CNC Emco Turn 365 PDF

Emcoturn 365
Modular CNC-Turning Center for Complete Machining
Machine Description
Emcoturn 365
Ref.-No. EN 4054 Edition F2002-04
EMCO Maier Ges.m.b.H.
P.O. Box 131
A-5400 Hallein-Taxach/Austria
Phone ++43-(0)62 45-891-0
Fax ++43-(0)62 45-869 65
Internet: www.emco.at
E-Mail: service@emco.co.at
Introduction
For more than five decades EMCO has been developing wood and metal working machines
and has been successfully on the market since 1980 with computer controlled machine tools
and systems for industry and training.
Our experience over decades and new customer requirements led to the development and
the construction of the EMCOTURN 365 lathe for complete machining from blank to
components ready for installation.
Due to an optimum distribution of machining sequences high production flexibility, half

processing time and, thus, double productivity are achieved.
Due to various accessories and special equipment such as integrated swivelling loader, bar
feed and loading magazine, tool holder, tool fracture control and an external measurement
station still a higher degree of automation can be achieved.
Due to the worldwide industrial use of our machines we dispose of a service network which
covers all world areas. Immediately available service engineers, telephone service as well
as a 100 % spare part supply exceeding the 10-year obligatory provision is something
natural for us.
One of our more than 100 general representatives worldwide will inform you on particular
new developments and their retrofitting possibilities.
The present user's manual for the EMCOTURN 365 comprises the description of the machine
and the accessories, instructions and procedures for handling and realization of cleaning
and maintenance work by the user as well as stipulations to be observed for the prevention
of accidents and machine damage.
We therefore ask all machine operators to read the subject user's manual prior to start-up
and also at a later point of time and to observe the guidlines attending it as exactly as
possible. Your machine will ofer you, on the other hand, permanent operatability and long
live.
For any inquiries or proposals for improvement with a view to the present operating
instructions please get directly in touch with
EMCO MAIER Gesellschaft m. b. H.

Abteilung Technische Dokumentation
A-5400 HALLEIN, Austria
EC conformity
The CE sign certifies together with the EC declaration of conformity that the
machine and the manual correspond to the EC guideline for machines 89/392/
EEC and its modifications 91/368/EEC and 93/68/EEC.
All rights reserved, duplication only upon authorization of Messrs. EMCO MAIER
© EMCO MAIER Gesellschaft m. b. H. , Hallein/Taxach - Austria
3
4
Contents
Adequate Use ............................................................................ 9 The Main Spindle ø45 ........................................................... B10

Warranty conditions for new EMCO machines ......................... 9 Dimensions spindle connection ......................................... B10
Clamping cylinder with bore .............................................. B11
Safety recommendations ......................................................... 10 Clamping cylinder without bore ......................................... B11
Technical data of the machine - metric ................................... 13 Connection values for tensioning tubes ............................ B12
Technical data of the machine - inch ....................................... 17 Machine with clamping cylinder with bore ..................... B12
Machine with clamping cylinder without bore ................ B12
Declaration of conformity ......................................................... 21
Position of tensioning tube during the change
of clamping devices ....................................................... B13
A Installation of the machine Clamping devices - General hints ......................................... B13
Position of tensioning tube by changing clamping devices ..... B13
Machine acceptance ................................................................ A1
Clamping devices - spindle ø65 ............................................ B14
Machine number .................................................................. A1
Screwing the tensioning tube into the clamping cylinder .. B14
Electrics number .................................................................. A1
Spindle insert sleeves ........................................................ B14
Operation panel number ...................................................... A1
Order numbers ............................................................... B14
Scope of supply ....................................................................... A3 Necessary hollow-out diameter ..................................... B14
Basic machine ...................................................................... A3 Mounting the insert sleeves ........................................... B15
Tool set ................................................................................ A3 Dismounting the insert sleeves ...................................... B15
Packing ................................................................................ A3 Three-jaw power chuck ...................................................... B16
Modules ............................................................................... A3 Mounting the chuck ........................................................ B16
Transport of machine ............................................................... A4 Adjusting the minimum value "X" ................................... B17
Transport with pallet ............................................................ A4 Dimensions of the chuck ................................................ B17
Transport without pallet ....................................................... A4 Dimensions of the jaws .................................................. B18
Transport with crane ............................................................ A5 Clamping ranges of the chuck ....................................... B19
Transport safety devices ...................................................... A6 Clamping force diagram KFD-HS 175/3 ........................ B19
Installation plan, dimensions of the machine .......................... A7 Clamping force diagram KFD-HS 200/3 ........................ B20
Basic machine ...................................................................... A7 Clamping force diagram KFD-HS 250/3 ........................ B20
Machine with bar loader and chip conveyor ........................ A8 Collet chuck QUADRO-NC ................................................ B21
Machine with gantry loader and chip conveyor ................... A8 Technical data ................................................................ B21
Clamping possibilities - outline ...................................... B21
Installation criteria .................................................................... A9 Clamping variant 1 (basic variant) ................................. B22
Requirements on installation surface .................................. A9 Clamping variant 2 ......................................................... B22
Installation possibilities ........................................................ A9 Clamping variant 3 ......................................................... B22
Anchoring on the ground ................................................. A9 Mounting the collet chuck .............................................. B23
Without anchorage on the ground ................................. A10 Changing the collets ...................................................... B23
Additional criteria for installation ........................................ A10 Clamping force diagrams ............................................... B24
Electrical connection - Machines with Sinumerik 810D/840D ..... A11 End face driver ................................................................... B25
Mains connection data ....................................................... A12 Mounting the end face driver ......................................... B25
Machine without counter spindle ................................... A12 Dimensions of the carrier plates .................................... B25
Machine with counter spindle ........................................ A12 Clamping force diagram for end face driver .................. B26
Electrical connection - Machines with Fanuc-Control ........... A13 Clamping devices - spindle ø45 ............................................ B27
Mains connection data ....................................................... A14 Screwing the tensioning tube into the clamping cylinder .. B27
Pneumatic connection ........................................................... A14 Spindle insert sleeves ........................................................ B27
Order numbers ............................................................... B27
Initial start-up ......................................................................... A15
Necessary hollow-out diameter ..................................... B27
Mounting the insert sleeves ........................................... B28
B Description and operation Dismounting the insert sleeves ...................................... B28
Three-jaw power chuck ...................................................... B29
Reference points ...................................................................... B2 Mounting the chuck ........................................................ B29
Machine zero point M .......................................................... B2 Dimensions of the chuck ................................................ B29
Tool fixture reference point T ............................................... B2 Dimensions of the jaws .................................................. B30
Measurement of the tools .................................................... B2 Clamping ranges of the chuck ....................................... B30
Coordinate system ............................................................... B2 Clamping force diagram KFD-HS 160/3 ........................ B31
Röhm - Collet chuck .......................................................... B32
Working area ........................................................................... B3
Technical data ................................................................ B32
Tool turret ................................................................................ B4 Outline collets ................................................................ B32
Working area ........................................................................ B4 Clamping principle ......................................................... B32
Tooling the tool turret ........................................................... B4 Mounting the collet chuck .............................................. B33
Weight counterbalance ........................................................ B5 Dismounting the collet chuck ......................................... B33
The main spindle ø65 .............................................................. B6 Clamping force diagrams ............................................... B34
Dimensions spindle connection ........................................... B6 Changing the collets ...................................................... B34
Clamping cylinder with bore ................................................ B7 Hainbuch - Collet chuck ..................................................... B35
Clamping cylinder without bore ........................................... B8 Tecnical Data ................................................................. B35
Connection values for tensioning tubes .............................. B9 Order numbers ............................................................... B35
Machine with clamping cylinder with bore ....................... B9 Clamping principle ......................................................... B35
Machine without clamping cylinder with bore .................. B9 Clamping force diagrams ............................................... B35
5
End face driver ................................................................... B36 C Programming and Operation
Mounting the end face driver ......................................... B36
Dimensions of the carrier plates .................................... B36 EMCO-specific - Sinumerik 810/840D
Clamping force diagram for end face driver .................. B37
Survey M Commands machine .............................................. C1
Counter headstock ................................................................. B38
Traversing range ................................................................ B38 Survey M Commands Gantry ................................................. C2
Tailstock ................................................................................. B39 Survey Machine Configuration M99 ....................................... C2

Travelling range ................................................................. B39 Channel 1 (machine) ....................................................... C2
Mounting the tailstock adapter ........................................... B39 Channel 2 (Gantry) ......................................................... C2
Tailstock thrust ................................................................... B40 Axes Description ..................................................................... C3
Removing the centre .......................................................... B40 Machine Control Panel ........................................................... C4
Adjusting the detector of the tailstock stroke ..................... B41
Key Description ....................................................................... C5
Hydraulics .............................................................................. B42
Open Machine Door ............................................................. C15
Hydraulic unit equipment ................................................... B42
Door Automatic ................................................................. C15
Oil level control .................................................................. B42
Hydraulic scheme .............................................................. B43 Clamping device control ....................................................... C16
Setting work on hydraulics ................................................. B44 Purpose ............................................................................. C16
System main pressure ................................................... B44 Function ............................................................................ C16
Clamping device pressure and ...................................... B44 Condition displays of the clamping device ....................... C16
sleeve thrust ................................................................... B44 Adjustment of the clamping device control ....................... C17
Minimum pressure for clamping devices ....................... B44 Bridging the final position clamping device detectors ...... C18
Switching off the final position detector ........................ C18
Pneumatics ............................................................................ B45
Activate the final position detector ................................ C18
Compressed air supply ...................................................... B45
Pressure setting ................................................................. B45 Switch On/Off Sequence ...................................................... C19
Pneumatic scheme ............................................................ B45 Switch On the Machine ..................................................... C19
Approach Reference Point ............................................ C19
Central lubrication .................................................................. B46
Switch Off the Machine ..................................................... C20
Function and monitoring .................................................... B46
Lubrication after longer standstill periods .......................... B47 Chip Conveyor ...................................................................... C20
Workpiece collection device (option) ..................................... B48 Spindle Brake ....................................................................... C21
Adjustment of the height of the collecting tray .................. B48 Workpiece Collection Device (Option) .................................. C21
Adjusting the stroke of the collecting tray .......................... B49 Tailstock ................................................................................ C21
Workpiece ejector with flushing system (option) ................... B50 C Axes .................................................................................. C22
Mounting the ejector .......................................................... B51
Self-made ejector ............................................................... B51 Tool Turret ............................................................................ C22
Examples for self-made ejectors ................................... B52 Influencing the Tool Turret in
Adjusting the stroke ........................................................... B53 AUTOMATIC and JOG Mode ....................................... C22
Operating instructions ........................................................ B53 Machine Configuration .......................................................... C23
Y-Axis (option) ....................................................................... B54 Clamping Device Left ........................................................ C23
Technical datas .................................................................. B54 Clamping Device Right ..................................................... C23
Working Area ..................................................................... B54 Continuous Operation ....................................................... C23
Programming .................................................................... C23
Toolholders ............................................................................ B55
Single toolholders VDI-30 .................................................. B55 R Parameter ......................................................................... C24
Double toolholders VDI-30 ................................................ B57 Workpiece Counter (R90, R91) ........................................ C24
Driven toolholders VDI-30 .................................................. B58 Machining Time (R98, R99) .............................................. C24
Performance curve spindle ø65 ............................................ B59 Freeprogrammable Outputs ................................................. C25
Survey ............................................................................... C25
Performance curve spindle ø45 ............................................ B59 Standard Setting ............................................................... C25
Environmental Protection Notes ............................................ B60 Y-Axis .................................................................................... C26
Environmental burdens in machining production .............. B60 Programming .................................................................... C26
Lubricants ....................................................................... B60 Programming example for using the Y-axis ..................... C26
Cooling lubricants .......................................................... B60
Solvents and cleaning agents ........................................ B61 Cycle Programming .............................................................. C27
Special problems with chips containing residual oil ...... B61 Roughing Cycle "CYCLE95" ............................................. C27
Problems with oil mists and oil vapours, dust etc. ......... B62 Threading Cycle "CYCLE97" ............................................ C30
Further burdens ............................................................. B62 Drilling Cycle "CYCLE83E" ............................................... C33
Measures of environmentally compatible design in Tapping "CYCLE84E" ....................................................... C35
machining production ......................................................... B62 Grooving Cycle "CYCLE93" .............................................. C37
General hints .................................................................. B62 TRANSMIT-Programming ................................................ C40
Hints for correct handling of utilities ............................... B62 Cylinderinterpolation ......................................................... C42
Synchronization of two Spindles ....................................... C44
Programming the automatic tailstock ............................... C45
Supporting on more length positions ............................ C45
"TAKEOVER" - Cycle Mainspindle-Counterspindle ......... C46
Bar Loading Cycles ........................................................... C49
Bar Loader Interface ............................................................. C50
Serial Interface ...................................................................... C53
Signal names .................................................................... C53
Maximum Cable Length .................................................... C53
Connection to PC .............................................................. C53
6
D Programming and Operation Cutter Radius Compensation ........................................... D33
G40 Cancel Cutter Radius Compensation ....................... D35
EMCO-specific - Fanuc 21i-T G41 Cutter Radius Compensation Left ............................ D35
G42 Cutter Radius Compensation Right .......................... D35
Machine Control Panel ........................................................... D1
G52 Local Coordinate ....................................................... D36
Axes Description ..................................................................... D1 G53 Selection of the Machine Coordinate System .......... D37
Description of Keys ................................................................. D2 G54 to G59 Selection of a Workpiece Coordinate System D37
G70 Measuring in Inches .................................................. D39
Switch On/Off Sequence ...................................................... D10
G71 Metrical Measuring .................................................... D39
Switch ON the machine .................................................... D10
G72 Finishing Cycle .......................................................... D39
Approach reference point ............................................. D10
G73 Contour Roughing Cycle ........................................... D40
Switch OFF the Machine .................................................. D11
G74 Face Roughing Cycle ................................................ D42
Open Machine Door ............................................................. D11 G75 Pattern Repeating Cycle ........................................... D44
Door Automatic (Option) ................................................... D12 G76 Face Cut-in Cycle ..................................................... D45
Open door automatically ............................................... D12 G77 Side Cut-in Cycle (X Axis) ........................................ D46
Close automatic door .................................................... D12 G78 Multiple Threading Cycle (Thread cutting OD/ID) .... D47
Automatic program start ............................................... D12 Drilling cycles with driven tools ......................................... D48
Clamping Device Control ...................................................... D13 G12.1/G13.1 Polar Coordinate Interpolation .................... D56
Purpose ............................................................................. D13 G7.1 Cylindrical interpolation ............................................ D59
Function ............................................................................ D13 G51.2 / G50.2 Polygonal Turning .................................... D61
Condition displays of the clamping device ....................... D13 G90 Absolute Programming ............................................. D64
Adjustment of the clamping device control ....................... D14 G91 Incremental Programming ........................................ D64
Bridging the final position clamping device detectors ...... D15 G92 Adjustment for maximum Spindle Speed ................. D64
Switching off the final position detector ........................ D15 G92.1 Coordinate System Setting .................................... D64
Activate the final position detector ................................ D15 G94 Feed Rate in Minutes ................................................ D65
Standard Tailstock ................................................................ D16 G95 Feed Rate in Revolutions ......................................... D65
Programming .................................................................... D16 G96 Constant Cutting Speed ............................................ D65
Adjusting the detection of the tailstock quill ..................... D16 G97 Constant Rotational Speed ....................................... D65
Automatic Tailstock .............................................................. D17 M-Commands - Survey ......................................................... D66
Programming .................................................................... D17 Bar Feed / Bar Loader Interface ........................................... D72
Adjustment of the tailstock stroke monitoring ................... D17 Reversing Play Compensation ............................................. D77
Spindle Brake ....................................................................... D18 Input of the reversing play ............................................ D77
C-axis .................................................................................... D18 Chip conveyor ....................................................................... D78
Workpiece Collection Device (Option) .................................. D19 Program interruption to open the door ................................. D78
Tool Turret ............................................................................ D19 Tool Data Measuring with Scratching ................................... D79
Manual operation .......................................................... D19 Tool Data Measuring with the Optical Preset Device ........... D80
Influencing the Tool Turret in
Serial Data Interface ............................................................. D81
AUTOMATIC and JOG Mode ....................................... D19
Signal names .................................................................... D81
Programming ................................................................ D20
Transmission cable ........................................................... D81
Macro Variables .................................................................... D20 Settings for data transmission .......................................... D81
Calling up Variables .......................................................... D20 Transmission of NC-programs .......................................... D81
Workpiece Counter ........................................................... D20
Machining Time ................................................................ D21
Free Programmable Outputs ................................................ D21 E Maintenance of the machine
Standard Setting ............................................................... D21
Maintenance survey ................................................................. E1
Survey Program Input, Administration ................................. D22 Filling quantities ................................................................... E2
G-Commands - Survey ......................................................... D23 Lubricant recommendations .................................................... E2
Short description G-Commands ........................................... D24 Cooling lubricants .................................................................... E3
G00 Rapid Traverse ........................................................ D24 Chlorin-free coolants ............................................................ E4
G01 Linear Interpolation (Feed) ...................................... D25
Clamping pressure and clamping dev. function ...................... E5
Einfügen von Fasen und Radien ...................................... D25
Insertion of Chamfers and Radii ....................................... D25 Power chuck ............................................................................ E5
Direct Drawing Input ......................................................... D26 Collet chuck ............................................................................. E6
G02 Circular Interpolation Clockwise ............................... D28 Bright parts .............................................................................. E6
G03 Circular Interpolation Counterclockwise ................... D28
G04 Dwell ......................................................................... D28 Visula examination of all hoses ............................................... E6
G10 Data Setting .............................................................. D29 Central lubrication .................................................................... E7
Zero point shift G92 ...................................................... D29 Oil level check ...................................................................... E7
Zero point shift with workpiece Air inclusions ........................................................................ E7
coordinate systems G54 to G59 ................................... D29 Lubrication in case of major periods of standstill ................ E7
G20 Longitudinal Turning Cycle ....................................... D30 Installation of lines ............................................................... E8
(OD/ID Machining Cycle) .............................................. D30 Hydraulic unit ........................................................................... E8
G20 Longitudinal Turning Cycle ....................................... D30 Reduction of hydraulic pressure .......................................... E8
G21 Thread Cutting Cycle ................................................ D31 Additional regular checks ..................................................... E8
G24 Face Turning Cycle ................................................... D31 Cleanliness .......................................................................... E8
G28 Reference Point Return ............................................ D32 Hydraulic oil change ............................................................ E9
G33 Thread Cutting ......................................................... D32
7
Coolant device ....................................................................... E10 F Additional instructions
Drawing out the cooling lubricant tank .............................. E10
Cooling lubricant level ........................................................ E11 Sauter - Tool Turret
Cleaning the cooling lubricant tank .................................... E11 Knoll - Chip Conveyor
Belt tension ............................................................................ E12 Bristol - Electrostatic Airfilter
Change of battery in the control Siemens 810 D/840 D ........ E13
Change of battery in the hard disk unit MMC .................... E13
Change of the battery ventilator insert of the G Spare Parts List
NC-CPU board (Sinumerik 840D) ..................................... E14
Change of the battery of the
CCU-board (Sinumerik 810D) ........................................... E14
8
ADEQUATE USE / WARRANTY CONDITIONS
Adequate Use
The EMCOTURN 365 lathe is designed for complete machining by turning, drilling and
milling of machinable metals and plastics.
Machining of other materials is not admitted and may be carried out in particular cases only
after consultation with the machine manufacturer.
Adequate use also includes compliance with the operating, maintenance and repair
instructions indicated by the manufacturer.
The EMCOTURN 365 may excusively be operated by persons familiar with the operation,
maintenance and repair and who know the hazards.
All regulations for the prevention of accidents and safety instructions for work with machine
tools and CNC machine tools have to be complied with at any time.
In case of inadequate use of the EMCOTURN 365 the manufacturer renounces any liability
and the responsibility is transferred exclusively to the user.
Warranty conditions for new EMCO machines

1. The warranty period for new EMCO machines is, without limitation of operating hours, 12
months after initial shipment of the machine from EMCO or its authorized representative.
Should the installation be completed by EMCO or its authorized representative, the
warranty period begins with the completed installation of the machine.
If a delay of installation occurs which is not caused by EMCO or its representative, the
warranty period becomes invalid 12 months after scheduled installation date.
2. The warranty extends to the elimination of all defects in material or workmanship which
affect the regular function of the machine.
3. Occuring defects must be immediately reported to the EMCO respresentative or the next
EMCO service department with detailed description of the defect in written or oral form,
followed by a written verification.
4. Defects which are correctly reported and under warranty will be corrected by either
repair or replacement delivery to the original buyer free-of-charge; defective parts are to
be returned to EMCO or the EMCO authorized respresentative, freight prepaid, if
requested.
5. Warranty for spare parts: Emco guarantees to the original buyer that, only those parts
sold directly by Emco or through an authorized representative will be free from defects,
which render part commercially unacceptable in material and workmanship, for a period
according to applicable national law, at least three (3) months, but not to exceed six (6)
months from the date of initial shipment or installation by Emco or its representative.
In the case of repeated claims for the same part: Warranty replacement does not extend
the period of the original warranty.
6. There is no claim of warranty for defects which occured by:
Negligence of operating instruction manuals, safety and handling regulations or other
instructions regarding delivery, installation, set-up or usage of the machine, incorrect
set-up resp. installation, as well as, unauthorized, not expressed regulated or allowed
alternations or modifications of the machine by the original buyer or third parties, natural
wear, improper or negligent handling, chemical, electro-chemical or electrical influences,
inadequate energy supply or force majeure.
7. Any service performed by EMCO or its authorized representative beyond warranty will
be charged at EMCO¦s or its authorized representative’s regular rates.
9
SAFETY RECOMMENDATIONS
Safety recommendations
Read instructions Personal protective equipment

Read the instructions completely before you start Do not wear loose working clothes. Mind that the
up the machine. working clothes are tight around the wrists and
Prior to start of work get familiar with all functions hips.
and operating elements. During the work it might Mind that your hair does not get caught in the
be too late. machine (in such a case wear hair protection).
Protect your eyes with safety-glasses.
Electrical connection When removing chips use a chip hook and gloves.
Electrical connection of the machine must only
carried out by an authorized electrics expert. Setting, maintenance and adjusting work
Local protection measures have always to be All setting, maintenance and adjusting work must
borne in mind. only be carried out during standstill of machine
and EMERGENCY-OFF key actuated.
Observe local regulations The inspection and maintenance instructions for
Observe your country's regulations for work machine and accessories are to be observed. This
involving machine tools and CNC machine tools saves costs, excludes major standstills of the
machine, reduces hazards and saves the environ-
Authorized operation ment.
The machine may only be operated by authorized
persons. Tools, operating materials and spare parts
Authorized persons are exclusively persons Only use tools, operating materials and original
familiar with operation, maintenance and repair spare parts recommended by EMCO.
and who are instructed on hazards. For parts not supplied by EMCO, EMCO does not
assume liability.
Protect machine
Protect the machine (main switch can be locked) Disposal of noxious materials
during adjustment, maintenance and repair work When handling auxiliary and operating materials
against unauthorized start-up. (cooling lubricants, cleaning solutions, lubricating
oils, etc.) observe the safety regulations for these
Start-up materials.
Make sure that prior to each start-up the machine Take adequate measures for the appropriate
is in perfect maintenance state and that no safety storage and disposal of noxious materials.
features have been removed.
Claim
No modifications on machine In the event of a collision or other instance of
Modifications on your own on safety features, damage contact immediately the representative
bridgings of control features as well as any or manufacturer.
interference with the electric/electronic part of the In case of complaints, damage, confusions and
machine are prohibited. spare part orders always indicate the machine
number, electric number and software version.
In case of hazards EMERGENCY-OFF
In case of hazards immediately stop machine with Machine supervision
EMERGENCY-OFF. Never leave running machine unattended.
Before leaving the working place switch off
Tool change machine and protect against unauthorized start-
Change machining tools only during standstill of up (lock main switch and remove key).
machine. Only use tools and sealing bolts with O
ring on the shaft, always close all stations
(otherwise danger of coolant and chip entry in the
internal area of the tool turret!). In case of tool
change always turn driven tool holder into locking
position.
10
SAFETY RECOMMENDATIONS
Danger, Attention, Note

Please always mind the regulations for prevention
accidents and safety rules indicated in the
individual chapters and the additional instructions.
Important instructions concerning the technical
safety and the staff protection are emphasized
particularly:
Danger
refers to possible danger to persons during
working and operating procedures.
Attention
is indicated in working and operating pro-
cedures which have to be observed exactly to
avoid possible damage of the machine and
slight danger of injury for operators.
Note
is indicated if something particular has to be
observed when an activity is carried out.
Enviromental Protection Notes

refer to the avoidance of special waste,
responsible handling of environmentally
noxious substances as well as possibilities
for saving auxiliary and operating materials.
11
12
TECHNICAL DATA
Technical data of the machine - metric

:RUNLQJUDQJH VSLQGOH¡ VSLQGOH¡
6ZLQJRYHUEHG >PP@ ¡ ¡
6ZLQJRYHUFURVVVOLGH >PP@ ¡ ¡
6OLGHSDWK;= >PP@
'LVWDQFHPDLQVSLQGOHWDLOVWRFN >PP@
'LVWDQFHPDLQVSLQGOHFRXQWHUVSLQGOH >PP@
0D[VL]HRIZRUNSLHFHZLWKWDLOVWRFN >PP@ ¡î ¡î
0D[VL]HRIZRUNSLHFHZLWKFRXQWHUVSLQGOH >PP@ ¡î ¡î
0DLQVSLQGOHVSLQGOH VSLQGOH¡ VSLQGOH¡
6SLQGOHQRVHDFFWR',1 $ $
6SLQGOHH[WGLDPLQIURQWEHDULQJ >PP@ ¡ ¡
&ODPSLQJV\VWHPRSWLRQDOPDLQVSLQGOH
&ODPSLQJF\OLQGHUZLWKRXWERUHIRUFKXFNSDUWVXSWR >PP@ ¡ ¡
&ODPSLQJF\OLQGHUZLWKERUHPD[KROH >PP@
0D[VL]HRIFKXFN >PP@ ¡ ¡¡
&RXQWHUVSLQGOHVSLQGOH VSLQGOH¡ VSLQGOH¡
6SLQGOHH[WGLDPLQIURQWEHDULQJ >PP@ ¡ ¡
7UDYHOSDWK= >PP@
7UDYHOVSHHG >PPLQ@
*ULSSLQJIRUFH >1@
&ODPSLQJV\VWHPFRXQWHUVSLQGOH
&ODPSLQJF\OLQGHUZLWKRXWERUHIRUFKXFNSDUWVXSWR >PP@ ¡ ¡
&ODPSLQJF\OLQGHUZLWKERUHPD[KROH >PP@ ¡ ¡
0D[VL]HRIFKXFN >PP@ ¡ ¡
7DLOVWRFN VSLQGOH¡ VSLQGOH¡
,QQHUFRQH 0. 0.
7DLOVWRFNWUDYHOSDWK >PP@
0D[WKUXVWK\GUDXOLFDOO\FRQWUROOHG >1@
)HHGGULYHV VSLQGOH¡ VSLQGOH¡
'&PRWRUVLQ;DQG=D[HV
)HHGLQJIRUFH;= >1@
5DSLGVSHHG;= >PPLQ@
$FFHOHUDWLRQVSHHGIURPWRUDSLGWUDYHUVH;= >V@
'ULYHPDLQVSLQGOH VSLQGOH¡ VSLQGOH¡
$&PRWRURXWSXW'& >N:@
6SHHGUDQJHLQILQLWHO\YDULDEOH >USP@
0D[WRUTXH >1P@
3RVLWLRQLQJYDULDWLRQ3V9',;== >P@
Subject to technical modifications!
13
TECHNICAL DATA
'ULYHFRXQWHUVSLQGOH VSLQGOH¡ VSLQGOH¡

(OHFWURQLFVSHHGDQGSRVLWLRQV\QFKURQL]DWLRQZLWKWKHPDLQVSLQGOH
$&PRWRURXWSXW'& >N:@
0D[WRUTXH >1P@
6SLQGOHLQGH[LQJ VSLQGOH¡ VSLQGOH¡
3URJUDPPDEOHK\GUDXOLFDOO\DFWXDWHGGLVNEUDNH
'LYLVLRQ >@
&D[LVURXQGD[LV VSLQGOH¡ VSLQGOH¡
5HVROXWLRQRIWKHURXQGD[LV >@
5DSLGWUDYHUVH >USP@
7RROV\VWHP VSLQGOH¡ VSLQGOH¡
5HYROYHUW\SHWRROWXUUHWZLWKGLUHFWLRQORJLFRSWLRQDOZLWKGULYHQWRROV
7RROKROGLQJIL[WXUHVDFFRUGLQJWR',19',
WKHUHRIGULYHQVWDWLRQVRSWLRQDO
&\FOHWLPH >V@
,QGH[LQJDFFXUDF\RQUDGLXVPP >PP@
5HSURGXFWLRQDFFXUDF\RQUDGLXVPP >PP@
'ULYHQWRROVWDWLRQVRSWLRQDO VSLQGOH¡ VSLQGOH¡
7RUTXHFRQVWDQWZLWK'& >1P@
6SHHGUDQJH >USP@
+\GUDXOLFXQLWV VSLQGOH¡ VSLQGOH¡
0XOWLFLUFXLWK\GUDXOLFXQLWIRUSRZHUFKXFNDQGWDLOVWRFN
)LOOLQJOHYHO >O@
0D[SUHVVXUHIRUFODPSLQJGHYLFH >EDU@
0D[SUHVVXUHIRUWDLOVWRFN >EDU@
3QHXPDWLFV VSLQGOH¡ VSLQGOH¡
6XSSO\SUHVVXUH >EDU@
6XSSO\TXDQWLW\ >OPLQ@
/XEULFDWLRQV\VWHP VSLQGOH¡ VSLQGOH¡
*XLGHZD\VEDOOVFUHZV DXWRPFHQWUDORLOOXEULFDWLRQ
0DLQVSLQGOHFRXQWHUVSLQGOH JUHDVHOXEULFDWLRQ
&RRODQWGHYLFH VSLQGOH¡ VSLQGOH¡
7DQNFDSDFLW\ >O@
'HOLYHU\SUHVVXUHZLWKEDUEDU >OPLQ@
,QWHUQDOFRRODQWIHHG YLDWRROWXUUHW
%DUIHHG VSLQGOH¡ VSLQGOH¡
6HULHVSUHSDUDWLRQIRUWKHLQVWDOODWLRQRIWKHEDUIHHG
&KLSFRQYH\RU VSLQGOH¡ VSLQGOH¡
SROHSOXJIRUDVVHPEO\FKLSFRQYH\RULQFOXGHGLQEDVLFPDFKLQH
14
TECHNICAL DATA
(OHFWULFDOFRQQHFWLRQ VSLQGOH¡ VSLQGOH¡

3RZHUVXSSO\ >9@ 3(9a 3(9a
0D[YROWDJHIOXFWXDWLRQV >@
)UHTXHQF\ >+]@
&RQQHFWHGORDGRIWKHPDFKLQHZLWKRXWFRXQWHUVSLQGOH >N9$@
&RQQHFWHGORDGRIWKHPDFKLQHZLWKFRXQWHUVSLQGOH >N9$@
0D[SUHOLPLQDU\IXVHIRUPDFKLQHZLWKRXWFRXQWHUVSLQGOH >$VORZ@
0D[SUHOLPLQDU\IXVHIRUPDFKLQHZLWKFRXQWHUVSLQGOH >$VORZ@
5HTXLUHGVKRUWFLUFXLWSRZHU >N9$@
'LPHQVLRQVZHLJKW VSLQGOH¡ VSLQGOH¡
+HLJKWRIWXUQLQJD[LVDERYHIORRU >PP@
7RWDOKHLJKW >PP@
,QVWDOODWLRQVXUIDFH:['ZLWKRXWFKLSFRQYH\RU >PP@ î î
7RWDOZHLJKWRIWKHPDFKLQH >NJ@ DSSUR[ DSSUR[
6RXQGSUHVVXUHOHYHO VSLQGOH¡ VSLQGOH¡
PHGLDWHGVRXQGSUHVVXUHOHYHO >GE$@
:LWKWKHIROORZLQJFRQGLWLRQV
0HDVXULQJPHWKRGHQYHORSLQJVXUIDFHDFFRUGLQJWR',1
0HDVXUHGSRLQWPGLVWDQFHDQGPDERYHJURXQG
2SHUDWLQJPRGHPD[LPXPVSHHGGXULQJLGOHUXQQLQJ
15
16
TECHNICAL DATA
Technical data of the machine - inch

:RUNLQJUDQJH VSLQGOH¡ VSLQGOH¡
6ZLQJRYHUEHG >LQ@ ¡ ¡
6ZLQJRYHUFURVVVOLGH >LQ@ ¡ ¡
6OLGHSDWK;= >LQ@
'LVWDQFHPDLQVSLQGOHWDLOVWRFN >LQ@
'LVWDQFHPDLQVSLQGOHFRXQWHUVSLQGOH >LQ@
0D[VL]HRIZRUNSLHFHZLWKWDLOVWRFN >LQ@ ¡î ¡î
0D[VL]HRIZRUNSLHFHZLWKFRXQWHUVSLQGOH >LQ@ ¡î ¡î
0DLQVSLQGOHVSLQGOH VSLQGOH¡ VSLQGOH¡
6SLQGOHH[WGLDPLQIURQWEHDULQJ >LQ@ ¡ ¡
&ODPSLQJV\VWHPRSWLRQDOPDLQVSLQGOH
&ODPSLQJF\OLQGHUZLWKRXWERUHIRUFKXFNSDUWVXSWR >LQ@ ¡ ¡
&ODPSLQJF\OLQGHUZLWKERUHPD[KROH >LQ@ ¡ ¡
0D[VL]HRIFKXFN >LQ@ ¡ ¡¡
&RXQWHUVSLQGOHVSLQGOH VSLQGOH¡ VSLQGOH¡
6SLQGOHH[WGLDPLQIURQWEHDULQJ >LQ@ ¡ ¡
7UDYHOSDWK= >LQ@
7UDYHOVSHHG >IWPLQ@
*ULSSLQJIRUFH >OEI@
&ODPSLQJV\VWHPFRXQWHUVSLQGOH
&ODPSLQJF\OLQGHUZLWKRXWERUHIRUFKXFNSDUWVXSWR >LQ@ ¡ ¡
&ODPSLQJF\OLQGHUZLWKERUHPD[KROH >LQ@ ¡ ¡
0D[VL]HRIFKXFN >LQ@ ¡ ¡
7DLOVWRFN VSLQGOH¡ VSLQGOH¡
,QQHUFRQH 07 07
7DLOVWRFNWUDYHOSDWK >LQ@
0D[WKUXVWK\GUDXOLFDOO\FRQWUROOHG >OEI@
)HHGGULYHV VSLQGOH¡ VSLQGOH¡
'&PRWRUVLQ;DQG=D[HV
)HHGLQJIRUFH;= >OEI@
5DSLGVSHHG;= >IWPLQ@
$FFHOHUDWLRQVSHHGIURPWRUDSLGWUDYHUVH;= >V@
'ULYHPDLQVSLQGOH VSLQGOH¡ VSLQGOH¡
$&PRWRURXWSXW'& >KS@
0D[WRUTXH >IWÂOEI@
3RVLWLRQLQJYDULDWLRQ3V9',;== >LQ@
17
TECHNICAL DATA
'ULYHFRXQWHUVSLQGOH VSLQGOH¡ VSLQGOH¡

(OHFWURQLFVSHHGDQGSRVLWLRQV\QFKURQL]DWLRQZLWKWKHPDLQVSLQGOH
$&PRWRURXWSXW'& >KS@
0D[WRUTXH >IWÂOEI@
6SLQGOHLQGH[LQJ VSLQGOH¡ VSLQGOH¡
3URJUDPPDEOHK\GUDXOLFDOO\DFWXDWHGGLVNEUDNH
'LYLVLRQ >@
&D[LVURXQGD[LV VSLQGOH¡ VSLQGOH¡
5HVROXWLRQRIWKHURXQGD[LV >@
5DSLGWUDYHUVH >USP@
7RROV\VWHP VSLQGOH¡ VSLQGOH¡
5HYROYHUW\SHWRROWXUUHWZLWKGLUHFWLRQORJLFRSWLRQDOZLWKGULYHQWRROV
7RROKROGLQJIL[WXUHVDFFRUGLQJWR',19',
WKHUHRIGULYHQVWDWLRQVRSWLRQDO
&\FOHWLPH >V@
,QGH[LQJDFFXUDF\RQUDGLXV >LQ@
5HSURGXFWLRQDFFXUDF\RQUDGLXV >LQ@
'ULYHQWRROVWDWLRQVRSWLRQDO VSLQGOH¡ VSLQGOH¡
7RUTXHFRQVWDQWZLWK'& >IWÂOEI@
6SHHGUDQJH >USP@
+\GUDXOLFXQLWV VSLQGOH¡ VSLQGOH¡
0XOWLFLUFXLWK\GUDXOLFXQLWIRUSRZHUFKXFNDQGWDLOVWRFN
)LOOLQJOHYHO >8VJDO@
0D[SUHVVXUHIRUFODPSLQJGHYLFH >SVL@
0D[SUHVVXUHIRUWDLOVWRFN >SVL@
3QHXPDWLFV VSLQGOH¡ VSLQGOH¡
6XSSO\SUHVVXUH >SVL@
6XSSO\TXDQWLW\ >JDOPLQ@
/XEULFDWLRQV\VWHP VSLQGOH¡ VSLQGOH¡
*XLGHZD\VEDOOVFUHZV DXWRPFHQWUDORLOOXEULFDWLRQ
0DLQVSLQGOHFRXQWHUVSLQGOH JUHDVHOXEULFDWLRQ
&RRODQWGHYLFH VSLQGOH¡ VSLQGOH¡
7DQNFDSDFLW\ >8VJDO@
'HOLYHU\SUHVVXUHZLWKEDUEDU >JDOPLQ@
,QWHUQDOFRRODQWIHHG YLDWRROWXUUHW
%DUIHHG VSLQGOH¡ VSLQGOH¡
6HULHVSUHSDUDWLRQIRUWKHLQVWDOODWLRQRIWKHEDUIHHG
&KLSFRQYH\RU VSLQGOH¡ VSLQGOH¡
SROHSOXJIRUDVVHPEO\FKLSFRQYH\RULQFOXGHGLQEDVLFPDFKLQH
18
TECHNICAL DATA
(OHFWULFDOFRQQHFWLRQ VSLQGOH¡ VSLQGOH¡

3RZHUVXSSO\ >9@ 3(9a 3(9a
0D[YROWDJHIOXFWXDWLRQV >@
)UHTXHQF\ >+]@
&RQQHFWHGORDGRIWKHPDFKLQHZLWKRXWFRXQWHUVSLQGOH >N9$@
&RQQHFWHGORDGRIWKHPDFKLQHZLWKFRXQWHUVSLQGOH >N9$@
0D[SUHOLPLQDU\IXVHIRUPDFKLQHZLWKRXWFRXQWHUVSLQGOH >$VORZ@
0D[SUHOLPLQDU\IXVHIRUPDFKLQHZLWKFRXQWHUVSLQGOH >$VORZ@
5HTXLUHGVKRUWFLUFXLWSRZHU >N9$@
'LPHQVLRQVZHLJKW VSLQGOH¡ VSLQGOH¡
+HLJKWRIWXUQLQJD[LVDERYHIORRU >LQ@
7RWDOKHLJKW >LQ@
,QVWDOODWLRQVXUIDFH:['ZLWKRXWFKLSFRQYH\RU >LQ@ î î
7RWDOZHLJKWRIWKHPDFKLQH >OEV@ DSSUR[ DSSUR[
6RXQGSUHVVXUHOHYHO VSLQGOH¡ VSLQGOH¡
PHGLDWHGVRXQGSUHVVXUHOHYHO >GE$@
:LWKWKHIROORZLQJFRQGLWLRQV
0HDVXULQJPHWKRGHQYHORSLQJVXUIDFHDFFRUGLQJWR',1
0HDVXUHGSRLQWPGLVWDQFHDQGPDERYHJURXQG
2SHUDWLQJPRGHPD[LPXPVSHHGGXULQJLGOHUXQQLQJ
19
20
Declaration of conformity
Product: CNC Turning Centre
Machine data: Model Type

EMCO ET 365
Address of manufactorer: Emco Maier Ges.m.b.H.

Salzachtal Bundesstrasse Nord 58
A-5400 Hallein
Bases of standards: EN 292-1; EN 292-2; EN 294; EN 418; EN 60204-1; EN 954-1;

EN 1037; EN 1050; EN 1088
Regulations: MSV (BGBl. Nr. 306/1994, 27.4.94)
Test certificates:
Particular notes,
enclosures: Electrical documentation as applicable
We herewith declare that the above-mentioned product referring to the subject declaration is in conformity
with the currently valid stipulations of the directive of the Council dated June 22th, 1998 for the alignment
of the legal stipulations of the member states for machines (98/37/EEC), with the directive of the
Council dated May 3rd, 1989 for the alignment of the legal stipulations for electromagnetic compatibility
(89/336/EEC) and its modifications dated April 28th, 1992 (92/31/EEC) and July 22nd, 1993 (93/68/
EEC), and with the directive of the Council dated February 19th, 1973 concerning low voltage equipment
(73/23/EEC) and its modification dated July 22nd, 1993 (93/68/EEC).
Furthermore, the conformity of the subject product with the above-mentioned standard bases and
regulations is effective.
Place, date: Hallein, 27.12.00
Authorized person: Head of quality department Peter Binggl ..............................................
EN
A Installation of the machine
Machine acceptance
heck the machine for any transport damage and
completeness of the delivery.
If you find any defects, please contact the dealer
or the insurance company.
In case of complaints always specify the exact
designation of the machine and the machine
number and the electric number.
Machine number
9 3( +]
, The adhesive plate with the machine number (1)
1 $ ,
PD[ $ 6
is to be found laterally on the machine above the
('RNX6HU1R 5$9%D lockable main switch.
)DEU1R 5$1 The machine numer is also stamped into the
%DXMDKU<HDURIFRQVWU machine bed.
0DGHE\(0&20$,(5*HVPE++DOOHLQ$8675,$
1
Electrics number
Machine number
The adhesive plate with the electrics number is
mounted on the left side of the machine on top at
the switch cabinet.
The electrics number consists of a 9-digit number
(2) followed by the version number (3).
R6A101000 E Example of a complete electrics number:

SCHA. SCHR. MONT. R6A 101 000 V1.30 (see illustration)
Verkabelung Maschine
Plan: 09 / 2 V 1.30 BAW.

Note:
The wiring diagrams valid for your machine
2 3 are to be found in the electrical documen-
Electrics number tation which is in the switch cabinet of the
machine.
An electrical documentation can also be
obtained under order number ZVP 674 150
and indicating the version number (e.g. V1.30)
from EMCO.
Operation panel number

R6A115000 E
The adhesive plate with the operation panel
BEDIENPULTMONT. number is mounted on the rear side of the
Verkabelung Maschine
Plan: 09 / 2 operation panel.

V 1.00 BAW.
The number consists of a nine-digit number (4)
and the version number (5).
4 5
Example: R6A115000 V01.00
Operation panel number
A1
MACHINE ACCEPTANCE INSTALLATION
Diagnosis Service Software numbers

® displays ® Version
For the full identification of the software of your
¯ machine three numbers are necessary:
Versiondates NCU • Siemens NC-software number (1)
System Versionstamp/date Module-code • Siemens MMC-software number (2)
34.07.00-NCU572 H0 kmpmain...... 9001.34.07 • EMCO software number (3)
00000000000000000
Monitor Loader ....................................................................................................

Communic. Monitor .............................................................................................
Communic. System .............................................................................................
SIMATIC System .................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
1 Siemens software numbers

Call-up of the Siemens NC-software number By pressing the respective softkeys you reach
the screen page on which the desired number is
to be found.
Diagnosis Service
® displays ® Version
Version
® MMC Siemens NC-number (1)
Diagnosis-menu/Service-displays/Version
¯
Versiondates MMC
Siemens MMC-number (2)
File Version date time size
Diagnosis-menu/Service-displays/Version/Versi-
on MMC
mmc0.exe 34.04 28.Jun.1996 13:32:14 162 133
File ................... ................... ............. .............

File ................... ................... ............. .............
File ................... ................... ............. .............
File ................... ................... ............. .............
File ................... ................... ............. .............
File ................... ................... ............. .............
2
Call-up of the Siemens MMC-software number
Diagnosis PLC-IBN
® ®
D B 8 0 . D B W 0
¯
PLC-Status-display
Operand Format Value EMCO-software number

DB80.DBW0 H 0064
By pressing the opposite key combination the
page is called up on the screen of the control on
which the EMCO software number (3) is to be
seen (e.g. 0064).
3
Call-up of the EMCO-software number
A2
INSTALLATION SCOPE OF SUPPLY
Enter machine and control specific numbers here!
Electrics number Operation panel number
Siemens-NC-software number
Siemens-MMC-software number
EMCO-software number
Machine number
Numbers on the machine

Scope of supply
Basic machine Modules
2-axes CNC lathe, incl. 12-fold tool turret with ¨ SINUMERIK 810 D control
direction logic, control, hydraulic unit, coolant ¨ SINUMERIK 840 D control
device, machine lamp, switch cabinet air con-
¨ spindle bore ø45 mm
ditioning device, interface for foot switch and
chip conveyor, workpiece counter, user's manual ¨ spindle bore ø65 mm
and electrical documentaion. ¨ clamping cylinder without bore
¨ clamping cylinder with bore
Tool set ¨ 12-fold TC tool turret
¨ 12-fold TCM tool turret
• 1 tailstock adapter (only tailstock machine)
(driven tools)
• 1 ejection key for tailstock tools
• 1 tension tube spanner ¨ tailstock
• 1 spindleholder (for mounting the tension tube) ¨ counter spindle ø45 mm
• 1 hook wrench ¨ counter spindle ø65 mm
• 1 double-ended spanner 8×10 ¨ clamping cyl. without bore for counter spindle
• 1 spanner 13
• 1 switchboard key SDB 3
¨ clamping cyl. with bore for counter spindle
• 1 Allan key SW 3, 4, 5, 6, 8, 10 each ¨ brake right side
¨ gantry
¨ automatic door mechanism
Packing ¨ high-pressure pump
The machine is delivered bolted to a wooden ¨ handwheel
pallet (4 saucer head screws M12). The outside ¨ signal lamp
packaging depends on the country of destination
and the agreement made.
After unscrewing the hexagonal nuts M12/SW 19
the machine can be lifted off the pallet.
A3
TRANSPORT INSTALLATION
Transport of machine
(119.96") (76.417")
(5.079") (60.079") (37.598") (6.575")
(42.402") (45.079")
(14.567")
(42.717")
(127.953") (85.827")
1
Position of stack forks(1) and of center of gravity of the machine with the transport
Transport with pallet
Caution:
The machine may only be transported on the
pallet if the machine is fixed on the pallet by
4 500 kg means of anchor bolts.
Lifting capacity ............... min. 4 500 kg (9 920 lb)

Fork width ............................ min. 1 000 mm (40")
Fork length .......................... min. 1 800 mm (71")
transport with pallet
Transport without pallet
Attention:
• The lifting points and the fork widths have
to be adhered to exactly so that there is no
deformation at the machine base.
• The coolant tank must be removed during
transport.
Furthermore, the coolant pump(s) has
4 000 kg (have) to be lifted upward (see "transport
safety devices" in this chapter).
Lifting capacity ............... min. 4 000 kg (8 820 lb)

Fork width ............................ min. 1 000 mm (40")
transport without pallet Fork length .......................... min. 1 800 mm (71")
A4
INSTALLATION TRANSPORT
Transport with crane
4 000 kg
8 820 lb
1 2
Transport with crane-rack
The crane-rack may be requested by EMCO if

needed.
Ref-No. .................................................... R60 007
Danger: • Handle shackles (1) through the openings on

• Pay attention to the safe load of the purchase! the top of the machine, and hang them into the
• The crane-rack may only be hanged in the provided link plates on the machine-base.
rails ans ears provided for, to avoid tipping • Hang in hoist arm (2) into the hooks in the chip
of the machine. space.
A5
TRANSPORT INSTALLATION
Transport safety devices
Mind:
• Prior to start-up of the machine all transport
devices have to be removed.
• Keep the transport safety devices and
remount them when transporting the ma-
chine again.
Transport safety device A

Securing of the control panel
Position:
on the upper side of the control
A B C
Transport safety device B
Front view of the machine - left side
Securing of the chip guard door
Position:
At the front side of the machine in the area of the
door handle
D
Transport safety device C
1 Securing of slide Z 2 (2 nd headstock)
Position:
Mounted between the spindle noses
Transport safety device D

Securing of the Z slide
Position:
Mounted at the pulley of the Z slide (slide for tool
turret)
The transport safety device D must be accessible
from the back side after opening the door (1).
Transport safety device E

Securing of the swivel device for the coolant
E pumps (hexagon head screw M6 galvanized)
2
Position:
At the guide rail of the swivel device
3
Coolant pump
4
• Detach pump bracket (4) with the mounted
5 coolant pump (5) by loosening the hexagon
socket screws (3).
• Push bracket with pump (5) downward in the
long hole of the swivel device (2).
Hold pump min. 10 mm above the ground of the
coolant tank.
Lateral view of the machine - right side • Tighten hexagon socket screws (3).
A6
INSTALLATION INSTALLATION PLAN
Installation plan, dimensions of the machine
Basic machine
(73.701")
(43.228")
(37.795")
(14.646") (20.866")
(119.961")
(24.094")
(67.245")
Hydraulic manometer (76.417")
(23.6")
pressed air
(23.6") (61")
(25")
(25")
(89")
(38.228")
(38.78")
A
B B
(53.15")
(12.283")
(28.15") (12.008")
(60")
(3.937")
(57.756")
(65.63")
(24.67")
(116.22")
A Setting screws (8) resp. levelling elements (4) Space for operation
(see "Installation criteria")
B Bores ø18×120 for anchor bolts Space for maintenance

(0.709"×4.724")
A7
INSTALLATION PLAN INSTALLATION
Machine with bar loader and

chip conveyor
Machine with gantry loader and

chip conveyor
A8
INSTALLATION INSTALLATION CRITERIA
Installation criteria
Requirements on installation
surface
The machine is to be installed on a pavement as
horizontal as possible with adequate carrying
power and vibration stability.
When screwing down the machine bores for the
anchor bolts have to be mounted.
Z Installation possibilities
0° Note:
When using a gantry loader or a bar feed
magazine the machine has to be anchored
Aligning the machine on the ground.
Anchoring on the ground

Required accessories (order no.):
1 set of setting angles (4 pcs.) ............... Q6Z 460
4 pcs. levelling elements ......................... 881 500
4 pcs. anchor bolts FHA 1860 B ............. 573 045
• Drill 4 anchor bolts ø18 × 120 in a distance of

1 1667 × 971 mm (see installation plan).
2 • Place the machine above the bores.

• Insert levelling elements (4) and align machine
3 horizontally.
80 Nm 4 • Loosen setting angles (2) at the screws (1).
• Thread in achor bolts (3) and push them into
the anchor bore until the distance between the
washer of the anchor bolt and the setting angle
(2) is approx. 5 mm (see sketch).
30 Nm • Retighten setting angle (2).

• Pretension anchor bolts (3) with 80 Nm.
(anchorage in the ground)
• Reloosen hexagon nuts of the anchor bolts and
attach insulating disk (5).
• Tighten anchor bolts with 30 Nm (holding down
the machine).
3 5
Installation with levelling shoes and anchor bolts
A9
INSTALLATION CRITERIA INSTALLATION
Without anchorage on the ground

• Insert levelling elements (4) and align machine
horizontally.
Notes:
• If the machine is not anchored, you can also
use setting screws M20×80 DIN 933-8.8 (8)
with counter nuts (7) instead of levelling
elements.
Steel plates¨100×20 (6) have to be placed
below the setting screws.
4 6 7 8 Mind: no vibration damping!
Installation without anchorage
Additional criteria for

installation
In addition to the required capacity and vibration • The specific noise load of a machine operator
stability further requirements are to be met by is to be noted.
the installation surface and the installation site:
• It has to be taken into account that in accor-
• The installation site has to comply with dance with the operating situation a highly
building authority regulations so that in case qualified operator works on the lathes who
of possible leakage of cooling lubricant, has to carry out exacting programming and
lubricating and hydraulic oil, the environment supervising activities.
is not burdened.
Sometimes the situation can be improved by
An ideal situation would be provided if the sound insulation walls.
installtion site at the same time fulfilled the
From studies we know that the double dis-
function of a collecting tray.
tance to a nearby source of noise decreases
the sound level by 3 to 5 dB(A).
• Vibration-proof features as favourable as
possible to avoid a transmission of vibrations When doubling the number of similar sources
(particularly when working in the upper speed of noise the level is increased by 3 dB(A).
range, with bar work, when machining heavily
unbalanced workpieces, with interrupted cut, • Heat sources with inconstant temperature
when using driven tools etc.) to nearby near the machine as well as air drafts will
objects. influence the quality of the place of work as
well as the operating position of the machine.
• Good and sufficient lighting of the working If necessary, adequate measures for pro-
space facilitates operation of the machine and tection are to be taken.
increases the quality of work.
• Unfavourable light and sun radiation may lead

to reflections on the control screen and, thus,
impair the visibility of information items.
A10
INSTALLATION ELECTRICAL CONNECTION
Electrical connection - Machines with control

Sinumerik 810D/840D
Danger:
Terminal strip The electrical connection of the machine and
+1DL2-X1 its accessories may only be established by
1 an electrics expert.
Feed cables must be idle during the connec-
tion.
Electrical connection of the

machine
• Remove side wall (3).
/ / / 3(
• Unscrew cover (2).
• Thread feed cable (4) from below through the
2 3 4 cable screwed joint into the connecting box
under the cover (2).
• Connect the three pases L1, L2 and L3 to the
terminal strip +1DL2-X1 (1) (connecting ter-
minals 1, 2 and 3).
• Connect earth contact (yellow/green core) to
the connecting terminal 4 of the terminal strip
(1).
• Remount cover (2) and side wall (3).
• Control of the correct connection
Control the connection by checking the rotary
direction of the hydraulic unit (5) or the switch
cabinet fan (6).
The rotary direction of the hydraulic unit (5) is
marked at the fan cover.
In case of wrong rotary direction switch off the
machine immediately and interchange two
phases of the main connection.
left side of the machine - E-connection Caution:

Connecting this machine to a mains protected
by leakage current circuit breaker is admittable
only with using an all-current-sensitive
leakage current breaker.
Reason:
The drives used for this machine can cause
DC leakage currents which will impair the
protective function of the leakage current
breaker (no release).
Types of the all-current-sensitive leakage
current breaker tested by EMCO:
SIEMENS 5 SZ6 468 - OKG00
5 6 EMCO Order-no. ZME 280 720
back-side of the machine ABB F804 - 63/0,3
A11
ELECTRICAL CONNECTION INSTALLATION
Mains connection data
Attention:
A preliminary fuse is ordered forcible!
The specified value of the fuse has to be kept
strictly.
Machine without counter spindle

Power supply ................................... 3/PE 400V ~
Frequency ............................................... 50/60 Hz
Max. voltage fluctuations ........................ +5/-10%
Connected load ......................................... 20 kVA
Max. preliminary fuse ........................... 50 A/slow
Required short circuit power ................ 1100 kVA
Feed cross section .......... acc.to local regulations
Machine with counter spindle

Power supply .................................. 3//PE 400V ~
Frequency ............................................... 50/60 Hz
Connected load - spindle ø45 .................. 25 kVA
Connected load - spindle ø65 .................. 28 kVA
Max.preliminary fuse - spindle ø45 ..... 50 A/slow
Max.preliminary fuse - spindle ø65 ..... 63 A/slow
Feed cross section ......... acc. to local regulations
Note:
Further information about electrical con-
nection is to be found in the electrical docu-
mentation of your machine.
In case of different specifications the data in
the electrical documentation are valid.
A12
INSTALLATION ELECTRICAL CONNECTION
Electrical connection -
Machines with Fanuc-
Control
By machines with Fanuc-control the electrical
connection has to be established on the right side
of the machine, where the ballast transformer is
mounted.
Danger:
The electrical connection of the machine and
its accessories may only be established by
an electrics expert.
Feed cables must be idle during the connec-
tion. Follow also the local regulations!
1 2 3 • Set main switch (2) to position "0".

Ballast transformer on the machine • Dismount transformer cover (1).
terminal part B terminal part A • Thread feed cable (3) through the cable screwed
at the bottom of the transformer box.
• Connect the three phases of the feed cable to
the fuse terminals.
3( / / / (terminal part A - see illustration beside)
• Connect earth contact to the earth terminal.

3

3( 0

Caution:
• The cable (4) is set to the standard connection,
the 400V-variant.
By using other voltage variants the cable
4
(4) has to be reconnected!
Terminal strip of the transformer • Be sure, that only the yellow cable (4) will
be reconnected.
The connections of all other cables in the

tronsformer may not be changed, otherwise
the electrical part of the machine could be
damaged.
(
3
0

3
/ / / / / / / / / • Reconnect cable (4) to the voltage variant you

4 need.
(terminal part B - see illustration beside)
• Mount cover (1).
3×400 VAC
3×230 VAC 3×480 VAC • The machine will be switched ON with the main
(standard)
switch (2).
Voltage variants, terminal part B
A13
ELECTRICAL CONNECTION / PNEUMATIC CONNECTION INSTALLATION
Mains connection data
Attention:
A preliminary fuse is ordered forcible!
The specified value of the fuse has to be kept
strictly.
Power supply .................................. 3/PE ~ 400 V

3/PE ~ 230 V
3/PE ~ 480 V
Frequency ............................................... 50/60 Hz
Connected load ......................................... 20 kVA
Max. preliminary fuse:
400V-Version ........................................ 63 A/slow
230V-Version ........................................ 50 A/slow
480V-Version ........................................ 32 A/slow
Feed cross section .......... acc.to local regulations
Note:
Further information about electrical con-
nection is to be found in the electrical docu-
mentation of your machine.
In case of different specifications the data in
the electrical documentation are valid.
1
p = 6 bar
p = 87 psi
Pneumatic connection
Supply pressure .............................. 6 bar (87 psi)
Supply quantity .............................. min. 300 l/min
• Connect air supply at the connection piece (3)

of the pneumatic unit laterally at the machine
(compressed air supply ø10 mm).
open
2 • By pushing the manual slide (2) upward the
pneumatic maintenance unit is supplied with
close compressed air.
3 • The air pressure set is to be seen at the
manometer (1) of the machine.
• Closing the air supply by pushing the manual
Rear side of the machine - air supply slide (2) downward.
A14
INSTALLATION INITIAL START-UP
Initial start-up
• All bright parts are sprayed with oil-soluble
preservation agent and need not be treated prior
to initial start-up.
• Check the oil level for the central lubrication on

the rear side of the machine on the tank (3), if
necessary refill oil.
• Connect compressed air.
• Check oil level of the hydraulics on the oil level

gauge (4) on the rear side of the machine, if
necessary refill oil.
Therefore open door (5).
• Fill coolant into coolant tank (2) (filling capacity

230 l; also see coolant recommendations).
To draw out coolant lubricant tank see "Coolant
device" in chapter "E Maintenace".
1 2
Lateral view of the machine - main switch • Switch on machine at main switch (1).
• Press "AUX-ON" key on the operation panel of

the control, thus the auxiliary units are switched
on.
After major standstills this key should be
subsequently pressed various times and in case
of initial start approx. 10 times.
Every time the key is pressed a lubricating
impulse is emitted to the slideways and ball
screws.
• Further operation is described in chapter "C

operation and programming EMCO specific".
Notes:
• Filling quantities, qualities and recommen-
dations for lubricants, hydraulic oil and
cooling lubricant are to be found in the
chapter "Maintenance".
• In case that no hydraulic pressure is built
up after switching on the auxiliary drives
(key "AUX ON"), the mains connection is
probably wrong (wrong rotary field).
Remedy: Clamp two phases interchanged
3 4 5 (see Electrical documentation).
Rear view of the machine - oils
A15
B Description and operation
1 2 3 4 5
6 7 8 9
1 Sinumerik 810 D or 840 D control

2 Electric handwheel (option)
3 Main spindle
4 Tool turret (12-fold)
5 Counter spindle or tailstock
6 Main switch
7 Manometer für spindle 1
8 Manometer for spindle 2/tailstock
9 Inspection glass for coolant level
B1
REFERENCE POINTS DESCRIPTION
Reference points
Machine zero point M

The machine zero point lies exactly in the rotating
axis of the machine at the plane face of the main
spindle nose (spindle 1).
Tool fixture reference point T

The tool fixture reference point T lies at the
surface area of the tool turret disc in the axis of
Reference points on the machine the tool station.
Measurement of the tools

The tool fixture reference point T is described
from an incremental coordinate system whose
origin lies in the tool tip.
Note:
EMCO offers special devices for easy mea-
surement of the tools.
Measurements of the tools Coordinate system
Coordinate system
B2
DESCRIPTION WORKING AREA
Working area
size ø65
size ø45
*) Dimension 100 mm (3.94") with adapter (included in the additional pack of the basic machine)
B3
TOOL TURRET DESCRIPTION
Tool turret
The EMCOTURN 365 is equipped with a 12-fold
tool turret.
Depending on the type of the machine the tools
can also be driven.
Number of tool supports ................................... 12

Tool supports acc. to DIN69880 ............... VDI 30
driven tool stations (optional):
number of driven stations ................................. 12
torque (const. with 40% DC) .. 16 Nm (11.8 ft·lbf)
speed range ....................................... 0-4000 rpm
Working area of the tool turret disk (metric) Working area

Note:
The opposite figure is valid for all types of
tool turrets.
(Machines with and without driven tools.)
Tooling the tool turret

Working area of the tool turret disk (inch)
Danger:
Tooling the tool turret may only be carried out
during standstill of the machine.
• Insert tool turret VDI (5) into support (2) of the

tool turret disc (1).
) • Turn hexagon socket screw (3) in the direction
) of the arrow and tighten it.
The toothing of the eccentric (4) engages in the
toothing of the toolholder (5), pressing it against
the tool turret disc (force F 1) and upward at the
same time (force F 2).
• In clamped condition the toolholder lies on the
clamping surface of the tool turret disc and is
1
Mounting2the VDI
3 toolholder
4 5 fixed in the centre axis of the VDI mounting
bore.
B4
DESCRIPTION TOOL TURRET
Attention:
• Tool supports not used have to be closed
with a VDI cover holder with O-ring.
Thus, the penetration of coolant and chips
is avoided.
• Use indexable insert geometries which
guarantee short-chip material machining.
Long chips might jam tools, tool turrets and
clamping devices and also impair cutting
results. Long chips might also cause pro-
blems during clamping in the counter head-
stock.
Furthermore, the machine is cleaned easier
from short chips than from long ones.
• Prior to refeeding the bar material move the
tool turret near (approx. 2-3 mm) the
clamping devices of the main headstock.
Only then refeed bar. Then move tool turret
together with bar material to the desired
length. Otherwise damage or dislocating of
the tool turret is possible.
Use an absorbing toolholder for the stop
(EMCO accessories).
Weight counterbalance
Attention:
max. 32 Nm To avoid unnecessary disturbances on the tool
(23.6 ft·lbf) turret during tooling of the tool turret you have
to pay attention to an adequate weight
counterbalance.
Weight moment .......... max. 32 Nm (23.6 ft·lbf)
Tool tool turret always in such a way that the tool

weights are distributed as evenly as possible on
the tool turret disc.
The maximum weight moment must on no account
be exceeded, otherwise disturbances on the tool
turret might occur.
The reason for this can be found in too high loads
during the switch-over of the tool turret drive
between swivel device and the driven tools.
even tooling of the tool turret
B5
MAIN SPINDLE Ø65 DESCRIPTION
The main spindle ø65
Note:
The following data are valid for spindle 1 (left)
as well as for spindle 2 (right).
Spindle connection .......... acc. to DIN 55 026-A6 Spindle connection .......... acc. to DIN 55 026-A6
Chuck size spindle 1/2 ............. max. ø9.8"/ø7.8" Chuck size spindle 1/2 ....... max. ø250/ø200 mm
Speed ......................................... max. 4 200 min-1 Speed ......................................... max. 4 200 min-1
Torque spindle 1/2 ................... max. 114/94 ft·lbf Torque spindle 1/2 ................... max. 155/128 Nm
Clamping system: Clamping system:
Cylinder with bore ....................... hole max. ø2.6" Cylinder with bore ............... hole max. ø66.5 mm
Cyl. without bore ............. chuck parts max. ø7.8" Cyl. without bore ...... chuck parts max. ø200 mm
Dimensions spindle connection
Section A–A:
Connection dimensions of the main spindle ø65
B6
DESCRIPTION MAIN SPINDLE Ø65
Clamping cylinder with bore
Hydraulic clamping cylinder with bore

Röhm SZS-E 66/120
Type ............................. 459-109 with safety valve
Piston stroke .................................. 35 mm (1.38")
Piston area A ..................................... 105.8 cm²
B ..................................... 120.0 cm²
Working pressure ............... max. 50 bar (725 psi)
Speed ......................................... max. 5 000 min-1
dyn. balanced .................. Q 6.3 acc. to VDI 2060
Clamping cylinder with bore for spindle ø65
B7
Clamping cylinder without bore
Hydraulic cylinder without bore

Röhm OVS 115
with safety valve
Piston stroke .................................. 32 mm (1.26")
Piston area A ....................................... 87,9 cm²
B ....................................... 91,3 cm²
Working pressure ............... max. 50 bar (725 psi)
Speed ......................................... max. 6 500 min-1
dyn. balanced .................. Q 6,3 acc. to VDI 2060
Clamping cylinder without bore for spindle ø65 and ø45
B8
Connection values for tensioning tubes
Machine with clamping cylinder with bore
stroke 35
connection values for tensioning tubes ø65, clamping cylinder with bore
Machine without clamping cylinder with bore
stroke 32
Clamping cylinder for tensioning tubes ø65, clamping cylinder without bore
B9
The Main Spindle ø45
Note:
The following data are valid for spindle 1 (left)
as well as for spindle 2 (right).
Spindle connection .......... acc. to DIN 55 026-A5 Spindle connection .......... acc. to DIN 55 026-A5
Chuck size spindle 1/2 ....................... max. ø6.3" Chuck size spindle 1/2 ................ max. ø160 mm
Speed ......................................... max. 6 300 min-1 Speed ......................................... max. 6 300 min-1
Torque spindle 1/2 ............................ max. 86 Nm Torque spindle 1/2 ............................ max. 86 Nm
Clamping system: Clamping system:
Cylinder with bore ..................... hole max. ø1.79" Cylinder with bore ............... hole max. ø45,5 mm
Cyl. without bore ............. chuck parts max. ø6.3" Cyl. without bore ...... chuck parts max. ø160 mm
Dimensions spindle connection
Section A–A:
Connection dimensions of the main spindle ø45
B10
Clamping cylinder with bore

Hydraulischer Hohlspannzylinder
Röhm SZS-E 45/102
Typ ......................... 459-109 mit Sicherheitsventil
Kolbenhub ........................................ 25 mm (.98")
Kolbenfläche A ....................................... 92,0 cm²
B ..................................... 102,5 cm²
Betriebsdruck ..................... max. 50 bar (725 psi)
Drehzahl ..................................... max. 6 300 min-1
dyn. gewuchtet ................... Q 6,3 nach VDI 2060
Clamping cylinder with bore for spindle ø45
Clamping cylinder without bore

The clamping cylinder without bore for the spindle
ø45 is identical with that of spindle ø65.
Data and connection values are to be seen at the
beginning of this chapter under "Spindle ø65 /
clamping cylinder without bore".
B11
Connection values for

tensioning tubes
Machine with clamping cylinder
with bore
stroke 25
connection values for tensioning tubes ø45, clamping cylinder with bore
Machine with clamping cylinder

without bore
stroke 32
Clamping cylinder for tensioning tubes ø45, clamping cylinder without bore
B12
DESCRIPTION CLAMPING DEVICES FOR SPINDLE Ø65
Clamping devices -
General hints
• The position of the tensioning tube during
mounting and changing the collets has to be
observed.
The following table is valid for machines with
clamping cylinder without bore and with bore.
Position of tensioning tube during the change of clamping devices

Pressure collet chuck Pull collet chuck
Chuck (jaw chuck)
(Röhm chuck) (Hainbuch collet chuck)
Dismounting Dismounting
Mounting Dismounting Mounting Mounting
Collet changing Collet changing
spindle 1
chuck closed collet open collet open
Dismounting Dismounting
Mounting Dismounting Mounting Mounting
Collet changing Collet changing
spindle 2
chuck closed collet open collet open
• With using own clamping devices, they have to

be balanced exactly.
• When working with the bar feed you have to

take care that the diameters of the guide tube
Notes:
and the spindle insert sleeves are exactly in
• The switch-over of the control from condition
conformity.
"chuck" to "collet" is described in chapter "C
Operation and Programming EMCO-specific"
• The delivered tensening tube fits to the power
under "Machine configuration".
chuck and the collet chuck.
• For setting the clamping device control see
chapter "C/D Programming and Operation".
• Mind that clamping devices are maintained and
• For setting the clamping pressure see
serviced according to the manufacturer's
"Hydraulics" further below in this chapter.
regulations.
Safe clamping and a long durability can only be
guaranteed observing this item.
B13
CLAMPING DEVICES FOR SPINDLE Ø65 DESCRIPTION
Clamping devices - spindle ø65

Screwing the tensioning tube
into the clamping cylinder
Hazard:
Screwing in the tensioning tube into the
clamping cylinder may only be carried out
during machine standstill.
The procedure described in the following is valid

for cylinders with bore and without bore.
• Screwing in is carried out with dismounted
clamping device.
• Insert tube (1) from the front into the main
spindle (2) until stop and turn it into the support
of the clamping cylinder.
• Tighten tensioning tube (1) with the tensioning
1 2 3 3 4 tube key (4) supplied.
The main spindle is held tight with the key (3).
Mounting the tensioning tube
Spindle insert sleeves

The insert sleeves are necessary for work with
the bar feed facility and with workpieces pro-
truding far into the main spindle.
10 insert sleeves for each case are necessary.
These insert sleeves have to be hollowed out by
the customer to the necessary internal diameter.
Caution:
Without the adequate insert sleeves problems
during machining may occur (unbalanced
mass, bad workpiece quality).
5 6 7 8 5 workpiece
6 insert sleeves
7 tensioning tube
Order numbers
8 clamping device Adapter set consisting of fixing flange,
clamping nut, counter sleeve and various fixation
Clamping principle with insert sleeves
material .................................................... R6Z 260
1 insert sleeve ......................................... R6Z 270
Necessary hollow-out diameter
D nec = D W+1
D nec [mm] ..... necessary hollow-out diameter

D W [mm] ..... workpiece diameter
B14
1 2 3 4 5 6 7 8 9 6 Mounting the insert sleeves
Hazard:
Mounting the spindle insert tube may only be
carried out during machine standstill.
• Raise cover (1) after loosening the clamping

screw.
• Loosen fastening screw (2) and take off second
cover (3) upwards.
• Screw fixing flange (7) onto the clamping
cylinder with bore (9) by means of the enclosed
three hexagon socket screws M5×8 (8).
• Insert counter sleeve (11) into the tensioning
tube (10) and mount clamping device (12) (see
specific clamping device).
• Insert insert sleeves (6) from behind through
the clamping cylinder with bore and the
tensioning tube.
You need 10 insert sleeves which have to be
hollowed out to the diameter corresponding to
the bar material.
• Screw clamping nut (5) onto the fixing flange
(7) to fix the insert sleeves.
Mounting the insert sleeves - figure 1
Fasten clamping nut (5) with moderate manual
force.
• Fixation of the clamping nut (5) by tightening
the hexagon socket screws M6×25 (4).
• Remount cover (3) and close and clamp cover
(1).
Dismounting the insert sleeves

After unscrewing the clamping nut (5) the insert
sleeves can be pushed out backward by means
of a suitable tube (13 ) (collect insert sleeves).
The diameter of the tube (13) must be larger than
the internal diameter of the insert sleeve.
10 6 11 12 The insert sleeves can also be pushed out forward
Mounting the insert sleeves - figure 2 after removing the chuck (insert sleeves fall into
the chip room).
Notes:
• At least every second insert sleeve must
have the necessary hollow-out diameter,
each first insert sleeve may have a larger
internal diameter.
• The fixation flange (7) need not be dis-
13
mounted any more after taking off the insert
Dismounting the insert sleeves sleeves.
B15
Three-jaw power chuck

The following three power clamping chucks are
available for spindle ø65:
Chuck Ord.-nr.
Power chuck KFD-HS ø175/3 438 060
1
Attention:
To guarantee faultless function and distur-
bance-free operation of the chuck please also
2
observe the manufacturer's instruction en-
closed with the respective chuck.
X
Mounting the chuck

• Screw in tensioning tube and traverse into
foremost position (tensioning tube projects from
spindle).
3 4 • Clean carefully chuck support of the main
spindle and thread connection of the tensioning
Mounting chuck KFD-HS 175/3 and 200/3 tube.
• KFD-HS 175/3 and 200/3:
5 Pull clamping cylinder (2) in chuck (1) in
maximum rear position (jaws in max. internal
position).
KFD-HS 250/3:
Push clamping cylinder (6) in chuck (5) in front
position (jaws in outermost position).
• Remove screw plugs (4) and press fastening
screws (3) of the chuck to the inside.
6
• Turn chuck until stop onto the tensioning tube.
Take care that the threads of chuck and
X tensioning tube are not damaged.
• Turn back chuck until the carrier of the main
spindle can be inserted into the chuck support.
In this position press chuck against main spindle
and tighten fastening screws (3) reciprocally.
• Check minimum size "X" and correct it if
necessary (see next page).
• Check function and jaw stroke of the chuck.
• Mount screw plugs (4).
3 4 • Check chuck regarding facing accuracy and true

running.
Mounting chuck KFD-HS 250/3
B16
Adjusting the minimum value "X"

To be able to guarantee faultless function of the
chuck, the minimum value "X" has to be in
accordance with the following table.
Chuck Min. value X

+1
KFD-HS ø175/3 25,5 –0,5
7 +1
KFD-HS ø200/3 24,5 –0,5
+1
KFD-HS ø250/3 32,3 –0,5
X Chuck KFD-HS 175/3 and 200/3:

• Loosen fastening screws (3).
• Adjust minimum value X by turning the chuck
against the main spindle.
• Refix chuck on the main spindle.
3
Chuck KFD-HS 250/3:
• The minimum value X is adjusted by turning the
insert nut (7) against the tensioning tube.
Adjusting the minimum value X (KFD-HS 250/3)
Dimensions of the chuck
Note:
Single chuck dimensions may deviate from
the dimensions indicated in the instruction
enclosed with the chuck.
øamin bmin Omin

Chuck c d øA C øD* E øF G H L øM øN Q T U
øamax bmax Omax
29 0 16
KFD-HS 175/3 15 55 175 108 6 16 133,4 M12 19,45 2,5 56 68 M72×1,5 108 M8
33 24,5 31
35 8,5 16,5
KFD-HS 200/3 19 60 200 110 6 16 133,4 M12 19,45 2,5 66 80 M72×1,5 112 M12
40 32,5 35
43,8 6 2
KFD-HS 250/3 19 75 250 130 6 15 133,4 M12 19,45 2,5 66 80 M72×1,5 132 M12
50 47,5 25
*) short cone size acc. to DIN 55 026
B17
Dimensions of the jaws

Reversible interchangeable jaws UB, hardened
The jaws enclosed with the chucks are already
ground at the chuck.
KFD-HS KFD-HS KFD-HS

ø175/3 ø200/3 ø250/3
$ A 56 68 75
* * ) B 26 34,7 36
C 37,5 45 19
0 DH7 12 17 17
/ E 3,5 5 5
+
& F 14 17 21,5
( G 15 19 19
2 H 29 33,5 37,5
- 5 J 8,4 13 13
1 1 K 13,5 19 19
L 20 20 24
.
M 10 10 12
N 4 5 6
O 4 7 7,5
P 5 10 18
3 4 +
' % Q 5 5 7
R 1/16"×90° 1/16"×90° 1/16"×90°
Weight 0,17 kg 0,35 kg 0,46 kg
hardened reversible interchangeable jaws UB Ord.-nr. 574 675 571 220 586 175
Soft top jaws AB

For high-accuracy clamping.
The jaws are to be turned under clamping force
to the desired diameter.
Jaws hardened subsequently have to be ground.
KFD-HS KFD-HS KFD-HS

. ø175/3 ø200/3 ø250/3
A 55 66,7 75
B 26,5 36,5 36,5
+
& C 38 53 53
(
D+0,05 12 17 17
- 5 ' E 3,5 5 5
F 31 36 44
* ) G 15 19 19
H 28 43 43
%
J 8,4 13 13
K 13,5 19 19
$
R 1/16"×90° 1/16"×90° 1/16"×90°
Weight 0,32 kg 0,7 kg 0,88 kg
soft top jaws AB Ord.-nr. R3Y 230 R3Y 410 586 165
B18
Clamping ranges of the chuck

The clamping ranges are valid for chuck KFD-HS
with reversible interchangeable jaws UB.
A1 A2 A3 A4 J1 J2 J3
KFD-HS 175/3 6 - 82 ——— 54 - 133 90 - 180 36 - 114 71 - 149 116 - 196
KFD-HS 200/3 12 - 98 26 - 112 82 - 165 132 - 218 61 - 144 110 - 198 162 - 248
KFD-HS 250/3 22 - 144 40 - 156 94 - 210 146 - 262 76 - 192 128 - 244 182 - 298
Clamping force diagram KFD-HS 175/3
clamping cylinder with bore clamping cylinder without bore

Clamping force [daN]
1
1
2 2
hydraulic pressure [bar] hydraulic pressure [bar]

max. pressure max. pressure
1 Clamping force of the jaws

2 Actuating force at the tensioning tube Reduction of clamping force with
high speeds
Total clamping force [daN]
A
B Minimum centrifugal force of the
top jaw;
Maximum centrifugal force of the

top jaw;
Speed [min-1]
B19

clamping cylinder with bore clamping cylinder with bore

1 1
2 2

A
B Minimum centrifugal force of the
top jaw;
Größte Fliehkraft der Aufsatz-

backe;
Speed [min-1]
1 Clamping force of the jaws

2 Actuating force at the tensioning tube Clamping force diagram KFD-HS 250/3
clamping cylinder with bore clamping cylinder with bore

1
2

Minimum centrifugal force of the

A top jaw;
B

top jaw;
Speed [min-1]
B20
Collet chuck QUADRO-NC
Technical data
Clamping range:
acc. to clamping variant ................ ø3 to ø65 mm
Suitable collets ....................... 185E, RF52, 173E
max. actuating force ........... 3 000 daN (6700 lbf)
max. speed .......................................... 4 000 min-1
Clamping possibilities - outline
variant 1 185E, ø4-60 mm
union
nut 1
RF52,
ø35-61 mm
body
ø61-65 mm
variant 2
2 × RF52, ø35-61 mm
union
ø61-65 mm nut 2
variant 3
173E, ø3-42 mm
Outline of clamping possibilities (order numbers see variants)
B21
Clamping variant 1 (basic variant)
The basic variant comprises the following com-

ponents:
• body (1) ⎫
• pressure sleeve (2) ⎬ order no. 586 390
• union nut 1 (3) ⎭
Suitable collets
Steel collets
E 185 .................................................... ø4-60 mm
E 185 .. SW8-17, 19, 22, 24, 27, 30, 32, 36 mm
E 185 .............. ¨SW7-16, 18, 20, 22, 25, 40 mm
Rubberflex collets
RF 52 .................................................. ø35-61 mm
1 2 3 Steel collets ........................................ ø61-65 mm
Clamping variant 1
Clamping variant 2
In contrast to variant 1, a double clamping
pressure sleeve (5) is mounted here.
Union nut (3) and body (1) are used from the
basic variant.
Double clamping pressure sleeve
order no. ................................................... 586 120
Note:
When clamping with the double clamping
5 3 pressure sleeve (5) a spacer is put between
the collets.
Clamping variant 2 Suitable spacers are available with EMCO.
Clamping variant 3
In this variant a pressure sleeve (6) for collets of
series 173 E is mounted into the body (1) of vari-
ant 1.
A particular union nut (7) is necessary.
Pressure sleeve with union nut
order no. ................................................... 586 395
Collets
173 E .................................................... ø3-42 mm
6 7
Clamping variant 3
B22
Mounting the collet chuck

• Screw in tensioning tube and traverse it into
foremost position (tensioning tube protrudes
spindle).
• Remove dirt from spindle nose and tensioning
1 2 3 4 5 6 7 8 tube connection.
• Insert pressure sleeve (5) into the body (3)
according to the collets to be used and fix with
screw (4).
• Insert collet (6).
If the double clamping pressure sleeve (clam-
ping variant 2) is used insert the 1st collet after
securing the 1 st pressure sleeve, introduce
spacer, then insert the 2 nd pressure sleeve with
the second collet.
• Screw on union nut (8) by means of the double-
ended wrench supplied and secure with screw
(7).
• Screw preassembled unit onto the tensioning
tube; observe position of the driver (2).
• Reduce clamping pressure to approx. 4.5 bar
and traverse tensioning tube into rear position
(open collet).
• Screw collet chuck tight onto spindle nose with
tensioning screws M12 (1).
• Functional test:
It must be possible to open and close the collet
with a clamping pressure of 4.5 bar.
• Dismounting the chuck is carried out according
to mounting in reverse sequence.
Changing the collets

• Traverse clamping cylinder into rear position
(clamping cylinder open).
Caution: • Screw off union nut (8) after loosening the
If the union nut is screwed off with closed securing screw (7) by means of the double-
collet, the screw (4) is damaged, a faultless ended wrench.
function of the chuck cannot be guaranteed
any more. • Exchange collet (6).
• Screw on union nut (8) again and secure with
the screw (7).
Note:
• For changing the collets with clamping vari-
ant 2 (double clamping pressure sleeve) the
entire chuck has to be dismounted from the
spindle.
• For changing the pressure sleeves the
complete collet chuck has to be dismounted.
B23
Clamping force diagrams
Caution:
To avoid damages at the collet chuck the
maximum actuating force of 3 000 daN (6700 lbf)
must not be exceeded.
Clamping cylinder with bore Clamping cylinder without bore

Clamping fore [daN]
e
rc
fo e
ng rc
pi fo
am ng
cl pi
m
force cla orce
ating ing f
actu actua
t
B24
End face driver

Order no. ................................................. 586 140
The basic equipment comprises the end face
driver including lathe center and carrier plates for
turning work in anticlockwise rotation.
Spannkreis-ø
Clamping circle diameter ................ ø13–100 mm
Mounting the end face driver
Danger:
Mounting the end face driver may only be
carried out during standstill of the machine.
• Dismount the tensioning tube.
1 2 3 4 5 • Carefully clean the spindle bore.

• Put end face driver (3) on the spindle nose and
Mounting the end face driver fix it with the screws M12 (1).
In doing so, observe the position of the recess
(2) for the driver on the main spindle.
• Put the respective carrier plate (5) onto the end
face driver; (4) mind driver.
Dimensions of the carrier plates
Carrier plates - toothed

Clamping circle
Rotation Rotation
diameter
range [mm] direction
B C D
øS [mm]
12 13 - 24 left 7 36 4
20 21 - 40 left 13 30 4
32 33 - 64 left 22 30 10
Carrier plates with interchangeable

HM-driving chucks 9.5×3.2
(4-sided usable)
Clamping circle
Rotation range
diameter
[mm]
B C
øS [mm]
50 51 - 100 25 24
If during work with end face drivers straight or

right tools are used, you have to use a special
toolholder so that the tool can be machined across
the entire length.
Carrier plates with HM driving chucks
B25
Clamping force diagram for end face

driver
Workpiece strength Clamping ratio [1] Ftail [daN]

[daN/mm²] Rotation diam./Clamping circle diam. Standard
values for
tailstock
Chip section [mm²]
(chip depth × feed)
Example:
Machining A (turning against headstock):

Chip section ............................... 3×0.3 = 0.9 mm²
Workpiece strength ........................... 63 daN/mm²
Clamping circle
Clamping ratio ..................................... 60/50 = 1.2

diam. 50
diam.ø50
Rotation
tail
Tailstock force acc. to diagram:
Ftail = 160 daN
Machining B (radial cut):

Conversion factor: .................................. 1,5 × F tail
Machining C (turning against tailstock):

Conversion factor: ......................................2 × F tail
B26
Clamping devices - spindle ø45
Screwing the tensioning tube

into the clamping cylinder
Hazard:
Screwing in the tensioning tube into the
clamping cylinder may only be carried out
during machine standstill.
The procedure described in the following is valid
for cylinders with bore and without bore.
• Screwing in is carried out with dismounted
clamping device.
• Insert tube (1) from the front into the main
spindle (2) until stop and turn it into the support
of the clamping cylinder.
1 2 3 3 4 • Tighten tensioning tube (1) with the tensioning
tube key (4) supplied.
Mounting the tensioning tube The main spindle is held tight with the key (3).
Spindle insert sleeves

The insert sleeves are necessary for work with
the bar feed facility and with workpieces pro-
truding far into the main spindle.
11 insert sleeves for each case are necessary.
These insert sleeves have to be hollowed out by
the customer to the necessary internal diameter.
Caution:
Without the adequate insert sleeves problems
during machining may occur (unbalanced
mass, bad workpiece quality).
5 6 7 8 5 workpiece
6 insert sleeves
7 tensioning tube
Order numbers
8 clamping device Adapter set consisting of fixing flange,
clamping nut, counter sleeve and various fixation
Clamping principle with insert sleeves
material .................................................... R6Z 210
1 insert sleeve ......................................... R6Z 220
Necessary hollow-out diameter
D nec = D W+1
D nec [mm] ..... necessary hollow-out diameter

D W [mm] ..... workpiece diameter
B27
1 2 3 4 5 6 7 8 9 6 Mounting the insert sleeves
Hazard:
Mounting the spindle insert tube may only be
carried out during machine standstill.
• Raise cover (1) after loosening the clamping

screw.
• Loosen fastening screw (2) and take off second
cover (3) upwards.
• Screw fixing flange (7) onto the clamping
cylinder with bore (9) by means of the enclosed
three hexagon socket screws M5×8 (8).
• Insert counter sleeve (11) into the tensioning
tube (10) and mount clamping device (12) (see
specific clamping device).
• Insert insert sleeves (6) from behind through
the clamping cylinder with bore and the ten-
sioning tube.
You need 10 insert sleeves which have to be
hollowed out to the diameter corresponding to
the bar material.
• Screw clamping nut (5) onto the fixing flange
Mounting the insert sleeves - figure 1 (7) to fix the insert sleeves.
Fasten clamping nut (5) with moderate manual
force.
• Fixation of the clamping nut (5) by tightening
the hexagon socket screws M6×25 (4).
• Remount cover (3) and close and clamp cover
(1).
Dismounting the insert sleeves

After unscrewing the clamping nut (5) the insert
sleeves can be pushed out backward by means
of a suitable tube (13 ) (collect insert sleeves).
The diameter of the tube (13) must be larger than
the internal diameter of the insert sleeve.
10 6 11 12
Mounting the insert sleeves - figure 2 The insert sleeves can also be pushed out forward
after removing the chuck (insert sleeves fall into
the chip room).
Notes:
• At least every second insert sleeve must
have the necessary hollow-out diameter,
each first insert sleeve may have a larger
internal diameter.
• The fixation flange (7) need not be dis-
13
mounted any more after taking off the insert
Dismounting the insert sleeves sleeves.
B28
Three-jaw power chuck

Ref-No. KFD-HS 160/3 ............................ 574 670
Attention:
To guarantee faultless function and distur-
bance-free operation of the chuck please also
observe the manufacturer's instruction en-
closed with the respective chuck.
Mounting the chuck

• Screw in tensioning tube and traverse into
foremost position (tensioning tube projects from
1 spindle).
• Clean carefully chuck support of the main
spindle and thread connection of the tensioning
tube.
2
• Pull clamping cylinder (2) in chuck (1) in
maximum rear position (jaws in max. internal
X=25,5 position).
• Remove screw plugs (4) and press fastening
screws (3) of the chuck to the inside.
• Turn chuck until stop onto the tensioning tube.
Take care that the threads of chuck and
tensioning tube are not damaged.
• Turn back chuck until the carrier of the main
spindle can be inserted into the chuck support.
3 4 In this position press chuck against main spindle
Mounting the chuck and tighten fastening screws (3) reciprocally.
• Check minimum size "X" and correct it if
necessary:
Loosen fastening screws.
Adjust minimum value X by turning the chuck
against the main spindle.
Refix chuck on the main spindle.
• Check function and jaw stroke of the chuck.
• Mount screw plugs (4).
• Check chuck regarding facing accuracy and true
running.
Note:
Single chuck dimensions may deviate from
the dimensions indicated in the instruction
Dimensions of the chuck enclosed with the chuck.
B29
Dimensions of the jaws
Reversible interchangeable jaws UB, hardened Soft top jaws AB

The jaws enclosed with the chucks are already For high-accuracy clamping.
ground at the chuck. The jaws are to be turned under clamping force
to the desired diameter.
Jaws hardened subsequently have to be ground.

[

[

+

hardened reversible interchangeable jaws UB soft top jaws AB
Clamping ranges of the chuck

The clamping ranges are valid for chuck KFD-HS
with reversible interchangeable jaws UB.
Clamping ranges for KFD-HS 160/3 with jaws "UB"
B30
clamping cylinder with bore clamping cylinder without bore

1 1
2 2

Max. Druck Max. Druck
1 Spannkraft der Backen

2 Betätigungskraft am Zugrohr
Reduction of clamping force with
high speeds
A Minimum centrifugal force of the

B top jaw;

top jaw;
Speed [min-1]
B31
Röhm - Collet chuck

The collet chuck is available as accessory from
EMCO.
Order no. .................................................. 575 001
Technical data
Type ........................................... Röhm KZF 40/5
Clamping range:
acc. to clamping variant ......................... 2-42 mm
Collets .................................. 173E, Rubberflex 36
Work. pressure-clamp.cyl. with bore max. 27 bar
Work.press.-clamp.cyl.without bore max. 29 bar
Actuating force ............................ max. 2 500 daN
Speed ......................................... max. 6 000 min-1
Outline collets
Collets Collets Rubber Flex
173E acc. to DIN 6343 series 36
Clamp. range Clamp. Clamp. Clamp.
toler. range tolerance
2-42 6-36 6-29 h13 8-42 2 ±0,3
Grading of the colets: 1 mm
Danger:
• Workpieces with diameters deviating from the
tolerance of the inserted collets must not be
1 2 3 clamped since concentric running accuracy
and clamping force are not sufficient.
Collet chuck for spindle diam.45 - clamping • During work with bar feed use adequate
principle guide tubes.
• With longer bar material use spindle insert
sleeves.
• Mind machine configuration (chuck/collet).
Clamping principle
During clamping the tensioning tube (1) is pressed
forward by the clamping cyinder with (without)
bore.
The cone of the pressure sleeve (2) presses the
collet (3) together, the workpiece is clamped.
By drawing back the tensioning tube (1) the
workpiece is relieved.
B32
• Screw in tensioning tube and traverse it into

foremost position (tensioning tube protrudes
from spindle).
• Slightly oil pressure sleeve (7) with slideway

oil, insert it into the body (2) and fix it with the
screw (6).
1 2 3 4
• Screw preassembled unit until stop onto the
tensioning tube.
Turn unit back again 2-3 rotations.
In doing so, observe position of the driver bolt,
which is thread into the recess (1) of the body.
• Fix collet by means of 4 hexagon socket screws

M10 (5) on the spindle nose.
• Insert collets (8).
• Screw on union nut (4), tighten by means of the

double-ended wrench supplied and secure with
the screw (3).
• Functional test:
Actuate collet chuck at max. 5 bar.
It must be possible to open and close the collet
perfectly.
5 6 7 8
Mounting the collet chuck • Adjust the desired clamping pressure (see
following diagrams).
Dismounting the collet chuck

• Dismounting the collet chuck is carried out
according to mounting in reverse order.
During this procedure the tensioning tube is in
backmost position (collet open).
B33
• Traverse clamping cylinder with bore into

1 2
backmost position (collet open).
• Unscrew securing screw (1).
• Unscrew union nut (2).
• Pull out union nut (4) and replace by new one.
• Remount union nut (2), tighten and secure with

screw (1).
Attention:
If the union nut is screwed off with closed
clamping device condition, the screw can be
(3) damaged.
The function of the chuck is impaired by this,
thus, the chuck must no longer be used.
3 4
Clamping force diagrams
Attention:
To avoid damage at the collet chuck the
maximum actuating force of 2 500 daN must
not be exceeded.
Clamping cylinder with bore Clamping cylinder without bore

clamping force [daN]
Spannkraft [daN]
e
rc
fo et
g rc
pi
n fo
am ng
cl pi
m
force cla force
ting ting
actua actua
B34
Hainbuch - Collet chuck

Tecnical Data
Type ....... Hainbuch Axzug 65/KK5 with stopper
Clamping range ................................. max. 65 mm
Collets ................................................... SK 65 BZI
Work. pressure-clamp.cyl. with bore .... max. 43 bar
Work.press.-clamp.cyl.without bore ..... max. 49 bar
Actuating force ............................ max. 4 500 daN
Speed ......................................... max. 6 000 min-1
Order numbers
Collet chuck .............................................. 440 700
Collets ................................................. auf Anfrage
Special attachments
pneumatic changing device PP 65 .......... 440 710
manual changing device MV 65 .............. 440 720
1 2
Dimensions - clamping principle

Danger:
• Workpieces with diameters deviating from the
Clamping cylinder with bore tolerance of the inserted collets must not be
clamped since concentric running accuracy
and clamping force are not sufficient.
• During work with bar feed use adequate

guide tubes.
e
rc • With longer bar material use spindle insert
fo
ng sleeves.
pi • Mind machine configuration (chuck/collet).
am
cl
e
forc
at ing
a ctu
Clamping principle
hydraulic pressure [bar] During clamping the tensioning tube is pressed
back by the clamping cyinder with (without) bore.
The cone of the pressure sleeve (1) presses the
Clamping cylinder without bore collet (2) together, the workpiece is clamped.
By drawing frontward the tensioning tube the
workpiece is relieved.
e
rc
fo
ng
pi Clamping force diagrams
am
cl
orc e
ati ng f
actu Attention:
To avoid damage at the collet chuck the
maximum actuating force of 4 500 daN must
hydraulic pressure [bar] not be exceeded.
B35
End face driver

Order no. ................................................. 573 090
The basic equipment comprises the end face
driver including lathe center and carrier plates for
turning work in anticlockwise rotation.
Clamping circle diameter ................ ø12–100 mm
Spannkreis-ø
Mounting the end face driver
Danger:
Mounting the end face driver may only be
carried out during standstill of the machine.
• Dismount the tensioning tube.

• Carefully clean the spindle bore.
1 2 3 4 5
• Put end face driver (3) on the spindle nose and
Mounting the end face driver fix it with the screws M12 (1).
In doing so, observe the position of the recess
(2) for the driver on the main spindle.
• Put the respective carrier plate (5) onto the end
face driver; (4) mind driver.
Dimensions of the carrier plates

Clamping circle
Rotation Rotation
diameter
range [mm] direction
B C D
øS [mm]
Carrier plates - toothed 12 13 - 24 left 7 36 4
20 21 - 40 left 13 30 4
32 33 - 64 left 22 30 10
Carrier plates with interchangeable

HM-driving chucks 9.5×3.2
(4-sided usable)
Clamping circle
Rotation range
diameter
[mm]
B C
øS [mm]
50 51 - 100 25 24
If during work with end face drivers straight or

right tools are used, you have to use a special
toolholder so that the tool can be machined across
the entire length.
Carrier plates with HM driving chucks
B36
Clamping force diagram for end face

driver
Ftail [daN]
Workpiece strength Clamping ratio [1]
[daN/mm²] Rotation diam./Clamping circle diam. Standard
values for
tailstock
Chip section [mm²]
(chip depth × feed)
Example:
Machining A (turning against headstock):

Chip section ............................... 3×0.3 = 0.9 mm²
Workpiece strength ........................... 63 daN/mm²
Clamping circle
Clamping ratio ..................................... 60/50 = 1.2

diam. 50
diam.ø50
Rotation
tail
Tailstock force acc. to diagram:
Ftail = 160 daN
Machining B (radial cut):

Conversion factor: .................................. 1,5 × F tail
Machining C (turning against tailstock):

Conversion factor: ......................................2 × F tail
B37
COUNTER HEADSTOCK DESCRIPTION
Counter headstock
The counter headstock (spindle 2) can be designed
according to the machine type as follows:
Spindles:
¨ spindle size ø65
¨ spindle size ø45
Clamping cylinders:
¨ clamping cylinder with bore
¨ clamping cylinder without bore
Machine with counter headstock
Note:
The designs of the spindles and clamping
cylinders are identical with those of the main
spindle (spindle 1).
For all data, connection dimensions and
clamping devices refer to this chapter above
"spindle diam. 65" and "spindle diam. 45".
Traversing range
spindle 1 spindle 2 The counter spindle can be traversed exactly to
position via the control Siemens 840D (axis Z2).
The slide drive is carried out via a separate AC-
motor.
Traverse path .................................. max. 510 mm
Traverse path of spindle 2
B38
DESCRIPTION TAILSTOCK
Tailstock
Cone of tool support ..................................... MK 4
Tailstock stroke ............................... max. 500 mm
Tailstock extension (adapter) .................. 100 mm
Tailstock thrust .............................. 1000 – 8100 N
Travelling range
Travelling range of the tailstock, with and without adapter
1 2 3 Attention:
• Prior to mounting tools carefully clean the
support flange and the tailstock cone.
• Unless the adapter is used, the protection
A ring (5) must be mounted with the O-rings
(4) and (7) to prevent dirt and corrosion on
the tailstock support.
4
• Unless the tailstock is needed, mount
5 protection ring and unclamp tools from the
tailstock to avoid collisions.
6
I
I View A:
7
8 Mounting the tailstock adapter
• Unscrew protection ring (5) by loosening the 3
socket head screws M6 (6).
1
Take care that you do not lose the O-rings (4)
2 and (7).
• Screw adapter (1) with the 5 socket head screws
5 (2) on the support (3).
Mount adapter in such a way that the markings
6 (8) of tailstock and adapter are opposite each
other so that the position of the tailstock axis is
Tool support on the tailstock (with and without not dislocated.
adapter)
B39
TAILSTOCK DESCRIPTION
Tailstock thrust
Attention:
tailstock thrust [N]
During adjustment of the tailstock thrust mind:

• workpiece material
• clamping device used and adjusted clamping
force
For adjusting the tailstock clamping force refer
to "Hydraulics" further below in this chapter.
hydraulic pressure [bar]
Tailstock clamping force
Removing the centre

The centre (7) and other tailstock tools can be
removed from the tailstock cone by means of the
ejection key (6) included in the scope of supply.
1 2
Tailstock with centre punch and ejection key
B40
DESCRIPTION TAILSTOCK
Adjusting the detector of the

tailstock stroke
Diagnosis PLC-IBN
®
The position of the tailstock is controlled by the
¯ proximity detectors (5) and (6).
The adjustment of the detector is carried out by
Z 1 0 regulating the switching mechanism (4).
¯ • Set "JOG" mode.

PLC-Status-Display
Operand Format Value • Call up PLC-status control via the softkeys

Z10 H 0011
"Diagnosis/PLC-IBN".
• Call up counter Z10.

Enter "Z10" and confirm by means of the Enter
key.
A table with the operand "Z10" in format "B"
and a value (1) is displayed on the screen.
1 • Jump into the column "format" by means of the

Call-up of the "counter 10" on the screen cursor keys and overwrite the format "B" with
"H".
Detail X: • Loosen counternut (3).
• Adjust setting screw (2) by means of an Allan

key flush with the counternut (3).
• Clamp workpiece and approach tailstock against

the workpiece.
(For adjustment of the tailstock thrust refer to
"Hydraulics" further below in this chapter).
2 3
• Turn setting screw (2) from the tailstock, until
View A: the value (1) of the counter 10 on the screen
2 indicates more by a number of 1 (e.g. change
of the value from "0011" to "0012").
3
• Turn setting screw back until the value (1)
counts back again by "1" (from "0012" to
"0011").
4
• Turn in screw (2) by another rotation into the
5
tailstock.
6
• Secure setting screw (2) by means of the
counternut (3) in this position.
Detail view - tailstock, adjusting the stroke
B41
HYDRAULICS DESCRIPTION
Hydraulics
Power .......................................................... 1.5 kW
X Speed hydraulic drive .......................... 1425 min-1
Conveying capacity ............................... 10.7 l/min
System pressure ...................................70–80 bar
Tank capacity .................................................. 10 l
Hydraulic unit equipment
The operation part of the hydraulics is accessible

1 2 below the control after opening the cover (1).
Hydraulics of the machine The system pressure is set by the manufacturer
and cannot be changed.
Manometer- pressure
3 4 5 6 Operation part no. control no.
System pressure 2 ———
Clamping device 1 3 7
Gantry - blank gripper 4 8
Gantry - finished part gr. 5 9
Clamp. dev. 2 / tailstock 6 10
Note:
Unless an extension step exists on your
machine, the following extension steps move
up (no gaps on the mounting plate).
The position of the manometer, however,
7 8 9 10 remains unchanged.
Detail X - Operation part of the hydraulics
Oil level control
Attention:
• The oil level of the hydraulic system,
however, has to be controlled prior to each
switch-on of the machine.
• The system-pressure has to be 0 bar by filling
in oil (pressureless - see Maintenance)!
• Pay attention to the positions of the cylinders
with refilling hydraulic ol - see "Maintenance"
• Open machine door (11) on the rear side of the

machine.
• The oil level (12) can be read at the oil level
gauge and must be between the upper and the
lower mark.
2 11 12
• Close machine door again.
Oil level control at hydraulics
B42
Clamping cyl. Clamping cyl. Portal Portal Portal gripper Portal gripper-
left right blank part gripper finish part gripper swivelling head reversing cyl..
(105/80/35) (105/30/32) (22×20) (22×20) (22×33) (18/16×5)
Q=0,85 l/min Q=0,85 l/min Q=0,75 l/min Q=0,75 l/min
DESCRIPTION
QL =4 l/min QL=0,5 l/min

Q=15 l/min Q=15 l/min V=7 cm³ V=7 cm³ V=12 cm³ V=12 cm³
V=195 cm³ V=120 cm³
B43
Tool turret Indexation Indexation Automatic door Tailstock
Q max=16 l/min left right (25/18/730) (40/28)
Qeff =0,84 l/min (25/16/20) (25/16/20) Q=11,8 l/min Q S=1,5 l/min - slow feed
Hydraulic scheme fully equipped (all options and accessories)

V=35 cm³ Q=0,7 l/min Q=0,7 l/min V=393 cm³ QE=12 l/min - rapid feed
V=5,8 cm³ V=5,8 cm³ V=204 cm³ (diff.)
V0 =3–4 l
p0=55 bar
Hydraulic scheme
HYDRAULICS
HYDRAULICS DESCRIPTION
Setting work on hydraulics

System main pressure
The system main pressure set can be read on the
manometer (2) on the rear side of the machine
X after switching on the machine and the auxiliary
drives.
System pressure ...................................70–80 bar
Caution:
The hydraulic pressure is set by the manu-
facturer.
1 2 A change of the system pressure may only be
carried out by EMCO service engineers.
Hydraulics of the machine
Clamping device pressure and

sleeve thrust
The clamping device pressure and/or sleeve
thrust is set at the valves (6) and/or (7).
Left spindle .................... pressure control unit (6)
Right spindle/tailstock ........ press. control unit (7)
The pressure set can be read on the manometers.

Left spindle .................................... manometer (3)
Right spindle/tailstock ................... manometer (8)
Setting procedure
3 4 5 6 7 8
• Open flap (1) beneath the control.
Setting the pressures (detail X) • Loosen fixation screw (4) at the respective
valve.
• Carry out pressure setting at handle (5)
max. press. [bar] (see table and corresponding chuck):
clamp. cyl. Pressure increase ............... clockwise direction
Clamping device clamp. cyl. Pressure reduction ........anticlockwise direction
without
with bore
bore
• Retighten fixation screw (4).
Spindle ø65
• Close flap (1).
Chuck KFD-HS 175/3 34 44
Chuck KFD-HS 200/3 40 50
Chuck KFD-HS 250/3 50 50 Minimum pressure for clamping
Collet chuck - Quadro NC 29 34 devices
Spindle ø45
The minimum pressure for clamping devices is
Chuck KFD-HS 160/3 34 38 set by the hydraulic system and is approx. 20%
Collet chuck - Röhm 27 29 below the clamping device pressure.
Collet chuck - Hainbuch 43 49
If the pressure falls below the minimum clamping
Tailstock
device pressure and with running main spindle
Sleeve thrust 65
an EMERGENY-OFF condition is caused and an
max. clamp. dev. pressure/sleeve thrust alarm is displayed.
B44
DESCRIPTION PNEUMATICS
1 2 3 Pneumatics
The pneumatics is needed for the options work-
piece collection device and workpiece ejector
spindle ø45.
Due to the the installed automatic condensate
diverter (1) the pneumatic unit is maintenance-
free.
Compressed air supply

Supply pressure ....................................min. 6 bar
Supply quantity .............................. min. 300 l/min
By opening the manual slide (4) the pneumatic
unit is supplied with compressed air.
Pressure setting
The pneumatic pressure is set by the manu-
facturer and should not be changed.
The pressure set can be controlled at the
manometer (3) of the pressure control (2).
Pressure set .................................................. 6 bar
4
Rear side of the machine - pneumatic unit
Pneumatic scheme
collecting tray collecting tray

stroke movement swivel movement workpiece ejector
ø25 × 1450 mm ø50 × 50 mm ø16 × 160 mm
Pneumatic scheme
B45
CENTRAL LUBRICATION DESCRIPTION
Central lubrication
Lubrication pulse (after slide path) 150 m (490 ft)
Lubricant per lubrication point ................ 0,06 cm³
Pump flow .......................................... 100 cm³/min
adm. operational viscosity ................ 20-1500 cSt
Tank capacity .................................. 2,7 l (0.7 gal)
The central lubrication automatically supplies the

slideways (4 roller slideways per slide) and the
recirculating ball spindles with slideway oil.
The lubrication pump (1) will be activated auto-
matically after a traversed slide path of 150 m.
This value is set at works and may not be
changed.
1
Addiational a lubrication pulse is given by
Position of the lubrication pump pressing the key "AUX ON".
Function and monitoring

After activation the lubrication pump (1) by the
control, the dosing elements (7) will be filled with
slideway oil.
6 After a renewed activation of the lubrication pump
the filled dosing elements will be evacuated into
the lubrication points and already refilled.
This sequence lasts for approx. 4 sec.
7 This function is supervised by the pressure switch

(4) in the lubrication pump:
• If the pressure switch (4) doesn't react after
approx. 20 sec., alarm "510 301-Low pressure
central lubrication" appears.
• If the oil level drops below the "Min." indicator
the float switch (3) reacts and alarm "510 300-
Float switch central lubrication" appears.
In both cases the program will be continued for
approx. 150 sec., a new program start is not
possible.
After this time the program stops and alarm
"510 104-Low pressure central lubrication" appears.
Check the oil level at the lubrication pump and
check pump and lubrication pipes for damages.
1 2 3 4 5
1 ... lubrication pump

2 ... oil tank with "min.-"/"max.-" indicator
3 ... float switch
4 ... pressure switch
5 ... filler neck
6 ... dosing element
B46
DESCRIPTION CENTRAL LUBRICATION
Lubrication after longer

standstill periods
If the machine is not used for a longer period
preceed a manual lubrication before and after
$8; the standstill period.
Therfore press the "AUX ON"-key 2 or 3 times
with an interval of 5 sec..
Each press triggers a lubricating pulse.
Note:
Informations about maintenance and oil
quality se chapter "D Maintenance".
Note:
The central lubrication is an open lubrication
system, that means that the slideway oil is
"lost" after use.
It gets into the coolant (see coolant treatment)
or flows down the machine.
A sparingly use of the central lubrication is
recommended and will be reached by the
presettings at works.
B47
WORKPIECE COLLECTION DEVICE DESCRIPTION
Workpiece collection
device (option)
Y
X
1 2 3 4 5 3 4 6
Front view of the machine - workpiece collection device
The workpiece collection device is mounted by

the manufacturer.
The workpieces can be deposited in the collecting
tray (4) by spindle-1 as well as by spindle-2.
Swivelling in the swivel arm (3) is controlled by
the pneumatic cylinder.
After collecting the workpiece the collecting tray
(4) is traversed via the pneumatic cylinder (5) to
the unloading station and unloaded by a rocking
motion into the collecting tray (6).
The collecting tray (6) can be unlocked from the
anchorage by slight lifting and thus be removed
from the machine.
7 4
Adjustment of the height of the
collecting tray
The collecting tray (4) can be adjusted in its height
according to the workpiece.
• Loosen locking screws M6 (7).
• Shift collecting tray (4) into desired height.
• Retighten locking screws (7).
Detail X - height adjustment of the collecting tray
B48
DESCRIPTION W ORKPIECE COLLECTION DEVICE
Adjusting the stroke of the

collecting tray
The limit switch (1) is actuated during approaching
the swivel arm (3) with the guiding unit (11)
against the control cam (10).
The stroke movement of the cylinder (5) is thus
stopped.
The adjustment of the stroke is carried out by
regulating the control cam (10) via the clamping
jaw (9).
• Interrupt air supply (close manual slide valve of

the pneumatics).
• Draw swivel arm (3) by hand into the desired
position, in which the workpiece should be
collected.
• Loosen both hexagon screws SW13 (8) and
8 9 5 10 11 push clamping part (9) against the guiding unit
(11) of the swivel arm.
Detail Y - Adjusting the stroke of the collecting
tray (positions 1–7 see front view) • Fix clamping part (9) in this position by
tightening both screws (8).
• Close machine door.
• Reestablish air supply on the manual slide valve
of the pneumatics.
The swivel arm (3) returns to its initial position.
B49
WORKPIECE EJECTOR DESCRIPTION
Workpiece ejector with flushing system (option)

Upon order the workpiece ejector with integrated As standard 2 ejector variants are supplied with
rinsing system is installed in the spindle system the consignment:
of spindle 2.
Variant 1:
The operation of the ejector is carried out via a
for ejecting workpieces without bore
pneumatic cylinder.
Ejector and integrated rinsing system are trigger- Variant 2:
ed via the control. for ejecting workpieces with bore (with mounted
driving device)
Stroke of the ejector
The ejector should be engaged on the rotating
minimal stroke ............................................ 70 mm
workpiece. Thus, chips cannot get behind the
maximal stroke ......................................... 160 mm
clamping device (sector B) to destroy sealings.
() .. Measures in brackets for spindle

ø65
Workpiece ejector - variant 1 (solid shaft ejector)
() .. Measures in brackets for spindle

ø65
Workpiece ejector - variant 2 (hollow shaft ejector)
B50
DESCRIPTION WORKPIECE EJECTOR
Mounting the ejector
Danger:
Mounting and dismounting of the ejector may
only be carried out during standstill of the
machine.
1 2
• Swivel out ejector.
• Screw desired ejector (1) onto ejector bar (2).
• Tigthen ejector (1) with fork wrench SW17 or
SW19.
Counterhold ejector bar with a fork wrench
SW11.
Mounting the ejector
Self-made ejector
Self-made ejectors can be mounted instead of or

on the ejectors supplied with the standard
equipment.
You have to observe the following items if you

make your own ejector:
• Determine precisely the dimensions of the
ejector in accordance with the workpiece and
Connection dimensions for self-made ejectors
the inserted clamping device.
(variant 1, connection dimension of the ejector bar)
• Provide bores for the rinsing system.
Minimum diameter of the bore ø3,5 mm.
• If the workpiece will be opened by boring or is
hollow, provide free running bores resp. free
running hollow-outs (øA), with it the ejector
won't be damaged by the tool.
• The ejector variant 2 supplied can be reworked
according to application (smaller external
diameter, free-running hollow-out øA).
Connection dimensions for self-made ejectors

(variant 2)
B51
WORKPIECE EJECTOR DESCRIPTION
Examples for self-made ejectors
1 2 3 4 1 ...... workpiece
2 ...... collet
3 ...... self-made ejector
4 ...... standard ejector
L ...... according to clamping device
Example of a self-made ejector for workpieces with an external diameter of < ø20 mm
1 ...... workpiece
2 ...... collet
3 ...... self-made ejector
1 2 3
d ...... larger than workpiece bore

D ...... smaller than external workpiece diameter
L ...... according to clamping device
Example of a self-made ejector for workpieces with an external diameter < ø35 mm
B52
DESCRIPTION WORKPIECE EJECTOR
Adjusting the stroke
The stroke of the pneumatic cylinder for the

ejector is supervised over the contact cam (2)
from the limit switch (3).
By reaching the limit switch position the forward
movement of the cylinder stops, and the ejector
moves back to the rear final position.
By adjusting the position of the limit switch the

stroke can regulated individually.
maximal stroke ............................... 90 mm (3.54")
• Open cover (1) lateral on the machine.

• By turning the pinion (4) with a scredriver the
position of the limit switch can be adjusted
1 turnround = 4 mm (.157") stroke
1 • Check the adjusted stroke by moving the ejector
forwards (M-funktion M22).
Lateral side of the machine - right side
• Close cover (1).
Operating instructions
To guarantee an error-free operation, the
following notes have to be observed!
• The connecting tube may not be dismounted,

2 3 4 1 otherwise the ejector bar has no bearing!
Adjusting the stroke of the ejector • With ejector - variant 1 - never traverse against
rotating parts!
• Take care that the ejector is not damaged during
machining the workpiece on spindle 2 (e.g.
boring open the workpiece - drill moves against
ejector).
• Never approach ejector - variant 2 with rotating
spindle!
1. clamp workpiece
2. set ejector
3. switch on spindle
• The flushing of the spindle may only carried out
if:
- ther is no workpiece in the clamping device
- the pressure of the coolant device is max.
3.5 bar (no high-pressure coolant pump)
Otherwise the sealings of the ejector will be
damaged.
B53
Y-AXIS DESCRIPTION
Y-Axis (option)
Because of the mounting of a Y-slide on the XZ-

slides and the using of driven tools it is possible
to program classic milling works on a CNC-lathe.
You can use axial and radial tools.
: ;<
Technical datas
stroke of Y-slide ................. +40 / –40 mm (1.57")
feed force ................................... 4000 N (900 lbf)
speed range ...................................... 0–4000 rpm
Torque ...................... constant 16 Nm (11.8 ft·lbf)
rapid traverse ................... 7,5 m/min (24.6 ft/min)
Coordinate system of Y-axis
Working Area
Danger:
To avoid crashes, the tool turret may only be
swiveled in Y-position "0"!
Working area - tool turret with Y-axis
B54
DESCRIPTION TOOLHOLDERS
Toolholders
Single toolholders VDI-30
Radial holder Radial holder "over head"

for left hand rotation (M4) for right hand rotation (M3)
shaft ...................................................... ¨ 20 mm shaft ...................................................... ¨ 20 mm
Order-No. R4Z 410 Order-No. R4Z 420
Axial holder Axial holder "over head"

for left hand rotation (M4) for right hand rotation (M3)
shaft ...................................................... ¨ 20 mm shaft ...................................................... ¨ 20 mm
Set of support plates Cut-off holder

for shaft ......................................................... ¨ ¾" for left hand rotation (M4)
shaft height for cut-off blades ................... 26 mm
Order-No. R4Z 490
Order-No. R4Z 450
B55
TOOLHOLDERS DESCRIPTION
Internal toolholder "long" ø25 Internal toolholder "short" ø25

for internal facing up to 3 mm below rot. centre
Order-No. R4Z 310
Order-No. R4Z 330
Collet support ESX 25 Floating holder ESX 16

for internal toolholder ø25 for internal toolholder "short" ø25
Clamping range ...................................... 2–16 mm Clamping range ...................................... 1–10 mm
Internal toolholder "short" Internal toolholder "short" ø32

without bore, for hollowing out by customer
B56
DESCRIPTION TOOLHOLDERS
Double toolholders VDI-30
Double toolholder Double toolholder "over head"
Double internal toolholder "long" ø25 Double internal toolholder "short" ø25
Double internal toolholder "short" ø32
Order-No. R6Z 320
B57
TOOLHOLDERS DESCRIPTION
Driven toolholders VDI-30
Double milling holder ER 25 Milling holder axial ER 25

Clamping range ...................................... 1–16 mm Clamping range ...................................... 1–16 mm
Speed .......................................... max. 4000 min-1 Speed .......................................... max. 4000 min-1
Torque ............................................... max. 30 Nm Torque ............................................... max. 30 Nm
Ref-No. 440 400 Ref-No. 440 410
Milling holder radial ER 25

Clamping range ...................................... 1–16 mm
Speed ....................................... max. 10 000 min-1
Torque ............................................... max. 16 Nm
Ref-No. 440 420
B58
DESCRIPTION PERFORMANCE CURVES
Performance curve spindle ø65

M left
P left
Performance P [kW]
Torque M [Nm]
M right
P right
speed n [min -1]

Characteristic curves for machine with spindle ø65 (left and right spindle)
Performance curve spindle ø45

P left
P right Performance P [kW]

Torque M [Nm]
M left
M right
speed n [min-1]
Characteristic curve for machine with spindle ø45 (left and right spindle)
B59
E NVIRONMENTAL PROTECTION NOTES DESCRIPTION
Environmental Protection Notes
In addition to the constantly increasing require- For a better comprehension of the solutions
ments of productivity and flexibility of working offered a short outline on the environmental
processes the demand for environmental compa- problems occurring in machining production is
tibility has become of utmost importance. provided prior to the hints proper.
Avoiding environmental damage in the past years
has become a central issue of society. We can
no longer shift the blame on others according to
the principle “don’t hit me but hit the others”. Rat-
her, everybody has to contribute in his sphere of
responsibility.
Machining production, too, contains many areas
that may represent a burden to environment. Environmental burdens in
The main burdens are:
machining production
• chips contaminated with cooling lubricant Lubricants
• auxiliary materials and utilities (cooling lubri-
cants, cutting oils, lubricating oils etc.) The use of lubricants in machining production is
• special waste (oily cleaning clothes, used indispensable. Frequently the lubricants are not
emulsions etc.) used with optimum efficiency out of ignorance.
• formation of oil mist Particularly when storing the lubricants the
• annoyance caused by noise; vibrations materials are handled in a careless way which is
• waste heat, etc. why the lubricants reach the soil and add to
burdening the ground water.
Based on the necessity of the protection of our
environment, laws and stipulations were created Leakages, damaged barrels, carelessness when
the observation of which aims at the improvement handling oils, lacking or poorly serviced oil
of the present situation. Additionally, the control separators, empty barrels being “washed out” by
of the compliance with these regulations has the rain in the open air are just a few examples
become stricter recently. Increasingly, also small for the situation to be found too often in the
companies are subjected to this trend and have companies.
to guarantee an environmental compatibility as Nor does the existence of oil barrels in the most
high as possible of their production. Thus, reacting out-of-place corner of production represent a
in time a to a changed situation turns out to be of desirable solution. Oil-contaminated bay floors
utmost importance for the business. and dirty machines - as a result of incorrect
handling of lubricating oils - represent an essen-
It is EMCO’s aim to contribute to an improvement tial impairment of the quality of the place of work
of the present environmental and waste disposal and, thus, indirectly also of the quality of the
situation in machining production. results achieved.
The following important hints are to be intended

as a contribution.
Cooling lubricants
By observing these hints you will render a direct
service for the protection of our environment in Just like greases, cooling lubricants, too, are an
general and also for the quality improvement of indispensable factor in machining production.
your own working area. Cooling lubricants are highly developed chemical
The hints are described in such a way that their products that require careful handling.
observation will not cause additional costs and in Wrong handling may lead to serious damage of
most cases even a reduction of costs is possible health.
in the short-term perspective.
B60
DESCRIPTION ENVIRONMENTAL PROTECTION NOTES
Finely sprayed emulsions (open working space) Solvents and cleaning agents
reach the “lung” and are not eliminated any more.
Similarly, the wrong handling of emulsions may Cleaning agents are amply used in machining
lead to skin diseases (oil acne, oil eczema etc.) production for washing of machined workpieces
and via injuries of the skin also to infections. as well as in repairs and for cleaning utilities.
But the chlorinated hydrocarbons (e.g. trichloro-
By adequate hygienic measures of the company ethylene, trichloroethane, perchloroethylene etc.)
these dangers can be avoided. are amply used.
Emulsions are highly dangerous to ground water For the user these substances represent a source
and must in no case be spilled away carelessly. of danger that is not evident. Particularly due to
Biodegradable cooling lubricants do not represent the seemingly non-problematic use of these
a solution in this respect since these emulsions substances (inflammable, very good liposolubility,
are innocuous for the environment when being little odour etc.) these substances obscure the
supplied but during operation, due to the conta- fact that they are serious poisons of the liver and
minations occurring (leakage oils from lost oil the nerves.
lubrication, frictions etc.) loose their biological
innocuousness and thus cannot be disposed of Therefore, it is necessary to handle these
any more via sewage system. substances adequately. Additionally, these sub-
stances are able, due to their little density, to
A particular source of danger are the residual penetrate without problems through concrete
emulsions that adhere to the chips. When storing floors (even very thick ones) and thus contaminate
the chips in the open air or under roofs permea- the ground water. Due to their low boiling point
ble to water the residual emulsion may be washed these substances evaporate from open plants
out by the rain and thus reaches the sewage (e.g. open cleaning tray).
system or the ground water. A very unfavourable feature is the fact that these
substances are not decomposed biologically and
The durability of cooling lubricants is limited. thus represent a serious environmental hazard.
Since cooling lubricants contain organic sub-
stances they are prone to infestation by micro- In the past this has led to environmental burdens
organisms. If their number increases too much which today lead to a contamination of the ground
the emulsion “tilts” over and has to be renewed. If water reservoir.
the growth of these microorganisms is avoided
the service life can be prolonged.
1 kg of chlorinated hydrocarbons may
By service measures and careful handling of render forever unusable 40 millions litres
emulsions the durability can be prolonged con- of drinking water!
siderably.
Essentially, these microorganisms reach the

emulsion: Special problems with chips
• via the air containing residual oil
• via dirty water
With the chips considerable quantities of lubri-
• via leakage oils
cants and emulsions are “discharged” by the
• via waste getting in touch directly or indirectly
machine.
with the emulsion (cigarette ends, empty tins of
By drop-off of the chips a part of these substances
drinks etc.)
can be recovered (as valuable auxiliary ma-
• via the workpiece machined
terials). The remaining quantities are “lost” during
• via operating staff
transport and storage until further use and thus
• via lacking hygienic conditions in the company
also contribute to ground water contamination.
Observing the following hints of care you can
Chips are not waste but represent valuable
contribute considerably to an improvement of the
raw materials!
situation and to cost savings.
B61
Therefore, it is necessary: Measures of environmentally

• that the chip containers are not used as waste compatible design in machining
baskets (cigarette ends, plastic cups etc. are
not to be thrown into the chip container)
production
• that the chips are collected in accordance with
grades General hints
• that the chips reach their further use without oil, • The best way to remove waste is to not cause it
if possible, since otherwise they burn more at all!
when charged into the steel furnace.
• Thus, avoid as much as possible any special
Problems with oil mists and oil waste!
vapours, dust etc. • Handle substances noxious to the environment
with great efficiency!
Oil mists are caused by evaporation and mixing
of lubricants or emulsions by draughts in the • Mind correct operation when handling danger-
working space. An essential factor in the for- ous substances!
mation of oil mist is also represented by the user • “Carefree” handling of problematic substances
of compressed air when cleaning workpieces, is not a simple offence, it damages your health
machines and devices. The same holds also true and increases the burden on environment and
for dust development during dry machining. on costs!
In addition to representing a burden to the working • Use the right dosages!
environment (machines and devices become oily), • Observe the instructions of the manufacturer!
oil mists and vapours contribute to health hazards
of the operating staff. • Avoid any unnecessary waste!
Hints for correct handling of utilities

Further burdens
In addition to the burdens illustrated particularly Lubricant oils
annoyance by excessive noise, problems with Storage of lubricant oils:
accumulating waste heat and the use of other
problem substances connected indirectly with • Avoid any kind of loss of lubricant; during
machining production (e.g. cold cleaning agents, storage, use (leaking lines, sealings), during
pour-in resins, packaging materials etc.) re- refilling and transport etc. Accordingly.
present further burdens for the machine operating This also applies to used oil.
staff and the environment. • Pay attention that the storage is on solid ground
and that the oil containers cannot tilt.
Drop trays must be able to collect the residual
oil.
• Prevent empty oil barrels stored in the open air
against wash-out by rain.
• Used lubricant oils are special waste and have
to be disposed of as such.
• Identify clearly those containers which are
available for the collection of different disposal
substances (e.g. used oil, barrel for used oil
filters, oily cleaning rags etc.).
B62
Use of lubricant oils: • Check regularly the concentration of the emulsion

(too fat emulsions lead to a major health hazard
• Only use adequate lubricants (wrong lubricants
and also attack machine parts).
are consumed faster, lead to formation of fumes
and to unnecessary disposal quantities). • Check daily the filling level of the emulsion; too
little emulsion quantities are warmed up ex-
• When using lubricant oils mind the compatibility
cessively and thus promote bacterial growth.
with other auxiliary materials (e.g. emulsions);
instructions are provided by the manufacturer • Avoid unnecessary splashing of emulsions (e.g.
of the products. by skinning geometries).
• In case of doubt try to get information since the • With major standstill times of the machines
wrong use of the product may lead to con- repump the emulsion quantity at least once daily
siderable costs. (oxygen activation!).
• Take care of the lubricants! Regular cleaning or • Remove the chips after operation from the
change of filters will increase service life. machine (short after-running of the chip con-
veyor will be sufficient in most cases).
• Close carefully the filling outlets.
Mind during change of emulsion:
• The used emulsions are to be pumped into
containers designated clearly for that purpose
Cooling lubricants (independently of persons; to be understood by
Only use cooling lubricants that are compatible everybody as a prevention against emer-
with the lubricants used. (Incompatibility among gencies) to avoid confusion!
each other will result in shorter life time of the • Do not mix carelessly the emulsions to be
cooling lubricant used.) disposed of with other substances since the
disposal costs might increase considerably.
If possible, use cooling lubricant without halogens
(these are considerably cheaper for disposal). • Clean the entire coolant circuits very carefully
(contaminations particularly in corners of
Observe the storage conditions for the con- difficult access are a source for bacteria which
centrate containers (no frost, no excessive heat will attack again immediately the freshly pre-
etc.). pared emulsion).
Mind: When using system cleaning agents
Multi-use containers help to reduce disposal the costs of the disposal of the emulsion
quantities and are therefore to be preferred. may be increased!
• Mind the correct mixing ratio during fresh
Take particular care of your cooling lubricants! preparation!
Due to thorough care the service life is at least
doubled. • Emulsions should not be mixed for storage and
Mind the following hints for care: then stocked.
• Avoid any contamination of the emulsion.

• The cooling lubricant container is not a waste
basket.
Avoid mixing of residual oils in the emulsion
(used oils are lighter than the emulsion and
remain on top. They cover the emulsion and
prevent oxygen supply. Thus, there is an ideal
source for anaerobic microorganisms).
• Regularly eliminate the used oils on top (daily
prior to operation start), or simply by skimming
off.
• Avoid contamination of the emulsion by leaking
oils (e.g. leaky pneumatic system etc.).
B63
Hints for correct handling of chips Hints for the correct handling of dangerous
substances
Basical hints:
Try to resort to alternative substances; use
Chips represent a valuable raw material! They
dangerous substances only if it is indispensable
are not to be treated as waste.
to use them!
When handled incorrectly, chips may contaminate
The cost argument can frequently not be sup-
the ground water and the soil (if adhered with
ported with a view to increasing disposal costs
emulsions and lubricants).
and often also because of the incorporation of
the disposal costs in the overhead costs.
• Chips are to be stored in the state as they leave
the machine tool in an oil-proof container which
Avoid the use of dangerous substances whenever
makes it possible to drop off the residual
it is possible by:
emulsion (used oils).
Quantitative avoidance:
• On the bottom of the container a collecting tray
• by renouncing problem substances and/or
has to be placed where the dropped-off emulsion
change to products that can be recycled or
may collect without mixing with the chips. An
decompose
outlet valve should facilitate emptying of the
dropped-off lubricant. Qualitative avoidance:
• by saving measures and optimization in use
• A sufficiently long drop-off period is to be
provided as well as an adequately high tempera-
If dangerous substances cannot be avoided only
ture (in winter not in unheated environments) so
such substances should be used that can be
that the residual materials show a viscosity which
recycled by:
favours a complete drop-off.
• material reutilization (recycling)
• The collection of emulsions (oils) has to be
• biochemical reutilization (composting)
according to grades so that during refilling into
• energetic reutilization (burning)
the cooling lubricant circuit necessary conta-
mination items will not reach the circuit.
Waste that cannot be avoided nor recycled has
• The chips should also be collected and stored to be disposed of as innocuously as possible
according to the grades since a mix-up will lead (disposal after adequate pretreatment).
to an impairment of the quality of the raw
material. So-called special waste requires particularly
careful handling.
• The chip container must not represent the waste
A list of these special wastes is to be found on
basket in production; waste must not be mixed
the following pages. This outline forms an extract
with valuable raw materials.
of ÖNORM S 2101 in which special wastes are
• After drop-off the chips - also classified according indicated that need supervision.
to grades - are to be stored intermediately until
For all these substances the following applies:
being carried away by the scrap dealer.
• information and notification required
• The collection of the residual oil dropping down • records required
has to be guaranteed so that in this phase there • innocuous disposal required
is no hazard to soil and ground water. • declaration required (accompanying certificate)
• In any case the storage in the open air or under
inadequately fixed roofs is to be avoided since
here the residual oils may be washed out by
rain.
B64
Designation Key- Properties State 1) note

number 2) Origin (examples)
oil-contaminated soil 31 423 hazard to water solid 1) during collection, transport and storage
(excavated material) (also pasty) is protected against heat
2) oil accidance, mineral oil extraction, old
charges
used filter ans absorption 31 434 hazard to water solid 1) classification with a view to properties
masses if charged with other see 1) ist to be carried out according to the
special waste that needs filtered material
supervision 2) water preperation, production of foods
and luxury foods, chemical industry,
laundries, adsorptive gas and liquid
cleaning process
METALL WASTES 35
dust containing nonferrous 35 321 toxic solid 1) may contain lead, cadmium, arsenic,
metals hazard to water beryllium. Particular measures avoid
explosive dust explosions required.
2) Production of processing of prongs.
Production of aluminium, Foundries,
production of lead, magnesium, ignition
stones and pyrotechnical products,
electrical engeneering.
mercury batteries 35 324 toxic solid 2) production of batteries, trade, application

hazard to water
dry batteries, containing mercury 35 325 toxic solid 2) production of batteries, trade, application
and silver hazard to water
WASTE PRODUCED BY 54
MINERAL OIL PRODUCTS
oils, acid 54 101 hazard to water liquid 2) textile industry
caustic with pH<3
may form explosive
gases with air
used oils 54 102 hazard to water liquid to 1) also hydraulic oils and brake liquids
residues from used oil solid 2) trade and industry, filling stations
treatmentmay be toxic car repair workshops
may form explosive
gases with air
drilling cutting and grinding oils 54 109 hazard to water liquid 2) metal machining
may form explosive
gases with air
synthetic coolants and 54 401 hazard to water liquid 2) metal machining
lubricants
drilling and grinding oil 54 402 hazard to water liquid 2) metal machining
emulsions and emulsions mixes
oil-water mixes 54 408 hazard to water liquid
B65
Designation Key- Properties State 1) note

number 2) Origin (examples)
contents of oil seperators and 54 702 hazard to water liquid to

of petrol seperators solid
sludge from oil seperating 54 703 hazard to water liquid to
plants solid
sludge from container cleaning 54 704 hazard to water liquid to
and barrel cleaning solid
paraffine oil sludge 54 706 hazard to water liquid to 2) petrol chemistry, comercial trade
solid
grinding sludges, oil containing 54 710 hazard to water liquid to 2) metal, glass and rock machining
solid
used oil binding materials 54 926 hazard to water
used oil and air filters 54 928 hazard to water

(containing mineral oil)
perchlorethylene (per) 55 209 hazard to water liquid 2) chemical industry, textile industry,
laundries, degreasing, production of
coating agents
trichlorethane 55 212 hazard to water liquid 2) chemical industry, textile industry,
toxic only the 1.1.2 laundries, degreasing, production of
trichlorethane, coating agents
detrimental to health
trichlorethylene (tri) 55 213 hazard to water liquid 2) chemical industry, textile industry,
detrimental to health laundries, degreasing, production of
coating agents
cold cleaning agents 55 214 hazard to water liquid 2) industry and trade
solvent mixes, 55 220 hazard to water, liquid 2) industry and trade

halogen-containing may be toxic
diluent for cellulose lacqers 55 359 hazard to water, kann liquid 2) cleaning and degreasing of metallic
mit Luft explosive Gase surfaces, production of coating agents,
bilden textile industry, plastics processing,
chemical industry
paraffine oil 55 360 hazard to water, kann liquid 2) cleaning and degreasing of metallic
mit Luft explosive Gase surfaces
bilden
solvent mixes, halogen-free 55 370 hazard to water, liquid 2) industry and trade
may be toxic,
may form explosive
gases with air
lösemittelhaltige Schlämme, 55 401 hazard to water, liquid to 2) industry and trade, concentration
halogenhaltig may be toxic pasty
lösemittelhaltige Schlämme, 55 402 hazard to water, liquid to 2) industry and trade, concentration
halogenfrei may be toxic pasty
B66
C Programming and Operation
EMCO-specific - Sinumerik 810/840D
Survey M Commands machine
(Channel 1)
M0 Programmed stop M 50 Deselect direction logic

M1 Optional stop
M 57 Main spindle oscillation on
M3 Main spindle on clockwise M 58 Main spindle oscillation off
M4 Main spindle on counterclockwise
M 59 Chip conveyor interval time (in connection
M5 Main spindle stop
with H word)
M2=3 Counter spindle on clockwise
M 65 Feed hold / read-in lock KUPA/EMCO bar
M2=4 Counter spindle on counterclockwise
loader
M2=5 Counter spindle stop
M 66 Release feed KUPA/EMCO bar loader
M3=3 Driven tool on clockwise
M 71 Rinse on
M3=4 Driven tool on counterclockwise
M 72 Rinse off
M3=5 Driven tool stop
M 73 Runtime measuring on
M7 Coolant 2 on (high pressure coolant)
M 74 Runtime measuring off
M8 Coolant 1 on (standard coolant)
M9 coolant off M 81 Channel 1 waits until M30 in channel 2
M 10 Spindle brake spindle 1 on M 89 Release spindle rotation with open clamp-
M 11 Spindle brake spindle 1 off ing device
M2=10 Spindle brake spindle 2 on M 90 Reset M89
M2=11 Spindle brake spindle 2 off
M 96 Set nominal workpiece number reached
M 17 Subprogram end
M 99 Machine configuration (in connection with
M 20 Tailstock back (Hxxx back end position) H word)
M 21 Tailstock forward (Hxxx front end posi-
M 103 Read lockout, until spindle speed (S1/S2)
tion)
is reached
M 22 Eject part
M 105 Read lockout, until spindle (S1/S2) stands
M1=22 Part ejector forward
M2=22 Part ejector backward M 150 Free programmable output (A57.0) on
M 160 Free programmable output (A57.0) off
M 23 Collection tray back
M 151 Free programmable output (A57.1) on
M 24 Collection tray forward
M 1=24 Collection tray forward in wait position
M 29 Collect part from counter spindle M 162 Free programmable output (A57.2) off
M 25 Open clamping device left
M 26 Close clamping device left
M2=25 Open clamping device right
M2=26 Close clamping device right
M 30 Program end M 165 Free programmable output (A57.5) off
M 31 Release open gantry door
M30 M32 Program end with restart (depending on M 157 Free programmable output (A57.7) on
1x key) M 167 Free programmable output (A57.7) off
M 158 Warning lamp red on
M 168 Warning lamp red off
SW5 - 10/01 C1
M COMMANDS, MACHINE CONFIGURATION PROGRAMMING AND OPERATION - SINUMERIK
Survey M Commands Gantry

(Channel 2)
M 17 Subprogram end M 67 Open finished part grip

M 68 Close finished part grip
M 25 Open clamping device left
M 26 Close clamping device left M 71 Rinse on
M2=25 Open clamping device right M 72 Rinse off
M2=26 Close clamping device right M 83 Pallet magazine step 1 position
M 30 Program end M 89 Release spindle rotation with open clamp-
M30 M32 Program end with restart (depending on ing device
1x key) M 90 Reset M89
M 60 Close gantry door H1 Raw part grip left, finished part grip right
M 61 Open gantry door H2 Raw part grip bottom, finished part grip top
M 65 Open raw part grip H3 Raw part grip right, finished part grip left
M 66 Close raw part grip H4 Raw part grip top, finished part grip bottom
Survey Machine Configuration M99
Channel 1 (machine) Channel 2 (Gantry)
H0 M99 manual chuck / end face driver H1 M99 raw part gripper outside clamping
clamping device left H2 M99 raw part gripper inside clamping
H1 M99 jaw chuck / pull collets left
H2 M99 pressure collets left H11 M99 finished part gripper outside clamping
H12 M99 finished part gripper intside clamping
H3 M99 Clamping device control left off
H4 M99 bar feed / loading magazine on

H5 M99 bar feed / loading magazine off
H10 M99 manual chuck / end face driver

clamping device right
H11 M99 jaw chuck / pull collets right
H12 M99 pressure collets right
H13 M99 Clamping device control right off
C2
PROGRAMMING AND OPERATION - SINUMERIK AXES DESCRIPTION
Axes Description
Axes description of machine with tailstock
Axes description of machine with counter spindle (spindle 2)
Axes description of machine with gantry loader (option)
C3
MACHINE CONTROL PANEL PROGRAMMING AND OPERATION - SINUMERIK
Machine Control Panel
6.,3 '5<
581 & ; & 4 57 )7
237 = = 4 4 4
[ 6723

6%/ & ; &

357 = =
$8; $8;
1 2 3
Machines with gantry loader (option) are equipped Machines with tailstock (option) are equipped with
the keys tailstock forward and tailstock
with the key Handling Start instead of the
additional NC Start key (2). backward instead of the free key and the key
clamping device right (3).
In this case the NC Start key (1) operates the
machine (channel 1) and the Handling Start key
(2) operates the gantry loader (channel 2).
C4
PROGRAMMING AND OPERATION - SINUMERIK KEY DESCRIPTION
Key Description
Skip
In skip operation the program blocks that are
marked with a slash "/" before the block number,
6.,3 will not be executed in program run (e.g.: /N100).
Dryrun
In dryrun operation the traversing movements will
'5< be executed with the feed set in setting data
"dryrun-feed" .
581 The dryrun feed works instead of the programmed
feed.
Single Piece Mode

With this key you can select single piece mode or
continuous operation in connection with an
[ automatic loading device.
Power-on status is single piece operation.
The additional key Single Piece Mode shows the
active status by light.
Optional Stop
At active function (key was pressed) the program
237 run will be stopped at blocks that contain the
6723 command M01.
The screen shows "Halt: M00/M01 active". Con-
tinue the program with the key NC Start.
When the function is not active, M01 (in the part
program) will be ignored.
Reset Key
Actuating Reset causes:
• Stop of working off the actual part program.
• Alarms and messages are cleared with the ex-
ception of Power On or Recall alarms.
• The channel will be set to the reset status, that
means:
- The NC control stays synchronous to the ma-
chine.
- All intermediate and working memory is cleared
(the contents of the part program memory stays
resident).
- The control is in basic setting and ready for
program run.
C5
KEY DESCRIPTION PROGRAMMING AND OPERATION - SINUMERIK
Single Block
This function allows to work off a part program
block by block.
6%/ The function single block can be activated in AU-
TOMATIC mode.
Active single block mode causes:

• Display SBL1 or SBL2 at the screen (in the line
channel).
• Display of "Halt: Single block mode" in the
message line (in interruption status).
• The actual block of the part program will be
worked off after pressing NC Start.
• Working off will be stopped after each block.
• The following block will be worked off after
pressing NC Start.
Deselect the function by pressing again on the
single block key.
SBL1
Single block mode with stop after every block
with machine functions.
Machining stop after every block that releases a
machine function (no stop with calculation blocks).
SBL2
Single block mode with stop after every block.
With active function the blocks will be worked off
as following:
Every block will be decoded one by one, at every
block occurs a stop.
Exceptions are only threading blocks without
DRYRUN. Here occurs the stop at the end of the
thread.
SBL2 can be selected only in Reset status.
Note
You can select either SBL1 or SBL2 .
Select SBL1 or SBL2 in AUTOMATIC or MDA

mode or with the softkey "program influence".
Program Test
Use this key for program test run without axes
movements. This test run is used to recognize
357 programming errors.
C6
NC Stop
After pressing the NC Stop key and takeover of
the function by the control, working off of the
running part program will be stopped.
You can continue working off by pressing NC
Start.
NC Start
After pressing the NC Start key the selected part
program will be started with the actual block.
Direction Keys
& ; & Use this keys to traverse the axes in the JOG
mode.
= =
& ; &
= =
Rapid
If this key is pressed simultaneous to a direction
key the responding axis traverses in rapid feed.
Reference Point
Pressing this key causes approaching the refer-
ence point in all axes..
Feed Stop
This key stops slide movements in AUTOMATIC
mode (not for threads).
Feed Start
This key continues programmed, interrupted slide
movements.
When spindle run was interrupted additionally first
the spindle run must be continued.
Direction Keys Gantry Loader

4 (Option)
Use this keys to traverse the axes of the gantry
4 4 4 loader in the JOG mode.
See chapter F Gantry Loader.
C7
Spindle Override
The actual spindle speed S is shown at the screen
as absolute value and in percent.
Valid for main spindle, counter spindle and driven
tools.
Setting range: 50 - 120 % of the pro-
grammed spindle speed
Step width: 5 % per key touch
100% spindle speed: 100% key.
Spindle Stop
This key stops the running of the main and coun-
ter spindle and driven tools. Before stopping the
spindle you must stop the slides.
Spindle Start
This key continues the programmed run of the
main and counter spindle and driven tools.
Programming
M3 Main spindle on clockwise
M2=3 Counter spindle on clockwise
M3=3 Driven tool on clockwise.
M4 Main spindle on counterclockwise
M2=4 Counter spindle on counterclockwise
M3=4 Driven tool on counterclockwise.
M5 Main spindle stop
M2=5 Counter spindle stop
M3=5 Driven tool stop
Raw Part Grip OPEN - CLOSE

(Option)
57 M 65 Open raw part grip

M 66 Close raw part grip
Swivel Grip Head (Option)

H1 Raw part grip left, finished part grip right
H2 Raw part grip bottom, finished part grip top
H3 Raw part grip right, finished part grip left
H4 Raw part grip top, finished part grip bottom
Finished Part Grip OPEN - CLOSE

(Option)
)7 M 67 Open finished part grip
M 68 Close finished part grip
C8
Gantry Door Open/Close (Opti-

on)
M 60 Close gantry door
M 61 Open Gantry door
With M60 or key closed gantry door:
The gantry door will open and close together with
the machine door.
With M61 or key opened gantry door:
The gantry door keeps open, irrespective of the
movement of the machine door.
Magazine Step (Option)

See chapter F Gantry Loader.
The raw part magazine steps for one position.
M 83 Pallet magazine step 1 position
Clamping Device Left

This key actuates the clamping device on the left
side.
Switchover chuck/collet see "Machine configu-
ration".
Via NC program
M25 ........ Open clamping device left
M26 ........ Close clamping device left
Clamping Device Right (Option)

This key actuates the clamping device on the right
side (counter spindle).
Switchover chuck/collet see "Machine configu-
ration".
Via NC program
M2=25 .... Open clamping device right
M2=26 .... Close clamping device right
Tailstock Forward, Backward

These keys move the tailstock forward and back-
ward.
Actuating the tailstock in the program
M20 Tailstock back (back end position)
M21 Tailstock forward
The tailstock goes to the last manual
clamping position in JOG
M20 H... Tailstock back
M21 H... Tailstock forward
The tailstock goes to the Z-position
determined by H
C9
Coolant
This key switches the coolant device on or off.
The last with M07 or M08 activated coolant de-

vice will be switched on or off.
M7 High pressure coolant device
M8 Standard coolant device
M9 Coolant off
The additional coolant key shows the actual sta-

tus.
Chip Conveyor (Option)

Switch on chip conveyor:
Forward: Press key shorter than 1 second.
Backward: Press key longer than 1 second
The chip conveyor will be switched off after

approx. 35 seconds.
This value is set at works.
Tool Turret
In JOG mode this key swivels the tool turret for
one position.
Auxiliary OFF
This key switches off the auxiliary drives of the
$8; machine. Effective only at spindle and program
stop.
Auxiliary ON
This key switches the auxiliary drives of the ma-
$8; chine to ready status (hydraulics, feed drives,
spindle drives, lubrication, chip conveyor, cool-
ant).
The key must be pressed for approx. 1 second.
Short pressing the AUX ON key is a quit function
and effects a lubrication impulse.
C10
Mode Selection Switch

Teach In
Creating programs in dialogue with the machine
in MDA mode.
MDA
Manual Data Automatic
Control of the machine by working off one block
or a sentence of blocks. The input of the blocks
occurs via operation panel.
Jog
Manual traverse
Conventional traversing of the machine by con-
tinuous moving of the axes via direction keys or
via incremental moving of the axes via direction
keys or via handwheel.
Inc Var
Incremental Feed variable
Traverse incremental value with variable incre-
ment width (setting data)
Inc 10
Incremental Feed
Traverse incremental value with fix step width of
10 increments.
Inc 100
Incremental Feed
Traverse incremental value with fix step width of
100 increments.
Repos
Repositioning, approach back to contour in JOG
mode.
Automatic
Control of the machine by automatic working off
of programs.
Ref
Approaching the reference point (Ref) in JOG
mode.

Feed Override Switch

The rotary switch with 23 positions allows to alter
the programmed feed F (meets 100 %).

The selected feed value F in % is displayed at
the screen.

Setting range:
0 % to 120 % of the programmed feed.
In rapid feed 100 % will not be exceeded.
C11
EMERGENCY OFF
Actuate the red button only in emergency situa-
tions.
Effects:
Normally all drives are stopped with maximum
deceleration by EMERGENCY OFF.
Unlock: Turn button
To continue press the following keys:
RESET, AUX ON, OPEN and CLOSE door.
Key Switch Special Operation

The key switch can be set to "AUTOMATIC" or
"SETUP" (manual) position.
Only by pressing the consent key the respective
function of the key switch will be released (see
consent key).
This key switch allows some dangerous move-
ments with open door in tipping operation (with
consent key).
DANGER
Active special operation increases the dan-
ger of accidents.
The key must be used only by authorized
persons, who have the knowledge about the
dangers and are careful in operation.
Keep the chip guard door closed also during
setup operation.
Take off key always after working in special

operation (danger of accidents).
Observe the local safety regulations (e.g.:

SUVA, BG, UVV ....).
Key Switch Data Protection

Position 0
Part program input is locked.
Tool wear can be compensated.
Position 1
Part program input is released.
Possible further inputs:
Zero offsets, tool geometry, setting data.
With active single piece key the limit proximity
switches of the clamping device are not active
(for test run without workpiece).
C12
Additional NC Start Key

Same function as NC START key at the machine
control panel (Siemens).
(Double equipment for better comfort).
Handling Start (Option)

Machines with gantry loader are equipped with
the key Handling Start instead of the second NC
Start key.
For Gantry loader machines the NC Start key (Sie-
mens keyboard) is effective for the machine
(channel 1), the Handling Start key is effective
for the gantry loader (channel 2).
Additional Key Single Piece

mode
Key light on: single piece mode is active
Additional Key Clamping Device

Left
Key light on: Part clamped
Additional Key Coolant

Key light on: Coolant runs
Key flashes: Coolant on was programmed but
coolant does not run (Dryrun or switched off
manually)

Right
Key light on: Part clamped
The additional keys have the same function as

on the machine control panel (Siemens).
Consent Key
Axis movements via direction keys and tool turret
movements at open door are allowed by pressing
the consent key (precondition: key switch in
position setup).
C13
MAIN SWITCH, SIGNAL LAMP PROGRAMMING AND OPERATION - SINUMERIK
Main Switch
Function:
0 - OFF
1 - ON
The main switch has no emergency off function,

that means the drives run out (unbreaked).
The programs in the NC core will be lost with
switching off.
The main switch can be locked (unauthorized
operation of the machine).
Signal Lamp (Option)

The signal lamp is divided in three indication fields
(white, green, red) which indicate the operating
status of the machine.
Operating statii:
WHITE
Flashing ...................................... lack of raw parts
Permanent light .............................. loading active
GREEN
Flashing ................. automatic operation selected
Permanent light ......... automatic operation active
RED
Permanent light ........ Alarm / EMERGENCY OFF
C14
PROGRAMMING AND OPERATION - SINUMERIK OPEN MACHINE DOOR
Open Machine Door
Danger:
Do not remove or bypass control or safety
devices of the machine.
These devices are installed for your own
safety and in case of elimination will increase
the risk of accidents.
For reasons of safety door safety switches are

used for supervising.
Note:
After the machine has been switched on the
door must be opened and closed once as
otherwise message "door open" is emitted.
This measure serves to check whether the
door safety switch is operating.
Door safety switch If NC START-key is pressed with open door, mes-

sage "door open" appears. The NC START com-
mand will not be executed.
To open the chip guard door the consent key must
be pressed.
Thus the door lock bolt will be released and the
door can be opened.
Therefore the following conditions must be met:
1. All spindle drives must stand still.
2. No part program must be active.
Door Automatic
By machines with the attachment "Door Auto-
matic" the door lock bolt will be released and the
door opened automatically by pressing the
consent key.
The machine door will also be opened auto-
matically, if the bar feed / loading magazine or
handling is active.
Key "Close Door"

Machines with the door automatic have a "close
door"-key instead of the additional NC-Start key.
By pressing this key simultaneous with the
+ consent key, the machine door will be closed (in
the JOG-mode).
If there is no bar feed / loading magazine or
handlig active, the program will be started
automatically, when the machine door is closed.
C15
CLAMPING DEVICE CONTROL PROGRAMMING AND OPERATION - SINUMERIK
Clamping device control

Purpose
With automatic workpiece loading for safety
1 2 reasons prior to switching on the main spindle, it
is automatically asked if the clamping device is
within the permitted clamping area.
b1
For this purpose the control must know certain
data of each clamping device.
a Function
(Example jaw chuck)
With opened jaw chuck (1) the clamping cylinder
b2
with bore is in front (right) position.

The sensor (2) measures the distance (b1) and
thus the condition "chuck open" is defined.
When closing the jaw chuck the piston (1) moves
backwards with the tensioning tube (traversing
movement a), thus the measurable distance
Sensors for the clamping device control changes (b).
The new distance (b2) defines the condition
"chuck closed and workpiece clamped".
If the chuck is closed without workpiece, the
piston (1) moves until stop to the left. The distance
b is bigger than b2 and thus the control knows
that no workpiece is clamped and emits an alarm.
Condition displays of the

clamping device
The condition of the clamping device is indicated
at the additional clamping device keys:
Clamping device key dark

Clamping device open
Clamping device key clear

Clamping device closed, workpiece clamped;
the clamping device pressure is achieved, the
final position of the clamping device has not been
reached.
Clamping device key blinks

Clamping device closed, no workpiece clamped;
the clamping pressure is achieved, the final
position of the clamping device has been reached.
C16
PROGRAMMING AND OPERATION - SINUMERIK CLAMPING DEVICE CONTROL
Adjustment of the clamping

device control
During this procedure the final positions of the
clamping device for the clamping condition open
maximum clamping area
and closed are adjusted (see "clamping device
permitted clamping area key dark" and/or "clamping device key blinks").
device closed
device open
(clamping device closed, Furthermore, the permitted clamping area is

Clamping
Clamping
workpiece clamped)
defined (see "clamping device key lights").
Note:
The adjustment of the clamping device control
must be carried out:
Safety area • after each clamping device change
• in case of the emission of the alarms
Clamping and safety areas 510 100, 510 108, 520 108 - "clamping
device 1/2 open missing"
Procedure
Note:
Prior to the adjustment check the machine
configuration for the clamping device (chuck/
collet)!
• Set operating mode selector to "JOG".

• Delete actual datas
$8; +
Delete the actually stored values by actuating
simultaneously the key "AUX ON" and the
clamping device key.
• Open clamping device

Release key "AUX ON" and actuate clamping
device key once; the clamping device is opened.
• Close clamping device

Actuate clamping device key once; the clamping
device is closed.
• The control computes and stores the permitted

clamping area with the help of the identified
final positions.
C17
CLAMPING DEVICE CONTROL PROGRAMMING AND OPERATION - SINUMERIK
Bridging the final position

clamping device detectors
With "Key switch data protection"

Key switch - position "1"
With active single piece key the final position

sensors of the clamping devices are not active.
Application
test run without workpiece
Programming with H-word

If clamping is to be carried out in an area
maximum clamping area exceeding the limits of the permitted clamping
area, the final position control must be switched
permitted clamping area
off (clamping in the safety area).
(clamping device closed,
workpiece clamped)
Caution:
Consider that with this possibility the survey
function is permanently switched off.
Safety area For this reason it may only be used if this
clamping state (clamping in the safety area)
required clamping
cannot be changed by other measures (e.g.
area collet change, chuck change, etc.).
Clamping area outside of the permitted area
Switching off the final position

detector
Spindle 1 H3 M99
Spindle 2 H13 M99
Activate the final position detector

Spindle 1 H1/H2 M99
Spindle 2 H11/H12 M99
C18
PROGRAMMING AND OPERATION - SINUMERIK SWITCH ON/OFF SEQUENCE
Switch On/Off Sequence
Switch On the Machine

(machines with one tool turret)
Switch on main switch at the electrical cabinet

(cabinet fan runs).
$8; Open and close the chip guard door once for
checking the door safety switch.
Press key AUX ON for at least 1 second (main

drive fan runs, axes active).
Approach Reference Point
Possibility A:
Referencing axis by axis
=
Press the +Z key
The slide traverses to the reference point in Z.
Press the +X key

; The slide traverses to the reference point in X.
(Only after the collision-free area was reached in
Z)
= Press the Z2 key

The slide traverses to the reference point in Z2.
Press the tool turret key to reference the tool

turret.
Note:
After reaching the reference points the
software limit switches are active.
Possibility B:
Automatic referencing
Press the key "reference". The axes traverse to

the reference point one after the other.
C19
SWITCH ON/OFF SEQUENCE, CHIP CONVEYOR PROGRAMMING AND OPERATION - SINUMERIK
Switch Off the Machine

$8; Press AUX OFF.
Switch off main switch
Notes:
• Switching off the machine occurs with the
main switch.
We recommend to switch off the machine
only at ready position of the tool turret.
• Interruptions of operating are done with the
RESET key.
RESET stops all running machine functions.
Chip Conveyor
Example Programming:
%1 M 59 H ....
N10 M59 H180
While program run the chip conveyor is switched
N20 ...
on in certain intervals, runs approx. 35 s and is
switched off again. The time from switch on to
The chip conveyor is switched on all 180 sec-
switch on is programmed with H (max. 4 digits) in
onds, runs for approx. 35 s and is switched off.
seconds. By it for every part program the interval
time can be programmed depending on the
amount of chips.
This interval time stays resident until the next
Note: M59 is programmed, also after machine off - on.
To avoid contamination of the emulsion the Overstore in MDA mode is possible.
chips should be removed out of the machine
before end of working. Manual Operation:
A short run out of the chip conveyor is recom-
mended. Forward: Press key shorter than 1 second.
Backward: Press key longer than 1 second
C20
PROGRAMMING AND OPERATION - SINUMERIK SPINDLE BRAKE, WORKPIECE COLLECTION, TAILSTOCK
Spindle Brake
Programming
M10 Main spindle brake on
Note: M11 Main spindle brake off
The brake force is set at works (hydraulics) M2=10 Counter spindle brake on
and must be altered by a service technician M2=11 Counter spindle brake off
only.
Manual operation
JOG mode
$8;
Brake on: AUX ON + Spindle Stop
Brake off: Reset
Workpiece Collection
Device (Option)
The swivelling operation can only be carried out
via CNC program. Swivelling in and out is possi-
ble only with closed door.
Programming
M1=22 Ejector forward
M2=22 Ejector backward
M22 Eject (forward and backward)
M 23 Collecting tray backward
M 24 Collecting tray forward
M 1=24 Collecting tray forward in waiting po-
sition
M 29 Collect part from counter spindle
Tailstock
Programming
M20 Tailstock back (back end position)
M21 Tailstock forward
The tailstock goes to the last manual
clamping position in JOG
M20 H... Tailstock back
M21 H... Tailstock forward
The tailstock goes to the Z-position
determined by H
The tailstock goes up to 20 mm before end posi-

tion with rapid feed, then with reduced feed.
When the tailstock overtravels the determined
position (JOG or H...) an alarm occurs.
Manual operation
Tailstock forward / backward
C21
C AXES, TOOL TURRET PROGRAMMING AND OPERATION - SINUMERIK
C Axes
JOG operation of the C axes For milling planes (square, hexagon, etc.) the C
axis and the tool slide must be moved together in
The following program must be executed in MDA
a certain relation (= hob milling).
before operating the C axes in JOG mode:
The software accessory "Transmit" allows simple
Main spindle
programming of such planes.
SPOS[1]=0 (switch on C axis)
G0 C0 (C axis movement) Description with programming example see
M30 "Transmit".
Counter spindle Switch on the C axes
SPOS[2]=0 (switch on C axis)
SPOS=0..360 (angle in degree)
G0 C2=0 (C axis movement)
SPOS[1]= Main spindle
M30
SPOS[2]= Counter spindle
Deselection of the C axes
M3, M4, M5
Tool Turret
Manual operation
JOG mode, the tool turret swivels on key tip for
one position.
Influencing the Tool Turret in AUTO-

MATIC and JOG Mode

Altering swivel speed

The swivel speed can be altered with the feed

override switch.
Interruption of the swivel sequence
$8; To avoid a collision while swivelling you can in-

terrupt swivelling with the key AUX ON.
Keep the key AUX ON pressed!
(otherwise swivelling will be continued) traverse
out of the danger area with the direction keys X,
Z (the override switch must not be at 0).
Aborting the swivel sequence

When aborting with EMERGENCY OFF or RE-
SET, the tool turret looses its reference point.
Remedy:
Unlock EMERGENCY OFF, RESET, AUX ON,
chip guard door open-close, Traverse tool turret
with AUX ON and X, Z key out of the danger
area, referencing with tool turret key.
C22
PROGRAMMING AND OPERATION - SINUMERIK MACHINE CONFIGURATION
Machine Configuration
Clamping Device Left

H1 M99 jaw chuck (outside clamping)
H2 M99 collet chuck (inside clamping)
H3 M99 Clamping device control left off
Clamping Device Right

H11 M99 jaw chuck (outside clamping)
H12 M99 collet chuck (inside clamping)
H13 M99 Clamping device control right off
Continuous Operation
H4 M99 Release continuous operation (se-
lect continuous/single piece mode
with key [ )
H5 M99 Single piece mode
Programming
H.. and M99 must be programmed in the same
program block.
The machine configuration can be written in a
part program or can be entered in MDA - over-
store.
The machine configuration stays resident also

with switch off and on the machine until it will be
overwritten by a new H.. M99 command.
C23
R-PARAMETER PROGRAMMING AND OPERATION - SINUMERIK
R Parameter
The control Sinumerik 840 D offers 100 calcu-
lating variables (= R parameter) of type REAL as
standard.
The array from R0 to R89 is free available for the
user, the array R90 to R99 is reserved for EMCO.
Workpiece Counter (R90, R91)

Actual workpiece number
The actual workpiece number is shown in param-
eter R90.
Nominal workpiece number
The nominal workpiece number is shown as pa-
Example rameter R91.
250 pieces are to be machined.
Function
• Set nominal workpiece number R91 = 250 • If a nominal workpiece number is entered in
The workpiece counter counts down from 250 parameter in R91, parameter R90 will count
to 0 and emits the message "nominal workpiece from the nominal workpiece number down to 0.
number reached". When the nominal workpiece number is worked
off, the control shows the message "nominal
• Set nominal workpiece number R91 = 0 workpiece number reached".
Set actual workpiece number R90 = 0 • When nominal workpiece number R91 and ac-
The workpiece counter counts from 0 up to 250 tual workpiece number R90 are set to 0, pa-
and emits no message. rameter R90 counts from 0 upward.
Programming
The call-up of the workpiece counter in the pro-
gram is carried out just before the M30 command
with L700 P1.
Machining Time (R98, R99)

Example
The actual machining time of the whole part pro-
%1 gram is stored in R98.
.
. Runtime measuring R99
.
Runtime is the machining time for a single ma-
T6D7
chining sequence (e.g. finishing).
M6
M3 S4000 F... R98 M73 Runtime measuring start
M73 M74 Runtime measuring stop
.
The measured runtime is stored in R99.
. R99
.
M74
Format for parameter R98 and R99
T7D1
. Example: 6347.387
M2 = 63 min, 47 s, 387 ms
C24
PROGRAMMING AND OPERATION - SINUMERIK FREEPROGRAMMABLE OUTPUTS
Freeprogrammable Out-
puts
Survey
M-fuction
Output signal Input signal Query in part-program
on off
A57.0 M 150 M 160 E44.0 $A_IN[9]
A57.1 M 151 M 161 E44.1 $A_IN[10]
A57.2 M 152 M 162 E44.2 $A_IN[11]
A57.3 M 153 M 163 E44.3 $A_IN[12]
A57.4 M 154 M 164 E44.4 $A_IN[13]
A57.5 M 155 M 165 E44.5 $A_IN[14]
A57.6 M 156 M 166 E44.6 $A_IN[15]
A57.7 M 157 M 167 E44.7 $A_IN[16]
You have the possibility to set several functions

for the freeprogrammable outputs with machine
datas.
• The output won't be resetted with M30/reset,

but only with the M-function.
• The output will be resetted after a time, adjusted
with machine datas.
• By setting the output a feed hold will be triggered
in this channel, in which the M-function wa
pragrammed, until the belonging input will be
"one".
• By setting the output a read lockout will be
triggered in this channel, in which the M-function
wa pragrammed, until the belonging input will
be "one".
Standard Setting
• The output will be resetted with the Reset-key
or with M30
(or with the M-function)
• Feed hold and read lockout won't be triggerd.
For other settings please contact EMCO-Service

Department.
C25
Y-AXIS PROGRAMMING AND OPERATION - SINUMERIK
Y-Axis
Programming
G19 ........... choose working plane (YZ) for lateral DIAMOF .... diameter programming off
area-working, in-feed coordinate is X DIAMON ... diameter programming on
G17 ........... choose working plane (XY) for facing,
M10 ........... spindle clamping on
in-feed coordinate is Z
M11 ........... spindle clamping off
G18 ........... Resetting for lathing
Programming example for using the Y-axis

(lateral area-working - areas 1 and 2)
Drawing for example part

⎧ N1750 T5 D1 .............. milling diameter = 10
⎪ N1760 G95 ................. belongs to SPOS
milling area 1
Programming notes ⎪ N1770 SPOS[1]=0 ..... activate C-axis

⎪ N1775 M10 ................. spindle clamping on
To avoid crashes, the Y-axis should be traversed ⎨ N1780 SETMS(3) ....... driven tool = master spindle
to position 0 after every use. ⎪ N1800 G95 S2700 M3
⎪ N1810 G0 X76 Y-25 Z-13
⎪ N1820 G1 Y25 F0.2
⎩ N1830 G0 Z-23
...
⎧ N2010 G0 X100 Y0 Z-30.5

⎪ N2020 G19 ................. choose working plane (YZ)
⎪ N2030 T5 D2 .............. milling diameter = 10
⎪ N2050 POCKET2(100,72,0,64,8,20,0,-30.5,
⎪ 0.05,0.2,8,3,0.2,1,0,0.1,2700)
⎪
milling area 2
N2060 G0 Z-33.5 Y0
⎪ N2070 G0 X73
⎨ N2080 G1 X64 F0.1
⎪ N2090 G1 Y20 Z-30.5 G41
⎪ N2100 G3 Y20 Z-30.5 J-20
⎪ N2110 G0 G40 Y0 Z-30.5 X90
⎪ N2120 X120 M5
⎪ N2125 M11 ................. spindle clamping off
⎪ N2160 M9
Working areas ⎩ N2170 M30
C26
PROGRAMMING AND OPERATION - SINUMERIK CYKLES / "CYCLE95"
Cycle Programming
Roughing Cycle "CYCLE95"

This cycle can be used for external or internal,
longitudinal or transversal roughing or finishing
operations. The largest diameter for external
roughing and the smallest diameter for internal
roughing sets the start point for the roughing
cycle.
The last position in your program must be out of
the roughing area made by the cycle, otherwise
an alarm "wrong startpoint" appears.
Machining type
ORQJLWH[WHUQDO ORQJLWLQWHUQDO longitud. outside /

value kind of machining
9DUL 9DUL
/ facing inside
; ;
1 l o roughing
2 f o roughing
3 l i roughing
4 f i roughing 1)
= = 5 l o finishing
6 f o finishing
7 l i finishing
IDFLQJH[WHUQDO IDFLQJLQWHUQDO 8 f i finishing 1)
9DUL 9DUL 9 l o compl. machining
; ;
10 f o compl. machining
11 l i compl. machining
12 f i compl. machining 1)
1) Only used for the machining behind a
shoulder
= =
roughing cycles
Notes:
• It is important to choose the right cutting
edge position, because G41/G42 is acti-
vated automatically!
• Further informations see Siemens-book
"Cycles"_4-18
C27
CYKLES / "CYCLE95" PROGRAMMING AND OPERATION - SINUMERIK
Example
external contour longit. turning
Name of contour subprogram .................................................. SCHRUPP1
Depth of cut ............................................................................... 3
Finishing allowance in Z .......................................................... 0,05
Finishing allowance in X .......................................................... 0,3
Finishing allowance contour paralel ........................................ 0
Roughing feedrate .................................................................... 0,3
Undercut feedrate ..................................................................... 0,1
Finishing feedrate ..................................................................... 0,12
Type of machining .................................................................... 9
Dwell time for chip breaking .................................................... 0
Chip breaking length ................................................................ 0
G54
G53 G0 X610 Z350 Z2=760
&RQWRXU&217
N1 T1 D1 G96 S250 M4 G0 X65 Z0
G1 F0,18 X-1,6
G0 X65 Z5
CYCLE95("CONT1",3,0.05,0.3,0,0.3,0.1,0.12,9,0,0)
G0 X200 Z100
¡ ¡ M30
¡
¡ Subroutine for contour: CONT1:
G1 X35 Z2
Z0
X40 Z-1
Z-5
X50
X58 Z-10
external contour logitudinal turning Z-25
X38 Z-45
Z-50
X60 CHR=0,3
Z-50,4
[ M17
Example - external contour facing
G54
G53 G0 X610 Z350 Z2=760
N1 T1 D1 G96 S250 M4 G0 X65 Z0 ;roughing tool
G1 F0,18 X-1,6
G0 X65 Z5
¡
¡
CYCLE95("CONT",1,0.02,0.05,0,0.3,0.1,0.12,10,0,0)
G0 X200 Z100
M30
[ Subroutine: CONT
G1 X100 Z-12
Z-10 CHR=1
X25
Z0 CHR=1

X22
external contour facing M17
C28
Example
internal contour longit. turning
G54
G53 G0 X610 Z350 Z2=760
&RQWRXU&217,
N5 T5 D1 G96 S250 M4 ; boring bar
CYCLE95("CONTI1",3,0.05,0.3,0,0.3,0.1,0.12,11,0,0)
G0 X200 Z100
M30

5
[

Subroutine: CONTI1

¡
¡
0
¡
¡
G1 X40 Z0 F0,12
[ X38 Z-2,5
ERUH¡ Z-10
X40 Z-12,5
Z-20
X30 CHR=0,3
Z-30 F0,1
X20 RND=0,3
internal contour longitudinal turning Z-40
X17
M17
Example - internal contour facing
G54
G53 G0 X610 Z350 Z2=760
....
N1 T1 D1 G96 S250 M4 G0 X65 Z0 ; boring bar
¡
CYCLE95("CONT",1,0.02,0.05,0,0.3,0.1,0.12,10,0,0)
¡
G0 X200 Z100
M30
[ Subroutine: CONT
G1 X25 Z-12
Z-10 CHR=1
X100
Z0 CHR=1
X103
[ M17
internal contour facing
C29
Threading Cycle "CYCLE97"
constant feed-in depth constant chip-load

It is possible to make cylindrical or tapered,
VARI=1/2 VARI=3/4 external or internal threads with constant pitch,
longitudinal or transversal. The threads can be a
= = = = = “single start” or a “multiple start” thread.
You can choose between two different ways of
feed-in: constant feed-in depth or constant chip-
load.
radial infeed angular infeed alternating side

"0°" e.g. "26°" cuting "-29°"
value thread infeed
1 outside constant infeed

2 inside constant infeed
3 outside constant chip section
4 inside constant chip section
infeed possibilities for "CYCLE97"
Note:
Further informations see Siemens-book
"Cycles"_4-33
Numer of roughing passes insteel accoring

to Sandvik
external / internal (metric. threads 60°)
number of number of
pitch pitch
cuts cuts
0,5 4 3 12
0,75 4 3,5 12
1 5 4 14
1,25 6 4,5 14
1,5 6 5 14
1,75 8 5,5 16
2 8 6 16
2,5 10
C30
Example - external thread
Thread pitch .........................................................................................2

Thread size .......................................................................................... 0
Start point in Z-axis .............................................................................0
Start point in Z-axis ......................................................................... -10
Diameter at start point ...................................................................... 30
Diameter at end point ....................................................................... 30
Approach length ...................................................................................5
Run out length ..................................................................................... 2
Depth of thread (radial/no sign) ......................................................... 1,227
Finishcut allowance .............................................................................0,1
Infeed angle (+/-) .............................................................................. 26
Degree of rotation of thread start ....................................................... 0
Number of roughing passes ................................................................ 8
Number of idle passes ........................................................................ 1
Type of cycle ........................................................................................ 3
Number of starts .................................................................................. 1
G54
G53 G0 X610 Z350 Z2=760
N2 T2 D1 G95 S2000 M3 ; Threading tool pitch 2mm
CYCLE97(2,0,0,-10,30,30,5,2,1.227,0.1,26,0,8,1,3,1)
G0 X200 Z100
N3 T3 D1 G95 S1500 M3 ;Threading tool pitch 3mm
CYCLE97(3,0,-25,-40,50,50,5,3,1.84,0,-29,0,12,2,3,1)
G0 X200 Z100
M30
WKUHDG0[
Calculation of radial depth of thread

WKUHDG0[
"external thread - 60°"
t = 0,6134 x p
t ................................................. thread depth
p .............................................................. pitch

external thread
C31
Example - internal thread
Thread pitch .........................................................................................4

Thread size .......................................................................................... 0
Start point in Z-axis .............................................................................0
Start point in Z-axis ......................................................................... -20
Diameter at start point ...................................................................... 35,67
Diameter at end point ....................................................................... 35,67
Approach length ...................................................................................5
Run out length ..................................................................................... 2
Depth of thread (radial/no sign) ......................................................... 2,165
Finishcut allowance .............................................................................0
Infeed angle (+/-) ............................................................................. -29
Degree of rotation of thread start ....................................................... 0
Number of roughing passes ............................................................. 14
Number of idle passes ........................................................................ 0
Type of cycle ........................................................................................ 4
Number of starts .................................................................................. 1
G54
G53 G0 X610 Z350 Z2=760
N4 T4 D1 G95 S1000 M3 ; Threading bar pitch 4mm
CYCLE97(4,0,0,-20,35.67,35.67,5,1,2.165,0,-29,0,14,0,4,1)
G0 X200 Z100
N5 T5 D1 G95 S3000 M3 ; Threading bar pitch 1,5mm
CYCLE97(1.5,0,-30,-40,18.37,18.37,5,0,0.812,0,29,0,6,0,4,1)
G0 X200 Z100
M30
Calculation of radial depth of thread

"internal thread - 60°"
[

¡ 0 t = 0,5413 x p
[

t ................................................. thread depth
¡ 0 p .............................................................. pitch

C32
PROGRAMMING AND OPERATION - SINUMERIK CYKLES / "CYCLE83E"
Drilling Cycle "CYCLE83E"

This cycle is used for drilling of deep holes, either
in X-axis or z-axis direction.
Also you can choose between CHIP-BREAKING
or SWARF-REMOVAL.
Note:
"Cycles"_2-13
Example -
drilling on the main spindle
Absolut start point ............................................... 1
Absolut end point ............................................. -75
First drill depth (absolut) ................................. -30
Depth reduction ................................................ 10
Dwell at start point .............................................. 0
Dwell at end point ............................................... 0
Type:

0 = Chip breaking; 1 = Swarf removal .............. 1

Drilling axis:

0 = X - axis; 1 = Z - axis ..................................... 1

G54
G53 G0 X610 Z350 Z2=760
N8 T8 D1 G95 S1000 M3 F0,12; drill diam. 10
G0 X0 Z2
CYCLE83E(1,-75,-30,10,0,0,1,1)
G0 X200 Z10
M30
C33
CYKLES / "CYCLE83E" PROGRAMMING AND OPERATION - SINUMERIK
Example Example
drilling with driven tools (axial): drilling with driven tools (radial):
Absolut start point ............................................... 1 Absolut start point ............................................. 62

Absolut end point ............................................. -30 Absolut end point ............................................... -5
First drill depth (absolut) ................................. -15 First drill depth (absolut) .................................. 40
Depth reduction .................................................. 3 Depth reduction .................................................. 5
Dwell at start point .............................................. 0 Dwell at start point .............................................. 0
Dwell at end point ............................................... 0 Dwell at end point ............................................... 0
Type: Type:
0 = Chip breaking; 1 = Swarf removal .............. 1 0 = Chip breaking; 1 = Swarf removal .............. 1
Drilling axis: Drilling axis:
0 = X - axis; 1 = Z - axis ..................................... 1 0 = X - axis; 1 = Z - axis ..................................... 0

¡
¡
¡ ¡
¡
¡
axial drilling with driven tools radial drilling with driven tools
G54 G54
G53 G0 X610 Z350 Z2=760 G53 G0 X610 Z350 Z2=760
N8 T8 D1 ; drill diam. 6mm - driven N8 T8 D1 ; drill diam. 6mm - driven
STOPRE ; Stop read STOPRE ; Stop read
SETMS(3) ; set driven tools as MASTER- SETMS(3) ; set driven tools as MASTER-
SPINDLE SPINDLE
G95 S1000 M4 G0 X20 Z2 F0,12 G95 S1000 M3 G0 X70 Z-20 F0,12
SPOS[1]=0 ; turn on C-axis and position at SPOS[1]=0 ; turn on C-axis and position at
0° 0°
CYCLE83E(1,-30,-15,3,0,0,1,1) CYCLE83E(62,5,40,-5,0,0,1,0)
G0 X200 Z10 M5 G0 X200 Z10 M5
SETMS(1) ; set main spindle as MASTER- SETMS(1) ; set main spindle as MASTER-
SPINDLE SPINDLE
M5 M5
M30 M30
C34
PROGRAMMING AND OPERATION - SINUMERIK CYKLES / "CYCLE84E"
Tapping "CYCLE84E"
Note:
"Cycles"_2-17
Axial at the Main spindle or Counter

spindle without Floating holder
At the mainspindle
Absolut start point ............................................... 3
tap M20×2,5 Absolut end point ............................................. -25
Thread pitch (+ → M3 / – → M4) .................. -2,5
Tapping speed (rpm) ...................................... 600
Retract speed (rpm) ....................................... 800
Tapping axis:
0 = X - axis; 1 = Z - axis ..................................... 1

STOPRE ; Stop read
axial tapping on main- or counterspindle SETMS(1)
G54
G53 G0 X610 Z350 Z2=760
N8 T8 D1 M5 ; tap M20 x 2,5
G0 X0 Z5
CYCLE84E(3,-25,-2.5,600,800,1)
"–"spindle direction
G0 X200 Z10
M30
At the counter spindle

STOPRE ; Stop read
SETMS(2)
G55
MIRROR Z0
G53 G0 X610 Z350 Z2=760
N8 T8 D1 M5 ; tap M20 x 2,5
G0 X0 Z5
CYCLE84E(3,-25,-2.5,600,800,1)
"–" spindle direction
G0 X200 Z10
M30
C35
CYKLES / "CYCLE84E" PROGRAMMING AND OPERATION - SINUMERIK
Axial with driven tools without Radial with driven tools without
floating holder floating holder
Es kann mit herkömmlichen Bohr- und Fräs-

haltern axial oder radial Gewinde gebohrt wer-
den.
tap M10×1,5

tap M6×1
¡
¡
¡
axial tapping with driven tools (without floating radial tapping with driven tools (without floating
holder) holder)
Absolut start point ............................................... 2 Absolut start point ............................................. 65

Absolut end point ............................................. -20 Absolut end point .............................................. 40
Thread pitch (+ → M3 / – → M4) ..................... -1 Thread pitch (+ → M3 / – → M4) ................... 1,5
Tapping speed (rpm) .................................... 1000 Tapping speed (rpm) .................................... 1000
Retract speed (rpm) ..................................... 2000 Retract speed (rpm) ..................................... 2000
Tapping axis: Tapping axis:
0 = X - axis; 1 = Z - axis ..................................... 1 0 = X - axis; 1 = Z - axis ..................................... 0
G54 G54
G53 G0 X610 Z350 Z2=760 G53 G0 X610 Z350 Z2=760
N8 T8 D1 ; tap M6 x1 - driven tool N8 T8 D1
SETMS(3) SETMS(3) ; tap M10 x1,5 - driven
G0 X20 Z2 G0 X70 Z-20
SPOS[1]=0 SPOS[1]=0
CYCLE84E(2,-20,-1,1000,2000,1) CYCLE84E(65,40,1.5,1000,2000,0)
"–" poss. turning direction re- G0 X200 Z10 M5
verse for angle holder STOPRE ; Stop read
G0 X200 Z10 M5 SETMS(1)
STOPRE ; Stop read M5
SETMS(1) M30
M5
M30
C36
Grooving Cycle "CYCLE93"

With this cycle it is possible to make symmetric
or asymmetric grooves at the OD, ID and at the
face.
Via the parameter VARI you can define the
location of the groove and the start point.
If you use two digits, you can program the
chamfer according to the drawing and you don´t
have to calculate the length of the chamfer.
; 9$5, ; 9$5,
; ;
9$5, 9$5,
= = = =
; 9$5, ; 9$5,
; ;
9$5, 9$5,
= = = =
9$5, 9$5,
; ; ; ;
9$5, 9$5,
= = = =
9$5, 9$5,
; ; ; ;
9$5, 9$5,
= = = =
startpoint and situation of the grooves
Notes:
• Keep in mind that the next higher tool-offset
number is called up automatically for the
other side cutting edge!
Example:
IKeep in mind that the next higher tool-offset
number is called up automatically for the
other side cutting edge.
• Further informations see Siemens-book
"Cycles"_4-5
C37
Example - grooving cycle
1. Start point in X-axis .................................... 40

2. Start point in Z-axis ..................................... -5

3. Width of groove (no sign) ............................ 5

4. Depth of groove (radial) ............................. 10
5. Angle of surface at sart of groove ............... 0
6. Angle of the flank at start point side ......... 30

7. Angle of the flank at opposite side .............. 5
8. Radius/chamfer:
external at start point side ....................... -0,8
(“–” for chamfer)
9. Radius/chamfer:

external at opposite side .......................... -0,8
(“–” for chamfer)
10. Radius/chamfer:
at bottom at start point .............................. 0,5
(“+” for radius)
11. Radius/Fase:
at bottom at opposite side ........................ 0,5
(“+” for radius)
12. Finish cut allowance at bottom ................. 0,2
grooving cycle 13. Finish cut allowance at flanks .................. 0,1
14. Feed in depth without sign ......................... 10
15. Dwell at bottom ............................................. 0
16. Type of cycle ............................................... 15
G54
G53 G0 X610 Z350 Z2=760
N1 T1 D1 G96 S250 M4 G0 X65 Z0
G1 F0,18 X-1,6 G0 X65 Z5
CYCLE95("ROUGH5",4,0.05,1,0,0.35,0.1,0.15,9)
G0 X200 Z100
N9 T9 D1 G96 S180 M4 F0,12 ;
(grooving tool 3,5 mm / D1 - rh cutting)

¡ CYCLE93(40,-5,5,10,0,30,5,-0.8,-0.8,0.5,0.5,0.2,
5
0.1,10,0,15) ;
(D2 - lh cutting edge)
G0 X200 Z100
[ [ ¡ M30
Subprogram for contour

example for groove
ROUGH5:
G1 X36 Z2
Z0
X40 CHR=2
Z-45
X60
M17
C38
Example - face-groove
1. Start point in X-axis .................................... 40

2. Start point in Z-axis ...................................... 0
3. Width of groove (no sign) ............................ 6
4. Depth of groove (radial) ............................... 5
5. Angle of surface at sart of groove ............. 90
6. Angle of the flank at start point side ......... 30

7. Angle of the flank at opposite side ............ 15

8. Radius/chamfer:
external at start point side ........................ 0,5

(“+/–” -radius/chamfer)

¡ 9. Radius/chamfer:
external at opposite side ........................... 0,5
10. Radius/chamfer:
at bottom at start point side ...................... 0,5
11. Radius/Fase:
at bottom at opposite side ........................ 0,5
face-groove
12. Finish cut allowance at bottom ................. 0,2
13. Finish cut allowance at flanks .................. 0,1
14. Feed in depth without sign ........................... 5
15. Dwell at bottom ............................................. 0
16. Type of cycle ............................................... 16
G54
G53 G0 X610 Z350 Z2=760
... ;machining
G0 X200 Z100
N9 T9 D1 G96 S180 M4 F0,12 ;
(grooving tool 3,5mm (D1 - upper cutting edge)
CYCLE93(40,0,6,5,90,30,15,0.5,0.5,0.5,0.5,0.2,
0.1,5,0,16) ;
(D2-lower cutting edge)
G0 X200 Z100
M30
C39
CYKLES / "TRANSMIT" PROGRAMMING AND OPERATION - SINUMERIK
TRANSMIT-Programming
TRANSMIT Û TRANSform - Milling Into Turning
With Transmit you can programm any contours

at the face of the part.
Activation:
main spindle ............................................. TMCON
counter spindle ...................................... TMC2ON
Deactivation:
general .................................................... TMCOFF
Note:
"Cycles"_11-36
Example - Hexagon A/F30

<

& G54
G53 G0 X610 Z350 Z2=760
6 WDUWSRLQW
STOPRE ; Stop read
TMCON
; & N1 T1 D1 ; axial and mill DM 10 - tool
type 100
( QGSRLQW
G95 S950 M4 F0,1 ; offset: L1...Z-length, L3...X-
length, R...radius e.g. 5

G0 X17,32 Y10 G41 Z-2
G1 Y0 F0,12
point X Y
X8,66 Y-15
S 17,32 10
X-8,66
1 17,32 0 X-17,32 Y0
2 8,66 -15 X-8,66 Y15
3 -8,66 -15 X8,66
4 -17,32 0 X17,32 Y0
5 -8,66 15 Y-10
6 8,66 15 G0 Z10 X150 G40 M5
7 17,32 0 TMCOFF
M30
E 17,32 -10
C40
PROGRAMMING AND OPERATION - SINUMERIK CYKLES / "TRANSMIT"
Subprogram macro for hexagon

milling works with Transmit
EXTERN HEXAGON (REAL,REAL) ;

has to programmed at the beginning!
....
M5 Z20 X100
STOPRE ; Stop read
TMCON
N8 T8 G95 ; AXIAL ENDMILL DIA14
G95 S900 M4 F0.12
Z-11.5
HEXAGON(17,5) ; A/F 17, radius of mill - 5
G0 X100 Y0 M5
TMCOFF
.....
%_N_HEXAGON_SPF
;$PATH=/_N_WKS_DIR/_N_IMTS98_WPD
PROC HEXAGON (REAL SW,REAL RAD) SAVE
R1=SW/2
R2=COS(30)
R3=TAN(30)
R4=R1/R2
R5=R1*R3
G0 X=R4+RAD+2 Y0
G1 G42 F0.2 X=R4 Y0
X=R5 Y=R1
X=-R5 Y=R1
X=-R4 Y0
X=-R5 Y=-R1
X=R5 Y=-R1
X=R4 Y=0
Y3
G40 G0 X=R4+RAD+2 Y0
RET ; end of subprogram (M17)
Example - key-flats A/F 30

< G54
& G53 G0 X610 Z350 Z2=760
STOPRE ; (Stop read)
( QGS 6 WDUWS TMCON ; end mill cutter dia 10, - tool
type 100
; & N1 T1 D1 ; offset: L1...Z-length, L3...X-
length, R cutter radius e.g. 5)
G95 S950 M4 F0,1
G0 X15 Y15 G41 Z-4
G1 Y10 F0,14

F0,12 Y-15
G2 X-15 Y-15 CR=21,21 F1
point X Y
G1 X-15 Y15 F0,12
S 15 15 G0 Z10 X-100 Y-100 G40 M5
1 15 -15 TMCOFF
2 -15 -15 M30
E -15 15
C41
CYKLES / "CYLINDERINTERPOLATION" PROGRAMMING AND OPERATION - SINUMERIK
Cylinderinterpolation Example 1
G54
To be used for milling contours at the circum- G0 D0 G53 X600 Z400 Z2=760
ferance. .....
Therfore it is necessary to make a "developed N1 T1 D1 ; radial end mill ø5
view". STOPRE
SETMS(3)
G95 S1000 M3
G0 X26 Z-9,5
SPOS[1]=0
5 TRACYL(24)
G54
5 [ G19

ATRANS Z-8

G1 X22 F0,06

G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059

S G3 Z-3,013 Y6,283 CR=3
¡
¡ î
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
¡

ATRANS Y12,566

G2 Z-0,987 Y2,224 CR=3

G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
<± G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
=
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
developed view - example 1
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
G0 X26
X150 Z150 M5
TRAFOOF
G54
G18
....
C42
PROGRAMMING AND OPERATION - SINUMERIK CYKLES / "CYLINDERINTERPOLATION"
Example 2
G54
G0 D0 G53 X600 Z400 Z2=760
.....
N1 T1 D1 ; radial end mill ø5
STOPRE
5
SETMS(3)
G95 S1000 M3
5 G0 X20 Z2
[ SPOS[1]=0

TRACYL(24)

G54

G19
S G0 Z1 Y0
¡ î

G1 Z0 F0,06
G2 Z-0,987 Y2,224 CR=3
¡
G1 Z-3,013 Y4,059

G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
<±
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
= G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
developed view - example 2 ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
G0 Z10
X150 Z150 M5
TRAFOOF
G54
G18
....
C43
CYKLES / "SPINDLESYNCHRONIZATION" PROGRAMMING AND OPERATION - SINUMERIK
Synchronization of two Spindles
Polygonalturning
Workpiece and driven tool are synchronized.
To be used for machining hexagons, Squares,...in

soft materials like brass, Aluminium, plastic and
similar materials.
Advantage:
Hexagons,.Squares,... with open tolerances can
be machined quickly.
....
N10 T10 D1 S1800 M4 G95 ; mill diam. 10 mm
G0 X22 Z1
COUPDEF(S3,S1,-2,1,”CO”,”DV” ;
(Folgespindel,Leitspindel, ”–”-direction of rotation
with spidle ratio S3:S1=2:1 )
SPCON(1)
SPCON(3)
COUPON(S3,S1,0) ; (couple function
ON)
G1 Z-15 F0,1
X26
G0 X100 Z100
COUPOF(S3,S1) ; (couple function
OFF)
+(;VL]H SPCOF(1)
SPCOF(3)
M5
polygonalturning (hexagon) ...
Note:
Every spindle can be synchonized with each
other according to machine setup.
C44
PROGRAMMING AND OPERATION - SINUMERIK CYCLES / "AUTOM. TAILSTOCK"
Programming the automatic

tailstock
here you will find two different cases of appli-
cations.
• tailstock suports the shaft at one length position
• tailstock suports the shaft at two or more diffe-
rent length position (used for multiple bar feed
out)
Supporting on one length position Supporting on more length positions

• Clamp the shaft into the mainspindle just as • Clamp the shaft into the mainspindle just as
you would machine it. you would machine it.
• Move tailstock towards the part in JOG mode. • Move tailstock towards the part in JOG mode
• Then the preasure builds up and the machine until preasure builds up.
memorizes this position. • Press Softkey “Diagnosis”
• Move tailstock back into home-position • Press Softkey “PLC”
• Press Softkey "Read in Operand"
in program: • Set cursor to "TAILSTOCK.PLC" an press
.... Softkey "OK".
M5 • The listened value in the table is the position to
M21 ; Tailstock forward be programmed.
N2 T2 D1 G96 S200 M4
.... ; machining
M5
1 unit = 5 mm = 1u
M20 ; tailstock back to home position PP
M30
PP X Home

position
PP
X
in program:
....
M5
M21 H425 ; Tailstock forward
N2 T2 D1 G96 S200 M4
.... ; machining
M5
M20 H220 ; retract tailstock 200 mm (to
the right)
... bar feed out 100 mm
M21 H325 ; Tailstock forward 100 mm
(to the left)
.... machining
M20 ; tailstock back to home
position
M30
C45
CYKLES / "TAKEOVER" PROGRAMMING AND OPERATION - SINUMERIK
"TAKEOVER" - Cycle
Mainspindle-Counterspindle
This cycle is used for part transfer from main- to
counterspindle at bar- or swing loader machines.
Example for bar machine, without

pulling out the bar stock via the
counterspindle
=
WRJJOHSRLQW*WR*=
WDNHRYHUSRVLWLRQ=
takeover with bar machine
name of cut-off subprogram .................. CUTOFF ....

position in Z2 to switch from G0 to G1 ......... 360 G0 X300 Z20 M5 M9
G1 feedrate in mm/min ................................. 6000 N12 T12 D1 ; parting off tool 3mm
takeover position Z2 ....................................... 330 STOPRE
spindle orientation S2 to S1 in degree ............. 0 SETMS(1)
shoulder location 0=NO; 1= YES ..................... 1 G95 S100 M3 ; if takeover at the fly is required
G0 X250 Z-50,25 (e.g. for part length 50mm)
TAKEOVER(“CUTOFF”,360,6000,330,0,1)
STOPRE
SETMS(2)
G55
MIRROR Z0
N100 T1 D2 ....
Subprogram: “Cutoff”
G0 X49 Z-50,25
G96 S150 M3
G1 F0,1 M8 X-1
G91 G0 Z1 Z2=2
G53 G90 G0 X600 Z400 Z2=760 M5 M9 D0
M17
C46
PROGRAMMING AND OPERATION - SINUMERIK CYKLES / "TAKEOVER"
Takover for bar machine, with pulling Takover for bar machine with pulling
out via counterspindle out via counterspindle and grip
closer cut off length
name of cut-off subprogram ................ CUTOFF1 name of cut-off subprogram ................ CUTOFF2
position in Z2 to switch from G0 to G1 ......... 360 position in Z2 to switch from G0 to G1 ......... 395
G1 feedrate in mm/min ................................. 6000 G1 feedrate in mm/min ................................. 6000
takeover position Z2 ....................................... 330 takeover position Z2 ....................................... 292
spindle orientation S2 to S1 in degree ............. 0 spindle orientation S2 to S1 in degree ............. 0
shoulder location 0=NO; 1= YES ..................... 1 shoulder location 0=NO; 1= YES ..................... 0
.... ....
G0 X300 Z20 M5 M9 G0 X300 Z20 M5 M9
N12 T12 D1 ; parting off tool 3mm N12 T12 D1 ; parting off tool 3mm
STOPRE STOPRE
SETMS(1) SETMS(1)
G95 S100 M ; if takeover at the fly is required M5 ; if there is no spindle rotation
G0 X250 Z3,25 wanted
TAKEOVER(“CUTOFF1”,360,6000,330,0,1) G0 X250 Z3,25
STOPRE TAKEOVER(“CUTOFF2”,395,6000,292,0,0)
SETMS(2) STOPRE
G55 SETMS(2)
MIRROR Z0 G55
N100 T1 D2 .... MIRROR Z0
N100 T1 D2 ....
Subprogram: “Cutoff1”
Subprogram: “Cutoff2”
M25
G91 Z2=103,5 G9 M25
M26 G91 Z2=246,6 G9
G90 G0 X49 Z3,25 M26
G96 S150 M3 G4 F0,3
G1 F0,1 X-1 M8 M2=25
G91 G0 Z1 Z2=2 G9 Z2=-158
G53 G90 G0 X600 Z400 Z2=760 M5 M9 D0 M2=26
M17 G90 G0 Z3,25 X32
G96 S150 M4
G1 F0,1 X-1 M8
G91 G0 Z1 Z2=2
G53 G90 G0 X600 Z400 Z2=760 M5 M9 D0
M17
C47
CYKLES / "TAKEOVER" PROGRAMMING AND OPERATION - SINUMERIK
Takeover for chucking parts

(manual or loaded by swing loader)
name of cut-off subprogram ................ CUTOFF3

position in Z2 to switch from G0 to G1 ......... 400
G1 feedrate in mm/min ................................. 1000
takeover position Z2 ....................................... 390
spindle orientation S2 to S1 in degree ............. 0
shoulder location 0=NO; 1= YES ..................... 1
....
G53 G0 X600 Z400 D0 M5 M9
STOPRE
SETMS(1)
M5 ; if there is no spindle rotation wanted
TAKEOVER(“CUTOFF3”,395,6000,292,0,1)
STOPRE
SETMS(2)
G55
MIRROR Z0
N100 T1 D2 ....
Subprogram "Cutoff3"
M25
Z2=760
M17
C48
PROGRAMMING AND OPERATION - SINUMERIK CYKLES / "EMCOLADER",
KUPA", "IRCO_FMB"
Bar Loading Cycles

There are three different bar loading cycles
“LOADER”, “KUPA” and “IRCO_FMB”. Those
cycles can be found in support - usere cycles
and filled out via an input mask.

)LQPPPLQ
loading cycle
"KUPA":
"EMCOLADER" G54
G0 G53 D0 X600 Z400 Z2=760
(1) name for program after bar change ........... __ N12 T12 D1 ; damped bar stop
(2) name for program to machine remnant ..... __ KUPA(””,””,-78,0,0.25,100,0.5,4000,3,2,1,1)
(3) pick-up position in Z ................................... -78 G0 Z40
(4) pick-up position in X ..................................... 0 X50
(5) bar stop position in Z ............................... 0,25 N1 T1 D1 G96 S250 M4 ; roughing tool
(6) safety position in Z .................................... 100 .... ; machining
(7) bar stop position in Z (for new bar) .......... 0,5
(8) feedrate in mm/min ................................. 4000 "IRCO_FMB":
(9) dwell time partschatcher forward ................. 3
(10) dwell time for remnant drop down ............. 2 G54
(11) spindle oscilating 0=OFF 1=ON ................. 1 G0 G53 D0 X600 Z400 Z2=760
(12)0=parts catcher N12 T12 D1 ; damped bar stop
1=chip conveyor IRCO_FMB(”NEWBAR”,””,-50,0,0.25,100,0.5,
2=remnant machining ................................... 1 4000, 3,2,1,1)
G0 Z40
X50
in program: N1 T1 D1 G96 S250 M4 ; roughing tool
.... ; machining
G54
G0 G53 D0 X600 Z400 Z2=760
Subprogram "NEWBAR":
N12 T12 D1 ; damped bar stop
EMCOLADER(””,””,-78,0,0.25, 100,0.5,4000, T10 D1 G95 S2000 M4
3,2,1,1) G0 X52 Z3,25
G0 Z40 G1 F0,1 X-1 M8
X50 G0 Z0,2
N1 T1 D1 G96 S250 M4 ; roughing tool X250 Z150
.... ; machining M17
C49
BAR LOADER INTERFACE PROGRAMMING AND OPERATION - SINUMERIK
Bar Loader Interface

(stored programmable)
This kind of programming is used in the cycles "EMCOLOADER", "KUPA"
and "IRCO_FMB".
M-functions
M57 main spindle oscillation ON
M58 main spindle oscillation OFF
M67 feed ON (automatic mode)
M68 feed OFF
M69 bar changing
M32 restart machine after M30 (dependent from the status of the "1×-
key").
Signals
(connection load see Electrical Documentation of the machine/wiring
diagram=1DX1.D1/page 1)
EMCO Ù bar feed / bar loading magazine

EMERGENCY OFF contact of the Emergency Off switch
machine door closed door safety board
bar changing A52.7
feed command A52.6
SPM open A52.2
bar feed / bar loading magazine Ù EMCO

NOT-AUS embedment in Emergency Off-line
bar end E37.5
start after bar changing E37.6
failure E37.7
loading magazine has feeded E37.2
Signal-transfer PLC to NC
bar end $A_IN[6] (status like inverted E37.5).
loader has feeded $A_IN[8] (status like E37.2).
start after bar changing $A_IN[7] (setted with M69 "bar
changing" and resetted with E37.6
"start after bar changing").
Examples
Query "bar end" Query "start after bar changing"

If $A_IN[6]==0 GOTOF KSTE M69 ; bar changing A52.7 is setted.
MSG("bar end")
STOPRE
;This program part will only be passed through
STNW:MSG("waiting for start after changing")
by bar end.
If $A_IN[7]==1 GOTOB STNW
MSG("");delete message
MSG("");delete message
KSTE:
...
...
C50
PROGRAMMING AND OPERATION - SINUMERIK BAR LOADER INTERFACE
Example for machining with bar feed
M25 ; open clamping device

M67 ; feed ON
IF $A_IN[6]==0 GOTOF NOEND ; Query singal end of bar
MSG("END OF BAR")
M158 ; signal lamp on
M0
M168 ; signal lamp off
NOEND:M26
M68 ; feed hold
...... ; machining
M30 M32
Example for machining with bar loading magazine
M25 ; open clamping device

M67 ; feed ON
IF $A_IN[6]==0 GOTOF NOEND ; Query singal end of bar

MSG("END OF BAR")
;bar changing program:
M57 ; main spindle oscillating ON

M69 ; bar changing
AAA:
MSG("CHANGE OF BAR")
IF $A_IN[7]==0 GOTOF ENDWE ; waiting for E37.6, start after bar
changing
GOTOB AAA
ENDWE:M58 ; main spindle oscillating OFF
MSG(" ")
;bar beginning program:
NOEND:M26
M68 ; feed hold
...... ;machining
M30 M32
C51
C52
PROGRAMMING AND OPERATION - SINUMERIK SERIAL INTERFACE
Serial Interface
The 25-pin sub-D-jack ist mounted laterally on
SH the operatiom panel.
Pin occupation: identical with system Sinumerik
TXD 800
RXD
Signal names
RTS
SH Schielding
CTS TXD Transmit data
DSR RXD Receive data
RTS Request to send
GND CTS Clear to send
DTR DSR Data send ready
CD
GND Ground
CD Carier identification
RI DTR Data terminal ready
RI Ring indicator
Maximum Cable Length

Serial interface - occupation
The maximum cable length depends the bit rate.
Standard Values
machine side PC-side
9 600 bd ................................................ max. 10 m
19 200 bd ................................................ max. 7 m
38 400 bd ................................................ max. 5 m
Attention:
• Don't overshoot maximum cable length!
• Don`t use schield for signal ground GDN!
female connection,
9 poles
Connection to PC
The plug load you see in the plot beside.
plug connection
25-poles
Cable connection machine-PC
C53
C54
D Programming and Operation
EMCO-specific - Fanuc 21i-T
Machine Control Panel
6.,3 '5<
581 ; &

237 = =
6723

*5$3+ [ & ;

$8; $8;
*)
*) By machines with door automatic instead of the external cycle-start-key
Axes Description
Axes description of machine
D2003-03 D1
KEY DESCRIPTION PROGRAMMING, OPERATION EMCO-SPECIFIC
Description of Keys
Reset Key
Actuating Reset causes:
• Stop of working off the actual part program.
• Alarms and messages are cleared with the ex-
5(6(7 ception of Power On or Recall alarms.
• The channel will be set to the reset status, that
means:
- The NC control stays synchronous to the ma-
chine.
- All intermediate and working memory is
cleared (the contents of the part program
memory stays resident).
- The control is in basic setting and ready for
program run.
Skip (skip block)

In skip operation program blocks marked before
the block number with a slash "/", are skipped
6.,3 during program run (e.g.: /N100).
Active with illuminated LED.
Dryrun (Test run feed)

In dryrun operation traversing motions are
executed with the feed value preset in the setting
'5< date "test run-feed".
581 The test run feed is effective instead of the
programmed motion commands.
Spindle commands are not executed.
Caution:
The test run feed normally is higher than the
programmed feedrate.
Be sure, that no workpiece is clamped before
starting the Dry Run.
By machining parts pay attention, that the Dry
Run mode is switched off (LED of the key is
off), before starting the machine.
Single Piece Operation

With this key the single piece operation or
continuous operation in connection with automatic
loading facilities are available.
[ The switch-on state is single piece operation.
The active single piece operation is indicated by
the illumination of the respective LED at the
machine control panel.
D2
PROGRAMMING, OPERATION EMCO-SPECIFIC KEY DESCRIPTION
Graphic Simulation
With this key you can execute a program test run
without axis movement. The programmed tool
path is displayed on the screen. This test run
*5$3+ serves for testing and recognizing program errors.
After leaving the graphic simulation the reference
point is to be approached again.
Remark:
To display the programmed path during the
program test in Graphic Mode press *5$3+ and
softkey "GRAPH".
The workpiece dimensions (Length=W and
Diameter=D) are to be set in [µm] in the screen
"G.PRM".
Single Block
This function allows to work off a part program
block by block.
The function single block can be activated in AU-
TOMATIC mode.
Active single block mode causes:

• The actual block of the part program will be
worked off after pressing NC Start.
• Working off will be stopped after each block.
• The following block will be worked off after
pressing NC Start.
Deselect the function by pressing again on the
single block key.
The Mode is active, when the LED is lightening.
Optional STOP
At active function (key was pressed) the program
run will be stopped at blocks that contain the
237 command M01.
6723 Continue the program with the key NC Start.
When the function is not active, M01 (in the part
program) will be ignored.
NC STOP
After pressing the NC Stop key and takeover of
the function by the control, working off of the
running part program will be stopped.
You can continue working off by pressing NC
Start.
NC START
After pressing the NC Start key the selected part
program will be started with the actual block.
D3
; & Direction Keys

With these keys the NC axes can be traversed in
operating mode JOG.
= = Unless the machine is referenced, you must
simultaneously press the key AUX ON to move
the axes (release).
& ;
Rapid
If this key is pressed simultaneous to a direction
key the responding axis traverses in rapid feed.
Feed STOP
This key stops slide movements in AUTOMATIC
mode (not for threads).
Feed START
This key continues programmed, interrupted slide
movements.
When spindle run was interrupted additionally first
the spindle run must be continued.
Clamping Device
The clamping device is operated using this key.
Clamping direction see M90-M92.
Via NC program
M25 ........ open clamping device
M26 ........ close clamping device
Tailstock forward, tailstock

backward
With these keys the tailstock is moved forward or
backward.
Via NC program
M20 ........ tailstock backward (rear final position)
M21 ........ tailstock forward (clamping position)
Tool Turret
In JOG mode this key swivels the tool turret for
one position.
D4
Spindle Speed Override

The set spindle speed value S can be changed
manually.
Setting range: 50 - 120 % of the pro-
grammed spindle speed
Step width: 10% per key pressure
100% spindle speed: 100% key
Spindle STOP
This key stops the running of the main and coun-
ter spindle and driven tools. Before stopping the
spindle you must stop the slides.
Spindle START
This key continues the programmed run of the
main and counter spindle and driven tools.
Programming
see "M-functions" forwards in this chapter
Rotation directions
see "Axes description" forwards in this chapter
Coolant
With this key the coolant device is switched on
and/or off.
The LED indicates the running of the coolant
pump.
With open chip guard door the coolant pump runs
only as long as the key is pressed.
If this key is pressed in operating mode AUTO-
MATIC after the coolant has been switched on in
the program with M8, the coolant pump is switched
off and the LED flashes. Switch on again by
pressing the key again.
Programming:
M8 Coolant on
M9 Coolant off
D5
Chip Conveyor (option)

Switch on chip conveyor:
Forward: press key less than 1 second, forward
run for about 35 s (LED illuminates).
Backward: press key less than 1 second, back-
ward run as long as key is pressed (LED flashes
slowly), then forward run for about 35s.
The running time of the chip conveyor is set in
the counter C8 (by the manufacturer, approx. 35
seconds).
The intermission time is set in the counter C12
(by the manufacturer 300 seconds).
Interrupt chip conveyor:
For emptying etc. simultaneously press AUX ON
and chip conveyor key (LED flashes quickly).
Switch on again with chip conveyor key.
Reference Point
By pressing this key in operating mode REFER-
ENCE approaching the reference points in all axes
is carried out.
Auxiliary OFF
This key switches off the auxiliary drives of the
$8; machine. Effective only at spindle and program
stop.
Auxiliary ON
With this key the auxiliary units of the machine
are made ready for operation (hydraulics, feed
$8; drives, spindle drives, lubrication chip conveyor,
coolant).
The key must be pressed for about 1 second.
Short pressing of the AUX ON key is a quit
function and effects a lubricating impulse of the
central lubrication.
Release prior to referencing

If the slide must be released prior to referencing
(e.g. from a collision exposed position), press $8;
and the respective direction key simultaneously.
Swivelling free the tool turret

If, in case of an accruing alarm, the tool turret
must be swivelled free, press the keys $8; and
simultaneously.
D6
Mode Selection Switch

Automatic
Control of the machine by automatic working off
of programs

Edit
Edit part programs
MDI
Manual Data Input
Control of the machine by working off of blocks or
sequences of blocks. Input of blocks via operation
panel.
Manual operation
Conventional traversing of the machine by
continuous movement of the axes via direction
keys or incremental movement of the axes via
direction keys or handwheel.
Incremental feed 1 - 1000

See manual operation, traverse increments with
fix step width from 1 to 1000 increments (µm or
inch/10000).
Ref
Manual approaching the reference point (Ref)

Feed Override Switch
The rotary switch with 20 positions allows to alter

the programmed feed F (meets 100 %).
The selected feed value F in % is displayed at the
screen.

Setting range:
0 % to 120 % of the programmed feed.
In rapid feed 100 % will not be exceeded.
D7
EMERGENCY OFF
Actuate the red button only in emergency situa-
tions.
Effects:
Normally all drives are stopped with maximum
deceleration by EMERGENCY OFF.
Unlock: Turn button
To continue press the following keys:
RESET, AUX ON, OPEN and CLOSE door.
Key Switch Special Operation

The key switch can be set to "AUTOMATIC" or
"SETUP" (manual) position.
Only by pressing the consent key the respective
function of the key switch will be released (see
consent key).
This key switch allows some dangerous move-
ments with open door in tipping operation (with
consent key).
Danger:
Active special operation increases the danger
of accidents.
The key must be used only by authorized
persons, who have the knowledge about the
dangers and are careful in operation.
Keep the chip guard door closed also during
setup operation.
Take off key always after working in special

operation (danger of accidents).
Observe the local safety regulations (e.g.:

SUVA, BG, UVV ....).
Key Switch Data Protection

Position 0
• Part program input is locked
• Tool wear can be compensated
Position 1
• Part program input is released
• Possible further inputs:
Zero offsets, tool geometry, setting data
• With active single piece key the limit proximity
switches of the clamping device are not active
(for test run without workpiece)!
D8
Additional NC START Key

The additional keys have the same function as on
the machine control panel (Siemens).
Key "Close Door " with Door

Automatic
Notes see "Open Machine door"
Consent Key
Axis movements via direction keys and tool turret
movements with open door are admitted by
pressing the consent key (prerequisite key switch
in position SET UP).
be pressed, too.
Main Switch
Function:
0 - OFF
1 - ON
The main switch has no emergency off function,

that means the drives run out (unbreaked).
The main switch can be locked (unauthorized
operation of the machine).
Signal Lamp (Option)

The signal lamp is divided in three indication fields
(white, green, red) which indicate the operating
status of the machine.
Operating statii:
WHITE
Flashing ...................................... lack of raw parts
Permanent light .............................. loading active
GREEN
Flashing ................. automatic operation selected
Permanent light ......... automatic operation active
RED
Flashing .................... Alarm / EMERGENCY OFF
D9
SWITCH ON SEQUENCE PROGRAMMING, OPERATION EMCO-SPECIFIC
Switch On/Off Sequence

Switch ON the machine
Switch on the main switch at the electrical cabinet.
Open Chip guard door (with consent key) and

close again; this sequence checks the function of
the door safety switch.
Press AUX ON (auxiliary drives) for at least 1
second to activate the auxiliary drives (Hydraulic,
axes, coolant).
$8;
After a longer period of standstill press the key
multiple (every press a lubrication pulse).
REF mode is active after switching on the machine
and the auxiliary drives (independent from the
position of the mode selection switch)
( )
Approach reference point
;
$8; + = =
When the slide is near X+ or Z+ end position or in
an area with the danger of a crash, select JOG
mode and traverse free the slide by simultanous
;
pressing the AUX ON key and the corresponding
( )
direction key.

Press reference key.
The slides approach the reference point first in X
and afterwards in Z.
Select desired operation mode.
Notes:
• After reaching the reference point the
software limit switches are active.
• With an active tool turret alarm the key AUX
ON must be pressed simultanous with the
reference key, to approach te reference
point.
• When an overtravel message is shown
always with approaching the reference point,
switch on the machine and press simul-
tanuously the keys &$1 and 3 4 until the
screen display appears.
This error can occur e.g. if the axis position
was altered when the machine was switched
off (motor shaft turned).
D10
PROGRAMMING, OPERATION EMCO-SPECIFIC SWITCH OFF SEQUENCE / OPEN MACHINE DOOR
Switch OFF the Machine

$8;
Press AUX OFF.
Switch off main switch
Notes:
• Switching off the machine occurs with the
main switch.
We recommend to switch off the machine
only at ready position of the tool turret.
• Interruptions of operating are done with the
5(6(7 RESET key.
RESET stops all running machine functions.
Open Machine Door
Danger:
Do not remove or bypass control or safety
devices of the machine.
These devices are installed for your own
safety and in case of elimination will increase
the risk of accidents.
For reasons of safety door safety switches are

used for supervising.
Note:
After the machine has been switched on the
door must be opened and closed once as
otherwise message "door open" is emitted.
This measure serves to check whether the
door safety switch is operating.
Door safety switch
If NC START-key is pressed with open door, mes-
sage "door open" appears. The NC START com-
mand will not be executed.
be pressed.
Thus the door lock bolt will be released and the
door can be opened.
Therefore the following conditions must be met:
1. All spindle drives must stand still.
2. No part program must be active.
D11
MACHINE DOOR / DOOR AUTOMATIC PROGRAMMING, OPERATION EMCO-SPECIFIC
Door Automatic (Option)

Open door automatically
On machines that are equipped with the acessory
"automatic door", the door will be opened auto-
matically when releasing the locking bolt (with
consent key T).
In automatic mode the door will be opened
automatically with programmed stop or program
end (M0, M1, M2, M30).
Close automatic door

Machines with automatic door have a "close door"
+ key instead of the additional "NC start" key.

When this key is pressed simultaneous with the
consent key the door will be closed automatically.
Automatic program start

With active M96 the program will be started
automatically after closing the door.
M96 is self-holding until switching off the machine,

for safety reasons it must be activated again after
switching on the machine.
M96 is disactivated by M97.
M96/M97 also can be used without automatic

door.
D12
PROGRAMMING, OPERATION EMCO-SPECIFIC CLAMPING DEVICE CONTROL
Clamping Device Control

Purpose
With automatic workpiece loading for safety
1 2 reasons prior to switching on the main spindle, it
is automatically asked if the clamping device is
within the permitted clamping area.
b1
For this purpose the control must know certain
data of each clamping device.
a Function
(Example jaw chuck)
With opened jaw chuck (1) the clamping cylinder
b2
with bore is in front (right) position.

The sensor (2) measures the distance (b1) and
thus the condition "chuck open" is defined.
When closing the jaw chuck the piston (1) moves
backwards with the tensioning tube (traversing
movement a), thus the measurable distance
Sensors for the clamping device control changes (b).
The new distance (b2) defines the condition
"chuck closed and workpiece clamped".
If the chuck is closed without workpiece, the piston
(1) moves until stop to the left. The distance b is
bigger than b2 and thus the control knows that no
workpiece is clamped and emits an alarm.
Condition displays of the

clamping device
The condition of the clamping device is indicated
at the additional clamping device keys:
Clamping device key dark

Clamping device open
Clamping device key clear

Clamping device closed, workpiece clamped;
the clamping device pressure is achieved, the fi-
nal position of the clamping device has not been
reached.
Clamping device key blinks

Clamping device closed, no workpiece clamped;
the clamping pressure is achieved, the final position
of the clamping device has been reached.
D13
CLAMPING DEVICE CONTROL PROGRAMMING, OPERATION EMCO-SPECIFIC
Adjustment of the clamping

device control
During this procedure the final positions of the
clamping device for the clamping condition open
maximum clamping area
and closed are adjusted (see "clamping device
permitted clamping area key dark" and/or "clamping device key blinks").
device closed
device open
(clamping device closed, Furthermore, the permitted clamping area is

Clamping
Clamping
workpiece clamped)
defined (see "clamping device key lights").
Note:
The adjustment of the clamping device control
must be carried out:
Safety area • after each clamping device change
• in case of the emission of the alarm "clam-
Clamping and safety areas ping device open missing"
Procedure
Note:
Prior to the adjustment check the machine
configuration for the clamping device (chuck/
collet)!
• Set operating mode selector to "JOG".

• Delete actual datas
Delete the actually stored values by actuating
$8; + simultaneously the key "AUX ON" and the
clamping device key.
• Open clamping device

Release key "AUX ON" and actuate clamping
device key once; the clamping device will be
opened.
• Close clamping device

Actuate clamping device key once; the clamping
device will be closed.
• The control computes and stores the permitted

clamping area with the help of the identified fi-
nal positions.
D14
PROGRAMMING, OPERATION EMCO-SPECIFIC CLAMPING DEVICE CONTROL
Bridging the final position

clamping device detectors
With "Key switch data protection"

Key switch - position "1"
With active single piece key the final position
sensors of the clamping devices are not active.
Application
test run without workpiece
Programming with H-word

If clamping is to be carried out in an area
maximum clamping area exceeding the limits of the permitted clamping
area, the final position control must be switched
permitted clamping area
off (clamping in the safety area).
(clamping device closed,
workpiece clamped)
Caution:
Consider that with this possibility the survey
function is permanently switched off.
Safety area For this reason it may only be used if this
clamping state (clamping in the safety area)
required clamping
cannot be changed by other measures (e.g.
area collet change, chuck change, etc.).
Clamping area outside of the permitted area
Switching off the final position

detector
M-code M93
Activate the final position detector

M-code M91/M92
D15
STANDARD TAILSTOCK PROGRAMMING, OPERATION EMCO-SPECIFIC
Standard Tailstock
Programming
M20 Tailstock quill backward (back po-
sition)
M21 Tailstock quill forward
The tailstock quill moves to the
adjusted clamping position.
If the tailstock quill overtravels the adjusted
position (JOG), alarm occurs.
Adjusting the detection of the

tailstock quill
The position of the tailstock quill is monitored by
the proximity switches (1) and (3).
The monitoring of the forward position of the
tailstock quill can be adjusted by traversing the
proximity switch (1).
• Chose the JOG-mode.

• Set the deliberated pressure for the tailstock
quill (see "Hydraulic unit" in chapter "B Des-
cription").
• Clamp workpiece in clamping device, traverse
tailstock into deliberated position and clamp it.
• Move Tailstock quill forward by pressing the
key .
• Loosen screw (2) for the proximity switch (1)

with an allen wrench, key size 5.
• Traverse proximity switch into the right direction,
until message " Tailstock in intermediate po-
sition " occurs (arrow 1).
• Retraverse proximity switch (1) in left direction,
1 until the message just disappears (arrow 2).
• Clamp proximity switch in this position.
2 Control of the adjusting

• Move tailstock quill backwards by pressing the
key
• Press key to move tailstock quill forwards.

1 2 3 There may no message appear on the screen.
Adjusting the proximiy switch
D16
PROGRAMMING, OPERATION EMCO-SPECIFIC AUTOMATIC TAILSTOCK
Automatic Tailstock
6<67(0 ß PMC Programming
M20 Sleeve backward (rear final position)
M21 Sleeve forward (first to be done
PMCPRM manually)
The tailstock moves to the clamping
position approached last in JOG
DATA M20 H... Sleeve backward (not less than H11)
M21 H... Sleeve forward
The sleeve moves to the Z-position
G.DATA indicated under H
The tailstock moves until 20 mm before final
ß
position in rapid motion, then with reduced feed.

Para- If the sleeve passes over the determined posi-
Address Description
meter-Nr. tioned (JOG or H..), there is an alarm.
Counter
0030 D0060
(momentary position) Adjustment of the tailstock
0031 D0062 Clamping position
stroke monitoring
Call-up of parameters "D0060 / D0062" on the
screen The position of the tailstock is monitored by the
proximity detectors (5) and (6).
Setting the monitoring is carried out by displacing
the connecting link (4).
• Set operating mode "JOG".

• Call up parameter "D0060" via the softkeys
"PMC à PMCPRM à DATA à G.DATA in the
2 3 4 system menu.
• On the screen the parameter "D0060" is dis-
played with a value (1), e.g. "0011".
• Loosen counter nut (3).
• Set setting screw (2) flush with counter nut (3)
by means of Allan key.
• Insert workpiece and approach tailstock against
the workpiece.
(Setting the tailstock contact pressure see under
"hydraulics" in chapter "B Description").
• Turn setting screw (2) out of the tailstock until
the value (1) of the parameter "D0060" on the
screen shows more by the number 1 (e.g.
change of the value from "0011" to "0012").
• Turn setting screw back again, until the value
(1) counts back again by "1" (from "0012" to
"0011").
• Turn screw (2) still another rotation into tail-
stock.
• Secure setting screw (2) with the counter nut
2 3 4 5 6 (3) in this position.
Detail drawing - tailstock, adjustment of the stroke • Exit from the parameter display with 5(6(7 .
D17
SPINDLE BRAKE / C-AXIS PROGRAMMING, OPERATION EMCO-SPECIFIC
Spindle Brake
Programming
M10 Main spindle brake on
M11 Main spindle brake off
Manual operation
JOG mode
$8;
Brake on: AUX ON + Spindle Stop
Brake off: Reset
Note
The brake force is set at works (hydraulics)
and must be altered by a service technician
only.
C-axis
For milling surfaces (square, hexagon, etc.) the
C-axes and the tool slide must be moved in a
certain relation to each other (=hobbing).
With the "polar coordinate-interpolation" such
surfaces can be programmed easily.
Switching on the C-axis

after M5 with M52
G0 C0..360.xxx (angle in degree)
Deselection of the C-axis
M53 or M3, M4, M5, M10
Note
Once in a program the C-axis has to be
referenced after M52 with the command G28
C...
Operation JOG of the C-axes

By pressing the respective "C"-key on the
& & operating panel of the control, the C-axis can be
moved manually in JOG operation.
D18
PROGRAMMING, OPERATION EMCO-SPECIFIC WORKPIECE COLLECTION DEVICE
TOOL TURRET
Workpiece Collection
Device (Option)
The swivelling operation can only be carried out
via CNC program. Swivelling in and out is possi-
ble only with closed door.
Programming
With feed-hold function
M 24 Collecting tray forward
Without feed-hold function

M 240 Collecting tray forward below spindle
M 241 Collecting tray forward into waiting
position
Tool Turret
Manual operation
JOG mode, the tool turret swivels for one position
at each key press.
Swivel free at active alarm:

Press AUX-ON and tool turret key simultanously.
Influencing the Tool Turret in AUTO-

MATIC and JOG Mode
Aborting the swivel sequence

When aborting with EMERGENCY OFF or RE-
SET, the tool turret looses its reference point.
Remedy:
Unlock EMERGENCY OFF, RESET, AUX ON,
chip guard door open-close, Traverse tool turret
with AUX ON and X, Z key out of the danger area,
5(6(7 referencing with tool turret key.
D19
MACRO VARIABLES PROGRAMMING, OPERATION EMCO-SPECIFIC
Macro Variables
The control FANUC-21i offers calculating varia-
bles in order to create custom macros.
For a detailed information see Description -
Chapter 15).
Calling up Variables
The variables will be shown in the function "OFF-
SET/SETTING à [+] à MACRO:
#1 - #33: local variables
cleared with Power OFF
#100 - #149: Common variables
Cleard with Power OFF
#500 - #531: Common variables
Hold on with Power OFF
#1000 and above: System variables
To read / write NC-data
Workpiece Counter
Programming Parts Count
(corresponds to system variable #3901)
The parts counter can be programmed by using
the macro variables, programming a block with Shows the actual workpiece number. It is also
e.g. Nxx #500=#500+1. displayed in the main screens at the right upper
The number of machined parts will be displayed side.
in "OFFSET/SETTING no. 500 of MACRO sreen.
Parts Required
Example (corresponds to system variable #3902)
250 pieces are to be machined.
Shows the nominal workpiece number.
• Set "Parts Required = 250".
The workpiece counter counts from 0 upwards Parts Total
to 250 and emits the message "2011 - Required
Number of Pieces". This value can only be set by parameter 6712. It
will be incremented with "1" by M2 or M30.
• Set "Parts Required = 0".
Set "Parts Count = 0". The Fanuc parts counter is located in the function
The workpiece counter counts from 0 upwards 3$*( 3$*(
to 250 and emits no message. SETTING/OFFSET à SETTING à à .
Settings can only be made in the MDI-mode.
Note
See also "Fanuc-Control Description" - Chapter
Function
11.4.9. • If a nominal workpiece number is entered in the
variable "Parts Required", "Parts Count" will
count from 0 up to the nominal workpiece
number.
If the nominal workpiece number is worked off,
message "2011 - Required Number of Pieces"
will appear.
• If "Parts Required" and "Parts Count" will be set
to 0, both variables counts from 0 upwards.
D20
PROGRAMMING, OPERATION EMCO-SPECIFIC FREEPROGRAMMABLE OUTPUTS
Machining Time
The timers are located below the workpiece
counter, together with the current date and day
time.
Power On Time Free Purpose

Can be used, for example, as a total timer for
Displays the total time which the machine is coolant flow.
switched ON.
Cycle Time
Operating Time
Indicates the running time of one operation (pro-
Indicates total running time, excluding stop time gram), excluding feed hold and stop time.
and feed hold.
Date and Time
Cutting Time (#3011 corresp. to date, #3012 corresp. to time)
Displays actually set date and time
Displays the total time during cutting with a
programmed feedrate (time in active Cycle
START).
Free Programmable Out-

puts
M-function You have the possibility to set several functions
Output Input
for the freeprogrammable outputs with machine
signal on off signal
datas.
Y 7.0 M81 M80 X 20.4
Y 7.1 M83 M82 X 20.5 • The output won't be resetted with M30/reset,
Y 7.2 M85 M84 X 20.6 but only with the M-function.
Y 7.3 M87 M86 X 20.7
• The output will be resetted after a time, adjusted
Survey with machine datas.
• By setting the output a feed hold will be triggered
in this channel, in which the M-function wa
pragrammed, until the belonging input will be
"one".
• By setting the output a read lockout will be
triggered in this channel, in which the M-function
wa pragrammed, until the belonging input will
be "one".
Standard Setting
• The output will be resetted with the Reset-key
or with M30
(or with the M-function)
• Feed hold and read lockout won't be triggerd.
For other settings please contact EMCO-Service

Department.
D21
PROGRAM INPUT, ADMINISTRATION PROGRAMMING, OPERATION EMCO-SPECIFIC
Survey Program Input, Administration

Program input occurs in EDIT mode ( ).
Listing of the most frequent edit functions:

List programs Program block input
• Press the key 352* (eventually 2x). • Enter NC commands (e.g. N90G0X9Z-6).
• The screen shows all stored programs. • Take over the block with (2% ,16(57 .
3$*(
• Scroll list: and 3$*( . • Delete backward while input: &$1
• Entering a block number at the beginning of a
Call program
block is not necessary.
• List programs ( 352* ).
• Enter program number e.g.O1234. Insert block
• Press softkey O-SRH. • Put the cursor on the block end (EOB sign ";")
• When the entered program is in memory, it will of that block, that should be before the new
be caleed up, otherwise alarm 71 is shown. block.
• Enter the new block.
Create new program
• List programs ( 352* ). Delete block
• Enter free program number e.g. O5678. • Put the cursor on the beginning of the block to
(2% be deleted and press the keys (2% and '(/(7( .
• Press the key sequence ,16(57 , and ,16(57 .
• The new program is opened and you can enter
the program blocks.
Rename program
Insert word
• Call program.
• Put cursor on program number (e.g. O1234), • Put the cursor on that word that should be before
the new word.
enter new program number and press key $/7(5 .
• Enter new word (address and value, e.g. X0)
and press key ,16(57 .
Copy program
• Call the program to be copied. Find word
• Press softkey OPRT and the right menu extension
key . • Enter word (e.g. X50) or address of the word to
• Press softkeys EX-EDT, COPY, ALL. be found (e.g.: X).
• Enter new program number (without O) and • Press cursor key .
press the key ,1387 .
• Press the softkey EXEC. Alter word
• Put cursor on the word to be altered.
Delete program
• Enter new word and press the key $/7(5 .
• List programs ( 352* ).
• Enter program number e.g.O1234 and press the Delete word
key '(/(7( .
• Put cursor on the word to be deleted.
• The entered program will be deleted. '(/(7( .
• Press the key
• Delete all programs: O-9999 '(/(7( .
D22
PROGRAMMING, OPERATION EMCO-SPECIFIC G-COMMANDS / SURVEY
G-Commands - Survey
The Fanuc control uses for the G commands the Use the following table to find the description of
allocation groups A, B, C; that means one the G commands in the Fanuc manuals.
command has different numbers in different
groups. Example
The Fanuc control is programmed with the G71 Inch input can be found in the Fanuc manuals
commands of allocation group C, but the Fanuc as G21.
manuals describe the allocation group A.
Code Code Code Code

Meaning Meaning
Grp. C Grp. A Grp. C Grp. A
G00 Rapid motion G00 G54 Selection workpiece-coordinate system 1 G54
G01 Linear interpolation G01 G55 Selection workpiece-coordinate system 2 G55
G02 Circular interpolation/clockwise G02 G56 Selection workpiece-coordinate system 3 G56
G03 Circular interpolation/counter-clockwise G03 G57 Selection workpiece-coordinate system 4 G57
G04 Dwell time G04 G58 Selection workpiece-coordinate system 5 G58
*)
G05 Machining in quick cycle G05 G59 Selection workpiece-coordinate system 6 G59
*)
G07 Interpolation with fictitious axis G07 G65 Macro call G65
G07.1 G07.1 G66 Modal macro call G66
Cylindric interpolation
(G107) (G107) G67 Modal macro call end G67
G10 Data setting G10 *) Axis mirroring for double turret heads on or
G68 G68
G11 End data setting G11 tare cut mode
G12.1 Mode G12.1 *) Axis mirroring for double turret head off or
G69 G69
G112 "Polar coordinate interpolation" (G112) tare cut mode end
G13.1 End mode G13.1 G70 Input in inch G20
G113 "Polar coordinate interpolation" (G113) G71 Input in mm G21
G17 Selection level XpYp G17 G72 Finishing cycle G70
G18 Selection level ZpXp G18 G73 Contour roughing cycle (ID/OD) G71
G19 Selection level YpZp G19 G74 Face roughing cycle G72
G20 Longitudinal turning cycle (AD/ID) G90 G75 Pattern repeating cycle G73
G21 Thread cutting cycle G92 G76 End face cut-in cycle G74
*)
G22 Memorized traverse limit on G22 G77 Cut-in cycle G75
*)
G23 Memorized traverse limit off G23 G78 Multiple threading cycle G76
G24 Facing cycle G94 G80 Drilling cycle end G80
*)
G25 Spindle speed monitoring on G25 G83 Cycle for face drilling G83
*)
G26 Spindle speed monitoring off G26 G84 Cycle for face tapping G84
G27 Reference position - return check G27 G85 Reaming cycle axial G85
G28 Return to reference point G28 G87 Side drilling cycle G87
G30 Return to 2nd reference point G30 G88 Side tapping cycle G88
G31 Cancel remaining path G31 G89 Reaming cycle radial G89
G33 Thread and oil groove cutting G32 G90 Absolute programming —
G34 Thread cutting with variable lead G34 G91 Incremental programming —
G36 Autom. tool correction X G36 Set coordinate system or maximum spindle
G92 G50
G37 Autom. tool correction Z G37 speed
G40 Deselection cutter radius compensation G40 *)
G92.1 Workpiece coordinate system G50.3
G41 Cutter radius compensation left G41
G42 Cutter radius compensation right G42 G94 Feed per minute G98
G50.2 G50.2 G95 Feed per rotation G99
Polygonal turning end
(G250) (G250) G96 Constant cutting speed G96
G51.2 G51.2 G97 Const. cutting speed off G97
Polygonal turning
(G251) (G251) G98 Return to initial level —
G52 Setting local coordinate system G52 G99 Return to level mit point R —
Setting machine coordinate system Commands with different group cycles
G53 G53
traverse movements only in rapid motion *) see Fanuc control description
D23
G-BEFEHLE / G00 PROGRAMMING, OPERATION EMCO-SPECIFIC
Short description G-Commands

On the following pages you will find a short description of the G-commands
of the control Fanuc 21 TB, allocation group C.
This description represents an extract from the programming instructions
for the control Fanuc 21 TB and is mainly intended as programming aid.
For detailed information referring to the individual commands see the
programming instructions for the control Fanuc 21 TB.
In case of ambiguities and contradictions the specifications in the original
Fanuc instructions are valid.
Note:
In these instructions the command classification of the allocation group
C is described as used on the Fanuc control at the EMCO machine.
In the descriptive material of Fanuc the allocation group A is described
- if you use the Fanuc material you therefore have to recode the
commands according to the scheme (see survey G-commands).
G00 Rapid Traverse

Format
N.... G00 X(U)... Z(W)...
The slides are traversed with max. speed to the

programmed target point (tool change position,
starting point for the following machining pro-
cedure).
Notes
;
• A programmed slide feed F is suppressed during
G00.

• The rapid speed is set definitively.
• The feed override switch is limited to 100%.

Example
¡
absolute G90
N50 G00 X40 Z56
; incremental G91
N50 G00 U-30 W-30.5
Absolute and incremental values G00
D24
PROGRAMMING, OPERATION EMCO-SPECIFIC G-COMMANDS / G01
G01 Linear Interpolation (Feed)
; Format
N... G01 X(U)... Z(W).... F....
Linear slide movements (face, longitudinal, taper
turning) at the programmed feedrate.
(
Example
absolute G90
6 N.. G95
.....
N20 G01 X40 Z20.1 F0.1
¡
¡
incremental G91
N.. G95 F0.1
.....
N20 G01 X20 W-25.9
S ...... Start point
; E ...... End point
Absolute and incremental measures for G00
Insertion of Chamfers and Radii

Example
....
N 95 G 01 X 26 Z 53
; N 100 G 01 X 26 Z 27 R6
N 105 G 01 X 86 Z 27 C3
N 110 G 01 X 86 Z 0

&
....
Notes
• Chamfers and radi can be inserted between two
G00/G01 movements only.
¡
G • The movement, which is programmed in the se-

5
cond block, has to start at point b (drawing).

E With incremental programming the distance from
F point b has to be programmed.
¡
• With single block mode the tool stops first at

point c and then at point d.
=
• If the movements in one of the blocks are so
Insertion of chamfers and radii short, that there is with inserting a chamfer or
radius no intersection point, alarm no. 055
occurs.
D25
G-COMMANDS / G01 PROGRAMMING, OPERATION EMCO-SPECIFIC
Direct Drawing Input

Commands Tool movements
X2... (Z2...) A... ; ;=

1 Note:
Bold printed commands can be executed
only with the option comfort programming. $
;=

=
;
;=
A1...
X3... Z3... A2...
$
;=

2
$
;=

=
;
;=

X2... Z2 ... R...
X3... Z3... $
or 5
3 A1 ... R... ;=
$
X3... Z3... A2...
;=

=
;
;=
X2... Z2... ,C...
X3... Z3... $
or
&
4 A1... ,C...
;= $
X3... Z3... A2...
;=

=
; ;=

X2... Z2... R1...
X3... Z3... R2...
X4... Z4...
;= 5 $

5
or
5 A1... R1... ;=
X3... Z3... A... R 2... $
X4... Z4...
;=

=
D26
Commands Tool movements
; &
X1... Z 1... ,C 1... ;=

X3... Z 3... ,C 2...
X4... Z4...
;= $
or
6
A1... ,C 1... &
X3... Z3... A2... ,C2... ;= $
X4... Z4...
;=

=
; & ;=
X2... Z 2... R1...
X3... Z 3... ,C 2...
X4... Z4... $
;=
or 5
7
A1... R1...
;=
X3... Z3... A2... ,C2... $
X4... Z4...
;=

=
; ;=

X2... Z 2... ,C 1...
X3... Z 3... R2...
;= 5 $
X4... Z4...

8 or
&
A1... ,C 1...
;= $
X3... Z3... A2... R2...
X4... Z4... ;=

=
Note:
• Missing intersection point coordinates need not • The following G commands must not be used
to be calculated. for the blocks with chamfer or radius.
In programs angles (A), chamfers (C) and radi
G-Codes in group 00:
(R) can be programmed directly.
G05, G7.1, G10, G11,
The following block after a block in which C or
G27, G28, G30, G31,
R was specified, has to be a block with G01.
G92, G92.1,
To command a chamfer is possible only with
G52, G53,
the comma-character ",C". Otherwise alarm for
G72, G73, G74, G75, G76, G77, G78
illegal use of C-axis will appear.
G-Codes in group 01:
• The input of angles (A) is possible with the
G02, G03, G20, G21 and G24
option comfort programming only.
They must not be used between the blocks with
chamfer or radius, which define the succession
numbers.
D27
G-COMMANDS / G02, G03 PROGRAMMING, OPERATION EMCO-SPECIFIC
G02 Circular Interpolation

Clockwise
G03 Circular Interpolation
Counterclockwise
Format
* 0 . N... G02 X(U)... Z(W)... I... K... F...
* or
N... G02 X(U)... Z(W)... R... F...
5 X,Z ............ End point of the arc
( U,W, I,K .... Incremental circle parameters
(Distance from start point to centre
of arc, I is related to X, K to Z)
6 R ................ Radius of arc
The tool will be traversed to the target point along

the defined arc with the programmed feed F.
Rotational direction and parameter of an arc Note
• Programming the value 0 for I and K can be

omitted.
• With the input of R only an arc < 180° can be
done. R is alway entered positive.
G04Dwell
Format
N... G04 X(U)... [sec]
or
N... G04 P... [msec]
The tool movement will be stopped at the last

reached position for a dwell defined by X,U or P -
sharp edges - transititions, cleaning cut-in ground,
precise stop
Note
• With address P no decimal point is allowed
• The dwell time starts at the moment when the
tool movement speed is zero.
• t max. = 2000 sec, t min. = 0,1 sec
• input resolution 100 msec (0,1 sec)
Examples
N75 G04 X2.5 (U2.5) (dwell time= 2.5sec)
N95 G04 P1000 (dwell time = 1 sec =
1000 msec)
D28
G10 Data Setting

With the command G10 control data can be
overwritten, parameters can be programmed, tool
data can be written etc.
In user practice G10 is mainly advisable to pro-
gram the workpiece zero point.
Attention
• The format G10 P0 X(U).. Z(W).. and/or G92
X(U).. Z(W).. is placed above all other zero
point shifts (from G52 to G59)!
• The shift is not displayed on the screen!
• Attention with programs which were pro-
grammed for former control types (Fanuc 0- Zero point shift G92
T, Fanuc 21-T).
Format
Remedy
First call up G10 P0 X0 Z0 (reset of the zero N.. G10 P0 X(U).. Z(W)..
point shift in G92) and input the following P0.....selection zero point shift G92
two blocks:
G10 L2 P1 X(U).. Z/W).. ; Input/Display (MDI mode)
G54 ;
OFFSET/SETTING Ù "+" (2×) Ù "W-SHIFT"
• G92 is placed above G54 to G59 and EXT!
Therfore the shifts of G54 to G59 and EXT
will be added to the shift of G92!
Zero point shift with workpiece

coordinate systems G54 to G59
In general with this control it is advisable to use

one of six preset workpiece coordinate systems
G54 to G59 when setting a workpiece-zero point
shift, since here all overwritten values can be
controlled and reproduced on the screen at any
time. (The description of the commands G54 to
G59 is carried out later in this chapter.)
Format
Notes:
N.. G10 L2 P1 X(U).. Z(W)
• The call-up of the selected workpiece coordinate
(overwrites workpiece coordinate system G54)
system in the program must be carried out in
the next block. N.. G54
• By calling up the external workpiece coordinate (calls up workpiece coordinate system G54 in the
system the basis of all coordinate systems called program)
up in the following is shifted by the dimension
G10 L2 ............ overwriting the entered workpiece
entered there.
coordinate system.
• The selected workpiece coordinate system can
P0 .................... selection of the external work-
be overwritten or replaced by another one within
piece coordinate system.
a program as often as you want by means of
P1 (...bis P6) .. selection of the workpiece co-
the format mentioned above.
ordiante system G54 (...to G59).
• The workpiece coordinate systems overwritten
in this way can be controlled after reading in
Input/Display (MDI mode)
under the function SETTING / OFFSET under
picture WORK. OFFSET/SETTING Ù "WORK"
(see descriptions G54 to G59)
D29
; G20 Longitudinal Turning Cycle

(OD/ID Machining Cycle)
8
.
Format
;
:
= N... G20 X(U)... Z(W)... F... (straight)
or
N... G20 X(U)... Z(W)... R... F... (taper)
=
X(U), Z(W) ..... Absolute (incremental) coordinates
of the contour point K
; R [mm] ........... Incremental taper dimension in X
with direction (+/-)
Longitudinal turning cycle without taper
Notes
; • This cycle is modal and will be deselected by a
G command of the same group.
8
• For following blocks only the altered coordinates

. have to be programmed (see example).
5
• A negative taper parameter (-R) defines the

;
taper as shown in the drawing.

:
=
;
Longitudinal turning cycle with negative taper R
;
N100 G91

.....
N110 G20 U-4 W-66 F0.18

N115 U-8
N120 U-12
N125 U-16
=
N130 G00 .....
Example: G20 Longitudinal turning cycle
D30
PROGRAMMING, OPERATION EMCO-SPECIFIC G-COMMANDS / G21, G24
; G21Thread Cutting Cycle

= :
Format
8 N... G21 X(U)... Z(W)... F... ............... (straight)
or
. ; N... G21 X(U)... Z(W)... R... F... ........... (taper)
=
F ......... Thread pitch [mm]
) R [mm] ........... Incremental taper dimension in X
with direction (+/-)
Straight thread cutting cycle
Notes
= : G command of the same group.

8 have to be programmed (see example).
5
.
; • A negative taper parameter (-R) defines the
taper as shown in the drawing.
=
Tapered thread cutting cycle
; G24 Face Turning Cycle
Format

8 N... G24 X(U)... Z(W)... F... ............... (straight)
or
. :
; = N... G24 X(U)... Z(W)... R... F... ........... (taper)
R ......... Incremental value of the taper in Z axis

=
Notes
Face turning cycle without taper G command of the same group (G0, G1, G2).
;
have to be programmed (see example).
8
5 .:
;
= = A negative taper parameter (-R) defines the taper
as shown in the drawing.
;
Face turning cycle with negative taper R
D31
G28 Reference Point Return

(approach reference point)
Format
N... G28 X(U)... Z(W)... C(H)...
X,Z,C ..... absolute coordinates of the inter-
mediate position
U,W,H ... incremental coordinates of the inter-
mediate position
The G28-instruction is used to approach the
reference point via an intermediate position (X(U),
Z(W)).
First the withdrawal is carried out to X(U) and/or
Z(W), subsequently the reference point is ap-
proached. Both movement sequences are carried
out with G00!
Note:
After the first selection of the C-axis (with M52)
the command
G28 C0
must be carried out to reference the C-axis.
G33 Thread Cutting

Format
; N... G33 X(U)... Z(W)... F...
= :
F ......... Thread pitch [mm]
Straight, tapered an scroll threads can be cut.
8
Because of no automatic return to the start point,

the multiple threading cycle G78 will be preferred.
Machining routines like knurling are also possible.
;
= Note
• With taper threading the thread pitch has to be
defined with the higher value in X or Z axis.
) • Continuous thread cutting is possible (multiple
threads)
Measures for thread cutting
D32
PROGRAMMING, OPERATION EMCO-SPECIFIC G-COMMANDS / CUTTER RADIUS COMPENSATION
Cutter Radius Compensation

During tool measurement the tool tip is measured
only at two points (touching the X and Z axes).
The tool offset therefore only describes a theo-
retical cutter tip.
This point is traversed on the workpiece in the
programmed paths.
5
With movements in the axis directions (longitudi-
nal and face turning) the points on the tool tip
touching the axes are used.
Tool tip radius and theoretical cutter tip
No dimensional errors are therefore produced on
the workpiece.
With simultaneous movements in both axis

directions (tapers, radii) the position of the
theoretical cutter point no longer coincides with
the point on the tool tip actually cutting.
Dimensional errors occur on the workpiece.
Maximum dimensional error without cutter radius
compensation with 45° movements:
Tool tip radius 0,4 mm 0,16 mm path distance
0,24 mm distance in X and Z.
If cutter radius compensation is used, these
dimensional errors are automatically calculated
and compensated by the control.
Movements parallel to the axes and oblique
For the cutter radius compensation you must enter

the cutter radius R and the cutter position T when
entering the tool data.

The cutter position is indicated by a number (see
draft).
To decide the cutter position look at the tool as it

is clamped on the machine.

Cutter position
D33
G-COMMANDS / CUTTER RADIUS COMPENSATION PROGRAMMING, OPERATION EMCO-SPECIFIC
Tool pathes with selection / cancellation of the cutter radius compensation
5
*
*
*
*
Frontal approach or leaving of an edge point Approach or leaving an edge point at side behind
programmed tool path

real traversed tool path
* With arcs always the tangent of the end or start
point of the arc will be approached.
5 The approaching path to the contour and the
leaving path from the contour must be larger than
5 the tool tip radius R, otherwise program inter-
ruption with alarm.
5
If contour elements are smaller than the tool tip
* radius R, contour violations could happen. The
software computes three blocks forward to
Approach or leaving an edge point behind recognize this contour violations and interrupt the
program with an alarm.
Tool pathes with program run with active cutter radius compensation
5
5
5
5
* *
*
*
Tool path at an inner edge Tool path at an outer edge > 90°
programmed tool path

real traversed tool path
* With arcs always the tangent of the end or start

point of the arc will be approached.
5 If contour elements are smaller than the tool tip
radius R, contour violations could happen. The
5 software computes three blocks forward to
5 recognize this contour violations and interrupt the
* program with an alarm.
Tool path at an outer edge < 90°
D34
PROGRAMMING, OPERATION EMCO-SPECIFIC G-COMMANDS / CUTTER RADIUS COMPENSATION
G40 Cancel Cutter Radius

Compensation
The radius compensation will be cancelled with
G40. Cancellation is only permitted in combination
with a linear traversing command (G00, G01)
G00 or G01 can be programmed in the same block
or as the first traversing movement after cancel-
lation.
G41 Cutter Radius

Compensation Left
If the programmed tool path (viewed in the
direction of machining) is on the left of the material
to be machined, the radius compensation is to be
selected with G41.
Notes
• No direct change between G41 and G42 - cancel
with G40 previously.
• Cutter radius R and cutter position T must be
defined.
• Selection is only permitted in conjunction with
G00 or G01.
• Change of tool correction is not possible with
active cutter radius compensation.
Definition G41 cutter radius compensation left
G42 Cutter Radius

Compensation Right
If the programmed tool path (viewed in the
direction of machining) is on the right of the
material to be machined, the radius compensation
is to be selected with G42.
Notes see G41!
Definition G42 cutter radius compensation right
D35
G52 Local Coordinate

During programming in a workpiece coordinate
system (G54 to G59) a "subsidiary coordinate
system" can be set up within the selected
workpiece coordinate system to facilitate the
programming of certain functions.
Such an additive coordiante system is called a
local coordinate system.
Format
N.. G52 X(U).. Z(W).. C(H).. ;
(Setting up a local coordinate system)
N.. G52 X(U)0 Z(W)0 C(H)0 ;
(Deleting a local coordinate system)
The workpiece zero point set in the selected
workpiece coordinate system is shifted by the po-
sitive and negative dimensions indicated in the
local coordinate system.
After deleting the local coordinate system the zero
point is reset to the workpiece zero point originally
set in the selected workpiece coordinate system.
Local
coordinate system
_ Local
IP G54: workpiece
coordinate system
coordinate system 1
G55 G56 G57
G58 _
IP G59: workpiece
coordinate system 6
Origin of the machine coordinate system
Reference point
Note
• During the set-up of local coordinate systems,
workpiece and machine coordinate systems
remain unchanged.
• Traverse commands immediately after the
selection or deselction of the local coordinate
system must be absolute dimension commands.
Attention:
By pressing the RESET key the existing local
coordinate system is deleted and during the
subsequent block search it is overread.
Also if coordinates for any axis of the local
coordinate system are set newly, the existing
local coordinate system is deleted.
D36
PROGRAMMING, OPERATION EMCO-SPECIFIC G-COMMANDS / G53, G54-G59
G53 Selection of the Machine

Coordinate System
A coordinate system with its origin on the machine
zero point is called machine coordinate system.
After switching on the machine the machine
coordinate system must be set by reference point
approach prior to indicating the command G53.
G53 is a G-code effective once for the selection
of the machince coordinate system. Commands
are thus only valid in the block with G53 and are
exclusively traversed in rapid motion!
Format
N.. G53 X.. Z..
Notes
• With command G53 cutting radius correction
and tool correction are switched off.
• G53 must be indicated in absolute dimension.
With incremental dimension values the command
G53 is ignored.
G54 to G59 Selection of a

Workpiece Coordinate System
A coordinate system used for machining work-
pieces is called workpiece coordinate system. It
is determined by a machining program and is to
be set prior to machining start. A workpiece
coordinate system already set can be altered by
shifting the point of origin.
Six (specified via G54 to G59) preset workpiece
coordinate systems and an external workpiece
coordinate system are available:
EXT workpiece coordinate system 0

G54 workpiece coordinate system 1
D37
G-COMMANDS / G54-G59 PROGRAMMING, OPERATION EMCO-SPECIFIC
All workpiece coordinate systems specified via

G54 to G59 are shifted altogether via the EXT
workpiece coordinate system.
Workpiece coordinate Workpiece coordinate Workpiece coordinate Workpiece coordinate

system 1 (G54) system 2 (G55) system 3 (G56) system 4 (G57)
ZO
3
ZOF FS4 Workpiece coordinate
FS
S1 FS ZO
2 system 5 (G58)
ZO
ZOFS5
FS Workpiece coordinate
EXO ZOF
S6 system 6 (G59)
Machine zero point
EXOFS: ..................... external workpiece zero point value

ZOFS1 Ù ZOFS6 ..... workpiece zero point correction value
There are two possibilities to set the workpiece

coordinate systems:
(1) Input via the manual input keyboard
(operating mode MDI à function OFFSET /
SETTING à softkey WORK).
(2) Programming via G10: separate shift of the
individual workpiece coordinate systems
including the external work coordinate system
(see chapter G10).
Notes
• The workpiece coordinate systems 1 to 6 are
set after reference point approach.
• The coordinate system G54 is selected during
switch-on.
D38
PROGRAMMING, OPERATION EMCO-SPECIFIC G-COMMANDS / G70, G71, G72
G70 Measuring in Inches

Format
N5 G70
By programming G70 the following values will be
converted to inches:
• Feedrate F [mm/min, inch/min, mm/rev, inch/
rev]
• Offset values (zero point, geom., wear, ...)
Remark: [mm, inch]
It is also possible to exchange the control from • Movement pathes [mm, inch]
metric-system to inch-system in the "SETTING • Display of actual position [mm, inch]
screen" à "SETTING", by inserting "1" as the • Speed [m/min, feet/min]
"INPUT UNIT".
All the coordinate systems in the control screen Notes
will be converted immediately, including all of • For clearness G70 should be defined in the first
the tool offsets. block of the program
The programs themselves will not be converted! • The measuring system which was programmed
Before running the machine with the converted last will be active - also after main power off/on.
measuring system: • To get back to the origin measuring system it is
Switch machin OFF and ON, to perform a best to use the MDI mode (e.g. MDI G70 Cycle
reference point return. Start)
G71Metrical Measuring
Format
N5 G71
See G70!
G72 Finishing Cycle

Format
N... G72 P... Q...
P... ...... Block number of the first block for the pro-
gram of finishing shape.
Q ........ Block number of the last block for the pro-
gram of finishing shape.
After rough cutting by G73, G74, G75 the G72
command permits finishing.
The programmed shape between P and Q which
was also used for rough cutting, will be repeated
without cutting depth division and without finishing
offset.
Notes
• F, S and T functions specified between P and Q
are only effective for G72. They are not effective
for G73, G74 and G75!
• The finishing cycle G72 must only be pro-
grammed after the cycles G73, G74 and G75.
D39
G73 Contour Roughing Cycle

(Stock removal in turning)
Format
N... G73 U 1... R...
N... G73 P... Q... U 2+/-... W+/-... F... S... T...
first block U1 [mm] depth of cut, incremental,

without sign, in the drawing
& shown as U 1
$ R [mm] retract height
8
% second block P ........... block number of the first
block for the programmed
5

shape
Q .......... block number of the last
shape
U2 [mm] distance and direction of
8
finishing offset in X direc-

Program instruction
tion (diameter or radius
designation), in the drawing
$
shown as U2/2
: W [mm] Distance and direction of
finishing offset in Z direc-
Turning cycle contour tion, incremental, without
sign
F, S, T Feed, speed, tool
Before machining the tool is at point C. Between
the block numbers P and Q a contour (A to A' to
B) will be programmed, it will be machined with
the corresponding cutting depth division onto the
defined finishing offset (2. block, in the drawing
U2/2).
Contour without undercut

The first contour block from A to A' must contain
a G0 or G1 movement in X direction only.
Contour with undercut
Contour without undercut The first contour block from A to A' must contain
a G0 or G1 movement in X and Z direction.
Notes
• F, S and T functions between P and Q are
Contour with undercut ignored.
• The point C (tool position before the cycle) must
be out of the contour.
Undercut • The first movement from A to A’ must be G00 or
G01, is permitted in X only (G00 X...) and must
be programmed in absolute coordinates.
• Between P and Q no subroutine call is permitted.
• By using G73 as an OD Roughing Cycle:
Coordinate X C has to be greater than XB.
• By using G73 as an ID Roughing Cycle:
Coordinate X C has to be less than X B.
D40
Example contour turning cycle with G73:

Machining the contour shown beside.
Program:
; O2000
N10 G95 G1 F0.5
N11 G0 X85 Z20
N12 T0101
N20 M3 S3000

N30 G00 X85 Z2

(Start point for cycle)
N40 G73 U2 R2
N50 G73 P60 Q120 U2 W1
(Contour turning cycle)
N60 G0 X10

N70 G1 Z-15

N80 X30
= N90 X60 Z-30
N100 Z-40

N110 X70
N120 X80 Z-50
Example contour turning N130 G0 X85 Z20
N140 S3000 F0.6 T0202
(Select finishing tool)
N150 G0 X85 Z2
(Start point for finishing)
N160 G72 P60 Q120 (Finishing cycle)
N170 M30
D41
G74 Face Roughing Cycle

(Stock removal in facing)
Format
& N... G74 W 1... R...
N... G74 P... Q... U+/-... W2+/-... F... S... T...
$
$
first block W1 [mm] depth of cut in Z, incre-
mental, without sign, in the
drawing shown as W 1
R [mm] retract height
second block P ........... block number of the first
Tool path 5 shape
8
Program instruction shape

U [mm] distance and direction of
%
: : tion (diameter or radius
designation), in the drawing
shown as U/2
Face Roughing cycle contour W2 [mm] Distance and direction of
tion, incremental, without
sign, in the drawing shown
as W2
Before machining the tool is at point C. Between
the block numbers P and Q a contour (A to A' to
B) will be programmed, it will be machined with
the corresponding cutting depth division onto the
defined finishing offset (2. block, in the drawing
W2).
Notes
• F, S and T functions between P and Q are
ignored.
• The point C (tool position before the cycle) must
be out of the contour.
• The contour between A' and B has to be
programmed decreasing, that means the dia-
meter has to decrease.
• The first movement from A to A’ must be G00 or
G01, is permitted in Z only (G00 X...) and must
be programmed in absolute coordinates.
• Between P and Q no subroutine call is permitted.
D42
Example Facing cycle with G74:

Machining the contour shown beside.
Program:
; O2001
N10 G95 G1 F0.5
N11 G0 X85 Z20

N12 T0303
N20 M3 S3000
N30 G00 X85 Z2
(Start point for facing cycle)

N40 G74 W2 R2
N50 G74 P60 Q120 U2 W1
(Facing cycle)

N60 G0 Z-35
N70 G01 X80 Z-35
N80 Z-30
= N90 X50 Z-25
N100 X30 Z-15
N110 X20
Example facing cycle N120 Z0
N130 G0 X85 Z20
N140 S3000 F0.6 T0404
(Select finishing tool)
N150 G0 X85 Z2
(Start point for finishing)
N160 G72 P60 Q120 (Finishing cycle)
N170 M30
D43
G75 Pattern Repeating Cycle

Format
N... G75 U 1+/-... W 1+/-... R...
N... G75 P... Q... U 2... W2... F... S... T...
first block U1 ................. Start point for the cycle in

:
: the X axis (radius desi-
gnation), in the drawing
shown as U 1
W1 ................ Start point of the cycle in
88
the Z axis, in the drawing

shown as W 2
R .......... number of repetitions (equal
& to cut division)
$ second block P ........... block number of the first
shape
% shape
U2 [mm] distance and direction of
8

tion (diameter or radius de-

signation), in the drawing
$
: shown as U/2
W2 [mm] Distance and direction of
Pattern repeating
tion, incremental, without
sign, in the drawing shown
as W2
The G75 cycle allows machining parallel to the
shape of the workpiece, the pattern will be shifted
to the finished shape step by step.
Application for semifinished products (forged, cast
parts)
; Example:
O2002
N1 G95 G0 X85 Z0
N5 T0707 M3 S2000 F0.5

N10 G75 U5 W5 R5

N15 G75 P20 Q80 U2 W1
N20 G0 X20
N30 G1 Z-15

N40 X40
N50 X70 Z-30

N60 Z-40
N70 X75 Z-50

N80 X80
N90 M30
=
The contour in N20 (20/0) - N80 (80/-50) will be
Example Pattern repeating machined in 5 infeeds.
D44
G76 Face Cut-in Cycle

(Deep Hole Drilling Cycle for end face
peck drilling)
Format
N... G76 R...
N... G76 X(U)... Z(W)... P... Q... F...
first block R [mm] retraction height for chip
breaking (incremental
without sign), drawing:
R1
sec. block X(U), Z(W) Absolute (incremental)
4 4 4 4 4 coordinates of the con-
tour edge point K
$ or
Z(W) Absolute (incremental)
3
drilling depth
P [µm] Incremental feed in X
direction (no sign); P <
3
8
tool width!
Q [µm] ...... Cutting depth in Z dir-
ection (no sign)
F ............... Feed rate
. 5
= :
;
Notes:
• Without addresses X(U) and P G76 can be used
Deep hole drilling / Face Cut-in Cycle
as drilling cycle (Move tool to X=0 before!)
• With cut-in cycle the infeed P has to be smaller
than tool width B.
Example:
Axial groove, 10mm wide and 10mm deep
T1212 ; (axial cut-in tool 3mm width)

G96 S120 M4 ;
G0 X80 Z1 ;
G76 R0.5 ;
G76 X94 Z-10 P2800 Q4000 F0.06 ;
G0 X150 Z100 ;
M5 ;
D45
G77Side Cut-in Cycle (X Axis)
Format
N... G77 R...
N... G77 X(U)... Z(W)... P... Q... F...
first block R [mm] Retraction height for chip

4 4 breaking, in the drawing
shown as R 1
$ sec. block X(U), Z(W) Absolute (incremental) co-
ordinates of K
3 P [µm] Cutting depth in X direction
(no sign)
Q [µm] Incremental infeed in Z
3
direction (no sign)

F ........... Feed
8
3
Note
• The infeed Q must be smaller than tool width B.
3
5
• Tool width will not be taken into consideration

with this cycle.
3
= . :
;
Cut-in cycle in X Example:

Radial groove, 10mm wide and 10mm deep
T1111 ; (radial cut-in tool 3mm width)

G96 S120 M4 ;
G0 X102 Z-20 ;
G77 R0.5 ;
G77 X80 Z-27 P4000 Q2800 F0.06 ;
G0 X150 Z100 ;
M5 ;
D46
G78Multiple Threading Cycle

(Thread cutting OD/ID)
Format
N... G78 P 1... Q1... R1...
N... G78 X(U)... Z(W)... R 2... P 2... Q2... F...
first block:
P1 .................. is a 6 digit parameter divided in digit
couples:
PXXxxxx
Note: The first two digits of this parameter
• Negative taper parameter R defines the taper define the number of finishing cuts
as shown in the drawing. PxxXXxx
• By using G78 as an OD Threading Cycle: The next two digits define the
Coordinate X S has to be greater than X K chamfer value PF (see drawing)
• By using G78 as an ID Threading Cycle:
Coordinate XS has to be less than X K PF [mm] × 10
PxxXXxx=
F
PxxxxXX
3 Defines the flank angle of thread in

[°] .
(allowed: 80, 60, 55, 30, 29, 0)
Q1 ................. Minimum cutting depth [µm] incre-

mental
8
R1 ................. Finishing offset [mm]

incremental
.
4
3 second block X(U), Z(W) Absolute (incremental)

) 6
5
coordinates of the point K

3
R2 [mm] Incremental taper value

;
with sign (R=0 cylindrical

= : thread)
P2 [µm] Thread depth (always po-
sitive), in the drawing shown
Multiple threading cycle as P2
Q2 [µm] Cutting depth of the first cut
(radius value) without sign
F [mm] Thread pitch
Formulars for the calculation of the cutting depth

for point K in X (metric system):
Example: Thread O.D. (external thread):
N5 T0505 (Thread O.D. M60×2) ;
t = 0,6134 × pitch
G97 S800 M3 ;
G0 X60.5 Z2 ;
Thread I.D. (internal thread):
G78 P041060 Q150 R0.1 ;
G78 X57.546 Z-20 P1226 Q150 F2 ;
t = 0,5413 × pitch
G0 X150 Z150 M5 ;
D47
Drilling cycles with driven tools

Survey of the drilling cycles
Hole machining P rocedure at the Withdrawal

G-code Drilling axis Applications
(– direction) bore bottom (+direction)
G80 ——— ——— ——— ——— Cycle end
Cutting feed Cycle for face
G83 Z -axis Dwell time R apid motion
interrupting drilling
Intermis s ion
Cycle for face
G84 Z -axis Cutting feed s pindle in counter- Cutting feed
tapping
clockwis e direction
G85 Z -axis Cutting feed ——— Cutting feed F ace reaming cycle
Cutting feed
G87 X-axis Dwell time R apid motion S ide drilling cycle
interrupting
Intermis s ion
Cycle for s ide
G88 X-axis Cutting feed s pindle in counter- Cutting feed
tapping
clockwis e direction
Cycle for s ide
G89 X-axis Cutting feed Dwell time Cutting feed
reaming
Systematics G98/G99
G98 .... After reaching the drilling depth the tool

*
Starting
Start moves to the starting level

level
G99 .... After reaching the drilling depth the tool

moves to the withdrawal level - defined
Withdrawal in by R-parameter
starting level
If no G98 o G99 is active, the tool returns to the
starting level. If G99 (withdrawal on withdrawal
* level) is programmed, the address R must be
Starting
Start defined. With G98, R can be omitted!

level
5 R defines the position of the withdrawal level with

Withdrawal in reference to the last Z-position (initial position for
Withdrawal
withdrawal level drilling cycle). With a negative value for R, the

withdrawal level is below the initial position, with
level
a positive value above the initial position.

Withdrawal behaviour G98, G99 Operating sequence
1: The tool traverses with rapid motion from the
initial position (S) to the level defined by R
E (R).
2: Cycle specific drilling up to final depth (E).
3: a: With G98 the withdrawal is carried out up
D to the starting level (initial position S).
b: with G99 up to the withdrawal level (R).
4: With the NC-parameter "5102#6" can be
defined, how the parameter R has to be
programmed in dependent upon G90/G91:
( 5 6 inremental distance ............................. set to 0
absolute distance ................................ set to 1
Operating sequence G98, G99
D48
PROGRAMMING, OPERATION EMCO-SPECIFIC G-COMMANDS / G80, G83, G87
G80 Delete Drilling Cycle (G83 to G89) G83 Face Drilling/Face Peck Drilling Cycle
Format G87 Side Drilling/Side Peck Drilling Cycle
N... G80
Format G83
The drilling cycles must be deselected by G80 or
N... G98(G99) G83 X(U)... C(H)... Z(W)... R...
another G-code of group 1 (G00, G01, ...), since
Q... P... F... (M...) (K...)
they are modally effective.
Format G87
N... G98(G99) G87 Z(W)... C(H)... X(U)... R...
Q... P... F... (M...) (K...)
Starting
4 4 4 level
G98(G99) .. withdrawal to starting level (with-
drawal level)
²=
X(U) ........... G83: hole position absolute (incre-
G83 (G99)
mental) in the X-axis

²;
G87: drilling depth absolute (incre-
Z(W) .......... G83: drilling depth absolute (incre-
mental) in the Z-axis
P R G87: hole position absolute (incre-
Starting C [°] ........... drilling position
4 4 4 level R [mm] ...... incremental value of the withdrawal
level with reference to the starting
point in the Z/X-axis (with sign)
G83 (G98)
²=
Q [µm] ....... drilling depth per infeed for peck drilling
²;
P [msec] .... dwell time on the hole bottom:
P1000 = 1 sec
F ................ feedrate
P (M) ............. M-code for C-axis clamping (when
parameter "5110" is defined)
(K) ............. number of the cycle repetitions (to be
Face drilling cycle G83 used only for incremental pro-
gramming)
G87 (G99) G87 (G98)
Notes
• Setting of parameter "5101#2":
Set 1: Drill reacts back to R after each step
Set 2: Drill reacts back to specified distance in
Starting
Starting
= =
parameter "5114".
level
level
²; ²; • It is not necessary to program C, X and Z within

the cycle for the position of the hole, if in the
previous block before the tool has been already
traversed to the drilling position. In this case
R
just the drilling depth (Z for G83, X for G87)

4
4
needs to be commanded.
• Unless Q is specified, a division of cuts is not
carried out, i. e. drilling to Z-end point in one
movement. Therefore, Q has to be called
4
4
together with each following drilling position

command.
4
4
Side drilling cycle G87
D49
Example - G83 drilling cycle / deep-hole drilling

cycle in Z-direction (with driven tool axial
cycle)
N3 T0303; (drill, driven tool axial)
M52 ; selection of the main spindle
as C-axis.
G28 C0 ; refenence C-axis (necessary
only once after first call of
M52 in program)
M13 ; (or M14) selection of driven tool
with clockwise tool rotation
normally (read note)
G97 S2000 ; constant spindle speed.
G0 X50 Z10 C30 ; positioning the tool.
G83 Z-42 R-8 Q6000 F0.5 ;
(bore 1 (Q6000 = 6mm cutting depth per feed
during deep-hole drilling).).
C150 Q6000 ; bore 2.
C270 Q6000 ; bore 3.
G80 M15 ; deselection drilling cycle
and switch off speed of the
tool.
Note: M53 ; deselection of the main
The direction of rotation for the drilling tools spindle as C-axis.
normally is fixed for right hand tools.
The reason to change the direction of rotation
depends on the design of the tool holder, when Example - G87 drilling cycle / deep-hole drilling
the gear of the holder reverses it's direction. cycle in X-direction (with driven tool radial
cycle)
N7 T0707 (drill, driven tool radial);

as C-axis.
G28 C0 ; reference. C-axis (necessary
only once after first call of
M52 in program).
M13 ; (...or M14)...selection driven
tool and sense of rotation of
the tool (read note).
G0 X50 Z-20 C30 ; positioning the tool.
G87 X18 R-6 Q6000 F0.5 ;
(bore 1 (Q6000 = 6mm cutting depth per feed
during deep-hole drilling).)
C150 Q6000 ; bore 2.
C270 Q6000 ; bore 3.
and switch off speed of the
tool.
M53 ; deselection of the main
spindle as C-axis.
D50
G84 Cycle for face tapping with/

without compensation chuck
G88 Cycle for side tapping with/
without compensation chuck
Tapping without compensation chuck is named
"Rigid Tapping".
Starting
Face tapping and side tapping (G84 and G88)
level
can be performed in conventional mode or in rigid
mode.
G84 (G99)
²=
²;
Format G84
N... G98(G99) G84 X(U)... C(H)... Z(W)... R...
P... F... (M...) (K...)
P R Format G88
N... G98(G99) G88 Z(W)... C(H)... X(U)... R...
Starting P... F... (M...) (K...)
level
G98(G99) .. withdrawal to starting level (withdrawal
G84 (G98)
level)
²=
X(U) ........... G84: hole position absolute (incre-
²; mental) in the X-axis
G88: drilling depth absolute (incre-
P mental) in the Z-axis
G88: hole position absolute (incre-
Cycle for face tapping G84
C[°] ............ drilling position
G88 (G99) G88 (G98) R [mm] ...... incremental value of the withdrawal
= = point in the Z/X-axis (with sign)
P [msec] .... dwell time at the hole ground:
²; ²;
P1000 = 1 sec
F ................ feed
Starting
Starting
(M) ............. M-code for C-axis clamping (when

level
level
parameter "5110" is defined)

(K) ............. number of the cycle repetitions (to be
R
used only for incremental programming)
General
P
• The spindle turns clockwise for right hand taps.

At the bottom of the hole the spindle changes
its direction to retract the tool counterclockwise.
Cycle for side tapping G88
Note:
In case, that the direction of the tool will even
not change its direction with M13/M14 to
clockwise, the special invertion command
M214 has to be used to reverse the direction
of the tool rotation.
D51
• During the tapping feedrate and spindle override

are without function, and assumed to 100%
• Tapping with comensation chuck:
Notes: In conventional mode, the tool will rotate or stop
• The direction of rotation for the drilling tools in synchronization with the motion along the
normally is fixed for right hand tools. tapping axis (Z for G84 and X for G88).
The reason to change the direction of • Rigid tapping:
rotation depends on the design of the tool M29 Sxxxx has to be programmed in a block
holder, when the gear of the holder reverses before the cycle.
it's direction. The spindle motor is controlled like a servo-
• Do not insert a dwell in the cycle for tapping motor, so that a faster tapping is possible.
with longitudinal compensation. • Mode "Feed per minute":
For bigger drills insert the commands M10/ The pitch of the thread equals from feed divided
M11 (main spindle clamp/unclamp) in order by the spindle speed.
to ensure, that the mainspindle keeps its
position. • Mode "Feed per rotation":
The feedrate is equal to the screw lead (=pitch).
Example - G84 rigid tapping cycle: Example - G88 rigid tapping cycle:
without longitudinal compensation in Z- without longitudinal compensation in X-
direction (with driven tool/axial cycle) direction (with driven tool/radial cycle)
N4 T0404 (tap M6x1, driven tool N8 T0808 (tap M6x1, driven tool
axial); radial);
M52 ; selection of the main M52 ; selection of the main
spindle as C-axis. spindle as C-axis.
G28 C0 ; reference C-axis G28 C0 ; reference C-axis
(necessary only once (necessary only once
after first call of M52 in after first call of M52 in
program). program).
M214 ; reverse of rotation dir- M214 ; reverse of rotation dir-
ection (necessary only ection (necessary only
for left hand thread - for left hand thread -
read note) read note)
M13 ; selection driven tool M13 ; selection driven tool
G97 ; selection of constant G97 ; selection of constant
spindle speed [rpm] spindle speed [rpm]
G0 X50 Z10 C30 ; positioning of the tool. G0 X80 Z-30 C30 ; positionining the tool.
M29 S1000 ; selection tapping without M29 S1000 ; selection tapping without
longitudinal compensation longitudinal compensa-
and speed for tool. tion and speed for tool.
G84 Z-20 R-6 P500 F1; thread 1. G88 X50 R-6 P500 F1; thread 1.
C150 ; thread 2. C150 ; thread 2.
G80 M15 ; deselection drilling cycle G80 M15 ; deselection drilling cycle
and switch off speed of and switch off speed of
the tool. the tool.
M53 ; deselection of the main M53 ; deselection of the main
D52
Example - G84 drilling cycle for tapping with Example - G88 drilling cycle for tapping with
longitudinal compensation in Z-direction (with longitudinal compensation in X-direction (with
driven tool/axial cycle) driven tool/radial cycle)
N1 T0101 (tap M6x1, driven tool N2 T0202 (tap M6x1, driven tool
axial); radial);
M52 ; selection of the main M52 ; selection of the main
G28 C0 ; reference C-axis G28 C0 ; reference C-axis
(necessary only once (necessary only once
after first call of M52 in after first call of M52 in
program). program).
M214 ; reverse of rotation dir- M214 ; reverse of rotation dir-
ection (necessary only ection (necessary only
for left hand thread) for left hand thread)
M13 ; selection driven tool M13 ; selection driven tool
G97 S1000 ; selection of constant G97 S1000 ; selection of constant
spindle speed [rpm] and spindle speed [rpm] and
speed for tool speed for tool
G0 X50 Z10 C30 ; positioning of the tool. G0 X80 Z-30 C30 ; positionining the tool.
G84 Z-20 R-6 P0 F1 ; thread 1. G88 X50 R-6 P0 F1 ; thread 1.
G80 M15 ; deselection drilling cycle G80 M15 ; deselection drilling cycle
and switch off speed of and switch off speed of
the tool. the tool.
M53 ; deselection of the main M53 ; deselection of the main
Example - G84 rigid tapping cycle without lon-

gitudinal compensation in Z-center line (with
main spindle/axial cycle)
N10 T1010 (tap M6x1, fixed tool axi-
al);
M204 ; for left hand thread only
M3 ; selection of main spindle
G97 S1000 ; selection of constant
spindle speed [rpm] and
speed for tool
G0 X0 Z10 ; positioning of the tool.
M29 S1000 ; select rigid mode
G84 Z-20 R-6 P0 F1 ; thread 1.
C150 ; thread 2.
C270 ; thread 3.
D53
G85 Cycle for Face Reaming

G89 Cycle for Side Reaming
Format G85
Starting
N... G98(G99) G85 X(U)... C(H)... Z(W)... R...
level
P... F... (K...) (M...)
G85 (G99)
Format G89
²=
N... G98(G99) G89 Z(W)... C(H)... X(U)... R...
²; P... F... (K...) (M...)
P
G98(G99) .. withdrawal to starting level (with-
drawal level)
R X(U) ........... G85: hole position absolute (incre-
Starting G89: drilling depth absolute (incre-
level mental) in the X-axis
G85 (G98)

²=
G89: hole position absolute (incre-
²; mental) in the Z-axis
P C[°] ............ drilling position
R [mm] ...... incremental value of the withdrawal
point in the Z/X-axis (with sign)
Reaming cycle G85 P [msec] .... dwell time at the hole bottom:
P1000 = 1 sec
F ................ feed
G89 (G99) G89 (G98) (K) ............. number of cycle repetitions (only for
incremental programming)
= = (M) ............. M-code for axis clamping (when
²; ²; parameter "5110" is defined)
Notes
• If G99 (withdrawal to withdrawal level) is
Starting
Starting
programmed, the address R must also be

level
level
defined. With G98 R can be omitted!

R
• It is not necessary to program C, X and Z within

the cycle for the position of the hole, if in the
previous block before the tool has been already
traversed to the drilling position. In this case
P
just the drilling depth needs to be commanded.

• The withdrawal to the start point is carried out
Cycle for side reaming G89 with the double feed speed, which has been
programmed in block G85/G89.
• A division of the cut is not possible by indicating
the Q-parameter.
D54
Example - G85 drilling cycle / reaming cycle in

Z-direction (with driven tool/axial cycle)
N5 T0505 (reamer, driven tool axial);
as C-axis.
G28 C0 ; reference. C-axis
(necessary only once after
first call of M52 in program).
tool with clockwise tool ro-
tation normally (read note)
G0 X50 Z10 C30 ; positioning the tool.
G85 Z-32 R-8 P500 F0.5 ; bore 1.
C150 ; bore 2.
C270 ; bore 3.
G80 M15 ; deselection of the drilling
cycle and switch off speed
of the tool.
M53 ; deselection of the main spindle
as C-axis
Note:
The direction of rotation for the drilling tools Example - G89 Drilling cycle / reaming cycle
normally is fixed for right hand tools. in X-direction (with driven tool/radial cycle)
The reason to change the direction of rotation
depends on the design of the tool holder, when N9 T0909 (reamer, driven tool radial);
the gear of the holder reverses it's direction. M52 ; selection of the main spindle
as C-axis
G28 C0 ; reference. C-axis
(necessary only once after
first call of M52 in program).
tool with clockwise tool ro-
tation normally (read note)
G97 S2000 ; constant speed of the tool.
G0 X50 Z-40 C30 ; positioning the tool.
G89 X28 R-6 P500 F0.5 ; bore 1.
C150 ; bore 2.
C270 ; bore 3.
G80 M15 ; deselection of the drilling
cycle and switch off speed
of the tool.
M53 ; deselection of the main spindle
as C-axis
D55
G-COMMANDS / G12.1, G13.1 PROGRAMMING, OPERATION EMCO-SPECIFIC
G12.1/G13.1
Polar Coordinate Interpolation
The polar coordinate interpolation is adequate for
Level of the polar

& machining the end face of a turned part or grinding
Rotary axis the camshaft on lathes.
coordinate (virtual axis)
interpolation It converts a command programmed in the
Cartesian coordinate system into the movement
of a linear axis X (tool movement) and a rotating
axis C (workpiece rotation) for the path control.
The rotary axis C serves as axis address for the
Linear axis
second (virtual) axis.
This axis is set immediately after programming
; G12.1 at coordinate C0.
Here an angle of 0 is supposed as tool position.
Origin of the
workpiece coordinate
system
Format
N.. G12.1 ; starts the operating mode and en-
ables polar coordinate interpolation
: geometry program (based on Car-
tesian coordinates)
N.. G13.1 ; terminates the operating mode po-
lar coordinate interpolation.
Notes:
• Also with diameter programming for the linear
axis (X-axis) radius programming is used for
the rotary axis (C-axis). G12.1 chooses a level (G17) in which the polar
coordinate interpolation is carried out.
• Cutter position 0 must be assigned to the tool in The level G18 used by G12.1 before programming
the offset data. is deleted.
However, the miller radius must be entered. It is reestablished by means of the command
• In G12.1- mode the coordinate system must not G13.1 (polar coordinate interpolation end).
be altered. After switching on the machine or with a system
• G12.1 and/or G13.1 must be programmed in RESET the condition "polar coordinate inter-
the mode "cutter radius compensation off" (G40) polation" is also cancelled, (G13.1) selected and
and cannot be started or terminated within the level defined by means of G18 is used.
"cutter radius compensation on" (G41 or G42).
• G12.1 and G13.1 are to be programmed in se- G-codes which may be programmed in the
parate blocks. mode "polar coordinate interpolation:
In a block between G12.1 and G13.1 an
interrupted program cannot be brought to a new G-Code Use
start. G01 Linear interpolation
G02, G03 Circular interpolation
• The arc radius with circular interpolation (G2
G04 Intermission
oder G3) can be programmed by means of an
R-command and/or via I- and J-coordinates. G40, G41, Cutter radius compensation
(polar coordinate interpolation is applied on the
• In the geometry program between G12.1 and G42 tool path after the tool compensation)
G13.1 no rapid motion (G0) must be pro-
grammed (see adjoining scheme). G65, G66,
User macro command
G67
G98, G99 Feed per minute, feed per rotation
D56
PROGRAMMING, OPERATION EMCO-SPECIFIC G-COMMANDS / G12.1, G13.1
Example 1 - polar coordinate interpolation
X- axis with diameter programming and C-axis

with radius programming.
N1 T0101 (end mill Dm 10);

& driven tool axial / miller radius 5.0, cutter
radius position 0.
M13 ; (...or M14)...selection driven tool
and direction of the tool rotation.
G97 S1000 constant speed of the tool.
6 tartpoint
WDUWSNW M52 ; selection of the main spindle as
C-axis
; G28 C0 ; reference. C-axis (necessary
only once after first call of M52
in program).
(ndpoint
QGSNW G52 C.. ; poss. shift of angle of C-axis.
G40 G0 X60 C0 Z-6 ;
Positioning the tool in rapid motion (poss.
point X C deselection cutter radius compensation).
G12.1 ; start of the polar coordinate
S 34,64 10
interpolation.
1 34,64 0
G42 G1 X34.64 C10 F0.1 ;
2 17,32 -15 to point S in feed and selection cutter radius
3 -17,32 -15 compensation.
4 -34,64 0 C0 ; to point 1.
5 -17,32 15 X17.32 C-15 ; to point 2.
6 17,32 15 X-17.32 ; to point 3.
7 34,64 0 X-34.64 C0 ; to point 4.
E 34,64 -10 X-17.32 C15 ; to point 5.
X17.32 ; to point 6.
X34.64 C0 ; to point 7.
C-10 ; to point E.
G40 X60 Z10 ; move away from the part in the
feed and deselection cutter radius
compensation.
G13.1 end of the polar coordinate inter-
polation.
G52 C0 ; poss. reset of offset of the angle
in the C-axis.
M53 ; poss. deselection of the main
spindle as C-axis.
G0 X150 Z150 M15 ;
Release in rapid motion and speed driven
tool off.
D57
Example 2 - polar coordinate interpolation with

cutter radius compensation
X-axis with diameter and C-axis with radius

programming.
N1 T1212; (end mill Dm10, axial driven tool,

virtual axis cutter radius 5.0, cutter radius
&
programmed
tool path
position 0)
M13 ; (or M14) rotation direction
G97 S1000 ; constant spindle speed
& tool path after cutter M52 ; selection on C-axis
radius G00 X120.0 C0 Z... ; positioning at the starting
compensation position
N204 N203 G12.1 ; start of the polar coordinate
tool
N202
interpolation
N201
G42 G01 X40.0 F... ; ü
N205 = ; C10.0 ï geometry
N206 N207 N200
G03 X20.0 C20.0 R10.0 ; ï program
G01 X-40.0 ; ï (based on
C-10.0 ; ý Cartesian
G03 X-20.0 C-20.0 I10.0 J0 ; ï coordinates in
G01 X40.0 ; ï X-C'plane)
Polar coordinate interpolation with cutter radius C0 ; ï
compensation G40 X120.0 ; þ
G13.1 ; polar coordinate interpola-
tion end
Z... ;
X... C... ;
M30 ;
D58
PROGRAMMING, OPERATION EMCO-SPECIFIC G-COMMANDS / G7.1
G7.1 Cylindrical interpolation

This function enables the development of a
cylinder surface in programming.
In this way e.g. programs for cyclindrical cam
machining on lathes can be created.
The traverse amount of the rotary axis C pro-
grammed by indication of the angle is converted
in the control into the distance of a fictitious linear
axis along the external surface of the cylinder.
Thus, it is possible that linear and circular
interpolations on this area can be carried out with
another axis.
Format
G1 G19 G90 W0 H0 ; (or G1 G19 G91 Z0 C0 ;) determine centre of the reference level (PRM1022#C=6).
G7.1 C.. ; (or G7.1 H.. ;) activates the mode cylinder interpolation with indication of the
cylinder diameter (in [mm] for the calculation of the path feed rate.
: Geometry program.
G7.1 C0 ; (or G7.1 H0 ;) terminates the mode cylinder interpolation.
G18 ; reset to the original plane
Calculating of Y[mm]- into C[°]-coordinates for

path programming With G19 the level is determined in which the
rotary axis C is preset in parallel to the Y-axis.
Yp [mm ] ⋅ 360[°] The block structure for the geometry program is
Cp =
2π ⋅ Rcyl [mm ] then as follows:
G1 Z.. [in mm] C.. [in °] ; linear interpolation.
Cp [°] .............. distance to move in C-axis G2 (G3) Z.. [in mm] C.. [in °] R.. [in mm] ; circular
Yp [°] .............. drawing distance to be calculated interpolation.
Rcyl [mm] ........ radius of the cylinder surface
Notes:
• The reference point of the cylinder must be G3) must be programmed via an R-command
entered incrementally, since otherwise it would and must not be programmed in degree and/or
be approached by the tool! via K and J-coordinates.
• In the offset data cutter position 0 must be • In the geometry program between G7.1 C.. and
allocated to the tool. However, the miller radius G7.1 C0 no rapid motion (G0) and/or positioning
must be entered. procedures causing rapid motion movements
(G28) or drilling cycles (G83 to G89) must be
• In mode G7.1 the coordinate system must not
programmed.
be changed.
• The feed entered in the mode cylindric inter-
• G7.1 C.. and/or G13.1 C0 must be programmed
polation is to be considered as traverse speed
in the mode "cutter radius compensation off"
on the unrolled cylinder area.
(G40) and cannot be started or terminated within
"cutter radius compensation on" (G41 or G42).
• G7.1 C.. and G7.1 C0 must be programmed in
separate blocks.
• In a block between G7.1 C.. and G7.1 C0 an
interrupted program cannot be restarted.
• The arc radius with circular interpolation (G2 or
D59
G-COMMANDS / G7.1 PROGRAMMING, OPERATION EMCO-SPECIFIC
Example 1 - cylinder interpolation
X-axis with diameter programming and C-axis with

angle programming.
N2 T0202 (end mill Dm 12); driven tool radial / cutter radius 6.0, cutter radius position 0.
M13 (...or M14)...selection driven tool and sense or rotation of the tool.
G97 S1000 constant speed of the tool.
M52 ; selection of the main spindle as C-axis.
G28 C0 ; reference. C-axis (necessary only once after after first call of M52).
G52 C.. ; poss. shift of the angle of the C-axis.
G40 G0 X60 C0 Z-100 ; positioning the tool in rapid motion (poss. deselection cutter radius
compensation).
G19 W0 H0 ; (or G19 G91 Z0 C0).. determine incrementally centre point of the reference
level.
G7.1 C57.299; start of the cylinder interpolation with cylinder diameter notation in [mm].
G42 G1 G94 Z-120 F350 ; selection cutter radius compensation outside the workpiece on point S.
X48 F100 ; feed in X.
C30 F250 ; to point 1.
G2 Z-90 C60 R30 F250 ; to point 2.
G1 Z-70 ; to point 3.
G3 Z-60 C70 R10 ; to point 4.
G1 C150 ; to point 5.
G3 Z-70 C190 R75 ; to point 6.
G1 Z-110 C230 ; to point 7.
G2 Z-120 C270 R75 ; to point 8.
G1 C360 ; to point 9.
X60 F350 ; move away in X.
G40 Z-100 ; deselection cutter radius compensation outside the workpiece.
G7.1 C0 ; end of the cylinder interpolation by deselection of the cylinder radius.
G95 ; deselection G94 (feed in mm/min).
G52 C0 ; poss. reset of the shift of the angle in the C-axis.
M53 ; poss. deselection of the main spindle as C-axis.
G0 X150 Z150 M15 ; release in rapid motion and speed driven tool off.
G18 ; reset to original plane
D60
G51.2 / G50.2 Polygonal Turning
During polygonal turning, workpiece and tool are

turned in a certain relation to each other in order
to produce workpiece contours.
By changing the transmission ratio between tool
and workpiece or changing the number of cutting
tools the part contour can be altered.
The advantage compared with polar coordinate
interpolation is to be found in the shorter machining
time, however, the part contour is not exactly poly-
gonal.
Polygonal turning is mainly used for the production
of e.g. collar head screws and hexagonal screws.
Format:
G51.2 P... Q... ;
P ...... integer number 1 to 9
transmission number of the main spindle
Q ..... integer number 1 to 9
transmission number of the axis of the
driven tool (=Y-axis)
Negative sign for Q is negative sense of
rotation of the tool.
$²% Q-... Negative sign for Q means negative dir-
ection of the tool rotation.
P:Q = 1:2 G250;Spindle synchronisation OFF
%
$ Example 1:
• transmission ratio P:Q = 1:2
• single-edged tool
D
E G51.2 P1 Q2 ; (or Q-2)
The use of a tool with a cutter signifies that the
% cutter tip describes an ellipse, with "A+B" as long
$ and "A–B" as short side.
You receive the marked area in the adjoining
picture as workpiece contour.
A ...... workpiece radius

B ...... workpiece radius
Polygonal turning with single-edged tool
D61
Example 2:
P:Q = 1:2 • Transmission ratio P:Q = 1:2
• double-edged tool (offset 180°)
G51.2 P1 Q2
A rectangle results as workpiece contour (see
adjoining picture).
Example 3:
• transmission ratio P:Q = 1:2
• three-edged tool (offset 120°)
G51.2 P1 Q2
A hexagon results as workpiece contour (see
adjoining picture).
Polygonal turning with double-edged tool
Notes:
P:Q = 1:2 • For thread-cutting an error occurs at the starting
point during synchronous operation.
During thread-cutting the synchronization is to
be switched off with G50.2.
• The following signals are effetive and/or not
effective for the axis of the driven tools (Y-axis)
in synchronous operation:
valid signals :
- machine look
- servo off
invalid signals:
- feed stop
- lock
- oversteering
Polygonal turning with three-edged tool - test run (in block G51.2 the rotation signal is
not waited for during the test run).
• The Y-axis cannot be approached with a traver-
se command "Y...", it can only be indicated with
the ratio to the main spindle speed.
• In the position display of the Y-axis during the • To return to the reference point the command
movement of the Y-axis the machine coordinate "G28 V0" must be entered.
values change from 0 to the parameter setting In case of the input of G50.2 the Y-axis would
(traverse amount per rotation). stop in an undefined position. This could cause
Absolute and/or relative coordinate values are problems in case that the same contour is to be
not updated. machined with two tools (roughing Ù finishing).
• Absolute position recognition cannot be applied By programming "G28 V0" first the tool and
to the Y-axis. spindle are brought into the same position prior
to further machining similar to the first machining
• Manual continuous feed or handwheel feed are
procedure (the tool starts turning as soon as the
not possible if the Y-axis works in synchronous
spindle receives the "one rotation signal" of the
operation.
position encoder).
• The Y-axis in synchronous operation does not
• The Y-axis for the control of the tool rotation
belong to the number of the simultanously
during polygonal turning is the 4 th axis.
controlled axes.
D62
Example for Polygonal Turning:

Hexagon with key size 32mm
…
G0X110Z80M5
N11T909 driven 3-edge tool, dia 100 mm
G97S1000M4 Main spindle ON, counterclock-
wise
M214 reverse of rotation direction of
driven tool (necessary only for
left hand thread)
G0X32Z5 Positioning of the tool
G51.2P1Q2 (or Q-2)
transmission ratio P:Q = 1:2
G1Z-5F.1 machining
G0 X100 Z20 Releasing position
G50.2 Synchronization OFF
M5 Spindle stop
G0X150Z20 Tool changing position
...
D63
G-COMMANDS / G90, G91, G92 PROGRAMMING, OPERATION EMCO-SPECIFIC
G90 Absolute Programming G92 Adjustment for maximum

Format Spindle Speed
N... G90 Format
The addresses have to be programmed as N... G92 S... (Spindle speed limit)
following: With the command G92 the max. spindle speed
X ......... Diameter can be declared (rpm) for the constant cutting
U+/- .... Incremental in diameter (except some speed (G96).
cycles)
Z+/- .... Absolute (referred to the workpiece zero
point)
W+/- ... Incremental (actual) traverse distance
Notes
• Direct switchover from block to block between G92.1 Coordinate System
G90 and G91 is permitted.
• G90 and G91 may also be programmed with Setting
some other G functions See alse to "Attention" on this side!
(N... G90 G00 X... Z...).
Format
N... G92 X... Z... (Set coordinate system)
oder
N... G92 U... W... (Shift coordinate system)
G91 Incremental Programming Example

You want to shift your workpiece zero from the
Format right to the left side of the workpiece
N... G91 Diameter of workpiece = 30 mm
The addresses have to be programmed as Length of workpiece = 100 mm
following:
X,U ..... Diameter Program
Z,W .... Incremental (actual) traverse distance N... G90 ................... Programming absolute
with sign ... .............................. Workpiece zero point right
Notes see G90. ... .............................. Right side of contour is
finished
N180 G00 X35 ........ Retract
Attention N185 Z-100 ............. Movement distance = work-
• The format G10 P0 X(U).. Z(W).. and/or G92 piece length
X(U).. Z(W).. is placed above all other zero N190 G92 X35 Z0 . New zero point on the left
point shifts (from G52 to G59)! side
• The shift is not displayed on the screen!
• Attention with programs which were pro- ... .............................. Workpiece zero point left
grammed for former control types (Fanuc 0- ... .............................. Machine left side
T, Fanuc 21-T). N305 G00 X35 ........ Retract
Remedy N310 Z100 ............... Movement distance = work-
First call up G10 P0 X0 Z0 (reset of the zero piece length
point shift in G92) and input the following two N315 G92 X35 Z0 . Workpiece zero point left
blocks: again
G10 L2 P1 X(U)... Z(W)... ; ... .............................. etc.
G54 ;
Zero offset with G92 is modal and it is not
cancelled through M30 or RESET!
In this way, do not forget to reset the zero offset
G92 before program is finished.
When zero offset will be inserted incrementally,
the values U and W will be added to the last valid
zero offset.
D64
PROGRAMMING, OPERATION EMCO-SPECIFIC G-COMMANDS / G94, G95, G69, G97
G94Feed Rate in Minutes

The entry of the command G94 means that all
values programmed under "F" (feed) are in mm/
min.
G95Feed Rate in Revolutions

The entry of the command G95 means that all
commands programmed under "F" are in mm/
revolution.
G96Constant Cutting Speed

Unit: m/min
The control continually computes the spindle
speed corresponding to the respective diameter.
G97Constant Rotational Speed

Unit: rev/min
D65
M-COMMANDS PROGRAMMING, OPERATION EMCO-SPECIFIC
M-Commands - Survey
Code Meaning Code Meaning
M00 Programmed stop M80 Reset freely programmable exit 1
M01 Selective stop M81 Set freely programmable exit 1
M02 Program end M82 Reset freely programmable exit 2
M03 Main spindle ON in clockwise direction M83 Set freely programmable exit 2
M04 Main spindle ON in counter-clockwise direction M84 Reset freely programmable exit 3
M05 Main spindle stop M85 Set freely programmable exit 3
M08 Coolant ON M86 Reset freely programmable exit 4
M09 Coolant OFF M87 Set freely programmable exit 4
M10 Spindle clamping ON M90 Manual chuck
M11 Spindle clamping OFF M91 Tensile clamping device
M13 Driven tool - spindle ON in clockwise direction M92 Pressure clamping device
M14 Driven tool - spindle ON in counter-clockw. dir. Cancel final position monitoring (no alarm if part
M93
M15 Driven tool - spindle stop clamped and final position reached )
M20 Tailstock backward M94 Bar feed, bar feed magazine active
M21 Tailstock forward M95 Bar feed, bar feed magazine not active
M23 Collecting tray backward M96 Auto Cycle Start with closed door ON
M24 Collecting tray forward (swivel under spindle) M97 Auto Cycle Start with closed door OFF
M25 Open clamping device M98 Call-up subroutine
M26 Close clamping device M99 Subroutine end
Tapping without longitudinal compensation for Main spindle ON in clockwise direction with
M29 M103
driven tools waiting time, until spindle speed is reached
M30 Program end Main spindle ON in counter-clockwise direction
M104
M39 AWZ positioning ON with waiting time, until spindle speed is reached
M40 AWZ positioning OFF M108 SINIS minimal coolant ON (option)
M48 hydr. tool probe swivel IN in working area M109 SINIS minimal coolant OFF
M49 hydr. tool probe swivel OUT Driven tool - spindle ON in clockwise direction
M113
M50 Deselection direction logic with waiting time, until spindle speed is reached
M52 Selection C-axis Driven tool - spindle ON in counter clockw. dir.
M114
M53 Deselection C-axis (also with M10) with waiting time, until spindle speed is reached
M57 Spindle oscillation ON (S....frequency) M190 automatic changing of screen OFF
M58 Spindle oscillation OFF M191 autom. changing of screen ON (into alarm mode)
M60 Tool probe calibration Reverse of rotation direction for main spindle ON
M204
M61 Start of tool measuring (M3 = M4, M4 = M3)
Bar feed / bar loading magazine feed ON with Reverse of rotation direction, main spindle OFF
M66 M205
feed stop (M3 = M3, M4 = M4)
Bar feed / bar loading magazine feed ON Reverse of rotation direction for driven tool ON
M67 M214
without feed stop (M13 = M14, M14 = M13)
M68 Bar feed / bar loading magazine feed OFF Reverse of rotation direction for driven tool OFF
M215
Start bar change (without feed stop / read-in (M13 = M13, M14 = M14)
M69
release) M230 Collecting tray backward (without feed hold)
M70 Precise stop fine M240 Collect. tray forward below spindel (without feedhold)
M71 Flushing pump for spindle ON M241 Collect. tray forward to wating pos.l (without feedhold)
M72 Flushing pump for spindle OFF
$WWHQWLRQ
If you switch from the main spindle over to the driven tool spindle or vice-versa, the command M3, M4, M13, M14
must be programmed in a separate line.
M-code and S-code must not be programmed in one line, the S-code must be programmed in the next line.
D66
PROGRAMMING, OPERATION EMCO-SPECIFIC M-COMMANDS / M0-M21
M0 Programmed Stop M8 Coolant ON

Unconditional The coolant will be switched on.
These command effects a stop in the execution M9 Coolant OFF

of the part program.
The coolant will be switched off.
Main spindle, feed and coolant will be switched
off.
The chip protection door can be opened without M10 Spindle clamping ON
triggering an alarm. Spindle clamping is activated
With "NC START" the program run can be M11 Spindle clamping OFF
continued. After that the main drive will be
switched on with all values which were valid Spindle clamping is switched off
before.
M1 Programmed Stop M13 Driven Tool ON Clockwise

Conditional The driven tool is switched on provided that a
spindle speed or cutting speed has been pro-
M01 works like M00, but only if the key 237
6723 was
grammed, the chip protection door is closed and
a workpiece correctly clamped.
pressed.
With "NC START" the program run can be M14 Driven Tool ON
continued. After that the main drive will be Counterclockwise
switched on with all values which were valid
before. The same conditions as described under M13 apply
here, but counterclockwise rotation direction.
M2 Main Program End
M15 Driven Tool Off
M02 works like M30.
The tool drive is braked electrically.
At the program end the driven tool is automatically
switched off.
M3 Main Spindle ON Clockwise
The spindle is switched on provided that a spindle M20 Tailstock BACK
speed or cutting speed has been programmed,
the chip protection door is closed and a workpiece M21 Tailstock FORWARD
correctly clamped.
M03 must be used for all right-hand cutting or
• The main spindle must be stopped for traversing
overhead clamped tools.
the tailstock
• The main spindle can not be switched on and
M4 Main Spindle ON NC Start will be ignored, as long as the tailstock
Counterclockwise is in an undefined position (not in front or back
end position)
The same conditions as described under M03 • If the tailstock is in an intermediate position after
apply here. power on, it traverses to the back end position
M04 must be used for all left-hand cutting or nor- automatically after pressing the AUX ON key.
mal clamped tools. • After pressing the tailstock key the screen
shows the message "Tailstock in intermediate
M5 Main Spindle Off position" as long as the tailstock reaches a
defined position (back end position or clamping
The main drive is braked electrically. position). The tailstock can be positioned in tip
At the program end the main spindle is auto- mode.
matically switched off.
D67
M-COMMANDS / M25-M87 PROGRAMMING, OPERATION EMCO-SPECIFIC
M23 Workpiece Collection M39 Driven Tool Positioning ON

Device BACK M40 Driven Tool Positioning
The collecting tray flaps back and leaves the OFF
working room. The positioning of the driven tool will be activated
or deselected.
M24 Workpiece Collection
Device FORWARD M50 Direction Logic CANCEL of
The collecting tray flaps forward to catch the Tool Change
workpiece.
Effective blockwise.
The swivel sequence can occur only via CNC pro- The following tool change will be done clockwise
gram. Swivel in and swivel out is possible only (not necessarely on the shortest way).
with closed door.
The supervision records only the swivel move- M52 Selection Main Spindle as
ment but not the needed time. That means: The
execution time for the commands "workpiece tray C-axis
back" and "workpiece tray forward" must be M53 Deselection Main Spindle
considered with programming (G4 - dwell time) as C-axis
The main spindle is defined as C-axis.
M25 OPEN Clamping Device Deselection can also be carried out by means of
M26 CLOSE Clamping Device M10 (spindle clamping).
Notes
• If you change the clamping device, check the M70 Precise STOP Fine
clamping direction and adapt the machine confi-
If M70 is programmed in a traversing block, the
guration with M90-92.
following traverse movement will be started only
• Open and close the clamping device is possible
after the axes have reached the target point (short
only with main spindle stop.
axis stop).
• The program run will be continued only after the
clamping device is opened or closed completely.
• Opening the clamping device (manual or with M80-87 Freely Programmable
M25) is completed only after the pressure switch Exits
and the end position proximity switch have
acknowledged.. see earlier in this chapter
Manual operating
Clamping device key
M29 Selection Rigid Tapping

(without longitudinal
compensation)
Is programmed in connection with S-code imme-
diately before the cal of cycle G84 or G88
M30 Program END

With M30 all drives are switched off and the
control is returned to the start of the program.
Moreover, the counter level is increased by 1.
D68
Machine Configuration M90-M95

The M functions M90 - M95 describe the confi-
guration of the machine (type of clamping device,
bar feed / loader active, not active).
The control requires these data to control and

supervise the corresponding functions correctly.
Procedure
• Set the key switch "data protection" on position
1.
• For the corresponding change at the machine
(e.g. other clamping device) enter the respec-
tive M function in the MDI mode.
• The set machine configuation is kept, until it is
deselected by an opposite M function (also after
switching off the machine).
M90 Manual Chuck M94 Bar Feed / Bar Loader

(no clamping supervision) Active
M91 PULL Clamping Device M95 Bar Feed / Bar Loader not
Clamping device that closes when the connecting Active
tube pulls, e.g.:
EMCOTURN 325:
• Pneumatic jaw chuck, that clamps from outside M96 Automatic Cycle-Start
to inside
• Pneumatic collet chuck
when Door Closed
(Option)
EMCOTURN 345:
• Hydraulic jaw chuck
The machining program starts as soon as the chip
guard door is closed.
The option "automatic cycle start when door
M92 PUSH Clamping Device closed" can also be used without automatic door.
Clamping device that closes when the connecting For safety reasons this function must be activated
tube pulls, e.g.: again (M96) after every machine off-on.
EMCOTURN 325:
• Pneumatic jaw chuck, that clamps (a tubular M97 CANCEL M96
workpiece) from inside to outside
EMCOTURN 345:
• Hydraulic collet chuck
M93 Clamping Limit Monitoring

CANCEL
No clamping supervision
D69
M-COMMANDS / M98-M99 PROGRAMMING, OPERATION EMCO-SPECIFIC
M98 Subprogram Call

Format
N... M98 P...
P ......... The first four digits from the right deter-

mine the subprogram number, the other
digits the number of repetitions.
Notes
• M98 can be designated in the same block as
the movement command (e.g. G01 X25 M98
P25001).
• When the count of repetitions is not specified,
Main program Subprogram the subprogram is called once (M98 P5001).
• When the programmed subroutine does not exist
2 an alarm occurs.
• A two loop subprogram call can be executed.
(N... M98 P25001 ; the program will be called
two times)

103 1[[[[0
M99 Subprogram End,

103
Jump Instruction
2
Format

N... M99 P...

M99 in the main program

Without jumping address:
1[[[[0
Jump to the program start.
With jumping address Pxxxx:
Jump on block no. xxxx
Subroutine call from a main program
M99 in the subprogram
Without jumping address:
Jump to the calling up program, on the next block
after the calling up block (see drawing).
With jumping address Pxxxx:
Jump to the calling up program on block no. xxxx
Note
• M99 must be the last command in the sub-
program.
• The jump-back occurs automatically into the
next following block in the main program.
• M99 cannot be used internal the main program
as a jump instruction.
To perform a jump instruction in the main pro-
gram it is possible to use the command GOTO
For example:
To jump from the actual position in program to
block number N12, program the command
GOTO12 in a seperate block.
D70
M103 Main Spindle ON clockwise M204 Reverse of Rotation Dir-

with Waiting Time ection of the Main Spindle
Same code as M3, but: ON
The following blocks only then will be executed, if This command reverses the commands M3 and
the spindlespeed has been reached. M4: M3=M4, M4=M3.
M104 Main Spindle ON counter M205 Reverse of Rotation Dir-

clockwise with Waiting Time ection of the Main Spindle
Same code as M4, but: OFF
The following blocks only then will be executed, if This command delets the reverse the commands
the spindlespeed has been reached. M3 and M4: M3=M3, M4=M4.
M113 Driven Tool ON clockwise M214 Reverse of Rotation Dir-

with Waiting Time ection of Driven Tool ON
Same code as M13, but: M214 reverses the commands M13 and M14
The following blocks only then will be executed, if (driven tool on): M13=M14, M14=M13.
the spindlespeed of driven tool has been reached.
M114 Driven Tool ON counter M215 Reverse of Rotation Dir-

clockwise with Waiting Time ection of Driven Tool OFF
Same code as M14, but: M215 delets the reverse the commands M13 and
The following blocks only then will be executed, if M14: M13=M13, M14=M14.
the spindlespeed of driven tool has been reached.
D71
M-COMMANDS / BAR FEED, BAR LOADER PROGRAMMING, OPERATION EMCO-SPECIFIC
Bar Feed / Bar Loader Interface
General
• The signals from the machine to the loader are
free programmable in the part program via M
functions.
• The signals from the loader to the machine can
be called free in the part program and can be
used for jumps (branches) or waiting loops.
• The part program will always be started
automatically by the machine, also at bar end.
M Functions
M57 Main spindle swing on
M58 Main spindle swing off
M66 Bar feed / Bar loader FEED ON with feed
stop/input release
M67 Bar feed / Bar loader FEED ON without
feed stop/input release
M68 Bar feed / Bar loader FEED OFF
M69 Start bar change without feed stop/input
release
M71 Turn Spindle and clean clamping device
ON
M72 Turn Spindle and clean clamping device
OFF
Control signal (MACRO variable)

Bar end ........................................................ #1000
Loader has pushed forward ........................ #1001
Start after bar change ................................. #1002
By means of these signals (MACRO variable) you
can branch in the part program and call or skip
corresponding program parts or program a waiting
loop.
Activate / Deactivate
M94 Activate bar feed / bar loader
M95 Deactivate bar feed / bar loader
D72
PROGRAMMING, OPERATION EMCO-SPECIFIC M-COMMANDS / BAR FEED, BAR LOADER
Program Example for Operating a Bar Feed

Used functions
(aktive until M68 FEED OFF)
N20 IF [#1000EQ0] GOTO 10
Query whether signal "bar end" is active.
The MACRO variable #1000 is compared with
zero (EQ0).
When signal "bar end" is active (#1000 = 0) the
program jumps to block number 10.
This creates an infinite loop (waiting loop), as long
as "bar end" is active.
Program
%
:5000
M94 Activate bar feed / bar loader
G0 X20 Z100 T101 Place bar stop

M25 Open clamping device
M67 Bar feed ON Regular bar feed
G1 G94 F1000 Z150 Accompany bar to stop position
M26 Close clamping device
M68 Bar feed OFF
N10 Block number for jump address Infinite loop at bar

N20 IF [#1000EQ0] GOTO 10 Query for bar end end
G0 X50 Z180 Approach free position

T202
G0 X30 M3 S3000
G1 G95 F0.3 Z150
.... Part machining
....
....
G0 X50 Z180
M30
%
Alternative
Note When the bar feed / bar loader gives the signal
This programming example was created for "loader has pushed forward", you need not to pro-
the EMCOTURN 325. gram the function "bar feed OFF" (M68).
On other machines a larger traversing area
can be programmed. Changes in program:
• M66 Bar feed / Bar loader FEED ON with feed
stop/input release instead of M67
• Cross out M68 (bar feed OFF).
D73
Program Example for Operating the Bar Loader EMCO LM800
Note
This programming example was created for
the EMCOTURN 345.
Mind the machining area on other machines.
%
:2000 (example for loaderprogram with MKE LM 800)
G28U0W0
G92S5000
G10P0Z-200
T0202 (bar stop)
G0X100Z50
X0Z30
Z-15 (pick up position)
M25 (clamping device opening)
M66 (feed in ON)
G1G94F6000Z0.4 (feed out position 0.4 for facing)
G4X0.5 (delay time)
IF[#1000EQ1]GOTO10 (check end of bar:
if "yes", control will read next line, if "not" jump to line number N10)
G1G94F8000Z250 (position to trop the rest pice)
M69 (start bar change)
G0Z0.4 (position for the new bar)
N20
IF[#1002EQ0]GOTO20 (check barfeed feeded forward)
M66 (feed in ON)
N10 M26 (clamping device closing)
M66 (check barfeed feeded backward)
G0Z30
X150Z120 (index position)
G95
T1212
....................... (standard program to machine the part)
M30 (end of program)
Information:
Keep-relay: K1 = 1xxx1xxx
aktivate lader: M94
D74
Program Example for Operating the Bar Loader Kupa LM
Used functions
M66 Bar feed / Bar loader FEED ON with feed
stop/input release
M69 Start bar change
IF [#1000EQ1] GOTO 66
Query whether signal "bar end" is not active.
The MACRO variable #1000 is compared with one
(EQ1).
When signal "bar end" is not active (#1000 = 1)
the program jumps to block number 66 and a nor-
Note
mal bar feed will be done.
When signal "bar end" is active, no jump is done
the EMCOTURN 345.
and the rest piece will be ejected and the bar
change will be proceeded.
Subprogram for bar loader
% :1000 (KUPALOADER SPF)

M94 Activate bar loader
T0404 Place bar stop
G0 X0 Z-20 Stop position
IF [#1000 EQ1] GOTO 66 Jump over bar change
G0 X0 Z150 Approach free position
M24 Swivel in workpiece tray
G4 X3 Dwell
M66 Bar feed - eject rest piece Bar change
M23 Swivel out workpiece tray
G4 X1 Dwell
G0 X0 Z20 Stop position
M69 Bar change
N66 M66 Bar feed until bar stop
G1 G94 F2000 Z.5 Bar stop pushes bar to clamping position
G4 X.5 Dwell Bar feed
G0 X120 Z100 Approach tool change position
(M66) Some KUPA-types (software versions) need this command,
when an alarm occurs remove this command out of the program.
M99 Subprogram end
Main program
% :1234 (MAINPROGRAM)
G28 U0 W0 Approach reference point
G92 S4000 Spindle speed limit
G10 P0 Z-200 Zero offset
M98 P1000 Subprogram call
Bearbeitung
N300 M30 Program end
D75
Program Example for Operating a Bar Loader

(not for Kupa LM and EMCO LM800 loaders)
Used functions
(aktive until M68 FEED OFF)
IF [#1000EQ1] GOTO 10
Query whether signal "bar end" is active.
The MACRO variable #1000 is compared with one
(EQ1).
When signal "bar end" is not active (#1000 = 1)
the program jumps to block number 10 - the bar
change will be skipped.
IF [#1002EQ0] GOTO 100
Query whether signal "start after bar change" is
active.
The MACRO variable #1002 is compared with
zero (EQ0).
When signal "start after bar change" is not active
(#1002 = 0) the program jumps to block number
100.
This creates an infinite loop (waiting loop), until
"start after bar change" is active.
Alternative to the following program

When the bar feed / bar loader gives the signal
"loader has pushed forward", you need not to pro-
gram the function "bar feed OFF" (M68).
Changes in program:
• M66 Bar feed / Bar loader FEED ON with feed
stop/input release instead of M67
• Cross out M68 (bar feed OFF).
Note
the EMCOTURN 325.
D76
Subroutine for bar loader
%
:1000 (KUPA-BAR LOADER-CYCLE-METR)
M94 Activate bar loader
T202 Swivel in bar stop

G0 Z10
X0 Z0 Position bar stop Normal bar feed
M66 Bar feed on
G1 G94 F1000 Z0 Bar forward
IF [#1000EQ1] GOTO 10 Inquiry bar end

G0 Z100 Releasing the bar stop
M67 Bar feed on Residual
G1 G94 F1000 Z100 Residual workpiece ejection workpiece ejection
G4 X2 Dwell time 2 seconds

T202 Bar stop
Bar change
G0 X0 Z3 Position bar stop at beginning of bar
Waiting loop at
N100 Block no. for jump address
bar change
IF [1002EQ0] GOTO 100 Inquiry start after bar change
end
T202 Bar stop
G0 X0 Z3 Position bar stop Bar feed after bar
M66 Bar feed on change
G1 G94 F1000 Z3 Bar forward
G0 X100 Z100
T1212 Rough facing device
G96 S120 M4 G95 F.15
G0 Z10 First part
X38 Z0 machining
G1 X-1 F.15 M8
G0 X150 Z10 M5 M9
GOTO 30 Jump to program end
N10 M26 Close clamping device

G0 X100 Z80 Bar stop backward Normal part
G95 Selection feed in mm/r machining
N30 M99 Subroutine end
%
D77
REVERSING PLAY COMPENSATION PROGRAMMING, OPERATION EMCO-SPECIFIC
Reversing Play Compensation

Only for EMCOTURN 325.
The control compensates the reversing play of

the slides.
After every readjustment of the slideways the
reversing play must be measured and entered
into the machine parameters. See "F Maintenance
and Readjustment works".
To alter the parameter first set write enable:
• Set the key switch "data protection" on position

1.
• Select MDI mode ( ).
2))6(7
• Press the key 6(77,1* .
• Press the softkey SETING

• Move the cursor on PARAMETER WRITE.
• Enter: 1 ,1387 .
• The screen shows alarm 100.
• Cancel alarm 100 with &$1 5(6(7 .
• Now the machine parameters can be altered.
Input of the reversing play
• Press the key 6<67(0.
• Press the softkey PARAM.

• Enter: 1851 and softkey NO.SRH.
• The scren shows: 1851 BACKLASH X, Z
• Enter the measured values for the reversing play
in X and Z.
Notes:
To avoid accidentally altering reset the write
enable parameter back to 0 (is done auto-
matically when switching off the machine).
For Emcoturn 345-II:
The reversing play for the driven tool has to
be adjusted by setting a compensation value
in the parameter "5321" (\#1):
1 revolution = 4096 increments
D78
PROGRAMMING, OPERATION EMCO-SPECIFIC CHIP CONVEYOR, OPEN DOOR
Chip conveyor
Programming:
While the programming is running, the chip
conveyor is switched on in certain intervals, runs
for the period set in C8 and is switched off again.
• The intermission time between the running
periods is programmed in the counter C 12 (ex
works: 200 s).
• Only the time in which the program is active is
calculated.
• If the chip conveyor is switched on (LED above
conveyor key is illuminating), it runs according
to the running time C8 even if the program is
terminated.
Manual operation:
6<67(0 ß PMC Switch on chip conveyor:
Forward: press key less than 1 second, forward
run for time C8 (LED is illuminating).
PMCPRM Backward: press key more than 1 second, reverse
run as long as key is pressed (LED is flashing
slowly), in the subsequent forward run for time
COUNTR C8.
Interrupt chip conveyor:
ß
For emptying etc. press simultaneously AUX ON

C08 = Run Time [sec] and chip conveyor key (LED is flashing quickly).
C12 = Intermission Time [sec] Switch on again with chip conveyor key.
Adjustment of run time/intermission time of the

chip conveyor Note
To avoid contaminations of the emulsion, the
chips are to be removed from the working area
prior to operation end.
Thus, a manual after-running of the chip
conveyor is recommended.
Program interruption to
open the door
Sequence:
• Set feed override switch to 0%.
• Press key NC Stop.
• Door can be opened (consent key)..

• Close door
• Press key NC Start.
• Set override switch to 100 %.
D79
TOOL DATA MEASURING PROGRAMMING, OPERATION EMCO-SPECIFIC
Tool Data Measuring with Scratching

• Clamp a worpiece with measured diameter and
length and return the slides of the machine to
reference point.
• Start spindle in MDI mode
(M03/M04 S ....)
• Swivel in the desired tool.
X correction
• Scratch with the tool on the diameter of the
workpiece (B).
2))6(7
; • Press the key 6(77,1* and the softkey GEOM.
• Select tool station number of the respective tool

% with cursor keys , .
$ • Press the softkey OPRT.

0
=
'
• Enter the workpiece diameter e.g. 47.

• Press the softkey MEASUR.
• The X value will be taken over into the tool data
/
register.
; Z correction
Dimensions for scratching method: • Scratch with the tool on the face of the work-
A Scratching on face piece (A).
B Scratching on circumference
2))6(7
D Work piece diameter • Press the key 6(77,1* and the softkey GEOM.
L Work piece length + chuck length
with cursor keys , .
• Press the softkey OPRT.
• Enter the length L (workpiece length + chuck

length - see drawing), e.g. = % 72.
• Press the softkey MEASUR.

• The Z value will be taken over into the tool data
register.
Repeat this sequence for every required tool.
D80
PROGRAMMING, OPERATION EMCO-SPECIFIC TOOL DATA MEASURING
Tool Data Measuring with the Optical Preset Device
• Mount optical preset device

• Clamp gauge with toolholder in tool turret disk.
• MANUAL mode, traverse gauge into the reticule
of the optical preset device (at open door in
setup mode with consent key).
• Press key 326 and softkey REL.
• Press keys ; $ and .
• Softkey PRESET drücken (X-Wert wird ge-

löscht).
• Press the keys = % and .
• Press the softkey PRESET (Z value will be

deleted).
• Set mode selection switch to INC 1000 and tra-
verse in W to position -20 mm (= length of the
gauge).
• Set W value to 0 again ( = % , , PRESET).
• Swivel in tool and traverse it into the reticule.

2))6(7
• Press the key 6(77,1* .
• Press the softkey OPRT.

with cursor keys , .
X correction
• Set cursor to the X-value of the selected offset-
number.
• Press the key ; $ and the softkey INP C.
• X value is taken over into the tool data memory.
Z correction
• Set cursor to the Z-value of the selected offset-
number.
• Press the key = % and the softkey INP C.
• Z value is taken over into the tool data memory.
D81
SERIAL DATA INTERFACE PROGRAMMING, OPERATION EMCO-SPECIFIC
Serial Data Interface

You can send data (programs, tool data, machine
data) from the control to the PC (e.g. for archive)
SCREEN or also create programs at a PC and send it to the
SD control.
RD
RS Signal names
CS SCREEN Schielding
DR SD Transmit data
RD Receive data
0V RS Request to send
CD CS Clear to send
DR Data send ready
0V Ground
RI
CD Data terminal ready
RI Ring indicator
Transmission cable
To transmit data between control and Personal
Computer you need a cable with the pin assigne-
Serial interface - occupation
ment as shown beside.
machine side PC-side

(D-Sub 25) (D-Sub 9) Settings for data transmission
Standard values of the control:
• 9600 baud
• 2 Stop bits
• 7 Data bits
• Parity even
Please set your PC equivalent to the control.
Transmission of NC-programs
female connection,
9 poles • EDIT mode
• Press key 6<67(0
• 3 x press the right menu extension key

• Press the following softkeys:
ALL IO, PROGR, OPRT, PUNCH, EXEC.
Data will be transmitted. The transmission is
executed successfully, when no error message
appears.
plug connection
25-poles
Cable connection machine-PC
D82
E Maintenance of the machine
Maintenance survey
Note:
Pay attention to the maintenace instructions Danger:
in the enclosed manuals in chapter "E Addi- All maintenance work may only be carried out
tional Instructions"! with the machine switched off.
1000 h 11
200 h 12
40 h 5 5
8h 1 2 1 3
8h 4
40 h 6 7 8
200 h 12 9 12
1000 h
2000 h 15 13 14
check, if necessary supplement change cooling lubricant
oil, change oil clean, if necessary exchange
grease battery change
E1
SURVEY MAINTENACE
Details
No. Inspection-maintenance item Activity Interval [h] see
1 clamping device pressure, clamping device function to be checked 8 D5

2 power clamping chuck to be greased 8 D5
3 hydraulics - system pressure, oil level to be checked 8 D8
4 cooling lubricant level to be checked 8 D10
5 collet chuck to be oiled 40 D6
6 bright parts on the machine to be oiled 40 D6
7 cooling lubricant tank to be cleaned 40 D10
8 central lubricating system - oil level to be checked 40 D7
9 cooling lubricant concentration to be checked 200 D10
10 all hoses to be checked 200 D6
)
11 hydraulics oil change 1000* D8
12 main motor, feed motors - belt tension to be checked 2000 D12
)
13 tool turret oil change 2000** —
14 cooling lubricant to be changed 2000 D10
15 buffer battery of Sinumerik 810D/840D to be changed if necessary D13
*) first hydraulic oil change after approx. 500 h
**) Pay attention to the maintenance-notes in the added instructions of the manufactorer of the tool turret
Filling quantities
Hydraulics ........................................................ 10 l
Central lubrication system ............................. 2,7 l
Cooling lubricant tank ................................... 230 l
Lubricant
recommendations
Application Denomination acc. to DIN Recommendation
BP Energol HLP 32
CASTROL Hyspin AWS 32
ESSO Nuto H 32
Hydraulic oil:
Hydraulics MOBIL DTE Oil 32
HLP DIN 51524 ISO VG 32
SHELL Tellus S 32
OMV Hyd HLP 32
TRIBOL 943 AW/32
CASTROL Magnaglide D 68
Central lubrication KLÜBER Lamora Super Pollad 68
Slideway oil:
collet chuck MOBIL Vactra 2
CGLP DIN 51502 ISO VG 68
bright parts OMV Glide 68
TRIBOL 1060/68
EMCO Sliding paste
CASTROL Grease MS 3
KLÜBER Altemp Q NB 50
power chuck Grease MOLUB ALLOY Topfit 3284
OMV Signum LM
RÖHM F 80
TRIBOL 4020/460-2
E2
MAINTENANCE COOLING LUBRICANTS
Cooling lubricants
BP-recommendation
Q J
LR LQ
UDW LQG QJ
SH J J
U LOOL J QJ DO
O LQ LR J LQ J RUL
R Q P HW
UD G OV LQ QJ FK LQ E QJ P
QH UHD X LQG ZL RD DU HS QL P XV
JH WK HP JU VD EU JH GH KR QLX UUR
O O O O O O O O O L IH
%3W\SH WHH WHH WHH WHH WHH WHH WHH WHH WHH OXP RQ &07W\SH
V V V V V V V V V D Q
)HGDUR0
)HGDUR0
$TXDVRO65.
PLQHUDOFRQVLVWHQFH
$TXDVRO
$TXDVRO65&X
:DWHUVROXEOHW\SHV
$TXDVRO$
)HGDUR+
2/(;6%(3
2/(;6%
%LR.8
$TXDVRO
$TXDVRO
)RUWH
&XWRUD0 $TXDVRO65.
V\QWKHWLF
2/(;6% $TXDVRO65.
)OXLG61)5
)OXLG
%H]RUD;$
%H]RUD0
&RRO
6HYRUD
6HYRUD
6HYRUD
6XSHUNXW
8QLSOXV
QRQZDWHUVROXEOHW\SHV
&RRO
6HYRUD
6HYRUD
6HYRUD
6XSHUNXW
6XSHUNXW
7RSNXW
8QLSOXV
''(
3OXV
2/(;&)6
7RSNXW
3OXV
6XSHUNXW
&RRO
3OXV
0DLQDSSOLFDWLRQ
ORZPDLQWHQDQFHSURGXFWVRI&07LQWHUQDWLRQDO
6XLWDELOLW\JLYHQ
E3
COOLING LUBRICANTS MAINTENACE
Chlorin-free coolants

Q
WQ RWL VO
&
&
WHQ FH DW
@ WR QR H
W W RF US @ VX LUW VO P
V
7\SH OL >

D D Q UR VD DW XR
\LW \LW RO HX LRV H
VR VR DU OD >¡ HV UX KS F P V UUH
FV W@6 FV W@6 HQ @ Y RUU H DH KS VR OH \ 0 I
L9 L9 L + R WR U OX K3 HW RO O QR
F> F> 0> S & Q * 6 6 D $ Q
&DVWUROW\SHV
V +\VRO5
Q
R
LV
O
X
$OXVRO%
P
H 6\QWLOR;366\QWLOR
V
LO 9DULRFXW& ² î
R
WD
H
9DULRFXW& î
Q 9DULRFXW& ² ²
&LPFRROW\SHV
O V &LPVWDU4XDOVWDU
X Q
P LR
V &LPSHULDO
H
209W\SHV
O V 8QLPHW$65
X Q
P R
LV
H $OXPHW$/
KLJKO\UHFRPPHQGHG î QRWUHFRPPHQGHG
UHFRPPHQGHG
:LWKUHPDLQLQJXQGHUWKHLQGLFDWHGYDOXH PL[WXUHUDWLRFRRODQWZLWKZDWHUFRUURVLRQSUHYHQWLRQ
ZRQ
WEHJXDUDQWHHG
Hints for cooling lubricant selection:

An incorrectly selected or used sooling lubricant •Content mateials (chlorine, nitrite, phenols, etc.)
may show decisive effects on the manufacturing •Corrosion protection
process and thus, cause high costs indirectly. •Viscosity
After the end of service life cooling lubricants •Resistence to aging, serving life
represent special waste that need supervision and •Resistence against microorganisms
have to be disposed of adequately. The disposal •Emulsifying capacaty
costs accuring are of decisive influence on the •Foaming behaviour
economy or the cooling lubricant use. •Dirt elimination property
If machining is carried out with high power, the main •Wetting capacity
task of a cooling lubricant consists in an effective •Filtering capacity
cooling of tool and workpiece. Therefore use of •Transparency
water-soluble cooling lubricants is to be preferred. •Compatibility with metals, plastics
For complicated machining processes better results •Residual behaviour
can be achieved with non-water soluble cooling •Inflammability
lubricants. •odour
High efficiency for flushing away the chips is •Compatibility with health (formation of mist, skin
influenced less by the type of cooling lubricant than compatibility, toxicity, cancerogenity,..)
by the kind and arrangement of the cooling lubricant Non-water soluble sooling lubricants are generally
nozzles as well as by the quantity and pressure of without problems.
the cooling lubricant stream. Problems occur with the formation of mist and chip
In addition the following items are to be observed: deoiling.
• Disposal (cleavage-, decomposition property)
E4
MAINTENANCE CLAMPING DEVICES
Clamping pressure and

clamping dev. function
Clamping pressure and clamping device function
must be controlled at least every 8 hours (daily)
to be able to detect possible errors or damage in
time.
Clamping pressure
• The clamping pressure set for clamping device
1 (3) and 2 (4) can be read at the manometers
(1) or (2).
• Check all control lines to the valves and
clamping cylinder for damage.
Clamping device function

• Check total condition of clamping device every
1 2 3 4
day and remove dirt.
Clamping dev. manometer and clamping device
• Reduce clamping pressure to approx. 3–4 bar
and open and close clamping device via control
keyboard.
The clamping device must move perfectly.
Power chuck
Danger:
• Maintenance work on the chuck may only
be carried out during standstill of the
machine.
• Also observe the instruction supplied with
the chuck.
Every 8 operating hours

• Lubricate the chuck at all existing 6 grease
nipples (5) and (6).
• Remove clamping jaws from guides and clean
the guides and oil them slightly.
Every 1000 operating hours

• Dismantle chuck, clean all parts and grease
them again.
During the cleaning intervals check smooth
5 6 running of the chuck.
(3×) (3×) It must be possible to open and close the chuck
perfectly with a clamping pressure of approx.
Grease nipples on power chuck 4 bar.
E5
CLAMPING DEVICES/BRIGHT PARTS MAINTENACE
Collet chuck
Danger:
Maintenance work on mounted collet chucks
may only be carried out during standstill of
the machine.
The general condition of the collet chuck has to

be checked every day and possible dirt has to be
removed from the collet chuck.
Lubrication interval ...... every 40 operating hours
• Slightly oil movable parts of the collet chuck
with slideway oil.
Caution:
The collets should be free from oil during use,
slightly oil otherwise the clamping force may be reduced
by too little friction.
Maintenance of collet chuck
Bright parts
Danger:
Cleaning and oiling of parts in the working
area of the machine may only be carried out
during standstill of the machine.
The bright parts such as cover sheets and plate

covers have to be cleaned every week.
slightly oil bright parts
Then slightly oil the parts with slideway oil.
Visual examination of all

hoses
To increase the operational safety, all hoses
(hydraulic, pneumatic, collant device) should be
checked for leaks in regular intervals (all six
month).
Therefore dismount cover sheets ans check, if
hoses fret or are wet or damaged.
E6
MAINTENANCE CENTRAL LUBRICATION
Central lubrication
The slide guides are supplied with slideway oil
via the central lubrication.
The lubrication is carried out automatically
according to the way traversed of the individual
slides.
Oil level check

Interval of checks ......... every 40 operating hours
• Check oil level in the oil tank
• Check lubricant lines and connection points for
tightness and penetrability.
The oil tank (1) with the slideway oil is on the rear
side of the machine and can be seen via an
opening in the machine shell.
The oil level must be between the two limit marks
on the tank.
If the oil level is too low, an alarm message is
indicated by the control.
If necessary, refill slideway oil in the charging hole
(oil quality see "Lubricant recommendations").
1
Central lubrication at the machine
Air inclusions
In case of air inclusions in the lubricant lines
slightly untighten the screw connections upstream
of the dosing elements and actuate lubricant pump
until oil flows out without bubbles from the
screwed connections.
Retighten screwed connections.
PD[
PLQ
Lubrication in case of major

1 2
periods of standstill
Central lubrication / detail
If the machine is not used for a major period, the
lubrication should be activated manually prior
and after the period of standstill.
$8; To do this, press the "AUX ON" key approx. 10
times. Whenever you press, a lubricating impulse
is transmitted.
E7
HYDRAULICS MAINTENACE
Hydraulic unit
Danger:
Maintenance work at the hydraulics may only
be carried out with the machine switched off
and with reduced hydraulic pressure.
Reduction of hydraulic pressure

After switching off the machine the hydraulic
pressure is decreased automatically down to a
residual pressure.
The residual pressure must be reduced by a
service engineer prior to every maintenance work.
• Open door (1) at the rear side of the machine.
• Open the accumulator drain valve (2) with an
allen wrench..
• Wait a few seconds, until the residual pressure
is reduced to 0, then close the valve (2).
• Carry out maintenance work.
1 3
Reduction of hydraulic pressure
Installation of lines Additional regular checks

By changing and installation of hydraulic lines • Pay attention to noises
note the following points: • Monitor oil level
• Check for leaks
• Never use brute force in order to avoid trans-
verse forces and stresses in pipes and equip- In addition we would like to draw your attention to
ment. the following:
Ensure the pipes are fastened well. • VDI-guidelines, commissioning and mainten-
• Do not use hemp or putty as sealants. ance of hydraulic equipment, VDI-3027
This can result in contamination and thus • Prosals of the CE TOP
functional breakdowns.
• In order to prevent external leaks, observe the Cleanliness
installation instructions of the manufactorers of
screwed joints. Pay attention to the cleanliness to the following:
We recommend screwed joints with flexible • for the enviroment
sealing elements.
• for units, line connections, equipment
• Ensure hose lines are laid correctly.
Avoid scuffing or knocking the lines. • for the hydraulic oil
• Caution - pay attention to contamination,
moisture
Only fill using filters (system filters or mobile
filter stations with fine filters)
E8
MAINTENANCE HYDRAULICS
Hydraulic oil change
Attention:
Upon purchase of the machine the hydraulic
system is equipped with a special initial filling
oil.
The first oil change including filter change
must therefore be carried out after 500
operation hours at the latest.
Interval .................... every 1000 operation hours

1 Filling quantity ................................................. 10 l
The hydraulic oil should be changed in hot

operation state.
With each oil change the oil filter, too, has to be
changed.
• Switch off machine and reduce residual pressure
in the hydraulic system (see side before).
2 • Open oiling screw (1).

• Open oil drain screw (3) and drain used
hydraulic oil into a suitable container.
• Close drain screw (3) again.
• Dismount filter (4) by opening the four hexagon
socket screws (5) and replace it.
• Fill in new hydraulic oil.
The oil level can be controlled at the oil level
gauge (2).
Mind not to fill beyond the maximum mark
(approx. 10 l).
Attention:
Pay attention to the positions of the hydraulic
cylinders by refilling hydraulic oil:
3 4 5 Door autom.: door closed
Tailstock: moved backwards (right side)
Maintenance work at the hydraulics Clamping cyl.: forwards (chuck open / collet
closed)
• Dispose used oil and filter according to the en-

vironmental regulations.
• Close door.
• Switch on machine and check pressure on the
manometer.
The pressure varies between 70 and 80 bar.
E9
COOLANT DEVICE MAINTENACE
Coolant device
Danger:
Maintenance work at the cooling system may
only be carried out during standstill of the
machine.
Drawing out the

cooling lubricant tank
For refilling the cooling lubricant or for cleaning,
the cooling lubricant tank can be drawn out
forward.
A
• Open door (1) at the rear side of the machine.
• Swivel out backward coolant pump (4) and

possibly jetting pump on the sheet (2) (see
direction of arrow in fig. on the opposite).
The pump brackets engage in swivelled-out
state.
1
View of the machine from the rear • Draw coolant tank forward.
• Carry out maintenance work.
1 • Insert coolant tank again.
• Swivel coolant pump in again by slightly lifting

2 the rail (3).
• Close door (1).
Swivelling out the coolant pump - view A
E10
MAINTENANCE COOLANT DEVICE
Cooling lubricant level

Check interval ....................... 8 operation hours
The cooling lubricant level is checked at the front
side of the machine on the display (2) of the
cooling lubricant tank (1).
When refilling the cooling lubricant observe the
composition and the miscibility of the existing li-
quid (also see cooling lubricant recommen-
dations).
Attention:
Use fundamental only chlorine-free coolants.
The share of chlorine in the coolant is
responsible for the rusting of bright machine
parts.
1 2
Display of the cooling lubricant level
Cleaning the cooling lubricant
tank
Cleaning interval ............. 200 operation hours
• Remove dirt from coolant tank and inserted
sieves (chips, etc.).
• Check return flow lines for cleanness and rinse
them if necessary.
Notes:
• Dispose cooling lubricants acc. to environ-
mental requirements (special waste!)
• Do not use fluorine chlorinated hydro-
carbons (e.g. trichloroethylene, trichloro-
ethane etc.) for cleaning the tank.
• During cleaning mind complete elimination
without residues of deposits!
Remaining contaminations are sites of
growth for bacteria which attack the newly
filled emulsion and reduce its service life.
• Use rags and solvents only sparingly.
• Dirty cleaning rags (cleaning paper) have to
be disposed of as special waste.
E11
BELT TENSION MAINTENACE
Belt tension
Check the belt tension of the drives in regular
intervals according to the table below.
In addition the belts have to be checked for their
general condition.
In case of defects such as severe contamination
with lubricants and cooling lubricants or fractures
or similar, the belts have to be changed.
Control interval ................ 2000 operation hours
Belts to be controlled (acc. to equipment of

machine):
• main spindle (spindle 1) ø65, ø45
• counter spindle (spindle 2) ø65, ø45
• X-slide
• Z-slide
• Z2-slide (Z-stroke of spindle 2)
Danger:
The belt tensions may only be checked with
the machine switched off.
Make sure that the machine is protected
Control of belt tension against unauthorized start-up!
im- control force

pression Fp [N]
drive depth
belt type order-no.
initial after
E [mm] assembly run-in
Spindle 1 ø65 7,3 120-143 98-120 Polyflex 4-grooves, 11M-1400 mm ZRM 471 114
Slides X, Z, Z2 2,0 11 11 HTD 5M-25-450; 90 teeth ZRM 600 903
E12
MAINTENANCE CHANGE OF BATTERY
Change of battery in the

control
Siemens 810 D/840 D
In the control battery-buffered storages and clock
units are used to save data in case of power
failure.
Buffer time of the batteries .......... min. 3 years
The buffer batteries are monitored by the control.
If the buffer tension falls below a certain value a
message is emitted on the screen by the control.
To avoid data loss the buffer batteries have to be
changed within 6 weeks after the first display of
this message.
Danger:
Never try to reactivate batteries by heat or
other means or to recharge them.
The batteries may run out and/or explode!
Change of battery in the hard

disk unit MMC
Battery:
Order no. (Siemens) ...... 6FC5 247-0AA18-0AA0
Note:
To avoid data loss the control must not be
switched off during the battery change.
• Remove back cover of control.

• Take out plug X11 (2) and pull battery (1) out of
the fixing device.
• Insert new battery into fixing device and insert
plug X11 again.
• Remount cover of control.
1 2
Buffer battery on the hard disk unit MMC
E13
CHANGE OF BATTERY MAINTENACE
Change of the battery ventilator

insert of the NC-CPU board
(Sinumerik 840D)
Ventilator insert:
Order no. (Siemens) ...... 6FC5 247-0AA06-0AA0
Danger:
1 2 3
• The exchange of the ventilator insert may
only be carried out with the machine switched
off.
• The exchange must be carried out within 15
minutes after switching off the machine,
since the data can be protected only during
this period.
• Switch off machine.

• Open switch cabinet of the machine.
• The ventilator insert (3) is situated on the NCU
box (1).
• Press catch (2) on the ventilator insert (3) to
the top and at the same time pull out insert.
• Introduce new ventilator insert (3), mind en-
gaging of the catch (2).
3 2 • Close switch cabinet.
Ventilator insert on the NC-CPU board
Change of the battery of the

CCU-board (Sinumerik 810D)
4 5 6 7
Battery:
Order-n.. (Siemens) ....... 6FC5 247-0AA18-0AA0
• Switch off machine.

• Open switch cabinet of the machine.
• Pull out CCU-board (5) of the CCU-box (7) after
untightening of the 4 screws (4).
Danger:
The CCU-board has to be handled with care,
because it is an very high sensitiv electronical
part.
• Change battery (6) with a new one of the same

type.
The buffer of the stored datas will be inherited
4
of a capacitor for approx. 15 min.
• Set CCu-board (5) in CCU-box (7) and tighten
the screws (4).
Battery on the CCU-board
E14
F Additional instructions
Sauter
Tool Turret
Knoll
Chip Conveyor
Bristol
Electrostatic Airfilter
F1
F2
BA 640 e
O p e r a t i n g i n s t r uc ti on s
for
Disk-Type Tool Turret
with electrical drive
and slide unit
0.5.453.216 - 085 612

087 822
104 410
105 672
Type plate at turret housing
Series Size
Classification
0.5.453.2 16 number
085 612 Identification

number
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\640db.fm
Order
number
Gear
ratio
Edition: 02-04-05
Table of contents
1 Safety information . . . . . . . . . . . . . . . . . . . . 5
1.1 Use within specifications . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Required skills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Liability and warranty . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.9 Symbols in instructions for specific actions . . . . . . . . 8
1.10 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Product description . . . . . . . . . . . . . . . . . . 11
3.1 The parts of the turret and the slide unit. . . . . . . . . . 11
3.2 Possible options and deviating designs . . . . . . . . . . 13
3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Admissible loads and dimensions . . . . . . . . . . . . . . 17
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\ba640eIVZ.fm
2
Table of contents
4 Assembly and installation . . . . . . . . . . . . . 19

4.1 As-delivered condition . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Fitting the turret-drive motor . . . . . . . . . . . . . . . . . . . 20
4.3 Fit turret onto the machine . . . . . . . . . . . . . . . . . . . . 22
4.4 Align turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5 Fitting the tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6 Align tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.7 Electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . 27
4.8 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.9 Cooling lubricant supply . . . . . . . . . . . . . . . . . . . . . . 28
4.10 Determination of reference point . . . . . . . . . . . . . . . 29
5 Additional equipment, toolholders and

spindle units . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 Toolholders and spindle units. . . . . . . . . . . . . . . . . . 30
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Check lubricant of turret gearbox chambers . . . . . . 34
6.3 Bevel gears and roller bearings on gearbox nose . . 35
6.4 Spindle units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.5 Slide unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3
Table of contents
7 Fault finding and repair . . . . . . . . . . . . . . . 36

7.1 Faults and remedies. . . . . . . . . . . . . . . . . . . . . . . . . 36
7.2 Engaging the ratchetting clutch . . . . . . . . . . . . . . . . 39
7.3 Determining belt tension on the slide unit . . . . . . . . 41
7.4 Belt replacement – belt tension . . . . . . . . . . . . . . . . 41
7.5 Basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.6 Replacing the cooling lubricant valve . . . . . . . . . . . . 46
7.7 Replacing and setting the proximity switches. . . . . . 47
8 Replacement parts . . . . . . . . . . . . . . . . . . . 54
8.1 Proximity switches . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.2 Tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3 Cooling lubricant system . . . . . . . . . . . . . . . . . . . . . 57
8.4 Gear head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.5 Housing and indexing unit . . . . . . . . . . . . . . . . . . . . 61
8.6 Carrier and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.7 Slide unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Ordering replacement parts
Appendix
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EP-1039 e
Function diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . SK-1226 e
Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP-446 e
4
Safety information
1 Safety information
The disk-type tool turret corresponds to the state of the art and
the recognized technical safety rules. Nevertheless hazards
and risks can occur.
1.1 Use within specifications

Install and operate turret only in machines complying with the
relevant regulations for workspace protection.
1.2 Required skills

Only trained and competent personnel may work on the disk-
type tool turret; this personnel must have been instructed in
accordance with the operating instructions and directly on the
disk-type tool turret.
1.3 Electrical installation
All work on the electrical system is to be carried out by a

competent specialist engineer only in order to avoid any
incorrect installation which may cause a hazard of injury to
persons or damage to equipment.
1.4 Hydraulic system
IMPORTANT
On delivery, the cylinders of the turret are filled with hydraulic oil
and its openings are plugged.
1.5 Disposal
Comply with all national and regional disposal regulations and
laws.
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_si.fm
5
Liability and warranty
1.6 Liability and warranty
The information contained in these Operating Instructions is in

conformity with the knowledge at the point of printing.
Subject to modifications which occur within the framework of
continuous further development.
All liability and warranty shall be excluded if

• use within specifications is not complied with,
• the disk-type tool turret including accessories is incorrectly
operated,
• the disk-type tool turret including accessories is
incompetently repaired and maintained,
• conversions and functional changes are implemented without
approval by the manufacturer,
• no original replacement parts are used,
• no spindle heads complete with position locking device
according to product information PI 29.3 are used,
• no tool holders with a cylinder shank according to DIN 69 880
are used.
6
Warnings
1.7 Warnings
WARNING1
Designates a potentially hazardous situation which may cause
serious injury or even death.
WARNING1
Risk of electric shock due to high voltages!
WARNING1
Risk of injury due to a hanging load!
CAUTION1
Designates a potentially hazardous situation which may cause
damage to the product or property in its vicinity.
IMPORTANT1
For application notes and other useful information.
Disconnect energy supply

Before continuing work release machines.
1.8 Symbols
➪ Designates an instruction for a specific action. Specific actions

to be executed in sequence are additionally numbered.
i Designates additional information.

1) Classification of signal words according to ANSI Z535.4
7
Symbols in instructions for specific actions
1.9 Symbols in instructions for specific actions
• Use lifting gear.
• Maximum load XXX kg,

for inclined pull of 45° maximum load YYY kg.
max. max.
xxx kg YYY kg
• Tightening torque of 23 Nm
23 Nm
• Screw M10, quality 12.9, at marked places lubricated with

MoS2, tightening torque 70 Nm.
M10 - 12.9 MoS2 70 Nm
• Visual inspection
1.10 Abbreviations
adm. admissible
a.o. among others
approx. approximately
fig. figure
if nec. if necessary
incl. inclusive
max. maximum
8
Transport
2 Transport
WARNING
Serious injury hazard (crushing) to fingers and hands posed by any
unexpected and sudden slide unit movements.
Therefore:
Before each transportation, the slide must be brought into its
bottom position and held there in position by means of the
transport retainer device (1). To this end, use retaining plate
complete with 2 bolts M10X20.
• Before the turret is operated or the motors installed the transport

packing (1) must be removed!
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_tr.fm
9
Transport
WARNING
Do not stay underneath or within the swivelling range of
hanging loads!
IMPORTANT
Slinging
• Screw in ring bolts DIN 580 on the turret housing and on slide unit
up to the contact surface. A further ring bolt must be screwed into
the fastening hole of the SAUTER tool disk.
• Make sure that the hoisting angle at the ring bolts does not exceed
45°. Use the ring bolt only for transporting the tool turret with the
tool disk and tool drive.
2 3
Size of turret .16

Ring bolts 2 ×M16
Mass of turret with motor and
standard tool disk approx. 300 kg
(without toolholders)
max. dimensions:
Length (without motor) approx. 515 mm
Width approx. 450 mm
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_tr.fm
Height approx. 550 mm
Lift
• Use lifting gear.
10
Product description
3 Product description
3.1 The parts of the turret and the slide unit
1 2
1 Tool disk
2 Electric supply
3 Turret drive motor
4 Hydraulic supply/Cooling lubricant connection
5 Turret housing
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_pb.fm
11
Product description
7
6
10
6 Locating disk
7 Slide unit
8 Tool holder
9 Locating hole
10 Setbold bore for clamping the tool holders
12
Product description
3.2 Possible options and deviating designs
Cooling lubricant valve
IMPORTANT
The cooling lubricant transfer of the disk-type tool turret can be desi-
gned variously. The standard version as well as the option medium
pressure cooling lubricant device, are described in these Operating
instructions. However, the design of your disk-type tool turret could
deviate from these.
Standard version 7 / 14 bar see chapter 8.3, page 57
Medium pressure ≤ 25 bar see chapter 8.3, page 57

cooling lubricant device
with see Operating Instructions
Fluid Rotary Feedthrough BA 691 for
Fluid Rotary Feedthrough
13
Technical data
3.3 Technical data

Turret
Turret size 0.5.453. ... .216
Number of indexing positions (8) 12 (24)

Adm. mass moment of inertia of tool disk
with holders
kgm2 2.5
Maximum unbalanced load (load torque) of tooling Nm 32

Operating times 1)
Turret rotation per 30° indexing step
• incl. acceleration and braking s 0.14
• rotation only s 0.06
Turret unlock or lock s 0.14
Maximum indexing frequency 2) min-1 18
Hydraulic operating pressure ± 10 % bar 50
Hydraulic fluid volumes:
Turret unlock or lock cm3 35
Mass
• Turret including tool disk and slide unit kg approx. 300
• Maximum tooling kg approx. 60
Ambient temperature range °F +50 .... +104
°C +10 ... +40
Adm. cooling lubricant pressure
• constant flow standard bar 7

version
• flow cut off during indexing bar 14
• with medium pressure valve (Option) bar 25
1) Conditions: – hydraulic supply adequately dimensioned
– turret at operating temperature
– with the given mass moment of inertia
– without any non-productive times caused by the control
2) There may possibly occur a reduction in the permissible switching
frequency, depending on the cutting efficiency of the tool drive.
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_td.fm
14
Technical data
Turret and tool drive
Turret size 0.5.453. ... .216
Turret drive
max. adm. motor speed with SW1) 270 min -1 4,000

with SW 340 min -1 2,000
max. adm. motor torque Nm 10
Turret – drive ratio 12

Tool drive S3 - 40%ED, 10 min
max. adm. motor speed min
8,000
max. adm. motor torque 2) Nm 10

Drive ratio 2
Coupling according to DIN 5480 16x0.8
(standard version, further possibilities on request)
Use together with SAUTER Spindle units series

0.5.941. ... with patented integrated spindle locking
system, according to Product information PI 29.3,
shank diameter 30mm.
1) SW: Spanner width of the tool disk
2) The torques specified refer to processing without shock loads. When
processing is subject to shock loads (e.g. milling) a reduction in the
values by up to 50% or more needs to be taken into account!
15
Technical data
Slide unit
Turret size 0.5.453. ... .216
Slide unit drive:

• max. adm. motor speed min -1 4,000
max. adm. motor torque Nm 5
Nm 2
max. motor torque continuous duty
Drive ratio of the synchronous belt drive 2
Height of stroke mm ±40
Stroke inclusive overshoot mm ±48
Pitch of ball spindle mm 5
Quick motion speed m/min 10
Adm. cutting force for turning kN 6
Positioning accuracy µm ≤ 10
16
Admissible loads and dimensions
3.4 Admissible loads and dimensions
carriage
of the machine additional
fixing device
Illustration corresponds to right-hand version

( left-hand version - mirror image ).
Maximum tangential torque 1) Ttan Nm 1,500
equivalent tangential torque ± Fy N 5,500
at tool overhang D mm 265

equivalent
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_ld.fm
chip cross section A mm2 2.5

(St60; ks ≈ 2.200 N/mm 2 )
17
Admissible loads and dimensions
Adm. axial load1) ± Fz N 8,000
at tool overhang D mm 220
Adm. radial load1) ± Fx N 10,000
Loads with a calculated safety ≥1,3
1) The admissible loads apply when processing without shock loads. In combined
and/or shock load situations (interruptions in cutting), the values will reduce!
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_ld.fm
18
Assembly and installation
4 Assembly and installation
4.1 As-delivered condition

• The disk-type tool turret is supplied aligned in Position 1, with or
without tool disk and AC servomotor in accordance with the order.
• The pistons have been bled and connections A1 / B1 und L1 are
closed with plastic plugs to prevent hydraulic oil from escaping.
• Parts, which are not possible to assemble or parts, which are
necessary for the assembly, are enclosed loose.
• The disk-type tool turret has been test run.
• The slide unit is locked in its bottom position by means of a
transport retaining device.
• The drive motor for the slide unit is not fitted (motor not included in
the scope of delivery).
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_li.fm
1. see Hydraulic diagram “HP-...” in the appendix to these operating instructions
19
Fitting the turret-drive motor
4.2 Fitting the turret-drive motor

4.2.1 Motor shaft with key groove according to DIN 6885/1
8 9 10
5 4 3 2 1
➪ 1. Check the height of the feather key (10) on the motor shaft (1).
If necessary replace or adapt feather key (according to motor
manufacturer).
2. Mount ratchetting clutch (2) on motor shaft (1).
Secure screw (3) with suitable locking fluid (e.g. LOCTITE 221).
3. Check:
• Are marking (7) on motor support (8) and pin (6) in pinion (5)
in line?
• Is slot (4) in ratchetting clutch (2) in line with the pin (6)?
• Is the sealing ring (9) in place and undamaged?
4. Mount AC motor with ratchetting clutch (2) and make sure that
slot (4) and pin (6) engage.
IMPORTANT
Set proximity switch S10 “Ratchetting clutch engaged”,
see chapter 7.7.4 Proximity switch S10 “Ratchetting clutch engaged“, page 51.
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ac.fm
20
Fitting the turret-drive motor
4.2.2 Motor shaft with key clamping hub
7 8 9 TA
6
4 3 2 1
➪ 1. Check whether circlip (9) is fitted in the hub of the ratchetting

clutch (2).
2. Fit the ratchetting clutch (2) on motor shaft (1), make sure that the
circlip (9) is in touch with the end face of the motorshaft (1).
3. Tighten hexagon socked screw on ratchetting clutch (2).
Tightening torque TA
[Nm]
M6 DIN 912-12.9 17
M8 DIN 912-12.9 41
M10 DIN 912-12.9 83
4. Check:
• Are marking (6) on motor support (7) and pin (5) in pinion (4)
in line?
• Is slot (3) in ratchetting clutch (2) in line with the pin (5)?
• Is the sealing ring (8) in place and undamaged?
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ac.fm
5. Mount AC motor with ratchetting clutch (2) and make sure that
slot (7) and pin (8) engage.
IMPORTANT
Set proximity switch S10 “Ratchetting clutch engaged”,
see chapter 7.7.4 Proximity switch S10 “Ratchetting clutch engaged“, page 51.
21
Fit turret onto the machine
4.3 Fit turret onto the machine
3, 4 2
IMPORTANT
The hole for the pivot bush (2) must already exist in the slide in the
required position and quality.
➪ 1. Mount turret together with pivot bush (2) and fasten with screws
and washers (3,4) supplied.
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_arm.fm
2. Note the tightening torque!
M16 - 12.9 MoS2 280 Nm
22
Align turret
3. Make electrical connections,

see Wiring diagram “EP-...” and Function diagram “SK-...” in the appendix to
these Operating Instructions.
4. Make hydraulic system connections,

see Hydraulic diagram “HP-...” in the appendix to these Operating Instructions.
Central lubrication (1) is not included within the scope of delivery of the
turret.
(For details on how to connect the central lubrication system, see the
operating instructions of the machine).
4.4 Align turret
Pivot bush
1 2
➪ 1. Lock turret.
2. Align the connecting surface (1) or face surface (3) of the tool disk
parallel or vertical to the feed axes (2).
3. Note the tightening torque!
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_arm.fm
M16 - 12.9 MoS2 280 Nm
23
Fitting the tool disk
4.5 Fitting the tool disk
Working position
(if tool disk not already fitted)
➪ 1. Remove the cover plate (2).

2. Clearly mark the rotational position of the teeth (tooth gap to tooth,
item 8) on both bevel gears.
3. Remove the coupling sleeve (6), for that:
• Loosen circlip (3),
• Withdraw the coupling sleeve (6).
4. Force back piston (5) to the stop - direction disk-type tool turret
central point, perhaps slightly open vent screw E.
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_mws.fm
5. Put the T-slot nuts (7) into their correct angular positions.
6. Fit tool disk (1) in the correct angular position
[- fitting area (9) -].
24
Fitting the tool disk
7. Slightly slacken the screw in the working position to allow the tool
disk to be aligned later. It is covered by the coupling sleeve (6).
8. Insert coupling sleeve (6) in marked position (marking in turret axis
direction) into gearing, using bush (4).
9. Insert circlip (3).
25
Align tool disk
4.6 Align tool disk
➪ 1. Lock turret with prescribed pressure.

2. Unscrew cover plate (1).
3. Insert plug gauge (4) in locating hole (2) of the tool disk. Put the dial
gauge to machine spindle, scan the plug gauge (4) above and
below.
4. Twist the tool disk, until dial gauge display - difference equals zero.
CAUTION
If this is not done, clutch problems and bearing damage can occur.
5. Tighten screws.
M8 - 12.9 MoS2 39 Nm
IMPORTANT
The screw is covered in working position (3) by the coupling sleeve
and is accessible only after swivelling the tool disk.
6. Screw on the cover plate (1); remember the sealing rings

[are they in place and undamaged?].
26
Electrical installation
4.7 Electrical installation

• Circuit,
see Wiring diagram “EP-...” and Function diagram “SK-...” in the appendix to
these Operating Instructions.
4.8 Hydraulic system

• Circuit,
see Hydraulic diagram “HP-...” in the appendix to these Operating Instructions.
• Filtering ≤ 20 µm
Description of the hydraulically actuated functions

• Lock and unlock turret.
• Disengage and engage turret drive.
• Disengage and engage tool drive.
• The functions are initiated via a 4/2-way valve.
• All pistons can be bled separately.
• The turret has 3 connections: A / B / L.
• The leakage oil port L is provided to allow leakage oil to be returned
and to protect the gearbox chamber from overpressure.
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ehk.fm
27
Cooling lubricant supply
4.9 Cooling lubricant supply
• Transmitted through a valve (1) in the working position.

• Supply pressure,
see “Technical data – Turret”.
• Connection, designated “K”, on rear bedding plate (2).
IMPORTANT
In order to achieve an extended service life of the cooling lubricant
valve, it is recommended to filtrate the cooling lubricant by ≤ 100 µm.
Post-connected loads (spindle units with internal cooling lubricant
guide a.o.) may require a higher degree of filter fineness.
Note and comply with the manufacturer's instructions!
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ehk.fm
28
Determination of reference point
4.10 Determination of reference point
➪ 1.
2.
Hydraulic pressure: 10 bar !
Lock turret in position 1.
3. Put marking (2) between tool disk (1) and
cooling lubricant ring (3).
4. Rotate coupling sleeve until marking (4) points to turret axis.
5. Unlock turret hydraulically, proximity switch S5 (8) energized.
6. By means of AC motor, rotate tool disk (1) clockwise (as viewed
on the tool disk (1)) until the proximity switch S1
“Reference point turret“ (5) is deenergized and then energized
again.
7. Rotate tool disk (1) further until the zero pulse is detected at the
rotary encoder (6). The reference point offset is determined from
this zero pulse.
8. Rotate tool disk (1) further until the two markings (2) on the tool
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ref.fm
disk (1) and on the cooling lubricant ring (3) are positioned exactly
one above the other.
9. Check the function with spindle units in place.
10. Increase pressure: Hydraulics approx. 50 bar.
29
Additional equipment, toolholders and spindle units
5 Additional equipment, toolholders and

spindle units
This turret has been designed for use with the following toolholders
and additional equipment:
• toolholders with cylinder shank for stationary tools
• spindle units with cylinder shank for drive tools
5.1 Toolholders and spindle units

• Use only toolholders, spindle units and plugs with O-ring in
accordance with DIN 69 880 Part 1 (July 1990 Issue).
For information on SAUTER toolholders and spindle units for the
SAUTER disk-type tool turret 0.5.450/460.2.../3... please ask for
Product information PI 29.3.
The warranty loses its validity if defective third-party makes
are used.
CAUTION
Functional faults may be caused by an ingress of chips and
contamination. Close open tool locations and cooling lubricant bores by
means of closing plugs Z2-30 according to DIN 69 880.
• If at all possible, change the toolholder in a horizontal position!
• Clean contact surfaces of tool disk and toolholder.
Tightening torques for the locking screws for the thrust pieces
Shank diameter d1 Max. tightening torque TA max

DIN 69 880 [mm] [Nm]
20 10
25 10
30 25
40 50
50 50
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_zus.fm
30
Toolholders and spindle units
5.1.1 Installing/changing the toolholders
Chips
1 2 3
Cooling lubricant
TA max
5
6
➪ 1. Check the sealing rings (4) on the new toolholder (6) [make sure
they are in place and undamaged!].
2. Pay attention to position of the aligning shoulder (2); if necessary
modify.
3. Unscrew pressure pieces (1).
4. Remove toolholder (6) or seal plug (3) to be replaced.
5. Insert new toolholder. Tighten thrust piece (1) with 20% of
maximum tigthening torque.
6. Align toolholder to centre of rotation with set screws (5).
7. Firmly screw on pressure piece (1). Observe tightening torques,
see table Tightening torques for the locking screws for the thrust pieces, page
30.
31
Toolholders and spindle units
5.1.2 Installing/changing the spindle units
CAUTION
Do not change tools while the tool disk is in the working position as
this can cause overloading of the drive train!
1 - ENgaged 2 - DISengaged
1. Check:
• Are the sealing rings in place and undamaged?
• Is the clutch profile undamaged and has it been cleaned?
• Is the spindle locking mechanism engaged?
2. Remove toolholder (6) or seal plug (3) to be replaced.
3. Insert new holder. Tighten thrust piece with 20% of maximum
tigthening torque. Observe index position of spindle units (7).
4. Align holder to centre of rotation with set screws (5). [Necessary
with angled spindle units]. If necessary modify aligning shoulder.
5. Firmly screw on thrust piece (1). Observe tightening torques,
see table Tightening torques for the locking screws for the thrust pieces, page
30.
32
Maintenance
6 Maintenance
WARNING
Danger of serious injury in result of
sudden movement of the slide unit.
Before start working with the slide unit
secure the slide in lowest stop position.
Clearing required prior to any works

• Use the EMERGENCY-OFF switch of the machine.
• Set motor protection switch for disk-type tool turret into OFF
position.
6.1 Lubricant table
Lubrication of the roller bearings, bevel gears and seals
Element Amount of lubricant Lubricant Manufacturer
Roller Initially:
bearings Fill 1/3 of bearing space
ISOFLEX NBU 15 Klüber
Seals Fill space around sealing lips
Toothing Fill teeth gaps
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_wart.fm
33
Check lubricant of turret gearbox chambers
6.2 Check lubricant of turret gearbox chambers
• The condition of the lubricant must be checked after no more than

4,000 operating hours. Before checking, remove the
proximity switch S1 “Reference point turret” (1) or
VSTI plug (2).
Possible conditions of the turret chamber when checking
Condition of Grease
grease
None left Severely Mixed with water Mixed with oil
used
Cause Natural wear Turret sealing Hydraulic seals
defective in turret defective
Action Add approx. 20 g of Risk of break- If oil loss ≥ 1 cm3/
needed grease down! Call for minute: Call for
service (Check service.
turret sealing).
34
Bevel gears and roller bearings on gearbox nose
6.3 Bevel gears and roller bearings on gearbox nose

• Bevel gears (1) and roller bearings (2) can be accessed after
removing the cover plate (3). Regrease the bevel gears and check
for unwanted cooling lubricant after 4,000 operating hours, see table
Lubrication of the roller bearings, bevel gears and seals, page 33.
6.4 Spindle units

• Clean clutch profile each time before using.
• Lubricant should be checked according to the conditions of use but
after no more than 2,000 operating hours.
6.5 Slide unit

• The guide of the slide unit is greased by the centralized lubricating
system of the machine.
• Proportioning by intergrated proportioning valves.
• The number of grease pulses may be adapt to the machine. The
minimal number of gear pulses is 1 pulse per hour.
35
Fault finding and repair
7 Fault finding and repair
WARNING
Danger of serious injury in result of
sudden movement of the slide unit.
Before start working with the slide unit
secure the slide in lowest stop position.
7.1 Faults and remedies
Fault Cause Remedy Implementation
1. Turret
replace damaged
does not swivel gears damaged service
parts
drive motor defective replace motor user
axis misaligned relative align the axle to

does not lock service
to locating disk the locating disk
check proximity
user,
proximity switch S1 switch, replace if
see 7.7.1,
defective or misadjusted necessary, or re-
page 47
adjust
2. Tool drive
does not engage / replace damaged

clutch sleeve damaged user
disengage parts
does not rotate drive motor defective replace motor user

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_st.fm
replace damaged
gearwheels damaged service
parts
36
3. Center height
is not correct,
turn back tool disk
tool disk collision with turret in a
in ring groove, and service
misaligned relative locked condition
align
to locating disk
4. Cooling lubricant
is not being cooling lubricant valve replace damaged user,

transferred damaged parts see 7.6, page 46
blow cooling
cooling lubricant valve/
lubricant valve and user
line blocked
line clear
outlet between cooling lubricant valve replace cooling user

tool disk and turret leaking lubricant valve see 7.6, page 46
5. Ratchetting clutch
engage ratchetting
clutch as per
user
is disengaged preset torque exceeded manual,
see 7.2, page 39
adjust the current
limiter at the motor
37
6. Slide unit
center heigth no turret displaced in slide

realign turret user
longer correct unit
drive motor defective replace motor user

no movement
possible in slide
direction replace user
synchronous belt torn
synchronous belt see 7.4, page 41
check proximity
proximity switch S13 switch, replace if user
incorrect misadjusted necessary, or see 7.7.5, page 53
positioning in slide readjust
direction
motor shaft encoder or
replace motor user
control unit defective
Service
i SAUTER Feinmechanik GmbH
Carl-Zeiss-Straße 7
D-72555 Metzingen
Germany
Telephone ++49 (0) 7123 –926 – 0

Fax ++49 (0) 7123 –926 – 193
Telex 254 328 wisa
e-mail service@sauter- gmbh.com
38
Engaging the ratchetting clutch
7.2 Engaging the ratchetting clutch
1 2
7 Variant A Variant B
6 3
4
5
CAUTION
After disengaging the ratchetting clutch check the locking state!
7.2.1 Variant A: Motor with brake
Procedure, if the turret is unlocked:
➪ 1. Dismount tool in working position.

2. Turn the tool disk (7) manually until ratchetting clutch (2) engages.
3. Check on proximity switch S10 (1).
4. Drive to reference point.
Procedure, if the turret is locked:
➪
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_kupp.fm
1. Dismount tool in working position.

2. Rotate coupling sleeve (6) with hexagon wrench (5) until ratchetting
clutch (2) engages.
3. Check on proximity switch S10 (1).
39
Engaging the ratchetting clutch
7.2.2 Variant B: Motor without brake
Procedure, if the turret is unlocked:
➪ 1. Turn tool disk by hand approximately to position 1 ±1.5°.

2. Put out the tool in position 1.
3. Lock hydraulically => turret is locked.
Procedure, if the turret is locked:
➪ 1. Rotate coupling sleeve (6) jerky with hexagon wrench (5) until
ratchetting clutch (2) engages.
2. Check on proximity switch S10 „Ratchetting clutch engaged“ (1).
IMPORTANT
The ratchetting clutch has only one latching position.
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_kupp.fm
40
Belt replacement – belt tension
7.3 Determining belt tension on the slide unit
5N
s/2
7.4 Belt replacement – belt tension
4 3
➪ 1. Move to lowest stop position.

F:\Sauter\FRAME-AR\TD\0-5-453-\453_riem.fm
2. Switch off power to turret.

3. Unscrew the 3 screws (2).
41
Belt replacement – belt tension
4. Use the drive motor to move the plate (4) such that the
synchronous belt can be removed.
5. Remove existing synchronous belt (1) and clean abrasions from
turret.
6. Mount new synchronous belt.
7. Tense synchronous belt (1) by lever in hole (3) - pay attention to
test load,
see chapter 7.3 Determining belt tension on the slide unit, page 41
8. Fasten the screws (2).

9. Move away lever.
F:\Sauter\FRAME-AR\TD\0-5-453-\453_riem.fm
42
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_grund.fm
7.5
Basic setting
Basic setting
43
Basic setting
➪ 1. Install turret hydraulically. Reduce hydraulic pressure to 10 bar for

the purposes of setting.
2. Install turret electrically, without AC servo motor.
3. Unlock hydraulically (pressure approx. 10 bar). If not possible via
control, relocate connector on hydraulic valve.
4. Turn tool disk by hand approximately to position 1 ±1.5°.
5. Lock hydraulically.
6. Align tool disk (1) in accordance with description,
see chapter 4.6 Align tool disk, page 26
7. Mark exactly the rotational position of tool disk (1) and cooling
lubricant ring (3).
8. Turn gearwheel (6) by hand until pin (11) and marking (18) line up.
9. Unlock hydraulically, take down proximity switch S4, place round
sock (9) - approx. 15 mm thick - between control piston (5) and
housing.
10. Lock hydraulically; marking on tool disk (1) must be in line with
that of the cooling lubricant ring (3).
11. Pull plug (7), take down the bore-circlip ring (17), remove the
pinion shaft (13) to the back, until the gearing (12 and 16) is
disengaged.
12. Turn coupling sleeve (4) until marking - centre tooth - is in line with
the turret axis.
13. Carefully place straight spindle unit, centered locking, in working
position and tighten.
14. Unlock disk-type tool turret hydraulically. Do not remove round
sock (9), mark rotational position of spindle locking mechanism
with a pencil (15).
15. Move pinion shaft (13) axial until the gearing (12) is engaged; go
on moving and try, if it is possible to engage the gearing (16)
without big expenditure of force. Displace the pinion shaft in the
gearing until it is possible to engage both gearings (12 and 16)
without big expenditure of force. While doing it the marking (15) at
the spindle unit (14) must not twist.
IMPORTANT
In case of best gearing it is not possible to assemble the neighbouring
rotational positions.
16. Lock hydraulically and observe the spindle head while doing so.
When locking, the rotational position at the spindle head should be
maintained.
If necessary, correct as described under step 15.
44
Basic setting
17. Fit bore-circlip ring (17) and plug (7).

18. Fit AC servo motor with ratchetting clutch in correct position and
install electrically.
19. Hydraulically unlock disk-type tool turret, remove round sock (9),
and add proximity switch.
20. Increase hydraulic pressure up to 50 bar.
21. Determine reference point,
see chapter 4.10 Determination of reference point, page 29.
45
Replacing the cooling lubricant valve
7.6 Replacing the cooling lubricant valve
1
2 3
➪ 1. Unscrew the grub screw (1), through several turns.

2. Remove the valve carrier (2). The valve bushing (3) is now
accessible.
3. Install in reverse order.
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_akm.fm
46
Replacing and setting the proximity switches
7.7 Replacing and setting the proximity switches

For location of the proximity switches,
see Wiring diagram “EP-...“ in the appendix to these Operating Instructions.
7.7.1 Proximity switch S1 “Reference point turret“
0.6
Changing the proximity switch
➪ 1. Loosen clamps (1).

2. Pull out holder (2) for proximity switch (5), measure
dimension X and note this.
3. Unscrew thrust screw (3).
4. Unscrew proximity switch (5).
5. Fit new proximity switch with existing sealing ring and
disk (4), and screw into holder (2); but replace sealing ring, if
necessary.
IMPORTANT
If necessary, redetermine the reference point after replacing
proximity switch S1,
see chapter 4.10 Determination of reference point, page 29.
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NähS.fm
47
Setting the proximity switch

1. Put the turret into any defined position (pos. 1... 4..) - lokked
or unlocked.
2. Set the proximity switch (5) according to the noted
dimension X, or measure dimension a with depth gauge,
paying attention to hole (10) and gear (9).
Set proximity switch (5) to X = a - 0.6 and lock with thrust
screw (3), during that control dimension X.
3. Insert holder (2) and fasten.
4. Electrically install proximity switch (5).
5. Check - proximity switch energized.
6. Check - proximity switch deenergized when hole (10) under
proximity switch.
48
7.7.2 Proximity switch S4 “Checking turret drive disengaged“ and

proximity switch S5 “Checking turret drive engaged“
0.6

1. Loosen clamps (1) and pull out holder (2).
2. Measure dimension X and note.
3. Unscrew thrust nut (4) and inset (5).
5. Screw the new proximity swich in the holder (2).
6. Set the proximity switch according to the noted dimension X
or measure dimension a with depth gauge, set proximity
switch to X = a - 0.6 and counterlock with inset (5) and
thrust nut (4), during that control dimension X.
7. Position holder (2) in hole and fix with clamps (1).
8. Install proximity switch (3) electrically.

1. Lock turret;
proximity switch S4 can now be set.
Unlock turret;
2. Loosen clamps (1); turn holder (2) until proximity switch (3) is
deenergized.
3. Move back through about 90°.
4. Fix holder (2) with clamps (1).
5. Check switching function several times.
49
7.7.3 Proximity switch S6 “Checking tool drive engaged“ and

proximity switch S7 “Checking tool drive disengaged“
1 Eccentric
S6
0.6 Engaged
Disengaged
0.6
S7
Replacing the proximity switch

1. Unscrew clip and pull proximity switch (2) out from eccentric
bush (1).
2. Fit new proximity switch (2).
3. Fit new proximity switch (2) with gap to switching surface.
4. Take cable through hole (4) in terminal box and install
electrically,
see Wiring diagram “EP-...“ in the appendix to these Operating
Instructions.

1. Lock turret;
Unlock turret;
2. Undo fixing screw (3); set proximity switch (2) to correct gap
with 0.6 mm shim.
3. With eccentric bush (1), set proximity switch centre on
circuit board.
4. Check switching function several times.
50
7.7.4 Proximity switch S10 “Ratchetting clutch engaged“
0.6

1. Loosen clamps (1) and pull out holder (2).
2. Measure dimension X and note.
3. Unscrew thrust nut (4) and inset (5).
5. Screw new proximity switch into holder (2).
6. Set proximity switch according to noted dimension X or
measure dimension a with depth gauge, set proximity switch
to X = a - 0.6 and counterclock with inset (5) and
thrust nut (4), during that control dimension X.

7. Position holder (2) in hole and fix with clamps (1).
8. Install proximity switch (3) electrically.
51

1. Ratchetting clutch engaged.
2. Slightly slacken clamps (1).
3. Set initial state for proximity switch as attenuated (LED on),
turn holder (2) if necessary.
4. Turn holder (2) until signal change is detected as
unattenuated (LED off).
5. Turn back holder (2) by approx. 45° (LED on).
6. Fix holder (2) with clamps (1).
7. Check: rotate ratchetting clutch by 360°; the LED must be
permanently ’illuminated’.
52
7.7.5 Proximity switch S13 „Reference point slide unit“
3
0.6
➪ 1. Loosen setscrew (3).

2. Pull out bush (2), measure dimension X and note.
4. Screw new proximity switch into bush (2) and fasten with
setscrew (3) - maximum tightening moment 0.2Nm!
IMPORTANT
If necessary, redetermine the reference point of the slide unit after
replacing of proximity switch S13.

1. Set the proximity switch according to the noted dimension X
or measure dimension a with depth gauge, set proximity
switch to X = a - 0.6, during that control dimension X.
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_NS_S13.fm
2. Insert bush (2) and fasten.

3. Electrically install proximity switch (1).
4. Check - proximity switch energized.
5. Check - proximity switch deenergized.
53
Replacement parts
8 Replacement parts
8.1 Proximity switches
IMPORTANT
Only use the order form if you wish to order any replacement parts.
Table: Summary: Proximity switches
Ident
Denomination Figure Denomination Qty.
No.
S1 Proximity switch 1 Proximity switch 004 157 1

“Reference point turret”
1 2 3 4 2 Sealing ring 061 465 1
3 Thrust ring 061 466 1
4 O-ring 060 308 1
S4 Proximity switches 1 Proximity switch 076 749 2

S5 “Turret drive 1 2
disengaged“and 2 Thrust nut DIN 46320 081 754 2
3
“Turret drive
3 Inset DIN 46320 081 755 2
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_NÄHS.fm
engaged“ 4
4 O-ring 060 308 2
54
Proximity switches
Table: Summary: Proximity switches
Ident
Denomination Figure Denomination Qty.
No.
S6 Proximity switches 1
1 Proximity switch 076 749 2
S7 “Tool drive 2
engaged“ and 2 Eccentric bush 059 349 2
“Tool drive 3
3 Clip 034 133 2
disengaged“
S10 Proximity switch 1 Proximity switch 004 157 1

“Ratchetting clutch 1 2
engaged” 2 Thrust nut DIN 46320 081 754 1
3
3 Inset DIN 46320 081 755 1
4
4 O-ring 060 308 1
S 13 Proximity switch 1 2 3 1 Proximity switch 004 157 1

"Reference point slide unit"
2 Bush 036 515 1
3 Setscrew DIN 913 - 45H 000 245 1

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_NÄHS.fm
55
Tool disk
8.2 Tool disk
Clamping for tool holders d

Ident-N° Qty.
DIN 69880 (standard) [mm]
18 067 502 ..1.)

22 042 973 1.)
28 042 784 1.)
36 043 287 1.)
42 043 951 1.)
1) Number of positions
IMPORTANT
F:\Sauter\FRAME-AR\TD\0-5-695-\eng\760_8_WzSch.fm
56
Cooling lubricant system
8.3 Cooling lubricant system

The cooling lubricant transfer of the disk-type tool turret can be
designed variously,
see chapter 3.2 Possible options and deviating designs, page 13.
1
2
6 5 4 9 8 7
IMPORTANT
No. Ident-No. Denomination Qty.
1 060 885 FU-groove ring 1
2 064 593 O-ring 1
3 036 588 Spaghetti hose 0.6m

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_KE16.fm
for standard version
4 101 904 Cooling lubricant valve, complete 1
of this:
5 033 424 Bush 1
6 059 658 O-ring 1
57
Cooling lubricant system
for medium pressure valve
7 101 353 Cooling lubricant valve, complete 1
of this:
8 086 925 Bush 1
9 058 501 O-ring 1

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_KE16.fm
58
Gear head
8.4 Gear head
140 10
130
120
100
90
20
80
70
60 30
50 40
IMPORTANT
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GeKo16.fm
10 039 405 FU groove ring 1
20 084 301 Angular ball bearing 4
59
Gear head
30 062 201 Deep groove ball bearing 3
40 067 468 O-ring 1
50 085 017 Rotary shaft seal 1
60 030 013 Stepped ring 2
70 058 521 O-ring 1
80 067 467 O-ring 1
90 084 912 Surface ring 1
100 062 132 O-ring 2
120 067 228 O-ring 4
130 062 351 O-ring 1
140 058 521 O-ring 1

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GeKo16.fm
60
Housing and indexing unit
8.5 Housing and indexing unit
220
150
210
200 230
190
210
180 240
250
170
260
160
150
IMPORTANT
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GuIndex16.fm
150 077 321 ROTO surface ring 2
160 058 076 O-ring 1
170 064 915 T-slot nut 11
61
Housing and indexing unit
180 077 298 FU groove ring 1
190 058 951 O-ring 1
200 063 466 O-ring 1
210 076 787 Surface ring 2
220 074 390 O-ring 1
230 058 665 O-ring 1
240 060 801 O-ring 1
250 040 937 Thrust needle roller and cage assembly 1
260 079 073 Added-process part 1

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GuIndex16.fm
62
Carrier and gearbox
8.6 Carrier and gearbox
320
330
340
310
350
300
290
360
280 370
380
390
400
410
IMPORTANT

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_TuG16.fm
290 077 325 Needle roller and cage assembly 2
300 036 584 Needle bearing cup with open end 1
310 084 404 Auxiliary cylinder 1
320 000 008 DU bush 1
63
Carrier and gearbox
340 084 030 Inner ring of needle roller bearing 1
360 066 853 O-ring 3
390 076 753 O-ring 1
400 058 501 O-ring 2
410 067 228 O-ring 2

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_TuG16.fm
64
Slide unit
8.7 Slide unit
Motor Fanuc α 2/3000 Motor Siemens

with brake 1 FT6061 with brake
1 MA =2.9Nm MA =12Nm
IMPORTANT
1 085 794 Synchronous belt 1
6 085 788 Axial angular contact ball bearing 1

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_ers_SchlE.fm
65
Ordering replacement parts
FAX Company:
++49 (0) 7123–926–193
Street:
++49 (0) 7123–926–0
Post Code
Location:
service@sauter-gmbh.com
Name:
After Sales Service
SAUTER Feinmechanik GmbH Tel.:
Postfach 1551
D-72545 Metzingen
Germany Fax:
Assembly Ident-N° Denomination Qty.
i Read off the following data from the type plate and always complete.
Typ
Ident-Nr.
Com. Nr.
We will be pleased to answer your enquiries and receive your feedback information.
Anhang
I Appendix
A Wiring diagram . . . . . . . . . . . . . . . . . . . . .EP-1039 e
B Function diagram . . . . . . . . . . . . . . . . . . . SK-1226 e
C Hydraulic diagram . . . . . . . . . . . . . . . . . . . HP-446 e

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\640_Anhang.fm
67
Installation and
Operating Instructions
Hinge band conveyor type S
GB
Table of contents
Page
1 Description of machine and functions .............................................................................. 5
2 Danger and safety instructions .......................................................................................... 6
2.1 General instructions ....................................................................................................... 6
2.2 Instructions for repair and maintenance work and malfunctions ................................... 7
3 Unpacking and handling ..................................................................................................... 8
3.1 Unpacking ...................................................................................................................... 8
3.2 Handling ......................................................................................................................... 8
4 Assembly and installation ................................................................................................ 9
4.1 Screwing together several container parts .................................................................... 9
4.2 Electrical connection ...................................................................................................... 9
4.3 Loosening the tension device hinge band .................................................................... 10
4.4 Mounting the hinge band ............................................................................................. 12
4.5 Mounting the shackle type connectors ........................................................................ 13
4.6 Mounting the locking bolts ........................................................................................... 14
4.7 Tensioning the hinge band ........................................................................................... 16
5 Switching on and operating ............................................................................................. 18
5.1 Before initial operation ................................................................................................. 18
5.2 Switching on ................................................................................................................. 18
5.3 Switching off ................................................................................................................ 18
6 Maintenance ....................................................................................................................... 19
6.1 Adjusting the drive shaft .............................................................................................. 19
6.2 Changing the broach bars ........................................................................................... 19
6.3 Checking the hinge bande tension ............................................................................... 20
6.4 Changing individual hinge band plates ......................................................................... 20
6.4 Maintenance table ....................................................................................................... 18
7 Information on coolants / tanks ....................................................................................... 21
8 Maintenance table ............................................................................................................. 22
9 Eliminating malfunctions ................................................................................................. 25
10 Accessories ....................................................................................................................... 26
10.1 Stripping device ........................................................................................................... 26
3
1 Description of machine and functions

Function
- Conveying metal shavings and small parts
- Prepurifying the cooling lubricant (for wet processing)
Scope
- Decentral use in single and interlinked machine tools
- Central use for waste disposal from machine groups and entire production areas
- Suitable for long swarfs, snarl chips, wool-type filings, dry and wet processing
Mode of operation
- Loose material falls in feed opening onto the endless hinge band
- Continuous transfer of the loose material to the discharge opening
- Throwing the loose material at the discharge opening into the container or another
conveyer for removal.
- Do not use the plant for other than the intended purposes.
- Note the Regulation for the Prevention of Accidents (Unfallverhütungs-
vorschrift) VBG 10 when operating the plant.
- The discharge station must be visible during machine controlled operation.
Noise level: < 70 dB(A)
Optional equipment
- Coolant tank
- Coolant purification systems (e.g. magnetic separator, centrifugal separator,
band filter, superfine strainer)
- Low lift and jetting pumps for purification elements and machines
- Swarf mill
- Brush-off device
- Sustainer
- Chip carriage
- Sieve drum
- Piping with aggregates, valves, etc.
Since nearly every plant is constructed for the special needs of the customer, deviations from the form and position of the parts and structural
components described in this documentation may occur. In this case the operating instructions should be applied analogously.
5
2 Danger and safety instructions
2.1 General instructions
- Always observe all statements and instructions in the

operating instructions delivered with the plant.
- It is forbidden for unqualified persons to work at the plant.
- Observe correct fastening if components were installed by
customer.
- Never bypass safety contrivances (e.g. safety clutch).
- The operation of safety contrivances must always be
guaranteed.
- Work on the electrical plant may only be carried out by

qualified personnel.
- Observe the relevant VDE requirements and connection
requirements of the responsible Electricity Board.
- Do not stand in or reach into the feed opening.
- Do not reach into the discharge opening.
- Cover the scraper belt and all driving elements before

starting.
- Do not remove covers while plant is in operation.
6
2.2 Instructions for repair and maintenance work and for malfunctions
I 0 - Switch off the main switch.

- Secure the plant against being started accidentally.
- Ensure that the plant is dead.
- Depressurize the plant.
- Close pipe valves.

- Remove all noxious materials.
- Coolants must not enter the environment.
- When handling chips, wear protective clothing, safety boots

and protective gloves.
7
3 Unpacking and handling
3.1 Unpacking
Scraper conveyors over 8 m in length are delivered in several container parts.

The hinge bands of divided conveyors are rolled up on separate pallets.
For conveyors in several parts, scraper belts are rolled up on separate pallets.
Small parts (screws, sealings etc.) are delivered loose in the scraper conveyor
container or in separate packing.
If mounting rails are required for inserting the hinge band, they are fastened to the
hinge band or pre-mounted on the hinge band conveyor and lacquered in red.
Mounting rails must absolutely be preserved because the hinge band cannot be
inserted without them.
3.2 Handling
- Do not stop beneath suspended loads!
- By crane:
Always transport by crane if no longer in the
original packing. Use the suspension devices
provided (e.g. eye hooks, lifting screws)
- By stacker truck:
Only in the original packing and
with the greatest of care.
8
4 Assembly and installation

- Put plant on even ground!
- Ensure a firm and secure position.
- Secure the plant against being started accidentally.
4.1 Screwing together several container parts
- Join container parts at the joint locations and align in parallel.
Note identification markings (2) of the container flanges.

The identification marking (numbers or symbols) must agree with that of the opposite
flange (3).
(1) 1
4 2
- Insert the sealings supplied (1) and join container parts completely.
- Align the containers such that all bore holes are in alignment with the container flanges
opposite.
- Insert but do not tighten hexagon head screws and hexagon nuts.
- Drive in preassembled rollpin spring (4).
- Tighten hexagon head screws
4.2 Electrical connection
- Connect power supply to motor(s) and pump(s)

- Note the correct direction of rotation (see arrow)
9
4.3 Loosening tension device hinge band

Type 1
type 1
Model with flange bearing: 2
1
- Remove the top coverings (2)
- Loosen the fastening screws (4) on both
sides of the gearing end frame but do not
unscrew completely
- Loosen clamping bolts (3) on both sides of
the gearing end frame and turn backward
completely 6
- Loosen hexagon head cap screw (5) on 5
both sides and remove hand guard (6)
- Push backward gearing end frame (1)
against the conveying direction to the stop
3
- Tighten fastening screws (4) on both sides 4
of the gearing end frame
- Mount hinge band mounting rails
(see Chapter 4.4)
Type 2
2
type 2
Model with pedestal bearing:
- Dismantle protective covering at the drive 1
- Loosen the fastening screws (1) on the drive 1

motor (2)
- Turn back clamping bolts (3) on both sides 3
- Release the tension of the drive chain by

moving the drive motor in the direction of
the arrow (2)
- Loosen the fastening screws (4) on the
pedestal bearing
6
- On both sides, evenly screw in the clamping
screws (6) and tighten the hinge band in the
direction of the arrow 4
- Tighten the fastening screws (4) at the
pedestal bearing
- Mount hinge band mounting rails
5
(see Chapter 4.4)
10
Type 3
Model with band support: Type 3
- Disassemble hand guard (1) on the left and on
the right by removing the fastening screw (6)
2
- Loosen the fastening screws (2) on both sides 2 3
1
of the drive motor (3) but do not unscrew
completely
- Loosen lock nuts (4) of the clamping bolts (5)
- Turn back the clamping bolts (5) completely
- Push backward the drive motor against the
conveying direction (direction of arrow) to the
stop
- Tighten fastening screws (2) on both sides of 6
the drive motor
- Mount mounting rails (see chapter 4.4)
2
5
4
Type 4 Type 4
Deflection side model:
- Loosen lock nuts (2) of the clamping bolts (3)
on both sides
- Open the clamping bolts (3) at the guide roller
as far as possible
- Press the guide roller (1) towards the
discharge opening (direction of arrow)
- Fix clamping bolts (3) with lock nuts (2)
in loosened position on both sides
- Mount mounting rails (see chapter 4.4)
2
3
11
4.4 Mounting the hinged band

1
For heavy, divided hinge bands, mounting rails

(2) are included in the delivery. The hinge band 2
cannot be inserted without mounting rails!
Keep mounting rails (2) ! 3
4
- Position the beginning of the hinge band (3) on the

mounting rails (2)
The driver webs (6) of the hinge band point

upward in conveying direction.
The side rims (5) of the hinge band must
be closed at the back (against conveying
direction).
- Turn the drawing chain wheel (1) so that the first

roller (3) of the hollow pin chain can be pushed into
a tooth space
- Insert the hinge band into the container (4)
- Insert the hinge band up to the guide sprocket
wheel using the drive motor in jogging skip or the
crank handle
- Danger of injuries during the

inserting procedure:
- Never touch movable parts of the 5
hinge band conveyor with the
hands! 6
- Do not pull or push the hinge band
without the proper tools!
7
If the hinge band jams and piles up:
Briefly change the sense of rotation of drive
motor or crank handle.
- When the hinge band has reached the guide

sprocket wheel:
- Use a hook (7) or a suitable tool to pull the hinge
band around the chain wheel. At the same time,
switch on or slowly move on the drive motor in
jogging skip
12
- Danger of injuries!
- Never pull the hinge band around
the guide sprocket wheel by hand
- Continue the inserting procedure until the

beginning of the hinge band has reached the
drawing chain wheels.
- Steadily pull the hinge band with a hook or a
suitable tool in conveying direction to avoid
piling up or jamming. 8
- Switch off the drive motor
9
- Only Type S2: 10
- Position the beginning of the hinge band on 11
the mounting rails (10)
Insert a roller (8) between the cover plates 12
(9) of the hollow pin chains and fasten with
locking bolts (11). Blocking of the hinge
band (12) is thus rendered more difficult
Depending on the hinge band size, two or

more people are needed for inserting. The
drive motor or a crank handle can be used
for inserting. See chapter 6.2 for mounting
the crank handle
4.5 Mounting the shackle type connectors

- Insert the roller (3) between the cover
1 2 3 4 5
plates (2) of the hollow pin chain (only
required for Type S2)
- Connect the ends of the hollow pin chains
with shackle type connectors (1)
The bolts of the shackle type

connectors (1) point outward.
- Place the cover plates (4) onto the

inserted shackle type connectors
- Mount the locking rings (5)
- Remove the mounting rails
13
4.6 Mounting the locking bolts

Type 1
Type 1
Model with flange bearing:
- Turn the hinge band such that the
connecting brackets of the hinge band
plates are flush with the mounting 1
3
boring (4) 2
1
- Mount a washer (2) with split-pin (1) on
the locking bolt (3) 2
- Join the hinge band plates. 4
- Put the locking bolts (3) through the
shackle type connectors (7) and the
connecting brackets (6) of the joint
hinge band plates
- Mount the second washer (2) and split-pin
(1) on the locking bolt
Type 2
Type 2
Model with pedestal bearing:
- Turn the hinge band such that the 5
connecting brackets (6) of the hinge 1
band plates are accessible through
the oblong hole (5) 3 2
1
- Mount a washer (2) with split-pin (1) on
the locking bolt (3)
2
- Join the hinge band plates
hinge band plates
- Mount the second washer (2) and split-pin
(1) on the locking bolt
Dismantling is carried out in reverse

order
6
3
7
14
Type 3
with band support: Type 3
- Turn the hinge band such that the 8
connecting brackets of the hinge band
plate are in flush with the mounting
boring (8)
- Mount a washer (2) with split-pin (1) 1
on the locking bolt (3) 1
- Join the hinge band plates
connecting brackets (6) of the 2
3
joint hinge band plates
2
- Mount the second washer (2) and
split-pin (1) on the locking bolts
Type 4
Deflection side model: Type 4
- Turn the hinge band such that the

connecting brackets (6) of the hinge 8
band plates are accessible through the
oblong hole (8)
- Mount a washer (2) with split-pin (1)
on the locking bolt (3)
- Join the hinge band plates 1 1
shackles type connectors (7) and the
2
hinged band plates
3
- Mount the second washer (2) and
split-pin (1) on the locking bolt 2
Dismantling is carried out in

reverse order.
6
3
7
15
4.7 Tensioning the hinge band
Type 1 Type 1
Model with flange bearing:
- Loosen the fastening screws (3) on both
sides of the gearing end frame
- Loosen the lock nuts (1) of the clamping
bolts (2) on both sides
- On both sides, evenly screw in the clamping 1
bolts in the direction of the arrow
2
- Check hinge band tension as described in
chapter 6.3
- Tighten the lock nuts of the clamping screws
- Tighten the fastening screws (3) at the gear
end frame 3
Type 2 Type 2
Model with pedestal bearing: 2
- Loosen the fastening screws (1) at the
drive motor (2)
1
- Turn back the clamping bolts (3) on both
1
sides
- Loosen the fastening screws (4) on the
3
pedestal bearing on both sides
- On both sides, evenly screw in the clamping
bolts (5) and tension the hinge band in the
direction of the arrow
- Check hinge band tension (see chapter 6.3)
- Tighten the fastening screws (4) at the 5
pedestal bearing
- Tension the drive chain by means of the
4
clamping bolts (3) by moving the drive
motor (2) in the direction of the arrow
- Check the chain tension of the drive
chain (see chapter 8)
16
Type 3
with band support: Type 3
- Loosen the fastening screws (1) on both 1
sides of the gearing end frame (4), but
do not unscrew completely
- Loosen the lock nut (2) of the clamping 1
bolt (3) on both sides
- On both sides, evenly tighten the
clamping bolts while checking the hinge
band tension continuously as described
in chapter 6.3
- Tighten lock nuts (3)
- Tighten fastening screws (1) on bothsides
of the gearing end frame (4)
4
1
3
2
Type 4
Deflection model: Type 4
- Loosen lock nuts (2) on both sides
- On both sides, evenly tighten the clamping
bolts (3) in the direction of the arrow
- Check hinge band tension continuously as
described in chapter 6.3
- Check the adjustment of the guide roller (1)
(see chapter 6.3)
- Tighten lock nuts (2)
2
3
17
5 Switching on and operating

5.1 Before initial operation
- Electrical components must be connected by qualified personnel (note voltage, frequency,

strength of current and direction of rotation)
- Do a leak test on pipings for liquids (possible transport damage)
- Set all switches at “0” or “OFF”
- Fill up with required liquids (coolants, lubricants, oils, etc.)
- The entire installation must be free of coarse parts (tools, etc.)
5.2 Switching on
- Make sure that nobody is in the danger area of the hinge band conveyor!
- For the operation of the installation, the regulations for prevention of
accidents VBG 10 must be observed!
- All danger areas accessible to people must be covered!
Sequence for switching on:

- Lifting pump(s)*
- Low lift pump(s)*
- Scraper conveyor
- Auxiliary aggregates (swarf mill, sieve drum, magnetic drum etc.)*
- Jetting pump(s)*
5.3 Switching off
Switch off scraper conveyors with coolant system with a time delay of approx. 5 mins. to
the processing machine (purification of the coolant)
Sequence for switching off:

- Jetting pump(s)*
- Low lift pump(s)*
- Lifting pump(s)*
- Auxiliary aggregates (swarf mill, sieve drum, magnetic drum etc.)*
- Scraper conveyor
*if supplied with this model
18
6 Maintenance
6.1 Adjusting the drive shaft
Only necessary if distance “A” is not the

same on both sides
- Loosen the axial shaft locks on both sides of

the drive shaft bearings
- Move the chain wheels with the shaft in an
axial direction until distance “A” is the same on
both sides
- Fasten the axial shaft locks on both sides
A A
6.2 Attaching the manual crank
Examples for the use of the crank

handle:
Aligning the hinge band for dismantling
Loosening coarse parts blocking the
hinge band A
Reversing mode when not possible with
drive motor mm
12
mm
- Loosen connection between drive motor and 3 00
safety clutch. If necessary remove drive mo-
B
tor.
- Expel the rollpin spring of the safety clutch
- Remove the safety clutch from the drive shaft
- Attach the manual crank to the drive shaft and Ø A B
insert hexagon head screw. If necessary
25 M8 26
make manual crank as illustrated.
35 M10 36
19
6.3 Checking the hinge band tension
- Switch off the hinge band conveyor and secure A

against unintended start-up
- Check the hinge band tension between the drive
shaft and container bottom
~ 10 mm
Hinge band tension:
When applying moderate pressure from
below, the hinge band must give approx.
10 mm
Dimension A must be the same on both
sides
6.4 Changing individual hinge band plates
- Dismantle the hinge band

- Cut off the heads (3) of the connecting bolts (1) using appropriate tools (e.g. by means of a
abrasive cutting-off machine, saw, etc.) on one side
- Pull the connecting bolts (1) out of the hinge band plate
- Remove hinge band plate (2)
2
Hinge band plate
2
Hinge band plate
1
with scraper
2
Hinge band plate
with driver rail
To install a new hinge band, clamping bolts (1) (with borings), washers
and split-pins have to be used.
Mind the length of the connecting bolts such as they do not rub at the container.
20
7 Information on coolants / tanks
- Circulate coolants continuously (weekend circulation recommended)

- Do not feed any organic matter
- Avoid foreign oil charge
- Temperature should be below 25°C for emulsion, if possible
- pH-value should be within neutral range
- Hardness of the initial water should not exceed 15° dH
- Hardness due to upgrading must not exceed 20° dH
Cleaning the coolant tanks
- Cleaning intervals greatly depend upon the kind of processing, material, coolant and
working hours; no general interval can therefore be specified
A cleaning interval between four and eight weeks is recommended as standard value
21
22
8 Maintenance table
Subassembly/ Interval Action Safety instructions/
component remarks
Drive 3 months Check tension and tighten if necessary, Steps:

- Drive chain (only for model lubricate drive chain - Remove protective covering
with flange bearing with (1)
chain drive) - Loosen hexagon head cap
screw (2)
- Press take-up pulley (4) in
the direction of the arrow (5)
against drive chain (3) (force
1 of pressure approx. 20 N)
- Tighten hexagon head cap
5 screw (2)
2 4 - Mount protective covering
3 (1)
- Drive chain (only for model 3 months Check tension and tighten if necessary, - Remove protective covering
with pedestal bearing with lubricate drive chain Loosen hexagon head cap
chain drive) screws (7)
- Evenly unscrew hexagon
6 head cap screws (8) in the

direction of the arrow (6)
until the tension of the drive
chain is approx. 20 N
- Tighten hexagon head cap
7
screws (7)
8 - Mount protective covering
component remarks
- Bearing of drive shaft and --- Check wear and smooth running Check and replace if necessary
lateral axis, chain wheels when changing the hinge band
Hinge band 3 months Check tension and tighten if necessary For setting, see Chapter 4.5
3 months Check for damage Replace damaged parts
Electrical equipment
- Motor(s) --- See operating instructions of manufacturer
- Wiring 3 months Check for ruptures and damage Replace defective wiring
- Level switch 3 months Check function Exceed both switch points by

manual actuation
- Protective gear 3 months Check function
Sieve basket --- Empty and clean
Pumps --- See operating instructions of manufacturer

Containers 6 months Check for leaks, damage and corrosion Hazardous substances must in
no case penetrate
6 months Check stability Container must be safely and

solidly fastened
--- Check guide rails for wear Check when changing the hinge
band
23
24
component remarks
Coolant tanks 500 Check for contamination (sludge deposits) and Depending on the tooling method,
working clean, if need be. the interval may be greatly
hours shortened.
Coolant tanks are special accesso-

ries and are therefore not installed in
every plant.

9 Eliminating malfunctions
Malfunction Possible causes Remedy
Drive motor races, hinge band does not Drive chain torn (for model with chain drive) Replace drive chain
move
Rollpin spring of the safety clutch on the Drive in new rollpin spring
drive sheared off
Hinge band blocked by large parts, safety Remove parts

clutch has triggered Turn the drive band in reverse
direction if necessary (see Chap-
ter 6.2)
After restarting, the safety clutch
automatically reengages and
continues to operate
Safety clutch defective (loud rattling noise) Immediately switch off swarf con-
veyor
Inform service technician or re-
place complete safety clutch
Never bridge the safety clutch or
modify the setting

Accumulation of swarfs in front of the guide Dismount hinge band and look
sprocket wheel over installation
Hinge band does not move centrally Axial shaft lock loose Adjust drive shaft (see Chapter
(strikes the hand guard on one side) 6.1)
25
10 Accessories
10.1 Stripping device
Scope
- Used in case snarl chips are forming as well as in case chips are conglutinating
(e.g. due to oil)
Function
- By means of spring pressure (4) a movable scraper (1) will be moved along the
hinge band (2)
- Conglutinated chips will be eliminated
B C
Setting
- The stripping device (1) has to fit close to the hinge band (2) (A)
- Move stripping device fully in the direction of the arrow (B) until it reaches the stop
- Set the adjusting screw (3) to a distance (C) of 2 mm approx between the screw (3)
and the scraper (1).
26
22174/S-bed-gbV1.3.p65/08.01Wü
Kühlmittelreinigungsanlagen KNOLL Maschinenbau GmbH Telefon 07581/2008-0

Späneförderanlagen Schwarzachstr. 20, Postf. 1362 Telefax 07581/2008-140
Nieder- und Hochdruckpumpen D-88342 Bad Saulgau E-mail info@knoll-mb.de
web www.knoll-mb.de

CNC Emco Turn 365 PDF

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

CNC Emco Turn 365 PDF

Încărcat de

Drepturi de autor:

Formate disponibile

Emcoturn 365

Modular CNC-Turning Center for Complete Machining

EMCO Maier Ges.m.b.H.

P.O. Box 131

Phone ++43-(0)62 45-891-0

Fax ++43-(0)62 45-869 65

Due to an optimum distribution of machining sequences high production flexibility, half

EMCO MAIER Gesellschaft m. b. H.

Adequate Use ............................................................................ 9 The Main Spindle ø45 ........................................................... B10

Tailstock ................................................................................. B39 Survey Machine Configuration M99 ....................................... C2

Warranty conditions for new EMCO machines

Read instructions Personal protective equipment

Danger, Attention, Note

Enviromental Protection Notes

Technical data of the machine - metric

Subject to technical modifications!

'ULYHFRXQWHUVSLQGOH VSLQGOH¡ VSLQGOH¡

Subject to technical modifications!

(OHFWULFDOFRQQHFWLRQ VSLQGOH¡ VSLQGOH¡

Subject to technical modifications!

Technical data of the machine - inch

Subject to technical modifications!

'ULYHFRXQWHUVSLQGOH VSLQGOH¡ VSLQGOH¡

Subject to technical modifications!

(OHFWULFDOFRQQHFWLRQ VSLQGOH¡ VSLQGOH¡

Subject to technical modifications!

Product: CNC Turning Centre

Machine data: Model Type

Address of manufactorer: Emco Maier Ges.m.b.H.

Bases of standards: EN 292-1; EN 292-2; EN 294; EN 418; EN 60204-1; EN 954-1;

Regulations: MSV (BGBl. Nr. 306/1994, 27.4.94)

Place, date: Hallein, 27.12.00

Authorized person: Head of quality department Peter Binggl ..............................................

R6A101000 E Example of a complete electrics number:

Plan: 09 / 2 V 1.30 BAW.

Operation panel number

Plan: 09 / 2 operation panel.

Diagnosis Service Software numbers

Monitor Loader ....................................................................................................

1 Siemens software numbers

File ................... ................... ............. .............

Operand Format Value EMCO-software number

Enter machine and control specific numbers here!

Electrics number Operation panel number

Numbers on the machine

(5.079") (60.079") (37.598") (6.575")

Transport with pallet

Lifting capacity ............... min. 4 500 kg (9 920 lb)

Lifting capacity ............... min. 4 000 kg (8 820 lb)

Transport with crane

Transport with crane-rack

The crane-rack may be requested by EMCO if

Danger: • Handle shackles (1) through the openings on

Transport safety devices

Transport safety device A

Transport safety device D

Transport safety device E

Installation plan, dimensions of the machine

B Bores ø18×120 for anchor bolts Space for maintenance

Machine with bar loader and

Machine with gantry loader and

Anchoring on the ground

• Drill 4 anchor bolts ø18 × 120 in a distance of

'ULYHFRXQWHUVSLQGOH VSLQGOH¡ VSLQGOH¡

(OHFWULFDOFRQQHFWLRQ VSLQGOH¡ VSLQGOH¡

'ULYHFRXQWHUVSLQGOH VSLQGOH¡ VSLQGOH¡

(OHFWULFDOFRQQHFWLRQ VSLQGOH¡ VSLQGOH¡

/ / / / / / / / / • Reconnect cable (4) to the voltage variant you