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7CAUTION

Contents

1. MSDS
2. This is an original instruction manual officially issued by Mori Seiki The contents of this manual are subject to change without notice due to improvements to the machine or in order to improve the manual Consequently please bear in mind that there may be slight discrepancies between the contents of the manual and the actual machine Changes to the instruction
3. ATC APC APC QO
4. 5 Failure to observe the following warnings may result in a fire or machine damage Mori Seiki is not liable for any fire whose cause is other than a product defect 1 When machining using coolant e Obtain the MSDS MATERIAL SAFETY DATA SHEET from the coolant manufacturer directly by yourself as the customer and use coolant without any chemical effects on the machine Please be sure to pay careful attention to the effects on the human body and the storage method described in the MSDS e Before starting automatic operation check the amount of coolant in the coolant tank and replenish coolant if necessary When insufficient coolant is applied to the cutting point the machined part will heat up due to insufficient cooling and this may result in a fire 2 When machi
5. To guard operators from danger the machine is equipped with safety devices as shown below WARNING 1 Be ready to press the EMERGENCY STOP Emergency Stop button during machine operation 2 Do not place any obstacle in front of an EMERGENCY STOP Emergency Stop button 3 Even when the EMERGENCY STOP Emergency Stop button is pressed confirm all operations have come to a complete stop before approaching moving parts 4 Do not modify or remove safety related devices on your own If the safety devices are replaced be sure to confirm whether they works properly before starting the machine operation Contact Mori Seiki for further information 5 Do not operate the machine with protective covers removed or while other safety devices are in invalid status 6 Do not put too much confidenc
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7. GL mode when operating the machine If operating the machine with the door interlock switched to the SETTING mode awareness of the dangers involved and particular attention given to safety during machine operation is essential Only persons who are trained sufficiently in safety and machine operation are permitted to switch the door interlock function to the SETTING mode and operate the machine Following completion of the operation ensure the door interlock is switched back to the NORMAL mode immediately Unexpected machine operation Serious injury Machine damage CI Separate volume OPERATION MANUAL DOOR INTERLOCK FUNCTION 2 2 Do not modify or remove the door interlock function 3
8. _ 4
9. gt 00010 N00000002 MEM xxx tz rt xxx 0000H 00 05 CNC 1 C 1 0
10. sp RR 44 lt gt 1 2 2 do 3 lt gt 1 C 2 2 C note A click is clearly audible when the door is completely closed 4 Turn the two electrical cabinet door keys CW to lock the door 5 Remove the key
11. lt Basis gt This machine was designed and built using state of the art technology for the purpose of machining workpieces with cutting tools This machine complies with generally recognized safety regulations standards and specifications at the time of manufacture This machine is suitable for manual and automatic operation lt Tools gt This machine is capable of using common tools such as milling cutters drills taps and boring bars Contact Mori Seiki before using grinding tools or special tools lt Materials gt This machine is designed for machining metal resin and plastics It was not intended for the machining of materials such as magnesium carbon ceramics and wood Contact Mori Seiki before using these materials About this Manual
12. gt N Coolant Flow Direction 3 4 5 Filter to be Cleaned Cleaning Line Filter The line filter is a unit for removing chips in coolant to be supplied to the spindle unit In order to prevent the spindle unit being damaged clean the line filter when either of the following occurs When the visual indicator of the pressure switch turns red right to the top Only for 1 5 MPa specifications When a PLC alarm EX0509 THRU SP COOLANT FILTER CLOGGED is displayed on the screen on the NC operation panel N CAUTION 1 Clean the filter within an hour when
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14. Remove any smudges from the operation panel with a detergent soaked cloth DANGER Turn OFF the main power and disconnect the plant side power supply breaker N CAUTION Use limonene based liquid detergent that satisfies the following conditions The detergent must be free of constituents with adverse affects on human beings such as offensive smells or those that cause skin irritation The detergent must not cause hardening dissolving or swelling of the operation panel s synthetic resin etc SPINDLE 73 9 SPINDLE 1 Spindle Warm Up 1 P 2
15. 30 mm 9 Y Z 9 7 10 VEL f EI
16. NC WRAWELCNTS Y NC G Dae RERE RE 0 D Y Z70 Y Y Z70 MG Y D i 1 H
17. Residual Pressure Release Valve WARNING Inspect the pressure gage periodically If not set at the correct value adjustment is necessary Serious injury Machine failure Procedure 1 Supply the compressed air by rotating the cock to a vertical position 2 Check that the pressure gage is set at 0 5 MPa green mark 3 If necessary pull upward and rotate the pressure adjustment knob to adjust the pressure Increasing pressure Rotate the knob CW Reducing pressure Rotate the knob CCW C note If the pressure cannot be adjusted check the plant side air source 4 Push the pressure adjustment knob downward The air filter is equipped with a float type automatic drain unit Draining is normally performed automatically by the drain unit However if draining is not performed automatically or if foreign matter has accumulated in the bottom of the bowl turn the manual drain cock CCW to drain manually 124 PNEUMATIC DEVICES 17 3 Air Fil
18. NC QO tH 133 DC 3 6V e NC DC 3 6V CO 133 Procedures to Replace Batteries N CAUTION 1 1 2 3 4 5 6 Change the NC memory back up battery and servo absolute position sensing battery with power supplied to the NC If the batteries are changed with the NC power supply turned OFF the d
19. SME Ke lt amp l l amp C 1 we P a Y PA Y C b No 99 100 CHIP CONVEYOR OPTION ALARMS 189 Open the electrical cabinet door QM35 Ifthe QM77 QM78 switch is OFF clean the internal chip conveyor 1 left side looking from the front of the machine If the QM36 QM55 switch is OFF clean the internal chip
20. 3 2 lt 77 Do not manually feed the axes during temporary machine stops except when absolutely necessary Always return the axes to their original positions before restarting operations Component interference 12 When removing burrs on a workpiece by hand ensure the workpiece is removed from the machine prior to performing the deburring procedure Entanglement Injury 13 Always work at a safety margin of at least 20 cm from the window This impact resistant window could be substantially deformed to ease the impact of an ejected tool With further impact the window could break or be penetrated Injury 14 Never restart machining after searching for a block executed in the program Unexpected machine operation 15 Stop machine operation immediately and contact the Mori Seiki Service Department following malfunction of any device related to the door interlock function Injury Machine damage 16 This machine is equipped with a read ahead function for the running
21. C C note Confirm that the STATE display indicates ORIGIN SET and that INITIAL SET ABS is displayed at the lower left of the screen 7 Move the cursor to Origin P input 1 and press the INPUT key C note Confirm that the STATE display changes from ORIGIN SET to ORIG RTN 8 Feed the X axis in the minus direction using the manual pulse generator to establish the X axis zero point The STATE display on the ABS POSITION SET screen changes from ORIG RTN to Complete to indicate completion of zero return position establishment C note The feed axis stops automatically at the next grid If the axis overtravel exceeds 30 mm the procedure may be incorrect Check the procedure and repeat 9 For the Y or Z axis display the screen of the axis by pressing Next axis and repeat steps 5 to 7 10 Turn ON the power again and perform zero return operation using the following procedure to confirm that the zero point position is correct CD Sepa
22. N CAUTION 1 Back up stored programs parameters set before shipping and offset data Programs destroyed parameter data and or offset data lost C note Mori Seiki is not liable for problems resulting from destroyed programs or lost data that have not been backed up If necessary to perform a memory clear operation contact the Mori Seiki Service Department for assistance Data deleted The data stored in common variables 147 pallet number of machine loaded pallet 148 spindle tool number and 149 MAPPS tool management offset number tool group number is not updated immediately if the NC is busy This means data of these common variables are not guaranteed in the timing of data updating The NC enters the busy state mainly caused by background input output processing through the RS 232C interface However other processing could also make the NC busy Therefore if certain processing uses the data in the common variables above and when such processing is very important it is necessary to check if the data in them have been updated to the latest number using a user macro Machine damage MACHINE OPERATION 41 9 3
23. CD GO Separate volume OPERATION MANUAL Machine Condition Screen 171375 A02 N pese Functions SQ123 X47 CLAMP WITH TOOL CHECK SQ124 X48 CLAMP CHECK SQ121 X49 UNCLAMP CYLINDER UP CHECK SQ101 X5F POT UP FIN SQ102 X60 POT DOWN FIN SL1 X68 LUBRICATING FLOAT SWITCH SP1 X69 LUBRICATING PRESSURE SWITCH se pes Dmmmaxior HYDRAULIC PRESSURE SWITCH 9123 HYDRAULIC LV SW UNCLAMP UNIT HYDRAULIC PUMP THERMAL SP3 X4E MAIN AIR PRESSURE SWITCH SQ48 X41 FRONT DOOR LOCK FIN SQ49 amp FRONT DOOR CLOSE amp LOCK FIN 5030 X40 FRONT DOOR CLOSE FIN SQ133 X42 MAGAZINE DOOR CLOSE FIN SQ100 X43
24. WARNING Do not approach machine without sufficient caution while operating in setting mode SETTING MODE Note that setting the INTERLOCK MODE key switch to SETTING to enable limited machine operations with the door open is extremely dangerous In daily operations set the key switch to NORMAL remove the key from the switch and store it in a safe location Only persons who are trained sufficiently in safety and machine operation are permitted to switch the door interlock function to the SETTING mode and operate the machine 28 CAUTION LABELS 10 11 Possible accidents resulting in serious injury or death during machine operation with the door open are described below
25. MSDS MSDS C ee Pot Balls C note 1 Uniformly grease the surfaces of the pot balls 2 Do not grease the tapered section of the pot Greasing the tapered section of the pot may lead to runout at the tool tip during spindle tool rotation resulting in adverse effects on the machining accuracy The following table shows equivalent product names for your information The oils other than recommended oils are not guaranteed on the dynamic characteristics N CAUTION Receive the MSDS MATERIAL SAFETY DATA SHEET from the lubricant manufacturer directly yourself as the customer Work environment management and the storage and disposal of oils are the sole responsibility of the cust
26. 1 2 MUT eun c fj Rot TAPIA R
27. vb it 117 FAN COOLER SEO deiade t a f ato 117 Cleaning Air Filter and Radiator 15 2 C dal A se e D e ue SOR cueste ree tree Qaqaqa eed s Rd 118 Replacing Cooling Oil EREN ONAA EE 118 Flow of Cooling Oil and Positions where it is Used 0 al Mm 119 OIL TEMPERATURE CONTROLLER E 22 sce bd abdita nd s 119 Cleaning Air Filter and Condenser AEN rptu EAE 120 Replacing Cooling Oil 1623 AS BUA Z4 ee FAT eb be ea ted ptr rade 122 Flow of Cooling Oil and Positions where it is Used 5 1 MR I 123 PNEUMATIC DEVICES 1 123 Air Pressure Inspection and Adjustment 152 SCENIC IG SEE st beo E Lv eed tud dn i dadas 123 Manual Draining from Air Filter 17 3 i 124 Air Filter Mist Separator Inspection and Filter Element Replacement 17 4 125 Flow of Compressed Air and Positions where it is Used sk SEE Em ue oe ave tee 127 Air Circuit Diagram fme
28. CC EX0560 4 The three primary causes of a spindle oil air pressure abnormality are outlined below Check the air pressure by following the procedures below and perform troubleshooting procedures as necessary 1 Mist separator clogging For details on the checking procedure refer to Manual Draining from Air Filter page 123 Air Filter Mist Separator Inspection and Filter Element Replacement page 124 2 Incorrect adjustment of spindle oil air pressure switch ET For details on the adjustment procedure refer to Incorrect Adjustment of Spindle Oil Air Pressure Switch page 186 3 Spindle oil air pressure switch malfunction For details the troubleshooting procedure refer to lt Spindle Oil Air Pressure Switch Malfunction gt page 186 lt Incorrect Adjustment of Spindle Oil Air Pressure Switch gt Ifthe cause of the problem is not related to the mist separator element check the spindle oil air pressure switch to confirm the air pressure is at the set value 0 4 MPa While observing the gage on
29. 3 NC N CAUTION 1 Change the NC memory back up battery and servo absolute position sensing battery with power supplied to the NC If the batteries are changed with the NC power supply turned OFF the data stored in the memory may be lost 2 Before changing the batteries save the memory data such as parameters and programs as backup in an external I O device such as a memory card or USB memory Mori Seiki is not liable for problems that result from destroyed programs or lost data that have not been backed up 3 Always ensure that the polarity of the batteries is correct If the polarity is reversed the memory data may be lost when turning OFF the NC power 136 ELECTRICAL CABINET gt Procedure le
30. amp FIR 1 2 1 BEA ORME IRA 1 Y F Main Power Switch in Electrical Cabinet 3 Precautions when Opening Closing Electrical Cabinet Door A DANGER Prior to performing electrical cabinet maintenance and inspections take care to ensure the plant side power supply circuit breaker is turned OFF Even when the main switch on the electrical cabinet is turned OFF parts in the cabinet may still hold residual current resulting in an electric shock if touched accidentally C note Do not touch devices installed inside the electrical cabinet at heights of 2 m or greater above the ground as these devices do not require maintenance and inspections Keep the keys user s responsibility to prevent the loss a SE IEEE Opening Electrical Cabinet Door with Main Power OFF
31. 1 5 MPa PLC EX0509 AN 1 EX0509 1 1 EX0566 A
32. Be Procedure for Replacing Unclamp Unit Tank Oil Fill Port Cap 2 3 4 5 6 7 8 9 Oil Level Gage Drain Plug Move the spindle head along the Z axis in the negative direction to the stroke end Turn OFF the main power Remove the front cover of the spindle head Remove the drain plug and drain all oil from the tank Replace the drain plug Remove the fill port cap Pour oil while checking the oil level gage Remount the fill port cap Remount the cover HYDRAULIC UNIT 8 NJ 12 HYDRAULIC UNIT 12 1 Precautions when Performing Maintenance Work DANGER Turn OFF the main power N CAUTION P 1 If the oil level decreases rapidly the pump unit or the machine
33. spindle bearing 1 0 mm x spindle speed min 212 million if abnormal vibration or chattering is generated during machining due to improper combination of jig cutting tool work material etc change the machining conditions to appropriate values Damaged bearing and cutting tool Adversely affected machining accuracy NC NC PROGRAM 43 2 GOO X Y Z 2 X Y H4 2 dn 3 092 G92 X YZ 3 If X Y and Z axis movements are specified in the same block in the G00 mode the tool path is not always a straight line from the present position to the prog
34. N 21 AN N w DANGER Cover power supply cables on the floor with rigid insulated plates Electric shock WARNING N Always keep the floor area around the machine clean wit
35. pLc PLC PLC NC NC pic Machine parts and electrical failure related alarms If a PLC alarm occurs the screen automatically changes to the PLC ALARM screen displaying the alarm number and message The alarm cannot be reset because machine damage will result unless properly corrected Contact the Mori Seiki Service Department for assistance The reasons and measures for the PLC alarm can be verified on the screen Alarm Help Function Refer to PLC Alarm Screen in the separate volume OPERATION MANUAL C note If an N
36. 2 7 C 8 9 CD m 10 107 RAT Bo 11 10 5 Clean the inside of the tank using a neutral detergent 6 Clean the suction filter and the fill port filter with kerosene and blow compressed air N CAUTION 1 Protective glasses must be worn to prevent eye damage from dust or foreign matter those who wearing glasses included 2 Use caution when using kerosene and make sure there is no open flame in the vicinity 7 When the suct
37. a 1 b 4 a b c GRET x100 e E Refer to the separate volume OPERATION MANUAL lt Zero Point Adjustment gt N CAUTION If ZERO POINT SET is set to VALID while the present position data is lost all feed axis interlocks are cancelled In this condition axis movement is to be performed with extreme care If an axis is moved carelessly the table may come into contact with protective covers causing serious damage a Move the
38. N WARNING 7 Turn OFF the main power before performing maintenance and inspections 2 Do not pour water over the coolant cooling unit N CAUTION The coolant cooling unit may stop when dust or dirt of the air filter prevents airflow If this case push in the pressure switch to reset the switch after cleaning the air filter N Protective glasses must be worn to prevent eye damage from chips or foreign matter when using the air gun those who wearing glasses included C Take care not to damage the copper pipe of the condenser Gas leakage Procedure 1 Turn OFF the main power 2 Remove the air filter 3 Remove dust and oil from the air filter using a compressed air gun or wash the air filter with a neutral detergent COOLANT COOLING UNIT OPTION 145 4 4 Remove dust and oil from the condenser using a compressed air gun or a blush Air Filter Pressure Switch Condenser
39. d d Keep this manual in a clearly marked location to ensure easy access when necessary Contact the Mori Seiki Service Department if any part of the manual is unclear Contact the Mori Seiki Service Department or your distributor if this manual is lost or damaged The contents of this manual are subject to change without prior notification due to improvements to the machine All rights reserved re
40. 4 5 ATC BEER 6 7 AN 1 2
41. 6 H60439A BAR 1 READ THE INSTRUCTION MANUAL carefully before installing or operating the machine 2 STRICTLY OBSERVE all instructions written on the caution plates 3 NEVER OPERATE the machine without the protective cover interlock or other safety devices in place 4 NEVER ATTEMPT TO CHANGE the settings for CNC parameters without consultine MORI SEIKI 5 The machine starts and moves automatically NEVER TOUCH OR STAND near revolving or moving parts 6 ALWAYS DISCONNECT the power source before inspecting repairing or performing maintenance to the machine 7 NEVER RE USE windows or guards after damage Replace promptly with only recommended products FAILURE TO OBSERVE THE ABOVE INSTRUCTIONS MAY CAUSE SERIOUS PERSONAL INJURY OR MA
42. 12 73 20 cm 74 75 76
43. DI lt gt 159 N CAUTION If the screen displays the message requesting battery replacement change the NC memory back up battery and the servo absolute position sensing battery Continued usage of the machine without replacement of the batteries while the alarms are displayed causes the battery low voltage alarms to occur Replacing the batteries after the alarms are activated shuts off the power and deactivates the alarm and may cause the memory data to be lost lt Message Requesting Battery Replacement gt 00010 N00000002 MEM xex 0000H 00M 00 05 Please replace batteries for CNC memory backup and absolute pulse coder Memory backup might not be possible when using the battery at this condition Also the machine might not work properly Please refer to manuals for replacement procedure Replace batteries and press CONFIRM soft key As the accumulate time reaches the inspection time on BATTERY REPLACEMENT in the PERIODICAL INSPECTION 1 screen the message requesting battery replacement is displayed Change the batteries when this message is displayed then press CONFIRM C Note Pressing CONFIRM sets the ACCUMULATE TIME
44. 3 4 5 6 7 Do not leave articles such as tools and rags inside the Bolts used for fixtures should be periodically replaced C note Mori Seiki does not accept responsibility for acci
45. ZERE 123 1 119 144 x 117 m SH E LY 4 2 124 172 105 105 m 105 5 sss m 96 119 99 148 100 148 103 60 106 65 97 106 170 41
46. atc 200 17 2 ATC Conditions Required for ATC Operation ATC Completion of ATC Cycle C note The spindle tool is on standby at the middle pot after completion of the ATC cycle QI Confirming ATC Stopped Position in ATC Cycle page 200 The conditions to carry out the ATC cycle are described below ATC POWER SUPPLY CUT OFF DURING ATC OPERATION 200 MO6 M33 ATC AIC 8 C lt Toe UNS gt 7 When changing or returning a tool by executing an MO6 tool change or M33 tool return command the conditions required
47. 8 VEA _ _ iR Status Cause Countermeasure Reference Controller not operating Contact the Mori Seiki Service Power indicator lamp Main power not supplied or wiring to Department for assistance __ on operation panel not power source L1 L2 disconnected illuminated Lamp is not illuminated Replace the when controller is Lamp defective parts contact the Mori Seiki ti Service Department for perating assistance FAN COOLER ERRORS 183 Status Cause Countermeasure Reference Piping on suction side of pump Check the piping seals and tighten loose if necessary If the malfunction continues to occur contact the Mori Seiki Service Department for assistance Suction strainer clogged Clean suction strainer
48. Tank Capacity gt lt Hinge Type gt 2 Do not supply coolant during machine operation 3 Do not fill above the upper limit on the oil level gage Chip Conveyor Specifications e NN Oil Level Gage et NVX5060 NVX5080 442 L NVX5100 494 L gt Hinge Drum Filter Type NVX5060 NVX5080 584 L NVX5100 636 L gt 1 2 3 AN 1 2 Procedures 1 Remove the coolant tank cover 2 Supply coolant up to the upper limit on the oil level gage 3 Remount the cover N CAUTION 1 Do not supply coolant during machine operation 2 Do not fill above the upper limit on the oil level gage COOLANT UNIT 99 13 3 C
49. 3 Press the manual lubrication button again and confirm that the lubricant pressure rises to between 1 0 MPa 1 2 MPa If a lubricating unit abnormal pressure alarm is caused by a relief valve malfunction disassemble and clean the relief valve according to the following procedure Relief Valve Adjusting Screw Valve Valve Guide e T gt Relief Valve Disassembly lt gt 1 C 2 2 C E 3 4 QO
50. 5 7 APC APC Workpiece Setting and APC APC Specifications oO gt Dig APC APC 3 H60942A BAB hole in the taper shank of the tool holder and the magazine pot with a clean cloth to remove chips and dust Machine malfunction Damage to the machine e A WARNING Do not put your hands into the APC while the indicators on the APC operation panel are lit Never enter the APC H60989A Ra CAUTION LABELS 31 7 2 APC 21 20 APC
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52. 110101JP MORI SEIKI CO LTD Nagoya Head Office O 2 35 16 Meieki Nakamura ku Nagoya City Aichi 450 0002 Japan Phone 81 52 587 1811 Fax 81 52 587 1818 Tokyo Branch 18th floor Shinagawa Intercity Tower A 2 15 1 Konan Minato ku Tokyo 108 6018 Japan Phone 81 3 5460 3570 Fax 81 3 5460 9610 Nara Campus No 1 Plant O 362 Idono cho Yamato Koriyama City Nara 639 1183 Japan Phone 81 743 53 1121 Fax 81 743 52 8713 Nara Campus No 2 Plant O 106 Kita Koriyama cho Yamato Koriyama City Nara 639 1160 Japan Phone 81 743 53 1125 Fax 81 743 55 0489 Iga Campus o 201 Midai Iga City Mie 519 1414 Japan Phone 81 595 45 4151 Fax 81 595 45 5417 Chiba Campus O 488 19 Suzumi cho Funabashi City Chiba 274 0052 Japan Phone 81 47 410 8800 Fax 81 47 410 8834 lt NORTH AMERICA SOUTH AMERICA gt DMG Mori Seiki USA MORI SEIKI U S A INC Head Office 2400 Huntington Blvd Hoffman Estates Illinois 60192 Phone 1 847 593 5400 1 847 593 5433 Technical Centers Chicago Dallas Los Angeles San Francisco Seattle Detroit Cincinnati Boston New Jersey Charlotte MORI SEIKI CANADA LTD Head Office amp Technical Center O 6497 Edwards Blvd Mississauga Ontario LST 2V2 Canada Phone 1 905 565 1331 Fax
53. 32 L 2 32 GEE 4 2 d IVA C UA S68 BA ILA EAT 80W 90 22 e 7 m OM af us 10 2M NT A 3 Z J AI YV SXZ46 0 5 1 D 20 1000 gt 1 GE 1 3 EP RO BT BT2
54. 5 9 CEU i WARNING 7 Always stop the machine before removing chips inside it during operation Entangled or crushed by the moving parts Stop the machine and coolant supply before adjusting the direction or volume of coolant supply Entanglement or crushing by moving parts Stop spindle rotation before opening the door during automatic operation Pressing the automatic operation button STOP Stop during automatic operation stops axis movement but not spindle rotation Entangled with the spindle 55 Before opening the door to remove chips during machining operation make sure that the door interlock function is NORMAL After removing chips close the door before restarting machine operation Injuries N CAUTION Do not touch chips or cutting tools with your bare hands Injured Do not move the axes or change cutting tools manually
55. 13 8 2 Turn the discharge rate adjusting valve by hand to adjust the shower coolant discharge rate C note The discharge rate is decreased as the valve is turned CW and increased as the valve is turned CCW Adjusting Additional Tool Tip Coolant Discharge Rate Option ATC ATC Arm Pay attention to interference with the nozzle like this AN gt 1 2 C o m N
56. 97 m AY Coolant Tank Cover Ay DANGER Turn OFF the main power Procedures 1 Turn OFF the main power 2 Wait until the coolant level is stabilized after the coolant inside machine is returned to the coolant tank 3 Remove the coolant tank cover 4 Drain coolant using a dedicated suction device 5 Clean the tank with a spade or shovel 6 Supply coolant CD Replenishing Coolant page 97 7 Remount the coolant tank cover 8 Push the coolant button a ON On on the operation panel to confirm coolant is supplied COOLANT UNIT 101 13 5 Coolant Unit Mounted On Coolant Tank Option
57. 2 3 4 AN 7 2 3 4 ow c H From the crack coolant may permeate and accelerate degradation of the polycarbonat
58. No ATC Cycle Operation Recommended Recovery Procedure Spindle Orientation ORIENTATION The button lamp of the spindle rotation button ORT Spindle 4 Orientation is illuminated ATC Shutter Open ATC SHUTTER CLOSE Pot Moving Down POT UP ATC SHUTTER CLOSE 2 ATC Arm Normal Rotation ATC ARM BACKWARD gt POT UP gt ATC Before Tool Unclamp SHUTTER CLOSE note 3 1 When the pot comes loose Move backward the ATC arm to the home position manually POT UP gt ATC SHUTTER CLOSE 2 Remove the tool if mounted on the pot or spindle then perform the operation after ensuring safety to operate the machine ATC Arm Normal Rotation ATC ARM FORWARD POT UP gt ATC During Tool Unclamp SHUTTER CLOSE sm note 4 When the pot comes loose POT UP gt POT DOWN gt Move forward the ATC arm to the home position manually gt POT UP SHUTTER CLOSE d 1 7 ATC POWER SUPPLY CUT OFF DURING ATC OPERATION 203 No ATC Cycle Operation Recommended Recovery Procedure Arm Normal Rotation ARM FORWARD gt POT UP gt ATC After Tool Clamp
59. gt DANGER Always turn OFF the main power and disconnect the power supply breaker of the plant side before replacing trays of the spiral type internal chip conveyor 1 Operate the chip conveyor to remove chips 2 Remove the maintenance side cover necessary to replace the trays N CAUTION Since the maintenance side cover is heavy take care not to drop it 3 Remove the rear side cover To change the trays at the left side of the machine Specifications with magazine door remove the handrail the cover and the step in order from 1 to 3 Specifications without magazine door remove the cover To change the trays at the right side of the machine Remove the rear side cover 4 CHIP CONVEYOR OPTION 141 lt gt Left Side n D E a S 3 Ne 25 SN m lt i Left Side Maintenance Cover Step lt gt lt Right Side gt Right Side Maintenanc
60. 8 E A 19 4 WARNING Before placing rags on the conveyor belt disconnect power Entanglement of hands or feet Serious injury 4 Keep pressing the chip conveyor button gt BACK Reverse until the chip conveyor discharges chips and rags out of the machine For further details on the cleaning procedure refer to the manual supplied with chip conveyor Adjusting External Chip Conveyor Belt Hinge with Drum Filter Specifications Movable Chain Guide Headend Panel SAN gt 1 2 Take Up Bolt Headend Cover ao y
61. 3 QM63 4 C A Strainer WARNING Turn OFF the main power Procedure 1 Set the main power switch in the OFF position 2 Remove the hexagon socket head cap screws fixing the coolant pump to the tank 3 Pull the coolant pump out of the tank 4 Remove the screw and the strainer 5 If clogged clean the strainer 6 Reverse the above procedure to reassemble the pump 7 Operate the coolant pump to confirm coolant is supplied When the Coolant Pump is Not Operating Procedure 1 Check if the coolant button 4 ON On on the operation panel is illuminated 2 If it is not check the following points e STATUS indicator ATC HP ATC home position on the operation panel is illuminated e Door is closed C note Depending on the parameter settings an interlock that prohibits coolant supply when the door is open may be activated e Machine is NOT i
62. V Tool clamp is illuminated on the No operation panel screen Yes Y Unclamp the tool and confirm the No retention stud bolt is not loose Yes Y C Tighten retention stud bolt and clamp tool Y Y Alarm display disappears No Switch malfunction or faulty contacts or wiring pay Contact the Mori Seiki Service Department for assistance Yes Y Recovery REMOVING CHIPS ENTANGLED IN CUTTING TOOL AND WORKPIECE 195 15 REMOVING CHIPS ENTANGLED IN CUTTING TOOL AND WORKPIECE Se oe FA A N A e
63. No 70 81 gap between collet segments about 2 3 mm and apply 1 0 5 1 0 one shot for 0 5 to 1 0 sec at each location Type igi riori Part No No 70 81 MM METAFLUX 70 81 METAFLUX W20042 C C note 1 1 Wear protective glasses to avoid grease entering the eyes those who wear glasses included 2 2 MoS2 lubrication is not allowed to use 3 3 The nozzle does not need to be inserted to the rear of the collet 5 5 Release the Emergency Stop status 6 6 Repeatclamp unclamp operations several times with no 2 3 tool in the spindle to apply grease evenly 9 4
64. The warm up program shown below is for cases where the regularly used maximum rotation speed is 10000 C note 1 T1isa small diameter tool that can be rotated at more than the maximum spindle speed for each machine specifications 9 2 Cleaning Spindle Tapered Section and End Face AN 7 N CAUTION 1 Do not use compressed air Machine failure due to chips and coolant entry SPINDLE 75 2 2 Tomaintain spindle accuracy clean the spindle tapered section and end face daily to remove dust and chips gt Procedure 1 1 Confirm spindle rotation has stopped completely 2 2 Remove the tool from the spindle 3 3 Press the EMERGENCY STOP Emergency Stop button 4
65. C 1 2 Turn OFF the main power Procedure 1 Set the main power switch in the OFF position 2 Confirm the valve is set as shown in the figure 3 Remove the check valve using a spanner and monkey wrench C note When the check valve is being removed the residual coolant in the piping may spill out 4 If clogged clean with compressed air N CAUTION When using a compressed air gun wear protective glasses to prevent eye damage from dust or foreign matter those who are wearing glasses included C note 1 Take care to reinstall the check valve in the correct direction to ensure coolant is supplied 2 When reinstalling the check valve air enters the piping This air may prevent coolant from being discharged temporarily after reinstalling the check valve COOLANT UNIT PROBLEMS 170
66. QO ENEE SAN 1 A DANGER 7 Turn the power OFF before performing maintenance and inspection procedures If absolutely necessary to work with the power ON exercise extreme caution Electric shock Entanglement 2 Never close the operator door when working inside the machine with the main power switch ON Locked Rapid machine operations initiated unexpectedly 3 Ensure the main power switch is turned OFF and locked at all times when performing maintenance procedures considered dangerous if the power is ON For locking the main power switch refer to separate volume OPERATION MANUAL Main Power Switch 4 Provide clear warning that the machine is being maintained and operations cannot be performed Accident 5 Electrical wiring work is to be performed by qualified electrical engineers only Electric shock 6 Before performing maintenance and inspection procedures inside the electrical cabinet or on motors transformers or machine lighting confirm the main power is turned OFF Note that when the main power switch is turned OFF parts may still contain residual e
67. 17 1 ATC ATC Cycle When power supply is cut off during ATC operation complete the ATC operation by moving the ATC manually N CAUTION 1 Contact the Mori Seiki Service Department for assistance prior to performing a magazine ATC recovery operation Mori Seiki does not accept responsibility for accidents that occur as a result of recovery operations performed at the discretion of the user 2 Do not perform a manual magazine ATC operation unless absolutely necessary to rectify a problem that has occurred Starting a manual operation without taking the necessary precautions will cause the ATC arm or tool to collide or interfere resulting in damage to the machine 3 Before operating the ATC manually sufficiently understand the machine structure and its conditions to ensure safety If a tool is mounted on the pot or spindle remove the tool and then perform the operation ATC ATC Shutter Open Pot Moving Down ATC ATC Arm Normal Rotation Tool Change ATC Arm Home Position Pot Up gt ATC Shutter Close ATC C
68. removed High tension terminals and live parts are exposed and may cause electric shocks MALFUNCTIONS AT MAIN POWER ON 155 3 AN 3 Do not open the amplifier cover with the main power turned ON otherwise you could sustain an electric shock N CAUTION Do not touch radiators regenerative resistors or amplifier motors when the main power is turned ON or immediately following machine operation as surface parts reach high temperatures Burn
69. BALM NC 00010 N00000002 MEM ttt xxx BALM FTT 0000H OOM 00 05 15 45 43 lt gt When the battery level falls the battery low voltage alarms are activated and either the message requesting battery replacement or the following alarm messages are displayed BALM on the upper side of the screen becomes red at this time Change the NC memory back up battery and servo absolute position sensing battery and deactivate the alarms 00010 N00000002 MEM xix xxx BALM 0000H OOM 00 08 15 45 48 lt NC Memory Back Up Battery gt No dice Alarm No Message EX2562 NC BATTERY ABNORMAL 252 000 BATTERY FAULT 000 gt SERVO Absolute Position Sensing Battery Message EX2561 SERVO BATTERY ABNORMAL S52 oo9F n
70. gt gt CD WARNING 7 Before dismantling the machine remove the power cord and air hose connected to the machine 2 There is alive part inside the electrical cabinet and the operation panel Be sure to pay sufficient attention during the operation Electric shock 3 Dismantle air cylinders after eliminating pressure Bursting accident N CAUTION Machine owners are responsible for appropriate machine disposal Do not disturb the environment when you dispose the machines Be sure to observe the laws of your country and regulations of local government concerning environmental conservation and recycling Liquid Contact local governments when disposing liquids such as lubricants grease hydraulic oil coolants appropriately Electronic Device Appropriately dispose electrical parts in the operation panel monitor keyboard electrical parts
71. 157 158 135 i 117 182 42 32 87 52 51 55 44 73 67 HEEK 94 87 162 87 58 88 101 91 89 63 63 180 179 119 184 118 120 118 122 36 APC
72. 4 Fill Port Cap note Oil replenishment is possible even while the machine is operating But oil supply will stop during replenishment and if the oil supply stops for a long period the mist will also stop So finish replenishment quickly if it is being done while the machine is operating 2 Remove the fill port cap C note The internal pressure is released when the fill port cap is loosened 3 Supply oil from a bottle containing the designated oil ULTIMA plant derived lubricant for mist made by TANAKA IMPORT GROUP N CAUTION 1 Use genuine ULTIMA plant derived lubricant for mist Mori Seiki cannot accept any responsibility for trouble or problems such as fire health problems or machine damage caused by using an unauthorized oil 2 The designated oil may not be available in some areas In that case use the following equivalent products Castrol CareCut ES1 Castrol CareCut ES2 3 Do not mix in an oil different from the oil in current use When changing to a different brand of oil drain all the original oil from the tank completely clean the inside of the tank and then add the replacement oil Mori Seiki is not responsible for problems arising from the mixing of different brands of oil or the use
73. 55 AN 7 N gt 1 2 3 4 5 6 7 8 9 10 55 o GAR
74. AN 1 2 ES1 ES2 3 C 1000 cc
75. ATC AIC ATC Sm a C 4 ATC ATC ATC ATC C 5 ATC ATC 202 POWER SUPPLY CUT OFF DURING ATC OPERATION No ATC gt 6 9 m C ATC Z 203
76. 2 lt 3 Capto AN al 2 1 2 90 ATC 100000 gt 7 2 Type Part Stamina Grease RL2 Shell W20043 C note 1 Wear protective glasses to avoid grease entering the eyes those who wear glasses included 2 The nozzle does not need to be inserted to the rear of the collet 5 Release the Emergency Stop status 6 Repeat clamp unclamp operations several times with no tool in the spindle to apply grease evenly Capto Specifications Collet N CAUTION Grease the tool clamp unit once every two weeks to maintain tool unit performance Even if two weeks have not passed
77. 7 Understand the contents of this manual thoroughly Store this manual close to the machine to enable easy reference whenever necessary Do not allow persons who lack basic knowledge of the machine or sufficient training to perform operation maintenance or programming of the machine Mori Seiki is not liable for accidents Determine the most appropriate settings Do not change or modify the machine without prior consultation with Mori Seiki Mori Seiki is not liable for accidents Take adequate safety measures for both machine and operators Provide operators with sufficient training and education prior to operation as well as periodically Prohibit anyone without sufficient safety training from entering the plant and vicinity of the machine This machine is manufactured for use by persons with normal senses and not physically challenged Not compliant for use by persons with implanted medical device directives such as pacemakers Actual machine operations are the sole responsibility of the user Do not export resell or relocate the machine to a destination with different laws or standards If by any chance an accident occurs managers or supervisors must rescue the injured person then call an ambulance as necessary and take emergency measures such as first aid 20 PRECAUTIONS FOR OPERAT
78. 144 50 117 119 99 100 IL 500 108 107 134 1000 124 88
79. 7 When the EMERGENCY STOP Emergency Stop Do not touch lamps used to illuminate the interior of the machine during machine operation or immediately following power OFF Burns Do not stop spindle rotation while a tool is in contact with the workpiece Cutting tool and machine damage button or Z RESET key has been pressed to stop the machine during a threading operation or a hole machining operation especially a tapping operation carefully feed the axes after checking the condition of the work and cutting tool Collision or interference between workpiece and cutting tool When the EMERGENCY STOP Emergency Stop button or Z RESET key has been pressed to stop the machine while an APC cycle is in progress for the machines with APC carefully move the axes after checking the workpiece and cutting tool for damage Workpiece and cutting tool collide or interfere with each other When releasing the hard overtravel on a machine with that function the axis movement interlock can be released by pressing the 2nd O T Release button Do not move the axis in the direction in which the hard overtravel occurred For safety reasons feed the axes usin
80. ll Manual Lubrication Button Suction Filter FIR 1 2 3 10 C CO EX0557 174 Confirm if the cause of the lubricating unit abnormal pressure alarm is in either the lubricating unit or piping by checking the lubricating unit operation Discharge Outlet Plug Insertion Point Procedure 1 Remove the line filter discharge piping 2 Place a plug over the line filter discharge outlet
81. Lubrication Button Wat m Pressure Gage Using the manual pulse generator perform full stroke travel of each axis to check for abnormal sounds or operation 66 PREPARATION FOR MACHINE OPERATION AFTER PROLONGED IDLE PERIOD gt Travel Distance of Each Feed Axis mm Model Axis Travel mm X 600 NVX5060 Y 530 Z 510 X 800 NVX5080 Y 530 Z 510 X 1050 NVX5100 Y 530 2 510 MACHINING CHAMBER 6 N 7 MACHINING CHAMBER N 1 Cleaning Machining Chamber Observation Window 1 2 E
82. RL2 Capto lt HSK No 70 81 2 1 5 2 90 ATC 100000 Shae 2E BB OILS 59 i Replacement Replenish Oil Supplied to Type Quantity L Interval ment Interval duele Idemitsu Lubricating Unit Tank for Spindle Daphne Mechanic Oil 32 2 Lubricating Unit Tank for Shell slideways ball screw nuts Tonna Oil S68 ia As required Shell ATO mitank Gelco Power Gear 80W 90 6 4 ieee Fan Cooler 7 x Daphne Super Multi Oil 2M operation Idemitsu Every 2000 Oil Temperature Controller Tank Daphne Super Multi Oil 2M 10 hours of operation Unclamp Unit Tank Snell 0 5 1 year As required P Tellus Oil SX Z46 i y 3 Idemitsu Every 1090 Hydraulic Unit Tank Daphne Hydraulic Fluid 32 20 hours of As required operation Magazine Roller Manual Application ET Shell _ Magazine Pot Shifter Manual Alvania EP Grease RO As required As required Application Pot Balls Manual Application BT BT Dual Once every Contact two weeks
83. 149 4 tt 138 46 196 17 154 70 E 33 E 20 89 E 93 127 34 66 103 5 73 137
84. N CAUTION The acrylic cast is an acrylic resin window mounted on the machine side of the lattice window Leaving the acrylic cast in a damaged state may accelerate its degradation lt Procedure gt 1 2 3 4 5 6 7 8 Remove the tool from the spindle and the workpiece from the table Turn OFF the main power Remove the window frame plate Remove the old window Remove silicone sealant on the window frame plate After confirming the mounting direction inside outside of the new window apply silicone sealant to the edges of outside face of the new window Mount a new window C note Confirm that the window parts No is correct when making an order Fix the window by tightening the screws on the window frame plate 70 MACHINING CHAMBER 9 1 9 Set the replacement date on the PERIODICAL INSPECTION 1 screen CO 1 Separate volume OPERATION MANUAL PERIODICAL INSPECTION 1 Screen 7 3 Cleaning Machining Chamber Sweep chips accumulating on the slideway protective covers
85. 3 4 5 5 8 Locked In Prevention Key A H80444A B
86. Mount the window so that the letters on the manufacturing sticker can be read from outside the machine AN Manufacturing Sticker gt 1 2 3 4 5 6 7 C HEX Fe Window Frame X41173 Acrylic Cast Plate Parts No X41173 W14622 Window Parts No W14622 Window Holding Cover
87. When an alarm message is displayed confirm the status of the LED LEDs located above the servo spindle amplifiers in the electrical cabinet LED In normal operation the LEDs indicate the status of the servo spindle amplifiers However when a malfunction occurs the 1 LEDs indicate alarm and warning codes When more than one malfunction occurs on a single axis the LEDs indicate only the latest alarm code WARNING 1 1 Do not operate switches with wet hands otherwise you could sustain an electric shock 2 2 Do not operate the machine with the amplifier cover
88. The possible causes of abnormal sounds emitted when coolant pump is operating are outlined below Replenish the coolant or perform maintenance work when it becomes necessary Cause Reference Items 168 Low oil level in the coolant tank Coolant Level Check page 168 170 Coolant pump strainer clogging Coolant Pump Strainer Clogging page 170 Malfunction of check valve Contact the Mori Seiki Service Department for assistance COOLANT UNIT PROBLEMS 173 Cause Reference Items Malfunction of coolant pumps Contact the Mori Seiki Service Department for assistance 174 LUBRICATING UNIT ALARMS N
89. JU CU PR 3 E SU En Before operating or programming the machine or performing maintenance procedures read and understand the instruction manuals thoroughly This machine is manufactured for use by persons with normal senses and not physically challenged Not compliant for use by persons with implanted medical device directives such as pacemakers Actual machine operations are the sole responsibility of the user Prior to machine operation take necessary training and education Assume that something is impossible unless the manual specifically states that it can be done Never operate maintain or program the machine while under the influence of alcohol or drugs Never operate maintain or program the machine while taking medicines which may induce sleep or reduce concentration Take off accessories such as a ring or a tie which may be entangled by the machine and trim clothing fastener button or belt and hair Entanglement Wear safety shoes eye protectors and a hardhat at all times If an emergency situation such as an accident and a fire occ
90. 6 1 gt N A a WARNING lt Industrial Robot Specifications gt Only qualified personnel trained and approved in accordance with local regulations may operate robots Unauthorized personnel may not operate robots under any circumstances including teaching and inspection Personnel assisting robot operators must be fully qualified lt Stacker Crane Specifications gt The stacker crane used with the machine has a capacity of less than 5 tons Only qualified personnel may operate the stacker crane 42 NC NC PROGRAM 10 Nc NC PROGRAM 10 1 Before Creating Program Ad WARNING 1 1 Select the appropriate spindle speed cutting feedrate and cutting depth If appropriate operating conditions
91. 4 C sgg 5 6 10 er 14 3 Procedure 1 Turn OFF the main power 2 Remove the line filter 3 Clean the filter element with kerosene and blow compressed air through the filter N CAUTION 1 Protective glasses must be worn to prevent eye damage from dust or foreign matter those who wearing glasses included 2 Use caution when using kerosene and make sure there is no open flame in the vicinity 4 When the filter element is badly fouled or damaged replacement is necessary C note When replacing the filter element contact the Mori Seiki Service Department 5 Remount the line filter 6 Press the manual lubrication button for 10 seconds to bleed air from the piping Stop pressing the button when the pointer reaches the green mark
92. PLC EX2551 A N C EX2551 QM63 QF80 2 PLC alarm EX2551 THERMAL OVERLOAD TRIP 2 occurs when the thermal relay QF80 of the oil temperature controller is OFF note EX2551 also occurs when the thermal QM63 for the coolant pump is OFF ALARMS RELATED TO PNEUMATIC DEVICES 186 10 ALARMS RELATED TO PNEUMATIC DEVICES EX0560 EX0560 AIR PRESSURE LOW 10 1 3 7 CD 123
93. The operator will become entangled with the spindle if the spindle starts while the operator is touching the tool The operator will become entangled with the spindle if the operator touches the tool while the spindle is rotating A workpiece and or tool will fly out if the tool is hit against the workpiece due to programming error A workpiece will fly out if machining automatic operation is started while the workpiece is not clamped correctly A workpiece will fly out due to excessively heavy cutting force The operator or a person standing near the machine will be splashed with chips and coolant during machining resulting in injury or health problems particularly if chips or coolant get into the eye The operator will be caught in the table or the column during axis feed The operator will be injured by touching the tool or tool magazine while the ATC is operating The operator will become entangled with the APC if the APC starts operations during setup operation such as mounting a workpiece 10 The operator will become entangled with the APC by touching the pallet fixture or workpiece while the APC is operating 11 The operator will become caught in the chip conveyor when the operator s hand or foot comes into contact with the chip conveyor while it is operating For the SETTING mode refer to the s
94. about 5 10 times If the filter deteriorates replace it with a new filter 18105 Part No E18105 gt Procedure 1 1 Turn OFF the main power 2 2 Disconnect the plant side power supply breaker 3 3 Remove the screws and pull out the filter 4 Clean the filter using one of the following methods ELECTRICAL CABINET 135 AN EE C 5 18 4 Replacing Batteries e Press on the filter in a tank of water e Remove foreign matter using a vacuum
95. 5 9 1 Before fixing a workpiece always check that the setup button lamp or the last pallet indicator is not illuminated When the setup indicator is illuminated the pallet is changed automatically This can be a hazardous situation 2 Do not enter the APC or pallet pool When entering the APC or pallet pool always stop the machine and disconnect the main power Serious injury 3 Do not put your hand inside the machine while a pallet is being loaded or unloaded Entanglement Serious injury 4 With pallet pool specification machines do not try to touch the pallet at a position other than the setup station Entanglement Serious injury 5 When mounting or removing a fixture or workpiece at the setup station do not apply force in directions that will lift or tilt the pallet Falling of the pallet A WARNING Door is automatically locked and cannot be opened from inside To work Inside the machine turn and remove the key to prevent the door from being locked Take the key with you H60435A 8 Turning the locked in protection key makes it impossible to fully close the door so the door cannot be closed If it is necessary to carry out cleaning or maintenance inside the machine turn the power OFF turn the key and remove it Ta
96. The window has a 2 layer construction of toughened glass and polycarbonate that prevents being crashed through Toughened glass prevents the pane from becoming frosted by splashing chips The window is a consumable part Replace it at regular intervals or in case of necessary Perform visual inspection at least once a week DANGER Turn OFF the main power and disconnect the plant side power supply breaker WARNING 1 Replace the window at regular intervals once every 5 years Perform visual inspection at least once a week Regardless of the replacement interval replace the window immediately in any of the following cases When damaged Workpiece Chips or coolant ejection Serious injury When cracked even it is slight 68 MACHINING CHAMBER
97. 25 35 Nem note 1 The new filter element comes with an O ring set inside Apply oil on the O ring without removing it 2 Use the same oil that is used in the hydraulic unit Check the O ring of the case for damage If the O ring is damaged replace it with a new one C Note 1 Evenatiny scratch will cause an oil leakage if the unit is used under high pressure 2 Forthe model No of the O ring of the case contact the Mori Seiki Service Department Wipe any stains off from inside the case Mount the new filter element on the case Turn the case clockwise to reinstall it on the head Tighten the hexagonally shaped part at the bottom of the case with a spanner Tightening Torque 25 35 Nem 12 9 Flow of Hydraulic Oil and Positions where it is Used Hydraulic Unit Solenoid Valve Spindle Tool Unclamp 94 HYDRAULIC UNIT 12 10 Hydraulic Circuit Diagram
98. 7 Measure the other axis using the same procedure 8 Record the backlash measurements and contact the Mori Seiki Service Department for assistance ATC POWER SUPPLY CUT OFF DURING ATC OPERATION 199 17 POWER SUPPLY CUT OFF DURING ATC OPERATION ATC P N ATC C ATC
99. WARNING Observe the information on the caution labels Caution labels are marked according to the following warning levels DANGER Failure to follow the instructions will result in serious injury or death WARNING Failure to follow the instructions could result in serious injury or death CAUTION Failure t
100. E 2 C note When the message demanding grease replenishment is displayed replenish grease even if two weeks have not passed Replace the filter element although one year has not yet passed in the following cases When replacing the hydraulic oil When the visual indicator turns red MAINTENANCE ROUTE MAP 55 3 MAINTENANCE ROUTE MAP 1 EE REL NO Component Refer to 80 Manual Draining from Lid Attached ATC under ATC Arm page 80 ATC Unit ATC Replenishing Replacing ATC Unit Tank 81 Oil page 81 Replenishing Replacing Unclamp Unit Unclamp Unit 84
101. Fan Cooler Spindle Head OIL TEMPERATURE CONTROLLER 119 16 OIL TEMPERATURE CONTROLLER 16 1 Cleaning Air Filter and Condenser Air Filter tE gt 7 2 AN g C 3 40 C 4 5 6 i ee
102. Z70 0001 n 158 164 Z71 0001 n 158 EX2550 1 187 Z73 0001 n 158 EX2551 2 183 185 157 EX2561 158 165 EX2562 NC 158 151 84 H 84 24 cee E 26 N 67 NC 151
103. any insufficient description or errors in this manual We want to know how you think we can make this manual better Please restrict your comments to those concerning this http Awww moriseiki com manual only Comments can also be submitted using the company website at http www moriseiki com Name of Manual MAINTENANCE MANUAL HX NVX5000 4 EOJPEN Number of Revisions x Name Department Telephone Address Chapter Comments Requests For Mori Seiki s Use Do not write below this line No Description Reception No Received by 2 35 16 450 0002 2
104. 3 not put too much confidence in interlock function Ensure safety procedures are followed at all times 9 2 Data N 1 2 3 147 148 149 MAPPS NC BUSY NC BUSY KTO RS 232C
105. speed for the machining programs used for the day The percentage in the table below indicates the ratio to the maximum rotation speed of the machining programs of that day Step Warm Up Speed Time 10 oe 10 minutes 2 10 ndn 10 minutes ZN 3 50 57 5 minutes 5 i 99 5 minutes 4 5 100 52 5 minutes gt Program example 8000 min warm up program shown below is for cases where the maximum rotation speed for the machining programs of the day is 8000 min O0001 T1 1 S400 M03 G04 X600 0 S2000 G04 X600 0 S4000 G04 X300 0 S6000 74 SPINDLE G04 X300 0 M05 M30 C 1 T1 2 C
106. M CEO sss measures lt To prevent automatic operation start gt Press either of the axis feed amount selection button amp x1 x10 and x100 To ensure operator safety if automatic operation is started by mistake Set override switches rapid traverse cutting feed rate to the lowest setting Turn the single block function ON Turn the machine lock function ON Activate the coolant OFF mode by pressing the coolant button 5 OFF Off for longer than one second To prevent spindle rotation start Turn the operation selection key switch to 5 OFF Enter S0 by MDI operation To ensure operator safety if the spindle i
107. C note 1 T1isa small diameter tool that can be rotated at more than the maximum spindle speed for each machine specifications Spindle Warm Up after Extended Idle Period Perform the spindle warm up before restarting the machine after an idle period of two weeks or more referring to the table below C note Adjust the rotation speed for warm up based on the regularly used maximum rotation speed The percentage in the table below indicates the ratio to the regularly used maximum rotation speed Step Warm Up Speed Time 60 2 8 60 minutes 8 15 28 15 minutes 2 10 3 VUE 10 minutes 10 MS 10 minutes o 60 gt 100 60 minutes gt lt Program example gt 10000 min O0001 T1 1 S500 M03 G04 X3600 0 S2500 G04 X900 0 S5000 G04 X600 0 S7500 G04 X600 0 S10000 G04 X3600 0 M05 M30 C ste 1 T1
108. Use the padlock when performing maintenance work only Under normal conditions remove the padlock and store it with the key 6 6 Inspectreplace the air filter element PNEUMATIC DEVICES 125 gt 45 C O lt gt a b DD c
109. u me 120 gt 120 a me B j TT a iR Status Cause Countermeasure Reference Power indicator lamp on operation panel not illuminated Controller not operating Main power not supplied or wiring to power source L1 L2 disconnected Contact the M
110. When an alarm or warning occurs the LEDs are illuminated flash or are extinguished as shown below QI Refer to Amplifier Manufacturer s Manual for alarm details and countermeasures LED zm 1 BH LED Alarm Displays 1 axis F1 437 F1 37 F1 37 F1 37 F1 Flash 37 Flash F1 Flash 37 Flash F Axis No Alarm Code F Axis No Alarm Code LED 2 88 LED Alarm Displays 2 axes 11416 T HHEI2I E IH T F1 46 F1 OF E7 F1 Flash 46 Flash F1 OFF 9F Flash E7 Flash F Axis No Alarm Code F Axis No Alarm Code 8 Example 1 No 46 When motor overheating alarm No 46 occurs on No 1 axis 2 the No 2 axis enters the emergency stop status LED LED Warning Displays gt F 4 9F F 1 9 F F1 9F F1 9F F ES EE pad F1 O
111. Coolant Pump Strainer Clogging gt gt 7 2 3 1 5 6 7 gt 1 2 TS Do C
112. into the chip bucket using a broom TurnOFF the main power and disconnect the plant side power supply breaker gt L N CAUTION 1 7 Do not use compressed air Machine failure due to chips and coolant entry 2 2 To maintain machining accuracy clean the machining chamber after completion of machining operations 3 3 Do not get on top of the protective covers when cleaning the machining chamber Machine damage Injury 7 4 Replacing Machine Light DANGER sr F Turn OFF the main power MACHINING CHAMBER 71 1 2 3 4 5 6 7 8 9 10 11
113. 88 89 89 Ni JI 89 lt r HYDRAULIC UNIT ALARMS 165 No Hydraulic oil level sufficient 1 Replenishing hydraulic oil Yes Yes 1 Oil leakage visible No Tighten connections If hose is damaged contact Mori Seiki If oil is leaking from pump contact Mori Seiki Cleaning suction strainer 2 Recovery No recovery Yes Cleaning radiator Radiator clogged Recovery No No recovery Suction strainer clogged Yes Y Cleaning suction strainer No a Recovery No recovery Turn ON motor breaker thermal relay reset switch QM70 No recovery Contact the Mori Seiki Service Department for assistance C gt Recovery Refer to Checking Oil Level Replenishing Cil page 88 Cleaning Suction Strainer and Tank page 89 Cleaning Radiator page 89 Cleaning Suction Strainer and Tank pa
114. Procedure 1 Turn OFF the main power 2 Remove the fill port cap 3 Place a drain pan beneath the drain plug 4 Remove the drain plug and drain oil in the tank 5 Wrap sealing tape around the threaded section of the plug 6 Replace the drain plug 7 Supply oil while checking the oil level gage Steps 2 gt lt Fil Port Cap pg Sealing Tape Drain Pan Drain Plug 8 Replace the fill port cap 9 Turn ON the main power 10 Confirm pump pressure and suction noise are normal HYDRAULIC UNIT 89 C note If the suction noise is louder than prior to oil replacement check the oil level again 12 5 Checking Pressure Gage Green Mark gt Procedure 1 1 Turn ON the main power and NC power supplies C note Confirm all machine operations have come to a complete stop 2 2
115. gt 1 2 Gun Holder N CAUTION When using the coolant gun wear protective glasses to prevent eye damage from dust or foreign matter those who wear glasses are included C note The shapes of the coolant gun and gun holder slightly differ with each machine How to Use the Coolant Gun Procedure 1 Pull out the coolant gun from the gun holder 2 Pull the coolant gun lever and remove chips accumulated inside the machine Cleaning Coolant Gun Remove the nozzle head and remove chips and foreign matters Nozzle Head 106 COOLANT UNIT AN N CAUTION Do not touch chips with bear hands If handling chips wear gloves tha
116. 1922 RIN I ETSI FORRITI ottiene 137 Operating External Chip Conveyor IE v dri Mm 137 Cleaning External Chip Conveyor 19 4 aite e t eia 138 Adjusting External Chip Conveyor Belt Hinge with Drum Filter Specifications 19 5 Y OO RR TRI BE TR hus 139 Y Strainer Check and Cleaning 19 6 OF L ed rud 140 Replacing Trays of Spiral Type Internal Chip Conveyor Option 20 27 52 8 GAE A 144 COOLANT COOLING UNIT OPTION 204 eap A reb pd dde e etr eid 144 Precautions when Using Coolant Cooling Unit 20 27 EF DADE Eee OD ER aa E a a T ss s 144 Cleaning Air Filter and Condenser ANA dels tira i um 146 SEMI DRY CUT SYSTEM OPTION ZEE nri EE 146 Adjusting the Oil Supply Quantity 21 2 2 UD T ho et LL UE ML T 146 Replenishing Oil 22 etnies 148 OIL SHOT OIL MIST OPTION 224 i 148 Replenishing Oil for Oil Shot and Oil Mist 2 CHAPTER 2 TROUBLESHOOTING MEE DL
117. 170 S 67 172 67 168 67 HE b 169 70 96 196 167 21 um 168 154 144 19 144 58 SIM 1 29 2 29 HKI 70 203 190 37 137 c 137 195 137 76
118. d 7 6 7 8 8 9 9 10 0 5 MPa Removing Air Filter Assembly Case Slide the lock button downward and rotate the assembly case 45 degrees CW or CCW Pull the assembly case downward to remove C note Take care not to damage the O ring mounted in the upper part of the assembly case Inspecting Replacing Filter Element If the filter element is clogged replace it using the following procedure a Rotate the baffle CCW to remove the baffle and filter element b Mount a new filter element on the valve guide Gn For the part number of the filter element refer to the manual supplied with pneumatic device c Rotate the baffle CW to secure the baffle and filt
119. E ee o1sore Z 1045 190900 2 4 amp E amp 1090900 edWzz waqsa t p S eo oorg i eawzz 1 otoyg i _ _ 2 mE ME E uogons jo pur 1 9 1 1e Jeug uuely pues q CS l 91 I IE ous DooZ0 y gt 10uS 109900 lt 0900 4 amp E 10020 4 E UO i 1 1 xog Bui oos 1 BOE 1 1 ET X x M X X X I T _ 1 OL Ore 1 19 Qipedeo angooy3 1928805 12 ioedeo ouesey zv BEM Af gdWZ L BepIIS sIXV A xog p 3 SIXY X INN MAINS SKV IO SKV PUN fo os XA B BUREKA AZ PAN 80 Las I REA sa O oorg ununzrono N uusnus T W SJ REL ny Suuna utu s snous g uu 46 EI A px 1045 H9 F0 meses 7 x 6 EA 100910 01 1000 EUN Log y orior ezvr i D 1 NN MaS Jeg SIXV X GID SKVX Kemepi S sxv x OZ BEX X A Xe 22 CO oor 012070 IX L 404S 1 2900 OMS 0 0 9 10uS 1 9990 0 1 4 GE 129900 IXY AER WO 9x 4 KEK 1 2900 I EM I I T H if X 1 X X X 1 1 1 i I I 1 apis Jepun siXv z qd epis Jepun SIXY Z JAN Maias leg Sxv z 9 9 Aemapiis epis Jeddn sixv Z Ix CUI AA
120. 178 178 180 e 108 179 180 LUBRICATING UNIT ALARMS 175 Lubricating unit abnormal pressure alarm triggered Y Change to lubricant with No appropriate viscosity Y Confirm if generated in either lubricating unit or piping Y Disconnect piping from lubricating unit tank and check lubricating unit 2 Appropriate lubricant viscosity Yes Pressure does not rise Pressure rises normal NETS Sasa EE MEER CERE M Alarm generated by 1 Alarm generated by A lubricating unit malfunction piping malfunction Y Y Suction filter cleaning replacement Air removal 3 Recovery Recovery 4 No Recovery No Recovery 1 Alarm generated by Lubricant leakage check relief valve malfunction R 8 cec e ces ecovery Dis
121. 2 3 4 5 6 7 s ss c Yo AN er a
122. 1 1 rat TT E 24 V N Y 24V 200V TN lt p C 200V D 472 COOLANT UNIT PROBLEMS C Pump motor not rotating s No Reset turn ON motor breaker thermal relay Motor breaker thermal relay ON and confirm status If thermal tripped again check motor load Yes No Magnet switch ON Magnet switch motion related 24 V supplied
123. 205 Z Z N 2 3 5 MD GRT e Before performing the ATC recovery procedure confirm that the Z axis is positioned at the machine zero point If it is not return the Z axis the machine zero point according to the following procedure WARNING 2 Return the Z axis carefully To return the Z axis to the machine zero point the axis interlock must be released Since the axes can be moved even if the ATC arm is not in the home position during interlock bypass ON M31 component interference may occur Do not approach moving parts during operation Procedure 1 Check if the status indicator Z is illuminated If it is the Z axis is at the machine zero point Move to ATC Recovery Operation page 205 If the Z axis is not at the machine zero point return the Z axis to the machine zero point by following th
124. 4 t 5 T 4 C D No 168 170 168 169 170 168 COOLANT UNIT PROBLEMS C Coolant Unit Problems D 1 Coolant pump in operation yee Yes Y Enough Coolant 8 Yes Y Yes C Check Valve Clogging 4 No Coolant Pump Strainer Clogging 5 No t Yes Spindle Coolant Nozzle Clogging Contact the Mori Seiki Service Department for assistance No Y Contact the Mori Seiki Service Department for assistance No Refer to D
125. 146 SEMI DRY CUT SYSTEM OPTION 27 SEMI DRY CUT SYSTEM OPTION 21 1 Adjusting the Oil Supply Quantity 2 pari 2 n C c E 0 4 0 6 MPa 0 5 MPa Normally set the oil regulating knob at 2 Oil consumption with the oil regulating knob set at 2 varies according to the diameter of the nozzle or the oil hole as shown in the chart below Adjust the setting with the oil regulating knob in accordance with the cutting conditions C note The supplied air pressure should be 0 4 to 0 6 MPa 0 5 MPa recommended Oil consumption with oil regulating knob at 2 gt 2 gt
126. PLC PLC T x lt Numerical controller NC related alarms including failed programming servomotor or servo amplifier malfunctions Ifa NC alarm occurs The screen automatically changes to the NC ALARM screen which displays the alarm number and the message Eliminate the cause of the alarm by confirming the details of the alarm message on the screen then press the Z RESET key Note If a PLC alarm occurs while the NC ALARM screen is displayed PLC alarm indicator at the top right hand side of the screen flashes red Refer to the NC manufacturer s manual for details 1 2 PLC EX PLC Alarm Alarm Starting with EX PLC ES
127. REGULAR INSPECTION LIST 53 118 2000 120 124 1 2 1 76 2 138 3 6 ATC 80 ATC 83 86
128. The ATC main arm must be at the home The front door must be closed position 17 7 Recovery Operation AN ATC 204 3 ATC FIR 1 2 3 4 5 6 e N CAUTION 1 When operating ATC manually confirm the start 3 lt conditions for each operation Confirming Start Conditions for ATC Operation page 20
129. gt 1 g Z70 0001 X 2 QD 135 3 The recovery procedure for the alarm Z70 ABS ILLEGAL 0001 X Axis name is outlined below using the X axis as an example lt Procedure gt 1 Press the function selection key 2 MESSAGE and confirm that Z70 ABS ILLEGAL 0001 X is displayed at the upper left of the screen 2 Replace the batteries Replacing Batteries page 135 3 Set ZERO POINT SET to VALID using the following procedure gt 15 Function selection key SETTING OPE PANEL gt OPE PANEL gt Next Page OO lt gt AN NN
130. red amp gt ac XE ED SAMT ze SSES ss s POWER L1_L2 Do i S Met e lt 118
131. Y h y C p No 88 89 HYDRAULIC UNIT ALARMS 163 Hydraulic pressure setting is 7 MPa No Yes Switch may be malfunctioning Contact Mori Seiki Service Department for assistance No Replenishing hydraulic oil Hydraulic oil level sufficient Yes 1 Tighten connections Oil leakage visible 2 If hose is damaged contact Mori Seiki 3 If oil is leaking from pump contact Mori Seiki No Cleaning suction strainer 2 J Recovery No recovery C If alarm condition not released contact the Mori Seiki for assistance No Refer to D Checking Oil Level Replenishing Cil page 88 Cleaning Suction Strainer and Tank page 89 164 HYDRAULIC UNIT ALARMS 5 2 EX0568 SJ
132. 2 For the SMC manufactured tank use oil with a viscosity of ISO VG32 or lower Machine damage 25 CHAPTER 2 TROUBLESHOOTING 10 11 12 13 14 15 16 17 aus u uso esconde bn tru rn mue ua en auqa uqa ALARM MESSAGE eC cA INPUT OUTPUT SIGNAL CONFIRMATION PROCEDURE PRSE MALFUNCTIONS AT MAIN POWER ON aaa aa Qasapaq aduana anak WHEN BATTERY REPLACEMENT REQUESTED MELY FOR Taini aien a a A E AN A aa HYDRAULIC UNIT ALARMS vue a OS E A E een a A usa a s COOLANT UNIT PROBLEMS Pp p mama Torr E E E ETA LUBRICATING UNIT ALARMS DFAT Oe CMS FAN COOLER ERRORS amie 1 2 NUN OIL TEMPERATURE CONTROLLER ERRORS osos uM UM E UE ALARMS RELATED TO PNEUMATIC DEVICES EE CHIP CONVEYOR OPTION ALARMS ZERO POINT RETURN COMMAND ALARM TRIGGERED EP A tie cca V ZIA ene an ner eR ER dS SOFT OVERTRAVEL ALARM w J222 Ve mds PS aaa ya SPE eo ALARMS RELATED TO TOOL CLAMPING TARKOITIN FWE E IUE E E us tas nane ee nois idet
133. 3 CC 4 Oil air is a mixture of lubricant supplied from the lubricating tank and air supplied from the pneumatic device to lubricate the spindle bearings To ensure optimum spindle bearing service life check the oil air lubricant flow daily zuze Observation Window JHIES Mixing Valve 3 Lubricating Unit DANGER 1 Do not check oil air lubrication when machine is in operation 2 Select the handle mode and take steps to ensure other personnel do not operate the machine during this procedure lt Procedure gt 1 Remove the three bolts securing the air panel and open the air panel 2 Press the manual lubrication button 3 Check that oil air lubricant is flowing through the hose while pressing the manual lubrication button 3 C note The mixing valve is mounted on the back side of the air panel 4 Remount the
134. gt 7 2 C 3 a O b O O O Ring Tighten d Jom pu Case C note Contact the Mori Seiki Service Department and state the part No indicated in the table above when ordering the line filter and filter element Filter Element Case C note The location of the line filter may differ depending on the machine model Procedure 1 Turn OFF the main power 2 Remove the case from the head by turning the hexagonally shaped part at the bottom of the case counterclockwise with a spanner C note Put the drain
135. note value in the parameter chart attached when shipping 1 Parameter values differ depending on the machine type Refer to the Parameter TMR1 and TMR2 values are correct Yes Pressure switch or other oil air pump wiring pump electrical cabinet sid No side and e loose No Parameter must be reset Contact the Mori Seiki Service Department for assistance Repair wiring E Reco very No recovery Spindle oil air switch wiring connection malfunction Contact the Mori Seiki Service Department for assistance LUBRICATING UNIT ALARMS 178 Checking Lubricating Unit Operation 7 4
136. indicated below Perform maintenance and inspections by following the inspection intervals below 84 88 97 107 146 148 70 81 a T
137. 2 OT 1 gt 1 2 3 2 4 5 6
138. 74 187 73 98 123 31 112 97 65 26 111 65 107 74 107 D 108 FOR 4 104 178 0 107 A AAA TO AEA s BH 70 152 47 T 40 TA 132 66 132 A A A 140 153 154
139. MAINTENANCE MANUAL Applicable Model NVX5060 40 NVX5060 50 NVX5080 40 NVX5080 50 NVX5100 40 NVX5100 50 Jt Applicable NC Unit M730BM MSX 853IV M750BM MSX 855IV Before starting operation maintenance or programming carefully read the manuals supplied by Mori Seiki the NC unit manufacturer and equipment manufacturers so that you fully understand the information they contain Keep the manuals carefully so that they will not be lost MORI SEIKI THE MACHINE TOOL COMPANY ris HX NVX5000 4 E0JPEN 2011 06 Y d
140. 2 3 4 a AN CUN DR NC b c d e 5 O C O 6 6 1 2 3 4 5 6 When an air gun is used protective glasses must be worn to prevent eye damage from chips those who wearing glasses included Filter Stop the high pressure coolant pump Remove the hex bolts securing the cover and remove the cover Pull out the filters Pull the filter and remove it from the cover part
141. NC E f gx x J ab CA pie H p EU Cuc PH It is recommended to install the automatic fire extinguishing equipment as the fire extinguisher As for the capability selection or warranty consult with the manu
142. WHEN BATTERY REPLACEMENT REQUESTED 157 4 WHEN BATTERY REPLACEMENT REQUESTED NC When the screen displays the message requesting battery replacement or any of the battery low voltage alarms change the NC memory back up battery and the servo absolute position sensing battery Continued usage of the machine without replacement of the batteries while the alarms are displayed may cause the memory data and servo motor position data to be lost Message Requesting Battery Replacement 4 1 AN N NC
143. gt s 47 1 gt MDI SO lt gt
144. 91 2 135 140 5 67 EE Inspection Item nterval Replenishing ATC Unit Tank Oil page 81 Replenishing Unclamp Unit Tank Oil page 84 Checking Oil Level Replenishing Oil page 88 for Hydraulic Unit Lubrication Replenishing Coolant page 97 Replenishing Lubricant page 107 Replenishing Oil for Semi Dry Cut System page 146 Option Replenishing Oil for Oil Shot and Oil Mist page 148 Option Replacing Machine Light page 70 Replacement Replacing O Ring of Retention Knob for Center Through Through Spindle Coolant Specifications page 79 As Required Adjusting Coolant Discharge Rate page 103 Adjustment Adjusting Shower Coolant Discharge Rate Option page 103 Adjusting Additional Tool Tip Coolant Discharge Rate Option page 104 Adjusting the Oil Supply Quantity for Semi Dry Cut System Option page 146 Cleaning Cleaning Coolant Gun page 105 Option Manual Draining from Pneumatic Device Air Filter page 123 Cleaning Line Filter page 101 CLEANING OPERATION PANEL page 72 Confirmation PREPARATION FOR MACHINE OPERATION AFTER PROLONGED IDLE PERIOD page 65 R
145. IA Sc E qH
146. 3 Do not touch any rotating part make sure that the part has stopped rotating before touching it Entanglement Serious injury 4 Do not try to remove chips from the workpiece and tool while the spindle is rotating Entanglement Serious injury 5 5 Cover your hair and do not wear loose clothing or jewelry to avoid becoming entangled or caught in the machine Always wear safety shoes when operating the machine Entanglement Serious injury 6 6 Donotleave any tools or instruments on the operation panel or on any moving part of the machine 7 7 Donotlean against the machine while it is operating Leaning on the covers can be very dangerous 5 6 Tooli
147. AN d 9 cm pm mme recessu 7 0 N CAUTION Clamp the suction pipe with a pipe wrench and turn the suction strainer CCW using a monkey wrench If the suction strainer is turned without being clamped with a pipe wrench the suction pipe will be turned simultaneously causing oil leakage b Clean the suction strainer with kerosene N CAUTION Use caution when using kerosene and make sure there is no open flame in the vicinity c Dry the suction strainer using compressed air N CAUTION Protective glasses must be worn to prevent eye damage from dust or foreign matter those who are wearing glasses included d Apply sealing tape to the threade
148. R1 2 mm 3 0 mm 7 07 mem d 12 4 1 6 mm 2 01 i 73 1 0 mm 0 79 dein 2 0 8 0 8 mm 0 50 em P 0 2 QO 21 2 Replenishing Oil gt 7 2 Oil Holes Diameter of Cross Sec with the Oil Con Oil Hole 1 tion of Oil Same sumption oil hole Hole mm2 Cross Sec cc h tion 3 0 mm 7 07 DU 12 4 1 6 mm 2 01 dan e 7 3 1 0 mm 0 79 M i 0 8 0 8 mm 0 50 mm 0 2 For details refer to the manual supplied with semi dry cut sys tem Oil Regulating Knob Procedure 1 Turn OFF the main power SEMI DRY CUT SYSTEM OPTION 147 C DET 2 3
149. The pot must be moved up e The tool must be clamped The STATUS indicator TOOL CLAMP tool clamp is lit ATC e The ATC shutter must be closed if featured 8 8 Fora sensor tool the spindle orientation has completed e The button lamp of the spindle rotation button ORT Spindle Orientation is lit 9 9 The machine is not in the synchronized tapping operation 10 ATC 77 72 T 13 10 There is no magazine or ATC related alarm The STATUS indicator ERROR error is not lit 11 The interlock functions are not bypassed The STATUS indicator ERROR error is not blinking 12 A T command is specified 13 A pot is po
150. 2 Press the x10 or x100 button as necessary if the distance to be moved is large However when the needle on the lever type dial test indicator is to be aligned with the measuring point always select the x 1 button X Measuring X Axis Direction Y Measuring Y Axis Direction Z Measuring Z Axis Direction 4 1 4 4 Stop rotating the manual pulse generator when the needle 0 turns 1 4 of a rotation and set the scale to 0 5 5 Display the CURRENT POSITION RELATIVE COORDINATE screen using the following procedure e Function selection key POS REL CO GL Separate volume OPERATION MANUAL CURRENT POSITION RELATIVE COORDINATE Screen a a Press ORIGIN b b Press ALL AXES X YZ 0 000 The incremental coordinate position data for all the axis X Y Z is reset to 0 000 6
151. NC 2 Donotopen the doors of the electrical cabinet the NC unit and the operation panel unless it is absolutely necessary Dust foreign matter and moisture may enter to the devices Machine malfunction 3 3 The machine cannot operate correctly unless the power is properly supplied If the power supply is momentarily cut off during machine operation due to a power failure or lightening the machine may operate unexpectedly In these cases turn OFF the main power immediately 5 3 Door Interlock Function
152. 2 90 ATC 100000 QO gt 1 2 3 Collet Draw Bar N CAUTION 1 Grease the tool clamp unit once every two weeks to maintain tool unit performance Even if two weeks have not passed replenish grease in either of the following cases Every 90 hours of operation 100000 rotations of the ATC Separa
153. 3 4 5 AWARNING EY Do not operate without shutting H60432A A WARNING DO NOT EXCEED THE SPEED LIMITATION OF A TOOL OR A TOOL HOLDER FAILURE TO FOLLOW THIS WARNING MAY RESULT IN A SERIOUS ACCIDENT H50433A X8 Keep all the doors closed while the machine is operating The area inside the front door contains many sources of potential danger e The spindle rotating at a high speed with a tool clamped in it e The table which moves along many directions with a number of workpieces e Splashing coolant and flying chips While the spindle is rotating do not open the doors to remove chips or touch the workpiece and tools Serious injury Do not remove the covers unless absolutely necessary Do not start machine operation without the safety devices in place
154. 4 Before placing rags the conveyor belt to clean stop the chip conveyor gt N CAUTION 1 1 Do not operate the chip conveyor intermittently 2 2 The chip conveyor cannot carry materials larger than cutting chips C C note 1 1 Close the door before starting the chip conveyor operation 2 2 Carefully consider the appropriate cutting conditions to generate chips which can be removed from the machining chamber 3 3 When operating the chip conveyor pay careful attention to the followings Check if there is any foreign matter on the chip conveyor belt Check if too many chips have accumulated on the chip conveyor belt Check if there i
155. EMF M01 0007 gt 7 2 3 4 5 M01 OPERATION ERROR 0007 lt To Cancel the Alarm State gt 1 Read the alarm number and message displayed on the screen Place the INTERLOCK MODE key switch in the NORMAL position 3 Close the front door 4 Select a manual mode 5 Feed the axis that caused the soft overtravel alarm in the opposite direction away from its limit For this operation use handle feed jog feed or rapid traverse mode The alarm state is cleared 194 ALARMS RELATED TO TOOL CLAMPING 14 ALARMS RELATED TO TOOL CLAMPING EX0021 EX0165 EX0166 When an alarm EX0021 EX0165
156. O 79 103 si 103 104 146 105 x 123 101 72 m 65 67 m 70 74 137 73 91 is 110 123
157. cannot be determined contact the Mori Seiki Service Department or the cutting tool manufacturer Workpiece ejection Machine damage 2 2 Note that machining conditions vary in accordance with the status of the work cutting tools or fixture Conditions determined by automatic programming are not necessarily the most suitable for individual user s purposes Determining operating conditions is the sole responsibility of the customer Workpiece ejection Machine damage 3 3 Programmer must create an easy to read and thoroughly checked program in order to prevent the machine operator from
158. gt lt Procedure for Replenishing ATC Unit Tank Oil gt 40 Taper No 40 Specifications D lt Cover E _ 9 LIT we Fill Port Plug Oil Level Gage ATC UNIT ATC 82 50 Taper No 50 Specifications Machine Cover A Oil Level Gage D 4 F NI i p D nc O mer ire Fill Port Plug tr e x4 J Extension Rail ATC ATC ANN ATC Unit 1 1 Turn OFF the main power 2 2 Remove the machine cover 3 3 Remove the fill port plug 4 4 Pour oil while checking the oil level gage 5 5 Remount the fill port plug and machine cover ATC ATC UNIT 83 lt ATC
159. gt 1 2 3 4 5 6 7 8 oil Level Gage Machine Cover Procedure for Replacing ATC Unit Tank Oil Fill Port Plug 1 2 3 4 5 6 7 8 4 Machine Cover Drain Plug Turn OFF the main power Remove the machine cover Remove the drain plug and drain all oil from the tank Wrap sealing tape around the threaded part of the plug Replace the drain plug Remove the fill port plug Pour oil while checking the oil level gage Remount the fill port plug and machine cover 84 UNCLAMP UNIT 11 UNCLAMP UNIT 11 1
160. 133 133 27 5 135 131 132 132 40 134 27 42 146 154 O BAe DEG 79 149 72 152 193 178 101 196 157
161. E A Figure A Electrical Cabinet Parts Layout 3 1 Screen Not Displayed when Power Turned ON gt 7 NC KA7 GS1 652 Perform the following confirmation procedures Contact Mori Seiki prior to performing the procedures as specialized knowledge is required All procedures are to be performed with extreme care by licensed electrical technicians with maintenance experience in strict accordance with the recommendations of the Mori Seiki Service Department lt Confirmation gt 1 Plant side main breaker is turned ON N Main power is turned ON 3 When th
162. action in compliance with the instructions of operators 3 3 For queries or concerns related to the contents of the instruction manuals circuit diagrams and ladder diagrams contact the Mori Seiki Service Department for assistance 4 ERERARBHOO F2 Z Ju WA e ZL BE CDW TIA 4 4 Ifthe cause of a problem cannot be determined or if it cannot be remedied contact the Mori Seiki Service Department for assistance gt Maintenance Inspection Sequence Daily Oil Replenishment and Inspection by Machine Operator Maintenance and Repairs by Maintenance Engineers Service Request Call to the Mori Seiki Service Department 52 REGULAR INSPECTION LIST 2 REGULAR INSPECTION LIST that require regular inspection and maintenance are
163. 3 C Perform the spindle warm up periodically to ensure optimum bearing service life N CAUTION 1 Do not rotate the spindle without a tool clamped in the spindle Machine damage 2 Perform the spindle warm up below the maximum permissible rotation speed of the tool and fixture Workpiece ejection Serious injury Machine damage 3 Ensure that the tool and fixture mounted securely before performing the spindle warm up Serious injury Machine damage Daily Spindle Warm Up After turning on the power perform the spindle warm up referring to the table below before operating the machine C note Adjustthe rotation speed for warm up based on the maximum rotation SW RAO
164. 5 Wrap sealing tape around the threaded part of the plug 6 6 Replace the drain plug 7 7 Remove the fill port cap 8 8 Pour oil while checking the oil level gage CL SHAR 58 QJ For oil types refer to OILS page 58 9 WHOS vv FEMORIS 9 Remount the fill port cap 10 70 Turn ON the main power and confirm the pump generates a Suction sound 11 11 Turn OFF the main power and check the oil level 12 72 If the oil level is still low add oil again 13 73 In built in type remount the maintenance cover 122 OIL TEMPERATURE CONTROLLER 163 Flow of Cooling Oil and Positions where it is Used Oil Temperature Controller a Spindle Head FERE PNEUMATIC DEVICES
165. CO emm A DANGER Gww sFTsksuc s cw sa Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury N CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor injury or damage to the machine Failure to observe the precautions hazards warnings and cautions will lead to the hazards indicated in square brackets injuries or machine trouble C note Indicates items that must be taken into consideration CD Indicates items to be referred to 2 Indicates hints Example Indicates program applied examples CONTENTS FOR SAFE MACHINE OPERATION REGULAR MAINTENANCE TROUBLESHOOTING INDEX CONTENTS FOR SAFE MACHINE OPERATION OR AN DB tee aaa 19 FOR USERS AND SUPERVISORS D MESSAGES S Cuna
166. Discharge Rate Adjusting Valve 11 7111414 prr r7 62112112 Normal Coolant Injection Coverage Without Tool Tip Coolant Additional Coolant Injection Coverage With Tool Tip Coolant A DANGER Turn OFF the main power N CAUTION Adjust the nozzle position to prevent interference with the ATC arm or the tool during ATC arm rotation Procedure 1 Turn OFF the main power 2 Turn the discharge rate adjusting valve by hand to adjust the shower coolant discharge rate C note 1 The discharge rate is decreased as the valve is turned CW and increased as the valve is turned CCW 2 If tool tip coolant is unnecessary turn the valve CW to the end to stop the coolant supply COOLANTUNIT 105 Coolant Gun Option AN C 13 9 Ht
167. MAGAZINE DOOR LOCK FIN SQ143 amp MAGAZINE DOOR CLOSE amp LOCK FIN 64 LIMIT SWITCH SOLENOID VALVE INSTALLATION POSITIONS ET re ns Functions SQ401 X77 4 4 AXIS CLAMP CHECK OPTION SQ403 X93 5 5 AXIS CLAMP CHECK OPTION SP148 X78 1 HIGH PRESSURE COOLANT FILTER CLOG1 OPTION SP149 X78 2 HIGH PRESSURE COOLANT FILTER CLOG2 OPTION SP149 X79 PCF HIGH PRESSURE COOLANT PCF PUMP FLOAT SWITCH OPTION 0547 X7B HIGH PRESSURE COOLANT FLOW SW
168. Replenishing Replacing Unclamp Unit Tank Oil DANGER Turn OFF the main power AN N CAUTION 1 1 Perform the maintenance work for the unclamp unit from the machining chamber Take due care not to damage the table while performing the maintenance work 2 2 If the oil level continues to decrease following replenishment contact the Mori Seiki Service Department for assistance 58 CD For oil types refer to OILS page 58 gt lt Procedure for Replenishing Unclamp Unit Tank Oil gt 1 Z Movethe spindle head along the Z axis in the negative direction to the stroke end 2 2 Turn OFF the main power
169. X 6 Measure the X axis backlash using the following C 1 1 2 a X 0 050 X b X 0 000 X c g 0 013 X 0 050 c X X 0 000 c X 0 004 c
170. E 88 3 nu cys S Us jme 89 2 4 Item Status Cause Reference Items Recovery Procedures Checking Oil Level Replenishing Oil page 88 Pressure Does Low Oil Level In Tank Replacing Oil page 88 Not Rise Suction Strainer Clogging Cleaning Suction Strainer and Tank page 89 Air Entry Into Piping Item 4 2 Pressure Item 1 Fluctuation Pressure Gage Reading Abnormal When necessary to replace the pressure gage contact the Mori Seiki Service Department for assistance Hydraulic Oil Viscosity Inappropriate OILS page 58 Checking Oil Level Replenishing Oil page 88 Abnormal Low Oil Revelan Tank Replacing Oil page 88 i Lae Suction Strainer Clogging Cleaning Suction Strainer and Tank page 89 Pressure Fluctuation Item 2 Pump Component Damage Wearing Contact
171. OIL AIR LUBRICATION AIR SUPPLY YV4011 SCALE AIR BLOW OPTION YV5311 Y58 THROUGH SPINDLE AIR BLOW OPTION YV2340 Y4D AUTO DOOR OPEN AUTO DOOR SPEC YV2341 Y4E AUTO DOOR CLOSE AUTO DOOR SPEC YV121 Y7A OIL MIST OPTION YV131 Y7C OIL SHOT OPTION YV2281 Y79 OIL AIR LUBRICATION SIR SUPPLY YV6471 Y77 THROUGH SPINDLE AIR CHANGE OPTION PREPARATION FOR MACHINE OPERATION AFTER PROLONGED IDLE PERIOD 65 6 PREPARATION FOR MACHINE OPERATION AFTER PROLONGED IDLE PERIOD s n fF Perform the following operations after machine has been idle 2 for two days or more Full Stroke Travel of Axes Two Days or More Operations Machine Idle Period Re
172. IMPORTANCE OF INSPECTIONS Daily inspection by operators and regular inspection by maintenance engineers are the keys to long lasting machine accuracy Prior to inspection confirm the following points 1 Any abnormality discovered during daily inspections must be reported to maintenance engineers Repair or replacement is to be performed immediately 2 2 Maintenance engineers must take immediate and proper
173. P m N 2 The window is constructed with 2 layer of toughened glass and polycarbonate that prevents from being crashed through When cleaning the machining chamber observation window remove any smudges from the inside and outside of the window using a detergent soaked cloth DANGER Always turn OFF the main power and disconnect the power supply breaker of the plant side before cleaning the machining chamber observation window N CAUTION When cleaning the machining chamber observation window use commercially available neutral detergent without abradant or alkaline material or detergent for glass that satisfies the following conditions The detergent must be free of constituents with adverse effects on human beings such as offensive smells or those that cause skin irritation The detergent must not cause hardening dissolution or swelling of the polycarbonate
174. Precautions when Operating Special Specification Machines 2z oe F lt gt NC 36 31 SICK SKU 3 1 4 1 5 1
175. Single Solenoid Valve Spindle Air Purge Tool Tip Air Blow Single Solenoid Valve Taper Air Blow Double Solenoid Valve ATC Shutter Opening Closing Cylinder Double Solenoid Valve Pot Up Down Cylinder 127 Q41141 001 1 2 PNEUMATIC DEVICES Air Circuit Diagram 17 5 H Wonisod euuou sejeoipur Byer T yl L1 1G92AA OS9ZAA 1 wel j 5 1685 ZALIN eros S ggg 9dW0 1 pag PAWO I 36 07 1 190 m0 1 190 i 0 1 3 90 m 4 92 1 3010 a 12878 fk ___ PEAN E E 9 T m 1 1 spel edWo l rt EH 1 g4 1
176. s sp Dieta Br 1 sm 0 No 190 WHEN BATTERY REPLACEMENT REQUESTED 161 Press the RESET key when the machine operation is in ready status and the status indicator MRDY machine ready is illuminated Is the battery alarm displayed No Display the screen requesting battery replacement TumOFFtheNCpower Function selection key SYSTEM Y Turn OFF the main power Press CONFIRM on the requesting battery Turn back ON the main and NC power replacement screen The ACCUMULATE TIME field becomes 0 and the LAST INSPEC DATE field displays the date in Y PERIODICAL INSPECTION 1 screen Is the alarm Z70 displayed No Yes Y Is the alarm Z70 displayed Establish each axis zero point No Yes 1 Establish each axis zero point 1 Y Display the PERIODICAL INSPECTION 1 screen Function selection key SYSTEM gt Y PERIODIC INSPECT Recovery Recovery Move the curs
177. 3 Turn the electrical cabinet door interlock key switch to the ON Main Power Switch in Electrical Cabinet Main Power Switch on Inside of Door 18 3 Cleaning Back Fin Filter Back Fin Filter Ad WARNING 1 a TurnOFF the main power and disconnect the plant side power supply breaker AN N CAUTION 1 1 Dustand dirt may damage the filter and prevent air flow Clean the filter periodically 2 2 Do not wash the filter by hand Filter damage 3 5 10 3 The filter may gradually deteriorate after being cleaned
178. LUBRICATING UNIT ALARMS 7 1 EX0557 EX0557 OIL AIR LUBRICANT PRESSURE LOW E EY CU a I d 7 C l gt No 58 108
179. edW2 2 0 1 0 Aemapiis SKV A g SIXV A IO SV JB A Jo ed 8 0 18S ircuit Diagram LUBRICATING UNIT Lubricating Oil C E 14 6 112 CkaAMedN 145 Ex dN we ZHO9 0S 0 1 1 07 vg vju 321 0 1 0 ido oewoyny Cris ERE Ed uoneledo onewoyny csi iE 9 1045 Lo9LO 9x 4 amp Er aaro 1 0 1 0 70 A N87 TON MODS e SV X GIO Skv X 4ewepls skyX i 3 5 UNL BEX EER X ae Xe 1 2 0 1 1 0 v 0 1 1 0 v LX YS Loy o 9 1045 192900 1908 109900 91908 1 20900 LEY GER 1 0070 9 4 E 100500 be AEA 109900 9 4 GEK 12900 HS fans m 1 i 1 y ee p e M M X W M M X M M 6uiaoa apis Jepun sixy z pe epis dd sv Z I ORL B Z FRITZ 1 1 TIN MODS ed shw Z do 7ewepliS epis 12ddn shv Z 7 Y
180. 124 E gt 186 gt 186 gt 0 4 MPa 0 4 MPa 0 4 MPa Pneumatic Devices gt
181. 3 A See a 8 4 3 Loosen the lock nut of the take up bolt 4 Turn the take up bolt CW to the end and tension the belt enough 5 Return the take up bolt about one and half turn CCW Adjust the right and left tension of the belt equally 6 Ifthe gap between the main chain gear and frame B is not even readjust the take up bolt 7 Tighten the lock nut 8 Remount the parts and covers Y Y Strainer Filter 22 Plug A Relief Pipe WARNING Turn OFF the main power Procedure 1 Loosen the plug and disconnect the relief pipe 2 Remove the orifice and the filter 3 Check the filter and clean it using a steel brush if it is clogged with chips N CAUTION When using a compr
182. Spiral Conveyor 7 Shift the spiral conveyor to replace the tray CHIP CONVEYOR OPTION 143 C 8 8 C 1 2 2 Y As EE SP SET Y BH 9 Tray 7 0 11 12 2 8 C note Pay attention so that the spiral conveyor will not interfere with the coolant tank 8 Remove the 8 bolts to remove the tray 8 note 1 There two trays at the front and the back 2 Depending on the positions of the bolts move the Y axis
183. OIL TEMPERATURE CONTROLLER ERRORS CD For details refer to the manual supplied with oil temperature controller lt 8 gt 23 id pr amp c ER ad lt J L1 L2 i 2 7
184. Y Z X Axis Scale Y Axis Scale Z Axis Scale cx MN 09 9 K 90 L min Rated Flow 90 L min T 0 05 Ma 0 2 Set 0 05 MPa MPa Max Permissible 1 Pressure 0 2 MPa 1 well YV4011 8 t 1 0 OMI Table Mount Sensor Air Blow Optical Sensor Air Blow OMI Side n 7 Option Option Draw Back Cylinder IN Option 50 20 0 1 7 15 mm 0 1 Set 0 1 sec Travel 15 mm Set 0 1 sec 8 t 1 0 98 t 1 0 0 8kN m 1 0kN 1 0MPa 1 0MPa ih oup UP DOWN 5 1 YV2021 i 6t 1 0 6t 1 0 ke Black Black 1 0MPa 1 0MPa A B NM CN Draw Back Cylinder DOWN NU YV6450 5 LD xindicates home position 130
185. o N Co
186. 009F n 158 ATC 205 ATC 200 Y ATC 80 MD pc UN E Y 139 ATC 81 Z B Z52 000 158 BTUBT 2 270 0001 n 158 771 0001 n 158 C Z73 0001 n 158 Capto 77 E 125 89 EX0069 155 a EX0451 154 88 om RA EX0557 ORA 146 174 180 EX0559 175 EX0560 186 EX0560 186 EX0561 APY 162 EX2561 158 EX0566 EX2562 NC 158 ds 101 S52 009F n 158 EX0567 176 252 000 158 EX0568
187. FIRE PREVENTION AND COUNTERMEASURE 23 machine may operate unexpected manner causing damage the machine e Managers or supervisors must report the fire to the fire department 24 SAFETY DEVICES 4 SAFETY DEVICES xs N w A a o
188. Deficiency in tension if the belt is stretched as indicated by arrow M S Tight Side Stretch Lock Nut WARNING Turn OFF the main power before take up adjustment Entanglement of hands or feet Serious injury Procedure 1 Remove the headend cover movable chain guide and headend panel in this order 2 Loosen the bolt A CHIP CONVEYOR OPTION 139 3 4 5 1 5 C 6 B 8 19 5 Y Y Strainer Check and Cleaning gt 1 2
189. MSDS N 7 N w A a o 2 injuries and machine damage by fire Mori Seiki is not responsible for accidents and fires arising from disregard for the warnings 1 Do not use a flammable coolant such as an oil based coolant that may catch fire If there is no choice but to use a flammable coolant it is the user s responsibility to deal
190. 3 2 3 4 Procedure After Disassembling Cleaning Lubricating Unit Relief Valve gt 1 Mount the reassembled relief valve on the pump 2 Remove the line filter discharge piping 3 Soak the suction filter in lubricant in the tank 4 Bleed air from the piping by pressing the manual lubrication button C note Continue to press the manual lubrication button until lubricant is discharged to ensure residual air is removed from the piping 5 After air removal is completed insert a plug into the pump discharge outlet Procedure When Lubricating Unit Abnormal Pressure Alarm is Triggered by Piping Abnormality gt 1 Press the manual lubrication button for more than 10 seconds 2 Repeat step 1 above 3 or 4 times at intervals LUBRICATING UNIT ALARMS 179 3 1 0 1 2 MPa 7 6 Relief Valve Disassembly Cleaning
191. IDA IL fg 58 Spindle Lubricating Unit Remove the fill port cap and pour oil while checking the oil level using a dedicated oil can N CAUTION 1 Use only clean oil 2 When refilling never remove the strainer Gn For oil types refer to OILS page 58 14 2 Cleaning Lubricating Unit Line Filter Pressure Gage Line Filter Filter Element zw HL E Pressure Gage Line Filter WARNING Turn OFF the main power 108 LUBRICATING UNIT gt 1 2 3 AN 7 2
192. Q40238 001 YV701 gt lt P 1 2 Rc3 8 2 Rc3 8 T T B els 2 Rc3 8 2 Rc3 8 72478 Plugged SP2 a Y Rc3 4 757 Rc1 2 Rc3 4 Plug o af n imme Lj Surfaca C i Gage pd g Tas rE lt PS ON 16 1 re s TOOL UNCLAMP ON If Oil Level Reaches the Lower Limit 16 L z m C3 Iu gt 20L Hydraulic Unit o Indicates Home Position No Symbol Order No Parts Name Model Q ty Maker S I 1 U00241C HYDRAULIC UNIT AZH 0676 021 1 hd de FUJIKO gee L AJB 2 PRESSURE GAGE GV50 173X16MPa 1 ERRA 3 UVN 1A4 22 4 Q25 60638 1 NACHI FUJIKO UNI PUMP SHI KASA 4 ADAPTER 22 PG16 BUSHING 1 NEOFLEX HYDRAULIC UNIT 95 No Symbol Order No Parts Name Model Q ty Maker x 80l A 5 SL9 FLOAT SWITCH LSN 80L A M 1 ASK 5 EK 6
193. 1 2 3 4 5 6
194. 1 d Select the axis feed amount x1 with the axis feed amount selection button or switch e e Select the axis to be measured using the axis selection Switch 3 3 While observing the lever type dial test indicator rotate the manual pulse generator until the gage stylus is aligned with the measuring point C note 1 1 Take care not to rotate the needle on the lever type dial test 1 indicator more than a single rotation to prevent damage to the gage CHECKING CORRECTING INACCURATE MACHINING 197 2 x10 x100 x1
195. 70 the Z axis to where the Z machine zero point value Z becomes 0 by rotating the manual pulse generator Z Machine zero point return of the Z axis completed Interlock bypass mode is now invalid 11 GOO G91 G28 ZO Z 11 Command G00 G91 G28 Z0 to complete the Z axis machine zero point return 17 6 ATC Confirming Start Conditions for ATC Operation ATC When operating ATC manually confirm the start conditions for each operation AN N CAUTION 1 7 An ATC operation performed with ATC interlocks released will allow each operation without ATC start conditions causing machine interference When interlocks are released to perfo
196. For recommended recovery operation Confirming ATC Stopped Position in ATC Cycle page 200 8 8 Press the EXEC soft key C note AIC When rotating the ATC arm forward or backward follow the X X guidance massage and press the manual axis feed button X or X ATC ATC moves as requested 9 9 After completing manual operation press the EXIT soft key C C note ATC Before completing the manual operation ensure the ATC is in the ATC home position The ATC manual operation and automatic operation are not possible unless the main arm is at the home position 10 10
197. Change oil in oil tank if contaminated Oil not supplied when Oil level in oil tank too low Add oil Replacing Cooling pump operating Oil page 118 Low oil circulation with loud pump noise Viscosity too high Change oil and then check the oil Replacing Cooling oil temperature too low temperature Make sure the Oil page 118 machine is installed at a site within Separate volume the specified ambient temperature INSTALLATION range and free from direct MANUAL sunlight Environmental Conditions Relief valve clogged or Contact the Mori Seiki Service malfunctioning Department for assistance Pump or motor bearing damaged Contact the Mori Seiki Service Department for assistance QM80 PLC PLC alarm EX2551 THERMAL OVERLOAD TRIP 2 occurs when EX2551 2 the thermal relay QM80 of the fan cooler is OFF C C Note EX2551 QM63 EX2551 also occurs when the thermal relay QM63 for the coolant pump is OFF OIL TEMPERATURE CONTROLLER ERRORS 184 9
198. Remove dust and chips 5 5 Use a clean cloth to clean the spindle tapered section 6 6 Clean the spindle tapered section using a spindle cleaner BIG TEKUSA SC40 40 BIG TEKUSA SC50 50 Spindle Cleaner Ex BIG DAISHOWA SEIKI CO LTD BIG TEKUSA SC40 Taper No 40 BIG TEKUSA SC50 Taper No 50 7 HSK Lubricate the spindle collet Only when using an HSK tool holder CD For the lubricating method Greasing Tool Clamp Unit 76 page 76 76 SPINDLE 9 3 Greasing Tool Clamp Unit BT BT 2 BT BT Dual Contact Specifications GY S Gc e CONSO REA SE AN 2 1
199. gt X Gs 0 ed Cleaning Coolant Tank and Filters 4 FLESH Cou Chip Bucket Specifications page 99 Coolant Unit Mounted On Coolant Tank a Option page 101 Adjusting Coolant Discharge Rate Replenishing Coolant page 97 27 page 103 SOME HN Fs M Uem V Z ved ER Adjusting Shower Coolant Discharge 2 Rate Option 103 3 Pi 197 Adjusting Additional Tool Tip Coolant 04 Discharge Rate Option page 104 105 Coolant Gun Option page 105 65 Forced Lubrication page 65 107 Replenishing Lubricant page 107 Cleaning Lubricating Unit Line Filter js 107 page 107 Lubricating Unit Cleaning Lubricating Unit Tank Suction 72105 AOZ JL 2 OFS Filter and Fill Port Filter page 108 108 Che
200. 0 013 0 004 0 009 2 Z Os procedure note 1 to rotate the needle lever type dial test indicator more than a single rotation to prevent damage to the gage 2 When measuring the backlash specify motion in one direction only to position the axis a Turn the manual pulse generator to feed the X axis in the plus direction until the value on the screen reads X 0 050 b Feed the X axis in the minus direction until the value on the screen reads X 0 000 c Read the dial on the lever type dial test indicator and record the value Here the value on the dial is assumed to be 0 013 d Feed the X axis in the minus direction until the value on the screen reads X 0 050 e Feed the X axis in the plus direction until the value on the screen reads X 0 000 f Read the dial on the lever type dial test indicator Here the value on the dial is assumed to be 0 004 The difference between the values recorded in steps c and f 0 013 0 004 0 009 is the axis backlash 198 CHECKING CORRECTING INACCURATE MACHINING 7 8
201. 30 INDEX Page Page A CHECKING CORRECTING INACCURATE MACHINING 196 Abnormal Sounds emitted from Coolant Pump 172 Chip Bucket Specifications 97 Additional Tool Coolant Discharge Rate A Chip Conveyor Chip Conveyor Specifications 31 ption m CHIP CONVEYOR OPTION 137 Adjusting Coolant Discharge Rate 103 m CHIP CONVEYOR OPTION ALARMS 187 Adjusting External Chip Conveyor Belt Hinge with Drum Filter Specifications 138 Chip Conveyor Specifications 98 Adjusting Machine Level 196 Cleaning Air Filter and Condenser 119 144 Adjusting Shower Coolant Discharge Rate Option 103 Cleaning Air Filter and Radiator 117 Adjusting the Oil Supply Quantity 146 Cleaning Back Fin Filter 134 Air Circuit Diagram 127 Cleaning Coolant Gun 105 Air Filter Mist Separator Inspection and Filter Element Cleaning Coolant Tank Chip Conveyor Specifications Replacement 124 100 Air Pressure Inspection and Adjustment 123 Cleaning Coolant Tank and Filters Chip Bucket Air Remeval 178 Specifications 99 ir Ov Al Cleaning External Chip Conveyor 137 arm EX0560 AIR PRESSURE LOW 186 Cleaning Eine Filter 101 EX2561 SERVO BATTERY ABNORMAL 158 Cleaning Lubricating Unit Line Filter 107 EX2562 NC BATTERY ABNORMAL 158
202. 6 gt lt Step 6 gt 7 7 Remove the tank upper plate 8 8 Clean the suction strainer using the following procedure a a Remove the suction strainer FIR 7 8 gt Steps 7 8 gt Pipe Wrench Suction Pipe N 502 Tank Upper Plate NT Monkey Wrench Z s Suction Strainer HYDRAULIC UNIT 91 AN z s b AN ee EE cc
203. 7 2 8 9 70 7 Confirm all cables are properly insulated prior to Do not operate with wet hands DANGER machine operation Electric shock Electric shock Confirm no personnel or obstacles remain inside protective covers or close to rotating or moving parts before starting machine operation Entanglement Collision WARNING Do not change machine specifications parameters or modify the machine without prior consultation with Mori Seiki Impaired machine performance Machine service life reduction When operating noise may be produced change cutting conditions to limit the generation of noise or ensure the operator wears protective gear t
204. ER CS 06 1 ou Sines INDUSTRY 7 OIL RESERVOIR 20L 1 NACHI FUJIKO SHI t 7 4 i T 8 RADIATOR 3A92 001 1050 1 TRAD amp MASUDA FILTER AIR BREATHER 22 MANUFACTUR ING H at 6 6n 19 LEVEL GAGE MARUWA PUT ET 11 W12037A LINE FILTER DTII 04 30 15 JVRC1 2 1 YAMASHIN FIL TER 12 SP2 E66769A PRESSURE SWITCH PK6732 E30094 1 EFECTOR i 13 Yv701 U50587A EN AUS MKT 79041 023 1 MARUKA MACHINERY 96 COOLANT UNIT 73 COOLANT UNIT 13 1 Precautions when Selecting Coolant wz aza WARNING Disregarding the following warnings will result in serious
205. Procedure 1 Turn OFF the main power 2 Turn the two electrical cabinet door keys CCW to release the door lock Turn the main power switch to the OPEN RESET N CAUTION If the main power switch is in a position other than OPEN RESET the door cannot be opened Attempting to force the door open in this condition could damage the electrical cabinet door or the main power switch e 4 Open the electrical cabinet door Closing Electrical Cabinet Door with Main Power OFF Procedure 1 Turn OFF the main power 2 Pressing the part 1 shown in the figure below adjust the setting of the main power switch on the inside of the door to match the setting of the main power switch in the electrical cabinet 1 Main Power Switch on Inside of Door 3 Close the electrical cabinet door ELECTRICAL CABINET 133 C 4 2 9 o xs EE
206. 15 1 18 8 T 108 6018 362 639 1183 106 T 639 1160 201 519 1414 488 19 274 0052 TC 33 lt NORTH AMERICA SOUTH AMERICA gt DMG Mori Seiki USA MORI SEIKI U S A INC MORI SEIKI CANADA LTD MORI SEIKI MEXICO S A DE C V MORI SEIKI BRASIL LTDA EUROPE MORI SEIKI GmbH MORI SEIKI U K LTD MORI SEIKI FRANCE S A S MORI SEIKI ITALIANA S R L MORI SEIKI ESPANA S A MORI SEIKI Moscow LLC TEL 052 587 1811 TEL 03 5460 3570 TEL 0743 53 1121 TEL 0743 53 1125 TEL 0595 45 4151 TEL 047 410 8800 FAX 052 587 1818 FAX 03 5460 9610 FAX 0743 52 8713 FAX 0743 55 0489 FAX 0595 45 5417 FAX 047 410 8834 DMG MORI SEIKI Turkey DMG MORI SEIKI ISTANBUL MAKINE TICARET VE SERVIS LIMITED SIRKETI ASIA OCEANIA DMG MORI SEIKI Singapore DMG MORI SEIKI SOUTH EAST ASIA PTE LTD DMG MORI SEIKI Malaysia DMG MORI SEIKI Malaysia Sdn Bhd DMG MORI SEIKI Vietnam DMG MORI SEIKI Vietnam Co Ltd DMG MORI SEIKI Thailand MORI SEIKI Manufacturing Thailand CO LTD DMG MORI SEIKI Taiwan DMG MORI SEIKI Taiwa
207. 178 5 180 WARNING Turn OFF the main power Procedure 1 Loosen the nut and remove the adjusting screw spring and valve C note The valve guide cannot be removed 2 Clean the disassembled relief valve with compressed air and kerosene C Note Take care to check for dust contamination of the tapered section If scratches are visible on the tapered section of the relief valve replacement is necessary 3 Perform the above procedure in reverse to reassemble 4 Bleed air from the piping on Refer to Air Removal page 178 for details on bleeding air from the piping 5 Adjust the relief valve QI Refer to Relief Valve Adjustment page 180 for details on the relief valve adjustment procedure 180 LUBRICATING UNIT ALARMS 7 7 Relief Valve Adjustment 178 gt
208. 7 Thermometer Sensor Condenser WARNING Ensure that the power is turned OFF Procedure 1 Turn OFF the main power 2 Remove the air filter Pay sufficient care not to catch the thermometer sensor with the air filter C note The condenser is exposed when the filter is removed 3 Wash the air filter with a neutral detergent and tepid water not warmer than 40 degrees 4 Remove the neutral detergent using freshwater 5 Dry the air filter using compressed air 6 Clean the condenser fins using a brush or a compressed air 7 gun N CAUTION Protective glasses must be worn to prevent eye damage from dust or foreign matter those who wearing glasses included Remount the air filter OIL TEMPERATURE CONTROLLER 120 AN 16 2 Replacing Cooling Oil gt Oil Temperature Controller Maintenance Cover Reservoir Tank N CAUTION Do not forget reinstall the air filter prior to operation Built In Type
209. DC 3 6 V 132 7 8 1 0 A amp W N Confirm BATTERY REPLACEMENT accumulate time Remove the battery cover Replace the old batteries with new ones Change batteries with power supplied to the NC CD Opening Closing Electrical Cabinet Door page 132 In order to confirm the changing of batteries correctly measure the voltage on the back of the battery box e SERVO Absolute Position Sensing Batteries 3 6 VDC e NC Memory Back Up Batteries 3 6 VDC Close the electrical cabinet door CD Opening Closing Electrical Cabinet Door page 132 Mount the battery cover Move the cursor to BATTERY REPLACEMENT and press CHECK COMPLETE gt EXECUTE The setting in the ACCUMULATE TIME of the PERIODICAL INSPECTION 1 screen field becomes 0 and the LAST INSPEC DATE field displays the date CHIP CONVEYOR OPTION 137 19
210. Function selection key SYSTEM PERIODIC INSPECT 1 4 143 00010 N00000002 EAT 00010 N00000002 17 20 20 DS 3 43 DATA SVR E DIR PERIODICAL INSPECTION 1 som cam PERIODICAL CHECK ITEM ACCUMULATE TIME INSPECTION TIME kasr INSPEC DATE 1 p 2008 06 18 WEEKLY INSPECTION o 50 2008708718 3 0 pon 2008 06 18 THREE MONTHLY INSPECTION 0 500 2008708718 0 m 2008 06 18 SEMIYEARLY INSPECTION 0 1000 2008708718 1 0 2000 2008 06 18 YEARLY INSPECTION p 2000 2008706718 9504 43800 2009 01 02 MACHINING CHAMBER WINDOW 9504 43800 2009 01 02 z N CD suas 132 DC3 6V e NC
211. GL5 ATC HD 80W 90 808 90 80W 90 HD 80W 90 ay Hr OX SE P 7 UF DTE24 a NEW BIET I 32 ed L DX32 32 C B cun ey 2M No 3 2SP DX2 ae pets NEW ap eae 2M 2 r ieu 32 N E ZR sh EPO RO AP N O No 0 Recommended Oils Type Oil Supplied to Idemitsu Mobil Shell Castrol Daphne Lubricating Unit Tank for Mechanic Oil DTE Oil Light Tellus oil S32 Hyspin AWS 32 spindle 32 Tellus Oil 32 Lubricating Unit Tank for slideways and ball sc
212. Hydraulic Unit Installation Positions Hydraulic Unit 88 HYDRAULIC UNIT 12 3 Checking Oil Level Replenishing Oil Hind So OFF the main power and supply oil when the oil level is lower than the lower limit on the oil level gage lt Fill Port Cap nil Oil Level Gage 12 4 Replacing Oil IR 1 2 3 4 5 6 7 lt 2 7 gt oil Level Gage 8 9 70
213. NC v NC NC 77 AN 7 2
214. Y70 0 YV2300 3 SQ48 4 amp SQ49 Confirmation 1 The front door lock command is turned OFF Y70 0 on the PMC SIGNAL STATUS screen 2 The door lock mechanism coil YV2300 is OFF The door lock mechanism confirmation switch SQ48 is turned ON The door lock mechanism confirmation switch SQ49 is turned ON 5 X41 5 The front door lock completion signal X41 is turned ON on the diagnostic screen C C note SHAE Diagnostic screen s gt NC gt I F gt Function selection key I 0 SYSTEM NC SYSTEM gt PLC I F Diagnostic Screen Input signal address gt INPUT key
215. 3 Press the manual lubrication button for more than 10 seconds C note If the pressure rises when the manual lubrication button is pressed lubricating unit operation is normal If the pressure does not rise when the manual lubrication button is pressed the cause of this alarm is a lubricating unit abnormality CD Refer to EX0557 OIL AIR LUBRICANT PRESSURE LOW page 174 recovery sequence for further countermeasures Air Removal 7 5 gt 1 2 3 4 C 5 gt 1 10
216. CHIP CONVEYOR OPTION 19 1 Precautions when Using External Chip Conveyor ced WARNING 1 7 Do not operate the chip conveyor or perform maintenance and inspection tasks without reading and obtaining a thorough understanding of the contents of the chip conveyor instruction manual 2 2 Keep the chip conveyor instruction manual to hand in a safe place to enable immediate reference when operating the chip conveyor and performing maintenance and inspection tasks 3 3 not place hands or feet inside the chip conveyor during operation Entanglement serious injury 4
217. 7 2 U WARNING Disregard for the warnings below may lead to serious injury and machine damage 1 Only qualified technicians are to perform hoisting work 2 When two or more persons are involved in the lifting of workpieces or fixtures clear communication and cooperation is necessary 3 Use only wires shackles and jigs of the dimensions specified in the manual Furthermore lifting equipment used must be strong enough to support the weight of the load 4 Before lifting the workpiece or fixture check that it is held securely 5 Ensure the workpiece or fixture is well balanced in both the crosswise and lengthwise directions when raised slightly from the floor 6 When mounting or removing a fixture or workpiece at the setup station do not apply force in directions that will lift or tilt the pallet 7 When a p
218. O Replacing O Ring of Retention Knob for Center Through Through Spindle Coolant Specifications OULZZOES tve amp i7 2rktmhDIBEICXOzxs3 L Damage or wearing of the O ring may cause coolant leakage When tool holder is removed from spindle and magazine to perform tool exchange replace the O ring if it is damaged or worn n db Retention Knob A O JIS B2401 P 9 2 WO6009 O Ring JIS B2401 P 9 Type 2 Parts No W06009 gt Procedure 1 O 1 Remove the O ring from the groove of the retention knob using a tool with a sharp pointed end e g a small flat head screwdriver 2 O 2 Insert a new O ring into the groove C C note O Take care not to damage the new O ring ATC 80 ATC UNI
219. Adjusting Coolant Discharge Rate Fully Open KS y em Fully Closed Weer BAS the discharge rate adjusting valve by hand to adjust the coolant discharge rate C C Note When the valve is in the horizontal position fully closed coolant is not discharged The coolant discharge rate is increased as the valve is turned toward the vertical position fully open NY V 13 7 Adjusting Shower Coolant Discharge Rate Option Discharge Rate Adjusting Valve DANGER w OI m LPy Turn OFF the main power FIR Procedure 1 Turn OFF the main power 104 COOLANT UNIT 2 C
220. Coolant Pump Operation Check page 168 2 When the Coolant Pump is Not Operating page 170 Coolant Level Check page 168 Confirming Coolant Pump Flow Control Valve Setting Check Valve Clogging page 169 Coolant Pump Strainer Clogging page 170 Coolant Pump Operation Check C sgg 2 lt L 97 Check if the coolant pump is rotating the direction of the arrow on the pump C note If the pump is rotating in the opposite
221. Data 10 10 11 12 1Z QoS D MM ce or 41 Precautions when Operating Special Specification Machines NC 42 NC PROGRAM a a math nos 42 Before Creating Program IAE S DE 42 Cutting Conditions lici RR ant 44 MAINTENANCE AND INSPECTION pip aa DENN I anaku a s cee 46 DISPOSITION OF MACHINES CHAPTER 1 REGULAR MAINTENANCE 1 cg ioi Bee cscs cc PO 51 IMPORTANCE OF INSPECTIONS Pree hed TIN E t Wet 52 REGULAR INSPECTION LIST oou audatenel toits iere toute gh 55 MAINTENANCE ROUTE MAP BB euo s s sui ect su ub Auer i I 58 OILS SPRUE HAs p Dp 58 Recommended Oils 42 SALA uya Pe Nn ota tet late inte 60 Oil Equivalents UZwFRZXZA4 w 3 VL2Z4EFNUZBBBBRI tenenti trata 63 LIMIT SWITCH SOLENOID VALVE INSTALLATION POSITIONS shanka ea tale ait 63 Limit Switch Solenoid Valve List LE i RE 65 PREPARATION FOR MACHINE OPERATION AFTER PROLONGED IDLE PERIOD u oett mto 65 Forced Lubrication 6 2 SD BIO SEA s Ej BE ertet tros e
222. MORI SEIKI U K LTD Head Office 202 Bedford Avenue Slough SL1 4RY England Phone 44 844 800 7647 Fax 44 844 800 7648 Technical Centers London Birmingham MORI SEIKI FRANCE S A S Head Office Declaration of EC Conformity gt Mori Seiki declares that the machine tool shipped to Europe machining center or multi axis machine is designed and manufactured in conformity with the following requirements 1 EC directive Machinery Directive 2006 42 EC EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC 2 EN standards EN ISO 12100 1 EN ISO 12100 2 EN 50370 1 EN 50370 2 EN 60204 1 EN 12417 Machine Model Description of machine models is omitted because this manual applies to multiple machine models Manufacturer MORI SEIKI CO LTD 2 35 16 Meieki Nakamura ku Nagoya City Aichi 450 0002 Japan Contact Address for Inquiry Regarding Technical Files Parc du Moulin 1 Rue du Noyer BP 19326 Roissy en France 95705 Roissy CDG Cedex France Phone 33 1 39 94 68 00 Fax 33 1 39 94 68 59 Technical Centers Mori Seiki France Sud Est S A S Prague MORI SEIKI ITALIANA S R L Head Office amp Technical Center Via Riccardo Lombardi N 10 20153 Milano Italy Phone 39 02 4894921 Fax 39 02 48914448 MORI SEIKI ESPANA S A Head Office amp Technical Center Edificio Sant Cugat Trade Center Ill Avda de les Corts Catalanes 9 11 Entidad 16D 08173 Sant Cugat del Valles Barcelona Spain Phon
223. PNEUMATIC DEVICES No Symbol Order No Parts Name Model Q ty Maker 1 Men U40587A AEN VE VQ21A1 5Y0 C8 F X78 2 SMC 2 gt U44314A ss mi AR20 02BG 1 1 SMC 3 U40265A L s ide AS2001F 06 SMC 4 YV6450 U44378A NE NKN 02990 1 SMC 5 gt U45085A ra pee CQ2B50 15DZ 1 SMC ELECTRICAL CABINET 131 18 ELECTRICAL CABINET 18 1 Electrical Cabinet View NC NC Memory Back Up Batteries Main Power Switch Electrical Cabinet Door Keys SERVO Absolute Position Sensing Batteries AN N CAUTION When you approach the electrical cabinet step onto the shaded are only see the illustration below Slipping on the coolant tank could result in serious injury if you step outside the shaded area xt x 32 ELECTRICAL CABINET Opening
224. Replacing Machining Chamber Observation Window 2 1 E 1 1 5
225. WAO v 2 Fill Port Oil Level Gage Drain Pan Drain Plug Sealing Tape OIL TEMPERATURE CONTROLLER 121 gt A WAL lt Stand Alone Type gt ra Port Cap Oil Level Gage Sealing Tape Drain Plug AX WARNING Ensure that the power is turned OFF gt Procedure 1 1 Turn OFF the main power 2 2 In built in type remove the maintenance cover 3 3 Place a drain pan in front of the drain plug 4 4 Remove the drain plug and drain all oil from the tank 5
226. Yes Yes No Y Power supplied to motor C Magnet switch malfunction 3 Yes No C Motor malfunction C Confirm 24 V supply circuit protector D Y 200 V supplied to magnet switch lower terminal No Yes Check wiring connections between motor and magnet switch Y 200 V supplied to magnet switch upper terminal Yes Magnet switch malfunction No C Confirm 200 V supply breaker J 6 2 When Coolant is Spilled on the Floor Ilfcoolant is spilled on the floor one of the following maintenance inspections may not have been properly performed Perform the following inspections if necessary Y 139 Y Strainer Check and Cleaning page 139 For cleaning chip conveyor filter refer to the manual supplied with chip conveyor 6 3 Abnormal Sounds emitted from Coolant Pump
227. gt gt lt gt fF F gt KEEN Function selection key SYSTEM NC SYSTEM lt Mainte To Abs pos C 1 SET 2 0 10011 OF 3 No 10011 3 No 10011 5963000 5 963 C note 1 When the zero point position has been established the STATE display on the Actual Position Setting screen indicates Complete When the zero point position has not been established the STATE display indicates NG 2 Check that the value displayed on the Zero P of
228. holding fixture and workpiece are all tightened Securely Serious injury Machine damage by workpiece Tool ejection 9 9 Before starting the spindle carefully check that the cutting tool is mounted correctly and the spindle speed is appropriate Serious injury Machine damage by workpiece Tool ejection 70 10 When handling mounting removing or moving a heavy object use appropriate equipment such as a crane or a hoist Serious injury 36 MOUNTING WORKPIECES AND CUTTING TOOLS MOUNTING WORKPIECES AND CUTTING TOOLS Se SAN purge rre e rege err pa a E e e n re rt 1 2
229. 1 905 565 0234 MORI SEIKI MEXICO S A DE C V Head Office O Calle 4 n m 25 Local D 2 piso Fraccionamiento Industrial Alce Blanco Naucalpan Estado de M xico 53370 Mexico Phone 52 55 5359 8785 Fax 52 55 5359 4271 Technical Center O Monterrey MORI SEIKI BRASIL LTDA Head Office O Av dos Imar s 437 Indian polis CEP 04085 000 S o SP Brasil Phone 55 11 5543 1762 Fax 55 11 5543 1948 Technical Center O Curitiba The export of this product is subject to an authorization from the government of the exporting country Check with the government agency for authorization lt EUROPE gt MORI SEIKI GmbH Head Office Antoniusstrasse 14 73249 Wernau Germany Phone 49 7153 934 0 Fax 49 7153 934 220 Technical Centers Stuttgart M nchen Hamburg D sseldorf Chemnitz MORI SEIKI U K LTD Head Office O 202 Bedford Avenue Slough SL1 4RY England Phone 44 844 800 7647 Fax 44 844 800 7648 Technical Centers DL London Birmingham MORI SEIKI FRANCE S A S Head Office O Parc du Moulin 1 Rue du Noyer BP 19326 Roissy en France 95705 Roissy CDG Cedex France Phone 33 1 39 94 68 00 Fax 33 1 39 94 68 59 Technical Centers Mori Seiki France Sud Est S A S Prague MORI SEIKI ITALIANA S R L Head Office amp Technical Center Via Riccardo Lombardi N 10 20153 Milano Italy Phone 39 02 4894921 39 02 48914448 MORI SEIKI ESP
230. 12 13 LED LED Mounting Plate LED K LED Unit LED fat bo LED LED 4 LED ED LED ED ED 4 LED LED C A LED f E C LED Turn OFF the main power Wipe the coolant and chips off the external surfaces of the LED unit Remove the LED mounting
231. 2 SHUTTER CLOSE ATC SHUTTER CLOSE FIXTURE 8 POT UP POT UP X 46 2 qat 4 POT DOWN Por DOWN 5 ARM FORWARD ARM ZERO POSITION Y 0 O FIXTURE 6 ATC ARM BACKWARD TOOL CLAMP 1 uL 7 ORIENTATION ORIENTATION z 00 SCREEN OFF MANUAL VIEWER a 1 A TC ATC C note 1 The indicator of the CONDITION item on the screen is lit to indicate that the ATC is in that status 2 When the ATC is at the home position the indicators of ATC SHUTTER CLOSE POT UP ARM ZERO POSITION and TOOL CLAMP are illuminated ATC 206 POWER SUPPLY CUT OFF DURING ATC OPERATION 7 gt 7 the number heading the required operation and press the INPUT key CL ATC 200
232. 3 3 Remove the front cover of the spindle head Front Cover of spindle head UNCLAMP UNIT 85 4 4 Remove the fill port cap Fill Port Cap 5 6 Oil Level Gage 5 Pour oil while checking the oil level gage 6 Remount the fill port cap 7 Remount the cover 86 UNCLAMP UNIT gt 1 2 3 4 5 6 7 8 9 0 5 L Tank Capacity 0 5 L Sealing Tape Z
233. DRA YAY SD weet het enna cnt aides oaths Coolant Gun Option 24 4M SM A DARE PE Fa ss etate bringe tsm How to Use the Coolant Gun Cleaning Coolant Gun TINA ciao nace tet dA ERES Coolant Pump 13 11 2 5 F OL EFA Lees Flow of Coolant and Positions where it is Used Pop rome n LUBRICATING UNIT 14 1 FEBS O AGG Leere A Az Replenishing Lubricant 14 2 Cleaning Lubricating Unit Line Filter 14 3 Cleaning Lubricating Unit Tank Suction Filter and Fill Port Filter 1424 tn t d Checking Oil Air Lubrication 14 5 FI issu temere cr ep tete Flow of Lubricant and Positions where it is Used 14 6 Lubricating Oil Circuit Diagram 96 RDRAM 110 13 15 16 17 18 19
234. Display the TOOL MANAGEMENT screen and check the tool data E gt Function selection key OFFSET TOOL MANAGE 1 11 Correct the tool data as necessary CL wm MAPPS Separate volume MAPPS TOOL MANAGEMENT SYSTEM INSTRUCTION MANUAL A NC 42 ATC 80 ATC 199 P ATC 199 PLC EX 151 ATC 200 ATC 199 S 204 S52
235. EX0166 EX0167 related EX0167 to tool clamping is triggered the retention stud bolt may be or the switch may be malfunctioning Confirm according to the following procedure C C note An alarm is triggered if the nex command is specified without the tool being clamped Ensure the tool is clamped before issuing the next command Y
236. EX0509 THRU SP COOLANT FILTER CLOGGED is displayed otherwise EX0566 THRU SP CLNT UNIT ALARM is triggered and machine operation is completely stopped N Although you can change the coolant flow to use the filter on the other side during the cleaning operation ensure that the adjusting handles are placed correctly and that the coolant flow has definitely changed otherwise the following injuries and machine damage could result Spewing coolant on removing the cover leads to injuries such as eye damage Coolant not being discharged from the spindle or pressure failure damages workpieces Continuous pump operation without the normal coolant discharge rate damages the pump Changing Coolant Flow Turn and position the adjusting handles by hand as shown in the figure below Adjusting Handle Coolant Flow Direction 3 For details refer to the line filter instruction manual published separately 2 Stop the high pressure coolant pump prior to cleaning the filter 5 Never put the filter close to fire during the cleaning procedure 102 COOLANT UNIT 6 5 1
237. EX0559 OIL AIR LUBRICANT WATCH DOG ALM F3 EX0567 242 JP WESS dute aee ts 176 EX0567 LUBRICANT WATCH DOG ALARM SESS Say UD rain tats aS e qa t etat e a eb a bean 178 Checking Lubricating Unit Operation CB sg Lm up Sa Ore gadis 178 Air Removal 726 UNV ET INIT ODay Bi I PCI costae tt oe i ASO ae e uyankuy E tcs 179 Relief Valve Disassembly Cleaning RE NT CC i 180 Relief Valve Adjustment 87 MSHS AU Od rd AO M 180 Lubricant Leakage Check 16 10 11 12 13 14 15 16 17 Z 22129 Fa ra yun FAN COOLER ERRORS a m U U uuu iR OIL TEMPERATURE CONTROLLER ERRORS E 7 7 dat doe retire ets ALARMS RELATED TO PNEUMATIC DEVICES 10E EX0560 7712 U 34 I TANSI YA esi eio te aaa yan hun EX0560 AIR PRESSURE LOW CB acducencecit ette CHIP CONVEYOR OPTION ALARMS 1121 EX2550 AE SNE apa I SNR fh i nn EX2550 THERMAL OVERLOAD TRIP 1 E Cae a a C M ZERO POINT RETURN COMMAND ALARM TRIGGERED ieu au eee eee asi S SOFT OVERTRAVEL ALARM seen eite een ind ALARMS RELATED TO TOOL CLAMPING rrr REMOVING
238. EX0568 HYDRAULIC OIL LEVEL LOW HYDRAULIC PUMP OVERLOAD p a O QUA a Tecra Bl xL EDIS Y F 4 M E QM70 7 J 2l C
239. Page Opening Electrical Cabinet Door with Main Power OFF 132 Opening Electrical Cabinet Door with Main Power ON 133 Opening Closing Electrical Cabinet Door 132 Operating External Chip Conveyor 137 P PLC Alarm Alarm Starting with EX 151 PNEUMATIC DEVICES 123 Screen Displayed but Cannot Advance when OK Soft Key POWER SUPPLY CUT OFF DURING ATC OPERATION 199 PRECAUTIONS FOR OPERATORS 20 Precautions when Opening Closing Electrical Cabinet Door 132 Precautions when Operating Special Specification Machines 41 Precautions when Performing Maintenance Work 87 Precautions when Selecting Coolant 96 Precautions when Using Coolant Cooling Unit 144 Precautions when Using External Chip Conveyor 137 PREPARATION FOR MACHINE OPERATION AFTER PROLONGED IDLE PERIOD 65 R Recommended Oils 58 REGULAR INSPECTION LIST 52 REGULAR MAINTENANCE 47 Relief Valve Adjustment 180 Relief Valve Disassembly Cleaning 179 REMOVING CHIPS ENTANGLED IN CUTTING TOOL AND WORKPIECE 195 Replacing ATC Unit Tank Oil 83 Replacing Batteries 135 Replacing Cooling Oil 118 120 Replacing Machine Light 70 Replacing Machining Chamber Observation Window 67 Replacing Oil 88 Replacing O Ring of Retention Knob for Center Through Through Spindle Coolant Specifications 79 Replacing the Line Filter Element 91 Re
240. SERVO WARNING 009F n Z70 0001 n ABS ILLEGAL 0001 n 271 0001 n DETECTOR ERROR 0001 n Z73 0001 n ABS WARNING 0001 n C 1 n C note 1 The name of the axis is indicated in n If the n axis is unclear for indication contact the Mori Seiki service department WHEN BATTERY REPLACEMENT REQUESTED 159 gt AN 1 2 3 4 5 6 NC NC NC USB
241. X X RT Spindle Lubricant Tank Mixing Valve Spindle Oil air Lubrication Branching Z Axis Feed Box Receiving Valve Lubrication Branching Z Axis Slideway Z Axis Gib Valve Z Axis Ball Nut Lubrication Slideway Lubricant Tank Branching Z Axis Slideway Z Axis Gib Valve Lubrication Branching Y Axis Feed Box Receiving Valve Box Lubrication Y Axis Cable Guide z Y Axis Slideway Y Axis Gib Branching Y Axis Ball Nut X Axis Feed Valve Box Lubrication B hi Y Axis Slideway Y Axis Gib AE Ing X Axis Receiving Box Lubrication X Axis Cable Guide Branching X Axis Slideway X Axis Gib Valve X Axis Ball Nut Lubrication Q44266 B01 1 3 28dS 00LGXAN 080SXAN Buneouqn Apog OOLSXAN 080SXAN amp ts 2 4 E 1 99900 i dWz 2 0 1 1 079 uonong jo x 1045 1 9990 0 zx ous XioMS 109900 Z 10 5 10920 4 E 129900 BY KEK 00020 KY EK 100900 zx 4 amp E 00220 1 E ae Ae Ex xog i t li 1 t Ly 4 i 1 1 1 1 1 T 1 T X M M X X N X M X owesey lerBEM AG
242. 1 C a b 1 2 MPa muli u C ae 1 2 MPa c Following relief valve disassembly and cleaning adjust the relief valve using the following procedure It is necessary to bleed air from the piping prior to adjustment Refer to Air Removal page 178 for details on bleeding air from the piping lt Procedure gt 1 Lift the pump until positi
243. 101 1 dr GONE S20x089 2 i NMOG EZ N3L0 0 Fh 208 it 9090 9 0 S 0 o 22 2 35019 061 lt edo 980 9270 E LI id A ann uondo mopuin Auer SeN NAOd d 4601 AT Oy edWwo l S i 1 219 1 Ed OLE SJnSSaJd JeWo1 0 12 Jo lqtseuu q xe lqtsstuu q Xe z 24 Yt edA EO au g 2195 1822 ge E IZIZAA LLOLAA 16v9AA 1 A edH0 1P edn0 1 i 102AA 1POZAA 3 0 1 1 8 0 1 1 89 0 1 1 II 2 I SET 2 oiek V LPI m B I E 1 E 1 gdN0 L mdMG L 9dWS 1 p Un Oz moi paie z dW S0 eS LELAA 121AA 0 1 8 SL O 1 v SL 0 3 v 0 1 1 8 ay gg Fas eee eunssaig asMuled Xe I N 1 Jo 40 C018 00 2 td Q Q Q CD y Y vondo 6umno J iuusS lt tono wea vendo SW 10 arpuids BNO uondo xoeg mesa moja Av du alpuGS lt E lt 44 lt NY uzcru vs v jeder SOLLIE 971 1 210 i 1 ed F0198 96 LIESAA d SO HIE ideSiued Xew ZHO9 0S Tas y 1u 32170 1 0 uondo iv e
244. 123 17 PNEUMATIC DEVICES 7 1 Air Pressure Inspection and Adjustment Pressure Adjustment Knob Green Mark Manual Drain Cock gt 1 2 0 5 MPa 3 C 4 17 2 Manual Draining from Air Filter
245. Ayutthaya 10230 Thailand Phone 66 35 746720 Fax 66 35 746731 Technical Center Bangna DMG MORI SEIKI Taiwan DMG MORI SEIKI Tai wan Co Ltd Head Office amp Technical Center No 12 3 Industrial 33 Road Industrial Park Taichung City 40768 Taiwan R O C Phone 886 4 2355 6490 Fax 886 4 2355 6505 MORI SEIKI HONG KONG LIMITED Head Office amp Technical Center Unit 08 23 F The Metropolis Office Tower 10 Metropolis Drive Hung Hom Kowloon Hong Kong Phone 852 2757 8910 Fax 852 2757 7839 MORI SEIKI SHANGHAD CO LTD Head Office O Room 4301 4307 Maxdo Center No 8 Xing Yi Road HongQiao Development Zone Shanghai 200336 China Phone 86 21 5208 0270 Fax 86 21 5208 0273 Technical Centers O Shanghai Beijing Tianjin Dalian Shenzhen Chongqing Guangzhou Suzhou Wuhan Qingdao DMG MORI SEIKI Korea DMG MORI SEIKI Korea Co Ltd Head Office amp Technical Center O 110 Kofomo Techno Center II 3 Na 505 3 Ho Sihwa Industrial Complex 1289 5 Jeongwang dong KR 429 932 Siheung si Korea Phone 82 31 488 0500 Fax 82 31 488 0567 DMG MORI SEIKI Indonesia PT MORI SEIKI Indo nesia Head Office amp Technical Center Komplek Gading Bukit Indah Blok M 01 Jl Bukit Gading Raya Kalapa Gading Jakarta Utara 14240 Indonesia Phone 62 21 453 1199 Fax 62 21 4585 7414 The export of this product is subject to an authorization f
246. Checking Lubricating Unit Operation 178 D Checking Oil Level Replenishing Oil 88 Checking Oil Air Lubrication 110 Daily Spindle Warm Up 73 Checking Pressure Gage 89 Data 40 Diagnostic Screen Display Procedure 152 INDEX Page Page DISPOSITION OF MACHINES 46 HYDRAULIC UNIT ALARMS 162 Door Interlock 40 Hydraulic Unit Installation Positions 87 Door Interlock Function 27 E Impact resistant window 67 ELECTRICAL CABINET 131 IMPORTANCE OF INSPECTIONS 51 Electrical Cabinet View 131 INPUT OUTPUT SIGNAL CONFIRMATION EX0069 DOOR LOCK TIME OVER 155 PROCEDURE 152 EX0509 THRU SP COOLANT FILTER CLOGGED 101 EX0557 OIL AIR LUBRICANT PRESSURE LOW 174 L EX0559 OIL AIR LUBRICANT WATCH DOG ALM 175 Legal Obligation 32 EX0560 AIR PRESSURE LOW 186 Light 70 EX0561 HYDRAULIC PRESSURE LOW 162 LIMIT SWITCH SOLENOID VALVE INSTALLATION EX0566 THRU SP CLNT UNIT ALARM 101 POSITIONS 63 EX0567 LUBRICANT WATCH DOG ALARM 176 Limit Switch Solenoid Valve List 63 EX0568 HYDRAULIC OIL LEVEL LOW HYDRAULIC Locked In Prevention Key 31 PUMP OVERLOAD 164 Lubricant Leakage Check 180 EX2550 THERMAL OVERLOAD TRIP 1 187 Lubricating Oil Circuit Diagram 112 EX2551 THERMAL OVERLOAD TRIP 2 183 185 LUBRICATING UNIT 107 EX2561 SERVO BATTERY ABNORMAL 158 LUBRICATING UNIT ALARMS
247. Cleaning Lubricating Unit Tank Suction Filter and Fill Port Filte 108 S52 SERVO WARNING 009F n 158 752 BATTERY FAULT 000 158 Cleaning Machining Chamber 70 Z70 ABS ILLEGAL 0001 n 158 Cleaning Machining Chamber Observation Window 67 771 DETECTOR ERROR 0001 n 158 CLEANING OPERATION PANEL 72 Z73 ABS WARNING 0001 n 158 Cleaning Radiator 89 ALARM LIST 157 Cleaning Spindle Tapered Section and End Face 74 ALARM MESSAGE 151 Cleaning Suction Strainer and Tank 89 Alarm Not Triggered but Operation Abnormal 165 Closing Electrical Cabinet Door with Main Power OFF 132 ALARMS RELATED TO PNEUMATIC DEVICES 186 ALARMS RELATED TO TOOL CLAMPING 194 Closing Electrical Cabinet Door with Main Power ON 133 ATC Cvdle 199 Conditions Required for ATC Operation 199 y Recovery Operation 205 Confirming ATC Stopped Position in ATC Cycle 200 Confirming Coolant Pump Flow Control Valve Setting Check ATC Recovery Sequence 200 Valve Clogging 169 ATC UNIT 80 Confirming Start Conditions for ATC Operation 204 COOLANT COOLING UNIT OPTION 144 B Coolant Gun Option 105 Backlash Check 196 Coolant Level Check 168 Battery Low Voltage Alarms 158 Coolant Pump 106 Before Creating Program 42 Coolant Pump Operation Check 168 BT BT Dual Contact Specifications 76 Coolant Pump Strainer Clogging 170 COOLANT UNIT 96 C Coolant Unit Mounted On Coolant Tank Option 101 ale COOLANT UNIT PROBLEMS 167 Capto Specifications 77 Cutting Conditions 42 CAUTION LABELS 26
248. Closing Electrical Cabinet Door 8 2 7 2 m k N gt 7 2 2 3 OPEN RESET Re OPEN RESET
249. Confirm the pressure is set at the point indicated by the green mark 12 6 Cleaning Radiator Radiator OFF the main power and remove dust adhering to the radiator with a compressed air gun AN N CAUTION EE Protective glasses must be worn to prevent eye damage from dust or foreign matter those who are wearing glasses included 12 7 Cleaning Suction Strainer and Tank gt Procedure 1 1 Turn OFF the main power 90 HYDRAULIC UNIT 2 2 Place a drain pan beneath the drain plug 3 3 Remove the drain plug and drain the oil from the tank 4 4 Wrap sealing tape around the threaded section of the plug 5 5 Replace the drain plug 6 6 Disconnect the piping lt
250. Cooling Cil page 118 for Fan Cooler 2000 Hours Replacement Replacing Cooling Oil page 120 for Oil Temperature Controller Pneumatic Device Air Filter Mist Separator Filter Element Replacement page 124 1 Week Confirmation Machining Chamber Observation Window Inspection 2 Weeks Lubrication Greasing Tool Clamp Unit page 76 2to 3 Months m N Adjusting External Chip Conveyor Belt Hinge with Drum Filter Specifications page 138 after Start of Adjustment U First Slack Option se 6 Months conhrmation Manual Draining from Lid Attached under ATC Arm page 80 Cleaning Replacing ATC Unit Tank Oil page 83 Replacing Unclamp Unit Tank Oil page 86 Replacement Replacing the Line Filter Element page 91 for Hydraulic Unit 1 Year Replacing Batteries page 135 Replacing Trays of Spiral Type Internal Chip Conveyor Option page 140 Adjustment Adjusting External Chip Conveyor Belt Hinge with Drum Filter Specifications page 138 Option 5 Years Replacement Replacing Machining Chamber Observation Window page 67 C 1 2 2 1 7i 1 184
251. E 51 IMPORTANCE OF INSPECTIONS lt 52 REGULAR INSPECTION LIST 55 MAINTENANCE ROUTE MAP Wi NETTE 58 OILS UEykATvVT VLZ74RJULPZBIUBE eee 63 LIMIT SWITCH SOLENOID VALVE INSTALLATION POSITIONS 37 65 PREPARATION FOR MACHINE OPERATION AFTER PROLONGED IDLE PERIOD e EP 67 MACHINING CHAMBER EJ CE JP OM I wa ntu nOn TDi hr Dacus 72 CLEANING OPERATION PANEL SENI nne E E EMEN E D E DEI A MC 73 SPINDLE ATG LOS secca 80 UNIT 272722 SEU RT S 84 UNCLAMP UNIT bey P IP 87 HYDRAULIC UNIT Z I3 S Z uusha deiade e Shan Sus fete eC MU qr UE pM TM ETE 96 COOLANT UNIT THESES IS oue ated a S AAEE 107 LUBRICATING UNIT prs ay kapun NEUEN EUER PEN ERE 117 FAN COOLER dimos MRNA EUR 119 OIL TEMPERATURE CONTROLLER 123 PNEUMATIC DEVICES L Su ZZ Zi SSES 131 ELECTRICAL CABINET 137 CHIP CONVEYOR OPTION RIMIS 144 COOLANT COOLING UNIT OPTION eT 146 SEMI DRY CUT SYSTEM OPTION 22 OIL SHOT OIL MIST OPTION IMPORTANCE OF INSPECTIONS 51 7
252. E E HI 131 ELECTRICAL CABINET 1821 rini t n REFERENT ER sala dee rni e nds 131 Electrical Cabinet View 182 rel PET on secte echar nn tr t ntn e er e E ta dte P uu tri 132 Opening Closing Electrical Cabinet Door Precautions when Opening Closing Electrical Cabinet Door mm 132 Opening Electrical Cabinet Door with Main Power OFF BRU OO e rodeo tette taie 132 Closing Electrical Cabinet Door with Main Power OFF 133 Opening Electrical Cabinet Door with Main Power ON ERRARE C rt E a 133 Closing Electrical Cabinet Door with Main Power ON 18 3 Tal BRO E WA e e o pe Rag 134 Cleaning Back Fin Filter 8 EE 135 Replacing Batteries MR 137 CHIP CONVEYOR OPTION 1951 TLS 137 Precautions when Using External Chip Conveyor 14
253. Opening Electrical Cabinet Door with Main Power ON WARNING When an alarm is triggered and it is necessary to open the electrical cabinet while the power is supplied for maintenance purposes contact the Mori Seiki Service Department for assistance as specialized knowledge is required for this purpose All activities and procedures for responding to the alarm are to be performed with extreme care by licenced electrical technicians with maintenance experience in strict accordance with the recommendations of the Mori Seiki Service Department MAINTENANCE AND INSPECTION page 44 separate vol ume OPERATION MANUAL Electrical Cabinet Door Interlock Key Switch Procedure 1 Turn the electrical cabinet door interlock key switch to the OFF 2 Turn the two electrical cabinet door keys CCW to release the door lock 3 Insert a screwdriver into the lock release screw hole provided on the main power switch and open the door while turning the screwdriver CW y 7 H Lock Release Screw Hole Closing Electrical Cabinet Door with Main Power ON Procedure 1 Close the electrical cabinet door note A click is clearly audible when the door is completely closed 2 Turn the two electrical cabinet door keys CW to lock the door 134 ELECTRICAL CABINET 3
254. Serious injury The spindle speed must be lower than the allowable speed of the tool For the allowable speed of the tool contact the tool manufacturer Tool ejection Serious injury Damage to the machine and tool 5 5 2 Safety During Machine Operation 2 nig oF H60446A BAB 7 A WARNING Do not approach moving parts during operation H60437A 1 Do not stand near the moving parts of the machine while the machine is operating Entanglement Serious injury 30 CAUTION LABELS N Pay attention to moving parts of the rear and side of the machine as well as the front of the machine
255. Specifications Shell If the Stamina Grease RL2 replenishing Capto Specificati interval is less pecifications thanitwo weeks replenish Tool Clamp As required grease in each Unit of following HSK METAFLUX eels Specifications METAFLUX 70 81 30 hours of operation 100000 rotations of the ATC C E 1 zw note 1 For details refer to the figure 2 Use only recommended grease 60 OILS Magazine Roller Magazine Pot Shifter C my KOR ILE 2 4 2 Oil Equivalents E
256. Y KERR S ets 79 Replacing O Ring of Retention Knob for Center Through Through Spindle Coolant Specifications Y c r 80 UNIT 101 ATCR A cst vi ena 80 Manual Draining from Lid Attached under Arm 102 ATi d eL Arr E 81 Replenishing Replacing ATC Unit Tank Oil FE iris Soa 84 UNCLAMP UNIT p 27222 2 272 EE 22220 ua Saut bmp tete ki 84 Replenishing Replacing Unclamp Unit Tank Oil RPE ees Nr 87 HYDRAULIC UNIT SIB c RE 87 Precautions when Performing Maintenance Work 12 2 End e rte e E mc ater et cd 87 Hydraulic Unit Installation Positions 12 3 Him HO REGE sciet dressed abeat d o E UD e CH 88 Checking Oil Level Replenishing Oil EE n uninamiz rates 88 Replacing Oil 12 5 JP OD WE uu sa E e Sh Cd 89 Checking Pressure Gage 12262 27 A A 89 Cleaning Radiator 19 7 2225 SAB e tet e IRE e 89 Cleaning Suction Strainer and Tank 19 8 em e JS s LS l saa tua st pa We as a aad A RD t ond 91 Replacing the Line Filter Element 12 9 93 Flow of Hydraulic Oil and Positions where it is Used 12 13 14 EE B RS a t dout
257. a Shake the filter in four directions in a light oil such as kerosene or light diesel oil N CAUTION Use caution when using a light oil such as kerosene or light diesel oil and make sure there is no open flame in the vicinity b Brush the filter to remove sludge c Blow off residual accumulations with an air gun d Rinse the filter well in clean light oil e Dry the filter with an air gun Replace the O rings with new ones C note Install the new O rings carefully in the mating groove since they can slip off relatively easily Remount the filters and cover COOLANT UNIT 103 AN N CAUTION 1 O 7 For the size of the O rings refer to the line filter instruction manual published separately 2 2 Forthe tightening torques of the cover and the drain plug refer to the line filter instruction manual published separately 3 3 After remounting the cover ensure that it is mounted in the correct direction 13 6
258. conveyor 2 right side looking from the front of the machine If the QM34 QM35 switch is OFF clean the external chip conveyor Reset the chip conveyor motor breaker thermal relay switch QM36 QM55 QM77 QM78 QM34 lt ae C Press the automatic operation button START Start switch Chip clogging point visible Yes Press the chip conveyor button FOR Forward Recovery or BACK Reverse to remove chips No Y z z Yes 8 Intermittent chip conveyor operation Operate chip conveyor continuously Recovery No Y C 1 Remove chip conveyor from machine body p Y Chip clogging point visible Remove chips Y Cutting conditions appropriate zx Change cutting condition settings JR Yes Y Contact the Mori Seiki Service Department for assistance No Refer to b Cleaning Coolant Tank and Filters Chip Bucket Specifications page 99 Cleaning Coolant Tank Chip Conveyor Specifications page 100 190 ZERO POINT RETURN COMMAND ALARM TRIGGERED 12 ZERO POINT RETURN COMMAND ALARM TRIGGERED Z70 0001 X X
259. cursor to ZERO POINT SET using the cursor control keys J b Set ZERO POINT SET to VALID using the cursor control keys t 4 Prepare for zero point return position establishment according to the following procedure a Place the INTERLOCK MODE key switch in the NORMAL position b Close the door c Turn the operation selection key switch to ON or i PANEL EDIT d Select the axis feed amount selection button or switch Jo x100 e Select a feed axis using the axis selection switches ZERO POINT RETURN COMMAND ALARM TRIGGERED 191 f 1 1 1 Al 10 3 I4 5 e f Rotate the manual pulse generator to feed the axis until the markers meet as shown below 5 Display the Actual Position Setting screen ss
260. d Qa 162 EX0561 HYDRAULIC PRESSURE LOW 5D EX0568 eu 164 EX0568 HYDRAULIC OIL LEVEL LOW HYDRAULIC PUMP OVERLOAD 5g Or eee UE ES ES Lee ipn d e DUAL Mt 165 Alarm Not Triggered but Operation Abnormal Z2 2I FISY 167 COOLANT UNIT PROBLEMS 6p A DN entume eade atate deir ete 167 When Coolant is Not Supplied FD DTN SA ROS II EHE EHE 168 Coolant Pump Operation Check AE E mamas Edd mda 168 Coolant Level Check 169 Confirming Coolant Pump Flow Control Valve Setting Check Valve Clogging ee 170 Coolant Pump Strainer Clogging cu aS ESI IUe eS ss Ol 170 When the Coolant Pump is Not Operating 6 27 QVE dT UE e ge M b b d e CIARA 172 When Coolant is Spilled on the Floor 63 Abnormal Sounds emitted from Coolant Pump JE BS asa QS adore dada as nde alin LA e 174 LUBRICATING UNIT ALARMS 1 C EX0557 AWET YS YVI Z ATII uas seien edet 174 EX0557 OIL AIR LUBRICANT PRESSURE LOW EX0559 MWET mat yu RVA T ARES Gt kk eate eerta 175
261. direction wiring is connected in the reverse phase Confirm the machine main breaker and plant side connections Do the pump at idle speed Idle running will result damage to the pump Coolant Level Check Check the coolant level using the level gage on the coolant tank Replenish coolant if the gage indicates that the coolant level is close to the lower limit L mark Replenishing Coolant page 97 COOLANT UNIT PROBLEMS 169 ov MI M T Confirming Coolant Pump Flow Control Valve Setting Check Valve Clogging 4 s Check Valve WARNING gt 7 2 3 AN
262. misreading or inputting incorrect values Component interference Erroneous operation Workpiece ejection 4 4 Always check that the decimal place is correctly gt entered during program input Component interference Workpiece ejection a E nerd N CAUTION When machining forged or cast works create a program that takes workpiece shape variations into consideration or perform pre machining to determine a uniform cutting allowance Workpiece ejection Cutting Conditions 10 2 gt Dig WARNING 1 7 For machines equipped with a high speed spindle mm min 120
263. of non specified oils C note The tank capacity is 1000 cc Take care not to exceed the upper limit on the oil level gage If the oil level exceeds the upper limit the internal pressure will not rise and mist will not be formed 4 Remount the fill port cap Oil Level Gage 148 OIL SHOT OIL MIST OPTION 22 OIL SHOT OIL MIST OPTION 22 1 Replenishing Oil for Oil Shot and Oil Mist Remove the fill port cap and pour oil while checking the oil level using a dedicated oil can a Fill Port Cap S an AN N CAUTION 1 1 When changing to a different brand of oil drain all original oil from the tank and clean the tank Machine damage 2 SMC ISO VG32
264. operation If chips accumulate on the conveyor they may not be removed from the chip conveyor resulting in damage to the chip conveyor Stop the chip conveyor before placing rags on the chip conveyor belt Entanglement Machine malfunction and damage 32 CAUTION LABELS 510 Legal Obligation The exportation of this product may be subject to an authorization from the government of the exporting country Check with the government agency for authorization Der Export dieses Produkts bedart uU der Genehmigung der Regierung des exportierenden Landes Die Genehmigung ist bei entsprechenden Beh rde einzuholen L exportation de ce produit peut n cessiter une autorisation du gouvernement du pays exportateur V rifiez si une autorisation est n cessaire aupr s de agence gouvernementale L esportazione di questo prodotto potrebbe essere soggetta all autorizzazione del governo della nazione esportatrice Controllare con l agenzia di governo per l autorizzazione necessaria La exportaci n de este producto puede estar sujeta a una autorizaci n del gobierno del pa s exportador Compruebe en la agencia gubernamental si necesita una a
265. pan underneath the line filter in order to catch the spilt oil 3 Replace the filter element by following the procedure below a Remove the old filter element It is easy to take the filter element off the case as it is secured only with the O ring b Apply some oil on the inner diameter of the O ring in the new filter element HYDRAULIC UNIT 93 C 1 O O 2 O C 1 f 1 JU co i ef 2 O 8
266. recovery Spindle oil air switch wiring connection malfunction Contact the Mori Seiki Service Department for assistance 7 3 EX0567 EX0567 LUBRICANT WATCH DOG ALARM PC EX0567 LUBRICANT WATCH DOG ALARM is triggered if EX0567 lubrication pump pressure is not turned ON within a certain amount of time or if PC parameters are not set properly Respond in accordance to the recovery procedure below I LUBRICATING UNIT ALARMS 177 C PC TMR1 TMR2
267. the discharge piping connection is loose or piping is damaged 2 2 Checkif visible discharge piping connections are loose or piping is damaged LUBRICATING UNIT ALARMS 181 C note To check piping and piping connections that are not visible for looseness or damage contact the Mori Seiki Service Department for assistance FAN COOLER ERRORS 182 8 FAN COOLER ERRORS CL I For details refer to the manual supplied with fan cooler
268. the screen is the same as the parameter No 10011 value excluding the last three digits If the values are different input the parameter No 10011 value excluding the last three digits on the screen Example When the parameter No 10011 is 5963000 the value of the Zero P should be 5 963 2 The parameter value is referred to the parameter chart attached when shipping 192 ZERO POINT RETURN COMMAND ALARM TRIGGERED 6 1 6 Move the cursor to Absolute posn set input 1 and press X the INPUT key to perform X axis primary setting C ORR 53 7 1 AU C dd 8 X X
269. to avoid interference with the trays WARNING HEC c s c When moving the Y axis turn ON the main power After moving it turn OFF the main power again 9 Remove chips on the oil pan completely 9 Oil Pan 10 Check whether the oil pan is damaged or not 11 Mount new trays 12 Reinstall the parts by performing steps 2 to 8 in reverse COOLANT COOLING UNIT OPTION 144 20 COOLANT COOLING UNIT OPTION N 0 1 Precautions when Using Coolant Cooling Unit xs E 1 272 227 ks AREE AST S OO REG 56 CARE N A um ae S Vo misce WARNING 7 Operate the coolant cooling unit or perfo
270. to avoid grease entering the eyes those who wear glasses included 2 The nozzle does not need to be inserted to the rear of the 5 collet Type i ad D i RS di ad Shell W20043 6 2 gt 3 HSK E gt Spindle lt Front View gt Collet Se ee 2 1 2 90 5 Release the Emergency Stop status 6 Repeat clamp unclamp operations several times with no tool in the spindle to apply grease evenly HSK Specifications gt Spindle lt Section View gt N CAUTION Grease the tool clamp unit once every two weeks to m
271. to the coolant tank Remove the coolant tank cover Drain coolant using a dedicated suction device Clean the tank with a spade or shovel Blow compressed air through the coolant filters N CAUTION 1 Protective glasses must be worn to prevent eye damage from chips or foreign matter those who wearing glasses included 2 Take care to prevent excessive spray of coolant and chips Remount the coolant filters Supply coolant QI Replenishing Coolant page 97 Remount the coolant tank cover 100 COOLANT UNIT 70 AY 13 4 10 Push the coolant button ON On on the operation panel to confirm coolant is supplied Cleaning Coolant Tank Chip Conveyor Specifications mg LULA lt gt 1 2 3 4 5 6 7 8
272. while automatic operation is suspended and manual operation mode is selected If it becomes necessary to do these manually always return the axes or the tools to the previously located position before restarting the program Tool collision with workpiece or fixture Machine damage Procedure 1 2 3 9 10 Press the automatic operation button Press the automatic operation button STOP Stop to suspend program execution at a position where chips will be removed from the workpiece easily Select any of the manual mode keys STOP Stop Press the spindle rotation button O Spindle rotation stops Make sure the INTERLOCK MODE key switch is in NORMAL Open the door Remove chips from the workpiece using a proper hand tool Close the door Press the spindle rotation button z REV Reverse The spindle restarts rotating at the speed it was rotating before stopped NOR Forward or B Press the mode selection button MEM Memory START Start The program is restarted 196 CHECKING CORRECTING INACCURATE MACHINING 76 CHECKING CORRECTING INACCURATE MACHINING
273. with fires and accidents caused by the coolant 2 If using a flammable coolant do not carry out unmanned operation 3 If using a flammable coolant install appropriate automatic fire extinguishing equipment 4 If using a flammable coolant the coolant cooling unit must be installed Contact Mori Seiki 5 If a flammable oil based coolant is used its viscosity will increase in cold temperatures which may result in tripping of the coolant pump thermal relay Although this problem will be cleared by using a coolant with a lower viscosity such coolant may have a low ignition point raising the risk of fire 6 Receive the MSDS MATERIAL SAFETY DATA SHEET from the coolant manufacturer directly yourself as the customer and use coolant without any chemical effects on the machine Take careful note of the effects on the human body and the storage method described in the MSDS N CAUTION 1 Use coolant that satisfies the following conditions Coolant must be free of constituents with adverse affects on human beings such as offensive smells or those that cause skin irritation Coolant must not deteriorate during storage Coolant must not include constituents that adversely affect machining accuracy Coolant must be free of constituents forming a dry film which deteriorates electric conductivity Coolant must not corrode the machine Coolant must not peel off machine coating Coolant must not cause hardening or swelling of
274. 174 EX2562 NC BATTERY ABNORMAL 158 M F MACHINE OPERATION 37 FAN COOLER 117 Machine Zero Point Confirmation Return 203 FIRE PREVENTION AND COUNTERMEASURE 21 MACHINING CHAMBER 67 Flow of Compressed Air and Positions where it is Used MAINTENANCE AND INSPECTION 44 125 MAINTENANCE ROUTE MAP 55 Flow of Coolant and Positions where it is Used 106 MALFUNCTIONS AT MAIN POWER ON 153 jd of Cooling Cil and Positions where it is Used 118 Manual Draining from Air Filter 123 Flow of Hydraulic Oil and Positions where it is Used 93 Manual Draining fomi Lig Attached undstATE Am 80 Flow of Lubricant and Positions where it is Used 111 Message Requesting Battery Replacement ual 7 MOUNTING WORKPIECES AND CUTTING TOOLS 36 FOR SAFE MACHINE OPERATION 17 FOR USERS AND SUPERVISORS 19 N Forced Lubrication 65 NC Alarm 151 Full Stroke Travel of All Axes 65 NC PROGRAM 42 G O Greasing 58 oil controller 119 Greasing Tool Clamp Unit 76 Oil Equivalents 60 OIL SHOT OIL MIST OPTION 148 H OIL TEMPERATURE CONTROLLER 119 ew AE SARI ae 105 OIL TEMPERATURE CONTROLLER ERRORS 182 184 HSK Specifications 78 28 Hydraulic Circuit Diagram 94 SES 95 HYDRAULIC UNIT a OPEN DOOR THEN CLOSE Display does Not Disappear when Door Opened Closed 154 INDEX Page 52 SERVO WARNING 009F n 158 SAFETY DEVICES 24 Safety During Machine Operation 1 29 Safety During Machine Operation 2 29 Safety Precautions 26 safety window 67
275. 4 Contact the Mori Seiki Service Department for assistance prior to performing a manual operation Mori Seiki does not accept responsibility for accidents that occur as a result of recovery operations performed at the discretion of the user Always follow the guidance displayed on the screen when operating the ATC manually Procedure gt 1 Place the INTERLOCK MODE key switch in the NORMAL position 2 Close the front door 3 Close the magazine door 4 Turn the operation selection key switch to 27 ON or PANEL EDIT 5 Press the mode selection button MDI MDI 6 Display the ATC MANUAL OPERATION screen gt ANNA gt ATC Function selection key SETTING OPE PANEL ATC MANU OPE 4 N00000 TIME 0 0 sec 1 ATC AT 2 ATC ATcC 3 pv FER Oy FE X OA RIKERE 5 AT GC Y 6 ATGC 7 1 slI 200 mm min 0 min AUTO me DOOR OPERATION CONDITION TIME 0 0 sec CLOSE 1 ATC SHUTTER OPEN ATC SHUTTER OPEN
276. 5A 0 25 007098 Chip flush coolant MTH4 40 4 0 730 1 210 E55181 Drum filter cleaning pump MTH2 60 6 0 635 1 040 E55503 Coolant circulating pump MTH4 40 4 0 730 1 210 E55516 C C note jh 13 11 The coolant cooling unit pump is built into the unit Flow of Coolant and Positions where it is Used 1 2 Coolant Tank Coolant Pump 1 Coolant Pump 2 Spindle Coolant Chip Flush Coolant LUBRICATING UNIT 107 14 LUBRICATING UNIT 14 1 Replenishing Lubricant MIS Y h Slideway Lubricating Unit AN 7 2 CL 3
277. A A S A Head Office amp Technical Center O Edificio Sant Cugat Trade Center III Avda de les Corts Catalanes 9 11 Entidad 16D 08173 Sant Cugat del Valles Barcelona Spain Phone 34 935 75 36 46 Fax 34 935 75 08 47 MORI SEIKI Moscow LLC Head Office amp Technical Center O Business Center Salut build 1 27 5th floor Sushchevskaya St Moscow 127055 Russia Phone 7 495 969 2895 Fax 7 495 969 2890 DMG MORI SEIKI Turkey DMG MORI SEIKI ISTANBUL MAKINE TICARET VE SERVIS L M TED RKET Head Office amp Technical Center Ferhatpa a Mah Gazipa a Cad No 11 34885 Ata ehir stanbul Turkey Phone 90 216 471 66 36 Fax 90 216 471 80 30 Printed in Japan 101101EN lt ASIA OCEANIA gt DMG MORI SEIKI Singapore DMG MORI SEIKI SOUTH EAST ASIA PTE LTD Head Office amp Technical Center O 3 Tuas Link 1 Singapore 638584 Phone 65 6660 6688 Fax 65 6660 6699 DMG MORI SEIKI Malaysia DMG MORI SEIKI Malaysia Sdn Bhd Head Office No 19 Jalan U1 31 Seksyen Ul Hicom Glenmarie Industrial Park 40150 Shah Alam Selangor Malaysia Phone 60 3 5569 5282 Fax 60 3 5569 5286 DMG MORI SEIKI Vietnam DMG MORI SEIKI Vietnam Co Ltd Technical Centers O Hanoi Ho Chi Minh City DMG MORI SEIKI Thailand MORI SEIKI Manufac turing Thailand CO LTD Head Office D 40 Moo 4 Rojana Industrial Park 2 Rojana Road Tambol U Thai Amphur U Thai
278. Bitte tao yaaa ap rare Na en icu ea anda ned 26 CAUTION LABELS JES 1 n sa DH DOR a 33 WORKING ENVIRONMENT a Fe uut tid hn bas aha A LE eC DA ME EM M ELE 34 SETUP OPERATION Pima nE 36 MOUNTING WORKPIECES AND CUTTING TOOLS 37 MACHINE OPERATION TES mc unayma ME DA am Pn Pt EE IE 42 NC PROGRAM RERUMS oeste coded edat Ed ute en cavete e 44 MAINTENANCE AND INSPECTION BROOM y III PP 46 DISPOSITION OF MACHINES FOR USERS AND SUPERVISORS 19 7 FOR USERS AND SUPERVISORS 1
279. C alarm is triggered while a PLC alarm message is displayed the NC alarm indicator at the top right hand side of the screen flashes red QI For the PLC alarm table the sequence alarm table refer to ADDITIONAL MATERIALS of LADDER DIAGRAM 152 INPUT OUTPUT SIGNAL CONFIRMATION PROCEDURE 2 INPUT OUTPUT SIGNAL CONFIRMATION PROCEDURE When machine malfunctions occur confirm the cause of the problem by checking the status of input and output signals on the diagnostic screen For reference purposes a system outline of this machine is shown below Input Signal from Machine Button X600 X1FFF X40 X5FF Proximity Switch Limit Switch Preparatory Control Signals NC PMC I a 3 Y600
280. CHINE DAMAGE H60430A XE Be sure to follow the instructions on the caution label Failure to follow the instructions may result in serious injury damage to the machine and damage to workpieces CAUTION LABELS 27 5 2 Turning ON OFF Power H60440A T 20 e DANGE A H60431A amp amp Hazardous voltage Turn power O F F before servicing e 1 7 Turn the power OFF before performing the followings Electric shock Entanglement Before performing any work inside the machine for maintenance and cleaning HHR NC e Before performing any work inside the electrical cabinet and the NC unit Before leaving the machine 2
281. CHIPS ENTANGLED IN CUTTING TOOL AND WORKPIECE PLO OD HS We PLC CHECKING CORRECTING INACCURATE MACHINING 1 0 d Adjusting Machine Level FF OTE MN Cm Backlash Check ATC L e Bre ife amp l a POWER SUPPLY CUT OFF DURING ATC OPERATION eo EPIRI a au 17 2 ATC A Tos ef Me e REL ors captant snes ia ren Kc GER ee Cur Conditions Required for ATC Operation 1723 ATO OD a ed ae te eed e E E b p nbn um renes ATC Recovery Sequence ATG ESTEE OD TER uno ot e e e X Ree ed b e ete weeds Confirming ATC Stopped Position in ATC Cycle S bs be m eben Ebo vet ale ha ey Machine Zero Point Confirmation Return 17 6 ah Mete tee eut Confirming Start Conditions for ATC Operation ITT ATG SKK ATC Recovery Operation 196 200 204 FOR SAFE MACHINE OPERATION 10 11 12 19 FOR USERS SUPERVISORS ME AQ EK ISI a fc MEAT ukan s RC ua aaa la OR Uv E sim aa 20 PRECAUTIONS FOR OPERATORS a suu LEER 21 FIRE PREVENTION AND COUNTERMEASURE O SOS n n oaa 24 SAFETY DEVICES SERE
282. EU NER Z c BIBIT S Z 1 LUBRICATING UNIT No Symbol Order No Parts Name Model Q ty Maker RN hi FEES Poet eevee P98052A i SHOWA E PS89508 20 eas SED Ms P980S1A 27 as SET M ld P3090934 a6 NG SE NE UT 6 P98044A Met EHE DPB20 9946 MESS ZB FAM BON Eno JD406 PS Ow NM VIR CONNEGHOR LUBRICATING UNIT 7 7 E 7 114 Q44266 B01 2 3 9 ds 090SXAN 5uneoudn Apog 090SXAN x 104S Loo900 Buleoed SIXY X GID SKW A BAER
283. Ensure that the power is turned OFF FIR Procedure 1 1 Turn OFF the main power 2 2 Place a drain pan beneath the drain plug 3 3 Remove the drain plug and drain all oil from the tank 4 4 Wrap sealing tape around the threaded part of the plug 5 5 Replace the drain plug 6 6 Remove the fill port cap 7 7 Pour oil while checking the oil level gage CL 58 For oil types refer to OILS page 58 8 8 Remount the fill port cap 9 9 Turn ON the main power and confirm the pump generates a Suction sound 10 70 Turn OFF the main power and check the oil level 11 11 If the oil level is still low add oil again 15 3 Flow of Cooling Oil and Positions where it is Used
284. ITCH OPTION SQ131 X61 ATC SHUTTER OPEN FIN SQ132 X62 ATC SHUTTER CLOSE FIN SP12 X6A SIL up AIR PRESSURE SP5 X6B MAN OIL PRESSURE SL2 X6C SW OIL AIR LUBRICATION FLOAT SWITCH YV171 Y5D OIL AIR LUBRICATION OIL SUPPLY YV2221 Y8C 4 4 AXIS UNCLAMP OPTION YV2261 Y8D 5 5 AXIS UNCLAMP OPTION YV2300 Y70 FRONT DOOR UNLOCK YV2011 Y40 AIR BLOW YV2041 Y41 2 SPINDLE AIR BLOW2 Wero Ws 1 ERIE YV6491 Y4B 2 SPINDLE DRAW BACK2 ROTARY JOINT THRU SP COOLANT SPEC YV2601 Y42 TOOL UNCLAMP YV2021 Y78 SENSOR AIR BLOW OPTION YV2651 Y46 ATC SHUTTER OPEN YV2650 Y45 AIC ATC SHUTTER CLOSE YV2581 Y43 DOWN YV2580 Y44 POT UP YV2350 Y74 MAGAZINE DOOR UNLOCK YV2281 Y79
285. Inaccurate machining is caused by various cutting conditions factors such as the type of jigs tools and coolant used If consider the machine body a reduction in machining precision is caused primarily by incorrect machine level adjustment and excessive backlash Check the items below to confirm machine body related precision adjustments 16 1 Adjusting Machine Level Using level measure the machine horizontal level and degree of twisting Machine level adjustment is required as incorrect machine level adjustment or excessive twisting will result in a reduction in machining precision CI Separate volume I
286. L A i LE 151 ALARM MESSAGE ti ING 2 EET 151 NC Alarm deg cg Uode 57 SG M tae kk A SS 151 PLC Alarm Alarm Starting with EX 2 RE 152 INPUT OUTPUT SIGNAL CONFIRMATION PROCEDURE 153 MALFUNCTIONS POWER ON EA 153 Screen Not Displayed when Power Turned ON 32 esse 154 Screen Displayed but Cannot Advance when OK Soft Key Pushed 3 3 154 OPEN DOOR THEN CLOSE Display does Not Disappear when Door Opened Closed 3247 SEXO0451 D e EE EL ee RR 154 When EX0451 is Displayed gs5 FEXO069 E P EIS LR e NE 155 EX0069 DOOR LOCK TIME OVER 15 leu phase Se I aspas 157 WHEN BATTERY REPLACEMENT REQUESTED asan tasas d 157 Message Requesting Battery Replacement 462 PROG FN RS EE AES RD to end ph 158 Battery Low Voltage Alarms MELZ DUI T E 162 HYDRAULIC UNIT ALARMS Bet EX0561 ES CABE esee eee
287. N 9F ON F1 ON 9F ON F Axis No Warning Code F Axis No Warning Code 3 5 EX0069 EX0069 DOOR LOCK TIME OVER Y70 This alarm is triggered when the front door unlock signal Y70 X41 is turned OFF but operator door lock completion signal X41 is not turned ON Contact the Mori Seiki Service Department as 3 specialized knowledge is required for confirmation All procedures are to be performed with extreme care by licensed electrical technicians with maintenance experience in strict accordance with the recommendations of the Mori Seiki Service Department 156 MALFUNCTIONS AT MAIN POWER ON gt 1 PMC
288. NSTALLATION MANUAL Level Checking Adjustment 16 2 Backlash Check When machining accuracy varies substantially confirm the machine backlash FIR Procedure 1 1 Using a magnet stand attach a lever type dial test indicator to the spindle head 2 2 Prepare for handle feed operation using the following procedure CI Separate volume OPERATION MANUAL Handle Switches a a Place the INTERLOCK MODE key switch in the NORMAL position b b Close the front door c EP Turn the operation selection key switch to f ON or Aie PANEL EDIT d
289. ORS 2 PRECAUTIONS FOR OPERATORS 7 2 3 aE Ue j 4 5 6 7 8 MD
290. Q da a I I eL LE RE 20 PRECAUTIONS FOR OPERATORS 9 JU OBI EN ulus un ient dena ua aus DM RN ORUM Dd id aed 21 FIRE PREVENTION AND COUNTERMEASURE DE eec ET C kuu haved a sas 24 SAFETY DEVICES E E SE E E EUN 26 CAUTION LABELS 5p eC ro Je BCD i u a usha una una 26 Safety Precautions b CBS fe ka ta batter a 27 Turning ON OFF Power 5 97 EU Be eco eel chat metas tnt 27 Door Interlock Function 54 a B En EH OD E IS GT o rn 1 tct ec 1 29 Safety During Machine Operation 1 5 5 2 29 Safety During Machine Operation 2 AS cM M 30 Tooling and ATC 5 7 ABG APO TERR Le se Semen dete ertet Det uwa 30 Workpiece Setting and APC APC Specifications e a 31 Locked In Prevention Key ek beet ele head 31 Chip Conveyor Chip Conveyor Specifications CSI EE dr lE n E u a it 32 Legal Obligation D SS Q rt dicii ILL M I EL 33 WORKING ENVIRONMENT M dero soe S H 34 SETUP OPERATION CED E A A E ERD E a D 36 MOUNTING WORKPIECES AND CUTTING TOOLS 9 aon a a a r A 37 MACHINE OPERATION 9 1 ET A AI e a a uma ge a a aaa ee 40 Door Interlock gn FTES ON 40
291. REMOVING CHIPS ENTANGLED IN CUTTING TOOL AND WORKPIECE qe CHECKING CORRECTING INACCURATE MACHINING HERCEM 2 2 POWER SUPPLY CUT OFF DURING OPERATION ALARM MESSAGE 454 7 ALARM MESSAGE When an alarm occurs a message appears on the screen on the NC operation panel Note the number and the details of the alarm which are necessary when contacting with the Mori Seiki Service Department 1 1 NC NC Alarm NC NC be C
292. RICATING UNIT ALARMS C note Parameter values differ depending on the machine type Refer to the value in the parameter chart attached when shipping gt EE PC TMR4 TMR6 TMR42 No Parameter must be reset Parameter durs TMR42 Contact the Mori Seiki Service values are correct Department for assistance Yes Pressure switch or other oil air Yes pump wiring pump side and Repair wiring electrical cabinet side loose No Recovery No
293. Return SHUTTER CLOSE to ATC Home Position C NOTE 5 When the pot comes loose Move forward the ATC arm to the home position manually POT UP gt ATC SHUTTER CLOSE Pot Up POT UP ATC SHUTTER CLOSE Sl 6 E note Refer to Machine Zero Point Confirmation Return page 203 Before an ATC recovery operation the Z axis must be at the machine zero point Machine Zero Point Confirmation Return 17 5 Z Z Z M31 Pik ATC gt 1 Z Z
294. T 10 ATc ATC UNIT 10 1 ATC Manual Draining from Lid Attached under ATC Arm Sealing Tape AN ATC 6 ATC ATC gt 7 2 AIC 3 C 4 5 ATC Drain Plug ATC ATC Arm Drain Pan A DANGER Turn OFF the main power N CAUTION Check that there is no accumulated coolant inside the lid under the ATC arm once every six
295. T SYSTEM OPTION page 146 OIL SHOT OIL MIST OPTION 87 LONE NIT 7 119 U C U page 8 uy 09 OIL TEMPERATURE CONTROLLER i page 119 N mm Refer t Component efer to 123 Air Pressure Inspection and Adjustment page 123 HEH 123 Manual Draining from Air Filter Pneumatic Devices page 123 124 Air Filter Mist Separator Inspection and Filter Element Replacement page 124 RIA JV SES s d Cleaning Back Fin Filter page 134 Electrical Cabinet 135 Replacing Batteries page 135 MAINTENANCE ROUTE MAP 57 ovn Refer to Component TA Cleaning Air Filter and Radiator 2 2222 3 ee Fan Cooler 117 page 117 118 Replacing Cooling Oil page 118 97 i
296. Tank Oil page 84 dM Spindle Warm Up page 73 SE M Cleaning Spindle Tapered Section and r5 rer TS End Face page 74 HAY Ce IFAD Greasing Tool Clamp Unit page 76 P ust 2 Us Replacing O Ring of Retention Knob nont 2 i cr d for Center Through Through Spindle PET s Coolant Specifications age 79 79 Replacing Machining Chamber 67 Observation Window page 67 ame 70 Cleaning Machining Chamber Machining Chamber edid y 8 70 page 70 Replacing Machine Light page 70 56 MAINTENANCE ROUTE MAP N Refer t e Component ere M OC PREPARATION FOR MACHINE 65 OPERATION AFTER PROLONGED 4 EN mA IDLE PERIOD page 65 137 CHIP CONVEYOR OPTION 6 137 Ass AN HY Fe Ks a COOLANT COOLING UNIT OPTION Pi cx gk T page 144 Others Hi dx 146 SEMI DRY CU
297. Y1FFF Y40 Y5FF e Output Signal to Machine Lamp e Solenoid Valve e Relay e Commands to External Devices co PMC Programmable Machine Controller CD PMC Programmable Machine Controller Sequencer relays NC signals between machine and NC gt lt Meaning of Signals gt zs Signal Item X40 Input signals from operation panel or machine side limit X5FF switches Y40 mU Output signals from PMC to display panel or solenoid PMC hdd sale Y5FF valve X600 i X1FFF PMC NC Output signal from PMC to NC Y600 i Y1FFF PMC NC Input signal from NC to PMC gt lt Diagnostic Screen Display Procedure gt Find out the input signal address by checking the Ladder Diagrams or the Electrical Diagram to check t
298. Z 341 B Z NS 7 i pi D Ll te 4 dX iy i a pul LUBRICATING UNIT 115 No Symbol Order No Parts Name Model Q ty Maker 270088 BI UNIT PORT 2 1 P98052A i 1 Sowa P98066A 1 Sowa P98065A PLUNGER SEL 1 Sowa P3890934 a6 NG SE NE UT P98044A dm MEE DPB20 9946 AA EON Eco oe PS Ow TIRE CONNEGIOR Ec 400555 T a 1 Pa IOWA 116 LUBRICATING UNIT Q44266 B01 3 3 Spindle Oil Air Lubrication Spindle Bearing 02 5 t 0 75 2 4MPa Kt bd 0 03cc 1 x3 0 03cc 1 Shot x 3 Air Supply 40 12000min 94 0 t 1 0 Spinde 40 12000min 2 2MPa 1 2 a gt F 16 5 min 1 Shot 16 5 min 0 1 0 18L mln 50 60HZ C SP5 08 MPa e Set 0 8 MPa Down Off 2 0 L Reservoir Capacity 2 0 L 1 2 L Effectiv
299. aintain tool unit performance Even if two weeks have not passed replenish grease in either of the following cases Every 90 hours of operation SPINDLE 79 ATC 100000 100000 rotations of the ATC Refer to the separate volume OPERATION MANUAL PERI ODICAL INSPECTION Screen for alarm display gt Procedure 1 Confirm spindle rotation has stopped completely 2 2 Unclamp the spindle and remove the tool from the spindle CD Separate volume OPERATION MANUAL Removing from the Spindle 3 Leaving the spindle unclamped press the EMERGENCY STOP Emergency Stop button 4 2 mm 4 Insert lubrication spray nozzle METAFLUX 70 81 into the e
300. air panel LUBRICATING UNIT 111 14 5 Flow of Lubricant and Positions where it is Used Z Z Z Z ija AS a Z Z Y Y Y h 7 Mad RU aS Y Y X pax X mes X
301. al Cabinet Door page 132 188 CHIP CONVEYOR OPTION ALARMS CC EX2550 QM94 QM75 Ed C note EX2550 also occurs when the thermal relay of the coolant gun QM94 or that of the shower coolant QM75 is OFF C Y QM35 QM36 QM55 QM77 QM78 QM34 QM77 QM78 1 QM36 QM55 2 QM34 QM35 ADS RTE ED 5 BCA Y C
302. allet removed from the setup station is being returned to position for example when mounting and removing jigs or changing the pallet confirm the phase relative orientation of the setup station turntable and the pallet and ensure the pallet is mounted in the correct position N CAUTION Disregard for the cautions below may lead to physical damage serious injury machine damage machine service life reduction and impaired machining accuracy 1 When clamping a tool such as an end mill in the tool holder do not tighten the tool in the holder while the holder is in the spindle Always tighten the tool in the holder by using the special tool holder clamp base before mounting the holder in the spindle 2 When removing a tool from the spindle manually make sure that it is properly supported before unclamping Also take care to ensure the cutting tool does not fall except machines with a U axis MACHINE OPERATION 37 9 MACHINE OPERATION 1 2 3 E
303. assembling cleaning diusti ional No Recovery a valve P TEM m itun tion 55 5 Contact the Mori Seiki Service Wee ust ere teat he 7 Department for assistance No Refer to OILS page 58 Cleaning Lubricating Unit Tank Suction Filter and Fill Port Filter page 108 Checking Lubricating Unit Operation page 178 Cleaning Lubricating Unit Tank Suction Filter and Fill Port Filter page 108 Air Removal page 178 Lubricant Leakage Check page 180 Relief Valve Disassembly Cleaning page 179 Relief Valve Adjustment page 180 7 2 EX0559 EX0559 OIL AIR LUBRICANT WATCH DOG ALM PC EX0559 OIL AIR LUBRICANT WATCH DOG ALM is triggered whenoi air lubrication is not operated well because PC d EX0559 parameter is not set properly or automatic drive is operated for a long time without the spindle turning Confirm according to the following procedure 176 LUB
304. ata stored in the memory may be lost Before changing the batteries save the memory data such as parameters and programs as backup in an external I O device such as a memory card or USB memory Mori Seiki is not liable for problems that result from destroyed programs or lost data that have not been backed up Always ensure that the polarity of the batteries is correct If the polarity is reversed the memory data may be lost when turning OFF the NC power Remove the battery cover Replace the old batteries with new ones Open the electrical cabinet door with the main power ON QI Opening Electrical Cabinet Door with Main Power ON page 133 In order to confirm the changing of batteries correctly measure the voltage on the back of the battery box e SERVO Absolute Position Sensing Batteries 3 6 VDC e NC Memory Back Up Batteries 3 6 VDC Close the electrical cabinet door GO Closing Electrical Cabinet Door with Main Power ON page 133 Remount the battery cover 160 WHEN BATTERY REPLACEMENT REQUESTED gt Procedures to Clear Alarms After completing the battery replacement clear the alarms in the following flowchart and reset the accumulate time
305. ation gt 1 1 Check the door lock mounting position for gaps or warping 2 2 Check for door lock device key damage 3 3 Check the door lock device key locking action Co 24 SAFETY DEVICES page 24 for the position of door lock devices for each machine 3 4 EX0451 When EX0451 is Displayed When a servo spindle amplifier malfunction occurs the NC following messages appear on the NC operation panel EX0451 EX0451 SPINDLE DRIVE UNIT ALARM NC D 2 Press D before pressing NC SYSTEM soft key to confirm the alarm code
306. chemical parts rubber parts synthetic resin parts etc Coolant must not have electric conductivity equivalent to metal Coolant must not be of high viscosity 2 When using water soluble coolant observe the following points COOLANT UNIT 97 Add diluted coolant mixture to coolant tank after mixing in a separate container Use coolant at the concentration specified by the supplier If coolant of improper concentration is used workability is degraded and rusting of the machine and workpiece occurs causing damage to the machine and adversely affecting machining accuracy Contact the coolant supplier for the recommended hardness levels of wate
307. cking OiLAir Lubrication 110 page 110 58 OILS 4 OILS 4 1 Recommended Oils qH AN MSDS MSDS N CAUTION Receive the MSDS MATERIAL SAFETY DATA SHEET from the lubricant manufacturer directly yourself as the customer Work environment management and the storage and disposal of oils are the sole responsibility of the customer Take careful note of the effects on the human body described in the MSDS Use the following recommended oils Using other oils may degrade the machine performance
308. cleaner e Clean the filter using a compressed air gun N CAUTION Protective glasses must be worn to prevent eye damage from dust or foreign matter those who wearing glasses included C note Using neutral detergent is effective for removing oily foreign matters 5 Remount the filter and the cover 1 NC Display the PERIODICAL INSPECTION 1 screen If the cumulative time is close to inspection time replace the NC memory back up battery and SERVO absolute position sensing battery and reset the cumulative time AN 1 NC NC NC 2 USB
309. d section of the suction pipe and reattach the suction strainer 9 Clean the inside of the tank with kerosene N CAUTION Use caution when using kerosene and make sure there is no open flame in the vicinity 10 Remove foreign matter from around the drain plug using a brush 11 11 Remount the hydraulic unit Replacing the Line Filter Element gt 1 C The line filter is mounted to remove foreign matter from the hydraulic oil If th
310. dards that prevail in the relevant country or region Consequently it cannot be exported sold or relocated to a destination in a country with different laws or standards The export of this product is subject to an authorization from the government of the exporting country Check with the government agency for authorization 990730 About Declaration of Conformity EC 7 EC Machinery Directive 2006 42 EC EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC EN EN ISO 12100 1 EN ISO 12100 2 EN 50370 1 E E E N 50370 2 N 60204 1 N 12417 gt gt F 450 0002 2 35 LI gt MORI SEIKI GmbH Head Office Antoniusstrasse 14 73249 Wernau Germany Phone 49 7153 934 0 Fax 49 7153 934 220 Technical Centers Stuttgart M nchen Hamburg D sseldorf Chemnitz
311. dents arising from the use of non specified replacement parts or parts replaced without prior consultation Do not climb on top of the machine Falling machine Entanglement in tool Ejection from machine with the bolts specified by Mori Seiki that have appropriate strength Bolt breakage Workpiece fixture cutting tool ejection Serious injuries Machine damage Interlock functions including ATC manual operating interlock must be ON when operating the machine If necessary to operate the machine with the interlocks released awareness of the dangers involved and particular attention given to safety during machine operation is essential Following completion of the operation ensure the interlocks are turned back ON immediately Unexpected machine operation Serious injury Machine damage Do not modify or remove interlock functions Do not put too much confidence in interlock function Ensure safety procedures are followed at all times N CAUTION Do not touch chips or tool cutting edges without wearing protective gloves Injury Management of keys supplied with the machine operation panel electrical cabinet auxiliary devices is the sole responsibility of the customer Keys not used on a regular basis electrical cabinet key must be removed from the lock and stored in a secure location Do not use chlorinated hydrocarbon acetone or equivalent erosive solvent Damage to synt
312. e 34 935 75 36 46 Fax 34 935 75 08 47 DMG MORI SEIKI Turkey DMG MORI SEIKI iSTANBUL MAKINE TICARET VE SERVIS LIMITED SIRKETI Head Office amp Technical Center Ferhatpasa Mah Gazipasa Cad No 11 34885 Atasehir istanbul Turkey Phone 90 216 471 66 36 Fax 90 216 471 80 30 About the Machine gt NC i gt 3 gt
313. e Capacity 1 2 L Wa OW GE 229 M F 17Wx2P 0 9 L Send Alarm Signal at Lower than 0 9 L HE No Symbol Order No Parts Name Model Q ty Maker 1 P40377A PLUNGER DM3 3 0 03CC 1 SHOWA 2 LUBRICATING UNIT L0B4 8297E 1 SHOWA FAN COOLER 447 15 FAN COOLER Se WARNING Ensure that the power is turned OFF when performing maintenance 15 1 Cleaning Air Filter and Radiator gt Procedure 1 1 Turn OFF the main power 2 2 Remove the air filter C note The radiator is exposed when the filter is removed 3 40 C 3 Wash the air filter with a neutral detergent and tepid water not warmer than 40 degrees 4 4 Remove the neutral d
314. e Cover 4 C N Rear Side Cover 4 Remove the spiral conveyor cover C note The following illustration shows the spiral conveyor cover at the right side but there is also a spiral conveyor cover at the left side 142 CHIP CONVEYOR OPTION Spiral Conveyor Cover Spiral Conveyor 5 5 Remove screw at the front side to disconnect the spiral conveyor from the motor 6 1 2 6 Remove a pair of clamps holding the spiral conveyor C z C note Remove the clamps at the side where the trays are changed Spiral Holding Clamp Connecting Screw
315. e NC power is turned ON KA7 is activated GS1 GS2 power lamps are illuminated 154 MALFUNCTIONS AT MAIN POWER ON 3 2 Screen Displayed but Cannot Advance when OK Soft Key Pushed Possible causes are operation panel function key malfunction breakage or poor connector connection Contact the Mori Seiki Service Department for assistance 3 3 OPEN DOOR THEN CLOSE Display does Not Disappear when Door Opened Closed Th The primary cause is a door lock device malfunction If unable todetermine the cause after the following confirmation contact the Mori Seiki Service Department for assistance gt lt Confirm
316. e causing a remarkable decrease in strength An impact on part of the window may cause cracking on the entire window this is attributed to the property of toughened glass and is not a problem When hit with a strong impact Strength decreases extremely after having been subject to a strong impact even the appearance looks normal When visibility of the window cannot be secured and became difficult to grasp the conditions in the machining chamber Serious injury Machine damage 2 Turn OFF the lock device by turning the door lock release key remove the key and bring it with you when you enter the machine Locked in machine Serious injury 3 Do notreplace the window on your own Please contact the Mori Seiki Service Department when replacing the window 4 Mori Seiki is not responsible for problems arising from the use of non specified replacement window parts N CAUTION 1 Take care not to drop the window 2 Take care the steps in the machining chamber 3 If the window is damaged take due care to avoid injury caused by touching the damaged part of the glass 4 Using a material other than a silicone based one for caulking can degrade the polycarbonate C note The window is a consumable item and is not covered by the warranty MACHINING CHAMBER 69 Front Door
317. e do Hydraulic Circuit Diagram Z RI rte caet COOLANT UNIT 13 1 Precautions when Selecting Coolant 19 9 BO its uet dade Replenishing Coolant He MS Nas SAGAS teas tento e te a einn Chip Bucket Specifications dou ASSAI Ree o ama Road Chip Conveyor Specifications 13 3 uuu Cleaning Coolant Tank and Filters Chip Bucket Specifications 13 4 Cleaning Coolant Tank Chip Conveyor Specifications 135 Coolant Unit Mounted On Coolant Tank Option KK Cleaning Line Filter 13 6 2 7 ORE Lue Adjusting Coolant Discharge Rate 137 Adjusting Shower Coolant Discharge Rate Option 13 8 Adjusting Additional Tool Tip Coolant Discharge Rate Option 13 9 Zr
318. e filter is clogged the hydraulic oil cannot pass through the filter element and foreign matter in the oil cannot be removed Replace the filter element by following the procedures below lt Replacement Interval gt Annually when replacing the hydraulic oil or when the visual indicator turns red C note Perform visual inspection of the indicator daily When the machine is not in operation the indicator will not be displayed in red 92 HYDRAULIC UNIT gt 1 Necessary parts Filter Element one spare filter element is shipped with the machine Name Part No W12037 Line Filter W12037 O U Filter Element With W12028 W12028 O Ring CC Normal Almost Clogged Clogged Indicator C
319. e in safety devices protective covers and doors This is not the explosion proof specification machine Recognition of the dangers involved in machining procedures is required at all times Dangers such as the ejection of a large workpiece or harmful dust or an explosion caused by the machining of metals such as magnesium are not preventable even if the door is closed SAFETY DEVICES 25 7 7 If protective covers or safety devices are damaged contact the Mori Seiki Service Department Door Lock Device Door Lock Device EMERGENCY STOP Emergency Stop Button MORI SEIKI NVX5080 Locked In Prevention Key mg EMERGENCY STOP Emergency Stop Button 26 CAUTION LABELS 5 CAUTION LABELS E ee SAN N a gt
320. e procedure below Place the INTERLOCK MODE key switch in the NORMAL position Close the front door Turn the operation selection key switch to PANEL EDIT Display the PROGRAM CHECK MDI screen ON 2 MDI gt 9 Mode selection button MDI MDI Function selection key PROG ATC 204 POWER SUPPLY CUT OFF DURING ATC OPERATION 6 M31 6 Input M31 and press the INSERT key 7 7 Press the automatic operation button START Start interlock bypass mode is now valid x 8 1 8 Select the axis feed amount selection button or switch 1 9 9 Select a feed axis using the axis selection button 10 Z 0
321. eaffirming Machine Level Separate volume INSTALLATION MANUAL 54 REGULAR INSPECTION LIST Inspection Inspection Item Interval Cleaning Machining Chamber Observation Window page 67 Cleaning Machining Chamber page 70 Cleaning Cleaning Spindle Tapered Section and End Face page 74 en Cleaning External Chip Conveyor 137 Option aily Spindle Warm Up page 73 Checking Line Filter Indicator of Hydraulic Unit page 91 Confirmation Checking Oil Air Lubrication page 110 Air Pressure Inspection and Adjustment page 123 Cleaning Air Filter and Condenser page 144 for Coolant Cooling Unit Option 50 Hours Cleaning Cleaning Air Filter and Radiator page 117 for Fan Cooler Cleaning Air Filter and Condenser page 119 for Oil Temperature Controller Cleaning Coolant Tank and Filters Chip Bucket Specifications page 99 Cleaning Coolant Tank Chip Conveyor Specifications page 100 500 Hours Cleaning Cleaning Lubricating Unit Tank Suction Filter and Fill Port Filter page 108 Cleaning Lubricating Unit Line Filter page 107 Cleaning Cleaning Back Fin Filter page 134 1000 Hours Confirmation Pneumatic Device Air Filter Mist Separator Inspection page 124 Replacement Replacing Oil page 88 for Hydraulic Unit Replacing
322. em resulting in a fire caused by heat Before starting automatic operation reconfirm that the tools and programs to be used are correct Failure to use the correct tools and programs may result in an accident or a fire Especially with a program in which the same pattern is executed repeatedly confirm that the tool is selected correctly before starting the second set of repetitions after the first machining Create a program while fully considering the safe machining conditions which can also minimize the heat generated by rubbing Creating programs without this consideration may result in a fire or machine damage The conversational programming function creates NC programs based on general machining conditions but the final responsibility for determining the machining conditions rests with the user Mori Seiki is not liable for the machining outcome of the conversational programming function During and after machining completely remove chips if necessary Failure to remove chips completely may result in a fire depending on the workpiece material and machining conditions Ifa fire breaks out If by any chance a fire occurs stop usage of the machine and contact the Mori Seiki Service Department regardless of use of the fire extinguisher or the operation of the fire extinguishing equipment Although there are no abnormalities in the external appearance the wiring or piping may be damaged inside the machine and the
323. eparate volume OPERATION MANUAL CAUTION LABELS 29 5 4 1 Safety During Machine Operation 1 A A j H60441A B E 1g oF e 3 BERR H60442A BRE 1 2
324. er element d Remount the assembly case note Do not use tools when reinstalling the assembly case to prevent damage to the case Inspect replace the mist separator filter element using the same procedure with step 6 Tighten the manual drain cock by CW rotation Turn the cock to the vertical position to restart compressed air supply 10 Check for air leakage and confirm the air pressure is set at 0 5 MPa 17 4 Flow of Compressed Air and Positions where it is Used mn ATC in Mach 126 PNEUMATIC DEVICES Plant Side Compressed Air Filter Regulator Mist Separator Single Solenoid Valve Mixing Valve Spindle Oil Air Lubrication
325. essed air gun wear protective glasses to prevent eye damage from dust or foreign matter those who are wearing glasses included 4 Remount the filter the orifice and the plug N CAUTION Put the orifice into the correct position after cleaning procedure Back wash can not be performed without the orifice 140 CHIP CONVEYOR OPTION 19 6 Replacing Trays of Spiral Type Internal Chip Conveyor Option 1 2 AN 3 gt O
326. etergent using freshwater 5 5 Dry the air filter using compressed air 6 6 Cleanthe condenser fins using a brush or a compressed air gun s AN N CAUTION Ir _________ Protective glasses must be worn to prevent eye damage from dust or foreign matter those who wearing glasses included 7 Remount the air filter AN N CAUTION Do not forget reinstall the air filter prior to operation 118 FAN COOLER 15 2 Replacing Cooling Oil Fill Port Cap Drain Plug Oil Level Gage Fan Cooler AX WARNING
327. facturer of the fire extinguisher When installing the fire extinguisher consult with Mori Seiki as well If a mist collector is also installed the mist collector should be shut off when the fire extinguisher is activated Other wise the fire extinguishing agent will be exhausted of and the fire will not be extinguished For handling of the fire extinguisher refer to the instruction manual of the fire extinguisher manufacturer Follow the instructions of the fire extinguisher manufacturer and execute periodical inspection and appropriate maintenance After the fire extinguisher is activated replenish the fire extinguishing agent or exchange the fire extinguisher in accordance to the instructions of the fire extinguisher manufacturer Do not use the machine before the fire extinguisher is ready to be activated If the automatic fire extinguishing equipment allows switching between automatic manual operations set the extinguisher to automatic mode Before starting automatic operation Reconfirm that all parts of the tools and tool holders are securely tightened Insufficient tightening leads to insufficient tool clamping and may result in an accident or a fire caused by heat Reconfirm that the workpiece is securely clamped If a workpiece is not clamped securely it may shift and make contact with a tool resulting in a fire caused by heat Do not use worn or damaged tools If worn or damaged tools are used chips may clog th
328. fer to 2 Forced Lubrication Two Days or More Written Below 2 Written Below Spindle Warm Up 2 Two Weeks or More QJ 73 QI Spindle Warm Up page 73 6 1 Forced Lubrication 10 AN el Pressure Gage 6 2 bearings N CAUTION Supplying too much lubricant to the spindle bearings may Press the manual lube button for 10 seconds to supply lubricant to the nuts on the ball screws and the spindle cause spindle seizure or fire Manual Full Stroke Travel of All Axes
329. for ATC operation must be satisfied If the ATC cycle cannot be executed even if the correct operation sequence is followed check the ATC if the following conditions are satisfied Conditions 1 The front door is closed Separate volume OPERATION MANUAL DOOR INTERLOCK FUNCTION 2 MDI DNC 2 An automatic mode memory MDI DNC is selected 3 3 The STATUS indicator MRDY machine ready is lit 4 4 The machine is not in the reset state 5 Z 5 Z axis must be at the machine zero point 6 ATC 6 An ATC cycle has completed 7 ATC 7 The STATUS indicator ATC HP ATC home position is lit The conditions that light the status indicator ATC HP ATC home position shown below are satisfied The ATC main arm must be at the home position
330. g RE 65 Full Stroke Travel of All Axes MERA MC NER 67 MACHINING CHAMBER T MEZAR SEU OUR Amas estendere i E t obo endete t Pn oaa 67 Cleaning Machining Chamber Observation Window 4 2 HE EPA SSS ER teens tel ptu 1 67 Replacing Machining Chamber Observation Window T EE 70 Cleaning Machining Chamber ES cops EUM 70 Replacing Machine Light 11 8 10 11 12 VDD E Amm 72 CLEANING OPERATION PANEL zj pem 73 SPINDLE 9 EMRS set d ebd dats 73 Spindle Warm Up TH Daily Spindle Warm Up EBR ts 74 Spindle Warm Up after Extended Idle Period 9 2 74 Cleaning Spindle Tapered Section and End Face 98 sapete ne cute chess rtp pateret 76 Greasing Tool Clamp Unit cms 76 Dual Contact Specifications Lutte lir tete Ma tad t o a a ass eee 77 Capto Specifications inu cm 78 HSK Specifications 94 YF AIL A IAS Yy PO OU YT CAULK AE KILI F
331. g the handle feed x 1 until the hard overtravel status has been canceled Interference between carriage and covers Touch Panel 1 Use a finger to touch the panel as it can be easily scratched Use a touch pen if one is supplied with the machine Do not touch the panel with anything with a solid tip such as a ballpoint pen anything sharp or a fingernail Do not press more than one key at the same time Machine damage by unexpected machine operation Do not use commercially available liquid crystal protective film Improper operation of touch panel Do not touch the panel while wearing gloves Improper operation of touch panel scratches If the touch panel is smudged wipe the smudging off gently with a commercially available cleaning cloth using the ball of a finger not a fingernail Do not use cleaning fluid containing alcohol Deterioration of touch panel malfunction 40 MACHINE OPERATION 9 1 Door Interlock Ay WARNING 1 The door interlock function must be in the NORMAL 7477
332. ge 89 5 3 Alarm Not Triggered but Operation Abnormal E BO rate N 88 88 89 nta lt rf 166 HYDRAULIC UNIT ALARMS 2 2 RE 1 58 OG 88
333. he signal status on the screen to locate the cause of the malfunction gt NC UF gt Function selection key SYSTEM gt NC SYSTEM gt gt gt gt PLC I F gt Diagnostic Screen Input signal address gt INPUT key MALFUNCTIONS AT MAIN POWER ON 153 3 MALFUNCTIONS AT MAIN POWER ON E 9 When trouble occurs following turning ON of the main power supply perform the following recovery procedures referring to the Electrical Cabinet Parts Layout below
334. hetic resin parts or sealing wiper Disposal of industrial waste such as oil coolant chips and refrigerants is to be performed in strict compliance with safety and environmental protection laws as stipulated by the proper national and local authorities DISPOSITION OF MACHINES 46 72 DISPOSITION OF MACHINES pem 1 2 So 3 AN ri TEENS gt gt
335. hout material or fluid such as water and oil remained to ensure the work area for safe machine operations Tripping Slipping Depending on the types of the coolant or the machining conditions a large amount of coolant mist may be generated If a health problem such as sore eyes is caused install a mist collector option QI For mist collector specifications when using a flammable coolant not recommended or installing the fire extinguisher refer to FIRE PREVENTION AND COUNTERMEASURE page 21 N CAUTION 1 N 3 Do not use cellular phones electrical welding equipment or other devices that generate electromagnetic waves around the machine Unexpected machine operation Ensure that the workplace is sufficiently illuminated Reduced operating efficiency and safety Take care not to trip over the footswitch Injury 34 SETUP OPERATION SETUP OPERATION WARNING 1 1 During setup implement the following safety N w a o gt lt 4 5 x10 100
336. in the electrical cabinet cable measuring device encoder etc after having contacted the local government to check whether the devices and parts are recyclable Battery Contact local governments to check whether batteries and dry cell batteries are recyclable and appropriately dispose them Machinery Parts Appropriately dispose machine parts as recyclable resources such as casting sheet metal ball screw bearing and valve as Scraps Hose Appropriately dispose hoses as recyclable resources or plastic waste after having drained the liquid inside lt Refrigerant gt Refrigerants are used in all cooling systems such as oil temperature controllers coolant cooling units coolers in the electrical cabinet The disposal of these cooling systems and recovery of refrigerants should be handled by professionals Contact local governments to check whether the machines are recyclable lt Machining Chamber Observation Window gt The machining chamber observation window consists of polycarbonate and tempered glass Contact local governments to check whether the material is recyclable and appropriately dispose them lt Document gt Contact local governments to check whether all the related documents and CDs attached to the machine are recyclable and appropriately dispose them 15 CHAPTE REGULAR MAINTENANCE 10 11 12 13 14 15 16 17 18 19 20 21 c Meme
337. ion filter is badly fouled or damaged replacement is necessary C Note When replacing the suction filter contact the Mori Seiki Service Department 8 Remount the lubricating unit 9 Supply lubricant Gn Replenishing Lubricant page 107 10 Turn ON the main power 11 Press the manual lubrication button for about 10 seconds to supply lubricant to the slideways 110 LUBRICATING UNIT 14 4 Checking OilAir Lubrication Air Panel a o mg 1 2 gt 1 2
338. ke the key with you when you enter the machine Chip Conveyor Chip Conveyor Specifications Ir 373v478 amp H60447A BFE 1 3 A WARNING Do not put any part of your body into the chip conveyor Otherwise you will be nd entangled with rotating parts of the conveyor FoTIVR7EE H60438A RE 1 Do not attempt to reach inside the chip conveyor or put your feet in it while it is operating Entanglement Serious injury 2 Keep the chip conveyor operating all the time during automatic
339. leaning Coolant Tank and Filters Chip Bucket Specifications gt 7 2 3 4 5 6 A 1 2 7 8 CD 97 9 Coolant Filter DANGER Turn OFF the main power lt Procedures gt 1 2 3 4 5 6 7 8 9 Turn OFF the main power Wait until the coolant level is stabilized after the coolant inside machine is returned
340. lectrical energy Using a tester confirm parts are free of residual energy prior to performing maintenance procedures Maintenance procedures undertaken with the power turned ON must be performed by qualified electrical engineers Electric shock 7 Do not open electrical cabinet doors or the operation panel except to perform maintenance and inspection procedures Dust and moisture entry Machine damage 8 Do not overtighten bolts Machine distortion Bolt breakage 9 Before installing or transferring the machine read and make sure you understand the manuals or drawings supplied with the machine When it is necessary to lift the machine using equipment such as a hydraulic jack lift it up on flat ground with adequate strength paying due attention to machine balance in order to prevent the machine from toppling over Machine toppling over Injury INSTALLATION MANUAL WARNING 1 Consult the Mori Seiki Service Department prior to performing replacement procedures Use specified parts at all times Impaired machine performance and safety MAINTENANCE AND INSPECTION 45 C 2 3
341. lpulds uBnoJuL T 2E lt lt lt Se X X x SL 0 1 v6 Le lputds SANE 428 PNEUMATIC DEVICES No Symbol Order No Parts Name Model Q ty Maker 1 cde U44376A UE NKN 02995 1 SMC 2 U40533A xc AS3001F 10 1 SMC 3 U41710A E CBG1BA80 75 DCJ5592J 1 SMC 4 Mt U44377A NA NKN 02992 1 SMC 5 U41977A ma CREE CBG1LA20 190 DCK655GK 1 SMC 6 YV5891 U40587A sn VG21A1 5Y0 C8 F X78 1 SMC 7 eas U44375A PNTA WV2Q22 05 X 1 SMC 8 4 U44319A SO END IE s VXD2130 03 5DZ1 BLX690 2 SMC Wetet U44015A 10 U80000A SLC 2 500 1 TACO 11 e gt U44297A VX2320 02 5DZ1 B X726 2 SMC 12 U40096A E INA 12 226 1 SMC 13 YV5821 U44389A x NKN 02993 1 SMC 14 U40155A RE ms AS2051F 08 1 SMC 15 YV2281 U49609A I Ui A NKN 02991 1 SMC 16 YV5821 U27014A UNE LCB4 8297E 1 RUM x 17 gt P40377A DM3 3 0 03 1 18 YV5311 U49619A a EAT dive NKN 03035 1 SMC FERE PNEUMATIC DEVICES 129 Q41141 001 2 2 Scale Option X
342. manual are made in revised editions which are distinguished from each other by updating the instruction manual number Should you discover any discrepancies between the contents of the manual and the actual machine or if any part of the manual is unclear please contact Mori Seiki and clarify these points before using the machine Mori Seiki will not be liable for any damages occurring as a direct or indirect consequence of using the machine without clarifying these points All rights reserved reproduction of this instruction manual in any form in whole or in part is not permitted without the written consent of Mori Seiki Copyright 2011 MORI SEIKI CO LTD All rights reserved The product shipped to you the machine and accessory equipment has been manufactured in accordance with the laws and stan
343. may be malfunctioning Contact the Mori Seiki Service Department for assistance 2 Maintain oil at the correct level to prevent air being suctioned through the pump unit 4 If foreign matter accumulates in the tank oil cannot be kept free from contamination causing pump damage N w Keep oil free from contamination A 5 5 Clogged radiator causes oil pressure to be raised 6 6 Clogged suction strainer causes pumps and piping damage 7 7 If the oil pressure setting is incorrect hydraulic unit malfunction and damage may result CD 58 QI For oil types refer to OILS page 58 12 2
344. months Accumulated coolant prevents the ATC arm from unlocking tools causing noise ATC operation failure lt Procedure gt 1 Turn OFF the main power 2 Place a drain pan under the lid attached under the ATC arm 3 Remove the drain plug in the lid C note Contact the Mori Seki Service Department if the coolant has drained out after removing the drain plug 4 Wrap sealing tape around the threaded section of the plug 5 Mount the drain plug to the lid attached under the ATC arm ATC ATC UNIT 81 10 2 ATC Replenishing Replacing ATC Unit Tank Oil A DANGER Turn OFF the main power AN N CAUTION 1 7 Use a stable ladder or service platform at all times when performing this procedure 2 2 Iftheoillevel continues to decrease following replenishment contact the Mori Seiki Service Department for assistance CD 58 Gn For oil types refer to OILS page 58 lt ATC
345. n Co Ltd MORI SEIKI HONG KONG LIMITED MORI SEIKI SHANGHAI CO LTD DMG MORI SEIKI Korea DMG MORI SEIKI Korea Co Ltd DMG MORI SEIKI Indonesia PT MORI SEIKI Indonesia DMG MORI SEIKI India DMG Mori Seiki India Machines and Services Pvt Ltd DMG MORI SEIKI Australia DMG MORI SEIKI Australia PTY LTD exe 0120 124 280 aims 0077 78 0222 Bl ABC XXXXXX NV501XXXXX NV5000 40 E 3 IP TEL 047 410 8825 TEL 0595 45 6065 FAx 047 410 8837 FAx 0595 45 4156 E Mail service chiba moriseiki co jp E Mail service ctr moriseiki co jp
346. n the emergency stop condition 3 Open the electrical cabinet to confirm the motor breaker thermal relay QM63 is ON 4 If not turned ON activate the thermal C note Do not change the value A set on the thermal current setting dial COOLANT UNIT PROBLEMS 171 El ZH ES When the cause of problem cannot be determined after checking the points above qualified electrical technicians familiar with the necessary electrical safety precautions are to perform the checks in the following flowchart If machine check and recovery are difficult for the users to perform contact the Mori Seiki Service Department for assistance C 7 J E i Hbc m p WR AL
347. ng and ATC 1 Az T ALCAUT ION Do not touch tool in operation 1 1 Do not try to touch the tools in the magazine while the machine is operating Keep away from the other moving parts as well Injury Serious injury 2 Clamp workpieces and tools securely Falling of workpieces and tools Damage to the machine and tool 3 Depth of cut and cutting feed must be selected from a smaller value 4 Use tools within the limit of each machine model only Tool interference with the workpiece fixture and cover 5 Before mounting a tool in the magazine clean the tapered
348. ning using flammable coolant not recommended e Do not use a flammable coolant such as oil based coolant as it has high risk of a fire which may spread to the entire machine If a flammable coolant is used out of necessity any consequent fire or accident must be dealt with as the users responsibility e Always monitor the machining process and do not carry out unmanned operation Install appropriate automatic fire extinguishing equipment to quickly extinguish fire at an early stage e Check the flash point and the ignition point of the coolant to be used Manage the material of the tools and workpieces and tool wear so that the temperature during machining does not exceed these points e When coolant becomes a mist inside the machine it may burn explosively in abnormal temperature conditions Change the coolant discharge method so that no coolant mist becomes suspended inside the machine or install equipment to collect the coolant mist generated e Use an explosion proof mist collector e Check the instructions on coolant in the manuals in advance and follow them 3 When machining without using coolant including dry cutting and semi dry cutting e Check and manage the materials of the tools and workpieces to be used to prevent fire due to heat generated in the machining process 4 When machining workpieces made of flammable material e Always monitor the machining process and do not carry out unmanned operation Install approp
349. o avoid injury due to excessive noise levels Impaired hearing This is not the explosion proof specification machine Dangers such as the ejection of a large workpiece or harmful dust or an explosion caused by the machining of metals such as magnesium are not preventable even if the door is closed Do not rely on door and protective devices alone Recognition of the dangers involved in machining procedures is required at all times Operators must wear safety glasses at all times including operators wearing prescription glasses Eye damage due to ejected foreign matter Do not wear gloves when operating the machine Entanglement Machine malfunction Serious injury death Do not grind workpieces with emery cloths It may get entangled When the machine is operated by more than one operator cooperation and communication between them is required at all times Accident Keep a safe distance away from spindles or other rotating parts Entanglement Do not place hands or feet inside the chip conveyor if installed during operation Entanglement 10 Stop the machine before removing chips or adjusting the direction or volume of coolant supply Entanglement 38 MACHINE OPERATION 77
350. o follow the instructions could result in minor injury or in damage to the machine Purchase a replacement caution label and re affix in original position when a label peels off becomes blurred and cannot be read or a part with a label attached is replaced Do not fix anything on top of a caution label or paint over it Ensure caution labels attached to the machine are written in the native language of the operator Contact the Mori Seiki Service Department on purchasing new caution labels and other inquiries QI 3 Separate volume INSTALLATION MANUAL Chapter 3 DIA GRAMS CAUTION LABELS 5 1 Safety Precautions SAFETY PRECAUTIONS 1 2 3 4 5
351. omer Take careful note of the effects on the human body described in the MSDS C note Do not mix different brands of oil even when identified as being of equivalent quality and viscosity EmA DTE S32 an SIA DNAS Iz OILS 61 CBEBRT NEW e 3 68 68 Tem s osa 80W 90
352. on the meter Cleaning Lubricating Unit Tank Suction Filter and Fill Port Filter Tank Manual Lubrication Button gt 7 2 3 CC 4 Fill Port Filter Tank Suction Filter WARNING Turn OFF the main power Procedure 1 Turn OFF the main power 2 Remove the lubricating unit from the machine 3 Remove the tank C note Take care not to spill lubricant when removing the tank 4 Remove the suction filter and the fill port filter LUBRICATING UNIT 109 5 6 gt AN 1
353. oned close enough to the oil level to enable adjustment of the relief valve adjustment screw and perform adjustment using the following procedure C note Adjust the relief valve while the suction filter is soaking in the lubricant a Start the pump with the manual lubrication button b Setthe pump discharge pressure to 1 2 MPa using the relief valve adjustment screw Increasing Pressure Turn the adjustment knob to the right Reducing Pressure Turn the adjustment knob to the left C note If unable to set the pressure to 1 2 MPa the pump is malfunctioning Contact the Mori Seiki Service Department for assistance c Tighten the lock nut after adjustment 2 2 After adjusting the relief valve remove the cap and reconnect the pump discharge piping 3 1 0 MPa 3 Ensure air removal is performed sufficiently and the discharge pressure exceeds 1 0 MPa 4 4 Confirm the following points if the pressure level set in the above p
354. oor must be closed POT DOWN The magazine must not be rotating The ATC shutter must be opened ATC The ATC main arm must be at the home position The pot must be up 5 ATC The front door must be closed 6 ATIC ARM BACKWARD ARM FORWARD Z completed Z axis must be at the machine zero point The tool must be clamped The spindle orientation must be The pot must be down The ATC shutter must be opened ATC POWER SUPPLY CUT OFF DURING ATC OPERATION 205 ATC MANUAL OPERATION Screen Operation Start Conditions 7 ORIENTATION
355. or to BATTERY REPLACEMENT and press CHECK COMPLETE EXECUTE The ACCUMULATE TIME field becomes 0 and LAST INSPEC DATE field displays date in PERIODICAL INSPECTION 1 screen Recovery No Refer to ZERO POINT RETURN COMMAND ALARM TRIGGERED page 190 162 HYDRAULIC UNIT ALARMS HYDRAULIC UNIT ALARMS 5 1 EX0561 EX0561 HYDRAULIC PRESSURE LOW 7 MPa HO Hak gt Y 1 2 Jo
356. ori Seiki Service Department for assistance Lamp is not illuminated when controller is operating Lamp defective Replace the lamp For required parts contact the Mori Seiki Service Department for assistance OIL TEMPERATURE CONTROLLER ERRORS 185 Status Cause Countermeasure Reference Oil not supplied when pump operating Low oil circulation with loud pump noise Piping on suction side of pump loose Check the piping seals and tighten if necessary If the malfunction continues to occur contact the Mori Seiki Service Department for assistance Suction strainer clogged Clean suction strainer Change oil in oil tank if contaminated Oil level in oil tank too low Add oil Replacing Cooling Oil page 120 Viscosity too high oil temperature too low Change oil and then check the oil temperature Make sure the machine is installed at a site within the specified ambient temperature range and free from direct sunlight Replacing Cooling Oil page 120 Separate volume INSTALLATION MANUAL Environmental Conditions Relief valve clogged or malfunctioning Contact the Mori Seiki Service Department for assistance Pump or motor bearing damaged Contact the Mori Seiki Service Department for assistance 1
357. osition of the ATC when the power supply is cut off or the emergency button is pressed No 4 5 6 When the pot is at the down position as in No 4 5 6 in the following table the pot may come loose from the down position No ATC K L eue es P 1 3 v 2 ATC gt ATC 2 ATC ATC ATO C 3 1 ATC gt hy KER 2
358. placing Trays of Spiral Type Internal Chip Conveyor Option 140 Replenishing Coolant 97 Replenishing Lubricant 107 Replenishing Oil 146 Replenishing Oil for Oil Shot and Oil Mist 148 Replenishing Replacing ATC Unit Tank Oil 81 Replenishing Replacing Unclamp Unit Tank Oil 84 Pushed 154 Screen Not Displayed when Power Turned ON 153 SEMI DRY CUT SYSTEM OPTION 146 servo 154 SETUP OPERATION 34 SOFT OVERTRAVEL ALARM 193 SPINDLE 73 spindle amplifier 154 Spindle Warm Up 73 Spindle Warm Up after Extended Idle Period 74 Tooling and ATC 30 travel distance 66 TROUBLESHOOTING 149 Turning ON OFF Power 27 UNCLAMP UNIT 84 W WHEN BATTERY REPLACEMENT REQUESTED 157 When Coolant is Not Supplied 167 When Coolant is Spilled on the Floor 172 When EX0451 is Displayed 154 When the Coolant Pump is Not Operating 170 WORKING ENVIRONMENT 33 Workpiece Setting and APC APC Specifications 30 Y Strainer Check and Cleaning 139 Z52 BATTERY FAULT 000 158 Z70 ABS ILLEGAL 0001 n 158 Z71 DETECTOR ERROR 0001 n 158 Z73 ABS WARNING 0001 n 158 INDEX Page Page ZERO POINT RETURN COMMAND ALARM TRIGGERED 190 Comment Form J H Date T improve this manual we invite you to make comments on
359. plate from the machine Remove the four bolts securing the LED unit from the back of the mounting plate Remove the LED unit from the mounting plate Remove the cable from the LED unit Connect the cable to a replacement LED unit Attach the LED unit to the mounting plate Tighten the four bolts on the backside of the LED mounting plate to secure the LED unit 10 Mount the LED mounting plate to the machine 11 Turn ON the main power 12 Press the LIGHT Machine Light button to turn ON the LED lamp 13 Make sure that the LED lamp lights C note If the light is not illuminated or turns ON slowly turn OFF the main power and confirm the lamp is inserted correctly Name Part No Model No Manufacturer LED IDEC LED Unit oe pel Sp ANGOR IDEC Corporation 72 CLEANING OPERATION PANEL 8 CLEANING OPERATION PANEL A A i
360. production of this instruction manual in any form is not permitted without the written consent of Mori Seiki Various manuals and documents are supplied with the machine in addition to this manual Keep them close to the machine to enable easy reference The important precautions are compiled in the FOR SAFE MACHINE OPERATION section You must read this section before performing any operations relating to the machine The following number formatting is used in this manual Thousand separator comma Decimal separator period Signal Word Definition A xa EE AN EF ee
361. program and retains the read ahead program commands stored in the NC memory during a temporary stop of automatic operation in order to eliminate latency time when restarting Therefore check the program commands or present positions of the axes when stopping the machine temporarily In cases such as when discontinuing the machining press the 7 RESET key to clear the program commands stored in the NC if necessary Changing the program start position after a temporary stop in particular may cause accidents after the machining is restarted since the program commands stored in the NC are activated Pay extra attention to the difference in the specifications in relation to other manufacturers machines because the read ahead program data may be cleared at temporary stops on these machines Unexpected machine motion Interference 17 f the coolant supply is not sufficient tools workpieces and chips will reach high temperatures shortly after the production Do not touch them until the temperature drops N CAUTION 1 If abnormal noise or vibration is generated during machine operation determine the cause and take appropriate action Machine damage Impaired machining accuracy 2 When machining workpieces such as ceramics or carbon contact the Mori Seiki Service Department for appropriate countermeasures Operators could absorb powder type chips or chips may enter into the sliding part of the machine or bearing ga
362. ps 3 Perform spindle and controlled axis test running procedures prior to machining Thermal displacement adversely affecting machining accuracy MACHINE OPERATION 39 4 5 6 7 APC APC 8
363. r used to dilute the coolant Diluting the coolant using water that is too hard makes the coolant separate and diluting it using water whose hardness is too low makes the coolant froth easily Do not mix water and concentrated coolant in the coolant tank 13 2 Replenishing Coolant Chip Bucket Specifications A Tank Capacity NVX5060 302 L NVX5080 353 L NVX5100 416 L IB Procedures 1 2 3 AN 7 Remove the coolant tank cover 2 Supply coolant up to the upper limit on the oil level gage 3 Remount the cover N CAUTION 1 When supplying coolant ensure the coolant filters are installed 98 COOLANT UNIT 2 3
364. rammed end point Make sure that there are no obstacles in the tool path remembering the rapid traverse rate of X Y and Z axis movement Workpiece or fixture interference with tool or tool holder When setting the coordinate system using the machine coordinate system setting function specify the X Y and Z values in the G92 block correctly Component interference 44 MAINTENANCE AND INSPECTION 11 MAINTENANCE AND INSPECTION N w OFF CI A a
365. rate volume OPERATION MANUAL ZERO RETURN OPERATION For stroke travels refer to the separate volume INSTALLATION MANUAL AXIS TRAVEL DIAGRAMS WARNING Do not stand near moving machine parts during a zero point return operation Before starting a zero point return operation always confirm that there are no personnel or obstacles near moving parts Failure to observe these warnings may result in serious injury or damage to the machine personnel may be crushed by moving parts and the machine may be damaged due to component interference C note If the axis is not returned to the zero point correctly contact the Mori Seiki Service Department for assistance SOFT OVERTRAVEL ALARM 193 13 SOFT OVERTRAVEL ALARM aa aw cA c xc sar Software limit positions are set with parameters or a program If an axis is fed beyond its limit the following alarm occurs stopping the axis feed This alarm is called as the soft overtravel alarm
366. replenish grease in either of the following cases Every 90 hours of operation 100000 rotations of the ATC Refer to the separate volume OPERATION MANUAL PERI ODICAL INSPECTION Screen for alarm display Procedure 1 Confirm spindle rotation has stopped completely 2 Unclamp the spindle and remove the tool from the spindle 78 SPINDLE CI 4 6 RL 1 1 C 1 2 Separate volume OPERATION MANUAL Removing from Spindle 3 Leaving the spindle unclamped press the EMERGENCY STOP Emergency Stop button 4 Spray grease Stamina Grease RL2 towards the six gaps between collet segments Apply one shot approx for one second at each location C note 1 Wear protective glasses
367. rew i Oil No 2 Magna 68 nuts m Gelco Power Apolloil Wide Unit Tank Gear LW MDDG SES SUM BONGO 80W 90 80W 90 Spirax HD Gear 80W 90 Daphne Super Tellus Oil Unclamp Unit Tank Hydro X SX Z 46 Daphne DTE 24 Tellus Oil S32 5 Hydraulic Unit Tank ere Fluid DTE Oil Light Tellus Oil 32 Hyspin AWS 32 s inti oj Velocite Oil No Morina Oil2 _ M 3 Morlina Oil HS2 Daphne Oil Temperature Controller Tank Super Multi Oil e QI No Tellus Oil C5 2M 62 OILS Recommended Oils Type Oil Supplied to Idemitsu Mobil Shell Castrol Magazine Roller Manual Application Daphne I Eponex Alvania EP Spheerol EPLO Magazine Pot Shifter Manual Grease SR No Mobilux EPO Grease RO Grease Application Pot Balls Manual Application 0 LIMIT SWITCH SOLENOID VALVE INSTALLATION POSITIONS 63 LIMIT SWITCH SOLENOID VALVE INSTALLATION POSITIONS H4801028 A01 SQ YV SP amp SL POSITION Maa YV6491 YV121 YV2580 YV2350 YV2581 SQ100 YV2650 SQ133 YV2651 SQ143 SE E IN 5 1 Limit Switch Solenoid Valve List
368. riate automatic fire extinguishing equipment to quickly extinguish fire at an early stage e Check and manage the tools and machining conditions to be used so that the temperature during machining does not exceed the ignition point e Materials such as magnesium may burn explosively when exposed to water while burning Check the fire fighting methods and equipment in advance and install the equipment at suitable locations for quickly extinguishing fire 5 When installing a fire extinguisher 22 FIRE PREVENTION AND COUNTERMEASURE 7 OAKS iO a E IE UE ve GB
369. rm maintenance and inspections with reading and obtaining a thorough understanding of the contents of the coolant cooling unit instruction manual published separately N Keep the coolant cooling unit instruction manual on hand to enable immediate reference N CAUTION When using the coolant cooling unit always use it with machine temperature follow up control Do not use the unit with constant temperature control or room temperature follow up control even when the control method can be switched Thermal displacement adversely affecting machining accuracy N 1771105 Cleaning Air Filter Condenser 0 2 SAN 1 2 D N w gt 1
370. rm an ATC recovery operation ensure all interlocks are reactivated immediately following completion of the operation 2 ATC 2 If ATC operation start conditions are not satisfied prior to initiating an ATC cycle an alarm is generated ATC ATC MANUAL OPERATION Operation Start Conditions Screen 1 The front door must be closed ATC SHUTTER OPEN ATC The ATC main arm must be at the home RUE n 2 ATC position ATC SHUTTER CLOSE The pot m st pe up 3 The front door must be closed UP The magazine must not be rotating e The ATC shutter must be opened ATC The ATC main arm must be at the home position 4 amy RR The front d
371. rocedure differs remarkably from the pressure of the pump with the line filter discharge outlet disconnected to the piping route Lubricant leakage is not occurring on 180 For details on oil leakage inspection procedures refer to Lubricant Leakage Check page 180 e Distributor is not malfunctioning Air removal has been performed sufficiently 7 8 Lubricant Leakage Check If the lubricating unit operation is normal bleed air from the piping and check for lubricant leakage from the piping gt Procedure 1 1 Press the manual lubrication button for more than 10 10 seconds with the line filter discharge outlet connected to the piping route C C note If the pressure does not rise
372. rom the government of the exporting country Check with the government agency for authorization DMG MORI SEIKI India DMG Mori Seiki India Machines and Services Pvt Ltd Head Office o Parimala Towers 64 Jalahalli Camp Cross Off MES Road Yeshwanthpur Bangalore 560 022 India Phone 91 80 4089 6500 Fax 91 80 4113 1285 Technical Centers O New Delhi Pune Ahmedabad DMG MORI SEIKI Australia DMG MORI SEIKI Australia PTY LTD Head Office O 6 6 Garden Road Clayton VIC 3168 Australia Phone 61 3 85 404 600 Fax 61 3 85 404 601 Technical Centers DL Melbourne Sydney Perth Printed in Japan 101101EN
373. s any abnormal noise during the operation 192 Operating External Chip Conveyor GO For operation procedures refer to the separate volume OPER e ATION MANUAL Chip Conveyor Buttons 19 3 Cleaning External Chip Conveyor 1 ej 7 Press the chip conveyor button FOR Forward on the operation panel Chip conveyor start Chips discharge 2 ol 2 Press the chip conveyor button o STOP Stop Chip conveyor stop 3 3 Place an adequate quantity of rags on the conveyor belt 138 CHIP CONVEYOR OPTION E zi FA 4
374. s started by mistake Setthe spindle speed override switch to the lowest setting When using a manually tightened fixture remove the clamp handle or tightening tool from the fixture after tightening Serious injury Machine damage by tightening tool ejection Forthe default setting of the spindle speed limit check the rating plate on the door Specify a spindle speed limit that is the lowest of the individual permissible rotation speeds for the tool holder and cutting tool Serious injury Machine damage by workpiece Tool ejection Clamp workpieces and cutting tools securely Serious injury Machine damage by workpiece Tool ejection Determine the depth of cut and cutting feedrate for test cutting with safe operation as the first priority Do not give priority to productivity when making these determinations Serious injury Machine damage by workpiece Tool ejection Select the most appropriate cutting tool and holder for the material and shape of the workpiece to be machined as well as the cutting method and check that the workpiece can be machined without any problems Serious injury Machine damage by workpiece Tool ejection Impaired machining accuracy SETUP OPERATION 35 8 8 Make sure that the cutting tool holder workpiece
375. sitioned at the next tool position 17 3 ATC ATC Recovery Sequence 200 Confirming ATC Stopped Position in Cycle page 200 203 Machine Zero Point Confirmation Return page 203 204 Confirming Start Conditions for ATC Operation page 204 ATC 205 Recovery Operation page 205 17 4 ATC Confirming ATC Stopped Position in ATC Cycle z ATC A standard ATC cycle consists of the following steps during normal machine operation POWER SUPPLY CUT OFF DURING ATC OPERATION ATC 201 JLT C ATC note Refer to the following table to confirm the actual p
376. t have resistance to cutting Injury 1310 Coolant Pump 2 part numbers for the coolant pumps are as follows Use them when performing maintenance and inspections If you have any questions contact the Mori Seiki Service Department kW MTH4 40 4 0 730 1 210 E55516 MTH2 6073 0 325 0 520 E55433 MTH4 40 4 0 730 1 210 E55181 MTS20 70R38 5 5 E55261 VKNO85A 0 25 U07098 MTH4 40 4 0 730 1 210 E55181 MTH2 60 6 0 635 1 040 E55503 MTH4 40 4 0 730 1 210 E55516 Specifications Model Output kW Parts No Spindle coolant Shower coolant MTH4 40 4 0 730 1 210 E55516 Coolant gun MTH2 60 3 0 325 0 520 E55433 For drawing up through spindle coolant MTH4 40 4 0 730 1 210 E55181 Through spindle coolant pump on MTS20 70R38 5 5 E55261 coolant tank For coolant cooling unit VKN08
377. te volume OPERATION MANUAL PERIODICAL INSPECTION screen 2 Be sure to use a spray grease with nozzle when greasing tool clamp unit 3 Do not insert fingers deep into the hole of the spindle tapered section as there is a collet deep in the hole Injury Procedure 1 Confirm spindle rotation has stopped completely 2 Unclamp the spindle and remove the tool from the spindle CD Separate volume OPERATION MANUAL Removing a Tool from the Spindle 3 Leaving the spindle unclamped press the EMERGENCY STOP Emergency Stop button SPINDLE 77 4 4 T 1 1 4 Spray grease Stamina Grease RL2 towards the four gaps between collet segments near the end face of the draw bar Apply one shot approx for one second at each location RH z Eb W20043 C 1 2 5 6
378. ter Mist Separator Inspection and Filter Element Replacement Filter Element Residual Pressure Release Valve Baffle Air Filter mm mmm Pressure Gage I FE ual Drain Cock Lock Button Assembly Case Mist Separator A zs WARNING Turn OFF the main power lt gt lt Procedure gt 1 1 Turn OFF the main power 2 2 Turn the cock to a horizontal position to shut off the compressed air supply 3 REAP AIC 90 3 Turn the residual pressure release valve 90 degree CW to remove residual pressure 4 4 Confirm the pressure gage indicates 0 MPa 5 5 Padlock the residual pressure release valve Residual Pressure Release Valve C note
379. the Mori Seiki Service Department for assistance Oil Leakage From Connections Tighten connections 4 Oil Leakage Hose Deterioration Damage Contact the Mori Seiki Service Department for assistance Oil Leakage From Pump Contact the Mori Seiki Service Department for assistance COOLANT UNIT PROBLEMS 167 6 COOLANT UNIT PROBLEMS 6 1 When Coolant is Not Supplied Problems related to the supply of coolant can be divided into two categories cases when coolant is not supplied when the coolant pump is operating and cases when the coolant pump is not operating The confirmation and recovery procedures for both cases are outlined below 1 2 Y lt C 5 2 3
380. the spindle oil air pressure switch use a flat head screwdriver to rotate the adjustment screw on the pressure switch to set the pressure value at exactly 0 4 MPa Spindle Oil Air Lubrication Air Pressure Switch lt Spindle Oil Air Pressure Switch Malfunction gt When neither clogging of the mist separator filter element or incorrect adjustment of the spindle oil air pressure switch is the cause of the problem the pressure switch may be malfunctioning Contact the Mori Seiki Service Department for assistance C note When contacting the Mori Seiki make sure to inform the service representative that alarm number EX0560 4 has been triggered CHIP CONVEYOR OPTION ALARMS 187 77 CHIP CONVEYOR OPTION ALARMS 11 1 EX2550 1 EX2550 THERMAL OVERLOAD TRIP 1 sz Ad WARNING the electrical circuit diagrams to confirm the power supply status then open door with extreme caution referring to 132 QI Opening Closing Electric
381. to 0 and dates on the LAST INSPEC DATE in the PERIODICAL INSPECTION 1 screen QI lt Procedures to Replace Batteries gt page 159 for the battery replacing procedure 158 WHEN BATTERY REPLACEMENT REQUESTED lt 1 gt HEAD 1 MEM x88 xxx xe 00010 N00000002 DOOOH OOM 00 05 1 0 50 2008 00 18 37 ARR 0 500 2008 06 18 0 1000 2008 06 18 1 0 2000 2008 06 18 9504 43800 2009 01 02 2010 02 02 lt PERIODICAL INSPECTION 1 Screen gt iik 0000H OOM 00 05 PERIODICAL INSPECTION 1 PERIODICAL CHECK ITEM ACCUMULATE TIME INSPECTION TIME LAST INSPEC DATE WEEKLY INSPECTION 0 50 2008 06 18 THREF MONTHLY INSPECTION n 500 2008 06 18 SEMIYEARLY INSPECTION 0 1000 2008 06 18 YEARLY INSPECTION 0 2000 2008 06 18 MACHINING CHAMBER WINDOW 9504 43800 2009 01 02 0 8760 2010 02 02 42 Battery Low Voltage Alarms
382. urs report it immediately to the supervisor and follow the instruction of the supervisor FIRE PREVENTION AND COUNTERMEASURE 21 1 3 FIRE PREVENTION AND COUNTERMEASURE 7 MSDS MSDS BIBL THER 2
383. utorizaci n Wi p y The product shipped to you the machine and accessory equipment has been manufactured in accordance with the laws and standards that prevail in the relevant country or region Consequently it cannot be exported sold or relocated to a destination in a country with different laws or standards The export of this product is subject to authorization from the government of the exporting country Check with the government agency for authorization WORKING ENVIRONMENT 33 6 WORKING ENVIRONMENT E

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