SP43 Machine & Maintenance

WIRE ELECTRICAL DISCHARGE MACHINE
INSTRUCTION MANUAL
MAKINO ASIA PTE. LTD.
W0721C-I1E-01
Safety SP43
Chapter 1 SAFETY
W0721C-I1E-01 Safety.fm
SP43 Safety
Contents
1 SAFETY INFORMATION
1.1 Important Information ...............................................................................1
1.1.1 Utilizing safety functions...................................................................1
1.2 Safety Information on Operation ..............................................................2
1.2.1 Observing the safety ........................................................................2
1.2.2 Handling the covers .........................................................................2
1.2.3 Precautions on operation .................................................................2
1.3 Precautions on Checking .........................................................................4
1.4 Precautions on Maintenance....................................................................5
2 WARNING LABELS
2.1 Kinds and Meaning of Warning ................................................................6
2.2 Location of Warning Labels ......................................................................7
2.2.1 Machine Front View .........................................................................8
2.2.2 Machine Left View............................................................................9
2.2.3 Machine Right View .......................................................................10
2.2.4 Machine Rear View ........................................................................10
2.3 List of Safety Precautions.......................................................................11
2.3.1 Automatic operation .......................................................................11
2.3.2 Manual operation ...........................................................................11
2.3.3 Routine checking and maintenance ...............................................12
Safety SP43
Operating the machine carelessly or without reading carefully or understanding the

operating instructions give in this manual could cause a critical accident.
1 SAFETY INFORMATION
1.1 Important Information
• What are important points to avoid hazards are the attention to foresee the
possibility of hazard and prudential actions, and knowledge about entire
machine that backs up such actions. Read intensively this Instruction Manual so
as to know well about possible hazardous places and what hazards are hidden.
Further, make sure the machine movements and utilize safety functions built in
the machine so that you can protect yourself and the machine. For instance,
utilize the soft limits properly.
• Thus, inhibit a such method that you learn the operation by operating the
machine on trial.
• Designate the operators. Unaccustomed operation leads to a careless
operation, causing a danger.
• Keep this Instruction Manual at hand (in a place near the machine) so that the
operator can consult whenever doubtful or uncertain.
• Immediately get the Instruction Manual or equivalent one, if it is missing.
1.1.1 Utilizing safety functions
• Utilize fully the safety functions such as soft limits and covers.
• Routine checking is important. Repair immediately if any faults are found. Do
not operate the machine before repair.
• Before operation, confirm the location of EMERGENCY STOP button, and
make preparation so that you can press the button immediately in case of
emergency.
• For instance, where you cannot reach the EMERGENCY STOP button with
your left hand if right hand got caught by the machine, operate with the left
hand so as to press the button with your right hand.
• Thus, take care and make preparation at all times for accidental causes that will
occur abruptly.
W0721C-I1E-01 1
SP43 Safety
1.2 Safety Information on Operation
It is important to learn operating methods correctly. Learning the operation by

operating the machine through a try and error way without reading the Instruction
Manual is wrong. This way of operation is very dangerous and strictly inhibited.
1.2.1 Observing the safety
To protect the operator and machine, the safety functions are provided and the
warning labels are affixed.
Main safety functions include EMERGENCY STOP button, axis stroke limits (soft
limits) and safety covers. The warning labels to avoid hazards are described on
the following pages.
1.2.2 Handling the covers
Close all covers and wire box when operating the machine. These covers protect
the operator from hazardous movable parts and an electric shock.
1.2.3 Precautions on operation
The precautions on operation are as listed below.

• Only the designated persons must operate the machine.
• Before turning on the main switch, pay attention to the following:
* Check if there is a person at the rear of machine or in a blind spot.
* Confirm the location of EMERGENCY STOP button so as to press it to
avoid a danger in case of emergency.
* Check if there is possibility of interference between movable parts and
workieces on the table, portable operation panel, or fixtures or tools on the
machine, whichever directions respective axes move in.
* Check if the wire box is at the specified position.
* Check if any parts have been still removed, or the machine has been
restored to normal condition after maintenance or inspection.
* Check if a trouble has been repaired correctly, and it is already confirmed.
2
Safety SP43
• When the operator is doing a job far away from the main switch, take proper
measure so that the third person cannot turn it on, or tag a signboard,
indicating”UNDER JOB. DO NOT TURN THE POWER ON”.
• Check that no obstacle exists, or the power supply cable does not interfere with
the workpiece or fixture, when moving the axes manually.
• Do not touch the wire during machining, as high voltage is applied.
• Take care of your fingers not to get caught between workpiece and lower head
when loading/unloading the workpiece.
• During work inside or outside the work tank where portable operation panel is
placed on the workpiece or work tank, you may accidentally press the axis
move keys on the portable operation panel by your elbow. Take always care of
the location of portable operation panel.
• Placing the tools such as a workpiece clamp or hex. Wrench on the elevating
work tank causes a danger. Do not place them at all times.
• Do not place anything at all in the vicinity of work tank.
• Never put your hand into the X, Y, Z axis stroke during automatic operation.
When putting your hand into the stroke unavoidably during automatic wire
threading, make preparation so that you can press the EMERGENCY STOP
button with other hand to avoid unexpected hazardous machine motion.
• Provide sufficient illumination.
• Do not clean the machine by air blow.

• Never relocate or bypass the stroke limiting dogs, interlock limit switches, and
interlock circuits.
• Dress yourself properly. Arrange your hair and clothes so that you are not
caught by the machine. Do not wear a ring or other accessories or gloves.
• Wear protection glasses and safety shoes to ensure safety.
W0721C-I1E-01 3
SP43 Safety
1.3 Precautions on Checking
During a checking, pay attention to the following:
• Checking, repair, and maintenance of the machine or equipment must be

performed after thorough examination by only the personnel who knows well
about the structure, operation, and possible hazards.
• Follow traditional practices executed in your shops.
• Dress yourself properly. Arrange your hair and clothes so that you are not
caught by the machine. Do not wear a ring or other accessories or gloves.
Wear protection glasses and safety shoes to ensure safety.
• During a checking or maintenance, the personnel may not be seen from the
third person. Tag or stick a warning sign indicating “UNDER INSPECTION” to
the main switch or a proper place necessary for hazard prevention.
• During work with the power turned on, stick a warning sign to a visible place
such as operation panel to notify the third person that the work is under way.
• Before turning on the power switch, clear unnecessary workpieces or goods off
the machine and its periphery, and also make sure the location of
EMERGENCY STOP button.
• In checking the operating condition or making a check with the covers left open,
pay attention to the following:
* Do not touch rotating or moving parts.

* Do not touch moving axes.
* Be careful about the parts which are going to start.
4
Safety SP43
1.4 Precautions on Maintenance
During the maintenance, pay attention to the following:
• The maintenance of the machine or equipment must be performed after

thorough examination by only the personnel who knows well about the
structure, operation, and possible hazards.
• Do not perform maintenance (repair) other than those mentioned in the

instruction manual.
• The machine installation, relocation, or repair must be performed by the

qualified personnel only.
• Upon connection with AC power supply, the source voltage is applied to the
machine and equipment. Hazardous voltage is present in the equipment even if
the breaker of the equipment is opened.
• The voltage remains in many places for about 10 seconds after the main power
switch is turned off.
• In performing maintenance or adjustment, press the EMERGENCY STOP

button with a lock to shut off the power supply, so that the third person cannot
start the machine accidentally from other place.
In the power off status where the maintenance and adjustment are not
performed, first tag a signboard to a visible place such as operation panel,
indicating that maintenance is under way and the machine operation is
inhibited, so that the third person does not operate the machine accidentally.
• Attach a breaker or circuit breaker with a fuse for overcurrent protection

regulated by the law, if not attached to the equipment.
Please contact the nearest service centers, when you have uncertain points in the
instruction manual, and you don’t know how to perform maintenance or adjustment.
W0721C-I1E-01 5
SP43 Safety
2 WARNING LABELS
2.1 Kinds and Meaning of Warning
Possibility of injury or damage

Major (urgent) Medium (possible) Minor (potential)
Death
DANGER WARNING
Serious injury
CAUTION
Minor injury,
material loss
The Instruction Manual lists precautions concerning the operation and

maintenance.
The precautions are classified into four categories according to the degree of
danger
DANGER
Failure to follow the instructions will cause an urgent danger which leads to
the death or a serious injury.
WARNING
Failure to follow the instructions can cause a condition where there is a
possibility of death or a serious injury.
CAUTION
Failure to follow the instructions can cause a condition where there is a
possibility of medium or minor injury. This may also be used to alert the
operator of unsafe traditional practices.
NOTE
Useful information on the machine operation.
6
Safety SP43
2.2 Location of Warning Labels
Possible hazardous places are indicated with the illustration and text on the
warning labels.
• The warning labels give the following information:
• Contents and nature of danger (danger, warning, caution)
• Degree of damage cause by danger
• How to avoid danger
The labels with thick leader lines and illustrations enclosed with thick frames are stuck
to the machine.
When a warning label peeled off or has become illegible, please get it from us or our
agents, and stick to the original position. When a part where a warning label is stuck
was replaced, stick a new warning label to the same position as before.
W0721C-I1E-01 7
SP43 Safety
2.2.1 Machine Front View
Maintain machine
periodically
If not, machine
movement may be bad,
machining may be
inferior or mechanical
parts may be broken.
Fig.1 Warning labels (Machine Front View)
8
Safety SP43
2.2.2 Machine Left View
MECHANICAL UNIT
BREAKS DOWN.
CLEAN PERIODICALLY
CLEAN TANK.
Fig.2 Warning labels (Machine left view)
W0721C-I1E-01 9
SP43 Safety
2.2.3 Machine Right View
MECHANICAL UNIT
BREAKS DOWN.
CLEAN PERIODICALLY
CLEAN TANK.
Fig. 3 Warning labels (Machine right view)
2.2.4 Machine Rear View
Fig.4 Warning labels (Machine rear view)
10
Safety SP43
2.3 List of Safety Precautions
2.3.1 Automatic operation

• During operation in dry run mode.............. Getting pinched your hand or body.
resulting in cut or fracture of a bone
• During automatic wire threading ............... Getting pinched or caught your hand
in, or burned.
• During machining ...................................... Feeling an electric shock, or

getting pinched your hand or body.
Dielectric fluid splashes.
2.3.2 Manual operation

• Portable operation panel ........................... Leaving carelessly this panel on
the workpiece or work tank allows
you to press the axis move button
by your elbow, causing a serious
accident. Not knowing that you are
operating portable operation panel
at the rear of machine, the third
person may operate the main
operation panel, causing an
accident.
• Setup of workpiece
Loading/unloading .................................... Workpiece, if falling, breaks your
bone, cuts or pinches your leg.
Centering................................................... Getting pinched your hand or body,
resulting in fracture of a bone.
• Axis movement.......................................... Getting pinched your hand or body,
resulting in fracture of a bone.
Getting pinched your body by the
rear of machine, resulting in death.
• MDI operation............................................ Be careful with possible danger in
both automatic and manual
operations. Electric shock, fracture
of a bone, bruise, etc.
W0721C-I1E-01 11
SP43 Safety
2.3.3 Routine checking and maintenance

• Replacing wire bobbin ................................. Bobbin, if falling, hurts your foot.
• Cleaning wire box........................................ Wire cuts or pierces your hand, or
it bounds and enters your eye.
• Cleaning head ............................................. Getting cut or pinched your hand.
• Cleaning wire feed rollers............................ Getting caught your had in.
• Replacing fluid filter ..................................... Unless you wait for water pressure
drops, the dielectric fluid blows out
and wets the floor, causing you to
be slipped and stumbled.
• Replenishing fluid ........................................ Fluid, if spilling, wets the floor,
causing you to be slipped and
stumbled.
• Cleaning fluid .............................................. Getting pinched your hand or body
• Cleaning filter in dielectric fluid cooler ......... Dust enters your eyes or the fan
cuts your fingers.
• Maintaining electrical parts.......................... Electric shock, burn, fire.
• Maintaining power supply cable .................. Electric shock, burn, fire.
• Chemicals (antirust agent,
antiseptic agent, cleaner, acid) ................... Attach your skin or enter your eyes
2.3.4 Others
• Tools ........................................................... Getting hart due to falling,

pinching, or slipping tools.
2.3.5 Warning labels
The warning labels give information on the degree of danger, kind of danger, and
how to avoid danger about the very hazardous places.
Among them, the warning labels enclosed with thick frames are stuck to the
machine. Understand well the contents of information given with these labels.
12
Installation SP43
Chapter 2 INSTALLATION
W0721C-I1E-01 Installation.fm
SP43 Installation
Contents
1 PRECATION ON INSTALLATION
2 INSTALLATION PLACE REQUIREMENTS

2.1 Installation Environment .......................................................................... 1
2.2 General View........................................................................................... 3
2.3 Layout plan...............................................................................................5
3 NECESSARY FACILITIES
3.1 Machine Facilities .................................................................................... 7
3.1.1 Machine specifications .................................................................... 7
3.1.2 Drain piping facility .......................................................................... 7
3.1.3 Drain duct and hose .........................................................................8
3.1.4 Air supply piping ............................................................................. 9
3.2 Power supply facility .............................................................................. 10
Installation SP43
1 PRECATION ON INSTALLATION
(1) The machine must be installed or relocated by only the qualified personnel
designated by Makino.
(2) The “Installation” manual covers the installation requirements and facilities
necessary for machine installation. For the safety use of machine, prepare
the facilities that satisfy completely the installation requirements.
2 INSTALLATION PLACE REQUIREMENTS
2.1 Installation Environment
Select an installation place while taking care of the following points:

(1) A place free from vibration and shock
(2) A light place free from dust
(3) A place not exposed to direct sun light
(4) A place of less temperature change
(5) The cooling fans are provided, one each at the machine, NC power supply
unit, and dielectric fluid • air pressure supply unit. Therefore, the installation
place should ensure the intake and exhaust air flow.
(6) Ensure sufficient service area by referring to the layout plans (Fig.2).
(7) Provide a space for easy workpiece mounting and dismounting.
(8) An easily accessible place to carry in and out the machine
(9) A place durable to the machine weight
(10) A place where the floor surface around the machine is applied with the
anti-slip treatment.
(11) In order to prevent the radio wave interference, a shield room may be
required, depending on the environment.
(12) Ensure the dielectric fluid disposal place since the dielectric fluid cannot be
drained directly into a general drainage because it contains chips.
A drain port is provided on the rear of dielectric fluid • air pressure supply
unit.Connect the hose described in 3.1.2 Drain piping facility (see Fig.3).
W0721C-I1E-01 1
SP43 Installation
[Installation conditions]
Ambient temperature : 10~35°C (optimum 20±1°C)
Relative humidity : 35~75% (no condensation)
Vibration : 0.07G or less
[Machine heating value]

At full operation : 8.1kW
[Machine noise]
Equivalent continuous A load sound-pressure level : 66dB
Peak C load instantaneous sound-pressure level : 3.1×10-2Pa
2
Installation SP43
2.2 General View
Fig.1-1 SP43 general view
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SP43 Installation
Fig.1-2 SP43 general view (for Japan)
4
Installation SP43
2.3 Layout plan
Fig.2-1 SP43 layout plan
W0721C-I1E-01 5
SP43 Installation
Fig.2-2 SP43 layout plan (for Japan)
6
Installation SP43
3 NECESSARY FACILITIES
3.1 Machine Facilities
3.1.1 Machine specifications
Machine size (W × D × H) : 2550mm × 2550mm × 2250mm

Floor space required : 3400mm × 3900mm
Machine mass : 3700kg (inc. NC power unit)
3.1.2 Drain piping facility
The drain facility is required to drain the dielectric fluid for maintenance and to
prevent flood in case of a machine trouble.
Prepare the following:
• Drainageway
• Drain hose (inside diameter ø25mm)
After installation of the machine, connect a drain hose to the over flow hose
nipple provided at the side of dielectric fluid • air pressure supply unit, and lead it
to the drainageway.
After connection, set the valves as follows:

Clean tank drain valve : Fully close
Dirty tank drain valve : Fully close
Over flow
hose nipple
Clean tank
drain valve
Dirty tank
drain valve
Fig.3 Drain piping facility
W0721C-I1E-01 7
SP43 Installation
3.1.3 Drain duct and hose
Drain duct and drain hose must be remove from the machine during
transportation.
During installation, ensure O-ring is fixed innto the groove (fig.4).
O-rings
Drain hose Hose band Socket head

bolt, washer
Drain duct
Fig.4 Drain duct
8
Installation SP43
3.1.4 Air supply piping
The air pressure is required for the machine to operate. The machine stops if the
air pressure lowers below 0.3MPa during operation. Prepare stable air pressure
source.
Prepare the following:
Air pressure source
Pressure : 0.6MPa or more
Flow rate : 100L/min (atmospheric pressure) or more
Air hose
Inside dia.: ø8mm
An air supply coupler is attached to the machine as a standard accessory.

Connect the prepared air hose to this coupler.
Confirm with the pressure gauge that the air pressure is the specified value. If out
of the specified value, adjust it with the regulator.
If a compressor in the factory is stopped once, then it is started abruptly, the auto drain
may be kept open, causing the pressure not to rise up to the specified value. In this
case, reconnect the coupler.
Regulator
Air supply
coupler
Pressure gauge
Air filter (5µm) Mist separator (0.3µm)
Fig.5 Air supply piping facility
W0721C-I1E-01 9
SP43 Installation
3.2 Power supply facility
Prepare the following power supply facility.

Power supply specifications: AC200V ±10%, 50Hz ±1%
AC200/220V ±10%, 60Hz ±1%
Total power supply capacity : 18kVA
Circuit breaker capacity : 50A
Earth-leakage breaker : For inverter circuit, working current 50mA
(if a shield room is not available)
Connection terminals : Crimp terminals fixed with M6 screws
Grounding work : Special Class-3 grounding is recommended.
(Grounding resistance 10 ohms or less)
Power cable size : 8mm2
10
Description Of Product SP43
Chapter 3 DESCRIPTION OF
PRODUCT
W0721C-I1E-01 Description Of Product.fm

SP43 Description Of Product
Contents
1 PRECAUTIONS
1.1 Handling the machine...............................................................................1
1.2 Precautions on safety...............................................................................1
1.3 Precautions on working ............................................................................1
2 MAIN SPECIFICATIONS
2.1 Mechanical Specifications ........................................................................3
2.2 Specifications detail..................................................................................3
2.3 Part name and axis direction....................................................................6
2.4 Machine coordinate system, orgin, and reference point...........................9
3 POWER SWITCH ...........................................................................................10
4 MOUNTING DEVICES
4.1 Mounting plate........................................................................................12
(1) Table (U-shape) ...................................................................................12
(2) Table (Square) (Option).......................................................................13
(3) Table (Square) (USA standard specification only)...............................14
4.2 Workpiece clamping ...............................................................................15
1 PRECAUTIONS
1.1 Handling the machine

(1) Designate the personnel exclusively for this machine.
(2) Only the designated personnel can perform the maintenance and repair after
making a prior investigation.
1.2 Precautions on safety

(1) After confirming the loaction of EMERGENCY STOP button, turn on the
Power switch and start operation.
(2) Do not clean the table, or workpiece at the machine periphery using the air
blow.
(3) Keep the doors and covers on the NC power supply unit and the dielectric
fluid • air pressure supply unit.
1.3 Precautions on working

(1) Illuminate properly the machine periphery, and always keep the machine and
its environment in order.
(2) Take care not to hit the lower head with the workpiece, when mounting or dis
mounting the workpiece.
(3) Make sure that the workpiece fasteners or workpiece does not interfere withe
the upper and lower heads.
(4) Make sure that htere is no obstacle in moving ranges, when moving the X, Y,
U, V, and Z axes.
(5) Do not block the vents provided on the top and sides of machine, NC power
supply unit, and dielectric fluid • air pressure supply unit.
W0721C-I1E-01 1
2 MAIN SPECIFICATIONS
2.1 Mechanical Specifications
Travel
X-axis (Beam longitudinal) 450 mm
Y-axis (Table cross) 300 mm
Z-axis (Upper head vertical) 320 mm
U-axis (Upper head longitudinal) ±101 mm
V-axis (Upper head cross) ±101 mm
Table
Table size 730 mm x 500 mm U-shaped
730 mm x 500 mm Square (option)
730 mm x 540 mm Square (USA standard
specification only)
Max. loading capacity 800 kg

Table surface geometry 64-M8 tap, 38-M6 tap U-shape
55-M8 tap, 28-M6 tap Square (option)
73-M8 tap, 38-M6 tap Square (USA standard
specification only)
Floor to table surface distance 970 mm

Work tank size 890 mm x 850 mm
Max. workpiece size 730 mm x 500 mm x 300 mm
Squrare workpiece mount plate (Optional)
Cross plate (Optional)
Sliding square jig (Optional)
Machine Dimensions
Width x Depth x Height 2550 mm x 2550 mm x 2250 mm
Floor space required 3400 mm x 3900 mm (incl. maintanence
space)
Machine weight 3700 kg

(incl. NC power unit)
2
2.2 Specifications detail

(1) Head
Wire guide V-flat diamond : 0.25 std
Wire electrode diameter ø0.2 mm, ø0.25 mm, ø0.3 mm
(2) Wire feed unit

Wire feedrate 0 , 50~360 mm/s
Wire tension 2 ~ 20 N {0.2 ~ 2.0 kgf}
Max. wire reel weight 20 kg (optional) Large capacity wire feeder
(3) Feedrate
Rapid traverse rate X, Y, Z - 2000 mm/min
U, V - 1000 mm/min
Servo feedrate 0.01 - 50 mm/min
Jog feedrate 50, 150, 600 mm/min
(4) Automatic wire threading unit

Type Water jet
Min. prepared hole dia. ø1.4 mm / 100 mm plate thickness
ø0.5 mm / 30 mm plate thickness
(Wire ø0.20mm, no slit, both nozzle close)
Threading time 15s / 30 mm plate thickness
(Retry 3, wire ø0.20 mm, no angle cut.)
(5) Taper machining unit

Max. taper angle ±35º / 100mm plate thickness
(mechanical)
(6) Motors
Axis feed motors X, Y - AC 0.5kw
U, V, Z - AC 0.4kw
Flushing pump motor 2.2 kw x 2
Filter pump motor 0.55 kw
Tank filling pump motor 1.6 kw
Circulation pump motor 0.37 kw
Dielectric cooler compressor 1.1 kw
W0721C-I1E-01 3
(7) Power source requirements

Power supply AC 200/220 V ±10%, 50/60 Hz±1%, 21 kVA
Terminals - Crimp terminals with M6 screws
Grounding - Class C grounding
(Ground resistance below 10 ohms)
Air pressure source 0.6 MPa or more, 100 L/min(must be

clean & dry), Connection port ø8
coupler (standard accessory)
(8) Tank capacity

Dielectric supply tank 750 L
Clean tank 130 L
Dirty tank 620 L
Work tank 430 L
(9) Accuracy
Positioning accuracy ±0.015 mm
Repeatability ±0.015 mm
(10) Machining performance

Profile machining accuracy ±0.005 mm / 40 mm plate thickness
(SKD-11, wire ø0.20 mm )
Roundness ±0.005mm / ø30 mm,40 mm plate thickness
(SKD-11, wire ø0.20 mm )
Surface roughness 20 µmRY ; 1st cut
12 µmRY ; 2nd cut
4 µmRY ; Micron cut
(SKD-11, 40mm plate thickness,
wire ø0.20 mm)
(11) Dielectric fluid control

Flushing Upper and lower independent digital control
Tank filling Rapid fill / circulation change over
Temperature ±0.5 ºC (tuned to machine temp.)
Conductivity 1~200 µS/cm
Filtering system Inside-out type paper filters x 4 pcs
4
(12) Machining power supply

Circuitry Transistor pulse
Max. machining current 45 A (Standard)
55 A (Option, USA standard only)
Current setting 128 steps
OFF interval 256 steps
Voltage regulating circuit Standard
New LL power supply circuit Standard
Power unit cooling system Forced air cooling
Power supply 3.2 kVA (Standard)
6.4 kVA (Option, USA standard only)
(13) Electrical
NC power suply unit Model MGW-R
Work light (Optional for USA only)
Automatic power failure recovery
Power line filter (Optional)
Export transformer (Optional)
(14) Dielectric fluid • air pressure supply unit size

Floor space x height 820 mm x 1900 mm x 1550 mm
Weight 300 kg (w/o water)
(15) NC power supply unit size

Floor space x height 520 mm x 1250 mm x 2200 mm
Weight 400 kg
(16) Installation conditions

Ambient temperature 10~35 ºC (optimum 20±1 ºC)
Relative humidity 35~75 % (no condensation)
Machine heating rate 8.1 kW { 6970 kcal/h }
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6
2.3
SP43
U,V,Z axes
-U +U Wire feed unit
Protective cover
(1) Front View
NC Power &
Wire guide unit supply unit
(Upper)
+Z
Upper head
Description Of Product
-Z
Part name and axis direction
+X -X
Work tank
Work table
Fig.1 Name of each part (SP43 Front View)

Lower head
Bed
(2) Left side view
Dielectric fluid
air pressure
supply unit
NC power supply unit
Wire box
Fig.2 Name of each part (SP43 left side view)
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8
SP43
NC power
Wire feed unit -V +V supply unit
Protective cover
U, V, Z axes
(3) Right side view
Wire guide unit

Upper head
Work tank
Description Of Product
+Y -Y
Work table
Lower head
Fig.3 Name of each part (SP43 right side view)

Bed
2.4 Machine coordinate system, orgin, and reference point

(1) Coordinate system
The machine coordinate system and the work coordinate system are available as
coordinate systems. The machine coordinate system is an intrinsic to the
machine, and it cannot be set arbitrarily. On the other hand, the work coordinate
system can be set arbitrarily. The coordinate words used in a program are speci-
fied in the machine coordinate system (G53) or in the work coordinate system.
(2) Machine coordinate system, machine origin, and reference point
The machine origin of each axis of X,Y,U,V positions at the one end of each axis
stroke.
U, V
X, Y reference point
Machine coordinate
reference point
SP43: X225, Y150
(wire vertical position)
V-axis stroke
Y-axis stroke
X, Y machine
U-axis stroke
origin
U, V machine origin
X-axis stroke
Fig.4 Machine coordinate system
The NC controller manages each axis current position, record of machining start
point, pitch error compensation, wire vertical position, etc in the machine coordi-
nate system. When the reference point reutrn (auto, manual, or G28)is executed,
each axis returns to the reference point and thus, the machine coordinate system
is set correctly. Immediately after the power on, the machine coordinate system
is disordered, and therefore the reference point return must be executed. The
reference point of X and Y axes is positioned in the center of stroke in the nozzle
close status.
SP43 reference point : X225. Y150
The reference point of U and V axes is positioned at the wire vertical position
(almost center of U,V stroke.)
W0721C-I1E-01 9
3 POWER SWITCH
Main switch
EMERGENCY STOP ON button

button SOURCE lamp
OFF button
Fig.5 NC power supply unit
10
(1) Power ON procedure
Before turning the power ON, ensure that the dielectric fluid tank is full.
(a) Turn the main switch ON. At this time, the source lamp comes on.
(b) Press the ON button on the main operation panel. After several seconds, the
initial screen will appear.
(2) Power OFF procedure
The power OFF must be ececuted on other than the EDIT screen.
(a) Press the OFF button on the main operation panel. At this time, the screen
on main operation panel disappears.
(b) Turn the main switch OFF. At this time, the SOURCE lamp goes off.
W0721C-I1E-01 11
4 MOUNTING DEVICES
4.1 Mounting plate

(1) Table (U-shape)
Fig.6 SP43 Table (U-shape)
12
(2) Table (Square) (Option)
Fig.7 SP43 Table (Square) (Option)
W0721C-I1E-01 13
(3) Table (Square) (USA standard specification only)
Fig.8 SP43 Table (square) (USA standard specification only)
14
4.2 Workpiece clamping
Stud bolt
Nut M8
Washer M8
Adjusting bolt M8
Nut M8,
Clamp Washer M8
Workpiece
Stud bolt M8
Adjusting bolt M8
Workpiece fixture
Clamp (System 3R)

Socket head bolt M6
Adjusting bolt M6
Workpiece Cross plate (System 3R)
Clamp
Nut M8
Washer M8
Stud bolt M8
Adjusting bolt M8
Workpiece fixture
Fig.9 Workpiece clamping
W0721C-I1E-01 15
Be careful with the interference between head and fasteners.
To clamp the workpiece, use the left or right workpiece fixture.

(Vibration prevention)
Do not tighten excessively the bolts and nuts that clamp the workpiece. Otherwise, the
workpiece fixture could deform or the tapped holes in the workpiece fixture could be
broken. Where large clamping is required for heavy workpieces, increase the number
of clamping positions or use workpiece support (optional).
• M6 screw recommended tightening torque:

About 12 Nm
• M8 screw recommended tightening torque:
About 29 Nm
Workpiece fixture
Fig.10 Screw recommended tightening torque
16
For the bolts that clamp the workpiece, screw them in the tapped holes up to the length
at least 1.5 times the diameter (L=15D). Otherwise, the tapped holes in the workpiece
fixture could be damaged.
• M6 screw recommended insertion length L:

About 9mm or more
• M8 screw recommended insertion length L:
About 12mm or more
Workpiece Workpiece
Workpiece fixture Workpiece fixture
Too short insertion length (L < 1.5D) > 1.5D)

Proper insertion length (L >
=
Fig.11 Screw recommended insertion length
W0721C-I1E-01 17
Fasteners (optional)
Fig.12 Fasteners
18
Maintenance SP43
Chapter 4 MAINTENANCE
W0720C-I1E-01 Maintenance.fm
SP43 Maintenance
Contents
1. PREAUTIONS ON MAINTENANCE
2. WIRE AND CONFIGURATION

2.1 Wire ..........................................................................................................2
2.1.1 Wire used .........................................................................................2
2.1.2 Straightness of recommended wire..................................................3
2.1.3 Wire path..........................................................................................4
2.2 Configuration ............................................................................................6
2.2.1 Wire guide unit (upper).....................................................................6
(1) Configuration of wire guide unit (upper).....................................6
(2) Function of each component .....................................................6
2.2.2 Wire guide unit (lower) .....................................................................8
(1) Configuration of wire guide (lower) ............................................8
(2) Function of each component .....................................................8
2.2.3 Wire winding unit............................................................................10
(1) Configuration of winding unit ...................................................10
(2) Function of each components..................................................10
2.2.4 Upper head ....................................................................................11
2.2.5 Lower head ....................................................................................12
(1) Lower head configuration ........................................................12
(2) Function of each component ...................................................12
(3) Prohibited removal...................................................................15
(4) Wire loading method................................................................15
2.2.6 Taper cutting unit ...........................................................................18
(1) Appearance .............................................................................18
(2) Taper machining and mechanical limitation.............................18
2.2.7 Z-axis .............................................................................................20
2.2.8 Dielectric fluid system ....................................................................21
2.2.9 Air system ......................................................................................28
Maintenance SP43
2.2.10 Work tank .......................................................................................31
3. ROUTINE INSPECTION AND CLEANING

3.1 Daily Inspection, Cleaning, and Adjustment...........................................35
3.1.1 Checking available wire quantity and removing wire in wire box ...35
3.1.2 Cleaning the wire tip sensor...........................................................35
3.1.3 Checking wear of energizing plate.................................................36
(1) Changing of energizing position (upper head)
and energizing plate ................................................................36
(2) Changing of energizing position of lower head........................37
(3) Replacing worn out energizing plate........................................39
(4) Cleaning energizing plate ........................................................41
3.1.4 Cleaning diamond guide and press guide......................................43
3.1.5 Open-close motion of press guide .................................................44
(1) Checking open-close motion of press guide............................44
(2) Cleaning press guide open-close piston..................................45
3.1.6 Checking wear of dielectric nozzle.................................................46
3.1.7 Checking fluid level in dielectric tank .............................................46
3.1.8 Checking pressure of fluid filter......................................................48
3.1.9 Checking air pressure of regulator.................................................48
3.2 Weekly Inspection, Cleaning, and Adjustment .......................................49
3.2.1 Cleaning clutch roller (D-shaft) and I-roller, and checking wear ....49
(1) Cleaning the clutch roller (D-shaft) ..........................................49
(2) Cleaning I-roller and checking wear ........................................50
3.2.2 Checking felt pads for dirtiness ......................................................51
(1) Position change and replacement of felt pad...........................51
(2) Changing position and replacing felt pads for wire guide ........52
3.2.3 Cleaning nozzle guard, and checking damage ..............................53
3.2.4 Cleaning the winding roller (M-shaft) and pinch roller (L-shaft) .....55
3.2.5 Cleaning the radiator and filter for dielectric fluid cooler unit .........56
3.2.6 Cleaning conductivity sensor .........................................................57
3.2.7 Cleaning inside walls of work tank,
work tank door seals, and work table.............................................58
3.3 Monthly Inspection, Cleaning, and Adjustment ......................................59
W0720C-I1E-01
SP43 Maintenance
3.3.1 Inverting clutch roller (D-shaft) .......................................................59

3.3.2 Adjusting tension of powder clutch.................................................60
3.3.3 Cleaning a die of wire guide unit (upper) .......................................63
3.3.4 Wire vertical alignment...................................................................63
(1) Confirmation before performing wire vertical alignment ..........63
(2) Wire vertical alignment ............................................................64
3.3.5 Cleaning inside of clean tank (monthly) and dirty tank (yearly)......66
4. REPLACING CONSUMABLES
4.1 Replacing Diamond Guide and Press Guide..........................................68
4.2 Replacing V-Guide .................................................................................71
4.2.1 Replacing method (upper head).....................................................72
4.2.2 Replacing method (lower head) .....................................................73
(1) Replacing the V-guide .............................................................73
(2) Replacing V-guide pulley .........................................................73
4.3 Changing Cutter Edge Position, and Replacement ................................75
4.4 Replacing Dielectric Nozzle and Nozzle Guard......................................77
4.4.1 Dielectric nozzle and nozzle guard for standard machining...........77
4.4.2 Dielectric nozzle for high speed machining....................................78
4.4.3 Laminar nozzle...............................................................................79
4.4.4 Head cover.....................................................................................79
4.5 Replacing worn out winding roller (M-axis) and pinch roller (L-axis) ......80
4.6 Replacing Fluid Filters ............................................................................81
4.7 Replacing jet filter element .....................................................................83
4.8 Replacing ion exchange resin ................................................................84
4.9 Replacing Air Filter Elements .................................................................86
5. OTHER CLEANING AND ADJUSTMENT

5.1 Maintaining Jet for Automatic Wire Threading .......................................88
5.1.1 Cleaning dust protection mesh.......................................................88
5.1.2 Cleaning the jet nozzle (upper) ......................................................89
5.1.3 Adjusting jet water..........................................................................92
5.2 Maintaining Nozzle Holder for Automatic Wire Threading......................93
5.2.1 Removing nozzle holder (water separator) ....................................93
Maintenance SP43
5.2.2 Removing a pipe for automatic wire threading...............................96

5.2.3 Checking Nozzle Holder (Water Separator)...................................97
5.3 Adjusting Nozzle Guard Height ..............................................................98
5.4 Mounting Head Cover ............................................................................99
5.5 Maintaining K-Shaft ..............................................................................101
5.5.1 Removing the K-roller ..................................................................101
5.5.2 Replacing the K-shaft bearing......................................................102
5.5.3 Adjusting Pinch Roller (L-Shaft) Pressing Force..........................103
5.6 Adjusting Wire Tip Sensor....................................................................104
5.7 Cleaning and adjusting drain valve on head ........................................106
6. REMEDY FOR TYPICAL TROUBLES

6.1 Wire Break............................................................................................107
6.1.1 Wire break in head during machining ..........................................108
6.1.2 Wire break in wire system during machining (wire feeding).........108
6.1.3 Wire break in workpiece during machining ..................................110
6.1.4 Wire break during automatic threading ........................................112
6.2 Operation Failure during Machining .....................................................114
6.2.1 Dielectric fluid spouts from upper head........................................114
6.2.2 Water leaks from nozzle holder (water separator) .......................114
6.2.3 Many bubbles in work tank ..........................................................114
6.2.4 Low dielectric fluid pressure.........................................................115
6.2.5 Large curl of used wire.................................................................115
6.2.6 False detection of “WIRE BREAK” alarm.....................................116
6.2.7 Alarm “HEAD PROTECT DETECTED” occurred.........................117
6.2.8 Alarm “BACK BLOCK OUT DUE TO SHORT” or
“BACK LENGTH OUT DUE TO SHORT” occurred ...................... 117
6.3 Machining Performance Failure ...........................................................118
6.3.1 Decreased machining speed and unstable machining ................118
6.3.2 Faulty machining accuracy ..........................................................120
6.3.3 Faulty finished surface .................................................................121
6.4 Faulty Wire System ..............................................................................122
6.4.1 Wire cannot be feed.....................................................................123
6.4.2 Wire cannot be feed.....................................................................123
W0720C-I1E-01
SP43 Maintenance
6.4.3 Clutch roller (D-shaft) rotates intermittently..................................124

6.4.4 Loose wire between clutch roller (D-shaft) and C-pulley..............124
6.4.5 Noisy clutch roller (D-shaft)..........................................................125
6.4.6 Slippery clutch roller (D-shaft)......................................................125
6.4.7 Slippery I-roller .............................................................................125
6.4.8 Wire tangles with wire winding section.........................................125
6.4.9 Wire is rewound up to A-shaft (at AWT).......................................126
6.4.10 Wire is not rewound up to wire tip sensor ....................................126
6.4.11 Wire cannot be cut with cutter......................................................126
6.4.12 Water leaks from nozzle holder (water separator) .......................127
6.4.13 Wire runs out of wire guide unit (upper) at wire cut......................127
6.4.14 No jet water is injected .................................................................127
6.4.15 Press guide does not open or close.............................................127
6.5 Low Wire Threading Success Rate ......................................................128
6.5.1 Faulty water jet.............................................................................128
6.5.2 Wire does not enter prepared hole in workpiece..........................129
6.5.3 Wire easily gets stuck after lower head........................................130
6.5.4 Frequent touch retry after completion of AWT .............................130
6.6 Operation Failure at Power ON or OFF or Power Failure ....................131
6.6.1 Wire is rewound up to supply reel
(in use of large capacity wire spool loader)..................................131
6.7 Troubles during Maintenance...............................................................131
6.7.1 K-roller cannot be removed..........................................................131
6.7.2 Energizing plate cannot be removed............................................131
6.7.3 Vertical alignment position varies.................................................131
7. MEASURE OF OBSTRUCLE
7.1 Adjustment of clutch roller against wire vibration .................................133
7.2 Line-up of Wire Feed System ...............................................................134
8. MAIN CONSUMER PARTS

8.1 Consumable Parts List .........................................................................137
8.2 Precautions on Consumables ..............................................................139
Maintenance SP43
How to Use Maintenance Chapter
To maintain high machine performance, execute maintenance items

given herein.
Keep the Maintenance manual at hand so that you can consult it as

necessary.
This manual covers the maintenance and repair only.
Contents of Maintenance chapter

Precautions on Maintenance................... Read together with “Safety” chapter.
Routine Inspection and Cleaning ............ Lists items requiring periodical
inspection, cleaning, and adjustment.
These items are listed based on the
contents of checksheet attached to the
machine.
Replacing Consumables ......................... Gives a replacing method for parts of
which replacement interval is different
depending on the operating conditions.
Read together with Routine Inspection
and Cleaning.
Additional Cleaning and Adjustment ....... Gives maintenance information
(cleaning and adjustment methods)
necessary in case of a trouble.
Remedy for Main Troubles ...................... Lists measure against failure by
symptom (including repair).
Main Consumables List ........................... Lists consumables necessary for
maintenance.
W0720C-I1E-01
SP43 Maintenance
1. PREAUTIONS ON MAINTENANCE
(1) Maintain the machine by only the persons who have already received safety
training including the operation and maintenance of this machine.
(2) Do not perform maintenance (service) other than that listed in the Instruction
Manual.
(3) Install, relocate, or maintain the machine by only the competent persons
designated by us.
However, maintenance personnel for this machine may perform only the
repair that is listed in "6.Remedy for typical trouble".
(4) Upon connection of AC power supply, the supply voltage is applied to the
machine. It is very dangerous to touch the machine internal parts unless all
phases of system power lines are disconnected. Even if the power switch or
circuit breaker is turned off, hazardous voltage may be present in the
machine from external system controller.
(5) The voltage remains in many places for 10 seconds even after the main
power switch is turned off.
Extreme care should be taken when making an access to the live parts.
(6) In performing maintenance or adjustment, always press the EMERGENCY
STOP button with a lock to prevent an unexpected starting from remote
place. If maintenance cannot be performed with the EMERGENCY STOP
button with a lock kept pressed, lock the movable axes and winding rollers in
advance. Further, tag a sign board at an easy-to-see place on the front side
of machine, indicating that the maintenance is underway and any operation
is prohibited, so that a person other than maintenance personnel does not
operate the machine during maintenance.
(7) Before performing maintenance and inspection, check the main circuit
breaker (for primary power supply) for ON-OFF function.
(8) Be sure to install an overcurrent protective breaker or a circuit breaker with a
fuse specified by the law, if it is not installed.
(9) An accidental shortcircuit could generate overcurrent, causing a severe
damage to the machine or a serious injury to human body.
(10) Use an insulated instrument if measurement is done. Never turning on the
circuit breaker forcibly under overload condition.
(11) When you have some questions about the Instruction Manual or you don’t
know how to do maintenance because of no instruction, please contact our
nearest service center or agents.
1
Maintenance SP43
2. WIRE AND CONFIGURATION
2.1 Wire
2.1.1 Wire used

Standard machining condition have been set using the following wire electrodes.
Our recommended wire electrodes are as follows:
Standard speed machining
1) ø0.20, ø0.25, ø0.30 Hitachi Cable [ HBZU ] 3kg bobbin
2) ø0.10, ø0.15(option) Hitachi Cable [ HBZU ] 5kg, 10kg bobbins
High speed machining (option, USA standard only)
1) ø0.25, ø0.3 Berkenhoff GmbH [MEGACUT-D]
2) ø0.25 (reserved order), ø0.3 Berkenhoff GmbH [MEGACUT HS]
Taper machining (option)
1) ø0.25 (reserved order), ø0.3 Berkenhoff GmbH [MEGACUT HS]
Prohibit the use of high speed AWT mode (Retry 3) at 10kg bobbin.
There is a fear of wire break.
Marking
Marking
1 crest
2 crest
Fig.1 Mounting of supply reel (A-shaft) and wire straightness
W0720C-I1E-01 2
SP43 Maintenance
2.1.2 Straightness of recommended wire

(1) Draw the wire out of bobbin by about 1500mm and mark at the 1000mm
position from the end, then hang it down vertically as shown in Fig.1.
(2) Measure dimensions L & W and also the number of crests in L with the wire
hung. In addition, calculate the curl ratio as follows.
Curl ratio = ((1000-L)/1000) x 100 [%]
(3) Make sure that the W, curl ratio and number of crests satisfy the tolerance in
Table 1.
Table 1
W Curl ratio Number of crest
40mm or less 2% or less 2 cress or less
3
Maintenance SP43
2.1.3 Wire path

The wire path and main components are shown in Fig.2~3.
The wire drawn out from a supply reel (A-shaft) by the wire feed unit and it is fed
between upper and lower heads and dumped into a wire box.
B-pulley Looseness
detection switch
C-pulley
Felt pad
Felt pad
H-roller
Clutch roller
Supply reel (D-shaft)
Wire feed
unit
I-roller
Guide block
Fine hole automatic

wire threading unit
Wide roller
(A2-shaft)
Wire guide unit (upper)
Upper head
Fig.2 Wire path(1)
W0720C-I1E-01 4
SP43 Maintenance
Wire winding unit Upper head
Lower head
Wire guide unit

Wire box
(lower)
Fig.3 Wire path(2)
5
Maintenance SP43
2.2 Configuration
2.2.1 Wire guide unit (upper)

(1) Configuration of wire guide unit (upper)
[220] Felt pad
[213] Jet nozzle

[214] Sensor air blower
[215]
Wire tip sensor
[216]
Guide hole (lower)
[217]
[218] Positioning guide
Cutter
[219]
Cutter mounting
plate
Fig.4 Wire guide unit (upper)
(2) Function of each component

[212] Die
It guides the wire.
[213] Jet nozzle (upper)
It injects jet water to thread the wire in the start hole of the workpiece and
lead the wire up to [243] K-roller.
W0720C-I1E-01 6
SP43 Maintenance
Cleaning is required if the jet water is turbulent during automatic wire threading. For
cleaning of jet nozzle (upper), see "5.1.2 in Maintenance".
[214] Sensor air blower

It blows the air to remove the water attaching to the [215] wire tip sensor.
[215] Wire tip sensor

It detects the wire tip during automatic wire threading.
Clean the sensor with a swab everyday before start of machining.
[216] Guide hole (lower)

Insert a wire tip into this hole to check for wire bending.
Replace the wire if the wire tip extremely deviates from the hole.
[217] Positioning guide

It corrects dislocation of wire from the water stream.
[218] Cutter
It cuts the wire at the start of automatic wire threading.
Do not touch the cutter during automatic wire threading.
Shift a cutting position if the cutter becomes dull. For a shifting method of cutter cutting
position, see "4.3 in Maintenance".
[219] Cutter mounting plate
[220] Felt pad

It removes dust attaching to the wire, and prevents the wire from bouncing.
7
Maintenance SP43
2.2.2 Wire guide unit (lower)

(1) Configuration of wire guide (lower)
Main components of wire guide unit (lower) are shown in Fig.5.
[248] Nozzle holder

(water separator) [246] Pipe [243] K-roller (lower jet)
[249] [247] Protection pipe

Nozzle holder
mounting block [250] Drain pipe [245] Nozzle (lower)
Fig.5 Wire guide unit (lower)
[243] K-roller (lower jet)

It turns the directrion of wire by means of roller and its circumferential groove
guide the wire up to [245] nozzle (lower).
[244] K-shaft cover (lower jet)

It guides the wire up to [248] nozzle holder (water separator) by means of
lower jet.
[245] Nozzle (lower)

It guides the wire coming out of [243] K-roller to [246] pipe.
[246] Pipe
It guides the wire coming out of [243] K-roller to [248] nozzle holder (water
separator).
W0720C-I1E-01 8
SP43 Maintenance
[247] Protection
pipe
[243] K-roller
(lower jet)
[244] K-shaft
cover
[245] Nozzle [246] Pipe

(lower)
Fig.6 K-shaft
[247] Protection pipe

It protects [246] pipe, and also guides the pipe up to [245] nozzle (lower)
when mounting or demounting the pipe.
[248] Nozzle holder (water separator)

It separates the wire from the water stream that carries the wire, then it
guides the wire to the winding roller.
[249] Nozzle holder mounting block
[250] Drain pipe
9
Maintenance SP43
2.2.3 Wire winding unit

(1) Configuration of winding unit
Main components of wire winding unit are shown in Fig.7.
[254] Protection cover (L, M shafts)
[252] Pinch
roller (L-shaft)
[251] Winding
roller (M-shaft)
[255] Wire box
[253] M-shaft motor
Fig.7 Wire winding unit
(2) Function of each components

[251] Winding roller (M-shaft)
It is driven by the motor to wind up the wire sandwiched between winding
roller and [252] pinch roller (L-shaft).
[252] Pinch roller (L-shaft)

The oil in wire debris and compressed air attaching onto [251] winding roller
(M-shaft) and [252] pinch roller (L-shaft) will cause rollers to be slipped.
Clean the [251] winding roller (M-shaft) and [252] pinch roller (L-shaft) periodically
(every week). For the cleaning, see "3.2.4 in Maintenance".
W0720C-I1E-01 10
SP43 Maintenance
[253] M-shaft Motor

It drives [251] winding roller (M-shaft).
[254] Protection cover (L,M-shaft)

It prevents the wire in [256] wire box (1) and [257] wire box (2) from
touching directly the wire winding unit.
[255] Roller cover

It prevents the wire from tangling with [251] winding roller (M-shaft) and
[252] pinch roller (L-shaft).
2.2.4 Upper head

The upper head is vertically symmetric to the lower head.The components of
upper head, and parts replacement and adjustment are same as in the lower
head.
Fig.8 Upper head
11
Maintenance SP43
2.2.5 Lower head

(1) Lower head configuration
The components of lower head are shown in Fig.9.
[232] Power supply spring [229] Dielectric nozzle

[236] Plate washer
[230] Nozzle guard
[231] Head cover
[237] Power supply angle
[222] Press guide
[238] Lock nut
[235] Drain valve [234] Head
mounting block
[221] Diamond guide
[223] Guide retainer
[228] Press
[227] Wire guide bracket guide bracket
[225] Energizing plate [224] V-guide
[226] Spacer
[239] Wire support (1)
[224] V-guide
[242] Door
Fig.9 Lower head

[221] Diamond guide
A V-groove in the diamond guide holds the wire electrode (hereinafter
referred to as wire.)
Change the diamond guide according to the wire diameter used. For a changing
method, see "4. in Maintenance".
W0720C-I1E-01 12
SP43 Maintenance
[222] Press guide

It presses the wire against the [221] diamond guide.
Only one kind of [222] press guide is used regardless of wire diameter.
Replace the press guide, if worn out. For the replacement, see "4.1 in Maintenance".
[223] Guide retainer

It prevents a cracking of [221] diamond guide and [222] press guide when
they are tightened.
[224] V-guide
It guides the wire to the groove of [221]diamond guide, and pushes the wire
against the [225] energizing plate. Check the V-guide for wear before start of
machining.
Replace the V-guide, if worn out. For the replacement, see "4.2 in Maintenance".
[225] Energizing plate

It supplies the machining current to the wire.
Check the wire contact surface of the plate before start of machining. For the
replacement, see "3.1.3 in Maintenance".
[226] Spacer
Insert a [226] spacer if [225] energizing plate has worn extremely. For an
inserting method, see the "3.1.3 in Maintenance".
[227] Wire-guide bracket

The [224] V-guide is mounted.
[228] Press guide bracket

Mount the [222] press guide and [224] V-guide.
13
Maintenance SP43
[229] Dielectric nozzle (see 4.4 about details)

It injects the dielectric fluid. There are three types of [229] dielectric nozzles.
(Fig.10)
Use the nozzle type according to the workpiece or machining method.
Inreplacing the [229] dielectric nozzle, remove the [230] nozzle guard.
[230] Nozzle guard
Type-0, D8 High speed Type-8, D8 Laminar nozzle

Type-8, D6 (nozzle guard only)
Fig.10 Dielectric nozzle
For a taper machining over 10º taper, use the type-8 (for 15º taper) nozzle guard.
Do not expand the stroke, when using the type-8 (for 15º taper) nozzle guard.
Otherwise, the nozzle guard will collide against the work table.
Do not expand the stroke with the type-8 (for 15º taper) attached, when using the
type-0 work table (optional).
In the case of type-0 work table (optional), the type-8 (for 15º taper) nozzle guard will
collide against the work table when the nozzle approaches to the workpiece.
The dielectric fluid pressure will not rise to the specified value, if dielectric nozzle edge
wears or is damaged. Since the dielectric fluid pressure affects the machining
accuracy, check the dielectric nozzle before start of machining.
W0720C-I1E-01 14
SP43 Maintenance
[230] Nozzle guard

The [229] dielectric nozzle is mounted.
The height of nozzle guard must be adjusted. For the adjustment, see "5.3 in
Maintenance".
The nozzle guard requires periodical maintenance (every week). For the maintenance,
see "3.2.3 in Maintenance".
(3) Prohibited removal

The parts that must not be loosened during adjustment or replacement are
shown with X in Fig.11.
Fig.11 Prohibited removal
(4) Wire loading method

Route the wire in the order shown in Fig.12.
[201] Supply reel (A-shaft)
[202] Wide roller (A2-shaft)
This roller absorbs a bounce generated when the wire is fed from the [201]
supply reel (A-shaft) so as to minimize the variation in wire tension.
15
Maintenance SP43
[204] B-pulley
[207] Clutch roller (D-shaft)

[206] C-pulley
[201] Supply reel (A-shaft)
[202]
Wide roller
(A2-shaft)
Fig.12 Wire loading method
[203] Looseness detection switch
[204] B-pulley
[205] Felt pad

Remove dust attaching to the wire.
The felt pad requires periodical inspection (every week). For the inspection, see
"3.2.2 in Maintenance".
[206] C-pulley
[207] Clutch roller (D-shaft)

A resistance force generated in this roller gives the wire tension.
As shown in Fig.13, route the wire counterclockwise via the rear groove of
[207] clutch roller (D-shaft), [206] C-pulley, and front groove of [207] clutch
roller (D-shaft) in this order.
The clutch requires periodical maintenance (every week and month). For the
maintenance, see "3.2.1 and 3.3.1 in Maintenance".
W0720C-I1E-01 16
SP43 Maintenance
[206] C-pulley [207]

Clutch roller (D-shaft)
[208] H-roller
[209] I-roller
[210] Guide block
Setscrew M4
Fig.13 C and D shafts

[208] H-roller
[209] I-roller
The [208] H-roller eliminate wire looseness between D and H,I shafts. The
[208] H-roller together with the [209] I-roller sandwiches the wire by means
of a spring. The [208] H-roller can be moved in the arrow direction when
pushed with your finger (Fig.13).
The I-roller requires periodical inspection (every week). If a deep groove is made in the
I-roller and the wire slips during wire feed, loosen a setscrew M4 and shift the roller in
the arrow direction (Fig.47)
[210] Guide block

It prevents the wire from running out of [208] H-roller [209] I-roller.
[211] Felt pad (H,I rollers)

It removes dust attaching to the wire, and also prevents the wire from
running
out of [208] H-roller and [209] I-roller. Weekly inspection, cleaning, and
adjustment.
The felt pad (H,I rollers) requires periodical inspection (every week). For the
inspection, see "3.2.2 in Maintenance".
17
Maintenance SP43
2.2.6 Taper cutting unit

(1) Appearance
-U +V
-V +U
Fig.14 Appearance of taper cutting unit
(2) Taper machining and mechanical limitation

The wire tilt angle T is specified by the program.
At this time, the travel amount U ( V) in the U,V axis is determined by the
distance between upper and lower guides (13.3 + Z1 + 13.4) and T.
Fig.17 shows the relation between max. tilt angle T and workpiece
thickness.
Precautions on taper machining:

(a) The maximum value of U ( V) must be less than about 101mm.
(b) The tilt angle must be less than 15°.
(c) For some nozzles, the tilted wire could interfere with the nozzle wall.
The circled portion in Fig.16 shows the relation between nozzle and wire.
(d) As the dielectric fluid stream is vertical, the flushing effect on the machining
area is low. Particularly, the condition becomes worse when a machining is
done with the nozzle tip kept away from the top (bottom) surface of
workpiece.
(e) As shown below, U ( V) differs greatly depending on the machining
profile even if the T is same.
W0720C-I1E-01 18
SP43 Maintenance
Fig.15 Machining profile and U/V axis travel
The taper angle may be over ±15° at the corner depending on the shape, which
exceeds the specification range, thus affecting the accuracy and finished surface
quality.
Type-8 nozzle r
for 10° taper about 4mm
Fig.16 Nozzle and wire
19
Maintenance SP43
2.2.7 Z-axis
The Z-axis moves up and down the upper head.
Z-axis position and taper machining

In a taper machining, the Z-axis coordinate must be entered as an NC value.
Enter Z-axis machine coordinate Z1 on main operation panel.
Correlation between Z-axis position, work table, and diamond guide is shown
Fig.16. NC input value Z1 for Z-axis position (machine coordinate) in taper
machining:
0<= Z1 <
= 320 (SP43)
The distance from start of R of the upper head diamond guide at the Z axis zero
point to the workpiece mounting surface is same as that of lower head...13.4mm
Relation between max. tilt angle and workpiece thickness

Max. tilt angle [ ° ]
35
Max. tilt angle = tan-1
t + 13.4 × 2
(t > 105)
Fig.17 Relation between max. tilt angle and workpiece thickness
W0720C-I1E-01 20
SP43 Maintenance
2.2.8 Dielectric fluid system
The dielectric fluid supplied to the upper and lower heads and the jet for
automatic wire threading are controlled by the dielectric fluid supply unit based
on the NC commands.
Also, the dielectric fluid • air pressure supply unit cools, stores, filtrates, and
deionizes the dielectric fluid.
(1) Dielectric fluid circuit diagram and dielectric fluid • air pressure supply
unit.
Fig.18 Dielectric fluid circuit diagram
21
W0720C-I1E-01
[307] Pressure gauge
[303] Rotary valve [310] Dielectric fluid cooler

(flushing / lower)
[402] Air filter (5µm)
[403] Mist separator (0.3µm) [311] Ion pump(P3)

[301] Dielectric fluid filter [304] Rotary valve
(flushing / upper)
[404] Regulator
[302] Coupler
[305] Rotary valve [405] Pressure gauge
(ion exchange resin)
[312] Flushing
[308] Clean tank lid pump (upper)(P2)
[306] Ion exchange resin [309] Flushing

pump (lower)(P1)
Maintenance
[321] Dielectric fluid [318] Float switch [315] Overflow hose nipple
pressure sensor
[319] Water level gauge Dirty tank Clean tank [316] Clean tank drain valve [314] Rotary valve [313] Rotary valve
(low flushing / upper) (low flushing / lower)
[322] Rapid / circulation pump(P5) [317] Conductivity sensor
[320] Dirty tank drain valve
Fig.19 Dielectric fluid • air pressure supply unit (1)
22
SP43
SP43 Maintenance
[312] Flushing pump [311] Ion pump (P3) [308] Clean tank lid [309] Flushing pump
(upper)(P2) (lower)(P1)
[323] Pressure switch (LS 60)
[324] Filter pump (P4)

[319] Water level gauge
[325] Bypass
50Hz area: shut

60Hz area: 5/6 rot. open
Fig.20 Dielectric fluid • air pressure supply unit (2)
(2) Function of each component (Fig.19, 20)

[301] Dielectric fluid filters
They filtrate the fluid in dirty tank.
After filtration, the fluid is stored in the clean tank.
Replace the filters when [307] pressure gauge indicates 0.23Mpa. For replacement of
ion exchange resin, see "4.8 Maintenance"
[303] Rotary valve (flushing / lower)

It changes over for automatic wire threading for lower head.
23
Maintenance SP43
[304] Rotary valve (flushing / upper)

It changes over for automatic wire threading for upper head.
[305] Rotary valve (ion exchange resin)
It changes over for ion exchange.
[306] Ion exchange resin
It maintains the water quality (conductivity)
The ion exchange resion activated resin is used.
The ion exchange resin is a consumable and replaced when the conductivity is
reduced or the entire surface becomes brown. For replacement of ion resin, see
"4.8 Maintenance"
[307] Pressure gauge (LS 60)

It indicates the pressure of [301] dielectric fluid filters. Replace the filter when
the pressure gauge indicates 0.23Mpa.
[309] Flushing pump (lower)(P1)
It is controlled by the inverter, based on the command from NC controller, it
feeds the lower jet for AWT and the fluid (flushing from lower head).
[310] Dielectric fluid cooler unit
It cools the dielectric fluid to keep it to the same temperature as machine
temperature.
The cooler alarm may sound when the ambient temperature is below 10oC.
[311] Ion pump (P3)

It feeds the fluid for circulation to the [306] ion exchange resin and the
[310] dielectric fluid cooler.
[312] Flushing pump (upper)(P2)
Same as [309] flushing pump (lower)(P1), based on the command from NC
controller, it feeds the upper jet for AWT and the fluid (flushing from upper
head).
[313] Rotary valve (low flushing / lower)
It changes over for machining of finishing for lower head.
W0720C-I1E-01 24
SP43 Maintenance
[314] Rotary valve (low flushing / upper )

It changes over for machining of finishing for upper head.
[315] Overflow hose nipple
A drain port to prevent excessive dielectric fluid from spilling out of the tank.
Be sure to connect a hose of ø25 ID to lead the fluid to the drainage.
[316] Clean tank drain valve
When this valve is opened, the water in the clean tank is drained. Leave this
valve normally closed.
[317] Conductivity Sensor
It is to detect the conductivity of the dielectric fluid inside the dirty tank.
Clean the sensor periodically (every month). For cleaning, see "3.2.6 Maintenance".
[318] Float switch

Detect the lower limit of fluid level in dirty tank
[319] Water level guage
Show the upper limit of fluid in dielectric tank. (For checking of fluid level,
(See "3.1.7 in Maintenance".)
[320] Dirty tank drain valve
When this valve is opened, the water in the dirty tank is drained. Leave this
valve normally closed.
[321] Dielectric fluid pressure sensor
They detect the fluid pressure for upper and lower heads, and jet.
[322] Rapid / circulation pump (P5)
It fills the work tank with the fluid in a submerged machiing.
Do not touch the ALL pumps in operation because they are hot.
[323] Pressure switch (LS 60)

It prevents [301] dielectric fluid filter from being ruptured.
25
Maintenance SP43
[324] Filter pump (P4)

It feeds the fluid in the dirty tank to the clean tank through [301] dielectric
fluid filters.
[325] Bypass
50Hz area: All close, 60Hz area: open by 5/6 turn.
(3) Filling the tanks of dielectric fluid
Fill the tanks before turning on the NC unit, if the dielectric fluid is drained from
dielectric tank for installation or cleaning.
(a) Checking before tank filling
Confirm that the pump unit is turned off.
(i) Call the MACH OPE screen on the main operation panel, and move to the
third set of function keys by pressing f • c key, then press f • 8 key to turn
off the pumps.
Starting the pump in the clean tank and the dirty tank in empty status causes a pump
trouble. Never start the pump.
(ii) Close the [321] clean tank drain valve.
Feed city water

[319] Water level guage
Overflow
Clean tank Dirty tank
Fig.21 Tank filling
W0720C-I1E-01 26
SP43 Maintenance
(b) Tank filling

(i) Feed the city water to clean tank from the clean tank lid, and make the
water overflow from clean tank to dirty tank.
(ii) Start the [324] filter pump when the water level in dirty tank reaches
indicated marking on the water level guage. See "3.1.7 Maintenance"
Call the MACH OPE screen on the main operation panel, and move to
the third set of function keys by pressing f • c key, then press f • 8
key to turn on the pumps.
Call the COND MAIN screen on the main operation panel, and set the
COND. (17: conductivity) to “1”, and the [324] filter pump will start.
After tanks are full, return the COND. to original value.
(iii) Feed the water up to the level of [319] water level gauge in dirty tank.
Do not feed water over the marking of the [319] water level gauge in dirty tank. Excess
water will be drained out from the [315] overflow hose nipple.
The dielectric fluid quantity will gradually reduce due to evaporation

during circulation. If automatic water feeder (optional) is not attached, check the water
level before operation and add water as necessary.
27
Maintenance SP43
2.2.9 Air system

(1) Pneumatic circuit diagram
[406]
Pressure
switch
[404] Regulator
[403] Mist separator (0.3µm)
[402] Air filter (5µm)

[401] Air pressure source
Fig.22 Pneumatic circuit diagram
W0720C-I1E-01 28
SP43 Maintenance
[406] Pressure switch
[407] Air manifold
Fig.23 Air pressure control
(2) Function of each part (Fig.24, 25)
[401] Air pressure source

Flow rate required : 100 L/min
Line pressure : 0.6 MPa
Air temperature : 35°C (min. 10°C ~ max. 50°C)
[402] Air filter (5 µm)
It cleans the compressed air.
Replace [412] filter element (5 µm) periodically (every year).
For the replacement, see “4.9 Maintenance”.
[403] Mist separator (0.3 µm)

It cleans the compressed air and removes the water (oil) through the filter.
Replace [413] filter element (0.3 µm) periodically (every year).

For the replacement, see “4.9 Maintenance”.
If a compressor in the factory is stopped once, then it is started abruptly, the auto drain
may be kept open, causing the pressure not to rise up to the specified value. In this
case, reconnect the coupler.
29
Maintenance SP43
[403]Mist separator (0.3µm) [402] Air filter (5µm) [405] Pressure gauge
OUT
Coupler
[404] Regulator
IN
[412] Filter element (5µm) Auto drain [413] Filter element (0.3µm)
Fig.24 Air filter, mist separator, and regulator
[404] Regulator
It adjusts the compressed air to proper pressure 0.6 MPa.
For the adjustment, rotate the valve under [404] regulator.

It indicates the air pressure to be supplied to the machine.
Proper pressure is 0.6 MPa.
Adjust the [404] regulator to attain proper pressure.
[406] Pressure switch

Automatic wire threading is not executed when the pressure switch operated
and [405] pressure gauge (1) indicates 0.3 MPa or less.
[407] Air manifold
Do not touch [407] air manifold carelessly during operation because it is very hot.
W0720C-I1E-01 30
SP43 Maintenance
2.2.10 Work tank

(1) Work tank configuration
[511] Float switch (2)
[502] Arm seal [501] Work tank
[503] Arm cover
[504] Gate
[505] Work plate
[506] Small door

[514] CMR card
[507] Big door
[509] Rapid feed, circulation port
[508] Door interlock
/ rapid , circulation drain port
[514] CMR card
[509] Rapid feed, circulation port

/ rapid, circulation drain port
Fig.25a Work tank
31
Maintenance SP43
1 Turn the lever outwards to release lock.

2 Pull the handle towards you.
1 3 Gently lower the door.
2
3
1
Fig.25b Opening small door (work tank)
about 87.5mm
Head submerged float SW ON
about 70mm
Head submergiable level
Fig.26 Head submerged float and head submerged water level
[515] Gate UP and DOWN switch

[516] Work tank
filling switch
Fig.27 Work tank UP and DOWN switches
W0720C-I1E-01 32
SP43 Maintenance
(2) Function of each part (Fig.25~27)

[501] Work tank
Containment for dielectric fluid
Sludge can cause rust and reduction in sealing performance.
For cleaning of work tank, see "3.2.7 Maintenance".
[502] Arm seal

Prevents the fluid from leaking through arm hole in [501] work tank.
[503] Arm cover

Protects the arm also prevents the fluid leakage from the arm. It expands and
contacts along the Y axis.
[504] Gate
Moves up and down to adjust the fluid level by operating the [514] gate up and
down switch.
[505] Work plate

For mounting of workpiece and fixtures.
Sludge can cause rust on the work plate(table).
For cleaning for work plate, see "3.2.7 Maintenance".
[506] Small door

For minor adjustment / cleaning to the workpiece.
[507] Big door

For mounting of workpiece / fixtures, cleaning to the work tank.
[508] Door interlock

To prevent opening door by accident when tank is filled with fluid.
Getting caught in between will result in serious injury or death.
[509] Rapid feed, circulation port / rapid drain port

For feeding / draining of dielectric fluid and providing circulation during
machining. Float switch (1) selects rapid feed or circulation.
33
Maintenance SP43

Selects rapid feed or circulation.

This float switch detects the fluid level at the start of automatic wire threading.
The fluid level lowers to this [511] float switch(2) position, if AWT is executed
when the work tank is full. The fluid level returns to original height after AWT
finished. The fluid level does not lower in the submerged AWT mode.

Use to activate door interlock.

Prevents the upper head from being submerged when the work tank is full.
[514] CMR card

For relay of energizing cable
[515] Gate up and down switches

Use this switch to move up and down the [504] gate manually.
[516] Work tank filling switch

Turn on this switch when filling the [501] work tank with dielectric fluid by
manual operation.
(3) Work tank filling

(a) The [504] gate can be moved up and down by operating the [515] gate up
down switch. Adjust the [504] gate height so that the fluid level
is higher than workpiece height by 40mm.
(b) To fill the work tank, press the [516] work tank filling switch key. Pressing the
key once more cancel tank filling, and drains the dielectric fluid. In the case
of memory run mode, specify M28 (fill ON) and M29 (fill OFF) in a program.
If the fluid level in work tank is too high and the [513] float switch(4) operated, the
machine goes in warning stop status and both machining and filling are turned off. The
[513] float switch(4) will operate if the fluid level rises up to about 87.5mm above the
nozzle edge. However, this value will vary within ±10mm depending on the fluid level
fluctuation, or dispersion in performance of [513] float switch (4) itself.
The fluid level varies when the fluid is discharged from upper and lower heads, and
depending on the water mode selected. Before machining , be sure to confirm the fluid
level. The upper head (Z-axis) may be submerged until 70mm from the lead edge of
nozzle.
W0720C-I1E-01 34
SP43 Maintenance
3. ROUTINE INSPECTION AND CLEANING
This section describes a inspection, cleaning, and adjustment to be performed

periodically.
3.1 Daily Inspection, Cleaning, and Adjustment
3.1.1 Checking available wire quantity and removing wire

in wire box
Before start of machining, check if available wire quantity is enough for

machining. Also, check the wire quantity in wire box, and if it reaches about half
of wire box, remove it.
3.1.2 Cleaning the wire tip sensor
At automatic wire threading, the presence of wire is checked using a

photosensor. The sensor, if dirty, cannot detect a wire at the AWT. Before start of
machining, clean the sensor with a dry swab or dampened with the water.
Do not use a cleaner, except the water. Otherwise, the sensor could corrode, causing a
detection failure. (Never use acide)
Detection
Device
Wire tip sensor
Fig.28 Cleaning wire tip sensor
35
Maintenance SP43
3.1.3 Checking wear of energizing plate

(1) Changing of energizing position (upper head) and energizing plate.
A worn energizing plate causes low machining speed or frequent wire break.
Before start of machining, check the wire contact face of energizing plate.
If there is a deep flaw, insert a standard accessory spacer as shown in Fig.29
(three faces can be used). When all of the three faces have been used, rotate the
energizing plate by 180°. A total of six faces can be used. When six faces have
all been used, replace the energizing plate.
Energizing plate part No.: Z248W0200300
Push the energizing plate against the wire guide bracket, and fix with socket
head bolts (M4) (see Fig.29).
Foreign matters, if present on the mounting surface, make a space between mounting
surface and energizing plate,causing low power supply efficiency or corrosion. Before
attaching the energizing plate, always clean the mounting surface with K200 supplied.
After cleaning, wash completely with the water.
If a spacer is not used, insert the spacer at the position shown with ( ) in Fig.29.
180°
180°
Wire guide bracket
Socket head bolt
Spacer
Energizing plate
(Z248W0200300)
Fig.29 Replacing the energizing plate
W0720C-I1E-01 36
SP43 Maintenance
Energizing plate
(Z248W0200300)
Depth of flaw (reference)

0.5
Fig.30 Depth of flaw requiring replacement
(2) Changing of energizing position of lower head.
Please be careful with direction of rotation.
Before adjustment, lock screw must be loosen. Otherwise, the push block will be
damage.
After adjustment, lock screw must be tighten back. Otherwise, the energizing plate and
base will be damage (Fig.32).
Torque driver
Adjustment screw
Lock screw
Fig.31 Energizing plate adjustment
37
Maintenance SP43
Energizing base Energizing plate
lock screw
Energizing plate and base

will be damage if contact is
not kept with each other.
Fig.32 Damage to energizing plate and energizing base
Procedure
(a) Turn the LOCK screw COUNTER-CLOCKWISE and loosen the fixing of the
energizing plate.
(b) Turn the ADJUSTMENT screw about three turns CLOCKWISE.
(c) Turn the LOCK screw CLOCKWISE with torque 1.2Nm [12kgfcm].
W0720C-I1E-01 38
SP43 Maintenance
(3) Replacing worn out energizing plate.
The energizing plate can be used 16 times in all.

The energizing plate can be used 4 times when the adjustment screw is moved
(Fig. 33-a).
And it can be used another 4 times when it rotated fore and aft (Fig.33-b, 33-c).
And it can be used another 8 times when it is rotated from side to side.
Energizing plate (Z248W0200400)
Adjustment screw
Nut plate
180°
Fig.33-a After 4(12) times of usage Fig.33-b After fore and aft rotation
180°
Fig.33-d After side to side rotation Fig.33-c After 8(16) times of usage
( ) : The number of times after side to side rotation
Fig.33 Optimizing usage to the energizing plate
39
Maintenance SP43
Lock screw
Energizing plate
Knob
Torque driver
Door
Adjustment screw
Fig.34 Replacing energizing plate(1)

Procedure
(a) Turn the lock screw countier-clockwise to loosen energizing plate(Fig.34).
(b) Turn and remove knob and door.
(c) Pull out the energizing plate and the adjustment screw. Remove the
adjustment screw.
(d) Clean the energizing base (metal) and the energizing plate by acid. If
there is sludge, clean with swab.
(e) Remove bolts and nut plate. Replace and reassemble the energizing plate.
Nut plate does not protrude from energizing plate (Fig.35).
Nut plate
Socket Head bolt
Energizing plate
Fig.35 Replacing energizing plate (2)
W0720C-I1E-01 40
SP43 Maintenance
(f) Reassemble adjustment screw (fig.36) and install it to lower head (fig.34).
Adjustment screw end is intalled to the nut plate.
Adjustment screw
does not protrude
from the nut plate
Fig.36 Adjustment to energizing plate
(g) Reassemble knob and door, turn lock screw clockwise with torque 1.2Nm
[12Kgfcm].
(4) Cleaning energizing plate
Procedure
(a) Loosen the socket head bolts and remove the V-guide base (fig.37).
(b) Loosen the pan head screw, and remove the V-guide pulley.
(c) Clean the contact surface of the energizing base with K200. After cleaning,
wash out K200 completely with water.
(d) Reassemble the V-guide pully and tighten pan head screws with 1.2Nm
torque.
(e) Pushing the V-guide in the left and downward direction, tighten bolts to
1.2Nm [12Kgfcm] with torque driver (Fig.38)
After cleaning, wash out K200 completely with water.
41
Maintenance SP43
Push block
Energizing base
Push plate
V-guide base
Socket head bolt
Pan head screw
V-guide pulley
Fig.37 Cleaning slug pile
V-guide
Fig.38 V-guide adjustment
W0720C-I1E-01 42
SP43 Maintenance
3.1.4 Cleaning diamond guide and press guide
The diamond guide and press guide, if dirty, may lower the machining accuracy.
Before start of machining, clean them with a swab dampened with K200
supplied.
For cleaning, remove the nozzle guard or head cover to open the guides. After
cleaning, wash completely with the water. At this time, clean also the V-guide.
The diamond guide and press guide, if worn out, lower the machining accuracy. If there
is a deep flaw in diamond guide or press guide, replace it. (See "4.1 in Maintenance")
Replacement interval by wear: 6000 hours
When the press guide is replaced, replace the V-guide, too.
V-guide
Press guide
Diamond guide
Press guide
V-guide
Fig.39 Cleaning diamond guide
43
Maintenance SP43
3.1.5 Open-close motion of press guide

(1) Checking open-close motion of press guide
If the press guide do not fully open, the jet for automatic wire threading cannot
pass, thus reducing the AWT success rate. Also, if the press guide do not close
completely, they cannot hold the wire, thus reducing the machining accuracy.
Check open-close motion when cleaning the diamond guide and press guide.
In case of abnormal open-close motion, follow the instruction given in “6. Remedy for
typical trouble”.
The open-close motion may not be speedy because a sealing mechanism and a guide
open-close motion damping mechanism are built in the head. Slow motion is not a
trouble.
Diamond guide Press guide
Fig.40 Checking open-close motion of press guide
W0720C-I1E-01 44
SP43 Maintenance
(2) Cleaning press guide open-close piston

If the press guide is not fully opened or closed, clean the press guide open-close
pistons following the procedure given below.
Cleaning procedure
(a) Remove caps on both sides of head mounting block (1), and the pistons (1)
and (2) will be disclosed.
(b) Remove pistons (1) and (2) from the head mounting block (1). An M3 tapped
hole is provided in piston (1) and (2) respectively. When you cannot remove
them by hand, use an M3 screw.
(c) Wipe pistons (1) and (2) to remove dust.
(d) With the wire support (2) removed, move the press guide bracket to check
for bearing operation. If the bearing operation is not smooth, the bearing
must be replaced. In this case, please contact the nearest service center.
(e) Install the wire support (2), then insert the piston (1) and (2) into the cylinder,
and mount the caps.
trouble.
After the work is finished, make sure that the press guide is fully closed (open).
Cap Spring O-ring Cap
Socket head Socket head

bolt bolt
O-ring
Piston (2) Piston (1)
Press guide bracket
Mini Y-packing Piston (1)
Fig.41 Press guide open-close pistons
45
Maintenance SP43
3.1.6 Checking wear of dielectric nozzle
The dielectric fluid pressure will not rise to the specified value, if dielectric nozzle
edge wears or is damaged. Since the dielectric fluid pressure affects the
machining accuracy, check the dielectric nozzle before start of machining.
Replace the dielectric nozzle, if the protrusion is less than 0.5 mm when
pushing the dielectric nozzle with your finger. (See 4.4 in Maintenance)
Dielectric nozzle
Nozzle guard
Min. protrusion 0.5

Fig.42 Wear of dielectric nozzle
A dielectric nozzle wear checking is not necessary in the case of machining with the
nozzle kept away.
3.1.7 Checking fluid level in dielectric tank
The fluid level in the dielectric fluid supply unit will lower due to splashing or
evaporation, thus requiring addition of dielectric fluid.
(1) Machine with automatic water feeder (optional)
When the fluid level in the dielectric tank lowers to the lower limit during filter
pump running (when the work tank is empty), the float switch (in dirty tank)
turns on to add dielectric fluid (water) automatically.
(2) Machine without automatic water feeder

Add dielectric fluid (water) up to the level between the marking on the water
level guage during filter pump running (when the work tank is empty).
W0720C-I1E-01 46
SP43 Maintenance
In tank filling, take care not to allow the fluid level in the clean tank to exceed the
marking on the water level guage. (Excess dielectric fluid will be discharged to drain
via the overflow hose nipple.)
Lack of dielectric fluid will cause the filter pump to be damaged.

Always keep the dielectric fluid level between the marking on the water level guage.
Water level guage
Marking
Water level guage
Fig.43 Adding dielectric fluid
47
Maintenance SP43
3.1.8 Checking pressure of fluid filter
Before start of machining, check the pressure gauge for fluid filter, and when
pressure is 0.23 MPa, replace the fluid filter (See 4.6).
The warning “WATER RESERVOIR FILTER NEEDS REPLACING” is displayed, when
the pressure of fluid filter reached 0.25 MPa.
Pressuage guage
Fig.44 Pressure gauge for fluid filter
3.1.9 Checking air pressure of regulator
The machine stops when air pressure drop below 0.3 MPa during machine run.
Before start of machining, confirm that the air pressure of regulator is 0.6 MPa.
Pressuage
Air supply guage
coupler
Regulator
Fig.45 Air supply piping facility
W0720C-I1E-01 48
SP43 Maintenance
3.2 Weekly Inspection, Cleaning, and Adjustment
3.2.1 Cleaning clutch roller (D-shaft) and I-roller, and

checking wear
(1) Cleaning the clutch roller (D-shaft)
Dirty V-grooves (2 places) of clutch roller (D-shaft) due to presence of oil

causes the wire to be slipped, resulting in a wire feed failure or wire rewind
failure during automatic wire threading. Perform cleaning as follows.
Cleaning procedure:
(a) Remove the wire from the clutch roller (D-shaft).
(b) Clean the grooves with a cotton thread dampened with the K200 supplied
or alcohol or with a brush. If the K200 is used, wipe it off with the water so
that it does not stay on the roller surface.
(c) After drying the roller, tangle the wire and confirm that the wire does not
slip.
In cleaning the clutch roller (D-shaft), check that no damage is found in the V-grooves.
A damage, if found, will affect the wire running performance. Replace the clutch roller
(D-shaft) with a new one.
Clutch roller (D-shaft) part No.: 15EC100F411
The use of clutch roller (D-shaft) for a long term will cause even wear on the bottom of
V-groove on the front side. In this case, invert the clutch roller (D-shaft) (see fig.58).

(15EC100F411)
Fig.46 Replacing clutch roller (D-shaft)
49
Maintenance SP43
(2) Cleaning I-roller and checking wear
The I-roller prevents the wire from loosening at the clutch roller (D-shaft).
Dirty I-roller surface or a deep wire trace on the roller causes the wire to be slipped,
resulting in a wire feed failure or wire rewind failure during automatic wire thread-
ing.
Clean the I-roller surface with K200 supplied or alcohol. If K200 is used, wipe it
off with the water so that it does not leave on the roller surface.
If a deep wire trace is found on the I-roller surface, change its position following
the procedure given below.
Changing procedure:
(a) Thread the wire.

(b) Loosen setscrew.
(c) Shift the roller to the position where there is no wire trace, and fix the roller.
Take care not to lose a bushing when replacing the I-roller.

If a position to be changed is no longer left, replace the I-roller with a new one.
I-roller part No.: 6EC100A747
I-roller
(6EC100A747)
Bushing
Setscrew
Fig.47 Replacing I-roller
W0720C-I1E-01 50
SP43 Maintenance
3.2.2 Checking felt pads for dirtiness

(1) Position change and replacement of felt pad
The felt pad is provided to wipe off dirt (oil) attaching to the wire surface.
Check how extent the felt pad is dirty. If it is extremely dirty and it cannot
clean the wire, change its position.
The position can be changed if pulling the knob and rotating the pad. If an
entire felt pad is dirty, replace it following the procedure given below.
Replacing procedure:
(a) Remove a truss head screw.
(b) Remove a washer, spring, and knob, then replace the felt pads. At this
time, if either side has not been used yet, exchange to that side.
Felt pad part No.: 1EC100B703
(c) Reassemble the knob, spring, and washer in this order, then fix with a truss
head screw.
Dust remover
Felt pads
(1EC100B703)
Knob
Spring
Washer
Truss head screw
Fig.48 Replacing felt pads
51
Maintenance SP43
(2) Changing position and replacing felt pads for wire guide unit
The felt pad prevents a wire from bouncing caused when the wire is broken.
If the wire bounces at wire break, increase a pressing force of felt pads. If felt
pads (1) and (2) are extremely dirty, change the position. With a hex nut
loosened, rotating the felt bracket (1) clockwise increases a clamping force.
For the felt pad (2), its position can be changed by removing a setscrew.
If entire felt pads (1) and (2) are dirty, replace them with new ones. Remove
each felt pad from the felt bracket, then affix new pad respectively.
Felt pad (1) part No.: 6EC220B714=1
Felt pad (2) part No.: 6EC220B716=1
If the felt bracket (2) locked with a setscrew is shifted, the contact surface of felt
pads(1) and (2) must be at the center of die (* portion).
Felt pad (1) (6EC220B714=1) Felt pad (2) (6EC220B716=1)

Felt bracket (1) Felt bracket (2)
Hex nut
Setscrew
Fig.49 Replacing felt pads
W0720C-I1E-01 52
SP43 Maintenance
3.2.3 Cleaning nozzle guard, and checking damage
A damaged nozzle guard will reduce the dielectric fluid pressure, or allow the
nozzle guard to inflate by the fluid pressure, thus pushing up the workpiece.
Check the nozzle guard for evidence of a crack or any other damage.
Replace the nozzle guard if damaged. (See 4.4)
Also, a dirty nozzle guard may lead to a detection failure of head collision.
Wash the nozzle guard periodically (every week) with the water.
Fig.50 Examples of damaged nozzle guard
The nozzle guard is a consumable part. Do not use the nozzleguard deformed by
collision.
Chipping of laminar nozzle hole allows the dielectric fluid to splash, causing low
machining speed. In such a case, replace the laminar nozzle (See Fig.51).
The nozzle guard surface is plated to detect head collision. A plating will
corrode and peel during a long period of operation. When a plating
peeled over a wide range, replace the nozzle guard. (See Fig.52)
The nozzle guard may be damaged internally due to a collision, even if no
external crack is found. If the nozzle guard isdamaged, it expands by the fluid
pressure, causing a head collision alarm. Replace the nozzle guard if it is damaged.
53
Maintenance SP43
[Normal] [Defective]
Fig.51 Example of damaged laminar nozzle
Peeled plating
Fig.52 Peeled plating
W0720C-I1E-01 54
SP43 Maintenance
3.2.4 Cleaning the winding roller (M-shaft) and pinch roller

(L-shaft)
Dirty winding roller (M-shaft) and pinch roller (L-shaft) causes a wire to be
broken or tangled. Clean the rollers following the procedure given below.
Your hand, hair, or clothes could be caught by shafts and winding rollers. First, take
proper measures such as turning OFF the POWER switch so that the shafts and rollers
in the winding unit do not run. Further, tag a sign board at an easy-to-see place on the
front side of machine,indicating that the maintenance is under way and any operation
is prohibited, so that a person other than maintenance personnel does not operate the
machine during maintenance.
Cleaning procedure:
(a) Remove the wire box (1) from the machine to make work easier. If it is
not to be removed, shift the XY axes where you can perform work easily,
and remove the wire box (2) instead. (See Fig.100)
(b) Remove protection cover (L, M shafts) and roller cover. (See Fig.101)
(c) Clean the surface of winding roller (M-shaft) and pinch roller (L-shaft)
with the K200 supplied or thinner. If K200 was used, wipe it off using the
water so that the K200 does not remain on the roller surface.
(d) If the gears on winding roller (M-shaft) and pinch roller (L-shaft) are dirty,
clean them with a brush.
(e) After cleaning, reassemble the parts in the order of (d) through (a).
Pinch roller
(L-shaft)
Gears
Winding roller
(M-shaft)
Fig.53 Cleaning for winding roller and pinch roller
55
Maintenance SP43
3.2.5 Cleaning the radiator and filter for dielectric fluid

cooler unit
Much dust on the radiator or filter of the dielectric fluid cooler reduces the cooling
performance of cooler, causing a temperature control failure. Perform cleaning
following the procedure given below.
Cleaning procedure:
(a) Pull strap to remove the filter attached to the radiator (cooling fins) of the
dielectric fluid cooler.
(b) Tap the filter outdoors, or blow off the dust with an air gun.
(c) Blow off the dust on the radiator with an air gun.
Dielectric
fluid cooler
Strap
Filter
(Radiator)
Fig.54 Cleaning radiator and filter for dielectric fluid cooler (1)
Fig.55 Cleaning radiator and filter for dielectric fluid cooler (2)
W0720C-I1E-01 56
SP43 Maintenance
3.2.6 Cleaning conductivity sensor
A dirty conductivity sensor shortens the life of ion exchange resin.

Remove a cap on the conductivity sensor in the clean tank, and clean the
detection device in the sensor.
Clean tank
Cap Detection device
Loosen
Clean the
detection sensor
Fig.56 Conductivity sensor
57
Maintenance SP43
3.2.7 Cleaning inside walls of work tank, work tank door

seals, and work table
Door seal
Fig.57 Cleaning inside walls of work tank
Presence of foreign matters (sludge) between work tank and door seals reduces
the sealing performance.
Before start of machining, remove foreign matters in seals, and clean the
inside walls of work tank.
If the sludge is allowed to leave on the work table, a rust occurs there, then it will
spread over entire work table.
After machining, clean the work tank.
W0720C-I1E-01 58
SP43 Maintenance
3.3 Monthly Inspection, Cleaning, and Adjustment
3.3.1 Inverting clutch roller (D-shaft)
The groove on front side wears faster than the groove on rear side, thus causing
a loose wire between C and D rollers. To prevent uneven wear, invert the clutch
roller (D-shaft) periodically following the procedure given below.
Procedure:
(a) Disengage the wire from clutch roller (D-shaft).
(b) Loosen socket head bolts, and remove clutch roller (D-shaft).
(c) Invert and reinstall the clutch roller (D-shaft), and fix with socket head bolts.
In inverting the clutch roller (D-shaft), check that no damage is found in the V-grooves.
A damage, if found, will affect the wire running performance.
Replace the clutch roller (D-shaft) with a new one.
Clutch roller (D-shaft) part No.: 15EC100F411
Powder
Groove on rear side clutch
Groove on front side Flange
Socket head
bolt
Setscrew
(to lock flange)
Clutch roller (D-shaft) Invert clutch roller (D-shaft)

(15EC100F411)
Fig.58 Inverting clutch roller (D-shaft)
59
Maintenance SP43
3.3.2 Adjusting tension of powder clutch
As the time goes by, the powder clutch that generates wire tension reduces its
torque. To maintain high accuracy machining, adjust the tension of powder clutch
Preparation for measurement:

(a) Remove the wire bobbin from A-shaft
(b) Remove the clutch roller (D-shaft) by loosen socket head bolt.
(c) Remove set screw and tighten a measuring rod into the tapped hole until it
lock with the shaft.
(d) As shown below, hook a tension gauge (optional) to a groove in the
measuring rod (optional) at right angle, and measure the torque of powder
clutch. Add 50g to a reading when the tension gauge is used horizontally.
Setscrew
Fig.59 Removal of clutch roller (D-shaft)

Tension gauge
(0-200g) (optional)
Roller running
direction
Measuring rod
(optional)
Fig.60 Adjusting tension of powder clutch
W0720C-I1E-01 60
SP43 Maintenance
Measurement (first)
MEM
(a) RUN / RUN
(b) O13901 IN
(c) START ...........When started, the message “2401: MEASURE

1ST TENSION” is displayed on the screen, and
the clutch roller (D-roller) starts to rotate. Hold the
tension gauge at the specified position so that the
roller does not rotate.
(d) In about 1 minute later when the buzzer sound, read the scale of tension
gauge as precise as possible.
(e) STOP After reading the scale, press the STOP key.
RUN MACRO
(f) Press PROG DATA
(g) SEARCH
(h) [Scale value] IN Assuming that reading of

tension gauge is 195g,
input that value with a
decimal point, “195.”.
Measurement (second)
(a) START ....... When started, the message “2402: MEASURE 2ND
TENSION” is displayed on the screen, and the clutch roller
starts to rotate again. Hold the tension gauge in the same
manner as first measurement.
(b) In about 1 minute later when the buzzer sounds, read the scale of tension
gauge.
(c) STOP
RUN MACRO
(d) Press PROG DATA
61
Maintenance SP43
(e) SEARCH keys.
(f) [Scale value] IN Input the measured value of

second measurement with a
decimal point (.).
(g) START
( STOP ............When calculation of wire tension completed, the message

“2400: TENSION ADJUSTMENT COMPLETED” is
displayed, and the operation stops.
Confirming tension after adjustment

(a) START ..........The message “2403: MEASURE 3RD TENSION” is
displayed.
(b) Read the scale of tension gauge.
Normal value: 250-300g (Tension 5 TAP)
(c) STOP ..........After reading the scale, press the STOP key.
(d) START ..........Message “2404: MEASURE 4TH TENSION” is displayed.

(e) Read the scale of tension gauge. Normal value: 700-800g(Tension 10 TAP)
(f) STOP
(g) RESET
After adjustment, if the measured result does not satisfy the normal range, retry
adjustment from (2).
If repeated measurement and adjustment cannot attain normal value, the powder
clutch reaches its life.
Do not expand the tension gauge forcibly by applying excessive force, nor use for
another purpose.
Do not use a tension gauge other than the attached gauge.
W0720C-I1E-01 62
SP43 Maintenance
3.3.3 Cleaning a die of wire guide unit (upper)
A die prevents the wire vibration and tilt, and stabilizes the jet water injected from
the jet nozzle (upper).
Contamination of die at the wire entrance makes the wire insertion hard. Clean
the die with the compressed air, etc.
Die
Setscrew
Fig.61 Die
3.3.4 Wire vertical alignment

Using the wire vertical aligning jig contained in optional maintenance set, adjust
the wire verticality with respect to the workpiece mounting surface.
Always perform the wire vertical alignment before start of machining, if the workpiece
is thick, or high machining accuracy is required. The alignment is also required after
the
diamond guide and the press guide are replaced.
Though the adjustment can be made in the same manner using the wire vertical
aligning jig attached to the old EC series, the machine parameters must be changed.
Before performing the wire vertical alignment, confirm the item in paragraph (1) below.
(1) Confirmation before performing wire vertical alignment

Two kinds of wire vertical aligning jigs are available, 100mm and 50mm in
thickness. The machine parameters and Z-axis position during execution of
vertical alignment vary depending on which jig is used.
Before performing the alignment, confirm the following items.

Confirming parameters No.672 and 673
63
Maintenance SP43
(a) On the SET screen, press SET DATA
(b) P A SEARCH
(c) Press MACHINE PARAMETR .
(d) Press 6 7 2 SEARCH to confirm the set value of parameter No.672, and
No.673.
(e) If a value listed in the following table is not set, enter correct value by
pressing the IN key.
Table 2 Wire vertical alignment
Items Kind of jigs 100mm thick 50mm thick

PRM No.672 (jig to gauge distance) 100000 µm 50000 µm
PRM No.673 (jig to gauge distance) 120000 µm 70000 µm
Z-axis machine coordinate at vertical alignment 120mm 70mm
Execution of wire vertical alignment with wrong parameter setting or

improper Z-axis scale position will cause the following alarm because the dimension
calculated internally does not meet actual one.
• During alignment, alarm 1720 “MEASURING APPROACH NEVER

TOUGH PART” occurs.
• There is a large error though alignment finished.
(2) Wire vertical alignment
(a) Position the Z axis to 70mm reading on the scale.

(120mm in the case of vertical aligning jig for old EC series)
(b) Load the wire.
After loading, dry the wire guide unit (upper) and the upper head.
(c) Install the wire vertical aligning jig (see Fig.63).
Clean the contact surface of wire vertical aligning jig and work table, and
install the jig on the table. For checking installation, confirm the
parallelism of top surface (right side) of wire vertical aligning jig against
X,Y-axis movements; it must be within ±1 µm. If not parallel, adjust finely
the screws (3 pcs). Also, clean the contact surface of the wire using
alcohol.
(d) Connect the cable of wire vertical aligning jig to the cable connector
(see Fig.62).
W0720C-I1E-01 64
SP43 Maintenance
(e) Adjust the upper head position.

Move the X and Y axes to locate the wire to the start position of wire vertical
alignment shown in Fig.64. On the main operation panel, press RUN , f • 1
MAN RUN , f • c (function change to ), f • 6 VERTICAL ALIGNMNT
keys in this order. The START key lamp then lights up, and the vertical
alignment starts. When it is finished, the START key lamp goes off.
The wire tension for wire vertical alignment is automatically set when the “VERTICAL
ALIGNMENT” key is pressed.
Fig.62 Wire vertical aligning method
Work table
Adjusting screw
Wire vertical aligning jig

Wire position
Fig.63 Installing wire vertical Fig.64 Start wire position for

aligning jig wire vertical alignment
65
Maintenance SP43
3.3.5 Cleaning inside of clean tank (monthly) and dirty

tank (yearly)
The deposition of sludge in the work tank and dirty tank makes dielectric fluid
dirty, machining speed unstable, or ion exchange resin life shorter.
Clean the inside of clean tank on monthly basis and dirty tank on yearly basis.
The dielectric fluid filter must be removed after the “PUMPS OFF” is turned on and the
filter pressure lowers to 0 MPa.
Replacing and cleaning procedure:

(a) Press MACH OPERAT key on the main operation panel to call the MACH
OPE screen, and press f • c key to open the third page of function keys,
then press f • 8 (PUMPS OFF) key.
Dirty tank over

flow hose nipple
Socket head bolt
Dirty tank
drain valve
Clean tank
drain valve
Fig.65 Cleaning dielectric tank
(b) Connect drain hoses to both dirty tank and clean tank drain valves and empty
dielectric tank of fluid. Loosen 4x socket head bolt and remove the filter
casing.
Clean tank can be clean by opening the clean tank lid.
For the drain hose, refer to the drain piping facility in the Installation section.
W0720C-I1E-01 66
SP43 Maintenance
(c) Clean the bottom and side walls of the tank with a soft cloth.
Assemble the filter casing back to the dielectric tank after cleaning.
(d) Disconnect a drain hose (ID ø25mm) from the hose nipple at the bottom of
dirty tank and clean tank. Close the clean and dirty drain hose valve.
(e) Fill the clean tank and dirty tank with the fluid by referring to the Tank Filling in
"9.1 (2) Maintenance".
It is recommended to replace dielectric fluid in either of following cases:

• Machining of carbide alloy after a long-time machining of copper
• Machining of iron after long-time machining of carbide alloy or copper
• Water becomes dirty
• Machining speed is not stable
• Wire electrode becomes extremely black after machining
• Machining speed is slower than usual
• Wire is broken frequently
67
Maintenance SP43
4. REPLACING CONSUMABLES
4.1 Replacing Diamond Guide and Press Guide
The diamond guide and press guide, if worn out, lower the machining accuracy.
If there is a deep flaw in diamond guide or press guide, replace it.
When the press guide is replaced, replace the V-guide, too.

For a V-guide replacing method, see Replacing V-guide (4.2).
Standard life of diamond guide: 6000 hours

(a) Upper head
Wire support
Torque driver
Pan head screw

Press retainer
Diamond guide
Press guide
Wire guide bracket Diamond guide Wire guide bracket
Press retainer
Press guide
Pan head screw
Wire support
(b) Lower head
Fig.66 Replacing diamond guide
W0720C-I1E-01 68
SP43 Maintenance
(a) Remove the door and head cover.
(b) Open the guide with the “GUIDE OPEN” key on the main operation panel.
Loosen pan head screws and remove the diamond guide together with
the press retainer.
(c) Clean the diamond guide mounting surface with the K200 supplied.
After cleaning, wash out K200 completely with the water.
(d) Pushing the diamond guide against the wire guide bracket, slide the guide
until the bottom of guide gets stuck by a pin on the bracket. Holding the
the guide, tighten the pan head screws to 1.2Nm with the torque driver so
that the guide is fixed together with the press retainer. At this time, apply the
Mecha P-700 supplied to the screws.
(e) After fixing the diamond guide, check for tilt as shown in Fig.67. Particularly,
the tilt in vertical direction must be within 3µm/5mm.
(f) Replace the press guide in the same manner as that of diamond guide.
Always use a torque driver to tighten screws to 1.2Nm when fixing the diamond guide
and press guide. At this time, apply the Mecha P-700 supplied to the screws.
The K200 supplied is an acid, and therefore it must be washed out
completely with the water after cleaning.
Turn on the “GUIDE OPEN” key on the main operation panel to open the guide when
replacing the diamond guide and the press guide.
The presence of chips on the mounting surface of diamond guide and press guide
could tilt the diamond guide and the press guide.
Table 3 Replacing parts
Parts No. Applicable wire dia.

Diamond guide 20EC080A404 ø0.10 mm
20EC080A405 ø0.15 mm
20EC080A406 ø0.20 mm
20EC080A407 ø0.25 mm
20EC080A408 ø0.30 mm
Press guide 20EC080A409 Common
69
Maintenance SP43
Fig.67 Checking tilt of diamond guide
Fig.68 Checking tilt of press guide
Fig.69 Checking level diference of guide
Fig.70 Checking Parallelism of guide
W0720C-I1E-01 70
SP43 Maintenance
4.2 Replacing V-Guide

Replace the V-guide together with diamond guide and press guide.
V-guide
Press guide backet • Part No. : 18EC80A702

• Stamp No.: 10 (color: blue)
8
Reference
dimension : about 9.10mm
Wire support (2)
Pan head
screws
Wire support (1)
V-guide
• Part No. : 15EC80B701

• Stamp No.: 1 (color: black)
8
Reference
(a) Upper head dimension : about 8.70mm
Press guide backet

７
• Part No. : 20EC90A702
• Stamp No.: 1 (color: black)
Reference
dimension : about 8.70mm
Pan head
screws
V-guide
V-guide pulley • Part No. : 20EC090A701=2

V-guide bracket
(b) lower head
Fig.71 Replacing V-Guide
71
Maintenance SP43
4.2.1 Replacing method (upper head)
Loosen a pan head screw, and remove the wire supports (1), (2) and worn
V-guide. Pushing new V-guide and wire supports (1), (2) against the press guide
bracket, tighten the pan head screw to 0.8Nm with the torque driver
(see Fig.72, 73).
After replacement, confirm that the guide can be opened and closed normally.
Always use a torque driver to tighten screws to 0.8 Nm when fixing the V-guide.
The wire supports (1) and (2), if not mounted normally, it will affect the
success rate of automatic wire threading (see Fig. 72~74 ).
The V-guide, if not mounted normally, it will affect the machining accuracy
(see Fig.72~74).
( Good ) ( No Good )
V-guide
Pan head
screw
Wire
support (1)
Press guide
bracket
Fig.72 Mounting V-guide on press guide bracket side (Upper)
Pan head
Wire support (2)
screw
Press guide
bracket V-guide
Fig.73 Mounting V-guide on V-guide bracket side (Upper)
W0720C-I1E-01 72
SP43 Maintenance
4.2.2 Replacing method (lower head)

(1) Replacing the V-guide
Replacing method of lower head is the same as the upper head.
Press guide
backet
V-guide
Pan head
screw
Wire support
Fig.74 Replacing V-guide on press guide bracket side (Lower)
(2) Replacing V-guide pulley

Procedure
(a) Loosen the bolts, and remove the V-guide base.
(b) Loosen the pan head screws, and remove the V-guide pulley.
(c) Turn the V-guide pulley 90 degrees. (The V-guide pulley can be used 4 times
in all). Replace the V-guide pulley when it has been used 4 times.
(d) Tighten the pan head screw to 1.2Nm with the torque driver when fixing the
V-guide pulley.
(e) Pushing the V-guide base in the left and downward direction, tighten the
bolts to 1.2Nm with torque driver (Fig.74).
Always use a torque driver to tighten screws to 1.2Nm when fixing the V-guide pulley
and V-guide base.
Machine accuracy will be affected if the V-guide is not mounted properly.
73
Maintenance SP43
Plate spacer
V-guide base
Socket head bolt
V-guide pulley
Pan head screw
Fig.75 Replacing V-guide pulley
W0720C-I1E-01 74
SP43 Maintenance
4.3 Changing Cutter Edge Position, and Replacement
As the cutter cuts the wire repeatedly in automatic wire threading, the cutter edge
chips and becomes dull. In case of dull edge, change the cutter edge position, or
replace the cutter following the procedure given below.
Changing procedure:
(a) Loosen a truss head screw, and shift a plate spring that holds the cutter
mounting plate. (See Fig.76)
(b) Remove two socket head bolts, then the cutter body.
(c) Loosen a set screw on the cutter (lower), and rotate the cutter (lower) to
change the edge position. When the edge is determined, tighten the set
screw on the cutter (lower)(See Fig.77).
(d) The same is done for cutter (upper) except this time, shaft is pressed lightly
from top before tightening setscrew.
(e) Rotate cutter (upper) to change cutting position. Press shaft lightly when
tightening the set screw.
Cutter part No.: 6EC220A706=1 (common to upper and lower)
(f) After setting the cutter, confirm that the cutter mounting plate (upper)
rotates smoothly. If the cutter body mounting plate (upper) not rotate
smoothly due to sludge, clean it following the cleaning procedure given
below.
Take care not to have your hand injured by the plate spring during work.
Cleaning procedure:
(a) Loosen a truss head screw, and shift a plate spring that holds the cutter
mounting plate. (See Fig.76)
(b) Remove two socket head bolts, then the cutter body.
(c) Loosen a setscrew on the shaft, remove the cutter mounting plate
(upper), and wash it with city water.
(d) Reassemble as shown in Fig.76. Tighten the set screw by hand lightly to
fix the shaft.
(e) After setting, confirm that the cutter mounting plate (upper) rotates
smoothly.
75
Maintenance SP43
Cutter mounting plate (upper) Shaft
Washer
Setscrew
Plate spring
Cutter (upper)
(6EC220A706=1)
Cutter (lower)
(6EC220A706=1)
Setscrew
Truss head screw
Socket head bolt
Setscrew
Cutter mounting plate (lower)
Fig.76 Cutter
Cutter mounting plate (upper) Cutter (upper)

Shaft
(6EC220A706=1)
Setscrew Washer
Setscrew
Cutter mounting plate (lower) Cutter (lower) Shock absorber plate

(6EC220A706=1)
Fig.77 Mount position the cutter (lower)
W0720C-I1E-01 76
SP43 Maintenance
4.4 Replacing Dielectric Nozzle and Nozzle Guard

Replace the dielectric nozzle, if worn out. Replace the nozzle guard, if damaged.
After replacement, check if the head protect function operate normally.
Table 4 Comparison
ø6 Type8 ø8 Type8 ø8 Type0 ø6 Laminar

Style
Nozzle Standard Machining - -

Close High Speed Machining X - -
Both Nozzle Away Machining - -
o
Taper Machining 10 10o 45o 10o
For AWT
-- Recommanded -- Reduction in performance X -- Impossible
The angles of the taper machining mentioned above are those that are mechanically
possible.
For the angles at which the machining is possible, refer to the "Machining Conditions".
4.4.1 Dielectric nozzle and nozzle guard for standard

machining
Nozzle
guard
Dielectric
nozzle
Type 0 Type 8
Fig.78 Dielectric nozzle for standard machining
Table 5 Replacing parts
Type 0 (ø8) Type 8 (ø8)

Nozzle guard 6EC80A418 18EC130A401
Dielectric guard 4EC80A708=1 4EC130A708=1 (Upper head)
18EC130A701 (Lower head)
77
Maintenance SP43
Do not expand the stroke with the type 8 nozzle guard, if type 0 work table (optional) is
used. Otherwise, the nozzle guard will collide against the work table.
The type-8 dielectric nozzles are different between upper headand lower head, thus
requiring extreme care.
Cooling holes
[For upper head: white] [For lower head: brown]

Fig.79 Dielectric nozzles, type-8
4.4.2 Dielectric nozzle for high speed machining
Table 6 Parts for high speed machining [Type8 (ø6)]

Nozzle
spacer
Upper head Lower head
Nozzle spacer 18EC80A719 18EC130B705
Nozzle
guard Nozzle guard 18EC130B401
Dielectric nozzle 18EC80A717 18EC130B706
Insulation 18EC130B703
Nozzle
Insulation
Fig.80 Dielectric nozzles for high speed machining
Level difference
For upper head For lower head

Fig.81 Nozzle spacer
W0720C-I1E-01 78
SP43 Maintenance
Cooling holes
[For upper head: white] [For lower head: brown]
Fig.82 Dielectric nozzle for high speed machining
Do not expand the stroke with the nozzle guard for high speed machining. Otherwise,
the nozzle guard will collide against the work table.
Nozzle spacer and dielectricare different between upper head and lower head, thus
requiring extreme care.
4.4.3 Laminar nozzle
Laminar nozzle does not have a nozzle or spacer nozzle. It comprises of just the
nozzle guard itself. It can be used for both upper and lower head.
Part number : 20EC130A401
4.4.4 Head cover

Head cover (black) is used when using laminar nozzle.
Lock nut
Except Laminar
Pan head bolt Laminar nozzle
nozzle
Bush
O-ring
Head cover
Plate washer
(Brown)
Head cover
(Black)
Except Laminar nozzle Laminar nozzle
Fig.83 Head cover
79
Maintenance SP43
4.5 Replacing worn out winding roller (M-axis) and pinch

roller (L-axis)
Groove is form on the surface of a worn out roller after long hours of usage.
Wire will easily curl which may result in wire breakage. Invert or replace the
rollers when a groove is present. The roller can only be inverted twice.
Standard life of roller : 5000 hours X 2 = 10000 hours
Winding roller, Pinch roller part number : 18EC100A701
Roller life may be shorter than 10000 hours depending on its usage.
Hand, hair or clothes may be caught in between the roller/shaft.

Switch off power supply before any maintenance work is to be done.
Tag a sign board at an easy-to-see place on the front side of machine, indicating that
the maintenance is under way and any operation is prohibited, so that a person other
than maintenance personnel does not operate the machine during maintenance.
Replacement procedure:
(a) Remove wire box(1). Remove wire box(2) instead if unable to remove box(1).
(b) Remove the protection cover (L, M-axis)
(c) Loosen the socket head bolt and remove the rollers.
(d) Invert / replace rollers.
Pinch roller (L-axis)
Winding roller
(M-shaft)
Socket
head bolt
Inverting rollers
Fig.84 Replacing L, M axis roller
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SP43 Maintenance
4.6 Replacing Fluid Filters
Replace the fluid filters if they reached the life or damaged, following the
procedure given below.
The fluid filter must be removed after the “PUMPS OFF” is turned on and the filter
pressure lowers to 0 MPa.
then press f • 8 (PUMPS OFF) key.
(b) Open the filter casing top cover.
(c) Remove the couplers connecting dielectric fluid filters.
(d) Attach the filter removing jig (optional), then remove the filters.
Couplers Filter removing jig (optional)
Dielectric fluid filters
Fig.85 Dielectric fluid filters
Slowly take out the dielectric filter while draining the fluid, as the filter containing the
fluid is heavy.
(e) Insert new dielectric fluid filters, and connect the couplers.
Dielectric fluid filter part No.: Z476A1010500 (WF-8)
(f) Close the filter casing top cover.
(g) Specify the PUMPS OFF from the main operation panel.
(h) Run the filter pump for 10 to 20 minutes.
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Maintenance SP43
Easy removal of dielectric fluid filter by using the air

The fluid filter contains dielectric fluid and becomes heavy. If it is difficult to
remove the filter, expel dielectric fluid by supplying air into the filter. As a result,
the filter can be easily removed.
Removal steps
(a) Make sure that the valve of the filter removing jig (optional) is closed.
(b) Attach the filter removing jig (optional), and connect the air supply coupler.
(c) Rotate slowly the valve about 45 degrees to supply air into the fluid filter.
(d) Expel dielectric fluid contained in the filter by the air.
(e) Close the valve and disconnect the air supply coupler.
Valve Air supply coupler

Open
Close
Fig.86 Easy removal of dielectric fluid filter
For the machine with only one air supply coupler attached, utilize the air supply coupler
already attached to the machine. However, if the air supply coupler is removed during
the machining, the machine stops accordingly.
A full opening of the valve on filter removing jig (optional) causes a large volume of air
to be supplied at once, resulting in a rupture of the filter.
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SP43 Maintenance
4.7 Replacing jet filter element
The stained jet filter element causes the clogging of protection mesh and
low-flow, those cause drifting jet. Replace jet filter element every 2 months.
Replacing procedure
(a) Loosen six socket head bolts, then remove the jet filter case.
(b) Loosen nut, then remove the jet filter element.
(c) Remove scale and dirt accumulating inside the filter case with water
(d) Clean inside and outside of the new jet filter element with water and a brush.
(e) Set the new jet filter element to the jet filter case with nut and filter retainer.
(f) Reassemble to the flange with six socket head bolts.
(g) After Jet on for about 10min, clean dust protection mesh to remove to
residual dust.
Jet filter element must be replaced under jet off.
Filter case must be fixed with reliability.
Please use only genuine parts. Otherwise, other element cannot filter out the slug.
That slug passed through the element causes wear of jet nozzle.
Please replace jet filter element every 2 months, even if it is not stain.
When inserting an element, it is not necessary to fill the filter case with the fluid.
Flange
Filter case
Jet filter element
(Z474N1010100)
Fig.87 Stainless steel jet filter case
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Maintenance SP43
Filter retainer
Socket head
Nut
bolts
O-ring
Flange
Filter case
Jet filter element

(Z474N1010100)
Fig.88 Stainless steel jet filter case assembly
4.8 Replacing Ion Exchange Resin
Replace the ion exchange resin when it cannot provide the specified conductivity
(water quality). The ion exchange resin life has expired when the conductivity
(water quality) indication does not reach the set value in about 30 minutes,
except immediately after change of dielectric fluid.
then press f • 7 (ION OFF) key.
The ion exchange resin can be replaced even during machining.
(b) Disconnect the tube coupler from the bottle lid. In such a case, be careful
that the water leaks from the bottle lid and tube coupler.
(c) Disengage the band, and remove the bottle.
(d) Put the used ion exchange resin into a bag attached.
Ion exchange resin part No.: Z429G0170100 (MR-151, 10L)
One-time replacement requires 20L resin. One bottle stores 10L resin, and therefore
load the resin of 2 cartridges to attain 20L.(See Fig.90)
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SP43 Maintenance
(e) Close the bottle lid. In such a case, clean the packing.
(f) Push the bottle against the rear plate, and fix with band.
(g) Connect tube couplers. Take care of the direction of water flow.
(h) Cancel the ION OFF from the main operation panel.
(i) Set the conductivity (water quality) to the desired value.
(j) Confirm that the water quantity is normal and no leakage is found at joints.
In storing the ion exchange resin, avoid dry or freezing condition where the ion
exchange capability degrades extremely. To avoid dry resin, put the resin in two
overlapped vinyl bags filled with water, and store it at a cool and dark place. The
storage period is maximum 6 months though it will vary depending on the storage
condition, because the ion exchange capability degrades as the time goes by even if it
is not used.
Knob Lid
Tube couplers
Band
Main bottle
Fig.89 Ion exchange resin cartridge
Fig.90 Quantity of ion exchange resin
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Maintenance SP43
4.9 Replacing Air Filter Elements
Replace the air filter element (5 µm) and mist separator element (0.3 µm), when
they have been used for one year or the pressure dropped by 0.1 MPa.
(a) Disconnect the air supply coupler.
The machine stops and a machining is interrupted, if the air supply coupler is
disconnected during machining.
Pressure guage
Air supply
coupler
Air filter
Regulator
Fig.91 Replacing filter element (1)
(b) Pull down the knob, rotate the case to remove.
Filter element Knob
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SP43 Maintenance
(c) Rotate the filter element to remove, then replace it.
Filter element
(d) Return the case to home position, and reconnect the airsupply coupler.
(Replace the mist separator element in the same manner.)
Filter element for air filter (5 µm) Type: 111585 (SMC)
Filter element for mist separator (0.3 µm)Type: 630617 (SMC)
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Maintenance SP43
5. OTHER CLEANING AND ADJUSTMENT
5.1 Maintaining Jet for Automatic Wire Threading
5.1.1 Cleaning dust protection mesh
Clean the dust protection mesh following the procedure given below, if the jet
water for automatic wire threading is turbulent or jet water pressure is low.
Water supply block
Socket head bolt

Dust protection
mesh
O-ring
Fig.94 Cleaning a dust protection mesh

Cleaning procedure:
(a) Loosen two socket head bolts, and remove the water supply block.
(b) Remove an O-ring and a dust protection mesh from the drain block.
(c) Clean the dust protection mesh with the water. At this time, use a soft tooth
brush to remove completely the dust clogging in the mesh.
(d) After completion of cleaning, reassemble in the order of steps (c), (b), and (a).
(e) After completion of assembly, inject the jet water to confirm that no water
leaks in the joints of water supply block.
When a dust protection mesh is not removed from the water supply block, inject the jet
water while holding the mesh by hand. At this time, inject the jet water into the work
tank to prevent the jet (dielectric fluid) for AWT from splashing outward.
Do not pick the dust protection mesh with a sharp edge because it is very thin and
vulnerable.
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SP43 Maintenance
5.1.2 Cleaning the jet nozzle (upper)
The jet nozzle is contaminated with water scale and sludge. Dirty jet nozzle may
cause the jet to be deviated. Clean the jet nozzle once a week.
Cleaning procedure:
(a) Remove the die mounting block, and remove the needle from the nozzle
body.
(b) Clean the needle tip with an acid such as K200. After cleaning, wash it with
the water.
(c) With the needle removed, insert a swab dampened with an acid such as
K200 into the nozzle body from the bore at the leading end of nozzle body to
clean the orifice (jet discharge port) in the nozzle body. After cleaning, wash
with the water.
Socket head bolt
Die mounting Nozzle

block body
Needle
Apply P700 Nozzle body

to packing need not be re- Nozzle
moved from the bracket
nozzle bracket
Nozzle body
Orifice
Swab
Push and rotate the swab to

clean the edge of the orifice.
Fig.96 Sectional view of nozzle

Fig.95 Nozzle body cleaning body
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Maintenance SP43
(d) After the cleaning finished, screw the needle into the nozzle body. In such a
case, tighten the needle lightly by hand.
In the even of hard screwing, apply Mecha P700 to the packing.
Tightening the needle with a tool could the jet nozzle to be damaged.
Tighten the needle fully. Insufficient tightening causes the jet to be deviated.
(e) Install the die mounting block.
If slug contamination is too severe, clean the nozzle jet accordingly as

shown in Fig.97, 98.
(a) Remove the die and needle accordingly as shown previously (a).
(b) Loosen the socket head bolt and remove the water supply block.
(c) Loosen the socket head bolt and remove the nozzle base. Nozzle body
need not to be remove in this case.
(d) The nozzle base is cleaned together with the nozzle body by
supersonic wave machine.
(e) Install the nozzle base while aligning it to the 3 positioning pin (Fig.98).
(f) Install the water supply block.
(g) Install the needle and die accordingly as shown previously (d)~(e).
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SP43 Maintenance
Socket head bolt

Water supply
block
Nozzle base
Nozzle body
Positioning pins
Fig.97 Cleaning of jet nozzle
Positioning pins
Nozzle base
Socket head bolt Nozzle body
Fig.98 Installation of nozzle base
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Maintenance SP43
5.1.3 Adjusting jet water
The shifted jet water affects the automatic wire threading performance. If shifted,
adjust the jet nozzle (upper) through the procedure given below. The jet water
should be adjusted after cleaning in (5.1.1) and (5.1.2) has completed.
Preparation : Workpiece having a prepared hole of ø2 – ø3 mm
(a little larger than jet water diameter).
Adjusting procedure:
(a) Execute the reference point return operation to align vertical position of
upper and lower heads.
(b) Remove upper and lower head covers and doors.
(c) Manually thread the wire into a prepared hole of the workpiece. If the jet
water position is scarcely shifted, thread the wire in the automatic mode as
usual.
(d) Using the wire centering function, position
Adjustment
the wire in the center of preparedhole. screw (XY
(e) Start the M6 (automatic wire threading) direction)
to inject the jet water. After jet water
is injected, press the STOP button.
Thus, the jet water can be adjusted at
the position of automatic wire threading.
(f) Injecting the jet water, adjust the position Fig.99 Adjusting jet water
and tilt of jet nozzle (upper) so thatthe
jet water can pass through internal parts of upper and lower heads and a
prepared hole without interference. During adjustment, move up and down
the Z axis to confirm that the jet water is not shifted.
(g) After adjustment has completed, restart the M6 (automatic wire threading) to
make sure that the threading is successfully completed.
During adjustment, the jet water (dielectric fluid) for AWT may splash. The
maintenance personnel should wear glasses to protect eyes from splashing water.
During adjustment, the jet water (dielectric fluid) for AWT may splash. Wipe the water
immediately if it spills on the floor or machine (except inside of work tank).
The axis can be moved on the RUN MANUAL screen during M6 stop.
However, if M6 key on the RUN MANUAL screen was used, no axis can be moved
even in the M6 stop status.
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SP43 Maintenance
5.2 Maintaining Nozzle Holder for Automatic Wire

Threading
5.2.1 Removing nozzle holder (water separator)
A wire debris remaining in AWT piping or nozzle holder (water separator) due to
wire break will lead to an AWT failure. Overhaul the nozzle holder following the
procedure given below.
First, take proper measures such as turning OFF the POWER switch so that the shafts
and rollers in winding unit do not run. Further, tag a sign board at an easy-to-see place
on the front side of machine, indicating that the maintenance is under way and any
operation is prohibited, so that a person other than maintenance personnel does not
operate the machine during maintenance.
The water, if remaining in the work tank, will leak from AWT piping during disassembly.
Before starting work, confirm that the water level in the work tank is lower than the
AWT piping.
Disassembling procedure:
(a) Remove the wire box from the machine to make work easier. If it is not to be
removed, shift the XY axes where you can easily perform work, and remove
the wire box (2) instead.
(b) Remove truss head screws, and pull out the protection covers (L, M shafts).
(c) Loosen a circular knob, and pull out the pipe clamp bushing from the nozzle
holder (water separator).
(d) Remove four socket head bolts, and pull out the nozzle holder (water
separator). During disassembly or reassembly, take care not to allow
interference between ceramic parts at the edge of nozzle holder (water
separator) and winding rollers. Also, take care not to lose O-rings attached to
the nozzle holder bracket.
(e) After cleaning, reassemble the nozzle holder (water separator) in the order of
(d) through (a).
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Maintenance SP43
Wire box (3)

Wire box (2)
Wire box (1)
Fig.100 Wire boxes
Protection cover (L, M-axis)
Truss screw (3 places)
Fig.101 Protection cover (L, M-axis)
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SP43 Maintenance
Nozzle holder Socket head bolts

(water separator) (4 places) Circular knob
Pipe clamb
bushing
Fig.102 Removing nozzle holder (1)
O-ring
Fig.103 Removing nozzle holder (water separator) (2)
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Maintenance SP43
5.2.2 Removing a pipe for automatic wire threading
After step (d) in paragraph (5.2.1), disassemble the pipe as follows.

(a) Holding a protection pipe, pull out the inner pipe. Do not remove a protection
pipe. It guides the pipe to be inserted into the nozzle (lower) in the lower
head mounting block.
The protection pipe is only inserted into the nozzle (lower) in the lower head
mounting block and not fixed. If it is removed, insert into the nozzle (lower) in
the lower head mounting block.
(b) Clean the inside of pipe. At this time, check if the pipe curves. The pipe is OK
if you can see the opposite side when looking into the pipe. If not, straighten
the pipe. If the pipe is extremely curved, replace it with a new one.
Pipe part No.: 20EC100B701
(c) Reassemble the pipe in the order of (b) and (a).
Pipe clamb
bushing
Protection
pipe
Fig.104 Removing a pipe (1)
Fig.105 Removing a pipe (2)
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SP43 Maintenance
5.2.3 Checking Nozzle Holder (Water Separator)
The water may leak from the nozzle holder (water separator), if the nozzle in the
nozzle holder (water separator) is shifted or the drain hose faces upward.
Check them as follows.
Nozzle holder
(water separator)
Adjusting valve Setscrew
Hose must be inserted completely.
Fig.106 Nozzle holder (water separator)
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Maintenance SP43
5.3 Adjusting Nozzle Guard Height
If a clearance between nozzle guard edge and top/bottom of workpiece is not set
properly, the lower head could collide against the workpiece, or dielectric fluid
pressure may not rise to the specified value. Adjust the nozzle guard height
Dielectric nozzle
Nozzle guard
Lock nut
Plate washer
Power supply spring
Power supply angle
Head cover
Fig.107 Adjusting nozzle guard height
(a) Loosen a lock nut, and rotate the nozzle guard to adjust so that a clearance
between nozzle guard edge and workpiece top/bottom face is 0.5 mm.
However, only if a wire below ø0.15 mm is used, adjust the Z axis so that a
gap between nozzle guard edge and workpiece top face is 3 mm. (A gap
between nozzle guard edge and workpiece bottom face is 0.5 mm)
(b) Tighten a lock nut to fix the nozzle guard, then again confirm the clearance
between nozzle guard edge and workpiece top/bottom face.
(c) Check that the head protect function operates normally.
If not operated normally, adjust the power supply spring.
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SP43 Maintenance
Power supply spring Nozzle guard
Fig.108 Nozzle guard
Take care not to be injured by the power supply spring when rotating a lock nut or
nozzle guard.
For easy adjustment of nozzle guard, tighten a little the lock nut.
The lock nut should be tightened by hand. If it is tightened excessively and it cannot be
loosened, loosen by inserting a wrench into a hole on side face of lock nut.
5.4 Mounting Head Cover
When mounting the head cover, tighten the screws to 0.8Nm with the torque
driver. When using the laminar nozzle, if the head cover position is shifted, the
water jet for automatic wire threading will touch the laminar nozzle, causing AWT
failure. Therefore, when using the laminar nozzle, mount the head cover
following the steps given below.
Adjustment procedure:
(a) Fix tentatively the head cover, and attach the laminar nozzle.
(b) Perform auto wire threading, then mount the head cover jig on the laminar
nozzle.
(c) Fix the head cover so that the wire is fit in the notch of the head cover jig.
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Maintenance SP43
Plate washer
Torque drive
Head cover
Head body
Fig.109 Mounting head cover
Excessive tightening could damage the head body. Always use proper torque.
The head cover is different between upper head and lower head, thus requiring
extreme care.
Cutting
For upper head For lower head
Fig.110 Head cover jig
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SP43 Maintenance
5.5 Maintaining K-Shaft
5.5.1 Removing the K-roller
A debris, if falling into the K-shaft, will cause the wire to be broken at the wire
winding unit. To remove foreign matters in the K-shaft, the K-roller must be
removed.
(a) Remove circular knobs, then the entire K-shaft cover.
(b) Remove a socket head bolt, then push out the entire K-roller (Fig.111) toward
the right with a wrench.
(c) Remove foreign matters in the K-shaft. At this time, rotate the K-roller by
hand to confirm that it rotates smoothly. If the K-shaft rotation is not smooth
or it gets stuck, replace the K-shaft bearing following the procedure given in
paragraph (5.5.2).
(d) Reassemble in the order of (c) to (a).
Socket head bolt

K-roller
Circular
knobs
K-shaft cover
Lower head
Fig.111 Removing the K-roller
The machining sludge entering the K-shaft clamping surface causes the K-shaft to be
tilted, thereby resulting in K-roller rotation failure. Clean the clamping surface when
clamping the K-shaft to the lower head.
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Maintenance SP43
5.5.2 Replacing the K-shaft bearing
Frequent wire break at the wire winding unit is caused by a rotation failure of
K-roller. Remove the plug, so that you can confirm the K-roller under rotation.
If K-roller rotation is not smooth or it does not rotate, replace the bearing followng
the procedure given below.
Preload adjusting collar Bearing cover (2)
Socket head bolt

K-shaft
Flat head screw
Bearing retainer
Bearing
(Z241A0017000)
Packing
K-roller
Bearing cover (1)
Fig.112 Configuration of K-roller
Replacing procedure
(a) Remove three socket head bolts, then the bearing cover (2).
(b) Remove a flat head screw, then the K-roller and the bearing. At this time, the
bearing cover (1) is not necessarily removed.
(c) Remove the bearing from the K-roller, and replace it. In removing the
bearing, take care not to lose the preload adjusting collar.
Bearing type: Z241A0017000 (DDRF-1960ZZ made by NMB)
(d) After replacement, reassemble parts in the order of (c) through (a). At this
time, tighten three socket head bolts with equal torque.
Applying grease into the K-roller can extend the bearing life. Recommended grease:
• NOK KLUBER SEALUB S13
• MARUTEMP GREASE
• ALBANIA GREASE
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SP43 Maintenance
5.6 Adjusting Pinch Roller (L-Shaft) Pressing Force
It is necessary to pressing force of the pinch roller (L-axis) according to the wire
diameter.With reference to the adjusment plate (fig.115), the adjusment screw
can be set to achieve the required pressing power for different wire diameter. The
pressing power increases when the adjustment screw is turned
counterclockwise.
Protection cover
(L, M axis)
Adjustment
screw mount
Adjustment screw
Fig.113 L-axis pressing force
Adjustment Adjustment line

screw mount
Adjustment
screw
Fig.114 Adjustment screw Fig.115 Adjustment plate
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Maintenance SP43
5.7 Adjusting Wire Tip Sensor
The amplifier panel (right side: wire guide unit (upper)) for the wire tip sensor will
appear, if the cover on the fine hole automatic wire threading unit is removed.
Make sure that the switches are set as follows. If not, re-set them correctly.
(See Fig.116)
Run mode switch : LIGHT position

Timer switch : NORMAL position
Then, confirm that the sensitivity of sensor has been adjusted correctly. If correct,
a run indicator (red lamp) and a margin indicator (green lamp) for amplifier are
both turned on when a wire is threaded. If either lamp or both lamps are not
turned on, adjust the sensor sensitivity following the procedure given below.
(a) Clean the sensor (see 3.1.2 Maintenance).
(b) Thread a wire.
(c) Rotate the gain control fully counterclockwise. Then, rotate it clockwise
gradually until a run indicator (red lamp) turns on.
(d) Remove a wire from the sensor. Rotate again the gain control clockwise until
a run indicator (red lamp) turns on.
A gain pointer is attached on the outside of gain control.
(e) Adjust the gain control to the center of positions where a run indicator
(red lamp) turns on in (c) and (d).
(f) Confirm the sensitivity.
If the wire tip sensor malfunctions in spite of several times of adjustment, please
contact our nearest service center or agents.
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SP43 Maintenance
Wire tip sensor
Wire guide unit

(upper)
Run indicator (red) Margin indicator (green)
Gain control
Pointer (indicator)
Timer switch Run mode switch
Fig.116 Adjusting wire tip sensor
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Maintenance SP43
5.8 Cleaning and Adjusting Drain Valve on Head
A wire may be broken in the head if the drain valve on the head is clogged.
To check for clogging, block the dielectric nozzle with your finger and inject the
water jet. At this time, confirm that the water comes out of the drain valve on the
side of head cover. If no water comes out, a drain hole for cooling water pipe
running through the head cover is clogged. Clean the drain valve following the
procedure given below (fig.117)
Adjusting Procedure
(a) Remove the head cover.
(b) Remove foreign matters in cooling water drain hole using a toothpick, etc.
(c) Mount the head cover, and confirm that the water comes out of the drain
valve.
Drain vlave Head cover
Guide retainer
Press bracket
Cooling water
drain hole
V-guide
Fig.117 Drain valve
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SP43 Maintenance
6. REMEDY FOR TYPICAL TROUBLES
6.1 Wire Break
Causes of wire break are different depending on where it was broken.

In case of a wire break, stop the machine and confirm where a wire was broken
from the wire length.

C-pulley
V-guide
Energizing
plate
Upper
head
V-guide
Wire winding section
Pinch roller
Diamond guide
(L-shaft)
(press guide)
Workpiece
K-roller
Winding roller V-guide Lower
(M-shaft) head
Wire box
Energizing
plate
V-guide pulley
Fig.118 Confirming wire break location
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Maintenance SP43
6.1.1 Wire break in head during machining
(1) Wire break in the vicinity of diamond guide

• Dirty or damaged diamond guide
Dirty diamond guide will cause a wire break. Check if diamond guide is
dirty or damaged, when a wire was broken in the vicinity of diamond guide.
(See 3.1.4 in Maintenance)
• Inaccurate mounting of diamond guide (press guide)
Inaccurate mounting of diamond guide (press guide) will cause a wire
break. Check if diamond guide is mounted accurately, when a wire was
broken in the vicinity of diamond guide. (See 4.1 in Maintenance)
(2) Wire break in the vicinity of energizing plate and V-guide
• Worn-out energizing plate
Worn-out energizing plate will cause a wire break.
Check if the energizing plate has worn out, when a wire was broken in the
vicinity of energizing plate and V-guide. (See 3.1.3 in Maintenance)
• Dirty or damaged V-guide
Dirty or damaged V-guide abrades the wire, causing a wire break. Check if
the V-guide is dirty or damaged, when a wire was broken in the vicinity of
energizing plate and V-guide even after checking energizing plate for wear.
• Too large pushing amount of energizing plate
Too large pushing amount of energizing plate will cause a wire break.
The pushing amount varies depending on the type of V-guides. Set the
energizing plate as specified. (See 4.3.2 in Maintenance)
6.1.2 Wire break in wire system during machining

(wire feeding)
(1) Wire break between clutch roller (D-shaft) and C-pulley

• Local wear of clutch roller (D-shaft)
A wire may be broken between clutch roller (D-shaft) and C-pulley, when
clutch roller (D-shaft) is inverted at the routine maintenance where either
groove of clutch roller (D-shaft) wears extremely. Replace the clutch roller
(D-shaft). (See 3.3.1 in Maintenance)
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SP43 Maintenance
(2) Wire break between K-roller and wire winding section

• Faulty K-roller rotation
A wire can be broken between K-roller and wire winding section, if K-roller
does not rotate by any reason. Check the K-roller for rotation.
(See 5.5 in Maintenance)
• Slip due to dirty pinch roller (L-shaft) and winding roller (M-shaft)
Dirty wire winding section allows the wire to slip, causing a wire break.
Clean the pinch roller (L-shaft) and winding roller (M-shaft).
Dirty diamond guide will put large friction on the wire, causing a wire break.
Check if diamond guide is dirty or damaged, when a wire was broken in the
vicinity of diamond guide. (See 3.4.4 in Maintenance)
Inaccurate mounting of diamond guide (press guide) will put large friction
on the wire, thus causing a wire break.
Check if diamond guide is mounted accurately, when a wire was broken in
the vicinity of diamond guide. (See 4.1 in Maintenance)
Worn-out energizing plate will put large friction on the wire, causing a wire
break.
Check if the energizing plate has worn out, when a wire was broken in the
vicinity of energizing plate and V-guide. (See 3.1.3 in Maintenance)
energizing plate and V-guide even after checking energizing plate for wear.
• Too large wire tension
A wire will easily be broken between K-roller and wire winding section, if
tension setting is too large.
Reconfirm the wire diameter and tension setting of machining conditions.
• Deteriorated wire
Wire black with oxidation lowers its tensile strength, and it will be easily
broken. Do not use such wire, otherwise it reduces the machining
accuracy.
Too large pushing amount of energizing plate will put large friction on the
wire, thus causing a wire break.
energizing plate as specified. (See 4.2 in Maintenance)
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Maintenance SP43
6.1.3 Wire break in workpiece during machining
(1) Wire break immediately after machining (machining length up to 5mm)

• Flushing failure
In the case of complicated workpiece geometry, a flushing of dielectric fluid
becomes insufficient, causing a wire break in the workpiece.
Set the work tank height so that the workpiece is submerged in dielectric
fluid when the work tank is full.
• Improper machining condition
A machining is unstable at the start of machining and a wire is easily
broken if machining power is large.
In this case, use approach condition of small machining power.
• Imperfect continuity due to an insulation such as rust on workpiece
The rust or black skin on workpiece surface is an insulation. Remove it
before machining.
• Concentrated sparks
Extremely high machining power may cause sparks to be concentrated in a
part of workpiece.
Lower the machining power.
(2) Wire break during machining (machining length over 5 mm)

(a) Low dielectric fluid pressure
• Worn-out dielectric nozzle
A dielectric nozzle, if worn out, increases a gap to workpiece, thus reducing
the fluid pressure. In such a case, replace dielectric nozzle.
• Improperly adjusted or damaged nozzle guard
In a machining with the nozzle kept close, if a gap between nozzle guard
and workpiece is too large, the closeness to workpiece is lowered,
reducing the fluid pressure. Set the gap to 0.5 mm.
Further, if nozzle guard is damaged, the fluid pressure lowers. Damaged

nozzle guard not only causes low fluid pressure, but also pushes the
workpiece, thus causing low machining accuracy. Replace the nozzle guard.
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• Complicated workpiece geometry

For the workpieces where dielectric nozzle cannot be kept close because
of complicated geometry or the workpieces having many slits or holes, the
fluid pressure does not rise.
In this case, execute a machining with the nozzle kept away.
(b) Improper machining condition

Change of standard machining power to higher value will cause a wire break
easily. Avoid use of extremely high machining power.
(c) Deteriorated wire

Wire black with oxidation lowers its tensile strength, and it will be easily
broken. Do not use such wire, otherwise it reduces the machining accuracy.
(d) Faulty workpiece

The presence of pin holes in workpiece allows sparks to be concentrated
there, causing a wire break.
(e) Damaged or loose power supply cable

Loose or damaged power supply cable connected to the head and work table
causes a wire break.
If the power supply cable is damaged, stop use of it immediately, and please
contact our nearest service center or agents.
(f) Bubbles mixing into slits

• Bubbles generated from head
Many bubbles may be generated between a gap between head cover and
door.
Adjust the head cover and door.
• Bubbles generated in work tank (at tank filling)

Bubbles may mix into the fluid during tank filling when the fluid level in bed
tank is low. Add dielectric fluid (water) if FLUID LEVEL LOW alarm
occurred. (See 3.1.7 in Maintenance)
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Maintenance SP43
6.1.4 Wire break during automatic threading
(1) Wire break between clutch roller (D-shaft) and C-pulley

• Excessively wear of clutch roller (D-shaft)
A wire may be broken between clutch roller (D-shaft) and C-pulley, when
clutch roller (D-shaft) is inverted at the routine maintenance where either
groove of clutch roller (D-shaft) wears extremely. Replace the clutch roller
(D-shaft). (See 3.3.1 in Maintenance)
(2) Wire break between K-roller and wire winding section at completion of wire
threading
A wire can be broken between K-roller and wire winding section, if K-roller
does not rotate by any reason.
Check the K-roller for rotation. (See 5.5 in Maintenance)
Dirty wire winding section causes the wire to slip, resulting in a wire break.

Dirty diamond guide will put large friction on the wire, thus causing a wire
break. Check if diamond guide is dirty or damaged, when a wire was
broken in the vicinity of diamond guide. (See 3.1.4 in Maintenance)

Inaccurate mounting of diamond guide (press guide) will put large friction
on the wire, thus causing a wire break.
Check if diamond guide is mounted accurately, when a wire was broken in
the vicinity of diamond guide. (See 4.1 in Maintenance)

Worn-out energizing plate will put large friction on the wire, causing a wire
break. Check if the energizing plate has worn out, when a wire was broken
in the vicinity of energizing plate and V-guide.
• Improper machining condition
Change of standard machining power to higher value will cause a wire
break easily.
Avoid use of extremely high machining power.
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energizing plate and V-guide even after checking the energizing plate for
wear.
• Run-out of wire in lower head

A wire may be broken, if automatic wire threading failed and it ran out of
the guides.
Improve AWT success rate by, for instance, changing the prepared hole
diameter.
• Wire threading at adjacent hole

If prepared holes are adjacent, a wire may be threaded at adjacent hole
and it touches the workpiece after completion of threading.
Confirm the position of prepared holes.
If a wire touches the workpiece, the wire may be broken when wire feed starts.In the
automatic run mode, the touch retry occurs before machining and a wire threading is
again executed.

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6.2 Operation Failure during Machining
6.2.1 Dielectric fluid spouts from upper head
• Dislocation of wire support

Wrong positioning the wire support (2) in the upper head may allow
dielectric fluid to blow up during a close machining. Adjust the position of
wire support (2). (See 4.2 in Maintenance)
6.2.2 Water leaks from nozzle holder (water separator)
• Faulty drain
Folded or bent drain hose allows water to leak from the nozzle holder
(water separator).
• Dislocated nozzle for nozzle holder (water separator)

The nozzle for nozzle holder (water separator), if dislocated, cannot
separate the wire from jet, thus allowing the jet to blow out of the nozzle
holder (water separator). Confirm the nozzle position.
(See 5.2.3 in Mantenance)
• Disordered water separating air

The water leaks from the nozzle holder (water separator), if the water
separating air adjusting valve is closed. (See 5.2.1 in Maintenance)
6.2.3 Many bubbles in work tank
• Bubbles generated in work tank (at tank filling)

Bubbles may mix into the fluid during tank filling when the fluid level in bed
tank is low.
Add dielectric fluid (water) if FLUID LEVEL LOW alarm occurred.
• Bubbles generated from head

Many bubbles may be generated between a gap between head cover and
door. Adjust the head cover and door.
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6.2.4 Low dielectric fluid pressure

the fluid pressure.
In such a case, replace dielectric nozzle. (See 3.1.6 in Maintenance)

workpiece, thus causing low machining accuracy. Replace the nozzle
guard. (See 3.2.3 in Maintenance)

6.2.5 Large curl of used wire

The used wire may curl extremely, if K-roller does not rotate by any reason.

The used wire may curl extremely, if diamond guide is dirty.
Check if diamond guide is dirty or damaged. (See 3.1.4 in Maintenance)

The used wire may curl extremely, if diamond guide (press guide) is not
mounted accurately. Check if diamond guide is mounted accurately.
The used wire may curl extremely, if the energizing plate has worn
excessively.
Check if the energizing plate has worn out. (See 3.1.3 in Maintenance)
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Maintenance SP43

The used wire may curl extremely, if V-guide is dirty or damaged.
Check if the V-guide is dirty or damaged.
The used wire may curl extremely, if deteriorated wire is used.
Replace the wire.

The used wire may curl extremely, if the pushing amount of energizing
plate is too large.
6.2.6 False detection of “WIRE BREAK” alarm
(1) Loose wire between clutch roller (D-shaft) and C-pulley

• Worn clutch roller (D-shaft)
As the time goes by, the clutch roller (D-shaft) wears.
Large wear allows a wire to loosen between clutch roller (D-shaft) and
C-pulley. Invert the clutch roller (D-shaft). (See 3.2.1 in Maintenance)
• Dislocated clutch roller (D-shaft)

The clutch roller (D-shaft), if dislocated to front or rear, allows a wire to
loosen between clutch roller (D-shaft) and C-pulley, causing false detection
of wire break. Check if clutch roller (D-shaft) is attached accurately.
(2) Slip due to dirty pinch roller (L-shaft) and winding roller (M-shaft)
Dirty wire winding section allows the wire to slip, causing false detection of
wire break. Clean the pinch roller (L-shaft) and winding roller (M-shaft).
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6.2.7 Alarm “HEAD PROTECT DETECTED” occurred
• Head touches work fixture or workpiece

If this alarm occurred, check the head for evidence of damage.
In case of a heavy collision, stop operation and please contact our nearest
service center or agents.
Pay attention to abnormal sound in machine after collision, regardless of
the extent of nozzle guard deformation.
Before machining, confirm in the dry run mode that there is no possibility of
collision. Even in a light collision, replace the nozzle guard if damaged.
• Collision of nozzle guard during Z-axis down movement
The head protect function does not function to the nozzle guard edge. Pay
extreme attention during machining with Z axis movement. In case of a
heavy collision, not only nozzle guard, but also the diamond guide may be
damaged. Even in a light collision, replace the nozzle guard if damaged.
• Touch of wire debris or cut-off workpiece
Wire debris or cut-off workpiece touches the head.
Check if wire debris or cut-off workpiece is present in the vicinity of head.
6.2.8 Alarm “BACK BLOCK OUT DUE TO SHORT” or

“BACK LENGTH OUT DUE TO SHORT” occurred
(1) Cut-off workpiece touches wire

During machining, workpiece debris falls, causing alarm “BACK BLOCK
OUT DUE TO SHORT” or “BACK LENGTH OUT DUE TO SHORT”.
Remove workpiece debris.
(2) Wire tangles with wire winding section

When a wire box is full, a wire cannot be discharged from the wire winding
section, causing the wire to tangle with the winding roller (M shaft).
Tangling wire touches the machine, thus causing alarm “BACK BLOCK OUT
DUE TO SHORT” or “BACK LENGTH OUT DUE TO SHORT”.
Remove the roller cover, then the wire. (See 3.2.4 in Maintenance)
(3) Wire flows over wire box

When a wire box is full, a wire flows over wire box and touches the machine,
thus causing alarm “BACK BLOCK OUT DUE TO SHORT” or “BACK
LENGTH OUT DUE TO SHORT”. Remove wire from the wire box.
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(4) Rust on workpiece (at restart after long interruption)

If machining has been interrupted for long time, the workpiece rusts and
adequate gap cannot be attained. Avoid too long interruption.
(5) Stress in workpiece

Stress may resides in the workpiece.
As residual stress is relieved gradually, the workpiece deforms as the time
goes by and adequate gap cannot be attained.
Relieve residual stress through refining, etc.
(6) Poor water quality

If water quality is poor, adequate gap cannot be attained, thus causing alarm
“BACK BLOCK OUT DUE TO SHORT” or “BACK LENGTH OUT DUE TO
SHORT”.
• Low conductivity
Too high setting of conductivity reduces the water quality.
Set the conductivity condition properly.
• Faulty conductivity sensor

Dirty conductivity sensor reduces water quality lower than actual display.
Clean the conductivity sensor. (See 3.2.6 in Maintenance)
6.3 Machining Performance Failure
6.3.1 Decreased machining speed and unstable machining
(1) Decreased machining speed by low fluid pressure

the fluid pressure.
In such a case, replace dielectric nozzle. (See 3.1.6 in Maintenance)

workpiece, thus causing low machining accuracy. Replace the nozzle
guard. (See 3.2.3 in Maintenance)
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(2) Improper machining condition

Change of standard condition setting may decrease machining speed or
make machining unstable.
(3) Low wire tension

Low wire tension cannot retain proper gap with respect to the workpiece,
thus causing reduced machining speed or unstable machining.
Adjust the powder clutch. (See 3.3.2 in Maintenance)

If water quality is poor, adequate gap cannot be attained, thus making a
machining unstable.

(5) Power supply failure

Energizing plate, if worn out, may decrease machining speed or make
machining unstable.
Check the energizing plate for wear. (See 3.1.3 in Maintenance)
• Dirty energizing plate mounting surface or presence of foreign matters

If energizing plate mounting surface is dirty or it is mounted with the
presence of foreign matters, power is not supplied completely, thus causing
reduced machining speed or unstable machining.
Also, this condition will cause an electrolytic corrosion on the energizing
plate bracket, and will further make energizing plate mounting unstable.
Clean the mounting surface so as not to allow the presence of foreign
matters when mounting the energizing plate.
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Maintenance SP43
• Damaged or loose power supply cable

Loose or damaged power supply cable connected to the head and work
table will cause reduced machining speed or unstable machining.
If the power supply cable is damaged, stop use of it immediately, and
please contact our nearest service center or agents.
• Too small pushing amount of energizing plate

Too small pushing amount of energizing plate will decrease machining
speed or make machining unstable.
6.3.2 Faulty machining accuracy
(1) Inaccurate mounting of diamond guide (press guide)

Tilt diamond guide (press guide) will lower the machining accuracy.
In case of faulty machining accuracy, check if diamond guide is mounted
accurately. (See 4.1 in Maintenance)
(2) Dirty or damaged diamond guide

Dirty diamond guide will lower the machining accuracy.
In case of faulty machining accuracy, check if diamond guide is dirty or
damaged. (See 3.1.4 in Maintenance)
(3) Change in machine temperature

The machine deflects as the body temperature changes.
Control the room temperature, and also avoid direct air flow to the machine.
Particularly, if an air conditioner stops at the weekend, allow time for the
machine to tune its temperature to the room temperature before machining
of measurement.
(4) Faulty wire vertical alignment

If wire vertical alignment is disordered, high machining accuracy will not be
attained. Adjust the wire vertical alignment each time the wire diameter is
changed. (See 3.3.4 in Maintenance)
(5) Stress in workpiece

goes by and the machining accuracy lowers.
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If water quality is poor, adequate gap cannot be attained, thus causing low
machining accuracy.


thus causing low machining accuracy.
6.3.3 Faulty finished surface
(1) Streaks on finished surface

Streaks may appear on the finished surface, if K-roller does not rotate by
any reason.
Dirty wire winding section allows the wire to slip, causing streaks on the
finished surface.

Dirty diamond guide allows the wire to vibrate, causing streaks on the
finished surface.
Check if diamond guide is dirty or damaged. (See 3.1.4 in Maintenance)

Tilt diamond guide (press guide) allows the wire to vibrate, causing streaks
on the finished surface. Check if diamond guide is mounted accurately.
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Maintenance SP43

Worn-out energizing plate allows the wire to vibrate, causing streaks on the
finished surface. Check if the energizing plate is dirty or damaged.


Dirty or damaged V-guide abrades the wire, thus causing streaks on the
finished surface.
Check if the V-guide is dirty or damaged, when a wire was broken in the
vicinity of energizing plate and V-guide even after checking the energizing
plate for wear.
• Flushing failure
Insufficient flushing of dielectric fluid to the machining area in a machining
of end face, streaks may appear on the finished surface.
Set the work tank height so that the workpiece is submerged in the fluid.
• Low wire tension

thus causing streaks on the finished surface.
(2) Uneven finished surface

• Change in machine temperature
As the body temperature changes, the machine deflects, thus resulting in
uneven finished surface. Control the room temperature, and also avoid
direct air flow to the machine.
Particularly, if an air conditioner stops at the weekend, allow time for the
machine to tune its temperature to the room temperature before machining
or measurement.
• Stress in workpiece
goes by and the machining accuracy lowers.
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SP43 Maintenance

thus causing streaks on the finished surface.
(3) Black finished surface

The finished surface may become black when dielectric fluid has
deteriorated. Replace the dielectric fluid. (See 3.3.5 in Maintenance)
6.4 Faulty Wire System
6.4.1 Wire cannot be feed
• Wire break
A wire may be broken after it was threaded. (See 6.1.4 in Maintenance)
6.4.2 Wire cannot be feed
(1) Slip on clutch roller (D-shaft)

• Dirty clutch roller (D-shaft)
Dirty clutch roller (D-shaft) allows a wire to slip, making wire feed
impossible. Clean the groove of clutch roller (D-shaft).
• Dirty I-roller
Dirty I-roller allows a wire to slip, making wire feed impossible.
Clean the I-roller surface. (See 3.2.1 in Maintenance)
• Worn I-roller
Worn I-roller allows a wire to slip, making wire feed impossible.
Shift the position of I-roller. (See 3.2.1 in Maintenance)
(2) Clutch roller (D-shaft) does not rotate

Low wire tension makes wire feed impossible.
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Maintenance SP43
6.4.3 Clutch roller (D-shaft) rotates intermittently

As the time goes by, the clutch roller (D-shaft) wears. Large wear allows a
wire to loosen between clutch roller (D-shaft) and C-pulley.
Large looseness causes a wire slip on the clutch roller (D-shaft), resulting
in intermittent rotation of clutch roller (D-shaft).
Invert the clutch roller (D-shaft). (See 3.3.1 in Maintenance)

loosen between clutch roller (D-shaft) and C-pulley.
Large looseness causes a wire slip on the clutch roller (D-shaft), resulting
in intermittent rotation of clutch roller (D-shaft).
Check if clutch roller (D-shaft) is attached accurately.
Dirty wire winding section allows a wire to slip, making a wire feed
unstable, and resulting in intermittent rotation of clutch roller (D-shaft).
6.4.4 Loose wire between clutch roller (D-shaft) and

C-pulley


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6.4.5 Noisy clutch roller (D-shaft)
• High metallic sounds (continuous sounds)

High metallic sounds from clutch roller (D-shaft) are not abnormal.
Proper adjustment of powder clutch can reduce this sounds.
6.4.6 Slippery clutch roller (D-shaft)


6.4.7 Slippery I-roller
• Dirty I-roller
Dirty I-roller allows a wire to slip, making wire unspooling impossible.
Clean the I-roller surface. (See 3.2.1 in Maintenance)
• Worn I-roller
Worn I-roller allows a wire to slip, making wire unspooling impossible.
Shift the position of I-roller. (See 3.2.1 in Maintenance)
6.4.8 Wire tangles with wire winding section
• Full wire box

When a wire box is full, a wire cannot be discharged from the wire winding
section, causing the wire to tangle with the winding roller (M shaft).
Remove the roller cover, then the wire. (See 3.2.4 in Maintenance)
• Large wire curl

Extremely large wire curl causes a wire to be hooked to the roller cover.
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Maintenance SP43
6.4.9 Wire is rewound up to A-shaft (at AWT)
• Faulty sensitivity of wire tip sensor

Too strong sensitivity of wire tip sensor causes a wire to be wound up
excessively during automatic wire threading. Adjust the sensitivity of wire
tip sensor. (See 5.7 in Maintenance)
• Dirty wire tip sensor

The sensor surface, if soiled with sludge, etc., causes a wire to be wound
up excessively during automatic wire threading.
Clean the sensor surface with a cotton swab.
• Dew on wire tip sensor surface
The presence of dew on sensor surface causes a wire to be wound up
excessively during automatic wire threading.
Check if drew on the sensor surface is removed by the sensor air blow.
6.4.10 Wire is not rewound up to wire tip sensor

Too weak sensitivity of wire tip sensor causes a wire to be wound up
excessively during automatic wire threading.
Adjust the sensitivity of wire tip sensor.
6.4.11 Wire cannot be cut with cutter
• “CUTTER MOTION ABNORMAL” alarm

The “CUTTER MOTION ABNORMAL” alarm occurs, if a cutter failed to cut
off the wire because of wear.
Change the cutting position of cutter. (See 4.3 in Maintenance)

Too weak sensitivity of wire tip sensor causes a cutting failure of wire
during automatic wire threading.
Adjust the sensitivity of wire tip sensor. (See 5.7 in Maintenance)
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6.4.12 Water leaks from nozzle holder (water separator)

separate the wire from jet, thus allowing the jet to blow out of the nozzle
holder (water separator). Confirm the nozzle position.
• Disordered water separating air

The water leaks from the nozzle holder (water separator), if the water
separating air adjusting valve is closed. (See 5.2.3 in Maintenance)
• Faulty position of wire support

Wrong positioning the wire support (2) in the lower head may allow
dielectric fluid to leak during a close machining. Adjust the position of wire
support (2). (See 4.2 in Maintenance)
6.4.13 Wire runs out of wire guide unit (upper) at wire cut
• Disordered felt pad

Weak wire holding force of felt pad allows a wire to run out of the guide
when a wire is cut off by the cutter.
Adjust the felt pad to stronger holding force. (See 3.2.2 in Maintenance)
6.4.14 No jet water is injected
• Lower jet is selected

Check the MACH OPE screen.
6.4.15 Press guide does not open or close
• Dirty piston
If the piston does not move smoothly, the press guide bracket may not be
closed completely.
Clean the piston. (See 3.1.5 in Maintenance)
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Maintenance SP43
• Faulty bearing for press guide turning shaft

The presence of sludge in the bearing for press guide turning shaft causes
the press guide bracket not to turn smoothly.
This problem may be solved by opening and closing the press guide
bracket several times by hand. But if no improvement is attained where the
press guide is not closed (or opened) completely, please contact our
nearest service center or agents.
trouble.
6.5 Low Wire Threading Success Rate
6.5.1 Faulty water jet
(1) Weak jet

• Clogged dust protection mesh
When the water jet is weak (jet fluctuates), the dust protection mesh could
be clogged. (See 5.1.1 in Maintenance)
• Clogged jet filter

The jet filter will reach its life, if water jet is weak though the dust protection
mesh was cleaned. Replace the jet filter. (See 4.7 in Maintenance)
(2) Water jet expands or becomes flat

• Dirty jet nozzle (upper)
Clean the jet nozzle (upper). (See 5.1.2 in Maintenance)
Similar phenomenon may arise though water jet is weak. Before cleaning the jet nozzle
(upper), confirm item (1) above.
(3) Water jet shifts from prepared hole during AWT

• Dislocated jet nozzle (upper)
Frequent cleaning may dislocates the jet nozzle (upper). Adjust the jet
nozzle position, if the shift amount is large and automatic wire threading
success rate lowered. (See 5.1.3 in Maintenance)
(upper), confirm items (1) and (2) above.
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6.5.2 Wire does not enter prepared hole in workpiece
(1) Water jet shifts from prepared hole during AWT

• Dislocated jet nozzle (upper)
Frequent cleaning may dislocates the jet nozzle (upper). Adjust the jet
nozzle position, if the shift amount is large and automatic wire threading
success rate lowered. (See 5.1.3 in Maintenance)
(upper), confirm items in 6.5.1.
(2) Faulty prepared hole geometry

• Small prepared hole diameter
The wire threading success rate will lower extremely where the prepared
hole diameter exceeds the specified range for AWT. Check the
specification. (See 2.2 in Description of product)
• Burr at mouth of prepared hole

The presence of burr at the mouth of prepared hole not only blocks a wire
insertion but also causes a touch detection. Deburr the prepared hole.
However, a chamfering at the exit of prepared hole should be minimum.
Otherwise, the water jet curves after it passed through the prepared hole,
thus lowering the wire threading success rate.
• Too large distance between workpiece and nozzle guard

Too large distance between workpiece and nozzle guard allows a wire to
run out from there. Check the distance.
(3) Unsuitable retry mode

• Use of retry mode 0
Retry mode 0 does not execute retry in case of AWT failure. If retry is
necessary, use retry mode 1 or 3.
• Use of retry mode 3

Retry mode 3 is a high speed mode of retry 1. Therefore, the AWT success
rate and reliability will be lowered a little. Use retry mode 1 when an
unmanned operation is executed.
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Maintenance SP43
6.5.3 Wire easily gets stuck after lower head
(1) Frequent touch detection (in use of fine hole AWT unit)
Small prepared hole diameter allows a wire to touch the workpiece easily
after it passed K-shaft, resulting in a touch detection.
Set machine parameter No.0703 to larger value.
(2) Blocked wire path, or sticking

• Presence of foreign matters
Wire debris will be present in the K-roller, pipe for AWT, or nozzle holder
(water separator). Check respective parts.

separate the wire from jet, thus causing a wire to be stuck at the nozzle of
nozzle holder (water separator). Confirm the nozzle position.
6.5.4 Frequent touch retry after completion of AWT
(1) Faulty AWT start point

• Dislocated prepared hole
Dislocated prepared hole allows a wire to touch the prepared hole after
wire threading. Check the prepared hole position.
• Wrong wire threading at adjacent hole

If the distance between prepared holes is small, a wire may be threaded at
adjacent hole, causing a touch retry.
Keep off adjacent holes as far as possible.
(2) Wire runs out of head internal parts

Because of reduced wire retention force, a wire is threaded at a place out
of the wire path in the head, depending on the wire curl, thus causing a
touch retry. Prepare a hole as large as possible.
• Wrong wire threading at adjacent hole

If the distance between prepared holes is small, a wire may be threaded at
adjacent hole.
In this case, a wire runs out of the wire path in the head, causing a touch
retry. Keep off adjacent holes as far as possible.
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6.6 Operation Failure at Power ON or OFF or Power Failure
6.6.1 Wire is rewound up to supply reel (in use of large

capacity wire spool loader)
• Limitation in use of large capacity wire feeder

When a wire is cut off, a wire is continuously rewound until the main switch
is turned off after the OFF button on main operation panel was pressed.
Turn off the main switch immediately after the OFF button on main
operation panel was pressed, or hold the clutch roller (D-shaft) by hand.
6.7 Troubles during Maintenance
6.7.1 K-roller cannot be removed
• Tilt K-roller
The K-roller, if pulled obliquely, will get stuck to the K-shaft cover. Pull the
K-roller straight.
6.7.2 Energizing plate cannot be removed
• Corrosion of energizing plate mounting surface

If energizing plate mounting surface has corroded, the energizing plate
may not be removed.
Remove slowly the energizing plate with long-nose pliers while removing
sludge in corroded area using the K200 supplied.
6.7.3 Vertical alignment position varies

Low wire tension reduces the wire straightness, thus making wire vertical
alignment performance and machining accuracy unstable. Adjust the
powder clutch. (See 3.3.4 in Maintenance)
(2) Faulty jig

• Generation of a solvent film on jig surface
If the jig is cleaned with solvent, a film is generated on the jig surface,
causing an insulation failure. Use only a cotton swab when cleaning the jig
surface; do not use solvent.
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Maintenance SP43
• Generation of an oxidation film on jig surface

An oxidation film may be generated on the jig surface.
Change the wire touch position.
(3) Faulty wire

• Film on wire surface
The wire surface is coated with oil such as paraffin, etc. This film may
cause an insulation failure.
Clean the wire surface with a cotton swab dampened with alcohol.
If a wire has deteriorated and rust or oxidation film is generated on the wire
surface, wire vertical alignment and machining accuracy will be unstable.
Do not use deteriorated wire.
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7. MEASURE OF OBSTRUCLE
7.1 Adjustment of clutch roller against wire vibration
Adjust position of clutch roller (D-shaft) according to the following when the wire
vibrates when moving along the R-groove of the clutch roller(D-shaft).
(a) Loosen set screw on the flange.
(b) Adjust the clutch roller forth and back so that the wire should go up on the
groove side of the clutch roller and not slip down and interfere with the wire
coming from C-pulley. Lock the set screw when new position is confirmed.
(c) Loosen socket head bolt on the press roller base and adjust the press roller
base so that the press roller could sit fully on the clutch roller grove.
Socket head bolt
Press roller base
C-pulley Wire don’t interfere
Power clutch
Socket head bolt
Press roller base
M4 set screw
(to lock flange)
Socket head bolt
Fig.119 Clutch roller position
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Maintenance SP43
7.2 Line-up of Wire Feed System
Fig.120 shows the wire feed system as viewed from the right of machine.
The wire must be straight in the Y axis direction. If the verticality between
diamond guides is correct, a machining is possible even though a section
between positioning guide and K-shaft is zig-zag in the Y axis direction.
However, since the wire given with the tension tends to become straight, it often
comes out of the groove of each guide. As a result, the wire tension fluctuates
and damages the machined surface. Also, when the wire disengages from the
diamond guide, it may cause a machining failure. Further, if the diamond guide,
V-guide, and K-shaft are not straight, the wire is not loaded into the diamond
guide during automatic wire threading.
Though the machine has been assembled with taking care of the line-up of these
parts in the factory, check the straightness and line-up of these parts when the
head collides against something, any part is dislocated, or the wire easily
disengages from the diamond guide.
Y-axis direction
Positioning guide
V-guide
Energizing plate Upper head
V-guide
Diamond guide
Workpiece
Diamond guide
V-guide
Lower head
Energizing plate
V-guide pulley
K-shaft
Fig.120 Line-up in Y-axis direction
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Adjust wire straightness between positioning guide, diamond guide, and K-shaft.
(a) Thread the wire.
(b) Perform wire vertical alignment (see 3.3.4 in Maintenance).
(c) Remove the energizing plates and V-guides of upper and lower heads.
(d) Feeding the wire at 5 TAP (5 cm/s), press the GUIDE OPEN Key.
(e) Slowly push the wire at the middle position between upper and lower heads in
the X direction by your finger. The pushed wire will enter the groove of
diamond guide. At this time, the adjustment is OK if the wire does not swing
forward and backward. In such a case, for more exact confirmation, clamp
the workpiece to the table in parallel with the X axis, and use it as the guide
for the finger movement.
(f) Relocate the positioning guide or K-shaft or both of them in the Y-axis direc-
tion
(cross direction), when the wire runs out extremely in cross direction or the
wire does not enter the groove.
(g) After adjustment, install the V-guides, and confirm by turning on/off the
GUIDE OPEN that the wire enters the groove without running out in cross
direction (Fig.121).
(h) If it runs out in the cross direction, the V-guide position in the cross direction is
improper, and return to step (f).
The above operation assumes that the diamond guide is in correct position
No cross run-out (Good) Cross run-out (N.G.)
Fig.121 Wire runs out in cross direction when it fits in diamond guide
135
W0720C-I1E-01
V-guide pulley
Maintenance
Fig.122 Influence of positioning error in Y-axis direction
136
SP43
SP43 Maintenance
8. MAIN CONSUMER PARTS
8.1 Consumable Parts List
Parts Name Parts No. Remarks

Diamond guide 20EC080A404 For ø0.10mm
20EC080A405 For ø0.15mm
20EC080A406 For ø0.20mm
20EC080A407 For ø0.25mm
20EC080A408 For ø0.30mm
Press guide 20EC080A409 Common to both upper and lower
Energizing plate Z248W0200300 For upper head
Z248W0200400 For lower head
Dielectric fluid nozzle 4EC80A708=1 Type 0, for upper and lower head
4EC130A701=1 Type 8, for upper head (std. speed)
18EC130A701 Type 8, for lower head (std. speed)
18EC80A717 Type 8, for upper head (high speed)
18EC130B706 Type 8, for lower head (high speed)
20EC130A401 Laminar nozzle
Nozzle guard 6EC80A418 Type 0
18EC130A401 Type 8
V-guide 15EC80B701 For upper and lower heads,
positioning guide for wire guide unit
(upper)
20EC090A701=2 Pulley type, for lower head
20EC090A702 For lower head
Energizing base 20EC090A401 For lower head
Dielectric fluid filter Z476A1010500 WF8
Ion exchange resin Z429G0170100 MR-151 (10L), One-time
replacement requires 20L
Jet filter element Z474N1010100 MK100 9.75
Felt pad 1EC100B703 For B-shaft
6EC220B714=1 Wire guide unit (upper) (1)
6EC220B716=1 Wire guide unit (upper) (2)
Cutter 6EC220A706=1 Common to both upper and lower
137
Maintenance SP43
Parts Name Parts No. Remarks

K-shaft bearing Z241A0017000 DDRF-1960ZZ (NMB)
Clutch roller (D-shaft) 15EC100F411
I-roller 6EC100A747
Pipe 20EC100B701-00
L,M axis roller 18EC100A701
Wire Z332Y2100030 (For ø0.1) HBZU10 P3RT
3K-reel
Z332Y2150030 (For ø0.15) HBZU15 P3RT
3K-reel
Z332Y2200050 (For ø0.2) HBZU20 P5RT
5K-reel
Z332Y2200100 (For ø0.2) HBZU20 P10RT
10K-reel
Z332Y2200200 (For ø0.2) HBZU20 P20RT
20K-reel
Z332Y2250050 (For ø0.25) HBZU25 P5RT
5K-reel
Z332T2250100 (For ø0.25) HBZU25 P10T
10K-reel
Z332Y2250200 (For ø0.25) HBZU25 P15T
20K-reel
Z332Y2300050 (For ø0.3) HBZU30 P5RT
5K-reel
Z332Y2300100 (For ø0.3) HBZU30 P10T
10K-reel
Z332Y2300200 (For ø0.3) HBZU30 P15L
20K-reel
W0720C-I1E-01 138
SP43 Maintenance
8.2 Precautions on Consumables

The use of unspecified cconsumables could cause the machine to malfunction.
Be sure to use the specified consumables only.
(1) Dielectric fluid filter

The use of unspecified dielectric fluid filter may not remove the sludge
completely, making the dielectric fluid dirty, thereby causing a damage of
equipment such as pump or a wire break. Always use the specified fluid
filter.
(2) Ion exchange resin

The use of uspecified ion exchange resin allows the ion exchange resin to
flow out of the cartridge, thereby causing a damage of equipment such as
pump. Always use the specified ion exchange resin.
Also, the use of unspecified ion exchange resin could reduce the ion life
time. Always use the specified ion exchange resin.
(3) Wire electrode

The use of unspecified wire electrode could cause the wire to curl or slip,
resulting in a wire break. Always use the specified wire electrode.
139
Glossary Of Terms SP43
Chapter 5 GLOSSARY OF TERMS
W0721C-I1E-01 Glossary Of Terms.fm

SP43 Glossary Of Terms
1 GLOSSARY OF TERMS
The terms used in this manual are listed below:
A
Absolute command A position to which the machine moves is programmed
with the coordinates.
Additive A chemical substance added in dielectric fluid (water).
Aerial discharge An electrical discharge is taken place in the air because

dielectric fluid is not fed to the machining area.
Affected layer A layer of workpiece affected by an electrical discharge

phenomenon.
Air drier A unit to remove the water mixing in the compressed air
to be supplied to the machine.
Air pressure source The air supplied to the machine. It is also called an air
source.
Arm A cylindrical component to which the lower head is

attached. It is also referred to as lower arm or lower head
arm.
Arm cover A component that covers the arm.
Arm seal A component that prevents the water from leaking from
the boundary between table and arm.
A-shaft See the supply reel (A-shaft).
Automatic power After the power failed, the NC is automatically turned on

failure recovery to restart and continue machining.
Automatic wire A function to load the wire up to the winding roller

threading (AWT) automatically. It is provided with four retry modes
depending on the recovery operation in case of AWT
failure.
Auxiliary nozzle An auxiliary dielectric fluid nozzle used to prevent aerial

discharge caused by a flushing failure.
Axis It refers to X, Y, U, V, and Z axes.
1
B
Backlash A play generated when machine moving direction is
reversed.
Backlash compensationA play generated when a motion is reversed is

compensated by shifting the moving amount in order to
ensure accuracy.
Barrel The machined surface is not parallel to the wire feed

direction.
Bug A defect in a software.
Bypass A change made to electric wiring or dielectric fluid piping.

Or, modification to disable the sensors (detectors)
provided on the machine.
C
Central processing NC power supply unit.
unit (CPU)
Circular arc A part of circle. It is also referred to as a circle simply.
Clamp A metallic fitting to fix the machine components during

transportation or installation of machine. It also implies
the fixture or fastener that fixes the workpiece during
machining.
Clamp plate A plate to clamp the workpiece. It is also referred to as a

clamp simply.
Clean tank A tank to contain clean dielectric fluid after removing the
machining debris with a filter. It is also called a clean or
dielectric fluid tank.
Clutch roller (D-shaft) A roller that generates the wire tension by means of
powder clutch. It is also called the D-shaft or D-roller.
Conductivity See the water quality.
Core A machining profile to be cut off.
Coreless machining A part corresponding to a cut-off part is all machined up

to the sludge so that no cut-off part remains. It is also
referred to as a coreless simply.
W0721C-I1E-01 2
Corner deformation Deformed corner profile.
Corner radius A round portion at the corner.
CPU NC power supply unit.
C-pulley A roller to adjust the winding angle to the clutch roller

(D-shaft). It is also called the C-shaft.
Curl See the curly property.
Curly property A circular curve remaining in the wire. It is also called a

curl or wire curl.
Cut-off A profile part (core) is cut off from the workpiece.
D
Debris See the sludge.
Diamond guide A component provided in the head to support the wire. It

varies depending on the wire diameter.
Die A cylindrical component that determines wire position.
Dielectric fluid The fluid to cool the machining area. The same fluid is
used for the jet for automatic wire threading. The water
is used as dielectric fluid.
Dielectric fluid nozzle It eliminates a gap between workpiece and nozzle guard
to prevent the dielectric fluid pressure from lowering. It is
also referred to as a nozzle including the nozzle guard.
Dielectric fluid filter It filtrates the sludge contained in the dielectric fluid. It is
also called a filter element, or dielectric fluid filter
element. Also, it is referred to as a filter simply.
Dielectric fluid supply A unit that filtrates the dielectric fluid and adjusts the
unit water conductivity. It is also called a pump unit.
Dirty tank A tank to collect dielectric fluid already used for

machining.
Dog A switch to limit the movement of an axis.

Drain An operation to drain the water.
3
E
Edge positioning The edge face of workpiece is detected through touch
sensing as a reference plane.
Electric conductivity See the water quality.
Electrode See the wire.
EMERGENCY STOP A button to stop the machine immediately in case of a

BUTTON machine trouble button including a machine operation
out of control.
Energizing plate A component that supplies the power directly to the wire.
It is also called a feeder.
F
Fastener Generic name of clamp plate, stud bolt, jig, and fixture. It
is also called a clamp, clamp plate, jig, or fixture.
Felt pad A component to clean the wire surface.
Fill See the work tank filling.
Filter element A filtration part in the clean tank.In general, a component

that stores the filter element is called the filter casing.
Filter pump A pump to suck the dielectric fluid from dirty tank (bed
tank) and to feed it to the dielectric fluid filter.
Finishing A machining to finish the workpiece to final dimensions,

surface roughness, and accuracy using weak energy.
First cut The first machining to the workpiece.
Float switch Floating on the fluid level, it detects the dielectric fluid
level. It is also called the float.
Flushing Dielectric fluid is blown to the machining area from the

dielectric nozzle.
Flushing machining A machining is executed with the flushing, not in the

submerged mode.
W0721C-I1E-01 4
G
Gap A gap between + pole and - pole. In the case of wire
electrical discharge machine, it is a gap between wire
and workpiece.
Gap voltage Voltage applied to the gap.
Guide unit See the wire guide unit (upper).
Guide retainer A component that secures the support guide and the
diamond guide to the head.
H
Head A component to support the wire, to supply electric
power, and to feed the flushing water.
Head collision A function to detect an electric touch between head and

protecting function workpiece/workpiece fastener and to stop the machine. It
is also called the head protection.
Head body The body of head.
H-roller A component that prevents the wire from loosening at the

clutch roller (D-shaft). It provides the touch function in
automatic wire threading. It is also referred to as H-shaft
simply.
I
Incremental command A position to which the machine moves is specified with
the distance from the previous position.
Initial discharge The first discharge when an electrode approaches the

workpiece.
Inspection A checking included in the operation and maintenance.
Interlock A device that prohibits an abrupt opening of door or

cover, or an abrupt operation of machine.
Ion Same as ion exchange (resin).
Ion exchange (resin) Improves the water quality (conductivity) of dielectric fluid
(water).
I-roller A component that prevents the wire from loosening at

the clutch roller (D-roller).
5
J
Jet See the upper jet, and lower jet.
Jet filter Filter for jet nozzle (upper). Also called a jet filter element.
Jet nozzle See the jet nozzle (upper).
Jet nozzle (upper) Jet provided at the wire guide unit (upper). It is also called
the jet nozzle or upper jet. It is also referred to as a jet
simply.
Jet water Rapid water flow boosted by jet discharge. In this case, it
implies the jet from the jet nozzle (upper). It also called
the jet flush.
K
K-shaft cover (lower jet)A component that covers the K- shaft roller. It contains
the lower jet in it.
K-shaft roller A roller that bends the wire fed from the lower head by
90o. It is also referred to as the K-shaft simply.
L
Least command The minimum commandable value to move a numerically
increment controlled drive system.
Limit Limitation
Lower head Head provided on the lower side.
Lower jet Jet provided inside the K-shaft cover.
M
Machine Implies the entire machine including the power supply
unit and the dielectric fluid supply unit.
Machine body Implies the machine only, not including the power supply
unit and the dielectric fluid supply unit.
Machining condition Electrical and mechanical conditions for machining.

Normally, the machining condition refers to those that
displayed on the CONDITION screen of main operation
panel.
Machining speed The axis moving speed during machining. Also, it refers
to the stock removal per minute.
W0721C-I1E-01 6
Machining voltage Gap voltage during machining.
Macro A kind of program.
Main switch Main power switch for entire machine.
Maintenance It implies the maintenance work listed in the maintenance

section of the instruction manual. The other maintenance
not covered in the instruction manual is to be done by our
service representative.
Medium finish A machining to attain medium quality. It is also called a

machining semi-finish machining.
Micron machining A machining to attain high profile accuracy and fine

surface through 3 to 4 repetitional machining.
Model data A set of machining conditions.
Model plan A combination of model data.
Modification A component not approved by Makino is attached, or a

parameter setting or a program change not covered by
the Instruction Manual is made.
Multiple-piece Multiple pieces are manufactured from one workpiece.

machining
N
NC See the NC power supply unit.
NC function Numerically controlled functions provided by the NC

power supply unit. They are, in general, software
functions not incorporating mechanical or electrical
components.
NC power supply See the NC power supply unit.
NC power supply A unit that controls the machine. It is also referred to as

unit (generator) NC, NC power supply, or CPU.
Nozzle Generic name of dielectric fluid nozzle and nozzle guard.
Nozzle away Nozzle tip is kept away from the workpiece surface by
more than 0.5mm during a machining.
7
Nozzle close Nozzle tip is close to the workpiece surface within

0.5mm.
Nozzle guard A guard of dielectric fluid nozzle. It provides a nozzle

height adjusting mechanism and a head protection
function.
Nozzle holder A mechanism that separates dielectric fluid from the wire.
It is also called the water separator or water separating
block.
Nozzle (lower) A component to lead the wire fed from the K- shaft to the
pipe for automatic wire threading.
O
OFF button "OFF" button on the main operation panel. It does not
shut off all the power supplied to entire machine, unlike
the main switch.
Offset A deviation from the specified position or path.
ON button "ON" button on the main operation panel. It does not turn
on all the power supplied to entire machine, unlike the
main switch.
Option See the optional accessory.
Optional accessory A function or component added to the standard machine.

It is also called an option.
Overcut A portion which is cut over the target profile.
Overtravel A movement over the set travel amount.
P
Pallet A workpiece mounting table that can be moved.
Pallet magazine A mechanism to store pallets. The pallet magazine for the
U32 provides a transfer mechanism to the machine.
Parameter In this Instruction Manual, the parameters include the

system parameters, machine parameters, and set data
controlled by the NC unit.
Pinch roller (L-shaft) A roller comprising a winding section. It is also called the
L-shaft roller, L-shaft, or L-roller.
W0721C-I1E-01 8
Pitch error An error between specified and actual value is corrected.

compensation
Portable operation An auxiliary operation box for remote machine control.

panel
Positioning Moves an axis to the specified position.
Power cable A cable to supply the power to the head.
Powder clutch A device to generate wire tension. It is installed on the

clutch roller (D-shaft).
Prepared hole A hole made at the machining start point before an

electrical discharge machining to insert a wire. It is also
called a start hole or initial hole.
Pressure switch A switch that detects the pressure electrically.
Protective cover A cover mounted on the wire feed unit to protect the
operator from touching the wire.
Pump unit See the dielectric fluid supply unit.
R
Recess time The time after one pulse is finished until the next pulse is
started. It is also called the off time.
Reference point return See the zero point return.
Repair Maintenance not covered in this Instruction Manual is to

be done by our service representative.
Residual stress A force that is compressed in the workpiece by external

cause and tries to return. In general, it seems to be same
as strain.
Retry (function) Recovery operation in case of automatic wire threading

failure, and it is available with four different operations. It
is also referred to as retry mode.
Rough machining A machining with large energy at fast speed.
S
Second cut A machining method in which the workpiece is finished
through more than two-time machining in an electrical
discharge machining.
9
Sensor air blow The air to remove the water at the wire edge sensor. It is
also referred to as an air blow simply.
Shaft It implies the shaft for a roller or pulley.
Sludge Minute metallic debris generated in electrical discharge

machining. It is also called debris.
SOURCE lamp A lamp indicating ON/OFF of main power supply.
Standard accessory A function and a component attached to the machine as

standard.
Standard machine A basic machine without optional accessories. Optional

accessories can be added according to the applications.
Standard tool A tool attached to the machine as a standard accessory.
Start hole See the prepared hole.
Straightening function See the wire straightening function.
Straightness Wire curling
Stroke Travel amount of X, Y, U, V, and Z axes.
Submerged machining In the submerged machine, a machining is executed with

(machine) the work tank filled with dielectric fluid.
Subprogram When a certain part of program is used repeatedly, that

part is programmed separately and assigned with the
program number.
Supply reel (A-shaft) A reel to feed the wire. It is also called the A-shaft.
Support guide A component that supports the wire (electrode). It is used

in a combination with the diamond guide.
Surface roughness The degree of smoothness of finished surface.
T
Table See the work table.
Taper angle Wire tilt angle.
W0721C-I1E-01 10
Taper machining A machining method in which the wire is tilted in the

workpiece height direction by shifting the relative position
of upper and lower heads.
Tension See the wire tension.
Tension gage A tool to measure the wire tension.
Thermal refining A thermal treatment to remove the stress (strain) of

workpiece so that the workpiece is physically stabilized.
Torque driver A tool that can tighten screws and bolts with a desired
tightening torque.
Touch sensing Electrical sensing that the wire touches the workpiece.
U
Unmanned operation A machine operates automatically for a certain period
without an operator.
Upper head A component that holds the wire and supplies the power.
It is also referred to as a head simply.
Upper jet See the jet nozzle (upper).
User macro A macro program opened to the user.
V
Vertical alignment Adjustment of relative position between upper head and
lower head. It is also called the wire vertical alignment.
Vertical alignment jig A jig used for vertical alignment. It is also called the wire
alignment.
W
Water quality It implies the degree of electric flow in the dielectric fluid.
It is also called electric conductivity or conductivity.
Water separator See the nozzle holder.
Winding roller (M-shaft)A roller comprising the winding section. It is also called
the M-shaft roller, M-shaft, or M-roller.
Wire An electrode for electrical discharge machining. It is also

called an electrode or wire electrode.
11
Wire breakage A wire is broken during machining. It is also called a wire

break.
Wire drive Generic name of wire unspooling unit and wire winding
unit. It is also called the wire feed unit.
Wire electrode See the wire.
Wire feed rate Indicating how fast the wire is fed per minute. It is the
feedrate at the winding section if the wire is already
threaded. it is also called the wire speed.
Wire guide See the diamond guide.
Wire guide unit (lower) It guides the wire routed to the lower head up to the wire
winding unit.
Wire guide unit (upper) A unit that threads the wire into the workpiece by means
of jet nozzle (upper). It is also referred to as the guide unit
simply.
Wire straightening Retry 2 mode for automatic wire threading.

function
Wire system Generic name of mechanisms for wire feed.
Wire tension A force that pulls the wire to eliminate a slack.
Wire unspooling unit It feeds out the wire at the specified tension and feedrate.
Wire vertical See the vertical alignment.

alignment (function)
Wire winding unit The unit that collects the wire at the specified speed.
Workpiece The material having electric conductivity to be machined

with a wire. It is also referred to as a work simply.
Workpiece mounting A plate on which a workpiece is mounted. It is also

table referred to as a work table or table.
Workpiece thickness Thickness of workpiece
Work tank It surrounds the work table to prevent water splashing

and to collect the water, and further it is filled with the
water for a submerged machining.
W0721C-I1E-01 12
Work tank filling Fill the work tank with dielectric fluid in the submerged
machine. it is also referred to as filling simply.
Zero point return It returns the axis to the zero point set in the software. it is
also called the reference point return.
13

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WIRE ELECTRICAL DISCHARGE MACHINE

MAKINO ASIA PTE. LTD.

Operating the machine carelessly or without reading carefully or understanding the

1.1 Important Information

1.1.1 Utilizing safety functions

1.2 Safety Information on Operation

It is important to learn operating methods correctly. Learning the operation by

1.2.1 Observing the safety

1.2.2 Handling the covers

1.2.3 Precautions on operation

The precautions on operation are as listed below.

• Do not touch the wire during machining, as high voltage is applied.

• Do not place anything at all in the vicinity of work tank.

• Provide sufficient illumination.

• Do not clean the machine by air blow.

• Wear protection glasses and safety shoes to ensure safety.

1.3 Precautions on Checking

During a checking, pay attention to the following:

• Checking, repair, and maintenance of the machine or equipment must be

• Follow traditional practices executed in your shops.

* Do not touch rotating or moving parts.

1.4 Precautions on Maintenance

During the maintenance, pay attention to the following:

• The maintenance of the machine or equipment must be performed after

• Do not perform maintenance (repair) other than those mentioned in the

• The machine installation, relocation, or repair must be performed by the

• In performing maintenance or adjustment, press the EMERGENCY STOP

• Attach a breaker or circuit breaker with a fuse for overcurrent protection

2.1 Kinds and Meaning of Warning

Possibility of injury or damage

The Instruction Manual lists precautions concerning the operation and

2.2 Location of Warning Labels

• The warning labels give the following information:

• Contents and nature of danger (danger, warning, caution)

• Degree of damage cause by danger

• How to avoid danger

2.2.1 Machine Front View

Fig.1 Warning labels (Machine Front View)

2.2.2 Machine Left View

Fig.2 Warning labels (Machine left view)

2.2.3 Machine Right View

Fig. 3 Warning labels (Machine right view)

2.2.4 Machine Rear View

Fig.4 Warning labels (Machine rear view)

2.3 List of Safety Precautions

2.3.1 Automatic operation

• During machining ...................................... Feeling an electric shock, or

2.3.2 Manual operation

2.3.3 Routine checking and maintenance

• Tools ........................................................... Getting hart due to falling,

2.3.5 Warning labels

2 INSTALLATION PLACE REQUIREMENTS

2 INSTALLATION PLACE REQUIREMENTS

2.1 Installation Environment

Select an installation place while taking care of the following points:

[Machine heating value]

2.2 General View

Fig.1-1 SP43 general view

SP43 Machine & Maintenance

SP43 Machine & Maintenance

SP43 Machine & Maintenance