MAINTENANCE

MANUAL
Ver No. N20M1904

Horizontal CNC Turning Center

NL 2000/M, 2000B/BM
CONTENTS
1. User Manual

2.User Manual of Turret(EWS)

2.1 NL2000 STD Turret
2.2 NL2000B STD Turret
2.3 NL2000M/2000BM Mill Turret(BMT55)

3.User Manual of Hydraulic Pos-

Clamp Braker(SUNTES)
User manual
Safety Handling Specification Operation Maintenance

NL2000/M
NL2000B/BM

N20M190
Instroduction

Thank you for choosing the our machine tool. We are proud to have

you among our company family of users.

This machine user manual provides brief and compact information

for understanding machine specifications and functions, and also

for machine installation and inspection/adjustment/maintenance.

Please understand fully and keep this manual as a guide to maintain

the machine in best condition for a long period.

※ This manual was considered complete and accurate at the time

of publication, however, due to our desire to constantly improve

the quality and specifi cation of all our products, it is subject to

change or modifi cation.

www.smartmachinetool.com
115-28, Techno valley 1-ro , Jillye-myeon,
Gimhae-si, Kyungnam, Korea
Construction

Safety precautions

Ⅰ. Handling

Ⅱ. Specification

Ⅲ. Operation

Ⅳ. Technical data

Ⅴ. Maintenance
Safety articles

1. General Safety ····························································1

2. Clothing and Personal Safety ·······································2

3. Safety Related to Operation ·········································3

4. Safety Related to Gripping Workpiece and Tooling ··········5

5. Safety Related to Maintenance ·····································7

6. Safety Related to the Workplace ···································9

7. Safety Related to the Chip Conveyor ·····························9

8. Safety precautions nameplates ····································9

9. Noise Emission ·························································10

Instruction
(1) The purpose of safety precautions is to protect operator injury and machine damage from incidental accidents.
Safety precautions must be understood and observed because they will be applied to the setting and
operations of all machine as well as this machine.
(2) Fully understand the safety guidance and User manual then operate the machine. SMART has no
responsibility in case that the indicated precautions wouldn't observed and / or accident due to improper
use.

(3) There are 3 kinds of safety regulations such as DANGER, WARNING and CAUTION related to safety in this

manual. Their meanings are as follows.

[Symbols]

The following warning indications are used in this manual to draw attention to information of particular

importance.

Indicates an imminent hazard which, if not avoided, will result in death or serious injury.
Danger

Indicates hazards which, if not avoided, could result in death or serious injury.
Warning

Indicates hazards which, if not avoided, could result in minor injuries or damage to devices or
equipment.
Caution
1. General Safety
1. There are high voltage terminals on the electrical cabinet, transformer, motors,

junction boxes, and other equipment (with a battery warning mark attached).
Never touch any of them.
2. Make sure that all doors and covers should be closed before turning on the power. If
any door or cover is opened, first stop the work and cut off the main breaker.
3. Never modify the machine in any way that will affect its safety.
Danger We take no responsibility for any personal accidents or machine trouble due to improper
use.
4. Never touch the rotating workpiece or tool with your bare hands or any other objects.
Fail to observe this warning may result in a fatal wound due to contact with the rotating
workpiece.

1. Make sure to memorize the position of the EMERGENCY STOP button so that you can
press it immediately from any position.
2. Take care not to touch any of the switches arbitrarily while the machine is in operation.
3. Never touch your fingers in chuck or tool.
4. To prevent incorrect operation of the machine, carefully check the position of the
switches before operation.
5. If finding out any doubtful thing from the machine, stop the machine operation
immediately and call the responsible person then operate the machine again after
solving its trouble.
6. Always turn off the power switch on the operation panel and main power breaker
before leaving the machine so that someone else can not operate it arbitrarily.
7. If two or more operators work together, establish mutual signals so that they can
Warning
communicate to confirm the safety to each other before proceeding to each new step.
8. Do not touch a rotating workpiece or the tool with your bare hands or any other object.
9. Do not modify the machine in any way that will affect its safety.
Be sure to use the specified and standard parts as replacement or consumable
parts so as to maintain the shipped machine specifications.
We don't take any responsibility for personal accidents or machine trouble due to
inobservance of this warning.
10. Do not stay in front of the chuck area while a spindle is rotating.
11. We don't take any responsibility for personal accidents or machine trouble due to
unauthorized attachments, modification, any other abuse or misuse by a customer.

1
 1.If there is a power failure, turn off the main power breaker immediately.
2.Take care not to impact the CNC unit, the operation panel, or the electrical cabinet.
3.Do not change the parameter or other electrical setting values without valid reason.
If it is necessary to change a setting value, fi rst check that it is safe after confi rming
its work from the responsible person and then make a note of the original value so
that it can be reset.
4.Never remove and/or damage any of the safety nameplates. If the nameplates
become illegible or damaged, purchase it from SMART and attach the replacement
Caution its original position so that everybody can see it.
5.Do not open any doors or safety covers while the machine is in automatic operation.
6.Stop all machine operations and turn off the power before cleaning the machine or
any of the peripheral equipment.
7.After a job has been completed, set up each part of the machine so that it is ready
to be for the next series of operations.
8.Do not eject the compressed air of the air gun to the human body.

2. Clothing and Personal Safety

1. Tie back long hair, which could be entangled driving mechanism.
2. Wear safety equipment(helmet, goggles, safety shoes, etc.) that can guarantee the
safety.
3. Always wear a helmet if there are any overhead obstacles in the work area.
4. Always wear a protective mask when machining the workpiece such as magnesium
alloys or graphite.
5. Never wear loose or baggy clothing.
6. Always completely fasten buttons and tie up the arms of clothing to avoid entangling
Caution
with rotating parts.
7. Do not operate the machine while under the influence of drugs with powerful effects,
unprescribed drugs, or alcohol.
8. Do not operate the machine if you feel faint or lose consciousness.
9. Always use gloves when loading or unloading workpiece or tools and when removing
chips.

2
3. Safety Related to Operation
1. Do not adjust the coolant nozzles while the machine is in operation.
2. Do not remove or move the safety devices such as dogs, limit switches in order to
increase axis travel.
3. Do not wipe the workpiece or remove chips with your hand or with a rag while the
Danger
tool is rotating; always stop the machine and remove chips using the brush.
4. Do not operate the machine with any of the safety covers removed.

1. Do not allow chips to accumulate during machining the heavy-duty workpiece since
they become hot and may take fire.
2. Check that the belts such as spindle, feed axis and tool post have the correct tension
before operating the machine.
3. Warm up the spindle and all of the axis feed mechanisms before operation. (Operate
the machine in the automatic mode for 10 to 20 minutes at 1/3 to 1/2 maximum
spindle speed or maximum axis feed rate.)
4. Make the program for the warming-up operation so as to execute the function of the
Warning
full range of machine components, If operation is to be performed at maximum spindle
speed, pay special attention to the warming-up operation.
5. Do not operate the switches on the operation panel with wearing gloves, which could
lead to incorrect operation or other mistake.
6. When finishing the work, turn off the switch as following order; power switch on the
CNC operation panel, main power breaker and factory power supply.

3
 1. Close all doors and covers of the CNC unit, operation panel, electrical cabinet, and
junction boxes to protect the damage from coolant, chips and oil.
2. Check all electrical cables for damage to prevent accidents due to current leakage or
electric shock.
3. Do not handle coolant with bare hands since it may cause irritation. Operators with
allergies should take special precautions.
4. Do not operate the machine during violent thunderstorm like thunder or lightning.
5. Check the safety covers regularly to make sure that they are properly closed and that
they are not damaged. Repair or replace any damaged covers immediately.
6. Always obtain assistance in handling loads beyond your capacity.
7. The work for fork lift, crane or hoist must be carried out by the authorized person.
8. When using fork lift, crane or hoist, make sure that there are no obstruction in the
vicinity of machine working range.
9. When lifting the machine, workpiece or other parts, always use suitable wire rope or
Warning slings so as to secure from load. Refer to the instruction manual as regards to the
machine's weight or installation.
10. Be sure to check the sling, wire rope, crane, hoist or forklift before using it. If finding
out the defectiveness, repair or replace it immediately.
11. Always wear gloves and use a brush to remove chips from tool tips; never use bare
hands. Fail to observe this warning may result in serious injury.
12. Stop all machine operations before mounting or removing a tool.
13. Switch key related to the safety must be managed by the responsible person:
locking-release key of safety door, electrical cabinet key.
14. Do not stay in front of the chuck area while a spindle is rotating.
15. We don't take any responsibility for any personal accidents or machine trouble
due to unauthorized attachments, modification, any other abuse or misuse by a
customer.

4
4. Safety Related to Gripping Workpiece and Tooling
1.Do not rotate the spindle more than maximum allowable speed. This may result in
fatal injury that spring out the workpiece.
2.If the chuck or the jig being used is not SMART products, check the maximum safe
operating speed and maximum allowable pressure of the manufacturer, then operate
them within maximum conditions.
Danger
3.Make sure to set the machining condition securely when cutting the heavy or big
diameter workpiece. Set the machining condition according to the instruction
manual of chuck maker.

1. Always use tools suitable for the work and which conform to the machine specifications.
2. Replace tools quickly since badly worn tools may result in a sudden accident or
machine damage.
3. Before starting to rotate the spindle, check that any part which are bolted or clamped
to the chuck or the steady rest are properly secured.
4. If the center hole on large bar workpiece is too small, the workpiece could come off
when a load is applied. Make sure that the hole is big enough and that it has the
correct angle.
5. Take care not to be caught your fingers in the chuck.
6. Always use the crane or lifting gear for heavy chucks, steady rests, and workpieces.
7. Be sure not to turn off the power under the condition of clamping the workpiece.
8. Always close the front shield before starting to rotate the spindle.
Warning
9. Specially pay attention to the machining condition and the workpiece balancing
when the spindle is rotating at maximum allowable speed.
10. If special jaws(larger than standard soft-top jaws) are used, observe the following
points:
- Lower the spindle speed because centrifugal force reduce the gripping force of
chuck.
- Jaw nuts must be positioned within outer diameter of the chuck.
- Machine the jaws with the workpiece shape.
11. Securely tighten the bolts on the chuck body and the jaws to the specified torque
according to the instruction manual of chuck maker.

5
 · For safe chucking

I&HQWULIXJDOIRUFH

① The gripping force of chuck must be set to enough the

&XWWLQJIRUFH

safety factor(2~3 or more). Run the spindle within the

allowable speed range.

6SLQGOHVSHHG ② In constant peripheral speed cutting, calculate the

&XWWLQJVSHHG actual machining speed before designating G50
&LUFXPIHUHQFHWRGLDPHWHUUDWLR
0DFKLQLQJGLDPHWHU
(maximum speed limit function).

0XVWEH
GHHS
③ Secure the jaw gripping depth as much as possible.

④Before machining an unbalanced workpiece, carry

Warning out balancing of the workpiece weight by gradual

&ODPSLQJ %DODQFH changing the spindle speed.
EORFN ZHLJKW

7VORW -LJ ⑤Never attempt to install jigs using T-nut.

Be sure to fi x the jigs with bolts.
No chucks prepared by SMART have T-groove.
-DZ

&\OLQGHU +ROORZFKXFN ⑥When inserting a bar material into the hollow chuck,
ensure that the bar does not protrude from the rear
end of the cylinder.

&KXFN

⑦ Never use double chucking method.

:RUNSLHFH

1 . Make sure that the tool length is not to interfered with fixtures or other objects.
2. Perform a test operation after mounting a tool.
3. After machining soft jaws, check that the workpiece is correctly clamped and the
Caution
chuck pressure is correct.

6
5. Safety Related to Maintenance
1. Always turn off the main power breaker and lock it before carrying out any maintenance
work so that someone else can not operate the machine inadvertently during
maintenance work.
2. After the power has been turned off for a short while, check the voltage with a multimeter
or similar instrument to make sure that there is no residual voltage. Also discharge
the capacitors.
Danger 3. The inclined or vertical feed axes are installed with servo motor or electromagnetic
brake device so that their feed axes can not slip down automatically by brake
mechanism even being turned off the power.
4. Do not remove or modify overtravel limit switches, interlock limit switches, proximity
switches, or other safety devices.

1. Maintenance work for electrical parts must be carried out by qualified personnel.
2. Even if the door of the electrical cabinet is open, the power can not be cut off. When
working inside the electrical cabinet or repairing the machine, always turn off the
main breaker and lock it with key.
3. When carrying out maintenance in high places, always use a suitable ladder or a
service platform and always wear a helmet.
4. Always turn off the main power breaker and lock it before electrical work is carried
out.
Warning 5. Never approach your hands such as belts or pulleys.
6. Do not start the machine until all of the removed covers for maintenance have been
refitted.
7. Wipe up any water or oil immediately so as not to slip and keep the maintenance
area and the workplace clean and tidy at all times.
8. Check that working tool is still remained around machine inside or vicinity after
maintenance work: this is extremely dangerous.

7
 1. Maintenance work should be carried out by qualified personnel in accordance with
the instructions of the person in charge.
2. Always use the SMART replacement parts or approval parts.
3. Read the manuals thoroughly fi rst then perform the machine operation and the
maintenance work.
4. Do not use compressed air to clean the machine or to remove chips.
5. Always use gloves when removing chips: never touch chips with bare hands.
6. When changing a fuse, check that the new fuse has the correct rating. (Using a fuse
with too high a rating could result in damage to the equipment.)
7. Use only the specifi ed grades of hydraulic oil, lubricating oil, and grease or their
Caution equivalents.
Follow the instructions indicated on the instruction plate concerning the brands of
oil to be used, lubrication points, amount to be used, and oil change intervals.
8. If one of the belts in a set has stretched beyond the prescribed limit, change the
entire set.
9. Stop all machine operation before cleaning the machine or the surrounding area.
10. Disposal of industrial waste such as oil, coolant, chips and refrigerants is to
be performed in strict compliance with environmental protection laws as stipulated
by the proper national and local authorities.

8
6. Safety Related to the Workplace
1. Immediately remove all water and oil spills from the floor of machine vicinity and
keep the floor dry to prevent accidents.
2. Keep combustible materials away from the work area and any other place where
there are hot chips.
3. Always provide sufficient lighting in the work area.
4. Always provide sufficient working space for maintenance work when installing the
machine.
5. Never place tools or other potentially dangerous object on top of the headstock,
Warning turret and covers.
6. Protect all cables which are along the floor from being damaged by chips: damaged
cables and wires will cause current leakage and short-circuit.
7. Use strong service platforms only and make sure that nothing can slip off them.
8. Make sure that the nominal cross-sectional area of the power supply cable between
the factory power supply switch and the machine main power breaker is such as to
enable a stable supply for operation at the maximum output.

7. Safety Related to the Chip Conveyor

1. Before carrying out maintenance work or other jobs on the chip conveyor, make
sure that the power supply is turned off and that the conveyor itself is placed in
the completely stopped status. Failure to observe this precaution causes serious
personal injury.
2. During the operation of the chip conveyor, keep hands away from and do not insert
Warning
any region of your body into any sections of the conveyor. Chip conveyor can be
operated at any time under condition that the power is turned on, therefore never
touch it.

8. Safety precautions nameplates

Safety nameplates are attached on the machine to secure the operators and the machine from
danger. Do not remove these nameplates. If nameplates are damaged or become illegible, please
purchase them from SMART and make sure that they are attached on their proper position.

9
MEMO
Ⅰ. Handling and installation

1. Guide to select a installation site ··············· Ⅰ-1

1.1. Care in handling a precision machine ·············· Ⅰ-2

2. Removal of the transit clamps ···················· Ⅰ- 9

3. Leveling the machine ····························· Ⅰ -10

3.1. Leveling procedure ···································· Ⅰ- 10

4. Connecting the power ····························· Ⅰ- 11

4.1. Inspection of cable connection ······················ Ⅰ- 11
4.2. Power requirement ····································· Ⅰ- 11
4.3. Electrical work ·········································· Ⅰ- 11

5. Air source requirements ···························Ⅰ-12

5.1. Air sorce ··················································Ⅰ-12
5.2. Selection of compressor ······························· Ⅰ-12

6. Lubricant oil required at installation ·············Ⅰ-12

Handling and installation
This section outlines the procedures for handling and installing your machine when it has to be moved to a
place area due to any change in your plant layout.
Most precautions noted may also apply to the initial installation of an machine at your plant.
 Ⅰ. Handling
1. Guide to select a installation site
In order to ensure high machine accuracy and performance, the following points should be considered
with regard to the installation site.
Avoid the following places when choosing the installation site for the machine:

1. Foundation work is advised for sites where the subsoil is soft, to prevent the machine from tilting
or sinking after installation.
2. The installation site should be as far as possible from vibration sources such as roads, stamping/
press equipment, or planer machine tools.
If nearby sources of vibration are unavoidable, prepare dampening pits around the foundation to
reduce the vibration effects. (During operation : Less than 0.5G)
3. NC malfunctions could result from the proximity of high-frequency power generators, electric
discharge machines, and electric welding machines, or when power is supplied from the same
distributor panel as these machines.
For wiring details, consult our service engineer dispatched to assist with installation.
4. The ideal operating environment calls for an ambient temperature of 20˚C (60˚F), with humidity
between 30 and 75%.
5. Keeping the ambient temperature at a constant level is an essential factor for accurate machining.
6. In order to maintain static machine accuracy within guaranteed values, the machine installation
site should be located so that it is unaffected by air currents within the factory.
Although air-conditioning is not required, the optimal ambient temperature range is 17˚C to 25˚C.
(63˚F to 77˚F)
Allowable temperature range during machine operation: 5˚C to 40˚C (41˚F to 104˚F)
7. To maintain static machine accuracy at levels even higher than the standard guaranteed values :
a. Keep the ambient temperature variance for 24 hours (1 day) within ±2˚C (3.6˚F).
b. Ambient temperature variances from floor level to a height of about 5 meters (16.4ft) should
be held within 1˚C (1.8 ˚F).
8. Dynamic load (acceleration, inertia, vibration) is not relevant respect to static load (Machine
weight).

Ⅰ-1
1.1. Foundation Plan_NL2000/M, 2000B/BM

Ⅰ- 2
1 .2 Installation Diagrams
Proper installation of the machine is essential to guarantee the best performance and longevity of
the machine. So make sure to carefully read and understand the contents of this manual and to
install the machine as it is manufactured for the high quality in precision.

Provided suffi cient space to allow the chip conveyor (option) and coolant so that
they can be removed easily and the electric cabinet door and other doors be opened
CAUTION and closed smoothly.

( ) : inch

Tolerance of floor
Flatness 10mm
Single ± 10mm
Dimensions
Accumulated ± 20mm

Ⅰ- 3
1. 3 Adjusting machine level
The machine must be carefully leveled because the accuracy of the level during the initial
installation process will greatly affect the working accuracy and the service life of the machine.

(1) Put down the machine on the floor with adjusting bolts assembled.

(2) Loosen the lock nuts securing the jack bolts.

Ⅰ- 4
(3) Adjust the horizontal level of the machine until the spirit levels indicate as shown on the figure
below.

Read the value perpendicularly because the value

varies according to the reading position.
CAUTION

(4) Tighten the lock nuts to secure the jack bolts.

Note1. As general method of foundation drawing, thickness of

concreate will be depend on the status of ground.
Note2. Operator needs to prepare parts for installation of machine.
1) jack bolt M30------------------7pcs
2) Nut M30----------------------7pcs
3) Leveling plate 110 x 18t mm-------7pcs

Above parts will be provided as standard.

Ⅰ- 5
 (5) Foundation Plan
1) Place the machine on the temporary jack
bolts and adjust the level
Clamp the jack bolt plate with the washer
and the jack bolt so that the plate is
parallel to the ground.

(M14X500L)

2) Pour the secondary concrete untill the

surface is flush with the ground surface
The secondary concrete should protrude
a little around thr jack bolt plate.
Compact secondary concrete well so that
it will stick to the back face of the jack bolt
plate satisfactorily

Note : Secondary concrete :

Use a mixture of concrete and non-
shrink agent.
(M14)

3) After the secondary concrete has been

cured, remove the temporary bolts
and adjust the machine level again.

Note : The curing period vary based on a

(M14X500L)
veriety condotions.
The machine can now be installed as
shown left.

Ⅰ- 6
1.4. Care in handling a precision machine
This model is built in one unit and it can be easily moved without separating it into consisting units.
(Note that the coolant tank is installed separately.)

Moving machine :

There is method for moving the entire machine to any desired location;

by a forklift truck.

(1) Moving by a forklift truck

unit : mm

unit : mm
(Pipe dimensions)

Ⅰ-7
Ⅰ. Handling

2. Removal ofthe transit clamps

When the machine is shipped, the transit clamps are installed in order to fix each of axes.
After the installation of machine, be sure to remove each of the transit clamps.
Note 1. Before operating the machine, be sure to disassemble the transit clamps.
2. If operating the machine without removal of transit clamps, a severe damage may
be brought on the performance of machine such as machining accuracy and so on.

Location of transit clamps

Ⅰ- 8
 Ⅰ. Handling
3. Leveling the machine
The Machine must be carefully leveled because the accuracy of the level at the initial installation
will greatly affect the working accuracy and the service life of the machine.

3.1. Leveling procedure

(1) Measure the machine level at both right and left ends of bed ways in the X-and Z-axis directions.
Mount the precision level plate in the tool clamp slot.
(2) Readings are taken on both longitudinal and transverse directions while both leveling bolts and
the foundation bolt nuts are tightened firmly.

Level gauge

*Tolerance : 0.02mm per 1000mm(0.00025 in./ft) /

Accuracy of level : 1grad. = 0.01mm per 1000mm(0.000125 in./ft)

Ⅰ- 9
4. Connecting the power

4.1. Inspection of cable connection

The operator can check correctness of cable connection by reading the pressure gauge whether it
indicates the specified pressure level.
Confirm that the pressure gauge indicates the set pressure [3.92MPa{40kgf/cm2(568.9psi}].
When it indicates the specified pressure level, the electrical connection is correct.

4.2. Power requirement

Item Specifications
Voltage AC 220V -3Ø
Voltage regulation ± 10%
Power requirements 30 kVA
Main spindle motor 27.5 kVA
Coolant motor 1.5 kW
Hyd. motor 1.55 kVA
Control circuit 1 kVA
NC device 1 kVA
Chip conveyor 0.25 kVA
Turret Index Motor 1.2 kW
Tool Drive Motor 5.5 kW

4.3. Electrical work

1. Connect the ground to the external protector connection terminal (PE) located
inside the control box.
2. Do not connect the power cord and the grounding wire in serial; if attempted, it will give
adverse affect to other equipment or cause malfunctioning of the leak breaker, etc.
3. When a leak breaker is used, select the one meeting the following rating.
- For inverter circuit use
- Sensitive current of 75mA/100mA or more
Caution - Middle-sensitivity high-speed inverter type
4. If more than one machine tool is connected to the same single power source, the
value of “inductance of power source” for each machine is obtained by dividing the
value in the table by the number of machine tools to be connected.
5. Wiring inductance in 164.05ft(50m) cable is approximately 12μH when general
KIV cable is used.

Ⅰ- 10
 Ⅰ. Handling
5. Air source requirements

5.1. Air sorce

Pressure
0.5MPa(5kgf/cm2/71.2psi) or higher

Discharge
100Nℓ/min(3.53ft3/min) (ANR) or larger (Use a 0.75 kW(1HP) compressor or equivalent.)

5.2. Selection of compressor

a. The minimum required discharge pressure off a compressor is 0.5MPa(5kgf/cm2/ 71.2psi).
When selecting a compressor, allow approximately 40% margin.
b. Required discharge volume is 3.53ft3/min(100Nℓ/min) (ANR). With this volume, an air gun can
be used at the same time as the air blast.
c. There are three compressor operation types; manual unloader, automatic unloader, and pressure
switch types.
The compressor should be a pressure switch type for this machine model.
d. The compressor should be 1HP(0.75 kW) ins size. For details, comtact a compressor marker.

6. Lubricant oil required at installation

The user is responsible for supplying the lubricant oil specified in section Ⅴof this manual
(Lubrication Chart and Lubricating oil specification).
(For optional specification systems, contact your SMART representative regarding the appropriate
lubricant oil.)

Ⅰ- 11
MEMO
Ⅱ.Specif ications

1. Construction of machine ···················· Ⅱ-1

2. Machine specificatons························ Ⅱ-2

3. Dimensional drawings ······················· Ⅱ-3

4. Construction of units ······················· Ⅱ-5

4.1. Head Stock ································ Ⅱ-5
4.2. Chucking system ································ Ⅱ-6
4.3. Carriage - X/ Z-axis ···························· Ⅱ-7
4.4. Tool post ········································ Ⅱ-8
4.5. Oil supply unit ··································· Ⅱ-9
4.6. Electric devices ································ Ⅱ-11
4.7. Tailstock - Option ····························· Ⅱ-13
4.8. Tool Eye - Option ····························· Ⅱ-13
1. Construction of machine

Ⅱ-1
 2. Machine Specifications
NL2000B NL2000BM
Ⅱ. Specifications

Ⅱ-2
3. Dimensional drawings
1. Top view _ NL2000(M),2000B(BM)
Unit : mm[inch]

2. Front view _ NL2000(M),2000B(BM)

Ⅱ-3
 3 . Side view_ NL2000(M), 2000B(BM)

Ⅱ-4
4. Construction of units

4.1. Head Stock

The headstock is a Meehanite casting that has been normalized before machining.
The headstock and rigid spindle with super precision bearing are manufactured in a temperature
controlled envieonment and assembled and tasted in a clean room, virtually eliminating
the possibility of thermal growth. The spindle is directly driven by AC spindle motor through
Micro Ribstar-belt(NL2000/M,2000B/M).

* Cs-axis(Main spindle)

The machine has drill ing and milling functions in addition to turning functions. Spindle position is
detected the B z sensor.
The spindle can be positioned at any angular position(360˚ ) in units of 0.001̊ by the sensor.

Ⅱ-5
4.2. Chucking system
A chuck mounted on the spindle front end is connected to the rotary hydraulic cylinder through
draw tube. Advance of cylinder piston to the chuck side allows chuck jaw to be opened through
wedge mechanism, and the retraction allows it to be closed. The rotary hydraulic cylinder is
composed of cylinder part, check valve and rotary joint part. The check valve, even when supply
oil pressure unusually drops due to pressure source trouble, etc., is fitted to maintain constant
pressure in the cylinder. Chuck jaws must be formed to the configuration of workpiece to be
chucked. The chuck has restrictions to the usage to maintain safety, high accuracy and long service
life, and cautions for handling. Read the enclosed Chuck Instruction Manual thoroughly, and follow
the instructions.

Ⅱ-6
4.3. Carriage - X/Z - axis
Z-axis ball screw with saddle is connected directly to the AC servo motor. The saddle moves
along on the Z-axis Box Guide way on bed body.
X-axis servo motor is directly connected to the X-axis ball screw too. The tool post moves along the
carriage of X-axis, Box Guideway on saddle.

▶ Main specifications

NL2000B NL2000BM

Ⅱ-7
4.4. Tool post

Thetool post is securely clamped on the base of tool post except

when the position of tool post is divided correctly by curvic
coupling of high precision during its rotating. When the tool
post is indexed, the tool post is rotated under the unclamped
status by servo motor. If the motor encoder confirms its position,
the servo motor is stopped and the tool post is clamped.

BMT holders fixed firmly by 4 screws,boast of a strict tolerance & righid construction. Especially
rotating tool holders can be mounted in all 12 stations.

1. Sequence diagram of turret indexing

Compare the current tool Turret unclamp
Command No. and called tool No. (Hyd. solenoid on)

Check the position of Confirm the unclamp with

called tool No. Turret rotation prox. sensor("OFF")

Turret clamp (Hyd. Confirm the unclamp

Solenoid on) with prox. sensor("NO") End

2. Timmingchart

Ⅱ-8
4.5. Oil supply unit
1. Hydraulic power unit
The tailstock, which supports the right center of the workpiece against the headstock, consists of
the tailstock quill with live center and tailstock body.
The rigid tailstock body is mounted on solid wrap around box ways. the guide ways are hardened

Ⅱ. Specifications
and precision ground. Auto lubrication is provided to the tailstock quill as well as the guide ways.
The 100mm quill stroke is activated by either the program or foot switch.

▶ Main specifications

NL2000B NL2000BM

Ⅱ-9
 2. Lubrication system

Thereliable way lube system is provided in order to prevent the

wear of slide way surface and smooth movement of X, Z-axis
and tailstock.

Lubrication specification :
Tank capacity : 3L
Oil : Vactra Oil No. 2(VG68)

3. Coolant system

Coolant tank and pump provide the

necessary coolant volume for any
cutting conditions.
Coolant nozzles of turret are provided
for each turret station for perfect
coolant flow to any type of tools.

▶ Main specifications

NL2000B NL2000BM

Ⅱ-10
4.6. Electric devices
1. Operation console

The operation console is located on the right side for easy

operation. A convenient tool measure function automatically
calculates and enters the offset amount.
Manual control of turret indexing and spindle are provided for
easier set up. Digital alarm systems provide diagnostic of both
machine and control functions.
▶ Main specifications

NL2000B NL2000BM

2. Electrical cabinet

Electrical cabinet includes all electric components in it; NC unit,

spindle & servo drive units, I/O parts, power supply, etc.

▶ Main specifications

NL2000B NL2000BM

3. Lamp

Installed inside the machine, the lamp is an LED lamp of waterproof

structure. Illuminating over the inside of the machine, this lamp
would assure optimum working condition by eliminating eyestrain
and fatigue.

Ⅱ-11
 4. Foot switch

The foot operated pedal switch located at the front of the machine is
designed for safety requirements with protection cover. The switch body
with a waterproof structure is made of die-casting aluminum alloy.
Ⅱ. Specifications

5. Door interlock switch

Operating with a separate actuating key which is fixed

on the movable front door, the door interlock device
is installed as one of safety devices at above the front
door to ensure operator's safety. If an attempt is made
to start rotating the spindle, index the turret or feed an
axis while the front door is in the open, this device is
automatically actuated to stop the machine operations
and display the alarm message on monitor.

6. Pressure switch

The pressure switch is installed as a safety devices for

hydraulic systme. If the hydraulic pressure drops below
the specified value, this switch would operate to stop
the machine operation with warning signal to protect
personnel and the machine from all possible hazards.

Ⅱ-12
4.7. Tailstock(Progammable tailstock)

The tailstock, which supports the right center

of the workpiece against the headstock,
consists of the tailstock quill with live center
and tailstock body.
The tailstock quill is hydraulically driven
forward and backward.
The rigid tailstock body is mounted on solid

wrap around box ways. The guide ways

are hardened and precision ground. Auto
lubrication is provided to the tailstock quill as well as the guide ways.
The tailstock body can be moved by moving the carriage after connecting the traction bar to the
carriage.

▶ Main specifications

NL2000B NL2000BM

4.8. Tool presetter - Option

The tool eye is used for measuring the position of the service wire of
tool for tool offset setting, automatic service wire wear compensation.
When measuring, arms goes down to measuring point by torque motor
(forward). If measuring sensor which is attached at the end of the
arm finishes measuring the service wire, arm returns to the project by
torque motor(backward). Checking of finishing of forward and backward
movement is done by proximity switch. In case of setting tools with tool
eye, standard program starting points was set as machine starting point
by parameter.

Ⅱ-13
Ⅲ. Operation

1. Before starting operations ············ Ⅲ-1

1.1. NC operation ···················· Ⅲ-1
1.2. Tool offset ····················· Ⅲ-2
1.3. Setting of start point ················ Ⅲ-3
1.4. Automatic operation ················ Ⅲ-4
1.5. Sefety funtion ··················· Ⅲ-5

2. Power switches ················· Ⅲ-6

2.1. Electric cabinet ··················· Ⅲ-6
2.2. Main operation device ················ Ⅲ-7

3. Operation ··················· Ⅲ-16

3.1. Power ON ···················· Ⅲ-16
3.2. Warming-up ··················· Ⅲ-18
3.3. Manual REF. point return ············· Ⅲ-19
3.4. Manual jog feed ················· Ⅲ-21
3.5. Rapid traverse during jog traversing ········ Ⅲ-21
3.6. Handle feed ··················· Ⅲ-22
3.7. Spindle operation ················· Ⅲ-22
3.8. Chucking operation ················ Ⅲ-25
3.9. Cautions on operating the turret ·········· Ⅲ-30
3.10. Interlock ····················· Ⅲ-30
3.11. Finishing work and power off············ Ⅲ-31
Ⅲ. Operation

4. Tool setting & Coordinates Establishment ···· Ⅲ-32

4.1. Establishment of coordinate of fundamental Tool ··· Ⅲ-32
4.2. Setting of tool ·················· Ⅲ-34

5. Program code ················· Ⅲ-35

5.1. T code······················ Ⅲ-35
5.2. S code ····················· Ⅲ-36
5.3. G code ····················· Ⅲ-38
5.4. M code ····················· Ⅲ-40
1. Before starting operations

This section deals mainly with the operating procedures of your

turning center under manual control. So information given here
is essential to every operator, whether you are new to a turning
center or an "old professional".
Follow these three points:
(1) Actually operate the turning center by yourself in reference to
this User manual.
(2) Learn the symbols for the numerical control terms.
(3) After you have a general idea of how your turning center
operates, read this manual repeatedly and also the
Programming Manual of NC unit maker.

Bring the machine to a complete stop by turning off the main switch before operations
such as setup or adjustments inside the chip guard are carried out.

Danger Also turn off and lock-out the main switch before you attempt to work inside the machine

Ⅲ. Operation
at the rear side of the machine.

1.1. NC operation
Before you begin to operate the machine automatically, make it a rule to check the following points
against a process sheet, a program manuscript, or any other chart giving detailed machining
instructions:
(1) Setting of hydraulic power chuck jaws and their gripping pressure
(2) Installation and arrangement of individual cutting tools with respect to their operating sequence
(3) Setting of tool offsets
(4) Setting of zero offsets
(5) Setting of feedrate override to 100%
(6) Setting of soft-wired limit positions for each axis
(7) Positioning of the turret to the turret indexing position
(8) Positioning of tailstock or spindle.

All essential information on the setup and check-up procedures is described in the sections that
follow.

Ⅲ-1
 1.2. Tool offset
For appropriate dimension and reference position of each cutting tool, see maintenance section of
this manual. Install tool and holder on the position other than reference position. It is very difficult
to align cutting points of each tool to specified reference position in order to attach tool on holder.
Tool tip worn during cycle causes larger work diameter than specified.
NC program is executed, assuming that every cutting tool has been correctly installed, because
variable factors such as installation position and reference position shall be corrected. The corrected
difference refers to tool offset value. Tool offset shall be made before first machining, after first
cutting, and during cycle, because tool wear degree must be considered even if installed as
specified first.
NC system has tool offset function that corrects tool error automatically when each tool is indexed
into cutting position.
As in the figure, tool tip is placed in the following coordinate point for reference point.

X-axis : +56mm(diameter) Z-axis : -20mm Actual cutting

Actual tool tool
Offset value of tool position is -56.00mm on X-axes and +20.00mm position
Ⅲ. Operation

in Z-axes, as in the figure above. If tool is correctly installed on

Reference tool
reference point, offset value is "0" on both axes.

(ø
Ref. tool position

X axis : +56mm on work diameters

Z axis : -20mm
In case of machining without tool offset, tool will move along dot
line as in the figure below.
After tool offset value is input, tool moves along correct program
routine indicated full line. Tool offset is made automatically when
tool (T-groove plate) moves by inputting desired offset value for
each cutting tool of tool(T-groove plate).
For measurement and input of tool offset, refer to instruction manual Tool line without offset
Tool line offset at X=-56.000 and Z=20.000

of NC unit.

* Tool offset check

1. After first offset value is input into NC, make first cutting operation and measure
machining area dimension.

Notice 2. In case of error, make tool offset again for correction.

3. In case of dimension error due to tool wear, measure actual machining dimension
of work and add the error to offset value.

Ⅲ-2
1.3. Setting of start point
Start point for initial machining

If the start point of tool post is changed according to work

configuration, non-machining time can be reduced. When work or
machining process has been changed, the start point for machine
reference point shall be changed.
(1) Setting of X-axis start point
Setting procedure of start point is as follows.
A) As in the left figure, machine the outside diameter of work at manual cycle using reference tool.
B) Move tool away from work only at Z-axis direction and measure machining area with micrometer.
Then assume that measured value is 102.880mm.
C) Turn off machine lock switch and move tool so that the position on monitor display is the
same with start point (Coordinate point G50) of program.
(2) Setting of Z-axis start point
A) Rotating spindle, contact reference tool on the sectional surface of work.
B) Adjust Z-axis coordinate point of monitor to "0" at the area where tool contacts the sectional

Ⅲ. Operation
surface of work.
C) In case the cutting of work face is 2mm and Z of G59 is 200mm, move tool 198mm at "+Z"
direction, referring to the position value of monitor.
The point is start point of Z-axis.

Resetting of starting position after power failure.

To prepare for such case that the power source is unexpectedly disconnected during
operation or power failure occurs, it is recommended to check and record the relation
between the zero position and starting position.
When setting of zero position for X and Z axis is completed, follow the procedure
described below.
1. Return the tool to the zero position for X and Z axis.
2. Record the numerical values for X and Z axis which are displayed on the position
display unit at that time.
3. Return the tool to the starting positions for X and Z axis and continue the
Caution
machining operation.
4. Suppose that the power source is disconnected or power failure occurs.
5. Turn the power source on.
6. Return the tool to the zero positions of X and Z axis.
7. Reset the display on the position display unit to 0 for both of X and Z axis.
8. Move the tool in "-" direction for both of X and Z axis until the values recorded as
above are displayed.

Ⅲ-3
 Thus, the tool is returned to the starting position.
When, however, time elapses after power failure, machining dimensions may become different
because of thermal displacement etc. of the machine.
* The above procedures can be also adapted to each of axes, X and Z-axis.

1.4. Automatic operation

When tool setting, setting of starting position and tape checks are all completed,
automatic operation is to be started by setting the tape or memorizing the tape on the
numerical control unit. Prior to automatic operation, however, be sure to check for the
following points.
1. Check the set value of feedrate.
Override switch. Normally, it is recommended to set it to 100%.
2. Check the set value of spindle speed override switch. Normally, it is recommended
Ⅲ. Operation

to set it to 100%.
3. Check the dry run toggle switch is OFF.
If lamp is ON, turn OFF the toggle switch, and lamp is turned OFF.
Caution
4. Set the machine lock toggle switch is OFF
5. Check whether that the optional block skip toggle switch is set to the ON or OFF.
Usually, set this switch to OFF when cutting the first workpiece and keep it ON
when cutting the second and subsequent workpieces.
6. Check whether the optional stop toggle switch is set to the ON or OFF.
Usually, set this switch to ON when cutting the fir st workpiece and keep it turn OFF
when cutting the second the subsequent workpieces.

Ⅲ-4
1.5. Sefety funtion
In this machine, there are safety functions to protect the machine or operator from the mistake of
operation.

A. Travel limit
1) Over travel
This region is set up by TRAVEL LIMIT function of NC, and the end point is stroke end of each
axis.
2) Emergency stop
If the axis passes beyond the OT range, the switch for EMERGENCY is operated and the
machine becomes the emergency stop state.

B. Level check of lubrication oil

If the oil is reduced under the set level, the machine becomes the ALARM state.

C. Pressure check
If the pressure of pneumatic, hydraulic and lubrication line drop less than the set value, the

Ⅲ. Operation
machine become the ALARM state.

D. Setting time check

If the time for each motion exceeds its setting time, the machine becomes the ALARM state.

E. Safety door switch

The front door opening is detected and locked by CE certified safety switch. All automatic
operations are only effective at the door-closed status.

F. Front door
Front door window has double panel construction, tempered glass and polycarbonate. And the
sheet metal located in the lower of window has double panel construction.

Ⅲ-5
 2. Power switches

2.1. Electric cabinet

Composed of a variety of electric device, it has also the function to turn ON/ OFF the main power.

Main power N.F.B. switch

To turn ON/ OFF the main power.
Automatic cutting off overvoltage
Ⅲ. Operation

Cooling fan
To modulate the inside
temperature

Ⅲ-6
2.2. Main operation device
As the device for operating the machine and programming, it consists of monitor and operational
devices, etc..

Monitor
Display the input data and machine
state

Main operation panel

Emergency stop switch

Switch to stop the machine operation
immediately on emergency, and to be
released with CW turning.

Handle

Ⅲ. Operation
That as manu pulses to rotate the command device

A. Operation panel switches

1. Rotary switches for selection

1) Feedrate override selection rotary switch

To select the feedrate speed in manual/ automatic operation.

Symbol Description Function

0 0% Impossible feedrate
10~200 10~200% Speed in proportion Max. feedrate

This funtion is ignored in canned cycle or tapping cycle.

Feedrate Feedrate Feedrate Feedrate

% % % %
(mm/min) (mm/min) (mm/min) (mm/min)
10 0 50 250 100 500 150 750
10 50 60 300 110 550 160 800
20 100 70 350 120 600 170 850
30 150 80 400 130 650 180 900
40 200 90 450 140 700 190 950
200 1000

Ⅲ-7
 2) Spindle override selection rotary switch

To select the spindle speed in manual/ automatic operation.

Symbol Description Function

0~150 0~150% Speed in proportion to the commanded

a. This function is ignored in canned cycle or tapping cycle.

b. Selection over 100% is ignored when max. speed is commanded.

2. Push buttons for selection

1) Cycle start switch

It can be used to start the automatic operation in AUTO mode regarding CNC

CYCLE START machining program called by operator.

The called program will be run automatically as soon as releasing the cycle
start switch during pressing it under the condition of satisfying for automatic
Ⅲ. Operation

operation.

Be careful that program will be activated to cycle start as soon as releasing this
switch during pressing it under the state of satisfying the condition for automatic
operation.
Caution
Before cycle start, be sure to check the axis stroke etc. for preventing from
unexpected human accident and the machine damage.

2) Cycle stop

CYCLE STOP This switch is used to hold the axis feed temporarily during automatic operation.
When pressing this switch, the auxiliary functions (M, S and T) during program
execution still stop after its completion. And axis feed and Dwell also stop.
In order to release the hold state and restart automatic operation, press cycle
start switch once.

Ⅲ-8
3) Mode selection switch

Mode selection switch is the basic operating switch to select the operation type of turning
center.

Symbol Description Function

Edit mode can input the CNC program and save into the memories.
[EDIT] button And it is also possible to modify/ delete the program and load the
program which is already saved.

AUTO mode can load the machining program which is saved into
memory and run the automatic operation of loaded program. It is

Ⅲ. Operation
[MEM] button also possible to edit in back ground during AUTO operation.
Back ground edit is the function that edits another program on display
monitor during the automatic operation. For more details, refer to
the CNC manual.

MDI mode can input and execute a simple program. The program
made by MDI mode will be deleted on display monitor after
executing one cycle.
[MDI] button And program under writing will be also deleted in spite of pressing
the reset button on MDI panel.
MDI mode can input the parameter related to CNC and each kinds
of data.

[HND] button Axis feed with MPG

[JOG] button Jog mode can operate the jog feed of each axis.

Reference point return mode can move each axis to the machine
[ZRN] button
reference point by manual operation.

Ⅲ-9
 4) Rapid traverse override selection push button

To select the speed rate of rapid traverse in manual/ automatic operation.

**in case that front door of machine is open, speed rate is F0 locked.

Symbol Description Function

F0 F0 speed 2000mm/min. feed
25, 100 25%, 100% Speed in proportion to max. rapid feed.

5) Function key
Ⅲ. Operation

Symbol Description Function

When pressing the single block switch, internal lamp is ON, which
means to work the function of single block. This switch is used
[Single block]
to execute the program sequentially by one block step during
selection
automatic operation.
push button
To continue the operation after finishing the single block, press
Cycle start switch again.

This switch is used to stop the program temporarily with M-code

(M01) during automatic operation. Press this switch, internal lamp
flickering. And if M01 is executed in automatic operation, internal
[Optional
lamp in switch is ON, the program will hold while program is
stop]
maintaining its automatic operation state.
selection
In order to continue the operation, lamp is flickering when program
push button
is restarted.
To release the optional stop, press again this switches to stop the
lamp flickering.

Ⅲ-10
 When pressing this switch, internal lamp is ON, skips the block
that begins with "/" in automatic program and executes the next
block automatically.
[Optional If the block skip signal is ON before CNC reads the block including
block skip] "/", corresponding block is ignored. But, if the block skip signal is
push button ON while CNC reads the block including "/", corresponding block is
not skipped.
To release the optional block skip state, press this switch again
and turn OFF the lamp.

Dry run switch is available in automatic operation.

The machine will be operated by the dry run speed regardless of
the commanded speed in program.
[Dry run]
When pressing this switch, internal lamp is ON and the machine
push button
becomes the dry run state. It the dry run signal is ON or is changed
ON to OFF during axis feeding, the speed is decelerating to 0 and
then accelerates as much as the dry run speed to be set.

Ⅲ. Operation
6) Feed selection push button

To select the feed quantity per a graduation of handle.

Symbol Description Function

- Meter : 0.1mm per a graduation
X100 100times
- Inch : 0.01inch per a graduation

- Meter : 0.01mm per a graduation

X10 10times
- Inch : 0.001inch per a graduation

- Meter : 0.001mm per a graduation

X1 1times
- Inch : 0.0001inch per a graduation

Ⅲ-11
 7) Coolant button

To select the operation/ stop of coolant device.

Symbol Description Function

[ON/OFF] button To select ON/OFF of coolant

8) Spindle drive
Ⅲ. Operation

This switch only works with handle, jog, or ZRN mode. In auto
mode, you can use the switch only when running the manual
interruption function.

Symbol Description Function

While pressing this key the main axis will be oriented in the fi
xedposition.(0 ˚).
[ORT] button
When the orient is completed, the lamp will be turned on.
Commentary) It's available in the manual mode.

The main axis will be circulated at the speed of 24rpm only

[SPJ] button
while pressing this key.

The main axis turns CW with the preset speed when this switch
[CW] button
is on. The rotation speed is input value from the [MDI] mode.

Ⅲ-12
 In manual mode, press the spindle rotation stop switch for
[STOP] button
stopping the rotating spindle.

The main axis turns CCW the preset speed this

[CCW] button switch is on. The rotation speed is input value from the [MDI]
mode.

9) Work room light switch

To select ON/ OFF of work light.

10) Chip conveyor selection push button

To select the forward / stop of chip conveyor device.

Ⅲ. Operation

Ⅲ-13
 3. Key switches for selection

1) Program protect switch

This switch prevents the existing program from editing. If the key switch
setting is same as left figure, it is impossible to edit and save, also
impossible to reset the coordinate system, input by MDI and input the
parameters. This switch is used to protect the existing NC data.

2) Chuck-fastening condition selection switch

INT. You can choose the direction of chucking. You need the key when running
this function. You may skip this switch depending on the situation.
Ⅲ. Operation

4.Lamp

Zero position
Please return to the initial point if it's not returned to the
initial point when turning on initially since the lamp blinks.

It indicates the state of CLAMP/ UNCLAMP of chuck

- CHCL(MAIN) : It indicates the clamp state of main chuck.
- CHCL(SUB) : It indicates the clamp of sub chuck

Alarm
- NC : The lamp is turned on when occurring NC Alarm turned off when alarm is disposed &
reset
- MC : This indicates the side of M/C. When the cause of alarm is disposed & reset, the lamp
is turnet off.

Ⅲ-14
5. RS-232C / LAN

The connector interfacing RS-232C/LAN PORT and external input/ output

device are located on the main operation panel in the machine.

Ⅲ. Operation

Ⅲ-15
 3. Operation

3.1. Power ON
As the process preparing to operate the machine, there can be some differences in the actual
action by operation devices.

1. Precautions in power ON
The machine will operate correctly with 200~220V power source. If the power source of factory is
380~440V, separated transformer is required. Power should be supplied to machine through this
transformer.
Otherwise serious damage on the machine will occur. And wiring between machine and transformer
should be executed by who have qualification.

a. Power source : 380~440V b. Power source : 200~220V

POWER TRANSFORMER
Ⅲ. Operation

CONTROL BOX CONTROL BOX

Q1 : MAIN NFB NF1 : Noise Filter(Option) Shunt Trip (Option)

Q2 : Additional NFB (Option) TM11 : Power Transformer (Option)

According to the type of machine and selected options, the specification and species of electric
device would be different. Regarding the capacity of each electric device with the type of
machine, refer to the electric circuit diagram. The axes of machine are fixed by bracket in order to
fix it during shipment. Before supplying power to machine, remove the bracket which fixed axes
of machine.

Ⅲ-16
2. Main power on

- Spindle fan ON
1 Main N.F.B switch ON
- Work light available

3. NC power on

- Monior ON
1 Push the NC power on button - Lub. pump ON
- Cooling fan ON

4. Operation stop and restart

The following sheet describes methods to stop the machine operation and the change of machine
and NC state after that.

The best method to stop the machine on emergency state is to push state
is to push EMERGENCY STOP switch, so always be aware of the location

Ⅲ. Operation
Caution of those switches.

Item 1 2 3 4 5 6 7 8
Main NC Power Emergency Mode Single Optional Feed rate
Description power OFF OFF stop change
Cycle stop
block stop 0%
Condition None Automatic operation
Tool change
Axis movement
Impossible Possible
Machine Spindle rotation
state Coolant ON/OFF

Work light ON/OFF Impossible Possible

Operation call OFF ON OFF ON
lamp
Sequence Impossible Possible
execution
Sequence recall
NC Command buffer Impossible Possible
state recall
Tapera buffer recall
Machine state Impossible Possible
recall
- Abnormal stop - Normal stop
Remark
- Impossible to restart - Possible to restart

Ⅲ-17
 3.2. Warming-up
1. Purpose of warming-up
When the machine is operated again after standstill for a long time or after various troubles, the
warming-up of the machine is necessary for the stability of lubrication, fluid temperature and
precision and for the machine life. Operation without enough warming-up after long standstill
may cause abnormal wear of sliding ways and spindle bearing breakage. When starting operation
in the morning, operator should perform the machine warming-up. Especially operator must do
sufficient warming-up in cold area.
For the warming-up, auto-operation by means of program is more desirable than manual
operation. Periodic warming-up ensures the spindle life.

2. Method of warming-up
1) Load-free operation more than 15 minutes.(longer in winter)
2) To check tool change function.
3) To check the spindle rotation and orientation stop function.
Ⅲ. Operation

4) To check lubrication, hydraulic and coolant device function.

3. Step for warming-up

1 Perform ref. point return

2 Search program

Select auto. mode with operation mode

3
selection switch
CYCLE START

- Check button light

4 Push cycle start button
- Check machine action

Ⅲ-18
3.3. Manual REF. point return
1. Abstract of reference point
Reference point is used for setting the coordinate system or for traversing to specific position in
order to change tools during machining. This reference point can be used from the 1st reference
point to 4th reference point but only 1st reference point and 2nd reference point are standard
function, the other can be usable when additional request issued. The position of each reference
points is set in parameter for each axis. The returning to the reference point is operated at a time
by automatic command, and especially the 1st reference point can be operated by manual.

The 1st reference point

1. Reference point return can be operated at a time manually and automatically.
2. At the first time to ON the machine power, once reference point return in manual should be
operated. By this, coordinate system of machine will be set and automatic operation can be
operated normally. In case of not operating reference point return in manual after power ON,
automatic operation cannot be executed.
3. When the servo of machine is absolute type, the coordinate system of machine is memorized

Ⅲ. Operation
in CNC without power supply, the machine can be operated correctly without executing
reference point return.
4. When the return is completed, reference point return lamp in operation panel will be ON.

The 2~4th reference point

1. Reference point return can be operated at a time automatically.
2. It mainly used for moving tool post to specifi c position in order to change tools during
machining.
3. When the return is completed, reference point return lamp in operation panel will fl icker.

Ⅲ-19
 2. Direction of manual REF. point return
A. The direction of manual reference point return in all axes is positive.
Z-axis REF. Pt. DOG
1st REF. Pt.

X-axis REF. Pt. DOG

X, Z-axis the 1st REF.
Pt. return possible zone

Chuck Chuck

3. Method of manual REF. point return

A. In order to manual reference point return, the conditions below should be satisfied before
returning to the 1st reference point.
- Tool eye should be up.
Ⅲ. Operation

- Jog traverse of axis should be possible.

B. The 1st reference point manual return is absolute type. The axes will return as follows.
- During rapid traversing to the direction of reference point return.

C. There are 2 methods in the 1st reference point return as follows.

- In case of pressing +direction jog switch of each axis until reference point return is completed.
- In case of pressing zrn switch and + direction jog switch of each axis once and releasing.

D. Manual reference point return in X, Z-axis

When the axis is returned to reference
point, press reference point return
1 Selecting REF. Pt. mode switch after checking whether the
interference or collision is occurred or
not.

Ⅲ-20
3.4. Manual jog feed
Each axes can be traversed using jog traverse switch in operation panel.

1. Operation method for jog traverse

Press the switch shown in left side, then

1 Jog mode selection
machine becomes jog mode.

Select Feedrate with feederate

2
override selection switch
The axis will traverse while the relevant
Press Jog swithc assigned to the
switch of direction and axis, that want to
3 direction, then the axis will
be traversed, is pressed. The axis traverse
traverse
will stop when the swith is released.

Ⅲ. Operation
3.5. Rapid traverse during jog traversing
Using the jog axis traverse switch and rapid traverse switch in operation panel, each axes can be
traversed in rapid.

1. Operation method for jog rapid traverse

Press the switch shown in left side, and then

1 Jog mode selection
the machine becomes jog mode.
Decide the axis and direction that want to be
traversed. The axis will traverse in rapid while
Axis traverse by pressing jog
the relevant switch of axis direction switch
2 switch with rapid traverse
and rapid traverse switch is pressed. The axis
switch at the same time
will keep traversing at the speed set by the
feed override when rapid traverse switch is
released.

Ⅲ-21
 3.6. Handle feed
Each axes can be traversed by minute step using MPG(Manual Pulse Generator.)

1. Handle operation method

Press handle mode selection switch of

1 Handle mode selection
axis that want to be traversed.
As shown in left side figure, the axis will
Traversing axis by rotating MPG be traversed in + direction by rotating
2
in the direction wanted MPG in + direction, and traversed in -
direction by rotating MPG in - direction.
Ⅲ. Operation

3.7. Spindle operation

1. Manual operation of spindle
In spindle operation, spindle select method is different according to manual operation or
automatic operation. In order to operate spindle in manual, first select spindle and then operate
selected spindle. But in order to operate spindle automatically, command spindle that want
to be operated, regardless of currently selected spindle. Then corresponding spindle will be
selected and can execute commanded operation.
In the basic 2-xes turning center with main spindle only, additional spindle selection is needless.
(Ref. return mode, jog traversing mode, handle mode)

* Spindle rotation condition

- Door close status
- Safety switch lock status
- In case that spindle override isn't 0%(Check spindle override switch)

Ⅲ-22
2. The speed of spindle in manual operation
Spindle speed in manual operation will be decided by the value that was commanded with
S-code in automatic mode. Therefore, in case that spindle rotation isn't comanded automatically
after NC power ON at the first time, spindle manual operation cannot cause actual rotation. For
example, if S1000 was commanded, in case of commanding spindle rotation in manual with
100% of spindle override, spindle will rotate by 1000r.p.m..

3. Manual stop on rotating spindle

Press the switch shown in left side, then spindle on rotating will stop.
However, stop switch operation is only valid in manual mode (handle mode, jog
mode, ref. return mode).

After commanding spindle stop, spindle will not stop instantly but decelerate and
stop. Therefore check that the spindle stops completely before opening the front
Caution
door. To open the front door without checking that spindle stops may cause accident.

Ⅲ. Operation
4. Spindle automatic command
Command M-code and S-code as follows, then it is possible to command main spindle
automatically. M-code and S-code can be used independently or together and another operation
or rotating direction command is possible during rotation of spindle.
M03 ; Spindle forward rotation
M04 ; Spindle reverse rotation
S___ ; Spindle rotation speed command
a. Command M-code and S-code together
Spindle will be rotated with the speed commanded by S-code and in the direction commanded
by M-code.
b. Command M-code only
If S-code was commanded in advance, spindle will rotate with the speed commanded. But if
not after power ON, spindle will not rotate actually.
c. Command S-code only
If S-code is commanded during spindle rotation, spindle speed will be accelerated or
decelerated by commanded S-code.
If S-code is commanded when the spindle is stop, spindle doesn't rotate. After this, in case of
commanding M-code only, spindle will rotate with the speed commanded by S-code.

Ⅲ-23
 5. Stop the rotating spindle
In case of commanding M-code as follows, it can stop spindle on rotating.
M05 ; Spindle stop

6. Spindle override operation

It can be used on changing actual rpm without changing commanded rpm of spindle(S command
rpm).
Spindle speed can be adjusted from 0% to 150% by 10% regardless of mode.
For example, if commanded rpm is 1000rpm, spindle will rotate as follows according to the
status of spindle override.

0%: 0rpm, 50% : 500rpm, 80% : 800rpm, 100% : 1000rpm, 150% : 1500rpm
However, in case of exceeding the maximum rpm of spindle, to operate override cannot increase
rpm.

Regarding the following cases, spindle speed will be fixed at 100% regardless of spindle override
Ⅲ. Operation

switch.
- On commanding spindle orientation
- On tapping work

Ⅲ-24
3.8. Chucking operation
The chuck is the device that fixes the workpiece to be machined with the hydraulic or air pressure,
and is rotated accompany with workpiece by spindle motor.
The workpiece clamped in chuck will be machined by the tool attached to turret.

The chuck can fix the workpiece by means of 3 jaws which are acted by Chuck
jaw
hydraulic pressure etc. as shown in right side figure.
In case that the shape of workpiece or the condition of machining is
peculiar, special type chuck such as index chuck etc. would be used. Chuck

1. Construction
The construction of chucking system is shown is below.
Hydraulic chuck
Draw tube

Ⅲ. Operation
Hydraulic rotary cylinder

Construction of chucking system

2. Installation of hydraulic chuck

ⓐ Press the power ON button on the panel to turn on the machine control circuit, and depress
the chuck for switch pedal. This cause the draw tube in the spindle bore to move forward.

ⓑ Fasten the draw tube in the spindle with the chuck. Use the fixture of draw tube furnished
with the machine.

ⓒ Secure the chuck body onto the spindle end, using mounting bolts.

ⓓ Adjust the draw tube so that the outer ends of the master jaws become flush with the peripheral
surface of the chuck body when the top jaws are in the OPEN condition

The individual chuck jaws can be moved in the "opening" direction as the draw tube is turned in
the counterclockwise direction. Removal of the hydraulic chuck from the spindle is the reverse of
installation in steps from ⓒ to ⓑ.

Ⅲ-25
 3. Chuck operation
Chuck can be operated in manual using switches as listed below that are located on the chucking
mode operation panel.
According to the shape of workpiece and the conditions of machining, chucking methods can be
divided into two kinds of methods as follows.
a. Chucking mode
Inward mode (ID mode)
As shown in left side, jaw of chuck is clamped/
Clamp Unclamp
unclamped as it is operated in the direction of
arrows.
If the jaw clamps the outside of workpiece as it
moves inward, workpiece will be clamped to fix. If
jaw moves in the opposite direction, workpiece will
be unclamped.

Outward mode (OD mode)

As shown in left side, jaw of chuck is clamped/
Clamp Unclamp
Ⅲ. Operation

unclamped as it is operated in the direction of

arrows.
It the jaw clamps the inside of workpiece as it
moves outward, workpiece will be clamped to fix. If
jaw moves in the opposite direction, workpiece will
be unclamped.

4. Restrictions in machine operation according to the status of chucking.

There are some restrictions in machine operation in case of the unclamp status of chuck as
follows.
- Rotation command of spindle cannot be executed.
- Automatic operation of machine cannot be started.

Ⅲ-26
5. Chuck grip confirmation
To ensure your safety in using the chuck grip confirmation unit, read the following information
carefully to understand the function and construction of the unit and observe the instructions.

Hydraulic chuck
Hydraulic rotary cylinder
Draw tube

Proximity switch

Hex socket head bolt

Proximity switch

Ⅲ. Operation
Dog

Hollow chuck cylinder

Position of the dog moving with the hydraulic rotary cylinder piston is detected by the proximity
switches to confirm the chuck jaw position. (Option)

6. Adjustment of oil pressure for hydraulic chuck

The gripping pressure of the chuck jaws is dependent upon the working pressure of hydraulic fluid
which is determined by the setting of the chuck pressure adjusting valve installed at the front of
the machine.
A clockwise turn of the valve knob increases the working oil pressure directed into the chuck
cylinder and counterclockwise turn decreases it. The allowable maximum pressure is indicated in
the table below. Adjust the pressure meeting the types of chuck.

Ⅲ-27
 7. Maximum permissible spindle speeds and oil pressure setting
Maximum permissible spindle speed varies depending on types of chuck and cylinder to be
used.
See the table below :

NL2000B/BM

This table indicates the permissible spindle speed for standard chuck. If a chuck
other than those indicated above is used, follow the instruction on the name plate
Caution
at the front cover of the machine.

Danger by discharge of chuck or wokpiece.

Do not exceed recommended speed of chuck related with max. permissible input
Warning
force.

8. How to set maximum spindle speed

The maximum spindle speed, which is limited due to chuck specifications, influence of
centrifugal force on chuck fripping force, imbalance of the workpiece, etc. can be set by program.

Format :
G50 S○○○○ ·········· To be specified in a block without other command
↑
Specify the required maximum spindle speed.
Programmed maximum spindel speed is effective until another spindle speed is designated.

9. General precaution for using power chucks

In order to insure maximum safety in operation, the following points call for your special notice:
1) Select the right chuck that matches the machine's capacity.
2) The maximum spindle speed and maximum allowable pressure limit(maximum setting) are
indicated on the instruction plate attached to the front of the left cover.
The maximum spindle speed refers to the speed at which the chuck can be turned, with
its gripping force maintained more than one-third of its rating, while the outer ends of the
individual top jaws are positioned evenly with the peripheral surface of the body.

Ⅲ-28
 3) When soft top jaws larger than standard ones provided with the machine are prepared by
the customer and used with the chuck, keep in mind that developing centrifugal force and
decreasing efficiency may reduce the actual gripping force. Be sure to reduce the spindle
speed accordingly.
4) Where jaw nuts shown below go beyond the peripheral surface of the body, only one bolt
secures the corresponding jaw and a very dangerous condition is created.
Always locate the jaw nuts within the periphery of the body as shown below. It is a good and
safe practice to use soft top jaws that are made to fit the actual work configuration.

Hard jaw Hard jaw

Jaw nut Jaw nut

Incorret Corret

5) Before starting spindle rotation, be sure to close the front door.

Ⅲ. Operation
10. Change of chuck gripping direction - ID / OD gripping
Gripping direction of the power chuck - ID gripping and OD gripping-can be changed by the
key switch.
The change of gripping direction may be made only while the spindle stops.

11. Greasing
The chuck has grease nipples either on the chuck front face or on its periphery. Apply grease to the
nipples at least once a week.
Since chips and foreign matter accumulate on the jaw moving surfaces on the chuck, clean them
every day and lubricate them with the mobilux grease2.

Ⅲ-29
 12. Cutting soft top jaws of power chuck
There are three different methods applied in cutting soft top jaws of chuck jaws for chucking a
particular lot of parts.
- by pulse feed hand wheel
- by auto or memory
- by manual data input(MDI)

They are all basically the same operations, and it is advisable to use the tape or the manual
data input when a good finish on the chucking surfaces of the jaws is essential.

3.9. Cautions on operating the turret

When indexing the turret, retract it to a position where rotating of the turret does not
Ⅲ. Operation

cause interference between the tools in the turret and the workpiece or chuck.

Caution For 0.5 seconds after the completion of turret indexing, the turret may not be clamped
securely. Therefore, do not start machining within this period.

3.10. Interlock

The door interlock function is provided to ensure operator's safety.

When an attempt is made to start the spindle, index the turret or feed an axis while the
Warning
front door is open, an alarm occurs to stop the machine.

Ⅲ-30
3.11. Finishing work and power off
After finishing operation, please maintain good condition by following the steps.

Step Operation Location Remark

Check the machine state/
5. 1 Refer to user manual
interference and set-up state.
2 Confirm the machine stop
Move the axes to proper Machine
3 Manual or MDI operation
position
Unload the workpiece and
6. 4 Refer to user manual
clean the machine.
Main OP Operator call lamp
5 Push emergency stop button
panel flickering.
MDI/LCD
6 Push NC power off button Monitor extinguished
device
Electric
7. 7 Turn off main N.F.B switch
cabinet
Check machine state and clean
8 Machine
around

Ⅲ. Operation

Ⅲ-31
 4. Tool setting & Coordinates Establishment
Usually a lathe has one working material coordinates and shows the zero point of working material
system establishing the distance from the zero point of the machine coordinates in advance.

4.1. Establishment of coordinate of fundamental Tool

A. Searching Method of the initial point of the workpiece from the reference point of machine.

1. To make the mode selection handle set the Machine reference point

MDI mode.
2. Rotate the spindle +X
-Z +Z
EX) S 500 …… Instruct the speed -X 100

200
M3 ……… Instruct Direction
Cycle START …… START rotation X : -400.000
Z : -100.000
3. Select the manual mode (HNDL,JOG)

50
4. Select the fundamental tool, and then press
the button of SPINDLE START. (CW/CCW)
Work center (Reference point)
Ⅲ. Operation

5. Process the section of workpiece

6. Record the feed distance of Z-axis in the POS display.
7. Relative coordinate W becomes ORIGIN into zero(0).
POS → [REL] →[OPRT] →[ORIGIN] → W (twinkling) → [EXEC]
8. Precess the outer-diameter smoothly.
9. Record the feed distance on the X-axis on the POS display.
(The absolute value of Machine coordinate X)
Measure the inner/outer diameter of the processing material.
10. The above size mentioned(9) added to the outer/inner diameter becomes the origin of tool
material
11. The relative coordinate U becomes origin into zero(0).
POS → [REL] → [OPRT] →[ORGIN] → U (twinkling) → [EXEC]

And so the origin of workpiece is (450, 100), and the coordinate is established G50X450,Z100.

Note It's necessary to start operating in the same position since the coordinate is
established in the present position, in case of G50.
So establish G50 after returning to the origin in G28 & G30.
G28U0W0
G50X450.Z100.
:
:

Ⅲ-32
B. Establishment of the second reference point
1. Move the tool table to the desiring position where is no interference of workpiece & tools.
At this time, input the machine coordinate as the second reference point to the parameter
1241(X,Y).
Condition of parameter input : The mode should be MDI, and the parameter-writing on the
operating board shall be OFFSET/SETTING → PARAMETER WRITE ⇒ 1,
SYSTEM → 1241 → [No. SRH] → Data Input
2. To make origin the relative coordinate (U0, W0)
POS → [REL] → [OPRT] → [ORIGIN] →[ALTEXE]
3. Establish G50 on the basis of U. W coordinate.

+X
-Z +Z

50
50
-X

120

Ⅲ. Operation
50

150

G28U0W0.
G50X240Z150.
:
:
↓
G30U0W0
G50X140Z100
:
:
After this, it's the same the establishment of G50 coordinates against the origin point.

Ⅲ-33
 4.2. Setting of tool
A. Setting of fundamental tool
In the basis of the position of the fundamental tool, input the amount from the fundamental
tool to the each tool to the tool offset. Geometric difference length of each tool.
By shifting the fundamental tool in the chapter 4.1. the initial point(U0.W0)
1. Select the tool which the operator wants to set.
2. Touch the tool to the surface of the processing material.
Input the W-value to the relating tool offset among U-W-Value in hte offset display.
Ex) Incase of U10, W-15
OFFSET/SETTING → [OFFSET] → [GEOM] → [OFFSET NO.] → [No. SRH] → Shift cursor to Z
→ -15 → [INPUT]
3. Touch the X-axis to the outer diameter part of the processing material.
At this time, input the U-value to the offset of related tool among U in the offset display.

B. Direct input of tool offset

Ⅲ. Operation

It's possible to establish the tool offset briefly by using the function of offset direct input of
tool, in case of this equipment.
1. The operation is the same as 4.1. A. 5..
2. OFFSET / SETTING → [OFFSET] → [GEOM] → OFFSET No. → [No SRH] → X, Measure value of
diameter → [MEASUR] → Measure finish (The value of tool offset is input against the center
of tool material.)
3. The feed is made toward the section of Z-axis.
4. Z, 0 (In case of setting the section as the zero point of program) → [MEASUR] → Measure
finish

Note When using both G50 and Tool OFFSET direct input for each program in hte same
equipment, tool offset is applicable doubly, so it is dangerous.
Please pay attention to this case.

Ⅲ-34
5. Program code
Please refer to NC instruction manual for programming method and other code.

5.1. T code
This function is used to the selection of tool & the offset of tool position. It's the instruction to the
numeral-T2+2 following ADDRESS T.
1. Instruction T2+2
2. Instruction of tool offset number
This instruction is used to deal with the offset number & the offset amount in the memory.
The offset number of tool & the amount of offset are inputted by the MDI-keyboard.
The offset amount is added to the movement -action algebraically, and the tool is located at the
end of offset.
Once start the offset, the tool moves to the designated offset-position.
3. In the following case, the tool-offset is disregarded.
In case of resetting the control
Instruction 0(zero) or 00(double zero) to the tool offset.

Ⅲ. Operation
4. The offset-amount of tool.
5. The range of offset-amount is as follows.

Input by Meter-type 0 ~ ± 999.999 mm

Input by Inch-type 0 ~ ± 99.9999 inch

Note 1. When the T-function code is instructed in the same block as the movement-
instruction of the shaft, T-function code is executed with the movement-instruction
of the shaft.
2. The T-function code is not programmed with the instruction of the supplement of the
circular (G02, G03) in the same block.

Ⅲ-35
 5.2. S code
A. Speed instruction of spindle
The speed of main spindle is instructed directly by 4 step digits.

<Procedure>
1. Input the ADDRESS S, and then input 4 unit-numerals.
2. By M03(Positive direction) and M04(Reverse), the spindle will rotate as the speed instructed
item 1..
3. It's possible to change the speed of spindle easily according to item 1. & 2..
4. When instruction M05, the rotating of spindle will stop. If instructing code(M05), the spindle
will stop.

When instructing M03, the spindle will rotate at the speed instructed before.

Note 1. When rotating the spindle for the first time, instruct according to the item 1. & 2..
2. In case that the rotation direction of spindle is wrongly programmed, the spindle is
rotated as the speed instructed before by changing M03 or M04.
Ⅲ. Operation

3. The spindle is rotated at the highest speed when instructing the speed more than
the highest speed established.
4. The speed of spindle rotation indicates in the right lower part.
5. The output of the spindle driving motor is equal to the limit value of spindle speed,
and the max. efficiency of the output is censored by the load-motor in the operation
board.
6. When the main speed is not controlled by the fixed control, the S function
instruction which is equal to the axis operating instruction is executed at the same
time.
7. The speed of spindle is not checked when the spindle starts rotating by M03 or
M04 code and changing the speed only by s-function instruction. But the speed is
checked when S-function code is used with M03 or M04 in the same block.

B. Max. spindle SETTING (G50)

The spindle speed in the mode of fixed main speed is decided by the numerals following after S.

Note 1. It's necessary to set before entering the mode of the constant surface speed control
(G96).
2. It's impossible to instruct the general S-function code in the G50 block.

Ⅲ-36
C. Constrant surface speed control. (G96, G97)
The spindle speed continues when the position of tool (the diameter of workpiece) is changed or
the cutting speed is instructed by S-function code.
1. Selection of the efficiency constant surface speed control
G96 : Establishment of the efficiency of constant surface speed control.
G97 : Establishment of the No-efficiency of the constant surface speed control.
2. Instruction of cutting-speed.
The cutting speed indicates by the four-digit-numerals following after ADDRESS.
Input : Matrix m/min
Input : Inch ft/min
When the constant surface speed control is not established again, the four-digit behind
ADDRESS S becomes the spindle speed.
EX) G50 S1900 *The max. spindle speed is set as 1,900 R.P.M.
G96 S0120 *The main speed is set 120m/min(constant surface speed control.)
G97 S1000 *Spindle speed : 1000 R.P.M.
S 600 * Spindle speed : 600 R.P.M.

1. The spindle speed will be fixed as the setting value by G50 when the main speed is

Ⅲ. Operation
Note
controlled as the fixed degree.
2. The constant surface speed control requires the coordinate system since the correct
presentation of the diameter of workpiece in the X-coordinate.
3. When the fixed degree of constant surface is controlled, the main speed continues
in the tool-path, but it doesn't continue in the tool-position offset by offset total
amount.
4. In case of the constant surface speed control, it's possible in the negative region
(-region) of X-coordinate.
5. The instructed S-value in the G96 changed in the G97 mode, and it continues
without re-establishment when returning to G96 mode again.
6. When the mode G96 changing to G97, the speed is adapted if R.P.M is not
programmed behind S of G96 mode, that is the spindle speed doesn't change when
changing G96 mode to G97 mode in case that there is no establishment.
7. The main speed doesn't response to the position of tool, in the urgent feed to instruct
by G00. It begins from the end of block.

Ⅲ-37
 5.3. G code
The following listed items are for the preparation functions for this machine.

Note 1. The G-code of each special specification should be ordered before ordering the
machine.
When inputting the G-code of special specification which is not prepared, the alarm
will turn up.
2. The G-code of group 00 is not modal. When instructing the modal G-function &
unmodal G-function in the same block, only unmodal function will operate and the
modal function will shift to the next appendix.
3. The G50 code is programmed only when the function of fixed main speed control is
not executed.
4. "*" Indication will be operated when turning on the power.
5. Group 00 function is not modal. It only has effectiveness in the specified block.
6. When instruction G-code function which is not listed in the table, the alarm will
occur.
Ⅲ. Operation

7. Some G code functions are programmed differently with the group in spite of the
same block.
When programming more than two G-codes of the same group in the same block,
the efficiency can be obtained equal to the one program.
8. G function code will be indicated by the group.

G-code List
(○ : Std, ☆ : Opt)
G-code Function
Group Remark
A B C EIA/ISO
G 00 G 00 G 00 01 Positioning (rapid traverse)
G 01 G 01 G 01 01 Linear interpolation (cutting feed)
G 02 G 02 G 02 01 Circular interpolation CW.
G 03 G 03 G 03 01 Circular interpolation CCW.
G 04 G 04 G 04 00 Dwell
G 10 G 10 G 10 00 Data setting
G 11 G 11 G 11 00 Data cancellation
G 17 G 17 G 17 16 Plane selection X/Y Plane
G 18 G 18 G 18 16 Plane selection Z/X Plane
G 19 G 19 G 19 16 Plane selection Y/Z Plane
G 20 G 20 G 20 06 Inch data input
G 21 G 21 G 21 06 Metric data input.

Ⅲ-38
 G-code Function
Group Remark
A B C EIA/ISO
G 27 G 27 G 27 00 Reference position return check
G 28 G 28 G 28 00 Return to reference position
G 30 G 30 G 30 00 Return to 2nd,3rd or 4th reference position
G 31 G 31 G 31 00 Skip function
G 32 G 32 G 32 01 Threading
G 40 G 40 G 40 07 Tool nose radius compensation cancel
G 41 G 41 G 41 07 Tool nose radius compensation (left)
G 42 G 42 G 42 07 Tool nose radius compensation (right)
G 50 G 92 G 90 00 Coordinate system setting, maximum spindle speed setting
G 52 G 52 G 52 00 Local coordinate system
G 53 G 53 G 53 00 Machine coordinate system
G 54 G 54 G 54 14 1st settable zero offset
G 55 G 55 G 55 14 2nd settable zero offset
G 56 G 56 G 56 14 3rd settable zero offset
G 57 G 57 G 57 14 4th settable zero offset
G 58 G 58 G 58 14 5th settable zero offset

Ⅲ. Operation
G 59 G 59 G 59 14 6th settable zero offset
G 65 G 65 G 65 00 Macro Call
G 70 G 70 G 72 00 Finishing cycle
G 71 G 71 G 73 00 Stock removal in turning
G 72 G 72 G 74 00 Stock removal in facing
G 73 G 73 G 75 00 Pattern repeating cycle
G 74 G 74 G 76 00 End face peck drilling
G 75 G 75 G 77 00 Outer diameter/internal diameter drilling cycle
G 76 G 76 G 78 00 Multiple threading cycle
G 90 G 77 G 20 01 Outer diameter/internal diameter cutting cycle
G 92 G 78 G 21 01 Threading cycle
G 94 G 79 G 24 01 End face turning cycle
G 96 G 96 G 96 02 Constant surface speed control
G 97 G 97 G 97 02 Constant surface speed control cancel
G 98 G 94 G 94 05 Feed per minute
G 99 G 95 G 95 05 Feed per rotation
- G 90 G 90 03 Absolute command
- G 91 G 91 03 Incremental command
- G 98 G 98 11 Return to Initial Level
- G 99 G 99 11 Return to R position

Ⅲ-39
5.4 . M code

Caution! this chapter is description of M signal used for FANUC 0iT.

separate Option can be required according to model.

M code list

Marking Model
NL X-Z : 2AXIS
M X-Z : 2AXIS + MILL(C-AXIS) SPINDLE
Y X-Z-Y : 3AXIS + MILL(C-AXIS) SPINDLE
SY X-Z-Y-B : 4AXIS + SUB(A-AXIS) + MILL(C-AXIS) SPINDLE

Marking Description
O Not available
X Available
A Options
M code that runs after completing axis traverse signal distribution when it
*
is commanded along with axis traverse

M-Code Content NL M SY Y
M00 * Program Stop O O O O
M01 * Optional Stop O O O O
M02 * Program End O O O O
M03 Main Spindle CW Rotation O O O O
M04 Main Spindle CCW Rotation O O O O
M05 * Main Spindle Stop O O O O
M07 Coolant Pump 2 On O O O O
M08 Coolant Pump On O O O O
M09 * Coolant, Air Off O O O O
M10 Main Chuck Clamp O O O O
M11 * Main Chuck Unclamp O O O O
M13 Mill Spindle CW Rotation X O O O
M14 Mill Spindle CCW Rotation X O O O
M15 * Mill Spindle Stop X O O O
M19 * Main Spindle Orientation O O O O
M21 IN POSITION CHECK ON O O O O
M22 * IN POSITION CHECK OFF O O O O
M23 CHAMFERING ON O O O O

Ⅲ-40
M-Code Content NL M SY Y
M24 * CHAMFERING OFF O O O O
M25 Tail Stock Quill Forward O O X O
M26 * Tail Stock Quill Reverse O O X O
M27 RIGID TAPPING FOR.(CW) O O O O
M28 RIGID TAPPING REV.(CCW) O O O O
M29 RIGID TAPPING MODE ON O O O O
M30 * Program END O O O O
M33 Chip Conveyor Forward(ON) O O O O
M34 Chip Conveyor Stop(OFF) O O O O
M35 X-AXIS MIRROR IMAGE ON O O O O
M36 Y-AXIS MIRROR IMAGE ON X X O O
M37 Z-AXIS MIRROR IMAGE ON O O O O
M38 MIRROR IMAGE OFF O O O O
M39 * Mill Spindle Orientation X O O O
M40 GEAR NEUTRAL X O O O
M41 1st GEAR SELECT O O - -
M42 2nd GEAR SELECT O O - -
M43 3rd GEAR SELECT A A X X
M44 C2-AXIS CONNECT X X O X
M45 C1-AXIS CONNECT X O O O
M46 C-AXIS DISCONNECT X O O O
M47 FEED OVERRIDE EFFECT O O O O
M48 FEED OVERRIDE NOT EFFECT O O O O
M49 LUB. PUMP HOLD O O O O
M50 LUB. PUMP ON O O O O
M51 AIR BLOW 1 ON A A A A
M52 AIR BLOW 1 OFF A A A A
M53 AIR BLOW 2 ON A A A A
M54 AIR BLOW 2 OFF A A A A
M55 AIR ZERO CHECK A A A A
M56 Arbitrary speed threading ON A A A A
M57 Arbitrary speed threading OFF A A A A
M58 Groove of thread measurement A A A A
M59 Re-machining thread A A A A
M60 Polygon Turning Mode ON(Sub.-Mill Spindle) X X O X
M61 Polygon Turning Mode ON(Main-Mill Spindle) X O O O
M62 Polygon Turning Mode OFF X O O O
M67 C AXIS BRAKE OFF X O O O
M68 C AXIS BRAKE HIGH X O O O
Ⅲ-41
 M-Code Content NL M SY Y
M69 C AXIS BRAKE LOW X O O O
M71 1ST PRESSURE OF M. CHUCK A A A A
M72 2ND PRESSURE OF M. CHUCK A A A A
M73 PARTS CATCHER STRETCH A A A A
M74 PARTS CATCHER RETRACT A A A A
M75 WORK EJECTOR ON A A A A
M76 TOOL PRESETTER ARM STRETCH (PSM ON) A A A A
M77 TOOL PRESETTER ARM RETRACT (PSM OFF) A A A A
M78 PROG' T/S BASE CLAMP A A A A
M79 PROG' T/S BASE UNCLAMP A A A A
M83 AUTO SHUTTER OPEN A A A A
M84 AUTO SHUTTER CLOSE A A A A
M85 AUTO DOOR OPEN A A A A
M86 AUTO DOOR CLOSE A A A A
M87 SIDE DOOR OPEN X X X X
M88 SIDE DOOR CLOSE X X X X
M89 * EXT WORK COUNTER UP A A A A
M90 AUTO CYCLE START COMMAND O O O O
M91 NC TIMER START O O O O
M92 NC TIMER STOP O O O O
M93 STEADY REST #1 CLAMP A A A A
M94 STEADY REST #1 UCLAMP A A A A
M95 TURRET RAPID OVERRIDE 100% O O O O
M96 TURRET RAPID OVERRIDE 50% O O O O
M97 TURRET RAPID OVERRIDE 25% O O O O
M98 Sub-program Call O O O O
M99 Sub-program End O O O O
M103 Sub Spindle CW Rotation X X O X
M104 Sub Spindle CCW Rotation X X O X
M105 * Sub Spindle Stop X X O X
M110 Sub Chuck Clamp X X O X
M111 * Sub Chuck Unclamp X X O X
M119 * Sub. Spindle Orientation X X O X
M121 TORQUE LIMIT SKIP NO.1 ON O O O O
M122 TORQUE LIMIT SKIP NO.1 OFF O O O O
M123 TORQUE LIMIT SKIP NO.2 ON O O O O
M124 TORQUE LIMIT SKIP NO.2 OFF O O O O
M125 TORQUE LIMIT SKIP NO.3 ON O O O O
M126 TORQUE LIMIT SKIP NO.3 OFF O O O O

Ⅲ-42
M-Code Content NL M SY Y
M131 SPINDLE SYNCHRONOUS CONTROL ON X X O X
M132 SPINDLE SYNCHRONOUS CONTROL OFF X X O X
M133 SERVO INTEGRAL CONTROL MODE X X O X
M134 SERVO INTEGRAL CONTROL MODE CANCLE X X O X
M135 PHASE SHIFT MODE ON X X O X
M136 1ST SPINDLE LOAD DETECT MODE O O O O
M137 1ST SPINDLE LOAD DETECT MODE CANCEL O O O O
M138 2ND SPINDLE LOAD DETECT MODE X O O O
M139 2ND SPINDLE LOAD DETECT MODE CANCEL X O O O
M140 ROBOT CALL A A A A
M145 C1/C2-AXIS CONNECT X X O X
M146 C1/C2-AXIS CONNECT CANCEL X X O X
M150 BAR FEEDING A A A A
M151 BAR CHANGE A A A A
M160 * EXT. Tool Counter Up A A A A
M178 PROG' S/R BASE #1 CLAMP A A A A
M179 PROG' S/R BASE #1 UNCLAMP A A A A
M193 STEADY REST #2 CLAMP A A A A
M194 STEADY REST #2 UCLAMP A A A A
M201 EXTERNAL M CODE 01 OUTPUT A A A A
M202 EXTERNAL M CODE 02 OUTPUT A A A A
M203 EXTERNAL M CODE 03 OUTPUT A A A A
M204 EXTERNAL M CODE 04 OUTPUT A A A A
M205 EXTERNAL M CODE 05 OUTPUT A A A A
M206 EXTERNAL M CODE 06 OUTPUT A A A A
M207 EXTERNAL M CODE 07 OUTPUT A A A A
M208 EXTERNAL M CODE 08 OUTPUT A A A A
M220 WAITING FOR ANOTHER PATH X X X X
M211 TOOL COUNTER No.1 O O O O
M212 TOOL COUNTER No.2 O O O O
M213 TOOL COUNTER No.3 O O O O
M214 TOOL COUNTER No.4 O O O O
M215 TOOL COUNTER No.5 O O O O
M216 TOOL COUNTER No.6 O O O O
M217 TOOL COUNTER No.7 O O O O
M218 TOOL COUNTER No.8 O O O O
M221 WAITING FOR ANOTHER PATH X X X X
M222 WAITING FOR ANOTHER PATH X X X X
M278 PROG' S/R BASE #2 CLAMP A A A A

Ⅲ-43
 M-Code Content NL M SY Y
M279 PROG' S/R BASE #2 UNCLAMP A A A A
M325 1ST PRESSURE OF QUILL (LOW) A A A A
M326 2ND PRESSURE OF QUILL (HIGH) A A A A
M335 SPINDLE LOAD OBSERVATION MACRO VARIABLE X X O X
M336 SERVO T/S MACRO VARIABLE X X O X
M338 MACRO VARIABLE MODE OFF X X O X

Ⅲ-44
Ⅵ.Technical data

1. Tooling system ··············································· Ⅳ-1

1.1. NL 2000/ 2000B···················································· Ⅳ-1
1.2 . NL 2000M/ 2000BM ············································· Ⅳ-2

2. Tool interference diagram ································ Ⅳ-3

2.1. NL 2000/2000B····················································· Ⅳ-3
2.2. NL 2000M/ 2000BM ··············································· Ⅳ-3

3. Working range diagram ··································· Ⅳ-4

3.1. NL 2000/2000B ···················································· Ⅳ-4
3.2. NL 2000M/ 2000BM··············································· Ⅳ-5

4. Main spindle speed / output graph ··················· Ⅳ-10

4.1. Spindle motor torque diagram·································· Ⅳ-10

4.2. Milling motor torque diagram ·································· Ⅳ-10

 1.

1.1.
Boring Bar Boring Bar Sleeves
Ø3/8"-D1.5" Ø1/2"-D1.5"
Ø5/8"-D1.5" Ø1"-D1.5"
Ø1 1/4"-D1.5"

Ø3/8"-D2" Ø1/2"-D2"
NL 2000/2000B

Ø5/8"-D2" Ø1"-D2"
Ø1 1/4"-D2" Ø1.5"-D2"
Tooling system

Boring Bar Boring bar holder O.D Tool Clamper

Ø1.5" (D1.5")
Ø2"
(D2")

O.D Tool
Drill Drill Sockets 1"
MT#2-D1.5" MT#3-D1.5"
MT#3-D2" MT#43-D2"

Face Tool Holder

12st Turret
U-Drill U-Drill holder Cap
(D1.5")
(D2")
U-Drill Sleeves
Ø3/4"-D1.5" Ø1"-D1.5"
Ø1 1/4"-D1.5"

Ø3/4"-D2" Ø1"-D2"
Ø1 1/4"-D2" Ø1.5"-D2"

Ⅳ-1
Ⅳ. Technical data
 Ⅳ. Technical data

Ⅳ-2
1.2.
Boring Bar Boring Bar Sleeves
Ø3/8"-D1.5" Ø1/2"-D1.5"
Ø5/8"-D1.5" Ø1"-D1.5"
Ø1 1/4"-D1.5"

Boring Bar I.D Tool holder

Ø1.5" D-1.5"
O.D Tool Holher
NL 2000M/ 2000BM

Drill Drill Sockets

MT#2-D1.5" MT#3-D1.5"

O.D Tool
1"

U-Drill U-Drill holder Cap

(D-1.5")

U-Drill Sleeves
Ø3/4"-D1.5" Ø1"-D1.5"
Ø1 1/4"-D1.5" 12st Turret Face Tool Holder

Axial T/Mill holder

ER25(Ø3~Ø16)

Radial T/Mill holder

2. Tool interference diagram

2.1 NL2000/2000B
Unit : mm(inch)

Ⅳ-3
2. Tool interference diagram

2.2. NL 2000M/ 2000BM

Unit : mm(inch)

Ⅳ-3
3. Working range diagram

3.1. NL 2000/2000B
Unit : mm(inch)

Ⅳ-4
3.2. NL2000M/2000BM
Unit : mm(inch)

Ⅳ-5
4. Main spindle speed / output graph
What is a motor's rated output
The temperature of the inside of a motor is increasing as the working hours. Temperature increasing
limit is decided by the kind of insulation material and F insulation material si used in case of
SMART type, acceptable maximum temperature is 155℃.

1) Continuous rating
Continuous rating is the motor's output in the condition of keeping the heat balance without
over-run the acceptable maximum temperature even if operate the machine continuously.
Therefore in the condition, hours of operating is all right.

2) 30 minutes rating
In case of driving in the same temperature with surroundings, after 30 minutes, it reaches at
the acceptable maximum temperature and the output is decreasing and heat balance is broken
remarkably, then it can be said the motor's output if this time is 30 minutes rating. To drive in 30
minutes rating after reaching at the acceptable maximum temperature, don't drive because the
temperature of the motor has to be dropped until it becomes the same with surroundings.

4.1. Spindle motor torque diagram

▷NL2000/M

Ⅳ-6
 ▷NL2000B/BM

4.2. Milling motor rorque diagram

▷NL2000M/2000BM
Ⅳ. Technical data

Ⅳ-10
Ⅴ. Inspection and maintenance

1. Lubrication unit ················· Ⅴ-2

1.1. Adjusting and cleaning centralized lubrication unit ··· Ⅴ-6

2. Hydraulic unit ·················· Ⅴ-7

2.1. Adjusting and cleaning hydraulic unit ········· Ⅴ-7

3. Cleaning coolant tank ·············· Ⅴ-9

4. Tensioning belts ················Ⅴ-10

4.1. Adjusting V-belt between the spindle and main motor ···
························· Ⅴ-10

5. General trouble shooting ············· Ⅴ-11

5.1. Head stock ··················· Ⅴ-11
5.2. Chuck ······················ Ⅴ-12
5.3. Carriage(X, Z -axis) ················ Ⅴ-13
5.4. Lubrication unit ·················· Ⅴ-13
5.5. Air unit ····················· Ⅴ-13
5.6. Hydraulic unit ·················· Ⅴ-14
5.7. Coolant unit ··················· Ⅴ-15
Inspection and maintenance

This section deals with the maintenance requirements which must be met by every user in order to insure
excellent, trouble-free performance and prolonged life.
It also outlines some basic steps to pinpoint possible causes of trouble, together with troubleshooting hints,
if your machine is found out of order in any way, or in need of readjustment or repair.
To insure a maximum productive time with a minimum of downtime, the machne must be periodically
inspected and carefully serviced.
A periodical inspection schedule is presented below. In addition to the regular maintenance items given
here. There are some maintenance items which should be checked according to the actual condition of the
machine, as described in this section.

Primary check items

Frequency Inspection Items

(1) Check oil level through the oil level gauges in the hydraulic power unit, slideway
lubricating oil tank and coolant tank.
Daily (2) Check source pressure of the hydraulic unit, chuck
pressure and tailstock pressure.
(3) Supply lubricating oil to the power chuck master jaw.

(1) Check the bedways for level and straightness.

(2) Flush out the hydraulic power unit and change the hydraulic fluid.
Monthly (3) Change coolant in the coolant tank.
These three items must be carried out after the first month of operation following
initial installation of the machine.

(1) Change hydraulic oil in the hydraulic unit.

Every six months (2) Supply lubrication oil to chip conveyor.
(3) Canger coolant in the coolant tank.
◆ Periodical inspection schedule

Frequency
Number of
No. Inspection Inspection item
Daily Weekly months
1 6 12
* Arranging the machine periphery in order, cleaning
1 General the machine and its periphery (especially, the ●
floor)
* Checking the chuck unit and its periphery to scan
●
for chips.
* Checking for secure mounting of the top jaws. ●

2 Headstock * Checking for smooth clamping/ unclamping of

●
chuck.
* Greasing the chuck jaw. ●

* Removing any chips from the coolant collector. ●

* Checking for secure mounting of the cutting tools
●
and the holder.
3 Toolpost
* Checking the turrets and the cutting tools to scan
●
for chips.
* Checking the oil levels, and if necessary, refilling. ●
Lubrication
4 * Checking the oiling filters. ●
unit
* Checking ofr oil leakage and for damaged piping. ●

* Checking for appropriate pressure. ●

* Checking the oil levels, and if necessary, refilling. ●

Hydraulic
5 * Checking the strainers. ●
power unit
* Replacing the hydraulic oil. ●

* Checking for oil leakage and for damaged piping. ●

* Checking the coolant levels, and if necessary,
●
refilling.
* Checking the degree of dirtiness of the filters and
6 Coolant unit ●
cleaning.
* Checking the degree of dirtiness of the coolant and
●
if necessary, replacing.
7 Air unit * Checking the element and if necessary, replacing. ●
* Checking the name plates for abnormalities such
●
as damage or missing.
8 Name plate
* Please order our nearest service center, if
●
necessary.
Electrical * Checking if the door is fully closed. ●
9 control *Checking the electrical components for dirt and
cabinet ●
discoloration and checking for loose terminal screws.
Ⅴ. Maintenance

* Checking for loose connector/ terminals between

10 Connectors ●
units.
11 Foundation * Checking and adjusting the bed level using a level. ●

Ⅴ-1
 1. Lubrication unit
A. Always use the specified lubricating oil.
1. If the oil other than specified is used, the lubrication unit might fail to operate normally.
2. Lubricating oil used in common with coolant or hydraulic oil might cause corrosion of
lubrication unit, or mixing of oils result in lubrication failure, which, in turn, leads to damages
on the slide way surfaces.

B. For coolant, use the specified coolant.

1. Coolant usually contains chemical additives such as activator. If improper coolant is used,
lubricating oil will be affected by chemicals and therefore, use the specified coolant so far as
possible.
2. If coolant which is not our recommendation is to be used, check to be sure that it will not
cause any following problems. Mixing with lubricating oil, possible parting, peeled paint,
rusting, and swelling of packings. If a problem is found during the use of the coolant, avoid
the use of such coolant.

C. Amount of lubricating oil and its discharge condition must be checked everyday.
1. Whether or not lubricating oil is properly supplied can be checked by checking oil level in the
tank. For normal oil consumption amount, refer to the table on the next page.
2. Prior to shipment of the machine from our plant, the oil and the coolant tanks are flushed out
and therefore must be refilled during the initial installation of the machine.

D. The replacement period is determined on the base of eight hours operation a day. Delayed
replacement or use of any product other than recommended oil may damage the machine.
Ⅴ. Maintenance

Ⅴ-2
Lubrication chart

Lubrication
NO Parts name Q'ty Specified oil Remarks
point
1 Oil inlet -Supply as required,
Ball screw VACTRA NO 2 : MOBIL then clean the
2 Level gauge & Slide 3.0ℓ TONNA T68 : SHELL
way WAY LUB’ 68 : CALTEX strainer and
3 Drain plug the inner tank.

Lubricating oil specification

Suppliers
MOBIL TOTAL CALTEX ESSO Oilling points
Type of lubrication
DROSERA Hyd. power
ISO VG32 DTE 24 RANDO HD-32 NUTOH-32
ZS32 unit
DROSERA Way lubricant Guide ways &
ISO VG68 Vactra #2 FIBIS K-53
MS58 68 Ball screws
Lithium soap type
Mobilux Multifax 2 or Power chuck
Multi-purpose
grease 2 Multifax Ep 2 jaws & Turret
grease

Note 1. We do not have any experience in using the oils other than those indicated by
an asterisk (*). Selection should thus be made from them. Because slide-way
lubricating oil contains additives such as extreme-pressure additive, it could incur
variety of troubles if reacting with other oils or coolant. Therefore, pay special
attention to the use of slide way lubricating oil.
2. As for service point or amount of lubricating oil of the machine, refer to the
instruction manual of respective machine models.
3. Lubricating oil used in common with coolant or lubricating oil used in common with
hydraulic oil might cause corrosion of lubrication unit or turbines of oils to result in
lubrication failure, which, in turn, leads to damages on the slideway surface or ball
screw. (We take no responsibility for the troubles caused by using the lubricating
oil which is not our recommendations.)
4. As for oil replenishment for the optional accessories such as special chucks or
chip conveyor, refer to the special instruction manual supplied with individual
accessories.
Ⅴ. Maintenance

5. When slideway lubricating oil mixed with coolant and some trouble appears,
contact your local SMART representatives. They have optional accessories such as
oil skimmer.

Ⅴ-3
 Lubricating circuit diagram

Specification
Pump
Flowrate
(at an operating viscosity
Pressure port 0.1ℓ/min
of 140mm2/S(cSt)and a
back pressure of p=5bar)

Pressure Perm. operating viscosity 32~1300mm2/S(cSt)

Pressure gauge switch
Max. operating pressure 15±1 bars
Capacitor-run motor
Relief valve Motor (with built-in thermostatic switch)
Operating voltage 50/60Hz, AC 100/110V

Operating current 0.55A(220V/60Hz)

Power consumption Approx. 46W

Pressure regulatingvalve Operating time Max. 4min.
Levle indicator Four times of pump
Min. dwell time
operating time
Operating interval Max. 25 times/ hour

A: Pumping start
Lubricating cycle time(10min)
B: Oil feeding start(Distributor)
Pump operation Interval
C: Oil feeding finish(Distributor)

D: Pressure switch activates

E: Pressure regulating valve activates

F: Pressure relief valve activates
Pressure regulating valve stop)
G: Pressure switch return

H: Oil suction start (Distributor)

I: Oil suction stop(Distributor)

J: Pressure relief valve stop

Lubricating cycle diagram

1. The pump starts running and delivers the oil quantities premiered in the piston distributor
to the lubrication points of the machine. As soon as the operating pressure is reached in the
centralized lubrication system (12kg/cm2), pressure switch is on for 15 seconds as set in times.
Ⅴ. Maintenance

Afterwards, the pump motor will be switched off, the interval time preselected in the time will
run down.
The lubrication cycle is completed.

Ⅴ-4
2. After the pressure in the system has been released, the metering chambers of the piston
distributors are refilled.
Further lubrication cycles will be repeated in accordance with the interval time set. (10 minutes)
3. The lubrication cycle is repeated pump on for 6 seconds; pump off for 3 seconds for all 45 seconds,
when machine NC power is turned on.
After 45 seconds, if the Axis moving time is 10 minutes, the pressure switch has been turned on
for 15 seconds.
The interval time -10 minutes is repeated. If the moving Axis has been dwelled for over 1 hour
after the NC power was turned on, the pump is switched on for 15 seconds.
The period is repeated automatically.
4. Intermediate lubrication is possible by pressing push button shortly.
5. In case of critically low oil level, the alarm lamp will light via the connected float switch.

Oil specification ISO VG68

Amount 3ℓ (0.8 gal)
Replenish as required.
Oil change Low lubrication level alarm detected by the level swithc occurs in approx.
interval 70~80 hour operation. Check oil level every day and replenish lubricating oil
before the alarm occurs.

Check oil level before starting day's operation.

Caution

Press the alarm RESET button on the

⇒ Press the PUSH button.
operation panel.

This delevers lubricating oil.

Repeat the above indicated steps several times.
The centralized lubricating oil tank is accessible by opening the oil filter
port cover. The lubricating oil is fed to the bed slideway, the cross-slide
slideway, the X, and Z-axis drive ball screws and the tailstock quill.
Ⅴ. Maintenance

Ⅴ-5
 1.1. Adjusting and cleaning centralized lubrication unit
1. Adjusting pump delivery
The delivery amount to each lubrication point is controlled by the metering type distribution
valve with automatic intermittent lubrication pump, and no further adjustment is necessary.

2. Maintenance and countermeasure

When no lubricating oil is delevered :
a. Oil level is low.
Replenish the lubricating oil of the same brand.
b. The pump is at a rest : The pump operates intermittently.
The pump operation interval is set at 5 minutes.
c. The oil strainer is clogged.
Clean the oil strainer at least every six months.
d. The motor dose not rotate. Check wiring.

3. Replenishing lubrication oil

a. The lubricating oil to be replenished must be clean and it must be of the same brand as currently
used.
b. Specified lubricating oil : ISO VG 68

4. Cleaning the filter of lubrication unit

a. When cleaning the tank and the filter, never use thinner or trichlen
(trichloroethylene) showing high volatile characteristics.
b. Oil strainer cleaning procedure :
① Power off
② Remove the cover of lubrication pump unit.
③ Take out the oil strainer on the cover of lubrication pump unit and
clean it.
④ Clean the oil strainer with compressed air and kerosene, and clean
the tank inside with a neutral detergent.
⑤ Reinstall the cover of lubrication pump unit.
Ⅴ. Maintenance

Ⅴ-6
2. Hydraulic unit
Refer to the 'Hydraulic unit manual instruction' for the detailed
contents of operation, maintanence and handling hydraulic unit.

2.1. Adjusting and cleaning hydraulic unit

1. Oil supply

Oil specification ISO VG32

Amount 20ℓ (5.3gal)
Oil change interval Replenish every 6 month

The rapid drop of oil level can cause machine malfuction. In such a case, contact the nearest
DMC service center.

2. Cleaning hydraulic unit

Clean the filter and oil tank when replenish the oil, and also check the actuator pressure.

Power off the machine when cleaning the hydraulic unit.

Caution

a. Cooling radiator
Removethe dust and substance on the radiator using comperssed air.

b. Oil tank
1. Disassemble the power line and alram line.
2. Loosen the drain plug and drain the all oil from the tank.
3. Take off the hydraulic hose and drain hose.
4. Move the hydraulic unit for cleaning the tank.
Ⅴ. Maintenance

5. Loosen the bolts assembling tank with bracket.

6. Detach the upper plate from the tank.
7. Take off the suction strainer using spanner and monkey wrench.

Ⅴ-7
 8. Clean the suction strainer with kerosene and dry it using compressed air.
9. Reassemble the suction strainer after winding sealing tape around suction pipe.
10. Drain the left oil through the oil outlet and clean the oil tank inside with kerosene.
11. Reasemble all parts consulting above procedure in reverse order.

Operate the machine again and check the machine condition according to trial
run instruction after reassembley.
Caution

3. Adjustment of hydraulic Pressure

The following outlines the methods of setting functional units for operating pressure. Since
the pressure lines for the turret(s) have been adjusted at our factory before shipment, they will
not require readjustments, during the initial installation and subsequent normal service of the
machine.

When readjustment is to be made by your plant personnel, extreme caution must

be taken in accordance with the instructions given here to avert any mechanicla
trouble in the drive lines.
Warning Any necessary adjustment must be made only by authorized personnel, and careless
tampering must be avoided under all operating conditions.

<NL2000/2500A>

<NL2000M/2500AM>
Ⅴ. Maintenance

<Ruducing valve position>

Ⅴ-8
2.2 Hydraulically-operated actuator

The hydraulically-operated actuators are indicated below :

1) Turret clamp/unclamp cylinder
2) Headstock chuck cylinder
3) Tailstock spindle
4) C-axis
5) Tailstock clamp/unclamp

<Schematic>

Ⅴ. Maintenance

Ⅴ-9
 1. Hydraulic specifications
1.1 General view and Specification of Hydraulic Unit
<Specifications>
Maximum operating pressure 568.5psi
Pump delivery 5.3gal/6.3gal/min(50/60Hz)
Viscosity 20~88 cSt
Oil used ISO VG32
Power supply Power line AC 220/380V 50/60 Hz

<General View>
Ⅴ. Maintenance

Ⅴ-10
<Name of major parts>
No. Unit name Q’ty Type Remarks
1 OIL TANK 1 SPCC t2.3, SPCC t3.2(20ℓ) HYDTEC
2 VANE PUMP/MOTOR 1 UVN-1A-1A3-1.5-4-10 NACHI
3 MOTOR BRACKET 1 HYDTEC
4 AIR BREATHER 1 SH-AB-1138-40 SHC
5 SUCTION FILTER 1 PK-SS-08(#150) SHC
6 OIL COOLER 1 C187-01 DM
7 PRESSURE GAUGE 1 Ø63x100BAR (D TYPE) DAHO
8 LEVEL GAUGE 1 SH(DM)-C-65 SHC(DMC)
9 PRESSURE SWITCH 1 PK5723(with cable) IFM

<Circuit diagram>

Ⅴ. Maintenance

Ⅴ-11
 1.2 General view of Main Valve Unit
1.2.1 NL 2000/2000B

<General View>

< Name of major parts >

No. Unit name Q’ty Type Remarks
1 MANIFOLD 1 SS41
2 SOLENOID VALVE 1 SS-G01-E3X-R-C1 NACHI
3 CHECK VALVE 2 OC-GO1-P1 NACHI
4 REDUCING VALVE 2 OG-G01-PC-K NACHI
5 ORIFICE 1 Ø2.5 HYDTEC
6 SOLENOID VALVE 1 SS-G01-C5-R-C1 NACHI
7 PRESSURE GAUGE 2 Ø60x60bar(BD TYPE) N.F/WIKA
Ⅴ. Maintenance

Ⅴ-12
1.2.2 NL 2000M/2000BM
<General View>

< Name of major parts >

No. Unit name Q’ty Type Remarks
1 MANIFOLD 1 SS41 HYDTEC
2 SOLENOID VALVE 1 SS-G01-E3X-R-C1 NACHI
3 SOLENOID VALVE 1 SS-G01-A3X-R-C1 NACHI
4 CHECK VALVE 1 OC-G01-P1 NACHI
5 RUDUCING VALVE 2 OG-G01-PC-K-20 NACHI
6 2 PRESS REDUCING VALVE 1 OGS-G01-PCC-K-C1 NACHI
7 ORIFICE 1 ø2.5 HYDTEC
8 CHECK VALVE 1 OC-G01-T1-5831 NACHI
9 PRESSURE GAUGE 3 Ø60x60bar(BD type) N.F/WIKA
Ⅴ. Maintenance

Ⅴ-13
 1.2.3 General view of Sub Valve Unit
<General View>

<Name of major parts>

No. Unit name Q’ty Type Remarks
1 MANIFOLD 1 SS41 HYDTEC
2 SOLENOID VALVE 1 SS-G01-E3X-R-C1 NACHI
3 SOLENOID VALVE 1 SS-G01-A3X-R-C1 NACHI
4 THROTTLE CHECK VALVE 1 OCY-G01-B-Y NACHI
5 CHECK VALVE 1 OC-G01-P1 NACHI
Ⅴ. Maintenance

Ⅴ-14
1.2.4 General view of Sub Valve Unit
<General View>

<Name of major parts>

No. Unit name Q’ty Type Remarks
1 MANIFOLD 1 SS41 HYDTEC
2 SOLENOID VALVE 1 SS-G01-E3X-R-C1 NACHI
3 THROTTLE CHECK VALVE 1 OCY-G01-B-Y NACHI

Ⅴ. Maintenance

Ⅴ-15
 3. Cleaning coolant tank
1. Procedure to clean the separately installed coolant tank.
a. Remove the cover at the side of the coolant pump.
b. Draw the coolant out of the tank by the pump.
c. Pull out the coolant tank to the right until the pump protrudes from the side cover, and
pull it out to the front.
d. Clean inside the coolant tank.
e. Clean the filter.
f. After cleaning the tank, reinstall the coolant tank.
The coolant tank must not protrude from the front rail. If the coolant tank is not installed
correctly, coolant will leak.
Ⅴ. Maintenance

Ⅴ-16
4. Tensioning belts

As a safety precaution, always turn OFF the machine when adjusting the belt tension
or when replacing the belt.
Warning

4.1. Adjusting V-belt between the spindle and main motor

When the V-belts are worn or loosen after using
for a long period, it is advisable to tension them
or replace them with new ones.
Tensioning the V-belts must be performed 3
months after initial installation, thereafter ever 6
months.

Adjust the belt tension as below procedure ;

Unfasten the lock bolt① on the motor bracket.

↓
Unfasten the adjusting bolt ①, ②.
↓
Unfasten the adjusting bolt ②.
↓
Check for the bending tension of the adjusting bolt ①, and slowly fasten
the bolt.
↓
C heck the bending tension (δ) of the V-belt based on the tension(F) as
shown in the below index.
↓
Fasten the nut②, after getting the set value (δ).

NL2000B/BM

Ⅴ-17
 5. General trouble shooting

5.1. Head stock

If a problem occurs with the spindle, check the LCD indication at the spindle unit in the
electric control cabinet and contact your local SMART service representative.
* Tools/ devices to be used : Tester and multi meter.

Trouble Cause Remedy

- The magnetic contactor is tripped. - Reset the magnetic

Overtheating - If the alarm state cannot be contactor.
of headstock cleared after resetting the - Contact your local SMART
contactor, the motor is faulty. service representative.

- The power switch is off.

- Turn ON the power.
- If the power switch is not off,
- Change the no-fuse breaker
Motor does the no-fuse breaker or the
or the magnet contactor.
not rotate magnet contactor is faulty.

If the lamp is not lit, the

Change the inverter.
inverter is faulty.

The motor hums Heavy load or short Decrease the machine side load, or
but does not rotate acceleration time setting. increase the acceleration time setting.

Check if the motor is overloaded. Decrease the machine side load.

The motor is
overheated - Check if motor cooling is obstructed. - Remove the obstacles.
- If not obstructed, the motor is faulty. - Change the motor.

The motor does not

Check if the motor is overloaded. Decrease the machine side load.
rotate smoothly

*. No spindle rotation.

Is the power chuck closed?

Ⅴ. Maintenance

Ⅴ-18
5.2. Chuck
* Refer to the instruction manual supplied by the chuck maker.

Trouble Cause Remedy

Disassemble the chuck and

Chuck component part is damaged.
replace the broken parts.

The rotary hydraulic cylinder

The chuck does Chuck the hydraulic system.
does not function.
not operate.
Disassemble the chuck and
The sliding portion is seized. remove or correct the seized
portion. If necessary replace.

Large volume of chips are

Master jaw stroke Disassemble and clean the chuck.
accumlated inside the chuck.
is not sufficient.
Draw pipe is loosened. Remove and clean the draw pipe.

Master jaw stroke is insufficient. Adjust master jaw stroke.

Chuck clamping force is insufficient. Set the hydraulic pressure correctly.

Top jaw are not shaped correctly

Shape the top jaws correctly.
to the work piece diameter.
Work piece slips
in the chuck. Calculate cutting force; Change
Cutting force is too high.
cutting conditions.

Master jaw and other sliding

Grease them.
parts not lubricated correctly.

Spindle rotation speed is too high. Lower spindle speed.

If the chuck is shaking,

The chuck is shaking.
retighten the bolts.

Foreign matter on serration of Remove the top jaws and

master and chuck jaws. clean the serration.

Top jaw clamping bolts are loose. Tighten the bolts to the specified torque.
Accuracy is not high. Soft jaws are not shaped correctly. Shape them correctly.

Soft jaws are too high causing

deformation, or top jaw Lower the top jaws.
clamping bolts are loose.

The work piece is deformed due to

Lower the gripping force.
excessively high gripping force.
Ⅴ. Maintenance

Ⅴ-19
 *. No chuck jaw movement.

No
Is the oil pressure set to the required level? Adjust the chuck pressure.
→

↓Yes

No
Is the draw tube connected properly between the hydraulic. Adjust the draw tube setting.
→

↓Yes

No
Do the master jaws move normally? Remove chips and apply machine oil.
→

5.3. Carriage(X, Z -axis)

Trouble Cause Remedy

Bolts, tapper pins and/

Tighten them.
Positioning is not accurate. or nuts are loose.

Coupling is loose. Retighten the coupling.

5.4. Lubrication unit

Trouble Cause Remedy

Lubricating oil is insufficient. Add lubrication oil.

Lubricating oil pressure drops
Leak from hte lubrication pipe. Retighten the pipe.
below 89kPa
Lubrication pipe is clogge. Clean the pipe.

*. No lubricating oil flow to slideways.

Lubricating oil is not consumed in one to two days.

↓Yes

Yes
Lubrication pump is faulty. Adjust centralized lubrication unit.
→

↓No

Yes
The distributing valve is not moving. Replace.
→

5.5. Air unit

Trouble Cause Remedy
Air flow volume decreases due to
Element is clogged. Change the element.
high air flow resistance.
Ⅴ. Maintenance

An excessive volume of water is

found in the pipe downstream from Water has accumulated. Discharge the water.
the element.

Ⅴ-20
5.6. Hydraulic unit
Trouble Cause Remedy
Check the connection of
The pump does not rotate.
the power cable.
The pump is rotating in the
Check the polarity of the power supply.
reverse direction.
Suction pipe is clogged. Check the suction pipe.
Strainer is clogged. Clean the strainer.
Leak in suction pipe. Check the suction pipe and its joint.
Oil is not
discharged. Replenish the hydraulic oil with
Suction filter is not completely
the same grade up to the reference
immersed in oil.
line in the level sight gauge.
Discharge volume adjusting sleeve
Loose the sleeve.
is tightened excessively.
Replace the oil entirely with
oil of correct viscosity.
Hydraulic oil viscosity is too high.
* Warm the oil using a heater
as temporary measures.
Although oil The relief valve is not operating correctly. Disassemble and check the relief valve.
is discharged, Load is not applied in the
Check the circuit and apply the load.
pressure is not built hydraulic circuit.
up. Leak in the hydraulic system. Check the piping and repair the leak.
Oil is not discharged Seals inside the pump are broken.
or volumetric
Contact your local SMART
efficiency lowers Slide portions are worn abnormally service representative.
when pressure is due to dust and foreign matter.
built up.
Strainer is clogged. Clean the strainer.
Air is sucked from the suction Check the point where air is sucked by
pipe or other portion. applying oil on the suspected portions.
Check the return pipe and prevent
Bubbles inside the reserve tank.
generation of bubbles.
Repeat inching of the pump
Bubbles trapped inside the piping.
to discharge the bubbles.
Noise is
Replenish the specified grade of
excessively large.
Low oil level. the hydraulic oil up to the reference
line in the level sight gauge.
Pump mount base is not rigid. Use rigid base; check loose bolts as well.
If the wear is abnormal, check for
oil contamination, water in the oil,
Seizure on sliding portions of the pump.
oil viscosity, and oil temperature
during pump operation.
Heat generation due to improper If the pump surface temperature
Pump generates volumetric efficiency. rises excessively, stop pump
Ⅴ. Maintenance

heat.
Seizure on sliding portions of the pump. operation immediately.

Ⅴ-21
 *. No pressure building-up of hydraulic power unit.

Yes Check if the overload relay in the

The hydraulic power unit pump motor is operating.
→ control box is tripped.

↓No

Yes
The filter is clogged. Clean the filter.
→

↓No

No
The hydraulic oil in the tank is filled to the specified level. Replenish the hydraulic oil.
→

5.7. Coolant unit

Trouble Cause Remedy

Filter of the coolant tank is clogged. Clean the filter.

Coolant is insufficient. Refill the coolant.

Coolant is not
supplied. - The electromagetic swithc is tripped. - Reset the electromagnetic
- If the electromagnetic switch is not switch.
tripped, the coolant pump is faulty. - When the coolant pump fails,
contact your SMART service.

*. No coolant supply.

Yes Check if the overload relay in the

The coolant pump motor is not rotating.
→ control box is tripped.

↓No

Yes
The strainer is clogged. Clean the strainer.
→

↓No

No
The coolant in the coolant tank is filled to the specified level. Replenish the coolant.
→
Ⅴ. Maintenance

Ⅴ-22
 NL2000 STANDARD TURRET ASS’Y

Head Office : 15, Pyeongsan-ro, Uichang-gu, changwon-si, Gyeongsangnam-do, South Korea

http : //www.ewskorea.co.kr
Tel : 055-267-8089
Fax : 055-262-3118
Head Office : 15, Pyeongsan-ro, Uichang-gu, Changwon-si, Gyeongsangnam-do, South Korea

This manual is intended for the user’s information only. Unauthorized distribution and illegal use outside
the said intention of the company is strictly prohibited.

EWSMNE-ST20-009(1)
 Table of Contents
Documents

Foreword ------------------------------2pg

1. Serial Number ------------------------------3pg

2. Installation
1. Mounting information ------------------------------4pg
2. Dimensional information for turret unit
------------------------------4pg
installation
3. To align the precision of turret ass’y ------------------------------5pg
4. Coolant Supply Instruction ------------------------------6pg
5. Information of nipple to Hydraulic and
------------------------------7pg
lubricant
6. Cycles for disk clamp & unclamp ------------------------------8pg

3. Performance
1. Specification of turret unit ------------------------------9pg
2. Illustration of Holder Assembly Diagram -----------------------------10pg

4. Installation
1. Parts List -----------------------------17pg
2. Sensor/Hyd./Lub. supply instruction -----------------------------23pg

5. Troubleshooting Checklist
1. Self-diagnosis -----------------------------24pg
2. Itemized Maintenance Procedure -----------------------------26pg
3. Notice Before Placing Service Parts -----------------------------29pg

6. Daily checklist for self-maintenance -----------------------------30pg

7. Spare Parts -----------------------------31pg

8. Accessories -----------------------------33pg

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 Foreword

Thank you for purchasing our product.

Please read the entire user manual prior to use. Reading this manual will help you to
maintain the product at the best condition of the point of manufacturing.
Following the instructions contained in this manual will ensure the best performance
and the extended life from the product.

1. Please use the recommended parts.

This mill turret unit is built on the patented platform and design of our company.
Using the recommended parts will ensure the product performance and help get the
most out of the product.

2. Please refer to “Troubleshooting” before calling for service.

It will save our and YOUR time and resources to solve problems by referring to
“Troubleshooting” section of this manual for the most cases.

3. Be sure to follow the instruction below when ordering service parts.

The design of the product is subject to change for upgrade. Please be sure to
provide the serial number of this unit to match the correct parts of the product is
being serviced.

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1. Serial Number

The serial number is the vital information you need to provide when calling for service
or ordering for repairing parts.

Serial Plate

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 2. Installation
2-1 Mounting information
Use M12X1.75 EYE BOLT 2EA

Please pay attention that indicated edge of Disc while installation or

carrying

2-2 Dimensional information for turret unit installation

260
2 256 2 203.5
10 75 75 86 10 2 50 68 50 35.5
33 172 33 22 29 5-M6 TAP

6-M6 TAP

(135.9)
35 90

100
115

10
15
7
15

15
25

27
40

5
8

50

35
55
125

130
205

190
180

175

130
110
268
335

335
110

295
130
90
93
105

110
130
39

48
40
25

20

5-Ø18 HOLE 2-Φ10.5 HOLE

14
13
Φ15 C/B
58 55 117 33 120 174.5

7 85 5 263 10 2-M12 TAP 188.5 11

2-M10 TAP
FOR LIFTING 319.5

Bolt Spec Q’ty N.m/ea

M16 X L60 5 131

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 2-3 To align the precision of turret ass’y.
For the first-time installation of the product, please use “TEST MANDREL” below, or utilize
something like as described in the picture below by inserting a test bar measurable for inside
diameter using boring holder in your possession.

Initially, take a note of the center discrepancy of spindles as the first procedure (please
contact the manufacturer), grind the SPACER (approximately 5.3mm) that is inserted between
Cross Slide and Turret unit. After then, reassemble as instructed below.

Setting holder(BMT type)

Instruction
Purpose: To measure H.V direction parallelism of turret assembly for the Main chuck’s
center.
Please see the example below

Move the turret right and left after putting the dial gage needle in contact with the point
of the external diameter of round bar attached on the Setting holder.

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 2-4 Coolant Supply Instruction

Coolant Supply Hole

(PT1/2xPT3/4)

In the case of low oil pressure, disassemble the coolant supply hose, clean the inside using
the air gun and follow the instructions described in the picture for disassembly.

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2-5 Information of nipple to Hydraulic and Lubricant

UNCLAMP OF DISC (PT3/8)

COOLANT SUPPLY (PT1/2xPT3/4)

CLAMP OF DISC (PT3/8)

OIL TO CURVIC COUPLING

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2-6 Cycles for disk clamp & unclamp

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3. Performance
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3-1 Specification of turret unit

Descriptions Units Specifications

Type of disc - STD

Tool Quantity ea 12

mm type : BITE 25x25

OD Bite mm
inch type : BITE 25.4x25.4
mm : Φ40
Boring holder mm
inch : Φ38.1

Index Time sec 0.15

Clamping Force kgf 3,553(35bar)

Transmission Ratio INDEX=1:24

Indexing Accuracy mm ±0.01

Repeat Accuracy mm ±0.005

Index Motor Power Fanuc ß8/3.000is

Weight(without Motor and Holders) kg 205

Proximity switch for Clamp & Unclamp N/O, 2-wire

Lubrication Method OIL

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3-2 Illustration of Holder Assembly Diagram
1) Tooling Array
*MM TYPE 17.20BMT40X40IKPL25
U-DRILL HOLDER

5.20BMT25PL25
FACE HOLDER

KCL729
BLOCK, CLAMP

KCL730
BLOCK, SUPPORT

*INCH TYPE

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2) Tooling Interference Diagram
*MM TYPE

Φ5 1
Φ4

4
80
Φ
54
6

8
06
6.
20
Φ
Φ219.354

*INCH TYPE

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 3) Dimensions of tool holders

*MM TYPE

FACE HOLDER
(5.20BMT25PL25)

SCREW, H/S CAP

(4-M12xL60)

BITE BLOCK
(KCP730-729)
(2-M8xL25)

2-? 7.8 Drill Point

2-O-RING
(AS568A-014)

2-O-RING
(AS568A-016) SCREW, FLAT H/S HEAD
SET SCREW, FLAT END (2-M6xL12)
(M6xL10)

? 9 Ball Endmill Dp 8

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 BORING HOLDER
(17.20BMT40X40IKPL25)

SCREW, H/S CAP

(4-M12xL65)

SCREW, H/S CAP

2-? 7.8 Drill Point (3-M6xL20)

COOLANT NOZZLE
(2-KD15/M6)
3-PT PLUG
SET SCREW, FLAT END (PT1/8)
(6-M10xL35)

BACK PLATE
(KBP 20704)

SCREW, FLAT H/S HEAD

(2-M6xL15)

2-O-RING
(1AP9)
2-O-RING
(AS568A-014)
2-SET SCREW, FLAT END
(M6xL10) 2-O-RING
(AS568A-016)

? 9 Ball Endmill Dp 8

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*INCH TYPE

FACE HOLDER
(5.20BMT254PL25)

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BORING HOLDER
(17.20BMT381X40IKPL25)

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 BLOCK, CLAMP
(KCL729)

M12x1.75 Tap Thru'

10.2 Drill 2- 9.0 Drill Thru'
14 C/Bore' Dp9

BLOCK, SUPPORT
(KCL732)
(KCL730)

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4. Parts List.
4-1.Parts List

Complete Assembly Illustration

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Illustration of Turret Disc & Curvic

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Illustration of Motor & Sensor & shafts for Index

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No. Article Number Article Name Spec Q'ty Remarks
1 K8965C000100 PIN, SPINDLE K89 65 C 0001 00 2 SM45C
2 K6012M000100 CURVIC COUPLING 1 K60.12M.0001.05(PVO) 1 SCM415
3 SPPI02010040 PIN TAPER DIN EN 22 339 x10x40 4
4 SPPI01010020 PIN PARALLEL DIN6325 x10x20 1
5 SPOR01AS568A173 O-RING OR 215.57x2.62x 1
6 SPBO03005035 SCREW, H/S CAP DIN912 xM 5x35 6
7 SPBO03010100 SCREW, H/S CAP DIN 912 - M10 x 100 6
8 K1120S000600 FLANGE, DISC K11.20S.0006.01 1 GC30
9 SPOR07OVO212222005 OV-SEAL OV 212x222x5 1
10 DRG114F101009 COLLAR DRG 114Fx101x9 1 SM45C
11 MPBE016821 BEARING BALL 6821 105x130x13 1
12 K7130M000100 PLATE, SUPPORT K71.30M.0001.01 1 SM45C
13 SPOR02Q4430 QUAD RING 04430x129.54x7.00 1
14 SPOR011AP009 O-RING SPOR011AP009 18
15 K2220S002600 SHAFT,MIAN K22.20S.0026.01 1 SM45C
16 SPOR011BP080 O-RING OR 1BP 80xx 2
17 K6012M000100 CURVIC COUPLING 2 K60.12M.0001.05(PX) 1 SCM415
18 SPOR011BP105 O-RING OR 1BP 105xx 1
19 K1230M000100 FLANGE, IN-SIDE K12.30M.0001.04 1 SM45C
20 SPPI02010035 PIN TAPER SPPI02010035 2
21 K8910M251500 PISTON PIN K89.10M.2515.00 1 SM45C
22 SPBO03012030 SCREW, H/S CAP DIN912 xM12x30 8
23 K6012M000100 CURVIC COUPLING 3 K60.12M.0001.05(PVI) 1 SCM415
24 SPBO03005045 SCREW, H/S CAP SPBO03005045 4
25 K2520S001500 ADAPTER, COOLANT K25.20S.0015.02 1
26
27 SPOR011BP014 O-RING SPOR011BP014 2
28 SPOR12016020001.25 BACK UP RING BACK UP 16x20x1.25 1
29 SPOR011AP004 O-RING SPOR011AP004 1
30 SPOR011BP016 O-RING SPOR011BP016 2
31 SPOR01AS568A131 O-RING OR 42.52x2.62x 1
32 SPBO05004006 SCREW, BUTTON H/S CAP BUTTON xM4x06 6
33 K1520S005400 NAME PLATE K15.20S.0054.00 1 SUS304
34 SPBO03006035 SCREW, H/S CAP DIN912 xM 6x35 4
35 SPPL01PT116 PT PLUG SPPL01PT116 1
36 SPPL01PT18 PT PLUG SPPL01PT18 51
37 K1520S004400 NAME PLATE K15.20S.0044.02 1 GC25

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38 SPOR01AS568A046 O-RING SPOR01AS568A046 1
39 SPOR12094.4085001.7 BACK UP RING SPOR12094.4085001.7 1 TEFRON
40 SPOR02Q4340 QUAD RING SPOR02Q4340 1
41 K8565C000100 NOZZLE K85.65C.0001.08 1 BrC2
42 SPOR02Q4342 QUAD RING 04342x91.44x5.33 1
43 SPOR12099.4090001.7 BACK UP RING BACK UP 99.4x90x1.7 1 TEFRON
44 SPBO03010055 SCREW, H/S CAP DIN 912 - M10x55 4
45 K1625S001500 SHAFT,DISTRIBUTE K16.25S.0015.02 1 SM45C
46 SPOR04TC105135014 OIL SEAL TC 105x135x14 1
47 SPBO03010050 SCREW, H/S CAP DIN912 xM10x50 6
K0320S009700 DISC(MM) K03.20S.0097.04
48 1 SM45C
K0320S009800 DISC(INCH) K03.20S.0098.03
49 SPNO03KCP12/6L23 COOLANT PIPE KCP12x06xL23xM10 4
50 SPNO03KCP12/6L13 COOLANT PIPE KCP12x06xL13xM10 4
51 K90-060187 KEY K90 -060187 12 SM45C
52 SPBO03006015 SCREW, H/S CAP DIN912 xM 6x15 22
53 K3140M000500 COVER, OUT-SIDE K31.40M.0005.01 2 SM45C
54 SPBO05004008 SCREW, BUTTON H/S CAP BUTTON xM 4x08 1
55 SPOR011AG090 O-RING OR 1AG 90xx 2
56 SPBO03010080 SCREW, H/S CAP DIN912 xM10x80 6
57 SPNU01008001.0 NUT DIN934 xM08x1.0x 4
58 MPSW01FL7M2J6HD PROXIMITY SWITCH FL7M-2J6HD xx 2
59 SPPI01010030 PARALLEL PIN SPPI01010030 2
60 SPBO03006020 SCREW, H/S CAP DIN912 xM 6x20 8
61 K0840M000100 DOG, SENSOR K08.40M.0001.2 1 SM45C
62 K8830C000300 SPRING K88.30C.0003.0 1 SWP
63 K0740M000100 BRACKET, SENSOR DOG K07.40M.0001.1 1 SCP1
64 K3155M003000 FRAME COVER K31.55M.0030.02 1 SM45C
65 SPBO03004008 SCREW, H/S CAP DIN912 xM 4x 8 1
66 SPTI01DA2S8 TIE MOUNTS SPTI01DA2S8 1 동아베스텍

67 K8155M000200 HOUSING, ADJUSTABLE K81.55M.0002.2X 1 SM45C

68 SPBO03006025 SCREW, H/S CAP DIN912 xM 6x25 5
69 K5155M000200 GEAR. SHAFT K51.55M.0002.0X 1 SCM415
70 MPBE016206ZZ BEARING BALL 6206ZZ 30x62x16 2
71 DRG038030072.5 COLLAR DRG 38x30x72.5(1) 1 SM45C
72 SPCS02R062 RING,C-type SPCS02R062 1
73 SPDI01SUB3M003 DISTRIBUTOR DISTRIBUTOR_3 1
74 SPDI01SUBDB004 ELBOW DISTRIBUTOR_2 1

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75 SPNE02APT12PT34 ADAPTER-A HOSE PT1/2XPT3/4_A 1
76 SPNE02APF38PT38 ADAPTER-A HOSE PT3/8XPF3/8_A 2
77 K9665M000300 SERIAL PLATE K96.65M.0003.01 1 AL t0.8
78 SPBO12002.5007.3 RIVET SPBO12002.5007.3 4
79 K0112S001600 FRAME K01.12S.0016.01 1 GC30
80 MPBT012505GT655 TIMMING BELT 250-EV5GT-655 1
81 K5455M000100 TIMING PULLEY K54.55M.0001.4X 1 SM45C
82 MPLE02300028032 LOCKING ELEMENT SWLE300 xx 28X32 2
83 K3565C000100 RETAINER K35.65C.0001.4 1 SM45C
84 MOTOR,SERVO Fanuc β8-3000i 1
85 SPBO03008030 SCREW, H/S CAP DIN912 xM 8x30 4
86 SPKE01006006028 KEY, SQUARE-PARALLEL DIN6885 B 6x6x28 1
87 K5340M000100 PULLEY, MOTOR K53.40M.0001.5 1 SUS303
88 K3350C000100 CAP, MOTOR K33.50C.0001.00 1 SHP1
89 SPWS02004000 WASHER, SPRING DIN127-A 4xx 2
90 SPBO03004015 SCREW, H/S CAP DIN912 xM 4x15 2
91 SPBO07008030 SET SCREW, FLAT END DIN913 xM 8x30 2
92 SPNU09008000 NUT DIN934 xM08x 2
93 K0620S001600 BRACKET, SERVO MOTOR K06.20S.0016.2X 1 SM45C
94 SPWS01010000 WASHER, PLANE SPWS01010000 4
95 SPWS02010000 WASHER, SPRING DIN127-A10xx 4
96 SPBO03010035 SCREW, H/S CAP SPBO03010035 4

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4-2. Sensor/Hyd./Lub. supply instruction

Proximity Switch (FL7M-2J6HD)

Checking Clamp/Unclamp of Disc)

Hydraulic Line for

Hydraulic Line for
Unclamping Disc (PT3/8)
Clamping Disc (PT3/8)

Lubrication Line for

Curvic Coupling (PT1/8)

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5. Troubleshooting Checklist
5-1. Self-diagnosis (mechanical elements)

No. Category Symptoms & parts Checklist and troubleshoot Procedure No.

1 Cutting Check the insert in use. Check the fastening or wear on

vibration the insert.

1-1 Fastening of Check whether the bolts are

frames. fastened securely.

1-2 Holder clamp Check if the holder is properly

assembly-related. clamped.

2 Index error Not turning after 1) Check the cabling is securely A-1
unclamp. connected for Unclamp proximity

switch.

2) Check CURVIC COUPLING for

any hindrance material.

→ Unclamp the disc by force,

and no turning remains if the

diagnosis is right.

3) Excessive stress or snap on A-3

motor belt.

2-1 Interruptive noise 1)Wear or chip on the gears

while turning. 2)Proximity switch not aligned to A-2

full unclamp.

→ Unclamp the disc and

realign the switch.

3)Check the gear back-lash

between Curvic gear and Gear

shaft.

2-2 Wobbling movement 1) Reset the index point of the

during clamp after machining center.

index. 2) Adjust the parameter of motor

load for wobbling at indexing.

(Refer to the operation manual of

the product concerned.)

2-3 Clamp operation Check the cabling for Clamp

malfunction. proximity switch.

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No. Category Symptoms & parts Checklist and troubleshoot Procedure No.

3 Clamp/ Check the clamp

unclamp cable.
inversed
4 Coolant Check clogging of the
supply piping.
5 Indexing Banging noise is A-4
noise detected when
Set a valve for adjusting of
Rotating tools are
unclamping parts.
passing during
index.
6 Defective Too much deviation for 1) Check the disc is being clamped

accuracy of accuracy of work-piece firmly.

Disc 2) Check the torsion of disc. A-5

Crash between turret and

machine may cause the torsion

of disc.

3) Check the Clamping jaw of main

spindle.

Accurate performance is affected

by condition (torsion of

aged) of main spindle.

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 5-2 Itemized Maintenance Procedure

A-1. Checking the cabling of proximity switch

There are two ways of checking the cabling of the proximity switch. First, check the signal
changes between “0”-“1” on the parameter when the normal proximity is realized.
Secondly, open the cover illustrated in the picture below to check the proximity switch. There
is the Unclamp near the disc and please replace the wiring of Clamp Check switch next to it if it
is not “on” when the proximity is made.

Proximity switch

A-2. Adjusting the proximity switches for clamp & unclamp.

1 2 The proximity switch as

illustrated in the picture
(Unclamp) should be
assembled as pushed to the
far left as possible at Unclamp
position of DOG. (To be
detected at the full stroke)

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 A-3. How to adjust the tension of belt
Set screw for adjusting
tension of belt

Pluck the belt to rebound for

checking the frequency

BELT

Set screw for adjusting

tension of belt

DISCRIPTION BELT Specs Deflection(mm) Weight Load(kgf)

INDEX 250-EV5GT-655 2.17 2.2

Warning. When you assemble the belt, you must check it has been in Pulley
groove. If it is not tightly hooked and it starts to turn, the belt will be damaged.

Dimension for assembling motor pulley

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 A-4. Indexing noise

Try to use "Flow control valve" of solenoid valve, which controls B Drain, to control flow rates.
But, if the speed of Clamp of disc is too slow, 'Time over error' could be occurred in the control
system, it should be active in proper range.

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 A-5. How to measure disc torsion

A B

1) Install the Indicator on Turret body.

2) Adjust “A””B” until the indicator’s value makes the proper range(±0.03mm Within/100mm
intervals). Parallelism to head in the direction of X-axis should be tested.
3) Same distance intervals to check the "C" ; range(±0.02mm Within/The entire interval).

*If you are outside the criteria, should be re-assembled by disc.

*If you need to re-assemble, please contact the manufacturer.

5-3 Notice before placing service parts

Please be sure to provide the serial number of the our Mill turret unit and the Repairing parts
number when ordering for service parts as designs and the applicable parts are subject to
change for upgrade without prior notice.

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6. Daily checklist for self-maintenance
No Checklist Period Remarks

1 Is there any oil leakage? Daily

Check after 6 months

and again after 3
2 Is the tension of belt correct?
years. Conduct
periodic checks.
Is there no detachment of some
Prevent the cutting oil
3 covers for preventing cutting oil Daily
inflow into the turret.
inflow?
Do you provide the grease for gear in
4 10cc~20cc/Year
right time?
The wrong reference
Is there disc twisting when turret point caused by turret
5 Daily
clamps? crash has to be
adjusted.
The disc accuracy is
Is there rough edge on the work piece gone caused by turret
6 Daily
after machining? crash has to be
adjusted.
Clamp speed has to
be adjusted →
Is there loud locking noise from curvic
7 Daily Hydraulic power for
coupling when turret clamps?
clamp has to be
reduced.
Replace sensors or
Is there no problem for adjust distance
8 Once/Month
CLAMP/UNCLAMP sensors? between sensor and
dog.
If there is interruption
during indexing or too
9 Is there no damage for indexing belt? Once/Month much tension for belt,
belt can be damaged
→ replace

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 7. SPARE PARTS
No. Article Number Article Name Spec Q'ty Remark
1 DRG038030072.5 COLLAR DRG 38x30x72.5(1) 1 SM45C
2 DRG114F101009 COLLAR DRG 114Fx101x9 1 SM45C
3 MPBE016206ZZ BEARING BALL 6206ZZ 30x62x16 2
4 MPBE016821 BEARING BALL 6821 105x130x13 1
5 MPBT012505GT655 TIMMING BELT 250-EV5GT-655 1
6 MPLE02300028032 LOCKING ELEMENT SWLE300 xx 28X32 2
7 MPSW01FL7M2J6HD PROXIMITY SWITCH FL7M-2J6HD xx 2
8 SPBO03004008 SCREW, H/S CAP DIN912 xM 4x 8 1
9 SPBO03004015 SCREW, H/S CAP DIN912 xM 4x15 2
10 SPBO03005035 SCREW, H/S CAP DIN912 xM 5x35 6
11 SPBO03005045 SCREW, H/S CAP SPBO03005045 4
12 SPBO03006015 SCREW, H/S CAP DIN912 xM 6x15 22
13 SPBO03006020 SCREW, H/S CAP DIN912 xM 6x20 8
14 SPBO03006025 SCREW, H/S CAP DIN912 xM 6x25 5
15 SPBO03006035 SCREW, H/S CAP DIN912 xM 6x35 4
16 SPBO03008030 SCREW, H/S CAP DIN912 xM 8x30 4
17 SPBO03010035 SCREW, H/S CAP SPBO03010035 4
18 SPBO03010050 SCREW, H/S CAP DIN912 xM10x50 6
19 SPBO03010055 SCREW, H/S CAP DIN 912 - M10x55 4
20 SPBO03010080 SCREW, H/S CAP DIN912 xM10x80 6
21 SPBO03010100 SCREW, H/S CAP DIN 912 - M10 x 100 6
22 SPBO03012030 SCREW, H/S CAP DIN912 xM12x30 8
23 SPBO05004006 SCREW, BUTTON H/S CAP BUTTON xM4x06 6
24 SPBO05004008 SCREW, BUTTON H/S CAP BUTTON xM 4x08 1
25 SPBO07008030 SET SCREW, FLAT END DIN913 xM 8x30 2
26 SPBO12002.5007.3 RIVET SPBO12002.5007.3 4
27 SPCS02R062 RING,C-type SPCS02R062 1
28 SPDI01SUB3M003 DISTRIBUTOR DISTRIBUTOR_3 1
29 SPDI01SUBDB004 ELBOW DISTRIBUTOR_2 1
30 SPKE01006006028 KEY, SQUARE-PARALLEL DIN6885 B 6x6x28 1
31 SPNE02APF38PT38 ADAPTER-A HOSE PT3/8XPF3/8_A 2
32 SPNE02APT12PT34 ADAPTER-A HOSE PT1/2XPT3/4_A 1
33 SPNO03KCP12/6L13 COOLANT PIPE KCP12x06xL13xM10 4
34 SPNO03KCP12/6L23 COOLANT PIPE KCP12x06xL23xM10 4
35 SPNU01008001.0 NUT DIN934 xM08x1.0x 4

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36 SPNU09008000 NUT DIN934 xM08x 2
37 SPOR011AG090 O-RING OR 1AG 90xx 2
38 SPOR011AP004 O-RING SPOR011AP004 1
39 SPOR011AP009 O-RING SPOR011AP009 18
40 SPOR011BP014 O-RING SPOR011BP014 2
41 SPOR011BP016 O-RING SPOR011BP016 2
42 SPOR011BP080 O-RING OR 1BP 80xx 2
43 SPOR011BP105 O-RING OR 1BP 105xx 1
44 SPOR01AS568A131 O-RING OR 42.52x2.62x 1
45 SPOR01AS568A046 O-RING SPOR01AS568A046 1
46 SPOR01AS568A173 O-RING OR 215.57x2.62x 1
47 SPOR02Q4340 QUAD RING SPOR02Q4340 1
48 SPOR02Q4342 QUAD RING 04342x91.44x5.33 1
49 SPOR02Q4430 QUAD RING 04430x129.54x7.00 1
50 SPOR04TC105135014 OIL SEAL TC 105x135x14 1
51 SPOR07OVO212222005 OV-SEAL OV 212x222x5 1
52
53 SPOR12016020001.25 BACK UP RING BACK UP 16x20x1.25 1
54 SPOR12094.4085001.7 BACK UP RING SPOR12094.4085001.7 1 TEFRON
55 SPOR12099.4090001.7 BACK UP RING BACK UP 99.4x90x1.7 1 TEFRON
56 SPPI01010020 PIN PARALLEL DIN6325 x10x20 1
57 SPPI01010030 PARALLEL PIN SPPI01010030 2
58 SPPI02010035 PIN TAPER SPPI02010035 2
59 SPPI02010040 PIN TAPER DIN EN 22 339 x10x40 4
60 SPPL01PT116 PT PLUG SPPL01PT116 1
61 SPPL01PT18 PT PLUG SPPL01PT18 51
62 SPTI01DA2S8 TIE MOUNTS SPTI01DA2S8 1
63 SPWS01010000 WASHER, PLANE SPWS01010000 4
64 SPWS02004000 WASHER, SPRING DIN127-A 4xx 2
65 SPWS02010000 WASHER, SPRING DIN127-A10xx 4

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8. Accessory
1) TEST BAR

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 NL2000B STANDARD TURRET ASS’Y

Head Office : 15, Pyeongsan-ro, Uichang-gu, changwon-si, Gyeongsangnam-do, South Korea

http : //www.ewskorea.co.kr
Tel : 055-267-8089
Fax : 055-262-3118
Head Office : 15, Pyeongsan-ro, Uichang-gu, Changwon-si, Gyeongsangnam-do, South Korea

This manual is intended for the user’s information only. Unauthorized distribution and illegal use outside
the said intention of the company is strictly prohibited.

EWSMNE-ST20-010(1)
 Table of Contents
Documents

Foreword ------------------------------2pg

1. Serial Number ------------------------------3pg

2. Installation
1. Mounting information ------------------------------4pg
2. Dimensional information for turret unit
------------------------------4pg
installation
3. To align the precision of turret ass’y ------------------------------5pg
4. Coolant Supply Instruction ------------------------------6pg
5. Information of nipple to Hydraulic and
------------------------------7pg
lubricant
6. Cycles for disk clamp & unclamp ------------------------------8pg

3. Performance
1. Specification of turret unit ------------------------------9pg
2. Illustration of Holder Assembly Diagram -----------------------------10pg

4. Installation
1. Parts List -----------------------------19pg
2. Sensor/Hyd./Lub. supply instruction -----------------------------25pg

5. Troubleshooting Checklist
1. Self-diagnosis -----------------------------26pg
2. Itemized Maintenance Procedure -----------------------------28pg
3. Notice Before Placing Service Parts -----------------------------31pg

6. Daily checklist for self-maintenance -----------------------------32pg

7. Spare Parts -----------------------------33pg

8. Accessories -----------------------------35pg

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 Foreword

Thank you for purchasing our product.

Please read the entire user manual prior to use. Reading this manual will help you to
maintain the product at the best condition of the point of manufacturing.
Following the instructions contained in this manual will ensure the best performance
and the extended life from the product.

1. Please use the recommended parts.

This mill turret unit is built on the patented platform and design of our company.
Using the recommended parts will ensure the product performance and help get the
most out of the product.

2. Please refer to “Troubleshooting” before calling for service.

It will save our and YOUR time and resources to solve problems by referring to
“Troubleshooting” section of this manual for the most cases.

3. Be sure to follow the instruction below when ordering service parts.

The design of the product is subject to change for upgrade. Please be sure to
provide the serial number of this unit to match the correct parts of the product is
being serviced.

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1. Serial Number

The serial number is the vital information you need to provide when calling for service
or ordering for repairing parts.

Serial Plate

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 2. Installation
2-1 Mounting information
Use M12X1.75 EYE BOLT 2EA

Please pay attention that indicated edge of Disc while installation or

carrying

2-2 Dimensional information for turret unit installation

260
2 256 2 203.5
10 75 75 86 10 2 50 68 50 35.5
33 172 33 22 29 5-M6 TAP

6-M6 TAP

(135.9)
35 90

100
115

10
15
7
15

15
25

27
40

5
8

50

35
55
125

130
205

190
180

175

130
110
268
335

335
110

295
130
90
93
105

110
130
39

48
40
25

20

5-Ø18 HOLE 2-Φ10.5 HOLE

14
13
Φ15 C/B
58 55 117 33 120 174.5

7 85 5 263 10 2-M12 TAP 188.5 11

2-M10 TAP
FOR LIFTING 319.5

Bolt Spec Q’ty N.m/ea

M16 X L60 5 131

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 2-3 To align the precision of turret ass’y.
For the first-time installation of the product, please use “TEST MANDREL” below, or utilize
something like as described in the picture below by inserting a test bar measurable for inside
diameter using boring holder in your possession.

Initially, take a note of the center discrepancy of spindles as the first procedure (please
contact the manufacturer), grind the SPACER (approximately 5.3mm) that is inserted between
Cross Slide and Turret unit. After then, reassemble as instructed below.

Setting holder(BMT type)

Instruction
Purpose: To measure H.V direction parallelism of turret assembly for the Main chuck’s
center.
Please see the example below

Move the turret right and left after putting the dial gage needle in contact with the point
of the external diameter of round bar attached on the Setting holder.

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 2-4 Coolant Supply Instruction

Coolant Supply Hole

(PT1/2xPT3/4)

In the case of low oil pressure, disassemble the coolant supply hose, clean the inside using
the air gun and follow the instructions described in the picture for disassembly.

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2-5 Information of nipple to Hydraulic and Lubricant

UNCLAMP OF DISC (PT3/8)

COOLANT SUPPLY (PT1/2xPT3/4)

CLAMP OF DISC (PT3/8)

OIL TO CURVIC COUPLING

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2-6 Cycles for disk clamp & unclamp

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3. Performance
3-1 Specification of turret unit

Descriptions Units Specifications

Type of disc - STD

Tool Quantity ea 12

mm type : BITE 25x25

OD Bite mm
inch type : BITE 25.4x25.4

Boring holder - Φ50, Φ50.8

Index Time sec 0.15

Clamping Force kgf 3,553(35bar)

Transmission Ratio - INDEX=1:24

Indexing Accuracy mm ±0.01

Repeat Accuracy mm ±0.005

Index Motor Power - Fanuc ß8/3.000is

Weight(without Motor and Holders) kg 205

Proximity switch for Clamp & Unclamp - N/O, 2-wire

Lubrication Method - OIL

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3-2 Illustration of Holder Assembly Diagram
1) Tooling Array
*MM TYPE 17.20BMT50X40IKPL25
U-DRILL HOLDER

5.20BMT25PL25
FACE HOLDER

1.20BMT25PL25
EX/OD HOLDER

*INCH TYPE 17.20BMT508X40IKPL25

U-DRILL HOLDER

5.20BMT254PL25
FACE HOLDER

1.20BMT254L40PL25
EX/OD HOLDER

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2) Tooling Interference Diagram
*MM TYPE

196.0
68

68
6.0
19

56
4
.35

0
209
514

480

*INCH TYPE

195.26
8

4
.55
208
56
0
514

480

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 3) Dimensions of tool holders
*MM TYPE

FACE HOLDER
(5.20BMT25PL25)

SCREW, H/S CAP

(4-M12xL60)

BITE BLOCK
(KCP730-729)
(2-M8xL25)

2-? 7.8 Drill Point

2-O-RING
(AS568A-014)

2-O-RING
(AS568A-016) SCREW, FLAT H/S HEAD
SET SCREW, FLAT END (2-M6xL12)
(M6xL10)

? 9 Ball Endmill Dp 8

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 U-DRILL HOLDER
(17.20BMT50X40IKPL25)

SCREW, H/S CAP

(4-M12xL65)

17.20BMT50X40PL25-P

BACK PLATE
(KBP 20706)

2-? 7.8 Drill Point

SCREW, H/S CAP

(3-M6xL20)

SET SCREW, FLAT END

(6-M10xL30) 3-PT PLUG
(PT1/8)

SCREW, FLAT H/S HEAD

(2-M6xL12)

COOLANT NOZZLE 2-O-RING

(2-KD15/M6) (AS568A-014)
SET SCREW, FLAT END 2-O-RING
(M6xL10) (1AP9)
2-O-RING
(AS568A-016)

? 9 Ball Endmill Dp 8

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 EX/OD HOLDER
(1.20BMT25L40PL25)

SCREW, H/S CAP

(4-M12xL40)

SET SCREW, FLAT END

(M6xL10)

BITE BLOCK
(KCP730-729)
(2-M8xL25) PT PLUG
(4-PT1/8)

COOLANT NOZZLE SCREW, FLAT H/S HEAD

2-O-RING
(2-KD15/M6) (2-M6xL12)
(AS568A-014)

2-O-RING
(AS568A-016)

SCREW, H/S CAP

(2-M8xL25)

2-? 9 Ball Endmill Dp 8

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 *INCH TYPE

FACE HOLDER
(5.20BMT254PL25)

SCREW, H/S CAP

(4-M12xL60)

BITE BLOCK
(KCP730-729)
(2-M8xL25)

2-Φ7.8 Drill Point

2-O-RING
(AS568A-014)

2-O-RING
(AS568A-016) SCREW, FLAT H/S HEAD
(2-M6xL12)
SET SCREW, FLAT END
(M6xL10)

Φ9 Ball Endmill Dp 8

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 U-DRILL HOLDER
(17.20BMT508X40IKPL25)

SCREW, H/S CAP

(4-M12xL65)

17.20BMT508X40PL25-P

BACK PLATE
(KBP 20706)

2-? 7.8 Drill Point

SCREW, H/S CAP

(3-M6xL20)

SET SCREW, FLAT END

(6-M10xL30) 3-PT PLUG
(PT1/8)

SCREW, FLAT H/S HEAD

(2-M6xL12)

COOLANT NOZZLE 2-O-RING

(2-KD15/M6) (AS568A-014)
SET SCREW, FLAT END 2-O-RING
(M6xL10) (1AP9)
2-O-RING
(AS568A-016)

? 9 Ball Endmill Dp 8

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EX/OD HOLDER
(1.20BMT254L40PL25)

SCREW, H/S CAP

(4-M12xL40)

SET SCREW, FLAT END

(M6xL10)

BITE BLOCK
(KCL730-729)
PT PLUG
(4-PT1/8)

COOLANT NOZZLE SCREW, FLAT H/S HEAD

SET SCREW, FLAT END O-RING
(2-KD15/M6) (2-M6xL12)
(M12xL25) (2-AS568A-014)

SCREW, H/S CAP

(2-M8xL25)

O-RING
(2-AS568A-016)

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 BLOCK, CLAMP
(KCL729)

M12x1.75 Tap Thru'

10.2 Drill 2- 9.0 Drill Thru'
14 C/Bore' Dp9

BLOCK, SUPPORT
(KCL732)
(KCL730)

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4. Parts List.
4-1.Parts List

Complete Assembly Illustration

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Illustration of Turret Disc & Curvic

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Illustration of Motor & Sensor & shafts for Index

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No. Article Number Article Name Spec Q'ty Remarks
1 K8965C000100 PIN, SPINDLE K89 65 C 0001 00 2 SM45C
2 K6012M000100 CURVIC COUPLING 1 K60.12M.0001.05(PVO) 1 SCM415
3 SPPI02010040 PIN TAPER DIN EN 22 339 x10x40 4
4 SPPI01010020 PIN PARALLEL DIN6325 x10x20 1
5 SPOR01AS568A173 O-RING OR 215.57x2.62x 1
6 SPBO03005035 SCREW, H/S CAP DIN912 xM 5x35 6
7 SPBO03010100 SCREW, H/S CAP DIN 912 - M10 x 100 6
8 K1120S000600 FLANGE, DISC K11.20S.0006.01 1 GC30
9 SPOR07OVO212222005 OV-SEAL OV 212x222x5 1
10 DRG114F101009 COLLAR DRG 114Fx101x9 1 SM45C
11 MPBE016821 BEARING BALL 6821 105x130x13 1
12 K7130M000100 PLATE, SUPPORT K71.30M.0001.01 1 SM45C
13 SPOR02Q4430 QUAD RING 04430x129.54x7.00 1
14 SPOR011AP009 O-RING SPOR011AP009 18
15 K2220S002600 SHAFT,MIAN K22.20S.0026.01 1 SM45C
16 SPOR011BP080 O-RING OR 1BP 80xx 2
17 K6012M000100 CURVIC COUPLING 2 K60.12M.0001.05(PX) 1 SCM415
18 SPOR011BP105 O-RING OR 1BP 105xx 1
19 K1230M000100 FLANGE, IN-SIDE K12.30M.0001.04 1 SM45C
20 SPPI02010035 PIN TAPER SPPI02010035 2
21 K8910M251500 PISTON PIN K89.10M.2515.00 1 SM45C
22 SPBO03012030 SCREW, H/S CAP DIN912 xM12x30 8
23 K6012M000100 CURVIC COUPLING 3 K60.12M.0001.05(PVI) 1 SCM415
24 SPBO03005045 SCREW, H/S CAP SPBO03005045 4
25 K2520S001500 ADAPTER, COOLANT K25.20S.0015.02 1
26
27 SPOR011BP014 O-RING SPOR011BP014 2
28 SPOR12016020001.25 BACK UP RING BACK UP 16x20x1.25 1
29 SPOR011AP004 O-RING SPOR011AP004 1
30 SPOR011BP016 O-RING SPOR011BP016 2
31 SPOR01AS568A131 O-RING OR 42.52x2.62x 1
32 SPBO05004006 SCREW, BUTTON H/S CAP BUTTON xM4x06 6
33 K1520S005400 NAME PLATE K15.20S.0054.00 1 SUS304
34 SPBO03006035 SCREW, H/S CAP DIN912 xM 6x35 4
35 SPPL01PT116 PT PLUG SPPL01PT116 1
36 SPPL01PT18 PT PLUG SPPL01PT18 51
37 K1520S004400 NAME PLATE K15.20S.0044.02 1 GC25

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38 SPOR01AS568A046 O-RING SPOR01AS568A046 1
39 SPOR12094.4085001.7 BACK UP RING SPOR12094.4085001.7 1 TEFRON
40 SPOR02Q4340 QUAD RING SPOR02Q4340 1
41 K8565C000100 NOZZLE K85.65C.0001.08 1 BrC2
42 SPOR02Q4342 QUAD RING 04342x91.44x5.33 1
43 SPOR12099.4090001.7 BACK UP RING BACK UP 99.4x90x1.7 1 TEFRON
44 SPBO03010055 SCREW, H/S CAP DIN 912 - M10x55 4
45 K1625S001500 SHAFT,DISTRIBUTE K16.25S.0015.02 1 SM45C
46 SPOR04TC105135014 OIL SEAL TC 105x135x14 1
47 SPBO03010050 SCREW, H/S CAP DIN912 xM10x50 6
48 K0320S009800 DISC K03.20S.0098.03 1 SM45C
49 SPNO03KCP12/6L23 COOLANT PIPE KCP12x06xL23xM10 4
50 SPNO03KCP12/6L13 COOLANT PIPE KCP12x06xL13xM10 4
51 K90-060187 KEY K90 -060187 12 SM45C
52 SPBO03006015 SCREW, H/S CAP DIN912 xM 6x15 22
53 K3140M000500 COVER, OUT-SIDE K31.40M.0005.01 2 SM45C
54 SPBO05004008 SCREW, BUTTON H/S CAP BUTTON xM 4x08 1
55 SPOR011AG090 O-RING OR 1AG 90xx 2
56 SPBO03010080 SCREW, H/S CAP DIN912 xM10x80 6
57 SPNU01008001.0 NUT DIN934 xM08x1.0x 4
58 MPSW01FL7M2J6HD PROXIMITY SWITCH FL7M-2J6HD xx 2
59 SPPI01010030 PARALLEL PIN SPPI01010030 2
60 SPBO03006020 SCREW, H/S CAP DIN912 xM 6x20 8
61 K0840M000100 DOG, SENSOR K08.40M.0001.2 1 SM45C
62 K8830C000300 SPRING K88.30C.0003.0 1 SWP
63 K0740M000100 BRACKET, SENSOR DOG K07.40M.0001.1 1 SCP1
64 K3155M003000 FRAME COVER K31.55M.0030.02 1 SM45C
65 SPBO03004008 SCREW, H/S CAP DIN912 xM 4x 8 1
66 SPTI01DA2S8 TIE MOUNTS SPTI01DA2S8 1 동아베스텍

67 K8155M000200 HOUSING, ADJUSTABLE K81.55M.0002.2X 1 SM45C

68 SPBO03006025 SCREW, H/S CAP DIN912 xM 6x25 5
69 K5155M000200 GEAR. SHAFT K51.55M.0002.0X 1 SCM415
70 MPBE016206ZZ BEARING BALL 6206ZZ 30x62x16 2
71 DRG038030072.5 COLLAR DRG 38x30x72.5(1) 1 SM45C
72 SPCS02R062 RING,C-type SPCS02R062 1
73 SPDI01SUB3M003 DISTRIBUTOR DISTRIBUTOR_3 1
74 SPDI01SUBDB004 ELBOW DISTRIBUTOR_2 1
75 SPNE02APT12PT34 ADAPTER-A HOSE PT1/2XPT3/4_A 1

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76 SPNE02APF38PT38 ADAPTER-A HOSE PT3/8XPF3/8_A 2
77 K9665M000300 SERIAL PLATE K96.65M.0003.01 1 AL t0.8
78 SPBO12002.5007.3 RIVET SPBO12002.5007.3 4
79 K0112S001600 FRAME K01.12S.0016.01 1 GC30
80 MPBT012505GT655 TIMMING BELT 250-EV5GT-655 1
81 K5455M000100 TIMING PULLEY K54.55M.0001.4X 1 SM45C
82 MPLE02300028032 LOCKING ELEMENT SWLE300 xx 28X32 2
83 K3565C000100 RETAINER K35.65C.0001.4 1 SM45C
84 MOTOR,SERVO Fanuc β8-3000i 1
85 SPBO03008030 SCREW, H/S CAP DIN912 xM 8x30 4
86 SPKE01006006028 KEY, SQUARE-PARALLEL DIN6885 B 6x6x28 1
87 K5340M000100 PULLEY, MOTOR K53.40M.0001.5 1 SUS303
88 K3350C000100 CAP, MOTOR K33.50C.0001.00 1 SHP1
89 SPWS02004000 WASHER, SPRING DIN127-A 4xx 2
90 SPBO03004015 SCREW, H/S CAP DIN912 xM 4x15 2
91 SPBO07008030 SET SCREW, FLAT END DIN913 xM 8x30 2
92 SPNU09008000 NUT DIN934 xM08x 2
93 K0620S001600 BRACKET, SERVO MOTOR K06.20S.0016.2X 1 SM45C
94 SPWS01010000 WASHER, PLANE SPWS01010000 4
95 SPWS02010000 WASHER, SPRING DIN127-A10xx 4
96 SPBO03010035 SCREW, H/S CAP SPBO03010035 4

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4-2. Sensor/Hyd./Lub. supply instruction

Proximity Switch (FL7M-2J6HD)

Checking Clamp/Unclamp of Disc)

Hydraulic Line for

Hydraulic Line for
Unclamping Disc (PT3/8)
Clamping Disc (PT3/8)

Lubrication Line for

Curvic Coupling (PT1/8)

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5. Troubleshooting Checklist
5-1. Self-diagnosis (mechanical elements)

No. Category Symptoms & parts Checklist and troubleshoot Procedure No.

1 Cutting Check the insert in use. Check the fastening or wear on

vibration the insert.

1-1 Fastening of Check whether the bolts are

frames. fastened securely.

1-2 Holder clamp Check if the holder is properly

assembly-related. clamped.

2 Index error Not turning after 1) Check the cabling is securely A-1
unclamp. connected for Unclamp proximity

switch.

2) Check CURVIC COUPLING for

any hindrance material.

→ Unclamp the disc by force,

and no turning remains if the

diagnosis is right.

3) Excessive stress or snap on A-3

motor belt.

2-1 Interruptive noise 1)Wear or chip on the gears

while turning. 2)Proximity switch not aligned to A-2

full unclamp.

→ Unclamp the disc and

realign the switch.

3)Check the gear back-lash

between Curvic gear and Gear

shaft.

2-2 Wobbling movement 1) Reset the index point of the

during clamp after machining center.

index. 2) Adjust the parameter of motor

load for wobbling at indexing.

(Refer to the operation manual of

the product concerned.)

2-3 Clamp operation Check the cabling for Clamp

malfunction. proximity switch.

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No. Category Symptoms & parts Checklist and troubleshoot Procedure No.

3 Clamp/ Check the clamp

unclamp cable.
inversed
4 Coolant Check clogging of the
supply piping.
5 Indexing Banging noise is A-4
noise detected when
Set a valve for adjusting of
Rotating tools are
unclamping parts.
passing during
index.
6 Defective Too much deviation for 1) Check the disc is being clamped

accuracy of accuracy of work-piece firmly.

Disc 2) Check the torsion of disc. A-5

Crash between turret and

machine may cause the torsion

of disc.

3) Check the Clamping jaw of main

spindle.

Accurate performance is affected

by condition (torsion of

aged) of main spindle.

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 5-2 Itemized Maintenance Procedure

A-1. Checking the cabling of proximity switch

There are two ways of checking the cabling of the proximity switch. First, check the signal
changes between “0”-“1” on the parameter when the normal proximity is realized.
Secondly, open the cover illustrated in the picture below to check the proximity switch. There
is the Unclamp near the disc and please replace the wiring of Clamp Check switch next to it if it
is not “on” when the proximity is made.

Proximity switch

A-2. Adjusting the proximity switches for clamp & unclamp.

1 2 The proximity switch as

illustrated in the picture
(Unclamp) should be
assembled as pushed to the
far left as possible at Unclamp
position of DOG. (To be
detected at the full stroke)

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 A-3. How to adjust the tension of belt
Set screw for adjusting
tension of belt

Pluck the belt to rebound for

checking the frequency

BELT

Set screw for adjusting

tension of belt

DISCRIPTION BELT Specs Deflection(mm) Weight Load(kgf)

INDEX 250-EV5GT-655 2.17 2.2

Warning. When you assemble the belt, you must check it has been in Pulley
groove. If it is not tightly hooked and it starts to turn, the belt will be damaged.

Dimension for assembling motor pulley

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 A-4. Indexing noise

Try to use "Flow control valve" of solenoid valve, which controls B Drain, to control flow rates.
But, if the speed of Clamp of disc is too slow, 'Time over error' could be occurred in the control
system, it should be active in proper range.

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 A-5. How to measure disc torsion

A B

1) Install the Indicator on Turret body.

2) Adjust “A””B” until the indicator’s value makes the proper range(±0.03mm Within/100mm
intervals). Parallelism to head in the direction of X-axis should be tested.
3) Same distance intervals to check the "C" ; range(±0.02mm Within/The entire interval).

*If you are outside the criteria, should be re-assembled by disc.

*If you need to re-assemble, please contact the manufacturer.

5-3 Notice before placing service parts

Please be sure to provide the serial number of the our Mill turret unit and the Repairing parts
number when ordering for service parts as designs and the applicable parts are subject to
change for upgrade without prior notice.

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6. Daily checklist for self-maintenance
No Checklist Period Remarks

1 Is there any oil leakage? Daily

Check after 6 months

and again after 3
2 Is the tension of belt correct?
years. Conduct
periodic checks.
Is there no detachment of some
Prevent the cutting oil
3 covers for preventing cutting oil Daily
inflow into the turret.
inflow?
Do you provide the grease for gear in
4 10cc~20cc/Year
right time?
The wrong reference
Is there disc twisting when turret point caused by turret
5 Daily
clamps? crash has to be
adjusted.
The disc accuracy is
Is there rough edge on the work piece gone caused by turret
6 Daily
after machining? crash has to be
adjusted.
Clamp speed has to
be adjusted →
Is there loud locking noise from curvic
7 Daily Hydraulic power for
coupling when turret clamps?
clamp has to be
reduced.
Replace sensors or
Is there no problem for adjust distance
8 Once/Month
CLAMP/UNCLAMP sensors? between sensor and
dog.
If there is interruption
during indexing or too
9 Is there no damage for indexing belt? Once/Month much tension for belt,
belt can be damaged
→ replace

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 7. SPARE PARTS
No. Article Number Article Name Spec Q'ty Remark
1 DRG038030072.5 COLLAR DRG 38x30x72.5(1) 1 SM45C
2 DRG114F101009 COLLAR DRG 114Fx101x9 1 SM45C
3 MPBE016206ZZ BEARING BALL 6206ZZ 30x62x16 2
4 MPBE016821 BEARING BALL 6821 105x130x13 1
5 MPBT012505GT655 TIMMING BELT 250-EV5GT-655 1
6 MPLE02300028032 LOCKING ELEMENT SWLE300 xx 28X32 2
7 MPSW01FL7M2J6HD PROXIMITY SWITCH FL7M-2J6HD xx 2
8 SPBO03004008 SCREW, H/S CAP DIN912 xM 4x 8 1
9 SPBO03004015 SCREW, H/S CAP DIN912 xM 4x15 2
10 SPBO03005035 SCREW, H/S CAP DIN912 xM 5x35 6
11 SPBO03005045 SCREW, H/S CAP SPBO03005045 4
12 SPBO03006015 SCREW, H/S CAP DIN912 xM 6x15 22
13 SPBO03006020 SCREW, H/S CAP DIN912 xM 6x20 8
14 SPBO03006025 SCREW, H/S CAP DIN912 xM 6x25 5
15 SPBO03006035 SCREW, H/S CAP DIN912 xM 6x35 4
16 SPBO03008030 SCREW, H/S CAP DIN912 xM 8x30 4
17 SPBO03010035 SCREW, H/S CAP SPBO03010035 4
18 SPBO03010050 SCREW, H/S CAP DIN912 xM10x50 6
19 SPBO03010055 SCREW, H/S CAP DIN 912 - M10x55 4
20 SPBO03010080 SCREW, H/S CAP DIN912 xM10x80 6
21 SPBO03010100 SCREW, H/S CAP DIN 912 - M10 x 100 6
22 SPBO03012030 SCREW, H/S CAP DIN912 xM12x30 8
23 SPBO05004006 SCREW, BUTTON H/S CAP BUTTON xM4x06 6
24 SPBO05004008 SCREW, BUTTON H/S CAP BUTTON xM 4x08 1
25 SPBO07008030 SET SCREW, FLAT END DIN913 xM 8x30 2
26 SPBO12002.5007.3 RIVET SPBO12002.5007.3 4
27 SPCS02R062 RING,C-type SPCS02R062 1
28 SPDI01SUB3M003 DISTRIBUTOR DISTRIBUTOR_3 1
29 SPDI01SUBDB004 ELBOW DISTRIBUTOR_2 1
30 SPKE01006006028 KEY, SQUARE-PARALLEL DIN6885 B 6x6x28 1
31 SPNE02APF38PT38 ADAPTER-A HOSE PT3/8XPF3/8_A 2
32 SPNE02APT12PT34 ADAPTER-A HOSE PT1/2XPT3/4_A 1
33 SPNO03KCP12/6L13 COOLANT PIPE KCP12x06xL13xM10 4
34 SPNO03KCP12/6L23 COOLANT PIPE KCP12x06xL23xM10 4
35 SPNU01008001.0 NUT DIN934 xM08x1.0x 4

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36 SPNU09008000 NUT DIN934 xM08x 2
37 SPOR011AG090 O-RING OR 1AG 90xx 2
38 SPOR011AP004 O-RING SPOR011AP004 1
39 SPOR011AP009 O-RING SPOR011AP009 18
40 SPOR011BP014 O-RING SPOR011BP014 2
41 SPOR011BP016 O-RING SPOR011BP016 2
42 SPOR011BP080 O-RING OR 1BP 80xx 2
43 SPOR011BP105 O-RING OR 1BP 105xx 1
44 SPOR01AS568A131 O-RING OR 42.52x2.62x 1
45 SPOR01AS568A046 O-RING SPOR01AS568A046 1
46 SPOR01AS568A173 O-RING OR 215.57x2.62x 1
47 SPOR02Q4340 QUAD RING SPOR02Q4340 1
48 SPOR02Q4342 QUAD RING 04342x91.44x5.33 1
49 SPOR02Q4430 QUAD RING 04430x129.54x7.00 1
50 SPOR04TC105135014 OIL SEAL TC 105x135x14 1
51 SPOR07OVO212222005 OV-SEAL OV 212x222x5 1
52
53 SPOR12016020001.25 BACK UP RING BACK UP 16x20x1.25 1
54 SPOR12094.4085001.7 BACK UP RING SPOR12094.4085001.7 1 TEFRON
55 SPOR12099.4090001.7 BACK UP RING BACK UP 99.4x90x1.7 1 TEFRON
56 SPPI01010020 PIN PARALLEL DIN6325 x10x20 1
57 SPPI01010030 PARALLEL PIN SPPI01010030 2
58 SPPI02010035 PIN TAPER SPPI02010035 2
59 SPPI02010040 PIN TAPER DIN EN 22 339 x10x40 4
60 SPPL01PT116 PT PLUG SPPL01PT116 1
61 SPPL01PT18 PT PLUG SPPL01PT18 51
62 SPTI01DA2S8 TIE MOUNTS SPTI01DA2S8 1
63 SPWS01010000 WASHER, PLANE SPWS01010000 4
64 SPWS02004000 WASHER, SPRING DIN127-A 4xx 2
65 SPWS02010000 WASHER, SPRING DIN127-A10xx 4

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8. Accessory
1) TEST BAR

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 Turrets & Tool holders

User manual
(Instruction & Maintenance)

NL2000M/BM
EWSMNE-BS20-046(1)
 NL2000M/BM MILL TURRET ASS’Y

Head Office : 15, Pyeongsan-ro, Uichang-gu, changwon-si, Gyeongsangnam-do, South Korea

http : //www.ewskorea.co.kr
Tel : 055-267-8089
Fax : 055-262-3118
Head Office : 15, Pyeongsan-ro, Uichang-gu, Changwon-si, Gyeongsangnam-do, South Korea

This manual is intended for the user’s information only. Unauthorized distribution and illegal use outside
the said intention of the company is strictly prohibited.

EWSMNE-BS20-046(1)

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 Table of Contents
Documents

Foreword ------------------------------3pg

1. Serial Number ------------------------------4pg

2. Installation
1. Mounting information ------------------------------5pg
2. Dimensional information for mill turret unit
------------------------------6pg
installation
3. To align the precision of turret ass’y ------------------------------7pg
4. Coolant/Hyd./Lub. supply instruction ------------------------------8pg
5. Power circuit of Mill & Index for two-motor type -----------------------------10pg
6. Cycles for Mill & Index -----------------------------11pg
7. Wiring of terminal box -----------------------------12pg
8. Instruction for Holder Clamping -----------------------------13pg

3. Performance
1. Specification of mill turret unit -----------------------------15pg
2. Mill’s torque graph -----------------------------15pg
3. Dimensions of holder’s attachment -----------------------------16pg
4. Illustration of Holder Assembly Diagram -----------------------------17pg

4. Parts List
1. Parts List -----------------------------31pg

5. Troubleshooting Checklist
1. Self-diagnosis(mechanical elements) -----------------------------39pg
2. Itemized Maintenance Procedure -----------------------------41pg
3. Notice before placing service parts -----------------------------50pg

6. Daily checklist for self-maintenance -----------------------------51pg

7. Spare Parts -----------------------------52pg

8. Accessories -----------------------------55pg

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 Foreword

Thank you for purchasing our product.

Please read the entire user manual prior to use. Reading this manual will help you to
maintain the product at the best condition of the point of manufacturing.
Following the instructions contained in this manual will ensure the best performance
and the extended life from the product.

1. Please use the recommended parts.

This mill turret unit is built on the patented platform and design of our company.
Using the recommended parts will ensure the product performance and help get the
most out of the product.

2. Please refer to “Troubleshooting” before calling for service.

It will save our and YOUR time and resources to solve problems by referring to
“Troubleshooting” section of this manual for the most cases.

3. Be sure to follow the instruction below when ordering service parts.

The design of the product is subject to change for upgrade. Please be sure to
provide the serial number of this unit to match the correct parts of the product is
being serviced.

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1. Serial Number

The serial number is the vital information you need to provide when calling for service
or ordering for repairing parts.

Serial Plate

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2. Installation
2-1 Mounting information
Use M12X1.75 EYE BOLT 2EA

Please pay attention that indicated edge of Disc while installation

or carrying.
28
60

5-16x2

Bolt Spec Q’ty N.m/ea

M16 X L60 5 131

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2-2 Dimensional information for mill turret unit installation

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 2-3 To align the precision of turret ass’y.

For the first-time installation of the product, please use “TEST MANDREL” below, or utilize
something like as described in the picture below by inserting a test bar measurable for inside
diameter using boring holder in your possession.

Initially, take a note of the center discrepancy of spindles as the first procedure (please
contact the manufacturer), grind the SPACER (approximately 5.3mm) that is inserted between
Cross Slide and Turret unit. After then, reassemble as instructed below.

Setting holder(BMT type)

Instruction
Purpose: To measure H.V direction parallelism of turret assembly for the Main chuck’s
center.
Please see the example below

Move the turret right and left after putting the dialgage needle in contact with the point
of the external diameter of round bar attached on the Setting holder.

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 2-4 Coolant/Hyd./Lub. supply instruction

PT3/8
PT1/2xPT3/4
(UNCLAMP) PT1/2
(COOLANT SUPPLY)
PT3/8
(CLAMP)

OIL TO GEAR BOX

OIL TO CURVIC COUPLING

Inlet for lubrication oil Curvic

Disc

Flow control valve

A B
Solenoid valve
b
P T(Drain)
Pressure gage

M
Motor
Hydraulic pump
Oil spec. These are just for samples to help your understanding
Contents Spec. Maker Remarks
Clamp/Unclamp HYSPIN VG32 CASTROL
Lubrication HYSPIN VG10 CASTROL Oil Type
Coolant SUPEREDGE47 CASTROL

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 ☞ Caution when wiring lubrication to turret unit from machine

Basically, this turret unit has measuring valve in lubrication system for each gears which are
Index and tool rotating, therefore please follow the right fig. below when wiring lubrication
Otherwise lubricate oil from machine could not be supplied to each gears for index and
tool rotating then, gears could be damaged seriously when gears are working.
After gears are damaged result in not sufficient supplying of lubricate oil, then terrible noise
will occur and gears will not be out of service.

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 2-5 Power circuit of Mill & Index for two-motor type

⑩ ⑨ ⑧ ⑦ ⑪ ⑥ ④ ⑫ ③ ⑤ ②

No. Parts Name Spec Roles

1 AC Servo motor Fanuc β8-3000i Disc index
2 Spindle motor βiI3/12000, 3.7/5.5kW Tool’s rotating
Proximity switch FL7M-2K6HD Confirming mode of
3
(DC 2WIRE, N/C) orientation
Proximity switch FL7M-2J6HD
4 Confirming turret’s unclamp
(DC 2WIRE, N/O)
Proximity switch FL7M-2J6HD
5 Confirming turret’s clamp
(DC 2WIRE, N/O)
6 Center shaft Power transfer
7 Curvic coupling Consisted of 3-piece
8 Disc flange Supporting turret
9 Drive shaft Rotating mill-tool holder
10 Coolant nozzle Max. 70bar Supplying coolant
11 Dog,clamp&unclamp Confirming clamp&unclamp
12 Dog, orientation connecting for motor&shaft

* Index motor should be consisted of Absolute type.

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2-6 Cycles of Milling & Index

3. 기계 성능

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2-7 Wiring of terminal box

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 2-8 Instruction for Holder Clamping

Screw

O-RING

Please follow the instructions below to maintain Holder at its best condition. Insert the Holder
into Disc with its clean handle as a pre-condition for the extended life of machining center body.
(To prevent the leakage of cutting oil into the machining center)

Without the O-ring inserted at the marked place, the possible leakage of cutting oil can cause
quality problems. (Please refer to the size of O-rings)
Damage or excessive noise may be made at the marked point by the unnecessary clamp force.
Please consult the values in the table below for fastening.

TOOL SIZE CLAMPING SCREW N.m O-RING SIZE(Maker)

BMT45 M8 20/1ea 1AG40(NOK)
BMT55 M10 40/1ea 1AG50(NOK)
BMT65 M12 60/1ea 1AG60(NOK)
BMT75 M12 60/1ea 1AG70(NOK)
BMT85 M12 60/1ea 1AG80(NOK)

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 Notice

X
Coupling position;
Drive shaft of
gear box

Please don’t detach a drill (or end mill etc.) of holder on the marked position (aligned with the
Headstock). When disassembled at indicated position, some important components which are
Bevel gears and coupling could be damaged seriously.
Therefore, please be sure to detached tools(Drill, endmill) at except the marked point using
wrench and spanner or after detaching tool holder from the Disc.

WRENCH

SPANNER

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3. Performance
3-1 Specification of Mill turret unit

Descriptions Units Specifications

Type of disc - BMT55

Tool Quantity ea 12
mm type : Ø40
Boring holder mm
inch type : Ø38.1(1.5 in)
Index Time sec 0.2
Clamping Force kgf 3,553(35bar)
Max RPM rpm 5,000
Indexing Accuracy mm ±0.01

Repeatability mm ±0.005

Servo Motor FANUC β8/3000i

βiI3/12000,
Spindle Motor
3.7/5.5kW(FANUC)
Running ratio Mill=1:1, Index=1:24

Weight(without holders) kg 210

Coupling type DIN1809

Lubrication Way Oil

3-2 Mill’s torque graph

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3-3 Dimensions of holder’s attachment

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3-4 Illustration of Holder Assembly Diagram

1) Tooling Array

*MM TYPE
17.15BMT40X60HC11IK
U-DRILL HOLDER

40.55251809SL
AXIAL DRIVEN HOLDER

2.5525HC11
OD HOLDER

2.15BMT25X60
5.5525HC11 OD HOLDER
FACE HOLDER

60.55251809X60SL
RADIAL DRIVEN HOLDER
*INCH TYPE

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2) Tooling interference Diagram
*MM TYPE

?5
32
.4
?4

48
70

? 480

? 206
.068

? 540
94
?4

*INCH TYPE

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3) Dimensions of tool holders.

AXIAL DRIVEN HOLDER

(40.55251809SL)

85
64
15

15.1
15.1

64

85
14

Ø6
.8
(1AP7)
O-RING

32

MaxØ16

Ø42
100

Ø25
50
(30)
(59)

(Ø2-Ø16)
ER25 DIN6499
29

5
30

(4-M10xL35)
SCREW, H/S CAP
75
104

45

(1AG50)
O-RING
18.5
29
10.5

8
Ø17
Ø40
Ø55 h6

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 RADIAL DRIVEN HOLDER
(60.55251809X60SL)

ER25 DIN6499 (29.5) 94.5

85 (Ø2-Ø16) 50 42.5 43 9

26

26
Ø42

Ø25
60±0.01

MaxØ16

60
100

190
30
5
SCREW, H/S CAP
(4-M10xL85)

75
104
45
O-RING
(1AG50)

18.5
29
Ø16.4

10.5
14
8
15.1
Ø17
O-RING
(2-1AP7) Ø40
.8
Ø6 Ø55 h6
2-
42.5
32

32
15
32

32
43

15.1
14
32 32
42.5 42.5

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 Coo..,, LLttdd..
WSS KKoorreeaa C
EEW
M6xL10
(SET SCREW, FLAT END)
BOLCK, CLAMP
(KCL730)
BOLCK, CLAMP
SCREW, FLAT H/S HEAD
(KCL729)
(2-M6xL12)

21
NOZZLE
(2-KD15_M6)
SCREW,H/S CAP
SCREW,H/S CAP (4-M10xL40)
(2-M8xL25)
O-RING
C1 C1
(1AP9) C1
M12xL20
(SET SCREW, FLAT END)
OD TOOL HOLDER
(2.5525HC11)

O-RING
2-AS568A-014
SET SCREW, FLAT END
*MM TYPE

(2-M8xL8)
 Coo..,, LLttdd..
4-M10xL50
(SCREW,H/S CAP)

WSS KKoorreeaa C
EEW
2-M8xL25
(SCREW,H/S CAP)
M12xL20
(SET SCREW, FLAT END)
M8xL8

22
(SET SCREW, FLAT END)
KCL729
(BLOCK CLAMP)
KCL730
(BLOCK CLAMP)
2-KD15xM6
(NOZZLE) M8xL8
(SET SCREW, FLAT END)
M6xL10
(SET SCREW, FLAT END)
2-M6xL12
(SCREW,F/H/SOCKET HEAD)
FACE HOLDER
(5.5525HC11)

O-RING
2-AS568A-014
 Coo..,, LLttdd..
93
2-SCREW, H/S CAP

WSS KKoorreeaa C
(DIN912 xM10xL35)
14.5 64 14.5
13

14
COOLANT NOZZLE
45

COOLANT NOZZLE (KD15_M6xL24)

EEW
32
32

(KD15_M6)
64

2-SCREW, H/S CAP

116

(DIN912 M10xL65)
32

32

SUPPORT, CLAMP
(KCL738)
71

BLOCK, CLAMP

39
(KCL768)
25

23
14 4-3X45°
SET SCREW, FLAT END
(M6xL10) 25 25
2-SCREW, FLAT H/S CAP 2-O-RING
21.5 50 21.5 (DIN7991 xM6xL12) (AS568A-014)
2-SCREW, H/S CAP
(DIN912 M8xL25) 65 51
SET SCREW, FLAT END
(DIN913 xM12xL20)
OD TOOL HOLDER

30
(2.15BMT25X60)

60
2-O-RING
70
(1AP9)
*INCH TYPE

35
3-PT PLUG

10
39 15 39 26 10 80 (DIN906 xPT1/16xL6)
 U-DRILL HOLDER
(17.15BMT40X60HC11IK)

4-M10xL70
(SCREW,H/S/CAP) A2

4-M6xL15
6-M10xL30
(SCREW, H/S CAP)
(SET SCREW, FLAT END)

KBP55707
(BACK PLATE)

2-M6xL10 O-RING
(SET SCREW, FLAT END) (1AP11)

2-O-RING
(AS568A-014) 2-PT1/8
2-KD15/M6 (PT PLUG)
(COOLANT NOZZLE)
2-M6xL12 PT1/8
(SCREW,F/H/SOCKET HEAD) (PT PLUG)

1AP9
(O-RING)

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 Coo..,, LLttdd..
WSS KKoorreeaa C
EEW
BOLCK, CLAMP
(KCL730)
BOLCK, CLAMP SCREW, FLAT H/S HEAD
(KCL729)

25
(2-M6xL12)
NOZZLE
(2-KD15_M6)
SCREW,H/S CAP
SCREW,H/S CAP
(4-M10xL40)
(2-M8xL25)
O-RING
(1AP9)
OD TOOL HOLDER
(2.55254HC11)

O-RING
(2-AS568A-014)
SET SCREW, FLAT END
(2-M8xL8)
 Coo..,, LLttdd..
WSS KKoorreeaa C
4-M10xL50
(SCREW,H/S CAP)

EEW
2-M8xL25
(SCREW,H/S CAP)
M12xL20
(SET SCREW, FLAT END)
M8xL8

26
(SET SCREW, FLAT END)
KCL729
(BLOCK CLAMP)
FL153005S M8xL8
(KEY HOLDER) KCL730 (SET SCREW, FLAT END)
(BLOCK CLAMP)
2-KD15xM6
(COOLANT NOZZLE)
2-M6xL12
(SCREW,F/H/SOCKET HEAD)
(5.55254HC11)
FACE HOLDER

2-O-RING
(AS568A-014)
M5xL12
(SCREW,H/S CAP)
 Coo..,, LLttdd..
WSS KKoorreeaa C
93
2-SCREW, H/S CAP
14.5 64 14.5 (DIN912 xM10xL35)
14
13

EEW
COOLANT NOZZLE
45

COOLANT NOZZLE
(KD15_M6xL24)
32
32

(KD15_M6)
64
2-SCREW, H/S CAP
116

(DIN912 M10xL65)
32

32
SUPPORT, CLAMP
(KCL769)
71

BLOCK, CLAMP

39
(KCL768)
25

27
14 4-3X45°
SET SCREW, FLAT END 2-SCREW, FLAT H/S CAP 2-O-RING
(M6xL10) 25.4 25.4 (DIN7991 xM6xL12) (AS568A-014)
21.1 50.8 21.1
2-SCREW, H/S CAP 65 51
(DIN912 M8xL25)
SET SCREW, FLAT END
(DIN913 xM12xL20)
OD TOOL HOLDER

30
(2.15BMT254X60)

60
70
2-O-RING
(1AP9)

35
3-PT PLUG

10
39 15 39 26 10 80 (DIN906 xPT1/16xL6)
 U-DRILL HOLDER
(17.15BMT381X60HC11IK)

4-M10xL70
(SCREW,H/S/CAP)

4-M6xL15
6-M10xL30
SCREW, H/S CAP
SET SCREW, FLAT END

KBP55707
BACK PLATE

2-M6xL10 O-RING
SET SCREW, FLAT END
(1AP11)

2-O-RING
(AS568A-014) 2-PT1/8
2-KD15/M6 (PT PLUG)
COOLANT NOZZLE
2-M6xL12 PT1/8
SET SCREW, FLAT END (PT PLUG)

1AP9
(O-RING)

M5xL12
(둥근머리 렌지볼트)
FL153005
(KEY, HOLDER)

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BLOCK, CLAMP
(KCL729)

M12x1.75 Tap Thru'

10.2 Drill

2- 9.0 Drill Thru'

14 C/Bore' Dp9

SUPPORT, CLAMP
(KCL730)

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 BLOCK, CLAMP
(KCL768)
M12x1.75 Tap Thru'
Ø10.3 Drill Thru'
2-Ø9 Drill Thru'
Ø14 C/B Dp9
60
15 30 15 20

16.891
10

10
9

22.25

15°
5.359
30 30

3.4 53.2 3.4

SUPPT, CLAMP
(KCL738)

53
9.715

15°
3.15

24.5

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4. Parts List.
4-1.Parts List

Complete Assembly Illustration

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Illustration of Turret Disc & Curvic

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Illustration of Gear box

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Illustration of Motor & Sensor & shafts for Index & Milling

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No. Article Number Article Name Spec Q'ty Remarks
1 SPPL01PT116 PT PLUG SPPL01PT116 1
2 SPBO03006030 SCREW, H/S CAP DIN912 xM 6x30 8
3 K1555M000300 NAME PLATE,12각 K15.55M.0003.0X 1 GC25
4 SPPL01PT18 PT PLUG SPPL01PT18 26
5 SPOR011AP009 O-RING SPOR011AP009 18
6 SPOR01AS568A264 O-RING OR 190.09x3.53x 1
7 SPOR12094.4085001.7 BACK UP RING SPOR12094.4085001.7 1 TEFRON
8 SPOR02Q4340 QUAD RING SPOR02Q4340 1
9 SPBO03006012 SCREW, H/S CAP DIN912 xM6xL12 4
10 K7055M000100 PLATE,GUIDE K70.55M.0001.2X 1 SM45C
11 MPNU01ZMV030 LOCK NUT ZMV30 M30x1.5 1 YHB
12 K1755M000800 SHAFT, CERNTER K17.55M.0008.00 1 SCM415
13 K0112M003900 FRAME K01.12M.0039.04 1 GC30
14 SPOR011AG090 O-RING OR 1AG 90xx 2
15 K3140M000500 COVER, OUT-SIDE K31.40M.0005.01 2 SM45C
16 SPBO05004008 SCREW, BUTTON H/S CAP BUTTON xM 4x08 1
17 SPBO03010080 SCREW, H/S CAP DIN912 xM10x80 6
18 SPNU01008001.0 NUT DIN934 xM08x1.0x 6
19 MPSW01FL7M2J6HD PROXIMITY SWITCH FL7M-2J6HD xx 2
20 K7155M000100 SUPPORT,BEARING K71.55M.0001.1X 1 SM45C
21 SPBO03005012 SCREW, H/S CAP DIN912 xM5x12 2
22 MPSW01FL7M2K6H PROXIMITY SWITCH FL7M-2K6HD xx 1
23 K6128A282801 COUPLING, FLEXIBLE K61 28 A 2828 00 1
24 SPBO03006025 SCREW, H/S CAP DIN912 xM 6x25 22
25 SPPI01010030 PARALLEL PIN SPPI01010030 2
26 K3155M002900 FRAME COVER K31.55M.0029.02 1 SM45C
27 SPWS02010000 WASHER, SPRING DIN127-A10xx 8
28 SPBO03010035 SCREW, H/S CAP SPBO03010035 8
29 MOTOR, SPINDLE FANUC βi 3_10000 1
30 SPPI02010035 PIN TAPER SPPI02010035 4
31 SPBO03010030 SCREW, H/S CAP DIN912 xM10x30 10
32 K0355M000300 DISC,BMT55 K03.55M.0003.02 1 SM45C
33 K1055M000200 FLANGE, FRONT K10.55M.0002.1X 1 SM45C
34 SPOR04TC105135014 OIL SEAL TC 105x135x14 1
35 DRG114F101009 COLLAR DRG 114Fx101x9 1 SM45C
36 MPBE016821 BEARING BALL 6821 105x130x13 1
37 SPOR01AS568A172 O-RING OR 209.8x2.62x 1

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38 SPOR07210220005 OV-SEAL OV 210x220x5 1
39 SPOR011BP012 O-RING OR 1BP 12xx 6
40 SPBO03005015 SCREW, H/S CAP DIN912 xM 5x15 6
41 SPBO03010100 SCREW, H/S CAP DIN912- M10 x 100 6
42 SPPI02010040 PIN TAPER DIN EN 22 339 x10x40 2
43 K1155M000300 FLANGE, DISC K11.55M.0003.01 1 GC30
44 K7130M000100 PLATE, SUPPORT K71.30M.0001.01 1 SM45C
45 SPOR011AP007 O-RING OR 1AP 7xx 1
46 SPOR011AP004 O-RING OR 1AP 4xx 2
47 SPOR011AP005 O-RING SPOR011AP005 1
48 K7255M000100 SPACER,GEAR BOX K72.55M.0001.1X 1 SM45C
49 K2255M000100 SHAFT,MIAN K22.55M.0001.4X 1 SM45C
50 SPOR02Q4430 QUAD RING Q4430x129.54x7.00 1
51 SPOR011BP080 O-RING OR 1BP 80xx 2
52 K6012M000100 CURVIC COUPLING 2 K60.12M.0001.05(PX) 1 SCM415
53 SPOR011BP105 O-RING OR 1BP 105xx 1
54 K1230M000100 FLANGE, IN-SIDE K12.30M.0001.04 1 SM45C
55 K8910M251500 PISTON PIN K89.10M.2515.00 1 SM45C
56 SPBO03012030 SCREW, H/S CAP DIN912 xM12x30 8
57 K6012M000100 CURVIC COUPLING 3 K60.12M.0001.05(PVI) 1 SCM415
58 SPPI01010020 PIN PARALLEL DIN6325 x10x20 1
59 K8965C000100 PIN, SPINDLE K89 65 C 0001 00 2 SM45C
60 K6012M000100 CURVIC COUPLING 1 K60.12M.0001.05(PVO) 1 SCM415
61 SPCS02R047 RING, C-type DIN472 J47xx 1
62 DRG036030003 COLLAR DRG 36x30x3 1 SM45C
63 MPBE016906ZZ BEARING, BALL 6906ZZ 30x47x9 2
64 SPOR011AP006 O-RING SPOR011AP006 2
65 K0840M000100 DOG, SENSOR K08.40M.0001.2 1 SM45C
66 K8830C000300 SPRING K88.30C.0003.0 1 SWP
67 SPBO03006015 SCREW, H/S CAP DIN912 xM 6x15 10
68 K0740M000100 BRACKET, SENSOR DOG K07.40M.0001.1 1 SCP1
69 MPBE016006ZZ BEARING, BALL 6006ZZ 30x55x13 2
70 K0755M000200 PLATE, ORIENTATION K07.55M.0002.0X 1 SCP415
71 K0855M000300 DOG ORIENTATION K08.55M.0003.03 1 SM45C
72 SPBO03004008 SCREW, H/S CAP DIN912 xM 4x 8 1
73 SPTI01DA2S8 TIE MOUNTS SPTI01DA2S8 1
74 SPPL01PT14 PT PLUG DIN906 xPT1_4xL6 1
75 K0555M000300 BRACKET, MILL MOTOR K05.55M.0003.0X 1 SM45C

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76 SPDI01DB004M010 DISTRIBUTOR DB4 M10 1
77 SPNE02APT12PT34 ADAPTER-A HOSE PT1/2XPT3/4_A 1
78 SPDI01SUBDB004 ELBOW DISTRIBUTOR_2 2
79 SPNE02APT38PT38 ADAPTER-A HOSE PT3/8XPT3/8_A 2
80 K9665M000300 SERIAL PLATE K96.65M.0003.01 1 AL t0.8
81 SPBO12002.5007.3 RIVET SPBO12002.5007.3 4
82 MPBE016206ZZ BEARING BALL 6206ZZ 30x62x16 2
83 SPCS02R062 RING,C-type SPCS02R062 1
84 K5455M000100 TIMING PULLEY K54.55M.0001.4X 1 SM45C
85 MPBT012505GT655 TIMMING BELT 250-EV5GT-655 1
86 K8155M000200 HOUSING, ADJUSTABLE K81.55M.0002.2X 1 SM45C
87 K5155M000200 GEAR. SHAFT K51.55M.0002.0X 1 SCM415
88 DRG038030072.5 COLLAR DRG 38x30x72.5(1) 1 SM45C
89 MPLE02300028032 LOCKING ELEMENT SWLE300 xx 28X32 2
90 K3565C000100 RETAINER K35.65C.0001.4 1 SM45C
91 MOTOR,SERVO Fanuc β8-3000i 1
92 SPBO03008030 SCREW, H/S CAP DIN912 xM 8x30 4
93 SPKE01006006028 KEY, SQUARE-PARALLEL DIN6885 B 6x6x28 1
94 K5340M000100 PULLEY, MOTOR K53.40M.0001.5 1 SUS303
95 K3350C000100 CAP, MOTOR K33.50C.0001.00 1 SHP1
96 SPWS02004000 WASHER, SPRING DIN127-A 4xx 2
97 SPBO03004015 SCREW, H/S CAP DIN912 xM 4x15 2
98 K0620S001600 BRACKET, SERVO MOTOR K06.20S.0016.2X 1 SM45C
99 SPNU09008000 NUT DIN934 xM08x 2
100 SPBO07008030 SET SCREW, FLAT END DIN913 xM 8x30 2
101 SPWS01010000 WASHER, PLANE SPWS01010000 4
102 SPBO07004006 SET SCREW, FLAT END DIN913 xM 4x 6 1
103 SPBO08005012 SET SCREW, CYLD END M5xL12 1
104 K2540C000200 ADAPTER, COOLANT K25.40C.0002.08 1
105 SPBO03005045 SCREW, H/S CAP SPBO03005045 3
106 SPOR011AP014 O-RING 1AP14 2
107
108 SPOR12016020001.25 RING, BACK UP BACK UP 16x20x1.25 1
109 K8565C000100 NOZZLE, COOLANT K85.65C.0001.08 1
110 SPOR011AP016 O-RING 1AP16 2
111 SPOR011AP004 O-RING 1AP4 1
112 SPOR02Q4336 RING, QUAD Q4336 1
113 KBR085075.6001.7 RING, BACK UP 85x75.6x1.7(Q4336용) 1

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114 SPBO03010090 SCREW, H/S CAP DIN912 xM10x90 4
115 SPOR011AP009 O-RING SPOR011AP009 1
116 SPPL01PT18 PT PLUG SPPL01PT18 1
117 SPOR01AS568A131 O-RING OR 42.52x2.62x 1
118 SPBO07004005 SET SCREW, FLAT END DIN913 xM 4x 5 2
119 SPKE01006006012 KEY, SQUARE-PARALLEL DIN6885 B 6x6x12 1
120 MPOR01G045052004 OIL SEAL G 45x52x4 1
121 MPBE027007A5 BEARING, A/C/B 7007A5TYSUMP4 35x62x14 1
122 K2055M000200 SPINDLE,DRIVE K20.55M.0025.00 1 SCM415
123 DLR40706 COVER,GEAR BOX DLR40706 1 BrC2
124 SPBO05005008 SCREW, BUTTON H/S CAP BUTTON xM 5x08 2
125 SPOR01062001.5 O-RING OR 62x1.5x PERBUNAN 1
126 MPOR01G042052004 OIL SEAL G 42x52x4 1
127 DRG045F035009 COLLAR DRG 45Fx35x9(1) 1 SCM415
128 SPOR01AS568A036 O-RING OR 60.05x1.78x 1
129 SPKE02006006016 KEY, BOTH ROUND DIN6885 A 6x6x16 1
130 DRG037030005 COLLAR DRG 37x30x5 1 SM45C
131 DRG047040005 COLLAR DRG 47x40x5 1 SM45C
132 K3030M000100 COVER K30.30M.0001.01 1 SM45C
133 SPBO03005020 SCREW,H/S CAP DIN912 xM 5x20 4
134 MPOR01G035042004 OIL SEAL G 35x42x4 1
135 K2030M001000 SHAFT, DRIVE K20.30M.0010.01 1 SCM415
136 MPBE016906ZZ BEARING, BALL 6906ZZ 30x47x9 3
137 DRG036020004 COLLAR DRG 36x20x04 1 SM45C
138 GS19-19-002 BELVEL GEAR GS19-19-002 1 SCM415
139 SPBO03006040 SCREW,H/S CAP SPBO03006040 1
140 SPBO07008008 SET SCREW, FLAT END DIN913 xM 8x 8 1
141 SPPL01PT116 PT PLUG SPPL01PT116 1
142 SPNE11003.9010.8 INSERT PP003.9010.8 xx 1 BrC2
143 MPNU01KM004 LOCK NUT KM04 32x6x M20X1.0 1
144 SPOR01049.5002 O-RING OR 49.5x2.0x 1
145 SPOR01S067 O-RING OR S 67xx 1
146 K3055M000100 COVER, BODY K30.55M.0001.2 1 SM45C
147 SPBO03006012 SCREW, H/S CAP DIN912 xM6xL12 4
148 MPBE027204A5 BEARING, A/C/B 7204A5TYSUMP4 20x47x14 1
149 DRG041.2F020048.75 COLLAR DRG 41.2Fx20x48.75 1 SM45C
150 K8055M000200 HOUSING,GEAR BOX K80.55M.0002.13 1 SM45C

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5. Troubleshooting Checklist
5-1. Self-diagnosis (mechanical elements)

No. Category Symptoms & parts Checklist and troubleshoot Procedure No.
1 Cutting Check the insert in Check the fastening or wear on
vibration use. the insert.
1-1 Fastening of Check whether the bolts are
frames. fastened securely.
1-2 Holder clamp Check if the holder is properly A-1
assembly-related. clamped.
2 Index error Not turning after 1)Check the cabling is securely A-2
unclamp. connected for Unclamp
proximity switch.
2)Check CURVIC COUPLING
for any hindrance material.
→ Unclamp the disc by force,
and no turning remains if the
diagnosis is right.
A-5
3)Excessive stress or snap on
motor belt.
2-1 Interruptive noise 1)Wear or chip on the gears
while turning. 2)Proximity switch not aligned A-3
to full unclamp.
→Unclamp the disc and
realign the switch.
3)Check the gear back-lash A-7

between Curvic gear and

Gear shaft.
2-2 Wobbling movement 1)Reset the index point of the
during clamp after machining center.
index. 2)Adjust the parameter of
motor load for wobbling at
indexing.
(Refer to the operation manual
of the product concerned.)
2-3 Clamp operation Check the cabling for Clamp A-2
malfunction proximity switch.

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No. Category Symptoms & parts Checklist and troubleshoot Procedure No.
3 MILL(Rotating Orientation check Check if the signal of orientation is A-4
Tool) signal actively transmitting.
malfunction
3-1 Orientation position The direction of drive shaft of A-4
malfunction mill is not positioned right.
3-2 Abnormal noise Check on the wear of gears A-8
happens during and drive shafts.
milling. A-8

3-3 Drive shaft is not 1)Check if the coupling is not A-6

working while the Fastened tightly.
motor is rotating. 2)Gear box have been
damaged A-8
by wear of Bevel gear or crash
3-4 Uneven surface or Check the precision of holder
inferior precision. 1)Check the bearing preload–
Diagnosis correct if there is
the extreme deflection
toward axis
2)Center discrepancy caused
by disc clash.
3)Check the locking of drill/
endmill to the collet.
3-5 Not turning at all as Make your machine(X/Z) to
commanded. be at the Origin position again
4 Clamp/ Check the clamp
unclamp cable.
inversed
5 Coolant Check clogging of the piping.
supply
6 Replacement A-9
of spindle
motor
7 Reset Disc’s Disc stopped at You should reset the Disc’s A-10
Origin posi- abnormal position origin position when index
tion. when command. motor or belt is replaced.

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 5-2 Itemized Maintenance Procedure
A-1. Holder Clamp Illustration
Be pay attention at the marked Length regarding each screw sizes to fasten securely

TOOL SIZE CLAMPING SCREW(M) Limit length(L)

BMT45 M8 Less then 14
BMT55 M10 Less then 17
BMT65 M12 Less then 21
BMT75 M12 Less then 21
BMT85 M12 Less then 21

A-2. Checking the cabling of proximity switch

There are two ways of checking the cabling of the proximity switch. First, check the signal
changes between “0”-“1” on the parameter when the normal proximity is realized.
Secondly, open the cover illustrated in the picture below to check the proximity switch. There is
the Unclamp near the disc and please replace the wiring of Clamp Check switch next to it if it is
not “on” when the proximity is made.

Maintenance COVER

Position dog

For clamp s/w

For unclamp s/w

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A-3. Adjusting the proximity switches for clamp & unclamp.

1 2 The proximity switch as

illustrated in the picture
(Unclamp) should be
assembled as pushed to the
far left as possible at Unclamp
position of DOG. (To be

A-4. How to reset of Orientation error by Drive shaft’s stop position or Dog.

1. Drive shaft와 Coupling의 dog부의 상태를 아래 그을 참조해 정상과 비정상상태를 확인해야

합니다.

The state of normal position

Slotted groove or
set-screw on Dog or
Coupling ;
This for position of
The Red light “ON” orientation
A state of Vertical “Normal”

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 The state of abnormal position

Slotted groove or
The Red light “OFF”
set-screw on Dog or
Coupling;
A state of not Vertical “Abnormal”
The position of
abnormal orientation

2. If the position of either the drive shaft or orientation dog is the state of abnormal.
You need to readjust it as the next procedures.

How to readjust the positions of Orientation dog and the Drive shaft.

1. Make sure the mill spindle motor moveable by hand through the parameter operation.
2. Unfasten a little the indicated set screw to make the orientation dog moveable.

Set screw

Orientation dog

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 3. Insert the indicated FIXTURE into the Disc and then, clamp the Fixture by screws.
Adjust the Orientation dog until the Switch’s red light “ON”

Fixture
(Refer to Page41)

4. Fasten tightly the indicated Set screw.

Set screw

5. Make the power of mill spindle motor on and command “orientation” on operation panel.
Then, the spindle motor turns and stops at its previous original position.
Most of those cases, the orientation position of mill spindle motor tends to lose.

6. In case of its position is stated with abnormal, you need to revise the value of the mill
spindle Motor’s correct orientation position through the machine parameter.
Confirm the drive shaft as the picture below.

A state of Vertical “Normal”

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7. After unclamp the Disc through machine parameter, confirm the abnormal noise at the drive
shaft and holder’s shaft end indexing the Disc to right and left manually.
If the abnormal noise happens, please put the value into parameter again.

Driven holder

If the drive shaft is not at the normal position,

it makes crash noise between Drive shaft
and holder’s shaft end.

A-5. How to adjust the tension of belt

BELT

Set screw for adjusting tension

of belt

BELT Spec. Deflection Weight Load(kgf)

250-EV5GT-655 2.17 2.2

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 A-6. Dimensions for assembling motor pulley and Coupling

Motor pulley for Index motor

Coupling for Spindle motor

One screw on Coupling

Before you attach Spindle motor, make sure that indicated two screws to be
unfastened
After you finish attach Spindle motor, please fasten tightly indicated two screws.
Otherwise, Drive shaft may not be turned while spindle motor is working.

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 A-7. How to adjust Eccentric housing for Disc index

When the gear shaft for the index was replaced and disc Index makes not good noise during
the Disc turns, you can adjust the distance between Curvic gear and Gear shaft by our particular
unit.
Please refer to the next below.

Eccentric housing
Screw for clamping housing

Pulley, index

Gear shaft Indicator

1) Make the Pulley and Gear shaft fastened

2) Unfasten a little all screws of Eccentric housing.
3) Install the Indicator on Pulley’s hole.
4) Adjust the Eccentric by shaft until the indicator’s value makes the proper
range(0.2mm to 0.25mm) turning with full stroke of the pulley to right and left direction.
5) You have got finished then, fasten the all screws of Eccentric housing.

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A-8. How to replace and adjust Gear box

1. Detach Name plate and adapter until you can see the Gear box.

2. Replace the Gear box by new one or repaired one.

3. If you changed particular parts only from the Gear box, you can use it without some
procedures through the Pins. Because the housing of the Gear box could keep its original
position by Pins.

4. If you replaced the Gear box ass’y, please follow some procedures below.
1) Fasten the Gear box with each screws.
2) Clamp the Disc.
3) Unfasten the gear box until it is possible to move a little and confirm oil leak around the
Gear box.
4) Adjust the Gear box until the Drive shaft have a parallel state against driven holder.
; You can find the proper value by Indicator.
(1) Turn the Gear box to left and then, set the dial to “0”.
(2) Turn the Gear box to right and then, confirm the value.
(3) Position the Gear box at half position by Indicator.
(4) Fasten the Gear box tightly.
(5) Confirm the noise turning mill spindle with 500~1,000rpm.

Screw for clamping Gear box

Gear box

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 A-9. How to assemble Spindle motor

Make sure that the Coupling must to be assembled to transfer shaft prior to Assemble Spindle
motor to Coupling

1. Open the maintenance cover.

2. Insert the half side of Coupling into transfer shaft until it will stop at left side coupling.
3. Fasten tightly the screw at the right side of Coupling through the indicated hole

Screw for the right-side

Hole for clamping coupling

of right-side

Screw for the left-side

Maintenance cover

Coupling for right-side

Coupling for left-side

X
Please do not fasten coupling on Spindle motor
Prior to attach to Frame.

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 A-10. How to reset of Disc’s Nr.1 position

If you disassemble Index motor from Frame duo to replacement of wearing belt,
Damaged motor or Disc, you need to set the Disc on Nr.1 position again.
When it come to setting on Nr.1, please contact with business office where youpurchased.
Because the method of setting is different according to each makers of controller.

5-3 Notice before placing service parts

Please be sure to provide the serial number of the our Mill turret unit and the Repairing parts
number when ordering for service parts as designs and the applicable parts are subject to
change for upgrade without prior notice.

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6. Daily checklist for self-maintenance
No Checklist Period Remarks

1 Is there any oil leakage? Daily

Is there any foreign material in
2 Daily Cleaning
the Drive Shaft of Disc?
Alignment between live
Is the live tool noise louder than tool holder and shaft of
3 Daily
before? gear box is gone. Bearing
or bevel gear is damaged.
Check after 6 months
and again after 3
4 Is the tension of belt correct?
years. Conduct
periodic checks.
Using a plastic plug similar
to the standard Steel Plug
Is the plug for Disc Holder a recommended here can
5 Daily
standard product? damage the bearing and
cause the leakage of
cutting oil.
Incorrect precision may
6 Is the shaft of Holder clean? Daily occur as wears inside the
Disc are caused.
Erroneous precision may
Is the Taper side of the spindle of
7 Daily occur as chipping of Taper
the rotation tool clean?
side may be caused.
Is the O-ring assembled before Prevent the leakage of
8 Daily
inserting Holder? cutting oil into Disc.
Is there no detachment of some
Prevent the cutting oil
9 covers for preventing cutting oil Daily
inflow into the turret.
inflow?
Prevent the twisting of
Do you use excessive force in
10 Daily bearings at the end of
assembling the Holder?
rotating tool shaft
Do you use the spanner and the Damages to the coupling
11 nut when disassembling collet nut Daily of rotating tool and the key
of rotating tool? of Drive Shaft.
If there is interruption
during indexing or too
Is there no damage for indexing
12 Once/Month much tension for belt, belt
belt?
can be damaged →
replace

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7. SPARE PARTS
No. Article Number Article Name Spec Q'ty Remarks
1 DRG036020004 COLLAR DRG 36x20x04 1 SM45C
2 DRG036030003 COLLAR DRG 36x30x3 1 SM45C
3 DRG037030005 COLLAR DRG 37x30x5 1 SM45C
4 DRG038030072.5 COLLAR DRG 38x30x72.5(1) 1 SM45C
5 DRG041.2F020048.75 COLLAR DRG 41.2Fx20x48.75 1 SM45C
6 DRG045F035009 COLLAR DRG 45Fx35x9(1) 1 SCM415
7 DRG047040005 COLLAR DRG 47x40x5 1 SM45C
8 DRG114F101009 COLLAR DRG 114Fx101x9 1 SM45C
9 KBR085075.6001.7 RING, BACK UP 85x75.6x1.7(Q4336용) 1
10 MPBE016006ZZ BEARING, BALL 6006ZZ 30x55x13 2
11 MPBE016206ZZ BEARING BALL 6206ZZ 30x62x16 2
12 MPBE016821 BEARING BALL 6821 105x130x13 1
13 MPBE016906ZZ BEARING, BALL 6906ZZ 30x47x9 2
14 MPBE016906ZZ BEARING, BALL 6906ZZ 30x47x9 3
15 MPBE027007A5 BEARING, A/C/B 7007A5TYSUMP4 35x62x14 1
16 MPBE027204A5 BEARING, A/C/B 7204A5TYSUMP4 20x47x14 1
17 MPBT012505GT655 TIMMING BELT 250-EV5GT-655 1
18 MPLE02300028032 LOCKING ELEMENT SWLE300 xx 28X32 2
19 MPNU01KM004 LOCK NUT KM04 32x6x M20X1.0 1
20 MPNU01ZMV030 LOCK NUT ZMV30 M30x1.5 1 YHB
21 MPOR01G035042004 OIL SEAL G 35x42x4 1
22 MPOR01G042052004 OIL SEAL G 42x52x4 1
23 MPOR01G045052004 OIL SEAL G 45x52x4 1
24 MPSW01FL7M2J6HD PROXIMITY SWITCH FL7M-2J6HD xx 2
25 MPSW01FL7M2K6H PROXIMITY SWITCH FL7M-2K6HD xx 1
26 SPBO03004008 SCREW, H/S CAP DIN912 xM 4x 8 1
27 SPBO03004015 SCREW, H/S CAP DIN912 xM 4x15 2
28 SPBO03005012 SCREW, H/S CAP DIN912 xM5x12 2
29 SPBO03005015 SCREW, H/S CAP DIN912 xM 5x15 6
30 SPBO03005020 SCREW,H/S CAP DIN912 xM 5x20 4
31 SPBO03005045 SCREW, H/S CAP SPBO03005045 3
32 SPBO03006012 SCREW, H/S CAP DIN912 xM6xL12 4
33 SPBO03006012 SCREW, H/S CAP DIN912 xM6xL12 4
34 SPBO03006015 SCREW, H/S CAP DIN912 xM 6x15 10
35 SPBO03006025 SCREW, H/S CAP DIN912 xM 6x25 22

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36 SPBO03006030 SCREW, H/S CAP DIN912 xM 6x30 8
37 SPBO03006040 SCREW,H/S CAP SPBO03006040 1
38 SPBO03008030 SCREW, H/S CAP DIN912 xM 8x30 4
39 SPBO03010030 SCREW, H/S CAP DIN912 xM10x30 10
40 SPBO03010035 SCREW, H/S CAP SPBO03010035 8
41 SPBO03010080 SCREW, H/S CAP DIN912 xM10x80 6
42 SPBO03010090 SCREW, H/S CAP DIN912 xM10x90 4
43 SPBO03010100 SCREW, H/S CAP DIN912-M10 x 100 6
44 SPBO03012030 SCREW, H/S CAP DIN912 xM12x30 8
45 SPBO05004008 SCREW, BUTTON H/S CAP BUTTON xM 4x08 1
46 SPBO05005008 SCREW, BUTTON H/S CAP BUTTON xM 5x08 2
47 SPBO07004005 SET SCREW, FLAT END DIN913 xM 4x 5 2
48 SPBO07004006 SET SCREW, FLAT END DIN913 xM 4x 6 1
49 SPBO07008008 SET SCREW, FLAT END DIN913 xM 8x 8 1
50 SPBO07008030 SET SCREW, FLAT END DIN913 xM 8x30 2
51 SPBO08005012 SET SCREW, CYLD END M5xL12 1
52 SPBO12002.5007.3 RIVET SPBO12002.5007.3 4
53 SPCS02R047 RING, C-type DIN472 J47xx 1
54 SPCS02R062 RING,C-type SPCS02R062 1
55 SPDI01DB004M010 DISTRIBUTOR DB4 M10 1
56 SPDI01SUBDB004 ELBOW DISTRIBUTOR_2 2
57 SPKE01006006012 KEY, SQUARE-PARALLEL DIN6885 B 6x6x12 1
58 SPKE01006006028 KEY, SQUARE-PARALLEL DIN6885 B 6x6x28 1
59 SPKE02006006016 KEY, BOTH ROUND DIN6885 A 6x6x16 1
60 SPNE02APT12PT34 ADAPTER-A HOSE PT1/2XPT3/4_A 1
61 SPNE02APT38PT38 ADAPTER-A HOSE PT3/8XPT3/8_A 2
62 SPNE11003.9010.8 INSERT PP003.9010.8 xx 1 BrC2
63 SPNU09008000 NUT DIN934 xM08x 2
64 SPOR01049.5002 O-RING OR 49.5x2.0x 1
65 SPOR01062001.5 O-RING OR 62x1.5x PERBUNAN 1
66 SPOR011AG090 O-RING OR 1AG 90xx 2
67 SPOR011AP004 O-RING OR 1AP 4xx 2
68 SPOR011AP004 O-RING 1AP4 1
69 SPOR011AP005 O-RING SPOR011AP005 1
70 SPOR011AP006 O-RING SPOR011AP006 2
71 SPOR011AP007 O-RING OR 1AP 7xx 1
72 SPOR011AP009 O-RING SPOR011AP009 18
73 SPOR011AP009 O-RING SPOR011AP009 1

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 74 SPOR011AP014 O-RING 1AP14 2
75 SPOR011AP016 O-RING 1AP16 2
76 SPOR011BP012 O-RING OR 1BP 12xx 6
77 SPOR011BP080 O-RING OR 1BP 80xx 2
78 SPOR011BP105 O-RING OR 1BP 105xx 1
79 SPOR01AS568A131 O-RING OR 42.52x2.62x 1
80 SPOR01AS568A036 O-RING OR 60.05x1.78x 1
81 SPOR01AS568A172 O-RING OR 209.8x2.62x 1
82 SPOR01AS568A264 O-RING OR 190.09x3.53x 1
83 SPOR01S067 O-RING OR S 67xx 1
84 SPOR02Q4336 RING, QUAD Q4336 1
85 SPOR02Q4340 QUAD RING SPOR02Q4340 1
86 SPOR02Q4430 QUAD RING Q4430x129.54x7.00 1
87 SPOR04TC105135014 OIL SEAL TC 105x135x14 1
88 SPOR07210220005 OV-SEAL OV 210x220x5 1
89
90 SPOR12016020001.25 RING, BACK UP BACK UP 16x20x1.25 1
91 SPOR12094.4085001.7 BACK UP RING SPOR12094.4085001.7 1 TEFRON
92 SPPI01010020 PIN PARALLEL DIN6325 x10x20 1
93 SPPI01010030 PARALLEL PIN SPPI01010030 2
94 SPPI02010035 PIN TAPER SPPI02010035 4
95 SPPI02010040 PIN TAPER DIN EN 22 339 x10x40 2
96 SPPL01PT116 PT PLUG SPPL01PT116 1
97 SPPL01PT116 PT PLUG SPPL01PT116 1
98 SPPL01PT14 PT PLUG DIN906 xPT1_4xL6 1
99 SPPL01PT18 PT PLUG SPPL01PT18 26
100 SPPL01PT18 PT PLUG SPPL01PT18 1
101 SPTI01DA2S8 TIE MOUNTS SPTI01DA2S8 1
102 SPWS01010000 WASHER, PLANE SPWS01010000 4
103 SPWS02004000 WASHER, SPRING DIN127-A 4xx 2
104 SPWS02010000 WASHER, SPRING DIN127-A10xx 8
Memo.

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8. Accessory
1) WRENCH

2) SPANNER

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3) PLUG

4) DRILL SOCKET

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5) COLLET

6) Orientation setting holder

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 E001-0010FMV Rev2

SB122010523 Rev2

HYDRAULIC POSI-CLAMPER

INSTRUCTION MANUAL

MODEL: PC – 140 Y – 01
PC – 200 Y – 01
PC – 300 Y – 01
PC – 450 Y – 01
PC – 650 Y– 01

Read and understand this instruction manual before operating

the hydraulic posi-clamper.
Improper operation or servicing might cause a serious accident.

SANYO SHOJI CO., LTD.

HEAD OFFICE: 2-29-2, Minami Kaneden, Suita City, Osaka Japan
TEL: (06)6384-1212 FAX: (06)6338-1415

TOKYO OFFICE: 4-9-3, Shiba, Minato-ku, Tokyo Japan

TEL: (03)3769-3434 FAX: (03)3769-1033

NAGOYA OFFICE: 1-20-25, Nishiki, Naka-ku, Nagoya-city, Aichi Japan

TEL: (052)231-3455 FAX: (052)231-3566
 E001-0010FMV Rev2

TABLE OF CONTENTS

1. INTRODUCTION ............................................................................................................... 2

2. WARNINGS (Make sure to observe them) ......................................................................... 2

3. CAUTIONS ......................................................................................................................... 2

4. GENERAL DESCRIPTION ................................................................................................ 2

4-1. Components................................................................................................................ 3
4-2. Operation.................................................................................................................... 3

5. SPECIFICATIONS ............................................................................................................. 4

6. INSTALLATION ................................................................................................................. 5
6-1. Installing the disc....................................................................................................... 5
6-2. Installing the clamper unit ........................................................................................ 5
6-3. Air bleeding ................................................................................................................ 6

7. MAINTENANCE ................................................................................................................ 7
7-1. Checking clamper unit bolts and bolts for securing clamper unit to bracket
for loose ...................................................................................................................... 7
7-2. Checking clamper and tubing for oil leak.................................................................. 7
7-3. Checking disc sliding surface..................................................................................... 7
7-4. Checking pads for wear.............................................................................................. 8

8. EXPENDABLE PARTS AND REPLACEMENT PROCEDURE ........................................ 8

8-1. Expendable parts ....................................................................................................... 8
8-2. Procedure for replacing pad assembly ....................................................................... 9

9. TROUBLESHOOTING GUIDE........................................................................................ 11

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 E001-0010FMV Rev2

1. INTRODUCITON

This manual is written to give the user necessary operating, routine servicing and preventive
maintenance instructions for the hydraulic posi-clamper (hereinafter referred to as “the
clamper”). Read this manual thoroughly and become completely familiar with the clamper
unit before proceeding with operating and servicing.

2. WARNINGS

2-1. Use caution to prevent the disc from rotating when carrying out periodic servicing.
If the disc rotates when carrying out periodic servicing (when the disc is not clamped),
a serious accident may occur. Apply a brake in other system or a mechanical lock
before carrying out servicing. After making sure that the disc won’t rotate, perform
inspection and servicing.

2-2. Keep the disc sliding surface clean.

Remove oil, grease and rust from the disc sliding surface. Failure to do so will cause a
poor clamping force, leading to an unexpected mechanical movement or action and in
the worst case a serious accident. See “7-3. Checking disc sliding surface” on page 6.

3. CAUTIONS

3-1 . Use general mineral oil (hydraulic oil) with an ISO viscosity index of 32 or equivalent
for this clamper. Never under any circumstances, use brake fluid.

3-2. Keep water away from the clamper and the disc.
If there is a possibility of exposure to water, use a cover or equivalent to protect against
it.

3-3. Adjust the supply pressure so that it becomes zero when the clamping force is released,
to secure a clearance between the pads and the disc.

4. GENERAL DESCRIPTION

This hydraulic posi-clamper is designed to clamp the disc from both sides with pads (friction
materials) by supplying oil pressure. Its compact design makes it easy to install and save
space.

When the clamper is released, the clearance between the pads and disc is secured by both the
spring force and the restoring force of the packings which have been compressed and
deformed during clamping, thus requiring no adjustment.

See next page for the unit’s components and its operation.

-2-
 E001-0010FMV Rev2

4-1. Components

11 PAD 2
10 MODEL PLATE 1
9 BLEED SCREW 1
8 STEEL BALL 1
7 RETURN SPRING 2
6 PISTON 2
5 PACKING 2
4 O RING 1
3 HEX.SOCKET HEAD 2
BOLT
2 BODY(T) 1
1 BODY 1
No Part Name Q’ty

4 – 2. Operation

(1) When oil pressure is supplied through the oil supply port of the hydraulic posi-clamper,
the pistons advance to force the pads (friction materials) against the disc,
producing clamping force.
(2) When the oil pressure is removed, the pistons and pads retreat due to the forces
of both the packings which have been compressed and deformed during clamping,
and the return springs so that a clearance is created between the pads and disc,
thus releasing the clamping force.

Note: The clamper is originally designed for use as a holding and emergency brake;
however, it can be used as a usual service brake, depending on the quantity of
absorbed energy and operating frequency.
Consult us if you want to use the clamper as a service brake or about the details of
emergency braking application.

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 E001-0010FMV Rev2

5. SPECIFICATIONS

Model PC-140Y PC-200Y PC-300Y PC-450Y PC-650Y

Disc outer
50 to 100 to 100 to 150 to 260 to
diameter (mm)
Disc thickness
3 6 6 10 10
(mm)
Pad
measurements 18 x 13 x 4 25 x 17x 4 32 x 20 x 5 48 x 30 x 5 70 x 50 x 5
(mm)
[L x W x T]
Pad surface area
2.16 4.06 6.10 14.07 35.12
(cm 2)
Pad wear
2 2 2 2 2
allowance (mm)
Cylinder
14 20 30 45 65
diameter (mm)
Cylinder area
154 314 707 1590 3317
(mm2)
General General General General General
mineral oil mineral oil mineral oil mineral oil mineral oil
Fluid to be used (Hydraulic oil) (Hydraulic oil) (Hydraulic oil) (Hydraulic oil) (Hydraulic oil)
ISO viscosity ISO viscosity ISO viscosity ISO viscosity ISO viscosity
grade 32 grade 32 grade 32 grade 32 grade 32
Operating
0.15 - 5 0.1- 05 0.1- 5 0.05- 5 0.05- 5
pressure (MPa)
Tapped hole for M14 x depth
M6 x depth 16 M8 x depth 15.5 M10 x depth 19 M16 x depth 26
mounting (mm) 21.5

Weight (kg) 0.20 0.35 0.69 1.3 3.3

Pad model DB-0480-01 DB-0481-01 DB-0482-01 DB-0483-0 1 DB-0484-01

Mechanical life 3 million of 3 million of 3 million of 3 million of 3 million of

of body operations operations operations operations operations
3 million of 3 million of 3 million of 3 million of 3 million of
Life of packing operations operations operations operations operations
or 5 years or 5 years or 5 years or 5 years or 5 years

Braking force

-4-
 E001-0010FMV Rev2

Note: Braking force = 2 x 0.4 x (operating pressure x cylinder area – 20N)

0.4 represents the frictional coefficient of the pads obtained after fitting.
20N represents return spring force.
In the case of non-backlash, the braking force will be lower than the values shown
above.

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 E001-0010FMV Rev2

6. INSTALLATION

6-1. Installing the disc

1) Install the disc with the axial runout not exceeding 0.05 mm at the periphery of the
disc.

2) Install the disc securely on the rotating shaft to prevent its axial displacement.

3) Wipe away oil, grease, dirt, etc. from the disk surface with alcohol or thinner.

6-2. Installing the clamper unit

1) The clamper unit can be installed in all directions (vertical, horizontal, up/down).
However, it is advisable to install the clamper with the bleed screw positioned
upward so that air bleeding is easily and securely carried out.

2) Install the clamper so that the distance (a) between the clamper mounting bracket and
the center of the disc, and the penetration (b) into the disc are obtained as specified in
Table 1.
Make sure the bracket is parallel to the disc.
3) Select proper mounting bolts according to the size, strength grade, and the length of
threaded engagement into the tapped hole (See Table 1). Attach the clamper to the
bracket to the specified tightening torque. (Torque the 2 mounting bolts evenly.)

-6-
 E001-0010FMV Rev2

Table–1
Model PC-140Y PC-200Y PC-300Y PC-450Y PC-650Y
Dimension (a) (mm) 25 0.2 27.5 0.2 34 0.2 39.5 0.2 50 0.2
Dimension (b) (mm) 8 10 12 18 29
Mounting bolt size M6 M8 M10 M14 M16
Strength grade 4.6 or more 4.6 or more 4.6 or more 4.6 or more 8.8 or more
Dimension (c) (mm) 9 – 15 10 – 15 13 – 18 16 – 21 20 – 25
Tightening torque (N-m) 4.6 11.2 22.0 62.0 144

4) Connect the oil tubing to the oil supply port (size: Rc 1/8) of the clamper.
Support or protect the tubing if needed.
Use general mineral oil (hydraulic oil) with an ISO viscosity index of 32 or equivalent
for this clamper.
Never under any circumstances, use brake fluid.

6-3. Air bleeding

Bleed air from the interior of the clamper and the piping in the following manner:
Note that air bleeding should be performed after the clamper is installed on the disc.

1) Connect one end of a transparent vinyl hose (6 mm inner dia.) to the bleed screw
and put the other end in a container.

2) With oil pressure supplied to the clamper, loosen the bleed screw using a 10 -mm
wrench at the hex. part of the bleed screw to let oil flow out through the bleed screw.
Tighten the bleed screw just before the oil pressure becomes zero.
3) Repeat step 2) until oil coming from the bleed screw contains no air bubble.

4) After making sure there is no air bubble in the oil coming from the bleeder, tighten the
bleed screw securely. (Reference torque: 6 N-m)
5 ) Air bleeding is now over. Operate the clamper several times to check if there is no oil
leakage or malfunction of the device.

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 E001-0010FMV Rev2

7. MAINTENANCE

Periodic inspection is necessary to maintain the performance of the clamper. Be sure to

perform periodic checks.

7-1. Checking clamper unit bolts and bolts for securing to the bracket for looseness

Check the clamper unit bolts listed as No.3 in “4–1. Components” on page 3 and the bolts
attaching the clamper to the bracket for looseness.
Tighten any loose bolt to the torque as shown in the table below (applicable for both the
clamper unit bolts and the bolts for securing to the braket).

Model PC-140Y PC-200Y PC-300Y PC-450Y PC-650Y

Tightening torque (N-m) 4.6 11.2 22.0 62.0 144

7-2. Checking the clamper and tubing for oil leak

(1) Check the clamper for oil leak. If any oil leak should be found, consult us.

(2) Check tubing (including connectors) for oil leak. If any oil leak is found, retighten the
connectors or replace the tubing with new one.

7-3. Checking disc sliding surface

(1) Care should be taken not to allow oil or grease on the disc sliding surface. If the disc
sliding surface appears dirty with oil or grease, clean it with alcohol or thinner.

(2) Check the disc surface for rust or roughness. If any rust or roughness is found, correct
the surface with sand paper.

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7-4. Checking pads for wear

* Check both the right and left pads (2 pcs.).

With the disc clamped (or with oil pressure applied), look at the pad either from direction
A or B as shown in the figure below. If the “Face C” is level or near level with the “Face
D” of either of the backing plates (metal square plates bonding the pad), it suggests that
the pad is worn to its limit. Replace both the right and left pads (2 pcs.) with new ones,
referring to “8 – 2. Procedure for replacing pad assembly” on page 9 (For information on
pad models, see “8 – 1. Expendable parts ”.) .

New pad Pad wear limit

“Face C” is situated at a position inner than “Face C” is at the same level as “Face D”.
“Face D”; therefore, the backing plate is
invisible from outside.

Details of pad assembly

Note: If a brake pad which exceeds the wear limit continues to be used, the return spring will
contact the disc to damage it.

8. EXPENDABLE PARTS AND REPLACEMENT PROCEDURE

8-1. Expendable parts

[See also the component parts list (on page 3)]

Part Name & Model

Particulars PC-140Y PC-200Y PC-300Y PC-450Y PC-650Y
Pad kit
Pad (Assy) x 2
DB-0480-K01 DB-0481-K01 DB-0482-K01 DB-0483-K01 DB-0484-K01
+
Return spring x 2

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8-2. Procedure for replacing pad assembly

1) Remove the clamper from the bracket. Remove the hex. socket head bolt and divide
the body into the right and left halves.

2) Remove the return spring and the pad from each half.

3) Install the piston on each half by pushing in.

4) Install a new pad and a new return spring on each half.

When installing a new return spring , first insert the tip of the return spring into the
2 holes (2 locations) in the backing plate (square metal plate to which the pad is
attached) and then install the return spring into the groove in the two halves and
.

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5) After checking the O ring is fitted in the O ring groove in the body , assemble
the divided halves & together, using caution so as not to let the return springs
and the pads installed inside the halves & come off, with hex. socket
head bolts in the opposite sequence of Step 1).
Tighten both hex. socket head bolts to the torque specified in the Table on page 6.

6) Reinstall the clamper unit on the bracket/disc, referring to “6 – 2. Installing the

clamper” on page 5.

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9. TROUBLESHOOTING GUIDE

Clamping
force?

Clamping Oil pressure

force released? supplied?

Positive Oil pressure Pad worn to

clamping? released? the max?
Measures 1

Measures 2

Measures 3

Measures 4

Measures 6
Measures 5
Good

Measures 1 Increase oil supply pressure.

Remove oil or grease from the pad sliding surface of the disc.

Measures 2 Check disc for runout or axial displacement, and the Clamper body.

Measures 3 Check valves and electric circuit.

Measures 4 Replace pads with new ones.

Measures 5 Check oil leak.

Measures 6 Check oil supply, valves and electric circuit.

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