EMCO Concept Turn 60

PC-controlled lathe for training

Description of the machine

EMCO Concept Turn 60
Ref.-No. EN 1060
Edition A2013-09

These instructions are also available at any time on

request as electronic copy (.pdf).

Translation of Original operating instructions

EMCO Maier Ges.m.b.H.

P.O. Box 131

A-5400 Hallein-Taxach/Austria

Phone ++43-(0)62 45-891-0

Fax ++43-(0)62 45-869 65

Internet: www.emco-world.com

E-Mail: service@emco.at
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2
 Preface

For over five decades, EMCO has been developing metal machining machines and has been
a successful player since 1980 with computer-controlled machine tools (CNC machines), in
particular in the training sector.

The lathes and milling machines in the EMCO Concept TURN and EMCO Concept MILL
have profited from this immense body of experience.
The newly designed compact machines comply totally both in design and construction and
in safety with today's requirements.

Concept machines are controlled via a conventional Personal Computer (PC). This type of
use facilitates efficient training on a wide variety of CNC controllers (Siemens, Fanuc, etc.)
with but a single machine.
The CNC monitor for the installed CNC controller is simulated on screen, with the data being
entered via a keyboard, exchangeable depending on the controller in each case.

Because our machines are used in industry throughout the world, we have a comprehensive
service network.
Service technicians on call immediately, telephone service and a 100% spare part supply
system, as well as a 10-year supply guarantee is something we perceive as obvious.

You can stay abreast of any special new developments (e.g. clamping options for workpieces
or tools, new software applications, etc.) and determine whether they can be retrofitted from
our distributors, of whom there over 100 throughout the world.

In these operating instructions are a complete description of safety rules, transport, instal-
lation, handling and maintenance of the machine.
Accordingly, read these instructions through completely before operating the machine.

EMCO MAIER Gesellschaft m. b. H.

Technical Documentation Department
A-5400 HALLEIN, Austria

EC compliance

The CE symbol, together with the EC compliance declaration, certifies that the
machine and instructions comply with the directives under which the products are
covered.

All rights reserved. Copying only with permission from EMCO MAIER
© EMCO MAIER Gesellschaft m. b. H., Hallein/Taxach - Austria

3
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Content
Adequate use..............................................................................7
Warranty terms for new EMCO machines..................................8
Safety Regulations......................................................................9
Fire and explosion protection................................................11
Prevention.........................................................................11
Firefighting measures........................................................11
Awareness.............................................................................13
Technical Specification for the machine...................................15
PC configuration....................................................................17
EC Declaration of Conformity...................................................19
A Setting up the machine
Machine takeover......................................................................21
Machine number and electrics number................................21
Deliverables............................................................................. 22
Basic machine...................................................................... 22
Modules................................................................................ 22
Data medium........................................................................ 22
Packaging............................................................................. 22
Transporting the machine.........................................................23
Transport without machine base...........................................23
Transport with machine base (option)...................................24
Set-up plan, machine dimensions............................................25
Basic machine.......................................................................25
Machine with base (option)...................................................26
Set-up criteria............................................................................27
Installation area.....................................................................27
Ergonomics...........................................................................27
Machine without machine base............................................27
Machine with machine base (option)....................................28
Foundation requirements..................................................28
Setting up with steel plates...............................................28
Setting up with levelling elements.....................................28
Additional Set-up Criteria......................................................29
Electrical connection................................................................ 30
Set the mains voltage........................................................... 30
Mains connection specification.............................................31
Machine-PC connection...........................................................31
Initial Start-up............................................................................32
Switching On/Off Process....................................................... 33
Switch the machine on......................................................... 33
Reference the axes individually....................................... 33
Reference automatically.................................................. 33
Switching the machine off.................................................... 34
B Machine Description
Machine Elements- Overview.................................................. 35
Points on the machine - coordinate system............................ 36
Machine zero point M....................................................... 36
Reference point R............................................................ 36
Workpiece zero point W................................................... 36
Workpiece housing reference point N (T)........................ 36
Safety equipment......................................................................37
EMERGENCY-OFF key.........................................................37
Door-locking system.............................................................37
Key switch............................................................................ 38
"Automatic" setting........................................................... 38
"Set-up mode" setting...................................................... 38
Enable button....................................................................... 39
Functions of the Enable key............................................. 39
5
Content
Machine working area.............................................................. 40
Machine base............................................................................41
Machine bed..............................................................................41
Carriage....................................................................................41
Carriage drives..........................................................................41
Main drive..................................................................................41
Main spindle..............................................................................42
Tool turret................................................................................. 43
Clamping the tools and aligning at tip height....................... 43
Outer machining tools...................................................... 43
Inner machining tools....................................................... 44
Tailstock (option)...................................................................... 45
Clamping devices......................................................................47
Overview...............................................................................47
The 3-jaw turning chuck....................................................... 48
Mounting the chuck.......................................................... 48
Clamping ranges.............................................................. 48
The collet chuck device........................................................49
Mounting the collet chuck device......................................49
Mounting collet chucks......................................................49
Removing the collet chuck................................................49
Clamping workpieces........................................................50
Clamping ranges...............................................................50
Tools and accessories..............................................................51
Turning tools..........................................................................51
HM cutting inserts.................................................................51
Drilling tools...........................................................................52
Tailstock accessories............................................................52
Accessories for tool turrets...................................................52
Technological data................................................................... 53
1. Cutting speed V................................................................ 53
2. Speed S............................................................................ 53
3. Feed F.............................................................................. 53
Summary.............................................................................. 53
Finding the speed................................................................. 54
Recalculating the feed......................................................... 55
Speed-torque characteristic curve...........................................56
C Machine maintenance
Maintenance overview - graphic illustration............................ 58
Maintenance overview - Table..................................................59
Recommended lubricants.........................................................59
Unprotected parts.................................................................... 60
Hoses and lines....................................................................... 60
Clamps (option)........................................................................ 60
Spindle nuts..............................................................................61
Roller guides.............................................................................61
Check the EMERGENCY OFF key............................................62
Tailstock (option).......................................................................62
Main drive belt.......................................................................... 63
Exchanging the main drive belt............................................ 63
Pneumatic servicing unit (option)............................................ 64
water separator.................................................................... 64
Viewing plates.......................................................................... 65
Spare Parts List
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6
 Adequate Use

Adequate use

The Concept Turn 60 machine is intended for turning machinable metals (alu-
minium, brass, mild steel) and machinable plastics.
Machining other materials is not permitted, or in special cases must take place
only after consultation with the manufacturer.
Proper use also includes compliance with the operating and maintenance in-
structions issued by the manufacturer.
The machine must be used only by those persons who have been entrusted with
its operation, maintenance and repair and have been instructed in the dangers.
All accident prevention and safety instructions for working on machine tools
must be obeyed at all times.
If the machine is used improperly, any liability on the part of the manufacturer
will be inadmissible and the user alone will bear responsibility.
When installing the machine in a complete system, or if other changes are made
to the machine, the system or machine is to be brought into compliance with
CE regulations and their associated guidelines and instructions before start-up.
Start-up before this is explicitly forbidden.

7
Warranty Terms

Warranty terms for

new EMCO machines

1. The warranty period for new EMCO machines is 12 months, with no limit on
the hours run, from delivery of the machine by EMCO or its authorised dis-
tributor. If EMCO or its authorised distributor also carries out the installation,
the warranty begins to run from completion of the machine's installation.
If the installation is delayed for reasons for which EMCO or its distributor are
not responsible, the warranty ends 12 months after the scheduled installation
date.
2. The warranty includes the rectification of all material and design faults which
impair the proper functioning of the machine.
3. Defects occurring are to be reported to the EMCO distributor or to the nearest
EMCO service agency without delay, with a detailed description of the fault
in writing or orally, with subsequent confirmation in writing.
4. Properly reported defects covered by the warranty will be resolved free of
charge by rectification of the fault or delivery of a spare part for the customer;
defective parts are to be returned to EMCO or its distributor on request. The
customer is to bear the costs and risks of this despatch.
5. The warranty period for spare parts is six months from delivery or installa-
tion, but in cases of repeated claims under this warranty only the deliverables
provided for the first claim are covered.
6. Warranty claims are inadmissible for faults that are caused by:
Failure to obey the operating instructions, safety and licensing regulations
or other instructions related to the delivery, set-up, commissioning or use of
the machine, inappropriate or improper use, faulty installation or commis-
sioning, as well as independent interventions or changes by the customer
or by a third party that are not explicitly ordered or permitted, fair wear and
tear, defective or negligent handling, chemical, electro-chemical or electrical
factors, inadequate energy supplies and force majeure.
7. The customer is to bear the costs for services that are not provided under
warranty.

8

Safety Regulations
Read instructions
Read the instructions through completely before
operating the machine.
Before beginning work, familiarise yourself with
all functions and control elements.
During work, it can be too late.
Set up and connect machine
The minimum set-up area (see set-up plan) as
well as adequate access or escape routes for
support in the event of unforeseen events must
be available.
The foundation requirements and the compressed
air and electrical supply must be guaranteed in
accordance with the operating instructions.
Only a certified electrician should connect the
machine to the mains.
Observe local regulations
Always observe local regulations when connect-
ing the machine to the mains and when working
with machine tools and CNC machine tools.
Authorised Use
The machine may only be operated by authorised
persons.
Authorised persons are exclusively those who are
entrusted with its operation, maintenance and re-
pair and who have been instructed in the dangers.
Securing machines
Secure the machine against unauthorised start-
ing, especially during adjustment, maintenance
and repair work (lockable master switch).
Start-up
Before starting the machine, make certain that
it is in a properly maintained condition, and that
no safety devices have been altered or removed.
Tool change - working area
Only change tools when the machine is off.
Risk of injury - sharp tools.
Do not use blunt or damaged tools!
Use only tools and locking bolts with an O-ring on
the shaft and always lock all stations (otherwise,
there is a risk of coolant and chips penetrating
into the tool turret).
Always turn power tools into an engaged position
when changing tools.
9
Safety Regulations
Do not change machine
Unauthorised changes to safety devices, over-
rides of monitoring equipment, as well as any
interventions in the electrical/electronic area are
forbidden.
These devices have been installed for your own
safety. By removing them you exposed yourself
and others to a sharply increased risk of acci-
dents.
Cleanliness
Always keep workplace and machine in a clean
condition. Clear floors that are contaminated with
oil and coolant. You could slip.
Clear away parts that are lying around. You could
stumble.
EMERGENCY SHUTDOWN in a danger situ-
ation
In danger situations, the machine must be
stopped immediately with the EMERGENCY
SHUTDOWN switch.
It is mandatory to report failures caused by
the control system which lead to personal
injury
The machine is fitted with electronic safety
systems. These systems employ mature tech-
nology. However, should errors occur, such as
an axial drive or axial accelerations exceeding
programmed speeds, these must be reported to
the manufacturer in writing immediately.
Personal safety equipment
Do not wear loose work clothing. Take care that
work clothing fits tightly around the hips and
wrists.
Ensure that your hair does not get caught in the
machine (wear headdress).
Protect your eyes with safety goggles.
When removing chips, use a chip hook and pro-
tective gloves.
Wear protective gloves. Workpieces etc. may slip
from the hand.
Wear protective gloves; tools, workpieces and
machine parts can become very hot.
No protruding parts
To keep the risk of injury as low as possible,
clamped workpieces/bar materials should not
protrude beyond the machine cladding.
The prohibition plate on the machine must not
be removed!
Safety Regulations
Set-up, Maintenance and Adjustment Work
Any set-up, maintenance and adjustment work
may only take place when the machine is
switched off and the EMERGENCY SHUTDOWN
switch thrown.
Observe the inspection and maintenance regula-
tions for the machine and its accessories.
When using laser measuring equipment, it is
essential to obey the manufacturer's regulations
and instructions.
Observing inspection intervals saves you money,
prevents long outages, reduces the danger of ac-
cidents and protects the environment.
Noise stress
High frequency vibrations and therefore high
noise stress (e.g. thin-walled workpieces) can oc-
cur while machining workpieces - wear earmuffs.
As a remedy, procure suitable clamping devices
and/or change machining parameters.
Tools, Resources, Spare Parts
Only use tools, resources and original spare parts
recommended by EMCO.
EMCO assumes no liability for parts that it has
not supplied.
Observe clamping pressures
Too high a clamping pressure damages work-
piece and machine; if the pressure is too low, the
workpiece is not clamped securely.
This also increases the risk of injury for the user!
Disposal of Difficult Waste
In dealing with auxiliary and environmental
resources (coolant lubricant agents, cleaning
agents, lubricant oil, etc.), observe safety and
disposal regulations for the difficult waste con-
cerned.
Take the relevant precautions for legitimate stor-
age, labelling and disposal.
In case of damage
In the case of collision or other damage, contact
your representative immediately.
In the event of complaints, claims, if there are
any ambiguities and when ordering spare parts,
always quote the machine number, the electrics
number and the software version.
Machine supervision
Never leave running machines unsupervised.
Before leaving the workplace, switch the machine
off and secure it against unauthorised starting
(lock the master switch and remove the key).
10
Safety key for
• Key Switch Special Operations Mode
• Data protection key switch
• Switchgear cabinet and terminal box
• Padlock for master switch
are only to be safeguarded by authorised persons
who have appropriate training and the required
knowledge of the dangers of such machines, and
exercise appropriate caution.
Danger, Attention, Note
Always observe the accident prevention and
safety instructions mentioned in the individual
chapters.
Important information which concerns technical
safety and operator protection is always specially
highlighted:
Danger:
relates to a possible risk to people during
work and operational procedures.
Caution:
appears next to work and operational pro-
cedures which must be observed exactly in
order to prevent possible damage to the ma-
chine or minor injury to the operator.
Instructions:
will be given if there are special precautions
to be observed when carrying out a certain
activity.
Environmental note:
relates to the avoidance of hazardous waste,
responsible handling of environmentally-
damaging substances, as well as ways of
economising on auxiliary and operational
resources.
 Safety Regulations

Fire and explosion protection

Various greases, lubricants and coolants are

required to operate the machine.
If these resources are used incorrectly or not in
accordance with the regulations, these can catch
fire.
Fires or even explosions may occur, with serious
injuries and damage to humans and the machine.
In addition, toxic oxides of carbon, nitrogen, sul-
phur and phosphorus, as well as toxic organic
and inorganic substances are generated during
combustion.

Prevention
• In theory, you should use water-miscible cool-
ants in the right mixing ratio, because with these
the risk of ignition is very low to negligible.
• When machining slightly inflammable materials
with coolants that are immiscible with water, the
machine is to be equipped with explosion valves
and fire extinguishing systems (on request).
• Use all resources only in accordance with the
manufacturer's instructions.
(operating area, mixing ratio, machining materi-
als)
• Do not mix resources with each other.
(physical and chemical properties may be
changed by this).
• Clean the machine regularly and thoroughly.
(coolant and lubricant residues, etc.)
• Instruct users of the machine regularly in the
risks.

Firefighting measures
• Isolate the machine from the mains
• Individual protection equipment:
Protective overalls and breathing apparatus
• Suitable fire extinguishers
Foam, CO2, powder, no water
Ensure that there is an approved and checked fire
extinguisher near the machine.

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12
 Safety Regulations

Instructions
The Safety Regulations chapter is to be presented to all those who are involved with
the operation, servicing and repair of this machine. The regulations must be read, un-
derstood and this confirmed in writing.
The machine description must also have been read and understood.

Confirmations
I hereby confirm that I have been briefed on the
• safety regulations for this machine
• special safety regulations in the individual chapters of this machine description under
the heading "Danger, Caution, etc."
• Proper use
• special sources of risk on this machine (suspended loads, strong magnetic fields,
etc.)
• duty to report to the manufacturer of the machine any kind of dangerous fault con-
nected with the control unit
and am aware of these.

Name Department Date Signature

_____________________ _ ___________________ _ _________ _ ________________________

_____________________ _ ___________________ _ _________ _ ________________________

_____________________ _ ___________________ _ _________ _ ________________________

_____________________ _ ___________________ _ _________ _ ________________________

_____________________ _ ___________________ _ _________ _ ________________________

_____________________ _ ___________________ _ _________ _ ________________________

_____________________ _ ___________________ _ _________ _ ________________________

_____________________ _ ___________________ _ _________ _ ________________________

_____________________ _ ___________________ _ _________ _ ________________________

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14
 Technical Specification

Technical Specification for the machine

Work area
Revolving diameter over bed [mm] ø130
Revolving diameter over plane carriages [mm] ø60
Maximum turning diameter [mm] ø60
Maximum part length [mm] 215
Traversing ranges
Carriage traverse X [mm] 60
Carriage traverse Z [mm] 280
Main spindle
Spindle connection according to the factory standard
Spindle boring [mm] ø16
Chuck diameter (manual chuck) [mm] ø74
Penetration into chuck [mm] ø15
Penetration into chuck [mm] ø15
Main spindle drive
AC asynchronous motor, max. output (30% ED) [kW] 1,1
Rated motor speed [rpm] 1400
Spindle speed range [rpm] 300 – 4200
Max. torque (30% ED) [Nm] 10
Feed drives
3-phase stepped motor, resolution [µm] 0,5
Task feed in X/Z, continuously variable [mm/min] 0 – 2000
Rapid traverse speed in X/Z [mm/min] 3000
max. feed force in X/Z [N] 1000
average position variation range according to VDI 3441 in X/Z [µm] 8/8
Tool turret
Number of tool positions 8
Tool housings inside/outside 4/4
Max. tool cross-section [mm] 12 × 12
Max. shaft diameter for drill rods [mm] ø10
Lubrication system
Guideways Greasing system
other lubrication points on the machine Greasing system
Hand-operated tailstock (option)
Quill diameter [mm] ø22
Quill travel [mm] 35
Quill inner cone MK 1
Automatic tailstock (option)
Electromechanical tailstock with end position monitoring
Quill travel [mm] 15

We reserve the right to make technical changes!

If information differs from the technical specification, the values given in it prevail!

15
Technical Specification

Pneumatics unit (option)

Basic pneumatics unit with filter and oiler for automatic clamp and automatic door system
Supply pressure [bar] 6
Hose connection [mm] ø10
Compressed air quality according to DIN ISO 8573-1, purity class 4
Automatic clamp (option)
Pneumatic 3-jaw chuck with full clamping cylinder, pressure monitoring and blower device
Chuck diameter [mm] ø76
Automatic doors (Option)
pneumatically operated, incl. end position monitoring
Operating conditions
required ambient temperature [°C] +10 to +35
Atmospheric humidity [%] 40 to 70
Electrical connection
Power supply (plug-in) [V] 1/N/PE 115/230~
Max. voltage fluctuations [%] ±10
Frequency [Hz] 50/60
Machine load connection value [kVA] 1,3
Max. series fuse rating for the machine [A, gG] 13
Short circuit resistance [kArms] 10
Lead cross-section [mm²] min. 3 × 1.5
Paintwork
Light grey RAL 7035
Graphite grey RAL 7024
Red RAL 3020
Black RAL 9004
Dimensions/weights
Height of rotating axis above hall (without machine base) [mm] 322
Installation area W×D (without options) [mm] 895×745
Height overall (with doors open) [mm] 600
Total weight of the machine (without options) [kg] 150
Sound pressure level
average sound pressure level [db(A)] 65
under the following conditions:
Measuring procedure:.Enveloping surface measurement procedure according to DIN 45 635
Measuring point: 1 m distant and 1.6 m above the floor
Operating status: Maximum speed under no load conditions
Declaration:
The quoted figures are emission levels and not necessarily safe working levels. Although there is a correlation between the
degree of noise emission and the degree of noise stress, this cannot be used reliably to decide whether further protective
measures are required or not. Factors that affect the actual degree of stress on the occupants include the characteristics of
the working area, other noise sources, etc., i.e. the number of machines and other processes running in the vicinity, as well as
the duration for which an operator is exposed to the noise. The permitted stress level can also vary from country to country.
However, this information should enable the user to make a better assessment of the dangers and risks.

We reserve the right to make technical changes!

If information differs from the technical specification, the values given in it prevail!

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 Technical Specification

PC configuration
Configuration
Computer components
minimum recommended
IBM or IBM-compatible processor 1 GHz 2 GHz
free hard disk space 400 MB
32 bit - 1 GB
Working memory (RAM) 256 MB
64 bit - 2 GB
VGA graphics card, resolution min. 800×600
Windows XP (SP3)/
Operating system (32 or 64 bit) Windows 7/8
Vista/7/8
10/100 MB,
TCP/IP network card (machine connection to the PC)
RJ45 plug
Screen 14" colour screen
Keyboard MF-2
2 USB interfaces for connecting the external keyboard from USB 2.0 (2×)
(option and higher

We reserve the right to make technical changes!

If information differs from the technical specification, the values given in it prevail!

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18
 REV.04
EC DECLARATION OF CONFORMITY en

Product: PC-controlled lathe for training

Machine data: Model Type No.

EMCO CONCEPT TURN 60
-

Address of manufacturer: EMCO Maier GmbH

Salzburger Strasse 80
A-5400 Hallein

Bases of standards: EN ISO 14121-1:2007 EN ISO 13849-1:2008+AC:2009

EN ISO 12100-1:2003+A1:2009 EN ISO 12100-2:2003+A1:2009
EN 60204-1:2006+A1:2009 EN ISO 23125:2010+A1:2012
Name and address of the person authorised to compile the technical file:

We hereby declare that the above mentioned product(s) is in accordance with the valid regulations of
following terms:

- Directive 2004/108/EC of the European Parliament and of the Council of 15 December 2004 on the
approximation of the laws of the Member States relating to electromagnetic compatibility and repealing
Directive 89/336/EEC;

- Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and
amending Directive 95/16/EC;

Place, date:

Authorized person:
 A Setting up the machine

Machine takeover
Check the machine for any possible transport
damage and for completeness of the delivery.
If you detect a fault, please contact the dealer or
insurance company immediately.
With complaints or repeat orders of replacement
parts and accessories, the machine number, the
electrical number, control console number and
software version are always to be specified.

2 Machine number and

electrics number
Concept Turn 60
110/230VAC 1/N/PE 50/60Hz The nameplate with the machine number (1) and
Imax=11 A Icw<=10 kArms the electrical number (2) are located on the side
Fuse for the supply line
Fuse for the supply line 13A gG of the machine above the lockable master switch.
E-Doku.Ser.No.: A6D_V00
Fabr.No.: A6D 133601
The machine number is also stamped on the
Baujahr/Year of constr.: 2013 machine base.
Made by EMCO MAIER Ges.m.b.H. Hallein/AUSTRIA

1
Machine number (1) and electrics number (2)

Instructions:
You will find the circuit diagrams applicable to
your machine in the electrical documenta-
tion, which is located in the machine switch-
gear cabinet.
An Electrical Documentation pack can also be
purchased, quoting the following order num-
bers and the EMCO electrical part number:
ZVP 677 974

21
Deliverables Set-up

Deliverables
Basic machine
Inclined bed lathe (1) with continuously variable
main drive, 8x tool turret, ***chip bin***, chip
guard cladding, safety package

Modules
Grab:
… …USB stick with machine data (2)
… …Lathe tool documents: 8×0.2/4×0.5/4×1.0 (4)
… …Single open-ended wrench SW8 (3)
1 … …Allen key SW3, 4, 5, 8 (5)
… …Grease gun (6)
… …User handbook and electrical documentation
(7)
Options:
… …Controller......................................................
… …Machine base
… …Swivelling table for machine base
2 … …Manual tailstock
… …Controller keypad with key module
… …3-jaw manual chuck
5
3 … …Collet chuck
… …Electronic hand wheel
4 Automation:
… …I/O extension board
… …Pneumatics unit
… …Automatic doors
… …pneumatic power chuck
7 … …electromechanical tailstock
6 … …5. Axis (rotary swivel unit)
… …Robotics interface
… …DNC interface

Machine with options, deliverables
Data medium
A USB data stick with machine-specific data
(MSD and PLC) is packed with the machine.
It contains data specially for this machine and is
needed for its configuration.
This data must not be used on any other machine!

Packaging
The machine will be delivered bolted to awooden
pallet (4 mushroom head bolts). The external
packaging varies according to country of delivery
and contractual agreement.
After removing the 4 M12/SW 19 hexagonal
nuts,  the machine can be lifted from the pallet.

22
Set-up Transport

Transporting the machine

Transport without
machine base

Position of the forks (1) while transporting the machine

Transport with pallet

kg ~230 kg kg ~150 kg
with pallet without pallet Caution:
The machine should be transported on the
pallet only if it is fastened to the pallet with
all the anchor bolts.
Also note the positions of the forks (1).

Lifting capacity................................. min. 230 kg

Fork width.................................. 800 - 1 000 mm
Fork length................................... min. 1 200 mm

2 3
Transport with lifting bars
ox .
appr m
 m Transport without pallet
12 0 0
The machine is transported with suitable lifting
bars (2), which are pushed through the lifting
angles (3) on both sides of the machine.

Caution:
Ensure that the lifting angle is bolted firmly
to the machine!

Lifting capacity..................................min. 150 kg

Lifting bars.................... ø35 × approx. 1 200 mm

23
Transport Set-up

Transport with
machine base (option)

Position of the forks (1) while transporting the machine with base (option)

Transport with pallet

kg ~310 kg kg ~230 kg
with pallet without pallet Caution:
The machine should be transported on the
pallet only if it is fastened to the pallet with
the anchor bolts.

Lifting capacity..................................min. 310 kg

Fork width.................................. 800 - 1 000 mm
Fork length................................... min. 1 200 mm

Transport without pallet

Caution:
The lifting points and fork dimensions must
be observed, so that no distortion is caused
to the machine pillars.

Transport with forklift Lifting capacity................................. min. 230 kg

Fork width..................................... 700 - 800 mm
Fork length................................... min. 1 200 mm

24
Set-up Set-Up Plan

Set-up plan, machine dimensions

Basic machine

25
Set-Up Plan Set-up

Machine with base (option)

26
Set-up Set-Up Criteria

Set-up criteria
Installation area
Ensure that the selected installation area is thor-
oughly clean (free from excessive dust and similar
contamination), in order to protect the machine,
as well as the PC and peripherals.

The following criteria must also be met:

Room temperature................................. 12-35°C
Atmospheric humidity............................. 40-70%

Climatic conditions at the installation site
Ergonomics
The machine facilitates ideal operation through
its ergonomic design.
However, ensure that there is adequate lighting
when choosing the installation site.

Machine without machine base

The machine must be installed on a stable base.
Weight of the machine.............................. 150 kg
Ideal table height........................ approx. 750 mm
Installation width × installation depth..................
1200 × 1200 mm

Danger:
Ensure the load capacity of the table is com-
patible with the weight of the machine!
ca. 750 mm

1200×1200 mm

Alignment of the machine

27
Set-Up Criteria Set-up

Machine with
machine base (option)
Order no. A7Z 210

Foundation requirements
The machine should be set up on a base that is
level as far as possible, with the corresponding
load-bearing capacity and vibration stability.

Setting up with steel plates

• Use the supports (2) enclosed with the machine
as a base.
• Align the machine horizontally on the setting
screws (3).
±0° • Fix the alignment by tightening the locknuts (1).

Setting up with levelling elements

Alignment of the machine

To achieve a degree of vibration damping, we

recommend the use of levelling elements (4).
Order number (4 units required)..............F3Z 150

• Screw the setting screws (5) and locknuts (6)

delivered with the elements into the machine
pillars from beneath.
• Place the machine with the setting screws on
the levelling elements (4) and align the machine
horizontally.
• Fix the alignment by tightening the locknuts (6).

1 2 3 4 5 6

Setting up with steel plates or levelling elements

28
Set-up
Additional Set-up Criteria
As well as the required load-bearing capacity
and vibration stability, the set-up surface or
place should fulfil some other requirements.
• The set-up area must comply with building
regulations, so that any possible leakages of
coolant, lubricating oil or hydraulic oil will not
harm the environment.
Ideally, the set-up area should also fulfil the
function of a catch basin.
• Furthermore, the set-up area should be el-
evated and well-aired.
Observe workplace safety guidelines (permit-
ted Maximum Workplace Exposure and TRK
limit values should not be exceeded)
• The best possible vibration damping proper-
ties, to limit the transfer of vibrations to neigh-
bouring objects (especially with high speed
work, bar work, work on workpieces that are
seriously out of balance, for interrupted cut-
ting, use of power tools, etc.).
• Good and adequate lighting in the workplace
facilitates working with the machine and im-
proves quality.
29
Set-Up Criteria
• Inconvenient light or sunshine can lead to
reflections on the control screen and thus
influence the visibility of the information.
• Attention should be paid to the special noise
stress faced by those working on the ma-
chine.
• It should be considered that, depending on the
operational situation, a highly qualified techni-
cian may be working at the machine, who will
be required to carry out sophisticated program-
ming and monitoring tasks.
Sometimes sound-absorbing walls can bring
about an improvement in the situation.
Tests have shown that doubling the distance
from a nearby sound source produces an at-
tenuation of between 3 and 5 dB(A).
Doubling the number of equivalent sound
sources leads to an increase in the level of
3 dB(A).
• Heat sources with fluctuating temperature
close to the machine, as well as draughts,
influence both the quality of the workplace
and the working accuracy of the machine.
If necessary, appropriate protective meas-
ures should be taken.
Electrical Connection Set-up

Electrical connection

Danger:
Only a trained electrician should connect the
1 mains power to the machine and its acces-
sories.
The supply cable must be de-energised on
2
connection.

• Thread the mains lead (3×1.5 mm², not included

PG union on the machine in the machine as delivered) (6) through the PG
union (2) on the side of the switchgear cabinet
(1).
• Connect the Live phase to the terminal strip =
1+L1-X0 (3) (terminal L1)
1
• Connect the neutral lead to the terminal N of the
terminal strip +=1+L1-X0 (3).
• Connect earth wire (yellow/green wire) to the
equipotential terminal on the terminal strip (3).

2 Set the mains voltage

Caution:
It is essential to set the mains voltage before
the machine is connected to the power supply
so as to avoid damage to the machine!
=1+L1-X0 =1+L1-X1

The machine can be operated with 2 voltages -

115 V and 230 V.
3 The setting is made with a bridge (jumper) on the
L1 N PE N 1 2 3
terminal strip =1+L1-X1 (4):
-X0

-X1

4 Power
Terminal strip = 1+L1-X1
supply

5 Jumper (5) across terminals

L N PE 230 V ~
1 and 2
Jumper (5) across terminals
115 V ~
2 and 3

6 1 2 3 1 2 3

5
230V~ 115V~

Switchgear cabinet and terminals

30
Set-up Electrical Connection / Connection with PC

Mains connection specification

Caution:
A series fuse is mandatory for the machine!
It is essential to obey the given fuse rating.

Power supply.............................. 1/N/PE ~ 230 V

1/N/PE ~ 115 V
Frequency............................................ 50/60 Hz
Max. voltage fluctuations........................... ±10%
Rated output............................................1.3 kVA
Max. series fuse .................................... 13 A gG
Lead cross-section.................... min. 3 × 1.5 mm²

Instructions:
Detailed information on the electrical con-
nection is in the electrical documentation for
your machine.
If any information differs, the information from
the electrical documentation is to be deemed
correct.

Machine-PC connection
The machine is controlled from a PC.
Either the PC keyboard, or the keypad controller
available from EMCO as an accessory can be
used as the data entry device.
1 2
• Plug the machine's mains cable with the plug
(2) into the corresponding connection on the
network card (1).

Machine-PC network card connection
Instructions:
To connect the machine with the PC, a net-
work card must be inserted into the PC and
installed correctly.
For insertion, installation and network set-
tings, see WinNC controller description, "In-
stallation" chapter.
Card type: . .............. Ethernet network card

31
Initial Start-Up Set-up

Initial Start-up
• All uncoated parts are to be cleaned of rust
protection agents with a clean cloth.
• Check all connections to the machine.
• Degrease the machine before starting up (see
machine maintenance).
• Open the air supply at the valve (2) (option).

1 • Tool and workpiece must be tightly and securely

clamped.
• Switch on machine at the master switch (1).
• See the switching on and off procedure for the
machine, as well as the software description,
for further use.

Master switch on the machine

Instructions:
If the machine is no longer in use:
• Clean the machine thoroughly
• Lightly oil uncoated parts.
• Secure the machine against unauthorised
access (key switch on the control console,
lockable master switch).
2 • Place a dust guard (packaging) over the
machine.
After the machine is switched off for a long
period, all activities that are described under
"Starting up for the first time" must be carried
out.

Pneumatics unit (option) on the machine

32
Set-up Switching O n

Switching On/Off Process

Switch the machine on
Open the air supply (option).

Switch on the master switch (1) at the switchgear

cabinet.
1
Open and close the chip guard door to check
Master switch each of the door limit switches once and close
again.
"Alt + M" or
Hold down the "AUX ON" key for approx. 1 sec-
ond.
Pressing the "AUX ON" keys powers up all the
drives.

Reference the axes individually

Pressing the +Z key
"6" or Carriage moves to the reference point in the Z
axis
Pressing the +X key
"8" or Carriage moves to the reference point in the X
axis
(Only after the collision-free space in the Z axis
has been reached).

Instructions:
After reaching the reference points the soft-
ware limit switches are active.

Reference automatically

"5" or Pressing the "Reference point" key moves the

axes automatically to their reference points one
after another.

For further use of the machine, refer to your "Soft-

ware Description".

33
Switching Off Set-up

Switching the machine off

"Alt + N" or Press the AUX OFF key.

Ending the controller software (WinNC).

Ending Windows

Switch off the master switch (1)

Shut off the air supply.

1

Master switch
Instructions:
• The machine is switched off with the master
switch.


It is recommended that the machine is
switched off only with the tool turret idle.
• Operations can be interrupted with the
Reset key.


RESET interrupts all running machine func-
"0" or tions.

34
 B Machine Description
1 2 3 4 15

5
18
6
11
7
19
8
9
10
16
17

12

20

13

14

Machine Elements- Overview

1. Chip guard doors 12. Spindle head
2. 8x tool turret 13. Machine base
3. X carriage 14. Chip bin
4. Z carriage
5. Switchgear cabinet Accessories/options
6. Machine nameplate 15. Tailstock
7. Door opening button 16. Easy Cycle comfort package
8. EMERGENCY SHUTDOWN button 17. Machine base with tool drawer and PC shelf
9. Key switch 18. Pneumatics, maintenance unit and valves
10. Machine master switch (lockable) 19. Optical tool preset device
11. Door-locking system 20. Collet chuck

35
Points of the Machine / Coordinate System Description

Points on the machine -

coordinate system
Machine zero point M
The machine null point M is in the rotating axis
on the front of the spindle nose.
The machine null point is the origin of the coor-
dinates system.
R
N
+X
(T)

M W
Reference point R
The reference point is a specified fixed point on
the machine. It is used to calibrate the measure-
+Z ment system.
The reference point must be approached each
time after the machine is switched on, in order to
make the distance between the points M and N
(T) known to the control system.

Points on the machine

Workpiece zero point W
The workpiece zero point W can be freely pro-
grammed by the user.
By programming a workpiece zero point, the ori-
gin of the coordinate system will be shifted from
+X the machine zero point M to the workpiece zero
–S1
point W.

+Z Workpiece housing reference point N

(T)
Distances to the tool tip are measured from this
point.
The tool housing reference point N (T) is precisely
on the front of the tool turret disk in the axis of the
Coordinates system housing boring for inside machining tools.
However, the housing boring must be swivelled.

36
Description Safety Equipment

Safety equipment
Safety equipment is built into the basic machine,
meaning that its operation is free from risk to a
considerable degree.

Danger:
Safety devices must never be removed from
the machine.
Mechanical or electrical bypassing of the
safety devices are also forbidden.

EMERGENCY-OFF key
The EMERGENCY-OFF key (2) should be pressed
1
immediately in a danger situation.
On pressing the key (2), the power supply to the
main drive, the feed motors and the auxiliary
drives will be cut off immediately.
To unlock the EMERGENCY-OFF key, turn the
button clockwise.

Instructions:
After pressing the EMERGENCY-OFF key, the
reference point must be approached again.

Door-locking system
A door-locking mechanism (1) is built into the ma-
chine, which only permits the chip guard doors to
be opened if the main drive has stopped.
4 2 3 A program cannot be started if a door is open.
Open the chip guard doors by pressing the Con-
firm key "T" (4).

37
Safety Equipment Description

Key switch
The key switch (3) can be switched to the posi-
tions "Automatic" and "Set-up mode."

"Automatic" setting
The "Automatic" switch setting is the working
setting of the machine in which all safety devices
are enabled.

"Set-up mode" setting

Instructions:
The carriage can only be moved by hand with
the chip guard doors closed if:
• the reference point was approached
or
• if the key switch is in the "Setup mode"
position.

With the switch in this position, the carriages can

be moved by hand with the chip guard doors open
(for two-handed operation in conjunction with the
Enable key - see next page).

Danger:
• In the "Set-up mode" switch setting, there
is an increased risk of accidents.
• In set-up mode, keep the machine door
closed insofar as the work process permits
this.
• After conclusion of the set-up work, switch
the key switch immediately to "Automatic"
again and remove the key.
• The key should only be given to people who
have the required knowledge of the dangers
that exist and are familiar with the machine.

38
Description Safety Equipment

Enable button
The function of the Enable key depends on the
position of the key switch.

Instructions:
If the Enable key is held down for more than
40 seconds, then the function of this key is
interrupted. The Enable key must then be
released and pressed again.

Functions of the Enable key

Key switch position on "Automatic"
• Loosen the locking bolts of the chip guard doors
with the main spindle stationary.
The machine doors can be opened.

Key switch position at "Set-up mode"

• Move the carriage in JOG mode with the un-
reached reference point and the machine doors
open.
Position of the Enable key
• Manual movement of the carriage with the chip
guard doors open.
• Swivelling the tool turret with the chip guard
doors open (swivelling by one position respec-
tively).

39
Working Area Description

Machine working area

Turning circle at the

tool turret

40
Description Machine Components

Machine base
The machine base is a massive welded con-
struction for housing the machine bed and all the
electrical equipment.

Machine bed
The machine bed is manufactured from grey cast
1 2 3 4 5 iron, extremely resistant to torsion and vibration-
damping.
Spindle stock, carriage unit and tailstock (option)
are built on to the machine bed.

Carriage
All guides are formed as high quality precision
roller guides, with high feed forces and high
traverse speeds.
Lubrication is via grease nipples with long-life
grease.

6 7 8 9 10
Pos.
1 Main spindle
Pos.
6 Drive belt
Carriage drives
2 Z carriage 7 Main drive Carriages are moved with step motors via recir-
culating ball spindles.
3 X carriage 8 Machine bed
Spindles of large dimensions, rigid spindle nuts
4 X spindle 9 Z spindle and zero-play axial bearings produce high posi-
5 X drive 10 Z drive tioning and working accuracy.
Feed speed................................ 0-2000 mm/min
Rapid traverse speed.................... 3000 mm/min
Longitudinal carriage travel..................... 290 mm
Transverse carriage travel........................ 60 mm
Incremental resolution..............................0.5 µm
max. longitudinal carriage feed force....... 1000 N
max. transverse carriage feed force......... 1000 N

Main drive
The main spindle is driven by an asynchronous
AC motor.
Speed range (continuous)............300 - 4200 rpm
max. output.............................................. 1.1 kW
max. torque.............................................. 10 Nm

41
Main Spindle Description

Main spindle
The main spindle is driven by an AC motor via a
V-belt.
It is mounted in sealed for life lubricated roller
bearings and is therefore zero maintenance.
The clamp is tightened at the tapped borings
provided for this purpose, according to the type
of clamp.
Clamps must have a centring flange.
Spindle connection...................Factory standard
Max. chuck size............................................ ø74
Speed range................................300 - 4200 rpm
Power:............................................. max. 1.1 kW
Torque..............................................max. 10 Nm

Connection mass at the spindle nose (factory standard)

42
Description Tool Turret

Tool turret
Number of tool housings................................... 8
(4 outer and 4 inner machine tools in each case)

Maximum turning circle diameter

Turning tools...................................... ø129.5 mm
Cutting tool........................................ ø140.0 mm

Clamping the tools and aligning

at tip height
Before you clamp a tool, read in the WinNC soft-
ware about using the tool turret via the PC.
tool turret
Outer machining tools

Danger:
Tools should only be clamped with the ma-
chine stationary.

A maximum of 4 outer machining tools can be

clamped.
• Set the desired tool turret position.
• Place the tool (4) in the housing (1) and set
the tool protrusion. The protrusion should be
1 2 3 4 approx. 13.5 mm, and for cutting tools approx.
22 mm.
Clamping outer machining tools
• Insert spacers (3) to set the tool at tip height.
• The tool is clamped by tightening the two lock-
ing screws (2) with an Allen key SW3.
5
9.
12

14
0

13,5-22
Instructions:
Aids to setting the tip height are the dimen-
sion "30 mm" between tool cutting edge and
30

transverse carriage surface, or the centring

tip in the main spindle or tailstock, or a
clamped centring drill in the fitted triple-jaw
chuck.
Set tip height and tool protrusion

43
Tool Turret Description

Inner machining tools

1. Inner turning chisel
A maximum of 4 inner machining tools can be
clamped.
Required shaft diameter......................... ø10 mm

• Push the inner chisel (1) into the housing boring

(2) on the tool turret.
• Turn the chisel (1) so that the cutting edge of the
turning chisel is exactly at turning axis height.
• Clamp the chisel (1) by tightening both locking
screws (3) with an Allen key SW3.

1 2 3
2. Drilling tools
Clamping the inner turning chisel
Maximum shaft diameter........................ ø10 mm

• Push the clamping sleeve (5) with the corre-

sponding interior diameter on to the borer (4).
• Plug the borer (4) with the clamping sleeve (5)
into the tool turret housing boring (2).
• Clamp the borer and clamping sleeve by tight-
6 ening both locking screws (3) with an Allen key
SW3.

7
Should the tip height not match, then proceed
as follows:
• Loosen the four Allen screws SW5 (6).
• Turn the tool turret disk (7) until the tip height
4 5 2 3 of the boring tool corresponds.
Clamping boring tools • Retighten the four Allen screws (6).
• After setting the boring tools to tip height, all
other clamped tools must be reset to the tip
height.

Instructions:
Aids to setting the tip height are the dimen-
sion "30 mm" between tool cutting edge and
transverse carriage surface, or the centring
tip in the main spindle or tailstock, or a
clamped centring drill in the fitted triple-jaw
chuck.

44
Description Tailstock

Tailstock (option)
The tailstock is used to counter-support work-
pieces with rolling particles and for boring and
centring tasks.
Quill diameter..........................................  22 mm
Quill inner cone........................................... MK1
Quill travel....................................... max. 35 mm
Quill travel for 1 turn of the handwheel.......1 mm
The quill is moved via the handwheel (3). On the
side at the quill is a millimetre scale (1) for setting
the quill travel. The tailstock is clamped at the
clamping lever (4) and the quill at the clamping
lever (2).
The quill inner cone houses the tailstock acces-
1 2 3 4 sories, which are simply pushed into the cone.
When the quill is turned back to the stop, the tool
Tailstock housed by the cone is ejected automatically.

Instructions:
Always swivel the convertible clamping lever
(2) after clamping the tailstock to the right, to
avoid a collision with the tool turret.

45
 Blank page

46
Description Clamping Devices

Clamping devices
All clamps given here are available as accesso-
ries from EMCO.

Overview

Main spindle
The main spindle is manufactured in accordance
1 with the factory standard. The chuck is mounted
with 3 fixing screws on the housing threads (1) at
the spindle nose, the chuck being mounted with
2 4 fixing screws on the housing threads (2).

Main spindle spindle nose Triple-jaw chuck ø74 mm

Order no. .............................................. A6Z 630

It is used for central clamping of circular, hexago-
nal and dodecagonal workpieces.

Collet chuck

Triple-jaw chuck A6Z 630

Order no. .............................................. A5Z 040

Collet chucks can clamp circular workpieces
with maximum revolving accuracy. Collet chucks
do not leave behind any clamping marks on the
workpiece.

Collet chuck A5Z 040

47
Clamping Devices Description

The 3-jaw turning chuck

Also, observe the instructions enclosed with the
chuck.

Mounting the chuck

Danger:
• The chuck should only be fitted when the
machine is stationary.
• To mount the flange, only M5×12 screws to
DIN 912 should be used; the chuck should
only be tightened with M5×35 screws.


If the screws are longer, the chuck could
not lie flush on the spindle nose and if the
screws are too short these could tear out.

1 2 3 4 5

Mounting the chuck

• The spindle nose (1) and borings on the flange
(2) and chuck (4) must be free from dirt.
• Screw the flange (2) with the three M5×12 cylin-
drical screws (3) to the spindle nose and tighten
the screws.
• Mount the chuck (4) with the M5×35 cylindrical
screws (5) on the flange (2).

Clamping ranges

Danger:
• The maximum permitted clamping ranges
must never be exceeded. Exceeding this
can lead to the jaws breaking.
• The jaw protrusion must never be more than
7 mm, otherwise there is a risk of the jaws
breaking.
• After clamping workpieces, pull out the
chuck key.
d 10
7
d
5
d

11

12

13
d6

d8

9
d

d 5 min. d 6 max. d 7 min. d 8 max. d 9 max. d10 min. d 11 min. d12 max. d 13 max.
2 24 23 68 88 2 23 68 88

Maximum clamping range of the 3-jaw turning chuck (data in [mm])

48
Description Switching on

The collet chuck device

Also, observe the instructions enclosed with the
collet chuck device.
Collet chucks can clamp circular workpieces
with maximum revolving accuracy. Collet chucks
do not leave behind any clamping marks on the
workpiece.
Clamping range.............................. 1.5 to 16 mm
Collet chuck type . ..................................ESX 25

Mounting the collet chuck device

Danger:
• The chuck should only be fitted when the
1 2 3 machine is stationary.
• Only M5x10 screws to DIN 933 should be
Mounting the collet chuck device used to fit the chuck.


If the screws are longer, the chuck could
not lie flush on the spindle nose and if the
screws are too short these could tear out.

• The spindle nose (1) and the chuck boring (3)

must be free from dirt.
• Screw the collet chuck device (3) with the three
M5×10 cylindrical screws (2) to the spindle nose
and tighten the screws.

Mounting collet chucks

4 • Unscrew the locknut (5).
• Insert the collet chuck (4) in the clamp housing
5 (5) at an angle, so that the eccentric ring (6)
engages in the collet chuck groove.
6 • Screw the collet chuck with its clamping nut on
to its holder.

Removing the collet chuck

Mounting collet chucks • Tighten the locknut (5).
• If the locknut is unscrewed, the eccentric ring
(6) in the locknut presses out the collet chuck
(4).

49
Clamping Devices Description

Clamping workpieces
• Fit the appropriate collet chuck.
• Push the workpiece (5) into the collet chuck.
Ensure that the workpiece is pushed far enough
into the collet chuck.
If the clamping is too short, the workpiece can
be flung out of the device.
• Tighten the locknut (4) with the clamping pin (2).
Resist the collet chuck holder (3) with the sec-
ond clamping pin (1).

1 2 3 4 5
Clamping workpieces

Clamping ranges

Danger:
The clamping ranges given in the table must
always be observed.
If collet chucks are too large, workpieces can-
not be clamped securely.

Nominal ø Clamping range Order

Collet
chuck [mm] [inches no.
2.0 1,5-2,0 1/16-5/64 225 020
2.5 2.0-2.5 3/32 225 025
3.0 2.5-3.0 7/64 225 030
4.0 3.0-4.0 1/8-9/64-5/32 225 040
5.0 4,0-5,0 11/64-3/16 225 050
6.0 5.0-6.0 13/64-7/32-15/64 225 060
7.0 6.0-7.0 1/4-17/64 225 070
8,0 7.0-8.0 9/32-19/64-5/16 225 080
9.0 8.0-9.0 21/64-11/32 225 090
10.0 9.0-10.0 23/64-3/8-25/64 225 100
11.0 10.0-11.0 13/32-27/64 225 110
12.0 11.0-12.0 7/16-29/64-15/32 225 120
13.0 12.0-13.0 31/64-1/2 225 130
14.0 13.0-14.0 33/64-17/32-35/64 225 140
15.0 14.0-15.0 9/16-19/32 225 150
16.0 15.0-16.0 10/16-5/8 225 160
Complete set of collet chucks 225 000

50
Description Tools

Tools and accessories

Turning tools

Tool no. Order no. Description

1 271 070 Side cutting tool right

2 271 050 Side cutting tool left

3 271 060 Side cutting tool neutral

Outer thread cutter

4 260 630
maximum pitch 1.5 mm

Inner thread cutter ø10x60 mm

5 271 170
maximum pitch 1.5 mm

6 271 140 Boring bar ø10x60 mm

7 264 020 Cutting mount

HM cutting inserts
matching tool
HM plate Order no. Description
no.

260 610 Set of 10 HM cutting inserts for steel

1, 2, 3, 6
271 056 Set of 10 HM cutting inserts for aluminium

Set of 5 HM cutting inserts for outer threads, maximum

260 631 4
pitch 1.5 mm

Set of 5 HM cutting inserts for inner threads, maximum

271 175 5
pitch 1.5 mm

271 086 Set of 5 HM cutting inserts for cutting mount 7

51
Tools / Accessories Description

Drilling tools

Description Order no.

Set of HSS [high-speed steel] spiral drills

260 628
9 spiral drills ø2-10 (1 mm steps)

HSS spiral drills

A6Z 050
ø12 mm, extra short

HSS centring drills  

ø6.8 mm 573 770
A8, DIN333 271 220

Tailstock accessories

Description Order no.

Rolling particles MK1

Rolling particles 3x mounted to counterbalance A5Z 260
longer workpieces.

Accessories for tool turrets

Description Order no.

Reducing sleeves
A6Z 270
8 reducing sleeves ø2 to ø9 mm for clamping drills.

52
Description Technological Data

Technological data

1. Cutting speed V 2. Speed S

D [mm] · π · S [rpm] V [m/min] · 1000

V [m/min]= S [rpm]=
1000 D [mm] · π

V [m/min]........... Cutting speed The main spindle speed can be calculated from
D [mm].............. Workpiece diameter the cutting speed and the workpiece diameter.
S [rpm].............. Main spindle speed

The maximum permitted cutting speed is depend- 3. Feed F

ent on:
The feed F is programmed on the EMCO Concept
• Workpiece material Turn 60 in [mm/min].
The higher the material rigidity, the lower the
cutting speed.
F [mm/min] = S [rpm] · F [mm/rev]
• Turning chisel material
Hard metal tools allow higher cutting speeds
than HSS tools. F [mm/min]........ Feed in [mm/min]
F [mm/rev]......... Feed in [mm/rev]
• Feed size
S [rpm].............. Main spindle speed
The larger the feed, the lower the cutting speed.
• Chip depth
The higher the chip depth, the lower the cutting Summary
speed.
Cutting speed
Cutting speed for programming exercises on
the EMCO Concept Turn 60:
Speed calculation
Workpiece material:...... ***Automat aluminium***
Turning chisel:................................... Hard metal
Cutting speed - turning:...............150-200 m/min Feed calculation
Cutting speed - cutting:.................. 60-80 m/min
Feed size - turning:.................... 0.02-0.1 mm/rev
Feed size - cutting:.................. 0.01-0.02 mm/rev The tables on the next page will save you a cal-
culation task.

53
Technological Data Description

Finding the speed

1000 ⋅ v
n=
d⋅π

n [rpm].......................rpm
v [m/min].......................Cutting speed
d [mm].......................Turning diameter

1000
00 00 00 00

00
30 25 20 15

40
00
500 10
0
400 75
]
300 p m
[r 50
0
n
d
200 ee 35
0
Sp
Cutting speed v [m/min]

0
100 20
0
15

0
50 10
40
60
30

20

10

3 5 10 20 30 40 50 100 200
Turning diameter d [mm]

54
Description Technological Data

Recalculating the feed

Example
Given:
• Main spindle speed........................ n=1700 rpm
• Feed......................................... F=0.06 mm/rev

Wanted:
• Feed speed.................F V= approx.100 mm/min

0.2
10

15

20

30

40
20

30

50

70

0
0.15

0.1
10
Feed F [mm/rev]

0.05
Fe
ed
sp
ee
d
F
V
n
[m
m
/m
in
0.02
]

0,01
100 200 500 1000 2000 3000 4000

Speed n [rpm]

55
Technological Data Description

Speed-torque characteristic curve

M [Nm]

12,0

11,0

10,0

9,0

8,0

7,0
Torque

6,0

5,0

4,0

3,0

2,0

1,0

0,0
0 500 1000 1500 2000 2500 3000 3500 4000 4500

n [min-1]
rpm

56
 C Machine maintenance

• Maintenance overview - graphic illustration............................. 58

• Maintenance overview - Table................................................. 59
• Recommended lubricants....................................................... 59
• Unprotected parts................................................................... 60
• Hoses and lines...................................................................... 60
• Clamps (option)...................................................................... 60
• Spindle nuts........................................................................... 61
• Roller guides.......................................................................... 61
• Check the EMERGENCY OFF key.......................................... 62
• Tailstock (option).................................................................... 62
• Main drive belt........................................................................ 63
• Pneumatic servicing unit (option)............................................ 64
• Viewing plates........................................................................ 65

Danger:
• All repair and maintenance tasks may only be carried out with the machine
switched off.
• Ensure that while this is in progress the machine is secured against start-
ing, e.g. the master switch is barred with a personal padlock.
• After repairs and servicing, the machine should only then be switched on
if all cladding plates are fitted.
• Never clean the machine with compressed air, as chips may penetrate the
guide rails and damage these!

57
Overview Maintenance

12 5 years

9 10 500 hours

5 8 40 hours

4 2 8 hours

3 1 8 hours

6 7 40 hours

11 9 10 500 hours

check,
oil exchange
exchange if necessary

Cleaning, grease
exchange if necessary (via grease nipples)

58
Maintenance Overview/Recommended Lubricants

Interval
No. Object of inspections and maintenance Activity
[h]
1 Clean chip area and chip bin
2 Door plate: check for damage
8
3 Clean clamp
4 Pneumatics option: Check the condensate separator
5 Check all hoses and lines
6 Clean and oil unprotected parts on the machine
40
7 EMERGENCY SHUTDOWN button: Check function
8 Option: Oil tailstock quill
9 Roller guides (X/Z spindles): Grease grease nipples
10 Spindle nuts (X/Z spindles): Grease grease nipples 500
11 Main drive: Check belt
12 Door plate exchange 5 years

Observe the maintenance notes in the manufacturer's instructions enclosed with the individual machine
components and the safety data sheets for the resources. These are enclosed with the machine.

Recommended lubricants
Designation according to
Use Recommendation
DIN
BP Maccurat D 68
CASTROL Magnaglide D 68
JOKISCH BBÖ 68
• unprotected parts
Slideway oil: KLÜBER Lamora D 68
• Collet chuck
CGLP DIN 51502 ISO VG 68 MOBIL Vactra 2
• Tailstock
OMV Glide 68
SHELL Tonna S68
TRIBOL 1060/68
Slide paste
EMCO
Universal grease
HAINBUCH
2085/0003
KLÜBER
Grease: Altemp Q NB 50
• Spindle nuts MOLUB ALLOY
DIN 51804/T1 NLGI 2 Topfit 3284
• 3-jaw chuck OMV
DIN 51807-1 Signum LM
RÖHM
F 80
SHELL
Retinax HDX 2
TRIBOL
4020/460-2
Grease:
• Roller guides on lithium soap base CASTROL Spheerol EPL 2
NLGI 2
Pneumatic oil: CASTROL Magnaglide D 32
• Compressed air oiler
DIN 51524 ISO VG32 MOBIL HLP 32

59
Unprotected Parts / Lines / Clamps Maintenance

Unprotected parts
Danger:
Parts in the working area of the machine
should only be cleaned and oiled if the ma-
chine is idle.

Unprotected parts such as cover plates and fin

coverings are to be cleaned weekly.
Then oil the parts lightly with slideway oil.

• Lightly oil unprotected parts

Hoses and lines
• Check hoses and lines To improve operating safety, a visual check for
leaks should be made at regular intervals (roughly
every six months) of the hose surfaces for all
Machine working area pneumatic lines, as well as all electrical power
lines.
To do this, remove the corresponding cladding
plates and check whether a hose/line has failed
or is moist or damaged anywhere.

Danger:
• Damaged lines/hoses are to be replaced
immediately by authorised technicians!
• Ensure that pneumatic lines are depressu-
rized (bleeding)
• Work on the electrical system is allowed
only when the machine has been switched
off and isolated from the mains!

Clamps (option)
Clamps (collet chucks, jaw chucks) are to be
cleaned daily of chips and other dirt, in order
to guarantee ease of access and thus secure
clamping.

Instructions:
Also observe the instructions enclosed with
the relevant clamp!
Clean

60
Maintenance Spindle Nuts / Guides

Spindle nuts
Longitudinal and transverse spindles are recir-
culating ball spindles produced to the highest
standards.
Accordingly, ensure that spindle nuts are greased
regularly to avoid damage.
Lubrication interval .......................... 500 hours
Lubrication . ................via grease nipples (2, 3)
Grease.............. see lubricant recommendations

1 • Remove carriage cover (1).

Machine working area • Greasing the X spindle nuts via the grease nip-
ples (2)
• Greasing the Z spindle nuts via the grease nip-
2 ples (3)
• Refit the carriage cover (1).

Grease nipples for spindle nuts

Roller guides
Longitudinal and transverse carriages run in pre-
cision roller guides.
4 These must be greased at regular intervals
Lubrication interval .......................... 500 hours
Greasing...............................via grease nipples
Grease.............. see lubricant recommendations

5 • Remove carriage cover (1).

• Greasing the X guide via the grease nipples (4)
• Greasing the Z guide via the grease nipples (5)

Grease nipples for roller guides

61
EMERGENCY OFF Key / Tailstock Maintenance

Check the EMERGENCY

OFF key
For safety reasons, you must check the function-
ing of the emergency shutdown button monthly:
To do this, press the EMERGENCY OFF key and
then clear the EMERGENCY OFF condition in
each case.
If an alarm is triggered when an EMERGENCY
OFF state is induced, the machine safety is no
longer guaranteed.
No further work can be performed with this
machine until it has been repaired by a service
engineer.

Example:
- Press the EMERGENCY OFF key
- Unlock the EMERGENCY OFF key
- RESET
- AUX ON
- Open and close the machine door
EMERGENCY OFF key on the machine .
.
.

Tailstock (option)
• Clean the tailstock quill (2) regularly and mois-
ten lightly with slideway oil.
• Clean the quill inner cone (1) thoroughly.

2 1

Tailstock

62
Maintenance Main Drive Belt

Main drive belt

The main drive belt should be checked at least
every six months for condition and tension.
If there are signs of wear, the belt should be
changed immediately.

Belt ................................. Poly-V belt 864 PJ4

Order no. . ....................................ZRM 800 864

Danger:
1 The main drive belt should only be changed
when the machine is stationary.
Cover for spindle stock and belt

Exchanging the
main drive belt
• Remove the left machine cover (1).
• Loosen all 4 locking screws (2).
• Loosen the setting screw SW17 (4) to a point
where the drive belt (3) can be removed.
• Replace the drive belt (3) with a new belt.
• Tension the belt using the setting screw (4).
The tension must be set so that the belt can
be depressed between the two belt disks by
approx. 10 mm under a testing force of 66 N
(≈ 6.6 kg).
• Lock the belt setting by tightening all 4 locking
screws (2).
• Fit the machine cover (1).

2 3 4

Fp =66 N
E=10 mm

Changing and tensioning the drive belt

63
Pneumatics Maintenance

Pneumatic servicing unit

(option)
The oil level of the compressed air oiler must be
checked daily at the servicing unit tank (3).
1 If necessary, it must be topped up with an ap-
propriate oil.
2
A sensor monitors the oiler level. If it falls below
3 the danger level, an alarm message pops up on
the controller screen.
• Unscrew the filler screw (2) and fill with oil up
to the "max" mark on the tank (3).
• The controller (1) is used to set the air/oil mix-
ture ratio.
This is preset in the factory and should not be
changed.

4 See lubricant recommendations for oil type

5
water separator
Pneumatics unit on the machine (option) To keep the compressed air free of water as far
as possible, a water separator is built into the
servicing unit.
The separator tank (4) is drained by loosening the
locking screw (5) on the tank.

64
Maintenance Door Plate

Viewing plates
The machine door has a polycarbonate safety
window
Danger: The polycarbonate viewing disk (PC disk) offers
Viewing disk ageing: penetration safety against flying parts such as
The door plate must be exchanged at least chuck jaws or broken tool tips.
every 3-5 years or exchanged immediately if
there is visible damage!
Reason:
Through contact with coolant, the polycar-
bonate viewing disk undergoes an ageing
process (embrittlement), in which the ability
to retain flying parts is lost within a few years.

Cleaning recommendations Servicing the viewing disk

Dusty PC plates must be wiped with water, a soft The safety-critical retention capability of the PC
cloth or sponge - never rub dry! Electrostatically disk is lost after a few years through the effect
charged PC plates attract dust and must therefore of coolant.
be blown clean with ionised air. This ageing or brittleness of the PC disk cannot
We recommend that you do not use a harsh be detected by visual examination, and therefore
cleaner for basic cleaning. Razor blades or other the door plate must be renewed in principle at
sharp tools, corrosive or strongly alkaline clean- least every 5 years.
ers, solvents, petrol containing lead and tetrachlo-
In addition, the PC disk must be inspected visu-
ride must not be used.
ally at regular intervals so as to exchange it im-
A microfibre cloth moistened simply with water
mediately if the following damage occurs:
has a good and broadly smear-free cleaning
effect. For more severe, in particularly greasy • plastic distortion (buckling) through past impact
contamination, benzole-free pure petrol (washing stresses
petrol, light petrol) can also be used for PC. • Cracks
Paint sprays, grease, sealant residues, etc. can • Damage to the surrounding seal
be removed before hardening by light rubbing with
a soft cloth soaked in ethyl alcohol, isopropyl-
alcohol or ether. Rust spots can be removed with
a 10% oxalic acid solution.
All mechanical systems, e.g. with rotating brush-
es, strippers, etc. are unsuitable for PC, even if
the brushes are fed with copious quantities of run-
ning water, as the plate surface can be scratched.
Minor, shallow scratches can be repaired or made
invisible by hot air polishing.

65
 Blank page

66