Safety regulations and

table of contents 1
Information concerning
these instructions 2

Operating
At the last minute 3
instructions Description of the machine
and technical data 4
MF sprint 42/65
Brief instructions for the
machine operator 5
Machine operating elements
and controls 6
Setting, make ready and
operation 7
Polling and processing
a program/programing help 8
Interface description 9
Maintenance and care 10
11
Parameter setting,
M commands, standard cycles
and PLC fault description

Catchwords 12

Doc.-No.: ABB002G0 V 2.0

History
Changes compared to the operating instructions V 1.0

Chapter Page Description

4 Data added, American dimensioning system
4-22 to 4-29 New diagrams
4-33, 4-35 to 4-43 New pictures added
5 5-5 to 5-6 NEW, variant 1+2
6 6-2, 6-4 New pictures added
6-22 NEW, operating element 21, pre-requisites
7 7-13 New pictures added
7-18 to 7-19 New pictures added
7-33 to 7-34 Text change
7-57 New pictures added
7-63 to 7-65 NEW
7-69 to 7-96 NEW
8 8-19 NEW, date and time
9 9-2 to 9-4 New picture, text changes
9-9 to 9-16 NEW
10 10-9 to 10-10 NEW, weekly maintenance
10-13 to 10-16 NEW
10-18 New, belt tension setting
11 11-12 to 11-31 NEW
11-44 to 11-45 NEW, customer module
11-56 to 11-65 NEW
11-70 to 11-91 Text changes or text added
11.10 NEW, PLC error description

The publisher reserves all rights, including reprinting and copying of parts of this handbook and its translation.

Reproduction or copying with an electronic copying system of any part of this manual is forbidden unless approved in writing, this also
includes for learning and training purposes.

The original (German) language version of the manufacturer is binding for technical contents.

Issue: V 2.0
Ident No.: 2264098
E 1999 GILDEMEISTER Drehmaschinen GmbH
 afety regulations and
table of contents

Table of contents

1 SAFETY REGULATIONS AND

PRECAUTIONARY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Symbol and information explanation . . . . . . . . . . . . . . . . . . . . . 5
1.3 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.8 Conformity declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2 INFORMATION CONCERNING THESE INSTRUCTIONS . . . . 2-3

2.1 Who are these instructions intended for? . . . . . . . . . . . . . . . 2-4
2.2 What is included in these instructions? . . . . . . . . . . . . . . . . . 2-4
2.3 Where to find information not contained in
these instructions? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Symbol and information explanation . . . . . . . . . . . . . . . . . . . 2-7

3 AT THE LAST MINUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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4 DESCRIPTION OF THE MACHINE AND

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1 Description of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.1 Concept of the machine . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.2 Machine assembly groups . . . . . . . . . . . . . . . . . . . . . 4-4
4.1.3 Optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.1.4 Operation of the machine in accordance with
its intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.1.5 Warning against misuse . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.2 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.2.1 Key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.2.2 Emergency stop cut-out . . . . . . . . . . . . . . . . . . . . . . 4-10
4.2.3 Agreement button . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.2.4 Isolating protection devices around the working
space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.2.5 Rotational speed control . . . . . . . . . . . . . . . . . . . . . . 4-12
4.2.6 Workpiece clamping . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.2.7 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.2.8 Safety devices for setting and maintenance
spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.2.9 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.2.10 Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.2.11 Chip conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

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4.3 Lubricants and coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.3.1 Lubricant filling quantities . . . . . . . . . . . . . . . . . . . . . 4-15
4.3.2 Bar loading magazine filling quantities . . . . . . . . . . 4-16
4.3.3 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.3.4 Coolant lubricant filling quantity . . . . . . . . . . . . . . . . 4-18
4.3.5 Handling lubricants and coolants . . . . . . . . . . . . . . 4-19
4.4 Technical data (from commission 502501) . . . . . . . . . . . . . 4-20
4.5 Working documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.5.1 Main spindle capacity data MF sprint 42 . . . . . . . . 4-22
4.5.2 Driven tool/counter spindle capacity data . . . . . . . 4-24
4.5.3 Main spindle clamping force diagram . . . . . . . . . . . 4-25
4.5.4 Counter spindle clamping force diagram . . . . . . . . 4-26
4.5.5 Coolant feed rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.5.6 Auxiliary time: main drive (without bar)
MF sprint 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.5.7 Auxiliary times: feed drives . . . . . . . . . . . . . . . . . . . . 4-29
4.5.8 Times and paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4.6 Working space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4.6.1 Co-ordinate system; spindle and axis
designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
4.6.2 Working space, cross . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4.6.3 Working space, longitudinal . . . . . . . . . . . . . . . . . . . 4-36
4.6.4 External and internal machining . . . . . . . . . . . . . . . 4-37
4.6.5 Internal machining . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.6.6 Cross drilling on main spindle . . . . . . . . . . . . . . . . . 4-39
4.6.7 Parting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4.6.8 Clamping means connections . . . . . . . . . . . . . . . . . 4-41
4.6.9 Tool interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

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5 BRIEF INSTRUCTIONS FOR THE MACHINE

OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1 Starting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2 Stopping the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 EMERGENCY STOP cut-out . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Loading the bar loading magazine . . . . . . . . . . . . . . . . . . . . 5-5

6 MACHINE OPERATING ELEMENTS AND CONTROLS . . . . . 6-2

6.1 Machine operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Operating panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3 Menu technology and softkey bars . . . . . . . . . . . . . . . . . . . 6-28
6.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6.3.2 Screen divisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.3.3 Info system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
6.3.4 Grafical operator support . . . . . . . . . . . . . . . . . . . . . . 6-32
6.3.5 Softkey USER menu . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

7 SETTING, MAKE READY AND OPERATION . . . . . . . . . . . . . . 7-5

7.1 Switching the machine on and off . . . . . . . . . . . . . . . . . . . . 7-5
7.1.1 Switching on the machine . . . . . . . . . . . . . . . . . . . 7-5
7.1.2 Swiching off the machine . . . . . . . . . . . . . . . . . . . . 7-8
7.1.3 EMERGENCY STOP cut-out . . . . . . . . . . . . . . . . . 7-9
7.2 Setting and make ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.2.1 A review of the work sequence . . . . . . . . . . . . . . 7-10
7.3 A review of the clamping device . . . . . . . . . . . . . . . . . . . . . 7-12
7.4 Spindle locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.5 Fitting and removing the clamping means . . . . . . . . . . . . 7-16
7.5.1 Removing the clamping means . . . . . . . . . . . . . . 7-16
7.5.2 Fitting the clamping means . . . . . . . . . . . . . . . . . 7-20
7.6 Check and set the clamping pressure . . . . . . . . . . . . . . . . 7-22
7.7 Loading the tool holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.8 Scratching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.9 Driven tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

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7.10 Operating life monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

7.10.1 Spare tool administration system . . . . . . . . . . . . 7-33
7.11 Pick-off device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.11.1 Application possibilities . . . . . . . . . . . . . . . . . . . . . 7-35
7.11.2 Basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.11.3 Set up pick-off position . . . . . . . . . . . . . . . . . . . . . 7-39
7.11.4 Pick-off unit unloading cycle . . . . . . . . . . . . . . . . 7-42
7.11.5 Counter spindle ejector . . . . . . . . . . . . . . . . . . . . . 7-43
7.11.6 Conveyor belt operation . . . . . . . . . . . . . . . . . . . . 7-46
7.12 Off-cut disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
7.12.1 Setting the off-cut disposal . . . . . . . . . . . . . . . . . . 7-48
7.12.2 Off-cut jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
7.13 Bar machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
7.13.1 Change of spindle reduction tubes . . . . . . . . . . . 7-51
7.13.2 Material requirements . . . . . . . . . . . . . . . . . . . . . . 7-53
7.13.3 Integrated bar loading magazine . . . . . . . . . . . . 7-55
7.13.4 Bar section machining . . . . . . . . . . . . . . . . . . . . . . 7-69
7.13.5 Bar machining with an external bar pusher . . . . 7-71
7.13.5.1 Operation and M functions with an external
bar pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
7.13.5.2 Machining with external bar feeder . . . . . . . . . . . 7-74
7.13.5.3 Machining sequence with external bar feeder . 7-74
7.13.5.4 Example program for external bar feeder . . . . . 7-76
7.13.5.5 Reloading bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
7.13.5.6 External bar feeder with work end cut-out . . . . 7-79

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7.13.6 Machining with an external bar loading

magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
7.13.6.1 Machining sequence with an external bar
loading magazine . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
7.13.6.2 Example program for external bar loading
magazines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
7.13.6.3 Reloading bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
7.13.6.4 Switching off the external bar loading when
work completed . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
7.14 Changing to work without an external bar pusher . . . . . . 7-87
7.15 Remaining material disposal . . . . . . . . . . . . . . . . . . . . . . . . 7-88
7.16 Triple warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89
7.17 Shift end circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90
7.18 Leukhardt swivel wire sensor . . . . . . . . . . . . . . . . . . . . . . . 7-92
7.19 Polygon turning in recess and straight turning method . 7-94
7.20 Thread cutting without compensating chuck (option) . . . 7-95

8 POLLING AND PROCESSING A PROGRAM/

PROGRAMING HELP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.1 Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.2 Select program for editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.2.1 Select program for editing on the fixed disk . . . . . . . 8-4
8.2.2 Select program for editing in the NCK memory . . . . 8-5
8.3 Automatic machining of a workpiece . . . . . . . . . . . . . . . . . . . 8-6
8.4 Compensate for tool wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.5 Data input, data output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.5.1 Read out the part programs and attendant workpiece
data in the punched tape format . . . . . . . . . . . . . . . . 8-12
8.5.2 Back up of NCK data in a workpiece program . . . . 8-12
8.5.3 Read out workpiece data . . . . . . . . . . . . . . . . . . . . . . 8-14
8.5.4 Read in data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.5.5 Load part programs from the fixed disk memory
into the NCK memory . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.5.6 Loading NC data read in with the part program,
into the NCK memory . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.6 Reading date and time for the part program . . . . . . . . . . . 8-19

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9 INTERFACE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.1 Serial interface for program transfer . . . . . . . . . . . . . . . . . . . 9-3
9.1.1 Changing the interface parameters . . . . . . . . . . . . . . 9-4
9.2 Interface for bar feeding unit . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.2.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.2.2 Prerequisites for safe operation . . . . . . . . . . . . . . . . . 9-5
9.2.3 Introduction, general description . . . . . . . . . . . . . . . . . 9-6
9.2.4 Interface architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.2.5 Pin assignment of the bar feeding unit . . . . . . . . . . . . 9-9
9.2.6 Function of the individual signals . . . . . . . . . . . . . . . 9-11
9.2.7 Explanation of the signals . . . . . . . . . . . . . . . . . . . . . 9-11
9.2.8 Operating and M functions . . . . . . . . . . . . . . . . . . . . . 9-16

10 MAINTENANCE AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10.1 Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.2 Acknowledging maintenance work . . . . . . . . . . . . . . . . . . . 10-4
10.3 Daily checks prior to starting work . . . . . . . . . . . . . . . . . . . 10-6
10.4 Daily maintenance after shift end . . . . . . . . . . . . . . . . . . . . 10-8
10.5 Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.6 Maintenance plan for machine operator . . . . . . . . . . . . . 10-11
10.7 Switching off the power to the machine . . . . . . . . . . . . . 10-13
10.7.1 Hydraulic, accumulator pressure reduction . . . . 10-13
10.7.2 Depressurisation of the pneumatics . . . . . . . . . . 10-13
10.8 IRCO bar loading magazine SIMAG,
maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
10.9 Inspection work
(necessary every 2,500 hours) . . . . . . . . . . . . . . . . . . . . . 10-17
10.9.1 Checking the safety devices . . . . . . . . . . . . . . . . 10-17
10.9.2 Machine inspection . . . . . . . . . . . . . . . . . . . . . . . . 10-18

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11 PARAMETER SETTINGS, M COMMANDS,

STANDARD CYCLES AND PLC FAULT MESSAGES . . . . 11-3
11.1 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.1.1 Setting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
11.1.2 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50
11.2 Description of the M commands . . . . . . . . . . . . . . . . . . . . 11-70
11.3 Gildemeister cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-82
11.3.1 Review of Gildemeister cycles . . . . . . . . . . . . . . . 11-82
11.3.2 Description of the Gildemeister cycles . . . . . . . . 11-84
11.4 Siemens cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-88
11.4.1 Siemens cycles review . . . . . . . . . . . . . . . . . . . . . . 11-88
11.5 Administration of the R parameters . . . . . . . . . . . . . . . . . 11-89

12 CATCHWORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

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 1.1 Intended use
1 Safety regulations and precautionary measures

1 Safety regulations and precautionary measures

GILDEMEISTER lathes are constructed in accordance with the EC

machine directives 89/392 EEC and the latest state of the art tech-
nology and are operationally safe. Prerequisite for the perfect and
safe operation of this machine, however, being the correct transport,
installation and commissioning as well as careful operation and
maintenance.

Ensure that the information contained in the

D planning documentation covering preparatory measures

D Transport and installation instructions
D operating instructions
D programming manual

is strictly adhered to.

1.1 Intended use

Prior to switching on / starting up the machine ensure that no person

is endangered by the start up of the machine.

Observe the setting, maintenance, inspection activities and dates,

including the data for the exchange of parts / items of equipment
outlined in the operating instructions.
Only authorised persons are permitted to undertake this work.

Safety regulations V 1.0 page 3

Doc.-No.: A000G1
1.1 Intended use
1 Safety regulations and precautionary measures

This CNC lathe including its options are intended for:

D Machining of primarily rotating workpieces of various metallic

materials.
D Handling of workpieces, unmachined parts, bar stock and tools as
applicable according to the machine design and its peripheral
equipment.

Operating system and controls are intended for operation by a

trained and authorised person.

Not permissible are:

D the wearing of long hair and jewellery, including rings,

D reaching into the machine with the hands or tools while running, or
into rotating clamping means and workpieces,
D programming rotational speeds exceeding the maximum rotational
speed specified for the chucking means used,
D modifying/defeating or putting out of action (additions or con-
versions) safety devices such as safety position switches, inter-
lockings, covers etc.
D painting over or removing plates, information signs, decals etc.
D operating the machine by unauthorised or uninstructed persons,
D turning of ceramic, magnesium and artificial resin impregnated/
bonded laminated wood.
D making program changes (software) to programmable control
systems.
D the use of equipment which generates electromagnetic radiation
(e.g. cellular phones, electrical welding equipment) within a 2 m
perimeter of the machine.
D operating the machine when the safety window is damaged.
D entering the machine working space.

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 1.2 Symbol and information explanation
1 Safety regulations and precautionary measures

1.2 Symbol and information explanation

Warning, caution!
This symbol is used when warning of possible danger of injury or to
health independent of the severity of danger.

This symbol is used when referring to particular information or instruc-

tions and prohibitions intended to avoid damage.

This symbol indicates advantageous and economical applications and

uses.

This symbol indicates situations requiring the notification of the

authorised service.

1.3 General safety instructions

Incorrect use of the machine or operation or maintenance which does

not correspond to the intended use or is undertaken by untrained
persons can result in the danger of injury, to health or damage to
property.
The owner must ensure that only appropriately qualified and
authorised personnel work on the machine.

D Check at certain intervals that the personnel operating the ma-

chine are aware of safety and dangers by taking the operating
instructions into consideration

Fixed or moving safety devices

Ensure that all movable protection hoods and doors are closed prior to
starting up the machine. Do not open during operation.
Do not put permanently fitted safety devices out of operation.

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1.3 General safety instructions
1 Safety regulations and precautionary measures

Safety window
The safety window is primarily made of polycarbonate glass which,
due to its elasticity, is subject to deformation if hit by an ejected part.
Maintain a safety spacing of at least 200 mm from the window.

Pressure vessel (hydraulic accumulator)

Pressurised media imply possible danger of injury. If pressure vessels
are fitted they are subject to regular inspection in accordance with the
pressure vessel regulations and, if necessary, acceptance inspection
at the installation site of the machine. Ensure that all pressure vessel
test certificates are kept in a safe place.

Oils, lubricants and coolants

Due to their additives, these products imply a possible danger to
health and environment.

Selection and application are exclusively in the hands of the owner.

Operating instructions to be prepared by the owner covering the
handling of these materials should contain:

D Designation of the material

D Designation of danger to persons and the environment
D Protective measures and behaviour directives, e.g.
- Wear protective gloves made of resistant plastic material
- Avoid contact with eyes and skin
- Do not inhale vapours and fumes
- Fire, naked flame and smoking are forbidden
D Behaviour in the event of danger, first aid
D Correct disposal

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 1.3 General safety instructions
1 Safety regulations and precautionary measures

Rotational speed limitation

Enter the value as a parameter when the max. chuck speed is less
than the max. speed of the machine. In addition, set this value on the
separate speed limiter for power operated chucks (option). Access to
these settings is only possible via key switch or a password.

D The owner must ensure that the operators, maintenance and

service personnel are fully familiar with all safety and warning
instructions and that these are adhered to.
D Keep all safety and danger warning information on the machine in
a legible condition.
D All working methods are forbidden which influence the safety of
the machine.
D The operator must notify his superior of any changes to the
machine encountered which may impair safety.
- Stop and secure the machine immediately, overcome malfunc-
tions at once.
D Where necessary, the owner is obliged to ensure that the
operating personnel wear personal protective equipment as well
as tight fitting clothing
D The machine safety can be impaired by:
- conversions or changes made to the machine.
- the use of additional equipment (options) on the machine
differing from that intended or approved by the manufacturer.
- the use of spare and wear parts other than those intended by
the manufacturer.
- non observance of the prescribed schedules or those specified
in the operating for repetitive checks/inspections.
- when the hydraulic hose lines are not exchanged at suitable
intervals, even if no safety relevant faults are detected (guide
value: 5 years from the date of manufacture).

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1.4 Operation
1 Safety regulations and precautionary measures

1.4 Operation

Observe the switching off procedures stated in the operating instruc-

tions for all work concerning operation, installation, maintenance and
service of the machine.

In other words:
D Switching off the machine
- Stopping at cycle end
- Open protection hood.
- Button: machine DRIVES OFF
- Main switch: OFF
- Secure the main switch against switching on again

Main switch
Do not switch off the main switch during the machining program, as
this will result in machine damage.

EMERGENCY STOP
Actuate the emergency stop button in the case of danger.

Chip conveyor

Do not reach into the running chip conveyor or undertake any

manipulations.

D Operation of the chip conveyor is only admissible when the chip

bath is correctly positioned below so that it is not possible to reach
into the ejection shaft of the chip conveyor.
Do not remove chips manually.
Switch off the machine prior to cleaning the chip ejector opening.

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 1.4 Operation
1 Safety regulations and precautionary measures

Workpiece machining

D Take care when using other available chucking means:

- Critically check whether they are still suitable for this modern
lathe.
D Contact the individual clamping means manufacturer following a
collision resulting in damage to such elements prior to continuing
to use these clamping means.
D Clamping means and clamping processes are particularly impor-
tant due to the inherent dangers:
- Following each clamping means change, reset the clamping
stroke control and the clamping pressure as described in the
operating instructions.
- Only use clamping means up to the permissible maximum
rotational speed. Set the rotational speed limitation accordingly.
- Keep to the information for setting the clamping pressure and
path monitoring.
D Correctly insert workpieces and ensure that the machine is clean.
D Working with clamping means, tailstock and steady rest:
Observe the sequence - danger of injury from dropping workpiece:
- 1. Secure the workpiece
- 2. Release the tailstock clamping
- 3. Open the clamping means
D Remove the workpiece from the clamping means prior to
switching off the machine.
D Take note of the workspace limits when fitting and swivelling the
tool holder.
D Take the wear to the cutting edge of the cutting tool into considera-
tion.
D Take particular care when bar machining the following:
- Do not machine bar stock without checking the run-out
- Do not permit the bar end to protrude from the main spindle
when machining bar stock.
- Insert spindle reduction tubes into the tension and connection
pipe when machining bar sections.
Internal diameter of the reduction pipe = bar diameter +1 mm.

Safety regulations V 1.0 page 9

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1.4 Operation
1 Safety regulations and precautionary measures

General

D Check the machine filling levels and top up, if necessary, prior to
switching on the machine.
D Check the machine for leaks and overcome cause.
D Ensure a clean and well arranged workplace on the machine.
D Take care when removing swarf, only use swarf hooks and hand-
broom.
D Do not throw any waste into the coolant or chip removal.
D Set additional lubrication impulses following an extended stoppage
(2 days and longer).

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 1.5 Maintenance and care
1 Safety regulations and precautionary measures

1.5 Maintenance and care

Set the main switch to OFF prior to undertaking maintenance or repair

work and padlock to prevent unauthorised reactivation. This also
applies to work on the chip conveyor and switch cabinet as well as
peripheral equipment.

D Only trained personnel are permitted to undertake maintenance

and care in accordance with the information laid down in the
operating instructions.
D Only use lint free cleaning cloths for cleaning the machine.
D Under no circumstances clean the machine with compressed air or
a high pressure cleaner (steam jet). Chips could enter the guide-
ways, spindle bearings or tool holders.
D Only clean the safety window with a mild household cleaner, under
no circumstances use strong alkaline cleaning agents.
D Prior to cleaning the machine with water or other cleaning agents,
cover/apply adhesive tape to all openings for safety or/and
function reasons to prevent the ingress of liquids. Particularly
endangered are electric motors and switch cabinets.
D Completely remove covers/adhesive tape once cleaning is
finished.

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1.6 Repairs
1 Safety regulations and precautionary measures

1.6 Repairs

Only personnel trained and authorised by GILDEMEISTER are per-

mitted to undertake repair work.

Set the main switch to OFF prior to undertaking repair work and
secure against switching on again with a padlock. This also applies to
work on the chip conveyor, switch cabinet and other peripheral
equipment.

Take particular care if the machine must be operational for certain

repair work.

D Ensure that no persons are in the danger zone.

D Protect the danger zone against access to unauthorised persons
over a wide area using additional barriers or fences.
D When exchanging parts carefully fix the individual parts and larger
modules onto lifting means and secure, to exclude any danger.
Only use suitable and technically perfect lifting means, as well as
load bearing devices with a suitable bearing capacity! Do not stand
or work below suspended loads!
D Ensure that a second person is present when working on live parts
who can actuate the main switch in an emergency. Close off the
working area with a red and white safety chain and a warning
plate. Only use insulated tools!
D Only trained and qualified staff with special knowledge and expe-
rience are permitted to work on electrical and technical liquid
systems. Observe the currently valid regulations (IEC ..., ISO ...,
EN ..., country specific accident prevention regulations).
D Depressurise the machine at the reservoir drain valve when
equipped with hydraulic systems with pressure vessels.
D Only use original spare parts.

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 1.6 Repairs
1 Safety regulations and precautionary measures

D Close the stop valve on the pneumatic system and depressurise

the machine.
D Refit safety devices immediately upon completing repair work and
check their function, if it was necessary to dismantle safety
devices for undertaking these repairs.
D Exchange damaged safety windows.
D Check the function of the safety devices in the case of damage,
exchange damaged parts.
D Clean off oil or lubricants from the machine and in particular from
connections and screw fittings prior to starting repair work!
Do not use aggressive cleaning agents! Only use lint free cleaning
cloths!
D Tighten screw fittings released during repair work with a torque
corresponding to the screw quality (deviations can be found in the
corresponding chapter).

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1.7 Guarantee
1 Safety regulations and precautionary measures

1.7 Guarantee

The manufacturer accepts neither liability nor guarantee,

D if the instructions contained in the operating and programming
instructions, planning, transport and installation instructions are
ignored,
D if the machine, including additional equipment is incorrectly used,
D if the machine, including additional equipment is not correctly
maintained and repaired,
D if safety devices are not used or put out of operation,
D if any technical or functional modifications have been undertaken
which are not approved by the manufacturer.

1.8 Conformity declaration

In the case of non-observance of the safety regulations and pre-

cautionary measures the conformity declaration supplied with the
machine in accordance with the 89/392/EEC machine directive
becomes null and void.

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 2 Information concerning these instructions

2 Information concerning these instructions

These operating instructions are intended to simplify familiarisation

with the machine and its operation in accordance with its intended
possibilities of use.

The operating instructions contain important information for the safe,

correct and economical operation of the machine.

Observation of these instructions helps:

D to avoid dangers,
D to reduce repair costs and down time,
D to increase reliability and operating life of the machine.

Supplement these operating instructions by existing national

regulations for accident prevention and protection.

Ensure that these operating instructions are always at the place of

operation of the machine.

All persons who work with or on the machine must have read and
observe these operating instructions.

Also observe the recognised technical rules for safe and correct work
as well as the binding directives for accident prevention applicable in
the country of operation in addition to these operating instructions.

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Doc.-No.: ABB002G0
2.1 Who are these instructions intended for?
2 Information concerning these instructions

2.1 Who are these instructions intended for?

This GILDEMEISTER lathe being a solidly built machine with a high

capacity as well as a high technical standard requires careful
handling.

Only trained personnel are permitted to operate the machine.

The necessary knowledge can, amongst others, be obtained in a

special training program. In addition, the operator should be familiar
with the operation of conventional lathes and be knowledgeable in the
basic cutting technology (e.g. cutting materials, materials, cutting
values, cooling etc.). The configuration and operating method of CNC
lathes and CNC controls must also be known (e.g. setting, tool
compensation, program selection etc.).

The personnel assigned to work on the machine must have read the
operating instructions and in particular the Safety Instructions
chapter prior to starting work on the machine.

2.2 What is included in these instructions?

These instructions describe the daily operation and maintenance of

machines and controls. Chapter 6 and chapter 7 are particularly
important for the operators.

Chapter 5 contains brief instructions for machine operators for simple

daily repetitive work, which can also be performed by trained auxiliary
personnel.

We hope that these instructions will be of assistance during the

learning period and in the event of any problems being encountered.

Not all of the machine equipment described in these instructions may

be fitted to your machine.

Note
It is important that you read chapter 3 ”At the last minute”.
This chapter describes amendments and extensions, which have not
yet been integrated into this documentation.
In addition, this chapter contains a description of the equipment which
has been specially incorporated into your machine.

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 2.3 Where to find inform. not contained in these instr.?
2 Information concerning these instructions

2.3 Where to find information not contained in these instructions?

Planning documentation
The planning documentation includes preparatory measures which
must be taken into consideration by the owner to permit the machine
to be directly installed and connected when delivered.

D Content:
- Foundation details
- Space requirements
- Connection values for necessary external utilities
- List of materials to be provided

Transport and installation instructions

D Transport
The transport instructions contain details necessary for transport
from the manufacturer to the final customer. They include details of
the round slings for crane transport.
- Crane transport
- Unloading and loading instructions
- Transport on armoured rollers
- Lifting with hydraulic jacks

D Installation instructions
The installation instructions contain details necessary for the
installation of the machine.
- Machine installation
- Connection to external power supplies
- Cleaning

This does not include commissioning/start up details. This work may

only be performed by authorised representatives.

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2.3 Where to find inform. not contained in these instr.?
2 Information concerning these instructions

Programming manual
Programming is described in the programming manual.

Electrical technical documentation

This contains details necessary for repair work to the electrical
equipment (switch cabinet, controls and drives).

D Content:
- Safety instructions
- Circuit diagrams
- Legend for circuit diagram system
- Position plans for equipment on the machine and in the switch
cabinet
- Terminal diagrams
- Description of main and feed drives
- Description of the controls
- Equipment lists
- Spare and wear parts

Mechanical technical documentation

The mechanical technical documentation contains details which are
necessary for repair work on the mechanical equipment (mechanical,
hydraulics, lubrication and pneumatics).

D Content:
- Safety instructions
- Module group description
- Fluid diagrams
- Equipment lists
- Spare and wear parts lists

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 2.4 Notes
2 Information concerning these instructions

2.4 Notes

For reasons of clarity these operating instructions do not contain all

detailed information covering all variations of this product. For this
reason not every conceivable installation situation, operation or repair
can be taken into consideration.

Contact the GILDEMEISTER representative if you require further

information or encounter particular problems which are not dealt with
in detail in the operating instructions.

Rights for changes serving the purpose of technical advance are

reserved.

2.5 Symbol and information explanation

Warning, caution!
This symbol is used to give a warning of possible danger of injury or to
health irrespective of the severity of the danger.

This symbol is used to highlight special instructions or warnings where

material damage could result.

This symbol indicates advantageous and economical applications.

This symbol characterises situations requiring the authorised service

to be notified.

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2.5 Symbol and information explanation
2 Information concerning these instructions

Symbol and information explanation

The following symbols found in these instructions indicate information and work sequences.
A review of their meanings:

Information symbols Display symbols

Warning, caution Screen content

Danger of damage to property Lamp lit

Advantageous application Wait

Notify service department Activity results

Activity symbols Key symbols

Perform manual activity Press direction key

Change module Move cursor

Oil, grease or lubricate module Move to reference point

Clean module Press confirmation key

Measure / check Press softkey in the

horizontal softkey bar
Visual inspection

Key switch in setting operation Press softkey in the

vertical softkey bar
Key switch in standard operation

Actuate key switch

Rotary switch setting ON

Rotary switch setting OFF

Data input

Top up

Drain

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3 At the last minute

3 At the last minute

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 4.1 Description of the machine
4 Description of the machine and technical data

4 Description of the machine and technical data

4.1 Description of the machine

4.1.1 Concept of the machine

This lathe can be used for machining bar material.

The machine is equipped as standard with a chip conveyor, coolant

unit, bar loading magazine, offcut disposal system and Pick-off device.

The following machine variations are available:

D with C-axis and stop brake (spindle 1), tool drive and counter
spindle (carriage 1), pick-off device in lower counter spindle
position.
D with C-axis and stop brake (spindle 1), tool drive and counter
spindle (carriage 1), tool drive (carriage 2), counter spindle
stopping device, pick-off device in lower counter spindle position.

The machine can, of course, be equipped with diverse options, see

chap. 4.1.3

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4.1 Machine description
4 Description of the machine and technical data

4.1.2 Machine assembly groups

13 14 15 16 17 18

12 19

11
10 20

8 7 6 5 4 3 2 1

21 22 23 24 25 26

SINUMERIK

27 28 29 30 31 33001210

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 4.1 Machine description
4 Description of the machine and technical data

The machine comprises the following assembly groups:

1 Base

2 Machine bed

3 Compound slide rest 1

4 Pressure gauge for clamping pressure (counter spindle)

5 Pressure reduction valve for clamping pressure (counter spindle)

6 Pneumatic pressure reduction valve

7 Pressure reduction valve for clamping pressure (main spindle)

8 Pressure gauge for clamping pressure (main spindle)

9 X2-axis feed drive

10 Z2-axis feed drive

11 Tool drive 2

12 Clamping device

13 Main spindle (spindle H)

14 Tool holder 2

15 Compound slide rest 2

16 Tool holder 1

17 X1-axis feed drive

18 Tool drive 1

19 Counter spindle

20 Z1-axis feed drive

21 Bar loading magazine

22 Switch cabinet

23 Working space light

24 Operating panel

25 Hydraulic unit

26 Chip conveyor

27 Off-cut ejector

28 Off-cut disposal system

29 Pick-off device

30 Off-cut box

31 Finished part box

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4.1 Machine description
4 Description of the machine and technical data

4.1.3 Optional modules

The machine variations can be equipped with the following options.

1. Coolant cleaning
The coolant cleaning system permits the removal of soiling from the
coolant.

2. Coolant spray gun

The coolant spray gun permits flushing chips (soiling) out of the
working space.

3. Oil mist separator

The oil mist separator draws in oil or coolant mist from the machine
working space.

4. Spindle reduction tubes

The spindle reduction tubes serve for bar guidance within the turning
spindle.

5. Conveyor belts
The workpieces being removed are separated and protected against
damage using a flat or compartment indexing belt.

6. Tool monitoring
Monitoring units, e.g. sensors, monitor the sensitive drilling tools and
thus also protect the following tools.

7. Control lamps (three fold)

The controls lamp is on the machine and display the various operating
conditions.

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 4.1 Machine description
4 Description of the machine and technical data

8. Polygon machining device

The polygon machining device on carriage 1 allows the production of
key surfaces during the turning operation.

9. Thread cutting unit

The thread cutting unit permits the production of threads with a short
chamfer or an overrun also behind a collar.

10. Overload clutch

This unit stops the machine if an axis overload occurs.

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4.1 Machine description
4 Description of the machine and technical data

4.1.4 Operation of the machine in accordance with its intended use

Which type of workpiece can be machined?

This machine is suitable for the turning of bar workpieces. This must
be closed off at the rear when machining tubular material.

Which materials?
This machine is suitable for the machining of all commercially
available steel, cast, copper, aluminium, brass, gunmetal and plastic
qualities allowing chip removal.

Please contact your GILDEMEISTER representative if you are

uncertain whether your material can be machined on this lathe.

Particular suitability
This machine is distinguished by a short setting time and a high
degree of productivity. It is particularly suitable for the efficient
manufacture of small to medium batch sizes.

Regular cleaning and maintenance

This machine will only operate reliably and without malfunction when
regularly cleaned and maintained.

Ensure that chapter 10 Maintenance and care is observed.

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 4.1 Machine description
4 Description of the machine and technical data

4.1.5 Warning against misuse

In spite of the safety and stability of the machine certain points must
be observed:

Do not turn ceramic workpieces!

Fine dust is generated when turning ceramic workpieces. This dust

can enter every corner and quickly affect important mechanical
functions. In addition, the lubrication and cooling system could
become blocked.

Do not turn magnesium workpieces!

Danger of fire when turning magnesium workpieces.

Do not turn artificial resin bonded laminated wood!

Fine dust is generated when turning artificial resin bonded laminated

wood. This dust can enter every corner and quickly adversely affect
important mechanical functions. In addition, the lubrication and cooling
system could become blocked.

Observe the limit values!

Observe the stated maximum rotational speeds of the main drive and
the clamping means as well as the maximum feed forces when
programming (refer to chapter 4.4).

Under no circumstances exceed these values!

Take note of the cutting and feed force increase as a consequence of

worn cutting tools.

Observe the manufacturer’s instructions!

Observe the manufacturer’s instructions concerning limit values.

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4.2 Safety devices
4 Description of the machine and technical data

4.2 Safety devices

This machine is equipped with the safety devices described in the

following. In addition, further safety measures are integrated as
component parts of the machine and controls in accordance with the
provisions of the EC machine directive 89/392 EEC.

All safety devices are for your personal protection.

Do not set out of operation or defeat.

Following repair work ensure that the safety devices are returned to
their original condition.

Include safety devices in the regular maintenance procedures (see

chapter 10).

4.2.1 Key switch

Access to certain operating modes or settings is only possible by

means of a key switch or a password. The operator must ensure that
the use of this key is limited to authorised and trained operators.

Set the parameters or setting values independent of the machining

means employed, e.g. chuck. Match with each change over.

4.2.2 Emergency stop cut-out

These buttons have a clearly identifying red yellow colour and are to
be hit in the event of danger.

All movements are stopped. The power to drives is cut-off which could
cause danger.

Release the -EMERGENCY STOP BUTTON- after overcoming the

dangerous situation.

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 4.2 Safety devices
4 Description of the machine and technical data

4.2.3 Agreement button

It is only permitted to start movement in manual operation and with the

protection hood open when the agreement button is pressed with one
hand and the function button with the other hand. The movement is
stopped as soon as one of the buttons is released.

The agreement button is only operational when the machine is

in setting operation (see chapter 6).

Always press the agreement key first in order to start a movement to

avoid contouring errors or similar in conjunction with the agreement
key and the function keys and release the agreement key last after
ending a movement.

4.2.4 Isolating protection devices around the working space

The lathe working space implies particular dangers as a consequence

of the movements of the slides, tool holders and spindles. It is
enclosed with panelling on all sides. Access is only possible via a
protection hood which is locked mechanically and by the controls.
Starting of these movements is only possible when the protection
hood is closed.

The panelling and protection hood including the safety windows are
designed to withstand parts flying out as a result of a collision or
breakage. This only applies when permissible rotational speeds and
weight of the clamping means are not exceeded.

Always exchange damaged parts following a collision, in particular the

safety window and its mounting.

Slide, tool holder and spindle movements which are possible with the
protection hood opened or closed, can be found in chapter 6.

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4.2 Safety devices
4 Description of the machine and technical data

4.2.5 Rotational speed control

The spindle rotational speeds (0 r.p.m and the max. value) are subject
to special monitoring. It is only possible to open the protection hood
when the spindle is stationary.

The maximum permissible machine rotational speeds are contained in

the technical data.

Only use clamping means which are designed for the maximum
rotational speed of the machine.

4.2.6 Workpiece clamping

The safety of the workpiece clamping is guaranteed with the

clamping pressure monitoring. Insufficient clamping pressure
prevents a start up or causes the stoppage of the turning spindle.

Ensure that the pressure switch is always set at 5 bar less than the
clamping pressure.

Check and record at regular intervals the clamping force on the power
chucks in accordance with the default values in the pulling force
diagram using a commercially available clamping force measuring
instrument. This work must be performed by trained personnel (see
chapter 10).
This also applies after changing the chuck.

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 4.2 Safety devices
4 Description of the machine and technical data

4.2.7 Hydraulic

Two hydraulic accumulators are built into the machine. Each hydraulic
accumulator has a separate safety valve to relieve the hydraulic
accumulator.

Every operator must have the following pressure accumulator tests

performed in accordance with local pressure vessel regulations:

D Internal test
D Pressure test
D External test

The test intervals must be laid down by the owner in accordance with
local regulations. The tests must be performed by an approved expert.

4.2.8 Safety devices for setting and maintenance spaces

The machine is panelled on all sides. Access to areas during setting

and maintenance work where dangerous movements are performed
are electrically monitored. It is only possible to open the doors or flaps
using special tools.

A plate on these doors and flaps indicates that they may only be
opened when the machine is stationary, otherwise danger of a tool
breakage could result.

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4.2 Safety devices
4 Description of the machine and technical data

4.2.9 Noise protection

The machine is conceived such that the noise emission values at the
workplace do not exceed the values specified in the technical data.

Cutting noise could cause the quoted value being exceeded under
unfavourable conditions. In such a case the noise emission values
can be reduced by changing the cutting, tool or clamping conditions.

4.2.10 Emission

The machine is ready to be connected to an oil mist extraction

system.

4.2.11 Chip conveyor

Do not operate the machine unless the chip box is correctly installed
below. Ensure that it is not possible to reach into the ejection shaft of
the chip conveyor.

Do not remove chips by hand.

Switch off the machine before cleaning the chip ejector.

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 4.3 Lubricants and coolants
4 Description of the machine and technical data

4.3 Lubricants and coolants

Ensure that the functions of the coolants and lubricating oils are not
negatively affected by each other. The lubricating oil must behave
neutral when in contact with the coolant, experience has shown that
you should have the compatibility of lubricating oil and coolant
confirmed in writing by the supplier, if these products are purchased
from different sources.

4.3.1 Lubricant filling quantities

D 12 l (3.17 gal) Hydraulic oil for the tank and pipe system
D 3 l (0.793 gal) Lubricating oil (capacity of the fresh oil container)
With automatic lubrication the consumption is
approx. 0.1 (6 in3) l per 100 operating hours.
D 1 kg (2.2 lb) heavy duty grease paste for lubricating the chuck
and steady rest

Operating instructions MF sprint 42/65 V 2.0 page 4-15

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4.3 Lubricants and coolants
4 Description of the machine and technical data

4.3.2 Bar loading magazine filling quantities

D Standard*

Make Type Oil type Quantity (l) (gal)

IRCO SIMAG-65 ISO VG 100 110 (29)

G-781

D Option

Make Type Oil type Quantity (l) (gal)

FMB Turbo 10-65 ISO VG 150 120 (32)

IEMCA TAL 65 auto ISO VG 150 70 (19)

Sameca Monosam 65 ISO VG 68 110 (29)

LNS Super Hydrobar ISO VG 100 120 (32)

* It is also permissible to operate the bar loading magazine with a

≥ 10% coolant emulsion.

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 4.3 Lubricants and coolants
4 Description of the machine and technical data

4.3.3 Lubricant table

Several brand names are listed here as a guide for the lubricant selec-
tion.
(Selection and sequence of manufacturers does not represent an as-
sessment according to suitability and quality.)

Manufac- Lubricating oil Hydraulic oil Lubricating grease

turer’s ISO G68 ISO HM32 ISO XM2
DIN CG68 DIN HLP32 DIN K2K

ARAL Deganit B 68 Vitam GF 32 ARALUB HI2

Deganit BW 68 Vitam GE 32

BP Maccurat 68 D Energol HLP-D 32 Energrease LS 2

Energol HP-C 68 Energol HLP 32

Castrol MAGNA BTH 68 HYSPIN AWS 32 LZV-EP

VARIO HDX

DEA Novan CGLP 68 astron HLP 32 Glissando 20

Actis HLPD 32

elf MOGLIA 68 ELFOLNA 32

Moglia HXE 68 ELFOLNA DS 32
HYGLISS 68 ELFOLNA HMD 32

Esso FEBIS K 68 NUTO H 32 BEACON 2

Fuchs RENEP 68 K RENOLIN MR 10 RENOLIT FWA 160

RENOLIN B 10

Mobil Vactra oil No. 2 Mobil DTE 24 Mobilux 2

Shell Tonna oil TX 68 Tellus oil 32 Alvania Fett G 2

Hydrol DO 32

We accept no liability for machine damage resulting from the use of

unsuitable lubricants.

* Clamping means lubrication grease:

Adhere to the instructions of the clamping means manufacturer.

Operating instructions MF sprint 42/65 V 2.0 page 4-17

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4.3 Lubricants and coolants
4 Description of the machine and technical data

4.3.4 Coolant lubricant filling quantity

D 180 l (48 gal) coolant lubricant

(capacity of the chip conveyor)
Specially matched combinations of lubricating oil and coolant lubri-
cants are offered by:
(Selection and sequence of manufacturers does not represent an as-
sessment according to suitability and quality.)

Manufacturer Coolant lubricant

Aral Sarol-series

Castro Synitol R

Fuchs Ratak-Resist 68 CF

Mobil Mobilmet 151/221-series

Ensure that the mixing ratios are maintained in accordance with the
manufacturer’s information:

D e.g. too thin, machine guideways and workpiece will oxidize

D too thick, insufficient cooling effect

D The pH value of the coolant lubricant used must be within the

range of 8.5 - 9.5

Ensure that the coolant does not foam.

If necessary add a de-foaming agent.

Further information is available from your coolant manufacturer’s.

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 4.3 Lubricants and coolants
4 Description of the machine and technical data

4.3.5 Handling lubricants and coolants

Oil, lubricants and coolants

These products may represent a danger to health and the
environment due to their additives.

Selection and use are solely the responsibility of the owner. The
handling of these materials must be laid down in an operating manual
to be prepared by the owner, which should contain:
D Designation of the materials
D Statement of the dangers to persons and the environment
D Protective measures and behaviour directives, e.g.
- Wear protective gloves made of a resistant plastic
- Avoid contact wit the skin and eyes
- Do not breath in fumes or mist
- Fire, naked flames and smoking are forbidden

Please clarify in advance where and how the used lubricants and
coolants are to be disposed of in an environmentally sound manner.

Lubricant fumes can be generated during turning, in particular when

using a bar feeding unit and machines with counter spindles. GILDE-
MEISTER offers an oil mist separator to be fitted to the extraction unit.

The use of coolant lubricants with an oil proportion of 15% or more or

combustible coolant lubricants in conjunction with an air tight working
space enclosed on all sides implies
danger of fire or explosion.

Please contact the manufacturers with regard to preventive measures.

Operating instructions MF sprint 42/65 V 2.0 page 4-19

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4.4 Technical data
4 Description of the machine and technical data

4.4 Technical data (from commission 502501)

MF sprint 42 MF sprint 65
Working range
Bar dia. normal 42 mm 1.654” in 65 mm 2.559” in

Main spindle
Spindle head dia., internal/external (flat flange) 85H5/140h5 3.346/5.512” 110H5/170h5 4.33/6.693” in
mm in mm
Spindle hole dia. 56 mm 2.205” in 79 mm 3.11” in
Clamping tube internal dia. 45 mm 1.772” in 68 mm 2.677” in
Dia. in front bearing 90 mm 3.543” in 120 mm 4.724” in

Main drive
Max. drive rating 40%/100% duty cycle 19/14 kW 25.5/18.8 HP 28/21 kW 37.5/28.1 HP
Rotational speed range* 31-6300 min-1 31-6300 r.p.m 25-5000 min-1 25-5000 r.p.m
Max. torque 40%/100% duty cycle 181/134 Nm 133/99 ft-lbf 320/240 Nm 236/177 ft-lbf
Max. track speed when thread cutting 10 m/min 32.81 ft/min 10 m/min 32.81 ft/min
Speed of the C axis 120 min-1 120 r.p.m 120 min-1 120 r.p.m
C axis torque 180 Nm 133 ft/lbf 180 Nm 133 ft/lbf

Slide 1
Facing path/longitudinal path 155/280 mm 6.102”/11.024” 155/280 mm 6.102”/11.024”
in in
Rapid traverse speed X/Z 22.5/22.5 73.82/73.82 22.5/22.5 73.82/73.82
m/min ft/min m/min ft/min
Feed force X/Z 900/900 daN 2025/2025 lbf 900/900 daN 2025/2025 lbf
Spindle thread pitch x dia. X 15x25 mm 0.591”/0.984” 15x25mm 0.591”/0.984”
in in
Spindle thread pitch x dia. Z 15x32 mm 0.591”/1.26” 15x32 mm 0.591”/1.26”
in in

Slide 2
Facing path/longitudinal path 82/130 mm 3.228”/5.118” 82/130 mm 3.228”/5.118”
in in
Rapid traverse speed X/Z 22.5/22.5 73.82/73.82 22.5/22.5 73.82/73.82
m/min ft/min m/min ft/min
Feed force X/Z 900/900 daN 2025/2025 lbf 900/900 daN 2025/2025 lbf
Spindle thread pitch x dia. X/Z 15x25 mm 0.591”/0.984” 15x25mm 0.591”/0.984”
in in

* Max. permissible rotational speed range for the machine is not applicable for machining bar ends (incl. short part
loader).

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 4.4 Technical data
4 Description of the machine and technical data

MF sprint 42 MF sprint 65
Tool holder
Number of tools 8 8
Shank dia. as per DIN 69880 30 mm 1.181” in 30 mm 1.181” in
Number of driven tool stations 4 4

Counter spindle
Clamping dia. with collet 42 mm 1.654” in 42 mm 1.654” in
Clamping dia. with 3 jaw chuck 42 mm 1.654” in 65 mm 2.559” in
Spindle head dia. (flat flange) 120h5 mm 4.724” in 120h5 mm 4.724” in
Positioning unit Pitch infinite infinite infinite infinite
Grad (Deg.) Grad (Deg.)
Max. rating 40%/100% duty cycle 3000 min-1 7.6/4.6 kW 10.2/6.2 HP 7.6/4.6 kW 10.2/6.2 HP
Max. torque 40%/100% duty cycle 3000 min-1 24/14.7 Nm 17.7/10.9 ft-lbf 24/14.7 Nm 17.7/10.9 ft-lbf
Max. rotational speed (tool holder 1) 5000 min-1 5000 r.p.m 5000 min-1 5000 r.p.m
Max. rotational speed (tool holder 2) 5000 min-1 5000 r.p.m 5000 min-1 5000 r.p.m

Hydraulic
Contents (compl.) 10.5 l 2.77 gal 10.5 l 2.77 gal
Pump rating 1.5 kW 2.01 HP 1.5 kW 2.01 HP

Coolant unit
Contents 180 l 49 gal 180 l 49 gal
Pump rating 1.7 kW 2.28 HP 1.7 kW 2.28 HP
Feed rate at 6 bar (87 psi) 22 l 5.81 HP 22 l 5.81 HP

Dimensions and weight

Total length, with chip conveyor 3500 mm 137.795” in 3500 mm 137.795” in
Total depth, with switch cabinet 1645 mm 64.764” in 1645 mm 64.764” in
Total height, with switch cabinet 1765 mm 69.488” in 1765 mm 69.488” in
Machine weight, incl. switch cabinet 5000 kg 11025 lbf 5000 kg 11025 lbf
Weight of integrated bar loading magazine 900 kg 1985 lbf 900 kg 1985 lbf

Noise emission values db(A) 77 77

Workplace based constant noise level
(DIN 45635 part 1-04.85 (ISO 3740-1980), measured
as a cutting cycle as per DIN 45635 part 1601-07.78)

Operating instructions MF sprint 42/65 V 2.0 page 4-21

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4.5 Working documentation
4 Description of the machine and technical data

4.5 Working documentation

4.5.1 Main spindle capacity data MF sprint 42

P Md
[kW] (HP) [Nm] (ft.lbf)

25 (33.5)
20 (26.8)
P (S6)
16 (21.44)
12,5 (16.75)
10 (13.4) P (S1)
8 (10.72)
6,3 (8.44)
5,0 (6.7) Md (S6) 200 (147.6)
4,0 (5.36) 160 (118.1)
3,2 (4.29) 125 (92.3)
2,5 (3.35) 100 (73.8)
2,0 (2.68)
Md (S1) 80 (59)
1,6 (2.14) 63 (46.5)
1,3 (1.74) 50 (36.9)
1,0 (1.34) 40 (29.5)
0,8 (1.07) 32 (23.5)
0,6 (0.80) 25 (18.5)
0,5 (0.67) 20 (14.8)
0,4 (0.54)
0,32 (0.43)
20
25
31
40
50
63
80
100
125
160
200
250
315
400
500
630
800
1000
1250
1600
2000
2500
3150
4000
5000
6300

n [min --1
] (r.p.m)

33001010

P (S1) = 100% duty cycle Md (S1) = 100% duty cycle

P (S6) = 40% duty cycle Md (S6) = 40% duty cycle

Duty cycle = maximum 10 minutes operating duration

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 4.5 Working documentation
4 Description of the machine and technical data

MF sprint 65

P Md
[Nm] (ft.lbf)
[kW] (HP)

32 (42.88)
P (S6)
25 (33.5)

20 (26.8)

16 (21.44)
P (S1)
12,5 (16.75) 500 (369)

10 (13.4) 400 (295)

8 (10.72) 315 (232.5)

6,3 (8.44) 250 (184.5)

5,0 (6.7)

4,0 (5.36)
Md (S6) 200 (147.6)

160 (118.1)

3,2 (4.29) 125 (92.3)

2,5 (3.35) 100 (73.8)

2,0 (2.68) 80 (59)

1,6 (2.14) Md (S1) 63 (46.5)

1,3 (1.74) 50 (36.9)

1,0 (1.34) 40 (29.5)

0,8 (1.07) 32 (23.5)

0,6 (0.80) 25 (18.5)

0,5 (0.67)

0,4 (0.54)

0,32 (0.43)
1000

1250

1600

2000

2500

3150

4000

5000
20

25

31

40

50

63

80

100

125

160

200

250

315

400

500

630

800

n [min --1
] (r.p.m)
33001020

P (S1) = 100% duty cycle Md (S1) = 100% duty cycle

P (S6) = 40% duty cycle Md (S6) = 40% duty cycle

Duty cycle = maximum 10 minutes operating duration

Operating instructions MF sprint 42/65 V 2.0 page 4-23

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4.5 Working documentation
4 Description of the machine and technical data

4.5.2 Driven tool/counter spindle capacity data

P Md
[kW] (HP) [Nm] (ft.lbf)

10 (13.4)

8 (10.72)

6,3 (8.44) P (S6)

5,0 (6.7)

4,0 (5.36)

3,2 (4.29)

2,5 (3.35) P (S1)

2,0 (2.68)

1,6 (2.14)

1,3 (1.74)

1,0 (1.34)
Md (S6) 32 (23.5)

0,8 (1.07) 25 (18.5)

0,6 (0.80) 20 (14.8)
0,5 (0.67) 16 (11.8)
0,4 (0.54) 10 (7.4)
0,32 (0.43) Md (S6) 8 (5.9)
0,25 (0.33)

0,2 (0.26)
20

25

31

40

50

63

80

100

125

160

200

250

315

400

500

630

800

1000

1250

1600

2000

2500

3150

4000

5000

n [min --1
] (r.p.m)
33001030

Relative duty cycle S1 - 100%

40% duty cycle
P [kW] 7,6 4,6
Md [Nm] 24 15
nnenn [min-1] 3000
nmax [min-1] 5000

Duty cycle = maximum 10 minutes operating duration

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 4.5 Working documentation
4 Description of the machine and technical data

4.5.3 Main spindle clamping force diagram

MF sprint 42

60 (13500)

50 (11250)

40 (9000)
[KN] (lbf)

34 max (7644)

30 (6750)
29 max (6519)
Fz
20 (4500)
Fz = Fd

Fd
10 (2250)

0 10 20 30 40 50
(147) (294) (441) (588) (735)

P [bar] (psi) 1160477

33001040

MF sprint 65

60 (13500)
57 max (12814)

50 (11250)
49 max (11016)

40 (9000)
[KN] (lbf)

Fz
30 (6750)

20 (4500) Fd
Fz = Fd

10 (2250)

0 10 20 30 40 50
(147) (294) (441) (588) (735)

P [bar] (psi) 1160477

33001050

Operating instructions MF sprint 42/65 V 2.0 page 4-25

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4.5 Working documentation
4 Description of the machine and technical data

4.5.4 Counter spindle clamping force diagram

[KN] (Ibf) 20 (4500)

15 (3375)

13 max (2925)
11,5 max
10 (2250) Fd (2587)
Fz; Fd;

Fz
5 (1125)

0 10 20 30 40 50
(147) (294) (441) (588) (735)

P [bar] (psi) 11604480

33001060

4.5.5 Coolant feed rate

90 (295.3)

80 (262.5)

70 (229.7)

60 (196.9)
H [m] (ft)

50 (164.1)

40 (131.2)

30 (98.4)

20 (65.6)

10 (32.8)

0 20 40 60 80
(5.28) (10.57) (15.85) (21.14)

Q [l/min] (gal/min) 1160518

33001070

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 4.5 Arbeitsunterlagen
4 Beschreibung der Maschine und technische Daten

4.5.6 Auxiliary time: main drive (without bar) MF sprint 42

Clockwise running
n [min-1] (r.p.m) 6500
6000
5500
5000
4500
4000
3500
3000
Acceleration 2500
2000
Braking
1500

t [ s ] 1000
500
3,0 2,5 2,0 1,5 1,0 0,5
0,5 1,0 1,5 2,0 2,5 3,0
500
1000
t [ s ]

1500
2000
2500
n [ min --1 ] (r.p.m)
3000
3500
Counter clockwise
4000 running
4500 n [min-1] (r.p.m)
5000
5500
6000
6500 1160239
33001080

Operating instructions MF sprint 42/65 V 2.0 page 4-27

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4.5 Working documentation
4 Description of the machine and technical data

MF sprint 65

5000
Clockwise running
n [min-1] (r.p.m) 4500

4000

3500

3000

2500
Acceleration
2000
Braking 1500

1000
t [ s ]
500
3,0 2,5 2,0 1,5 1,0 0,5
0,5 1,0 1,5 2,0 2,5 3,0
500
t [ s ]
1000

1500

2000

2500 n [ min --1 ] (r.p.m)

3000

3500 Counter clockwise

running
4000 n [1/min]
4500

5000

1160225
33001090

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 4.5 Working documentation
4 Description of the machine and technical data

4.5.7 Auxiliary times: feed drives

Rapid traverse speed V = 22.5 m/min (24.6 yd/min)

320 (12.599”)
Z1
280 (11.024”)
[ mm ] ( in )

260 (10.236”)

240 (9.449”)
s

220 (8.661”)

200 (7.874”)

180 (7.087”)

160 (6.299”) X1

140 (5.512”)

120 (4.724”)
Z2
100 (3.937”)
X2
80 (3.150”)

60 (2.362”)

40 (1.575”)

20 (0.787”)

0
0.2 0.4 0.6 0.8 1.0

t [ sec ]
1036923_1
31410191

Operating instructions MF sprint 42/65 V 2.0 page 4-29

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4.5 Working documentation
4 Description of the machine and technical data

4.5.8 Times and paths

Clamping times
Clamping unit, main spindle 25 bar; 2.5 mm
(367.5 psi; 0.098 in)
open/close 0.2/0.2 s
Clamping unit, counter spindle 25 bar; 2.5 mm
(367.5 psi; 0.098 in)
open/close 0.2/0.2 s

Positioning times for C4-axis

Cycle: Braking - Reference point - Positioning
all times without workpiece: (bar)

- Times for braking and reference point run from rotational speed:
MF sprint 42

n [r.p.m] Brake + Reference = Total time

point
0 - 1600 0,1 s 0,4 s 0,5 s
0 - 2000 0,2 s 0,4 s 0,6 s
0 - 3000 0,5 s 0,4 s 0,9 s
0 - 4000 0,8 s 0,4 s 1,2 s
0 - 5000 1,3 s 0,4 s 1,7 s
0 - 6300 2,0 s 0,4 s 2,4 s

MF sprint 65

n [r.p.m] Brake + Reference = Total time

point
0 - 1600 0,2 s 0,4 s 0,6 s
0 - 2000 0,3 s 0,4 s 0,7 s
0 - 3000 0,5 s 0,4 s 0,9 s
0 - 4000 0,9 s 0,4 s 1,3 s
0 - 5000 1,6 s 0,4 s 2,0 s

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 4.5 Working documentation
4 Description of the machine and technical data

- Positioning

C4-axis 45° 0,24 s

C4-axis 90° 0,28 s
C4-axis 135° 0,31 s
C4-axis 180° 0,34 s
C4-axis 270° 0,39 s
C4-axis 360° 0,45 s

Indexing times for tool holders

Angle Swivel + Locking = Total time

45° 0,26 s 0,24 s 0,50 s
90° 0,42 s 0,24 s 0,66 s
135° 0,58 s 0,24 s 0,82 s
180° 0,74 s 0,24 s 0,98 s

Integrated bar magazine times

-- Auxiliary times
Bar change until waiting position measuring sensor 10 s

-- Main time
Bar change until turning position ”chuck clamped”: 24 s
(default times for 3.2 m (3.5 yds) long rods)

Operating instructions MF sprint 42/65 V 2.0 page 4-31

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4.6 Working space
4 Description of the machine and technical data

4.6 Working space

The technical drawings with representations of the working space and

the tool holders can be found on the following pages.

These drawings are intended to allow a quick review of the range of

applications of the machine and the workpieces to be machined.

In the working space plans we have taken the largest possible turning
diameter and turning lengths into consideration for the use of standard
tools.

If under exceptional circumstances the limit values specified by us are

exceeded, it is important that collision situaton be given sufficient
thought with the aid of the required tool data (tool holder and cutting
tools).

Legend for the technical drawings

M Machine zero point N Tool reference point

R Reference point R1, R2 MG Counter spindle zero point

T Tool holder reference point A Control zero point

M1 = Spindle 1 (counter spindle and driven tools, tool holder 1)

M2 = Spindle 2 (driven tool, tool holder 2)
M3 = not available
M4 = Spindle 4 (main spindle)

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 4.6 Working space
4 Description of the machine and technical data

4.6.1 Co-ordinate system; spindle and axis designation

T1

+X1

N1 1.
R1

M1=3 M1=3
C1+

4. M1=4 MG +Z
M
A
M2=3
C1--
M2=4 M1=4
+X2 R2
B

N2

T2
2.

1039295
33001100

Operating instructions MF sprint 42/65 V 2.0 page 4-33

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4.6 Working space
4 Description of the machine and technical data

View A

+X1

T1

M4=4
C4+ N1

N2

T2

+X2

1039295
31410210

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 4.6 Working space
4 Description of the machine and technical data

4.6.2 Working space, cross

+X1

1
N1

M=0

N2

+X2

1036644_1
31410271

Operating instructions MF sprint 42/65 V 2.0 page 4-35

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4.6 Working space
4 Description of the machine and technical data

4.6.3 Working space, longitudinal

Control dimensions refer to point ”A”

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 4.6 Working space
4 Description of the machine and technical data

4.6.4 External and internal machining

Main spindle:

D Turning length for carriage 1 = max. 120 (4.724”)

D Turning length for carriage 2 = max. 95 (3.74”)

Counter spindle:

D Collect clamping = max. Ø 42x50 deep (Ø 1.654” x 1.969” deep)

D Chuck clamping 1 = Ø 25x50 deep (Ø 0.984” x 1.969” deep)
D Chuck clamping 2 = Ø 65x20 deep (Ø 2.559” x 0.787” deep)
D Drilling depth = 70 (2.756“)

ZMN1=154,5
+X1 (6.083”)

N2
A

+Z
M=0 120
(4.724”)
70
(2.756”)
MG
+X2 N2
90
(3.543”)

1039803
ZMN2=116,5 33001120
(4.587”)

Operating instructions MF sprint 42/65 V 2.0 page 4-37

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4.6 Working space
4 Description of the machine and technical data

4.6.5 Internal machining

Main spindle:

D Drilling depth = 85 (3.346”) with a protrusion of 80 (3.15”)

D Drilling depth = 45 (1.772”) with a protrusion of 120 (4.724”)

Counter spindle:

D Drilling depth = 70 (2.756”)

ZMN1=279,5 (11.004”)
+X1
A
80
(3.15”) N1
+Z
M=0
45
(1.772”) 70
(2.756”)
120
(4.724”)

+X2 N2 MG

70
(2.750”)
120
(4.724”)

1039803
ZMN2=92,5
(3.642”) 33001130

M Machine zero point

N Tool reference point

MG Counter spindle zero point

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 4.6 Working space
4 Description of the machine and technical data

4.6.6 Cross drilling on main spindle

ZMN1=78,5
(3.091”)

N1
13 (0.512”)
(2.028”) (2.992”)

+X1
76

+X1
N1
2 4 (0.157”)
51,5

(0.079”)

(0.157”)
4
+Z +Z
M=0 M=0
85 MG

A
MG
(2.992”) (2.028”)

A
51,5

N2
+X2 +X2
76

27 (1.063”)

N2

ZMN2=92,5
1039803
(3.642”)
33001140

D Drilling depth, carriage = ca. 40 (1.575”)

D Drilling depth, carriage 2 = ca. 40 (1.575”)
D When cross drilling from carriage 1 take note of carriage 1 part
length in main and counter spindle

Operating instructions MF sprint 42/65 V 2.0 page 4-39

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4.6 Working space
4 Description of the machine and technical data

4.6.7 Parting

D Part off with counter spindle machine with carriage 2.

D Exclude collision with counter spindle chuck.
D Use a mirror image parting tool for disk shaped workpiece and in-
crease bar protrusion dependent upon the tools being used.

ZNM1=11,5
(0.453”) 20,5
N1 (0.807”)

M=0 +Z
MG

A
N2 3,7
(0.146”)

ZMN2=114,5 1039803
(4.508”) 33001150

page 4-40 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 4.6 Working space
4 Description of the machine and technical data

4.6.8 Clamping means connections4

MF sprint 42 main spindle (from commission 502501)

H5

Operating instructions MF sprint 42/65 V 2.0 page 4-41

Doc.-No.: ABB002G0
4.6 Working space
4 Description of the machine and technical data

MF sprint 65 main spindle (from commission 502501)

page 4-42 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 4.6 Working space
4 Description of the machine and technical data

MF sprint 42/65 counter spindle (from commission 502503)

Operating instructions MF sprint 42/65 V 2.0 page 4-43

Doc.-No.: ABB002G0
4.6 Working space
4 Description of the machine and technical data

4.6.9 Tool interface

27,5
45
35

48
54
0
M8 12/16 tief (4x)
(Pos.1;3;5;7) 46 38
SW 240

0
DIN 69880--30
Ø160

(8x) 38

+X1

10,5
ø8
M (8x)
+Z
ø8
(8x)
10,5

Ø160

49,5
38
DIN 69880--30
+X2
SW 240

0 (8x)

38 M8 12/16 tief (4x)

49,5
(Pos.1;3;5;7)
0
27,5
54
48

35
45

1037081_1
31410351

page 4-44 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 5.1 Starting the machine
5 Brief instructions for the machine operator

5 Brief instructions for the machine operator

These brief instructions are intended as an assistance fortrained auxi-

liary personnel.

5.1 Starting the machine

Prerequisite:

The machine is set

The first workpiece has been correctly machined

The controls are in the AUTOMATIC operating mode

The bar loading magazine is loaded

Start the machine:

Close the protection hood

Wait until the green lamp in the button has lit

Press CYCLE START key

The workpieces are being machined

Operating instructions MF sprint 42/65 V 2.0 page 5-3

Doc.-No.: ABB002G0
5.2 Stopping the machine
5 Brief instructions for the machine operator

5.2 Stopping the machine

Stop the machine in the event of a tool breakage or cutting problems.

Press CYCLE STOP key,

Notify the setter

Check the offcut box when changing shifts, empty if necessary.

5.3 EMERGENCY STOP cut-out

Hit these buttons which are in the warning colours red-yellow in the
event of danger.

page 5-4 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 5.4 Loading the bar loading magazine
5 Brief instructions for the machine operator

5.4 Loading the bar loading magazine

Variant 1

Do not reach into the bar loading magazine during operation.

Prerequisite:
The material supply is empty and an remainder from the current part
program is in the collet.

The material support surface is 310 mm, i.e. 5 bars can be laid on the
supply surface with a bar diameter of 60 mm, plus 1 bar which is
already in the guide channel.

The machine has stopped due to lack of material, fault message 9458
- 9458: M: load material into bar loader.

CYCLE STOP button

Load material

- Ensure that the bars are bevelled and do not jam when loading.
- Lay the bars flush to the left in the material supply.
- Only insert one layer. The bars must not lay on top of each other.
- Ensure that the layer does not protrude beyond the rubber lips of
the filling opening.
- When machining tubes ensure that these are provided with closing
plugs.
- Check the bar diameter with the setting data and adapt if neces-
sary. (The correct feed force is automatically set with the bar dia-
meter). As from the PLC version 05.02.1999 the feed force can be
automatically set from the part program using the variable R 738
(ᇅ bar diameter information).

// Press RESET key

I Press CYCLE START key

Operating instructions MF sprint 42/65 V 2.0 page 5-5

Doc.-No.: ABB002G0
5.2 Stopping the machine
5 Brief instructions for the machine operator

(Variant 2)

Do not reach into the bar loading magazine during operation.

Prerequisite:
There is no material in the machine or the guide channel, or a
clamped remaining piece does not match the part program variables,
R720, R725, R712.

The machine has stopped due to lack of material, fault message 9156
- 9156: F: bar operation loader: no bar found.

CYCLE STOP button

Load material

- Ensure that the bars are bevelled and not jammed when loading.
- Lay the bars flush to the left in the material supply.
- Only insert one layer. The bars must not lay on top of each other.
- Ensure that the layer does not protrude beyond the rubber lips of
the filling opening.
- When machining tubes ensure that these are provided with closing
plugs.
- In the JOG mode, position bar in the first infeed position before the
collet.
- Close the collet.
- Check the bar diameter with the setting data and adapt if
necessary. (The correct feed force is automatically set with the bar
diameter). As from the PLC version 05.02.1999 the feed force can
be automatically set from the part program using the variable
R 738 (ᇅ bar diameter information)..

// Press the RESET button

Enter a zero at VARIABLE R741

I Press the CYCLE START button

page 5-6 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
Operating instructions MF sprint 42/65 V 2.0 page 6-1
Doc.-No.: ABB002G0
6.1 Machine operating elements
6 Machine operating elements and controls

6 Machine operating elements and controls

6.1 Machine operating elements

1 2

8 7
3

9
6 SINUMERIK

33001230

page 6-2 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.1 Machine operating elements
6 Machine operating elements and controls

This section briefly explains where the individual operating

elements are located and what there functions are.

1 Data interface

2 Socket
230 V, 150 W

3 Operating hour counter

The operating hour counter displays the total number of duty
hours of the machine (important for regular maintenance work).

4 Main switch
The machine can be switched on and off and locked with a ma-
ximum of 3 padlocks.

5 Motor protection switch for chip conveyor

This switch is automatically triggered if the chip conveyor is
overloaded, e.g. in the event of a chip jam. Overcome the cause
leading to the triggering and switch the motor overload switch on
again.

6 EMERGENCY STOP
The machine can be stopped immediately from any operating
status using the emergency stop button (red-yellow).

7 Hydraulic pressure display

8 Hydraulic oil level display

9 Operating panel (see 6.2)

Operating instructions MF sprint 42/65 V 2.0 page 6-3

Doc.-No.: ABB002G0
6.1 Machine operating elements
6 Machine operating elements and controls

10

SINUMERIK

14 13

15 12
16
11
17
18

33001220

page 6-4 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.1 Machine operating elements
6 Machine operating elements and controls

10 Releasing the manual protection hood

The protection hood can be manually unlocked if the machine
power supply is off (main switch is switched off), by pressing the
release bolt with a rod shaped tool.

Ensure that the main switch is switched off a secured.

Located behind the plate are:

11 Pneumatic operating pressure display

12 Pneumatic pressure regulator (operating pressure)

13 Counter spindle clamping pressure display

14 Main spindle clamping pressure display

15 Main spindle tensile stress pressure monitor

16 Main spindle compressive stress pressure monitor

17 Counter spindle tensile stress pressure monitor

18 Counter spindle compressive stress pressure monitor

Operating instructions MF sprint 42/65 V 2.0 page 6-5

Doc.-No.: ABB002G0
6.2 Operating panel
6 Machine operating elements and controls

6.2 Operating panel

SIEMENS SINUMERIK
A
H
B
I
C
J
D
K
E
L
F
M
G
N 29
O P Q R S T U
V W X Y Z

7( 8( 9: / .
%U-- ” \

4[ 5] 67 *,
1 <
2 >
3 T
-- ^

SIEMENS SINUMERIK =? 0. . (
+-- A
A B C D E F G
H I J K L M N
O P Q R S T U
V W X Y Z

^ >
( ( : . U--
7 8 9 / % ”
\
M
4[ 5] 67 * ,
1< 2> 3T -- ^
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= 0 . + A

^
22 23 24 25 26 27 28
M >

4a 4b 5 6a 6b

8a 8b 0 I
1
7 0 1
10 11 13 14 17 19 20
2
1234 1234

%S X 0 I
F1 S+ F+
REF

%F Z // TEACH
0 I F2

9 1 Y
12 MDA
X Y
1 2 3
2
3
10 T
15 Z Z
4
1 3

Y X
100 C F3 I
0

10a 10b 14 16 18 21
31410420

page 6-6 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.2 Operating panel
6 Machine operating elements and controls

Protection Protection Key- Inching,

Machine operating modes Comments
hood hood switch movement
open closed

Machine automatic operation

Automatic operation

Individual block

Machine automatic operation or manual control

or /
Ch ki means
Chucking
M command

Bar machining, feed forward M command

Integrated bar loading magazine M command

Keyboard 21

Machine manual control

Main drive (spindle 4) Spindle keys M command

or

Tool drive and Spindle keys

counter spindle
i dl (spindle
( i dl 1+
1 2)

+ manual max 2 m/min

max.
Feed drive direction keys
Manual max. 2 m/min
direction keys

Chip
p conveyor
y
+ /

I
M command/
cycle controls

Coolant lubricant unit 0 / I

M command

Spindle locking (spindle 4/1) M command

Pick-off device M command/

softkey

Offcut ejector M command/

softkey

Move to reference point Manual

direction
keys or

Tool holder T command/

softkey

Operating instructions MF sprint 42/65 V 2.0 page 6-7

Doc.-No.: ABB002G0
6.2 Operating panel
6 Machine operating elements and controls

2 Bar loading magazine

The machine is informed whether or not work is to be performed

with a bar feeding unit by turning the key switch.

0 D The machine operates independently of the bar loading

magazine

1 D The machine operates with the bar loading magazine

3 CNC controls key switch

The key switch has 4 settings which are assigned functions by
the controls operating system. In addition, the key switch has
three different colour coded keys, which can be removed in the
specified positions:

Switch setting Removal position Function

Setting 0
-- Data is only displayed

Setting 1
0 +1 key 1 Generate, edit, delete workpiece data read in
black and out

Setting 2
0 + 1 + 2 key 2 Generate, edit, and delete interface data, archive
green lists and setting data

Setting 3 The system is loaded with the Siemens MMC

0 + 1 + 2 + 3 key 3 standard data when running up. All data in the
red ”user” directory are password protected. Important!
Only use for start up/commissioning and service!

page 6-8 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.2 Operating panel
6 Machine operating elements and controls

4a Unlock protection hood (open)

The protection hood is unlocked when this button is pressed.
The white lamp in the button signals that the protection hood
can be opened, all movements are stopped.

Use the manual hood release if you have to manually release

the protection hood (only permissible with the main switch
switched off). The protection hood must then be opened with
increased force to overcome the switch resistance (see
page 6-4, Pos. 10).

4b Close protection hood

The green lamp in the button signals that the protection hood is
correctly connected and locked.

5 EMERGENCY STOP
The machine can be stopped immediately from any operating
status using the emergency stop button (red-yellow).

6a Machine DRIVE OFF BUTTON

0
This button switches off the drives.

Only activate this button when the program is stopped and the
spindles are stationary.

6b Machine DRIVES ON BUTTON

I
The drives are switched on with this button. The lamp in the
button signals that the drives are switched on.

Operating instructions MF sprint 42/65 V 2.0 page 6-9

Doc.-No.: ABB002G0
6.2 Operating panel
6 Machine operating elements and controls

7 Agreement
Prerequisites:
The protection hood is open

Operating mode JOG

Key switch setting ( )

Actuation of the key permits the execution of dangerous

movements with the protection hood open. Here, in addition to
actuating and holding this key with one hand the required func-
tion key must be pressed with the other hand. The movement
stops as soon as one of these keys is released.

8a Chip conveyor reverse

The transport belt reverses for as long as this key is pressed.
This serves to run the transport belt free in the event of a
possible chip blockage.

Prerequisites:

The protection hood is open

JOG operating mode

Key switch setting ( )

Press and hold agreement key

Actuate function key

the chip conveyor is running

Release function key

Release agreement key

page 6-10 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.2 Operating panel
6 Machine operating elements and controls

8b Chip conveyor forward

The chip conveyor transport belt moves forward for as long as
this key is pressed.

Prerequisites:

The protection hood is open

JOG operating mode

Key switch setting ( )

Press and hold agreement key

Press function key

the chip conveyor is running

Release function key

Release agreement key

With the hood closed, the chip conveyor can only be switched
on with M commands or with the I key or switched off with the
0 key (Override).

9 Handwheel
The handwheel can be used for several functions dependent
upon the selected menu:

- Feed override (0-150%).

- Rotational speed override (50-150%).
- Moving the axes in 0.1/0.01 or 0.001 mm increments.

Operating instructions MF sprint 42/65 V 2.0 page 6-11

Doc.-No.: ABB002G0
6.2 Operating panel
6 Machine operating elements and controls

10 Keys for handwheel operation/movement by increment

%S Override spindle
This function applies to all spindles.

%F Override feed and rapid traverse

This function applies to all slides.

10a Movement by increments with variable increment

dimension
1 Increment dimension corresponds to 0.001 mm

10 Increment dimensions corresponds to 0.01 mm

100 Increment dimensions corresponds to 0.1 mm

10b Movement by increments with manual direction keys

X X axis, movement by increments

Z Z axis, movement by increments

Y Y axis, movement by increments (only for MF twin)

C C axis, movement by increments

page 6-12 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.2 Operating panel
6 Machine operating elements and controls

Prerequisites:
JOG operating mode
1 2 3 4

F+
Slide selection

1 10 100 Select increment dimension

Do not select a manual direction key.

With protection hood open:

Key switch setting ( )

Press and hold agreement key

The axis moves by one increment by pressing the required

manual direction key.

Increment movement with handwheel

JOG operating mode

1 2 3 4

F+
Select slide

1 10 100 Select increment size*

With protection hood open:

Key switch setting ( )

Press and hold agreement key

Turn handwheel
An increment movement is started with each pulse from the
handwheel.

* Selection 100 entails movements in increments of 10 .

Operating instructions MF sprint 42/65 V 2.0 page 6-13

Doc.-No.: ABB002G0
6.2 Operating panel
6 Machine operating elements and controls

REF
11 Move to reference point
Prerequisites:
Key switch setting ( )

The protection hood is closed

JOG + operating mode REF

Reference point

Manual direction key

or
Cycle start

// 12 Reset
Prerequisites:
Key Cycle stop is pressed.

Messages from the monitoring systems are deleted, where

these are not POWER ON or acknowledgement alarms.

The controls are put into the ”Reset” condition, i.e.

- the NC controls remain synchronous with the machine.

- all intermediate and working memories are deleted (however,
the content of the part program memory is retained).
- the controls are in the start position and ready for a new
program run.

page 6-14 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.2 Operating panel
6 Machine operating elements and controls

13 Operating modes

JOG operating mode

Conventional operation of the machine due to continuous axis

movement using the direction keys or by incremental movement
of the axes using the direction keys or the handwheel.

TEACH IN operating mode

TEACH

Creating programs in dialog with the machine.

MDA operating mode

MDA

Control the machine by processing a block or a sequence of

blocks. The blocks are entered via the operating panel.

AUTOMATIC operating mode

Machine control by automatic processing of programs.

Operating instructions MF sprint 42/65 V 2.0 page 6-15

Doc.-No.: ABB002G0
6.2 Operating panel
6 Machine operating elements and controls

14 SPS-Keys
0 I
F1
are function keys of the programmable logic controls.
0 I F2
Prerequisites:
Key switch setting ( )

The protection hood is closed

Lamp in the key is lit up green

JOG operating mode

or
AUTOMATIC operating mode
or
MDA MDA operating mode

Chip transporter ON, override

I
The chip transport override can be switched on with this key to
override the NC program. The light diode signals the override
status. The override is cancelled by pressing the key again.

Chip transporter OFF, override

0
The chip transport override can be switched off with this key to
override the NC program. The light diode signals the override
status. The override is cancelled by pressing the key again.

Coolant lubricant ON, override

I
Using this key it is possible to switch on the coolant lubricant for
circuit 1 (tool turret) overriding the NC program. The light diode
signals the override status. The override can be cancelled by
pressing the key again.

Coolant lubricant OFF, override

0
Using this key the coolant lubricant for all connections can be
switched off overriding the NC program. The light diode signals
the override status. The override is cancelled by pressing the
key again.

page 6-16 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.2 Operating panel
6 Machine operating elements and controls

F1
Activating optional stop M01

F2
Activating standard mask out level

F3
Activate the mask out level 8, e.g. can be used for
programming ”Stop at cycle end”

15 Chuck actuation

(Only when the deselected spindle does not

have a foot switch for the chuck)

Prerequisites:
The protection hood is open

JOG operating mode

1234

S+
Select spindle

Open chuck

Close chuck

16 Cycle keys
I

Program sequences can be automatically started or stopped

using these keys.

Cycle stop (red)

For stopping in any operating mode.

The turning spindle stops. Feed movements are immediately
stopped with the exception of thread cutting.
Started M, S, T functions are not performed. A program
interrupted in this manner can be restarted:
by pressing the cycle start key.

Operating instructions MF sprint 42/65 V 2.0 page 6-17

Doc.-No.: ABB002G0
6.2 Operating panel
6 Machine operating elements and controls

Feed stop (red)

For stopping in any operating mode.

The turning spindle continues running. Feed movements are

immediately stopped with the exception of thread cutting.

Started M, S, T functions are completed. A program interrupted

in this manner can be continued:
by pressing cycle start.

Cycle start (green)

I

For starting an NC Program.

Prerequisites:

A valid NC program must be selected

(see chapter 8)

No PLC fault displays and no NC fault displays

no PLC Messages

JOG operating mode

or
AUTOMATIC operating mode

Key switch setting ( )

The protection hood is closed

Lamp in the key lights up green

page 6-18 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.2 Operating panel
6 Machine operating elements and controls

17 Spindle keys

MF sprint:
With these keys the main spindle (spindle 4), the counter spindle
(spindle 1) and the two driven tools (spindle 2) are controlled.

MF twin:
These keys control the main spindle (spindle 4), the counter
spindle (spindle 3) and the two driven tools (spindle 1 and 2).

The symbol on the keys indicate the rotational direction from the
view of the operator.

Spindle, counterclockwise or clockwise running

Start the spindle rotation in the arrow direction at the entered

1234
speed. The spindle selected with the key is active.
S+

Prerequisites:
The protection hood is closed

JOG operating mode

The rotational speed value must have been entered Sx=...

Key switch setting ( )

Store

Enter rotational speed value

Press enter key

Press cycle start key

Lamp in the key lights up green

Operating instructions MF sprint 42/65 V 2.0 page 6-19

Doc.-No.: ABB002G0
6.2 Operating panel
6 Machine operating elements and controls

Spindle STOP

Is effective for all running spindles.

Spindle inching operation

The spindle turns for as long as this key is pressed.

Prerequisites:
The protection hood is closed

JOG operating mode

Key switch setting ( )

Lamp in the key lights up green

(Inching operation is always functional)

18 Manual direction keys

X Y

Prerequisites:
Z Z The protection hood is closed

Y X JOG operating mode

Key switch setting ( )

Lamp in the key lights up green

or
The protection hood is open

JOG operating mode

Key switch setting ( )

with agreement key, max. 1 m/min

page 6-20 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.2 Operating panel
6 Machine operating elements and controls

The axes for manually controlled feed movement are selected

using these keys. The direction keys can also be pressed in
conjunction with the rapid traverse key. When a key is pressed
the slide moves in the marked direction. The slide moves
diagonally if two direction keys are pressed simultaneously.

X
X Direction keys for moving the slide in X+ or X- direction.

Z Z
Direction keys for moving the slide in Z+ or Z- direction.
These keys can also be used for traversing the counter spindle

Rapid traverse

For moving the slides in rapid traverse with the protection hood
closed. The key must be pressed simultaneously with a direction
key to allow the slides to move at maximum speed set in the
parameter.

1234
19 Spindle switch over key
S+
The spindle selection is switched onward with this key.
Only the existing spindles are taken into consideration.

MF sprint:
1 ᇅ Counter spindle/driven tools slide 1
2 ᇅ Driven tools slide 2
4 ᇅ Main spindle

MF twin:
1 ᇅ Driven tools slide 1
2 ᇅ Driven tools slide 2
4 ᇅ Main spindle

Operating instructions MF sprint 42/65 V 2.0 page 6-21

Doc.-No.: ABB002G0
6.2 Operating panel
6 Machine operating elements and controls

1234
20 Slide switch over key
F+
The spindle selection is switched onward with this key.
Only the existing slides are taken into consideration.

MF sprint:
1 ᇅ Compound slide rest 1
2 ᇅ Compound slide rest 2
3 ᇅ Loading axis

MF twin:
1 ᇅ Compound slide rest 1
2 ᇅ Compound slide rest 2
3 ᇅ Z3 (Slides 3)

21 Keyboard for the integrated bar loading magazine

1 2 3
(Only if an integrated bar loading magazine is fitted)

page 6-22 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.2 Operating panel
6 Machine operating elements and controls

Segment 1 open/close
1

Prerequisite:
Open: - none
Close: - inserter lowered, material pusher forward
safety zone segment
LED lights up when the segment is open.

Segment 2 open/close
2

Prerequisite:
Open: - none
Close: - inserter lowered, material pusher forward
safety zone segment
LED lights up when segment is open.

Segment 3 open/close
3

Prerequisite:
Open: - none
Close: - inserter lowered, material pusher forward
safety zone segment
LED lights up when segment is open.

Operating instructions MF sprint 42/65 V 2.0 page 6-23

Doc.-No.: ABB002G0
6.2 Operating panel
6 Machine operating elements and controls

Raise/lower longitudinal pusher

Prerequisite:
Raise: - Material pusher at rear
Lower: - Material pusher at rear, inserter lowered
LED lights up when longitudinal pusher is raised.

Raise/lower inserter

Prerequisite:
Raise: - Material pusher at rear, longitudinal pusher raised
Segments raised
Lower: - none
LED lights up when inserter is raised.

Segment 4/5 open/close (Option)

4

Prerequisite:
Open: - none
Close: - Inserter lowered, material pusher forward
Safety zone segment (key preselection
not required, is activated automatically)
LED lights up when segment is open.

Move to fixed stop

LED flashes, when activated

LED light up when fixed stop is reached.

page 6-24 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.2 Operating panel
6 Machine operating elements and controls

Open/close steady rest

Prerequisite:
Open: - none
Close: - material pusher in front of steady rest safety zone
LED lights up when steady rest is open.

Raise/lower stopper

Prerequisite:
Open: - none
Close: - material pusher in front of stopper safety zone
LED lights up when stopper raised.
Preselection channel 3

1234
Material pusher forward/return
F+ Z Z
Prerequisite:
Forward: inserter lowered
Return: inserter lowered

- If an LED of the cylinder control flashes the message

”Undefined position” appears.
- If a prerequisite for the operation is not fulfilled the fault: ”F:
bar operation: Inadmissible command” appears.

Operating instructions MF sprint 42/65 V 2.0 page 6-25

Doc.-No.: ABB002G0
6.2 Operating panel
6 Machine operating elements and controls

22 Machine area
M

You can switch back to machine operation from any area at any
time using the machine area key.

23 RECALL
^
You can return to higher ranking menu using this key.

24 Sofkeys

These keys are allocated a function via a menu bar on the

screen. The selected key is optically highlighted in the symbol.

25 ETC
>
The softkey bar is extended in the same menu using this key.

26 Area switch over

You can switch over into the area menu bar using this key.
When changing the area the cancelled area is noted. The area
is returned to again by pressing the area switch-over keytwice.

page 6-26 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.2 Operating panel
6 Machine operating elements and controls

SIEMENS SINUMERIK
A
H
B
I
C
J
D
K
E
L
F
M
G
N 29
O P Q R S T U
V W X Y Z

7( 8( 9: / . %U-- ” \

4[ 5] 67 *,
1< 2> 3T -- ^
=? 0. .( +-- A

>
M
^

27 28
31410410

27 Numerical keypad with correction pad and entry

Refer to the SINUMERIK 840 C operating instructions for a

function description of the individual keys.

28 Cursor block with control keyboard

Refer to the SINUMERIK 840 C operating instructions for a

function description of the individual keys.

29 Alpha numeric block

Refer to the SINUMERIK 840 C operating instructions for a

function description of the individual keys.

Operating instructions MF sprint 42/65 V 2.0 page 6-27

Doc.-No.: ABB002G0
6.3 Menu technology and softkey bars
6 Machine operating elements and controls

6.3 Menu technology and softkey bars

6.3.1 General

After switching on the controls the switch-on picture shows when

the controls are operational.
When running up, the programs stored under the workpiece
”STANDARD” and the parts programs of the last workpiece
selected in the NC memory are loaded.

By pressing the key

^ RECALL

the MACHINE operating area is entered in the JOG operating

mode.

By pressing the

area switch over key,

five operating areas are displayed in the softkey bar.

Machine Parameter Program Utility Diagnosis

The menu tree of the selected area is entered by pressing a

softkey.

page 6-28 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.3 Menu technology and softkey bars
6 Machine operating elements and controls

The parts programs in the SINUMERIK 840 C can be edited at

two different memories:

- in the NCK memory (volatile RAM memory)

- on the fixed disk (MMC CPU)

If you are working with a volatile RAM memory, store the

changed or newly written programs on the fixed disk if they are
to be retained after the controls are switched off.
If you edit a program on the fixed disk the program must be
loaded in the NCK memory for processing.

It is possible to edit parts programs on the fixed disk during the

program sequence in automatic operation by selecting the
operating mode ”PROGRAM”.

Operating instructions MF sprint 42/65 V 2.0 page 6-29

Doc.-No.: ABB002G0
6.3 Menu technology and softkey bars
6 Machine operating elements and controls

6.3.2 Screen divisions

1 2 3 4 5 6

7 8 9 10 11 31410430

1 - Operating mode, operating function, channel condition

(area specific)

2 - Alarms, messages, comments

3 - Display of the selected area

4 - Channel status, display program influences

(area specific)

5 - Clock display, cancel condition for the existing alarm channel-

Inter-area status displays using icons

6 - BAG and channel number (area specific)

7 - Working windows NC displays, text, input keys

8 - Dialog text (area specific)

9 - Horizontal softkey bar with 7 softkey functions

10 - Input (area specific)

11 - Vertical softkey bar with 7 softkey functions

(area specific)

page 6-30 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.3 Menu technology and softkey bars
6 Machine operating elements and controls

6.3.3 Info system

Fault in info system

The following can be displayed in the area DIAGNOSIS:

- all currently existing faults/messages

Fault-No. - fault text
- Alarm logs
Date - time - fault No. - fault text

Display of current faults/messages:

Press area switch over key

Press DIAGNOSIS

Switching over of the faults/messages is made using the

keys of the vertical softkey bar.

Display of the alarm logs:

Press area switch over key

Press DIAGNOSIS

Press SERVICE DISPLAYS

Press ALARM LOGS 1

or

press ALARM LOGS 2

The alarm logs are realised as a circulating buffer; i.e. the

oldest entries are written over by new alarms.

Operating instructions MF sprint 42/65 V 2.0 page 6-31

Doc.-No.: ABB002G0
6.3 Menu technology and softkey bars
6 Machine operating elements and controls

6.3.4 Grafical operator support

A graphical support is offered if you edit a parts program in the

NCK memory.
After selecting a program with the data selector:

Press EDIT

Press SUPPORT

The following softkey functions are now available:

-- CONTOUR

-- TURN

-- DRILLING AND MILLING

-- LEVEL
Further pictures for entering programming data appear after
pressing one of the softkeys offered.

Press the ”STORE” softkey to take over the programming data

into the parts program.

page 6-32 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.3 Menu technology and softkey bars
6 Machine operating elements and controls

6.3.5 Softkey USER menu

A menu is offered operating mode pictures

-- AUTOMATIC

-- JOG

-- JOG/REFPOINT

-- MDA
using the USER softkey, from which it is possible to branch into
further pictures.

The following shows the menu structure.

The chapter numbers beneath the individual menus refer to the
chapter in the operating instructions which contain information
covering these menus.

Operating instructions MF sprint 42/65 V 2.0 page 6-33

Doc.-No.: ABB002G0
6.3 Menu technology and softkey bars
6 Machine operating elements and controls

MF sprint:

User

Set GM_cycles Sie_cycles User

Operation
parameter plan plan diagnosis

Kap 11

GM_cycles GM_cycles
1 2

Kap 11 Kap 11

Program Pick-off Div. Work- Option

mach.- Temperat. Service- Siemens-
sequence Turret ejector piece dress. Releases Version
functions data diagnosis
times dat
1
Kap 8 Kap7/8 Kap 7 Kap 11 Kap 11 Kap 11 Kap 11 Kap 11

Clamping Tool Tool Material Machine Chuck Abricht-

means change Counter Options Options
measuring transport functions daten
zero points pnt.

Kap 11 Kap 11 Kap 11 Kap 11

Workpiece R-param.
counter counter Maint. Data

Kap 11 Kap 11 Kap 10 Kap 11

Ref.-point Spindle
Count.
Turret Scratching + integr. zero point
Chuck 4 Chuck 1 spi. to
turret fit toler. bar loader manage-
ment
Kap 7 Kap 7 Kap 11 Kap 11 Kap 11 Kap 11 Kap 11

Material Conv.
feeding belt

Kap 11

intergr. ext.
Chip prg. Oil mist Div.
bar bar
conv. run. Leukhardt seperator selections
loader loader
time

Kap 11 Kap 11 Kap 11 Kap 11 Kap 11

Manufac-
Setting Setting turer’s
1 2 entries
31410630/1

page 6-34 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 6.3 Menu technology and softkey bars
6 Machine operating elements and controls

MF twin:

User

Set GM_cycles Sie_cycles User

Operation
parameter plan plan diagnosis

Kap 11

Program Conv. Chuck Various Tool GM_cycles GM_cycles

sequence Turret belt part m/c func- manage- 1 2
loader tions ment
Kap 8 Kap7/8 Kap 7 Kap 7/9 Kap 11 Kap 11

Work Option
Temperat. Service Siemens-
piece dress. Releases Version
data diagnosis
times data

Kap 11 Kap 11 Kap 11 Kap 11 Kap 11

Clamping Tool Tool

Counter Material- Machine Chuck Dressing
means change Options Options
measuring transport functions data
zero points pnt.

Kap 11 Kap 11 Kap 11

Workpiece R-param.
counter counter Maint. Data

Kap 11 Kap 11 Kap 10 Kap 11

Measuring Chip prg. Ref.-point Spindle

Turret
Measuring
Scratching probe ref. probe conv. run. Leukhardt Oil mist Div. + zero
time seperator selections fit toler. offset
measuring

Kap 7 Kap 7 Kap 11 Kap 11 Kap 11 Kap 11 Kap 11

Material Conv.
feeding belt Chuck 4 Chuck 3 Chuck 2

Kap 11 Kap 11

ext. Chuck 4 Chuck 4 Chuck 4 Check 3 Chuck 3 Chuck 3

bar parameter path parameter parameter path parameter
loader 1 2 1 2

Kap 11 Kap 7/11 Kap 7/11 Kap 11 Kap 7/11 Kap 7/11 Kap 11

31410630/2

Operating instructions MF sprint 42/65 V 2.0 page 6-35

Doc.-No.: ABB002G0
6.3 Menu technology and softkey bars
6 Machine operating elements and controls

page 6-36 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.1 Switching the machine on and off
7 Setting, make ready and operation

7 Setting, make ready and operation

7.1 Switching the machine on and off

7.1.1 Switching on the machine

The following steps are necessary in order to switch on the machine:

Check oil level and top up if necessary (see chapter 10, Checks prior
to starting work)

If necessary, release the EMERGENCY STOP button on the

operating panel and the integrated bar loading magazine.

If any peripheral units such as bar feeders etc. are connected also
here the EMERGENCY STOP buttons must be released.

Switch on main switch

I Press ”Drive ON” key

Press ”Release protection hood” key

Open protection door

Ensure no workpiece is in the clamping means.

Open clamping means main spindle

Push back the bar until it is flush with the collet.

Remove the workpiece from the counter spindle

Close clamping means

Close the protection hood

The protection hood function test is now completed.

Operating instructions MF sprint 42/65 V 2.0 page 7-5

Doc.-No.: ABB002G0
7.1 Switch the machine on and off
7 Setting, make ready and operation

Check the basic setting of the finished part pick off unit and the
offcut ejector.

// Press the ”Reset” key

A pending fault message is cancelled.

// Press the ”Reset” key

Further fault messages are cancelled.

Move to reference points

Move to the reference point each time the machine is switched on. In
this manner the machine measuring system is activated.

To move to reference point all auxiliary units must be in their start

position or working position, e.g. the tool holders must be locked. The
protection doors and all electrically monitored subsidiary doors must
be closed.

The reference point movement can be started independent of the

slide position.

The LED’s above the keys flash for as the long reference point has
not been moved to.

REF
REFERENCE and JOG

M Select MACHINE area

Select JOG operating mode

page 7-6 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.1 Switch machine on and off
7 Setting, make ready and operation

REF
Press ”Reference” key

The initial mask JOG REFPOINT

Press ”cycle start” key

The slides move to the reference points. The screen shows the
individual spacings between tool holder zero point and the
machine zero point for X and Z.

Also observe G54 (see programming instructions)

Sequence for reference run (axes):

1) X1 and X2
2) Z1 and Z2

LED above the JOG key lights up

LED above ”Reference” key extinguishes

Initial mask JOG

Move the slide to the start point of your automatic program

or
to a position in which the machine can be set without obstruc-
tion.

As an alternative you can move each axis individually to the

reference point.
1 2 3 4

For this preselect the axes with the slide selection key F+
and
move with the direction key .

Operating instructions MF sprint 42/65 V 2.0 page 7-7

Doc.-No.: ABB002G0
7.1 Switching the machine on and off
7 Setting, make ready and operation

7.1.2 Swiching off the machine

Only switch the machine off when the spindles and axes are
stationary. Otherwise machine damage can result.

Prior to switching off the machine the workpiece must be removed

from the chucking means of the counter spindle. The hydraulic
pressure drops slowly after switching off the machine.

This implies the danger that the workpiece will be released from the
chucking means.

Proceed as follows when switching off the machine:

D Terminate the running program

Remove the workpiece from the counter spindle

0 Press ”Drives OFF” key

Main switch in position 0

The operating hour counter stops. The screen is black.

page 7-8 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.1 Switching the machine on and off
7 Setting, make ready and operation

7.1.3 EMERGENCY STOP cut-out

Only use the EMERGENCY STOP BUTTON when danger exists.

You can immediately stop the machine in any operating condition.
For this press the red EMERGENCY STOP BUTTON.
This stops the slide and spindle feeds immediately in a defined
manner. All movements are stopped.
No further moving machine function is possible.
In order to restart the machine, reset the EMERGENCY STOP
BUTTON.
Following this proceed as described in this chapter Switching on the
machine.
Whereby the main switch must not be actuated, and manner also it is
not necessary to move the axes to the reference point.

Operating instructions MF sprint 42/65 V 2.0 page 7-9

Doc.-No.: ABB002G0
7.2 Setting and make ready
7 Setting, make ready and operation

7.2 Setting and make ready

7.2.1 A review of the work sequence

D Select clamping means

Do not exceed the maximum rotational speed and clamping force of

the clamping means. Set the parameter accordingly.

- Set parameters for clamping means

- Select collet or chucking jaws

D Lock spindle
D Fit clamping means completely
- Determine end positions

Set clamping pressure and spindle rotational speed accordingly.

Do not exceed the maximum jaw weight.

- Select tools
- Remove tools from tool holder which are not required, fit tools
required
- Enter tool dimensions in the tool compensation memory
- Close off the tool positions not required in the tool disc using
plugs and O rings.

page 7-10 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.2 Setting and make ready
7 Setting, make ready and operation

D Switch on collision monitoring (see Fig. 1)

31410710

Fig. 1

D Load workpiece programs

D Load tool program

Run through the program first without material.

Operate at reduced rapid traverse and feed (Override).

D Produce and measure the first workpiece.

- Correct the tools and/or program in accordance with the result.

The work steps are described in detail on the following pages.

Operating instructions MF sprint 42/65 V 2.0 page 7-11

Doc.-No.: ABB002G0
7.3 A review of the clamping device
7 Setting, make ready and operation

7.3 A review of the clamping device

The clamping device on the main spindle (Fig. 2) and on the counter
spindle (Fig. 3) serve for clamping the workpieces. The clamping
pressure set on the pressure reduction valve acts on the clamping
cylinders.

The clamping devices are opened or closed by pressing the

”Open chuck”

”Close chuck”

keys.

Enter the following in the control parameters:

D Type of clamping means

D Clamping mode (tension/pressure clamping)

The clamping unit is monitored to ensure that safe clamping is

guaranteed.

Clamping pressure monitoring function

Pressure failure or too low pressure prevent a start up of the turning
spindle or stop same.

Ensure that the pressure switches of the clamping units are always
set at 5 bar lower than the clamping pressure.

page 7-12 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.3 A review of the clamping device
7 Setting, make ready and operation

Main spindle clamping unit

1 2 3 4

6 7 8

5
1160135
33001260

Fig. 2
1 Cover 6 MF sprint 42: M10x40 DIN 933 - 10.9 (Md = 70 Nm)
2 Clamping ring MF sprint 65: M12x40 DIN 933 - 10.9 (Md = 120 Nm)
3 Internal chucking cylinder 7 Tension tube
4 Ring 8 Spanntop coupling
5 Protection against torsion

Counter spindle clamping unit

1 2 3

1160254
33001270

Fig. 3
1 Flange 3 Spindle
2 Piston with clamping tube

Operating instructions MF sprint 42/65 V 2.0 page 7-13

Doc.-No.: ABB002G0
7.4 Spindle locking
7 Setting, make ready and operation

7.4 Spindle locking

The spindle locking for the main and counter spindle is made using
one hydraulic spindle brake each.

Close protection doors

M Select MACHINE area

Select JOG operating mode

Press STORE

You can stop the spindles in a defined position using the M

commands:

M4=19
S4 = 90 ᇅ e. g. 90_ angle = Stop the main spindle (S4)
in a defined position.

M1=19
S1 = 90 ᇅ e.g. 90_ angle = Stop the counter spindle (S1)
in a defined position.

Confirm entry

Press CYCLE START key

Main spindle:
M 412 (Clamping ON)

or

M 413 (Clamping OFF)

page 7-14 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.4 Spindle locking
7 Setting, make ready and operation

Counter spindle:
M 112 (Clamping ON)

or

M 113 (Clamping OFF)

Confirm entry

Press CYCLE START key

In the case of a counter spindle without stopping brake the counter

spindle can be locked by blocking a driven tool on tool holder 1 (e.g.
using an open jaw spanner).

Do not leave the tool in the working space when overcoming the
locking.

Operating instructions MF sprint 42/65 V 2.0 page 7-15

Doc.-No.: ABB002G0
7.5 Fitting and removing the clamping means
7 Setting, make ready and operation

7.5 Fitting and removing the clamping means

The clamping cylinder and tensioning tube form a screwed and

secured unit.
The clamping means couplings are screw fitted to the spindle with the
tensioning tube and the chuck body (see Fig. 4, Fig. 5 and Fig. 6).

7.5.1 Removing the clamping means

Three jaw chuck

3 1 4
Ø30,2

Ø25,5

2
27

3
0
45,5

1036965
31410740

Fig. 4
1 Three jaw chuck
2 Fixing screws (torque as per manufacturer’s instructions)
3 False jaw
4 Tensioning tube

page 7-16 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.5 Fitting and removing the clamping means
7 Setting, make ready and operation

M Select MACHINE area

Select JOG operating mode

Spindle locking

Open protection hood

Move clamping jaws together

Dismantle interchangeable false jaws

Unscrew chuck fixing screws

Move clamping jaws apart

The chuck will release from the spindle flange.

Unscrew the chuck and connection piece from the tensioning

tube by turning counterclockwise

Lay aside the chuck

Operating instructions MF sprint 42/65 V 2.0 page 7-17

Doc.-No.: ABB002G0
7.5 Fitting and removing the clamping means
7 Setting, make ready and operation

Spanntop chuck (Main spindle MF sprint 42)

6 2 1 3 4 5

7--36
7--30
M

42

0
max.61,5
0

50
min 50

1160487
33001281

Fig. 5
1 Spanntop chuck size 42 4 Clamping head
2 Clamping head coupling 5 Change device
3 DIN 912 M10x50-10.9 6 Tension tube

Spanntop chuck (Main spindle MF sprint 65)

Fig. 6
1 Spanntop chuck size 65 4 Clamping head
2 Spanntop coupling 5 Change device
3 DIN 912 M12x30-10.9 6 Tension tube

page 7-18 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.5 Fitting and removing the clamping means
7 Setting, make ready and operation

Spanntop chuck (Counter spindle)

5 4 1 3 2 6
Md=33Nm

7--30

7--36
ø5--42

ø22,5
82,5 max

71

24

0
80,0 min

1036935
31410760

Fig. 7
1 Spanntop chuck size 42 4 Clamping head
2 Clamping head coupling 5 Change device
3 DIN 912 M8x25-10.9 6 Tension tube

M Select MACHINE area

Select JOG operating mode

Spindle locking

Open protection door

Release collet

Remove collet with change device

Unscrew chuck fixing screws

Unscrew clamping head coupling by turning counter clockwise

from the tensioning tube (if necessary, using special tools
belonging to the clamping means)

Operating instructions MF sprint 42/65 V 2.0 page 7-19

Doc.-No.: ABB002G0
7.5 Fitting and removing the clamping means
7 Setting, make ready and operation

7.5.2 Fitting the clamping means

Three jaw chuck

Grease clamping means

Grease connection thread

M Select MACHINE area

Select JOG operating mode

Spindle locking

Open protection hood

Bring tension tube to front position

Carefully clean spindle flange

if necessary check the chuck flange for concentricity

< 0.01 mm

Screw in chuck as far as possible by turning clockwise

Turn back until screw fitting holes match

Loosely screw in the chuck fixing screws

Move back tension tube

Lightly tighten the chuck fixing screws

Close protection door

Release spindle locking

Open protection door

page 7-20 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.5 Fitting and removing the clamping means
7 Setting, make ready and operation

Check run-out (< 0.01), if necessary, align chuck

Close protection door

Spindle locking

Tighten chuck fixing screws

Check and record the clamping force on the power operated chuck in
accordance with the data shown in the clamping force diagram using
a clamping force measuring instrument.

If a chuck flange is required for fitting the chucking means, ensure

that it is checked for a concentricity and run-out of < 0.01 mm.

Spanntop chuck
Greasing the clamping means

Greasing the connection thread

Press operating mode key

M Select MACHINE area

Select JOG operating mode

Open protection door

Move tension tube to the front position

Carefully clean the spindle flange

Push the chuck in the spindle and tighten with fixing screws.

If necessary, check flange for concentricity < 0.01 mm

Connect Spanntop coupling to the tension tube by turning

clockwise.

Operating instructions MF sprint 42/65 V 2.0 page 7-21

Doc.-No.: ABB002G0
7.6 Check and set clamping pressure
7 Setting, make ready and operation

7.6 Check and set the clamping pressure

Checking and setting the clamping pressure The clamping pressure

must be matched to the workpiece type and must not exceed the ma-
ximum permissible clamping pressure of the clamping means used.
The currently set clamping pressure can be read off from the pres-
sure gauge:
Main spindle clamping pressure pressure display (Fig. 8/1)
Counter spindle clamping pressure pressure display (Fig. 8/2)

1 2

3 4 31410770

Fig. 8

Change clamping pressure

Adjust pressure on the pressure reduction valves:

Main spindle pressure regulator (Fig. 8/3)

Counter spindle pressure regulator (Fig. 8/4)

The max. permissible clamping force is engraved on the chuck.

The actuation force values can be found in the clamping force-
actuation force diagram on the machine.

Ensure that the pressure switch is always set at 5 bar lower than the
clamping pressure.

page 7-22 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.7 Loading the tool holder
7 Setting, make ready and operation

7.7 Loading the tool holder

Danger of injury
Always wear protection gloves when loading the tool holder.

Swivel tool holder for a tool change:

Press ”Cycle Stop” key

The automatic sequence is interrupted

or
Select JOG operating mode

Traverse the slide so that the tool can swivel freely without the tool
colliding when swivelling.

Operating instructions MF sprint 42/65 V 2.0 page 7-23

Doc.-No.: ABB002G0
7.7 Loading the tool holder
7 Setting, make ready and operation

Press USER

Press OPERATION

Press TURRET

Fig. 9

Press TURRET_FORWARD

The tool holder is indexed forward one station

Press TURRET_RETURN

The tool holder is indexed back one station

page 7-24 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.7 Loading the tool holder
7 Setting, make ready and operation

Remove unrequired tools.

Fit the tools required for workpiece machining.

Ensure that the tools are clean and free of chips/swarf prior to fitting.

Close off the unused tool holder positions using a plug and O ring.
Ensure that the tool holder is in contact with the tool surface.

The tool positions 1, 3, 5 and 7 can be fitted with driven tools.

Press TURRET _ START POS.

The tool holder position swung into working position is that

which was operative at the time of the automatic sequence
interruption (except in JOG operation).

The start position is set as the actual position after pressing the
”RESET” key.
A message is transmitted if the actual position does not conform with
the start position when starting the cycle.

Operating instructions MF sprint 42/65 V 2.0 page 7-25

Doc.-No.: ABB002G0
7.8 Scratching
7 Setting, make ready and operation

7.8 Scratching

Prerequisites

- The spindle is running in accordance with the tool cutting edge

position
- The workpiece turning diameter is known
- The end face of the workpiece is known

Traverse the slide so that the tool can swivel freely without the tool
colliding when swivelling.

M Select MACHINE area

Select JOG operating mode

Press STORE

Select input field for channel 1 or 2

Deselect tool compensation, enter DO

Press enter key

I Press ”Cycle Start” key

Enter tool position number T

Press enter key

I Press ”Cycle Start” key

The selected tool holder position is swivelled into the working

position.

page 7-26 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.8 Scratching
7 Setting, make ready and operation

M Select MACHINE area

Press USER

Press PARAMETER SETTING

Press TOOL MEASURING

Press SCRATCHING

Fig. 10

Input fields

Correction No. D=
Position No. (T) P0=
Tool type P1=.. (A picture to determine the
tool type can be called up
using the help key)
Cutting radius P4=..
Workpiece diameter in mm or inches
Workpiece length in mm or inches

P5, P6, P7, P8, P9 are set to zero

Operating instructions MF sprint 42/65 V 2.0 page 7-27

Doc.-No.: ABB002G0
7.8 Scratching
7 Setting, make ready and operation

Press D NO. READ OUT

Scratch workpiece in the X direction using handwheel

Press TAKE OVER

The calculated distance between tool tip and tool holder zero
point appears in field P2= ..

Scratch workpiece using handwheel in the Z direction

Press TAKE OVER Z

The calculated distance between tool tip and tool holder zero
point appears in field P3= ..

Press TAKE OVER DATA

The data is taken over in the tool compensation memory.

page 7-28 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.9 Driven tools
7 Setting, make ready and operation

7.9 Driven tools

Make the machine operational and swing in the driven tool.

Manual setting
M Select MACHINE area.

Select JOG operating mode

1 2 3 4

S+ Preselect spindle 1 or spindle 2

Press STORE

Enter rotational speed value S1 or S2

Press enter

I Press CYCLE START key

or Pressing key starts the driven tool

Check the rotational direction of the tool used.

The rotational speed of the driven tool is set.

To stop press the spindle stop key.

Repeat the setting procedure for the other tool holders.

All set point values are deleted using the RESET key.

Operating instructions MF sprint 42/65 V 2.0 page 7-29

Doc.-No.: ABB002G0
7.9 Driven tools
7 Setting, make ready and operation

Setting using the M function

Swiveling in the tool.

M Select MACHINE area

Select JOG operating mode

Press REPLACE

Select turning direction

M1 (driven tools 1) = 3 or 4
M2 (driven tools 2) = 3 or 4

S1 = ...
S2 = ...

Press enter key

I Press ”cycle Start” key

Check the tool rotational direction.

page 7-30 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.10 Operating life monitoring
7 Setting, make ready and operation

7.10 Operating life monitoring

Press USER

Press OPERATION

Press PROGRAM SEQUENCE

Fig. 11

The operating life function can be switched active/inactive in the

menu mask.

The tool table with D compensations also provides columns for the
set point operating life and the actual value operating life. In addition,
it is possible to select in one column whether the operating life is to
be counted in machining time in minutes or number of workpieces.

If ”Minutes of machining time” is shown for the tool operating life, the
actual operating life for this tool is counted up when it is in operation.
The tool machining time is recorded with a resolution in seconds
when the tool is swung in, the slide moves in automatic and the
movement is not a rapid traverse (main time).

Operating instructions MF sprint 42/65 V 2.0 page 7-31

Doc.-No.: ABB002G0
7.10 Operating life monitoring
7 Setting, make ready and operation

Fig. 12

If ”number of workpieces” is shown as the operating life for a tool

then the tool compensation is recorded and the actual operating life
counted up with the counter signal (M 18).
A maximum of 19 tool compensations with ”number of workpieces”
can be processed. If more than 19 tool compensations are defined
on a number of workpieces basis as operating life, then only the first
19 compensations are processed.

The tool operating life has elapsed when the value for the actual ope-
rating life reaches or exceeds the set point operating life value. The
operating life is not processed when the set point operating life is 0 or
the operating life administration system is not active.

Once the operating life of a tool has elapsed and no replacement tool
is present for this tool or the spare tool administration system is inac-
tive, the machine stops at the end of the program and emits a fault:
”Tool operating life has elapsed”.
The operator must change the tool or tip and reset the operating life
to 0.

page 7-32 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.10 Operating life monitoring
7 Setting, make ready and operation

7.10.1 Spare tool administration system

Press USER

Press OPERATION

Press PROGRAM SEQUENCE

Fig. 13

The spare tool administration system can be switched active/inactive

in the menu mask.

In the operating life table also a follow-up D number can be specified.

Once the operating life has elapsed and the spare tool administration
system is selected, the follow-up D number is used as spare tool.
When using the spare tools it is absolutely necessary to enter the tool
position in the first table column.

Operating instructions MF sprint 42/65 V 2.0 page 7-33

Doc.-No.: ABB002G0
7.10 Operating life monitoring
7 Setting, make ready and operation

Programming and design:

D If D and T are programmed together in a block, the follow-up D

number as well as the T number specified for the following tool
are used, if the original tool operation life has elapsed.
D If only D is programmed in a block then the replacement D
number is used when the operating life has elapsed.
D If only T is programmed in a block, then the programmed tool
position is swung in.

A maximum of 19 operating life times can elapse. If a further

operating life elapses the machine will stop at the end of the cycle
and emit the message ”Operating life elapsed”, even if spare tools
are specified for these tools.

If more than one D number is assigned for a tool, a set point

operating life can only be entered for one D number. For the second
D number, the tool position recognises that it is no longer to be used.
In this case the specific follow-up D number replaces this D number.

With the spare tool administration system activated the program

running time increases by 0.5 seconds per tool call up, as the
operating life is checked for each T and D value. If the operating life
of a tool has elapsed, the spare tool is used. In this case the program
running time is increased considerably (approx. 3 seconds per
elapsed tool), because also the operating life of the spare tool must
be checked and the spare tool as well as its D value can only be
invoked by the PLC by way of program interrupt.

page 7-34 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.11 Pick-off device
7 Setting, make ready and operation

7.11 Pick-off device

7.11.1 Application possibilities

The machined workpieces are picked up automatically from the main

or counter spindle by the pneumatically driven pick-off device and
transported to the workpiece box or the conveyor belt.

max. workpiece « = 65 mm

max. Workpiece length = 120 mm

The workpiece length is dependent upon the tool being used, see
working space, longitudinal, chapter 4.

Operating instructions MF sprint 42/65 V 2.0 page 7-35

Doc.-No.: ABB002G0
7.11 Pick-off device
7 Setting, make ready and operation

7.11.2 Basic setting

The pick-off device is located to the right in the tool space when in
the start position. The chute (Fig. 14/1) protrudes through a window
in the right hand side panel (Fig. 14/4) above the workpiece box
(Fig. 14/6) or the conveyor belt.

The chute is provided with an outlet flap (Fig. 14/2), which is opened
by a cam (Fig. 14/3) in the starting position.

The cam is located inside the right hand side wall and is accessible
when the workpiece box panelling (Fig. 14/5) is dismantled.

The pick-off device is located outside of the chip chute when in the
start position. The inlet opening is covered when in the start position.

1 2 3 4

1037108
31410780

Fig. 14

page 7-36 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.11 Pick-off device
7 Setting, make ready and operation

Move the pick-up device into the start position/working position.

Close the protection door

Select JOG operating mode

Press USER

Press OPERATION

Press PICK-OFF/EJECTOR

Fig. 15

Operating instructions MF sprint 42/65 V 2.0 page 7-37

Doc.-No.: ABB002G0
7.11 Pick-off device
7 Setting, make ready and operation

Press PICK-OFF FORWARD

The pick-off moves to the working position

Press the softkey for as long as the condition ”1” is signalled
for this softkey on the screen.

Press PICK-OFF RETRACT

The pick-off moves to start position

Press the softkey for as long as the condition ”1” is signalled
for this softkey on the screen.

page 7-38 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.11 Pick-off device
7 Setting, make ready and operation

7.11.3 Set up pick-off position

Close protection door

Select JOG operating mode

1 2 3 4

F+ Select slide 2

Move the slide 2 in -Z/+X using the direction keys

Move back the slide in both directions approx. 1 mm once the slide
end positions have been reached (move free of limit switch).

Press USER

Press OPERATION

Press PROGRAM SEQUENCE

Set channel 2 to ”0” (see chapter 8)

^ Select start mask

Select AUTOMATIC operating mode

Press SELECT PROG./JOB

Position the cursor at the top in the menu selection list

Enter the SPF number (”Workpiece pick-off”sub-program”)

Press enter key

Press SELECT PROG./JOB

The program is displayed on the screen.

Operating instructions MF sprint 42/65 V 2.0 page 7-39

Doc.-No.: ABB002G0
7.11 Pick-off device
7 Setting, make ready and operation

Set the feed on the handwheel to 10%

Select SINGLE BLOCK operating mode

I Press ”Cycle Start” key

The program is processed block for block.

Press the ”Cycle start” key again after each step.

The following unloading program is an example.

%SPF1051 Spindle 1 finished part unloading

N15 G54
N20 G59 X0 Z=R723
N25 T* D0 M645 Chute forward * tool position free or short tool

N30 M831
N35 G0 G53 Z200 M1=5 Unloading cycle start position.
A gap of 1 mm must be provided between the setting
screw and the stop plate
N40 G0 G53 X70
N45 G4 F0.1
N50 M133 Chuck open
N55 G4 F0.1
N60 G1 G53 G94 Z260 F8000 Ejection. Ejector must be flush with the jaws.
N65 G4 F0.2
N70 M644 Chute retracts
N75 M608 Start conveyor belt
N80 R1=2 L710 Tool change point
N85 @620 R699 Part counter
N90 @121 R701 K1 K100
N95 M18 Part counter
N100 R701=0
N9999 M17

NOTE: Differences in traverse path between N 35 and N 60 = pick-off depth

(Path of the ejector head)

After checking the unloading program, set the channel 2 to ”1” again
using the USER channel menu.

page 7-40 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.11 Pick-off device
7 Setting, make ready and operation

You have two possibilities of setting the pick-off position

- Mechanical adaptation
- Changing the coordinates

Mechanical adaptation
Set the set screw (Fig. 16/1) so that the ejector of the counter spindle
is flush with the clamping jaws when in the rear position of the
unloading program. The length of the pull-out (Fig. 16/2) can be
adjusted as required.

3 1

31410500

Fig. 16

Changing the coordinates

Only authorised persons are permitted to undertake program
changes.

Move the Z axis until an air gap of approx. 1 mm exists between

setting screw (Fig. 16/1) and stop plate (Fig. 16/3).
Take over the coordinates for the Z axis into the unloading program.

Operating instructions MF sprint 42/65 V 2.0 page 7-41

Doc.-No.: ABB002G0
7.11 Pick-off device
7 Setting, make ready and operation

7.11.4 Pick-off unit unloading cycle

D Tool holder 2 can operate on the main spindle

Ensure that no collision can occur.

D Slide 1 moves to the pick-off position.

The ejector is not actuated if an incorrect X or Z position is moved
to.
D Pick-off slide moves to the pick-off position (Fig. 17/1)
D Counter spindle clamping device (Fig. 17/2) is released.
D Slide 1 moves in +Z1 direction (Fig. 17/3). The workpiece
(Fig. 17/4) is ejected from the ejector (Fig. 17/5) into the chute
(Fig. 17/6).
D The pick-off slide moves to the start position (Fig. 17/7) and brings
the workpiece to the workpiece lay-up.

4 5

1 7
3
2

6
31410550

Fig. 17

page 7-42 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.11 Pick-off device
7 Setting, make ready and operation

7.11.5 Counter spindle ejector

The counter spindle is equipped with an ejector. The ejector is

mechanically actuated by the pick-off unit slide. The setting screw
(Fig. 18/4) moves forward against the plate (Fig. 18/3) moving the
ejector rod (Fig. 18/2) forward against the spring (Fig. 18/5). The
setting screw mounting allows it to move.

Changing the ejector plate

Screw the screw into the ejector plate (Fig. 18/1)

Fit the new ejector plate

Setting the ejector

Adjust the setting screw (Fig. 18/4) on the pick-off device slide
as required.

The ejector path is determined by the programming of the Z1

axis.

1 2

3 4 5

31410560

Fig. 18

Operating instructions MF sprint 42/65 V 2.0 page 7-43

Doc.-No.: ABB002G0
7.11 Pick-off device
7 Setting, make ready and operation

Move ejector to start position/working position

Close protection door

Select JOG operating mode

Press USER

Press OPERATION

Press PICK-OFF/EJECTOR

Fig. 19

page 7-44 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.11 Pick-off device
7 Setting, make ready and operation

Press EJECTOR FORWARD

The ejector moves to the operating position

Press the softkey until the status ”1” is signalled for this softkey
on the screen.

Press EJECTOR RETURN

The ejector moves to the start position.

Press the softkey until the status ”1” is signalled for this softkey
on the screen.

Operating instructions MF sprint 42/65 V 2.0 page 7-45

Doc.-No.: ABB002G0
7.11 Pick-off device
7 Einrichten, Rüsten und Betreiben

7.11.6 Conveyor belt operation

Close protection door

Select JOG operating mode

Press USER

Press OPERATION

Press PICK-OFF/EJECTOR

Fig. 20

Press RUN CONVEYOR BELT EMPTY

The conveyor belt is switched on.

The belt continues to run until the time entered under running
time has elapsed (see 11.1, ”Conveyor belt” setting parameter).

page 7-46 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.12 Off-cut disposal
7 Setting, make ready and operation

7.12 Off-cut disposal

Bar off-cuts which do not permit a complete machining of the work-

piece are transported into the off-cut box by the off-cut disposal
system.

Workpiece length 20 40 60 80 100 120

Off-cut length max. 90 110 130 150 170 190

3 4 5 6 7 8 9

1 2

31410790

Fig. 21

1 Main spindle
2 Tool holder 1
3 Ejector cylinder
4 Unloading position
5 Off-cut
6 Off-cut holder
7 Setting screw
8 Disposal chute
9 Off-cut box

Operating instructions MF sprint 42/65 V 2.0 page 7-47

Doc.-No.: ABB002G0
7.12 Off-cut disposal
7 Setting, make ready and operation

7.12.1 Setting the off-cut disposal

Select JOG operating mode

1 2 3 4

F+ Select slide 1

Move the slide 1 into the collision free swivel position

Select the tool position of the off-cut holder (e.g.T8/D18):

Press STORE

Tx/Dx

Press enter key

I Press ”Cycle start” key

Move slide 1 to position X0

Open protection door

Open main spindle clamping device

Set off-cut holding jaws to off-cut diameter

Push the off-cut into the off-cut holder with a new bar

page 7-48 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.12 Off-cut disposal
7 Setting, make ready and operation

Swivel the tool holder 1 into the unloading position

Enter M 631

The off-cut is ejected by the ejector cylinder into the disposal

chute.

Set the disposal chute to the off-cut middle using the setting screw.

Enter M 630

The ejector cylinder moves back to its start position

The off-cuts are transported into the off-cut box and must be disposed
of at regular intervals.

Return the off-cut box to the holder after emptying, otherwise new
off-cuts will drop onto the off-cut box holder.

Operating instructions MF sprint 42/65 V 2.0 page 7-49

Doc.-No.: ABB002G0
7.12 Off-cut disposal
7 Setting, make ready and operation

7.12.2 Off-cut jam

An off-cut jam will form if the off-cut box is not emptied.

In this case the ejector cylinder no longer reaches the front end
position.

Overcome off-cut jam:

Enter M 630

The ejector cylinder moves to its start position.

Open the off-cut box and remove the off-cut.

Using M 630 and M 631 the ejector cylinder forward and return
movement is repeated and the end position acknowledged.

page 7-50 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

7.13 Bar machining

You can machine bar material using various options:

D Bar machining with integrated bar loading magazine
D Bar machining with external bar loading magazine (option)
D Bar section machining only with the lathe (Option)
D Bar machining with bar feeding (Option)

7.13.1 Change of spindle reduction tubes

Spindle reduction tubes are required when machining bars or bar

sections. These guide tubes are inserted into the spindle.

The internal diameter of the spindle reduction tube

- must be 2 mm larger than the diameter of the longitudinal
pusher used when using an integrated bar loading magazine
and
- Diameter of the material to be machined 1 mm larger when
machining bar sections
- for external bar feeding units the diameter must be matched to
the longitudinal pusher.

Insert the spindle reduction tube as follows:

Press the ”Cycle stop” key

Open the protection hood

Clear the working area behind the spindle, unlock and move the
loader

Operating instructions MF sprint 42/65 V 2.0 page 7-51

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

The spindle can no longer be started

Remove the clamping ring (Fig. 22/2) for the spindle reduction
tube, by loosening the three screws.

Pull out the spindle reduction tube (Fig. 22/1)

31410800

Fig. 22

Push the spindle reduction tube through up to the stop

(Fig. 23/1)

Fit the clamping ring

31410810

Fig. 23

page 7-52 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

7.13.2 Material requirements

D Bar straightness
Ensure that the straightness does not exceed a tolerance of 0.5 mm
per running metre. This information refers to a uniform bend and not a
short kink within one metre.

D Rotational speed limits

Information concerning the rotational speed limits are given as guide
values in the manufacturer’s operating instructions.

D Workpiece remaining length (ext. bar feeding unit)

The workpiece remaining length is determined by the length of the
spindle motor with open centre clamping unit and the clamping means
fitted. Observe the operating instructions of the bar feeding unit
manufacturer.

D Workpiece remaining length (integr. bar loading magazine)

(see Kap. 7.13.3)

D Machining profile bars

Always pay particular attention when loading new profile bars into the
bar feeding unit. In all cases undertake machining on the lathe with a
collet chuck. If pressure collets are used in accordance DIN 6343,
then, if necessary, secure against torsion in the chuck.

Operating instructions MF sprint 42/65 V 2.0 page 7-53

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

Bar preparation
Conically adapt the bar end to 30° when using the maximum holder
diameter of the guide tube (See Fig. 24)

ø 0,3 A
A
d = 0,8xD

D
d

0,3 A
+0,3
d +0,2

A
0,1 A
d

31410820

Fig. 24

Hollow bars: (tubes)

Produce a closing plug in order to avoid oil loss and oil smearing with
lathe coolant.

ø 0,3 A
A

d = 0,8xD
d

O -- Ring
31410830

Fig. 25

page 7-54 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

7.13.3 Integrated bar loading magazine

Setting and equipping the bar loading magazine

Close machine protection door

Close bar loading magazine protection hood

Select JOG operating mode

1 2 3 4

F+ Select slide 3

Z Press the direction key ”Z-” or ”Z+” until the longitudinal pusher
is in the middle of the segment.

1
Open segment 1

2
Open segment 2

3
Open segment 3

4
Open segment 4/5 (Option)

The light diode above the keys are illuminated when the
segment is open

Open machine protection door

Open bar loading magazine protection hood

Condition, triple signal lamp

green: flashing or steady light
and
yellow: flashing (Attention! bar change imminent)

Unlock the catcher hooks and remove the longitudinal pusher

Close machine protection door

Close bar loading magazine protection hood

Move the short pusher into the start position (direction key ”Z-”)

Operating instructions MF sprint 42/65 V 2.0 page 7-55

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

Open machine protection door

Open bar loading magazine protection hood

Condition, triple signal lamp

green: flashing or steady light
and
yellow: flashing (Attention! bar change imminent)

Exchange the following parts of the bar loading magazine in

order to adapt the bar loading magazine to a new bar diameter:

- the upper and lower segments of the guide channel

The segments are locked with spring loaded tension bolts
(Fig. 26/1).
To remove the segments pull the tension belts and remove the
segment from the guide.

After inserting the segments check to ensure that they are correctly
engaged.

1 1

31410470

Fig. 26

page 7-56 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

- the right hand holder (Fig. 27/1) of the longitudinal pusher

Fig. 27

Open the locking beneath the machine bath of the bar loading
magazine in order to exchange other parts.

For this pull out the bolt (Fig. 28/1) and lock the lever (Fig. 28/2)
Then push the top section of the bar loading magazine to the left.

2
33001500

Fig. 28

Operating instructions MF sprint 42/65 V 2.0 page 7-57

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

Open the flap (Fig. 29/1)

31410440

Fig. 29

- the guide bush (Fig. 30/1)

- the centering jaws (Fig. 30/2) of the steady rest (Option)

1 2

Fig. 30

page 7-58 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

Push the top section of the bar loading magazine onto the lathe.
Check to ensure that the locking has engaged.

Replace the bolt (Fig. 28/1).

Set the separation using the star handle screw (Fig. 31/1) (left
hand side of the bar loading magazine).

1 31410510

Fig. 31

Set the measuring tracer (Fig. 32/1) for the start of the bar (right hand
side of the bar loading magazine) for extremely thick or thin material.

31411000

Fig. 32

Operating instructions MF sprint 42/65 V 2.0 page 7-59

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

Close machine protection door

Close bar loading magazine protection hood

Move the short pusher into the middle of the segment (direction
key ”Z-”).

Open protection door

Open bar loading magazine protection hood

Insert the longitudinal pusher into the channel and connect to

the short pusher with the catcher hook

Close machine protection door

Close bar loading magazine protection hood

1
Close segment 1

2
Close segment 2

3
Close segment 3

4
Close segment 4/5 (Option)

The light diodes above the keys are cancelled when the
segments are closed.

page 7-60 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

Aligning the Q axis of the integrated bar loading magazine

Installation dimension: bar loading magazine « machine is to be
40 mm

After installing check the Q axis of the integrated bar loading

magazine and align in case of a deviation of ± 2 mm.

Turn key switch to setting ”2”

Press USER

Press USER DIAGNOSIS

Press ALIGNMENT DATA OPTIONS

Press ALIGNMENT DATA

Press REF. POINT. + LOOSEN COMP.

Fig. 33

Operating instructions MF sprint 42/65 V 2.0 page 7-61

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

It is now necessary to remeasure the Q axis and correct same using

the reference point offset.

The longitudinal pusher front edge spacing in relation to the collet

front edge
should be: up to machine No. 502500 56 ± 2 mm
from machine No. 502501 64 ± 2 mm.

After determining the difference it is necessary to offset the rear end

limit by this value.
It is not necessary to correct a difference of ± 2 mm.

page 7-62 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

Loading the bar loading magazine

(Variant 1)

Do not reach into the bar loading magazine during operation.

Prerequisite:
The material supply is empty and an remainder from the current part
program is in the collet.

The material support surface is 310 mm, i.e. 5 bars of 60 mm

diameter each can be placed on the supply surface, plus 1 bar which
is already in the guide channel.

The machine stops due to lack of material, fault message 9458

- 9458 : M : Load material into the bar loader.

CYCLE STOP button

Load material

- Ensure that the bars are bevelled and not jammed when loading.
- Lay the bars flush to the left in the material supply.
- Only insert one layer. The bars must not lay on top of each other.
- Ensure that the layer does not protrude beyond the rubber lips of
the filling opening.
- When machining tubes ensure that these are provided with closing
plugs.
- Check the bar diameter with the setting data and adapt if
necessary. (The correct feed force is automatically set with the bar
diameter). As from the PLC version 05.02.1999 the feed force can
be automatically set from the part program using the variable
R 738 (ᇅ bar diameter information).

// Press the RESET key

I Press the CYCLE START key

Operating instructions MF sprint 42/65 V 2.0 page 7-63

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

Loading the bar loading magazine

(Variant 2)

Do not reach into the bar loading magazine during operation.

Prerequisite:
There is no material in the machine or the guide channel, or a
clamped remaining piece does not match the part program variables,
R720, R725, R712.

The machine has stopped due to lack of material, fault message 9156
- 9156 : F : bar operation loader: no bar found.

CYCLE STOP button

Load material

- Ensure that the bars are bevelled and not jammed when loading.
- Lay the bars flush to the left in the material supply.
- Only insert one layer. The bars must not lay on top of each other.
- Ensure that the layer does not protrude beyond the rubber lips of
the filling opening.
- When machining tubes ensure that these are provided with closing
plugs.
- Position bar in the first infeed position before the collet using JOG
operation.
- Close the collet.
- Check the bar diameter with the setting data and adapt if
necessary. (The correct feed force is automatically set with the bar
diameter). As from the PLC version 05.02.1999 the feed force can
be automatically set from the part program using the variable
R 738 (ᇅ bar diameter information).

// Press the RESET button

Change VARIABLE R741 to zero

I Press the CYCLE START button

page 7-64 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

Workpiece remainder in the integrated bar loading magazine

Fig. 34

The workpiece remainder is automatically calculated and set via the

variables R714, R720, R725, R712 and the max. pusher position in
front of the chuck.

The variable R720 must always include the total workpiece length.

When pushing forward several times other variables are required for
the intermediate positions.

In the event of tolerances in the bar feeding system the remaining

material can be corrected by a setting parameter. (See chap. 11.1,
Parameter settings, ”Integrated bar loading magazine”).

Operating instructions MF sprint 42/65 V 2.0 page 7-65

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

Strategy for the integrated bar loading magazine

Program branching is possible using the SINUMERIK 840C, i.e. a
special subprogram can be called up for the bar loading magazine, in
order to machine the face surface of a newly loaded bar.

%MPF1000 %MPF2000
N10 (MACHINE:MF-SPRINT 65 WITH N10 (MACHINE:MF-SPRINT 65 WITH BAR
BAR LOADER) LOADER)
N20 (WORKPIECE: HEAD PIECE) N20 (WORKPIECE: HEAD PIECE)
N30 (DRAWING : TRADE FAIR) N30 (DRAWING : TRADE FAIR)
N40 (MATERIAL : C15 RD22X3000) N40 (MATERIAL : C15 RD22X3000)
N50 N50
(**************************************) (**************************************)
N60 L1000 (READ IN VARIABLES N60 L752 (PROGRAM LEADER)
+LIMITS
N70 L751 (PROGRAM LEADER)
N80 L760 (BAR LOADER START PROGRAM)
N8010 [WAIT M 10,1,2] N8010 [WAIT M 10,1,2]
N90 @714 N70 @714
N100 @121 R700 K0 K8020 (MACHINING) N80 @121 R700 K0 K8020 (MACHINING)
N110 @121 R741 K0 K8200 (BAR CHANGE) N90 @121 R741 K0 K8200 (BAR CHANGE)
(**************************************) (**************************************)
N8020 [WAIT M 20,1,2] N8020 [WAIT M 20,1,2]
N120 M1 M99(OPTIONAL STOP) N100 M1 M99 (OPTIONAL STOP)
N8030 [WAIT M 30,1,2] N8030 [WAIT M 30,1,2]
N130 @714
N140 R752 =R742 (NOTE WITHOUT LOADER
FLAG)
N8040 [WAIT M 40,1,2] N8040 [WAIT M 40,1,2]
N150 @714 N110 (PUSH MATERIAL FORWARD WITH
SLIDE 1)
N160 @121 R700 K0 K8050
N170 L1040 (PUSH MATERIAL FORWARD)
N8050 [WAIT M 50,1,2] N8050 [WAIT M 50,1,2]
N200 L1011 (ROUGHING) N200 L2011 (RFM)
N8060 [WAIT M 60,1,2] N8060 [WAIT M 60,1,2]
N210 L1012(CENTRE DRILLING D3.2 N210 L2012 (1st PRETURNING FINISHING
DRILLING D4.5) 2nd PRETURNING)
N8070 [WAIT M 70,1,2] N8070 [WAIT M 70,1,2]
N300 L1051 (UNLOADING) N300 L2016 (THREAD)
N8100 [WAIT M 100,1,2] N8100 [WAIT M 100,1,2]
N320 L1039 (PICK-OFF) N320 L2039 (PART-OFF)
N8110 [WAIT M 110,1,2] N8110 [WAIT M 110,1,2]
N330 @714 N330 @714

page 7-66 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

N350 @121 R752 K1 K-8020 (LOADER NOT N350 @121 R752 K1 K-8020 (LOADER NOT
SWITCHED ON) SWITCHED ON)
N360 @121 R741 K0 K8200 (BAR CHANGE) N360 @121 R741 K0 K8200 (BAR CHANGE)
N370 @100 K-8020 N370 @100 K-8020
N8200 [WAIT M 200,1,2] N8200 [WAIT M 200,1,2]
N380 L1041(BAR CHANGE: PUSH OUT OFF- N380 L2041 (BAR CHANGE: PUSH OUT OFF-
CUT) CUT)
N8210 [WAIT M 210,1,2] N8210 [WAIT M 210,1,2]
N390 L1042 (UNLOAD OFF-CUT) N390 L2042 (UNLOAD OFF-CUT)
N8220 [WAIT M 220,1,2] N8220 [WAIT M 220,1,2]
N400 L1010 (MACHINE BAR START) N400 L2010 (MACHINE BAR START)
N410 @100 K-8010 (RETURN TO START) N410 @100 K-8010 (RETURN TO START)
N8300 [WAIT M 300,1,2] N8300 [WAIT M 300,1,2]
N3000 (WORK END) N3000 (WORK END)
N9999 M30 N9999 M30

Operating instructions MF sprint 42/65 V 2.0 page 7-67

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

START START
AG1 AG2

Variable definition

Move free Move free

Bar loader
init M64 M65
Synchronization mark N8010

1 1
R700 R700
0 0
1 1
R741 R741

Synchronization mark 0 0
N8020

A A

Synchronization mark N8030

Key switch pos. Note

material push forward
Synchronization mark N8040

1
R700
0
Material advance
M69 M72
M437 M73
M65
Synchronization mark R700=1
N8050

Machining Machining
subprograms subprograms

Synchronization mark N8090

Discharge in chute Preturning finished part

R701 = 0

Synchronization mark N8100

0
R700

Workpiece pick- Workpiece pick-

off without mo- off with moving
ving to fixed to fixed stop
stop Part-off workpiece
R700 = 0 R700 = 0

Synchronization mark N8110

0 0
R752 R752
1 1
0 0
R741 R741
Synchronization mark N8200 1 1

Push out off-cut Push out off-cut

Synchronization mark N8210

Unload off-cut Unload off-cut

Synchronization mark N8220

Machine bar Machine bar

start end start end
Synchronization mark N8300

END END
314109801

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 7.13 Bar machining
7 Setting, make ready and operation

7.13.4 Bar section machining

Ensure that under no circumstances the bar end protrudes beyond the
rear stop of the spindle reduction tube and that it is not introduced into
a rotating spindle. Non-observance will lead to injuries to persons and
damage to the machine.

Determine the max. permissible rotational speed individually. This is

based on the bar material used, the bar length and the bar diameter.

0 1
Turn the ”Material transport” key switch to the 0 position

Prerequisites:
Tool holder equipped with:

D Material stop
D Bar gripper
D Tool

Work sequence: loading through the working space

Move the compound slide rest to the tool change over point

Swing in the material stop (User menu TURRET see page 7-24)

Open clamping means

Open protection door

Load the bar

Position the material stop in front of the bar

Pull the bar in front of the material stop

Operating instructions MF sprint 42/65 V 2.0 page 7-69

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7.13 Bar machining
7 Setting, make ready and operation

Wear protective gloves when pulling the bar forward.

Close the clamping means

Close the protection door

I Start the machining program

Work sequence: loading from the rear

Swing in the material stop (user menu TURRET, see page 7-24)

Position compound slide rest

Open clamping means

Open protection door

Load the machine

Push or pull forward the bar against the material stop

Wear protective gloves when pulling the bar forward.

Clamp the clamping means

Close the protection door

I Start machining program

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 7.13 Bar machining
7 Setting, make ready and operation

7.13.5 Bar machining with an external bar pusher

7.13.5.1 Operation and M functions with an external bar pusher

Key switch ( ) bar operation

When switched off, the machine only operates without the bar
pusher.

In the switched on position and when all other conditions (e.g.

parameter) are fulfilled the machine operates together with the bar
pusher.

Machine on
I
This key is provided independent of the bar socket option, however,
has anadditional function with this option.
The machine and the bar pusher are switched on.

M 65, bar operation, interrogation of bar end

Using this M function the bar end message is interrogated by the
machine.
Once the bar end has been reached the R parameter R 741 = 1 is set
which can be used in the part program for branching and thus for
starting various reactions.

Operating instructions MF sprint 42/65 V 2.0 page 7-71

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

M66, bar operation, handshake short part magazine, bar loading

magazine with positioning without mechanical stop
Using this function an output is switched on and set on the interface
(pin 24). The part program stops until the acknowledgement signal is
activated by the bar pusher (on pin 23).
Correspondingly a simple method is provided to synchronise the
sequences of the loading magazine and the machine using this
handshake function. However, it is necessary that the sequence is
identically processed on both sides.

The following variations could be present:

Acknowledgement after a bar change:
Signal, bar is in the first push-in position.
Acknowledgement after pushing forward into the turning position:
Signal, bar is in the turning position.
Acknowledgement after clamping the chuck.
Signal, release part machining
(also refer to the corresponding example programs)

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 7.13 Bar machining
7 Setting, make ready and operation

Bar inching
The bar can be jogged forward with the protection hood closed and
the operating mode JOG or AUTOMATIC selected.
Ensure that the machine chuck is open.
For this poll a user menu.

Press USER

Press OPERATION

Press DIV. MACH. FUNCTION 1.

Fig. 35

Press BAR JOG

The bar is moved forward.

Operating instructions MF sprint 42/65 V 2.0 page 7-73

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

7.13.5.2 Machining with external bar feeder

Fit the bar feeder and commission (start-up) in accordance with the
bar feeder manufacturer’s operating instructions.

Using a bar feeder it is possible to machine bar sections which are

automatically fed forward.

7.13.5.3 Machining sequence with external bar feeder

Prerequisites:

D Fit the spindle reduction tube (see chapter 7.13.1).

D Align the bar feeder in accordance with the instructions of the bar
feeder manufacturer.

Insert a bar in the bar feeder (in accordance with the bar feeder
operating instructions).

Switch on the bar feeder

(Main switch on bar feeder, if provided, as per the operating
instructions)

Turn the BAR OPERATION key switch on the machine to (I)

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 7.13 Bar machining
7 Setting, make ready and operation

Work sequence
Swing in the material stop (user menu TURRET, see page 7-24)

Position the compound slide rest

Open clamping means

Close the protection door

Lamp in the key is illuminated green

The bar is pushed into the working space

If necessary part off the bar end so that the part program can start in
the required position.

Select the machining program

I Start the machining program

Using the program command M65 it is possible to check that sufficient

bar material is in the feed. The following message appears at the
material end:

M 9447 Bar operation: Bar end reached

Operating instructions MF sprint 42/65 V 2.0 page 7-75

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

7.13.5.4 Example program for external bar feeder

The example program for machining is provided with a bar feeder,

showing the way of bar loading in manual and semi-automatic
operation. In semi-automatic operation the off-cut can be removed
from the front and bar end machining performed.

Prerequisite:
Material feeding selected (see chapter 11.1)

Program start
NXXX .... Start conditions
N197 T... D... Swing in material stop
N198 G00 Position compound slide rest
N199 M436 Open clamping means
N200 .... Push bar forward

Manual sequence
N201 M65 Interrogate bar end (*)
Meldung: M9447 bar operation:: Bar end reached
N202 M437 Close clamping means
N203 .... Create part contour
Part off
NXXX @100 K-.... Program end with return to start
and restart

Semi-automatic sequence
N300 M437 Close clamping means
N301 M65 Interrogate bar end (*)
N302 @714
N303 @121 R741 K1 K320 Interrogate the bar end event
N305 G0 X ... Z ... Compound slide rest in secure
position
N306 M436 Open clamping means
Meldung: M9447 Bar machining: Bar end reached
N307 M437 Close chuck
N.... Bar machining
N320
N322 .... Create part contour
Part off
NXXX @100 K-.... Program end with return
to start and restart

(*) Interrogation of bar feeding for material end.

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 7.13 Bar machining
7 Setting, make ready and operation

7.13.5.5 Reloading bars

Prerequisite
Protection door is open

Clamping means is open

Work sequence

- Material end recognition (NC block with M65)

Message M 9447: Bar operation: bar end reached

Cycle STOP

Open protection door

Remove off-cut

Wear protective gloves when removing off-cuts.

Swivel out the bar feed guide channel

Message M 9151: Bar operation: not operational

Insert new bar

Swing in the bar feeder guide channel

Observe message on bar feeder (if present)

Close protection door

Swivel in material stop

Position compound slide rest

Select JOG operating mode

Operating instructions MF sprint 42/65 V 2.0 page 7-77

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

Press USER

Press OPERATION

Press DIV. MACH. FUNCTION 1

Fig. 36

Press BAR INCHING until the bar is pushed forward to the

material stop.

Close clamping means

I START cycle
(all messages are deleted)

page 7-78 V 2.0 Operating instructions MF sprint 42/65

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 7.13 Bar machining
7 Setting, make ready and operation

7.13.5.6 External bar feeder with work end cut-out

Remove remaining material

Turn the key switch BAR OPERATION on the machine to (O)

Switch off main switch on bar feeder (if provided)

Operating instructions MF sprint 42/65 V 2.0 page 7-79

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

7.13.6 Machining with an external bar loading magazine

Install the bar loading magazine and undertake the start up

(commissioning) in accordance with the operating instructions of the
bar loading magazine manufacturer.

A bar loading magazine automatically pushes the material bar forward

and loads a new bar from a supply magazine.

7.13.6.1 Machining sequence with an external bar loading magazine

Prerequisite

D Insert the spindle reduction tube (see chapter 7.13.1).

D Check the parameter entries when changing the clamping means.
D Align the bar loading magazine in accordance with the bar loading
magazine manufacturer’s instructions.

Insert the bars in the supply magazine (in accordance with the
bar loading magazine operating instructions)

Switch on the bar loading magazine main switch (if supplied)

Turn the BAR OPERATION key switch on the machine to (I)

page 7-80 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

Work sequence
Open clamping means

Close the protection door

Swivel in material stop (TURRET user menu, see page 7-24)

Position compound slide rest

Select JOG operating mode

Align the first bar in accordance with the bar loading magazine
manufacturer’s information.

Press USER

Press OPERATION

Press DIV. MACH. FUNCTION 1

Fig. 37

Operating instructions MF sprint 42/65 V 2.0 page 7-81

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

Press INCH BAR until the bar is pushed up against the

material stop.

Bring compound slide rest into the start position

Select AUTOMATIC operating mode

Select machining program

I Start the machining program

The remaining bar material is automatically disposed of. New bars are
automatically loaded until the magazine is empty.

page 7-82 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

7.13.6.2 Example program for external bar loading magazines

A special program section or a sub--program can be selected for the

bar loading magazines in order to machine a cross surface of the
newly loaded bar.

Prerequisite:
Material feeding selected (see chap. 11.1)

Main program
N.... Push bar forward
Machine contour
Part off
Pick-off part
N ....
N200 M65 Interrogate bar end
N201 @714 Interpreter stop
N202 @121 R741 K1 K320 Interrogate the bar end event
N203 M834 Execution with bar end
N204 G0 X0 Z.. T1 D.. M4=5 Start operation, spindle stop
N205 M436 Open chuck for bar change
N206 M437 Close chuck after bar change
N207 R1 = 0 L 710 Move to tool change
N208 .... First bar machining
N220 Execution, if no bar end
N222 @100 K-... Return to restart

If tt is necessary to have the spindle turning when changing in a new

bar (e.g. with polygon material), change the blocks N204/N205.

N....
N204 T1 D....
N205 M834
N206 G95 G0 Z0 Z... Start condition
S4=200 M4=3 Spindle ON
N207 M433 Chuck open for bar change
with release for spindle run

Note that the spindle running time with the chuck open is limited to
90 sec.

Operating instructions MF sprint 42/65 V 2.0 page 7-83

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

Example program for an external short part loading magazine of

a bar loading magazine with positioning without mechanical stop
SPF1040 Push material forward with
short part magazine or bar
loading magazine with
positioning without mechanical
stop
N10 M814
N15 G54
N20 G59 X0 Z=R720
N25 T8 D8 Material stop
N30 M834
N35 G0 G95 Z20 M4=5
N40 G0 X0
N45 @121 R700 K0 K90 Interrogate whether already
pushed forward
N50 @121 R752 K1 K90 Interrogate whether loader
switched on
N55 G0 Z=-R725-2 Pick-off material
N60 M433 Chuck open
N61 M69 Push bar forward
N65 G1 G94 Z0.5 F5000

N67 M66 dependent upon loader type

handshake
(Bar in turning position)

N70 M437 Clamp chuck

N700 G4 F0.5 or dependent upon loader type

handshake M66
(release part machining,
pusher raised)

N75 M65 Release with bar end

Bar change
N80 @714
N85 R700=1 Note pushing forward
N90 Jump target N45, N50
N95 R1=2 L710 Tool change point
N9999 M17

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Doc.-No.: ABB002G0
 7.13 Bar machining
7 Setting, make ready and operation

SPF1041 Bar change with short part

magazine or bar loading
magazine with positioning
without mechanical stop
N10 M814
N15 G54
N20 G59 X0 Z=R720
N25 T8 D18 Remaining material holder
N30 M834
N35 G0 Z50
N40 G0 X0
N45 M4=5
N50 (M4=19 S4=0
N55 G1 G94 Z=-R725-1 F2000
N60 M436 Chuck open
N65 M69 Pushing forward allowed

N70 M66 Push remaining material in

holder

N75 G4 F0.5
N80 M437 Clamp chuck
N85 G0 Z50
N100 T8 D8 Material stop
N105 G0 X0 (S4=100 M4=3
N110 G1 G94 Z=-R725+5 F2000
N115 M436 Chuck open
N120 M69 Pushing forward allowed

N125 G4 F2 Waiting time or as per loader

type Handshake M66
(bar in position)

N130 M437 Clamp chuck

N132 G4 F0.5 or depending on loader type

handshake M66
(pusher raised)

N135 G0 Z20
N140 R1=2 L710 Tool change point
N9999 M17

Operating instructions MF sprint 42/65 V 2.0 page 7-85

Doc.-No.: ABB002G0
7.13 Bar machining
7 Setting, make ready and operation

7.13.6.3 Reloading bars

It is possible to reload bars at any time. The following work steps are
required if the loading magazine bar support is empty:

- Bar loading magazine

The machine stops in the program.
- Short part loading magazine
The machine stops in the program.
- Reloading the bars on the bar support
- Pre-turning bars in the machine (bar loading magazine
dependent)

Machining program is continued

7.13.6.4 Switching off the external bar loading when work completed

Remove remaining material

Turn BAR OPERATION key switch on the machine to (O)

Switch off the main switch on the bar feed (if provided)

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 7.14 Changing to work without an ext. bar pusher
7 Setting, make ready and operation

7.14 Changing to work without an external bar pusher

Remove remaining material

Turn BAR OPERATION key switch on the machine to (O)

Switch off bar loading magazine

(main switch on bar loading magazine, if provided, as per the
operating instructions)
(see programming example)

Programming example for working without an external bar

pusher
N10 Machine : MF-Sprint 65
N60 L1000 Read in variables + limits
N70 L751 Program lead
N8010 Wait M 10, 1, 2
N100 @714
N110 @121 R700 K0 K8020 Machining
N120 @121 R741 K0 K8200 Bar change

N8020 Wait M 20, 1, 2

N200 M1 M99 Optional stop
N210 @714
(N215 @125 R761 K1 K8030 Interrogate remaining number
of pieces
(N220 M0 Quantity reached! Run empty?)
N8030 Wait M 30, 1, 2

N300 @714
N310 R752 =0 Record flag without loader
/N315 R752 =1 Record flag without loader

N8040 Wait M 40, 1, 2

N400 @714
N410 @121 R700 K0 K8050
N420 L1040 Push material forward

Operating instructions MF sprint 42/65 V 2.0 page 7-87

Doc.-No.: ABB002G0
7.15 Remaining material disposal
7 Setting, make ready and operation

7.15 Remaining material disposal

There are two methods of remaining material disposal:

D Automatically to the rear through the external bar pusher

D To the front through the machine turning spindle

Remaining material can cause damage

- to the machine covers within the workspace
- to the chip conveyor transport belt

Proceed as follows in order to avoid damage and take into considera-

tion in the machining program.

- Remaining bar material is to be removed manually from the

clamping means. For this program the function program stop
(move slide free and cancel door locking) after recognising
material end.

Wear protective gloves when removing remaining material.

- With an existing workpiece pick-off system structure the machine

program so that also the disposal of the remaining material is
possible using this unit.

Prerequisite:
- Turned clamping diameter of the remaining material.

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Doc.-No.: ABB002G0
 7.15 Triple warning light
7 Setting, make ready and operation

7.16 Triple warning light

Machine operating condition

The warning lamp is fitted to an upright tube above the switch cabinet.
The machine operating condition is displayed by the triple warning
lamp.

Red Signals a machine fault

Yellow Signals the protection hood is open

Green Signals automatic operation with a feed override of > 75%

Bars can be loaded. The loading flap is free.

Operating condition of the integrated bar loading magazine

Flashing red:
Signals that the bar loading cycle has started.
The loading flap is locked by a lifting magnet, so that bar
loading is currently not possible.

Flashing yellow:
Signals that a bar change is due shortly.
(approx. 200 mm of material is still available)

Note:
If the loading flap is not closed on time then the display
switches to flashing red and a cycle stop is triggered.
After closing a cycle start by pressing a button is necessary.
Important! Do not press the RESET button.

Flashing green:
Signals that the material supply in the bar loading magazine
has been used up and the last bar has rolled in.

Operating instructions MF sprint 42/65 V 2.0 page 7-89

Doc.-No.: ABB002G0
7.17 Shift end circuit
7 Setting, make ready and operation

7.17 Shift end circuit

Press USER

Press OPERATION

Press PROGRAM SEQUENCE

Fig. 38

The shift end circuit can be switched active/inactive in the menu mask.

page 7-90 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.17 Shift end circuit
7 Setting, make ready and operation

The machine stops at the following points when selecting the shift end
cut-out:

Manual machine loading:

with workpiece count impulse M18

Machine with automatic material guidance or production related

default values:

1st example:
When the loader takes away the OK signal (this happens
when the loader is not in order or material is used up).
The part program runs with cycle on in a waiting loop.

2nd example:
Production via a subtracting piece counter. With a counter
reading of 0 the machine stops at the programmed M0, M1 in
the part program.
In both cases the shift end is started via the program running
time monitoring.

When the shift end cut-out is selected in the mask the message
”Automatic cut-out selected” appears. Once the shift end is reached
based on the above event, the machine (hydraulics) is switched off.
Fault ”System is switched off” appears. The machine can now only be
switched on again using the ”Machine on key”, if the pending fault
message has been deleted. The selection is automatically reset in the
same manner.

Operating instructions MF sprint 42/65 V 2.0 page 7-91

Doc.-No.: ABB002G0
7.18 Leukhardt swivel wire sensor
7 Setting, make ready and operation

7.18 Leukhardt swivel wire sensor

Using this function, for example, it is possible to check whether a tool

(drill) is broken or the pick-off unit is empty.
With the start of the swivel wire sensor the swivel wire moves until it
hits a stationary object. This can either be the drill being checked, or, if
no obstacle is present, a stop (screw) etc. The swivel wire sensor
emits a signal whether the obstacle found in the position corresponds
with the previously taught-in position or not.

Press USER

Press PARAMETER SETTER

Press MACHINE FUNCTIONS

Press LEUKHARDT

Fig. 39

page 7-92 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 7.18 Leukhardt swivel wire sensor
7 Setting, make ready and operation

In the menu mask it is possible to set whether the program is to stop

in case of an error on the M function which triggered the test or if the
R parameter should be set.
In the same manner the swivel angle is taught-in in this mask as well
as a possibly required function test. The swivel angle reaching up to
the stop is taught-in.

The test is made using M functions in automatic operation.

A check is made whether an obstacle (e.g. drill tip) prevents reaching

the taught-in swivel angle (TEST_KO) using M171 for the swivel wire
sensor 1 or M271 for the swivel wire sensor 2. If the swivel wire
swings through to the taught-in stop then either the program stops on
the M function or the R parameter R755 is set for the swivel wire
sensor 1 or R756 for swivel wire sensor 2 is set to 1.

Using M170 for the swivel wire sensor 1 or M270 for swivel wire
sensor 2 a check is performed whether the swivel path is free of an
obstacle. If the swivel wire prematurely touches an obstacle e.g. a
workpiece in the pick-off chuck, the program either stops on this
M function or the R parameter R755 for the swivel wire sensor 1 or
R756 for swivel wire sensor 2 is set to 1.

Operating instructions MF sprint 42/65 V 2.0 page 7-93

Doc.-No.: ABB002G0
7.19 Polygon turning in recess and straight ......
7 Setting, make ready and operation

7.19 Polygon turning in recess and straight turning method

The polygon turning in recess method is possible on the MF sprint

42/65 on turret 1 on the main spindle.

Here the following conditions must be taken into consideration:

D Can be used for the machining of aluminium, brass and plastic.

Cannot be used for machining steel.

D A recess width of a = 11 mm results in a maximum possible width

across the flats of 34 mm (corresponds to an initial diameter of
40 mm).
D Cutting data:

Tool drive rotational speed: n2 = 3500 r.p.m.

Main spindle rotational speed: n4 = 1750 r.p.m.

Feed: s = 0.06 mm/rev.

The polygon turning function in the straight turning method is also

possible from turret 1 on the main spindle.

Here the following conditions must be taken into consideration:

D Can also be used with steel (several passes)

D Polygon is possible up to the maximum machine open centre
D Provide the fly cutter with an orthogonal clearance
D The tolerances required by DIN 475 part 1 for widths across flats
of series 1 are adhered to (corresponds to tolerance h 13).

page 7-94 V 2.0 Operating instructions MF sprint 42/65

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 7.20 Thread cutting without compensating chuck
7 Setting, make ready and operation

7.20 Thread cutting without compensating chuck (option)

Thread cutting is possible without a compensation chuck in all

programmable axis variations in C axis operation
(linear axes - C axis).

1. Fixed spindle / rotating tool:

Slide X1 with C1

Slide Z1 with C1

Slide X2 with C2

Slide Z2 with C2

2. Rotating spindle / fixed tool:

Slide Z2 with C1

Slide Z1 with C4

Slide Z2 with C4

C1 = Tool drive tur. 1 / counter spindle

C2 = Tool drive tur. 2

C4 = Main spindle

Operating instructions MF sprint 42/65 V 2.0 page 7-95

Doc.-No.: ABB002G0
7.20 Thread cutting without compensating chuck
7 Setting, make ready and operation

To 1. (thread cutting with driven tools)

The following capacity limit values must be taken into consideration:

D The max. torque is Md = 24 Nm. This corresponds to the thread

size M12 in steel (Ck 45).
D The maximum rotational speed of the C axis is n = 2083 rev./min.
D The smallest possible thread is M4.
D The thread cutting operation is limited to 270 threads incl. forward
stroke.
D The tool operating life can be up to 30% less than with thread
cutting with a compensated chuck due to possible tooth play in the
tool drives.

To 2. (thread cutting with fixed tool on the main or counter spindle)

Take the following capacity limit values into consideration:

D Maximum thread size is M30 x 3,5 in C45 on the main spindle

D Maximum thread size is M12 x 1,5 in Ck45 on the counter spindle

In all cases when thread cutting without a compensation chuck,

an additional time of 0.7 sec each must be taken into considera-
tion for switching on the C axes.

page 7-96 V 2.0 Operating instructions MF sprint 42/65

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 8.1 Review
8 Polling and processing a program/programing help

8 Polling and processing a program/programing help

8.1 Review

The programming manual shows how the SINUMERIK 840 C

controls are programmed.

8.2 Select program for editing

Programs can be stored

D on the fixed disk in the ”LOCAL” directory under workpiece names

D or during processing in the ”volatile” NCK memory

Operating instructions MF sprint 42/65 V 2.0 page 8-3

Doc.-No.: ABB002G0
8.2 Select program for editing
8 Polling and processing a program/programing help

8.2.1 Select program for editing on the fixed disk

Press area switch over switch

Press PROGRAM

Select ”NCK” directory using the cursor keys

Press enter key

Select workpiece

Press enter key

Select program

Press enter key

Press EDIT

You can now undertake program changes via the keyboard using the
ASCII editor.

Store the program after making the entry.

D If you do not want to process the program immediately

then press STORE

The program is taken over into the fixed disk memory.

D Press STORE and LOAD if you want to

subsequently process the program

The program is taken over into the fixed disk memory and loaded the
NCK memory.

page 8-4 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 8.1 Review
8 Polling and processing a program/programing help

8.2.2 Select program for editing in the NCK memory

Press area switch over switch

Press PROGRAM

Select ”NCK” directory using the cursor keys

Press enter key

Select program area ”MPF or SPF” using the cursor keys.

Press enter key

Select required program using the cursor keys

Press EDIT

You can now undertake program changes using the keyboard with
the aid of the ASCII editor.

If the changed program is to be retained after switching off the

controls, then ensure that the program is stored on the fixed disk.

Press SECURE TO DISK

The program is taken over into the fixed disk memory.

Operating instructions MF sprint 42/65 V 2.0 page 8-5

Doc.-No.: ABB002G0
8.2 Select program for editing
8 Polling and processing a program/programing help

8.3 Automatic machining of a workpiece

M Press ”Machine area” key

Press ”Automatic” key

// Press ”Reset” key

Check that the correct workpiece name and the main program
number is displayed on the screen field for channel 1 and 2.
D If this is the case continue on page 8-7

D If this is not the case:

Press SELECT PROGR./JOB

Select the directory ”LOCAL” using the cursor keys

Press enter key

The workpieces in the ”LOCAL” directory are listed

Select the required workpiece using the cursor keys

Press SELECT PROGR./JOB

Dialog text ”Load workpiece?” is displayed

Press SELECT PROGR./JOB

Dialog text ”Workpiece data being loaded” is displayed.

The workpiece name and the main program number are displayed in
the screen field ”Program indicator”.

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Doc.-No.: ABB002G0
 8.1 Review
8 Polling and processing a program/programing help

Press ”Unlock protection hood” key

Open protection hood

Check that the tool and workpiece are correctly seated

Clamp chuck

Close protection hood

Press ”Close protection hood” key. The green indicator lamp in the
key must be illuminated.

// Press ”Reset” key

Press USER

Press OPERATION

Press PROGRAM SEQUENCE

The mask ”Program sequence” appears on the screen (Fig. 1).

Check that the necessary slide is activated for the workpiece
machining.

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8.2 Select program for editing
8 Polling and processing a program/programing help

Fig. 1

Activating the control channels

Channel 1 = slide 1
Channel 2 = slide 2
Channel 3 = Special channel

The controls of the integrated bar loader run in channel 3.

It is only necessary to activate channel 3 for special functions.

If in the operating mode Automatic only the program is to be started for one
slide, then the other channels are inactive.

Position the cursor on the input field behind the channel No.

enter 0

Press enter key

The 0 appears in the input field.

If a channel is to be activated enter a 0 in place of a 1.
An entry is only possible in the control condition ”RESET”.
If a slide is not activated the part program of the other slides run beyond
the wait marks.

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 8.1 Review
8 Polling and processing a program/programing help

Chuck condition
Prior to starting a program set the condition parameter of the chuck in
accordance with the current machine condition (visual inspection of
the working space is necessary).
The input can be made in any operating mode.

The workpiece can be machined if all settings are correct.

I Press the ”Cycle start” key

The workpiece is machined

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8.2 Select program for editing
8 Polling and processing a program/programing help

8.4 Compensate for tool wear

The compensation values can be entered in the automatic operating

mode.

M Press ”Machine area” key

Press TOOL WEAR OPERATING LIFE

The tool compensation mask appears on the screen

Set the cursor onto the input position

Enter the compensation value using the keyboard

max. input value: 0.99 mm

Press the ”Change word” key

The compensation is calculated and taken over into the compen-

sation memory

The entered value is taken over as the current wear compensation

factor if the enter key is pressed after entering the compensation
value.

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 8.1 Review
8 Polling and processing a program/programing help

8.5 Data input, data output

The data can be read in from an external unit via the V24 interface or
transmitted to an external unit.
The ”Standard” setting is used

Check the interface setting

Select ”Service” area

Press UNITS

Select the top window using the ”Home” key

Select ”Standard” with the cursor keys

Press EDIT

The mask with the current interface setting appears (Fig. 2)

Fig. 2

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8.2 Select program for editing
8 Polling and processing a program/programing help

8.5.1 Read out the part programs and attendant workpiece data in the
punched tape format

All part programs are stored in the path ”Workpiece name”.

If further workpiece based data is also transmitted, this must be
backed up first.
Also transmittable are TOA, ZOA, RPA, SEA data.

Data transmitted in ”punched tape format” can be externally edited

and read in again.

The directory structure and job list are not jointly printed out

Data output in ”PC format” are used to back up the workpiece

programs and data.
All files are transmitted, the job list and the directory structure.
The data can only be externally processed using the program
PCIN.

8.5.2 Back up of NCK data in a workpiece program

Select ”Utilities” area

Press NC

Select ”LOCAL” directory using the cursor keys.

Press enter key

Set cursor on the workpiece name under which the data is to be

backed up.

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 8.1 Review
8 Polling and processing a program/programing help

Press START BACK UP

You can select data for a back up in the selection field ”NC source”
using the toggle keys:
e.g.
Tool compensation (TOA) from 0 to 100
Setting data (SEA)
Zero point offset (ZOA)
R-Parameter (RPA)

After entering in the other input fields:

Press OK

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8.2 Select program for editing
8 Polling and processing a program/programing help

8.5.3 Read out workpiece data

Select ”Utilities” area

Press DATA OUTPUT

The upper section of the parameterized interface is displayed in the

mask shown

Select the ”LOCAL” directory using the cursor keys

Press the enter key

All workpieces are displayed in the ”LOCAL” directory.

Position the cursor on the workpiece names

Select the upper window using the home key

Set cursor to ”Format”

Select ”Punched tape format” using the toggle key

Once the external unit is ready to transfer data:

Press OUTPUT START

The dialog mask appears

!!! External PC transmission running !!! Punched tape format MPF13

1325

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 8.1 Review
8 Polling and processing a program/programing help

8.5.4 Read in data

Prior to transmitting the program of a new workpiece, enter the name

of the directory.

Turn key switch to 1

Select ”Program” area

Select ”LOCAL” using the cursor keys

Press enter key

Press NEW

Enter the workpiece names into the dialog mask using the keyboard

Press enter key

Press OK

The file GILDEMEISTER ”JOB LIST” is automatically copied into the

data of this workpiece

Read in data
Select ”UTILITY” area

Press DATA INPUT

The upper section of the mask shows the parameterized interface.

Set cursor to ”User”

Press enter key

Select ”LOCAL” using the cursor keys

Press enter key

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8.2 Select program for editing
8 Polling and processing a program/programing help

All workpieces are displayed in the ”LOCAL” directory.

Set cursor to workpiece name

Press enter key

Once the external unit is ready for data transfer:

Press ENTER START

The dialog mask appears

!!!External PC transmission running !!! Punched tape format MPF13

1325

The message ”110019 check fault protocol” may appear after the
data transfer

Press OK (Dialog box is acknowledged)

Press FAULT LOG

The program file was created without transfer end character if the
message ”11053 transmission not identified” appears.
The programs are nevertheless stored.

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 8.1 Review
8 Polling and processing a program/programing help

8.5.5 Load part programs from the fixed disk memory into the NCK
memory

To permit all programs of a workpiece to be loaded into the NCK

memory it is necessary to store a ”JOB” list under the workpiece
name. The list includes all loading instructions as well as designation
of the main program for channel 1 and 2.

Edit JOB list

JOB list GILDEMEISTER

D Delete all user programs:

CLEAR.MPF [0.9999] Delete all main programs
CLEAR.SPF [1000.9999] Delete the subprograms SPF 1000
to SPF9999

D Loading instructions
LOAD.* loads all files (MPF, SPF) under the
workpiece to which the job list belongs.

Standard instructions for loading the main and subprograms:

LOAD.MPF[0.9999] loads all MPF’s from MPF0 to MPF9999

LOAD.MPF[1000.9999] loads all SPF’s from SPF 1000 to
SPF9999

D Start preparation:
Select the main programs, which are started with ”Cycle start”

SELECT name CH=nr

SELECT % xxxx CH=1 xxxx = Number of the main

progr. for channel 1
SELECT % yyyy CH=2 yyyy = Number of the main
progr. for channel 2

Load part programs

see chapter 8.3, automatic machining of a workpiece.

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8.2 Select program for editing
8 Polling and processing a program/programing help

8.5.6 Loading NC data read in with the part program, into the NCK
memory

This data is not loaded with the GILDEMEISTER JOB list.

Select ”Utility” area

Press NC

Select the directory ”LOCAL using the cursor keys

Press input key

Set cursor to workpiece name

Press enter key

Select data using cursor

e. g.
% TOA
% SEA
% ZOA
% RPA

Press START LOADING

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 8.1 Review
8 Polling and processing a program/programing help

8.6 Reading date and time for the part program

The programmer now has the possibility to read the day of the week, date and time of
day from the part program.

This is possible using the following program commands:

Day of the week: Result of the variables:

@3b0 Var K1 K197 K235 K1 K0 Z. B.: 1=Monday, 2=Tuesday, .... 7=Sunday

Date, day:
@3b0 Var K1 K197 K236 K1 K0 Z. B.: 26

Date, month:
@3b0 Var K1 K197 K237 K1 K0 Z. B.: 06

Date, year:
@3b0 Var K1 K197 K238 K1 K0 Z. B.: 98

Hour:
@3b0 Var K1 K197 K239 K1 K0 Z. B.: 08

Minute:
@3b0 Var K1 K197 K240 K1 K0 Z. B.: 12

Seconds:
@3b0 Var K1 K197 K241 K1 K0 Z. B.: 33

For Var it is necessary to set an optional R_parameter, e.g. R801

This function extension can be used from the following PLC software versions:

MF_twin > 24.06.98

MF_sprint > = 01.07.98

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page 8-20 V 2.0 Operating instructions MF sprint 42/65
Doc.-No.: ABB002G0
9 Interface description

9 Interface description

Fig. 1

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 9.1 Serial interface for program transfer
9 Interface description

9.1 Serial interface for program transfer

A V24/V28 interface is available (Fig. 1) for the data exchange

between the controls and an external data unit.

D V24/V28 interface (identical to RS-232 C or DIN 66020).

The V24/V28 is a bit serial interface. The cable length for the
connection cable between the socket for the serial interface and
the external data carrier is max. 5 m.

D 20mA interface
The 20 mA interface is a bit serial current interface. The maximum
cable length of the connection cable between the socket for the
serial interface and the external data unit is max. 300 m.

Data format

The controls are factory pre-set as follows.

Fig. 2

Use a type LIYCY (screened) cable.

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9.1 Serial interface for program transfer
9 Interface description

9.1.1 Changing the interface parameters

The data format is adapted to the external data unit within a certain
range.

Select ”Service” area

Press UNIT

Select the bottom window using the ”Home” key

The bottom window frame changed colour to blue

Select the interface to be changed using the cursor keys

Press EDIT

The mask showing the current interface setting is masked in on the

screen (Fig. 2)

Select the field to be changed using the cursor keys

Select the value using the toggle key

Save the setting

or

^ Abort without changing

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 9.2 Interface for bar feeding unit
9 Interface description

9.2 Interface for bar feeding unit

9.2.1 Safety instructions

We would point out that the functions and circuit description in the
interface description must be observed.

We expressively point out that deviations from this description are

only permitted following agreement with GILDEMEISTER.

The conformity declaration supplied with the machine (EC machine

directive 89/392/EEC) and the CE symbol are only applicable to the
extended overall plant when type and make of the peripheral unit are
agreed and approved with GILDEMEISTER.

The conformity declaration supplied with the machine will lose its
validity in the case of non-observance.

9.2.2 Prerequisites for safe operation

D Safe switching off of the bar feeding unit with the lathe
protection hood open.

The main danger to the lathe resides in the fact that the bar could be
pushed through when the protection hood is opened and the operator
is working within the working space.

- In order to safely exclude this danger the signals Protection hood

closed (Pin 8-9 and 10-11, 2-channels from the lathe) are
provided for a safe switching off.
- In addition, the return message from the normally closed contacts
of the power contactor is necessary for the bar forward function of
the bar feeding unit (pin 21-22), in order to avoid a fault in the
above mentioned 2 channel cut-out.

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9.2 Interface for bar feeding unit
9 Interface description

D Provide the following circuitry in the bar feeding unit:

Protection hood closed signal

Release the feed movement of the bar securely on 2 channels using
this signal. Correspondingly, the protection hood is securely switched
off on 2 channels with the protection hood opened.

Ensure that both signals are processed in an intrinsic contact tech-

nology. Ideally both signals release the two motor contactors directly
or lock same when the protection hood is opened.

Processing of these signals in the software (PLC) of the bar feeding

unit is not permitted.

Protection hood cut-out signal

With this return signal of the N/C contacts for the power contactors
bar forward the lathe is notified that the above mentioned 2 channel
cut-out is functioning correctly, with the protection hood open. In each
case one N/C of the above mentioned motor contactors is switched in
series and offered to the lathe as a potential free return message.

The lathe cyclically tests the protection hood each time the protection
hood is closed to ensure that the 2 channel cut-out is operating
correctly. In case of a fault release of the complete unit is denied.
As a consequence the personal safety is assured in the case of an
individual fault. The system excludes that a person could be
endangered in the event of a second fault.

9.2.3 Introduction, general description

- Ident. number: 1 048 137

- Document: 06.11.1998

The bar feeding unit serves for the precise guidance of bar material
(outside of the machine). The bars are automatically advanced by the
bar feeding unit.

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 9.2 Interface for bar feeding unit
9 Interface description

9.2.4 Interface architecture

Socket location

- Side wall of switch cabinet on the main spindle side

Socket type

- 24 pole socket
- Make: Harting type HAN 24E
- Socket insert (No. 09300240304)

Electric socket data

- Supply voltage
3 x 400 VAC, max. 6 A
- Control signals
24 VDC 2 mA - 1.5 A

Load capacity of the lathe contacts

- 24 VDC, max. 1.5A

Load capacity of the bar feeding unit contacts

- 24 VDC, 20 mA - 1.5 A

Circuit diagram

- Refer to the circuit diagram in the Electric Technical Documen-

tation for details of the circuit construction.

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9.2 Interface for bar feeding unit
9 Interface description

If no bar feeding unit is connected a blind plug must be fitted to

operate the machine having the following bridges.

Bridges: Contact 4, contact 5 (Emergency stop channel 1)

Bridges: Contact 6, contact 7 (Emergency stop channel 2)

Bridges: contact 21, contact 22 (return signal of hood

cut-out contact)

This blind plug forms part of the lathe scope of delivery.

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 9.2 Interface for bar feeding unit
9 Interface description

9.2.5 Pin assignment of the bar feeding unit

Contact 1 Supply voltage, bar feeding unit

2 3 x 400 VAC, max. 6 A
3 3 x 400 VAC, max. 6 A
Signal flow: lathe for bar pusher

Contact 4 EMERGENCY STOP button bar pusher channel 1

5 EMERGENCY STOP button bar pusher channel 1
Signal flow: bar pusher (potential free)
lathe

Contact 6 EMERGENCY STOP button bar pusher channel 2

7 EMERGENCY STOP button bar pusher channel 2
Signal flow: bar pusher (potential free)
lathe

Contact 8 Lathe protection hood closed channel 1

9 Lathe protection hood closed channel 1
Signal flow: lathe (potential free)
bar pusher

Contact 10 Lathe protection hood closed channel 2

11 Lathe protection hood closed channel 2
Signal flow: lathe (potential free)
bar pusher

Contact 12 24 VDC - supply voltage for signals of the

contact 13 to 17 and 24
Signal flow: bar pusher to lathe

Contact 13 Bar operation on

Signal flow: lathe to bar pusher

Contact 14 Bar pusher automatic release

Signal flow: lathe to bar pusher

Contact 15 Push bar forward

Signal flow: lathe to bar pusher

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9.2 Interface for bar feeding unit
9 Interface description

Contact 16 Bar inching key

Signal flow: lathe to bar pusher

Contact 17 Bar change release

Signal flow: lathe to bar pusher

Contact 18 24 VDC supply for signals of contact 19 to 20

Signal flow: lathe to bar pusher

Contact 19 Bar pusher operational

Signal flow: bar pusher to lathe

Contact 20 Material present

Signal flow: bar pusher to lathe

Contact 21 Feedback for normally closed contact of power contactors

22 Bar forward
Signal flow: bar pusher (potential free)
to lathe

Contact 23 Acknowledge handshake on lathe

Signal flow: bar pusher to lathe

Contact 24 Handshake request to bar pusher

Signal flow: lathe to bar pusher

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 9.2 Interface for bar feeding unit
9 Interface description

9.2.6 Function of the individual signals

The text describing all signals always refers to the active status of a
signal, i.e. the signal carries 24 VDC or the contact is closed.

9.2.7 Explanation of the signals

D Supply voltage 3 x 400 V/max. 6A

(Pin 1-3)
The supply voltage is protected in the lathe with a 6A motor protection
switch.
Signal flow: lathe to bar pusher

D EMERGENCY STOP button from bar feeding unit

(Pin 4-5 and 6-7)
The EMERGENCY STOP button must be potential free, with 2
separate normally closed contacts and is integrated in the
EMERGENCY STOP circuit.
Signal flow: bar pusher (potential free) to lathe

D Lathe protection hood closed

(Pin 8-9 and 10-11)
These two signals must be securely linked with two channels in the
electrics so as to exclude danger to persons as a result of functions of
the bar feeding unit (e.g. advance) in the working space of the lathe
when the protection hood is not closed.
Ensure that danger to persons is excluded by a single fault in
accordance with the safety category III (EN 954).
Signal flow: lathe (potential free) to bar pusher

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9.2 Interface for bar feeding unit
9 Interface description

D Bar operation on
(Pin 13, supply pin 12)
The bar feeding unit is switched on with this lathe signal. This signal
implies that:

- the lathe is switched on (DRIVES ON)

- the key switch BAR OPERATION ON is active
- the PLC parameters for bar operation are active

If this signal is 0 then the bar feeding unit is switched off and does not
react to the following signals (Pin 14-17).
Signal flow: lathe to bar pusher

D Automatic release of bar pusher

(Pin 14, supply pin 12)
This lathe signal permits the bar pusher to enter automatic operation.
The bar pusher guides the bar. This signal is independent of the lathe
operating mode, as then the bar must also be guided when the lathe
spindle is switched on in ”MANUAL CONTROL” operating mode.
Signal flow: lathe to bar pusher.

D Push bar forward

(Pin 15, supply pin 12)
This lathe signal notifies the bar pusher that the bar must be fed
forward.
Prerequisite is the signal ”Automatic release” pin 14.
Signal flow: lathe to bar pusher.

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 9.2 Interface for bar feeding unit
9 Interface description

D Inching bar
(Pin 16, supply pin 12)
Using this signal the lathe pushes forward the bar in inching mode.
Prerequisite is that the protection hood is closed (signal 8-9 and
10-11) as well as the signal BAR OPERATION ON.
Signal flow: lathe to bar pusher.

D Release bar change

(Pin 17, supply pin 12)
This lathe signal only switches by means of the corresponding M
function and remains switched on for approx. 1.5 sec. if the signal
”material available” is switched by the bar pusher.
If the signal ”material available” is switched off by the bar pusher, the
signal is retained until the bar pusher switches back to ”material
available”.
Bar loading magazine, short part magazine
These bar pushers can prepare the bar change as far as is possible
using these signals and the loader-internal material end evaluation,
while the last part is being machined.
The bar change is concluded using the next signal pin 15 ”Push bar
forward”.
Signal flow: lathe to bar pusher.

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9.2 Interface for bar feeding unit
9 Interface description

D Bar pusher operational

(Pin 19, supply pin 18)
This signal from the bar pusher displays that the unit is operational, all
safety units are functioning thus ensuring reliable and safe operation.
This signal must be reset when the automatic release is given by the
lathe and the bar pusher is not in automatic operation.
Signal flow: bar pusher to lathe

D Material present
(Pin 20, supply pin 18)
This signal of the bar pusher indicates whether material is available.
Signal switched on means ”Material available”.
This must not be changed except in conjunction with the material
evaluation in the bar pusher and not based on operating mode change
or other functions.
Signal flow: bar pusher to lathe

D Feedback of the normally closed contacts of the power

contactors
Bar forward
(Pin 21-22)
Using this potential free contact, the bar pusher signals the cut-out of
the units by the signals Lathe protection hood closed (pin 8-9 and
10-11). The lathe checks whether the person safety relevant cut-out
functions correctly with the opening of the protection hood.
Signal flow: bar pusher (potential free) to lathe.

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 9.2 Interface for bar feeding unit
9 Interface description

D Acknowledge handshake on lathe

(Pin 23, supply pin 18)
This signal is used in different variations and serves to optimise the
machining ancillary times of the lathe.
This bar pusher signal acknowledges the lathe request signal pin 24
(M function).
The part program is correspondingly continued after acknowledge-
ment.
The following variations have been realised to date:
Acknowledgement following a bar change:
Signal, bar is in first push-in position.
Acknowledgement after pushing forward into turning position:
Signal, bar is in turning position.
Acknowledgement, when pushing forward to turning position starts.
Signal, bar is pushed forward.
Acknowledge after cancelling ”Push bar forward” pin 15.
Signal, release part machining
The signal sequence is -0-1-0- and must be switched on for at least
150 ms. If other variations are possible, the lathe manufacturer must
be notified in order to optimise the part program.
Signal flow: bar pusher to lathe

D Request handshake from lathe to bar pusher

(Pin 24, supply pin 12)
This signal is used in different variations and serves to optimise the
machining ancillary times of the lathe. The lathe signal is switched on
by an M function in the part program and passed onto the bar pusher.
The lathe stops the part program until acknowledged (see pin 23).
Signal flow: lathe to bar pusher

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9.2 Interface for bar feeding unit
9 Interface description

9.2.8 Operating and M functions

Key switch ( ) bar operation

When switched off, the machine only operates without bar pusher.

When switched on and when all other conditions (parameters) are

fulfilled the machine operates together with the bar pusher.

Machine on
I
This key is also present independent of the bar socket option,
however, receives a further function with this option.
The machine and the bar pusher are switched on.

M65, bar operation, interrogation of bar end

Using this M function the machine sets the release of the bar change.
Once the bar end is reached the parameter R741 = 1 is set. This can
be used in the part program for branching and thus for setting various
reactions.
The R parameter is reset when the material present signal is set
again.

M66, bar operation, handshake short part magazine

Using this function an output is switched on and thus set on the inter-
face (pin 24). With this the part program stops until the acknowledge
signal is set by the bar pusher (to pin 23).
Correspondingly this handshake function makes it possible to
synchronise sequences between the short part magazine and the
machine is a simple manner. However, it is necessary that the
sequence is prepared identically on both sides.

M69 Push bar forward to stop

This is used to activate the push bar forward signal. It is deleted the
next time the chuck is closed.

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 10.1 Maintenance instructions
10 Maintenance and care

10 Maintenance and care

10.1 Maintenance instructions

All machines are subject to maintenance and care intervals. For the
GILDEMEISTER lathe, all necessary maintenance intervals, which
are not repeated daily, are displayed as a message on the screen
when switching on the machine.

The data specified in these maintenance instructions are valid for the
machine, the integrated bar loading magazine, chip conveyor and pre
transformer.
Refer to the individual manufacturer s instructions for other peripheral
units such as, for example, bar feeding units.

Only cancel the message after performing the maintenance

work.

Only use original spare parts!

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10.2 Acknowledging maintenance work
10 Maintenance and care

10.2 Acknowledging maintenance work

For some maintenance work the performance of the maintenance

must be acknowledged. For this use the softkeys to retrieve a
screenmask.

Press USER

Press USER DIAGNOSIS

Press SERVICE DATA

Press MAINTENANCE

The maintenance intervals for grease lubrication, switch cabinet filter

mats and ISM (Integrated Spindle Motor) are displayed.

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 10.2 Acknowledging maintenance work
10 Maintenance and care

D Grease lubrication (only for machines up to commission number

501505)
A fault message is transmitted after the elapse of the interval time.
The program is locked until the maintenance is performed and
confirmed with the ”Maintenance performed” softkey.

D Switch cabinet filter mats

Interval times of from 500 to 2000 hours are permissible. The values
can be entered in accordance with local ambient conditions. A fault
message is transmitted after the elapse of the interval time. The start
of a program is locked until the maintenance is performed and
confirmed with the corresponding softkey ”Maintenance performed”.

D ISM filter mats (Integrated Spindle Motor)

Interval times of from 500 to 2000 hours are permissible. The values
can be entered in accordance with local ambient conditions. A fault
message is transmitted after the elapse of the interval time. The start
of a program is locked until the maintenance is performed and
confirmed with the corresponding softkey ”Maintenance performed”.

Recommendation:
Match the interval times to the machine conditions. We would
recommend an interval time of 500 hours.

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10.3 Daily checks prior to starting work
10 Maintenance and care

10.3 Daily checks prior to starting work

The hydraulics and fresh oil unit are located at the rear of the
machine.

Perform the following listed work prior to each shift with the machine
switched off!

Hydraulic unit filling level

Ensure that the oil level in the inspection glass (see pos. 13,
page 10-10) is in the upper third between the marks.
There is a leak in the system if the hydraulic oil level is too low.

Top up with a corresponding quantity of oil (for oil grade refer

to chapter 4.3) if the container oil level is insufficient (see
Pos. 1, page 10-10).

In the event of a fault message F... (HYDRAULIC: FILTER

BLOCKED) have the filter insert changed by authorised personnel.

Do not wash out the filter, dispose of in accordance with the

regulations.

Fresh oil lubrication filling level

Ensure that the oil is above the black mark (see pos. 2, page
10-10) and a filling approx. 3/4.

Top up with the corresponding quantity of oil if there is

insufficient oil in the container (for oil grade refer to chapter
4.3).

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 10.3 Daily checks prior to starting work
10 Maintenance and care

Coolant lubricant level

Check the inspection glass on the chip conveyor for the

coolant level. The inspection glass must be filled to the top
mark (see Pos. 10, page 10-10).

Top up with coolant lubricant as required using a coolant with

the correct mixing ratio.

Filling level of the integrated bar feeding magazine

Check the oil level of the bar loading magazine on the

inspection glass (see Pos. 3, page 10-10). Fill the inspection
glass up to the top mark.

If the container has too little oil, please top up with the corres-
ponding quantity (for oil grade, refer to chapter 4.3).

The bar loading magazine may also be operated with a ≥ 10%

coolant emulsion.

Check the bar feeding unit (option)

Check the oil level of the bar feeding unit in accordance with
the manufacturer’s information.

If the container has too little oil, please top up with the corres-
ponding quantity (for oil grade, refer to chapter 4.3).

If irregularities and/or damage is found during the above mentioned

controls:

Do not switch on machine

Contact your service department!

After switching on the machine

Activate additional lubrication pulses following an extended down
time (longer than 2 days) prior to moving the axes with M49. Observe
the waiting time of approx. 3 min. after each lubrication pulse.

Operating instructions MF sprint 42/65 V 2.0 page 10-7

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10.4 Daily maintenance after shift end
10 Maintenance and care

10.4 Daily maintenance after shift end

Prerequisites

D Open protection hood.

D Switch off main switch and secure against switching on again.

Work sequence:

Clean the working space with suitable means at the end of

each shift (hand broom etc.).

Clean machine lamp (see Pos. 4, page 10-10).

Do not use compressed air!

(Take note of the safety instructions contained in chapter 1)

Check and clean the safety window in the protection hood for
damage (see Pos. 5, page 10-10).

Check the slide plates and scrapers in the working space for
damage (see Pos. 4, page 10-10).

Check clamping means for damage (see Pos. 8, page 10-10).

Check operating elements on the control panel for damage

(see Pos. 12, page 10-10).

Clamping means (chuck/steady rest)

Lubricate clamping means with heavy duty grease paste

(for lubricant type refer to 4.3). Observe the manufacturer’s
lubricating instructions.

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 10.5 Weekly maintenance
10 Maintenance and care

10.5 Weekly maintenance

Filter mats

Check the machine filter mats. Renew them if these are soiled
or wet (see pos. 9, page 10-10).

- Switch cabinet doors

- Spindle motor fan ventilator (ISM)

- Oil mist separator (Option)

Change the filter mats once per month.

Do not operate without filter mats, as this may lead to damage to

electronic components.

Checking the air servicing unit

Check the pneumatic air servicing unit according to the

manufacturer’s information.
Drain off the water.

Pressure accumulator control.

Work sequence

Switch on the machine

Wait until the system pressure is displayed

Switch off the machine

Observe the system pressure gauge

This procedure may take a little time depending upon the number of
consumers (5 to 10 minutes).

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10.5 Weekly maintenance
10 Maintenance and care

The indicator speed is faster when the displayed system pressure

has dropped below the value of the accumulator pre-tension (refer to
table).

System pressure Accumulator pre-tension

(bar) (bar)
50 - 60 40
(for turret) 50 - 60 (for turret) 40

If the switch over point of the indicator speed is below the

value of the accumulator pre-tension have the pressure
accumulator refilled by authorised persons to the given value
of the accumulator pre-tension (see table).
Two pressure accumulators are installed in the machine. One
is behind the hydraulic unit, the second can be reached after
dismantling the right hand rear panelling.

The pressure accumulator is defective and must be exchanged

if the pressure drops continuously, without a clearly visible
change to the indicator speed.

If irregularities and/or damage is found during the following described

checks:

Contact your service department!

Empty chip collection container

Switch off the chip conveyor.

Do not manually remove the chips and swarf. Ensure that the swarf/
chip collection conveyor is correctly repositioned below the ejection
shaft of the chip.

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 10.6 Maintenance plan for machine operator
10 Maintenance and care

10.6 Maintenance plan for machine operator

3 6 5 7 12
SINUMERIK

4 8 10

13 1

9 2

11

33001241

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10.6 Maintenance plan for machine operator
10 Maintenance and care

Daily maintenance plan before starting work

1 Hydraulic unit

- Oil container

2 Fresh oil lubrication

- Oil container

3 Bar feeding units

Daily maintenance work after completing work

3 Bar feeding unit

4 Working space
- Cleanliness and damage
- Machine lamp
- Scraper and pusher plates
5 Separating protection devices
- Safety window
- Metal sheets
6 Spindle motor
- Filter mats
Fresh oil lubrication
- Leak oil collector
7 Tool turret
- Damage
8 Power operated chuck (main spindle/counter
spindle)
- Chuck
- Clamping jaws
9 Switch cabinet
- Filter mats
Oil mist separator
- Filter mats
10 Chip conveyor
11 Air servicing unit

= Visual control, = clean, = grease, = change, = top up, = empty

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 10.7 Switching off the power to the machine
10 Maintenance and care

10.7 Switching off the power to the machine

Prerequisites

D Open protection hood

D Switch off machine at main switch and secure to prevent
switching on.

10.7.1 Hydraulic, accumulator pressure reduction

Release screws with the size 5 Allen key (Fig. 1)

Check the pressure reduction on hydraulic pressure gauge.

31780421

Fig. 1

10.7.2 Depressurisation of the pneumatics

Close the central stop cock and vent the unit

Check the pressure reduction on the pneumatic pressure

gauge.

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10.8 IRCO bar loading magazine SIMAG
10 Maintenance and care

10.8 IRCO bar loading magazine SIMAG, maintenance and care

1 2 3 4 5 33001250

Fig. 2

1 Locking plate 4 Spacer tube

2 Rear section 5 Pusher head

3 Intermediate piece 6 Lubrication nipple

For a perfect function of the SIMAG ensure that the maintenance and
care instructions are adhered to.

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 10.8 IRCO bar loading magazine SIMAG
10 Maintenance and care

Maintenance review

6 months
Monthly
Weekly
Daily
Grease the material pusher J

Check the function of the material pusher bearing J

control device
Check the chain tension J

Check the function of the chain return pulley J

Clean the complete unit J

Check the clamping force of the clamping collar J

Check the oil level at the inspection glass J

Recommended lubricants for material pusher and bearings:

Klüber grease ISOFLEX NBU 15

In order to avoid damage to plastic components ensure that no

aggressive cleaning agents are used.

The lubrication and maintenance intervals are valid for single shift
operation. Halve or third the given times if the unit is used in 2 or 3
shift operation!

Maintenance of the pneumatics

For single shift operation:

daily: Check the operating pressure for the work circuit.

Check the pneumatic control operating pressure.

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10.8 IRCO bar loading magazine SIMAG
10 Maintenance and care

Maintenance of the bar loading magazine oil unit

Clean the intake filter (Fig. 3/1) once per week using washing
benzine and thoroughly blow down. The cleaning intervals may be
shorter dependent upon the materials being machined!

We recommend that the oil container be fully cleaned as main-

tenance work after 2500 operating hours. For this the following steps
are necessary.

- Open the bar loading magazine cover plate.

- Release the fixing screws and remove the filter holder.
- Clean, or replace the intake filter!
- Pump off all the oil.
- Remove the deposits at the bottom (oil sludge).
- Replace the filter holder and screw in place.
- Fill with new oil (refer to chapter 4.3 for the oil type and grade)
- Close the bar loading magazine cover plate

31410670

Fig. 3

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 10.9 Inspection work
10 Maintenance and care

10.9 Inspection work (necessary every 2,500 hours)

Only personnel authorised by the manufacturer are permitted to

undertake inspection work.

10.9.1 Checking the safety devices

D EMERGENCY STOP button

D Verriegelung und Funktion der Schutztür der Maschine

- with the main switch switched off and
- the spindle running

D Locking and function of the protection hood of the integrated bar

loading magazine

D Agreement key and function key

- Move axes by max. 2 m/min
- Move chip conveyor

D Actuate with the function key

- Clamping devices (open/close)

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10.9 Inspection work
10 Maintenance and care

10.9.2 Machine inspection

D Spindle motor (spindle 4)

- check axial play on the spindle flange
- check radial play on the spindle flange
D Clamping device (spindle 4)
- check clamping cylinder concentricity
- check clamping cylinder run-out
- check power clamping means concentricity
- measure power clamping means clamping force
D Counter spindle motor (spindle 1)
- check axial play on chuck flange
- check radial play on chuck flange
D Clamping device (Spindle 1)
- leaks on the clamping device
D Spindle holding device (Option)
- Check secure seating of all mechanical, hydraulic and electri-
cal components on the main and counter spindle.
D Compound slide rest
- Check the toothed belt, feed X and Z axes for wear

Setting the belt tension

Use the belt tension measuring instrument from MULCO or
CONTITECH for setting the belt tension.
The measuring range of the unit is 30...300 1/sec.

Axis Belt frequency (Hz)

X1 100...110
X2 60...80
Z1 140...160
Z2 180...200
Counter spindle/tool drive 1 75...85
Encoder drive 200...220
Tool drive 2 140...150

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 10.9 Inspection work
10 Maintenance and care

D Tool drive
- Grease change
D Hydraulic group
- Hydraulic oil change
- Hydraulic oil filter change
- Check hydraulic lines for leaks or damage
D Guides (slide plates are removed)
- Check guideways (roller guides)
D Others
- If required, a geometric check can be made in accordance with
DIN 8605 by an authorised manufacturer service.
- Ask about a maintenance contract.

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page 10-20 V 2.0 Operating instructions MF sprint 42/65
Doc.-No.: ABB002G0
 11.1 Parameters
11 Parameter settings, M commands

11 Parameter settings, M commands, Standard cycles

and PLC fault messages

11.1 Parameters

In the operating mode masks

AUTOMATIC
JOG
JOG/REFPOINT
MDA

a menu can be selected in which further masks can be selected.

The individual parameters can be read or changed after selecting
these masks.

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11.1 Parameters
11 Parameter settings, M commands

11.1.1 Setting parameters

D Clamping means zero point

Press USER

Press PARAMETER SETTING*

Press CLAMPING MEANS ZERO POINT

(Mask Cutt. Cntr. Zero Point)

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter settings, M commands

The contents of the R parameters of the last workpiece saved is

shown.

R 712 Width of the parting tool

R 714 Spindle clamping means height 4
R 720 Unloading length of the workpiece in spindle 4
R 721 Spindle 1 clamping means height 1
R 724 Loading length of workpiece in spindle 1
R 725 Finished part length
R 738 Workpiece diameter

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11.1 Parameters
11 Parameter settings, M commands

D Tool change points

Press USER

Press PARAMETER SETTING*

Press TOOL CHANGE PNT.

Cycles to be used: L 710 Move to tool change point

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter settings, M commands

Enter the axis coordinates here, which are to be moved to when

selecting the cycle L 710. The values are transferred to the axis
specific R parameter:
X axis R 690
Z axis R 691

The max. values correspond to the positive software limit switch

dimensions.

Enter values:
Turn the key switch to position 1

Position the cursor on the input field

Enter the coordinate

Press the enter key

Value is displayed in the input field

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11.1 Parameters
11 Parameter settings, M commands

D Workpiece counter

Press USER

Press PARAMETER SETTING*

Press COUNTER

Press WORKPIECE COUNTER

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter settings, M commands

- Total quantity counter

The counter permanently counts-up and can be reset as required.
- Shift counter
Counts can be made for 3 shifts.
Activate a counter when starting the shift.
The counter can be reset as required.
- Subtracting workpiece counter
Enter a set point quantity to count down a targeted number of
workpieces.

Turn key switch to position 1

Position cursor on input field

Enter required set point quantity

Press enter key

The value is displayed in the ”SET POINT” field

The remaining quantity is permanently transferred into the R

parameter R 761.
A message is transmitted when the remaining quantity is 0.
At ”Rest = 0” the program can be allowed to continue running with
cycle start.
Branching into a part program can be programmed using the R
parameter R 761.
If the machine now stops it can be restarted with cycle start. The
ACTUAL QUANTITY will now be greater than the SET POINT
QUANTITY.

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11.1 Parameters
11 Parameter settings, M commands

D R-Parameter counter

Press USER

Press PARAMETER SETTING*

Press COUNTER

Press R PARAMETER COUNTER

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter settings, M commands

The contents of the R parameters are shown here.

Counting can be performed with these parameters in the part
program.

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11.1 Parameters
11 Parameter settings, M commands

D Material feeding

Press USER

Press PARAMETER SETTING*

Press MATERIAL TRANSPORT

Press MATERIAL FEEDING

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter settings, M commands

Preselecting the material feeding

Turn key switch to position 1

Position the cursor on the input field

Enter the number in accordance with the type

Press the enter key

The type selected is displayed in the enter field

0 ᇅ No material feeding connected to the machine

1 ᇅ External bar loading magazine

2 ᇅ External bar feeder

3 ᇅ External short part magazine

6 ᇅ Integrated bar loading magazine

- Simple de-selection of the loader servo axis by the ”parking axis”

function
With the CNC - issue 5.7 and 6.X....the possibility exists to separate
an axis configurated in the drive system by software by accessing the
”parking axis” from the drive monitoring.
The drive can be hardware removed.
To date this property is only used for the loading axis ”Q” when a
machine is converted to an external loader interface.
This function is selected when the integrated loader is de-selected in
the ”material feeding” setting mask (no ”6” entered).
Press the main switch ”OFF/ON” after de-selecting the main switch!

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11.1 Parameters
11 Parameter settings, M commands

D Integrated bar loading magazine (setting 1)

Press USER

Press PARAMETER SETTING*

Press MATERIAL TRANSPORT

Press MATERIAL FEEDING

Press INTEGR. BAR LOADER

Press SETTING 1

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter settings, M commands

Feed path for advance (M73)

The feed path from the machine chuck to the material stop is divided
using this percent factor.
This means that a part of the stop path can be pushed forward at the
speed given in the parameter ”Feed path for advance (M73)”.
The pusher covers the remaining path at the speed given under
parameter ”Speed to material stop” (move to fixed stop), up to the
material stop.
(Optimum auxiliary time behaviour, as the material stop is in the
workpiece machining position.)

The factor must be ”0” for part lengths of less than 80 mm.
In this case the pusher moves at the ”Speed to material stop”
speed until reaching the material stop.
The function M69 provides an alternative for short parts or parts with
multiple pushing forward.

For part lengths greater than or equal to 80 mm

Default setting = 80 %
For part lengths less than 80 mm
Default setting = 0 %

As from PLC version 03.05.1999 the manual adjustment of the feed

forward path divisions in % values is no longer required.
The divisions 80%, feed path for advance ( M73 ), and 20% remaining
path, speed to material stop is performed automatically by the part
program by reading the variable R725 ”Workpiece length”.
The switch over shaft is within the range:
Up to 80 mm operation is performed with 0% division.
The above division starts at 80 mm.

Feed path for advance (M73)

Refer to menu point ”Feed path for advance (M73)” for the effect of
this parameter.
This feed speed is only effective when the path division is switched
active.
The max. speed amounts to 15 m/min and can be changed in
accordance with the situation.

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11.1 Parameters
11 Parameter settings, M commands

Speed to material stop

Refer to menu point ”Feed path for advance (M73)” for the effect
of this parameter.
The feed speed is effective independent of the path division.
The max. speed is 12 m/min and can be reduced depending upon the
situation.
This may be necessary with the path division in accordance with
requirements. (Excessive impact on the material stop).

Rapid speed for traverse return

This parameter determines the pull back speed of the material pusher
during an automatic bar change and when operating manually.
Attention, do not change this parameter unless agreed with the
machine manufacturer.
Default setting = 35 m/min

JOG speed for bar pushing

Refer to the ”Bar diameter” menu point for the effect of this parameter.
Default setting = 12 m/min
This function can be used as from PLC version 15.01.1998.

JOG force for bar pushing

Refer to the ”Bar diameter” menu point for the effect of this parameter.
Default setting = 35 %
This function can be used as from PLC version 15.01.1998.

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 11.1 Parameters
11 Parameter settings, M commands

Feed moment for M69

The max. moment when pushing forward the bar to the material stop
is set with this parameter. (M69)
In the machine part program, set the material stop as close as
possible to the bar start position so that the bar in contact can be
simultaneously moved to the target position (reduction of the impact
energy).
Attention: an excessive value or path can lead to the destruction of the
driver head or misalignment of the turret guide!
A multiple feed forward is also possible using this function.
Default presetting = 15 %
This feed torque can be changed in accordance with your require-
ments.
Set the feed torque so that uniform pushing of the selected material is
just about possible using the material pusher. This is dependent upon
the material length, diameter and weight.

Clamp moment turn

This parameter influences the contact pressure of the material pusher
after the machine chuck has clamped. The clamping moment is
increased to the entered value prior to starting the turning procedure.
Default presetting = 3 % (upper limit 9%)
This turning clamping moment can be increased or reduced in
accordance with your requirements.
Set the clamping moment so that the selected material is securely
guided by the material pusher during machining. This is dependent
upon the material length, diameter and weight. The driver axis ”Q”
may become overheated in the case of an excessive value and
corresponding requirements.
In this case reduce or increase the value correspondingly so that the
bar is still securely guided!

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11.1 Parameters
11 Parameter settings, M commands

Remaining material correction value (mask Residue part)

The workpiece remaining length is automatically calculated and set
via the variables R714, R720, R725, R712 and the max. pusher posi-
tion in front of the chuck. (Also refer to chap. 7.13.3).
Ensure that the reference dimension of the loader (Q axis) is correctly
set in relation to the machine!!!!
Ensure that the spacing between the loader and the machine is
40 mm as a result of the presetting reference dimension!
A correction of the remaining material length can be entered using this
parameter by the relationship of the bar length to the workpiece length
and the tolerances in the feed system.
If the remaining material length is always too long, then reduce the
preset default value in accordance with your requirements.
Attention - when reducing and with a corresponding ratio between the
bar length and the workpiece length it may happen that during the fast
forward movement the max. pusher position in front of the chuck is
reached and the drive axis is switched off. In this case slightly
increase the correction value.

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 11.1 Parameters
11 Parameter settings, M commands

The previous default value of 20 mm can be set to 0. A switching off of

the feed axis by the front CNC software limit switch, during the last
part feed is prevented by the new PLC version 03.05.1999. An adap-
tation to changes resulting from mech. tolerances or wear, which
affect the remaining material calculation can still be performed using
this parameter.
Default presetting = 0 mm (+/-- values)

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11.1 Parameters
11 Parameter settings, M commands

Correction first slide

During a bar change the new bar pushed the remaining material out of
the collet and into the remaining material collection dish. This first
slide position from the collet is calculated from the values in the R
parameters:
First slide position = (R714+R720) - (R712+725)

Attention: R720 must always include the total workpiece length!

If the individual position is required for multiple pushing forward,
these values must be entered in free R parameters!
This value is not always reached due to internal tolerances in the bar
loader or installation tolerances. (The workpiece presetting is 40 mm
between the bar loading magazine and the machine)
The position of the new bar can be corrected using this parameter.
(+/-- input values are possible)
Default presetting - 0 mm

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 11.1 Parameters
11 Parameter settings, M commands

Attention:
After installing the unit check the positioning by simulating an
automatic bar change and correct if necessary. For this ensure
that an offcut is cut and clamped in the machine chuck.
Take particular care when undertaking this check in order to
avoid a collision.
Following this once off setting the only correction encountered
are those to meet your requirements.
Bar diameter
An automatic setting of the feed force is performed with this parameter
in accordance with the bar diameter.
Default presetting = 60 mm

Set the bar diameter so that uniform pushing of the selected material
is just about possible using the material pusher. This is dependent
upon the material length, diameter and weight.

A manual setting of the bar diameter is not required as from PLC

-- Version 03.05.1999.
The settings are automatically performed by the part program by
reading the variable R738 ”Unmachined part diameter”.
In the part program enter the correct bar diameter in this
variable.
Currently 3 force areas are set in accordance with the bar diameter.
The switch over shafts are: 0 to 25 mm
26 to 45 mm
46 to 65 mm
The effect of the parameter can be checked in the ”Manufacturer’s
information” user mask.

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11.1 Parameters
11 Parameter settings, M commands

Special setting possibilities of bar diameter: 99.0 mm

This value allows to set the feed force in accordance with the condi-
tions. Attention, it might be necessary to undertake speed adaptation
in accordance with the behaviour. With larger force requirements and
high speeds damage to the driver or misalignment of the turret might
occur!
For this function two new parameters have been introduced in ”Setting
mask 1”.
1) JOG force for bar pushing = Default 35 %
2) JOG speed for bar pushing = Default 12 m/min

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 11.1 Parameters
11 Parameter settings, M commands

Setting instructions for special cases, input bar diameter 99 mm:

First setting: Jog force for bar pushing = Default 35 %
With this value the actually required force for each material is
determined. The setting should be such that the bar can be securely
pushed forward over the total free feed range, without the ”Fixed stop
reached” message being displayed.
Setting aid: The ”FIXED STOP” LED flashing on the operating panel
during the feeding forward means that the fixed stop function is
selected, bar is securely pushed forward to the fixed stop! LED steady
lit during pushing forward means ”Fixed stop” was reached prematu-
rely. The clamping torque now drives the bar away!
Stop the process using the ”RESET” key, increase the value and
repeat the feed test!
The value found automatically sets the feed force parameter in the
”Manufacturer’s entries” setting mask!

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11.1 Parameters
11 Parameter settings, M commands

Second setting: Jog speed for bar pushing = Default 12 m/min

After determining the jog force it may occur that the bar speed must
be adapted. (see comment above)
If the jog force is greater than ”35 %”, first reduce the default value by
6 m/min”. Now move in jog operation to the remaining material at this
speed, with the found jog force and with an inserted bar. The impact
behaviour of the new bar on the remaining material can now be
evaluated on site!
The speed can now be increased, until the set impact is acceptable.
Once the value is determined this must be entered in two setting
masks.
Setting 1
Speed to material stop:
Manufacturer’s entries
Search bar feed:
Feed bar to remaining material:
The remaining material must now be manually removed from the
chuck. Bring the new bar into position and start the machine automatic
mode.

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 11.1 Parameters
11 Parameter settings, M commands

D Integrated bar loading magazine (setting 2)

Press USER

Press PARAMETER SETTING*

Press MATERIAL TRANSPORT

Press MATERIAL FEEDING

Press INTEGR. BAR LOADER

Press SETTING 2

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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11.1 Parameters
11 Parameter setting, M commands

Program modification via setting parameters

Push back bar after first feed:
This function can be selected in the ”Setting mask 2”.
Bit on ”1” = Function ”On”
This function provides the possibility to push back a new bar (first
feed) which has moved too far through the chuck using the material
stop until the stop position coincides with the driver position!

Attention, prerequisite is that the driver positioning is correctly

set using the first push in correction! It is not possible to push
back the driver over a longer distance!
Take note when using that in the part program the remaining material
collar first moves back a certain distance with the combined material
stop and then lowers the stop, to push the bar into position! In addi-
tion, the part program must be extended with the M command M 437
”Clamp chuck 4” in the next block when the stop is in position with the
bar pushed back! (Extend standard program % SPF 1041)

M73 - Feed bar (without clamping):

The selection of this function can be made in the ”setting mask 2”.
Bit on ”1” = Function ”On”
This function offers the possibility of triggering the clamping of the
pushed forward bar via the part program.
Depending upon the application it may occur that the message ”Fixed
stop reached” comes too early and the chuck clamps too early by the
PLC.
For this reason the workpieces will be sporadically too short. By
selecting this function the clamping (M 437) can be made via the part
program with a short dwell time (G04) beforehand, dependent upon
the application. The bar can now correctly press against the material
stop.

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 11.1 Parameters
11 Parameter setting, M commands

Steady rest on longitudinal pusher:

Close guidance of the material bar or the longitudinal pusher is of
advantage in order to realise very high rotational speeds and good
running properties.
An optimum guidance of the system and a good turning quality can be
achieved with the switching over to ”Steady rest on longitudinal
pusher”.
An optimum guidance is realised with a play of 1 mm. The steady rest
is closed by this selection when the last segment opens.
The diameter of the steady rest jaws can be freely selected when
ordering or the steady rest jaws are supplied as standard with a hole
size of 5 mm diameter permitting the customer to adapt them by
boring out.
In addition we recommend that a maximum play of 5 mm between the
material bar and the guide channel is not exceeded.

Oil pump ”OFF” by longitudinal slide back:

Using this function the running properties of the loader can be
influenced with profiled material.
The oil pump only switches ”OFF”, when the longitudinal slide is in the
rear position and swings up.

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11.1 Parameters
11 Parameter setting, M commands

D Integrated bar loading magazine (Manufacturer’s entries)

Press USER

Press SETTING PARAMETER*

Press MATERIAL TRANSPORT

Press MATERIAL FEEDING

Press INTEGR. BAR LOADER

Press MANUFACTURER’S INPUTS

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter setting, M commands

Attention! Only change these parameters after agreement with

the manufacturer.
The exception parameters are listed below.
Feed force Autom., search bar
Feed force Autom., bar end piece
Feed force Autom., push bar
Feed force Autom., push out end piece
Speed push out end piece
Speed repeat push out end piece
Speed up to measuring sensor

Attention! These parameters are automatically set up. (Refer to

Parameter description ”Bar diameter”)
Attention! The following parameters are influenced by the special
bar diameter setting possibility: 99 mm.

Search bar feed

Bar feed, remaining material

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11.1 Parameters
11 Parameter setting, M commands

Clamping torque, move to fixed stop

This parameter determines the clamping torque with which the bar is
pressed against the material stop after the ”Fixed stop reached”
function is switched on.
The bar is pressed against the stop with this clamping torque for as
long as the chuck is open.
After clamping the system switches over to the parameter ”Turn,
clamping torque”.

Display aid: ”FIXED STOP” LED on the operating panel

LED flashes during pushing forward this means that the fixed stop
function is selected, and the bar is securely pushed against the fixed
stop!
LED constant light means the ”Fixed stop” has been reached.
The clamping torque now drives the bar against the material stop

Dependent upon the application it is possible that the message

”Fixed stop reached” is obtained too early and the chuck
clamped too early by the PLC. (Only M73)
This will result in the workpieces sporadically being too short.
It is possible to change the values until perfect function is
achieved.
In setting 2 the function ”M 73 Feed bar (without clamping)” can
be selected by influencing the program. (Refer to the description
there)
Default presetting = 15%

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 11.1 Parameters
11 Parameter setting, M commands

Spring path tolerance

This parameter takes into account the path fault, caused by the drive
chain when moving onto the fixed stop and the driver pressing the bar
with the clamping torque.
This path fault is correspondingly compensated in the control system.
With fault messages: 9154 ”Fault when moving to fixed stop”
9157 ”Fixed stop was not reached”
If this fault is triggered during processing and the part program data in
the R variables is corrected, first check the chain tension and then the
reference dimension of the ”Q” axis No.: 20.
In case of a fault the default value can be increased in tenths until the
above are checked.

Default presetting = 30 mm

Return path at G220

This parameter determines the return path of the material pusher
when the ”Move to fixed stop” function is switched off.

Attention! Do not change this parameter until agreed with the

machine manufacturer.
Default setting
Return path with G220 = 0.001 mm
All specified default values may change depending upon the
development level!
Please contact the manufacturer in case of doubt!

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11.1 Parameters
11 Parameter setting, M commands

D External bar feeder

Press USER

Press SETTING PARAMETER*

Press MATERIAL TRANSPORT

Press MATERIAL FEEDING

Press EXTERN. BAR LOADER

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter setting, M commands

The reaction to the material end signal is selected.

The signal is set by the bar feed.

Preselection 0 = Stop at material end

Turn key switch to setting 1

Enter 0

Press enter key

The value ”0” is displayed in the input field

If the signal is set by the bar feed, cycle stop is switched once
clamping the clamping means and the part program are completed.

Preselection 1 = no stop at material end

Turn key switch to setting 1

Enter 1

Press enter key

Value ”1” is displayed in the input field

If there is no reaction to the signal then the part program continues to

be processed.
A branch can be programmed in the part program with the parameter
R 741 (Material end).

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11.1 Parameters
11 Parameter setting, M commands

D Conveyor belt

Press USER

Press SETTING PARAMETER*

Press MATERIAL TRANSPORT

Press CONVEYOR BELT

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter setting, M commands

Selection of the conveyor belt type

Turn key switch to setting 1

Position cursor on input field

Enter number in accordance with type

Press enter key

Selected type is shown in input field

Select conveyor belt running time

Turn key switch to setting 1

Position cursor on input field

Enter conveyor belt running time

Press enter key

Running time is shown in input field

The conveyor belt is switched on with the function M 608.

The running time does not stop with ”Cycle Stop”.

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11.1 Parameters
11 Parameter setting, M commands

D Chip conveyor program running time

Press USER

Press SETTING PARAMETER*

Press MACHINE FUNCTIONS

Press CHIP CONV. PROG. RUNT.

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter setting, M commands

Selecting the chip conveyor type

Turn key switch to setting 1

Position cursor on input field 1

Enter ”1”

Press enter key

Selected type is shown in the input field

The chip conveyor can be operated via M commands or at intervals,

or in constant operation.

Selecting the chip conveyor running time

Turn key switch to setting 1

Position cursor on input field

Enter running time

Press enter key

The running time is displayed in the input field

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11.1 Parameters
11 Parameter setting, M commands

D Chip conveyor program running time (continued)

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 11.1 Parameters
11 Parameter setting, M commands

Select the chip conveyor pause time

Turn key switch to setting 1

Position cursor on input field

Enter pause time

Press enter key

Pause time is displayed in the input field

With the entered values the chip conveyor runs in interval made with
the program operating.
If the value 0 is entered for the pause time, the chip conveyor runs
constantly with the program operating.
If the value 0 is entered for the pause time, the chip conveyor must be
controlled by the M functions.

Select program running time

Turn key switch to setting 1

Position cursor on input field

Enter running time

Press enter key

Running time is shown in the input field

Permissible input values:
min. 1 minute
max. 180 minutes

For running time monitoring programming is necessary in the part

program M 99. The program running time is monitored from cycle start
or from M 99 to M 99. If, for example, the program sequence is inter-
rupted due to a malfunction or lack of material the cycle stop is com-
pleted at the latest after entering the program time (spindles stop).

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11.1 Parameters
11 Parameter setting, M commands

D Leukhardt (sensor)

Press USER

Press SETTING PARAMETER*

Press MACHINE FUNCTIONS

Press LEUKHARDT

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter setting, M commands

Selection of tool monitoring

Turn key switch to setting 1

Position cursor on input field

Enter ”0” to deactivate

Enter ”1” or ”2”* to activate

Press enter key

Condition is displayed in the input field

Start the learn procedure:

Move slide/tool holder into position

Press Test OK

Press Test KO

* 1 ᇅ R parameters are set

2 ᇅ In case of interrogation ”not in order” the data release is
blocked by the channel blocked, which had triggered the
M function

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11.1 Parameters
11 Parameter setting, M commands

D Oil mist separator

Press USER

Press SETTING PARAMETER*

Press MACHINE FUNCTIONS

Press OIL MIST SEPARATOR

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter setting, M commands

Selecting the operating mode

Turn key switch to setting 1

Position cursor on input field

Enter ”0”, if no oil mist separator is fitted.

Enter ”1” when the controls are to be made using the operating keys.
Enter ”2” when the oil mist separator is switched on with cycle start
and is to be switched off after cycle stop with the opening of the wor-
king space door and the elapse of the after run time.
Enter ”3”. The oil mist separator starts with cycle stop for an after run
time of 10 seconds.

Press enter key

The operating mode is shown in the input field

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11.1 Parameters
11 Parameter setting, M commands

D Customer module (Option)

Press USER

Press SETTING PARAMETER*

Press MACHINE FUNCTIONS

Press DIVERSE SELECTIONS

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter setting, M commands

The option can be selected via the PLC machine data bit

The reaction to the outputs can be selected as follows for certain

events.
DB197_DW233
Value 0 - No reaction to EMERGENCY STOP and reset
Value 1 - All outputs are reset with an EMERGENCY STOP
Value 2 - All outputs are reset with a reset
Value 3 - All outputs are reset with EMERGENCY STOP
or reset

Operating instructions MF sprint 42/65 V 2.0 page 11-45

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11.1 Parameters
11 Parameter setting, M commands

D Chuck 4 (main spindle)

Press USER

Press SETTING PARAMETER*

Press CHUCK

Press CHUCK 4

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter setting, M commands

Select the main spindle clamping mode

Turn key switch to setting 1

Position cursor on input field

Enter ”1” for tension clamping

Enter ”0” for pressure clamping

Do not enter ”0” in both input fields.

Press enter key

The clamping value is displayed in input field

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11.1 Parameters
11 Parameter settings, M commands

D Chuck 1 (counter spindle or driven tools

Slide 1)

Press USER

Press SETTING PARAMETER*

Press CHUCK

Press CHUCK 1

* Setting data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”1”.

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 11.1 Parameters
11 Parameter setting, M commands

Selecting the counter spindle clamping mode

Turn key switch to setting 1

Position cursor on input field

Enter ”1” for tension clamping

Enter ”0” for pressure clamping

Do not enter ”0” in both input fields.

Press enter key

Clamping value is shown in the input field

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11.1 Parameters
11 Parameter settings, M commands

11.1.2 Diagnosis

D Temperature

Press USER

Press USER DIAGNOSIS

Press TEMPERATURE

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 11.1 Parameters
11 Parameter setting, M commands

D Data

Press USER

Press USER DIAGNOSIS

Press SERVICE DATA

Press DATA

The start up date is entered during the first start up.

Production time
The time is displayed in which the machine operates in automatic
operating mode.

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11.1 Parameters
11 Parameter settings, M commands

D Workpiece times

Press USER

Press USER DIAGNOSIS

Press WORKPIECE TIMES

Displayed are
- Main times
- Auxiliary times
- Total part times
- The carriage during the machining of a workpiece.

The function M 99 must be programmed in the part program for the

time figures.
The times are counted from cycle start or from M 99 to M 99.

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 11.1 Parameters
11 Parameter setting, M commands

D Counter spindle to turret 1

Press USER

Press USER DIAGNOSIS

Press ALIGNMENT DATA OPTION

Press ALIGNMENT DATA* (Mask DRESS)

Press COUNTER SPIND. TO TURRET

* Alignment data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”2”.

Operating instructions MF sprint 42/65 V 2.0 page 11-53

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11.1 Parameters
11 Parameter settings, M commands

D Reference point + slack compensation

Press USER

Press USER DIAGNOSIS

Press ALIGNMENT DATA OPTION

Press ALIGNMENT DATA* (Mask DRESS)

Press REFER. POINT + FIT TOLER.

Data for X2 and V2 or Z2 and W2 must be identical.

* Alignment data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”2”.

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 11.1 Parameters
11 Parameter setting, M commands

D Integrated bar loading magazine

Press USER

Press USER DIAGNOSIS

Press ALIGNMENT DATA OPTION (Mask DRESS)

Press ALIGNMENT DATA* (Mask DRESS)

Press INTEGRAT. BAR LOADER

Shown are the dimensions for the bar loading magazine type 4200 (as
from machine 502501) For other machine dimensions: see P. 11-56

* Alignment data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”2”.

Operating instructions MF sprint 42/65 V 2.0 page 11-55

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11.1 Parameters
11 Parameter settings, M commands

Aligning the integrated bar loader beside the machine

Switch off the main switch.
Insert longitudinal pusher and remeasure:
The distance from the leading edge of the short pusher (nose) to the
leading edge of the long pusher is 1355 mm
Push short pusher with long pusher out of the loader.

The dimensions for the 501501-502500 amount 990 mm

machines to
From machine 502501-50.......
MF sprint 42 1060 mm
MF sprint 65 1050 mm

Measured from the front face of the loader to the leading edge of the
longitudinal pusher.
Switch on main switch.
Enter the length of the long pusher in the aligning data of the inte-
grated bar loader 1355 mm.
The value 0.00 is shown in Bag 2 Q axis when the longitudinal pusher
is swung out.
When swung in the value -1355 mm is shown. Push short and long
pushers back to the fixed stop. Read off the displayed value e.g.
3250 mm.
Calculate software limit switch plus

Machine 502501-50....
501501-502500
MF sprint 65 MF sprint 42 MF sprint 65
1355 mm 1355 mm 1355 mm Length of the pusher
+ 3250 mm + 3250 mm + 3250 mm Working space
+ 17.5 mm + 17.5 mm Control 0 point
+ 24 mm 0 mm + 10 mm Software limit switch minus
spacing from collet
= 4619 mm = 4622.5 mm = 4632.5 mm Software limit switch plus

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 11.1 Parameters
11 Parameter setting, M commands

The software limit switch minus results from the length of the longitudi-
nal pusher

Machine 502501-50....
501501-502500
1355 mm 1355 mm 1355 mm Length of the longitudinal
pusher
+ 24 mm + 0 mm + 10 mm Spacing to machine 0 Point
+ 17.5 mm + 17.5 mm Control 0 point
= 1379 mm = 1372.5 mm = 1382.5 mm Software limit switch minus

Enter dimensions
Determine reference point offset
Enter reference point offset 0.00 mm
Move to reference point

Displayed value 4500 mm 3 metre loader 5500 mm 4 metre loader

Open protection hood
Move the short pusher manually to the fixed stop and read off the
value
Displayed value e.g. 4600 mm 5600 mm
Calculation: 4600 mm 5600 mm displayed value
e.g. - 4619 mm - 5619 mm Software limit switch plus
= - 19 mm = - 19 mm Reference point offset

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11.1 Parameters
11 Parameter settings, M commands

Enter reference point offset

Delete reference points and move to again
Move Q axis to software limit switch plus
Check spacing from fixed stop, should be approx. 0.2 mm
Adapt reference point offset
Move Q axis to software limit switch
Displayed value

Machines 501501-502500 502501-502...

MF sprint 65 MF sprint 42 MF sprint 65
24 mm 17.5 mm 27.5 mm

Machines 501501-502500 502501-502...

MF sprint 65 MF sprint 42 MF sprint 65

As from software stand PLC: 03.05.99 and UMS 30.03.99 the second software limit
switches are required for the Q axis!!!!
2259 1. Limit switch plus 4619 mm 4622.5 mm 4632.5 mm
2299 1. Limit switch minus 1359 mm 1352.5 mm 1362.5 mm
2339 2. Limit switch plus 4619 mm 4622.5 mm 4632.5 mm
2379 2. Limit switch minus 1379 mm 1372.5 mm 1382.5 mm

User mask for aligning integrated bar loader max. pusher

position before chuck

1379 mm 1372.5 mm 1382,5 mm

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 11.1 Parameters
11 Parameter setting, M commands

Adjusting the bar loader behind the machine

1110mm
1070mm
17.5mm
40mm 1020mm
Control 0 point
50mm
integrated
ISM
bar-
Collet
loader

Chuck body
50mm

Machine zero point 40mm

33001300

e.g. MF sprint 65 as from machine No. 502501

Spacing between bar loader (front face) and machine (hood) amounts
to 40 mm movement to Q axis reference point
Move Q axis with longitudinal pusher to the software minus limit
switch.

Display on screen up to machine 502500 Q= 24 mm

as from machine 502501 MF sprint 42 Q= 17.5 mm
MF sprint 65 Q= 27.5 mm

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11.1 Parameters
11 Parameter settings, M commands

Open protection hood and remove collet, measure from the front edge
of the chuck body to the leading edge of the longitudinal pusher using
a depth gauge.

Up to machine 502500 set point 56 mm +/- 1 mm

From machine 502501
MF sprint 42 set point 50 mm +/- 1 mm
MF sprint 65 set point 60 mm +/- 1 mm

Measured value e.g. MF sprint 65 as from machine No. 502501

56 mm
The bar loader working space is 4 mm too large.
Reduce both software limit switches plus parameter 2259 and
2339 and the reference point offset by 4 mm.
Delete reference point and move to again

Measured value e.g. MF sprint 65 as from machine No. 502501

64 mm
The bar loader working space is 4 mm too small.
Increase both software limit switches plus parameter 2259 and
2339 and the reference point offset by 4 mm.
Delete reference point and move to again

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 11.1 Parameters
11 Parameter setting, M commands

Channel No. for loader

The entry permits the bar loader functions to be allocated a control
channel 1, 2 or 3. In order to save auxiliary time with more complex
part programs, the default setting is [ 3 ].(Bar change time can be
reduced).

Position for segments 1, 2, 3 and (4, 5 (Option))

At this input position the dimension ”Segment position to machine
zero point” can be entered. There are bar loaders with 3 and 5 seg-
ments dependent upon the bar length. The dimensions are preset and
must only be changed after new measurements!

Default setting
As from machine 502501 to 50.........
Bar loading magazine type 3200
Segment 1 = 3600 mm
Segment 2 = 2900 mm
Segment 3 = 2200 mm
Default setting
Machine 501501 to 502500
3200 bar loading magazine
Segment 1 = 3800 mm
Segment 2 = 3100 mm
Segment 3 = 2300 mm
Default setting
Machine 501501 to 502500
Bar loading magazine type 4200
Segment 1 = 4375 mm
Segment 2 = 4140 mm
Segment 3 = 3470 mm
Segment 4 = 2800 mm
Segment 5 = 2120 mm

The dimensions influence the correctly timed opening of the segment

whilst the material pusher pushes forward.

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11.1 Parameters
11 Parameter settings, M commands

Steady rest start

This dimension includes the longitudinal pusher dimension, the

remaining path refers to the machine zero point as in Fig. 1. Changes
”Length of longitudinal pusher” also means parameter changes
in this parameter!

Default setting
Machine 501501 to 502500
Start steady rest = 2500 mm
Default setting
From machine 502501 to 50.........
Start steady rest = 2530 mm

The dimensions control the timely opening of the steady rest prior to
the longitudinal pusher moving through. At this moment the loader oil
pump is also switched off.

Measurement probe pos.

These dimensions indicate how far a new bar is to be pushed using
the short driver. Following this the short driver moves back and the
longitudinal pusher is swung in. The dimensions always refer to the
machine zero point(see page 59).

Default setting
Machine 501501 to 502500
Position probe = 1208 mm
Default setting
Machine 502501 to 50....
Position probe = 1272 mm

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 11.1 Parameters
11 Parameter setting, M commands

Safety zone for segments open

These dimensions are a tolerance window to control whether the
corresponding segments have opened. If a segment has not opened a
fault is triggered.

Default setting
Safety zone for segment open = 150 mm
The dimensioning always refers to the machine zero point (see Fig. on
page 59).

Longitudinal slide length

In this parameter the actual length of the exchangeable longitudinal
pusher must be entered.
The dimensional accuracy should be to one comma because this
parameter automatically influences the bar measuring!
Attention, also the parameter ”Start steady rest” is influenced!
Default setting
Length of longitudinal pusher = 1355 mm

max Pos. of short pusher at bar searching

This position indicates how far the short pusher is allowed to move
when the automatic bar search program is started following main
switch OFF - ON or following other operations.
Default setting
Machine 501501 to 502500
Bar loading magazine type 3200
max Pos. of short pusher when searching for bar stock =
3250 mm
Default setting
Machine 501501 to 502500
Bar loading magazine type 4200
max Pos. of short pusher when searching for bar stock =
4250 mm
Default setting
Machine 502501 to 50...
Bar loading magazine type 3200
max Pos. of short pusher when searching for bar stock =
3320 mm

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11.1 Parameters
11 Parameter settings, M commands

max pusher position before chuck

This position indicates the maximum position of the driver before the
collet.
The last part can be produced if this position is moved to and the fixed
stop is reached, without the machining having to be stopped.
Default setting
Effective as from PLC date 03.05.1999!
Machine 501501 to 502500
max pusher position before chuck = 1379 mm
Default setting
Effective as from PLC date 03.05.1999!
Machine 502501 to 50...
max pusher position before chuck = 1382.5 mm

All specified default values can change depending on the

development level! Please contact the machine manufacturer in
case of uncertainty!

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 11.1 Parameters
11 Parameter setting, M commands

D Spindle zero offset

Press USER

Press USER DIAGNOSIS

Press ALIGNMENT DAT OPTION

Press ALIGNMENT DATA* (Mask DRESS)

Press SPINDLE ZERO M. OFFSET

* Alignment data can only be changed with key switch (Chap. 6, Pos. 3 ) in position ”2”.

Operating instructions MF sprint 42/65 V 2.0 page 11-65

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11.1 Parameters
11 Parameter settings, M commands

D Optionen

Press USER

Press USER DIAGNOSIS

Press ALIGNMENT DAT. OPTION (Mask DRESS)

Press OPTIONS

Module groups marked with ”1”, are fitted to this machine.

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 11.1 Parameters
11 Parameter setting, M commands

D Options

Press USER

Press USER DIAGNOSIS

Press ALIGNMENT DAT. OPTIONS

Press OPTIONS

Module groups marked with ”1”, are fitted to this machine.

Operating instructions MF sprint 42/65 V 2.0 page 11-67

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11.1 Parameters
11 Parameter settings, M commands

D Releases

Press USER

Press USER DIAGNOSIS

Press RELEASES

Here the releases for the program sequence are shown.

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 11.1 Parameters
11 Parameter setting, M commands

D Version

Press USER

Press USER DIAGNOSIS

Press VERSION

The following is displayed

- Version of the NC software
- Version of the PLC software with Ident. No. and date of issue
- Version of the UMS with details of the language, Ident. No. and
date of issue

An additional mask can be selected using the info key, which

describes the switching on of the machine.

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11.2 Description of the M commands
11 Parameter settings, M commands

11.2 Description of the M commands

The method of operation of the M functions is described in the

following.
The number concept is designed so that the hundredths position is
simultaneously an indication of the spindle.

M1.. = Spindle 1
M2.. = Spindle 2
M3.. = Spindle 3
M4.. = Spindle 4

With the designation ”Mx=..” the x must be replaced by the number of

the required spindle.

MF MF
sprint twin
42/65
M 00 Program stop
The sequence is stopped in automatic operation following a
block with M 00, e.g. for manual intervention. The program is X X
continued from this point after pressing the ”Cycle start” key.
M 01 Program optional stop
The function is identical with M 00, the stop is only performed
when the function ”Programmed stop” (M 01) is activated via the X X
F1 key on the machine control panel.
M 02 Program end
M 02 indicates the program end with resetting the program to
the program start. This is written in the last block. The controls X X
are set to the start position.
Mx= 03 Spindle clockwise running
This function causes the start of the spindle in the clockwise X X
direction at the previously programmed rotational speed.
Mx= 04 Spindle counterclockwise run
This function causes the spindle to start counterclockwise X X
at the previously programmed rotational speed.

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 11.2 Description of the M commands
11 Parameter setting, M commands

MF MF
sprint twin
42/65
Mx= 05 Spindle stop
This function causes the spindle to stop. X X
M 06 Unlock turret
With the MF twin, the tool spindle can be positioned and the
turret released using this command. (Preparation for indexing) X X
M 09 Coolant off
This function switches all coolants and preselections back to low X X
pressure.
Mx=14 C-Axis on
This functions switches the corresponding spindle in cycles X X
L 701/L 703/L 705/L 707 in C axis operation.
Mx=15 C-Axis off
This function switches the corresponding spindles back to X X
spindle operation in the cycles L 702/L 704/L 706/L 708.
M 17 Sub program end
M 17 marks the end of a sub program. This is written in the last X X
block.

M 18 Counting pulse for workpiece counter X X

Mx=19 Stop spindle in defined position
This function brings the spindle to a controlled stop at a position
programmed with this command in the Sx address between 0˚ X X
and 360˚.
M 30 Program end
Function as M 02
M 49 Lubrication impulse
This function triggers a lubrication impulse. X
Following this the pause time set start via the parameter.

Operating instructions MF sprint 42/65 V 2.0 page 11-71

Doc.-No.: ABB002G0
11.2 Description of the M commands
11 Parameter settings, M commands

MF MF
sprint twin
42/65
Functions for bar feeders
D Standard interface

M 65 Interrogation of bar end

This function triggers an interrogation of the bar feeding cycle
whether the bar end has been reached. Dependent upon the
result of this interrogation targeted action can be started. (See X X
description of the GILDEMEISTER interface for bar feeders)
M 66 Handshake short part magazine
Using this function an output is switched on and thereby set to
the interface (Pin 24). The part program is stopped until the
acknowledgement signal is set by the bar pusher (on Pin 23).
Correspondingly, a synchronisation can be simply made bet- X X
ween the short part magazine and the machine using this
handshake function. It is, however, absolutely necessary that the
sequence preparation is identical on both sides (see the descrip-
tion of the GILDEMEISTER interface for bar pushers).
M 69 Pushing bar forward
This function permits the bar to be fed forward. X X

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 11.2 Description of the M commands
11 Parameter setting, M commands

MF MF
sprint twin
42/65
D Integrated bar loading magazine
M 64 Searching bar end
X
Using this function the driver moves to the bar end.
M 65 Bar end interrogation
A new bar is loaded into the bar loader once the bar end is X
reached.
M 66 Eject remaining material
Using this function the remaining material is pushed forward out X
of the chuck and into the remaining material dish.
M 67 Automatic door
This function prepares the opening of the door during the next
X
program stop (M0, M01, M30).
M 69 Push bar forward to stop
The chuck is opened by this function, the bar is pushed forward X
to a previously positioned stop.
M 72 Bar relief
Using this function the clamping torque of the driver reduces to X
0%. This function is in preparation for the pushing forward of the
bar with M 73.
M 73 Pushing the bar forward to a precise dimension
Using this function a bar is pushed forward to a path dimension. X
The dimension is calculated from the workpiece length and the
width of the parting tool.
M 95 Chip conveyor off
This function switches off the chip conveyor. X X
M 96 Chip conveyor on
This function switches on the chip conveyor. X X

Operating instructions MF sprint 42/65 V 2.0 page 11-73

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11.2 Description of the M commands
11 Parameter settings, M commands

MF MF
sprint twin
42/65
M 99 Program running time monitoring
With this function the running time (cycle time) of a workpiece is X X
monitored. If this time is exceeded or with pending warnings a
”Program stop” is performed.
M 108 Tool holder 1 coolant on
This function switches on the coolant for X X
tool holder 1.
M 109 Tool holder 1 coolant off
This function switches off the coolant for X X
tool holder 1.
M 112 Clamp spindle 1
This function switches on the brake for spindle 1 and X
thus locks the chuck.
M 113 Release spindle 1
This function releases the brake on spindle 1. Only then is a X
rotation of the spindle released.
M 133 Open chuck 1 with spindle turning
This function opens chuck 1 with the spindle running, e.g. X X
picking off the parts from the main spindle. In the same manner
this function releases the switching on of spindle 1 (M1=03,
M1=04) with the chuck open.
M 136 Open chuck 1
This function opens the chuck with the spindle stationary. X X
M 137 Clamping chuck 1
This function closes the chuck with the spindle stationary. X X
M 154 High pressure coolant for tool holder 1 on
This function switches on the additional high pressure coolant X X
for tool holder 1.
M 155 High pressure coolant for tool holder 1 off
This function switches off the additional high pressure coolant X X
for tool holder 1.
M 161 Special function for applications in cycles
Channel 1: Undertake ”Cycle STOP/START”. -- --

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 11.2 Description of the M commands
11 Parameter setting, M commands

MF MF
sprint twin
42/65
M 162 Swivel tool holder 1 forward
This function suppresses the next swivel process for automatic X X
direction recognition.
M 163 Swivel back tool holder 1
This function suppresses the next swivel process of the X X
automatic direction recognition.
M 170 Checking the swivel wire system of tool holder 1
Interrogation if ”taught in angle” is reached X X
M 171 Checking tool holder 1 with swivel wire system
Interrogation if ”taught in angle” is not reached X X
M 173 Switch tool monitoring for turret 1 inactive
Tool position monitoring is switched off X
M 208 Tool holder 2 coolant on
This function switches on the coolant for X X
tool holder 2.
M 209 Tool holder 2 coolant off
This function switches off the coolant for X X
tool holder 2.
M 233 Open chuck 2 with spindle turning
This function opens chuck 2 with the spindle running. In the X
same manner switching on of spindle 2 (M2=03, M2=04) is
released by this function with the chuck open.
M 236 Open chuck 2
This function opens the chuck with the spindle stationary. X
M 237 Clamp chuck 2
This function closes chuck 4. The set clamping pressure must X
be reached and the clamping end limit must not be reached.
M 250 Super high pressure coolant on tool holder 2 on
This function switches on the super high pressure at turret 2 X

Operating instructions MF sprint 42/65 V 2.0 page 11-75

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11.2 Description of the M commands
11 Parameter settings, M commands

MF MF
sprint twin
42/65
M 251 Super high pressure coolant on tool holder 2 off
This function switches off the super high pressure X
M 254 High pressure coolant on tool holder 2 on
This function switches on the additional high pressure coolant X X
for tool holder 2.
M 255 High pressure coolant on tool holder 2 off
This function switches off the additional high pressure coolant X X
for tool holder 1.
M 261 Special functions for use in cycles
Channel 2: Undertake ”Cycle STOP/START”. -- --
M 262 Swivel tool holder 2 forward
This function suppresses the next swivel process for automatic X X
direction recognition.
M 263 Swivel tool holder 2 backward
This function suppresses the automatic direction recognition for X X
the next swivel process.
M 270 Checking the swivel wire system of tool holder 2
Interrogation if ”taught in angle” is reached X X
M 271 Checking with swivel wire system of tool holder 2
Interrogation if ”taught in angle” is not reached X X
M 273 Switch turret 2 tool monitoring inactive
The tool position monitoring is switched off X
M 307 Spindle 3 coolant on
This function switches on the internal coolant for spindle 3. X
M 309 Spindle 3 coolant off
This function switches off the internal coolant for spindle 3. X
M 312 Clamping spindle 3
This function switches on the brake of spindle 3 and thus locks X
the chuck.
M 313 Release spindle 3
This function releases the brake on spindle 3. Only then is the X
rotation of the spindle released.

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 11.2 Description of the M commands
11 Parameter setting, M commands

MF MF
sprint twin
42/65
M 333 Open chuck 3 with spindle turning
This function opens chuck 3 with the spindle turning, e.g. to take X
over semi- finished parts from spindle 4. In the same manner
switching on spindle 3 (M3=03, M3=04) with the chuck open is
released with this function
M 336 Open chuck 3
This function opens chuck 3 with the spindle stationary. X
M 337 Clamping chuck 3
This function closes chuck 3. The set clamping pressure must X
be reached and the clamping end limit must not be reached.
M 350 Coolant on for spindle 3
This function switches on the outer coolant for spindle 3. X X
(e.g. jaw flushing)
With MF sprint coolant for counter spindle
M 351 Coolant off for spindle 3
This function switches off the outer coolant for spindle 3. X X
With MF sprint, coolant for counter spindle
M 361 Special function for use in cycles
Channel 3: Perform ”Cycle STOP/START” -- --
M 407 Spindle 4 coolant on
This function switches on the inner coolant for spindle 4. X
M 409 Spindle 4 coolant off
This function switches off the inner coolant for spindle 4. X
M 412 Clamping spindle 4
This function switches on the brake for spindle 4 and thus locks X X
the chuck.
M 413 Release spindle 4
This function releases the brake on spindle 4. Only then is the X X
rotation of the spindle released.
M 433 Open chuck 4 with spindle turning
This function opens chuck 4 with the spindle running, e.g. when X X
pushing bar material forward. In the same manner this function
releases the switching on of spindle 4 (M4=03, M4=04) with the
chuck open.

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11.2 Description of the M commands
11 Parameter settings, M commands

MF MF
sprint twin
42/65
M 436 Open chuck 4
This function opens the chuck when the spindle is stationary. X X
M 437 Clamping chuck 4
This function closes chuck 4. The set clamping pressure must X X
be reached and the clamping end limit must not be reached.
M 450 Coolant on for spindle 4
This function switches on the outer coolant for spindle 4. X X
M 451 Coolant off for spindle 4
This function switches off the outer coolant for spindle 4. X X
M 607 Open conveyor belt cover
This function opens the conveyor belt cover
M 608 MF twin
Open conveyor belt cover and conveyor belt on
This function opens the conveyor belt cover and switches on the X
conveyor belt.
The conveyor belt is switched off after the elapse of the set
running time. Enter the running time in
Menu mask : User/......../conveyor belt

MF sprint
Conveyor belt on
The function switches on the conveyor belt. X
The conveyor belt is switched off after the elapse of the set
running time. Enter the running time in
Menu mask : User/......../conveyor belt
M 630 Remaining material ejector in home position
This function moves the ejector to its home position X
M 631 Remaining material ejector in remaining material collector
With this function the remaining material is ejected out of the X
chuck and into the remaining material collector.

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 11.2 Description of the M commands
11 Parameter setting, M commands

MF MF
sprint twin
42/65
M 638 Ejector in home position
The function moves the ejector into the home position X
M 639 Ejector in end position
With this function the workpiece is ejected from the chuck of the X
counter spindle and into the pick off.
M 642 Finished part pick off in home position
This function moves the pick off to its home position X
M 643 Finished part pick off in working position
This function moves the pick off to the working position X
M 644 Finished part pick off in home position
This function moves the pick--of to its home position X
Block continued switching is made without acknowledgement by
the limit switch
M 645 Finished part pick off in working position
This function moves the pick off to the working position X
Block continued switching is made without acknowledgement by
the limit switch
M 650 Integr. handling: Unmachined part take up
This function lifts the workpiece and closes the gripping chuck X
M 651 Integr. handling: Move unmachined part to working space
This function opens the working space flap and transports the X
unmachined part into the working space
M 652 Integr. handling: move gripper out of the working space
This function opens the gripping chuck, moves it out of the X
working space to the start position and closes the flap.
M 661 Open loading flap
This function opens the loading flap to the working space. X
M 662 Close loading flap
This function closes the loading flap to the working space. X

Operating instructions MF sprint 42/65 V 2.0 page 11-79

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11.2 Description of the M commands
11 Parameter settings, M commands

MF MF
sprint twin
42/65
D Slide - spindle allocation
These M functions are applicable to the slide for which they were
programmed.

M 811 Slide operates with the slide spindle on the spindle 4

The rotational speed actual value of the spindle / driven tool is X X
allocated to the slide.
M 812 Slide operates with the slide spindle on spindle 3
The rotational speed actual value of the spindle / driven tool is X
allocated to the slide.
M 813 Slide operates with spindle 3
The rotational speed actual value of spindle 3 is allocated to the X
slide
M 814 Slide operates with spindle 4
The rotational speed actual value of spindle 4 is allocated to the X X
slide.
M 821 Slide operates with the spindle of the other slide
The rotational speed actual value of the spindle / driven tool of X X
the other slide is allocated to the slide.
D Spindle - Set point value allocation
This M function is applicable for the slide on which it is programmed.
Program them in a block before programming a rotational speed set
point change.
M 831 Spindle - set point value allocation for spindle 1
The programmed rotational speed set point value for spindle 1 is X X
allocated.
M 832 Spindle - set point value allocation for spindle 2
The programmed rotational speed set point value for spindle 2 is X X
allocated.
M 833 Spindle - set point value allocation for spindle 3
The programmed rotational speed set point value for spindle 3 is X
allocated.
M 834 Spindle - set point value allocation for spindle 4
The programmed rotational speed set point value for spindle 4 is X X
allocated.

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 11.2 Description of the M commands
11 Parameter setting, M commands

D M functions for customer module

MF MF
sprint twin
42/65
M 850 Activate output 0 X X
M 851 Activate output 1 X X
M 852 Activate output 2 X X
M 853 Activate output 3 X X
M 854 Activate output 4 X X
M 855 Actvate output 5 X X
M 856 Activate output 6 X X
M 857 Activate output 7 X X
M 860 Deactivate output 0 X X
M 861 Deactivate output 1 X X
M 862 Deactivate output 2 X X
M 863 Deactivate output 3 X X
M 864 Deactivate output 4 X X
M 865 Deactivate output 5 X X
M 866 Deactivate output 6 X X
M 867 Deactivate output 7 X X

M 971 Special function for users in cycles

2nd software limit switch X2/Z2 on, -- --
dyn. software limit switch U2/W2 on,
Parameter block 3 on
M 972 Special function for users in cycles
dyn. software limit switch U2/W2 off, -- --
Parameter block 3 off
M 973 Special function for users in cycles
2. software limit switch X2/Z2 off -- --

Operating instructions MF sprint 42/65 V 2.0 page 11-81

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11.3 Gildemeister cycles
11 Parameter settings, M commands

11.3 Gildemeister cycles

11.3.1 Review of Gildemeister cycles

In the masks for the operating modes

AUTOMATIC
JOG
JOG/REF. POINT
MDA

a review of the Gildemeister cycles can be selected in two masks.

Press USER

Press GM CYCLES REVIEW

Press GM CYCLES 1

page 11-82 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.3 Gildemeister cycles
11 Parameter setting, M commands

Press USER

Press GM CYCLES REVIEW

Press GM CYCLES 2

Operating instructions MF sprint 42/65 V 2.0 page 11-83

Doc.-No.: ABB002G0
11.3 Gildemeister cycles
11 Parameter settings, M commands

11.3.2 Description of the Gildemeister cycles

L 701 C axis 1 ON
The C axis drive of spindle 1 is switched on with this cycle

L 702 C axis 1 OFF

The C axis drive of spindle 1 is switched off with this cycle

L 703 C axis 2 ON
The C axis drive of spindle 2 is switched on with this cycle

L 704 C axis 2 OFF

The C axis drive of spindle 2 is switched off with this cycle

L 707 C axis 4 ON
The C axis drive of spindle 4 is switched on with this cycle

L 708 C axis 4 OFF

The C axis drive of spindle 4 is switched off with this cycle

L 710 Move to tool change point

Slides 1 or 2 R1 =1 (X ⇒ Z)
=2 (Z ⇒ X)
=3 only X
=4 only Z
all other values (X + Z)

With this cycle the slide axes move to the tool change points.
The cycle is programmed for slide 1 or slide 2.
Program the axis movement sequence in accordance with
the table in the R parameter R1.
The co-ordinates are entered in the user / setting / tool
change point mask in the channel specific R parameters
R 690 / R 691

page 11-84 V 2.0 Operating instructions MF sprint 42/65

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 11.3 Gildemeister cycles
11 Parameter setting, M commands

L 720 Coupling slides 1 + 2 ON

This cycle switches on the coupling operation of slides 1 and
2.
Program this function in a program for slide 2 in a separate
block.
Ensure that slide 1 does not move during the performance
time.

L 721 Coupling slides 1 + 2 OFF

This cycle switches off the coupling operation of slides 1 and
2.
Program this function in a program for slide 2 in a separate
block.
Ensure that the slide 1 does not move during the perfor-
mance time.

L 722 Include an offset of spindle 1 to tool holder 1 in the

calculation

L 723 Take out an offset of spindle 1 to tool holder 1 of your

calculation

L 725 Polygon machining spindle 4 - Spindle 1 ON

L 726 Spindle synchronous run angularity synchronisation

Sp.1 with Sp.4 ON
This function switches on the synchronous run of the main
and counter spindle.
Program this function in a separate block.

L 727 Spindle synchronous run Sp.1 with Sp.4 off

The synchronous run of the main and counter spindle is
switched off with this function.
Program this function in a separate block.

Operating instructions MF sprint 42/65 V 2.0 page 11-85

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11.3 Gildemeister cycles
11 Parameter settings, M commands

L 728 Spindle synchronous run:

Spindle 4 with spindle 1 ON

L 730 Select move to fixed stop

Moving to the fixed stop for slide 1 is performed using this
function.
Program this function in a program for slide 1 in a separate
block.
The following fault conditions are recognised in the cycle:
Fixed stop not reached.
Fixed stop not in tolerance window
Parameter R 724 is zero.
In the event of a fault the program is stopped with M 00. The
program must be aborted at this point.

L 731 Cancel moving to fixed stop

Moving to fixed stop for slide 1 is switched off using this
function.
This function is required for switching off the functions
Moving to fixed stop and parting off control in case of a fault.

L 732 Parting off control

This function controls whether the workpiece was parted off.
Program this function in a program for slide 1 in a separate
block.
If the workpiece is not parted off the message ”part not
parted off” is displayed and the program stopped with M 00.
A start to continue is not possible.
Program this function on slide 1 in a separate block.

page 11-86 V 2.0 Operating instructions MF sprint 42/65

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 11.3 Gildemeister cycles
11 Parameter setting, M commands

L 733 Move to fixed position with monitoring

Move to fixed stop

L 746 Position for slide 2 with the same type of machining

L 751 Carriage 1 basic setting

With this cycle all functions for carriage 1 are returned to
their basic setting.

L 752 Carriage 2 basic setting

With this cycle all functions for carriage 2 are returned to
their basic setting.

L 760 Integr. bar loader start program

With this cycle all functions for the bar loader are returned to
their basic setting.

L 780 Part off to part off length

L 790 Transfer GI data to SEA (Mask Rot. speed contr.)

L 799 Special cycle channel 2

Operating instructions MF sprint 42/65 V 2.0 page 11-87

Doc.-No.: ABB002G0
11.4 Siemens cycles
11 Parameter settings, M commands

11.4 Siemens cycles

11.4.1 Siemens cycles review

In the operating mode masks

AUTOMATIC
JOG
JOG/REF POINT
MDA

A review of the Siemens cycle can be selected.

Press USER

Press SIE CYCLES REVIEW

page 11-88 V 2.0 Operating instructions MF sprint 42/65

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 11.5 Administration of the R parameters
11 Parameter settings, M commands

11.5 Administration of the R parameters

Channel specific R parameters:
MF sprint MF twin
R 690 - Co-ordinate tool change point axis 1 X X
R 691 - Co-ordinate tool change point axis 2 Z Z
R 692 - Co-ordinate tool change point axis 3 Y1/Z3
R 693
R 694
R 695
R 696
R 697 - Parameter counter 1 D D
R 689 - Parameter counter 2 D D
R 699 - Parameter counter 3 D D

Central R parameter:
R 700 - Chuck loader status Spindle 4 Spindel 4
R 701 - Chuck loader status Spindle 1 Spindle 1
R 702 - Chuck loader status Spindle 2
R 703 - Chuck loader status Spindle 3
R 704 - Special chuck loader status
R 705 - Loading and unloading type
R 706 - freely available
R 707 - freely available
R 708 - freely available
R 709 - Variable with multiple use
R 710 - Variable with multiple use
R 711 - Chuck length (to leading edge jaw/gripper) Spindle 4 Spindle 4
R 712 - Parting width
R 713 - Working space length axis Z3
R 714 - G54 chuck height Spindle 4 Spindle 4
R 715 - G55 chuck height spindle 3 (reference to machine zero point MNP1) Spindle 4 Spindle 3
R 716
R 717
R 718
R 719 - Pull forward during pick off
R 720 - Workpiece zero point (main spindle) Spindle 4 Spindle 4
R 721 - chuck length (up to leading edge jaw/teeth) Spindle 1 Spindle 3
R 723 - Workpiece zero point on (pick off spindle) Spindle 1 Spindle 3
R 724 - Clamping position on finished part in Spindle 1 Spindle 3
R 725 - Finished part length

Operating instructions MF sprint 42/65 V 2.0 page 11-89

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11.5 Administration of the R parameters
11 Parameter settings, M commands

MF sprint MF twin
R 727 - C axis angle offset (zero point offset) Spindle 4 Spindle 4
R 728 - C axis angle offset (zero point offset) Spindle 1 Spindle 3
R 729 - Angular offset between Sp4 - Sp1 Sp4 - Sp3
R 730 - determined angular offset at workpiece transfer
R 731 - determined Z co-ordinate after ”Moving to fixed stop”
R 732 - determined Z co-ordinate after ”parting off control”
R 733 - Coupling operation ON/OFF
R 734 - Move to fixed stop - overflow path Slide 1 Slide 3
R 735 - Move to fixed stop - left hand window Slide 1 Slide 3
R 736 - Move to fixed stop - right hand window Slide 1 Slide 3
R 737 - Move to fixed stop - retraction path Slide 1 Slide 3
R 738 - Workpiece diameter
R 739
R 740 - Sensor stop at cycle end
R 741 - Signal material end (1 = material end)
R 742 - Key switch, bar feeding/loading system on
R 743 - Signal ”Run machine empty and shift end ON”
R 744 - Signal from loader ”machining A” on AG1
R 745 - Signal from loader ”machining B” on AG1
R 746 - Signal from loader ”machining A” on AG2
R 747 - Signal from loader ”machining B” on AG2
R 748 - Signal from loader ”shift end”
R 749
R 750 - Flag for signal ”Stop at cycle end”
R 751 - Flag for signal ”Material end”
R 752 - Flag for key switch ”bar feeding off”-
R 753 - Flag for ”Run machine empty and shift end”
R 754
R 755 - Leukhardt system 1: negative test result
R 756 - Leukhardt system 2: negative test result
R 757 - Tool break monitoring fault flag
R 758
R 759

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 11.5 Administration of the R parameters
11 Parameter settings, M commands

MF sprint MF twin
R 760 - Workpiece counter (total quantity)
R 761 - Workpiece counter (Subtraction counter, remaining quantity)
R 762
R 763
R 764
R 765
R 766 - Clamping moment for integrated bar loader
R 767
R 768
R 769
R 770
R 771
R 772
R 773
R 774
R 775
R 776 - Dialog programming (input parameter)
R 777 - Dialog programming (Default text user text)
R 778 - Conversion metric - imperial (Factor 1 or 25.4)
R 779 - Conversion metric - imperial(Factor 1 or 2.54)
R 780 - 01. Measured value post process measuring
R 781 - 02. Measured value post process measuring
R 782 - 03. Measured value post process measuring
R 783 - 04. Measured value post process measuring
R 784 - 05. Measured value post process measuring
R 785 - 06. Measured value post process measuring
R 786 - 07. Measured value post process measuring
R 787 - 08. Measured value post process measuring
R 788 - 09. Measured value post process measuring
R 789 - 10. Measured value post process measuring
R 790 - 11. Measured value post process measuring
R 791 - 12. Measured value post process measuring
R 792 - 13. Measured value post process measuring
R 793 - 14. Measured value post process measuring
R 794 - 15. Measured value post process measuring
R 795 - 16. Measured value post process measuring
R 796 - New measured values are available (when >< 0)

Operating instructions MF sprint 42/65 V 2.0 page 11-91

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page 11-92 V 2.0 Operating instructions MF sprint 42/65
Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9000 F: Machine: EMERGENCY STOP

BMK - Ident.: S07031, S40841, A07031, A04011, X14021
Cause:
1 EMERGENCY STOP key, Emergency safety
combination 840C not operational or over
temperatures

2 Loading device external interface signal

Remedy:
1 Have the above possibilities checked by corres-
pondingly qualified personnel.

9033 F: M Function processing: M function inadmissible

BMK - Ident.: not present
Cause:
1 An M function was written which is not
evaluated in the PLC.
2

Remedy:
1 Actuate RESET key.
Using the M function list please check that the
written M function for this machine is permis-
sible. The list can be found in the operating
instructions covering this machine.
An attendant option selection might be missing.
2

page 11.10 - 2 V 2.0 Operating instructions MF sprint 42/65

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 11.10 Fault description
11 Parameter setting, M commands

9034 F: Spindle 1: ASS 1 of KK 1 signals a fault

BMK - Ident.:
Cause:
1 Internal CNC fault
Refer to the value in DB41 DW14 for the cause.

Remedy:
1 Notify DMG service if frequently encountered.
Notify value from DB41 DW21.

9035 F: Spindle 2: ASS 1 from KK 1 signals a fault

BMK - Ident.:
Cause:
1 Internal CNC fault
Refer to the value in the DB41 DW14 for the
cause.
2

Remedy:
1 Notify DMG service if frequently encountered.
Notify value from DB41 DW21.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 3

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9036 F: Spindle 3: ASS 1 from KK 1 signals a fault

BMK - Ident.:
Cause:
1 Internal CNC fault
Refer to the value in the DB41 DW14 for the
cause.
2

Remedy:
1 Notify DMG service if frequently encountered.
Notify value from DB41 DW21.
2

9037 F: Spindle 4: ASS 1 from KK 1 signals a fault

BMK - Ident.:
Cause:
1 Internal CNC fault
Refer to the value in the DB41 DW14 for the
cause.
2

Remedy:
1 Notify DMG service if frequently encountered.
Notify value from DB41 DW21.

9038 F: Tool holder 1: ASS 2 from KK 1 signals a fault

BMK - Ident.:
Cause:
1 Internal CNC fault
Refer to the value in the DB41 DW14 for the
cause.
2

Remedy:
1 Notify DMG service if frequently encountered.
Notify value from DB41 DW14.

page 11.10 - 4 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9039 F: Tool holder 2: ASS 3 from KK 1 signals a fault

BMK - Ident.:
Cause:
1 Internal CNC fault
Refer to the value in the DB41 DW21 for the
cause.
2

Remedy:
1 Notify DMG service if frequently encountered.
Notify value from DB41 DW21.
2

9040 F: Tool holder 1: Not locked

BMK - Ident.: A36111, Y36261
Cause:
1 Tool turret incorrectly positioned.
Swivel operation interrupted.
Hydraulic group, hydraulic valve, valve control,
limit switch S5 defective or incorrectly adjusted.
2

Remedy:
1 Unlock tool holder via service mask, press reset
and undertake new reference run from T1.
Valve selection, hydraulic function and function
of limit switch must be assured.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 5

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9041 F: Tool holder 1: not released

BMK - Ident.: A36111, Y36271
Cause:
1 Hydraulic group, valve selection, limit switch
defective or incorrectly adjusted.
2

Remedy:
1 Check valve selection and, if necessary, assure
hydraulic function, Check limit switch, readjust
or replace, if necessary.
2

9044 F: Tool holder 1: Inadmissible T value

BMK - Ident.:
Cause:
1 T value entered is higher than the number of
tool positions
2

Remedy:
1 Delete T value with reset and replace with
correct T value
2

page 11.10 - 6 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9045 F: Tol holder 1: T value could not be taken over

BMK - Ident.:
Cause:
1 A new T value was registered during turret
swivelling. Internal CNC fault
2

Remedy:
1 Notify DMG service
Cancel fault with reset
2

9046 F: Tool holder 2: Not locked

BMK - Ident.: A37111, Y37261
Cause:
1 Tool turret incorrectly positioned.
Swivel operation interrupted.
Hydraulic group, hydraulic valve, valve selec-
tion, limit switch S5 defective or incorrectly
adjusted.
2

Remedy:
1 Release tool holder using service mask, confirm
reset and make new reference run by entering
T1.
Assure valve selection, hydraulic function and
function of the limit switch.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 7

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9047 F: Tool holder 2: not released

BMK - Ident.: A36111, Y36271
Cause:
1 Hydraulic group, valve selection, limit switch
defective or incorrectly adjusted.
2

Remedy:
1 Check valve selection and, if necessary, assure,
hydraulic function, check limit switch, readjust or
replace, if necessary.
2

9050 F: Tool holder 2: Inadmissible T value

BMK - Ident.:
Cause:
1 Entered T value higher than number of tool
positions
2

Remedy:
1 Cancel T value with reset and replace with
correct T value
2

page 11.10 - 8 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9051 F: Tool holder 2: T value could not be taken over

BMK - Ident.:
Cause:
1 A new T value was registered during turret
swivelling.
Internal CNC fault
2

Remedy:
1 Notify DMG service
Cancel fault with reset
2

9052 F: Clamp system parameters 4: Inadmissible type

BMK - Ident.: not present
Cause:
1 MF_sprint: Incorrect selection in DB195
2 MF_twin: incorrect selection in
ASM_mask_chuck_4

Remedy:
1 Contact Gildemeister
2 Enter correct type

9053 F: Clamp system parameters 4: Inadmissible chucking mode

BMK - Ident.: not present
Cause:
1 Incorrect selection in ASM_mask_chuck_4
2

Remedy:
1 Enter chucking mode in ASM_mask_chuck_4
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 9

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9054 F: Clamp system parameters 4: Inadmissible working

direction
BMK - Ident.: not present
Cause:
1 Incorrect selection in ASM_mask_chuck_4
2

Remedy:
1 Enter chucking mode in ASM_mask_chuck_4
2

9055 F: Clamp system 4: Inadmissible command

BMK - Ident.: not present
Cause:
1 Inadmissible clamp system operation.
2 Spindle 4 not stationary.

Remedy:
1 e.g. working space door open
2 Program spindle stop. Press spindle stop key.

page 11.10 - 10 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9056 F: Clamp system 4: Pressure loss

BMK - Ident.: F18041 / F18061
Cause:
1 MF_sprint: F18041 / F18061
Pressure switch incorrectly set
2 MF_twin: F18041
Pressure switch incorrectly set

Remedy:
1 Correctly set pressure switch
2 Correctly set pressure switch

9057 F: Clamp system 4: Faulty input signals

BMK - Ident.: S18021
Cause:
1 Input signals are not plausible e.g. foot switch
open/close simultaneously.
2

Remedy:
1 Check wiring.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 11

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9060 F: Clamp system 4: Monitoring triggered

BMK - Ident.: AS18121
Cause:
1 Clamping path monitoring (analog path
recording) triggered.
2

Remedy:
1 Set clamping path in accordance with operating
instructions.
! Switch off the clamping path monitoring in
case of total clamping paths of less than 80
increments ! (Clamping mode 3)
2

9061 F: Clamp system 4: Maximum performance time exceeded

BMK - Ident.: F18041 (F18061 MF_sprint)
Y18241, Y18251
Cause:
1 No reaction from pressure switches with
clamping command.
2 Faulty valve selection or valve defective

Remedy:
1 - Set pressure switch.
- Check selection and signal lines.
2 Check selection by diagnosis.
Mechanically check valve.

page 11.10 - 12 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9062 F: Clamp system 4: Max rotational speed exceeded

BMK - Ident.: A17511
Cause:
1 Excessive rotational value speed programmed.
- Only with settable rotational speed monitoring
2 Drive parameter-limit value set too high.

Remedy:
1 Check program.
2 Check drive parameter.

9063 F: Clamp system 4: Spindle running time without clamping

pressure exceeded
BMK - Ident.: - None -
Cause:
1 The NC program stops after the command
M433 before the command M437 has arrived.
Sequential fault or program was stopped with
feed stop.
2

Remedy:
1 Can only be overcome by a new start (RESET).

9064 F: Clamp system 3 parameter: Inadmissible type

BMK - Ident.: not present
Cause:
1 MF_twin: Incorrect selection in
ASM_mask_chuck_3
2

Remedy:
1 Enter correct type
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 13

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9065 F: Clamp system 3 parameter: Inadmissible chucking mode

BMK - Ident.: not present
Cause:
1 MF_twin: Incorrect selection in
ASM_mask_chuck_3
2

Remedy:
1 Enter clamping mode in ASM_mask_chuck_3
2

9066 F: Clamp system 3 parameter: Inadmissible working direction

BMK - Ident.: not present
Cause:
1 MF_twin: Incorrect selection in
ASM_mask_chuck_3
2

Remedy:
1 Enter clamping mode in ASM_mask_chuck_3
2

9067 F: Clamp system 3: Inadmissible command

BMK - Ident.: not present
Cause:
1 Inadmissible clamping operation.
2 Spindle 4 position not in halt

Remedy:
1 e.g. working space door open
2 Spindle stop programming. Press spindle stop
key.

page 11.10 - 14 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9068 F: Clamp system 3: Pressure loss

BMK - Ident.: F24041
Cause:
1 MF_twin: Pressure switch incorrectly set
2 Pressure loss on clamping device

Remedy:
1 Correctly set pressure switch
2 Check clamping hydraulic

9069 F: Clamp system 3: Faulty input signals

BMK - Ident.: S24021
Cause:
1 Input signals are not plausible. e.g. foot switch
open/close simultaneously.
2

Remedy:
1 Check wiring.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 15

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9072 F: Clamp system 3: Monitoring triggered

BMK - Ident.: S24021
Cause:
1 Clamping path monitoring (analog path
recording) triggered.
2

Remedy:
1 Set clamping path in accordance with operating
instructions.
! Switch off the clamping path monitoring if the
total clamping paths are less than 80 incre-
ments ! (clamping mode 3)
2

9073 F: Clamp system 3: Maximum performance time exceeded

BMK - Ident.: - None -
Cause:
1 The NC program stops after the command
M433 before the command M437 has arrived.
Sequential fault or program was stopped with
feed stop.
2

Remedy:
1 Can only be overcome by a new start (RESET).
2

page 11.10 - 16 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9074 F: Clamp system 3: Max. rotational speed exceeded

BMK - Ident.: A23511
Cause:
1 Excessive rotational speed value programmed.
- only with settable rotational speed monitoring -
2 Drive parameter-limit value set too high.

Remedy:
1 Check program.
2 Check drive parameter.

9075 F: Clamp system 3: Spindle running time without clamping

pressure exceeded
BMK - Ident.: - None -
Cause:
1 The NC program stops after the command
M433 before the command M437 has arrived.
Sequential fault or program was stopped with
feed stop.
2

Remedy:
1 Can only be overcome by a new start (RESET).
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 17

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9076 F: Clamp system 2 parameter: Inadmissible type

BMK - Ident.:
Cause:
1 Clamping type incorrectly entered
2

Remedy:
1 Check and correct.
2

9077 F: Clamp system 2 parameter: Inadmissible clamping mode

BMK - Ident.:
Cause:
1 Clamping mode incorrectly entered
2 Check and correct.

Remedy:
1
2

9080 F: Clamp system 2: Pressure loss

BMK - Ident.: F20031, F20041
Cause:
1 MF_twin: Pressure switch incorrectly set
2 Pressure loss at clamping device

Remedy:
1 Correctly set pressure switch
2 Check clamp hydraulics

page 11.10 - 18 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9085 F: Clamp system 2: Maximum performance time exceeded

BMK - Ident.:
Cause:
1 No reaction on pressure switches allowing a
clamping command.
2

Remedy:
1 - Set pressure switch.
- Check selection and signal lines.
2

9088 F: Clamp system 1 parameter: Inadmissible type

BMK - Ident.: not present
Cause:
1 MF_sprint: incorrect selection in DB195
2

Remedy:
1 Contact Gildemeister
2

9089 F: Clamp system 1 parameter: Inadmissible chucking mode

BMK - Ident.: not present
Cause:
1 MF_sprint:
Incorrect selection in ASM_Bild_chuck_1
2

Remedy:
1 Enter clamping mode in ASM_mask_chuck_1
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 19

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9090 F: Clamp system 1 parameter: Inadmissible working direction

BMK - Ident.: not present
Cause:
1 MF_sprint:
Incorrect selection in ASM_Bild_chuck_1
2

Remedy:
1 Enter clamping mode in ASM_mask_chuck_1
2

9091 F: Clamp system 1: Inadmissible command

BMK - Ident.: not present
Cause:
1 Incorrect clamping condition
2

Remedy:
1 Change clamping condition in advance
2

9092 F: Clamp system 1: Pressure loss

BMK - Ident.: F20041 / F20061
Cause:
1 MF_sprint: F20041 / F20061
Pressure switch incorrectly set
2

Remedy:
1 Correctly set pressure switch
2

page 11.10 - 20 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9093 F: Clamp system 1: Faulty input signals

BMK - Ident.: None
Cause:
1 Input signals are not plausible. e.g. open/close
key simultaneously.
2

Remedy:
1 Check hardware
2

9097 F: Clamp system 1: Maximum performance time exceeded

BMK - Ident.: None
Cause:
1 The NC program stops after the command
M133 before the command M137 has arrived.
Sequential fault or program was stopped with
feed stop.
2

Remedy:
1 Can only be overcome by a new start (RESET).
2 Check hydraulic valves, check switching output

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 21

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9100 F: Tool holder 1: Strobe not present

BMK - Ident.: A36111
Cause:
1 Strobe signal (I 06.5) not present in locked
condition
Angle position generator defective of incorrectly
adjusted, input defective, wire break
2

Remedy:
1 Check angle position generator, if necessary
adjust or replace.
2

9101 F: Tool holder 1: Parity fault

BMK - Ident.: A36111
Cause:
1 Defective angle position generator, defective
input, wire break
2

Remedy:
1 Check line and inputs, if necessary replace
angle position generator.
2

page 11.10 - 22 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9102 F: Tool holder 1: Incorrect position

BMK - Ident.: A36111
Cause:
1 After locking the tool holder is in the incorrect
position.
Strobe read over, strobe did not arrive, locked
too late (defective interference suppresser in
valve plug X36271).
2

Remedy:
1 Each strobe must last at least 20 ms at full
swivel speed, if necessary reduce speed,
if necessary replace valve plug.
Adjust the angle position generator if this fault
only occurs in one swivel direction.
2

9103 F: Tool holder 2: Strobe missing

BMK - Ident.: A37111
Cause:
1 The strobe signal (I 07.5) is missing in locked
condition.
Angle position generator defective or incorrectly
adjusted, defective input, wire break
2

Remedy:
1 Check angle position generator, if necessary
adjust or replace.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 23

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9104 F: Tool holder 2: parity fault

BMK - Ident.: A37111
Cause:
1 Defective angle position generator, defective
input, wire break
2

Remedy:
1 Check lines and inputs, if necessary replace
angle position generator.
2

9105 F: Tool holder 2: Incorrect position

BMK - Ident.: A37111
Cause:
1 After locking the tool holder is in incorrect posi-
tion.
Strobe read over, strobe did not arrive, locked
too late (defective interference suppresser in
valve plug X36271).
2

Remedy:
1 Each strobe must last at least 20 ms at full
swivel speed, if necessary reduce speed,
if necessary replace valve plug.
Adjust the angle position generator if this fault
only occurs in one swivel direction.
2

page 11.10 - 24 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9106 F: Chip conveyor motor over current

BMK - Ident.: Q10711
Cause:
1 Motor protection switch triggered by thermal
overheating.
Cause could by a chip jam.
2

Remedy:
1 Remove chip jam and push--in motor protection
(overload) switch (fitted in the switch cabinet
side wall)
2

9107 F: Hydraulic: Filter blocked

BMK - Ident.: F09061 / F09071
Cause:
1 MF_sprint: Filter soiled (F09061)
2 MF_twin: Filter soiled (F09071)

Remedy:
1 Change filter insert
2 Change filter insert

9108 F: Hydraulic: Minimum level reached

BMK - Ident.: S09051
Cause:
1 Insufficient hydraulic oil
2

Remedy:
1 Top up hydraulic oil
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 25

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9109 F: Monitoring auxiliary units

BMK - Ident.: K07321
Cause:
1 K07321 not energized
2

Remedy:
1 Wiring K07321, check switch on conditions from
A07031.
2

9110 F: Input modules: Control voltage loss

BMK - Ident.: F02061 / A 02011
Cause:
1 Automatic cut-out F02061 triggered by over
current
2 24 Volt power pack switched off following a
short circuit or is defective.

Remedy:
1 Switch on the automatic cut-out. Find short
circuit in the case of repeated failure of the
automatic cut-out.
2 If short circuit, find cause, otherwise check the
24 Volt power pack.

page 11.10 - 26 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9111 F: Valve: Control voltage loss

BMK - Ident.: F02231 / A 02011
Cause:
1 Automatic cut-out F02231 triggered by over
current
2 24 Volt power pack switched off following a
short circuit or is defective.

Remedy:
1 Switch on the automatic cut-out. Find short
circuit in the case of repeated failure of the
automatic cut-out.
2 If short circuit, find cause, otherwise check the
24 Volt power pack.

9112 F: Drive package: Over temperature

BMK - Ident.: A16011
Cause:
1 E/R module signals over temperature
2

Remedy:
1 D Allow supply module to cool down
D Rethink machining sequence, possible
rewrite program
D Switch machine on/off
2

9113 F: Lubrication: Minimum level reached

BMK - Ident.: S09661
Cause:
1 Insufficient lubricating oil
2

Remedy:
1 Top up lubricating oil
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 27

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9114 F: NC: Over temperature

BMK - Ident.: A04011
Cause:
1 NC controls temperature monitoring signals
over temperature.
Note: The machine is switched to the
EMERGENCY STOP condition.
2

Remedy:
1 Check control cabinet cooling and check
ventilator of the controls. Following this switch
on the machine and cancel fault.
2

9116 F: Cycle control: Maximum program running time exceeded.

BMK - Ident.: not present
Cause:
1 Program fault: In program M99 is skipped in the
cycle.
2 Machine has stopped due to a fault or is running
in a loop so that M99 is not reached.
3 Monitoring time in ASM_mask_selection is less
than the cycle time of the part program

Remedy:
1 Write M99 in cyclical machining.
2 Check why the machine has stopped (can
possibly be identified from the block number) or
why it has run into a program loop.
3 Select longer monitoring time in ASM_mask_se-
lection.

page 11.10 - 28 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9117 F: Pick-off device type parameter: Inadmissible value

BMK - Ident.: None
Cause:
1 MF_sprint: Incorrect selection in DB195 or
PLC machine data
2

Remedy:
1 Contact Gildemeister
2

9118 F: Offcut ejector: Monitoring triggered

BMK - Ident.: S15361, S15371, Y15161
Cause:
1 The cylinder end positions were moved forward/
pulled back after the start, elapse of the
monitoring time not reached.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select the
corresponding user mask, and press the
direction keys again.
A ”1” must appear in status, if this is not the
case, reset or replace cylinder switch.
2 Check output selection and valves.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 29

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9119 F: Finished part pick-off: Monitoring triggered

BMK - Ident.: MF-Twin: S15811, S15821, S15831, S15841

BMK - Ident.: MF-sprint: S15341, S15351, Y15131, Y15141

Cause:
1 The cylinder end positions were moved forward/
pulled back after the start, elapse of the
monitoring time not reached.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select the
corresponding user mask, and press the
direction keys again.
A ”1” must appear in status, if this is not the
case, reset or replace cylinder switch.
2 Check output selection and valves.

9120 F: Material feeding type parameter: Inadmissible value

BMK - Ident.: None
Cause:
1 MF_mach: Incorrect selection in DB195 or
PLC-machine data
2

Remedy:
1 Contact Gildemeister
2

page 11.10 - 30 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9121 F: Bar operation: Inadmissible command

BMK - Ident.: None
Cause:
1 Inadmissible operation in the machine status,
or prerequisites for the performance of this
function not fulfilled.
2

Remedy:
1 Create operating mode, or fulfil sequence
condition. ( For further information refer to the
operating instructions, chapters 5, 7 and 11)
2

9122 F: Bar operation, material pusher monitoring triggered

BMK - Ident.: MF-sprint: S40771, S40781, Y40271, Y40281
Cause:
1 The cylinder end positions were moved forward/
pulled back after the start, elapse of the
monitoring time not reached.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select
corresponding icon, and press the key again.
A ”1” must appear in the status of the selected
input / output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 31

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9123 F: Loader bar operation: Monitoring triggered

BMK - Ident.: MF-sprint: S40811, S40821, Y40241, Y40251
Cause:
1 The cylinder end positions were moved forward/
pulled back after the start, elapse of the
monitoring time not reached.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select
corresponding icon, and press the key again.
A ”1” must appear in the status of the selected
input / output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2

9124 F: Bar operation, steady rest: Monitoring triggered

BMK - Ident.: MF-sprint: S40861, Y40471, Y40481
Cause:
1 The cylinder end positions were moved forward/
pulled back after the start, elapse of the
monitoring time not reached.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select
corresponding icon, and press the key again.
A ”1” must appear in the status of the selected
input / output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

page 11.10 - 32 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9125 F: Bar operation, stopper: Monitoring triggered

BMK - Ident.: MF-sprint: Y40421
Cause:
1 The cylinder end positions were moved forward/
pulled back after the start, elapse of the
monitoring time not reached.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select
corresponding icon, and press the key again.
A ”1” must appear in the status of the selected
input / output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

9126 F: Bar operation, segment 1: Monitoring triggered

BMK - Ident.: MF-sprint: S40721, Y40321, Y40331
Cause:
1 The cylinder end positions were moved forward/
pulled back after the start, elapse of the
monitoring time not reached.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select
corresponding icon, and press the key again.
A ”1” must appear in the status of the selected
input / output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 33

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9127 F: Bar operation, segment 2: Monitoring triggered

BMK - Ident.: MF-sprint: S40741, Y40341, Y40351
Cause:
1 The cylinder end positions were moved forward/
pulled back after the start, elapse of the
monitoring time not reached.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select
corresponding icon, and press the key again.
A ”1” must appear in the status of the selected
input / output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

9128 F: Bar operation, segment 3: Monitoring triggered

BMK - Ident.: MF-sprint: S40761, Y40371, Y40381
Cause:
1 The cylinder end positions were moved forward/
pulled back after the start, elapse of the
monitoring time not reached.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select
corresponding icon, and press the key again.
A ”1” must appear in the status of the selected
input / output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

page 11.10 - 34 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9129 F: Coupling prog. L-721 interrupted -undertake new start-

BMK - Ident.: not present
Cause:
1 Unfortunate program constellation
2

Remedy:
1 D Rewrite program, if necessary change
synchronisation
D Switch machine off/on.
2

9130 F: Coupling prog. L-720 interrupted -undertake new start-

BMK - Ident.: not present
Cause:
1 Unfortunate program constellation
2

Remedy:
1 D Rewrite program, if necessary change
synchronisation
D Switch machine off/on.
2

9131 F: ISM-1: Max. front bearing temperature exceeded

BMK - Ident.: A17051, M17021, NTC resistance
Cause:
1 Bearing overheated
2 Sensor defective

Remedy:
1 Set, change bearing
2 Check sensor

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 35

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9132 F: ISM-1: Max. rear bearing temperature exceeded

BMK - Ident.: A17051, M17021
Cause:
1 Bearing overheated
2 Sensor defective

Remedy:
1 Set, change bearing
2 Check sensor

9133 F: ISM-2: Max. front bearing temperature exceeded

BMK - Ident.: A23051, M23021, NTC resistance
Cause:
1 Bearing overheated
2 Sensor defective

Remedy:
1 Set, change bearing
2 Check sensor

9134 F: ISM-2: Max. rear bearing temperature exceeded

BMK - Ident.: A23051, M23021, NTC resistance
Cause:
1 Bearing overheated
2 Sensor defective

Remedy:
1 Set, change bearing
2 Check sensor

page 11.10 - 36 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9135 F: Tool holder 1: Tool drive has not positioned

BMK - Ident.: M19021
Cause:
1 Positioning the tool drive for swivelling has not
functioned.
E.g. missing spindle release for spindle 1.
2

Remedy:
1 Press reset, create prerequisites for spindle
release.
2

9136 F: Tool holder 1: Reference pre-contact not found

BMK - Ident.: A36111
Cause:
1 Signal from initiator S1 not found during
reference run.
Turret does not turn or turns too slowly.
2

Remedy:
1 Check turret disk if turned through more than
360_, check initiator S1, if necessary , readjust
or replace.
If turret disk does not turn create prerequisites
for spindle release of spindle 1.
If turret disk turns < 360_, press reset and
restart reference run with T1.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 37

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9137 F: Tool holder 1: Default coupling disengaged

BMK - Ident.: A36111
Cause:
1 Mechanical blocking, tightness or collision.
Overload when milling or drilling.
Signal I 06.5 from initiator S10 missing
2

Remedy:
1 Overcome cause for overload, following this
re-engage coupling. In swivel operation by
turning the turret disk manually, when milling/
drilling using hexagonal head spanner in the
tool holder.
2

9138 F: Tool holder 2: Tool drive has not positioned

BMK - Ident.: M21021
Cause:
1 Positioning the tool drive for swivelling has not
functioned.
e.g. no spindle release for spindle 1.
2

Remedy:
1 Press reset, create prerequisites for spindle
release.
2

page 11.10 - 38 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9139 F: Tool holder 2: Reference pre-contact not found

BMK - Ident.: A36111
Cause:
1 Signal from initiator S1 not found during
reference run.
Turret does not turn or turns too slowly.
2

Remedy:
1 Check turret disk if turned through more than
360_, check initiator S1, if necessary , readjust
or replace.
If turret disk does not turn create prerequisites
for spindle release of spindle 1.
If turret disk turns < 360_, press reset and start
reference run with T1.
2

9140 F: Tool holder 2: Detent coupling disengaged

BMK - Ident.: A36111
Cause:
1 Mechanical blocking, tightness or collision.
Overload when milling or drilling.
Signal I 06.5 from initiator S10 missing
2

Remedy:
1 Overcome cause for overload, following this
re-engage coupling. In swivel operation by
turning the turret disk manually, when milling/
drilling using hexagonal head spanner or the
tool holder.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 39

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9141 F: Lubrication: Defective pressure switch

BMK - Ident.: S09651
Cause:
1 Pressure switch contact does not close or open.
2

Remedy:
1 D Check oil level
D Check pressure with pressure gauge
D Check lubrication motor
D Replace pressure switch
2

9142 F: Lubrication: No pressure

BMK - Ident.: S09651
Cause:
1 Pressure switch contact does not close.
2

Remedy:
1 D Check oil level
D Check pressure with pressure gauge
D Check lubrication motor
2

page 11.10 - 40 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9143 F: Cooling element: Drive chopper temperature too high

BMK - Ident.: A160, A17011, A19011, A21011, A23011,
A29011
Cause:
1 - Drive overloaded
- Ambient temperature too high
2

Remedy:
1 D Check machining requirements
D Check ambient temperature in accordance
with planning documentation. Is the machine
subject to direct sun radiation?
2

9144 F: Motor temperature pre-warning DX142-DW

BMK - Ident.: M.....(Servo motor)
Cause:
1 Overloaded
2 Defective motor

Remedy:
1 Check program and machining requirements
2 Check motor, replace if necessary

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 41

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9145 F: Command channel ASS4: Fault when moving to fixed stop

BMK - Ident.: None
Cause:
1 Internal CNC fault
Refer to the value in DB41 DW14 for the cause
2

Remedy:
1 Notify DMG service if frequently encountered.
Notify of DB41 DW14 value.
2

9146 F: Switch cabinet: Temperature limit reached

BMK - Ident.: A17051
Cause:
1 - Ambient temperature too high
- Sensor not in order
- Sensor not at correct location
2

Remedy:
1 Check, replace sensor if necessary
2

page 11.10 - 42 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9147 F: Conveyor belt: Part control not run through

BMK - Ident.: S 15131
Cause:
1 The finished part has not passed through the
control.
2 D Light barrier is soiled or incorrectly adjusted.
D Defective light barrier.

Remedy:
1 Open the working space and check part running
sequence.
2 Check, replace light barrier if necessary

9148 F: Conveyor belt: Cover not opened / closed

BMK - Ident.: S 15121
Cause:
1 Cover jammed (Chips?).
Proximity switch incorrectly adjusted or
defective.
2

Remedy:
1 Check, if necessary replace proximity switch.
2

9149 F: Machine: Not switched on

BMK - Ident.: K07161
Cause:
1 D Machine was switched off manually
D EMERGENCY STOP condition
D Shift end circuit switched off
2

Remedy:
1 D Overcome EMERGENCY STOP condition
D Switch on machine via keys
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 43

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9150 F: Pneumatic system: No system pressure

BMK - Ident.: F15221 / Y15181
Cause:
1 D No central air supply
D Pressure loss > 500msec
D Valve Y15181 not switched on
2

Remedy:
1 D Switch on central air supply
D Check pressure loss
2

9151 F: Bar operation: Not operational

BMK - Ident.: X14021 Pin. 19
Cause:
1 External bar feeding unit obtains signal from the
interface.
2

Remedy:
1 Refer to operating instructions, chapter 9
Interface description. ext. bar feeding unit.
2 Refer to operating instructions of the corres-
ponding bar feeding unit.

page 11.10 - 44 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9152 F: Motor protection switch: circuit diagram pg.72

-immediate stop-
BMK - Ident.: Q.......(Various drives)
Cause:
1 Motor protection switch triggered (hydraulic,
coolant pump, ....).
2

Remedy:
1 Check the assignment as per circuit diagram
72/... and overcome the precise cause.
2

9153 F: Bar operation loader: Fixed stop reached

BMK - Ident.: None
Cause:
1 When an ejecting offcut, the pushing forward
movement was blocked, in spite of feed repeat.
(M66)
2 The bar remains clamped on the fixed stop in
spite of M72 and chuck open.
The fixed stop function was not switched off.
Excessive spring path tolerance in loading
system.

Remedy: See operating instructions, chapter 5, 7, and 11

1 Check bar guidance, bar guidance tolerance
and collet for blockages.
Can only be overcome with RESET and auto-
matic restart.
2 Increase spring path tolerance setting para-
meters by a factor of 10, if then no malfunction,
check the reference dimension of the Q axis, or
the chain tension and reset. Subsequently
regenerate default value.
Can only be overcome with RESET and auto-
matic restart.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 45

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9154 F: Loader bar operation: fault when moving to fixed stop

BMK - Ident.: not present
Cause:
1 When searching for bar and no material found.
If M73/M69 are simultaneously programmed.
Excessive spring path tolerance in loading
system.
2 Defective measuring sensor ( S40641), or
sensor was not actuated.
During loader raise, the lever is not pressed
fully down. (Mechanical jam)
Attention new bar is pushed through up to the
last turning part until the fault is triggered.
3 System fault in PLC, the command channel was
interrupted during the traverse path trans-
mission.

Remedy:
1 Check material presence.
Correct program.
Increase spring path tolerance setting para-
meters by a factor of 10, if then no malfunction,
check the reference dimension of the Q axis, or
the chain tension and reset, subsequently
regenerate the default value.
Can only be overcome with RESET and
automatic restart.
2 Change limit switches, repair mechanical part.
3 Can only be overcome with RESET and
automatic restart.
In exceptional circumstances with PLC full
delete mode/ END original delete mode.

page 11.10 - 46 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9155 F: Loader bar operation: Pusher position not at rear

BMK - Ident.: S40651
Cause: Limit switch, Q axis reference point
1 not actuated
2 During loading the long pusher impacts too hard
on the short pusher holder.
Q axis is shaken out of this position in this
manner.

Remedy:
1 Check limit switch and actuation
(Attention, check swing out position of the long
pusher)
2 Set pneumatic cylinder end position damping.

9156 F: Loader bar operation: No bar found

BMK - Ident.: None
Cause:
1 When starting the bar search no bar start was
found throughout the maximum path, because
off-cut is too short, excessive tolerance in
loader, or no material in chuck.
2 On the occasion of an abort during the bar
change or by actuating the reset key the
variable R741 was sporadically written over.
Condition ”1” can be entered => no material
present. Consequence: the part program
constantly runs in bar change.

Remedy:
1 Clamp correct offcut size, see variable data.
Check Q axis reference dimensions.
Clamp material.
2 Directly write over variable R741 with the value
zero.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 47

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9157 Loader bar operation: Fixed stop not reached

BMK - Ident.: None
Cause:
1 During material advance with M73 or M69
the feed path control has switched off.
Excessive tolerance in the loader.
2 During last part advance prior to bar change the
software limit switch (+24) of the Q axis was
crossed when hitting the stop.
3 With M72, relieve bar, or M69 increase
clamping torque the fixed stop reached prere-
quisite was not present.
The fixed stop function was switched off by the
system.

Remedy:
1 Increase spring path tolerance setting para-
meters by a factor of 10, if then no malfunction,
check the reference dimension of the Q axis, or
the chain tension and reset, subsequently
reproduce default value.
2 With the setting parameter ”offset correction”,
when the value is on ”0 ” or a smaller positive
value is entered, increase this sum by a factor
of ”5”.
ATTENTION: Offcut will be larger.
3 Actuate reset key and restart program, or in
exceptional cases PLC full delete mode, end
original delete mode.

page 11.10 - 48 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9158 F: Loader bar operation: fault in position calculation

BMK - Ident.: None
Cause:
1 Is triggered when the short pusher runs onto the
offcut with the new bar and simultaneously the
max. position of the short pusher in front of the
first segment is reached.
2

Remedy: See operating instructions, chapter: 11

1 Adjust ”max. position short pusher” parameter
by +/-- 10 mm.
2

9159 F: Loader bar operation: Measuring tracer is not lowered

BMK - Ident.: S40641
Cause:
1 Defective measuring tracer, or was not
actuated.
Measuring tracer lever was not pressed down
when inserting. (Mechanical jam)
Attention, new bar is pushed through up to the
last turning part until the fault is triggered.
2

Remedy:
1 Change limit switch, repair mechanical part.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 49

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9160 F: Loader bar operation: Long pusher is not lowered

BMK - Ident.: MF-sprint: S40781, Y40281
Cause:
1 The cylinder end position was not reached after
the start and elapse of the monitoring time.
2 Valve selection missing.

Remedy:
1 Check cylinder limit switch, for this select the
corresponding symbol picture, and press the
key again.
Make the selection in status.
A ”1” appears in input / output diagnosis, reset
the cylinder switch if this is not the case, replace
of check point 2.
2 Check output control and valves.

9161 F: Loader bar operation: Chuck 4 is not closed

BMK - Ident.: F18041 (F18061 MF_sprint) Y18241, Y18251
Cause:
1 No reaction at pressure switches with clamping
command.
2 Incorrect valve selection or defective valve.

Remedy:
1 - Set pressure switch.
- Check selection and signal lines.
2 Check selection by diagnosis
Mechanically check valve.

page 11.10 - 50 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9162 F: Loader bar operation: Chuck 4 is not opened

BMK - Ident.: F18041 (F18061 MF_sprint) Y18241, Y18251
Cause:
1 No reaction at pressure switches with clamping
command.
2 Incorrect valve selection or defective valve

Remedy:
1 - Set pressure switch.
- Check selection and signal lines.
2 Check selection by diagnosis
Mechanically check valve.

9163 F: Ventilator: Loss of control voltage

BMK - Ident.: F02271 / A 02011
Cause:
1 Automatic cut-out F02271 tripped by over
current.
2 24 Volt mains unit is switched off by a short
circuit, or is defective.

Remedy:
1 Switch on the automatic cut-out. Search for
short circuit in case of a repeated failure of the
automatic cut-out.
2 In case of a short circuit, search for cause of the
fault, otherwise check the 24 Volt mains unit.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 51

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9164 F: Bar operation: Oil pump motor over current

BMK - Ident.: Q40111
Cause:
1 System soiled
2 Defective motor protection switch

Remedy:
1 Clean system
2 Check hardware

9165 F: Bar operation: No oil pressure

BMK - Ident.: F40671
Cause:
1 System soiled
2 Defective pressure switch

Remedy:
1 Clean system
2 Check pressure switch

page 11.10 - 52 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9166 F: Rot. speed monitoring S3: Unit damaged or triggered

BMK - Ident.: A23511
Cause:
1 Rotational speed monitoring triggered
2 Gear generator pulses not correct

Remedy:
1 D Parameter for max. rotational speed OK?
D Drive OK?
D Check A23511 in switch cabinet
D Delete fault, switch on machine
2 D Check A23511 in switch cabinet
D Check gear encoder A23441
D Check impulse evaluation unit A23431
D Delete fault, switch on machine

9167 F: Rot. speed monitoring S4: Unit damaged or triggered

BMK - Ident.: A17511
Cause:
1 Rotational speed monitoring triggered
2 Gear encoder impulses not OK

Remedy:
1 D Parameter for max. rot. speed OK?
D Drive OK?
D Check A17511 in switch cabinet
D Delete fault, switch on machine
2 D Check A17511 in switch cabinet
D Check gear encoder A17441
D Check impulse evaluation unit A17431
D Delete fault, switch on machine

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 53

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9168 F: Auxiliary drive: General fault

BMK - Ident.: K07321
Cause:
1 A mains contactor of the auxiliary drive has not
dropped out when the hood ws opened.
(Chip conveyor)
2

Remedy:
1 Check corresponding hardware.
2

9169 F: Drive package: Mains contactor faulty

BMK - Ident.: A16011
Cause:
1 The feedback from the supply module is
missing although the operative prerequisites are
given.
2

Remedy:
1 Check maintenance flaps (are all correctly
closed?).
If necessary, switch the main switch on and off
again (Contact DMG Service if encountered
frequently).
2

page 11.10 - 54 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9170 F: Drive package: Not operational

BMK - Ident.: A16011, A17011, A19011, A21011, A23011, ......
Cause:
1 Overload
2 Unit defective

Remedy:
1 Check program and processing (tool O.K.?, new
NC program, ...)
2

9171 F: Coupling operation: Offset in coupling operation

BMK - Ident.: None
Cause:
1 Due to a drive malfunction in coupling operation
the master axis tries to slave the following axis
via an actual value calculation.
Fault in the drive system, operating fault in one
axis or the hardware was forced open in
coupling operation.
2

Remedy:
1 Check safety circuit and hardware of the drive
control.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 55

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9172 F: Bar operation: Bar not correctly rolled in

BMK - Ident.: None
Cause:
1 The bar has not properly rolled into the guide
channel.
Segment 1 checks by closing/opening whether
the bar is out of position.
2

Remedy:
1 Check bar feeder that the bar is correctly raised,
reset if necessary.
2

9173 F: Bar operation: Segment within zone not opened correctly

BMK - Ident.: None
Cause:
1 The corresponding segment did not signal
”opened” on time. (The ”open” signal must
come approx. 150 mm in front of the segments).
2

Remedy:
1 Check air selection of the segments and elec-
trical controls. An additional fault is signalled in
the event of an electrical fault.
2

page 11.10 - 56 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9174 F: Clamping spindle 4: Execution faulty

BMK - Ident.: F17731
Cause:
1 Commands for clamping released/set are not
acknowledged.
2

Remedy:
1 Check pressure switch
2

9175 F: Clamping spindle 4: Inadmissible command

BMK - Ident.: None
Cause:
1 Spindle is not stopped
2

Remedy:
1 Check program, press spindle stop
2

9176 F: Clamping spindle 4: Monitoring triggered

BMK - Ident.: F17731
Cause:
1 Pressure signal has changed
2

Remedy:
1 Check hydraulic (Pressure peak/loss?)
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 57

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9177 F: Clamping spindle 3: Faulty execution

BMK - Ident.:
Cause:
1 Commands for clamping release/set are not
acknowledged.
2

Remedy:
1 Check pressure switch
2

9178 F: Clamping spindle 3: Inadmissible command

BMK - Ident.: None
Cause:
1 Spindle is not stopped
2

Remedy:
1 Check program, press spindle stop
2

9179 F: Clamping spindle 3: Monitoring triggered

BMK - Ident.: F23721
Cause:
1 Pressure signal has changed
2

Remedy:
1 Check hydraulic (Pressure peak/loss?)
2

page 11.10 - 58 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9180 F: Clamping spindle 1: Faulty execution

BMK - Ident.:
Cause:
1 Commands for clamping release/set are not
acknowledged.
2

Remedy:
1 Check pressure switch
2

9181 F: Clamping spindle 1: Inadmissible command

BMK - Ident.:
Cause:
1 Spindle is not stopped
2

Remedy:
1 Check program, press spindle stop
2

9182 F: Clamping spindle 1: Monitoring triggered

BMK - Ident.:
Cause:
1 Pressure signal has changed
2

Remedy:
1 Check hydraulic (Pressure peak/loss?)
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 59

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9183 F: Integrated handling : Horizontal axis not in Z+

BMK - Ident.: Y15261, S15381, S15371
Cause:
1 The handling axis does not move out of working
space.
D Dividing plate open limit switch incorrect
D Cylinder limit switch incorrectly set.
D Axis does not reach path because chips
have entered the unit.
D No pneumatic pressure.
2

Remedy:
1 Check above mentioned points
2

9184 F: Integrated handling : Horizontal axis not in Z--

BMK - Ident.: Y15261, S15381, S15371
Cause:
1 The handling axis does not move out of working
space.
D Dividing plate open limit switch incorrect
D Cylinder limit switch incorrectly set.
D Axis does not reach path because chips
have entered the unit.
D No pneumatic pressure.
2

Remedy:
1 Check above mentioned points.
2

page 11.10 - 60 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9185 F: Integrated handling: Vertical not in +

BMK - Ident.: S15331, S15341
Cause:
1 D Limit switch on cylinder incorrectly set.
D Axis did not reach the path because chips
have entered the unit.
D No pneumatic pressure.
2

Remedy:
1 Check above mentioned points.
2

9186 F: Integrated handling: Vertical not in --

BMK - Ident.: S15331, S15341
Cause:
1 D Limit switch on cylinder incorrectly set.
D Axis did not reach the path because chips
have entered the unit.
D No pneumatic pressure.
2

Remedy:
1 Check above mentioned points.
2

9187 F: Integrated handling: Gripper not open

BMK - Ident.: S15311, S15321
Cause:
1 Pressure switch incorrectly set.
Pressure loss.
2

Remedy:
1 Check pressure. Set pressure switch.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 61

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9188 F: Integrated handling: Gripper not closed

BMK - Ident.: S15311, S15321
Cause:
1 Pressure switch incorrectly set.
Pressure loss.
2

Remedy:
1 Check pressure. Set pressure switch.
2

9189 F: Int. Handling : Swivel unit not in chuck part pos.

BMK - Ident.: S15351, S15361
Cause:
1 D Cylinder limit switch incorrectly set.
D The axis does not reach the path because
chips have entered the unit.
D No pneumatic pressure.
2

Remedy:
1 Check above mentioned point.
2

9190 F: Int. Handling : Swivel unit not in shaft part pos.

BMK - Ident.: S15351, S15361
Cause:
1 D Cylinder limit switch incorrectly set.
D The axis does not reach the path because
chips have entered the unit.
D No pneumatic pressure.
2

Remedy:
1 Check above mentioned point.
2

page 11.10 - 62 V 2.0 Operating instructions MF sprint 42/65

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 11.10 Fault description
11 Parameter setting, M commands

9191 F: Int. Handling : Infeed belt motor contactor triggered

BMK - Ident.: Q15211
Cause:
1 Motor M15211 overloaded (workpieces
jammed?).
2

Remedy:
1 Overcome overloading.
2

9192 F: Leukhardt system 1: Does not react or faulty

BMK - Ident.: None
Cause:
1 MF_masch: Incorrect selection in DB195 or
PLC machine data
2

Remedy:
1 Contact Gildemeister
2

9193 F: Leukhardt system 2: Does not react or faulty

BMK - Ident.: None
Cause:
1 MF_masch: Incorrect selection in DB195 or
PLC machine data
2

Remedy:
1 Contact Gildemeister
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 63

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9194 F: Bar operation segment 4: Monitoring triggered

BMK - Ident.: MF-sprint: S40871, Y40441, Y40451
Cause:
1 The cylinder end positions were not reached
after the start forward/return and the elapse of
the monitoring time.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select cor-
responding symbol icon and press key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves

9195 F: Bar operation segment 5: Monitoring triggered

BMK - Ident.: MF-sprint: S40881, Y40221, Y40231
Cause:
1 The cylinder end positions were not reached
after the start forward/return, and elapsing of
the monitoring time.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select cor-
responding symbol icon and press key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

page 11.10 - 64 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9196 F: Counter spindle ejector: Monitoring triggered

BMK - Ident.: MF-sprint: S15311, S15321, Y15121
Cause:
1 The cylinder end positions were not reached
after the start forward/return, and elapsing of
the monitoring time.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select the
corresponding M function (M638 return, M639
forward).
A status ”1” must appear for each input/output,
if this is not the case reset or replace the cylin-
der switch.
2 Check output selection and valves.

9197 F: Tool holder 1: switch S36171 does not switch

BMK - Ident.: S36171
Cause:
1 Switch defective or incorrectly adjusted
2 Tool holder does not reach the unlocking
position

Remedy:
1 Adjust or replace switch
2 Check hydraulic pressure, check roller valve,
check tool holder

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 65

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9198 F: Tool holder 2: switch S37171 does not switch

BMK - Ident.: S37171
Cause:
1 Switch defective or incorrectly adjusted
2 Tool holder does not reach the unlocking
position

Remedy:
1 Adjust or replace switch
2 Check hydraulic pressure, check roller valve,
check tool holder

9199 F: Customer module waits for acknowledgement

BMK - Ident.: XL46011
Cause:
1 M850 to M857 were written and not
acknowledged.
2

Remedy:
1 The M functions must be acknowledged
externally (see circuit diagram page 460)
2

page 11.10 - 66 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9200 F: Overload coupling X1 triggered

BMK - Ident.: S27121
Cause:
1 Collision, the set torque was exceeded and the
coupling was triggered.
2

Remedy:
1 Switch the machine to agreement mode, then
delete the fault and move against the release
direction to free the corresponding axis using
the pressed agreement key.
2

9201 F: Overload clutch Z1 triggered

BMK - Ident.: S27141

Cause:
1 Collision, the set torque was exceeded and the
coupling has tripped.
2

Remedy:
1 Switch the machine to agreement mode, then
delete the fault and move against the release
direction to free the corresponding axis using
the pressed agreement key.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 67

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9202 F: Overload clutch X2 triggered

BMK - Ident.: S28121
Cause:
1 Collision, the set torque was exceeded and the
coupling has tripped.
2

Remedy:
1 Switch the machine to agreement mode, then
delete the fault and move against the release
direction to free the corresponding axis using
the pressed agreement key.

9203 F: Overload clutch Z2 triggered

Cause:
1 Collision, the set torque was exceeded and the
coupling has tripped.
2

Remedy:
1 Switch the machine to agreement mode, then
delete the fault and move against the release
direction to free the corresponding axis using
the pressed agreement key.
2

page 11.10 - 68 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9204 F: Overload clutch Z3 triggered

BMK - Ident.: S29121

Cause:
1 Collision, the set torque was exceeded and the
coupling has tripped.
2

Remedy:
BMK - Ident.: S28141
1 Switch the machine to agreement mode, then
delete the fault and move against the release
direction to free the corresponding axis using
the pressed agreement key.
2

9205 F: Loading flap not opened

BMK - Ident.: S43121 (closed), S43781 (open)
Cause:
1 Loading flap is not opened.
D Limit switch not actuated.
D No pneumatic pressure.
2

Remedy:
1 Check
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 69

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9206 F: Loading flap not closed

BMK - Ident.: S43121 (closed), S43781 (open)
Cause:
1 Loading flap is not opened.
D Limit switch not actuated.
D No pneumatic pressure.
2

Remedy:
1 Check
1 Insert chuck key.
2

9207 F: Chuck key 1 not locked

BMK - Ident.: S18921
Cause:
1 The chuck key is not inserted.
2

Remedy:
1 Insert chuck key.
2

page 11.10 - 70 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9208 F: Chuck key 2 not locked

BMK - Ident.: S22921
Cause:
1 The chuck key is not inserted.
2

Remedy:
1 Insert chuck key.
2

9209 F: Steady rest not opened

BMK - Ident.: F41041 (open), F41051 (closed)
Cause:
1 Pressure signals are not acknowledged or drop
off.
2

Remedy:
1 Check pressure settings.
2

9210 F: Steady rest not closed

BMK - Ident.: F41041 (open), F41051 (closed)
Cause:
1 Pressure signals are not acknowledged or drop
off.
2

Remedy:
1 Check pressure settings.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 71

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9215 F: Collision from Tool Monitor 1

BMK - Ident.: A44111
Cause:
1 The evaluation unit has determined a tool break
or a collision.
This message must entail an immediate stop of
the feed drives.
2

Remedy:
1 Tool change, check the dimensions of the
turned workpiece.
Only delete the fault in the manual control
following an operating mode change.
2 If no machine related fault then check the
evaluation sensor.
See unit manufacturer’s operating instructions.

9216 F: Tool break from tool monitor 1

BMK - Ident.: A44111
Cause:
1 The evaluation unit has determined a tool
break.
This message should entail a cycle stop in a
minimum of time.
2

Remedy:
1 Change tool, and check dimension of the turned
workpiece.
Fault can be deleted in automatic mode.
2 If no machine related fault then check the
evaluation sensor.
See unit manufacturer’s operating instructions.

page 11.10 - 72 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9217 F: Tool Monitor 1 not operational

BMK - Ident.: A44111
Cause:
1 This message indicates that the evaluation unit
has determined a fault in the system. An event
flag or variable is set to stop the machine, in
order to perform a targeted stop in the part
program. (Stop at end of cycle)
2

Remedy:
1 If no machine related fault then check the
evaluation sensor.
See unit manufacturer’s operating instructions.
Fault can be deleted in automatic mode.
2

9218 F: Tool wear from Tool Monitor 1

BMK - Ident.: A44111
Cause:
1 This message is encountered in the event of
heavy tool wear, notable hardness or dimen-
sional fluctuations of the workpiece.
As a result of this message an event flag or
variable is set to stop the machine, permitting a
targeted stop of a part program. (Stop at cycle
end)
2

Remedy:
1 Change tool and check turned workpiece
dimensions.
Fault can be deleted in automatic mode.
2 If no machine related fault then check the
evaluation sensor.
See unit manufacturer’s operating instructions.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 73

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9219 F: Idle cut from Tool Monitor 1

BMK - Ident.: A44111
Cause:
1 This recognises the lack of a workpiece or tool.
An immediate cycle stop is triggered as a con-
sequence of this message to stop the machine.
2

Remedy:
1 Change tool, and check dimension of turned
workpiece.
Fault can be deleted in automatic mode.
2 If no machine related fault then check the
evaluation sensor.
See unit manufacturer’s operating instructions.

9220 F: Collision from Tool Monitor 2

BMK - Ident.: A44111 / One display unit for 2 slides
Cause:
1 The evaluation unit has determined a tool break
or a collision.
This message must be accompanied by an
instantaneous feed drive stop.
2

Remedy:
1 Change tool and check turned workpiece
dimensions.
Only delete fault manual control following an
operating mode change.
2 If no machine related fault then check the
evaluation sensor.
See unit manufacturer’s operating instructions.

page 11.10 - 74 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9221 F: Tool break from Tool Monitor 2

BMK - Ident.: A44111 / One display unit for 2 slides
Cause:
1 The evaluation unit has determined a tool break
or a collision.
This message must entail a cycle stop as
quickly as possible.
2

Remedy:
1 Change tool and check turned workpiece
dimensions.
Fault can be deleted in automatic mode.
2 If no machine related fault then check the
evaluation sensor.
See unit manufacturer’s operating instructions.

9222 F: Tool Monitor 2 not operational

BMK - Ident.: A44111 / One display unit for 2 slides
Cause:
1 This message indicates that the evaluation unit
has determined a fault in the system.
An event flag or variable is set to stop the
machine, permitting a targeted stop of a part
program. (Stop at cycle end)
2

Remedy:
1 If no machine related fault then check the
evaluation sensor.
See unit manufacturer’s operating instructions.
Fault can be deleted in automatic mode.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 75

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9223 F: Tool wear from Tool Monitor 2

BMK - Ident.: A44111 / One display unit for 2 slides
Cause:
1 This message is encountered is the event of
heavy tool wear, notable hardness of dimen-
sional fluctuations of the workpiece.
With this message an event flag or variable is
set to stop the machine, permitting a targeted
stop of a part program. (Stop at cycle end)
2

Remedy:
1 Change tool and check turned workpiece
dimensions.
Fault can be deleted in automatic mode.
2 If no machine related fault then check the
evaluation sensor.
See unit manufacturer’s operating instructions.

9224 F: Idle cut from Tool Monitor 2

BMK - Ident.: A44111 / One display unit for 2 slides
Cause:
1 This recognises a lack of workpiece or tool.
An immediate cycle stop is triggered by this
message to stop the machine.
2

Remedy:
1 Change tool and check turned workpiece
dimension.
Fault can be deleted in automatic mode.
2 If no machine related fault then check the
evaluation sensor.
See unit manufacturer’s operating instructions.

page 11.10 - 76 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9225 F: System is switched off

BMK - Ident.: not present
Cause:
1 The activated shift end circuit has switched the
machine off.
2

Remedy:
1 Actuate machine ON key.
2

9226 F: Chip conveyor blocked

BMK - Ident.: S10871
Cause:
1 Chip conveyor blocked.
2

Remedy:
1 Clean chip conveyor.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 77

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9227 F: Turret 1: Tool drive not disengaged

BMK - Ident.: A36111, Y36271
Input I 06.4
Cause:
1 Tool spindle does not disengage
Hydraulic group, valve Y36271, valve voltage
2 Limit switch S7 defective

Remedy:
1 Ensure engage and disengage function, subse-
quently new reference run of turret with T1.
Assure hydraulic pressure, and valve function
2 Check limit switch S7, replace if necessary

9228 F: Turret 1: Tool drive not engaged

BMK - Ident.: A 37111
Cause:
1 Tool spindle cannot be disengaged.
Turret disk incorrectly positioned, driven tool
incorrectly positioned.
2 Limit switch defective or incorrectly adjusted

Remedy:
1 Unlock turret using service mask, remove driven
tool, relock turret. Reposition driven tool when
turret is correctly positioned.
2 Check limit switch, readjust or replace.

page 11.10 - 78 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9229 F: Turret 2: Tool drive not disengaged

BMK - Ident.: A44111, Y37271
Cause:
1 Tool spindle does not disengage
Hydraulic group, valve Y37271, valve voltage
2 Limit switch S7 defective

Remedy:
1 Ensure engage and disengage function, subse-
quently new reference run of turret with T1.
Assure hydraulic pressure, and valve function.
2 Check limit switch S7, replace if necessary

9230 F: Turret 2: Tool drive not engaged

BMK - Ident.: A37111
Cause:
1 Tool spindle cannot be disengaged.
Turret disk incorrectly positioned, driven tool
incorrectly positioned.
2 Limit switch defective or incorrectly adjusted

Remedy:
1 Unlock turret using service mask, remove driven
tool, relock turret. Reposition driven tool when
turret is correctly positioned.
2 Check limit switch, readjust or replace.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 79

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9231 F: Workpiece measuring not operational

BMK - Ident.: A42671, A42672
Cause:
1 The ”Operational” signal from the workpiece
measuring unit has failed during the measuring
cycle.
2 The IR connection, for example, was interrupted
due to covering the transmitter or receiver

Remedy:
1 Abort program with reset, because the loaded
measured values are faulty
2 Ensure reliable visual link between transmitter
and receiver.

9232 F: NC-SW 6.XX required for cycle

BMK - Ident.: not present
Cause:
1 A standard cycle was processed which requires
the NC software release 6 or better.
This machine is equipped with an older software
version.
2

Remedy:
1 Use old standard cycle or change NC software.
2

page 11.10 - 80 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9233 F: Unloader not operational

BMK - Ident.:
Cause: The unloader connected via the interface
signals not operational:
1 Fault has occurred in unloader
2

Remedy:
1 Find fault on unloader
2

9234 F: Tool corrections could not be loaded

BMK - Ident.:
Cause: The previously made tool correction was trans-
mitted to the PLC using the ”Start reloading”
key. Here a transmission fault occurred.

Remedy:
1 Extend the tool correction to at least 124 D
parameters.
2 The number of tool correction parameters
(D parameters) must be at least 15 (P0...14).

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 81

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9235 F: Number of read tools is 0

BMK - Ident.:
Cause: No tool numbers within the D parameter
D101-D124 were found in the PLC transferred
tool corrections.

Remedy:
1 Please check the data block in the presetting
unit.
2

9236 F: Turret position number was not found

BMK - Ident.:
Cause: The turret position number read by the reading
head was not found within the data block.

Remedy:
1 Please check the data block at the
positions D21-D32 (turret 2) and D41-D52
(turret 1) on the existing numbers
(GLOBAL\TURRET\TOA1) and whether this file
was loaded.
2

page 11.10 - 82 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9237 F: Tool number not found

BMK - Ident.:
Cause: The tool number read by the reading head was
not found within the data block.

Remedy:
1 Please check the entered data block. Was the
current data block entered, loaded and do the
tools made available match this data block?
2

9238 F: R parameters could not be transmitted

BMK - Ident.:
Cause: After loading all tools the ”Reloading completed”
key was pressed and an R parameter transmis-
sion fault was encountered.
Remedy:
1 Undertake a reload
2

9239 F: Hardware fault in evaluation unit

BMK - Ident.: -A42711
Cause: The evaluation unit has recognised a fault

Remedy:
1 Check the evaluation unit
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 83

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9240 F: Fault in telegram traffic

BMK - Ident.: -A42711
Cause: A fault has occurred in the data transfer
between the reading head and the transponder
or within the serial communication.

Remedy:
1 Check the evaluation unit and the reading
heads
2

9241 F: Reading head hardware fault

BMK - Ident.: -A42711
Cause: A reading head has recognised a fault, or is not
correctly connected.

Remedy:
1 Check the reading head.
2

9242 F: Faulty telegram from measuring unit

BMK - Ident.:
Cause: The measuring unit telegram does not corres-
pond to the specified format.

Remedy:
1 Check the measuring unit telegram
2

page 11.10 - 84 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9243 F: R parameter of the measuring unit is -0-

BMK - Ident.:
Cause: An R parameter number with -0- was received.

Remedy:
1 Check the measuring unit telegram
2

9244 F: [EOT] without data from measuring unit

BMK - Ident.:
Cause: An [EOT] without following data was received.

Remedy:
1 Check the measuring unit telegram
2

9245 F: R parameters could not be transmitted

BMK - Ident.:
Cause: A fault occurred on the NC with the subsequent
data transfer of the R parameter.

Remedy:
1 Repeat the procedure
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 85

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9246 F: Data from measuring unit without an [EOT]

BMK - Ident.:
Cause: Data was received without the subsequent end
recognition [EOT]

Remedy:
1 Check the measuring unit telegram
2

9250 F: Serial interface fault, transmit CP315

BMK - Ident.: -A04011
Cause: A fault was encountered when transmitting via
the serial interface with CP315

Remedy:
1 Undertake the procedure again.
2 Check the CP315 and its connection.
3 Fault if the red fault LED on CP315 is lit.

9251 F: Serial interface fault, CP315 received

BMK - Ident.: -A04011
Cause: A fault has occurred when receiving via the
serial interface with CP315

Remedy:
1 Undertake the procedure again
2 Check the CP315 and its connection
3 Fault if the red fault LED on CP315 is lit

page 11.10 - 86 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9252 F: Int. handling: Push-forward cylinder not forward

BMK - Ident.: MF-sprint: S40871, Y40251
Cause:
1 The cylinder end position was not reached after
the start forward and the elapse of the moni-
toring time.
2 No valve selection

Remedy:
1 Check the cylinder limit switch. For this select
the corresponding symbol picture and press the
key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

9253 F: Int. handling: Push-forward cylinder not returned

BMK - Ident.: MF-sprint: S40861, Y40241
Cause:
1 The cylinder end position was not reached after
the start of the forward run and the elapse of the
monitoring time.
2 No valve selection

Remedy:
1 Check the cylinder limit switch. For this select
the corresponding symbol and press the key
again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 87

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9254 F: Int. handling: rotary axis not in 0 deg. pos.

BMK - Ident.: MF-sprint: S40721, Y40271
Cause:
1 The cylinder end position was not reached after
the start of the forward run and the elapse of the
monitoring time.
2 No valve selection

Remedy:
1 Check the cylinder limit switch. For this select
the corresponding symbol and press the key
again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

9255 F: Int. handling: rotary axis not in 90 deg. pos.

BMK - Ident.: MF-sprint: S40741, Y40281
Cause:
1 The cylinder end position was not reached after
the start of the forward run and the elapse of the
monitoring time.
2 No valve selection

Remedy:
1 Check the cylinder limit switch. For this select
the corresponding symbol and press the key
again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

page 11.10 - 88 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9256 F: Int. handling: clamping not raised

BMK - Ident.: MF-sprint: S40761, Y40321
Cause:
1 The cylinder end position was not reached after
the start of the forward run and the elapse of the
monitoring time.
2 No valve selection

Remedy:
1 Check the cylinder limit switch. For this select
the corresponding symbol and press the key
again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

9257 F: Int. handling: clamping not lowered

BMK - Ident.: MF-sprint: S40771, Y40331
Cause:
1 The cylinder end position was not reached after
the start of the forward run and the elapse of the
monitoring time.
2 No valve selection

Remedy:
1 Check the cylinder limit switch. For this select
the corresponding symbol and press the key
again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 89

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9258 F: Int. handling: Separation not closed

BMK - Ident.: MF-sprint: S40811, Y40341
Cause:
1 The cylinder end position was not reached after
the start of the forward run and the elapse of the
monitoring time.
2 No valve selection

Remedy:
1 Check the cylinder limit switch. For this select
the corresponding symbol and press the key
again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

9259 F: Int. handling: Separation not open

BMK - Ident.: MF-sprint: S40821, Y40351
Cause:
1 The cylinder end position was not reached after
the start of the forward run and the elapse of the
monitoring time.
2 No valve selection

Remedy:
1 Check the cylinder limit switch. For this select
the corresponding symbol and press the key
again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves

page 11.10 - 90 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9260 F: Int. handling: Loading unit not forward

BMK - Ident.: MF-sprint: S40651, Y40371
Cause:
1 The cylinder end position was not reached after
the start of the forward run and the elapse of the
monitoring time.
2 No valve selection

Remedy:
1 Check the cylinder limit switch. For this select
the corresponding symbol and press the key
again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

9261 F: Int. handling: Loading unit not returned

BMK - Ident.: MF-sprint: S40631, Y40381
Cause:
1 The cylinder end position was not reached after
the start of the forward run and the elapse of the
monitoring time.
2 No valve selection

Remedy:
1 Check the cylinder limit switch. For this select
the corresponding symbol and press the key
again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 91

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9262 F: Int. handling: Workpiece not found

BMK - Ident.: MF-sprint: S40641
Cause:
1 The cylinder position of the loading unit was not
reached after start of twisting and the elapse of
the monitoring time.
2 No valve selection

Remedy:
1 Check the cylinder limit switch, for this select
the loading unit forward and twisting symbol,
then press the key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset the cylinder switch, replace or check
point 2.
2 Check output selection and valves.

9263 F: Int. handling: Not in home position

BMK - Ident.: MF-sprint:
Cause:
1 One of the cylinder end positions for the start
position was not moved to before starting.
2

Remedy:
1 Select the corresponding symbol ”Select move
to home position” and press the corresponding
key.
The message home position reached must
appear in the status, restart the cycle once this
is performed
2

page 11.10 - 92 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9390 M: Chip carriage not in position

BMK - Ident.:
Cause:
1 Chip carriage has been removed
2 Switch defective

Remedy:
1 Fit chip carriage to machine
2 Check switch

9391 M: Coolant supply flow monitor

BMK - Ident.: F10461
Cause:
1 Central coolant valve blocked
2 Check outlet at central coolant valve

Remedy:
1 Clean valve or replace
2 Change output card

9392 M: Unloading not possible

BMK - Ident.:
Cause:
1 The unloader cannot unload any further parts,
because the part memory is full.
2

Remedy:
1 Empty unloader, or overcome part jam
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 93

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9393 M: Option is not activated

BMK - Ident.: None
Cause:
1 A function was selected which is not active by
parameter.
2

Remedy:
1 Clarify with Gildemeister.
2

9394 M: Workpiece measurement, change measuring sensor

battery
BMK - Ident.: None
Cause:
1
2

Remedy:
1 Change battery in accordance with measure-
ment system manufacturer’s instructions.
2

page 11.10 - 94 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9395 M: Tool measurement: Measuring sensor in working position

BMK - Ident.: A42021
Cause:
1 Operational message when the closing cap is
removed from the measuring sensor.
The main spindle release is withdrawn.
2

Remedy:
1 Fit closing plug, when the measuring sensor is
no longer required.
2

9396 M: Automatic cut-out selected

BMK - Ident.: None
Cause:
1 Message from selecting the shift end circuit in
the user mask. (”1”)
2

Remedy:
1 Set shift end switch to ”0”.
2

9397 M: Processing delay, see MW 140

BMK - Ident.: None
Cause:
1 PLC module running time too long to quit for
alarm module processing.
2

Remedy:
1 The alarm function is only informative, change
PLC when time allows.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 95

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9398 M: Gantry not in automatic

BMK - Ident.:
Cause:
1 No automatic message from handling system.
2

Remedy:
1 Switch handling system to automatic.
2

9399 M: Tool operating life on Rev. 2 elapsed

BMK - Ident.:
Cause:
1 Tool operating life elapsed
2 Faulty operating life table

Remedy:
1 Check in the operating life table to find the tool
whose operating life has elapsed.
Replace tools with elapsed tool life.
Set actual time for replaced tool to 0. Acknow-
ledge fault message.
2 Correct operating life table.
If a tool is not to be monitored, set actual and
set point time to 0.

page 11.10 - 96 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9400 M: Operating life on a tool on Rev.1 elapsed

BMK - Ident.:
Cause:
1 Tool operating life elapsed
2 Faulty operating life table

Remedy:
1 Check in the operating life table to find the tool
whose operating life has elapsed.
Replace tool with elapsed tool life. Set actual
time for replaced tool to 0. Acknowledge fault
message.
2 Correct operating life table.
If a tool is not to be monitored, set actual and
set point time to 0.

9401 M: Counter spindle ejector: Position not defined

BMK - Ident.: MF-sprint: S15311, S15321, Y15121
Cause:
1 The cylinder end positions are left after
switching the machine off and on again.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select the
corresponding M functions (M638 return, M639
forward).
A ”1” must appear in the status in accordance
with the input -- output diagnosis, if this is not
the case, reset or replace the cylinder switch.
2 Check output selection and valves.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 97

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9402 M: Bar operation segment 5: Position not defined

BMK - Ident.: MF-sprint: S40881, Y40221, Y40231
Cause:
1 The cylinder end positions are left after
switching the machine off and on again.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select the
corresponding symbol icon, and press the key
again.
A ”1” must appear in the status of the selected
input -- output diagnosis, if this is not the case,
reset or replace the cylinder switch, or check
point 2.
2 Check output selection and valves.

9403 M: Bar operation segment 4: Position not defined

BMK - Ident.: MF-sprint: S40871, Y40441, Y40451
Cause:
1 The cylinder end positions are left after
switching the machine off and on again.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select the
corresponding symbol icon, and press the key
again.
A ”1” must appear in the status of the selected
input -- output diagnosis, if this is not the case,
reset or replace the cylinder switch, or check
point 2.
2 Check output selection and valves.

page 11.10 - 98 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9405 M: Tool measuring: No or both main spindles running

BMK - Ident.: not present
Cause:
1 The spindle to be scratched is stopped or both
main spindles are running.
2

Remedy:
1 If the X or Z values are to be taken over, only
the spindle must run on which scratching is
currently being made.
2

9406 M: Door: Safety contact triggered

BMK - Ident.:
Cause:
1 The automatic door has encountered resistance
2

Remedy:
1 Open and close door again.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 99

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9407 M: Door: Calibration run or internal fault

BMK - Ident.: A12631
Cause:
1 This message is always encountered during
initial opening or closing.
2 Unit defective (if the fault is constantly present).

Remedy:
1 Not required.
2 Check unit.

9408 M: Coolant soiled

BMK - Ident.: S11151
Cause:
1 Coolant cleaner is soiled.
2

Remedy:
1 Clean according to operating instructions.
2

page 11.10 - 100 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9409 M: Tool measurement: Measuring sensor reference size

missing
BMK - Ident.: not present
Cause:
1 No reference value for switching surface moved
to. The fault is generated when the sensor is hit
by a tool to be measured.
2

Remedy:
1 Record reference value of the corresponding
switching surface in the ”Reference sensor”
mask.
2

9410 M: Special coolant fault

BMK - Ident.: S11231, Q11221,
Various, dependent upon type of special
equipment
Cause:
1 Coolant overflow, motor protection switch
triggered.
2

Remedy:
1 Check coolant level and motor protection
switch.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 101

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9411 M: Tool holder 2 not in start position

BMK - Ident.: A37111
Cause:
1 If the program is interrupted the tool holder is
swung into a different position using keys.
2

Remedy:
1 Swivel the tool holder back to the start position
or abort the program with reset.
2

9412 M: Tool holder 1 not in start position

BMK - Ident.: A36111
Cause:
1 If the program is interrupted the tool holder is
swung into a different position using keys.
2

Remedy:
1 Swivel the tool holder back to the start position
or abort the program with reset.
2

page 11.10 - 102 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9413 M: Tool measuring: No reference measuring tool dimension

BMK - Ident.: not present
Cause:
1 No reference dimension of the switching surface
moved to. The fault is shown when the sensor is
to be referenced. This is made in the ”Sensor
referencing” mask.
2

Remedy:
1 Enter the reference tool dimension with which
the sensor is to be referenced. In the ”Sensor
referencing” mask, it is only necessary to enter
the dimensions from the sides for which the
sensor is to be referenced.
2

9414 M: Tool measuring: Measuring sensor not moved to X

BMK - Ident.: not present
Cause:
1 Measuring sensor not hit in when actuating the
”Take over X”
This fault is only formed with the PLC software
version < 30.04.98
2

Remedy:
1 Move to sensor first and then press key.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 103

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9415 M: Tool measuring: Measuring sensor not moved Z

BMK - Ident.: not present
Cause:
1 Measuring sensor not hit when actuating the
”Take over Z”
This fault is only formed with the PLC software
version < 30.04.98
2

Remedy:
1 Move to sensor first and then press key.
2

9416 M: Tool measuring: Tool compensation not cancelled

BMK - Ident.: not present
Cause:
1 The tool compensation selected last is still
active.
2

Remedy:
1 Permit to run through on both channels ”D0”.
2

9417 M: Tool measuring: D. No. inadmissible

BMK - Ident.: not present
Cause:
1 The field number is written with ”0” in the
measuring mask.
2

Remedy:
1 Enter required D. No.
2

page 11.10 - 104 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9418 M: Tool measuring: Inadmissible tool type

BMK - Ident.: not present
Cause:
1 The field number is written with ”0” in the
measuring mask.
2

Remedy:
1 Enter tool type 1 to 9 (turning tools).
2

9419 M: Tool measuring: Inadmissible diameter

BMK - Ident.: not present
Cause:
1 No workpiece diameter details in ”Scratching”
mask.
2

Remedy:
1 Enter diameter and repeat procedure.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 105

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9420 M: Tool measuring: Inadmissible length

BMK - Ident.: not present
Cause:
1 No workpiece length in ”Scratching” mask.
2

Remedy:
1 Enter length and repeat procedure.
MF_twin:
- Part in main spindle:
Length from machine zero point to front face.
- Part in counter spindle:
Length from machine zero point to front face.
MF_sprint:
- Part in main spindle:
Length from collet front edge to front face.
(R714 must have correct content)
- Part in counter spindle:
Length from gripping jaw front edge (chuck 1) to
front face ( R721 must have correct content).
2

9421 M: Tool measuring: P2 and P3 of D No. are zero

BMK - Ident.: not present
Cause:
1 Both dimensions, X and Z, are zero.
The fault is generated when actuating the ”Take
over data” key.
2

Remedy:
1 Minimum 1 dimension, X or Z must not equal
zero in P2 or P3.
2

page 11.10 - 106 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9422 M: Tool measuring: Slide-spindle selection not admissible

BMK - Ident.: not present
Cause:
1 The input parameter ”Spindle” or ”Slide” are not
correctly filled out in the SCRATCHING mask.
2

Remedy:
1 Enter parameter.
Slides:
1 = scratching with slide 1
2 = scratching with slide 2
Spindle: details of the spindle on which the tool
is to be fitted (for example, it can be measured
on spindle 4 and later used on spindle 3 !!!)
1 = Tool for counter spindle with MF_sprint
2 = Tool for counter spindle with MF_twin
4 = Tool for main spindle
2

9423 M: Leukhardt system 1: Negative test results

BMK - Ident.: A44021
Cause:
1 The learnt function (OK/KO) was not fulfilled.
2

Remedy:
1 Check monitored function or tool.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 107

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9424 M: Leukhardt system 2: Negative test results

BMK - Ident.: A44041
Cause:
1 The learnt function (OK/KO) was not fulfilled.
2

Remedy:
1 Check monitored function or tool.
2

9425 M: Integrated handling: Incorrect function code

BMK - Ident.: None
Cause:
1 Internal sequence fault
2

Remedy:
1 Read in FX157 again, (possibly by completely
deleting in the PLC)
2

9426 M: Integrated handling: No part in the take over position

BMK - Ident.: S15411
Cause:
1 No parts in the infeed.
Part jammed.
2

Remedy:
1 Refill with parts. Check part feeder.
2

page 11.10 - 108 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9427 M: Int. handling: No reserve parts on the feeding belt

BMK - Ident.: S15421
Cause:
1 Part supply running out.
2

Remedy:
1 Refill with parts.
2

9428 M: Conveyor belt: Compartment ridge not reached

BMK - Ident.: S15061
Cause:
1 Transport conveyor jammed, the conveyor belt
cannot switch to the next compartment.
2 Readjust limit switch.

Remedy:
1 Overcome part jamming.
2 Check limit switch.

9429 M: Conveyor belt: Discharge belt full

BMK - Ident.: S15761
Cause:
1 The discharge belt cannot take any further
parts.
2

Remedy:
1 Empty discharge belt.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 109

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9430 M: Bar operation: No bars found

BMK - Ident.: None
Cause:
1 The bar search program has not found any
material or the clamp offcut is too short.
An additional message 9154 can be triggered.
2

Remedy:
1 Adapt material to the application.
2

9431 M: Bar operation: Loader has no defined condition definition

BMK - Ident.: None
Cause:
1 One of the cylinder end positions was left after
switching the machine off/on.
2 No valve selection.

Remedy:
1 First run the machine to the reference, with this
all necessary cylinders are selected.
If the message is not cancelled then check the
cylinder limit switch. Select the corresponding
symbol icon, and press the key again.
A ”1” must appear in the selected input/output
diagnosis status, if this is not the case, reset,
replace the cylinder switch or check point 2.
2 Check output selection and valves.

page 11.10 - 110 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9432 M: Cycle control: Cycle STOP is being processed

BMK - Ident.: None
Cause:
1 Cycle stop was activated, by key or by a certain
fault message, which was than also displayed.
2

Remedy:
1 Key cycle start.
2

9433 M: Dynamic software limit switch:

Axis Z2 in reduction area
BMK - Ident.: None
Cause:
1 The working space software limit switches are
moved by coupling operation at excessive
speed.
In this case the speed of both slides is reduced
correspondingly.
2

Remedy:
1 Change processing mode, so that the reduction
area is not moved to, or reduce machining
speed.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 111

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9434 M: Dynamic software limit switches:

Axis X2 in reduction area
BMK - Ident.: None
Cause:
1 The working space software limit switch was
started by coupling operation at high speed.
In this case the speed of both slides is reduced
correspondingly.
2

Remedy:
1 Change processing mode, so that the reduction
area if not moved to, or reduce the machining
speed.
2

9435 W: Bar operation: Oil pump motor over current

BMK - Ident.: Q40111
Cause:
1 see fault 9164 / 9165
2

Remedy:
1 see fault 9164 / 9165
2

page 11.10 - 112 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9436 W: Ventilator: Control voltage failure

BMK - Ident.: A02011
Cause:
1 24V power unit triggered.
2

Remedy:
1 Check power unit.
2

9437 M: Loader is not swivelled in

BMK - Ident.: A40151
Cause:
1 The safety switch panel latch is not correctly
engaged.
2 Defective safety switch

Remedy:
1 Mechanical check
2 Check safety switch

9438 M: Loading is not closed

BMK - Ident.: A40171
Cause:
1 The safety switch panel latch is not correctly
engaged.
2

Remedy:
1 Mechanical check
2 Check safety switch

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 113

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9439 M: Cooling unit: Over temperature

BMK - Ident.: A13011
Cause:
1 - Ambient temperature too high.
- Unit defective
2

Remedy:
1 Check ambient temperature in accordance with
planning documentation.
Check unit.
2

9440 M: Cooling unit: Filter blocked

BMK - Ident.: A13011
Cause:
1
2

Remedy:
1 Change filter.
2

9441 M: Cooling unit: Motor protection switch triggered

BMK - Ident.: Q13011
Cause:
1 Motor overloaded
2

Remedy:
1 Check drive and motor protection switch.
2

page 11.10 - 114 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9442 M: Conveyor belt: Motor protection switch triggered

BMK - Ident.: M15021
Cause:
1 Motor overloaded
2

Remedy:
1 Check drive and motor protection switch.
2

9443 M: Maintenance flap: Top left open

BMK - Ident.: S12321
Cause:
1 Flap opened for maintenance purpose.
Switch incorrectly adjusted.
2

Remedy:
1 Close flap.
Check switch.
2

9444 M: Maintenance flap: Bottom left open

BMK - Ident.: S12322
Cause:
1 Flap opened for maintenance purpose.
Switch incorrectly adjusted.
2

Remedy:
1 Close flap.
Check switch.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 115

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9445 M: Maintenance flap: Open on right hand side

BMK - Ident.: S12323
Cause:
1 Flap opened for maintenance purpose.
Switch incorrectly adjusted.
2

Remedy:
1 Close flap.
Check switch.
2

9446 M: Oil mist separator: Motor protection switch triggered

BMK - Ident.: Q11021
Cause:
1 Oil mist separator overloaded.
2

Remedy:
1 Check oil mist separator as per operating
instructions.
2

9447 M: Bar operation: Bar end reached

BMK - Ident.: None
Cause:
1 Material in bar feeding unit is used up, the bar
change starts.
2

Remedy:
1 Only indicates a bar change.
2

page 11.10 - 116 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9448 M: Parameter Switch cabinet temperature: Inadmissible

value
BMK - Ident.: None
Cause:
1 Incorrect parameter setting.
2

Remedy:
1 Incorrect internal default value. Only DMG
service personnel permitted to make changes.
2

9449 W: Switch cabinet: Preheating limit, over temperature

reached
BMK - Ident.: A17051
Cause:
1 Ambient temperature too high.
Sensor defective.
2

Remedy:
1 Check temperature in accordance with planning
documentation.
Test sensor.
2

9450 M: Tool holder 2: Swivel speed throttled/stopped

BMK - Ident.:
Cause:
1 The speed override is reduced.
2

Remedy:
1
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 117

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9451 M: Tool holder 1: Swivel speed throttled/stopped

BMK - Ident.:
Cause:
1 The speed override is reduced.
2

Remedy:
1
2

9452 W: Pre-warning ISM-2: Rear bearing temperature exceeded

BMK - Ident.:
Cause:
1 Bearing excess temperature
Sensor defective.
2

Remedy:
1 Check message, contact DMG service if
encountered frequently.
2

9453 W: Pre-warning ISM-2: Front bearing temperature exceeded

BMK - Ident.: A23051
Cause:
1 Bearing overheated
Sensor defective.
2

Remedy:
1 Check message, contact DMG service if
encountered frequently.
2

page 11.10 - 118 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9454 W: Pre-warning ISM-1: Rear bearing temperature exceeded

BMK - Ident.: A23051
Cause:
1 D Bearing overheated.
D Sensor defective.
2

Remedy:
1 Check message, contact DMG service if
encountered frequently.
2

9455 W: Pre-warning ISM-1: Front bearing temperature exceeded

BMK - Ident.: A17051
Cause:
1 D Bearing overheated
D Sensor defective.
2

Remedy:
1 Check message, contact DMG service if
encountered frequently.
2

9456 M: Irregular temperature values (cable break?)

BMK - Ident.: A17051, A23051
Cause:
1 Sensors provide values which are outside the
valid value range.
Wiring fault.
Sensor defective.
2

Remedy:
1 Check wiring and sensors.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 119

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9457 M: Setting operation selected

BMK - Ident.:
Cause:
1 Only operating status display
2

Remedy:
1 Only operating status display
2

9458 M: Please put material in bar loader

BMK - Ident.: S40631
Cause:
1 Material used up
2

Remedy:
1 Insert new material.
2

9459 M: Bar operation, material pusher: Position not defined

BMK - Ident.: MF-sprint: S40761, S40771, Y40271, Y40281
Cause:
1 The cylinder end positions were left after
switching the machine off/on.
2 No valve selection.

Remedy:
1 Check cylinder limit switch, for this select the
corresponding symbol icon, and press the key
again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset or replace the cylinder switch or check
point 2.
2 Check output selection and valves.

page 11.10 - 120 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9460 M: Bar operation, infeeder: Position not defined

BMK - Ident.: MF-sprint: S40811, S40812, Y40241, Y40251
Cause:
1 The cylinder end positions were left after
switching the machine off/on.
2 No valve selection.

Remedy:
1 Check cylinder limit switch. Select the corres-
ponding symbol icon, and press the key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset or replace the cylinder switch or check
point 2.
2 Check output selection and valves.

9461 M: Bar operation, steady rest: Position not defined

BMK - Ident.: MF-sprint: S40861, Y40471, Y40481
Cause:
1 The cylinder end positions were left after swit-
ching the machine off/on.
2 No valve selection.

Remedy:
1 Check cylinder limit switch. Select the corres-
ponding symbol icon, and press the key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset or replace the cylinder switch or check
point 2.
2 Check output selection and valves.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 121

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9462 M: Bar operation Stopper: Position not defined

BMK - Ident.: MF-sprint: Y40421
Cause:
1 The cylinder end positions were left after
switching the machine off/on.
2 No valve selection.

Remedy:
1 Check cylinder limit switch. Select the corres-
ponding symbol icon, and press the key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
replace the cylinder valve.
2 Check output selection and valves.

9463 M: Bar operation segment 1: Position not defined

BMK - Ident.: MF-sprint: S40721, Y40321, Y40331
Cause:
1 The cylinder end positions were left after
switching the machine off/on.
2 No valve selection.

Remedy:
1 Check cylinder limit switch. Select the corres-
ponding symbol icon, and press the key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset or replace cylinder switch or check point 2.
2 Check output selection and valves.

page 11.10 - 122 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9464 M: Bar operation segment 2: Position not defined

BMK - Ident.: MF-sprint: S40741, Y40341, Y40351
Cause:
1 The cylinder end positions were left after
switching the machine off/on.
2 No valve selection.

Remedy:
1 Check cylinder limit switch. Select the corres-
ponding symbol icon, and press the key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset or replace cylinder switch or check point 2.
2 Check output selection and valves.

9465 M: Bar operation segment 3: Position not defined

BMK - Ident.: MF-sprint: S40761, Y40371, Y40381
Cause:
1 The cylinder end positions were left after
switching the machine off/on.
2 No valve selection.

Remedy:
1 Check cylinder limit switch. Select the corres-
ponding symbol icon, and press the key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset or replace cylinder switch or check point 2.
2 Check output selection and valves.

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 123

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9466 M: Offcut ejector: Position not defined

BMK - Ident.: S15361, S15371, Y15161
Cause:
1 The cylinder end positions were left after
switching the machine off/on.
2 No valve selection.

Remedy:
1 Check cylinder limit switch. Select the corres-
ponding symbol icon, and press the key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset or replace cylinder switch or check point 2.
2 Check output selection and valves.

9467 M: Finished part pick-off: Position not defined

BMK - Ident.: MF-sprint: S15341, S15351, Y15131, Y15141
Cause:
1 The cylinder end positions were left after
switching the machine off/on.
2 No valve selection.

Remedy:
1 Check cylinder limit switch. Select the corres-
ponding symbol icon, and press the key again.
A ”1” must appear in the status of the selected
input/output diagnosis, if this is not the case,
reset or replace cylinder switch or check point 2.
2 Check output selection and valves.

page 11.10 - 124 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9468 W: Lubrication: Minimum level reached

BMK - Ident.: F09661
Cause:
1 Lubricating oil shortage
2

Remedy:
1 Top up lubricating oil.
2

9469 W: Chopper: over temperature

BMK - Ident.: A16011
Cause:
1 Switch cabinet cooling failure, ambient
temperature too high.
2

Remedy:
1 Check temperature according to planning
documentation.
Check cooling unit.
2

9470 W: Motor protection switch: Circuit diagram Bl.72

-Stop at M30/M99-
BMK - Ident.: Diverse
Cause:
1 Monitoring unit triggered.
2

Remedy:
1 Check unit in accordance with circuit diagram
page 072/....
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 125

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9471 W: Hydraulic: Minimum level reached

BMK - Ident.: F09051
Cause:
1 Hydraulic oil shortage
2

Remedy:
1 Top up hydraulic oil.
2

9473 W: Hydraulic: Filter blocked

BMK - Ident.: F09071
Cause:
1 Filter signals blockage.
2

Remedy:
1 Clean or replace filter.
2

9474 W: Switch cabinet: over temperature

BMK - Ident.: A13011
Cause:
1 Ambient temperature too high.
2

Remedy:
1 Check temperature in accordance with planning
documentation.
2

page 11.10 - 126 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9475 W: Switch cabinet cooling: Filter blocked

BMK - Ident.: A13011
Cause:
1 Filter
2

Remedy:
1 Change filter
2

9478 W: Chip conveyor: Motor overcurrent

BMK - Ident.: Q10711
Cause:
1 Motor blocked M10711.
2

Remedy:
1 Remove chip jam or check motor protection
switch.
2

9479 M: Clamp system 1: Position not defined

BMK - Ident.: F20041, F20061, Y20241, Y20251
Cause:
1 Inadmissible condition in machine status
Clamp is neither clamped nor fully open.
2

Remedy:
1 Perform CLAMP or RELEASE command.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 127

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9482 M: Clamp system 2: Position not defined

BMK - Ident.: F20031, F20041, Y20071, Y20081
Cause:
1 Inadmissible condition in machine status.
Clamp is neither clamped nor fully open.
2

Remedy:
1 Perform CLAMP or RELEASE command.
2

9485 M: Clamp system 3: Position not defined

BMK - Ident.: F24041, Y24241, Y24251
Cause:
1 Inadmissible condition in machine status.
Clamp is neither clamped nor fully open.
2

Remedy:
1 Perform CLAMP or RELEASE command.
2

9486 M: Clamp system 3: Clamping stroke limitation reached

BMK - Ident.: S24121, A23021
Cause:
1 Incorrect setting parameter.
Clamp has reached an incorrect clamping end
position.
2

Remedy:
1 Check application setting and rematch.
2

page 11.10 - 128 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9488 M: Clamp system 4: Position not defined

BMK - Ident.: MF_sprint F18041, F18061, Y18241, Y18251

BMK - Ident.: MF_twin F18041, Y18241, Y18251

Cause:
1 Inadmissible condition in machine status.
Clamp is neither clamped nor fully open.
2

Remedy:
1 Perform CLAMP or RELEASE command.
2

9489 M: Clamp system 4: Clamping stroke limitation reached

BMK - Ident.: S18121
Cause:
1 Incorrect setting parameter.
Clamp has reached an incorrect clamping end
position.
2

Remedy:
1 Check application setting and rematch.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 129

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9491 F: Tool holder 2: Is not released

BMK - Ident.:
Cause:
1 No tool holder swivel release.
For safety reason the tool holder must not
swivel e.g. working space door not closed.
2

Remedy:
1 Recreate swivelling conditions.
Press reset if the swivel process was inter-
rupted, following this perform new reference run
with T1
2

9492 M: Tool holder 2: Does not swivel

BMK - Ident.:
Cause:
1 Tool holder does not leave its start position or
does not reach its target position.
No spindle release, max. spindle rotational
speed in parameter extremely limited, drive is
defective
2

Remedy:
1 Check interfacing bits for spindle release.
Parameter for rotational speed limitation, check
spindle 2 (at least 500 r.p.m).
Check drive.
2

page 11.10 - 130 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9493 M: Tool holder 2: Actual position unknown

BMK - Ident.:
Cause:
1 Actual position is unknown. E.g. by interrupting
the swivel process.
2

Remedy:
1 Select T1 and perform new tool holder
reference run.
2

9494 F: Tool holder 1: Not released

BMK - Ident.:
Cause:
1 No swivel release for tool holder.
For safety reasons do not swivel the tool holder
e.g. working space door not closed.
2

Remedy:
1 Recreate swivelling conditions.
Press reset if the swivel process was inter-
rupted, following this perform new reference run
with T1
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 131

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

9495 M: Tool holder 1: Does not swivel

BMK - Ident.:
Cause:
1 Tool holder does not leave its start position or
does not reach its target position.
No spindle release, max. spindle rotational
speed in parameter extremely limited, defective
drive
2

Remedy:
1 Check interfacing bits for spindle release.
Parameter for rotational speed limitation, check
spindle 2 (at least 500 r.p.m).
Check drive.
2

9496 M: Tool holder 1: Actual position unknown

BMK - Ident.:
Cause:
1 Actual position is unknown. E.g. by interrupting
the swivel process.
2

Remedy:
1 Select T1 and perform new tool holder
reference run.
2

page 11.10 - 132 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

9497 M: M function decoding: MFU Bit not picked-up

BMK - Ident.: not present
Cause:
1 An M_function has been performed which is not
possible, or not necessary for an option selec-
tion.
2 End position of a unit not acknowledged

Remedy:
1 Actuate RESET key.
2

200000 First move to reference points

BMK - Ident.: None
Cause:
1 Large display on screen for operator guidance
2

Remedy:
1 See text display
2

200001 Option is not activated

BMK - Ident.: None
Cause:
1 Large display on screen for operator guidance.
Machine option not activated.
2

Remedy:
1 Check whether option is possible on the
machine.
If yes, activate the corresponding PLC_machine
datum.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 133

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

200002 Maintenance, grease lubrication recommended

BMK - Ident.: None
Cause:
1 Large display on screen for operator guidance
Maintenance actual time has reached set point
value.
This display appears each time the machine is
switched on, as long as the work is not acknow-
ledged.
2

Remedy:
1 Perform maintenance and confirm performance
by acknowledging in user mask.
The actual value is set to zero.
2

200003 Maintenance, Switch cabinet filter change

recommended
BMK - Ident.: None
Cause:
1 Large display on screen for operator guidance
Maintenance actual time has reached set point
value.
This display appears each time the machine is
switched on, as long as the work is not acknow-
ledged.
2

Remedy:
1 Perform maintenance and confirm performance
by acknowledging in user mask.
The actual value is set to zero.
2

page 11.10 - 134 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 11.10 Fault description
11 Parameter setting, M commands

200004 Maintenance, spindle motor filter recommended

BMK - Ident.: None
Cause:
1 Large display on screen for operator guidance
Maintenance actual time has reached set point
value.
This display appears each time the machine is
switched on, as long as the work is not acknow-
ledged.
2

Remedy:
1 Perform maintenance and confirm performance
by acknowledging in user mask.
The actual value is set to zero.
2

200005 ”Inspection work recommended”

BMK - Ident.:
Cause:
1 The monitoring units for an inspection have
elapsed
2

Remedy:
1 Undertake inspection in accordance with
operating instructions and reset the monitoring
units.
2

Operating instructions MF sprint 42/65 V 2.0 page 11.10 - 135

Doc.-No.: ABB002G0
11.10 Fault description
11 Parameter setting, M commands

200006 Inadmissible maintenance time (please check)

BMK - Ident.: None
Cause:
1 Large display on screen for operator guidance
Maintenance actual time has reached set point
value.
This display appears each time the machine is
switched on, as long as the work is not acknow-
ledged.
2

Remedy:
1 Correct time in user maintenance mask.
2

page 11.10 - 136 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0
 12 Catchwords

A I
Activity symbols . . . . . . . . . . . . . . . . . . . . . . 2-8 Information symbols . . . . . . . . . . . . . . . . . . . 2-8
Auxiliary time . . . . . . . . . . . . . . . . . . . . . . . 4-27 Installation instructions . . . . . . . . . . . . . . . . 2-5
Intended use . . . . . . . . . . . . . . . . . . . . . . 3, 4-8
B Interface description . . . . . . . . . . . . . . . . . . . 9-2
Isolating protection devices . . . . . . . . . . . . 4-11
Bar loading magazine
filling quantities . . . . . . . . . . . . . . . . . . . . . 4-16
Bar machining . . . . . . . . . . . . . . . . . . . . . . 7-51 K
Bar machining with an Key switch . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
external bar pusher . . . . . . . . . . . . . . . . . 7-71
Key symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

C
L
Capacity data . . . . . . . . . . . . . . . . . . . . . . . 4-22
Loading the bar loading magazine . . . . . . 5-5
Checks prior to starting work . . . . . . . . . . 10-6
Lubricant filling quantities . . . . . . . . . . . . 4-15
Chip conveyor . . . . . . . . . . . . . . . . . . . . . . 4-14
Lubricant table . . . . . . . . . . . . . . . . . . . . . . 4-17
Clamping device . . . . . . . . . . . . . . . . . . . . 7-12
Clamping force diagram . . . . . . . . . . . . . . 4-25
Clamping means . . . . . . . . . . . . . . . . . . . . 7-16 M
Conformity declaration . . . . . . . . . . . . . . . . . 14 M commands . . . . . . . . . . . . . . . . . . . . . . . 11-3
Coolant lubricant filling quantity . . . . . . . 4-18 Machine assembly groups . . . . . . . . . . . . . . 4-4
Machining with an external
D bar loading magazine . . . . . . . . . . . . . . . . 7-80
Maintenance after shift end . . . . . . . . . . . 10-8
Display symbols . . . . . . . . . . . . . . . . . . . . . . 2-8
Maintenance instructions . . . . . . . . . . . . . 10-3
Maintenance plan . . . . . . . . . . . . . . . . . . 10-11
E Mechanical technical documentation . . . 2-6
EC machine directives 89/392 ECC . . . . . . 3
Electrical technical documentation . . . . . . 2-6
EMERGENCY STOP . . . . . . . . . . . . . . . . . . . 8
EMERGENCY STOP cut-out . . . . . 4-10, 7-9

G
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Operating instructions MF sprint 42/65 V 2.0 page 12-3

Doc.-No.: ABB002G0
12 Catchwords

N T
Noise protection . . . . . . . . . . . . . . . . . . . . 4-14 Times and paths . . . . . . . . . . . . . . . . . . . . 4-30
Tool holder . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
O Transport and installation instructions . . . 2-5

Off-cut disposal . . . . . . . . . . . . . . . . . . . . . 7-47

Operating elements . . . . . . . . . . . . . . . . . . . 6-2 W
Optional modules . . . . . . . . . . . . . . . . . . . . 4-6 Workpiece machining . . . . . . . . . . . . . . . . . . . 9

P
Parameter settings . . . . . . . . . . . . . . . . . . 11-3
Pick-off device . . . . . . . . . . . . . . . . . . . . . . 7-35
Planning documentation . . . . . . . . . . . . . . 2-5
PLC fault messages . . . . . . . . . . . . . . . . . . 11-3
Pressure vessel . . . . . . . . . . . . . . . . . . . . . . . . 6
Programming manual . . . . . . . . . . . . . . . . . 2-6

R
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rotational speed control . . . . . . . . . . . . . 4-12
Rotational speed limitation . . . . . . . . . . . . . . 7

S
Safety devices . . . . . . . . . . . . . . . . . . . . . . 4-10
Safety instructions . . . . . . . . . . . . . . . . . . . . . . 5
Safety regulations . . . . . . . . . . . . . . . . . . . . . . 3
Safety window . . . . . . . . . . . . . . . . . . . . . . . . . 6
Scratching . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Screen divisions . . . . . . . . . . . . . . . . . . . . 6-30
Standard cycles . . . . . . . . . . . . . . . . . . . . . 11-3
Switching off the machine . . . . . . . . . . . . . 7-8
Switching on the machine . . . . . . . . . . . . . 7-5

page 12-4 V 2.0 Operating instructions MF sprint 42/65

Doc.-No.: ABB002G0