OPERATING & MAINTENANCE MANUAL

OF MACHINE TOOL

D: 02 : 221 : 05 : 02

ELECTRONICA, PUNE WARRANTY CERTIFICATE

ELEKTRA ULTRACUT f-2
Date:
This warranty certificate is issued for Machine tool.
Sr. No._________________________ with its power supply unit
Sr. No._________________________
M/s. __________________________
For the period of 12 months from the date of installation but not exceeding
15 months from the date of shipment, against manufacturing defects,
Components and parts only. Manufacture / supplier shall not be responsible
for any defects, injuries to personnel arising out of mishandling of the
equipment following of procedure not prescribed in our manual or negligence
from the operating staff.

DATE OF INSTALLATION:
WARRANTY ENDS ON

For ELECTRONICA

Agent

Customer Seal

(This portion to be detached and sent back to supplier within 10 days from
the date of installation)
WARRANTY CERTIFICATE
DATE: ________
TO,
ELECTRONICA
44, MUKUNDNAGAR,
PUNE - 411037.
ELEKTRA ULTRACUT f-2 SR NO.
DATE OF INSTALLATION
WARRANTY ENDS ON

:
:

____________________________________________________
For ELECTRONICA
Agent
Customer Seal

ATTENTION!
THE STANDARD ELEMENTS USED IN THIS MACHINE LIKE
GRUNDFOS PUMP, FLOPPY DISK DRIVE ARE OF REPUTED
MAKE. OFTEN THESE ELEMENTS GET DAMAGED DUE TO
IMPROPER USAGE & POOR MAINTENANCE.
THE WARRANTY FOR SUCH ELEMENTS IS VOID IF THE
DAMAGE IS DUE TO IMPROPER MAINTENANCE.

Electronica Machine Tools Ltd.

WARRANTY
IS VOID IF
RECOMMENDED
SPARES/
CONSUMABLES
ARE NOT USED.

Electronica Machine Tools Ltd.

24-C

INDEX
CHAPTER

DESCRIPTION

PAGE
NO.

1)

INTRODUCTION

2)

PREPARATION TRANSPORTATION, &

INSTALLATION OF THE SYSTEM

11

3)

INSTRUCTIONS FOR OPERATOR REGARDING

MECHANICAL COMPONENTS

18

4)

MAINTENANCE

22

5)

INSTRUCTIONS FOR OPERATOR REGARDING

SETTING UP & OPERATION OF THE MACHINE

25

6)

MORE INFORMATION ON WIRE DRIVE SYSTEM

WITH AUTOMATIC WIRE THREADING.

30

24-C

LIST OF FIGURES
Note : All figures at the end of this manual.
FIG. NO
1.

DESCRIPTION
FLOOR PLAN

2.

FOUNDATION DETAILS

3.

EARTHING SCHEME.

4.

MACHINE TOOL SLINGING DIAGRAM

5.

TRANSPORT LOCK X, Y

6.

TRANSPORT LOCK U, V, Z

7.

UPPER FLUSHING ASSEMBLY (SAWT)

8.

LOWER FLUSHING ASSEMBLY (SAWT)

9.

UPPER FLUSHING ASSEMBLY (AWT)

10.

LOWER FLUSHING ASSEMBLY (AWT)

11.

LOWER HOUSING ASSEMBLY

12.

WIRE GUIDE SYSTEM

13.

WIRE DRIVE SYSTEM (SAWT)

14.

AWT ASSEMBLY.

15.

JOB CLAMPING

16.

WORK TABLE LAYOUT.

17.

WORK TABLE LAYOUT -1.

18.

WORK TABLE LAYOUT -2.

19.

WORK TABLE LAYOUT -3.

24-C

CHAPTER 1
INTRODUCTION
The ELEKTRA Wire cut electrical discharge machine comprises of
Machine Tool, a power supply Unit (ELPULS), and a Dielectric unit and a
chiller unit. The machine tool unit comprises of a main worktable (fixed
type) on which the workpiece is clamped, a moving column on X & Y
axes, wire drive mechanism and auxiliary axes U & V & Z are mounted
on the moving column. The X and Y axes are moved in steps of 1
micrometer by means of D.C. servo motor. The U& V axes which parallel
to X & Y axes respectively are driven by the same motors which drives
the table. The traveling wire which is continuously fed from wire feed
spool which moves through the workpiece and is supported under
tension between a pair of wire guides which are located at the opposite
sides of the workpiece. The lower wire guide is stationary whereas the
upper wire guide which is supported by the U-V table can be displaced
transversely, along U and V axes, with respect to the lower wire guide.
The upper wire guide can also be positioned along Z axis by moving the
quill. A series of electrical pulses generated by the pulse generator unit
are applied between the workpiece and the traveling wire electrode, to
cause the erosion of the workpiece material. As the material removal or
24-C

machining proceeds, the worktable carrying the workpiece is displaced

transversely by the X-Y controller and the driver along a predetermined
path programmed in the controller. The path specifications can be
supplied to the controller via a program which is stored on floppy disk or
directly the controller (MDI made) When the X-Y table is moving along
the predetermined path, if the U-V table is kept stationary, a straight cut
with a predetermined pattern is formed. In order to produce taper
machining, the wire electrode has to be tilted. This is achieved by
displacing the upper wire guide (along U-V axes) with respect to the
lower wire guide. The desired taper angle is achieved by simultaneous
control of the movement of X-Y axes and U-V axes with their respective
predetermined paths stored in the controller. The path information of XY table and U-V table is supplied to the controller in terms of linear and
circular elements via floppy disks. While the machining is continued, the
machine zone is continuously flushed with water passing through the
nozzles on the both sides of the workpiece. Since water is used as a
dielectric medium, it is very important that water does not ionize.
Therefore to prevent the ionization of water an ion exchange resign is
used in the dielectric distribution system to maintain the conductivity of
the water constant. The part programming system comprising of an
24-C

ASCII keyboard, CRT with a fine resolution graphics features, double

sided double density floppy disk drive. The geometry of the profile and
the motion of the wire electrode tool along the profile is fed to the part
programming system through keyboard, in terms of various definitions
of points, lines and circles as the tool path element, in a totally menu
driven, conversational mode. The wire compensation (for wire diameter
and machining over-cut) and taper gradient can be specified for the
total path or for each element separately. After the profile is fed to the
computer, all the numerical information about the path is calculated
automatically and it's printout can be generated if required. The entered
profile definition, the profile is recorded by the computer on the floppy
disk which is then removed and put in the controller for execution of the
program.

24-C

CHAPTER 2
PREPARATION, TRANSPORTATION AND
INSTALLATION OF THE SYSTEM
ELEKTRA CNC WIRECUT EDM is supplied in 3 cases.
Case No. 1 contains Machine tool
Case No. 2 contains Power supply unit.
Case No.3 contains Dielectric unit, Dielectric cooling unit,
Loose components, accessories, spares etc.
Unload the cases carefully without tilting them. The slinging marks are
given on the cases. Use them while putting the ropes around the cases.
The cases should be taken to their place of installation on pallet trucks
or forklift trucks. Care should be taken not to tilt the cases while they
are being shifted. Avoid any jerks during shifting. The capacity of the
pallet trucks should be 3 tons. After opening the case, lift machine tool
from the platform by using nylon ropes. Do not allow ropes to touch the
machine anywhere while lifting. Lift the power supply unit, dielectric unit
with the help of nylon ropes as shown in their respective manual. Open
the boxes of loose items and Dielectric cooling system and check the
contents as per the packing slip inside the boxes. Check up all the four
units for apparent damage. If any damage is found inform Electronica -

24-C

Pune, immediately. If damages are heavy please arrange for necessary

insurance formalities. It is advised to take the photographs of the
machine to have the record of damages.
PREPARATION FOR INSTALLATION
Do not transport the machine on open pieces, as this will cause heavy
jerks to the machine. It should be transported by using pallet or forklift
trucks. It is recommended to lift the machine without jerks. If the
installed machine tool is to be transferred from one place to another
CLAMP THE MAIN SLIDES BEFORE TRANSPORTATION.
PLACE OF INSTALLATION.

The machine should be placed in an air conditioned room so that it

will be free from dust and heat. The place should be kept clean. The
area allocated should be sufficiently large to accommodate the
following items,

Machine tool, Power supply unit, and Pump filter unit and chiller
should be arranged as shown in floor plan (Ref. Fig. 4).

Storage space for workpiece preferably a separate cupboard.

Storage space for electronic cassettes closed space protected from
heat & direct sunlight.

Storage space for job files, manuals, record forms etc.

Tool kit for periodic maintenance.
Space for movement of material and the operator.
3 phase electrical connection with neutral & separate earth.

24-C

ENVIRONMENTAL CONDITIONS
The surroundings of the machine should be kept absolutely clean.
Ensure following conditions

Constant room temperature of 20+/- 1 c using an air conditioner.

fairly constant input supply voltage . The variation should not be
more than 1%. Use a servo controlled voltage stabilizer to achieve
this condition.

Frequently cleaning the surrounding area.

A good and well directed source of light. The worktable and all
control panels should be sufficiently illuminated.

AVOID FOLLOWING SITUATIONS

Direct sunlight on machine tool, power supply unit and dielectric unit.
Dust or fumes in the surrounding area.
Rain water directly coming on the machine.
Wetting of floor when machining is in progress. Relative humidity
more than
70%.

A common point of 3 phase power supply for WIRE CUT EDM and
other machines like welding sets, heavy presses etc. which draw
heavy current intermittently.

Heavy vibrations near the machine.

24-C

FOUNDATION DETAILS (Ref. Fig.5)

The machine should be kept on a rigid foundation. Foundations
confirming to the standard machine tool requirements should prove
adequate. A flat hard concrete floor at least 200 mm thick is
recommended in the area where machine is to be installed. Do not use
separate concrete blocks as foundation under the leveling pads of the
machine. If the place of installation does not have industrial flooring and
if there are many machines inducing vibrations, isolated foundation
flooring is recommended.
INSTALLATION OF MACHINE TOOL
1. Installation work of machine tool is an important factor which affects
accuracy of the job done, machine tool life and maintenance. So it
should be done carefully and systematically.
2. Remove the transport locks (Ref. Fig. 2, 3). The machine tool is to be
placed on five leveling pads. Install these leveling pads in their places
before the machine is placed.
3. The level of the floor should be sufficiently horizontal as the range of
adjustment of pads is limited. Level the machine in both x & y
directions with the help of precision level (sensitivity = 0.02 mm /1
m) .See to it that all the axes be at the center while checking the
level. The reading should be within half division.
4. After leveling the machine see to it that lock-nuts are tightened so
that the level is not disturbed.
5. All the 3 units viz. The machine tool, the power supply unit & the
Pump filter unit should be located as per the floor plan given. Leave a
distance of 500 mm between unit & wall. This will prove useful at the
time of maintenance.
6. Make all the connections of the generator with the machine tool. See
whether all cables are intact.
24-C

7. Make all the connections of the generator with the machine tool.
8. Fill distilled water in P.F. unit, put filters and resin and check the
connections of all the 3 phase motor & see that all interconnecting
pipes are tightened properly.
9. Check the supply from the stabilizer. Check voltage between neutral
& earth, it should be less than 1 volt. Check direction of motor
rotation & valve fitting.
10.Make wire verticality with the help of verticality block, before making
wire vertical dial the block within 2 microns w. r. t. Z axis.
11.Load some job and start sparking.
LEVELING PROCEDURE
1) When the m/c tool is being placed on the floor ensure that the gap
between the floor and m/c base is 110 mm to 115 mm, it must not be
less than 110 mm. Gap can be adjusted by adjusting the leveling bolts
on the m/c tool base. The gap of 100 to 115 mm is to be maintained to
avoid the obstruction of drain pipe with the PF unit and proper
alignment of wire collection box.
2) After the m/c tool is placed on the floor as per the floor plan in the E
and C readiness check list, clean all the ground surfaces provided on the
m/c base.
3) There are 8 leveling bolts on m/c base. Lift the bolts no. 2, 4, 5 and 7
and ensure that the bolts no. 1, 3, 6 and 8 are touching the floor.
4) Keep all the axes at the middle position of total stroke. Take the spirit
level of accuracy 0.020/meter.
Keep the spirit level on surface marked A in diagonal direction as
shown in fig and note the results.
Keep the spirit level on surface marked B, note the result.
Depending on the results of above checks, adjust the leveling bolts
no. 1 and 3 such that the level of m/c is within 4-5 divisions.
Place the spirit level on the surface marked C and D and ensure
24-C

that the level of the m/c is within 4-5 divisions. If not, adjust the bolts
no. 6 and 8.
Place the spirit level on the surface marked A in vertical and
horizontal direction and level the m/c within 3 divisions by adjusting the
bolts no.6 and 3 respectively.
Similarly place the spirit level on the surface marked B, C and
D and level the m/c within 3 division of the spirit level by adjusting the
leveling bolts
5) After leveling the m/c, adjust the leveling bolts no.2, 4, 5 and 7 such
that the leveling pads touch the floor and then tighten all the leveling
bolts and lock them by nut on the bolt. After this check once again the
level of the m/c is not disturbed and is within 3 divisions of the spirit
level.
Please note that the leveling should be done by keeping the spirit level
on the ground surface provided on the base and not by keeping the
spirit level on the job stand, it may create inaccuracy in the squareness
of the X and Y axis.

LEVELING BOLT
GROUND SURFACE

24-C

SAFETY PRECAUTIONS
Machine tool table is clamped to prevent its vibration during transport.
Remove these clamps before machine tool operation. This is most
important.
(Ref. Fig. 2, 3).
1. Not leave do doors open of the power supply unit, NC controller and
machine tool control panel during operation.
2. The power supply should be turned OFF if these doors are to be
opened.
3. Do not operate the machine when the floor is wet.

24-C

SPECIFICATIONS OF VOLTAGE STABILIZER (3 PHASE)

1. ULTRACUT F2

: 15 KVA, @ 415 V line to line

2. Input voltage

: 310 V to 467 V line to line.

i. e . 180 -- 270 V / phase.

3. Output voltage

: 415 V line to line

i. e . 240 V phase to neutral.

4. Output voltage regulation : 1%

/ phase of output voltage.

5. Voltage correction rate

: 35 V / sec.

6. Terminations

: 5 way socket on rear door (20 A)

7. Overload protection

: With SIEMENS contactor & 3 phase

: thermal overload relay .

8. Other protections

: Single phasing presetter, over - voltage

tripping.

24-C

CHAPTER 3
INSTRUCTIONS FOR OPERATOR REGARDING MECHANICAL
COMPONENTS .
1. SPECIFICATIONS :
1.1.

TRAVEL RANGE
TRAVEL RANGE
LONGITUDINAL

LATERAL
VERTICAL

1.2.

AXIS

ULTRACUT F 2

600 mm

40

400 mm

40

325 mm

WORK PIECE SIZE

WORK PIECE SIZE

ULTRACUT F 2

TABLE SIZE

1.3.

860 X 580mm

Max. WORK PIECE SIZE

1150 X 810 X 300 mm

Max. WORK PIECE Wt.

1000 Kg.

FEED
Main table feed rate

900 mm/ min

Resolution
Wire feed rate

0.0005 mm
0 - 15 m / min

Wire tension

2.5 kgf
24-C

1.4.

WIRE GUIDE
WIRE GUIDE TYPE
Wire
diameter

1.5.

Diamond closed

electrode

0.1, 0.25 STD

0.15 , 0.2 , 0.3 OPT

TAPER CUTTING ANGLE

1.5 TAPER CUTTING

Max. Taper Angle

15  / 100 mm

2.0 MACHINE COORDINATE SYSTEM, ORIGIN AND REFERENCING

The coordinate systems are classified into the machine coordinate
system and the work coordinate system.
The machine coordinate system is intrinsic to the machine and cannot
be set arbitrarily, while the work coordination system can be set
arbitrarily.
Machine coordinate system, machine origin and reference
point.
Each machine origin of X, Y, U, V axes are at either end of the stroke of
each axis. The NC unit uses the machine coordinate system to control
the machining start position, pitch error compensation, wire verticality
etc.

24-C

3.0 CAUTIONS FOR SAFETY

To protect the operator and the machine from hazards, observed the
following items.
1) Confirm the position of the EMERGENCY STOP button before turning the
power on.
2) Fully illuminate on and around the machine, and keep the surrounding in
good order.
3) Keep closed the cover and the doors of the generator, NC unit, control
panel and dielectric fluid supply unit.
4) Never relocate or bypass the stroke limit, interlock limit switches etc.
5) Keep away from rotating rollers.
6) When coming close to the machine during machining, keep away from the
wire roller, upper and lower flushing assemblies which bear high voltage.
7) When loading / unloading the work piece, avoid interference with the
lower flushing nozzle to avoid damage to the lower diamond guide and
flushing assembly.
8) Make sure that the workpiece and the bridges do not interfere with the
upper and lower flushing nozzle.
9) Do not keep workpiece, tools or any other material on the table or U/V
covers which could obstruct during movement.

24-C

10)

Before moving the table (X & Y axes) or U or V axis, make sure that

there is no obstruction in the travel range before actual machining of the

job.
11)

Designate an operator solely responsible for machine operation.

12)

Maintenance and repair must be done by authorised personnel.

Make sufficient preparation before working on the machine.

13)
14)

Do not operate the machine with protective covers removed.

Carryout periodic maintenance of filtration system.

24-C

CHAPTER 4
MAINTENANCE
Table to indicate periodic maintenance.
Activity
1. Check for debris in the wire
guides & clean with the help of
acetone & soft cloth.
2. Cleaning of Worktank & all the
areas
where
particles
accumulate.
3. Check for the gap between
lower nozzle & workpiece. The
gap should be maintained 0.2
mm. The gap can be adjusted by
rotating the nozzle mount until
the gap is maintained & then
lock it with the screw.
4. Cleaning of Wire Drive Assembly
which includes Idler, feed &
pressure rollers to keep them
free from dust & water.

Daily

Weekly

24-C

Monthly

Quarterly

5. Worktable height is the distance

between the table top &
diamond center of lower wire
guide. This distance can be
checked with help of slip
gauges. Guide span is the
distance between the diamond
centers of both upper & lower
wire guides with Z axis position
at zero. This distance can also
be checked by slip gauges. The
distance of diamond center from
wire guide face is 3.75.

Activity

Daily

Weekly

Monthly

6. Check for wire verticality

7. Check for the groove on the
current carbide pick up. If the
groove has touched the upper
or lower edge replace the
current carbide pick up or
changing the position could
solve the problem.
8. Clean debris on ceramic roller
big and ceramic roller small.
9. Check for debris or groove in
the pallet hole, if the hole is
clogged then remove and clean
it. If it is not possible replace the
pallet.
10. Check for the groove on wire
feed & wire tension rollers. If in
case groove is observed
replace the rollers.

24-C

Quarterl
y

11. Check flushing nozzles, if in

case the nozzles are damaged
replace them.
12. Clean the groove on all the
idler rollers and check the
rollers rotate smoothly.
13. Check for play in gears & belt
tension.

14. Check for the movement of the

tank bellow by moving the
table in Y direction see that no
obstruction is there. By moving
the table in X direction check
for the obstruction due to seal
to wire guide arm.

24-C

Activity

Daily

Weekly

15. Check for the play in lower

flushing assembly mounting. If
any play is observed tight the
two mounting screws on the
insulator. Every time the
screws are tightened flushing
assembly is to be trued with
the help of dial gauge.
16. Lubrication of Ballscrews.

Monthly

Quarterl
y

17. Check the bearing in the lower

idler roller. If bearing is found
faulty replace the same.
18. Clean the E/W connections &
check terminals for loose
connections.
19. Check for the cleanliness of
flow meters, if the dirt is
accumulated in the flow meters
remove the top nut, pointer
etc. and clean the flow meters
with
acetone
or
diluted
hydrochloric acid by passing
cloth from top to bottom.
20. Lubrication of L.M. Guides of X,
Y, U, V & Z axes. Use
CENTOFLEXLDS 18 Special for
lubrication.
21. The squareness of the wire
verticality block is to be
checked with the help of dial.
The squareness is to be
maintained within 0.005 mm
22. Water in the P.F unit.

23.Clean solenoid valve diaphragm.

24. Mounting nuts of the pump &

brackets.

24-C

LUBRICATION SYSTEM
A manual centralized lubrication system is provided on the machine
for lubrication of X, Y, U, V and Z axis Ballscrews and LM Guide
shoes.
Operate the lever of hand pump 2-3 times
Carry out the lubrication once in a month
Schematic diagram : Refer figure no. 4.1 (page no. 24-B )
Part list : Refer page no.24-C
TECHNICAL DATA :
Lubrication pump

: Hand grease pump Cenlub make

H-600-6

Capacity of lubrication pump

: 1 Kg.

Liquid grease

: NLGI grade 00/000

( Fuchs make Renolit LZR 000 or by
ITW make OMEGA-77. Used under
Licence by Magna Industrial Co. Ltd. )

NOTE :
Refilling of the liquid grease is to be done periodically, if the level of the
liquid grease goes down. Ensure that the liquid grease is pure and doesnt
contain any contamination.

24-C

24-C

ELEKTRA

S S

U AXIS

S S
7

LUBRICATION CIRCUIT DIAGRAM

Y AXIS

S S

X AXIS

S S
B

S S

S S

S S

V AXIS

S S

S S

Z AXIS

ULTRACUT f2
FIG. NO. 4.1

S S

PART LIST

S.N

ITEMCODE
74150401027

DESCRIPTION
HAND GREASE PUMP CENLUB MAKE H-

QTY.
1

1
600-6
2

53110200000

10 M.

74343100009

SUPER FLEXIBLE NYLON TUBE 6 OD X 4

ID
5 WAY JUNCTION

3
4

53110230028

4MM TUBE NYLON CENLUB MAKE

20M

55200020000

25

74343100011

20

55200500001

METERING CARTRIDGES D1-0.16CC

(CENLUB)
M6X0.75 BANJO ASSLY. FOR DIA 4MM
TUBE
0001IAL BANJO M6X DIA 4

55200060000

PLUG M10 X 1

24-C

CHAPTER 5
INSTRUCTIONS FOR OPERATOR REGARDING SETTING UP
AND OPERATION THE MACHINE
WORKING LAYOUT
Figure shows the layout of the worktable on which the job is to be
mounted in order to perform accurate machining of the component For
mounting the job at a position other than the work table, make use of
adjustable bridge
(Optional

accessory).

The

maximum

job

size

which

can

be

accommodated on the worktable is given in the specifications. To mount

the job of maximum size refers to the figure which depicts the way in
which it is to be done. The distance between the two jobs stands
between which the nozzle of the lower flushing assembly moves in X
direction is shown in the figure. Fixed bridge when mounted on the job
stands lies outs the limits of the nozzle travel. The distance between the
wire guide center and job stand edge is 15 mm as shown in the figure.
The round job clamping can be done on the machine with the help of
round job holders provided in the optional accessories. To wire cut the
job up to 25 mm in diameter smaller 'L' shaped profile is to be used and
for jobs up to 50 mm in diameter the larger ' L ' shaped profile is to be
used. A reference hole of 8 mm is provided on the round job holder for
making the wire vertical.
Workpiece mounting
The worktable can handle the workpiece of maximum size as mentioned
in the specifications. Heavier workpiece may affect the accuracies and
load the coordinate table. (Before mounting the job, grease the
mounting surface of the worktable). The job should be clamped firmly on
24-C

the job stands and bridges to ensure proper electrical contact.

SETTING UP AND OPERATION
Place the machine tool, dielectric unit, power supply unit and chiller as
per the floor plan. Keep the chiller unit inside the room in which machine
tool is accommodated. The interconnections are to be made as per the
instructions mentioned in the manual of the power supply unit.
After power on :

Power on led on front panel glows.

Machine will not start in absence of any phase or over voltage /

under voltage condition.

Display may show some reading, let it be anything.

Wire feed and wire tension are in OFF condition.

Gap voltage meter shows Nil voltage.

Gap current meter shows nil current.

Conductivity of dielectric fluid is shown on it's meter.

INTERCONNECTIONS
Seven cables are required for interconnections. Ensure that all wires are in
good condition. Every cable has its code number. See to it that the cable
with one code number is fitted to the connector having its respective code
number. Make the connections so that there should not be any play.
Tighten all connectors properly. A voltage stabiliser is must for this
machine. Check output voltage of stabiliser, for specifications of stabiliser
Chapter 2.
CHECK THE FOLLOWING
24-C

Dielectric pump operation.

Select wire feed function to vary the speed of the traveling wire.

Jogging in X, Y axes with "FR1, FR2 & FR3 speed. Also in 1 micron,
10 microns, 100 microns & 1 mm steps.

Check deioniser by pressing the switch, Meter reading will decrease

towards zero. It may not reach up to zero.

PREPARATION FOR MACHINING

1. Selection of wire :Use brass wire specified by M/s. Electronica, Pune, INDIA. It must be
free from any twists, corrosion and kinks, any of these defects may
lead to wire breakage or unstable machining.
2. Wire threading :- (MANUAL)
Wire threading is to be done as per the procedure given below a)

Mount the wire reel on its shaft so as to unspool the wire in the
direction as shown in the figure. Tighten the nut firmly in a
clockwise on to the reel.

b) Wound the wire over the rollers as shown and then thread the wire
through the wire guides, over the carbide current pick up and
through the pallet of the flushing assemblies.
c)

The wire should pass through the groove centers of the wire guides.
Confirm that the wire is positioned at the center of the dielectric
fluid flushing port in order to the wire surrounding completely by the
water

column.

d) The wire must remain in contact with the nylon roller at all times so
that it is insulated from the machine tool.
e)

Do not touch the wire or any part of the wire feed mechanism,
24-C

during machining since all are electrically live.

3. Wire tension and wire feed rate
The wire tension is to be adjusted according to the workpiece thickness
and size of wire used. Proper tension is set by adjusting the knob of
wire tension. The wire feed is to be adjusted on the basis of thickness
of the job and energy settings.

4. Automatic Wire Threading :

The machine has optional automatic wire threading attachment
(AWT).
For threading of wire with AWT the wire should be of hard type.
Insertion of wire up to AWT is manual. Hence while changing the wire
spool first insertion of wire is manual. Refer to chapter no. 6 for more
details on wire drive with Automatic wire threading system.
FLUSHING AT LOW & HIGH FLUSHING
The interfacing of machine tool with pump filter unit is done by connecting
the two hoses coming from flow meters to the distributor block .The drain
pipe that is fixed to the tank emerges into the tank of filtration unit
between the cutout of the tank. By adjusting the knob of the flow meters
pressure of water coming out of the flushing assemblies can be adjusted.
For high speed cutting, flushing at high pressure is selected. The pressure
/ flow selection is also programmable.
To carry on the cutting at lower speed or while taking the second cut on
the job already usually low flushing pressure is selected.
24-C

Dielectric fluid flushing parameters

Confirm that conductivity of the dielectric fluid is within the specified the
specified range. Press the flush switch on the control box. Adjust dielectric
fluid flow valve by watching the flushing pressure fluid flowing from the
upper & lower flushing pressure should be approximately 12 kg / cm .
The function of the deioniser is to reduce the conductivity of dielectric fluid
through the ion exchange reaction of resin.
CONDUCTIVITY CORRECTION
When the conductivity goes too low or too high than the set values'
Conductivity control unit ` following corrective measures should be taken.

EVENT

ACTION

Conductivity higher than the set Add distilled water or change the
higher value.
resin in deionizer if the resin is
tending to become inactive.
Conductivity lower than the set Add tap water.
lower value.

CHAPTER 6
MORE INFORMATION ON WIRE DRIVE SYSTEM WITH
AUTOMATIC WIRE THREADING.
1.1WIRE DRIVING SYSTEM
Wire supply & control parts
1. Wire supply part consists of real shaft for mounting wire electrode & a
24-C

device for preventing from separation of wire.

2. For M/C with AWT- Reel shaft has internally the torque motor
generating back tension felt break arrangement is provided
3. For without AWT -Wire control part consists of feeding roller controlling
the tension of wire & a tension roller.
4. Looseness detecting sensor or spool empty sensor.
5. Idler roller Guidance of wire from wide roller to pulley.
6. Felt Rod

- Remove dust of wire.

7. Belt Tension Pulley Adjust position of pulley to control tension of flat

belt.

24-C

No.

Name

Functional description

Wire Electrode

--

Wire Reel locking Nut

Locking wire reel on the shaft, done by

turning nut in clockwise direction.

Wide Roller

Guidance of wire from wire electrode

Wire Guide Roller

Feeding Pulley

Flat Belt

Tension Pulley

Idle Pulley

Spring Bracket

10

Wire Detecting Spring

1.2 Wire Guide, Upper Part

Wire is passed through a couple og roller

without going separation.
Including a power brake adjusting
tension applied on wire, a DC geared
motor controlling direction of revolution
of feeding pulley, & a rotary encoder
detecting speed of revolution of feeding
pulley.
Stirring tension pulley, needs periodic
cleansing because its worn out during
long time use.
Tension is generated by inserting wire
between tension pulley & flat belt. Needs
periodic cleansing because the surface of
pulley becomes dirty during long time
use.
-Bracket fixing one end of wire detecting
spring.
In operating mode of AWT, increases the
probability to accomplish
AWT
by
feeding up & down detecting the contact
of wire on spring resulted from wire
bending.

24-C

1. There are diamond dies guide upholding wire correctly & conducting
part transferring electric power to wire.
2. Includes a jet nozzle generating water jet necessary for AWT

NO.

Name

Functional description

Upper guide block

Upper wire guide body.

Seal guide -B

Part for guiding wire to connect on

conducting pin.

Front guide block

Front guide block has internally revolving

ring, conducting pin & seal guide.

Sleeve

Guidance of seal guide holder.

Seal guide pin

A pin fixing seal guide, marks a contact of

wire with conducting pin in AWT mode,
makes it easy to thread wire.

Dust cap

Cap protecting invasion of impurities.

Indexing ring

Conducting ring

Jet nozzle

A ring to turn conducting pin easily by

hands, engraved index numbers on it help
operator to identify the rotary position
avoiding duplicates of abrasive grooves
resulted from electrically discharging
during long time use.
Electric power is transferred to wire
through this device. Due to its
consumptive property, turn its rotary
position of contacts to index number (1/8
revolution), or if you use up all position,
replace it with new part.
Flushing water jet in AWT mode.

24-C

10

Upper wire guide

Diamond dies guide)

A guide to support the correct position of

wire has to change to the diameter of
wire to be used. Because of its
consumptive property, it is recommended
to replace with new one to maintain high
precision machining.

11

Upper nozzle cap

A nozzle cap for water jet.

12

Double nozzle (Ext.)

13

Double nozzle (Int.)

14

Knock cylinder

15

Guide block screw

16

Wire approach

17

Seal guide holder

18

Connecting pin locking

screw

A nozzle for flushing water jet, can be

changeable to the shape of work piece to
be machined.
A nozzle for flushing water jet, can be
changeable to the shape of work piece to
be machined.
A cylinder driving seal guide holder, in
AWT mode, makes it easy to thread wire
by maintaining the concentricity of
diamond dies guide & seal guide.
A screw supporting upper wire guide
(Diamond dies guide ) if replacement,
dissembled by turning it in counterclockwise.
A guide inducing injection of wire
electrode into the guide block.
A holder supporting seal guide &
approach.
A screw locking conducting pin. If you
rotate or replace conducting pin, unlock
by rotating screw in counter clockwise
with wrench.

1.3 Wire guide lower part

24-C

1. This part has the same structure as the upper part. There are diamond
dies, conducting part & guide approach helping draining of water jet in
AWT mode.
2. The wire passed through lower guide is introduced into the lower roller
under the lower guide.
NO.

Name

Double nozzle (Ext.)

Double nozzle (Int.)

Guide approach.

Lower wire guide

Diamond dies guide)

Regularizing ring

Upper nozzle cap

Lock nut

Front guide block

Conducting pin (Current

Pickup)

Functional description
A nozzle for flushing water jet can be
changed as per shape of workpiece to be
machined.
Guidance of wire introducing into lower
part, & prevention from spreads of water
jet in AWT mode.
A guide to support the correct position of
wire, has to change to the diameter of
wire to be used. Because of its
consumptive property, it is recommended
to replace with new one to maintain high
precision machining.
Regularizes water jet from lower part.
A nozzle cap for water jet. In machining,
its recommended to minimize a gap
between workpiece & this cap.
Locking nozzle cap in operation of
machine
Front guide block has internally revolving
to conducting pin,& seal guide.
Electric power is transferred to wire
through this device. Due to its
consumptive property, turn its rotary
position of contacts to index number (1/8
revolution), or if you use up all position,
replace it with new part.

24-C

10

Indexing ring

A ring to turn conducting pin easily by

hands
Hands, engraved index numbers on it help
operator to identify the rotary position
avoiding duplicates of abrasive grooves
resulted from electrically discharging
during long time use.

11

Sleeve

Guidance of seal guide holder.

12

Seal guide pin

13

Seal guide - B

14

Lower seal guide holder

15

Seal guide

16

Knock cylinder

17

Lower guide block

A pin fixing seal guide, makes a contact of

wire with conducting pin, in AWT mode,
makes it easy to thread wire.
Guiding part of wire part contact on
conducting pin
A holder
approach.

supporting

seal

guide

&

Guiding part inducing wire into lower

feeding roller.
A cylinder driving seal guide holder, in
AWT mode, makes it easy to thread wire
by maintaining the concentricity of
diamond dies guide & seal guide.
Lower wire guide body.

24-C

1.4 Wire feeding system, lower part

1. This part is feeding wire which passes through lower wire guide block
to capstan roller of wire feeding drive located behind the main body by
winding wire with capstan roller & pinch roller.
2. A flat belt driving lower roller is activated by capstan roller of wire
feeding drive.
3. In AWT mode, guidance & feeding of wire is done by air jet into the
wire approach pipe.
4. Pinch roller is pushed softly by the spring connected to spring locator.
If the pinch roller is pushed strongly, wire is bent to separate from
guide path & wire threading fails.
NO.

Name

Functional description

Lower roller ,ceramic roller

big

Together with pinch roller, feeds wire to

the caps of wire feeding drive located on
the backside of machine when wire
arrives at the capstan of wire feeding
drive, this part rotates slipperily by one
way clutch.

Pinch roller

Pushing lower roller by elasticity of spring.

Guide path insulator

Guide path

Air nozzle

Wire approach pipe

Front plate

Part for insulating & supporting guide

path.
A guide transferring the wire passed
through lower wire feeding roller to the
backside of machine by transition of wire
by 90.This part is insulated to detect the
signal of wire arrivals in AWT mode.
Wire is smoothly transferred to the
backside of machine by the air stream
generating inside nozzle through wire
approach pipe.
This pipe is a path of wire from lower
roller to capstan roller of wire feeding
driver on the backside of machine.
A flange of lower part of wire feeding
system.
24-C

Insulator front

Arm

10

Spring locator

11

Flat belt

Lower housing is insulated from lower

arm by this part. & should be cleaned
periodically.
A part fixing & supporting lower wire
guide part.
A bolt for adjusting the pushing force of
pinch roller. In the case of separation of
wire from this, loose the bolt to the
reduce the force by turning the bolt in
counter clockwise direction.
Drives
lower
rollers
together
by
connecting the axis of lower roller & the
capstan roller of wire feeding driver on
the backside of machine.

1.5 Drive part (wire feeding part)

1. Composed of a cone to isolate air jet stream passed through wire
approach pipe & wire feeding roller to wind the wire with constant
feeding rate.
2. Feeding part retrieves wire to wire collection box by pinch roller
connecting to main capstan roller & spring block.

24-C

NO.

Name

Wire approach pipe

Wire feeding roller (pinch

roller)

Spring block

DC geared motor

Drive pulley

Flat belt.

Adjustable roller.

Functional description
This pipe is a path of wire from lower
roller to capstan roller of wire feeding
driver on the backside of machine.
Wire is winded tightly by two feeding
rollers (main capstan & pinch roller). A
long time use causes a dirty surface on it,
so should be cleaned regularly.
This part forces pinch roller to be pushed
by main roller, with the pressure of spring
Connected with main roller with timing
belt.
Connected with main roller, maneuvers
lower roller by flat belt.
Revolves lower roller by connecting the
axis of lower roller & the axis of feeding
roller of wire driving part.
A roller keeping the tension of flat belt by
elasticity of spring.

1.6 Automatic wire threading part.

1. This part is to clamp & cut wire, & to exhaust the waste to be cut.
2. This part has the function that makes the end of wire to be easy to reguide for AWT, because the end of wire become bent in the failure of
24-C

automatic wire threading (abbr. AWT)

NO.

Name

Functional description
This part fixes one end of detecting
spring. In AWT mode, its possible to
adjust the shape of cutting edge of wire &
the time required for cutting by varying
the distance from internal seal guide to
wire cutter arm.
This part has alternating motion to cut
wire.

Cutter dies holder

Wire cutter arm

Cutter actuating motor

Actuates wire cutting arm.

Wire clamp

Clamps wire in AWT mode.

Fork shaft

Processing the waste of wire by winding.

Cylinder

Moves wire
direction.

Wire ejection plate

Ejects the waste of wire wound on the

fork shaft.

ejection

plate

in

front

MAINTENANCE & CHECKING ITEMS FOR WIRE DRIVE SYSTEM

Items to check daily when starting & ending machining.
24-C

No.
1
2

Item to check
Lower arm & seal
plate cleaning (when
ending machining
Work tank

Nozzle checking

Dust box checking

Conducting pin
checking.

Amount of work fluid

checking.

The dielectric value

of work fluid
checking.

Automatic wire
threading checking.

Cutting wire
operation checking

Contents to check
Upper & lower guide block.
Remove wire chip & machining chip in the
work fluid supplying unit.
1. Check whether there are
injuries or
cracks at tip of upper & lower nozzle
surface.
2. If work fluid leaks out, it results in
breaking the wire due to lower pressure.
1. Check the amount of wire in dust box.
2. The dust box is usually full of wire after
about 25 hours of machining. So
remove wire in case of long time
machining.
It is worn away in about 25 hours in case
of first cut. Check remaining time in the
consumptive parts display.
It results in breaking the wire &
decreasing machining speed.
Check the fluid surface level of work fluid
supplying unit. If not enough, supply work
fluid.
Check that the dielectric value is in the
range of display.
Check that error or warning occurs under
automatic wire threading in the air.
If error occurs or same warning occurs
continuously more than three items, check
unit referring to section 4
Checking whether error or warning occurs
when cutting wire.

24-C

Details

Trouble shooting Wire is broken frequently

Posit
ion

2
3

Cause of broken wire

Management

1. Cooling error due to

blocking of cooling hole
of upper dies guide.
2. Low touching pressure
due to wear of upper
conducting pin.

1. Clean upper dies guide with rust

remover. If needed remove dust
in hole with needle.
After fixing dies guide, detect
wire squareness.
2. Check upper conducting pin, &
then change the position or
replace it.

1. Detecting machining gap

Check the wear of upper
error due to conducting pin
conducting pin.
wear.
1. Insufficient work fluid in Increase the pressure of upper
upper nozzle.
fluid jet.
1. Clean lower dies guide with rust
remover & blow air to it. If
needed remove dust in hole with
needle.
1. Cooling error due to After fixing dies guide detect
wire squareness.
blocking of cooling hole
For details refer maintenance &
of lower dies guide.
check data.
2. Lower touching pressure
due to wear of lower 2. Check lower currant pick up &
then change the position or
conducting pin.
replace it.
3. In
case
of
For details refer maintenance &
JW60A/JW120A,lower
moving pin malfunction
check data.
3. Check operation of actuator &
clean it.
For details refer maintenance &
check data.

24-C

ITEMS TO CHECK WEEKLY.

No.

Item to check

Wire guide block

clean.

Cooling water drain

hole cleaning.

Current pick up
check.

Winding roller
cleaning.

Air pressure control

unit checking.

Machine origin
restoring.

Contents to check
Clean upper & lower wire guide block
with weak acid.
Clean lower wire guide block approach
dies with weak acid.
After cleaning & assembly ensure
proper forward & backward motion of
seal guide pin .Automatic wire
threading may fail because of it.
Pump air in to hole. If there is not
enough cooling water, supply it.
It results in breaking the wire at
current pick up unit.
Change the position at every 25 hours.
It results in breaking the wire &
decreasing machining speed.
Clean wire winding roller. If black line
is seen along the path of wire, clean it
with rust remover.
It results in extrusion of wire in work
tank.
Clean ceramic roller big & small.
Draw water from air unit using drain
valve.
If the water soaks into air cylinder it
results in malfunction or failure.
Restore machine origin of X, Y, Z axis.
It may happen that true machine origin
and the coordinate of NC or different
after long time machining.

24-C

Details

Wire tension is too

high.

Check whether wire is twisted or

crossed so that wire does not get
loose.

If lower roller rotation is bad call

Electronica.

TROUBLE SHOOTING STOP DUE TO BACK DATA ZERO

THE ERROR IS NOT RECOVERED AFTER TRACK BACK
CHECK THE FOLLOWING

IS START HOLE SMALL

CURVED OR DEVIATED
SO THAT WIRE & WORK
ARE TOUCHED?

MOVE WIRE WITH JOB UNDER

SPARK. IF VOLTAGE IS NOT
ZERO. RESTORE THE WIRE TO
ORIGINAL POSITION AND
RERUN NC

YES

NO

IS THERE WIRE CHIP IN

START HOLE?

YES

REMOVE WIRE CHIP & RERUN

NC

YES

TURN ON SPARK & LOWER JET

PRESSURE IF SPARK IS NOT
OPERATIVE LOWER WT. IF
SPARK STARTS INCREASE WT &
JET PRESSURE TO ORIGINAL

NO
ARE WIRE AND WORK
TOUCHED BECAUSE
START HOLE IS TOO
SMALL & JET PRESSURE
IS TOO STRONG?
NO
DOES WIRE EXTRUDE
IN
WORK TANK

NO

YES

24-C

CUT WIRE AND RECONNECT IT

AND THEN RERUN NC.

DOES THE WIRE TOUCH

MACHINE IN WIRE
COLLECTION BOX OR
WINDING ROLLERS?

YES

PUT WIRE IN WIRE

COLLECTION BOX & RERUN
NC. IF NEEDED CUT WIRE &
RECONNECT IT & THEN
RERUN NC.

NO
WHEN SPARK STARTS AFTER
CUTTING WIRE &
RECONNECTING IT OUT SIDE
OF WORK, IS THE VOLTAGE
ZERO?

YES

YES

CALL A/S CENTER OF JINYOUNG

24-C

THE MACHINE IS NORMAL.

RESTORE WIRE TO START
HOLE & RECONNECT IT &
CHECK ABOVE THINGS
UNDER SPARK

X = 1800 FOR DL35

1900

4200

24-C

* POSITION OF AIRCONDITIONER

100

ELEKTRA

FIG.NO.: 1

ULTRACUT F 2

D:02:221:07:03

GEN.
HT.= 2000

600

FLOOR PLAN

ALL DIMENSIONS ARE IN MM.

1700

WT. 4000 Kg

HT.= 2300

MACHINE TOOL

165

700

TEMP. TO BE MAINTAINED 20 1C

250

1950

TOTAL HEAT GENERATED 10 Kcal/Hr.

1200

HT.= 1300

PUMP FILTER

WIRE FEED
ASSLY

WIRE COLLECTION
BOX

1205

650

1000

ROOM SIZE :- 4600 X 4200 X 3000

X = 1575 FOR DL25

3680

950

4600

MACHINE BASE

85

24-C

930

180

600

475

ELEKTRA

1435

75(TYP.)

1100

FOUNDATION DETAILS

FIG. NO.: -2

ULTRACUT f-2

INSTRUCTION:-THE FOUNDATION BLOCK TO BE

CASTED ON THE RABBLE

75X75X20 MS PLATE 6 NO,S

100 (TYP.)

G.L.

115

24-C

47

ELEKTRA

R
Y
B

3 CORE

M.S. BRASS BOLT

8 PIN ALLIED PLUG

C71

REAR PANEL

3 PIN ALLIED PLUG

M6 BRASS BOLT

EARTH PIT

EARTHING
THROUGH
BUNCH

MACHINE TOOL

FIG. NO. 3

ULTRACUT f-2

DIELECTRIC SUPPLY UNIT

M6 BRASS BOLT

EARTHING SCHEME

MAIN INPUT 3

STABILISER

STABILISER OUTPUT 3

EARTH

EARTH BUS BAR. EARTHING WIRE

C70

GENERATOR

24-C
ELEKTRA

MACHINE TOOL SLINGING DIAGRAM

FIG. NO.: -4

ULTRACUT f-2

24-C

NOTE : ALL DIMENSIONS ARE IN MM

ELEKTRA

TRANSPORT LOCK X & Y

TRANSPORT LOCK X

TRANSPORT LOCK Y

ULTRACUT f-2
FIG. NO.: -5

24-C

TRANSPORT LOCK Z

ELEKTRA

TRANSPORT LOCK U, V, Z

4 NO,S

TRANSPORT LOCK-U

FIG. NO.: -6

ULTRACUT f-2

2 NO,S

TRANSPORT LOCK-V

24-C

ELEKTRA

15

12

10

UPPER FLUSHING ASSEMBLY (SAWT)

11

1
1
1
4
4
3
2
1
1

412034121XX
412074213XX
412104301XX
412104302XX
412104303XX

5
6
7
8
9

10 412104304XX
11 50300000027
12 73010004010
13 73010004012
14 73010004016
15 73010106020
16 74150101064
17 74150101089

ULTRACUT f-2
FIG. NO.: -7

412034115XX

412034112XX

412034107XX

QTY.

412034103XX

ITEM CODE

SR.NO.

24-C

ELEKTRA

10

14

12

13

LOWER FLUSHING ASSEMBLY (SAWT)

11

74150101003
74150101015
74150101017

12
13
14

QTY.

ULTRACUT f-2
FIG. NO: -8

50300000027

11

412124209XX

10

412104508XX

412104509XX

412104506XX

7
9

412104505XX

412104502XX

412104503XX

412104501XX

3
5

41208010064

412034121XX

ITEM CODE

SR.NO.

24-C

11

17

15

18

12

19

ELEKTRA

4121241164X
4121241174X

15
16

14

13

4121241154X

14

4121241194X
4121241214X

18
19

f-2

CARBIDE CURRENT PICKUP

APPROACH UPPER

GUIDE

UPPER FLUSHING ASSEMBLY ULTRACUT

FIG.NO.:-9
(AWT)

4121241184X

17

UPPER WIRE

SEAL GUIDE HOLDER

NOZZLE UPPER

NOZZLE UPPER

4121241144X

10

RING

GUIDE BLOCK

4121241134X

4121241123X

11

SLEEVE

4121241094X

RING

PIN HOLDER

4121241084X

4121241114X

RING

4121241074X

10

NOZZLE CAP

4121241063X

12
13

16

JET NOZZLE

4121241053X

GUIDE BLOCK SCREW

4121241044X

JOINT

4121241033X

GUIDE HOLDER

4121241024X

2
3

GUIDE BLOCK

DESCRIPTION

4121241012X

ITEM CODE

SR.NO.

24-C

11

18

ELEKTRA

GUIDE APPROCH

WIRE GUIDE

4121242044x
4121242054x
4121242064x
4121242074x
4121242083x
4121242094x

4121242114x
4121242124x

10

11
12
13
14
15
16
17
18

3
7

GRUB

WIRE GUIDE

LOWER WIRE GUIDE

RING

JOINT

f-2

GUIDE BLOCK (LOWER)

LOWER FLUSHING ASSEMBLY ULTRACUT

FIG.NO.:-10
(AWT)

15

10

SEAL GUIDE HOLDER

LOCK NUT

4121242034x

12

GUIDE BLOCK (L.F.)

4121242013x

CARBIDE CURRENT PICKUP

4121241214x

GUIDE

NOZZLE CAP

4121241184X

4121242184x

5
6

LOWER FLUSH. NOZZLE

RING

4121241134x

4121242174x

SLEEVE

4121241094x

PIN HOLDER

DESCRIPTION

4121241084x

ITEM CODE

SR.NO.

13

14

17

16

24-C

11

12

10

ELEKTRA

2
4

1
2
3
4
5
6
7
8
9
10
11
12

SR.NO.

4121244011x
4121244703x
4121244804x
4121044304x
4121244542x
4121244572x
4121244562x
4121244532x
4121244522x
4121241194x
4121244164x
50100080016

ITEM CODE

DOWEL PIN 6x50

LOWER HOUSING ASSEMBLY

DOWEL PIN 6x20

FIG. NO.: -11

ULTRACUT f-2

CLUTCH BEARING

DRIVER ROLLER

APPROACH UPPER

BACK PLATE

INSULATOR BACK

INSULATOR FRONT

FRONT PLATE

CONTACT PLATE

GUIDE BLOCK COMP.

LOWER ROLLER (SMALL)

LOWER ROLLER (BIG)

LOWER FLUSH. HOUSING

DESCCRIPTION

24-C

ELEKTRA

AWT ASSLY.

4121243001X

WIRE GUIDE SYSTEM

WIRE DRIVE ASSLY.

4121230001X

FIG. NO.: -12

ULTRACUT f-2

WIRE FEED ASSLY.

ARM ASSLY.

4121944001X

4121031001X

LOWER ASSLY.

4121242001X

UPPER ASSLY.

DESCRIPTION

4121241001X

ITEM CODE

SR.NO.

24-C

ELEKTRA

FIG. NO.: -13

ULTRACUT f-2

WIRE TENSION ASSLY.

WIRE SPOOL

ASSLY.

WIRE DRIVE SYSTEM (SAWT)

4121034003X

4121234003X

6
7

IDLER ROLLER ASSLY.

4121233003X

W AXIS ROLLER

SPOOL ASSLY.

CLUCH ROLLER ASSLY.

4121231003X

4121232003X

WIDE ROLLER ASSLY.

4120739003X

BELT ROLLER COMP.

4120730503X

DESCRIPTION

ITEM CODE

S.NO.

24-C

12

26

13

10

20

SECTION

16

X-X

17

25

22

24

14

23

11

ELEKTRA

18

21

15

19

41212411940
41212420940
41212430130
41212430240
41212430340
41212430440
41212430540
41212430640
41212430730
41212430840
41212430940
41212431140
41212431240
41212431320
41212431430
41212431540
41212431640
41212431740
41212431840
41212431940
41212432140
41212434030
41212436030
41212438030
50300000016
72060017003
74140103008

DESCRIPTION

DESCRIPTION

GUIDE CASE 1

CASE HOLDER

WIRE GUIDE
PLATE
CUTTING HOLDER

APPROCH UPPER

RADIAL BRG

KNOCK CYLINDER

AIR HAND COMP

WIRE CUTTER COMP

CONE UPPER
SPRING
UPPER CONE HOLDER
LATCH SHAFT COMP

UPPER CONE MOUNT

INSULATOR Z
INSULATOR BUSH

AWT MOUNTING
AWT MOUNT PLATE

WIRE EJECT PLATE

WIRE GUIDE 0.6MM

APPROCH LOWER

WIRE GUIDE
WIRE GUIDE JW300

UPPER GUIDE APPROCH

GUIDE APPROUCH

AWT ASSEMBLY

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

NO.

SR
3
2
1
1
1
1
1
1
1
3
1
1
1
1
1
1
4
1
1
1
1
1
1
1
2
1
6

QTY

FIG. NO.: -14

ULTRACUT f-2

WORK PIECE

CLAMPING OF JOB

CLAMP WITH SCREWS

ELEKTRA

JOB CLAMPING
24-C

ULTRACUT f-2
FIG. NO.: -15

24-C
ELEKTRA

WORKTABLE LAYOUT

WORK TABLE WITH MAXIMUM SIZE MOUNTED

JOB

FIG. NO.: -16

ULTRACUTf-2

ALL DIMENSIONS ARE IN mm

JOB SUPPORT

WORKTABLE WITH FIXED AND MOVABLE

BRIDGE MOUNTED

ELEKTRA

WORKTABLE LAYOUT-1
24-C

ULTRACUT f-2
FIG. NO.: -17

ALL DIMENSIONS ARE IN mm

WORKTABLE WITH MAXIMUM SIZE JOB MOUNTED

ELEKTRA

WORKTABLE LAYOUT-2
24-C

SPRINTCUT f-1
FIG. NO.: -18

ALL DIMENSIONS ARE IN mm

JOB SUPPORT

WORKTABLE WITH SMALL JOB MOUNTED

ELEKTRA

WORKTABLE LAYOUT-3

24-C

ULTRACUT f - 2
FIG NO.19