Operating Instructions

BA 1118 e

Disc-Type Tool Turret

0.5.476.520

2009-11-26

The present manual is part of the product.

• The manual should be kept in an easily accessible place during the product’s lifetime.
• The manual should be passed on to the next owner /user of the product.
• Make sure that any possible supplement received is duly added to the manual.

Manual Translation
 Type plate on turret housing
1 Classification number (series, size)
2 Identification number
3 Order number

BA 1118 e

Classification number Identification number

(series, size)

0.5.476.520 130 332

132 105
 Table of contents

Liability and warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Use within specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Required skills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Notes on product-specific risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Designation of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Assembly and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1 Basic adjustment for tool drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Central lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Tool holders and spindle units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4 Repairs after fault conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5 Aligning the tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.6 Adjusting the angular encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.7 Replacing the angular encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.8 Proximity switch S7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.9 Cooling lubricant valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.10 Tool drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.11 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.12 Adjusting the tool drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.13 Proximity switches S10 and S11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Basis-BA 2009-11-13

BA 1118 3
Table of contents

Appendix

EP-870
Wiring diagram
Disk-type tool turret

EP-1022
Wiring diagram
Tool drive

SK-919
Diagram of functions
Disk-type tool turret

SK-1587
Diagram of functions
Tool drive

Contact/Order information

4 BA 1118
 Liability and warranty

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

• the notes and instructions contained in these Operating
Instructions are not complied with,
• the product is not used as directed,
→ Use within specifications, page 6
• the product including accessories is incorrectly operated,
• the product including accessories is incompetently repaired
and maintained,
• conversions and functional changes are implemented without
approval by the manufacturer,
• no suitable spindle units are used as stipulated in SAUTER
Product Information PI 29.3, for example,
• no suitable tool disks and tool holders are used,
• no original replacement parts are used.

BA 1118 5
Safety notes

1 Safety notes
The 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.
➣ Operate turret only in perfect condition and in compliance
with the Operating Instructions.

1.2 Required skills

• Work may only be performed on the turret by qualified staff.

These are persons who are able to identify risks and to
prevent possible hazards on the basis of their special
training and their experience (IEC 60 201-1).
• All work on the electrical system is to be carried out by a
qualified electrical engineer only.
• Only trained and competent personnel may work on the
turret; this personnel must have been instructed in
accordance with the Operating Instructions and directly on
the turret.

1.3 Notes on product-specific risks

Setting tasks require a 24 V DC power supply.

Clearing required prior to any work:

➣ Switch the machine off.
➣ Depressurize turret.

6 BA 1118
 Safety notes

WARNING
In the event of a fault or a collision, unexpected rotation of the
tool disk is possible.
Injury hazard.

CAUTION
Do not attempt any further switching operations, if the turret is
damaged, as otherwise considerable consequential damage
may be caused.
➣ Call SAUTER Service.

CAUTION
Functional faults may be caused by an ingress of chips and
contamination.
➣ Close open tool locations and cooling lubricant bores by
means of suitable closing plugs.

For manual operation, turn the motor shaft with the help of a
hexagonal pin wrench, complete with T-grip.

WARNING
A reversal of the moment of the motor results in the
acceleration of the motor shaft. The hexagonal pin wrench may
thus be unexpectedly accelerated.
Therefore, in order to avoid the ejection of the hexagonal pin
wrench and resulting injuries, firmly grip the hexagonal pin
wrench.

1.4 Disposal
➣ Comply with all national and regional disposal regulations
and laws.

BA 1118 7
Product description
Designation of parts

2 Product description

2.1 Designation of parts

3 4

5a

5b
2

6
1 7

8
14
15

13

12

11 10

There may be slight differences compared to the figures.

8 BA 1118
 Product description
Designation of parts

1 Angular encoder
2 Turret motor
3 Proximity switch S7
“Check pre-indexation”
4 Turret housing
5a Electric supply for tool drive motor
5b Flange plate for tool drive motor
6 Cooling lubricant connection
7 Electric supply for turret motor
8 Solenoid

9 Solenoid
10 Proximity switch S10
“Tool drive engaged”
11 Proximity switch S11
“Tool drive disengaged”
12 Tool drive coupling
13 Locating disk
14 Tool drive motor 1)
15 Covering hood for electric components

without fig.:
Connection for central lubrication of tool drive
→ Page 14
Cooling lubricant valve
→ Page 41

1) not included in scope of delivery

BA 1118 9
Product description
Technical data 0.5.476.520

2.2 Technical data

Number of indexing positions 8 or 12 or 16

Perm. tangential torque 1) Nm 3,000

(turret locked)
at calculated safety 1.3

Perm. mass moment of inertia of tool disk, kgm2 1.8 – 7.5 2)

tool holders, and tools

Perm. unbalance (load moment) Nm 63

caused by tool holders and tools

Indexing times 2)
41 + α
i × ---------------- × 0,. 17 + 0,. 1
Theoretical cycle time s n
(unlock /turn /lock)
at rotating angle α [degrees]

Gear ratio i see turret type plate

Motor speed n rpm see motor rating plate

Perm. indexing frequency min-1 10 – 5.5 2)

Operating voltage /mains frequency see motor rating plate

Degree of protection IP 65

Turret mass kg approx. 70

(without tool disk)

Perm. ambient temperature range °C +10 ... + 40

°F +50 ... + 104

Operating pressure for cooling lubricant 3) bar 25

1) The perm. loads refer to processing without load shocks. Whenever processing is subject
to intermittent cuts, shocks or impacts, a significantly reduction in the values needs to be
taken into account.
2) Depending on gear ratio and mains frequency
3) In order to achieve an extended service life of the cooling lubricant valve, it is advisable to
filter the cooling lubricant by ≤ 100µm. 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!

10 BA 1118
 Product description
Technical data 0.5.476.520

Tool drive 1)

Mass (without any motor) kg approx. 65

Gear ratio i 32/32

Perm. speed 2) on tool drive nperm rpm 4 000

coupling

Max. perm. torque 2) 3) Mperm Nm 32 63 63

on tool drive coupling

Transferable power 2) Pperm kW 6 6 8

Suitable for spindle units

coupling profile 16 × 0.8 20 × 0.8 25 × 1.25

1) The data stated here may differ on special versions.

2) Mperm is the permissible peak load for the gears.

The torque must be limited on the motor frequency converter to the value
indicated, while adhering to the gear ratio involved!
The useful power data depend on the performance characteristic curve of the motor type
used.
3) The permissible torque can be utilized for non-pulse machining operations.
For strongly pulsed machining operations - e.g. inserted tooth milling cutters and others -
only a significantly reduced drive torque should be applied to protect the gears against
any overloads.

BA 1118 11
 Assembly and installation
Basic settings

3 Assembly and installation

3.1 Basic adjustment for tool drive motor

➣ Align tool drive coupling properly using spindle unit or

adjusting device 1) and/or set mark (6) of coupling
sleeve (5) parallel to screw-on surface by means of the tool
drive motor (coupling position).
➣ Reset coupling position.
→ Page 45

1) Special accessories

BA 1118 13
Assembly and installation
Central lubrication

3.2 Central lubrication

IMPORTANT
A connection to the central lubrication system is recommended
for achieving an optimum operational reliability and service life.

CAUTION
Risk of material damage by inappropriate lubricants.
• The lubricant should n o t contain any of the following
substances:
Soda soap Polygycol
Soda complex soap Silicon oils (methyl, phenyl)
Bentonite Perfluoro-alkylether
Polycarbamide greases Polyphenylether oil

• The lubricant should be selected in such a way that no

unwelcome interactions will arise, if the original lubricant
and the lubricant for the central lubrication system are
mixed.
Please contact the lubricant manufacturer, if necessary.
Condition of supply
• The product is lubricated with grease.
Lubricant used:

CENTOPLEX CX4/375 (KLÜBER)

• The M 8×1 threaded connections for the central lubrication

system are clogged and marked acc. to DIN 51 502.

AN
K C
000−2 CG

Connecting
➣ Connect all the connections marked for central lubrication
systems to the central lubrication system of the machine.
➣ The volume of lubricant should be metered for each
connection on the basis of the following standard values:

3
Oil approx. 0.09 - 0.18 [cm / h]

3
Grease approx. 0.06 - 0.12 [cm / 24 h]

14 BA 1118
 Assembly and installation
Tool holders and spindle units

3.3 Tool holders and spindle units

This turret has been prepared for the use of the following tool
holders and spindle units 1):
• tool holders with cylinder shank: for fixed tools
• spindle units with cylinder shank: for driven tools

Only use tool holders, spindle units and plugs with O-ring seals
in compliance with German standard DIN 69 880, part 1 (as of
July 1990).
For information on the tool holders and spindle units offered by
SAUTER for the SAUTER disk-type tool turret, please ask for
Product Information PI 29.3.
The warranty shall become void, if faulty foreign 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 suitable closing plugs.

Installing / changing tool holders

Preparation

IMPORTANT
If possible, change tool holders in a horizontal position!

➣ Clean the contact surfaces of the tool disk and

the tool holder.

1) Customized versions may also differ from the present version.

BA 1118 15
Assembly and installation
Tool holders and spindle units

Chips
1 2 3 Cooling lubricant

TAmax

➣ Observe the version of the tool holder (6) and shift the
position of the alignment device (2), if necessary.

Checking
➣ Are the sealing rings (4) on the new tool holder (6) fitted and
are they undamaged?

Installing / changing
➣ Undo setbolt (1).
➣ Remove the tool holder (6) or closing plug (3) to be
changed.
➣ Fit new tool holder (6).
➣ Use 20 % of the maximum tightening torque TA max of the
setbolt to tighten the setbolt.
→ Tightening torques: Table, page 16
➣ Use adjusting screws (5) to align the tool holder (6) to the
center of rotation.
➣ Tighten setbolt (1) – observe tightening torque TA max.

Tightening torques of the clamping screws of the setbolts

shank diameter d1 DIN 69880 [mm] max. tightening torque TA max [Nm]
20 10
25 10
30 25
40 50
50 50

16 BA 1118
 Assembly and installation
Tool holders and spindle units

Installing / changing spindle units

CAUTION
Danger of overload of the drive train. Remove the spindle unit
prior to the change of tool!

Preparation
➣ Clean the contact surfaces of the tool disk and the spindle
unit.

➣ Observe the version of the spindle unit and shift the position
of the alignment device, if necessary.

Checking
➣ Are the sealing rings (4) on the new spindle unit (6) fitted
and are they undamaged?
➣ Is the coupling profile undamaged and clean?

➣ Is the integrated spindle locking system engaged?

Installing / changing
➣ Undo setbolt (1).
➣ Remove the spindle unit (6) or closing plug (3) to be
changed.
➣ Fit new spindle unit (6).
➣ Use 20 per cent of the maximum tightening torque TA max of
the setbolt to tighten the setbolt. Observe the engaging
position of the spindle units.
→ Tightening torques: Table, page 16
➣ Use adjusting screws (5) to align the spindle unit (6) to the
center of rotation (required for angle spindle units).
➣ Tighten setbolt (1) – observe tightening torque TA max .

BA 1118 17
 Manual mode

4 Manual mode

In manual mode, the mechanical functions of the disk-type tool

turret will be checked:
• following initial assembly to the machine
• during troubleshooting
• after a renewed setup following fault conditions

Clearing required prior to any work:

➣ Switch the machine off.
➣ Depressurize turret.

1. Undo fixing screws of covering hood,

withdraw covering hood to rear.
If necessary, use push-off screw.

2. Remove screw plug on motor housing.

Unlock turret

3. Use a hexagonal pin wrench, complete with T-grip, to rotate

the motor shaft.
➪ If the disk-type tool turret is locked, the locating disk (or
tool disk) does not co-rotate; the centre position of the lock
can be felt.

BA 1118 19
Manual mode

WARNING
A reversal of the moment of the motor results in the
acceleration of the motor shaft. The hexagonal pin wrench may
thus be unexpectedly accelerated.
Therefore, in order to avoid the ejection of the hexagonal pin
wrench and resulting injuries, firmly grip the hexagonal pin
wrench.

4. Keep the same direction of rotation, continue to rotate.

➪ The disk-type tool turret unlocks; a reversal of the moment
on the motor shaft can be felt.

Rotate tool disk

5. Keep direction of rotation, continue to rotate disk until

locating disk (or tool disk) starts to turn as well.
6. Keep direction of rotation, continue to rotate disk until
locating disk (or tool disk) has reached the position required,
then press in the keeper by means of a screwdriver.
➪ The preindexing bolt engages into a hole.
➪ The tool disk cannot be rotated any further.

20 BA 1118
 Manual mode

Lock turret

7. Reverse direction of rotation on the motor shaft whilst

simultaneously pressing in keeper.
➪ The disk-type tool turret locks.
The lock resistance can be felt when rotation is continued.
The locking process ends, if the centre position of the lock
can be felt.

On completion of setup or maintenance work:

8. Screw in plug and fit covering hood.

Note position of cables in order to avoid any pinching of the
same.

Lock turret in position 1

IMPORTANT
For some setup and maintenance work the disk-type tool turret
has to be locked in position 1.

Precondition
• Numeral 1 of the locating disk has reached its 12 o’clock
position relative to the turret base area.
or
• Position 1 of the tool disk is in working position.

1. Use a hexagonal pin wrench, complete with T-grip, and

rotate the motor shaft until position 1 has been reached.
2. Press in the keeper by means of a screwdriver and rotate the
motor shaft until the disk-type tool turret locks (see above).

BA 1118 21
 Maintenance
Safety notes

5 Maintenance
Turret maintenance comprises the following tasks:
• Cleaning,
• Checking,
• Setting and
• Repair.

The service life of the turret is

approx. 2 – 3 million indexing operations.

The service life of the tool drive unit is

approx. 8 000 operating hours.

These values apply to

• collision-free operation,
• compliance with the specified operating conditions and the
permissible loads,
→ Technical data, page 10

5.1 Safety notes

→ Page 6

BA 1118 23
Maintenance
Service intervals

5.2 Service intervals

Plan your tasks carefully in order to provide for troublefree operation and
reduce necessary downtimes to a minimum.

IMPORTANT
➣ Maintenance intervals must be adapted
to the operating conditions involved.

if required Clean tool drive coupling. User

Check tool drive coupling for damage, User

replace if necessary.
SAUTER Service

after 4000 operating hours Check cooling lubricant valve for wear User
of the machine and leakage. → Page 41
respectively Replace any defective parts.

Check oil of the turret gearbox User

chamber; → Page 25
if necessary, replenish oil.

Check grease condition of tool drive User

unit; if necessary, replenish grease. → Page 27

after 21⁄2 years respectively Check all electrical lines and User
connections for mechanical damage as
well as embrittlement. Specialist electrical
Replace any defective parts. engineer 1)

after 8000 operating hours Change the oil of the turret gearbox User
of the machine chamber. → Page 25
respectively
The service life of the tool drive unit SAUTER Service
may possibly be reached, depending
on the operating conditions involved.
A general overhaul is recommended
for further trouble-free operation.

after approx. 2–3 million The service life of the turret may SAUTER Service
indexing operations possibly be reached, depending on the
respectively operating conditions involved.
A general overhaul is recommended
for further trouble-free operation.

1) These are persons who are able to identify risks and to prevent possible hazards
on the basis of their special training and their experience
(IEC 60 201-1).

24 BA 1118
 Maintenance work
Turret gearbox chamber

5.3 Maintenance work

Turret gearbox chamber

The turret gearbox chamber has to be serviced after 4,000 operating hours.

Clearing required prior to any work:

➣ Switch the machine off.
➣ Depressurize turret.

IMPORTANT
Improperly disposed used oil is a danger for our environment.
➣ Pay attention to the legal regulations for the waste disposal
of used oil.

In line with the setup position of the disk-type tool turret, the
following apertures (1) for draining or replenishing oil are
provided:

1 1

Checking the oil

➣ Carefully unscrew oil drain plug and drain the oil
(max. 10 cm3) into a suitable container.

BA 1118 25
Maintenance work
Turret gearbox chamber

Assess oil condition

Condition Cause Action

Oil black or brown, without

Natural consumption –
metallic abrasion
Oil black or brown, with Internal parts of turret are
metallic abrasion damaged
Oil white, mixed with cooling Request SAUTER Service!
Turret sealings are damaged
lubricant

None oil left Turret sealings are damaged

Changing the oil

➣ Open oil drain plug, drain waste oil.

➣ Close oil drain plug.
➣ Remove screw plug from oil charging hole.

Fill oil

300 cm3

lubricating oil C acc. to ISO 6743 / 6

viscosity ISO VG 46 acc. to DIN 51 562

➣ Screw in screw plug.

26 BA 1118
 Maintenance work
Tool drive

Tool drive

• The product is lubricated with grease.

Lubricant used:

CENTOPLEX CX4/375 (KLÜBER)

• Lubrication must be checked after 4,000 operating hours

respectively.

Clearing required prior to any work:

➣ Switch the machine off.
➣ Depressurize turret.

➣ Clear access to opening on tool drive.

➣ Remove screw plug off opening.
➣ Rotate gear and assess grease condition:

Condition Cause Measure

Grease: black or brown, Trace of natural wear –

without metallic abrasion

No grease visible on gear Natural consumption ➣ Replenish grease.

approx. 105 cm3
CENTOPLEX CX 4 / 375

Grease: black or brown, Internal parts of turret

with metallic abrasion are damaged ➣ Request SAUTER Service!
Grease: white, mixed with Turret sealings
cooling lubricant are damaged

Grease mixed with oil

➣ Re-insert screw plug.

BA 1118 27
Repairs after fault conditions
Possible faults and remedies

5.4 Repairs after fault conditions

Clearing required prior to any work:

➣ Switch the machine off.
➣ Depressurize turret.

Fault Cause Remedy Who carries out

this task?

Turret

Incorrect center height, Collision when turret is Turn back tool disk in User
tool disk offset relative locked the annular groove and → Page 30
to locating disk align

Tool disk does not Gearwheels are SAUTER

rotate defective Service

Proximity switch S11 Check proximity switch User

does not switch S11; if necessary, set → Page 46
or replace

Turret is difficult to Insufficient oil in the Check oil User

operate gearbox chamber → Page 25

(Thermo protection Contactor is defective Check motor drive User

device has responded)

Turret no longer locks or Collision during SAUTER

the pre-indexing bolt pivoting Service
gets caught

Tool disk does not stop Angular encoder is not Check angular User
in the selected position correctly adjusted or encoder, set or replace → Page 31,
defective if necessary page 33

Proximity switch S7 Check proximity switch User

does not switch S7, set or replace if → Page 38
necessary

Tool disk stops in Chips between tool Remove tool disk, User
between two positions disk and turret remove chips

Leakage oil escapes Seals are defective SAUTER

Service

28 BA 1118
 Repairs after fault conditions
Possible faults and remedies

Fault Cause Remedy Who carries out

this task?

Cooling lubricant is not Cooling lubricant valve Replace cooling User

being transferred is defective lubricant valve → Page 41

Cooling lubricant valve / Blow cooling lubricant

line is blocked valve / line clear

Cooling lubricant Cooling lubricant valve Replace cooling

escapes between tool is defective lubricant valve
disk and turret

Tangential play of tool Collision while turret is SAUTER

disk when turret is locked Service
locked

Wear due to lack of oil

Tool drive

Tool drive does not Tool disk is displaced Align tool disk User
engage → Page 30

Tool drive coupling is SAUTER

defective Service

Pinion shaft is defective Replace defective User

part, → Page 43
adjust solenoid

Solenoid is defective Replace solenoid and

adjust

Tool is not driven Gearwheels are SAUTER

defective Service

Tool drive motor is Replace tool drive User

defective motor

Proximity switch S10 Check proximity switch User

does not switch S10, set or replace if → Page 46
necessary

BA 1118 29
Repairs after fault conditions
Aligning the tool disk

5.5 Aligning the tool disk

Preparation

➣ Lock turret.
→ Manual mode, page 19

Aligning

1
1

➣ If necessary, undo screws (1).

➣ Align the locating hole to center height of the machine;
use a plug gauge (2) if required.
➣ Tighten screws (1).

M10 - 12.9 MoS 2 77 Nm

30 BA 1118
 Repairs after fault conditions
Adjusting the angular encoder

5.6 Adjusting the angular encoder

IMPORTANT
Setting tasks require a 24 V DC power supply.

Preparation
➣ Lock disk-type tool turret in position 1.
→ Manual mode, page 19

➣ Undo claws by means of a hexagonal pin wrench.

Adjusting

➣ Rotate angular encoder out of position until illuminated diode

lights up.
➣ Clamp in angular encoder by means of the claws.

BA 1118 31
Repairs after fault conditions
Adjusting the angular encoder

Checking the setup for symmetry

1. Use hexagonal pin wrench with T-grip for rotating the motor
shaft.
2. Rotate motor shaft until illuminated diode on the angular
encoder or the indication “Position 1” on the machine are
extinguished.
3. Note the T-grip position.

WARNING
A reversal of the moment of the motor results in the
acceleration of the motor shaft. The hexagonal pin wrench may
thus be unexpectedly accelerated.
Therefore, in order to avoid the ejection of the hexagonal pin
wrench and resulting injuries, firmly grip the hexagonal pin
wrench.

4. Carefully continue to rotate until a moment reversal can be

felt on the motor shaft.
5. Note the T-grip position.

The distance between the two grip positions characterizes the

angle range.

6. Repeat steps 1 to 5 with reverse direction of rotation. The

angle α must be the same for both directions of rotation!

By turning the angular encoder out of position, any

dissymmetry can be removed.

32 BA 1118
 Repairs after fault conditions
Replacing the angular encoder

5.7 Replacing the angular encoder

The location of the angular encoder depends on the disk-type tool turret
version (without / with fluid rotary feedthrough).

IMPORTANT
Setting tasks require a 24 V DC power supply.

Angular encoder, centrally positioned

Preparation
➣ Lock disk-type tool turret in position 1.
→ Manual mode, page 19

1
2

➣ Note the position of the cable outlet (2) on the

angular encoder (1), remove attachment.
➣ Undo cables (3) on terminal strip (note where they are
connected).

➣ Undo claws by means of a hexagonal pin wrench.

BA 1118 33
Repairs after fault conditions
Replacing the angular encoder

Replacing

➣ Undo setscrew.
➣ Carefully withdraw angular encoder.
➣ Connect new angular encoder electrically.
→ Wiring diagram Disk-type tool turret EP-870
in the appendix to these Operating Instructions

➣ Rotate shaft of the angular encoder until the illumination of

the LED on the angular encoder indicates the “Position 1”
setting.
This indication must remain whilst the following steps are
carried out.

IMPORTANT
The LED is used only to indicate position 1 during the
adjustment work. It is no position indicator during operation.

34 BA 1118
 Repairs after fault conditions
Replacing the angular encoder

➣ Ensure that the cable outlet is in its correct position.

➣ Insert the shaft of the angular encoder into the bore of the
flexible shaft and introduce carefully until the angular
encoder is in contact with the plate. Ensure that the claws
are in their correct position!
➣ Use setscrew to attach the angular encoder to the shaft.
➣ If necessary, check the adjustment of the angular encoder.
→ Page 32
➣ Use claws to secure the angular encoder.
➣ Fit covering hood. Note position of cables in order to avoid
any pinching of the same.

Angular encoder, in side position

Preparation
➣ Lock disk-type tool turret in position 1.
→ Manual mode, page 19

3 2

➣ Note the position of the cable outlet (2) on the angular

encoder (3), remove attachment.
➣ Undo cables (1) on terminal strip (note where they are
connected).

BA 1118 35
Repairs after fault conditions
Replacing the angular encoder

Replacing

➣ Undo claws by means of a hexagonal pin wrench.

➣ Carefully withdraw angular encoder.
On the shaft of the angular encoder, a disk is located which is
fixed in position by means of a setscrew.
➣ Undo setscrew and remove disk.
➣ Connect new angular encoder electrically.
→ Wiring diagram Disk-type tool turret EP-870
in the appendix to these Operating Instructions

➣ Rotate shaft of the angular encoder until the illumination of

the LED on the angular encoder indicates the “Position 1”
setting.
This indication must remain whilst the following steps are
carried out.
➣ Fit disk in its correct position.

36 BA 1118
 Repairs after fault conditions
Replacing the angular encoder

➣ Ensure that the cable outlet is in its correct position.

➣ Insert the angular encoder into the opening of the plate,
note the position of the claws!
➣ If necessary, check the adjustment of the angular encoder.
→ Page 32
➣ Use claws to secure the angular encoder.
➣ Fit covering hood. Note position of cables in order to avoid
any pinching of the same.

BA 1118 37
Repairs after fault conditions
Proximity switch S7

5.8 Proximity switch S7

IMPORTANT
Setting tasks require a 24 V DC power supply.

Clearing required prior to any work:

➣ Switch the machine off.
➣ Depressurize turret.

➣ Undo fixing screws of covering hood, withdraw covering

hood to rear. If necessary, use push-off screw.

Replacing

1 2 3

➣ Undo clip (3) and withdraw proximity switch (1) from

eccentric bushing (2).

38 BA 1118
 Repairs after fault conditions
Proximity switch S7

Checking
.

brown
black 8 24 V
V
blue
11

−
H-Signal ≥ 90% of rated voltage

➣ Apply a voltage of 24 V DC to the proximity switch (1).

The proximity switch is energized when the LED lights up.
➣ Insert tested/new proximity switch (1).

Adjusting
➣ Unlock disk-type tool turret.
→ Manual mode, page 19
➣ Move disk-type tool turret into a location between two
positions.
If the keeper (M) is operated, the preindexing bolt (4) can be
pressed in partially only.
a

M x

3 2 1

➣ Set switching distance x = 0.3 – 0.5 mm.

➣ Determine dimension a.
a = stroke of the preindexing bolt (4) up to the damping
ring (5) when the solenoid is operated manually
(corresponds to the press-in depth of the keeper (M)).

BA 1118 39
Repairs after fault conditions
Proximity switch S7

➣ Adjust proximity switch (1) on eccentric bushing (2) such that

+0.5
its signal begins to drop after a+ 2 mm immersion depth
of the preindexing bolt.
Any greater immersion depth may cause the motor to be
blocked.
➣ Tighten clip (3).

➣ Fit covering hood. Note position of cables in order to avoid

any pinching of the same.

Function test
➣ Switch on turret.
➣ Check switching process repeatedly.

40 BA 1118
 Repairs after fault conditions
Cooling lubricant valve

5.9 Cooling lubricant valve

• Cooling lubricant valves for SAUTER Disk-type tool turrets

are executed depending on the order involved.
The cooling lubricant connection may be situated on the
valve.
• Cooling lubricant valves are wearing parts and must
therefore be inspected after 4,000 operating hours of the
machine respectively.
• For ordering replacement parts, the identification number of
the cooling lubricant valve can be indicated, if engraved.
Otherwise, the order number (i.e. Comm. No. on the turret
nameplate) must be given.
• Operating pressure and filter fineness for cooling lubricant:
→ Technical data

Clearing required prior to any work:

➣ Switch the machine off.
➣ Depressurize turret.
➣ Turn off cooling lubricant supply unit.

Replacing

➣ Unscrew screw plug (2).

➣ Withdraw cooling lubricant cartridge complete with
screw plug (2).
➣ Check cooling lubricant cartridge; if necessary, replace
bushing (3) and O-ring seal (1).
➣ Refit cooling lubricant cartridge complete with screw plug.

BA 1118 41
Repairs after fault conditions
Tool drive motor

5.10 Tool drive motor

Clearing required prior to any work:

➣ Switch the machine off.
➣ Depressurize turret.

Dismantling

1 2 3

➣ Remove tool drive motor (3).

➣ Slacken clamping screws (2).
➣ Remove pinion (1).

Prepare and attach new motor

IMPORTANT
Attach pinion axially to stop at front end of shaft or on shaft
collar, depending on the version involved.

➣ Tighten clamping screws (2) crosswise.

M6 12Nm

➣ Mount turret motor with pinion.

42 BA 1118
 Repairs after fault conditions
Solenoid

5.11 Solenoid
The solenoid determines the engagement path. The coupling end positions
are controlled by means of the proximity switches S10 “Tool drive engaged”
and S11 “Tool drive disengaged”.

Clearing required prior to any work:

➣ Switch the machine off.
➣ Depressurize turret.

Preparation
➣ If necessary, remove the covering hood on the tool drive unit.
If a tool disk is fitted, the tool holder location must be
accessible in working position:
➣ If necessary, disassemble spindle unit.

Replacing

2 3 4 5 6

➣ Unscrew the 4 screws (5) on flange plate (4) of solenoid (6).

➣ Remove solenoid together with flange plate by tilting slightly,
so as to eject needle roller (2) out of control fork (1).
➣ Unscrew the 3 screws (3) and take down flange plate (4).

BA 1118 43
Repairs after fault conditions
Solenoid

7 8

6
X

➣ Press in armature, measure and write down dimension X.

➣ Unscrew nut (8) and bushing (7).
➣ Screw nut (8) on to new solenoid.
➣ Replace needle roller (2), if necessary.
➣ Screw on bushing (7), adjust to dimension X and lock with
nut (8).

➣ Tighten solenoid (6) with screws (3) to flange plate (4).

➣ Insert solenoid with flange plate by tilting slightly, so as to
bring needle roller (2) into control fork (1).
➣ Fasten solenoid using screws (5).

CAUTION
Operational failures may occur, if the coupling is not correctly
adjusted.
➣ Adjust final position of coupling and then proximity switches.
→ Page 45

44 BA 1118
 Repairs after fault conditions
Adjusting the tool drive coupling

5.12 Adjusting the tool drive coupling

➣ Lock turret.

1 2

A ± 0.4 mm
4 3

A = clearance
from the pinion shaft (2) to the edge of the tool disk (1).

Coupling profile clearance A ±0.4 [mm]

11 ×0.8 DIN 5480 41
14 ×0.8 DIN 5480 49.5
16 ×0.8 DIN 5480 58.5
20 ×0.8 DIN 5480 65
24 ×1.25 DIN 5480 83

➣ Adjust clearance A using nut (3) and bushing (4).

Adjusting the proximity switches

→ Page 46

BA 1118 45
Repairs after fault conditions
Proximity switches S10 and S11

5.13 Proximity switches S10 and S11

Positions of proximity switches:

→ Page 9

IMPORTANT
Setting tasks require a 24 V DC power supply.

Preparation

➣ Unscrew magnetic assembly housing cover (4 screws).

S11 S10

0.3
0. 5 ±

3
0.5
±0
.3

dimensions in mm

Replacing

➣ Loosen clip (2) and remove proximity switch (1) resp.

withdraw proximity switch from eccentric bushing (3).
➣ Insert new proximity switch and fasten slightly.
➣ Install proximity switch electrically.

46 BA 1118
 Repairs after fault conditions
Proximity switches S10 and S11

Adjusting

➣ Adjust center of proximity switch S11 to switching edge

using eccentric bushing (3).
➣ Set proximity switch (1) at distance of x = 0.5±0.3 mm of the
switching edge.
➣ Tighten clip (2).

Checking

➣ Engage and disengage, while checking proximity switch

signal.

➣ Screw on cover again.

BA 1118 47
 Replacement parts

6 Replacement parts

A
B

IMPORTANT
Request assembly guideline MR 02.025!

A
Turrets (without tool drive)

Indexing → Page 50
Clamping and angular encoder → Page 51
Gear, drive, pre-indexation → Page 52

B
Tool drive for turret

0.5.476.520 - 130 332 → Page 54

0.5.476.520 - 132 105 → Page 58
→
→

BA 1118 49
Replacement parts
Indexing

Indexing

Setscrew is only applied

and secured (LOCTITE 221)

No. Ident No. Designation Qty.

1 058 073 O-ring seal 1

2 102 048 Replacements parts group Indexing 3

50 BA 1118
 Replacement parts
Clamping and angular encoder

Clamping and angular encoder

1 2 3

No. Ident No. Designation Qty.

1 067 586 Disk (for tuning) 1

2 063 385 O-ring seal 1

3 Replacements parts group Clamping 1

4 105 500 Angular encoder 1

BA 1118 51
Replacement parts
Gear, drive, pre-indexation

Gear, drive, pre-indexation

1 2 3 4 5 6

8 9 10

52 BA 1118
 Replacement parts
Gear, drive, pre-indexation

No. Ident No. Designation Qty.

1 071 904 Sealing ring 1

2 067 810 O-ring seal 1

3 069 340 O-ring seal 1

4 063 365 O-ring seal 1

5 065 718 O-ring seal 1

6 Motor 1) 2) 1

7 004 157 Proximity switch 1

8 070 460 Sealing ring 1

9 067 659 Compression spring 1

10 064 813 Solenoid 1

1) will be supplied complete with housing and bearing

2) data according to motor’s nameplate

BA 1118 53
Replacement parts Tool Drive
for turret 0.5.476.520 - 130 332

Tool drive

Gear, coupling

5
11 10 9

12

13
4

3 14

15
2
(2)
(1)
1
16

54 BA 1118
 Replacement parts Tool Drive
for turret 0.5.476.520 - 130 332

No. Ident No. Designation Qty.

1 083 885 Radial seal for rotating shaft 2

2 089 166 Deep groove ball bearing 2

3 110 572 Gearwheel 1

4 036 588 Spaghetti hose 0.638 m

5 078 218 O-ring seal 1

6 072 997 O-ring seal 1

7 058 075 O-ring seal 1) 1

8 111 254 O-ring seal 1) 2) 1

9 085 031 Deep groove ball bearing 1

10 075 534 Deep groove ball bearing 1

11 106 120 O-ring seal 1

12 034 592 FU groove ring 1

13 058 506 O-ring seal 1

14 110 617 Cylindrical roller bearing 1

15 106 418 O-ring seal 1

16 Tool drive coupling 1

W 16×0,8 – DIN 5480

130 336 Tool drive coupling 1

W 20 ×0,8 – DIN 5480

Tool drive coupling 1

W 24 × 1,25 – DIN 5480

1) for motor FANUC alpha 22/3 000

2) for motor SIEMENS 1FT6 086

BA 1118 55
Replacement parts Tool Drive
for turret 0.5.476.520 - 130 332

Magnetic assembly

3 4 5

1
6

Cut-out 90° rotation

10

56 BA 1118
 Replacement parts Tool Drive
for turret 0.5.476.520 - 130 332

No. Ident No. Designation Qty.

1 062 132 O-ring seal 1

2 059 591 O-ring seal 20

10

4 001 710 Needle roller 1

5 118 321 Solenoid 1

6 076 749 Proximity switch 2

7 001 710 Needle roller 1

8 000 989 O-ring seal 1

9 060 308 O-ring seal 1

BA 1118 57
Replacement parts Tool Drive
for turret 0.5.476.520 - 132 105

Tool drive

Gear, coupling

5
11 10 9

12

13
4

3 14

15
2
(2)
(1)
1
16

58 BA 1118
 Replacement parts Tool Drive
for turret 0.5.476.520 - 132 105

No. Ident No. Designation Qty.

1 083 885 Radial seal for rotating shaft 2

2 089 166 Deep groove ball bearing 2

3 110 572 Gearwheel 1

4 036 588 Spaghetti hose 0.638 m

5 078 218 O-ring seal 1

6 072 997 O-ring seal 1

7 058 075 O-ring seal 1) 1

8 111 254 O-ring seal 1) 2) 1

9 085 031 Deep groove ball bearing 1

10 075 534 Deep groove ball bearing 1

11 106 120 O-ring seal 1

12 034 592 FU groove ring 1

13 058 506 O-ring seal 1

14 110 617 Cylindrical roller bearing 1

15 106 418 O-ring seal 1

16 Tool drive coupling 1

W 16×0,8 – DIN 5480

130 336 Tool drive coupling 1

W 20 ×0,8 – DIN 5480

Tool drive coupling 1

W 24 × 1,25 – DIN 5480

1) for motor FANUC alpha 22/3 000

2) for motor SIEMENS 1FT6 086

BA 1118 59
Replacement parts Tool Drive
for turret 0.5.476.520 - 132 105

Magnetic assembly

3 4 5

1
6

Cut-out 90° rotation

10

60 BA 1118
 Replacement parts Tool Drive
for turret 0.5.476.520 - 132 105

No. Ident No. Designation Qty.

1 062 132 O-ring seal 1

2 059 591 O-ring seal 20

10

4 001 710 Needle roller 1

5 118 321 Solenoid 1

6 076 749 Proximity switch 2

7 001 710 Needle roller 1

8 000 989 O-ring seal 1

9 060 308 O-ring seal 1

BA 1118 61
 1 3 5 7 9 11 13 15 17 19 21 23
2 4 6 8 10 12 14 16 18 20 22 24 25 26

82

81

80 27
79
78
77 28
76 29
75
74
30

73 31
72 32
71 33*
70
69 34
68
35
67

66 36

65 37

64 * Winkelpositionsgeber: Anbau variabel

63 62 61 59 57 55 53 51 49 47 45 43 Angular encoder: variable installation
60 58 56 54 52 50 48 46 44 42 41 40 39 38 Capteur de position angulaire: Montage variable

Survey: Disk-type tool turret 0.5.480.5.. 0.5. 480.5..

Contact
Order information

Service
SAUTER Feinmechnanik GmbH
Postfach 1551
D-72545 Metzingen
Germany

++49(0) 7123–926–0

++49(0) 7123–926–193

@ service@sauter-feinmechanik.com

IMPORTANT
Please indicate in your orders:

Product data as per nameplate on the housing

1. Classification number (series, size)
2. Identification number
3. Order number

Ordering data as per replacement-parts drawing and table

4. Identification number and quantity of the spare part requested.

Client
5. Company
6. Client’s name and phone number.