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REGULAR MAINTENANCE GUIDE

DuraVertical 635 eco

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IMPORTANCE OF INSPECTIONS

The key to long-lasting machine accuracy is to perform daily inspections and regular inspection by maintenance engineers.

In case of concerns, maintenance engineers must take action within the instructions of operators.

If the cause of a problem cannot be determined or fixed, contact the Mori Seiki Service Department for assistance.

1.2.3.

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Daily

250 Hours500 Hours

1000 Hours

1 Week

2000 HoursAs Required

REGULAR INSPECTION LIST

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2022243036

CONTENTS

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DAILY CLEANING1. Machine Chamber

REGULAR INSPECTION

CAUTIONDo not use compressed air

To maintain machining accuracy, clean the chamber after completion of operations.

Do not touch chips with bare hands. If handling chips, wear gloves that have resistance to cutting.

Do not get on top of the protective covers when cleaning the machining chamber.

PROCEDURE1. Bring the spindle to the machine zero point.

2. Turn OFF the main power and disconnect the breaker.

3. Remove chips accumulating on the slideway protective covers.

4. Apply grease to the X-axis protective covers regularly.

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DAILY CLEANING2. Machining Chamber Observation Window

REGULAR INSPECTION

CAUTIONUse commercially available neutral detergent or fragance-free detergent for glass.

PROCEDURE1. Turn OFF the main power and disconnect the breaker.

3. Unlock the door lock device

4. Remove inside-outside smudges of the window with a detergent soaked cloth.

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DAILY CLEANING3. Coolant Tank Filter

REGULAR INSPECTION

PROCEDURE1. Turn OFF the main power

2. Wait until the coolant level is stabilized after the coolant inside machine is returned to the coolant tank.

3. Remove the hose and cables 1 and 2.

4. Loosen the bolt 3.

5. Pull out the chip conveyor and the coolant tank. (4)

CAUTION

Protective glasses must be worn.

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DAILY CLEANINGREGULAR INSPECTION

3. Coolant Tank FilterPROCEDURE6. Remove the bolts and top cover (5)

7. Remove the three coolant filters (6)

8. Drain the coolant pumps

9. Drain the coolant using a special suction device

10. Clean the coolant tank with a space or shovel.

11. Blow compressed air through the coolant filters.

12. Reinstall the coolant filters.

This procedure continues next page

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DAILY CLEANING3. Coolant Tank Filter

REGULAR INSPECTION

PROCEDURE13. Push the coolant tank into the machine unitl firmly pressed against the casting surface of the bed.

14. Adjust the jack bolts to secure coolant tank to the floor.

15. Mount the coolant pump

16. Connect the cables and hoses

17. Refill coolant

18. Reinstall the coolant top covers

19. Push the coolant button [ON] on the operation panel to confirm coolant is supplied.

CAUTIONCoolant tank must make contact with the cast iron surface of the bed or coolant will splash and may cause injury.

Confirm that part 1 is in contact with part 2.

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DAILY CLEANING4. Spindle Tapered Section and End Face

REGULAR INSPECTION

CAUTIONDo not use compressed air

Handle tool with care due to sharp edges

Hold tool with both hands and prepare a waist-height tool rack to minimize physical effort.

Make sure the spindle is supported when removing a cutting tool.

PROCEDURE1. Spindle rotation must be stopped completely.

2. Remove the tool from the spindle

3. Press the emergency stop.

4. Remove dust and chips

5. Clean the spindle tapered section with a spindle cleaner.

6. Lubricate the spindle taper with the MOLYKOTE powder spray Ident. No.: 2254885.

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DAILY CLEANING4. Chip Conveyor

REGULAR INSPECTION

CAUTIONProtective glasses must be worn.

Glooves must be worn.

PROCEDURE1. Remove dust or foreign material off the chip conveyor.

2, Empty container when full.

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DAILY CONFIRMATION5. Spindle Warm-Up

REGULAR INSPECTION

CAUTIONDo not rotate the spindle without a tool clamped.

Perform the warm-up below the maximum permissible rotattion speed of the tool and fixture.

Ensure the tool and fixture are secured before performing spindle warm-up.

PROCEDURE1. Perform spindle warm up to ensure optimum bearing service life.

2. Refer to this table before performing the spindle warm up and operating the machine.

Step Warm-Up Speed Time

1

2

3

4

5

5%

25%

50%

75%

100%

10 min

10 min

5 min

5 min

5 min

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DAILY CONFIRMATION6. Air Pressure Inspection and Adjustment

REGULAR INSPECTION

CAUTIONInspect pressure gage periodically. Adjust it if it’s not at the correct value.

PROCEDURE1. Check that the pressure gage is set at 0.6MPa (green mark).

2. If necessary, pull upward and rotate the pressure adjustment knob to adjust pressure/

Increasing pressure: Rotate knob clock wise.Reduce pressure: Rotate know counter clock wise.

3. Push the pressure adjustment knob downward.

If pressure cannot be adjusted, check the plant side air source

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DAILY LUBRICATION7. Spraying Powder Lubricant onto Spindle Taper

REGULAR INSPECTION

PROCEDURE1. Lubricate the spindle taper with the following powder lubricant.

MOLYKOTE powder sprayIdent. No.: 2254885

CAUTIONBe sure to spray the powder lubricant onto the spindle taper everyday

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1 WEEK CONFIRMATION1. Machining Chamber Observation Window Inspection

REGULAR INSPECTION

PROCEDURE1. Make sure window is clean and on place.

2. Clean or replace if necessary.

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1 WEEK CONFIRMATION2. Magazine Tool Pot Damage Inspection

REGULAR INSPECTION

PROCEDURE1. Make sure magazine tool runs properly. If not, seek assistance to repair or replace.

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1 WEEK LUBRICATION3. Greasing Tool Locks of ATC Arms

REGULAR INSPECTION

PROCEDURE1. Spray grease to the tool of the ATC arms regularly after cleaning.

METAFLUX spray.

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1 WEEK LUBRICATION4. Cleaning/Greasing Front Door Rail

REGULAR INSPECTION

PROCEDURE1. Apply grease to the front rail.

2. Confirm that the door runs smoothly.

3. Repeat process if necessary.

CAUTION

Protective glasses must be worn.

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1 WEEK LUBRICATION5. Greasing X-axis Protective Cover

REGULAR INSPECTION

PROCEDURE1. Apply grease to the X-axis protective cover

2. Confirm that the X-axis runs smoothly.

3. Repeat process if necessary.

CAUTION

Protective glasses must be worn.

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250 HOURS CONFIRMATION1. Checking Oil Level for Tool Clamp Unit Tank

REGULAR INSPECTION

PROCEDUREReplenish oil if close to the lower limit.

1. Turn OFF the main power.

2. Shut off the compressed air supply.

3. Confirm the pressure gage on the pneumatic device indicates 0 MPa.

4. Remove the oil by turning it counter clock wise. If jammed, use a hook spanner to loosen.

5. Supply oil while checking the oil level.

6. Remount the oil tank.

7. Restart compressed air supply.

CAUTIONTurn OFF the main power.

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500 HOURS CLEANING1. Cleaning Coolant Tank

REGULAR INSPECTION

PROCEDURE1. Turn OFF the main power

2. Wait until the coolant level is stabilized after the coolant inside machine is returned to the coolant tank.

3. Remove the hose and cables. (1 and 2)

4. Loosen the bolt 3.

5. Pull out the chip conveyor and the coolant tank. (4)

CAUTION

Protective glasses must be worn.

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PROCEDURE6. Remove the bolts and top cover (5)

7. Remove the three coolant filters (6)

8. Drain the coolant pumps

9. Drain the coolant using a special suction device

10. Clean the coolant tank with a space or shovel.

11. Blow compressed air through the coolant filters.

12. Reinstall the coolant filters.

500 HOURS CLEANING1. Cleaning Coolant Tank

REGULAR INSPECTION

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1000 HOURS CONFIRMATION1. Pneumatic Device Air Filter Inspection

REGULAR INSPECTION

PROCEDURE1. Turn OFF main power.

2. Shut off the compressed air supply.

3. Confirm the pressure gage indicates 0 MPa.

4. Inspect/replace the air filter element. (Refer to the following page for further instructions).

5. Restart compressed air supply.

6. Check for air leakage and confirm the air pressure is set at 0.6 MPa.

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Removing Air Filter Assembly CaseSlide the lock downward and rotate the assembly case 45 degrees CW or CCW. Pull the assembly case downward to remove.

Inspecting/Replacing Filter ElementHandle with care the O-ring mounted on top of the assembly.

Do not use tools when reinstalling case to prevent damage.

If clogged, replace:

a. Rotate baffle CCW to remove it along filter element.

b. Mount a new filter element on the valve guide.

c. Rotate the baffle CW to secure it along filter element.

d. Remount the assembly case

1000 HOURS CONFIRMATION1. Pneumatic Device Air Filter Inspection

REGULAR INSPECTION

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1000 HOURS CONFIRMATION2. Checking Clamp Force for Tool Clamp Unit

REGULAR INSPECTION

PROCEDURE1. Contact Mori Seiki Service Department for assistance.

DMG / MORI SEIKI USA, Charlotte

4345 Morris Park DriveCharlotte, NC 28227

Phone +1 (704) 940 - 3380

Fax: +1 (704) 840 - 1101

Service Hotline: +1 (855) 364 - 6674

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1000 HOURS CONFIRMATION3. Wear/Damage Inspection of Electrical Cabinet Door Packing

REGULAR INSPECTION

PROCEDURE1. Turn OFF main power.

2. Inspect that door opens and closes correctly.

3. Check for dust and foreign matter inside and clean carefully if necessary.

CAUTION

Protective glasses must be worn.

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1000 HOURS CONFIRMATION4. Replacing Main Filter

REGULAR INSPECTION

PROCEDURE1. Turn OFF main power.

2. Remove pressure from the pneumatic device.

3. Remove the bolts securing the filter cover and then the filter cover.

4. Remove main filter

5. Clean the filter.

6. Install the new main filter to the filter cover. 7. Reinstall the filter cover to the original position.

8. Secure the filter cover with the bolts

9. Restart compressed air supply.

CAUTIONAfter the procedure, confirm that the pressure is set at the correct value.

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2000 HOURS CLEANING1. Cleaning Filter

REGULAR INSPECTION

PROCEDURE1. Turn OFF main power.

2. Remove pressure from the pneumatic device.

3. Remove the filter cover.

4. Turn the filter to remove.

5. Wash the filter in lye, and blow it with compressed air.

6. Reinstall the filter in the original position.

7. Apply some oil to the O-ring of the filter cover.

8. Reinstall filter cover and restart compressed air supply.

CAUTIONWear protective glasses.

If the filter deteriorates, replace it with a new one.

Confirm pressure is set at the correct value.

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2000 HOURS REPLACEMENT2. Pneumatic Device Air Filter Element Replacement

REGULAR INSPECTION

PROCEDURERemoving Air Filter Assembly CaseSlide the lock downward and rotate the assembly case 45 degrees CW or CCW. Pull the assembly case downward to remove.

Inspecting/Replacing Filter ElementHandle with care the O-ring mounted on top of the assembly.

Do not use tools when reinstalling case to prevent damage.

If clogged, replace:

a. Rotate baffle CCW to remove it along filter element.

b. Mount a new filter element on the valve guide.

c. Rotate the baffle CW to secure it along filter element.

d. Remount the assembly case

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2000 HOURS REPLACEMENT3. Cleaning Electrical Cabinet Cooler

REGULAR INSPECTION

PROCEDURE1. Turn OFF main power.

2. Disconnect the plant-side power supply breaker.

3. Remove the cooler cover and the connector.

4. Blow the condenser fin downward.

5. Remove the panel cover.

6. Remove foreign matter with a vacuum cleaner.

7. Reattach the panel cover.

8. Reconnect the connector

9. Reattach the cooler cover.

CAUTIONDo not use inflammable products

Condenser fins and parts exposed to air have to be cleaned every 2000 operating hours. Depending on environment, it might require more frequent cleaning.

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2000 HOURS REPLACEMENT3. Cleaning Electrical Cabinet Cooler

REGULAR INSPECTION

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2000 HOURS REPLACEMENT4. Replacing Cooling Oil

REGULAR INSPECTION

PROCEDURE1. Turn OFF main power.

2. Remove the left-rear side cover

3. Place an oil pan beneath the drain plug.

4. Remove the drain plug and drain all oil from the tank.

5. Wrap sealing tape around the plug’s thread.

6. Replace the drain plug.

7. Remove the fill port cap.

8. Pour oil while checking the oil level gage.

9. Remount the fill port cap.

10. Turn ON the main power and confirm the pump generates a suction sound.

11. Turn OFF the main power and check oil level.

12. If oil level is still low, add oil again.

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2000 HOURS CONFIRMATION5. Spindle Taper Damage Inspection

REGULAR INSPECTION

PROCEDURE1. Spindle rotation must be stopped completely.

2. Remove the tool from the spindle

3. Press the emergency stop.

4. Remove dust and chips

5. Check spindle taper is not damage.

CAUTIONDo not use compressed air

Handle tool with care due to sharp edges

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AS REQUIRED LUBRICATION1. Replenishing ATC Unit Tank Oil

REGULAR INSPECTION

PROCEDURE1. Turn OFF main power.

2. Remove the machine cover.

3. Remove the fill port plug.

4. Pour oil while checking the oil level gage.

5. Remount the fill port plug and machine cover.

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AS REQUIRED LUBRICATION2. Replenishing Coolant

REGULAR INSPECTION

PROCEDURE1. Remove the top cover

2. Supply coolant up to the upper limit on the oil level gage.

3. Remount the covers.

CAUTIONWhen supplying coolant, ensure the coolant filters are installed.

Do not supply coolant during machine operation.

Do not fill above the upper limit on the oil gage.

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AS REQUIRED LUBRICATION3. Replenishing Lubricant

REGULAR INSPECTION

PROCEDURE1. Remove the fill port cap and pour oil while checking the oil level.

CAUTIONUse only clean oil.

Shell Gadus S2 V220 00

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AS REQUIRED LUBRICATION4. Replenishing Oil for Tool Clamp Unit Tank

REGULAR INSPECTION

PROCEDURE1. Turn OFF the main power

2. Shut off the compressed air supply.

3. Confirm the pressure gage on the pneumatic device indicates 0 MPa.

4. Remove the oil tank by CCW rotation. If tight, use a hook spanner to loosen.

Handle with care the O-ring mounted in the upper part of the oil tank

5. Supply oil while checking the oil level.

Apply some oil to the O-ring.

6. Remount the oil tank.

Do not use tools when reinstalling the oil tank to prevent damage to the case.

7. Restart compressed air supply.

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AS REQUIRED LUBRICATION5. Greasing Magazine

REGULAR INSPECTION

PROCEDURE1. Make sure magazine tool runs properly. If not, seek assistance to repair or replace.

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AS REQUIRED ADJUSTMENT6. Adjusting Coolant Discharge Rate

REGULAR INSPECTION

PROCEDURE1. Make sure the coolant discharge works properly.

2. If problems arised, refer to maintenance manual and seek for asistance.

CAUTION

Protective glasses must be worn.

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AS REQUIRED CLEANING7. Cleaning Coolant Gun

REGULAR INSPECTION

PROCEDURE1. Remove the nozzle head and remove chips and foreign matters.

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AS REQUIRED CLEANING8. Cleaning Operation Panel

REGULAR INSPECTION

PROCEDURE1. Turn OFF the main power.

2. Disconnect the plant-side power supply (breaker).

3. Remove any smudges from the operation panel with a detergent-soaked cloth.

CAUTIONUse limonene-based liquid detergent that satisfies the following conditions:

Coolant must be free of constituents with adverse affects on human beings such as offensive smells or skin irritaion.

The detergent must not cause hardening, dissolving, or swelling of the operation panel’s synthetic resin, etc.

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AS REQUIRED CLEANING9. Manual Draining from Pneumatic Device Air Filter

REGULAR INSPECTION

PROCEDURE1. If condensate or foreign matter has accumulated in the bottom of the bowl, push the manual drain valve upwards to drain manually.

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AS REQUIRED CLEANING10. Cleaning Magazine

REGULAR INSPECTION

PROCEDURE1. Make sure magazine tool runs properly. If not, seek assistance to repair or replace.

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AS REQUIRED CONFIRMATION11. Preparation for Machine Operation After Prolonged idle period

REGULAR INSPECTION

Two days or more

One year or more

Page 71

Page 64

Page 46 and 52

Operations Machine Idle Period Refer to maintance manual

Full Stroke Travel of Axes

Spindle Warm Up

Replacing Coolant

Checking Oil Levels

Cleaning and greasing X-axis protective covers

Cleaning and greasing axis Guide rails

Two weeks or more

One year or more

One year or more

One year or more

Using the manual pulse generator, perform full stroke travel of each axis for check for abnormal sounds or operation.

Written bellow

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__

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AS REQUIRED CONFIRMATION12. Reafirming Machine Level

REGULAR INSPECTION

PROCEDURE1. Refer to separate volume, “INSTALLATION MANUAL.”