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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FOR SAFE OPERATION -27-

5 SAFETY PRACTICES WHEN CHUCKING A WORKPIECE

The workpiece gripping capacity of a chuck is lowered as the gripping faces of the chuck jaws
become worn. Furthermore, the workpiece holding capacity of the chuck jaws is greatly
influenced by the nature of the workpiece.

1. Heavy workpieces with a large diameter apply a large force to the chuck jaws and the force
applied to the chuck jaws can exceed their workpiece holding capacity in some cases.

2. As the spindle speed increases, the forces acting on the workpiece to cause it to fly out of
the chuck increase.

3. Improper maintenance, foreign matter, rusting, and inadequate greasing cause reduction of
the workpiece holding capacity of the chuck.
Finally, the machining method determines both the exact force that will be applied to the
workpiece and the chuck jaws, and whether this force exceeds the workpiece holding
capacity of the chuck jaws.
Therefore, review the workpiece holding capacity of the chuck each time the job changes or
at regular intervals if the same job is carried out continuously. Machining which generates
forces exceeding the workpiece holding capacity of the chuck will cause the workpiece to fly
out while the spindle is rotating, causing serious injuries or damage to the machine.

WARNING

1. A limit is imposed on chuck plunger thrust. If the plunger thrust
exceeds the allowable value, the chuck could be damaged and the
workpiece and chuck jaws could fly out of the chuck, causing
serious injuries or damage to the machine.
For the allowable plunger thrust, refer to the instruction manuals
prepared by the chuck and c ylinder manufacturers.

2. The allowable chucking pressure must be set to a value lower tha n
the cylinder pressure that generates the cylinder thrust allowable for
the chuck, or the allowable cylin der pressure, whiche ver is the lower.
If this restriction is not observed, the chuck and cylinder may be
damaged. If the damage occurs while the spindle is rotating, the
workpiece and chuck jaws will fly out, causing serious injuries or
damage to the machine.
For the allowable maximum pressure of the chuck or the cylinder,
refer to the instruction manuals prepared by the chuck and cylinder
manufacturers.

3. Use only the specifi ed bol ts to mount the chuck and ch u ck ja ws and
tighten them to the specified torque. Check at regular intervals that
the bolts are securely tightened. If the bolts are not tightened to the
specified torque the workpiece might fly out, causing serious
injuries or damage to the machine, and the chuck could be damaged.

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WARNING

4. If a thrust exceeding the allowable cylinder thrust is applied to the
chuck, the component parts or bolts of the chuck will be damaged,
causing loss of chuck gripping force. If this happens while the
spindle is rotating, the workpiece or chuck jaws will fly out, causing
serious injuries or damage to the machine.
For the allowable cylinder thrust, refer to the instruction manuals
prepared by the chuck and c ylinder manufacturers.

5. Take the height of the top jaw into consideration when determining
the chucking pressure. If the height is greater than the standard
height, reduce the cylinder thrust. If you f ail to observe this warnin g,
large forces will act on the top jaw mounting bolts and the master
jaw, which could cause damage to the top jaw or master jaw. If
trouble of this nature occurs while the spindle is rotating, the
workpiece or chuck jaws will fly out, causing serious injuries or
damage to the machine.
For the relationship between top jaw height and allowable cylinder
thrust, refer to the instruction manuals prepared by the chuck and
cylinder manufacturers.

6. When clamping or unclamping a workpiece in the chuck, ensure that
your hands will not be trapped by the workpiece, soft jaws, or
tailstock (if featured). If you work without sufficient care you could
be seriously injured.

7. When machining long workpieces, always hold the free end of the
workpiece securely with the tailstock (if featured) or a steady rest (if
featured). If you do not support the free end the workpiece could
bend or shake while the spindle is rotating, causing accidents
involving serious injuries or damage to the machine.

8. Before clamping a workpiece in the chuck, check using a pressure
gage that the correct hydraulic or air pressure is supplied to the
cylinder that actuates chuck operation. If no pr essure is supplied or
the pressure level is low, the workpiece will fly out when the spindle
is started, causing serious injuries or damage to the machine.

9. The T-nuts in the chuck must not protrude from the master jaw. If
they do the master jaw or T-nuts may be damaged, and machining
accuracy will be impaired. Breakage of the T-nuts or master jaw
while the spindle is rotating could cause accident s involving serious
injuries or damage to the machine.

10. Mount soft jaws in the chuck in a well-balanc ed manner. Poor
balance will cause runout of the spindle and could cause the soft
jaws to fly out while the spindle is rotating, causing serious injuries
or damage to the machine. It will also adversely affect machining
accuracy.

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FOR SAFE OPERATION -29-

WARNING

11. When clamping a workpiece in a 3-jaw chuck, the workpiece
(finished faces) cannot be clamped stably if contact is only made at
three points. If a workpiece is machined while clamped in this very
unstable way, it may fly out due to cutting resistance, causing
serious injuries or damage to the machine.
The workpiece must be clamped at six points, or with face contact
(jaws shaped to the shape of the workpiece).

12. Do not use top jaws with a serration of a different pitch from that of
the master jaws. If such top jaws are used, the serration may be
damaged when the workpiece is clamped in the chuck due to
insufficient length of the areas of engagement. If the spindle is
rotated af ter suc h damage has occurr ed, the workpie ce and top jaws
will fly out, causing serious injuries or damage to the machine.

13. Do not use excessively heavy jaws. If the spindle is rotated with top
jaws heavier than the standard soft or hard jaws fixed to the chuck,
the loss of chuck gripping force due to centrifugal force will be
larger than the loss seen with standard chuck jaws; the loss increase
is equal to the increase in centrifugal force corresponding to the
difference in mass between the standard and heavy jaws. If the
workpiece is machined under such conditions, it will fly out, causing
serious injuries or damage to the machine.

14. Always use the T-nuts specified by the chuck manufacturer. If the
bolts used to mount the top jaws cannot be screwed a sufficient
depth into the T-nuts, the T-nuts may break. Conversely, if the bolts
protrude past the bottom faces of the T-nuts, it will not be possible to
secure the top jaws by tightening the bolts . If one of these problems
exists while the spindle is rotating, the workpiece and top jaws will
fly out, causing serious injuries or damage to the machine.

15. Clamp workpieces at the center of the master jaws' stroke or within
their appropriate stroke range. If a workpiece is clamped in the
chuck with the jaws positioned near the stroke end it will not be
possible to clamp the workpiece securely and it may slip and fly out
of the chuck as a result of impact during cutting, causing serious
injuries or damage to the machine.'

16. The machine user must take responsibility for setting the rotational
speed of the chuck.
The allowable maximum speed of the chuck specified in the
instruction manual or catalog prepared by the chuck and cylinder
manufacturers is intended for reference purposes only. It will not
guarantee safety under all operating conditions. The appropriate
speed is influenced by the shape and mass of the top jaws, the
chuck gripping force, the workpiece dimensions and shape, cutting
force, and how the chuck is maintained and inspected. The machine
user has responsibility for all these factors. If the spindle is rotated
too fast under the given conditions the workpiece will fly out,
causing serious injuries or damage to the machine.

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WARNING

17. If there is a gap between the workpiece rear end face and the chuck
locator face or the jaw face on which the workpiece should be
seated, and the workpiece rotation center line is tilted with respect to
the chuck rotation center line, or if the workpiece has burrs on it
(cast or forged workpiece), the depth of cut will exceed the planned
amount and the cutting force will therefore exceed the workpiece
holding capacity of the chuck. If such conditions apply while the
spindle is rotating, the workpiece will fly out, causing serious
injuries or damage to the machine. If such a problem is anticipated,
carry out test cutting at a low spindle speed to ensure safety.

18. Never leave the top jaws and/or T-nuts in the chuck after they have
been loosened. If the spindle is started with the loose top jaws and
T-nuts left in the chuck they will fly out, causing serious injuries or
damage to the machine.

19. Lubricate the chuck every day with the specified grease. If the chuck
is not lubricated properly, problems such as reduced gripping force,
abnormal chuck jaw wear, and seizure will occur. If machining is
carried out under such conditions, the workpiece will fly out,
causing serious injuries or damage to the machine. Also note that
the use of grease other than the specified grade will accelerate
corrosion or wear, causing loss of gripping force.

20. Clean out any chips that accumulate inside the chuck.
Accumulation of chips inside the chuck reduces the gripping for ce
and shortens the jaw stroke. If machining is carried out under such
conditions the workpiece will fly out, causing serious injuries or
damage to the machine.

21. Give full consideration to the type of chuck and cylinder used when
setting the chucking pressure. Even if the same hydraulic pressure
is applied to the chuck, the chuck gripping force will vary according
to the manufacturer and type of chuck and cylinder.
For details on the chuck gripping force , consult the chuck and
cylinder manufacturers.
If the chuck gripping force is different from that intended, the
workpiece could fly out when the spindle is started, causing serious
injuries or damage to the machine.

22. Only a qualified technician should perform hoisting work.
Operation of the crane by a person unfamiliar with safe operation
practices could cause accidents involving serious injuries or
damage to the machine.

SO-NL-B9E/O

FOR SAFE OPERATION -31-

WARNING

23. When two or more people are involved in workpiece hoisting work,
they must cooperate carefully, communicating as fully as possible.
If one worker moves a machine element or operates the crane
without noticing that there is another worker inside or near the
machine, he could seriously injure that worker.

24. Use only wires, shackles and jigs of the dimensions specified in the
manual. They must be strong enough to support the weight of the
workpiece. If the workpiece is hoisted using equipment that cannot
bear its weight, it will fall, causing serious injuries or damage to the
machine.

25. Before lifting the workpiece, check that it is held securely. If it is not
it will fall when hoisted, causing serious injuries or damage to the
machine.

26. Make sure that the workpiece is well balanced in both the crosswise
and lengthwise directions after hoisting it a little above the floor. If
you continue to hoist the workpiece although it is not properly
balanced, it will fall, causing serious injuries or damage to the
machine.

27. Deburr soft jaws after shaping them. Switch off the power before
starting the deburring work. If you do not switch the power off the
machine could operate unexpectedly if someone carelessly
interferes with the machine controls, causing serious injuries or
damage to the machine.

28. Do not machine the counterbore depth of the soft jaw mounting
bolts. This will weaken the sof t jaws. In addition, t he mounting bolt s
will contact the bottom of the master jaw T groove, making it
impossible to hold the soft jaws securely . If machining is carried out
in this condition the workpiece and soft jaws will fly out, causing
accidents involving serious injuries or damage to the machine.

29. After forming soft jaws, close the front door while a workpiece is
gripped in the chuck, set the spindle speed setting switch to the
lowest setting, rotate the spindle in manual operation, gradually
increase the spindle speed to the maximum speed used in the
program, and check whether the workpiece gripping conditions are
appropriate: check that the workpiece does not come out of the
chuck, and that no vibration is generated. If machining is carried out
although the workpiece gripping conditions are inappropriate, the
workpiece will fly out, causing accidents involving serious injuries
or damage to the machine. It will also seriously affect machining
accuracy.

SO-NL-B9E/O

-32- FOR SAFE OPERATION

CAUTION

1. When soft jaws are used, they must be made of a softer material than the
workpiece. If they are harder, the workpiece could be distorted or scratched.

2. Do not modify the chuck unnecessarily since this will adversely affect accuracy
and functions and reduce the chuck service life.

3. When machining is carried out using a bar feeder or bar supporter, close the front
door while a workpiece is gripped in the chuck, set the spindle speed setting
switch to the lowest setting, rotate the spindle in manual operation, gradually
increase the spindle speed to the maximum speed used in the program, and
check if any vibration is generated, If there is any vibration, take the following
measures to eliminate it.

a. If bar materials to be machined is bent to an extent that exceeds the

allowable range specified by the bar feeder manufacturer, correct the bend.

b. Change the maximum spindle speed used in the program to a speed that

does not cause vibration of the machine body or the bar feeder.
c. Adjust the alignment of the machine and bar feeder.
d. Check that appropriate guide bushes are used in the spindle through-hole.

If the vibration cannot be eliminated by taking the measures listed above, contact
the bar feeder manufacturer or Mori Seiki. If machining is carried out under
vibration being generated, this will cause damage to the machine. It will also
seriously affect machining accuracy.

4. Never subject the chuck, chuck jaws, or workpiece to shock by tapping them with
a hammer, etc., since this will adversely affect accuracy and functions and reduce
the chuck service life.

5. When stopping the machine for a long time after switching the power off, always
remove the workpiece from a holding device. If the workpiece is left held in the
holding device after the power has been switched off, its weight will cause the
jaws of the chuck or fixture to open or the tailstock spindle or the tailstock body
(programmable tailstock specification) to retract if the workpiece is held using the
tailstock, and the workpiece will fall causing damage to the machine. Leaving the
workpiece in the holding device will give adverse affect to the life of the chuck
and the clamp mechanism of the tailstock.

6. Choose the machining conditions with particular care when shaping soft jaws,
since this work involves intermittent machining. Inappropriate machining
conditions could cause damage to the cutting tool or cause machining defects.

SO-NL-B9E/O

FOR SAFE OPERATION -33-

6 SAFETY PRACTICES DURING MACHINE OPERATION

WARNING

1. Do not insert bar stock into the spindle while the spindle is rotating
or you will be entangled in the machine. The length of the bar stock
must be shorter than the spindle length unless a bar feeder is used.
If the bar stock protrudes from the spindle it will increase spindle
runout, and could bend, causing accidents involving serious injuries
or damage to the machine.

2. While the spindle is rotating, never open the front door to remove
chips or touch the workpiece or cutting tools, since you could
become entangled in the machine and seriously injured. You may
also be injured by chips wrapped around the workpiece.

3. Do not lean against the machine while it is operating. If, for example,
the workpiece or chuck jaws fly out of the chuck and strike a cover
while you are leaning against it, you will receive the full impact of the
blow and be injured.

4. After completion of a cycle, always check that the cycle start
indicator is not lit and that the program end indicator is lit before
removing the machined workpiece and setting a new workpiece.
Remember that the program execution does not stop when a cycle is
completed and the machine could start operating and seriously
injure you.

5. Before pressing the automatic operation (cycle start) switch to start
automatic operation, make sure that the dry run function is invalid
(OFF) and that all other switches, such as the spindle override
switch, the rapid override switch, and the feedrate override switch
are set to the proper position. If automatic operation is started with
the dry run function valid (ON) or any of the override switches set
incorrectly, the axes could be fed in an unexpected manner and the
spindle could be rotated at an unexpected speed, causing accidents
involving serious injuries or damage to the machine.

6. Never leave any objects on any moving part of the machine. Objects
left on moving parts may be crushed, or may damage the machine.
In addition, objects left on top of the machine may fall off due to
machine vibration etc., injuring plant personnel.

7. A machine with special specifications must be operated in
accordance with those specifications. If it is operated incorrectly it
may operate in an unexpected manner, causing accidents involving
serious injuries or damage to the machine.

SO-NL-B9E/O

-34- FOR SAFE OPERATION

WARNING

8. Some switches have transparent covers to prevent them from being
pressed by mistake. Keep these covers closed except when actually
pressing the switches. If a switch cover gets broken contact Mori
Seiki.
If these covers are kept open or are removed and a switch is pressed
unintentionally, the machine will operate in an unexpected manner,
causing accidents involving serious injuries or damage to the
machine.

9. Pressing the feed hold switch during automatic operation stop s a xis
movement but does not stop spindle rotation. Therefore, select a
manual mode and confirm that spindle rotation has stopped before
opening the door. If you open the door while the spindle is rotating
you may be entangled with the spindle and seriously injured.

10. Always stop the machine before removing chips inside it during
operation. Also stop the machine and coolant supply before
adjusting the direction or volume of coolant supply. If you attempt
these operations while the machine is operating you could be
seriously injured by being entangled in the rev olving parts of the
machine or crushed by its moving parts.

11. Before opening the front door to remove chips from inside the
machine during machining operation, make sure that the door
interlock function is valid. After removing the chips, close the front
door before restarting machine operation. If the machine interlock
function is invalid, it will be possible to open the door while the
machine is operating, and this could cause accidents involving
serious injuries or damage to the machine.

12. Be aware that the machine will start automatic operation if the
automatic operation (cycle start) switch is pressed by mistake while
the conditions required to start automatic operation are satisfied and
an automatic mode is selected. If this switch is pressed carelessly,
automatic operation will start unexpectedly, and this could cause
accidents involving serious injuries or damage to the machine.

13. If the single block function is made valid during auto matic ope ration,
the next block is stored in the buffer register.
T o stop the process currently being executed in order to execute
another process in this condition (i.e., with the data for the nex t
block stored in the buffer register), clear the data in the buffer
register by pressing the reset key. If you attempt to execute another
process while the data is still stored in the buffer memory, the
machine will operate in an unexpected manner, and this could cause
accidents involving serious injuries or damage to the machine.

SO-NL-B9E/O

FOR SAFE OPERATION -35-

WARNING

14. While the machine is temporarily stopped during machining - for
example when checking a program, performing test cutting, or
cleaning chips out of the machine - do not feed the axes or index the
turret head in manual operation. Or, if it is absolutely necessary to
do so, be sure to return the axes and turre t to their original po sitions
before restarting the program. If machining is restarted without
returning them to their original positions, the turret will move in
unexpected directions, causing collisions between the cutting tools,
holders, or turret head and the workpiece, chuck, or tailstock (if
featured), which could cause serious operator injuries or damage
the machine. The workpiece could also be machined with the wrong
tool, and the cutting tool could be damaged.

15. Before switching the machine lock function from "valid" to "invalid",
wait until one program operation cycle has been completed. After
switching from "valid" to "invalid", always execute a zero return
operation. Switching between "valid" and "invalid" during program
execution will create a discrepancy between the position designated
in the program and the actual machine position, which could cause
accidents involving serious injuries or damage to the machine.

16. When carrying out unmanned operation over extended periods, or
machining using an inflammable coolant such as oil-based coolant
or an inflammable workpiece, there is a likelihood of fire to occur. If
a fire were to develop in the machine, it could cause accidents
involving serious injuries or damage to the machine.
Mori Seiki will not accept responsibility for the loss due to a fire.
Install automatic fire extinguishing equipment and operate the
machine using great caution for the prevention of fire.

17. If the door interlock function is "released" while the single block
function is valid, it constitutes very danger situation since the door
is unlocked permitting the door to be opened even while the
machine is operating, independent of the DOOR UNLOCK switch
state (lock or unlock), the selected mode, or executed operation
(automatic operation and manual operation). If the necessary
operation requires work to be carried out with the door open while
the machine is operating, this work must be limited only to that
which is absolutely necessary and must be carried out very
carefully.
Work which is carried out with the door open while the machine is
operating will cause injuries due to the operator being entangled in
the rotating p a rts of the machine, crushed by its moving par t s , being
struck by a workpiece or chuck jaws that have flown out of the
machine, or being splashed by chips and coolant.

SO-NL-B9E/O

-36- FOR SAFE OPERATION

CAUTION

1. Before starting mass production, always check the program and perform test
cutting in the single block mode. If you fail to do this the workpiece could collide
with the cutting tool during machining, causing damage to the machine.
Machining defects could also be caused.

2. In the case of machines that feature a hard-overtravel function, when a hard­overtravel alarm has occurred, the interlock axis movement interlock can be
released by pressing the 2nd O.T. release button. Be very careful not to move
the axis in the wrong direction after pressing this button. If the axis is fed further
in the direction in which hard overtravel occurred, the turret head and carriage
may collide with the covers, causing damage to the machine. For the sake of
safety, feed the axes using handle feed (1) until the hard-overtravel alarm has
been cleared.

3. Be aware that the program will be executed at an unexpected feedrate if the dry
run function is made valid mistakenly during automatic operation, and this could
cause damage to the machine.

4. When the EMERGENCY STOP button or reset key has been pressed to stop the
machine during a threading operation or a hole machining operation, especially a
tapping operation, carefully feed the axes after checking the workpiece and
cutting tool carefully for damage. If you feed the axes without due care, the
workpiec e an d cu t ti ng t oo l ma y c o ll id e or in te r fere with each o the r, and this could
cause damage to the machine.

5. Keep the chip conveyor operating all the time during automatic operation. If
chips accumulate on the conveyor it will not be possible to expel them and the
chip conveyor could be damaged. (Applies only to machines equipped with a
chip conveyor.)

6. Do not press the reset key during background editing since automatic operation
will be reset and the machine will stop suddenly: this could cause damage to the
machine.

7. Before positioning the saddle to join it with the tailstock, first retract the X-axis in
the positive direction so that the turret head and other machine elements will not
interfere with the tailstock when the saddle is moved to the joint position.
Interference could cause damage to the machine. (Applies only to machines with
a programmable tailstock.)

8. Check that no abnormal noise or vibration is generated during machine
operation. If there is any abnormal noise or vibration, determine the cause and
take appropriate action.
Continuing to operate the machine without taking any action could cause
machine faults. It will also adversely affect machining accuracy.

9. Never move the axes or rotate the turret head manually while the automatic
operation is temporarily stopped. If it becomes necessary to do these manually,
always return the axes or the turret to the previously located position before
restarting the automatic operation.
If the automatic operation is restarted after indexing other tool or without returning
to the previous position, a tool may be hit against the workpiece or the chuck, or
other problem may occur, causing damage to the machine.

SO-NL-B9E/O

FOR SAFE OPERATION -37-

CAUTION

10. If abnormal vibration or chattering is generated during machining due to improper
combination among jig, cutting tool, workpiece material, etc., change the
machining conditions to proper values. If machining is continued forcibly under
the machining conditions with improper values, it will bring critical problems for
the machine and accuracy such that the bearings is damaged quickly and cutting
tool is worn excessively will take place.

SO-NL-B9E/O

-38- FOR SAFE OPERATION

7 TO ENSURE HIGH ACCURACY

The accuracy of the finished product cannot be maintained unless the following points are
observed when operating the machine. Failure to observe these points can also cause accidents
involving serious injuries and damage to the machine. Study these points carefully before
operating the machine.

WARNING

1. Provide a chucking allowance that is large enough to ensure that the
workpiece will not come out of the chuck due to cutting forces or the
centrifugal force generated by spindle rotation. Depending on the
shape of the workpiece, it may need to be supported by the t a ilstock
(applies only to machines equipped with a tailstock). If the
workpiece flies out of the chuck during machining it could cause
serious injuries or damage to the machine.

2. If the center of gravity of the workpiece does not coincide with the
center of rotation for the chu ck (non-circular workpieces, eccentric
workpieces, etc.), fit a balancing weight to correct the balance and
choose mac hin in g co ndi tio ns such as spi ndl e sp eed car ef ull y. If the
workpiece is rotated without correcting the balance it could fly out of
the chuck, causing and serious injuries or damage to the machine.
Failure to correct the balance will also adversely affect machining
accuracy. If a balancer is fitted, do not rotate the spindle with no
workpiece mounted to it. This will cause wear or seizure of the
spindle bearing, causing machine faults.

3. Workpiece materials and shapes vary widely among machine users,
and Mori Seiki cannot predict the requirements for individual cases.
Give full consideration to the workpiece material and shape in order
to set the appropriate machining conditions. If inappropriate
settings are used, the workpiece or cutting tool could fly out during
machining, causing accidents involving serious injuries or damage
to the machine. Inappropriate settings will also adversely affect
machining accuracy.

CAUTION

SO-NL-B9E/O

When setting the tooling, refer to the turret interference diagram and axis travel
diagram in the maintenance manual (DRAWINGS or PARTS LIST published
separately) so as to avoid interference. In the case of machines with two spindles, also
make sure th er e will be no int erf eren ce d uri ng wo rkpi ec e tra nsf er. Careless tooling w ill
lead to interference between the tools and the workpiece, chuck, chuck jaws, covers,
tailstock (if featured) or headstock 2 (if featured), which could cause damage to the
machine.

FOR SAFE OPERATION -39-

NOTE

1. When chucking or supporting a workpiece, take the rigidity of the workpiece into
account when determining the chucking or supporting method and chucking
pressure or tailstock thrust force (if a tailstock is featured), so as not to distort the
workpiece. If the workpiece is distorted the machining accuracy will be adversely
affected.

2. If any chips become entangled with the workpiece or cutting tool, machining
accuracy will be adversely affected. Select a cutting tool and machining conditions
which do not cause entangling of chips.

3. When starting work and prior to machining, break in the spindle and each controlled
axis. Using the machine without breaking it in first will cause thermal displacement,
which will adversely affect machining accuracy.

8 PRECAUTIONS WHEN OPERATING SPECIAL SPECIFICATION

MACHINES

8-1 Industrial Robot Specification

WARNING

Only properly authorized persons trained and approved in accordance
with local regulations may operate robots.
Unauthorized persons may not operate a robot for any reason, including
teaching and inspection. Anyone working with the robot operators must
also be properly authorized.

8-2 Stacker Crane Specification

WARNING

The stacker crane used with the machine has a capacity of less than 5
tons. Only properly authorized persons may operate the stacker crane.

SO-NL-B9E/O

WARNING DISPLAY ON TURNING ON POWER -1-

WARNING DISPLAY ON TURNING ON POWER

The cautions to be observed in order to ensure safe machine operation are indicated on the
caution labels fixed at appropriate locations on the machine. They are also stated in the
Instruction Manual supplied with the machine.

Failure to follow these safety instructions will cause operator injuries and/or damage to the
machine. To impress upon the operator that the safety instructions must be strictly observed, a
message to this effect is displayed on the screen when the power is turned on.

The screen displays the message with the following contents when power is turned on:

(WARNING)

The machine is designed and manufactured
for well-trained operators who have a
basic knowledge of machine operation.
DO NOT operate this machine unless this
applies to you. To avoid accidents, you
are required to read and understand the
information on the caution labels, i n
the manuals and follow instructions
carefully. Failure to follow these
instructions may result in injury, or
damage to the machine. Being aware of
this warning, press [ OK ] soft-key.

The contents of the displayed message may vary depending on NC models.

NOTE

<Operation procedure>

CAUTION

1) Read and understand the contents of the message. Then, press the [OK] soft-key.

2) Turn the power on after that.

Before pressing the [OK] soft-key, read the message carefully.

For detail of turning on the power, refer to "Turning on the Power" in this
manual.

OMA-SC9405-A1E

-2- WARNING DISPLAY ON TURNING ON POWER

<For weekly timer specification>

In the case of machines equipped with the weekly timer, this message confirmation step after
turning on the power is not required in order to set the machine in the ready status to allow a cycle
start initiated by the weekly timer. In this case, cycle start by using the automatic operation switch

(cycle start) or manual operation is not possible.

To start the cycle by using the automatic operation switch (cycle start) or operate the

NOTE

machine manually, carry out the message confirmation step.

OMA-SC9405-A1E

PREFACE

This manual provides the information necessary to operate the machine. Information explained in
each chapter is briefly described below.

DOOR INTERLOCK FUNCTION:

CHAPTER A : OPERATION PANELS

CHAPTER B : MANUAL OPERATION

CHAPTER C : CHUCKING

The door interlock function is provided to ensure the operator's safety.
This chapter deals with the purpose and specifications of the door interlock function.
Before operating the machine, read this chapter carefully.

Switches used to turn on/off the power supply, the functions and operational procedure of
the switches and keys on the operation panel are explained.

The procedure used to turn on/off the power supply, and to stop the machine in emergency
cases are described.

This chapter also provides the procedure to feed the axes or to start/stop the spindle
manually.

This chapter explains the cautions for chucking a workpiece and the procedure for adjusting
the chucking pressure.

The soft jaw shaping procedure is also explained.

CHAPTER D : PROGRAM EDITING

This chapter explains the procedure used to input programs to the NC and to edit the
program stored in the NC memory. The procedure for inputting/outputting NC program
using an external I/O device is also explained. Note that the programming procedure is not
explained in this chapter, refer to the programming manual for the programming procedure.

CHAPTER E : SETTING OF COORDINATE SYSTEM

This chapter explains the coordinate system used in creating programs and machining
workpieces.
There are the following three kinds of coordinate system settings:

 The coordinate system set using the tool geometry offset function (G00 T_ ;)
 The coordinate system set using the coordinate system setting function (G50 X_ Z_ ;)
 The work coordinate system (G54 to G59)

The procedures for setting the above coordinate systems are explained.
The operating procedure for the manual in-machine tool presetter is also explained.

CHAPTER F : PREPARATION BEFORE STARTING MASS PRODUCTION

This chapter explains the procedures for checking a program and finishing a workpiece
within the specified tolerance before starting mass production. The checkups before starting
mass production are also explained.

SIGNAL WORD DEFINITION

A variety of symbols are used to indicate different types of warning information and advice.
Learn the meanings of these symbols and carefully read the explanation to ensure safe operation

while using this manual.

<Symbols related with warning>

The warning information is classified into three categories, DANGER, WARNING, and CAUTION.
The following symbols are used to indicate the level of danger.

DANGER

WARNING

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury or damages to the machine.

The information described following the caution symbol must be strictly observed.

<Other symbols>

Indicates the items that must be taken into consideration.

NOTE

Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.

The information described in the DANGER frame must be strictly
observed.

Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.

The information described in the WARNING frame must be strictly
observed.

Indicates useful guidance relating to operations.

Indicates the page number or manual to be referred to.
The number in ( ) indicates the section number.

Indicates the procedure used for displaying the required screen.

<Lamp indication>

Indicates that the indicator is lit.

Indicates that the indicator is blinking.

FLOW UNTIL THE PRODUCT IS COMPLETED

General operation flow to finish a product is shown below along with the reference sections.
Follow and understand the flow so that the operation can be performed smoothly.

Describes the instruction manual or item to be referred to.

1) Examine the drawing to determine the machining required

Production
planning and
programming

Setup operation

2) Determine the tools to be used

"TOOLING SYSTEM" in the

MAINTENANCE INFORMATION

3) Examine the workpiece clamping method and the fixtures

4) Create the program

5) Turn on the power supply

6) Store the program into memory

7) Creat e the program using the
conversational program min g func tio n

8) Check the program using the simulation function
(Correct the program if necessary)

9) Check or adjust the chucking pressure

10) Shape soft jaws

11) Mount the tools and workpiece to the machine

12) For the center-work, set the tailstock

Check or adjust the tailstock spindle thrust

PROGRAMMING MANUAL

"TURNING ON THE POWER" in Chapter B

Chapter D "PROGRAM EDITING"

OPERATION MANUAL FOR

CONVERSATIONAL PROGRAMMING

OPERATION MANUAL FOR

CONVERSATIONAL
PROGRAMMING

"ADJUSTING THE PRESSURE" in Chapter C

"Adjusting the Chucking Pressure" in Chapter C

"SHAPING SOFT JAWS FOR FINISHING in Chapter C

Chapter B "MANUAL OPERATION"

"TOOLING SYSTEM" in the
MAINTENANCE INFORMATION

"Tailstock Operation in Chapter B

"ADJUSTING THE PRESSURE" in
Chapter C
"Adjusting the Tailstock
Spindle Thrust" in Chapter C

Mass Production

13) Measure and input the tool geometry offset value

14) Set the workpiece zero point

Chapter E "SETTING OF COORDINATE SYSTEM"

15) Check the program by carrying out dry run

operation (Correct the program if necessary)

STARTING MASS PRODUCTION"

16) Check the machining condition by carrying out

test cutting (Correct the program if necessary)
(Input the tool wear offset value if necessary)

17) Machine the workpiece in automatic operation

18) Product is completed

-1-

Chapter E "SETTING OF

COORDINATE SYSTEM"

Chapter F "PREPARATION BEFORE

Chapter F "PREPARATION

BEFORE STARTING MASS
PRODUCTION"

NOTE

1. Operation steps 4) and 6) above should be skipped when a program is created using
the conversational programming function.

2. Operation step 7) above should be skipped when the conversational programming
function is not used for creating a program.

-2-

DOOR INTERLOCK FUNCTION

The door interlock function is provided to ensure the operator's safety while operating the
machine.

This chapter deals with the purpose and specifications of the door interlock function.
Before operating the machine, read this chapter carefully.

WARNING

The door interlock function serves only to ensure the safety of the
machine operator by inhibiting manual operations (spindle rotation,
axis feed, etc.) and all automatic operations when and while the door
is open with the interlock ON; it will not afford protection against
hazards that could occur as the result of erroneous operation.

If the door interlock function is released, single block operation, MDI
operation and all manual mode operations are permitted even when
the door is open, and if the door interlock function is released after
setting the single block function ON, the door can be opened even if
the machine is operating.

The customer must understand the specifications of the door
interlock function, recognize potential hazards, and operate the
machine with safety always in mind and without relying on the door
interlock function too much.

To ensure safety in operation, the customer is requested to promote
safety and not rely solely on the interlocks provided by the door
interlock function, e.g. by giving appropriate safety training to
operators and maintenance technicians, etc.

OMA-CENLFDILKB2-A1E

CONTENTS

DOOR INTERLOCK FUNCTION

1 DOOR INTERLOCK FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

2 DOOR INTERLOCK FUNCTION CONTROLS AND THE FUNCTIONS. . . . . . . . . . . . . P-4

3 PRECAUTIONS ON USING THE DOOR INTERLOCK FUNCTION. . . . . . . . . . . . . . . . P-9

4 USING THE DOOR INTERLOCK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-10

4-1 Door Interlock Function of Manual Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-11

4-2 Door Interlock Function of Automatic Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-15

4-2-1 For the Machine not Equipped with Robot. . . . . . . . . . . . . . . . . . . . P-15

4-2-2 For the Machine Equipped with Robot. . . . . . . . . . . . . . . . . . . . . . . P-19

5 DOOR LOCK AND UNLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-24

5-1 Lock and Unlock of Manual Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-24

5-1-1 Door Unlock Switch (Manual Door Type). . . . . . . . . . . . . . . . . . . . . P-25

5-1-2 Interlock when the Door Is Unlocked (Manual Door Type) . . . . . . . P-25

5-1-3 Releasing the Door Interlock Function (Manual Door Type) . . . . . . P-26

5-1-4 Emergency Stop and Door Unlock (Manual Door Type) . . . . . . . . . P-26

5-2 Lock and Unlock of Automatic Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-27

5-2-1 Opening/Closing the Door (Automatic Door Type). . . . . . . . . . . . . . P-28

5-2-2 Releasing the Door Interlock Function (Automatic Door Type) . . . . P-29

5-2-3 Emergency Stop and Door Unlock (Automatic Door Type) . . . . . . . P-30

5-3 Keeping the Door Unlocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-30

5-4 Door Unlock Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-31

1 DOOR INTERLOCK FUNCTION

This section describes the outline of the door interlock function and the potential hazards which
exist in the door interlock function.

The door interlock function is developed to ensure the operator's safety during machine operation.
Before starting the machine operation, make sure that the door interlock function is valid. When

the door interlock function is made valid, machine operation is enabled or disabled in response to
the closing or opening of the machine door. Spindle (or rotary tool spindle) rotation, turret
indexing, axis feed and other manual operations excluding mounting and removing of a workpiece
and all automatic operations are inhibited when and while the door is opened.

Although it is possible to release the door interlock function unavoidably, the operators must
understand that there are potential hazards, which will lead to serious injury or death, in carrying
out intended operation while the door is open. For this purpose, the indicator blinks in red and the
electronic buzzer beeps while the door interlock function is released.
This indicator and buzzer indication is given until the door interlock function is made valid again.
The operators must understand that there are various dangers when carrying out maintenance or
other work while the door interlock function is released and they must pay sufficient care under
such conditions. After completing the intended work with the door interlock function released,
make the door interlock function valid. Restart machine operation only after making sure that the
door interlock function is valid.

DOOR INTERLOCK FUNCTION P-1

For details of the operation of the door interlock function and the restrictions on
machine operation, refer to page P-10 (4).

For the potential hazards (accidents caused by improper operation and those occurring
unexpectedly) that will occur if the machine is operated with the door open, the caution label as
indicated below is attached to the machine (front) door so that the operator may recognize the fact
that the door must be kept closed.

Explanation concerning the potential hazards and the meaning of the caution
label is given in the brochure titled "SAFETY GUIDELINES".

(H42245)

(WARNING label "Do not operate without shutting door.")

P-2 DOOR INTERLOCK FUNCTION

<Potential hazards which are anticipated in the door interlock function and examples of
possible accidents>

1. When the door interlock function is "RELEASED"

2. When the single block function is set valid and the door interlock function is "RELEASED"
during automatic operatio n

When the door interlock function is "RELEASED" machine operation is permitted even when the
door is open. Due to this fact, the following human-caused or unexpected accidents described
below will occur.

In addition, with the door interlock function, if the single block function is made valid and the door
interlock function is "RELEASED" the door can be operated even while the machine is operating,
which causes the occurrence of the following human-caused or unexpected accidents described
below.

To prevent occurrence of such accidents and to allow safe operation of the machine, Mori
Seiki recommends to set the door interlock function to "VALID" when the machine is
operated.
Anticipated danger and possible accidents, which exist or will likely occur are described below.

WARNING

Customers will machine a variety of workpiece types, and will therefore
use a variety of workpiece holding fixtures and cutting tools. Cutting
methods and cutting conditions will also vary depending on the
customer's own know-how and Mori Seiki cannot predict the details of
machining in all cases. It is, therefore, the customer's responsibility to
determine the relevant factors and ensure safe operation by avoiding
dangers that will otherwise occurring in machining.

1. The operator will become entangled with the spindle
if the spindle starts while the operator is touching
the chuck or workpiece.

2. The operator will become entangled with the spindle
if the operator touches the chuck or the workpiece
while the spindle is rotating.

The accidents described above, in which the operator
becomes entangled with the rotating parts of the machine,
will result in serious injury or death.

DOOR INTERLOCK FUNCTION P-3

3. A workpiece will fly out if the spindle rotation is
started while the workpiece is not clamped correctly.

4. A workpiece and/or chuck jaw will fly out if the
cutting tool (turret) is hit against the workpiece due
to programming error.

5. A workpiece will fly out due to excessively heavy
cutting force or lowered workpiece gripping force of
the chuck caused by centrifugal force.

As described above, a workpiece or a chuck jaw,
disengaged from the chuck due to some reason, flies out
to hit the operator or a person standing near resulting in
serious injury or death.

6. The operator will be caught or entangled by moving
parts such as turret during axis feed or indexing
motions, resulting in serious injury or death.

7. The operator or a person standing near the machine
will be splashed with chips and coolant during
machining, resulting in injury or health problems
(particularly if chips or coolant get into the eyes).

P-4 DOOR INTERLOCK FUNCTION

2 DOOR INTERLOCK FUNCTION CONTROLS AND THE

FUNCTIONS

The machine is equipped with the controls, such as the DOOR INTERLOCK key-switch, the status
indicator, the electronic buzzer, and the caution label, used to operate the door interlock function.
It is also equipped with the door lock device which locks the door when the door is closed under
certain conditions.

This section explains the installation position of the controls related with the door interlock function
and the door lock device as well as the functions of the controls.

<Installation positions>

The switches and other controls for the door interlock function are mounted on the operation panel
and the door lock device is mounted to the door.

Operation panel

Door lock device

Door lock device

Open Close

The specifications and the installation positions of the door interlock function

NOTE

Top View

Door lock device

Screen

MDI Panel

Operation panel

Door

Front View

controls and the door lock device will vary according to the machine model and

Door unlock switch

specification. For details, contact Mori Seiki.

<Door interlock function controls>

Never operate without safety
door interlock switch

5. WARNING label

in "NORMAL" position.
Failure to do so could cause
serious injury or death.

DOOR INTERLOCK FUNCTION P-5

4. Volume adjusting knob

2. Status indicator

The arrangement of the controls for the door interlock function will vary according to the

NOTE

machine model and specification.

DOOR INTERLOCK

NORMAL RELEASE

1. DOOR INTERLOCK key-switch
(manual-return type)

P-6 DOOR INTERLOCK FUNCTION

The functions of the controls are summarized below:

No. Control Function

1. DOOR INTERLOCK
key-switch

DOOR INTERLOCK

NORMAL RELEASE

Makes the door interlock function valid, invalid (partly), and invalid.

<NORMAL>

When the DOOR INTERLOCK key-switch is placed in the
NORMAL position, the door interlock function is made valid.

Keep the DOOR INTERLOCK key-switch in the NORMAL
position.

<RELEASE>

When the DOOR INTERLOCK key-switch is placed in the
RELEASE position, the door interlock function is partially
made invalid.

Under such condition, there are potential hazards in
operating the machine. To warn this state, the status
indicator [INTERLOCK RELEASED] blinks in red and the
electronic buzzer beeps.

Pay suffici ent care if it becomes necessary to operate the
machine under such condition.

NOTE

1. Make sure that the status indicator [INTERLOCK
RELEASED] blinks in red and the electronic buzzer

beeps when the DOOR INTERLOCK key-switc h is
placed in the RELEASE position.

<Part No.>
E61133

2. If the disconnection of the status indicator or
electronic buzzer circuit is detected, the door
interlock function cannot be released even if the
DOOR INTERLOCK key-switch is placed in the
RELEASE position.

DOOR INTERLOCK FUNCTION P-7

No. Control Function

2. Status Indicator

<Part No.>
E54065

The status indicator blinks in red under any of the following
conditions to give warning (interlock released, or abnormal state) to
the operator.

1. The DOOR INTERLOCK key-switch is placed in the
RELEASE position.

2. The electronic buzzer circuit disconnection is detected.

3. An abnormal state of the control system of the door interlock
function is detected.

NOTE

1. The status indicator [INTERLOCK RELEASED]
blinks in red rapidly if the electronic buzzer circuit
disconnection or abnormal state of the control
system is detected, or if the power is turned on while
the DOOR INTERLOCK key-switch is in the
RELEASE position.

2. If power is turned on while the DOOR INTERLOCK
key-switch is in the RELEASE position, press the
EMERGENCY STOP button and return the DOOR
INTERLOCK key-switch into the NORMAL position.
After that turn on power again.

3. Electronic buzzer

<Part No.>
E36013

The electronic buzzer beeps under any of the following
conditions to give warning (interlock released, or abnormal state)
to the operator.

1. The DOOR INTERLOCK key-switch is placed in the
RELEASE position.

2. The status indicator circuit disconnection is detected.

3. An abnormal state of the control system of the door interlock
function is detected.

NOTE

1. The electronic buzzer beeps rapidly if the status
indicator circuit disconnection or abnormal state of
the control system is detected, or if the power is
turned on while the DOOR INTERLOCK switch is in
the RELEASE position.

2. If power is turned on while the DOOR INTERLOCK
key-switch is in the RELEASE position, press the
EMERGENCY STOP button and return the DOOR
INTERLOCK key-switch into the NORMAL position.
After that turn on power again.

3. The electronic buzzer is attached to the rear of the
WARNING label.

P-8 DOOR INTERLOCK FUNCTION

No. Control Function

4. Volume adjusting knob

Warning label

Electronic
buzzer

Volume adjusting knob

<Part No.>
E36013

5. WARNING label

<Part No.>

Japanese H45417
English H45418
German H45419
French H45420
Italian H45421
Spanish H45422
Portuguese H45423
Danish H45424
Dutch H45425
Swedish H45426
Norwegian H45427
Finnish H45428
Chinese H45429

The knob adjusts buzzer beep volume. Use a fine flat head
screwdriver to turn the adjusting knob from externals.

CW rotation: Increases volume.
CCW rotation: Decreases volume.
The knob is set at 40

G position in the CW direction from the

minimum volume position.

CAUTION

Do not decrease volume excessive ly.
If buzzer beeps only faintly, the warning beeps might
not be recognized during interlock release or abnormal
state, constituting hazards.

The caution label gives information related with the door interlock
function.

Read and follow the instruction printed on the label.

CAUTION

Never remove or make the label dirty.
Place an order with Mori Seiki for the label, if the letters
on the label become dirty, or if the label is damaged or
lost.
Use the WARNING label in the language
understandable to the operators.

The <Part No.> indicates the part number of each component parts. Use these numbers

NOTE

to order the controls if they are damaged, or if the label become dirty, damaged, or lost.

DOOR INTERLOCK FUNCTION P-9

3 PRECAUTIONS ON USING THE DOOR INTERLOCK FUNCTION

This section indicates the items to be carefully attended to when using the door interlock function.
Please read carefully and understand the cautionary items indicated below.

WARNING

CAUTION

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 int erlock func tion 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 data, 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 inter mittently. You must recognize that
the door interlock function is in the released state if 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".

1. If disconnection of the status indicator circuit or the electronic buzzer circuit is
detected, or if abnormality of the door interlock control system is found, contact
Mori Seiki.

Remove the cause of the abnormality, and turn on power supply after pressing
the EMERGENCY STOP button or turning off power supply once, then the error
indication will be cleared.

2. If power is turned on while the DOOR INTERLOCK key-switch is set in the
RELEASE position, the status indicator [INTERLOCK RELEASED] blinks in red
and the electronic buzzer beeps rapidly to warn that the machine is in the
abnormal state.

1) Return the key-switch to the NORMAL position.

2) Press the EMERGENCY STOP button and turn off power.

3) Turn on power again.

In the Mori Seiki's OPERATION MANUALs, all operation procedures are explained

NOTE

assuming that the door interlock function is valid and the door is closed.

P-10 DOOR INTERLOCK FUNCTION

4 USING THE DOOR INTERLOCK FUNCTION

This section describes how the door interlock function should be used for the machine equipped
with a manual door and also for the machine equipped with an automatic door.

1. Door interlock function for the machine equipped with a manual door
Page P-11 (4-1)

2. Door interlock function for the machine equipped with an automatic door
Page P-15 (4-2)

The automatic door is optional. When the machine is equipped with the automatic door,

NOTE

the door interlock function operates in different manner between the machine not
equipped with a robot (operation is assumed to be performed by an operator) and the
machine equipped with a robot (operation is assumed to be performed by the robot).
Refer to the manual dealing with the machine of the same type as installed to the
customer's shop.

WARNING

If the door interlock function is "released", this constitutes a very
dangerous situation since the following operations are permitted, which
may lead to injuries.

1. Even when the door is open, automatic operati on with the si ngle
block function valid (single block operation) is permitted.

2. Even when the door is open, automatic operation is permitted under
the MDI mode (MDI mode operation).

3. Even when the door is open, all operations are permitted in the
manual mode.

4. If the door interlock function is "released" while the single block
function is valid, the door is unlocked permitting the door to be
opened even while the machine is operating, independent of the
selected mode or the operation presently carried out (automatic
operation, manual operation).

To ensure safety in operation, the customer is requested to promote
safety and not rely solely on the interlocks provided by the door interlock
function, e.g. by giving appropriate safety training to operators and
maintenance technicians, etc.

If the necessary operation requires work to be carried out with the door
open or the door to be opened while the machine is operating after
releasing the door interlock function, this work must be limited only to
that which is absolutely necessary and must be carried out very carefully.

Mori Seiki recommends the customer to use the machine with the door closed and the
door interlock function valid.

4-1 Door Interlock Function of Manual Door

The specifications of the available door interlock function for the machines equipped with the
manual door are explained in details below along with the procedure for using the door interlock
function.

<Manual and automatic operation (door interlock function valid)>

DOOR INTERLOCK FUNCTION P-11

DOOR INTERLOCK

NORMAL

RELEASE

If the DOOR INTERLOC K key- switch is p lac ed in the NORMAL position
while the door is open, only the following manual operations are
permitted.

1. Inching and IN/OUT operation of the tailstock spindle (tailstock
specification)

CAUTION

When holding a workpiece using the tailstock, do not move
the tailstock spindle out in the tailstock spindle "out"
operation without first making sure that your hand will not be
caught by the tailstock spindle. If the tailstock spindle is
moved out without taking adequate care, there is a danger
that your hand will be caught between the tailstock spindle
and the workpiece.

2. Clamp/unclamp operation of the chuck

3. Changing the spindle speed range to the neutral (transmission
specification)

All operations are enabled when the door is closed.

P-12 DOOR INTERLOCK FUNCTION

<Manual and automatic operation (door interlock function released)>

DOOR INTERLOCK

NORMAL RELEASE

Automatic operation

Rotation of spindle
(rotary tool spindle

Jogging of spindle
(rotary tool spindle

Turret indexing Possible

Manual
operation

Axis feed
Coolant supply Possible

If the DOOR INTERLOCK key-switch is placed in the RELEASE
position while the door is open, automatic operation is permitted
conditionally.
In manual operations, there are no restrictions with an exception that
rapid traverse rate for axis movement is clamped at a certain value.

Door Opened

Status

DOOR INTERLOCK
key-switch: RELEASE

Possible under certain conditions

*1

)

*1

)

Possible

Possible

Possible under certain conditions

*2

*3

NOTE

Chip conveyor
C-axis selection
Spindle gear range change

*1

Some of specifications and options may not be featured on your machine,

*1

*1

*1

Possible
Possible
Possible

depending on the model and specifications.

*2

Automatic operation is possible only while the single block function is valid or MDI
mode is select ed.

For the machine equipped with the loader, even if the workstocker front door is open,
automatic operation is possible while the single block function is valid or MDI mode
is selected.

*3

Rapid traverse rate for rapid traverse operation and that in zero return operation are
clamped at 5 m/min. For jog and manual pulse generator feed operation, no such
restriction is provided.

DOOR INTERLOCK FUNCTION P-13

<Restrictions on operations>

1. With the door opened, it is possible to carry out such operations as shaping soft jaws and
measuring the tool offset data by rotating the spindle and indexing the turret head in the
manual mode (handle, jog, rapid traverse, zero return).

NOTE

1. Since the rapid traverse rate of the axis which has the fastest rapid traverse rate is
clamped at 5 m/min, the clamp feedrate of other axes may be lower than 5 m/min.

2. When moving an axis after releasing the door interlock function, if the DOOR
INTERLOCK key-switch is placed in the NORMAL position while the axis is moved
at a rate faster than 500 mm/min, the door interlock function becomes valid and the
axis is stopped . In this case, excessive servo error alarm may occur.

This alarm does not occur when the DOOR INTERLOCK key-switch is placed in the
NORMAL position after axis movement is stopped by releasing the axis feed switch.

2. With the door opened, it is possible to check the program or carry out test cutting in the
memory (tape) mode by making the single block function valid.

If automatic operation is executed with the door open and the single block function set

NOTE

valid, rapid traverse rate is clamped at 5 m/min. For cutting feedrate, no such restriction
applies.

For the machine equipped with the loader, the axis feedrate of the loader is also clamped
at 5 m/min.

3. With the door opened, it is possible to execute the MDI mode operation.

<Precautions on automatic operation>

If the single block function is made invalid during automatic operation under the following

NOTE

conditions, the machine is placed in the feed hold mode and the error message is
displayed (EX2029 CYCLE START PERMISSION IMPERFECT).

 The door is open.
 The DOOR INTERLOCK key-switch is placed in the RELEASE position.
 The single block function is valid.

The machine can restart by pressing the automatic operation (cycle start) after making the
single block function valid.

P-14 DOOR INTERLOCK FUNCTION

<Potential hazards>

Please also refer to pages 2 and 3, where several examples of potential hazards and
possible accidents are described.

WARNING

If the door interlock function is "released", this constitutes a very
dangerous situation since single block operation, MDI operation and
manual operations (restriction applies on rapid traverse rate for axis
movement) are permitted while the door is open, which may lead to
injuries.

If the door interlock function is "released" while the single block function
is valid, the following danger exists since the door is unlocked permitting
the door to be opened even while the machine is operating, independent
of the selected mode or the operation presently carried out (automatic
operation, manual operation).

Since serious human accidents including death could be caused due to
the danger described above, sufficient care must be paid.
Anticipated danger and possible accidents, which exist or will likely occur,
are described below.

1. The operator becomes entangled in the rota ting p arts of the machine
because the spindle starts rotating while the operator is touching the
chuck or the workpiece or the operat o r touches the chuck or the
workpiece while the spindle is rotating.

2. A workpiece or chuck jaw that becomes disengaged from the chuck
while the spindle is rotating due to some reason (e.g. mischucking,
lowered workpiece gripping force caused by excessively heavy
cutting force or centrifugal force, interference of a cutting tool with
the workpiece caused by programming error or incorrect program
check) flies out and strikes the operator or a person standing nearby .

3. The operator is caught by, or entangled in, the moving or rotating
turret.

4. The hand or foot of an operator comes into contact with the chip
conveyor while it is operating and becomes entangled with the
conveyor.

5. The operator or a person standing near the machine is splashed with
chips and coolant, or chips and coolant get into the eyes.

For other danger, the customer is required to pay due attention.

4-2 Door Interlock Function of Automatic Door

The specifications of the available door interlock function for the machine equipped with the
automatic door are explained in details below along with the procedure for using the door interlock
function.

The automatic door is optional. When the machine is equipped with the automatic door,

NOTE

the door interlock function operates in different manner between the machine not
equipped with a robot (operation is assumed to be performed by an operator) and the
machine equipped with a robot (operation is assumed to be performed by the robot).
Refer to the manual dealing with the machine of the same type as installed to the
customer's shop.

4-2-1 For the Machine not Equipped with Robot

The specifications of the available door interlock function for the machine equipped with the
automatic door (without robot), which is assumed to be operated by an operator, are explained in
details below along with the procedure for using the door interlock function.

DOOR INTERLOCK FUNCTION P-15

<Manual operation (door interlock function valid)>

DOOR INTERLOCK

NORMAL

RELEASE

If the DOOR INTERLOC K key- switch is p lac ed in the NORMAL position
while the door is open, only the following manual operations are
permitted.

1. Inching and IN/OUT operation of the tailstock spindle (tailstock
specification)

CAUTION

When holding a workpiece using the tailstock, do not move
the tailstock spindle out in the tailstock spindle "out"
operation without first making sure that your hand will not be
caught by the tailstock spindle. If the tailstock spindle is
moved out without taking adequate care, there is a danger
that your hand will be caught between the tailstock spindle
and the workpiece.

2. Clamp/unclamp operation of the chuck

3. Changing the spindle speed range to the neutral
(transmission specification)

All operations are enabled when the door is closed.

<Automatic operation (door interlock function valid)>

DOOR INTERLOCK

NORMAL

RELEASE

If the DOOR INTERLOCK key-switch is placed in the NORMAL
position, automatic operation can be executed even while the door is
open. However, the codes executable with the door opened are
restricted to M00, M01, M02, M30, and automatic door open/close M
codes (M85/M86), and other M codes, S codes, T codes and axis
movement commands cannot be executed unless the door is closed.

P-16 DOOR INTERLOCK FUNCTION

<Manual and automatic operation (door interlock function released)>

DOOR INTERLOCK

NORMAL RELEASE

Automatic operation

Rotation of spindle
(rotary tool spindle

Jogging of spindle
(rotary tool spindle

Turret indexing Possible

Manual
operation

Axis feed
Coolant supply Possible

If the DOOR INTERLOCK key-switch is placed in the RELEASE
position while the door is open, automatic operation is permitted
conditionally. In manual operations, there are no restrictions with an
exception that rapid traverse rate for axis movement is clamped at a
certain value.

Door Opened

Status

DOOR INTERLOCK
key-switch: RELEASE

Possible under certain conditions

*1

)

*1

)

Possible

Possible

Possible under certain conditions

*2

*3

NOTE

Chip conveyor
C-axis selection
Spindle gear range change

*1

Some of specifications and options may not be featured on your machine,

*1

*1

*1

Possible
Possible
Possible

depending on the model and specifications.

*2

Automatic operation is possible only while the single block function is valid or MDI
mode is select ed.

For the machine equipped with the loader, even if the workstocker front door is open,
automatic operation is possible while the single block function is valid or MDI mode
is selected.

*3

Rapid traverse rate for rapid traverse operation and that in zero return operation are
clamped at 5 m/min. For jog and manual pulse generator feed operation, no such
restriction is provided.

DOOR INTERLOCK FUNCTION P-17

<Restrictions on operations>

1. With the door opened, it is possible to carry out such operations as shaping soft jaws and
measuring the tool offset data by rotating the spindle and indexing the turret head in the
manual mode (handle, jog, rapid traverse, zero return).

NOTE

1. Since the rapid traverse rate of the axis which has the fastest rapid traverse rate is
clamped at 5 m/min, the clamp feedrate of other axes may be lower than 5 m/min.

2. When moving an axis after releasing the door interlock function, if the DOOR
INTERLOCK key-switch is placed in the NORMAL position while the axis is moved
at a rate faster than 500 mm/min, the door interlock function becomes valid and the
axis is stopped . In this case, excessive servo error alarm may occur.

This alarm does not occur when the DOOR INTERLOCK key-switch is placed in the
NORMAL position after axis movement is stopped by releasing the axis feed switch.

2. With the door opened, it is possible to check the program or carry out test cutting in the
memory (tape) mode by making the single block function valid.

If automatic operation is executed with the door open and the single block function set

NOTE

valid, rapid traverse rate is clamped at 5 m/min. For cutting feedrate, no such restriction
applies.

For the machine equipped with the loader, the axis feedrate of the loader is also clamped
at 5 m/min.

3. With the door opened, it is possible to execute the MDI mode operation.

<Precautions on automatic operation>

If the single block function is made invalid during automatic operation under the following

NOTE

conditions, the machine is placed in the feed hold mode and the error message is
displayed (EX2029 CYCLE START PERMISSION IMPERFECT).

 The door is open.
 The DOOR INTERLOCK key-switch is placed in the RELE ASE position.
 The single block function is valid.

The machine can restart by pressing the automatic operation (cycle start) after making the
single block function valid.

P-18 DOOR INTERLOCK FUNCTION

<Potential hazards>

Please also refer to page 2 and 3, where several examples of potential hazards and
possible accidents are described.

WARNING

If the door interlock function is "released", this constitutes a very
dangerous situation since single block operation, MDI operation and
manual operations (restriction applies on rapid traverse rate for axis
movement) are permitted while the door is open, which may lead to
injuries.

If the door interlock function is "released", and the automatic door open
command (M85 or AUTOMATIC DOOR OPEN switch) is given while the
single block function is valid, t he following danger ex ist s since the door is
unlocked permitting the door to be opened even while the machine is
operating, independent of the selected mode or the operation presently
carried out (automatic operation, manual operation).

Since serious human accidents including death could be caused due to
the danger described above, sufficient care must be paid. Anticipated
danger and possible accidents, which exist or will likely occur, are
described below.

1. The operator becomes entangled in the rota ting p arts of the machine
because the spindle starts rotating while the operator is touching the
chuck or the workpiece or the operat o r touches the chuck or the
workpiece while the spindle is rotating.

2. A workpiece or chuck jaw that becomes disengaged from the chuck
while the spindle is rotating due to some reason (e.g. mischucking,
lowered workpiece gripping force caused by excessively heavy
cutting force or centrifugal force, interference of a cutting tool with
the workpiece caused by programming error or incorrect program
check) flies out and strikes the operator or a person standing nearby .

3. The operator is caught by, or entangled in, the moving or rotating
turret.

4. The hand or foot of an operator comes into contact with the chip
conveyor while it is operating and becomes entangled with the
conveyor.

5. The operator or a person standing near the machine is splashed with
chips and coolant, or chips and coolant get into the eyes.

For other danger, the customer is required to pay due attention.

4-2-2 For the Machine Equipped with Robot

The specifications of the available door interlock function for the machine equipped with the
automatic door, which is assumed to be operated according to the robot operation, are explained
in details below along with the procedure for using the door interlock function.

<Manual operation (door interlock function valid)>

DOOR INTERLOCK FUNCTION P-19

DOOR INTERLOCK

NORMAL

RELEASE

If the DOOR INTERLOC K key- switch is p lac ed in the NORMAL position
while the door is open, only the following manual operations are
permitted.

1. Inching and IN/OUT operation of the tailstock spindle (tailstock
specification)

CAUTION

When holding a workpiece using the tailstock, do not move
the tailstock spindle out in the tailstock spindle "out"
operation without first making sure that your hand will not be
caught by the tailstock spindle. If the tailstock spindle is
moved out without taking adequate care, there is a danger
that your hand will be caught between the tailstock spindle
and the workpiece.

2. Clamp/unclamp operation of the chuck

3. Changing the spindle speed range to the neutral (transmission
specification)

All manual operations are enabled when the machine door is closed.

P-20 DOOR INTERLOCK FUNCTION

<Automatic operation (door interlock function valid)>

DOOR INTERLOCK

NORMAL

RELEASE

Checking "door open"

Robot fence

The explanation is given below assuming that the robot fence is
installed as shown in the illustration below.

When the DOOR INTERLOCK key-switch is placed in the NORMAL
position, contents of operation differ depending on whether or not the
robot fence door is open.

Automatic door

Checking "door close"
(with lock device)

Machine

Robot

Checking "robot fence door close"

Operation panel

Close

Robot fence door

Open

1. If the robot fence door is open
Automatic operation can be executed even while the machine door is open. However, the

codes executable with the machine door opened are restricted to M00, M01, M02, M30, and
automatic machine door open/close M codes (M85/M86), and other M codes, S codes, T
codes and axis movement commands cannot be executed unless the machine door is
closed.

2. If the robot fence door is closed
Automatic operation (includes MDI mode operation) can be executed while the machine

door is open under the following restrictions.

a. Spindle start command (M03, M04) cannot be executed.
b. Rotary tool spindle start command (M13, M14) cannot be executed.

DOOR INTERLOCK FUNCTION P-21

<Manual and automatic operation (door interlock function released)>

DOOR INTERLOCK

NORMAL RELEASE

If the DOOR INTERLOCK key-switch is placed in the RELEASE
position while the machine door is open, automatic operation is
permitted conditionally.

In manual operations, there are no restrictions with an exception that
rapid traverse rate for axis movement is clamped at a certain value.

The following table shows the permitted and prohibited operations if the DOOR INTERLOCK key­switch is placed in the RELEASE position while the machine door is open.

Door Opened

Status

DOOR INTERLOCK
key-switch: RELEASE

Automatic
operation

Robot fence door open
Robot fence door close

Possible under certain conditions
Possible under certain conditions

*2

*2

Rotation of spindle
(rotary tool spindle

*1

)

Possible

Jogging of spindle
(rotary tool spindle

*1

)

Possible

Manual
operation

NOTE

Turret indexing Possible
Axis feed

Possible under certain conditions

Coolant supply Possible
Chip conveyor
C-axis selection
Spindle gear range change

*1

Some of specifications and options may not be featured on your machine,

*1

*1

*1

Possible
Possible
Possible

depending on the model and specifications.

*2

Automatic operation is possible only while the single block function is valid or MDI
mode is select ed.

*3

Rapid traverse rate for rapid traverse operation and that in zero return operation are
clamped at 5 m/min. For jog and manual pulse generator feed operation, no such
restriction is provided.

*3

P-22 DOOR INTERLOCK FUNCTION

<Restrictions on operations>

1. With the machine door opened, it is possible to carry out such operations as shaping soft
jaws and measuring the tool offset data by rotating the spindle and indexing the turret head
in the manual mode (handle, jog, rapid traverse, zero return).

NOTE

1. Since the rapid traverse rate of the axis which has the fastest rapid traverse rate is
clamped at 5 m/min, the clamp feedrate of other axes may be lower than 5 m/min.

2. When moving an axis after releasing the door interlock function, if the DOOR
INTERLOCK key-switch is placed in the NORMAL position while the axis is moved
at a rate faster than 500 mm/min, the door interlock function becomes valid and the
axis is stopped . In this case, excessive servo error alarm may occur.

This alarm does not occur when the DOOR INTERLOCK key-switch is placed in the
NORMAL position after axis movement is stopped by releasing the axis feed switch.

2. With the machine door opened, it is possible to check the program or carry out test cutting in
the memory (tape) mode by making the single block function valid.

If automatic operation is executed with the machine door open and the single block

NOTE

function set valid, rapid traverse rate is clamped at 5 m/min. For cutting feedrate, no such
restriction applies.

3. With the machine door opened, it is possible to execute the MDI mode operation.

<Precautions on automatic operation>

If the single block function is made invalid during automatic operation under the following

NOTE

conditions, the machine is placed in the feed hold mode and the error message is
displayed (EX2029 CYCLE START PERMISSION IMPERFECT).

 The machine door is open.
 The DOOR INTERLOCK key-switch is placed in the RELEASE position.
 The single block function is valid.

The machine can restart by pressing the automatic operation (cycle start) after making the
single block function valid.

<Potential hazards>

Please also refer to page 2 and 3, where several examples of potential hazards and
possible accidents are described.

DOOR INTERLOCK FUNCTION P-23

WARNING

If the door interlock function is "released", this constitutes a very
dangerous situation since single block operation, MDI operation and
manual operations (restriction applies on rapid traverse rate for axis
movement) are permitted while the machine door is open, which may lead
to injuries.

If the door interlock function is "released", and the automatic door open
command (M85 or AUTOMATIC DOOR OPEN switch) is given while the
single block function is valid, the following danger exists sinc e the
machine door is unlocked permitting the machine door to be ope ned even
while the machine is operating, independent of the selected mode or the
operation presently carried out (automatic operation, manual operation).

Since serious human accidents including death could be caused due to
the danger described above, sufficient care must be paid. Anticipated
danger and possible accidents, which exist or will likely occur, are
described below.

1. The operator becomes entangled in the rota ting p arts of the machine
because the spindle starts rotating while the operator is touching the
chuck or the workpiece or the operat o r touches the chuck or the
workpiece while the spindle is rotating.

2. A workpiece or chuck jaw that becomes disengaged from the chuck
while the spindle is rotating due to some reason (e.g. mischucking,
lowered workpiece gripping force caused by excessively heavy
cutting force or centrifugal force, interference of a cutting tool with
the workpiece caused by programming error or incorrect program
check) flies out and strikes the operator or a person standing nearby .

3. The operator is caught by, or entangled in, the moving or rotating
turret.

4. The hand or foot of an operator comes into contact with the chip
conveyor while it is operating and becomes entangled with the
conveyor.

5. The operator or a person standing near the machine is splashed with
chips and coolant, or chips and coolant get into the eyes.

For other danger, the customer is required to pay due attention.

P-24 DOOR INTERLOCK FUNCTION

5 DOOR LOCK AND UNLOCK

This section describes how the door is locked and unlocked for the machine equipped with a
manual door and the machine equipped with the automatic door.

1. Lock and unlock of manual door
Page P-24 (5-1)

2. Lock and unlock of automatic door
Page P-27 (5-2)

The automatic door is optional.

NOTE

5-1 Lock and Unlock of Manual Door

For the machine equipped with the manual door, the door is locked and cannot be opened when
the door is closed with the indicator above the DOOR UNLOCK switch not lit. To open the door,
unlock the door by using the DOOR UNLOCK switch.

WARNING

If the door interlock function is "released" while the single block function
is valid, it constitutes very danger situation since the door is unlocked
permitting the door to be opened even while the machine is operating,
independent of the DOOR UNLOCK switch position (lock or unlock) or the
selected mode. If the necessary operation requires work to be carried out
with the door open while the machine is operating, this work must be
limited only to that which is absolutely necessary and must be carried out
very carefully.

Work which is carried out with the door open while the machine is
operating will cause injuries due to the operator being entangled in the
rotating part s of t he machine, crushed by it s moving p art s, being struck by
a workpiece or chuck jaws that have flown out of the machine, or being
splashed by chips and coolant.

NOTE

1. The machine recognizes that the door is closed when the door is closed and locked.
Even if the door is closed, the machine does not recognize it closed unless it is
locked. Such status is recognized as the door is open.

In the manuals published by Mori Seiki, the expression "door is closed" means that
the door is closed and locked.

2. When power is turned on, the NC checks the functions of the door lock device and
those of the contactor for spindle/axis drive motors.
After turning on the power, open the door once and close it again. The machine
does not get ready unless the door is opened and closed after turning on power.

5-1-1 Door Unlock Switch (Manual Door Type)

DOOR INTERLOCK FUNCTION P-25

DOOR UNLOCK

The DOOR UNLOCK switch, provided on the operation
panel, is used to release the door lock device.

NOTE

1. The door cannot be opened unless the door
lock is released.

2. Switch configuration may differ depend in g
on the mach ine.

3. With the automatic door type machine, this
switch has no function even when it is
pressed.

Door Function

When the DOOR UNLOCK switch is pressed, the indicator of the switch is lit and the
door lock is released. The door can be opened in this state.

The door lock is also released when the M02 or M30 command in a program is read.

Unlock

The status indicator of the switch is lit and the door can be opened.

Even if the M02 or M30 command is executed in the MDI mode, the door lock

NOTE

cannot be released.

When the DOOR UNLOCK switch is pressed while the indicator of the switch is lit with
the door closed, the indicator goes off and the door is locked. In this state, the door
cannot be opened.

Lock

If the door is closed again after being opened once, the indicator of the switch
goes off and the door is locked.

5-1-2 Interlock when the Door Is Unlocked (Manual Door Type)

The door cannot be unlocked even when the DOOR UNLOCK switch is pressed under the
following status.

1. While the spindle (rotary tool spindle) is rotating

2. During automatic operation

3. During turret head indexing

4. Parts catcher extended (parts catcher specification)

5. While the spindle mode is being changed to the C-axis (milling specification)

6. While the spindle range is being changed (transmission specification)

P-26 DOOR INTERLOCK FUNCTION

5-1-3 Releasing the Door Interlock Function (Manual Door Type)

If it becomes necessary to carry out a work with the door opened after releasing the door interlock
function, follow the steps indicated below.

DOOR UNLOCK

DOOR INTERLOCK

NORMAL RELEASE

1) Press the DOOR UNLOCK switch.
The indicator of the switch is lit and the door lock is

released.

2) Open the door.

3) Place the DOOR INTERLOCK key-switch in the
RELEASE position.

4) Set the single block function ON for executing an
automatic operation to check the program or carry
out test cutting.

5) Carry out necessary work.

If the DOOR INTERLOCK key-switch is placed in

NOTE

the NORMAL positio n while carrying out operation
in the door interlock released state, all machine
operations stop.

6) After completing the necessary work, set the door
interlock function ON.

DOOR INTERLOCK

NORMAL RELEASE

a) Place the DOOR INTERLOCK key-switch in

the NORMAL position.

b) Return the single block function to invalid if the

operation has been executed with the single
block function set ON.

c) Close the door.

The indicator of the DOOR UNLOCK switch goes of f
and the door is locked.

5-1-4 Emergency Stop and Door Unlock (Manual Door Type)

When the machine enters the emergency stop state, the door is placed in the unlocked state.
When the emergency stop state is reset while the door is closed (not locked), the door is locked.

If the emergency stop state is reset while the door is open, the following message is

NOTE

displayed.
"EX4002 OPEN THE DOOR TH EN CLOSE"
In this case, the alarm is released when the door is closed and locked.

5-2 Lock and Unlock of Automatic Door

For the machine equipped with the automatic door, the door is locked and cannot be opened when
the door is closed. T o open the door, either execute the door open M code (M85) in the automatic
operation mode (includes MDI mode) or open it manually in the manual mode using the
AUTOMATIC DOOR OPEN switch. By the execution of the M85 code or by the operation of the
AUTOMATIC DOOR OPEN/CLOSE switch, the door is unlocked and opened.

DOOR INTERLOCK FUNCTION P-27

NOTE

1. The automatic door is optional.

2. The machine recognizes that the door is closed when the door is closed and locked.
Even if the door is closed, the machine does not recognize it closed unless it is
locked. Such status is recognized as the door is open.

In the manuals published by Mori Seiki, the expression "door is closed" means that
the door is closed and locked.

3. When the power is turned on, the NC checks the function of the door lock device and
those of the contactor for the spindle/axis drive motors. If the door is closed when
the power is turned on, the function check is automatically executed and the
machine is set ready.
If the door is open when the power is turned on, close the door by using the
AUTOMATIC DOOR CLOSE switch. The machine does not get ready unless the
door is closed after turning on the power.

P-28 DOOR INTERLOCK FUNCTION

5-2-1 Opening/Closing the Door (Automatic Door Type)

The door can be opened or closed either by executing the door open/close M code (M85/M86) or
operating the AUTOMATIC DOOR OPEN/CLOSE switch.

<Using the door open/close M codes>

When opening/closing the automatic door in automatic operation (includes MDI operation),
execute the M codes (M85/M86).

Door Command Function

Unlock

Lock

Door open

(M85)

Door close

(M86)

When this command is executed, the door is automatically
unlocked and opened.

When this command is executed, the door is closed and after
the completion of door closing, it is locked automatically.

<Using the AUTOMATIC DOOR OPEN/CLOSE switch>

AUTOMATIC

DOOR OPEN

AUTOMATIC

DOOR CLOSE

The AUTOMATIC DOOR OPEN/CLOSE swit c h, pr ov id e d
on the option panel, is used to open/close the automatic
door manually.

The AUTOMATIC DOOR OPEN/CLOSE switch is

NOTE

not operative when the PANEL key-switch is
placed in the (OFF) position.

Switch Function

When this switch is pressed, the indicator in the switch is lit and the door is

AUTOMATIC

DOOR OPEN

unlocked and opened.

AUTOMATIC

DOOR CLOSE

When this switch is pressed, the door is closed and after the completion of
door closing, the indicator in the switch is lit and the door is locked.

DOOR INTERLOCK FUNCTION P-29

5-2-2 Releasing the Door Interlock Function (Automatic Door Type)

If it becomes necessary to carry out a work with the door opened after releasing the door interlock
function, follow the steps indicated below.

1) Open the door by executing M85 (door open
command) or by pressing the AUTOMATIC DOOR
OPEN switch.

This door opening operation is not necessary if

NOTE

the program has been ended after the execution
of M85.

DOOR INTERLOCK

NORMAL RELEASE

DOOR INTERLOCK

NORMAL RELEASE

2) Place the DOOR INTERLOCK key-switch in the
RELEASE position.

3) Set the single block function ON for executing an
automatic operation to check the program or carry
out test cutting.

4) Carry out necessary work.

If the DOOR INTERLOCK key-switch is placed in

NOTE

the NORMAL positio n while carrying out operation
in the door interlock released state, all machine
operations stop.

5) After completing the necessary work, set the door
interlock function ON.

a) Place the DOOR INTERLOCK key-switch in

the NORMAL position.

b) Return the single block function to invalid if the

operation has been executed with the single
block function set ON.

c) Close the door by executing M86 (door close

command) or by pressing the AUTOMATIC
DOOR CLOSE switch.

The door is locked.

This door closing operation is not necessary if the

NOTE

program begins with the door close command
(M86).

P-30 DOOR INTERLOCK FUNCTION

5-2-3 Emergency Stop and Door Unlock (Automatic Door Type)

When the machine enters the emergency stop state, the door is placed in the unlocked state.
When the emergency stop state is reset while the door is closed (not locked), the door is locked.

If the emergency stop state is reset while the door is open, the following message is

NOTE

displayed.
"EX4002 OPEN THE DOOR TH EN CLOSE"
In this case, the alarm is released when the door is closed and locked by pressing the

AUTOMATIC DOOR CLOSE switch.

5-3 Keeping the Door Unlocked

Since the machine is equipped with the door lock device, the door is automatically locked when it
is closed and if the door is locked it is not possible to open the door from the inside of the machine
(inside of the door). To keep the DOOR UNLOCKed when the door is closed with a person
working inside the door for setup, cleaning, inspection, or repair, a door lock prevention key is
provided.

Depending on the machine models, the door lock prevention key may not be provided.

NOTE

Door lock prevention key

Turn the key counterclockwise and the door is not locked.
When the door is closed with the door lock prevention key

turned counterclockwise, the door is not locked.

The specifications and the installation positions of the door lock device will vary according

NOTE

to the machine model and specification.

WARNING

The door is automatically locked when it is closed and the locked door
cannot be opened from the inside of the machine (inside of the door). To
carry out maintenance or inspection work inside the machine, make the
lock device invalid by turning the door lock prevention key; remove the
key and bring it with you when you enter the machine. To prevent the
door being locked by mistake, lock a padlock in the hole at the end of the
door lock hasp. If the door is closed by mist ake while the d oor lock device
is valid, the door is locked and you may be cooped up in the machine. If
the machine is started while you are inside the machine, you will be
entangled with the rotating part or crushed bet ween sliding parts to be
seriously injured.

5-4 Door Unlock Lever

DOOR INTERLOCK FUNCTION P-31

<If an operator is cooped up>

If an operator is cooped up in the machine, follow the
steps below to save the cooped operator.

1) Press the EMERGENCY STOP button disregarding
the power on/off state.

2) Insert the door lock prevention key into the keyhole
at the outside of the door lock device that is installed
at the top of the machine cover. Then, turn the key
counterclockwise to release the door lock.

This allows the door to be opened and the operator
to leave the machine.

Door lock device

Door unlock lever

Front cover

When the door is closed with a person being inside the
machine, the door is locked. To make the door lock
invalid, follow the steps indicated below.

1) Remove the cover at in-machine side of the door
lock device equipped position.

2) When the DOOR UNLOCK lever in the lock device
is turned on, the door is unlocked to open the door.

NOTE

1. Depending on the machine models, the
DOOR UNLOCK lever may not be provided.

2. Make sure the door lock device position
beforehand, since it varies with the machine
models.

CHAPTER A

OPERATION PANELS

Switches used to turn on/off the power supply, the functions and operational procedure of
the switches and keys on the operation panel are explained.

The operation mode in which the switch or operation is valid is indicated by illustration of the
MODE selection switch.

See the example below.

<Example>

5-10 Axis Feed Switches [AXIS DIRECTION]

Valid mode

CAUTION

1. Please note that accessories and functions of the machine given in the
explanation in this manual are not always available with your machine
according to its delivery.
Also please note that some of these accessories and functions cannot be
installed after the installation of the machine. For details, please contact
Mori Seiki.

2. Although illustrations of the machine, those of keys, switches, buttons and
indicators, and those of the screen display are drawn to actual machines
and controls, they could differ from the actual ones due to specification
changes or improvements of the machine.
If illustrations and screen display used in the explanation differ from your
machine, making it difficult to understand the explanation, please contact
Mori Seiki.

CONTENTS

A : OPERATION PANELS

1 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

2 INTERLOCK FUNCTIONS THAT ENSURE SAFE OPERATION . . . . . . . . . . . . . . . . . . A-5

3 MANUALS SUPPLIED WITH THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

4 SWITCHES FOR POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

4-1 Arrangement of Power Supply Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

4-2 Functions of Power Supply Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

4-2-1 Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

4-2-2 Electrical Cabinet Door Interlock Key-Switch

[CONTROL BOX DOOR INTERLOCK] . . . . . . . . . . . . . . . . . . . . . . A-10

4-2-3 Power Supply Lamp [POWER SUPPLY] (Option). . . . . . . . . . . . . . A-11

4-2-4 NC Power ON/OFF Switches [ON/OFF] . . . . . . . . . . . . . . . . . . . . . A-12

4-2-5 Emergency Stop Button [EMERGENCY STOP] . . . . . . . . . . . . . . . A-13

4-2-6 2nd O.T. Release Button [2nd O.T. RELEASE] (ZL-253). . . . . . . . . A-13

4-2-7 RS232C Interface Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14

4-2-8 100 VAC Service Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14

4-2-9 Memory Card Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15

5 OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16

5-1 Arrangement and Names of Switches and Keys

on Machine Operation Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16

5-2 Head Selection Switches [HEAD CHANGE]. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19

5-2-1 In the Memory Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19

5-2-2 In Modes Other Than the Memory Mode. . . . . . . . . . . . . . . . . . . . . A-20

5-3 Panel Key-Switch [PANEL] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21

5-4 Mode Selection Switches [MODE] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-22

5-5 Automatic Operation Switches [CYCLE]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25

5-6 Function Switches [FUNCTION] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26

5-6-1 Single Block Switch [SBK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27

5-6-2 Optional Stop Switch [OSP]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-29

5-6-3 Block Delete Switch [BDT]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30

5-6-4 Dry Run Switch [DRN] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31

5-6-5 Machine Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-32

5-6-6 Presetter Switches [PSM/PST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-33

5-6-7 Chuck Clamp Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-34

5-6-8 Tailstock Spindle Interlock (Tailstock Specification) . . . . . . . . . . . . A-35

5-6-9 Work Counter (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-36

5-6-10 Auxiliary Function Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-37

5-6-11 Chuck Footswitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-38

5-6-12 Chuck Jaw Stroke End Detection Switch. . . . . . . . . . . . . . . . . . . . . A-39

5-6-13 Zero Point Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-41

5-6-14 Tailstock Position Adjustment (ZL-253) . . . . . . . . . . . . . . . . . . . . . . A-42

5-6-15 Spindle OFF Mode Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-43

5-7 Status Indicators [STATUS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-45

5-8 Chuck Opening/Closing Footswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-48

5-8-1 Construction of the Chuck Opening/Closing Footswitch . . . . . . . . . A-49

5-9 Spindle Switches [SPINDLE]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-50

5-9-1 Spindle Speed Setting Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . A-52

5-9-2 Spindle Override Meter [OVERRIDE] . . . . . . . . . . . . . . . . . . . . . . . A-53

5-9-3 Spindle Neutral Gear Switch [SPINDLE NEUTRAL]

(Transmission Specification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-53

5-9-4 Spindle Gear Position Display Unit [GEAR]

(Transmission Specification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-54

5-10 Axis Feed Switches [AXIS DIRECTION]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-55

5-11 Feedrate Override Dial [OVERRIDE] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-56

5-12 Rapid Traverse Rate Override Switches [RAPID OVERRIDE] . . . . . . . . . . . . . . A-57

5-13 Handle Switches [HANDLE] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-58

5-13-1 Axis Selection Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-58

5-13-2 Axis Feed Amount Selection Switches . . . . . . . . . . . . . . . . . . . . . . A-59

5-13-3 Manual Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-59

5-14 Turret Indexing Switches [TURRET] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-60

5-15 Coolant Switches [COOLANT] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-61

5-16 Machine Light Switch [LIGHT]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-62

5-17 Chip Conveyor Switches [CHIP CONVEYOR] . . . . . . . . . . . . . . . . . . . . . . . . . . A-62

5-18 Tailstock Spindle Switches [TAILSTOCK] (Tailstock Specification) . . . . . . . . . . . A-63

5-19 Milling Switches [MILLING] (MC Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-64

5-20 Door Unlock Switch [DOOR UNLOCK]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-65

5-21 Programmable Tailstock Switches (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-66

5-22 Steady Rest Switches (Steady Rest Specification) . . . . . . . . . . . . . . . . . . . . . . . A-67

5-23 Parts Catcher Switches [PARTS CATCHER OUT/IN]

(Parts Catcher Specification). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-68

5-24 Manual Lubrication Pushbutton. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-69

5-25 Chucking Pressure Adjustment Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-70

5-26 Tailstock Spindle Thrust Adjustment Handle (Tailstock Specification). . . . . . . . . A-71

5-27 Steady Rest Pressure Adjustment Handle (Steady Rest Specification) . . . . . . . A-72

6 NC OPERATION PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-73

6-1 Soft-Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-74

6-2 Page Selection Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-75

6-3 Cursor Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-76

6-4 Program Edit Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-76

6-5 Key Input Buffer Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-77

6-6 Data Entry Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-78

6-7 Input Key (INPUT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-78

6-8 Reset Key (RESET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-78

6-9 Shift Key (SHIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-79

6-10 Cancel Key (CAN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-79

6-11 Function Selection Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-80

7 FUNCTION SELECTION KEYS AND DISPLAY SCREENS. . . . . . . . . . . . . . . . . . . . . A-81

7-1 Function Selection Key (POS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-82

7-1-1 Actual Position (ABSOLUTE) Screen . . . . . . . . . . . . . . . . . . . . . . . A-82

7-1-2 Actual Position (INCREMENTAL) Screen . . . . . . . . . . . . . . . . . . . . A-83

7-1-3 Actual Position (Total Position Data) Screen . . . . . . . . . . . . . . . . . . A-86

7-1-4 Operating Monitor Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-87

7-1-5 Handle Interruption Screen (Option) . . . . . . . . . . . . . . . . . . . . . . . . A-88

7-2 Function Selection Key (PROG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-89

7-2-1 Program Edit Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-90

7-2-2 Program Directory Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-93

7-2-3 Presently Executed Program Screen. . . . . . . . . . . . . . . . . . . . . . . . A-95

7-2-4 MDI Mode Operation Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-95

7-3 Function Selection Key (OFFSET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-96

7-3-1 Tool Geometry Offset Data Setting Screen . . . . . . . . . . . . . . . . . . . A-98

7-3-2 Tool Wear Offset Data Setting Screen. . . . . . . . . . . . . . . . . . . . . . . A-99

7-3-3 Work Coordinates Data Setting Screen . . . . . . . . . . . . . . . . . . . . . A-100

7-3-4 Setup (Tooling) (Conversational Programming) Screen . . . . . . . . A-101

7-3-5 Setup (Jaw Cutting) Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-102

7-3-6 Setup (Tool Change Position Setting)

(Conversational Programming) Screen . . . . . . . . . . . . . . . . . . . . . A-103

7-4 Function Selection Key (CAPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-104

7-5 Function Selection Key (SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-104

7-5-1 Input/Output Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-105

7-5-2 CAP Parameter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-106

7-5-3 NC System Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-107

7-5-4 System Composition Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-115

7-5-5 File Maintenance Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-116

7-6 Function Selection Key (MESSAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-119

7-6-1 NC Alarm Message Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-119

7-6-2 PLC Alarm Message Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-119

7-6-3 Alarm History Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-120

7-6-4 Periodical Maintenance Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . A-121

7-7 Function Selection Key (SETTING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-125

7-7-1 Operation Panel Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-126

7-7-2 Rotary Tool Setting Screen (MC Type) . . . . . . . . . . . . . . . . . . . . . A-128

7-7-3 PC Work Counter Screen (option). . . . . . . . . . . . . . . . . . . . . . . . . A-128

7-7-4 Tool Life Management Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-130

7-7-5 Load Monitor Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-132

7-7-6 Setting Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-133

7-7-7 Timer Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-134

7-7-8 Weekly Timer Screen (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . A-134

7-7-9 Communication Parameter Screen . . . . . . . . . . . . . . . . . . . . . . . . A-135

7-7-10 Parts Catcher Setting/Operation Screen . . . . . . . . . . . . . . . . . . . . A-136

7-8 Function Selection Key (NETWORK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-136

7-9 Help Key (HELP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-136

1 SAFETY PRECAUTIONS

The following are the safety precautions that must be kept in mind at all times while operating the
machine.

OPERATION PANELS A-1

DANGER

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 accidents involving serious
injuries.

ON

DANGER

Always lock out the power to the
machine before carrying out work

O

F

F

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 pow er 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.

A-2 OPERATION PANELS

DANGER

WARNING

Before st arting machine operation,
check that there are no personnel or
obstructions inside 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.

Before operating or programming the
machine, or performing maintenance
work, carefully read the instruction
manuals provided by Mori Seiki 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
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.

OPERATION PANELS A-3

1. READ THE INSTRUCTION MANUAL
carefully before installing or operating
the machine.

2. STRICTLY OBSERVE all instructions
written on the caution plates.

3. NEVER OPERATE the machine
without the protective cover,interlock,
or other safety devices in place.

4. NEVER ATTEMPT TO CHANGE the
settings for CNC parameters without
consulting MORI SEIKI

5. The machine starts and moves
automatically,NEVER TOUCH OR
STAND near revolving or moving parts.

6. ALWAYS DISCONNECT the power
source before inspecting,repairing,or
performing maintenance to the
machine.

7. NEVER RE-USE windows or
guards after damage. Replace
promptly with only
recommended products.

FAILURE TO OBSERVE THE ABOVE
INSTRUCTIONS MAY CAUSE SERIOUS
INJURY OR MACHINE DAMAGE.

Never operate without
safety door interlock
switch in “NORMAL”
position.

Failure to do so could
cause serious injury
or
death.

WARNING

WARNING

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
understand 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.

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

A-4 OPERATION PANELS

CAUTION

Establish a working environment in which you
can work safely. Working in an unsuitable
environment may cause unexpected
accidents.

1. Ensure that the workplace is adequately
lit.

2. Remove obstacles from the area around
the machine.

3. Change power supply cables or wires if
they are damaged.

Damaged cables and wires may leak
current and are extremely dangerous.

4. Cover all the cable running on the floor
with rigid insulated plates.

5. Do not leave service tools inside the
machine.

6. Secure adequate space and passages to
carry out the intended work safely.

7. 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.

8. Use a working bench strong and stable
enough to support the weight of the
workpieces and tools.

9. If it is necessary to stack workpieces
(products), make sure that they are
stacked stably.

10. Keep the area around the machine
clean; remove chips and foreign matter
near the machine.

OPERATION PANELS A-5

2 INTERLOCK FUNCTIONS THAT ENSURE SAFE OPERATION

This machine features the following interlock functions to ensure the operators safety.

CAUTION

<Front door interlock>

<Chuck interlock>

)

Before starting the machine, always make sure these functions are valid. Mori Seiki is
not responsible for accidents that occur as a result of the machine being operated
without first validating these interlock functions.

The front door interlock function disables manual operation
such as spindle rotation and the cycle start of automatic
operation while the front door is open.

If a workpiece flies out of the chuck due to improper clamping
or a programming error, the operator will be safe because the
front door is closed. The front door interlock function also
prevents any accident caused by starting spindle rotation
while the operator is touching the chuck or workpiece.

DOOR INTERLOCK FUNCTION

The chuck interlock function disables spindle rotation and the
cycle start of automatic operation while the chuck is
unclamped. If the spindle is started while the workpiece is
not clamped by the chuck, there is a danger that the
workpiece will disengage from the chuck.

<Tailstock spindle interlock
(for machines with tailstock)>

The tailstock spindle interlock function ensures operator
safety by preventing such acci den ts.

The tailstock spindle interlock function disables the cycle
start of memory (tape) operation when the tailstock spindle is
in the IN position (inside the tailstock body) or when it is in
the OUT position due to inching operation while the tailstock
spindle interlock is valid.

If the memory (tape) operation is started while a workpiece is
not held by the center (tailstock spindle), there is a danger
that the workpiece will disengage from the chuck.

The tailstock spindle interlock function ensures operator
safety by preventing such acci den ts.

Page A-35 (5-6-8)

A-6 OPERATION PANELS

<Electrical cabinet door interlock>

When the electrical cabinet door interlock key-switch is valid,
power cannot be turned ON while the electrical cabinet door
is open.

The electrical cabinet door interlock function protects the
operator from sustaining an electrical shock by touching a
live device inside the electrical cabinet after turning on the
power while the electrical cabinet door is open.

Page A-10 (4-2-2)

3 MANUALS SUPPLIED WITH THE MACHINE

Before using the machine, carefully read the manuals supplied with it, and make sure you fully
understand the information they contain. Store manuals carefully so that they do not get lost.

<Safety guidelines>

Contains the safety related information that sets out basic

1. READ THE INSTRUCTION MANUAL
carefully before installing or operating
the machine.

2. STRICTLY OBSERVE all instructions
written on the caution plates.

3. NEVER OPERATE the machine
without the protective cover,interlock,
or other safety devices in place.

4. NEVER ATTEMPT TO CHANGE the
settings for CNC parameters without
consulting MORI SEIKI

5. The machine starts and moves
automatically,NEVER TOUCH OR
STAND near revolving or moving parts.

6. ALWAYS DISCONNECT the power
source before inspecting,repairing,or
performing maintenance to the
machine.

7. NEVER RE-USE windows or
guards after damage. Replace
promptly with only
recommended products.

FAILURE TO OBSERVE THE ABOVE
INSTRUCTIONS MAY CAUSE SERIOUS
INJURY OR MACHINE DAMAGE.

Never operate without
safety door interlock
switch in “NORMAL”
position.

Failure to do so could
cause serious injury
or
death.

<Operation manual>

rules for the operator to follow in order to operate the
machine safely.

You must read and understand the safety guidelines
before using the machine.

OPERATION PANELS A-7

<Programming manual>

<Maintenance manuals>

Contains operation procedures, setup methods, and the
functions of the switches and keys used for machine
operation. (This manual)

Contains NC language and coding rules for creating
programs.

Contain information about machine dimensions and
specifications, as well as descriptions of adjustment
procedures for major machine units.

<NC operation and maintenance manual (prepare d by NC manufacturer)>

Contains detailed information on programming and NC
unit maintenance.

A-8 OPERATION PANELS

4 SWITCHES FOR POWER SUPPLY

The arrangement of the switches related to the power supply, and their functions, are described
here.

4-1 Arrangement of Power Supply Switches

The numbers indicate the subsections where explanations of switches are given.

4-2-9 "Memory Card
Interface"

NC operation panel

ON

OFF

4-2-4 "NC Power ON/OFF
Switches [ON/OFF]"

4-2-8 "100 VAC Service Outlet (Option)"

Operation panel

EMERGENCY ST O P

4-2-5 "Emergency Stop
Button [E ME RGENCY
STOP]"

Lower side of the operation panel

4-2-7 "RS232C Interface Connector"

Machine Front

Electrical cabinet

CONTROL BOX

DOOR INTERLOCK

ON OFF

4-2-1 "Main Switch"

4-2-2 "Electrical Cabinet Door Interlock Key-Switch
[CONTROL BOX DOOR INTERLOCK]"

Machine Rear

4-2-3 "Power Supply Lamp [POWER SUPPLY] (Option)"

The position and shapes of switches may differ according to the machine model and

NOTE

specifications.

4-2 Functions of Power Supply Switches

The switches used to turn the power on and off, and the switches related to the power supply , are
described here.

4-2-1 Main Switch

The main switch, located on the electrical cabinet door, is
used to turn the machine power supply on and off.

It also works as a non-fused circuit breaker.

NOTE

OPERATION PANELS A-9

The arrangement and shapes of the main
switches may vary according to the machine
model and specifications.

Switch Position Function

Power is supplied to the machine when the main switch is placed in this position.

CAUTION

Do not place the main switch in the ON position while the primary
power is not supplied to the main switch.

ON

If the main switch is pl aced in t he ON position repeatedly although
the primary power is not supplied to the main switch, the main
switch will be damaged.

Power to the machine is turned off when the main switch is placed in this

OFF

position.
The switch functions as a non-fused circuit breaker and returns to the center

position between and in the following case s.

1. Power supply is automatically turned off due to overcurrent.

TRIP

2. Power supply is turned off by the automatic power supply shutoff function.

To turn on the machine power supply again, place the main switch in the OFF
position, and then place it in the ON position.

When opening the electrical cabinet door, place the main switch in the OPEN

RESET position.

OPEN RESET

CAUTION

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.

A-10 OPERATION PANELS

4-2-2 Electrical Cabinet Door Interlock Key-Switch [CONTROL BOX DOOR INTERLOCK]

CONTROL BOX

DOOR INTERLOCK

ON OFF

electrical shock if he/she touches an energized part inside
the electrical cabinet when the power is turned ON while
the electrical cabinet door is open.

This key-switch is provided to protect the operator from

NOTE

1. For daily operation, set t he ke y- swit c h i n the ON position and keep the key removed.

2. This key-switch is for the electrical cabinet door.
For the front door interlock function, refer to "DOOR INTERLOCK FUNCTION".

3. The switch configuration and switch name differ according to the machine model and

specifications.

Interlock Switch Position Function

The electrical cabinet door interlock function is valid when

CONTROL BOX

DOOR INTERLOCK

ON OFF

this key-switch is placed in this position.
The power supply cannot be turned on while the electrical

cabinet door is open.

Valid

Invalid

DANGER

Normally, the CONTROL BOX DOOR

NOTE

INTERLOCK key-switch should be placed in the
ON position for operating or maintaining the
machine.

The electrical cabinet door interlock function is invalid

CONTROL BOX

DOOR INTERLOCK

ON OFF

when this key-switch is placed in this position.
The power supply can be turned on while the electrical

cabinet door is open.

Always switch off the power before carrying out inspection or
maintenance work in the electrical cabinet. 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.

4-2-3 Power Supply Lamp [POWER SUPPLY] (Option)

This lamp indicates whether or not power is being

POWER SOURCE

supplied to the machine. The lamp is lit when power is
supplied.

If the POWER SUPPLY lamp is not lit although the

NOTE

power is turned on at the shop power distribution
board, the lamp may have failed. In this case,
replace the lamp using the following procedure.

<Replacing the lamp bulb>

1) Turn off the power supply at the shop power
distribution board.

2) Remove the cap; turn it counterclockwise.

OPERATION PANELS A-11

Page B-14 (4)

3) Remove the bulb; turn it counterclockwise.

3)

2)

4) Set the new bulb; turn it clockwise.

5) Set the cap; turn it clockwise.

6) Turn on the shop power supply and make sure that
the lamp is lit.

4)

5)

A-12 OPERATION PANELS

4-2-4 NC Power ON/OFF Switches [ON/OFF]

ON

OFF

The NC power ON and OFF switches are on the NC
operation panel and used to turn the power to the NC
system on and off, respectively.

The shapes of NC operation panels and the

NOTE

arrangement and shapes of the NC power ON and
OFF switches may vary according to the machine
model and specifications.

Power Supply

to NC

ON

OFF

Switch Function

Power is supplied to the NC when this switch is pressed.

ON

This switch is also used as the second power ON switch for
turning on the machine ready signal after resetting the
emergency stop state.

Power to the NC is turned off when this switch is pressed.

OFF