660/850VMC ( HEIDENHAIN )

OPERATING
MANUAL
Original Instructions

PARTS LIST
 PREFACE

This manual is intended to help the operator and service technician to fully understand

our machine before their operation. Also for the personal safety and prevent any

damage on the machine, the operator and service technician need to read clearly this

manual before using this machine. For a long lasting of the machine’s quality,

precisely daily maintenance is recommended. As this is a necessary instrument

manual, please put this manual with the machine for quick reference.

All the drawings, pictures, in this manual, are for description without anything

concerned with dimension, accuracy or other details, according to our continuous

improvement policy, we reserve the right to change the machine specifications and

designs without pre-notice.

For the first owner and user of this machine, under normal operation and maintenance

within one year, if some parts have materials or manufacturing defect, we will repair

them or provide replacement parts free of change. If the defect is caused by the

abnormal operation or maintenance, the it is beyond the guarantee.

If there is any complaint or service required for this machine in the future, providing

correct machine model, serial number and clear description to our local dealer or us

are necessary and can shorten the time of investigation. Any suggestion or comment

are warmly welcomed for us!

Ⅰ. GENERAL CONTENTS
1. GENERAL ................................................................................................................ 1-1
1-1. Introduction........................................................................................................ 1-1
1-2. To Our Customer............................................................................................... 1-2
1-3. Product Guarantee ............................................................................................ 1-3
1-3-1. The Contents of Guarantee....................................................................... 1-3
1-4. Safety Precautions ............................................................................................ 1-5
1-5. Safety Equipment .............................................................................................1-12
1-6. Indicator Description.........................................................................................1-12
1-7. Safety Instructions ............................................................................................1-13
1-8. Summary of Treatment of Waste......................................................................1-16
2. MACHINE SPECIFICATIONS ..................................................................................... 2-1
2-1. General Specifications....................................................................................... 2-1
2-1-1. Main Features ........................................................................................... 2-1
2-1-2. Dimensional Drawings .............................................................................. 2-2
2-1-3. Working Space Required .......................................................................... 2-4
2-1-4. ATC Moving scope range.......................................................................... 2-5
2-1-5. Caution Labels On the Machine................................................................ 2-6
2-1-6. Machine Specifications...........................................................................2-11
2-1-7. Standard Accessories ..............................................................................2-12
2-1-8. Optional Accessories ...............................................................................2-12
2-1-9. Power Specifications................................................................................2-13
2-1-10. Tool Shank and Pull Stud.......................................................................2-14
2-1-11. Mechanical origin ...................................................................................2-17
2-2. Spindle Motor Output Characteristic.................................................................2-18
2-3. All Moving Elements .........................................................................................2-20
2-4. Stroke Diagrams...............................................................................................2-21
2-5. Safety Related Elements ..................................................................................2-23
2-6. Level of Noise and Brightness ..........................................................................2-25
2-6-1. Noise Level ..............................................................................................2-25
2-6-2. Brightness level........................................................................................2-25
2-7. Check list ..........................................................................................................2-26

3. MACHINE INSTALLATION......................................................................................... 3-1

0-1
 3-1. General Preparation & Selecting Location......................................................... 3-1
3-2. Foundation and Layout...................................................................................... 3-2
3-3. Installation Procedure........................................................................................ 3-2
3-3-1. Unpacking ................................................................................................. 3-2
3-3-2. Proper Method for Lifting Machine ............................................................ 3-3
3-3-3. Proper Method for Lifting Machine ( Forklift ) ......................................... 3-4
3-3-4. Leveling Machine ...................................................................................... 3-5
3-3-5. Install Z-axis Servo Motor and Remove Supporter ................................... 3-6
3-3-6. Install the Coolant Tank and Chip Disposal Box ....................................... 3-7
3-3-7. Connecting Power Supply......................................................................... 3-7
3-3-8. Each Axis Servo Motor Grid Adjustment ................................................... 3-8
3-3-9. Tool Change Point Adjustment ................................................................. 3-9
3-3-10. Clean & Lubricating Machine .................................................................3-10
3-4. Checkups During the Test Run.........................................................................3-10
3-5. The procedure for Power-UP and Power-OFF .................................................3-11
3-5-1. Power Up .................................................................................................3-11
3-5-2. Power Down.............................................................................................3-12
3-6. Maintenance of Windows .................................................................................3-13
3-7. Installation guild of drain pipe for electrical air conditioner ...............................3-14
3-7-1. Recommendation.....................................................................................3-14
3-7-2. Oil Separator install and adjustment ........................................................3-15
4. OPERATION ............................................................................................................... 4-1
4-1. Control panel description................................................................................... 4-1
4-2. Power Socket description .................................................................................. 4-8
5. LUBRICATION ............................................................................................................ 5-1
5-1. Automatic Lubrication System ........................................................................... 5-1
5-2. Lubrication Structure ......................................................................................... 5-2
5-3. Electric Cabinet and Power cable...................................................................... 5-3
6. MAINTENANCE .......................................................................................................... 6-1
6-1. Adjusting Belt Tension....................................................................................... 6-1
6-2. Pneumatic system ............................................................................................. 6-2
6-2-1. Pneumatic Control Circuit ......................................................................... 6-2
6-2-2. Pneumatic tank ......................................................................................... 6-3

6-3. Remove chip and renew coolant ....................................................................... 6-4

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 6-4. Notice for maintenance and inspection.............................................................. 6-5
6-5. Maintenance and Inspection List ....................................................................... 6-8
6-6. Spare part list for maintenance.........................................................................6-12
6-6-1. Vital element ............................................................................................6-12
6-6-2. Machine spare .........................................................................................6-13
6-6-3. Machine spoilage part ..............................................................................6-15
7. ARM-CAM TYPE ATC................................................................................................. 7-1
7-1. Timing Chart ...................................................................................................... 7-1
7-2. Relationship Between Proximity Switch, Dog and Scale for confirmation.......... 7-2
7-3. Dog Adjustment and Installation of Proximity Switch......................................... 7-3
7-3-1. Dog Adjustment ........................................................................................ 7-3
7-3-2. Installation of Proximity Switch.................................................................. 7-4
7-3-3. Tightness torque of axis coupling.............................................................. 7-4
7-4. Emergency Stop and Method of Recovering Normal State after Power Failure 7-5
7-5. Maintenance and Inspection.............................................................................. 7-5
7-5-1. Oil Amount Confirmation ........................................................................... 7-5
7-5-2. Oil change................................................................................................. 7-6
7-5-3. Confirming Dog, Proximity Switch and Chain............................................ 7-6
7-6. Confirmation of Timing Belt for Driving .............................................................. 7-6
7-7. Adjusting Brake Gap.......................................................................................... 7-7
7-8. Angle positioning of spindle adjustment ............................................................ 7-8
7-9. Z axis first home position set （ARM type） ...................................................7-10
8. CAROUSEL TYPE AUTOMATIC TOOL EXCHANGING SYSTEM ............................ 8-1
8-1. The structure profiled diagram of carousel type tools magazine. ...................... 8-1
8-1-1. Carousel type tools magazine................................................................... 8-2
8-2. Tool Clamping and unclamping system............................................................. 8-3
8-3. Z axis secondary home position set （carousel type） .................................... 8-4
8-4. Spindle orientation angle adjustment.（carousel type） ................................... 8-5
8-5. Adjusting and set of air pressure ....................................................................... 8-6
8-6. Adjusting for oil feeder of Pneumatic system..................................................... 8-6
8-7. The tools back ward of spindle adjusting and inspection................................... 8-6
8-8. Air blast of spindle for adjustment and inspection.............................................. 8-7

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Ⅱ. ELECTRIC CONTENTS
Carousel ATC Trouble Shooting ............................................................................... A-1
Machinery Interface Cannot Initialize (NOT READY)................................................ B-1
Circuit Diagram ......................................................................................................... C-1
Spare Parts List ...................................................................................................... D-1
M-Code..................................................................................................................... E-1

Ⅲ. PARTS LIST
SPINDLE HEAD .........................................................................................................01
COLUMN ....................................................................................................................02
TABLE ........................................................................................................................03
SADDLE .....................................................................................................................04
MACHINE BASE ........................................................................................................07

Ⅳ. OPTIONAL ACCESSORIES

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1. GENERAL
1-1. Introduction
A trained and qualified personnel is allowed to preceed operation and maintenance.

This manual covers the following areas for the benefit of those who operate and
maintain the machine.

The experienced of the CNC machine center as well as the beginner should read it
thoroughly to operate this machine correctly so that the machine works efficiently.
The operator must thoroughly read and understand the safety guidelines to ensure
the safety of personnel and the machine, to avoid serious injury, loss of life or
substantial damage of the machine.

Note : There may be some difference between the manual and the machine due to
the machine improvement.

Chapter 1 : Lists the points that the operator must observe in order to ensure the safety of
the machine and personnel. Note that these are only the bare essential
considerations in a normal working environment and more care may be
required depending on the actual circumstances.

Chapter 2 : Describes the specifications of the whole series of machines. You can
convenient to determine which of the specifications your machine conforms to
and to mark the next appropriately.

Chapter 3 : Describes the machine accepted from the manufacture to your factory until it
can be commenced working.

Chapter 4 : Introduces the operation panels. For more detailed information’s must refer to
the CNC controller operation manual.

Chapter 5 : Describes the automatic lubrication system and others.

Chapter 6 : Describes the procedures for maintenance, inspections and adjustment. For
more detailed information, please ask a company engineer.

Chapter 7 : Describes the arm type ATC construction and about the related key point
electrical units be adjusted.

Chapter 8 : Describes the carousel type automatic tools changing system and its operation
procedures.

1-1
1-2. To Our Customer
We are indeed pleased at your selection of a brand new our company product.
660 / 850VMC multi-functional vertical CNC machine center series are the rugged,
precision made machine tool. With proper care, it will give you superior working
finishes for years sine now.

This operating and maintenance manual will assist you in operating and maintaining
this quality machine tool. We suggest that this manual to be stored at a place that is
easily accessible to the operator for instant reference. To ensure security and
smooth operating of this equipment, the operator is required to read this manual
thoroughly and have a good understanding of it before operation.

All the drawings, diagrams shown in this manual are used for illustrative purposes
only. The actual dimensions or tolerances of all components are not provided in this
manual. We reserve the right to continuously improve our products’ performance
with engineering changes.

Under normal operation and maintenance, all components of this machine are
warranted for one full year. Any improper practice or maintenance which are not
recommended by us will cause expiration of the warranty. Upon receiving the
machine. Please check all the accessories listed in the packing list and the machine
condition as well. Any problem or damage, please inform your dealer immediately.

We look forward to serving you in the future, and take this opportunity to wish you
every success in the profitable operation for your new 660 / 850VMC machine center
series.

Should any service or parts be required, please indicate the serial number of your
machine when communicating with our company.

1-2
1-3. Product Guarantee
1-3-1. The Contents of Guarantee

DUGARD protects your purchase with one year guarantee for the first owner of this

machine from the date when both parties sign the acceptance of the product

shipped from our factory. Under normal usage, if this product has problem during

the guarantee period, we will offer technical support aid. During the guarantee

period we will offer free services and replacement for the defective parts subject to

the service record. The spindle is guaranteed for a period of twelve (12) months or

5,000 hours subject to the shorter period. In addition to above guarantee, we also

provide in time technical support, including Service Instructions, parts supply and

troubleshooting .

This warranty only covers the delivered machine and does not apply to any loss

and/or damage, direct or indirect, resulting from such malfunction or failure.

The limit of spindle service life:

1. If the spindle speed is over 9000rpm, the tool dynamic balance needs grade 2.5G.

If the spindle speed is over 12000rpm, the tool dynamic balance needs grade

1.0G.

2. If a continuous usage over Nmax.×75％rpm, the machine must be shut down at

least one hour after every 24 hours of operation.

3. Allotment of speeds: about 70% below Nmax.×75％rpm, about 20% between

Nmax.×75％ to 90％rpm and about 10% over Nmax.×90％

1-3
We do not offer guarantee for any of following items, and the repair parts and service
fees need to be charged according to company regulations.
1. Changing machine specifications or accessories causes troubles or damages -
user himself or user’s consigned people changes, takes apart or modify the
machine or its accessories, and causes troubles or damages.
2. The troubles caused by force majeure or improper operation -
(1)Damages or troubles caused by natural disasters such as earthquake, typhoon,
fire, flood, lightning stroke, unstable voltage, etc… and environmental factors
such as sulfur gas, chemical, mouse damage, insect pest, etc… .
(2)Troubles or damages caused by misuse such as intentional destruction,
incorrect power, voltage, pneumatic pressure or improper operation.
(3)Troubles or damages caused by improper maintenance (machine warm-up).
3. Consuming parts and accessories
The consuming parts inside and outside the machine body and the accessories
such as light bulbs, fluorescent tubes, water sweeping brush, rubber oil hose,
rubber scratch bar, rubber cushion, filtering (asbestos) net, power cords, fuses,
batteries, etc… They are consuming parts which need replacement under normal
use, and are not guaranteed.
4. Sorry for no free charge service under following situations -
(1) The guarantee period is over.
(2) Request a service for maintenance or adding/replacing lubricant.
(3) Request a correction on precision, function, etc… which are not specified in
the product specification handbook or purchase contract.
(4) After guarantee period is over, a service fee for inspection should be charged
according to company regulations although there is no replacement of parts.

1-4
1-4. Safety Precautions
This machine is provided with a number of safety devices to protect personnel and
equipment from injury and damage.

However, these cannot cover all aspects of safety, therefore the operator must
thoroughly read and understand this chapter before operating the machine. The
operator should also take into consideration other aspects of safety related to
particular environmental conditions and materials.

Spare space around the machine should be reserved so the technician can open the
electric cabinet door for maintenance or reparation.

The service of a qualified electrician should be used to connect the machine to plant
power. The power supply voltage must be the same as the machine requires.

Be sure that all wiring is in accordance with local building codes. This machine is a
multifunction vertical CNC machine center with automatic operation and typical
manual operate model. It is primary used to cut the materials such as steel, cast iron,
copper, aluminum…etc.

It is not recommended to cut a danger material such as Magnesium or worked in a

potential explosion environment.

1. Basic operating practices

(1) Some control panels, transformers, motors, junction boxes and other parts have
high-voltage terminals, these should not be touched, or a severe electric shock
will be sustained.

(2) Do not touch a switch with wet hands. This, too, can produce an electric shock.

(3) Make sure that all doors and safety cover are fitted before switching on the
power. If any door or safety cover is to be removed, first cut off and lock the main
breaker.

(4) The emergency stop push button switch location should be well known so that it
can be operated at any time without having to look for it.

(5) Before replacing a fuse, power off the machine.

(6) Provide sufficient working space to avoid hazardous falls.

(7) Water or oil can make floors slippery and hazardous. To prevent accidents, all
floors should be dry and clean.

(8) Before operating switches, always check that they are the right ones.

(9) Never touch a switch accidentally.

1-5
 (10) Work benches near the machine must be strong enough to prevent accidents.
Articles should be prevented from slipping off the bench surface.

(11) If a job has to be done by two or more operators, coordinating signals should be
given at each step of the operation. Unless a signal is given and acknowledged,
the next step should not be taken.

(12) Do not handle coolant with bare hands since it is liable to cause irritation.
Operators with allergies should take special precautions.

(13) Do not operate the machine during violent thunderstorms.

(14) Do not remove or otherwise interfere with safety devices such as stop dogs,
limit switches, or interlocks in order to increase axis travel.

(15) Do not modify the machine in any way that is likely to affect it safety.

(16) This machine is not suitable for working under the potential environment of
explosion.

(17) If there is a danger of explosion or fire because flammable material is to be cut

or a danger of fire due to coolant, ensure there is a fire extinguisher at hand.
Additional, please ask for the supplier whom providing the materials with
potential explosion dangerous, that he has the duty to supply the safety required
notice for cut the danger materials. (Ex : Magnesium)
Materials recommend being use for the machine as following:
1. Steel 2. Iron 3. Cast iron 4. Aluminum alloys 5. Copper alloys.
Other materials should be selected carefully by operators.
(18) check slings, chains, hoists, and other lifting gear for defects before use. Repair
or replace defective gear immediately.
2. Routine inspections
When checking belt tensions, do not get your fingers caught between the belts and
pulley.
(1) Check pressure gauges for proper readings.
(2) Check motors, gear boxes and other parts for abnormal noises.
(3) Check the motor lubrication, and sliding parts for evidence of proper lubrication.
(4) Check safety covers and safety devices for proper operation.
(5) Check belt tensions. Replace any set of belts that has become stretched with a
fresh matching set.

1-6
3. Warm up
(1) Warm up the machine, especially the spindle and feed shaft by running them for
10 or 20 minutes at about half or one-third the maximum speed in the automatic
operation mode.
(2) If the machine is used for actual machining immediately after being started,
following a long idle period, sliding parts may be worn due to lack of oil. Also,
thermal expansion of the machine components can jeopardize machining
accuracy. To prevent this condition, always warm the machine up.
(3) Thermal expansion may cause inferior machining accuracy. Warm up should be
performed to avoid these malfunctions as abnormal worn-out of slide face, stick
slip and so on. Due to the sufficient warm up, thermal expansion becomes stable,
and the machine can manufacture products which have evenness and high
machining accuracy.
(4) Warm up is always required before daily operation. In cold district, warm up
should be done sufficiently. Check the operation, lubrication and so on of each
part during warm up.
4. Coolant
When selecting a coolant, take the following items into consideration by consulting
the supplier of the coolant.
(1) Use water-soluble coolant.
If oil-based coolant is used the coolant temperature rises as its delivery
decreases, causing thermal distortion of the machine. In addition, it is necessary
to take precautions against fire hazards, such as installing a fire extinguisher,
since oil-based coolant is flammable.
(2) Take the lubricity, corrosion - prevention performance, and anti - foaming
characteristics into consideration.
(3) Make sure that the coolant has no adverse affects on the human body. Since
water-soluble coolant often causes poisoning, pay sufficient attention to the
hygiene of the operators.
(4) Make sure that the coolant does not cause curing or expansion of rubber or
plastic products, or chemical products.
(5) Make sure that mixing of the coolant with the recommended lubricating oil does
not cause problems. In some cases the mixing of coolant with lubricating oil
causes a chemical change, resulting in discoloration or solidification of the
coolant.

1-7
5. Operation
(1) Do not work with long hair that can be caught by the machine. Tie it up at the
back, out of the way.
(2) Do not operate switches with gloves on. This could cause malfunctions, etc.
(3) Whenever a heavy workpieces must be moved, two or more persons should
always work together if there is any risk involved.
(4) Only trained, qualified workers should operate forklift trucks, cranes or similar
equipment and apply slings.
(5) Whenever operating a forklift truck, crane or similar equipment, special care
should be taken to prevent collisions and damage surroundings.
(6) Wire ropes or slings should be strong enough to handle the loads to be lifted and
should conform to the mandatory provisions.
(7) Hold Grip workpieces securely.
(8) Stop the machine before adjusting the coolant nozzle at the tip.
(9) Never tough a turning workpieces or spindle with bare hands or in any other way.
(10) To remove a workpieces from the machine, stop the tool and provide plenty of
distance between the workpieces and the tool.
(11) While a workpieces is turning, do not wipe it off or remove chips with a cloth or
by hand. Always stop the machine first and then use a brush and a sweeper.
(12) Do not operate the machine with safety front door removed.
(13) Use a brush to remove chips from the tool tip not by bare hands.
(14) Stop the machine whenever installing or removing a tool.
(15) Whenever machining magnesium alloy parts, wear a protective mask.
(16) Always use safety shoes with steel toe caps and oil-resistant soles.
(17) Never wear loose or baggy clothing.
(18) Always completely fasten buttons and hooks on the arms of clothing to avoid
the danger of entanglement in drive mechanisms.
(19) Do not operate the machine while under the influence of drugs with powerful
effects, unprescribed drugs, or alcohol.
(20) Do not operate the machine if you suffer from dizziness or fainting spells.
(21) Always use gloves when loading or unloading workpieces or tools and when
removing chips from the work area to protect your hands from sharp and heat
generated during machining.
(22) Always wear helmet of there are any overhead obstacles in the work area.
(23) During automatic operation, never open the machine door.
(24) When performing heavy-duty machining, carefully prevent chips from being
accumulated since hot chips can catch fire.

1-8
 (25) Wear a safety glasses at all times during the operation of the machine to avoid
coolant splashing into eyes.
(26) When the machine working for a heavy-duty cutting or want to obtain highly
machining quality. It may be required and recommended to use coolant for
prevent the fire hazard generated and take good performance.
(27) KEEP AREA AROUND MACHINE well light(>500 lux) and dry.
6. To interrupt machining
When leaving the machine temporarily after completing a job, turn off the power
switch on the operation panel, and main circuit breaker.
7. Completing a job
(1) Always clean the machine or equipment. Remove and dispose of chips and clean
cover windows, etc.
(2) Do not clean the machine or equipment, before it has stopped.
(3) Return each machine component to its initial condition.
(4) Check wipers for breakage. Replace broken wipers.
(5) Check coolants, oils and lubricants for contamination. Change them if they are
seriously contaminated.
(6) Check coolant, oil and lubricant levels. Add ,if necessary.
(7) Check the chip tank filter.
(8) Before leaving the machine at the end of the shift, turn off power switch on the
operating panel, machine main circuit breaker and factory feeder switch in that
order.
8. Safety devices
(1) Front door, rear guard and splash guard.
(2) Overtravel limit switches.
(3) Emergency stop push button switch.
9. Maintenance operation preparations
(1) Do not proceed to any maintenance operation unless instructed to do so by the
foreman.
(2) Replacement parts, consumables (packing, oil seals, O-rings, bearing, oil and
grease etc.) should be arranged in advance.
(3) Prepare to record preventive and corrective maintenance operations.
(4) Thoroughly read and understand the safety precautions in the instruction
manual.
(5) Thoroughly read the whole maintenance manual and fully understand the
principles, construction and precautions involved.

1-9
10. Maintenance operation
(1) Those not engaged in the maintenance work should not operate main circuit
breaker or the control power ON switch on the operating panel,. For this purpose,
“Do not Touch the Switch, Maintenance Operation in Progress!” or similar
wording should be indicated on such switches at any other appropriate locations.
Such indication should be secured by a semi-permanent means in the reading
direction.
(2) With the machine turned on, any maintenance operation can be dangerous. In
principle, the main circuit breaker should be turned off through out the operation.
(3) After the power has been switched off for a short while, check the voltage with a
multi-meter or similar instrument to make sure that there is no residual voltage.
Also discharge the capacitors.
(4) The electrical maintenance should be done by a qualified person or by others
component to do the job. Keep close contact with the responsible person. Do not
decide by yourself.
(5) Overall limit and proximity switches and interlock mechanisms including
functional parts should not be removed or modified.
(6) When working at a height, use steps or ladders which are maintained and
controlled daily for safety.
(7) Fuses, cables, etc. Made by qualified manufacturers should be employed.
(8) Always switch off the main power breaker and lock it before replacing bulbs or
other electrical equipment and use products with the same specifications as the
original.
(9) Do not start the machine until all of the covers removed for maintenance have
been refitted.
(10) Do not use compressed air to clean the machine or to remove chips.
(11) Always use gloves when clearing away chips; never touch chips with bare
hands.
11. Until operation is begun after maintenance
(1) Arrange things in order around the section to receive the maintenance, including
working environments. Wipe water and oil off parts and provide safe working
environments.
(2) All parts and waste oils should be removed by the operator and placed far
enough away from the machine to be safe.
(3) The maintenance person should check that the machine operates safely.
(4) Maintenance and inspection data should be recorded and kept for reference.

1-10
12. If the personal is trapped by axes movement, then the release procedure is shown
as below：
(1) Press the Emergency-STOP button.
(2) Reset the Emergency-STOP button.
For FANUC controller the NC control is ready.
For Mitsubishi controller the NC control is ready.
For Heidenhain controller then pressing POWER ON and CE to make NC
controller ready.
For Siemens controller then press RESET to make NC controller ready.
(3) Switching to manual mode.
(4) Press axes movement control device together with enable device to release the
togged personal.

1-11
1-5. Safety Equipment
Please pay extra care on practicing these safety tips previously mentioned to
prevent hazardous accident. Also please take note on the following safeguards and
realize their functions to maintain the machine running in normal condition and
longer life.

Item Equipment Function Position

1 Splash guard To prevent chips and coolant from emitting Machine front
2 Emergency stop To immediately disable machine function. Control panel
3 Lubricant alarm To prevent slide ways from wearing. Control panel
4 Overload alarm To prevent motor from overloading Control panel
5 X-axis limits switch To prevent X-axis from overtravel. Saddle of X-axis
6 Y-axis limits switch To prevent Y-axis from overtravel. Saddle of Y-axis
7 Z-axis limits switch To prevent Z-axis from overtravel. Column of Z-axis
X,Y&Z axis CNC parameter
8 To prevent X,Y & Z axis overtravel.
software switch setting
To prevent operator touch the tools
9 ATC guard ATC
magazine while it on rotating.
Manual tools To assist operator easily and safety to Front side of
10
interlock device change tools. spindle guard
Movable doors To protect operator insulated dangerous Top of both
11
interlock device and injury from the automatic operation. movable doors
To prevent personnel be electric shocked
12 Cabinet door safety Electric cabinet
from the electrical device.

1-6. Indicator Description

Green (down) : Running

Orange (middle) : program cycle end.

Red (up) : alarm

1-12
1-7. Safety Instructions

All machining centers contain hazards from rotating cutting tools, belts, pulleys,
high voltage electricity, noise and compressed air.

Rotating cutting tools can cause severe injures, Never approach or

touch rotating cutting tools. Verify that all cutting tools are properly
clamped and secure before operating machine.

Rotating pulleys and belts can severely injure you. Never place any
part of your body near rotating or moving parts. Always ensure
guards are in place before operating this machine.

High voltage electricity can severely injure or kill you. Never attempt
to adjust or repair electrical circuits unless you are familiar with the
circuits and are qualified to work on the electrical circuits. Always
keep electrical cabinet closed when operating this machine.

Compressed air can injure you. Do not work on compressed air

systems without first disconnecting the source of compressed air.
Always wear safety glasses when performing maintenance on
compressed air system.

1-13
SAFETY LABEL NO. 1:

Rotating Cutting Tools Safety Label.

Located as shown in the Figure "Safety Label Locations".

SAFETY LABEL NO. 2:

Electrical Shock Danger Label.

Located as shown in the Figure "Safety Label Locations".

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 DANGER - Immediate hazards which WILL result in death or permanent injury.

WARNING - Unsafe operating practices could result in severe physical injury.

CAUTION - Unsafe operating practices could result in severe physical injury.

Note:
Do not modify or alter this equipment without our written approval. Unauthorized
changes may lead to hazardous conditions. Address any question to our service
Department.

1-15
1-8. Summary of Treatment of Waste

(1) The treatment of air pollution during operation.

The fine dust and coolant spray, which are brought about during machining, indeed
result in air pollution. An air filter of dust collector is necessary.

(2) The treatment of waste too.

Deposit worn-out or damaged tool in the bucket. Appoint some qualified scrap metal
company to dispose.

(3) The treatment of waste lubricant and grease.

Deposit waste lubricant and grease in certain container. Appoint some qualified
recycling company or POL agent to dispose.

(4) The treatment of waste coolant

Deposit waste coolant in certain container. Appoint some qualified sewage
treatment company to dispose.

(5) The treatment of waste machine.

A machine that is out of work after a long period of service should be replaced.
Appoint some qualified scrap metal company to dispose.

(6) The treatment of packing materials

The machine is properly packed by the manufacturer with various materials for safe
delivery. After unpacking, these packing materials should be disposed in
classification as follows:

A. Plastics : Appoint some qualified recycling company to dispose.

B. Metal : Give them to our service persons or appoint some qualified scrap metal
company to dispose.

C. Wood : Appoint some qualified recycling company to dispose.

The disposal of wastes, such as oil, coolant, and chips, must comply the local regulations.

1-16
2. MACHINE SPECIFICATIONS
2-1. General Specifications
2-1-1. Main Features

1. Z- axis servo motor 12. Spindle

2. Heat exchanger 13. Table
3. Electrical box 14. X- axis servo motor
4. Main power switch 15. Warning lamp
5. Head stock body 16. Control panel
6. Y-axis servo motor 17. Chip bucket
7. Column 18. Tool magazine
8. Lubricator 19. Guard shield
9. Machine base 20. Oil cooler
10. Spindle motor 21. Transformer
11. Cylinder 22. Saddle

Figure 2-1

2-1
2-1-2. Dimensional Drawings

660VMC
850VMC

Figure 2-2

Figure 2-3

2-2
 660VMC
850VMC

Figure 2-4 top view

2-3
2-1-3. Working Space Required
Following is a top view drawing and show with the working space required for easy
to operate and maintenance.

Figure 2-5

2-4
2-1-4. ATC Moving scope range

A B C D
660/850VMC 115 300 223 638

Figure 2-6

2-5
2-1-5. Caution Labels On the Machine
1. Safety related information, which must be strictly observed by all machine
operators is given on caution labels. These caution labels are attached to the
machine.

Figure 2-7

The position of caution labels on the machine.

2-6
Picture of safety labels and instructions
(1) WARNING :

Keep off machine when in automatic mode. Can

cause severe injury. Set control in manual model
before standing on machine. Turn off and lock out
power at electrical panel before servicing.

(2) WARNING :

Do not operate before shutting

door.
Keep off machine when in
Do not operate before shutting door. Keep off
automatic mode.
Can cause severe injury.
Set control in manual mode
machine when in automatic mode. Can cause
before standing on machine.
Turn off and lock out power
at electrical panel before
servicing.
severe injury. Set control in manual mode before
standing on machine. Turn off and lock out power at
electrical panel before servicing.

(3) WARNING :
Keep hands, clothing and body clear off tool/spindle
rotation. Machine starts and moves automatically.
SAFETY INSTRUCTION
Before working near spindle ;
1. Return all tools to magazine.
2. Set in manual mode, stop spindle.
3. Hang “Do not touch” sign on operator’s panel.
4. Wear safety helmet.
(4) INDICATION :

Describes the moving direction of all axis and define

the meaning of direction to each axis. To prevent
fault in operation.

(5) CAUTION :

Always wear safety shoes with steel toe caps and

oil-resistant soles to prevent slide down.

2-7
(6) DANGER :

Compressed air can injure you. Do not work on

compressed air systems without first disconnecting
the source of compressed air. Always wear eye
protection when performing maintenance on
comprised air system.

(7) INDICATION :

Don’t unclamp tools when it clamped in spindle.

Keep the tool vertically to insert it into spindle.

(8) INDICATION :

This push button is used for manual tools clamping

and unclamping. Keep press this button that the tool
would be unclamped from spindle. Release this
button tools would be clamped by spindle.

(9) DANGER :

High voltage electricity can severely injure or kill you.

Never attempt to adjust or repair electrical circuits
unless you are familiar with the circuits and are
qualified to work safely on the electrical circuits.
Always turn off the power before attempting to work
on this machine.
(10) DANGER :
Hazardous voltage. Will cause severe injury or death.
SAFETY INSTRUCTION
1. Verify power in lock out before servicing.
2. Resident voltage-check components with multitester
before touching.
3. Refer to maintenance manual for fuse replacement
procedures.

2-8
(11) INDICATION :
200-400V / 3PH / 50HZ
Describe the required power voltage which is 220 or
PREWIRED TO 400V
ATTENTION ! 440V/3Ph/60HZ. It has to pay attention for only open
Only open after interrupting the main switch
the door of cabinet after interrupting the main switch.

(12) INDICATION :
Showing with the serial NO. and manufacturing date of
this machine been produced.

(13) INDICATION :
A name plate show the machine is in compliance
with the CE requirement.

(14) CAUTION :
To be ground by user. A ground rod made of solid
copper 8 feet in length , 3/4” in diameter should be
driven in the earth with 6 inch approximately
exposed above concrete floor. Connect a suitable 10
gage wire from screw marked ( ) in electrical
cabinet ground rod.
(15) DANGER :
Rotating pulleys, belts and chains can severely injure
you. Never place any part of your body near rotating or
moving parts. Always ensure guards are in place
before operating this machine.

(16) INDICATION :
Indicates machine weight, spindle speed required air
Machine weight: pressure, voltage, required capacity of power.
Spindle speed: Air required:

Main Volt: Power required:

2-9
(17) CAUTION:

To shut off the main power of entire machine and

then operator can open electrical cabinet.

0211-00298000

(18) INDICATION :

Lifting / Point position.

N010-03001000

2-10
2-1-6. Machine Specifications

Description 660VMC 850VMC

Table
Table size 810×510mm ( 31.9”×20” ) 1000×510mm ( 39.4”×20” )
T-Slots (no.×w×dis) 5 × 18mm ×1000mm ( 5×0.71”×3.94” )
Max. Table load 500kg ( 1100 lbs )
Travels
X Travel 660mm ( 26” ) 850mm ( 33.5” )
Y Travel 530mm ( 20.8” )
Z Travel 510mm ( 20” )
Spindle
Spindle nose to table 150 ~ 660mm ( 5.9” ~26” )
Spindle center to column 585mm ( 23” )
Spindle taper BT40 ( opt.CT40,DIN40 )
Belt Drive : 80~8000 rpm (opt. 10000,12000rpm)
Spindle speed
Direct Drive : 12000rpm (opt. 15000rpm)
Spindle diameter 70mm ( 2.8” )
Feed Rates
Rapid on X,Y,Z axis 30/30/24min ( opt. 30/30/30m/min.)
Cutting feed rate 10m/min ( 394IPM )
Accuracy
Positioning P0.014mm (±0.004/300mm)
Repeatability PS 0.010 (±0.003mm)
Tool changer
Tool capacity Arm 24 (opt. Carousel 20)
Max. tool diameter 76mm (3”) (Tool is next pocket)
Max. tool diameter 120mm (4.7”) (Without tool is next pocket)
Max. tool weight 7kg (15 lbs)
Motor
Belt drive (F) : 7.5/11kw (10/15HP)
Spindle motor
Direct DRIVE (F) : 5.5/7.5KW (7.5/10HP)
Drive motor X , Y, Z (F) 1.8/1.8/2.5kw (opt. 3.0/3.0/4.0kw)
Coolant pump 1HP (0.76kw)
General
Power required 15 KVA
Air required 5.5kg/cm2,200 L/min
2200×2115×2600mm 2430×2115×2600mm
Floor space (L×W×H)
(86.6”×83.2”×102.3”) (95.6”×83.2”×102.3”)
Machine weight 5550kg (12787 lbs) 5800kg (12787 lbs)

Note :The manufacturer reserves the right to modify the design, specifications,
mechanisms,...etc. without notice. All the specifications shown above are just for
reference.

2-11
2-1-7. Standard Accessories
1. 24-station arm type ATC
2. Coolant system
3. Fully enclosed splash guard
4. Work light
5. Central lubrication system
6. Pilot light
7. Spindle air blast
8. Rear chip flash system
9. Air blast chip blower cutting air blast
10. Air purge curtain
11. Tools &tool box
12. Leveling bolts and pads
13. Operation manual & parts list

2-1-8. Optional Accessories

1. BT-40,CT-40 or DIN-40 pull studs

2. Chip conveyor
3. Belt : 10000rpm/12000rpm spindle
4. Directly coupled : 12000rpm spindle
5. 4th axis preparation
6. 4th axis complete set
7. Spindle oil chiller
8. Coolant through spindle
9. Chip flushing device at rear side
10. Automatic tool length measurement
11. Heat exchanger for electric cabinet
12. Dual screw type chip conveyor
13. 20-station carousel type ATC
14. 32-station chain type tool magazine
15. Oil skimmer
16. Air gun
17. Coolant gun
18. Linear scale

2-12
2-1-9. Power Specifications

Item 660VMC / 850VMC

Voltages 3-phase, 380~ 415 VAC by local user
Frequency 50/60 Hz ± 1 Hz
Voltage tolerance ± 10 % or below
Power gross load capacity 20 KVA
Cable requirement
Primary power cable*1 14 m/m² or more
Grounding cable 14 m/m² or more

*1 These values are calculated if :

allowable max. temperature of insulation material 65℃
ambient temperature 35℃
metal duct wiring.
The ground resistance must be 100 Ω or below.

2-13
2-1-10. Tool Shank and Pull Stud

(1)
BT-40 Tool shank

16.6 65.4
60 °

17H8
44.45

16.1
53
53

M16xP2

7/24 TAPER
10 22.6 22.6

25 2

Figure 2-8

BT-40 Pull stud

60

M16xP2 5 35 19
45
°
23

17

15
10

28 3

Figure 2-9

2-14
(2)
CT- 40 Tool shank

34.93 MIN
19.05

11.176

3.175 68.25
22.61 25.02
5/8"-11UNC
44.45 MAX

44.45

16.28

16.38
56.36
72.72

9.195 7/24 TAPER

3.835

Figure 2-10

CT-40 Pull stud

Figure 2-11

2-15
(3)
DIN- 40 Tool shank

35 MIN
19.1

11.176

3.2 68.4
22.8 25
M16
50 MAX
72.3 0.05

44.45

17

16.1
7/24 TAPER
7

Figure 2-12

DIN-40 Pull stud

54

26

20

15 °
19

M16 7
17g6
23

19
14
45

30
°

4 2

Figure 2-13

2-16
2-1-11. Mechanical origin

+Z

Origin position

+X +Y

660VMC 850VMC
X 660 850
X1 -330 -425
X2 330 425
Y 530
Y1 265
Y2 -265
Z 660
Z1 150
Z2 510

Figure 2-14

2-17
2-2. Spindle Motor Output Characteristic

(1) 8000 RPM SPINDLE (QAN-200L)

TORQUE(N-m) POWER (KW)

100 15

90

80 S6-40%(11.5KW) 12
73.2N-m
70 S6-60%(9.8KW)
62.4N-m
60 9
S1(7.5KW)
50 47.7N-m
S6-40%
40 S6-60% 6
S1
30
1500rpm

20 3

10

0 1000 2000 3000 4000 5000 6000 7000 8000

Spindle speed (rpm)
Figure 2-15

(2) 10000 RPM SPINDLE (QAN-200L)

TORQUE(N-m) POWER (KW)

100 15

90

80 S6-40%(11.5KW) 12

70 S6-60%(9.8KW)
60.4N-m
60 9
51.5N-m S1(7.5KW)
50

40 39.4N-m S6-40% 6
S6-60%
30 S1
1818rpm

20 3

10

0 2000 4000 6000 8000 10000

Spindle speed (rpm)

Figure 2-16

2-18
 (3) 12000 RPM SPINDLE (QAN-200L)

TORQUE(N-m) POWER (KW)

60 15

50 48.8N-m
S6-40%(11.5KW) 12
41.6N-m
40 S6-60%(9.8KW)
9
31.8N-m
S1(7.5KW)
30
S6-40%
S6-60% 6
20 S1
2250rpm

3
10

0 2000 4000 6000 8000 10000 12000

Spindle speed (rpm)

Figure 2-17

2-19
2-3. All Moving Elements
(1) X axis moving direction

Figure 2-18
(2) Y axis moving direction

Figure 2-19

2-20
 (3) Z axis moving direction

Figure 2-20

2-4. Stroke Diagrams

(1) X axis travel distance

Figure 2-21

2-21
(2) Y axis travel distance

Figure 2-22

(3) Z axis travel distance

Figure 2-23

2-22
2-5. Safety Related Elements
(1)

Figure 2-24
(2)

Figure 2-25

2-23
(3) Chip CONV Installation

Figure 2-26

2-24
2-6. Level of Noise and Brightness
2-6-1. Noise Level
1. Measuring instrument:
Instrument Model Serial No. Calibration due
Bruel & Kjaer Precision
integration Sound level meter Type 2236 2015199 2010/03/11
(conforms with IEC651 Type I)

2. Reference document:
Measurement procedure used: BS EN ISO 11202:1996
3. Measuring condition:
a. Idle running at 80% spindle maximum rotational speed.
b. Spindle speed:6400 rpm (max: 8000 rpm)
4. Measuring positions: 3
:Background

2 4

Controller panel

1
Distance: 1 m from the machine surface.
Height: 1.6 m from the floor.
Measuring points are defined by clause 1.7.4.2(u) of Machinery Directive
2006/42/EC Annex I.
4. Test results:
Measure Position Noise Level (dB(A)) Record NO.
Background 59.9 15
1 62.6 6
2 62.8 7
3 64.1 8
4 63.1 9

2-6-2. Brightness level

we used digital lux meter to measure the lighting. The meter is produced by TES
electronic corp., the type is TES 1332. The brightness lighting we measured is about
600 lux under the light. The distance is 285 mm from the spindle nose. It can take well
vision when operating the machine.

2-25
2-7. Check list
1. Before machine installation to ensure all the attachment parts be received.

Item Object Remark

1 Chip disposal box and coolant water tank
2 Tool box for maintenance and screws… etc.
3 Hose (Ø 1/2”)
4 Machine operate instruction
5 Controller operate instruction
6 Optional accessories

2. Check list for maintenance

Item Job Interval

1 Clean machine (Do not use air compressor) Daily
2 Checking electrical circuit connection Weekly
3 Replacing coolant and clean coolant tank 3 months
4 Check and clean motor Annually
5 Slide (x-axis) Annually
6 Saddle (z-axis) Semiannually
7 Spindle nose Annually
8 Automatic lubrication unit Weekly

2-26
3. MACHINE INSTALLATION
3-1. General Preparation & Selecting Location
The electrical power should meet the specifications. Attempting to run the milling
machine center from any other source can cause severe damage and void the
warranty.

Do not switch POWER ON button on the control panel until the installation
preparation is completed.
Do not attempt to operate the machining before all of the installation procedures
have been completed.
Never service the machining center before the power be connected completely.
Never leave machine when the electrical cabinet door opened and the power is on.
The high voltage may be present in ALL areas of the electrical cabinet.
Never reach into the holes in the vertical column. The counterweight inside can
cause severe injury as it moves up and down.

To upgrade the operation efficiency and accuracy of precision machining, a proper

foundation is required.

It is recommended to locate the machine in a place away and without the influence of
damping, chemical gas or trembling. The machine body is not allowed to be exposed
to sunshine or rain. Please be sure not to install the machine adjacent to planing
machine, milling machine molding or punching machine. Otherwise, it will result in
poor performance.
During operation the ambient temperature of machine always keep it at 0 to 45℃
(32 to 113℉). Where the humidity is considerably fluctuating and/or it is highly
humid ; normally 75% and below in relative humidity.
A higher humidity would deteriorate insulation and might accelerate the deterioration
of parts. Though special dehumidification is not required, avoid locating the machine
at a place apt to be humid.
Avoid using the machine under such environments as to be especially dusty and/or
to have a vaporous organic corrosive gas highly concentrated.
A distance of at least 20” (500mm) is required from machine to wall and objects or
between machines to ensure easy reparation, cleaning and maintenance of machine
as well as easy opening of the door of electric cabinet.

3-1
3-2. Foundation and Layout
With special torque-resistant capability at the machine base, the machine requires
no particular foundation. Just provide 6” (150mm) thick of concrete on the floor and
leave space for component leveling.
Do not use wood foundation which, with nature of unsuitability, may cause the
machine to move gradually.
Install the machine on the first or second floor. Take the stress of ceiling and
foundation into careful consideration to see if machine load can be offset.

Figure 3-1

3-3. Installation Procedure

3-3-1. Unpacking
Remove the top cover of wooden case first and then the plates on four sides.

Carefully take out fittings at first, if necessary. Remove the set screws used for
holding the machine on the base.

Disassembling packing crate and remove skids as carefully as possible to avoid

damaging the machine. If the machine is damaged during transportation, contact
your local dealer and the transportation company who delivered your machine
immediately.

Be sure to check your machine against the packing list which is shipped with every
machine. In case of shortages, note items not received and contact your local dealer.

3-2
3-3-2. Proper Method for Lifting Machine

Figure 3-2
Use crane for lifting the machine:
1. Insert two M36 eye-bolts in column and two M36 eye-bolts in base.
2. Place four wire rope through the eye-bolts for lifting as shown in Figure 3-2.
3. Lift the machine above the ground about 50mm (2”), then move it to the
determined place.
Caution:
1. Move table to the middle of the saddle and the saddle near to the column
as close as possible while the machine is being moved.
2. Watch out for the machine balance during moving.
3. The safety loading ability of required for crane and sum of all the safety
straps used must more than 5000kgs at least.
4. Place protection material on any part of the machine that might be
touched by straps.
5. Only an authorized crane operator should use the crane.
6. Before placing the machine, fix the adjusting screw on the base, make the
machine as close as possible to the floor, and position the leveling pads in
their most suitable place, so as to increase the stability of machine.
7. Used for lifting machine’s belt or wire rope that their load capacity must
more 5 tons at least. The length of belt or wire rope needed is two 1200
mm and two 2800mm.
8. If workplace’s weight more than 25kg, it will need use crane to load it to
the machine and unloaded.

9. All lifting/rigging shall follow the local standards/regulations.

3-3
3-3-3. Proper Method for Lifting Machine ( Forklift )

Forklift required : Load capacity 8 Tons or above.

Delivery method : (refer to Figure.3-3)

1. If machine is fastened on a skid, use fork directly. If machine is not fastened on a

skid, use foot pads to lift machine higher than folk's height before using fork.

2. Delivering machine as figure shown below.

Figure 3-3
Note: Before placing the machine, fix the adjusting screw on the base, make the machine
as close as possible to the floor, and position the leveling pads in their most
suitable place, so as to increase the stability of machine.

3-4
3-3-4. Leveling Machine
It is necessary to level the machine before starting to operate the machine.
Please prepare the following tools to adjust machine leveling.

1. Accurate spirit leveling gauge (spec. 0.02mm/1000mm or 0.001 in/4ft).

2. Two adjustable wrench.

Clean the table surface thoroughly, set one of the spirit leveling gauge on the
longitudinal direction and the other on the cross direction of the slide.

If there is only one leveling gauge available, then use it on both directions
alternately.

Adjust the eight leveling screws bolts1 located at the bottom of the machine base
(as shown in Figure 3-4) until the machine is leveled within 0.02mm/1000mm
(0.001”/4ft) in both directions.

Lock the nuts 2 on the leveling screws, and recheck the level to see whether the
level of machine is still correct.

Suggestion: For the newly installed machine, check its level once every week.
When the foundation is rigid enough, then you may level the machine
once per month.

Figure 3-4

3-5
3-3-5. Install Z-axis Servo Motor and Remove Supporter

1. During installing of axis couplings, level it with the mark of ball screw.
2. Use torque wrench to tighten (30N.m.) those screws (M8) on the coupling.
3. Switch on the power until the panel light is ready, use MPG to move the spindle
(z axis ) upward approximately 35mm and then discharge the supporting plate.
4. Discharge the fitting plate (for shipping) of X,Y axis.

Figure 3-5

3-6
3-3-6. Install the Coolant Tank and Chip Disposal Box
1. Take the coolant tank placed into the bottom of machine from its front until
touched the machine base. Installing two chip disposal boxes onto the coolant
tank from both sides of coolant tank.
2. Link the power line to water pump and connect the hose between the outlet of
pump and the joint of splash nozzle.
3. Tightening all the hoses with fasteners in the connected positions.
4. Filling the coolant into the coolant tank to proper level for about 250 liters volume.
5. chip conveyor is installed completely.

3-3-7. Connecting Power Supply

1. Make sure the voltage of incoming power supply is the right type that the machine
requires or as marked on the unit.
2. Connect the power wires per electrical code in your area.
3. Power wires, grounding and over-voltage protector should comply with the local
electricity regulations.
4. Power system
a. 400V
b. 3 phase 50/60Hz
c. Over 50 Amp
5. The external power cable requires wires diameter. 16 ~ 25mm and a 75A
non-fuse switch (NFB breaker)
6. After the wires are completely installed, check if the voltage is 400V ± 10%.
7. Confirm if the motor phase is correct.
8. Compress air source : Pressure 6 ~ 8 kgf/cm²
Capacity :200L/min.

Note : Do not turn on the machine motor when its voltage is different from power
voltage and contact electric technician for reparation.

3-7
3-3-8. Each Axis Servo Motor Grid Adjustment

1. Make zero return, the position coordinate is zero.

2. Use hand wheel to move the dog towards limit switch until the home position dog
touches the limit switch. When the position dog touch the limit switch, the
following parameters from “ 1 “ change to “ 0 “.

Axis Heidenhan Controler

X I4
Y I5
Z I6
4 th I7

3. When the limit switch touches the position dog, the readings of X and Y、Z axis
coordinate value must between at 5.5 ~ 6.5mm. ( The distance is half rotation of
ballscrew’s running.) If readings not in above range, please adjusts the position
dog to make the readings in the range.

3-8
3-3-9. Tool Change Point Adjustment

The Z-axis servo motor is too high for packing, so it has to be removed during
delivery. After reinstalling the Z-axis motor onto the machine, the Z-axis grid amount
and tool change point must be readjusted.

1. Carousel Type Tool Change

a. Adjust the grid amount according to section 3-3-7, then set Z-axis return to the
zero point.

b. Fix a dial indicator onto the table with its probe pointing upward.
c. Place a tool shank in the pot, touch the bottom face of the tool shank with the
indicator. Then zero the indicator.

d. Place this same tool shank on the spindle. Use hand wheel to move the Z-
axis downwards till the bottom face of the tool shank touches the gauge at
zero.

e. Set the Z-axis coordinate readings on the screen to parameter MP 4210.13 &
MP 4210.14.

2. Arm Type Tool Magazine

a. Adjust the grid amount according to section 3-3-7, then set Z-axis to home
position.

b. In Manual operation mode, use help function, select “ Tool pocket (pot ) down”
to turn the pot down.

c. Fix a dial indicator onto the table with its probe pointing upward.

d. Place a tool shank in the pot, touch the bottom face of the tool shank with a
indicator. Then zero the indicator.

e. In HANDLE mode, move X-axis to move the indicator away.

f. In Manual operation mode, use help function, select “ Tool pocket (pot) up” to
turn the pot up.

g. Place this same tool shank on the spindle. Use handwheel to move the Z-axis
downwards till the bottom of the shank touches the indicator at zero.

h. Set the Z-axis coordinate readings on the screen to parameter MP 4210.14.

i. If the coordinate value is beyond 3-5mm, move the limit dog fixing plate and
readjust the grid amount and tool change point.

3-9
3-3-10. Clean & Lubricating Machine
All protective coating must be removed before using machine. Do not attempt to
move any ways if the coating still exists.

Be cautious while selecting a suitable cleaning agent. Paraffin applied with a clean
brush will soften the protective coating. The protective coating can then be removed
with clean rags.

Note : 1. Do not use gasoline or any other flammable solution to clean the machine.
2. Clean and lubricate all the exposed ways of table and saddle. Drive the table &
saddle to one end of travel. Clean and lubricate ways thoroughly then drive table
& saddle to the other end and clean and lubricate ways thoroughly as well. Be
sure to use a suitable lubricant such as Sunoco Waylube#11180 or Mobil Vactra
Oil #2.

3. This job has to be done after the machine is already under normal power
supplied.

3-4. Checkups During the Test Run

After level adjusted and machine cleaned are finish. To proceed a test running of
machine which turn rotating the spindle by half of maximum speed for about 20
minutes.

1. Check ups on the machine before operation.

A. Check to be sure that the spindle head supporter, counter weight supporter and
fixture of ATC are removed. (Operation with them will damage the machine.)
B. Check for missing parts or accessories.
C. Check each part of the machine be lubricated ensure that it is provided with the
specified amount and brands of lubricating oil. (Centralized lubrication or
lubrication for the spindle head, table and saddle…etc.)
D. Check hoses and pipes of lubrication system for their correct and firm
connection.
E. Check that the coolant tank installation on the machine is secure.

2. A. During the test running, move the safety doors to enclose and open for
inspecting the interlock function of safety doors is normal or not.
B. If there is any malfunction be happened such as obvious abnormal noise
arising or alarm message generated during the test running. Please contact
with the local dealer or the service persons of our company immediately.

3-10
3-5. The procedure for Power-UP and Power-OFF
3-5-1. Power Up
‧ DO NOT touch any switches or buttons when hand are
DANGER wet.
‧ CHECK the machine environment is clean so that
convenient for operation.
‧ CHECK cooler oil, coolant and pneumatic pressure are
sufficient to work.
‧ WARM UP the machine for approx. 15 minutes after
CAUTION turning the power ON
‧ WHEN setting the spindle speed above 3000 rpm, pay the
closest attention.

Power-up procedure is a systematic method of safely turning on the control and readying
the machine for operation. The following is a comprehensive description of the 3 axes
procedure:
1. Turn MAIN SWITCH "ON".
2. TFT flat panel will be display “POWER INTERRUPT” and service pack information,
press CE key to clear the message and continue.
3. The TFT flat panel will display “TRANSLATE PLC PROGRAM”. The PLC program of
the TNC is automatically translated.
4. Shown “the machine guard is opened”.
5. If alarm message “H00 Emergency stop buttons - > unlock” appeared, release the
emergency button.

Figure 3-6

6. Press the POWER ON push-button about 2 sec on the TNC operator’s panel.
7. Please open the guard and close again.
8. Then press the “NC start” to the zero return procedure of Z, X and Y.

3-11
3-5-2. Power Down

All personnel must know the location of Emergency Stop

buttons and how to use them in case of Emergency.

‧ ALWAYS lock the Main Switch by locker to protect

unauthorized personnel.
CAUTION
‧ DO NOT leave keys on the switches or lockers after
machine is turned off.
To prevent damage to control, machine tool or drives during shutdown, follow the
Power-Down procedure listed below:
1. Establish a condition which ensures that the machine tool will not be damaged when
control is shutdown. Ideally, establish an end-of-program condition with all axes at
Home position. If this can not be accomplished, a cycle stop is adequate, but try to
position the axes clear of the workpieces.
2. Press Emergency Stop push-button. If rotating, spindle will dynamically brake to a
stop. Any axis motion will also cease. Power is removed from axes drive motors and
spindle drive motor, thus disabling axes and spindle.
3. Switch to manual operation mode
Select the soft-key for power OFF, display will show a message “Do you really wish to
switch off the control?”. Confirm machine power off with the YES soft-key.

Figure 3-7
4. Turn disconnect switch OFF.
NOTE: The machine is placed in E-Stop before the control is turned OFF is to remove
power in two distinct steps; first from the drive motor, then from the drives. Removing all
power at once can damage the machine.

3-12
3-6. Maintenance of Windows

A. Replacement method of PC (6mm thickness) window

- Replacement period: one year
- Replacement procedure as following:
1.
Turn the power off.

2.
Loosen the screws on press
plate of window.
(the sequence of press plate’s
dismantling:(1Æ2Æ3Æ4)

3.
Clean the surface between
window and guard, then restore
the new window.
Turn the power on.
(the sequence of press plate’s
installation: (4Æ3Æ2Æ1)

3-13
3-7. Installation guild of drain pipe for electrical air conditioner
3-7-1. Recommendation

When retrofitting air conditioner for electrical cabinet, please connect the drain
outlet beneath of the air conditioner with the drain pipe by strip. Please put the
other end of pipe into the bucket or drain system in the factory. Please make sue
the proper of drain pipe to avoid any gum in the pipe resulting the main system or
control system damaged burnout 。(Fig.3-5)

Note: Temperature setting between 25℃ ~ 28℃.

Figure 3-8 Sketch for drain pipe installation

3-14
3-7-2. Oil Separator install and adjustment

Oil separator sent with machine has to be put at the rear side of machine base,
gust beneath the outlet of waste oil. The bigger room inside of the oil separator tank
is for collecting the waste oil. Please fill the coolant liquid and adjust bolts to make
the waste oil evacuated smoothly. (Fig 3-6)

Figure 3-9 Oil separator tank adjustment

3-15
4. OPERATION
4-1. Control panel description

The following illustrated diagrams just provide the new add buttons and its
function described in machine. For any other detailed information, you must refer
to the CNC controller operation manual.

4-1
Indication Function

Relay 24VDC Power Button.

Press the button to turn DC 24V power and Ger. Servo
drive ready.

X – Axis Positive Travel Button.

In Manual Mode, press this button to move table in x-
axis positive direction. Adjust the speed rate switch to
control the travel speed.

X – Axis Negative Travel Button

In Manual Mode, press this button to move the table in
x – axis positive direction. Adjust the speed rate to
control the travel speed.

Y – Axis Positive Travel Button

In Manual Mode, press this button to move the table in
Y – axis positive direction. Adjust the speed rate to
control the travel speed.

Y – Axis Negative Travel Button

In Manual Mode, press this button to move the table in
Y – axis negative. Adjust the speed rate switch to
control the travel speed.

Z – Axis Positive Travel Button

In Manual Mode, press this button to move the head in
Z – axis positive direction. Adjust the speed rate switch
to control the travel speed.

Z – Axis Negative Travel Button

In Manual Mode, press this button to move the table in
Z – axis negative. Adjust the speed rate switch to
control the travel speed.

4-2
Indication Function

The 4th – axis Negative Travel Button

In Manual Mode, press this button to move the 4th –

4 axis in positive direction. Adjust the speed rate switch

to control the travel speed.

The 4th – axis Negative Travel Button

In Manual Mode, press this button to move the 4th –
4 axis in negative direction. Adjust the speed rate switch
to control the travel speed.

Rapid Button
Press axis button and this button simultaneously can
move the axis according to speed rate.

Spindle CW Button
In Manual Mode, press this button to rotate the
spindle
in clockwise direction. Be sure to input S value,
otherwise the spindle will not rotate.

Spindle OFF Button

In Manual Mode, press this button to rotate the
spindle
rotation.

Spindle CCW Button

In Manual Mode, press this button to rotate the
spindle
in counterclockwise direction. Be sure to input S
value,
otherwise the spindle will not rotate.

Tool Change Enable Button

Before changing tool manually, press this button to
confirm. Tool unclamp PB will not execute without
confirmation.

4-3
Indication Function

Coolant ON / OFF Button

Press this button to turn NO / OFF the coolant
system.

Reset Overtravel Button

Press this button to resume the axis motion when it
touches the travel limit.

Permissive Enable Button

This button’s function is the same as the Permissive
button on the MPG.

Guard Unlock Button

1. When machineing program is running, the

safety guard can not allow to be opend
even if turn the Manual Mode Key Switch at
ON position.
2. When machineing program is not running,
and the Manual Mode Key Switch is at
ON position, the safety guard can be
opened following by step 3 as below.
3. Press GUARD to open operation door
DOOR

“ ”.
4. The door is automatically locked after being
closed.
5. Press GUARD to open the operation door.
If one wants to open the other doors, press
GUARD again.
6. The speed of the spindle and axial
movements are limited
7. When the guard is opened, the movements
can be allowable by hold-to-run

4-4
Indication Function

Worklamp
Press this button to turn NO / OFF the worklight. (The
power switch of the worklight itself has to be turned
on.

NC Start Button
Press this button to start the commands or start the
program.

NC Stop Button
Press this button to hold the commands or program
execution. Press SNC start button to resume.

The 5th – axis Negative Travel Button

In Manual Mode, press this button to move the 5th –

5 axis in positive direction. Adjust the speed rate switch

to control the travel speed.

The 5th – axis Negative Travel Button

In Manual Mode, press this button to move the 4th –

5 axis in negative direction. Adjust the speed rate switch

to control the travel speed.

R GE N
ME EMERGENCY STOP
E

CY

Press this button to stop the machine

completely.
In case of any emergency cases:
S TOP 1. Press the emergency button which is nearest
button as soon as possible.
2. Machine will be stopped immediately.
3. Screen will display the alarm message
"Emergency".
4. After the emergency situation has solved, turn
the switch clockwise to release the emergency
button.
5. Then press “POWER ON” and NC control is
ready automatically.

4-5
Indication Function
Manual Mode Key Switch
DOOR 1. When machineing program is running, the
safety guard can not allow to be opend
even if turn the Manual Mode Key Switch at
ON position.
2. When machineing program is not running,
and the Manual Mode Key Switch is at
ON position, the safety guard can be
opened following by step 3 as below.
3. Press GUARD to open operation door
DOOR

“ ”.
4. The door is automatically locked after being
closed.
5. Press GUARD to open the operation door.
If one wants to open the other doors, press
GUARD again.
6. The speed of the spindle and axial
movements are limited
7. When the guard is opened, the movements
can be allowable by hold-to-run
Magazine rotation soft button:
If manual magazine rotation is needed, press this
button in Manual Operation, and then press " MAG
CW " or " MAG CCW " to rotate the magazine to the
desired position. Press it again to stop it.

MAG CW soft button :

Press this button to run the magazine in CW direction.

MAG CCW soft button :

Press this button to run the magazine in CCW
direction.

Coolant Floor Clean soft button :

Press this button to activate the Coolant Floor Clean,
and press it again to stop it.

4-6
Indication Function

Chip Conveyer CW soft button :

Press this button to run the chip conveyer in CW

direction, and press it again to stop it.

Chip Conveyer CW soft button :

Press this button to run the chip conveyer in CCW

direction, and press it again to stop it.

M07 (Coolant Through Spindle or Tool) soft button :

When spindle is running and pressing this button,

activate M07 function, and press it again to stop it.

M23 (Air Blow) soft button :

Press this button to activate M23, and press it again

to stop it.

Lubrication soft button :

Press this button to pump lubrication automatically for

15 seconds.

Below Bar Chart :

Function swift button display.

Upper Bar Chart :

Function swift button display.

4-7
4-2. Power Socket description

(1) Power socket wire number :

1 8
2 9
3 10
4 11
5 12
6 13
7 14

NO. Wire number NO. Wire number

R1,S1,T1,E
1 8
L11,L12,L13,E
2 U11,V11,W11,E 9 U5A,V5A,W5A,E
3 U10,V10,W10,E 10 U5B,V5B,W5B,E
4 U9,V9,W9,E 11 U15,V15,W15,E
5 U5,V5,W5,E 12 U27,V27,W27,E
6 U6,V6,W6,E 13
7 U1,V1,W1,E 14

4-8
(2) Graph description

Indication Function
(1) Spindle cooler connector.

(2) Remote type through spindle coolant suction power

cable connector.

(3) Remote type through spindle coolant separation power

cable connector. or Paper tape type through spindle
coolant control cable connector.

(4) Remote type through spindle coolant power cable

connector. or Paper tape type through spindle coolant
power cable connector.

(5) Chip conveyor connector

(6) Coolant flusher connector

4-9
 Indication Function
(7) Coolant connector

(9) Auger conveyor connector. (Right)

(10) Auger conveyor connector. (Left)

(11) Clean gun connector.

(12) Oil skimmer connector.

(8) (13) (14) Reserve

4-10
5. LUBRICATION
5-1. Automatic Lubrication System

The automatic lubrication system includes intermittent pumping and metering valves
for proportional distribution and includes an alarm for low fluid level warning. Still,
please check the fluid level before operation. Add the following recommended
lubricant to the reservoir：

Lubricating Checking Tank

Method Oil grade system
point period capacity
1.CASTROL
2.MAGNA BD68
Automatic When buzzer Oil fill to upper
1 2 Liters 3.MOBIL, VACTRA 2
lubricating unit alarms limit of oil gauge
4.SHELL, SPIRAX HD 90
5.ESSO, GEAR OIL GX90
Use specific
1.MOBIL, MET7351 or
coolant oil to
MET457
different
2.SHELL, GALLIAD or
material i.e.
2 Coolant As required 250 Liters MACRON 32
steel. copper
3.ESSO, DRT45 or DRT 44
and special
CASTROL,
steel, copper
4.HYSOL, HYSOL GS
alloy etc.
Note:
1. We recommended the CASTROL lubricant oil is the principal choice in our
machine to make sure the performance. The names of product are show as
above.
2. The use of low combustion temperature coolant fluids is forbidden.
3. There are lots of a variety types of coolant available on the market. Our company
does not specify the type of coolant to be used. Choose a coolant suitable for the
user’s applications by consulting the supplier, taking the following requirements
into consideration.
(1) The coolant must be free of constituents with adverse effects (smell, poisoning,
etc.) on human beings.
(2) The coolant must not deteriorate during storage.
(3) The coolant must not cause corrosion of the machine.
(4) The coolant must not peel the coating off the machine.
(5) The coolant must not cause deterioration of accuracy.
(6) The coolant must not cause swelling of rubber parts.

5-1
 4. Note that a company cannot be held responsible for any trouble arising from the
use of coolant if the user without according recommendation described as above
to choose and replace the coolant.
5. Before turning on the machine, please make sure that the pressure gauge and the
lubrication system are working properly. Under normal conditions, the pressure
gauge will go up to 60Psi first, then slowly down to zero.
6. The lubricator would provide oil one time to lubricate each one of X、Y、.Z axis after
sum of them moved for 10 minutes. It can be set the interval lubricating time for
providing oil by DGN 505 (unit : second ), and the pressure will maintain 10
second. If the pressure decreases drastically after going up, this indicates that
there might be a problem of oil leaking. In that case, a proper reparation is
required.
7. If the lubrication low then alarm message “LUBE LOW” on. At the same time
Single Block ON.
5-2. Lubrication Structure
Following is lubricant linking path which show the oil from lubricator to saddle, table,
and spindle head.

Link to X axis ballscrew Link to saddle

Back view of table (X axis)

Link to lubricator

Link to table Link to Y axis ballscrew

Bottom view of saddle (Y axis)

5-2
 Link to Z axis ballscrew

Link to saddle Link to spindle head

Link to lubricator

Figure 5-1

5-3. Electric Cabinet and Power cable

1. The main power cable can be put into the cabinet through the bottom of the cabinet.
The main switch is located on the right side of the cabinet. And electrical diagram
can be found inside the cabinet.

2. Make sure the voltage of incoming power supply is the right type that the machine
requires or as marked on the unit.

3. Connect the power wires per electrical code in your area.

4. Power wires, ground and over-voltage protector should comply with the local
electricity regulations.

5. For wiring to other voltages, be sure to rewire the spindle motor & coolant system
and transformer to correct voltage. The relevant currents, fuses and overload relays
are shown in the electrical manual. See Note 2.

Note : 1. Do not turn on the machine motor when its voltage is different from power
voltage and contact electric technician for reparation.

2. The spindle drive is a 400 volts only and must be replaced for other
voltages.

5-3
6. MAINTENANCE
6-1. Adjusting Belt Tension
The new belt tension between spindle motor and spindle should be 10.9 mm elastic
length when pressed by 4.1 kg at the distance center between spindle and motor.
After a period of time, if the belt turned looser, adjust the belt to be 10.9 mm by 4.1 kg.
1. If want to increase tension of belt that may first loosen four screws 1 properly.
Rotating the adjusting screws 3 by clockwise direction to push the motor seat 2.
Make the belt’s elastic length between spindle motor and spindle is to be
extended 10.9 mm by 4.1 kg. Tighten the screws 1 , then could obtain normal
tension of belt required.
2. When belts had been olden in a long period used or for considering keep machine
efficient transmission torque. It will need to replace the belts. Loosen screws 1
and rotate the adjusting screws 3 by counter-clockwise direction to make the
motor seat 2 move near to spindle. Until the belt is fully relaxed and easy
removed. Replace the belt by new one and re-set belt tension follow same method
such as item 1 described.

1
2
3

Figure 6-1 Adjusting belt tension

6-1
 6-2. Pneumatic system
6-2-1. Pneumatic Control Circuit

Spindle air blast

Cutting air blast

Tool magayine cylinder

Pressure setting
5.5kg/cm

Pressure setting (Auto drain)

Pneumatic inlet

Air tank

Air blaster
Water reservoir (manual drain)
Spindle air ring

Drain

Figure 6-2

6-2
6-2-2. Pneumatic tank
The machine is equipped with a pneumatic tank separately for the pressure
requirement of tool change; in order to provides the operator with a stable and efficient
tool change operation. The air pressure inside the air tank is supplied by air
compressor through pressure gauge ( filter particle and water ), thus; it’s temperature is
higher than air and lower moisture. The air inside the air tank which cooling by air will
produced moistures that might be lower down the performance of air tank, this will
caused the air tank inefficient and in stable. The machine is equipped with a filtrate
drain valve at the rear side of the machine (see drawing). Please have the machine
maintained after three months and drain out the filtrate the same; in order to return it’s
performance. Please check the manual drain (see drawing ) of pressure gauge and
drain out it’s filtrate everyday.

Figure 6-3

6-3
6-3. Remove chip and renew coolant
1. When there is too much chip deposited 6–4 in the machine or before the end of work
everyday. It is necessary to take a little time for removing the chip from the machine.
First should turn off the power on the operate panel, then opening the safety doors.
Use a brush to clean chip in all the working area to fall into the chip disposal box or
the chip conveyor. Pull out the chip disposal box from the both sides of machine.
Clean-up the chip where inside the chip disposal box. Replace chip disposal box into
the initial position. If employ a chip conveyor must use a dust absorber to clear out
the chip on conveyor.
2. When the coolant quality is seriously contaminated or in accordance with the
required of routine maintenance list to decide the timing for clean water tank and
renew coolant. Always recommend to clean water tank and renew coolant will be
done for one time per every 3~6 months.

6-4
6-4. Notice for maintenance and inspection
Execute an emergency stop or switch off the main power supply before carrying out
maintenance and inspection work. If the machine is still in an operable condition
during this work and for example, a sensor is inadvertently touched, the machine may
move due care is therefore required. Before operating the machine, make sure that
there are no obstacle to motion in the vicinity of the machine.

1. Maintenance and inspection work must be performed without tail in order to keep
the machine operating at its peak performance and make it safe to operate at all
times.
2. Device a maintenance and inspection plan and carry it out on a regular basis.
3. Proceed with maintenance and inspection as planned even if this interferes with
the production plan.
4. Before starting on the maintenance and inspection work, turn the power switch off.
5. When working inside the electric control cabinet or repairing the machine, set the
power switch to the OFF position and lock it.
6. Do not use air to clean the machine. This may cause dust or sand particles to
cover and inserting to the bearings or slide ways.
7. Use only lubricating oils which are recommended by a company.

In order to operate the machine correctly and make the most of machine’s functions
and performance ,all operators must thoroughly understand the machine.

To keep the machine operating at its highest level, it must be inspected every day. If
an abnormality is discovered during daily inspection, it must be reported to the
supervisor and the person responsible for machine maintenance .

Quick action should be taken. For problems that cannot be repaired by the user or
those for which the cause cannot be isolated, contact you’re company service
representative.

6-5
 Daily Replenishing Oil and Inspections by the Machine Operator.

Maintenance and Repairs by Maintenance Mechanics

Service Request Call to a company Representative.

.
1 Lubricating Oil and Supplying Coolant
Always use the types of oil specified by a company.
Do not mix the oil of different brands even if they are indicated as the “ equivalent
oil ”.
My company will not be responsible for any problem a rising from the use of oil not
specified by a company if the user not follow with ours recommendation.

1.1 Storing Oil

If oil is stored in user’s shop, observe the following points to prevent the oil from
being degraded. It is advisable to obtain only the amount of oil to be used.

(1) Store the oil in a place where it will not be subject to direct sunlight or rain.
(2) Keep the oil clean. No foreign matter and water should be allowed to enter the
oil storage tank.
(3) Never use degraded oil or oil with foreign matter or water.
(4) If a middle tank is used, remove foreign matter and water from the tank at least
once a year.

6-6
1.2 Cautions When Replenishing Oil

(1) Always use the same oil jug for the same oil. Never use a jug used for different
brand oil.
(2) Never remove the filter from the filter port when supplying oil.
(3) If oil other than specified by a company used mistakenly or different brands of
oil are mixed, clean the tank and piping run immediately.

1.3 Disposing Waste Oil

Disposing factory waste oil without legal permission is not allowed.

Always ask the service company when disposing oil.

1.4 Supplying Oil

Supplying Oil to the Slide way Lubricating Oil Tank

(1) Check the lubricating oil tank volume with the oil level gage installed on the
lubricating oil tank.
(2) Remove the cap on the oil supply port.
(3) Supply the specified lubricating oil from the oil jug while checking the oil level
with the oil level gage.

1.5 Supplying Coolant to the Coolant tank

(1) Press the coolant off switch to stop coolant supply.

(2) Check the coolant tank volume with the coolant oil level gage.
(3) Supply coolant from the top of coolant tank.

1.6 Check Before Daily Operation

Before turning on the power

(1) Make sure that there are no abnormalities for external piping, cables and
coating intact, all doors closed…etc.
(2) Check the shop floor around the machine for the hazards from such as
coolant ,hydraulic oil ,lubricating oil ,and obstacles.

1.7 After Turning On the Power

(1) Listen to the sound of the hydraulic unit when it is operating.

(2) Make sure that the cooling fan in the electrical cabinet is operating.
(3) Make sure that the switches and indicators on the operation panel operate
correctly.
(4) Check the screen display ; no alarm should be indicated.

6-7
6-5 Maintenance and Inspection List
1. List of maintenance and inspection
Cycle Inspection
1. Remove chips, dust and other foreign matter around the table,
base ,saddle ,tool length measuring device, etc.
2. Wipe off lubrication, coolant and chips from the machine surface
3. Wipe off all foreign matter from the slide ways not protected by
the covers ( base slide ways ).
4. Clean the slide ways covers.
5. Clean the exposed limit switches and around them.
6. Clean the electrical carefully.
7. Check to be sure that the water reserved in the air filter bowl is
Daily inspection completely drained.
8. Check to be sure that pressure is correctly built-up :
Lubricant pressure : 1.2MPa (12kg f/cm²)
Supply air : 5.5kgf/cm²
9. Check the coolant, hoses and coolant tanks and remove all
foreign matter if any.
10.Check the amount of coolant and replenish if necessary.
11.Check to be sure that the indicator lights on the operation panel
correctly turn on or flicker.

1. Carry out daily maintenance.

2. Check the spindle front end, tool holders and other attachment
Weekly ( 50H )
for the burrs, cracks and other damages. Clean around the
Maintenance
spindle.

1. Carry out weekly maintenance.

2. Clean inside the electrical control cabinet and NC equipment
and replace filters if they are considerably dirty.
3. Check the machine level. Also check the lock nuts on the
leveling block bolts and anchor blots for tightness.
4. Clean the air filter. Replace it, if necessary. Never use thinner or
similar agents in cleaning the air filter.
Monthly ( 250H ) 5. Clean the slide ways wipers. Replace them, if necessary.
Maintenance 6. Check to be sure that the solenoids and limits switches can
correctly function.
7. Check to be sure that wiring is properly done without looseness
or disconnection.
8. Check to be sure that the interlock devices and timers can
function normally.
Drain the coolant, clean inside the tank and hose and then fill the
coolant tank with new coolant.

6-8
 Cycle Inspection
1. Carry out weekly and monthly maintenance.
2. Clean the NC equipment, electrical control unit and machine.
3. Clean all the motors.
Maintenance 4. Check the bearings in the motor for noise. Replace the
Every six bearings, if necessary.
Months 5. Visually check the electrical devices and reply panel.
( 1500H) 6. Check each indicator and the voltmeter if it is correct. Adjust
or replace it, if necessary.
7. Check the machine movement and functions using a test
tape.

2. Oil lubricant contrast

Trademark \ place (1) OIL SYRINGE (2) OIL COOLER (3) AIR FILTER

美浮 Mobil Vactra2 D.T.E oil Light D.T.E oil Light

殼牌 Shell Tonna oil 68 Tubro oil T32 Tubro oil T32

Exxon Febis 68 Teresso 32 Teresso 32

Gulf Gulfway 68 Harmony 32 Harmony 32

6-9
3. Inspection and Maintenance items
Inspection Intervals
Daily 50H 250H 750H 1500H 3000H
Inspection and Maintenance items (Weekly) (Monthly) (Every 3 (Every 6 (every
months) months) year)

Inside the machine :

1. Remove chips on the X-axis slide

0
Cover.
2. Remove Chips on the spindle. 0
3. Clean the window in the operator’s
0
door.
4. Remove chips on other parts inside
0
the machine.
5. Clean the flood coolant nozzles. 0 (If clogged)

Outside the machine:

1. Discharge chips from the base. 0

2. Clean the sheet filter in the coolant
0
tank.
3. Clean the nozzles for the cover
0 (If clogged)
Coolant system.

Checking the oil level:

1.Check the oil level in the coolant
tank.
0
2. OIL SYRINGE (1) 0
3. OIL COOLER (2) 0
4. AIR FILTER (3) 0
5. ATC Mechanism (1) 0
6. Cylinder (2) 0

Check the pressure:

1. Check the air pressure by the

0
pressure gauge for 5kgf-cm²

6-10
 Inspection Intervals
Inspection and Maintenance items Daily 50H 250H 750H 1500H 3000H
(Weekly) (Monthly) (Every 3 (Every 6 (every
months) months) year)

Area around the machine :

1. Tighten the retention bolt of the tools. 0
2. Check the tips for breakage, cracking an
0
other damage.
3. Check the filters in the electrical control
0
and other damage.
4. Make sure that the emergency stop
0
Buttons function correctly.
5. Change the fluorescent lamp inside the
0
Machine.
6. Tighten the tool screw. 0
7. Check the machine level. 0
8. Clean the bottom of the coolant tank and
0
change the coolant.
9. Check the indicator lamps on the
operation panels for correct lighting and 0
blinking.
10. Visually check the electrical parts and
0
relay panel.
11. Check the wipers at the slide cover for
0
damage.
12. Check the hoses connected to the
0
movable units for damage.
13. Remove chips inside the Z-axis slide
0
cover of column front.
14. Adjust the spindle belt tension 0
15. Add grease 0
16. Check the accuracy on head stock 0
17. Check and adjust if the pressing block
between linear guide and block become 0
loose.

Note : Inspection and Cleaning after Operation

After operation, clean the machine and at the same time check the followings :
1. The acrylic window must change once for keep sling clean and avoid dangers happen
every two years, please.
2. Machine for possible breakage or abrasion.
3. Tools for possible disappearance or abrasion.
4. Sliding surface lubricant and hydraulic unit tanks for oil level.
5. Hydraulic piping for possible oil leakage.

6-11
6-6. Spare part list for maintenance
6-6-1. Vital Element

Item Description Specification. Manufacturer Ergion Q’ty Remark

Germany
1 Control HEIDENHAIN H530 HEIDENHAIN
德國
1
Germany
2 Spindle Motor QAN200L HEIDENHAIN
德國
1
Germany
3 Server Motor QSY155B HEIDENHAIN
德國
2
Germany
4 Server Motor QSY155D HEIDENHAIN
德國
1
Taiwan
5 8000RPM Spindle #40(BT/CT/DIN) CHEVALIER 1
台灣
Taiwan
6 Collet #40(BT/CT/DIN) 丸榮 1
台灣
ESX20-6509 Japan CTS
7 Joint ROCKY 1
(20L/min) 日本 Opt
Taiwan
8 Booster Cylinder DJ2T-T-3.5 中日 1
台灣
Taiwan
9 Ball Screw 40mmxP12/C3 銀泰(PMI) 3
台灣
SFC-080SA-30B- Taiwan
10 Coupling 羅昇 3
16BC 台灣
Taiwan
11 Linear Guide Way MSA35S AMT鼎耀 3
台灣
Taiwan
12 24 station arm type #40-24(BT/CT/DIN) 臻賞 1
台灣
Taiwan Opt.
13 32 station arm type #40-32(BT/CT/DIN) 德大 1
台灣
華樂士 Taiwan
14 Coolant Pump TPHK2T3-3 1
(WALRUS) 台灣
YET-C2P2 Taiwan
15 Oil squirt 裕祥(ISHAW) 1
(110V/100W) 台灣
Taiwan Opt.
16 Spindle Freezer HBO-250 哈伯(HABOR) 1
台灣
Taiwan Opt.
17 Electric Converter HPC-25A 哈伯(HABOR) 1
台灣

6-12
6-6-2. Machine Spare

Item Part No. Description Spec. Q’ty Remark

1 D03-M021410 Spindle sea BT40/8000rpm 1 spindle

2 D05-M020680 Draw bar set BT40 1 spindle

3 2930-01062000 Collet BT40 1 Spindle

PMI PDWC
4 2939-05008A00 Ball screw(X) 1
40-P12-3.5X1-1399L
PMI PDWC
5 2939-05005A00 Ball screw (Y)
40-P12-3.5X1-1059L
R40-12B3-FDWC-873-
6 2939-05006000 Ball screw (Z)
1201-0.008 PMI
Tool changing
7
arm

8 Tool sleeve 2
Deep groove
9 4902-62070500 6207 P5
ball bearing
Angular contact
10 4925-35072000 35TAC 72B 0
ball bearing

11 5021-29300020 Coupling SFC-080SA-30B-16BC

12 5021-29300040 Coupling SFC-090SA-30B-35B

13 5200-29020020 Pressure switch KP-1

14 6004-TC406508 Oil seat TCØ40xØ65x8

15 6101-21300010 O Ring G130

YET-C2P2-3L-110V
16 6313-29004000 Oil filler

17 6501-15005000 PUPM MTH2-30/3A 60HZ

18 6502-26013000 Solenoid valve MVSC-220-4E2-AC110

19 6502-26014000 Solenoid valve MVSC-220-4E1-AC110

6-13
Item Part No. Description Spec. Q’ty Remark

20 6502-26015000 Solenoid valve MVDC-220-3E1-AC110 Air Seal

21 6502-26016000 Solenoid valve MVSC-300-4E1-AC110 Cylinder

22 7103-02021600 MPG Cable 16c 捲線 25x80x25

24 7201-29004010 Limit switch SN-02-R12-ES502E Axis location

25 7202-26001000 Proximity switch E2E-X2D1-N M8 Spindle location

26 7221-80111025 Push button 25mm(黑)

27 7251-62009000 TE Contactor LC1-D096F7 Electric box

28 7271-12000002 Relay MY2NJ DC24V 2 Electric box

29 7391-05635000 Relay unit RBD16 DC24V 1 Electric box

30 0409-00078000 Ventilating fan 12cm/110V 2 Electric box

6-14
6-6-3. Machine Spoilage Part

Item Part No. Description Spec. Q’ty Remark

Machine illumination
1A 5022-29040050 Work lamp 2
QP2026-L

1B 5022-29040020 Work lamp 2 QP2033-L

2 ZG8911-000002 Warning lamp 110V 2

3 6004-TC406508 Oil seat TC40x65x9 2 Z axis oil-proof

4 O Ring 祈瀛 D40 2 Pneumatic cylinder

6-15
7. ARM-CAM TYPE ATC
7-1. Timing Chart

Figure 7-1

7-1
7-2. Relationship Between Proximity Switch, Dog and Scale for
confirmation

HOME POSITION CHECK SENSOR

REFERENCE SCALE

GAP 0.3~0.5mm

1
2
3
4
24V
0V
HOME AND CLAMP / UNCLAMP
POSITION CHECKING DOG

STOP SIGNAL OUTPUT DOG

TERMINAL BLOCK
STOP SIGNAL OUTPUT
SENSOR

CLAMP AND UNCLAMP POSITION DIRECTION OF ROTATION

CHECK SENSOR
SET SCREW
DOGS LOCKING SET SCREWS
(For 4 sensors)

PILOT LAMP

Figure 7-2

1. The figure shown above is an example of a state of original (standby) position and
it shows the center of the original position.

＊ As for the original position, there are some original positions whose states are a
little different from that shown in this figure owing to the scattering of signal and
others.

2. When the dog stops in the original position or the tool unclamp/clamp position, as
long as the reference scale is within the range of the scale for confirmation, it is in
a normal condition. If it happens that the reference scale is beyond the range of
the scale for confirmation, adjustment shall be made according to section “ 7-3-1
Dog Adjustment ”.

3. As for the sequence signal, the OFF signals of the proximity switch are utilized.

7-2
7-3. Dog Adjustment and Installation of Proximity Switch

Before shipping our products, the position of the dog groove has been adjusted
strictly allowing the lag time of the controller of this units. Moreover, enough trial
running has been carried out. Therefore, it is almost unnecessary to modify the dog
and proximity switch. However, if it happens that the dog adjustment and the proximity
switch fixing work are required, pay attention to the following matters.

7-3-1. Dog Adjustment

The dog adjustment is generally refered to the dog for stopping the cam shaft,
because the need of adjustment arises almost from the deviation of stop position due
to overrun. And as to the dog for confirming the position, the adjustment is carried out
only when the interrogative setting of original position between the dog and cam shaft
is required.

Adjusting Procedures:
1. Remove the fan cover of motor, and release the brake using the manual releasing
device so that the fan can be rotated by hand.

2. Rotate the fan as required by hand and coincide the reference scale (on the output
shaft side) of the cam shaft with the reference scales of the housing in the two
places A and B. Using a scale or the like so the three reference scales are in a
straight line accurately as shown in "Figure 7-2".

3. In this state, the reference scale comes nearly to the center of the original position
(marking B position) as shown in "Figure 7-2" However, if it happens that the
position of the reference scale deviates largely from the required position, the
position of the reference scale shall be adjusted so as to come to the center of the
original position by rotating the dog or confirming position (dog A) in the required
direction after loosening two set screws for fixing the dog A. (see Figure 7-2)

4. Tighten the set screw for fixing the dog A, apply the brakes, and then carry out the
automatic operation of ATC. Record the maximum positional deviation after
observing the positional difference between the reference scale and the scale for
confirmation for several times.

5. After releasing the set screw of the dog (dog B) for stopping the cam shaft, rotate
the dog B by an angle corresponding to the maximum positional deviation plus a
margin in the required direction with reference to the phase confirming scales of the
dogs A and B.

7-3
 6. After tightening the set screw of the dog B, carry out the automatic operation of ATC
again and confirm whether the adjustment is satisfactory or not. The adjustment is
completed when mounting the cover is finished, and now do not forget to apply the
brakes.

7-3-2. Installation of Proximity Switch

1. The distance of 0.3mm between the dog and the proximity switch shall be set
accurately using a feeler gauge.

2. The operation pilot lamp shall be fixed at right angles to the set screw without fail as
shown in "Figure 7-2"

3. The set screw shall be coated with "Nevi Lock" and tightened with 1.5kgf-cm torque.

7-3-3. Tightness torque of axis coupling

While re-installing of axis couplings, make sure the tightness torque of the axis
coupling. The specification and portion is shown below.

Figure 7-3

7-4
7-4. Emergency Stop and Method of Recovering Normal State after
Power Failure

When the emergency stop, power failure and others occur during the operation of this
ATC unit. It is possible to reverse the ATC unit operation using the drive motor as a
method of returning to the original position. However, the following method of
returning by hand is recommended from the stand point of safety and reliability.

Recovering Procedures:

1. The power supply shall be shut off for the sake of safety.

2. Remove the fan cover of motor, and release the brake using the manual releasing
devise.

3. While observing the scale for confirming the dog, rotating the motor fan by hand
and let the ATC unit return to the original (standby )position
＊1. As for the original position, refer to "Figure 7-2".

＊2. As for the rotating direction of motor fan, either forward or reverse rotations are
possible.
4. Mount the fan cover and apply the brakes without forgetting.

5. Turn on the power supply.

＊Remarks:

The aforementioned procedure is applicable when the ATC units is attached to the
machine main body.

7-5. Maintenance and Inspection

In order to operate this unit normally and maintain its performance for a long time, pay
attention to the following matters.

7-5-1. Oil Amount Confirmation

When using this unit under the condition that the cam follower, spine and others are
not bathed with oil, it may be broken down, so pay attention to the oil amount all the
time. The oil level indicates the proper oil amount, which should be higher than the
center of the oil gauge.

7-5
7-5-2. Oil change
The lubricating oil should be changed every year. However, when the deterioration
of oil is found out, change the oil immediately.

Lubricating oil: Gear Oil ISO VG220

Amount of oil supplied: About 5.5L

7-5-3. Confirming Dog, Proximity Switch and Chain

1. Periodically removing the cover of the electrical box, and confirm the tightness of
the dog, proximity switch and chain.

2. In addition, confirm the location of the reference scale in the dog position
confirmation zone when the dog stops.
＊Refer to "Figure 7-2 relationship between proximity switch, dog, and scale for
confirmation.

3. When the location of the reference scale is greatly changed in a short period, it is
considered that the looseness of dog and chain, slip of brake, and abnormal wear
exist, so special attention shall be paid.

4. When the chain is greatly loosened, give it proper tension with the idler sprocket.
＊How to give the chain proper tension is : After removing the cover, release the nut
for fixing the idler shaft slightly, and hit the head of nut lightly to move the idler
shaft slightly.
＊There are some cases when the dog original position relative to the cam shaft is
shifted from the required position that causes the chain tightened, in such a case,
readjust the original position referring to the section "7-3-1 Dog Adjustment".

7-6. Confirmation of Timing Belt for Driving

1. Confirm the existence of the looseness, defect and others of the timing belt
periodically.

2. When the looseness, defect and others are found out, adjust the tension or replace
the belt with new one.

7-6
7-7. Adjusting Brake Gap
When using the brake for a long time, the gap (g) of brake will increases gradually
owing to the wear of the friction plate. When the gap (g) becomes over 0.6mm, It is
difficult to attract the magnet (2) when the armature is excited, and consequently, the
brake cannot be released. When using the brake continuously after that, the motor
will rotate with brakes on, consequently, the brake and motor generate abnormal heat
and the malfunction of brake motor occurs.

In order to use this unit safely, the inspection or the adjustment of gap shall be carried
out periodically. (About every year or every 1 to 1.5 million times of brake operations)

How to adjust the gap: BRAKE CONSTRUCTION DRAWING

(1) FIELD
1. Remove the fan cover
(2) ARMATURE
(10).
(3) FAN ASSEMBLY
2. Raise up the finger of the (4) SPRING 1
finger washer out of the (5) SPRING 2
groove of the round nut to (6) ROUND NUT
remove the finger washer. (7) FINGER SPRING

3. Tighten the round nut (6) (8) KEY

until it is lightly locked. (9) HEXAGON SOCKET HEAD CAP SCREW

(10) FAN COVER

4. Then, rotate the round nut
(11) FAN COVER FIXING SCREW
by 100 to 180° in the
g : GAP
direction of the looseness.
(Proper gap: 0.3±0.1mm)

5. Bend the finger of finger washer, which is nearest to the groove of the round nut.

＊ There are some cases where the clip nut (A nut in which the round nut and the
finger spring are united) is used instead of the round nut and the finger spring.
However, the procedure of adjustment is the same.

7-7
7-8. Angle positioning of spindle adjustment （arm type）
1 Two positioning block on the front of spindle would be removed to prevent
interruption when unsuitable adjustment.
2. In Manual mode, press MOD key. Choose HELP function. In HELP menu, select the
(# 302 Z to toolchange position) function, then press NC START key. The Z axis would
return to the toolchange position coordination.
3. Select the ( #301 S to toolchange position) function. Then press NC START key. The
spindle would be orientated.
4. Select the (# 309 Tool pocket put out ) function, then press NC START key. The tool
pocket come down. Choose the ( #311 Tool arm to unclamping pos.) function, then
press NC START key. The arm of tool exchange catching tool by 65°
5. Inspecting the difference of spindle angle positioning by vision. The set value is 10
for one degree turned every time. Key in the angle approximation value and revised
it.
6. Enter the MP (Machine Parameter ) mode by press MOD key, then input the code
number “95148” and press ENT. Now find the spindle orientation angle parameter
MP 3430, then input the spindle angle adjusting value to MP 3430, then the set
would be done.
7. To excite the spindle positioning and inspecting the angle whether it is correct or not.
The inspection methods could use positioning block to measure the slot of both
sides gap where it is on the disc. Measures the approximate equi-distance by vision
that no interruption is admitted.
8. If necessary to revise that makes the direction for jugementted in advance. The
negative value would be more when moving forward for clockwise, and moving
forward of counter-clockwise the negative value would less.
9. After the parameters had revised. It would necessary to do the M19 of spindle
positioned again, that ensure the revised of position is whether correct or not.
10. When the adjustment of angles positioning had finished. Choose the ( #309 Tool
pocket put out. ) ( # 310 Tool pocket put in.) ( #311 Tool arm to unclamping pos. )
( #312 Tool arm to clamping pos. ) (#313 Tool arm to basic pos.) function, and press
NC START key to exciting these tool exchange arm function.
11. It is finished that after locking two positioning block in the front of spindle is tighten.
12. Before the spindle positioned. It necessary to adjust a proper distance about 2 mm
gap between the limit switch and block. The limit switch indicating lights in range of
inspection positioning block areas would light up green color, on both shoulder
would light up red color. Other areas would no actives.

7-8
7-9 The Z axis zero point of tool exchange arm for correcting and set
(arm type)

1. In Manual mode. Press MOD key. Choose the HELP menu, select the ( # 302 Z to
toolchange position ) function, then press NC START key to return Z axis to
toolchange position.
2. Installing standard tool into the arm of tool exchange. (arm of tool exchange return
to 0∘position)
3. Place a pad on the table and a measure gauge be holed on it. To adjust the gauge
probe touch tool rod surface about 0.1~0.2mm and turn the probe to zero position.
4. Remove the standard tool from arm. Choose MANUAL mode and press TOOL
UNCLAMP button, then re-loading standard tool into spindle.
5. Set the ratio at *100. Choose the handwheel of X and Y axially. Place the gauge
under the spindle center. Choose axially of Z and moving Z axis with standard tool
until gauge probe touch to the front of tool face. Make the probe on the zero
position.
6. Press the function key of POS and soft key of ALL. Look at Z axis coordinate
value. This value is the lattice moving amount of Z axis. The lattice moving
amount of Z axis is set in parameters MP 4210.14. Noted: Loading the standard
tool in the arms. The gap between push up and pull down about 0.2~0.5mm. So it
had to consider take the practice measuring of average value for revise that tools
exchanging would more smooth.
7. How to set the parameters MP 4210.14 f Z axis moving amount？ Press the MOD
key, then input code NUMBER “ 95148 ” and press ENT key. Now you can into the
parameter menu. Find the parameters of MP 4210.14. Key-in Z axis lattice moving
amount into parameters MP 4210.14, then the set would be done.
8. For return the Z axis to the tool change position and limit block position recheck.
The inspection methods please reference that the proper distance between limit
block and switch for adjustment and inspection at item MP 4210.14.
9. The home position set of arms and spindle for make sure.
10. Move the measure gauge to the front face of standard tools. Check the gauge
probe whether in the home position or not.

7-9
8. Carousel type automatic tool exchanging system
8-1. The structure profiled diagram of carousel type tools magazine.
Air Cylinder Floating Joint

Reduction Motor

Deep Slot Ball Bearing Leading Rod

Limit Switch Cam Component

Figure 8-1
Cover _　_鯨 F_

Sliding Seat

Tool Magazine Over

Tool Disc Geneva Wheel

Fixed Axis

Figure 8-2

Linking Mechanical Auto Door

Springs
Pads

Figure 8-3

8-1
8-1-1. Carousel type tools magazine

The tools magazine is on the left of spindle head, tools magazine would be rotated with
GEVEVA driving shaft by reduction motor. The tools positioned by GENEVA driving shaft.
All the these of every times moved is ensured by the limit switch messages which to make
sure the tools is on the correct position or not.

1m

Proximity Switch Geneva Driving Shaft

Between the limit switch end and the GENEVA detect block surface gap would be kept
in 0.5 ～ 1mm distance. Before the machine is delivered, the gap has been set by
manufacturer.

8-2
8-2. Tool Clamping and unclamping system

Tools are fixed in the spindle taper hole with about 800kgs force on it due to pressure
working on the pull rod. When unclamping command has been executed, the unclamping
cylinder would be moved, because the spring pressure results the piston pushing pull rod
until to open the four-leaves chuck which would be relieved the tool-tail screw bar. Pull rod
must pushing the tools tail screw bar more than 0.4 mm（0.016〞）

8-3
8-3. Z axis secondary home position set （carousel type）

1. Loading the standard tools into carousel turret.

2. Place a and on the table and hold with a measure gauge. To adjust the gauge probe
touch tool rod surface about 0.1～0.2 mm and turn the probe to zero position.

3. Remove the standard tools from arm. Choose HANDLE model and press TOOL
UNCLAMP button, then re-loading standard tool into spindle.
4. Turn the ratio set at ＊100. Choose the handwheel of X and Y axially. Place the
gauge under the spindle center. Choose axially of Z and moving Z axis with standard
tool until gauge probe on the Zero position.

5. In Manual mode, press the MOD function key, then press the soft-key HELP.

6. Select the ( # 102 Z to TC position put out ) function then press the NC SSTART key.
The Z axis will move to the first tool change fixed point (unlatch tool). Lock at Z axis
REF. Coordinate value. This value is the lattice moving amount of Z axis and this
coordinate value must be set in MP4210.13.

7. Now select the ( # 103 Z to TC position put in ) function and press the NC START key.
The Z axis will move to the second tool change fixed point ( latch tool ). Look at Z axis
REF, coordinate value. This value is the lattice moving amount of Z axis and this
Coordinate value must be set in MP 4210.14.

8. Check the standard tool front face to touch with measure gauge whether it iin the zero
position or not.

8-4
8-4. Spindle orientation angle adjustment.（carousel type）
1. Remove the two fixing block which in the front of spindle head. To avoid interrupted
when incorrect adjustment.
2. Choice the Manual mode, press the MOD FUNCTION key, then press the soft-key
HELP.
3. Select the ( # 103 Z to TC position put in ) function, and press the NC START key. The
spindle head down to the second zero point.
4. Select the ( # 101 Magazine to spindle ) function, and press the NC START key. The
spindle would be orientated.
5. Select the ( #104 Magazine to spindle ) function, and press the NC START key. The
spindle would be orientated.
6. Inspecting the difference of spindle orientation angle by vision. Every time to adjust
angles of 1 degree that the pre-set value is 10. Key in the angle of approximate value
for adjusting and correcting it. The angle value be set in MP 3430.
7. To execute the spindle orientation and inspecting the angle whether it is correct or not.
The inspection methods could use positioning block to measure the slot of both sides
gap which on the tool disc. Measures the approximate equi-distance by vision that no
interruption is admitted.
8. If necessary to revise that makes the direction for judgement in advance. The
negative value would be when moving forward for clockwise, and moving forward of
counter clockwise the negative value would less.
9. After the parameters are revised. It would necessary to do the function ( #101 S to TC
position ) of spindle orientation again, that ensure the revised of position is correct or
not.
10. When the adjustment of angles positioning is finished. Move the tool magazine back
to home (basic) position. Choose the ( # 105 Magazine to basic position) function
and press the NC START button, the magazine would move to basic side.
11. .It is finished that after locking two fixing block in the front of spindle is tighten.
12. Before the spindle is positioned, It necessary to adjust a proper distance about 2 mm
gap between the proximity switch and block. The limit switch indicating lights in range
of inspection positioning block would lights up green color, on both shoulder would
lights up red color. Other areas would no actives.

8-5
8-5. Adjusting and set of air pressure

1. To adjust the air pressure of pneumatic system that the pressure of gauge value can
be controlled at 5.0kg/cm², The pressure value would be more when turn along the
clock wise direction, and to turn along counter-clockwise would less.

2. The pressure source of pneumatic system minimum values doesn't below 5.0 kg/cm2.

3. The pressure value at 4.5 kg/cm2 and deviation pressure set at 0.5 kg/cm2.

8-6. Adjusting for oil feeder of Pneumatic system

1. It would feed with one drop per exchanged tools 6～8 times.

2. Along the clockwise to adjust.

3. The lubrication oil of pneumatic system prefers to the ISO-VG32 ore oil.

8-7. The tools back ward of spindle adjusting and inspection

1. First to close the air blast adjustable button of spindle or dismantling the pipe of
electric-magnetic valve which connected with the air blast of spindle. In the same time
to ensure air pressure on 5 kg/cm2 at least.

2. Choose the MANUAL models press SPINDLE STOP, then press TOOL UNCLAMP
button and Installing tools into spindle.

3. Takes Z axis hand wheel and turn the ratio to 100 times
4. Move the front surface of standard tools to touch with measure gauge about 0.1～0.2
mm. Turn the dial gauge back to zero point.

5. Press the TOOL UNCLAMP button by right hand and holding the tool rod by left hand
in the same time. Relieve the tool and takes the reading of measure gauge. This
values is tool backward amount of spindle. Standard value is 0.4～0.5 mm.

6. If the readings do not in the range of standard value. It would be adjusted the tool
backward adjustable screws on the spindle top side. When the screws had adjusted
finish, then lock the screws tighten and rechecked it to ensure.

7. Open the air blast adjusting button of spindle. Turn it to properly position or
re-connected the air pipe.

8. The gap between the tools unclamping screws and tool punching rod above the
spindle. It must more than 1 mm in the state of no tools be clamped.

8-6
8-8. Air blast of spindle for adjustment and inspection

1. The air blast adjustable device of spindle installed on the back of vertical column.
There is a adjustable button for air volume controlled which above the secondary
electric-magnetic valve from left side for countering.

2. If air volume is too low would result unable to blow-out the chip. In the opposite, if air
volume is too large would create a interrupting force for tools install and relieve.
Except this it would involve the noise. So the air volume has to proper adjusted.

3. It’s necessary to recheck for normal or not when exchanging tool for automatic and
manual operations after adjusted.

Note:

1. In the operation of ATC. It would be necessary to select a station which no tools in

there when to execute the first tool go into the center of spindle head. Thus, you
can avoid the dangerous of ATC tools directly to impact spindle.

2. Please don’t put your head in work area when the ATC is activating. It could prevent
the injury.

3. Please don’t directly dismantle the ATC by yourself without any instruction before
proceeding. Therefore, it could avoid the dangerous.

8-7
Electric Manual
(HEIDENHAIN)
iTNC 530
 CONTENTS

Carousel ATC Trouble Shooting ……………………..………...……A1

Machinery Interface Cannot Initialize (NOT READY).…….……….B1

Circuit Diagram ……………….……………………………………….C1

Spare Parts List…………..……………………………………………D1

M-Code……………………..…………………………………………..E1
Carousel ATC Trouble Shooting

A-1
Carousel ATC Trouble Shooting
In Manual mode, press the MOD key, choose the HELP function.

HELP MENU :

a. Spindle tool >0 : start function : key NC START.

#101 S to TC position.
#103 Z to TC position put in.
#104 Magazine to spindle.
#106 Tool unclamping.
#102 Z to TC position put out.
#108 Magazine turn clockwise.
#109 Magazine turn counter-clockwise.
#103 Z to TC position put in.
#107 Tool clamping.
#105 Magazine to basic position.
#110 Magazine reference.
#111 Delete spindle status(TO)

b. Spindle tool = 0 : start function : key NC START.

#101 S to TC position.
#102 Z to TC position put in.
#108 Magazine to spindle.
#109 Tool unclamping.
#104 Z to TC position put out.
#106 Magazine turn clockwise.
#103 Z to TC position put in.
#107 Tool clamping.
#105 Magazine to basic position.
#110 Magazine reference.
#111 Delete spindle status(TO)

A-2
ARM ATC Trouble Shooting
In Manual mode, press the MOD key, choose the HELP function.

HELP MENU :

a. start function: key "NC start"

#301 S to toolchange position.

#302 Z to toolchange position.
#309 Tool pocket put out.
#311 Tool arm to unclamping pos.
#305 Tool unclamping.
#312 Tool arm to clamping pos.
#306 Tool clamping.
#313 Tool arm to basic pos.
#310 Tool pocket put in
#317 Magazine turn cw (right).
#318 Magazine turn ccw (left).
#319 Magazine reference.
#320 Delete spindle status(T0)

b. start function: key "NC start"

#301 S to toolchange position.

#302 Z to toolchange position.
#305 Tool unclamping.
#306 Tool clamping.
#309 Tool pocket put out.
#310 Tool pocket put in
#311 Tool arm to unclamping pos.
#312 Tool arm to clamping pos.
#313 Tool arm to basic pos.
#317 Magazine turn cw (right).
#318 Magazine turn ccw (left).
#319 Magazine reference.
#320 Delete spindle status(T0)

A-3
Machinery Interface Cannot
Initialize (NOT READY)

B-1
Machinery Interface Cannot Initialize (NOT READY)

PLC Alarm Message Trouble Shooting

00. Circuit breaker.

Cause :
Circuit overloaded.
Shooting :
1. Check the motor overload protector and reset it, then press CE key.
2. Check if the motor is stuck.
3. Check if the motor wiring is ok.
4. Check if the power voltage is normal.
5. Check if the motor is leaking electricity.

03. Pneumatic pressure.

Cause :
Air pressure too low.
Shooting :
Increase air pressure.

09. Machine guard is open!

Cause :
Spindle door are opened and unlocked.
Shooting :
Close the safety door.

12. Lubricating axes.

Cause :
Lubrication pressure cannot reach.
Shooting :
1. Lubrication tubes is broken.
2. The lubrication pump is failed.

13. Lubrication oil level low.

Cause :
Lubrication oil level too low.
Shooting :.
Increase lubrication.

B-2
14. spindle_cooler_alarm.
Cause :
Spindle cooler pump alarm.
Shooting :.
Check spindle coller pump sensor.

15. Fill_grease_execute_M87_ack.
Cause :
Must fill up grease.
Shooting :.
Please fill up grease and execute M87 confirm.

19. Axis motion from and position.

Cause :
Axes are in end position. (The dog touch the limit switch.)
Shooting :
Move axes away from end position.

23. Drives not operational.

Cause :
The drives are lucked.
Shooting :
Check the connectors X70, X71, X72. On the inventor module. Either of these
connector is loosen or not.

29. Spindle nominal rpm.

Cause :
The spindle maximum rpm is setting incorrect.
Shooting :
Set a correct maximum rpm in MP3450.

39. Tool not clamped.

Cause :
Tool clamp limit switch is dysfunction.
Shooting :
Tool clamp limit switch is broken or wire failure.

B-3
51. Tool change basic position.
Cause :
Tool magazine not in basic position.
Shooting :
Check the limit switch of magazine in basic position is broken or wire failure.

52. Tool change timeout.

Cause :
Tool check time tooling.
Shooting :
1. increase air pressure.
2. Check the tool camp and unclamp limit switch or tool magazine limit switch or tool
counter sensor is broken or wire failure.

54. TC magazine reference.

Cause :
Magazine counter sensor not in position.
Shooting :
Turn the magazine to pocket 1 and choose the HELP (#110 Magazine reference)
function then key NC START.

55. TC magazine timeout.

Cause :
Magazine counter sensor is dysfunction and the magazine is still turn.
Shooting :
Check the magazine counter sensor if the sensor is broken or wire failure.

93. Feed poti = 0

Cause :
Axes are not motion federate override is 0%.
Shooting :
Turn up the federate override.

B-4
Circuit Diagram
Electric Diagram
(HEIDENHAIN)
iTNC 530

A11
Sep.2010
 
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 SPARE PARTS LIST

NO COMMENT DESCRIPTION MODEL Q’TY REMARK

1 EUCHNER Limit switch (X+,Y,Z)N1AR-502-M 3
2 TE MAGNETIC CONTACTOR LC1-D50F7 1
3 TE MAGNETIC CONTACTOR LC1-D80F7 1 QP35/40
4 TE MAGNETIC CONTACTOR LC1-D09F7 6
5 TE MAGNETIC LOCK LAD9V2 2
6 TE OVERLOAD PROTECTOR GV2-M08 (2.5-4) 1
7 TE OVERLOAD PROTECTOR LRD-05 0.63~1A 2
8 TE OVERLOAD PROTECTOR LRD-06 1~1.6A 1
9 TE OVERLOAD PROTECTOR LRD-07 1.6-2.5A 1
10 TE OVERLOAD PROTECTOR LRD-08 2.5~4A 1
11 PAMOTEK RELAY MODULE RDB16-V2 1
12 TE NFB C60N/1P/1A 60862 1
13 TE NFB C60N/1P/2A 2
14 TE NFB C60N/1P/6A 60866 1
15 TE NFB C60N/2P/1A 1
16 TE NFB C60N/2P/D6A 1
RP1240D-24C(24V/1
17 REIGN Power Supply 1
0A) (DIN RAIL)
18 FUJI BRAKER EA53C 50A 1 1320/QP16/20
19 FUJI BRAKER FUJI EA103C 75A 1 QP24/25
20 FUJI BRAKER FUJI EA103C 100A 1 QP28/35/40
21 FUJI BRAKER COVER BZ-TB20B-3 2
22 LGE TRANSFORMER 900VA 1
23 PAMOTEK I/O BOARD IR-34 3
24 OMRON RELAY MY2NJDC24V 4
25 OMRON RELAY SCOKET PYF-08N 4
26 OMRON RELAY MY4NJDC24V 3
27 TE SAFETY E-STOP MODULE XPS-AF5130 1 CE
28 Fuji BREAKER COIL BZF40BT 1 CE
29
30
31
32
33
34

D-1
 M-Code

M-Code Function Type Remark

M00 STOP program run / Spindle STOP /

Coolant OFF.
M01 Conditional stop.
STOP program run / Spindle STOP /
M02 Coolant OFF / Clear status display
(depending on machine parameter / Go
to block 1.
M03 Spindle ON clockwise.
M04 Spindle ON counter clockwise.
M05 Spindle STOP.

M07 Coolant through spindle ON / coolant

through tool ON.
M08 Coolant ON.
M09 Coolant OFF.
M10 Clamping all axes.
M11 Unclamping all axes.
M13 Spindle ON clockwise / coolant ON.

M14 Spindle ON counterclockwise / coolant

ON.
M19 Spindle orientation 0 degree.
M20 Spindle orientation degree cycle 13.
M23 Cutting air blow ON.
M24 Cutting air blow OFF.
M30 Same as M02
M31 Cutting without M3 / M4 monitoring.
M40 Auxiliary output timer duration ON.
M41 Auxiliary input quit.
M44 Unclamping axis 4
M45 Unclamping axis 5
M50 Chip conveyor OFF.
M51 Chip conveyor ON.

M52 Chip conveyor ccw on (user’s

resppmsobiit)
M64 Clamping axis 4

E-1
M-Code Function Type Remark
M65 Clamping axis 5
M68 Coolant floor clean ON.
M69 Coolant floor clean OFF.
M71 Axis Limit 1.
M72 Axis Limiit 2.
M73 Axis Limit 3
M80 Work piece counter reset.
M81 Workpiece counter increment by 1.
M82 Tool torque monitoring OFF.
M83 Tool torque monitoring ON.

E-2
PARTS LIST
 01. SPINDLE HEAD
2005/12/29

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

01-001A 7531-00001120 SPINDLE MOTOR 1 β8/8000i Fanuc

01-001B SPINDLE MOTOR 1 IPH7107-2NF02 SIEMENS

01-001C SPINDLE MOTOR 1 QAN-200L HEIDENHAIN

01-002 2930-01013000 MOTOR SEAT PLATE 1

01-003 2930-09058000 LIMIT SWITCH SEAT 1
01-004 2930-V2550700 MOTOR ADJUSTING SCREW 2
PILLOW
01-005 2930-V26X0800 DOG 2
01-006 2932-01095000 SETTING SCREW 4 M20×2.5P×112L
01-007 2932-01095001 COMPRESSION SPRING 4
01-008 2934-01080000 PRESSING PLATE 1 d32×D36
01-009 2934-03058000 DOG 1
01-010A 2939*01080001 BASE PLATE 1
01-010B 2934*01036001 BASE PLATE 1 CAROUSEL
01-011 2935-01007000 SEAL PLATE 1
01-012 2935-02025000 SETTING BLOCK 4
01-013 2935-03042000 WINDOW 2
01-014 2939-01001000 SPINDLE SEAT 1
01-015 2939-01023002 SEPARATING BLOCK 1
01-016 2939-01024002 SHEET METAL 1
01-017 2939-01025001 PROTECTION GUARD 1
01-018 2939-01026001 BRACKET 1
01-019 2939-01027000 PROTECTION GUARD 1
01-020 2939-01028000 PROTECTION GUARD 1
01-021 2939-01029000 TIMING PULLEY 1
01-022 2939-01031000 SETTING PLATE 1
01-023 2939-01032001 CYLINDER SUPPORTING 4
SCREW
01-024 2939-01033001 PROTECTION GUARD 1
01-025 2939-01034001 PROTECTION GUARD 1
01-026 2939-01035001 CYLINDER 1 DJ2T-T-3.5 160
01-027 2939-02006000 SETTING PLATE 1
660/850VMC
 01. SPINDLE HEAD
2005/12/29

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

01-028 2939-07008000 SETTING PLATE 2
01-029 4709-32360000 TAPER RETAINING RING 1 d32×D36
01-030 5200-29081020 MALE CONNECTOR 2 SPC10-02NJ(PT1/4")
01-031 2939-01088000 LEFT COVER 1
01-032 5905-29007000 OPTICS SCALE 1
01-033 2939-01096000 ADJUSTING ROD 4
01-034 6203-29120303 NIPPLE 2 PT3/8"×3/8
01-035 6203-29120606 NIPPLE 1 PT3/4"×3/4"
01-036 6203-29130303 NIPPLE 1 PT3/8"×3/8"N
01-037 6207-29031200 SPRINKLER PIPE 1 PT3/8"×200L
01-038 6327-13009000 VOLUME TYPE DISTRIBUTOR 1 DPB21-0.4
01-039 7202-29001000 PROXIMITY SWITCH 1 E2E-X3D1-N M12
01-040 2939-01084000 CHECK VALVE 1
01-041 6101-10100110 O RING 2 P10A
01-042 6101-10110010 O RING 4 P11
01-043 2935-01009000 BLOCK 1
01-044 4207-06000000 LOCK NUT 1 AN06 M30X1.5P
01-045 2939-01002002 SPINDLE 1
01-046 2939-01018002 DRAW BAR 1
01-047 2930-01062000 COLLET 1 BT40-45 °
01-048 6315-20400000 ALUMINUM PIPE 4
01-049 6302-00040000 NUT 4
01-050 6326-31200000 VOLUME TYPE DISTRIBUTOR 2 DPB-12 0.16cc
01-051 6304-06120000 JOINT 2 M10X1P-M12X1P
01-052 6304-00100010 JOINT 2 M10X1.0
01-053 5022-29010240 PROTECTION DUCT 1 R68.2-100-32
660/850VMC
 02. COLUMN
2005/12/29

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

02-001 0042-29001000 OIL COOLER 1
02-002 6313-29004000 LUBRICATOR 1 YSF-C2-03-6-V2-P2
02-003 7201-29004010 LIMIT SWITCH 1 SN-02-R12-ES502E
02-004A 7531-00001117 SERVO MOTOR 1 β22B/2000is Fanuc

02-004B SERVO MOTOR 1 IFK7101-5AF71-1AH SIEMENS

02-004C SERVO MOTOR 1 QSY-155D HEIDENHAIN

02-005 2931-03004000 SPACER (A1) 1

02-006 2931-03006000 SPACER (A3) 1
02-007 2931-03007000 SPACER (B1) 1
02-008 2932-03031000 BEARING BLOCK 1
02-009 2932-03034000 BEARING SPACER 1
02-010 2932-03040001 COVER PLATE 1
02-011 2934-03010000 PRESSING PLATE 30
02-012 2934-03017000 COUPLER SEAT 1
02-013 2934-03019000 SPACER 1
02-014 2934-03020000 SPACER 1
02-015 2934-03028000 LIMIT STOP 2
02-016 2934-08001001 ATC INTERFACE CARD 1
02-017A 2934-08060000 24 STATION CAM-ARM TYPE 1 BT40
02-017B 2934-08060A00 24 STATION CAM-ARM TYPE 1 CT40
02-017C 2934-08060B00 24 STATION CAM-ARM TYPE 1 DIN40
02-018 6004-TC406508 OIL SEAL 1 TC40×65×8
02-019 2935-09063000 COVER PLATE 1
02-020 2939-02001000 COLUMN 1
02-021 2939-02002000 SPACER (A) 1
02-022 2939-02003000 SPACER (B) 1
02-023 2939-02004000 SWITCH SEAT 1
02-024 2939-02005000 SETTING SEAT 1
02-025 2939-02011000 BRACKET 1
02-026 2939*05003000 LINEAR GUIDE WAY 2
02-027 2939-05006000 Y AXIS BALLSCREW 1
QP2026/2033-EN
 02. COLUMN
2005/12/29

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

02-028 2939-09005000 BRACKET 1
02-029 2939-09007000 DESCRIPTION 1
02-030 2939-09055000 COVER PLATE 1
02-031 2939-09057000 PLATE 1
02-032 2939-02007A01 Z AXIS TELESCOPIC COVER 1
02-033 5905-29007000 OPTICS SCALE 1
02-034 4925-35072000 ANGULAR CONTACT 4 35TAC72B
BALL BEARING
02-035 4208-03515002 LOCK NUT 1 YSF M5×1.5P
02-036 4405-05050200 TAPER PIN 1 5#×50L
02-037 4711-08004000 COUPLING 1 CP104 35×30
02-038 4902-62073000 DEEP GROOVE BALL 1
BEARING
02-039 6308-00060000 TEE JOINT 1 PKD-6
02-040 6304-00100010 JOINT 1 PQ10T-M10×1.0P
02-041 6326-31200000 VOLUME TYPE DISTRIBUTOR 1 DPB-12 0.16cc
02-042 6305-00060000 90 ° ELBOW 1 PH601
02-043 6303-00060000 SLEEVE 3 PB-6
02-044 6302-00060000 SLEEVE CAP 3 PA-6
02-045 6303-00040000 SLEEVE 2 PB-4
02-046 6302-00040000 SLEEVE CAP 2 PA-4
02-047A 2934-08055C00 CAM SET 1
02-047B 2934-08072000 CAM SET 1
02-047C 2934-08072A00 CAM SET 1 HEIDENHAIN

660/850VMC
 03A.TABLE (660VMC)
2005/12/29

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

03A-001 6326-31500000 VOLUME TYPE DISTRIBUTOR 1 DPB15-0.16
03A-002 2930-V26X0800 LIMIT DOG 2
03A-003 2934-03010000 PRESSING PLATE 4
03A-004 2934-03056001 PLUG 16
03A-005 2934-03058000 LIMIT DOG 1
03A-006 2939-03001000 TABLE 1
03A-007 2939-03002000 SETTING PLATE 2
03A-008 2939-03003000 SETTING PLATE 1
03A-009 2939-03004000 BRACKET 1
03A-010 2939-03010001 TABLE FRONT COVER 1
03A-011 2939-03011001 TABLE BACK COVER 1
03A-012 5905-29010000 OPTICS SCALE 1
03A-013 6309-02060000 JOINT 1 JD-206
03A-014 6312-01040000 HOSE CLAMP 2 PZ-0104
660/850VMC
 03B. TABLE (850VMC)
2005/12/29

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

03B-001 6326-31500000 VOLUME TYPE DISTRIBUTOR 1 DPB15-0.16
03B-002 2930-03008000 LIMIT DOG 1
03B-003 2930-V26X0800 PRESSING PLATE 2
03B-004 2934-03010000 PLUG 4
03B-005 2934-03056001 LIMIT DOG 16
03B-006 2934-03058000 TABLE 1
03B-007 2939-03004000 SETTING PLATE 1
03B-008 2939-03009000 SETTING PLATE 1
03B-009 2939-03012001 BRACKET 1
03B-010 2939-03013001 TABLE FRONT COVER 1
03B-011 2939-03016000 TABLE BACK COVER 2
03B-012 2939-03017000 OPTICS SCALE 1
03B-013 6309-02060000 JOINT 1 JD-206
03B-014 6312-01040000 HOSE CLAMP 2 PZ-0104
660/850VMC
 04A. SADDLE (660VMC)
2005/05/09

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

04A-001 2601-04016000 STOP BLOCK 2
04A-002 7201-29004010 LIMIT SWITCH 2 SN-02-R12-ES502E
04A-003A 7531-00001116 SERVO MOTOR 1 β8/3000is Fanuc

04A-003B SERVO MOTOR 1 1FK7083-5AF71-1AG SIEMENS

04A-003C SERVO MOTOR 1 QSY-155B HEIDENHAIN

04A-004 2931-03004000 SPACER (A1) 1

04A-005 2931-03007000 SPACER (B1) 1
04A-006 2932-03034000 BEARING SPACER 1
04A-007 2934-03010000 PRESSING PLATE 38
04A-008 2934-03019000 SPACER 1
04A-009 2934-03020000 SPACER 1
04A-010 2934-03026000 LIMIT STOP 1
04A-011 2939-03004000 BRACKET 1
04A-012 2939-04001000 SADDLE 1
04A-013 2939-04002000 X AXIS SWITCH SEAT 1
04A-014 2939-04003000 Y AXIS SETTING SEAT 1
04A-015 2939-04004000 X AXIS SETTING SEAT 1
04A-016 2939-04005000 COVER PLATE 1
04A-017 2939-04011000 SETTING BRACKET 1
04A-018 2939-04012000 COVER PLATE 1
04A-019 2939-04013000 SETTING BRACKET 1
04A-020 2939-04015000 COVER PLATE (F) 1
04A-021 2939-04016000 COVER PLATE (B) 2
04A-022 2939-04017000 PLATE 1
04A-023 2939-04018000 SWITCH SEAT 1
04A-024 2939*05001000 X AXISLINEAR GUIDE WAY 2
04A-025 2939-05004A00 X AXIS BALLSCREW 1
04A-026 2939-07002000 BRARING SEAT 1
04A-027 2939-07004000 RING 1
04A-028 2939-03005A00 X AXIS RIGHT TELESCOPIC 1
COVER
04A-029 2939-03006A00 X AXIS LEFT TELESCOPIC 1
COVER
660/850VMC
 04A. SADDLE (660VMC)
2005/05/09

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

04A-030 2939-03007A00 BRACKET 4
04A-032 6312-01040000 HOSE CLAMP 5 PZ-0104
04A-033 6326-31500000 VOLUME TYPE DISTRIBUTOR 1 DPB15-0.16
04A-034 4208-03515003 LOCK NUT 2 YSK M35×1.5P
04A-035 4902-62070500 DEEP GROOVE BALL BEARING 1 6207 P5
04A-036 4925-35072000 ANGULAR CONTACT BALL 3 35 TAC 72B
BEARING
04A-037 5021-29300020 COUPLING 1 SFC-080SA-30B-16BC

04A-038 5905-29007000 OPTICS SCALE 1

04A-039 6302-00040000 NUT 5 PA-4CS
04A-040 6302-00060000 NUT 2 PA-6
04A-041 6303-00040000 SLEEVE 5 PB-4CS
04A-042 6303-00060000 SLEEVE 2 PB-6
660/850VMC
 04B. SADDLE (850VMC)
2005/05/09

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

04B-001 7201-29004010 LIMIT SWITCH 1 SN-02-R12-ES502E
04B-002A 7531-00001116 SERVO MOTOR 1 β8/3000is Fanuc

04B-002B SERVO MOTOR 1 1FK7083-5AF71-1AG SIEMENS

04B-002C SERVO MOTOR 1 QSY-155B HEIDENHAIN

04B-003 2931-03004000 SPACER (A1) 1

04B-004 2931-03007000 SPACER (B1) 1
04B-005 2932-03034000 BEARING SPACER 1
04B-006 2934-03010000 PRESSING PLATE 42
04B-007 2934-03019000 SPACER 1
04B-008 2934-03020000 SPACER 1
04B-009 2934-03026000 LIMIT STOP 1
04B-010 2939-04002000 X AXIS SWITCH SEAT 1
04B-011 2939-04003000 Y AXIS SETTING SEAT 1
04B-012 2939-04004000 X AXIS SETTING SEAT 1
04B-013 2939-04005000 COVER PLATE 1
04B-014 2939-04010000 SADDLE 1
04B-015 2939-04011000 SETTING BRACKET 1
04B-016 2939-04012000 COVER PLATE 1
04B-017 2939-04017000 PLATE 1
04B-018 2939-04019000 COVER PLATE (F) 1
04B-019 2939-04020000 COVER PLATE (B) 2
04B-020 2939*05007000 X AXISLINEAR GUIDE WAY 2
04B-021 2939-05008A00 X AXIS BALLSCREW 1
04B-022 2939-07002000 BRARING SEAT 1
04B-023 2939-07004000 RING 1
04B-024 2939-03007A00 BRACKET 4
04B-025 2939-03014A00 X AXIS RIGHT TELESCOPIC 1
COVER
04B-026 2939-03015A00 X AXIS LEFT TELESCOPIC 1
COVER
04B-027 2601-04016000 STOP BLOCK 1
660/850VMC
 04B. SADDLE (850VMC)
2005/05/09

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

04B-028 6312-01040000 HOSE CLAMP 5 PZ-0104
04B-029 6326-31500000 VOLUME TYPE DISTRIBUTOR 1 DPB15-0.16
04B-030 4208-03515003 LOCK NUT 2 YSK M35×1.5P
04B-031 4902-62070500 DEEP GROOVE BALL BEARING 1 6207 P5
04B-032 4925-35072000 ANGULAR CONTACT BALL 3 35 TAC 72B
BEARING
04B-033 5021-29300020 COUPLING 1 SFC-080SA-30B-16BC

660/850VMC
 07. MACHINE BASE
2005/05/09

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

07-001 2939-07005000 STOP BLOCK 2
07-002 5905-29007000 OPTICS SCALE 1
07-003 6312-01040000 HOSE CLAMP 4 PZ-0104
07-004A 7531-00001116 SERVO MOTOR 1 β8/3000is Fanuc

07-004B SERVO MOTOR 1 1FK7083-5AF71-1AG SIEMENS

07-004C SERVO MOTOR 1 QSY-155B HEIDENHAIN

07-005 2930-V26X0800 SPACER (A1) 1

07-006 2931-03004000 SPACER (A1) 1
07-007 2931-03006000 SPACER (A3) 1
07-008 2931-03007000 SPACER (B1) 1
07-009 2932-03034000 BEARING SPACER 1
07-010 2934-03010000 PRESSING PLATE 28
07-011 2934-03019000 SPACER 1
07-012 2934-03020000 SPACER 1
07-013 2934-03058000 LIMIT BLOCK 1
07-014 2939-04005000 COVER PLATE 1
07-015 2939-04017000 PLATE 1
07-016 2939*05002000 Y AXISLINEAR GUIDE WAY 2
07-017 2939-05005A00 Y AXIS BALLSCREW 1
07-018 2939-07001000 MACHINE BASE 1
07-019 2939-07002000 BRARING SEAT 1
07-020 2939-07004000 RING 1
07-021 2934-03026000 BLOCK 1
07-022 2939-07007001 BRACKET 1
07-023 2939-07008000 SETTING PLATE 2
07-024 2939-09052000 SETTING PLATE (X) 1
07-025 2939-09053000 SETTING PLATE (Y) 1
07-026 2939-04008A00 BRACKET (YF) 2
07-027 2939-04009A00 BRACKET (YB) 2
07-028 4925-35072000 ANGULAR CONTACT BALL 3 35 TAC 72B
BEARING
660/850VMC
 07. MACHINE BASE
2005/05/09

NO. PART NO. DESCRIPTION Q'TY SIZE MODEL

07-029 5021-29300020 COUPLING 1 SFC-080SA-30B-16BC

07-030 2939*04006A00 Y AXIS RIGHT TELESCOPIC 1

COVER
07-031 4208-03515003 LOCK NUT 2 YSK M35×1.5P
07-032 4902-62070500 DEEP GROOVE BALL BEARING 1 6207 P5
07-033 2939-07011000 PAD
07-034 2930-V2100200 LEVEL BOLT
07-035 2930-V2100300 HEX. NUT
07-036 4405-05050200 TAPER PIN 2
07-037 6306-04010000 JOINT 1 5#50L
07-038 4009-36000000 EYE BOLT 2 P1-401
07-039 2940-07006000 CONNECTING PLATE 2 M36×4P
07-040 2939-04007A00 Y AXIS RIGHT TELESCOPIC 1
COVER
07-041 6326-31200000 VOLUME TYPE DISTRIBUTOR 1 P-12
07-042 6305-00060000 90 ° ELBOW 2 PH601
07-043 5022-29010120 PROTECTION DUCT 1 CBO-1-26×38
07-044 2939-09085000 OIL SKIMMER 1
07-045 2932-04008000 FILTER GAUZE 1
07-046 6203-29120404 NIPPLE 1 PT1/2"×1/2"N
660/850VMC
 40#-24T TOOLS
DISK TYPE MAGAZINE
INSTRUCTION
 CONTENTS
1. INSTRUCTION ............................................................... 1
2. Structure ......................................................................... 2
3. Electrical control ........................................................... 11
4. ATC CAM...................................................................... 14
5. Trouble Shooting .......................................................... 27
6. Magazine maintenance ................................................ 32
1. INSTRUCTION
1. This system is using cylindrical cam reel to reducing the speed by gear, the
cylindrical cam is driven by an motor, this motor atta-ched with automatic power off
brake, to produce the indexing angle and ositioning the POT. While POT is on
position, the pne-umatic cylinder will drive the flat type cam, to make the clamping
jaws goes up and down, the movement of the clamping jaws will also drive the POT
to rotate horizontally or upright, and this will make the tool changing to be quick &
smoothly.
2. Every single rotation cycle of cylindrical cam will drive the POT for one indexing,
and in every 360° rotation of the cylindrical cam, there are 270° to be the angle of
movement of the cam,and 90° to be the angle of non-movement. This design will
helps the brake motor to stop and positioning.(The rotation angle of the brake motor
will be 45°±20°)
3. The effective rotate angle for the clamping cam is approximately 100°,10° plus on
both the left and right side to be the angle of non-movement.
4. The motor is 3 phases,220V 200W.The gear reducing ration is 1:20,the attached
automatic power off brake can be rotate either clockwise (CW) or counter clockwise
(CCW). For every single indexing, the using time theoretically is 0.7 second, and
the com- plete indexing cycle (24 index) will take 16.8 seconds.
5. The travel of clamping cylinder is ψ50mm ×100mm, detected by magnetic ring.
6. The solenoid valve is 2 phases,24V,1/4”PT. (For pneumatic ATC).
7. The Proximity Sensors:brand name:BALLUFF(ISO-9001) REG NO:19279-01
Specification :M12 ×1,detecting distance 2mm, Voltage:10-30V
DC≦130mA≦800HZ PNP 3 cords.
8. The distvibution diagram of the pneumatic cylinder and electro magnctic valve &
cam-type connecting diagram of circuit are in showed fig(1). (For pneumatic ATC).
9. Tool capacity:24 standard tool magazine with tool sleeve, max. Tool size:80mm or
106mm.
10. Max. Tool length:300mm.
11. Max. Tool weight:8Kg.
12.The material of the POT is Nylon.mixture with 33﹪glass fiber, one piece forged, with
the tolerance of the weight up to 100Kg, and the highest thermo tolerance is 120℃to
-20℃.
13.The counting and positioning of the rotation is controlled by PLC, through the
detection of the proximity sensors,this tooling system can rotate clockwise (CW) or
counterclockwise (CCW) .To execute the tool indexing by selecting the nearest path.
14.The total weight of the automatic tool changing system, is approximately 140Kg, the
clamping arm and cover excluded, (the weig-ht of the body and tool plate is light, but
still carry high rigidity, the cylinder and drive motor are located on the back si-de of
tool magazine, to bring the convenience for maintenance & repair.)
15.The drawing and size of the tool magazine please reference to fig(2).

1
2. Structure

2
Body & magazine plate ass’y part diagram

item Part no. Description Size Q’TY Remark

01 MB-4049-2 Atc Cover SPHC 1 24T
02 MB-403 Arm Assembly 1
03 MB-405 DEXII Assembly 1
04 MB-4064-5 Plate S45C 1
05 MB-401 MOTER/CAM Assembly 1
06 MB-4001 Pot Body FC-25 1
07 MB-404 Tool Pot Assembly 1
09 MB-4037 Body Cover SPHC 1
10 Commercial Products Bearing CF-10 24
11 Commercial Products Nut M10*p1.5 24
12 Commercial Products Cap Screw M10*p1.5*35L 1
13 Commercial Products Bearing 6008ZZ 2
14 Commercial Products Set Screw M6*1.0P*6L 4
15 Commercial Products Cap Screw M8*1.25P*20L 1
16 MB-4004 Shaft Cover S45C 1
17 MB-4003-1 Shaft S45C 1
18 MB-4002 Disk FC-25 1
19
20 MB-4067 Number Plate ACRY 1
21 Commercial Products Number Mark 1
22 MB-402 Pot Up-Down Assembly 1
23 Commercial Products Cap Screw M8*1.25P*25L 2
24 Commercial Products Spring ∮8 2
25 MB-4007-1 Tool Suport Fc-25 1
26 Commercial Products Cap Screw M8*1.25P*25L 2
27 Commercial Products Spring ∮8 2
28 Commercial Products Set Screw M8*1.25P*35L 2
29 Commercial Products Nut M8*1.25P* 2
30 MB-5304 Cover Acry 1

3
ARM ASSEMBLY PARTS

4
NO. Part no. Description Specification Dim； Quantity
60° 2
1 MB-4034 Home key 65° 2
70° 2
Commercial
2 Plat Screw M6*1.0p*15L 2
Products
Commercial
3 Plat Screw M6*1.0p*15L 12
Products
430 ㎜ 114 ㎜ 2
460 ㎜ 129 ㎜ 2
4 MB-4028 Case 500 ㎜ 149 ㎜ 2
530 ㎜ 164 ㎜ 2
600 ㎜ 199 ㎜ 2
430 ㎜ 1
460 ㎜ 1
5 MB-4025 Arm BT、CAT、HSK 500 ㎜ 1
530 ㎜ 1
600 ㎜ 1
BT 64 ㎜ 2
460 ㎜ 129 ㎜ 2
6 MB-4030 Pin 500 ㎜ 149 ㎜ 2
530 ㎜ 164 ㎜ 2
600 ㎜ 199 ㎜ 2
Commercial
7 Cap Screw M8*1.25p*50L 4
Products
8 MB-4035 Case 1
Standard 24 ㎜ 2
9 MB-4033 Pin Plate
Dex2 21 ㎜ 2
Commercial
10 Cap Screw M6*1.0p*15L 6
Products
11 Spring 1 ψ1.1×ψ9×14T×41L 2
430 ㎜ 65 ㎜ 2
460 ㎜ 80 ㎜ 2
12 MB-4029 Movement pin 500 ㎜ 100 ㎜ 2
530 ㎜ 115 ㎜ 2
600 ㎜ 150 ㎜ 2
13 MB-4032 Stop Movement 2
14 MB-4031 Pin ψ8×16L 2
15 Spring 2 ψ1.2×ψ11×20T×78.5L 2
Commercial
16 Conex ψ40×ψ45 2
Products

5
Pot ass’y part diagram
item Part no. Description Size Q’TY Remark
1 MB-4023 Knob Powder Metallurgy 24
2 MB-4020 Tool Sleeve Nylon Carbon 24 60°
2* MB-4020-1 Tool Sleeve Nylon Carbon 24 90°

2* MB-4020-2 Tool Sleeve Nylon Carbon 24 60°(Reverse)

2* MB-4020-2 Tool Sleeve Nylon Carbon 24 90°(Reverse)
3 Commercial Products Hexagon bolt M35×35L 96
4 Commercial Products Steel Ball ψ8 96 BT
4* Commercial Products Steel Ball ψ6 96 CAT/DIN
ψ1.2×7.8od×10T
5 Commercial Products Spring 96
×25L
6 MB-4024-1 Housing BT/CAT 24
6* MB-4024-2 Housing DIN 24
7 MB-4021 Shaft S45C 24
8 Commercial Products Clip S10 48
9 MB-4022 Fixing Bolt S45C 24
10 Commercial Products CAP M6×45L 24

6
Pot up-down mechanism ass’y part diagram

7
item Part no. Description Size Q’TY Remark
1 MB-4011 Shaft S45C 1
2 Commercial Products Cap Screw M8*1.25P*55L 1 60°
3 Commercial Products Spring ψ8 1 90°

4 Commercial Products Sensor SD-LB 2 60°(Reverse)

5 Commercial Products Sensor Housing 2 90°(Reverse)

6 Commercial Products C-Ring S18 2

7 MB-4012 Adaptor S45C 1 BT
8 Commercial Products Nut M6*p1.0 1 CAT/DIN
9 MB-4066 I Joint S45C 1
10 MB-4009 Cam FCD60 1
11 Commercial Products Cap Screw M6*1.0P*20L 10
12 Commercial Products Spring M6 10
13 MB-4104 Spawl FCD55 1
14 MB-4008 Plate S45c 1
15 Commercial Products Oil Joint 1/8 PT 2
16 Commercial Products Bearing 6004ZZ 2
17 Commercial Products Cap Screw M8*1.25P*40L 1
18 MB-4010 Shaft S45C 1
19 Commercial Products R-ring R42 1
20 MB-4039 Collar S45C 1
21 Commercial Products Cap Screw M6*1.0P*25L 1
22 MB-4006 Sleeve S45C 1
CA-ψ63×100L CA-ψ63×100L
23 Commercial Products 1
(+Adjusting Valve) (1/4PT×ψ8*2)

8
Motor & Cam ass’y part diagram

9
item Part no. Description Size Q’TY Remark
1 Commercial Products Motor 4P/ 380V/1/4HP/1:20 1
2 Commercial Products Cap Screw M8*1.25P*25L 2
3 Commercial Products Nut M8*1.25P 2
4 Commercial Products C-Ring S18 1
5 MB-4013 Gear 36T S45C 2
6 Commercial Products Square Key 5×5×30L 1
7 Commercial Products Set Screw M6*1.0P*6L 2
8 Commercial Products Square Key 8×8×45L 1
9 Commercial Products Set Screw M6*1.0P*20L 4
10 Commercial Products Nut M6*1.0P 4
11 Commercial Products Cap Screw M8*1.25P*16L 4
12 Commercial Products Spring ψ8 4
13 MB-4014 Motor Support SS41 1
14 Commercial Products Cap Screw M8*1.25P*16L 4
15 Commercial Products Spring ψ8 4
16 MB-4017 Cam SCM435 1
17 MB-4015 Cam Housing FCD55 1
18 Commercial Products Bearing 30204JR 2
19 MB-4018 Adjusting Plate S45C 1
20 Commercial Products Set Screw M6*1.0P*20L 4
21 Commercial Products Proximate Sensor M12*p1.0/PNP/4mm 1
22 MB-4019 Sensing Device Powder Metallurgy 1
23 MB-4016 Shaft S45C 1
24 Commercial Products C-Ring S18 1
25 Commercial Products Square Key 5×5×6L 1
26 Commercial Products Set Screw M5*0.8p*5L 1

10
3. Electrical control

SEQUENCE DIAGRAM OF ELECTRIC ACTION

Si gna l f o rm ma ch ine 1 3 5 7 9 11 13
ON
Gradie nt action Grad ient moto r

Mo tor A cti on 1
OF F
ON
S ensor sw i tc h sig nal 3 OF F
ON
Limit sw itc h sig nal 5 OF F

ON
Lim it s witc h si gna l 4
OF F
ON
AT C Motor ci rcuit 6
A T C Action

OF F
ON
H ome confirmat io n 9 OF F
Senso r swi tch

ON
Motor cla mp sign al 8 OF F
ON
M ot or st op signa l 7 OF F

Fe ed bac k si g na l to mac hin e 2 4 6 8 10 12

1. Tool selection (Tool selection power for C.W or C.C.W-tool to tool)

2. Tool counter & positioning signal (to stop indexing motor)

3. Power on for fool clamping cylinder.

4. Positioning signal of tool falling (contracting of cylinder)

5. Tool change motor start (from home)

6. Tool clamping confirmation, tool release signal, motor stop.

7. Tool release finish, motor power on.

8. Tool change confirmation, tool release signal, motor stop.

9. Arm power on & home position.

10. Motor stop & home confirmation.

11. Protruding of cylinder starts, tool pot home position.

12. Protruding of cylinder positioning signal (Tool change finish)

13. Indexing motor rotating to next order-pot.

11
Motor & Limits switch wiring diagram
3φ Motor wiring diagram Sensor Switch
DC24V PNP

U1 W2

(+)Positive Out p ut
BROW N
3φ AC400V V1 U2
Output S ig n al lin e o ut put
BL ACK
W1 V2
(-) N ega tive Ou tput
BLUE

BRA KE

Air Pressure wiring diagram

Cyli nder
WAR80B1 60 -CA

3/8 × φ8 Valve for c ylinder s peed 3/8 × φ8 Valve for c ylinder s peed

b a

SO L
F.R. L.

A IR

Note : The solenoid valve in the frame of dotted line is for vour reference excluded in the
standard accessory.

12
 CAM I Type terminal description

NO. Function Remark

1 Positive

2 Negative

3 Counter

4 Sensor of counter

5 Position in

6 Poxition

7 Clamping up

8 Clamping down

9 Cam Up

10 Cam Middle

11 cam Down

Please refer layout located in the wire-connecting box of motor to get the
solution.

1. Please connect first group ( U1,V1,W1 ) for low speed.

2. Please connect second group ( U2,V2,W2 ) for high speed.

13
4. ATC CAM
Control element position explanatory drawing

12 13 14
11 15
16
10

17
9

18
8

19
7

20
6

21
5

22

4
23
3
2 1 24

Specification afiuned
NO. Control element Function Q’TY Model
Disk type iso50-24DV
Gradient structure Control tool disk
A 1/4HP × 4P 1 3φ220V 60HZ
motor 1 position reverse turn
Tool change structure
BALLUFF φ12 DC24V
B Sensor switch 2 origin point number
PSC40F-BV00-002
1
(PNP)
one tool signal
Positioning signal of
tool falling BALLUFF φ12 DC24V
C Sensor switch 3
(contracting of PSC40F-BV00-002
1
(PNP)
cylinder)
Positioning signal of
D Sensor switch 4 tool falling (protruding YAMATAKE-SL1-A 1 DC24V
of cylinder)
Positioning signal of
E Sensor switch 5 tool falling (protruding YAMATAKE SL1-A 1 DC24V
of cylinder)
Tool change Tool change structure
F 1/2 HP × 4P 1 3φ220V 60Z
structure motor 6 power source
Stop signal of motor BALLUFF φ12 DV24V
G Sensor switch 7
(tool change) PSC20B-BV00-002
1
(PNP)
Tool clam signal BALLUFF φ12 DV24V
H Sensor switch 8
(tool change) PSC20B-BV00-002
1
(PNP)
Origin point
BALLUFF φ12 DV24V
I Sensor switch 9 confirmation signal
PSC20B-BV00-002
1
(PNP)
(tool change)

14
Input shaft

15
item Part no. Description Size Q’TY Remark
101A A4020SC000A1 Case 1
101B A4020SC000B1 Case cap 1
102 A402A0100001 Cam shaft 1
103 A402A0200001 Tune-up cap 2
104 A402A0300001 Tune-up screw cap 2
105 A402A0400001 Cam shaft sprocket 1
114 A402C0100000 Cam 1
127 A402F0100001 Big umbrella gear 1
201 HR30206 Tapered roller bearing 2
213 0-55×2 O ring φ55×2 2
214 G75 O ring G75 2
218 DFK5×5×20 Double round ended key 5×5×20 1
219 DFK10×8×55 Double round ended key 10×8×55 1
224 HI-M6×16 Inner hex. Head screw M6×16 12
226 HI-M8×20L Inner hex. Head screw M8×20L 2
227 HI-M8×25L Inner hex. Head screw M8×25L 13
228 HI-M8×35L Inner hex. Head screw M8×35L 2
241 PT1/2” Oil plug PT1/2” 4
242 OI-28 Oil level gauge φ28mm 1
246 PIN-T-8×32L Taper pin φ8×32L 3
247 PIN-P-8×32L Parallel pin φ8×30L 2

16
Output & Motor

17
Output parts
item Part no. Description Size Q’TY Remark
101A A4020SC000A1 Case 1
106 A402B0100001 Spline (output) shaft 1
107 A402B0200001 Transmit wheel 1
108 A402B0300001 Bearings tube 1
109 A402B0400001 Bearings tube fixture 1
110 A402B0500001 Bearings tube gasket 1
111 A402B0600001 Front fix cap 1
112 A402B0900001 Back fix cap 1
134 RB00020000A1 Bearings φ20 6
203 HR30211 Tapered roller bearing 2
208 AN08 Sun’s nut AN08 1
209 AN11 Sun’s nut AN11 1
210 AW08 Sun’s gasket AW08 1
211 AW11 Sun’s gasket AW11 1
215 G80 O ring G80 1
216 G100 O ring G100 1
224 Inner hex. Head screw 4
225 Inner hex. Head screw 6
226 Inner hex. Head screw 5
233 Inner hex. Head screw 6
240 PT1/8” Oil plug PT1/8” 1
244 USH 50×60×6 USH Oil seals USH 50×60×6 1

Motor parts
item Part no. Description Size Q’TY Remark
128 A402F0200001 Small umbrella gear 1
129 A402F0300001 Motor fixture 2
130 A402F0900001 Adjustment sheet 1
202 HR32008 Tapered roller bearing 32008 2
208 AN08 Sun’s nut AN08 1
210 AW08 Sun’s gasket AW08 1
229 HI-M10×20L Inner hex. Head screw M10×20L 4
230 HI-M10×30L Inner hex. Head screw M10×30L 4
252 MR 1/2HP Motor 1/2HP 1

18
Rocker & Idler sprocket

19
Rocker parts
item Part no. Description Size Q’TY Remark
101B A4020SC000B1 Case cap 1
115 A402D0100001 Rocker 1
116 A402D0200001 Rocker shaft 1
117 A402D0300001 Rocker stand packing cap 1
135 RB00024000A1 Bearings φ22 1
136 RB00024000A2 Bearings φ24 1
205 HK3516 Needle bearings HK3516 8
206 AXK1108 Thrust bearings AXK1108 2
207 AS1108 Thrust bearings AS1108 1
212 G50 O ring G50 2
223 HI-M6×14L Inner hex. Head screw M6×14L 4
224 HI-M6×16L Inner hex. Head screw M6×16L 1
233 HI-M6×8L Settled screw M6×8L 1
237 SC-M12 Hexagonal 1

Idler sprocket
item Part no. Description Size Q’TY Remark
131 A402J0100001 Idler shaft 1
132 A402J0200001 Idler sprocket 1
133 A402J0300001 Idler outside cap 1
235 CO-M5×8L Bury screw M5×8L 4
236 SC-M10 Hex. Nut M10 1
238 WS-M10 Gasket M10 1
245 C12S Shaft ouch C12 1

20
Rocker

21
Rocker parts
item Part no. Description Size Q’TY Remark
101A A4020SC000A1 Case 1
118 A402E01000A1 Brake signal wheel 1
119 A402E01000B1 Cam signal wheel 1
120 A402E0200001 Signal fixture 1
121 A402E0300001 Signal shaft 1
122 A402E0400001 Dustproof cap 1
123 A402E0500001 Signal cap 1
124 A402E0600001 Signal cap(have hole) 1
125 A402E0700001 Signal sprocket 1
126 A402E0800001 Signal try up parcel 1
204 BR6202 Deep groove ball bearing 6202 4
217 DFK4×4×10 Double round ended key 4×4×10 4
220 HI-M4×8L Inner hex. Head screw M4×8L 8
221 HI-M4×10L Inner hex. Head screw M4×10L 8
222 HI-M5×16L Inner hex. Head screw M×16L 2
231 HS-M5×5L Setting blot M5×5L 1
232 HS-M5×10L Setting blot M5×10L 2
239 PF-308 Plastics screw M3×8L (KSS) 4
243 TC15×24×5 TC type Oil seals 15×24×5 1
249 AG-16 Wire studs (KSS) KSS 1
250 TM-10A600V Terminal plate 1

22
Adjustment of arm
The steps of arm adjustment

1. Push down clutch link.

2. Rotate motor by using the wrench and turn the arm to the angle of setting up
edged tool.

3. Adjusting the arm to hold the edged tool.

4. Tighten up the setup screw.

23
DEX-2 IIME CHART

24
 Power output direction

*The wide side of tuneup cap.

t
u
n
e
u
p
c
a
p

must be to the direction of power

output.

25
Dismantled procedure
How to take the spine ( output ) shaft :
1. Turn to start position, remove the case cap of screw (227) and pin (246).
2. Remove the case cap (101B)
3. Loose hexagonal screw (255), remove the front fix cap (111).
4. Remove the spline (output) shaft (106), and transmit wheel (107)、sun’s nut (208)、sun’s
gasket (210), and take the new shaft.
5. Assembler it, you ca reverse in connection.

Change the bearings on bearings tube :

1. Turn to start position, remove the case cap of screw (227) and pin (246).
2. Remove the case cap (101B).
3. Rotate the bearings tube (108).
4. Remove the side settled screw (223).
5. Use special tool to remove the bearings, take the new bearings, use the no air rubber
to fastener the settled screw (223).
6. Assembler it you can reverse in connection.

Take rocker apart in many steps :

1. Turn to start position, remove the case cap of screw (227) and pin (246).
2. Remove the case cap (101B).
3. Then remove the rocker of settled screw down (224).
4. Use the teardown tool, removed the rocker shaft (116).
5. Remove the thrust bearings AXK1108 (206)(207), and needle bearings HK3516(205).
6. Bearings number : φ22(135) 、φ24(136) taken apart the rocker is now replaced new
product.
7. Assembler it you can reverse in connection.

26
5. Trouble Shooting
Condition Reason Trouble Shooting
Tool disk stops without 1.Brake fail to work or 1.Please check electronic brake
positioning overload wiring in correct connection or not?
2.Sensor switch with far If partfail to work
distance 2.Move sensor switch closer to
sensor
Tool disk non-stop rotating 1.Sensor switch break down 1.Replace sensor switch
2.Sensor switch with far 2.Move sensor switch Closer to ensor
distance
Pot break Tool disk rotated while tool Replace new tool pot & adjust arm
clamping Clamping position again
Shake during tool clamp & 1.Cam out lubrication 1.Fill lubricant oil
returning 2.Cylinder speed out of 2.Adjust cylinder pressure & speed
balance valve
Tool pot is not Bolt of positioning bolt or pot Adjust it to normal & tighten
positioning(loosen) bolt are loosen
Tool disk dose not work 1.Induction switch dose not 1.Adjust reed switch to normal
during tool selection work position
2.Induction switch break down 2.Replace reed switch
3.Motor break down 3.Repair motor
4.Electronic break bread down 4.Check wiring & replace
5.Check sensor switch
Cylinder does not work 1.Proximity switch for tool 1.Replace proximity switch
During tool change counter positioning is break 2. Tool disk positioning
down 3.Check cylinder air, solenoid valve
2.Tool disk is not positioning works or not?
3.Cylinder has no pneumatic 4.Rotating motor bolt manually to let
air ATC arm back to original position
4.ATC arm does not home 5.Check reed induction switch
ATC fail to work during 1.Tool clamp positioning reed 1.Adjust reed switch to proper
Tool change switch fail to work position
2.Induction switch break down 2.Replace new reed induction switch
ATC motor over-heat 1.Break is not released 1.Check commutator to electriey or
2.Break is break down not?
3.Commutator is break down 2.Replace brake
3.Replace commutator
ATC fail to work after tool 1.Sensor is in wrong position 1.Adjust sensor to proper position
clamping; 2.Sensor switch is break down 2.Replace sensor switch
ATC fail to work after 180°
degrees tool change;
ATC home stop & home
Sensor switch does not
work
ATC stop position out of 1.Sensor is in wrong position 1.Adjust 3 sensor at the same time to
2.Positioning ring of sensor proper angle
switch is in wrong angle 2.Rotate set ring, adjust 3 sensor
switch to proper angle
ATC tool clamping position Arm & ATC spindle are not Loosen taper ring key & align it again
out of accuracy aligned

27
A. POT CHANGE SEQUENCE
1.Take down the peripheral metal sheet 2 Unlock the hexangular screw bolt M10 and
and numeral acrylic cover. recede 10mm on the shaft cover. (Remark :
do not move the 4 pieces fixing bolt)

3 Pull out the plate to the M10 screw bolt 4 Strip down the hexangular screw bolt M6
position. which be instead pot.

5 Take down the broken pot (push the pot 6 Confirm the fixing bolt and knob the correct
forward inner side and take the pot upward, position for the new pot.
then extract it).

28
7 Stow down the new pot(the surface of knob 8 Lock the hexangular screw bolt M6 which
recline the pot body and push forward into the new pot.
the plate.

9 Push the plate to the original position and 10 Check the fixed clearance of the plate.(can
lock it. not have clearence).

11 Check the correct angled 90 degree

which the replaced pot(test on the practically
tool exchanged).

29
B. Motor of magazine replacement

1. Power off.
2. Wire off the wiring connect box of motor.
3. Take off M16 bolts (4pcs) on motor seat, and then disassembly the motor.
4. Disassembly the S18 ring & M6 bolt from damage motor & re-assembly those
parts onto new motor.
5. Please make sure the motor specification is correct before you replace it.

C. Cylinder replacement

1. Turn off the power & cylinder.

2. Take off Ø8 pipe.
3. Take off induction switch & mark original position before remove it.
4. Take off M8 bolt on cylinder.
5. Please take care to replace correct specification of cylinder before you fit it on,
and then get back the induction switch to original position.

D. Induction switch replacement

1. Power off.
2. Disassembly the wire of induction switch in the electric box.
3. Please loosen the seat of reed switch & take it out.
4. Replace new part & take care of the sensor position, push it to upward &
downward until to end of both sides.

E. Proximity switch of tool magazine replacement method

1. Power off.
2. Take off the front cover & outer sheet metal cover.
3. Take off the wires of proximity switch in the wire box.
4. Take off the M12 bolt on proximity switch.
5. Replace new part & make sure the sensitive distance is 4mm.

30
 - Note -
1. Please use standard tool during maintenance & repair.
2. We suggest you replace part which is bought from original supplier.
3. Please take care of the part specification before replacement. You can get the
specification from the part list.
4. Please make sure the sensitive distance during replace proximity switch & reed
switch.
5. Please take care the wire numbers & location in case you have to replace the wire
connecting.
6. In any case of abnormal or damage condition on the product, there should be
someone checking the product. We strongly ask the service man has to be well
trained & qualified engineer or expert come to check or repair the problem. This
is to ensure safety of operator & engineer.
7. Before disassembly the product, please make sure there are enough human
beings to support the load. If there are not enough human beings, please use
lifter, crank or any other carrier to support the weight.

31
6. Magazine maintenance
Item Description Method Tool Routine Remark
Take off number Grease
A Body fix board cover, fill oil Oil Gun
manually
Take off sheet metal, Grease
B Pot slide fill Lubrication oil Oil Gun
manually
Take off sheet metal Grease
1 Lubrication Arm slide block &
C cover, clean & fill oil Half
position pin
manually year
Take off ATC cover, Grease
D Cam Slide fill lubrication oil Oil Gun
manually
Take off front cover Grease
E Motor Gear Oil Gun
& outer sheet metal
Inner taper face of
A Clean pot
pot
2 Cleaning Replace inner Drain the old oil, and
Once a SHELL
B lubrication oil of fill New lubrication
month TELLUS 32
ATC oil
Sensor switch of
A magazine is Check manually
loosen or not?
Sensor switch of
B ATC is loosen or Check manually
not?
Sensor switch of
C cylinder is loosen Check manually
or not?
3 Loosen Any bolt is loosen Check manually &
D
or not? optically
Bolt on arm is
E Check manually Half
loosen or not?
year
Shake the arm to
F see if backlash is Check manually
too big
Check if magazine
G Check manually
is loosen or not?
Pot ball is falling
A Check optically
down or not?
Noise or heat on
B Check manually
4 Other check motor?
Solenoid valve of
C cylinder is out of Check manually
air?

32