Mgma-015 6 (1-2)

11 MAINTENANCE
MANUAL 11
GM63/90Il MUL TI WHEEL GRINDER

1/2
1mut!1TOYODA MACHINE WORKS, LTD.1999
Read the operation manual and become fully familiar with its contents before operating this machine.
Store this operation manual at a location set aside for it so that it can be accessed immediately whenever necess~ry.
Handing Over the Machine

Strictly observe the following points when the machine is handed over:
80th this manual and the other accompanying documents must be handed over to the new owner.
Refer to the chapter on "Warning labels" and check all the warning labels.
If any warning label or manual is missing, contact Toyoda Machine Works, Ltd.
Contact the Toyoda Machine Works, Ud. when the machine is handed overo
This machine may be classified as "strategic goods" under the Foreign Exchange and Foreign
Trade Control Act.
In order to export this machine from Japan, permission must be obtained in compliance with this
Act.
This machine has been manufactured to be in compliance with laws, standards, and regulations,
and standards of the country or region where it is used.
Accordingly, it cannot be exported to a country or region with different laws, standards, and
regulations.
Guarantee
Cost-free Repairs
Faults and failures that occur while the machine is being used under normal conditions of use in compliance with the handling criteria (listed in the operation manual), and the operation manuals, affixed
labels, etc., are repaired free of cost within the term ofthe guarantee.
The coverage of the guarantee is limited to repairs to the delivered machine body only. Other damage
caused directly or indirectly is not covered by the guarantee.
The term of the guarantee is one year, commencing at delivery and acceptance.
Chargeable Repairs
1)
2)
3)
4)
5)
Repairs done afier the term of the guarantee, and those done within the term of the guarantee under the
fOllowing conditions, are chargeable.
Failure and damage due to misuse by the client, or due to modifications or repairs undertaken without
the approval of Toyoda Machine Works, Ud.
Failure and damage caused by unpredictable events such as fire, acts of God; lightning, abnormal
voltages, and so on.
Failure and damage arising from toppling ofthe machine during transportation or shifiing ofthe machine by the client, or due to inappropriate handling.
Failure and damage caused by not complying with the handling criteria.
Wear and tear, abrasion, and deterioration of consumable parts in normal use.
About the Manual

This operation manual is subject to change without notice due to our policy of continually improving the
machine and the operation manual. This can lead to sorne discrepancies between the manual and the
machine: please bear this in mind.
Where there is a difference between the machine and the text of the operation manual, or if the meaning of any part of the text is unclear, please contact Toyoda Machine Works, Ud.
Reproduction of this operation manual in whole or in part without prior consent is prohibited.
Preface
[Maintenance Manual]
Maintenance Manual
This manual explains matters relating to the maintenance
and preventive maintenance ofthe GM6311. It also provides
necessary guidance about methods of inspection (daily
inspections and other regular interval inspections),
diagnostic procedures when a fault occurs, part replacement
procedures, adjustment procedures, and maintenance and
preventive maintenance.
Other Manuals
[Operation Manual]
Operation Manual
This manual explains the basic method of operation of
GM6311 and explains its functions. This manual is used to
find out an operation, and when you are unsure how to
proceed during the course of an operation.
[Installation & Specification Manual]

Installation & Specification Manual
This manual explains the specifications of the machine
delivered to the client. It includes details of the configuration
of the machine and a list of consumable parts.
In addition, electric circuit diagrams and a special accessory
operation manual are appended.
Note that discrepancies between the contents of this manual

and the actual machine delivered to you may arise due to
our policy of continual improvement.
If you have been supplied with a manual for a machine made
to your specifications, the information given in that- manual
has precedence over the information in this manual.
This manual may not be reproduced by any means, in whole
or in part, without permission.
If the machine is so Id or transferred to another location, it
must be accompanied by this manual and any other manuals that were supplied with it.
MS-DOS and Windows are trademarks of Microsoft Corp., USA.
lilnlllM
HOW TO READ THIS MANUAL
a)
GM6311
Representation of Safety Caution Marks

This manual contains the following indications to enable you to use the machine safely,
and in order to prevent hazards to personnel and damage to property.
& DANGER
I&WARNINGI
1& CAUTIONI
Failure to observe items in this category will result in death or severe

injury.
Failure to observe items in this category can lead to death or severe injury.
Failure to observe items in this category can lead to injuries or property

damage.
In addition to the above. the following indications are also used in this manual.
IMPORTANT This is an item that requires attention during machine operation or

otherwork.
Failure to observe such items can lead to damage to the machine.
NOTE
This is information for reference during machine operation and other work.
1 leiT,I] .J!I
HOW TO READ THIS MANUAL
b)
GM6311
Representation of Switches and Lamps

Pushbuttons, sWitches, le.vers, and lamps are indicated in the following way in this manual.
Device
Selection Switch
SINGLE BLOCK
ON
[SJ
RAPID FEED OVERRlDE (%)
10
100
[2]
Pushbutton Switch
[
Representation in Text
lIIustration
EMERGENCY STOP
START
Example: Place the [SINGLE BLOCK] selection switch in

the rON] position.
Indicates that the [SINGLE BLOCK] switch is to
. be set to the rON] position.
Example: Place the [RAPID FEED OVERRIDE] selection
switch in the [100%] position.
Indicates that the [RAPID FEED OVERRIDE]
selector switch is to be set to the 100%
position.
Example: Turn the [EMERGENCY STOP] pushbutton

switch clockwise to release the lock.
]
Example: Press the [START] pushbutton switch.
Example: Press the [ACTIVATE] pushbutton switch.
ACTIVATE
Lamp
NCRESET
MASTERON
STARTWHEEL
SPINDLE
GENERAL ERROR
8
Circuit Breaker
Example: Press the [NC RESET] pushbutton switch.

Some pushbutton switch es have covers to
prevent their operation by mistake. The cover
is indicated by a dotted-Iine frame.
.
Example: The lamp in the [MASTER ON] pushbutton

switch lights.
Hatching inside the trame of a lamp iIIustration
indicates that the lamp is lit.
Example: Press the [START WHEEL SPINDLE]
pushbutton switch.
The lamp in the [START WHEEL SPINDLE]
pushbutton switch f1ashes, then Iights
continuously when the wheel spindle has
started.
Example: The [GENERAL ERROR] lamp goes out.
Example: Set the main power breaker to the rON]

position.
Example: Set the main power breaker to the [OFF]
position.
..
"
INDEX
1.
SAFETY CAUTIONS
1.1
1.2
1.3
Cautions Relating to Maintenance and Preventive Maintenance ............................................. 1

1.1.1
General...................................................................................................................... 1
1.1.2
When Switching the Power ON and OFF ................................................................... 1
1.1.3
In Manual Operation .................................................................................................. 3
1.1.4
Ouring Wheel Changing Work ............................... ,................................................... 4
1.1.6.
Installation ..... ;........................................................................................................... 4
1.1.5
When Remedying Trouble .......................................................................................... 4
Areas of Potential Oanger ........................................................................................................ 5

1.2.1
High-voltage Locations ............................................................................................... 5
1.2.2
Wheel and Workpiece Orive Sections, Rotary Section Of the Truing RolI ..... ,............ 5
1.2.3
Axis Motion Ranges .................................................................................................. 6
Protective Functions ............................................................................................................... 7

1.3.1
1.4
Labels ..................................................................................................................................... 9
1.4.1
1.5
2.
3.
. 4.
5.
....
Types, Functions, and Positions of Interlocks for Protective Functions ...................... 7

Types and Fixing Locations of Warning Labels .......................................................... 9
Related Laws, Regulations, and Standards ........................................................................... 11
DAILY INSPECTION
2.1
Inspection before Pressing the [MASTER ON] Butlon ............................................................ 1 _
2.2
Inspection after Pressing the [MASTER ON] Butlon ............................................................... 9
2.3
Inspection after Starting the Wheel Spindle .......................................................................... 24
REGULAR INSPECTION
3.1
Monthly Inspection .................................................................................................................. 1
3.2
Every 3-month Inspection ........................................................................................................ 1
3.3
Every 6-month Inspection ........................................................................................................ 4
3.4
Every 1-year Inspection ........................................................................................................ 30
P.ARTS REPLACEMENT IN REGULAR INTERVALS

4.1
Every Six Months ................................................................................................................... 1 .
4.2
Every Year .............................................................................................................................. 1
4.3
Every Two Years ..................................................................................................................... 3
4.4
Every Five Years ......................................................................................,.............................. 7
4.5
Parts Replacement in Intervals of Specified Operating Hours .................................................. 9
TROUBLESHOOTING
5.1
Precautions on Troubleshooting .............................................................................................. 1
5.2
Basics of Error Processing ..................................................................................................... 2
5.3
Trouble Report Fon:n ............................................................................................................... 3
Il-n-JI"
5.4
5.5
5.6
Afier the Occurrence of Error ................................... ,.............................................................. 4

5.4.1
Displaying Error Information ....................................................................................... 4
5.4.2
Kinds of Error Display and Description of Alarm Codes ............................................. 7
5.4.3
Resetting the Error .....................................................................,.............................. 10
Diagnosis and Corrective Action ........................................................................................... 15

5.5.1
Diagnosis and CorrectiveAc"tion -AlarmA ............................................................... 16
5.5.2
Diagnosis and Corrective Action - Alarm B ........................., .................................... 97
5.5.3
Diagnosis and Corrective Action - Alarm C ............................................................. 117
5.5.4
Diagnosis and Corrective Action - Alarm D ............................................................. 120
5.5.5
Diagnosis and Corrective Action - Alarm E ............................................................. 121
5.5.6
Diagnosis and Corrective Action - Alarm F .............................................................. 205
5.5.7
Diagnosis and CorrectiveAction -Alarm G ............................................................. 273
Servo System Alarms ..........................................................................................................329

5.6.1
5.7
5.8
Inverter Alarms ..................................................................................................................... 330

5.7.1
Alarms of the Wheel Spindle Motor Inverter ............................................................ 330
5.7.2
Diamond RolI Motor Inverter .................................................................................... 339
OH Cooler Alarms ................................................................................................................ 342

5.8.1
5.9
Servo System Alarms ............................................................................................. 329
Wheel Spindle Bearing Lubricating OH Cooler Alarms ............................................ 342
Electric Cabinet Cooler Alarms ............................................................................................ 344
5.10 Sizer Monitor ....................................................................................................................... 345

5.11
Indicating Lamps on the CNC Unit ...................................................................................;... 346

5.11.1
Power Unit (TP-2391) .............................................................................................. 346
5.11.2
MCUL Unit .............................................................................................................. 348
5.11.3
CNUE Unit .............................................................................................................. 350
5.11.4 . DSUS Unit .............................................................................................................. 351

5.11.5
PLC-48 Unit ............................................................................................................ 354
5.12 CNC Information .................................................................................................................. 356

5.12.1
Servo Monitor ......................................................................................................... 356
5.12.2
Servo Information Trace Display ............................................................................. 357
5.12.3
Saving ProductionlMaintenance Information ............................................................ 358
5.12.4 Version Display ...................................................................................................... 360

5.12.5
5.13
Cycle Time History ................................................................................................. 362
Diagnosis Using TOYOPUC ................................................................................................ 363

5.13.1
Reading the Electric Circuit Diagrams .................................................................... 363
5.132
Control by CNC and TOYOPUC ....... :...................................................................... 373
5.13.3
Checking the Circuit U~ing Hellowin ....................................................................... 384
6.
REPLACEMENT ANO AOJUSTMENT

6.1
Cautions on Replacing/adjusting the Parts ....... ~ ..................................................................... 1
6.2
Cleaning and Replacing the Filter ........................................................................................... 2
6.3
6.4
6.5
6.2.1
Cleaning and Replacing the Wheel Spindle Bearing Lubricating Oil Rlter .................. 2
6.2.2
Cleaning and Replacing the Lubricating Oil Filter ..................................................... 4
6.2.4
Replacing the Air Filter .............................................................................................. 6
6.2.4
Cleaning the Oil Cooler Filter ................................................................................... 8
Cleaning the Tanks and Changing the Oil .............................................................................. 9

6.3.1
Cleaning the Wheel Spindle Bearing Lubricating Oil Tank

and Changing the Lubricating Oil ........................................................................... 9
6.3.2
Cleaning theLubricating Oil Tank and Changing the Lubricating Oil ......................... 11
6.3.3
Cleaning the Hydraulic Oil Tank and Changing the Hydraulic Oil ............................. 13
6.3.4
Cleaning the Coolant Tank ...................................................................................... 15
Replacing the Pumps .......................................................................................................... 16

6.4.1
Replacing the Wheel Spindle Bearing Lubrication Pump and Motor ......................... 16
6.4.2
Replacing the Lubrication Pump and Motor ............................................................. 18
6.4.3
Replacing the Hydraulic Oil Pump and the Motor .................................................... 20
6.4.4
Replacing the Coolant Pump .....................................:............................................. 22
Replacing the Oil Coolers ........ ;............................................................................................ 23

6.5.1
6.6
6.7
6.8
,
I
6.9
Replacing the Wheel Spindle Bearing Lubricating Oil Cooler .................................... 23
Replacing the Sizer Amplifier and Head ................................................................................ 25

6.6.1
Replacing the Sizer Amplifier .................................................................................. 25
6.6.2
Replacing the Sizer Head ........................................................................................ 26
6.6.3
Replacing and Adjusting the Lateral Locator ........................................................... 28
6.6.4
Replacing the Proximity Switch ............................................................................... 29
Replacing the Battery ........................................................................................................... 31

6.7.1
Replacing the CNC Memory Backup Battery ........................................................... 31
6.7.2
Replacing the PLC Battery ...................................................................................... 32
6.7.3
Replacing the Display Memory Backup Battery ...................................................... 34
Replacing the Fan Motors ..................................................................................................... 35

6.8.1
Replacing the Fan Motor at Operation Panel ........................................................... 35
6.8.2
Replacing the CNC .Card Fan Motor ......................................................................... 35
Replacing the Control Cabinet Cooler ................................................................................... 36'
6.10 Replacing the Wheel Orive Belt ..........................................................................;................. 37

6.11
Replacing the Servo Amplifier ............................................................................................... 39

6.11.1
Outline of Servo Amplifier Replacement ................................................................... 39
6.11.2
Replacing the Wheelhead Infeed Axis Servo Amplifier ............................................. 40
6.11.3
Replacing the Wheel Truer Feed Servo Amplifier ..................................................... 46
6.11.4
Replacing the Steady Rest Shoe Feed Servo Amplifier ........................................... 52
6.11.5
Replacing the Work Spindle Positioning Servo Amplifier ......................................... 61
6.11.6
Replacing the Footstock Spindle ServoAmplifier .................................................... 64
6.11.7
Replacing the Taper Correction Feed Servo Amplifier ............................................... 67
6.11.8
Replacing the Work Spindle Servo Amplifier ............................................................ 70
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6.12
Replacing the Servomotors ................................................................................................... 73

6.12.1
Canceling the Position-offset Safety Protection Function ........................................ 74
6.12.2
Replacing the Right Wheelhead Infeed Servomotor. .................................................
6.12.3
Replacing the Left Wheelhead Infeed Servomotor .................................................... 91
6.12.4
Replacing the Wheel Truer Infeed Servomotor ........................................................ 102
6.12.5
Replacing the Wheel Truer Traverse Servomotor ..................................................... 116
6.12.6
Replacing the Work Spindle Drive Servomotor ..................... '" ................................ 130
6.12.7
Replacing the Footstock Spindle Servomotor ................................. :....................... 142
6.12.8
Replacing the Work Spinqle Drive Servomotor ........................................................ 156
6.12.9
Replacing the Right Steady Rest Feed Servomotor ................................................ 171
6.12.10 Replacing the Left Steady Rest Feed Servomotor .................................................. 184
6.12.11 Replacing the Middle Steady Rest Feed Servomotor ............. :................................ 197
6.12.12 Replacing the Taper Correction Servomotor ............................................................ 210
6.13
6.14
6.15
Replacing he Inverter ...........................................................................................................222

6.13.1
Replacing the Wheel Spindle Motor Controllnverter ............................................... 222
6.13.2
Replacing the Truer Motor Controllnverter .............................................................. 224
Replacing the Inverter Controlled Motor .................................... '" ......................................... 225

6.14.1
Replacing the Wheel Spindle Motor ........................................................................ 225
6.14.2
Replacing the Diamond RolI Motor ......................................................................... 227
6.14:3
Replacing the Diamond RolI Head .......................................................................... 228
Replacing the CNC Cards .................................................................................................... 230

6.15.1
Outline of CNC Card Replacement ........................:................................................ 230
6.15.2
Arrangement if ROMs and Settings in CNC Cards .................................................. 232
6.15.3
Replacing the Power Supply Unit ........................................................................... 234
6.15.4
Replacing the MCUL Unit ....................................... :................................................ 235
6.15.5
Replacing the DSUS Unit ....................................................................................... 237
6.15.6
Replacing the CNUE Unit .......................................................................;; .............. 239
6.15.7
Replacing PLC-48 Unit ...........................................................................................240
6.15.8
Replacing ROMs .................................................................................................... 241
6.15.9
Replacing the Panel PC and the Peripherals .......................................................... 242
6.1.5.10 Replacing the TOYOPUC ....................................................................................... 248

6.15.11 Replacing the Pulse Generator ................................................................................ 252
7.
DATA SAVING
7.1
7.2
7.3
Data Configuration .................................................................................................................. 1

7.1.1
Data Kind .................................................................................................................. 1
7.1.2
Data Back-up ............................................................................................................ 2
Outputting the CNC Data ........................................................................................................ 4

7.2.1
Outputting the Grinding Data ..................................................................................... 5
7.2.2
Outputting the Setup Data ......................................................................................... 8
7.2.3
Outputting the Maintenance Parameter .................................................................... 11
7.2.4
Outputting the NC Data Collectively ......................................................................... 14
Inputting the CNC Data ......................................................................................................... 17

7.3.1
Inputting the Grinding Data ...................................................................................... 18
7.3.2
Inputting the Setup Parameters ............. :: ................................................................ 21
7.3.3
Inputting the Maintenance Parameters .................................................................... 23
1'lillllM
7.4
7.5
7.6
7.7
7.8
..
7.9
7.3.4
Inputting the CNC Data Collectively ......................................................................... 25
7.3.5
Inputting the InternalAbsolute Position Data .: ......................................................... 28
Inputting/Outputting the TOYOPUC Data ..........................................................., .................. 30

7.4.1
Outputting the TOYOPUC Data ..............................................................................: 30
7.4.2
Inputting the TOYOPUC Data .................................................................................. 34
Installing the Panel PC System Software ............................................................................. 39

7.5.1
Setting the Date ...................................................................................................... 40
7.5.2
Setting the Backlight Timer ..................................................................................... 41
7.5.3
Installing the HMI Software ...................... ,............................................................... 42
7.5.4
Installing the Hellowin Software ............................................................................... 42
Inputting/Outputting the HMI Data Collectively ...................................................................... 43

7.6.1
Outputting the HMI Data Collectively ....................................................................... 43
7.6.2
Inputting the HMI Data Collectively .......................................................................... 46
Inputting/Outputting the Zero Offset Data .............................................................................. 49

7.7.1
Outputting the Zera Offset Data ............................................................................... 49
7.7.2
Inputting the Zero Offset Data .................................................................................. 52
Initializing the Memory .......................................................................................................... 55

7.8.1
Initializing the CNC Data ......................................................................................... 55
7.8.2
Checksum Operation ............................................................................................... 62
7.8.3
Initializing the TOYOPUC Data ................................................................................ 63
7.8.4
Initializing the HMI Data .........................................................,................................ 64
7.8.5
Formatting the Floppy Disk ........................................................................~.:........... 66
Inputting/Outputting the Inverter Parameters ......................................................................... 70

7.9.1
Outputting the Wheel Spindle Motor Inverter Parameters ......................................... 70
7.9.2
Inputting the Wheel Spindle Motor Inverter Parameters ............................................ 71
7.9.3
Outputting the Diamond RolI Shaft Motor Inverter Parameters ................................. 81
7.9.4
Inputting the Diamond RolI Shaft Motor Inverter Parameters .................................... 82
APPENDIX
Appendix 1
Data Sheet ................................................................................................................ 1
Appendix 2
Grinding Data Format .............................................................................................. 20
Appendix 3
Production Maintenance Information Format ...................................: ....................... 21
Appendix 4
Table of Error Messages :............................................................, ............................ 24
Appendix 5
Technical Terminology ........................................,...... ;............................................. 66
"
li'ml 1bt
1. SAFETY CAUTIONS
GM6311
1.1
Cautions Relating to Maintenance and Preventive Maintenance
1.1.1
General
Lt.
WARNING
Switch off the power to the machine befo re cleaning it or changing parts.
If you attempt this work while the machine is operating, a part of your body could be
trapped and you could sustain injuries.
Lt.
CAUTION
After finishing work with tools used for setup changes, maintenance, or preventive maintenance, remove
these tools from the machine.
1.1.2
When Switching the Power ON and OFF
/ Lt.
DANGER
Voltage is supplied to the electric control cabinet, terminal boxes, operation panels,
and other equipment. .
Severe injuries, or death, can result from electric shocks or burns.
Before turning the power on, close the doors and covers.
Lt.
DANGER
Check that there are no cables with damaged insulation.

If any cable is damaged, do not turn the power on.
Request the person responsible for preventive maintenance to take corrective action.
Lt.
WARNING
Do not turn on the power if there is anyone inside the machine.

When the machine starts operation, the person's body could be trapped, and he/she
could sustain severe injuries.
Always switch off the power before entering the machine to carry out setup change work
such as wheel changes, maintenance/preventive maintenance work, troubleshooting and
so on.
Lt.
WARNING
Check that there is nobody inside the machine before pressing the [MASTER ON]
pushbutton switch.
1-1
I IIDIIIt4
1. SAFETY CAUTIONS
GM6311
CAUTION
Do not leave tools or parts inside the machine. This can cause an accident when the machine is operating.
Tke tools and parts outside the machine on completing the work.
CAUTION
Afier carrying out maintenance/preventive maintenance or repair work, check that there is no detached or
loose piping.
This can lead to oilleakage when the [MASTER ON] pushbutton switch is pressed.
CAUTION
In order to protect the wheel bearing, do not turn the power off while the wheel is rotating.
In an emergency or in the event of an error, this caution may be ignored and the power turned off.
CAUTION
. Exit the HMI screen before turning off the power. When screen display indicates that the computer has
shut down, turn off the power.
In an emergency or in the event of an error, this caution may be ignored and the power turned off.
CAUTION
Even afier the power is cut off, the screen remains lit by the backup battery of the panel computer.
The screen goes off after the protective timer has timed out. Turn off the UPS (uninterrupted power
supply) before attempting maintenance or preventive maintenance work on the panel computer.
CAUTION
Even afier the [EMERGENCY STOP] pushbutton switch is pressed, the wheel spindle bearing lubrication
pump keeps operating for the timer-set periodo
If the piping for wheel spindle bearing lubrication system is disconnected, lubricating oil will spout from the
disconnection.
Check that the grinding wheel has stopped rotating and turn off the power before attempting to change the
grinding wheel or to carry out maintenance or preventive maintenance.
1-2
EklnlJIJ*,
1. SAFETY CAUTIONS
GM6311
In Manual Operation
1.1.3
~~
@~
\".
&.....
""
il
il
&
WARNING
Close the doors before starting the wheel spindle.

Run the wheel spindle at idle for one minute or more at start of operation, or three
minutes or more at re-start after wheel ch~mge and check that there is no irregularity.
&
WARNING
Do not enter inside the machine while it is operating. During operation, you will not
be able to anticipate machine motions. If you are trapped by the machine or struck
by it, you could sustain severe injuries.
&
WARNING
When operating the machine step by step manually (for example to make individual
parts), do not operate the pushbutton switches with your arm, leg, or any part of
your body is in contact with the machine.
You may be trapped by the machine and you could sustain severe injury.
&
CAUTION
Before pressing the [ACTIVATE] pushbutton switch, check that the operation pushbutton switch es on the
screen are set correctly for the operation to be performed.
Do not press the [ACTIVATE] pushbutton switch without confirmation.
&
CAUTION
When the [STOP WHEEL SPINDLE] pushbutton switch is pressed, the wheel
continues to rotate due to inertia. Do not touch the wheel while it is rotating or you
will be injured.
Confirm that the wheel has stopped rotating before carrying out work such as
position memory operations.
1-3
1. SAFETY CAUTIONS
GM6311
1.1.4
During Wheel Changing Work
DANGER
Do not stand beneath the hoisted wheel spindle or accessory parts.
Hoisting work and operation of the forklift or crane are allowed only by authorized
persons.
WARNING
You cannot anticipate the motions of the machine during operation.

The wheel or loader may move and trap your body, and a head injury could lead to
death.
Turn the power off before entering the machine for wheel change work.
1.1.5
When Remedying Trouble
WARNING
When trouble occurs with the machine, press the [EMERGENCY STOP] pushbutton
switch to stop the machine, and follow the instructions of the qualified person your
company has appointed. Do not take any action until the qualified person has
arrived.
WARNING
Turn off the power before entering inside the machine.
1.1.6
Installation
DANGER
Do not stand under a raised machine or unit.
Hoisting work and operation of the forklift or crane are allowed only by authorized
persons.
WARNING
Only a qualified electrician should perform electrical connection.
WARNING
Wear a hard hat and safety shoes when leveling, wiring and piping the machine.
Also, wear goggles ~hen connecting air pipes.
14
NiliJI].!1
. 1. SAFETY CAUTIONS
GM6311
1.2
Areas of Potential Danger .
1.2.1
High-voltage Locations
DANGER
Hazardous high voltage.

Do not open doors or covers during operation.
Only a qualified person should carry out maintenance inspections. Switch off the
power first.
(1) There are high voltages in each part of the machine. High voltages are supplied not just to
the electric control cabinet, operation panel, and terminal boxes, but also to the induction
motor connector, the induction motor terminal box, and the servomotor connector.
Maintenance, inspection, and repairs must be carried out by the qualified person appointed
by your company afier the power has been turned off.
(2) Only open the door of the electric control cabinet afier the power has been shut off at the
main breaker (this is the power supply breaker associated with the electrical electric
control cabinet: the electric control cabinet that supplies the factory power supply).
(3) Some devices inside the electric control cabinet remain Iive even afier the main power
supply has been shut off.
These include electrical devices such as the inverter control unit, the OC stabilized power
supply, the servo amplifier, the servo amplifier power supply unit, condensers, and so on.
Afier the power supply"has been shut off, confirm that the charge has been discharged
from these devices before performing maintenance and inspection work.
(4) In some cases there are devices inside the electric control cabinet whose power supply is
not shut off even when the main power supply is shut off. For example, in accordance with
the client's specifications, there may be power outlets, Iighting units inside the electric
control cabinet, and so on. Do not attempt to disassemble devices whose power supply
has not been shut off.
(5) Even when the main power supply has been shut off, the voltage is still applied at the
primary side. Do not touch the primary side wiring, and do not remove the protective cover.
1.2.2
Wheel and Workpiece Orive Sections, Rotary Section Of the Truing RolI
CAUTION
The wheel does not stop immediately.

If you touch the wheel while it is rotating you will be injured.
Confirm that rotation of the wheel has stopped.
(1) If you touch the wheel while it is rotating you will be injured. Keep your hands clear of
the wheel while it is rotating.
Before carrying out work in which itis necessary to touch the wheel, for example
position memory operations, stop the wheel drive, and confirm that the rotation of the
wheel has stopped.
(2) If you reach toward part of a workpiece that is rotating, you could be entangled in the
machine and injured. Stop the rotation of the workpiece before carrying out work such
as setting up a measuring jig.
(3) If you touch the diamond roll while it is rotating you will be injured. Keep your hands
clear of the diamond roll while it is rotatng.
When changing the diamond roll, stop the rotation of the diamond roll and turn off the
power befo re starting the work.
1-5
IllillJlt*,
1. SAFETY CAUTIONS
GM6311
1.2.3
Axis Motion Ranges
&.
WARNING
While the wheel cover is opening or closing do not put your body or any part of your
body within the range of motion of the wheel cover.
You could be trapped by the wheel cover and sustain severe injury.
Open and close the wheel cover by operation from the tront operation panel. Check
that there is nobody inside the safety fence before starting the operation.
&.
CAUTION
When the wheel cover is opened, or during a wheel change operation, the grinding
wheel may fall unexpectedly, or you may be trapped by the wheel cover, causing you
severe injury.
&.
CAUTION
When the wheelhead advances, the minimum clearance between the workpiece, work
spindle and tailstock is Omm. If you place your body or part of your body within the
range of motion of the wheelhead, you could be trapped and sustain severe injury. Do
not enter the range of motion of the wheelhead while the machine is operating.
Tum off the power before attempting to replace parts.
Wheel cover
1-6
1. SAFETY CAUTIONS
. GM6311
1.3
Protective Functions
1.3.1
Types, Functions, and Positions of Interlocks for Protective Functions
(a)
Protective functions for personnel

1) Front door
In the case of the specification with the window, the window is assured strength by
using a 2-ply construction with two materials: cast acrylic and polycarbonate. Do not
change these for other materials.
2) Function to prevent trapping in the shutter
The automatic door specification has a function whereby the door is pushed back by
spring force at the door closing end, in order to keep the damage to a minimum if
someone got trapped in the door. If someone is trapped, the spring is compressed,
and shear force is minimized. However, take all precautions to avoid getting trapped in
the door.
3) Safety plug specification (option)
The rear door is equipped with a safety plug. When the plug is removed in order to
open the rear door, an emergency stop is automatically applied.
4) Ooor switch with an electromagnetic lock (option)
The rear door is provided with a door switch with an electromagnetic lock. This switch
prevents the door from being opened while the wheel is still rotating after the
[EMERGENCY STOP] pushbutton switch has been pressed.
5) Area sensor (photoelectric type) (option)
This sensor is mounted on the front door for loading/unloading workpieces. Entering
into the area covered by this area sensor during automatic operation causes an
emergency stop.
(b)
Protective functions for the machine

1) Motor overload protection function
Normally, a thermal overload relay is used to provide overload protection for the motor.
This relay is shipped from Toyoda Machine Works, Ud after being matched to the
rated current. The load setting is marked on it with white paint. Do not change this
setting. The thermal overload relay is mounted on a panel inside the electric control
cabinet.
2) Protection of the inverter and inverter motor
Various parameters are set for the inverter and the inverter unit that protects the
inverter. The load setting value in the parameters is indicatedin the electrical circuit
diagrams. The inverter unit parameters can be changed at the console unit provided,
but do not change them.
3) Wheel spindle overload protection
For wheel spindle overload protection, overload current flowing in the wheel spindle
motor is detected. The following three methods of overload detection are available
depending on the type of inverter. There are also two types of detection for during rapid
feed of the wheel head and during grinding.
Overload current detection by a current sensor

Overloads are detected by a combination of a current sensor and a current converter.
Oetection by a printed circuit board incorporated into the inverter
1-7
I i1tllJ11!1.
1. SAFETY CAUTIONS
GM6311
4) Wheel spindle bearing protection
If the [EMERGENCY STOP] pushbutton switch is pressed while the wheel spindle is
rotating, the wheel does not stop immediately but keeps rotating for a certain period
due to inertia. The wheel spindle bearing lubrication pump keeps operating to protect
the wheel spindle bearing during this periodo
1-8
UIHlllm
1. SAFETY CAUTIONS
GM6311
1.4
Labels
1.4.1
Types and Fixing Locations of Warning Labels

The following warning labels are affixed to the machine. (For the fixing locations, see Fig 1 in the
following pages.)
Make sure you fully understand the contents of the warning labels and abide by them during your work.
Description
Labels
DANGER
High voltage.
May shock, burn or cause death.

Do not open any door or cover while In operation. Only qualified
personnel to perform malntenance aftrt locklng out power.
ARNING
A
.,. ,
,.~.~tlO~
WARNING
....
,., lIIf.,.
ti , t
A rotating wheel can shatter, spreadlng debris.

Debris from a shattered wheel can cause serve Injury.
Be sure to lock wheel guard in place and wear safety glasses at all
s 1..
k
......
"
,. ,d t
::.~,!.::!:.~'.""
times.
WARNING
Machlne can move at any time without warning.
May result severe crushing and injury.
l1a, , u~" 11"".'.
l/'UIII<I,..
no"
'Do
<ln,Jo,.".
I/nd
, Do not touch any moving part whlle In operatlon.
I'~UCh
1111'
.~""II. p"r"
OI'Ia
op",.a "</011.
'11
CAUTION
Wet and slippery surface.
Slipping can cause bruises or fractures.
$"Pp,n/l "
b, " . tI,. 1,
1I .,cb
lO '
"'''u".
1'.' ' .
10 ti
Watch your step and wear safety shoes.
,tlg, "nd
I r r, .h
CAUTION
Allow time for wheel to stop rotating.
Touching a rotating wheel results in serve Injury.
Confirm that grlnding wheel has completely stopped.
General Safety Considerations .
2 ..... O\M _ _
~_
t*
""'"""'________
4.
_ _ ...., ... _
===.1.~'="::
.... ..--., ' ....1.
:=-:~-=..,--
-----
:I,.""","""'_.~._
e
"
........
__
1-9
li'rID]I'!'
1. SAFETY CAUTIONS
GM6311
General Safety
Considerations
A-1
A-2
.:.
....
.
.
E-1
A-3
C-1
Fig 1 Safety Label Locations
IMPORTANT When the maehine is delivered to your faetory, please make

sure that all warning labels are attaehed. Keep the labels
elean so that they can be easily read. If they are soiled and
iIIegible or lost, please eontaet loyoda Maehine Works Ud.
promptly for new la beis and attaeh the new ones at the erreet positions. If you are selling the maehine, please inform
us of the address of the new maehine user. lhe manuals
and other doeuments must be forwarded with the machi ne.
1-10
IklnIJI'*,
1. SAFETY CAUTIONS
GM6311
1.5
Related Laws, Regulations, and Standards
The personnel who operate the manipulator and data storing device
(including the programmable sequence controller and fixed sequence
controller) that controls the manipulator motion (in/out, extend/bend, up/
down, and/or rotation, and combinations of thse motions) must be
trained in accordance with local regulations. Only employees trained in
accordance with local regl.Jlations and your company's guideline are
permitted to operate and maintain such equipment.
1-11
lil}11]1J;1
2.
DAILY INSPECTION
2.1
Inspection before Pressing the [MASTER ON] Button

Item
Amount of
lubricating oil
Amount of hydraulic
( e ) oH
Oillevel gauge
Oillevel gauge
Oillevel gauge
Amount of
lubricating oil for
(d )
Unit tank
oil-mist lubrication
system
Amount of
( e ) workhead gear-box Oillevel gauge
lubricating oil
( f ) Amount of coolant
NOTE
Contents
Point
Amount of wheel
( a ) spindle bearing
lubricating oil
( b )
GM6311
Coolant level
gauge
Make sure that the oillevel is

between "H" (upper Iimit) and "L"
(Iower Iim it) levels
between "H" (upper limit) and "L"
(Iower Iimit) levels
between "H" (upper Iim it) and "l"
(Iower limit) levels
Tank Capacity
H (upper limit):
140 L
L (Iower Iim it):
94.4 l
H (upper Iimit):
13 L
L (Iower Iim it):
5.4 L
H (upper limit):
50 L
L (Iower lim it):
34 L
Make sure that the lubricating oil

H (upper Iimit):
level is aboye the "Iower Iimit" (m in.)
1.7 l
indication on the tank.
between "H" (upper Iim it) and "L"
(Iower Iim it) levels
Make sure that the coolant level is
between "H" (upper limit) and "LO
(Iower limit) levels while the coolant
system is stopped.
H (upper Iimit):
1.2 l
Tank capacity:
1300 l
Observe the color of lubricating and hydraulic oil.

If it is turbid in white, coolant could have been mixed into the lubricating and
hydraulic oil.
IMPORTANT The.f1oor layout diagram below is only for reference. Floor layout of your
machine, supplied separately,. should be referred to.

Tank capacity may differ from the values indicated in the table aboye
depending on your machine's specifications. Therefore, confirm the capacity of the tanks specified in the hydraulic/pneumatic circuit diagrams or by
the nameplate affixed to the tanks.
2-1
liltllllM
2. '
DAILY INSPECTION
GM6311
Oil level gauge

spindle bearing lubricating oil)
Oil level gauge (hydraulic oH)
--
Oillevel gauge (oH-mist lubricating oil)

level gauge
(Iubricating oil)
- .....
Lo
1--
Oillevel 9
(workhead gear-box
lubricating oil)
,- --
lftl:: - - =:: :; :\
2-2
MIlfilllM
2.
DAILY INSPECTION
(a)
GM6311
Checking the Wheel Spindle Bearing Lubricating Oil Level and Replenishing the
Lbricating Oil
DiI level gauge of wheel spindle

bearing lubricating oil
Wheel spindle bearing
,r.rl/,.,f",n oil filler port
Check the wheel spindle bearing lubricating oillevel by

the oillevel gauge at the wheel spindle bearing
lubricating oil tank and make sure that the lubricating
oillevel is between the upper limit (H) and the lower
limit (L) lines.
If the lubricating oillevel is lower than the lower limit
(L), open the filler port cap and supply the specified
lubricating oil until the lubricating oillevel reaches the
upper limit (H) line.
IMPORTANT Pay attention so that the area

around the oil filler port is clean
and foreign matter will not enter
the tank while replenishing the
wheel spindle bearing I}Jbricating
oil.
Upper limit (H)
For the wheel spindle bearing

lubricating oil, only use the specified oil indicated below.
Lower limit (L)
IMPORTANT If lubricating oil other than the

specified oil is used, lubrication
performance will be degraded.
The wheel spindle bearing will
generate heat or may be damaged. Always use the specified
lubricating oil.
Wheel spindle bearing lubricating oil
Specification:
ISO viscosity grade VG32
Specified lubricating oil:
Mobil DTE Oil Light
2-3
2.
DAILY INSPECTION
(b)
GM6311
Checking the Lubricating Dil Level and Replenishing the Lubricating Oil
Check the lubricating oillevel by the oillevel gauge at

the lubricating oH tank and make sure that the lubricat- .
ing oHlevel is between the upper limit (H) and the
lower Iimit (L) Iines.
If the lubricating oHlevel is lower than the lower Iimit
(L), open the filler port cap and supply the specified
lubricating oH until the lubricating oillevel reaches the
upper Iimit (H) line.
DiI level gauge of

lubricating oil
around the oil filler port is clean

lubricating oil.
Upper limit (H)
Lower limit (L)
For the lubricating oil, use the recommended oH

indicated below or the equivalent. If other kind of
lubricating oil is used, lubrication performance will be
degraded.
'
Lubricating oil
Recommended lubricating oil:
Mobil Vacuoline Oil1409
Equivalent Lubricating Oil (ISO viscosity grade: VG68)

Manufacturer
Lubricating Oil
ESSO
Powerex DP68
Shell
Tetra Oil68
24
Ulill]lg
2.
DAILY INSPECTION
(e)
GM6311
Cheeking the Hydraulie OH Level and Replenishing the Hydraulie OH

Check the hydraulic oillevel by the oillevel gauge at
the hydraulic oil tank and make sure that the hydraulic
oillevel is between the upper limit (H) and the lower
limit (L) lines.
If the hydraulic oillevel is lower than the lower limit (L),

open the filler port cap and supply the specified hydraulic oil until the hydraulic oillevel reaches the upper
limit (H) line.

around the oil filler port is elean
hydraulie oil.
OH level gauge of
hydraulic oH
For the hydraulic oil, use the recommended oil indicated below or the equivalent. If other kind of hydraulic
oil is used, performance will be degraded.
Hydraulic oil: ISO viscosity grade: VG22

Upper limil (H)
Recommended hydraulic oil: Mobil DTE 22
Lower limil (L)
2-5
Illf(I)I14 .
2.
DAILY INSPECTION
(d)
GM6311
Checking the Lubricating Oil Level and Replenishing the

Lubricating Oil for Oil-mist Lubrication Unit
&
CAUTION
Replenish the lubricating oil only after shutting off the air source. Otherwise, the oil
in the tank could blow off due to residual pressure.
You must wear safety goggles for this work.
~_ _-
Lubricating oH filler port

(oil-mist lubricating oil)
Lower limit of lubricating oil
(oil-mist lubricating oil tank) (L)
Check the lubricating oillevel by the oillevel gauge at

the oil-mist lubrication unit tank and make sure that
the lubricating oillevel is aboye the lower limit (L) line.
(L), open the filler port cap and supply the specifie~
lubricating oH until the lubricating oH level reaches the
upper limit.
around the oiJ filler port is clean

the tank whiJe replenishing the
lubricating oiJ.
For the lubricating oil, use the
recommended oiJ indicated below
or the equivalent. If lubricating oiJ
of other viscosity is used, bearing
and other lubricated parts may
generate heat and lubricating
performance may be degraded
considerably.
Lubricating oil for oil-mist lubrication system:

ISO viscosity grade: VG1 O
Recommended lubricating oil:
2-6
Mobil Velocite No. 6
i gli,l] 1M
2.
DAILY INSPECTION
(e)
GM6311
Checking the Lubricating Oil Level and Replenishing the Lubricating Oi! for
Workhead Gear-box Lubrication Unit
Check the lubricating oillevel by the oillevel gauge
provided at the rear of the workhead and make sure
that t~e lubricating oillevel is above the lower limit (L)
line.
(L), open the filler port cap and supply the lubricating
oil until the hydraulic oillevel reaches the upper limit.
DiI level gauge
oil filler port
2-7
IlliVln 114
2.
DAILY INSPECTION
(f)
GM6311
Checking the Coolant Level
IMPORTANT The coolant system supplied with the machine differs depending on the
machine specification.
Please refer to the Instruction Manual of the coolant system of your
machine.
.
Make sure that the coolant level gauge pointer is in the

following range.
Coolant level
Upper limit
(during operation)
Upper limit
(coolant pump
stopped)
While the coolant system is operating (coolant pump

is operating):
Upper Iimit (during operation) - Lower Iimit
While the coolant system is stopped (coolant pump is
stopped):
Upper Iimit (coolant pump stopped) - Lower Iimit
Pointer
Lower limit
If the coolant level is below the lower Iimit, supply

water. Then, replenish undiluted coolant corresponding
to the amount of supplied water.
IMPORTANT If coolant is replenished exceeding
the upper limit (coolant pump
stopped) while the coolant pump is
stopped, coolant will overflow
when the coolant pump starts
operating.
NOTE
I Immediately after the replenishing of

water, scratch tends to be left on the
ground workpiece surface due to wheel
grids f10ating in coolant. To prevent
such a problem, circulate coolant for a
while after replenishing water.
2-8
I I-nl]I,d
2.
DAILY INSPECTION
2.2
Inspection after Pressing the [MASTER ON] Button
GM6311
IMPORTANT The table below includes all devices of the m~chine including the optional
devices. Therefore, the information below may contain the devices that are
not included in your machine. Check the available devices referring to the
hydraulic/pneumatic circuit diagrams of your machi ne. The setting pressure
may differ from the standard values indicated in the table below depending
on the machine specifications. For the pressure settings of your machine,
reter to the hydraulic/pneumatic circuit diagrams of your machine or the
nameplate affixed to the devices.
Point
Item
Contents
Standard Setting*
The pressure gauge pointer is within the green band range,

Pressure gauge
lubrication pump pressure
indicating the value speeified in the nameplate. ,
1.7MPa
Right wheel spindle

bearinglubrication
pressure

indicating the value speeified in the nameplate.
1.5MPa
Left wheel spindle bearing

Pressure gauge
lubrication pressure
1.54 MPa

O.5MPa
Pressure gauge

O.015MPa
(e) Hydraufie unit pump pressure Pressure gauge

indicating the value specified in the nameplate.
3.0MPa
(d)
Footstock spindle center

Pressure gauge
advance (reduced pressure)
1.8MPa
(e)
Bearing lubricalion rnist

pressure
(a)
Pressure gauge
(b) Lubrication pump pressure Pressure gauge

Wheelhead slideway
lubrication pressure
(f) Wheel spindle bearing

lubrication mist pressure
(g)
(i)
Seady rest seafing air
pressure
Lubricating on dri:s for oiknist
lubrication
Pressure gauge

O.3MPa
Pressure gauge
The pressure gauge pointer is Vvithin the green band range,

O.03MPa
Pressure gauge

O.05MPa
Measure the number of drips per minute and rnake sure that
tt is within the setting range speeified in the nameplate.
20 - 50 drips/min
Rlter elogging (wheel

Indication of the
spindle bearing lubricating
fi~er
oil)
Filler indication must be blue.
Blue indication:
Red 'indication:
Normal
Abnormal
Indication of the
filtar
Rlter indication must be blue.
Blue indication:
Red indication:
Normal
Abnormal
(k) Rlter dogging Qubricaling oiJ)
(1) AirfiHer
(m) Belttension
Check the drain pipe for blockage and the case for reserved
water.
BeH tension meter Measure bett tension with the bett tension meter
*: The values may vary according to the machine specifications.
2-9
26 to 31 mm deflection at
49N (per belt)
Illnlllm
2.
DAILY INSPECTION
GM6311
Inspection Locations
IMPORTANT The f100r layout diagram below is only for reference. Floor layout of your
machine, supplied separately, should be referred to.
Settings may differ from the values indicated in the table aboye depending
on your machine's specifications. Therefore, confirm the pressure settings
and other setting values specified in the hydraulic/pneumatic circuit diagrams or by the nameplate affixed to the devices.
Floor Layout Diagram
(e)
..
(g) (e)
(1)
--
~~
(i~
.J.1 !:t
~-
(f) -:; ~II
(a )--:::-!:r-
/'
.
.
,I
\
I
....("
,
r-
liI;;
.. l~
I'1 "
'~'
1.- ~
..r- h
~ --- r-(m)
,...
'--'l
, UI
~
--
.m.... ~
'
11.,
2-10
.1
Gt
mE6
~ __ =::::::JII'"
~(a)
- .
I[W

.:
lA.~.
---
(e)
-Tri; -' ~
rIJ
...
,!
_.Il
?~
._.JtI1
---,
~~
I[ pr""'
Ir
..[\~.
p
E= r-
l...!
r-
\~(a)
~
~ 1I
I
..Q
f---'
11
I flnl]
2 ..
(a)
DAILY INSPECTION
GM6311
Reading the Wheel Spindle Bearing Lubrication Pump Pressure Gauge and
Adjusting the Pressure
Green
band

lubrication
(1) Read the pressure gauge and make sure that the
pointer is within the green band range.
Pressure setting range:
1.6 -1.8 MPa
If the pointer is not in the green band range, adjust

the pressure by turning the pressure adjusting
screw of the wheel spindle bearing lubrication
pump.
(2) Loosen the lock screw.
Pressure
adjusting screw
l.
(3) Adjust the pressure by turning the pressure adjusting screw.
Lock screw
CW ....... Pressure increases.

CCW ..... Pressure decreases.
(4) Afier obtaining the required pressure, lock the

pressure adjusting screw by securing the lock
screw.

lubrication oil pressure gauge
Pressure range:
Right wheel spindle bearing lubrication oil pressure
1.45 - 1.55 MPa
Lefi wheel spindle bearing lubrication oil pressure
1.5 -1.6 MPa
Right wheel spindle bearing

lubrication oil pressure gauge
2-11
I fin'] 1m
2.
DAILY INSPECTION
(b)
GM6311
Reading the Lubrication Pump Pressure Gauge and Adjusting the Pressure
Green
Wheelhead slideway lubrication
oil pressure gauge
Flow control
valve
Pressure
regulating
valve
Lubrication pump pressure setting range:
Pressure
adjusting
screw

screw of the wheel spindle bearing lubrication
pump.
0.4 - 0.6 MPa
Wheelhead slideway lubrication oil pressure

setting range:
0.014 - 0.016 MPa

the pressure with the f10w control valve.
(2) Adjust the pressure by turning the pressure adjusting screw while observing the lubrication pump
pressure gauge.
(3) Adjust the f10wrate by turning the f10w adjusting

screw while observing the wheelhead slideway
lubrication oil pressure gauge.
CCW ..... Flowrate decreases to cause pressure to
decrease.
adjusting
CW ....... Flowrate increases to cause pressure to

increase.
2-12
2.
Mil1lIIM
DAILY INSPECTION
(e)
GM6311
Reading the ,Hydraulie Unit Pump Pressure Gauge and Adjusting the Pressure
Hydraulic unit pump

pressure gauge
Green band
2.9 - 3.1 MPa

screw of the hydraulic unit pump.
(2) Loasen the lock screw.
(3) Adjust the pressure by turning the pressure adjusting screw.

Pressure
adjusting screw
Lock screw
(4) After obtaining the required pressure, lock the

pressure adjusting screw by securing the lock
screw.
2-13
2.
I II{I]I'!I
DAILY INSPECTION
GM6311
(d)
Reading the Pressure Gauge of Footstock Spindle Center Advance Pressure

(Reduced) and Adjusting the Pressure (Hydraulically-operated Footstock)
Pressure gauge of footstock spindle

center advance pressure (reduced)
IMPORTANT Location of the pressure gauge

differs depending on machine
specifications.
Read the indication of the correct
pressure gauge by checking the
pressure gauge name indicated in
the nameplate.
Pressure setting value should also
be checked by the nameplate or
referring to the hydraulic/pneumatic circuit diagram.
Green
Pressure setting range: 1.7 - 1.9 MPa

screw of the pressure regulator.
(2) Loosen the lock nut.
(3) Adjust the pressure by turning the pr~ssure adjusting screw.

Lock nut
Pressure
adjusting
screw
cw ....... Pressure increases.


advance pressure regulator
(4) After obtaining the required pressure, lock the

pressure adjusting screw by securing the lock nut.
2-14
2.
DilT,I]I'*,
DAILY INSPECTION
GM6311
(e)
Reading the Bearing Lubrication Mist Pressure Gauge and Adjusting the Pressure
Pressure gauge of diamond roll
bearing lubrication mist pressure
Bearing mist
pressure adjusting
device
Green band
0.3 MPa
0.25 - 0.35 MPa

Pressure
adjusting
screw
NOTE
Adjustment will be impossible

unless the source pressure of
the air (air pressure at the
primary side) is higher than
115% of the setting pressure.
Example: Setting pressure ....... 0.3 MPa

In this case, the source pressure must be higher
than 0.35 MPa.
If pressure adjustment is not possible even after
increasing the source pressure, the filter may have
been clogged. In this case, clean or change the
filter.
(2) Pull the pressure adjusting screw up until the
orange band is exposed.
Adjust the pressure by turning the pressure adjusl- .
ing screw.
CW (viewed from the top) ...... Pressure increases.
CCW (viewed from the top) ... Pressure decreases.
215
2.
EIIXI]I'*,
DAILY INSPECTION
GM6311
(f)
Reading the Pressure Gauge of Wheel Spindle Bearing. Lubrication Mist Pressure
and Adjusting the Pressure
Mist pressure gauge

(Ieft wheel spindle
bearing)
Mist pressure gauge

(right wheel spindle
bearing)
Air pressure
gauge (regulator)
Green band
Pressure setting range: 0.03 MPa

Pressure
adjusting

Lock nut
(2) Loosen the lock nut.
(3) Adjust the pressure by turning the pressure

adjusting screw of the pressure regulator.
Adjust the pressure whileobserving the pressure
gauge.
2-16
2.
1IIlI111M
DAILY INSPECTION
GM6311
(g)
Reading the Air Regulator Pressure Gauge of Rest Sealing Air and Adjusting the
Pressure
Pressure gauge of rest

sealing air
Rest
Green band

(2) Pull the pressure adjusting screw up until the

Adjust the pressure by turning the pressure
adjusting screw.
Pressure adjusting
screw

Adjust the pressure while observing the pressure
gauge.
. 2-17
EI-n', M
I
2.
DAILY INSPECTION
GM6311
(h)
Reading the Pressure Gauge of Correct Workpiece Holding Check Air Pressure
and Adjusting the Pressure
(1) Load a workpiece into the machine and perform a

series of operation from work spindle advance to
footstock spindle center advance.
r:::r
Correct workpiece
holding check air
pressure
See 5.8 "Outline ofManuaI Operation"

(OperationManual).
Correct workpiece holding check

air pressure regulating valve
Green band
Green band
(2) Read the pressure gauge of the air regulating valve
and make sure that the pointer is within the green
band range.
(3) Pul! the pressure adjusting screw down until the
Adjust the pressure by turning the pressure adjusting screw.
CW (viewed from the bottom)
Pressure increases.
CCW (viewed from the bottom)
Pressure decreases.
Pressure adjusting
screw
Adjust the pressure while observing the pressure

gauge.
NOTE
If the pressure does not in

crease even if you turn the
pressure adjusting screw, the
hose could be damaged or air
leak at the center.
Check the workpiece if it is
correctly held by the center. If
. the air is leaking, clean the
workpiece center hole and the
footstock spindle center. Hold
the workpiece again and check.
2-18
li-nIJI,*,
DAILY INSPECTION
2.
GM6311
(i)
Adjusting
on Drips tor Oil-mist Lubrication
Air bypass
circuit f10w
control valve
(1) Count the number of oi! drips ina minute using a

stopwatch. The number of oi! drips can be observed through the dome in the mist lubrication oi!
tank.
Make sure that 20 to 50 drips of mist oi! are
observed.
Lock nut
(2) If the counted number of drips is not within the

range above, adjust the number of drips b turning
the oi! drip amount adjusting screw.
CW The number.of oi! drips increases.
Dome
(oi! drip
observing
window)
CCW The number of oi! drips decreases.

The number of oi! drips increases when the adjusting screw is turned clockwise.
The number of oi! drips decreases when the adjusting screw is turned counterclockwise.
Di! drip amount

adjusting screw
Mist lubrication oi!
tank
NOTE
If the number of oi! drips cannot

be reduced even if you turn the
adjusting screw, increase the
amount of air flowing through
the by pass circuit by opening
the air bypass circuit flow
control valve.
After loosening the lock nut by
turning it clockwise, turn the
flow adjusting screw counter
clockwise. This will reduce the
number of oi! drips.
NOTE
2-19
Although lubricating oH
consumption amount is not in
direct proportion to the number
of oi! drips, bearings could not
be lubricated well if the oH drip
count is adjusted too less since
the oi! is supplied in micro-fog
formo Make sure to adjust the
number of oi! drips appropri
ately.
2.
1Ilnl]11
DAILY INSPECTION
GM6311
Checking the Wheel Spindle Bearing Lubricating Oil filter

lubricating oil filter
(a) Mechanical Clogging Indication

Clog indication
Observe the status of the clogging indicator aboye

the filter.
Red indication:
Blue indication:
The filter element has been

clogged.
Normal state
If the red indication is observed, replace the filter

element.
r:::r
See 6.2.1 "Cleaning and Replacing the Wheel

Spindle Bearing Lubricating OH Filter".
NOTE
Electric type
The indicator may show "red

indication" due to pump surge
pressure immediately after the
pressing of the [MASTER ON]
button. If this occurs, press the
clog indication reset button
once to check if the indication
returns to blue. When the
indication returns to blue, the
filter is not clogged. If the
indicator continuously gives red
indication even after the
pressing of the reset button, the
filter element has been clogged
and must be replaced.
(b) Electric Clogging Indication

If the filter is clogged, the screen display the alarm
message "G46C: Wheel spindle bearing filter
, clogged".
NOTE
2-20
The filter element might have

been deformed due to pressure
difference upstream and down
stream of the filter if the
clogging indication is given. It
is recommended to check and
clean the filter element in
regular intervals disregarding the
indication of filter clogging.
2.
IktIIJI'4.
DAILY INSPECTION
GM6311
(k)
Checking the Lubricating Oil Filter
Lubricating oil
filter
Observe the status of the clogging indicator aboye

the filter.
Clogging
Red indication:
Blue indication:
Filter element has been

clogged.
Normal state
If the red indication is observed, replace the filter

element.
cr
See 6.2.1 "CIeaning and RepIacing the Wheel

Spindle Bearing Lubricating Oil Filter".
NOTE
The indicator may show "red

indication" due to pump surge
pressure immediately after the
pressing of the [MASTER ON]
button. If this occurs, press the
clog indication reset button
once to check if the indication
returns to blue. When the
indication returns to blue, the
filter is not clogged. If the
indicator continuously gives red
indication even after the press
ing of the reset button, the filter
element has been ,clogged and
must be replaced.
NOTE
The filter element might have

been deformed due to pressure
difference upstream and
downstream of the filter if the
clogging indicator shows "red
indication". It is recommended
to check and clean the filter
element in regular intervals
disregarding the indication of
the clogging indicator.
Lubricating oi! filter
2-21
2.
IklllllJ4
DAILY INSPECTION
GM6311
(1)
Checking the Air Filter
~CAUTION
If remaining air pressure blows out, coarse particulate may injure your eyes.
Wear safety goggles.
(1) Shut offthe power according to the procedure as

described in <Shutting OFF the Power> in Page 6-
1.
NOTE
For the type of the air filter used

in your machine, refer to the
hydraulic/pneumatic circuit of
your machine or the nameplate
affixed to the filter.
The photo shows the air filter Type:

AF4000-04BD-7-40AW3050-03BDG
Airfilter
(2) Shut off the air by the air shutting off lever cock.
(3) Water reserved in the filter is automatically drained

through the automatic drain.
If water remains in the filter or the filter element is
dirty, remove the case and clean the inside.
r:::r
2-22
See 6.2.3 "Replacing theAir Filter".
2.
Ik-fleJlrd
DAILY INSPECTION
GM6311
(m)
Checking and Adjusting Wheel Spindle Orive Belt Tension
(1) Remove the safety plug at the right side-door and

open it.
(2) Loosen the clamp bolt of the belt inspection
window cover at the pulley cover and open the
window.
Clamp bolt
(3) Check the wheel spindle drive belt tension.
eJ~ )
40N ~26-31 mm
8elt inspection
window cover
_ )
Push the belt at the center of its span by 49 N

force to check if the belt deflects 26 to 31 mm.
(4) To adjust belt tension, loosen the two motor base
clamp bolts once and then tighten them lightly.
(5) Turn the motor base slide bolt clockwise or counterclockwise to adjust belt tension.
(6) After adjusting belt tension, securely tighten the
motor base clamp bolts.
NOTE
Belt tension may change when

the motor base clamp bolts are
tightened.
After tightening the motor base
clamp bolts, check belt tension
again.
(7) Close the belt inspection window at the pulley

cover and fix the window cover in place by tightening the clamp bolt.
(8) Close the right side-door and insert the safety plug.
2-23
2.
U1nl ]1M
DAILY INSPECTION
GM6311
2.3
Inspection after Starting the Wheel Spindle

Check the coolant flow rate afier stating the wheel spindle.
If coolant amount is not sufficient, it will cause burning of the ground workpiece.
Coolant nozzle
(1) Place the [AUTO/MANUAL] switch in the

[MANUAL] position.
(2) Close all doors.
r:::r
See 5.2.2 "Closing the Doors" (Operation Manual).
(3) Press the [START WHEEL SPINDLE] button.
r:::r
See 5.3.1 "Starting the Wheel Spindle"

(OperationManual).
(4) Place the [COOLANT - OFF/ON] switch in the

rON] position. The coolant pump starts operating
to discharge coolant from the coolant nozzle.
~CAUTION
If you touch a rotating wheel, you
will get injured.
Keep away from the rotating wheel.
Check the amount coolant visually.
2-24
ii'iT,lllht
3.
REGULAR INSPECTION
GM6311
Check the machine in regular intervals as indicated below.
3.1
Monthlylnspection
The items that need inspection every month are shown in the table below.
Description
Part
Category
Chuck and drive pin

Work spindle center and
footstock spindle center
Consumable
parts
ti Check for wear.
Check for wear.
Wheel spindle drive belt ) Check for wear.
J Check for wear.
Rest shoes
Sizer contact and locator

Check for wear.
contacts
V
3.2
J Check for accumulation of dirt and dust.
Cooler
Oil cooler filter
OH-mist
lubrication
system
Wheel spindle bearing oil-mist

lubrication
I
Truer shaft bearing oil-mist (
lubrication
Check if mist oH is supplied.

Adjust oil-mist lubrication system.
Check if mist oH is supplied.
Adjust oil-mist lubrication system.
Pressure switch
Coolant pressure switch
Check the piping of the pressure switch for

blockage.
Every 3-month Inspection

The item that needs inspection every three months is shown in the table below.
Category
CNC unit
Part
CNC unit cooling fan
3-1
Description
Check the CNC cooling fan for the
following:
If the fan is operating.
If the fan is operating without abnormal
noise.
.
If the area around the fan is free of
accumulation of mist, dust and other
foreion matter.
I rlr,IJIt!'
3.
REGULAR INSPECTION
GM6311
Footstock
spindle
center
spindle center
lubricating oil cooler filter
Right wheel spindle

bearing oi
hose

oil-mist
Diamond roll shaft bearing

oil-mist hose
Coolant cooler filter
3-2
11-"1)114
3.
REGULAR INSPECTION
GM6311
<Pressure Switch Inspection Procedure>
(1) Shut off the power according to the procedure as
1.
(2) Disconnect the pressure switch piping and check
the pipe for existence of chips and other foreign
matter that block it.
If the pipe is blocked, remove chips and other
foreign matter by compressed airo
Coolant pressure
switch
Pressure switch
piping
(3) Connect the pipe to the pressure switch.

<Belt Inspection Procedure>
described in <Shutting OFF thePower> in Page 6-
1.
(2) Open the belt inspection window and check the
belt for wear.
(3) Close the belt inspection window.
Belt inspection window
<Control Cabinet Cooling Fan Inspection Window>

The following describes the procedure for an
example cooling tan.
described in <Shutting OFF the Power> in Page 61.
(2) Open the control cabinet door.
(3) Check the wire netting at the suction opening of
the cooling unit installed on the door for the accumulation of dust and foreign matter.
Exhaust
opening
(4) Check the exhaust opening for the accumulation of

dust and foreign matter.
(5) Close the control cabinet door.
(6) Place the circuit breaker on the control cabinet to
the [ON] position.
Observe the fan if it is operating without noise and
also the occurrence of an alarm at the cooler.
Suction
opening
CF See 5.9 "Electric Cabinet Cooler Alarms".
3-3
3.
REGULAR INSPECTION
3.3
Every 6-month Inspection
I iW'J 1M
GM6311
The item that needs inspection every six months is shown in the table below.
Category
Bearings
Check the bearings for generation of noise and run-out.
Rubber covers
Check the rubber covers for breakage, wear, 1055 of

elasticity and peeling.
Check the slide covers for breakage, wear and entry of
coolant beyond the slide cover.
Slide covers
Wheel spindle and diamond

ron shaft
Mechanical
parts
Description
Part
Check the wheel spindle and the diamond ron shaft for
run-out.
Wheelhead slide
the wheelhead slide for the amount of gap'(radial

J Check
and thrust directions) using a dial indicator.
Run-out of master bar
Mount a master bar in the chuck joumal holder and check

J the
run-out.
Contact ot sizer
j Check the sizer contacts tor wear.
Machine level
Air hoses
Air breathers
Check the machine level using a level gauge. Also check

jack bolts tor looseness.
j Check the air hoses tor conapse, detormation and
breakage.
Filter in the wheel spindle

bearing lubrication line
Hydraulicl
pneumatic parts Filters in lubrication line
Pumps
Joints
Distribution valves
/
Switch es
Check the filter elements tor clogging.

Check the filter elements for clogging.
Check the pumps tor generation

abnormal heat, and tor oil leaks.
Check the pipe joints for looseness, brakage and oilleaks.
~v
ot abnormal noise and
Check if the lubricating oi! is correctly s,upplied to the_

bearings.
.
Check the lamps for breakage and entry of coolant and the
micro-switches for breakage.
Check the float switch plastic covers and switch cables for
breakage.
Check the clamp nuts for looseness, the lamps tor
breakage, and the cables for breakage.
Pressure switches
! Float switches
Motor connectors
Check the motor connectors for looseness and breakage.
Motor insulation resistance
Measure the insulation resistance value.

than 20 Mil
It must be larger
Motor winding resistance
Measure the insulation resistance value.

than 20 il.
It must be less
/'
Check the water-proof packing for wear, the water-proof

fitting tor looseness, the terminals for looseness, and the
terminal box for entry of coolant.
J Terminal box
Connectors and connection/

Check the terminal blocks, colinectors and connection units
units at the CNC unit and
for looseness.,
connected devices
Screen protective sheet
Check the protective sheet for conapse and b(eakage of

float and the visibility of the screen if breakage or wear ot
the protective sheet has made the screen unclear.
UPS
Check if the UPS requires replacement (replacement period

is specified on the labeJ).
Source voltage
Measure the voltage at the primary side of the circuit

breaker on the control cabinet.
..
Supply grease through the greasing points.
Lubrication
tor filter clogging due to oil and
Proximity switches
CNC related
electrical parts
Check the air breathers

dust.
v
Ball screw
Ban screw support bearings J Supply grease through the greasing points.
34
3.
1i-"I] 1'4
REGULAR INSPECTION
(a)
GM6311
Inspection of the Workhead

Descriptjon
Part
Check the bearing for generation of abnormal noise and also

check the run-out amount of the master bar if it is within the
allowable limit.
Check the air breather filter for clogging due to oil and dust.
Air breather
Measure the insulation resistance value. It must be larger
Motor insulation
resistance
than 20 MO.
Measure the insulation resistance value. It must be less than
200.
Check the stroke of chuck jaws to clamp a workpiece if it is as
Chuck clamp stroke
specified in the drawinQ.
Joints
Check the piping joints for looseness, breakage and oilleaks.
Work spindle ram
Check if lubricating oil is supplied from the distribution valve.
lubrication
Check the connector for looseness, breakage and entry of
Motor wiring connector
coolant.
Faceplate bearing
Workhead rear cover
Air breather
Ram lubrication distribution valve

Work spindle
drive servomotor (C-axis)
Connector
Air breather
NOTE
The chuck dimensions and chucking method differ depending on the user's specifi
cations. Please refer to the tooling drawing, etc.
3-5
lienlJl1
3.
REGULAR INSPECTION
GM6311
Spindle Drive Servomotor (e-axis

1.
(3) Disconnect the motor power cables U, V and W at
the work spindle (e-axis) amplifier.
(4) Measure the resistance across the following
terminals with the Megohmtester set at the
500 Mn range.
U-E
V-E
W-E
E: Earth
IMPORTANT Make sure to disconnect the power
cables at the terminals before

measuring the resistance.
Otherwise, the amplifier will be
damaged.
Work spindle drive

servomotor
(5) Measured resistance value should be 20 Mn or

larger.
If the measured value is less than 20 Mn, insulation of the motor power cables may be faulty.
Therefore, also measure the insulation resistance
of the motor independently.
Disconnect the motor power cable connector of the
workhead and measure the resistance across the
following terminals with the Megohmtester set at
the 500 Mn range.
Pin A (U) - E (earth)

Pin B (V) - E (earth)
Pin e (W) - E (earth)
<Measuring Winding Resistance ofWork Spindle Drive Servomotor (e-axis

r}~J"
: .' e,
,
.:-<"_
CJ-{'::
\ ~:_!,;~.f
(1) Disconnect the motor power cable connector of the
following terminals of motor side connector with the
multimeter.
_~_'
.~>(;:.~
Make sure that measured resistance value is less

than 20 n.
Pin A (U) - Pin B (V)

Pin B (V) - Pin e (W)
Pin e (W) - Pin A (U)
IMPORTANT Do not use a Megohmtester for
measuring motor winding resistance. If used, the motor will be

damaged. Always use a multimeter when measuring motor winding resistance.
3-6
lilnl]ITd
3.
REGULAR INSPECTION
GM6311
<Measuring Insulation Resistance ofWork Spindle Orive Servomotor (Z-axis

1.
(3) Oisconnect the motor power cables U, V and W at
the work spindle (Z-axis) amplifier.

500 MQ range.
U-E
V-E
Motor power cables (U, V, W)
W-E
E: Earth

measuring the resistance. Otherwise, the amplifier will be damaged.
(5) Measured resistance value should be 20 MQ or
larger.
Work spindle drive
servomotor
If the measured value is less than 20 MQ, insulation of the motor power cables may be faulty.
Oisconnect the motor power cable connector of the
following terminals with the Megohmtester set at
the 500 MQ range.
PinA(U) - E (earth)
Pin B (V) - E (earth)
Pin (W) - E (earth)
(E)
<Measuring Winding Resistance ofWork Spindle Orive Servomotor (Z-axis

(1) Oisconnect the motor power cable connector of the
multimeter.
Make sure that the measured insulation resistance
is less than 20 Q.

Pin B (V) - Pin (W)
Pin (W) - Pin A (U)

damaged. Always use a multimeter
when measuring motor winding
resistan ce.
3-7
3.
IflnIJI'!'
REGULAR INSPECTION
(b)
GM6311
Inspection of the Wheelhead Infeed Axis

Parts
Descrlption
Wheelhead slide cover
Check the wheelhead slide cover for breakage.
Motor connector
Check the connector for looseness and breakage.
Ball screw support bearing
Check the bearing for generation of abnonnal noise. Also check the
run-out of the ball screw shaft if it is within 0.02 mm TIR.
Measure the insulation resistance.
Measure the winding resistance.
It must be larger than 20 Mil.

It must be less than 20 il.
Xm-axis servomotor
Xs-axis servomotor
<Measuring Insulation Resistance ofWheelhead Infeed Axis Servomotor (XmlXs-axis

1.
the wheel infeed axis (Xm/Xs-axis) amplifier.

500 Mil range.
U-E
V-E
W-E
~~<-
'~.
E: Earth

measuring the resistance. Other. wise, the amplifier will be damaged.
~,,;, Xm-axis servomotor

power cable
Motor connector... :.
(5) Measured resistance value should be 20 Mil or

larger.
If the measured value is less than 20 MO, insulation of the motor power cables may be faulty.
wheelhead infeed axis motor and measure the
resistance across the following terminals with the
Megohmtester set at the 500 Mil range.
Pin A (U) - Pin O (E)
Pin B (V) - Pin O (E)
Pin e (W) - Pin o (E)
3-8
o: Earth
MilrllllM
3.
REGULAR INSPECTION
GM6311
<Measuring Winding Resistance of Wheellnfeed Axis Servomotor>

(1) Disconnect the motor power cable connector ofthe
multimeter.
Motor connector
(V)
Make sure that the measured insulation resisfance

is less than 20 O.
Pin B (V) - Pin e (W)
Pin e (W) - Pin A (U)
'IMPORTANT Do not use a Megohmtester for
(e)
Inspection of the Wheel Spindle

Parts
Description
Joints
Check the joints for looseness, breakage, oilleaks and air leaks.
Motor connectors
Check the connectors for looseness and breakage.
Amount of float
Measure the amount of wheel spindle lift (radial and thrust directions)
with a dial indicator.
3-9
It must be larger than 20 MQ.

It must be less than 20 Q.
3.
IllrllJ I14
REGULAR INSPECTION
GM6311
<Measuring Insulation Resistance of Wheel Spindle Motor>

1.
Remove the front cover.
(3) Disconnect the output cables U, V, W from the

inverter.

500 MO range.
U-E
V-E
W-E
E: Earth
cables at the terminals befare

measuring the resistance. Otherwise, the inverter wiJI be damaged.
Terminal box
(5) Measured resistance value should be 20 MO or

larger.
If the measured value is less than 20 MO, insulation of the motor power cables may be faulty.
Disconnect the motor power cables at the terminal
box.
Resistance measurement at the motor side wiring:
U-E
V-E
W -E
E: Earth
<Measuring Winding Resistance of Wheel Spindle Motor>

terminals at the motor terminal box with the
multimeter.
U-V
V-W
W-U
Make sure that the measured resistance value is
less than 20 O
IMPORTANT Do not use
aMegohmtester for
measuring motor winding resistance. If used, the motor wiJI be

3-10 .
I ilnl]I,*,
3.
REGULAR INSPECTION
(d)
GM6311
Inspection of Wheel Truer
Description
Parts
Slide cover
Check the wheelhead slide cover for breakage.
Motor connector
Sall screw support bearing
Check the bearing for generation of abnorrnal noise.
It must be larger than 20 Mn.

It must be less than 20 Q.
Wheel truer infeed axis servomotor

Slide cover
3-11
Illrtl]lt!1
3.
REGULAR INSPECTION
GM6311
<Measuring Insulation Resistance of Wheel Truer Infeed Axis Servomotor>

1.
(3) Disconnect the motor cables U, V and W at the

wheel truer infeed axis (U-axis) amplifier.

500 Mil range.
U-E
V-E
W-E
E: Earth

cables at the terminalsbefor'
measuring the resistan ce. Otherwise, the amplifier will be damaged.
(5) Measured resistance value should be 20 Mil or
larger.
If the measured value is less than 20 Mil, insulation of the motor power cables may be faulty.
Loosen and disconnect the motor cable connector

of the wheel truing infeed axis (U-axis) motor and
measure resistance across. the following connector
terminals with the Megohmtester set at the 500
Milrange.
A (U) - D (E)
B (V) - D (E)
(W) - D (E)
3-12
D:Earth
I ilnl]I,*,
3.
REGULAR INSPECTION
GM6311
<Measuring Winding Resistance of Wheel Truer Traverse Axis Servomotor>
(1) Disconnect the motor power cable connector arid

measure the resistance across the following
terminals of motor side connector with the multimeter.
is less than 20 Q.
PinA(U) - E
Pin B (V) - E
Pin (W)- E
E: Earth

damaged., Always use a multimeter when measuring motor winding resistance.
<Measuring Insulation Resistance of Wheel Truer Traverse Axis Servomotor>

1.
(3) Disconnect the output cables A 1 (U), A2 (V) and
A3 (W) at the whee truer traverse feed (W-axis)
inverter.

500 MQ range.
U-E
V-E
W-E
Wheel truer traverse axis servomotor
power cable (U, V, W)
Motor connector
E: Earth
MIA.]ijM~iI Make sure to disconnect the power


larger.
Loosen and disconnect the motor cable connector
of the wheel truer traverse axis (W-axis) motor and
measure resistan ce across the following connector
'
500 MQ range.
PinA(U) - O (E)
Pin B (V) - O (E)
Pin e (W) - o (E)
o (E): Earth
3-13
1ilnl] 1M
3.
REGULAR INSPECTION
GM6311
<Measuring Winding Resistance of Wheel Truer Traverse Axis Servomotor>

Motor connector
(1) Disconnect the motor power cable connector and

measure the resistance across the following
terminals of motor side connector with the multimeter.
is less than 20 n.
Pin A (U) - B (V)
Pin B (V) - e (W)
Pin e (W) -A(W)

3-14
Ikiril]I'*,
3.
REGULAR INSPECTION
(e)
GM6311
Inspection of Diamond RolI Head

Description
Parts
Diamond roll shaft run-out
Check the run-out of the diamond roll shaft if it is within 0.01 mm TlR.
Meas~re
the insulation resistance.
It must be larger than 20 Mil.

It must be less than 20 il.
<Measuring Insulation Resistance of Diamond RolI Shaft Motor>

1.
. (2) Open the control cabinet door.
(3) Detach the operation panel and the case of the
diamond roll shaft inverter and disconnect the
output cables U, V, W from the terminal box.
500 MQ range.
U-E
V-E
W-E
E: Earth

measuring the resistance. Otherwise, the inverter will be damaged.
3-15
illillJIJ;l
3.
REGULAR INSPECTION
GM6311
larger.
Loosen and remove the motor power cable connector and measure the resistance across the following terminals at the terminal box terminalswith the
Megohmtester set at the 500 MQ range.
U-E
V-E
W-E
E: Earth
<Measuring Winding Resistance of Diamond ROII Shaft Motor>

(1) Measure the resistance across the fOllowing
multimeter.
U-V
V-W
W-U

less than 20 Q.
IMPORTANT Do not use a Megohmtesterfor
(f)
Inspection of Footstock Spindle

Parts
Description
Footstock ram
Check theram for scratches and wear.
Motor connector
Check the motor connector for looseness and breakage.
Footstock ram lubrication

distribution valve
Check if lubricating oil is discharged from the distribution valve.
Motor windlng resistance
Measure the winding resistan ce.
It must be larger than 20 M n.

It must be less than 20
n.
rp:e~~ljfW'- Draln pipe

Check if lubricating oil
flows out of the drain
pipe.
Distribution
valve
Footstock ram
3-16
1III]ID
3.
REGULAR INSPECTJON
GM6311
<Measuring Insulation Resistance of Footstock Spindle Servomotor>

1.
footstock spindle (,Z-axis) amplifier.
500 MQ range.
U-E
V-E
W-E
Footstock spindle (,Z-axis)

motor cable (U. V. W)
E: Earth
cables at the terminals before measuring the resistance. Otherwise, the

inverter will be damaged.
Motor connector

larger.
Loosen and remove the motor power cable connector and measure the resistance across the following terminals at the terminal box terminals with the
Megohmtester set at the 500 MQ range.
Pin A (U) - D (E)
Pin B (V) - D (E)
Pin (W) - D (E) E: Earth
<Measuring Winding Resistance of Footstock Spindle Servomotor>

Motor connector

multimeter.
Pin A (U) - B (V)
Pin B (V) - e (W)
Pin e (W) -A(V)
less than 20 Q.

3-17
I (In1lln,
3.
REGULAR INSPECTION
(g)
GM6311
Inspection of Rest Feed Axis

Parts
Description
Also check if lubricating oil is
Rest feed ram
Check the ram for scratches and wear.

dischan::ed from the distribution valve.
Motor connector
Check the motor connector for looseness and breakage.
Bottom shoe hinge pin
Check the hinge pin for wear and gap.
It must be larger than 20 MO.

It must be les s than 20 O.
Distribution valve
<Measuring Insulation Resistance of Footstock

Spindle Servomotor>
Ram

1.
rest feed axis (V-, Y- and A-axis) amplifier.
Motor connector
(4) Measure the resistan ce across the following

500 MQ range.
Hinge pin
U-E
V.. E
W-E
E: Earth

measuring the resistance. Otherwise, the inverter will be damaged.
larger.
If the measured value is less than 20 MQ, nsulation of the motor power cables may be faulty.
Loosen and remove the motor power cable connector and measure the resistance across the
following terminals at the motor connector terminals with the Megohmtester set at the 500 MQ
range.
Pin A (U) - D (E)
Pin B (V) - D (E)
Pin (W) - D (E)
3-18
D (E): Earth
Illii,lJlhl
3.
REGULAR INSPECTION
GM6311
<Measuring Winding Resistance of Footstock Spindle
Servomotor>
terminals at themotor terminal box with the
multimeter.
PinA (U) - B (V)
Pin B (V) - e (W)
Pin e (W) -A (V)
less than 20 Q.
3-19
IliUl)ltt .
REGULAR INSPECTION
3.
eh)
GM6311
Inspection of the Chuck

NOTE
The chuck used in the machine differs depending on the specifications.

Please refer to the tooling drawing supplied with the machi ne.
Parts
Chuck
Description
Check the workpiece clamping stroke.
Prepare the master work that corresponds to the lower

limit of the tolerance of the chucking section and
actually clamp the master work with the chuck to
check if the master work slips in the chuck .
. (i)
Inspection of the Sizer

Description
Parts
Contacls
Check the diamond tip at the contact tor wear and measure repeatability
l
in sizing operation.
Joints
Check the joints for looseness, breakage and oilleaks.
Proximity switch
Check the clamp nut tor looseness, the dog tor looseness and the
proximity switch cables tor breakage.
Sizer
contacts
Sizer
--
Inspection of the Panel pe

Description
Parts
UPS
Check the specified date ot replacement at the label.
Screen protective sheet
Check the protective sheet tor breakage, wear and other detects that
make the screen unclear.
UPS
3-20
I Irle)1M
3.
REGULAR INSPECTION
(k)
GM6311
Inspection of the CNC Unit

Description
Parts
Connectors
(1)
Check the terminal block, the connectors and the units for looseness.
Inspection of the Wheel Spindle Bearing Lubrication Pump Unit

Parts
Description
Air breather Qn the oillevel

gauge)
Check the air breather for clogging of the filter due to oil mist, dust and
other foreign matter.
.
Oillevel gauge
Check the oillevel gauge for breakage of the plastic case and the cable.
Pump
Check the pump for generation of abnormal noise and heat and also for
oilleaks.
Tenninal box
Check the water-proof packing for wear, the terminals for looseness and the
terminal box for entry of coolant.
Measure the insulation resistance value. It must be larger than 20 MU.
Measure the winding resistance value. It must be less than 20 Q.
Pressure switch
(wheelhead)
Check the pressure switch for breakage and entry of coolant.
Oil level gaugel

air breather
Pressure
switch
Air breather
<Measuring Insulation Resistance and Winding Resistance of Motor>

described in <Shuttirig OFF the Power> in Page 6-
1.
(2) Open. the wheel spindle bearing lubrication pump
motor terminal box.
(3) Disconnect the motor cables U, V, W.
3-21
Illnl]'d
3.
REGULAR INSPECTION
GM6311
(4) Measure the insulation resistance across the
motor cable and the earth with the Megohmtester
set at the 500 Mn range.
U-E
V-E
W-E
IMPORTANT
E: Earth
Make sure to disconnect the power cables at the terminals before

(5) Measure the winding resistance across the motor
windings with the multimeter.
U-V
V-W
W-U
less than 20 n.
IMPORTANT
(m)
Do not use a Megohmtester for measuring motor winding resistan ce.

If used, the motor will be damaged. Always use a multimeter when
measuring motor winding resistance.
Inspection of the Lubrication Pump Unit

Description
Parts
Air breather
(in the oillevel gauge)
I
I
Float switch
Pump
Terminal box
Check the air breather for clogging of the filter due to oil mist, dust and
other foreign matter.
.
Check the oil float switch for breakage of the plastic case and the cable.
Check the pump for generation of abnormal noise and heat and also for
oilleaks.
,j Check the water-proof packing for wear, the terminals for looseness and the
terminal box for entry of coolanl
.,'1

Measure the insulation resistance value. It must be larger than 20 MU.

I
Measure the winding resistance value. It must be less than 20 U
Pump
DiI level with air breather

(functioning also as float switch)
3-22
iif,l]lhl
3.
REGULAR INSPECTION
GM6311
<Measuring Insulation Resistance and Winding Resistance of Motor>

1.
Terminal
box
(2) Open the lubrication pump motor terminal box.

(3) Disconnect the motor cables U I V, W.
(4) Measure the insulation resistance across the
motor cable and the earth with the Megohmtester
set at the 500 Mn range.
Motor terminal
box
U-E
V-E
W-E
E: Earth
IMPORTANT Make sure to disconnect the power cables at the terminals before
(5) Measure the winding resistance across the motor

windings with the multimeter.
U-V
V-W
W-U
less than 20 n.
IMPORTANT Do not use a Megohmtester for measuring motor winding resislance.

If used, the motor will be damaged. Always use a multimeter when
measuring motor winding resistance.
(n)
Inspection of the Pneumatic Device Controller Panel

Description
Parts
Air pressure switch
Check the lamp tor breakage and entry ot coolant and the microswitch
tor breakage.
Air pressure switch
3-23
li-nl]IJa
3.
REGULAR INSPECTION
(o)
GM6311
Oil Cooler
Description
Parts
Pump
Check the pump tor generation

oilleaks.
3-24
ot abnormal noise and heat and also tor
3.
I ilrl11lJ!1
REGULAR INSPECTION
(p)
GM6311
Measuring the Source Voltage
Lt.
DANGER
Factor:
Hazardous high voltage.
Trouble:
How to avoid: Do not touch exposed terminals and devices.
Primary side terminals
(1) Turn the power off according to the procedure as

(R, S, T)
1.
(3) Measure the voltage across the terminals as

indicated below at the primary side terminals using
a multimeter.
R-S
R-T
S-T
Circuit breaker
IMPORTANT When measuring the source volt-
age, insert the probes of the multimeter through the holes in the
cover. Never remove the cover.
NOTE
Example of Circuit Breaker
Phase rotation direction at the primary

side terminals of the circuit breaker is
R, S and T (from the left to the right).
To ensure correct operation, check the
rotation direction of the individual
motors.
Probe inserlion hole
3-25
I IIRIJI'd
3.
REGULAR INSPECTION
(q)
. GM6311
Checking the Machine Level

Place a precision level on the table top face and adjust
the machine level by turning the jack bolt.
NOTE
Use a precision level having the

sensitivity of 0.02 mmlm/div.
(1) Clean the table top face.

(2) Place a precision level on the table top face.
(3) Tighten the leveling blocks uniformly while observing the precision level indication.
.Place a precision level

on the table top face
llli
~
~
( I f11
Crosswise
direction
~
~ il /Ievel
Precioion
(4) Adjust the leveling blocks while observing the

precision level indication so that the level in the
crosswise direction and the one in the traverse
direction will show the levelness within one division
ofthe level.
(5) Check the leveling blocks if they support the
machine uniformly.
Adjust them so that the machine is supported by
them uniformly.
Traverse
direction
Finally, the machine level should be adjusted within

two divisions of the precision leve\.
Leveling block
IMPORTANT This adjustment is necessary to

perform grinding without chattering by supporting the machine with
jack bolts evenly. Obtaining the
accurate machine level is not the
main purpose.
If level adjustment moved the
machine conslderably, check the
positional relationship between the
machine and the loader. Adjust
the loader position if necessary.
\
3-26
lilfll]lg
3.
REGULAR INSPECTION
(r)
(a)
GM6311
Greasing the 8,earings Supporting the Wheelhead Traverse Feed 8all Screw
Wheelhead Left Feed Sa" Screw
1.
(2) Supply grease through the greasing nipples at the
left side of the bed with a grease gun.
Grease: Multemp LRL3
NOTE
Greasing piping is fi"ed with the

specified grease befo re shipping the
machine. Supply the replenishing
amount of grease, 0.01 to 0.015 L,
with the grease gun.
Greasing nipples
Greasing
nipples

1.
right side of the bed with a grease gun.
Grease: Multemp LRL3
(s)
Greasing the Wheelhead Traverse Feed 8all Screw Nut

1.
right side of the wheelhead with a grease gun.
Grease: Alvania Grease EP1 (Shell)
NOTE
I Greasing piping is fi"ed with the

specified grease befo re shipping the
machine. Supply the replenishing
amount of grease, 0.01 to 0.015 L,
with the grease gun.
3-27
lilfll]lk'
3.
REGULAR INSPECTION
(t)
GM6311
Taper Corrector
Part
Descriptlon
Taper correction shaft

backlash
Measure backlash with a dial indicator.
Motor connector
Rotary shaft bearing

lubrication
Check if lubricating oil is supplied from the lubrication distribution valve.
Motor insulation resistan ce
Measure the insulation resistance value. It must be larger than 20 MQ.
Measure the winding resistance value. It must be less than 20 Q.
3-28
3.
iil.1'Dm
REGULAR INSPECTION
GM6311
<Measuring Insulation Resistance of Taper Corrector Axis Servomotor>

1.

the taper corrector axis (S-axis) amplifier.
500 MO range.
U-E
V-E
W-E
E: Earth

measuring the resistance.
Otherwise, the amplifier will be
damaged.
(5) Measured resistance value should be 20 Mo or

larger.
If the measured value is less than 20 Mo, insulation of the motor power cables may be faulty.
taper corrector axis (S-axis) and measure the
resistance across the following terminals with the
Megohmtester set at the 500 Mo range.
A (U) - D (E)
S (V) - D (E)
C (W) - D (E)
3-29
D (E): Earth
liliVII]ltl
3.
REGULAR INSPECTION
3.4
GM6311
. Every 1-year Inspection

The items that need inspection every year are shown in the table below.
Category
Mechanical parts
(a)
Description
Part
Unearguide
Check the linear gUide for play and wear.
Wheel Truer Traverse Feed Axis Linear Guide

describedin <Shutting OFF the Power> in Page 61.
Linear guide
(2) Open the wheel truer traverse feed axis slide cover.
0= See 6.12.5 "Replacing the Wheel Truer Traverse

Servomotor".
(3) Check the external appearance of the linear guide.

Check the linear guide for wear and damage.
(4) Apply the test indicator fixed cn the bed onto the
truer traverse axis and push the wheel truer to
check if there is a play.
(5) Close the wheel truer traverse feed axis slide cover.
(b)
Wheel Truer Infeed Axis Linear Guide

Wheel truer infeed axis

described in <Shutting OFF the Power> in Page 61.
(2) Open the wheel truer infeed axis slide cover.
0= See 6.12.4 "Replacing the Wheel Truer Infeed

Servomotor".
(3) Check the external appearance of the linear guide.

Linear guide
(4) Apply the test indicator fixed on the truer body

onto the truer infeed axis and push the truer infeed
axis to check if there is a play.
(5) Close the wheel truer infeed axis slide cover.
3-30
lilr,lll'*,
4.
PARTS REPLACEMENT IN REGULAR INTERVALS
4.1
Every Six Months

Replaeement
by User
Part Name
Unit
GM6311
Part No. and Other Information
Panel PC
Sereen protective sheet
Possible
GSH-008
Lubrication pump unit
Lubrieating oil
Possible
Vaeuoline 1409 (Mobil)
If the screen protective sheet is scratched causing

unclear screen display, peel off it and affix new protective sheet to the screen.
Sereen
proteetive sheet
4.2
Every Year
Part Name
Unit
Replaeement
by User
Part No. and Other

Information
Wheel head (Ieft)
Air breather
Possible
MSA-60N
Wheel head (right)
Air breather
Possible
MSA-60N
Workhead
Air breather
Possible
MSA-60N

lubrication pump unit
Oillevel gauge/Air breather
Possible
CLT-1-B1-0B-B0-130 (1 pe.)
Lubrieating oil
Possible
DTE Oil Light (Mobil)
Lubrica1ion pump unit
Possible
CLT-1-B1-0B-40-80
Possible
CLT-1-B1-0B-B0-130 (1 pe.)
Hydraulie oil
Possible
DTE22 (Mobil)
Hydraufie pump unit
NOTE
In the column of "Replacement by User", "Possible" is entered for the items that
can be replaced by the user. If replacement by the user is hard since a jig or
special apparatus is necessary, 'Toyoda" is entered.
Even for the items identified as "Possible", replacement may need time and a
trained persono If the user judge that replacement is not easy, please contact
your local Toyoda Machinery Work's service center.
4-1
4.
PARTS REPLACEMENT IN REGULARINTERVALS
Mi-n-,it'
GM6311
(a) Air Breather (MSA-60N)
(1) Loosen the cap by turning it counterclockwise.

Remove the cap the replace the filter in the air
breather.
(2) Tighten the cap by turning it clockwise.
(b)
on Level Gauge/Air Breather
(1) Turn the cap on oillevel gauge to the [OPEN]

position.
Remove the cap by pulling it aboye.
(2) Replace the filter.
(3) Close the cap and turn it to the [CLaSE] position.
4-2
IllrIIJI'!I
4.
4.3
EveryTwo Years
Replaeement
bv User
Part Name
Unit
Oilseal
Toyoda
28-80060210-0 (2 pes.)
Oilseal
Toyoda
28-80060214-0 (1 pe.)
O ring
Toyoda
PG-EM-220 (1 pe.)
O ring
Toyoda
PG-EM-230 (1 pe.)
O ring
Toyoda
PG-EM-50 (1 pe.)
O ring
Toyoda
PG-EM-100 (1 pe.)
O ring
Toyoda
PG-CM-12 (6 pes.)
Oilseal
Toyoda
28-80060220-0 (2 pes.)
O ring
Toyoda
PG-EM-21O (1 pe.)
O ring
Toyoda
PG-CM-12 (6 pes.)
Dust seal
Possible
28-71040151-0 (1 pe.)
O ring
Possible
PG-EM-58 (1 pe.)
Oilseal
Possible
G1501657 (1 pe.)
Ollseal
Possible
S15018014 (1 pe.)
O ring
Possible
PG-CM-140 (1 pe.)
O ring
Possible
AS568-173 (1 pe.)
Seraper
Possible
SER-95 (1 pe.)
Paeking
Possible
SKY-95 (1 pe.)
Oilseal
Possible
MB-R1523001-A (2 pes.)
Paeking
Possible
SKY-38 (1 pe.)
Seraper
Possible
SDR-38 (1 pe.)
O ring
Possible
PG-EM-50 (1 pe.)
O ring
Possible
PG-EM-60 (1 pe.)
O ring
Possible
PG-CM-26 (1 pe.)
O ring
Possible
PG-EM-55 (1 pe.)
Seraper
Toyoda
SER-90 (1 pe.)
Oilseal
Toyoda
DKB3-120 (1 pe.)
Seraper
Toyoda
SER-75 (1 pe.)
Wheelhead

lubricating oil filter
Possible
FH-TK300-40-06M (1 pe.)
Lubrication pump unit
Lubricating oil filter
Possible
FH-TK300-40-02M (1 pe.)
(])
"C
.;
o::
oC
Cl
Wheel spindle
bearing
(])
"C
.;
~
...J
Wheel truer infeed ram
Work spindle faeeplate
Hydraulieally-operated
footstock
Automatie eenterdistanee eorreetion

type footstoek
4-3
GM6311
4.
111111]1'41
GM6311
Pneumatie device
controller panel
Air filter
Possible
AF4000-D4BD-7-40 (1 pe.)
Airfilter
Possible
AW3050-03BDG (1 pe.)
Oilcocler
Filter
Possible
NOTE
In the replacement of an oil seal in the wheel spindle bearing, if foreign matter
enters the bearing or the bearing is damaged, spindle accuracy cannot be
guaranteed.
Please contact your local Toyoda Machine Work service center when replacing an
oil seal of the wheel spindle bearing.
4.
PARTS REPLACEMENT IN' REGULAR INTERVALS
I i.flalIJd
GM6311
{a} Wheel Spindle Bearing
(1) Remove the wheels and the wheel f1anges
r::::r
See 6.4.1 "Removing a Wheel"

(OperationManual).
(2) Remove the pulley.

(3) Remove the drain cock.
(4) Disassemble the right bearing and replace the,oil
seal.
=J.'"-..... '(5) Disassemble the left bearing and replace the oil
seal.
bearing
Drain cock
NOTE
For the bearing disassembling procedure, please contact uso
IMPORTANT If the bearing is damaged or

foreign matter enters it, bearing
performance could be deteriorated
considerably.
If oil seal must be replaced, please
return the wheel spindle assembly
to us by installing the spare wheel
spindle assemblyin the machi ne.
{b} Work Spindle Faceplate
Bearing retainer

1.
For the machine equipped with the chuck, loosen
and remove the' chuck clamp bolts and remove the
chuck.
(2) Fit the center extracting tool on the center and
remove the center by turning the center extracting
tool clockwise.
(3) Loosen and remove the faceplate clamp bolts and
remove the faceplate.
(4) Loosen and remove the seal cap clamp bolts.
Remove the seal cap.
Remove the oil seal and the O ring from the seal
cap.
(5) Loosen and remove the bearing retainer clamp
bolts. Remove the bearing retainer.
Remove the oil seal and the O ring from the bearing retainer.
(6) Set a new oil seal and O ring in the bearing retainer.
(7) Attach the bearing retainer to the workhead and
tighten the clamp bolts.
(8) Mount a new oil seal and O ring to the cap.
(9) Attach the cap to the workpiece and tighten the
clamp bolts.
4-5
I flr(l]IXt
4.
GM6311
(e) Wheel Truer Infeed Ram

(1) Remove the wheel.
r::::r
Diamond roll
head
(2) Remove the diamond roll head.
r::::r
Coolant cover
clamp bolts
Diamond roll head
See 6.3 "Changing the Wheels"

(OperationManual).
See 6.14.3 "Replacing the Diamond Roll Head".
(3) Loosen and remove the eight coolant cover clamp

bolts, and open the coolant cover.
(4) Loosen and remove the seal cap clamp bolts, and
remove the seal cap.
(5) Remove the dust seal from the seal cap and set a
new dust seal.
(6) Mount a new seal cap and clamp it in place by
tightening the clamp bolts.
(7) Close the coolant cover and tighten the clamp
bolts.
(8) Mount the diamond roll head.
r::::r
See 6.14.3 "Replacing the Diamond Roll Head".
(9) Mount the wheel.
r::::r
See 6.3 "Changing the Wheels"

(OperationManual).
Coolant cover
(d) Hydraulieally-operated Footstoek

1.
(2) Disassemble and remove the footstock spindle ram
and replace the scraper.
I Ilnl]I,!1 .
4.
4.4
Every Five Years
Wheelfeed
Taper corrector
Automatie wheel
guard open/elose
unit (option)
,
Automatie wheel
guard eompensator
(option)
Diamond roll head
Replaeement Part No. and Other

by User
Information
Part Name
Unit
Angular ring
Toyoda
MB-JB640001 (2 pes.)
Bearing
Toyoda
K-BB-6208P5 (4 pes.)
Bearing
Toyoda
K-BB-6008 (2 pes.)
Thrust angular eontaet ball

bearing
Toyoda
38-02050054-0 (1 pe.)
O ring
Toyoda
PG-EM-110 (2 pes.)
O ring
Toyoda
PG-EM-95 (1 pe.)
Toyoda
K-BB-6016LU (1 pe.)
Bearing
Needle bearing
Toyoda
K-NB-NKX30T2Z (2 pes.)
Thru~t
Toyoda
K-NB-WS81106 (1 pe.)
Toyoda
K-BB-7005 (1 pe.)
Toyoda
K-BB-7006 (1 pe.)
OUseal
Toyoda
S25408 (1 pe.)
O ring
Toyoda
PG-EM-55 (1 pe.)
O ring
Toyoda
PG-EM-40 (1 pe.)
OUseal
Toyoda
8406211 (1 pe.)
Toyoda
20-99781104-0 (1 pe.)
Toyoda
PB-JB630001-A(1 pe.)
Toyoda
30TAC62BDFFC10PN7A
(1 pe.)
Toyoda
K-BB-6004 (1 pe.)
Angular eontact ball

bearing
Toyoda
PB-JB699001-A (1 pe.)
Seraper
Toyoda
SER-95 (1 pe.)
Paeking
Toyoda
SKY-95 (1 pe.)
O ring
Toyoda
PG-EM-145 (1 pe.)

bearing
Toyoda
PB-JB650001-A (1 pe.)
Oilseal
Toyoda
G42556 (1 pe.)
O ring
Toyoda
PG-EM-95 (1 pe.)
O ring
Toyoda
PG-EM-75 (1 pe.)

bearing
Toyoda
K-BB-7204C (1 pe.)
bearing
Angular eontaet ball

bearing
bearir!Q
Tapered roller bearing
Wheel truer infeed

unit

bearing
Wheel truer traverse bearing
feed unit
Bearing
Workhead
GM6311
4--7
,I
I klill]
4.
Automatie
eenter-distanee
eorreetion type
footstoek
Rest
1,'
GM6311
Angular eontaet ball bearing
Toyoda
K-BB-7204C (2 pes.)
Bearing
Toyoda
MB-JH315001-A (1 pe.)
Needle bearing
Toyoda
K-NB-NK25/16R (2 pes.)
Thrust bearlng
Toyoda
K-NB-81106T2 (1 pe.)
Thrust bearlng
Toyoda
K-NB-81105T2 (1 pe.)
O ring
Toyoda
PG-EM-80 (2 pes.)
Bearing
Toyoda
K-BB-6003LLU (2 pes.)
Needle bearing
Toyoda
K-NB-RNA4902R (1 pe.)
Bearing
Toyoda
K-NB-81104T2 (1 pe.)
O ring
Toyoda
PG-EM-110 (2 pes.)
Needle bearing
Toyoda
K-NB-NK22116R (1 pe.)
Thrust bearlng
Toyoda
K-NB-81105T2 (1 pe.)
Seraper
Toyoda '
SER-56 (2 pes.)
Bearing
Toyoda
K-BB-7203A-P6 (2 pes.)
O ring
Toyoda
PG-EM-35 (2 pes.)
Oilseal
Toyoda
D17308 (2 pes.)
Needle bearing
Toyoda
Needle bearing
Toyoda
Thrust bearing
Toyoda
K-BB-51104 (2 pes.)
Thrust bearing
Toyoda
K-BB-51105 (2 pes.)
O ring
Toyoda
PG-EM-70 (2 pes.)
O ring
Toyoda
PG-EM-58 (1 pe.)
Bearing
Toyoda
K-BB-7007-P6 (1 pe.)
Bearing
Toyoda
K-BB-7003-P6 (1 pe.)
Oilseal
Toyoda
G48626 (1 pe.)
Oilseal
Toyoda
S35488 (1 pe.)
O ring
Toyoda
PG-EM-60 (1 pe.)
O ring
Toyoda
PG-EM-30 (1 pe.)
Bearing
Toyoda
K-NB-G24x32x4 (2 pes.)
K-NB-NK19/16R+1R15x 19x 16
(1 pe.)
K-NB-NK24/16R+1 R20 x 24 x 16
(1 pe.)
111111]1141
4.
4.5
Parts Replacement in Intervals of Specified Operating Hours

Unit
Panel PC
(a)
Replacement
by User
Part Name
LCD screen
Possible
UPS
Possible
GM6311
Replaeing the LCO Sereen of Panel PC

It is recommended to replace the
ON).
LeO screen every 5000 hours of operation (power
To elongate the Leo screen life, setting is so made to turn off the screen if operation is
not performed at the screen. The screen turns on when you touch the screen for a
while.
If you have not used the screen, the screen automatically goes off after the elapse of
set length of time.
Even if the screen is off, machine operations such as operation of buttons on the
operation panel and grinding operation can be proceeded normally.
For the procedure for replacing the panel pe
r::::r
(b)
Leo screen, see the following.
See 6.15.9 "Replacing the Panel PC and the Peripherals".
Replaeing the UPS

An UPS is used to supply power to the panel pe if power failure occurs. Since the
UPS keeps the power ON for the timer-set period after the machine is turned off, do not
try to change the UPS until the screen goes off.
For the procedure tor replacing the UPS, seethe following,
r::::r
See 6.15.9 "Replacing the Panel PC and the Peripherals".
IMPORTANT If the machine will be left off for more than one month, place the
power switch of the UPS to the OFF position.
If the switch is left ON, the UPS will discharge and will fail to
operate when the power is switched on.
When switching on the machine with the UPS switch set OFF,
make sure to set the switch in the ON position.
4-9
I ilnl] 1M
5. TROUBLESHOOTING
GM6311
5.1
Precautions on Troubleshooting
WARNING
When trouble occurs with the machine, press the [EMERGENCY STOP] pushbutton
switch to stop the machine, and follow the instructions of the qualified person your
company has appointed. Do not take any action until the qualified person has
arrived.
.
WARNING
Turn off the power before entering inside the machine.
5-1
ilnl]ltd
5. TROUBLESHOOTING
GM6311
5.2
(a)
Basics of Error Processing

After the Oeeurrenee of an Alarm
(1) Display the alarm information
cr See 5.4 "After the Occurrence of Error".

(2) Investigate the alarm to locate the cause.
If you cannot find the cause of the alarm, contact
your local Toyoda Machine Works Service Center
using the Trouble Report Form.
cr See 5.3 "Trouble Report Form".

(3) Eliminate the cause of the alarm.
cr See the relevant section in the Maintenance

Manual.
(4) Reset the alarm state.
cr See 5.4.3 "Resetting the Error".

(b)
Inaeeurate Grinding
(1) Measure the ground accuracy.
Dimensional accuracy measurement results
should be plotted according to time.
Roundness measurement results should be recorded with the phase datum position marked in
the chart.
(2) Estimate the cause of inaccuracy referring to this
manual.
cr See 11.5 "Corrective Actions for Inaccurate

.Grinding".
If you cannot find the cause of inaccuracy, contact
cr See 5.3 "Trouble Report Form".

(3) Eliminate the cause of inaccuracy.
If you want us to take corrective action, contact
cr See5.3 "TroubleReportForm".
(4) Perform test grinding to check the accuracy of
ground workpiece.
(e)
Troubles on User Speeifieations

If the manual of the user specifications is supplied
with the machine, loca te and eliminate the cause
of the trouble referring to the manual.
Ifyou cannot find the cause of the trouble, contact
5-2
I iW'] 11
5. TROUBLESHOOTING
GM6311
5.3
Trouble Report Form

After the occurrence of an error or a trouble, if you need to contact us to take corrective
actions, please use the form given below. The information you enter in the form will help
us locate the cause and determine the best corrective actions so that the downtime of the
machine will be minimized.
Contact:
Toyoda Machine Works, Ltd.

1-1, Asahi-cho, Kariya, Aichi Pref., 448 JAPAN
Phone: +81-566-25-5161 Fax: +81-566-25-5484
Trouble Report
Company
Phone
Oepartment
Address
Fax
Name
Machine Model
NC
MachineNo.
Oelivered
Occurred
Y/MIO:
Y/M/D:
Alarm Code No.
Exec. Program No.
Alarm Message
Buff. Program No.
Trouble Related Unit name:
------------------------------------------------------------------------------------------------------------.-- Trouble Involved Axes: XR, Xl, ZR, Zl, UR, Ul, YR, Yl, Cl, CR, RR, Rl, O, Wl, Q, PR,
........................... ~!:t.~~.yy.~....................................................................... .
ON lamp:
Occurred at Power ON, MASTER ON, Manual Operation (
cycle), Automatic Operation, Others
--------------------------------------------------------------------------------------------------------------- Frequency: Always, Frequent L
Ambient Temperature:
times/hour), Sometimes
times/hour), Others
CO
Oetails
--------------------------------------------------------------F--------------------------------------------- ----
Alarrn Code No.
Exec. Program No.
Alarrn Message
Buff. Program No.
o
o
U!Wl D
I
5. TROUBLESHOOTING
GM6311
5.4
. 5.4.1
(a)
After the Occurrence of Error

Displaying Error Information
Displaying Error Information (Daily Operation)
(1) Click the [ERROR] button on the screen.
The DISPLAY FAULT COMMENT screen is displayed.
NOTE
I If an error occurs, the DISPLAY FAULT

COMMENT window automatically
opens.
To close the window, click the
[CLOSE] button at the screen. The
DISPLAY FAULT COMMENT window
closes.
I I-nl] 1M
5. TROUBLESHOOTING
GM6311
(b)
Displaying Error Information (Maintenance)

(1) Click the [MAINTE MENU] button on the screen.
The MAINTENANCE MENU screen is displayed.
(2) Click the [ERROR DISPLAY] button on the screen.

The ERROR DISPLAY MENU screen is displayed.
(3) Click the [ERROR DISPLAY] button on the screen.

The ERROR DISPLAY COMMENT screen is
displayed.
NOTE
I Click the erro~ or warning number field,

and the window showing details of the
error or warning opens.
To c10se the window, click the
[CLOSE] button at the screen. The
detail information display window
closes.
5-5
lilllll
5. TROUBLESHOOTING
GM6311
(e)
Displaying the Error Log

(1) Click the [MAINTE MENU] bution on the screen.
(2) Click the [ERROR DISPLAY] bution on the screen.

(3) Click the [ERROR LaG DISPLAY] bution on the

screen.
The DISPLAY RECORD OF FAULT screen is
displayed.
NOTE
I After the occurrence of an error, the

error information is registered to the
error log when error releasing operatlon is carried out or the power is shut
off.
1liDl ] 1M
5. TROUBLESHOOTING
GM6311 .
5.4.2
Kinds of Error Display and Description of Alarm Codes
(a)
Error Display Screen (Daily Operation)

NOTE
I For diagnosis of the error, check the

indicated alarm code, and refer to the
relevant explanation in this Maintenance Manual.
Alarm Code
Program No. in Execution
r--~------~-------,
G415 EXECUT
00000
NOOOO
I
L_CN~TIE~~U~ _____\
Alarm Message
__ ~
Sequence No. in Execution
r-----------------,
READ
00000
NOOOO
I
L-------~-----t--~
Buffering Program No.
Buffering Sequence No.
Error/Warning Indication
Display
Alarm Code
Error
A-E
Warning
F -G
AlarrnCode
I I I
I
Display
CNC Status afier Occurrence of Error
Emergency stop
Immediate stop (without deceleration) and return
Immediate stop (without deceleration)
Stop afier deceleration
Single block stop
Only display of Warning
Only display of Warning (detected py PLC)
5-7
Display
Phenomena
00-99
Suffix (numbers)
Display
Cause of Error
Error in operation
Error in operation
Error in NC program
Error in NC program
Machine fault
Error in software
Error in hardware
Error in hardware
Error in hardware
Error in grinding data
5. TROUBLESHOOTING
GM6311
(b)
Error Display Screen (Maintenance) and Error Log Screen

For diagnosis of the error, check the
indicated alarm code, and refer to the
relevant explanation in this Maintenance Manual.
NOTE
Alarm Code
Unit No.
/
Error Detected
CPU No.
r---/---I---}-------,
G415
O -
00
00
~_~fMTIE~~Ucr __\-----~
Alarm Message
Axis No.
Sequence No. in Execution
~rog~m N~in Executi: _
I
I
Error/Warning Indication
Display
AlarrnCode
Error
A-E
Warning
F -G
\
EXECUT
READ
00000
00000
Error Occurrence
1-__ ,
_ --=,ate
11.03.00.14.36.07
NOOOO
NOOOO
I
I
I
L-------f----\----~
Buffering Program No.
Buffering Sequence No.
Error Detected CPU No.
Unit No.
Display
Unit No.
Display
Other than NC operation
MCUL
DSUS1
DSUS2
DSUS3
CPU
1111,1]114
5. TROUBLESHOOTING
GM6311
Error-occurring axis number indication
NCAxes
Q)
XM:
Right wheelhead infeed (master)
XS:
Rightwheelhead infeed (slave)
C:
Work spindle (angular position)
Z:
Work spindle (position)
U:
Wheel truer infeed
W:
Wheel truer traverse
B:
Taper correction
V:
Steady rest 1
Y:
Steady rest 2
10
A:
Steady rest 3 (not used)
11
,Z:
Footstock spindle
(ti
(J)
AlarmCode
I I
Display
CNC Status afier Occurrence of Error
Emergency stop
Immediate stop (without deceleration) and return
Immediate stop (without deceleration)
Stop afier deceleration
Single block stop
Only display of Warning
Only display of Warning (detected by PLC)
..
5-9
Display
OO-FF
Display
Phenomena
Suffix (numbers)
Cause of Error
Error in operation
Error in operation
Error in NC program
Error in NC program
Machine fault
Error in software
Error in hardware
Error in hardware
Error in hardware
Error in grinding data
I'KIII'4
5. TROUBLESHOOTING
GM6311
5.4.3
(a)
Resetting the Error

Resetting the E.rror by the Error Resetting Function
The ERROR DISPLAY screen is displayed.
(2) Check the alarm message and remove the cause
by referring to the Maintenance Manual.
O'See Section 5.5 "Diagnosis and Corrective

Action" in the Maintenance Manual.
(3) For errors tor which the alarm code begins with
"G", follow the steps indicated below to reset the
error.
MANU- AUTO
(2)
(4) Place the [AUTO/MANUAL] selector switch in the

[MANUAL] position.
(5) Click the [CLaSE] button at the screen.

The DISPLAY FAULT COMMENTwindow closes.
(6) Click the [OP PANEL] button.at the screen.

The OPERATION PANEL window opens.
(7) Click the [FAULT RESET] button on the screen.

Press the [ACTIVATE] button.
The error state is reset.
NOTE
If the error cannot be reset even when

the [ACTIVATE] button is pressed, the
cause of the error could have not been
removed. Repeat the steps aboye
again after removing the cause.
NOTE
For errors for which the alarm code

begins with "A", "B", "C", "O", "E" or"F",
reset the NC.
O' See item (b) "Resetting the Error by the NC

ACTIVATE
ResetFunction ".
NOTE
r:::r
5-10
Some errors for which the alarm code

begins with ~G" require the [MASTER]
button to be pressed.
See item (c) "Resetting the Error by Pressing the

[MASTER] Button".
UOleJ1td
5. TROUBLESHOOTING
GM6311
{b}
Resetting the Error by the NC Reset Function

displayed.
(2) Check the alarm message and remove the cause
by referring to the Maintenance Manual.
r:::r
See Section 5.5 "Diagnosis and Corrective

Action" in tbe Maintenance Manual.
(3) For errors for which the alarm code begins with "A",
"B", "C", "D", "E" or "F", follow the steps indicated
below to reset the error.
(4) Place the [AUTO/MANUAL] selector switch in the

[MANUAL] position.
MANU- AUTO
(2)
(5) Press the [NC RESET] button.

The error state is reset.
NCRESET
0
.J~~
NOTE
If the error cannot be reset even when

the [NC RESET] button is pressed,
the cause of the error could have not
been removed. Repeat the steps
aboye again after removing the cause.
NOTE
Sorne errors for which the alarm code

begins with "G" require the [MASTER]
button to be pressed.
r:::r
See item (e) "Resetting tbe Error by Pressing tbe

(MASTER] Button ".
NOTE
',:
r:::r
5-11
Sorne errors for which the alarm code

begins with "A" or "F" require the
power to be turned off and then back
on.
See item (d) "Resetting tbe Error by Turning tbe

Power OFF and ON ".
Iklii,I]I,t
5. TROUBLESHOOTING
GM6311
(e)
Resetting the Error by Pressing the [CONTROL ON] Button

The following describes the required action afier the
occurrence of "G420 Low air pressure".

displayed.
Example: G420
Low air pressure (pressure lower than the set
value, air leak, clogged filter)
Remove the cause and reset the error by pressing
the [MASTER] button.
(2) Confirm the error message and remove the cause

of the error by referring to the Maintenance Manual.
Example:
Cause:
Action:
Result:
MASTER
Clogged air filter element

Element is changed.
The correct air pressure is
recovered.
(3) Press the [MASTER] button.

The error is reset.
NOTE
5-12
If the error state cannot be reset even

afier the pressing of the [MASTER]
button, there may be another error.
Check the status again if another error
has occurred.
Ilenll1hl
5. TROUBLESHOOTING
GM6311
(d)
,Resetting the Error by Turning the Power OFF and ON

displayed.
Example: F002
The position data has varied exceeding the limit
set for a maintenance parameter while the operation ready signal is off.
Check the setting for the maintenance parameter,
or check axis movement mechanical system.
Cause:
Error occurred when the

servomotor was changed
(correct operation).
Action:
The position shift protection

function is canceled.
r:::r
See 6.12.1 "Canceling tbe Position-offset Safety

Protection Function" in tbe Maintenance Manual.
Example: A001
After writing a para meter, turn off the power once
and turn it back on.
Cause:
EMERGENCY STOP
Setting of the maintenance

parameter was changed
(correct operation).
(2) Locate the cause by referring to the Maintenance

Manual.
For alarms that will occur while correct operation is
performed, during such as replacement of a servomotor, follow the steps indicated in the Maintenance Manual.
(3) Press the [EMERGENCY STOP] button.
This step is not necessary if the machine has
already been in the emergency stop state after the
occurrence of "A" alarm, for example.
(4) Click the [QUIT HMI] bution on the screen.
5-13
I IlnlJ 1M
5. TROUBLESHOOTING
GM6311
(5) The HMI window opens and the message of "ARE
YOU SURE YOU WANT TO QUIT WINDOWS
AFTER QUIITING HMI? " is displayed. Click the
[Yes] butlon on the screen.
The HMI window closes and the message box as
shown below opens.
(6) After making sure that the wheel has completely

stopped, turn the circuit breaker to the [OFF]
position.
cj='
See 3.3.4. "Shutting the Power OFF" in the

OperationManual.
(7) Turn back the circuit breaker to the [ON] position.

cj='
514
See 3.3.1 "Turning the Power ON" in the

Operation Manual.
II-nl]IU
5. TROUBLESHOOTING
GM6311
5.5
Diagnosis and Corrective Action

This section deals with Alarm Ato Alarm G.
Example
Alarm No.: AOOO
Messages
Causes
----------------------------------- IThe messages displayed on the screen I

: PARAMETER IS WRITTEN
Corrective Action : Turn OFF the power and turn it back ON.
IHow the alarm was detected I
Description
Maintenanc parameters were written.
Auxiliary axis parameters were written.
A parameter was written at the initialization of SERCANS.
Causes and Corrective Action

Causes
------1 Probable causel
1. Maintenance parameters were written.

2. Auxiliary axis parameters were written.
3. A para meter was written at the initialization of
SERCANS.
Corrective Action-----IAction to be takenl
1. Exit the HMI, stop the windows, shut off the

power then turn it back on.


IMPORTANT Alarms of 900's or G alarms may be added or changed according

to the user's specifications.
For alarms specific to user's specification, please refer to the .
operation manual prepared for ita If such a manual is not available or it does not cover the information of the specification
dependent alarms, please contact your local Toyoda Machine
Works service center.
NOTE
Alarms for which the user cannot take corrective action, such as
syntax error of a canned cycle program, are not described below.
Therefore, this manual does not cover all alarm messages that will be
displayed on the screen.
If an alarm not described in this manual occurred, please contact your
local Toyoda Machine Works service center using the Alarm Report.
When an alarm number is indicated without any message or explanation, it means that the information will be added for the relevant machine. It is not an omission.
When an alarm message is indicated without any explanation, it
means that the message is not applicable to your machine.
5-15
MIIT,IJI"
5. TROUBLESHOOTING
GM6311
5.5.1
Diagnosis and Corrective Action - Alarm A
Alarm No.: AOOO
Messages
Causes
: PARAMETER 18 WRITIEN
Corrective Action : Turn OFF the power and turn it back ON.
Description
Maintenance parameters were written.

Auxiliary axis parameters were written.

Causes
Corrective Action
1. Maintenance parameters were written.
2. Auxiliary axis parameters were written.

5-16
111,(1)114
5. TROUBLESHOOTING
GM6311
Alarm No.: A001
Messages
Causes
: INTERNALABSOLUTE POSITION INPUT
Corrective Action : Press the MASTER button.
Description
The internal absolute position data was input.

Causes
Corrective Action
The internal absolute position data was input at

theAXIS POSITION DATASETTING screen.
Reset the alarm status by following the pracedure indicated below:

1) Press the NC RESET button.
2) If warning F002 is ON, clear positional deviation.
For the procedure to c1ear positional deviation, refer to 6.12.1 "Canceling the Positionoffset Safety Protection Function" in the
Maintenance Manual.
3) Press the [MASTER] button.
5-17
II-R-],4
5. TROUBLESHOOTING
GM6311
Alarm No.: A002
Messages
Causes
: OPERo PREP. IS EFFECTUATED DURING INIT. OF ENCODER ROTATION AMOUNT

DATA
Corrective Action : Clear the multi-turn clear parameter.
Description
The [MASTER] button was pressed during multi-turn clear processing.

Corrective Action
Causes
The MASTER ON signal was turned on in the
state "1" is set tor the multi-turn clear parameter
(maintenance parameter).
Reset the alarm status by tollowing the procedure indicated below:

1) Set "O" tor the tollowing multi-turn clear
parameter (maintenance parameter).
M10061, M10071, MI0081 ,M10091
M10101, M10111, M10121, MI0131
M10141, M10151, M10161, MI0171
2) Shut off the power and turn it back on.
5-18
li-RI]114
5. TROUBLESHOOTING
GM6311
AlarmNo.: A012
Messages
Causes
: DISCREPANCY BETWEEN MAINTENANCE PARAMETERAND SERCOS PARAMETER
Corrective Action : Initialize the SERCANS.
pescription

Causes
Corrective Action
5-19
Milnl]IJd
5. TROUBLESHOOTING
GM6311
Alarm No.: A400
Messages
Causes
: OPER. PREP. NOT RELEASED IN INTERVALAFTER OPER. PREP.IS OFF AT

CNCUNIT
Corrective Action : Correct the sequence programo
Description
Although the CNC sends the CNC ready OFF to the PLC, the ready signal from the PLC is not turned
off.

Causes
Corrective Action
1. The PLC is in the halt state.
1. Start the PLC.
2. The sequence program is incorrect.
2. Correct the sequence programo
3. Data communications between the MCUL and

the PLC is abnormal.
3. Replace the MCUL unit or the PLC unit.
4. An error occurred in the servo system.
It is necessary to save the CNC data or the

sequence program before replacing the unit
and recover the saved data or the program
afier the replacement.
Refer to 6.15.7 "Replacing the PLC-48 Unit".
4. Check the alarm status information display of
the CNC and take corrective action by referring to Maintenance Manual, 5.11 "Indicating
Lamps on the CNC Unit" and 5.6 "Servo
System Alarms".
5-20
Illfl'JIM
5. TROUBLESHOOTING
GM6311
Alarm No.: A401
Messages
Causes
: SEQUENCER DO ES NOT RESPOND FOR AN INTERVAL AFTER INTERN. ABS.

POS. ENTERED
Corrective Action : Correct the sequence programo
Description
The ready signal from the PLC is not turned off although the CNC sends the alarm A (emergency stop
level) signal to the PLC.

Causes
Corrective Action
1. The ~LC is in the halt state.
1. Start the PLC.
2. Correet the sequenee programo
3. Data eommunieations between the MCUL and
3. Replace the MCUL unt or the PLC unt.
the PLC s abnormal.
It s necessary to save the CNC data or the

sequence program before replaeng the unit and
recover the saved data or the program after
the replaeement.
r::::r
5-21
See 6.15.7 "Replacing the PLC..s Unit".
illnlJlt*,
5. TROUBLESHOOTING
GM6311
Alarm No.: A430
Messages
Causes
: SERVO ERROR (SERCOS OPTICAL CABLE DISCONNECTED)
Corrective Action : Change the optical fiber cable or check the data transfer speed.
Description

Causes
Corrective Action
5-22
lilfll].bl
5. TROUBLESHOOTING
GM6311
Alarm No.: A434
Messages
Causes
: SERVO ERROR (UNKNOWN PARAMETER FOR CYCLE COMMUNICATION)
Corrective Action : Initialize the SERCANS.
Description

Causes
Corrective Action
5-23
1Ilnl ] 1141
5. TROUBLESHOOTING
GM6311
Alarm No.: A447
Messages
Causes
: SERVO ERROR (DRIVE ERROR)
Corrective Action : Change the drive.
Description
An alarm occurred with the driver.
A number in ( ) represents the servo system alarm number.
Refer to Maintenance Manual 5.6 "Servo System Alarms".

Causes
Corrective Action
Find the cause by referring to Maintenance Manual

5.6 "Servo System Alarms".
Find the action to be taken by referring to Maintenance Manual 5.6 "Servo System Alarms".
5-24
iflf{l)lht
5. TROUBLESHOOTING
GM6311
Alarm No.: A449
Messages
Causes
: SERVO ERROR (PHASE CHANGE (2 TO 3) IMPOSSIBLE)
Corrective Action : Check the data transfer speed. Change the DSUS unit and the drive.
Description

Causes
Corrective Action
5-25
1(1)ll]ltt
5. TROUBLESHOOTING
GM6311
Alarm No.: A450
Messages
Causes
: SERVO ERROR (PHASE CHANGE (3 TO 4) IMPOSSIBLE)
Corrective Action : Check the data transfer speed. Change the DSUS unit and the drive.
Description

Corrective Action
Causes
5-26
liltilJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: A457
Messages
Causes
: SERVO ERROR (AMPLlFIER OVERHEAT)
Corrective Action : Check the mechanicalload or change the drive.
Description
The temperature of the servo amplifier heat sink has exceeded the allowable limit.

Causes
Corrective Action
1. The cooling fan is faulty.
1. Replace the servo amplifier.
2. The cooling unit of the electric cabinet is faulty.
2. Replace the cooling unit.

CJ=' See 6.11 "Replacing the Servo Amplifier"
and 6.9 "Replacing the Control Cabinet
Cooler".
5-27
ill1111lM
5. TROUBLESHOOTING
GM6311
Alarm No.: A459
Messages
Causes
: SERVO ERROR (LlMITVOLTAGE ERROR)
Description
An abnormality occurred with the power supply tor the control.

Causes
Corrective Action
1. The cable supplying the power tor the control is
1. Check and replace the cable or the connector.
taulty.
2. Check and replace the power supply unit.
2. The power supply unit is faulty.
5-28
I ili11]I'!'
5. TROUBLESHOOTING
GM6311
Alarm No.: A460
Messages
Causes
:SERVO ERROR (FEEDBACK ERROR)
Corrective Action : Change the drive or the encoder.
Description
The output signal from the motor encoder or the externally mounted encoder exceeded the allowable limit.
The motor encoder detected an abnormal condition.

Causes
Corrective Action
1. The encoder cable is broken.
1. Replace the encoder cable.
2. The encoder interface is faulty.
2. Replace the encoder interface.
3. The feedback cable and the power cable run

too closely with each other.
3. Run the feedback cable apart from the power

cable.
5-29
iflnl,lm
5. TROUBLESHOOTING
GM6311
Alarm No.: A462
Messages
Causes
: SERVO ERROR (COMMUNICATION ERROR)
Corrective Action : Change the DSUS unit.
Description

"
Causes
Corrective Action
5-30
1Ilnl]1M
5. TROUBLESHOOTING
GM6311
Alarm No.: A463
Messages
Causes
: SERVO ERROR (OUT OF ALLOWABLE SHIFT RANGE)
Corrective Action : Check the NC programo
Description
An axis movement command to move an axis beyond the axis movable range was executed.

Causes
Corrective Action
Maintenance parameter is not set correctly.
Set the maintenance parameter correctly.
5-31
IIInl11M
5. TROUBLESHOOTING
GM6311
Alarm No.: A552
Messages
Causes
: NO RESPONSE FOR A CERTAIN INTERVAL DURING MUTUAL CPU MONITOR

(MCU-DSU)
Description
MCUL and DSUS monitor the run state with each other. MCUL monitored by DSUS is in halt.

Causes
Corrective Action
1. The MCUL unit is faulty.
1. Replace the MCUL unit. Refer to 6.15.4

"Replacing the MCUL Unit".
2. The DSUS unit is faulty.
2. Replace the DSUS unit. Refer to 6.15.5

"Replacing the DSUS Unit".
5-32
li-1In'd
5. TROUBLESHOOTING
GM6311
Alarm No.: A553
Messages
Causes
: NO RESPONSE FOR A CERTAIN INTERVAL IN MUTUAL CPU MONITOR (DSU POSITION)
Description
DSUS and DSUSA monitor the run state with each other. DSUSA monitored by DSUS is in halt.

Corrective Action
Causes
1. The DSUSA card is faulty.
1. Replace the DSUSA cardo
2. The DSUS card is faulty.
2. Replace the DSUS cardo

(j='
5-33
See 6.15.5 "Replacing the DSUS Unit".
5. TROUBLESHOOTING
GM6311
Alarm No.: A555
Messages
Causes
: MUTUAL CPU MONITORTASK GETS NO RESPONSE FORACERTAIN INTERVAL

(MCU-DSU1)
Corrective Action : Change the DSUS1 unit.
Description
MCUL and DSUS1 monitor the run state with each other. DSUS1 monitored by MCUL is in halt.

Corrective Action
Causes
1. The DSUS1 unit is faulty.
1. Replace the DSUS1 unit. Refer to 6.15.5


5-34
5. TROUBLESHOOTING
GM6311
Alarm No.: A556
Messages
Causes
: MUTUAL CPU MONITOR TASK GETS NO RESPONSE FORACERTAIN INTERVAL

(MCU-DSU2)
Description
MCUL and DSUS2 monitor the run state with each other. DSUS2 monitored by MCUL is in halt.

Causes
Corrective Action


"Replacing the MCUL Unif'.
5-35
11'"']1,*'
5. TROUBLESHOOTING
GM6311
Alarm No.: A557
Messages
Causes
: MUTUAL CPU MONITOR TASK GETS NO RESPONSE FORACERTAIN INTERVAL

(MCU-DSU3)
Description
MCUL and DSUS3 monitor the run sta te with each other. DSUS3 monitored by MCUL is in halt.

Corrective Action
Causes


5-36
IflFllJanl
5. TROUBLESHOOTING
GM63U
Alarm No.: A60S
Messages
Causes
: VME-SYSTEM FAILURE
Corrective Action : Follow the corrective action for the other simultaneously occurring error.v
..
Description
VME SYSTEM FAIL occurred.

Causes
Corrective Action
1. Watchdog alarm occurred.
Check tbe alarm information display of the CNC

and replace the uni~ that causes other than
system fail. (System fail occurs in all units.)
2. Click alarm occurred.

3. System fail could occur in units not causing
the alarm of item 1.
5-37
0= See 6.15 "Replacing the CNC Cards".
lili,I)Ir,
5. TROUBLESHOOTING
GM6311
Alarm No.: A609
Messages
Causes
: POSITION WATCHDOG ERROR
Description
Watchdog alarm occurred at the DSUSA cardo

Causes
Corrective Action
The DSUSA card is faulty.
Replace the DSUS unit.
cr See 6.15.5 "RepIacingtbe DSUS Unit".
5-38
111111]1M
5. TROUBLESHOOTING
GM6311
Alarm No.: A615
Messages
Causes
: CHANGE IN EFFECTIVE ABSOLUTE POSITION EXCEEDS PERMISSIBLE RANGE
Corrective Action : Check the mechanicalload or change the servo amplifier.
Description
Amount of variation of encoder's feedback data exceeded the allowable Iimit.

Causes
Corrective Action
Amount of variation of encoder's feedback data exceeded 1.5 times the variation amount that would
be detected in the operation at the maximum
feedrate.
1. Check the mounting and connection of the motor

encoder.
5-39
2. Replace the motor encoder.
r::r
See 6.12 "Replacing tbe Servomotors".
IllJilllrd
5. TROUBLESHOOTING
GM6311
Alarm No.: A616
Messages
Causes
: EXCESSIVE DEVIATION
Description
Positional deviation amount exceeded the allowable limit.

Causes
Corrective Action
1. The encoder is faulty.
1. Replace the motor encoder.
2. Connection of the motor encoder is faulty.
2. Check the cable connection.
3. Load inertia is excessively high.
3. Lower the load.
cr
5-40
See 6.12 "Replacing the Servomotors".
lin]M
5. TROUBLESHOOTING
GM6311
Alarm No.: A617
Messages
Causes
: SERVO NOT READYWITHIN INTERVALAFTER OPERo PREP.IS TURNED OFF
Description
When the ready signal is turned off, the servo ready signal does not go off within 2 seconds.

Causes
Corrective Action
1. The servo amplifier is faulty.
1. Replace the servo amplifier. Refer to 6.11

"Replacing the Servo Amplifier".

5-41
MiIRI]1M
5. TROUBLESHOOTING
GM6311
Alarm No.: A618
Messages
Causes
: SERVO NOT READY WITHIN'INTERVALAFTER OPERo PREP. IS TURNED ON
Corrective Action : Change the DSUS unit, the servo amplifier and the servomotor.
Description
When the ready signar is turned on, the servo ready signar does not go on within 4 seconds.

Causes
Corrective Action
1. Replace the servo amplifier. Refer to 6.11


5-42
ifliT'I].'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: A621
Messages
Causes
: EXCESSIVE DEVIATION OF ACTUAL SPEED FROM COMMANDED SPEED DURING TRAVERSE
Description
Actual motor speed exceeded 1.2 times the maximum motor speed.

Causes
Corrective Action
2. Connection of the motor encoder is faulty.
1. Replace the motor encoder. Refer to 6.12

"Replacing the Servomotors".
2. Check the cable connection. Refer to 5.13
"Diagnosis Using TOYOPUC".
3. Load inerta is excessively high.
3. Lower the load.
543
IkIRIJI'!'
5. TROUBLESHOOTING
GM6311
Alarm No.: A622
Messages
Causes
: EXCESS. OEVIATN OF VAllO ABS. POS. FROM THEORET. TARGET POS. OURINGTRAV.
Description
Positional deviation amount of the moving axis exceeded the allowable positional deviation amount that
is calculated based on the specified feedrate.

Causes
Corrective Action
1. The motor or the motor encoder is faulty.
1. Replace the motor or the motor encoder.

Refer to 6.12 "Replacing the Servomotors".
2. Mechanicalload increased excessively.
2. Check mechanicalload.
544
IlliTin-M
5. TROUBLESHOOTING
GM6311
Alarm No.: A626
Messages
Causes
: SERVO ERROR (HANDSHAKING ERROR)
Description
The monitoring timer has counted up at the power on.

Causes
Corrective Action
The DSUS unit is faulty.
r::::r
5-45
See 6.15.5 "Replacingtbe DSUS Unit".
ll-fin-N
5. TROUBLESHOOTING
GM6311
Alarm No.: A628
Messages
Causes
: SERVO ERROR (UNDEFINED INTERRUPTION ERROR)
Description
Undefined interruption error occurred.

Causes
Corrective Action
cr
5-46
illrll]I'd
GM6311
Alarm No.: A657
Messages
Causes
: SERVO ERROR (MOTOR OR V-BUS OVERCURREND
Corrective Action : Change the servo amplifier.
Description
Servomotor current exceeded the allowable limit.
LEO indication at the servo amplifier: 1

Causes
Corrective Action
1. The alarm occurred when the control power was

turned on:
1. If the alarm occurred when the control power

was turned on:
The OSUSA card or the servo amplifier is faulty.

2. The alarm occurred w.hen the ready signal was
turned on:
Replace the OSUS unit or the servo amplifier.

2. If the alarm occurred when the control on signal
was turned on:
Replace the servo amplifier.
The servo amplifier is faulty.

3. The alarm occurred when the servo power was
turned on:
3. The alarm occurred when the servo power was

turned on:
a) Replace the motor. Refer to 6.12 "Replacing the Servomotor".
a) Motor grounding is faulty.

b) The power module is faulty.
b) Replace the servo amplifier. Refer to 6.11

c) The OSUSA card is faulty.

d) Wiring of the motor main circuit is incorrect.
4. The alarm occurred at the start or stop of the
motor:
Selection of the motor and amplifier combination is inadequate.
e) Replace the OSUS unit. Refer to 6.15.5

"Replacing the OSUS Unit".
d) Correct motor wiring.
4. The alarm occurred at the start or stop of the
motor:
Set the motor type (maintenance parameter)
again.
547
5~
litl'lht
TROUBLESHOOTING
GM6311
Alarm No.: A658
Messages
Causes
: SERVO ERROR (MOTOR OVERLOAD)
Description
Load exceeding the allowable limit was applied.

Causes
Corrective Action
1. The alarm occurred when the power was turned

on:

on:
2. The alarm occurred during the operation ofthe

motor:
a) The motor is operated under the torque exceeding the rated torque.
b) The holding brake has not been released.
3. Although the motor rotates, required torque is
not output.
The alarm occurred after operating the motor
fora while:
a) Incorrect wiring in the motor main circuit or
one ofthe motor main circuit lines (U, V, W)
is open.
b) Selection of the motor and amplifier combination is inadequate.
4. The alarm occurred even during operation below the rated torque:
The DSUSA card or the-servo ampHfier is fatllty.
5-48
2. The alarm occurred during the operation ofthe

motor:
a) Review motor load.
b) Release the brake by exciting it.
3. Although the motor rotates, required torque is
not output.
The alarm occurred after operating the motor
fora while:
a) Correct the motor wiring. Refer to 5.13
b) Review the motor and servo amplifier combination.
4 . Th e a larm occurre d even d
' opera t'Ion beurmg
low the rated torque:
Replace the DSUS unit or the servo amplifier.
Reter to 6.11 "Replacing the Servo Amplifier"
and-6.1-5.5 "Replacing the DSUS Unit".
1Ilfll] 1'41
5. TROUBLESHOOTING
GM6311
Alarm No.: A659
Messages
Causes
: SERVO ERROR (HEAT SINK OR MOTOR OVERHEAT)
Description
Servo amplifier overheat was detected.

Causes
Corrective Action

on:

on:
2. The alarm occurred during motor operation:
a) The cooling fan is faulty.
a) Replace the servo amplifier.
b) Ambient temperature is high.
b) Lower ambient temperature.
c) The motor has been operated at the state

exceeding the maximum continuous torque.
c) Lowerload.
549
O'> See 6.11 "Replacing tbe Servo Amplifier".
t,
ik' 11IM
5. TROUBLESHOOTING
GM6311
Alarm No.: A660
Messages
Causes
: SERVO ERROR (CIRCUIT PROTECTOR TRIP)
Corrective Action : Check the source voltage or change the servo amplifier.
Description
An alarm was detected at the amplifier control power.
LED indication at the servo amplifier: 7

Causes
Corrective Action

turned on:

turned on:
a) Input voltage is lower than 160 V.
a) Adjust input voltage (200 - 220V AC).
b) The servo amplifier is faulty.


Input voltage fluctuates excessively (lower than
160 V).
5-50

Adjust input voltage (200 - 220V AC).
II-RIIIM
5. TROUBLESHOOTING
GM6311
Alarm No.: A661
Messages
Causes
: SERVO ERROR (REGENERATIVE ERROR OR OVERVOLTAGE)
Corrective Action : Check the source voltage or change the servo amplifier.
Description
OC voltage in the main control circuit exceeded 415 V.

Causes
Corrective Action
turned on:
turned on:
2. The alarm occurred when the main power was

turned on.
Input voltage is too high or input voltage waveform is distorted.

a) Load inertia is too high.

turned on.
Adjust input voltage (200 - 220V AC).

a) Adjust load inertia within the specified value.
b) Replace the servo amplifier.
b) The regeneration transistor/resistor is faulty.

c) External regeneration resistor is faulty.
c) Replace the external regeneration resistor.
r:::r
5-51
See 6.11 "Replacing the Servo Amplifier".
Iflnl] 1141
5. TROUBLESHOOTING
GM6311
Alarm No.: A662
Messages
Causes
: SERVO ERROR (OVERSPEEO)
Corrective Action : Change the OSUS unit or the servo amplifier.
Description
The power module is faulty.

Causes
Corrective Action
CJ=' See 6.11 "Replacing the Servo Amplifier".
5-52
5. TROUBLESHOOTING
GM6311
Alarm No.: A663
Messages
Causes
: SERVO ERROR (POWER ERROR)
Corrective Action : Check the source voltage.
Description
Overheat of the servo amplifier

Causes
Corrective Action
1. The cooling fan is faulty.
1. Replace the servo amplifier. Refer to 6.11 "Re_

placing the Servo Amplifier".
2. Ambient temperature is too high.
2. Lower ambient temperature.
5-53
1Ilrll]1,4
5. TROUBLESHOOTING
GM6311
Alarm No.: A664
Messages
Causes
: SERVO ERROR (NO RESPONSE ENCODER)
Corrective Action : Check the wiring or change the motor.
Description
No response signal is returned from the encoder.

Causes
Corrective Action
1. Replace the motor. Refer to 6.12 "Replacing
the Servomotor".

2. Replace the servo amplifier. Refer to 6.11 "Replacing the Servo Amplifier".
3. The DSUSA card is faulty.
4. Incorrect connection or disconnection between

the DSUSA card and the servo amplifier or between the servo amplifier and the motor encoder.
3. Replace the DSUS unit. Refer to 6.15.5 "Replacing the DSUS Unit".
4. Check the cable connection between the

DSUSA card and the servo amplifier or between
the servo amplifier and the motor encoder.
Refer to 5.13 "Diagnosis Using TOYOPUC".
5-54
IkliT,IJI"
5. TROUBLESHOOTING
GM6311
Alarm No.: A665
Messages
Causes
: SERVO ERROR (VOLTAGE DROP IN MAIN CIRCUIT)v
Corrective Action : Check the so urce voltage or change the servo amplifier.
Description
Power supply voltage of the servo amplifier main circuit is lowered below 100 V OC.

Causes
Corrective Action
turned on:
turned on:

turned on:

turned on:
a) Source voltage is too low.
a) Adjust source voltage (200 - 220V AC).
b) The rectifier is broken.
a) Input voltage fluctuates excessively.
a) Adjust source voltage (200 - 220V AG).
r:::r
5-55
5. TROUBLESHOOTING
GM6311
Alarm No.: A666
lVIessages
Causes
: SERVO ERROR (OPEN PHASE DETECTED)
Corrective Action : Check the power source or change the servo amplifier.
Description
Open phase was detected in the three phases of power supply.

Causes
Corrective Action

turned on:

turned on:

turned on:
a) Open phase in the thee phases of power supply.
b) Loose input terminal connection of the servo
amplifier.
5-56
Replace the servo amplifier. Refer to 6.11 "Replacing the Servo Amplifier".
turned on:
a) Correct the power source.
b) Tighten the servo amplifier terminal.
lilnlllt!I
5. TROUBLESHOOTING
GM6311
Alarm No.: A667
Messages
Causes
: SERVO ERROR (PWM ERROR)
Corrective Action : Check the wiring or change the DSUS unit or the servo amplifier.
Description
The PMW signalline was broken.
LED indication at the servo amplifier: L

Causes
Corrective Action
1. The alarm occurred when the power or "servo

on" was turned on:
1. The alarm occurred when the power or servo

on" was turned on:
a) Connection between the DSUSA ca,rd and

the servo amplifier is incorrect or broken.
a) Check the connection between the DSUSA

card and the servo amplifierfor incorrect connection or broken cable.
b) The DSUSA card or the servo amplifier is

faulty.
a) Noise on the signal transmitted between the
DSUSAcard and the servo amplifier.
b) The DSUSA card or the servo amplifier s
faulty.
b) Replace the DSUS unt or the servo amplifiero

2. The alarm occurred durng motor operation:
a) Check the connecton between the DSUSA
card and the servo amplifier for broken cable.
b) Replace the DSUS unt or the servo amplifiero
o=- See 6.15.5 "Replacing tbe DSUS Unit" and 6.11

"Replacing tbe Servo Amplifier".
5-57
iili,IJ 1td
5. TROUBLESHOOTING
GM6311
Alarm No.: A668
Messages
Causes
: SERVO ERROR (MOTOR RUNAWAY DETECTED)
Description
Overcurrent was detected in the main circuit.

Causes
Corrective Action
CF See 6.11 "Replacing the Servo Amplifier".
5-58
IllnlJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: A669
Messages
Causes
: SERVO ERROR (DSUSA - SERVO AMP. I/F TIME-OUT)
Corrective Action : Check the wiring between the DSUSA card and the servo amplifier.
Description
Communication between the DSUSA card and the servo amplifier was suspended for longer than the
specified periodo

Causes
Corrective Action
1. Cables connecting the DSUSA card and the
1. Check the connection between the DSUSA card
servo amplifier were broken.
and the servo amplifier.
2. The DSUSA card or the servo amplifier is faulty.
2. Replace the DSUSA card or the servo amplifier.
0= See 6.15.5 "RepIacing the DSUS Unit" and 6.11

"RepIacingthe Servo Amplifier".
5-59
I Ilnl]1,4
5. TROUBLESHOOTING
GM6311
Alarm No.: A66F
Messages
Causes
: SPINDLE OVER-SPEED
Corrective Action : Check the wiring or change the servo amplifier.
Description
Work spindle speed exceeded 1.2 times the maximum motor speed.

Causes
Corrective Action
1. The alarm occurred when the power was tumed
2.
on:
on:
The alarm occurred during motor operation:

a) Improper setting of the maintenance parameters.
b) Improper setting of the work spindle motor
inverter parameters.
e) Incorrect wiring or connection between the

amplifier and the work spindle motor inverter.
d) Faulty servo amplifier.

a) Check the maintenance parameters.
b) Check work spindle motor inverter parameters.
c) Check the wiring between the amplifier and
the work spindle motor inverter.
d) Replace the servo amplifier.
e) Replace the work spindle motor inverter or
the work spindle motor.
1:':;'
e) Faulty work spindle motor inverter or the

work spindle motor.
~ Incorrect wiring between the work spindle
motor inverter and the work spindle motor.
5-60
~ Check the wiring between the work spindl~

cr
"-
1i'F(1) 1"
5. TROUBLESHOOTING
GM6311
Alarm No.: A670
Messages
Causes
: SERVO ERROR (NVRAM ERROR)
Description.
The motor was operated exceeding the rated regeneration capacity.
LEO indication at the servo amplifier: J

Causes
Corrective Action

turned on:

turned on:

turned on:
The regeneration transistor or the regeneration
resistor is faulty.
a) The motor operated in the state exceeding
regeneration capacity.
b) The regeneration transistor or the regeneration resistor is faulty.
e) Load inertia is too high.
5-61

turned on:
a) Replace the external regeneration resistor.
c) Adjust load inertia within the specified value.
O" See 6.11 "Replacing the Servo Amplifier".
li'rll]ltd
5. TROUBLESHOOTING
GM6311
Alarm No.: A671
Messages
Causes
: SERVO ERROR (DSPU CPU ERROR)
Description
CPU error

Causes
Corrective Action
The DSUSA card is faulty.
cr See 6.15.5 "Replacing the DSUS Unit".
5-62
Illi,I]I!*,
5. TROUBLESHOOTING
GM6311
Alarm No.: A672
Messages
Causes
: SERVO ERROR (ENCODER REVOLUTION NUMBER DATA ERROR)
Corrective Action : Change the motor.
Description
Amount of encoder revolutions is outside the range of Oto 1799 revolutions.

Corrective Action
Causes
a) The encoder is faulty.
b) Noise on the signal transmitted between the
encoder and the servo amplifier.
a) Replace the motor encoder. Refer to 6.11 "Replacing the Servo Amplifier".
b) Check the wirng between the encoder and the
servo amplifier.
Adjust the motor position after performing multturn clear processing.
~
5-63
See 5.13 "Diagnosis Using TOYOPUC".
I iltl l ] 1M
5. TROUBLESHOOTING
GM6311
Alarm No.: A673
Messages
Causes
: SERVO ERROR (LOW ENCODER BATTERYVOLTAGE ERROR)
Corrective Action : Change the eneoder battery.
Description
Voltage of the eneoder battery is low.

Causes
Corrective Action
1. The alarm oecurred when the control power was
1. The alarm oecurred when the control power was
turned on:
turned on:
a) Voltage of the baekup battery is low.
a) Replaee the battery and afier performing

multi-turn elear proeessing, adjust the motor position.
b) The encoder is faulty.

2. The alarm oecurred during motor operation.
e) Noise on the signal transmitted between the
encoder and the servo amplifier.
b) Replaee the motor.

2. The alarm oecurred during motor operation.
e) Check the wiring between the eneoder and
the servo amplifier.
d) The encoder is faulty.
d) Replaee the motor encoder.
r:::r
5-64
See 6.12 "RepJa,cing the Servomotors".
1Ilijl]1141
5. TROUBLESHOOTING
GM6311
Alarm No.: A674
Messages
Causes
: SERVO ERROR (INTERNAL REGENERATION RESISTOR OVERHEAT)
Description
The thermostat was actuated due to overheat of the regeneration resistor since the motor was operated
in the state the rated regeneration capacity was exceeded.
LED indication of the servo amplifier: H

Causes
Corrective Action

. turned on:

turned on:

a) Large regenerative power
a) Install an external regeneration resistor,
b) The cooling fan or the regeneration resistor

is faulty.
5-65
r:::r See 6.11 "Replacing the Servo Amplifier".
l'I"I]lh'
5. TROUBLESHOOTING
GM63U
Alarm No.: A676
Messages
Causes
: SERVO ERROR (WIRING CUT IN EXTERNAL ENCODER)
Corrective Action : Check the wiring or change the externally installed encoder.
Description
The signal cable of the external encoder was broken.

Causes
Corrective Action

turned on:

turned on:
a) Incorrect wiring or disconnection between the

external encoder and the DSUSA cardo
a) Correct the connection between the external encoder and the DSUSA cardo
b) The DSUSA card or the external encoder is

fa uIty.
b) Replace the DSUS unit or the external encoder.
2. The alarm occurred when the motor started

operating:
2. The alarm occurred when the motor started

operating:
Incorrect wiring or disconnection between the

external encoder and the DSUSA cardo
Correct the connection between the external encoder and the DSUSA cardo
5-66
5. TROUBLESHOOTING
GM6311
Alarm No.: A677
Messages
Causes
: SERVO ERROR (WIRING CUT IN ENCODER)
Correetive Aetion : Check the wiring or ehange the motor.
Description
Breakage of eneoder cable was deteeted.

Causes
Corrective Action
1. The alarm oeeurred when the power was turned

on:
1. The alarm oeeurred when the power was turned

on:
a) The eneoder is faulty.
a) Replaee the motor. Refer to 6.12 "Replaeing the Servomotor".

e) The DSUSA eard is faulty.
b) Replaee the servo amplifier. Refer to 6.11

"Replaeing the Servo Amplifier".
d) Ineorreet wiring or diseonneetion between the

DSUSA eard and the servo amplifier or between the eneoder and the servo amplifier
e) Replaee the DSUS unit. Referto 6.15.5 "Replaeing the DSUS Unit".
e) Error in serial eommunieation of the eneoder

2. The alarm oeeurred after the motor rotated a
slightly:
a) The eneoder is faulty.
b) Ineorreet wiring or diseonneetion between the
eneoder and the servo amplifier
d) Correet the eonneetion between the DSUSA

eard and the servo amplifier or between the
eneoder and the servo amplifier.
e) Check the wiring and the power souree of
the eneoder.
2. The alarm oeeurred after the motor rotated a
slightly:
e) Error in serial eommunieation of the eneoder
a) Replaee the motor eneoder.
d) Noise on the signal transmitted between the

DSUSA eard and the servo amplifier or between the eneoder and the servo amplifier.
b) Correet the eonneetion between the eneoder

e) Check the wiring and the power souree of
the eneoder.
d) Check the eonneetion between the DSUSA
card and the servo amplifier or between the
eneoder and the servo amplifier.
5-67
Iklrll]IJ*,
5. TROUBLESHOOTING
GM6311
Alarm No.: A678
Messages
Causes
: SERVO ERROR (SYNCHRONOUS SIGNAL ERROR)
Description
A synchronization signal is not generated within a specified length of time.

Corrective Action
Causes

(7='
5-68
lill1'14
5. TROUBLESHOOTING
GM6311
Alarm No.: A684
Messages
Causes
: SERVO ERROR (DSU RUN CHECK ERROR)
Corrective Action : Change the motor.
Description
Incorrect position data was detected.

Corrective Action
Causes
Replace the motor encoder.
The encoder is faulty.
r::::r See 6.12 "Replacing the Servomotors".
5-69
IklJ1n lM
5. TROUBLESHOOTING
GM6311
Alarm No.: A68A
Messages
Causes
: EXCESSIVE POSITIONAL ERROR WITH WORK SPINDLE
Description
The amount of spindle positional deviation exceeded the allowable limit.

Causes
Corrective Action

on:
1. The alarm occurred when the power is turned

on:
Replace the servo amplifier. Refer to 6.11 "Replacing the Servo Amplifier".
a) Spindle load is too high.

b) Improper setting of the parameters
a) Check the spindle load and the spindle

drive command.
e) Improper setting of the work spindle motor

inverter parameters.
b) Check the parameters.
d) Incorrect wiring or connection between the

amplifier and the work spindle motor inverter.
e) Check work spindle motor inverter parameters.

d) Check the wiring between the amplifier and
the work spindle motor inverter.
e) Large load fluctuation occurred.
1) Faulty servo amplifier.
e) Check the spindle load.
g) Faulty work spindle motor inverter or the

work spindle motor.
f) Replace the servo amplifier.
h) Incorrect wiring between the work spindle

g) Replace the work spindle motor inverter

or the work spindle motor. Refer to 6.12
"Replacing the Servomotors".
h) Check the wiring between the work spindle
5-70
1'111'lltd
5. TROUBLESHOOTING
GM6311
Alarm No.: A68B
Message:
Causes
: SERVO ERROR (OPTION CARD ERROR)
Corrective Action : Check the option card or the servo amplifier.
Descrjptjon
Option card is not set although the function that needs an optional card is set as the valid function.
Causes and Correctjve Actjon

Causes
Corrective Actjon

on:

on:
a) The option card is faulty.
a) Replace the option cardo

2. The alarm occurred while the power was on:
2. The alarm occurred while the power was on:
Loose connection of the option cardo
a) Insert the option card securely.

b) Replace the option cardo
5-71
lieiieJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: A68C
Messages
Causes
: SERVO ERROR (COMMAND ERROR)
Description
The command sent from the CNC or amount of command variation is outside the correct range.

Causes
Corrective Action

on:

on:
a) The servo amplifier is taulty.
a) Replace the servo amplifier. Reter to 6.11

b) The CNC is faulty.

Excessively large noise in the signa!.
b) Replace the CNC. Refer to 6.15 "Replacing

the CNC Cards".
Check the wiring.
5-72
I flf(ll1'41
5. TROUBLESHOOTING
GM6311
Alarm No.: A6aD
Messages
Causes
: SERVO ERROR (COMMUNICATION ERROR)
Description
Sending to or receiving from the CNC unit was disabled within the specified length of time.

Causes
Corrective Action

on:
1. The alarm occurred when the power was tumed

on:
a) Replace the servo amplifier. Refer to 6.11
a) The servo amplifier is faulty.

b) The CNC is faulty.
Excessively large noise in the signa!.
b) Replace the CNC. Refer to 6.15 "Replacing

the CNC Cards".
2. The alarm .occurred during motor operation:
Check the wiring.
5-73
I Irll] 1141
5. TROUBLESHOOTING
GM6311
Alarm No.: A68E
Messages
Causes
: SERVO ERROR (REGENERATION ERROR)
Description
The system judged that the regeneration resistor would be damaged since regeneration occurred
excessively frequently.

Causes
Corrective Action
on:
on:
2. The alarm occurred when the control on signal

was turned on:
2. The alarm occurred when the control on signal

was turned on:

a) Excessively large regeneration power

a) Check the motor operating conditions.
Large load inertia
Short acceleration/deceleration time
c) Replace the regeneration resistor.
Excessively frequent operation
d) Check the regeneration circuit.
Large gravitational torque
rJ=' See 6.11 "Replacing the Servo Amplifier".
b) Faulty servo amplifier

c) Regeneration resistor is faulty.
d) Incorrect wiring of the regeneration circuit.
5-74
MilnlllJd
5. TROUBLESHOOTING
GM6311
Alarm No.: A68F
Messages
Causes
: SERVO ERROR (SYNC. SIGNAL ERROR)
Description
Synchronization between the controller and the servo amplifier was disabled.
(The synchronizing signal intervals have differed excessively from the specified value.)

Causes
Corrective Action

on:

on:
a) Communication cable is broken or cable connection is incorrect.
a) Replace the communication cable or reconnect the communication cable.

c) The CNC card is faulty.

a) Excessively large noises.
c) Replace the CNC unit. Refer to 6.15 "Replacing the CNC Cards".
b) The CNC card is faulty.
a) Check the wiring.

b) Replace the CNC unit.
5-75
I onu 1m
5. TROUBLESHOOTING
GM6311 .
Alarm No.: A6A3
Messages
Causes
: COMMUNICATION ERROR (NaDE ID SETTING ERROR)
Corrective Action : Match the axis number and the node ID.
Description.
A station number is not set correctly for an amplifier.

Causes
Corrective Action
The amplifier station number differs from the axis

number.
Set the same number as the axis number for the

station number.
5-76
Miltll]
5. TROUBLESHOOTING
1M
GM6311
Alarm No.: A739
Messages
Causes
: DISAGREEMENT OF CHECKSUM
Corrective Action : Change the MPU unit that detected the error.
Description
Checksum result of the system software (PROM or flash ROM) has changed.

Corrective Action
Causes
2. The system software (PROM or flash ROM)
was replaced.
3. S-RAM was initialized.
1. Replace the MCUL unit. Refer to 6.15.4 "Replacing the MCUL Unit".
2. Execute the checksum calculation. Refer to
7.8.2 "Checksum Operation".
3. Execute the checksum calculation.
5-77
irIRI'.J!'
5. TROUBLESHOOTING
GM6311
AlarmNo.: A741
Messages
Causes
: SERVO NOT READY
Corrective Action : Change the DSUS unit and/or the servo amplifier.
Description
The servo ready signal was turned off during axis movement.

Corrective Action
Causes
1. The emergency stop button was pressed during axis movement.
1. Press the NC reset button.

2. Replace the servo amplifier or the PLC.
2. The SVRDY signal was turned off during axis

movement.
Check the servo ready signal circuit of the PLC.
r:::r
5-78
See 6.11 "Replacing the Servo Amplifier" and

6.15.7 "Replacing the PLC-48 Unit".
IflnlllM
5. TROUBLESHOOTING
GM6311
Alarm No.: A742
Messages
Causes
: SRAM PARITY ERROR
Corrective Action : Change the MCUL unit.
Description
S-RAM parity error occurred.

Causes
Corrective Action
1. The battery is faulty or has discharged.
1. Tighten the battery terminals securely or replace

the battery. Refer to 6.7 "Replacing the Sattery".
2. Replace the MCUL unit. Refer to 6.15.4 "Re_

placing the MCUL Unir.
5-79
IllnIJI,*,
5. TROUBLESHOOTING
GM6311
Alarm No.: A743
Messages
Causes
: BRAM PARITY ERROR (LL 8 BITS)
Description
B-RAM parity error occurred.
L (LOWER) L (LOWER) 8 bits

Causes
Corrective Action

the battery. Refer to 6.7 "Replacing the Battery".
5-80
1Ill
5. TROUBLESHOOTING
,'d
GM6311
Alarm No.: A744
Messages
Causes
: BRAM PARITY ERROR (LM 8 BITS)
Description
L (LOWER) M (MIDDLE) 8 bits

Causes
Corrective Action

5-81
liIRI]l !1
5. TROUBLESHOOTING
GM6311
Alarm No.: A745
Messages
: BRAM PARITY ERROR (UM 8 BITS)
Causes
Description
U (UPPER) M (MIDDLE) 8 bits

Causes
Corrective Action
1. The bttery is faulty or has discharged.

i;..
/i~
-"_.:
-,--.
~-
,>
..
...
, '
5-82
1(1)111I,!1 .
5. TROUBLESHOOTING
GM6311
Alarm No.: A746
Messages
Causes
: BRAM PARITY ERROR (UU 8 BITS)
Description
U (UPPER) U (UPPER) 8 bits

Corrective Action
Causes
1. Tighten the battery terminals securely or replace the battery. Refer to 6.7 "Replacing
the Battery".

2. The MCUL unit is faulty
5-83
lilnlllEl
5. TROUBLESHOOTING
GM6311
Alarm No.: A747
Messages
Causes
: SERVO NOT READY IN INTERVALAFTER OPERATION PREPARATION IS ON

(DSU1)
Corrective Action : Check the control on circuit or change the servo amplifier.
Description
The servo ready signal was not turned on within the specified length of time after turning on of the ready
signal.

Causes
Corrective Action
Although the ready signal was turned on, power is

not supplied to the main circuit of the servo amplifiero
1. Check the ready signal circuit of the PLC.

2. Replace the servo amplifier, the power supply
unit or the PLC.
r::::r
5-84
See 6.11 "Replacing the Servo Amplifier",

6.15.7 "Replacing tbe PLC-48 Unit" and 5.13
111111]'41
5. TROUBLESHOOTING
GM6311
Alarm No.: A748
Messages
Causes

(DSU2)
Description
The servo ready signal was not turned on within the specified length of time after turning on of the ready
signal.

Causes
Corrective Action


unit or the PLC.

O'" See 6.11 "Replacing the Servo Amplifier",
6.15.7 "Replacing the PLC-48 Unit" and 5.13
5-85
111"1]1141
5. TROUBLESHOOTING
GM6311
Alarm No.: A749
Messages
Causes

(DSU3)
Description
The servo ready signal was not tumed on within the specified length of time after turning on of the ready
signa\.

Causes
Corrective Action

not supplied to the main circuit of the servo amplifier.

unit or the PLC.
r::::r
5-86
See 6.11 "Replacing the Servo Amplifier",

6.15.7 "Replacing the PLC-48 Unit" and 5.13
nttlt.tAl
5. TROUBLESHOOTING
GM6311
. Alarm No.: A804
Messages
Causes
: NO RESPONSE FROM FIELD BUS IN A SPECIFYED TIME
Corrective Action : Change the communication device of the auxiliary axis.
Description
After sending the command in auxiliary axis communication. the response was not retumed within the
specified length of periodo

Causes
Corrective Action
1. The auxiliary axis communication cable is bro-
1. Check the auxiliary axis communication cable.
ken.
2. Set the servo amplifier parameters.
2. Setting error of the servo amplifier parameters.
3. The servo amplifier or the MCUL unit is faulty.
5-87
3. Replace the servo amplifier or the MCUL unit.
r:::r
See 6.11 ''Replacing the Servo Amplifier" and

6.15.4 "Replacing the MCUL Unit".
1il"l] 1141
5. TROUBLESHOOTING
GM6311
Alarm No.: ABOS
Messages
Causes
: OPERATION NOT READY IN A SPECIFYED TIME AFTER TURNED ON (ADDITIONAL AXIS)
Corrective Action : Change the communication device of the auxiliary axis.
Description
The control on finish signal was not turned on within the specified length of time after turning on of the
ready signal.

Causes
Corrective Action


unit or the PLC.
cr See 6.11 "Replacing the Servo Amplifier",

6.15.7 "Replacing the PLCta Unit" and 5.13
5-88
I (IJiIJI'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: A816
Messages
Causes
: OPERATION PREPARATION IS NOTCOMPLETED IN A CERTAIN INTERVALAFTER POWER-UP
Description
When the power was turned on, the servo system failed to finish the power on initialization processing
with the specified length of time.

Causes
Corrective Action
1. The axis specification set by the maintenance

parameters and the specification of the connected axis do not agree with each other.
1. Check the connection between the DSUS unit

2. SERCOS parameters or SERCANS parameters

were not set correctly.
Replace the DSUS unit. Refer to 6.15.5 "Replacing the DSUS Unit".
2. Set the SERCOS parameters, or initialize the
3. The servo amplifier or the motor is faulty.
SERCANS.
3. Replace the servo amplifier or the motor.
cr
5-89
See 6.11 "Replacing the Servo Amplifier" and

6.12 "Replacing the Servomotors".
1i-nl] 114
5. TROUBLESHOOTING
GM63U
Alarm No.: A840
Messages
Causes
: EXCESSIVE READING TOLERANCE BETWEEN MOTOR ENCODER AND ENCODER OUTSIDE
Corrective Action : Check the mounting of the internal and external encoder.
Description
When an external encoder is used, the positional offset amount between the built-in encoder data and
the external encoder data exceeded the allowable limit.

Causes
Corrective Action
1. The external encoder is not mounted correctly.
1. Mount the external encoder correctly.
2. The feedback cable of the external encoder is

broken.
2. Replace the feedback cable.
3. The feedback cable of the external encoder is

not mounted correctly.
5-90
3. Mount the feedback cable correctly.
MIII,I]I,*,
5. TROUBLESHOOTING
GM6311
Alarm No.: A850
Messages
Causes
: INCONSISTENCY BETWEEN CPU CREATE INFORMATION ANO CPU VES/NO

PARAMETER
Corrective Action : Check the connection status or parameter of all units.
Description
CNC units are not operating correctly.

Corrective Action
Causes
1. CNC units are not mounted correctly.
1. Mount the CNC units correctly.
2. CNC units are faulty.
2. Replace the CNC units. Refer to 6.15 "Replacing the CNC Cards".
5-91
EllnIJI'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: A861
Messages
Causes
: ERROR ORALARM ON BUILT-IN PLC BOARD
Corrective Action : Change the PLC unit.
Description
The error status signal of the PLC unit turned on.

Causes
Corrective Action
1. The PLC unit is faulty.
1. Replace the PLC unit. Referto 6.15.7 "Replacing the PLC4a Unit".

3. Jumper setting or parameter setting of the PLC
unit is faulty.
5-92

3. Correct the jumper setting or para meter setting
of the PLC unit.
5. TROUBLESHOOTING
GM6311
Alarm No.: A862
Messages
Causes.
: NAK RESPONSE BY SEQUENCER DURING COMMAND COMMUNICATION
Description
NAC was returned from the PLC unit.

Correctjve Actjon
Causes
1. Replace the PLC unit. Refer to 6.15.7 "Replacing the PLC-4s Unit".

3. Jumper setting or para meter setting of the PLC
unit is faulty.
5-93

3. Correct the jumper setting or para meter setting
of the PLC unit.
IllnlJI"
5. TROUBLESHOOTING
GM6311
Alarm No.: A863
Messages
Causes
: ERROR IN SERVO (DSUY RAM ERROR)
Description
An error was detected in the memory check executed after turning on the power.

Causes
Corrective Action
The RAM shared by DSUS and DSUSA is faulty.
Replace the DSUSA cardo
r::r
5-94
See 6.15.5 "Replacing tbe DSUS Unit".
liRulJd
5. TROUBLESHOOTING
GM6311
Alarm No.: A864
Messages
Causes
: ERROR IN SERVO (DSUY COMMON RAM ERROR)
Description
. In shared RAM check processing, interruption was disabled or interruption value was abnormal.

Causes
Corrective Action
The RAM shared by DSUS and DSUSA is faulty.
Replace the DSUSA cardo
cr
5-95
1lrll]ITd
5. TROUBLESHOOTING
GM6311
Alarm No.: A870
Messages
Causes
: ERROR IN SERVO (MOTOR TYPE ERROR)
Corrective Action : Change the DSUS unit or the servo amplifier.
Description
Motor type is incorrect.

Causes
Corrective Action
1. The DSUSA card or the servo amplifier is fau Ity.
1. Replace the DSUSA card or the servo amplifiero Refer to 6.15.5 "Replacing the DSUS Unit"
and 6.11 "Replacing the Servo Amplifier".
2. The combination with the motor is incorrect.
2. Check the motor type (maintenance parameter).
5-96
lin'IM
5. TROUBLESHOOTING
GM6311
5.5.2
Diagnosis and Corrective Action - Alarm B
Alarm No.: 8901
Messages
Causes
: Sizer count-over in 2nd rough grinding
Corrective Action : Check the sizer position setting.
Description
In direct sizing grinding, the sizing signal (AS 1) was not output although the wheelhead advanced to the
position of "workpiece finish diameter - count-over value (860 - PI350)".

Causes
Corrective Action
1. Wheelhead coordinate system is offset.
1. Establish the coordinate system by bringing the

wheel into contact with the master workpiece.
2. The sizer gauging head is faulty.
2. Repair of replace the sizer gauging head.
r:::r
See 6.6.2 "Replacing the Sizer Head".
WHEELHEAD
w R.AP IO FEED
~ ADVANCE
AIR CUT GRINDING
ROUGH GRINDING
2ND ROUGH GRINDING
1ST
AS1
j 3RD ROUGH GRINDING

!
!I
P'350/21
AS3
n
5-97
I Ilrll]IU
5. TROUBLESHOOTING
GM6311
Alarm No.: 8903
Messages
Causes
: Sizer count-over in 3rd rough grinding
Description
In direct sizing grinding, the sizing signal (AS3) was not output although the wheelhead advanced to the
Causes and Corrective Actjon

Correctjve Actjon
Causes
r:::r
WHEELHE.ll.D
t R.AP ID FEED
1j
.ADVAt~CE
AIR CUT GRINDING

1ST ROUGH GRINDING
2ND ROUGH GRINDING
AS1
3RD ROUGH GRINDING
!
!
P1350/2r~
y
~.
AS3
5-98
IllnlJlt*,
5. TROUBLESHOOTING
GM6311
Alarm No.: 8904
Messages
Causes
: Sizer count-over in 1st fine grinding
Description

Causes
Corrective Action

cr
WHEELHEAD
~ R.AP IO FEED
. .ADVANCE
AIR CUT GRINDING
1ST ROUGH GRINDING
2ND ROUGH GRINDING
AS1
3RD ROUGH GRINDING
AS3
!
! 1ST
!
PI350/2r~
/ y
~
AS4
5-99
FINE GR INO ING
Illfll)lht
5. TROUBLESHOOTING
GM6311
Alarm No.:
8905
Messages
Causes
: After the completion of grinding, coordinate value difference from the preceding operation is too large.
Corrective Action : Check the sizer position setting and the coordinate value.
Description
In direct sizing grinding, the difference between the coordinate values read at the completion of the
current and previous grinding cycle exceeded the allowable limit (A6?).

Causes
Corrective Action
1. Thermal displacement
1. Establish the wheelhead coordinate system after

completing warm-up operation.
2. Wear of diamond roll

3. Workpiece deflection due to grinding resistance
4. Run-out or poor roundness of the workpiece
2. Execute the diamond roll position memory operation again.
3. Lower infeed rateo Check the pushing amount
5. Faulty sizer
of the steady rest.
4. Check the pushing amount of the steady rest.

Check the roundness of the center hole in the
workpiece.
5. Check the sizer (contact, head, etc.) and repair or replace as needed.
()='
X AXIS
1\
1\
\V A.66/2
Previous sizer coordinate
A.67/2
\V
J~
A67/2
\Ir
-1
An alarm occurs when the current workpiece
center coordinate falls in the _
range.
5-100
IlIDIJI1!1
5. TROUBLESHOOTING
GM6311
Alarm No.: 8908
Messages
Causes
: Sizer count-over in 2nd fine grinding
Description

Causes
Corrective Action

r:::r
WHEELHEAO
~ RAP I O FEEO
11. PfJVANCE
AIR CUT GRlr~OING
1ST ROUGH GR I r~o I NG
2ND ROUGH GR I NO I NG
AS1
3RO ROUGH GRINOING
AS3
1ST F I r~E GR I NO I NG
AS4
2ND FINE GR I NO I NG
P1350/2r~
AS5
5-101
i.I,.]1M
i '
5. TROUBLESHOOTING
GM6311
Alarm No.: 8909
Messages
Causes
: Sizer count-over in micro grinding
Description
In direct sizing grinding, the sizing signal (AS?) was not output although the wheelhead advanced to the

Causes
Corrective Action

2. Repair of re place the sizer gauging head.
r:::r
WHEELHEAD
I
R.AP ID FEED
.ADVANCE
AIR CUT GRINDING
1ST ROUGH GRINDING
AS1
2ND ROUGH GRINDING
AS3
AS4
AS5
3RD ROUGH GRINDING

1ST FINE GRINDING
2ND FINE GRINDING
: MICRO FINE GRINDING
P,350/2rn
AS7
5-102
IllnlllJd
5. TROUBLESHOOTING
GM6311
Alarm No.: 890A
Messages
Causes
: Sizing signal ON in 2nd rough grinding
Corrective Action : Check the sizer position setting and the workpiece.
Description
In direct sizing grinding, the sizing signal (AS?) was already ON at the start of 2nd rough grinding.

Corrective Action
Causes


V' See 6.6.2 "Replacing tbe Sizer Head".
WHEELHEAD
~
~
R.AP ID FEED
.ADVANCE
AIR CUT GRINDING

1ST ROUGH GRINDING
\
~
~
5-103
2ND ROUGH
GRINDING
Ifn,Jlm'
5. TROUBLESHOOTING
GM6311
Alarm No.: B90C
Messages
Causes
: Sizing signal ON in 3rd rough grinding
Description
In direet sizing grinding, the sizing signal (AS7) was already ON at the start of 3rd rough grinding.

Causes
Corrective Action
1. Wheelhead eoordinate system is offset.

2. Sizing signal output point setting error (signal
output points AS 1 and AS7 are set too elosely
with ea eh other)
1. Establish the eoordinate system by bringing the

wheel into contaet with the master workpiece.
2. Set the signal output points eorrectly.
V' See 6.6.2 "Replacing the Sizer Head".
WHEELHEAD
~ ~~C~EED
AIR CUT GRINDING
1ST ROUGH GRINDING
2ND ROUGH GR I ND I NG
AS3 ""' _ _
AS 7' ON; 3RD ROUGH GR I ND I NG
5-104
Iflnl)I,!1
5. TROUBLESHOOTING
GM6311
Alarm No.: 8900
Messages
Causes
: Sizing signal ON in 1st fine grinding
Description
In direct sizing grinding, the sizing signal (AS7) was already ON at the start of 1st fine grinding.

Causes
Corrective Action

output points AS3 and AS7 are set too closely
";:With each other)

2. Set the signal output points correctly.
cr See 6.6.2 "Replacing tbe Sizer Head".
WHEELHEAD
~ R.AP I O FEED
: ADVANCE
AIR CUT GRINDING
1ST ROUGH GRINDING
2ND ROUGH GRINDING
AS1
AS3
AS7
.......
or~
3RD ROUGH GRI NO I NG
.
1ST FINE GR I NO I NG
5-105
lil)llllLt
5. TROUBLESHOOTING
GM6311
Alarm No.: B90E
Messages
Causes
: Sizing signal ON in 2hd fine grinding
Corrective Action : Check the sizer position setting and the workpie_ce.
Description
In direct sizing grinding, the sizing signal (AS7) was already ON at the start of 2nd fine grinding.

Causes
Corrective Action

output points AS4 and AS7 are set too closely
with ea eh other)

wheel into contaet with the master workpieee.
2. Set the signal output points correetly.
r:::r
WHEELHEAD
[( RAP ID FEED
;; ADVANCE
AIR CUT GRINDING
1ST ROUGH GRINDING
2ND ROUGH GRINDING
AS1
3RD ROUGH GRINDING
AS3
1ST
FINE
GR _
IND_ING
AS4
_
__
__
~
AS5 ON 2ND FIfijE GR IND ING
\.
5-106
i'ltJI]lt*,
5. TROUBLESHOOTING
GM6311
Alarm No.: 8912
Messages
Causes
: The gap eliminator ON at the start of contact detection cycle
CorrectiveAction : Check 8165 data orthe gap eliminator.
Description
At the start of the wheel truing contact detection cycle, the contact detection signal is already ON.

Causes
Corrective Action
1. Faulty sensor
1. Replace the sensor.
2. Coordinate system of contact detection posi-
2. Establish the contact position coordinate sys-
tion is offset.
temo
5-107
Ulnl]1M
5. TROUBLESHOOTING
GM6311
Alarm No.: 8913
Messages
Causes
: Contact detection gap eliminator not ON
Corrective Action : Check B169 data or the gap eliminator.
Description
The contact detection signal is not turned ON even when the wheel truer advances by the count-over
value beyond the contact detection target position.

Causes
Corrective Action
1. Faulty sensor
1. Replace the sensor.
2. Coordinate system of contact detection position is offset.
2. Establish the contact position coordinate systemo
5-108
111'11]Ja
5. TROUBLESHOOTING
GM6311 .
Alarm No.: 8916
Messages
Causes
: Out of taper OK range (+NG)
Corrective Action : Check the taper, sizing signal output point and grinding feedrate.
Description
After the completion of micro grinding, the sizer amplifier detected that the amount of taper exceeded
the taper OK range (+NG).

Causes
Corrective Action
1. Fluctuation of amount of taper due to workpiece

deflection
1. Lower the grinding feedrate to stabilize amount

oftaper.
2. Wheel was tapered in wheel truing cycle.
2. Check the diamond roll shaft and the wheel

truer infeed axis if they move during wheel truing.
3. Faulty wheel taper correction axis
3. Check the follow-up accuracy of the taper

correction axis.
5-109
Mi-finJd
5. TROUBLESHOOTING
GM6311
Alarm No.: 8917
Messages
Causes
: Out of taper OK range (-NG)
Corrective Action : Check the taper, sizing signal output point and grinding feedrate.
Description
After the completion of micro grinding, the sizer amplifier detected that the amount of taper exceeded
the taper OK range (-NG).

Causes
Corrective Action
1. Fluctuation of amount of taper due to workpiece
1. Lower the grinding feedrate to stabilize amount
deflection
oftaper.
2. Wheel was tapered in wheel truing cycle.
2. Check the diamond roll shaft and the wheel truer

infeed axis if they move during wheel truing.
3. Faulty wheel taper correction axis
3. Check the follow-up accuracy of the taper correction axis.
5-110
IflnlJIJd
5. TROUBLESHOOTING
GM6311
Alarm No.: 891A
Messages
Causes
: Abnormal workpiece run-out in 2nd fine grinding
Corrective Action : Check the sizer and the workpiece.
Description
The sizer output signal fluctuates excessively to cause the sizing signal (AS1 ) to repeat ON and OFF.

Causes
Corrective Action
1. The workpiece is not he Id between the centers

correctly.
2. The sizer contact does not touch the workpiece
correctly.
5-111
1. Adjust the footstock spindle center position.

2. Adjust the sizer contact position.
I IlnlJIJd
5. TROUBLESHOOTING
GM6311
Alarm No.: 891 e
Messages
Causes
: Abnormal workpiece run-out in 3rd rough grinding
Description
The sizer output signal f1uctuates excessively to cause the sizing signal (AS3) to repeat ON and OFF.

Causes
Corrective Action
1. The workpiece is not held between the centers

correctly.
correctly.
5-112
1. Adjust the footstock spindle center position.

lin'M
5. TROUBLESHOOTING
- - - - - - - - - - - - - - - - - - - - - . GM6311
Alarm No.: 891 D
Messages
Causes
: Abnormal workpiece run-out in 1st fine grinding
Description
The sizer output signal fluctuates excessively to cause the sizing signal (AS4) to repeat ON and OFF.

Corrective Action
Causes
correctly.
2. Insufficient rest shoe pushing amount
5-113

2. Adjust the rest shoe pushing amount.
ill)11]1'4
5. TROUBLESHOOTING
GM6311
Alarm No.:B91 E
Messages
Causes
: Abnormal workpiece run-out in 1st fine grinding
Description
The sizer output signal fluctuates excessively to cause the sizing signal (AS5) to repeat ON and OFF.

Causes
Corrective Action

correctly.
2. Insufficient rest shoe pushing amount
5-114

II-n-] 1M
5. TROUBLESHOOTING
GM6311
Alarm No.: 891 F
Messages
Causes
: Abnormal workpiece run-out in micro grinding
Description
The sizer output signal fluctuates excessively to cause the sizing signal (AS?) to repeat ON and OFF.

Causes
Corrective Action

correctly.
2. Insufficient reset shoe pushing amount
5-115

Mi-nIJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: 8920
Messages
Causes
: Abnormal offset amount in sizing grinding
Description
The sizing grinding offset amount (A31) exceeded the allowable Iimit (A68).

Causes
Corrective Action
1. Excessive wear amount of diamond roll
1. Replace the diamond roll.
2. Set allowable limit amount is too small.
2. Set the value appropriately taking the thermal

displacement into consideration.
5-116
Iflnl]lt*'
5. TROUBLESHOOTING
GM63H
5.5.3
Diagnosis and Corrective Action - Alarm C
Alarm No.: C922
Messages
Causes
: Drive pin IN signal not ON
Corrective Action : Check the drive pino
Description
The drive pin IN signal was not output although the drive pin IN cycle was repeated as many times as
setfor A13 (drive pin IN repeattime).

Causes
Corrective Action
1. The drive pin IN confirmation proximity switch

position is not adjusted correctly.
1. Adjust the position of the drive pin IN confirmation proximity switch.
2. Faulty drive pin IN confirmation proximity switch
2. Check the drive pin IN confirmation proximity

switch.
FOOTSTOCK
CENTER ADVANCE
The datum pin insertion signal is not output

though the drive pin is inserted in the pin hole.
5-117
5. TROUBLESHOOTING
. GM6311
Alarm No.:
C925
Messages
Causes
: Laterallocator signal not ON
Corrective Action : Check the laterallocator or related data
Description
In the execution of a location cycle, the location signal was not output from the TOYOPUC although the
locator moved by the locating stroke (B36/A65).

Corrective Action
Causes
1. Faulty laterallocator
1. Check the lateral locator.
2. Location position does not match the

workpiece.
r:::r
See Operation Manual, 7.8.7 "Mounting tbe

Locator".
2. Input the locating position correctly.
r:::r
See Operation Manual, 7.8.8 "Cbanging and

Adjusting tbe Locator Feeler".
The locator OK signal is not output though

the lecator moves a preset distance.
5-118
Illnl] 1)1
5. TROUBLESHOOTING
GM6311
Alarm No.: C926
Messages
Causes
: Laterallocation offset amount exceeded the PSW range.
Corrective Action : Correct the 832 or 835 data.
Description
The laterallocation offset amount (A37) exceeded the PSW setting range (835).

Causes
Corrective Action
1. Incorrectworkpiece shape (longitudinal position)
1. Change the workpiece.
2. Input error of w0rkpiece end face position
2. Input the workpiece end face position correctly.
3. Work spindle position (Z axis) advance end

PSW setting range data (835) has not been
input.
rJ=' See Operation Manual, 7.8.8 "Changing and

Adjusting the Locator Feeler".
3. Set the data for 835 (Standard: 0.5 mm).
rJ=' See Opertion Manual, 7.3.2 "Editing the

GrindingData".
Z AXIS
0< >8
;':
WORKHEAD
B32+A37
5-119
iklnlllM
5. TROUBLESHOOTING
GM6311
5.5.4
Diagnosis and CorrectiY9 Action - Alarm D
Alarm No.: 0407
Messages
Causes
,',:.
: Start signal not OFF within a preset time after the output of program end M code
"'""
Corrective Action : Check the sequence circuit.
Description
Although the CNC output the M02 signal, the start signal from the TOYOPUC was not turned OFF.

Causes
Corrective Action
1. The start signal hold condition, in the electric

circuit diagram, is not OFF.
1. Find the O and N number of the program by

displaying the DISPLAY FAULT COMMENT window and check th active cycle at the table in
the electric circuit diagram.
Example: The return start signal remained ON

(short-circuit ofthe [RETURN] button).
2. The M02 signal is not output from the CNC.
"1" is set for the maintenance parameter

MBOO61.
Check the cycle start condition of the active

cycle referring to the electrlc circuit diagram and
find the condition that remains ON by the maintenance PLC menu.
2. Set "O" for the maintenance parameter MBOO61.
5-120
'f~
':~/~
Illnl]I,a
5. TROUBLESHOOTING
GM6311
5.5.5
Diagnosis and Corrective Action - Alarm E
Alarm No.: E900
Messages
Causes
: Input error of wheel to workpiece gap data for test operation
CorrectiveAction : A120 ~ 10.
Description
For the wheel to workpiece gap data for test operation, a value smaller than O mm is input.

Corrective Action
Causes
Data input error for A 120 (gap between the wheel
and the workpiece)
A120/2
5-121
Set a value larger than O mm (dia.) for A 120.
Cl" See Operation Manual, 7.3.7 "Inputting the

Machine Constant Data" and 12.1 "M achine
ConstantData".
IIiii-] -1*1
5. TROUBLESHOOTING
GM6311
Alarm No.: E901
Messages
Causes
: Input error of rest to workpieee gap data for test operation
Correetive Aetion : Correet the data set for A 119.
Description
For the rest to workpieee gap data for test operation, a value smaller than O mm is input.

Causes
Corrective Action
Data input error for A 119 (gap between the rest

and the workpieee)
5-122
Set a value larger than O mm (dia.) for A119.
r:::r
See Operation Manual, 7.3.7 "Inputting the

Constant Data".
n'l M
'Mil
5. TROUBLESHOOTING
GM6311
Alarm No.: E902
Messages
Causes
: Grinding method input error
Corrective Action : Correct the data set for 805.
Description
For 805, a value other than "1 ", "2" and "3" is input.

Causes
Corrective Action
For 805 (grinding method), a value that cannot be

used is set.
Check the 805 data and set a correct value meeting the type of grinding.
cr
5-123
See Operation Manual, 7.3.2 "Editing the

Grinding Data" and 12.2 "Workpiece Data".
1II111JI'd
5. TROUBLESHOOTING
GM6311
Alarm No.:
E903
Messages
Causes
: V-axis 2ndt-step start diameter input error
Corrective Action : Correct the 878 data.
Description
s.
'e value set tor 878 (V-axis 2nd-step start diameter) is smaller than the value set tor 881 (V-axis 3rd~tart diameter).

Causes
Corrective Action
Input error tor 878 (V-axis 2nd-step start diameter)

or 881 (V-axis 3rd-step start diameter).
Input the correct vale tor 878 (V-axis 2nd-step

start diameter) or 881 (V-axis 3rd-step start diameter); the value set tor 878 (V-axis 2nd-step start
diameter) must be larger than the value set tor 881
(V-axis 3rd-step start diameter).
r:::r
V AXIS
5-124

5. TROUBLESHOOTING
GM6311
Alarm No.: E905
Messages
Causes
: Regrinding cycle start diameter input error
Description
The value set for 870 (regrinding cycle start diameter) is less than "O".
Regrinding cycle: Cycle for finishing the workpiece manually to be used when grinding cycle has
not been completed

Causes
Corrective Action
A regrinding cycle was started without inputting

the data for 870 (regrinding cycle start diameter).
Input the data for 870 (regrinding cycle start diameter).
r:::r
5-125

5. TROUBLESHOOTING
GM6311
Alarm No.: E906
Messages
Causes
: Work spindle speed input error
Corrective Action : Correct the data input for 806 - 811.
Description
The work spindle speed data (806 to 811) is less than "O" or larger than "250".

Causes
Corrective Action
No value is set or an incorrect value is set for the

work spindle speed (806 to 811).
Input the work spindle speed data (806 to 811)

correctly.
0= See Operation Manual, 7.3.2 "Editing the

B06 ........B11
WORK SP I NDLE SPEED
5-126
iklnl]lt'
5. TROUBLESHOOTING
GM6311
Alarm No.: E907
Messages
Causes
: Y-axis 2ndt-step start diameter input error
Description
The value set tor 879 (Y-axis 2nd-step start diameter) is smaller than the value set tor 882 (Y-axis 3rdstep start diameter).

Causes
Corrective Action
Input error tor 879 (Y-axis 2nd-step start diameter)

or 882 (Y-axis 3rd-step start diameter).
Input the correct value tor 879 (Y-axis 2nd-step

start diameter) or 882 (Y-axis 3rd-step start diameter); the value set tor 879 (Y-axis 2nd-step start
diameter) must be larger than the value set tor 882
(Y-axis 3rd-step start diameter).
rJ=' See Operation Manual, 7.3.2 "Editing the

y AXIS
5-127
lilnl,IJ!1
5. TROUBLESHOOTING
GM6311
Alarm No.: E908
Messages
Causes
: V-axis 1st-step feed start diameter input error
Correetive Aetion : Correet the 875 data.
Description
The value set for 875 (V-axis 1st step feed start diameter) is smaller than "O".

Causes
Corrective Action
No value is input for 875 (V-axis 1st step feed start

diameter) or the value input for 875 (V-axis 1st step
feed start diameter) is smaller than the value set
for 878 (V-axis 2nd step feed start diameter).
Input the eorreet value for 875 (V-axis 1st step feed
start diameter); the value set for 875 (V-axis 1st
step feed start diameter) must be larger than the
value set for 878 (V-axis 2nd step feed start diameter).
r:::r
V AXIS
.-
5-128

UittlJlhl
5. TROUBLESHOOTING
GM6311
Alarm No.: E909
Messages
Causes
: Y-axis 1st-step feed start diameter input error
Corrective Action : Correct the B76 data.
Description
The value set for B76 (Y-axis 1st step feed start diameter) is incorrect.

Causes
Corrective Action
No value is input for B76 (Y-axis 1st step feed start

diameter) orthe value inputfor B76 (Y-axis 1st step
feed start diameter) is smaller than the value set
for B79 (Y-axis 2nd step feed start diameter).
Input the correct value for B76 (Y-axis 1st step feed
start diameter); the value set for B76 (Y-axis 1st
step feed start diameter) must be larger than the
value set for B79 (Y-axis 2nd step feed start diameter).
o=-
y ,AXIS
5-129

illn-llM
5. TROUBLESHOOTING
GM6311
Alarm No.: E910
Messages
Causes
: 2nd rough-grinding start diameter input error
Description
The value set for 863 (2nd rough-grinding start diameter) is larger than the value set for 862 (1st roughgrinding start diameter).

Causes
Corrective Action
Input error for 863 (2nd rough-grinding start diameter) or 862 (1st rough-grinding start diameter).
Input the correct value for 863 (2nd rough-grinding

start diameter) or 862 (1st rough-grinding start diameter); the value set for 863 (2nd rough-grinding
start diameter) must be smaller than the value set
for 862 (1 st rough-grinding start diameter).
cr

WHEELHEAD
RAPID FEED
5-130
ADVAr~CE
111'11]1141
5. TROUBLESHOOTING
GM6311
Alarm No.: E911
Messages
Causes
: Y-axis finish diameter input error
Description
The value set tor 868 (Y-axis finish diameter) is smaller than "O".

Causes
Corrective Action
No value is set tor 868 (Y-axis finish diameter).
Set a correct value tor 868 (Y-axis finish diameter).
r:::r
y .AXIS
5-131

1I-nl] 114
5. TROUBLESHOOTING
GM6311
Alarm No.: E912
Messages
Causes
: X-axis finish diameter input error
Description
The value set for 860 (X-axis finish diameter) is less than 15 mm (in diameter) or in exeess of 75 mm
(in diameter).

Causes
Corrective Action
For 860 (X-axis finish diameter), a value outside

the allowable range was input.
For 860 (X-axis finish diameter), set a value larger

than 15 (in diameter) and smaller than 75 (in diameter).
r:::r
B60
5-132

EII}ll]lt!!
5. TROUBLESHOOTING
GM6311
Alarm No.: E914
.
Messages
Causes
: 1st rough-grinding start diameter input error
Description
The value set for 862 (1 st rough-grinding start diameter) is smaller than "O".

Causes
Corrective Action
No value is set for 862 (1 st rough-grinding start

diameter).
Set a correct value for 862 (1st rough-grinding start

diameter).
,
r:::r See Operation Manual, 7.3.2 "Editing tbe
I,RIHEELHEAD
RAPID FEED ADVANCE
5-133
5. TROUBLESHOOTING
GM6311
Alarm No.: E915
Messages
Causes
: 1st rough grinding start diameter > Air-cut grinding start diameter
Corrective Action : Correct the data so that 862 < 861.
Description
The value set for 862 (1st rough-grinding start diameter) is larger than the value set for 861 (a ir-cut
grinding start diameter).

Causes
Corrective Action
Input error for 862 (1st rough-grinding start diameter) or 861 (air-cut grinding start diameter).
Input the correct value for 862 (1st rough-grinding

start diameter) or 861 (air-cut grinding start diameter); the value set for 861 (air-cut grinding start
diameter) must be larger than the value set for 862
(1st rough-grinding start diameter).
O" See Operation Manual, 7.3.2 "Editing the

IOJHEELHEAD
RAPID FEED ADVAIJCE
5-134
lilnl]lt*'
5. TROUBLESHOOTING
GM6311
Alarm No.: E916
Messages
Causes
: V-axis finish diameter input error
Description
The value set for 867 (V-axis finish diameter) is smaller than "O".

Corrective Action
Causes
No value is set for 867 (V-axis finish diameter).
Set a correct value for 867 (V-axis finish diameter).

o=' See Operation Manual, 7.3.2 "Editing tbe
V AXIS
5-135
iiltl'1 lM
5. TROUBLESHOOTING
GM6311
Alarm No.: E917
Messages
Causes
: 1st fine grinding start diameter > 1st rough grinding start diameter
Corrective Action : Correct the data so that 864 < 863.
Description
The value set for 864 (1st fine-grinding start diameter) is larger than the value set for 863 (1st roughgrinding start diameter).

Causes
Corrective Action
Input errorfor 864 (1st fine-grinding start diameter)

or 863 (1st rough-grinding start diameter)
Input the correct value for 864 (1st fine-grinding

start diameter) or 863 (1st rough-grinding start diameter); the value set for 863 (1 st rough-grinding
start diameter) must be larger than the value set
for 864 (1 st fine-grinding start diameter).
r::r

WHEELHEAD
RAPID FEED ADVANCE
5-136
MilnlJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: E918
Messages
Causes
: Micro grinding start diameter > 2nd fine grinding start diameter
Corrective Action : Correct the data 50 that B66 < B65.
Description
The value set for B66 (micro-grinding start diameter) is larger than the value set for B65 (2nd finegrinding start diameter).

Causes
Corrective Action
Input error for B66 (micro-grinding start diameter)

or B65 (2nd fine-grinding start diameter)
Input the correct value for B66 (micro-grinding start

diameter) or B65 (2nd fine-grinding start diameter);
the value set for B65 (2nd fine-grinding start diameter) must be larger than the value set for B66 (micro-grinding start diameter).
r:::r

If\IHEELHEAD
RAPID FEED
5-137
ADVAr~CE
illill]IJd
5. TROUBLESHOOTING
GM6311
Alarm No.: E919
Messages
Causes
: 2nd fine grinding start diameter > 1st fine grinding start diameter
Correetive Aetion : Correet the data so that 865 < 864.
Description
The value set for 865 (2nd fine-grinding start diameter) is larger than the value set for 864 (1st finegrinding start diameter).

Causes
Corrective Action
Input error for 865 (2nd fine-grinding start diameter) or 864 (1st fine-grinding start diameter)
Input the eorreet value for 865 (2nd fine-grinding

start diameter) or 864 (1 st fine-grinding start diameter); the value set for 864 (1st fine-grinding start
diameter) must be larger than the value set for 865
(2nd fine-grinding start diameter).
r:::r
See Operation Manual, 7.3.2 "Editing tbe

\f\IHEELHEAD
RAPI DFEED ADVANCE
5-138
Mlli,I]lt!,
5. TROUBLESHOOTING
GM6311 .
Alarm No.: E920
Messages
Causes
: NC wheel truing point number data input error
Corrective Action : Correct the Cag data.
Description
The value set for Cag (wheel truing point number) is smaller than "2" or larger than "15".

Causes
Corrective Action
Input error for Cag (wheel truing point number)
Set a value larger than "2" or smaller than "15" for

Cag (wheel truing point number).
0= See Operation Manual, 7.3.3 "Editing tbe

Process Data" and 12.3 "Process Data".
5-139
5. TROUBLESHOOTING
GM6311
Alarm No.: E921
Messages
Causes
: The horizontal axis eoordinate value of the first NC wheel truing point is not on the
origino
Correetive Aetion .: Correet the C90 data.
Description
The value set for C90 (wheel truing point eoordinate value) is smaller than "-0.5" or larger than "O".

Causes
Corrective Action
The value set for C90 (wheel truing point eoordinate value) is ineorreet.
Correet the value set for C90 (wheel truing point

eoordinate value) to a value larger than "-0.5" and
smaller than "O".
cr
5-140

liIIXIJIJi,
5. TROUBLESHOOTING
GM6311
Alarm: No.: E922
Messages
Causes
: NC wheel truing feedrate input error
Correetive Aetion : Correet the feedrate data of the A21 point
Deseription
Wheel truing feedrate data is not input.

Causes
Corrective Action
The wheel truing feedrate data at the (A21 ) point is

"0.0001".
Input the eorreet wheel truing feedrate data at the

(A21) point.
Example:A21 = 4
Correet the C1 05 data.
o=- See Operation Manual, 7.3.3 "Editing the

A21
Wheel truing feedrate
15
C97 C101 C105 C109 C149
5-141
Ei1nl] 114
5. TROUBLESHOOTING
GM6311
Alarm No.: E923
Messages
Causes
: The horizontal axis coordinate value of the NC wheel truing point is too small.
Corrective Action : Correct the A21 or preceding point data.
Description
The horizontal axis coordinate value (A21-1) of the (A21) point is smaller than the horizontal axis
coordinate value of the preceding point.

Causes
Corrective Action
Interference of the diamond roll disables dressing.
Correct the horizontal axis coordinate value (A211) of the (A21) point so that it will be larger than
the horizontal axis coordinate value of the preceding point.
r::::r
A21
1
C90

C94 C100 C146
."
'
.,
.
.
,
., .
-->~61
C100 C94
C108 C104
5-142
li'iTI'~1d
5. TROUBLESHOOTING
GM6311
Alarm No.: E924
Messages
Causes
: A V-shape was formed in NC wheel truing operation
Corrective Action : Correct the point data of the (A21) point or preceding/succeeding point.
Description
The vertical axis coordinate values of the (A21) point and the preceding/succeeding points formed a Vshape.

Causes
Corrective Action
The vertical axis coordinate values input for the

(A21) point and the preceding/succeeding points
are incorrect to cause interference between the
diamond roll and the wheel.
Correct the vertical axis coordinate values input for

the (A21 ) point and the preceding/succeeding points
so that a V-shape will not be formed in the wheel.
A21
C91
C95
r:::r

15
C99 C103 C147
C95
C104
C99
5-143
i 'ITla] 1M
5. TROUBLESHOOTING
GM6311
Alarm No.: E925
Messages
Causes
: NC wheel truing method input error
Corrective Action : Correct the COO data.
Description
The value input for COO (truing method) is smaller than "O" or larger than "5".

Causes
Corrective Action
No value or an incorreet value was input for COO

(truing method).
Input a eorreet value COO (truing method); the value

must be in the range from 1 to 5.
er
5-144

il-n1llt!1
5. TROUBLESHOOTING
GM6311
Alarm No.: E926
Messages
Causes
: Minimum wheel diameter input error
Corrective Action :Correct the 851 data.
Description
For 851 (minimum wheel diameter data), a value smaller than.700 mm (in diameter) or larger than 1050
mm (in diameter) was input.

Causes
Corrective Action
Input error for 851 (minimum wheel diameter).
Input a correct value for 851 (minimum wheel diameter); the value must be larger than 700 mm (in
diameter) and smaller than 1050 mm (in diameter).
r:::r
5-145

I ilnll ID
5. TROUBLESHOOTING
GM6311
Alarm No.: E927
Messages
Causes
: Wheel R-seetion angle input error
Corrective Action : Correct the C31 data.
Description
The value input for C31 (wheel R-section angle) is smaller than "O" or larger than "90".

Causes
Corrective Action
No value or an incorrect value is input for C31 (wheel

R-section angle).
Input a correet value for C31 (wheel R-section

angle); the value must be larger than "O" and
smaller than "90".
5-146
Illil)-14
5. TROUBLESHOOTING
GM6311
Alarm No.: E928
Messages
Causes
: Wheel R-value input error
Corrective Action : Correct the C32 or C33 data.
Description
1. 80th ot C32 (wheel right-side R dimension) and C33 (wheelleft-side R dimension) are smaller than
"O".
2. Either C32 (wheel right-side R dimension) or C33 (wheelleft-side R dimension) is larger than 10 mm.
3. Although a value is set tor C37 (wheel right-side R-section length) is input, the value set tor C32
(wheel right-side R dimension) is smaller than "O".
4. Although a value is set tor C39 (wheelleft-side R-section length) is input, the value set for C33
(wheelleft-side R dimension) is smaller than "O".

Causes
Corrective Action
No value or an incorrect value is set tor C32/C33

(wheel R dimension).
For C32 (wheel right-side R dimension), input a

value largerthan "O" and smallerthan "10."
For C33 (wheelleft-side R dimension), input a value
larger than "O" and smaller than "10."
C39
C37
5-147
Mili,I]I,a
5. TROUBLESHOOTING
GM6311
Alarm No.: E929
Messages
Causes
: Wheel taper amount input error
Corrective Aetion : Correet the C41 data.
Description
The value input tor C41 (wheel taper amount) is larger than the allowable limit.

Causes
Corrective Action
An incorrect value is input tor C41 (wheel taper

amount).
Input a eorreet value tor C41 (wheel taper amount);

the value must be smaller than the allowable limit.
Wheel width (C21) /1250
Allowable limit:
r:::r

C41
T.APER
1<
C21
ABS (C41 ) <C21 /1 250. mm (O. 023

C21 :WHEEL W10TH
5-148
0
)
MIlnl]1M
5. TROUBLESHOOTING
GM6311
Alarm No.: E930
Messages
Causes
: Wheel erowning amount input error
Correetive Aetion : Correet the C40 data.
Description
The value input for C40 (wheel erowning amount) is "O" or outside the range of "0.02 to +0.02".

Causes
Corrective Action
No value or an ineorreet value is input C40 (wheel

erowning amount).
Input a eorreet value for C40 (wheel erowning

amount); an absolute value of the value to be input
must be smaller than 0.02.
r:::r
"
/._
..

.,
(~ (-)
1IIIillliilllliiiii- ~)
L---.....
--_1
5-149
(+)
lillll]114
5. TROUBLESHOOTING
GM6311
Alarm Noo: E931
Messages
Causes
: Interference between the diamond roll and the wheel during wheel truing
Corrective Action : Check the diamond roll and wheel interfrence, or correct the C25 data.
Description
The data that causes interference between the left wheel and the diamond roll during wheel truing was
input.

Causes
Corrective Action
1. Input error for C25 (wheel diameter difference
1. Correct the value set for C25 (wheel diameter
from the reference wheel)
difference from the reference wheel).
2. Wheel diameter differences exceeded the permissible value.
2. Review the shape so that the diameter difference between the wheels and the reference
wheel (C25) is smaller than the value "S18506 MI3958".
SI8506 : Diamond roll diameter
MI3958 : Distance from the diamond roll center
to the diamond roll outtine
r:::r
0-
-+~:
-,.- +... ...
::_:,": '.: ::+".:. ":s:::
..
.
..
.-.,+
. -....
... -.
.-. + ,,-_
--.
+
.n
.+
+~+t+. J~.:
.+.: .+.t+. +.'
+ .....
.
...
+.
~ . .+,
.-.
ss_.
. . .
_so
.
-.--.-
-. .-
+ ..
+ +

5-150
.....
:+
+ .
+
+
++
..,.
+
-..-
".
--.-0-
.+ "
...:..
:+
+
lito
o".
+.
111},IJI'd
5. TROUBLESHOOTING
GM6311
Alarm No.: E932
Messages
Causes
: Wheel truing infeed amount input error
CorrectiveAction : Correct the 871 data.
Description
The value set for 871 (wheel truing infeed amount) is larger than 0.1 mm (in diameter) or a negative
value is set for 871 (wheel truing infeed amount).

Causes
Corrective Action
No value or an incorrect value is set for 871 (wheel

truing infeed amount).
Input a correct value for 871 (wheel truing infeed

amount); the value must be smaller than 0.1.
r::::r See Operation Manual, 7.3.2 "Editing the

5-151
111)1IJlt!1
5. TROUBLESHOOTING
GM6311
Alarm No.: E933
Messages
Causes
: Input error of the wheel to wheel truer gap data
Corrective Action : Correct the A 121 data.
Description
The value set for A121 (wheel to wheel truer gap fortest operation) is smaller than 0".

Causes
Corrective Action
No value is input for A121 (wheel to wheel truer

gap for test operation).
Input a correct value for A121 (wheel to wheel truer

gap data for test operation).
Standard value: 10
r::r
....... _...-,;
l"
1:

Machine Constant Data" and 12.1 "Machine
ConstantData".
.'
-E
:.
,.,
:.
..J---+-~+ "
L
'.--..~_.I
! .::
.+
:~~-
4: :"
+.
..
"
..-
..-

"
"
:::+... :::
.:... ~. 4: + :_.
" "
....'.
-'.. -...........
........ . -
"
: .. ~ .. + . . . ':-.:
-,:+.
.....
.
'.
;.
:.
c.......... : "
+
+ +
+
~ +.' .:''''.
.... : .ti.....~ .,,+......
+ ' :
.... . ".
..
\/
:. ---'1"-
+
.._
."
5152
A121/2
" .
--
I-
J\
..
'.
" "
."
-
-:_.~
-:-
:.....
...
:.
+
+
+
+
IklnlJI'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: E934
Messages
Causes
: Wheel width input error
Description
The value set for C21 (wheel width) is smaller than 0".

Corrective Action
Causes
No value is input for C21 (wheel width).
Input a eorreet value for C21 (wheel width)
CF See Operation Manual, 7.3.2 "Editing tbe

5-153
1111,1]1'41
5. TROUBLESHOOTING
GM6311
Alarm No.: E935
Messages
Causes
: Diamond roll R data input error
Corrective Action : Correct the A71 data.
Description
The value input for A71 (diamond roll R) is smaller than "0.1" or larger than "5".

Causes
Corrective Action
An incorrect value is inputfor A71 (diamond roll R).
Input a correct value for A71 (diamond roll R); the

value must be larger than "0.1" and smaller than
"5".
r::::r See Operation Manual, 7.3.7 "Inputting the

MachineConstantData" and 12.1 "Machine
ConstantData".
:: ~
,": .:.:... .
~: ~..:.~,~::: ';;'.' ~
,.
.
.. ,
'.--. :.
....
..
' ~
-a ' .
a_ .
A71
5-154
lilnlJI'1
5. TROUBLESHOOTING
GM6311
Alarm No.: E936
Messages
Causes
: Diamond roll diameter input error
Corrective Action : Correct the SI8506 data.
Description
The value set for SI8506 (diamond roll diameter) is smaller than "O".

Causes
Corrective Action
No value is input for SI8506 (diamond roll diameter).
Input a correct value for SI8506 (diamond roll diameter).

Standard value: 120.
cr
5-155

Setting Data".
1ill,l] 1,41
5. TROUBLESHOOTING
GM6311
Alarm No.: E937
Messages
Causes
: Diamond roll width input error
Corrective Action : Correct the A75 data.
Description
The value set for A75 (diamond roll width) is smaller than "2" or larger than "16".

Causes
Corrective Action
The value setfor A75 (diamond roll width) is smaller

than "2" or largerthan "16".
Input a correct value for A75 (diamond roll width);

the value must be larger than "2" and smaller than
"16".
r::::r

Machine Constant Data".
~
A75
5-156
Iflri,,M
5. TROUBLESHOOTING
GM6311
Alarm No.: E938
Messages
Causes
: Wheel truing infeed amount input error
Correetive Aetion : Correet the A 125 data.
Description
1. The value input for A125 (wheel truing infeed amount) is smallerthan "O" or largerthan "0.2".
2. The value input for A126 (wheel truing infeed amount in initial gap) is smaller than "O" although a
value is input for A124 (wheel truing initial gap).

Causes
Corrective Action
1. No value or an ineorreet value is input for A125

(wheel truing infeed amount).
1. Input a eorreet value A 125 (wheel truing infeed

amount); the value must be smaller than "0.2".
2. No value or an ineorreet value is input for A124

(wheel truing initial gap) or A126 (wheel truing
infeed amount in initial gap).
2. V\l.hen a value is input for A 124 (wheel truing

initial gap), input a value smaller than "0.2" for
A126 (wheel truing infeed amount in initial gap).
O'" See Operation Manual, 7.3.7 "Inputting the
Milchine Constant Data" and 12.1 "Machine
ConstantData".
5-157
I 111,1] I'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: E939
Messages
Causes
: Wheel side face truing data input error
Description
The value set for A 104 (wheelhead position for wheel side face truing) is smaller than "O".

Causes
Corrective Action
No value is set for A 104 (wheelhead position for

wheel side face truing).
Input a correct value for A 104 (wheelhead position

for wheel side face truing).
cr See Operation Manual, 6.3.7 "Wheel Side Face

Dressing Operation" and 7.3.7 "Inputting the
Machine Constant Data".
Wheel side face truer
5-158
IilYlI] lb'
5. TROUBLESHOOTING
GM63H
Alarm No.: E940
Messages
Causes
: Wheel R-section length input error
Description
1. The value set for C37 (wheel right-side R-section length) is "O" or smaller with a value set for C32
(wheel right-side R dimension).
2. The value set for C39 (wheelleft-side R-section length) is "O" or smaller with a value set for C33
(wheelleft-side R dimension).

Causes
Corrective Action
No value is set for C37 (wheel right-side R-section

length) or C39 (wheelleft-side R-section length).
1. Input a value for C37 (wheel right-side R-section length).

2. Input a value for C39 (wheelleft-side R-section
length).
C94 ~ C90 + (A71 * TAN (C31/2.) * cas (C31
C122~C126-(A71
*TAN (C31/2.)* CaS(C31
=Diamond roll R
C31 =Wheel R-section angle
A71
CF See Operation Manual, 7.3.3 "Editing the

C39
C37
5-159
1(1)11]1141
5. TROUBLESHOOTING
GM6311
Alarm No.: E941
Messages
Causes
: Wheel cylindrical section length input error
Description
1. The value set for C36 (wheel right-side cylindrical section length) or C38 (wheelleft-side cylindrical section length) is a negative value.
2. For the wheel shape without R-section, the value set for C36 (wheel right-side cylindrical section
length) or C38 (wheelleft-side cylindrical section length data) is smaller than "O".

Causes
Corrective Action
No value is set for C36 (wheel right-side cylindrical

section length) or C38 (wheelleft-side cylindrical
section length).
Input a value for C36 (wheel right-side cylindrical

section length).
Input a value for C38 (wheel left-side cylindrical
section length).
~
C38
... ",,1/
1......
,....
,;'
.....
"
-.."
;"
,/'-
,/-'
A'!';8
~:? ~~

C36
/
j",
. !
,'/
--"
.... "".... .-
:::::.
::::: :::::
:::::
::;::::::::::~
:;:;:::
.---
;,;.;.
5-160
;.;.:
;.;.:
.:.
---
(-)
(+)
Iklfll]lhl
5. TROUBLESHOOTING
GM6311
Alarm No.: E942
Messages
Causes
: Wheel crowning width input error
Description
1. A negative value is set for C35 (wheel crowning width).
2. The value input for C35 (wheel crowning width) is larger than the wheelstraight section length (C21 C39 - C37 - C38 - C36).

Causes
Corrective Action
No value is input for C35 (wheel crowning width).
1. Input a value smaller than "O" for C35 (wheel

crowning width).
Corrective Action
2. Input a value smaller than the wheel straight

section length (C21 - C39 - C37 - C38 - C36)
for C35 (wheel crowning width).

C39 C38
, ",'-'" ""-
.",.
C35
,/
'"
,
/"
C36 C37
,/
....
,1/
....
".
"
.1-_..
",.r
.. ,
{~ (-)
11'llilitltl~lliil-
le-...
C21
--1
C35<C21- (C39+C37+C38+C36)
5-161
~~ (+)
Illnl]I,!1
5. TROUBLESHOOTING
GM6311
Alarm No.: E943
Messages
Caus~s
: Crowning center input error
Description
For C34 (wheel crowning center), a value not el ose to the wheel width center was input.

Causes
Corrective Action
The value set for C34 (wheel crowning center) is

ncorrect.
For C34 (wheel crowning center), input a value that

satisfies the following conditions.
C34 > C35/2.
C34 < C21 -
+ C38 + C38
(C35/2. + C36 + C37)
cr See Operation Manual, 7.3.3 "Editing the

C35
C39 C38
.-"
......
"-
'\
......
,1"
.,/
.......
.'
.- C34
.......
__
........
r
",
,,/ . - .. .....--+--t---+--+() (-)
__
.....C21
C34:>C39+C38+C35/2
C21-C34:>C36+C37+C35/2
5-162
"""--
lilijlJI'd
5. TROUBLESHOOTING
GM6311
Alarm No.: E944
Messages
Causes
: During wheel truing, the diamond roll and the wheel interfere with each other.
Corrective Action : Increase the value set for C35 (wheel crowning width).
Description
The value input for C35 (wheel crowning width) is smaller than the cylindrical section length of the
diamond rollo

Causes
Corrective Action
The value set for C35 (wheel crowning width) is

incorrect.
Input a correct value for C35 (wheel crowning width);

the value must be larger than the cylindrical section length of the diamond rollo
C35 > A75 - (A71
* 2)
A75: Diamond roll width

A71: Diamond roll R
r::::r
A71
5-163

I kliil] It1
5. TROUBLESHOOTING
GM6311
Alarm No.: E945
Messages
Causes
: Initial gap between the diamond roll and the next-step wheel is insufficient.
Corrective Action : Correct the C22 data, or change the wheel configuration to single wheel.
Description
The gap to the next-step wheel is too small.

Causes
Corrective Action
1. The value set for C22 (wheel truing gap stroke)

is incorrect.
1. Input a correct value for C22 (wheel truing gap

stroke).
2. The gap between the wheels is too small.
2. Input a value assuming a single wheel configuration.

DI/lMOND ROLL
SI9979 .,..
-."
,\...... .. -'.
,~
,.:,.~
'"
. .
'-
C23
.
.......".
........
....
..
~',
..

..
..
..
WHEEL
WHEEL
5-164
IllnlJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: E946
Messages
Causes
: During NC wheel truing operation, the wheel and the diamond roll interfere with each
other.
Corrective Action : Check the interference with the diamond roll unit and check the NC truing points.
Description
The wheel shape that causes interference between the wheel and the diamond roll was input.

Causes
Corrective Action
During NC wheel truing operation, the wheel and

the diamond roll interfere with each other.
Check and correct the wheel shape data.
cr See Operation Manual, 7.3.3 "Editing tbe

...
,
........
". -.
~;;fr:;;~
.. .....
.... ".
"
+.~..+~+'.::.
.. ...... .
-.:.
'''''.: +
",
..'" -:.
.+, .......
: .....; : ...
+4o
..
+,
. , . . .+
. ..
.. ..
4'
1flrll] 1141
5. TROUBLESHOOTING
GM6311
Alarm No.: E947
Messages
Causes
: The left wheel (No. 1 wheel) is not taken as the reference wheel.
Corrective Action : Set "O" for C23 or C25.
Description
A value is input for C23 (gap between the No. 1 wheel and left wheel) and C25 (diameter difference to
the reference wheel).

Causes
Corrective Action
The values set for C23 (gap between the No. 1 wheel
and left wheel) and C25 (diameter difference to the
reference wheel) are incorrect.
For C23 (gap between the No. 1 wheel and left

wheel) and C25 (diameter difference to the reference wheel), input "O".
r:::r
5-166

Ikl'IIJI1!1
5. TROUBLESHOOTING
GM6311
Alarm No.: E948
Messages
Causes
: Input error of the gap to the left wheel
Description
The value input for C23 (gap to the left wheel) is smaller than "O".

Corrective Action
Causes
No value is input for C23 (gap to the left wheel).
Input a eorreet value for C23 (gap to the left wheel).
rJ' See Operation Manual, 7.3.3 "Editing the

..
o -
+.".'.
+ .
:.::-:.---:."--..
..
./
04-
4- o
o
*o..
C23
.o.
....
+
-o-
+
-.
~
+ o
o
o
f4
WHEEL
WHEEL
5-167
lilill]I'1
5. TROUBLESHOOTING
GM6311
Alarm No,: E949
Messages
Causes
: Wheel truing initial gap input error
Description
The value input for C22 (wheel truing initial gap) is smaller than "O" or the value set for "MI3960".

Causes
Corrective Action
No value is input for C22 (wheel truing initial gap).
Input a correct value for C22 (wheel truing initial

gap).
()='

o. 1mm
__ 1
C23
..
....
t.
'.
.,.,...-
...
.....
..
.-..
+
.;4
."..+
WHEEL
WHEEL
5168
Mil)1']',d
5. TROUBLESHOOTING
GM6311
Alarm No.: E950
Messages
Causes
: Wheel truing data check has not completed.
Corrective Action : Check the sequence circuit.
Description
After correcting the wheel truing data, wheel truing data error check has not been executed.

Causes
Corrective Action
Seq uence circuit is incorrect.
Check and correct the sequence circuit.
5-169
lilrlIJIJ!'
5. TROUBLESHOOTING
- - - - - - - - - - - - - - - - - - - - - . GM6311
~Iarm
No.: E951
Messages
Causes
: The value set for A2.? (wheel end face position) is incorrect.
Corrective Action : Execute wheel end face position memory operation again.
Description
The value set for A2.? (Ieft end face of the reference wheel) is smaller than the value of W-axis righttraverse end origin (MI3964).

Causes
Corrective Action
Wheel end face position memory operation was

not executed correctly.
Execute wheel end face position memory operation correctly.
O" See Operation Manual, 7.3.7 "Inputting the

Constant Data".
t..27
5-170
Illrl'lltd
5. TROUBLESHOOTING
GM6311
Alarm No.: E952
Messages
Causes
: Wheel truing allowance amount input error
Description
The value set for A 124 (wheel truing initial gap) is a negative value.

Causes
Corrective Action
Data input error for A 124 (wheel truing initial gap)
Input a correct value for A124 (wheel truing initial

gap).
cr
5-171

ConstantData"
Ikllilllr*'
5. TROUBLESHOOTING
GM6311
Alarm No.: E953
Messages
Causes
: A-axis finish diameter input error
Description
The value set for 869 (A-axis finish diameter) is smaller than "O".

Corrective Action
Causes
No value is set for 869 (A-axis finish diameter).
Input a correct value for 869 (A-axis finish diameter).

869 (A-axis finish diameter):
The workpiece finish diameter where the middle
rest contaets.
r::::r
A AXIS
5-172

5. TROUBLESHOOTING
GM6311
Alarm No.: E954
Messages
Causes
: A-axis rest 1st-step start diameter input error
Corrective Action : Correct the B77 data.
Description
The value set for B77 (A-axis rest 1st-step start diameter) is smaller than "O" or the value set for B80 (Aaxis rest 2nd-step start diameter).

Causes
Corrective Action
No value is set for B77 (A-axis rest 1st-step start

diameter), or the value set for B77 (A-axis rest 1ststep start diameter) is smaller than the value set
for B80 (A-axis rest 2nd-step start diameter).
Set a correct value for B77 (A-axis rest 1st-step

start diameter); the value to be set for B77 (A-axis
rest 1st-step start diameter) must be larger than
the value set for B80 (A-axis 2nd-step start diameter).
CF See Operation Manual, 7.3.2 "Editing the

A AXIS
5-173
Mlli'IIIE'
5. TROUBLESHOOTING
GM6311
Alarm No.: E955
Messages
Causes
: A-axis rest 2nd-step start diameter input error
Description
The value set for 880 (A-axis rest 2nd-step start diameter) is smaller than the value set for 883 (A-axis
rest 3rd-step start diameter).

Causes
Corrective Action
No value is set for 880 (A-axis rest 2nd-step start

diameter), or incorrect value is set for 883 (A-axis
rest 3rd-step start diameter).
Set a correct value for 880 (A-axis rest 2nd-step

start diameter; the value to be set for 880 (A-axis
rest 2nd-step start diameter must be larger than
the value set for 883 (A-axis rest 3rd-step start
diameter).
()='
A .1IXIS
5-174

Iklr,IJI'*,
5. TROUBLESHOOTING
- - - - - - - - - - - - - - - - - - - - - . GM6311
Alarm No.: E969
Messages
Causes
: Contact detection start position input error
Description
The value set for C70 (Contact detection start position) is smaller than "O".

Causes
Corrective Action
No value is set for C70 (Contact detection start

position).
Set a correct value for C70 (Contact detection start

position).
cr
5-175

liliTIIJ,J;l
5. TROUBLESHOOTING
GM6311
Alarm No.: E970
Messages
Causes
: In NC wheel truing operation, the distance between the present and the next points is
smaller than the diamond roll R value.
Corrective Action : Correct the point data of the A21 or preceding/succeeding points.
Description
The data interval of the A21 point, causing the alarm, and the preceding/succeeding points is smaller
than the value set for A71 (diamond roll R).

Causes
Corrective Action
Distance between the wheel shape defining points

for NC truing is too short.
Set a larger data interval for A21 point, causing the

alarm, and the preceding/succeeding points; the
data interval must be larger than the value set for
A71 (diamond roll R).
Example:Alarm if "C98 - C94 < A71".
0= See Operation Manual, 7.3.3 "Editing tbe

A21
Horizontal coordinate
C90
C94
15
C98 C146
5-176
IIITIIJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: E971
Messages
Causes
: In NC wheel truing operation, the wheel R value is largerthan the diamond roll R value.
Corrective Action : Correct the R value of A21 point.
Description
The arc R value of the A21 point, causing the alarm, is smaller than the value set for A71 (diamond roll
R).

Causes
Corrective Action
Improper wheel arc R value is set for NC wheel

truing operation.
Set a larger wheel are R value for A21 point, eausing the alarm; the wheel are R value must be larger
than the value set for A71 (diamond roll R).
Example: Alarm if"C96 > A71"
CJ=' See Operation Manual, 7.3.3 "Editing tbe

A21
Rdimension
2
C92
15
C96 C100 C104 C148
DlpMOND ROLL
Pl
WHEEL
5-177
5. TROUBLESHOOTING
Alarm No.: E972
Messages
Causes
: In NC wheel truing operation, arc angle between two adjacent points is larger than
90.
Corrective Action : Correct the point data of A21 or the next point.
Description
For the arc shape data of A21 point, causing the alarm, a value that causes the arc angle to exceed
90 was input.

Causes
Corrective Action
In NC wheel truing operation, wheel truing is disabled since arc R shape angle is larger than 90.
Correct the arc shape data of A21 point, causing

the alarm, so that the arc R shape angle will be
smaller than 90.
cr
1
C90
C94
C98 C102 C146
Vertical coordinate
C91
C95
C99 C103 C147
Rdimension
C92
C96 C100 C104 C148
A21
See Operation Manua), 7.3.3 "Editing tbe

15
R (C1 04)
..
'
P4
P3
P3
..
--....""..P4
~-R(C104)
R (C1 04)---3-1
. .
P3
P4
5-178
1-nI1Ih'
5. TROUBLESHOOTING
GM6311
Alarm No.: E975
Messages
Causes
: In NC wheel truing operation, the distance between the present and the next points is
short.
Corrective Action : Correct the point data of A21 and the preceding/succeeding points.
Description
In NC wheel truing operation, the distance between two adjacent points is too short.

Causes
Corrective Action
In NC wheel truing operation, wheel truing is disabled since the distance between A21 point, causing the alarm, and the preceding or succeeding
point is too short.
Check and correct the distance between A21 point,

causing the alarm, and the preceding or succeeding point.
A21
o=-
15
C90
C94
C98 C102 C146
Vertical coordinate
C91
C95
C99 C103 C147
5-179

51'rl'IIJAl
5. TROUBLESHOOTING
GM6311
Alarm No.: E976
Messages
Causes
: In NC wheel truing operation, the diamond roll interferes with the wheel shape.
Corrective Action : Correct the point data of A21 and the preceding/succeeding points.
Description
In NC wheel truing operation, the distance between two adjacent points is too short.

Causes
Corrective Action
In NC wheel truing operation, wheel truing is disabled since the distance between A21 point, causing the alarm, and the preceding or succeeding
point is too short.
Check and correct the distance between A21 point,

causing the alarm, and the preceding or succeeding point.
A21
r::::r
C90
C94
C98 C102 C146
Vertical coordinate
C91
C95
C99 C103 C147
5-180
15

Ikltllllfd
5. TROUBLESHOOTING
GM6'311'
Alarm No.: E977
Messages
Causes
: In NC wheel truing operation, the value two times the R command vaJue is smaller
than the start to end point distance.
Corrective Action : Correct the NC point data.
Description
The R command value in the NC wheel truing data is incorrect.

Causes
Corrective Action
The R command value of the A21 point, causing

the alarm, is smaller than the point interval.
Set a larger value for the R command value of the

A21 point, causing the alarm; the R command value
must be larger than the point interval.
O' See Operation Manual, 7.3.3 "Editing tbe

A21
15
C90
C94
C98 C102 C146
Vertical coordinate
C91
C95
C99 C103 C147
Rdimension
C92
C96 C100 C104 C148
P3
(C98, C99)
P4 (C1 02, C1 03)
5-181
li-nlllJd
5. TROUBLESHOOTING
GM6311
Alarm No.: E978
Messages
Causes
: Wheel forming start initial gap input error
Description
The value set for C74 (wheel forming start initial gap) is smaller than "O".

Causes
Corrective Action
No value is set for C74 (wheel forming start initial

gap).
Set a correet value for C74 (wheel forming start

initial gap).
r:::r
5-182

MillllJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: E979
Messages
Causes
: Contaet deteetion rapid feed initial gap input error
Correetive Aetion : Correet the A 179 data.
Description
The value set for A179 (eontaet detection rapid feed initial gap) is smaller than "O".

Causes
Corrective Action
No value is set for A179 (contaet detection rapid

feed initial gap).
Set a correet value for A179 (contaet detection rapid

feed initial gap).
O' See Operation Manual, 7.3.3 "Editing the

5-183
MI.,.] lB
5. TROUBLESHOOTING
GM6311
Alarm No.: E980
Messages
Causes
: X-axis machining origin input error
Description
Input errorfor 841 (X-axis machining origin).

Causes
Corrective Action
The value set for 841 (X-axis machining origin) is

smaller than 70 (in diameter) or larger than 455 (in
diameter).
For 841 (X-axis machining origin), set a value larger

than 70 (in diameter) and smaller than 455 (in diameter).
The value set for 841 (X-axis machining origin) is

smaller than the finishing diameter.
For 841 (X-axis machining origin), set a value larger

than the finishing diameter.
O' See Operation Manual, 7.10 "Setting the Datum
Position ofGrinding and PSW".
5-184
1Ilrll] 1'*1
5. TROUBLESHOOTING
GM6311
Alarm No.: E981
Messages
Causes
: Y-axis machining origin input error
Description
Input error for 842 (Y-axis rest machining origin).

Causes
Corrective Action
The value set for 842 (Y-axis rest machining origin) is smallerthan 15 (in diameter) orsmallerthan
the value of "868 (Y-axis rest finishing diameter) +
876 (Y-axis rest 1st-step start diameter)".
For 842 (Y-axis rest machining origin), set a value

larger than 15 (in diameter).
For 842 (Y-axis rest machining origin), set a value
larger than the value of "868 (Y-axis rest finishing
diameter) + 876 (Y-axis rest 1st-step start diameter)".
r:::r
See Operation Manual, 7.10 "Settingthe Datum

y AXIS
842>868 +876
5-185
II-nIJlt*,
5. TROUBLESHOOTING
GM6311 .
Alarm No.: E982
Messages
Causes
: Work spindle loading/unloading position input error
Description
The value set for 843 (work spindle loading/unloading position) is smaller than 0".

Causes
Corrective Action
No value is set for 843 (work spindle loading/unloading position).
Set a correct value for 843 (work spindle loadingl

unloading position).
r::r
See Operation Manual, 7.10 "Setting the Datum

WORKHE.~D
.-
_~.
B43
5-186
,~",lt,
.----_. ;~~:
.
t~
I ilrllJI'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: E983
Messages
Causes
: Wheel end face position memory allowable limit value input error
CorrectiveAction : Correctthe 8141 data.
Description
The value set for 8141 (wheel end face position memory allowable limit value) is smaller than "O" or
larger than "1" mm.

Causes
Corrective Action
No value or an incorrect value is set for 8141 (wheel

end face position memory allowable limit value).
Set a correct value for 8141 (wheel end face position memory allowable limit value); the value must
be smallerthan "1".
Standard value: 0.5
r::::r

81 41
8140
--::;;.~......;;;::----
5-187
iklnl]."
5. TROUBLESHOOTING
GM6311
Alarm No.: E984
Messages
Causes
: Work spindle advance position input error
Corrective Action : Correet the 831 or 832 data.
Description
1. The value set for 832 (work spindle advanee position) is smaller than "O" or larger than the value set
for 843 (Z-axis loading/unloading position).
2. The value set for 831 (work spindle side faee wheel truer advanee position) is smaller than "O".

Causes
Corrective Action
1. No value or an ineorreet value is set for 832

(work spindle advance position).
1. Set a correct value for 832 (work spindle advanee position); the value must be smaller than
the value set for 843 (Z-axis loading/unloading
position).
2. No value is set for 831 (work spindle side face

wheel truer advance position).
2. Set a correct value for 831 (work spindle side

face wheel truer advance position).
cr
WORKHEAD
5-188
See Operation Manual, 7.6.2 "Adjusting the

Work Spindle Position".
IkliilJI'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: E985
Messages
Causes
: V-axis machining origin input error
Description
Input error for 848 (V-axis rest machining origin).

Causes
Corrective Action
The value set for 848 (V-axis rest machining origin) is smaller than 15 (in diameter) or smaller than
the value of "867 (V-axis rest finishing diameter +
875 (V-axis rest 1st-step start diameter)".
For 848 (V-axis rest machining origin), set a value

For 848 (V-axis rest machining origin), set a value
larger than the value of "867 (V-axis rest finishing
diameter) + 875 (V-axis rest 1st-step start diameter)".
cr

Position of Grinding and PSW".
- V AXIS
B48>B67 +B75
5-189
111'11]1,41
5. TROUBLESHOOTING
GM6311
Alarm No.: E986
Messages
Causes
: A-axis machining origin input error
Corrective Action : Correet the B44 data.
Description
Input error for B44 (A-axis rest machining origin).

Causes
Corrective Action
The value set for B44 (A-axis rest machining origin) is smaffer than 15 (in diameter) or smaffer than
the value of "B69 (A-axis rest finishing diameter) +
B77 (A-axis rest 1st-step start diameter)".
For B44 (A-axis rest machining origin), set a value

For B44 (A-axis rest machining origin), set a value
larger than the value of "B69 (A-axis rest finishing
diameter) + B77 (A-axis rest 1st-step start diameter)".
O' See Operation Manual, 7.10 "Setting tbe Datum
A AXIS
B44>B69+B77
5-190
I kllll] 1M
5. TROUBLESHOOTING
GM6311
Alarm No.: E987
Messages
Causes
: Theoretieal wheel end position input error
Description
Input errorfor 8140 (theoretieal wheel end position).

Causes
Corrective Action
The value set for 8140 (theoretieal wheel end position) is not in the range between the right and left
maehining origins of the W-axis: MI3964 (W-axis
right maehining origin) and MI1369 (W-axis left
maehining origin).
Correet the value set for 8140 (theoretieal wheel

end position) so that it is between the right and left
maehining origins of the W-axis.
MI3964 < 8140 < MI1396
r:::r
B140
5-191

iilill]lM
5. TROUBLESHOOTING
GM6311
Alarm No.: E988
Messages
Causes
: Wheel outside position memory range input error
CorrectiveAction : Correctthe 8142 data.
Description
The value set for 8142 (wheel outside position memory range) is smaller than "O".

Causes
Corrective Action
No value is set for 8142 (wheel outside position

memory range).
..
Set a correct value for 8142 (wheel outside position memory range) .
CJ=' See Operation Manual, 7.3.2 "Editing tbe

5-192
1Ilnl ] 1I
5. TROUBLESHOOTING
GM6311
Alarm No.: E989
Messag~s
Causes
: Maximum wheel diameter input error
Corrective Action : Correct the AS8 data.
Description
The value set for AS8 (maximum wheel diameter) is smaller than 700 (in diameter).

Causes
Corrective Action
Data input error for AS8 (maximum wheel diameter).
Set a correct value for AS8 (maximum wheel diameter); the value must be larger than 700 (in diameter).
r::::r
5-193

Machine Constant Data" and 12.1 "Machine
Constant Data".
I ilillJIr41
5. TROUBLESHOOTING
GM6311
Alarm No.: E98C
Messages
Causes
: Footstock spindle advance position input error
Description
The value set for 8189 (footstock spindle advance position) is smaller than "O".

Causes
Corrective Action
No value is set fer 8189 (footstock spindle advance

position).
Set a correct value for 8189 (footstock spindle advanee position).
cr
See Operation Manual, 7.5.2 "Adjusting the

Footstock Spindle Position".
FOOTSTOCK
5-194
IllnlJI'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: E98D
Messages
Causes
: Footstock spindle machining origin position input error
Description
The value setfor A130 (footstock spindle machining origin position) is smallerthan "O".
This alarm is valid only when A 130 is used for setting the footstock spindle machining origin position.

Causes
Corrective Action
No value is set for A 130 (footstock spindle machining origin position).
Set a correct value for A 130 (footstock spindle

machining origin position).
r:::r

Position of Grinding and PSW".
FOOTSTOCI<
A130
5-195
111.,111,*'
5. TROUBLESHOOTING
GM6311
Alarm No.: E98E
Messages
Causes
: Footstock spindle machining origin position input error
Description
The value set for 845 (footstock spindle machining origin position) is smaller than "O".

Causes
Corrective Action
No value is set for 845 (footstock spindle machining origin position).
Set a correct value for 845 (footstock spindle machining origin position).
(J='

FOOTSTOCK
B45
5-196
II-nlllJJ
5. TROUBLESHOOTING
GM6311
Alarm No.: E990
Messages
Causes
: Wheel outside position memory execution position error
Corrective Action : Execute the operation within the wheel width range.
Description
Wheel outside position memory operation was attempted outside the range set for 8142 (wheel outside
position memory range).

Causes
Corrective Action
Wheel outside position memory operation was attempted at an incorrect longitudinal position.
Execute the operation within the range setfor 8142

(Wheel outside position memory range).
r:::r
POSITION
MEMORY
5-197
See Operation Manual, 6.3.8 "Storing the

Diamond RolI Position".
ii'il')Y
5. TROUBLESHOOTING
GM6311
Alarm No.: E991
Messages
Causes
: Wheel end face position memory execution position error
Corrective Action : Execute the operation at the correct position.
Description
Wheel end face position memory operation was executed without brining the diamond roll into contact
with the wheel.

Causes
Corrective Action
The diamond roll OD position at the execution of

the wheel end face position memory operation is
outside the wheel OD range.
Bring the diamond roll into contact with the wheel

to execute wheel end face position memory operation.
cr
See Operation Manual, 6.3.8 "Storing the

Diamond Roll Position".
:::: r-
POSITION
MEMORY
......
:::: r-
....
,,'J.
:I~
t.'
SI 8504
5-198
Illnl]lt4
5. TROUBLESHOOTING
GM6311
Alarm No.: E992
Messages
Causes
: Wheel1 st-step rapid advanee position input error
Description
1. The value set for 830 (wheel1 st-step rapid advanee position) is larger than the value set for 841
(maehining origin).
2. The value set for 830 (wheel1 st-step rapid advanee position) is smaller than the value set for
MI3986 (advanee limit position).

Causes
Corrective Action
Input error for 830 (wheel 1st-step rapid advanee

position)
1. Input the eorreet value for 830 (Wheel1 st-step

rapid advanee position); the value must be
smaller than the value set for 841 (maehining
origin).
2. Input the eorreet value for 830 (wheel1 st-step

rapid advanee position); the value must be larger
than the value set for MI3986 (advanee limit
position).
r:::r
5-199

Ik-fin 1M
5. TROUBLESHOOTING
- - - - - - - - - - - - - - - - - - - - - . GM6311
Alarm No.: E993
Messages
Causes
: Rest 1st-step rapid feed position input error
Description
1. The value set for 874 (rest 1st-step rapid feed position) is larger than the value set for 848, 842 or
843 (rest maehining origin).
2. The value set for 874 (rest 1st-step rapid feed position) is smallerthan the value set for MI3987
(advanee limit position).

Causes
Corrective Action
Input error for 874 (rest 1st-step rapid feed position)
1. Input the correet value for 874 (rest 1st-step

rapid feed position); the value must be smaller
than the value set for 848, 842 or 843 (rest
maehining origin).
2. Input the eorreet value for 874 (rest 1st-step
rapid feed position); the value must be lar~er
than the value set for MI3987 (advanee limit
position).
o=' See Operation Manual, 7.3.2 "Editing the

5-200
1fl)1l) 114
5. TROUBLESHOOTING
GM6311
Alarm No.: E994
Messages
Causes
: V-axis offset data input error
Correetive Aetion : Correet the B87 data.
Description
The value set tor B87 (V-axis rest offset data tor all proeesses) is outside the range ot 0.2.

Causes
Corrective Action
The value input tor B87 (V-axis rest offset data tor
all proeesses) is larger than "0.2" or smaller than
Input the eorreet value tor B87 (V-axis rest offset

data tor all proeesses); the value must be smaller
than "0.2" and larger than "-0.2".
"-0.2".
O'" See Operation Manual, 7.3.2 "Editing the

V AXIS
/lBS <B87) <o. 2
5-201
if-n']IJa
5. TROUBLESHOOTING
GM6311
Alarm No.: E995
Messages
Causes
: Y-axis offset data input error
Description
The value set for 888 (Y-axis rest offset data for all processes) is outside the range of O.2.

Causes
Corrective Action
The value input for 888 (Y-axis rest offset data for
all processes) islarger than "0.2" or smaller than
Input the correct value for 888 (Y-axis rest offset

data for all processes); the value must be smaller
than "0.2" and larger than "-0.2".
"-0.2".
r:::r

y AXIS
ABS <BSS) <O. 2
5-202
I 1.li.1It'
5. TROUBLESHOOTING
GM6311
Alarm No.: E996
Messages
Causes
: A-axis offset data input error
Description
The value set tor 889 (A-axis rest offset data tor aH processes) is outside the range ot 0.2.

Causes
Corrective Action
The value input for 889 (A-axis rest offset data tor
aH processes) is larger than "0.2" or smaHer than
Input the correct value tor 889 (A-axis rest offset

data tor aH processes); the value must be smaller
than "0.2" and larger than "_0.2".
"-0.2".
r:::r

A AXIS
.lIBS (889) <O. 2
5-203
lilrllJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: E997
Messages
Causes
: The allowable limit for wheel end face position memory is exceeded
Corrective Action : Reduce the wheel end face direction fluctuation within the allowable limit.
Description
The wheel end face position memory operation was executed at an incorrect position.

Causes
Corrective Action
The position where wheel end face position memory

operation was executed is outside the allowable
range (B 141) from the theoretical wheel end face
position (8140).
Execute the wheel end face position memory operation near the theoretical wheel end face position (B140).
Standard value of 8141: 0.5 mm
CJ=' See Operation Manual, 6.3.8 "Storing the

Diamond RolI Position".
IMPORTANT If the wheel end face position is input in an incorrect manner,

the diamond ro" could interiere with the wheel to damage the
wheeJ.
POSITION
MEMORY
81 41
8140
~"i-+~:--
5-204
IllfllllM
5. TROUBLESHOOTING
GM6311
5.5.6
Diagnosis and Corrective Action - Alarm F
Alarm No.: F001
Messages
Causes
: WHEEL 2 DIA. 15 5MALLER THAN THE MIN. WHEEL DIA.
Corrective Action : Change wheel2.
Description
Wheel diameter 2 value is smaller than the minimum wheel diameter value.

Causes
Corrective Action
1. Replace the wheel. Refer to Operation Manual,
1. The wheel is too small.

2. The minimum wheel diameter is toollarge.
6.3 "Changing the Wheel".

2. Correct the minimum wheel diameter value.
Referto Operation Manual, 7.3.8 "Inputting the
5etting Data".
5-205
Milnll
5. TROUBLESHOOTING
1M
GM6311
Alarm No.: F002
Messages
Causes
: POSITION DATA VARIATION, WHILE MASTER ON SIGNAL OFF, IS GREATERTHAN

THE PARAMETER SET (MAINTENANCE PARAMETER) ALLOWABLE VALUE
Corrective Action : Check the mechanical movements or change the motor.
Description
1. Monitoring before power on:

The function compares the difference between the pulse output position (Iogical absolute position)
immediately before power off and the actual moved position (Iogical absolute position) immediately
after power on with the number of pulses for permissible movement during power off state. If the
result of comparison is as indicated below, the function outputs a warning.
1(Pulse output position immediately before power off) - (Actual moved position immediately after
power on)1 > Number of pulses for permissible movement during power off state
2. Monitoring during ready signal OFF:
The function compares the difference between the pulse output position (logical absolute position)
and the actual moved position (Iogical absolute position) immediately after power on with the number
of pulses for permissible movement during non-servo lock state. If the result of comparison is as
indicated below, the function outputs a warning.
1(Pulse output position) - (Actual moved position) 1> Number of pulses for permissible movement
during non-servo lock state

Causes
Correctiva Action
1. Internal absolute position was input at the axis
1. Clear positional offset. Refer to 6.12.1 "Can-
position information setting screen.
2. An axis was moved or a motor was replaced

while the power was OFF.
3. An axis was moved while the ready signal was
OFF.
celing the Position-offset Safety Protection

Function".
2. If the alarm is still on even after clearing positional offset, replace the position encoder.
3. Clear positional offset.
4. Emergency stop signal was input while an axis 4. Clear positional offset.
wasmoving.
5. Replace the position encoder.
5. Positional encoder is faulty.
I I
5-206
I
I
IllrllJlt*,
5. TROUBLESHOOTING
GM6311 .
Alarm No.: FOOA
Messages
Causes
: PRESENT POSITION DATAEXCEEDS THE +L1MIT (INTERFERENCE)
Corrective Action : Move the axis into the axis movable range.
Description
In manual operation, the selected axis was moved most closely to the interference axis in the plus (+)
side.

Corrective Action
Causes
In inching or pulse handle operation, the selected
axis was moved most closely to the interference
axis in the plus (+) side.
Actually, the alarm occurs if the selected axis is
moved to the position indicated below. In this state,
alarm FOOB also occurs with the interference axis.
(Present position ofthe plus side interference axis)
- (Interference range of the selected axis in the
plus side) + (Minus side interference range of the
interference axis in the plus side).
5-207
Move the selected axis in the minus (-) side.
r::::r
See Operation Manual, 5.5.1 "Moving an Axis

Using the Pulse Handle".
linl]lrd
5. TROUBLESHOOTING
GM6311
Alarm No.: F01 B
Messages
Causes
: PRESENT POSITION DATA EXCEEDS THE -LlMIT (INTERFERENCE)
Corrective Action : Move the axis into the axis movable range.
Description
In manual operation, the selected axis was moved most closely to the interference axis in the minus (-)
side.

Causes
Corrective Action
In inching or pulse handle operation, the selected

axis was moved most closely to the interference
axis in the minus (-) side.
Actually, the alarm occurs if the selected axis is
moved to the position indicated below. In this state,
alarm FOOA also occurs with the interference axis.
(Present position of the minus side interference
axis) - (Interference range ofthe selected axis in
the minus side) + (Plus side interference range of
the interference axis in the minus side).
5-208
Move the selected axis in the plus (+) side.
cr

I Ilnl] 1M
5. TROUBLESHOOTING
GM6311
Alarm No.: F093
Messages
Causes
: ATTHE START OF CIRCULAR INTERPOLATION, PRESENT POSITION IS OUTSIDE

THEOT
Corrective Action
Description
The circular interpolation start position is outside the axis movable range.

Causes
Corrective Action
Circular interpolation was executed although the

present position of the horizontal or vertical axis of
the arc command is outside the axis movable range.
Move the horizontal or vertical axis, presently outside the axis movable range, into the axis movable
range by using the pulse handle or in jog mode
operation. After that execute the circular interpolation command.
r::r See Operation Manual, 5.5.1 "Moving an Axis

Using tbe Pulse Handle".
5-209
iln]t*,
5. TROUBLESHOOTING
GM6311
Alarm No.: F094
Messages
Causes
: PRESENT POSITION IS OUTSIDE THE -OT
Corrective Action : Move the axis in the positive (+) direction in jog or handle feed mode.
Description
Present position lies outside the overtravellimit in the negative direction.

Causes
Corrective Action
1. The command to move an axis beyond the
1. Move the axis in the positive direction into the
overtravellimit in the negative direction is specified in NC programo
2. The position data outside the overtravellimit in

the negative direction is set in the machining
data.
3. An axis was moved beyond the overtravellimit

in the negative direction in jog mode operation.
axis movable range by using the pulse hand or

in jog mode operation then correct the NC program or machining data.

in jog mode operation then correct the machining data.

in jog mode operation.
cr
5-210

5. TROUBLESHOOTING
- - - - - - - - - - - - - - - - - - - - - . GM6311
Alarm No.: F095
Messages
Causes
: PRE8ENT P081TION 18 OUT81DE THE +OT
Corrective Action : Move the axis in the negative (-) direction in jog or handle feed mode.
Description
Present position lies outside the overtravellimit in the positive direction.

Causes
Corrective Action
1. The command to move an axis beyond the
1. Move the axis in the negative direction into the
overtravellimit in the positive direction is specified in NC programo

in jog mode operation then correct the NC program or machining data.
2. The position data outside the overtravellimit in

the positive direction is set in the machining
data.
3. An axis was moved beyond the overtravellimit
in the positive direction in jog mode operation.

in jog mode operation then correct the machining data.
in jog mode operation.
cr See Operation Manual, 5.5.1 "Moving an Axis

Using tbe Pulse Handle".
5-211
IllFilJIJa
5. TROUBLESHOOTING
GM6311
Alarm No.: F096
Messages
Causes
: WHEEL 1 OlA. IS SMALLER THAN THE MIN. WHEEL OlA.
Correetive Aetion : Change wheel1.
Descriptjon
Wheel diameter 1 value is smaller than the minimum wheel diametervalue.

Correctjve Actjon
Causes
1. The wheel is too small.
2. The minimum wheel diameter is toollarge.
1. Replaee the wheel. Refer to Operation Manual,

6.3 "Changing the Wheel".
2. Correet the minimum wheel diameter value.
Refer to Operation Manual, 7.3.8 "Inputting the
Setting Data".
5-212
li1rll]IJ41
5. TROUBLESHOOTING
GM6311
Alarm No.: F098
Messages
Causes
: IN SYNCHRONIZED CONTROL POSITION ERROR COMPENSATION MODE, THE

POSITION ERRORAMOUNT IS LARGER THAN THEALLOWABLE LlMIT.
Corrective Action : Check mechanicalload.
Description
When compensating tor the synchronization positional error, positional error amount between the
master and slave axes exceeded the allowable position error amount that corresponds to the presently
specified teedrate.

Causes
Corrective Action
1. Emergency stop was executed while the axis

tor which synchronization position error is being compensated tor is moving.
1. Recover position error compensation processing. Referto 6.12 "Replacing the Servomotors".
2. Afier replacing the motor of the synchronously

controlled axis, position has not been set correctly.
5-213
2. Afier replacing the motor of the synchronously

controlled axis, set the position of the other
synchronously controlled axis also.
Iklnl]I'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: F099
Messages
Causes
: IN SYNCHRONIZED CONTROL POSITION ERROR COMPENSATION MODE, THE

POSITION ERRORAMOUNT IS LARGERTHAN THE MAX.ALLOWABLE L1MIT.
Corrective Action : Check mechanicalload.
Description
When compensating for the synchronization positional error, positional error amount between the
master and slave axes exceeded the maximum allowable position error amount.

Causes
Correctjve Actjon
1. Emergency stop was executed while the axis

for which synchronization position error is being compensated for is moving.
1. Recover position error compensation processing. Refer to 6.12 "Replacing the Servomotors".
2. After replacing the motor of the synchronously

controlled axis, position has not been set correctly.
5-214
2. After replacing the motor of the synchronously

controlled axis, set the position of the other
synchronously controlled axis also.
lilrll]lhl
5. TROUBLESHOOTING
GM6311
Alarm No.: F133
Messages
Causes
: CORRESPONDING NC PROGRAM NOT FOUND
Correetive Aetion : Cheek the data.
Description
The NC program that eorresponds to the speeified O number does not exist.

Causes
Corrective Action
An O number of the NC program that is not sto red

in the CNC memory was speeified.
Correet the start number in the sequenee programo
5-215
Register the NC program eorresponding to the start

number.
IllyllJI'*,
5. TROUBLESHOOTING
- - - - - - - - - - - - - - - - - - - - - . GM6311
Alarm No.:
F138
Messages
Causes
: ILLEGAL CHINESE CHARACTER CODE
Corrective Action : Check the data.
Description
An iIIegal character code exists in the NC programo

Causes
Corrective Action
An iIIegal Chinese character code exists in the NC

programo
5-216
Correct the NC programo
lililll11!1
5. TROUBLESHOOTING
GM6311
Alarm No.: F143
Messages
Causes
: INPUT VALUE IS LARGER THAN THE SET MAX. VALUE
Description
The variable value is greater than the allowable maximum value.

Causes
Corrective Action
A value greater than the maximum value of a variable was going to be set.
Change the value so that it is smaller than the

maximum value and larger than the minimum value
of the variable.
5-217
i(lrll]IU
5. TROUBLESHOOTING
GM6311
Alarm No.: F144
Messages
Causes
: INPUT VALUE IS SMALLER THAN THE SET MIN. VALUE
Description
The variable value is smaller than the allowable minimum value.

Causes
Corrective Action
A value smaller than the minimum value of a variable was going to be set.
Change the value so that it is smaller than the

maximum value and larger than the minimum value
of the variable.
5-218
i(I"lllh'
5. TROUBLESHOOTING
GM6311
Alarm No.: F145
Messages
Causes
: SPECIFIEO VARIABLE IS NOT FOUNO
Description
A wrong variable name was specified.

Corrective Action
Causes
Correct the variable name.
A wrong variable name was specified.
5-219
lilTilllJd
5. TROUBLESHOOTING
GM6311
Alarm No.: F150
Messages
Causes
: INCORRECT CHINESE CHARACTER DESIGNATION
Description
An iIIegal character code exists in the part number.

Causes
Corrective Action
An iIIegal Chinese character code exists in the part

number.
5-220
Correct the part number.
Illnll l,*,
5. TROUBLESHOOTING
GM6311
Alarm No.: F151
Messages
Causes
: INCORRECT PROCESS NUMBER
Description
The number processes is "O" or larger than the maximum process number.

Causes
Corrective Action
An attempt was made to refer to the C data in the

state the number processes is "0" or larger than
the maximum process number.
Correct the number of processes ("1" to "maximum

process number").
5-221
II'fl'llt*,
5. TROUBLESHOOTING
GM6311
Alarm No.: F152
Messages
Causes
: INCORRECTVARIABLE NUMBER
Description
Corresponding variable number does not exist.

Causes
Corrective Action
The specified variable number does not correspond

to a variable name.
5-222
Correct the variable number.
lilxI-L'
5. TROUBLESHOOTING
GM6311
Alarm No.: F404
Messages
Causes
: SERVO ALAR M (DRIVE ERROR)
Description

Corrective Action
Causes
5-223
li-D-JIM
5. TROUBLESHOOTING
GM6311
Alarm No.: F600
Messages
Causes
: SPEED ERROR AMOUNT IS LARGER THAN THE ALLOWABLE L1MIT
Corrective Action : Check the mechanicalload.
Description
The feedrate command value to be output to the velocity controller exceeded 1.2 times the maximum
motor speed value.

Causes
Corrective Action
1. The motor or the encoder is faulty.

the Servomotors".
2. Mechanicalload increased.
3. Servo parameter settings are incorrect.
3. Set the servo parameters correctly.
5-224
1111,1]IJd
5. TROUBLESHOOTING
GM6311
Alarm No.: F601
Messages
Causes
: POSITIONAL ERROR EXCEEDED THE ALLOWABLE LlMIT
Description
Positional deviation exceeded the warning level maximum value calculated based on the specified feedrate.

Causes
Corrective Action
the Servomotors".
1. The motor or the encoder is faulty.
2. Mechanicalload increased.
3. Servo parameter settings are incorrect.
3. Set the servo parameters correctly.
5-225
1-nl)I'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: F603
Messages
Causes
: LOW BATTERY VOLTAGE
Corrective Action : Change the battery or retighten the battery terminals.
Description
Warning of low battery voltage

Causes
Corrective Action
1. Battery has been used to the life or it is faulty.
1. Replace the battery. Refer to 6.7 "Replacing

the Battery".
2. Battery connection error
2. Tighten the battery terminals.
5-226
li'fllJlbt
5. TROUBLESHOOTING
GM6311
Alarm No.: F609
Messages
Causes
: CALENDAR READ ERROR
Description
Clock cannot be read.

Causes
The MCUL unit is faulty.
Corrective Action
Replace the MCUL unit.
(j='
5-227
See 6.15.4 "Replacing the MCUL Unit".
il'll l]lr4
5. TROUBLESHOOTING
GM6311
Alarm No.: F611
Messages
Causes
: LOW ENCODER BATTERY VOLTAGE
Corrective Action . : Change the battery or retighten the battery terminals.
Description
Voltage of encoder battery is lower than the allowable value.

Causes
Corrective Action
Voltage of encoder battery is lower than the allowablevalue.
5-228
Replace the battery immediately.
O" See 6.7 "Replacing tbe Battery".
Illnlllta
5. TROUBLESHOOTING
GM6311
Alarm No.: F628
Messages
Causes
:PLCALARM
Correetive Aetion : Change the PLC unit.
Description
Alarm status of the PLC unit has turned ON.

Causes
Corrective Action
1. Replaee the PLC unit. Refer to 6.17.7 "Replacing the PLC-48 Unit".
2. Sequenee program error

3. Jumper setting or parameter setting ofthe PLC
is incorreet.
5-229

3. Change the jumper setting or eorreet the
para meter setting for the PLC unit.
I (1ITiIIIM
5. TROUBLESHOOTING
GM6311
Alarm No.: F701
Messages
Causes
: SIZER ERROR (LOW BATTERYVOLTAGE)
Corrective Action : Change the battery for auto-sizer.
Description
Voltage of the memory backup lithium battery in the sizer controller is low.

Causes
Corrective Action
Voltage of the memory backup lithium battery in

the sizer controller has been lowered to the level
that requires immediate replacement of the battery.
Replace the lithium battery on the CPU board in

the sizer controller.
5-230
0= See 6.7 "Replacing the Battery".
Ei'}"IIJ!'
5. TROUBLESHOOTING
GM6311
Alarm No.: F702
Messages
Causes
: SIZER ERROR (HIGH +5V POWER SUPPLY VOLTAGE)
Corrective Action : Check the power supply voltage of the auto-sizer.
Description
Voltage of the +5 V power supply in the sizer controller is high.

Causes
Corrective Action
The power supply in the sizer controller is faulty.
5-231
l,
Replace the power supplyin the sizer controller.
lilrllJIJ41
5. TROUBLESHOOTING
GM6311
Alarm No.: F703
Messages
Causes
: SIZER ERROR (LOW +5V POWER SUPPLY VOLTAGE)
Description
Voltage of the +5 V power supply in the sizer controiler is low.

Causes
Corrective Action
5-232
Replace the power supply in the sizer controller.
1
1
I ilfll]1J!1
5. TROUBLESHOOTING
GM6311
11
Alarm No.: F704
Messages
Causes
1
: SIZER ERROR (HIGH +15V POWER SUPPLYVOLTAGE)
1
1
Description

Causes
Corrective Action
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
.1
1i-nl] 1,4
5. TROUBLESHOOTING
GM6311
Alarm No.: F705
Messages
Causes
: SIZER ERROR (LOW +15V POWER SUPPLYVOLTAGE)
Description
Voltage of the +15 V power supply in the sizer controller is low.

Causes
Corrective Action
5-234
1IIFiI] 1'41
5. TROUBLESHOOTING
GM6311
Alarm No.: F706
Messages
Causes
: SIZER ERROR (HIGH -15V POWER SUPPLY VOLTAGE)
Description
Voltage of the -15 V power supply in the sizer controller is high.

Causes
Corrective Action
5-235
1lnl]IJ41
5. TROUBLESHOOTING
GM6311
Alarm No.: F707
Messages
Causes
: SIZER ERROR (LOW -15V POWER SUPPLYVOLTAGE)
Description
Voltage of the -15 V power supply in the sizer controller is low.
, I
I I

Causes
Corrective Action
I I
5-236
I I
IrIRIIIJt
5. TROUBLESHOOTING
GM6311
Alarm No.: F708
Messages
Causes
: SIZER ERROR (HIGH +24V POWER SUPPLY VOLTAGE)
Descrjptjon
Causes and Corrective Actjon

Causes
Corrective Actjon
5-237
lilrlIJI,*,
5. TROUBLESHOOTING
GM6311
Alarm No.: F709
Messages
Causes
: SIZER ERROR (LOW +24V POWER SUPPLY VOLTAGE)
Description
Voltage of the +24 V power supply in the sizer controller is low.

Causes
Corrective Action
I I
5-238
i I
ilnll 1M
M
5. TROUBLESHOOTIN'G
GM6311
AlarmNo.: F710
Messages
Causes
: SIZER ERROR (MEMORY ERROR)
Corrective Action : Change the auto-sizer CPU unit.
Description
Parity error occurred with the memory backup RAM in the sizer controller.

Corrective Action
Causes
The CPU board in the sizer controller is faulty.
5-239
Replace the CPU board in the sizer controller.
11-"1]1141_
5. TROUBLESHOOTING
GM6311
Alarm No.: F711
Messages
Causes
: SIZER ERROR (AJO BOARD MALFUNCTION)
Corrective Action : Change the auto-sizer AJO unit.
Description
The AJO board in the sizer controller malfunctioned.

I

Causes
Corrective Action
The AJO board in the sizer controller is faulty.
5240
Replace the AJD board in the sizer controller.
Illnl]lbt
5. TROUBLESHOOTING
GM6311
Alarm No.: F712
Messages
Causes
: SIZER ERROR (AMP. BOARD VO LTAG E APPLlCATION ERROR)
Corrective Action : Change the auto-sizer amplifier unit.
Description
Abnormal voltage is applied to the amplifier board in the sizer controller.

Causes
Corrective Action
The amplifier board in the sizer controller is faulty.
Replace the amplifier board in the sizer controller.
5-241
1(1)11]1,4
5. TROUBLESHOOTING
GM6311
Alarm No.: F713
Messages
Causes
: SIZER ERROR (ENCODER CABLE BREAKAGE OR SHORT-CIRCUIT: HEAD 1)
Corrective Action : Check the encoder cable.
Description
The encoder cable is broken or short-circuited (gauging head corresponding to head number 1).

Causes
Corrective Action
The encoder cable is broken or short-circuited

(gauging head corresponding to head number 1).
Check the encoder cable, and if faulty, replace the

cable.
5-242
I IIYII] 1'4
5. TROUBLESHOOTING
GM6311
Alarm No.: F714
Messages
Causes
Description

Causes
Corrective Action


cable.
5-243
li-Fin'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: F715
Messages
Causes
Description

Causes
Corrective Action


cable.
5-244
i klill]1M
5. TROUBLESHOOTING
GM6311
Alarm No.:
F716
Messages
Causes
Description
l\
Causes and Corrective Aclion

Causes
Corrective Action


cable.
5-245
I (-TiIJIU
5. TROUBLESHOOTING
GM6311
Alarm No.:
F717
Messages
Causes
: SIZER ERROR (WORK NUMBER, PROCESS NUMBER ERROR)
Correetive Aetion : Cheek the sequenee programo
Description
Part number or proeess number of the sizer input signal is abnormal.

Causes
Corrective Action
1. Partlproeess data not available with the sizer

is seleeted.
1. Cheek the wiring of the sizer input signal. Refer to 5.13 "Diagnosis Using TOYOPUC".
2. Partlproeess number parity error
Correet the sequenee programo
5-246
IkllI11lD
5. TROUBLESHOOTING
GM6311
Alarm No.: F718
Messages
Causes
: SIZER ERROR (RUN CHECK ERROR)
Corrective Action : Check the sequence programo
Description
Error in run check of the sizer and the PLC

Causes
Corrective Action
When testing the connection between the sizer and

the PLC, no response was returned from the PLC
within set periodo
Check the wiring of the sizer input signal. Refer to

5.13 "Diagnosis Using TOYOPUC".
5-247
Correct the sequence programo
IllnlllM
5. TROUBLESHOOTING
, GM6311
Alarm No.: F719
Messages
Causes
: SIZER ERROR (PARAMETER SETIING ERROR)
Description
Error in the sizer para meter settings

Corrective Action
Causes
Check the sizer parameters.
Error in the sizer parameter settings
5-248
II-nIJI'4
5. TROUBLESHOOTING
GM6311
Alarm No.: F720
Messages
Causes
: SIZER ERROR (PARAMETER SETTING RANGE ERROR)
Description
Sizer parameter setting value is outside the specified range.

Causes
Corrective Action
Sizer para meter setting value is outside the specified range.
5-249
Eilnlllr*'
5. TROUBLESHOOTING
GM6311
Alarm No.: F721
Messages
Causes
: SIZER ERROR (PARAMETER NOT SET)
Description
Sizer parameters have not been set.

Causes
Corrective Action
The sizer parameters have not been set or not transmitted to the sizer.
5-250
liliI1JIM
5. TROUBLESHOOTING
GM6311
Alarm No.: F722
Messages
Causes
: SIZER COMMUNICATION ERROR (PARITY ERROR)
Corrective Action : Check the para meter.
Description
In the communications with the sizer, when adjusting the contacts or setting the zero point, a parity
error occurred.

Causes
Corrective Action
1. Setting of the parameters for communication

with the sizer is incorrect.
2. Communication cable connected to the sizer

is broken or incorrectly connected.
5-251
1. Check the communication parameters.
2. Check the communication cable, and if faulty,

replace the cable. Refer to 5.13 "Diagnosis Using TOYOPUC".
I ilnl]1M
5. TROUBLESHOOTING
GM6311
Alarm No.: F723
Messages
Causes
: SIZER COMMUNICATION ERROR (OVERRUN ERROR)
Description
In the communications with the sizer, when adjusting the contacts or setting the zero point, an overrun
error occurred.

Causes
Corrective Action

2~
Communication cable connected to the sizer

5-252

IIIDI]IJ!1
5. TROUBLESHOOTING
GM6311
Alarm No.: F724
Messages
Causes
: SIZER COMMUNICATION ERROR (FRAMING ERROR)
Corrective Action : Check the parameter.
Description
In the communications with the sizer, when adjusting the contacts or setting the zero point, a framing
error occurred.

Causes
Corrective Action


5-253

111)11]11;,
5. TROUBLESHOOTING
GM6311
Alarm No.: F725
Messages
Causes
: SIZER COMMUNICATION ERROR (DATA ERROR)
Description
In the communications with the sizer, when adjusting the contacts or setting the zero point, a data error
occurred.

Causes
Corrective Action


5-254

lil"IJ I14
5. TROUBLESHOOTING
GM6311
Alarm No.: F726
Messages
Causes
: SIZER COMMUNICATION ERROR (PROTOCOL ERROR)
Description
In the communications with the sizer, when adjusting the contacts or setting the zero point, a protocol
error occurred.

Corrective Action
Causes

5-255

liliTI1Jlt*,
5. TROUBLESHOOTING
GM6311
Alarm No.: F727
Messages
Causes
: SIZER ERROR (ZERO POINT NOT SET FOR THE PRESENT WORKlPROCESS
NUMBER)
Corrective Action : Set the zero point for the present workpiece (part) number and the present process
number.
Description
Zero point has not been set for the presently selected part number/process number.

Causes
Corrective Action
An attempt was made to perform sizer controlled

grinding although the zero point has not been set
for the presently selected part number/process
number.
Set the zero point for the presently selected part

number/process number.
5-256
(J='
See Operation Manual, 7.8 "Changing the

Setup ofSizer and Lateral Locator".
111',1]1'41
5. TROUBLESHOOTING
GM6311
Alarm No.: F746
Messages
Causes
: SIZERADJUSTMENT ERROR (CONTACT ADJUSTMENT VALUE EXCEEDED THE

ALLOWABLE LlMIT)
Corrective Action : Adjust the contact.
Description
When adjusting the sizer contacts, the adjustment value exceeded the allowable limit.

Causes
Corrective Action
When adjusting the sizer contact, upper or lower

head adjustment value exceeded "O 50 11m".
5-257
Repeat contact adjustment.
r:::r
See Operation Manual, 7.8 "Changing the

Illi,I]lt!1
5. TROUBLESHOOTING
GM6311
Alarm No.: F747
Messages
Causes
: SIZERADJUSTMENT ERROR (CONTACT NOT ADJUSTED)
Corrective Action : Adjust the contact.
Description
Sizer contacts have not been adjusted.

Causes
Corrective Action
Zero point was set although sizer contacts have

not been adjusted.
Adjust the sizer contacts before setting the zero

point.
rJ=' See Operation Manual, 7.8 "Changing the

5-258
1Ilnl] 1M
5. TROUBLESHOOTING
GM63U
Alarm No.: F749
Messages
Causes
: SIZER ADJUSTMENT ERROR (HEAD MEASUREMENT VALUE IN ZERO POINT

SETTING IS OUTSIDE THE ALLOWABLE RANGE)
Corrective Action : Retract the head once and insert the workpiece again.
Description
When adjusting the zero point of the sizer, the measured value exceeded the allowable range.

Causes
Corrective Action
1. If the alarm occurred during sizer head adjustment, master diameter or finish diameter setting is incorrect or head inserted status is incorrecto
1. Check the master diameter or finish diameter

setting.
2. If the alarm occurred in equally dividing the width

or during end face head adjustment, position
data or central position data setting is incorrect
or head inserted status is incorrecto
Insert the head again afier retracting it once.

Refer to Operation Manual, 7.3.2 "Editing the
2. Check the position data or central position data
setting.
Insert the head again afier retracting it once.
5-259
IflnlJI'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: F750
Message
Causes
: SIZER AOJUSTMENT ERROR ("MASTER WORK OlA. - FINISH OlA." EXCEEOEO

THE ALLOWABLE L1MIT)
Corrective Action : Check the auto-sizer data.
Description
When adjusting the sizer, the value of "master diameter - finish diameter" exceeded the allowable Iimit.

Causes
Corrective Action
When setting the zero point, the value of "master

diameter - finish diameter" exceeded the allowable
Iimit (1 00 ).lm).
Check the set finish and master diameter values in

the sizer data.
r::::r See Operation Manual, 7.3.2 "Editing the

5-260
11'"']J4
5. TROUBLESHOOTING
GM6311
Alarm No.: F751
Messages
Causes
: SIZER AOJUSTMENT ERROR (FINISH OlA. IS NOT WITHIN THE PRESET RANGE
FROM THE MIN. FINISH OlA.)
Description
When adjusting the sizer, the finish diameter exceeded the range, set in reference to the minimum
finish diameter.

Causes
Corrective Action
When setting the zera point, the finish diameter is

beyond the range "minimum finish diameter + 25
mm".
Check the finish and minimum finish diameter values in the sizer data.
c::::r See Operation Manua~ 7.3.2 "Editing tbe

5-261
5. TROUBLESHOOTING
GM6311
Alarm No.:
F752
Messages
Causes
: SIZER ADJUSTMENT ERROR (POSITION DATA IS NOT WITHIN THE PRESET

RANGE FROM THE MEDIAN)
Description
When adjusting the sizer, position data exceeded the range, set in reference to the central position data.

Causes
Corrective Action
When setting the zero point, position data exceeded the range "central position 6.25 mm".
Check the position and central position data in the

sizer data.
5-262
1i-nl] 114
5. TROUBLESHOOTING
GM6311
Alarm No.: F754
Messages
Causes
: SIZER ADJUSTMENT ERROR (HEAD NUMBER, WORK NUMBER ANO OTHER

DATA DO NOT AGREE WITH THE DATA USED IN ADJUSTING THE CONTACTS)
Corrective Action : Adjust the contact again, then set the zero point.
Description
Head number, part number and process number set when adjusting the sizer do not agree with those
set when adjusting the contacts.

Causes
Corrective Action
Head number, part number and process number

set when adjusting the zero point do not agree with
those set when adjusting the contacts.
Execute the contact adjustment again, then set

the zero point.
5-263
CJ=' See Operation Manual, 7.8 "Changing the

lil)ll ]IU
5. TROUBLESHOOTING
GM6311
Alarm No.: F755
Messages
Causes
: SIZER ADJUSTMENT ERROR (MONITOR RANGE TURNED ON IN ZERO POINT

SETTING)
Corrective Action : Set the zero point afier tuming off the monitor range.
Description
In the adjustment of the sizer, monitor range was selected when setting the zero point.

Causes
Corrective Action
Zero point setting was attempted in the monitor

range selected state.
Change the range to the measurement range before setting the zero point.
5-264
1I.n.,11;1
5. TROUBLESHOOTING
GM6311
Alarm No.: F760
Messages
Causes
: LOW SIZER BATIERY WARNING
Corrective Action : Change the auto-sizer battery.
Description
Voltage of the memory backup Iithium battery in the sizer controller is low.

Causes
Corrective Action
Voltage of the memory backup Iithium battery in

the sizer controller has been lowered to the level
that requires replacement of the battery.
Replace the Iithium battery on the CPU board in

the sizer controller.
5-265
iiltll]IJ41
5. TROUBLESHOOTING
GM6311
Alarm No.: F854
Messages
Causes
: HMI COMMUNICATION ERROR (AFTER THE REQUEST OF COMMAND SEND,

SENDING DOES NOT END WITHIN PRESET TIME)
Corrective Action : Check the wiring between the CNUE unit and the HMI.
Description
Communications with the HMI were disabled for a certain periodo

Causes
Corrective Action
1. The communication cable connector is not set

correctly.
1. Check the communication cable connector if it

is set correctly.
2. The cable is broken.
2. Check the cable and make sure that it is not

bent.
3. The communication device is faulty.
3. Replace the communication device. Refer to

5.13 "Diagnosis Using TOYOPUC".
5-266
Milnl]
5. TROUBLESHOOTING
1M
GM6311
AlarmNo.: F8A1
Messages
Causes
: SPECIFIED AUX. AXIS DOES NOT EXIST
Descriptien
A station number error occurred in auxiliary axis communication.
Causes and Cerrective Actien

Causes
Cerrective Actien
In auxiliary axis communication, station number

setting in the NC is incorrect.
5-267
Check the maintenance parameter.
IllnlllId
5. TROUBLESHOOTING
GM6311
Alarm No.: F8A2
Messages
Causes
: AUX. AXIS NUMBER IS OUTSIDE THE SPECIFIED RANGE
Description
There is an error in the set number of connected stations in auxiliary axis communication.

Causes
Corrective Action
In auxiliary axis communication, the set number of

connected stations exceeded the allowable limit.
5-268
I Ilnl]1M
5. TROUBLESHOOTING
GM6311
Alarm No.: F8A3
Messages
Causes
: AUX. AXIS INITIAL COMMUNICATION ERROR (RELAY START ADDRESS) AT

SWITCHING ON THE POWER
Description
In auxiliary axis communication, a relay start address error occurred.

Causes
Corrective Action
Setting of maintenance parameter is incorrect.
5-269
Check the maintenance para meter.
IllnlllJa
5. TROUBLESHOOTING
GM6311
Alarm No.: F8A5
Messages
Causes
: AUX. AXIS INITIAL COMMUNICATION ERROR (RELAY BYTE COUNT OVER) AT

SWITCHING ON THE POWER
Description
In auxiliary axis communication, relay byte number over error occurred.

Causes
Corrective Action
Setting of maintenance para meter is incorrect.
5-270
Check the maintenance parameter:
I (II1IJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: F8A7
Messages
Causes
: AUX.AXIS INITIAL COMMUNICATION ERROR (RELAY RANGE OVER)AT SWITCHING ON THE POWER
Description
In auxiliary axis communication, relay area over error occurred.

Corrective Action
Causes
Setting of\maintenance parameter is incorrect.
5-271
I ili,IJIJ41
5. TROUBLESHOOTING
GM6311
Alarm No.: F8A9
Messages
Causes
: AUX. AXIS INITIAL COMMUNICATION ERROR (MASTER STATION ALREADY EXISTING) AT SWITCHING ON THE POWER
Description
In auxiliary axis communication, a master station other than NC exists.

Causes
Corrective Action
There is an error in the setting of a station number

for the auxiliary axis.
Check the set station number of the auxiliary axis.
5-272
Illnlll,d
5. TROUBLESHOOTING
GM6311
5.5.7
Diagnosis and Corrective Action - Alarm G
Alarm No.: G400
Messages
Causes
: PLC COMMUNICATION FAULT
Corrective Action : RECTIFY, RESET WITH RESET PB IN CONTROL PANEL.
Description
Communication between the PC link master station and a slave station is erroneous.
Communication between the DeviceNet master station and a slave station is erroneous.

Corrective Action
Causes
1. Link para meter setting is incorrect.
1. Check the link parameter by the peripheral
2. Communication related cards are faulty, communication cable is broken or not connected
securely.
(such as Hellowin) and see if the set values are

identical to those in the electric circuit diagram.
2. Check the wiring to the communication card

such as PLC LINK card and DeviceNet cardo
From the PLC address information displayed
at the occurrence of the alarm, find the faulty
station number by referring to the electric circuit diagram.
Check the station number based on the address
of the internal special relay of the PLC.
5-273
MillllJI!;l
5. TROUBLESHOOTING
GM6311
Alarm No.: G401
Messages
Causes
: PLC BATTERY FAULT (BATTERY ER6VC56 WITH CONNECTOR)
Corrective Action : RESUME TEMP. OP. BY PRESSING CONFIRM. SWITCH.
Description
Voltage of PLC-48 card memory back-up battery is lower than 3 V.
The indicating lamps at the PLC-48 card Iight in the manner iIIustrated below.
The data at register address S200 of the PLC-48 card will be "0022". (The data can be read using a
peripheral (Hellowin, etc.).
If the battery alarm of the PLC-48 card occurs, the CNC recognizes this and error code "F628" is displayed at the CNC.
PLC-48
POWER O
RUN
O
ERR
e
ALM
O ON
e:a=F.
~~
q
/
Battery connector
1\
\
Battery holder

Corrective Action
Causes
1. Battery Iife (approximately 5 years)
2. Mounting or connection of the battery is incorrect.
Pull the PLC-48 card out of the rack and check the
battery voltage.
1) Measure the voltage using a digital testero Normal battery voltage is 3.0 to 3.6 V.
The battery is set in the battery holder as shown
aboye. Replace the battery if necessary.
(j='
See Maintenance Manual 6.7.2 "Replacing

the Display Memory Backup Battery".
2) If measured voltage is within the allowable range

(3.0 - 3.6 V), check battery connection.
3) If battery voltage and cwonnection are correct,
the PLC-48 card will be faulty. Replace the
PLC-48 cardo
NOTE
Until a spare battery is not available, press the [RESET PLC/CNC

BATTERY ALARM] button in the control cabinet to allow the operation
to continue for a while.
Do not turn off the power to the machine until the battery is replaced.
5-274
II-n','4
5. TROUBLESHOOTING
GM6311
Alarm No.: G402
Messages
Causes
: CYCLE TIME OVER (GRINDING CYCLE TIME EXCEEDED PRESET TIME)
Corrective Action : IN MANUAL MODE CHECK EQUIPMENT OPERATION.
Description
Cycle time of the automatic cycle or wheel truing cycle exceeded the preset time.

Corrective Action
Causes
1. The override setting is other than 100%.
The alarm occurred due to incomplete cycle:
2. Operation of proximity switches, limit switch es
Check the following items by referring to the

cycle diagram supplied with the machine.
or pressure switches is faulty (example: dog is

not set correctly).
a) Cycle interrupted operation step (device)
3. Cables connected to proximity switches, limit b) Device involved with the trouble.
switches, pressure switches, solenoid valves,
motor, etc. are broken.
NOTE
4. Solenoid valve is faulty or motorfails to operate
according to the displayed

information.
correctly.
5. Cycle is interrupted due to uncontrollable cylinder operation speed due to oil leakage or oil
temperature change, faulty actuators, etc.
6. The TOYOPUC inpuUoutput card is faulty.
7.
Setting of the velocity data or timer data is

changed.
optional diagnosing circuit

I isIf the
selected, carry out checks
The alarm occurred although the cycle finished

correctly:
a) The data (velocity data, timer data) might have
been changed or actuator speed has been
changed due to oilleakage or oil temperature
change.
b) Change the setting for the cycle time over setting timer (internal timer ofTOYOPUC).
NOTE
Before the shipping, the value

I 1.5
times the cyCle time in the
specifications is sel
5-275
I f-R-] 1M
5. TROUBLESHOOTING
GM6311
Alarm No.:
G403
Messages
Causes
: CONDITIONS FOR CYCLE START NOT SATISFIED (EQUIPMENT POS., CONFIRMED DEVICE)
CorrectiveAction : CHECK, RECTIFY, PRESS FAULT RESET PB.
Description
During automatic or manual cycle of NC operation, sorne of necessary conditions are turned off.
Examples of cycles: Work spindle orientation cycle, grinding cycle, wheel truing cycle, phase indexing
cycle, etc.

Causes
Corrective Action
1. The signal of a device that detects unit positions, taken as the manual cycle conditions, is
turned OFF.
1. Check the conditions necessary for executing

the cycle at the electric circuit diagram and
check the ON/OFF status of the contact by
starting the Hellowin.
2. Cable of a device that detects unit positions,

taken as the manual cycle conditions, is broken or the related TOYOPUC input card is faulty.
5-276
2. If the condition is turned OFF even if the checked

conditions are all satisfied, check the conditions one by one to find which of the conditions
is turned OFF by executing the cycle in the
single block mode.
I klr,l] 1M
5. TROUBLESHOOTING
GM6311
Alarm No.: G404
Messages
Causes
: CONDITIONS FORAUTO CYCLE NOT SATISFIED (EQUIPMENT POS., CONFIRMED

DEVICE)
CorrectiveAction : CHECK IN MANUAL MODE, PRESS FAULT REST PB.
Description
1. During the execution of the cycles below, sorne of the conditions are turned OFF.
Phase indexing cycle
Work spindle orientation cycle
Grinding cycle
Wheelhead traverse cycle
Wheel truing cycle, etc.
2. The wheel spindle stopped during automatic operation.

Causes
Corrective Action
1. During the execution of the cycles below, sorne
1. During the execution of the cycles below, sorne
of the conditions are turned OFF.
of the conditions are turned OFF.
a) The signal of a device that detects unit positions, taken as the manual cycle conditions,
is turned OFF.
a) Check the conditions necessary for executing the cycle at the electric circuit diagram
and check the ON/OFF status of the contact by starting the Hellowin.
b) Cable of a device that detects unit positions,

taken as the manual cycle conditions, is
broken or the related TOYOPUC input card
is faulty.
2. The wheel spindle stopped during utomatic
operation.
a) The wheel spindle stopped rotating due to
chattering of the wheel spindle bearing lubrication pressure switch, etc.
b) Breakage of the wheel spindle start magnet
switch, or fa uIty TOYOPUC input cardo
c) Wheel spindle drive motor inverter is faulty.
In this case, inverter error is also displayed.
b) If there are no problems in the check aboye,

Execute the cycle manually to check which
of the conditions is turned OFF.
2. The wheel spindle stopped during automatc
operation.
a) Check the wheel spindle bearing lubrication
pressure. If the pressure is low, adjust the
pressure.
b) Check the pressure switch. Replace the
pressure switch if the pressure switch 15 .
fa uIty.
c) Check the ON/OFF status of the wheel
spindle bearing lubrication pressure confirmation circuit and the wheel spindle rotation,confirmation circuit If an error occurre.d
with the inverter, check the details of the error.
d) Check the magnet switch and the TOYOPUC
input card and replace them if faulty.
NOTE
If cable breakage, TOYOPUC input card faulty, etc, occurred before the
start of a cycle, that cycle cannot start. G404 alarm indicates the
alarm that occurred after the start of the cycle.
5-277
nEIle].!
5. TROUBLESHOOTING
GM6311
Alarm No.: G405
Messages
Causes
: QUALlTY CHECK REQUIRED (GRINDING COMPLETED BYVALUE PRESETWITH

COUNTER)
Corrective Action : MEASURE THE PART ACCURACY, RESET COUNTER.
Description
Count-of the quality check counter

Causes
Corrective Action
Count-of the quality check counter
Check the preset value and the present value of

the counter.
If the present value of the quality check counter has

reached the preset value (count-up), check the quality
of the ground workpiece and reset the counter.
<Quality check counter>
The counter counts the number of workpieces having
been ground after resetting the quality check counter.
If the count value reaches the value set for B025
(quality check counter preset value), the quality check
indicating lamp lights.
<Resetting the quality check counter>
Click the CURRENT field of the quality check counter.
The CURRENT field color changes.
Click the [RESET] button. The current value of the
quality check counter is reset to "O".
<Setting the quality check counter>
Click the SETUP field of the quality check counter.
The key panel dialog box opens. Input the desired
value.
NOTE
An external counter may be used depending on user's specifications.

In this case, refer to the special manual for user's specifications. If no
such manual is available, please contact your local Toyoda Machine
Works service center.
5-278
UIHIJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: G406
Messages
Causes
: POWER SUPPLY FAULT (ClRCUlT-BREAKER TRlPPED)
Corrective Action : CHECK SUPPLY AND MACHlNE, RESET CCT. BREAKER.
Description
A circuit protector was tripped.
A circuit protector is installed in each inputloutput circuit and the one in the power line where the alarm
occurred is tripped.

Causes
Corrective Action
1. A device having large rated current value was

connected to the power line in which the circuit
protector was tripped.
2. An alarm occurred in the power line in which
the circuit protector was tripped.
(Example: Short circuit of a device, short
circuit of the power line, etc.)
3. The circuit protector is faulty.
1. End the HMI.

2. After making sure that the wheel spindle has
stopped completely, turn off the machine.
3. Check the cable connection of the device connected to the power line in which the circuit
protector has tripped. lf the connection is loose,
tighten the cable connection securely.
4. Disconnect the secondary side power line from
4. When the circuit protector was replaced, the

one with smaller rating was installed.
the tripped circuit protector and measure resistance using a multimeter. lf there is a short
circuit, find the device that causes short circuit
and repair or replace it.
5. Connect the cables, turn on the main breaker
then the control on button. Measure current by
actually operating the machi ne. lf there are
devices that show large current value, repair or
replace it.
6. lf the alarm still occurs even after following the

steps 1) to 5), end the HMl and turn offthe power.
Replace the circuit protector.
NOTE
lf short circuit was caused due to the entry of coolant, the cause
cannot be found unless short circuit is checked immediately after the
entry of coolant. lf there is a trace of coolant entry, take measures
against the entry of coolant.
NOTE
Since devices that have low resistance, such as a solenoid valve, are
used, there are cases that low resistance cannot be judged as short
circuit.
NOTE
lf circuit protector failure occurs frequently, check the electric control

cabinet if it is vibrating. The contacts may burn due to vibration. lf
vib~ation is excessively large, take appropriate measures such as fixing
the cabinet.
5-279
li,llnN
5. TROUBLESHOOTING
GM6311
Alarm No.: G407
Message
Causes
: CONTROL PANEL COOLER FAULT
Corrective Action : CHECK, RECTIFY, PRESS FAULT RESET PB.
Description
The cooler or heat exchanger in the control cabinet is faulty.

Corrective Action
Causes
1. Cooler is faulty:
1. Cooler is faulty:
Take corrective action referring to the table.
See the table below.
2. Heat exchanger is faulty:
2. Heat exchanger is faulty:

Load current of the fan increases due to clogged
filter, causing the circuit protector to trip.
Alarm
Indication
Description
Clean or replace the filter.
Causes
Corrective Action
Temperature in the Cooling performance is not

sufficient (insufficient refrigerant)
control cabinet is
too high.
Fault in items 2 to 7
Check the cooling performance
Compressor
Compressor is overloaded.
(Thermal relay was tripped)
The compressor will restart

automatically.
Failure (Check by measuring the

coil resistance)
To be replaced by a service
engineer.
Failure of relays or conductors
Replace the power supply unit

board.
Could freeze.
Increase the temperature setting.
Insufficient refrigerant
To be repaired by a service
engineer.
External temperature is too high.
Higher than the operating range.
Dirty filter mat
Clean or replace the filter mal.
Ask the maker for repair.
1------------- - - - - - - - - - - - -
Evaporator
High pressure
monitoring
'------------- - - - - - - - - - - - - - - - - - - - - - - - ----------- Dirty condenser

Clean the condenser.
- - - - - - - - - - - - -------------------,-------------- Faulty condenser fan
Replace the condenser fan.
----------- Expansion valve does not operate. To be repaired by a service
engineer.
1------------- ----------- To be replaced by a service
Failure
engineer.
Condenser fan
Condenser fan does not operate

or is faulty.
Evaporator fan
Evaporator fan does not operate or Replace

is faulty.
Filter monitoring
Dirty filter mat
Replace
Clean or replace the filter mal.

o'
Temperature
sensor
Cable breakage or short circuit
5-280
Replace
IflnlJlt!!
5. TROUBLESHOOTING
GM6311
Alarm No.: G408
Message
Causes
: START CYCLE PB FAULT (PB REMAlNS TURNED ON)
CorrectiveAction : CHECK PB ON/OFF, PRESS FAULT RESET PB.
Description
The [START] butlon on the operation panel remains on for more than the set period of time (by the
internal timer).

Causes
Corrective Action
1. The [START] butlon on the operation panel is

faulty (remains on).
2. The input device or cable that connects to the
[START] button is faulty and the input signal
remains on.
5-281
1. Replace the [START] button.

2. Check the input device or cable that connects
to the [START] butlon, and if fa ulty, replace the
device or cable.
lilfil]ITd
5. TROUBLESHOOTING
GM6311
Alarm No.:
G415
Message
: CNC BATTERY FAULT
Causes
Corrective Action : RESUME TEMP. OP. BY PRESSING CONFIRM. SWITCH.
Description
Voltage of the battery in the CNC unit is lower than 3.35 V.
If the voltage is lower than 3.35 V, the BATWA (warning) lamp in the MCUL card lights. The UNVAL
(alarm) I~p lights if the voltage is lowered to 3.0 V or lower.

Causes
Corrective Action
1. The battery has been used to the lift (approximately 5 years).
1. Replace the battery.
r::::r See Maintenance Manual 6.7.1 "Replacing
2. Mounting or connection of a battery is incorrect.
tbe CNC Memory Backup Battery".
2. Check the cable connector for breakage of wire.
3. MCUL card is faulty (erroneous detection)
Insert the cable connector correctly.

3. Measure battery voltage with a multimeter. If
battery voltage is 3.6 V and there are no problems in the connector, connect the battery
again. If the BATWA lamp still comes on, the
MCUL card will be faulty. Replace the MCUL
cardo
r::::r

tbe MCUL Unit".
MCULcard
Lithium battery
- -O
r-
--
Caver
IMPORTANT The MCUL card has memory and it is backed up by a battery.

Before replacing the MCUL card make sure to save the data. If
the power is shut off in the state the memory is not backed up by
a battery, the data in the memory will be lost. Replace the
battery quickly with the power retained on.
5-282
lilnlJlm
5. TROUBLESHOOTING
GM6311
Alarm No.: G416
Message
Causes
: CNC READY OFF
Corrective Action : RECTIFY, PRESS NC RESET PB.
Description
The CNC servo ready is not turned on within a preset length of time after turning on of the operation
ready signal.

Causes
Corrective Action
1. The CNC unit is faulty.
1. Check the alarm status if an alarm other than

G416 occurred simultaneously.

3. Breakage of the cable connecting the CNC unit
and the servo amplifier, faulty PLC (PLC-4s),
faulty TOYOPUC input card
2. At the screen, check the contents and code

number of the alarm occurring simultaneously
with G416. Take corrective action for these
alarms.
3. If MC1 K is used independently for such as a
loader, not as an auxiliary axis of CNC, check
the details of the alarm at the MC1 K console
(MC1 K-P) and take corrective action by referring to the MC1 K instruction manual.
NOTE
G416 does not take place independently with an exception of MC1 K

alarm. Check alarms that occurred simultaneously with G416 and take
corrective action for them.
5-283
1Ilrll ] 1141
5. TROUBLESHOOTING
GM6311
Alarm No.: G417
Message
Causes
: SERVO READY OFF
Corrective Action : RECTIFY, PRESS NC RESET PB.
Description
The servo ready signal from the servo amplifier was turned OFF.

Corrective Action
Causes
1. If Indramat servo amplifier is used:
2. The servo ready signal cable is broken or its

connector is loose.
3. TOYOPUC input card is faulty.
a) Check the servo amplifier for failure.

An alarm number is displayed in the display
unit of the controller if a servo amplifier alarm
occurs. Record the alarm number.
b) Remove the cause of the alarm by referring
to the indication.
Refer to Maintenance Manual 5.6.2 "Servo
System Alarm (C Code)".
2. Check the cable of the servo ready signal and
its connector.
3. After confirming the servo ready circuit in the
electric circuit diagram, start the Hellowin and
check the ON/OFF status of the servo ready
signa!.
Segment alarm indicator
r----+~-- Terminal block
5-284
I iIF,I] 1M
5. TROUBLESHOOTING
GM6311
Alarm No.: G418
Message
Causes
: OVERRIDE SELECTOR SWITCH FAULT
Corrective Action : CHECK OPERATION, PRESS FAULT RESET PB.
Description
An error signal is output from the grinding feedrate/wheel dressing feedrate override selection switch.

Causes
Corrective Action
The override switch is faulty, its cable is broken or

its connector is loose.
Check the override switch, its cable and connector

for failure, breakage and loose connection. Take
appropriate measures according to the results of
check.
Grlnding federale override

(%)
Contnol cabinet
pu:-g
(Al
(D)
Grinding wheel override 2
(F)
(8)
(E)
(G)
Inhibit output
DPPDIH 1I11~:lIIC1UOTS
Dial TS
NlSS4
Wheel dressing override
(%)
Contnol cabinet
(D)
(A)
Wheel dressing ovenride 2
(P)
Wheel dressing override 2
(8)
Wheel dressing ovenride 4
(E)
Wheel dr.assing overrlde 8
(U)
Inhibit output
DPlOl-O-Ulnumum
Dial ti
1IISS5
5-285
iilnlJlf4
5. TROUBLESHOOTING
GM63U
Alarm No.: G419
Message
Causes
: HANDLEAXIS SELECTOR SWITCH FAULT
Corrective Action : CHECK OPERATION, PRESS FAULT RESET PB.
Description
An error signal (inhibit output) is output from the handle axis selector switch.

Causes
Corrective Action
The handle axis selector switch is faulty, the cable

is disconnected or a terminal is loosened on the
terminal block.
Check the handle axis selector switch for damage, disconnection or looseness at the terminal
block, and if fa uIty, correct the condition.
5-286
lilnlllm
5. TROUBLESHOOTING
GM6311
Alarm No.: G41A
Message
Causes
: Wheelhead retract overtravel
Corrective Action : Check the wheelhead retract position.
Description
The wheelhead most retracted position limit switch is on while the [MASTER] button is on.

Causes
Corrective Action
The wheelhead is located in the most retracted

position.
Advance the wheelhead using the handle, and press

the [RETURN] button to return the wheelhead to
the origino
5-287
lillle]IJJ
5. TROUBLESHOOTING
GM6311
Alarm No.: G420
Message
Causes
: LOWAIR PRESSURE FAULT (PRESSURE BELOW SETTING,AIR LEAK, FILTER

CLOGGED)
Corrective Action : RECTIFY, PRESS MASTER ON PB.
Description
The air pressure switch detected low pressure.
The pressure is lower than the pressure at which the pressure switch is turned OFF.
For the setting of the pressure switch, refer to the hydraulic/pneumatic circuit diagram supplied with the
machi ne.

Causes
Corrective Action
1. Low air source pressure
2. Breakage of the piping in the air circuit (air leakage)
1. Check the air intake valve in the machine, if it is

closed.
Open the valve fully and press the [MASTER]
button.
3. Faulty pressure switch

4. Breakage of pressure switch cable, faulty
TOYOPUC input card
If the pressure at the entry of the multi-dry filter

is lower than the set pressure, the air filter may
be clogged. Clean or replace the filter element.
r:::r

tbe Air Filter".
If the air filter is free of trouble, the pressure of

air source will be low. Check the piping to the
machine for leakage.
2. If the alarm occurs after pressing the [MASTER] button, air may leak through the piping/
hose. Check the piping and the hose for loose
connection and breakage.
3. If there are no problems in the check made according to items 1. to 3. above, the pressure
switch will be faulty. Replace the pressure
switch.
For the pressure switch type, refer to the hydraulic!-pneumatic circuit diagram supplied witb
the machine.
4. If the alarm still occurs when the [MASTER]
button after replacing the pressure switch, the
cable may be broken or the TOYOPUC input
card may, be faulty. Check the wiring referring
to the electric circuit diagram.
5288-
illnlJl'd
5. TROUBLESHOOTING
GM6311
Alarm No.: G421
Message
Causes
: LOW LUBRICANT LEVEL FAULT (OIL QUANTITY BECAME LESS THAN SETTING)
Corrective Action : REPLENISH, PRESS MASTER ON PB.
Description
The lubricating oillevel is below the lower limit of the float switch.

Causes
Corrective Action
1. Low lubricating oillevel
1. Check the amount of lubricating oil by the lubricating oillevel gauge and replenish the specified lubricating oil if the oillevel is low.
2. Setting error of the float switch

3. Faulty float switch
o=- See Maintenance Manual 2.1 "Inspection
4. Disconnection of the float switch, or faulty

TOYOPUC input card
before Pressing tbe [MASTER] Bution".

2. If the float switch is not turned ON although lubricating oil level is normal, check the setting
of the lower limit level of the float switch.
button although there are no problems in the
check made according to items 1. and 2. aboye,
the float switch will be faulty. Replace the float
switch.
4. If the alarm still occurs after replacing the float
switch, the cable may be broken or the
TOYOPUC input card may be faulty. Check
the wiring referring to the electric circuit diagramo
5-289
5. TROUBLESHOOTING
i-n.]1M
GM6311
Alarm No.: G422
Message
Causes
: LUBE PRESSURE FAULT (PRESS. BELOW SETIING, PIPING CLOGGED, PRESS.

AS RISED)
CorrectiveAction : RECTIFY, PRESS MASTER ON PB.
Description
The lubricating pressure switch has detected a low pressure.

Causes
Corrective Action
1. Low lubricating pressure (below the setting level)
1. Check the lubricating pressure with the pressure gauge. If it is too low, adjust the pressl,lre
with the pressure adjusting screw al the lubrication pump.
2. Damage in lubricating circuit piping

4. Setting error of the pressure switch
2. Check the lubricating circuit piping, and if damaged, replace the piping.
5. Discorinection of the pressure switch, or

3. Check the inside of the pressure switch for dust,

etc. Clean the inside, and if not corrected, replace the pressure switch.
4. Check that the pressure switch is set to the
level specified on the hydraulic/pneumatic circuit diagram, and if not, correct the setting.
5. Check the cable, and if disconnected, replace
the cable. If the cable is not disconnected, replace the TOYOPUC input cardo
if'
5-290
I Ilfll] 11;1
5. TROUBLESHOOTING
GM63U
Alarm No.: G423
Message
Causes
: LOW HYDRAULlC OIL LEVEL FAULT (OIL QUANTITY BECAME LESS THAN SETTING)
Corrective Action : REPLENISH, PRESS MASTER ON PB.
Description
The hydraulic oillevel is below the lower limit of the float switch.

Causes
Corrective Action
1. Low hydraulic oillevel
1. Check the amount of hydraulic oi! by the hydraulic oillevel gauge and replenish the specified hydraulic oil if the oillevel is low.

O' See Maintenance Manual 2.1 "Inspection
4. Disconnection of the float switch, or faulty

TOYOPUC input card
before Pressing the [MASTER] Button".

2. If the float switch is not turned ON although
hydraulic oillevel is normal, check the setting
of the lower limit level of the float switch.
button although there are no problems in the
check made according to items 1. and 2. aboye,
the float switch will be faulty. Replace the float
switch.
4. If the alarm still occurs after replacing the float
switch, the cable may be broken or the
TOYOPUC input card may be faulty. Check
the wiring referring to the electric circuit diagramo
5-291
Ik-flIJIJ!'
5. TROUBLESHOOTING
GM6311
Alarm No.: G426
Message
Causes
: HYDRAULlC OIL PUMP MOTOR OVERLOAD (OVERCURRENT MOTOR, THERMAL

RELAYTRIP)
Corrective Action : RECTIFY, SET THERMAL RELAY.
Description
An overcurrent flows to the hydraulic pump motor and causes the thermal relayto trip.

Corrective Action
Causes
1. The hydraulic pump is faulty.
When the thermal relay has tripped:
2. The motor is damaged or short-circuited.
Separate the hydraulic pump and run the motor

only.
3. Setting error of the thermal relay
1. If no error occurs, the pump is faulty. Connect

the pump andmeasure the motor current.
4. Damage to the thermal relay

5. Disconnection of the thermal relay circuit
a) If the measurement is abnormally higher than

the rated value, check the pump, and iffaulty,
replace the pump. If the measurement is a
little higher than the rated value, check the
pressure setting. Ifthe filter is clogged, etc.,
correct the condition.
2. If an error occurs when the motor runs without

load, the motor may be faulty.
b) Measure the insulation resistance and winding resistance, and if faulty, replace the motor. Turn the motor by hand, and if heavy,
repair the motor.
c) If the thermal relay trips under normal motor
current, check the setting for the thermal
relay, and adjust it to the appropriate value.
When the thermal relay has not tripped:
e) Check the thermal relay for damage, and if
damaged, replace the thermal relay.
1) If the thermal relay is not faulty, check continuity of the thermal relay circuit.
5-292
I kliilJIM
5. TROUBLESHOOTING
GM6311
Alarm No.: G427
Message
Causes
: LUBRICANT PUMP MOTOR OVERLOAD (OVERCURRENT MOTOR, THERMAL

RELAY TRIPPED)
Corrective Action : RECTIFY, SET THERMAL RELAY.
Description
An overcurrent flows to the lubrication pump motor and causes the thermal relay to trip.

Causes
Corrective Action
1. The lubrication pump is faulty.
When the thermal relay has tripped:
2. The motor is damaged or short-circuited.
Separate the lubrication pump and run the motor

only.
1. If no error occurs, the pump is faulty. Connect

the pump and measure the motor current.
4. Damage to the thermal relay

5. Disconnection of the thermal relay circuit
a) If the measurement is abnormally higher than

the rated value, check the pump, and iffaulty,
replace the pump. If the measurement is a
little higher than the rated value, check the
pressure setting. If the filter is clogged, etc.,
correct the condition.
2. If an error occurs when the motor runs without
load, the motor may be faulty.
b) Measure the insulation resistance and winqing resistance, and if faulty, replace the motor. Turn the motor by hand, and if heavy,
repair the motor.
c) If the thermal relay trips under normal motor
current, check the setting for the thermal
relay, and adjust it to the appropriate value.
When the thermal relay hasnot tripped:
e) Check the thermal relay for damage, and if
damaged, replace the thermal relay.
f) If the thermal relay is not faulty, check continuity of the thermal relay circuit.
5-293
5. TROUBLESHOOTING
GM6311
Alarm No.: G42D
Message
Causes
: LOW MIST OIL LEVEL FAULT (OIL QUANTITY BECAME LESS THAN SETIING)
CorrectiveAction : REPLENISH, PRESS MASTER ON PB.
Description
The float switch has detected the mist oillevel below the lower limit.

Causes
Corrective Action
1. Low mist oillevel (below the lower limit)
1. Check the amount of mist oil, and if short, supply mist oil.
3. Disconnection of the float switch cable, or faulty 2. If the error occurs with the sufficient amount of
mist oil, the float switch is faulty. Repair or
replace the float switch.
TOYOPUC input card
3. Check continuity of the float switch cable, and

if disconnected, replace the cable.
Check the TOYOPUC input card, and if faulty,
replace the cardo
5-294
5. TROUBLESHOOTING
GM6311
Alarm No.: G42E
Message
Causes
: LOW MIST OIL PRESSURE FAULT (PRESSURE BELOW SETTING, PIPING

CLOGGED)
CorrectiveAction : RECTIFY, PRESS MASTER ON PB.
Description
The pressure switch has detected a low oif mist pressure.

Causes
Corrective Action
1. Low oif mist pressure (below the setting level)
1. Check the oif mist pressure with the pressure
4. Setting error of the pressure switch
gauge at the reducing valve and find that it is at

the level specified on the hydraufic/pneumatic
circuit diagram. If it is too low, adjust the pressure with the air reducing valve.
5. Disconnection of the pressure switch cable, or

If the source air pressure is lowered due to a

clogged air filter, replace the air filter element.
2. Damage in air circuit piping (air leaks)
2. Check the air circuit piping, and if air leaks,

repair the piping.
3. If the error occurs with normal indication on the

pressure gauge, replace the pressure switch.
4. In the case of an adjustable pressure switch,

check that the pressure switch is set to the
level specified on the hydraufic/pneumatic circuit diagram.
5. Check continuity of the pressure switch cable,
and if disconnected, replace the cable.
replace the cardo
5-295
I (li1'lIT!'
5. TROUBLESHOOTING
GM6311
Alarm No.: G432
Message
Causes
: LOW COOLANT PRESS. (SOURCE PRESS.) (PRESS. BELOW SETTING, LEAK,

PIPECLOG)
Corrective Action : RECTIFY, PRESS MASTER ON PB.
Description
The pressure switch has detected a low coolant pressure (source pressure).

Causes
Corrective Action
1. Low coolant (source) pressure (below the set-
1. Check the coolant pump, and if faulty, replace
ting level)
the pump.
2. Damage in coolant circuit piping
2. Check the coolant piping for leaks. If any hose

is damaged, repair the piping.
4.
3. Check the inside of the pressure switch piping
Setting error of the pressure switch
for dust, etc. If clogged, clean the inside. Check

the pressure switch, and if damaged, replace
the switch.
5. Disconnection of the pressure switch cable, or

4.
Check that the pressure switch is set to the

level specified on the hydraulic/pneumatic circuit diagram, and if not, correct the setting.
5. Check continuity of the pressure switch cable,

and if disconnected, replace the cable.
replace the cardo
5-296
li-n-]I,!'
5. TROUBLESHOOTING
GM6311
Alarm No.: G452
Message
Causes
: Locator alarm
Corrective Action : Select the automatic mode and investigate operation confirmation failure of the locator devices.
Description
After the start of a location cycle, the cycle did not complete within the timer-set length of time.

Corrective Action
Causes
1. The laterallocator is faulty.
2. The signal cable of the laterallocator faulty signal or the measuring mode signal is broken or
the corresponding TOYOPUC input device is
fa uIty.
3. Timer-set length of time is too short.
1. Check the contents of the laterallocator alarm

signal and repair or replace the locator if it is
faulty.
2. Check the laterallocator cables for continuity

and insulation, and replace the cable if it is broken.
Check the corresponding TOYOPUC input device and replace a faulty device.
3. Set the timer correctly referring to the electric

circuit diagram.
5-297
lil)T,I]IJd
5. TROUBLESHOOTING
GM6311
Alarm No.: G455
Message
Causes
: Footstock spindle center over-advance (improper workpiece shape, incorrect clamp

state)
Corrective Action : Retract the footstock spindle center by selecting the manual mode and mount the
workpiece correctly.
Description
The footstock spindle center advanced excessively beyond the advance end.
For the control offootstock spindle center, either of the following two types is used.
a. An independent "over-advance" detection device is used.
b. The "retraction end" and "advance end" detection devices are used (over-travel if both are ON).
For the detection device, a limit switch or a proximity switch is used.

Causes
Corrective Action
1. The "over-advance" detection device operated
1. Ifthe "over-advance" detection device has oper-
due to "faulty workpiece center hole", "fallen

workpiece", "no workpiece" and other reasons.
In the case of a:
In normal state, the device is not ON.
The device turns ON if the footstock spindle
center moves beyond the advance end.
In the case of b:
In normal state, both of the devices are not ON
simultaneously.
80th devices turn ON simultaneously if the
footstock spindle center moves beyond the advanceend.
2. The "over-advance" detection devices are faulty
or not set correctly.
3. Cable to the "over-advance" detection device is

broken, or the corresponding TOYOPUC input
device is faulty.
5-298
ated:
Retract the footstock spindle after selecting the
automatic mode and check the center hole and
orientation of the workpiece.
2. Setthe "over-advance" detection device (adjusting the dog position, for example). Ifthe alarm
state cannot be cleared even after the setting,
replace the detection device.
3. Check the continuity of the wiring of the "overadvance" detection device and replace the cable
if it is broken.
Check the corresponding TOYOPUC input device and replace the faulty device.
lilRaJI'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: G456
Message
Causes
: Footstock spindle center advance error (workpiece not clamped correctly)
Corrective Action : Retract the footstock spindle center after selecting the automatic mode and mount
the workpiece correctly.
Description
In footstock spindle center advance operation, the advance end position or the footstock spindle center
IN state was not confirmed.

Causes
Corrective Action
1. Incorrect work workpiece orientation or center
If the footstock spindle center has not moved to

the advance end position:
hole in the workpiece
2. Footstock spindle setup change error
3.
1. Check the workpiece orientation and center hole
4. Faulty footstock spindle center advance end

confirmation device
5.
in it. If the workpiece orientation is incorrect,

set the workpiece correctly. If the center hole
is defective, replace the workpiece.
Setting error of footstock spindle center advance

end confirmation device
Cable of the "footstock spindle center advance

end" confirmation device is broken, or the corresponding TOYOPUC input device is faulty.
For the detection device, a limit switch or a proximity switch is used.
2. Check workpiece and the footstock spindle

center if the correct center is used meeting the
workpiece. Replace the footstock spindle center, if necessary.
If the footstock spindle center has moved to the
advance end position:
3. If the footstock spindle center advance end status is not detected although the workpiece is
correct, set the footstock spindle center advanee end detection device (adjust the advance
end dog position, for example).
4. Replace the footstock spindle center advance

end detection device.
5.
Check the continuity of the cable of the "advanee end" detection device. Replace the cable
if it is broken.
5-299
IliDl]IJa
5. TROUBLESHOOTING
GM6311
Alarm No.: G458
Message
Causes
: Footstock spindle center IN alarm (air lea k through the center hale)
Corrective Action : Check the workpiece holding state, retract the center and reset the NC.
Description
While the footstock spindle center was advancing, the workpiece correct clamp detection signal turned
OFF.
Although the air for detecting workpiece correct clamp state is OFF, the workpiece correct clamp
confirmation pressure switch turned ON or remained ON.
The workpiece correct clamp confirmation pressure switch turned ON although the footstock spindle
center is at the origino

Causes
Corrective Action
1. The workpiece correct clamp detection signal

turned OFF due to incorrect workpiece orientation.
If the workpiece status (orientation or center hale)

is incorrect although the footstock spindle center
has reached the advance end position:
2. Faulty center hale in the workpiece (dent, foreign matter, oval shape)
1. Retract the footstock spindle center and if the

workpiece orientation is incorrect, set the
3. The workpiece has through-hole and the

workpiece correct clamp detection signal fails
to turn ON.
4. Low air pressure (Iower than the set value)
5. Breakage in piping of correct clamp detection

air circuit (Ieakage of air)
6. Damaged or malfunction of the correct clamp

detection pressure switch
7.
Setting error of the correct clamp detection pressure switch
8. Cable of the workpiece correct clamp detection

pressure switch is broken, or the corresponding TOYOPUC input device is faulty.
2. Retract the footstock spindle center and clean

the workpiece center hale and the footstoc:;k
spindle center.
If the workpiece center hale has dent or its
shape is faulty, replace the workpiece or correct the center hale.
3. Replace the workpiece.
If the pressure switch does not operate although
the footstock spindle center has reached the advanee end position with the workpiece set in the
correct orientation:
4. With the footstock spindle center at the advance
end position, check the correct clamp detection air pressure by the pressure gauge of the
pressure-reducing valve. If the pressure jg Iow,
adjust the pressure with the pressure-reducing
valve.
If the air source pressure is low, eliminate the
cause of low source pressure and adjust the air
pressure with the pressure-reducing valve.
5. If the air pressure is stilllow although the pressure is adjusted with the pressure-reducing valve
with the footstock spindle center located at the
advance end position, check the correct clamp
..
detection air circuit for possible air leaks.
If leakage of air is found, correct the circuit.
5-300
I klnl] 1M
5. TROUBLESHOOTING
GM6311
Corrective Action
Causes
6.
If the alarm state cannot be released although

the correct clamp detection air pressure is normal, check the pressure switch if foreign matter exists in it. Clean the pressure switch if
necessary.
If the pressure switch operates with the workpiece

set in correct orientation with the footstock spindle
center in the advance end position and with the air
circuit in normal state:
7. Check the setting ofthe pressure switch (only
for pressure setting enabled type) and compare
it with the specified value indicated in the hydraulic/pneumatic circuit diagram. If the setting differs from the specified pressure value,
correct the setting.
8. Check the continuity of the cable of the pressure switch. Replace the cable if it is broken.
5301
li~r"l'kl
5. TROUBLESHOOTING
GM6311
Alarm No.: G45B
Message
Causes
: Work spindle index error (cycle time over)
Corrective Action : Check the work spindle orientation detection devices, and clear the alarm state by
pressing the reset button.
Description
Following operation did not complete within the timer-set length of time.
Work spindle orientation
Work spindle indexing to the loading/unloading position

Causes
Corrective Action
1. An alarm occurred with the C-axis servo amplifier.
1. Check the C-axis servo amplifier and motor

alarm.
Note that G458 alarm does not occur independently.
2. Correct the setting referring to the specification
2. Set length of time is too short.
5-302
in the electric circuit diagram.
,I
liliT JI,4
5. TROUBLESHOOTING
GM6311
Alarm No.: G463
Message
Causes
: Door open alarm
Corrective Action : Close the door and press the reset button.
Description
During automatic operation, the door opened or was opened.

Corrective Action
Causes
1. During automatic operation, the door opened or

wasopened.
1. Close the door.
2. Check if the lock nuts of the door close end
2. Setting error of the door close end detection

proximity switch
detection proximity switch and its dog are loose.

Adjust the proximity switch.
3. Faulty door close end detection proximity switch
4. Broken cable to the proximity switch or faulty

TOYOPUC input card
cr
See 6.3.3 "Replacing the Proximity Switch".
3. Replace the door close end detection proximity switch.
cr
See 6.3.3 "Replacing the Proximity Switch".
4. Check the proximity switch cable and the corresponding TOYOPUC card by referring to the
electric circuit diagram.
5-303
Ikln1lly
5. TROUBLESHOOTING
GM6311
Alarm No.: G464
Message
Causes
: Workpiece rotation alarm (workpiece rotating speed is outside the set range)
Corrective Action : Check the drive pin for breakage. Press the reset button to release the alarm state.
Description
During the execution of a grinding cycle, the workpiece speed sensor detected that the workpiece
rotating speed is outside the allowable range.
The workpiece is not rotating although the work spindle is rotating.
The workpiece speed sensor (example: proximity switch) remains ON after the input of the abnormal
workpiece rotation check command.
The workpiece speed sensor (example: proximity switch) remains OFF after the input of the abnormal
workpiece rotation check command.

Causes
Corrective Action
1. Due to the failure of the drive dog (example:
1. Check the workpiece drive device and check
drive pin), the workpiece does not rotate even if

the work spindle rotates.
the drive dog for breakage, wear and other problem.
Due to the failure of the drive dog, the workpiece

keeps rotating in the state it is in contact with
the wheel even after the work spindle stopped.
If the drive dog is broken or worn, replace the

drivedog.
2. Incorrect workpiece shape (example: incorrect

drive pin hole)
Check the operation of the workpiece drive device and confirm the workpiece clamping stroke.
3. Setting differs between the work spindle speed

and the workpiece speed sensor.
If the workpiece drive device is not operating

correctly, repair or replace the workpiece drive
device.
4. Due to the failure of the workpiece speed sen-
2. Check the workpiece shape (clamp section di-
sor (example: proximity switch), it remains ON

or OFF.
ameter, drive pin hole) and replace the workpiece

if the shape is incorrect.
5. Broken cable to the workpiece speed sensor or 3. After changing the work spindle speed, also
failure of the corresponding TOYOPUC input
device
change the setting for the workpiece speed

sensor (example: motion detector) meetingihe
work spindle speed.
4. Check if the workpiece speed sensor (example:

proximity switch) operates correctly. If the sensor does not operate correctly, replace it.
5. Check the continuity of the cable of the

workpiece speed sensor, and replace the cable
if it is broken.
Check the corresponding TOYOPUC input device and replace it if faulty.
5-304
1(1)11Jlt4
5. TROUBLESHOOTING
GM6311
IMPORTANT If a motion detector is used for sensing the workpiece speed, the
motion detector is set meeting the work spindle speed before

shipping and the setting position is marked with paint on the
motion detector. Do not change the work spindle speed unless
absolutely necessary.
If the work spindle speed is changed, change the motion detector setting accordingly.
Unless the motion detector setting meets the work spindle
speed, abnormal rotating speed may not be detected.
If abnormal rotation is not detected, it could cause serious
trouble such as breakage of the wheel and flying of broken
workpiece fragmento
5-305
li-iTiI]IJd
5. TROUBLESHOOTING
GM6311
Alarm No.: G466
Message
Causes
: Work spindle center IN alarm (a ir leak through the center hole)
Corrective Action : Check the workpiece holding state, retract the center and reset the NC.
Description
While the footstock spindle center was advancing, the workpiece correct clamp detection signal turned
OFF.
Although the air for detecting workpiece correct clamp state is OFF, the workpiece correct clamp
confirmation pressure switch turned ON or remained ON.
The workpiece correct clamp confirmation pressure switch turned ON although the footstock spindle
center is at the origino

Causes
Corrective Action
1. The workpiece correct clam'p detection signal

turned OFF due to incorrect workpiece orientation.
If the workpiece status (orientation or center hole)

is incorrect although the footstock spindle center
has reached the advance end position:
2. Faulty center hole in the workpiece (dent, for-
1. Retract the footstock spindle center and if the
eign matter, oval shape)
3. The workpiece has through-hole and the

workpiece correct clamp detection signal fails
to turn ON.
4. Low air pressure (Iower than the set value)
5. Breakage in piping of correct clamp detection

air circuit (Ieakage of air)
6. Damaged or malfunction of the correct clamp

detection pressure switch
7. Setting error of the correct clamp detection pressure switch
8. Cable of the workpiece correct clamp detection

pressure switch is broken, or the corresponding TOYOPUC input device is faulty.
workpiece orientation is incorrect, set the

2. Retract the footstock spindle center and clean

the workpiece center hole and the footstock
spindle center.
If the workpiece center hole has dent or its
shape is faulty, replace the workpiece, or correct the center hole.
3. Replace the workpiece.

If the pressure switch does not operate although
the footstock spindle center has reached the advanee end position with the workpiece set in the
correct orientation:
4. With the footstock spindle center at the advance
end position, check the correct clamp detection air pressure with the pressure gauge of the
pressure-reducing valve. If the pressure is low,
adjust the pressure with the pressure-reducing
valve.
If the air source pressure is low, eliminate the
cause of low source pressure and adjust the air
pressure with pressure-reducing valve.
5-306
5. TROUBLESHOOTING
GM6311
Corrective Action
Causes
5. If the air pressure is stilllow although the pressure is adjusted with the pressure-reducing valve
with the footstock spindle center located at the
advance end position, check the correct clamp
detection air circuit for possible air leaks.
If leakage of air is found, correct the circuit.
6. If the alarm state cannot be released although

the correct clamp detection air pressure is normal, check the pressure switch if foreign matter exists in it. Clean the pressure switch if
necessary.
If the pressure switch operates with the workpiece
set in correct orientation with the footstock spindle
center in the advance end position and with the air
circuit in normal state:
7. Check the setting of the pressure switch (only
for pressure setting enabled type) and compare
it with the specified value indicated in the hydraulic/pneumatic circuit diagram. If the setting differs from the specified pressure value,
correct the setting.
8. Check the continuity of the cable of the pressure switch and replace the cable if the cable
is broken.
5-307
I i-vill.hl
5. TROUBLESHOOTING
GM6311
Alarm No.: G46A
Message
Causes
: Wheelspindle bearing pressure alarm (Iow pressure, blocked pipe, pressure remain
high)
Corrective Action : After removing the cause, press the MASTER button.
Description
After the machine gets ready for operation, the pressure switch detected that the wheel spindle bearing
pressure lowered below the specified value.
Although the ready signar is OFF, the pressure switch is ON.

Causes
Corrective Action
1. Fai!ure of the wheelspindle bearing lubrication
1. Check the wheel spindle bearing lubrication oi!
pump, clogged wheel spindle bearing lubricating oi! filter, pressure setting error
pressure with the pressure gauge. If the pressure is low, adjust the pressure with the wheel
spindle bearing lubrication pump pressure and
the pressure adjusting screw.
2. Breakage of or oilleak from the spindle bearing

lubrication circuit
If the wheel spindle bearing lubrication oi! filter

is clogged, clean or replace the filter element.

4. Setting error of the pressure switch (only for
setting enabled specification)
5. Cable of the pressure switch is broken, or the
corresponding TOYOPUC input device is faulty.
If the pressure is not built up, the wheel spindle

bearing lubrication pump may be faulty and
should be replaced.
2. Check the piping and devices in the wheel

spindle bearing lubrication circuit. If damage or
oi! lea k is found, replace or repair the faulty
device.
3. If the alarm state cannot be released although

the wheel spindle bearing lubrication oi! pressure is normal, check the piping to the pressure switch for blocking due to foreign matter.
Check the pressure switch operation. If the
pressure switch is faulty, replace it.
4. Check the pressure switch setting by referring

to the hydraulic/pneumatic circuit diagram. lf
the setting differs from the specified value in
the diagrarn, adjust the pressure setting.
5. Check the continuity of the cable of the pressure switch. Replace the cable if it is broken.
5308
5. TROUBLESHOOTING
GM6311
Alarm No.: G46B
Message
Causes
: No wheel spindle bearing lubricating oil (Iow oillevel)
Corrective Action : Supply the lubricating oH and press the MASTER button.
Description
The float switch detected that the wheel spindle bearing lubricating oillevellowered below the lower
limit level.

Causes
Corrective Action
1. Low wheel spindle bearing lubricating oillevel
1. Check the wheel spindle bearing lubricating oil

level. Supply the lubricating oH if oil level is
low.

2. If the alarm state cannot be released even if the
4. Cable of the float switch is broken, or the corresponding TOYOPUC input device is faulty.
oillevel is normal, the float switch may be faulty.

Repair or replace the float switch.
3. If float switch setting has not been made, set
the flow switch.
4. Check the continuity of the cable of the float
switch. Replace the cable if it is broken.
5-309
111)11]lh1
5. TROUBLESHOOTING
GM6311
Alarm No.: G46D
Message
Causes
: Wheel spindle bearing lubricating oil temperature controller alarm
Corrective Action : Check the contents, remove the cause and press the reset button.
Description
After the machine gets ready for operation, the normal signal (alarm if the signal is OFF) of the wheel
spindle bearing lubricating oil temperature controller does not turn ON even after the elapse of the
preset time (set by the internal timer).

Causes
Corrective Action
1. Alarm occurred with the wheel spindle bearing
1. Find details of the alarm from the alarm indica-
lubricating oil temperature controller.
2. Normal signal cable from the wheel spindle bearing lubricating oil temperature controller is broken, or the corresponding TOYOPUC input device is faulty.
tion at the wheel spindle bearing lubricating oil

temperature controller.
Remove the cause referring to the instruction
manual of the wheel spindle bearing lubricating
oil temperature controller and clear the alarm
state byfollowing the operation reset procedure.
Example: Tripping ofthe compressor motorthermal relay
Check and replace the compressor motor.
2. Check the continuity of the normal signal cable.

Replace the cable if the cable is broken.
5-310
5. TROUBLESHOOTING
GM6311
Alarm No.: G470
Message
Causes
: Wheel spindle overload (overload in rapid wheelhead advance operation)
Corrective Action : Check the wheel and workpiece positions. Release the alarm state by pressing the
reset button.
Description
During wheelhead rapid advancement, the wheel spindle overload sensor detected motor overload state
(motor current exceeded the set value).
Causes
Corrective Action
1. Large stock of workpiece, inaccurate machi n-
1. Check the machining dimensions of the
ing in the preceding operation
2. Due to incorrect workpiece orientation, the wheel

interfered with the workpiece during rapid
wheelhead advancement.
3. The wheelhead feed coordinate system is offset.
4. During rapid wheelhead advancement, the wheel

interfered with the truing unit part, cover, etc.
workpiece in the preceding proeess and if the

stock is larger than the specified stock, change
the stoek setting or replace the workpiece.
2. Check the workpiece index position and orientation of mounting. Correct the workpiece status if incorrect.
3. Establish the wheelhead feed axis eoordinate
system.
4. Check the wheel and the cover for interierence.
5. Incorrect current sensor setting
Correet if an abnormality is found.
6. Faulty current sensor
5. Check the current sensor setting. If it differs
7. Cable of the current sensor is broken, or the

corresponding TOYOPUC input device is faulty.
from the setting made at the shipping, change

the setting correctly.
6. Measure wheel spindle motor current under noload state. If the current sensor operates although its setting is larger than the measured
current value, the current sensor may be faulty.
Replace the current sensor.
7. Check the continuity of the cable of the current

sensor and replace the cable if it is broken.
5-311
I Ilrll]
5. TROUBLESHOOTING
1"
GM6311
Alarm No.: G472
Message
Causes
: Low wheel spindle speed
Corrective Actien : Check the contents of alarm, remove the cause and press the reset button to release
the alarm state.
Description
In a grinding cycle, excluding a test cycle, or a wheel truing cycle, the wheel spindle stopped rotating
or wheel spindle speed went outside the allowable spindle speed range (the inverter speed increase
complete signar turned OFF).

Causes
Corrective Action
1. The speed command from the inverter is erro-
1. If the wheel spindle speed is outside the allow-
neous causing the wheel spindle speed to go

outside the allowable range.
able range, the inverter will be faulty. Refer to

the instruction manual of the inverter.
2. The [STOP WHEEL SPINDLE] button was

pressed.
2. Eliminate the cause of pressing of the [STOP

WHEEL SPINDLE] bulton and restore the operation.
3. Faulty wheel spindle inverter
4.
Wheel spindle inverter signar cable is broken,

or the corresponding TOYOPUC input device is
faulty.
5-312
3. Replace the wheel spindle inverter.

4. Check the signar cable from the wheel spindle
inverter referring to the electric circuit diagram
and check the cerresponding TOYOPUC input
cardo
lilnlJlt*,
5. TROUBLESHOOTING
GM6311
Alarm No.: G473
Message
Causes
: Wheel spindle inverter alarm (alarm indication)
Corrective Action : Check the contents of alarm, remove the cause and press the reset button to release
the alarm state.
Description
An alarm signal was output from the wheel spindle inverter.

Causes
Corrective Action
1. An alarm signal (wheel spindle overload, over

current, etc.) is output from the wheel spindle
inverter.
1. Find the alarm code displayed at the digital

operator of the wheel spindle inverter and take
appropriate corrective action.
2. Wheel spindle inverter alarm
(j='
3. Wheel spindle inverter signal cable is broken,
2. Find the alarm code displayed at the digital
or the corresponding TOYOPUC input device is

fa uIty.
operator of the wheel spindle inverter and take

appropriate corrective action.
(j='
See 5.7 "Inverter Alarms".
See 5.7 "Inverter Alarms".
3. Check the signal cable from the wheel spindle

inverter and the corresponding TOYOPUC input card referring to the electric circuit diagram.
5-313
II-nl]IJ41
5. TROUBLESHOOTING
GM6311
Alarm No.: G479
Message
Causes
: Sizer alarm
Corrective Action : Check the contents of alarm, remove the cause and press the reset button to release
the alarm state.
Description
The sizer normal signal is turned off.

Causes
Corrective Action
Failure of the sizer amplifier and the sizer gauging

head
Check the operation of the sizer amplifier and the

sizer gauging head. If an abnormality is found,
repair or replace the sizer amplifier or the sizer
gauging head.
Find details ofthe alarm referring to the instruction
manual of the sizer amplifier.
Remove the cause and release the alarm sta te
according to the operation restoring procedure described in the instruction manual of the sizer amplifier.
5-314
Illnl]IJ*,
5. TROUBLESHOOTING
GM6311
Alarm No.: G47C
Message
Causes
: AUTO-SIZER-RELATED LS, SOLACTION CHECK FAULT
Description
The auto-sizer is retracted in the return cycle; however, the most retracted position confirmation device
is not turned on within the set period of time.

Causes
Corrective Action
1. Faulty cylinder operation for advancing/retract-
1. Check the cylinder operation for advancing/re-
ing the auto-sizer
2. Faulty most retracted position confirmation de-
tracting the auto-sizer. If faulty, re place the

cylinder.
2. Check the operation of the most retracted posi-
vice
3. Disconnection of the most retracted position

device cable, or faulty TOYOPUC input device
tion device (proximity switch, etc.), and if faulty,

replace the device.
3. Check continuity of the cable for the most retracted position conflrmation device, and if disconnected, replace the cable.
Check the TOYOPUC input device, and if faulty,
replace the device.
5-315
5. TROUBLESHOOTING
GM6311
Alarm No.: G47D
Message
Causes
: Wheel spindle bearing lubrication pump motor overload (tripping of thermal relay due
to over-current)
Corrective Action : Remove the cause and reset the thermal relay.
Description
The thermal relay of the wheel spindle bearing lubrication pump motor tripped.

Causes
Corrective Action
1. Failure of the pump
If the thermal relay has tripped:
2. Damaged or shorl-circuit of motor
1. Check the pressure setting of the wheel spindle

bearing lubrication pump and if the pressure is
low or the pressure is not built up, shut off the
power according to the power shut-off procedure. Afier that check the wheel spindle bearing lubrication pump and the lubricating oil tank.
Check the suction port of the wheel spindle
bearing lubrication pump and clean the strainer
if the suction port is blocked due to foreign
matter.

4. Damaged th~rmal relay
5. Broken cable in the thermal relay circuit
If the lubricating oil is contaminated, change it

with fresh oil.
2. Measure the insulation and wiring resistance of

the motor. Replace the motor if the measured
resistance is incorrecto
3. Check the thermal relay setting referring to the

electric circuit diagram. If the set value differs
form the value specified in the electric circuit
diagram, change the setting correctly.
If the thermal relay has not tripped:
4. Replace the therrnal relay.
5. Check the continuity of the thermal relay circut and replace the cable if it is broken.
5-316
5. TROUBLESHOOTING
GM6311
Alarm No.: G48A
Message
Causes
: Wheel front cover LS error
Corrective Action : Check and adjust the LS dog position (replace if faulty). Press the reset button to
release the alarm state.
Description
Wheel front guard position compensating operation has not completed with the preset time.

Causes
Corrective Action
1. Faulty wheel front guard position compensation
1. Replace the wheel front guard position compensation motor.
motor
2. Faulty proximity switch detecting the wheel front

guard position compensation rotation
3. The output signal cable from the proximity
switch is broken, or the corresponding
TOYOPUC input device is faulty.
2.
Replace the proximity switch that detects the

wheel front guard position compensation rotation.
3. Check the continuity of the output signal cable

of the proximity switch. Replace the cable if
the cable is broken or short-circuited .
. Check the corresponding TOYOPUC input device and replace a faulty device.
5-317
I Ilnl ] 1M
5. TROUBLESHOOTING
GM6311
Alarm No.: G48B
Message
Causes
: Wheel front guard position compensating motor overload (tripping of thermal relay due
to over-current)
Description
Tne thermal relay of the wheel guard compensating motor tripped due to over current.

Corrective Action
Causes
1. Interference between the wheel front guard and

thewheel
2. Failure of the wheel front guard position compensating motor
1. Adjust the wheel front guard position.
2. Replace the wheel front guard position compensating motor.
3. Check the wheel front guard position compen-
3. Wheel front guard compensating feed screw

motion is heavy
5-318
sation feed screw. If the screw does not operate smoothly, repair or replace the screw.
111,,1]1141
5. TROUBLESHOOTING
GM6311
Alarm No.: G48C
Message
Causes
: Wheel front guard open/close motor overload (tripping of thermal relay due to overcurrent)
Description
The thermal relay of the wheel guard open/close motor tripped due to over current.

Corrective Action
Causes
1. Failure of the wheel guard open/close motor
1. Replace the wheel guard open/close motor.
2. Failure of the proximity switch detecting the
2. Replace the proximity switch detecting the

wheel guard openlclose end detection
wheel guard openlclose end detection
3. Corrosion of wheel guard hinge, or an object 3. Repair the wheel guard hinge.
blocking the wheel guard
Eliminate an interfering object.
4. An attempt was made to operate (open/close)

the wheel guard with the wheel guard fall preventing safety pino
4. Close the wheel guard after removing the wheel

guard fall preventing safety pino
Replace the safety pin confirmation device
(proximity switch).
5-319
5. TROUBLESHOOTING
GM6311
Alarm No.: G490
Message
Causes
: GRINDING WHEEL REPLACEMENT
Corrective Action : REPLACE WHEEL FOLLOWING WORK PROCEDURE MENU.
Description
The wheel diameter beca me smaller than the minimum diameter.

Corrective Action
Causes
1. The wheel diameter became smaller than the
minimum diameter (below the setting level).
2. Setting error of the minimum wheel diameter
NOTE
1. Replace the wheel.

2. Check the value set for minimum wheel diameter (A50). If a value other than Iisted below is
set, set a correct value for A50
The minimum wheel diameter varies depending on the specifications.

Refer to the related drawing.
5-320
Ik-nl]I'*,
5. TROUBLESHOOTING
GM6311
Alarm No.: G491
Message
Causes
: DIAMOND ROLL REPLACEMENT
Corrective Action : REPLACE DIAM. ROLL FOLLOWING WK PROCEDURE MENU.
Description
The total count of wheel truing times afier diamond roll change has exceeded the setting number of
times for diamond roll change.

Causes
Corrective Action
The diamond roll must be changed.
Change the diamond roll.
5-321
5. TROUBLESHOOTING
GM6311
Alarm No.: G49C
Message
: DIAMOND ROLL INVERTER FAULT (ACCORDING TO ERROR DISPLAY OR
MANUAL)
Causes
Description ,
The normal signal of the diamond roll inverter was turned OFF.

Causes
Corrective Action
1. An alarm occurred with the diamond roll inverter.
1. Check alarm indication on the diamond roll inverter unit.
2. Disconnection of normal signal cable or the frequency arrived signal cable from the diamond
roll inverter, or faulty TOYOPUC input device
Refer to the instruction manual for the diamond

roll inverter unit, check the contents of the alarm
displayed on the Digital Operator, and remove
the cause of the problem.
2. Check continuity of the normal signal cable and
the frequency arrived signal cable from the diamond roll inverter unit, and if disconnected, replace the cable.
"{
Check the TOYOPUC input device, and if fa uIty,

replace the device.
POWER
~
~
Digital Operator of Hitachi Inverter J100-015LF2
5-322
lilr(IJ1rd
5. TROUBLESHOOTING
GM6311
Alarm No.:
G49D
Message
Causes
: Low diamond roll speed alarm
Description
While the diamond roll was rotating, the speed arrived signal of the inverter was turned OFF.

Corrective Action
Causes
1. Failure of the diamond roll motor shaft
2.
1. Check the load current of the diamond roll motoro If the load current is large, repair or replace
the diamond roll motor.
Diamond roll inverter error
3. The speed arrived signal cable of the diamond

roll inverter is broken, or the corresponding
TOYOPUC input device is faulty.
2.
Check the diamond roll inverter for occurrence

ofalarm.
Eliminate the cause referring to the instruction
manual of the diamond roll inverter.
3. Check the continuity of the speed arrived signal cable of the diamond roll inverter. Replace
the cable if the cable is broken.
Check the corresponding TOYOPUC input device and re place a faulty device.
5-323
5. TROUBLESHOOTING
GM6311
Alarm No.: G4AO
Message
Causes
: Roundness measurement error (right sizer)
Description
As the result of roundness measurement with the right sizer gauging head advancing, the measured
value obtained exceeded the allowable limit value (B 184).

Corrective Action
Causes
1. Poor roundness of the workpiece
1. Check the cause of poor roundness and review
2. Foreign matter caught between the sizer contact
the rest shoe pushing stroke, micro-grinding

feedrate and other grinding conditions.
2. Execute measurement again to check if the
3. Faulty sizer gauging head
same trouble occurs again.
3. Check the repeatability of the sizer gauging

head. Replace the sizer gauging head if faulty.
5-324
5. TROUBLESHOOTING
GM6311
Alarm No.: G4A1
Message
Causes
: Roundness measurement error (Ieft sizer)
Description
As the result of roundness measurement with the left sizer gauging head advancing, the measured
value obtained exceeded the allowable Iimit value (B 184).

Causes
Corrective Action
1. Poor roundness of the workpiece
1. Check the cause of poor roundness and review
2. Foreign matter caught between the sizer contact
the rest shoe pushing stroke, micro-grinding

feedrate and other grinding conditions.
2. Execute measurement again to check if the
3. Faulty sizer gauging head
same trouble occurs again.
3. Check the repeatability of the sizer gauging

head. Replace the sizer gauging head if fa uIty.
5-325
5. TROUBLESHOOTING
GM6311
Alarm No.: G4CO to G4F1 (unit alarms)
G4F2 to G4G9 (part alarms)
Message
Unit Alarms (50 alarms)

Example:
G4CO
CHUCK FAULT (SW1: UNCLAMP END. SW2: CLAMP END. MOV1: CLAMP. MOV2:
UNCLAMP)
The underlined part is shown with part alarms G4F2 to G4F9.
G4C5
STEADY REST FAULT (SW1: RET END. SW2: ADV END. MOV1: ADV. MOV2: RET)
The underlined part is shown with part alarms G4F2 to G4F9.
Part Alarms (8 alarms)
(1) G4F2
SW1 CONFIRM.DEVICE FAULT

(THOUGH COMMAND IS ON, CONFIRM. DEVICE NOT OFF)
(2) G4F3
SW2 CONFIRM. DEVICE FAULT

(THOUGH COMMAND IS ON, CONFIRM. DEVICE NOT OFF)
(3) G4F4
MOV1 ACTION DEVICE FAULT

(THOUGH COMMAND IS ON, CONFIRM. DEVICE NOT WORK)
(4) G4F5
MOV2ACTION DEVICE FAULT

(THOUGH COMMAND IS ON, CONFIRM. DEVICE NOT WORK)
(5) G4F6
MOV1 OPERATION CYCLE TIME OVER

(CYCLE TIME GOES BEYOND SETTING)
(6) G4F7
MOV2 OPERATION CYCLE TIME OVER

(CYCLE TIME GOES BEYOND SETTING)
(7) G4F8
SW1 CONFIRM. DEVICE CHATTERING FLT

(CONF. DEVICE TURNED OFF W/OUT COMMAND)
(8) G4F9
SW2 CONFIRM. DEVICE CHATTERING FLT

(CONF. DEVICE TURNED OFF W/OUT COMMAND)
5-326
5. TROUBLESHOOTING
GM6311
NOTE
Unit alarms and part alarms are displayed at the same time to indicate
the location and the cause of the alarm.
Example:
G4C3
Causes
: RTOUCH PROBE FLT (SW1: RET END, SW2:

SWIVEL END, MOV1: SWIVEL, MOV2: RET)
Corrective Action : CHECK SW1 ,SW2,MOV1 ,MOV2 FOLLOWING

BELOW MESSAGE.
G4F3
Causes
: SW2 CONFIRM. DEVICE FAULT (THOUGH COMMAND IS ON, CONFIRM. DEVICE NOT OFF)
Corrective Action : CHECK CONF. DEVICE, RECTIFY, PRESS FAULT

RESET PB.

Causes
Corrective Action
1. Setting error of the confirmation device, or faulty

confirmation device
1. Check that the unit has moved to the end position. When the motion has been completed,
set the confirmation device at the end position
properly.
Example: Due to the setting error of the right

touch probe swivel end position proximity switch, the switch is not turned
on when the right touch probe has
swiveled.
2. Faulty operation device (solenoid valve, actuator, cylinder, etc.)
Example:The steady rest has started to advance, but the steady rest most retracted position proximity switch is
not turned off (remains on).
3. Interference or faulty actuator of the unit that

has a cycle time-over alarm, hydraulic pressure
drop, etc.
If the confirmation device is set correctly but it

is not turned on, replace the confirmation device.
Example: Replace the right touch probe swivel
end position confirmation proximity
switch.
2. If the unit is not moving, check the solenoid
valve, the actuator, etc. If faulty, repair or replace the parto
Example: Replace the right touch pro be swivel
cylinder.
3. If the unit has not moved to the end position,
Setting error of the confirmation device at the

end position, or faulty confirmation device
adjust, repair or replace the actuator such as a

cylinder, etc.
Example:The swivel end position proximity

switch is not turned on within the set
period of time when the right touch
pro be has swiveled.
Check the hydraulic pressure and f10wrate setting.

Example: Adjust the right touch probe swivel
f10w control valve.
When the unit has moved to the end position,
set the confirmation device at the end position
properly. If the device is not turned on, replace
the confirmation device .
. Example: Adjust the dog position for the right
touch probe most advanced (swivel
end) position proximity switch.
5-327
Illn]'4
5. TROUBLESHOOTING
GM6311
Causes
Corrective Action
4. Faulty confirmation with a confirmation device

tor the unit in motion other than the one at the
end position
4. Check the confirmation device tor the indicated

parto It it cannot be activated, replace the confirmation device.
Example:The most advanced (swivel end) position proximity switch is turned on

when the right touch probe is not advanced.
Example: It the right touch probe most retracted

position proximity switch remains on,
replace the proximity switch. -
5-328
1Ilr11] 1141
5. TROUBLESHOOTING
GM6311
5.6
Servo System Alarms
5.6.1
Servo System Alarms

Servo alarms include the alarms detected by the DSU
unit and those detected by the PWM unit (servo
amplifier).
1. Alarms Detected by the PWM Unit (Servo Amplifier)
PWM unit (servo amplifier)
Over-current detection (A657)

Power device error detection
OPOWER
fOl
Overload detection (A658)
lEJ
Over voltage detectin (A657)

Control circuit power supply error detection
(A660)
Alarm code
indicator
Alarm detection (CPU)
o: MCUL (CNUE)
4: DSU1
5: DSU2
6: DSU3
Alarm Code
~
~
ADDD-D-DD-DD
'-y-J
Alarm No.
'-y-J
o
[I]
Alarm axis
Sensor signal cable breakage detection

(A677)
No sensor response detection (A644)
External encoder signal cable detection
(A676)
Low main circuit power supply voltage
(A663)
Open phase of main circuit power supply
(A666)
External overheat detection (A659)
Internal regeneratin9 resistor overheat
detection(A661 )
Regeneration error detection (A661)
PWM signal cable breakage detection
(A667)
[JJ Battery alarm (A673)

[!] . Serial interface timeout error detection
(A664)
2. Alarms Detected by the DSU Unit
Click the [MAINTE MENU] button at the screen.
Click the [ERROR DISPLAY] button at the screen.
Click the [ERROR DISPLAY] button at the screen.
The DISPLAY FAULT COMMENTscreen is
displayed.
CJ=' See 5.5.1 "Diagnosis and Corrective Action Alarm A".

5-329
1li1'1IM
5. TROUBLESHOOTING
GM6311
5.7
Inverter Alarms
5.7.1
Alarms of the Wheel Spindle Motor Inverter
(a)
Mitsubishi's Inverter
If an alarm occurs with the inverter, the protection
function operates and the alarm number is displayed
at the display unit of the operation panel (DU04).
Find the corrective action to be taken referring to the
table below.
To reset the alarm state, press the [STOP/RESET]
key.
IEDC
1I
Alarm Code
E.OC1
Alarm Name
Shut off due to over-current during acceleration
Description
If inverter output current exceeds about 200% of the rated current during acceleration, the protection circuit operates to stop inverter output.
If the start signal is input with the power supplied only to the R1 and S1 terminals,
inverter output is stopped.
Points to Check
Corrective Action
Quick acceleration?
Short-circuit in output circuit?
Main power supply (R, S, T) ON?
Elongate acceleration time.

If "E.OC 1" always occurs at the start, try to start the operation afier disconnecting the motor. If "E.OC1" still occurs, pIe ase contact Toyoda Machine Works.
Supply the main power supply (R, S, T).
-E.O[21
Alarm Code
E.OC2
Alarm Name
Shut off due to over-current during constant-speed operation
Description
If inverter output current exceeds about 200% of the rated current during constant
speed operation, the protection circuit operates to stop inverter output.
Points to Check
Corrective Action
Sudden load fluctuation?

Eliminate sudden fluctuation of load.
5-330
IflnlllD
5. TROUBLESHOOTING
GM6311
IEDC3!
Alarm Code
E.OC3
Alarm Name
Shut off due to over-current during constant-speed operation
Description
Points to Check
Corrective Action
If inverter output current exceeds about 200% of the rated current during deceleration (other than during acceleration and constant speed operation), the protection
circuit operates to stop inverter output.
Ouick deceleration?
Mechanical motor braking timing too early?
Elongate deceleration time.
Check mechanical braking operation.
!f.Ou : !
Alarm Code
E.OV1
Alarm Name
Shut off due to regenerative over-voltage during acceleration
Description
If the main circuit DC voltage in the inverter becomes higher than the specified
value due to regenerative energy, the protection circuit operates to stop inverter
output.
The protection circuit also operates due to surge voltage generated in the power
supply system.
Points to Check
Corrective Action
Acceleration too slow?

Shorten the acceleration time.
1f.O u 2 I
Alarm Code
E.OV2
Alarm Name
Shut off due to regenerative over-voltage during constant speed operation
Description
Points to Check
Corrective Action
value due to regenerative energy, the protection circuit operates to stop inverter
output.
The protection circuits also operates due to surge voltage generated in the power
supply system.
Sudden load f1uctuation?
Eliminate sudden f1uctuation of load.

Use a brake unit or power supply regenerative converter (FR-RC) as needed.
!f.Ou3!
Alarm Code
E.OV3
Alarm Name
Shut off due to regenerative over-voltage during deceleration or stop
Description
value due to regenerative energy, the pr.otection circuit operates to stop inverter
output.
The protection circuits also operates due to surge voltage generated in the power
supply system.
Points to Check
Corrective Action
Ouick deceleration?
Elongate deceleration time (set the deceleration time meeting the load GD2).
Reduce deceleraton frequency.
Use a brake unt or power supply regenerative converter (FR-RC) as needed.
5-331
5. TROUBLESHOOTING
GM6311
IEr Hfl I
Alarm Code
E.THM
Alarm Name
Shut off due to motor overload (electronic thermal relay) (*1)
Description
. Points to Check
Corrective Action
The electronic thermal relay in the inverter senses overheating of the motor caused
by overload or lowered cooling performance during constant speed operation. If
the temperature reaches 85% of the set value, the inverter is placed in the prealarm state ("TH" indication) and the protection circuit operates to stop inverter
output.
Note that if a special motor such as a multi-pole motor is used or if multiple motors
are operated, an electronic thermal relay cannot protect the motors. In such operation, install a thermal relay at the inverter output side.
Motor overloaded?
Reduce load.
When a constant torque motor is used, change the setting for Pr.71 meeting a
constant torque motor.
IEfHf I
Alarm Code
E.THT
Alarm Name
Shut off due to inverter overload (electronic thermal relay) (*1)
Description
In the state the current higher than 150% of the rated output current is flowing, but
the current is lower than the level that causes over current protection shut off, the
electronic thermal relay operates to stop inverter output for protecting the output
transistor.
(Overload resistivity: 150%,60 sec.)
Points to Check
Corrective Action
Motor overloaded?
Reduce load.
(*1): When the inverter is reset, the internal accumulated thermal data of the electronic thermal relay is
initialized.
IEJ PF I
Alarm Code
E.IPF
Alarm Name
Momentary power failure protection (*2)
Description
Points to Check
Corrective Action
If power interruption occurs for longer than 15 msec (including inverter input interruption), the momentary power failure protection function operates to stop inverter
output for preventing malfunctioning of the control circuit. At this moment, the
alarm signal output contact opens (terminal B - C) and closes (terminal A - C) (*2).
If power failure continues for 100 msec or longer, the alarm signal output function
does not operate and when the power is recovered, the inverter re-starts if the start
signal is ON.
Note that the inverter continues operating under momentary power failure for within
15 msec.
Check the cause of momentary power failure~
Recover fram the momentary power failure.

_.
Use backup power supply.
Set the momentary power failure restart function.
(*2): At the occurrence of momentary power failure, no indication or output for this is provided. The protection
function operates, however, to protect the inverter itself from possible troubles. The over current protection function may operate when the power is recovered, depending on the operating conditions (load,
acceleration/deceleration time setting, etc.)
5-332
Hill)l!
5. TROUBLESHOOTING
GM6311
E.UVT
Alarm Name
Low voltage protection
Description
Points to Check
Corrective Actjon
The control circuit will fail to operate correctly if voltage of the supplied power
becomes low. In addition, other problems such as insufficient motor torque and
increased heat generation will occur. Therefore, if the source voltage is lowered to
about 150 V (about 300 V for the 400-V system), the protection function stops
inverter output.
If there is not short plug between P and P1, the low voltage protection function is
enabled.
Large-capacity motor started?
Short plug or DC reactor set between P and P1?
Check the power supply and related parts.
Connect the short plug or DC reactor set between P and P1.
IEFI n I
Alarm Code
E.FIN
Alarm Name
Fin overheated
Description
Points to Check
Correctjve Action
When the cooling fin is overheated, the overheat sensor operates to stop the inverter output.
Environmental temperature too high?
Cooling fin blocked?
Lower environmental temperature to the level within the specification.
If.
GF
Alarm Code
E.GF
Alarm Name
Output side ground fault over current protection
Description
Pojnts to Check
Corrective Actjon
If over current f10ws due to ground fault at the inverter output si de (load side), the
function stops inverter output.
Motor or cable grounded?
Eliminate ground fault.
IEflHf I
Alarm Code
E.OHT
Alarm Name
External thermal relay operated (*3)
Descriptjon
When an external motor overheat protection thermal relay or incorporated thermal

relay.operates (contact open), the function stops inverter output. The inverter
does not restart even after automatic reset of the relay contact unless the inverter
is reset.
Points to Check
Motor overheated?
Value "7" (OH signal) set for any of Pr.180 - Pr.186 (input terminal function selection)?
Corrective Actjon
,.
IE.uuf I
Alarm Code
Reduce load and operation frequency.
(*3): The output terminal to be used must be allocated by Pr.190 - Pr.195 (output terminal function selection).
The function operates only when "OH" is set for nay of Pr.180 - Pr.186.
5-333
Ileil l]lt!1
5. TROUBLESHOOTING
GM6311
lE.
bEI
Alarm Code
E.BE
Alarm Name
Brake transistor alarm detection
Description
Points to Check
Corrective Action
If an alarm occurs with the brake circuit, such as breakage of the brake transistor,
the function stops inverter output.
If this alarm occurs, power supply to the inverter must be shut off immediately.
load (GD2) too large?
Braking frequency appropriate?
Reduce the load.

Replace the inverter.
lE.aL r I
Alarm Code
E.OlT
Alarm Name
Stall prevention
Description
Operation frequency lowered to "O" by stall prevention operation.

("Ol" during stall prevention operation)
Points to Check
Corrective Action
Motor used under overload?

Reduce the load.
IE.DPf I
Alarm Code
E.OPT
Alarm Name
Option error
Description
Points to Check
Corrective Action
When a built-in option is used, the function stops inverter output if setting error or
connection error occurs.
This alarm code is displayed if AC power source is connected to R, S and T terminals when the setting is made to connect a high power factor converter.
Built-in option connected correctly?
Connect the built-in option correctly.

Contact Toyoda Machine Works.
EOP/-
Alarm Code
E.OP1
- E.OP3
Alarm Name
Option slot error
Description
If a functional error (communication error of a communication option) occurred

with the built-in option installedto the slot, the function stops inverter output.
Points to Check
Corrective Action
OP3
Option function setting and operation correct?

(Numbers "1" - "3" represent the slot numbers.)
Check the option function setting.
5-334
DiillJltJ
5. TROUBLESHOOTING
GM6311
lE.
PEI
Alarm Code
E.PE
Alarm Name
Parameter storing device error
Description
If an error occurs with the EEPROM where parameter values are stored, the function stops inverter output.
Points to Check
Parameter written too many times?
Corrective Action
IEPUE I
Alarm Code
E.PUE
Alarm Name
Para meter unit not installed
Description
If communications between the inverter and the para meter unit are interrupted
due to detaching the operation panel and the parameter unit although "2", "3", "16"
or "17" is set for Pro 75 "reset select I PU not installed check I PS stop selection",
If communication error occurs continuously more than the number of time set as
the maximum retry count with "Pro 121 9999" set by the RS-485 communication,
If communication is interrupted for more than the length of time set for Pro 122, the
Points to Check
Corrective Action
DU and/or PU installed securely?

Pro 75 setting correct?
Install the PC securely.
IErEf I
Alarm Code
ERET
Alarm Name
Retry count over
Description
Points to Check
Corrective Action
If the operation cannot be restarted normally within the set number of retry count,
Check the cause of alarm.
Take corrective action for the preceding error.
IELF
Alarm Code
E.LF
Alarm Name
Output open-phase protection
Description
Points to Check
Corrective Action
If any one of three inverter output side (load side) phases (U, V, W) is open, the
Check the wiring (motor normal?).
Motor rated current considerably lower than the inverter rated current?
Connect the cables correctly.

Check the setting for Pro 251 output open-phase protection".
IEfPU I
Alarm Code
E.CPU
Alarm Name
CPU error
Description
Points to Check
Corrective Action
If operation processing of the built-in CPU is not completed within the specified
length of time, the CPU judges it abnormal state and the function stops inverter
output.
..
Connect the cables securely.
5-335
IIIDI1II
5. TROUBLESHOOTING
GM6311
lE. S I
AJarm Code
E.6
AJarm Name
CPU error
Description
Points to Check
If operation processing of the built-in CPU for peripheral circuit is not completed
within the specified length of time, the CPU judges it abnormal state and the function stops inverter output.
Corrective Action
AJarm Code
E.7
AJarm Name
CPU error
Description
Points to Check
Corrective Action

lE. rr I
If operation processing of the built-in CPU for peripheral circuit is not completed
within the specified length of time, the CPU judges it abnormal state and the function stops inverter output.

IE.P24 I
AJarm Code
E.P24
AJarm Name
24 VDC power supply output short-circuit
Description
If short-circuit occurs with the 24 VDC power supply to be output from the PC
terminal, the function interrupts power supply output. If this occurs, all external
contact inputs are turned OFF. Resetting is not impossible using the RES terminal
input. To reset the alarm status, either use the operation panel or turn off and on
the power.
Points to Check
Corrective Action
PC terminal output short-circuited?

Correct the short-circuit point.
IEfrE I
Alarm Code
E.CTE
AJarm Name
Short~circuit
Description
Points to Check
Corrective Action
of operation panel power supply
If short-circuit occurs with the operation panel power supply (P5S of PU connector) , the function shuts off the power supply output. If this occurs, the operation
panel (parameter unit) cannot be used and RS-485 communication through the
PU connector is disabled. To reset the alarm status, either use the operation
panel or tum off and on the power.
PC terminal output short-circuited?
Check the PU cable.
E.nbl
Alarm Code
E.MB1
- MB7
Alarm Name
Brake sequence error
Description
If a sequence error occurs while the brake sequence function (Pr. 278 - Pro 285) is
used, the function stops inverter output.
Points to Check
Corrective Action
-'1
Check the cause of alarm.
..
Check the parameter settings and connect the cables correctly.
5-336
5. TROUBLESHOOTING
GM6311
Minor Fault
IFn
Alarm Code
FN
Alarm Name
Failure .of the fan
Description
With the inverter that has the built-in fan, "FN" is displayed at the operation panel
if the cooling fan stops due to trouble or operates in the manner different from the
setting for Pro 244 (cooling fan operation selection).
Points to Check
Corrective Action
Cooling fan abnormal?

Replace the fan.
Warning
lal 1
Alarm Code
Ol
Alarm Name
Stall prevention (over current)
Description
Points to Check
Corrective Action
During acceleration
If the motor current flow exceeds 150% (*4) of the rated current of the inverter, frequency increase stops until overload
current decreases to prevent the occurrence of shut off due
to over current. Frequency starts increasing again when motor
current decreased to 150% or less of the rated current.
During constantspeed operation
If the motor current flow exceeds 150% (*4) of the rated current of the inverter, frequency is lowered until overload cur~
rent reduces to prevent the occurrence of shut off due to over
current. The set frequency is restored when the motor current decreased to 150% or less of the rated current.
During deceleration
.If the motor current flow exceeds 150% (*4) of the rated current of the inverter, frequency decrease stops until overload
current reduces to prevent the occurrence of shut off due to
over current. Frequency starts decreasing again when motor
current decreased to 150% or less of the rated current.
Motor used under overload conditions?

There is a possibility of changing of acceleration time. Set the higher level for the
stall prevention function to operate by changing the setting for Pro 22 (stall prevention function operating level) or disable the stall prevenon function by setting an
appropriate value for Pro 156 (stall prevention function selection).
(*4): Stall prevention function operating level can be set as required. Before shipping, it is set at 150%.
lol
Alarm Code
Ol
Alarm Name
Slall preven1ion (over voltage)
Description
Points to Check
Corrective Action
I
If motor regenerating energy becomes excessive to the level
exceeding the brake performance, frequency decrease stops
to prevent the occurrence of shut off due to over voltage.
Deceleration continues when the regenerating energy is reduced.
During deceleration
Quick deceleration?
There is a possibility of changing of deceleration time. Elongate the deceleration
time by changing the setting for Pro 8 (deceleration time).
..
5-337
Ellrl']I};l
5. TROUBLESHOOTING
GM6311
(
IPS I
Alarm Code
PS
Alarm Name
PU stop
Description
With Pro 75 (PU stop selection), PU stop by the [STOP/RESEll key is set.
Points to Check
The [STOP/RESEn key at the operation panel pressed?
Corrective Action
Alarm Code
Description
Err
Ifrr
This alarm code' is displayed in the following cases:

The RES signal is ON.
An attempt was made to set a para meter in the extemal operation mode.
An attempt was made to change the operation mode during operation.
An attempt was made to set a para meter outside the allowable range.
Abnormal communications between the PU and the inverter.
An attempt was made to set a para meter, although writing of a parameter is
prohibited by the setting for Pro 77 (parameter write prohibition selection).
Corrective Action
5-338
"1111]114
5. TROUBLESHOOTING
GM6311
5.7.2
Diamond Rol! Motor Inverter

The diamond roll motor inverter (Panasonic: MBSK023CSA) is provided with the protection functions
indicated below.
If a protection function operates, a warning is given in the display unit of the operation panel.
<Protection Functions>
Alarm
Resetting
Procedure
(1 )
Monitor
Description of Protection
Corrective Action
Display
[Blinking]
[L]
When the motor output current

reaches the electronic thermal relay
tripping level and if this status continues for the timer-set length of time, the
monitor display begins blinking.
Large load
Check the diamond roll shaft if its
motion is heavy.
When the DC voltage at the converter

seetion is lowered below 200 VDC
(200 YAC specification), it is regarded
as momentary power failure and
inverter output is interrupted.
Check and adjust the power source.

If the power source is normal, check
the cables.
If the DC voltage further drops to 150

VDC, the control circuit is reset.
When the correct voltage level is
resto red after the resetting of the
control circuit, inverter operation
restarts automatically.
(2)
The inverter does not reAstart automatically if the setting for "automatic
restart prevention after power restoration" is YES".
[rp.]
Even if an operation command is

active when the power is turned on or
at the restoration from momentary
power failure, automatic restart is
prevented.
Execute the operation stop command

and then execute the operation start
command. (If operation command is
manually input.)
<Alarm resetting procedure>

(1) Warning display only
The alarm indication is turned off when the motor output current is lowered to the electronic thermal
relay operating level.
(2) Warning display and interruption of inverter output
When the voltage is restored, operation restarts automatically.
The inverter does not restart automatlcally if the setting for "automatic restart prevention after
power restoration" is "YES".
5-339
5. TROUBLESHOOTING
GM6311
Alarm
Resetting
Procedure
Monitor
Display
Description of Protection
The electronic thermal relay trips if the
converter output current exceeds the
current value set at the Inverter.
[O.C.]
Over
current
(3)
Parameter No.:
30
Braking start speed: 300 r/min
Corrective Action
Possible cause is short-circult or ground
fault of motor cable.
Disconnect the cable to the diamond roll at
the inverter and measure Insulation
resistance. If the cable is faulty, replace
the cable. If the motor is faulty, replace the
diamond roll unll.
If the insulation resistance is normal, check
the braking start speed if the set speed is
not appropriate.
[O.U.]
Interruption
due to
excessive
regenerating voltage
The electronic thermal relay trips if the DC

current of the converter exceeds 400 VDC.
Parameter No.:
31
10 sec
Deceleratlon time:
Check the para meter setting since the

deceleration time will be too short.
Inductance of the power factor improvement AC reactor Is too large. Select the
AC reactor meeting the inverter capaclty.
[Thr]
The electronic thermal relay trips if the

status In which the motor current is in
excess of the electronic thermal relay
setting value continues since such a status
is regarded as overload.
Check the diamond roll shaft if Its motion is

heavy.
The protecting device trips when the

abnormallty of the inverter controlling
microcomputer Is detected.
Shut off the power accordlng the power

shut off sequence and then turn the power
on.
Interruption
due to
overload
[Err]
CPU error
[CRU.]
Interruption
by selfdiagnosis
[O.L.]
External
forced trip
[E-0.5.]
Over-speed
protection
[E-CS.]
If the error occurs again, replace the

inverter.
The protecting device trlps when parameter
setting Is changed. This is normal
processing.
The newly set parameter data becomes

va lid when the tripped status is resel.
If the parameter setting Is so made to input

the external forced trip signal when the
terminals 15 and SG or 16 and SG are
opened, the protection device trips when
these terminals are opened.
The machine does not use this function.
The protection device trips when the

rotating speed exceeds 1.5 times the
speed set for parameter No. 75 (upper Iimit
speed) since this status is regarded as
over speed.
The machine does not use this function.
The protection device trips if an abnormality is detected in the CS signal from the
Check the CS slgnal cable for breakage.
motor.
[E.r T.]
Rotation
error
protection
When oYES" is set for parameter No. d2

(rotatlon error detection), the followlng
status is regarded as rotati0!1 error.
The motor rotates In the direction opposite
to the directlon specified by the command
and after the arrival of the set speed, it
does not stop even if the time two times
the set stop time has elapsed.
5-340
For this parameter "NO" Is sel.
111"11114
5. TROUBLESHOOTING
GM6311
<Alarm resetting procedure>
(3) When the protection device has tripped.
Click the [OP PANEL] button at the screen.
The OPERATION PANEL window opens.
Click the [FAULT RESET] button at the screen.
Press the [EXECUTE] button.
For CPU error, shut off the power and turn it back on.
5-341
i Iiii.] IJ41
5. TROUBLESHOOTING
GM6311
5.8
DiI Cooler Alarms
5.8.1
Wheel Spindle Bearing 'Lubricating OilCooler Alarms

lf an alarm occurs with the oil cooler, the alarm lamp on the oil cooler lights.
At the same time "G46D (wheel spindle bearing lubricating oil temperature controller alarm)" is displayed
at the operation panel screen.
Oil cooler
Alarm lamp
Power pilot lamp
Lamp
Status
Power pilot
lamp OFF
Cause
Power is not supplied to the oil cooler.

The fuse or the circuit protector in the
oil cooler control circuit is blown.
Negative phase protection reiay operated.
loose contact or breakage of contacts and cables
Corrective Action
Check the circuit protector in the oil

cooler power line, in the machine
control cabinet, if it has been blown.
Pump motor protection devices Ol1,

Ol3 and Ol5 operated.
The temperature of return oil is higher

than 45C.
Replace the fuse.

Turn ON the circuit protector.
Exchange the power cable connection at the terminals to change the

phase sequence.
Check and correct the cables and
terminais.
Check the lubricating oil for contaminatlon and entry of coolant. Change
the oil with the specified grade fresh
oil if necessary.
Check the bearings of the motor and

the pump for abnormal noise. If abnormal noise is observed, replace the
motor and the pump.
The oil pump motor M1 is overloaded.
Turn ON the circuit protector.
Check the fuse or the circuit protector in the oil cooler control panel.
Aiarm lamp
ON
Howto Reset
Check the temperature sensor. Replace the sensor or cable.
Press the reset button of

Ol1.
Stop the machine to allow the

oil to cool.
Cable of the temperature sensor is

broken or the sensor is faulty.
Check the lubricatlng 011 flow amount.

If the oil is contaminated, change It.
Circulating amount of lubricating oil

is insufficient.
See the protection functions explained in the next page.
Insufficient refrigerant.
The fan motor protection device
Ol21 operated.
The inverter electronic thermal relay
INV operated.
The thermal protector THP operated.
The refrigerating circuit pressure
switch GPS operated.
o'
5-342
1II111JI11
5. TROUBLESHOOTING
GM6311
The oil cooler is provided following protection functions.
1. Oil circulation circuit
a)
Ol1 (thermal relay for pump motor)

The thermal relay operates if the pump motor is overloaded due to the occurrence of alarm
with the circulation pump.
Since manual reset type relay is used, press the rest button of the thermal relay installed in
the control cabinet afier eliminating the cause of the alarm.
2. Cooling circuit
If an alarm occurs with the cooling circuit, the protection devices indicated below operate.
a)
Ol2 (thermal relay for fan motor)

The thermal relay operates when the fan motor is overloaded.
Since manual reset type relay is used, press the rest button of the thermal relay installed in
the oil cooler control cabinet afier eliminating the cause of the alarm.
b)
GPS (Refrigerating circuit pressure switch)

The pressure switch operates when the gas pressure in the refrigerating circuit is excessively
high.
Since manual reset type pressure switch is used, press the rest button aboye the pressure
switch body afier eliminating the cause of the alarm.
NOTE
c)
For the water-cooling type condenser specification machine, high- and lowpressure pressure switches are used and the pressure switch operates at
excessively high or low pressure.
INV (inverter electronic thermal relay)

The electronic thermal relay of the refrigerating compressor inverter operates when the compressor is overloaded.
The relay is automatic reset type and if the relay operates, allow the motor to cool.
d)
THP (thermal protector)

The thermal protector operates when the temperature of the refrigerating compressor dome
is excessively high.
An automatic reset type protector is used. However, resetting could sometimes take several
tens minutes.
5-343
lilft-]IJd
5. TROUBLESHOOTING
GM6311
5.9
Electric Cabinet Cooler Alarms

Code
Trouble
Temperature in the
cabinet is too high.
Compressor
Evaporator
Cause
Corrective Action
Cooling performance is low

(insufficient refrigerant).
Trouble of code 2 to code 7
Overload
(Incorporated thermal switch has
operated)
Fault (Test the operation based on
the coil resistance.)
Problem with the relay and/or
conductors
Could have frozen.
Check the cooling performance.

Contact your local Toyoda
Machine Works service .center.
The cooler will restart operation
automatically.
Insufficient amount of refrigerant
High-pressure
monitoring
External temperature is too high.

Machine Works service center.
Replace the power supply
board.
Change the temperature setting
value (increase the setting).
Temperature is outside the
operating range.
Dirty condenser
Clean.
Dirty filter mat
Clean or replace.
Faulty condenser fan
Replace.
Inactive expansion valve

Fault

Condenser fan
Failed to operate or faulty
Replace.
Evaporator fan
Failed to operate or f~ulty
Replace.
Filter monitor
Dirty filter mat
Clean or replace.
Temperature sensor
Broken wire or short-circuit
Replace.
(Instruction Manual for the Electric Cabinet Cooler)
5-344
Illitl Jl1!I
5. TROUBLESHOOTING
GM6311
5.10
Sizer Monitor
[Indication]
Top View of Sizer Amplifier
Rear
Pl1
,Monitor LEO
P10 i,"t
P11
P10
P9
P8
P7
P6
P5
P4
P3
P2
P1
Switching signal monitor SEL 1 (lit when ON)

Switching signal monitor SEL 2 (lit when ON)
A side balance monitor H
A side balance monitor M
A side balance monitor L
B side balance monitor H
B side balance monitor M
B side balance monitor L
FS monitor
Output SOURCE (open-emitter) setting monitor
Output SIN K (open-collector) setting monitor
P8
e /v PC8
21
The balance monitor indicates output signal is ON

when the LEO lights.
P1
The FS monitor indicates "device normal" when the LEO

lights.
pe
c~
P9
P4 \.,';
P3
.. ,
\.J
.-,
F'2 v
Pl
,-,
"v
. Front
Sizer amplifier
5-345
I(-nl)114
5. TROUBLESHOOTING
GM6311
5.11
Indicating Lamps on the CNC Unit
5.11.1
Power Unit (TP-2391)

The power supply circuit receives 1OOV AC from the electrical control cabinet, converts it
into OC by the OC stabilized power supply, and supplies it to the CNC unit. It also detects
the 1OOV AC power-down and DC fan error, and sends the alarm signal to the CNC unit.
AClOOV
C1 AC2
R~d-
I\.
BI~'
Yellow
-t.~').
POWER2card AC1 AC2

TP-2391
Er-
1 P12VA
"
J\J
3 OVA
5 FAL1I2
4 F.W11
CNFAN
'"'"
CNACl
172026-1 (AlIP)
r- 4 -12V
12 OY
5+12V
r-n
172026-1 (A1IP)
AC
AC
CNAC2
,...-
Ffr
4 5V
9 OV
6 5V
(IV
....
D~wer supply
K1 +X'1TK
(5V SOA)
(AIlP~
1-,.., 720?A-l
2 5V
7 OV
1\.1 T 1
CN5V
Fan motor
DC Sun-ace 25
109E1212M401
~wersup~~
OU-4(12 lA)
+l2V
AC
VI
OV
AC
Gl
FG
V2 -12V 1
G2
172026-1 (A1IP)
CNl2V
R~d.r-Ble.
Yellow
I~
I
I
1'1
",.
1"-
172026-1 CAlIP)
Terminal blo ck
M113CM-3A
4j y OV
+v -v
1\1
I'\.
I "
CNP1
POWER
Motherboard MBD11 or
TP-23780r
Motherboard MB012
TP-2424 (for S-typell rack)
IMPORTANT The 100V AC power-down error and

OC fan error signals are common
outputs. Therefore, check the color of
the LEO AC ON (green or red) on the
POWER2 card to identify which error
has occurred.
Green LEO OFFL ..... Power-down
Red LEO ON LL ........ OC fan error
5-346
5. TROUBLESHOOTING
GM6311
&
DANGER
A lethal high voltage is applied at each power terminal.

When the terminal is touched while the electrical power is applied, death
may result from the electrical shock.
Never touch these terminals while the electrical power is applied or during 5
minutes interval after the electrical power is turned OFF.
NOTE
The "5 minutes interval afier the electrical power is turned OFF" is
specified in consideration of the specifications for residual voltages in
the servo sections.
&
CAUTION
Cooling fan is installed at upper part of the rack.

If fingers are placed in the rotating fan, injuries may be caused by the rotating
fan blades.
Verify that the blades are stopped completely before starting maintenance work.
(1) Description ofthe Indicating Lamps

ACON Light:
POIER
ACON
5VON
O
+12VON
O
-12VON
O
Indlcating
lamps
O
AC 100V
input
termlnals
Grounding
terminals
AC100V
AC1
AC2
E
Lighting in green indicates that the AC 100V is supplied normally at

input terminals.
Lighting in red indicates that the DC fan at the upper part of the rack is
malfunctioning. In this instance, the CNC unit stops operating.
If the light is OFF, then it indicates that the AC 100V power line has been
interrupted. Check for the AC 100V voltage.
5VON Light:
Lighting indicates that the 5 V power output is supplied normally.
If this light is OFF while the ACON green light is ON, the 5 V power
supply is faulty.
+12VON Light:
Lighting indicates that the +12 V power output is supplied normally.
If this light is OFF while the ACON green light is ON, then the
+12 V power supply is faulty.
-12VON Light:
Lighting indicates that the -12 V power output is supplied normally.
If this light is OFF while the ACON green light is ON, then the
-12 V power supply is faulty.
5-347
iklnl]lt*'
5. TROUBLESHOOTING
GM6311
5.11.2 MCUL Unit
MCUL card (TP-2427), MCULA card (TP-2428)
The MCUL unit consists of the MCUL card and the MCULA cardo
MCUL
TBl
O RUN
The MCUL unit consists of:
+
O IPLO
O IPLl
OY
O IPL2
PG
C+)
C+)
C+)
C+)
(a) Main bus interface

(b) An operation processing module that generates the command signals
for the circuits to execute the operations in response to the system
control program
.
(c) Memory consisting of PROM, storing system control program, and
RAM
O MPG
(d) Externa I l/O interface serving as the interface between the CNC and
the data l/O devices in the main operation panel
O HALT
(e) Pulse handle and analog signal inputloutput module
O BRTOV
(f) Shared memory such as main bus RAM and the RAM backed-up by
battery
(g) Sub bus interface
O RMWER
(h) Calendar clock
O LocrO
(1) Indicating Lamps

RUNlamp
This lamp is lit while the CPU is operating correctly.
O VMETO
O SFAIL
CE3
O CLKAL
O YRMER
IPLO - IPL21amps
These lamps are lit when an interrupt request is given from a peripheral
device to the CPU.
The lamps are usually dimly lit.
MPGlamp
This lamp is lit when an input is given from the MPG.
O BA1WA
HALTlamp
This lamp is lit to indicate the error that the CPU is in the halt state.
The lamp 15 usually Not lit .
O UNVAL
O PCHER
O PWER
[DISPLAY]
BRTOVlamp
This lamp is lit to indicate the error that the bus right is not acquired
within a specified period afier the issuance of the bus request.
The lamp is usually not lit.
RMWERlamp
This lamp is lit to indicate the error that read/modify/write of bus memory
is attempted in units other than a byte width.
~-~
MCUL Card Nameplate
LOCTOlamp
This lamp is lit to indicate the error that a bus error (abnormally long data
transmission time, no response, etc.) occurred while the local bus is
used.
5-348
li-I1IJI141
5. TROUBLESHOOTING
GM6311
VMETOlamp
transmission time, no response, etc.) occurred while the main bus is
used.
SFAILlamp
eHl
This lamp is lit to indicate the error that the system operation is disabled.
CLKALlamp
This lamp is lit to indicate the error that the clock pulses are lost or the
clock frequency has changed.
VRMERlamp
This lamp is lit to indicate the error that the video RAM access is made
with a width other than the long word width.
[RS232C]
CE2
[AD, RS422]
BATWAlamp
The lamp indicates, if lit, that the battery voltage is lower than the warning level (Iower than 3.35 V). If the lamp is lit, check the battery to make
sure that it is plugged into the connector correctly. When the battery is
not plugged in correctly, it must be changed.
The pro~dure for changing the battery is explained in item (3).
UNVALlamp
[DA, MPG]
LITHIUM BAT
The lamp indicates, if Iit,that the battery voltage has dropped to the
warning level. The signal is latched.
If this lamp is lit, the data in the RAM backed up by battery might be
lost.
In this case, it is necessary to write the data again after resetting the
alarm state.
Note that an occurrence of this alarm interrupts automatic operation.
\
PCHERlamp
The RAM backed up by battery adds a parity bit to ensure correctness
of the data. If a parity error is detected, this lamp is lit.
If this lamp is lit, the data in the RAM backed up by battery might be
lost.
In this case, it is necessary to write the data again. Note that an occurrence of this alarm interrupts automatic operation.
PWERlamp
Lit to indicate the error that voltage of 12 V power supply falls outside
the allowable range.
IMPORTANT If battery voltage drops to the warning level, the low battery
voltage alarm occurs in approximately 8 days under the conditions that the environment temperature is 20C and no power is
supplied.
..
5-349
5. TROUBLESHOOTING
GM6311
5.11.3 CNUE Unit.
CNUE card (TP-2451)
eNUE
The CNUE card consists of the main bus interface and the Ethernet communication board.
(1) Indicating Lamps
RUN
ERR
TXD
RXD
RUNlamp
This lamp is lit while the CNUE is operating correctly.
ERRlamp
This lamp is lit when an error is detected in the Ethernet communication
board.
TXDlamp
This lamp is lit while data is being sent.
RXDlamp
This lamp is lit while data is being received.
CGl
[lOBASE2]
(2) Connectors
CG1 : For panel PC (For Ethernet 10 base 2: not installed)
CG2 : For panel PC (For Ethernet 10 base 5)
#
-CG2
[lOBASE5]
CNUA Card Nameplate
5-350
Iflnl]lkl
5. TROUBLESHOOTING
GM6311
5.11.4 DSUS Unit
DSUS card (TP-2441), DSUSA card (TP-2454), SERCIF card (TP-2455)
The DSUS unit eonsists of the DSUS eard and the DSUSA eard or the DSUS
eard, and the SERCIF eard.
DSUS
o RUN
O IPLO
O IPLl
O IPL2
O HALT
O STOP
O EXCEP
O BBSY
O LocrO
O BRTOV
~~ O RMWER
'""";;; O VMETO
'-'
O SFAIL
.--. O
CLKAL
SVALM
~~
~o
The DSUS unit eonsists of:

(a) Memory eonsisting of PROM, storing system control program, and
RAM
(b) Interface that exeeutes data l/O with sueh as servo amplifier
(e) Main bus interface
(d) Monitor interface that exeeutes data l/O with servo monitor
For details of the DSUSA ard, refer to the AC Servo System Maintenanee
Manual for GC32 series, and for details of the SERCANS eard in the SERCIF
eard, refer to the Applieation Manual for SERCANS.
(1) Indieating Lamps
RUNlamp
This lamp is lit while the CPU is operating eorreetly.
IPLO -IPL2lamps
These lamps are lit when an interrupt request is given from a peripheral
deviee to the CPU.
The lamps are usually dimly lit.
CNCRDY
O AON
O SVRDY
CFl
HALTlamp
This lamp is lit to indieate the error that the CPU is in the halt state.
(Double-bus fault state)
STOPlamp
This lamp is lit in the error state that the DSUS has stopped.
()
EXCEPlamp
::r:
This lamp is lit while the CPU is exeeuting an interruption proeessing.

The lamp is usually dimly lit.
BBSY lamp
Lit while the bus is used.
t-'
'-'
LOCTOlamp
[MON]
DSUS Card Nameplate
This lamp is lit to indieate the error that a bus error (abnormally long data
transmission time, no response, etc.) oeeurred while the local bus is
used.
5-351
IIlnlJII
5. TROUBLESHOOTING
GM6311
BRTOVlamp
CJ2
TB1
This lamp is lit to indicate the error that the bus right is not acquired
within a specified period after the issuance of the bus request.
RMWERlamp
[CNCRDY]
This lamp is lit to indicate the error that read/modify/write of bus memory
is attempted in units other than a byte width.
The lamp isusually not lit.
VMETOlamp
transmission time, no response, etc.) occurred while the main bus is
used.
[EX-ENC2]
CF2
[AMP IN]
CJ1
O
CF3
[AMP OUT
SFAILlamp
This lamp is lit to indicate the error that the system operation is disabled.
CLKALlamp
This lamp is lit to indicate the error that the clock pulses are lost or the
clock frequency has changed.
SVALM lamp
This lamp is lit when the servo error is detected by the DSUS cardo
[EX-ENC1]
CNCRDYlamp
This lamp is lit when the CNC gets ready and at the same time the relay
TB1 ofthe CNC is turned on. If a CNC alarm is detected, the lamp goes
off and the relay is turned off .
AONlamp
This lamp is lit when the power ON signar is output to the servo amplifier.
SVRDYlamp
This lamp is lit when the servo system is ready with the AON input and
the servo amplifier (motor) read.
5-352
1IIi11) 1141
5. TROUBLESHOOTING
GM6311
(2) Connectors
CF1 : For external monitoring device
CF2 : For receiving optical signals (not used)
CF3 : For sending optical signals (not used)
TB1 : Terminal block for CNCRDY signal
In the case of DSUSA
CH1 : For servo amplifier
CJ1 : For external encoder
CJ2 : For external encoder
In the case of SERCIF
CK1 : For receiving optical signals
CK2 : For sending optical signals
CK3 : For. RS232C
5-353
III'II]IJ4
5. TROUBLESHOOTING
GM6311
5.11.5 PLC-48 Unit
PLCIF card (TP-2479), PC3JNF-CPU card (TP-4582), PC2JNF-IO card (TP-4528)
The PLC-48 unit eonsists of the PLCIF eard, the PC3JNF-CPU eard and the
PC2JNF-10 eard.
P L C48
The PLC-48 unit eonsists of:

(a) 64 points of DC input
(b) M-Net (1 port)
CNPRG
(e) M-Net or eomputer link (1 port; seleeted by the switch)

(d) Extension 1/0 bus
(1) Indieating Lamps
POWER
D
RUN D
O
ERR D
ALM D RUN RUN
PC2MOD D A+
B+
PRG.2 D
A- BPRG.3 D
TXDA D
ERRA D
TXDB D OV OV
ERRB D OV OV
FAULT D
O
LINK
POWERlamp
This lamp is lit when 5 V is supplied to the PC3JNF-CPU eard.
It goes off if momentary power failure of 5 V power supply is deteeted.
RUNlamp
This lamp is lit while sequenee program 1 is exeeuted.
It opera tes in assoeiation with the RUN relay output.
ERRlamp
This lamp is lit when a major or minor fault oecurs.
ALM lamp
This lamp is lit when an alarm oeeurs.
PC2MODlamp
.....---...... -
---
This lamp is used for the indieation of the PC2 compatible mode and
the status of writing to memory.
If the lamp is lit, it indicates that the unit is set for the PC2 compatible
mode. If the lamp is blinking, it indieates that data is being written to
the flash memory.
PRG.21amp
This lamp is lit while sequence program 2 is exeeuted.
PRG.31amp
This lamp is lit while sequenee program 3 is exeeuted.
TXDAlamp
This lamp blinks while data is being sent from port A.
ERRAlamp
This lamp is lit if an alarm oceurs at port A.
TXDBlamp
This lamp blinks while data is being sent from port B.
ERRB lamp
This lamp is lit if an alarm oceurs at port B.
FAULTlamp
This lamp is lit if the 2-port M-NET is faulty.
5-354
NilnllId
.5. TROUBLESHOOTING
.--......... -
GM6311
(2) Switch es
RESET/START switch
X20-3F
START
RESET
O
PGID
(3) Connectors
c:=:::I
'--
l/O
BUS
\.....
CNPRG:
For writing to flash memory (not used)
PGID8:
For connecting peripheral device
1/08US:
For connecting expansion l/O cable
XOO-1 F:
For external inputs (32 points: XOO - X1 F)
X20-3F:
For external inputs (32 points: X20 - X3F)
(4) Terminal 810ck
c:=:::I
The PLC-48 is reset when the switch is set in the RESET position. When
the unit is reset, outputs and internal relays are turned OFF and the
program stops. If the switch is set into the START position with the .
program stopped, execution of the program restarts. In case a stop
code is output from an external device, however, program execution does
not restart even when the switch is set to the START position.
XOO-IF
LINK:
NOTE
Terminal block for M-netlcomputer link
The PLC-48 unit is configured on the base of the PC3JNF

(TOYOPUC PC3 series) by installing the CNC interface
PLCIF TP-2479 to it.
PC2JNF is also used as the built-in PC for other
manufacturer's NC unit. When it is used as the PLC-48 unit,
setting of internallink parameters differs from the setting
made at PC2JNF used as the built-in PC. Internallink
parameters should be set as explained in item (5) "Internal
Link Para meter Setting" below.
(5) Internal Link Para meter Setting

Since the PLC-48 unit has two communication modules as "2-port M-Net"
and "communication module with GC32CNC", setting of link parameters
is necessary.
(a) Setting for 2-port M-Net
Set "2-port M-Net" at Slot No. = O of Rack No. = O.
Set "82" for the 1/0 module type ID code.
For details, refer to the Instruction Manual for TOYOPUC PC3 Series
PC3JNF and PC3JNM.
(b) Setting for communication with GC32CNC
Set "undefined module" at Slot No. = 3 of Rack No.= O.
Set "08" for undefined module number.
Set "88" for the 1/0 module type ID code.
5-355
's. TROUBLESHOOTING
GM6311
5.12
CNC Information
5.12.1 Servo Monitor

(1) Click the [MAINTE MENU] button at the screen.
(2) Click the [eNC DATA] button at the screen.

The CNC DATA MENU screen is displayed.
(3) Click the [SERVO MONITOR] button at the

screen.
The DISPLAY SERVO MONITOR screen is displayed.
(4) Check the status of the servo system.
5-356
5. TROUBLESHOOTING
GM6311
5.12.2 Servo Information Trace Display
(2) Click the [CNC DATA] button at the screen.

(3) Click the [SERVO TRACE] button at the screen.

The DISPLAY SERVO TRACE screen is displayed.
(4) Check the tool paths of the individual axes.

To select the axis, click the [AXIS CHANGE]
button at the screen.
To display other kind of information, click ~,
[~ and 1:'] buttons at the screen.
5-357
~],
5. TROUBLESHOOTING
GM6311
5.12.3 Saving Production/Maintenance Information

(3) Set a floppy disk in the floppy disk drive.

Click the [STORE PM DATA] button at the screen.
5-358
11!ll'JI14
5. TROUBLESHOOTING
GM6311
(4) The PM DATA STORE dialog box is displayed.
Click the blank field of file names.
The key-panel window opens. Input the file name.
Example: To input TOYODA
Press the keys as [T], [O], [Y], [O], [D]
and [A].
(5) Click the [OK] button.

The data is written to the floppy disk and the
following message appears in the dialog box.
STORING"
NOTE
I To cancel the saving operation, click

the [CANCEL] button at the screen.
(6) On completion of saving, STORAGE COMPLETED" appears in the dialog box.

Click the [OK] button.
5359
lilnlJID
5. TROUBLESHOOTING
GM6311
5.12.4 Version Display
The system version of all CPUs in the CNC is displayed.
(1) Click the [MAINTE MENU] butlon at the screen.
(2) Click the [CNe DATA] butlon at the screen.

The'CNC DATA MENU screen is displayed.
(3) Click the [VERSION DISPLAY] butlon at the

screen.
The version of the CPUs is displayed.
5360
IflnlJID
5. T.ROUBLESHOOTING
GM6311
(4) Check the version.
Example of Version Display

CNC system type
01
CA3.E13
02
GM2000-4................. Machine model file
06
CC3.E1 ......... ........... DSUS system ROM
09
A_96T020
15
P07.10EE-O .............. HMI system software
16
RC8242-2 ................. Machine model information file
23
CK3.8
24
PS1.40EE
25
GMII000E0002
MCUL card system ROM
5-361
5. TROUBLESHOOTING
GM6311
5.12.5 Cycle Time History
The MAINTENANCEMENU screen is displayed.

(3) Click the [CYCLE HISTORY] button at the screen.

The cycle time history is displayed.
(4) Check the cycle time.
5-362
IllftlJltd
5. TROUBLESHOOTING
GM6311
5.13
Diagnosis Using TOYOPUC

This section describes the procedure for checking the 110 signals in the control circuit
using the GL 1 software of TOYOPUC. Discussion begins with howto read the electric
circuit diagrams and then continues to the circuit check procedure using the GL 1 software.
Please note that the circuit diagrams given below are only for reference purpose. The
electric circuit diagrams of your machine are supplied with the machine.
5.13.1 Reading the Electric Circuit Diagrams

(a)
Outline
The Grinding machines of Toyoda Machine Works are controlled by the CNC and the
TOYOPUC (programmable logic controller).
The electric circuit diagrams (Iadders) include the information on the inputs/outputs
(hardware) of the electric devices that comprise the machine and that on the sequence
programs (software).
The electric circuit diagrams are largely categorized by the devices, represented by the
device code numbers, and the information in the same category (device code number) is
broken down to the inputs (hardware), the sequence program (software), and the outputs
(hardware).
Device code 1
Inputs
Device code 1
"
(hardware)
Sequence
Device code 1
program
(software)
Output
(hardware)
Device code 2
Device code 2
Inputs
(hardware)
Sequence
Device code 2
program
(software)
Outputs
(hardware)
..
5-363
lili11]ln1
5. TROUBLESHOOTING
GM6311
(b)
Device Code Numbers and Electric Device Symbols

For all devices and coils/contacts, the corresponding symbols are given in the circuit
diagrams so that you can understand the function of the individual devices by simply
looking at the affixed symbols.
The device code numbers and the electric device symbols are described below.
I I
Device code numbers:

Device
cadeNa.
01
Cycle diagram
02
Panel PL screen
03
Alarm code table
04
Guidance codetable
05
Program number table
06
User macro table
07
M code table
08
P8Wtable
09
Register address map
MO
Power supply
M02
Operation panel pawer source section
DN1
D-NET
81
PM1
Program start
Control parameter
L1
PLC para meter + 1/0 module
M1
Comprehensive section
M1
Exchange signal
M2_1
Exchange signal
N1
CNC
N2
CNC-TOYOPUC
N3
TOYOPUC-CNC
N4
Manual pulse generator
NOTE
Device Name
The device code numbers vary according to the machine specifications. Please refer to the electric circuit diagram supplied
with your machine.
'
5-364
1I
lillllJlbt
5. TROUBLESHOOTING
GM6311
Device Code Designation
T1
I
Device Code No.

MO
Power supply
CR
J~
x
T 1
External Device Code
Serial
No.
Function Code
Motor
Emergency stop
CR
Relay
Retum
1l
110 modules
CB
Circuit breaker
Automatic or continuous
M1
lS
Limit switch
Manual
M2
Conveyor control signals
PS
Pressure switch
OFF
N1
CNC
FS
Float switch
N2
CNC-TOYOPUC
SS
Selector switch
N3
CNC-TOYOPUC
TM
limer
Workpiece confirmation
T1
Pump start
MS
Magnet switch
For automatic operation
T2
Coolant
SO
Solenoid valve
latch relay
T3
loader
Ol
Thermal relay
Fault
TOYOPUC Device Code
Work spindle
Input
Doors
Output
Table
Internal dummy
Wheelhead
Internal timer
Wheelchange
Wheel truing
CT
Internal counter
latch relay
5-365
Relays fixed during cycle

execution
Unit operation end
confirmation
None Sequence relay
c-
1i11,1] 1141
5. TROUBLESHOOTING
GM6311
Symbols
Symbol
o--o---
---D,
Selector switch
(Rotary switch)
Lo
Lo
~I
Symbol
Name
Name
~).
(NC contact)
Selector switch
~ !
,
ro I
--+Float switch
Electromagnetic switch
or relay
i
i
i
--+Pressure switch
-O-
--+ Surge
suppressor
--+Lamp
Snap switch
-O
--+lED
--O
Solenoid
(NO contact)
~
Push button switch
-O
Thermal relay (Ol)
(NC contact)
--+ Surge
suppressor
/f"'
--O
(NO contact)
----o/f"'Q
Mushroom
push button switch
(NC contact)
I
--O
$ ii
i i
--O
Blue
(NO contact)
Limit switch
ji
1 White
I
Proximity switch
5-366
--+Instantaneous contact
--+Time limit contact
(NC contact)
(NC contact)
I
Red
(NO contact)
f---
-o o- --Q.6.Q-
--O
- j f----j
Changeover push button
switch
No-fuse breaker
CBand CP
Cooling fan
1I.Fl., 1141
5. TROUBLESHOOTING
GM6311
(e)
Configuration of TOYOPUC System
CNC
PLC-48
DLNK terminal: Optional specification
(Built-in PLC)
DeviceNet
CNC <o> PLC

Intemal connectlon
by dummy
DLNK terminal 40/24

. Input
Pushbutton
switch
Output
Lamp
Output address
Input address
Y*u
X***
-,
InpuUoutput address
L***
l/O bus
DeviceNet remate l/O
master station
CPU DLNK
015
112
112
-M
IN1 OP terminal block
I Pu~hbutton I
SWItch
Output
Solenoid
IN40P terminal block
Relay
Input
Pushbutton
switch
Limit switch
Output address
Input address
Y***
X***
Input address
X***
5-367
lilil11 lld
5. TROUBLESHOOTING
GM6311
(d)
Input Circuit
Commonline
@
Card ~
[DC24V]
L24V1
~tli\'H1:~
El
number
"'DLINK T. 24/16 LOV2
Device code
Une number
EMERG-RET
Y
-""X600
TOYOPUC address
Selection switch
X601
AUTO
);~
MANUAL
fOO
HANDLE
n:/ r)v
Terminal block
MEMORY
ilti
NC MODE HANDLE
X603
NC':;-rn:/r)v
ft~iti"
X604
NC hiODE MEMORY
NC .:;- r~ti
X606
CONT I NUOUS OFF
NOT ATTACHED
rCoN6WHoS
I );~i;7,) B
M1PB4
i.
);~i;7,)
i..- _______ J
mfT ACT IVATE
M1 PB6
i..- ______
ACTIVATE
X607
mf'T
REVERSE
i!:f'T
Card Type
PLC-IN32
1**
DLNK, TERM40/24
DLNK, TERM160
DLNK-S 16/00
DLNK-S 8/8
DLNK-S 8/0
DeviceNet remote l/O unit terminal block (in operation panel)

(Input: 40 points, Output: 24 points)
32-point input terminal block of PLC unit in CNC rack in electric cabinet
Input card in l/O remote card
DeviceNet remote 110 unit installed in terminal box (16-point input type)
Extemally installed DeviceNet remote l/O unit (16-point input type)
Extemally installed DeviceNet remote l/O unit
(8-point input/8-point output type)
Extemally installed DeviceNet remote l/O unit (8-point input type)

rTOYPUC. address
X002
R 1
~Input
-
H
'--Manual mode
LSerial number
ss
M1
~Seri~ nomb"
External device code
ss: Selector switch
Device code
M1: Comprehensive section
5-368
IllnlJl'd
5. TROUBLESHOOTING
GM6311
C!I
~CIffiH6
[DC24V]
oo24V1
~I12
Card type
X183
LOV2
X~~
I
!
' ,
i
L__._. ___._____ ._J
~
Device code
TOYOPIC address
Pressure switch
11 T1 PS3 2
X184
LUBRICATION PRESSURE
X1S5
HYDRAULlC PUMP OIL

LOW POSITION FORCAST
T1 FS1
X186
HYDRAULIC PUMP OIL

LOW POSITION
T1FS2
X1S7
AIR MIST OIL LOW LEVEL
X1S8
LUBRICATION OIL LOW

POSITION
il'.'litiJ. .
Float switch
('FlbiElfF~i.y'1il
('FlbiEII:;tj ~J
11 T1 FS3 1
~.A
1- iEII:;tj ~J
r.miiEII:;tj ~J
LUBRICATION OIL LOW

POSITION FORCAST
T1FS5
T10L1
Proximity switch
Contact of external device
tF+
--t-O n-t
T10L3
(NC.)
;r"i~iEIIHN.y'1il
TOYOPUC UO card
terminal block
TR I P HYDRAUL IC PUMP
THERt,lAL RELAY
XOO9
Thermistor
iEIIJ.7f-::"-::1
ij"-o;? )1111.*
TR I P LUBR ICAT ION 01 L

PUMP THERMAL RELAY .
XOOA
ir.'~iEII ij"-o;? )1111.*
T1CR2E
XOOB
EMERGENCY STOP
.:J:*l'lI:.
Card Type
PLC-IN32

.
DeviceNet remote l/O unit installed in terminal box (16-point input type)
Externally installed DeviceNet remote l/O unit (16-point input tYpe)
Externally installed DeviceNet remote l/O unit
Externally installed DeviceNet remote l/O unit (8-point input type)
1**
DLNK, TERM40/24
DLNK, TERM160
DLNK-S 16/00
DLNK-S 8/8
DLNK-S 8/0
TOYOPUC address
X002
R 1
PS
~,~~\ ~M~~~
t
Serial number
~Se"" ",mb"
LExterna, device code
PS: Pressure switch
Device code
1: Footstock spindle center
5-369
lilnlllM
5. TROUBLESHOOTING
GM6311
(e)
Sequence ladder Diagram
--1 .H.
Coil/contact of the
same device code
Dummy coil
Coil contact of different

device code
L4~D5F
N20U72N 1.1132
T084
rommy
WHEEL HEAO COOLANT IN

~ ~ 1L,'t~IliIJ~A LJ
1.11 AE
~I~---r~--~-------------------DD~
7066
M3EE
\
01 F 7091
1.11 AA M4EB
Time-up contact
W1
Y19A
WHEEL HEAO COOLANT IN

~ ~ 1L, 't~IliIjR! ~ LJ
1410200 7 T2 90200 03F

1.1132 T084 M4A3 1.11 AE
N20U77r~
L436
,dd~,
~ ~ 1 L,f~jE~IliIJ~A LJ
ORESSER COOLANT IN
~~D~~U~--------------~
2
M,oB F
~ ~ 1 L,f~jE~WIJ~A LJ
ORESSER COOLANT IN
W1
Y19A
...:: "; ristittA LJ

BEO
N20U72N N102007T2
L430
1.1132 T084
~~~~-------------------------DD~
~~SHING
COOLANT
I~
iz :/ ~ i\~WIJ~i9titt A ~J
CENTER HOLE WASHING
COOLANT IN
7066
1.13EE
106 102P
1.1236 1.1229
OW11
1.14F3
01
021 F
1.11 BE 1.11 BO
~IliIJn*:/?
COOLANT PUMP
"'::''.J r;)t~*:/?
BEO WASHING PUMP
Coil/contact of device code

T2Dl T202 T2\V2 T2V16 T2W7 T20\'1 2D\'15
tIZDU12N
N10200
1TZ
Tl0llR
10es
1091
tl2DUHII
90200
105
10ZP
35304 33101 35308 33101 35804 35818 33102

35312
35810
:mM
35~
I~
35801
348013
wna
r-- Lis! of used contacts

Shows!ha paga and Une where
!he coills usad
. .
Example
I I
335
452
454
nevice code numbe~

1-T2: Coolant
Device code name- ~
601
381
\.
fUN
Electric circulL
dlagram No.
ON
Hardware output address

CNC <-> TOYOPUC inputloutput address
Dummy internal keep coi! address

5-370
300
Page I
I
~
FIJN[,
tollJl'.lt<
T2
UN
1
COOLANT
8/12
D"nn '~35-88647001-0
Hardware input address
Dummy counter address
""
DEVICE CODE
CONTENTS
TOYOPUC Dummy Addresses
Dummy timer address
235
lee
445
USER'S NO.
4 9 15
tolLKIRIl
TT"'-.underline: NC contact
Page Une
Page where coil is used
Coil na me
pAG[
PGE
353
liliT,n"d
5. TROUBLESHOOTING
GM6311
(f)
Inputs and Outputs of CNC and TOYOPUC

00
CNC
01
SB927
02
I
I
58927 i
011
L39F
i
!
SB923 1
04
L39E
5B926
SB926
03
021
SB923
05.
~B
-V
I
I
05
OSI
S8917
07
S8916
08
S8915
09
S8914
CNC SERVO Hl!ADY
So\IIPl.JNG
Address of
dummy coil L'-
L39S
Dummy COil::+S8916
0121/
L394"
!
I
S8915
CNC HIlADY
OH'
SB917
06
L398
S8920
S8920
i
i
013.
J.: 93
I~JC'_I
N2
OHI
10
SB914
Devlce
codeN2
NZD11
I"",,IN lWlZfI NZD5N
= lB....
NZDSN 52011 NN2Ol2N 52013 NZDI4N I12DI6Jl jNZDlBN NZDI7I NZDIBN

JIIll1
32101
1-
illliI
N2DZIN N2D22N NZDZ3 I12DUI

t"'"
18113
lliI!
18302
COIWU
47""
u. e T 10.
Dl!Vlce
ILP.CIW.
00J1III1S
HZ
o. e TI
1/35
CNC-TOYOPUC
1IlA'11m1lO.
CNC
f'lGE OOIUl1Il
cow
O'
.ZZ5""
"
00-00700001-0
APPO I NT ADDRESS CNC
r-_-...,
NtD2DO
M132
SBJ31
D1X'
L01 F
i
i
,!
AUTO MODE
Address of
dummy coil L'-
Dummy collj
~D
5BJ30
I LO
SBJ28!
I
i
MOl MODE
D4X
L01C
HANDLE MODE
D5X
5BJ27
"
L01 B
58025
Ii
L019
EFFECTIVE
POS l. MEMORY
~~--------------------~~+--O
NlD1N N3D2N NlOON
NlD4~
9217
NlD15~ NlD15~
Nlll6N N3D7N NlD8N N3D9N NlDlON NlD11N NlD13N NlDl4I

WQg
mm mm.
D7X
lR3A
lA
lR1H
~,~
49
lit<J.Wo UJJJJ
OONTENTS
5-371
CNC RESET
N3-
1/34
TOYOPUC-CNC
PiGE
116
5. TROUBLESHOOTING
GM6311
(g)
Output Circuit
IV
(De 24V)
LOV2
L24Vl
f'
Lamp~
Card type
MAIN~
Une number
DLIRK T.
!!~16
./
.~
MIPL2
-@o
Y618
Y618
~'=':-"------------------------
..,
RUNNING
15016
HIPL3
-R
E5P
Y619
..,
Y619
ABNORMAL
12809
E24V5
V
(DC24V)
Magos!
"""'~
LO~ 3
CONT.BOX
011
..,
15
Y065
TlMSl
Y065
55616
Relay
016
.., .i
YO~8
3,2702
T10LI
...,.9-
HYDRAULIC PUMP ON
T1SKMSI
~TlCRIE
YOS8
"
"
MASTER CONDITION
TlRECCRIE
Terminal block
Card Type
IN40P
1**
DLNK, TERM40/24
DLNK-S 00/16
DLNK-S 8/8
DLNK-S 0/8
Externally installed DeviceNet remote l/O unit (16-point output type)
(8-point inputl8-point output type)
TOYOPUC address
Y002
T1
CR
Device code
T1: Pump 5tart
5-372
~serial
Ext~rnal
number
device code
CR. Relay
lili11]lld
5. TROUBLESHOOTING
GM6311
5.13.2 Control by CNC and TOYOPUC
(a)
NC Mode
The NC control provides the three modes - the automatic mode in which an NC program
is executed, the handle (manual pulse gEmerator) mode in which an axis is moved by
turning the manual pulse handle, and the MOl mode in which the data is altered.
The NC mode is selected by the mode select switch on the operation panel; the mode
selection signal is sent to the CNC through the TOYOPUC (PLC card) and the NC
mode is changed according to the selection made by the NC mode selection switch.
* For changing the data, two signals (MOl mode signal and program protect OFF
signal) are necessary.
L01F
NC Mode
Automatic moda- N301 N - - ON: Automatic mode valid

L01E
MOl mode - - - N302N - - ON: MOl mode valid

L01D
Jog mode - - - N303N - - ON: Jog mode valid

(Not provided)
L01C
Handle mode - - N304N - - ON: Handle mode valid

L1FE
Program protect
CNC
N30482N
OFF: Program protect OFF *
r------...,
NtD200
M132
'
SE03t
I
.
01X
L01F
!I
I
AUTO MODE
D2J(
SE030
L01E
S8028
D4X
L01C
O
O
D5X
S8027
L01B
S8025
L019
O
D7X
I
iI
i
i
i
i
i
MDI MODE
HANDLE MODE
EFFECTlVE
POS!. MEIlORY
I
i
CNe RESET
TOYOPUC-CNC
5-373
116
lilil'JIJa
5. TROUBLESHOOTING
GM6311
(b)
Starting an NC. Cycle

An NC cycle starts when both the cycle start signal and the start NC program No. signal
are input to the CNC. It ends when the end of program (M02) signal is sent from the CNC
to the TOYOPUC.
Cycle start signal _ _ _---1
...
........" I
L -_ _ _ __
Program No.
End of program
For a start NC program number, program numbers from No. 1 to No. 64 are provided; for
details of starting of the individual start NC programs, refer to the program number list in
the electric circuit diagrams.
The start NC program number is sent to the eNC by the function instruction of the
TOYOPUC.
The FUN instruction is
executed when this
contact goes ON.
I~:t-----I
I
FUN105
MOVR 10d-+M70LI------i
I
Transmission destination address

M70 means M700
L: Lower-digit byte (M700 - M707)
H: Upper-digit byte (M708 - M70F)
Data type
d: Decimal
The function instruction FUN1 05 sends the decimal data to the designated address in
the BCD codeo
The function instruction indicated above sends the decimal data "10" to the lower-digit
byte of address M700 in the BCD codeo
1B
M700 (upper-digit byte)
Address
;.....---Transmission area
1.1007; 1.1000
1.1000
lo
Binary code
11
:3
1B
32
64
5-374
O; O
120
MOOF
O
- - -.... 2+8=10
5. TROUBLESHOOTING
GM6311
Program No. 10
M1 related eireuit
D35G
MOso
'4
/,n_
MIOS
10d
[MOVR
""
pc~~nRN
rl
D300
I
I
EIl70S
.:'~
D307
EIl700
BID302
E!l05
SB415
SB414
SB413
.:'~
RID3lJ3
SB412
!!!Z04
20~
IID3D4
Ii
!
DAII
L19F
-O
DA2R
LIS!
~!OI
SB409
~f07
91D301
SB409
1'lI700
;:'08
DA3R
L19D
DA4R
L19C
L19A
SB41 O
81D306
-O
DA5ll
,;,~
OFF
TR&1IsnJt
OFF
U1IT & START

1016 FlJIICTIOI
TR&1ISFI!R
OFF
U1IT & START

10 8 I'IJICTIOI
TR&1IsnJt
U1IT & START

1041'1J1CTIOI
EJ
TR&1IsnJt
OFF
U1IT .l START
10 2 I'IJICTIOI
TR&1IsnJt
U1IT & START

1011'1JICTIOI
TR&1IsnJt
EJ
OFF
CNC
E!!02
~~s
IID306
1I
DA5ll
SB411
E1!~03
TR&1IsnJt
UIIT .& START

1032 FlJIICTIOI
_ _ _ _-----J
APPOINT ADDRESS
,/
D306
ElI702
BID231
!!!Z06
D304
D306
D303
I
_
EIl70'
EIl701
OFF
U1IT & START

10 64 FlJIICTIOI
D302
N3 seeton eircult
I1D301
TR&1IsnJt
D301
EIl706
EIl70S
Slnca NC program
s1art number is up 10
"64",0300 (128) Is
nolused.
tO~1
sr
OIIT & START

10128
FlJIICTIOI
EIl707
~
U!F
eNe CICLE
ONIT A AlU SIGNA!.
-'-
NC related eireuit
M70L
I
I
I
I
DA7R
L;2.9
"U
DA8N
L198
I
II
UIIT .l
START SIGNAL
UNIT &
START SIGNAL
NO. 64
OFF
lINIT &
START SIGNAL
OFF
lINIT &
START SIGNA!.
NO. 16
OFF
lINIT &
START SIGNAL
NO. 8
lINIT&
START SIGNA!.
NO. 4
OFF
001 A
SIART SIGNAL
NO. 2
UNIT A
START SIGNA!.
NO. 1
OFF
(1).32
,I
Program # corresponding 10 Slart slgnal
Parameter
Unit
O Number
MI301
9001
MI302
9002
MI303
9003
MI304
9004
MI305
--
MI306
9006
MI307
9007
MI308
9008
MI309
9009
MI310
901~
A,B,C
A
B
e
A
IV
/
A
A
A
Name
Use
O
Main return
Sub return
Lower 2 digits of O number agree with the

FUNCTION transmission number.
If FUNCTlON transmission No. is "10,
program 9010 starts.
Wheel change position return
o
o
o
Sizer special cycle
5-375
Re-grinding cycle
Grinding cycle
liliTill l,*,
5. TROUBLESHOOTING
GM6311
Example: Starting continuous (full-automatic) cycle
A continuous (full-automatic) cycle means a grinding cycle including automatic workpiece
loading/unloading by a loading/unloading device.
Basic time chart of full-automatic cycle
Loader operation
(Ioading/unloading)
MIDIG
Full-automatic
cycle command
Operation of door,
footstock center, etc.
MID3G
Full-automatic
cycle start
MID33G
NC cycle start
command
N3D2N
-N3D8N
NC program No.
__________________
MO 2
Program end
1!21R4X
D89X
XOO
11059
~---llll--i
DIA
11019
T2TS
TOO5
T2TS
'lKl
TOO5
~rl~
DooX
K024
1I05A
____________________
D99X
11061
D3P
11074
T1I\1
xom
AUTO
----Q~~I---lI--I!--D
1-1
D99X
11061
D5G
DSG
11061
11063
DIIG
11098
DI3G
11088
AUTO CYCLE
~~r-~--~~~~--------------~
D1G
Tn
D3
1I07A
T021
1I07C
RUN COND!.
AUTO CYCLE
~Ir----------------------------
D3G
11070
111
K024
N1D199 &ID200 D20P
11131
D38G
D25G
T1DIJI
D33G
11132 11079 111 OE II08E
NIDA2X
IIOSC
111 AO
liOSO
r------,.-:IIfIF-r---illl:.....,.. ..... I-r-IIIJ.~-#--r-I 1-1---Oll------f

D5G
11081
NC CYCLE ON
DlP
1107
DIIG
11098
D33G
D28G
liOSO
IIOSC
D35\l
r---------r-~Ir---------------------
I--------II~
NC program No.
I~=
----------------------------(lIOVI
1-1
5-376
1011105
110d
IITOL
DNIT A
NC CYCLE
SELECT SIGNAL
~Il~------
li-n-JIM
5. TROUBLESHOOTING
GM6311
Example: Starting automatic cycle
An automatic cycle means a grinding cycle including manual workpiece loading/unloading
by a loading/unloading device.
An automatic cycle starts in response to the pressing of the START button by an operatoro
'
Basic time chart of automatic cycle
Pressing of START ~
button by an operator
\
M 1D 5 G
Operation of door,
i--+.-------.--+_....
Automatic cycle
start
1-----'
I
N3D2N
......N3D8N
NC program No.
MO 2
Program end
D2A
MID33G
NC cycle start
command
1101 A
NC cycle operatlon
!l2DIP
114D5
D97X
D3G
DSG
DllG
DI3G
D5
1I05F
11070
IIOS3
11088
11088
l/OSO
~~~~-~~~~~------~
SINGlE CYCl..E
RUN CONOI.
Condition for automatic

operation
.........
D5
"Ao. l/OSO
TlRI
xom
~------------,---------------------~I~
SiNGlE CYCLE
D5G
1/081
-..;r+-,,...----r---i 11-------'
PIIlDlX
Dooot
-o
DIOG
DIDC
1/084 1/085
D3G
070
7KI
K024
NID199 NID200 020P
1/131
NIDA2X D36G
1/132 1/079 l/lOE
IIOSE
D25G
TlDIU
D33G
I/OSC
111 AO
l/OSO
r------.~~~~~~h~~~*-~~I--------~D~------~
D6G
1/081
D4P
NC CiCLE ON
D37G
1107
1/08F
D33G
D25G
l/OSO
I/OSC
D36G
1--------r--l~I-----------~
__
--_II~
NI DIiI02A N2DA9N
11000
r~~6G-----------------[KOVR
\ FON 105
'IOd
1170L
DNIT A
Ne CiCLE
SELECT SICNAL
5-377
Ikllll]I'*,
5. tROUBLESHOOTING
GM6311
Example: Starting manual grinding cycle
....... .......y I'--------
7D13
Grinding cycle start signal
..,
N3DA2N
""--Na DAS r~
ProgramNo.
Program end (M02)
Signals of manual operation buttons displayed on the touch-panel screen are sent to the
TOYOPUC via the CNC.
APPOINT ADDRESS
CNC
Dn4N
L529
SI SIGNAL 10-L74
SB1321
Dn5N
L52A
Si SIGNAL ll-L75
5B1322
i
1
i1
Dn6lil
L528
SB1323
DrnR
Si SIGNAL 12-L76
!
I
L52C
581324
i1
5B1325
5B1326
IIIDII.8/
R2DrnR
L52C
M020
Si SIGNAL 15-L79
Si SIGNAL 16-L80
Manual mode
DI
M3CA
1I1D2H
M01C
D3
M3CC
DI5
M3D4
D7
TlDII1
M3Dl
DI3
MIAO
M3D3
DO ~ r-rD--lI--r--N---.-.....J 1-1--0111------<
nl~bl 19~W
D13
R2DA6liI
~A
DI3
GRINOING CYCLE
PB ON
M3H5 - ~
~oo
Wheelhead traverse condition
D7
M3D3
JfU
Si SIGNAL 14-L78
L._._._.J
581327
Si SIGNAL 13-L77
M3Dl
GR I NO I Na CYCLE
<NOT OFF AT SBIO
I1
112DA8B
DI5
L518
M3D4
O~I-I_ - - - J
NC program No.
I~~I-------------------~[MO~
M.:f~
'"
~
5-378
2~
FUNl 05
~7~
-1
-' GR I NO I NG CYCLE
UNIT A SELEC~.SIGNAL
liflIJIJ!J
5. TROUBLESHOOTING
GM6311
(e)
Sequenee Alarm
Among alarms, those of G400's are detected by the sequence of the TOYOPUC and
the alarm message of the detected alarm is displayed on the screen.
There are two kinds of sequence alarms such as standard alarms and option alarms.
Sequence alarm
Standard alarm: Max. 24 kinds

(24 alarm signals input from the port)
Option alarm:
Max. 74 kinds (sent bythe BCD code)
G4**
' - - - - ( 00 - FF )
";.
Alarm indication (1 - 24: Standard Input port)

A1arm No.
I
Devlce code used In alarm detection circuit
ERROR
USEOR
NOUSE
CODE Nej.
COILNq.
ERROR MESSAGE
G4001 'PLC COMMUNICATION FAULT

O
.1L 10111':/ RECTIFY, RESET WITH RESET PB IN CONTROL PANEL
"'. e:;: G401 ... PLC BATTERY FAULT (BATTERY ER6VC56 WITH
O,
CONNECTOR)
M1D14X RESUME TEMP. OP. BY PRESSING CONFIRM. SWITCH.
CYCLE TIME OVER
G402
GRINDING CYCLE TIME EXCEEDED PRESET TIMEI
O
'M1D25F IN MANUAL MODE CHECK EQUIPMENT OPERATION.
CONDITIONS FOR CYCLE START NOT SATISFIED
, ... ,,~',;! , G403
ItEQUIPMENT POS, CONFIRMED DEVICE)
O
M1066F CHECK RECTIFY PRESS FAULT RESET PB,
I
L-
eif.,,
ERROR
USEOR
NOUSE
CODE NO
PC
ERROR MESSAGE
COILNO.
G419
N4D1F
HANDLE AXIS SELECTOR SWITCH FAULT

CHECK OPERATION PRESS FAULT RESET PB.
G41A
WHEEL HEAD OVER TRAUEL

CHECK WHEEL HEAD POSITION (NILSIX)
G41C
Blank column: Can be used for machlne-speclfic alarms
, - I_ _ _
~)
NO.
G41B
An alarm related to the

machine: symbol O
No No .. An alarm expressed by Hex. code
ENTRY
G41 C: Input to CNC by Hex. code
5-379
1liT,lll'!'
5. TROUBLESHOOTING
GM6311
(1)
Standard Alarms
An alarm detected by the TOYOPUC isinput to one of 24 alarm ports in the
CNC, and the corresponding alarm code is selected in the alarm table to be
Alarm port Nos. 17 to 24 are used for troubleshooting of optional devices.
Alarm port
L1DF
Alarm No. 1
N3D449N
Alarm No. 11
Alarm NO.12
N3D459N L1D4
N3D460N
Alarm No. 24
N3D472N
L1D5
L1C8
ERROR CODE NO.

USE ORt-------I
NOUSE
COIL NO.
G400
1L1D1F
NO.
PLC COMMUNICATlON FAULT

CTlFY,RESETWITH RESETPB IN CONTROL PANEL
A1arm number
Alerm lable.No. (fixed)
(Port ellocation)
eNe
Contact of device code

; 1L1D1F in alarm detecMbLf~IP tion circuit
r'--'-O'A-LI'N-'l
,
8B479
M~~l,41
8B478
i.. ""''
Ml8A
PC
ENTRY
ERROR MESSAGE
Ml26
8B473
LIDF
L1~N
~,
LID9
~Or-------~~--~--O
OALI6N
LlDO
TI_
Ml8D
t--iIIr-------~~-~---~i-~
oO'
'1
~iO~~~TlON
G400
PLC CMMUNICATION
ERR~'~'_'_"'__' __"""" __I
G401
l...-.. _
iI
ili~A~ERY FAULT I.~. . . ~~~~~~~~_~AU'~~'_""'I
I
I
-1- --_.--.-...-._._-.
,G420
ALARM 7
LOW AIR PRESSURE
i7
G420
i-
L__.J
I
I
LOW AIR PRESSURE
r! ----------1'
------lI
...!... -..
,I,
G42D
ALARM 16
OILMIST
LUBRICATlON
LOW OIL LEVEL
l~.~. ~~!~~~r t~;:~~:J
---------_-_-__-__--I
I
r
Alarm part Nos. 17 to 24 are used
with program 3 for troubleshooting.
L_.__.___.__.__._._.___.__.______J
T1 section circuit
XI
XOOD
1121
Xl83
13P
T03B
TMR
13F
T03B
o
RI
XOOD
RIX
XOOC
D3P
MI8A
AIR'PRE8SURE DOWN
K=20
D3P
MI8A
AIR PRESSURE DOWN
5-380
IIInlJlt4
5. TROUBLESHOOTING
GM6311
(2)
Option Alarms
If an alarm is detected by the TOYOPUC, its alarm code ("**" of "G4**") is
input to the CNC in the BCD code using the function instruction.
ERROR CODE NO.

USE O R I - - - - - j
NOUSE COll NO.
PC
ENTRY
NO.
ERROR MESSAGE
G400 PLC COMMUNICATION FAULT

1l1D1F
CTIFY RESET WITH RESET PB IN CONTROL PANEL
AIarm number
CNe

: 1 L1D1 F in aiarm deteclLIDlf
rIon clrcul
. 't
1017
S8479
r--'-DALl
n
'-l
LIDF
r-~iio~G4N~gATlON L
Ii ALARM 2
12
PLC BATTERY FAULT
.
D I O
!
DAL2N
1I1D141
Alarm tabla No. (fixed)

(Por! allocation)
M037
S8478
LlDE
~~------------------~----~---{
'1
TID3F
NID1l2
DAL7R
M126
SB473
LID9
!I----llD--------"~-+----.,O
M18A
11
ALARM 1
PLC CMMUNICATION
1,
E~~~~_ _ _.__.____
-r ------------------------1I
G401
G400
--t.
ALARM 7
LOW AIR PRESSURE
G420
ALARM 16
OILMIST
LUBRICATION
LOW OIL LEVEL
i7
G401
PLC BATTERY FAULT
------.--------j
G420
LOW AIR PRESSURE
1 -------------------1
~ g:[~-;; w~~TI;1
l___ L~~~____I
_._-----------_._---------,
[L._______________________________
tor
J
_
Alarm port Nos. 17 to 24 are used
with program 3
troubleshooting.
T1 section circuit
RI
XOOD
T3f
T03B
RU
XOOC
R2!
T3F
X183
T03B
TMR
AIR PRESSURE DOWN
K=20
D3f
RI
M18A
XOOD
AIR PRESSURE DOWN

D3F
MI8A
Function instruction FUN100 transmits the hexadecimal constant number data to the
designated address. The function instruction aboye sends hexadecimal "S" to the lowerdigit word of address L1CO.
18
L1CO (upper-digitword)
Address
L1CO
1
L1C7 L1CS
O
18
32
O O
L1CFF
O
lit-
05
Hexadecimal code
84 128
5-381
loo
5. TROUBLESHOOTING
GM6311
D5F
MI8C
-----1[="
1-1
F1llI576
LICL
FUB100
Oh
]{KOV
22h
LICL
1I no alarm signal is glven to address l1 Cl when D5F is turned on, alarm No. 22 is lransmltted for alarm indlcation.
D5F
__ ~
FUJ576
MISC
f--N----.--1 eH
LlCL
ruW10D
J9WV
22h
Oh
L1CL
11 alarm slgnal22 is glven to address l1 Cl when D5F Is turned off, alarm No. OIs lransmltted to claar!he alarm.
CNC
pc-pANCTION
.
LUBRICATION OIL
PRESSURE FAULT
FAULT CLEAR
APPOINT ADDRESS
TRANSFER
Bit pattern for alarm number 22 (code G422)
i
58466
ALARM CODE OFF

FADLT
NOn
Mil
..
LICL
ro..,
128
58454
DAL33N
LlC5
58463
DAL34N
ALARM CODE OFF

32
DALJ6N
ALARM CODE
16
LlC4
58462
ALARM CODE OFF

64
ION I
UC3
58461
ALARM CODE OFF

8
58460
DALJ7N
LICl
58449
ALARM CODE
4
ALARM CODE
DALJ8N
ION I
ION I
UCO
58448
ALARM CODE OFF

1
5382
ALARM NO.
22
ALARMCODE
G422
I ilt11] 1M
5. TROUBLESHOOTING
GM6311
(d)
Axis Movements by Pulse Handle

After selecting the handle mode and the axis to be moved, turn the pulse handle to input
the c,?mmand pulses into the CNC, and the selected axis moves.
L01C
N3D4N
Handlemode
LODB
----1
Axis selection
N3D97N to N3D208N
LODO
----1
Command pulses
output from pulse
generator
A-phase
LJ
B-phase
Moving the X-axis

IUD1ND
M02E1
D
N4 T2]
T037
APPOIlfT ADDRESS
N1D200
M1 32
58030
N1D200
M1 32
58029
CNC
r-_o---_'
I
L01 ~
i
O
II
D3N
L01 O
JOG MODE
r-~co~----~~r--------------------------------i~~()
N4T2H
T03E1
o
N1D200
M132
58028
D4N
L01C
HANDLE MODE -----t::":-"" .___ .J

APPOIlfT ADDRliSS
N4DXl
M1E15
U~-----------------------------------+!~O
I
i
D192N
M1 6C
58218
i
LODA
U~------------------------------------~j----()
N4DZl
D193N
M168
S8211
LOD9
D~--------------------------------~~O
N4DA1
D194N
M160
S8216
LOD8
D~--------------------------------~~O
N4DBl
i
i
i
I
I
i
i
i
i
D195N
M167
58216
LOD7
58214
LOD6
AXIS SELECT
Z
AXIS SELECT
A
AXIS SELECT
n~--------------------------------~--O
N4DZ2
AXIS SELECT
D195N
M166
AXIS SELECT
D~--------------------------------~-O
N4DCl
HANDLE MODE
1 AXIS SELECT
AXIS SELECT X~ ....:~.:.._

D191N
58219
I
LODB
N4Dn
MOl MODE
D202N
M798
5B208
LODO
Dr---------------------------------r--O
L._._._'.J
5-383
AXIS SELECT
O-DnIM
5. TROUBLESHOOTING
GM6311
5.13.3 Checking the Circuit Using Hellowin
[MANUAL] position:
(2) Place the [NC MODE] switch in the [MDI] position.

(4) Click the [WINDOWS] button at the screen.

The MAl: WINDOWS MENUscreen is displayed.
(5) After clicking the upper left area of the screen,

click the [WINDOWS] button.
Characters "WINDOWS" change from gray to
black.
Click

The message of "ARE YOU SURE TO QUIT HMI?".
is displayed.
.
Click the [YES] button.
The HMI ends and the WINDOWS screen is
displayed.
5-384
'.
I i.r(l] 1M
5. TROUBLESHOOTING
GM6311
(7) Double click the Hellowin icon.
r'
The Hellowin starts and a new screen opens.
(8) Click [Setup] - [Setup Communication Module] at

the menu bar.
(9) The dialog box opens.

Select [Ethernet (Link)] for [Module].
5-385
1IIDIJI!
5. TROUBLESHOOTING
GM6311
(10)At the menu bar, click [PC] - [Read Datas] [AH Program + Parameter].
(11)The dialog box displays uProgram will read from

PC".
Click [Ves].
The read indicator is displayed and reading of the
programs/parameters starts.
(12)The dialog box showing the result of program

check opens.
Click the [Close] butlon at the screen.
'
(13)At the menu bar, click [DISPLAY] - [SEARCH].

The SEARCH dialog box opens.
'
5-386
Ul l]l}41
5. TROUBLESHOOTING
GM6311
(14)Select the circuit to be searched foro
Example: Coil of address M657
Click the check box of "coil".
A check mark is set in the check box.
Input "M657".
Click the [Next] button.
(15)Coil M657 is displayed.
(16)At the menu bar, click [Monitor] - [Start PCMonitor].
(17)The current status is displayed.
5-387
illtllJltt
5. TROUBLESHOOTING
GM6311
CR
T1
I
Device Code No.
MO
Power supply
)1'
T t
I
External Device Code
Serial
No.
Function Code
Motor
Emergency stop
CR
Relay
Retum
1l
1/0 modules
CS
Circuit breaker
Automatic or continuous
M1
lS
Limit switch
Manual
M2
Conveyor control signals
PS
Pressure switch
OFF
N1
CNC
FS
Float switch
N2
CNC-TOYOPUC
SS
Selector switch
N3
CNC-TOYOPUC
TM
limer
Workpiece confirmation
T1
Pump start
MS
Magnet switch
For automatic operation
T2
Coolant
SO
Solenoid valve
Latch relay
T3
loader
Ol
Thermal relay
Fault
TOYOPUC Device Code
Work spindle
Input
Doors
Output
Table
Internal dummy
Wheelhead
Internal timer
Wheelchange
Wheel truing
CT
Internal counter
latch relay
5-388
Relays fixed during cycle

execution
Unit operation end
confirmation
None Sequence relay
1""eJ-Id
5. TROUBLESHOOTING
GM6311
Symbols
Symbol
o--
--O"
..... 0 - -
Selector switch
(Rotary switch)
Lof--fH$-+--
---o--J
Symbol
Name
i
"11"j~
----,..r- --U~!-fi+~I
Name
----o-ro--
-Pressure switch
~t)
-Float switch
(NC contact)
Electromagnetic switch
or relay
Selector switch
--o
Surge
suppressor
-lamp
Snap switch
-lEO
I
--o.Q""-'---o5---(NO contact)
--O
Solenoid
Push button switch
--o -
(NC contact)
--o
Surge
suppressor
(NO contact)
~--:J:"Q
Mushroom
Thermal relay (Ol)
push button switch
(NC contact)
--o:O-LICO>-4.~~I
I
--o
j ~
! ~
Changeover push button

switch
-1 1- -1 1-A-
-OO-~
(NO contact)
-Instantaneous contact
-Time Iimit contact
(NC contact)
--o~1===Bd~-(NO contact)
No-fuse breaker
CBand CP
Limit switch
-:-P2::=;;:;9:q~-:-:(Nt contact)
Blue
0
11--'---.1
White
l
Red
Proximity switch
----<@\---
5-389
Cooling fan
111),1]11
5. TROUBLESHOOTING
GM6311
(e)
Configuration of TOYOPUC System
CNC
PLC-48
.DLNK terminal: Optional specification
(Built-in PLC)
.DeviceNet
CNC <-> PLC

Internal connection
by dummy
DLNK terminal 40/24

. Input
Pushbutton
switch
Output
Lamp
Output address
Input address
Y***
X***
InpuUoutput address
l/O bus
DeviceNet remote l/O
master station
CPU DLNK
-M
015
112
112
I Pu~hbutton I
SWItch
Output
Input
Solenoid
Pushbutton
switch
Relay
Limlt switch
Output address
Input address
Y***
X***
Input address
X***
5-390
iklnl]I!41
5. TROUBLESHOOTING
GM6311
(d)
Input Circuit
Commonline
G.l
L24V1
[DC24V]
e ,-/ number
~t!\!l1'F~
Card type
"'DLINK T. 24/16 LOV2
Device code
Line number
EMERG-RET
--X600
M1PB1
TOYOPUC address
Selection switch
X601
AUTO
~~
MANUAL
:100
HANDLE
l':/
r)v
Terminal block
MEMORY
i!1I!z;
X603
NC MODE HANDLE
X604
NC MODE MEMORY
NC ~- rjlfi
X606
CONT I NUOUS OFF
NC~-
M1 PB4
r J':/ r)v
~~i;1.)
IL _____ -1'
~fi'
ACT IVATE
ACTIVATE
X607
~f'i'
1.11PB5
t-t f-'lt.f_~_LA..!l,ACHED
,
REVERSE
~t'i'w'
REVERSE
L______ Ji
,
i%f'i'
M1 PB6
Card Type
PLC-IN32

(Input: 40 points, Outpt: 24 points)
Externally installedDeviceNet remote l/O unit (8-point input type)
. 1**
DLNK, TERM40/24
DLNK, TERM160
DLNK-S 16/00
DLNK-S 8/8
DLNK-S8/0
rTOYOPUC address
X002
R 1
t .. ~
H
'---Manual """,
Serial number
ss
M1
3
LSerial number
SS: Selector switch
Device code
M1: Comprehensive section
5-391
..
lifi111k'
5. TROUBLESHOOTING
GM6311
[DC24V]
Thermistor
T1~R2E
t----I"
Card Type
PLC-IN32
1**
DLNK, TERM40/24

Externally installed DeviceNet remote 110 unit (8-point input type)
DLNK, TERM160
DLNK-S 16/00
DLNK-S 8/8
DLNK-S 8/0
TOYOPUC address
X002
R 1
~,"~\ ~
t
PS
\
Monu.lmod,
Serial number
~Seri""U_
LExtemal device code
PS: Pressure switch
Device code
1: Footstock spindle center
5-392
I Ili11] 1'4
5. TROUBLESHOOTING
GM6311
(e)
Sequence ladder Diagram
--t r1t
Coil/contact of the
same device code
Dummy coil
Coil contact of different

device code
L4~D"
N2DU72N hl132
T084
M1 AE
t--il~--~~~~--------------------~I~~
7D65
M3EE
D,mmy
,<Id..,.
WHEEL HEAD COOLANT IN

t ~ , L- tNJfn'llmJ\ LJ
\
D1 F 7D91
h11 AA h14EB
Time-up contact
W1
Y19A
D1
M1BE
WHEEL HEAD COOLANT Ir~

t~'L-iNJfnll;m
N2DU77N N1 D200 7 T2 9D2OO D3F

L435
M132 T084 M4A3 M1 AE
;!LJ
t ~'L-~:iE~nlllmJ\ LJ
DRESSER COOLANT IN
~1I~~~D~~l~l------------,----~
t ~ 1L-~:iE~n'llmJ\ LJ
DRESSER COOLANT IN
W1
Y19A
...:: ':J r;st;~J\
LJ
BED WASHING COOLANT
N2DU72N N1D200 7T2

L430
M132 T084
I~
1z::" $1 j\~nlllm;st;~ J\ ':.l

CENTER HOLE WASHING
COOLANT IN
7D65
M3EE
1D5 1D2P
M236 M229
D1
D21 F
M1BE M1BO
~n'm1i*:/ -:J
COOLANT PUMP
11 D11 M
D5F D22F
h11 AE M1 B1
M1 A5
...:: ':J r;'st~*::"-:J
BED WASHING PUMP
35304
35312
lii
35~1
3530e 33101 35e04 35 el e 33102

35el0
:!llQ!
353,\
34lIoa
WlQ9.
Shows!he page and line where

lhe con is usad
ExampIe
I I
452
41>1 . nevice code numbe~

1-T2: Colant
Device code name'\
~
:w.
rt-"
11'-'"
Electric circult.
diagram No.
Hardware input address

Hardware output address
CNC <-> TOYOPUC inputloutput address
Dummy timer address
Dummy counter address
Dummy internal keep coil address
5-393
FllNG
l1N
T2
/ 8/12
COOLANT
I
D~n~35-88647001-0
TOYOPUC Dummy Addresses
X***
" Piii
DEV ICE croE

CONlBiTS
Page -
3fEl
USER'S NO.
~Underline: NC contac!
335
1%),,-
4 o 1 5
235
lea
1445
II1.!P
Page Une
Tl0ll~
10e;
mel
N20U11tl
e0200
105
l' LIst of usad contacls
tl20U12tI
Nl0200
H2
T201 T202 T2W2 T2W6 T2W7 T20Wl 20"15
Page where coil is used
Coi! name
I
tmi
PGE
353
lilrll]IJ!'
5. TROUBLESHOOTING
GM6311
(f)
Inputs and Outputs of CNC and TOYOPUC

00
...........,
,
.----;-l
CNC
01
S6927
02
03
SB926
04
S8923
sam
I
L39
5l12li1
L39
S89Z0
06
S8917
07
S6916
08
S6915
09
58914
SUZll
SUZII
CNe SI!HYO Rl!ADY
...
05
CNe RI!ADY
L39B
SAIlPLING
L398
al
.,
Address of
dummy coi! LOOO
11
L395
SUJ1
Dummy coa;:t-.. "

SUl6
L394
.,
.,.. i
31
SUIS
SUl41
~
~
LJ
10
1120'"
Devil:e
codeN2
I12DI" liZDZN NllD5N NllD5N NllOIIN iDI2N NllDI38 ml4N pzOI5N ..",,18N NllOI7ft NllOIBN
= e
18101
32101
""1'1
mm
18113
lliIt
U1302
NZDZIN I12D22N NllD23N NllD24

USOS
COll.'ID
"P.G IQ.
47B04
1"
o. e TI
OOIIJlAB
O'
OBYIQIOXIDlI
COItl!lI1S
""HZ
T ) O'
CNC-TOYOPUC
OUWJIICIIO.
CNC
P 11.
1/35
""
""
225
00- 0070000 1-0
r-------,
N1D200
M132
SBl31
D1X
L01 F
i
i
Dummy coil
~D
SBl28
i,
!I
i
SBl27
511126
Ii
i
L01E
O
D4X
L01C
D5X
L01 B
D7X
L01 9
!ID.l!&
12
Address of
dummy coi! LOOO
II
i
i
MOl MODE
'1
i
i
Ii
i
HANOLE MOOE
EFFECTlVE
POSi. MEMORY
'1
1=
-'~----------!I
9217
AUTO tlODE .
SBl30 1
!1
CNC RESET
,WQl
lN4TfH
'4911
~o:
N3P15~ N3P15~
tm'S 1IlJ.
5-394
IIJ~V.L;~ WIJJ
N3
1/34
I UUN1I:Nl~ TOYOPUC-CNC
PAGI
PAGE
116
I k-R-] 1M
5. TROUBLESHOOTING
GM6311
(9)
Output Circuit
(DC24V)
LOV2
MAIN
L24Vl
Lamp~
Card type
Une number
DLIJIlt T.24/16
./
~
n~
Y618 Y618
-@o-j H I l - ' - " - ' ' ' ' - - - - - - - - - - - - - - - - - - - - - - - i O
m
RUNNING
16016
Y619
o-j
~~
-@R
Y619
ABNORMAL
12809
,
'v
(DC24V)
Magn"'WIt~
LOV 3
CONT.BOX
011
.0
Y065
o-j
f-----o
TlMSl
Y065
T1~
Relay
016
o-j
YOS8
S2702
TlSKllSI
~TlCRIE
. "
I{
Y088
HYDRAULIC PUMP ON
SS816
MASTER CONDITION
~ J
TlRECCRlE
Terminal block
,1-
Card Type
IN40P
1**
DLNK, TERM40/24
DLNK-S 00/16
DLNK-S 8/8
DLNK-S 0/8
(8-point inputl8-point output type)
TOYOPUC address
Y002
CR
T1
Device code
T1: Pump start
5-395
3
-LSerialnUmber
CR: Relay
1lnl]lt*'
5. TROUBLESHOOTING
GM6311
5.13.2 Control by CNC and TOYOPUC
(a)
NC Mode
The NC control provides the three modes - the automatic mode in which an NC program
is executed, the handle (manual pulse generator) mode in which an axis is moved by
turning the manual pulse handle, and the MOl mode in which the data is altered.
The NC mode is selected by the mode select switch on the operation panel; the mode
selection signal is sent to the CNC through the TOYOPUC (PLC card) and the NC
mode is changed according to the selection made by the NC mode selection switch.
* For changing the data, two signals (MOl mode signal and program protect OFF
signal) are necessary.
L01F
NC Mode
Automatic moda-- N301 N - - ON: Automatic mode valid

L01E
MOl mode - - - N302N - - ON: MOl mode valid

L01D
Jog mode - - - N303N - - ON: Jog mode valid

(Not provided)
L01C
Handle mode - - N304N - - ON: Handle mode va lid

Program protect
ITOYOPUC I ...
'---_CNC_-'
N1D200
M132
L1FE
N30482N
OFF: Program protect OFF *
SBJ31
AUTO MODE
D2X
SBJ30
L01E
SOO28
L01C
MDI MODE
D4X
HANDLE MODE
D5X
SOO27
L01B
SOO2li
L019
EFFECTlVE
POS!. MEMORY
D7X
9217
18102
CNC RESET
13205
..2ill.
PAG!
TOYOPUC-CNC
5-396
116
IllnlJltJ
5. TROUBLESHOOTING
GM6311
(b)
Starting an NC Cycle
An NC pycle starts when both the cycle start signal and the start NC program No. signal
are input to the CNC. It ends when the end of program (M02) signal is sent from the CNC
to the TOYOPUC.
Cycle start signal _ _ _---1
. . . . . . . .
1 . . . . 1_
__
.........
,
Program No.
....----.
End of program
For a start NC program number, program numbers from No. 1 to No. 64 are provided; for
details of starting of the individual start NC programs, refer to the program number list in
the electric circuit diagrams.
The start NC program number is sent to the CNC by the function instruction of the
TOYOPUC.
The FUN instruction is
executed when this
contact goes ON.
I~:I-___
""'
FUN105
MOVR 10d-tM70LI-----I
Transmission destination address

M70 means M700
L: Lower-digit byte (M700 - M707)
H: Upper-digit byte (M708 - M70F)
Data type
d: Decimal
The function instruction FUN1 05 sends the decimal data to the designated address in
the BCD codeo
The function instruction indicated above sends the decimal data "10" to the lower-digit
byte of address M700 in the BCD codeo
16
M700 (upper-digit byte)
Address
;.
MOOO
MOOF
1.1001; 1.1008
lo
Binary code 11
..;
Transmission area
16
32
5-397
O; O
:
64 128
..
2+8=10
01
IIIRI]lt*'
5. TROUBLESHOOTING
QM6311
Program No. 10
M1 ralated eircuit
D35G
MeSO
FLN10S
[MOVR
,.,'"
PC-f1INCTION
T:RANSI'ER
lOe!
NC ralated eireuit
M7U..
CRC CYCLE
UNIr A START SIGNAL
D300
D707
D3Il1
D706
ulIr A STAltT
10128
F1IICTIOI
TJWISI'KII
OFF
UIIT A STAltT
10 64 F1IBCTIOI
TUISI'KII
OFF
DlIT A STAltr
10 32 JlUBCTI01
TUISI'KII
OFF
UBIr A START
1016 F1IBCTIOI
TJWISI'KII
DlIT A STAItT
10 8 FUBCTIOI
TJWISI'KII
D3IlS
l!I702
UBIT A START
10 4 FUBCTIOI
TJWISI'I!R
D3D7
D1(1)
Slnce NC program
start number Is up lo
EJ
OFF
D306
D701
OFF
DlIT A START
10 2 FUICTIOI
TJWISI'KII
UBIT A START
101 FUBCTIOI
TJWISI'KII
EJ
OFF
"64",0300 (128) Is
notused.
N3 saetion eireuit
APPOIIIT ADJlRI!SS
crr;
111)231
nl1
89415
UNIT A
START SIGNA!.
18101
IID301
89414
m06
.....
DA3II
IID3D2
89413
D705
.....
.lD303
.-
U9D
89412
1!1704
BlD3Il.
UNIr A
START SIGNAL
OFF
UNIr A
START SIGNA!.
NO. 32
OFF
UNIr A
START SIGNA!.
NO.16
OFF
UNIr A
START SIGNA!.
NO. 8
[J
UNIr A
START SIGNA!.
NO.'
UNIr A
START SIGNA!.
NO. 2
OFF
NO. 64
59411
D103
.....
BID3IlS
59410
El102
.....
DA7Il
IID3116
mOl
59J109
....,
IllD301
U99
SB40S
El100
UNIr A
START SIGNAL
NO. 1
.....
~
OFF
Program # corresponding ID S1art signal
Parameter
Unit
O Number
MI301
9001
A,B,C
MI302
9002
MI303
9003
M1304
9004
MI305
--
MI306
9006
MI307
9007
MI308
9008
MI309
MI310
9009
901()1?
e
A
V
/
Name
Main return
Sub retum
Use
Lower 2 digits of O number agree with the

FUNCTION transmission number.
If FUNCTION transmission No. is "10,
program 9010 starts.
/
O
Wheel change position return
Sizer special eyele
Re-grinding eyele
Grinding eyele
5-398
5. TROUBLESHOOTING
(Ii"'.'*'
GM6311
Example: Starting continuous (full-automatic) cycle
A continuous (full-automatic) cycle means a grinding cycle including automatic workpiece
loading/unloading by a loading/unloading device.
Basic time chart of full-automatic cycle
Loader operation
(Ioading/unloading)
MIDIG
Full-automatic
cycle command
Operation of door,
MID3G
Full-automatic
cycle start
MID33G
NC cycle start
command
N3D2N
--N3D8N
NC program No.
MO 2
______________
Program end
U21R4X
D99X
XM2
T2TS
11059
71<1
TOO5
~~~______________~Il~---
D90X
K024
liOSA
D99X
11061
D3P
11074
TlRI
DIG
XOOO
1I07A
1----II!1---i 11------Q.~o-----1III:---Il--ll---I J----{I
OlA
11019
T2TS
TOO5
099K
11061
06G
OSG
OIlG
11061
11083
11088
AUTO
DI3G
II06B
AUTO CYCLE
RUN COND!.
~~r-~--~~~~r-------------~
1I07A
T17
03
T021
11070
1I0~1~--------------------------~
rJ
'lEI
11070
K024
D5G
D4P
110'99 IIlD200 D20P
IIlDA2X D36G
D26G
TlOI.
D33G
1113211079 1I1OE IIOSE

IIOSC
lilAO
11060
r---,rlf-rlllF-...,.-:II!j:...... 1-rl~1I-,.....-i+-r--Il-l-----1DII-----{
11081
11131
AUTO CYCLE
1iC CICLE 011
D3TG
1107
IIOSF
D33G
D26G
liOSO
IIOSC
0~35G
IIOSE
~-------r-~J~------------
------~
11 DII02A N20ABN
11000
NC program No.
I~=
It----------------------------[KOVR
5-399
FOB 105
110d
1170L
UNIT A
Me CICLE
SELECT SIGNAL
I Ilnl]1M
5. TROUBLESHOOTING
GM6311
Example: Starting automatic cycle
An automatic cycle means a grinding cycle including manual workpiece loading/unloading
by a loading/unloading device,
An automatic cycle starts in response to the pressing of the START button by an operator,
Basic time chart of automatic cycle
Pressing of START ~
bulton by an operator
~
MID5G
r-+.--------------------~~
!-----'
Automatie eyele
start
N3D2N
-N3D8N
NC program No,
M02
Program end
D2A
NC cycIe operatlon
MID33G
NC eyele start
command
D2DIP
1101 A
Operation of door.
footstoek eanter. etc,
114115
D97X
D3G
DSG
DIIG
DI3G
D6
11051'
11070
11083
11088
11088
liOSO
~~~~--~--~--*---------------~
Automatie operation start eondition
START button
,rl ;J
J{
OIST
'111
I2TS
SINGLE CYCLE
RUN CONOI.
C d't' f
t'
on I Ion or automa le
operation
D4G /
D5
TlRI
V ,:I_-----Ir---------'::....i~
SINGLE CYCLE
1---'1'1:--.-----,---; 11--_ _ _---1
DIIJG
DIOC
11084 11085
'111
Ii1D199 HID200 D20P
IIIOA2X D36G
D26G
TlDI.
D33G
K024
11131 11132 11079 111 OE !lOSE!108C
lit AO
11080
I----~~~~~~~U~~+_~rl----~Olr---~
D6G
11091
NC ClCL! ON
D4P
1107
OIlG
11088
D33G
1I0801--_ _ _ _
Nl01.102A N20ABN
D26G
D361l
,-~II~I_------------~ r----~II~
IlOOC
I~~~Ir-----------------------~~~I
5-400
\ FUI 105
110d
H70L
l1NlT A
NC CICLE
SEUCT SIGNA!.
Iflf{IJlfd
5. TROUBLESHOOTING
GM6311
Example: Starting manual grinding cycle
Grlnding cycle start slgnal
7D13
..........
.....
...
L . . . . . I_
__
l'
t~3DA2N
....... N3DA8t~
ProgramNo.
Program end (M02)
Signals of manual operation butlons displayed on the touch-panel screen are sent to the
TOYOPUC via the CNC.
APPOINT ADDRESS
CNC
Dn411
L529
Si SIGNAL 10-L74
SB1321
Dn5ll
L52A
Si SIGNAL ll-L75
SB1322
iI
DI751l
L52B
SB1323
SB1324
________________________________
~ -{L~
__
SB1325
SB1326
DI8011
L52F
Si SIGNAL 12-L76
Si SIGNAL 13-L77
IIIDI
II~~
O
IIIDIIST
J
!
IIIDA3X
.,3'8A ~8't2J .,~& .,~b54

17
.,D3 0 "
DI5
"0~H04
"
DI3
Il2DA5Il
~ro
~A
DI3
JlXhll
Mjl
~
'\
GRlNOING CYCLE
PB ON
Wheelhead traverse condition
D7
.,303
"-F
Si SIGNAL 16-L80
Manual mode
M~~
00 cro---ll--r--N--.--UI---O"l-----......{
1.1020
Si SIGNAL 15-L79
;------------...."..&-----------------+-L-._--{.____
L-_S_B_13_2_7__
Si SIGNAL 14-L78
1.1301
11-1-----
Il2DA8Ii
DI5
L518
1.1304
GR I NO I NG CYCLE
(NOT OFF AT SBJO
00---11-1- - - - - 1
NC program No.
I-;~I----------------------------~[Mmm
M.:f~
~
'"
5-401
2~
FUN105
~7~
-' GRlNOING CYCLE

~ UN IT A SELECT SI GNAL
lilrl']1J41
5. TROUBLESHOOTING
GM6311
(e)
Sequenee Alarm
Among alarms, those of G400's are detected by the sequence of the TOYOPUC and
the alarm message of the detected alarm is displayed on the screen.
There are two kinds of sequence alarms such as standard alarms and option alarms.
Sequence alarm
Standard alarm: Max. 24 kinds

(24 alarm signals input from the port)
Max. 74 kinds (sent by the BCD code)
Option alarm:
G4**
~(OO-FF)
Alarm indication (1 - 24: Standard input port)
Alarrn No.
Device code used in alarm detection circuit
ERROR
USEOR
NOUSE
CODENC
O
O
O
T
L-
COll Ne;.
1/
ERROR MESSAGE
IPlC COMMUNICATION FAULT

1l1D1r.J RECTIFY RESET WITH RESET PB IN CONTROL PANEL
G401 .. PlC BATIERY FAUlT (BATTERY ER6VC56 WITH
CONNECTOR)
M1D14X RESUME TEMP. OP. BY PRESSING CONFIRM. SWITCH.
CYClE TIME OVER
G402
GRINDING CYClE TIME EXCEEDED PRESET TIME)
M1D25F IN MANUAL MODE CHECK EQUIPMENT OPERATION.
CONDITIONS FOR CYClE START NOT SATISFIED
G403
EQUIPMENT POS. CONFIRMED DEVICEI
M1D66F CHECK RECTIFY PRESS FAUlT RESET PB.
G400
~1
NO.
ERROR
USEOR
NOUSE
..,
No No.. An alarrn expressed by Hex. code
1-1_ _ _; . )
ERROR MESSAGE
COllNO.
G419
N4D1F
HANDLE AXIS SELECTOR SWITCH FAUlT

CHECK OPERATION, PRESS FAUlT RESET PB.
G41A
WHEEl HEAD OVER TRAUEl
PC
ENTRY
NO.
CHECK WHEEl HEAD POSITION (NILSIX)

G41B
G41C
"
An alarm related to the

machine: symbol O
CODENO
Blank column: Can be used for machine-speclfic alarrns
G41 C: Input to CNC by Hex. code
5-402
IIIITil)ltd
5. TROUBLESHOOTING
GM6311
(1)
Standard Alarms
An alarm detected by the TOYOPUC is input to one of 24 alarm ports in the
CNC, and the corresponding alarm code is selected in the alarm table to be
Alarm port Nos. 17 to 24 are used for troubleshooting of optional devices.
Alarm port
L1DF
Alarm No. 1
N3D449N
Alarm No. 11
Alarm No. 12
N3D459N L1D4
N3D460N
Alarm No. 24
N3D472N
L1D5
L1C8
ERROR CODE NO.

USE O R I - - - - - j
NOUSE
PC
ENTRY
ERROR MESSAGE
NO.
COIL NO.
G400 PLC COMMUNICATlON FAULT

1L1D1F
CTIFY, RESET WITH RESET PB IN CONTROL PANEL
Alarm number
eNe

; 1L1D1 F In alarm detecILlDIP t'
, It
MO I7
Ion Clrcu
SB479
O
DAL28
IIDI41
M037
S8478
LIDE
~~------------------~~--~--~
T1D3P
~"-ALARiTABLE'--'--l
fl'---L:I-g'AF-LI'N--l
810112
DAL7N
MISA
Ml26
SB473
LID9
~O~--------=~~---O
r"
'
l..=_.
1
1
ALARM 2
i
i
DALI6N
LlDO
MISD
~~II~------------~~--~~--~--~
PLC CMMUNICATION
ERROR
G401
PLC BATTERY FAULT
PLC BATTERY FAULT ..1- - - - - . - . - - -.............
G401
Ii
I --_.-.
..+-
ALARM 7
LOW AIR PRESSURE
!7
LOW AIR PRESSURE
...... _......._ .........._ .._.._._._.~
L___J
--1I
...._.--...
l'
I
i
-1
,G420
1.- .._
G420
I
TID6I'
G400
ALARM 16
OILMIST
LUBRICATION
l~.~_ ~!}itZ ~~~~:....!
LOW OIL LEVEL
-_._----_._.
[__
.
G42D
._._.
__._----,
A1arm part Nos. 17 to 24 are used
with program 3 for troubleshootlng.
._-----_..
--_._------_.-
T1 seetion cireuit
NI
XOOD
R2X
X183
T3P
T03B
t---N-------N------------------------I TMR
~
AIR PRESSURE DOWN
K=20
~
XOOD
MlSA
~---II~~--------------------~
NIX
XOOC
5403
AIR PRESSURE DOWN
tlaD'1lJ4
5. TROUBLESHOOTING
GM6311
(2)
Option Alarms
If an alarm is detected by the TOYOPUC, its alarm code ("**" of "G4**") is
input to the CNC in the BCD code using the function instruction.
ERROR
eODE NO.
USE ORI-------1
NOUSE
eOll NO.
1l1D1F
G400
pe
ENTRY
NO.
ERROR MESSAGE
PLC COMMUNICATION FAULT

CTlFY RESETWITHRESETPBINCONTROLPANEL
Alarm number
eNe

: 1L1D1 F in alarm detecP
MItW tion circuit
-'-DALI-R
'-l
LIDF
S8479
r-;-LA;;:BLE-
--... 6400
!
AURM 1
MIDI4X
M037
LlDE
88478
*;:'k.r
I1
PLC CMMUNICATION
6401
i._. !RR.~~._ _._.___ .
~iio~~?TION
DAL2R
PAULT
11- ~:'"~~~-1
I
T1D3P
M18A
&lD1I2
MUR
SB473
1126
LID9
D-----{lDI---------;....;.;.....-+---O
Ii
ALARM 7
LOW AIR PRESSURE
6420
..L - ...- ..-.---..--.-----1

!' G420
! 7 LOW AIR PRESSURE I
I
1~
--------.. .- . . --
..1-_. . . . . . . . .____. ..-J
I
I
I
L_._.__.J
TIDGP
Ml8D
"
ALARM 16
OILMIST
LUBRICATION
LOW OIL LEVEL
l.~~ . ~~~~t~:CAT~:J
_.__._._-_._._.
Alarm port Nos. 17 to 24 are used

with program 3 for troubieshooting.
._._.__J
._--"--"--"------'
T1 section circuit
RI
XOOD
R21
T3P
X183
T038
AIR PRESSURE DOWN
1--~------~------------------------4TMR
~
XOOD
M18A
~--~I~~--------------------------------------------4
AIR PRESSURE DOWN
HU
XOOC
Function instruction FUN100 transmits the hexadecimal constant number data to the
designated address, The function instruction above sends hexadecimal "5" to the lowerdigit word of address L1CO.
o
L1CO (upper-digitword)
L1CO
L1CFF
L1C7 L1CS
O
fl
lB
32
O O
....
06
1
..
Hexadecimal code
84 123
5-404
I Ili,IJItd
5. TROUBLESHOOTING
GM6311
D5F
MI8C
II-----I[=H
FUX576
LICL
Oh
rUJiOO
/22h
}[MOY
L1CL
D5F 1I no alarm slgnal is given lo address l1 Cl whan D5F is lumed on, alarm No. 22 is lransrnlttad for alarm Indlcation.
MI8C
I - - N - - - - - i =H
PUI576
LlCL
__ /
J9I6V
22h
FUnOO
Oh
LlCL
1I alarm signal22 is given lo address l1 Cl whan D5F is lurnad off, alarm No. Ois transmltted lo clear!ha alarm.
CIIC
LUBRICATION OIL
PRESSURE FAULT
FAULT CLEAR
APPOINT ADDRESS
PC-FANCTION
Ii
TRANSFER
Bttpattemfor alarm number22 (codeG422)
58466
FAULT
ro ..
ALARM CODE OFF

128
58464
DAL~~N
NOVII
58463
LlCS
584ti2
DAL34N
LlC4
58461
DAL35N
LlC3
ALARM CODE OFF

64
ALARM CODE OFF
32
ALARM CODE ION I
16
ALARM CODE OFF
8
LICL
ALARM NO.
22
58460
DAL37N
LlCl
58449
DAL3SIl
LlCO
58448
ALARM CODE ION I

4
ALARM CODE ION I
2
ALARM CODE OFF
1
5-405
ALARMCODE
6422
iilnlJlht
5. TROUBLESHOOTING
GM6311
(d)
Axis Movements by Pulse Handle

After selecting the handle mode and the axis to be moved, turn the pulse handle to input
the command pulses into the CNC, and the selected axis moves.
L01C
N3D4N
Handlemode
LODB
-.--1
Axis selection
N3D97N to N3D208N
LODO
-.--1
Command pulses
output from pulse
generator
A-phase
LJ
B-phase
Moving the X-axis

MIDIND
101026
APPOIBT ADDRliSS
CNC
r--li---'
NID200
101132
SI3030
L01
i
i
i
i
D------~=tHl:~--------------------------~i~O
N4T2J
i
I
!
NID200
D3N
T037
"'132
SI3029
LO1D
~~O-------4~m.----------------------------------I~--
-u;;
N4T2H
T036
o
NlD200
101132
=tHl:
513028
HANDLE MODE
iI
i
i
D4N
L01C
~O
J'
L-. __. _ .__ .
MDl MODE
JOG MODE
HANDLE MODE
APPOIBT ADDRliSS
N4DXI
AXIS SELECT X ~.~~._
101165
LOOB
58218
!
I
i
i
LOOA
U
N4DY'l
IoI16C
DI91N
58219
D192N
Ur------------------------------------+i--Q
N4DZI
D193N
101168
LOO9
58211
nr--------------------------------~--O
N4DAl
D194N
"'1 6D
58216
58216
S8214
LOO8
Ur---------------------------------~-O
N4Dal
"'1 67
D195N
LOO7
Ur---------------------------~I----O
N4DCI
101166
DI9aN
LOO6
D~-----------------------------------+i--O
AXIS SELECT
X
AXIS SELECT
y
AXIS SELECT
Z
AXIS SELECT
A
AXIS SELECT
B
AXIS SELECT
C
I
i
N4DZ2
101798
58208
D202N
uno
Ur-----------------------------------,~I---O
L._._._.J
5-406
AXIS SELECT
,z
5. TROUBLESHOOTING
GM6311
5.13.3 Checking the Circuit USing Hellowin
[MANUAL] position.
(2) Place the [NC MODE] switch in the [MOl] position.


The MAl: WINDOWS MENUscreen is displayed.
(5) After clicking the upper left area of the screen,

click the [WINDOWS] button.
Characters "WINDOWS" change from gray to
black.
Click

The message of "ARE YOU SURE TO QUIT HMI?".
is displayed.
Click the [VES] button.
The HMI ends and the WINDOWS screen is
displayed.
5-407
5. TROUBLESHOOTING
GM6311
(7) Double click the Hellowin icono
The Hellowin starts and a new screen opens.
(8) Click [Setup] - [Setup Communication Module] at

the menu bar.
(9) The dialog box opens.

Select [Ethernet (Link)] for [Module].
5-408
-IIlnl]l14
5. TROUBLESHOOTING
GM6311
(10)At the menu bar, click [PC] - [Read Datas] [AII Program + Parameter].
(11)The dialog box displays "Program will read from

PC".
Click [Yes].
The read indicator is displayed and reading of the
programs/parameters starts.
(12)The dialog box showing the result of program

check opens.
Click the [Close] bulton at the screen.
(13)At the menu bar, click [DISPLAY] - [SEARCH].

The SEARCH dialog box opens.
5409
E(._
5. TROUBLESHOOTING
GM6311
(14)Select the circuit to be searched foro
Example: Coil of address M657
Click the check box of "coil".
A check mark is set in the check box.
Input "M657".
Click the [Next] button.
(15)Coil M657 is displayed.
(16)At the menu bar, click [Monitor] - [Start PCMonitor].
(17)The current status is displayed.
5-410
Eilnlll
5. TROUBLESHOOTING
GM6311
Checking the Waveform for Servo System
5.14
The waveform of the servo system can be output

from the AK1 and AK2 terminals of the X3 connector in the servo amplifier.
WR-, WL-, RR-,

RL-, u- orY-axis
amOIlifi er
XR-, XL-, ZR-, ZL-, Clor CR-axis amplifier

...
I
~
O
O
O
o
eCexI]
U2
us
~Lo
L-
. . ox,
L-
ooe
O.
O"
[t
D
e e Ox:
U3
xI]
X5
ut
:~"~ D~:~
L-
.2-
U4
X3
"connector
X4
o,
UI
U2
e[]x
r;.
oo
O
X3
connector
10
X4
ol
X3
r-
r2
Output 1 waveform selection
AK1 Output
Analog output No. 1
Output 1 waveform scaling
AK10V
P-O-0420
Extended output 1 waveform selection P-0-0421

P-O-0422
AK20utput
r4
./ Analog output No. 2

AK2 O V
'-
Output 1 waveform selectlon
P-O-0420
P-O-0423
Output 2 waveform selectlon
P-0-0423
Extended output 2 waveform selectlon
P-0-0424
Output 2 waveform scallng
P-O-0425
Select the ID number In the waveform selection list (analog signallD

number table) given in the next page.
Extended output 1 waveform selection P-O-0421

Extended output 2 waveform selection P-O-0424
Select the signar number in the slgnal list of the extended signals glven in
the next page.
P-O-0422
P-O-0425
Scaling for 10 V
5-411
1Ilnl]1'4
5. TROUBLESHOOTING
GM6311
Waveforrn Selection List (Analog SignallD Number Table)
ID No.
Description
S-0-0036
Velocity command value
S-0-0037
Additional velocity command value
S-0-0040
Velocity feedback value
S-0-0047
Position command value
S-0-0051
Position feedback value 1 (motor encoder)
S-0-0053
Position feedback value 2 (external encoder)
S-0-0080
Torque command value
S-O-0084
Torque feedback value
S-0-0189
Position follow-up error
S-0-0258
Target position (standard position)
S-0-0259
Positioning speed
S-0-0347
Velocity loop error
S-0-0388
Motor temperature
P-0-0098
Max. allowable error model
P-0-0141
Display of current load ratio of drive (%)
P-0-0401
Active position correction value
Signal List (Extended Signals)

Value of P-0-0421
Ox00000001
Signal
At "scaling
=1.0"
Motor encoder (Sine signal)
0.5V/10V
Ox00000002
Motor encoder (Cosine signal)
0.5V/10V
Ox00000003
External encoder (Sine signal)
0.5V/10V
Ox00000004
External encoder (Casine signal)
0.5V/10V
Ox00000005
Position command error of position controller input
Ox00000006
DC BUS power
Ox00000007
Absolute DC BUS power
1kW/10V
Ox00000008
Effective current
S-0-0110/10V
Ox00000009
Ineffective current
S-0-0110/10V
OxOOOOOOOa
Load ratio
100%/1 OV
OxOOOOOOOb
Motor temperature
150C/10V
OxOOOOOOOc
Excitation current
S-Q-0110/10V
OxOOOOOOOd
Velocity command value of velocity command input
Rotary: 100 min-1 /10 V, Linear

100 m/min /10 V
1kW/10V
5-412
I I-nl]It!I
5. TROUBLESHOOTING
GM6311
(a)
Waveform Observation
When connecting a waveform measurement instrument to the servo amplifier, make
sure to turn off the power.
(b)
Observation of Motor Current Waveform and Veloeity Feedback Waveform

The following shows the setting at the waveform measurement instrument and the
parameter settings when measuring motor current waveform and velocity feedback
waveform.
X3
Motor current
r-
AK10utput
AK10V
AK2 Output
ro-
AK20V
'--
HIOKI Memory Hi-Coder
T
T
Velocity feedback
CH1: 1 V/div.,
200 msec/div.
CH2: 2 V/div.,
200 msec/div.
MEMmode
(e)
Servo Parameter Setting

X-axis
AK1
(velocity feedback)
(motor current)

Extended output 1 waveform selection
P-0-0420
P-O-0421
P-0-0422
=5-0-0040
=OXOOOOOO08
=1.0
Z-axis
AK2
(velocity feedback)
(motor current)

Extended output 2 waveformselection
P-0-0423
P-0-0424
P-O-0425
=5-0-0040
=OxOOOOOO08
=1.0
5-413

Mgma-015 6 (1-2)

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11 MAINTENANCE

GM63/90Il MUL TI WHEEL GRINDER

1mut!1TOYODA MACHINE WORKS, LTD.1999

Handing Over the Machine

About the Manual

[Installation & Specification Manual]

Note that discrepancies between the contents of this manual

MS-DOS and Windows are trademarks of Microsoft Corp., USA.

Representation of Safety Caution Marks

Failure to observe items in this category will result in death or severe

Failure to observe items in this category can lead to injuries or property

IMPORTANT This is an item that requires attention during machine operation or

Representation of Switches and Lamps

Example: Place the [SINGLE BLOCK] selection switch in

Example: Turn the [EMERGENCY STOP] pushbutton

Example: Press the [NC RESET] pushbutton switch.

Example: The lamp in the [MASTER ON] pushbutton

Example: Set the main power breaker to the rON]

Cautions Relating to Maintenance and Preventive Maintenance ............................................. 1

When Switching the Power ON and OFF ................................................................... 1

In Manual Operation .................................................................................................. 3

Ouring Wheel Changing Work ............................... ,................................................... 4

Installation ..... ;........................................................................................................... 4

When Remedying Trouble .......................................................................................... 4

Areas of Potential Oanger ........................................................................................................ 5

High-voltage Locations ............................................................................................... 5

Axis Motion Ranges .................................................................................................. 6

Protective Functions ............................................................................................................... 7

Types, Functions, and Positions of Interlocks for Protective Functions ...................... 7

Related Laws, Regulations, and Standards ........................................................................... 11

Inspection before Pressing the [MASTER ON] Butlon ............................................................ 1 _

Inspection after Pressing the [MASTER ON] Butlon ............................................................... 9

Inspection after Starting the Wheel Spindle .......................................................................... 24

Monthly Inspection .................................................................................................................. 1

Every 3-month Inspection ........................................................................................................ 1

Every 6-month Inspection ........................................................................................................ 4

Every 1-year Inspection ........................................................................................................ 30

P.ARTS REPLACEMENT IN REGULAR INTERVALS

Every Six Months ................................................................................................................... 1 .

Every Year .............................................................................................................................. 1

Every Two Years ..................................................................................................................... 3

Every Five Years ......................................................................................,.............................. 7

Parts Replacement in Intervals of Specified Operating Hours .................................................. 9

Precautions on Troubleshooting .............................................................................................. 1

Basics of Error Processing ..................................................................................................... 2

Trouble Report Fon:n ............................................................................................................... 3

Afier the Occurrence of Error ................................... ,.............................................................. 4

Displaying Error Information ....................................................................................... 4

Kinds of Error Display and Description of Alarm Codes ............................................. 7

Resetting the Error .....................................................................,.............................. 10

Diagnosis and Corrective Action ........................................................................................... 15

Diagnosis and CorrectiveAc"tion -AlarmA ............................................................... 16

Diagnosis and Corrective Action - Alarm B ........................., .................................... 97

Diagnosis and Corrective Action - Alarm C ............................................................. 117

Diagnosis and Corrective Action - Alarm D ............................................................. 120

Diagnosis and Corrective Action - Alarm E ............................................................. 121

Diagnosis and Corrective Action - Alarm F .............................................................. 205

Diagnosis and CorrectiveAction -Alarm G ............................................................. 273

Servo System Alarms ..........................................................................................................329

Inverter Alarms ..................................................................................................................... 330

Alarms of the Wheel Spindle Motor Inverter ............................................................ 330

Diamond RolI Motor Inverter .................................................................................... 339

OH Cooler Alarms ................................................................................................................ 342