Mazak Mechanical/Electrical Maintenance Class Outline

MECHANICAL MAINTENANCE Class will begin with explanations of how to use the manuals, provided by Mazak Corp. with each machine, in addition to any manuals provided by the training center. After explanations of manuals pertinent to Mechanical Maintenance, a maintenance specialist should be able to : View in detail the make-up of mechanical units for disassembly and re-assembly. Refer to maintenance manual and special training manuals/handouts for techniques and procedures. (Assistance and examples will be provided in class) Listed below are the main units that will be covered for all Turning and Machining Center Classes. Headstock: construction spindle removal adjustments Leveling of base and alignments Axis drive assemblies construction parts replacement and adjustments accuracy checks and compensations ATC Shifter, Magazine assembly construction alignments/adjustments Pallet Changer assembly construction alignments/adjustments Index / NC rotary table assembly construction alignments / adjustments Tool Length Measure assembly construction calibration Preventative Maintenance References ELECTRICAL MAINTENANCE The Electrical Maintenance items covered are as follows: Explanations of Electrical Circuit Diagram manual Data back-up and restoration procedures Explanations of Diagnostic screens on control Explanations of servo diagnostic display and uses for setting homes Servo drive & Spindle controller LED indicators and alarm references Upon completion of this part of the class, an Electrical Maintenance specialist should be able to : Trace all line voltages and control circuitry in the electrical manual Locate devices/components on machine using manual and/or machine decals Use control to monitor cause of alarms/malfunctions to minimize "downtime"

Mazak Advanced Control Maintenance Class Outline

Student "MUST" have basic knowledge of troubleshooting electrical circuits. The Mechanical/Electrical Maintenance Class is a prerequisite. CONTROL OVERVIEW - Diagnostic displays and push button orientation How to: Display needed screens for maintenance use How to: Use each of the diagnostic displays Review diagnostic trouble-shooting information from Mechanical/Electrical class. PROGRAMMABLE LOGIC CONTROLLER Discuss devices used in ladders and function of each device. Explanation of PLC ladder instructions. How to use Ladder display with written print copy. Alarm tracing though ladders with focus on: Address ranges for machine section, control section, control panel section, generation of PLC alarms, instruction boxes - activation of alarms, data registers - activation of alarms. Explanation of sub-programs for tool changes and tool measurement. Diagnostic troubleshooting using ladder monitors on simulators. SERVO SYSTEM / SPINDLE CONTROLLER Explanation of Servo Diagnostic screens on control Servo Drive & Spindle controller LED indicators and alarm references NUMERICAL CONTROL Explanations of binary and hexadecimal formats Data back-up and restoration procedures RAM clear and control re-initialization There will be study time in class. Following presentation and discussion of a subject there will be "Hands On" time to become familiar with diagnostic procedures.

Mazak Control Hardware Troubleshooting Maintenance Class Outline

CONTROL FAMILIARIZATION NC System Configuration Servo System Configuration Connection diagrams BOARD FUNCTIONS Relay Units Power Supplies Motion Controllers Digital I/O SRAM & DRAM PREVENTATIVE MAINTENANCE Battery Replacement Inspections of electrical cabinet components SERVO SYSTEM Explanations of servo set-up and configuration for open and closed loop feedback Explanations of servo related parameters Explanations of servo diagnostic screens on control Explanation of alarms generated in servo system Remedies for alarm conditions SPINDLE CONTROLLER Explanation of configuration and components Explanation of spindle related parameters Explanations of spindle diagnostic screens on control PLG feedback device adjustments Explanations of spindle generated alarm conditions and remedies NUMERICAL CONTROL Construction and explanations of card types and functions Data back-up and restoration procedures RAM clear and control re-initialization troubleshooting and remedies for NC alarm conditions