VERTICAL MACHINING

CENTER

INSTRUCTION

VMC-2516

LEADERWAY CNC TECHNOLOGIES CO., LTD.

NO. 36, Ln. 211, Taiming Rd.,
Wuri Dist, TAICHUNG 41468, TAIWAN
TEL: +886-4-2335-0711
FAX: +886-4-2335-0986
1-GENERAL

1
 TABLE OF CONTENT
Preface------------------------------------------------------------------------------------------------------------------ 4
Cautions on warning labels ---------------------------------------------------------------------------------- 6
Safety ------------------------------------------------------------------------------------------------------------------- 8
Safety precautions---------------------------------------------------------------------------------------------- 8
Before of operating machine --------------------------------------------------------------------------------- 9
Warm up and preparation ----------------------------------------------------------------------------------10
Caution of operating machine ------------------------------------------------------------------------------10
Operator requirement ---------------------------------------------------------------------------------------- 11
Material witch can be processed --------------------------------------------------------------------------- 11
Check before Power On --------------------------------------------------------------------------------------12
Check after power on machine -----------------------------------------------------------------------------13
Check of Manual Operation --------------------------------------------------------------------------------14
Machine life ----------------------------------------------------------------------------------------------------------15
Machine life limits ---------------------------------------------------------------------------------------------15
Guarantee-------------------------------------------------------------------------------------------------------15
TRANSPOTATION ------------------------------------------------------------------------------------------------16
PRECAUTION ------------------------------------------------------------------------------------------------16
Environmental requirement --------------------------------------------------------------------------------------17
Requirement point --------------------------------------------------------------------------------------------17
Power supply ---------------------------------------------------------------------------------------------------17
Ground connection--------------------------------------------------------------------------------------------17
Condition of storage ------------------------------------------------------------------------------------------18
Setting the ground --------------------------------------------------------------------------------------------------20
Ground required ----------------------------------------------------------------------------------------------20
Setting step -----------------------------------------------------------------------------------------------------21
Before power on -----------------------------------------------------------------------------------------------------22
Leveling adjust ------------------------------------------------------------------------------------------------------23
Leveling required ---------------------------------------------------------------------------------------------23
Adjust procedure ----------------------------------------------------------------------------------------------23
Tools system ----------------------------------------------------------------------------------------------------------24
Vibration required --------------------------------------------------------------------------------------------24
Tools specification ---------------------------------------------------------------------------------------------------25
ISO 40 serious -------------------------------------------------------------------------------------------------------25
BT-40 ------------------------------------------------------------------------------------------------------------25
DIN 40 -----------------------------------------------------------------------------------------------------------25
CAT 40 -----------------------------------------------------------------------------------------------------------25
ISO 50 serious --------------------------------------------------------------------------------------------------------26
BT 50 -------------------------------------------------------------------------------------------------------------26
DIN 50 -----------------------------------------------------------------------------------------------------------26
CAT 50 -----------------------------------------------------------------------------------------------------------26
2
Oil usage --------------------------------------------------------------------------------------------------------------27
Recommendation label ---------------------------------------------------------------------------------------27
Moving direction ----------------------------------------------------------------------------------------------------28
Coordinate system ----------------------------------------------------------------------------------------------29
Right-Hand Rule: ---------------------------------------------------------------------------------------------30
Maintenance point table -------------------------------------------------------------------------------------------31

3
Preface
 Safety is the first of all！We do not product machines but care about you very
much.
 We are pleased to know that you have decided to purchase our CNC machine
tool center. We are sure this machine, after operating on the production line of
your factory, will be able to promote your products of high stability and
excellent quality.
 It is our pleasure to introduce the relevant information regarding the safe use of
this machine and help you increase the production capability and operating this
machine in proper way can not only keep it at high precision and stable
condition but also keep you from damage or danger.
 Before using this machine, please be sure to read all of the Operation Manual,
Mechanical Manual and the safety regulations very carefully so as to ensure the
safety for the people and the machinery.
 Please put Manuals available around for the operator easy to get, do not put
them away. Do not damage it and make good use of them to ensure your safety.
Therefore, please good use of your experience, common sense and Manuals
instruction to remind you. When train your employees always think safety is
the first of all for all kinds of industries and job.
 We have put our efforts on offering safety and excellent machinery for our
customers in order to restore the normal operation and upgrade the technical
standard of our factory. Please feel free and take down what have happened in
detail and inform our factory or the nearest agent, service center to handle it for
you.

4
Be careful, if the dangerous or hazardous things happen will easy to cause
personnel death and heavy injury.

Be careful, if the warning things occur might cause people die or heavy
injury.

If the dangerous things occur will cause people injured or product damaged.

 Labels：Indicated some special purpose or production examined by Q.C.

dep.
Make sure that you can read all warning and instruction labels. Clean or
replace these labels if you cannot read the words or see the pictures. By using
a cloth, water and soap to clean them. Do not use solvent, gasoline or
unknown solution. You must replace new labels if they are broke, missing or
cannot be recognized. In addition to the information given on safety labels,
there is a variety of other cautionary information which must be observed by
operators during machine installation, operating and maintenance.
 Read all safety-related information carefully
 Failure to observe the danger of caution information can lead operators to
serious injury or damage to the machine. Always observe this information
during machine installation, operation and maintenance
 The health and safety measures applied to the machine are in conformance
with the following European standards:
 EN 292-1
 EN 292-2
 EN 294
 EN 349
 EN 418
 EN 1050
 ENV 1070
 The electrical equipment is in conformance EN 60204 standard.

5
Cautions on warning labels
The warning labels show in the table below are attached to this machine.
Fully the contents of each warning label and observe the mentioned items.

6
7
Safety
This machine is provided with a number of safety devices to protect personnel
and equipment from injury and damage. Operators should not rely solely upon
these safety devices but should operate the machine after fully understanding
what special precautions to take by reading the following statements
thoroughly.
Safety precautions
However, safe operation cannot be ensured if operators use a CNC Machine
Center improperly or do not follow safety rules properly. Failure to comply
with these rules may result in death, injury or damage to the machine and/or
products.

The basic conditions given below must always be strictly followed.

 Only qualified or trained personnel are permitted to maintain and/or operate th
machine.
 Read the instruction manual thoroughly and make sure the contents completel
understand in order to operate a machine efficiently and safely.
 Always keep this safety paragraph and instruction manual at a designated plac
near the machine so that they can be easily accessed whenever required.
 Use safety shoes, which are not damaged by oil, safety goggles with sid
covers, safety clothes and other relevant safety protection.
 The key of key-switch must keep by the senior and qualified personnel.
 Be sure there are no articles or material around the machine.
 A series machines start-up requires a PC with V24 interface for data transf
from/to the control system and an NC card. On the PC, WINPCIN Tool must b
used.
 Turn off the power source before going home, checking machine.
 An internal data backup must be carried out whenever the control system
switched off longer than 50 hours.
 The NC card must be plugged or removed only when the PC is turned off.
 All persons concern with operation and maintenance of this machine must b
aware of the emergency stop button and switch location, function and operation
 In the event power is failure, turn off the main circuit breaker immediately.
 Use the recommended hydraulic oil, lubricants and grease or acceptab
equivalents.
 Replacement fuses should have the proper current ratings.
 Protect the NC system, operating panel, etc., from shocks, because of
resulting failure or malfunction.
 Do not change parameters, volumes and other electrical setting
unnecessarily. If such change is unavoidable, record the values prior the
change so that they can be returned to their original setting if necessary.
8
 Do not soil, scratch or remove the caution plates.
 Whenever operating forklift truck, crane or similar equipment, special car
should be taken to prevent collisions and damage to surroundings.
Before of operating machine
 Check the power source of factory is fit for requirement.
 Check motors and other parts for abnormal noises.
 Check pressure gauge for proper readings.
 Check the lubrication motor, sliding parts for evidence of proper lubricant.
 The first time to operate the machine, after unpacking or keeping the
machine idle for a long period each slide way surface must be freshly
lubricated. Keep lubrication pump work till oil oozes out from wiper.
Contact our service station or agents in connection with what procedure
should be taken since it depends on the type of machine.
 Clean machine so that any abnormalities can be found.
 Make sure the lubrication oil pressure; pneumatic pressure and hydraulic
pressure indicate the correct values.
 Make sure the lubrication oil is properly supplied to the correct places.
 Check joints or fasteners of pipe, hose, wire and cable there are any leakage
or loose.
 Check coolant tank and oil reservoir are filled to indicated level or refill
them, if necessary.
 It is safe that all parts, chips and waste oil should be removed by the operator
and be placed to assigned storehouse and far from machine.
 Ensure the hoisting rope, transportation blocks and packing stuff are remove
completely before starting running the machine.

9
Warm up and preparation
 The power cable from the factory feeder switch to the machine main circuit
breaker check if there is a sufficient sectional area to handle the electric
power usage.
 Warm up the machine include NC unit or PC connection, especially the
spindle and feed shaft by running 10- 20 minutes at ball part half or one-third
the maximum speed in the automatic operation mode.
 Wire rope or slings should be strong enough to stand the load of lifting and
should be conform to the mandatory provisions.
 Tooling should conform to the machine specifications, dimensions and type.
 After installing a tool into spindle, make a trial run.
 Make trial run of ATC system, rate of feed axes, motor rotating and the basic
function of operation panel.

Do not rotate spindle unless the tool holder load into spindle
already
Caution of operating machine
 Always wear helmet, protecting glasses, safety shoes and other protecting
equipments as required while operating machine.
 The operations of this machine should not against the instruction of all
manuals.
 Do not settle down the machine near high electrical magnetic interference
(EMI) machine
 Do not wear loose clothing or jewel that can be caught by moving parts of
machine.
 Do not touch the chips and blade tip of the cutter with naked fingers.
 During operation, do not take the chips away or touch the rotating portion
parts with naked fingers or other articles.
 When performing heavy-duty machining, prevent carefully chips from being
accumulated since hot chips can catch fire.
 Before any rotation parts, moving articles or transmission feed stop
completely, do not touch the cutter or work pieces.
 Do not touches or press the buttons and switches with wet hands it might get
shock.
 Do not operate switches with gloves on, it will cause malfunction, etc..
 Always remember the location of emergency stop button so that you can
press the buttons right away if any unexpected accidence is occurred
 Never operate the machine or turn on the power source unless everything is
completely set down and inspected all right.
 Do not use fuses other than those specified or change parts for the sake of
saving money.
10
 Pay attention to and keep away from the high voltage devices or isolate with
cover.
 Stop machine before maintaining or adjusting the position of coolant hose,
cutter or disposing the chips
 Cables, cords or electric wire whose insulation is damaged can produce
current leaks and electric shocks. Before using check their condition.
 Do not cut a kind of material, which are easy to catch fire on the machine,
such as magnesium, magnesium ally or other material, which lower melting
point.
 Do not open the door or remove the covers of chip proof sheet metal, during
machine performance.
 Do not open the power cabinet door while the machine is operating. If it’s
necessary to open it, be sure the machine stops running totally.
Operator requirement
 User’s occupation
 Any manufacturing company/factory which does milling, drilling, boring
tapping process for metal or non-mental materials.
 Education requirement
 Any person who was graduates from junior high school acknowledges the
English capital, has the logic concept of mathematics, and knows how to
operate control keys, is qualified to learn and manipulate this machine. Either
man or women do for this job
Material witch can be processed
 Metal: Iron, Steel, Aluminum, Titanium, stainless, alloy.
 Non-metal: Plastics, Wood, Fiber, Polymer, Acryl.

11
 Check before Power On
Please make sure to do every check before operation each time. This can ensure
operator’s safe usage and machine’s normal work.
Before power on machine, please check if the wires and cables are damaged in
case of electric accident. Make sure that the wires and cables are not damaged.
Otherwise, it may happen electric leakage and cause serious casualties.
Checking procedure
Check Point Check Item Method Remark
．Filter, Regulator 1. Have water in the filter cup been By eye
& Lubricator Unit dried out?
2. Is there enough oil in the oil cup?
3. Is there enough compressible air
pressure?
．Spindle Oil 1. Check if there’s enough By eye
Cooler lubricant inside the spindle By hand
head.
2. Check if the joints of oil tubes
are locked tightly.
．Coolant Tank 1. Check if the chips are cleaned. By eye
．Chip Conveyor 2. Check if there’s enough coolant
in the tank. By hand
3. Check if the joints of tubes are By hand
locked tightly.
4. 4. Check if the joints of cables
are locked tightly.
．Coolant tank of 1. Check if the chips are cleaned. By eyes
right/left side 2. Check if other items are put
inside.
．Telescopic 1. Check if there are chips on it. By eye
Covers 2. Check if there is proper
quantity of Lubricant on its
face.
．ATC door 1. Check if the chips are cleaned. By eye
．Table 1. Check if the chips are cleaned. By eye
．Spindle 1. Check if spindle taper is clean. By eye
．Electric Cabinet 1. Check if the controller units By hand
．Operation and joints are fixed.
Cabinet 2. Check if the door is locked
well.

12
Check Point Check Item Method Remark
．Each ground 1. Check if terminal of ground wires By hand
wires. are locked tightly.
．Junction Box of 1. Check if terminal screws and By hand
ATC, Base and joints are locked tightly.
Spindle 2. Check if the cover of Junction
head…etc. Box is locked tight.
．Machine’s 1. Check if the machines’ bolts are By hand
surroundings locked tightly. By eye
2. Is the machine’s surrounding
clean?
Check after power on machine
Check Point Check Item Method Remark
．Motor 1. Is there any strange sound? By eye
2. Does it overheat? and ear
．Pneumatic 1. Press enough(5-7kg/c ㎡) By eye
system 2. Do the pipes leak?
．Spindle Oil 1. Is the temperature setting By eye
Cooler correct?
．LCD Screen 1. Does it show alarm message? By eye
．Operational 1. Does alarm lamp light? By eye
Panel
．Chip Conveyor 1. Clockwise rotate correctly. By eyes
．Chip Auger 2. Counter-clockwise rotate
correctly.
．Coolant Pump 1. Pump work normally. By eye
2. 2. Pipes are not leaking.

13
 Check of Manual Operation
Item Description Result
1. Can each axis go positive position? Negative □ Normal □ Abnormal
Position?
2. Does each axis have protection of over-travel? □ Normal □ Abnormal
Positive direction? Negative direction?
3. Does each axis go back to reference positions? □ Normal □ Abnormal
4. What is the spindle’s rotate direction? Can the □ Normal □ Abnormal
spindle orientation？Stop？Clamp/Unclamp？
5. Does Tool Magazine clockwise or □ Normal □ Abnormal
Counter-clockwise？

14
Machine life
Machine life limits
 Under normal operating and with well maintenance. The intended life of this
machine. About count by:
 8 hours x 5 days x 4 weeks x 12 months x 10years = 19200 hours
 There are many warning signs on the machine, please should be obeyed. In
addition to the waning signs, please should be obeyed the safety precautions
of the instruction manual.
 Only a skilled person is allowed to operate this machine. Otherwise, the
person must be trained until he know how to operate the machine safety and
efficiently.

Guarantee
 One year’s life is guarantee for any components in the machine.
 Key components – one year’s life is guarantee
 Spindle unit and bearing.
 linear guide ways
 ball screws and bearing
 Control unit, main motor and servo motor.
 ATC unit

15
TRANSPOTATION
PRECAUTION
 Only trained, qualified workers should operate forklift truck, crane or similar
equipments and apply slings.
 The wires used to lift should be checked that they are strong enough for the
weight of machine center and in good condition. The dimensions of steel ropes
specified in manual.
 Be sure that the wires will not run into any delicate parts of machine center.
 Before hoisting machine, make sure all moving units are fixed securely as well
as in place.
 Be careful and avoid the hoisting rope contacting with any piping unit, parts
and electric cables.
 Check around the site of machine and make it clean, proper to be installed, that
is, can keep machine away from jolt during move or transport machines.
 Always inspect slings, chains hoists and other lifting devices prior to us and
never work on or stand under a component while it is hanging from an
over-crane or other hoisting mechanism.
 The floor of machine located must be firm, in order to ensure vibration free
and secure fastening. Should the floor not be firm, a concrete foundation is
recommended.
 Keep the machine’s center of gravity at the center of the forks.
 Be careful during remove the wooden cage or vacuum package and keep away
from damage onto the machine inside or people around will get injured.
 Ensure that there is a little clearance between the back panel of machine and
forklift truck or use protective pad.
 Be sure electric cables and wires will not be damaged during hoisting machine
from the skid.
 Before hoisting the machine, make sure that each of the units is fixed securely.
 Be careful during remove the machine to proper site and install it.
 Keep clean around the machine and floor.
 Be sure electrical cables and wire will not be damaged during installing
machine.
 After installation and clean, connect the wire to the power source and ensure
the requirement of power capacity is proper.
 Before using, remove the anti-rusty oil by rags with paraffin or fuel oil.
Toluene compounds must not be use.
Note: Refer to the drawing following end of book.

16
Environmental requirement
Requirement point
 Where the machine center avoid exposing to the direct sunlight and/or near
to a heat source, etc.. Ambient temperature during operation is 0 to 40℃ (32
to 104℉).
 Avoid a location where the humidity is considerable fluctuating and/or it is
highly humid. Normally 75％ and below in relative humidity.
 Avoid using the machine center under such environment as to be especially
dusty or to have a vaporous, organic and corrosive gas highly concentrated.
 Flat and smooth ground without dust or other particles. The required bearing
pressure of the floor is at least 5000 kg/㎡.
 Where there is no vibration source around the factory.
 The machine must be protected from electrical noise sources, such as electric
welders and an electric discharge machines.
 Always ground machine independently, the ground resistance is 100 ohms or
less and the length of ground cable is as short as possible.
 The sound pressure level at the operator’s position is under 80dbs.
(According to JIS B6004, 1980; Method of sound measurement for machine
tools) It is the policy of the company to remedy the machine if the sound
level is over 80 DB while running test.
 Foundation should be constructed of either reinforced or non-reinforced
concrete with thickness and consistency compatible to industry for machine
weight.
 The 24V DC voltage must be generated as a functional extra low voltage
with safe electrical isolation and be grounded by the user.
Power supply
It is recommended that the electrical equipment of a machine only have one
power supply connection. When other voltages are required the machine, then
these should be supplied by equipment which is part of the machine such as
transformer, motor generator and so on.
The current standard voltage values

Republic Of China
 AC-220V±10% (single phase/60Hz).
Europe multitude
 AC-380V ±10% (3 phases/50Hz)
 AC-220V ±10% (single phase)
In States
 AC-230V ±10% (3 phases/60Hz).
Ground connection
 Don’t Cascade parallel connected with other machine in grounding.
17
 Parallel connection in grounding is OK.
 Voltage need correct by name plate on side of machine.
 Size of electrical wire ∮14 mm2 diameter(ground wire).
 Ground resistance below 100Ω.
Condition of storage
The machine and the NC must
not be subject to direct sunlight.

Maintenance space must be

secured.
The door must be able to open
without iterance.
The chip conveyor, chip bucket
and coolant tank must be able to
pull out from the machine
without interference.

The ground must be capable of

absorbing the vibration of other
machines, such as presses. If
vibration is felt where the
machine is installed, measure is
magnitude with a micrometer.

The ambient humidity must be

less than 75% and free of
condensation. Because many
electronic parts are use in the
machine and the NC, excessive
humidity must be avoided.

18
The surface where the machine
installed must be smooth and
flat.

The machine must not be subject

to chips scattered from other
machine or airborne dust.

The ambient temperature must

be between 0 and 30˚C

19
Setting the ground
Ground required
If you want to promote the effective product the best way is set out the ground.
The flat and smoothly floor could be good for settling down the machines. Refer
to the following drawing for the ground arrangement

A=350(V450/V650/V33i/V42i) [1] Concrete 5000pci

A=500(V1100/MV1100/MV1300) [2] Concrete 3000pci
A=700(LX1610/LX2210/MV1750) [3] Anti-oil/heat bronze
A=1000(LX-B all mode) [4] Anti-vibration polylone
[5] Anti-vibration sand
[6] Round-shapes stone Dia.
150~300 mm
The floor plate must be completed in compliance with the latest valid guidelines
and the generally adopted technical regulations. If applicable, contact a renown
engineer specialized in stoical calculation, observe the maximum floor pressure
of the local conditions.

20
Setting step
According to foundation drawing set the
foundation area.

First, put stones on the bottom.

(Stone dia.150~300 mm)

Fill up the sand and poly-foam plate on

the other side.

Put the oil-proof and anti-head stripe on

the side, then fill up the cement (3000
pci ), harden time about 7~10 days

Dig out the hole of anchor bolts.

Hoist machine higher and install the

anchor bolts.

Put whole machine into the position.

Fill up with 5000 pci cement harden time

2~4 days

The following drawing showing on the end of book.

21
Before power on
 Only the trained, qualified or authorized personnel can remove and settle
machine, accessories and so on.
 After transporting machine to the adequate site of factory, remove
vacuum package or accessories skid from shipping pallet.
 Remove the shackles, sling and eyebolts. Fixed brackets between
table-saddle and saddle-base and hoisting devices from machine.
 All the bare parts of the machine, which have been coated with a rust
inhibitor for transportation must be carefully cleaned by rags with
paraffin or fuel oil and wrung out. Note: Toluene compounds must not be
used.
 Takes away the brackets fixed onto the operation cabinet.

Unless power on, do not move away the fixed bracket under head stock
which is the last one to remove.
 Place the cover of the right side base and tighten the screws on it.
 Set down the accessories such as coolant tank with chip collection
trough, fixed pump on the plate of coolant tank.
 Set the transformer and chip conveyor to proper places then plug the
socket onto the bottom of power cabinet.
 Make sure the main power supplier switch is turned off before the
power cable connected to the power source.
 Connect the fasteners or joints of cables, wire and pipe wherever they
will be.
 Connect the main cable of machine with the terminal in power source
box of factory.
 Check if the power capacity or voltage is fitted on the machine
requirement.
 Check if the phrases of motors and pump are correct by phrase-meter.
 After everything being settled down, power on and turn on the main
power switches of machine, which is on operation cabinet and power
cabinet. Then check there is any abnormal signal or alarm appeared on
the CRT or operation panel.
 By using MPG, let the spindle headstock upward a little and take away
the supporting block under it.
Note:
If there is no display on the screen of operation panel after power on,
please refer to the parameter tables of electric manual to input data and
restart again.

22
Leveling adjust
Leveling required
Using leveling gage to check the level of machine. The gage reading must
be with 0.01mm/M. The leveling situation is very important to the accuracy
of this machine. We must do the following steps.
Adjust procedure
To complete this procedure follow the next procedure:
 After the processes of installation, the machine level may undergo minor
changes with the elapse of time. Make it a point to check the level
periodically.
 Move the table and saddle to the center position of machine by
programming or manual operating.
 Place the levels on the table to adjust or modify the foundation bolts and
nuts by the bubbles of level gauges, which are located on the center of
levels, that is, machine reach the static level.
 At first, adjust the front and rear of foundation bolts, then middle ones.
 Tighten the bolts and nuts orderly.
 After static level, move the table along Y-axis direction with three points
during the moving of full travel. The bubbles of level should be indicated
the movement within one grid of levels and modify bolts and nuts.
 Tighten the foundation nuts after leveling along the Y-axis direction.
 Follow the same steps as step 6 and 7 but along X-axis direction to
measure the dynamic level of X axis and the movement must be in half
grid of levels’ bubbles.

23
Tools system
ISO 40/50
Vibration required
 The tool must have a concentric running. Vibrations caused by radial
tool deviation may lead to a tool breakage and put the operating staff
into danger!
 Before the tool insertion, the wing surfaces must be cleaned from
soiling.
 Even the slightest foreign matters which may have fallen between the
wing surface cause radial deviation!
 Check radial deviation at tool holding cone with test bar (see figure)

The tool in use must be permitted for the according rotation speed by
the tool producer.

24
Tools specification
ISO 40 serious
BT-40

DIN 40

CAT 40

25
ISO 50 serious
BT 50

DIN 50

CAT 50

26
 Oil usage

OIL USAGE RECOMMENDATION

BRAND ISO MOBIL MOBIL SHELL BP CPC CALUBE
ITEM Synthetic oil
CUT 232 WCR-F200
(water soluble)
Lubricator of VG22 Velocite 10 Energol CS Spindle oil
Tellus 22

27
Recommendation label

pneumatic 22 R22
Lubricator system VG68 Tonna T68 Maccurat D Way
Vactra NO.2
Tonna S68 68 Lubricant 68
VG22 Velocite 10 Energol CS Spindle oil
Tellus 22
22 R22
VG32 Energol HP Circulation
Hydraulic system DTE Light SHC 624 Tellus 32
32 Oil R32
VG32 DTE Light SHC 624 Tellus 32 Energol HP Circulation
32 Oil R32
DTE Light SHC 624 Tellus 32 Energol THP Circulation
VG32
32 Oil R32
VG150 Mobilgear Energol GR-XP E.P Lubricant
SHC 629 Omala 150 150
600xp 150 HD 150
Moving direction

Axis Travel Direction of travel Origin

X Table Advance (+) direction (+) End
Left/right to left
Advance (-) direction
to right
Y Saddle/table Retraction (+) direction (+) End
Forward/backward Advance (-) direction
Z Head stock Up +) direction (+) End
Up/down down (-) direction

28
Coordinate system
The coordinate axes for NC machines are specified in standard specification
DIN 66 217. As a generalization, the following applies to linear axes X, Y and
Z, and the correlating rotary axes:
X Axis
The X axis is the principal axis in the positioning plane. It is usually located
parallel to the work piece clamping area and runs horizontally in most cases.
Y Axis
The position and direction of the Y axis results from the specifications for the X
axis and Y axis. A right-angled Cartesian coordinate system is used.
Z Axis
The Z axis is parallel to the axis of the work spindle or coincides with it. For
drilling and milling machines, the work spindle carries the tool. The work
spindle carries the work piece for lathes. The positive direction of the Z axis
runs from the work piece to the tool, or, in the case of lathes, from the work
spindle to the work piece.
Rotation Coordinates
The rotation axes A, B and C are assigned to the X, Y and Z coordinate axes
(see next page).
Based on the positive direction of the coordinate axes X, Y, Z, the positive
direction for the corresponding rotary axes A, B, C is given by clockwise
rotation.
Direction of Movement
If the tool support is moved, the direction of movement and axis direction are
rectified. The positive directions of movement are designated with +X, +Y, +Z,
etc.
If the work piece fixture is moved, the direction of movement and axis direction
are acting in opposite direction to each other. The positive directions of
movement are designated with +X’, +Y’, +Z’, etc.

29
Right-Hand Rule:
If you place your thumb in the direction of the positive X axis and your middle
finger in the direction of the positive Z axis, the position and direction of the Y
axis is determined by your pointer finger

30
Maintenance point table
POINT TIME D W M 6M Y
Machine body
Clean the chips on the table □ □ □ □ □
Clean and lubricate the table － □ □ □ □
Clean the chips on the chip plate □ □ □ □ □
Clean and lubricate telescopic covers － □ □ □ □
Clean guard and window □ □ □ □ □
Clean the chips between slide ways － － □ □ □
Clean and lubricate slide way － － □ □ □
Adjust wedge(box way type) － － － □ □
Check the slide way if it normal － － － □ □
Clean and lubricate ball screw － － － □ □
Check the ball screw if it normal － － － □ □
Check the level and adjust － － □ □ □
Antirust foundation bolt － － □ □ □
Clean the chip in wire conduit － － □ □ □
Check the wire conduit if it normal － － □ □ □
Drain out the recycle oil tank － □ □ □ □
Spindle
Clean and lubricate tool hold □ □ □ □ □
Check clamping force － － □ □ □
Check the tool release gap － － □ □ □
Change the motor belt － － － － □
Clean and lubricate tools □ □ □ □ □
Check and retighten pull stud □ □ □ □ □
Power cylinder
Check and refill oil tank □ □ □ □ □
Check the solenoid if it normal － □ □ □ □
Change oil － － － － □
Automatic tool changer unit
Remove the chip on disk － □ □ □ □
Clean and antirust guide chain － － □ □ □
Clean and antirust tool holder － － □ □ □
Check tool holder if it normal － － □ □ □
Clean and put antirust to the changer arm － － □ □ □
Add grease on the motion parts － － □ □ □

31
 TIME
POINT D W M 6M Y
Operation box
Check the bottom light if it is normal □ □ □ □ □
Check the switch if it is normal □ □ □ □ □
Electric cabinet
Clean heat exchange fan net － □ □ □ □
Clean and retighten electric parts － － □ □ □
Check the heat changer if it normal － － □ □ □
Check and retighten the locking bolts － － □ □ □
Oil cooler unit
Check and refill oil to the level □ □ □ □ □
Check the temp. setting □ □ □ □ □
Check the function key if it is normal □ □ □ □ □
Check the temp. sensor if it is normal □ □ □ □ □
Clean the fan net － □ □ □ □
Change the oil level － － － － □
Pneumatic unit
Check and adjust pressure － □ □ □ □
Check and refill oil into lubricate tank □ □ □ □ □
Check and adjust lubricate cycle － □ □ □ □
Check the pressure switch setting － □ □ □ □
Check the drain vale if it is normal － □ □ □ □
Change the air filter － － □ □ □
Check the solenoid if it is normal － － □ □ □
Lubricator system
Check and refill oil to the level □ □ □ □ □
Check and adjust pressure － □ □ □ □
Check if there is any leakage □ □ □ □ □
Check the pressure switch setting － □ □ □ □
Clean the enter filter － － □ □ □
Coolant system
Check and refill coolant liquid □ □ □ □ □
Remove chips and clean filter － □ □ □ □
Remove the chips from the chip bucket □ □ □ □ □
Check the chip conveyor if it is normal － － □ □ □
Check the pump if it is normal □ □ □ □ □
Check and add grease driven chain － － □ □ □
Change liquid and clean tank － － □ □ □

32
 TIME
POINT D W M 6M Y
Hydraulic system
Check and refill oil to the level □ □ □ □ □
Check and adjust pressure － □ □ □ □
Check if there is any leakage － □ □ □ □
Check the pressure switch setting － □ □ □ □
Check the solenoid if it is normal － － □ □ □
Change the clean filter net － － － □ □
Change oil and clean oil tank － － － － □

33
2-Equipment

1
 TABLE OF CONTENT
Spindle unit(Belt type) .............................................................................................................................. 4
Application ......................................................................................................................................... 4
Specification ....................................................................................................................................... 4
Warm up requirement ...................................................................................................................... 5
Warm up table ................................................................................................................................... 5
Caution for operation........................................................................................................................ 6
Maintenance ....................................................................................................................................... 6
Procedure of adjustment................................................................................................................... 6
Tool release cylinder .................................................................................................................................. 8
Application ......................................................................................................................................... 8
Out line (For belt type) ..................................................................................................................... 8
For coolant through spindle ............................................................................................................. 8
Specification ....................................................................................................................................... 9
Out line (For direct spindle) ............................................................................................................. 9
Specification ....................................................................................................................................... 9
Sketch drawing ................................................................................................................................ 10
Maintenance ..................................................................................................................................... 10
Trouble shooting ...............................................................................................................................11
Automatic tool change ............................................................................................................................ 12
Instruction ........................................................................................................................................ 12
Specification ..................................................................................................................................... 13
Out line description ......................................................................................................................... 13
Adjust arm to home position .......................................................................................................... 14
Modifying procedures of tool arm ................................................................................................. 14
Assembly drawing ........................................................................................................................... 15
Cycle command ............................................................................................................................... 17
Trouble Shooting ............................................................................................................................. 19
Motor of magazine replacement .................................................................................................... 21
Cylinder replacement ...................................................................................................................... 21
Induction switch replacement ........................................................................................................ 21
Proximity switch of tool magazine replacement method ............................................................. 21
Pneumatic system .................................................................................................................................... 23
Application ....................................................................................................................................... 23
FRL unit out line ............................................................................................................................. 24
Check point before operation ......................................................................................................... 25
Maintenance ..................................................................................................................................... 25
The sketch of pneumatic system .................................................................................................... 27
Power cylinder for tool release ....................................................................................................... 27
Lubrication system .................................................................................................................................. 28
Application ....................................................................................................................................... 28
Specification ..................................................................................................................................... 28
2
 Outside appearance ......................................................................................................................... 28
Check point before operation ......................................................................................................... 29
Caution for operation...................................................................................................................... 29
Maintenance ..................................................................................................................................... 29
Trouble shooting .............................................................................................................................. 29
The sketch of lubrication system.................................................................................................... 31
Cooler system ........................................................................................................................................... 33
Application ....................................................................................................................................... 33
The sketch of cooler system ............................................................................................................ 33
Effect area drawing ......................................................................................................................... 34
SPECIFICATION ........................................................................................................................... 34
Monitor display control panel ........................................................................................................ 34
Operation and function of control panel ....................................................................................... 35
Board setting function..................................................................................................................... 35
Check point before operation ......................................................................................................... 35
Caution for operation...................................................................................................................... 35
Caution for temperature setting .................................................................................................... 36
Maintenance ..................................................................................................................................... 36
Trouble shooting .............................................................................................................................. 36
Coolant system ......................................................................................................................................... 38
Out line ............................................................................................................................................. 38
Performance curves......................................................................................................................... 38
Pump specification .......................................................................................................................... 40
Maintenance ..................................................................................................................................... 40
Trouble shooting .............................................................................................................................. 41
The sketch of coolant system .......................................................................................................... 42
Transition Coupling ................................................................................................................................ 44
Application ....................................................................................................................................... 44
Adjusting Data ................................................................................................................................. 44
Wedges Adjustment ................................................................................................................................. 45
Application ....................................................................................................................................... 45
How to adjusting.............................................................................................................................. 45
Maintenance ..................................................................................................................................... 45

3
Spindle unit(Belt type)
Application
High-speed precise spindle is used on this kind of machine. The parts of spindle
are made through precise process and made from stable material. The Angular Ball
Bearing is assembled by professional people and technology with
constant-temperature environment. This kind of spindle is suitable for high
speed/light duty and low speed/heavy duty.
Adopt the Quill Type recurring coolant circuit and cooperate with high efficiently
temperature controller. It makes the spindle remains constant-temperature state and
create the best working accuracy.
Disk Springs and Draw Bar for clamping are adopted, so that the Spindle can
combine with Cutter Arbor tightly. When the machine is executing tool-changing,
the air blow holes in the middle of spindle can self-dust. Because of this, it will
keep the place that combines the spindle and draw bar clean.
Air purge of spindle nose use low-pressure airflow to bring effect. When spindle is
high-speed operating, the mist and dust will not permeate the bearings. By this
devise, it can ensure the spindle’s life.
The outside dimension and inside construction of spindle, please see the attached
documents for reference.

Specification
Item unit Note
Spindle mode #40 type I #40 type II #50
Cone taper 7/24 7/24 7/24
Housing Dia. mm 120 150 190
Max. speed rpm 10,000 10,000 6,000
Bearing inner Dia. mm 60 70 90
Lubricate grease grease Grease
Clamp force kgf 500 800 1800
Tool release gap mm 0.7~0.9 0.7~0.9 0.9~1.2
Transmission belt belt Belt
Air blow St. St St
Air purge St. St. St
Cooler interface St. St. St.
Weight kg 35 50 95
#40 type I spindle use on : V450/V650/V33I/V42I
#40 type II spindle use on: V1100/MV1100S/MV1300S/MV1750S
#50 type I spindle use on : MV1100D/MV1300D/MV1750D

4
Warm up requirement
The spindle designed with high precision, a kind of automatic CNC machine
center. For the spindle life, please before operating, follow up the table statements
of spindle warming up.
Warm up table

5
Caution for operation
1. Do not rotate spindle unless the tool holder loaded into spindle already.
2. The vibration amplitude of spindle with tool is less than 18um.
3. Adjust temperature controller on the cooler to the temperature be 3~5˚C below
room temperature, then make sure the actual operation of oil cooler.
4. Obey the specific statements and do not excess the cutting condition of tool maker.
5. The operation time for over 8000 rpm can not exceed 3 hours in each period of 4
hours.
6. After 4 hours idle time without operating spindle, the spindle speed should be less
than half speed of target speed for 5 minutes before raising spindle speed over 8000
rpm.
Maintenance
The spindle contains a draw bar witch clamps and release tool by the release
cylinder and the disk spring inside of draw bar. The end of draw bar is made to
clump by steel ball or collets chuck. When the tool is to be unclamp, the tool
release cylinder push down to the draw bar, meanwhile, the chuck move outward,
the tool release from the spindle cone. The disc spring force will supply the draw
bar with pull to draw it back to the initial position. On the other hand, during tool
clumping, the draw bar is acted downward and clumps the tool by the spring force.

REASONS FOR ADJUSTMENT:

 During tool exchanging, there are malfunction between the upper micro
switches and lower micro switch on the top of tool release cylinder.
 The tools pull hardly out of the spindle cone and cause tools interference.
 During tool changing, it is tool hold for delaying time.

Procedure of adjustment
1. Use the manual mode to clump the tool and measure the distance between
spindle nose and flange of tool by micro scale.(refer to the drawing 2)
2. If the distance is not on require, please adjust the push gap by the bolt the
bottom of tool release cylinder. Loose the nut and turn the bolt in clockwise to
enlarge the gap as long as decrease the gap by turning counterclockwise. (one
turn of bolt will move it 1.5 mm.) (refer to the drawing 1)
3. Check if the position is correct between the upper limit switch and the dog
plate. Make sure that the limit switch should be Just on the top point on the dog
whenever clamping or unclamping operation. The limit switch should have
contact space at 1.5~2 mm. it will cause none malfunction or action delay
during tool clamping and unclamping. (refer to the drawing 1)

6
7
Tool release cylinder
Application
Ideal way to generate huge hydraulic push force through pneumatic media. This
hydraulic pushing force is as for the power source of Spindle tool released.
Out line (For belt type)

For coolant through spindle

8
Specification
For #40 spindle For #50 spindle
Item unit Note
Action Air over oil
Input air pressure Kgf/cm2 6~7
Output force Ton 2.5~3 4~4.5
Push stock mm 13 17
Oil tank capacity c.c. 80
Refrigerant Oil ISO VG 32
Boost rate 25 39
Note: Please keep the oil leave of oil tank onto 50% full in tool release state.
Out line (For direct spindle)

Note: Please keep the oil leave of oil tank onto 50% full in tool release state.
Specification
For #40 spindle For #50 spindle
Item unit Note
Action Air over oil
2
Input air pressure Kgf/cm 6~7
Output force Ton 2.5~3.5 2.5~3.5
Max outlet value c.c. 70 120
Cylinder DIM mm 100 100
Oil tank capacity c.c. 80
Refrigerant Oil ISO VG 32
Boost rate 12.7 12.7

9
Sketch drawing

Maintenance
Daily work 1. Check the oil level.
Weekly work 1. Check the connectors to see any leak or loose.
Monthly work 1. Check the oil level and refill it.
Yearly work 1. Change the oil.

10
Trouble shooting
Trouble Possible reason Solution
 Hydraulic-pres  Joint leaking  Tighten joint.
sure Oil  Seal is broken  Change seal.
consumed  Pressure to low  Adjust pressure
unusually
 Tool can not  Joint leaking  Tighten joint.
release  Seal is broken  Change seal
 Oil level to low  Refill oil
 Piston can not  Solenoid broken  Change
back solenoid
 Note：First use or re-filling oil may cause the cylinder to have bubbles and
become low-pressure.
 Solution:
 Dismount the tool on the spindle.
 Press the Manual button on the Magnetic Valve for unclamp and clamp
several times. By this step, the bubbles in the tubes can be discharged.
 Re-assemble the tool and test the function for clamp and unclamp again

11
Automatic tool change
Cam type automatic tool changing system
Instruction
 This system is using cylindrical cam to reduce the speed by gear. The
cylindrical cam is driven by a motor, which attached with automatically
power-off brake to produce the indexing angle and positioning the tool
pocket. When POT is on position, the pneumatic 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.
 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 help the brake motor to stop and
positioning. (The rotation angle of the brake motor will be 45°±20°)
 The effective rotate angle for the clamping cam is approximately 100°, 10°
plus on both the left and right side to be the angle often movement.
 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 complete indexing cycle (24 index) will
take 16.8 seconds.
 The travel of clamping cylinder is ψ50mm ×100mm, detected by magnetic
ring.
 The solenoid valve is 2 phases, 24V, 1/4”PT. (For pneumatic ATC).
 The Proximity Sensors: brand name: BALLUFF (ISO-9001) REG NO:
19279-01Specification:M12×1,detecting distance 2mmVoltage:10-30V DC
≦130mA≦800HZ PNP 3 cords.
 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℃.
 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.

12
 The total weight of the automatic tool changing system, is approximately
140Kg, the clamping arm and cover excluded, (the weight of the body and tool
plate is light, but still carry high rigidity, the cylinder and drive motor are
located on the back side of tool magazine, to bring the convenience for
maintenance & repair.)

Specification
Tool mode ISO 40
Exchange arm type Swim arm
Exchange mode Random
Tools capacity No. 40
Tool hold mode Chain type
Tool exchange time sec 1.5
Max. tool weight kg 7
Max. tool length mm 250
Out line description

13
Adjust arm to home position
1. According the following sketch, the tool magazine accuracy is within ±1˚.
2. Because of the static angle of motor signal roller, motor needs to turn about
2.5 or 3 revolutions for taking off the conduction range. If the motor brake
turns over 2.5 revolutions, it will drive the tool arm. In general the stopping
range of motor brake is within half or 1 revolution and the conduction timing
of proximity switches set at 5˚ before returning home position.
3. If motor used quite long time, the brake will be exhausted and extended the
stopping range. Eventually the detector extinguished and made a false signal;
therefore the NC operating will break down.
4. If there is a lot of similar situations happened neither switch problem nor
electric elements broke. After checking tool arm at the tool changing position
is OK then it made a conclusion that the brake motor has been exhausted. It
should be replace the new one by authority service person.
5. If shrink the distance between sensor and original position of signal
conductive roller, the stopping range of brake motor will become so smaller
that original position deviate over range and get alarm easily.
6. Because of the varies factors for brake motor, so the supplier suggests that
every two years to replace the new one to keep within ±1˚ of the brake
accuracy.
Please refer to the following drawing
Modifying procedures of tool arm
 Pull down the clutch lever.
 Turn the tool arm to the position of tool holding angle by turning motor with
the wrench.
 Adjust the tool arm to hold the tool.
 Tighten the setscrews of tool arm.
Please refer to the following drawing

14
Assembly drawing
Boring tool sleeve

Motor drive

Pot down/up cam

15
Position sensor

Tool change arm

16
Cycle command
M6 T code Tool change cycle
MDI mode commend
[M21] Disk turning clockwise [M22] Disk turning count clockwise

MDI mode commend

[M19] Spindle rotation to original [M23] Tool hold to lower position

MDI mode commend

[M26] Tool release

17
MDI mode commend

MDI mode commend

[M25] Tool clamping

MDI mode commend

[M24] Tool hold to upper position

18
Trouble Shooting
Trouble  Tool disk stops without positioning
1. Brake fail to work or overload
Reason
2. Sensor switch with far distance
1. Please check electronic brake wiring in- correct connection or
solution not? If the part fail to work
2. Move sensor switch closer to sensor
Trouble  Tool disk non-stop rotating
1. Sensor switch break down
Reason
2. Sensor switch with far distance
1. Replace sensor switch
solution
2. Move sensor switch Closer to sensor
Trouble  Pot break
Reason 1. Tool disk rotated while tool clamping
solution 1. Replace new tool pot & adjust arm Clamping position again
Trouble  Shake during tool clamp & returning
1. Cam out lubrication
Reason
2. Cylinder speed out of balance
1. Fill lubricant oil
solution
2. Adjust cylinder pressure & speed valve.
Trouble  Tool pot is not positioning(loosen)
Reason 1. Bolt of positioning bolt or pot bolt are loosen
solution 1. Adjust it to normal & tighten
Trouble  Tool disk dose not work during tool selection
1. Induction switch dose not work
2. Induction switch break down
Reason
3. Motor break down
4. Electronic break bread down
1. Adjust reed switch to normal position
2. Replace reed switch
solution
3. Repair motor
4. Check wiring or sensor switch & replace

19
Trouble  Cylinder does not work during tool change
1. Proximity switch for tool counter positioning is break down
2. Tool disk is not positioning
Reason
3. Cylinder has no pneumatic air
4. ATC arm does not home
1. Replace proximity switch
2. Tool disk positioning
3. Check cylinder air, solenoid valve works or not?
solution
4. Rotating motor bolt manually to let ATC arm back to
original position
5. Check reed induction switch
Trouble  ATC fail to work during tool change
1. Tool clamp positioning reed switch fail to work
Reason
2. Induction switch break down
1. Adjust reed switch to proper position
solution
2. Replace new reed induction switch
Trouble  ATC motor over-heat
1. Brake is not released
Reason 2. Brake is break down
3. Commentator is break down
1. Check commentator to electrify or not?
solution 2. Replace brake
3. Replace commentator
 ATC fail to work after tool clamping;
 ATC fail to work after 180° degrees tool change;
Trouble
 ATC home stop & home
 Sensor switch does not work
1. Sensor is in wrong position
Reason
2. Sensor switch is break down
1. Adjust sensor to proper position
solution
2. Replace sensor switch
Trouble  ATC stop position out of
1. Sensor is in wrong position
Reason
2. Positioning ring of sensor switch is in wrong angle
1. Adjust 3 sensor at the same time to proper angle
solution
2. Rotate set ring, adjust 3 sensor switch to proper angle
Trouble  ATC tool clamping position out of accuracy
Reason 1. Arm & ATC spindle are not aligned
solution 1. Loosen taper ring key & align it again

20
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.
Cylinder replacement
1. urn 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.
Induction switch replacement
Power off.
Disassembly the wires of induction switch in the electric box.
Please loosen the seat of reed switch & take it out.
Replace new part & take care of the sensor position, push it to upward &
downward until to end of both sides.
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. 5.Replace new part & make sure the sensitive distance is 4mm.

21
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.

22
Pneumatic system
Application
Air Pressure Unit is the source of power to drive the air-pressure equipments, such as
spindle unclamp, tool pocket motions and air blowing...etc.
In the factory, the device that providing air pressure needs the functions of pressurization,
dust-sweeping, water-sweeping...etc., so that they can raise the reliability of long-term
operation for machine devices.
Safety control(CE request)

 Push the air pressure release valve to release position before to do any service work.

23
FRL unit out line

NO Name Unit Regulation

1 Pneumatic source entrance kgf/cm2 6~7
2 Air fillter u 5 micro
3 Lubrication oil tank c.c 50-ISO/VG22
4 Pressure gauge kgf/cm2 6~7
5 Adjust knob
6 Pressure control switch
7 Oil flow adjust knob
8 Oil floe watch view l/min 60
9 Oil entrance
10 Auto drain valves automatic

24
Pressure control switch adjusting

Range setup:4~4.5 bar

Diff setup: around 2 bar

Check point before operation

1. Check pressure supply before adjusting and check the air pressure gauge.
2. Adjust as necessary, what with watch the pressure gauge and clockwise rotation of the
knob results in a pressure increase or counterclockwise turn will reduce the pressure.
3. Check the lubricator tank oil level and refill it.
4. Check the pressure switch setting is on factory setting.

 The pressure setting between 6~7 kg/cm2.

 Air pressure required: 8 bar before regulator, 6 bar after regulator, 400 l/min
momentary.
 Push the air pressure release valve to release position before to do any service work.
Maintenance
Daily work 2. Check the pressure and adjust pressure.
Weekly work 1. Check pipe and connectors to see is there any leak or
loose.
2. Check the oil level and re-fill the oil
Monthly work 1. Check the filter
Half year work 1. Change the filter

25
Note:
From the main air supply line attach a 10 mm air supply line for machine. The
distance from the air compressor and number of machines attached should be taken
into consideration when determining the size of piping for the main air supply line.
Piping may consist of one or more of the following: galvanized pip, PVC pipe or
high pressure hose. Do not use quick disconnects; quick disconnects will restrict air
flow.
A”T” riser should be used to connect the main air supply line with the air supply line
to machine.
To prevent moisture from entering the machine air system, attach a drain to the
lowest point of the air supply line. The drain could be a self-relieving moisture
separator, a simple petcock, or a gate valve opened occasionally to release the water
build-up. An air dryer is preferred where higher moisture levels exist.
To help prevent contaminants from entering the air system on the machine, place a
filter in-line on the main air supply line.

The route sketch drawings following the end of book.

26
The sketch of pneumatic system
V serious

Power cylinder for tool release

27
Lubrication system
Application
The slide way and liner way of machine are in headstock and table, saddle and
the X,Y, Z axis ball screw, those areas need to be lubricated and all supplied by
the lubricating pump located at the rear side of this machine.
When we turn on the machine power the auto lube will be started automatically
and it will pump the lubricant to the areas mentioned above every 15 minutes.
Every shot of oil will last 30 seconds. It can be adjusted if necessary, please
refer to the operation manual.
Specification
Item Unit Note
Discharge capacity Cc/min 0~200
Discharge pressure Bar 0~20
Pump power KW 0.25
Volt 3 phase/220V
Oil mode ISO VG 68
Setting pressure Bar 10~12
Pressure protection device yes
Outside appearance

NO Name NO Name
7
1 Oil tank 6 Push button
2 Pump 7 Oil inlet
3 Pressure gauge 8 Adjust value
4 Entrance 9 fillter 9
5 Oil level gauge 10 Lamp light

28
Check point before operation
 Always sure proper, fresh lubricant and similar to viscosity(32-68 cST/40˚ C)
 The oil reservoir should always preserve clean lubricant and does not use recycle
oil.
Caution for operation
 The indicated lamp will light on if lubrication system operating normal.
 Turn the adjustable valve with CW to increase pressure and with CCW turn to
decrease pressure.

Maintenance
Daily work 3. Check the oil level and re-fill the oil
4. Check the pressure(push the button)
Weekly work 1. Check oil pipe and connectors to see is
there any leak or loose.
Monthly work 1. Clean the filter

When we have the following situation please hold on the push button for 10~15
seconds, this action should repeat 3 times, because for a long time no operation,
the lubrication is very little.
When
1. The machine is first time set up
2. Long time no operation.
3. Everyday before operation.
We should do this lubricating operation, go around and begin again 3 times when
hand off the pump will stop automatically.
We should re-fill from the oil entrance every day. When the oil level goes down
to 1/4, the operation panel will show “LUBE ALUMN”
Trouble shooting
Situation Cause Remedy
Pump can 1. There is some foreign 1. Disassemble the pump and take
not work particles in away the foreign particle
2. The viscosity of oil 2. Use suitable viscosity oil
either too high or too
low.
Pressure 1. The pressure not setting 1. Adjust pressure
to lower 2. The joint or pipe leaking. 2. Tighten joint or change pipe.

29
The control lubricator system is always has strong influence to the machine
accuracy and life of operation, so please take good can of operation and
maintenance.
The normal working condition is in the temperature of surrounding at 5-60˚
please do not over it or below it and please do not let the sun shine impinge on the
machine directly.

Max. Operating pressure should not over 12 kgf/cm2 (170 PSI)

The route sketch drawings following the end of book.

30
The sketch of lubrication system
V 450/V 650/V 33i/V 42i/V 1100

31
MV 1750S/D

32
Cooler system
Application
This cooler series is designed specifically to remove heat generated in the
spindle and gear box of CNC machine centers.
The following charts indicate the operating oil/liquid temperature for various
ambient room temperatures in order that precision of the finished work piece is
obtained.

The cooler is designed with built in protection for compressor and electrical
part while the voltage tolerance +/- 10%。

Frequency tolerance +/- 1˚C

The sketch of cooler system

Head stock

Spindle

33
Effect area drawing

SPECIFICATION
Item unit specification
Cooling capacity BTU/hr 4000
Kcal/hr 1000
Power source V AC 220V/380V 3φ 50/60
Hz
Oil pump power HP/KW 0.25/0.19
Total current A 3.8
Inlet and outlet bore size 1/2”x1/2”
Oil pump flow rate Litter/min 4.5
Refrigerant R-134a
Oil tank capacity Litter 20L
Refrigerant Oil ISO VG 32
Temp setting range ˚C +9.9~-9.9
Monitor display control panel

34
Operation and function of control panel

Board setting function

1. When ALARM LED lights up, it indicates pump overload switch、flow
switch、pressure switch or compressor overload switch is unusual. Please
check if the switch is turnoff, to reset it and refer remedy method from
manual, to clean the filter, etc. To avoid ALARM again.
2. When ALARM LED lights up and RE is displayed, it indicates power phase
is error. Please check the wiring connections. If you are using a single phase
power source, please adjust the “3” of S4 DIP-SW to the position OFF on
the electric board.
3. When ALARM LED lights up and O.S. is displayed, which mean oil/water
(SENSOR) is unusual.
4. When ALARM LED lights up and R.S. is displayed, which mean room
temperature (SENSOR) is unusual.
Check point before operation
1. When the power source is turned on , check to the power lamp is light up.
2. Push the ON/OFF key to light up the power lamp.
3. Check that the oil level is at lease at 80% level of the oil tank.
4. Check that the outlet and inlet of the oil tank is tightly secured.
Caution for operation
1. Avoid running the pump without oil.
2. When the pump is run in, the compressor shell run in about 30 seconds later.
3. Do not turn ON/OFF the cooler repeatedly. Otherwise, that would cause cooler
stop, and the overload switch may trip. When this happens, it is necessary to
take 2-3 minute break then the compressor start again.

35
Caution for temperature setting

1. We set the differential temp. between -3~-5˚ C。Do not over -7˚ C。
2. Setting protection for low temp. is 23˚ C, the compressor will stop running
when liquid temp. Low the setting value.
3. Please raise the setting temperature while the water congealed from pipe or
spindle out flange.
Maintenance
Daily work 1. Check the oil level.
2. Check the temperature setting
Weekly work 1. Clean the filter by brush or compressed air.
2. Check oil pipe and connectors to see is there any leak
or loose.
Monthly work 1. Wash the filter.
2. Clean up the dirt on radiator of oil cooler with
compressive air.
Yearly work 1. Change the oil.
Trouble shooting
Situation 1. Power lamp is off
Cause 1. LED burnt.
2. PCB board fuse blown
3. Transformer burnt
4. Wire 18,19 loose connection
Remedy 1. Replace PC board
2. Replace fuse
3. Replace transformer
4. Reconnect wire 18 & 19
Situation REV is lighted
Cause 1. 3 phase power reverse
2. Pressure reduction and differential value of 3 phase
is above ±10％
Remedy 1. Switch any 2 of the R.S.T wires
2. Stability power source
Situation OPS is lighted
Cause 1. Inlet oil pipe is clogged or loosened
2. Inlet & outlet are reversed
3. Pump motor runs reverse
4. Pump can not run
5. Circulation oil is not enough

36
 6. Oil filter is dirty
7. Oil pressure switch breakdown
Remedy 1. Check, clean and lock pipe
2. Correct position of in/outlet
3. Check over-relay of 51p red and white lines
4. Replace oil pump
5. Supply circulation oil
6. Replace new filter
7. Adjust oil pressure switch DIFF, 0.3 kgf/㎝ 2, range
0.5~0.8 cmHg
Situation PUMP is lighted
Cause 1. Overload relay is off
2. Pump switch is off
3. Inlet pipe is
Remedy 1. Reset switch
2. Reset pump switch
3. Clean pipe and
Situation HP is lighted
Cause 1. Condenser is too dirty
2. Air filter is not clean
3. Cooling fan doesn’t run or blades fall off
4. Cooling medium pressure switch breakdown
5. Cooling medium is leaking
Remedy 1. Use compress air to clean fins and restart cooler
2. Clean filter
3. Lock fan blades tightly or replace fan motor
4. Replace cooling medium pressure switch
5. Irrigate cooling medium.
Situation RA is lighted
Cause 1. Room temp. Sensor breakdown
Remedy 1. Replace RA sensor
Situation RO is lighted
Cause 1. Oil temp. Sensor breakdown
Remedy 1. Replace RO sensor
Situation OT is lighted
Cause 1. Oil temp. is to high
2. Temp. sensor blown
Checking cooling medium is enough or not
Remedy 1. Stop running cooler until oil temp. Returns to
normal range. Start again
2. Replace temp. sensor

37
 Supply cooling medium

Lack of cooling medium (the refrigerant)

The following condition is caused by lack of cooling medium:
No alarm information but the motors keep running, cooler can not reach to the
setting temperature and working machine’s spindle is hot.

If the avoid situation occurred, please call us or find the professional technician
at local market for repair service.

Coolant system
TPHK4T 3-2
The system circulates the coolant with low-pressure pump. It cools the heat
when tool is cutting and provides lubricant from coolant’s additive for cutting.
It also enhances the accuracy of work piece.
Pump of Coolant B provides flowing water for chip cleaning.
About the Coolant’s Additive, please follow the instruction of Additive’s
supplier to mix the additive with appointed percentage.
Out line

Performance curves

38
39
Pump specification
Item Unit Description
Motor TPHK4T 3-2
Nominal speed rpm 3500/2900
Frequency range Hz 60/50
Standard voltages V 220/380
Protection class IP54
Insulation class F
Pump
Flow rate max. L/min 185
Head high max. M 90
Max. pressure kg/cm² 10

Maintenance
Daily work 5. Clean the chip filter
Weekly work 2. Check the level and re-fill the oil
Monthly work 2. Clean the chips on the chip tank
3. Change the liquids.
NOTE:
 Do nit stare the pump at first time using until it has been filled with coolant.
 Every connection are made as shown on the inside of the terminal box cover.
 The pump should rotate counter 0 clockwise when viewed from the motor
end and arrows on the motor fan’s cover indicated the correct direction of
rotation.
 To reverse the direction of rotation, switch off the power supply and
interchange any two of inputting supply wire.

40
Trouble shooting
FAULT CAUSE
Pump does not work Power supply failure.
Control circuit has cut out or is defective.
Motor is defective or overload.
Pump is blocked by impurities.
Pump runs but deliver Pump is not filled with coolant in advance.
no coolant Suction or discharge pipe is blocked by impurities.
There is leakage in suction pipe.
Foot or check valve is blocked or suction head
beyond requirement.
Pump runs but reduced There is wrong direction of revolution
capacity (Three-phrase).
Suction head is lifted too great.
Suction or discharge pipe is blocked.
Pump is blocked by impurities.
Foot or check valve is partly blocked.
Pump stops during Thermal overload switch in motor or external motor
operating protection cuts out.
Control circuit is failure or cuts out.

Refer to the drawings following the end of book

41
The sketch of coolant system
Screw conveyor

M
M
M

42
Chip conveyor

M
M

43
Transition Coupling
Application
The hub claws and the nylon teeth are chamfered to allow for a “blind
assembly”. The ends of the teeth have pegs arranged reciprocally to
limit the axial positioning. The plug-in force varies depending on the
Shore hardness and priestess of the spider.
By observing the gap dimension “S” the electrical isolation is ensured,
as well as a high service lift of the coupling. This fact is gaining more
and more importance, due to the increasing precision of shaft encoders
and the existing demand for electro-magnetic compatibility.
Adjusting Data
ROTEX GS-P TYPE(Hub and clamping ring material-steel)
For direct type spindle
Coupling size Gap Tightening torque
S(mm) of clamping screw
Ta(N/m)
GS42-P 3 35
GS48-P 3.5 69
GS55-P 4 69
ROTEX GS TYPE(Hub material-Aluminum)
For ball screw
GS24- 2 10.5(M6).
GS28- 2.5 25(M8)
GS38- 3.0 25(M8)

44
Wedges Adjustment
Application
Because the wedges will be abraded after a long time use, the axis with box
way will cause chinks. It is a normal situation and it can be solved by wedges
adjustment.
Since the gib adjustment is important to keep a good static accuracy on each
axis, it is recommended to contact with our Technical Service before touching
to this portion.
How to adjusting
In order to increase the pre-load, loosen the tension bolt, and then turn the
pushing bolt CW for pushing. Apply the torque of 0.9 N-cm(10kgf.cm) to the
pushing bolt.
In order to decrease the pre-load, loosen the pushing bolt, and then turn the
tension bolt CW.
After setting the proper re-load, make sure that the tension bolt and pushing
bolt are locked firmly.

Maintenance

 After machine installation.

 Maintain one time after the new machine operates three months.
 Then, maintain the machine six months a time.
45