MAINTENANCE MANUAL

INTEGREX e-1060V/6 II

Manual No.: H575MA0050E

Serial No.:

Before using this machine and equipment, fully understand the contents of this manual to ensure proper operation. Should any questions arise, please ask the nearest Technical Center or Technology Center.

IMPORTANT NOTICE
1. Be sure to observe the safety precautions described in this manual and the contents of the safety plates on the machine and equipment. Failure may cause serious personal injury or material damage. Please replace any missing safety plates as soon as possible. No modifications are to be performed that will affect operation safety. If such modifications are required, please contact the nearest Technical Center or Technology Center. For the purpose of explaining the operation of the machine and equipment, some illustrations may not include safety features such as covers, doors, etc. Before operation, make sure all such items are in place. This manual was considered complete and accurate at the time of publication, however, due to our desire to constantly improve the quality and specification of all our products, it is subject to change or modification. If you have any questions, please contact the nearest Technical Center or Technology Center. Always keep this manual near the machinery for immediate use. If a new manual is required, please order from the nearest Technical Center or Technology Center with the manual No. or the machine name, serial No. and manual name. Issued by Manual Publication Section, Yamazaki Mazak Corporation, Japan
05.2011

2. 3.

4.

5. 6.

CONTENTS
Page

INTRODUCTION .................................................................................. 1-1

1-1 Outline of the Machine........................................................................................1-1
Intended use of the machine .................................................................................. 1-1 Operating positions................................................................................................. 1-1 Features.................................................................................................................. 1-2

1-1-1 1-1-2 1-1-3

1-2 1-3 1-4

List of Manuals to Be Used.................................................................................1-3 Numbering System for Pages.............................................................................1-3 Numbering System for Figures and Tables ........................................................1-3

SAFETY PRECAUTIONS..................................................................... 2-1

2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 Rule ....................................................................................................................2-1 Basic Safety .......................................................................................................2-1 Safety Considerations Relating to Operators including Clothing ........................2-3 Safety Considerations Relating to Machine Operation .......................................2-3 Safety Considerations Relating to Holding Workpieces and Tooling ..................2-4 Safety Considerations Relating to Maintenance .................................................2-5 Safety Considerations Relating to Workplace ....................................................2-7 Safety Considerations Relating to Chip Conveyor..............................................2-7 Safety Considerations Relating to Pallets...........................................................2-7

2-10 Safety Considerations Relating to Faceplate Jaws.............................................2-8 2-11 Safety Considerations Relating to Safety Devices..............................................2-8 2-12 Remarks on the Cutting Conditions Recommended by the NC..........................2-8

C-1

2-13 Safety Nameplates .............................................................................................2-9 2-14 Safety Considerations Relating to Mounting or Changing the Chuck (Pallet) by the User...........................................................................................2-14 2-15 Safety Considerations Relating to Gripping Force and Rotating Speed ...........2-16 2-16 Safety Devices .................................................................................................2-17 2-17 Safety Plate Locations......................................................................................2-19

OUTLINE OF THE MACHINE STRUCTURE ....................................... 3-1

3-1 3-2 3-3 Overview of Machine Units.................................................................................3-1 Definition of Coordinate Axes .............................................................................3-5 Maintenance Cover ............................................................................................3-6

REGULAR INSPECTION ..................................................................... 4-1

4-1 4-2 4-3 General...............................................................................................................4-1 Table of Inspection and Maintenance Items .......................................................4-2 Daily Inspection and Maintenance......................................................................4-5
Inside the machine.................................................................................................. 4-5 Outside the machine............................................................................................... 4-6 Checking oil levels .................................................................................................. 4-6 Checking pressures (hydraulic and air) .................................................................. 4-7 Changing or replenishing oils ................................................................................. 4-7 Around the machine................................................................................................ 4-8 Checking the Z-axis servo load .............................................................................. 4-8

4-3-1 4-3-2 4-3-3 4-3-4 4-3-5 4-3-6 4-3-7

4-4

Weekly Inspection and Maintenance ..................................................................4-9

Changing or replenishing oils ................................................................................. 4-9

4-4-1

C-2

4-4-2

Around the machine................................................................................................ 4-9

4-5

Monthly Inspection and Maintenance ...............................................................4-14

Around the machine.............................................................................................. 4-14

4-5-1

4-6

Every Six-Month Inspection and Maintenance .................................................4-14

Changing or replenishing oils ............................................................................... 4-14 Greasing ............................................................................................................... 4-16 Around the machine.............................................................................................. 4-22

4-6-1 4-6-2 4-6-3

4-7

Every One-Year Inspection and Maintenance ..................................................4-28

Changing or replenishing oils ............................................................................... 4-28 Around the machine.............................................................................................. 4-35

4-7-1 4-7-2

4-8

Inspection and Maintenance before Stopping the Machine for a Long Time .................................................................................................................4-39 Inspection and Maintenance before Starting the Operation after Stopping the Machine for a Long Time............................................................................4-40

4-9

MAINTENANCE OF MAJOR UNITS .................................................... 5-1

5-1 Mill Spindle and B-axis .......................................................................................5-1
Troubleshooting ...................................................................................................... 5-1 Construction of the spindlehead ............................................................................. 5-3

5-1-1 5-1-2

5-2

X-axis, Y-axis, Z-axis..........................................................................................5-4

Troubleshooting ...................................................................................................... 5-4 Construction of the axis drive systems ................................................................... 5-5 Replacing the sealing packing of the Z-axis counter balancer ............................... 5-8 Replacing the battery for the axis amplifiers ........................................................... 5-8

5-2-1 5-2-2 5-2-3 5-2-4

5-3

ATC Magazine..................................................................................................5-10

C-3

5-3-1 5-3-2

Troubleshooting .................................................................................................... 5-10 Construction of the ATC magazine....................................................................... 5-11

5-4

Table ................................................................................................................5-12
Troubleshooting .................................................................................................... 5-12 Construction of the table....................................................................................... 5-13 Turning spindle and C-axis connection/disconnection menu................................ 5-14 Restoring the operation if the C-axis zero point is lost in the turning mode.......... 5-16 C-axis connection mechanism.............................................................................. 5-17

5-4-1 5-4-2 5-4-3 5-4-4 5-4-5

5-5

Pallet Changer..................................................................................................5-18
Troubleshooting .................................................................................................... 5-18 Construction of the pallet changer ........................................................................ 5-19

5-5-1 5-5-2

5-6

Hydraulic System..............................................................................................5-20
Troubleshooting .................................................................................................... 5-20 Maintenance of the hydraulic unit ......................................................................... 5-20 Hydraulic circuit diagram ...................................................................................... 5-22

5-6-1 5-6-2 5-6-3

5-7

Pneumatic System............................................................................................5-25
Troubleshooting .................................................................................................... 5-25 Construction of the air unit.................................................................................... 5-25 Maintenance of the air unit ................................................................................... 5-26 Pneumatic circuit diagram .................................................................................... 5-28

5-7-1 5-7-2 5-7-3 5-7-4

5-8

Centralized Lubrication Unit .............................................................................5-32

Troubleshooting .................................................................................................... 5-32 Maintenance of the centralized lubrication unit..................................................... 5-32 Linear guide and ball screw lubrication................................................................. 5-32

5-8-1 5-8-2 5-8-3

C-4

5-8-4

Mill spindle bearing lubrication.............................................................................. 5-33

5-9

Spindle Cooling Unit .........................................................................................5-34

Troubleshooting .................................................................................................... 5-34 Construction of the spindle cooling unit ................................................................ 5-35 Cooling system circuit diagram............................................................................. 5-36

5-9-1 5-9-2 5-9-3

5-10 Coolant System ................................................................................................5-38

5-10-1 Troubleshooting .................................................................................................... 5-38 5-10-2 Construction of the coolant system....................................................................... 5-39 5-10-3 Coolant circuit diagram ......................................................................................... 5-40

5-11 Covers ..............................................................................................................5-41

5-11-1 Troubleshooting .................................................................................................... 5-41 5-11-2 Machine covers..................................................................................................... 5-41 5-11-3 Changing the proximity sensor ............................................................................. 5-42 5-11-4 Maintenance of the X-axis way cover ................................................................... 5-43

5-12 NC Unit and Electrical Control Cabinet.............................................................5-45

5-12-1 Troubleshooting .................................................................................................... 5-45 5-12-2 Resetting the thermal relay................................................................................... 5-46

INSTALLATION .................................................................................... 6-1

6-1 6-2 Precautions on Installing the Machine ................................................................6-1 Preparing for Installation.....................................................................................6-2
Environmental requirements ................................................................................... 6-2 External power source requirements ...................................................................... 6-4 Air source requirements.......................................................................................... 6-7 Items to be confirmed when carrying the machine ................................................. 6-8

6-2-1 6-2-2 6-2-3 6-2-4

C-5

6-2-5

Foundation work ..................................................................................................... 6-9

6-3

Installation ........................................................................................................6-10
Precautions on installation.................................................................................... 6-10 Lifting .................................................................................................................... 6-10 Masses of machine units ...................................................................................... 6-12 Unpacking, inspection and cleaning ..................................................................... 6-12 Location of the shipping brackets ......................................................................... 6-13 Installing the machine ........................................................................................... 6-14

6-3-1 6-3-2 6-3-3 6-3-4 6-3-5 6-3-6

6-4

Connecting to the Power and Air Sources........................................................6-15

Connecting to the power source ........................................................................... 6-15 Grounding ............................................................................................................. 6-17 Connecting to the air source................................................................................. 6-19

6-4-1 6-4-2 6-4-3

6-5

Test Run...........................................................................................................6-20
Checking the machine before starting test run ..................................................... 6-20 Electric inspection before switching the power ON............................................... 6-20 Checking the parameter settings .......................................................................... 6-21 Checking the machine in manual operation.......................................................... 6-21 Breaking in operation............................................................................................ 6-21

6-5-1 6-5-2 6-5-3 6-5-4 6-5-5

APPENDIX............................................................................................ 7-1
7-1 List of Sensors, Limit Switches, and Oiling Points ..............................................7-1
List of oiling points .................................................................................................. 7-1 List of sensors and limit switches ........................................................................... 7-2

7-1-1 7-1-2

7-2

List of Wearable Parts ........................................................................................7-6

C-6 E

INTRODUCTION

INTRODUCTION
This manual describes the machine(s) specified in the title of this manual. In this manual, machine model names are expressed using the abbreviation specified in the table below.
Model Name INTEGREX e-1060V/6 II Abbreviation e-1060V/6 II

1-1
1-1-1

Outline of the Machine

Intended use of the machine
The e-1060V/6 II is high-performance multi-tasking machines that provide high speed, high accuracy and high added value. They incorporate a table enabling turning operations on a 5-axis control machining center capable of contour control machining and milling on multiple faces by utilizing three linear axes and two rotational axes. It can minimize production lead time by enabling machining on multiple faces in a single setup in multi-tasking operations (turning and milling) on the O.D. and I.D. of a large-diameter workpiece.

1-1-2

Operating positions
The normal operating position of the machine is in the range shown in the figure below.
Magazine operating panel

Pallet changer operating panel

NC operating panel Fig. 1-1 Operating positions

e-Tower

1-1

INTRODUCTION

1-1-3
1.

Features
High productivity The multi-tasking (turning and milling) function enables process integration for large and heavy workpieces, and minimizes the lead time. The high-speed and high-power spindle with a maximum speed of 10000 min1, a motor output of 37/30 kW (30 min./cont.) and a maximum torque of 505 Nm (372.47 ftlbf), and the table with a maximum speed of 500 min1, a motor output of 37/30 kW (30 min./cont.) and a maximum torque of 2954 Nm (2178.76 ftlbf) allow heavy-duty operation in rough machining of steel, cast, and aluminum workpieces, and high-speed and high-accuracy operation in finish machining. Through-spindle coolant enables accurate hole machining at high speed. Adoption of low-inertia servomotors and high-speed ball screws has achieved a rapid traverse rate of 42 m/min (1653.54 IPM). Positioning time can be reduced even in positioning over a short distance. The newly developed CNC performs ultra-high-speed calculations and motions simultaneously, drastically reducing idle times for higher productivity. 2. Machine construction that guarantees high-accuracy The capability to cut multiple faces in a single setup enables high-accuracy machining without requiring a special fixture. In addition, the wide travel ranges of the X- and Y-axes assure highaccuracy pitch on the top surface. The use of cone couplings at the joint between the pallet and the table provides high rigidity and improved repeatability at pallet changes. 3. Abundant unmanned operational functions The standard tool magazine accommodates 40 tools, and optional tool magazines that accommodate 80, 120 or 160 tools, and optional tool hives that accommodate 180, 240, or 330 tools are also available. A 2-pallet changer is provided as standard, and a single level FMS (PALLETECH MANUFACTURING CELL) or MAZATROL FMS (PALLETECH HIGH RISE SYSTEM) is available as an option. The cut chips are forcibly expelled from the machine by the chip conveyors provided at the right and left sides of the table and flushed by Niagara coolant (mandatory option for machines shipped inside Japan and standard for machines shipped overseas) supplied from the ceiling. These functions assure unmanned operation with many kinds of workpieces over long periods.

1-2

INTRODUCTION

1-2

List of Manuals to Be Used

For this machine, the following manuals are provided.
Manual name Operating manual Maintenance manual Programming manual Parameter list, alarm list and M code list Tooling manual Parts list Electrical wiring diagrams Operating manual for optional specifications All aspects of operation All aspects of maintenance, including inspections and adjustment All aspects of CNC programming Detailed description of NC parameters, NC alarms and M codes Dimensional drawings of tool shank and stud bolt Part procurement Electrical connections All aspects of operation Coverage

1-3

Numbering System for Pages

1. Normal case 2 - 15 Page number in chapter Chapter number 2. For additional pages to be inserted 3 - 16 - 1 Additional page

1-4

Numbering System for Figures and Tables

1. Figure number Fig. 3 - 1 Chapter number Main machine components Number of figure in chapter Title (1/2)

Number of figures with this title, as indicated by the denominator, and the serial number of the figure within the figures with this title, as indicated by the numerator.

2.

Table number Table 2 - 1 Chapter number Safety nameplate details Number of table in chapter Title

HGMCGA0101E

1-3

INTRODUCTION

- MEMO -

1-4 E

SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
The precautions to be observed to ensure safe operation of the machine are described here. The machine must not be operated until these precautions have been thoroughly understood.

2-1

Rule
1. This section contains the precautions to be observed as to the working methods and states usually expected. Of course, however, unexpected operations and/or unexpected working states may take place at the user site. During daily operation of the machine, therefore, the user must pay extra careful attention to its own working safety as well as to observe the precautions described below. 2. The meanings of our safety precautions to DANGER, WARNING, and CAUTION are as follows: : DANGER

Failure to follow these instructions could result in loss of life.

: WARNING

Failure to observe these instructions could result in serious harm to a human life or body.

: CAUTION

Failure to observe these instructions could result in minor injuries or serious machine damage.

2-2

Basic Safety
! There are high voltage terminals on the electrical control cabinet, transformer, motors, junction boxes, and other equipment (with a high-voltage danger mark attached). DO NOT touch any of them under any circumstances. ! Make sure that all doors and safety covers are fitted before switching on the power. If any door or safety cover must be removed, first cut off and lock the main power disconnect switch.

DANGER

HGMCGA0074E

2-1

SAFETY PRECAUTIONS

! Memorize the position of the EMERGENCY STOP button so that you can press it immediately from any position. WARNING ! Take care not to touch any of the switches accidentally while the machine is in operation. ! Take care not to catch your fingers in the chuck. (For lathes) ! Never touch a rotating workpiece or the tool with your bare hands or any other object. ! To prevent incorrect operation of the machine, carefully check the position of the switches before operation. ! If in the slightest doubt about a procedure, ask the person in charge. ! Always switch off the main power switch on the operating panel and the main power disconnect switch when you are taking a break from work and are going to leave the machine. ! If more than one operator is using the machine, do not proceed to the next step without indicating to the other operator(s) that you are about to do so. ! Do not modify the machine in any way that will affect its safety. ! Do not enter the machine. If you have to enter the machine, take measures such as turning off the main power disconnect switch or pressing the EMERGENCY STOP button that disable machine operation. ! If there is a power failure, switch off the main power disconnect switch immediately. ! Do not subject the NC unit, the operating panel, or the electrical control panel to strong shocks. ! Do not change the parameter values, volume values, or other electrical setting values without good reason. If you need to change a value, first check that it is safe to do so, then make a note of the original value so that it can be reset if necessary. ! Do not paint, soil, damage, modify, or remove any of the safety nameplates. If the details become illegible or the nameplate is lost, obtain a replacement by sending the part number stamped at the bottom right-hand corner of the nameplate to Mazak and mount the replacement in the original position. (If a nameplate has been lost, obtain the part number from the Parts List supplied separately.) ! Do not open any doors or safety covers while the machine is in automatic operation. ! Stop all machine operations before cleaning the machine or any of the peripheral equipment. ! After a job has been completed, set up each part of the machine so that it is ready for the next series of operations.

CAUTION

2-2

SAFETY PRECAUTIONS

2-3

Safety Considerations Relating to Operators including Clothing

! Tie back long hair which could become entangled in drive mechanisms. ! Wear safety equipment (helmet, goggles, safety shoes, etc.) whenever possible. ! Always wear a helmet if there are any overhead obstacles in the work area. ! Always wear a protective mask when machining magnesium alloys. ! Always use safety shoes with steel toe caps and oil-resistant soles. ! Never wear loose or baggy clothing. ! Always completely fasten buttons and hooks on the arms of clothing to avoid the danger of entanglement in drive mechanisms. ! Always use gloves when loading or unloading workpieces or tools and when removing chips from the work area to protect your hands from sharp edges and heat generated during machining. ! Do not operate the machine while under the influence of drugs with powerful effects, unprescribed drugs, or alcohol. ! Do not operate the machine if you suffer from dizziness or fainting spells.

CAUTION

2-4

Safety Considerations Relating to Machine Operation

! The use of inflammable lubricant as coolant is not recommended as it is dangerous and may cause a fire. If such use is unavoidable, it is the responsibility of management to ensure a fire extinguisher is readily available as a safety measure. Additionally, if an inflammable lubricant is used, the machine should never perform unmanned operation. An operator must always be present to ensure safety. The same precautions must be taken when machining inflammable materials such as magnesium alloy. ! Close all doors and covers of the NC unit, operating panel, electrical control cabinet, and junction boxes to prevent damage from water, chips, and oil. ! Check all electrical cables for damage to prevent accidents due to current leakage or electric shock. ! Do not handle coolant with bare hands since it is liable to cause irritation. Operators with allergies should take special precautions. ! Do not operate the machine during violent thunderstorms. ! Check the safety covers regularly to make sure that they are properly fitted and that they are not damaged. Repair or replace any damaged covers immediately. ! If the machine door, the cover, or other glass sections are found to be damaged, immediately stop the machine and replace the damaged sections. Failure to observe this instruction may result in injury due to the possible flyaway of the chuck jaws or tool during machining. When ordering replacement parts from your MAZAK product distributor, refer to the Parts List and specify the part numbers. ! Always obtain assistance in handling loads beyond your capacity. ! Do not operate fork lifts or cranes or carry out slinging work unless you have undergone officially approved training. ! When using fork lifts or cranes, make sure that there are no obstructions in the vicinity of these machines. ! Always use wire rope or slings of a standard suitable for the load to be supported.

WARNING

2-3

SAFETY PRECAUTIONS

! Wait until the machine has come to a complete stop before adjusting the position of the coolant nozzle. WARNING ! Do not remove or otherwise interfere with safety devices such as stop dogs, limit switches, or interlocks in order to increase axis travel. ! Do not operate the machine with any of the safety covers removed. ! Always wear gloves and use a brush to clean chips off the tool tip; never use bare hands. ! Stop all machine operations before mounting or removing a tool. ! Check slings, chains, hoists, and other lifting gear for defects before use. replace defective gear immediately. Repair or

! Electromagnetic waves are radiated from the NC machine tool. Although the level of radiation is quite low compared to that from a cell phone terminal, reliable operation of medical electrical devices cannot be guaranteed, so be sure to determine in advance whether or not you can engage in operations at the operating panel by consulting the manufacturer of your medical electrical device and your physician. ! Do not allow chips to accumulate during heavy-duty cutting since they will be hot and could start a fire. CAUTION ! Warm up the spindle and all of the axis motion mechanisms before operation. (Operate the machine in the automatic mode for 10 to 20 minutes at maximum spindle speed or at 1/3 to 1/2 maximum axis motion speed.) ! Write the program for the warming-up operation so as to execute the functions of the full range of machine components. If operation is to be performed at spindle speeds in excess of 4000 min1, pay meticulous attention to the warming-up operation. ! Do not operate the operating panel switches while wearing gloves as this could lead to incorrect operation or other mistakes. ! When one series of operations is completed, switch off the power switch on the NC operating panel, the main power disconnect switch, and then the factory power supply.

2-5

Safety Considerations Relating to Holding Workpieces and Tooling

! Always use tools which are suitable for the work to be carried out and conform to the machine specifications. Always observe the restrictions on mass of tool insert and tool diameter stipulated in the specifications. [Max. insert mass: 20 g (0.04 lbs)] ! Replace tools promptly, since badly worn tools can cause accidents and injuries. ! Before starting operation, check that the workpiece is securely mounted and cannot become detached by the cutting forces applied to it during machining. ! Before mounting a cutting tool in the machine, make sure that the tool and its stud bolt are properly secured. ! Do not rotate a cutting tool or holder at speeds greater than the rated speed. ! Check maximum safe operating speeds with the manufacturer. ! Be very careful not to catch your fingers in workpiece holding devices. ! Always use the correct lifting gear for heavy fixtures and workpieces.

WARNING

2-4

SAFETY PRECAUTIONS

! Do not forget to consider the limitation for chuck and retainer when setting the spindle speed. WARNING ! Do not operate a spindle on which accessories are mounted at above the rated speed. If the chuck or the accessory being used is not a MAZAK product, check the maximum safe operating speed with the manufacturer. (Lathe) ! Before starting the spindle, check that any parts which are bolted or clamped to the chuck or the steady rest are properly secured. (Lathe) ! Never leave a workpiece chucked when switching off the power. ! Workpieces heavier than the design data of the machine must not be machined. If an attempt is made to machine a workpiece heavier than the value obtained by subtracting the masses of the chucks and jaws from the maximum supporting capacity of the machine, the workpiece may abruptly fly out to cause a hazardous situation. ! Mount the tool holder in the correct orientation by aligning it with the drive key. ! Occasionally check for looseness after using a milling chuck. CAUTION ! Make sure that the workpiece is correctly mounted on the pallet or table. ! Check that vices, fixtures, etc., have no overhang with respect to the table. ! Make sure that the tools are arranged in the tool magazine correctly in accordance with the tool data set in the TOOL LAYOUT screen. ! Check that the lengths of all tools to be used have been measured. ! Move the tool nose to the initial point (X0, Y0) to check the basic coordinate system. ! Perform a test operation after mounting a cutting tool and workpiece. ! Make sure that the tool length is such that the tool will not interfere with fixtures such as chucks or other objects. ! After machining soft jaws, check that they grip the workpiece correctly and that the chuck pressure is correct. (Lathe) ! Since the tool holders can be mounted from the left or the right, check that the tool holder is mounted facing the correct direction.

2-6

Safety Considerations Relating to Maintenance

! Always switch off the main power disconnect switch and lock it before carrying out any maintenance work. This will eliminate the possibility of the machinery being accidentally started by someone else. ! After the power has been switched off for a short while, check the voltage with a multimeter or similar instrument to make sure that there is no residual voltage. Also discharge the capacitors.

DANGER

2-5

SAFETY PRECAUTIONS

! Maintenance of electrical equipment must be carried out by qualified licensed electrical engineers only. WARNING ! Do not remove or modify limit switches, proximity switches, or other safety devices. ! When carrying out maintenance in high places, always use a suitable ladder or a service platform and always wear a helmet. ! Always switch off the main power disconnect switch and lock it before replacing bulbs or other electrical equipment, and use products with the same specifications as the original. ! Do not start the machine until all of the covers removed for maintenance have been refitted. ! Wipe up any water or oil spills immediately, and keep the maintenance area and the workplace clean and tidy at all times. ! Be absolutely certain to use the specified and standardized parts as replacement or consumable parts so as to maintain the as-shipped machine specifications. We take no responsibility for any personal accidents or machine trouble due to inobservance of this warning. ! Electromagnetic waves are radiated from the NC machine tool. Although the level of radiation is quite low compared to that from a cell phone terminal, reliable operation of medical electrical devices cannot be guaranteed, so be sure to determine in advance whether or not you can engage in operations at the operating panel by consulting the manufacturer of your medical electrical device and your physician. ! Maintenance work should be carried out by qualified personnel in accordance with the instructions of the person in charge. CAUTION ! Make sure you fully understand how to maintain the machine. ! Do not use compressed air to clean the machine or to remove chips. ! Always use gloves when clearing away chips; never touch chips with bare hands. ! Use only the specified grades of hydraulic oil, lubricating oil, and grease or their equivalents. ! When changing a fuse, check that the new fuse has the correct rating. (Using a fuse with too high a rating could result in damage to the equipment.) ! Follow the instructions on the instruction plate concerning the brands of oil to be used, lubrication points, amount to be used, and oil change intervals. ! Check the results of maintenance work in the presence of the person in charge. ! Stop all machine operation before cleaning the machine or the surrounding area. ! Substances that have adverse effects on the environment if not disposed of appropriately are used in some of the equipment used in Mazak machine tools. In order to protect the environment, dispose of machine tools and accessory equipment in accordance with the laws of the country concerned. Entrust the processing to a contractor who deals with industrial waste. Note that any expenses associated with this processing are to be borne by the customer.

2-6

SAFETY PRECAUTIONS

2-7

Safety Considerations Relating to Workplace

! Immediately remove all water and oil spills from the floor, and dry the floor to prevent accidents.

WARNING

! Use strong service platforms only and make sure that nothing can slip off them. ! Keep combustible materials well away from the work area and any other place where there are hot chips. ! Always provide sufficient lighting in the work area. ! Always provide sufficient working space and clear access to the machine and peripheral equipment and store tools and other potential obstacles in a prescribed place away from the machine. ! Never place tools or other potentially dangerous objects on top of the headstock, turret, or covers. ! Make sure that the nominal cross-sectional area of the power supply cable between the factory power supply switch and the machine main power disconnect switch is such as to enable a stable supply for operation at the maximum output. ! Protect all cables which will run along the floor from being damaged by chips, since this could cause short-circuiting.

2-8

Safety Considerations Relating to Chip Conveyor

! Before attempting any kind of work related to the chip conveyor, make sure that the chip conveyor is in a complete stop state with power supply shut off. Ignoring this will cause serious injury. ! While the chip conveyor is operating, never touch or extend your hands into any part of the chip conveyor. Ignoring this will cause your hands or fingers to be caught into the chip conveyor and injured seriously.

WARNING

2-9

Safety Considerations Relating to Pallets

! When mounting a pallet on the machine, mount the pallet correctly so that the pallet changer hook can be engaged in the pallet.

WARNING

Failure to observe the instruction above could result in serious harm to a human life or body. ! When removing a pallet in the set-up side, confirm that the pallet is unclamped. Failure to observe the instruction above could result in minor injuries or serious machine damage. (Refer to PART 2, 3-13 Pallet Changer Operation in the Operating Manual for the procedure for confirming if the pallet is unclamped.)

CAUTION

2-7

SAFETY PRECAUTIONS

2-10 Safety Considerations Relating to Faceplate Jaws

! Set the faceplate jaw base following the instructions given on the related caution plates. ! Securely tighten the faceplate jaw base clamp bolts (4 places). Torque specification: 421 Nm (310.5 ftlbf) ! Always set the stopper bolt to prevent the safety key from sliding to the unclamp side. ! Before rotating the faceplate table, make sure that stopper bolt is set in the groove (4 places) at the periphery side of the faceplate.

WARNING

2-11 Safety Considerations Relating to Safety Devices

! The machine is provided with various devices for the operators safety. Never cancel any of the devices. WARNING Failure to observe this instruction could result in serious harm to a human life or body.

2-12 Remarks on the Cutting Conditions Recommended by the NC

! Before using the following cutting conditions: Cutting conditions that are the result of the Mazatrol Automatic Cutting Conditions Determination Function Cutting conditions suggested by the Machining Navigation Function Cutting conditions for tools that are suggested to be used by the Machining Navigation Function Confirm that every necessary precaution in regards to safe machine setup has been taken especially for workpiece fixturing/clamping and tool setup. ! Confirm that the machine door is securely closed before starting machining. Failure to confirm safe machine setup may result in serious injury or death.

WARNING

2-8

SAFETY PRECAUTIONS

2-13 Safety Nameplates

The functions of this machine mean that it can be dangerous. Therefore, in order to prevent accidents, safety nameplates are affixed at hazardous locations and at parts whose misoperation can be anticipated, both on the machine and peripheral devices. Always observe the cautions on the safety nameplates, and take care to operate the equipment safely. Some representative nameplates are shown below (note that the nameplates that are not shown are equally important). 1. General safety nameplates The nameplates give basic and general safety precautions. Operators and related personnel are required to fully memorize and understand these precautions so that they can be strictly followed without reading or referring to the nameplates each time an operation is performed. 2. Danger <Safety Nameplates> (a) <Remark>

3.

Warning <Safety Nameplates> <Remark>

(a)
The machine is provided with various devices for the operator's safety. Never cancel any of the devices. Failure to observe this instruction could result in serious harm to a human life or body.
32556308970

2-9

2
(b)

SAFETY PRECAUTIONS

<Safety Nameplates>

<Remark> A nameplate bearing the same contents is available for horizontal machining centers.

Before using the following cutting conditions:

Cutting conditions that are the result of the Mazatrol Automatic Cutting Conditions Determination Function Cutting conditions suggested by the Machining Navigation Function Cutting conditions for tools that are suggested to be used by the Machining Navigation Function Confirm that every necessary precaution in regards to safe machine setup has been taken - especially for workpiece fixturing/clamping and tool setup. Comfirm that the machine door is securely closed before starting machining. Failure to confirm safe machine setup may result in serious injury or death.

Keep off machine when in automatic mode. Can cause sever injury. Set control in manual mode before standing on machine. Turn off and lock out power at electrical panel before servicing. Keep hands clear of tool changer. Tool changer rotates automatically. Can cause severe injury. Turn off and lock out power at electrical panel before servicing.

Keep hands, clothing and body clear of rotating tool/spindle. Machine starts and moves automatically. SAFETY INSTRUCTIONS
Before working near spindle; 1.Return all tools to magazine. 2.Set in manual mode and stop the spindle. 3.Hang "Do not touch" sign on operator panel. 4.Wear safety helmet.
22726344100 ENGLISH

(c)
1.Avoid accidentally touching controls while the machine is running. 2.Know function of each switch before operating. 3.Close chip guard before running part.
ENGLISH 41416052111

(d)

2-10

SAFETY PRECAUTIONS

<Safety Nameplates> (e)

<Remark>

BEFORE ENTERING MACHINING AREA, CONFIRM THAT ALL MACHINE MOTIONS ARE STOPPED. BE CAREFUL AROUND MACHINED CHIPS AND SLIPPERY SURFACES

42346405651

(f)
Never put your hands on the conveyor duringchi p conveyor operation. Failure t o c omply wit h this WARNING may cause your fingers or hands to be entangled resulting in se vere injury.

Several se als m ade of NBRsy nthetic ru bber (acr ylonitrile-butad iene r ubber) ar e used i n this machine.
Some types of coolant inclu de ingredients t hat m ay any weaken N BR. Before y ou use any coo lant,please co mfirm f rom t he coola nt m anufacturer that the coolant will not weaken NBRsynthetic rubber.
22726344810 ENGLISH

(g)

Keep off. Keep hands and feet clear during pallet change. Can cause severe injury.
SAFETY INSTRUCTIONS 1.Be alert for pallet movement when loading parts. 2.Make sure workpiece is clamped securely. 3.Do not lay tools on pallet or workpiece. 4.Turn off and lock out power at electrical panel before servicing.
32726344040 ENGLISH

(h)

Use the tool within the tools tolerable speed. Neglecting the usage can cause severe lnjury. MAX. SPINDLE SPEED
min-1
42366298750

2-11

2
(i)

SAFETY PRECAUTIONS

<Safety Nameplates>

<Remark> Rotate the spindle in the permissible operating speed ranges of the workpiece holders such as the chuck and the work rest (if the workpiece holders are used in multiple places, at the lowest of the maximum permissible speeds or less). The operating speed limit value inscribed on the nameplate does not denote the maximum permissible spindle speed.

(j)

(k)
Keep hands and body away from the tool operating area to prevent serious injury during auto mode operating.
Safety instructions
1.Be sure to switch to manual mode for tool replacement. 2.Be sure to turn off the power to the machine for maintenance. 3. Check if pull-stud is securely tightened to tool holder at tool loading. 4. Load the tools in magazine so as to achieve good balance.

Provided only on machines equipped with a magazine. Exercise due care about sudden operation of the magazine.

Do not open door when machine is in automatic mode.

32726344080 ENGLISH

2-12

SAFETY PRECAUTIONS

<Safety Nameplates> (l)

<Remark>

WARNING

Always observe the following procedures when entering the magazine. Failure to observe these instructions, may cause the operator get caught in the moving parts, which can lead to a serious injury. Rotate and pull out the key at the top of the magazine door handle with the door opened. When entering the magazine, the operator who has pulled out the key must keep it on his person to prevent the door from being closed.
31286266710

(m)

WARNING
The grounding work must be entrusted to an electrical engineer with publicly recognized qualifications. If the work is done by an unqualified person, it could result in serious injury, death, or damage to the machine. Grounding resistance: 10 max.

33736260480

4.

Other <Safety Nameplates> <Remark> Indicates a danger of electric shock.

(a)

2-13

SAFETY PRECAUTIONS

2-14 Safety Considerations Relating to Mounting or Changing the Chuck (Pallet) by the User
When the chuck (pallet) is mounted by the user after the installation of the machine or the chuck (pallet) is changed from the one mounted on the machine when it was installed, the information below must be stamped on the nameplate. The parameters must also be set meeting the chuck (pallet) to be used. 1. Information to be stamped on the chuck nameplate The information to be stamped on the chuck nameplate is indicated below.

MANUFACTURE (Manufacturer of chuck (pallet) and cylinder) Example:

KAWATATEC

CHUCK (Chuck (pallet) type) Example:

1302660011

CYLINDER (Cylinder type) Example:

MAX. PRESSURE (Maximum setting pressure) Example:

* For this item, stamp the value obtained from the allowable maximum thrust of the chuck (pallet) and the allowable maximum pressure of the cylinder. MAX. STATIC GRIPPING FORCE (Maximum static gripping force) Example:

MAX. SPEED (Allowable maximum chuck (pallet) speed) Example: 500 min1

* For this item, stamp the value specified in the chuck (pallet) catalog.

2-14

SAFETY PRECAUTIONS

2.

Information to be stamped on the maximum workpiece dimension nameplate The information to be stamped on the maximum workpiece dimension nameplate is indicated below.

MAX DIAMETER (Max. workpiece diameter): Example:

1250

D (mm)

MAX HEIGHT (Max. workpiece height): Example:

1216

H (mm)

* The maximum workpiece height is 1416 mm (55.75 in) from the chuck (pallet) mounting reference face. When the chuck (pallet) height is 200 mm (7.87 in), stamp 1216 which is obtained by the calculation of 1416 200. MAX MASS (Max. workpiece mass): W (kg) Example:
2000

* Loading of up to 2700 kg (5952 lbs) (total of chuck (pallet) and workpiece) is possible. When the chuck (pallet) weighing 700 kg (1543 lbs) is used, stamp 2000 which is obtained by the calculation of 2700 700.

Max. workpiece height: H Chuck (pallet) mounting reference face Chuck (pallet) height

2-15

SAFETY PRECAUTIONS

3.

Setting the parameter determining the clamp speed of turning spindle ! At the spindle parameter screen, set the allowable maximum speed of the chuck (pallet) to SA1 and SA2 of SPDL2 (turning spindle). If the maximum speed (machine specification) of the turning spindle is lower than the allowable maximum speed of the chuck (pallet), input the maximum speed of the turning spindle instead. (Maximum speed of the turning spindle of machine specification: 500 min1) Spindle parameter screen:
No. SA1 SA2 Maximum speed of turning spindle Name SPDL 2

Example:

If the allowable maximum chuck (pallet) speed is 450 min1, set 450 for this parameter. If the allowable maximum chuck (pallet) speed is 600 min1, set 500 for this parameter.

Note: !

To make the set value valid, it is necessary to turn the power off once and then turn it back on.

When the machine is shipped without a chuck (pallet) mounted in the machine, the parameter is set as below to ensure safety.
Mode Manual Max. Speed of Turning Spindle (min1) 10 Comment In the automatic mode, if a spindle speed of 18 min1 or faster is specified for the turning spindle, the turning spindle speed is clamped at 18 min1. Therefore, if you try to rotate the turning spindle exceeding this limit in automatic operation, the spindle rotates at 18 min1. Note that this does not indicate a failure of the machine.

Automatic

18

! Do not set a value larger than the allowable maximum speed of the chuck (pallet).

WARNING

2-15 Safety Considerations Relating to Gripping Force and Rotating Speed

! All operators must read the instruction manual of the chuck (pallet) to be used, which is provided by the chuck (pallet) manufacturer, before attempting machine operation and ensure that the information described in the instruction manual is thoroughly understood. ! Do not operate the chuck (pallet) at a speed higher than the rotating speed that is indicated in the gripping force - rotating speed diagram supplied by the chuck (pallet) manufacturer.

WARNING

2-16

SAFETY PRECAUTIONS

2-16 Safety Devices

1. 2. This machine is provided with various safety devices to protect the operator and the machines. The safety devices include interlock devices and emergency stop switches, as well as doors and covers. ! The machine is provided with various devices for the operators safety. Never cancel any of the devices. WARNING Failure to observe this instruction could result in serious harm to a human life or body. The functions of the safety device are indicated below. Arrangement of Safety Devices
No. 1 Name Operators door interlock Function 1. The operators door cannot be opened during automatic operation. 2. The operators door can be opened by pressing the door unlock button while the machine is stopped. 3. While the operators door is open with the machine set up switch set at the I position, axis feedrates (X-, Y-, and Z-axis) are restricted at the safety speed. 2 Magazine door interlock 1. If the magazine door is opened while the magazine is operating, the magazine stops operating. 2. While the magazine door is open, the magazine cannot be operated. 3 Pallet changer safety cover and door interlock 1. If the pallet changer safety cover is opened while the pallet changer is operating, the pallet changer stops operating. 2. Pallet change operation is disabled while the door is open. 4 Emergency stop buttons (5 places) 1. The emergency stop button is provided on each operating panel. 2. When the emergency stop button is pressed, the machine stops in the emergency stop state independent of the selected operation mode (automatic, manual). A safety plate is fixed to the machine with screws to give operators and persons nearby warning information that standing near the movable area of equipment and devices is dangerous. 1. Connections where voltage is higher than 24 volts are protected by a cover or other similar part. 2. When the door of the electrical control cabinet is opened, main power supply is shut off and the machine stops. (Option) 1. The front door is glazed with a laminated glass pane which has been proved to withstand an impact energy of 6558 J minimum, with respect to a reflector of class C drag as specified in EN12415, Annex B. 2. The laminated glass pane which has been proved to withstand an impact energy of 2236 J minimum as specified in EN12417 is used. 8 Machine outer cover 1. The outer cover which has been proved to withstand an impact energy of 8000 J minimum, with respect to a reflector of class C drag as specified in EN12415, Annex B is used. 2. The outer cover which has been proved to withstand an impact energy of 1192 J minimum as specified in EN12417 is used. 9 ATC maintenance door interlock The ATC maintenance door can be opened by pressing the door unlock button while the machine is in an emergency stop state.

5 6

Safety plate Safety measures on wiring between the electrical control cabinet and machine Operators door safety window glass

2-17

SAFETY PRECAUTIONS

Safety device locations

7 3 4 1

9 4 10
Fig. 2-1 Safety device locations

No. 1 2 3 4 5

Name Operators door interlock Magazine door interlock Pallet changer safety cover and door interlock Emergency stop buttons (5 places) Safety plate

No. 6 7 8 9 10

Name Safety measures on wiring between the electrical control cabinet and machine Operators door safety window glass Machine outer cover ATC maintenance door interlock Air pressure relief valve (USA only)

2-18

SAFETY PRECAUTIONS

2-17 Safety Plate Locations

The machine has safety plates at appropriate positions to give the information to be strictly followed to ensure safety of operators during operation. These safety plates must not be colored, stained, damaged, modified, nor detached. If the letters on the safety plates get blurred or if any of the plates is lost, immediately order the plate and replace the existing one with new one or affix the new one at the correct position. For ordering the safety plate, use the part number stamped at the lower right area of the plate. The part number is also found in the safety plate table.
6

7 15 14 16 17 10 13 Enlarged view 5 8 3

11 12 18 1 4

2 20

21

19 20 21 22
Fig. 2-2 Safety plate locations

18

2-19

SAFETY PRECAUTIONS

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 General Safety Instruction

Description DANGER WARNING WARNING WARNING WARNING CAUTION WARNING WARNING/ CAUTION WARNING CAUTION WARNING WARNING WARNING WARNING WARNING WARNING

Parts No. 25626328233 33116228032 32556308970 22726344100 41416052111 35766329180 35626328371 42346405651 44136243000 22726344810 32726344040 35766426340 42366298750 33306205220 25756426290 45766426320 45766443170 35756451240 35216237911 35756449430 32726344080 31286266710 45776365110 33736260480 42346292790

Danger at Electric Control Cabinet and Relay Box Warning on Canceling Safety Equipment Warning on Machining Navigation, Table, ATC and Spindle Warning on Operation at Operating Panel Warning on Flying Out of Workpiece Caution on Direct Mounting of Tool Warning on Entry to Machine Prohibition on Standing on Way Covers Warning on Chip Conveyor Operation and Caution on Coolant Supply Warning on Pallet Changer Operation Caution on Pallet Mounting Warning on Max. Mill Spindle Speed Warning on Chuck Operation Warning on Faceplate Jaw Chuck Square Pallet Rotating Speed Circular Pallet Rotating Speed Max. Workpiece Dimensions Max. Tool Dimensions Max. Tool Dimensions CAPTO C8

20 21 22 23 24

Warning on Magazine Operation Warning on Magazine Door Opening Air Pressure Indication [0.5 - 1.0 MPa (70 - 150 psi)] Warning about Grounding High-voltage Danger Mark

2-20 E

OUTLINE OF THE MACHINE STRUCTURE

3
3-1

OUTLINE OF THE MACHINE STRUCTURE

Overview of Machine Units
The machine consists of the following major units. (Refer to Fig. 3-1.) 1. Mill spindle head and B-axis When a milling tool is used, the spindle is driven by an AC inverter motor and the spindle is clamped by the coupling when a turning operation tool is used. A tool is clamped in the spindle by spring force and a hydraulic cylinder is used to unclamp a tool. Cooling fluid is circulated around the mill spindle outer casing to minimize temperature rise of the spindle due to generation of heat from the bearings. An AC servomotor is used to turn the B-axis (mill spindle head) via the roller gear cam. 2. X-axis The table travels longitudinally, driven by an AC servomotor and a ball screw. A position encoder used for position detection is built in the servomotor. Linear guides are used as the guide for the table to move on the base. 3. Y-axis The mill spindle head travels in the crosswise direction, driven by an AC servomotor and a ball screw. A position encoder used for position detection is built in the servomotor. Linear guides are used as the guide for the mill spindle head to move on the saddle. 4. Z-axis The saddle travels vertically, driven by an AC servomotor and a ball screw. A position encoder used for position detection is built in the servomotor. Linear guides are used as the guide for the saddle to move along the column. 5. ATC arm The roller-cam type ATC mounts/removes a tool to/from the spindle. 6. Tool shifter The tool shifter carries a tool between the magazine and the ATC. The tool shifter consists of the carrier pocket and the magazine shifter. The carrier pocket turns from the horizontal position to the vertical position, actuated by a hydraulic cylinder, while it is moving from the magazine standby position to the ATC standby position. A ball screw is used for moving the carrier pocket. Magazine shifter is the roller-cam type tool shifter that carries a tool between the magazine and the standby position at the magazine side. 7. Magazine The magazine stores tools. The magazine is driven by an AC inverter motor to index the specified tool to the tool change position.

3-1

OUTLINE OF THE MACHINE STRUCTURE

8.

Table An AC servomotor rotates (indexes) the pallet as the C-axis. For turning operation, the pallet functioning as the spindle is driven by an AC inverter motor. Switchover between the C-axis and the turning spindle is made mechanically in the following manner: In the C-axis mode, the worm and the worm wheel engage with each other (drop-worm method) and the gear for turning operation is disengaged by the shifter. In the turning spindle mode, the worm and the worm wheel are disengaged (drop-worm method) while the gear for turning operation is engaged by the shifter.

9.

Pallet changer By the rotation of the arm, a pallet on the table is changed with a pallet at the setup station. For the rotation of the arm, an AC inverter motor is used. At the setup station, a pallet can be turned manually to facilitate set up.

10. Hydraulic unit A hydraulic pump generates hydraulic pressure by pumping working oil reserved in the tank to operate hydraulic actuators. Refer to 5-6-3 Hydraulic circuit diagram. 11. Air unit An external air source is connected to the air unit to supply the pressure-regulated air to operate pneumatic actuators. Refer to 5-7-4 Pneumatic circuit diagram. The air unit consists of a filter (with automatic drain system), regulator (reducing valve), shut-off valve, etc. 12. Centralized lubrication unit Two lubrication systems are provided to supply lubricating oil to the lubrication points: one system supplies lubricating oil to the mill spindle bearings and the ball screws, and the other system supplies lubricating oil to the linear guides. Refer to 5-8 Centralized Lubrication Unit. By the intermittent operation of the pumps, lubricating oil is automatically supplied to the lubrication points in the preset intervals as below: in intervals of 4 minutes for the spindle bearings and in intervals of 5 minutes for the ball screws and the linear guides. 13. Cooling unit A trochoid pump is used to draw cooling fluid from the tank and feeds it to the oil chiller where cooling fluid is cooled. Then, the cooling fluid is fed to the outer case of the mill spindle and the turning spindle, and also to the cooling piping for the table bearings, and the turning operation gear and the worm. Cooling fluid absorbs heat from the spindle and other mechanical parts and is cooled by the radiator and the fan; cooled oil is then circulated to the tank. Refer to 5-9-3 Cooling system circuit diagram.

3-2

OUTLINE OF THE MACHINE STRUCTURE

14. Coolant system A coolant pump is used to feed coolant, pumped from the coolant tank, to coolant nozzles. Refer to 5-10-3 Coolant circuit diagram. Coolant has two functions; to cool cutting tools and to wash away chips. 15. Electrical control cabinet Control units (spindle driver unit, servo control unit, NC unit, etc.) and control circuits are housed in the electrical control cabinet. 16. NC unit Machine operation is controlled by the NC unit. status. It also has the function to diagnose the machine

Refer to 5-12 NC Unit and Electrical Control Cabinet. 17. Covers Covers are provide to prevent chips generated during machining from scattering outside the machine or entering the slideway surfaces as well as to protect operators from hazards. As the covers, the machine has the ATC cover which automatically opens and closes for the execution of automatic tool change operation and the pallet door which rotates along with the pallet change operation during automatic. At the setup station, the safety cover is provided. 18. Machine light Fluorescent tubes and LED lighting are used to light the inside of the machine. 19. Safety devices Refer to the safety considerations relating to safety devices.

3-3

OUTLINE OF THE MACHINE STRUCTURE

Pallet changer

Pallet changer safety cover

Spindle cooling tank Hydraulic unit

Main power disconnect switch

Centralized lubrication unit Table lubricating oil cooling tank Centering jig Pallet changer operating panel Air unit Magazine shifter Operators door NC operating panel Pulse handle operating panel Magazine ATC arm

Electrical control cabinet

ATC maintenance door Coolant tank ATC maintenance door operating panel Magazine door Saddle Spindle Magazine operating panel

Z-axis

Y-axis

X-axis

Pallet Table Column Base

Fig. 3-1

Machine construction - major units

3-4

OUTLINE OF THE MACHINE STRUCTURE

3-2

Definition of Coordinate Axes

In the manuals supplied with the machine, the coordinate axes are defined as indicated below. Note:
X-axis

The coordinate axes are defined assuming that an operator is standing in front of the machine.
Table movements in the longitudinal (forward/backward) direction Positive direction (+): Table movement to the machine front side

Negative direction (): Table movement to the machine rear side Y-axis Mill spindle head movement in the crosswise (right/left) direction Positive direction (+): Mill spindle head movement to the left

Negative direction (): Mill spindle head movement to the right Z-axis Mill spindle head movement in the vertical (up/down) direction Positive direction (+): Mill spindle head upward movement

Negative direction (): Mill spindle head downward movement B-axis Mill spindle turning Positive direction (+): Clockwise direction viewed from the operators door side

Negative direction (): Counterclockwise direction viewed from the operators door side C-axis Table rotation Positive direction (+): Clockwise direction viewed from the top

Negative direction (): Counterclockwise direction viewed from the top

+ + B-axis Y-axis + + (CW) C-axis (CCW) Z-axis

+ X-axis

Fig. 3-2

Definition of coordinate axes

3-5

3
3-3

OUTLINE OF THE MACHINE STRUCTURE

Maintenance Cover
! Do not remove the maintenance cover except for maintenance. ! Always set the main power disconnect switch to the OFF position and lock it before removing the maintenance cover. ! Do not switch on the main power supply before fitting the maintenance cover. If you fail to observe this instruction you could be entangled in or crushed by moving parts, resulting in serious injury. This machine has a maintenance cover as shown in Fig. 3-3. The maintenance work inside the machine can be performed by removing the maintenance cover.

WARNING

Maintenance cover

Fig. 3-3

Position of the maintenance cover

3-6 E

REGULAR INSPECTION

4
4-1

REGULAR INSPECTION
General
Regular inspection and maintenance is essential to maintain high accuracy for a long period. Therefore, regular inspection and maintenance must be given the top priority for operating the production facility. ! When carrying out inspection and maintenance, keep the doors of the electric control cabinet closed unless the intended inspection or maintenance requires the door to be open.

CAUTION

! Never use compressed air when cleaning inside the machine since it will cause sand grit, dust and other foreign matter to enter the bearings and slideways, causing the failure of the machine. ! Before carrying out maintenance or repair work on the machine, lock the main power disconnect switch in the OFF position with a padlock so that other workers cannot operate the machine. * The padlock should be prepared by the user.

WARNING

Fig. 4-1

Locking main switch in the OFF position (example)

Oiling: The machine has many places which require lubrication. For appropriate lubrication, the most important point is not to supply oil excessively. When supplying oil, follow the instructions given in this manual. Note: If lubricating oil is consumed faster than usual or if the machine generates abnormal noise, check the machine since such phenomena could be signs of machine failure.

4-1

4
4-2

REGULAR INSPECTION

Table of Inspection and Maintenance Items

Symbol indicates the inspection interval.
Approximate Operating Hours Daily Inspection/Maintenance Intervals Weekly 60 H Monthly 250 H Every 6 months 1500 H Every year 3000 H Refer to

Items Inside the machine 1. Removing chips around the mill spindle
2. Removing chips from on top of the Xaxis way cover
3. Removing chips on the pallet changer hook
4. Cleaning the window in the operators door
5. Removing chips on the TOOL EYE and laser tool length measuring unit (option)
6. Removing chips from inside the machine
7. Adjusting the in-machine chip conveyor hinge belt tension

4-3-1
4-3-1
4-3-1
4-3-1
4-3-1
4-3-1
Refer to the instruction manual supplied by the manufacturer.

(1 month after the installation; only at this time)

Outside the machine 1. Cleaning the 2-pallet changer hook coolant line filter by the manual handle
2. Removing chips from the conveyor
3. Cleaning the chip bucket
4. Cleaning the air filters of the table cooling fluid control unit
5. Cleaning the chip conveyor
Checking oil levels 1. Checking the hydraulic oil level
2. Checking the spindle cooling fluid level
3. Checking the table lubricating oil level
4. Checking the mill spindle lubricating oil level
5. Checking the slideway lubricating oil level
6. Checking the coolant level
Checking pressures (hydraulic and air) 1. Checking the hydraulic unit oil pressure
2. Checking the air pressure
Changing or replenishing oils 1. Replenishing coolant (as needed)
2. Replenishing lubricating oil of the centralized lubrication unit (as needed)
3. Cleaning the strainers of the mill spindle cooling fluid chiller unit and the table lubricating oil chiller unit

4-3-2
4-3-2
-

4-3-3
4-3-3
4-3-3
4-3-3
4-3-3
4-3-3

4-3-4
4-3-4

4-3-5
4-6-1

4-2

REGULAR INSPECTION

Approximate Operating Hours Daily

Inspection/Maintenance Intervals Weekly 60 H Monthly 250 H Every 6 months 1500 H Every year 3000 H Refer to

Items 4. Changing the hydraulic oil of ATC unit 5. Changing the hydraulic oil of magazine shifter unit 6. Changing the table lubricating oil and cleaning the suction filter 7. Changing the oil in compound oil control unit and cleaning the filter 8. Changing the oil in table cooling fluid oil control unit and cleaning the filter 9. Changing the B-axis lubricating oil Greasing 1. Greasing the carrier linear guide 2. Greasing the carrier ball screw 3. Greasing the ATC door linear guide 4. Greasing the counter balance 5. Greasing the NC operating panel linear guide Around the machine 1. Cleaning the exterior of the machine 2. Checking the machine and hydraulic unit for oil leaks 3. Collecting coolant from the oil pan below the magazine cover 4. Checking the Z-axis servo load 5. Cleaning the mill spindle taper hole 6. Tightening the retention knob 7. Checking the tools (inserts) for chipping, cracks, and other damage 8. Cleaning the tool shank 9. Cleaning the line filter of the throughspindle cooling system 10. Cleaning the air filters of the compound oil control unit 11. Cleaning the sensor detecting the presence of a tool in a tool pot in the magazine unit 12. Checking the indicator lamps on the operating panels 13. Checking the emergency stop buttons for correct operation 14. Checking the magazine chain tension

4-7-1 4-7-1 4-7-1 4-7-1 4-7-1 4-7-1

4-6-2 4-6-2 4-6-2 4-6-2 4-6-2

4-3-6 4-3-6 4-3-6 4-3-7 4-4-2 4-4-2 4-4-2 4-4-2 4-4-2 4-4-2

4-4-2 4-5-1 ( ) First one month 4-6-3

15. Checking the safety devices for correct operation 16. Checking the air unit drain function 17. Checking the wipers at the axis way cover for damage

4-6-3 4-6-3 4-6-3

4-3

REGULAR INSPECTION

Approximate Operating Hours Daily

Inspection/Maintenance Intervals Weekly 60 H Monthly 250 H Every 6 months 1500 H Every year 3000 H Refer to

Items 18. Clearing chips from inside the X-axis way cover 19. Cleaning the coolant tank and changing coolant 20. Checking hoses on moving units for damage 21. Cleaning the table filter 22. Cleaning the spindle lubricating unit filters 23. Cleaning the fans in the electrical control cabinet 24. Checking the in-machine lighting 25. Inspecting the machine for noise, vibration, and abnormal temperature rise 26. Changing the machine light (fluorescent lamp) and cleaning the window 27. Visually inspecting all electric parts and relay panel 28. Checking the foundation bolts

4-6-3 4-6-3 4-6-3 4-7-2 4-7-2 4-7-2 4-9

4-4

REGULAR INSPECTION

4-3
4-3-1

Daily Inspection and Maintenance

Inside the machine
! Switch off the power before cleaning inside the machine.

WARNING Perform the following work.

1. Removing chips around the mill spindle 2. Removing chips from on top of the X-axis way cover (spindle side and pallet changer side) If chips accumulate on the X-axis way cover during machining, discharge Niagara coolant to the X-axis way cover by adjusting its nozzle angle to wash away chips. If the machine is kept operated with chips accumulated on the X-axis way cover, the Xaxis way cover may be damaged. 3. Removing chips on the pallet changer hook (Inside the machine/setup station) If chips accumulate on the pallet changer hook during machining, discharge cover coolant to the pallet changer hook by adjusting its nozzle angle to wash away chips. If a pallet change operation is carried out with chips accumulated on the pallet changer hook, the machine may be damaged. In-machine conveyor Table 5. Removing chips on the TOOL EYE and laser tool length measuring unit (option) If chips accumulate on the TOOL EYE and laser tool length measuring unit, remove chips manually. If a measurement is carried out with chips accumulated on the TOOL EYE and laser tool length measuring unit, the machine may be damaged. 4. Operators door Pallet changer Pallet changer door

Setup station

Fig. 4-2

Inspection and maintenance inside the machine

4-5

REGULAR INSPECTION

4-3-2
1.

Outside the machine

Removing chips from the conveyor Check if chips are accumulated on the external chip conveyor belt through the window at the back of the coolant tank. When chips are accumulated on the belt, run the external chip conveyor for about five minutes.
Check for the accumulation of chips on the external chip conveyor belt. When chips are accumulated on the external chip conveyor belt, run the chip conveyor to dispose chips.

Fig. 4-3

2.

Cleaning the chip bucket ! If coolant, oil or other fluid gets spilled on the floor, wipe it off with a cloth and dry the floor immediately. If the floor remains wet with spilled fluid, personnel could slip over and be injured.

WARNING

! Do not touch chips with bare hands, otherwise you could be injured.

CAUTION Dispose of chips accumulated in the chip bucket several times a day according to the machine operating conditions.

4-3-3

Checking oil levels

Check the oil level at each of the tanks by the oil level gauge. If the oil level is lower than the allowable lower limit, replenish the specified oil. 1. 2. 3. 4. 5. Checking the hydraulic oil level Checking the spindle cooling fluid level Checking the table lubricating oil level Checking the oil level (mill spindle lubricating oil and slideway lubricating oil) Checking the coolant level ! Check to be sure that coolant level is higher than the lower limit line of the level gauge. If the machine is operated although coolant amount is insufficient, the way covers and other machine parts may be damaged due to chips accumulated in the machine caused by insufficient coolant discharge amount or the coolant pump itself may be damaged. Note that coolant could be consumed unexpectedly depending on conditions such as temperature and humidity.

CAUTION

4-6

REGULAR INSPECTION

4-3-4
1.

Checking pressures (hydraulic and air)

Checking the hydraulic unit oil pressure 0 MPa (0 psi): 7.0 MPa (1000 psi): 2. With power OFF With power ON

Checking the air pressure 0.5 MPa (70 psi)

4-3-5
1.

Changing or replenishing oils

Replenishing coolant (as needed) ! If coolant, oil or other fluid gets spilled on the floor, wipe it off with a cloth and dry the floor immediately. If the floor remains wet with spilled fluid, personnel could slip over and be injured. < Procedure > (1) Check the coolant level at the oil level gauge. Coolant tank capacity: 900 L (31.78 ft3) ! Since some kinds of coolant are injurious to health, you must be exercise due care when handling coolant. Do not handle coolant with bare hands.

WARNING

CAUTION (2) If the coolant level is low, replenish with the stipulated coolant to the upper limit level of the oil level gauge. If the coolant goes over the upper limit level, coolant returned to the coolant tank could overflow the tank when the coolant pump is stopped. Remark: For the selection of coolant, see PART 2, 4-3 Preparing Coolant in the Operating Manual.

4-7

REGULAR INSPECTION

4-3-6
1.

Around the machine

Cleaning the exterior of the machine Wipe off oil, coolant, chips, and other foreign matter from the surface of the machine. Use soft cloth soaked with neutral detergent to clean the screen and operating panels. 2. Checking the machine and hydraulic unit for oil leaks Visually check the machine, hydraulic unit, hydraulic piping/hose, and blocks and cylinders for oil leaks. If oil leak is found, appropriate measures must be taken. 3. Collecting coolant from the oil pan below the magazine cover

< Procedure > (1) Check the amount of coolant in the oil pan by observing the gauge. (2) If coolant is viewed through the gauge, loosen the knurled knobs and pull out the oil pan. Return the coolant reserved in the oil pan to the coolant tank. (3) Set the oil pan as before and tighten the knurled knobs. ! Make sure to check the amount of coolant in the oil pan and also to secure the oil pan. Otherwise, coolant leaks will occur. CAUTION

4-3-7

Checking the Z-axis servo load

After the installation of the machine, measure and record the Z-axis servo load (operator side and magazine side) and check the Z-axis servo load every day after that. If the read servo load exceeds the recorded load by more than 20%, refer to 5-2-1 Troubleshooting.

4-8

REGULAR INSPECTION

4-4
4-4-1

Weekly Inspection and Maintenance

Changing or replenishing oils
1. Replenishing mill spindle lubricating oil When replenishing the spindle lubricating oil, pay attention so that the oil level does not exceed the upper limit line of the oil level gauge of the lubrication unit. Tank capacity: 3 L (0.11 ft3) Lubricating oil consumption amount: 1.95 cm3 (0.12 in3) per hour * Recommended oil: Refer to 7-1-1 List of oiling points. When replenishing oil, use only the oil specified by Yamazaki Mazak. machine trouble and other problems will occur. Otherwise,

Note:

2.

Replenishing slideway lubricating oil When replenishing the slideway lubricating oil, pay attention so that the oil level does not exceed the upper limit line of the oil level gauge of the lubrication unit. Tank capacity: 3 L (0.11 ft3) Lubricating oil consumption amount: 36 cm3 (2.20 in3) per hour * Recommended oil: Refer to 7-1-1 List of oiling points. When replenishing oil, use only the oil specified by Yamazaki Mazak. machine trouble and other problems will occur. Otherwise,

Note:

4-4-2

Around the machine

Perform the following to maintain tool holding accuracy, etc. 1. Cleaning the mill spindle taper hole Clean the taper hole of the mill spindle with clean cloth. 2. Tightening the retention knob Check the retention knob for looseness and tighten it if loose. 3. Cleaning the tool shank Clean the tool shank with clean cloth.

4-9

REGULAR INSPECTION

4.

Cleaning the line filter of the through-spindle cooling system (option) Through-spindle coolant pressure: 0.8 MPa/1.5 MPa (120/220 psi) Check the indicator and if a half of the indicator is red, remove the bolts and clean the element of the line filter. For the position of the line filter, refer to Fig. 5-23.

Indicator

Bolt

MC111-01327
Fig. 4-4 Cleaning the line filter

5.

Cleaning the air filters of the compound oil control unit The air filters at the oil filling port side of the compound oil control unit can be removed by pulling the air filter upward while holding the knobs on the filter. After removing, clean the air filter using a brush, a hand held air nozzle or a vacuum cleaner. For details, refer to the LIQUID TUNER Instruction Manual, provided by KOUWAKOUGYO CO., LTD. Note: Do not use a hand held air nozzle near the machine since this could cause machine trouble.

Air filter of the spindle cooling fluid chiller unit Fig. 4-5 Locations of the air filters

Air filter of the table lubricating oil chiller unit

4-10

REGULAR INSPECTION

6.

Cleaning the sensor detecting the presence of a tool in a tool pot in the magazine unit Lightly swab the lens of the sensor (photoelectric sensor) detecting the presence of a tool in a tool pot with dry and clean cloth or a clean cloth soaked in water or neutral detergent. Note that use of organic solvents such as benzene, acetone, and thinner can cause malfunctioning of the sensor.

Sensor detecting the presence of a tool in a tool pot

Fig. 4-6

Location of the sensor detecting the presence of a tool in a tool pot in the magazine unit

4-11

REGULAR INSPECTION

7.

Checking the indicator lamps on the operating panels

FMS-ready specification Standard specification

NC operating panel Pulse handle operating panel

EMERGENCY STOP
EMERGENCY STOP

EMERGENCY STOP

1 CYCLE
PALLET CHANGE HOLD PALLET LOCK PIN LOCK UNLOCK PALLET CHANGE HOLD

LOCK

UNLOCK

PALLET LOCK PIN

1 CYCLE 1 CYCLE

PALLET CHANGE HOLD

Manual pallet rotation specification

Powered pallet rotation specification

Powered pallet rotation specification

TOOL SELECT AUTO MANUAL

EMERGENCY STOP

FORWARD

REVERSE

Magazine operating panel

Fig. 4-7

Checking the indicator lamps on the operating panels

4-12

REGULAR INSPECTION

Confirm that all of the indicator lamps on the operating panels turn on correctly. If there is an indicator lamp that fails to turn on, contact the Mazak Technical Center or Technology Center. NC operating panel Pulse handle operating panel Pallet changer operating panel Mill spindle tool magazine operating panel

4-13

4
4-5

REGULAR INSPECTION

Monthly Inspection and Maintenance

Around the machine
1. Checking the emergency stop buttons for correct operation Check that the emergency stop button arranged on the NC operating panel and pallet changer operating panel functions correctly. If an emergency stop button fails to function correctly, the button must be changed.

4-5-1

4-6
4-6-1

Every Six-Month Inspection and Maintenance

Changing or replenishing oils
1. Cleaning the strainers of the mill spindle cooling fluid chiller unit and the table lubricating oil chiller unit If the strainer is not properly inspected and cleaned, the pump and valves will be rapidly worn and further causing noises. Inspect, clean and replace the strainer regularly. Inspect, clean and/or replace the oil filing port filter/air breather and the strainer every six months. < Procedure > (For details, refer to the LIQUID TUNER Instruction Manual, provided by KOUWAKOUGYO CO., LTD.) (1) Shut off the power and place the main power disconnect switch to the OFF position. (2) Remove the maintenance covers, remove the strainer cap and take out the screen. For the spindle cooling fluid chiller unit, four strainers are provided, and for the hydraulic unit and the table lubricating oil chiller unit, one strainer is provided respectively. (3) Clean the screen with cleaning oil and check external appearance. If abnormality is found, replace the screen. (4) Clean and check the air breather and the oil filling port filter in the same manner. Replace the air breather or the oil filling port filter if abnormality is found. (5) Return the screen as before, i.e., the state before step (2).

No. 1 2 3 4 5
Fig. 4-8 Construction of the strainer

Parts name Body Cap Screen Gasket Plug

4-14

REGULAR INSPECTION

Strainer of the spindle cooling fluid chiller unit

Strainer of the spindle cooling fluid chiller unit

Fig. 4-9 Locations of the strainers (for mill spindle)

Strainer of the hydraulic unit

Strainer of the table lubricating oil chiller unit

Fig. 4-10

Locations of the strainers (for table)

4-15

REGULAR INSPECTION

4-6-2

Greasing
! Shut off the power before changing the hydraulic oil. ! When supplying grease, use only the grease specified by Yamazaki Mazak. Otherwise, machine trouble and other problems will occur.

WARNING 1.

Greasing the carrier linear guide

Carrier unit

A ATC arm Grease nipples

View A

Fig. 4-11

Greasing the carrier linear guide

< Procedure > (1) Place the main power disconnect switch to the OFF position. (2) Supply grease through the grease nipples. (Amount of grease: 2.4 cm3 (0.15 in3) 2 places) Note: When supplying grease, do not remove parts attached to the carrier unit. (If a part is removed, it can cause faulty tool change operations to result in alarm stop.)

4-16

REGULAR INSPECTION

2.

Greasing the carrier ball screw

Carrier unit

ATC arm B

Grease nipple

View B

Fig. 4-12

Greasing the carrier ball screw

< Procedure > (1) Place the main power disconnect switch to the OFF position. (2) Supply grease through the grease nipples. (Amount of grease: 2.4 cm3 (0.15 in3)) Note: When supplying grease, do not remove parts attached to the carrier unit. (If a part is removed, it can cause faulty tool change operations to result in alarm stop.)

4-17

REGULAR INSPECTION

3.

Greasing the ATC door linear guide

A
Greasing port of ATC door linear guide (upper)

A DETAIL
Greasing port of ATC door linear guide (lower)

Detach the cover.

Fig. 4-13 Greasing the ATC door linear guide

B DETAIL

< Procedure > (1) Place the main power disconnect switch to the OFF position. (2) Detach the cover. (2 locations on section B) (3) Supply grease through the grease nipple in section A. (Amount of grease: 2.2 cm3 (0.13 in3)) (4) Move the ATC door 560 mm (22.05 in). (5) Supply grease through the grease nipples in section B. (Amount of grease: 1.1 cm3 (0.07 in3) 2 places)

4-18

REGULAR INSPECTION

4.

Greasing the counter balance < Procedure > (1) Position the Z-axis at 1300 mm position and place the main power disconnect switch to the OFF position. (2) Remove the maintenance cover. The greasing panel is now visible.

Maintenance cover

Fig. 4-14

(3) Remove the front nozzle from the grease hand pump.
Screw 1/8 Nozzle

Reference part number: P21LA000210 Type: LG-400 Lube Fig. 4-15

(4) Fill the grease hand pump with grease (Toray Dow Corning SH33M). Amount of grease: 100 cm3 (6.1 in3) 2 places

4-19

REGULAR INSPECTION

(5) Remove the hexagon socket head plug on the greasing panel.

IN side

OUT side

Hexagon socket head Fig. 4-16

(6) Fit the grease hand pump to the bushing (IN side: upper left side), feeding grease to for the magazine side, on the greasing panel and supply grease. Confirm that grease oozes through the OUT port.

Greasing port 1/8

Front end of the grease hand pump

Fig. 4-17

Note 1: The greasing port size is PT1/8. If the type of the available grease hand pump differs from the specified type, use a bushing so that the grease hand pump is connectable to the greasing port. Note 2: If grease is supplied with the grease nipple fitted to the greasing port, the grease nipple is deformed and grease cannot be supplied correctly. Therefore, supply grease after connecting the front end of the grease hand pump to the greasing port. (7) Supply grease to the operator side (lower side on the greasing panel) in the same manner. (8) After finishing greasing, fit the hexagon socket head plug to the IN and OUT side ports.

4-20

REGULAR INSPECTION

5.

Greasing the NC operating panel linear guide

Turn the NC operating panel 120.

Detach the cover. Greasing port of NC operating panel linear guide

A DETAIL
(2 places)

Fig. 4-18

Greasing the NC operating panel linear guide

< Procedure > (1) Place the main power disconnect switch to the OFF position. (2) Turn the NC operating panel 120 and remove the covers (2 section A locations). (3) Supply grease through the grease nipples.

4-21

REGULAR INSPECTION

4-6-3
1.

Around the machine

Checking the safety devices for correct operation ! Since the machine may move unexpectedly, leading to a hazardous situation if a safety device is faulty, do not rest your body, or leave any unnecessary objects, on the moving units or within the range of movement of the units when performing inspections. If an abnormality is found in the inspection, contact Mazak Technical Center or Technology Center. A. Operators door interlock Check that the operators door interlock operates correctly by referring to PART 2, 2-9 Operators Door Interlock in the Operating Manual. B. Pallet changer safety cover interlock Check that the execution of pallet change operation is controlled according to the state of the pallet changer safety cover as indicated below. Safety Cover Closed Open 2. Pallet Change Operation Executed Not executed

WARNING

Checking the magazine chain tension ! Set the main power disconnect switch to the OFF position before checking the chain, otherwise you could sustain serious injury.

WARNING Although the magazine chain tension is adjusted after initial elongation of the chain before shipping, the magazine chain will be elongated during use of the magazine over a long time. Indexing of tools is carried out by the rotation of sprockets and slight slackness of the magazine chain causes no problems with indexing accuracy. However, if the slackness of the magazine chain is apparent to the touch , it will cause overloading of the drive motor. Therefore, the chain tension must be adjusted using the tension adjusting bolts.

4-22

REGULAR INSPECTION

40-tool magazine

Magazine chain tension adjusting section

Fig. 4-19

Tool magazine (40 tools)

80-tool magazine

Magazine chain tension adjusting section

Fig. 4-20

Tool magazine (80 tools)

4-23

REGULAR INSPECTION

120-tool magazine

Magazine chain tension adjusting section

Fig. 4-21

Tool magazine (120 tools)

160-tool magazine

Magazine chain tension adjusting section

Fig. 4-22

Tool magazine (160 tools)

4-24

REGULAR INSPECTION

3.

Checking the air unit drain function

Mist separator Drain port Phillips-head screwdriver

Fig. 4-23

Checking the air unit drain function

The automatic drain function of the mist separator is faulty in the following cases. A. Air is always leaking through the drain port. Corrective action: Poke the drain port several times with the Phillips-head screwdriver. If the air still leaks, refer to 5-7 Pneumatic System for the corrective action to be taken. B. Large amount of water is discharged from the drain port when the Phillips-head screwdriver is inserted into the drain port. Corrective action: The mist separator must be changed.

4-25

REGULAR INSPECTION

4.

Checking the wipers at the axis way cover for damage ! Set the main power disconnect switch to the OFF position before entering the machine. Otherwise, you may sustain serious or fatal injury.

WARNING Visually check the wipers at the X- and Y-axis way covers for damage. wiper, change it with new one as soon as possible.
Y-axis way cover

If damage is found in a

Wiper A

Wiper A

X-axis way cover

Wiper B

Wiper B

Fig. 4-24

Checking the wipers at the axis way cover for damage

5.

Clearing chips from inside the X-axis way cover See 5-11-4 Maintenance of the X-axis way cover for the procedure to remove the X-axis way covers.

4-26

REGULAR INSPECTION

6.

Cleaning the coolant tank and changing coolant ! If coolant, oil or other fluid gets spilled on the floor, wipe it off with a cloth and dry the floor immediately. If the floor remains wet with spilled fluid, personnel could slip over and be injured. < Procedure > (1) Pull out the tank to the machine front side. (2) Remove the filters, bucket, coolant pump, and top cover from the coolant tank. machine is equipped with the chip conveyor, remove the chip conveyor too. (3) Pump the coolant from the coolant tank. (4) If coolant level becomes low and pumping becomes impossible, loosen the drain plug of the coolant tank to completely discharge coolant from the coolant tank. (5) When the coolant is completely discharged from the coolant tank, remove chips and sludge deposited at the bottom of the tank. (6) Clean the inside of the coolant tank with rag. (7) After cleaning the coolant tank, refit the drain plug and other parts removed. (8) Supply new coolant to the coolant tank. For the procedure to supply new coolant, refer to 4-3-5 Changing or replenishing oils. If the

WARNING

7.

Checking hoses on moving units for damage ! Switch off the power before checking hoses on moving units for damage. Otherwise, you may sustain serious or fatal injury.

WARNING < Procedure > (1) Place the main power disconnect switch to the OFF position. (2) Move the e-Tower aside and check the hoses to the rear of the machine for damage. Check the hoses for damage such as cracks, abnormal bulge, and deterioration. If any damage is found, contact Mazak Technical Center or Technology Center.

4-27

4
4-7

REGULAR INSPECTION

Every One-Year Inspection and Maintenance

Changing or replenishing oils
! Shut off the power before changing the hydraulic oil. ! When replenishing oil, use only the oil specified by Yamazaki Mazak. Otherwise, machine trouble and other problems will occur.

4-7-1

WARNING 1.

Changing the hydraulic oil of ATC unit

ATC arm

Oil filler port

Oil level gauge

ATC unit

Drain hole Fig. 4-25 Changing the hydraulic oil of ATC unit

< Procedure > (1) Place the main power disconnect switch to the OFF position. (2) Loosen the drain plug to discharge the oil. (3) Tighten the drain plug. (4) Supply the fresh oil while observing the amount oil by the oil level gauge. (Amount: 6 L (0.21 ft3)) Note: When supplying the hydraulic oil, do not remove brackets and other parts attached to the ATC unit.

4-28

REGULAR INSPECTION

2.

Changing the hydraulic oil of magazine shifter unit

Oil filler port

Magazine shifter (Magazine shifter unit)

Oil level gauge

Drain port (at the bottom) Fig. 4-26 Changing the hydraulic oil of ATC unit

< Procedure > (1) Place the main power disconnect switch to the OFF position. (2) Loosen the drain plug to discharge the oil. (3) Tighten the drain plug. (4) Supply the fresh oil while observing the amount oil by the oil level gauge. (Amount: 3.6 L (0.13 ft3)) For the specified oil, refer to 7-1-1 List of oiling points.

4-29

REGULAR INSPECTION

3.

Changing the table lubricating oil and cleaning the suction filter

Lever

Cover

IN OUT

T-joint Pull out the coolant tank 770 mm (30.31 in). Fig. 4-27 Changing the table lubricating oil

Suction filter

Since the cooling fluid of the table unit circulates through the chiller unit, change the lubricating oil at the same time as changing the oil in the chiller unit. Clean the suction filter at the same time as changing the table cooling fluid. < Procedure > (1) Shut off the power and place the main power disconnect switch to the OFF position. (2) Drain the oil from the chiller unit. (Refer to 5. Changing the oil in table cooling fluid oil control unit and cleaning the filter.) The filter becomes visible when the coolant tank is pulled about 770 mm (30.31 in). The cooling fluid inside the table is drained by removing the plug fitted in the T-joint in the piping from the filter to the tank. (The cooling fluid starts draining when the plug is removed, so receive it with an oil pan until it stops.) (3) Turn the lever 90. The cover is released, allowing its removal. ! Before this step, place an oil collecting thing such as an oil pan under the suction filter unit since the lubricating oil in the suction filter unit will flow out when the cover is released. CAUTION

4-30

REGULAR INSPECTION

(4) Remove the suction filter. Since the suction filter is set in place using the spring, remove the suction filter while holding the spring. (5) Remove the suction filter with a spanner and clean it with a hand held air nozzle. (6) Fit the suction filter. Make sure to fit the suction filter correctly. Set it in the manner the open port faces the OUT side. (7) Attach the cover and return the lever to the horizontal position. Make sure that the cover is correctly clamped in place. through the cover. (8) Fit the plug to the T-joint. (9) Return the coolant tank to the previous position. (10) Supply the oil to the chiller unit. [35 L (1.24 ft3)]. (11) Turn on the NC power and the oil starts circulating from the chiller unit to the table and then to the chiller unit. (12) Replenish the oil while observing lowering of the oil level. * Maximum oil amount in the table unit is 35 L. Do not supply the oil exceeding this limit. 65 L (2.30 ft3) in total [Chiller unit: 35 L (1.24 ft3), Table unit: 30 L (1.06 ft3)] 4. Changing the oil in compound oil control unit and cleaning the filter ! Make sure to shut off the power before maintaining the machine. ! When replenishing spindle cooling fluid, use only the cooling fluid specified by Yamazaki Mazak. Otherwise, machine trouble and other problems will occur. Oil changing intervals for the spindle cooling fluid and working oil depend on machine operating conditions. In general, however, the oil should be changed in the first six months of machine installed and every year thereafter. For the specified spindle cooling fluid, refer to 7-1-1 List of oiling points. < Procedure > (For details, refer to the LIQUID TUNER Instruction Manual, provided by KOUWAKOUGYO CO., LTD.) (1) Shut off the power and place the main power disconnect switch to the OFF position. (2) Remove the cap at the oil filler port. (3) Place a drain collecting pan under the drain port and loosen the drain plug with a wrench. Oil (cooling fluid, working oil) will be discharged. (Spindle cooling fluid: 108 L (3.81 ft3), Working oil: 60 L (2.12 ft3)) (4) After making sure that the tank is completely emptied, set the drain plug on which new seal tape is wound to the drain port and tighten it securely. (5) Fill the tank with fresh oil through the air breather (oiling port filter) while observing the oil level with the level gauge. Be sure to fill the oil to the correct tank. (Spindle cooling fluid: 108 L (3.81 ft3), Working oil: 60 L (2.12 ft3)) Otherwise, lubricating oil can leak

WARNING

4-31

REGULAR INSPECTION

(6) Fit and tighten the cap at the oil filler port. Note: When changing the oil, check and clean the strainers. If a strainer is clogged, it will cause malfunctioning of the circulation pump. Furthermore, if the oil is not circulated through the cooling circuit, refrigerating cycle load increases unduly to lead to failure of the machine.

Oil filler port

Oil filler port

Oil level gauge (spindle cooling fluid)

Oil level gauge (working oil)

Drain (spindle cooling fluid)

Drain (working oil)

Fig. 4-28

Changing spindle cooling fluid and working oil

A.

Processing of refrigerant HFCs (hydrochlorofluorocarbons: alternatives to chlorofluorocarbons) are used as refrigerants in compound oil control units. HFCs must be collected and disposed of in accordance with the applicable national regulations. Therefore, when disposing of a compound oil control unit, contact a waste collection and disposal service company and ask for appropriate processing of the HFCs. Note: If you have no contact with an appropriate waste collection and disposal service company, please contact us. We will respond to your request at your expense.

4-32

REGULAR INSPECTION

5.

Changing the oil in table cooling fluid oil control unit and cleaning the filter ! Make sure to shut off the power before maintaining the machine. ! When replenishing spindle cooling fluid, use only the cooling fluid specified by Yamazaki Mazak. Otherwise, machine trouble and other problems will occur. Oil changing intervals for the table cooling fluid depend on machine operating conditions. In general, however, the oil should be changed in the first six months of machine installed and every year thereafter. For the specified table cooling fluid, refer to 7-1-1 List of oiling points. < Procedure > (For details, refer to the LIQUID TUNER Instruction Manual, provided by KOUWAKOUGYO CO., LTD.) (1) Shut off the power and place the main power disconnect switch to the OFF position. (2) Remove the cap at the oil filler port. (3) Place a drain collecting pan under the drain port and loosen the drain plug with a wrench. Oil (cooling fluid) will be discharged. (Table cooling fluid: 35 L (1.24 ft3)) (4) After making sure that the tank is completely emptied, set the drain plug on which new seal tape is wound to the drain port and tighten it securely. (5) Fill the tank with fresh oil (cooling fluid) while observing the oil level. 35 L (1.24 ft3)) (6) Fit and tighten the cap at the oil filler port. Note: When changing the oil, check and clean the strainers. If a strainer is clogged, it will cause malfunctioning of the circulation pump. Furthermore, if the oil is not circulated through the cooling circuit, refrigerating cycle load increases unduly to lead to failure of the machine. (Table cooling fluid:

WARNING

Oil filler port

Oil level gauge

Drain Fig. 4-29 Changing table cooling fluid

4-33

REGULAR INSPECTION

A.

Processing of refrigerant HFCs (hydrochlorofluorocarbons: alternatives to chlorofluorocarbons) are used as refrigerants in the table cooling oil controller unit. HFCs must be collected and disposed of in accordance with the applicable national regulations. Therefore, when disposing of a table cooling oil controller unit, contact a waste collection and disposal service company and ask for appropriate processing of the HFCs. Note: If you have no contact with an appropriate waste collection and disposal service company, please contact us. We will respond to your request at your expense.

6.

Changing the B-axis lubricating oil < Procedure > (1) Move the Z-axis down to the position where operation steps below will be facilitated. Shut off the power and place the main power disconnect switch to the OFF position. (2) Remove the plug from the oil filler tap and the level tap. (3) Remove the drain plug to drain the lubricating oil. (4) After completely draining the lubricating oil, fit the drain plug. (5) Supply the lubricating oil. When the oil begins flowing through the level tap, fit the plug to the filler tap and the level tap. Lubricating oil amount: 12 L (0.42 ft3)
Oil filler tap

Level tap

Drain plug

Fig. 4-30

4-34

REGULAR INSPECTION

4-7-2
1.

Around the machine

Cleaning the spindle lubricating unit filters < Procedure > (1) Take out the filter from the oil filler port and clean it by supplying compressed air from the inside of the filter using the hand held air nozzle. Note: Do not use a hand held air nozzle near the machine since this could cause machine trouble.

Oil filler port filter

Fig. 4-31

Cleaning the oil filler port filter

2.

Cleaning the spindle lubricating unit filters (suction port) < Procedure > (1) Switch off the power to the machine. (2) Take out the lubrication unit.

Lubrication unit

Pipe

Take out Tank Bolt

Suction filter MC111-01190

Fig. 4-32 Cleaning the suction filter (1/2)

4-35

REGULAR INSPECTION

Note:

Do not disconnect the pipes. Otherwise, air will enter the pipe and cause spindle trouble.

(3) Remove the drain plug to discharge lubricating oil. (4) Fit and tighten the drain plug after discharging the lubricating oil. (5) Remove the screws clamping the pump unit to the tank and separate the pump unit from the tank. (6) Remove the filter clamp and take out the suction filter.

Pump

(6 places)

Suction filter Tank Filter clamp

Fig. 4-33

Cleaning the suction filter (2/2)

(7) Clean the suction filter. Use washing oil (kerosene, etc.) to clean the suction filter. At the same time, clean the inside of the tank with rag.

4-36

REGULAR INSPECTION

3.

Cleaning the fans in the electrical control cabinet

Electrical control cabinet door

Fasteners

Fasteners

Fan guard Fan

Fig. 4-34

Cleaning the fans in the electrical control cabinet

< Procedure > (1) Place the main power disconnect switch to the OFF position. (2) Turn the fasteners, fitted at the top and bottom of the electrical control cabinet doors, to unlock them. (3) Open the electrical control cabinet doors. (4) Loosen the fan guard mounting bolts. (5) Remove the fan guard and clean the fan and fan guard with cloth. (6) Attach the fan guard and fix it by tightening the bolts. (7) Close the electrical control cabinet doors. (8) Turn the fasteners, fitted at the top and bottom of the electrical control cabinet doors, to lock them. ! Place the main power disconnect switch to the OFF position before cleaning the fans in the electrical control cabinet. WARNING

4-37

REGULAR INSPECTION

4.

Checking the in-machine lighting

In-machine lighting

Fig. 4-35

Checking the in-machine lighting

< Procedure > (1) With the power to the machine turned ON, check the in-machine lighting on the ceiling (2 locations) and the LED lights on the sides (4 locations) from inside the machine. If the lighting is dim, blown, or flickering, it must be replaced. When replacement of the lighting is necessary, contact the Mazak Technical Center or Technology Center.

4-38

REGULAR INSPECTION

4-8

Inspection and Maintenance before Stopping the Machine for a Long Time
When stopping the machine for longer than two weeks, carry out the following inspection and maintenance. 1. Applying rust preventive oil Discharging coolant Saving the NC data

Applying rust preventive oil ! Switch off the power before applying rust preventive oil.

WARNING If the machine is not operated for a long time, unpainted surface of the following parts will be rusted and the function of them will be deteriorated. Therefore, apply rust preventive oil to these parts if the machine will not be operated for a long time. 2. Linear guide rails (X-, Y-, Z-axis) Ball screws (X-, Y-, Z-axis) Way covers (X-, Y-, Z-axis) Pallet Table Pallet changer ATC magazine Spindle

Discharging coolant Completely discharge coolant from the coolant tank and clean both the inside and outside of the coolant tank. For details, refer to 4-6-3 Around the machine.

3.

Saving the NC data Save all NC related data to external recording media (memory card, etc.). For details of operation procedure to save the NC data using external recording media, refer to the instruction manual of the NC.

4-39

4
4-9

REGULAR INSPECTION

Inspection and Maintenance before Starting the Operation after Stopping the Machine for a Long Time
Before restarting the machine which has been stopped for longer than two weeks, carry out the following inspection and maintenance. 1. Wiping off rust preventive oil Replenishing coolant Usual inspection before starting the operation Inspecting the machine for oil leaks Warm-up operation Inspecting the machine for noise, vibration, and abnormal temperature rise Uploading the NC data

Wiping off rust preventive oil ! Switch off the power before wiping off rust preventive oil.

WARNING Remove rust preventive oil, applied as explained in 4-8 Inspection and Maintenance before Stopping the Machine for a Long Time, using the rag soaked with washing oil. 2. Replenishing coolant Replenish coolant to the coolant tank. For details, refer to 4-6-3 Around the machine. 3. Usual inspection before starting the operation Perform the inspection which are required before starting daily operation. For details, refer to PART 2, 3-1 Inspection before Starting Operation in the Operating Manual. 4. Inspecting the machine for oil leaks After switching on the power, visually check the machine, piping and hoses of the hydraulic unit, blocks, and cylinders for oil leaks. 5. Warm-up operation Run the machine for approximately three hours using the warm-up program (PNO. 6000) which is stored in the NC memory. Refer to the instruction manual of the NC. 6. Inspecting the machine for noise, vibration, and abnormal temperature rise Check the machine for generation of abnormal noise and vibration, and also for abnormal temperature rise at the motors and bearings. If any abnormality is found, take appropriate corrective action by referring to Chapter 5 MAINTENANCE OF MAJOR UNITS.

4-40

REGULAR INSPECTION

7.

Uploading the NC data Before starting the operation, upload the NC data having been saved to the micro disk before stopping the machine.

4-41

REGULAR INSPECTION

- MEMO -

4-42 E

MAINTENANCE OF MAJOR UNITS

MAINTENANCE OF MAJOR UNITS

If a machine trouble occurred, first check the following items and carry out inspection and maintenance according to the information described in this Chapter. If you contact Mazak Technical Center or Technology Center, the results of your check will very helpful to locate the cause of the trouble. 1. Call the diagnosis (alarm) screen and confirm the past alarms in addition to the latest alarm. (For details of the diagnosis (alarm) screen, refer to the Operating Manual of NC provided separately.) Check the trouble and alarm if it recurs. Check the ambient temperature if it is within the specified range. Check if momentary power failure has occurred. Check the source voltage for fluctuation. Check if conditions differ depending on motion direction - forward and reverse rotation, retract and advance motion, etc. Check if the trouble or alarm occurs only at specific operation or command. Check the trouble or alarm occurrence frequency. Check how long the machine has been operated.

2. 3. 4. 5. 6. 7. 8. 9.

10. Confirm if corrective action has been taken.

5-1
5-1-1

Mill Spindle and B-axis

Troubleshooting
Symptom Check Points and Probable Causes 1. Insufficient capacity or a trouble of external power supply Corrective Action Prepare the power supply which meets the requirements indicated in 6-2-2 External power source requirements. Lower the ambient temperature. Refer to 6-2-2

Mill spindle does not start. Mill spindle stops due to alarm.

2. Ambient temperature of the spindle drive unit is higher than 40C (104F). 3. Load is excessively large. 4. The spindle drive unit is defective. The spindle drive motor is defective. There is a trouble in the spindle. Mill spindle orientation does not complete. Mill spindle orientation status cannot be canceled. There is abnormal noise or abnormal vibration during mill spindle rotation. The spindle drive unit is defective. The spindle drive motor is defective. There is a trouble in the spindle.

Reduce load applied to the spindle. Contact Mazak Technical Center or Technology Center.

Contact Mazak Technical Center or Technology Center.

1. The spindle is rotating at a high speed with an unbalanced tool mounted in it. 2. The spindle drive unit is defective. The spindle drive motor is defective. Loose bolts

Replace the tool with a balanced tool. -

Contact Mazak Technical Center or Technology Center.

5-1

MAINTENANCE OF MAJOR UNITS

Symptom Tool clamp operation is not completed. Tool unclamp operation is not completed.

Check Points and Probable Causes 1. The sensor is defective. (Although the clamp/unclamp cylinder operates correctly, the sensor is not turned on.)

Corrective Action Replace the sensor.

Refer to 5-11-3

2. The sensor is not mounted Mount the sensor correctly. securely. (Gap between the sensor and the dog is larger than 0.5 mm (0.020 in).) 3. The hydraulic valve is defective Contact Mazak Technical Center or or blocked. Technology Center. (The clamp/unclamp cylinder fails to operate). 4. The clamp/unclamp cylinder is defective. (The clamp/unclamp cylinder does not operate although the hydraulic valve has no problems.) 5. The hydraulic unit is defective. (Hydraulic pressure is always lower than 7.0 MPa (1000 psi).) 6. Loose bolts Oil leak 1. The seal in the clamp/unclamp cylinder has been worn. 2. The seal in the mill coupling cylinder has been worn. ATC air blast is not supplied. ATC air blast does not stop. 1. An external air source is not connected. 2. The solenoid valve is defective. B-axis does not rotate. 1. There is an interfering object. Connect the external air source. Contact Mazak Technical Center or Technology Center. Remove the interfering object. Contact Mazak Technical Center or Technology Center. 6-4-3 Contact Mazak Technical Center or Technology Center. -

B-axis cannot be indexed correctly. 2. The B-axis drive servomotor is defective. 3. The B-axis drive mechanism is defective. B-axis and mill spindle coupling clamp/unclamp operation is not completed.

1. The sensor is defective or it is not Replace the sensor or adjust its mounted correctly. (Although the position. Contact Mazak Technical Center or Technology Center. clamp/unclamp operation is performed, the sensor fails to turn on.) 2. The solenoid valve is defective or Contact Mazak Technical Center or Technology Center. clogged. (Clamp/unclamp operation is not performed). 3. The hydraulic cylinder is defective. (Clamp/unclamp operation is not performed although the solenoid valve is normal).

Abnormal noise is generated during B-axis rotation. B-axis positioning is inaccurate.

There will be a trouble in the B-axis drive system, such as damaged bearing. 1. Loose bolts 2. Position encoder in the servomotor is defective.

Contact Mazak Technical Center or Technology Center. Tighten the loose bolts. Contact Mazak Technical Center or Technology Center.

5-2

MAINTENANCE OF MAJOR UNITS

5-1-2

Construction of the spindlehead

Through-spindle air valve

Flood coolant valve

Through-spindle coolant valve

B-axis coupling valve

Mill spindle coupling valve Spindle bearing oil-air lubrication air pressure switch Tool clamp/unclamp valve

Oil-air lubrication air valve

B-axis coupling clamp sensor

B-axis coupling unclamp sensor Tool unclamp sensor

Tool clamp sensor

Fig. 5-1

Construction of the spindlehead

A tool is clamped in the spindle by spring force. Tool unclamp operation is performed by the hydraulic cylinder. The mill spindle bearings are lubricated by oil-air. The pressure switch is provided to prevent lubrication failure problem even if air pressure is lowered.

5-3

5
5-2

MAINTENANCE OF MAJOR UNITS

X-axis, Y-axis, Z-axis

Troubleshooting
Symptom Check Points and Probable Causes 1. Bolts of axis drive parts (ball screw, coupling, linear guide, etc.) are loose. 2. The encoder in the servomotor is defective. Corrective Action Contact Mazak Technical Center or Technology Center. Refer to

5-2-1

Positioning cannot be made accurately.

Zero-point position is not fixed or the limit switch does not function correctly. An axis stops due to alarm.

1. The bolts fixing the zero-point return limit switch are loose. 2. The bolts fixing the zero-point dog are loose. 1. Load is excessively large.

Contact Mazak Technical Center or Technology Center.

Reduce load applied to the spindle.

6-2-1

2. Ambient temperature of the servo Lower the ambient temperature. control unit is higher than 40C (104F). 3. The servo control unit in the electrical control cabinet is defective. 4. The servomotor is defective. 5. N2 pressure in the counter balancer is low. Abnormal noise is generated during axis movement. 1. Replenish the N2 gas. 2. Contact Mazak Technical Center or Technology Center. Replace the wiper. Contact Mazak Technical Center or Technology Center. Contact Mazak Technical Center or Technology Center.

5-2-2

1. The wiper at the way cover is damaged. 2. The way cover is defective. 3. A trouble in the axis drive system such as damaged ball screw support bearing.

4-6-3 -

Z-axis servo load has increased more than 20%.

N2 pressure in the counter balancer is 1. Replenish the N2 gas. low. 2. Contact Mazak Technical Center or Technology Center.

5-2-2

5-4

MAINTENANCE OF MAJOR UNITS

5-2-2
1.

Construction of the axis drive systems

Construction

Z-axis drive AC servomotor

Y-axis linear guide Encoder

Encoder Y-axis drive AC servomotor

Y-axis ball screw

Spindle Saddle

Column X-axis ball screw Z-axis ball screw Z-axis linear guide X-axis drive AC servomotor Encoder

Table X-axis linear guide Base

Fig. 5-2

Construction of the axis drive systems

5-5

MAINTENANCE OF MAJOR UNITS

2.

Replenishing the gas for the counter balancer

Counter balancers

Gas filler ports

Counter balancing rods

Fig. 5-3

If the Z-axis servo load checked in 6-month inspection is larger than the Z-axis servo load checked and recorded after machine installation by 20% or more, replenish the N2 gas following the procedure below. Note it is necessary to remove the right and left ceiling covers before replenishing the gas. Refer to Fig. 5-4. < Procedure > (1) Position the Z-axis at the zero point and the Y-axis at 530 mm (20.87 in) position, then place the machine in an emergency stop state. (2) Fit plug A to the gas filler port, provided at the top end of the counter balancer. fitting the male and female plugs, connect the gas replenishing kit to them. Make sure that the lever cocks of the gas cylinder and regulator are closed. (3) Attach the regulator to the gas cylinder and after setting the lever in the exhaust position return it to the neutral position. (4) Open the lever cock of the gas cylinder to check that the pressure in the gas cylinder is higher than 7.0 MPa (1000 psi). If the pressure is lower than this, replace the gas cylinder since replenishing of the gas is impossible. (5) Set the pressure gauge at the counter balancer side to 7.0 MPa (1000 psi). Then, after

5-6

MAINTENANCE OF MAJOR UNITS

(6) Turn the lever to the replenish side to replenish the gas to the counter balancer. Watch the pressure gauge at the gas cylinder side and if the pressure gauge does not show pressure decrease any more, it indicates replenishing has completed. (7) Perform the steps above for counter balancer at the operator side and the magazine side.

N2 gas cylinder specification (for filling the two counter balancers) Gas kind: Gas pressure: N2 (Nitrogen) 14.7 MPa (2130 psi) or more

Gas cylinder capacity: 0.047 m3 (1.66 ft3) or more (N2 gas volume of 7 m3 (247.24 ft3) or more is required at atmospheric pressure) Gas purity: Connection port: 99% or more W22 female thread or W23 male thread adapter (fixture side)

Silencer 9A3754-020

Ball valve 9A3405-020

Pressure gauge (Gas spring side)

Pressure gauge (Gas cylinder Lever cock of gas cylinder side) N2 gas cylinder

Exhaust position

Lever Replenish position

High-pressure hose (Standard length: 2 m (6.56 ft))

Pressure: Approx. 14.7 MPa (2130 psi)

8FH20320000 Regulator 9A3127-040

High-pressure hose (Standard length: 0.5 m (1.64 ft))

Adapter 4ZJG63661A

8FH2030500

Set of gas replenishing fixture Not supplied with the machine.

Plug (female) 8FQC02HS00 Bolt DNJ-C-5 (To be purchased separately) Plug A DNJ-P-5

Supplied with the machine as the standard tool.

Plug (male) DNJ-C-CM (To be purchased separately)

Gas spring

Fig. 5-4

5-7

MAINTENANCE OF MAJOR UNITS

5-2-3

Replacing the sealing packing of the Z-axis counter balancer

The gas pressure may fall due to loss of the sealing performance of the packing caused by deterioration of or damage on the packing in the counter balancer. If the Z-axis servo load increases soon even after replenishing gas, contact Mazak Technical Center or Technology Center. As a rule, replace the sealing packing in the counter balancer every two years or 1500 km (932 miles) of Z-axis sliding.

5-2-4

Replacing the battery for the axis amplifiers

When alarm 12 ABSOLUTE POSITION WARNING is displayed, it indicates that the voltage of the battery used in the absolute position detection system is low. If this alarm message is displayed, replace the battery for all axis amplifiers by following the procedure below. Note: Keep the power to the machine on for at least 30 minutes before replacing the battery. Battery replacement must be completed within an hour.

1.

Battery type Manufacturer: Mitsubishi Electric Corporation

Manufacturers type: ER6V-C119B Mazak part No.: 2. D80MA016250

Battery replacement procedure (1) Turn off the input power breaker and confirm that the power to the drive unit for which the battery is to be replaced is turned off. (2) Open the cover of the battery holder on the upper part of the front of the drive unit. (3) Disconnect the battery cable connector from the drive unit and take out the battery.

Disconnect the battery connector.

Open the cover toward you while pushing the battery holder tab downward.

Fig. 5-5

(4) Connect the cable connector of the new battery to the same connector position where the battery cable connector was disconnected in step (3).

5-8

MAINTENANCE OF MAJOR UNITS

(5) Put the battery in the battery holder and close the cover.
Connect the cable connector of the new battery to the connector where the battery connector was disconnected.

Put the battery into the battery holder.

Fig. 5-6

5-9

5
5-3

MAINTENANCE OF MAJOR UNITS

ATC Magazine
Troubleshooting
Symptom Check Points and Probable Causes Refer to 5-11 Covers. 1. A tool exceeding the tool size specifications is stored in the magazine. 2. The magazine drive unit is defective. 3. The magazine rotation motor is defective. Corrective Action Refer to 5-11 Covers. Store the tools in the magazine. Refer to 5-11 PART 2, 4-1 in the Operating Manual -

5-3-1

ATC cover open/close operation does not complete. The magazine does not rotate. The magazine stop position is shifted from the correct index position.

Contact Mazak Technical Center or Technology Center.

The magazine shifter does not operate.

1. The magazine shifter motor with the reducer is defective. 2. The magazine shifter unit is defective. 3. The sensors and/or limit switches are defective, or they are not mounted correctly.

Replace the sensor or adjust its position. Contact Mazak Technical Center or Technology Center.

The carrier does not operate.

1. The sensor is defective or not mounted correctly. (Although the ATC standby pocket operates, the sensor is not turned on.) 2. The carrier is defective. 3. The hydraulic valve is defective. (The carrier does not operate.) 4. The hydraulic cylinder section is defective. (Although the hydraulic valve is free of troubles, the carrier does not operate.) 5. Oil is not supplied to the hydraulic valve.

Replace the sensor or adjust its position.

5-11-3 7-1-2, 7-1-3

Contact Mazak Technical Center or Technology Center.

The ATC arm does not operate. A tool cannot be returned to the magazine.

1. The drive motor is faulty. 2. The ATC unit is defective. The tool existence detection sensor is defective.

Contact Mazak Technical Center or Technology Center.

5-10

MAINTENANCE OF MAJOR UNITS

5-3-2

Construction of the ATC magazine

Magazine

Shift

Carrier

Spindle

Tool UP/DOWN

Magazine shifter

Tool rotation ATC unit

Fig. 5-7 Construction of the ATC magazine

5-11

5
5-4

MAINTENANCE OF MAJOR UNITS

Table
Troubleshooting
Symptom Check Points and Probable Causes Corrective Action Refer to 1. The pressure switch is defective. Contact Mazak Technical Center or Technology Center. (Although clamp/unclamp operation is executed, the pressure switch is not turned on.) 2. The solenoid valve is defective or blocked. (Pallet clamp/unclamp operation is not executed.) 3. The hydraulic cylinder is defective. (Although the hydraulic valve is free of problems, clamp/unclamp operation is not executed.) 4. The hydraulic unit is defective. (Hydraulic pressure is always lower than 7.0 MPa (1000 psi).) 5. The seal in the center shaft has worn.

5-4-1

Pallet clamp operation is not completed. Pallet unclamp operation is not completed.

(Turning operation)
Table temperature is abnormally high. The table does not rotate but roars. The motor does not rotate smoothly.

1. The table cooling fluid chiller is not operating.

Restore the chiller, referring to the LIQUID TUNER Instruction Manual, provided by KOUWAKOUGYO CO., LTD. Contact Mazak Technical Center or Technology Center. Reduce the load. Remove the object hindering table rotation. Contact Mazak Technical Center or Technology Center.

2. The table drive motor is loaded excessively or acceleration/ deceleration time is too short. 3. The table drive motor is overloaded.

(C-axis operation)
The table does not rotate. The table is not indexed correctly. Pallet clamp operation is not completed. Abnormal noise is generated from the C-axis servomotor. Pallet correct clamp detection air blast is not supplied. Pallet correct clamp detection air blast does not stop. Oil leak

1. An interfering object. 2. The table rotation motor is defective. 3. A trouble in the table. 4. Loose bolts 5. The worm is overloaded.

Contact Mazak Technical Center or 2. The air discharge port is blocked. Technology Center.

1. The solenoid valve is defective.

1. The seal in the pallet Contact Mazak Technical Center or clamp/unclamp cylinder has been Technology Center. worn. 2. The seal in the rotary joint has been worn.

Pallet positioning accuracy deviates. Zero-point return operation is not executed correctly.

1. Loose bolts Contact Mazak Technical Center or 2. The encoder in the servomotor is Technology Center. defective. The encoder in the servomotor is defective. Contact Mazak Technical Center or Technology Center.

5-12

MAINTENANCE OF MAJOR UNITS

5-4-2

Construction of the table

Turning operation drive gear engage/disengage confirmation sensors

PLG sensor

C-axis servomotor

Table drive motor for turning operation

Drain port Worm engage/disengage confirmation sensors

Fig. 5-8 Construction of the NC rotary table (1) Pressure switch for table clamp detection Pressure switch for pallet clamp/unclamp detection

Table orientation encoder

Gear engage/disengage solenoid valve Worm engage/disengage solenoid valve

Pallet unclamp solenoid valve Solenoid valve for air blow (pallet seating)

Solenoid valve for table unclamp

Lubrication switchover valve (turning operation gear/worm) Fig. 5-9 Construction of the NC rotary table (2)

5-13

MAINTENANCE OF MAJOR UNITS

5-4-3

Turning spindle and C-axis connection/disconnection menu

The turning spindle and C-axis connection/disconnection menu should be used only when the mode cannot be switched between the turning mode and milling correctly. The functions in this menu are valid only when the specified conditions are satisfied. < Procedure > (1) In the manual mode, press the displayed.
ATC MAINT. MAGAZINE SHT.CARI MAINT. PALLET MAINT. B AXIS C AXIS SPINDLE ATC MENU #4 ZERO RETURN #2 ZERO RETURN

(machine menu) key, and the following menu is

(2) Press the display selector key at the left end, and the second page of the menu is displayed.
OPTION TOOL BREAKAGE DETECT MAINTENANCE TOOL EYE COVER OPEN TOOL EYE COVER CLOSE

(3) Press the [MAINTENANCE] menu key, and the following menu is displayed.
MENU ENABLE TURNING. SPINDLE CONNECT TURNING. SPINDLE CANCEL C AXIS CONNECT C AXIS CANCEL WK LIGHT OFF CANCEL CONVEYOR OFF CANCEL

(4) Press the [MENU ENABLE] menu key together with the

(MF1 and MF2) keys.

The [MENU ENABLE] menu item is highlighted and the turning spindle and C-axis connection/disconnection menu becomes valid.
MENU ENABLE TURNING. SPINDLE CONNECT TURNING. SPINDLE CANCEL C AXIS CONNECT C AXIS CANCEL WK LIGHT OFF CANCEL CONVEYOR OFF CANCEL

Turning spindle and C-axis connection/disconnection menu

Pressing the [MENU ENABLE] menu key or selecting other menu item while the [MENU ENABLE] menu item is selected returns the display of the [MENU ENABLE] menu item to normal display. Note that, however, it is not possible to return the display to normal while the turning spindle and the C-axis are connected at the same time. Interlocks while the [MENU ENABLE] menu item is highlighted Switching the operation mode to automatic is prohibited. Rotation of the spindle/turning spindle is prohibited. [C] axis movement button is invalid. Rapid feed override is fixed at R1 (3%).

5-14

MAINTENANCE OF MAJOR UNITS

1.

[TURNING.SPINDLE CONNECT] menu item Conditions for operation: The C-axis is at the second zero point with the C-axis connected, and all axes/all servo are in stop. Pressing the [TURNING.SPINDLE CONNECT] menu key together with the + (MF1

and MF2) keys while the conditions for operation are satisfied turns off the turning spindle disconnection SOL (Y332) and then turns on the turning spindle connection SOL (Y331). The menu item is highlighted when - The turning spindle connection confirmation sensor (X2B5) turned on, and - The turning spindle disconnection confirmation sensor (X2B6) turned off. 2. [TURNING.SPINDLE CANCEL] menu item Conditions for operation: The C-axis is at the second zero point with the C-axis connected, the turning spindle is in the orient stop position, and all axes/all servo are in stop. Pressing the [TURNING.SPINDLE CANCEL] menu key together with the + (MF1

and MF2) keys while the conditions for operation are satisfied turns off the turning spindle connection SOL (Y331) and then turns on the turning spindle disconnection SOL (Y332). The menu item is highlighted when - The turning spindle connection confirmation sensor (X2B5) turned off, and - The turning spindle disconnection confirmation sensor (X2B6) turned on. 3. [C AXIS CONNECT] menu item Conditions for operation: The turning spindle is at the orient stop position with the turning spindle connected, the Caxis is at the second zero point, and all axes/all servo are in stop. Pressing the [C AXIS CONNECT] menu key together with the + (MF1 and MF2)

keys while the conditions for operation are satisfied cancels the turning spindle orientation state, turns off the C-axis disconnection SOL (Y334) and then turns on the C-axis connection SOL (Y333). The menu item is highlighted when - The C-axis connection confirmation sensor (X2B3) turned on, and - The C-axis disconnection confirmation sensor (X2B4) turned off. 4. [C AXIS CANCEL] menu item Conditions for operation: The C-axis is at the second zero point with the turning spindle connected, and all axes/all servo are in stop. Pressing the [C AXIS CANCEL] menu key together with the + (MF1 and MF2) keys

while the conditions for operation are satisfied turns off the C-axis connection SOL (Y333) and then turns on the C-axis disconnection SOL (Y334). The menu item is highlighted when - The C-axis connection confirmation sensor (X2B3) turned off, and - The C-axis disconnection confirmation sensor (X2B4) turned on.

5-15

MAINTENANCE OF MAJOR UNITS

5-4-4

Restoring the operation if the C-axis zero point is lost in the turning mode
The following explains the procedure for restoring the operation when the C-axis zero point is lost in the turning mode. Usually, it is not possible to move the C-axis in the turning mode. Therefore, if the C-axis zero point is lost, the menu functions that allow C-axis movement in the turning mode only when the specified conditions are satisfied are used to return the C-axis to the zero point. < Procedure > (1) In the turning mode, C-axis zero point lost alarm 9 ABSOLUTE POSITION MALFUNCTION occurred. (2) Press the (HOME) key to select the zero point return mode. (machine menu) key, and the following menu is

(3) In the manual mode, press the displayed.

ATC MAINT. MAGAZINE SHT.CARI MAINT. PALLET MAINT. B AXIS C AXIS

SPINDLE

ATC MENU

#4 ZERO RETURN

#2 ZERO RETURN

(4) Press the display selector key at the left end, and the second page of the menu is displayed.
OPTION TOOL BREAKAGE DETECT MAINTENANCE TOOL EYE COVER OPEN TOOL EYE COVER CLOSE

(5) Press the [MAINTENANCE] menu key, and the following menu is displayed.
MENU ENABLE TURNING. SPINDLE CONNECT TURNING. SPINDLE CANCEL C AXIS CONNECT C AXIS CANCEL WK LIGHT OFF CANCEL CONVEYOR OFF CANCEL

(6) Press the [MENU ENABLE] menu key together with the

(MF1 and MF2) keys.

The [MENU ENABLE] menu item is highlighted and C-axis movement is enabled.
MENU ENABLE TURNING. SPINDLE CONNECT TURNING. SPINDLE CANCEL C AXIS CONNECT C AXIS CANCEL WK LIGHT OFF CANCEL CONVEYOR OFF CANCEL

Do not use these four menu functions.

Pressing the [MENU ENABLE] menu key or selecting other menu item while the [MENU ENABLE] menu item is selected returns the display of the [MENU ENABLE] menu item to normal display. Interlocks while the [MENU ENABLE] menu item is highlighted Switching the operation mode to automatic is prohibited. Rotation of the spindle/turning spindle is prohibited. [C] axis movement button is invalid. Rapid feed override is fixed at R1 (3%).
+C

(7) Return the C-axis to the zero point by pressing the

(axis movement) button.

(8) Turn off the power supply to the NC and then turn off the main power supply.

5-16

MAINTENANCE OF MAJOR UNITS

(9) Turn on the main power supply and then the power supply to the NC. (10) Press the (HOME) key to select the zero point return mode.

(11) Press the C-axis link button to connect the C-axis. This completes the restoration of operation if the C-axis zero point is lost in the turning mode.

5-4-5

C-axis connection mechanism

Gear ratio Worm : Wheel 1 122

C-axis position encoder

C-axis drive motor

Wheel

Worm C-axis Disconnected State Worm Wheel

C-axis zero point sensor (SQ6/X2B7)

C-axis connection confirmation sensor (SQ220/X2B3) C-axis disconnection confirmation sensor (SQ221/X2B4)

C-axis disconnection confirmation sensor ON (SQ221/X2B4) C-axis connection cylinder Connection (YV510/Y333) Disconnection (YV511/Y334) C-axis Connected State

Worm

C-axis connection confirmation sensor ON (SQ220/X2B3)

Fig. 5-10

C-axis connection mechanism

5-17

5
5-5

MAINTENANCE OF MAJOR UNITS

Pallet Changer
Troubleshooting
Symptom Check Points and Probable Causes Pallet load exceeds the allowable limit. 1. There is an interfering object. 2. The home position return sensor is defective or it is not mounted correctly. 3. The hydraulic valve is defective or blocked. 4. The pallet changer rotating motor or its drive unit is defective. 5. The hydraulic unit is defective. (Hydraulic pressure is always lower than 7.0 MPa (1000 psi).) 6. Loose bolts Corrective Action Mount workpieces according to the instructions in the OPERATING MANUAL. Remove the interfering object. Replace the sensor or adjust its position. Contact Mazak Technical Center or Technology Center. Refer to PART 5, 1-1 in the Operating Manual 5-11-3 7-1-2, 7-1-3 -

5-5-1

Vibration is excessively large during pallet change cycle. Pallet change operation does not start even when a pallet change command is specified. Pallet change operation stops halfway.

Pallet change operation does not start even when a pallet change command is specified. The setup pin extend operation does not complete although the pallet in the setup station is indexed to the 0 position.

1. Insufficient capacity of external air source

Prepare and connect the air source meeting the specifications given in 6-2-3 Air source requirements.

6-2-3, 6-4-3

2. The home position return sensor Replace the sensor or adjust its is defective or it is not mounted position. correctly. (Although the setup pin operates, the sensor is not turned on.) 3. The solenoid valve is defective. Contact Mazak Technical Center or (The setup pin does not operate.) Technology Center. 4. The air cylinder is defective. (The solenoid valve is free of troubles and pipes are correctly connected.) 5. Loose bolts

5-11-3 7-1-2, 7-1-3

The setup pin cannot be retracted.

1. Insufficient capacity of external air source 2. The solenoid valve is defective. 3. The air cylinder is defective. 4. Loose bolts

Prepare and connect the air source meeting the specifications given in 6-2-3 Air source requirements. Contact Mazak Technical Center or Technology Center.

6-2-3, 6-4-3

Oil leak

The seal in the hydraulic cylinder has Contact Mazak Technical Center or been worn. Technology Center.

5-18

MAINTENANCE OF MAJOR UNITS

5-5-2

Construction of the pallet changer

Pallet changer drive motor

Pallet changer rotating unit

Pallet change hook

Loading station section

Hydraulic valve (Pallet unclamp)

Hydraulic valve (Pallet change hook UP/DOWN)

Pallet changer hook clamp detection gap sensor

Fig. 5-11

Construction of the pallet changer

5-19

5
5-6

MAINTENANCE OF MAJOR UNITS

Hydraulic System
Troubleshooting
Symptom Check Points and Probable Causes 1. Insufficient oil amount in the hydraulic unit tank. 2. The hydraulic unit filter is clogged. 3. Oil viscosity is too high. 4. Hydraulic unit pump or motor is defective. (There is no problems with the wiring.) 5. The relief valve of the hydraulic unit is defective. 6. Oil leak in the hydraulic circuit. Corrective Action Replenish the specified oil. Clean the filter. Change the oil to the specified oil. Contact Mazak Technical Center or Technology Center. Refer to 4-6-2 4-6-2 7-1-1 -

5-6-1

Pressure is always lower than 7.0 MPa (1000 psi). Hydraulic oil is not discharged. Heat generation from the pump or motor is excessive.

Noise level gets higher. Abnormal noise is generated.

1. The hydraulic unit filter is clogged. 2. Insufficient oil amount in the hydraulic unit tank. 3. Bolts used in the hydraulic unit get loose. 4. Hydraulic unit pump or motor is defective. 5. The external suction filter is clogged.

Clean the filter. Replenish the specified oil. Tighten the bolts. Contact Mazak Technical Center or Technology Center. Replace the filter cartridge. Contact Mazak Technical Center or Technology Center.

4-6-2 4-6-2 5-6-2 -

Oil amount in the hydraulic unit tank reduces.

There is oil leak in the hydraulic unit circuit.

5-6-2

Maintenance of the hydraulic unit

! Shut off the power to the machine before maintaining the hydraulic unit. observing this could cause operator's injuries or severe machine troubles. Failure to

CAUTION 1. Changing the hydraulic pressure gauge (For details, refer to the LIQUID TUNER Instruction Manual, provided by KOUWAKOUGYO CO., LTD.) < Procedure > (1) Loosen and detach the pressure gauge. (2) Mount the new pressure gauge after winding the threads with sealing tape.

5-20

MAINTENANCE OF MAJOR UNITS

2.

Replacing the external suction filter cartridge Replace the external suction filter cartridge by following the procedure below. Note that the replacement interval for the external suction filter cartridge varies depending on the operating status of the machine. The guide replacement interval is 500 to 1000 hours. < Procedure > (1) Fit a commercially available filter wrench or pipe wrench onto the polygonal part at the bottom of the cartridge and loosen the cartridge to remove it. Note : Oil will drip out at this time, so receive it with an oil pan.

(2) Apply a sufficient amount of grease or sealing agent to the gasket. (3) Screw the new cartridge into the head. Tighten until the gasket is crushed and the top face of the cartridge comes into contact with the head with a tightening torque of 40 Nm (29.5 ftlbf).

Head

Gasket

Cartridge

Compound oil control unit rear

Tightening direction

Fig. 5-12

Replacing the external suction filter cartridge

Consumable parts
Part Name Cartridge Part No. Type CS08B00A001A Maker Yamashin Filter Qty (pcs./machine) 1 Remark

5-21

MAINTENANCE OF MAJOR UNITS

5-6-3

Hydraulic circuit diagram

Fig. 5-13

Hydraulic circuit diagram

5-22

MAINTENANCE OF MAJOR UNITS

Drawing No.

0575HCD0100

5-23

5
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

MAINTENANCE OF MAJOR UNITS

Hydraulic circuit diagram parts list

Parts No. G34WA003441 25754167600 G27FH000220 G27FH001450 G16FH004412 G11FH001201 G16FH004431 25750426402 G27FH001980 G14FH001400 G16FH000350 G16FH004411 G14FH001541 G11FH001340 G17FH000230 G14FH001371 G23NS001001 G23NS002040 15750868813 G14FH001541 G17FH001900 G27FH000200 G14FH001541 G17FH000160 G16FH004460 G27FH000170 G16FH004411 G27FH001450 G27FH000060 G14FH001371 G17FH001160 G11FH001201 G16FH002850 Parts Name Oil control unit Manifold Block Plate Solenoid valve Reducing valve Solenoid valve Manifold Manifold Check valve Solenoid valve Solenoid valve Pilot check valve Reducing valve Flow regulator Pilot check valve Switch Switch Manifold Pilot check valve Free flow plate Sub plate Pilot check valve Flow regulator Solenoid valve Manifold Solenoid valve Plate Sub plate Pilot check valve Flow regulator Reducing valve Solenoid valve OCP-G01-A1-21 MOB-G01-A-10 MSA-01Y-T OCP-G01-A1-21 OCY-G01-W-Y-20 SA-G01-C6-C1-20 MOB-01X-B2-10 SA-G01-A3X-C1-30 MOB-G01-10 MSA-01Y-T-10 OCP-G01-W1-21 OCY-G01-W-Y-20 OG-G01-P1-20 SLD-G01-E3X-C1-10 FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI MOB-01Y-W4-10 OC-G01-T1-20 SA-G01-E3X-C1-11 SA-G01-A3X-C1-30 OCP-G01-A1-21 OG-G01-PC-K-20 OCY-G01-A-X-20 OCP-G01-W1-21 CP-20-514 CE10-373 FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI Nagano Nagano MOB-01X-B5-10 MOB-G01-10 SA-G01-A3X-C1-30 OG-G01-P1-21 SA-G01-E3X-C1-30 FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI FUJIKOSHI Type KMV-150-M37-001 Maker KOUWA KOUGYO Qty 1 2 1 2 1 1 2 1 1 3 3 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5.0 MPa (70 psi) S45C Dense bar Dense bar Remarks

G11FH001831 G20SV022990 G14FH001420

Reducing valve Cylinder Check valve

OG-G01-A1-21 CHDFFA40B-135ST OC-G01-P1-20

FUJIKOSHI SMC FUJIKOSHI

1 1 1

5-24

MAINTENANCE OF MAJOR UNITS

5-7
5-7-1

Pneumatic System
Troubleshooting
Symptom Check Points and Probable Causes 1. Insufficient capacity of external air source 2. Reducing valve in the air unit is defective. 3. Mist separator in the air unit is clogged. 4. Leak in the pneumatic circuit. 5. Air pressure switch, mounted in the spindle unit, is defective. Corrective Action Prepare and connect the air source meeting the specifications given in 6-2-3 Air source requirements. Replace the reducing valve. Replace the filter element. Contact Mazak Technical Center or Technology Center. Refer to 6-2-3

The pressure is lower than 0.5 MPa (70 psi).

5-7-3 -

Air is constantly leaking through Automatic drain of the mist separator is the drain port of the air unit. defective. Oil is accumulated in the mist separator for the scale.

Replace the mist separator.

4-6-3, 5-7-3 5-7-3, 6-2-3

Oil-mist concentration is high in the used air. Prepare and connect the air source meeting the specifications given in 6-2-3 Air source requirements. Replace the filter element. Replace the dryer.

5-7-2

Construction of the air unit

Air unit for the scale air purge circuit

Air unit for the main air circuit

Mist separator

Dryer

Reducing valve

Reducing valve

Mist separator Fig. 5-14

Pressure release valve Construction of the air unit

5-25

MAINTENANCE OF MAJOR UNITS

5-7-3
1.

Maintenance of the air unit

Changing the filter element of mist separator ! Shut off the power to the machine by turning the main power disconnect switch to the OFF position and disconnect the external air source before changing the filter element. Attempting to replace the filter element without taking these precautions could cause machine damage or severe injuries. The filter element is a consumable part and should be changed every two years. In the list given in 7-2 List of Wearable Parts, element assy indicates a set of filter element, O ring, and gasket. When changing the filter element, order the element assy.
Bolt (1)

WARNING

Body

Hole O ring (3) Gasket (4) Filter element

(2)

Upside down view of body Housing MC111-01143 Fig. 5-15 Changing the filter element

< Procedure > (1) Loose the four bolts and detach the body from the housing. (2) Fit a new O ring to the body. (3) Fit a new gasket to the body. (4) Insert a new filter element into the housing with the hole in the filter element facing up. (5) Fix the body to the housing with the bolts.

5-26

MAINTENANCE OF MAJOR UNITS

2.

Changing the filter element of the mist separator [only for the scale feedback system (option)] ! Shut off the power to the machine by turning the main power disconnect switch to the OFF position and disconnect the external air source before changing the filter element. Attempting to change the filter element without taking these precautions could cause machine damage or severe injuries. ! When disconnecting the joint of the external air source, do so only after closing the ATC door. If the external air source joint is disconnected while the ATC door is open, the shutter will close by its own mass to cause machine damage or severe injuries. The filter element is a consumable part and should be changed every two years. In the list given in 7-2 List of Wearable Parts, element assy indicates a set of filter element and O ring. When changing the filter element, order the element assy.
Body assembly

WARNING

Tension bolt

Filter element assembly

Case O ring (1) Case assembly

(2) Spanner hooking flats

Fig. 5-16

Changing the filter element

< Procedure > (1) Hold the case assembly by your hand. counterclockwise direction. Remove the case assembly by turning it in the

(2) Set the spanner on the spanner hooking flats on the filter element. Remove the filter element by turning it in the counterclockwise direction. (3) Replace the filter element with a new one. Set the spanner on the spanner hooking flats on the filter element and fix the element by turning it in the clockwise direction. Tightening torque: 0.35 0.05 Nm (0.26 0.04 ftlbf) (4) Hold the case assembly by your hand. Hand tighten the case assembly to the body assembly by turning the case assembly in the clockwise direction. Tightening torque: Approx. 2.2 Nm (1.62 ftlbf)

5-27

MAINTENANCE OF MAJOR UNITS

5-7-4

Pneumatic circuit diagram

Fig. 5-17

Pneumatic circuit diagram

5-28

MAINTENANCE OF MAJOR UNITS

Drawing No.

0575ACD0073

5-29

5
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

MAINTENANCE OF MAJOR UNITS

Pneumatic circuit diagram parts list

Parts No. G48SV001330 G45SV001010 G54SV000340 G50SV006070 G51SV000340 G45SV001730 G50SV004790 G20KT006070 G50SV007090 G50SV010190 G50SV006070 G51SV000340 G47SV000190 35764184780 15750233462 H14SV001860 G54SV000590 G50SV008200 G51SV000340 G50SV005950 Parts Name Mist separator Regulator Solenoid valve Solenoid valve Silencer Speed controller Solenoid valve Cylinder Solenoid valve Solenoid valve Solenoid valve Silencer Mist spray unit Bracket Manifold Mixing valve Speed controller Solenoid valve Silencer Solenoid valve LMV210-20 AS2200-02-08 VNC214B-10A-1D AN110-01 VX2130-02-1D-B SMC SMC SMC SMC SMC Type AM350-03BD-JR AR3000-03G-R VXD02130-03-1D VFS2420-1D-02 AN110-01 AS2051F VX2130-02-1D-B DA25X25-3-CS5B1 VFS-1120-1D-01-F-R VX2120-01-1D-B VFS2420-1D-02 AN110-01 LMU200-10 Maker SMC SMC SMC SMC SMC SMC SMC Koganei SMC SMC SMC SMC SMC Qty 1 1 1 1 2 2 1 1 1 (1) (2) (4) (1) 1 1 (1) 1 2 2 3 SPHC Dense bar Remarks

G77LA000450 G23SV001220 25750426402 35750869620 G50SV004890 G50SV008200 G51SV000340 G54SV001040 G50SV007960 G50SV005950 G50SV010130 G45CB001380 R67CB000920 G48SV002170 G48SV002180 G45SV000820 G23AM000680 35764184770 G54SV001530 G54SV000480 G54SV001720 G54SV001770 G73ZZ000080

Mixing valve Switch Manifold Manifold Solenoid valve Solenoid valve Silencer Speed controller Solenoid valve Solenoid valve Solenoid valve Regulator Gap sensor Separator Dryer Regulator Switch Bracket Speed controller Speed controller Speed controller Speed controller Vacuum generator

MIX-1A4B IS1000-01-X201

SMC

1 2 1 1 Dense bar FC250

VXD2130-03-1D VNC214B-10A-1D AN110-01 AS2000F-02-08 VNC214B-15A-1D VX2130-02-1D-B VT325-031D R1000-8-L-b3 GPS2-05-PGF-BLFL280004 AFD2000-02D IDG5-02B-S AR2000-02G 176-110-100-N1

SMC SMC SMC SMC SMC SMC SMC CKD CKD SMC SMC SMC Asia

1 2 2 1 1 (3) 2 1 2 1 1 2 1 1 SPHC

AS3001F-10 AS2200F-01-06 AS2051F-06 AS2311F-02-08S VUH05-016A

SMC SMC SMC SMC PISCO

1 (2) (2) (1) (1)

5-30

MAINTENANCE OF MAJOR UNITS

No. 45 46 47 48 49 50 51 52 53 54

Parts No. G54SV001480

Parts Name Speed controller

Type AS3001F-08

Maker SMC

Qty (1)

Remarks

G14JN002540 G52SV000310 G51SV001040 G45SV000670 R67CB001140 G54SV000270 G14JN003200 G50SV010130

Check valve Hand valve Silencer Regulator Gap sensor Speed controller Check valve Solenoid valve

KZU00-005E VHS40-03-X1 AN303-03 AR2000-02BG GPS2-07-PGF-BLFL353356 AS2051F-08 KZU00-035E VXD02130-03-1D-B

Ihara SMC SMC CKD CKD SMC Ihara SMC

1 1 1 1 1 2 3 1

5-31

5
5-8

MAINTENANCE OF MAJOR UNITS

Centralized Lubrication Unit

Troubleshooting
Symptom Check Points and Probable Causes 1. Piping is blocked. 2. The centralized lubrication unit pump is defective. Corrective Action Contact Mazak Technical Center or Technology Center. Refer to

5-8-1

Lubricating oil is not consumed.

Lubricating oil is consumed abnormally quickly.

Piping is loose.

Contact Mazak Technical Center or Technology Center.

5-8-2

Maintenance of the centralized lubrication unit

For the information on centralized lubrication unit maintenance, refer to the following sections. 4-5 Monthly Inspection and Maintenance 4-7 Every One-Year Inspection and Maintenance

5-8-3

Linear guide and ball screw lubrication

Circuit diagram and lubricating oil discharge amount (per cycle)
0.10 cm (0.0061 in ) 4
3 3

Linear guide bearings (4 places) Ball screw nut TAC bearings (2 places) Linear guide bearings (4 places) Ball screw nut TAC bearings (2 places) Linear guide bearings (4 places) Ball screw nut (2 places) TAC bearings (4 places) Chain pockets (4 places)

X-axis

0.05 cm (0.0031 in ) 0.10 cm (0.0061 in ) 2

3 3

0.10 cm (0.0061 in ) 4
3 3

Y-axis

0.05 cm (0.0031 in ) 0.10 cm (0.0061 in ) 2

3 3

0.10 cm (0.0061 in ) 4
3 3

Z-axis

0.05 cm (0.0031 in ) 2
3 3

0.10 cm (0.0061 in ) 4
3 3 3 3

Magazine
Fig. 5-18

0.05 cm (0.0031 in ) 4

Centralized lubrication circuit diagram

5-32

MAINTENANCE OF MAJOR UNITS

5-8-4

Mill spindle bearing lubrication

Circuit diagram and lubricating oil discharge amount (per cycle) Operation interval 4-minute cycle (OFF for 3 min. and ON for 1 min.)

Oil supply interval (approx.) Approx. 5 months (assuming operations of 10 hours/day and 31 days/month)

0.03 cm (0.0018 in ) 0.03 cm (0.0018 in ) 0.03 cm (0.0018 in ) 0.03 cm (0.0018 in ) 0.01 cm (0.0006 in )
3 3 3 3 3 3 3 3

Angular bearing Angular bearing Angular bearing Angular bearing Roller bearing

Fig. 5-19

Mill spindle bearing lubrication circuit diagram

5-33

5
5-9

MAINTENANCE OF MAJOR UNITS

Spindle Cooling Unit

Troubleshooting
Symptom Check Points and Probable Causes 1. Insufficient amount of spindle cooling fluid 2. Oil viscosity is too high. Corrective Action Replenish the specified spindle cooling fluid. Change the oil to the specified oil. Refer to 4-7-1 7-1-1 -

5-9-1

The following alarm message is displayed. 203 SPINDLE OIL PRESSURE DOWN

(Spindle cooling chiller unit)

3. Leak in the spindle cooling circuit. Contact Mazak Technical Center or Technology Center. 4. The chiller is defective. 5. Air filter is blocked. Wash the air filter. After washing the air filter, press the reset button in the relay box of the chiller unit. Remove the obstacle and press the reset button in the relay box of the chiller unit.

4-7-1

6. There is an obstacle near the suction and/or the exhaust port. 7. Ambient temperature is high.

Use the chiller unit in the environment where temperature is within the specified operating temperature range. If the chiller unit is directly subject to hot air, take measures so that the chiller unit will not be subjected to the hot air. After that press the reset button in the relay box of the chiller unit. Contact Mazak Technical Center or Technology Center. Clean the filter. Replenish the specified spindle cooling fluid. Tighten the bolts. Contact Mazak Technical Center or Technology Center. 4-7-1 4-7-1 -

Spindle cooling fluid is consumed abnormally quickly. Noise level gets higher. Abnormal noise is generated.

Leak in the spindle cooling circuit. 1. The filter is clogged. 2. Insufficient amount of spindle cooling fluid 3. Loose bolts 4. Hydraulic unit pump or motor is defective. 5. The chiller is defective.

The following alarm message is displayed. 206 SPINDLE LUB. CHILLER MALF.

Insufficient flowrate of table lubricating oil

Clean the filter in the chiller unit.

4-7-1

(Table lubrication chiller unit)

5-34

MAINTENANCE OF MAJOR UNITS

5-9-2

Construction of the spindle cooling unit

Lever

Cover

T-joint

Suction filtert

Trochoid pump

Table cooling unit [68 mm2/s (0.11 in2/s)]

Spindle cooling unit [2 mm2/s (0.0031 in2/s)]

Z-axis ball screw [2 mm2/s (0.0031 in2/s)]

Y-axis ball screw [2 mm2/s (0.0031 in2/s)]

Mill motor stator [2 mm2/s (0.0031 in2/s)]

Table motor stator [2 mm2/s (0.0031 in2/s)]

Mill spindle bearing [2 mm2/s (0.0031 in2/s)] Cross roller bearing Turning operation gear Worm

X-axis ball screw [2 mm2/s (0.0031 in2/s)]

68 mm2/s (0.11 in2/s)

Fig. 5-20

Construction of the spindle cooling unit

Cooling fluid, cooled by the spindle cooling fluid cooling unit is fed to the axis feed ball screws, the mill spindle motor outer case, the table drive motor (turning operation) outer case, and the mill spindle bearings. Cooling fluid, cooled by the spindle cooling fluid cooling unit is fed to the turning operation gears, cross roller bearings and worm shaft in the table. 68 mm2/s (0.11 in2/s) cooling fluid, heated by parts being cooled, is returned from the tank in the table to the chiller by the trochoid pump.

5-35

MAINTENANCE OF MAJOR UNITS

5-9-3

Cooling system circuit diagram

Circuit diagram of the cooling system for the spindle and the ball screw core

Cooling the mill spindle Cooling the Z-axis ball screw core

Cooling the Y-axis ball screw core

Table cooling Oil pump

Cooling the X-axis ball screw core

Cooling unit

Filters Fig. 5-21 Spindle cooling circuit diagram

Compound oil control unit

5-36

MAINTENANCE OF MAJOR UNITS

Circuit diagram of the table cooling system

Intermediate shaft (gear shift) Cross roller bearing lubrication Intermediate shaft (fixed gear) C-axis worm shaft and bearing lubrication Motor shaft

1 6 3/8 3/4 3/8

Solenoid valve VNC214B-10A-1D Silencer AN110-01 Silencer AN110-01

Hose relay section 25754168390 Fluid sensor SI1000-8E0511-E10907 Throttle valve 3.5 L/min [0.12 ft3/min] Solenoid valve VNC-214B15A-1D Throttle valve 2 L/min [0.07 ft3/min]
3/4 1/2 1 3/4

AIR IN
3/8

AIR IN

3/8

3/8

1/2

1/2

Solenoid valve VNC214B-10A-1D

1/2

1/2

AIR IN

3/4 3/4 3/4 1/2 1/2

3/4 1 1

1/2

1/2

Manifold 25750869610

Trochoid pump TOP-2MY750-206HBMVB0.5 Discharge: 11 L/min [0.39 ft3/min]

Filter SQ-06Z-037

Manifold 25750426402

Fig. 5-22

Circuit diagram of the table cooling system

5-37

MAINTENANCE OF MAJOR UNITS

5-10 Coolant System

5-10-1 Troubleshooting
Symptom
Coolant is not discharged. Coolant discharge volume is reduced. Coolant is not discharged.

Check Points and Probable Causes 1. The filter is clogged. 2. Coolant amount is insufficient. 3. Discharge nozzle is blocked. 1. Due to interlock
Tool unclamp Pallet unclamp ATC cover open Operators door open Coolant stop menu-key ON Special tool selected

Corrective Action Clean the filter. Replenish the specified coolant. Clean the nozzle. Remove the cause of interlock. -

Refer to

4-3-5 -

2. The coolant pump is defective. (There is no problems with the wiring.) 3. The solenoid valve is defective.
Coolant discharge does not stop.

Contact Mazak Technical Center or Technology Center.

The solenoid valve is defective.

Contact Mazak Technical Center or Technology Center.

5-38

MAINTENANCE OF MAJOR UNITS

5-10-2 Construction of the coolant system

Through-spindle coolant Coolant pump for flood and spindle-through coolant Flood coolant Niagara coolant

Line filter for through-spindle coolant

Coolant pump for Niagara coolant

Pallet changer cover coolant Cover coolant Coolant pump for cover coolant and pallet changer hook coolant X-axis cover coolant

Fig. 5-23

Coolant system

5-39

MAINTENANCE OF MAJOR UNITS

5-10-3 Coolant circuit diagram

Fig. 5-24

Coolant circuit diagram

5-40

MAINTENANCE OF MAJOR UNITS

5-11 Covers
5-11-1 Troubleshooting
Symptom
Door interlock alarm occurred although the door is not open. When moving an axis, abnormal noise is generated from the way cover. ATC cover open operation does not complete. ATC cover close operation does not complete.

Check Points and Probable Causes Limit switch is defective. 1. The wiper of the way cover is damaged. 2. Way cover is defective. 1. Insufficient capacity of external air source 2. Proximity switch is defective. (Although air cylinder has operated correctly, the proximity switch is not turned ON.) 3. The solenoid valve is defective. 4. Air cylinder is defective. (Solenoid valve is free of problems and the piping is free of disconnection.) 5. Loose bolts

Corrective Action Replace the limit switch. Replace the wiper. Contact Mazak Technical Center or Technology Center. Prepare and connect the air source meeting the specifications given in 6-2-3 Air source requirements. Replace the proximity switch. -

Refer to

6-2-3

5-11-3

Contact Mazak Technical Center or Technology Center.

5-11-2 Machine covers

Z-axis way cover

Y-axis way cover

Pallet changer safety cover

X-axis way cover

Fig. 5-25

Arrangement of cover

5-41

MAINTENANCE OF MAJOR UNITS

5-11-3 Changing the proximity sensor

Proximity sensor Washer Nut A Bracket

Washer Nut B Gap: 1.0 - 1.3 mm (0.04 - 0.05 in)

Dog MC111-01217
Fig. 5-26 Changing the proximity sensor

< Procedure > (1) Remove nuts A and B by using the wrenches and then remove the sensor from the bracket. (2) Set a new sensor in the bracket. (3) Tighten nuts A and B temporarily. (4) Measure the gap between the sensor front edge and the dog using the thickness gauge. (5) Adjust the gap by turning the nuts. Gap: 1.0 to 1.3 mm (0.04 to 0.05 in) Since the thread pitch of the sensor is 1 mm (0.04 in), one turn of the nut moves the sensor 1 mm (0.04 in) (6) Tighten nuts A and B at the same torque. (7) After adjusting the sensor, operate the related machine unit and make sure that the sensor operates ON/OFF correctly by observing the LED in the sensor. Note: The tightening torque varies according to the distance from the front end of the sensor head to the position of nut B. Tighten nuts A and B to the same torque within the allowable torque ranges for them.
LED

Allowable tightening torque of the nut Dimension A 10 mm (0.39 in) 11.8 Nm (8.7 ftlbf) Dimension A > 10 mm (0.39 in) 19.6 Nm (14.5 ftlbf)

Fig. 5-27

Proximity sensor

5-42

MAINTENANCE OF MAJOR UNITS

5-11-4 Maintenance of the X-axis way cover

! Shut off the power to the machine by setting the main power disconnect switch to the OFF position before entering the machine. Otherwise, you may sustain serious or fatal injury. WARNING < Procedure > (1) Move the X-axis (table) to the first zero-return point and switch off the power to the machine. (2) Unscrews all bolts A that hold the way cover (right) to the table and slide the No. 1 cover to the mill spindle side.

No. 3 No. 2 Mill spindle side () X-axis No. 1

(+)

X-axis way cover (right)

Bolt A

X-axis way cover (left)

Fig. 5-28

Maintenance of the X-axis way cover (1/2)

Carry out table maintenance or clean the area inside the X-axis way cover. (When cleaning the area inside the X-axis way cover, the left cover must also be removed. In this case, follow the steps indicated below. If only table maintenance should be carried out, follow the steps (12) and on after completing the maintenance.) (3) Switch on the power to the machine. (4) Move the X-axis (table) by turning the pulse handle near the stroke end at the mill spindle side. When moving the X-axis pay sufficient care so that the way cover and joint bars will not be subject to excessive force. (5) Switch off the power to the machine.

5-43

MAINTENANCE OF MAJOR UNITS

(6) Unscrew all bolts C that hold the X-axis way cover (left) to the table and side the cover to the Z-axis first zero point side.

() X-axis

(+)

Bolt C

X-axis way cover (left)

Fig. 5-29

Z-axis first zero point side

Maintenance of the X-axis way cover (2/2)

(7) Clean the area inside the X-axis way cover. (8) After completing the cleaning, close the X-axis way cover (left) and tighten bolts C. (9) Switch on the power to the machine. (10) Move the X-axis near the first zero-point by turning the pulse handle. (11) Switch off the power to the machine. (12) Pull the X-axis way cover (right) to the table side and fix the X-axis way cover (right) removed in step (2) to the table using bolts. (13) After recovering the X-axis way cover completely, move the X-axis (table) slowly in the entire stroke range by turning the pulse handle to check if the X-axis way cover is correctly fixed to the table. If abnormal noise is generated or irregular movements of the X-axis way cover are observed, stop the machine and review the operation step by step.

5-44

MAINTENANCE OF MAJOR UNITS

5-12 NC Unit and Electrical Control Cabinet

5-12-1 Troubleshooting
Symptom
Alarm message <052> blinks on the screen. Error with the LCD screen

Check Points and Probable Causes Voltage of the battery used to retain the NC data is low. (Battery has been used to the life.) Power supply to the display is faulty, or the display itself is faulty.

Corrective Action Replace the battery. The data will be lost if the battery is not changed.

Refer to Instruction manual of the NC

Contact Mazak Technical Center or Technology Center. Lower the ambient temperature of the machine. Replace the NC unit cooling fan. -

Alarm message <053> is displayed 1. Ambient temperature of the NC on the screen. unit is higher than 40C (104F).

2. Cooling fan of the NC unit is defective.

Alarm message <217, 218> is displayed on the screen.

1. Any of the motors is overloaded. 2. The unit which uses the motor for which the terminal relay has been tripped is defective. (The same alarm occurs again soon even when the thermal relay is reset after cooling the motor.)

Eliminate the cause of overload and 5-12-2 reset the thermal relay. Follow the maintenance instructions 5-1 to 5-11 for the individual units. If the cause is unknown, contact Mazak Technical Center or Technology Center. -

5-45

MAINTENANCE OF MAJOR UNITS

5-12-2 Resetting the thermal relay

If alarm message 217 THERMAL TRIP or 218 CONVEYOR THERMAL TRIP is displayed, any of the following thermal relays is tripped. This could be caused by the overload of the related motor. FR11 (thermal relay under magnetic contactor KM11) For flood coolant/through-spindle coolant pump motor FR33 (thermal relay under magnetic contactor KM33) For cover coolant/pallet hook coolant pump motor FR13 (thermal relay under magnetic contactor KM13) For chip conveyor motor (option) FR15 (thermal relay under magnetic contactor KM15)For in-machine chip conveyor motor 1 FR16 (thermal relay under magnetic contactor KM16)For in-machine chip conveyor motor 2 FR12 (thermal relay under magnetic contactor KM12) For Niagara coolant pump motor (option) FR1 (in the compound oil control unit) For hydraulic oil pump If a thermal relay is tripped, eliminate the cause and reset the thermal relay by pushing the corresponding reset button as shown below (Fig. 5-30). Thermal relay (other than FR10) are provided in the control panel.

FR10 to FR16 Reset button

Fig. 5-30

Thermal relay

5-46 E

INSTALLATION

6
6-1

INSTALLATION
Precautions on Installing the Machine
! Before starting the installation work, read Chapter 2 SAFETY PRECAUTIONS and make sure you thoroughly understand the information in this Chapter.

WARNING

! The floor must be completely dry and free of oil so that operators will not slip and fall during carrying and installation of the machine, electrical work, machine adjustments, or other work. ! Safety equipment (helmet, goggles, safety shoes, etc.) and clothing appropriate for the work to be undertaken must be worn. ! Use wire rope or slings whose specifications state that they can support the weight to be lifted, and inspect them for any abnormality before use. ! Lifting aids such as wire rope and slings must be secured at the specified locations, and the lifting angle must be correct. ! During piping and wiring work, check the matchmarks between the hose and fitting location when fitting hoses. ! Prepare an air source that meets the external air source requirements. ! Prepare a power source that meets the external power source requirements. ! When connecting the main power disconnect switch to the power source, carry out piping work such that the main power disconnect switch box is protected to IP54 standards. ! When carrying out machine adjustments, refer to the safety considerations relating to safety devices and make sure that all safety devices function correctly.

6-1

6
6-2

INSTALLATION

Preparing for Installation

Environmental requirements
1. Machine A. Ambient temperature +5 to +40C (+41 to +104F) Note: This indicates the temperature range for permitting normal machine operation but it does not indicate the range that allows machining accuracy to be maintained.

6-2-1

B.

Atmosphere Avoid the following places for installing the machine. Places where the machine is exposed to direct sunlight, near a heat source, or temperature varies excessively. Places near the exit where external air will flow in. Take into consideration environment so that machine generating heat will be easily dissipated. Do not apply wind blown from the air conditioner directly to the machine. Places where the floor is not strong enough to support the machine. Places near vibration generation equipment. Humid and dusty places.

Note 1: If the machine has to be installed near vibration-generating equipment, make foundation according to the specification of Mazak and take appropriate measures against vibration. Note 2: If the soil is weak, reinforce it by driving piles to avoid settling and subsidence of the soil after the installation of a machine.

6-2

INSTALLATION

2.

NC A. Ambient temperature Allowable temperature range during machine operation: +5 to +40C (+41 to +104F) B. Relative humidity Allowable relative humidity during operation: Note: 30 to 75% (no condensation)

As humidity increases, it impairs insulation and also accelerates deterioration of electric component parts. Although it is not necessary to take special dehumidifying measures, installation of a machine in humid places should be avoided.

C.

Atmosphere Although installation of the machine should be avoided in a dusty area or area where there is high concentration of organic or corrosive gas, if the machine must be operated under such environment, consult Mazak for appropriate measures.

D.

Vibration Allowable maximum vibration during operation: 4.9 m/s2 (16.08 ft/s2) or lower

Allowable maximum vibration during transportation: 34.3 m/s2 (112.53 ft/s2) or lower 3. Requirements for maintaining the guaranteed accuracy A. Basic requirements The machine should be installed at a site with tightly-packed soil no vibration-generating equipment nearby. B. Environmental requirements (air conditioned) Ambient temperature: Temperature variation: Relative humidity: Dust and other foreign matter: 20 2C (68 3.6F) 1C (1.8F)/30 min or lower 75% or lower 0.3 mg/m3 or lower

6-3

INSTALLATION

6-2-2

External power source requirements

! To prevent electric shock, ground the machine to earth in compliance with the applicable local regulations. In Japan, grounding of class C or higher (grounding resistance 10 or lower) is required. If the specified class of grounding work is impossible due to restrictions such as machine installation place environment, class D grounding (grounding resistance is 100 or lower) can be applied by mounting a earth leakage breaker (option) to the main power disconnect switch. ! Use cable conductors that meet the following requirements (200 VAC power source) Primary power cable: 150 mm2 (0.233 in2) or larger ([MLFC equivalent] Max. allowable temperature of insulator: 110C (230F)) Grounding cable: 80 mm2 (0.124 in2) or larger

WARNING

For details of the power source connection cable specifications corresponding to the available source voltage, refer to Table 6-2 List of total power requirements. Cable specifications are given in three groups of input voltages, [1] 200/220/230/240 VAC, [2] 380/400/415 VAC, and [3] 440/460/480 VAC. Note 1: When an earth leakage breaker is used, select one with a trip current of 200 mA. One with a trip current of 30 mA cannot be used for this machine equipped with inverters. If an earth leakage breaker is to be used, select the type that is appropriate for the use in the circuit where inverter driven equipment is connected. (This Note applies to the machine for Japanese market.) Note 2: Use an AC inverter-use circuit breaker as the main power disconnect switch of the factory. If an AC inverter-use circuit breaker is not used, the breaker may be tripped by the characteristic high-frequency leakage current of the AC inverter. (This Note applies to the machine for Japanese market.) 1. Power source voltage Allowable input voltage of the machines is determined from the following three groups according to the machine specifications. Make sure to check the allowable input voltage of your machine before connecting it to the power source. [1] [2] [3] Voltage: Voltage: Voltage: 200/220/230/240 VAC, 3 phase 380/400/415 VAC, 3 phase 440/460/480 VAC, 3 phase 10%

Permissible voltage fluctuation: 2. Frequency 50/60 Hz 1%

6-4

INSTALLATION

3.

Total power requirements When installing the machine, the machine may malfunction if the power capacity is insufficient and the service life of the electric parts will be shortened. In some cases, this may incur serious problems from the standpoint of safety. Therefore, always pay sufficient attention to the power facility so that sufficient power can be supplied to the machine.
Table 6-1 Power source 50/60 Hz 1% 3 phases (3 lines) 3 phases (3 lines) 3 phases (3 lines) Permissible voltage fluctuation Grand total of power requirement 10% See the separate table. * Install the transformer having the capacity (kVA) larger than the grand total of the continuous rating. See the separate table. * Provide the earth (metallic conduit wiring) having grounding resistance of 10 or less. 200/220/230/240 V 380/400/415 V 440/460/480 V Frequency Voltage

Power source connection cable

6-5

INSTALLATION Table 6-2 List of total power requirements Machine specifications Item Motor output 40/80 tools 42 52 (30 min) 7.0 kW 7.0 kW 11.0 kW 11.0 kW 7.0 kW 4.5 kW 0.2 2.01 6.32 2.50 1.57 1.15 0.52 1.96 16.25 1.5 kW 1.5 kW 0.2 kW 1.5 kW (2.5 kW) Not added (2.5 kW) Not added (0.26 kW) Not added (2.5 kW) Not added 1.1 4.58 79.94 89.74 (30 min) 120/160 tools 10000 min1

Spindle drive motor Servomotors

Continuous rating Short-period rating X-axis Y-axis Z-axis (master) Z-axis (slave) B-axis C-axis

30 kW/37 kW

Power requirement MATRIX of NC Other motors Hydraulic unit motor 2.2 kW Chiller unit 1 Chiller unit 2 3.91 kW 1.5 kW

Flood coolant pump 1.21 kW motor Cover coolant pump 0.88 kW motor Spiral conveyor Magazine drive motor Total power requirement ATC arm drive motor Tool shifter drive motor Tool carrier drive motor Pallet changer Control circuit (including slideway lubrication motors and cooling fans) Grand total of power requirement (kVA) Continuous rating Short-period rating 100.4 110.3 0.4 kW 1.5 kW

103.1 112.9

Power source connection cable size: [MLFC equivalent] Selection on the specifications of Max. allowable temperature of insulator: 110C (230F) Input voltage Power source connection cables (Ambient temperature: 30C (86F) or lower) Power cable Grounding cable [1] 200/220/230/240 V 150 mm (0.23 in2) 80 mm2 (0.12 in2)
2

[2] 380/400/415 V [3] 440/460/480 V 80 mm2 (0.12 in2) 38 mm2 (0.06 in2) 80 mm2 (0.12 in2) 38 mm2 (0.06 in2)

6-6

INSTALLATION

6-2-3

Air source requirements

Pressure Minimum discharge 0.5 to 0.9 MPa (70 to 130 psi) Standard With air blast option Dew point Oil mist concentration Note: 700 L/min (ANR) [24.72 ft3/min (ANR)]: Equivalent to 7.5 kW compressor 950 L/min (ANR) [33.55 ft3/min (ANR)]: Equivalent to 7.5 kW compressor

17C (1.4F) or lower (at atmospheric pressure) 30 mg/m3 (0.0000018 lbs/ft3) or lower

Supply clean air containing a minimum of water and moisture. Do not supply the air directly from the air compressor by connection through a short pipe. If the air is supplied directly from the compressor, hot air will be cooled in the machine and water and oil contained in the air will condense, blocking the valves and piping, corroding the related parts, and, in the worst case, resulting in the seizure of the spindle bearings. If the air to be supplied contains a large amount of water or it is hot, use auxiliary equipment like an air drier.

6-7

INSTALLATION

6-2-4
1.

Items to be confirmed when carrying the machine

Machine dimensions In order to carry the machine into the plant, an entrance that will allow the machine to pass through must be available (dimensions indicated in Fig. 6-1).
W

Fig. 6-1

Machine dimensions when carrying into the plant

Machine Standard High-torque table

W 3500 (137.80) 3500 (137.80)

H 3316 (130.55) 3316 (130.55)

D 6135 (241.54) 6480 (255.12) Unit: mm (in)

6-8

INSTALLATION

6-2-5

Foundation work
! If the machine has to be installed near vibration-generating equipment, make foundation according to the specification of Mazak and take appropriate measures against vibration.

CAUTION

! If the soil is weak, reinforce it by driving piles to avoid settling and subsidence of the soil after the installation of a machine. For machine installation, select a flat place; avoid places subject to direct sunlight, humid places, and places near vibration generation equipment. Although required foundation work will vary according to soil conditions, it is necessary to compact the ground well or pour concrete to avoid settlement or inclination of the soil after machine installation. Foundation parts
Part Name Plate Collar Anchor bolt Bushing Plate Collar Block Block Block Bolt Plate Bolt Nut Washer Anchor bolt Hexagonal socket head screw M16 120 Hex. Nut M24 Washer, M24 Set screw M6 16 Part No. 40/80-Tool 31276624280 44716100040 34716100030 44716100301 34716100010 44716100020 14746100580 34746100590 34746100600 44746100610 31276624270 34710400020 34710400030 42456104710 A05UJ001080 A06CB161200 A40JJ00M240 A41JJ00M240 A15B06X0160 3 22 22 22 22 22 22 22 22 22 5 5 5 2 2 2 22 22 44 Quantity 120-Tool 3 22 22 22 22 22 22 22 22 22 6 6 6 2 2 2 22 22 44 160-Tool 3 22 22 22 22 22 22 22 22 22 8 8 8 3 3 3 22 22 44

6-9

6
6-3

INSTALLATION

Installation
Precautions on installation
! Two or more workers must handle heavy objects. ! Use wire rope or a sling that can bear the weight to be lifted. ! The machine must be lifted properly. well balanced.

6-3-1

WARNING

Lift the machine slightly off the floor to check if it is

! The angle made by the wire rope or sling must be less than 60. ! Before lifting the machine, check that each machine unit is fixed in position and that there are no tools or anything else on the machine. CAUTION

6-3-2

Lifting
Lift the machine in the manner as shown in Fig. 6-2. Before lifting the machine, remove the X-axis way cover (left) and the cosmetic cover on the upper part opposite the operators door. (The machine is shipped with these covers removed.) Refer to 5-11 Covers and 6-3-4 Unpacking, inspection and cleaning. 1. At the machine front side: Fix the lifting blocks on the upper face at the base front (2 places) and hook the wire ropes on them [1]. At the machine rear side: Hook the wire rope on the lifting hooks (2 places) at the top of the column [2]. 2. Fix the machine units at the following positions using shipping brackets. Spindle head (Y-axis)At the center of Y-axis stroke [3] Table (X-axis) 1155 [4] Saddle (Z-axis) 1040 [5] 3. The wire rope and the crane must have the capacity indicated below. Wire rope At least 32 mm (1.26 in) diameter [6] Crane At least 30 t (66000 lbs) 4. 5. 6. 7. Place wood blocks or pads between the machine and wire ropes so that the machine will not be damaged by direct contact of the wire ropes. When lifting the machine, pay attention so that the wire ropes will not touch the piping, hydraulic equipment, wiring, control equipment, and covers. Make sure that the drain ports of hydraulic oil tank, coolant tank, and lubricating oil tank are all securely tightened so that oil will not leak. When carrying the machine using rollers, pay attention so that impact will not be applied to the machine.

6-10

INSTALLATION

Machine body

1 Fig. 6-2 Lifting the machine

6-11

INSTALLATION

6-3-3

Masses of machine units

Unit: kg (lbs)
e-1060V/6 II Machine body (standard specifications) Coolant tank Chip conveyor (front discharge type) 34620 (76324.10) 590 (1300.73) 720 (1587.33)

Note:

The figures indicated in the machine plates shall be applied if ones in the manual may differ.

6-3-4
1.

Unpacking, inspection and cleaning

Removing the shipping brackets The machine is shipped with its units fixed in place with shipping brackets so that they will not move during transportation. After installing the machine, remove all of shipping brackets. Store the removed shipping brackets and bolts in a suitable place to allow for reuse during movement or transport of the machine in the future. 2. Installing the cover and other part Install the cover and other part which are supplied in separate packages. Installing the X-axis way cover Install the X-axis way cover by referring to the explanation given in 5-11 Covers. 3. Cleaning Slideways and other machine parts are coated with rust preventive oil to protect the metallic surfaces from rusting. Since sand grits, dust and other foreign matter tend to stick to this rust preventive coating during the transportation of the machine, do not operate the machine before cleaning the machine. Remove rust preventive oil with rag soaked with washing oil. Note: Take care to avoid entry of cleaning oil into the slideway surfaces passing the wiper.

6-12

INSTALLATION

6-3-5

Location of the shipping brackets

Tool to be used: Allen wrench (10 mm, 17 mm)
Shipping bracket fixing the saddle (red)

Shipping bracket fixing the spindlehead - Magazine side (red)

Shipping bracket fixing the table - Column side (red)

Block for lifting the machine (red)

Shipping bracket fixing the table - Pallet changer side (red)

Shipping bracket fixing the spindlehead - Operator side (red)

Fig. 6-3 Location of the shipping brackets

6-13

INSTALLATION

6-3-6

Installing the machine

Machining accuracy is greatly influenced by installation conditions. No matter how precisely the slideway surfaces have been finished, machining accuracy will still be poor if the machine is not correctly installed. Tools to be used: Allen wrench (3 mm) Wrench (24 mm, 32 mm, 46 mm ) 1. Temporary leveling adjustments < Procedure > (1) With the machine lifted, fit the foundation bolts and foundation plates to the leveling bolt holes in the machine. (2) Lower the machine gently so that the foundation bolts are correctly inserted into the foundation holes prepared according to the foundation plan. Note: During this step, the leveling bolts cannot be used; pull them up from the bottom of the machine.

(3) Adjust the machine level temporarily by driving wedges under the machine. (4) After leveling the machine temporarily, fix the foundation bolts with mortar. When fixing the foundation bolts with mortar, the steel foundation plate bottom surface may be coated with grease to cut off the air.

24 (0.94) 400 (15.75) 230 (9.06) 140 (5.51) Unit: mm (in) 320 (12.60) 180 (7.09)
Fig. 6-4 Foundation bolts

6-14

100 (3.94)

108 (4.25)

INSTALLATION

2.

Checking interconnections After temporary leveling is finished, check and confirm the following items before switching the power on. Grounding (class C grounding work) Screws at terminals (must be tight) Connection of cannon connectors and other connectors Relays (must be fitted and connected correctly)

3.

Final level adjustment After the mortar has cured, adjust the machine level using the leveling bolts. levels on the bed and pallet upper surface. Precision level accuracy: 0.02 mm (0.00079 in)/division Place precision

For details on the procedure used to adjust the machine level and allowable leveling error, refer to the accuracy table supplied with the machine. After tightening the leveling nuts and foundation bolts, check the machine level again.

6-4
6-4-1

Connecting to the Power and Air Sources

Connecting to the power source
! Do not connect the power cable to the shop power distribution board until all installation work has been completed.

DANGER < Procedure > (1) Unscrew the bolts holding the main switch box cover in place, turn the switch to the OPEN RESET position and remove the cover.

Fig. 6-5 Connecting the power supply cable (1/2)

(2) Pass the power supply cable into the main switch box through the hole at the back of the electric control cabinet.

6-15

INSTALLATION

(3) Connect the wires to the R, S, and T terminals and the ground terminal of the NFB (no-fuse breaker).

MC111-01337 Fig. 6-6 Connecting the power supply cable (2/2)

6-16

INSTALLATION

6-4-2

Grounding
1. All electrical devices must be grounded in order to protect personnel and machines from electrical hazards. Grounding must be performed after the machine has been installed in accordance with the standards for electrical equipment. Ideally, the grounding point should be as close as possible to the machine, but depending on the machine installation site this may not always be possible. The work must be performed by personnel with publicly recognized qualifications. This will depend on the size of the company, but generally there will be a chief engineer or someone licensed to perform electrical work who should be asked to carry out the work. The work must be done in compliance with the applicable regulation (class C grounding in Japan). Grounding resistance: 10 max.

2. 3.

Cross-sectional area of wires: Refer to Table 6-2 List of total power requirements Measuring equipment: Earth resistance tester ! To prevent electric shock, ground the machine to earth in compliance with the applicable local regulations. In Japan, grounding of class C or higher (grounding resistance 10 or lower) is required. If the specified class of grounding work is impossible due to restrictions such as machine installation place environment, class D grounding (grounding resistance is 100 or lower) can be applied by mounting a earth leakage breaker (option) to the main power disconnect switch. Note 1: When an earth leakage breaker is used, select one with a trip current of 200 mA. One with a trip current of 30 mA cannot be used for this machine equipped with inverters. If an earth leakage breaker is to be used, select the type that is appropriate for the use in the circuit where inverter driven equipment is connected. (This Note applies to the machine for Japanese market.) Note 2: Use an AC inverter-use circuit breaker as the main power disconnect switch of the factory. If an AC inverter-use circuit breaker is not used, the breaker may be tripped by the characteristic high-frequency leakage current of the AC inverter. (This Note applies to the machine for Japanese market.) ! The grounding work must be entrusted to an electrical engineer with publicly recognized qualifications. If the work is done by an unqualified person, it could result in serious injury, death, or damage to the machine.

WARNING

WARNING

6-17

INSTALLATION

4.

The connections between the machines and ground should be made as indicated below. ! Never perform wiring as shown below.

WARNING
Machine Machine Machine

Fig. 6-7

When the grounding work is performed, no more than one wire should be connected to any terminal. The reason for this is to prevent a serious accident. For example, if a wiring plan like the one shown above is used, a faulty connection at one of the terminals could cause short-circuited current from another terminal to be fed back to the machine, resulting in serious damage. Independent connections

Machine

Machine

Machine

Each grounding resistance = 10 max.

Fig. 6-8

Common connection

Machine

Machine

Machine

The wires from the grounding terminal should be directly connected to each of the machines. 10 Grounding resistance = Number of machine
Fig. 6-9

6-18

INSTALLATION

6-4-3

Connecting to the air source

Connect the air hose to the connection port of the air unit.

Mist separator

Reducing valve External air source connection port

Fig. 6-10

Air unit

6-19

6
6-5

INSTALLATION

Test Run
Checking the machine before starting test run
1. Make sure that the lifting fixture and the shipping brackets are all removed. If the machine is operated while they are still attached, the machine will be damaged. 2. 3. 4. 5. 6. 7. Make sure that there are no missing parts or accessories. Make sure that the centralized lubrication unit tank is filled with the specified lubricating oil to the specified level. Make sure that the hydraulic unit tank is filled with the specified oil to the specified level. Make sure that the spindle cooling fluid tank and the turning spindle lubricating oil tank are filled with the specified oil to the specified level. Make sure that the hoses and cables of the circuits for hydraulic, pneumatic, and coolant circuits are correctly connected. Make sure that the coolant tank is correctly placed. Make sure that the coolant receiving opening in the tank is correctly placed under the chip disposal duct. 8. Make sure that the connection to the air source is correct.

6-5-1

6-5-2
1.

Electric inspection before switching the power ON

Check the phase sequence of power supply If the NC power is switched on while the phase sequence of power supply is incorrect, trouble such as runaway of the machine and blowing of fuses will occur. Therefore, under no circumstances switch on the NC power until the phase sequence is confirmed to be correct. A. Checking the phase sequence with the phase tester Connect the phase tester to the transformer as shown in the illustration below (U R, V S, W T). The phase tester must show clockwise rotation.
Transformer Phase tester

Fig. 6-11

Checking the phase sequence

6-20

INSTALLATION

2.

Receiving power If the phase sequence is correct, the main switch may be turned on. For the machine using the mill spindle drive motor: Turn on the main switch and check the indication of the LED lamps at the front panel of the spindle controller. Make sure that the LED lamps do not show an alarm indication.
Correct

Alarm

If any of the following letters is displayed in this position, it indicates that alarm has occurred. 1, 2, 3, 4, 5, 6, and E Fig. 6-12

6-5-3

Checking the parameter settings

Check the present parameter settings by referring to the parameter table in the electrical control cabinet.

6-5-4

Checking the machine in manual operation

Operate the machine manually to make sure that the following operations are executed correctly. Spindle rotation (mill spindle and turning spindle) Axis movement (X-, Y-, and Z-axis) ATC cycle Zero-point return

6-5-5

Breaking in operation
When operating the machine for the first time after the installation, pay special attention so that the machine can operate without abnormalities. Breaking in operation should be carried out for approximately 8 hours. not apply a large load to the machine. During breaking in, do

The machine is shipped with the program for breaking in operation (Pno. 6000) already input; use this program for breaking in operation (approx. 8 min/cycle).

6-21

INSTALLATION

- MEMO -

6-22 E

APPENDIX

7
7-1
7-1-1

APPENDIX
List of Sensors, Limit Switches, and Oiling Points
List of oiling points
The lubrication period is decided on the basis of eight hours operation a day. In case of the failure to change cooling fluid and use of other oil, some problems may be produced in the machine.

Fig. 7-1 No. 1 Lubrication Point Mill spindle

Lubricating point Qty 3 L (0.11 ft3) Recommended Oil MOBIL DTE 24 SHELL TELLUS OIL 32 Remarks Proper amount of lubricant is automatically supplied. Clean the filter every year. Change oil and clean the filter every year. 4-7-1 Refer to 4-4-1

Slide way Ball screw

3 L (0.11 ft )

MOBIL VACTRA OIL No. 2 SHELL TONNA OIL S68

3 4 5 6 7

Table

30 L (1.06 ft3) 35 L (1.24 ft3)

MOBIL SHC626

B-axis Spindle cooling unit Hydraulic power unit

12 L (0.42 ft3) 108 L (3.81 ft ) 60 L (2.12 ft )

3 3

MOBIL SHC629 MOBIL VELOCITE OIL No. 3 MOBIL DTE 24 SHELL TELLUS OIL 32

8 9 10 11 12 13 14

Shifter ATC Carrier linear guide Carrier ball screw ATC door linear guide NC control panel linear guide Counter balance

3.6 L (0.13 ft ) 6 L (0.21 ft3) 2.4 cm3 2 (0.15 in3 2) 2.4 cm3 (0.15 in3) 1.1 cm3 4 (0.07 in3 4) 1.1 cm3 4 (0.07 in3 4) 100 cm3 2 (6.10 in3 2)

MOBIL VACTRA OIL No. 2 SHELL TONNA OIL S68 <Grease> MOBIL MOBILUX EP2 SHELL ALVANIA GREASE RL2

Change oil every year.

4-7-1

Supply grease every 6 months in manual operation.

4-6-2

<Grease> SH33M (PASCAL)

7-1

APPENDIX

7-1-2

List of sensors and limit switches

Fig. 7-2

List of sensors and limit switches

7-2

APPENDIX

7-3

APPENDIX

Fig. 7-3

Table specifications

Fig. 7-4

Mill spindle specifications

7-4

APPENDIX

Fig. 7-5

Tool measurement specifications

7-5

7
7-2

APPENDIX

List of Wearable Parts

Service life of wearable parts below will vary according to the conditions under which they are used.
Location Name Element assy Element assy Part No. G48SV00130A G48SV00217B G06LAP00140 55755101200 Type AM-EL350 AFD20P-060AS 489011 Manufacturer SMC SMC Lube MAZAK To be Changed in 2 years 2 years 3 years 3 years Refer to 5-7-3 5-7-3 -

Air unit

Centralized lubrication unit Way cover

Filter set X-axis (R: Column side) wiper set X-axis (L: Pallet changer side) wiper set Y-axis wiper (left/right set) (Remark 1) X-axis pantograph (R: Column side) (Note 1) X-axis pantograph (L: Pallet changer side) (Note 1) Y-axis pantograph (Note 2) Z-axis pantograph (upper right) (Note 3) Z-axis pantograph (upper left) (Note 3) Z-axis pantograph (lower right) (Note 4) Z-axis pantograph (lower left) (Note 4)

55755100900

MAZAK

3 years

55765200200 25755139410

MAZAK MAZAK

3 years As needed

25755139140

MAZAK

As needed

25765217840 Z33HV00744H Z33HV00745H Z33HV00679G Z33HV00680G R61MB000281 G30TP000800

FA21021P111 SFN-06-100K

MAZAK HAUSUNG HAUSUNG HAUSUNG HAUSUNG Matsushita Taisei

As needed As needed As needed As needed As needed 1 year 1 year

Machine light Table

Fluorescent tube Lubrication section filter

Remark 1: The term Y-axis wiper refers to the set of parts indicated as [1] in the figure below.

[1] [1]

Note 1: Order two pantographs for one X-axis way cover. Note 2: Order four pantographs for one Y-axis way cover. Note 3: Order three pantographs for one upper Z-axis way cover. Note 4: Order four pantographs for one lower Z-axis way cover.

7-6

APPENDIX

Y-axis way cover Z-axis way cover (upper/lower right)

Z-axis way cover (upper/lower left) X-axis way cover (R: Column side)

X-axis way cover (L: Pallet changer side)

Fig. 7-6

Location of the way covers

7-7

APPENDIX

- MEMO -

7-8 E