MORISEIKI MAINTENANCE CLASS

7/21/2019 MORISEIKI MAINTENANCE CLASS

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J & H Machine Tools, Inc.4345 Morris Park Drive

Charlotte, NC 28227

Service DepartmentTelephone: 704-545-7056

Fax: 800-892-1862

Mori Seiki

Maintenance Class

Presented by

Lewis Craven



J & H MACHINE TOOL INC. is not a manufacture of parts and does notwarranty the use or the fitness of any product, component, or part installedduring the service or repair of the machine(s) described herein. It isunderstood and agreed that J & H is providing only the service ofrepairing, replacing, and/or maintaining equipment of the customer. J & Hspecifically disclaims all implied warranty including the implied warranty ofMERCHANTABILITY and FITNESS FOR ANY PARTICULAR PURPOSE.No employee or agent of J &H is authorized to make any warrantycontrary to the foregoing. In no case shall J & H be responsible to thecustomer for any special or consequential damage based upon a breachof agreement between J & H and the Customer or negligence. The

contents of this manual are subject to change without notice. Please bearin mind that there are discrepancies between the contents of this manualand the actual machines. If any part of this manual is unclear, Pleasecontact J & H Service Department at 704-545-7056. J & H will not beliable for any damages occurring as direct or indirect consequence ofusing this manual. This material is intended for trained qualifiedtechnicians only. ALL MATERIAL CONTAINED IN THIS MANUAL ISDIRECT COPY FROM THE FOLLOWING MANUAL OR PROCEDURES:Mori Seiki MAINTENANCE MANUALS, Mori Seiki SERVICE MANUALS

AND SERVICE CD, Fanuc OPERATOR MANUALS, FanucMAINTENANCE MANUALS, Mori Seiki OPERATOR MANUAL, Mori Seiki

PROGRAMMING MANUAL.

J & H SERVICE PROCEDURES, PICTURES, AND SERVICEINFORMATION CONTAINED IN THIS DOCUMENT IS CONSIDERED TOBE A PART OF THE J & H KNOWLEDGE BASE. THIS DOCUMENTDOES NOT CONTAIN APPROVED INFORMATION BUT RATHER AN

ACCOUNT OF AN EXPERIENCE USED SUCCESSFULLY IN THEPAST. USE THIS INFORMATION WITH CARE













CONSTRUCTION OF BALLNUTS

The ballscrews for X, Y and Z axis are all 45mm diameter with a 16 pitch. The major differencewith the ballscrews on the NH5000 (and NV5000) is that the ballnut is a single piece

construction. The backlash on the new design is compensated for by measuring the startingtorque on the screw, then either increasing or decreasing the size of the balls.

On the two piece designed ballnut, preload was compensated for by a ground shim plate

installed between the two pieces of the nut. This caused the force from the grooves to be appliedon the outer, upper edge of the ball bearings.

By utilizing the correct size balls, force is applied to all four corners by the grooves in the screw.It is more difficult to machine the actual threads of the screw, since even pitch and finish iscritical, but time is saved on the actual assembly of the ballscrew, and there is no loss of accuracy or repeatability.









Y-AXIS BALLSCREW

The Y-Axis construction on the NH5000 was designed to reduce the need for

the Dynamic Thermal Displacement Control.

The fixed end of the ballscrew is now at the motor side, on the upper part of thecolumn.

The ballnut is stretched from the lower Y nut.

The reason that the need for the DTC option is reduced with this designis that with the fixed end of the Y-axis ballscrew being at the top, theballscrew will expand downward when it heats up. Conversely, when the column



heats up, it will expand upward. Since the fixed end of the ballscrew is located along way from the X-axis linear guide (where the column rests), the ballscrew candevelop up to 3 times as much heat as the column and not show the effects of thermalexpansion.



45MM WideLinear Guide

Two Trucksper side on Z

3 Trucks per side on X

2 trucks per side on Y



Z axis motor directly coupled to the ballscrew.There is no separate brake.

Magazine mounting holes



The new column is designed to provide little interference for fixtures but stillprovide the rigidity expected from Mori Seiki. All covers inside the machine weredesigned with chip removal in mind. This machine also offers optional chipaugers on both sides of the table to move chips into the conveyor, which islocated in the front of the machine.

The chip conveyor and coolant tank is easily moved in and out of place by oneperson for maintenance or cleaning purposes.



CONSTRUCTION

The NH5000 is constructed using a three-piece level design, like theSH5000/SH-503/SH-403 designs. All axes are designed using THK linear guides.

The X-axis uses a THK/SNS45LC2QZSSHHC0E+1460LHE-II, the Y-axis aTHK/SHS45LR2QZSSHHC0E+1200LHE-II and the Z-axis aTHK/SNR45LC2QZKKHHC0E+1725LHE-II linear guide.

The ballscrew for all three axes is a 45mm diameter by 16 pitch lead. X-axis has630mm of travel, Y-axis 600mm and Z-axis has 670 mm.

Note in the picture above that the machine also has a new design for chipremoval. There are two chip augers on either side of the table that run fromunder the column all the way through the machine, including the setup station.There is also a conveyor located between the B-axis and the spindle to move thechips from the area inside the cutting envelope. This “triple trough” design is for maximum chip removal while maintaining high rigidity in the machine base.



The ways for each axis are covered with a new type sliding cover. The material islike a spring steel, so anything dropped on it will not dent. It is also designed toflex when chips get under the sliding seals instead of building up and separatingthe covers as in the past.

The X/Y cover, when installed or when being replaced, must be indicated in toensure flatness. It is adjustable by loosening the screws on the slotted mountingbrackets, adjusting the position, then tightening the bolts back. In the picturebelow, you can see the pantographic support of the X and Y axis.

X Axis Cover Y Axis Cover



All motors on the machine are easily accessible without having to remove but asingle access cover for each.

APC Motor

Chip Auger and Z-Axis Motor Under Setup Station



B-Axis Motor and Belt Drive

Magazine Motor and ATC Motor



X-Axis Motor

Y-Axis Motor



Conveyor Motor



ATC

FULL 4TH AXIS TABLE

SPINDLE + BALLNUT + APC AND 1 DEGREE INDEXER

AIR PANEL

SPINDLE

ELECTRICAL CABINET

EXTERNAL CHIP CONVEYOR

MAGAZINE

COOLANT TANK

COOLANT PUMPS

OIL COOLER

HYDRAULIC TANK

SSEMBLY IDENTIFICATION











REGULAR INSPECTION LIST

The items that require inspection and maintenance at regular intervals are indicated below.By referring to the machine specifications and other reference information, carry out inspection

and maintenance work at the specified inspection intervals. For information on items that have no

reference information in the list below, contact the person responsible for maintenance, Mori Seiki,

or the machine retailer.

Inspection ItemInspection

IntervalReference Information

Oil leak in pipe joints 50 hours

Air pressure (with pressure gage) 50 hoursElectrical cabinet air filter (cleaning) 50 hours

Oil cooler condenser and air filter (cleaning) 50 hours MAINTENANCE MANUAL

Door rail (cleaning) 50 hours

Front cover of the spindle (cleaning) 50 hours

Slideway protection covers (cleaning) 50 hours MAINTENANCE MANUAL

Operation functions (to be checked by manual operation) 500 hours OPERATION MANUAL

Temperature inside the electrical cabinet 500 hours

Coolant tank (cleaning) 500 hours MAINTENANCE MANUAL

Coolant tank filter (cleaning) 500 hours MAINTENANCE MANUAL

Slideway lubricating oil tank (cleaning) 500 hours MAINTENANCE MANUAL

Spindle bearing lubricating oil tank (cleaning) 500 hours MAINTENANCE MANUAL

Machine level using level 1000 hours MAINTENANCE MANUAL

Dynamic inspection by test cutting 1000 hours

Wear or damage of slide seals 1000 hours MAINTENANCE MANUAL

Slideway lubricating oil tank port filter (cleaning) 1000 hoursSpindle bearing lubricating oil tank filter at oil supply port(cleaning)

1000 hours

Abnormal noise and vibration of ball screw 1000 hours

Vibration, abnormal noise, and heat generation ofservomotors

1000 hours

Abnormal noise and vibration during spindle rotation 1000 hours

Spindle run-out 1000 hours

Backlash 1000 hours

Twisting 1000 hoursCrowning 1000 hours



Looseness of servomotor connectors 1000 hours This chapter

Magnet switch (operation check) 1000 hours

Cable breakage, damaged shielding 1000 hours

Control relay (actuation stroke) 1000 hours

AC spindle motor insulation resistance 1000 hours

Abnormal noise, heat generation, and vibration of ACspindle motor

1000 hours

Relay terminal screws(tightness inspection and tightening)

1000 hours

Connectors (tightness inspection and tightening) 1000 hours

Suction strainer in the hydraulic oil tank (cleaning) 1000 hours MAINTENANCE MANUAL

Air filter for air actuators (cleaning) 1000 hours This chapter

Lubricator (cleaning) 1000 hours This chapter

Air solenoid valve (disassemble to clean) 1000 hours

Inside the electrical cabinet (cleaning) 1000 hours MAINTENANCE MANUAL

Fans (cleaning) 1000 hours MAINTENANCE MANUAL

Hydraulic oil in hydraulic tank (oil change) 1000 hours MAINTENANCE MANUAL

Hydraulic oil tank (cleaning) 2000 hoursOil cooler or fan cooler (oil change) 2000 hours MAINTENANCE MANUAL

Air filter for air actuators (replacement of element) 2000 hours This chapter

Battery (replacement) 1 year MAINTENANCE MANUAL

Inspection ItemInspection

IntervalReference Information



OILING CHARTS

Oil Point Oil Type QuantityOil Change

Interval

Replenishing

Interval

1 Hydraulic unit tankDaphneHydraulic Fluid 32

20 L

Check oillevel gageEvery 1000

hours ofoperation

—

2 Oil cooler tankDaphneSuper Multi 2M

38 LEvery 2000

hours ofoperation

—

3 Coolant tank — 540 L As required Replenish asrequired

4

Spindle bearing/ballscrews/APC unitlubricating oil tank(oil-air lubrication)

DaphneMechanic Oil 32

2 L —Check oil level gage

Replenish asrequired

Table lubricating oiltank (1-degree indextable)


2 L —When carrying outdisassembly and

adjustment

5Table lubricating oiltank (full 4th-axisrotary table)

Tonna Oil S68 2 L —Check oil level gage

Replenish asrequired

6 ATC unit Spirax HD 80W-90 20 L — Replenish asrequired

1

2

3

45

6



(1) The oil indicated in the table above is used when the machine is delivered.

For equivalent oil, refer to "Oil Recommendations".

(2) For the oil handling method, refer to the MATERIAL SAFETY DATA SHEET providedby the oil manufacturer.

NOTE

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Oil Recommendations

(1) Use only the oil types listed below.

Never mix lubricating oils from different manufacturers.Mori Seiki cannot be held responsible for malfunctions that may occur either as the

result of mixing lubricating oils or from the use of a non-recommended lubricating

oils.

(2) Since the oil used for the oil cooler - Daphne Super Multi 2M - is a special type of

oil, if you use oil made by another maker, use a product that is equivalent to

number 10 in the table below.

(3) The table below shows the list of equivalent oil names only and it does not

guarantee the equivalence of dynamic characteristics.

Oil PointOil Type

Idemitsu Mobil Shell Castrol

Hydraulic unit tankDaphneHydraulic Fluid 32

DTE Oil LightTellus Oil S32Tellus Oil 32

Hyspin AWS32

Oil cooler tankDaphneSuper Multi 2M

MobilVelocite Oil No. 6

Tellus Oil C5 Hyspin AWS10

Spindle bearinglubricating oil tank(oil-air lubrication)


DTE Oil LightTellus OilR32 (XHVI)

—

Table(full 4th-axis rotary

table)

Daphne

Super Multi 68

Mobil

Vactra Oil No. 2

Tonna Oil S68 Magna BD68

CAUTION



CHECKING SERVOMOTOR CONNECTORS

<Checking interval>

Every 1000 hours of operation

<Checking procedure>

1) Turn off the power.

2) Remove the cover.

3) Make sure that servomotor connector is mounted

correctly.

4) Mount the cover.



CHECKING COOLANT MOTOR CONNECTOR AND CHIP

CONVEYOR MOTOR CONNECTOR

<Checking interval>


<Checking procedure>


2) Make sure that the connectors are mounted correctly.

Coolant motor connector Chip conveyor motor connector



CLEANING THE AIR FILTER

If the air filter element is clogged, the pressure of the air supplied to the actuators is decreased,causing their operation failure. Therefore, the air filter element should be cleaned at regular

intervals or the element should be replaced if it is heavily clogged.

The air filter is equipped with a float type automatic discharge unit.

Usually, the drain is automatically discharged through the discharge port.

However, if the drain is not automatically discharged or if foreign matter has accumulated at the

bottom bowl, operate the drain cock manually to discharge the drain.

Manual Discharge of the Drain

<Cleaning interval>

When the accumulation is not discharged automatically, or when foreign matter has accumulated

at the bottom of bowl

<Procedure>

Turn the manually operated drain cock at the bottom of the air filter counterclockwise to discharge

the drain.



Cleaning the Air Filter

Air Filter

If the air filter element is clogged, the air pressure supplied to the actuators is reduced, causing

their operation failure. Therefore, the air filter element should be inspected at regular intervals.

<Cleaning interval>


<Procedure>


2) Shut off the compressed air.

3) Turn and remove the case assembly.

An O-ring is attached in the upper part of the case.

Pay sufficient care not to break the O-ring while

removing the case.

4) Loosen the cross-recessed pan head screws on the

rod.

5) The filter element and the baffle come off.

6) Clean the filter element using neutral detergent.

(1) If the element cannot be cleaned, replace it.(2) When using the submicron filter (0.3 m),

replace the element since the element cannot

be cleaned.

7) Supply compressed air to the filter element from

inside.

8) Clean the case assembly using neutral detergent.

9) Assemble the air filter by following the disassembly

procedure in reverse.

10) Supply compressed air to make sure that there is noair leak.

AW3000-4000

Drain

Valve assembly

Case O-ring

OUT

O-ring

Case assembly(with case guard)

Cover Diaphragmassembly

Deflector

Valve spring

Filter element

IN

Body

Baffle

OUT

Valve O-ring

NOTE

NOTE



REPLACING THE MACHINE LIGHT

The lamp is a consumable part.

<Changing interval>

When the light cannot satisfactorily illuminate the working area.

<Lamp>

Fluorescent lamp: SLCE118 (Waldmann)

<Procedure>


2) Clean the lamp; wipe off coolant and chips.

3) Remove the screws of the clamp.

Hold the lamp so that it does not fall.

4) Remove the lamp unit.

5) Remove the glass tube by turning the clamp cap.

6) Pull connector terminal A out of connector terminal B.

Clamp Screw

NOTE

Glass tube

Clamp cap

Connector terminal A

Connector terminal B



7) Remove the wiring cover.

8) Remove the fluorescent lamp clamp.

9) Press the fluorescent lamp lock release button and

remove the fluorescent lamps.

Be careful that the fluorescent lamps do not fallinto the machine.

10) Mount new fluorescent lamps.

11) Connect the connector terminals A and B.

12) Turn on the power.

13) Press the machine light switch to turn on the

fluorescent lamps.

14) Make sure that the fluorescent lamps light.

If the lamps do not light or light slowly, turn off the

power and check the contact between the lamp

base and the mounting base.

15) Press the machine light switch to turn off the

fluorescent lamps.


17) Mount the fluorescent lamp clamp.

18) Mount the wiring cover.19) Mount the glass tube.

Wiring cover

Fluorescent lamp clamp

Fluorescent lamps

Fluorescent lamplock release button

NOTE

NOTE



20) Tighten the clamp cap.

When tightening the clamp cap, insert a tool such

as a screwdriver into each of the holes machined

in the parts, indicated by (1) and (2) in thediagram, and secure it tightly. Make sure that O-

rings are properly fitted before tightening the

clamp cap.

If the O-rings are loose, coolant or other

foreign matter may get into the fluorescent

lamp unit.

21) Mount the lamp unit on the clamp.

(1)

(2)

O-ring

NOTE

CAUTION



X-axis travel(Longitudinal movement of column)

630

Y-axis travel(Vertical movement of spindle head)

600

Z-axis travel(Cross movement of table)

670

Distance from table surface tospindle center

50~650

Distance from table center to spindlegage plane

100~800

Table working surface 500×500Table loading capacity kg (lb.) 500Maximum workpiece swing diameter ö730Maximum workpiece height 900Table surface configuration M16 24 100 mmMinimum table indexing angle ° 1 (0.001)Table indexing time sec 2.0 [90°]Spindle speed range*2 min-1 14000 (20000)

Number of spindle speed ranges 1Max. spindle torque N - m (ft/lbf) 221

1.4(14,000)Type of spindle taper hole 7/24 No. 40

Spindle bearing inner diameter 65Rapid traverse rate mm/min (ipm) 500000.54(X),0.44(Y),0.58(Z)

feedrate mm/min (ipm) 0~50000Jog feedrate mm/min (ipm) 0~1260 [15]Type of tool shank MAS BT-40 (CAT-40)Type of retention knob 90°Tool storage capacity 30, 40, 60, 120, 180Maximum tool diameter (with adjacent tools)

80

Maximum tool diameter (without adjacent tools) 180

Maximum tool length 400Maximum tool mass kg (lb.) 8 (12)Maximum moment (from gage line) 7.84(14.13)

N-m (ft/lbf)Method of tool selection 30 or 40

SPECIFICATIONS









Mesh size of coolant tank 30 16

Coolant filtration accuracyrequirementsat through spindle coolant spindlesystem specification

ì m 20

Positioning accuracy 0.005

Repeatability of positioning ±0.001



NUMERICAL CONTROL UNIT SPECIFICATIONS

The numerical control unit specifications for this machine are indicated below.

(1) Due to our policy of continuous improvement, NC unit specifications are subject to

change without notice.

(2) Some optional NC specifications and those which require a sequence program

change cannot be installed after shipping. Please contact us in advance for details.

: Standard : Option : Possible by changing sequence

*1 The standard least input increment for the B-axis is 1, 0.001 is availabe as an option

(full 4th-axis rotary table).

*2 For details, consultation is necessary.

NC Model MSG-501

1 CONTROLLED AXES

1-1 Controlled axes X, Y, Z, B

1-2 Simultaneously controllable axes(standard)

Positioning/linear interpolation/circular interpolation

3/3/2

1-3 Max. controllable axes (option)NC controlled axes 6

Max. simultaneously controllable axes 4

2 PROGRAMMING METHODS

2-1 Least input increment 0.001 mm/0.0001 in./0.001

2-2 Least command increment*1 0.001 mm/0.0001 in./0.001

2-3 Max. commandable value 99999.999 mm/9999.9999 in.

2-4 Absolute/incremental programming G90/G91

2-5 Decimal point programmingElectronic calculator type decimal pointprogramming can be selected by parametersetting.

2-6 Inch/metric conversion G20/G21

2-7 Programming resolution multiplied by 1/10Max. 9999.9999 mm/393.70078 in.Pulse coder needs to be replaced

2-8 Programming resolution multiplied by 10 Selectable by NC parameter setting

2-9 Tape code EIA/ISO code automatic discrimination

2-10 NC tape

8-unit (transmissivity: 40% or less)JIS C6243EIA RE-227-AISO 1729

*2

NOTE

NOTE


http://slidepdf.com/reader/full/moriseiki-maintenance-class 46/409*1 Cutting feedrate during look-ahead control. The cutting feedrate is 5000 mm/min

when look ahead control is not applied

NC Model MSG-501

3 INTERPOLATION3-1 Positioning G00

3-2 Linear interpolation G01

3-3 Circular interpolation G02/G03 (CW/CCW)

3-4 Hypothetical axis interpolation

3-5 Polar coordinate interpolation G12.1, G13.1

3-6 Cylindrical interpolation G7.1

3-7 Exponential function interpolation

3-8 Involute interpolation G2.2/G3.2

3-9 Helical interpolation

3-10 Helical interpolation B

3-11 Linear acceleration/deceleration aftercutting feed interpolation

3-12 Linear acceleration/deceleration beforecutting feed interpolation

Standard during look-ahead control

3-13 Bell-shaped acceleration/decelerationafter cutting feed interpolation

3-14 Bell-shaped acceleration/deceleration forrapid traverse

3-15 Spiral/conical interpolation

4 FEED

4-1 Cutting feedrate 1 - 50000 mm/min *1

4-2 F1-digit feed F1 - F9

4-3 Dwell G04

4-4 Thread cutting Position coder is required.

4-5 Pulse handle feed Manual pulse generator: 1 unit 1, 10, 100 (per pulse)

4-6 Automatic acceleration/deceleration Linear type (rapid traverse/cutt ing feed)

4-7 Rapid traverse rate override F0 (fine feed), 25/100%

4-8 Feedrate override 0 - 150% (10% increments)

4-9 Feedrate override cancel M48, M49

4-10 Second feedrate override For details, consultation is necessary.

4-11 Inverse time feed

NOTE





*1 For details consultation is necessary

NC Model MSG-501

7-5 External data inputExternal program number search, externaltool offset, and external work coordinatesystem shift

7-6 Tape operation with RS-232-C *1

7-7 Remote buffer DNC RS-232-C/RS-422 *1

7-8 High-speed remote buffer A: Binary input RS-232-C/RS-422

B: NC statement input RS-232-C/RS-422*1

7-9 External I/O device control For details, consultation is necessary.

7-10 Punching and setting of PMC parameters

7-11 Floppy cassette directory display For FANUC floppy cassette7-12 DNC1 *1

7-13 External sub-program call M198

7-14 DNC2 *1

7-15 Memory card interface

8 STM FUNCTIONS

8-1 Spindle speed function (S function) 5-digit S code

8-2 Spindle speed override 50 - 120% (10% increments)

8-3 Tool functions (T function) 4-digit T code

8-4 Miscellaneous function (M function) 3-digit M code

8-5 Secondary miscellaneous function Applicable for other than B codes

8-6 High-speed M/S/T/B interface

8-7 Constant surface speed control

9 TOOL OFFSET

9-1 Tool length offset G43, G44, G49

9-2 Tool position offset G45 - G489-3 Cutter radius offset C G40 - G42

9-4 Number of tool offsets

A set is defined as a radius and lengthcombination.If radius and length offset data are setindividually, the value indicates the number ofdata. (sets)

32

9-5 Additional number of tool offsets Option Total (sets)64, 99, 200,

400, 499, 999

9-6 Tool offset data memory B Geometry and wear offset data

9-7 3D tool offset

NOTE





NC Model MSG-501

11-10 Z-axis neglect11-11 Set zero Relative coordinate origin

11-12 Handle feed interruption

11-13 Program restart

11-14 Sequence number collation and stop

11-15 Running time display/Number of parts display

11-16 Expanded tape editing MAPPS provides the function

11-17 Addition of optional block skip functions BDT2 - BDT9

11-18 Background editing

11-19 Directory display/punch classified bygroup

11-20 Load meter display

11-21 Machine time stamp function

11-22 Tool escape and return

11-23 Clock function Screen display

11-24 Removal of controlled axes Parameter

11-25 Tool length measurement

11-26 Retrace function

11-27 Handle feed in tool-axis direction

12 PROGRAMMING SUPPORT FUNCTION

12-1 Circular arc radius command

12-2 Arbitrary angle, chamfer, corner Rdesignation

Not selectable for conversationalprogramming

12-3 Canned cycle

12-4 Sub-program Up to 4 nestings

12-5 Interruption type custom macro

12-6 Custom macro B

12-7 Programmable mirror image

12-8 Automatic corner override

12-9 Exact stop check G09

12-10 Exact stop check mode G61/G64

12-11 Programmable data input Substituted by offset amount program input

12-12 Playback





NC Model MSG-501

15-2 High-speed skip

15-3 Tool life management

15-4 Additional number of tools to be controlledby the tool life management function Total 512 sets

16 SAFETY AND MAINTENANCE

16-1 Emergency stop

16-2 Overtravel Only software overtravel is available.

16-3 Stored stroke limit 1

16-4 Self-diagnosisIncludes alarm display, I/O signal diagnosis,and ladder diagram.

16-5 Door interlock

16-6 Stroke check before movement

16-7 Stored stroke limit 2, 3

16-8 Stroke limit external setting

16-9 Spindle speed change detection

16-10 Alarm history display

16-11 Help function

16-12 Operation history display

16-13 Operator’s message history display

16-14 Abnormal load detection function

17 ENCLOSURE AND INSTALLATION

17-1 Enclosure construction Enclosed dust-proof type (IP54)

17-2 Environmental conditions

Operation ambient temperature:10 - 35C

Permissible temperaturevariation (max.): 1.1C/min.Relative humidity: 75% or less

Permissible vibration: 4.9 m/s2 or less

18 SERVO SYSTEM

18-1 Servomotor AC servomotor (without transmission)

18-2 Servo units IGBT PWM control

18-3 Position detectors Pulse coder, absolute position detection

18-4 Spindle drive motor AC i spindle motor

18-5 Spindle inverter IGBT PWM control



























INSTALLATION DRAWING

Make sure there is sufficient maintenance area for opening the CNC and electrical

cabinet doors, for pulling out the coolant tank and chip conveyor, etc.

Unit: mm

(1) Separatedarated units (step-down transformer, etc.) must not be located at exact positionshown in the drawing as long as interference is avoided.



FOUNDATION DIAGRAM

(1) Select a place that can support the weight of the machine.

(2) To obtain and maintain the intended levels of accuracy and performance from the

machine over a prolonged period of time, perform foundation work carefully and

pay attention to machine installation.

Unless foundation work is performed according to the foundation diagram, it will

adversely affect the accuracy (static and dynamic) and the life of the machine.

Unit: mm



ENVIRONMENTAL REQUIREMENTS

Consider the following requirements when selecting a site to install the machine.

<Ambient temperature, humidity, and altitude>

Install the machine at a site where the ambient temperature remains within the range

10 to 35C, the humidity does not exceed 75% RH (with no condensation), and the

altitude is lower than 1000 m. Failure to comply with these conditions could cause

trouble in the electrical systems of the NC unit and peripheral devices and lead to

machine failure.

Install the machine at a site where neither it nor the NC unit is subject to direct sunlight.

Direct sunlight will raise the temperature and cause thermal displacement, adversely

affecting machining accuracy.

<Vibration>

The machine must not be installed at a site subject to excessive vibration (greater than

4.9 m/s2). Excessive vibration could lead to machine failure and will adversely affect

machining accuracy.

<Dust>

(1) Choose an installation site that is as free as possible from dirt, dust, and mist. If

dirt and dust adhere to the cooling fan fitted inside the machine its cooling

capability will be impaired and this could lead to machine failure.(2) Install the machine at a site where it will not be reached by chips, water, and oil

scattered from other machines. These could cause machine failure.

<Installation ground>

Make sure the floor is strong enough to support the machine. The floor must not be

sloped or irregular in any way. Twisting or other distortion of the machine will adversely

affect machining accuracy.

<Maintenance area>

When installing the machine, refer to the installation drawing and other instructions and

provide sufficient maintenance area to allow the chip conveyor (if featured) and coolanttank to be removed, and the electrical cabinet door to be opened and closed, without

difficulty. If you do not provide sufficient maintenance area it will not be possible to

carry out maintenance work properly and the life of the machine will be shortened.

Refer to the INSTALLATION DRAWING in the DRAWINGS published separately.

CAUTION

NOTE

CAUTION

CAUTION

NOTE

CAUTION



FOUNDATION WORK

For the installation of the machine, conventional foundation work using foundation bolts is not

necessary due to its machine construction (three-point support structure) and the rigidity ofmachine.

Normally, it is good enough to support the machine if the thickness of the floor concrete is 500 mm

or more. However, if the ground does not have sufficient strength and is not capable of absorbing

the vibrations of other machines, the foundation work for absorbing the vibration is necessary.

Consult a civil engineer to determine the number and depth of piles and concrete thickness

because they differ according to the ground condition.

<Check items>

Concrete

Machine

Pit cover

Pit for absorbing vibration(Approx. 150 mm width)

Rubble

Piles (especially, drive them for soft ground.)

Ground

Concrete subslab 100

200

(300 - 800)Depth variesdepending onthe machinemodels.



PREPARATION FOR INSTALLATION

Mori Seiki service technicians will visit the customer to install the machine at the customer's plant.

To carry out installation smoothly, the following items should be prepared by the customer.

The items to be prepared must comply with the local regulations and the specifications of

the machine to be installed.

* Some machine specifications do not use pneumatic actuators.

For machines of these specifications, it is not necessary to prepare these items. If

you do not know whether or not your machine requires the air source and connection

hoses, please consult Mori Seiki.

Item to be PreparedReference

InformationCheck

Power source 3.1

Power cable 3.2

Grounding cable 3.3Main breaker for the shoppower distribution board

3.4

Air source* 3.5

Air connection hoses* 3.6

NOTE

NOTE

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Power Requirements

The power source must satisfy all of the requirements indicated below.

* Voltage fluctuation (drop) during spindle or servo system acceleration must be less

than 7%.

If voltage is lower than 200 V during servo system acceleration/deceleration, actualacceleration/deceleration time may be elongated than the theoretical time.

DANGER Power source wo rk mu st be entrusted to an electr ic ian with a l icense to

carry out electr ical work. I f a person without kno wledge of electr ical

safety pract ices at tempts this w ork, he or she co uld be electrocuted.

WARNING (1) For the power supply, provide isolated wiring directly from the input

power supply. If there is an excessive voltage drop, for example due

to insufficient capacity of the factory power supply, the machine may

malfunction, causing accidents involving serious injuries or damage

to the machine.

Select a primary power cable by accurately calculating the power

supply capacity at the supply side. Using an inappropriate cable

could lead to fire, injury, or damage to the machine.

(2) Do not install the machine close to major sources of electrical noise,

such as electric welders and electrical discharge machines. If thevoltage supply is not stable, the machine may malfunction, leading to

accidents involving serious injuries or damage to the machine.

If noise is continually entering the machine through power cables, it

can cause breakage or burning of electrical or electronic devices

inside the electrical control panel and this can lead to fire.

Item Range

Nominal power source voltagefluctuation range (200/220 VAC) +10%/15%*

Voltage dropWithin 15% of normal voltagefor 0.5 seconds.

Frequency fluctuation range(50/60 Hz)

1 Hz

Momentary power failure Less than 10 msec.

Voltage impulse

The peak value is 200% or less

of the effective value (rmsvalue) of the line voltage withpulse duration of 1.5 msec.

Waveform distortion of AC voltage 7% or less

Imbalance in line voltages 5% or less, or within 10 V

NOTE





Grounding Cable

For the grounding cable, consult the cable manufacturer to select the one which is sufficient to

take earth for the machine to be installed.When selecting the grounding cable, observe the applicable local regulations where the machine

is installed.

Meaning of "Leak Current"

Indoor electrical wiring and equipment are "insulated" in order to prevent current leakage.

However, when the insulation becomes old or damaged, or when the wires/equipment are

exposed to water, current leaks out and a "leak current" is generated.

Since leak currents can cause accidents that endanger human life, such as electric shock

and fire, due care is required. Particular care is necessary when using electrical

equipment in locations where there is exposure to water (where coolant is used, for

example).

Meaning of "Electric Shock"

When a person touches wiring or electrical equipment from which current is leaking,

electricity flows through that person's body to the ground. This is an "electric shock."

If the current is weak, the result is nothing more than a "shock" in the commonly

understood sense, but if it is strong, the life of the affected person may be endangered.

Note also that water on the body of the person subject to the shock will allow the electricity

to be conducted more easily, and for this reason you must take particular care not to touch

electrical equipment with wet hands.

DANGER (1 ) Be sure to car ry out the ground ing work . If the ground ing work is not

done, there wi l l be a danger of electrocut ion.

(2 ) The ground ing wi re shou ld be as shor t as poss ib le and shou ld have

the same thickness as the power wires. The grounding resistance

should be 100 or less. If the groun ding is in effect ive, there wil l be a

danger of electrocut ion.

WARNING Do not connect any other grounding wire to the ground. If a machine such

as an electric welder or electric discharge machine is grounded to the

steel reinforcing rods in the reinforced concrete structure of the plant, do

not connect the grounding wire of the machine to the reinforcing rods too.

Unless the grounding wire is connected to an independent ground, the

machine could malfunction due to noise from other machines, leading to




Main Breaker for the Shop Power Distribution Board

Use a breaker for an AC inverter as the main breaker on the shop power distribution board.

If another type of breaker is used, it may be actuated by the high-frequency leak current specific to AC inverters.

Leak current will not adversely affect operators.

Meaning of "Breaker"

This is a device that automatically shuts off the current within 0.1 seconds in the event of

an abnormal current flow such as a leak current.

By installing a breaker in the distribution panel, it is possible to prevent accidents due to

current leakage from electrical equipment and devices.

Since machine tools use many AC inverters, you must select a breaker of a type that will

not be erroneously actuated by the high-frequency leak current from the inverters.

Select the correct circuit breaker and power distribution board capacities by consulting the electric

part manufacturer based on the current consumption calculated by the following formula.

* Allowance for selection

For the power capacity required by the machine, refer to APPENDIX 1 "POWER

CAPACITY TABLE" in this manual.

NOTE

Current (A) =Total capacity (kVA) 1000

3 200 (V) 1.25 *

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Compressed Air Supply

Select a compressed air supply that can supply the required volume of compressed air at the

required pressure. For the selection, consult the compressor manufacturer.(1) Use only clean and dry air, 0.7 MPa, 10C or less.

If you use air that is moist or has a high concentration of dust, the pneumatic

devices could malfunction, causing damage to the machine. (Applies to machines

with pneumatic devices)

If the compressed air quality is not within the specified range, use a line filter,

dryer, etc. between the machine and the air source.

(2) The pressure setting of the compressor should be in the range from 0.5 to 1.0

MPa.

If the setting is higher than 1.0 MPa, pneumatic actuators used in the machine

could be damaged.

Hoses for Supplying Compressed Air

Select hoses for supplying compressed air that can comfortably withstand the compressed air

pressure. For advice on the selection, consult the hose manufacturer.

Compressed air supply port size: Rc 3/8

CAUTION





CARRYING THE MACHINE

When the machine is delivered to your shop, Mori Seiki's service technicians will install the

machine at the designated place. Refer to the information below if you move the machine afterinitial installation, for example due to a floor layout change.

If it becomes necessary to carry the machine due to relocation of the plant or selling of the

machine, contact Mori Seiki.

Preparation

Make the following preparations before moving the machine.

1) Before turning off the power, move each axis to the position where it should be fixed.

2) Turn off the main switch on the electrical cabinet.

3) Turn off the main breaker on the shop power distribution board.

4) Disconnect the power cable and the grounding wire.

5) Fix the machine units with transit clamps.

6) Turn off the compressed air.

7) Remove the compressed air supply hose.

8) Disconnect the cables of the coolant motor and chip conveyor motor.

9) Disconnect the cables and pipes of the oil cooler (fan cooler).

10) Remove the coolant tank and the chip conveyor from the machine.

11) Drain the coolant from the coolant tank.

12) Remove the jack bolts.



Carrying the Machine by Hoisting

Observe the following cautions when carrying the machine by hoisting.

WARNING (1) Only a qualified technician should perform machine hoisting work.

Operation of the crane or forklift by a person unfamiliar with safe

operation practices could lead to accidents involving serious injuries

or damage to the machine.

(2) Use only wires, shackles and jigs of the dimensions specified in the

manual. They must be strong enough to support the mass of the

machine. Check the mass of the machine by referring to the

specifications in this manual. If the machine is hoisted using

equipment that cannot bear its mass it will fall, causing serious

injuries or damage to the machine.

(3) Make sure that the machine is well balanced in both the crosswise

and lengthwise directions after hoisting it a little above the floor. If

you continue to hoist the machine although it is not properly

balanced, it will fall, causing serious injuries or damage to the

machine.

(4) If two or more people work together to lift the machine, they must

work carefully while exchanging signals. If someone operates the

machine or the crane inadvertently when other people are working

inside or close to the machine, it could cause serious injuries.

(5) Before hoisting the machine, check that no tools, rags, etc., have

been left inside it. When the machine is lifted, these articles could fall

out and injure plant personnel or damage the machine.

(6) If a crane is used to hoist the machine, do not carry the machine while

it is lifted to an excessive height. Lifting the machine excessively

high when carrying it will create more potential hazards than when

carrying it at a lower height.

(7) When moving the machine with a forklift, do not lift it high above the

ground. If it is moved in this condition, it may become unbalanced

and fall, or the forklift may topple over, causing serious injuries ordamage to the machine.

(8) Use a crane or forklift that can comfortably bear the mass of the

machine. If a crane or forklift without sufficient capacity to lift the

machine is used, the machine will fall, causing serious injuries or

damage to the machine.

(9) Lift the machine while it is supported at its center of gravity. If you

select a point other than the center of gravity, it may become

unbalanced and fall, causing serious injuries or damage to the

machine.



(1) If a rust-preventive coating is applied to the slideway surfaces, it must be removed

completely. Attempting axis feed while rust-preventive coating remains on the

slideways could cause machine failure.

(2) All transit clamps must be removed before switching the power ON. If a clampcannot be removed without switching the power ON first, remove it immediately

after switching the power ON. If axis feed is attempted while a clamp is still in

place, the machine will be damaged.

(3) Before hoisting the machine, check that all of its parts are clamped. Lifting the

machine while any of the parts is not clamped adequately could damage the

machine.

(4) When installing the machine, mount the coolant tank and the chip bucket by

pushing them into an appropriate position. Otherwise, coolant may be splashed

around the machine causing the operator or persons around the machine to topple

down and get injured.

(1) When moving the machine with rollers, set the number of rollers, and the material that

they are made of, so as to ensure that they can support the mass of the machine.

Also use skid and leading boards that can support the mass of the machine. If they

cannot support the mass of the machine the rollers, skid, or leading board may be

distorted, making it impossible to move the machine.

(2) After the machine has been installed, it must be leveled. Adjust the machine's crown

and distortion values according to the Accuracy Test Results Chart delivered with the

machine. If this adjustment is not carried out properly, machining accuracy will be

adversely affected.

CAUTION

NOTE



CONNECTING THE POWER CABLE

This section explains the connection of power cable from the shop power distribution board to the

transformer and then to the machine.

<Cable connection procedure>

Shop power source (360 - 436 VAC)1) Turn off the main breaker on the shop power

distribution board.

2) Turn off the breaker of the transformer.

3) Connect the power cable from the terminal blocks

L01, L02, L03 and in the electrical cabinet to the

terminal blocks (secondary) L01, L02, L03 and of

the transformer.

4) Connect the power cable from the terminal blocks

(primary) L1, L2 and L3 of the transformer to the

breaker on the shop power distribution board.

DANGER (1 ) Power source work must be entrus ted to an e lec t r ic ian wi th a l icense

to carry out electr ical work. I f a person witho ut knowledge of

electr ica l safety pract ices at tempts this w ork, he or she cou ld be

electrocuted.

(2 ) Be sure to car ry out the ground ing work . I f the ground ing work is not

don e, there wil l be a danger of electrocu tion.

WARNING Do not connect any other grounding wire to the ground. If a machine such

as an electric welder or electric discharge machine is grounded to the

steel reinforcing rods in the reinforced concrete structure of the plant, do

not connect the grounding wire of the machine to the reinforcing rods too.

Unless the grounding wire is connected to an independent ground, the

machine could malfunction due to noise from other machines, leading to


L1 L2 L3 N PE

L001 L002 L003436 V

415 V

400 V

380 V

360 V

200 V

N

N L 0 1

L 0 2

L 0 3

To the machine(200 VAC)





CONNECTION OF COMPRESSED AIR SUPPLY HOSE

Follow the procedure below to connect the compressed air supply hose.


2) Connect the compressed air supply hose from the air source to the air supply port (Rc 3/8) in

the air panel of the machine.

3) Start the compressor to supply the compressed air to the machine.

4) Make sure that there is no air leak at hose joints and pneumatic actuators.

5) Adjust the compressed air pressure to the specified value with the regulator in the air panel.

For the correct air pressure, refer to page MACHINE SPECIFICATIONS in the

MAINTENANCE INFORMATION published separately. REMOVING TRANSIT CLAMPS

After carrying the machine to the required place, remove all transit clamps before turning on the

power.

The transit clamps that cannot be removed before turning on the power should be

removed immediately after turning on the power. Attempting axis feed while the transit

clamps are in place will damage the machine.

Keep the removed transit clamps so that they will not be lost.

CAUTION







POWER CAPACITY TABLE

Breaker and power distribution board capacities are determined using the current

calculated by the following formula.

* Allowance for selection

B-axis (1-degree Indexing Table) Specification

(I94234 A04)

Machine Model NH5000

NC Model MSG-501

Spindle output 22/18.5 kW (14000 min1)

Powersupplymodule

Manufacturer FANUC

Model [PSM-37i] A06B-6110-H037

Servomotor

Motor model

X-axis B-axis

[22/3000i] A06B-0247-B100

[8/3000i] A06B-0227-B000

Inverter model [SVM2-40/80i] A06B-6114-H208

Motor model

Y-axis Z-axis

[22/3000i (with brake)] A06B-0247-B400

[22/3000i] A06B-0247-B100

Inverter model [SVM2-80/80i] A06B-6114-H209

Spindle

Manufacturer FANUC

Motor model [B132M/15000i] A06B-1713-B100#037Z

Output(30 min/continuous rating) (kW)

22/18.5

Inverter model [SPM-37i] A06B-6111-H037#H550

1 Inverter capacity (continuos rating) (kVA) 43.0

inverter 1 MagazineMotor model [6/2000] A06B-0034-B175#E0008

Inverter model [SVU-20] (I/O LINK) A06B-6093-H152

2 inverter 1 continous rating capacity (kVA) 1.4

inverter 2 APCMotor model [6/2000] A06B-0034-B075#E0008

Inverter model [SVU-20] (I/O LINK) A06B-6093-H152

3 inverter 2 continous rating capacity (kVA) (1.4)

4 Electrical cabinet (kVA) 2.8

NOTE

Current (A) =Total capacity (kVA) 1000

3 200 (V) 1.25 *



5

Other

unitmotor(kW)

Standard

ATC unit (kW) (2.2)

Coolant pump motor(kW)

1.04

Shower coolantpump motor (kW)

1.04

Chip conveyor(kW)

0.1 3 = 0.3

Hydraulic pumpmotor (kW)

2.2

Oil-air lubricatingpump (kW) 0.017

Oil cooler (kW) 1.5

Option

Through-spindlecoolant unit (kW)

7.35

Automatic coupler(kW)

0.0

Coolant gun (kW) 0.52

Chip conveyoroutside machine

(kW)0.1

Total of auxiliary units[power factor 0.8] (standard) (kVA)

(1.04 + 1.04 + 0.3 + 2.2 + 0.017 + 1.5)/0.8 = 7.7

Total capacity (standard)1 + 2 + (3) + 4 + 5

Continuous rating(kVA)

54.9

220 V 50 Hz transformer (kVA) 20

Machine Model NH5000

NC Model MSG-501

Spindle output 22/18.5 kW (14000 min

1)









Tightening Torque

The information above applies only to machines compatible with UL standards.

Cable Size Tightening Torque

AWG mm2 N•m

14 2.1

588

12 3.3

10 5.3

8 8.4

6 13.3

4 21.23 26.7

1 42.4

2648

1/0 53.5

2/0 67.4

3/0 85

4/0 107.2

250 127

4707350 177

500 253

NOTE



CONSUMPTION VOLUME OF COMPRESSED AIR

To operate the machine, it is necessary to supply the compressed air. Required volume of the

compressed air varies depending on how frequently the ATC and/or APC is operated. The tablebelow gives the units which use the compressed air and compressed air consumption volume in

each operation of them. Use the values in the following table to estimate the total required

compressed air volume to determine the capacity of the compressor.

Select the compressor which can supply the required volume with sufficient margin.

Otherwise, it will cause failure or damages of the machine.

<Standard>

<Option>

<60-tool specification (items (3) and (4) in the table for standard specification are replaced with

the following items for 60-tool specification)>

No. LocationOperating Time

(sec)

Consumption L

(ANR)

(1) Oil-air lubrication for spindle/ball screws 60 140 L/min

(2) Spindle nose air blow 1.3 4.1

(3) ATC shutter open/close 1.0 0.34

(4) Tool pot at the magazine/spindle side 1.2 0.26

(5) Pallet air blow for APC cycle 6.0 43

(6) APC setup station lock pin in/outIn 0.5 0.14

Out 0.5 0.14

(7) Air curtain for scale (each axis) 60 20


(sec)

Consumption L

(ANR)

(1) Tool tip air blow T1 470 T1 60

(2) Dust collector, automatic boring bar radius offset T2 496 T2 60

(3) Sensor air blow T3 368 T3 60


(sec)

Consumption L

(ANR)

(1) ATC shutter open/close 1.0 0.34

(2) Tool pot at the magazine/spindle side 1.2 0.47

(3) Chain hook release 0.2 0.01

(4) Tool pot unchucking 0.2 0.02

CAUTION



<Rack magazine specification (items (3) and (4) in the table for standard specification are

replaced with the following items for rack magazine specification)>

<Calculation example of air consumption volume>

When ATC operates five times and APC operates once in five minutes (for NH5000 without

options), the air consumption volume is calculated as indicated below.

Air consumption volume Q = (1) + 5 ((2) + (3) (open) + (4) (magazine side) + (4) (spindle side)

+ (3) (close)) + (5) + (7)

= 340 + 5 (4.1 + 0.34 + 0.26 + 0.26 + 0.34) + 43 + 20

= 429.5 L/min

According to the calculation above, the maximum air consumption volume of NH5000 is 429.5 L/

min.

In this calculation example, the volume of air consumed by optional devices is not

considered. Therefore, if the machine is equipped with options, add the air consumption

volume of the selected options, known from the table above, to the calculated value given

here.


(sec)

Consumption L

(ANR)(1) ATC shutter open/close 1.0 0.34

(2) Tool pot forward/backward movement 1.0 0.09

(3) Tool unclamping 0.2 0.03

(4) Transfer pot release 0.2 0.03

(5) Preventing tools from falling 0.1 0.02

(6) Magazine side pot release 0.2 0.03

(7) Rotating arm side 0.2 0.03

NOTE





NH5000 Hoisting Information

Wire length is described in the below-mentioned chart. Length hanging themachine, when extended, is total length. The B1 section shown in thebelow-mentioned picture only uses one shackle (8 t). The others all use two.









The NH5000 rests on three leveling bolts like the SH-500 and SH-400. The jackbolts themselves are the same as used on the NV5000. This design precludesthe need to turn the casting over to drill and tap the holes for conventionalleveling jacks.



























<Detail of B>



































The NH5000 has two lubrication units. One is for the spindle bearings and ballnut and thesecond is for the B axis lubrication.

B Axis lubrication – VG68 Oil Spindle and Ballnut lubrication – VG32

LUBRICATION



LINEAR BEARING LUBRICATION SYSTEM

THK QZ Lubricating System

THK has developed the QZ lubricationsystem which contains a fiber net with ahigh oil content to meet requirements for long-term, maintenance free technologyin LM guide applications.

Maintenance intervals are greatlyincreased using the QZ system. Lost oilis automatically replaced.Due to the high density fiber net in theQZ system, the appropriate amount of

oil is applied to exact locations and noexcess oil is wasted.

Increased maintenance intervals over the full range of loads from light to heavy.







HYDRAULIC SYSTEM

An overview of the HYDRAULIC SYSTEM is presented below.

The hydraulic system comprises the hydraulic unit, the valve units, the hydraulic devices, and thepiping.

When the power is turned on, the hydraulic motor starts and the pump draws hydraulic fluid.

The hydraulic fluid that flows out of the pump is supplied through the piping to the valve units.

The valve units reduce the pressure of the hydraulic fluid and determine its course, and the

hydraulic devices are actuated by the hydraulic fluid.

The hydraulic fluid is returned to the tank through the tank port.

Hydraulically-operated Actuators

The hydraulically-operated actuators are indicated below:

(1) Pallet clamp/unclamp

(2) Table clamp/unclamp

(3) APC arm up/down

(4) Pre-load changeover (20000 min1 specification)

(5) Fixture clamp/unclamp inside setup station (auto-coupler and 2-/3-station APC specifications)

(6) Fixture clamp/clamp inside machine (auto-coupler and 2-/3-station APC specifications)







<Detail of B>



HYDRAULIC PARTS LIST





<Names of major parts>

No. Unit Name Q’ty Type Manufacturer

81 Solenoid valve 1 SLD-G01-C6-C1-G30 NACHI82 Solenoid valve 1 SLD-G01-A3X-C1-G30 NACHI

83 Pressure reducingvalve

1 OG-G01-AC-5645D NACHI

84 Relief valve 1 OR-G01-P3-20 NACHI

85 Pilot operated checkvalve

2 OCP-G01-A1-21 NACHI

87 Orifice 1 φ2.0 NACHI

88 Base block 1 SIZE 01 × 3 NACHI

90 Solenoid valve 1 SLD-G01-C9-C1-30 NACHI91 Pressure gage 1 0.29 - 0.39 MPa: Green

The other: Red

GV50-173 × 1.6 MPa

NAGANO KEIKI

92 Dumper 1 FD10-771 NAGANO KEIKI

94 Check valve 1 OC-G01-T1-20 NACHI

95 Pressure switchvalve

1 OW-G01-P1-R-D2-30 NACHI

97 Pressure switchvalve

1 OW-G01-B1-R-D2-30 NACHI

98 Bolt kit 1 OTH-01-85-10 NACHI

99 Bolt kit 2 OTH-01-165-10 NACHI



<Circuit diagram>

2 - Rc3/8End plug

Set0.4 MPa

Tool UNCLAMP

UNCLAMP

Pallet CLAMP/UNCLAMP Table CLAMP/UNCLAMP

UNCLAMP

CLAMP UNCLAMP

CLAMP

SP23: Unclamp comfirmationSet to turn OFF at 4.9 MPa or less

SP2: Pressure comfirmationSet to turn OFF at 2.9 MPa or less



The picture below shows what each line is for that is located on top of the headstock casting.

Spindle Oil InCoolant Motor Oil In

Spindle Taper Air Blow

Tool Tip Air Blow

Spindle Face Air Blow

Oil Shot 1

Motor Oil Out

Spindle Oil Out Oil Hole Drill Coolant

Spindle Taper Air Blow

HYDRAULICS TO HEADSTOCK



The hydraulic lines going to the B Axis table are for Pallet Unclamp, Pallet Clamp and TableClamp. SP16 is also located under the front Z axis cover (between the table and spindle).

Table Clamp (yellow)

Pallet Clamp (red)

Pallet Unclamp (white)

Pallet Seating Switch SP16 (X13.4)

HYDRAULICS TO B AXIS TABLE





HYDRAULIC AIR BLEED PROCEDURE

If any hydraulic line is broken free from it’s fitting, air will enter into the hydraulic circuit and must

be bled from the system. To bled, go in order of the pictures shown below (1 ~ 7). Bleedingoperation should be done while at the ATC home position.

The correct hydraulic pressure when doing a tool change in AUTO mode is 4.9 ~ 6.0 Mpa. InMANUAL mode, the pressure should be 5.6 ~ 5.9 Mpa.

Behind Column Top of Magazine On Electrical Cabinet Rear of Spindle

1 5

64 72 3















































































1

2

3

4

5

6

7

8

9

10

11

12

12

15

16

17

A

Detail Drawing A

13

18

19

20

21

22

23

32

33

27

28

Detail Drawing B

24

26

25

37

38

Ｙ

Ｗ

Ｕ

Ｙ

ＷＷ

Ｗ

Ｙ

Ｚ

W；Applied Oil(Daphne Mechanic Oil 32)

Y：Applied Anaerobic Adhesive & Sealant (Three Bond 1344)Z ; Interference 0.01mm

U ; Pushing force 14700N(1500kgf)

35

14

39

MAS

CATDIN



A

詳細 A

詳細 B

1

2

3

4

5

6

7

8

9

10

11

12

13

17

18

19

20

23

24

14

37

38

39

40

43

44

45

46

47

48

15

16

41

42


W

WW

W



2

5 54

12

9

MAS1

MAS2

DIN

90°1

3

4 6 7 6 8913

14

15

X : Applied Grease (ALVANIA EP)


Y：Applied Anaerobic Adhesive & Sealant (Three Bond 1344)

X

W W

W WY

Side Through-spindle Coolant Type

Y

MAS1MAS290°

16 DIN

Side Through-spindle



THE SPINDLE and DRAWBAR

The spindle on the NH5000 will be standard 14,000 min-1, with an optional20,000 min-1 offered. It is powered by a 22/18.5 kW (30 HP) DDS spindle motor,

which allows tapping at 6,000 min-1. The starting torque on the spindle is 221N•m, which will reach 14,000min-1 in 1.4 seconds and only take 1.15 seconds toreturn to a complete stop.

The NH5000 will be offered with the standard BT-40 spindle and offer an optionalKM style package.

KM Spindle

KM Drawbar



BT Taper Spindle

BT Drawbar

The drawbar on the NH5000 develops 12,000N of clamping pressure, which is

1.5 times greater than previous models. Using the same tapered collet/sleevedesign as is used on the NV5000 develops the additional clamping force.

The dimensions of the tool are critical to ensure the drawbar decompresses the

correct amount in order to develop the correct clamping force. The proper

dimensions are illustrated by a drawing later in this chapter.



The rear of the drawbar is machined with a dog used to activate the tool clampproximity switches. These are used to ensure the spindle does not rotateunless the tool is securely clamped in the spindle taper.

SQ123

DGN X5.1

SQ124

DGN X5.2 CONDITIONOFF ON Clamp Without ToolON ON Clamp With ToolON OFF Miss-clampOFF OFF Unclamp

SQ121 DGN X5.6 Unclamp Cylinder Up Check

SQ124

SQ123

Dog

‹ó ×ÝÌß

Clamp without tool

SQ124=ON

SQ123=OFF

×ÝÌß

Clamp with tool

SQ124=STI LL ON

SQ123=J UST ON

Position of ideal

Ð½ ×ÝÌß

Miss clamp

SQ124=J UST OFF

SQ123=STI LL ON

±Ý ×ÝÌß

UnclampSQ124=OFF

SQ123=J UST OFF

2mm 7• 9mm 9• 12mm4mm

×ÝÌß

Clamp with tool

SQ124=ON

SQ123=ON

Position of ideal



2

4

6

8

10

12(mm)

ON

OFF

OFF

OFF

S Q 1 2

4

S Q 1 2

3

ON

or

OFF

ONor

OFF

OFF

or

ON

‹ó×ÝÌß

Clamp without tool

¸×ÝÌß

Clamp with tool

Ð½¸×ÝÌß

Miss clamp

±Ý ×ÝÌß

Unclamp

×ÝÌß’†S Ê’u

Center position of clamping

condition

1mm

1.78mm

ON



Collet structure to increase tool clamp force•„

Tool clamp force is increased about three times that of the disc spring with the tapers shown

in the following pictures.

14000min-1

#40 MORI-90

SIDE THROUGH COOLANT

DISK SPRING

Y73534A01

2 x 27 = 54pcs

COLLET(TRIPLE FORCE)

#40 MORI-90 : K60195A01

#40 DI N : K60197A01

COLLE T SLEEVE

F60198A01

A

B

VIEW B

VIEW A

TAPER

TAPER

EXPLANATION OF TOOL CLAMP FORCE



Tool clamp force tolerance at factory shipment•„

12kN (11• 16kN)

KELCH D-73614

The tool clamping force changes by the state of friction of the taper.

The following greases are applied on the taper at factory shipment.

Shell Alvania EP No.1

<This spindle is for the NV5000, but the principle is the same.>



The stroke at the rear end of the draw bar changes by five times the amount of the change in the colletposition.

Therefore, please use the tool and the retention knob suitable for the standard.

I t greatly influences the tool clamping signals.

GAUGE LINE

J IS STANDARD (UNIT : mm)



SPINDLE SPEED OUTPUT DIAGRAM

* Spindle speed outputs are expressed in 15 min. rating for low-speed range winding

and in 30 min. rating for high-speed range winding.

Motor Specifications

Output 22/18.5 kWRated time 15 min, 30 min∗/Continuous

Spindle speed 14000 min−1 (max.)Manufacturer FANUC

NOTE



to perform orientation command.

To move to reverse rotation, input value in - direction.

standard value less than 0.1mm (parallelism measured at )

ADJUSTING SPINDLE ORIENTATION



measurement

location

measurement

location



INTERFERENCE BETWEEN TOOL AND WORKPIECE

Unit: mm

(1) ATC operation with a maximum size tool is not possible when a maximum sizeworkpiece is loaded.

( )

NOTE



AXIS TRAVEL DIAGRAM

Unit: mm

(1) The drawing shows the axis movable range with interference between the spindle

head and a pallet taken into account in the state the B-axis is positioned at the zeropoint. Interference with the edge locator is disregarded.

NOTE



TOOL SHANK DIMENSIONS

(1) The dimensions given below are only for reference purpose and the tool holders

must not be manufactured by simply referring to the indicated dimensions. MoriSeiki is not responsible for any loss and problem arising from the user of tool

holders manufactured in such a manner.

(2) For the machine with the through-spindle coolant system, use the tool holders

corresponding to the coolant system (center-through type or side-through type)

equipped with the machine.

If the tool holder not corresponding to the machine specifications is used, through-

spindle coolant will not be discharged correctly, causing damage to the machine.

MAS

No. 40 Taper

Unit: mm

(1) n*1 7/24 Taper angle tolerance is (JIS B0614 taper angle tolerance class AT4).

Shank Screw Tenon

D1 l 1±0.15

r (max.)

d1 d2H8

g6H

l2(min.)

l3(min.)

l 4

+0.5

0

C(max.)

bH12

l5(min.)

t

0

−0.2

w

BT40 44.450 65.4 1 19 17 M16 30 43 9 0.5 16.1 21 22.6 0.12

Flange 7/24 Taper

angle

tolerance *1

AT D

References

D4D5

h8f

v

±0.1x

x1

+0.1

0

y

±0.4

y4

0

−0.4

Dia. at

small

end

d D6

BT40 53 63 25 16.6 5 10 2 2+0.0041

025.375 10 75.679

CAUTION

30° −15° 30°0−15°

φ D 6

φ D 5

φ D 4 φ

φ d 2

φ d 1

d

l5

v

xx1

f

y

y1

Gage surface

l1

l3

l2

l4

r

g

t t

b

°

NOTE

+AT4 0



CAT

No. 40 Taper

Unit: in.

Shank

D1 D2 D3 D4 d1 (Basic dimension)

Dimensions Tolerance Dimensions Tolerance Dimensions Tolerance Dimensions Tolerance Dimensions Tolerance

CAT-40 2.5000

−0.0022.219 ±0.010 1.750 ±0.010 2.863 ±0.002 1.750 ±0.002

Shank

d2 d3 L l2g N

Dimensions Tolerance Dimensions Tolerance Dimensions Tolerance Dimensions Tolerance

CAT-40 0.720 ±0.010 0.641±0.015

0 2.682±0.010

0 1.12 ±0.040 0.625−11

0.030

−0.060

Shank

l3 b1 t7 t8 Reference

Dimensions Tolerance Dimensions Tolerance Dimensions Tolerance Dimensions Tolerance d5

CAT-40 0.188 ±0.010 0.645 ±0.010 0.9850

−0.0150.890

0

−0.0150.86



Side Through-spindle Coolant Hole

No. 40 Taper

Unit: mm

(1) Hole positions for DIN specification tools conform to DIN69871-B.

(2) Chamfering is not allowed on coolant discharge holes (burrs should be removed).

(3) *1 If surface finish accuracy is not adequate, coolant leak problem might occur.

NOTE



RETENTION KNOB DIMENSIONS

Tables of Retention Knob

Check the retention knobs to be used referring to the tables below.

Six-digit codes are codes used for placing an order.

<No. 40 taper specification>

(1) For the side through-spindle coolant specification, use retention knobs of the standard

specification.

(2) For the center through-spindle coolant specification of No. 40 taper, only DIN type

retention knobs are available. Choose the one that meets the standard (MAS, CAT, or

DIN).

Type Drawing No.

Standard Center Through-spindle Coolant Specification

NT Tool BIG

MAS Mori 90° N29009

CAT Mori 90° N29014

DIN As specified bythe standard

Compatible tothe MASspecification

N29025 Compatible tothe MASspecification

N29030

Compatible tothe CATspecification

N29023 Compatible tothe CATspecification

N29028

Compatible tothe DINspecification

N29024 Compatible tothe DINspecification

N29029

MAS I As specified bythe standard

MAS II As specified bythe standard

NOTE



MAS Mori 90°

The dimensions given below are only for reference purpose and the tool holders must

not be manufactured by simply referring to the indicated dimensions. Mori Seiki is notresponsible for any loss and problem arising from the user of tool holders

manufactured in such a manner.

No. 40 Taper

Unit: mm

This drawing also applies to side through-spindle coolant specifications.

(N29009 A04)

CAT Mori 90°

The dimensions given below are only for reference purpose and the tool holders must

not be manufactured by simply referring to the indicated dimensions. Mori Seiki is not

responsible for any loss and problem arising from the user of tool holders

manufactured in such a manner.

No. 40 Taper

Unit: mm

CAUTION

NOTE

CAUTION



Cautions on Using Retention Knob

(1) Use only the retention knob that meets the machine specifications. Since retention

knobs of different specifications have different clamp mechanism, the one thatdoes not meet the machine specification must not be used. If such retention knob

is used, the collet will break and unexpected accidents will occur, causing damage

to the machine.

The shapes of the retention knobs as following illustration vary depending on

specifications.

(2) To use a retention knob of center/side through-spindle coolant specification, be

sure to apply sealant to the threads of the retention knob. If the retention knob of

center/side through-spindle coolant specification is used without applying sealant

or without an O-ring for the one that requires the use of an O-ring, coolant will leak

through the threads of the retention knob and could cause damage to the machine.

CAUTION

90°

Retention knob

θ



TOOL RESTRICTIONS

The dimensions and mass of the tools used with the machine are restricted by mainly

the capacity of magazine. Use the tools which are within the limits indicated below.

Tool Restrictions

MAS CAT DIN

Max. tool length A (mm) 400

Max. tool dia. B (mm) 80

Tool limitation C (mm) 32 34.925 35

Tool limitation D (mm) 63 44.45 50

Max. tool mass (kg) 8

Max. tool mass moment

(from gage line) (N•m)

7.84

CAUTION



MOUNTABLE ACCESSORIES OF SPINDLE HEAD

Unit: mm

1 2

1 9

0 . 9

8 ( B I G

P L U S

s p

i n d l e g a g e

p l a n e

)

S e c

t i o n

A - A

1 0

3 1

1

1

1

2

3 3

4

5

3 7 . 5

R 6 5

P . C .

D .

5 5

2 0

1 0

1 2 1 9

3 1

1 8

+ 0

. 0 3

- 0 . 0

1

1 9

. 6 ± 0

. 0 1

1 0

1 0

B

G . L

A

A

6

G . L

V i e w

B

S t a n

d a r d s p

i n d l e

( B

I G

P L U S )

1 2 3 6 5

S T D

O P T

O P T

S T D

O P T

4

S p i n d l e c o o l a n t n o z z l e

S t a n d a r d s p i n d l e

( B I G

P L U S )

O i l s h o

t n o z z l e

T h r o u g

h - s p i n d l e c o o l a n t

P o s i t i o

n i n g b l o c k

O i l - h o l e d r i l l c o o l a n t

T o o l t i p

a i r b l o w

O P T



OIL COOLER DIAGRAM

NU-YEC112BMH01

<Specifications>

Model NU-YEC112BMH01

Cooling capacity 4650 W

Room temperature: 35°C, Oil temperature: 38°C

200 V, 60 Hz

Compressor Totally-enclosed rotary type, 1100 W

3-phase, 200 V, 50/60 Hz, 2P

Condenser Fan cooling type, Fin and tube type

Cooler Circulating type, Fin and tube typeCasing: SS41 (Steel)

Fan/motor for condenser Fan: 300-mm dia. 6-vane fan

Liquid circulating pump motor Totally enclosed, double sided type, 400 W

3-phase, 200 V, 50/60 Hz, 4P

Liquid circulating pump NOP Trochoid pump 2P400C-216EVS

Displacement: 24.0/28.8 L/min

Relief valve set point: 0.4 MPa

Liquid temperature controller Machine temperature follow-up type (reference ±7°C)

Sensitivity: 0.2°CTemperature sensing device: Thermistor

Refrigerant and control R407C 800 g

Capillary tube

External dimensions 475 (W) × 590 (L) × 821 (H) mm

Coating Powder coating

Mass 94 kg

Power source 3-phase, 200 V, 50/60 Hz

Rated power 3.4 kVA

Fuses Power circuit: 3-phase, 200 V, 30 AThis unit is not equipped with a breaker (to be installed by thecustomer).

Control circuit: 100 V, 2 A

(The unit is equipped with a circuit protector.)

Room temperature(operating range)

5 - 40°C

Liquid temperature(operating range)

5 - 40°C

Noise level Max. 70 dB (A)

Liquid used Clean lubricating and hydraulic oil(Oil that could attack or corrode copper, aluminum, etc. cannotbe used )



Connection port size Inlet: Rc 3/4

Outlet: Rc 3/4

Protective devices Pressure switch (shutting off high pressure)

Spark quencher

Overload protector (compressor, pump motor)

Terminal block For alarm output (24NC, 0CAL “a” contact)

Remarks This unit is not waterproof and must be kept away from water.Splashing water may cause serious damage to the unit.

Model NU-YEC112BMH01



<General view>

S u c t i o n

E x h a u s t

S u c t i o n

E x h a u s t

E x h a u s t

2 - M 1 0 E y e b o l t

I n l e t 3 / 4 ”

O u t l e t 3 / 4 ”

O i l

s u p p l y

p o r t ( 1 ” )

O i l t y p e l a b e l

R c 1 / 4 ”

D r a i n

E x h a u s t

S e n s o r o u t l e t o n m a c h i n e s i d e



<Oil cooling medium circulation circuit>

C o n d e n s e r

M a x . o p e r a t i n g

p r e s s u r e : 3 .

2 M P a

W i t h s t a n d p r e s s u r e :

1 0 . 5 M P a

C o m p r e s s o r

M a x . o p e r a t i n g p r e s s u r e : 3 . 2 M P a


1 0 . 6 M P a

H i g h p r e s s u r e s i d e

L o w p r e s s u r e s i d e

C a p i l l a r y

t u b e

E v a p o r a t o r

M a x . o p e r a t i n g p r e s s u

r e : 2 . 0 M P a


1 0 . 5 M P a

O i l t e m p e r a t u r e s e n s o r

C l e a n l u b r i c a n t

M a x

. o p e r a t i n g p r e s s u r e : 0 . 5 M P a

a c h i n e t e m p e r a t u r e s e n s o r

T h e r m o s t a t



<Electrical parts list>

Code Unit Name Type Q’ty Manufacturer

M81

F3R

Compressor

Compressor internalthermostat

4KS250MAA, 1100 W3φ, 2P, 200 V, 50/60 Hz 1 MatsushitaElectric

M83 Trochoid pump motor FELQ-8T, 400 W

3φ, 4P, 200/200, 220 V, 50/60 Hz

1 YaskawaElectric

S2F High-pressure pressureswitch

FTB-Z231 (Manual return: 3.2 MPa)

VDE approved

1 SaginomiyaSeisakusho

K81M Magnetic switch forcompressor

SC-03, 100 VAC

TÜV approved

1 Fuji Electric

K83M Magnetic switch forTrochoid pump

SC-03, 100 VACTÜV approved

1 Fuji Electric

F81R Overcurrent relay forcompressor

TR-0N/3, 7.5 A set

TÜV approved

1 Fuji Electric

F83R Overcurrent relay forTrochoid pump

TR-0N/3, 2.2 A set 1 Fuji Electric

K1H Alarm relay HH62S-100V

VDE approved

1 Fuji Electric

N1 Thermostat T6DIK-A610A, 200 V

46-W24070

Negative phase prevention relay,40 sec. with built-in OFF timer

1 Taiko Sangyo

R3 Thermistor (Machine temperature)

06-W26381 1

R2 Thermistor (Oil temperature)

06-W24731 1

R1 Temperature adjustingvariable resistor

W-247 B2KΩ 1

Q1F Circuit protector CP31E/2, 2 A

250 VAC, 50/60 Hz

TÜV approved

1 Fuji Electric

Z1

Z2

Z3

Spark quencher 3CRE-50500

3CRE-50500

CRE-30680

VDE approved

1

1

1

Okaya Electric

H1 Operation indicating lamp(white)

MB105 WFU 1 Metro Electric

H2 Alarm indicating lamp(orange)

MB105 OFU 1 Metro Electric

X1 Terminal block AYBN016-1 AYBN011-1

IEC conformed

11 Fuji Electric



XP306 Connector Han 6E

Housing 09300060302

Insert 09330062602

Contact 09330006103 3 pcs.

09330006105 2 pcs.

1 HartingElectronic

XP307 Han 7D

Housing 09200030320

Insert 09210073031

Contact 09150006102 2 pcs.

09150006104 2 pcs.

09150006101 1 pc.

1

Code Unit Name Type Q’ty Manufacturer



<Electrical circuit diagram>

P o w

e r l a m p

( w h i t e )

P u m

p

A l a r m l a m p

A l a r m

C o m

p r e s s o r

T h e r m o s t a t

M a c h i n e

t e m p e r a t u r e s e n s o r

O i l t e

m p e r a t u r e s e n s o r

C i r c u i t p r o t e c t o r

T e m p e

r a t u r e a d j u s t i n g

v a r i a b l e r e s i s t o r

O F F a t

a b n o r m a l s t a t u s

2 0 0 V A C , 3 P , 5 0 / 6 0 H z

1 0 0 V A C , 5 0 / 6 0 H z

r m i n a l f o

r

t e r n a l l i n e s

3 . 5 s c r e w s )



BT Taper Spindle

BT Drawbar

Tool Clamp Switch Adjustment



The rear of the drawbar is machined with a dog used to activate the tool clamp proximity switches. These

are used to ensure the spindle does not activate unless the tool is securely clamped in the spindle taper.

SQ123DGN X5.1

SQ124DGN X5.2 CONDITION

OFF ON Clamp Without ToolON ON Clamp With ToolON OFF Miss-clampOFF OFF Unclamp

SQ121 DGN X5.6 Unclamp Cylinder Up Check







Adjustment of Unclamp Cylinder

A. Check the main hydraulic pressure. It should be 5.9 MPa.

B. Open the valve to activate the main pressure gauge.

C. The tool Clamp and Unclamp push buttons are found on the option panel. To assign the correct buttons,go to the CUSTOM PCMDI menu and type in [9][0], then press INPUT. This will take you to the CustomPanel assignment screen. Tool Clamp should be assigned to the 1-1 position, and Unclamp assigned tothe 1-2 position shown on the screen.

D. Open the ATC charge pressure gauge. It should read between 0.37 ~ 0.39 MPa.

E. Go to the Field Adjustment Mode and set D123.1 to a “1”. This will allow you to Clamp/Unclamp thespindle with the Operator door closed.

F. On the option panel, press the Tool Unclamp button. The light on the button will illuminate.

G. After verifying that ATC charge pressure becomes 0 MPa, close the valve for the ATC charge pressuregauge and push the Tool Clamp button.



H. Adjust the gap of the Tool Clamp proximity switch end face using the 12 mm MSR nut.

I. Unclamp the tool and verify the unclamping operation of the spindle . If unclamping (the pushingamount at the time of the Unclamp lamp) and tool knockout is outside the value 0.45 - 0.55mm, make an adjustment by loosening or tightening the MSR nut until the knockout is inside

the standard range.

During the Unclamp lamp state, the MSR nut (on both sides) adjusts the stroke of the cylinder evenly.

J. When in the unclamp state, tighten the Sphan rings on the MSR nut evenly.

K. When in the clamp state, screw in the two bolts (shown as #1 above) by hand until they bottom out, thentighten the locking nuts.

L. For the second time, verify whether the Sphan rings on the MSR nut (both sides) are locked securely. Uselocktite on the M6 hollow set screw, which is on the side of the nut.

M. Install SQ121 (tool clamp verification) and adjust the gap to 0. 5mm. Secure it using two cap screws M5 x12 (Y00312), two lock washers M5 (Y71005) and 2 M5 flat washers (Y70005).

N. After adjusting the tool knockout amount, please measure tool clamp force using a clamp force checker.Record the clamp force on the check sheet.

12 mm MSR Nut#1



There are two types of adjustments on the rear of the unclamp cylinder. One is for stroke and the

other is for the pressure.

2

The oil volume adjustment changes the hydraulic pressure by increasing or decreasing the area

behind the piston. The smaller the cavity area, the higher the pressure during automatic tool

change cycles.

1.5 5.5MpaThe stroke adjustment allows you to set the distance the unclamp cylinder will move during

clamp/unclamp. (0.5 0.7 )

ATC

0.5 0.7

Oil volume adjustment

Stroke adjustment



























































SPINDLE AND DRAWBAR



SPINDLE AND DRAWBAR

The tool clamp force on the NV5000 is developed using a combination of Belleville coned washers and a taper design on the drawbar and collet fingersthemselves.

This is necessary, as you can see by the illustration above, because this spindleis 240mm shorter than the SV-503 spindle. Although we keep the same kW and

torque on the NV spindle as has been offered on the SV-503, our accelerationtime is 56% faster and our clamping force is 50% greater on the NV.

Acceleration time

1.74 sec (0 - 12,000min-1)

Acceleration time

0.97 sec(0 - 12,000min-1)

Motor power 22/18.5kW

Max. torque 235.5N

SV-503

NV5000

790

550

Tool clamp force

8,000 N

Tool clamp force

12,000 N



The taper design of the collet fingers and drawbar is shown in the drawing below.

As the Belleville washers decompress, the taper on the collet fingers moveforward on the taper of the drawbar end. This multiplies the clamp force of theBelleville washers (400 N) by a factor of 3, allowing us to develop 12,000 N of clamping force.

Taper of drawbar endpiece

Collet taper



The drawbar assembly is exactly like the assembly of the SV-503.

Drawbar, Belleville washers, collet fingers, end piece, sleeve





























































































LADDER AND DIAGNOSTICS



FANUC 18iMB Control

Maintenance Screens

Looking at the screen after pressing the SYSTEM button, you will not see anydifferences between this, and the 18iMA control SYSTEM screen.



Even after selecting the PMC softkey, the controls still appear to be identical.

However, after pressing the PMCLAD softkey, the differences between the iMA

and the iMB control become apparent.

NOTE: You will still be prompted to enter the password “L” when selecting thePMCLAD function.



This is the PMC Program List Viewer screen. From this screen, you can select toview only the high speed sequence of the ladder (LEVEL1), the second order sequence (LEVEL2) or the entire ladder (GLOBAL).

The most useful selection will be the GLOBAL screen. Using the up/down cursor keys, move the cursor to highlight the GLOBAL selection, as shown above. Pressthe ZOOM softkey, and the ladder will be displayed.



This is the first screen that will appear differently from the one on an iMA control.This display will denote the “true” status of an address by highlighting it in purple.The coil R0056.2 above shows the cursor (yellow) is set on the coil, which is“true” or ON.

The status of the address that the cursor is lined up on is also shown on the lastline of the screen (in yellow). In the above screen, the coil R0056.2 is highlightedwith the cursor and also shows purple, and the bottom line of the ladder statesR0056.2 = ON.



In the screen displayed above, note that the cursor is set on the coil R0053.3.Since the address X0003.0 is not “true” (ON), there is no purple showing onR0053.3. The bottom line also clearly shows that R0053.3 is OFF.

All iMB controls will display the ladder in this manner.



If the PMCDGN selection is made from the PMCMDI menu screen, and STATUSis pressed, the diagnostic screen appears and works in the same fashion as theiMA control screen.

Type in the address (minus the bit number) that you want to look at and press theSEARCH softkey.



The difference in DGN screens is found when you select the TRACE functioninstead of pressing the STATUS softkey.

The SIGNAL TRACE setup screen is completely different from the iMA controlscreen. One option for MODE is to select SIGNAL TRANSITION. Then bysetting the STOP condition on None, it will allow the Trace Screen to continuedisplaying the status no matter how many times the signal changes states.

If TIME CYCLE is selected, the TRACE function will sample at the rate set upunder RESOLUTION for a period of time selected under TIME. In the exampleabove, any address that is selected will be sampled every 8msec for 392 seconds.





The PMC SIGNAL TRACE screen is brought up by pressing the far left softkey.The addresses that were selected on the previous screen are now displayed onthis screen. The TRACE function is started by pressing the START softkey.



In the example above, X0102.5 (Cycle Start button) has been pressed 5 times.Each white square denotes a transition change of the signal coming on and thespace between each square denotes the signal turning off.



























ELECTRICAL SYSTEM

An overview of the ELECTRICAL SYSTEM is presented below.

General

An outline of the electrical system is shown below.

Always replace batteries while the power is on.

If you replace the battery while the power is shut off, the stored absolute position data

will be lost.

DANGER (1 ) E lec t r ical wi r ing work must be ent rus ted to a l icensed e lec t r ical

technic ian. I f a person withou t know ledge of electr ical safety

pract ices at tempts this work, he or s he could be electrocuted.

(2 ) Before car ry ing out main tenance or inspection work ins ide the

electr ical cabinet, turn off the main circu it breaker in the plant. It isnot suf f ic ient to shut of f the power with the main sw itch of the

electr ical cabinet: som e parts inside the electr ical cabinet wil l st i l l be

l ive and could cause electrocut ion.

I f maintenance has to be carr ied out w hi le the power is on, i t must be

done with d ue care by a person author ized to perform electr ical work,

checking w hich parts are l ive by referr ing to the electr ical drawings.

CAUTION





DIAGNOSTICS FOR SWITCHES AND SOLENOIDS

DESIGNATION Device Dgn Name

ALARMS OCAL X15.1 OIL COOLER ALARM ATCAL X10.6 ATC INVERTER ALARM

FOOT SWITCH SF8 X11.3 SETUP STATION FOOT SWITCH

FLOAT SWITCH SL12 X14.4 COOLANT PUMP FLOAT SWITCHSL2 X18.3 OIL/AIRFLOAT SWITCHSL9 X15.2 HYDRAULIC LEVEL LOW

PRESSURE SWITCH SP12 X14.0 O/A LUBE AIR PRESSURE DOWNSP16 X10.2 PALLET SEATING CHECKSP2 X15.3 HYDRAULIC UNIT PRESSURE UPSP23 X10.3 PALLET UNCLAMP OKSP36 X6.5 HEAVY PRELOADSP37 X6.6 MIDDLE PRELOADSP38 X6.7 HIGH PRELOADSP5 X18.3 OIL/AIR LUBE PRESSURE SWITCHSP98 X7.0 WSS FIXTURE CLAMP DETECT

PROXIMITY SWITCH SQ100 X5.4 MAGAZINE DOOR LOCK DETECTSQ105 X19.0 POT SPINDLE SIDESQ106 X19.1 POT MAGAZINE SIDESQ112 X8.7 POT UNLOCK DETECTSQ121 X5.6 TOOL CLAMP DETECTSQ123 X5.1 TOOL CLAMP DETECTION 1SQ124 X5.2 TOOL CLAMP DETECTION 2SQ133 X5.3 MAGAZINE DOOR OPEN DETECTSQ247 X11.2 SETUP STATION HOME POSITION 2SQ248 X11.1 SETUP STATION HOME POSITION 1

SQ251 X19.5 TABLE UPSQ252 X12.4 TABLE DOWNSQ29 X17.0 SENSOR OTSQ301 X12.3 APC ARM UPSQ302 X12.3 APC ARM DOWNSQ32 X17.1 SENSOR DOWNSQ33 X17.2 SENSOR UP



SQ447 X14.5 COOLANT FLOW DETECTSQ562 X8.3 POT CLAMP FINISHSQ563 X10.7 POT UNCLAMP FINSQ71 X12.1 ATC ARM PULL DETECTSQ72 X12.0 ATC ARM HOME POSITIONSQ730 X10.0 SETUP STATION DOOR OPENSQ875 X10.1 SETUP STATION DOOR LOCK

SOLENOIDS YV2011 Y6.6 AIR BLOWYV2041 Y6.0 ATC AIR BLOWYV2181 Y8.1 COUPLING AIR BLOWYV2281 Y7.0 O/A LUBE AIR SUPPLYYV2650 Y11.1 ATC SHUTTER CLOSEYV2651 Y11.0 ATC SHUTTER OPEN

YV3081 Y10.4 SETUP STATION LOCK PIN DOWNYV680 Y11.6 POT MAGAZINE SIDEYV681 Y11.5 POT SPINDLE SIDEYV91 Y8.7 OIL HOLE DRILL

OPTIONS

PRESSURE SWITCH SP7 X12.5 TABLE DOWN FIN

FOOT SWITCH SF14 X9.0 WSS FIXTURE FOOT SWITCH

PROXIMITY SWITCH SQ447 X14.5 COOLANT FLOW DETECTIONSQ547 X16.7 THRU COOLANT FLOW DETECTIONSQ563 X10.7 POT UNCLAMPSQ562 X8.3 POT CLAMPSQ112 X8.7 POT UNLOCK

SOLENOIDS YV131 Y6.4 OIL SHOT 1YV141 Y6.5 OIL SHOT 2YV5231 Y8.5 DUST COLLECTOR AIR BLOW



LOCATION OF SOLENOIDS

YV2041 (Y6.0) ATC Air Blow & YV2011 (Y6.6) Air Blow

YV2651 (Y11.0) ATC Shutter Open & YV2650 (Y11.1) Shutter Close



YV3081 (Y10.4) Setup Station Lock Pin Down

YV91 (Y8.7) Oil Hole Drill







UNIT 3

SVM1

X&B

UNIT 1

PSM

UNIT 2

SPM

UNIT 4

SVM2

Y&Z

UNIT 5

APC

UNIT 6

MGKM1 / KM101

AP-POW 1

UNI T 31

ATC

CONTROL LAYOUT

AP-POW 2 AP-POW 3



QF7QF7QF7QF7 QF9QF9QF9QF9

QM7QM7QM7QM7

QF31QF31QF31QF31QF14QF14QF14QF14

QF12QF12QF12QF12

FOR OPTIONFOR OPTIONFOR OPTIONFOR OPTION

QM84QM84QM84QM84,QM86,QM94 etc,QM86,QM94 etc,QM86,QM94 etc,QM86,QM94 etc

QF24QF24QF24QF24

Refer to next pageRefer to next pageRefer to next pageRefer to next page



QM75QM75QM75QM75

SHOWERSHOWERSHOWERSHOWER

COOLANTCOOLANTCOOLANTCOOLANT

X15.7X15.7X15.7X15.7

QM70QM70QM70QM70

HYDRALICHYDRALICHYDRALICHYDRALIC

PUMPPUMPPUMPPUMP

X15.4X15.4X15.4X15.4

QM63QM63QM63QM63

COOLANTCOOLANTCOOLANTCOOLANT

PUMPPUMPPUMPPUMP

X15.6X15.6X15.6X15.6

QM80QM80QM80QM80

OIL COOLEROIL COOLEROIL COOLEROIL COOLER

ONONONON

QM35AQM35AQM35AQM35A

INSIDEINSIDEINSIDEINSIDE

CONVEYORCONVEYORCONVEYORCONVEYOR

SPIRALSPIRALSPIRALSPIRAL

X16.1X16.1X16.1X16.1

QM35QM35QM35QM35



SPIRALSPIRALSPIRALSPIRAL

X16.1X16.1X16.1X16.1

QM34QM34QM34QM34



X16.1X16.1X16.1X16.1

QM36QM36QM36QM36

OUTSIDEOUTSIDEOUTSIDEOUTSIDE


X16.2X16.2X16.2X16.2



LED

7 LED

7-Segment LED

MEANING OF THE 7-SEGMENT LED

















Motor List for NH5000

MOTOR NO.

THERMALNO.

UNIT NAME NAME OF

MOTOR

MOTOR RATING OUTPUT200V-50Hz/200-60/220-60VOLTAGE CURRENT

PHASE POLE

THERMAL RELAY SETTING

200v-50Hz 200V-60Hz 220V-60Hz

ATC Assembly ATC Arm Motor

Okubo Gear SankiM31

QF31BF4GT000A

U18116

2200 [W]200-60Hz

11/11/11A3φ 4P

11INSIDE CHIP

CONVEYOR 1CHIP

CONVEYORMOTOR

ENOMOTO FUJIELECTRIC

0.4 ~ 0.63 [A]M34

QM34

U10481 MGX1M01A200 AZR

0.1 [Kw]200V-6-Hz 220-60

0.55A 0.54A3φ 4P

0.62 0.55 0.54

INSIDE CHIPCONVEYOR 2 CYCROMOTORTOKYO SEIMITU

HATUJOUSUMITOMOHEAVY IND.

0.4 ~ 0.63 [A]M35

QM35

U11267 TC-EX

0.1 [Kw]200V-6-Hz 220-60

0.55A 0.54A3φ 4P

0.62 0.55 0.54INSIDE CHIP

CONVEYOR 2CYCROMOTOR

TOKYO SEIMITUHATUJOU

SUMITOMOHEAVY IND.

0.4 ~ 0.63 [A]M35A

QM35A

U11267 TC-EX

0.1 [Kw]200V-6-Hz 220-60

0.55A 0.54A3φ 4P

0.62 0.55 0.54COOLANT PUMP COOLANT

PUMP MOTORGRUNDFOS GRUNDFOS

4.0 ~ 6.3 [A]

M63QM63

E55503 MTH2-60/6

635 / 1040 [W]

5.8 / 6.0 / 6.0 [A]

3φ 2P 5.8 6.0 6.0

COOLANT PUMP COOLANTPUMP MOTOR

GRUNDFOS GRUNDFOS

4.0 ~ 6.3 [A]M75

QM75E55503 MTH2-60/6

635 / 1040 [W]5.8 / 6.0 / 6.0 [A]

3φ 2P5.8 6.0 6.0

HYDRAULIC PUMP HYD PUMPMOTOR

NACHI-FUJIKOSHI NACHI-FUJIKOSHI

6.0 ~ 10.0 [A]M70

QM70

U00237 UVN-1A-1A4-2.2-4-11

2200 [W]200V-50Hz 200-60 220-60

9.0 / 8.7 / 8.2 [A]

3φ 2P 9.0 8.7 8.2

LUBRICATION UNIT PUMP-MOTORSHOWA SHOWAM69U27014 LCB4-8297E

17 [W]100V-50Hz / 100V-60Hz

1.5 / 1.2 / 1.5 [A]3φ 2P

1.5 1.2 1.5



OIL COOLERWAKAYAMAPRECISION

9.0 ~ 14.0 [A]QM80

11.0 11.0 11.0COMP.

REFRIGERANTNATIONAL

7.0 ~ 11.0 [A]QM81

QM81R4KS25OMAA

1100 [W]

200V-50Hz/200-60/220/60

5.15/5.80/5.80 [A]3φ 2P 7.5 7.5 7.5

PUMP MOTOR

YASUKAWA1.7 ~ 2.6 [A]M83

F83R

NU-YEC112BMN01U07252

FELQ-8T

400 [W]200V-50Hz/200-60/220-60

2.2/1.93/1.95 [A]3φ 4P 2.2 2.2 2.2

FAN STYLE FANSUTAIRU DENNSHI SUTAIRU

DENNSHIM300

US15F22-ZMGWE55048 US15F22-ZMGWE55048

37 / 34 / 34 [W]200V-50Hz/200-60/220-60

0.210/0.200/0.230 [A]1φ 2PHEAT EXCHANGER STYLE FAN

KAMIYA SUTAIRUDENNSHI

M301

M302

KTCHBO-52B3BE55120

UZS15D22-MGWE67021

35 / 33 / 33 [W]200V-50Hz/200-60/220-60

0.190/0.170/0.206 [A]1φ 2P

Y AXIS COOLINGFAN

STYLE FAN

SUTAIRU DENNSHI SUTAIRUDENNSHI

M303

US15F22-ZMGWE55048 US15F22-ZMGWE55048

37 / 34 / 34 [W]200V-50Hz/200-60/220-60

0.210/0.200/0.230 [A]

1φ 2P



AP-POW BOARDS

AP-POW-1

XPOWP

L11A 1

L12A 2

L13A 3

XTRNS

L11A 1

L12A 2

GND 3

XCX1A

L51 1

L52 2

GND 3

XGS1P

L11A 1

L12A 2

GND 3

XGS2P

L11A 1

L12A 2

GND 3

XGS3P

L11A 1

L12A 2

GND 3

XM300

L51 1

L52 2

GND 3

XM301

L51 1

L52 2

GND 3

XM302

L51 1

L52 2

GND 3

XM303

L51 1

L52 2

GND 3

XQM80

R12 1

R12A 2

XKM63

24NC 1

CLTH1 2

CLT 3

XKM73

24NC 1

CLTH2 2

CHIP 3

XKM75

24NC 1

CLTH2 2

SWCLT 3

XCONS

R12B 1

L12A 2

24NC 3

CLTH1 4

CLT 5

N24 6

CHIP 7

CLTH2 8

SWCLT 9

10

N24 4 N24 4 N24 4

5



AP-POW-2

XM70A

U70 1

V70 2

W70 3

XM70

U70 1

V70 2

W70 3

GND 4

XM63A

U63 1

V63 2

W63 3

XM73A

U73 1

V73 2

W73 3

XM75A

1 1

1 2

1 3

XM63

U63 1

V63 2

W63 3

GND 4

XM73

U73 1

V73 2

W73 3

GND 4

XM75

U75 1

V75 2

W75 3

GND 4



AP-POW-3

XM36A

U36 1

V36 2

W36 3

XM36

U36 1

V36 2

W36 3

GND 4

XM34A

U34 1

V34 2

W34 3

XM35A

U35 1

V35 2

W35 3

XM351A

U35A 1

V35A 2

W35A 3

XM34

U34 1

V34 2

W34 3

GND 4

XM35

U35 1

V35 2

W35 3

GND 4

XM351

U35A 1

V35A 2

W35A 3

GND 4



Other Screens on the iMB Control

Most of the screens on the new iMB control will be familiar to all. This is the OPPNLscreen, which is identical to the iMA control.

This is a dogless zero return machine so the Zero Point Set function is active on thiscontrol.



The ATC Manual screen is also identical to the iMA control. Although we are using anOkubo gearbox driven by a Fuji Inverter, the manual recovery procedure is the same.



System Components Screen

The SYSTEM COMPONENT screen is arrived at by pressing the SYSTEM button. Themenu selections available are displayed above. For this picture, SYSTEM COMP. waschosen.

The information contained on this screen shows every version of software that iscurrently loaded into the machine. When updating software, always check this screenwhen finished to ensure the correct version has actually been loaded.



Timer Screen

This is the PMC Timer screen arrived at by pressing the SYSTEM button, PMC softkey,PMCPRM softkey and then Timer (as shown above). The following screens will be of the Counter, Keep Relay and Data screens.



Counter Screen

Keep Relay Screen



Data Table Screen

The Data Table C. Data screen is where you set up the Group Table Count. This willdetermine how the G. Data tables are sequenced.



Fanuc load monitor screen is displayed above, and the MAPPS load monitor screen isin the lower picture.



B-AXIS TABLE

The B-Axis table was developed using the proven design of the SH-500. We have had tremendoussuccess with this table design, and felt there was little room for improvement.

Indexing Table

Indexing Table Drive

3 piece coupling

Bearing

Gear

Drive



Rotary Table

Rotary Table Drive

Worm Wheel

Worm Shaft

ClampingHooksClamping

Piston

Worm Drive using a Belt



The B-Axis table will come standard as a 1° indexer with a full fourth axis offered as an option, asshown above.

You can see the three piece coupling on the picture of the indexing table, which is not used on the full4th axis table. The rotary table is using a hydraulic brake, as is normally the case, to hold the table in

position.

You can also see the difference in drive mechanisms between the two different tables. The Indexer uses a gear train mechanism to rotate the table, while the rotary table uses a belt drive attached to aworm shaft.



1

6

5

3

9

7

10

11

12

14

16

17 19

8

13

15

18 20

2

4

1 Degree Indexer



1726 23 1922 21 1315

24 20 18 1416

2

1

4

3

8

7

12

11

10

9

6

5

25



A

Detail Drawing A

2 3 4 5 6 7 9 108 11 12 13 14 16 1817 19 20 21 22 2423

25

26

27

28

29 30 31 33 3432

664656869 6667

70

7374 72 7175767778798082 818384858687

88899091

94

93

92

95

96

97

99

98

100

1

101

102

103

104

105

15

Apply Greese(ALVANIA EP)グリス塗布（アルバニアEP）

Apply Screw Lock(Three Bond)ネジロック塗布（スリーボンド 1344 ）

0 . 5

C l e a r a n c e

m m

スキマ

0 . 5 m m

C l e a r a n c e

- 0 . 0

3 m m

スキマ

- 0 . 0

3 m m

Apply Grease(ALVANIA EP)グリス塗布(アルバニアEP)



断面 C-C1 2 3 5 6 7 8 9 10 11

16 17 19 20 21 23 24

12 13 14 15

22

28272625

4

29

18

B

B

C

C



3

8

6

1

2

7

54

109

12 13

14

1511

16

Full 4th Axis



23

24

1719 15 13

2 4 6 8 1210

25

2122

20 16 14

1 3 5 7 9 11

18

26



A

Detail Drawing A

103

101

100

99

98

97

96

95

94

93

92

91

90

89

8788

86

85

84

83 82 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 61 58

59

60

57 56 55 54

41

40

39

38

37

36

35

343332313029282722

23

24

25

26

2120191817151413 16121110987654321

102

104

62

105

106

107

108

109

Apply Screw Lock(Three Bond)

ネジロック塗布（スリーボンド 1344）










Adjust based accuracy test results chart belong inductosynインダクトシン付属の検査表に基き現合

Apply worm gear oil at assembling組立時ウォームギヤオイルを塗布する

A p p

l y G r e a s e

( A L V A N I A

E P )

グリス塗布 ( アルバニア E P )

S t a r

t i n g

t o r q u e

3 . 9 ～ 4

. 4 N ･ m

起動トルク

3 . 9 ～ 4

. 4 N ･ m



C

C

断面 C-C

B

B

断面 B-B

(S=1/2

(S=1/1)3 4 5 6 8

2

1

7 9 10 11 12 13 14 1615 18 19 22 23 2524

27 2826

17 2120



PALLET DIMENSIONS

Tap Pallet Specification

Unit: mm



Unit: mm

(1) The value shown in ( ) indicates the dimension in inches.

(2) Hydraulic pressure applies only to the ports for clamping(3) When the pressure inside machine is increased, one port for unclamping needs to be

NOTE



T-slot Pallet Specification

Unit: mm



Unit: mm

(1) The value shown in ( ) indicates the dimension in inches.

(2) Hydraulic pressure applies only to the ports for clamping(3) When the pressure inside machine is increased, one port for unclamping needs to be

NOTE





























































































Documents

MORISEIKI MAINTENANCE CLASS