Applications Training

for
Integrex-100~400MkIII Series
Mazatrol Fusion 640MT-Pro

Publication # C373AT1000E
3/2005

CAUTION

This Manual is published to assist experienced personnel on the operation, maintenance

and/or programming of Mazak machine tools.

All Mazak machine tools are engineered with a number of safety devices to protect
personnel and equipment from injury or damage. Operators should not, however, rely
solely upon these safety devices, but should operate the machine only after fully
understanding what special precautions to take by reading the following documentation
thoroughly.

Do not attempt to operate or perform maintenance / repair on the machine without a

thorough understanding of the actions about to be taken. If any question exists, contact
the nearest Mazak service center for assistance.

Certain covers, doors or safety guards may be open or removed to more clearly show
machine components. These items must be in place before operating the machine.
Failure to comply with this instruction may result in serious personal injury or damage to
the machine tool.

This manual was considered complete and accurate at the time of publication, however,
due to our desire to constantly improve the quality and specification of all Mazak
products, it is subject to change or modification.
Notes:
 INTEGREX-100~400MkIII APPLICATIONS TRAINING
CONTENTS

SAFETY PRECAUTIONS .................................................................................................................. S1

LOCKOUT PROCEDURE .................................................................................................................. S1
INSTALLATION PRECAUTIONS.......................................................................................................S4
WARNINGS........................................................................................................................................ S5
DOOR INTERLOCK SAFETY SPECIFICATION ............................................................................... S11
SWITCH PANEL DIAGRAM............................................................................................................... S12

1 INTEGREX-100~400MkIII MANUAL ATC OPERATION .............................................................. 1-1

Updating the Current Tool in the Turret Pocket........................................................... 1-8

2 UPPER TURRET ALIGNMENT..................................................................................................... 2-1

3 LOWER TURRET ALIGNMENT.................................................................................................... 3-1

4 FIRST & SECOND SPINDLE ALIGNMENT.................................................................................. 4-1

4-1 Outline of the 1st Spindle & 2nd Spindle.......................................................................... 4-1
4-2 Alignment of the First Spindle........................................................................................ 4-1
4-3 Concentricity Adjustment Between the First and Second Spindle ................................ 4-5

5 RENISHAW TOUCH PROBE ADJUSTMENT PROCEDURE ...................................................... 5-1

5-1 Touch Probe Adjustment Procedure............................................................................... 5-1

6 TURRET CENTER OF ROTATION ADJUSTMENT PROCEDURE (Parameter B234) .............. 6-1

7 TOOL EYE CALIBRATION PROCEDURE ................................................................................... 7-1

7-1 Integrex-100~400ST Tool Eye Parallelism Adjustment................................................. 7-1
7-2 Tool Eye Parameters ..................................................................................................... 7-3
7-3 Parameter Screen Selection .......................................................................................... 7-4
7-4 Tool Eye Calibration Procedure.....................................................................................7-5

8 TURRET SIDE ATC POSITION ADJUSTMENT ........................................................................... 8-1

9 TOOL FUNCTIONS ....................................................................................................................... 9-1

9-1 Tool Function (4 Digit T-Code) ......................................................................................9-1
9-2 Tool Function (6 Digit T-Code_......................................................................................9-2
9-3 Next Tool Automatic Selection....................................................................................... 9-2

10 EIA/ISO PROGRAMMING EXAMPLE ........................................................................................ 10-1

11 COORDINATE SYSTEM SETTING.............................................................................................11-1

11-1 G125 Coordinate System Setting Macro .....................................................................11-1
11-2 G128.8 Coordinate System Setting Macro ..................................................................11-4

APPENDIX

PLC ALARMS .............................................................................................................. APP-1

ADDITIONAL PLC ALARMS........................................................................................ APP-1
M CODE TABLE ..........................................................................................................APP-15
LOWER TURRET M-CODES .................................................................................. APP-26
INTEGREX-MkIII STROKE DIAGRAMS ..................................................................... APP-29
INTEGREX-100MkIII............................................................................................... APP-29
INTEGREX-200MkIII............................................................................................... APP-35
INTEGREX-300/400MkIII........................................................................................ APP-43
Notes:
SAFETY PRECAUTIONS
The machine is provided with a number of safety
devices to protect personnel and equipment from
injury and damage. Operators should not,
however, rely solely upon these safety devices,
but should operate the machine only after fully
understanding what special precautions to take by
reading the following documentation thoroughly.
• BASIC OPERATING PRACTICES
DANGER:
1) Some control panels, transformers, motors,
junction boxes and other parts have high
voltage terminals. These should not be touched
or a severe electric shock may be sustained.
2) Do not touch any switches with wet hands.
This too, can produce an electric shock.
WARNING:
1) The emergency stop pushbutton switch
location should be well known, so that it can be
operated at any time without having to look for
it.
2) Before replacing a fuse, turn off the main
incoming power switch to the machine.
3) Provide sufficient working space to avoid
hazardous falls.
4) Water or oil can make floors slippery and
hazardous. All floors should be clean and dry
to prevent accidents
5) Do not operated any switch without a thorough
understanding of the actions about to be taken.
6) Avoid accidental operation of switches.
7) Work benches near the machine must be
strong enough to hold materials placed on
them to prevent accidents. Articles should be
prevented from slipping off the bench surface.
8) If a job is to be done by two or more persons,
coordinating signals should be given at each
step of the operation. The next step should not
be taken unless a signal is given and
acknowledged.
CAUTION:
1) In the event of power failure, turn off the main
circuit breaker immediately.
2) Use the recommended hydraulic oils, lubricants
and grease or acceptable equivalents.
3) Replacement fuses should have the proper
current ratings.
4) Protect the NC unit, operating panel, electric
control panel, etc. from shocks, since this
could cause a failure or malfunction.
5) Do not change parameters or electrical
settings. If changes are unavoidable, record
the values prior to the change so that they can
be returned to their original settings, if
necessary.
S-1
6) Do not deface, scratch or remove any caution
plate. Should it become illegible or missing,
order another caution plate from the supplier,
specifying the part number shown at the lower
right corner of the plate.
• BEFORE POWERING UP
DANGER:
Cables, cords or electric wires whose insulation
is damaged can produce current leaks and
electric shocks. Before using, check their
condition.
WARNING:
1) Be sure the instruction manual and the
programming manual are fully understood
before operating the machine. Every function
and operating procedure should be completely
clear.
2) Use approved oil resistant safety shoes, safety
goggles with side covers, safe clothes, and
other safety protection required.
3) Close all NC unit, operating panel, electric
control panel doors and covers.
CAUTION:
1) The power cable from the factory feeder switch
to the machine main circuit breaker should
have a sufficient sectional area to handle the
electric power used.
2) Cables which must be laid on the floor must be
protected from hot chips, by using rigid or
other approved conduit, so that short-circuits
will not occur.
3) Before first time operation of the machine after
unpacking it or from being idle for a long period
of time (several days or more), each sliding
part must be sufficiently lubricated. To do so,
push and release the pump button several
times until the oil seeps out on the sliding
parts. The pump button has a return spring, so
do not force it to return.
4) Oil reservoirs should be filled to indicated
levels. Check and add oil, if needed.
5) For lubrication points, oil specification and
appropriate levels, see the various instruction
plates.
6) Switches and levers should operate smoothly.
Check that they do.
7) When powering the machine on, turn on the
switches in the following order: first the factory
feeder switch, then the machine main circuit
breaker, and then the control power on switch
located on the operating panel.
8) Check the coolant level, and add coolant, if
needed.
• AFTER CONTROL POWER IS TURNED ON
CAUTION:
When the control power “ON” switch on the
operating panel is on, the "READY" lamp on
the operating panel should also be on (check to
see that it is).
• ROUTINE INSPECTIONS
WARNING:
When checking belt tensions, do not get your
fingers caught between the belt and pulley.
CAUTION:
1) Check pressure gages for proper readings.
2) Check motors, gear boxes and other parts for
abnormal noises.
3) Check the motor lubrication, and sliding parts
for evidence of proper lubrication.
4) Check safety covers and safety devices for
proper operation.
5) Check belt tensions. Replace any set of belts
that have become stretched with a fresh
matching set.
• WARM UP
CAUTION:
1) Warm up the machine, especially the spindle
and feed shaft, by running the machine for 10
to 20 minutes at about one-half or one-third the
maximum speed in the automatic operation
mode.
2) The automatic operation program should cause
each machine component to operate. At the
same time, check their operations.
3) Be particularly careful to warm up the spindle
which can turn above 4000 rpm.
If the machine is used for actual machining
immediately after being started up following a
long idle period, the sliding parts may be worn
due to the lack of oil. Also, thermal expansion
of the machine components can jeopardize
machining accuracy. To prevent this condition,
always make sure that the machine is warmed
up.
• PREPARATIONS
WARNING:
1) Tooling should conform to the machine
specifications, dimensions and types.
2) Replace all seriously worn tools with new ones
to prevent injuries.
3) The work area should be adequately lighted to
facilitate safety checks.
S-2
4) Tools and other items around the machine or
equipment should be stored to ensure good
footing and clear aisles.
5) Do not place tools or any other items on the
headstock, turret, covers and similar places
(For T/M).
CAUTION:
1) Tool lengths should be within specified
tolerances to prevent interference.
2) After installing a tool, make a trial run.
• OPERATION
WARNING:
1) Do not work with long hair that can be caught
by the machine. Tie it back, out of the way.
2) Do not operate switches with gloves on. This
could cause mis-operation.
3) Whenever a heavy workpiece must be moved,
if there is any risk involved, two or more people
should work together.
4) Only trained, qualified workers should operate
forklift trucks, cranes or similar equipment and
apply slings.
5) Whenever operating a forklift truck, crane or
similar equipment, special care should be taken
to prevent collisions and damage to the
surroundings.
6) Wire ropes or slings should be strong enough
to handle the loads to be lifted and should
conform to the mandatory provisions.
7) Grip workpieces securely.
8) Stop the machine before adjusting the coolant
nozzle at the tip.
9) Never touch a turning workpiece in the spindle
with bare hands, or in any other way.
10) To remove a workpiece from the machine other
than by a pallet changer, stop the tool and
provide plenty of distance between the
workpiece and the tool (for M/C).
11) While a workpiece or tool is turning, do not
wipe it off or remove chips with a cloth or by
hand. Always stop the machine first and then
use a brush and a sweeper.
12) Do not operate the machine with the chuck and
front safety covers removed (For T/M).
13) Use a brush to remove chips from the tool tip,
do not use bare hands .
14) Stop the machine whenever installing or
removing a tool.
15) Whenever machining magnesium alloy parts,
wear a protective mask.

CAUTION:
1) During automatic operation, never open the
machine door. Machines equipped with the
door interlock will set the program to single
step.
2) When performing heavy-duty machining,
carefully prevent chips from being accumulated
since hot chips from certain materials can
cause a fire.
• TO INTERRUPT MACHINING
WARNING:
When leaving the machine temporarily after
completing a job, turn off the power switch on
the operation panel, and also the main circuit
breaker.
• COMPLETING A JOB
CAUTION:
1) Always clean the machine or equipment.
Remove and dispose of chips and clean cover
windows, etc.
2) Make sure the machine has stopped running,
before cleaning.
3) Return each machine component to its initial
condition.
4) Check the wipers for breakage. Replace
broken wipers.
5) Check the coolant, hydraulic oils and lubricants
for contamination. Change them if they are
seriously contaminated.
6) Check the coolant, hydraulic oil and lubricant
levels. Add if necessary.
7) Clean the oil pan filter.
8) Before leaving the machine at the end of the
shift, turn off the power switch on the operating
panel, machine main circuit breaker and factory
feeder switch in that order.
• SAFETY DEVICES
1) Front cover, rear cover and coolant cover.
2) Chuck barrier, tail barrier and tool barrier (NC
software).
3) Stored stroke limit (NC software).
4) Emergency stop pushbutton switch.
• MAINTENANCE OPERATION PREPARATIONS
1) Do not proceed to do any maintenance
operation unless instructed to do so by the
foreman.
2) Replacement parts, consumables (packing, oil
seals, O rings, bearing, oil and grease, etc.)
Should be arranged in advance.
3) Prepare preventive maintenance and record
maintenance programs.
S-3
CAUTION:
1) Thoroughly read and understand the safety
precautions in the instruction manual.
2) Thoroughly read the whole maintenance
manual and fully understand the principles,
construction and precautions involved.
• MAINTENANCE OPERATION
DANGER:
1) Those not engaged in the maintenance work
should not operate the main circuit breaker or
the control power "ON" switch on the
operating panel. For this purpose, "Do not
Touch the Switch, Maintenance Operation in
Progress!" or similar warning should be
indicated on such switches and at any other
appropriate locations. Such indication should
be secured by a semi-permanent means in the
reading direction.
2) With the machine turned on, any maintenance
operation can be dangerous. In principle, the
main circuit breaker should be turned off
throughout the maintenance operation.
WARNING:
1) The electrical maintenance should be done by
a qualified person or by others competent to do
the job. Keep close contact with the
responsible person. Do not proceed alone.
2) Overtravel limit and proximity switches and
interlock mechanisms including functional parts
should not be removed or modified.
3) When working at a height, use steps or ladders
which are maintained and controlled daily for
safety.
4) Fuses, cables, etc. made by qualified
manufacturers should be employed.
• BEFORE OPERATION & MAINTENANCE BEGINS
WARNING:
1) Arrange things in order around the section to
receive the maintenance, including working
environments. Wipe water and oil off parts and
provide safe working environments.
2) All parts and waste oils should be removed by
the operator and placed far enough away from
the machine to be safe.
CAUTION:
1) The maintenance person should check that the
machine operates safely.
2) Maintenance and inspection data should be
recorded and kept for reference.
000X717-KY 11/98
 aaaaaaaaaa
aaaaa
! WARNING

ALWAYS TURN THE MAIN CIRCUIT BREAKER TO THE “OFF” POSITION & USE AN APPROVED
LOCKOUT DEVICE WHEN COMPLETING MAINTENANCE OR REPAIRS.

THE LOCKOUT PROCEDURE THAT FOLLOWS IS INTENDED TO SAFEGUARD PERSONNEL &

EQUIPMENT DURING MAINTENANCE OPERATIONS, AND, REPRESENTS THE MINIMUM
REQUIREMENTS. ANY ACTION SHOULD BE PRECEDED BY A “HAZARD ANALYSIS” TO DETERMINE
ANY ADDITIONAL SAFETY PRECAUTIONS THAT MAY BE NECESSARY TO ENSURE THE SAFETY OF
PERSONNEL AND EQUIPMENT.

NOTE: USE OF THE FOLLOWING LOCKOUT PROCEDURE IS MANDATORY WHEN COMPLETING

MAINTENANCE OR REPAIRS.

LOCKOUT PROCEDURE
1) THE LOCKOUT PROCESS MUST BE PERFORMED BY AUTHORIZED PERSONNEL ONLY.
2) INFORM ALL EFFECTED PERSONNEL OF YOUR INTENT TO LOCKOUT AND SERVICE THE
SPECIFIED MACHINE.
3) SHUT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES.
4) TURN OFF THE MACHINE AND INDIVIDUAL BUILDING CIRCUIT BREAKERS. MAKE SURE ALL
STORED ELECTRICAL ENERGY IS RELIEVED. (EG: SPINDLE & AXIS SERVO CONTROLLERS)
5) CONNECT THE LOCKOUT DEVICE AS SHOWN IN FIGURE 1, AND ATTACH THE APPROPRIATE
TAG AT THE MACHINE CIRCUIT BREAKER. THE TAG MUST IDENTIFY THE PERSON
RESPONSIBLE FOR THE LOCKOUT. THIS WILL ENSURE THAT POWER CANNOT BE
RESTORED BY ANYONE ELSE.
6) TEST THE MACHINE TO VERIFY THAT MACHINE SYSTEMS DO NOT OPERATE IN ANY WAY.
ONCE TESTING IS COMPLETE, MAKE SURE ALL SWITCHES ARE IN THE “OFF” POSITION.
CONFIRM THAT THE LOCKOUT DEVICES REMAIN PROPERLY INSTALLED.
7) COMPLETE THE REQUIRED MAINTENANCE OPERATIONS.
8) MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.
9) REMOVE THE LOCKOUT DEVICE. MAKE SURE ALL PERSONNEL ARE AT A SAFE LOCATION
BEFORE RESTORING MACHINE POWER.

PADLOCK

FIGURE

S-4
INSTALLATION PRECAUTIONS
The following subjects outline the items that
directly affect the machine installation and start-
up. To ensure an efficient and timely installation,
please follow these recommendations before
calling to schedule a service engineer.
• ENVIRONMENTAL REQUIREMENTS
Note:
Avoid the following places for installing the
machine:
1) Avoid exposure to direct sunlight and/or near a
heat source, etc. Ambient temperature during
operation: 0° thru 45°C (32°F to 113°F).
2) Avoid areas where the humidity fluctuates
greatly and/or if high humidity is present;
normally 75% and below in relative humidity. A
higher humidity deteriorates insulation and
might accelerate the deterioration of parts.
3) Avoid areas that are especially dusty and/or
where acid fumes, corrosive gases and salt are
present.
4) Avoid areas of high vibration.
5) Avoid soft or weak ground (minimum load
bearing capacity of 1025 lbs./ft2)
6) In pouring grout, fasten the leveling block
base plates with the collar retaining screws
to prevent the base plates from dropping.
When the grout has completely hardened,
level the machine properly, and tighten M24
nuts to secure the machine to the
foundation.
The machine must be anchored to the
foundation with J-bolts, expansion bolts or
other suitable method.
The machine accuracy and alignment
specifications quoted by Mazak can usually
be obtained when the minimum foundation
requirements are met. However, production
of close tolerance parts requires the use of an
appropriate certified foundation. Foundations
that do not meet certified specifications may
require more frequent machine re-leveling and
re-alignment, which can not be provided
under terms of warranty.
If any of these conditions cannot be met,
contact the nearest Mazak service office
immediately.

• FOUNDATION REQUIREMENTS
For high machining accuracy, the foundation
must be firm and rigid. This is typically
accomplished by securely fastening the
machine to the foundation with anchor bolts. In
addition, the depth of concrete should be as
deep as possible (minimum 6 - 8 inches). Note
the following:
1) There can be no cracks in the foundation
concrete or surrounding area.
2) Vibration proofing material (such as asphalt)
should be put all around the concrete pad.
3) Form a “cone” in the foundation for J-bolt
anchors, or use expansion anchors.
4) With the foundation anchor bolt holes open
pour the primary concrete at a minimum
thickness of 6 - 8 inches. Typically, the
concrete must have a minimum compression
rating of 2500 lbs. @ 250 lbs. compression
and strengthened with reinforcing rods. When
the concrete has cured, rough level the
machine, and install the J-bolts, leveling blocks,
etc., and pour grout into foundation bolt holes.
5) Mix an anti-shrinkage agent such as Denka
CSA with concrete, or use Embeco grout to fill
the foundation bolt holes.

S-5
 • WIRING
1) Use only electrical conductors with
performance ratings equivalent or superior.
2) Do not connect any power cables for devices
which can cause line noise to the power Desirable Independent Grounding:
distribution panel, such as arc welders and high
frequency machinery.
3) Arrange for a qualified electrician to connect NC Earth resistance:
the power lines. Machine Less than 100 ohms
4) Incoming supply voltage should not deviate
more than ±10% of specified supply voltage.
5) Source frequency should be±2 Hz of nominal Common Grounds:
frequency.

Resistance to ground
= 100 ÷ the number of
[ CAUTION ] devices connected to
the grounding (ohms)
VERIFY THE ACTUAL MACHINE ELECTRICAL
Note: Never ground equipment as shown below:
POWER REQUIREMENT AND THE MAIN
TRANSFORMER RATING (IF APPLICABLE), AS

WELL AS THE LOCAL ELECTRICAL CODE

BEFORE SIZING AND INSTALLING THE

INCOMING POWER WIRING.

PLEASE SEE THE ADDITIONAL CAUTIONS ON

THE FOLLOWING PAGE.

• GROUNDING
1) An isolated earth ground with a resistance to
ground of less than 100 ohms is required.
Typically, a 5/8” copper rod, 8 feet long, and
no more than 5 feet from the machine, is
sufficient. Building grounds or multiple
machines grounded to the same ground rod,
are not acceptable.
2) The wire size should be greater than AWG
(American Wire Gauge) No. 5 and SWG
(British Legal Standard Wire Gauge) No. 6.

000X713-KY 11/98

S-6
 ! CAUTION

A step-down transformer is optional on some machine models. Be certain to

verify the transformer Kva rating (where applicable), as well as local electrical
code requirements before sizing and installing the incoming power wiring.
Machines not equipped with a main transformer are wired for 230 VAC, 3 phase.
The end user must supply a step-down transformer where factory electrical
power varies more than ± 10% of the 230 VAC rating.
NOTE:
Step-down or voltage regulating transformers are external (peripheral) to the
machine tool and are considered the primary input line (source) for the machine.
Local electrical code or practice may require a circuit breaker or other switching
device for the isolation of electrical power when this type of transformer is used.
In such cases, the machine tool end user is required to supply the necessary
circuit breaker or switching device.
FAILURE TO COMPLY CAN RESULT IN PERSONAL INJURY AND DAMAGE TO THE
MACHINE. IF ANY QUESTION EXISTS, CONTACT THE NEAREST MAZAK SERVICE
CENTER FOR ASSISTANCE.

S-7
 WARNING
!
MAZATROL CNC CONTROLLERS PROVIDE PARAMETER SETTINGS TO LIMIT SPINDLE
RPM. THESE SETTINGS ARE BASED ON THE MAXIMUM SPEED SPECIFIED BY THE
CHUCK/ACTUATOR MANUFACTURER.

MAKE SURE TO SET THESE PARAMETERS ACCORDING TO CHUCK SPECIFICATION

WHEN INSTALLING A CHUCKING PACKAGE. ALSO, STAMP THE MAXIMUM SPINDLE
RPM ON THE CHUCK IDENTIFICATION PLATE LOCATED ON THE MACHINE TOOL
COVERS.

REFERENCE THE CNC PARAMETER MANUAL SUPPLIED WITH THE SPECIFIC MACHINE
TOOL TO IDENTIFY THE REQUIRED PARAMETERS TO CHANGE.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO

THE MACHINE, SERIOUS INJURY OR DEATH.

IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.

WARNING
!
MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO
PROTECT PERSONNEL AND EQUIPMENT FROM INJURY AND DAMAGE.

DO NOT REMOVE, DISCONNECT, BYPASS OR MODIFY ANY LIMIT SWITCH, INTERLOCK,

COVER, OR OTHER SAFETY FEATURE IN ANY WAY, EITHER MECHANICALLY OR
ELECTRICALLY.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO

THE MACHINE, SERIOUS INJURY OR DEATH.

IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.

S-8
 WARNING
!
MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO
PROTECT PERSONNEL AND EQUIPMENT FROM INJURY AND DAMAGE.

MACHINE OPERATOR DOORS AND COVERS ARE DESIGNED TO WITHSTAND

ACCIDENTAL IMPACT OF A BROKEN INSERT WHERE A MAXIMUM WEIGHT INSERT AT
MAXIMUM TOOL DIAMETER IS RUNNING AT MAXIMUM SPINDLE RPM

NEVER USE A CUTTING TOOL OR TOOL INSERT THAT EXCEEDS MACHINE

SPECIFICATIONS OR THAT OF A SPECIFIC TOOL HOLDER ITSELF, WHICHEVER IS LESS.
THIS RESTRICTION APPLIES TO DIAMETER, WEIGHT, MAXIMUM SPINDLE RPM,
MAXIMUM CUTTING TOOL ROTATION SPEED, ETC.

FOR COMPLETE SPECIFICATIONS, MAKE SURE TO REFERENCE OPERATION,

MAINTENANCE AND DETAIL SPECIFICATION DOCUMENTATION SUPPLIED WITH THE
MACHINE AND BY THE TOOLING MANUFACTURER.

NOTE: THE MAXIMUM INSERT WEIGHT FOR MAZAK MACHINES IS 20 gf. (0.04 lbs.).

FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO

THE MACHINE, SERIOUS INJURY OR DEATH.

IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.

S-9
 WARNING
!
BEFORE STARTING OPERATION, CHECK THAT THE WORKPIECE IS SECURELY MOUNTED
IN A VISE OR A SUITABLE FIXTURE. BE CERTAIN THAT THE MOUNTING IS SUFFICIENT
TO WITHSTAND CUTTING FORCES DURING WORKPIECE MACHINING.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO

THE MACHINE, SERIOUS INJURY OR DEATH.

IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.

WARNING
!
CONFIRM PROPER WORKPIECE FIXTURING/CLAMPING, TOOL SETUP AND THAT THE
MACHINE DOOR IS SECURELY CLOSED BEFORE THE START OF MACHINING.

VERIFY ALL SAFETY PRECAUTIONS OUTLINED IN THIS MANUAL BEFORE USING THE
FOLLOWING CUTTING CONDITIONS:

- CUTTING CONDITIONS THAT ARE THE RESULT OF THE MAZATROL FUSION 640
AUTOMATIC CUTTING DETERMINATION FUNCTION

- CUTTING CONDITIONS SUGGESTED BY THE MACHINING NAVAGATION FUNCTION

- CUTTING CONDITIONS FOR TOOLS THAT ARE SUGGESTED TO BE USED BY THE

MACHINING NAVAGATION FUNCTION

FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO

THE MACHINE, SERIOUS INJURY OR DEATH.

IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.

S-10
 CENGDB0551E
DOOR INTERLOCK SAFTY SPEC.
Determined by YMW Eng. H.Q. ‘99/9/1
Revised by YMC Prod. Eng. ’99.10.28
MACHINING CENTER
SET UP SWITCH
DOOR MODE
O (OFF) I (ON)
OPEN MANUAL Prohibit to move axis. Limit the rapid override. Max is 12%.
Prohibit to start spindle running. Prohibit to run chip spiral conveyor.
Prohibit to operate manual ATC. Can run spindle JOG.
Prohibit to operate manual Pallet Changer. Can run spindle Orient.
Prohibit to run chip spiral conveyor. Can operate manual ATC.
AUTO Prohibit cycle start. Prohibit cycle start.
Prohibit to run chip spiral conveyor. Prohibit to run chip spiral conveyor.

CLOSE MANUAL Door is always locked. Door lock can be released by pushing “DOOR UNLOCK SW” on operator panel.
I But, it can not release in operating ATC/Pallet changer/Axis/Spindle.
V Prohibit to move axis. Limit the rapid override. Max is 12%.
OPEN Prohibit to start spindle running. Chip spiral conveyor would stop.
Prohibit to operate manual ATC. Can run spindle JOG.
Prohibit to operate manual Pallet Changer. Can run spindle Orient.
Prohibit to run chip spiral conveyor. Can operate manual ATC.
AUTO Door is always locked. Door lock can be released by pushing “DOOR UNLOCK SW” on operator panel.
But, it can not release in auto operation running except single block stop or feed hold stop or M00 program
stop or M01 optional stop and spindle stop. If not, Alarm displayed “Door open invalid”.
If release the lock by note(*1), Alarm will occur Prohibit cycle start.
then stop the all motion. Chip spiral conveyor would stop.
Chip spiral conveyor would stop.

CLOSE MANUAL No Limitation. No Limitation.

AUTO No Limitation. Can not run auto operation.

TURNING CENTER
SET UP SWITCH
DOOR MODE O (OFF) I (ON)
Can operate CHUCK, TAILSLEEVE , Can operate CHUCK, TAILSLEEVE ,
STEADY REST for Loading workpiece. STEADY REST for Loading workpiece.

Can NOT operate Spindle, Axis, Turret, Can not operate Spindle running, but
MANUAL Coolant, ToolEye, Partscatcher, Can operate Spindle JOG and Spindle Orient.
Chip Conveyor. Limitation of speed for axis movement .
(Override is 10% max.)
OPEN
1 step index only for turret.
Can operate CHUCK, TAILSLEEVE , Can operate CHUCK, TAILSLEEVE ,
AUTO STEADY REST for Loading workpiece. STEADY REST for Loading workpiece.
Can not run Auto-operation. Can not run Auto-operation.
CLOSE MANUAL Can not open the front door in Spindle running, Axis moving, Auto-running( Cycle start, Feed hold ) due to
-> & Mechanical locking system. (Except Single Block Stop or M00 program stop or M01 optional stop)
OPEN AUTO But, if release the lock by note(*1), Alarm will occur then stop the all motion.
MANUAL No Limitation. No Limitation.
CLOSE AUTO No Limitation. Can not run Auto-operation.

*1 : Door lock mechanism can not be released in machine stop by NC power OFF.
If it is necessary to release the lock such as emergencies, the lock can be released by operating the
supplementary lock release mechanism of the main body of the safety door lock switch.
*2 : Override Limitation of Rapid speed of AXIS
Machining Center : 12%. Turning Center : 10%.
*3 : Chip Conveyor and Coolant should stop in the door open.

PED-EDS-001 S-11
 CENGDB0551E

APPENDIX

SWITCH PANEL for M640M (Machining Center)

DOOR UNLOCK
MACHINE SET UP
SWITCH
SWITCH

SWITCH PANEL for M640MT/T (Turning Center)

PED-EDS-001 S-12
1 INTEGREX-100~400MkIII MANUAL ATC OPERATION

Set the B-axis at zero degrees.

Press the “POSITION” menu key.
Press the “C-AX Connect” menu key with the “MFI” auxiliary key.
Place the “TOOL SELECT” switch to “F/H/0” and press.

Note: If a “256 TOOL ROTATION INHIBIT” alarm occurs, place the TOOL SELECT switch to

R/V/2 and press.

Press the “HOME” key and move the axes to home position as shown below:
Move X-axis to home position.
Move Y-axis to home position.
Move Z-axis to home position.

1-1
 Press the MDI key.
The MDI window will open:

Key in: M601S__ (where S__ is the desired tool number) to index the tool magazine to the

desired tool number.

Press the “MACHINE” key to display the ATC menu screen.

Turn MDI off by pressing any manual operation key.

Press the “ATC MAINTE.” menu key.

Press the “TOOL LOAD” menu key.

1-2
Verify that that the “MILL 0 ORIENT” key is highlighted.

If it is not, press the “MILLAXIS UNCLAMP” key, then the “MILL 0 ORIENT” key to orient the mill
spindle. Next press the “MILLAXIS CLAMP” key to re-clamp the mill spindle.

Press the “AXIS ATC POS” key to position the Y axis to the ATC position.

Press the “Display Select” Menu soft key (Left end of menu keys).

Press the “ATC MENU” key.

1-3
Verify that the shifter is at the ATC side. Move to the ATC side if currently at the Magazine side.

Press the “Menu Select” soft key (Right end of menu keys.)

Press the “ATC ARM SWING” menu key.

Turn the TOOL CLAMP/UNCLAMP key switch to the UNCLAMP position

1-4
Press the “ATC ARM CHG POS” key.

Turn the TOOL CLAMP/UNCLAMP key switch to CLAMP.

Press the “ATC ARM HOME POS” key.

1-5
Press the HOME key.

Move the Y-axis to the home position.

Press MDI menu key.

The MDI window will open:

Key in M602 S___ (Where “S___” is the proper next tool number.)

Key in M601 S___ (Where “S___” is the proper magazine position.)

1-6
Press the “Menu Select” menu soft key (Left end of menu keys).

Press the “ATC MAINTE” menu key.

Press the “TOOL UNLOAD” menu key.

1-7
Updating The Current Tool In the Turret Pocket

When the tool has been replaced by the ATC unit manually, set the number of the tool being mounted
on the turret on the TURRET TOOL window of the DIAGNOSTIC display.

When TNo 5 is mounted as shown above, perform operation following the procedure described below:

(1) Open the TURRET TOOL window and move the cursor to the first line of Tno. using the cursor keys

1-8
Press the MDI key.

-The MDI window will open on the monitor.

Input MDI data: M65 (ATC TOOL No. MEMORY CLEAR)

Do a tool change. (Eg: T01000.0001)

If you get an alarm, “Tool Number Mismatch” you forgot the M65.

NOTE: If you get a “Not in ATC Position” alarm, make sure the shifter is at the magazine side and
issue a M602S0, this will set the “Next Tool” display to zero.

1-9
Notes:

1-10
2 UPPER TURRET ALIGNMENT

1.Turret adjustment

Mount a test bar to the mill spindle.

2. Measure parallelism between X-axis and the turret.

Tolerance: 0.01mm (0.0004 in.) or less per L=100mm (4 in.)

3. If the turret is off center, mount a test bar as shown in the photo
and loosen all six turret mounting bolts.

(The photo shows the turret in H direction, but it will be easier to

do this with the turret in V direction.)

2-1
 4. Place the turret in V direction, loosen all six mounting bolts,
and fit an indicator to a side face of a test bar. While tapping a
turret box (arrow) with a soft hammer, adjust parallelism between
the X-axis and the turret so that it will be within tolerance. Some
old machines used a taper pin, but current machines do not (as of
November 2000).

5. Tolerance: 0.01mm (0.0004 in.) or less per L=100mm (4 in.)

After the turret mounting bolts are tightened, measure parallelism
between X-axis and the turret again.

2-2
Note:

The INTEGREX-100MKIII series only uses a set

screw for adjustment.
It will not move even if it is tapped with a soft
hammer.

Adjust by pushing or pulling a set screw (2 places,

arrow) in the two photos.

2-3
Notes:

2-4
3 LOWER TURRET ALIGNMENT
Note:

The concentric adjustment between the main & 2nd spindles must be completed before starting this adjustment.

1. Rotational Alignment

Select the turret No. 2 and place it toward the secondary

spindle. Then mount a magnet stand to the upper turret.

Mount a dial indicator as shown to measure parallelism

of the grooves for installing a boring bar holder.

Loosen the eight bolts for mounting a turret coupling.

Using a plastic hammer, tap the turret in a

rotational direction for parallel adjustment of the grooves
for a boring bar holder.

<Tolerance>
L = 5/1000 mm or less per 40 mm
(L = 0.0002 inch or less per 1.575 inch)

When the adjustment is completed, tighten the eight

turret coupling mounting bolts that have been loosened
before, and check the parallelism again.

3-1
2. Lower Turret Alignment

Mount a boring bar holder to the turret No. 2

and measure the center of the main spindle
and that of the lower turret.

Align the centers so that a runout (up/down)

becomes "0" in the X direction.

Also, find a place where a runout (right/left)

is the minimum in the Y direction.

Measure a difference between the center of the main

spindle and that of the secondary spindle.

With the X2-axis stationary, move the boring bar holder

toward the secondary spindle side and measure a
difference between the center of the secondary spindle
and that of the lower turret.

Take out a shim (indicated by a red arrow) from the

carriage base of the lower turret. Grind the shim so that the
turrets of the main and secondary spindles will be in a
range of tolerance in the X and Y directions.

<Tolerance>

Measure at the main spindle and at the secondary spindle. Tolerance must be 2/100 mm (0.0008inch) or less.

3-2
3. Parallel adjustment of the lower turret

Mount a millimess indicator to the upper surface of the

turret and measure parallelism by moving the Z2-axis.

Loosen the lower turret & linear guide mounting bolts

(M8 x 30) and check parallelism on the upper surface of
the turret using the adjusting bolts (M6 x 20) indicated by
a red arrow.

Tolerance: 5/1000 mm (0.0002inch) or less

Refer to the illustration below (the right photo is not good
for viewing).

3-3
4. Final alignment & checking

There are four adjusting bolts only at the main spindle side.

3-4
4 FIRST & SECOND SPINDLE ALIGNMENT

4.1 Outline of the 1st Spindle & 2nd Spindle

1st spindle (standard specifications): 22kw/350N.m and dia. 76 bore in 0.0001-deg. C-axis encoder

2nd spindle (standard specifications): 18.5kw/326N.m and dia. 76 bore in 0.001-deg. PLG encoder Secondary
spindle (optional specifications): 18.5kw/326N.m and dia. 76 bore in 0.0001-deg. C-axis encoder.

4.2 Alignment of the First Spindle

1. Check the current vertical alignment (spindle centerline parallelism to Z1 axis movement)

Mount a test bar to the 1st spindle and mount a millimess indicator on the test bar as shown below.

Note: The indicator is mounted on the top of test bar for this measurement.

4-1
2. Center height adjustment of the first spindle.

Lift the 1st. spindle using a crane, and remove the shims
(4 places) to grind.

Note:

Viewed from the chuck cylinder side and at the left side
of the 1st spindle.

The positioning pin (indicated by a red arrow) is located

between the spindle mounting bolts. Remove the pin
using an M6 pin puller and lift the spindle. After the shims
are ground, remember to put the positioning pin back.

Re-install the shims and hand-tighten the 1st spindle

mounting bolts. Re-check the spindle centerline
parallelism to Z axis movement.

<Tolerance>

L = 300 mm (11.811 inch)

A = 1/100 mm (0.0004 inch) or less
B = 5/1000 mm (0.0002 inch) or less.

4-2
3. Check the current horizontal alignment (spindle centerline parallelism to Z1 axis movement)

Mount a test bar in the 1st spindle and a millimess dial indicator to the side of the test bar as shown.

Note: The indicator is on the back of test bar for this measurement.

4-3
4. Center horizontal adjustment of 1st spindle.

Adjust the parallelism in the horizontal direction using

the adjusting bolts on the block indicated by the red
arrow.

The adjusting bolt A is a pull bolt while adjusting bolt B is

a push bolt.

<Tolerance>

L = 300 mm (11.811 inch) A = 1/100 mm (0.0004 inch) or less B = 5/1000 mm (0.0002 inch) or less
Tighten the 1st. spindle mounting bolts firmly and check parallelism both in the height direction and in the
horizontal direction again.

5. Center horizontal adjustment of the 1st spindle

Put a workpiece in the chuck for a test cut. Using a micrometer, measure the outer diameter at each end to check
for taper. Re-adjust as shown above to remove any taper.

<Tolerance>
0.0003 inch or less

Note:

Adjust in the following order:

X & Yt axis home position
X & Yt ATC position
Tool Eye parameter adjustment
Tailstock alignment or concentricity adjustment between the first & second spindle

4-4
4.3 Concentricity Adjustment Between the First and Second Spindle

NOTE: Make this adjustment after the 1st. spindle alignment is completed.

1. Check the current alignments

Mount a jig with reference to the 1st spindle, and

measure the outer diameter of the 2nd spindle to check
whether any variance exists.

Mount a test bar to the 2nd spindle and a millimess dial

indicator to the test bar to check the parallelism in the
height direction.

4-5
2. Center height adjustment of 2nd spindle

Based on the data obtained in step 1, remove the shims

for grinding. Loosen the mounting bolts (6 places) on the
2nd spindle.

Lift the 2nd spindle using a crane, and remove the shims
(4 places) to grind.

Re-install the shims that have been ground and

hand-tighten the mounting bolts on the 2nd spindle.
Re-check the parallelism in the height direction.

<Tolerance>

L = 300 mm (11.811 inch)

A = 1/100 mm (0.0004 inch) or less
B = 5/1000 mm (0.0002 inch) or less concentricity adjustment between the 1st & 2nd spindle
Make this adjustment after the 1st. spindle alignment is completed.

4-6
3. Concentricity adjustment between the 1st & 2nd spindle

Note: Make this adjustment after the1st spindle alignment has been completed.

Touch the dial indicator (A) attached to the 1st spindle to

the side of the test bar mounted to the 2nd spindle.

Touch the millimess dial indicator (B) attached to the

upper turret to the other side of the test bar.

Unlike the 1st spindle, the 2nd spindle does not have a
positioning pin. Therefore, adjust both spindles by using
the two measuring instruments as described above.

To fit the1st spindle, adjust the 2nd spindle in the right/left

direction using the adjusting bolts on the adjusting blocks
(2 places) indicated by a red arrow.

Tolerance = 1/100 mm (0.0004 inch) or less

4-7
3. Concentricity Adjustment Between the 1st. & 2nd. Spindle (Cont’d)

Note: Make this adjustment after the 1st spindle alignment has been completed.

Touch the dial indicator (A) attached to the 1st spindle to

the upper surface of the test bar mounted to the 2nd
spindle.

Touch the millimess dial indicator (B) attached to the

upper turret to the side face of the test bar, then tighten
the mounting bolts on the 2nd spindle.

Tighten the bolts little by little while checking the dial

indicator (A) and the millimess dial indicator (B).

4. Checking concentricity after adjustment.

Remove the test bar from the 2nd spindle and measure
the outer diameter as shown.

<Tolerance>

Tolerance = 1/100 mm (0.0004 inch) or less

4-8
5 RENISHAW TOUCH PROBE ADJUSTMENT PROCEDURE

Mount a touch probe to the milling spindle and apply a lever type dial indicator to the tool edge.

While turning the tool, adjust runout at the edge of the tool while rotating the spindle manually.

5-1
Descriptions of touch probe

5-2
5.1 Touch Probe Adjustment Procedure

As shown in the illustration below, the tool shank has four adjusting screws. Unscrew all the lock screws
and make an adjustment with the adjusting screws.

As shown in the picture below, set a lever indicator to the edge of the stylus and tighten or loosen the four adjusting
screws while turning the tool. With the four adjusting screws tightened, the runout of the lever indicator must be
within 0.02 mm (0.0008 in.) or less. After the adjustment is completed, tighten all the lock screws firmly.

5-3
Notes:

5-4
Turret Center of Rotation Adjustment Procedure (Parameter B234)

A
W- Axis Stroke

Reference
workpiece
origin
Turret center of rotation
A8 R
100mm

B234

A = The full W-axis stroke between head 1 & head 2.

To Determine the A value:

a) Move head 2 to head 1.
b) Touch the head 2 chuck face to the head 1 chuck face using a gauge block or feeler gauge
c) Make note of the W axis on the POSITION screen (absolute value).
d) Add this value to the gauge block or feeler gauge dimension to determine variable A.

R = The distance from the turret face to the center of rotation.

(See the adjustment procedure on the following page.)

Parameters:

A8 = The distance from the turret face to the reference workpiece origin.
B234 = The distance from the turret center of rotation to the reference workpiece origin.

Reference workpiece origin = 100mm from the chuck face.

6-1
Turret Center of Rotation Adjustment Procedure (Parameter B234)

1) Determine the turret center of rotation value ( R ).

a) Move the Z1 axis to head 1.

b) Touch the turret face to the chuck face using a gauge block or feeler gauge as shown below.

c) Make note of the Z1 axis on the POSITION screen (absolute value).

d) Add this value to the gauge block or feeler gauge dimension to determine variable B.
e) Repeat steps a ~ d for head 2 as shown below to determine variable C.

f) Add B to C and subtract from the Z1 axis stroke value A to determine the turret rotation diameter.
g) Divide by 2 for value R.

2) Add value R to the value of parameter A8.

3) Enter this value into parameter B234.

Formula:

B234 = A8 + R

R = [ A - (B +C) ] / 2

6-2
7 TOOL EYE CALIBRATION PROCEDURE

7.1 Integrex-100~400ST MkIII Tool Eye Parallelism Adjustment

Parallelism measurement between the tool eye sensors is taken with respect to points A and B as indicated by the
red arrows in the photo below.

It is unnecessary to check parallelism between the sensors between the upper turret and the lower turret.

7-1
1) Upper turret tool eye parallelism adjustment

Attach a magnetic stand with a millimess dial

indicator to the upper turret as shown.

Set the indicator to the outer point A and take a

reading to the lower point A.

Adjust as described in step (3).

2) Lower turret tool eye parallelism adjustment

Attach a magnetic stand with a millimess dial

indicator to the upper turret as shown.

Set the indicator to the outer point B and take a

reading to the lower point B.

Adjust as described in step (3).

3) Loosen the 4 tool eye mounting bolts and adjust

with a wrench as shown.

<Tolerance>

Parallelism must be 1/100mm (0.0004 inch) or

less.

7-2
7.2 Tool Eye Parameters

The upper turret parameters are shown in blue and the lower turret are in red.

Note:

Tool eye parameters must be adjusted whenever a home position confirmation sensor is replaced or accuracy
needs to be assured after a collision.

The address names and adjusting procedure are the same as for earlier Integrex machines.

For parameters B61 & B62, the measured value is entered. For parameter B63, one half of the measured value is
entered.

The input unit is 0.001mm (metric only). These parameters become valid immediately after the setting change.

7-3
7.3 Parameter screen selection

The parameter drawing on the previous page shows the same parameter address names for the upper and lower
turrets. Use the [TURRET SELECT] switch as shown below to select the parameter page for the desired turret.

7-4
8 TURRET SIDE ATC POSITION ADJUSTMENT
Using the ATC alignment tools shown below, adjust the tool change position at the turret side and the X-axis and
Yt-axis positions.

Note: Make sure no tools are in the turret or ATC arm.

From the ATC menu, select the “INTERLOCK NEG.” menu key.

CAUTION: Interlocks will be ignored, perform the following operation with extreme care.

Note: Make sure the X-axis and Yt-axis are in a position where no interference occurs before performing
the ATC arm swing-in operation.

Press the “ATC ARM SWING” menu key to swing in the ATC arm
as shown.

Mount the alignment tool B to the arm No. 1 and the alignment tool
C to the mill spindle respectively.

Move the X-axis and Yt-axis close to the ATC arm with the manual
hand wheel, and find a position where alignment tool A passes
through the alignment tools B and C smoothly.

Make note of the machine position value for input into parameter
data.

Remove the alignment tool A, and press the

“ATC ARM HOME POS” menu key to return the arm.

Remove the alignment tools B and C.

From the ATC menu, select the “INTERLOCK NEG.” menu key to
cancel the interlock neglect function.

8-1
Parameter Change

Input the values of the machine position noted above for X-axis and Yt-axis to the following parameters:

RL-16 (tool change position for Yt-axis)

RL-17 (tool change position for X-axis)

Note: Unlike previous M640, the parameter input unit of M640 MT-Pro is changed from 1/1000 to 1/10000.

8-2
9 TOOL FUNCTIONS

9-1 Tool Function (4-Digit T-Code)

Tool function, also referred to as T-code function, is used to designate the tool number and offset
number. Of a four-digit integer at address T, upper and lower two digits are respectively used to
specify the tool number and offset number.
T !!"".△△◇◇ ;

Tool ID code
Application direction
Tool offset number
Tool number
Use two digits after the decimal point to specify the application direction of the tool in accordance
with the registration on the TOOL DATA display.

△△ 0, 2, 4, 6, 8 1, 3, 5, 7, 9 11 13 14 15

DIRECTION ← ↓ → ← ↓ →

Note 1: The directions shown above may not all apply to some machine models.
Note 2: The reverse-display directions refer to a milling spindle orientation of 180 degrees, and
can be used for the application of a turning tool with the tip reversely directed.
In addition to the application direction, the ID code (A to Z) of the tool can also be designated in
accordance with the registration on the TOOL DATA display on condition that the bit 6 of the
parameter P111 is set to 1.

◇◇ 1 2 3 4 5 6 7 8 9 11 12 13
ID code A B C D E F G H J K L M
◇◇ 14 15 16 17 18 19 21 22 23 24 25 26
ID code N P Q R S T U V W X Y Z

Note 3: An alarm will result if no corresponding tool for the specified direction and ID code is
registered on the TOOL DATA display.
Note 4: Depending on the number of the decimal places, the T-code is processed as follows:
1) A designation of a single or two decimal places is always processed as that of the
application direction. It is not possible, therefore, to merely designate the ID code.
2) The T-code with three or five and more decimal places causes an alarm.
← direction without ID code”.
3) The default attribute of the T-code is of “←

Only one T-code can be included in a block, and the available range of T-codes depends on the
machine specifications. For further details, especially on how to number the actual tools to be
used, refer to the operating manual of the relevant machine.
The T-code can be given with any other commands in one block, and the T-code given together
with an axis motion command is executed, depending upon the machine specifications, in one of
the following two timings:
- The T-code is not executed till completion of the motion command, or
- The T-code is executed simultaneously with the motion command.

9-1
9-2 Tool Function (6-Digit T-Code)
This function is also used to designate the tool number and offset number. Of a six-digit integer
at address T, upper and lower three digits are respectively used to specify the tool number and
offset number. See the above description of the 4-digit T-code for the meaning of the decimal
fractions.
The available range of T-codes depends on the machine specifications. For further details, refer
to the operating manual of the relevant machine.
Only one T-code can be included in a block.
T !!!""".△△◇◇ ;

Tool ID code
Application direction
Tool offset number
Tool number
Set bit 4 of parameter P10 to “0” or “1” respectively to use 4-digit or 6-digit T-codes.

9-3 Next Tool Automatic Selection

You can designate return tool and a next tool for the machine provided with ATC function by
commanding T-code in the format shown below. The return tool refers to an unnecessary tool
returned to load another tool to be used. The assigned return tool is accomodated in the
magazine. The next tool refers to a tool used for the next machining, which can be assigned
when it is now accomodated in the magazine. The next tool in the magazine can be indexed at
ATC position beforehand by commanding the next tool, thus permitting reduced ATC time.
See Section 11-1 for the details of the application direction and ID code.
T !!!""".△△◇◇ A∗∗∗ B∗∗∗ ;

Next tool
Return tool
Tool ID code
Application direction

9-2
10 EIA/ISO PROGRAMMING EXAMPLE

10-1
O00000001 (Integrex-200S Programming Example)

#500=30. (SUB SHIFT )

N1(Edge Face)
G53 (T32 MODE)
M202
G28 U0 Y0
T0101.9 B2
G96 S250 M03
M08
G00 Z.1
G00 X10.
G00 X3.1 Z0
G99
G01 X-.0625 F.005
G00 Z.08 X2.6 Z.05
G01 Z-.995 X3.1
G00 X3.2 Z.05 X2.2
G01 Z-.995 X2.6
G00 Z.05 X1.8575
G01 X1.9017 Z-.0092 X2.04 Z-.0783 Z-.995 X2.2
G00 Z.0474 X1.7486
G01 X1.8617 Z-.0092 X2. Z-.0783 Z-1. X2.9375 X3.0975
G28 U0 Y0 M05

N2(Mill Hex on Face HD1)

G53
M302 M201
T0202.8 B3
G97 S2000 M203
G28 U0 Y0
M212
G0 C0
M211
G98 G00 Z1.
G17 UV
G12.1
G00 X1.6495 Y-.375 M08
Z.1
Z-1. F20.
G41 G01 X1. Y0
X.5 Y-.866
X-.5
X-1. Y0
X-.5 Y.866
X.5
X1. Y0
Z1. F100.
G40 X1.6495 Y.375
G13.1
M212
G28 U0
M302 M201
T0202.8 B3
G97 S2000 M203
G28 U0 Y0
M212 G0 C0
10-2
M211
M153
M250
B45.
M251
G125 X1. Y0 Z-1. R1
G17 UV
G00 Z.5
X0 Y1.616
G01 Z0 F20.
G41 G01 X1. Y.866 F10.
Y-.866
G40 Y-1.616 F10.
G0 Z.5
M212
M205
G69.5

N3(Drill 1/8" hole 45 degree Face)

G53
M302 M201
T0303.8 B11
G97 S2000 M203
G28 U0 Y0
M212
G0 C0
M211
M153
M250
B45.
M251
G125 X1. Y0 Z-1. R1 S#500
G17 UV
G98 G00 X.25 Y.3 M08
Z.1
G83 Z-.25 F2.
Y0
Y-.3
Z1. M09
G80
G69.5
M212
M154
G28 U0
T0303.8

10-3
N4 ( TRANSFER )
G28 U0 Y0
M202
M05 M305 G110
Z2 M306 G00 Z-#500 ( TRANSFER POSITION )
M544
M508 G98
G31 W-.1 F20.
M307
M06
G28 W0
G111
M545
M509 G50 W-#500 ( SUB SHIFT )
M300

N5(Edge Face HD2)

G53
G28 U0 Y0
G50 S3000
T1111.9 B12
G96 S250 M03
M08
G50 W-#500 (SUB SHIFT )
G00 Z.1
G00 X10.
G00 X3.1 Z-.9325
G99 Z-4.
G01 X-.0625 F.005
G00 Z-4.08
(Rough OD turn HD2)
X2.6 Z-4.05
G01 Z-3.005
X3.1
G00 X3.2
Z-4.05
X2.2
G01 Z-3.005
X2.6
G00 Z-4.05
X1.8575
G01 X1.9017 Z-3.9908
X2.0017 Z-3.9408
X2.04 Z-3.9217
Z-3.005
X2.2
(Finish OD Turn HD2)
G00 X3.1
Z-4.0474
X1.7486
G01 X1.8617 Z-3.9908
X2. Z-3.9217
Z-3.
X2.9375
X3.0975
G69.5
G28 U0 Y0 M05

10-4
N6(Mill 45 degree Face)
G53
M300 M201
G112 M19 S0
T1212.8 B13
G97 G112 S2000 M203
M212
G0 C0
M211
G28 U0 Y0
M153
M250
G00 B135.
M251
G125 X1. Y0 Z-3. R1 S#500
G98 G00
Z1.
G17 UV
G00 X0 Y-1.616 M08
Z.5
Z0 F20.
G01 G41 Y-.866 F10.
Y.866
Y1.616 F10.
G40
G00 Z.5
M205 M212
G69.5
M154

N7(Drill 1/8" hole 45 degree Face HD2)

G53
M302 M201
T1313.8 B1
G97 S2000 M203
G28 U0 Y0
M212
G0 C0
M211
M250
B135.
M251
G125 X1. Y0 Z0 R1 S#500
G17 UV
G00 Z.1
G98 G00 X-.25 Y.3 M08
G83 Z-1. F2.
Y0
T-.3
G0 Z5. M09
M205 M212
G80
G69.5
G28 U0 Y0
M30

10-5
Notes:

10-6
11 COORDINATE SYSTEM SETTING

11.1 G125 Coordinate System Setting Macro

Program position coordinate system rotation

1. Outline

This command is used to determine a new coordinate system through the translation of the origin of the currently
active workpiece coordinate system and the rotation on an axis of coordinate. Use this command to specify freely
a plane in space which is convenient for programming.

2. Programming format

G125 Xx 0 Zz0 Yy0 Rr Ss ; Program coordinate system rotation ON

G69.5 ; Program coordinate system rotation OFF

Xx0 Zz0 Yy0 : Coordinates of the center of rotation

Specify in absolute dimensions the translation of the workpiece origin.

Rr : Designation of plane rotation (1: valid, 0: invalid)

After the selection of the G17 (X-Y) plane, the workpiece origin is shifted to the point
(X, Z, Y) = (1, –2, 0) and the plane is rotated by 30 degrees on the Y’-axis. The new coordinate system (X’, Y’, Z’)
has thus been established. The sub spindle shift is zero.

-The cancel command G69.5 will set again the coordinate system subjected to the translation and rotation by the
preceding G125 command.

-In the G125 mode all the dimensions must be entered in radius values.

11-1
3. G125 Macro Program Example

O00000001 (sample 1)

N1(Mill Slot)
G53 ( T32 MODE )
M201
T0101.8 B2
G97 S2000 M203
G28 U0
M250
G00 B30.
M251
G17
G125 X2.5 Y0 Z-2. R1 S0.
G98 G00 C0
Z1.
G0 X4. Y0M08
Z.1
M211
G01 Z-.25 F20.
X-4. F10.
M212
G00 Z1.0
M205
G69.5
G28 U0Y0

11-2
G125 Macro Program Example (Cont’d)

N2(Drill .5" hole Solid Carbide)

G53 ( T32 MODE )
M201
T0202.8 B1
G97 S2000 M203
G28 U0 Y0
M250
B30.
M251
G17 G125 X2.5 Y0 Z-2. R1 S0.
G98 G00 X2. C0 M08
M211
Z1.0
Y-1.0
G01 Z.1 F20.
G01 Z-1. F7.5
G01 Z.1 F400.
G00 Y1.0
G01 Z-1. F7.5
G01 Z.1 F400.
M212
M09
M205
G69.5
G28 U0 Y0
M30

11-3
11.2 G128.8 Coordinate System Setting Macro

G128.8 Program position coordinate system rotation (G43.4 Supported)

1. Outline

This command is used to determine a new coordinate system through the translation of the origin of the currently
active workpiece coordinate system and the rotation on an axis of coordinate. Use this command to specify freely
a plane in space which is convenient for programming.

2. Programming format

G128 Ee Xx 0 Zz0 Yy0 Rr Ss Qq; Program coordinate system rotation ON

(If Xx. Yy or Zz omitted “0” is the default)

Xx0 Zz0 Yy0 : Coordinates of the center of rotation

Designation of plane rotation (1; valid, 0: invalid)

Rr : Designation of plane rotation (1: valid, 0: invalid)

Ss; Designation of Z2 axis shifter for transfer of HD2 (amount Z2 moved)

Q** Calculating point

0: Tip of tool
1.0: Center of ball nose (for mold machining)
2.0: Center of turret (for B axis contouring)

(Data Q is not necessary to command if choosing tip of tool for calculating point)

11-4
G128.8 Program position coordinate system rotation (Cont’d)

1) Y axis must be at home position before commanding the macro program.

2) B axis must be positioned to programming point before commanding the macro program.
3) X and Z axis do not require home position return before commanding the macro program.
4) Workpiece coordinate created by this macro program will be canceled by G53.5 or next tool change.
5) The following data is required in the TOOL DATA and SET UP SCREEN:

(TOOL DATA SCREEN) (SET UP SCREEN)

Tool Name Z Offset
Actual Tool Diameter
Tool Set X
Tool Set Z

6) Make sure parameters B234 and B263 are set properly.

11-5
Notes:

11-6
INTEGREX-100~400MkIII PLC ALARM LISTS

! As shown below, the alarm message in the DIAGNOSIS display varies between models
INTEGREX 300/400-III/IIIT and INTEGREX 300/400-IIIS/IIIST.

CAUTION

D135W0049E’
1. INTEGREX 300/400-III
Neither SP1 nor SP2 is displayed on the display.
2. INTEGREX 300/400-IIIS/IIIST
SP1 or SP2 is displayed on the display. The alarm message related to the secondary
spindle or W-axis is displayed with SP2.
Example: 250 SPINDLE START MISOPERATION ( , , )SP1
An alarm message related to the main spindle. SP1 is replaced with SP2 for an
alarm of the same message but related to the secondary spindle.
3. INTEGREX 300/400-IIIT
TR1 or TR2 is displayed on the display. The alarm message related to the lower turret is
displayed with TR2. (Only SP1/SP2 is used for IIIST.)
Example: 256 TURRET ROTATION PROHIBITED ( , , )TR1
An alarm message related to the upper turret (milling head). TR1 is replaced
with TR2 for an alarm of the same message but related to the lower turret.
Remark: Alarms shown in Section 2-1 “Alarm List for the INTEGREX 300/400-
III/IIIT/IIIS/IIIST” are all displayed with “SP1” in the INTEGREX 300/400-IIIS.

H374S5B012E APP-1
 II
Alarm List for the INTEGREX 300/400-II

Alarm No. and message Description Check and remedy Address

200: THERMAL TRIP Thermal relay for the hydraulic unit has Check that the hydraulic unit motor is X2
(EMERGENCY STOP) tripped. normal, and then turn the power off and on.
201: BREAKER TRIP Power line on/off circuit breaker QF2, QP3, Check the circuit breakers within the control X3 X4
QF4, QF81, or QF82 has tripped. panel and then reset the circuit breaker that
has tripped.
202: HYDRAULIC An oil pressure decrease below the Check the hydraulic unit and piping for X447
PRESSURE DOWN required level has activated the pressure abnormalities.
switch.
203: AIR PRESSURE An air pressure decrease below the Check the air supply port and piping for X446
DOWN required level has activated the pressure abnormalities.
switch SP30.
204: SPINDLE An alarm occurred at spindle controller. Turn off the main circuit breaker and then
CONTROLLER turn it back on.
―
MALFUNCTION If the alarm is not released, please contact
your MAZAK service representative.
205: MILLING An alarm occurred at milling spindle Turn off the main circuit breaker and then
CONTROLLER controller. turn it back on.
―
MALFUNCTION If the alarm is not released, please contact
your MAZAK service representative.
206: OPEN FRONT DOOR Coolant cover (front door) is opened during Close the coolant cover (front door) and XA
(EMERGENCY automatic operation. start the machine in automatic operation
STOP) mode.
211: NOT OPERATED M- M-codes which must not be used in Correct the program.
CODE SIMULTA. combination were selected at the same ―
time.
212: CHUCK The signal from the chuck open/close foot Fault in the chuck open/close foot switch X44E
OPEN/CLOSE switch has been input during chuck circuit (X44F)
SWITCH MALF. open/close command (M6, M7) in the
automatic operation.
213: ILLEGAL T code that does not exist in the Correct the program.
DESIGNATED TOOL specification is assigned. ―
No.
215: CHUCK SYSTEM An erroneous chucking action was detected The chuck unit has failed to grip the
―
MALFUNCTION during chucking operation. material.
The chuck open/close end sensor X440/
(SQ2/SQ3) is abnormal or faulty. X441
218: CHUCKING TYPE Type of chucking (inner/outer) of spindle Select the type of chucking.
―
NOT SELECTED chuck is not selected.
220: TURRET POSITION The milling head positioning /B-axis sensor The milling head positioning /B-axis sensor
SENSOR MALF. (encoder) signal has become invalid. (encoder) is in trouble.
The milling head index /B-axis motor is Turn off the main circuit breaker and then ―
malfunctioning. turn it back on.
If the alarm is not released, please contact
your MAZAK service representative.
221: TURRET CLAMP In spite of the fact that the milling head is The clamping confirmation sensor is X460
SENSOR actually clamped, the clamping confirmation abnormal or faulty.
MALFUNCTION sensor (SQ18) does not turn on.
In spite of the fact that the milling head is
actually unclamped, the clamping
confirmation sensor (SQ18) does not turn
off.
224: CHUCK SENSOR The chuck open or close confirmation The chuck open or close confirmation X440/
MALFUNCTION sensor fails in function, or both of the sensor (SQ2/SQ3) is abnormal or faulty. X441
sensors are ON simultaneously.

APP-2
 Alarm No. and message Description Check and remedy Address
225: FRONT DOOR For the machine with an optional automatic The front door open or close confirmation X14/
SENSOR door, the front door open or close sensor (SQ2/SQ3) is abnormal or faulty. XA
MALFUNCTION confirmation sensor fails in function, or both
of the sensors are ON simultaneously.
231: TOOL EYE The TOOL EYE extension or retraction The TOOL EYE arm is likely to be
―
POSITION SENSOR confirmation sensor (SQ7/SQ8) does not obstructed in the middle of its operation.
MALF. turn on, or both of the sensors are ON
Or the corresponding sensor is faulty. X444/
simultaneously.
X445
234: TOOL CLAMP The tool clamp check sensor fails to Adjust the setting of the TIM12 timer.
SENSOR function. ―
MALFUNCTION
236: PARTS-CATCHER For the machine with an optional automatic The parts catcher advance/retract end
SENSOR MALF. parts catcher, the advance end confirmation confirmation sensors are faulty or
sensor or retract end confirmation sensor malfunctioning. ―
does not turn on, or both of the sensors are
ON simultaneously.
243: MEASURING An error occurred at the workpiece Check the cause of error at the workpiece
CONTROLLER measurement controller (option). measurement controller. ―
MALF.
245: BAR-FEEDER An error occurred at the bar feeder Check the cause of error at the bar feeder
CONTROLLER controller. controller. ―
MALF.
248: EXTERNAL Failure of controller of a peripheral unit Check the cause of error at the controller of
CONTROLLER (No.1) (option) a peripheral unit (option). ―
MALF.
250: SPINDLE START 1. A spindle rotation command was given 1. Close the chuck and start operation X440/
MISOPERATION during mis-chucking. (Chuck sensor with the workpiece gripped. X441
provided.) Alternatively, the chuck open/close
check sensor may be improperly
adjusted.
→ Check the sensor.
2. A spindle rotation command was given 2. After closing the chuck using the chuck
even though the chuck was not closed. clamp command, designate the spindle
rotation command.
3. A spindle rotation command was given 3. Take steps so that the commands are
together with an orient command. not given together. ―
4. The M3, M4, M16, M17, M18 or M19 4. 1) Program error → Correct the
command was given in the milling mode. program.
2) Switch to the turning mode and
then designate the command.
5. A spindle rotation command was given 5. Retract the TOOL EYE. Also, check the X445
without the TOOL EYE at the backward backward end sensor.
end.
6. A spindle rotation command was given 6. Close the door and start the spindle X15
with the door not closed when the door rotation. XA
interlock switch was set to AUTO.
7. Alarm 297 CHUCK PRESSURE DOWN 7. Clear the alarm 297 or 296. X442
or 296 TAIL SLEEVE PRESSURE X443
DOWN is displayed. X480

APP-3
 Alarm No. and message Description
251: MILLING MOTOR 1. A milling spindle rotation command was
ROTATION PROHIB. given even though the chuck was not
closed.
2. A milling spindle rotation command was
given even though the milling tool was
not clamped.
3. A milling spindle rotation command was
given even though the milling head (B-
axis) was not clamped.
4. The M203, M204 or M219 command
was given in the turning mode.
5. A milling spindle rotation command was
given with the door not closed when the
door interlock switch was set to AUTO.
[When the door interlock option is
provided.]
6. Alarm 297 CHUCK PRESSURE DOWN
or 296 TAIL SLEEVE PRESSURE
DOWN is displayed.
7. The touch sensor for workpiece
measurement is mounted on the milling
head.
8. The milling tool rotation command is
given though the TOOL EYE is not
placed at the backward end.
252: AXIS MOVE An attempt was made to execute an axis
MISOPERATION movement under the axis movement
interdiction.
1. An attempt was made to execute an axis
movement with the magazine cover
opened.
2. An attempt was made to execute a
movement along the X-axis with the X-
axis interlock activated.
APP-4
Check and remedy Address
1. After closing the chuck using the chuck
clamp command, designate the milling
spindle rotation command.
―
2. After clamping the milling tool,
designate the milling spindle rotation
command.
3. After clamping the milling head (B- X460
axis), designate the milling spindle
rotation command and check the
milling head clamp sensor.
4. 1) Program error → Correct the
program.
―
2) Switch to the milling mode and
then designate the command.
5. Close the door and start the milling X15
spindle rotation. XA
6. Clear the alarm 297 or 296. X442
X443
X480
7. Change the touch sensor for a rotating
tool in the MDI or automatic mode. ―
8. Retract the TOOL EYE. Also check the X445
backward end sensor.
1. First close the magazine cover and XD
then execute the axis movement.
2. X-axis interlock is activated in the
following states:
1) When the milling head is not
clamped.
2) When the tool is not clamped. X460
3) When the milling head is not
positioned at the indexing position.
4) When the arm is positioned
somewhere between the stand-by
position and the swinging-in
position.
XD
5) When the magazine cover is
opened.
Note:
When states 1) to 5) occur, an axis
movement can be executed by the
manual pulse handle and the [ATC
MENU] → [INTERLOCK NEG.] menu
key operation. (Refer to PART 2.)
6) When the steady rest is connected.
7) When the tailstock body is
connected.
 Alarm No. and message Description
252: AXIS MOVE 3. An attempt was made to execute a
MISOPERATION movement along the Z-axis with the Z-
axis interlock activated.
4. An attempt was made to execute a C-
axis movement with the C-axis interlock
activated.
253: OVERLOAD An overload has been detected in a
DETECTION machine having an overload detection
option.
256: TURRET ROTATION This alarm display lights when an attempt
PROHIBITED has been made to turn the milling head or
when the conditions were unstable.
1. When the arm is at the milling head side
or at a swinging-in position between
stand-by and the milling head side.
In the automatic/manual mode:
2. The turning tool or milling tool has been
unclamped.
257: ILLEGAL M-CODE An illegal M code has been specified.
258: TNo. MISMATCH Since ATC has been aborted by pressing
the emergency stop button in the middle of
the ATC process, the number of the tool
mounted on the milling head is different
from that displayed on the NC display.
259: MODE CHANGE The rapid feed mode or zero point return
IMPOSSIBLE mode switch on the operating panel has
been pressed during tool nose
measurement with the TOOL EYE.
260: SLIDEWAY The pressure switch for slideway lubrication
LUBRICATION (SP67) does not turn on within a fixed time.
ALARM
261: HEAD LUBRICATION The pressure switch (SP25, SP26, SP27) in
ALARM the spindle cooling unit has worked.
264: THERMAL TRIP Thermal relay F13 for the coolant motor has
(SINGLE BLOCK) tripped.
Thermal relay F14 for the chip conveyor
has tripped.
267: BALL SCREW The pressure switch (SP7) for ball screw
LUBRICATION and C-axis gear lubrication does not turn on
ALARM or off within a fixed time.
The float switch (SL1) has turned off.
270: SPINDLE ORIENT Although a spindle orientation command is
EXCEED TIME given, the orientation confirmation signal
does not turn on within a predetermined
time.
272: TURRET INDEX Although a milling head indexing command
EXCEED TIME is given, the index confirmation signal does
not turn on within a predetermined time.
APP-5
Check and remedy Address
3. Z-axis interlock is activated in the
following states:
1) Same as states 1) to 7) for the
X-axis interlock.
Note: An axis movement can be ―
executed by the manual pulse
handle and the [ATC MENU] →
[INTERLOCK NEG.] menu key
operation. (Refer to PART 2.)
4. C-axis interlock is activated in the
following states: When the C-axis is ―
clamped.
Check the overload detection level.
Reduce the cutting load.
―
― ―
1. Set the arm to the stand-by position by
using the ATC menu. (Refer to PART ―
2.)
2. Clamp the tool using the clamp switch. ―
Correct the program. ―
Change the “TURRET TOOL” number
displayed in the DIAGNOSIS display to the
number of the current tool (that is, the ―
parenthesized numerals in alarm
messages).
The rapid feed or zero point return mode
cannot be selected during tool nose
―
measurement.
Check the lubricating grease amount, and X465
replenish grease if required.
Check the coolant level. X485
Check the regarding unit (e.g. chip X5
conveyor for clogging with chips) and then
reset the thermal relay. X6
Check the lubrication oil level, and X44C
replenish lubricating oil if required.
X44D
The spindle motor detector/controller is
abnormal.
―
The milling head index motor
detector/controller is abnormal. ―
 Alarm No. and message Description Check and remedy Address
275: ROBOT SERVICE For machines with an optional robot, The robot is malfunctioning (check the
EXCEED TIME although a robot service command is given, robot controller to examine the cause).
―
the confirmation signal does not turn on
within a predetermined time.
276: ATC CYCLE Although 120 seconds have passed since Reset the ATC unit using either of the
EXCEED TIME the issuance of the ATC command, the following methods:
operation complete signal does not turn on. (1) Cancel the ATC command by pressing
the emergency stop button.
(2) Release the emergency stop status by
pressing the RESET key. ―
(3) Execute the ATC reset function of the
machine menu.
If the ATC unit cannot be reset, please
contact your MAZAK service
representative.
279: PARTS CATCHER For the machine with an optional automatic The parts catcher advance/retract end
CYCLE EXCEED parts catcher, although a parts catcher confirmation sensor are faulty or
TIME advance/retract command is given, the malfunctioning.
―
advance end confirmation sensor or retract
end confirmation sensor does not turn on
within a predetermined time.
282: CHUCK CLAMP Although a chuck open/close command is Adjust the chuck open/close end sensor. X440/
EXCEED TIME given, the confirmation signal does not turn Or the sensor is in trouble. X441
on within a predetermined time.
The hydraulic system is abnormal. ―
286: FRONT DOOR For machines with an optional automatic Adjust the front door open/close end
EXCEED TIME door, although a door open/close command sensor. ―
is given, the confirmation signal does not Or the sensor is in trouble.
turn on within a predetermined time. The pneumatic system is abnormal. ―
292: SENSOR The correction value has exceeded the limit Check that the thermal sensor is correctly R1, R2,
MALFUNCTION No. 3 set in the thermal displacement wiring. R3
compensation.
293: SENSOR The correction value has changed largely Check that the thermal sensor is correctly R1, R2,
MALFUNCTION No. 4 than the previous one in the thermal wiring. R3
displacement compensation.
297: CHUCK PRESSURE The spindle chuck pressure remains Check the spindle chuck pressure. X442/
DOWN reduced in a machine having a spindle X443
chuck pressure guarantee option.
300: START COND. ERR. The cycle start button was pressed while Close the front cover. XA
(DOOR OPEN) the front cover (front door) was opened.
301: START COND. ERR. The cycle start button was pressed while Clamp the milling head. X460
(TUR UNCLAMP) the milling head was unclamped.
302: START COND. ERR. The cycle start button was pressed while Check the controller of the external unit.
―
(EXT RESET) the external reset signal was ON.
303: START COND. ERR. The start button was pressed while the Check the controller of the external unit.
―
(EXT FEED HOLD) external feed hold signal was ON.
308: C/S ERROR (TOOL The cycle start button has been pressed Retract (restore) the TOOL EYE arm into X445
EYE EXTEND) with the TOOL EYE arm placed in a position.
measurement position.
310: C/S ERROR During the restart of operation after manual Specify the same tool number as that which
(TNo.MISMATCH) interruption, a tool number different from was valid before interruption.
―
that which was valid before interruption has
been specified.
311: C/S ERROR (TAIL The cycle start button has been pressed Place the tail spindle at its zero point or
STOCK QUILL) with the tail spindle not placed at its zero advance end. ―
point or advance end.

APP-6
 Alarm No. and message Description Check and remedy Address
312: C/S ERROR (PT- The cycle start button has been pressed Retract (restore) the parts catcher into the
CATCHER EXTEND) with the parts catcher (workpiece unloader) position. ―
extended.
313: C/S ERROR (C/S A tailstock advance/retract command was Place the tail spindle advance/retract
QUILL COMMAND) given with the tail spindle advance/retract switch at the neutral position.
―
switch (SA2) not placed at the neutral
position.
320: TOOL UNCLAMP A milling head unclamping command has After the milling spindle motor has stopped,
IMP. (M-SP ROT.) been given during rotation of the milling perform the operations described at left. ―
spindle motor.

321: MODE CHANGE Mode changing has been attempted during The operation mode cannot be changed
IMPOSSIBLE the ATC cycle. during ATC. To change the mode, wait until
―
(DURING ATC ATC has been completed.
CYCLE)
322: RAPID MODE IMP. The rapid feed mode was selected without Carry out the zero-point return operation.
(ORIGIN RET UNF) carrying out the zero point return operation ―
after the power supply had been turned on.

324: DIFF. MODE (ORIGIN The automatic operation mode was
RET UNFIN.) selected without carrying out the zero-point
return operation after the power supply had
been turned on.
325: TL. EYE EXT. IMP. A TOOL EYE extend/retract command has
been given with the SET UP switch
remaining set to “O” and the front door
remaining open.
326: T/S QUILL EXT. IMP. The tail spindle has advanced with the
TOOL EYE arm extended.
The tail spindle has advanced/retracted
during the spindle rotation.
The tail spindle has advanced/retracted
during the milling spindle rotation.
327: NOT IN ATC START The condition to perform ATC is not
POSITION appropriate. The details are described at
the left. See D200/D201.
Carry out the zero-point return operation.
―
Change the setting of the SET UP switch to X11C/
“I”. Or close the front door. XA
Retract the TOOL EYE arm. X444
Stop the spindle.
Stop the milling spindle.
90 The machine is under locking
(D201) state. After releasing the
machine lock, press the cycle
start button. The ATC will be
executed.
91 The tailstock is in the connection
(D201) state. After releasing the
connection of the tailstock,
perform the ATC.
97 When the loading tool is ―
(D201) specified in the ATC, the shifter
is not placed at the ATC side.
Move the shifter manually on the
ATC side.
98 The magazine cannot be rotated
(D201) because the specified tool is
different from the loading tool
and the shifter is not placed on
the ATC side. Move the shifter to
the ATC side manually.

APP-7
 Alarm No. and message Description
327: NOT IN ATC START The condition to perform ATC is not
POSITION appropriate. The details are described at
the left. See D200/D201.
329: CHUCKING The inside/outside chucking selection is
SELECTION performed with the chuck not opened.
PROHIBITED The inside/outside chucking selection is
performed when the spindle or milling
spindle is not stopped.
340: CONDITION No.1 In a machine having a warming-up option
MISSING - the warming-up program number is not
registered.
- the front cover (front door) is open.
- The axis had not yet been initialized
when the NC unit was turned off.
341: CONDITION No.2 The M-code command for milling spindle
MISSING through air blowout has been issued during
coolant injection.
361: TAIL ALARM The tailstock amplifier has detected an
overload or too great an error.
The tailstock has moved during spindle
rotation.
365 CARRIER An alarm signal has been sent from the
CONTROLER carrier-use amplifier to the NC unit.
MALFUNCTION
366: SHIFTER An alarm signal has been sent from the
CONTROLER shifter-use amplifier to the NC unit.
MALFUNCTION
374: OPERATING A control (switch) on the operation panel
SWITCH FAULT was ON upon turning-on.
375: MOTOR & SERVO Since the electromagnetic switch OFF
TURNING OFF ERR. command for the motor and servo system
has been issued by activation of the
emergency stop or door interlock function
under CE machine specifications, the
electromagnetic switches did not turn off
within the required time.
376: MAIN POWER When the front door of a CE specifications
TURNING OFF machine was opened with the setup key
MALFUNCTION switch set to “O”, the electromagnetic
switch for spindle power did not turn off
within the required time.
377: COOLANT LEVEL The coolant level in the coolant unit of a
LOW machine of the high-pressure coolant
specifications has decreased.
APP-8
Check and remedy Address
99 The shifter is not placed in the
(D201) magazine side without the
loading tool when commanding
the ATC.
Move the shifter to the magazine
side/retract position manually.
9800 The tool command is given ―
(D200) incorrectly. Perform again.
9900 The ATC arm is not at the
(D200) reference point position. Move
the ATC arm to the reference
point position manually. Then
perform again the ATC.
Open the chuck (and remove the
workpiece.)
Stop the spindle or milling spindle. ―
Register the warming-up program number R18
(1 – 9999) in the MACHINE PARAMETER
display.
Close the front cover (front door). XA
To warm up the machine, return all axes to
their zero points before turning off the NC ―
unit.
Correct the program.
―
If the alarm is not cleared, please contact
your MAZAK service representative.
―
After turning NC power off, turn the main
circuit breaker off and then turn it back on.
―
If the alarm is not cleared, please contact
your MAZAK service representative.
After turning NC power off, turn the main
circuit breaker off and then turn it back on.
―
If the alarm is not cleared, please contact
your MAZAK service representative.
The control is faulty unless it has been
―
inadvertently turned on.
After turning NC power off, turn the main X10
circuit breaker off and then turn it back on.
If the alarm is not cleared, please contact
your MAZAK service representative.
After turning NC power off, turn the main X11
circuit breaker off and then turn it back on.
If the alarm is not cleared, please contact
your MAZAK service representative.
Check the coolant level in the coolant unit X492
and add coolant.
 Alarm No. and message Description
378: HIGH PRESSURE The thermal relays in the coolant unit of a
PUMP THERMAL machine of the high-pressure coolant
TRIP specifications have become tripped.
379: TANK PRESSURE The pressure in the coolant unit tank of a
LOW machine of the high-pressure coolant
specifications has decreased.
381: CONDITION The cycle start button has been pressed in
MISSING (SET UP automatic operation mode with the front
SWITCH) door open and the setup key switch set to
“O”.
For a machine of the front door lock pin
specifications, a manual-starting button has
been pressed with the front door open and
the setup key switch set to “O”.
382: COOLANT SYSTEM An error signal has been sent from the
MALF. coolant unit of a machine of the high-
pressure coolant specifications.
383: ATC ALM: In a machine of the 80/120-tool magazine
CARRIER&SHIFT. specifications, the cycle start command or
POS. MALF. the tool change command was issued when
the carrier and the shifter were not present
at their stand-by positions.
385: START COND. ERR. Under 20- or 40-tool magazine
(Z-AXIS POS.) specifications, executing the machine menu
function for opening the ATC cover has
been attempted with the Z-axis existing in
the minus direction relative to its zero point.
386: ATC STOP When the [ATC STOP] menu key in the
machine menu was pressed (that is, when
the menu was displayed in reverse mode),
the axis was moved to the ATC position by
the ATC command.
390: TOOL ON INTERFER An attempt has been made to return the tool
ALARM to a magazine pocket containing another
tool.
391: LD/ULD/ACHG During ATC, although returning the tool was
CONDITION ALARM attempted, the magazine pocket tool
confirmation sensor did not detect that tool
probably because of dropping.
Valid when bit 6 in parameter R59 is set to
“1”. (Standard setting: 1)
392: MAGAZINE MANUAL Under 20- or 40-tool magazine
INTERR. specifications, the tool change command
has been entered or the cycle start button
pressed with the magazine manual
interruption switch set to ON.
394: ATC CONTROLLER An alarm signal has been received from the
MALF. ATC amplifier.
APP-9
Check and remedy Address
Check the thermal relays of the coolant X490
unit.
Check and adjust the coolant unit tank X491
pressure.
Change the setting of the setup key switch
to “I” and then press the cycle start button.
Single-block automatic operation will be
activated.
―
Change the setting of the setup key switch
to “I” and then press the desired manual-
starting button. The override rate will be
reduced to 25%.
Check the coolant unit for alarms. X493
Before issuing the cycle start command or
the tool change command, move the carrier
and the shifter to their stand-by positions ―
using the required switch of the magazine
manual operations box.
Move the Z-axis in the plus direction
relative to its zero point before opening the
ATC cover. ―
Cancel the ATC stop mode by pressing the
[ATC STOP] menu key in the machine
menu. ―
Check the tool number of the tool to be
returned and that of the tool stored within ―
the magazine pocket.
Confirm whether the tool is mounted in the X475
ATC arm.
Check the magazine pocket tool
confirmation sensor for normal operation.
Change the setting of the magazine manual X1C
interruption switch to OFF.
After turning NC power off, turn off the main
circuit breaker and then turn if back on.
―
If the alarm is not cleared, please contact
your MAZAK service representative.
 Alarm No. and message Description Check and remedy Address
395: CHECK SENSOR The operational check sensors at both ends The positions of the operational check
MALF. (SEE D199) of the stroke have turned on. sensors or watchdogs are not correct or the
After the command has been issued, no sensors themselves are malfunctioning.
―
sensors did not turn on within the required Confirm the value of D199 on the
time. DIAGNOSIS display and examine the
sensor causing the alarm.
D199 Corresponding sensor ―
0 Normal ―
1 The X470 limit switch at the ATC X470
side of the shifter has not turned X471
on 20 seconds after the Y4F0
command for moving the shifter
to the ATC side has been issued.
The X471 limit switch at the
magazine side of the shifter has
not turned on 20 seconds after
the Y4F1 command for moving
the shifter to the magazine side
has been issued.
2 The X472 limit switch at the X472
extending side of the shifter has X473
not turned on 20 seconds after
the Y4F2 command for extending
the shifter has been issued.
The X473 limit switch at the
retracting side of the shifter has
not turned on 20 seconds after
the Y4F3 command for retracting
the shifter has been issued.
8 The chuck-clamping pressure X442
switch (X442) and the chuck- X443
unclamping pressure switch
(X443) are both on.
12 The top door open end sensor X14
switch (X14) and closed end X15
sensor switch (X15) of the
machine of the GL specifications
are both on.
397: MAGAZINE DOOR The magazine door has been opened Close the magazine door. XD
INTERLOCK during issuance of the tool change
command or the magazine rotation
command.
398: MAGAZINE COVER The magazine cover is open. Close the magazine cover. XD
OPEN X1C
The machine of the CE specifications has Change the setting of the magazine setup
its magazine setup switch remaining set to switch to OFF.
ON.
399: MAINTE./ADJUST The maintenance/adjustment parameters After turning NC power off, turn off the main
PARAM. ON are validated. circuit breaker and then turn it back on.
―
If the alarm is not cleared, please contact
your MAZAK service representative.

APP-10
 III
Alarm List for the INTEGREX 300/400-III IIIST
III
S/III (Addition)

Alarm No. and message Description Check and remedy Address

204: SPINDLE An alarm occurred at secondary spindle Turn off the main circuit breaker and then
CONTROLLER controller. turn it back on.
―
MALFUNCTION If the alarm is not released, please contact
SP2 your MAZAK service representative.
215: CHUCK SYSTEM An erroneous chucking action was detected The chuck unit on secondary spindle has
―
MALFUNCTION during chucking operation on secondary failed to grip the material.
SP2 spindle. The chuck open/close end sensor on X483/
secondary spindle (SQ62/SQ63) is X484
abnormal or faulty.
218: CHUCKING TYPE Type of chucking (inner/outer) of secondary Select the type of chucking.
NOT SELECTED spindle chuck is not selected. ―
SP2
224: CHUCK SENSOR The secondary spindle chuck open or close The secondary spindle chuck open or X483/
MALFUNCTION confirmation sensor fails in function, or both close confirmation sensor (SQ62/SQ63) is X484
SP2 of the sensors are ON simultaneously. abnormal or faulty.

250: SPINDLE START 1. A secondary spindle rotation command 1. Close the chuck and start operation X483/
MISOPERATION was given during mis-chucking. (Chuck with the workpiece gripped. X484
SP2 sensor provided.) Alternatively, the chuck open/close
check sensor may be improperly
adjusted.
→ Check the sensor.
2. A spindle rotation command was given 2. After closing the chuck of secondary
even though the chuck of secondary spindle using the chuck clamp
―
spindle was not closed. command, designate the spindle
rotation command.
3. A spindle rotation command was given 3. Retract the TOOL EYE. Also, check X445
without the TOOL EYE placed at the the backward end sensor.
backward end.
4. A secondary spindle rotation command 4. Close the door and start the XA
was given without the door closed. secondary spindle rotation.
5. Alarm 297 “CHUCK PRESSURE DOWN” 5. Clear the alarm 297. X448
is displayed. X449
252: AXIS MOVE An attempt was made to execute an axis
MISOPERATION movement under the axis movement
SP2 interdiction.

1. An attempt was made to execute a 1. Perform the X- and Y-axes zero point
movement along the W-axis (secondary return operation.
spindle traveling axis) without the X- and
Y-axes placed at the zero point.
2. An attempt was made to execute a 2. Perform the W-axis zero point return ―
movement along the X-, Z- (milling head operation.
traveling axis) and Y-axes without the W-
axis (secondary spindle traveling axis)
placed at the zero point.
3. Though the W-axis zero point return is 3. Retract the TOOL EYE. Also, check X445
not completed after power on, an attempt the backward end sensor.
was made to execute a movement along
the W-axis in – direction at rapid feed
without the TOOL EYE placed at the
backward end.
4 An attempt was made to execute a 4 Open the chuck on main spindle or
movement along the W-axis with a bar secondary spindle.
―
chucked both on main spindle and
secondary spindle.

APP-11
 Alarm No. and message Description Check and remedy Address
270: SPINDLE ORIENT Although a secondary spindle orientation The secondary spindle motor
EXCEED TIME command was given, the orientation detector/controller is abnormal.
―
SP2 confirmation signal does not turn on within a
predetermined time.
282: CHUCK CLAMP Although a chuck open/close command for Adjust the chuck open/close end sensor. X483/
EXCEED TIME secondary spindle was given, the Or the sensor is in trouble. X484
SP2 confirmation signal does not turn on within a
The hydraulic system is abnormal. ―
predetermined time.
329: CHUCKING The inside/outside chucking selection was Open the chuck of secndary spindle (and
SELECTION performed without the chuck of secondary remove the workpiece).
PROHIBITED spindle opened.
―
SP2 The inside/outside chucking selection was Stop the secondary spindle or milling
performed when the secondary spindle or spindle.
milling spindle is not stopped.

APP-12
 IIIT/III
III IIIST
Alarm List for the INTEGREX 300/400-III III (Addition)

Alarm No. and message Description Check and remedy Address

221: TURRET CLAMP In spite of the fact that the (lower) turret is The clamping confirmation sensor is X52
SENSOR actually clamped, the clamping confirmation abnormal or faulty.
MALFUNCTION sensor (SQ39) does not turn on.
In spite of the fact that the (lower) turret is
TR2/SP2 actually unclamped, the clamping
confirmation sensor (SQ39) does not turn off.
256: TURRET ROTATION A turret indexing command was given during Cancel the measurement mode. X198
PROHIBITED tool nose measurement with the TOOL EYE. X1F8
TR2/SP2 A turret indexing command was given with Change the setting of the SET UP switch
the SET UP switch remaining set to “O” and to “I”. Or close the front door.
the front door remaining open.
258: TNo. MISMATCH For resuming automatic operation after a Index the turret for the same face to
TR2/SP2 manual interruption, the indexed face of the continue the automatic operation.
―
turret is different from the face indexed
before the interruption.
272: TURRET INDEX Although a turret indexing command is The detector/controller of the turret
EXCEED TIME given, the index confirmation signal does not indexing motor is abnormal. ―
TR2/SP2 turn on within a predetermined time.

301: START COND. ERR. The cycle start button was pressed while the Clamp the (lower) turret. X52
(TUR UNCLAMP) turet was unclamped.
TR2/SP2
310: C/S ERROR For resuming automatic operation after a Use a tool of the same number to continue
(TNo.MISMATCH) manual interruption, the number of the tool the automatic operation.
―
TR2/SP2 in use differs from the number before the
interruption.

APP-13
- NOTE -

APP-14
M-CODE TABLE

III/I
III III
Miscellaneous Function (M-Code) for the INTEGREX 300/400-III T/IIIIS/IIIIST
!: Standard
": Optional
—: Special order

M-codes Description Category Remarks

M00 Program stop !
M01 Optional stop !
M02 Program end !
M03 Spindle normal rotation !
M04 Spindle reverse rotation !
M05 Spindle stop !
M06 Chuck unclamp (releasing workpiece) "
M07 Chuck clamp (holding workpiece) "
M08 Flood coolant ON !
M09 Coolant OFF !
M10
M11
M12 Milling spindle mode cancel (Turning mode selection) !
M13 Milling tool normal rotation !
M14 Milling tool reverse rotation !
M15 Milling tool stop !
M16 Spindle orientation 0° (for AJC) —
M17 Spindle orientation 120° (for AJC) —
M18 Spindle orientation 240° (for AJC) —
M19 Spindle orientation position (for the robot to insert a workpiece) "
M20 Robot service call "
M21 Robot service call "
M22 Robot service call "
M23 Robot service call "
M24 Robot service call "
M25 Robot service call "
M26 Robot service call "
M27 Robot service call "
M28 Robot service call "
M29 Robot service call "
M30 Reset & tape rewind !
M31 Tail spindle & tailstock body advance ! for 300/400-III/IIIT
M32 Tail spindle & tailstock body retract ! for 300/400-III/IIIT
M33 Low chuck pressure —
M34 High chuck pressure —
M35
M36
M37
M38
M39
M40

H374S5C010E APP-15
M-codes Description Category Remarks
M41
M42
M43
M44
M45 Air coolant blow ON (coolant stop: M09) "
M46
M47
M48 Parts catcher advance "
M49 Parts catcher retract "
M50
M51 Error detect OFF !
M52 Error detect ON !
M53 Chamfering OFF !
M54 Chamfering ON !
M55 Piece count —
M56 Front door open "
M57 Front door close "
M58 Chuck air blast "
M59
M60 C-axis unclamp !
M61
M62
M63
M64
M65
M66 C-axis clamp !
M67 C-axis brake (for machining by G01) !
M68 Cycle bar feeder call 1 —
M69 Cycle bar feeder call 2 —
M70
M71
M72 Inside chuck clamp —
M73 Outside chuck clamp —
M74 Steady rest - milling head connection mode release —
M75 Steady rest - milling head connection mode start —
M76
M77
M78
M79
M80
M81 Workpiece measurement start "
M82 Workpiece measurement end "
M83 Tool measurement start "
M84 Tool measurement end "
M85
M86 Steady rest 1 unclamp "
M87 Steady rest 1 clamp "

APP-16
M-codes Description Category Remarks
M88 Steady rest 2 unclamp —
M89 Steady rest 2 clamp —
M90
M91
M92
M93
M94
M95
M96 User macro interruption, valid —
M97 User macro interruption, invalid —
M98 EIA → EIA Subprogram call !
M99 EIA → EIA Return to main EIA program !
M100 Workpiece measurement DIA start "
M101 Workpiece measurement DIA end "
M102 Workpiece measurement STP start "
M103 Workpiece measurement STP end "
M104 Workpiece measurement GRV start "
M105 Workpiece measurement GRV end "
M106 Workpiece measurement WID start "
M107 Workpiece measurement WID end "
M108 Workpiece measurement DIS start (chuck barrier release) "
M109 Workpiece measurement DIS end "
M110 Tool tip measurement TOL start !
M111 Tool tip measurement TOL end !
M112 External tool compensation EXT start "
M113 External tool compensation EXT end "
M114 Z-axis offset measurement ZOF start "
M115 Z-axis offset measurement ZOF end "
M116 C-axis offset measurement COF start "
M117 C-axis offset measurement COF end "
M118
M119
M120 Measurement data print out "
M121
↓
M149
M150 Workpiece unload demand to robot —
M151 Milling spindle through air blow ON ! Only for turning tools
M152 Milling spindle through air blow OFF ! Only for turning tools
M153 Milling spindle through coolant ON !
M154 Milling spindle through coolant OFF !
M155 Chuck coolant ON (composed movement) "
M156 Chuck coolant OFF (composed movement) "
M157 Spindle through coolant blow ON (OFF: M159) "
M158 Spindle through air blow ON (OFF: M159) "
M159 M157, M158 OFF "
M160 Shower coolant ON/chuck stopper extend "

APP-17
M-codes Description Category Remarks
M161 Shower coolant OFF/chuck stopper retract "
M162 Workpiece rechucking (for a piece delivered by robot) "
M163 Tail spindle thrust low pressure " for 300/400-III/IIIT
M164 Tail spindle thrust high pressure " for 300/400-III/IIIT
M165
M166
M167
M168
M169 35K, 70K high pressure coolant ON (OFF: M9, M154) "
M170
M171
M172 Index 0°(KOUYOU) —
M173 Index 90°(KOUYOU) —
M174 Index 180°(KOUYOU) —
M175 Index 270°(KOUYOU) —
M176 Index 270°(KOUYOU) —
M177 Index 270°(KOUYOU) —
M178 Index 270°(KOUYOU) —
M179 Index 270°(KOUYOU) —
M180
↓
M197
M198 EIA → MAZATROL program call "
M199 EIA → MAZATROL program end "
M200 Milling point machining start !
M201 Milling line machining start !
M202 Turning mode !
M203 Milling tool normal rotation !
M204 Milling tool reverse rotation !
M205 Milling tool stop !
M206
M207 M208, M209 mode cancel !
M208 ATC prohibition mode during finishing, coolant ON !
M209 ATC prohibition mode during finishing, coolant OFF !
M210 C-axis clamp (for milling) !
M211 C-axis brake (for milling) !
M212 C-axis unclamp (for milling) !
M213 C-axis brake only (brake by M211) !
M214 C-axis unclamp only (unclamp by M212) !
M215 M213, M214 and M216 mode cancel !
M216 C-axis unclamp neglect mode (cancel: M215) !
M217
M218
M219 Milling tool orient !
M220
↓
M229

APP-18
M-codes Description Category Remarks
M230 Grinding mode ON "
M231 Grinding speed setting "
M232
M233
M234
M235
M236 C-axis servo gain normal !
M237 C-axis servo gain low !
M238 C-axis servo gain middle !
M239 C-axis servo gain high !
M240
M241
M242
M243
M244
M245
M246
M247
M248 Spindle speed check (for interlocking the start of cutting) !
M249 Milling head selection preparation !
M250 Milling head/B-axis unclamp !
M251 B-axis clamp !
M252 Milling spindle unclamp !
M253 Milling spindle clamp !
M254 Milling head/B-axis clamp !
M255
M256
M257
M258 Milling head air blow !
M259
M260 Polygon mode ON "
M261 Polygon mode OFF "
M262
↓
M273
M274 Steady rest coolant ON —
M275 Steady rest coolant OFF —
M276
↓
M330
M331 Spindle coil change fixed to high speed !
M332 Spindle coil change, valid !
M333
↓
M347
M348 Yt-axis selection !
M349 Y-axis selection !

APP-19
M-codes Description Category Remarks
M350
M351 M352 cancel !
M352 Spindle speed arrival signal check, valid !
M353
↓
M369
M370 Axis load detection, invalid "
M371 Axis load detection, valid "
M372 Axis load detection, temporarily invalid "
M373 Axis load detection, re-start "
M374 NC feed holding on overload detection "
M375 NC feed holding & spindle stop on overload detection "
M376 Overload detection level % setting "
M377 Overload detection time setting (unit: 0.1 sec) "
M378 Overload detection peak %/detection frequency setting "
M379 Overload detection table No. registration "
M380
↓
M389
M390 M391 cancel "
M391 Spindle mis-chucking cancel (M3/M4 completed with chuck open) "
M392
M393
M394 TOOL EYE extension possible during chuck close (when robot valid) !
M395 M394 cancel !
M396
↓
M600
M601 Magazine tool rotation !
M602
↓
M730
M731 Tail thrust 1 selection !
M732 Tail thrust 2 selection !
M733 Tail thrust 3 selection !
M734 Tail thrust 4 selection !
M735 Tail thrust 5 selection !
M736 Tail thrust 6 selection !
M737 Tail thrust 7 selection !
M738 Tail thrust 8 selection !
M739 Tail thrust 9 selection !
M740 Tail thrust 10 selection !
M741 Positioning tailstock to “Position 1” !
M742 Positioning tailstock to “Position 2” !
M743 Positioning tailstock to “Retract” !

APP-20
M-codes Description Category Remarks
M744
↓
M927
M928 Y-axis zero point return !
M929
M930 Yt-axis moving to ATC position !
M931
↓
M999

APP-21
Miscellaneous Function (M-Code) for the INTEGREX 300/400-IIII S/IIIIST
(Addition)
!: Standard
": Optional
—: Special order

M-codes Description Category Remarks

M300 Secondary spindle selection ! System M-code
M301
M302 Main spindle selection ! System M-code
M303 Secondary spindle normal rotation !
M304 Secondary spindle reverse rotation !
M305 Secondary spindle stop !
M306 Secondary spindle chuck unclamp (releasing workpiece) !
M307 Secondary spindle chuck clamp (holding workpiece) !
↓
M319 Secondary spindle orientation "
M320
M321 Increase of main spindle torque for synchronous rotation "
M322 Cancellation of M321 "
↓
M333 Torque limit of main spindle to 1/2 !
M334 Torque limit of main spindle !
M335 Keeping of nominal torque of main spindle !
M336 Cancellation of M337 !
M337 Torque limit of main spindle only at the starting and stopping !
↓
M350
M351 Cancellation of M352 !
M352 Spindle speed arrival signal check !
↓
M357 Secondary spindle chuck air blast start "
M358 Secondary spindle chuck air blast stop "
M359 Cancellation of M360 "
M360 Secondary spindle orientation clamp mode "
M361 Cancellation of M362 "
Simultaneous chuck operation on main and secondary spindles in TRS-
M362 "
CHK mode
M363 Cancellation of M364 "
Immediate completion of spindle/milling spindle start commands (M-
M364 "
code) in TRS mode
↓
M380 Spindle synchronous rotation mode !
M381 Spindle synchronous rotation mode cancel !
↓
M500 Release of chuck open/close interlock during spindle rotation !
M501 Cancellation of M500 !
M502 Main/secondary spindle synchronous rotation (Cross mode) " System M-code
M503

APP-22
M-codes Description Category Remarks
M504
M505 Cancellation of M502 " System M-code
M506 Master spindle chuck open after slave spindle chuck close ! System M-code
M507 The slave spindle chuck open after master spindle chuck close ! System M-code
M508 Pressing start !
M509 Cancellation of M508 !
M510
M511 Start of synchronous action of two spindles ! System M-code
M512 Cancellation of M511 ! System M-code
↓
M518 Interlock release during chucking of a bar workpiece by both spindles !
M519 Spindle orientation "
↓
M527 Check for workpiece chucked in the spindle "
M528 Modal workpiece check in TRS mode "
↓
M540 TRS-CHK mode start ! System M-code
M541 Cancellation of TRS-CHK mode ! System M-code
M542 TRS-BAR mode start ! System M-code
M543 Cancellation of TRS-BAR mode ! System M-code
M544 Cross-machining start " System M-code
M545 Cancellation of cross-machining " System M-code
M546 TRS-MOV mode start ! System M-code
M547 Cancellation of TRS-MOV mode ! System M-code

APP-23
Miscellaneous Function (M-Code) for the INTEGREX 300/400-IIII T/IIIIST
(Addition)

For the upper turret

!: Standard
": Optional
—: Special order

M-codes Description Category Remarks

M560 Spindle control and Constant cutting speed control for the upper turret !
M561 Spindle control and Constant cutting speed control for the lower turret !
M562 Axis movement synchronization !
M563 Cancellation of axis movement synchronization !

M949
M950 Stand-by M-code !
M951 Stand-by M-code !
M952 Stand-by M-code !
M953 Stand-by M-code !
M954 Stand-by M-code !
M955 Stand-by M-code !
M956 Stand-by M-code !
M957 Stand-by M-code !
M958 Stand-by M-code !
M959 Stand-by M-code !
M960 Stand-by M-code !
M961 Stand-by M-code !
M962 Stand-by M-code !
M963 Stand-by M-code !
M964 Stand-by M-code !
M965 Stand-by M-code !
M966 Stand-by M-code !
M967 Stand-by M-code !
M968 Stand-by M-code !
M969 Stand-by M-code !
M970 Stand-by M-code !
M971 Stand-by M-code !
M972 Stand-by M-code !
M973 Stand-by M-code !
M974 Stand-by M-code !
M975 Stand-by M-code !
M976 Stand-by M-code !
M977 Stand-by M-code !
M978 Stand-by M-code !
M979 Stand-by M-code !
M980 Stand-by M-code !
M981 Stand-by M-code !
M982 Stand-by M-code !

APP-24
M-codes Description Category Remarks
M983 Stand-by M-code !
M984 Stand-by M-code !
M985 Stand-by M-code !
M986 Stand-by M-code !
M987 Stand-by M-code !
M988 Stand-by M-code !
M989 Stand-by M-code !
M990 Stand-by M-code !
M991 Stand-by M-code !
M992 Stand-by M-code !
M993 Stand-by M-code !
M994 Stand-by M-code !
M995 Stand-by M-code !
M996 Stand-by M-code !
M997 Stand-by M-code !

APP-25
Integrex-100~400MkIII Lower Turret M-Codes
!: Standard
": Optional
—: Special order

M-codes Description Category Remarks

M00 Program stop !
M01 Optional stop !
M02 Program end !
M03 Secondary spindle normal rotation (for ST) !
M04 Secondary spindle reverse rotation (for ST) !
M05 Secondary spindle stop (for ST) !

M08 Coolant ON !
M09 Coolant OFF !

M30 Reset & tape rewind !

M51 Error detect OFF !

M52 Error detect ON !
M53 Chamfering OFF !
M54 Chamfering ON !

M58 Secondary spindle chuck air blast "

M300 Main spindle mode !

M301
M302 Secondary spindle mode !
M303 Main spindle normal rotation !
M304 Main spindle reverse rotation !
M305 Main spindle stop !

M358 Main spindle chuck air blast "

M560 Spindle control and Constant cutting speed control for the upper turret !
M561 Spindle control and Constant cutting speed control for the lower turret !
M562 Axis movement synchronization !
M563 Cancellation of axis movement synchronization !

M949
M950 Stand-by M-code !
M951 Stand-by M-code !
M952 Stand-by M-code !
M953 Stand-by M-code !
M954 Stand-by M-code !

APP-26
M-codes Description Category Remarks
M955 Stand-by M-code !
M956 Stand-by M-code !
M957 Stand-by M-code !
M958 Stand-by M-code !
M959 Stand-by M-code !
M960 Stand-by M-code !
M961 Stand-by M-code !
M962 Stand-by M-code !
M963 Stand-by M-code !
M964 Stand-by M-code !
M965 Stand-by M-code !
M966 Stand-by M-code !
M967 Stand-by M-code !
M968 Stand-by M-code !
M969 Stand-by M-code !
M970 Stand-by M-code !
M971 Stand-by M-code !
M972 Stand-by M-code !
M973 Stand-by M-code !
M974 Stand-by M-code !
M975 Stand-by M-code !
M976 Stand-by M-code !
M977 Stand-by M-code !
M978 Stand-by M-code !
M979 Stand-by M-code !
M980 Stand-by M-code !
M981 Stand-by M-code !
M982 Stand-by M-code !
M983 Stand-by M-code !
M984 Stand-by M-code !
M985 Stand-by M-code !
M986 Stand-by M-code !
M987 Stand-by M-code !
M988 Stand-by M-code !
M989 Stand-by M-code !
M990 Stand-by M-code !
M991 Stand-by M-code !
M992 Stand-by M-code !
M993 Stand-by M-code !
M994 Stand-by M-code !
M995 Stand-by M-code !
M996 Stand-by M-code !
M997 Stand-by M-code !

APP-27
- NOTE-

APP-28
 1.
Stroke Diagram
INTEGREX 100-ΙΙΙ
ΙΙΙ (Metric)

Stroke diagram (INTEGREX 100-ΙΙΙ - Metric -)

APP-29
Notes:
1. If B = 90°, the tool lengths that can be
measured using the TOOL EYE are
limited.
2. If B = 0°, when a special chuck or long
jaws are mounted the tool lengths that
can be measured using the TOOL EYE
may be limited.
3. BT40 spec.

Unit: mm

Drawing No. 1372ST00012

 INTEGREX 100-ΙΙΙ
ΙΙΙ (Inch)

Stroke diagram (INTEGREX 100-ΙΙΙ - Inch -)

APP-30
Notes:
1. If B = 90°, the tool lengths that can be
measured using the TOOL EYE are
limited.
2. If B = 0°, when a special chuck or long
jaws are mounted the tool lengths that
can be measured using the TOOL EYE
may be limited.
3. BT40 spec.

Unit: in. (mm)

Drawing No. 1372ST00041

 INTEGREX 100-ΙΙΙ
ΙΙΙS
ΙΙΙ (Metric)

Stroke diagram (INTEGREX 100-ΙΙΙS - Metric -)

APP-31
Notes:
1. If B = 90°, the tool lengths that can be
measured using the TOOL EYE are
limited.
2. If B = 0°, when a special chuck or long
jaws are mounted the tool lengths that
can be measured using the TOOL EYE
may be limited.
3. BT40 spec.

Unit: mm

Drawing No. 1372ST00022

 INTEGREX 100-ΙΙΙ
ΙΙΙS
ΙΙΙ (Inch)

Stroke diagram (INTEGREX 100-ΙΙΙS - Inch -)

APP-32
Notes:
1. If B = 90°, the tool lengths that can be
measured using the TOOL EYE are
limited.
2. If B = 0°, when a special chuck or long
jaws are mounted the tool lengths that
can be measured using the TOOL EYE
may be limited.
3. BT40 spec.

Unit: in. (mm)

Drawing No. 1372ST00051

 ΙΙΙ
INTEGREX 100-ΙΙΙ
ΙΙΙST (Metric)

Stroke diagram (INTEGREX 100-ΙΙΙST - Metric -)

APP-33
Notes:
1. If B = 90°, the tool lengths that can be
measured using the TOOL EYE are
limited.
2. If B = 0°, when a special chuck or long
jaws are mounted the tool lengths that
can be measured using the TOOL EYE
may be limited.
3. BT40 spec.

Unit: mm

Drawing No. 1372ST00032

 ΙΙΙ
INTEGREX 100-ΙΙΙ
ΙΙΙST (Inch)

Stroke diagram (INTEGREX 100-ΙΙΙST - Inch -)

APP-34
Notes:
1. If B = 90°, the tool lengths that can be
measured using the TOOL EYE are
limited.
2. If B = 0°, when a special chuck or long
jaws are mounted the tool lengths that
can be measured using the TOOL EYE
may be limited.
3. BT40 spec.

Unit: in. (mm)

Drawing No. 1372ST00062

 Stroke Diagram
III
INTEGREX 200-III

Stroke diagram (INTEGREX 200-III)

APP-35
Note: For BT Spec *1: 165 mm (6.5")
*2: 40 mm (1.57")
DOM./EX.
Main spindle
Hollow chuck of 8"

Unit: mm (in.)

Drawing No. 1373PGD0011

 INTEGREX 200-II
III
IIIS

Stroke diagram (INTEGREX 200-IIIS)

APP-36
Note: For BT Spec *1: 165 mm (6.5")
*2: 40 mm (1.57")
DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"

Unit: mm (in.)

Drawing No. 1373PGD0021

 INTEGREX 200-II
III
IIIT

Stroke diagram (INTEGREX 200-IIIT)

APP-37
Note: For BT Spec *1: 165 mm (6.5")
*2: 40 mm (1.57")
DOM./EX.
Main spindle
Hollow chuck of 8"

Unit: mm (in.)

Drawing No. 1373PGD0031

 INTEGREX 200-II
III
IIIST

Stroke diagram (INTEGREX 200-IIIST)

APP-38
Note: For BT Spec *1: 165 mm (6.5")
*2: 40 mm (1.57")
DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"

Unit: mm (in.)

Drawing No. 1373PGD0041

 INTEGREX 200-III
III (with work rest)

APP-39
Stroke diagram (INTEGREX 200-III) - with work rest -
Note: For BT Spec *1: 165 mm (6.5")
*2: 40 mm (1.57")

DOM./EX.
Main spindle
Hollow chuck of 8"
Work rest spec.: SLU2Z/SMW

Unit: mm (in.)

Drawing No. 1373PGD0110

 INTEGREX 200-III
IIIS
III (with work rest)

APP-40
Stroke diagram (INTEGREX 200-IIIS) - with work rest -
Note: For BT Spec *1: 165 mm (6.5")
*2: 40 mm (1.57")

DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"
Work rest spec.: SLU2Z/SMW

Unit: mm (in.)

Drawing No. 1373PGD0120

 IIIT
III (for Lower turret with milling capability)
INTEGREX 200-III

Unit: mm (in.)

1373PGD0050
Note: For BT Spec *1: 165 mm (6.5")
*2: 40 mm (1.57")

Hollow chuck of 8"

Drawing No.
Main spindle
DOM./EX.

Stroke diagram (INTEGREX 200-IIIT) - for Lower turret with milling capability -

APP-41
 III
INTEGREX 200-III
IIIST

APP-42
(for Lower turret with milling capability)

Note: For BT Spec *1: 165 mm (6.5")

Stroke diagram (INTEGREX 200-IIIST) - for Lower turret with milling capability -
*2: 40 mm (1.57")
DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"

Unit: mm (in.)

Drawing No. 1373PGD0060

 Stroke Diagram
INTEGREX 300-ΙΙΙ
ΙΙΙ (1000U, 10" hollow chuck)

APP-43
Stroke diagram (INTEGREX 300-ΙΙΙ [1000U, 10" hollow chuck])
Note:　BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)

DOM./EX.
10" CHUCK
MAIN SPINDLE
(THROUGH HOLE)

Drawing No. 1374PGD0020

 INTEGREX 300-ΙΙΙ
ΙΙΙS
ΙΙΙ (1000U, 10" hollow chuck)

APP-44
Stroke diagram (INTEGREX 300-ΙΙΙS [1000U, 10" hollow chuck])
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)

DOM./EX.
10" CHUCK
MAIN SPINDLE (THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE (THROUGH HOLE)

Drawing No. 1374PGD0050

 INTEGREX 400-ΙΙΙ
ΙΙΙ (1000U, 12" hollow chuck)

APP-45
Stroke diagram (INTEGREX 400-ΙΙΙ [1000U, 12" hollow chuck])
Note:　BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)

DOM./EX.
12" CHUCK
MAIN SPINDLE
(THROUGH HOLE)
Drawing No. 1374PGD0040
 INTEGREX 400-ΙΙΙ
ΙΙΙS
ΙΙΙ (1000U, 12" hollow chuck)

APP-46
Stroke diagram (INTEGREX 400-ΙΙΙS [1000U, 12" hollow chuck])
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)

DOM./EX.
10" CHUCK
MAIN SPINDLE (THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE (THROUGH HOLE)

Drawing No. 1374PGD0060

 INTEGREX 300-ΙΙΙ
ΙΙΙ (1500U, 10" hollow chuck)

APP-47
Stroke diagram (INTEGREX 300-ΙΙΙ [1500U, 10" hollow chuck])
Note:　BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)
DOM./EX.
10" CHUCK
MAIN SPINDLE (THROUGH HOLE)

Drawing No. 1374PGD0140

 II
INTEGREX 300-II

APP-48
IS (1500U, 10" hollow chuck)

Stroke diagram (INTEGREX 300-ΙΙΙS [1500U, 10" hollow chuck])

Note:　BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)
DOM./EX.
10" CHUCK
MAIN SPINDLE (THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE
(THROUGH HOLE)

Drawing No. 1374PGD0170

 II
INTEGREX 300-II

APP-49
IT (1500U, 10" hollow chuck)

Fig. 1-13 Stroke diagram (INTEGREX 300-ΙΙΙT [1500U, 10" hollow chuck])
Note:　BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)
DOM./EX.
10" CHUCK
MAIN SPINDLE (THROUGH HOLE)
Drawing No. 1374PGD0200
 II
INTEGREX 300-II

APP-50
IST (1500U, 10" hollow chuck)

Stroke diagram (INTEGREX 300-ΙΙΙST [1500U, 10" hollow chuck])

Note:　BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)
DOM./EX.
10" CHUCK
MAIN SPINDLE (THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE (THROUGH HOLE)

Drawing No. 1374PGD0230

 INTEGREX 400-ΙΙΙ
ΙΙΙ (1500U, 12" hollow chuck)

APP-51
Stroke diagram (INTEGREX 400-ΙΙΙ [1500U, 12" hollow chuck])
Note:　BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)
DOM./EX.
12" CHUCK
MAIN SPINDLE
(THROUGH HOLE)

Drawing No. 1374PGD0160

 II
INTEGREX 400-II

APP-52
I S (1500U, 12" hollow chuck)

Stroke diagram (INTEGREX 400-ΙΙΙS [1500U, 12" hollow chuck])

Note:　BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)
DOM./EX.
12" CHUCK
MAIN SPINDLE (THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE
(THROUGH HOLE)

Drawing No. 1374PGD0180

 II
INTEGREX 400-II

APP-53
IT (1500U, 12" hollow chuck)

Stroke diagram (INTEGREX 400-ΙΙΙT [1500U, 12" hollow chuck])

Note:　BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)
DOM./EX.
12" CHUCK
MAIN SPINDLE (THROUGH HOLE)
Drawing No. 1374PGD0220
 II
INTEGREX 400-II

APP-54
IST (1500U, 12" hollow chuck)

Stroke diagram (INTEGREX 400-ΙΙΙST [1500U, 12" hollow chuck])

Note:　BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")

Unit: mm (in.)
DOM./EX.
12" CHUCK
MAIN SPINDLE (THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE
(THROUGH HOLE)

Drawing No. 1374PGD0240