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16/9/2010 B Atsunyu gear grindi AGG301 lub motor trip & pressure not build up 6:20 8
6/9/10 B Final gear FGH202 4:30
11/9/10 B Sleeve line SNH404 Auto door problem 17:20
18/9/2010 A Hira gear HGH704 Part carrier Raise problem 7:15
20/9/2010 A Sleeve line SNH504 Auto door not working 1;30
28/9/2010 A Input shaft ISH408 Lubrication oil leakage problem 8:00
28/9/2010 B Hira gear HGH601 Auto door Obstacle detection alarm 16:00 1
18/9/2010 A Input shaft ISH311 Door open close problem 9:10
20/9/2010 C Sleeve line SNH604 Broach cutting coolant not coming 11:30
16/9/2010 C Hira gear grinding HGG501 Motor over load alarm 2:20
1/9/10 C Sleeve line SNH101 Broaching m/c hyd pipe have leakage 12;30 0
3/9/10 B Input shaft ISH201 LH slide down 16:00
7/9/10 B Sleeve line SGH201 Pull head open close both LS faulty 11:55
9/9/10 A Sleeve line SGH106 Cycle not complete 7:30
16/9/2010 C Input shaft ISH209 Component present senser not working 5:00 0
20/9/2010 B Input shaft ISH205 Area senser continuously high 4:00
27/9/2010 B Counter shaft CSH208 Deburing motor not ok 10:45
8/9/10 B Counter shaft grindi CSG104 Foot stock advance alarm 7:00
15/9/2010 C Sleeve line SNH302 Pusher not working 4:45
3/9/10 A Counter shaft CSH404 Out chute not working 7:20
18/9/2010 B Counter shaft CSH207 M/C master not On 3:45
Auto cycle not run & cutter slide continuouslyrotate
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Sum of Effective Time(In MIN) Count of Effective Time(In MIN)Machine No Total Machine No TotalIGH603 5760 SNH404 4ISH110 2040 ISH201 3
ISH319 930 FGH202 2ISH108 600 HGG501 2CSH301 480 IGH203 2ISH201 465 ISH110 2ISH210 460 ISH210 2MGH107 420 MGH105 2SNH404 395 SGH201 2MSH105 330 SNH504 2HGH302 320 AGG203 1AGG203 270 AGG301 1IGH203 270 AGG704 1MSH106 250 AGG705 1
AGH606 240 AGH202 1FGH202 230 AGH503 1CSG105 210 AGH601 1IGH404 180 AGH604 1SNH504 180 AGH606 1AGG705 170 AGH704 1CSG405 150 CSG104 1HGG501 150 CSG105 1ISH302 150 CSG201 1SGH107 150 CSG403 1ISH213 140 CSG405 1SNH503 140 CSH105 1
SGH201 135 CSH108 1AGG301 130 CSH207 1HGH601 120 CSH208 1HGH704 120 CSH209 1ISH408 120 CSH301 1ISH311 110 CSH404 1SNH604 105 FGG302 1IGG403 90 HGG401 1IGH303 90 HGH302 1IGH402 90 HGH601 1ISH205 90 HGH701 1ISH209 90 HGH704 1
SGH106 90 HGH804 1SNH101 90 HGH903 1CSH208 80 IGG403 1MGH105 80 IGH303 1CSG104 75 IGH402 1CSH105 75 IGH404 1SNH302 75 IGH501 1CSH207 60 IGH603 1
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CSH404 60 IGH801 1SGH205 60 IGH901 1SNH406 60 ISG203 1AGH202 55 ISG204 1AGH604 55 ISG405 1CSG403 55 ISH108 1
FGG302 55 ISH205 1IGH801 55 ISH209 1MGH106 55 ISH213 1AGG704 50 ISH302 1AGH601 50 ISH310 1CSH108 50 ISH311 1CSH209 50 ISH319 1ISG405 50 ISH402 1MSH104 50 ISH408 1SNH506 50 MGH106 1HGH804 45 MGH107 1ISH310 45 MSH104 1
AGH503 40 MSH105 1IGH901 40 MSH106 1ISG204 40 SGH101 1AGH704 30 SGH106 1CSG201 30 SGH107 1HGG401 30 SGH205 1HGH903 30 SNH101 1ISH402 30 SNH302 1ISG203 25 SNH406 1SGH101 25 SNH503 1HGH701 20 SNH506 1IGH501 20 SNH604 1
(blank) (blank)Grand Total 18305 Grand Total 89
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IGH603 5760 5760ISH110 2000 7760ISH319 930 8690
ISH108 600 9290CSH301 480 9770MGH107 420 10190ISH210 420 10610MSH105 330 10940HGH302 320 11260AGG203 270 11530MSH106 250 11780AGH606 240 12020IGH203 240 12260 SNH404 4 4ISH201 240 12500 ISH201 3 7CSG105 210 12710 FGH202 2 9
IGH404 180 12890 HGG501 2 11AGG705 170 13060 IGH203 2 13CSG405 150 13210 ISH110 2 15ISH302 150 13360SGH107 150 13510SNH503 140 13650ISH213 140 13790ISH201 135 13925AGG301 130 14055FGH202 120 14175SNH404 120 14295HGH704 120 14415
SNH504 120 14535ISH408 120 14655HGH601 120 14775ISH311 110 14885SNH604 105 14990HGG501 100 15090SNH101 90 15180ISH201 90 15270SGH201 90 15360SGH106 90 15450ISH209 90 15540ISH205 90 15630
IGG403 90 15720CSH208 80 15800CSG104 75 15875CSH105 75 15950SNH302 75 16025SNH404 70 16095CSH404 60 16155CSH207 60 16215
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SGH205 60 16275SNH504 60 16335SNH406 60 16395
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Date Shift Line Machine No From Up To Effective Ti
22/9/2010 B Ittai gear IGH603 7:00 5760
1/9/10 A Input shaft ISH110 8:30 16:00 2000
30/9/2010 B Input shaft ISH319 5:00 8:30 930
7/9/10 B Input shaft ISH108 7:00 17:00 600
08/09/10 C Counter shaft CSH301 3:00 11:30 480
08/09/10 A Two wheeler MGH107 7:00 14:00 420
14/9/2010 B Input shaft ISH210 16:00 19:05 420
13/9/2010 A Two wheeler MSH105 7:00 12:30 330
14/9/2010 B Hira gear HGH302 16:30 23:30 320
20/9/2010 B Atsunyu gear grindinAGG203 8:15 12:30 270
18/9/2010 A Two wheeler MSH106 7:00 12:00 250
14/9/2010 B Atsunyu gear AGH606 16:30 20:00 240
16/9/2010 C Ittai gear IGH203 3:00 7:00 240
29/9/201011:50PM
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22/9/2010 C Input shaft ISH201 12;30 4:30 240
27/9/2010 A Counter shaft grindinCSG105 8:00 11:30 210
10/09/10 A Ittai gear IGH404 8:00 3:30 180
22/9/2010 B Atsunyu gear grindinAGG705 4:00 7:40 170
20/9/2010 B Sleeve line SNH404 3:45 7:30 160
1/9/10 A Counter shaft grindinCSG405 10:30 12:30 150
7/9/10 B Input shaft ISH301 18:00 20:30 150
7/9/10 B Sleeve line SGH107 14:00 18;30 150
08/09/10 B Sleeve line SNH503 6:20 8:40 140
24/9/2010 A Input shaft ISH213 8;40 11:15 140
3/9/10 A Input shaft ISH201 13:30 15;45 135
16/9/2010 B Atsunyu gear grindinAGG301 6:20 8:30 130
6/9/10 B Final gear FGH202 4:30 6:30 120
11/09/10 B Sleeve line SNH404 17:20 19:30 120
18/9/2010 A Hira gear HGH704 7:15 9:20 120
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20/9/2010 A Sleeve line SNH504 1;30 3:30 120
28/9/2010 A Input shaft ISH408 8:00 10:00 120
28/9/2010 B Hira gear HGH601 16:00 20:00 120
7/9/10 A Final gear FGH202 7:40 9:30 110
18/9/2010 A Input shaft ISH311 9:10 11:00 110
20/9/2010 C Sleeve line SNH604 11:30 1:45 105
16/9/2010 C Hira gear grinding HGG501 2:20 4:00 100
1/9/10 C Sleeve line SNH101 12;30 2:00 90
3/9/10 B Input shaft ISH201 16:00 17;30 90
7/9/10 B Sleeve line SGH201 11:55 1:30 90
09/09/10 A Sleeve line SGH106 7:30 9:00 90
16/9/2010 C Input shaft ISH209 5:00 6:30 90
20/9/2010 B Input shaft ISH205 4:00 5:30 90
23/9/2010 B Ittai gear IGH303 17:30 19; 90
23/9/2010 B Ittai gear grinding IGG403 6:30 8:00 90
28/9/2010 C Ittai gear IGH402 4:36 6:20 90
27/9/2010 B Counter shaft CSH208 10:45 12:05 80
08/09/10 B Counter shaft grindinCSG104 7:00 8:15 75
11/09/10 C Counter shaft CSH105 12:45 2:00 75
15/9/2010 C Sleeve line SNH302 4:45 6:00 75
09/09/10 A Sleeve line SNH404 1:00 2:10 70
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3/9/10 A Counter shaft CSH404 7:20 8:20 60
18/9/2010 B Counter shaft CSH207 3:45 4:45 60
22/9/2010 C Sleeve line SGH205 2:00 3:00 60
24/9/2010 C Sleeve line SNH504 2:00 3:00 60
25/9/2010 C Sleeve line SNH406 3:00 4:00 60
1/9/10 A Two wheeler MGH106 10:30 11:30 55
4/9/10 B Final gear grinding FGG302 19:00 19:55 55
6/9/10 A Atsunyu gear AGH604 7:40 9:00 55
10/09/10 A Counter shaft grindinCSG403 9:40 10:35 55
16/9/2010 C Ittai gear IGH801 1:55 3:00 55
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22/9/2010 C Atsunyu gear AGH202 5:00 6:00 55
3/9/10 B Atsunyu gear grindinAGG704 10:00 111;30 50
4/9/10 B Sleeve line SNH506 7:40 8;30 50
20/9/2010 A Two wheeler MSH104 7:10 8:15 50
21/9/2010 B Counter shaft CSH108 9:00 9:50 50
28/9/2010 B Hira gear grinding HGG501 7:00 7:50 50
28/9/2010 B Counter shaft CSH209 6:00 7:00 50
29/9/2010 A Input shaft grinding ISG405 2:10 3:00 50
30/9/2010 C Atsunyu gear AGH601 12:30 1:20 50
4/9/10 B Input shaft ISH310 3:45 4:30 45
7/9/10 B Sleeve line SNH404 3;30 4:15 45
18/9/2010 C Sleeve line SGH201 1:15 2:00 45
27/9/2010 A Hira gear HGH804 1:30 2:15 45
18/9/2010 C Ittai gear IGH901 12:20 1:00 40
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25/9/2010 A Two wheeler MGH105 7:50 8;30 40
25/9/2010 C Input shaft ISH110 1:00 1:40 40
27/9/2010 A Two wheeler MGH105 7:00 8;40 40
28/9/2010 B Input shaft grinding ISG204 9:00 9:40 40
29/9/2010 A Input shaft ISH210 11:45 12:25 40
30/9/2010 B Atsunyu gear AGH503 5:00 5:40 40
6/9/10 C Input shaft ISH402 12:45 1:15 30
7/9/10 B Counter shaft grindinCSG201 6:00 6:30 30
21/9/2010 A Atsunyu gear AGH704 12:00 12:30 30
27/9/2010 C Hira gear HGH903 4:45 5:15 30
27/9/2010 C Hira gear grinding HGG401 3:00 3:30 30
29/9/2010 B Ittai gear IGh203 10;30 11:00 30
7/9/10 B Input shaft grinding ISG203 7:15 7:40 25
09/09/10 B Sleeve line SGH101 8:20 8:45 25
09/09/10 B Ittai gear IGH501 11:00 11:20 20
10/09/10 A Hira gear HGH701 10:40 11:00 20
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Breakdown
Change the Bearing now ok
ATC falling tool Unknown
Change the new bearing now ok
Change the wire now ok
Unknown Bolt changed
Pending from A shift Change the rotary s/w
M/C control not On Change the soleniod valve now ok welding done
Repair the wire by resoldering change the belt
Lub pump not ok
alarm no. 300 & 307 M/C Refrencing done So put new wire now ok
Welding done connect wire
Unknown change the push button
Component profile NGproblem
Hob spindle Bearingfaulty
oun s s e ac ngpulley spindle ring phaseopen or break so to becheck in Sunday now m/crunning
Check the ATC arm spring & camfollower bearing & tight it andchange the pin also but problemnot solve
Check & filled gas inchiller unit & restart nowok
Spindle motor over load alarm
Tail stock spindlebearing faulty
445 X axis softdisconnect
X axis motor coupling broken
Change the coupling & donereferencing now ok
Proper meshing done &push button repair
Programme not select& RH spindle REV notrun
Programmeselsector s/w faulty& Rev contactor burn
Programme s/w bypass in hardwiring & contactor change
Part carrier cylinder up/down mountingbolt broken
Change another motor now ok
M/c tool fallingproblem
Change its ATC cam follower bearing
Due to clamp /declamp soi. Foundshort
Turret Indexing abortalarm
Turret indexingmotor encoder wirebroken
Pump not build uppressure
Pump O ring found damage sochanged the O ring
Change the relay nowm/c ok
Z axis home positionnot ok
M/c door open closeproblem
Door broken fromone side
Component not clampand declamp
Check by manually operate but notok so pending
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Hyd. Oil level low Filled the hyd. Oil now ok Set the senser now ok
Soleniod valve jam
Unloader not working Replaced the photo senser now ok So set it now ok
Front door problem Change the seal
Auto door fault Welding done
Change the bolt Weld the block
Due to vibration Change the hyd. Pipe
Change the bolt
LS change
LH slide down Tight the cylinder chuck nut
Pump jam Checked & clean the pump now ok
Change the hose pipe
Auto door problem Welding done
Unknown Set the read s/w
LH slide not in homeposition
LH slide chuck nutopen & fall down
Took axis to position & chuck nuttight
When check & foundfixture clamp reads/w malfunction thenset it properly
Foot stocknotadvance
Part stand notworking
Check & change the soleniod valvenow ok
key pad changed nowok
Part present photosenser faulty
Cylinder sealdamage
Due to dog bolt broken somodifythe dog now ok
due to mounting
broken
relief valve, motor but stillnoise coming.Thenchange the sucktion pipe
fitting,M/C OK
Z axis 0VC softthermal alarm
Rh slide centeringpully belt tensionmounting boltbroken
Part carrier up downhyd pipe broken
Componentclamp/unclamp fault
May be programmefault
Check & found clamp unclampworking ok in Manual but problem
coming in auto applied M61, M62code with MDI working ok insteadof M12 & M13
Loading arm alignmentdone
Chuck centre notworking
Because its air regulator spring &pressure s/w faulty
Change the spring & pressure s/wnow ok
cylinder chuck notopen
Gripper cylinder interchange with CSH110
lub motor trip &pressure not build up
Set the lifter locking pinthen ok
Auto cycle not run &cutter slidecontinuously rotate
Vertical slide senser not working
Change the vertical slide senser &set horizental slode home senser
Its mounting platedamage
change the senser faulty
Part carrier Raiseproblem
Check Hyd. Pr. & cylinder found okclean soleniod now ok
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Auto door not working Weld the plate
O ring damage Reset the power now ok
Repair safety s/w now ok
Change the Soleniod valve now ok
Motor over load alarm Input conveyor jam
New pipe fitted
LH slide down Pending from A shift
Clean the cylinder
Cycle not complete Replaced the pressure s/w Alignment done now ok
senser faulty change the senser
Area senser faulty Bypass area senser
clean the valve now ok
Auto cycle not run Clean the cylinder change the pipe now ok
Remove AC connection
Deburing motor not ok Its belt broken Chanege the belt & pulley refitted Tight it
change the bolt Piston rod again fitted
Auto cycle not start By pass the senser
Gripper not working Welding done
Auto door not working Mounting plate bend Straight the plate now ok Welding done
Due to cylinder seal jam
So open the cylinder and changedcylinder seal
Lubrication oilleakage problem
change the wheel head assemblyO ring
Auto door Obstacledetection alarm
Auto door rubber shielding not ok
Check & auto door Rubber shielding clean & tight connection
So check & clean nowok
Chamfering L slidemotor not stop after auto cycle complete
Because its motor pulley not set withchange pulley andlocking plate open
So fitted & proper set the lockingplate
So done teaching of loader arm but not okthen Loader armalignment done
Door open closeproblem
Found its Safety s/wfaulty
Connect PB wire nowok
Broach cutting coolantnot coming
Coolant line SOIvalve faulty
So change the senser now ok
Adjust the conveyor Tension nowok
Alignment done &up/down flow adjust
Broaching m/c hydpipe have leakage
Table down pipebroken
Arm alignment doneMany times then ok
Remove the broken bolt then fittednew bolt now ok
MPCB top handle remove& unloader dog settingdone
Pull head open closeboth LS faulty
Limit s/w plunger stucked
Fitted one LS from SNH101 &bypass another LS
Chuck clamppressure s/w faulty
Component presentsenser not working
So clean the senser &adjust now ok
Area senser continuously high
Change the senser nowok
Drill broken again &again
Spindle coolant notcoming
Check valve faulty so bypass thevalve now ok
Conveyor inputsepretaor cylinder not working
Turret not clampalarm
Found chipsconveyor stuck andmay be its air catchsenser faulty
Clean the chips & bypass air catchsenser then reset alarm
Foot stock advancealarm
Shutter mountingbolt broken
Due to part presentsenser not working
Change the stooper now ok
Gripper cylinder mounting broken
Manually operate theturret now ok
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Out chute not working clean the guide way
M/C master not On
Welding done
Soleniod valve changed bypass the door s/w
Gripper jam
Cylinder jam
Done referencing So replace the new pump
Auto door not working
change the senser
due to guide way rod jam
Change the cylinder seal but its pusher notreturn because X2binput high so dogsetting done
Due to controlsupply shorting
Shorting in Component presentsenser so by pass it
Open motor & sendfor rewinding
Auto door open closeproblem
Auto door cylinder mounting platbroken
open the cover thenclean limit s/w nowok
Auto cycle startingover time
Auto door soleniodfaulty
Unloader gripper open close problem
So open the gripper cylinder andclean now ok
so check & forward limits/w bypass
Part unload photosenser faulty
Due to oil in junctionbox
clean its junction box & replacedthe amplifier
Check & change ServoAMP. But problem notsolve then change motor but motor heat up thendone its meshing properlybut after this m/c controltrip again & again soclean motor all connector now ok
Seprator No-2 solabnormal alarm
clean the cylinder and change flowcontrol
Change power supplybut not ok then changethe shorted senser
Ring loader servoAmp malfunction
Ring loader motor referencing lost
LM bush mountingopen, Railing wear out, Cyl. Air inputfitting broken
So check and fitted the bush andrail falling and change the air fittingnow m/c ok
Took out thermo
couplel clean it &refitted now ok
Part carrier notworking
Gripper settingdisturb & part carrier cylinder piston rodopen
Setting done & Piston rodreconnect
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Auto door not working Welding done
Welding done
NC alarm Referencing lost Referencing done
Soleniod valve faulty Inter changed the soleniod valve welding done
Photo senser faulty change the photo senser
New bolt fitted Setting done
change the senser setting done
Alarm bypass
cycle stop during Auto Change the read s/w
Door not working New bolt fitted
Tight the piston rod change the pipe
Unknown A axis drive clean & refitted now ok gap s/w bypass
Strip found broken so welding done Change the senser
Part clampingunclamping fault
Part clamp unclampboth senser high
part unclamp senser dog miss sobolt provided
Hose pipe alignmentdone
Auto door connectedstrip broken
Check & change pumpbut not ok then modifythe logic now under observation
Auto door open closefault
door cylinder guideplate broken
Interchange the coolantvalve & flow s/w & modifylogic now under observationclean the guide bush &lubrication done now ok
Unloader not ejectingcomponent in autoSeprator 2 open closealarm
clean the pull head nowok
Deburing unit notworking
Deburing unit boltbroken
Component overlapproblem
3rd stationcomponent presentsenser faulty
Part catcher detectalarm
Read s/w continuoushighPusher read s/wsignal fluctuation
Repair the wire thenrefitted now ok
Door mounting boltbroken
Bypass the shutter opensenser now ok
Tool lifter Sol.Abnormal
Pull head cylinder piston rod open
A axis INV. CurrentexcessMSTB air single off alarm
Auto door not openclose
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Ram up down not ok Change th fuse now ok
Unloader soi. Faulty clean the soleniod now ok
NC alarm So Refrencing done Change the senser
Foot stock adv. Alarm So bypass it Bypass the signal
Motor fitted now ok cleaned the fan
Auto cycle not start
Cycle not start Set the photo senser
Auto door not working Door stuck with track Alignment done S/w selsection made ok
change the flow control Clean the senser now ok
Robot not working read s/w setting done
Auto cycle not start Clamp signal miss Senser adjust So clean the slide now ok
Bypass the senser
Hydraulic oil leakage
Overload trip Same
Its relay fuse foundblown
Dog ram down pressures/w set
Unloader up/downproblem
So Auto locator cylinder nut tight now ok
M/c forget homeposition
Foot stock linear scale fault
Deburing motor to befitted
Motor to be fittedafter rewinding
part loader up downproblem
Componentunloader senser notsense in dog setting
So component unloading senser dog proper set
componentunloading limit s/wwire faulty
So check & cut the wire and jointthe wire
Clean the pressure s/wnow ok
NG componentsignal not coming
Change the Air catchsenser
Part ejector notworking
Found its flowcontrol faultyFound unloader notin position
Took unloader to home positionnow ok
Shutter open closefault
Shutter close signalnot come
Change the Soft Key Padfrom Sleeve line
Table up-down cyl.Pipe fitting wasloose
So tight the pipe fitting of check theoil leakage ok
So changed its soleniodvalve but not ok so needto change the cylinder
Spindle motor over weak
Spindle motor fannot work
Alarm resent hand over C shiftmotor fan clear
change the new cylinder now ok
componentfomd incomponent and OLRreset
Fitted its original J comunit after interchangedthe touch screen
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and PushButtoncover tobeprovided
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size pipefitting tobe kept in
spare
door cylinder mountingandProximity
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Rajamane120LPMpump tobe kept inspare andold pumpImpeller tobe madenew
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All shigiyamachineShutter door cylinder mountingandProximitysensors tobechecked
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AllOperator Panles tobecoveredby plastic
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