34 PARTS CATCHER ADVANCE M34 moves the parts catcher forward to the collect position. Operator door must be closed and tool setting arm, if fitted, must be parked. M35 PARTS CATCHER RETRACT M35 retracts the parts catcher. Operator door must be closed and tool setting arm, if fitted, must be parked. M44 RENISHAW TOOL SETTING ARM (TSA) UP M44 retracts the Renishaw Tool setting arm (TSA) to its parked (stowed) position. Operator door must be closed and parts catcher, if fitted, must be retracted. M45 RENISHAW TOOL SETTING ARM (TSA) DOWN M44 retracts the Renishaw Tool setting arm (TSA) to its down (active) position. Operator door must be closed and parts catcher, if fitted, must be retracted. M46 FEEDRATE OVERRIDE DISABLE (100%) M46 once programmed inhibits the use of the feedrate override selector switch and clamps the programmed feedrate to 100%. It is cancelled on receipt of any one of the following:M47 M02 M30 RESET EMERGENCY STOP OPERATING MODE CHANGE i.e. AUTO TO EDIT M47 FEEDRATE OVERRIDE ENABLE M47 is used to cancel M46 and allows the feedrate override selector to be used to modify any programmed feedrate with the exception of the cutting motion of a G74 or G84 tapping cycle. Feedrate override enable is assumed at control power on. M48 SPINDLE SPEED OVERRIDE DISABLE (100%) M48 once programmed inhibits the use of the Spindle Speed override keys and clamps the spindle speed to 100% of the programmed speed. It is cancelled on receipt of any one of the following:M49 M02 M30 RESET EMERGENCY STOP MODE CHANGE i.e. AUTO TO EDIT M49 SPINDLE SPEED OVERRIDE ENABLE M49 is used to cancel M48 and allows the spindle override keys to be used to modify the programmed spindle speed.
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Spindle speed override enable is assumed at control power on. M50 C-AXIS MODE OFF (Driven Tool Machines only) M50 cancels C-Axis mode and returns the main spindle/chuck to normal G96/G97 speed control. An S-word associated with a spindle start M-Code will command the spindle/chuck to rotate at the programmed speed. Processing the M50 code automatically releases the C-Axis brake mechanism. M50 may be programmed when the following functions are active:M51 takes the machine out of C axis mode. Any S word for speed programmed are output to Main Spindle Chuck - see Chapter 10 Driven Tools. G13.1 Polar Co-ordinate Interpolation OFF G40 Tool Nose Radius Compensation OFF M05 Spindle Stop
Also see Chapter 10, Driven Tools. M51 C-AXIS MODE ON (Driven Tool Machines only) M51 places the machine in C-Axis mode. The main spindle/chuck rotation is programmed via a C-word and any S-word associated with a spindle start M-Code is output to the active Driven Tool Spindle on the turret. M50 may be programmed when the following functions are active:M51 places the machine in C axis mode, i.e. the main spindle (chuck) is now programmed with a C word and any S words for speed are output to driven tool spindle on the turret - see Chapter 10 Driven Tools. G13.1 Polar Co-ordinate Interpolation OFF G40 Tool Nose Radius Compensation OFF M05 Spindle Stop The operator access door is held latched whilst M51 is active, even when the machine is not in-cycle. If a cycle is interupted when C-Axis mode is active the M50 code (C-Axis mode Off) must be processed to release the door latch.
Note;
Also see Chapter 10, Driven Tools. M52 C-AXIS BRAKE ON (In-Position Mode, Driven Tool FeatureDriven tool machines only) M52 applies a mechanical brake ON to the stationary spindle/chuck. The brake provides the necessary workpiece rigidity for certain machining operations using Driven Tools mounted in the turret. The M52 code is functional when C-Axis mode is set ON, i.e: M51 active. The M52 function remains ON until cancelled by:M50 - C-Axis Mode OFF M53 - C-Axis Brake ON (Interpolation Mode) M54 - C-Axis Brake OFF M52 is programmed in a block prior to a C-Axis rapid motion command. Also see Chapter 10, Driven Tools. M53 C-AXIS BRAKE ON- (Interpolation Mode, Driven Tool Feature)Half pressure - contouring (Driven tool machines only)
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M53 applies a mechanical brake partially ON to the spindle/chuck. The brake provides a degree of dampening and stability to the spindle/chuck during profile milling operations, using Driven Tools mounted in the turret. Brake pressure control and adjustment is given in Chapter 3 of this manual. The M53 code is functional when C-Axis mode is set ON, i.e: M51 active. The M53 function remains ON until cancelled by:M50 - C-Axis Mode OFF M52 - C-Axis Brake ON (In-Position Mode) M54 - C-Axis Brake OFF M53 is programmed in or before the first C-Axis feed motion block. Also see Chapter 10, Driven Tools. M54 C-AXIS BRAKE OFF (Driven Tool Machines only) M54 releases the brake from the spindle/chuck. The brake must be released using the M54 code prior to subsequent rotation of the spindle/chuck under C-Axis positioning control. The M54 code is functional when C-Axis mode is set ON, i.e: M51 active. The M54 function remains ON until cancelled by:M52 - C-Axis Brake ON (In-Position Mode) M53 - C-Axis Brake ON (Interpolation Mode) C-Axis Brake OFF command is also included in the functionality of the C-Axis Mode OFF (M50) code. M54 is programmed in a block following a C-Axis motion command. Also see Chapter 10, Driven Tools. M61 BARFEED MACRO CALL M61 is used to call the Barfeed macro to eject the billet and reload a new bar. Refer to chapter 13 for a description of the barfeed macro. M68 ADVANCE TAILSTOCK QUILL M68 advances the tailstock quill. M69 RETRACT TAILSTOCK QUILL M69 retracts the tailstock quill. M70 TO M73 CUSTOMER OUTPUTS (OPTIONAL) These codes can be used by a customer to switch on any ancillary equipment that he chooses to operate via the part programme. If the M70 - M73 option is provided, the machine will be equipped with four 110V AC triac modules and four 24V DC feedback terminals, for wiring details refer to the machines Electrical Schematic diagram. M70 - M73 can be configured to operate in 1 of 2 different modes:1) M70 - M73 outputs turn on and remain on until a different M70 - M73 code is programmed
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2)
M70 - M73 outputs turn on and remain on until the corresponding feedback input is obtained.
M74 COLLET CHUCK MODE DISABLE M74 places the control/machine back into normal chucking mode. Programmed in MDI mode only. M75 COLLET CHUCK MODE ENABLE M75 places the control/machine in collet chuck mode. Programmed in MDI mode only. M76 FORCE TURRET ROTATION CW M76 forces turret rotation to be in the clockwise direction. (Normal turret rotational is by shortest path). Refer to chapter 9 for a description of the use of M76. M77 FORCE TURRET ROTATION CCW M77 forces turret rotation to be in the clockwise direction. (Normal turret rotational is by shortest path). Refer to chapter 9 for a description of the use of M77. M78 CHUCK OPEN M78 opens the chuck jaws, whether a conventional chuck or a collet chuck is used. Used for Barfeed and Bar-puller applications. M79 CHUCK CLOSE M79 closes the chuck jaws, whether a conventional chuck or a collet chuck is used. Used for Barfeed and Bar-puller applications. M80 BARFEED EJECT/RELOAD NEW BAR M80 is used only in macro O9020 - Barfeed macro. Refer to chapter 13 for a description of the barfeed macro. M86 BARFEED PRESSURE ON (HYDRAFEED AND FEEDMASTER ONLY) M86 switches on Barfeed pressure to push the bar out of the Barfeeder. Refer to chapter 13 for a description of the barfeed unit. M87 BARFEED PRESSURE OFF (HYDRAFEED AND FEEDMASTER ONLY) M86 switches off Barfeed pressure. Refer to chapter 13 for a description of the barfeed unit. M90 BARFEED MODE ON M90 places the control in Barfeed mode. Programmed in MDI mode only. Refer to chapter 13 for a description of the barfeed unit. M91 BARFEED MODE OFF M91 takes the control out of Barfeed mode. Programmed in MDI mode only. Refer to chapter 13 for a description of the barfeed unit.
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M92 BARFEED ROTATION ON M92 rotates the spindle/chuck at a preset slow speed to assist barfeed advance. See Chapter 13, Barfeeder.M92 reduces chuck rotation to a jog value set by Keep Relays. Spindle rotation will be clockwise (CW as viewed from Tailstock to Headstock) - see chapter 13 Barfeeder. M93 BARFEED ROTATION OFF M93 stops spindle/chuck rotation. See Chapter 13, Barfeeder.M93 stops chuck rotation - see chapter 13 Barfeeder M94 INCREMENT PARTS COUNTER M94 increments the parts counter (when parameter 6710 is set to 94).M94 will increment the parts counter when parameter 6710 is set to 94. M98 SUBROUTINE CALL Refer to GE Fanuc operators manual. M99 END OF SUBROUTINE Refer to GE Fanuc operators manual.
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Chapter 8 Spindle Functions

Spindle Functions
The machine is fitted with a Headstock driven by an infinitely variable AC motor. Spindle speeds are specified in direct rpm (in 1rpm increments) by an S word. For spindle speed range, refer to Machine Specification, chapter 2, in this manual. The maximum programmable spindle speed may be set to a value below maximum RPM of the machine using the G92 Sxxxx command, see GE Fanuc Operators Manual II Programming, Chapter 9. The spindle rotation is started by programming an M03, M04, M13 or M14 code. The spindle may also be restarted by pressing the SPINDLE CW or SPINDLE CCW pushbuttons. M03 causes the spindle to rotate in a counter clockwise direction and M04 causes clockwise rotation. CW and CCW are viewed from Tailstock to Headstock. If the spindle is attempted to be restarted after an auto cycle interrupt, and the spindle CW or CCW pushbutton used does not match the last programmed spindle direction then the spindle restart is rejected and the operator prompted accordingly. Rapid axis moves are permitted to continue while the spindle is accelerating or decelerating. Programmed feed moves are not actioned until the spindle reaches its commanded speed. The following functions cause the spindle to stop:1. 2. 3. 4. 5. 6. 7. M00 Programme stop M01 Optional stop (when selected) M02 End of programme M05 Spindle stop M30 End of tape Spindle stop pushbutton Alerts generating spindle stop
Driven Tool Machines

When the machine is in C-Axis mode - M51 programmed - the main spindle (chuck) is programmed with a C word along with an appropriate feedrate. All S words for speed are output to driven tool spindle on the turret, as with normal rotation it must be started by programming an M03, M04, M13 or M14. The above seven functions which stop the main spindle (chuck) also apply to the driven tool spindle. The below spindle jog does not apply to the Driven tool spindle, only the main chuck spindle.
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Spindle Jog
This feature allows the spindle to be jogged at approximately 8 RPM whilst depressing either the SPINDLE CW or SPINDLE CCW pushbutton providing the machine is not in cycle or a cycle interrupted condition, and the operator door is closed. Spindle jogging is provided to allow hands off spindle workpiece inspection.
Page 8-2
Chapter 9 Tooling Functions

Tool Turret The turret disc is directly mounted onto a servo driven turret indexing head. Both 8 and 12 position Turrets are available in the Hawk range of turning centres.
Fig. 50 12 Position Turret - showing Rotation Directions
Turret Indexes The turret can be indexed at any point within the programmable range of the machine.
WARNING
When indexing the turret make sure that the indexing radius of the longest tool will clear the workpiece/ chuck and axis way guarding, so that a collision does not occur. Failure to follow this warning may result in personal injury and/or machine damage.
Normal turret indexes are bi-directional and shortest path. Forcing turret direction can be used - see below. To keep cycle time to a minimum, it is often desireable to keep the retract for a turret index to a minimum. It is therefore up to the operator/programmer to ensure that a turret index does not cause a collision. See WARNING.
Driven Tool Machines

On Driven Tool machines, turret indexes may require an orientation of the driven tool before a turret index can take place. This is to correctly position the drive mechanism inside the turret before indexing.
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T Word A 4-digit T code is programmed to select a turret position. The first 2 digits represent the turret position, the second 2 digits represent the offset number.
T xx xx Tool offset number Turret position

Programming example: N130 G00 X200 Z300 - Move to a safe turret index position N140 T0505 - Index to turret position 5 and use Offset value No. 5. N150 X150 Z237 - Next machining block Force Turret CW and CCW As mentioned previously normal turret indexes are bi-directional and shortest path. The following two M-codes are used to force the turret rotation in a particular direction:M76 - Force turret rotation clockwise (CW) M77 - Force turret rotation counter clockwise (CCW) These two M-codes are non-modal being active only on the block in which they are programmed. Both M-codes must be programmed on the same block as a T-code. e.g. N130 T0707 M76 - Index turret CW to position 7. Tool Life Management Refer to GE FANUC operators manual (B-63084EN/01) for a full description of this feature.
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Chapter 10 Driven Tools

Introduction The Driven Tools feature enables cutting tools mounted in the turret stations to be rotating tools. Drills, taps, boring tools, milling cutters, etc., may be mounted in the turret to perform specific rotating tool machining tasks in association with the spindle/chuck operating in C-Axis positioning/interpolating mode (M51) active. In C-Axis mode (M51), the spindle/chuck may be positioned in rapid or feedrate mode. Feedrate mode is adopted for profile milling applications under Cylindrical Interpolation (G07.1) mode, or Polar Co-ordinate Interpolation (G12.1) control. When interpolation modes G07.1 and G12.1 are turned off, the C-Axis is best utilised in a positioning role for hole making operations, for which the spindle/chuck moves to position at rapid rate. C-Axis Mode Enable/Disable The C-Axis mode of operation may be enabled/disabled when the following group of Gxx and Mxx codes are active: - G40 Tool Nose Radius Compensation OFF - M05 Spindle Stop - G13.1 Polar Co-ordinate Interpolation OFF - G07.1 C0 Cylindrical Interpolation OFF - Mxx where: Mxx = M51 C-Axis Mode Enable (Spindle/Chuck in C-Axis mode ON) or M52 C-Axis Mode Disable (Spindle/Chuck in C-Axis mode OFF) The codes should be processed in the order shown. C-Axis Initialisation Once in C-Axis mode, it is necessary to rotate the spindle/chuck to the C-Axis origin position prior to processing any specific C-Axis positioning command. The recommended block sequence for C-Axis initialisation is given below: G40 M05 G13.1 M51 G0 G28 C0 Rotate spindle/chuck to C-Axis zero position. C-Axis Positioning Mode Once the C-Axis is initialised, it may operate in positioning mode using the basic contouring mode G-codes G00 and G01. The Tool Nose Radius Compensation feature (G40 - G42) does not perform correctly in this mode
Page 10-1
and should be utilised in the interpolation mode of C-Axis application. C-Axis positioning mode is best utilised for hole making operations incorporating standard canned cycles to perform drill, tap and bore cycles. Programming Considerations 1. Positioning Mode Operation
Driven tools operating parallel to the Z-Axis perform Front machining cycles. Driven tools mounted in a right angle head on the turret (operating parallel to the X-Axis) perform Side machining cycles. See Fig. 51.
Fig. 51 Driven Tool Setup - Positioning Mode
2.
C-Axis Position Command
The C-Axis command defines the angular position in degrees around the workpiece.
Fig. 52 C- Axis Positioning
The figure above shows the spindle/chuck at the C 0.000 degree position. A positive C-Axis command (eg: C 0.000 to C+90) is seen as a CW rotation
Page 10-2
of the spindle/chuck to the +90 degree position. A negative C-Axis command (eg: C 0,000 to C-90) is seen as a CCW rotation of the spindle/chuck to the -90 degree position. The C-Axis should be treated as a linear axis in which there is only one zero degree point. A command from the zero point to C-1440 results in the spindle/chuck rotating four revolutions in the CCW direction to the minus 1440 degree position. 3. Canned Cycle Operation
Specific rules for establishing R and Z/X positions are as follows: a) b) The R-plane level measured from the Initial Position is a radial distance and is normally negative. The canned cycle hole depth is expressed as a Z-word in Front Machining mode and as an X-word in Side Machining mode. Hole Depth is measured as the distance from the hole bottom to the position of the axis program zero. Specifically in Side Machining mode, the hole depth X-value is expressed as a diameter distance from X0, the workpiece centre of rotation. Hole Depth Z or X commands are normally negative.
For further detailed information concerning Canned Cycle operation, refer to GE FANUC Operators Manual, publication B-63084EN/01, II-Programming, Chapter 13.3. Example 1: Canned Cycle - Front Machining
Fig. 53 Canned Cycle - Front Machining
N65 G0 G98 G40 N70 M5 N75 M50 N80 G13.1 N85 G07.1 C0 N90 G28 U0 W0 N95 T0404 N100 M51 N105 M54 N110 G0 G28 C0
Tool Radius Offset Cancel Spindle Stop C-Axis Mode Off Polar Co-ordinate Interpolation Off Cylindrical Interpolation Off XZ Retraction to Align Reference Point Tool Selection C-Axis Mode On C-Axis Brake Off Initialise C-Axis at zero degree position
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N115 M8 N120 F100 S760 M3 N125 X150 Z20 C90 N130 M52 N135 G83 R-18 Z-30 N140 M54 N145 G0 C180 N150 M52 N155 G83 R-18 Z-30 N160 M54 N165 G0 C270 N170 M52 N175 G83 R-18 Z-30 N180 G80 M9 N185 M5 N190 M50
Coolant On Feed/Speed (CW) for Driven Tool Rapid XC to Hole Position/Z at Clearance C-Axis Brake On Drill 30mm Deep/Retract to Initial Position C-Axis Brake Off Rotate C-Axis to 180 degree position C-Axis Brake On Drill 30mm Deep/Retract to Initial Position C-Axis Brake Off Rotate C-Axis to 270 degree position C-Axis Brake On Drill Hole 30mm Deep Cancel G83 Canned Cycle/Coolant Off Spindle Stop C-Axis Mode Off/C-Axis Brake Off
Example 2: Canned Cycle - Side Machining
Fig. 54 Canned Cycle - Side Machining
N265 G0 G99 G40 N270 M5 N275 M50 N280 G13.1 N285 G07.1 N290 G28 U0 W0 N295 T0505 N300 M51 N305 M54 N310 G0 G28 C0 N315 M8 N320 F100 S760 M3 N325 X150 N330 Z-15 C90 N335 M52 N340 G87 X10 R-23 Q15000 N345 M54 N350 G0 C-90
Tool Radius Offset Cancel Spindle Stop C-Axis Mode Off Polar Co-ordinate Interpolation Off Cylindrical Interpolation Off XZ Retraction to Align Reference Point Tool Selection C-Axis Mode On C-Axis Brake Off Initialise C-Axis at zero degree position Coolant On Feed/Speed (CW) for Driven Tool Rapid X-Axis to Clearance Rapid ZC Axes to +90 degree position C-Axis Brake On Peck Drill Through/Retract to R-position C-Axis Brake Off Rapid C-Axis to -90 degree position
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N355 M52 N360 G87 X10 R-23 Q15000 N365 G80 M9 N370 M5 N375 M50
C-Axis Brake On Peck Drill Through/Retract to R-position Cancel G87 Canned Cycle/Coolant Off Spindle Stop C-Axis Mode Off/C-Axis Brake Off
C-Axis Interpolation Mode Selection of Interpolation mode allows the machine to perform a variety of milling operations to the workpiece billet, from simple flat surface generation to complex profile machining. There are two interpolation functions which may be selected when the C-Axis is active and initialised; these are: Polar Co-ordinate Interpolation (G12.1). Cylindrical Interpolation (G07.1).
Programming Considerations 1. Interpolation Mode Operation
Profile milling of the end face of a billet is controlled via Polar Co-ordinate Interpolation with the driven tool mounted directly in the turret station. See Fig. 55. Milling operations peformed along the length of a billet is controlled via Cylindrical Interpolation with the driven tool mounted in a right angle head from the turret station. See Fig. 55.
Fig. 55 Driven Tool Setup - Interpolation Mode
2.
C-Axis Position Command
In Polar Co-ordinate Interpolation (G12.1) mode, the C-Axis is considered as a linear axis with metric (or imperial) measuring units. The X-C plance (see Fig. 56), programmed in Cartesian co-ordinates defines the end face machining of a workpiece billet.
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Fig. 56 C- Axis Position Command
In Cylindrical Interpolation (G07.1) mode, the C-Axis units remain in degrees measured around the billet periphery. The development of the cylinder into a Z-C plance (see Fig. 56) and programmed in Cartesian co-ordinates, defines the area around and along the length of the workpiece billet. 3. Programming Rules The chosen interpolation mode may be turned on once the C-Axis is active and initialised. When the interpolation mode is active: G00 rapid positioning mode is not allowed. Tool Nose Radius Compensation (G41/G42) may be applied, but must be cancelled (G40) prior to terminating the interpolation mode. M53 C-Axis brake (for profile milling) may be applied to offer stability to the metal cutting action. See Chapter 3 of this manual for Brake Pressure Control and Adjustment details. G12.1 Polar Co-ordinate Interpolation mode - ON G13.1 Polar Co-ordinate Interpolation mode - OFF G107.1 Hxxx.xxx Cylindrical Interpolation - ON where Hxxx.xxx is the radius of the cylinder G107 C0 Cylindrical Interpolation OFF
For Polar Co-ordinate Interpolation: X co-ordinate is a diameter value. C co-ordinate is a radius value. I co-ordinate is the incremental distance to the X-Axis centre point position for circular interpolation. J co-ordinate is the incremental distance to the C-Axis centre point position for circular interpolation.
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For Cylindrical Interpolation: Z co-ordinate is the actual position value along the billet. C co-ordinate is the actual angular position around the billet. R co-ordinate is the radius value for circular interpolation. Centre point co-ordinates are not allowed. The G18 interpolation plane must be established prior to invoking Cylindrical Interpolation mode. i.e: G18 W0 H0 where, W is the incremental mode address for the Z-Axis. and H is the incremental mode address for the C-Axis. The radius of cylinder (H-word) is specified in the G07.1 block when turning on Cylindrical Interpolation mode. It is not possible to change the cylinder radius until Cylindrical Interpolation is first turned off and then turned on again with the desired cylinder radius.
Example 1: Polar Co-ordinate Interpolation The example below is to be read in conjunction with the Polar Co-ordinate Interpolation feature description given in the GE FANUC Operators Manual, publication B-63084EN/01, II Programming, Chapter 4.4.
Fig. 57 Polar Co- ordinate Interpolation
N0186 G0 G18 G40 G97 G99 N0187 M5 N0188 M50 N0189 G13.1 N0190 G07.1 C0 N0191 G28 U0 W0 N0192 T0404 N0193 M51 N 0194 M54 N0195 G0 G28 C0 N0196 M8
TNRC Off. Speed in RPM. Feed/Rev. Spindle Stop C-Axis Mode Off Polar Co-ordinate Interpolation Off Cylindrical Interpolation Off XZ Retraction to Align Reference Point Tool Selection C-Axis Mode On C-Axis Brake Off Initialise C-Axis at zero degree position Coolant On
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N0197 S1000 M3 N0198 X120 Z20 C0 N0199 M53 N0200 G12.1 N0201 G42 G1 X40 F0.15 N0202 C10 N0203 G03 X20 C20 R10 N0204 G01 X-40 N0205 C-10 N0206 G03 X-20 C-20 I10 J0 N0207 G01 X40 N0208 C0 N0209 G40 X120 F5 M09 N0210 G13.1 N0211 M5 N0212 M50
Spindle Start (CW) for Driven Tool Advance to clearance position C-Axis Brake partially On Polar Co-ordinate Interpolation On TNRC On/Feed to profile ) ) Geometry Program ) (program based on Cartesian ) Co-ordinates on X-C plane) ) Feed to Profile Corner Feed to start point on profile Fast Feed to clearance/Coolant Off Polar Co-ordinate Interpolation Off Spindle Stop C-Axis Mode Off
Example 2: Cylindrical Interpolation The example below is to be read in conjunction with the Cylindrical Interpolation feature description given in the GE FANUC Operators Manual, publication B-63084EN/01, II Programming, Chapter 4.5. The Cylindrical Interpolation example program given in that chapter is to be ignored.
Fig. 58 Cylindrical Interpolation
N0286 G0 G40 G97 G99 N0287 M5 N0288 M50 N0289 G13.1 N0290 G07.1 C0 N0291 G28 U0 W0 N0292 T0404 N0293 M51
TNRC Off. Speed in RPM. Feed/Rev. Spindle Stop C-Axis Mode Off Polar Co-ordinate Interpolation Off Cylindrical Interpolation Off XZ Retraction to Align Reference Point Tool Selection C-Axis Mode On
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N0294 M54 N0295 G0 G28 C0 N0296 M8 N0297 S1000 M3 N0298 G00 Z100 X125 C0 N0299 M53 N0300 G01 X100 F.15 N0301 G19 W0 H0 N0302 G07.1 H60 N0303 G01 G42 Z120 F.25 N0304 C30 N0305 G02 Z90 C60 R30 N0306 G01 Z70 N0307 G03 Z60 C70 R10 N0308 G01 C150 N0309 G03 Z70 C190 R75 N0310 G01 Z110 C230 N0311 G02 Z120 C270 R75 N0312 G01 C360 N0313 G40 Z100 N0314 G07.1 C0 N0315 M54 N0316 X125 F5 M09 N0317 M5 N0318 M50
C-Axis Brake Off Initialise C-Axis at zero degree position Coolant On Spindle Start (CW) for Driven Tool Rapid Advance to Start Point C-Axis Brake partially On Feed Advance to Cutting Depth Zet Z-C Interpolation Plane Cylindrical Interpolation On TNRC On/Feed to profile ) ) ) ) Geometry Program ) (Program based on Cartesian ) Co-ordinates on Z-C plane) ) ) ) TNRC Off/Feed to Start Point Cylindrical Interpolation Off C-Axis Brake Off Fast Feed to Clearance/Coolant Off Spindle Stop C-Axis Mode Off
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Chapter 11 Toolsetter
Introduction This chapter describes how to use the Renishaw Tool Setting Arm (TSA) and the Renishaw High Precision Manual Tool Setting Arm (HPA) incorporating Renishaw macro Type B tool setting software. The documentation in this chapter has been reproduced with kind permission of Renishaw plc. The documentation and macro programs may not be reproduced, stored or transmitted, wholly or in part, in any form or by any means, without prior notice. TSA The Renishaw Tool Setting Arm (TSA) consists of a Motorised Hub, an arm which can be configured for different applications, an electronic interface and a probe. The TSA is used for setting X and Z Tool offsets.
Fig. 59 Probe Configuration
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HPA The Renishaw High Precision Manual Toolsetting Arm consists of Base assembly, Arm assembly and probe stylus. The HPA is a manually loaded arm which, like the TSA, is used for setting X and Z tool offsets.
4mm AF Allen key
1. 2. 3. 4. 5. 6. 7. 8. Fig. 60 Probe Configuration
Base Manual Locking Lever Protective Cover Arm Assembly Alignment Marker M5x20 Socket Head Capscrew (3 off) Clamping Collar Stylus Assembly
Macro Probing Routines

Probing routines (macros) are protected and stored within the main part program memory. Macro No. O9011 O9012 Description Semi Manual Tool Setting Auto Tool Setting Memory Used 3.7 kb 2.4 kb
NOTE: Macro O9012 is not available with the HPA Manual Tool Setting Arm. Manual Tool Setting The Manual Tool Setting MACRO O9011 will suit users who want to position the tool close to the stylus using Jog Mode before setting a tool. When using this method, it is not necessary to load any approximate tool data in the Tool Offset registers prior to running a cycle. NOTE: ALL tool movements within the macro are restricted to the (Bb) box distance (default 6mm (0.236in) maximum movement, and the moves are fully protected in the event of a collision.
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Auto Tool Setting - TSA only The Auto Tool Setting MACRO O9012 can be used to automatically position the tool to the stylus as well as set the tool. It will be necessary to load nominal tool data in the Tool Offset registers prior to running a cycle. If using the macro for calibration, it will also be necessary to enter nominal calibration data. Operator and Programming Notes 1. 2. 3. 4. 5. 6. Macro O9011 can be called with G124 Macro O9012 can be called with G125 - TSA only Probing macros can be called in MDI and Memory modes of operation. Probing feedrates are automatically converted to suit inch or metric programming. Tool setting routines inhibit the use of the feedrate override control. The Feed hold push button is still active. An active feedrate (programmed prior to invoking a tool setting routine) is not retained on completion of the tool setting routine, and must be reprogrammed as necessary. See chapter 14 for a list of variables used by Renishaw TSA macros. When the HPA is fitted to the machine - locked in position - turret index/jogs can only occur if the turret is at the Z-axis high limit.
7. 8.
Tool Setting Arm Activation - TSA

The Tool Setting Arm (TSA) is moved to its active (down) and stowed (up) position in two ways:1. 2. M44/M45 M-codes Operator panel membrane keys
M44 TSA Up M44 retracts the TSA to its parked - up (stowed) position. Operator door must be closed and parts catcher, if fitted, must be retracted. M45 TSA Down M45 moves the TSA to its down (active) position. Operator door must be closed and parts catcher, if fitted, must be retracted. Program example using M44 and M45 O0001 (TOOL PROBE) G21G90G0 G0X150Z230M9 M45 T0404 G98 G125 M44 G0X150Z230 M30 Program number Safe start position TSA down Turret index to position 4 with offset 04 Feed per minute Call macro O9012 TSA up Back to safe position End of program
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Tool Setting Arm Down Pushbutton This pushbutton is used to jog the Renishaw Tool Setting Arm (TSA) to its down position - Active position. It is only active when not in cycle, operator door closed and the spindle is stationary. Tool Setting Arm Up Pushbutton This pushbutton is used to jog the Renishaw Tool Setting Arm (TSA) to its up position - Stowed position. It is only active when not in cycle, operator door closed and the spindle is stationary.
HPA - Manual Toolsetting Arm

Fitting Arm 1. 2. 3. Remove the Protective cover (protective cap) by rotating the Manual Locking lever anticlockwise. Locate the tool setting arm on the base, lining up the alignment market (Red Dot) with the locking lever. Rotate locking lever clockwise to lock the arm in position. Probe is now armed.
Removing Arm 1. 2. 3. Rotate the locking lever anticlockwise and remove the arm. Locate the protective cap on the base, lining up the alignment marker (Red Dot) with the locking lever. Rotate locking lever clockwise to lock the cap in position.
TSA/HPA Calibration TSA/HPA calibration must be performed for the following reasons:S S S S S If it is the first time your probe system is to be used If a new stylus is fitted to your probe If it is suspected that the stylus has become distorted or that the probe has crashed At regular intervals to compensate for mechanical changes of your machine tool If repeatability of relocation of the probe in its operating position is poor. In this case, the probe may need to be re-calibrated each time it is selected.
Two different operations are used to calibrate a probe. They are:1. 2. Calibrating using the Manual Cycle - macro O9011 Calibrating using the Auto Cycle - macro O9012 - TSA only
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Stylus Alignment
When the probe system is assembled and mounted on the machine, the alignment must be set and position of the stylus must be found, before the Tool Setting cycles can be used. Stylus Alignment The faces of the cube stylus are accurately manufactured to be square and parallel to each other, so aligning just one face will automatically align all faces. Adjust the stylus face height so that the faces are central about the spindle centre line. Check that the stylus faces are aligned with the machine axes. It can be useful to use a tool mounted in the turret as a stylus triggering device. The machine coordinates at the trigger point can be compared to a second trigger point further along the stylus face. Usually alignment to within 0.010mm (0.0004in) is recommended, but this depends on the application. Stylus Position When calibrating for the first time it is recommended to use the macro O9011 Manual Cycle. Calibration must be made with a Master Tool of known dimensions. It is not necessary to have any idea of the stylus face coordinates because the macro runs incrementally from a start point and determines the calibration values based on the Master Tool dimensions. It can sometimes be done using the turret faces, using zero (0) Master Tool dimensions. Control Options The following features must be installed to support the Tool Setting Software. S S S Fanuc G31 Standard or High Speed Skip must be installed and operational. Fanuc user macro B programming option (standard on Hawk lathes). Sufficient part program memory to install this package together with working part programs.
Standard Calibration Data - Base Number 522 Calibration data will be stored in the following macro variables using the default Base Number. #522 = #523 = #524 = #525 = #526 = #527 = #530 = #531 = X+ Cube face X- Cube face Z+ Cube face Z- Cube face Y+ Cube face Y- Cube face X direction stylus size Z direction stylus size
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Adjusting the Software Back Off Distance The software will use the standard back off distance of 1mm, which is adequate for most installations. If the cycle will not run when installed, examine the tool measuring movements when triggering on the stylus. If the tool does not retract off the surface sufficiently after the first touch to enable a reseat of the probe, the back off distance should be increased to suit. Edit variable as follows in macro O9011. #529 = 1.0 ..... Change value to suit - factory set.
NOTE: If when running a cycle the machine axes do not move and NO alarm is generated, check that the relevant G code for feed / min has been selected.
Macro Parameters
Below is a list of all possible macro parameters for O9011 and O9012 macros. NOTE: It is recommended to use the decimal point with all input data, however, it may be possible on some machines to omit this. Entering Input Data on the cycle call line will override any other default conditions. Bb b= The box distance that the tool will move within, once moved to the start position in front of the stylus (Default = 6mm (.236in) Cc c= The cutter diameter offset. This may be used to set a cutter/drill to its centreline position by touching the stylus on one edge. (Default = 0) NOTE: Cc can also be used during a calibration cycle and only with vectors H5, H6, H7, H8. Hh h= The Tool Nose Vector. This is used to select the correct tool path movements and measuring direction for the type of tool. NOTE: The Tool Nose Vector will be taken from the Tool Offset page under the T address by default if Hh is not used. Tt t= Tool Offset number. This selects the Tool Offset number to be set. (Default will use the current active tool offset number, or the Tool number if the offset is not active.
NOTE: The Tool Offset will be the active Tool Offset, or the Tool Station if the Tool Offset is not active by default if Tt is not used. The input is also used to define the Tool Offset where the Master Tool dimensions are stored when calibrating the Probe Stylus. K1. 1.= This is used to indicate a Probe Stylus calibration cycle. One or two adjacent stylus faces will be set depending on the H input used.
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K2 2.= This is used to indicate a Probe Stylus calibration cycle. As for K1, but the OPPOSITE stylus face will also be set. This method will allow all faces of the stylus to be calibrated by touching on any two adjacent faces. (Experience stylus dimensions for the stylus size must be entered in #530 and #531 before this feature can be used). When K2 is used, the opposite stylus faces will be found by calculation. Example:X- stylus face = X+ stylus face - #530 Z- stylus face = Z+ stylus face - #531 Typical values for a 10mm (0.3937in) cube stylus. #530 = 19.940 (0.7850in) #531 = 9.970 (0.3925in) X diameter/radial width Z axis width
NOTE: When Kk is not used, tool setting is assumed. Do not mix K1 and K2 inputs on the same call line. Mm m= Broken tool checking tolerance (M.2 indicates a +2/-2 tolerance) (Default = 0). Rr r= Approach position in front of stylus (Default = 25mm [0.984in])
Ww
Uu Uu
Ww
Uu u= X axis tool tip geometry POSITIONING adjustment. This is additional to the Bb distance. (Default = 0). Ww w= Z axis tool tip geometry POSITIONING adjustment. This is additional to the Bb distance. (Default = 0). *Xx x= X axis Tool Offset RESULT adjustment amount. (Default = 0). *Zz z= Z axis Tool Offset RESULT adjustment amount. (Default = 0). NOTE: * These values can be used to make small compensations to the setting results. In applications where the nominal tool lengths are allowed for by the machining program, zero nominal values must be set in the tool registers. This is achieved by entering the tool geometry amounts in the Xx and Zz values.
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Tool Nose Vector Hh S S S The tool movement directions will be established by the selection of a suitable Hh vector number. Tools must be positioned to one of the positions shown according to the type of tool when using the Manual Cycle macro O9011. Hh numbers correspond with the T address on the Tool Offset page.
Bb H4 H8 H3 Bb
REAR TURRET MACHINE

X+
H5
H7
H1
H6
H2
Z+
H1 X+
H6
H2
FRONT TURRET MACHINE
H5
H7
H4
H8
H3
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Calibration Manual Calibration - Macro O9011

Introduction Calibration is achieved using macro O9011 directly as described here, or indirectly by using the Auto cycle O9012, which will also automatically position the Master Tool to the stylus for you. If using the Auto Cycle macro O9012, approximate calibration data MUST be entered in the calibration data variables before calibrating. Macro O9012 is not available with the HPA. Description The Probe must first be jogged to its down position using the TSA down push button, or manually fitted in the case of the HPA. The Master Tool must be selected in MDI mode and positioned in JOG or HANDWHEEL mode to a suitable start position. The cycle will move the Master Tool from the start position to the stylus face(s) as specified by the Tool Nose Vector Hh and then retract back to the start position. Calibration values are found for the stylus. Application a) b) c) d) The Probe Stylus faces must be set parallel to the axes. The Master Tool Offset Data must be entered in the Tool Offset register page before running the calibration. The Master Tool and Offset number should be selected using MDI mode, so that the screen information about the current tool is updated. Prepare a simple program to call the cycle using either the G124 or G65P9011 command and enter the K1. or K2. Input to indicate that a calibration cycle is required. Enter other optional inputs. (See Macro Parameters). Position the tool at a suitable start point in JOG or HANDWHEEL mode within the Bb box distance. Run the G124 cycle.
e) f)
Format [ ] denote optional parameters. G124 Kk [Bb Cc Hh Tt] Alternative: G65 P9011 Kk [Bb Cc Hh Tt] Example: G124K1.B10.C10.H3.T2. Macro Parameters Kk Bb Cc Hh Tt
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Outputs Calibration values for each stylus face can be found. The values are distances to the stylus faces in machine coordinates.
#531 X+ (#511)
#522 (#502) #530 Stylus (#510)
#523 (#503)
Z+ #525 (#505) #524 (#504)
NOTE: If the machine is set for diameter programming, then the #530 variable must be diametral. Example 1 - Calibration
Master Tool H3
When the program is run, the stylus calibration values are stored in #522 and #524 (+X, +Z faces). To set the opposite faces of cube #523 and #525 (-X, -Z faces), a new vector Hh must be used in with a different style Master Tool. Alternative: The K2. Input can be used to calibrate all four stylus faces. (See the Kk input description in Chapter 3 - Inputs). NOTE: Position the Master Tool within the box distance Bb from the face(s) of the stylus before running the cycle. 0500 G124K1.T2.H3. M30 Calibration program Calibration of two adjacent stylus faces. End program.
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Manual Tool Setting - Macro O9011

NOTE: The procedure for Tool Setting is the same as for Calibration, except that you do NOT enter Kk input. Description The Probe must first be jogged to its down position using the TSA down push button. The tool must be selected in MDI mode and positioned in JOG or HANDWHEEL mode to a suitable start position. The cycle will move the master tool from a start position to the stylus faces as specified by the Tool Nose Vector Hh and retract back to the start position. The Tool Offset values will be found and stored in the Tool Offset registers. Application a) b) c) d) The Tool Probe stylus faces must be calibrated before setting tools. It is NOT necessary to enter approximate tool offset values, unless using the Auto Cycle O9012. The tool and offset should be selected using MDI mode, so that the screen information about the current tool is updated. Enter the optional inputs as listed below in Inputs.
Alternative: The cycle can be run without any inputs provided the Tool/Offset is selected in MDI mode, and the Tool Nose Vector number is entered on the Tool Offset page under the T address. NOTE: Entering the input data on the cycle call line will override any other default conditions. e) f) Position the tool at a suitable start point in JOG or HANDWHEEL mode within the Bb box distance. Run the G124 cycle.
Format [ ] denote optional parameters. G124 [Bb Cc Hh Tt Mm Xx Zz Uu Ww] Alternative: G65 P9011 [Bb Cc Hh Tt Mm Xx Zz Uu Ww] Example: G124B10.C10.H3.T2.M.1X100.Z70.U3.W3 Macro Parameters Bb Cc Hh Tt Mm Xx Zz Uu Ww Outputs Set a Tool The Tool Offset register will be set. On machines with both geometry/wear registers, the wear compensations will be zeroed (o) and the geometry registers will be updated.
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Broken Tool Check When the Mm input for broken tool check is used, an alarm is generated and the machine will stop if the tool is out of tolerance. Example: Set a Turn Tool When the following program is run, the X and Z tool offset registers are set for tool 1.
H3
NOTE: Position the tool within the box distance from each face of the stylus before running the cycle. 0501 G124T1.H3. M30
Set a Turn Tool
Set the Turn Tool 1 End program.
Example: Set a Cutter to Centre Line When the following program is run, the side of the cutter will touch the stylus and because of the Cc input used, the tool will be set to centre line instead of the edge of the tool. This will be useful for drills etc. where the centre line position is required. NOTE: Position the tool within the box distance from the face of the stylus before running the cycle. 0502 G124T3.H8.C10.
Set a Cutter to Centre Line
Set tool 3 to centre line End program.
M30 Example: Set a Cutter Length
When the following program is run, the end cutter face will touch the stylus and set the Z length. NOTE: Position the tool within the box distance from the face of the stylus before running the cycle. 0503 G124T3.H7. M30
Set a Cutter for Length
Set tool 3 for Z length End program.
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Example: Set a Boring Tool When the following program is run, the X and Z tool offset registers are set for tool 2. NOTE: Position the tool within the box distance from each face of the stylus before running the cycle. 0504
H1
G124T4.H1. M30
Set the Boring Tool 4 End program.
Set a Boring Tool
Example: Broken Tool Check When the following program is run, the X and Z tool offset registers of tool 2 is checked for a broken tool condition.
H3
The TSA is jogged down manually. 0505 . . Complete the machining sequence with the current tool . (BROKEN TOOL CHECK) G28U0W0 Return tool to home G10P0X-12.1Z-160.2 Set program to X+, Z+ corner of the stylus G0X6.Z3. Move to start position G98 Feed per minute G124T5.H3.M.1 Broken tools check. A BROKEN TOOL alarm will result if the tool is out of tolerance G28U0W0 Return tool to home . Continue with next tool . NOTE: See the optional Auto cycle macro O9012 for a simpler programming method.
Broken Tool Check
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Example: Calibration and Tool Setting Cautions: When using either vector H1., H5., or H6., the tool must first be moved clear of the cube before returning home. Prior to setting tools, approximate tool offset values must be entered in the tool offset registers. O506(CALIBRATION/TOOL SETTING) G28U0W0 G10P0X-12.1Z-160.2 Set program to X+, Z+ corner of the stylus (OPTIONAL CALIBRATION) /T0303(MASTER TOOL) /G0X6. /Z3. /G124H3.K1. Calibrate probe /G28U0W0 /M00 (TOOL SETTING) T0101(20MM DRILL) G0X-10. Z3. G98 Feed per minute G124H7. Set drill length in Z G0X26. Z-15. G124H8.C20. Set drill to centre line G28U0W0 T0303(TURN TOOL) G0X6.Z3. G124H3. Set turn tool in X Z G28U0W0 T0414(GROOVING TOOL T4 OFFSET 14) G0Z-13. 10mm stylus X6. G124H4. Set tool in X Z G28U0W0 M30 NOTE: See the Auto Cycle macro O9012 for a simplified programming method.
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Auto Tool Setting - Macro O9012 - TSA Only

Caution: It is necessary to have calibrated the probe stylus, and enter nominal data in the Tool Offset register before running this cycle.
Description This macro is an optionally installed macro to supplement the O9011 macro. The cycle will automatically move the tool to the stylus start point where the O9011 macro is called. The cycle then returns to the original start point. Application Load nominal tool data into the Tool Offset registers before running the cycle. Program the Tool Setting Arm down (M45 M-code) and select the tool. The cycle will then measure the tool in either or both the X, Z directions depending on the vector used. Program the Tool Setting Arm Up (M44 M-Code). Format [ ] denote optional parameters G125 [Bb Cc Hh Kk Tt Mm Xx Zz Rr Uu Ww] Alternative: G65 P9012 [Bb Cc Hh Kk Tt Mm Xx Zz Rr Uu Ww] Example: G125B10.C10.H3.K1.T2.M.1X100.Z70.R30.U3.W3. Macro Parameters Caution: The H5 vector is for turning type tools ONLY because the approach path is around the X+ side of the stylus.
Bb Cc Hh Kk Tt Mm Xx Zz Rr Uu Ww
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Example: Showing Simplified Programming Format The Hh and Tt inputs are used in this example, but they are optional and default conditions could be used. O0050(TOOL SETTING) (*) (LOAD T1 DATA) G10P10001X76.Z85.Q2 G10P1X0Z0 (LOAD T3 DATA) G10P10003X95.Z38.Q8 G10P3X0Z0 (*) G28U0 G28W0 M45 (*) Optional loading of tool data
End of tool data loading
Tool setting arm down (active)
T0101(REAR BORE TOOL H1) G98 Feed per minute G125T1.H1W1. T0202 (BORE TOOL H2) G125T2.H2U2.W1 T0303 (TURN TOOL H3) G125T3H3 T0404 (REAR TURN TOOL H4) G125T4H4U-2. T0505(REAR TURN TOOL H5) G125T5.H5 T0606 (GROOVE BORE H6) G125T6.H6 T0707 (S/DRILL H7) G125T7.H7 T0707(S/DRILL X C/LINE H8) G125T7.H8C10. M44 M30 Tool setting arm up (stowed)
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Example: Broken Tool Check When the following program is run, the X and Z Tool Offset registers of tool 2 is checked for a broken tool condition.
H3
Broken Tool Check
0505 . . Complete the machining sequence with the current tool . (BROKEN TOOL CHECK) G28U0W0 Return tool to home M45 Tool Setting Arm Down (Active) G98 Feed per minute G125T5.H3.M.1 Broken tools check. A BROKEN TOOL alarm will result if the tool is out of tolerance G28U0W0 Return tool to home M44 Tool Setting Arm Up (Stowed) . Continue with next tool .
Page 11-17
Chapter 12 Parts Catcher

Introduction This chapter describes the use of the parts catcher. The parts catcher is an optional device fitted to the operator door to catch parts cut off from bar stock. The option is normally fitted to machines equipped with a Barfeeder.
Operator Door
Access Door
Catcher Open
Fig. 61 Parts Catcher fitted to Operator Door
Operation The Parts Catcher is advanced and retracted in two ways:1. 2. M34/M35 M-codes Operator panel membrane keys
M34 Parts Catcher Advance M34 moves the parts catcher forward to the collect position. Operator door must be closed and tool setting arm, if fitted, must be parked. M35 Parts Catcher Retract M35 retracts the parts catcher. Operator door must be closed and tool setting arm, if fitted, must be parked.
Page 12-1
Parts Catcher Advance Push Button This push button is used to jog the parts catcher down. It is only active when not in cycle and with the operator door closed.
Parts Catcher Retract Push Button This push button is used to jog the parts catcher up. It is only active when not in cycle and with the operator door closed. Operator and Programming Notes 1. 2. 3. The two push buttons are only active with the operator door closed. If a Tool Setting Arm is fitted it must be parked before the parts catcher can be advanced. Both M-codes are used in the M61 barfeed macro automatically. See chapter 13 for a description of the barfeed macro to catch an ejected billet.
Programming Example N350 T1010 N360 G97 S1500 M3 N370 G95 F0.06 N380 G0 X30 Z-5.1 N390 G1 X8 M8 N400 M34 N410 G1 X0 N420 M35 N430 G0 X30 N450 G0 X120 Z150 Parting off tool selected Direct RPM selected - Spindle started Feed per rev selected Move to position Feed with coolant ON Parts Catcher Advanced Feed to X0 - Material Parted off Parts Catcher Retracted Rapid clear in X axis Rapid X and Z axes to a safe position
Page 12-2
Chapter 13 Barfeeder
Introduction
This chapter describes the use of the barfeeder. The barfeeder is an optional device fitted to the Hawk range of lathes. As standard 3 different types of barfeed are fitted to Hawk lathes:1. Hydrafeed 2. Feedmaster 3. Multifeed Hydraulic operated unit Pneumatic operated unit Hydraulic operated multiple bar unit
Each of the above units is supplied with an operating manual, which should be used in conjunction with this chapter. Bar Preparation
30
The outboard end of the bar stock should be chamfered at an angle to match the pusher head. Typical pusher heads have a 30 degree angle. When hollow bar stock is being machined with a hydro-dynamic type bar feed unit, plug the outboard end of the tube to prevent hydraulic oil from the bar feed unit from flowing through the tube and mixing with the cutting fluid in the machine. M-Codes The following M-codes are used with the bar feed units:
30 )
O-RING
M90 - Bar Feed mode on. - MDI program only. M91 - Bar Feed mode off. - MDI program only. M92 Rotate Spindle CW - Reduces Spindle Rotation Speed to a jog value set by Keep Relays. - See Barfeed Spindle Rotation Bits for spindle speed.
HOLLOW STOCK BAR PLUG
M93 - Rotate Spindle CW OFF. - Spindle will stop. M78 - Open jaws. - Collet Open signal set on to barfeed unit when chuck is open. M79 - Close jaws. - Collet Open signal set off when chuck is closed.
WARNING
DO NOT Program an M87 M-code when the lathe is in cycle with a part in the chuck/barfeed. This will damage the barfeeder unit as the bar will not be held central and will vibrate violently.
M86 - Bar Feed Pressure on. - Hydrafeed and Feedmaster only. - Program at start of program. M87 - Bar Feed Pressure off. - Hydrafeed and Feedmaster only. - To be programmed carefully - see WARNING.
Page 13-1
M61 -
Used on Multifeed units only. Calls Macro O9020 (Multifeed Reload Macro). Macro detects end of bar and reloads a new bar. Optional parameter Zzzz.zzz - Z Axis Backoff. If no Zzzz.zzz value is programmed then a 150mm backoff is performed to eject billet.
M80 - NOT TO BE PROGRAMMED - Used in Macro O9020 - Eject Bars end (billet) and reloads new bar. Standard Barfeed Sequence for Multifeed Unit:Barfeed into AUTO mode. (Refer to Barfeed Operating Manual) S S S Program M90 in MDI mode - this puts machine in Barfeed Mode Load part program into memory Cycle start on the program
The part program consists of the following: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. S Part-off component. M92 - Reduce spindle speed to jog rate - only program if required. Index turret to Bar stop. Position X and Z axes to within 10mm off the end of Bar. Program M61 Zzzz.zzz - Check end of bar - reload new bar if necessary. Program M78 - Chuck open. Z axis move - Z move = length of bar. M79 - Chuck close. Move turret clear. M93 - Turn off spindle jog rate - only program if required. M91 in MDI mode, if necessary to take the lathe out of Barfeed mode. - machine component (centre drill and advance tailstock if necessary). machine component
Page 13-2
M61 - Macro Code (shown for information purposes only) O9020 (Multifeed Reload Macro) M69 #100=#1000 IF[#1000 EQ 0]GOTO 99 IF[#26 NE #0] GOTO 1 #26=150 N1#101=#26 G00W#101 M34 M78 M80 M35 G00W-#26 M80 G4X2.0 M79 N99 M99 Prog. No. Retract Tailstock Let #100 = user input value 1 or 0 Goto N99
Incremental Z move out Parts catcher out Chuck open Eject billet Parts catcher in Incremental Z move in Reload new bar Dwell 2 seconds Chuck close End of macro
Program M61 - 150mm +ve incremental Z move. Program M61 Z250 - 250mm +ve incremental Z move. Standard Barfeed Sequence for Hydrafeed and Feedmaster Barfeed into AUTO mode. (Refer to Barfeed Operating Manual) S S S Program M90 in MDI mode - this puts machine in Barfeed Mode Load part program into memory Cycle start on the program
The part program consists of the following: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. M86 - Barfeed pressure ON. Part-off component. Index turret to Bar stop. Program X and Z axes to within 10mm off the end of Bar. M78 - Chuck open. Z axis move - Z move = length of bar. M79 - Chuck close. Move turret clear. - Machine component. - Machine component.
Page 13-3
Barfeed Spindle Rotation Speed Bits - Keep Relay K Bits

K6.0 K6.1 K6.2 K6.3 K6.4 K6.5 K6.6 K6.7 SJ_B0 SJ_B1 SJ_B2 SJ_B3 SJ_B4 SJ_B5 SJ_B6 SJ_B7 SPINDLE JOG BIT 0 - BARFEED SPINDLE JOG BIT 1 - BARFEED SPINDLE JOG BIT 2 - BARFEED SPINDLE JOG BIT 3 - BARFEED SPINDLE JOG BIT 4 - BARFEED SPINDLE JOG BIT 5 - BARFEED SPINDLE JOG BIT 6 - BARFEED SPINDLE JOG BIT 7 - BARFEED RPM = 2 RPM = 5 RPM = 11 RPM = 22 RPM = 45 RPM = 92 RPM = 186 RPM = 370
K6.0 set K6.0, K6.1 set K6.0, K6.1, K6.2 set K6.0, K6.1, K6.2, K6.3 set K6.0, K6.1, K6.2, K6.3, K6.4 set K6.0, K6.1, K6.2, K6.3, K6.4, K6.5 set K6.0, K6.1, K6.2, K6.3, K6.4, K6.5, K6.6 set K6.0, K6.1, K6.2, K6.3, K6.4, K6.5, K6.6, K6.7 set
Page 13-4
Chapter 14 Reserved Macro Routines

The following macro subroutine numbers are reserved for specific machine functions. 9020 Barfeed macro-detect end of bar/reload new bar - Multifeed only. 9011 Renishaw Tool Setting Arm (TSA) Semi Manual Tool Setting macro. 9012 Renishaw Tool Setting Arm (TSA) Auto Tool Setting macro These macros should not be edited or deleted. All other macro subroutine numbers are available for customer usage. NOTE: If any macros are accidently erased or edited then the floppy disk copy as supplied with the machine should be reloaded. Refer to section on reloading machine software. Used Macro Variables Volatile common variables #100, #101 used by barfeed macro Non volatile common variables #509 used by Renishaw TSA macros #522 #503 #524 #525 #526 #527 #530 #531
Page 14-1
Chapter 15 Connection to Data Input/Output Devices

Connection to Data Input and Output Devices
CINCINNATI TURNING CENTRES are supplied with a common input and output RS232 serial data port located on the front face of control station housing. The port can be used to interface any RS232 serial data input output device such as a data printer or remote computer. Use the following information to prepare the interface: 1. 2.
Pin No Fanuc Signal Notation
Connector type:- 25 pin D type plug (female socket is mounted on machine). Connector pin out details:
Signal Function Input Signal to CNC
Output
Common Signal Notation
Signal from CNC
1 2 3 4 5 6 7 8* 20
FG SD RD RS CS DR SG CD ER
FG TD RD RTS CTS DSR SG DCD DTR
FRAME GROUND TRANSMITTED DATA RECEIVED DATA REQUEST TO SEND CLEAR TO SEND DATA SET READY SIGNAL GROUND DATA CARRIER DETECT DATA TERMINAL READY
A " A A A " "
NOTES: * Always link DCD to DTR on device plug. 3. Input/Output Device Parameters
Blankfeed before and after the Data at Data Output selectable Input/Output Device Code Coded Baudrate (bps) of Input/ Output Device selectable
I/O Channel No of Stop Bits selection via selectable 1 or 2 Parameter 0020
Channel 0 (Parameter -2202 = 0) Channel 1 (Parameter -0020 = 1) Parameter Settings
P 101.0
P 101.7
P 102
P 103
P 111.0
P 111.7
P 112
P 113
0=(1 stop bit) 1=(2 stop bits)
0=(Output) 1=(Not Output)
Selectable 0--6 eg: 0=(RS--232--C) See I/O Device code table in this chapter.
1=50 2=100 3=110 4=150 5=200 6=300
7=600 8=1200 9=2400 10=4800 11=9600

12=19200
For further information refer to GE Fanuc Operator manual. III Operation, chapter 2.4
Page 15-1
Input/Output Device and Code Number

Code Number Input/Output Device
0 1 2 3
RS--232--C (Used control codes DC1 to DC4) FANUC CASSETTE ADAPTOR 1 (FANUC CASSETTE B1/B2) FANUC CASSETTE ADAPTOR 3 (FANUC CASSETTE F1) FANUC PROGRAM FILE Mate, FANUC FA Card Adaptor FANUC FLOPPY CASSETTE ADAPTOR, FANUC Handy File FANUC SYSTEM P--MODEL H RS--232--C (Used control codes DC1 to DC4) Portable tape reader FANUC PPR FANUC SYSTEM P--MODEL G, FANUC SYSTEM P--MODEL H For further information refer to the GE Fanuc operator manual. 4. Selection of Input/Output device via parameter 0020 In MDI or Emergency stop state, select OFFSET/SETTING key on MDI keypad followed by [SETTING] softkey, set PARAMETER WRITE = 1 and set I/O channel to the required channel number (ie: 0, 1 or 4), then reset PARAMETER WRITE = 0. I/O Channel 4 (Memory Card) CINCINNATI VERTICAL MACHINING CENTRES are supplied with a PCMCIA MEMORY CARD SLOT which is located on the front face of the control station, and enabled when the I/O CHANNEL (Parameter 20) is set to 4. For further information on using the PCMCIA MEMORY CARD SLOT for data input/output refer to GE Fanuc Operator manual: III Operation, chapter 8.11.
4 5 6
Page 15-2
Chapter 16 Diagnostics
DANGER HIGH VOLTAGE
Lethal voltages are present in the magnetics and electrical control cabinets when the MACHINE MAIN DISCONNECT is ON. Current and voltage measurements should be attempted only by qualified electrical maintenance personnel. Before working on any electrical circuits, turn the machine Main Disconnect Device OFF and lock It. Capacitors in the Servo Drives require up to 20 minutes to completely discharge. Always verify that discharge is complete using a known working and calibrated voltmeter before commencing work on these units. Unless expressly stated in applicable Cincinnati Machine documentation or by the appropriate Cincinnati Machine Field Service Representative, do NOT work with electrical power ON. If such express statement of advice exists, working with electrical power ON should be performed by a Cincinnati Machine Field Service Representative. The customer and subsequent transferees must determine that any other person performing work with electrical power ON is trained and technically qualified. Failure To Follow This Instruction May Result In Death Or Serious Personal Shock Injury.
Page 16-1
PMC Input Address Reference List

PMC ADDRESS SCHEMATIC REF FUNCTION
X0004.0 X0004.1 X0004.2 X0004.3 X0004.4 X0004.5 X0004.7 X0005.0 X0005.1 X0005.2 X0005.3 X0005.4 X0005.5 X0005.6 X0005.7 X0006.0 X0006.1 X0006.2 X0006.3 X0006.4 X0006.5 X0006.6 X0006.7 X0007.0 X0007.1 X0007.2 X0007.3 X0007.4 X0007.5 X0007.6 X0008.0 X0008.1 X0008.2 X0008.3 X0008.4 X0008.5 X0008.6 X0009.1 X0009.2 X0009.5 X0009.6 X0021.0 X0021.1 X0021.2 X0021.3 X0021.7 X0023.0 X0023.1 X0023.2 X0023.3 X0023.4 X0023.5
FT_SW TXT_OK HYDPRS QLPRES H_FLTB A_LOW SKIP ALBIT1 ALBIT2 ALBIT4 T_LOCK T_INDX T_CRSH DR_CLD DR_LKD CM_OL HM_OL CON_OL CC_ADV CC_RET X_REF Z_REF C_REF PR_PCA PR_PCR EO_BAR BF_RDY BFMFIN BF_ALM P_EOB M70_FB M71_FB M72_FB M73_FB *ESPPB P_ACT P_STOW DT_1SW CB_PS LEV_LK COV_P *OV1 *OV2 *OV4 *OV8 KEY_SW MSTRPB CYSRPB PB_JO PB_JC PBQADV PBQRET
CHUCK JAWS FOOT SWITCH TRANSFORMER TEMPERATURE OK MACHINE HYDRAULIC PRESSURE QUILL HYDRAULIC PRESSURE HYDRAULIC FILTER BLOCKED TURRET AIR LOW PRESSURE SWITCH PROBE SKIP SIGNAL TURRET ALARM BIT 1 TURRET ALARM BIT 2 TURRET ALARM BIT 4 TURRET LOCKED TURRET INDEXED TURRET CRASH SWITCH OPERATOR DOOR CLOSED OPERATOR DOOR CLOSED & LOCKED COOLANT MOTOR OVERLOAD HYDRAULIC MOTOR OVERLOAD SWARF CONVEYOR MOTOR OVERLOAD CHUCK CYLINDER ADVANCED CHUCK CYLINDER RETRACTED X AXIS REFERENCE SWITCH Z AXIS REFERENCE SWITCH C AXIS ALIGN SWITCH PROXIMITY SWITCH PARTS CATCHER ADVANCED PROXIMITY SWITCH PARTS CATCHER RETRACTED BARFEED_END OF BAR SIGNAL BARFEED READY SIGNAL-MULTIFEED. AUTO DETECT SIGNAL HYDRAFEED AND FEEDMASTER BAR FEED M-CODE FINISH SIGNAL BAR FEED ALARM BARFEED PRE END OF BAR SIGNAL M70 FEEDBACK SIGNAL M71 FEEDBACK SIGNAL M72 FEEDBACK SIGNAL M73 FEEDBACK SIGNAL EMERGENCY STOP RENISHAW TSA ACTIVE (DOWN) RENISHAW TSA STOWED (UP) DRIVEN TOOL ONCE PER POSITION SWITCH C AXIS BRAKE PRESSURE SWITCH HPA LEVER LOCKED SWITCH HPA COVER FITTED SWITCH FEEDRATE OVERRIDE 1 FEEDRATE OVERRIDE 2 FEEDRATE OVERRIDE 4 FEEDRATE OVERRIDE 8 PART PROGRAM PROTECTION KEY PUSHBUTTON - MASTER START REMOTE CYCLE START PUSHBUTTON PUSHBUTTON CHUCK JAWS OPEN PUHSBUTTON CHUCK JAWS CLOSE PUSHBUTTON QUILL ADVANCE PUSHBUTTON QUILL RETRACT
Page 16-2
PMC Output Address Reference List

PMC ADDRESS Y0004.0 Y0004.1 Y0004.2 Y0004.3 Y0004.4 Y0004.5 Y0004.6 Y0004.7 Y0005.0 Y0005.1 Y0005.2 Y0005.3 Y0005.4 Y0005.6 Y0006.0 Y0006.1 Y0006.2 Y0006.3 Y0006.4 Y0006.5 Y0006.6 Y0006.7 Y0007.0 Y0007.1 Y0007.2 Y0007.7 Y0008.0 Y0008.1 Y0008.2 Y0008.3 Y0008.4 Y0008.5 Y0008.6 Y0008.7 Y0009.0 Y0009.1 Y0009.2 Y0009.3 Y0009.4 SCHEMATIC FUNCTION REF D_UNLK HYD_M CLT_ON X_BRK SL_JC SL_JO SL_Q_F SL_Q_R GREEN AMBER RED P_MV P_DIR CONFWD PBIT01 PBIT02 PBIT04 PBIT08 PARITY PSTART PTAB01 PTAB02 MODE01 MODE02 MODE03 M02_OP M70_OP M71_OP M72_OP M73_OP BF_ENB BF_MCD C_OPEN SL_APC SR_1 SR_2 BSOL_1 BSOL_2 BSOL_3 OPERATOR DOOR SHOTBOLT UNLOCK HYDRAULIC MOTOR CONTACTOR COOLANT PUMP CONTACTOR X AXIS BRAKE SOLENOID CHUCK JAWS CLOSE SOLENOID CHUCK JAWS OPEN SOLENOID QUILL FORWARD SOLENOID QUILL REVERSE MACHINE STATUS BEACON GREEN MACHINE STATUS BEACON AMBER MACHINE STATUS BEACON RED RENISHAW TSA MOVE SIGNAL RENISHAW TSA DIRECTION SIGNAL SWARF CONVEYOR FORWARD TURRET POSITION BIT 01 TURRET POSITION BIT 02 TURRET POSITION BIT 04 TURRET POSITION BIT 08 TURRET PARITY BIT TURRET START SIGNAL NO. TURRET TOOLS 1=12, 0=8 TURRET INERTIA 0=LOW/1=HIGH TURRET MODE BIT1 TURRET MODE BIT2 TURRET MODE BIT3 M2/M30 OUTPUT M70 OUTPUT M71 OUTPUT M72 OUTPUT M73 OUTPUT BAR FEED ENABLE BAR FEED M CODE COLLET OPEN - BARFEED SOLENOID ADVANCE PARTS CATCHER STEADY REST 1 OUTPUT STEADY REST 2 OUTPUT C AXIS BRAKE SOLENOID 1 C AXIS BRAKE SOLENOID 2 C AXIS BRAKE SOLENOID 3
Page 16-3
FANUC Operators Panel Connection Signals

The DI/DO signals at the following addresses (PMC) are used exclusively for the operators panel. PMC address bit 7 X8 bit 6 bit 5 bit 4 *ES PPB KD7 KD6 KD5 KD4 KD3 KD2 KD1 KD0 bit 3 bit 2 bit 1 bit 0
X20
X21
KEY
*OV8 *OV4 *OV2 *OV1
X22
KST
KA3
KA2
KA1
KA0
Y20
LD7
LD6
LD5
LD4
LD3
LD2
LD1
LD0
*ESP X8.4 Emergency Stop Pushbutton KEY (X21.7) Memory Protect Signal When Key = 1 Program storage and editing operations etc. can be performed. *OV1-*OV8 (X21.0 0- 21.3) Override Selector Switch Signals The override codes are input according to the table below. Rotary switch position 0% 10% 20% 30% 40% --150% *OV8 X21.3 1 1 1 1 1 --0 *OV4 X21.2 1 1 1 1 0 --0 *OV2 X21.1 1 1 0 0 1 --0 *OV1 X21.0 1 0 1 0 1 --0
(Binary code reverse signal) KD0 - KD7 (X20.0) - 20.7) KA0 - KA3 (X22.0 - 22.3), KST (X22.7) LDO - LD7 (Y20.0 - 20.7) These signals are processed directly by the controls management software as coded signals for the key switches and the LEDs. Therefore, they have no meaningful function to a maintenance engineer.
Page 16-4
FANUC Operator Station

Self-Diagnostic Function Status Display LED The operators panel PCB (located on the reverse side of the operators panel) is equipped with a green status display LED. It indicates the following status: Flashing about every second: On (Not flashing): Other than above: Test Mode The operators panel assumes the test mode if the control is turned on while depressing AUTO and SINGLE BLOCK keys at the same time. As soon as the test mode is active, all LEDs should flash seven times simultaneously, if any of the keys are depressed thereafter, the LED corresponding should illuminate. In the test mode, the depressed key is not transferred to the PMC nor is it possible to light the LED from the PMC. To finish the test mode, depress AUTO and DRY RUN at the same time. Normal Test mode Fault
Page 16-5
1 A
10
X
B C D
RS 232
x X1 1
X10
A 1 + X100 U
AUX 1 -Z
+ X +X X
-X +Z
X
+
100%
E F
Fig. 62 Operators Control Panel
FANUC Operator Station Key/LED - Diagnostic Address Table

BIT PCMADDRESS R292/R242
7
F3
PROGRAM STOP
6
F2
CYCLE STOP
5
F1
CYCLE START
4
E1 E2 C3
AXIS INHIBIT
3
D1
PGM RESTART
2
C1
DRY RUN
1
B1
SINGLE BLOCK
0
A1
AUTO
R293/R243
F4
SPINDLE CW
E4 D3
TSA UP
E3 C4
TURRET JOG +
D2
TSA DOWN
C2
PROGRAM TEST
B2
BLOCK DELETE
A2
EDIT
R294/R244
D4
SPINDLE DEC
B4
MPG X1
B3
OPTIONAL STOP
A4
ALIGN (HOME)
A3
MDI
R295/R245
E7
F6
SPINDLE CCW
F5
SPINDLE STOP
E5
D5
SPINDLE 100%
C5
TURRET JOG --
B5
MPG X10
A5
JOG
R296/R246
F8
COOLANT ON
E8
E7
E6
D6
SPINDLE INC
C6
AUX 1
B6
MPG X100
A6
PARTS CATCHER DOWN
R297/R247
D8
D7
C8 --Z
C7
B8
B7
A8
ID GRIP
A7
PARTS CATCHERUP
R298/R248
F9
COOLANT OFF
E9
D9 --X D10
C9
RAPID
TRAVERSE
B9 +X B10
A9
OD GRIP
R299/R249
F10
COOLANT AUTO
E10
C10 +Z
A10
OFFSET MEASURE
S S
Top row in table . . . . . . . . . . . . . Coordinates Bottom row in table . . . . . . . . . . Name of key
Page 16-6
Alarm Messages
Alarm messages are displayed in response to incorrect or missing feedback signals from the machine and certain part programming errors. This section describes the meaning of each alarm, the probable reasons for their occurrence and the recommended alarm recovery procedure in each case. All alarms cause the control to enter the alarm status and may invoke various machine reactions depending upon the severity of the alarm. It is necessary to depress RESET to cancel an alarm once the fault causing the alarm has been removed. If the fault is still present then the alarm message remains displayed. When the reason for a persistent alarm cannot be determined after following the alarm recovery procedures then contact Cincinnati Machine Service department for further advice. Alarm Number 1000 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 Alarm Message
KEEP RELAYS NOT SET EMERGENCY STOP SPINDLE DRIVE ALARM DRIVEN TOOL ORIENT TIMEOUT SP2 SPINDLE DRIVE ALARM SPINDLE ORIENTATION TIMEOUT SPINDLE ACC/DEC TIMEOUT SPINDLE DEC TO ZERO TIME COOLANT MOTOR OVERLOAD OPERATOR DOOR OPEN BATTERY LOW KEEP POWER ON NO T WORD PROGRAMMED - M76/M77 POWER DOWN CONTROL OPERATOR PANEL I/O ERR REMOTE I/O MODULE ERR DRIVEN TOOL SPINDLE ACC/DEC TIMOUT HYDRAULIC FILTER BLOCKED MACHINE HYDRAULIC PRESS FAIL QUILL PRESSURE FAILURE TRANSFORMER OVERTEMP CONVEYOR MOTOR OVERLOAD HYDRAULIC MOTOR OVERLOAD TURRET OVERLOAD TURRET SYSTEM ERROR TURRET CONNECTION ERROR TURRET UTILISATION ERROR TURRET UNLOCKING ERROR TURRET LOCKING ERROR TURRET REFERENCE ERROR TURRET INTERFACE ERROR TURRET CRASH SWITCH ERROR CHUCK IN UNGRIPPED CONDITION
Page 16-7
1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044 1045 1046 1047 1048 1049 1050 1051 1052 1053 1054 1055 1056 1057 1058 1059 1060 1061 1063 1064 1065 1066 1067 1068
INITIALISE ID/OD GRIP TURRET AIR PRESSURE LOW INITIALISE CHUCK JAWS T WORD RANGE ERROR INITIALISE TAILSTOCK QUILL
PARTS CATCHER ADVANCED TIMEOUT PARTS CATCHER RETRACTED TIMEOUT PARTS CATCHER NOT RETRACTED TOOL SETTING ARM NOT PARKED TOOL SETTING ARM ADVANCE TIMEOUT TOOL SETTING ARM RETRACT TIMEOUT NOT IN MDI MODE BAR FEED ALARM BAR FEED NOT IN AUTO MODE PROBE OPEN PROBE FAIL ILLEGAL TOOL OFFSET NUMBER T ILLEGAL TOOL NOSE VECTOR H INPUTS C AND H1-H4 MIXED BROKEN TOOL MINIMUM TAPPING SPEED 60RPM M44/M45 INHIBIT - CHUCK ROTATING SPINDLE CONTOUR MODE (C AXIS) TIMEOUT DRIVEN TOOL SPINDLE DEC TO ZERO TIMEOUT SP1 OR SP2 NOT STATIONARY M78/M79 INHIBIT - CHUCK ROTATING TURRET ALIGN FAILURE TURRET POSITIONING FAILURE OPEN / CLOSE OPERATOR DOOR SERVO AXIS ABNORMAL LOAD DETECTION HPA PROTECTIVE COVER NOT FITTED HPA LEVER NOT IN LOCKED
Page 16-8
ALARM NUMBER 1000
ALARM MESSAGE:
KEEP RELAYS NOT SET
MEANING OF ALARM:
The keep relay data has not been completed.
PROBABLE REASONS FOR ALARM:
1. The memory retention system of the control system has failed. 2. The control memory has been cleared.
CORRECT OUTPUT STATUS:
N/A
CORRECT INPUT/FEEDBACK STATUS:
Keep relay data set to Machine Dependant Parameter sheet as supplied with machine.
ALLOWABLE TIME:
Instant
CONTROL REACTION TO ALARM:
Feedhold and Spindle Stop This alarm is unlikely to be seen at any other time than at control power on.
ALARM RECOVERY PROCEDURE:
Set keep relay data to the values as defined on the Machine Dependant Parameter.
Page 16-9
ALARM NUMBER 1001
ALARM MESSAGE:
EMERGENCY STOP
MEANING OF ALARM:
Emergency Stop push button is depressed.
Emergency Stop push button has not been released. The Emergency Stop push button latches down when depressed and has to be turned clockwise to unlatch.
N/A
Input X8.4 HIGH
ALLOWABLE TIME:
Instant
Control enters EMG ALM status. Depressing Emergency Stop push button also initiates a hardware shut down of axes and spindle drives, and hydraulic unit.
1. Release Emergency Stop push button. 2. Depress RESET. 3. Realign machine axes and turret mechanism.
Page 16-10
ALARM NUMBER 1002
ALARM MESSAGE:
SPINDLE DRIVE ALARM
MEANING OF ALARM:
A signal was received from the spindle drive unit indicating that a spindle drive fault was active.
See ALARM RECOVER PROCEDURE below.
N/A
F45.0 is LOW when no fault present.
ALLOWABLE TIME:
Instant
Feedhold and spindle stop.
1. Power down machine and turn the main disconnect switch off. 2. After a few seconds turn the main disconnect switch back on. 3. Restart the machine. 4. If the spindle drive is still in a fault condition power down the machine, open the drives cabinet and check the general condition of wiring to and from the spindle drive and make sure all connections are secure. 5. To properly further diagnose any spindle drive fault it will be necessary to obtain advice/assistance from Cincinnati Machine Service Department.
Page 16-11
ALARM NUMBER 1003
ALARM MESSAGE:
DRIVEN TOOL ORIENT TIMEOUT
MEANING OF ALARM:
A request was made to orientate the Driven Tool spindle but the orientation complete was not recieved within the allocated time.
1. Faulty wiring to spindle encoder.
G74.6 HIGH
F49.7 HIGH
ALLOWABLE TIME:
6 seconds
1. 2. 3. 4.
Depress RESET. If necessary jog the turret into a safe position. Attempt to orienate driven tool spindle using M19code. If alarm still persists power down machine and turn off main disconnect switch 5. Open electrical cabinate door and check general condition of machine wiring to and from the spindle motor ancoder mounted in the back of the driven tool spindle motor.
Page 16-12
ALARM NUMBER 1004
ALARM MESSAGE:
SP2 SPINDLE DRIVE ALARM
MEANING OF ALARM:
A signal was received from the Driven Tool spindle drive unit (sp2) indicating that a spindle drive fault was active.
See ALARM RECOVERY PROCEDURE below
N/A
F49.0 LOW when no fault present
ALLOWABLE TIME: CONTROL REACTION TO ALARM:
Insant Feedhold and spindle stop.
1. Power down the machine and turn the main disconnect switch off. 2. After a few seconds turn the main disconnect switch back on. 3. Restart the machine. 4. If the spindle drive is still in a fault condition, power down the machine, open the electrical cabinet and check the general condition of wiring to and from the spindle drive and make sure all connections are secure. 5. To properly further diagnose any spindle drive fault it will be necessary to obtain advice/assistance from Cincinnati Machine Service Department.
Page 16-13
ALARM NUMBER 1005
ALARM MESSAGE:
SPINDLE ORIENTATION TIME OUT
MEANING OF ALARM:
A request was made to orientate the spindle but the orientation complete signal was not received within the allocated time.
1. Faulty wiring to spindle encoder.
G70.6 HIGH
F45.7 HIGH
6 seconds Feedhold and spindle stop.
1. Depress RESET. 2. If necessary jog the machine spindle back into the normal operating range. 3. Attempt to orientate spindle using M19 code. 4. If alarm still persists power down machine and turn off main disconnect switch. 5. Open electrical cabinet door and check general condition of machine wiring to and from the spindle motor encoder mounted in the back of the spindle motor. 6. Close electrical cabinet door and power up machine.
Page 16-14
ALARM NUMBER 1006
ALARM MESSAGE:
SPINDLE ACC/DEC TIME OUT
MEANING OF ALARM:
An attempt was made to start the machine spindle or change the current spindle speed, but the spindle motor up to speed signal was not received within the prescribed time.
1. Faulty wiring. 2. Faulty spindle drive unit.
For CW rotation:-For CCW rotation:
G70.5 ON, G70.4 OFF G70.4 ON, G70.5 OFF
F45.3 HIGH
1. Depress RESET to cancel alarm. 2. Retry starting the spindle using M03/4 and S code in MDI. 3 If alarm still persists power down machine and turn off main disconnect switch. 4. Open electrical cabinet door and check general condition of machine wiring to and from the spindle drive unit and make sure all connections are secure. 5. Close electrical cabinet door and power up machine.
Page 16-15
ALARM NUMBER 1007
ALARM MESSAGE:
SPINDLE DEC TO ZERO TIME
MEANING OF ALARM:
A spindle stop request was issued to the spindle drive but the spindle zero speed input was not received within the prescribed time. Can also occur even if spindle is stationary as spindle zero speed status is assumed when spindle is not in use.
1. Faulty wiring. 2. Faulty spindle drive unit.
G70.5 and G70.4 LOW
F45.1 HIGH
1. Depress RESET to cancel alarm. 2. Retry stopping and starting spindle in MDI mode. 3. If alarm still persists power down machine and turn off main disconnect switch. 4. Open electrical cabinet door and check general condition of machine wiring to and from the spindle drive unit and make sure all connections are secure. 5. Close cabinet door and power up machine.
Page 16-16
ALARM NUMBER 1008
ALARM MESSAGE:
COOLANT MOTOR OVERLOAD
MEANING OF ALARM:
The electrical overload unit used to protect the coolant pump motor has tripped out.
1. The coolant pump intake mesh is contaminated. 2. Faulty coolant motor. 3. Faulty overload signal wiring.
N/A
X6.0 HIGH
Instant Feedhold.
1. Power down machine and turn main disconnect switch off. 2. Open electrical door and reset the coolant motor overload unit. 3. Check if anything is blocking the coolant pump intake mesh. 4. Close electrical cabinet door and power up machine. 5. If the coolant overload retrips when the coolant is turned on it will be necessary to remove the motor and check for contaminants beyond the filter mesh and the condition of the motor windings.
Page 16-17
ALARM NUMBER 1009
ALARM MESSAGE:
OPERATOR DOOR OPEN
MEANING OF ALARM:
The OPERATOR DOOR CLOSED AND LOCKED switch signal was not received within the prescribed time when attempting to invoke an activation that required the operator doors to be electrically locked. Alternatively the OPERATOR DOOR LOCKED switch signal was lost during the machine cycle or while the spindle was rotating. 1. Operator door not fully closed restricting the door locking bolt from correctly inserting into the door latch. 2. Faulty opto--isolator output module. 3. Operator door opened during cycle or while the spindle was rotating. 4. Faulty wiring. Y4.0 LOW
X5.6 HIGH and X5.7 HIGH
0.25 seconds Feedhold and spindle stop.
1. Depress RESET to cancel alarm. 2. Open and close operator doors and attempt to restart the machine cycle. 3. If the alarm is reactivated monitor the door switch in the STATUS display. 4. If the switch is not functioning correctly check the condition of the wiring to and from the switches. 5. Check the condition of the relevant door unlock opto-isolator module.
Page 16-18
ALARM NUMBER 1010
ALARM MESSAGE:
BATTERY LOW KEEP POWER ON
MEANING OF ALARM:
The voltage of the control memory retention batteries dropped below the minimum permitted level. 1. Batteries need replacing. 2. Faulty wiring from batteries to control unit.
N/A
N/A
N/A Alarm 1010 will not be reported until the current machine cycle is complete. However the BAT alarm status may be displayed while the machine is in cycle. Any attempt to restart the machine cycle while this alarm is active will be rejected.
1. Refer to battery replacement procedure in GE Fanuc Operator Manual, IV Maintenance, chapter 1 immediately. 2. If the alarm still persists check the condition of the wiring from the battery housing to the control unit.
Page 16-19
ALARM NUMBER 1011
ALARM MESSAGE:
NO T WORD PROGRAMMED - M76/M77
MEANING OF ALARM:
No T word has been programmed on a block with an M76 or M77. 1. Programming error.
N/A
N/A
Instant Feedhold and spindle stop.
1. Depress RESET to cancel alarm. 2. Edit program to include a T word. 3. Restart program at a convenient/safe point.
Page 16-20
ALARM NUMBER 1012
ALARM MESSAGE:
POWER DOWN CONTROL
MEANING OF ALARM:
The X--axis has been selected for jog or handwheel before the machine is aligned. This alarm is posted to prevent an incorrect alignment on the X--axis.
Jogging axes away from chuck/part before alignment.
N/A
N/A
ALLOWABLE TIME:
Instant
Error posted -- power up inhibited.
1. Power down control. 2. Power back up control. 3. Align machine as normal.
Page 16-21
ALARM NUMBER 1013
ALARM MESSAGE:
OPERATOR PANEL I/O ERROR
MEANING OF ALARM:
A fault has occurred on the operator panel I/O.
1. Faulty operator panel.
N/A
X35 00000000
ALLOWABLE TIME:
Instant
Feedhold and spindle stop
1. Check wiring to operator panel I/O. 2. Replace operator panel.
Page 16-22
ALARM NUMBER 1014
ALARM MESSAGE:
REMOTE I/O MODULE ERROR
MEANING OF ALARM:
A fault has occurred on one of the remote I/O modules.
1. Faulty I/O module.
N/A
X19 00000000
ALLOWABLE TIME:
Instant
1. Check wiring to remote I/O modules. 2. Replace suspect remote I/O module.
Page 16-23
ALARM NUMBER 1015
ALARM MESSAGE:
DRIVEN TOOL SPINDLE ACC/DEC TIMOUT
MEANING OF ALARM:
An attempt was made to start the machine spindle or change the current spindle speed, but the spindle motor up to speed signal was not received within the specified time.
1. Faulty wiring. 2. Faulty spindle drive (sp2) unit.
For CW rotation:-For CCW rotation:--
G74.4 HIGH, G74.5 LOW G74.4 LOW, G74.5 HIGH
F45.3 HIGH
ALLOWABLE TIME:
20 seconds.
1. Depress reset to cancel the alarm. 2. Retry starting the spindle using M03/4 and S code in MDI. 3. If alarm persists power down machine and turn off main disconnect switch. 4. Open the electrical cabinet and check the general condition of wiring to and from the spindle drive and make sure all connections are secure. 5. If fault persists it will be necessary to obtain advice/assistance from Cincinnati Machine Service Department.
Page 16-24
ALARM NUMBER 1016
ALARM MESSAGE:
HYDRAULIC FILTER BLOCKED
MEANING OF ALARM:
The hydraulic filter is blocked.
1. Dirty hydraulic filter.
N/A
X4.4 LOW
ALLOWABLE TIME:
Instant
Feedhold
1. Power down control/machine (isolator off). 2. Refer to service manual for replacement of hydraulic filter.
Page 16-25
ALARM NUMBER 1017
ALARM MESSAGE:
MACHINE HYDRAULIC PRESS FAIL
MEANING OF ALARM:
The hydraulic pressure switch has detected a failure.
1. 2. 3. 4.
Low fluid level in hydraulic tank. Damaged hydraulic hose. Hydraulic pump failure. Defective or incorrectly adjusted hydraulic oil pressure switch. 5. Wiring problem.
N/A
X4.2 HIGH
ALLOWABLE TIME:
10 seconds
Feedhold/hydraulics off (E--Stop condition).
Check all of the above reasons for alarm -- correct as necessary. Machine power off (isolator off) to check wiring/hydraulic pump.
Page 16-26
ALARM NUMBER 1018
ALARM MESSAGE:
QUILL PRESSURE FAILURE
MEANING OF ALARM:
The quill pressure switch signal was lost with the quill advanced while in cycle.
1. Defective or incorrectly adjusted quill pressure switch. 2. Damaged hydraulic hose. 3. Wiring problem.
N/A
X4.3 LOW
ALLOWABLE TIME:
Instant
Check all of the above reasons for alarm -- correct as necessary. Machine power off (isolator off) to check wiring/hydraulic hoses.
Page 16-27
ALARM NUMBER 1019
ALARM MESSAGE:
TRANSFORMER OVERTEMP.
MEANING OF ALARM:
The main auto transformer is overheating.
1. 2. 3. 4.
Excessive loading of the machine. Incorrect supply voltage. Faulty transformer thermistor. Faulty machine wiring.
N/A
X4.1 HIGH
ALLOWABLE TIME:
Instant
Feedhold, spindle stop at the end of the current NC machine cycle.
1. Check that the current NC cycle is not overloading the machine. 2. Check that the incoming supply voltage to the machine is within specification. 3. Let the transformer cool down to see if the alarm can be reset. 4. If the fault is still present when the transformer has cooled down, then check the condition of the wiring and the function of the transformer thermistor.
Page 16-28
ALARM NUMBER 1020
ALARM MESSAGE:
CONVEYOR MOTOR OVERLOAD
MEANING OF ALARM:
The conveyor motor overload has tripped due to an overload condition.
1. 2. 3. 4.
Swarf conveyor jammed with excessive swarf. Defective swarf conveyor motor. Defective circuit breaker. Wiring problem.
N/A
X6.2 HIGH
ALLOWABLE TIME:
Instant
Feedhold.
Check all of the above reasons for alarm -- correct as necessary. Machine power off (isolator off) to check circuit breaker/wiring.
Page 16-29
ALARM NUMBER 1021
ALARM MESSAGE:
HYDRAULIC MOTOR OVERLOAD
MEANING OF ALARM:
The hydraulic motor circuit breaker has tripped due to an overload condition.
1. 2. 3. 4.
Excessive motor load due to high hydraulic pressure Defective hydraulic pump motor. Defective circuit breaker. Wiring problem.
N/A
X6.1 HIGH
ALLOWABLE TIME:
Instant
Hydraulics off -- feedhold (E--Stop condition)
Check all of the above reasons for alarm -- correct as necessary. Machine power off (isolator off) to check circuit breaker/wiring/pump--motor combination.
Page 16-30
ALARM NUMBER 1022
ALARM MESSAGE:
TURRET OVERLOAD
MEANING OF ALARM:
The electrical overload unit to protect the turret unit has tripped out.
1. Faulty overload wiring. 2. Faulty turret unit.
N/A
X6.7 HIGH
ALLOWABLE TIME:
Instant
Feedhold and Spindle stop.
1. Power down machine and turn main disconnect off . 2. Open electrical cabinet door and reset the Turret overload unit. 3. Close electrical cabinet and power up machine. 4. If the overload re--trips when a turret move is requested -- it will be necessary to check the wiring of the turret unit. -- refer to turret manual supplied with the machine. 5. If fault persists it will be necessary to obtain advice/assistance from Cincinnati Machine Service Department.
Page 16-31
ALARM NUMBER 1024
ALARM MESSAGE:
TURRET SYSTEM ERROR
MEANING OF ALARM:
The Turret Unit has issued a system error.
Faulty supply voltage to turret unit due to:-1. Faulty circuit breaker. 2. Faulty supply to circuit breaker.
N/A
X5.0, X5.1 and X5.2 all LOW
ALLOWABLE TIME:
Instant
Feedhold/spdl stop -- turret alignment is lost.
Check the following:-1. Turret circuit breaker operation. 2. Check supply to circuit breaker and turret. 3. Refer to turret maintenance manual supplied. 4. Power down/power back up machine -- if fault persists contact Cincinnati Machine Field service.
Page 16-32
ALARM NUMBER 1025
ALARM MESSAGE:
TURRET CONNECTION ERROR
MEANING OF ALARM:
The Turret Unit has issued an over voltage alert.
Faulty supply voltage to turret.
N/A
ALLOWABLE TIME:
Instant
Check the following:-1. Check supply voltage to turret. 2. Power down/power back up machine -- if fault persists contact Cincinnati Machine Field service.
Page 16-33
ALARM NUMBER 1026
ALARM MESSAGE:
TURRET UTILISATION ERROR
MEANING OF ALARM:
The Turret Unit has posted a utilisation error.
1. Over current. 2. Servo error. 3. Thermal detector in turret.
N/A
ALLOWABLE TIME:
Instant
1. Refer to turret maintenance supplied. 2. Power down machine -- power back up. If fault persists contact Cincinnati Machine Field Service.
Page 16-34
ALARM NUMBER 1027
ALARM MESSAGE:
TURRET UNLOCKING ERROR
MEANING OF ALARM:
The Turret Unit has posted an unlocking (unclamping) error.
1. 2. 3. 4.
Unlocking (unclamping) Switch fault. Unlocking (unclamping) Switch setting. Air supply fault. Wiring fault.
N/A
X5.0, X5.1 and X5.2 all LOW X5.3 LOW
ALLOWABLE TIME:
Instant
1. Check Air supply to unit -- pressure should be 5 Bar. 2. Refer to turret maintenance manual supplied. 3. Power down/power back up machine. If fault persists contact Cincinnati Machine Field Service.
Page 16-35
ALARM NUMBER 1028
ALARM MESSAGE:
TURRET LOCKING ERROR
MEANING OF ALARM:
The Turret Unit has posted a locking (clamping) error.
1. 2. 3. 4.
Locking (clamping) Switch fault. Locking (clamping) Switch setting. Air supply fault. Wiring fault.
N/A
X5.0, X5.1 and X5.2 all LOW X5.3 HIGH
ALLOWABLE TIME:
Instant
Page 16-36
ALARM NUMBER 1029
ALARM MESSAGE:
TURRET REFERENCE ERROR
MEANING OF ALARM:
The Turret Unit has posted a reference error.
1. 2. 3. 4.
Reference Switch fault. Reference Switch setting. Air supply fault. Wiring fault.
N/A
ALLOWABLE TIME:
Instant
Page 16-37
ALARM NUMBER 1030
ALARM MESSAGE:
TURRET INTERFACE ERROR
MEANING OF ALARM:
The Turret Unit has posted an interface error.
1. 2. 3. 4. 5.
Zero search (ref) missed. Position code error. Units servo timeout. PSTART signal timeout. Wiring problem.
N/A
ALLOWABLE TIME:
Instant
1. Check wiring of every signal to the unit. 2. Refer to turret maintenance manual supplied. 3. Power down/power back up machine. If fault persists contact Cincinnati Machine Field Service.
Page 16-38
ALARM NUMBER 1031
ALARM MESSAGE:
TURRET CRASH SWITCH ERROR
MEANING OF ALARM:
The turret has been knocked out of position causing an E-Stop condition.
1. Machine crash due to programming/operator fault.
N/A
X5.5 LOW
ALLOWABLE TIME:
Instant
Emergency Stop
Refer to service manual for a procedure of how to mechanically re--align the turret.
Page 16-39
ALARM NUMBER 1032
ALARM MESSAGE:
CHUCK IN UNGRIPPED CONDITION
MEANING OF ALARM:
The chuck jaws are in an ungripped condition, when in cycle or when a cycle start is attempted.
1. No component in chuck. 2. Chuck jaws not gripping component properly. 3. Cylinder switch fault.
N/A
X6.3 and X6.4 LOW
ALLOWABLE TIME:
Instant
Feedhold and spindle stop. Cycle start inhibited.
1. Press RESET key. 2. Check status of ID/OD Grip selection. 3. Using open/close chuck pushbuttons, check operation of chuck jaws. 4. Check operation of cylinder advance retract switches.
Page 16-40
ALARM NUMBER 1033
ALARM MESSAGE:
INITIALISE ID/OD GRIP
MEANING OF ALARM:
On power up ID or OD grip is not selected for the chuck.
See above.
N/A
N/A
ALLOWABLE TIME:
Instant
Feedhold.
1. Select ID or OD grip pushbutton.
Page 16-41
ALARM NUMBER 1034
ALARM MESSAGE:
TURRET AIR PRESSURE LOW
MEANING OF ALARM:
The main air supply to the machine went below the lower limit of 5 bar.
1. The air supply to the machine has been turned off either at the source of air supply or at the machine air regulator valve. 2. An air line on the machine has become disconnected or damaged.
N/A
X4.5 HIGH
ALLOWABLE TIME:
Instant
Feedhold and Spindle Stop
1. Reinstate air supply. 2., Depress RESET to cancel alarm. 3. Re--align Turret.
Page 16-42
ALARM NUMBER 1036
ALARM MESSAGE:
T WORD RANGE ERROR
MEANING OF ALARM:
A T word has been programmed which is greater than the number of Turret stations available.
1. Programming fault.
N/A
N/A
ALLOWABLE TIME:
Instant
Feedhold and Spindle Stop
1. Press RESET key. 2. Correct fault in part program. 3. Restart part program.
Page 16-43
ALARM NUMBER 1037
ALARM MESSAGE:
INITIALISE TAILSTOCK QUILL
MEANING OF ALARM:
An attempt has been made to cycle start with the quill either not fully advanced or not fully retracted.
1. Quill not advanced due to step advance being used in set up.
N/A
N/A
ALLOWABLE TIME:
Instant
Feedhold -- cycle start inhibited.
1. Press RESET key. 2. Advance or retract tailstock quill using pushbuttons. 3. Resume part program execution.
Page 16-44
ALARM NUMBER 1040
ALARM MESSAGE:
PARTS CATCHER ADVANCED TIMEOUT
MEANING OF ALARM:
The parts catcher has not advanced to its forward (collect) position in the available time.
1. Wiring fault. 2. Faulty solenoid. 3. Faulty advanced proximity switch.
Y8.7 HIGH
X7.0 HIGH X7.1 LOW X7.1 HIGH
(2 switch parts catcher) (1 switch parts catcher)
ALLOWABLE TIME:
8 seconds
Feedhold
1. Press RESET key. 2. Using the parts catcher advance and retract push buttons advance and retract the parts catcher and monitor the switch and solenoid states.
Page 16-45
ALARM NUMBER 1041
ALARM MESSAGE:
PARTS CATCHER RETRACTED TIMEOUT
MEANING OF ALARM:
The parts catcher has not retracted to its parked position in the available time.
1. Wiring fault. 2. Faulty solenoid. 3. Faulty retract proximity switch.
Y8.7 LOW
X7.0 LOW X7.1 HIGH
ALLOWABLE TIME:
8 seconds
Feedhold
1. Press RESET key. 2. Using the parts catcher advance and retract push buttons advance and retract the parts catcher and monitor the switch and solenoid states.
Page 16-46
ALARM NUMBER 1042
ALARM MESSAGE:
PARTS CATCHER NOT RETRACTED
MEANING OF ALARM:
An attempt has been made to move the Renishaw Tool Setting Arm (TSA) with the parts catcher not retracted.
1. Operator error
N/A
X7.1 HIGH
ALLOWABLE TIME:
Instant
Feedhold
1. Jog parts catcher to its parked position with pushbutton. 2. Proceed to move the TSA as required.
Page 16-47
ALARM NUMBER 1043
ALARM MESSAGE:
TOOL SETTING ARM NOT PARKED
MEANING OF ALARM:
An attempt has been made to move the parts catcher or start the spindle via M--codes with the Renishaw Tool Setting Arm (TSA) not parked.
1. Operator error
N/A
N/A
ALLOWABLE TIME:
Instant
Feedhold
1. Jog TSA to its parked position with the pushbutton. 2. Proceed to move parts catcher as required.
Page 16-48
ALARM NUMBER 1044
ALARM MESSAGE:
TOOL SETTING ARM ADVANCE TIMEOUT
MEANING OF ALARM:
The TSA has not advanced (to its active down position) within the allowable time.
1. Wiring fault. 2. Faulty TSA unit.
Y5.4 HIGH
X8.5 LOW X8.6 HIGH
ALLOWABLE TIME:
10 seconds
1. Press RESET key. 2. Using the pushbuttons advance and retract the TSA and monitor switch states. 3. Refer to TSA manual if fault persists.
Page 16-49
ALARM NUMBER 1045
ALARM MESSAGE:
TOOL SETTING ARM RETRACT TIMEOUT
MEANING OF ALARM:
The TSA has not retracted (to its parked -- stowed position) within the allowable time.
1. Wiring fault. 2. Faulty TSA unit.
Y5.4 LOW
X8.5 HIGH X8.6 LOW
ALLOWABLE TIME:
10 seconds
Feedhold and spindle
1. Press RESET key. 2. Using the pushbuttons advance and retract the TSA and monitor switch states. 3. Refer to TSA manual if fault persists.
Page 16-50
ALARM NUMBER 1047
ALARM MESSAGE:
NOT IN MDI MODE
MEANING OF ALARM:
An attempt has been made to program M74, M75, M90 or M91 M--codes in auto mode instead of MDI.
1. Operator error.
N/A
N/A
ALLOWABLE TIME:
Instant
Feedhold
1. Press RESET key. 2. Change mode to MDI and re--program M--codes.
Page 16-51
ALARM NUMBER 1048
ALARM MESSAGE:
BAR FEED ALARM
MEANING OF ALARM:
Multifeed unit -- out of bars. Hydrafeed and Feedmaster -- end of bar signal
1. Out of bars
N/A
Multifeed -- X7.5 LOW Hydrafeed and Feedmaster -- X7.2 LOW
ALLOWABLE TIME:
Instant
Feedhold
1. Press RESET key. 2. Reload bars to Barfeed unit. 3. Resume cycle.
Page 16-52
ALARM NUMBER 1049
ALARM MESSAGE:
BAR FEED NOT IN AUTO MODE
MEANING OF ALARM:
An attempt has been made to cycle start with the barfeed not in auto mode.
1. Barfeed unit not in automatic (auto) mode.
N/A
X7.3 HIGH
ALLOWABLE TIME:
Instant
Feedhold -- cycle start inhibited.
1. Press RESET key. 2. Place barfeed unit in auto mode. 3. Resume NC cycle as required.
Page 16-53
ALARM NUMBER 1050
ALARM MESSAGE:
PROBE OPEN
MEANING OF ALARM:
The probe open alarm is raised when the stylus is in contact with the surface before the skip move begins.
1. Probe error 2. Programming fault
ALLOWABLE TIME:
Instant
Feedhold
1. Return to reference and edit the part program. 2. If the stylus remains in an open (triggered) condition during any part of the cycle, the probe open alarm is raised. Check that the stylus is not in contact with the surface or check to see whether vibration is causing it to unseat during a move. 3. The alarm may also be raised at the start of a macro if the probe system is in error, (a probe open signal condition is forced by the Renishaw interface). 4. Check to make sure that the probe system is switched on in time before a skip move begins. A program dwell may be required. 5. Check that the status LED on the interface is changing state when the stylus is deflected. If this does not happen contact the supplier of the system for assistance.
Page 16-54
ALARM NUMBER 1051
ALARM MESSAGE:
PROBE FAIL
MEANING OF ALARM:
The alarm probe fail is raised when the expected surface is not contacted within the overtravel of the probe.
1. Probe fault 2. Programming fault
ALLOWABLE TIME:
Instant
Feedhold
1. Check the program and edit where necessary. 2. Check that the probe stylus has been calibrated on the machine. 3. Check that the status LED on the interface is changing state when the stylus is deflected. If this does not happen contact the supplier of the system for assistance.
Page 16-55
ALARM NUMBER 1052
ALARM MESSAGE:
ILLEGAL TOOL OFFSET NUMBER T
MEANING OF ALARM:
Tool offset T0 is not allowed. If using the T input on the cycle call line, check the value is not (0) zero, otherwise this alarm may occur if no tool or tool offset was selected in the MDI mode before running the cycle.
T0 programmed
ALLOWABLE TIME:
Instant
Feedhold
Caution: Make sure the turret is safely away from the probe stylus before indexing the turret. 1. Edit the program input value or select the tool in MDI before running the cycle again.
Page 16-56
ALARM NUMBER 1053
ALARM MESSAGE:
ILLEGAL TOOL NOSE VECTOR H
MEANING OF ALARM:
Only vector numbers 1 to 8 are allowed.
Programming fault.
ALLOWABLE TIME:
Instant
Feedhold
1. Check and correct the H input if used, or the T address on the tool offset page.
Page 16-57
ALARM NUMBER 1054
ALARM MESSAGE:
INPUTS C AND H1-H4 MIXED
MEANING OF ALARM:
It is not possible to set a cutter using the C input with a corner vector H1--H4 specified. Edit the program.
Programming fault.
ALLOWABLE TIME:
Instant
Feedhold
1. Edit/correct program.
Page 16-58
ALARM NUMBER 1055
ALARM MESSAGE:
BROKEN TOOL
MEANING OF ALARM:
This alarm is generated when the tool length error exceeds the programmed Mm tolerance. When the value is programmed it must be half the total tolerance (see examples).
Broken/damaged tool
ALLOWABLE TIME:
Instant
Feedhold
1. Replace broken/damaged tool
Page 16-59
ALARM NUMBER 1056
ALARM MESSAGE:
MINIMUM TAPPING SPEED 60 RPM
MEANING OF ALARM:
An attempt has been made to program a tapping speed greater than 60 rpm.
Programming fault.
N/A
N/A
ALLOWABLE TIME:
Instant
1. Press the reset key. 2. Correct fault in part program. 3. Restart the part program.
Page 16-60
ALARM NUMBER 1057
ALARM MESSAGE:
M44/M45 INHIBIT - CHUCK ROTATING
MEANING OF ALARM:
An attempt has been made to program an M44 -- TSA UP or an M45 -- TSA DOWN with the chuck rotating.
Programming fault.
N/A
N/A
ALLOWABLE TIME:
Instant
1. Press the reset key. 2. Correct fault in part program. 3. Restart the part program.
Page 16-61
ALARM NUMBER 1058
ALARM MESSAGE:
SPINDLE CONTOUR MODE (C AXIS) TIMEOUT
MEANING OF ALARM:
An attempt has been made to go into C AXIS mode (programming M51) but the acknowledgement signal has not been received within the allowable time.
1. Faulty wiring to spindle encoder 2. Faulty spindle drive -- SP1
G27.7 HIGH
F44.1 HIGH
ALLOWABLE TIME:
5 seconds
1. Depress RESET. 2. Attempt to program M51 again. 3. If alarm still persists power down machine and turn off main disconnect switch. 4. Open electrical cabinet door and check general condition of machine wiring to and from the spindle motor ancoder mounted in the back of the spindle motor. 5. To properly further diagnose any spindle drive fault it will be necessary to obtain advice/assistance from Cincinnati Machine Service Department.
Page 16-62
ALARM NUMBER 1059
ALARM MESSAGE:
DRIVEN TOOL SPINDLE DEC TO ZERO TIMEOUT
MEANING OF ALARM:
A spindle stop request was issued to the spindle drive -SP2 -- Driven Tool -- but the spindle zero speed input was not received within the prescribed time. Can also occur even if spindle is stationary as spindle zero speed status is assumed when the spindle is not in use.
1. Faulty wiring to spindle encoder 2. Faulty spindle drive -- SP2
G74.5 and G74.4 LOW
F49.1 HIGH
ALLOWABLE TIME:
12 seconds
1. Depress RESET to cancel alarm. 2. Retry stopping and starting driven tool spindle in MDI mode. 3. If the alarm still persists power down machine and turn the main disconnect switch off. 4. Open electrical cabinet and check the general condition of wiring to and from the spindle drive -- SP2 --and make sure all connections are secure. 5. If fault still persists it will be necessary to obtain advice/ assistance from Cincinnati Machine Service Department.
Page 16-63
ALARM NUMBER 1060
ALARM MESSAGE:
SP1 OR SP2 NOT STATIONARY
MEANING OF ALARM:
An attempt has been made to program an M51 -- C Axis mode ON or an M50 -- C axis mode OFF -- with either the chuck or driven tool spindle rotating.
1. Programming fault
G70.5, G70.4, G74.4 and G74.5 LOW
F 45.1 and F49.1 HIGH
ALLOWABLE TIME:
Instant
1. Press the RESET key. 2. Correct fault in part program. 3. Restart the part program.
Page 16-64
ALARM NUMBER 1061
ALARM MESSAGE:
M78/M79 INHIBIT - CHUCK ROTATING
MEANING OF ALARM:
An attempt has been made to program an M78 -- Release Chuck Jaws or an M79 -- Grip Chuck Jaws, with the chuck rotating.
1. Programming fault
N/A
N/A
ALLOWABLE TIME:
Instant
1. Press the RESET key. 2. Correct fault in part program. 3. Restart the part program.
Page 16-65
ALARM NUMBER 1062
ALARM MESSAGE:
UNEXPECTED HIT
MEANING OF ALARM:
The Toolsitting Arm stylus (either TSA or HPA) has been triggered while not in a probing cycle.
1. Programming fault 2. Setup problem.
N/A
X4.7 LOW
ALLOWABLE TIME:
Instant
1. 2. 3. 4.
Press the RESET key. Jog the axes away from the stylus. Correct fault in part program/setup. It may be necessary to reset the alignment of the stylus.
5. Restart the part program.
Page 16-66
ALARM NUMBER 1063
ALARM MESSAGE:
TURRET ALIGN FAILURE
MEANING OF ALARM:
The turret has failed to align with the specified time.
See ALARM RECOVERY PROCEDURE below.
N/A
X5.3 and X5.4 HIGH
ALLOWABLE TIME:
10 seconds
1. Power down machine, power back up and attempt to align the turret again. 2. If fault persists power down the machine and turn the main disconnect switch off. 3. Check all wiring to turret -- refer to electrical schematics. 4. If fault still persists it will be necessary to obtain advice/ assistance from Cincinnati Machine Service Department.
Page 16-67
ALARM NUMBER 1064
ALARM MESSAGE:
TURRET POSITIONING FAILURE
MEANING OF ALARM:
The turret has failed to move within the specified time.
See ALARM RECOVERY PROCEDURE below.
N/A
X5.3 and X5.4 HIGH after turret move
ALLOWABLE TIME:
10 seconds
1. Power down machine, power back up and attempt to move the turret again. 2. If fault persists power down the machine and turn the main disconnect switch off. 3. Check all electrical wiring to the turret. Fault can occur if there is a wiring fault with the turret Mode01, Mode02 or Mode03 Outputs -- refer to electrical schemes and turret manual supplied with this machine. 4. If fault still persists it will be necessary to obtain advice/ assistance from Cincinnati Machine Service Department.
Page 16-68
ALARM NUMBER 1065
ALARM MESSAGE:
OPEN / CLOSE OPERATOR DOOR
MEANING OF ALARM:
After a part program has been completed it is necessary to open and close the operator door before the program can be run again.
Operator door has not been opened / closed after the end of program.
N/A
N/A
ALLOWABLE TIME:
Instant
1. Press RESET key to clear alarm. 2. Open and then close the operator door. 3. Cycle start will take the machine back into cycle.
Page 16-69
ALARM NUMBER 1066
ALARM MESSAGE:
SERVO AXIS ABNORMAL LOAD DETECTION
MEANING OF ALARM:
The axis load detection feature has determined an excessive axis load.
1. Excessive cut.
N/A
F90.0 LOW
ALLOWABLE TIME:
Instant
Emergency Stop of axes and spindle.
1. Re--apply power to axes drives. 2. Re--align machine if necessary. 3. Examine part program and workpiece with a view to reducing depth of cut.
Page 16-70
ALARM NUMBER 1067
ALARM MESSAGE:
HPA PROTECTIVE COVER NOT FITTED
MEANING OF ALARM:
An attempt has been made to either:-1. Align the machine. 2. Rotate the chuck via spindle start M--Codes. 3. Jog the chuck with the JOG keys. 4. Move the parts catcher, if one is fitted, by push buttons or M--Codes.
1. HPA protective cover not in place. 2. Wiring fault.
N/A
X9.5 and X9.6 HIGH
ALLOWABLE TIME:
Instant
1. Press RESET to clear alarm. 2. Fit the protective cover and lock the lever by turning it clockwise. 3. If fault still persists, power down the machine and turn off at the main disconnect switch. 4. Open the electrical cabinet and check the general condition of wiring to and from the HPA probe assembly.
Page 16-71
ALARM NUMBER 1068
ALARM MESSAGE:
HPA LEVER NOT IN LOCKED POSITION
MEANING OF ALARM:
An attempt has been made to either:-1. Go into NC cycle -- via Cycle Start push button. 2. Jog the turret via the Turret Jog push buttons With the HPA lever not in its locked position.
1. Lever not in locked position 2. Wiring fault.
N/A
X9.5 HIGH
ALLOWABLE TIME:
Instant
1. Press RESET to clear alarm. 2. Lock the lever by turning it clockwise. 3. If fault still persists, power down the machine and turn off at the main disconnect switch. 4. Open the electrical cabinet and check the general condition of wiring to and from the HPA probe assembly.
Page 16-72
Operator Messages
Operator messages are displayed in response to various illegal commands or to indicate that the machine is waiting for operator intervention. These messages do not cause the control to enter the alarm status, and are mainly automatically cleared when the condition causing the message has been removed. 1000 HR SERVICE -- LUBE 2 HAND CONTROL -- USE AUX 1 PUSHBUTTON ALIGN AXES FIRST ALIGN TURRET CHUCK ROTATING DRIVEN TOOL SPINDLE NOT ORIENTATED PRESS HOME PB TO ORIENTATE SPINDLE AND REFERENCE TURRET DRIVEN TOOL SPINDLE ROTATING DRY RUN ACTIVE REPRESS FUNCTION NOT SUPPORTED HPA FITTED -- RETRACT Z TO HIGH LIMIT TO MOVE TURRET MACHINE NOT ALIGNED NOT IN AUTO OR MDI MODE OPEN OPERATOR DOOR FIRST OPERATOR DOOR NOT CLOSED PARTS COUNT = PRESET PRESS HOME PB TO ALIGN TURRET PROGRAM STOP M00 OR M01 RESTART SPINDLE FIRST SPINDLE OVERLOAD TURRET NOT ALIGNED USE CCW KEY TO RESTART USE CW KEY TO RESTART USE MPG HANDWHEEL X1 MACHINE UNALIGNED X AND Z REF SW TO ALIGN TURRET
Page 16-73
MESSAGE:
1000 HOUR SERVICE REQUEST - LUBRICATE AXES WAYS
REASONS FOR MESSAGE DISPLAY:
This message is displayed every 1000 hours that the machine power is on. It is a reminder to the operator to carry out routine machine maintenance, i.e. to relubricate the machine axes ways.
MESSAGE SELF CANCELLING:
No
TYPICAL OPERATOR REACTION TO MESSAGE:
Lubricate the machine axes ways by referring to the service manual as supplied with the machine. Depress the RESET pushbutton to clear message display.
MESSAGE:
2 HAND CONTROL - USE AUX 1 PUSHBUTTON
An attempt has been made to jog the turret without pressing the AUX 1 pushbutton.
Yes
Press the AUX 1 pushbutton in conjunction with the appropriate Turret Jog pushbutton.
Page 16-74
MESSAGE:
ALIGN AXES FIRST
An attempt was made to jog a mechanism before the machine axes were aligned.
Yes
Align machine axes.
MESSAGE:
ALIGN TURRET
An attempt was made to cycle start without first aligning the turret.
No
Align turret with home pushbutton key.
Page 16-75
MESSAGE:
CHUCK ROTATING
An attempt was made to jog the Renishaw TSA up or down via pushbuttons with the chuck rotating.
Yes
Stop the chuck rotation before attempting to move the TSA.
MESSAGE:
DRIVEN TOOL SPINDLE NOT ORIENTATED - PRESS HOME PB TO ORIENTATE SPINDLE AND REFERENCE TURRET
After successful axis align this message is displayed.
Yes
Pressing the Home pushbutton will orientate the driven tool spindle and then position the turret to station 1.
Page 16-76
MESSAGE:
DRIVEN TOOL SPINDLE ROTATING
An attempt was made to jog the turret with the driven tool spindle rotating.
Yes
Stop the driven tool spindle before attempting to jog the turret.
MESSAGE:
DRY RUN ACTIVE REPRESS
An attempt was made to restart the machine cycle in DRY RUN mode. For safety reasons the first press of the CYCLE START pushbutton in DRY RUN mode only displays the DRY RUN ACTIVE REPRESS message. Machine cycle is then started on the next press of the CYCLE START.
No
Acknowledge that DRY RUN is active and required then repress CYCLE START pushbutton.
Page 16-77
MESSAGE:
FUNCTION NOT SUPPORTED
An attempt was made to use a control function that is either not supported or has not been installed.
Yes
None
MESSAGE:
HPA FITTED - RETRACT Z TO HIGH LIMIT TO MOVE TURRET
An attempt was made to jog the turret with the HPA fitted and the Z axis not at its high limit.
No
Jog Z axis to high limit to allow turret movement.
Page 16-78
MESSAGE:
MACHINE NOT ALIGNED
An attempt was made to cycle start with either the axes not aligned or the turret not aligned.
No
Align axes and/or turret
MESSAGE:
NOT IN AUTO OR MDI MODE
An attempt was made to start the machine cycle while not in either AUTO or MDI mode.
Yes
Select AUTO or MDI mode
Page 16-79
MESSAGE:
OPEN OPERATOR DOOR FIRST
An attempt was made to: a) Open the chuck jaws. b) Close the chuck jaws. c) Retract the tailstock quill with the operator door closed.
Yes
Open operator door.
MESSAGE:
OPERATOR DOOR NOT CLOSED
An attempt was made to:-a) Restart the spindle. b) Jog the spindle. c) Jog the parts catcher. d) Align the axes without the operator access doors being fully closed.
Yes
Check that the operator access doors are fully closed and reattempt operation.
Page 16-80
MESSAGE:
PARTS COUNT = PRESET
The optional parts counter facility is indicating that the PART COUNT is equal to the preset PARTS REQUIRED value.
No
1. 2.
Depress RESET to cancel message and then reset the PART COUNT to zero. Reset quantity of parts required to new batch size if necessary or disable parts counter by setting quantity of parts required to zero.
MESSAGE:
PRESS HOME PB TO ALIGN TURRET
After successful axis align this message is displayed.
Yes -- after turret has aligned
Press HOME pushbutton to align turret
Page 16-81
MESSAGE:
PROGRAM STOP M00 or M0I
1. 2.
An M00 program stop code was encountered. An M01 optional stop code was encountered while the optional stop feature was enabled.
No
1.
2.
Open operator door to perform action required during program stop; inspection of part, removal of excess swarf etc. Depress CYCLE START to restart the machine cycle and cancel the PROGRAM STOP message. Note: Coolant and spindle are automatically restarted if previously active.
MESSAGE:
RESTART SPINDLE FIRST
An attempt was made to restart the machine cycle without first restarting the spindle. Spindle rotation had previously been stopped using the SPDL STOP pushbutton.
Yes
Restart the machine spindle using either the SPDL CW or SPDL CCW pushbutton depending on the spindle direction which was previously active.
Page 16-82
MESSAGE:
SPINDLE OVERLOAD
The spindle drive load limit signal was received from the spindle drive unit. No
Note: In the event of a SPINDLE OVERLOAD the machine enters a FEEDHOLD condition but the spindle is not stopped. To recover from this condition adopt the following procedure: 1. Turn the feedrate override selector to 10%. 2. Depress CYCLE START. This cancels the SPINDLE OVERLOAD message and restarts the machine cycle. 3. Increase the feedrate override but to a rate lower than that likely to retrip the spindle drive load limit. 4. Finally edit the part program feedrates to prevent recurrences of SPINDLE OVERLOAD on subsequent cycles.
MESSAGE:
TURRET NOT ALIGNED
An attempt was made to start NC cycle with the turret not aligned.
No
Align turret.
Page 16-83
MESSAGE:
USE CCW KEY TO RESTART
An attempt was made to restart the machine spindle using the SPDL CW pushbutton when previously the spindle had been stopped via the SPDL STOP pushbutton while rotating in the counter clockwise direction.
Yes
Depress the SPDL CCW pushbutton to restart the machine spindle.
MESSAGE:
USE CW KEY TO RESTART
An attempt was made to restart the machine spindle using the SPDL CCW pushbutton when previously the spindle had been stopped via the SPDL STOP pushbutton while rotating in the clockwise direction.
Yes
Depress the SPDL CW pushbutton to restart the machine spindle.
Page 16-84
MESSAGE:
USE MPG HANDWHEEL X1 MACHINE UNALIGNED
An attempt has been made to jog or handwheel the axes (with X10 or X100 increments) before the axes/machine are aligned.
Yes
Select X1 handwheel increment and move axes if desired.
MESSAGE:
X AND Z REF SW TO ALIGN TURRET
An attempt was made to align the turret with the X and Z axes not in their reference switches.
No
Jog X and Z axes to their positive limits.
Page 16-85
Index
A
Alarm Messages, 16--7 Auto Tool Setting -- Macro O9012 -- TSA Only, 11--15 Auto Tool Setting -- TSA only, 11--3 Axis, orientation, 2--6 axis, overtravel, 1--25
D
Diagnostics, 16--1 Disconnect Switch, 3--16 Driven Tool Machines, 8--1, 9--1
E
Electrical, Isolation Device, 1--24 EMC Directive Requirements, 2--4 Emergency Stop, Push Button, 1--24 Eyebolts, 1--7 Inch, 1--7 Metric, 1--8
B
Barfeed Spindle Rotation Speed Bits -- Keep Relay K Bits, 13--4 Barfeeder, 13--1 Bar Preparation, 13--1 M--Codes, 13--1 Standard Barfeed Sequence for Hydrafeed and Feedmaster, 13--3 Standard Barfeed Sequence for Multifeed Unit, 13--2 Batteries, Lithium, 1--27 Battery Replacement, 1--27
F
FANUC Operator Station, 16--5 Diagnostic Address Table, 16--6 FANUC Operators Panel Connection Signals, 16--4 Feed Hold, Push Button, 1--24 Fire, hazard, 2--4 Force Turret CW and CCW, 9--2 Fumes, 2--4 Function Description of M Codes, 7--2
C
Cable Slings, 1--12 Calibration, 11--9 Manual Calibration -- Macro O9011, 11--9 Carrying & Lifting Safety, 1--3 Centrifugal Force & Speed Limits for Chucks, 3--20 Chain, Lifting, 1--10 Chuck Centrifugal Force Limits, 3--20 Lubrication, 3--20 Safety, 3--19 Speed Limits, 3--20 Top Jaw Recommendations, 3--21 Types, 3--20 chuck operation, 1--25 safety, 1--25 Chuck Drawbar Force Control, 3--15 Chucks, 3--20 Control, 2--5 Controls, 3--1 Conveyor, 3--17 Conveyor, Controls, 3--17 Coolant, misting, 2--4
G
G codes, 6--1 GE FANUC 21i--TA CNC System, 3--1 General Chuck Safety, 3--19 Lifting, 1--7 Safety Instructions, 1--2 Guard, strength, 2--2 Guarding, Perimeter, 1--23
H
Hardware Axis Overtravel, 5--1 Hoist Ring, 1--9 Hooks P Type, 1--14 S Type, 1--14 U Type, 1--16 HPA -- Manual Toolsetting Arm, 11--4
Cincinnati Machine 91203597A001
Index
I
Input/Output Device and Code Number, 15--2 Input/Output Devices, 15--1 Install, Relocate Safety, 1--4 Interlock, Operator Sliding Door, 1--23 Isolation Device, Electrical, 1--24 Maintenance Safety, 1--5 Manual Calibration -- Macro O9011, 11--9 Manual Tool Setting, 11--2 Manual Tool Setting -- Macro O9011, 11--11 Material Safety Data Sheet, 1--6 Used with this Product, 1--6 Metric Lifting Points, Lifting Points -- Metric, 1--24 MSDS Material Safety Data Sheet, 1--6 MTB Operators control panel, 3--11
L
Lifting Beam & Spreader Bars, 1--10 Devices, 1--7 Information Safety, 1--17 Safety, 1--3 Limits Chucks, 3--20 Lithium Batteries, 1--27 Lubrication, Chucks, 3--20
N
Noise, 2--3 Nylon Slings, 1--13
O
Operating Devices, Optional, 3--17 Operation, Setup Safety, 1--4 Operator, Sliding Door, 1--23 Operator Messages, 16--73 Operator panel, Pushbutton decriptions, 3--2 Optional Operating Devices, 3--17
M
M Codes, Function Description, 7--2 M codes , 7--1 M44 TSA Up, 11--3 M45 TSA Down, 11--3 Machine Alignments & Program Points, 2--27 information, 2--1, 2--5 location, 2--4 Zero, 2--27 machine, orientation, 2--6 Machine Alignment & Program Points, 2--27 Machine Pressure -- Tailstock Thrust -- Chuck Drawbar Force Control, 3--15 Machine Start Up and Alignment Procedure, 4--1 Machine/Control Alignment Procedure, 4--2 Macro Parameters, 11--6 Macro Probing Routines, 11--2 M44 TSA Down, 11--3 M44 TSA Up, 11--3 Manual Tool Setting, 11--2 Operator and Programming Notes, 11--3 Tool Setting Arm Activation, 11--3 Macro Routines, 14--1 Macro Variables, 14--1 Main Power Disconnect Switch, 3--16
P
P Type Hooks, 1--14 Parts Catcher, 12--1 M34 Parts Catcher Advance, 12--1 M35 Parts Catcher Retract, 12--1 Operator and Programming Notes, 12--2 Perimeter, Guarding, 1--23 Personal Safety, 1--2 PMC Input Address Reference List, 16--2 PMC Output Address Reference List, 16--3 Precautions Safety, 1--1 Preferred Metric Lifting Eyebolts, 1--8 Printed circuit boards, handling, 1--22 Program, Points, 2--27 Pushbutton descriptions Automatic operation--programme source, 3--3 Axis/direction selection, 3--7 Coolant buttons, 3--9 Execution pushbuttons, 3--3
ii
Index
Miscellaneous controls, 3--10 Operation buttons, 3--5 Operation select, 3--6 Operator panel, 3--2 Spindle control buttons, 3--4 Specification, 2--7 Spindle Functions, 8--1 Spindle Jog, 8--2 Spindle Load Meter, 3--11 Spreader Bars & Lifting Beams, 1--10 Start Up and Alignment Procedure, 4--1 Start Up and Shut Down Procedures, 4--1 Stylus Alignment, 11--5 Adjusting the Software Back Off Distance, 11--6 Control Options, 11--5 Standard Calibration Data -- Base Number 522, 11--5 Stylus Position, 11--5 Swarf Conveyor, Controls, 3--17 System, information, 2--1
R
Range, drawings, 2--9 Relocation & Installation Safety, 1--4 Ring Hoist, 1--9 Rope Wire, 1--12
S
S Hooks, 1--14 Safety Cable Slings, 1--12 Chain, 1--10 Chuck Guidelines, 3--19 Features, 1--23 General Instructions & Considerations, 1--2 Hoist Ring, 1--9 Installation & Relocation, 1--4 Lifting & Carrying, 1--3 Lifting Information, 1--17 Maintenance, 1--5 Material Safety Data Sheet, 1--6 Nylon Slings, 1--13 P Type Hooks, 1--14 Personal, 1--2 Precautions, 1--1 S Hooks, 1--14 Setup & Operation, 1--4 Spreader Bars & Lifting Beams, 1--10 Tool, 1--3 U Hooks, 1--16 Wire Rope, 1--12 Work Area, 1--2 safety, chuck, 1--25 Safety And Usage Notes, 1--25 Setup, Operation Safety, 1--4 Sling Load Angle Chart, 1--13 Slings Cable, 1--12 Nylon, 1--13 Software and Hardware Axis Overtravel, 5--1 Software Axis Overtravel, 5--1 Software range, Cancel checking, 5--1
T
T Word, 9--2 Tailstock Thrust -- Chuck Drawbar Force Control, 3--15 Tool, Safety, 1--3 Tool Life Management, 9--2 Tool Nose Vector Hh, 11--8 Tool Setting Arm Activation, 11--3 Tool Turret, 9--1 Tooling Functions, 9--1 Toolsetter, 11--1 Top Jaw Chuck, 3--21 TSA/HPA Calibration, 11--4 Turret Alignment, 4--2 Turret Indexes, 9--1
U
U Type Hooks, 1--16
W
Wash Gun, 3--18 Wire Rope, 1--12 Work Area Safety, 1--2 workholding device, 1--25
Z
Z Axis, Machine Zero, 2--27
iii
Index
Zero, Machine, 2--27
iv

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OPERATING/PROGRAMMING SUPPLEMENT

DANGER HIGH VOLTAGE

Chapter 2 System Information . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 Functional Description of Controls . . . . . . . . . .

Chapter 4 Machine Start Up and Alignment Procedure . .

Chapter 5 Software and Hardware Axis Overtravel . . . . . .

Chapter 8 Spindle Functions . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 9 Tooling Functions . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 10 Driven Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Chapter 11 Toolsetter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Chapter 12 Parts Catcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Chapter 13 Barfeeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Chapter 14 Reserved Macro Routines . . . . . . . . . . . . . . . . . . 14-1

Chapter 15 Connection to Data Input/Output Devices . . . . 15-1

Chapter 16 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Chapter 1 Safety Precautions

Cincinnati Machine 91203597B001

General Safety Instructions And Considerations

Cincinnati Machine 91203597B001

WARNING 1 CUTTING TOOLS

Cincinnati Machine 91203597B001

Installation And Relocation Safety

Cincinnati Machine 91203597B001

Cincinnati Machine 91203597B001

Cincinnati Machine 91203597B001

THREAD SAFE WORKING LOAD 90 DEGREES 60 DEGREES 30 DEGREES

.500- 13 LBS. [KG]

1000 [453] 375 [170] 200 [90] 3449

1840 [834] 805 [365] 470 [213] 870

2940 [1333] 1340 [607] 805 [365] 21312

7880 [3573] 3670 [1664] 2390 [1083] 19489

PART NUMBER IDENTIFICATION PLATE NUMBER

STRAIGHT SHANK INCH

Fig. 1 Preferred Inch Lifting Eyebolts

Cincinnati Machine 91203597B001

SAFE WORKING LOAD 90 DEGREES 45 DEGREES

PART NUMBER IDENTIFICATION PLATE NUMBER

Fig. 2 Preferred Metric Lifting Eyebolts

5 MAX. NO LOAD LOAD YES

ISO METRIC M12

Fig. 3 Eyebolt Loading

Fig. 4 Eyebolt I.D. Plates - Inch and Metric

.12 .12 TYP.

1.4 THRU-4 3 TYP. PLACES

Fig. 5 Instruction Plate - Inch (Part Number 3375984)

Fig. 6 Instruction Plate - Metric (Part Number 3375983)

Cincinnati Machine 91203597B001

Observe all other safety precautions normally practiced on eyebolts.

CM HOIST RING PART NO.

CM IDENT. PLATE PART. NO.

3346225 3346225 3346225 3346225 3346225 3346225 3346225 3346225

.375- 16 .500- 13 .625- 11 1.000-8 M12X1.75 M16X2 M20X2.5 M30X3.5

12.0 28.0 60.0 230.0 27.0 59.0 100.0 229.0

CM HOIST RING PART NO.

3346225 3346225 3346225 3346225 3346225 3346225 3346225 3346225

.375- 16 .500- 13 .625- 11 1.000-8 M12X1.75 M16X2 M20X2.5 M30X3.5

12.0 28.0 60.0 230.0 27.0 59.0 100.0 229.0

Fig. 8 Hoist Ring Table

NOTE F=FORCE W=WEIGHT

Cincinnati Machine 91203597B001

SPREADER BARS AND LIFTING BEAMS

TO LOAD Fig. 9 Spreader Bar - Typical