mori seiki NL1500/500 User manual
HX-NL_4-C2JPEN
2011.06.P
MAINTENANCE MANUAL
Applicable Model
Applicable NC Unit
NL1500/500 NL1500MC/500 NL1500Y/500
NL1500S/500 NL1500SMC/500 NL1500SY/500
NL2000/500 NL2000MC/500 NL2000Y/500
NL2000S/500 NL2000SMC/500 NL2000SY/500
NL2500/700 NL2500MC/700 NL2500Y/700
NL2500S/700 NL2500SMC/700 NL2500SY/700
NL2500/1250 NL2500MC/1250 NL2500Y/1250
NL2500S/1250 NL2500SMC/1250 NL2500SY/1250
NL3000/700 NL3000MC/700 NL3000Y/700
NL3000/1250 NL3000MC/1250 NL3000Y/1250
NL3000/2000 NL3000MC/2000 NL3000Y/2000
NL3000/3000 NL3000MC/3000 NL3000Y/3000
M720BM (MSX-850IV)
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.
Copyright © 2010 MORI SEIKI CO., LTD. All rights reserved. 990730
•
•ThisisanoriginalinstructionmanualofficiallyissuedbyMori
Seiki.
•
•Thecontentsofthismanualaresubjecttochangewithout
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 manual are made in revised editions which are
distinguished from each other by updating the instruction
manual number.
•
•Shouldyoudiscoveranydiscrepanciesbetweenthe
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.
•
•Allrightsreserved:reproductionofthisinstructionmanualin
any form, in whole or in part, is not permitted without the
written consent of Mori Seiki.
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 an authorization
from the government of the exporting country. Check
with the government agency for authorization.
3
About Declaration of Conformity
EC <Declaration of EC Conformity>
NC
Mori Seiki declares that the machine tool shipped to Europe
(NC lathe, turning center, or multi-axis machine) is designed
and manufactured in conformity with the following
requirements.
1. EC 1. EC directive
Machinery Directive 2006/42/EC Machinery Directive 2006/42/EC
EMC Directive 2004/108/EC EMC Directive 2004/108/EC
Low Voltage Directive 2006/95/EC Low Voltage Directive 2006/95/EC
2. EN 2. EN standards
EN ISO 12100-1 EN ISO 12100-1
EN ISO 12100-2 EN ISO 12100-2
EN 50370-1 EN 50370-1
EN 50370-2 EN 50370-2
EN 60204-1 EN 60204-1
3. ISO 3. ISO standards
ISO 23125 ISO 23125
<Machine Model>
Description of machine models is omitted because this manual
applies to multiple machine models.
<Manufacturer>
MORI SEIKI CO., LTD.
450-0002 2 35 16 2-35-16 Meieki, Nakamura-ku, Nagoya City, Aichi 450-0002,
Japan
<Contact Address for Inquiry Regarding Technical Files>
MORI SEIKI GmbH
Head Office
Antoniusstrasse 14, 73249 Wernau, Germany
Phone: (49)-7153-934-0 Fax.: (49)-7153-934-220
Technical Centers
Stuttgart, München, Hamburg, Düsseldorf, Chemnitz
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
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 & Technical Center
Via Riccardo Lombardi N. 10, 20153 Milano, Italy
Phone: (39)-02-4894921 Fax.: (39)-02-48914448
MORI SEIKI ESPAÑA S.A.
Head Office & Technical Center
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
4
DMG / MORI SEIKI Turkey (DMG MORSEKSTANBUL MAKNE TCARET VE SERVS LMTED RKET)
Head Office & Technical Center
Ferhatpaa Mah. Gazipaa Cad. No.11 34885 Ataehir, stanbul, Turkey
Phone: (90)-216-471-66-36 Fax.: (90)-216-471-80-30
5
About the Machine
<Basis>
NC
This machine was designed and built using state-of-the-art
technology for the purpose of machining rotating workpieces
using cutting tools and soft jaws. 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.
<Tools>
*
This machine is capable of using common turning tools and
rotary tools* (such as milling cutters, drills, and taps). Contact
Mori Seiki before using grinding tools or special tools.
* * For machines equipped to use rotary tools.
<Materials>
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.
6
About this Manual
•
•Keepthismanualinaclearlymarkedlocationtoensureeasy
access when necessary.
•
•ContacttheMoriSeikiServiceDepartmentifanypartofthe
manual is unclear.
•
•ContacttheMoriSeikiServiceDepartmentoryourdistributor
if this manual is lost or damaged.
•
•Thecontentsofthismanualaresubjecttochangewithout
prior notification due to improvements to the machine.
• •Allrightsreserved:reproductionofthisinstructionmanualin
any form is not permitted without the written consent of Mori
Seiki.
•
•Variousmanualsanddocumentsaresuppliedwiththe
machine in addition to this manual. Keep them close to the
machine to enable easy reference.
• “ ”
•Theimportantprecautionsarecompiledinthe“FORSAFE
MACHINE OPERATION” section. You must read this section
before performing any operations relating to the machine.
•
•Thefollowingnumberformattingisusedinthismanual:
“,” Thousand separator: “,” (comma)
“.” Decimal separator: “.” (period)
7
Signal Word Definition
8 8DANGER
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
8 8WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
7 7CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor injury or damage to the
machine.
2 2NOTE
Indicates items that must be taken into consideration.
1 1Indicates items to be referred to.
5 5Indicates hints.
Example:
Indicates program-applied examples.
[]
[] Failuretoobservetheprecautions(hazards,warnings
and cautions) will lead to the hazards indicated in
square brackets [ ], injuries or machine trouble.
11
CONTENTS
FOR SAFE MACHINE OPERATION
1...................................................................................... 21
FOR USERS AND SUPERVISORS
2............................................................................................................... 22
PRECAUTIONS FOR OPERATORS
3 ........................................................................................................... 23
FIRE PREVENTION AND COUNTERMEASURE
4.......................................................................................................................... 26
SAFETY DEVICES
5.......................................................................................................................... 27
CAUTION LABELS
5-1 .................................................................................................................... 27
Safety Precautions
5-2 ................................................................................................................................... 28
Turning ON/OFF Power
5-3 .......................................................................................................................................................... 28
Bar Stock
5-4 ............................................................................................................................... 29
Door Interlock Function
5-5 1............................................................................................................................... 30
Safety During Machine Operation (1)
5-6 2............................................................................................................................... 31
Safety During Machine Operation (2)
5-7 .................................................................................................................... 31
Spindle Speed and Chucking
5-8 ............................................................................................................................... 32
Spindle Speed and Gripping Force
5-9 ........................................................................................................................................... 33
Locked-In Prevention Key
5-10 ................................................................................................... 33
Chip Conveyor (Chip Conveyor Specifications)
5-11 ............................................................................................................................................... 34
Legal Obligation
6.......................................................................................................................... 35
WORKING ENVIRONMENT
7.......................................................................................................................... 36
MACHINE OPERATION
7-1 ........................................................................................................................................... 43
Programming
7-2 ............................................................................................................................................... 44
Interlock
7-3 .......................................................................................................................................................... 44
Data
12
7-4 .............................................................................................................................................. 45
Precautions when Operating Special Specification Machines
8...................................................................................................................... 46
MAINTENANCE AND INSPECTION
8-1 ...................................................................................................................................................... 47
Machine Management
9...................................................................................................................... 49
DISPOSITION OF MACHINES
1
CHAPTER 1 REGULAR MAINTENANCE
1 .............................................................................................................. 53
IMPORTANCE OF INSPECTIONS
2 ....................................................................................................... 54
REGULAR INSPECTION LIST
3 ............................................................................................ 57
MAINTENANCE ROUTE MAP
4 ................................................................................................................................ 59
OILS
4-1 ......................................................................................................................................................... 59
Recommended Oils
4-2 ............................................................................................................................... 59
Oil Equivalents
5 ............................................................... 62
LIMIT SWITCH/SOLENOID VALVE INSTALLATION POSITIONS
5-1 NL1500, NL2000, NL2500, NL3000/700, NL3000/1250 ............................................................................. 62
NL1500, NL2000, NL2500, NL3000/700, NL3000/1250
5-2 NL3000/2000, NL3000/3000 ....................................................................................................................... 63
NL3000/2000, NL3000/3000
5-3 ......................................................................................... 63
Limit Switch/Solenoid Valve List
6......................................................................................... 69
PREPARATION FOR MACHINE OPERATION AFTER PROLONGED IDLE PERIOD
6-1 ....................................................................................................................................... 69
Forced Lubrication
6-2 ....................................................................................................................... 69
Full Stroke Travel of All Axes
7 ......................................................................................................................... 71
MACHINING CHAMBER
7-1 ............................................................................................................................... 71
Replacing Machining Chamber Observation Window
7-2 .......................................................................................................................................... 72
Cleaning Inside Machine
7-3 .......................................................................................................................................... 74
Cleaning Chuck
13
7-4 .................................................................................................................... 75
Inspection and Replacement of Slide Seals
7-5 ....................................................................................................................................... 77
Replacing Machine Light
8 ........................................................................................................... 80
CLEANING OPERATION PANEL
9 ........................................................................................................... 81
SPINDLE WARM-UP
9-1 ....................................................................................................................................... 81
Daily Spindle Warm-Up
9-2 ........................................................................................................................ 82
Spindle Warm-Up after Extended Idle Period
10 ........................................................................................................ 84
COOLANT UNIT
10-1 .................................................................................................................... 84
Precautions when Selecting Coolant
10-2 ....................................................................................................................................... 85
Replenishing Coolant
10-3 ...................................................... 86
Cleaning Coolant Tank and Filter (Chip Conveyor Right Side Discharge Specifications)
10-4 .................................................. 87
Cleaning Coolant Tank and Filter (Chip Conveyor Rear Discharge Specifications)
10-5 ............................................................................................................................ 89
Adjusting Coolant Discharge Rate
10-6 ....................................................................................................................................... 89
Coolant Pump
10-7 ............................................................................................... 90
Adjusting Oil Skimmer Separation Tank Drain (Option)
10-8 ................................................................. 91
Flow of Coolant and Positions where Used (Chip Conveyor Right Side Discharge Specifications)
10-9 .............................................................. 91
Flow of Coolant and Positions where Used (Chip Conveyor Rear Discharge Specifications)
10-10 .................................................................................................................. 92
Coolant Gun (Option)
92
How to Use the Coolant Gun
92
Cleaning Coolant Gun
11 .................................................................................................................. 94
HYDRAULIC UNIT
11-1 ............................................................................................................................... 94
Precautions when Performing Maintenance Work
11-2 / ................................................................................................................................ 94
Checking Oil Level/Replenishing Oil
11-3 ...................................................................................................................................................... 94
Replacing Oil
11-4 ............................................................................................................................................... 95
Checking Pressure Gage
11-5 ....................................................................................................................................... 96
Cleaning Radiator
14
11-6 ..................................................................................................... 96
Cleaning Suction Strainer and Tank
11-7 ......................................................................................... 98
Filter Element Replacement of Line Filter
11-8 ......................................................................................................................... 100
Flow of Hydraulic Oil and Positions where Used
11-9 ................................................................................................................................................ 102
Hydraulic Circuit Diagram
NL1500, NL2000.................................................................................................................................... 102
NL1500, NL2000
NL2500/700 ........................................................................................................................................... 107
NL2500/700
NL2500/1250 ......................................................................................................................................... 112
NL2500/1250
NL3000/700 ........................................................................................................................................... 117
NL3000/700
NL3000/1250 ......................................................................................................................................... 120
NL3000/1250
NL3000/2000, NL3000/3000 ................................................................................................................. 123
NL3000/2000, NL3000/3000
12 ............................................................................................................ 129
LUBRICATING UNIT
12-1 ............................................................................................................................................ 129
Replenishing Lubricant
12-2 ............................................................................................................................. 129
Cleaning Line Filter
12-3 ............................................................. 130
Cleaning Lubricant Tank, Suction Filter and Fill Port Filter
12-4 ..................................................................................................... 131
Flow of Lubricant and Positions where Used (Standard Specifications)
12-5 Y..................................................................................................... 132
Flow of Lubricant and Positions where Used (Y-Axis Specifications)
13 .............................................................................................. 133
OIL TEMPERATURE CONTROLLER
13-1 .................................................................................................................. 133
Cleaning Air Filter and Condenser
13-2 ............................................................................................................................................ 134
Replacing Cooling Oil
13-3
NL1500, NL2000, NL2500/700, NL3000/700, NL3000/2000, NL3000/3000
................. 135
Flow of Cooling Oil and Positions where Used (NL1500, NL2000, NL2500/700, NL3000/700, NL3000/
2000, NL3000/3000)
13-4 NL2500/1250, NL3000/1250...................................................................... 136
Flow of Cooling Oil and Positions where Used (NL2500/1250, NL3000/1250)
14 .............................................................................. 138
COOLANT COOLING UNIT (OPTION)
14-1 ................................................................................................... 138
Precautions when Using Coolant Cooling Unit
14-2 .................................................................................................................. 138
Cleaning Air Filter and Condenser
15
15 ..................................................................................... 140
SEMI DRY-CUT SYSTEM (OPTION)
15-1 ......................................................................................................................................... 140
Adjusting Oil Supply Quantity
15-2 .................................................................................................................................................... 140
Replenishing Oil
16 ........................................................................................................................ 142
PNEUMATIC DEVICES
16-1 .............................................................................................................. 142
Precautions when Performing Maintenance Work on Pneumatic Devices
16-2 ..................................................................................................................................... 142
Air Pressure Inspection and Adjustment
16-3 ............................................................................................ 143
Manual Draining from Air Filter
16-4 ............................................................................................... 143
Air Filter Inspection and Element Replacement
16-5 ...................................................................................................................... 144
Flow of Compressed Air and Positions where Used
16-6 NL1500, NL2000, NL2500, NL3000/700, NL3000/1250................................................... 145
Air Circuit Diagram (NL1500, NL2000, NL2500, NL3000/700, NL3000/1250)
16-7 NL3000/2000, NL3000/3000............................................................................................. 149
Air Circuit Diagram (NL3000/2000, NL3000/3000)
17 ........................................................................................................................... 152
ELECTRICAL CABINET
17-1 ............................................................................................................................................. 152
Electrical Cabinet View
17-2 ..................................................................................................................................... 152
Opening/Closing Electrical Cabinet Door
152
Precautions when Opening/Closing Electrical Cabinet Door
NL1500, NL2000152
NL1500, NL2000 (Not Provided with Electrical Cabinet Door Interlock Key-Switch)
NL2500, NL3000154
NL2500, NL3000 (Provided with Electrical Cabinet Door Interlock Key-Switch)
17-3 ................................................................................................................................. 156
Cleaning Electrical Cabinet Fan
17-4 ......................................................................................................................................... 157
Replacing Batteries
18 ..................................................................................... 159
CHIP CONVEYOR (OPTION)
18-1 .................................................................................................................. 159
Precautions when Using Chip Conveyor
18-2 ...................................................................................................................... 159
Operating Chip Conveyor
18-3 ............................................................................................................................. 159
Cleaning Chip Conveyor
18-4 .................................................................................................................. 161
Adjusting Chip Conveyor Belt
16
19 .............................................................................. 163
HIGH PRESSURE COOLANT UNIT (OPTION)
19-1 ............................................................................................................................. 163
Suction Pressure Inspection and Adjustment
19-2 .............................................................................................................. 164
Cleaning Notch Clean Filter
19-3 ................................................................................................... 164
Replenishing Coolant to Clean Tank
19-4 ......................................................................................................................... 165
Cleaning Coolant Tank
19-5 V .................................................................................................. 166
High Pressure Pump Oil Replacement and V-Belt Inspection
2
CHAPTER 2 TROUBLESHOOTING
1 ..................................................................................................... 169
ALARM MESSAGE
1-1 NC ............................................................................................................................................. 169
NC Alarm
1-2 PLC EX ............................................................................................... 169
PLC Alarm (Alarm Starting with “EX”)
2 ................................................................................................. 170
INPUT/OUTPUT SIGNAL CONFIRMATION PROCEDURE
3 ................................................................................................. 171
MALFUNCTIONS AT MAIN POWER ON
3-1 .......................................................................................................... 171
Screen Not Displayed when Power Turned ON
3-2 .................................................. 171
Screen Displayed but Cannot Advance when [OK] Soft-Key Pushed
3-3 ‘ ’..................................... 172
‘OPEN THE DOOR THEN CLOSE’ Display does Not Disappear when Door Opened/Closed
3-4 EX0451 EX0457 ............................................................................................. 172
When EX0451 or EX0457 are displayed
3-5 EX0069‘ ’ ........................................................................................................ 173
EX0069 ‘DOOR LOCK TIME OVER’
4 .......................................................................................... 175
WHEN BATTERY REPLACEMENT REQUESTED
4-1 .................................................................................................................. 175
Message Requesting Battery Replacement
4-2 ..................................................................................................................... 176
Battery Low Voltage Alarms
17
5 .................................................................................................. 180
ZERO POINT RETURN COMMAND ALARM TRIGGERED
6.................................................................................... 184
SOFT-OVERTRAVEL ALARM
7........................................................................................... 185
COOLANT UNIT PROBLEMS
7-1 ‘EX1557’......................................................................................... 185
‘EX1557 (COOLANT FLOW TOO LOW)’
7-2 ‘EX0578’ ................................................................................. 185
‘EX0578 (COOLANT OIL LEVEL LOW)’
7-3 ........................................................................................................... 185
When Coolant Spills on the Floor
7-4 .......................................................................................................................... 185
When Coolant is Not Supplied
186
Coolant Pump Operation Check
186
Coolant Level Check
186
Coolant Pump Strainer Clogging
187
Turret (Tool Holder) Coolant Nozzle Clogging
7-5 ....................................................................................................... 189
When the Coolant Pump is Not Operating
7-6 ...................................................................................................................... 190
Abnormal Sounds emitted from Coolant Pump
8...................................................................................................... 192
HYDRAULIC UNIT ALARMS
8-1 ‘EX2568’........................................................................................................ 192
‘EX2568 (HYDRAULIC UNIT ALARM)’
8-2 ............................................................. 193
Alarm Not Triggered but Hydraulic Unit Operation Abnormal
9 .................................................................................................. 195
LUBRICATING UNIT ALARMS
9-1 ‘EX0562’ ................................................................................................ 195
‘EX0562 (LUBRICANT PRESSURE LOW)’
9-2 ...................................................................................................................... 197
Checking Lubricating Unit Operation
9-3 ........................................................................................................... 197
Lubricating Unit Air Removal
9-4 ........................................................................................ 197
Lubricating Unit Relief Valve Disassembly/Cleaning
9-5 ................................................................................................... 199
Lubricating Unit Relief Valve Adjustment
9-6 .................................................................................................................. 199
Lubricating Unit Lubricant Leakage Check
18
10 ................................................................................... 201
OIL TEMPERATURE CONTROLLER ERRORS
11 .............................................................................................. 203
ALARM RELATED TO TURRET
11-1 ‘EX0357’................................................................................................ 203
‘EX0357 (TURRET INDEX TIME OVER)’
12 ................................................................................................. 205
WHEN SUB-STANDARD MACHINING OCCURS
12-1 ..................................................................................................................................... 205
Adjusting Machine Level
12-2 ................................................................................................................................. 205
Backlash Check
206
Headstock Inclination Adjustment
12-3 ..................................................................................................................................... 208
Turret Inclination Adjustment
12-4 ..................................................................................................................................... 212
Turret Center-Height Adjustment
12-5 ................................................................................................................................. 215
Tai lstoc k Ce nte r A dj ustme nt
12-6 2 ......................................................................................................................... 218
Headstock 2 Center Adjustment
13 ................................................................. 223
WORKING WITH SHORTER WORKPIECES (THE STEADY REST SPECIFICATIONS)
14 ................................................... 226
TOOL PRESETTER STYLUS BREAK STEM REPLACEMENT
14-1 ..................................................................................................................................... 227
Adjusting Stylus
15 ............................................................................ 230
REMOVING CHIPS ENTANGLED IN WORKPIECE
FOR SAFE MACHINE
OPERATION
1 21
FOR USERS AND SUPERVISORS
2 22
PRECAUTIONS FOR OPERATORS
3 23
FIRE PREVENTION AND COUNTERMEASURE
4 26
SAFETY DEVICES
5 27
CAUTION LABELS
6 35
WORKING ENVIRONMENT
7 36
MACHINE OPERATION
8 46
MAINTENANCE AND INSPECTION
9 49
DISPOSITION OF MACHINES
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35
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