mori seiki ZL-153, ZL-153S, ZL-153MC, ZL-153SMC, ZL-203 Operating Manual

OPERATION MANUAL

Applicable Model

ZL-153 ZL-153S
ZL-153MC ZL-153SMC
ZL-203 ZL-203S
ZL-203MC ZL-203SMC
ZL-253 ZL-253S
ZL-253MC ZL-253SMC

Applicable NC Unit

MSG-501

Before starting operatio n, maintenance, or programmin g, carefully read the
manuals supplied by Mori Seiki, the NC unit manufacturer, and equipment
manufacturers so that you fully understand the info rmation they contain.

Keep the manuals carefully so that they will not be lost.

OM-ZLFMSG501-A0E

 The contents of this manual are subje ct to change without notice due to

improvements to the ma chine or i n order to improve th e manual. Conse ­quently, please bear in mind that there may be slight discrepancies
between the contents of the manua l and the actua l machi ne. Change s to
the instruction manual are made in revised editions which are distin­guished from each other by updating the instruction manual number.

 Should you discov er any d iscre pancies between the con tents of the man -

ual and the actual machine , or if any part of the man ual is unclear, please
contact Mori Seiki and clarify these points before using the machine. Mori
Seiki will not be liable for any dam ages occurring as a direct or indirect
consequence of using the machine without clarifying these points.

 All rights reserved: re production of thi s instruction m anual in any form, in

whole or in part, is not permitted without the written consent of Mori Seiki.

The product shipped to you (the machine and accessory equip­ment) has been manufactured in accordance with the laws and
standards that prevail in the relevant country or region. Conse­quently it cannot be exported, sold, or relocated, to a destination in
a country with different laws or standards.

The export of this product i s subject to an authorization from the
government of the exporting country.

Check with the government agency for authorization.

990730

Machine Information

Description of machine: CNC lathe

Model name:

Machine serial No.:

Manufacturing date:

Representative:

Business hours: 8:30 - 17:30

CONTENTS

FOR SAFE OPERATION
WA RNING DISPLAY ON TURNING ON

POWER
PREFACE
SIGNAL WORD DEFINITION
FLOW UNTIL THE PRODUCT IS

COMPLETED
DOOR INTERLOCK FUNCTION
A: OPERATION PANELS
B: MANUAL OPERATION
C: CHUCKING
D: PROGRAM EDITING
E: SETTING OF COORDINATE SYSTEM
F: PREPARATION BEFORE STARTING

MASS PRODUCTION

INDEX

FOR SAFE OPERATION

This machine is intended for use by persons who have a basic knowledge of machine tools,
including cutting theory, tooling and fixtures. Mori Seiki cannot accept responsibility for accidents
that occur as a result of operation, maintenance, or programming of the machine by personnel
who lack this basic knowledge or sufficient training.

Workpiece materials and shapes vary widely among machine users. Mori Seiki cannot predict the
chucking pressure, spindle speed, feedrate, depth of cut, etc., that will be required in each case
and it is therefore the user's responsibility to determine the appropriate settings.

Each machine is shipped with a variety of built-in safety devices. However, careless handling of
the machine can cause serious accidents. To prevent the occurrence of such accidents, all
programmers and other personnel that deal with the machine must carefully read the manuals
supplied by Mori Seiki, the NC unit manufacturer, and equipment manufacturers, before
attempting to operate, maintain, or program the machine.

Because there are so many "things that cannot be done" and "things that must not be done" when
using the machine, it is impossible to cover all of them in the Instruction Manual. Assume that
something is impossible unless the manual specifically states that it can be done.

FOR SAFE OPERATION -1-

The following manuals are supplied with your CNC lathe:

1. Safety Guidelines prepared by Mori Seiki

2. Instruction Manual prepared by Mori Seiki

 MAINTENANCE MANUAL
 OPERATION MANUAL
 PROGRAMMING MANUAL

3. NC unit Operation and Maintenance Manuals prepared by the NC unit manufacturer

4. Instruction Manuals prepared by equipment manufacturers

In addition to the instruction manual, ladder diagrams and parameter tables are also supplied with
the machine to help with electrical maintenance, and there is an electrical circuit diagram in the
document compartment inside the electrical cabinet. Please make use of this material when
carrying out maintenance work.

Fundamental safety information is presented in the following pages.
All cautions on operation must be strictly observed when operating the machine, carrying out

maintenance work, or writing programs. Failure to observe fundamental safety information can
cause accidents in which the operator or other personnel working near the machine are seriously
injured, or the machine is damaged. All personnel that deal with the machine must carefully read
and thoroughly understand the information in the following pages before attempting programming
or operating the machine.
The vocabulary and terms used for machine parts and operations in the warnings, cautions and
notes are defined or explained in the manual texts and illustrations.
If you are unsure of the meaning of any word or expression, please refer to the corresponding
textual explanation or illustration. If you still cannot understand or are unsure of the meaning,
contact Mori Seiki for clarification.

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-2- FOR SAFE OPERATION

"Operator", as used in these cautions, means not only the operator who operates or supervises a
machine tool to perform machining, but also any person, including maintenance personnel who
maintain and inspect a machine tool or safety device or safety measures provided with it, and the
programmers who create programs used for machining, who are engaged in operations which
deal with a machine tool.

Therefore, all persons engaged in these operations must carefully read these cautions and related
materials, and thoroughly understand the contents before attempting to operate the machine.

SO-NL-B9E/O

FOR SAFE OPERATION -3-

1 CONSIDERATIONS BEFORE OPERATING THE MACHINE

The cautions that must constantly be born in mind when operating the machine are listed below.

1-1 Before Using the Machine

Listed below are important cautions that apply to all machine-related work (machine operation,
maintenance, inspection, programming, etc.).

DANGER

1. Never touch a switch, button, or key with wet hands.
If it is not properly grounded or is leaking current, you could receive
an electric shock.

2. Before starting machine opera tion, check t hat there is nobody ins ide
the protective cover or close to rotating or moving parts of the
machine. Never touch or stand near the rotating or moving parts of
the machine while it is operating; you could be seriously injured by
being entangled in the rotating parts or crushed by the moving parts.

3. Never operate the machine with the protective cover removed or
while interlocks or other safety devices are ineffective, since the
machine could operate in an unexpected manner , causing acci dents
involving serious injuries.
Contact Mori Seiki, the NC unit manufacturer or the relevant
equipment manufacturer immediately if the protective cover or
safety devices are damaged.

4. Always lock out the power to the machine before carrying out work
inside the machine - such as setup work or cleaning the inside of the
machine - and before carrying out inspections, repairs, or
maintenance work. In addition, set the main switch to the OFF
position and lock it, and place "PERSONNEL INSIDE MACHINE" or
"UNDER MAINTENANCE" signs around the machine to stop anyone
from switching on the power or operating the machine while the
work is in progress. If work inside the machine or inspection or
maintenance work is carried out with the power switched on,
machine elements could be moved, and the personnel carrying out
the work could be seriously injured by being entangled in the
rotating parts or crushed by the moving parts of the machine.

5. Always switch off the power before carrying out inspection or
maintenance work in the electrical cabinet or on motors and
transformers. If work has to be done while the power is switched on,
it must be carried out by a qualified electrical engineer, taking the
proper precautions; there is a danger of electric shock.

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-4- FOR SAFE OPERATION

DANGER

WARNING

6. Cover power supply cables that are run along the floor with rigid
insulated plates to prevent them from being damaged.
Damage to the insulation of the power supply cable could cause
electric shocks.

7. Even after the power is turned off, some devices will remain charged
and the temperature of motors, lights inside the machine, etc., will
remain high. Make sure that the charge has been discharged or the
temperature has fallen before carrying out maintenance work or
inspections on these devices. If you touch these devices/units
carelessly while they are still charged or while the temperature is
still high you could receive an electric shock or be burned.

8. Check that all cables are properly insulated before using the
machine. There is considerable danger of electric shock if da maged
cables are used.

1. Keep the floor area around the machine tidy and clean; do not leave
things lying on it, and clean up spilled water or oil immediately. If
you fail to do this, plant personnel may injure themselves by tripping
over or slipping on the floor.

2. Before operating the machine, check the area where you will have to
stand and walk to make sure you can operate the machine safely. If
you do not check your footing beforehand, you could loose your
balance while working and injure yourself by putting your han ds in a
dangerous place while trying to find support, or by falling over.

3. Before using a switch, button, or key , check visually that it is the one
you intend to use, and then press or set it decisively.
Pressing the wrong switch, button, or key by mistake can cause
accidents involving serious injuries or damage to the machine.

4. Always keep the front door closed during machine operation.
Leaving the machine running or operat ing it with t he front door open
could cause accidents involving serious injuries or damage to the
machine; plant personnel could be seriously injured by being
entangled in the rotating parts of the machine or crushed by its
moving parts, struck by a workpiece or soft jaws if they fly out of the
chuck, hit by flying chips, or splashed with coolant.

5. The parameters are set on shipment in accordance with the machine
specifications; do not change them without first consulting Mori
Seiki. If the parameters are changed without consultation, the
machine may operate in an unexpected manner, causing accidents
involving serious injuries or damage to the machine.

SO-NL-B9E/O

FOR SAFE OPERATION -5-

WARNING

6. The machine specifications are set before shipping so that the
machine can deliver its full performance. Changing the settings
without consultation may lead to accidents involving serious
injuries, impaired machine performance, and considerable
shortening of the machine service life. If the specifications and/or
settings have to be changed or the machine has to be modified to
meet new machining requirements or due to change s in the
operating conditions, consult Mori Seiki.

7. Before operating or programming the machine, or performing
maintenance work, carefully read the instruction manuals provided
by Mori Seiki, the NC unit manufacturer and the equipment
manufacturers so that you fully understand the information they
contain. Keep these instruction manuals safely so that you do not
lose them. If you do lose an instruction manual, contact Mori Seiki,
the NC unit manufacturer, or the relevant equipment manufacturer. If
you attempt to operate the machine without having carefully read the
instruction manuals first, you will perform dangerous and erroneous
operations which may cause accidents involving serious injuries or
damage to the machine.

8. Always observe the instructions in the caution labels stuck to the
machine. Carefully read the Safety Guidelines supplied with the
machine so that you fully understand them. If the writing on the
labels becomes illegible, or if the labels are damaged or peel off,
contact Mori Seiki. Also contact Mori Seiki if you cannot unde rstand
any of the labels. If you operate the machine without observing the
instructions on the labels, or without understanding them properly,
you will perform dangerous and erroneous operations which may
cause accidents involving serious injuries or damage to the
machine.

9. Never operate, maintain, or program the machine while under the
influence of alcohol or drugs. Your concentration will be impaired,
you may loose your balance and fall against dangerous parts of the
machine, and you may operate the machine incorrectly, causing
accidents involving serious injuries or damage to the machine.

10. Machine operators and authorized per sonnel working inside the
plant and in the vicinity of the machine must put their clothing and
hair in order so that there is no danger they will be entangled in the
machine. If you have uncontrolled long hair or loose clothing and it
gets caught in the machine, you will be seriously injured by being
entangled in the rotating parts of the machine or crushed by its
moving parts. Always wear safety shoes, eye protectors and a
helmet.

SO-NL-B9E/O

-6- FOR SAFE OPERATION

WARNING

11. The machine is equipped with interlock functions such as the door
interlock, chuck interlock, tailstock spindle interlock (applies only to
machines equipped with a tailstock) and electrical cabinet door
interlock to ensure the operator's safety. All the interlock functions
must be ON when operating the machine. If you have to operate the
machine with the interlocks released, you must recognize that there
are many hazards involved and pay particular attention to safety
while operating the machine in this condition. After finishing the
necessary work, you must switch the interlocks back ON.
If the machine is operated with the interlocks released, it may
operate in an unexpected manner, causing accidents involving
serious injuries or damage to the machine.

12. The door interlock function serves only to protect the machine
operator from accidents that can be prevented by inhibiting manual
and automatic operation of th e spindle, axis mov ement, an d all other
operations in automatic operation when the door is opened and
while it is open; it will not afford protection against other hazards.
For example, each machine user will machine a variety of workpiece
types and use a variety of workpiece holding fixtures, cutting tools,
and cutting conditions; you are still responsible for ensuring safety
with regard to the hazards that can arise from these user-specific
conditions.

13. If the door interlock function is released, the machine is able to
operate with some limitations while the door is open, exposing you
to danger. In daily production operation, the door interlock function
must be set "valid" and the key operating the switch must be
removed from the switch and kept safely.
When shaping soft jaws, measuring the tool offset dat a, program
check, test cutting or carrying out other setup work, it may be
necessary to release the door interlock function. If you have to carry
out work while the interlock function is released, you must recognize
that there are many hazards involved and pay particular attention to
safety. While the door interlock function is released, the warning
lamp blinks in red and the warning buzzer beeps intermittently. You
must recognize that the door interlock function is in the released
state when the warning lamp is blinking in red and the warning
buzzer is beeping intermittently. After finishing the necessary work,
you must switch the interlock function back valid.

SO-NL-B9E/O

FOR SAFE OPERATION -7-

WARNING

14. Before operating the machine, memorize the locations of the
EMERGENCY STOP buttons so that you can press one immediately
from any location and at any time while operating the machine. The
EMERGENCY STOP buttons are used to stop all operations in the
event of an emergency. If there is an obstacle in front of an
EMERGENCY STOP button it will not be possible to press it
immediately when an emergency occurs and this could cause
accidents involving serious injuries or damage to the machine.

15. Always switch the tailstock spindle interlock function ON before
carrying out center-work operations. If this function is OFF , it will be
possible to start automatic operation when the tailstock spindle is
extended, even though it may not support the workpiece correctly . If
automatic operation is started in this condition , the workpiece will fly
out, causing serious injuries or damage to the machine. (Applies
only to machines equipped with a tailstock.)

16. Adjust the position of the tailstock body so that the workpiece is
securely held by the tailstock spindle center when the tailstock
spindle is extended.
After making this adjustment, clamp the tailstock body to the be d. If
the tailstock body is not clamped to the bed, or if the position of the
tailstock body is incorrectly adjusted, it will be possible to start
automatic operation when the tailstock spindle is extended, even if
the workpiece is not supported by the t ailstock spindle center. If
machining is carried out while the workpiece is not supported by the
tailstock spindle center, the workpiece will fly out, causing serious
injuries or damage to the machine. (Applies only to machines
equipped with a tailstock.)

17. To prevent hazardous situations, the plant or equipment super visor
must bar entry to the plant or the vicinity of the machine to anyone
with insufficient safety training. Allowing persons witho ut suff icient
safety training unhindered into the plant and the vicinity of the
machine could cause accidents involving serious injuries.

18. Because of the inertia of the moving parts of the machine, they may
not be stopped immediately when the EMERGENCY STOP button is
pressed. Always confirm that all operations have stopped before
going near these parts. If you approach the moving parts of the
machine without due care you may be entangled in them and
seriously injured.

SO-NL-B9E/O

-8- FOR SAFE OPERATION

WARNING

CAUTION

19. Do not leave articles such as tools and rags inside the machine.
If the machine is operated with such articles inside it they may
become entangled with a tool and thrown out of the machine, and
this could cause accidents involving serious injuries or damage to
the machine.

20. When the machine is running, operating noise may possibly be
produced, depending on the cutting conditions and other factors.
When an operator works near the machine, either change cutting
conditions to limit generation of noises or the operator must wear
protective gear, meeting the level of generated noise, which will not
cause inconvenience for performing intended work. Working under
noises might impair operator's health, such as hearing.

1. User programs stored in the memory, parameters set before shipping, and the
offset data input by the user, can be destroyed or lost due to incorrect operation
or other causes. To protect data against destruction and loss, back it up using an
external I/O device (option), or other device.
If you fail to make backup files, Mori Seiki cannot accept responsibility for any
problem resulting from destroyed programs or lost parameter data and/or offset
data.
Keep the parameter table supplied with the machine in a safe place. Note that if
the data is destroyed it will take some time to set the parameters again.

2. Never touch chips or the cutting edges of tools with your bare hands since you
may be injured.

3. Take care not to stumble over the footswitch since you may be injured.

4. If it becomes necessary to perform a memory clear operation, contact Mori Seiki
first. If a memory clear operation is performed without due care, the entire
memory contents may be deleted, making the machine in operable.

5. The machine operator must have normal sensory perception. If a person who
has an abnormality affecting any sense operates the machine, he/she will not be
able to accurately confirm the machine status and surrounding conditions by eye/
ear/touch. Sensory confirmation is extremely important when operating the
machine and an inability to make such confirmations properly could cause
accidents involving serious injuries or damage to the machine.

6. Ensure that the workplace is adequately lit. If there is insufficient light, the
operator may trip over something or be unable to perform or check work
accurately, and this could cause accidents involving serious injuries or damage to
the machine.

SO-NL-B9E/O

FOR SAFE OPERATION -9-

CAUTION

NOTE

7. Remove any obstacles around the machine.
Secure adequate space around the machine for working and adequate
passageway, considering both ease of operation and safety. If there are any
obstacles or if there is insufficient space or passageway, the operator may trip
and fall or be unable to work properly, and this could cause accidents involving
serious injuries or damage to the machine.

8. Stack products (workpieces) stably. If they are not stacked stably they may fall
and injure the machine operator. Unstable stacking may also damage the
products (workpieces), causing defects.

9. Keep the area around the machine clean; remove chips and foreign matter near
the machine. If left, chips and foreign matter may cause plant personnel to fall
and injure themselves.

10. Use a working bench strong and stable enough to support the weight of the
workpieces and tools. If an unstable working bench is used the workpieces and
tools could fall off and injure the machine operator.

If a machine alarm or NC alarm occurs, check its meaning by referring to the alarm list in
the instruction manual or ladder diagram, and take the appropriate action. If this is
ineffective, consult Mori Seiki or the NC unit manufacturer and take action when you
understand clearly what to do.

SO-NL-B9E/O

-10- FOR SAFE OPERATION

1-2 Before Operating the Machine

The cautions that you must be aware of before operating the machine are listed below.

WARNING

1. Never stand in front of the spindle or other rotating parts. Never
stand in front of the chuck, since the workpiece, cutting tools, or
chuck jaws might fly out, particularly during test cutting, causing
accidents involving serious injuries.

2. Specify a spindle speed limit that is lower than the lowest of the
individual allowable speed limits for the chuck, fixture, and cylinder.
If you do not follow this instruction, the workpiece could fly out of
the machine, causing serious injuries or damage to the machine.

3. Clamp workpieces and cutting tools securely. Determine the depth
of cut and cutting feedrate for test cutting with safe operation as the
first priority; do not give priority to productivity wh en making these
determinations. If you fail to observe this warning, the tool or
workpiece could fly out of the machine, causing serious injuries or
damage to the machine.

4. Before starting spindle rotation, check that the workpiece is securely
clamped. Or, if performing center-work, check that the tailstock
spindle center securely supports the workpiece. (Applies only to
machines equipped with a tailstock.)
If the workpiece is not securely clamped or supported, it will fly out
when the spindle is rotated, causing serious injuries or damage to
the machine.

5. Before starting the spindle in manual operation, s et the spindle
speed setting switch to the lowest setting. After starting the spindle,
increase the spindle speed to the required speed gradually.
When stopping the spindle, first lower the spindle speed by setting
the spindle speed setting switch to the low speed position and then
stop it.
If the spindle is started at the high speed setting, the workpiece and
chuck jaws could fly out, causing serious injuries or damage to the
machine.

6. Do not start the spindle unless the machine's left side cover and
cylinder cover are removed. If you fail to observe this warning you
could be seriously injured by being entangled in the rot ating p a rt s of
the machine.

7. Never attempt to reach inside the chip conveyor or put your feet in it
while it is operating. You could be caught in the chip conveyor and
seriously injured. (Applies only to machines equipped with a chip
conveyor.)

SO-NL-B9E/O

FOR SAFE OPERATION -11-

WARNING

8. Never stand near the moving parts of the machine during a zero
return operation or rapid traverse operation since each axis is
returned to the zero point (or fed) at the rapid traverse rate.
Before starting a zero return operation or rapid traverse opera tion,
always make sure that no one is standing near the moving parts, that
the moving parts can be fed to the zero point (or fed) without
interference, and t hat you are moving the axis in the correct
direction.
Failure to observe these warnings could cause accidents involving
serious injuries or damage to the machine: personnel could be
crushed by the moving parts of the machine, and the moving parts
could strike obstacles.

9. Never stand near the moving parts of the machine during a jog feed
operation since each axis is fed at the jog feedrate set with the
feedrate override dial. Before starting jog feed operation, always
make sure that no one is standing near the moving parts and that the
moving parts can be fed without interference. Failure to observe
these warnings could cause accidents involving serious injuries or
damage to the machine: personnel could be cr ushed by the moving
parts of the machine, or the moving parts could strike obstacles.

10. For the machine equipped with the proximity switches for the zero
return, when the axis feed switch which moves the axis away from
the zero point is pressed in the zero return mode, the axis will be fed
in the opposite direction of the zero point at the set rapid traverse
rate while the switch is pressed; make sure that you feed the axis in
the correct direction.
For the machine not equipped with the proximity switches for the
zero return, when the axis feed switch which moves the axis away
from the zero point is pressed in the zero return mode, the axis will
be fed in the direction of the zero point at the set rapid traverse rate
while the switch is pressed; make sure that you feed the axis in the
correct direction.
Also make sure that you feed the axis in the correct direction
whenever you use an axis feed switch to feed an axis at a rapid
traverse rate or jog feedrate.
Feeding an axis in the wrong direction could cause accidents
involving serious injuries or damage to the machine: personnel
could be crushed by the moving p arts of the machine, or the moving
parts could strike obstacles.

SO-NL-B9E/O

-12- FOR SAFE OPERATION

WARNING

11. Select the appropriate chucking pressure and tailstock spindle
thrust force (applies only to machines equipped with a tailstock) for
the workpiece shape and material, and the cutting conditions. If you
cannot determine the appropriate chucking pressure, contact the
chuck manufacturer or cylinder manufacturer. If you cannot
determine the appropriate spindle thrust force (applies only to
machines equipped with a tailstock), contact Mori Seiki. If the
chucking pressure or spindle thrust force (applies only to machines
equipped with a tailstock) is not set appropriately in accordance with
the shape and material of the workpiece being machined and the
cutting conditions, the workpiece could fly out during machining,
causing serious injuries or damage to the machine. Incorrect setting
could also distort the workpiece.

12. Do not wear gloves when operating the machine. Wearing gloves
could cause your hands to get entangled in the rotating parts of the
machine.

13. Never remove burrs on a workpiece by hand while it is clamped by
the chuck or while it is fixed inside the machine. If the machine were
to start for some reason you would be seriously injured: you could
be entangled by the rotating parts of the machine or crushed by its
moving parts. You could also injure yourself by losing your balance.
Always remove the workpiece and perform the work outside the
machine.

CAUTION

14. Coordinate values and M, S, T, G, and F codes in the blocks skipped
during sequence number search operations do not change the
coordinate values or modal M, S, T, G, and F codes in the NC.
When searching for a block part wa y through a machining process
and restarting machining from that point, specify the M, S, T , G, and F
codes, and workpiece coordinate system, etc., in the MDI mode after
carefully checking the status of the machine and the NC. If
machining is restarted without specifying this information, the
machine may operate in an unexpected manner, causing accidents
involving serious injuries or damage to the machine.

1. When machining bar stock on a machine equipped with a bar feeder or spindle
through-hole, use straight workpieces only. When machining bar stock with a
diameter smaller than that of the spindle (or draw bar), always use guide bushes
in order to prevent vibration. If you use a bent workpiece or fail to use guide
bushes, the machine will vibrate and the workpiece will shake; this could cause
damage to the machine. It will also seriously affect machining accuracy.

2. Do not touch the lamp that illuminates the interior of the machine since, if a
halogen lamp or incandescent lamp is used, it will be very hot and will burn you.
Also wait some time before touching the lamp after turning the power OFF.

SO-NL-B9E/O

FOR SAFE OPERATION -13-

CAUTION

3. Never operate the machine without the shield cover of the chuck opening/closing
footswitch and the lock device in place.
If you step on the footswitch by mistake, or drop something on it, the chuck will be
unclamped and the workpiece that it was gripping will fall out, and this could
cause damage to the machine.

4. The service outlet on the operation panel (option) is provided for connection of
external I/O devices and must not be used to connect electric apparatus used for
maintenance and inspection. Do not connect external I/O devices with a current
capacity that exceeds the permissible current.
If maintenance or inspection apparatus or an external I/O device whose current
capacity exceeds the permissible current is connected to the outlet, the breaker
in the electrical cabinet could be tripped. If this happens while the machine is
operating, it could damage the machine or cause machining defects.

5. In order to open the electrical cabinet door, you must place the main switch in the

OPEN RESET position. If the main switch is at a position other than OPEN
RESET, it will not be possible to open the door. Attempting to force the door open

in this situation could cause damage to the electrical cabinet door or the main
switch.

6. When clamping or unclamping the chuck, pay sufficient care so that hand or
fingers will not be caught by the chuck or the chuck jaws. If caught by the chuck
or chuck jaws, hand or fingers will be injured.

SO-NL-B9E/O

-14- FOR SAFE OPERATION

2 TURNING THE POWER ON AND OFF

2-1 Before Turning the Power ON

Observe the following instructions before turning the power ON in order to prevent accidents
involving serious injuries or damage to the machine.

WARNING

CAUTION

After pressing the NC power switc h [ON], do not touch any of the
operation-related keys on the NC operation panel until the screen shows
"(WARNING)". The NC power switch [ON] is used in combination with
some of the switches and keys on the operation panel for purposes
related to maintenance and special operations.
If you accidentally use one of these combinations the machine will
operate in an unexpected manner, and this could cause accidents
involving serious injuries or damage to the machine.

1. Make sure that all bolts are tightened securely. Operating the machine with
insufficiently tightened bolts could cause damage to the machine.

2. Make sure that all connectors are connected securely. Operating the machine
with loose connectors could cause machine faults.

3. Make sure that all hydraulic hoses and air pipes are connected securely. If the
machine is operated while they are not connected securely, hydraulic oil or air will
leak when the power is turned ON, causing machine faults.

4. If the machine is equipped with any optional external equipment (bar feeder,
loader, robot, etc.), make sure that the electric cables and hydraulic/pneumatic
pipes for this equipment are connected correctly. Operating the external
equipment or the machine with incorrect connections will cause equipment or
machine faults.

5. Do not place the main switch in the ON position while the primary power is not
supplied to the main switch.
If the main switch is placed in the ON position repeatedly although the primary
power is not supplied to the main switch, the main switch will be damaged.

SO-NL-B9E/O

2-2 After Turning the Power ON

FOR SAFE OPERATION -15-

WARNING

1. T o prevent seizure of the chuck and cylinder, repeat the chuck
opening and closing operations several times, check that the soft
jaws or workpiece holding fixture are securely mounted, and then
break in the spindle. If the chuck or cylinder seizes, the chuck
gripping force will be reduced and the workpiece could fly out while
the spindle is rotating, causing serious injuries or damage to the
machine.

2. If the machine stops due to a power failure, turn the main disconnect
switch OFF immediately. If you do not turn the power OFF the
machine will start operating unexpectedly when the power is
restored, and this could cause accidents involving serious injuries
or damage to the machine.

3. The machine cannot operate correctly unless the specified power is
supplied. If the power supply is momentarily cut off during machine
operation due to a power failure or lightning, the machine may
operate unexpectedly and this could cause accidents involving
serious injuries or damage to the machine. If abnormal fluctuations
in the power supply voltage are likely, for example due to lightning,
switch the power OFF.

4. Check for oil leaks and check that all gages read the correct values.
Operating the machine while there is an oil leak or while gage
readings are incorrect will cause accidents involving serious
injuries, machine faults or damage to the machine.

CAUTION

1. After turning the power ON, check that the fans are operating normally. If the
machine is operated while the fans are not operating normally the heat inside the
machine will not be dissipated and this will cause damage to the machine and
machine faults.

2. After turning the power ON, check that the slideway lubrication pump is operating
normally. If the machine is operated while the pump is not operating normally,
lubricating oil will not be supplied to the slideways and this will cause damage to
the machine.
In order to protect the sliding parts, never feed the axes immediately after turning
the power ON; manually operate the slideway lubrication pump to supply
lubricating oil to the slideway surfaces first. Feeding the axes while no lubricating
oil is supplied will wear the sliding parts and ball screws and cause seizure and
other damage to the machine.

3. After turning the power ON, break in the spindle for about 15 minutes. If you do
not break in the spindle, the machine's service life and machining accuracy will
be adversely affected.

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CAUTION

4. To turn the power OFF, follow the sequence below:

- Check if an alarm or other abnormality has occurred.

- Press the EMERGENCY STOP button.

- Press the NC power switch [OFF] on the operation panel.

- Turn the main switch (no fuse breaker) OFF.
If you turn the main switch OFF during machine operation without following the
preliminary steps the machine will operate in an unexpected manner and this
could cause damage to the machine.

5. When turning the power ON after the machine has been stopped by a power
outage, check that the program, parameter data, offset data, etc. have not been
destroyed. If the machine is used with destroyed data, it could cause damage to
the machine.

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3 SAFETY PRACTICES DURING SETUP

"Setup" is the sequence of operations between turning the power to the machine ON and starting
mass production. It includes inputting of the program, shaping of soft jaws, setting of tool offsets,
program checking, and test cutting.

FOR SAFE OPERATION -17-

WARNING

1. The machine should normally be operated by one, well-trained
person only.
In cases where more than one operator is essential, the operators
must cooperate carefully, communicating as fully as possible. If one
operator presses buttons on the operation panel or feeds machine
axes while another is replacing a workpiece, soft jaws, a fixture, or
cutting tool, etc., that operator, or someone standing close by, could
be entangled in the machine and seriously injured.

2. In order to ensure operator safety, implement the following safety
measures during setup while the door is shut and the door interlock
function is released.

<To prevent starting of automatic operation>

1) Select the handle mode with the mode selection switch.

2) Unclamp the chuck.

3) Close the cover over the automatic operation (cycle start)
switch.
(Applies to machines equipped with covered switches.)

4) Set the spindle speed range to "Neutral".
(Applies only to machines equipped with a transmission.)

<To ensure operator safety if automatic operation is started by
mistake>

1) Set override switches (spindle speed, rapid traverse, cutting
feedrate) to the lowest position.

2) Switch the single block function ON.

3) Switch the machine lock function ON.

4) Establish the coolant OFF mode by pressing the coolant OFF
switch for longer than one second.

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WARNING

<To prevent starting of the spindle>

1) Unclamp the chuck.

2) Set the spindle speed range to "Neutral".
(Applies only to machines equipped with a transmission.)

3) Close the switch covers of the spindle normal rotation and
spindle reverse rotation switches.
(Applies to machines equipped with covered switches.)

4) Set the operation selection key-switch to the "operation
disable" position.
(Applies to machines equipped with a flat type operation panel.)

<To ensure operator safety if the spindle is started by mistake>

1) Set the spindle speed adjusting switch to the lowest setting.

<To prevent turret head indexing (for example when changing a
cutting tool)>

1) Set the turret indexing switch to the station number that is
currently indexed.

2) Close the switch cover over the turret indexing switch. (Applies
to machines equipped with covered switches.)

3) Set the operation selection key-switch to the "operation
disable" position. (Applies to machines equipped with a flat
type operation panel.)

3. When using a manually tightened chuck or fixture, always remove
the clamp handle or tightening tool from the chuck or fixture after
tightening. If the spindle is started with the clamp handle or
tightening tool still in place the handle/tool will fly out, causing
serious injuries or damage to the machine.

4. Always select the most appropriate cutting tool and holder for the
material and shape of the workpiece to be machined and cutting
method, and check that the workpiece can be machined without any
problems.
If an inappropriate cutting tool or holder is selected, the workpiece
could fly out of the chuck during machining, causing serious injuries
or damage to the machine. Machining accuracy will also be
adversely affected.

5. Make sure that the cutting tool, holder, soft jaws, and tailstock (if
featured) are all tightened securely. If they are not tightened
securely, the cutting tool or workpiece will fly out of the machine
during machining, causing serious injuries or damage to the
machine.

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FOR SAFE OPERATION -19-

WARNING

6. When mounting a rotary tool holder to the turret head, always mount
a tool in the tool holder. If the rotary tool spindle is started while
there is no tool mounted in the tool holder, the collet clamping nut
will be loosened and the collet clamping nut and collet will fly out
during rotation, causing serious injuries or damage to the machine.
(Applies to milling specification.)

7. The machine has a chuck interlock function that prevents starting of
the spindle unless the chuck clamp indicator is lit. Make sure this
interlock function works correctly by setting the correct chuck
clamping direction for the type of workpiece to be machined.
If the spindle starts rotating while the workpiece is not correctly
clamped in the chuck, the workpiece could fly out, causing serious
injuries or damage to the machine.

8. Before starting the spindle, carefully check the workp iec e chuc king
conditions, the chucking pressure, and the spindle speed. If spindle
rotation is started when the workpiece is grasped unstably or when
the chucking pressure or spindle speed is inappropriate, the
workpiece could fly out, causing serious injuries or damage to the
machine.

9. Be aware that the spindle will start rotating if the spindle normal
rotation switch or spindle reverse rotation switch is pressed by
mistake while a manual mode is selected and the conditions for
spindle rotation are satisfied. If these switches are pressed
carelessly the spindle will start rotating unexpectedly and this could
cause accidents involving serious injuries or damage to the
machine.

10. Since forged and cast workpieces have hard chucking portions due
to scale, use hard jaws for these workpieces. If the chucking contact
has to be a point or line contact, for example whe n cla m ping on the
draft of a casting, use spikes embedded in the jaws. If three soft
jaws are used, shape them so that the workpiece is clamped at six
points; avoid face contact between the jaws and workpieces with
scale on them.

11. Be aware that the turret head will start rotating if the turret head
index switch is pressed by mistake while the conditions for turret
indexing are satisfied and a manual mode is selected. If this switch
is pressed carelessly the turret will start rotating unexpectedly and
this could cause accidents involving serious injuries or damage to
the machine.

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WARNING

12. For the machine with the flat type operation panel, always place the
operation selection key-switch in the "operation enable" or
"operation disable" position after completing program entry.
Be aware that the program will be updated if program editing
operations are carried out with the operation selection key-switch at
the "operation and edit enable" position. If the program is executed
after being accidentally updated in this way the machine could
operate unexpectedly, causing serious injuries or damage to the
machine.

13. For the machine with the discrete type operation panel, always place
the edit enable key-switch in the "edit disable" position after
completing program entry. Be aware that the program will be
updated if program editing operations are carried out with the edit
enable key-switch at the "edit enable" position. If the program is
executed after being accidentally updated in this way the machine
could operate unexpectedly, causing serious injuries or damage to
the machine.

14. For the machine with the touch panel, always return the WRITE
PROTECT switch (PROGRAM) back to ON after completing program
entry. Be aware that the program will be updated if program editing
operations are carried out with the WRITE PROTECT switch
(PROGRAM) set OFF. If the program is executed after being
accidentally updated in this way, the machine could operate
unexpectedly, causing serious injuries or damage to the machine.

15. Workpiece materials and shapes vary widely among machine users.
Mori Seiki cannot predict the workpiece clamping method, spindle
speed, feedrate, depth of cut, and width of cut, etc., that will be
required in each case and it is therefore the user's responsibility to
determine the appropriate settings.
Note also that the machining conditions determined in automatic
programming are the standard conditions, which are not necessarily
the most suitable for the user's purposes and may have to be
changed in accordance with the workpiece, chuck, etc. The
conditions determined in automatic programming are for reference
only and the final responsibility for determining the conditions rests
with the user. (Conversational NC specification)
If you have difficulty determining these conditions, consult the
chuck and cylinder manufacturers and tool manufacturer.
Machining under inappropriate machining conditions can cause the
workpiece to fly out of the chuck during machining, causing serious
injuries or damage to the machine. It will also adversely affect
machining accuracy.

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FOR SAFE OPERATION -21-

WARNING

16. The chuck gripping force is reduced when the spindle is rotated
since the rotation applies centrifugal force to the chuck jaws. This
reduction of the chuck gripping force could cause the workpiece to
fly out of the chuck during machining, causing serious injuries or
damage to the machine. Therefore, when checking a program,
measure the chuck gripping force that will actually be applied when
the spindle is rotated at the speed used for machinin g by using a
gripping force meter. If the measured chuck gripping force value is
lower than that required to hold the workpiece safely, change
machining conditions such as the chucking pressure, spindle speed,
feedrate, and depth of cut.
Periodically measure the chuck gripping force with a gripping force
meter to make sure that the required gripping force is maintained. If
it is not, consult the chuck manufacturer and cylinder manufacturer.
For details on the relationship between the spindle rotation speed
and chuck gripping force, refer to the instruction manuals prepared
by the chuck manufacturer and cylinder manufacturer.

17. When using the stopper inside the spindle, make sure that the
adjusting shaft in the spindle does not protrude excessively from the
rear of the spindle (cylinder).
If there is excessive protrusion the adjusting shaft will fly out,
causing serious injuries or damage to the machine. (Spindle stopper
specification)

18. If the spindle gear range is changed when the spindle is stopped, the
spindle may rotate a little. Make sure that this rotation will not cause
any interference. (Applies only to machines equipped with a
transmission.)

19. When using a machine equipped with a hollow chuck, if machining is
carried out without using the chuck through hole, be sure to fit the
through hole cover provided as an accessory to the chuck. If
machining is carried out without the through hole cover fitted,
coolant and chips will get inside the chuck and cylinder, causing
their hydraulic circuits and those of other units to malfunction. If
machining is carried out under these conditions, the chuck gripping
force will be reduced and the workpiece will fly out, causing serious
injuries or damage to the machine.

20. When handling (mounting, removing, or moving) a heavy object, use
appropriate equipment such as a crane and a hoist.
If you handle a heavy object by your hands without using such
equipment, you could be seriously injured or physically disabled
due to heavy load.

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-22- FOR SAFE OPERATION

CAUTION

1. If no tool holders for rotary tools are mounted in the turret head, fit covers to the
rotary tool holder mounting holes after checking that the covers are fitted with O
rings. If covers are not fitted, chips and coolant will get inside the turret head and
may cause machine faults. (Applies to milling specification.)

2. Keep the machine light on during setup to ensure safety. If this light is off it will
not be possible to check conditions inside the machine or test cutting properly,
and this may cause damage to the machine or machining defects. In addition,
operators could be injured while working inside the machine.

3. If the machine is stopped for a day or longer, the oil film on the slideways may be
lost. If the machine is started in this condition the slideways and ball screws will
be worn and might seize.
Therefore, if the machine has not been operated for a day or longer, press the
manual lubrication pushbutton to forcibly lubricate the slideways.

4. In order to protect the lubrication pump motor, do not hold down the manual
lubrication pushbutton for longer than one minute when supplying lubricating oil
to the slideways manually. If the pushbutton is held down for longer than a
minute, the lubrication pump motor may fail.

5. Do not stop spindle rotation while the cutting tool is in contact with the workpiece.
This will cause damage to the tool and/or machine.

6. Do not turn the manual pulse generator dial any faster than 5 rotations per
second. If you do, the axis will not stop immediately when the manual pulse
generator is stopped and the actual amount of axis feed will not coincide with the
number of pulses generated. This could cause damage to the machine.

7. When the turret head is rotated with cutting tools mounted in it, tools with long
projection lengths could strike the Z-axis protector (cover or tailstock), etc.
Before rotating the turret, make sure that the tools in the turret do not interfere
with the protector (cover or tailstock), since interference will cause damage to the
machine.

8. When mounting an I.D. cutting tool in the turret head, make sure that the tool
shank does not project beyond the rear surface of the tool holder. If it does it will
interfere with the turret base, etc., during turret head rotation, causing damage to
the machine.

9. Remember that the direction of spindle rotation is determined by the tool
registration data and the spindle will rotate in the wrong direction if the settings
are incorrect. Machining while the tool is rotating in the wrong direction can
cause damage to the tool and the machine. (Applies only to milling specification.)

10. When shifting the coordinate system in order to check a center-work program, set
the shift direction and shift amount carefully to avoid interference between the
turret and tailstock, which could cause damage to the machine. (Applies only to
machines equipped with a tailstock.)

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FOR SAFE OPERATION -23-

CAUTION

11. An extraction bar used when removing the center from the tailstock body is fitted
inside the tailstock of some models.
It functions for shock-proofing when another bar, inserted from the rear of the
tailstock body, is tapped to remove the center. It also serves to prevent chips and
coolant from entering the tailstock body during machining. Do not operate the
machine without the extraction bar fitted inside the tailstock body since this could
cause damage to the machine. (Applies only to machines equipped with a
tailstock.)

12. When setting the coordinate system using the machine coordinate system setting
function, any mistake in specifying the X and Z values in the G50 block will cause
interference between the cutting tool, tool holder, or turret head, and the
workpiece, chuck, fixture, or tailstock (if featured), damage to the machine, or will
cause the cutting tool failing to reach the cutting position.

13. Support the workpiece securely before stepping on the chuck clamp/unclamp
footswitch to remove it. If you step on the footswitch without taking this
precaution the workpiece will fall and this could cause damage to the machine.

14. You will probably use a variety of workpiece shapes and materials, and the
chucking method will differ according to the workpiece type. Therefore, when
checking a program with the workpiece clamped in the chuck, check for
interference carefully, taking the workpiece shape and material, and the chuck
gripping force, into account. Depending on these factors, the cutting tool, holder,
or turret head might interfere with the workpiece, chuck, fixture, or tailstock (if
featured), causing damage to the machine.

15. If the workpiece is supported using the tailstock spindle, carelessly moving the
tailstock spindle in or retracting the tailstock body will leave the workpiece held by
the chuck alone. The workpiece may fall, causing damage to the machine, if it is
held only by the chuck. Therefore, before moving the tailstock spindle in or
retracting the tailstock body, ensure that the workpiece is held securely by a
crane or other appropriate means. (Applies only to machines equipped with a
tailstock.)

16. Mount cutting tools to the turret head in a well-balanced manner, and ensure that
there will be no interference between the cutting tools/holders and the workpiece
or machine. If a cutting tool projects too far it will interfere with the Z-axis
protector, tailstock (if featured), or workpiece, etc., when the turret head is
rotated, causing damage to the machine.

17. Whenever mounting or removing a tool to or from a rotary tool holder, remove the
rotary tool holder from the turret head and mount or remove a tool to or from the
rotary tool hol der out si de t he ma chin e. If a too l is mou nted or r emo ved to or fr om
the rotary tool holder mounted in the turret head, it could cause damage to the
machine. (Applies only to milling specification.)

18. When mounting a tool to a rotary tool holder using a collet, do not tighten the
collet clamping nut excessively. If the collet clamping nut is tightened
excessively, the nut will be damaged, which causes the tool and the machine to
be damaged. (Applies only to milling specification.)

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CAUTION

NOTE

19. In the case of machines equipped with a live center as the tailstock spindle
center, a live center must also be used for the tailstock spindle center. If the
workpiece is supported with a tailstock spindle center other than a live center, the
center will seize when the spindle is started, causing damage to the machine.
(Applies only to machines equipped with a tailstock.)

20. If the automatic operation (cycle start) switch is pressed at the background edit
screen under the conditions that the automatic operation (program) cycle has
completed and the memory mode is selected, the program called in the
foreground starts. Therefore, the machine operates in a manner different from
the program displayed on the screen (background area).

When mounting a rotary tool holder which is fixed on the turret head by bolting at two
faces, pay sufficient care on the order of tightening the bolts. If the tool holder is not
closely fit to the two mating faces of the turret head leaving a gap, accurate machining will
be impossible. (Applies only to milling specification.)

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FOR SAFE OPERATION -25-

4 SAFETY PRACTICES WHEN MOUNTING/REMOVING A CHUCK

WARNING

1. When mounting a chuck, chuck cylinder, or connection rod to the
spindle, read the instruction manuals provided by Mori Seiki, the
chuck manufacturer, and the chuck cylinder manufacturer. The
considerations that must be attended to are given in the instruction
manuals. If the chuck, chuck cylinder, or connection rod is mounted
to the spindle without understanding these considerations, the
chuck, chuck cylinder or connecting rod will be damaged, and if
machining is carried out after such damage has occurred, a
workpiece, the chuck, and/or chuck jaw could fly out, causing
accidents involving serious injuries or damage to the machine.

2. If a workpiece holding fixture other than the chuck supplied with the
machine is used, be sure to contact Mori Seiki to prevent accidents.
Mori Seiki is not responsible for accidents caused by the use of a
fixture prepared by the customer without consulting Mori Seiki.

3. If the chuck supplied with the machine is removed from the machine
and a specially prepared fixture is used instead of the chuck to hold
a workpiece, remove the chuck cylinder and the connecting rod if
they do not operate due to the mounting of the special fixture. If the
spindle is started wi th the ch uck cylinder and th e connecting rod still
mounted, the connecting rod will vibrate and the connecting r od and
the chuck cylinder could become detached, causing accidents
involving serious injuries or damage to the machine.

4. Leave the pilot bush mounted in the chuck.
If the machine is operated with the pilot bush removed, a master jaw
or a jaw of the chuck could fly out, causing accidents involving
serious injuries or damage to the machine.

5. The socket hole in the hex. socket head cap bolts used for mounting
chuck jaws and fixtures will become enlarged over a long period of
use. Check these hex. socket head cap bolts at regular intervals
and if a hex. wrench does not fit in the socket hole, replace the bolt
with new one.
If there is an excessive gap between the socket hole and hex.
wrench, the bolt cannot be torqued correctly. If the machine is
operated while a bolt is not torqued correctly, a workpiece, chuck
jaw or a fixture could fly out, causing accidents involving serious
injuries or damage to the machine.

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WARNING

6. The chuck or fixture that holds the workpiece must be secured to the
spindle using the threaded holes in the spindle nose. Do not mount
another chuck or fixtur e in a c huck or f ixture t hat is m ounted dire ctly
on the spindle. If a workpiece is held by a second chuck or fixture
mounted in this way, it will not be held securely when the spindle
rotates due to the centrifugal force acting on it, and the chuck or
fixture will fly out. This could cause accidents involving serious
injuries or damage to the machine.
If it is necessary to mount a chuck or fixture to hold a workpiece in
the chuck or a fixture which is directly mounted to the spindle,
contact Mori Seiki or the chuck manufacturer for the measures that
should be taken.

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