Document No: VM702H(S)9303E

VM702H/S Vertical Machining Center

Mechanical Instruction Manual

（Mechanical Part）

Table Dimension on X-axis: 750mm

Table Dimension on Y-axis: 420mm

Product Serial No：

 Instruction Manual Document No.: VM702H(S)9303E

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 Instruction Manual Document No.:VM702H(S)9303E
CONTENT

1 SPECIAL INSTRUCTIONS ................................................................................................... 1

2 SAFETY PRECAUTION........................................................................................................ 1

2.1 COMMON SENSE ...................................................................................................................... 1

2.2 BEFORE STARTING THE MACHINE .............................................................................................. 2
2.3 DURING OPERATING PROCESS .................................................................................................. 2
2.4 MAINTENANCE ......................................................................................................................... 4
2.5 SAFETY DEVICE ....................................................................................................................... 4
2.6 SAFETY AND WARNING SIGN ..................................................................................................... 5

3 STRUCTURE AND GENERAL DESCRIPTION.................................................................. 11

3.1 STRUCTURE DIAGRAM .......................................................................................................... 11

3.2 GENERAL DESCRIPTION ......................................................................................................... 12

4 MAIN SPECIFICATION AND CHARACTERISTICS........................................................... 14

4.1 MAIN SPECIFICATION.............................................................................................................. 14

4.2 TABLE DIMENSION DRAWING ................................................................................................... 14
4.3 TRAVEL AND MAXIMUM WORKPIECE DIMENSION ....................................................................... 15
4.4 TOOL SHANK AND PULL STUD BOLT DIMENSION ........................................................................ 15
4.5 TOOL CHANGE INTERFERENCE DIAGRAM ................................................................................. 16
4.6 CHARACTERISTICS................................................................................................................. 16
4.7 OUTPUT CHARACTERISTICS OF SPINDLE MOTOR ...................................................................... 17

5 TRANSMISSION SYSTEM ................................................................................................. 19

5.1 FEED SYSTEM........................................................................................................................ 19

5.2 TOOL MAGAZINE DRIVE SYSTEM .............................................................................................. 21
5.3 SPINDLE TRANSMISSION ......................................................................................................... 22

6 PNEUMATIC PIPELINE...................................................................................................... 25

6.1 PNEUMATIC PRINCIPLE ........................................................................................................... 25

6.2 PNEUMATIC PRINCIPLE (OPTION)............................................................................................. 25
6.3 THE REQUIREMENT OF AIR SOURCE ........................................................................................ 25

7 LUBRICATING SYSTEM .................................................................................................... 25

7.1 GUIDE WAY LUBRICATION ....................................................................................................... 25

7.2 UTILIZATION OF HIGH SPEED GREASE ...................................................................................... 26

8 COOLING SYSTEM ............................................................................................................ 26

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8.1 WORKPIECE COOLING AND CHIP REMOVAL .............................................................................. 26
8.2 CHAIN TYPE AUTOMATIC CHIP CONVEYOR (OPTIONAL).............................................................. 27
8.3 SPINDLE COOLANT ................................................................................................................. 28

9 CNC ROTARY WORKING TABLE (OPTIONAL) ............................................................... 28

10 INSTALLATION .................................................................................................................. 28

10.1 WORKING ENVIRONMENT ....................................................................................................... 28

10.2 OUTLINE DRAWING OF THE MACHINE TOOL SEE FIG. 19 ......................................................... 29
10.3 OUTLINE DRAWING OF THE MACHINE TOOL(OPTIONAL) ............................................................. 30
10.4 BASIC DESCRIPTION AND FOUNDATION DRAWING ..................................................................... 30
10.5 LIFTING AND OTHERS ............................................................................................................. 31
10.6 INSTALLATION........................................................................................................................ 32

11 MECHANICAL MAINTENANCE ......................................................................................... 33

11.1 DAILY MAINTENANCE .............................................................................................................. 33

11.2 WEEKLY MAINTENANCE .......................................................................................................... 34
11.3 MONTHLY MAINTENANCE ........................................................................................................ 34
11.4 HALF-YEARLY MAINTENANCE .................................................................................................. 34
11.5 YEARLY MAINTENANCE ........................................................................................................... 34

12 UTILIZATION ...................................................................................................................... 35

12.1 OPERATION ........................................................................................................................... 35

12.2 SELECT THE WORKPIECE FOR MACHINING ............................................................................... 35
12.3 DECIDE WHICH PART TO MACHINE ........................................................................................... 37
12.4 COMPILE THE PROCESS CHART............................................................................................... 37
12.5 COMPILE THE PROGRAM LIST .................................................................................................. 41
12.6 PROGRAM INPUT.................................................................................................................... 41
12.7 DRY RUN ...............................................................................................................................41
12.8 TEST CUTTING ....................................................................................................................... 41
12.9 DOES AFTER MACHINING ........................................................................................................ 42

13 COMMON FAILURES AND TROUBLE SHOOTING.......................................................... 42

13.1 COMMON FAILURES AND TROUBLE SHOOTING OF FEED SYSTEM ................................................ 42

13.2 COMMON FAILURES OF TOOL MAGAZINE AND MANIPULATOR ..................................................... 43
13.3 COMMON FAILURES AND TROUBLE SHOOTING OF MAIN DRIVE SYSTEM ....................................... 44
13.4 COMMON FAULT AND SOLUTION OF COOLANT SYSTEM.............................................................. 44
13.5 COMMON FAULT AND SOLUTION OF PNEUMATIC SYSTEM........................................................... 45
13.6 ALARM MESSAGES OF CNC SYSTEM ....................................................................................... 46
13.7 QUICK VIEW OF ALARM MESSAGES .......................................................................................... 49

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14 THE MAIN BROUGHT-IN COMPONENTS......................................................................... 49

15 ATTACHED FIGURE .......................................................................................................... 50

16 RECIRCULATION AND ENVIRONMENTAL PROTECTION.............................................. 56

16.1 METAL .................................................................................................................................. 56

16.2 PLASTIC ................................................................................................................................ 56
16.3 GLASS .................................................................................................................................. 56
16.4 OTHER MATERIALS................................................................................................................. 56
16.5 THE SCRAPPED OR DAMAGED PARTS ...................................................................................... 56

17 DECLARATION AND OTHERS.......................................................................................... 57

17.1 DECLARATION ....................................................................................................................... 57

17.2 ADDRESS AND CONTACTS ...................................................................................................... 57

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 Instruction Manual Document No.:VM702H(S)9303E
1 Special instructions

Thank you for using the Vertical Machining Center supplied by Neway CNC Equipment

(Suzhou) Co., Ltd. The machine tool is suitable for metal cutting. Other applications

deviated the original design should be avoided. For the safety and interest concerns, if

there are any failures of the machine, please contact the company.

Although the machine tool is equipped with safety devices, for some uncontrolled and

unexpected reasons, the operator should read the documents along with the machine

carefully and comprehend the structure, performance, operation and safety devices of

the machine completely before manipulating the machine.

Otherwise, if you have any doubt or difficulty about our machine tools, please call us by

the hotline 0512-6607-6668.

This Instruction manual is applied to VM702H/S.

2 Safety precaution

2.1 Common sense

2.1.1 Only can the trained personnel operate the machine tool.

2.1.2 Enough space should be reserved in the vicinity of the machine and the floor should be

clean.

2.1.3 Lighting should be sufficient in the working area.

2.1.4 Operator should wear anti-oil work shoes, clothes and glasses when working.

2.1.5 The long thing exposed such as hair, sleeve, etc. should be bound.

2.1.6 Don’t wear glove when approaching the rotary components.

2.1.7 Cut off the power supply before cleaning, wiping or checking the machine.

2.1.8 Switch off the main power supply switch immediately when the circuit is cut off.

2.1.9 Turn off all the NC device, operator panel and close the electrical cabinet door.

2.1.10 Use the machine according to the Instruction Manual. Don’t modify the parameter of

control system set by the supplier, raise the pressure of the hydraulic system or replace

the accessories at will.

2.1.11 Don’t touch the electrical device with wet hand.

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2.2 Before starting the machine

2.2.1 Open the guarding door and check if there is any person or other thing in the machine

tool.

2.2.2 Use the appointed lubricating oil.

2.2.3 Use the handle of lubricating pump to lubricate the guide way before start the machine if

the machine is to be used for the first time or unused for a long time.

2.2.4 Check if the liquid level of lubricating oil tank and coolant tank is above the liquid level

line.

2.2.5 Don’t put your hand between belt and pulley when checking the belt tension.

2.2.6 Check if the electrical cabinet door is closed.

2.2.7 Turn on the switch of the workshop, machine tool main switch and the on-off switch on

the operator panel in sequence.

2.2.8 Cut the main power supply immediately when the abnormal voltage fluctuation occurs as

the power supply failures or fulmination may cause accidents.

2.2.9 Prepare the working program and clarify the machining range before working.

2.2.10 Preheating can solve the problem that the workpiece machined is instable in accuracy as

the temperature difference of each component exists. Preheat the machine for 5 to 20

minutes, run the spindle at 4 or 5 kind of speed and move the axis in the whole travel

before working. Check each component when preheating and be careful when running

the spindle at maximum speed.

2.2.11 Check the switch on the operator panel before operating to guard against wrong motion

which may cause damage to the machine tool.

2.3 During operating process

2.3.1 The diameter, length and weight of the tool must be in accord with what stipulated by the

machine tool.

2.3.2 Don’t use the tool that is severely wore or broken. Replace it with a new one.

2.3.3 Make sure the connection of pull stud bolt, tool shank, auxiliary tool and cutting tool is

tight and reliable. The pull stud bolt used in the machine is standard and can’t be

replaced by the one made by the user. Otherwise, accident may occur as the accuracy

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or strength is not sufficient.

2.3.4 Use brush other than hand to clear away the chip on the tool.

2.3.5 Stop spindle and coordinate axis when the tool magazine is changing tool. Don’t reach

the action range of ATC mechanism.

2.3.6 If the tool is laid in spindle for a long time, the tool holder will get rusty as it expands with

heat and contracts with cold and is corroded by cutting fluid. So, the tool must be

exchanged to tool magazine before the machine stops.

2.3.7 Simulate the machining or test run before machining to check if the program is correct.

Check and rectify the machining origin, tool parameter, machining parameter and moving

track and clean the workpiece. Check if the workpiece is fixed or fastened and the

adjusting tool is removed.

2.3.8 Stop the machine when adjusting the direction of the cooling nozzle or the lighting

holder.

2.3.9 It is forbidden that two or more people manipulate the control panel simultaneously.

2.3.10 Don’t wear glove to press the button or turn the switch.

2.3.11 Using lifting device when loading or unloading the workpiece with over 20kg in weight. At

least two people are needed to load and unload the large workpiece,

2.3.12 Don’t beat center, tool, spindle, etc. during operation.

2.3.13 Don’t open the door when the machine tool is working.

2.3.14 Don’t clean the chip when machining. Use brush or cleaning liquid to clean the machine

after the spindle and coordinate axis stop.

2.3.15 Turn off the switch of the operator panel and main power supply switch when leaving the

machine tool for a while.

2.3.16 Clean the machine tool, clear away the chip and wipe the protective cover glass after

finishing machining. Restore the machine in its original state, place the switch, handle in

the non-work position, cut off the power supply and carry on the handover system

earnestly.

2.3.17 Press the key with appropriate strength and don’t beat the keyboard, key and display

screen.

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2.3.18 Stop the machine and eliminate the failure or notice the service people to maintain the

machine tool when abnormal phenomenon or failures occur.

2.3.19 Don’t put any tool or instrument on the operator panel or any component of the machine

tool.

2.3.20 Don’t touch the working light as it becomes hot after lighting for a long time.

2.4 Maintenance

2.4.1 Don’t carry out any maintenance operation without any permission or direction.

2.4.2 Only can the trained personnel do the appointed maintenance work.

2.4.3 The maintenance of electricity should be carried out by the professional personnel who

should have a good command of machine tool program.

2.4.4 Hang “Maintenance” sign in the vicinity of the machine when maintaining.

2.4.5 Cut off the power supply before replacing any electrical element.

2.4.6 To guard against unexpected hazards, take down the fuse or hang “machine tool in

inspection, power supply is forbidden” sign when maintaining.

2.4.7 Use ladder or relative safety equipment when working in high place.

2.4.8 Special cable and lifting device should be used when using hoisting apparatus.

2.4.9 The position of travel limit block and other switch shouldn’t be changed.

2.4.10 Use the designated one when replacing the component.

2.4.11 Contact the supplier and ask for help immediately when facing the problem difficult to

diagnose and solve.

2.5 Safety device

2.5.1 External protective cover.

2.5.2 Protective cover of each guide way and cooling, etc.

2.5.3 Travel limit block of each moving component.

2.5.4 Travel limit switch of each coordinate axis.

2.5.5 Software limit travel protection.

2.5.6 Emergency stop button.

2.5.7 The diagnosis function of control device, e.g. abnormal checking, overheating alarm, etc.

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2.6 Safety and warning sign

2.6.1 Machine tool nameplate

The machine tool nameplate gives clear indication of product name, model, serial

number, manufacturing date, table size, voltage, frequency, current, manufacturer name,

etc.

2.6.2 Warning sign

Applied where there is high voltage current and danger.

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2.6.3 Safety sign

The safety sign and daily inspection are the key points of this Instruction Manual. The

operator should be completely familiar with the content.

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2.6.4 Warning sign

Applied to tell operator not to step on the telescopic cover of guide way lest damage the

machine tool parts.

2.6.5 Jointed warning sign

Applied to remind operator to notice the details when the machine is running to guard

against accident.

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2.6.6 Warning sign

Applied to remind operator to clean oil collective box regularly.

2.6.7 Warning sign

Applied to remind the operator what should be done when dismantling the motor.

2.6.8 Warning sign

Applied to tell the operator to pay attention to safety and not to touch the cutter when the

machine is running to avoid injury.

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2.6.9 Warning sign

Applied to tell operator to be cautious and cut off power supply before entering the

working area.

2.6.10 Warning sign

Applied to give clear indication of tool specification and its maximum value should not be

exceeded.

2.6.11 Axis coordinate sign

Applied to tell the operator the right moving direction of each axis.

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2.6.12 Lifting sign

To show lifting mode and size of lifting bolt

2.6.13 Hint sign

Rotary Direction of handle

2.6.14 sign

To show the tools change position

2.6.15 Sign

to show the machine earthed position

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2.6.16 Lubricating sign

3 Structure and general description

3.1 Structure diagram (See Fig. 1)

① Tool magazine unit

② Spindle head unit

③ Base unit

④ Table unit

⑤ Drive unit of X axle

⑥ Drive unit of Y axle

⑦ Drive unit of Z axle

⑧ Column unit

⑨ Saddle unit

Fig. 1 Structural drawing

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3.2 General description

VM702H/S is a small size vertical machining center with fixed column. With mechatronics

design, it has a graceful outlook and can realize precision cutting. In a single set-up, it

can finish milling, drilling, boring, reaming, counterboring, tapping, etc automatically and

continuously and is suitable for the machining of a variety of complex parts such as

box-type parts, board-type parts, plate-type parts, case-type parts, etc. for small and

medium-batch. The workpiece machined by the machine is of high quality.

The machine tool has a good rigidity and high accuracy and is suitable for the following

industries: automobile and autobike component, mold, valve, electronic device, IT device,

optical device, medical treatment device, etc.

If equipped with CNC rotary table (optional equipment), the machine can process the

complex workpiece with 4 or 5 axes moving simultaneously and the working range is

enlarged.

The mechanical part is composed of mainframe, water tank subassembly, operating

station, electrical cabinet, air pressure pipeline, etc. The machine tool is capable of rigid

tapping.

The noise is measured according to GB/T16769 and the sound pressure does not

exceed 80dB（A）.

3.2.1 Base

With high rigidity design and manufacture, base, which is to endure the weight of the

machine tool, cutting force and cutting vibration, is the basic part of the machine tool.

There are 6 adjusting bolts to adjust the level of the machine tool.

The table, with an area of 750×420mm, is installed on the saddle that installed above the

guide way on the base. The table is convenient for loading and unloading the workpiece.

The table moves in front-rear direction (Y direction) along with the saddle on the base

and in left-right direction (X direction) on the saddle.

3.2.2 Column

Column is of high rigidity and installed on the base. Tool magazine is installed on the left

side of the column, electrical cabinet is on the rear and Z-axis feed motor is on the upper.

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3.2.3 Spindle head

Spindle head is installed on the guide way in the front of the column and moves in

up-down direction (Z direction) on the column. Spindle motor, spindle and air pressure

cylinder for tool pushing are installed in the spindle head. The power is transmitted from

motor to spindle by a toothed belt.

3.2.4 Tool magazine

Tool magazine is installed on the tool magazine support, which is fixed on the left side of

the column. Tool magazine can realize the storage and change of tool. Tool change is

quick, exact and reliable.

3.2.5 Operating station

The operating station is in the front right of the machine and is used to inputting and

modifying machining program. MDI operation, LCD display, automatic and manual

control switch, etc. are all installed in the NC panel in the station.

3.2.6 Electrical cabinet

The electrical cabinet, including NC equipment and heavy current device, is in the rear of

the machine tool. NC stores and reads machining program and sends drive signal for

each axis and automatic motion instruction. The relay circuit, power supply circuit, etc.

for mechanical action belong to heavy current device.

3.2.7 Air pressure pipeline

The air pressure pipeline controls the action such as tool releasing of spindle, toolbar

cleaning, tool pocket moving, etc.

3.2.8 Water tank part

Water tank part is in rear of machine and is used to supply cutting fluid to the cutting tool

and collect the chips generated during machining process.

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4 Main specification and characteristics

4.1 Main specification

Distance from machine tool bottom to the

900mm
working surface of table
Table dimension（length×width） 750×420mm
Left-right travel of table（X-axis） 650mm
Forward-Backward travel of table（Y-axis） 420mm
Up-down travel of spindle head（Z-axis） 500mm
Distance from spindle end surface to the 120 – 620mm
Distance from spindle center to the 470mm
Max. load of table 350kg
Lead screw dimension（Diameter × Lead）X φ32×16 / φ32×16 / φ32×10 mm
Rapid traverse speed X,Y：36m/min；Z：30m/min
Cutting feedrate 1~10000mm/min
Spindle taper hole BT40
Spindle speed 10～10000r/min
Spindle motor 5.5/7.5kW（rated / 30min）
Tool magazine capacity 20
Tool selecting method Random/Sequence
Tool change mode Cam tool change device
Maximum tool dimension ∅78×300mm
Maximum tool weight 8kg
Drilling capacity ∅30mm (steel)
Tapping capacity M16 (steel)
Milling capacity 150cm³/min (steel)
Air source 0.6 – 0.8MPa（280L/min）
Machine tool weight 4000kg
4.2 Table dimension drawing（see Fig. 2）
1
4
H
8

5
2
1
0
7 2
1 2 4
.0
0 5
9
+ 2
1
2
3
+ 0
.
1

5
0

8
7
5
0

Fig. 2 Machine tool table dimension drawing

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4.3 Travel and maximum workpiece dimension（see Fig. 3）

Fig. 3 Travel and maximum workpiece drawing

4.4 Tool shank and pull stud bolt dimension (see Fig. 4）

（1）BT40 knife handle and P40T pluck nail：

39
11.15
12.95

45°
18.95

22.5
M16
7.35

30° 3.25
16.40

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（2）SK40 knife handle and A40 pluck nail：

Fig. 4 Tool shank and pull stud bolt dimension drawing

4.5 Tool change interference diagram

The travele of tool changing arm pulling the tool is 115mm and the distance from spindle

end surface to the working surface of table is 120mm～620mm。' tool change interference

diagram' as following ：

Fig. 5 tool change interference diagram

4.6 Characteristics

4.6.1 Resin sand casting is adopted to the main castings such as base, saddle, table, spindle

head, column, etc. which is stable in structure. Box-type structure and reasonable rib

collocation ensure high rigidity and high strength and long term high accuracy and

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stability.

4.6.2 The motor of each axis is connected to high precision ball screw directly. Ball screw is

preloaded when installed to further improve the transmission rigidity and positioning

accuracy.

4.6.3 Linear rolling guide ways are adopted in all linear axes to damp vibration during high

speed feed, avoid crawl at low speed and keep high accuracy and stability.

4.6.4 Spindle motor ofβ6/10000i（10000rpm）, 5.5/7.5KW is connected to spindle（10000rpm）

via a synchronized toothed belt at a reduced speed ratio. The machine tool has a strong

machining capacity, high accuracy and stable quality.

4.6.5 To ensure the quality of the machine, all the brought-in components are supplied by

branded suppliers.

4.6.6 Full-enclosed protective covers are used to make full use of coolant and chips to prevent

operator from accidents.

4.6.7 The automatic chain chip conveyor release the working intensity of the operator

dramatically.

4.7 Output characteristics of spindle motor

4.7.1 Spindle adopts FANUCα6/10000i motor(H series). For the output characteristics, see the

following Fig.6：

Fig. 6 FANUCα6/10000i motor output characteristics diagram

4.7.2 Spindle adopts FANUCβ6/10000i motor(S series). For the output characteristics, see the

following Fig.7:

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Fig. 7 FANUC β6/10000i motor output characteristics diagram

4.7.3 Spindle adopts α8/10000i motor(H series’s option). For the output characteristics, see the

following Fig.8：

Fig. 8 FANUCα8/10000i motor output characteristics diagram

4.7.4 Spindle adoptsβ8/10000i motor(S series’s option). For the output characteristics, see the

following Fig.9：

Fig. 9 FANUC β8/10000i Motor output characteristics diagram

4.7.5 Spindle adopts1PH8103 motor(12000rpm max, option). For the output characteristics,

see the following Fig.10：

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Fig. 10 SIEMENS 1PH8103 motor output characteristics diagram

5 Transmission system

AC servo motors are used in the three coordinate axes and spindle.

5.1 Feed system

5.1.1 Feed system working principle

The feed drive mechanism drives table (X), saddle (Y), spindle head (Z) to realize X/Y/Z

axis feed motion and positioning via servo amplifying unit, servo motor and ball screw

after receiving instruction from the CNC system. See Fig.11 Feed system schematic

diagram.

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Fig. 11 Feed system schematic diagram

Specification of feed system：

23 20057497 Distance bushing,VM702S0602-71,45 M37307

22 20057490 Oil seal,EK SN70-TC03204007BA
21 20057489 Oil seal,EK SN70-TC02504008BA
20 20052688 Coupling,R+W EK2/60/A/16/19
19 20039878 Guide screw of Y axle,VM702H0625-71 M35618
18 20037348 Baffle plate,VM702S0625-50, urethane rubber M35487
17 20037339 Bearing seat,VM702S0600-1, HT300 M35485
16 20028058 Bearing,NSK 20TAC47BSUC10PN7B
15 20028057 Lock nut,YINSH/SWT F M20*1
14 20028049 Cover plate,VM601D0600-75,Q235-A M15725
13 20028047 Motor seat,VM601D0600-1,HT300 M15723
12 20028046 Baffle block,VM601D0600-51, urethane rubber M15722
11 20028045 Gland,VM601D0600-76,45 M15721
10 20014123 Soket head cap screw,NWMJ21-00-00 M6*12
9 20006103 Soket head cap screw,GB/T70.1 M10*40,12.9
8 20006001 Soket head cap screw,GB/T70.1 M6*20,12.9
7 20002858 Lock nut,YINSH/SWT F M24*1.5-6H
6 20001572 Pin,GB/T118 8*30,35
5 20001057 Soket head cap screw,GB/T70.1 M8*30,12.9
4 20000672 Soket head cap screw,GB/T70.1 M8*20,12.9
3 20000047 Plain washer,GB/T97.2 8,140HV
2 20000040 Spring washer,GB/T93 8,65Mn

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1 Servomotor
NO. Material No. Material description Drawing No.
The drive methods of the three coordinate axes are the same: servo motor is connected

to lead screw via non-clearance elastic coupling that is connected to motor shaft and

lead screw shaft without key, which features good concentricity and easy loading and

unloading. High speed ball screw with size of Ø32is used and pre-tensioned when

installed to raise the accuracy stability and rigidity and ensure the moving accuracy.

Linear rolling guide ways are adopted for all linear axes to damp vibration during high

speed feed, avoid crawl at low speed and keep high accuracy and stability.

The feed system uses semi-closed loop control system. The angle displacement

measuring device in the servo motor detects the displacement of the moving part

indirectly by detecting the rotation angle of motor shaft and feeds the data back to the

comparator that compares the data with the instructed one. The difference of comparison

is used to control the moving part and supplement the displacement until the difference is

in the allowable range of the control system.

5.2 Tool magazine drive system

5.2.1 Tool magazine outline drawing(see Fig. 12)

Fig. 12 Tool magazine outline drawing

5.2.2 Tool magazine working principle

Tool magazine drive system, including tool magazine, manipulator, etc. is used to realize

the tool change of the machining center. When the CNC system sends out the instruction,

tool change will be carried out automatically.

The indexing and tool change motion are realized by cam device. For details, see the

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Tool Magazine Instruction Manual.

The tool magazine has 20 stations. Tool is managed by PMC（Programmable Machine

Controller）. Tool needn’t coding and switch and tool is selected in sequence and random.

Every tool has a fixed tool station and is set by the operator. If the tool station or station

number is changed, it should be reset in CNC. For safety reasons, spindle tool number is

set 00, that is to say spindle has no tool. The tool to be machined is placed in 1~20

stations.

Like axis, tool magazine also has reference point. When machine tool is powered off, or

emergency stop button is released, or other need to return to zero, execute tool

magazine return to zero position and then tool station No. 1 (T01) is in the tool change

position. Tool change is divided into two circumstances: spindle has tool and spindle has

no tool. In the former circumstance, the tool station to be changed is the xx tool before

tool magazine acts; while in the latter circumstance, the tool station to be changed must

be empty, that is to say that it corresponds to xx tool station number of xx tool number in

spindle. For safety reasons, move X-axis in the negative limit position when spindle

orients in tool change process.

Tool change sequence: spindle move to tool change point → tool magazine selects tool

→ tool pot overturns → ATC clamps tool → spindle unclamps tool → ATC pulls tool →

spindle huffs → ATC turns to change tool → ATC loads tool → spindle clamps tool →

ATC returns to zero position→ tool pot returns to original position.

5.3 Spindle transmission

5.3.1 Spindle transmission principle

The power is transmitted from motor to spindle via a synchronized toothed belt.

To replace the transmission belt, the specification and supplier of the product should be

the same with the original one. The steps to replace the belt is as follows: take down

connecting air pipe of tool unclamp cylinder→take down tool unclamp cylinder→take

down cylinder rest→loosen adjusting screws→loosen motor plate→replace belt→install

cylinder rest→install tool unclamp cylinder→install connecting air pipe of tool unclamp

cylinder→tension the belt→lock motor plate. For the spindle head assembling schematic

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diagram, see Fig. 13.

SP motor
Cylinder

Connecting plate Belt pulley

C
y
l
i
n
d
e
r
r
e
s
t
Adjusting screw SP motor plate

Synchronized belt

Spindle head

Spindle unit

Fig. 13 Spindle box assembling schematic diagram

To tension the belt, loose the two adjusting screws, move the spindle motor plate and

then lock the nut in the plate. If the belt is too tight, the load to the spindle bearing will

increase and the service life of the tool will be reduced. Guard against oil or grease dirt

when replacing the belt.

Automatic tool clamping mechanism, including pull rod, belleville spring, pull stud bolt, is

installed in the spindle. The specification of toolbar and pull stud bolt of this machine is

BT40#. Tool clamping mechanism changes as different standard of toolbar and pull stud

bolt are used (User should notice this point when using machine tool and ordering taper

and pull stud bolt). The tensile force of the tool clamping mechanism is about 0.6t. The

drawbar, pushed by the piston under the air pressure in the cylinder above the spindle,

compresses the belleville spring to move forward until the gripper finger arrives at the

slot in front of the spindle. Tool unclamping is finished as the drawbar continues to move

forward and pushes the toolbar about 0.2mm away from the spindle taper hole. The force

for unclamping the tool is about 0.35t. During the tool unclamping process, the dry and

clean compressed air is delivered into the hole inside the drawbar and blown through the

taper hole of the spindle to clean the taper hole and toolbar surface. For the structure of

the spindle, see Fig. 14.

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5.3.2 Coolant through spindle (optional)

When working with materials like Al alloy, Ti alloy or Stainless steels, or the process

needs (small hole, deep hole or U axis drill is needed), coolant through spindle is

available for option. The pull rod, stud and the tools are of through bore. The sealed

rotary adaptor is installed at the rear part of the spindle. The mandril of the adaptor

rotates with spindle at high speed while the shell does not move. There is dedicated

water tank，filter and high pressure pump for coolant through function to ensure there is

enough coolant.

12 Draw bar 24 O-ring

11 End-on key of spindle 23 O-ring
10 Gland of ring packing 22 O-ring 34 Hexhead bolt
9 Belt wheel of spindle 21 O-ring 33 Plug screw
8 Dust collar of Font cove 20 Lock nut 32 Plug screw
7 Font cover of spindle 19 Lock nut 31 Plug screw
6 Distance bushing 18 Pull stud type clamping 30 Plug screw
5 Outside distance bushing 17 Positioned wheel 29 Soket head cap screw
4 Inside Distance bushing 16 Lock nut 28 Soket head cap screw
3 Font distance bushing 15 positioning wheel 27 Soket head cap screw
2 Sleeve 14 Draw bar plunger 26 Ring packing
1 Mandrel 13 Spring distance ring 25 O-ring
Fig. 14. The structure drawing of spindle

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6 Pneumatic pipeline

6.1 Pneumatic principle

Tool clamping, tool unclamping and spindle huffing are realized by compressed air. The

air pressure of the system is 0.5~0.7MPa. After filtered, the compressed air is delivered

to each implementing point. For the pneumatic principle, see Fig. 15

S
p
i
n
d
ll
e
a
i
r
T
o
ln
o
oy
p
c
k
e
td
Gas cooling Air curtain Tool unclamp

b
o
w
t
u
r
c
l
i
n
e
r
protection cylinder

6
6
YA5
YA1
Air gun

1
2
YA4 0.11MPa

YA2 YA3
AIR tank
0.6MPa
1
0

1
0

1
0
1
0

1
0
1
0

1
0
0.6-0.8MPa

Fig. 15 Pneumatic schematic diagram

6.2 Pneumatic principle (option)

CTS option Automatic door option Rotary table option
Tool unclamp cylinder
S
p
i
n
db
l
eo
S
p
i
n
d
l
eo
a
i
r

Air gun Gas cooling Air curtain protection Tool pocket turn Air cylinder for Gas liquid Rotary table
a
i
r
l
w

cylinder clamp
b
l
w

automatic door convertor

1
2

6 6
Needle
YA2 valve
1
0

YA4 YA3 YA4 YA3

0.6MPa 0.4MPa
AIR tank
1
0

Air source

Fig. 16 Pneumatic schematic diagram (option)

6.3 The requirement of air source

The flow of the air source is required to be more than 280L/min, and the pressure

0.6~0.8MPa. The pneumatic system is equipped with pressure switch. Alarm appears as

the pressure is less than 0.6MPa and disappears automatically as the pressure rises.

The water removed by the filter is drained from the bottom of the filter. Users should

check if the drain valve is jammed at regular intervals(half year a time).

7 Lubricating system

7.1 Guide way lubrication

The lubricating oil is supplied to the moving parts by the lubricating pump at fixed time

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and quantity to lubricate the three coordinate guide way surface: base—saddle guide

way surface, saddle—table guide way surface, spindle head—column guide way surface

and lead screw nut. When the machine tool is powered on, lubricating oil pumped by the

lubricating pump at a reduced speed inpours into every slider and ball screw nut. The

timing lubricating device is equipped with oil level switch. When the lubricating oil level is

below the set height, alarm will appear. Fill the tank with lubricating oil every two weeks.

For the lubricating principle, see Fig. 17.

Guideway slider of Y - axis

Guideway slider of Y - axis
Leadscrew nut of Y - axis
Guideway slider of Y - axis
VERSAⅢ Guideway slider of Y - axis
with oil
filter

Guideway slider of Z - axis Guideway slider of X - axis

Guideway slider of Z - axis Guideway slider of X - axis
Leadscrew nut of Z - axis Leadscrew nut of X - axis
Guideway slider of Z - axis Guideway slider of X - axis
Guideway slider of Z - axis Guideway slider of X - axis

Fig.17 Lubricating schematic diagram

Choose the lubricating oil with approximate viscosity as season and temperature change.

The oil with low viscosity will result in the malfunction of exhaust valve. It’s recommended

to use 32# (in winter) ~68# (in summer) hydraulic guide way oil.

7.2 Utilization of high speed grease

Quantitative NBU15 high speed grease, which is able to endure abrasion and

temperature rise and won’t flow away in high speed, is filled in the spindle bearing and

lead screw bearing. User needn’t replace it until overhauling the machine.

8 Cooling system

8.1 Workpiece cooling and chip removal

The cooling system includes: cooling water tank, cooling pump, chip rushing pump and

pipeline.

Emulsion or mineral oil is added to the coolant tank. The coolant pumped by the cooling

pump spurts from the nozzle of the spindle. The nozzle can be turned and the flow

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capacity can be adjusted according to the need. The coolant is precipitated and recycled

after flowing through the workpiece. The stop and start of the cooling pump is in control

of selecting button and the machining program.

The sprayer nozzle of coolant to the head stock is placed near spindle nose. Coolant

pump starts and stops to work with button control as well as M code in PLC to cool down

the workpiece and tool during the whole process. Each coolant spray is controlled by

combination of a ball valve and an adjusting valve. Flow and flow direction are controlled

and adjustable. 8 bamboo shape flush pipes are places at the underpan area from 3

directions. With the help of heavy pump pressure，the chips are flushed soon after it falls

to the underpan. Cutting heat and thermal deformation that cause processing inaccuracy

are carried away. The on and off function of the coolant pump control are also available

with buttons on control panel and M code in PLC. Water-soluble cutting fluid or oily

cutting fluid is suitable for the cooling system.

Note: the used cutting fluid can not be dumped at will. It should be disposed to avoid

environmental pollution.

Fig.18 Cooling system diagram

8.2 Chain type automatic chip conveyor (optional)

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chain type automatic chip conveyor isavailable according to customer requirement

8.3 Spindle coolant

The machine is equipped with spindle cooler to cool down spindle temperature through

coolant circulation, the result is removing the heat produced by high speed to keep

longer bear life and reducing the inaccuracy caused by thermal spindle deformation. For

more information please refer to the oil cooler operation manual supplied with the

machine compiled by the manufacture.

9 CNC rotary working table (optional)

4 axes simultaneous operation and indexing for certain rotary processing is realized with

installing CNC rotary table on this machine.With CNC indexing table, chuck and tailstock

center working together, disk and cylinder shape workpieces are processed like spiral

groove milling with 4 axes simultaneous operation. Indexing CNC rotary table is also

available with processing disk shape parts or with multi angles and surfaces.

10 Installation

10.1 Working environment

The working environment has a direct impact on the performance and service life of the

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machine. High temperature will reduce the service life of the electric element, high

humidity will cause the malfunction of CNC system and low temperature will increase the

oil viscosity and deteriorate the working condition of the pump. In addition, it’s necessary

to protect the CNC system against the electromagnetic pulse generated from

wire-electrode cutting, electric welding, etc. So the machine tool should be installed in

the workshop with good condition where the temperature, humidity, vibration, dust, etc.

are under control. To facilitate the maintenance and inspection, reserve appropriate

space for the machine tool.

Working environment of the machine tool

Environment temperature 10℃ ~ 40℃

Maximum temperature variation Less than 1℃ /min

Relatively less than75%，for a short time,

Environment humidity
maximum 95%

Input power supply AC3Φ220V 60Hz

10.2 Outline drawing of the machine tool See Fig. 19
2640
2466

2037

2340 2020
2385

Fig.19 Outline drawing of the machine tool

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10.3 Outline drawing of the machine tool(optional)

Fig.20 Outline drawing of the machine tool（Chip Conveyor）

10.4 Basic description and foundation drawing

10.4.1 The deeper the concrete foundation, the better the stability of the machine tool. Notice that

the there should not be chap in the concrete foundation.

10.4.2 Pre-measure and reserve the position of foundation bolt hole and adjusting hole. The hole

reserved had better be wedge-type and coarse to ensure the optimum strength after

grouted.

10.4.3 When grouting the concrete, reserve the earth hole and embed a copper bar of 2m long

and 15mm in diameter.

10.4.4 Install the machine 7-10 days after grouting the foundation. (The days are decided by the

specific conditions of the installing place)

10.4.5 Place the foundation bolt in the reserved hole after leveling the machine tool and then gout

the instant-dry cement.

10.4.6 Fine level the machine tool 7 days after the grouting.

The weight of the machine tool is 4 t. For the foundation drawing, see Fig. 21.

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A-A ( )
( )
6-M16
600

300
350
500

210
A A

2660
2160
860

2340
140

200
350 100
540 540 470

485
600

2020

Fig.21 Foundation drawing

10.5 Lifting and others

Lifting hole is cast in the base and lifting plate is mounted on the column. When lifting the

machine, prepare a solid lifting bar (45# steel) with a size of φ70×2400mm. Pass the

lifting bar through the lifting holes and lift the machine by hoisting cable. The carrying

capacity of the cable and the lifting capacity of crane shouldn’t be less than 8t. Remove

the coolant tank before lifting. To avoid the crash of guarding cover, electrical cabinet

and the machine tool, stretch the upper end of the cable and put soft wood or other soft

materials in the contacting area of machine tool and cable to protect the lacquer surface.

For the lifting drawing, see Fig. 22

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Fig.22 Lifting drawing

Support and tighten the moving parts before lifting and transporting the machine tool.

When the machine is placed in the installing place, take away the supports and

fasteners.

The sequence of taking away the supports and fasteners:

1) Move up the spindle head and then take away the supports and fasteners of the

spindle.

2) Take down the connecting plate of saddle and base.

3) Take down the connecting plate of saddle and table.

After taking apart the fasteners, clear away the rust preventive oil on the external

machining surface, e.g. guide way, spindle taper hole, etc.

Fill the lubricating pump, hydraulic oil tank, coolant tank with designated hydraulic oil or

coolant before starting the machine. Air pipe should be installed in the air source inlet in

rear of the column. The air pressure supplied is 0.5~0.7MPa.

10.6 Installation

10.6.1 Place the sizing block before laying down the machine. Make sure the sizing block support

the machine tool evenly.

10.6.2 Clear away the rust preventive oil with clean cotton cloth and then coat the machine tool

with lubricating oil.

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10.6.3 Confirm the specification of voltage, frequency and phase and ground before turning on

the machine tool.

10.6.4 Connect the air pipe and adjust the air pressure to 0.6~0.8MPa.

10.6.5 Connect the chip conveyor, cooling pump and hydraulic station and confirm the rotary

direction.

10.7 Level the machine

To ensure the accuracy, level the machine by following the steps:

1) Place the gradienter on the center of the table.

2) Adjust the adjusting bolts in the four corners, move X-axis and Y-axis repeated until

the machine tool is level.

3) Adjust other bolts and make the weight of the machine tool distributed evenly in each

bolt without affecting the level of the machine tool.

4) The level range is 0.03mm/m

5) In order to maintain the accuracy of the machine, check and level it at half-yearly

intervals.

11 Mechanical maintenance

In order to keep the performance and level of the machine, pay special attention to

routine maintenance.

Oil the machine tool according to the utilizing states. Select the oil with approximate

viscosity as the oil viscosity changes as the temperature changes in different seasons.

A small problem will lead to the scrap of the workpiece and even endanger the accuracy

and service life of the machine tool, so it’s necessary to do routine maintenance and

inspection. Should any unsolvable problems occurs, contact Neway CNC Equipment

（Suzhou）Co., Ltd. or the agent.

11.1 Daily maintenance

11.1.1 Check the liquid level of lubricating oil and coolant and top up, if necessary.

11.1.2 Check if the lubricating system, cooling system and chip conveyor are in normal working

state.

11.1.3 Check if the spindle orientation and spindle taper hole huffing are normal in MDI mode.

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11.1.4 Check if the motion of tool clamping and unclamping is normal in manual mode.

11.1.5 Clean the spindle taper hole with dust-free paper.

11.1.6 Clean the outward limit switches and blocks.

11.1.7 Clean chips in time keep clean of the vicinity of the machine tool.

11.1.8 Check if the pneumatic pressure is normal and draw off the water disposed by the air

source processing duplex.

11.1.9 Check if the electric system and cooling fan of the electrical cabinet are normal and if the

filter is jammed.

11.1.10 Check if the motion of tool magazine rotation and tool change are normal in manual mode.

11.1.11 Check if reference return and the action of each axis are normal in manual mode.

11.2 Weekly maintenance

11.2.1 Clean or replace the filter screen in the controller and heat exchanger.

11.2.2 Clean or replace the coolant.

11.2.3 Check if the coolant tank is clamped and clean the chip.

11.3 Monthly maintenance

11.3.1 Check the lubricating conditions of the three-axis guide ways and make sure the

lubricating is good.

11.3.2 Check or clean the proximity switch.

11.3.3 Adjust the tension of the spindle belt.

11.3.4 Check if the indicating and warning signs on the machine tool are clear.

11.4 Half-yearly maintenance

11.4.1 Check if the servo motor and spindle run normally and check if they are noisy.

11.4.2 Check if the input voltage is normal and the inside of the electrical cabinet is clean.

11.4.3 Check if the motor of chip conveyor clean the filter, if necessary.

11.4.4 Check if each part of the tool magazine is normal and key parts are damaged.

11.4.5 Check the level of the machine.

11.5 Yearly maintenance

11.5.1 Check the cam box and fill it with 30# hydraulic oil, if necessary.

11.5.2 Clean or replace the filter of the lubricating pump.

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11.5.3 Check if the lubricating pipes and joints and make sure there is no oil leak or damage.

11.5.4 Check if the bolts and joints connecting the electric device are tight.

11.5.5 Take down and clean the chip conveyor every year.

11.5.6 Check if the connection of protective cover is tight.

11.5.7 Check if the pneumatic pipeline leaks.

11.5.8 Check if the detecting switches and electromagnetic valves in the spindle are normal.

11.5.9 Check if the connection of key parts, e.g. motor stand, bearing stand, etc. is tight.

12 Utilization

The machining accuracy, efficiency and automatization of the machining center depend

on the quality of the mechanical part and the performance and stability of the CNC

system. Besides, in order to make full use of the machine tool, it’s essential to have a full

knowledge of the characteristics and machining technology of the machine tool and use

the machine tool reasonably. The following operating methods introduced is for

reference.

12.1 Operation

The most operation can be realized by pressing the keys and buttons on the operating

panel and control panel (For details, see Instruction Manual Electrical Part). Only the

following two kinds of operation should be carried out manually.

1) Unclamp the tool manually

In most circumstances, tool is loaded to the spindle by manipulator. In special

circumstances, it’s needed to load the tool to spindle by hand by pressing the

button at the right side of the spindle head in manual mode. (When the indicator

light lights, the tool is unclamped and vice versa.)

Note: The button is invalid when the machine is in machining state.

2) Tool magazine manual control

To facilitate the adjusting of the machine, a group of keys on the protective cover

at the lower right of tool magazine are designed for manual control of the tool

magazine. For the detailed operation, see Instruction Manual (Electrical Part).

12.2 Select the workpiece for machining

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The geometry and dimension of the workpiece should be in accord with chuck and the

travel of the machine tool. To raise the economic interest, consider the following

principles:

1) Small batch production when the workpiece is put into production repeatedly

To machine a workpiece by machining center, the time of prepared procedure such

as technology preparation, programming, etc. is long, but the tool, fixture,

technologic documents and program sheet can be repeatedly used. Therefore,

when the workpiece is put into production after test cutting, the production cycle and

machining time will be reduced dramatically.

2) The machining batch should be more than the economic lot size

Compared to the common machine tool, the flexible working time of a single

workpiece of a machining center is shorter while the adjusting time is longer, so it’s

uneconomical if the batch of the workpiece is small.

Machining Center Preparation Time –

Common Machine Tool Preparation Time

Economic = ———————————————————————————————————————

Lot Size K×（Machining Time of a Single Workpiece

in a Common Machine — Machining Time of

a Single Workpiece in a Machining Center）

Thereinto, Machining Center Preparation Time = Technology Preparation Time +

Debugging time

Debugging time = Machine Tool Adjusting Time + Workpiece Program Test Run

Time + Test Cutting Time + Fixture and Auxiliary Device

Validating Time

Here, only the adjusting time is part of machine tool starting time. For the workpiece

needing repeated production, the time of technology preparation and program

preparation should be divided by repeated production time. The machining time of a

single workpiece in a common machine is the summation of each NC machining

process time. and appropriately consider the influence of concentrating the

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procedure to short the whole processing cycle.

The compensation factor K should be at least 2, considering that the machining

center is much more expensive than the common machine tool. K should be larger

as the acquired skills improved.

3) Try best to do the integrated machining such as milling, boring, drilling, reaming,

tapping, etc.

4) The diameter of the workpiece for precision boring shouldn’t be more than φ120 mm

for the maximum tool change capacity of ATC device is φ120 mm. To machine the

bigger hole, load and unload the tool manually or use circular interpolation method

to mill the hole, but the precision is lower.

5) The geometry and dimension of the machine tool should be in accord with the size

of table and travel.

6) Consider the balance of plant capacity.

7) The small but with complex geometry workpiece that is unable to be machined in

common machine tool or uneasy to obtain a stable machining accuracy,

12.3 Decide which part to machine

12.3.1 Before machining, determine which working procedure should be done in the machining

center and button down the relationship of the procedure and its last and next one. For

example, which kind of datum face and hole should be machined before the workpiece is

machined in the machining center and what working procedure, allowance, etc. are left

after the workpiece is machined in the machining center.

12.3.2 Don’t use the machining center if other machine tool is more suitable and efficient to

machine the workpiece.

12.3.3 Decide whether to finish the machining once or twice in a single setup according to the

tool number needed and the requirement of workpiece accuracy and heat treatment.

12.3.4 Compile the process chart

The format of the process chart is manifold. The user can develop an appropriate format

according to the production custom and need. The process chart is the gist of program

list, tool adjusting list and machine tool adjusting and the working content of the operator.

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12.3.5 Be familiar with the relevant stipulations of the use of machine tools

1) The setting of each coordinate origin, the direction of each coordinate axis, the

setting of workpiece coordinate system and the travel range.

2) Range of spindle speeds instruction S

3) Feed range and instruction F

4) Tool and instruction T, tool change instruction

5) Cutting criterion

6) The working principle and instruction list of CNC system

7) The machining characteristics and operating methods of the machine tool

8) The approaching distance of tool (the distance from tool nose to the surface to be

machined after rapid traverse )

It’s recommended that:

Drilling, boring and reaming on the processed surface: 1~3mm

Drilling, boring and reaming on raw casting surface: 5~8mm（decided by the

allowance of the surface）

Tapping: 5~10mm

Milling: 5~10mm

12.3.6 Decide the sequence of working procedure

As the many process steps and tools are needed in the machining center, the

reasonable sequence arrangement of the working procedure is important to the

machining accuracy, machining efficiency and quantity of the tool. The sequence of the

working procedure is influenced by the following factors:

1) First do the heavy cutting and roughing, then the machining with little heat

productivity and low accuracy requirement (e.g. drilling a small diameter hole,

tapping, etc.), and finally finishing.

2) Machine the workpiece in the adjacent position first to shorten the idle travel

distance. Consider the tool moving track to reduce the displacement of each

coordinate axis.

It’s recommended to arrange the working procedure according to the following sequence:

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Mill the large end face (rough milling and finish milling is done independently) → rough

boring/semi-finish boring → end mill machining → drilling → tapping → hole finishing

(reaming, boring, finish milling)

12.3.7 Tool selection

The tools used in the machine include universal cutter and universal connecting toolbar.

Select the appropriate tool according to the requirement of machining and the process

chart, determine the tool position in the tool magazine (mark the tool station number) and

map out the tool card (used for tool preparation, adjustment and loading).

Note 1: if the tool length and deviation value can’t be decided at once, adopt the

following two methods:

1) First, set a nominal dimension, and then add tool compensation when programming.

Program with nominal dimension and modify the dimension by tool compensation

value (the difference value of nominal dimension and measured value).

2) Tool length is not written in the tool card and is zero in the program. Designate a

tool compensation number for each tool and input the measured tool length in the

tool compensation data list after the tool is prepared.

Note 2: Tool length, which is the tool compensation value or the measured length in the

working area after tool is loaded in the spindle, is the axial dimension from cutting edge

to spindle end face.

For the specification and dimension selecting of the toolbar, please refer to the

production sample provided by the toolbar manufacturer.

Special tools are used if the requirement of machining is special. Consider the

interchangeability of each kind of tool when selecting the tool, e.g. end milling with

circular interpolation besides boring can be used to machine the large sized hole.

Therefore, the user should have a full knowledge of the tool series and performance of

the machine tool and select the tool flexibly.

12.3.8 Cutting data determination

1) Take the cutting data in the Tool Cutting Manual for reference and modify it

according to the on-site experience. Use the data in the cutting database as much

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as possible as the development of automatic programming.

2) Modify the data according to the rigidity of the machining—technology system

(tool—workpiece—fixture—machine tool).

3) Modify the data considering tool service life. In medium and small batch production,

try best not to sharpen or replace the tool in a batch to reduce the adjusting time. To

reduce the machining time of heavy load cutting tool, e.g. end mill, rough boring

cutter for deep hole, etc., use larger cutting data to shorten the incorruptibility of the

tool to half or one third.

12.3.9 Tool preparation

Prepare the tool according to the technologic card, the steps are as follows:

1) Select the toolbar and cutter according to the card;

2) Sharpen the cutter or the boring cutter head;

3) Assemble the cutter head, toolbar and end taper and label it with the tool number;

4) Adjust the tool length to the set dimension, measure the tool length and record it in

the tool card. For high precision cutting, e.g. finish reaming, finish boring, etc. do

test cutting according to the selected cutting data and modify the adjusting data

according to the test cutting result.

12.3.10 Compile the “machine tool adjusting list”（it can be included in the process chart）

1) Designate the group number and the concrete tool compensation value when using

tool radius compensation and tool length compensation.

2) The application of on-site selecting switch（e.g. mirroring switch, block skipping

switch, select to stop switch, etc.）

3) The cooling method of the workpiece (which kind of coolant should be used)

4) Precautions of tool number setting, etc.

12.3.11 Coordinate calculation and working track diagram

Do the calculation according to the drawing. Calculate the input data of the CNC system

according to the working path and allowable programming error. The moving path is

simple for the point machining, simple dimension conversion is sufficient for the

programming, which can be further simplified if a reasonable workpiece coordinate

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position is selected and incremental method and absolute method are flexibly used.

Numerical calculation is the premise of programming for contour machining and it has a

close relationship with the workpiece contour and interpolating method of the CNC

system. The linear—circular interpolation system simplifies the calculation of the

workpiece composed by line and arc, just to calculate the connecting points of each

geometric element; Linear or circular approximation is used for the workpiece composed

by other curves. For the complicated tool motion, tool path can be drawn for the

programming.

12.4 Compile the program list

For details, see the Programming Manual.

12.5 Program input

There are many ways to input the program, among which, using the MDI device is a

simple way, but it spends more time and take up the machine starting time and it’s

error-prone for the long program.

12.6 Dry run

To check the program, test run the program after adjusting the machine. The methods for

test run are as follows:

1) Press “MACHINE LOCK” key to check the program.

2) Press “M,S,T LOCK” key to check if the axial movement meets the requirement. To

check the moving track, press “DRY RUN” to shorten the running time.

3) Press “Z-axis Lock” key to check the M, S and T functions.

4) Check if tool compensation and the sign are appropriate. Check if interference

exists in the motion of tool and each component or fixture.

5) The test run time shouldn’t be long. Try best to reduce the malfunction especially

the damage to the machine tool, workpiece, or tool.

12.7 Test cutting

When machining, check if the cutting data (can be modified by the OVERRIDE button),

machining sequence and tool path are reasonable. Modify the program after the

automatic cycle is over. Check the machining accuracy of the workpiece and take

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measures such as finish adjusting tool, modifying tool length and radius compensation,

editing the program, etc. to meet the accuracy requirements.

For the safety concerns, reduce the rapid traverse speed (in control of RAPID

FEEDRATE key).

12.8 Does after machining

The modified program after test cutting can be used for workpiece machining in batches.

After machining, store it in the memorizer. The program validated and modified after

production should be saved in the floppy disk or memory card for further use. In addition,

the technology document, program list, etc. should be amended for further use.

13 Common failures and trouble shooting

13.1 Common failures and trouble shooting of feed system

No. Failures Reasons Trouble shooting

Adjust the gland to

Lead screw bearing gland
compact the end surface
situation is not good
of the bearing
Lead screw bearing may be Replace the bearing with
broken a new one

Ball screw The coupling of motor and lead Tighten the coupling and
1 screw is loosened lock the screw
pair noise
Improve the lubricating
Lead screw lubricating is not
condition and ensure the
good
lubricating oil is sufficient

Ball is broken Replace it with a new one

Adjust the axial clearance

The axial preload is overlarge
and preload
Adjust the position of lead
Lead screw is not parallel to screw support to make
Ball screw guide way lead screw parallel to
2 guide way
not flexible
The axis of nut is not parallel to Adjust the position of nut
guide way rest

Screw bending deformation Adjust the lead screw

Lubrication
Oil leak, or lubricating system is Check the lubricating
3 of ball screw
blocked pipeline
not good

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13.2 Common failures of tool magazine and manipulator

Failures Reasons

Coupling connecting motor shaft and worm shaft

becomes loosened.
Frequency converter fails. Check if the input and output
voltage is normal.
Tool magazine No control output of PLC. The relay in the interface
does not rotate board is probably ineffective.

Mechanical connection is too tight.

Voltage of electric network is too low.

Tool
magazine Tool magazine
failure can not turn to Motor rotation failure, error in transmission mechanism.
the right position
Adjusting screw in the tool pot is loosened or spring is
Tool pot can not so loosened that the clamping force is insufficient.
clamp tool
Tool overweight

Fork position is incorrect resulting from inappropriate

Tool pot is not in adjustment and installation or excessive machining
right position error
when it goes up
Feedback signal is wrong resulting from the incorrect
and down
installation of limit switch or inappropriate adjustment.

Jaw spring force tool small

Tool is not Nut loose

clamped and
usually drops Tool overweight

Manipulat Lock not function

or failure
Tool can’t be Jaw spring is too tight and jaw can’t draw back. Loose
unclamped when the nut and the maximum load shouldn’t exceed the
clamped rated value.
Spindle not back to tool change point or tool change
Tool drops point shifts. It’s necessary to reset the tool change
during tool point.
change process Tool clamping or unclamping begins even though
manipulator not seize the tool correctly.

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13.3 Common failures and trouble shooting of main drive system

No. Failures Reasons Trouble shooting

1 Spindle heating Bearing is broken Replace it

The transmission belt
Tension the transmission
connecting to motor and
belt
Spindle stops spindle is over-loosened
2 during heavy There is oil on the surface of Wipe up after clearing
cutting transmission belt away the oil with gasoline
Transmission belt is ineffective
Replace it
after a long time utilization

Spring gripper is broken Replace it

3 Tool not clamp Belleville spring is invalid Replace it

Pull stud bolt in the tool holder

Replace it
is over-long
Tool is not
The pressure of cylinder and Adjust the pressure and
4 unclamped
stroke are insufficient. the position of travel switch
after clamped
Spindle head Transmission belt is loosened Adjust or replace the
5
too noisy or broken transmission belt
13.4 Common fault and solution of coolant system

No Failure Description failure cause

1、water level in tank is lower than
1、water flow is small or Intermittent
required
1 2、filter screen is blocked 2、filter screen is blocked

3、air stuck in pump 3、air stuck in pump

1、no water from coolant /chip conveyor 1、water level in tank is lower than
pump required
2 2、filter screen is blocked 2、filter screen is blocked

3、pump is broken 3、pump is broken

1、pump is stuck by foreign

1、no rotate on water pump
objects
3
2、circuit failture 2、circuit failture

3、pump is broken 3、pump is broken

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13.5 Common fault and solution of pneumatic system

No Failure failure cause Solution

Air source Increase Air source pressure
Air source
Pipe leak-off Replace broken sealing element .
1 pressure
pressure switch Replace the pressure switch
alarm
Alarm : pressure Change the pressure
Connection Right connection
lower voltage Connect to right power voltage
solenoid valve Pipe connection Correct connection
2
is not working sealing element Replace bad broken sealing element
foreign matter Cleaning foreign blocks
Spring is broken Replace spring
input and output change directions
can not adjust Spring is broken Change spring
3 reducing foreign matter Cleaning foreign blocks
valve sealing element Replace broken sealing element
reducing valve is Turn on the reducing valve
one-way inlet and outlet change directions
4
throttle valve Valve is broken Replace bad one
Air source increase air source pressure
with no air
5 wrong pipe correct and connect again
curtain
reducing valve deal with reducing valve trouble shooting
Air source Increase air source pressure
6 No air coolant valve turned off Turn on valve
solenoid valve deal with solenoid valve trouble shooting
Tools Change Air source Increase air source pressure
7
cylinder not solenoid valve deal with solenoid valve trouble shooting
Air source Increase air source pressure
wrong pipe Re-coonect pipes
No air through
8 solenoid valve deal with solenoid valve trouble shooting
spindle
throttle valve deal with throttle valve trouble shooting
reducing valve deal with reducing valve trouble shooting
Air source Increase air pressure
magazine
wrong pipe Re-coonect pipes
9 refuses to
solenoid valve deal with solenoid valve trouble shooting
change tools
tool change Replace tool change cylinder
10 no air refill air tank looses Replace air tank

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13.6 Alarm messages of CNC system

1) 1000 EMERGENCY STOP

Check if the EMERGENCY STOP button is pressed or not.

2) 1001 SPINDLE ALARM

The signal is sent from NC. Check the parameter and external signals.

3) 1004 AIR-PRESSURE ALARM

System pressure drops and exceeds stated pressure range, check the pressure

switch of the air source (X3.3 is 1 normally), make sure air source is provided well

and the pressure switch works well.

4) 1005 LUBRICATE.LOW OIL POS

Lubricating oil is not enough as stated, check the liquid position switch (X3.2 is 0

normally), make sure lubricating oil is sufficient and the liquid position switch works

well.

5) 1010 AIR-CONDITION NOT ON

Air-condition breaker is not on.

6) 1011 T-CODE ERROR

The input tool number is not standardized or it is more than 20.

7) 1012 ARM COUNT ALARM

When the tool magazine rotates, tool magazine counting signal is abnormal or tool

magazine stops at the incorrect position. Check if tool magazine counting signal

（X3.4）is normal.

8) 1013 TOOL CLAMP/UNCLAMP ERROR

When spindle needs to clamp/unclamp tool, the system does not detect the tool has

been clamped/unclamped;

Check if the tool is clamped /unclamped;

Check if tool clamping/unclamping solenoid valve and hydraulic system work

normally;

Check the circuit of tool clamping/unclamping detection (tool clamping detection

signal: X3.7, tool unclamping detection signal: X8.0).

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9) 1014 ATC NO HOME ALARM

Manipulator is unexpectedly stopped during tool change process or the induced

switch (ATC original point detection signal: X3.5) of manipulator back to original

point is abnormal.

10) 1017 MAG-ROT OVERTIME

Tool magazine stops at the wrong position.

Check if the tool magazine stopping position is right.

11) 1020 ARM-ROT OVERTIME

Manipulator stops at the wrong position.

Check if the manipulator stopping position is right.

Check if the position detection signal of manipulator and the circuit are normal.

(Manipulator original point detection signal: X3.5; manipulator brake signal: X3.6;

manipulator tool clamping signal: X8.1).

12) 1021 AXIS NO HOME ZERO

M06 instruction is executed when Z-axis doesn’t return to the second original point

of the machine tool.

Return Z-axis to the second original point (G91 G30 Z0) before executing M06

instruction.

13) 1022 M06 WAIT MAG T

There is no corresponding T code during tool change process.

Check if the tool number in the program exists in tool magazine;

Find out the reason and take measures.

14) 1024 TOOL CUP UP ERROR

Tool pocket doesn’t clamp the tool as T code is designated.

Check if the relevant electromagnetic valve is normal, the proximity switch is

damaged and check the relevant circuit. (Tool bush clamping tool detecting signal:

X8.3) and confirm that the air resource is right.

15) 1025 TOOL CUP DOWN ERROR

Tool pocket is not down when M06 is instructed.

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Check if the relevant electromagnetic valve is normal, the proximity switch is

damaged and check the relevant circuit. (Tool bush clamping tool detecting signal:

X8.2) and confirm that the air resource is right.

16) 1027 LUBRICATE NOT ON

Lubricating pump breaker is not on.

17) 1040COOLING FLUID LOW POS

The liquid level of water tank is low.

18) 1041 PULSH PUNP OFF

The contact of chip rinsing pump is off, please check the contactors.

19) 1042 COOLANT PUNP OFF

The contact of cooling pump is off, please check the contactors.

20) 1043 SP FAN OFF

The breaker of spindle fan is not on.

21) 1044 TURN PLATE ERROR

When the indexing pallet relaxes or locks, the inspection signal is not confirmed.

(Confirming signal: X5.2 or X5.1).

22) 1050 SP POS ERROR（F45.7）

Spindle positioning signal miss during the tool change process, just check if the

shield is good, check if tool changing position and 2nd reference point are right.

23) 2050 NC BATTERY VOLTAGE LOW

When this alarm appears, firstly observe the system state appearing in CNC state

display column (see “*” on the picture above). If word “BAT” appears, it means battery

voltage of control cell is low, so the battery needs to be replaced when the machine is

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on. If word “BAT” does not appear, it means driving battery voltage is low, so replace

the battery.

Note: the machine tool must be powered on when replacing the battery.

13.7 Quick view of alarm messages

1000 EMERGENCY STOP

1001 SPINDLE ALARM

1004 AIR-PRESSURE ALARM

1005 LUBRICATE . LOW OIL POS.

1010 AIR-CONDITION NOT ON

1011 T-CODE ERROR

1012 ARM COUNT ALARM

1013 TOOL CLAMP/UNCLAMP ERROR

1014 ATC NO HOME ALARM

1017 MAG-ROT OVERTIM

1020 ARM-ROT OVERTIME

1021 Z AXIS NO HOME ZERO

1022 M06 WAIT MAG T

1024 TOOL CUP UP ERROR

1025 TOOL CUP DOWN ERROR

1027 LUBRICATE NOT ON

1040 COOLING FLUID LOW POS

1041 PULSH PUMP OFF

1042 COOLANT PUMP OFF

1043 SP FAN OFF

1044 TURN PLATE ERROR

1050 SP POS ERROR

2050 NC BATTERY VOLTAGE LOW

14 The main brought-in components

The main brought-in components are supplied by branded suppliers. The following table

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is the list of the main brought-in components:

List of main brought-in components

No. Name Specification parameter and model Quantity Remarks

Made in
1 Spindle CAT40-10000RPM 1
Taiwan
Tool magazine DF-R4DE4NW13A03（＃40×20T） Taiwan
2 1
delta
Lead screw Japan
3 20TAC47BSUC10PN7B 12
bearing NSK
Ball screw of Taiwan
4 R32-16T4-FSDC-806-1027-0.008 1
X-axis PMI
Ball screw of Taiwan
5 R32-16T4-FSDC-604-825-0.008 1
Y-axis PMI
Ball screw of Taiwan
6 R32-10T5-FSDC-704-922-0.008 1
Z-axis PMI
Linear guide way Taiwan
7 MSA30A2DDF0A+R1160-20/20PAⅡ 1
of X-axis PMI
Linear guide way Taiwan
8 MSR30E2DDF1A+R840-20/20PAⅡ 1
of Y-axis PMI
Linear guide way Taiwan
9 MSR30LE2DDF1A+R960-20/20PAⅡ 1
of Z-axis PMI
Made in
10 Lock nut YSFM /SWT F 20×1.5 6
Taiwan
Made in
11 Lock nut YSFM /SWT F24×1.5 3
Taiwan

15 Attached figure

Fig.23 Base unit

Specification of base unit：

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29 20052850 Front guideway,VM702S0101-72,45 M36883
28 20052844 Baffle plate,VM702S0101-71,Q235-A M36879
27 20052842 Base,VM702S0101-1,HT300 M36878
26 20051890 After guideway,VM601D0101-72,45 M36706
25 20051889 Guideway of Y axle,VM601D0101-71 M36705
24 20044251 Soket head cap screw,GB/T70.1 M5*16,12.9-ZN
23 20043674 Hose clamps,JB/T8870 d32
22 20043558 Oil collected box,VM903H0102-72,Q235-A M35904
21 20043556 Oil water separator,VM903H0102-71,Q235-A M35903
20 20040615 Back plate,VM702S0100-73,Q235-A M35658
19 20039624 Press block,SWT K2
18 20036821 Supporting block ,VM702S0100-71,45 M35425
17 20028035 Drag chain,IGUS 1400.038.035.0
16 20028030 After cover,VM601D0100-72 M15707
15 20028029 Font cover,VM601D0100-73 M15706
14 20014123 Screw,NWMJ21-00-00 M6*12
13 20006959 Hose strengthened by steel wire ,OUYA 19
12 20006583 Soket head cap screw,GB/T70.1 M6*12,12.9
Right-angled pagoda-shape
11 20006336
connectors,OUYA G3/4(外)-19
10 20005332 Soket head cap screw,GB/T70.1 M8*40,12.9
9 20004106 Soket head cap screw,GB/T70.1 M6*16,12.9
8 20003129 Lock nut,,VM1204H0100-78,45 M01702
7 20003128 Sizing screw,VM1204H0100-77,45 M01701
6 20001057 Soket head cap screw,GB/T70.1 M8*30,12.9
5 20000549 Sizing block,VM905T0100-2,HT250 M00164
4 20000399 Plain Washer,GB/T97.2 6,140HV-ZN
3 20000395 Spring washer,GB/T93 6,65Mn-ZN
2 20000394 Spring washer,GB/T93 5,65Mn-ZN
1 20000373 Plain Washer,GB/T97.2 5,140HV-ZN
NO. Material No. Material description Drawing No.

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Fig.24 Column unit

Specification of column unit：

12 20052955 Guideway of Z axle,VM702S0151-71 M36902

11 20052847 Column,VM702S0151-1,HT300 M36881
10 20052043 Oil collected box,VM601D0151-72,Q235-A M36776
9 20039625 Press block, NWMQ93-01-00 A
8 20028043 Protective curtain,VM601D0150-72 M15719
7 20028041 Guide plat,VM601D0150-74,Q235-A M15717
6 20028040 Guide plate,VM601D0150-73,Q235-A M15716
5 20028039 Lifting plate,VM601D0150-76,45 M15715
4 20018675 Hexhead bolt,GB/T5782 M24*90,10.9
3 20001426 Plain washer,GB/T97.2 24,140HV
2 20001425 Spring washer,GB/T93 24,65Mn
1 20001057 Soket head cap screw,GB/T70.1 M8*30,12.9
NO. Material No. Material description Drawing No.

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Fig.25 Saddle unit

Specification of saddle unit：

19 20061236 Baffle plate,VM702S0401-72,Q235-A M37549

18 20052956 Guideway of X axle,VM702S0401-71 M36903
17 20052852 Saddle,VM702S0401-1,HT300 M36885
16 20039625 Press block, NWMQ93-01-00 A
15 20039624 Press block,SWT K2
14 20037316 Baffle plate,VM702S0400-76,Q235-A M35474
13 20037315 Cover,VM702S0400-75,Q235-A M35473
12 20037314 Bracketing,VM702S0400-74,Q235-A M35472
11 20037313 Assisted Guideway of X axle,VM702S0400-73,45 M35471
10 20037312 Guideway cover of X axle,VM702S0400-72 M35470
9 20028153 Shelf of drag chain,VM601D0400-75,Q235-A M15799
8 20014123 Soket head cap screw,NWMJ21-00-00 M6*12
7 20006583 Soket head cap screw 钉,GB/T70.1 M6*12,12.9
6 20006103 Soket head cap screw,GB/T70.1 M10*40,12.9
5 20004106 Soket head cap screw,GB/T70.1 M6*16,12.9
4 20001057 Soket head cap screw,GB/T70.1 M8*30,12.9
3 20000672 Soket head cap screw,GB/T70.1 M8*20,12.9
2 20000046 Plain washer,GB/T97.2 6,140HV
1 20000039 Spring washer,GB/T93 6,65Mn
NO. Material No. Material description Drawing No.

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Fig.26 Table unit

Specification of table unit：

13 20052854 Table,VM702S0451-1,HT300 M36887

12 20044003 Screw,GB/T77 M6*8,45H
11 20043717 Plug,VM903H0452-72,45 M35928
10 20039624 Press block,,SWT K2
9 20037284 Back plate,VM702S0450-73,1Cr13 M35456
8 20037283 Back plate,VM702S0450-72,1Cr13 M35455
7 20037282 Back plate,VM702S0450-71,1Cr13 M35454
6 20014123 Screw,NWMJ21-00-00 M6*12
5 20010101 O-ring,GB/T3452.1 15*2.65
4 20006583 Soket head cap screw,GB/T70.1 M6*12,12.9
3 20006103 Soket head cap screw,GB/T70.1 M10*40,12.9
2 20004106 Soket head cap screw,GB/T70.1 M6*16,12.9
1 20000046 Plain Washer,GB/T97.2 6,140HV
NO. Material No. Material description Drawing No.

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Fig.27 Spindle head unit

Specification of spindle head unit：

44 Spindle motor
43 20072003 Font cover,VM702S0200-81,Q235-A M38182
42 20062619 Bracket,VM702S0201-71,Q235-A M37604
41 20060125 Plate for switch,VM1103HR0201-73,Q235-A M37463
40 20052856 Spindle head,VM702S0201-1,HT300 M36889
39 20043492 Casement window,VM903H0209-51, organic glass M35889
38 20040232 Interface plate,VM702S0200-80,45 M35640
37 20039625 Press block, NWMQ93-01-00 A
36 20039621 Quantitative oiler,BIJUR ZJBM 18310C-40T
35 20039619 Quantitative oiler,BIJUR ZJBM 18310C-20T
34 20037786 Tool unclamp cylinder,HINAKA,DJ2A-160N15T3L1V
33 20036796 Bracket for drag chain,VM702S0200-73,Q235-A M35420
32 20036789 Bracket,VM702S0200-79,Q235-A M35419
31 20036787 Cover ,VM702S0200-78,Q235-A M35418
30 20036782 RIGHT cover,VM702S0200-77 M35415
29 20036774 Top cover,VM702S0200-75,Q235-A M35410

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28 20036754 Down cover,VM702S0200-74,Q235-A M35409
27 20036709 Left cover,VM702S0200-76 M35388
26 20036703 Plate for spindle motor ,VM702S0200-72,45 M35386
25 20036699 Tool unclamp cylinder seat,VM702S0200-2,HT250 M35385
24 20036501 Spindle unit,VM702S0200-71 M35374
23 20030817 Hexhead bolt,GB/T5783 M10*35,10.9
22 20022302 Water dispensed block,VM1706H0200-71,45 M15368
21 20014123 screw,NWMJ21-00-00 M6*12
20 20012064 Hexhead bolt,GB/T5783 M10*40,10.9
19 20010952 Oil dispensed block,BIJUR 22668J-6
18 20009681 Soket head cap screw,GB/T70.2 M5*12,8.8-ZN
17 20006583 Soket head cap screw,GB/T70.1 M6*12,12.9
16 20004106 Soket head cap screw,GB/T70.1 M6*16,12.9
15 20003237 Soket head cap screw,GB/T70.1 M16*60,12.9
14 20002993 Soket head cap screw,GB/T70.1 M8*25,12.9
13 20002247 Right-angledconnectors,,BIJUR 22646-1T
12 20001246 Soket head cap screw,GB/T70.1 M12*30,12.9
11 20001057 Soket head cap screw,GB/T70.1 M8*30,12.9
10 20000672 Soket head cap screw,GB/T70.1 M8*20,12.9
9 20000659 Adjusting block,VM905T0200-71,45 M00236
8 20000631 Hexhead nut,GB/T6170 M10,10
7 20000254 Soket head cap screw,,GB/T70.1 M10*50,12.9
6 20000046 Plain Washer,GB/T97.2 6,140HV
5 20000044 Plain Washer,GB/T97.2 16,140HV
4 20000041 Plain Washer,GB/T97.2 10,140HV
3 20000039 Spring washer,GB/T93 6,65Mn
2 20000037 Spring washer,GB/T93 16,65Mn
1 20000034 Spring washer,GB/T93 10,65Mn
NO. Material No. Material description Drawing No.

16 Recirculation and environmental protection

16.1 Metal

All the metal materials of the machine tool are recyclable.

16.2 Plastic

All the plastic materials of the machine tool can be recirculated through melting,

granulating and smashing.

16.3 Glass

It can be centralized treated by the glass suppliers after it is dismantled.

16.4 Other materials

The electrical and other materials can be disposed by the approved organization.

16.5 The scrapped or damaged parts

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The scrapped or damaged parts can’t be abandoned at will. For the unrecyclable parts,

hand them over to the approved organization.

17 Declaration and others

17.1 Declaration

Please notice that due to the continuous improvement of products, the description in this

Instruction Manual may be different from the machine tool delivered.

17.2 Address and contacts

Address: No. 69 Xunyangjiang Road, Suzhou, China

Company: Neway CNC Equipment (Suzhou) Co., Ltd.

Post code: 215153

Service hotline: 0512-6607-6668

Sale hotline: 0512-6607-0166

Fax: 0512-6607-1116

E-mail: cncsale@neway.com.cn

Website: http://www.newaycnc.com

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