KODERA CASTUGNON C558SSA Service Manual

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Troubleshooting

Ver.2

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Summary of Contents for KODERA CASTUGNON C558SSA

Page 1 Troubleshooting Ver.2...
Page 2 Index INTRODUCTION ..............................6 IN CONDUCTING SERVICE OPERATIONS ...................... 6 DIFFERENCES BETWEEN OLD C 551 SERIES AND SSA SERIES ............... 7 ISOLATION OF CAUSE <<UNIT OR BOARD?>> ..................... 8 ] ............................... 8 OW TO HECK PROBLEMS UPON STARTUP ........................... 9 .
Page 3 “C ” ..........................44 ONFIRM A FRONT DOOR “N .” ............................44 O AIR SUPPLY “T ” ............................44 ERMINAL RAN OUT “C ” ..........................44 ONFIRM A SAFTY COVER “P ” ...................... 45 LEASE CONFIRM IDDLE STRIP SETTING “P ”...
Page 4 “A ” ............ 67 UTOMATIC POSITION ADJUSTMENT IS FAILED LEASE ADJUST MANUALLY TROUBLESHOOTING ............................68 ....................... 68 RONT CANNOT BE STRIPPED ..........................68 HE CORE GETS BROKEN . (E .) ..............68 IRE LENGTHS ARE NOT MATCHED ACH LENGTH IS DIFFERENT .
Page 5 ......................97 HE REAR GRIP SCRATCHES THE WIRE ..................97 HE DISCHARGE CHUCK IS NOT OPENED AND CLOSED ..........98 HE SCREEN STOPS WITHOUT SWITCHING WHEN MEMORY READING IS FINISHED CPF-05A ............99 HERE ARE CASES WHERE THE ROLLER OF DOES NOT ROTATE RESISTANCE VALE BETWEEN THE PINS OF THE STEPPING MOTOR ...........
Page 6 Introduction This Service Manual provides handling of wire processing defects. It is intended that even those who are new to the service work related to this machine can understand it, but the main parts names and operations are described as already understood. (We assume that you understand the contents of the instruction manual.) The maintenance of individual mechanisms will be edited in separate sheets.
Page 7 Differences between old C 551 Series and SSA Series ⚫ The power source and board systems are almost newly designed. Those of old models cannot be used. MDU for height motors (E2P-MDU) is common. ⚫ The power supply is switched from transformer specifications to switching power source. The body weight has been reduced.
Page 8 Isolation of cause <<unit or board?>> While troubleshooting for each trouble will be explained later, relatively common error messages include [… motor error]. If [… motor error] does not resolve, isolate the cause before disassembling the unit or replacing the board. [How to Check] A: The unit moves (even slightly), but an error message is displayed.
Page 9 Problems upon startup The power does not turn on or nothing is displayed on the operation panel. Probable cause How to check Troubleshooting The correct power supply Measure it using Tester. Check the breaker, etc. of the voltage is not entered. Confirm the input of AC200V or switchboard in the building.
Page 10 board and FFCCHNG2 board. If the screen is displayed when you touch the FFC, the failure is attributable to this section. Check if the FFC connector is locked correctly. When the screen is all black: Check the harness between the CTGL board and the BKLPW board (liquid crystal backlight board).
Page 11 Messages and Troubleshooting Communication and displayed messages upon startup When the breaker of the main unit is turned ON and the power switch of the operation panel is turned ON, communication between each board is checked, the result is displayed, and the origin reset operation is performed simultaneously.
Page 12 About board p. 111 for the location of each board.) Stop with “MRAM: NG” display Meaning of error: CTGL board cannot recognize the MRAM16M board. The “MRAM16M board” stores origin data and memorized machining data. See p. 119 for the location of the MRAM16M board. Probable cause How to check Troubleshooting...
Page 13 Stopped with “Confirmation of communication” displayed. Meaning of error: Communication between the panel board (CTGL) and main board (CTGM3) cannot be established. See p. 111 for the location of each board and connector. Probable cause How to check Troubleshooting Communication between Check the harness of the CTGL Check that the PH5P white the CTGL board and...
Page 14 Stopped with “Crimper1: OK” displayed under “Main unit: OK ” Meaning of error: Communication between the panel board (CTGL) and crimper board (CTGP) at the rear end cannot be established. Probable cause How to check Troubleshooting Communication between Check the harness of the CTGL Check that the PH5P white the CTGL board and board and CTGP board of the...
Page 15 OFF, the applicator may (1) When the shaft is moving Check that the XH9P white be moving from the top -> Check the encoder. connector is securely inserted into dead center with its own the “OIS38” connector on the weight. Or, if the CTGP board of the crimper1 applicator has a heavy (Harness of encoder).
Page 16 dead center with its own (1) When the shaft is moving Check that the XH9P white weight. Or, if the -> Check the encoder. connector is securely inserted into applicator has a heavy the “OIS38” connector on the slide, it may be difficult CTGP board of the crimper1.
Page 17 Origin reset operation is performed, but it takes time until the linear screen is displayed. It may take about 10 seconds before “Main unit: OK” is displayed, and then the linear screen appears. This occurs when [Front waterproof] or [Rear waterproof] in the [Machine setting] screen is ON although C551SSA (not equipped with a waterproofing unit) is used.
Page 18 Motor error of each unit upon <Origin reset> If there is a failure in the origin reset operation, a motor error of the unit where the failure occurs is displayed. The indication following “Motor error” indicates the respective unit. When the machine stops due to an error during machining operation, the error displayed <upon origin reset>...
Page 19 remove the MDU box lid, and check of the cutter unit is not lit, replace that the LED on the MDU 5860 it with a non-defective MDU5860 board for the cutter is lit. (1st from board. When replacing, make the right of the upper row) sure that the rotary dip switch on the MDU5860 board is properly aligned.
Page 20 Harness failure. Check if the sensor harnesses If it is damaged, take emergency The same symptom as (brown, black and blue wires of 3P measures and replace it with a explained above will red connector), which are wired defect-free one as soon as occur when a sensor along a wall from the internal cutter possible.
Page 21 may become invalid if the motor or motor harness, it may motor is disassembled. lead to damage of the MDU5860 board, and the board may need to be replaced. Remove the unit from the main unit and replace the motor. (See “Service Manual - Unit”.)
Page 22 “Motor error Blade” (Case (2): All units do not move and this error message is displayed.) *If the front and rear crimpers can return to the origin. Meaning of error: MDU5860 cannot operate because control power supply (24V) is not supplied to MDU5860.
Page 23 MDU5860 to which the white 5P connector is inserted immediately before the failure has a problem. If the cutter unit fails to perform the origin reset operation at the step (1), start with other MDU. Switching power supply When the above checks are If the output of DC24V is stopped, failure performed, if the symptom is not...
Page 24 (2nd from the right of the upper the rotary dip switch on the row) MDU5860 board is properly aligned. (7) The MDU5860 board may be damaged by a short circuit in the harness or a short circuit in the motor. If the LED is lit, check the motor harness and the signal harness from CTGM3.
Page 25 Harness failure. Check if the sensor harnesses If any harness is damaged, take The same symptom as (brown, black and blue wires of 3P emergency measures and replace explained above will brown connector), which are wired it with a defect-free one as soon occur when a sensor along a wall from the internal M1 as possible.
Page 26 If there is a possibility of a is a possibility that a wire is failure attributable to motor broken or shorted circuited inside. manufacturing, warranty In a short circuit occurs in the may become invalid if the motor or motor harness, it may motor is disassembled.
Page 27 (2nd from the top, 1st from the left) Sensor failure. Under the normal conditions, the The “LED8” on the CTGM3 board When the sensor board is sensor response can be checked lights up for a moment upon origin abnormal, the unit tries to by “LED8”...
Page 28 stopped and the unit is locked), move the rear grip back and forth by hand. Extra tightening. Normally, it almost always does not Adjust the belt tension or replace move back and forth. belt if worn. If it moves, the belt may be broken, Remove foreign objects.
Page 29 motor is disassembled. lead to damage of the MDU5860 board, and the board may need to be replaced. Remove the unit from the main unit and replace the motor. (See “Service Manual - Unit”.) “Motor Error Rear move right and left” Meaning of error: Origin reset of rear chuck right and left movement (M7 Unit swing) fails.
Page 30 the sensor reads. If the CTGM3 board. sensor cannot read the operation of the motor, If you want to check the sensor the unit may exceed the board directly, open the lower door operation range, and in at the M7 Unit side and check the this case, there will be a sensor on the M7 Unit large pulley large hitting sound or...
Page 31 The shift down lever may remain at the lower position, or the chuck may remain closed and contact the cover sheet metal. Rotate the right and left moving part of M7 Unit by hand with the breaker of the main unit turned off to check if there is any abnormal resistance.
Page 32 “Motor Error Discharge” Meaning of error: Origin reset of discharge chuck unit (M8 Unit) fails. The sensor cannot read the origin. Probable cause How to check Troubleshooting MDU5860 board failure Open the lower door at M7 Unit, If the LED of only the MDU5860 remove the MDU box lid, and check for discharge is not lit, replace it that the LED on the MDU 5860...
Page 33 Harness failure. Open the lower door at the M7 Unit If any harness is damaged, take The same symptom as side and check if the sensor emergency measures and replace explained above will harnesses (brown, black and blue it with a defect-free one as soon occur when a sensor wires of 3P black connector), which as possible.
Page 34 Check if the linear rails rattle too Even a new linear rail rattles a much. little from its nature, but rattle that shakes the discharge chuck is Check if the front and rear bearings abnormal. Replace the linear rail. are stuck or the shaft is abnormally If the inner ring of the bearing worn.
Page 35 Probable cause How to check Troubleshooting MDU5860 board failure Open the lower door at M7 Unit, If the LED of only the MDU5860 remove the MDU box lid, and check for front waterproof is not lit, that the LED on the MDU 5860 replace it with a non-defective board for front waterproof is lit.
Page 36 Harness failure. Check if the sensor harness of the If any harness is damaged, take The same symptom as rear waterproof unit is damaged. emergency measures and replace explained above will Check if the S08 gray 3P connector it with a defect-free one as soon occur when a sensor on the CTGM3 board is as possible.
Page 37 Check if the front and rear bearings chuck is abnormal. Replace the are stuck or the shaft is abnormally linear rail. worn. If the inner ring of the bearing does not rotate, and the shaft is worn, both the bearing and the shaft need to be replaced.
Page 38 Probable cause How to check Troubleshooting MDU5860 board failure Open the lower door at M7 Unit, If the LED of only the MDU5860 remove the MDU box lid, and check for discharge is not lit, replace it that the LED on the MDU 5860 with a non-defective MDU5860 board for rear waterproof is lit.
Page 39 Harness failure. Check if the sensor harness of the If any harness is damaged, take The same symptom as rear waterproof unit is damaged. emergency measures and replace explained above will Check if the S09 white 3P it with a defect-free one as soon occur when a sensor connector on the CTGM3 board is as possible.
Page 40 are stuck or the shaft is abnormally If the inner ring of the bearing worn. does not rotate, and the shaft is worn, both the bearing and the shaft need to be replaced. Failure of the motor. With the harness from the motor If there is no abnormality in the Short circuit in the motor.
Page 41 side, remove the MDU box lid, and middle strip only is not lit, replace check that the LED on the it with a non-defective MDU5860 MDU5860 board for the middle strip board. When replacing, make is lit. sure that the rotary dip switch on (2nd from the top, 1st from the left) the MDU5860 board is properly aligned.
Page 42 Harness failure. Open the lower door at the M1 Unit If any harness is damaged, take The same symptom as side and check if the sensor emergency measures and replace explained above will harnesses (brown, black and blue it with a defect-free one as soon occur when a sensor wires of 3P black connector), which as possible.
Page 43 *Do not disassemble the part of the discharge unit by hand. motor. motor even if a failure of the motor alone is conceivable. Measure and check the resistance When the motor is short-circuited If there is a possibility of a value.
Page 44 Message displayed when processing proceeds from process start. Message displayed when processing proceeds to [Production mode], [Step by step mode], [Sample process], or [Sample without crimp]. “Please confirm Setting pieces” [Specified pieces] (target pieces) is 0, or [Current pieces] has reached [Specified pieces]. This message also appears when [Specified pieces] is smaller than [Current pieces].
Page 45 -> Check if the doors on the safety cover are closed firmly. “Please confirm Middle strip setting” This message is displayed if the middle strip setting is incorrect when the optional CMS-845A (middle strip device) is installed. -> Check the setting value of the middle strip and enter a correct value. “Please confirm Marker setting”...
Page 46 -> Touch [Process start] once, and then lower the crimp height from the [Crimper1] or [Crimper2] screen again. When [Process start] is touched, the no-load pressure is reset, and the crimp height can be raised.
Page 47 Messages displayed during <<processing>> An error may be displayed during continuous operation or step by step mode, etc. In most cases, if the settings you enter are not appropriate, a message is displayed on the screen when the machine stops because the moving part interferes with something. (Example: Motor error) If an obstacle is found on the mechanical operation line, turn OFF the power switch on the operation panel without hesitation, then turn ON the power switch after removing the obstacle.
Page 48 “Motor Error Guide pipe movement” Meaning of error: The sensor monitors rotation movement of the guide pipe in the crimper direction during processing every time, and this message is displayed when the sensor cannot read the movement properly, and the machine stops immediately. Turn OFF the power of the operation panel, remove obstacles such as wires during processing in the machine, and turn ON the power of the operation panel.
Page 49 Probable cause How to check Troubleshooting The grip contacts the Check using [Step by step mode]. Check the setting value of [Rear applicator during rear grip position]. (See p. 28 of crimping. INSTRUCTION MANUAL.) The setting value of [Rear Set an appropriate value to grip position] is not [Crimp position] of [Rear crimp].
Page 50 “Motor Error Rear move right and left” Meaning of error: The sensor monitors the rotation movement of the rear grip in the rear crimper direction after stripping every time, and this message is displayed when the sensor cannot read the movement properly, and the machine stops immediately.
Page 51 by the shift-down arm, preventing the movement. In other cases See “Motor Error Rear move right and left” on p. “Motor Error Discharge” Meaning of error: The sensor monitors the back and forth movement of the discharge chuck unit during processing every time, and this message is displayed when the sensor cannot read the movement properly, and the machine stops immediately.
Page 52 Meaning of error: The sensor monitors the back and forth movement of the front waterproof carry unit during processing every time, and this message is displayed when the sensor cannot read the movement properly, and the machine stops immediately. Touch [Origin reset] on the screen after removing obstacles such as wires under processing in the machine.
Page 53 Probable cause Failure inside rear Turn OFF the power switch on If the discharge chuck does not waterproof unit. the operation panel, turn OFF the move from the front end to the The rail, belt, pulley, breaker of the main unit, and move rear end of the movement with and/or motor, etc.
Page 54 core, and stepping out of the motor occurs. The location where the Be careful about the orientation of Check the orientation of the slit slit blade is stored does the slit blade. blade and the state of the guide not match the slit of the Install the slit guide pipe for 4 pipe and install it correctly.
Page 55 waterproof seal indicator LED is lit. the power switch box to disk feeder is disconnected and/or if The remaining waterproof seal the connector contact failure The waterproof seal in the indicator LED on the disc feeder is occurs. disc feeder is missing. lit in red.
Page 56 inside rotary shaft Check the rotary shaft by rotating Check if the waterproof seal the knob by hand. stopper pin in the rotary shaft is not damaged. If it is damaged, please repair or When the message is replace it. displayed even if the When there is the waterproof seal waterproof seal is...
Page 57 Detection of and handling examples for crimp force monitor errors Wire: UL1007 AWG # 24 (11/0.16), Terminal: J.S.T. Mfg. SBN-001T-1.0, Crimp height: 0.70 mm ± 0.05 Front crimp waveform Crimping with remaining sheath (all) The pressure rises faster than that of a defect-free product (standard waveform: blue) at the point indicated by the arrow.
Page 58 Front crimp waveform Crimping without terminals Since there is no terminal, the pressure hardly rises. A slight increase or decrease in pressure is caused by sliding load of the applicator ram. No terminals/Crimping miss Action: Adjust the applicator. ・ Remove curl of the wire. ・...
Page 59 Front crimp waveform Crimping with core wire break (less than 10%) At the point indicated by the arrow, the core is slightly cut, and therefore the maximum pressure value is low. However, the tolerance in yellow is not reached. Crimping with core wire break (less than 10%) Action: Set a larger on the linear screen.
Page 60 Front crimp waveform Deep crimping At the point indicated by the green circles, the pressure rises by the sheath. At the point indicated by the arrow, the pressure rises because the sheath is crimped together. Deep crimping ・At the front side →...
Page 61 Front crimp waveform Long strip Pressure does not rise at the point indicated by the arrow because the insulation does not have the sheath. The strip is 3.5 mm for this waveform. The strip is 2.5 mm for the standard waveform.
Page 62 Message displayed when using the optional strip sensor “Could not strip : Front (Rear).” Meaning of message: The strip sensor detected the failure of the strip based on the specified number. Judgment is done based on the sensor values of the core and sheath obtained upon execution of [Automatic position adjustment] in [Sensor set mode] or [Step by step mode].
Page 63 (In the case of Front) If oil or dirt is attached, clean them groove is generated, or if the with alcohol, etc. urethane roller deteriorates, the grip force is lowered. Replace it with a new one or a roller with a strong grip force.
Page 64 and forth by hand. suspected, check each part as Check if there is any looseness of referencing to “Motor Error Rear the screws of the rear grip or front move back & forth” on p. 26. and rear rattling of the chuck that affects the rear strip.
Page 65 tip with a dedicated fiber cutter. (3) Slowly insert the fiber until it stops from the fiber inlet. (4) Turn the fiber lock lever downward as pressing the fiber firmly. *Do not use any tool other than the dedicated fiber cutter to cut the fiber.
Page 66 reaches the core.) small as much as possible. The strip blade is worn Check the strip blade. When the Replace the strip blades. (See p. out or chipped. strip blade is worn out, the sheath 74 of C558/C555/C551SSA dust tends to remain on the strip INSTRUCTION MANUAL.) blade.
Page 67 “Front (Rear): Check the strip sensor value.” Content of Message How to check Troubleshooting Probable cause When the strip sensor is Check the items under the sensor Execute [Sensor Set] again. enabled, [Production value on the [Front (Rear) mode] is attempted Crimping] screen.
Page 68 Troubleshooting Front (Rear) cannot be stripped. In the [Basics] screen, check if an appropriate value is set to [Strip length] and if “0 (zero)” is set to [Half strip length]. Check if the values of [Core diameter] and [Blade move back] are appropriate. Check if the roller is slipped or the rear grip is slipped.
Page 69 Slip marks of the roller may be confirmed. The guide pipe does not Check if the guide pipe matches If the guide pipe is extremely match the diameter of the the wire. large, the wire may meander in wire. It is extremely large. the pipe, resulting in uneven wire lengths.
Page 70 ・The belt is loosened. the W unit roller) and perform a the bearing, extension of the belt, (Inside of unit) feed wire test using the M1 Unit etc. For this reason, consider ・A foreign object gets roller only. preparing a replacement unit. caught in the roller drive Check if the M1 Unit roller and W pulley and its belt.
Page 71 Front strip dimensions are not matched. (Each length is different.) Probable cause How to check Troubleshooting Since the core diameter is Check the state of the sheath of the Reduce [Core diameter] [Blade large, the sheath is pulled strip part. In the case of tear, the move back] in the range that the and extended during strip strip part may become a whisker...
Page 72 function in the [Basics] screen. (See p. 13 of C558/C555/C551SSA INSTRUCTION MANUAL.) The sheath is pulled and Visually check the blade tip of the Replace the strip blades. It is extended by wear and/or strip blade at the rear side. The recommended to replace the chipping of the strip blade can be checked easily if it is...
Page 73 The actually processed total length differs from the specified dimensions. Probable cause How to check Troubleshooting Back tension is applied. Remove the cause of load. If it is impossible to eliminate the ・Straightener is strong. ・Weaken straightener. load of straightener because curl ・The supply of wires is ・Prevent a wire from getting cannot be removed, etc., enter...
Page 74 the guide pipe, and a wire When there is a bend, it also Note that excessive use of cannot goes through becomes resistance. silicone spray inside the pipe may smoothly. cause slip of the rear grip. The inner diameter of the If there is too much play for the wire Replace the guide pipe with the guide pipe is too large for...
Page 75 Inspect and replace MDU5860. (When the waterproof unit Check the insertion position again Readjust the position of the is operating) The by Step by step mode. waterproof unit carry chuck and waterproof seal insertion insertion speed. position is not appropriate, and the wire is bent at the time of insertion, and it contacts the machine and is bent...
Page 76 The guide pipe is bent. The guide pipe may be bent due to the impact of falling. Probable cause How to check Troubleshooting When moving the guide Check it in [Step by step mode]. Adjust the Applicator position. pipe, it interferes with the If it contacts the shift down arm, applicator, etc.
Page 77 Stripped sheath is cut diagonally. The core is bent. Probable cause How to check Troubleshooting In the case of Front Check using [Step by step mode]. The inner diameter of the Lower the speed of [Front strip] in Replace the guide pipe with an guide pipe is too large.
Page 78 may be already made in the process of manufacturing, transporting, and packing the wires. Probable cause How to check Troubleshooting Scratches made when Check using [Step by step mode]. Adjust the center ring of the rear gripped by the center ring Check by pinching the wire with grip.
Page 79 The value of [Shift down Feed the wire to the front crimp Lower the value of [Start position]. start position] is too position by [Step by step mode], *[Start position] is the value that large. touch the [Shift down] button, and indicates the position at which the check the shift down operation.
Page 80 INSTRUCTION MANUAL). Variation of crimp position at the rear side As with the front, identify if the variation occurs in the strip size or the terminal position. If the strip size varies, check the core diameter setting. If the terminal position varies, check the area around the shift down operation.
Page 81 Since the value of [Core Set the optimum values to [Core diameter] is large for the diameter] and [Blade move back]. wire, or the value of (See p. 29 of [Blade move back] is C558/C555/C551SSA large, the sheath is likely INSTRUCTION MANUAL.) to be torn off, and [Core diameter] and [Blade move...
Page 82 the position where the wires fall varies. The position of the belt conveyor is Adjust the belt conveyor position. Increase the displaced. The rotation speed is low. speed of the belt. Since [Discharge retention time] is small, the Increase (2) [Discharge retention time] in [Motion]. wire drop position is unstable.
Page 83 hole diameter of the Check using [Step by step Adjust [Insertion length] and [Move back waterproof seal. When the mode]. Or, pinch the length] of [Front insertion] on the wire is inserted, the waterproof seal with fingers [Waterproof] screen. (See p. 65 of waterproof seal expands and insert the wire by hand C558/C555/C551SSA INSTRUCTION...
Page 84 seal. waterproof seal and the Also check the hole diameter of the guide carry chuck. plate of the waterproof seal carry chuck Failure of the waterproof and the diameter of the wire. seal carry pin. Check the carry pin. Check the height of the stopper.
Page 85 The wire is larger than the hole diameter of the Check using [Step by step mode]. Adjust [Insertion length] and waterproof seal. When the Or, pinch the waterproof seal with [Move back length] of [Rear wire is inserted, the fingers and insert the wire by hand insertion] on the [Waterproof] waterproof seal expands to check the feel.
Page 86 inserted into the waterproof seal. Slow [Insertion speed] of [Rear insertion] on [Waterproof]. If the wire is cooled, it is The carry chuck does not hardened, and it may be inserted. match the waterproof seal. Check the pair of the waterproof Also check the hole diameter of seal and the carry chuck.
Page 87 is OFF. “No waterproof seal is inserted” appears although the waterproof seal is inserted into the wire. C555SSA and C558SSA only. Probable cause How to check Troubleshooting The setting of the Check using [Step by step mode]. Adjust the front and rear positions detection position of the Check the front and rear positions with [Seal detection] and set them...
Page 88 A subtle change in the Check the crimp position, and if it is unstable, refer to p. 78 and make crimp position affects the adjustment to stabilize it. change in the crimp height. The crimping pressure does not change. If the pressure does not change from “0” kg after crimping, or if the pressure does not change properly as a certain value is indicated, check the area around the pressure sensor (load cell) of the crimp force monitor.
Page 89 damaged inside. Failure of the load cell Replace the load cell and the amplifier. matching amplifier as a set. The crimper (crimping device) does not work. Is the [Basics] screen set to [Crimp]? Isn’t “Half strip setting” or “No strip setting” selected? Isn’t the manual handle still attached? Is the crimper locked at the crimp bottom dead center and inoperable? Probable cause...
Page 90 mechanism. the location of air leakage. Air leakage from air tube In case of air leakage from the joint, close the air valve of the connection joint. machine and reinsert the tube. If air still leaks, cut the tip of the tube at right angle with a cutter by about 20 mm and reinsert it into the joint.
Page 91 [Setting pieces] or To increase or decrease the number of pieces during processing, [Current pieces] was increase or decrease [Current pieces] only by using the [+] and [-] keys. increased or decreased In this case, do not press [SET]. during processing. After the “Replace wire”...
Page 92 At the rear side Lower the rear end shift down. The position of the rear end shift down For adjustment, see p. 40 of C558/C555/C551SSA is too high. INSTRUCTION MANUAL. The air pressure of the rear shift down is low. Wear and deterioration of the rear shift Adjust the air regulator of the rear shift down.
Page 93 Positions of the air regulator and air solenoid valve of the rear shift down ・When you open the door at the discharge side, you can see the air regulator and solenoid valve at the upper left inside the door. Air regulator for the rear shift Discharge down side...
Page 94 Deformation of end feed terminal and terminal feeding failure Probable cause How to check Troubleshooting The terminal is deformed Check the resistance when pulling Consider using the optional TF-01 because it interferes with the terminal, such as when the or TF-03 (terminal feeder). the guide plate for the terminal reel is heavy.
Page 95 panel may be damaged. Contact failure of the touch The film harness is connected from the glass of the touch panel to panel. the CTGL board on the back of the operation panel. Unlock the connector part of the film harness by sliding it and reconnect the film harness to lock the connector.
Page 96 the air cylinder of the M7 the initial stage of wear or deterioration of the slide mechanism Unit guide plate and the including the air cylinder. internal slide mechanism. Close the air valve of the machine, and move the M7 Unit slide plate back and forth by hand to check if there is resistance.
Page 97 When the rear grip grips the wire, the wire contacts the center ring of the grip. The rear grip scratches the wire. Probable cause How to check Troubleshooting The center of the guide Check using [Step by step mode]. For adjustment of the guide pipe pipe ->...
Page 98 You can check the operation from (4) [Discharge chuck] in (23) [Test mode] on the [Machine setting] screen. (See p. 24 of C558/C555/C551SSA INSTRUCTION MANUAL.) Example of air cylinder inspection: Lower the air pressure of the discharge chuck to about 0.1 MPa, and open and close the discharge chuck by hand.
Page 99 encoder. harness and connector, and the encoder is rotating, there is a possibility of a failure of the CHA encoder. Replace the CHA encoder. CHA encoder Height motor Encoder gear Height motor gear There are cases where the roller of CPF-05A does not rotate. ->...
Page 100 Resistance vale between the pins of the stepping motor Motor model number (on the Resistance value: Approx. 1.5 Resistance value: Approx. 0.8 label) Ω ± 10% Ω ± 10% 103H7853-81420 (1.7A) Unit used Pin 1 <-> Pin 2 Pin 1 <-> Pin 4 Guide pipe movement (M1 Unit) Pin 1 <->...
Page 101 Problem of crimper (crimping device) There are cases where an error is displayed on the inverter in the crimper. The error indication can be seen from the slit on the crimper back cover. (See “Major error indications of crimper inverter” On p.
Page 102 Abnormal load is applied to the Inspect the applicator. crimper. Galling and/or overheat of the Remove the applicator and turn the crankshaft crankshaft, slider, and/or ram. with the manual handle to check if it rotates smoothly and there is any abnormal resistance.
Page 103 pulley in the crimper. Failure of crimper and inspect the cap screws of the the belt. encoder pulley and crankshaft pulley. Galling and/or overheat of the If the symptom is minor, it may be improved crankshaft, slider, and/or ram by applying the specified grease with a grease caused by lack of grease.
Page 104 to be disassembled. *Do not shock the ram bolt and/or applicator from the side. The load cell (pressure sensor) is deformed.
Page 105 Major error indications of crimper inverter ( Excerpt from Toshiba VF-S15 INSTRUCTION MANUAL) When the back cover of the crimper is removed, the inverter is installed, and the LED indicates the status. Normally is displayed when stopped. During the crimp operation, quick change of numbers and are repeated.
Page 106 Overcurrent during ・When an instantaneous power failure, etc. occurred, the rotating acceleration motor was started. During constant speed ・The load suddenly ・Reduce load fluctuations. operation changed. ・Check the load device. Overcurrent ・The load is abnormal. Overcurrent of arm ・Main circuit elements ・Replace the inverter.
Page 107 ・Overload operation of the motor. Overload of the main ・Load current is high at ・Reduce the load. element low speed. Overload trip of the ・The motor is sharply decelerated. resistor for power ・The power generation braking amount is too large. generation braking Overvoltage during ・The input voltage has changed abnormally.
Page 108 explained below. 1. Press the [STOP] key and check that Clr is displayed. 2. Press the [STOP] key again, and if the cause of the trip is removed, the error is reset. ・Overload protection OL1: InverterRegarding overload OL2: Motor overload and OLr: braking resistor overload, they cannot be reset by panel reset during the following cooling time.
Page 109 M7 Unit guide plate speed controller adjustment method When the lower door at the discharge side is opened, there are green and black air tubes with an air speed controller attached at each tip. Adjust the back and forth movement speed of the M7 Unit guide plate with this speed controller.
Page 110 Speed controller at the tip of black air tube: When it is rotated clockwise, the speed at which the guide plate moves forward is lowered. When it is rotated counterclockwise, the speed at which the guide plate moves forward is increased.
Page 111 About board Main board = CTGM3 board When the lower door at the operation panel side is opened, the board is located at the front. LED: 3.3V ON while power is Connector for FM-ONE (program distributed writing device) LED: 5V ON while power is distributed...
Page 112 SOL13 PH8P yellow (1.2.) Pickup of rear waterproof seal SOL14 (3.4.) Rotation of rear waterproof pin SOL15 (5.6.) Rear waterproof carry chuck close SOL16 (7.8.) Rear waterproof carry chuck open SOL17 PH8P green (1.2.) Signal light Green SOL18 (3.4.) Signal light Yellow SOL19 (5.6.) Signal light Red SOL20...
Page 113 PH3P brown Guide pipe movement origin PH3P red Blade origin PH3P orange Blade (cutting) PH3P yellow Rear grip back and forth movement origin PH3P green Rear grip right and left movement origin PH3P blue M8 Unit discharge chuck movement origin PH3P purple CMS-845A2 origin PH3P gray...
Page 114 LEDs on boards that can be checked in [Test Mode] Test mode ... The operation of solenoid valves and the operation signals of each board can be checked. Air supply is required to check the operation of the solenoid valves. The bottom screen is all off, but there is a part that is turned on in the normal time.
Page 115 ⑩ Marker: It is possible to test the signal when using the marker equipment. The LED45 on the CTGM3 board lights up. ⑪ Conveyor drive: It is possible to test the operation of the optional conveyor. The LED46 on the CTGM3 board lights up.
Page 116 ㉕ Camera 1/Camera 2: It is possible to test the signals to the camera unit. The LED23/LED24 on the CTGM3 board light up for a moment. To move to another screen, touch the [E] button at the bottom right. Execute the operation of return to the origin and return to the basic screen.
Page 117 Inside of Crimper If the back cover of the front and rear end crimpers is removed, there are the encoder, CTGP board, and inverter. Crankshaft CTGP board Crankshaft encoder OBW connector LED of “HSS”, which is the 4th LED from the right Inverter LED: RUN/RSL/CMP/SHD CTGP board connection destination...
Page 118 CTRL PH5P blue Communication with CTGM3 board PHD10P For writing FM-ONE programs Operation Panel How to open operation panel *Be sure to turn off the breaker of the main unit before starting the operation. Remove this screw only. ・Remove one cap screw (or Phillips screw) on the bottom of the operation panel. ・Hold the Emergency Stop Switch and lift the lower edge of the operation panel.
Page 119 Move it downward a little. Open the panel in this way.
Page 120 Back side of operation panel = CTGL board CTGL board Touch panel FFC BKLPW board OBW connector FFCCHNG2 board MRAM16M board (Machine data and processing memory) FFC for LCD display ・When replacing the CTGL board or replacing the operation panel ASSY, migrate the “MRAM16M board.”...
Page 121 CTGL board connection destination EXIO PH7P white Not in use RS232A PH3P white External RS232C communication (to the power box) RS232B PH3P red Not in use RS485A PH5P white Communication with CTGM3 board RS422 RS485B PH5P red Communication with front CTGP board RS422 RS485C PH5P blue Communication with rear CTGP board RS422...
Page 122 MDU5860 board ・Open the lower door at the discharge side and loosen the four pan screws on the MDU box lid. If you move the lid up, the lid can be removed. Loosen the four screws slightly. MDU layout sticker For the MDU layout in the box, see the MDU layout stickers attached on the inside of the door.
Page 123 Power source area The power source unit is located where you open the front door and remove the dust boxes. (1) SSAD board (3) 25V600W Switching power source (5 units in series) (2) CTGCTR board (4) 24V 300W Switching power source (1) SSAD board ...
Page 124 (2) CTGCTR board (1) SSAD board...
Page 125 Writing programs This is the procedure for writing programs to CTGM3 (main board), CTGP (crimper board), CTGL (operation panel board), and CTGCTR (sub power source board) by using FM-ONE (writing machine). (1) Plug the FM-ONE connector into the OBW connector of the board to which a program is written while the machine is ON and standby.
Page 126 Program writing starts. When writing is finished, “Complete. Again? Y/N” is displayed. (5) Disconnect the FM-ONE harness connector from the board. (6) Touch [Origin reset] from the [E] button on the operation panel to perform origin reset. Always perform origin reset after writing a program.
Page 127 Method of confirming program version and program to write Touch the mark at the upper left of the [Basics] screen, and the program version is displayed at the lower left of the screen. The meaning of each item is as follows: Panel means the operation panel CTGL board.

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