T54125A

Maintenance
Manual
T54125A
MAINTENANCE MANUAL
Index
CHAPTER 1 INTRODUCTION ___________________________________ 1
1.1. Maintenance Manual Target Public ............................................................................................... 2
1.2. General Note ................................................................................................................................. 2
CHAPTER 2 GENERAL MAINTENANCE __________________________ 3

2.1. Bed ................................................................................................................................................ 4
2.1.1. Leveling ............................................................................................................................................ 5
2.2. Headstock ..................................................................................................................................... 9
2.2.1. Position Encoder .............................................................................................................................. 9
2.2.2. Lubrication (Direct Drive Headstock and Geared Headstock) ....................................................... 10
2.2.3. Alignment ....................................................................................................................................... 10
2.2.3.1. Checking alignment using machined rod ......................................................................11
2.2.3.2. Vertical Plan ..................................................................................................................11
2.2.3.2. Horizontal Plan ............................................................................................................. 12
2.3. Motorization ................................................................................................................................ 13
2.4. Chuck and hydraulic cylinder ...................................................................................................... 15
2.4.1. Chuck/Cylinder assembly operation ............................................................................................... 15
2.4.2. Operation commands for chuck or collet chuck ............................................................................. 16
2.4.3. Chuck Control Messages .............................................................................................................. 16
2.5. Saddle and Cross slide ............................................................................................................... 18
2.5.1. Saddle Operation (Z Axis) .............................................................................................................. 18
2.5.1.1. Bearings replacement .................................................................................................. 19
2.5.1.2. Grease ......................................................................................................................... 19
2.5.1.3. Adjusting pre-load ........................................................................................................ 19
2.5.1.4. Procedure for replacing/adjusting the belt ................................................................... 20
2.5.2. Cross slide Operation (X Axis) ....................................................................................................... 21
2.5.2.1. Bearings replacement .................................................................................................. 22
2.5.2.1. Grease ......................................................................................................................... 22
2.5.2.3. Adjusting pre-load ........................................................................................................ 22
2.5.3. Guides ............................................................................................................................................ 23
2.5.4. Taper gib Adjustment ...................................................................................................................... 24
2.5.5. Tailstock micro switch sensor pin .................................................................................................. 25
2.6. Tailstock ...................................................................................................................................... 26
2.6.1. Access to tailstock .......................................................................................................................... 26
2.6.2. Lubrication ...................................................................................................................................... 26
2.6.3. Alignmemt ...................................................................................................................................... 27
2.6.3.1. Checking parallelism between tailstock quill and saddle longit. mov. (Z axis) ............. 27
2.6.3.2. Checking parallelism between headstock and tailstock center lines .......................... 28
2.6.3.2.1. Procedure for tailstock alignment ......................................................................... 29
2.6.4. Live Center ..................................................................................................................................... 30
2.7. Automatic Lubrication System .................................................................................................... 31
2.7.1. Periodical Maintenance ................................................................................................................. 32
2.7.2. Visual identification for lubrication points ....................................................................................... 36
2.8. Hydraulic System (Accessory) .................................................................................................... 38
2.8.1. Periodical Maintenance ............................................................................................................... 38
2.8.2. Settings for hydraulic chuck and hydraulic operated tailstock........................................................ 40
2.8.3. Hydraulic Diagram .......................................................................................................................... 41
2.8.4. Description of the valves and solenoids ........................................................................................ 42
2.8.5 Hydraulic Unit Components Function ............................................................................................. 42
2.9. Coolant system ........................................................................................................................... 43
2.10. Chip Conveyor (Accessory) ........................................................................................................ 46
T54125A Maintenance Manual - ROMI C620 v3.0

MAINTENANCE MANUAL
2.11. Coolant System and Chip Conveyor connectors ........................................................................ 47

2.12. Systems Supply .......................................................................................................................... 48
2.13. Abnormal Noises and Heating .................................................................................................... 49
2.14. Wipers ......................................................................................................................................... 49
2.15. Worklight ..................................................................................................................................... 50
2.16. Door glass Procedures for Replacement ................................................................................. 51
2.17. Electrical Interlock Safety Switch ................................................................................................ 52
2.18. Air Conditioning for Electric Panel (Accessory) .......................................................................... 53
2.19. Oil / Skimmer (Accessory) .......................................................................................................... 54
2.20. Horizontal Electrical Turret (Accessory) ...................................................................................... 55
2.21. 72 positions indexing (Accessory) .............................................................................................. 56
2.22. RS232 connection and electrical power outlet ............................................................................ 58
2.23. Electrical Panel - Ventilation Area ............................................................................................... 59
2.24. Checking all Electrical Connections ............................................................................................ 59
2.25. Preventive Maintenance Chart .................................................................................................... 60
T54125A Maintenance Manual - ROMI C620 v3.0

CHAPTER 1
INTRODUCTION
T54125A Maintenance Manual - ROMI C620 v3.0 1

1 - INTRODUCTION
1.1. MAINTENANCE MANUAL TARGET PUBLIC
Maintenance Manual
Instructions for:
Preventive Maintenance
Corrective Maintenance
Target public:
Maintenance Technicians
Inspection Technicians
Repair Technicians
1.2. GENERAL NOTE
IMPORTANT
All maintenance operations MUST BE PERFORMED WITH THE MACHINE SWITCHED
OFF.
Prior to perform any maintenance work, switch the machine off via the main switch and
lock it with padlock in order to prevent serious injuries or material damages.
Machine powered-up Machine switched off for maintenance activities
VIEW A
Main Switch Apply padlock to

lock main switch
2 Maintenance Manual - ROMI C620 v3.0 T54125A

CHAPTER 2
GENERAL
MAINTENANCE

2 - GENERAL MAINTENANCE
2.1. BED
The bed assembly is greatly responsible for the machine rigidity, and consequently for its accuracy.
The lathe bed has been carefully designed in order to achieve simple and solid construction. The illustration
below shows some of the most important parts of this assembly.
D
B
Bed and Columns
COLUMNS
The bed assembly, for 1000mm between centers machine version, is provided with a large column (A)
and a small column (B), both made of cast iron, to support the bed (C). For 2000mm between centers machine
version a middle column (D) is included.
The columns are rested on the ground by leveling screws, being 4 on the large column (A), 2 on the
small column (B) and 2 on the middle column (D).
LATHE BED
The lathe bed (C) is also built in cast iron, very rigid, to assure the saddle accurate movement. The
prism/plan type guides are tempered and machined.
The ribbing has been developed aiming at conciliating the high rigidity desired with a good condition of
chips outflow. However, good chips outflow depends on the type of chip generated, and this depends directly
on using suitable toolset.

2.1.1. Leveling
Introduction
For the machine accuracy and geometric stability, it is very important that the machine would be precisely
leveled. This procedure is performed by Romi during the machine installation, and the customer is recommended
to have the machine leveling checked after one month and at every six months.
WARNING:
This service could be bought from Romi, as it is

not included in the guarantee.
For leveling the machine, 2 high-accuracy (0,02mm/m) levels are required, at the position shown on
figure 1, ensuring that the leveling difference would be less than the tolerances specified for the longitudinal
and transversal directions. The bubbles always move towards the higher side. By tightening the screws on the
opposite side, the bubbles would be brought to the level center.
For example:
If the transversal level bubble would move towards the 2B screw area (see figure 2), tighten the 2A screw
for centralizing the bubbles.
When both bubbles would be centralized, the machine would be leveled. There is a tolerance for difference
of level from one to the other side, as shown on the following table:
TRANSVERSAL TOLERANCE ALLOWED FOR LEVELING: 0,04 mm/m
LONGITUDINAL TOLERANCE ALLOWED FOR LEVELING: 0,02 mm/m
Table 1

Procedure
a. Adjust all leveling screws until they touch the ground.

b. Use 2 high-accuracy levelers on the top of the cross slide, as shown on figure 1.
Note: Prior to use the levelers, remove the tool-holder base, and carefully clean the cross slide surface and
the levelers.
Cross slide
Levelers
Figure 1
c. Level the machine through the leveling screws until the bubbles within the levelers are approximately
at the center.
Example: If the bubble would be to the left, tighten the right side screws and vice-versa.
Note: The bubble would always move towards the tightened screw side.
Transversal Adjust
1) After the bubbles would be at the leveler center, with the cross slide at the lathe bed center, move the
cross slide fully to the left. Check the bubble position in the transversally placed leveler. Following
the same procedure as in item "c" above, perform leveling so that the bubble would be at the leveler
center.
2) Move the cross slide fully to the right and repeat the procedure in item "1" above.
3) After the bubble would be at the leveler center (transversal) at both ends and at the lathe bed center,
move the cross slide over the lathe bed fully from left to right, and check that the level variance will
not exceed the tolerance specified in table 1.
Should any difference of level exist above such tolerance, take the left end leveler reading as refe-
rence, and proceed as follows:
- If sides A and B are higher than sides B and C, tighten bolt 3B, located at the side opposite to the
higher side, until the transversal bubble leveler is approximately at the same level as the reference
plan (left end).
- If sides B and C are higher than sides A and B, tighten the 3A screw, located at the side opposite to
the highest side, until the transversal level bubble is approximately at the same level as the reference
plan (left end).
4) Move the cross slide again to the left, make a new reference and displace the cross slide to the right.
Check for any variations above tolerance specified in the table in relation to the reference. If there is
any difference, repeat the procedure.

Longitudinal Adjust
a. Position the cross slide at the lathe bed center, and take the level longitudinally placed for referen-
ce.
- Move the cross slide to the left, with the level longitudinally placed adjusting from zero to "X" lower
than the center.
- Move the cross slide to the right, with the level longitudinally placed adjusting from zero to "X" lower
than the center.
Consider "X" as the tolerance value specified in table 1
If the following conditions would occur, proceed as follows
=> For 1.000mm machine version:
Center above "X" higher than ends: Evenly loosen screws 2A and 2B. (fig.2).
Center lower than ends: Evenly tighten screws 2A and 2B. (fig.2).
Left end higher than center: Evenly loosen screws 1A and 1B (fig.2).
Left end above "X" lower than center: Evenly tighten screws 1A and 1B (fig. 2).
Right end higher than center: Evenly loosen screws 3A and 3B (fig.2).
Right end above "X" lower than center: Evenly tighten screws 3A and 3B (fig. 2).
SIDE A
1A 2A
LADO A
3A
Large
LADO
SIDE DD Column Small SIDE BB
LADO
Column
1B 2B 3B
LADO
SIDEC
C FIG. 2
Figure 2
1.000mm Machine Version

=> For 2.000mm machine version:
Center above "X" higher than ends: Evenly loosen screws 3A and 3B. (fig.3 ).
Center lower than ends: Evenly tighten screws 3A and 3B. (fig.3).
Left end higher than center: Evenly loosen screws 1A , 2A, 1B and 2B (fig.3).
Left end above "X" lower than center: Evenly tighten screws 1A, 2A, 1B and 2B (fig. 3).
Right end higher than center: Evenly loosen screws 4A and 4B (fig.3).
Right end above "X" lower than center: Evenly tighten screws 4A and 4B (fig. 3).
Then check the transverse and longitudinal levelling and in case of need repeat procedures until it brings
specified tolerances.
Consider "X" as the tolerance value specified in table 1
SIDE A
LADO A
1A 2A 3A 4A
Large Middle Small

SIDE COLUNA COLUNA COLUNA SIDE B B
LADO D D Column
GRANDE Column
CENTRAL
Column
LATERAL LADO
1B 2B 3B 4B
SIDE CC
LADO
Figure 3
2.000mm Machine Version
IMPORTANT
The levelling must be checked each 6 months to keep the machine in good
conditions of operation.

2.2. HEADSTOCK
Machine can be equipped with 2 types of headstocks:
DIRECT DRIVE HEADSTOCK
Spindle shaft is mounted on high precision bearings, permanently lubricated. Unless it is

necessary adjusments should not be done and parts should not be replaced.
Transmission from the spindle to motor is provided with pulleys and Poli-V belt.
GEARED HEADSTOCK
Geared headstock is comprised of a set of gears enabling a two manually selected

speed ranges. The couple gears lubrication is provided by an oil bath.
2.2.1. Position Encoder
The spindle is connected to a position encoder through an indented belt, with 1:1 transmission ratio.
The encoder function is to inform to the CNC control the spindle angular position and rotation, allowing perfect
synchronism between the spindle and advancement in a threading operation.
The position encoder unit is installed near the spindle and it is driven by pulleys and indented belt,
properly adjusted at the factory. Under normal working conditions, adjustments would not be necessary, but if
abnormal noises would occur at this portion of the machine, check the toothed belt. If teeth are damaged, the
belt should be replaced.
Toothed Belt Encoder assembly Encoder assembly Toothed Belt
Direct Drive Headstock Geared Headstock

Procedure for replacing/adjusting the belt:
- Loosen the bolts (1) and move leftwards the encoder assembly (2) through the oblong;
- Remove the old belt (3);
- Place the new belt;
- Adjust the belt tension by moving the encoder rightwards;
- Tight the bolts (1).
1
2
3
1
2
Direct Drive Headstock Geared Headstock
2.2.2. Lubrication (Direct Drive Headstock and Geared Headstock)
The spindle roller bearings are permanently lubricated with special grease estimated to last for the
entire roller bearings service life. These roller bearings are protected by labyrinths that prevent the grease to
be contaminated by oil.
NOTE
If by any reason, the spindle would require to be disassembled, its roller bearings should
be cleaned and lubricated again with special grease ISOFLEX NBU-15 (KLBER).
2.2.3. Alignment
Under normal conditions, aligning the headstock would not be necessary. However, if by any reason
missalignment would occur, of if the headstock would be replaced, maximum care should be taken with the
aligning operation.
NOTE
The alignment of the headstock is an operation that directly influences the machine
accuracy and shall be done by qualified personnel only.

2.2.3.1. Checking alignment using machined rod
Using 50-mm steel bar and 300-mm useful measuring length, perform measuring using millesimal
clock at three points of the rod, distributed over 300-mm length and check conicality. If necessary, perform the
headstock alignment according to the following procedures.
b
a) 0.015mm toward only
a
b) 0.020mm upward only
Roundness recommended for

the rod = 0.003mm
2.2.3.2. Vertical Plan
Aligning on the vertical plan is done by adjusting the height of the shims (1) that support the headstock
on the lathe bed.
HEADSTOCK HEADSTOCK
FRONT VIEW REAR VIEW
1
Geared Headstock

HEADSTOCK HEADSTOCK
FRONT VIEW REAR VIEW
Direct Drive Headstock

1
2.2.3.2. Horizontal Plan
On the horizontal plan, the headstock is aligned and locked at the proper position, through the bolts that
actuate on the machine headstock body and on the lathe bed, as shown on the figure below.
The following procedure shall be followed for aligning:
- Loosen the cartridge bolts (2);

- Keep the bolts (3) secured to the lathe bed;
- Actuate on the bolts (4) on the headstock.
After aligning, keep all bolts secured to headstock and

lathe bed.
4 2
Geared Headstock 2
3
3 Direct Drive Headstock

2.3. MOTORIZATION
The Motorization basically consists of an AC Electrical Motor (1) located at the large column (2), provided
with driver and driven pulleys and micro V belt.
After some time of use, the belt (3) may loosen due to natural wear-out. If this would occur, proceed as
follows to replace or adjust it:
Loosen the 4 bolts (4) that fix the support (5).

Actuate on the 2 nuts (6) and move the support (B) to replace and/or adjust the belt.
After replacing or adjusting the belt, tighten the nuts (6) and the bolts (4).
4
2
4
1
Geared Headstock machine version

Belts Tensioning
Belt Tension (Hz)
The table aside contemplates the values for Headstock Spindle New belt Used
belt tensioning, using the apparatus Optibelt
TT3. Geared A2-8" 60 a 62 56 a 58
In the absence of this apparatus, use an
apparatus suitable to micro V belt. Direct Drive A2-8" 53 a 54 49 a 51
Lifting eyebolts
If needing to transport/lift the electrical motor,

use the lift eyebolts.
Motor Weight (approx.)

230 kg (507 lb)
No
Do notexecute
performqualquer operao ou
any maintenance trabalho de
operation or manuteno, antes de reading
work before carefully ler cuidadosamente
the motor
o manual do motor que acompanha a mquina.
manual that comes together with the machine.
Main Motor - Fan
Always switch the main switch off prior to accessing the fan. Such access could only be done when
the spindle and fan would be fully stopped.
Never attempt to access those devices while the machine would be powered-up. Serious accident
risks would exist.
Cleaning the motor fan at every 4000 hours is recommended.

Do not use any chemicals that could affect the material.
Fan
Do No execute any
not perform qualquer operaooperation
maintenance ou trabalho
orde manuteno,
work antes de
before carefully ler cuidadosamente
reading the motor
o manual
manual do motor
that comes que acompanha
together a mquina.
with the machine.

2.4. CHUCK AND HYDRAULIC CYLINDER
2.4.1. Chuck/Cylinder assembly operation
2 1
3
The chuck (1) opening and closing motion is performed by a hydraulic cylinder (2), which applies a
force by draw tube (3) that interconnects both assemblies. To open the chuck, the cylinder applies a
compressive force, and to close it, the chuck applies a traction force.
The chuck may fasten the part by securing it by the inside or outside diameter depending on the
shape of the part to be machined. By using M codes (see list to follow), the CNC is informed on the
part fastening mode.
The cylinder motion, and consequently the chuck jaws motion (opened or closed), is informed to
CNC via two sensors located behind the cylinder, which indicate if the cylinder is pulled backwards
or forwards. Therefore, by using M code plus sensor information, the CNC controls the current chuck
position during machining.
The 3 chuck settings informed to CNC are:
Chuck Closed Without Piece - When the "chuck without part" sensor is activated
Chuck Unclamped - When the "chuck unclamped" sensor is activated
Chuck Closed With Piece - When none of the sensors above are activated.
In function of the actuation of these sensors, two messages may appear to warn that the plate is not
safe to operation: "Chuck Unclamped" or "Chuck Without Part. The function and message generated
by both sensors is inverted in function of the M code selected. When required, sensors must be
adjusted.
Function of solenoids and sensors on hydraulic chuck

Securing by Securing by
CNC signals Solenoid Sensor
outside inside
Chuck Chuck without
I05.2 input - S421
unclamped part
Chuck without Chuck
I05.3 input - S422
part unclamped
Q04.2 output Y422 - Closes chuck Closes chuck
Q04.1 output Y421 - Opens chuck Opens chuck

2.4.2. Operation commands for chuck or collet chuck
M24 Opens chuck

M25 Closes chuck
M24=24 Opens chuck with instant reply
M25=25 Closes chuck with instant reply
M81 Selects secure by inside
M82 Selects secure by outside
2.4.3. Chuck Control Messages
Chuck without part - There are two situations in which this message occurs:
1st When there is a command to secure the part and no part is present on chuck (or collet
chuck), thus activating the "chuck without part" sensor. This message generates Emergency
when occuring while the spindle is turning. If the spindle is stopped, it does not permit motion
of axes.
Possible causes: Check that there is part on chuck or whether the part is poorly secured,
etc...
2nd This message occurs after changing the part securing mode (M81, M82) and when the
"chuck without part" sensor is activated.
Possible causes: Check that the part is secured according to the mode selected. Check
sensors, solenoids, etc...
Chuck unclamped - This message usually occurs after opening the chuck. The command
generates this message after activating the output to release the part and with the "chuck
unclamped" sensor activated - this is not an alarm.
Possible causes: If this message is incorrectly generated, check that there is no part poorly
placed, sensor poorly adjusted or short circuited, etc...
Chuck fault when securing the part - Fault message. This message is generated by the
command after activating the output to secure the part and with the "unclamped part" sensor still
activated after expiring the supervision time. Generates audible alarm. The button "OK Operator"
resets audible alarm and the RESET key cancels the fault after eliminating the cause.
Possible causes: Check sensors, solenoids, etc... .
Chuck fault when releasing the part - Fault message. This message is generated by the
CNC after activating the output to release the part and without receiving any signal from the
"chuck unclamped" sensor within the supervision time. Generates audible alarm. The button
"OK Operator" resets audible alarm and the RESET key cancels the fault after eliminating the
cause.
Possible causes: Check sensors, solenoids. ,etc...

Programming error - Fault message. This message occurs when a command is issued to
change the part securing mode (M81, M82) with spindle rotating. It generates audible alarm, axis
stop and spindle blocking. The button "OK Operator" resets audible alarm and the RESET key
cancels this messsage after eliminating the cause.
Possible causes: Fix program...
Unclamped part - This message usually occurs after changing the part securing mode (M81,
M82) and when the "chuck without part" sensor is activated. It generates audible alarm, axis
stop and spindle blocking. The button "OK Operator" resets audible alarm and the RESET key
cancels this messsage after eliminating the cause.
Possible causes: Check that the part is secured according to the mode selected. Check sensors
and solenoids.
Chuck fault - This message may occur due to chuck motion without command or when two
sensors are activated simultaneously. It generates audible alarm, axis stop or spindle blocking.
The button "OK Operator" resets audible alarm and the RESET key cancels this messsage after
eliminating the cause.
Possible causes: Check sensors, solenoids, etc....

2.5. SADDLE AND CROSS SLIDE
The saddle movement (Z Axis) over the lathe bed and the cross slide (X Axis) over the saddle
provides the tool with the two movements required for the machining operation.
2.5.1. Saddle Operation (Z Axis)
The saddle moves over the Z axis direction, driven by a servomotor coupled to the ballscrew (2)
though pulleys (3) and toohhed belt (4). The ballscrew (2) is supported by a frontal bearing house
(5) mounted with angular contact ball bearing (6 e 6A) and by a rear bearing house (7) mounted with
one ball bearing (8).
The bearings are lubricated with long-life grease. The ballscrew and guides lubrication is done by
Automatic Lubrication System.
1 5 2
8
6A 6
REMARK
Check the belt conditions at every 4000 hours, and replace it if necessary.

2.5.1.1. Bearings replacement
The right bearing (5), placed beside the headstock, is assembled with a set
of angular contact roller bearings (6 and 6A) separated by a bushing (9). In case of Bearings
ballscrew removal, it is necessary to pay attention about the correct position for these arrangement (6 e 6A)
bearings assembly. DF ("O")
The shielded ball bearing (8) is assembled on the rear bearing (7) , with permanent
lubrication, and this does not requires a correct position for assembly.
2.5.1.2. Grease
Bearings (6 and 6A) are lubricated with grease (ISOFLEX NBU- Grease
Bearings total
15 Klber). This is a long lasting grease that, under normal working Qty
conditions, is specified for 10.000 working hours. The grease quantity 6 and 6A 4,0 c.c. 8,0 c.c.
is indicated on the right beside chart.
2.5.1.3. Adjusting pre-load
Angular contact ball bearings (6 and 6A) are assembled with standard load, named as pre-load, which
is a predefined load for the perfect functioning of angular contact ball bearings and to eliminate bearing
gap.
Pre-load is the contact pressure between bearing and cover, calculated with the ball bearings housed
in the bearing - see figure bellow.
In order to adjust the pre-load it is necessary to put the bearing (6) in the housing paying attention
to the correct assembly position and put the cover (10). Then put the internal bushing (11), the
external bushing (9) and the bearing (6 a) in the housing paying attention to the correct assembly
position - . After this it is necessary to register B measure and adjust the cover (12) respecting a
measure A, which means B amount + (0,010 to 0,030mm). For example: if B = 5mm, A = 5,01 to 5,03
mm. When tightening the cover (12) against the bearing, this additional amount will turn the bearing
contact pressure, which means, the pre-load itself.
Bear in mind that the pre-load adjusting should be done for cover 12 only after assembling the cover
(10).
After the complete bearing pre-load adjusting the ballscrew can be assembled.
Remark: Tighten screws M10 of covers (10 and 12) with 50 Nm torque. Tighten also the nut SKF (13)
with 30 Nm torque. Covers screws should be alternately (in "X"shape).
6A 6
10
13 12
B 11 9
ATTENTION!
Bushings (9 and 11) are factory adjusted and should not have their lengths modified.

2.5.1.4. Procedure for replacing/adjusting the belt
- Loosen the four bolts (1) and move the servomotor mounting flange (2) leftwards through the oblong;
- Remove the old belt;
- Put the new belt;
- Adjust the belt tension moving the mounting flange downwards.
- For finishing, tighten the bolts (1).
Belt Tensioning
The table below contemplates the values for belt tensioning, using the Optibelt TT3 device.
In the absence of this apparatus, use a device suitable to micro V belt. .
Belt Tension (Hz)

New belt Used belt
282 a 296 236 a 252

2.5.2. Cross slide Operation (X Axis)
The cross slide moves over the X axis direction, driven by a servomotor (1) coupled to the ballscrew
(2) through pulleys (3) and toothed belt (3).
The ballscrew is supported by 2 roller bearings (frontal and rear).
The ball bearing (7) is coupled to cross slide (6) and doe not require pre-loading.
Rear bearing (5) is assembled with a set of angular contact axial roller bearings (8 e 8A).
6A
3
1
7 8 8A
2

2.5.2.1. Bearings replacement
Rear bearing (5) is assembled with a set of angular contact axial ball bearings Bearings arrangements
(8 e 8A). In case of ballscrew disassembly it is necessary to pay attention about the (8 e 8A)
correct position when assemblying the bearings again.
DF ("X")
Shielded roller bearing (7) is coupled to the frontal bearing (6), with permanent
lubrication which does not require a correct assembly position.
2.5.2.1. Grease
Angular contact axial ball bearings are lubricated with grease

(ISOFLEX NBU-15-Klber). This is a long lasting grease that, under Bearings Grease qty. Total
normal working conditions, is specified for 10.000 working hours. The
8 e 8A 3,0 c.c. 6,0 c.c.
grease quantity is indicated on the right beside chart.
2.5.2.3. Adjusting pre-load
The angular contact ball bearings (8 and 8A) are assembled with standard load, named as pre-load,
which is a predefined load for the perfect functioning of angular contact ball bearings and to eliminate
bearing gap.
Pre-load is the contact pressure between bearing and cover, calculated with the ball bearings housed
in the bearing - see figure bellow.
In order to adjust pre-loading it necessary to put bearings (8 e 8A) in their housing - paying attention to
the correct assembly position. Then the cover (10) should be adjusted with a B measurement (equal
to the A measurement plus (0,040 to 0,060mm). For example: if A = 5mm, B = 5,04 to 5,06 mm.
When tighting the cover on the bearing this additional amount will turn the bearing contact pressure,
which means, the pre-loading. After bearing pre-loading the ballscrew (2) can be assembled.
A B
2 9
8 8A 10
11 Remarks: Cover screws (1) should be alternately (in X) with

50Nm torque.
Ajusting nut (9) torque is 24 Nm.

2.5.2.4. Procedure for the belt replacement or adjusting
3 4
5
3
1
2
- Remove the cover (1) loosing the clamping screw (2);

- Loosen 4 clamping screws (3) on the servo flange;
- Loosen 2 belt screws (4);
- Move servo flange upwards thru oblong hole;
- Remove he old belt (5);
- Put the new belt;
- Tighten 2 belt screws (4) in a similar way to adjust the belt tension;
- Tighten 4 clamping screws (3) on servo flange;
- Put the cover (1) an tighten the clamping screw (2).
Belt Tensioning Belt Tension (Hz)
The side table contemplates the values for belt tensioning, using New belt Used belt
the Optibelt TT3 device.
In the absence of this apparatus, use a device suitable to micro V 179 a 188 150 a 160
belt.
2.5.3. Guides
The saddle moves on the lathe bed driven by ballscrew (Z axis). The lathe bed is provided with tempered
and machined guides, being the saddle covered by turcite on the surfaces in contact to the lathe bed guides.
The contact between turcite and cast iron reduces the friction coefficient providing less displacement
strain.
A tempered and machined guide is placed atop the saddle. The cross slide slides over this guide through
the movement provided by X ballscrew. The elimination of gap between the cross slide guides and saddle
guides is achieved through a taper gib adjustment.

2.5.4. Taper gib Adjustment
ROMI C620 v3.0 machine has 3 taper gibs to eliminate the gap on sliding sub-assemblies. One is
located on the cross slide (X axis) and 2 are located on the longitudinal carriage (saddle) (Z axis).
Taper gibs should be adjusted (tightened) to eliminate the gap between the cross slide and the
saddle prism and the longitudinal and the bed. The excess on taper gibs tightenin may cause the
locking of the sub-assembly.
When adjusting the taper gib, take into consideration that this adjustment will displace the cap
laterally until the rule would accommodate and eliminate the gap.
For this reason, the ballscrew nut front bolts shall be loosen to allow the cap to move freely.
2 1
1
2
Longitudinal
carriage (saddle)
Cross slide adjusting screw
adjusting screw
Turcite
Longitudinal Taper gib

5 carriage (saddle)
adjusting screw
4 3
The taper gib adjust is an operation that directly influences the machine accuracy and shall
be done by qualified personnel only.
2.5.4.1. Procedures for adjustment of cross slide (X axis) taper gib:
A) Turn the machine off. Remove the four screws (1) and the two guide pins (2) that fix the cross slide
to the ballscrew. This way the cross slide is released;
B) Reach the adjusting screws (3 and 4) of cross slide taper gib through the chip scraper;
C) Loosen screw (3) with an 8mm Allen wrench to enable the taper gib adjustment;

D) Reach the screw (4) with a 5mm Allen wrench inside the screw (3). Tighten it with turn each time
to press the taper gib inside the cross slide until the elimination of the gap;
Caution: The excess of tightening may cause the cross slide locking on the guide;
E) After eliminating the gap, tighten the screw (3) until it touches the taper gib. Loosen the screw (4) until
the taper gib clamps between two screws;
F) Move the cross slide forward and backwards, with the hands, to make sure he is smoothly moving;
G) Align the cross slide holes over the ballscrew nut and tighten the screws (1) that fix the cross slide to
the ballscrew;
H) Turn the machine on. Move the cross slide to check if it moves smoothly without the overload on the
servomotor;
I) Pass the 8mm reamer thru the holes and put the guide pins (2) removed in the beginning of this
procedure.
2.5.4.2. Procedures for adjustment of longitudinal carriage (saddle) (Z axis) taper gib:
A) Turn the machine off. Loosen the screws (5) of Z axis ballscrew;
B) Access the adjusting screws (3 and 4) of longitudinal carriage taper gib;
C) Loosen screw (3) with na 8mm Allen wrench to enable the taper gib adjustment;
D) Reach the screw (4) with a 5mm Allen wrench inside the screw (3). Tighten it with turn each time
to press the taper gib inside the longitudinal carriage until the elimination of the gap;
Caution: The excess of tightening may cause the longitudinal carriage locking on the guide;
E) After eliminating the gap, tighten the screw (3) until it touches the taper gib. Loosen the screw (4) until
the taper gib clamps between two screws;
F) Tighten the screws of the ballscrew that were loosen in the beginning of this procedure;
G) Turn the machine on . Move the longitudinal carriage to check if it moves smoothly without the overload
on the servomotor.
2.5.5. Tailstock micro switch sensor pin
The pin is located behind the tailstock and is actuated to avoid the contact between the longitudinal carriage
(Z axis) and the tailstock, activating the micro switch sensor (S325) placed inside the longitudinal carriage.
The driving of this micro switch by the pin is treated in two different ways, depending on the situation it
occurs (JOG mode or AUTO mode).
If the micro switch is actuated during Z axis movement, in JOG mode, the following message will appear:
Warning! Axis in a collision area with the tailstock.
If the micro switch is actuated during Z axis movement, in AUTO mode, the following message will appear:
Z axis end of travelling.
Micro Switch
Sensor
Pin

2.6. TAILSTOCK
2.6.1. Access to tailstock
The tailstock is positioned at the right end of the machine lathe bed.
,
The machine is equipped with three front doors. The access to the tailstock is by displacing the right
door leftwards.
Right Door
2.6.2. Lubrication
The lubrication of the tailstock quill is done through greasers (1). This lubrication shall be performed at
every 8 working hours, but such period should be reduced under extreme working conditions.
Use DIN 51502 CGLP68 lube oil.
1
1
MANUAL TAILSTOCK HYDRAULIC TAILSTOCK

2.6.3. Alignmemt
Before checking tailstock alignment make sure the machine is correctly leveled. Tailstock leaves
the factory perfectly aligned and, under normal working conditions, the alignment is not necessary.
However a checking at every 4000 working hours is advisable.
If for any reason a misalignment occurs or a replacement is required it is a maximum care during
tailstock alignment procedures.
2.6.3.1. Checking parallelism between tailstock quill and saddle longitudinal

moviment (Z axis)
The checking between tailstock quill and saddle longitudinal movement should be performed
with the use of a thousandth dial (see below figure);
Maximum specified tolerance: (travel L =100mm):

XZ Plane = 0,005mm (forward - operator position)
YZ Plane = 0,005mm (upwards)
Figura / Diagram: L
L
YZ
b)
XZa)
ZZ
The quill parallelism on XZ and YZ planes is provided with the scraping. Under normal working
conditions this adjustment will not be required. In case of need to perform this procedure please
contact ROMI After Sales Service.

2.6.3.2. Checking parallelism between headstock and tailstock center lines
A) Alignment checking with the use of machined piece
Having a steel bar (50mm and 300mm long), follow the procedures below:
Clamp the piece between the chuck and the tailstock.
Perform a finishing machine operation removing minimum material from workpiece. (low feed
and low cutting speed).
Use a micrometer to measure the diameters of both ends of the piece, checking for the taper
angle.
Taper value divided by two or half of the taper value will indicate the displacement value of
tailstock for aproppriate adjustment.
In order to perform the adjustment see "Procedure for tailstock alignment".
B) Alignment checking with the use of machined rod
Having a 300mm long machined rod perform the measurement between centers with a thousandth
dial in three positions along said rod to check the misalignment. See allowed tolerances below:
b (YZ) a) 1000mm between centers =>0,015mm

2000mm between centers =>0,030mm
a (XZ) (tailstock forward - operator position)
b) 0,030mm
(upward - higher than headstock "at cold")
Recommended cylindricity
for the rod = 0,003mm
1. If a misalignment is found on YZ plane (height) it is necessary to perform geometric adjustments

and for this case it is necessary to contact ROMI After Sales Service.
2. If a misalignment is found on XZ plane (lateral) see next topic "Procedure for tailstock alignment"
to perform the adjustment.

2.6.3.2.1. Procedure for tailstock alignment
IMPORTANT
Aligning the movable headstock is an operation that directly influences the machine accuracy
and shall be done by qualified personnel only.
Tailstock is provided with a side system alignment through screws and keys which guarantees
the alignment between tailstock and headstock center lines.
In order to make this effective it is necessary to loosen screw (1), nuts (2) and adjust the
alignment through screws (3) and (4).
See the following example:
4 1
For tailstock moving to the right:

A) Loosen the screw (1) and nuts (2);
B) Loosen screw (3) and tighten screw (4) to obtain
the alignment;
C) Tighten screw (1) and nuts (2).
3
VIEW A

2.6.4. Live Center
The tailstock is provided with a MT5 Live Center, which can be extracted manually. For doing so, advance
the quill until the extraction slot would become visible, and then use the extraction wedge and hit it smoothly
until the live center be loosen from the quill. Remove the live center and extracting wedge manually.
Slot
MT5 live center
Quill
Extracting Wedge
IMPORTANT
For the assembly conservation, it is important to keep the MT5 live center mounted
to the assembly even if not in use, thus preventing impurities to enter.

2.7. AUTOMATIC LUBRICATION SYSTEM
The lathe bed, saddle and cross slide guides, and the ballscrews are lubricated by the Automatic
Lubrication System.
Lubrificao
Automtica
The system contains an intermittent automatic pump driven by electric motor with
regulated oil injection cycles The oil distributors deliver oil to the friction points.
Not all lubricant oils are compatible with all coolant liquids. The lubricant oil shall
present proper de-emulsifying behavior before the coolant liquid.
Lubricant suppliers can report on compatibility between lubricant oil and coolant
liquid.
Oil Discharge Volume and Cycle Time

The Lubricator MMXL-III is an intermittent plunge automatic pump that delivers:
1.5cc per stroke every 6 minutes (50Hz frequency);
1.5cc per stroke every 5 minutes (60Hz frequency).
Discharge Pressure
43 PSI (3 Kgf/cm2).
The system peak pressure would decrease when:
1 - The discharge volume decreases.
2 - The oil viscosity increases.
Oil viscosity range

150 to 8000 SSU at operating temperature.
Oil used: DIN 51502 CGLP 68 for guides.
Tank Capacity
0.5 gal (1.8 liters)
Lubrication Filter
It shall be periodically inspected and cleaned or changed, as required.
Motor
220 V (50/60 Hz), 3 Watt Synchronous.

2.7.1. Periodical Maintenance
Oil Level
Check the lubricating oil level on a daily basis, and fill up the oil level in the tank, if
necessary.
Do not remove the screen filter for filling-up the tank.
IMPORTANT
If the machine has remained stopped for some days, it is necessary to manually actuate
the lubrication system, checking the following procedure:
Check the plunge stem position.
Should the plunge stem be fully lowered, manually lift it until it sucks the oil, and let the
stem return to the original position lubricating all points of the machine.
Should the plunge stem not be fully lowered, the machine shall be switched on and wait
for the stem to return, and then lift it manually so that it would suck the oil, and let the
stem to return to its original position.
CAUTION !
After pulling the lever, do not push it down because it would to its original
position by the spring system.
Do not fill the oil tank while the axes are switched on. Switch them off
before filling.
Retorno por sistema de mola
IMPORTANT !
Should the lubricator not be actuating, the possible causes could be:
Low oil level
Contaminated oil
Clogged pipes
Disrupted pipes (line open)
Dirt in suction filter
Damage to pump piping
Improper oil viscosity
Air in the piping system
Pressure switch

Suction filter
Changing the suction filter every 12 months of operation is recommendable.

It is necessary to disassemble the pump detaching it from the tank to access the filter. Filter
Code: Romi R38059 / LUBE 489010
Suction
filter
Lock
Flow Units (dosimeters)

Replacing the flow units is recommendable at every 12 months.
In case of need for replacing the flow units, refer to lubrication scheme. See the flow unit codes
in the parts catalog.
Flow Unit
Line Filter
Changing the suction filter every 12 months of
operation is recommendable.
Filter Codes: ROMI R92135 / LUBE code:

109311
Line Filter

Setting the oil discharge volume
The following procedure is required for setting the oil discharge volume:
Regulate the lubrication pump by actuating on the regulator, turning it clockwise or

counterclockwise.
Apply sealing adhesive (to seal the setting) between the nut and regulator and between the nut and
bolt.
Firmly tighten the nut against the regulator.
NOTE: Proceed to setting only with the drive plunge completely free from the motor actuation.
Aplicar adesivo vedante
Porca
Regulador
REGULAR PARA
1.5cc

Changing oil
Never use oil of other type or brand. This could cause chemical decomposition forming
viscosity residue to different admixtures used by suppliers. This viscosity residue
could clog the dosing outlets to the lubrication points. Always use oil of recommended
viscosity and quality.
If changing the oil brand or supplier, fully change the oil in the system, including the
oil remaining in piping.
If changing the oil would be necessary, proceed as follows:
For changing the oil at the beginning of a work shift, drain the oil remaining in the tank, throughly
clean the tank, check the suction filters and fill-up the tank with clean oil.
If changing oil would occur at the end of a work shift or out of normal working hours, in addition to the
procedure above, completely drain the oil remaining in piping though forced lubrication, by actuating
the lubrication pump manually.
For this operation, the injector plunge

located in the lubrication unit must be
in its resting position, to prevent new
pressurization to occur at every 6 REMEMBER
minutes and switch the machine off. Never press
down the injector
piston
Manually pull the injector plunge,
release it and wait for the end of
pressurization. Repeat this procedure
at least for 20 times.
The lubrication unit upper part

shall always be kept clean.
Do not remove this screen to

add oil to the tank.

2.7.2. Visual identification for lubrication points
6 Front View
4 10
Rear View
A
7 8

10 Oil distributors
7
1
6
2
"A" Detail
ITEM POINT DESCRIPTION OF THE PART TO BE LUBRICATED

Inclined guide (left)
1
Inclined guide (left)
CROSS SLIDE Taper gib (right)
2
Horizontal guide (left)
3 X axis ballscrew
ITEM POINT DESCRIPTION OF THE PART TO BE LUBRICATED

4 Prism (external)
5 Prism (internal)
6 Gib (frontal)
SADDLE 7 Gib (rear lower)
8 Gib (rear upper right entrance)
9 Gib (rear upper - left entrance)
10 Z axis ballscrew

2.8. HYDRAULIC SYSTEM (ACCESSORY)
ROMI C620 v3.0 accessories Hydraulic Operated Tailstock, Hydraulic chuck, Brake for Direct
Drive Headstock and 72 positions Indexing for Geared Headstock need a Hydraulic Unit as mandatory
accessory to actuate them.
Hydraulic Unit Cover
TECHNICAL DATA
Volume 25 liters
Maximum Pressure 50 bar
13.4 l/min (50 Hz)
Flow rate
13,0 l/min (60 Hz)
Oil type DIN 51502 HLP 32
Working
50 C
Temperature
1 Oil Supply
2 Heat Exchangers
3 Level indicator 2
4 Oil Emptying Plug
3
4
2.8.1. Periodical Maintenance
Hydraulic Oil:
Check the oil level on a daily basis. In case level variation would be noticed, contact the maintenance
personnel in order to diagnose the cause and refill the unit.
The upper yellow mark of the Oil Level Indicator at the side of the hydraulic fluid tank indicates the
maximum oil level (rated capacity) of this hydraulic unit.
The bottom red mark below the Oil Level Indicator indicates the minimum level.
Never operate the pump with the oil level below the red mark.
Suction filter:
Inspect and clean the filter after the first 90 hours and at every 360 hours of operation. The filter is
located within the hydraulic unit.

Line filter:
Changing the oil, replacing the line filter filtering element and cleaning the tank are recommended
after the first 1000 hours and at every 2000 hours of operation, or in case of contamination.
Filtering element code: Romi S12654 / HDA 114.139
Note: The line filter is monitored by an electronic indicator, which is actuated when the filter is saturated; a
sound alarm and dirty filter message would occur at the control panel. During cold starts, actuation
of the indicator could occur because of the hydraulic oil viscosity increment; if this would occur, wait
until the oil would reach the normal working temperature. Is the filtering element is not contaminated,
the indicator would reset automatically; otherwise, the filtering element should be replaced and the
oil changed, if contaminated.
CAUTION !
Operating the hydraulic unit pump with the oil level below minimum could cause the
following accidents:
Air would flow more easily in the oil, and this would result in pump fault, noise, defective
valve, or unstable pressure.
Chatter would occur to piping, resulting in oil leakage. The hydraulic fluid quality would
be impaired.
Heat Exchanges :
In case of need for cleaning the heat exchanger, the external part shall be cleaned with compressed
air or water. The jet direction must be parallel to the vanes to prevent damage to them.
Better result can be achieved by adding detergent, but be careful about products that could da-
mage aluminum.
In case of oil or grease built-up, it would be necessary to clean by steam jet or hot water.
In case of need for cleaning the heat exchanges inner part, it should be disassembled. Dirt can
be removed by circulating degreasing product through the exchanger. Such operation can take
from 10 to 30 minutes.
The degreasing product remaining in the heat exchanger inside after the cleaning operation shall
be removed by running water.
IMPORTANT
The electrical motor must be protected during the cleaning operation.

2.8.2. Settings for hydraulic chuck and hydraulic operated tailstock
B
For accessing the Hydraulic Unit the protection
cover shall be removed. The pressure gauge is
located in the unit itself, as shown on the side
figure:
P(bar) 1. Pressure gauge Indicates the Tailstock working Pressure

1 3
2. Pressure gauge Indicates the Chuck working Pressure;
2 4 P(bar)
3. Setting Valve - Set the tailstock working Pressure;
4. Setting Valve - Set the Chuck working pressure;
T30977
VIEW A R
VIEW B
HYDRAULIC OPERATED TAILSTOCK
The tailstock maximum working pressure is 40 Bar.

The working pressure of the tailstock shall be setted in function of the weight of the workpiece to be
machined.
The quill advance force at 40 Bar is 948 Kgf.
HYDRAULIC CHUCK
Maximum
The side table shows the maximum Nose Hydraulic
Autoblok Chuck setting
(ASA) Cylinder
working pressure in function of the hydraulic pressure
chuck used: A2-8 Autoblok BHM/BHD 250 VNK 150-67 33 bar
Geared Headstock
Autoblok BHM/BHD 315 VNK 150-67 39 bar
A2-8 Autoblok BHM/BHD 250 VNK 150-67 33 bar
Direct Drive
Headstock Autoblok BHM/BHD 315 VNK 225-95 26 bar

72 positions
Indexador Brake
Freio Headstock
fordo Hydraulic Tailstock
Cabeote Hydraulic chuck
Indexing
72 Posies Cabeote
(accessory) (accessory)
Mvel (accessory)
Placa/Cilindro
(accessory)
T54125A
(acessrio) (acessrio) (acessrio)
2.8.3.
A4 A1 D T T1
A3 B3 B1 A2 B2
V23 A B
V2
V7
P T
Y163
V26 Y421 Y422
V29 G2
V22 V3
A B
S3
Hydraulic Diagram
P T
Y162
V45 V5
A B V4
Y423 Y424
P T
Y161 B G3
V6
A
V35 S2
G1 Unidade Hidrulica 2CV

Hydraulic litros
Tanque = 25 Unit
Vazo da Bomba = 16 litros/minuto
Presso mxima = 40 Bar
Maintenance Manual - ROMI C620 v3.0

41
2.8.4. Description of the valves and solenoids
Valves Solenoids Function
Y421 Unclamp Chuck
V2
Y422 Clamp Chuck
V3 - Setting the chuck working pressure
V4 - Limit the chuck working pressure
Y423 Forward tailstock
V5
Y424 Retract tailstock
V6 - Setting the tailstock working pressure
V45 Y161 Lock / Unlock spindle
V22 Y162 Low torque (brake of the headstock)
V23 Y163 High Torque (brake of the headstock)
2.8.5 Hydraulic Unit Components Function

Hydraulic Tailstock
1 - Quill speed setting valve (V7) 1.1 - Forward setting (20 mm/s at 40 bar) 1.2 - Retract setting (60 mm/s at 35 bar)
2 - Retention valve (V29) Do not change Do not change
3 - Pressure Switch (Quill forward) (S3) 3.1 - Factory Setting at 12 Bar
4 - Pressure Setting valve (V6) 4.1 - Set the tailstock Pressure according 4.2 - Pressure gauge - Indicate the
5 - Directional valve (V5) to the workpiece tailstock workingPressure
Hydraulic Chuck
6 - Pressure limit valve (V4) 6.1 - Factory setting according to the Do not change
chuck maximum pressure
7 - Pressure Setting valve (V3) 7.1 - Chuck working pressure setting 7.2 - Pressure gauge - Indicate the
according to the workpiece chuck pressure
8 - Directional valve (V2)
Hydraulic Unit
9 - Pressure Switch (Main Line) (S2) 9.1 - Factory Setting at 15 Bar - Do not
change
10 - Hydraulic Unit Pump 10.1 - Factory Setting (set to 45 Bar) - Do 10.2 - Pressure gauge - Indicate the
not change main Line Pressure
B A
10.1
10.2
A1 A2
10.1
10
B1 B2 10
Y322 Y321
Y422 Y421
5
8
4.1 4 4.2
7.2 7 7.1 3.1 3
6 6.1 2
S323
9.1 9 1.1 1 1.2
S423 P P
VISTA A VISTA B
T (Hydraulic chuck) T (Hydraulic Tailstock)

2.9. COOLANT SYSTEM
The complete coolant system contains one tank located at the machine rear portion. This system
is used for cooling the cutting tools and the workpiece during machining, in addition to cleaning the
machining area from chips. When starting the work shift, check the oil level at the tank viewer and, if
necessary, add oil of same characteristics.
To prevent cutting fluid contamination, clogging and other problems, pay attention to frequent
cleaning, which will depend on the type of chips produced during machining.
The first cleaning shall be carried out upon 360 hours of operation.
ATTENTION!
For performing the tank cleaning, the machine must be switched off.
The coolant tank is provided with two (2) filters. Clean the filters on a daily basis (one at a time).
When the machine would be machining materials such as: brass, aluminum, cast iron, or similar alloys,
the filters must be cleaned at every 4 hours.
Removing chips from the coolant tank case shall be done according to the need.
N Qty. Item
1 4 Leveling and mounting bolt
2
2 2 Filters
3 1 Drain plug
4 1 Level Viewer
4
3

Procedure for frequent cleaning:
For the tank thorough cleaning, it is necessary to remove the plug in order to drain all coolant liquid,
remove the other covers, and proceed with cleaning.
ATTENTION!
Use only cutting fluid specific for CND lathes, which fluid must be in the dilution proportion recommended
by suppliers. Use of improper cutting fluids could cause damages to the PVC protection, to electrical
components and could cause the machine components to rust.
Procedure for removing the coolant tank/conveyor set:
- Remove the chip conveyor connector (1) coupled to the machine;

- Remove the hose connector and fastening from the coolant pump (2);
- Remove the nose connector and fastening from the motor-pump (3) (wash gun -accessory);
- Remove the oil/cooler separator (OIL SKIMMER) (4) (accessory);
- Loosen the 4 leveling and mounting bolts (view A) and remove it backwards, according to the illustration
below.
For removing the coolant

tank and conveyor, pull
them backwards
View A
2 4
Oil / Cooler
Coolant Pump
Separator
Connector
connector
3 1
Motor-pump Chip
Connector Conveyor
(Wash Gun) Connector

OIL TYPE TANK CAPACITY
COOLANT
SYSTEM Mineral-base soluble oil with 60% 1.000mm Version - 180 Liters
mineral oil in formulation 2.000mm Version - 230 Liters
The coolant fluid volume in the tank must be monitored through the level viewer. The capacity mentioned
above represents the tank total volume.
ATTENTION!
The coolant liquid must be compatible with the oil used for lubrication, that is, it should present proper
de-emulsifying before the same.
Damages caused by using improper or impure coolant liquids are not covered by our guarantee.
WARNINGS
Do not dispose chips and coolant oil into improper locations.

Disposal of chips and coolant oil must be done by trained personnel and must comply with procedures
indicated by local environmental laws.
Do not perform any maintenance operation or work before carefully reading the motor-pump manual that
comes together with the machine.

2.10. CHIP CONVEYOR (ACCESSORY)
The drag conveyor belt shall be used for fine chips, while the caterpillar conveyor shall be used for
elongated or entangled chips originating from machining operations with or without coolant liquids.
Motor-reducer
Protection
Emergency button
Tank Drain plug
For performing periodical maintenance, it is necessary to remove the motor-reducer protection.

Note that for any actions, the conveyor must be switched off.
For emergency situations during the conveyor operation, the emergency button indicated above
must be actuated, which would interrupt the action.
Periodical maintenance shall be conducted to the conveyor motor-reducer, checking cleanliness of

air openings, as well as the regular control of lubricant and its changing, which would depend on the
working hours and operating temperature.
For checking the cleaning procedure and time for changing the lubricant, refer to the manual that
comes together with the accessory.
The conveyor tank must be periodically checked for presence of sediments. It must be cleaned
whenever necessary. The inspection periodicity is determined in function of the working conditions
existing at the usage site.
ATTENTION!
For further information about the chip conveyor, please refer

to the manual that comes together with the accessory.

2.11. COOLANT SYSTEM AND CHIP CONVEYOR CONNECTORS
Oil / Cooler
Coolant Pump Separator
Connector connector
Motor-pump Chip
Connector Conveyor
(Wash Gun) Connector
Do not connect or disconnect the Refrigeration and/or Chip Conveyor connectors while the Master Switch
would be at the ON position (switched on). Pay attention when inserting or extracting the connectors.
Ensure that they would not be wet when handling them. Electrical shock risk would exist.
If any device has been removed or not installed, ensure that the connector covers are at their proper
place.
The main voltage present at those connectors is 380VAC. The command signal used with the
Chip Conveyor is 24VDC.
Never connect any other device beside the Coolant Pump and Chip Conveyor specified for this machine,
under risk of causing severe damage do the machine/device and injury to the operator.
Keep the area of these two connectors always clean and free from any obstructions.

2.12. SYSTEMS SUPPLY
RESERVOIR SUPPLY /
OIL TYPE VOLUME REPLACE
(LITERS) FREQUENCY
DIN 51502 100 HOURS

AUTOMATIC LUBRICATION SYSTEM 1,8
CGLP 68 (MAX.)
DIN 51502
HYDRAULIC UNIT (ACCESSORY) 25 2.000 HOURS
HLP 32
COOLANT SYSTEM (1.000 MM VERSION) 180

MINIMUM
ACCORDING TO
COMPOSITION 60%
NECESSITY
MINERAL OIL
COOLANT SYSTEM (2.000 MM VERSION) 230

2.13. ABNORMAL NOISES AND HEATING
Pay careful attention to strange noises during operation. Noises may indicate problems, which if immediately
checked could prevent the machine to shut-down.
Likewise, abnormal heating of any equipment part may indicate problems that could cause the machine
to partially or fully shut-down.
2.14. WIPERS
The machine guides life directly depends on wipers care and maintenance. If the wipers would be damaged,
particles could clog the lubrication points, causing serious wear-out to the lathe bed machined guides. For such
purpose, the wipers shall be regularly checked and replaced, if damaged.
Tailstock wipers (4x) Quill wiper
Bed wipers (4x)
Cross slide wiper

2.15. WORKLIGHT
The Worklight basically consists of one reactor, sockets and fluorescent lamps, at it is mounted to the
rear cover upper part.
worklights
The rear enclosure covers (1) must be removed for purposes of reactor maintenance or lamp change.
Specifications:
Type Fluorescent
Voltage 220V
Frequency 50/60Hz
Do not attempt to access the lamps while the ma-
Power 13W
chine is powered on.
Reactor Quick Start-up Ensure that power would be cutoff before replacing
lamps or reactors.

2.16. DOOR GLASS PROCEDURES FOR REPLACEMENT
Frontal door glasses are fixed by metalic frames screwed in internal side of the doors.
Each glass is comprised of multi-layers of protection. If glass replacement is required it is necessary to
pay attention to the correct assembly position. See ROMI logo mark as a reference that should be placed in
front of the operator view.
Door Glass

2.17. ELECTRICAL INTERLOCK SAFETY SWITCH
The operators door is equipped with two Electrical interlock safety switch (1) located at the machine
upper part (as per drawing below). Electrical unlocking can only be done when the machine is
powered-up, releasing the doors opening. In need for opening the door without the machine being
powered-up, follow the procedure below:
1. Loosen the metal lock bolt (2) until unlocking the mechanical release key (3).
Note: The bolt (2) has a seal that would be broken-down when loosened.
2. Turn the mechanical release key (3) clockwise to the open padlock position (180) observing
the arrow indication; At this position, the safety lock becomes released, allowing the door to be
opened;
3. After opening the door, you must return the mechanical release key (3) to its initial position,
by turning it counterclockwise to the closed padlock position (-180) observing the arrow
indication.
4. Tighten the metal locking bolt (2) and seal again.
NOTE: If the machine would be powered-up with the lock actuation at the released position (padlock
open), it would not be possible to eliminate the emergency status, because the safety
electrical lock would generate a fault signal, thus keeping the safety status.
2 3

2.18. AIR CONDITIONING FOR ELECTRIC PANEL (ACCESSORY)
The air conditioning for electrical panel has been developed

to dissipate heat or to cool the air inside the panel, keeping it at
maximum 40C, thus protecting elements sensitive to temperature
variations.
Air conditioning is indicated for environment temperature from
+40C to +55C.
Frequent cleaning:
It shall be done using compressed air.
Filtering mat:
Using filtering mat would be necessary only when the

environment air would be too impure, thus preventing the condenser
to clog.
For checking the filtering mat change procedure, refer to the
manual that comes together with the accessory.
ATTENTION!
Prior to performing any maintenance works, the

air conditioning must be switched off.
ATTENTION!
For further information about the air conditioning,

please refer to the manual that comes together with the
accessory.

2.19. OIL / SKIMMER (ACCESSORY)
The equipment maintenance and cleaning assures proper functioning and longer life. Avoid using solvents
containing dichloride-ethane, hydrochloric methylene or acetone for cleaning. Keep the working area clean and organized
to prevent accidents.
ATTENTION
Ensure that the Skimmer is switched off when performing any intervention.
IDENTIFICATION OF PARTS IN CASE OF REPLACEMENT NEED
Illustr Scrapper (1)

ative
Figur Front case (2)
e
Rotating Pin (3)
Belt (4)
Driven pulley (5)
2
NOTE:
The customer must provide a container for
waste collection.
Recipient
4
5
3
ATTENTION!
Skimmer
Separador de
er leo/Refrigerante
mm de
Skiaradorerante
Improper waste disposal could contaminate the Sep efrig
le
o/R
environment; therefore, the local, state and federal Manual de

regulations must be followed. For further information de
Instrues
n ual
about the Skimmer, please refer to the manual that comes M a es
ru
together with the accessory. Inst S75
849
AS75849A
SP
o -
Pa ul
So
:
a o 0
aliz 71
er ci lano, 8
Com Corio 0 asil -338 0
Rua 47 - 90 SP - Br 3873 -951
- (11) 3865 r
05.0 Paulo .b
i S.
A. So one (11) i.com .br
m
Rom Telef w.ro mi.c
om
st rias , 56 il Fax et : ww r@ro
In d ri z gton - Br
as 0 rn
Inte ail: maq
fe
Byin e- SP 55-900 9
M at rola st 49 E-m
P Oe 34
Av. 53-900ara d' 5 19 55-2
13.4 a Brb +5 19 34
Sant one +55
Telef
Fax

2.20. HORIZONTAL ELECTRICAL TURRET (ACCESSORY)
The tool-holder turret essentially consists of an enclosure containing the operating components, and
securely mounted to the machine table or equivalent part.
The enclosure frontal part is provided with a tool-holder disk. Tool supports or similar devices can be
mounted to this disk, which has a centering feature and mounting threads.
By using a three-part coupling with frontal teeth, no axial disk displacements would occur during
locking and unlocking.
The rotation and locking movements are performed by a three-phase motor located at the enclosure
back part.
A connection to coolant oil allows direct oil supply into the disk.
The electrical components are under a protective cover at the turret back part. The turret is
watertight.
Eyebolt Motor and electrical
Disk
components
Coolant inlet
Coolant outlet
IMPORTANT Torre Eltrica

ca Horizontal
t ri l
e El 8 posies
To rr r i z on ta s
Ho osie
8 p
Do not perform any maintenance operation or work
Manual de
before carefully reading the turret manual that comes
de
Instrues
together with the machine. n ual
M a es
r u
Inst S47
568
A S47568A
In need for the electrical turret transporting/lifting use Indstrias Romi S.A.
Matriz
Av. Prola Byington, 56
13.453-900
Santa Brbara d'Oeste- SP - Brasil
C om r ia iza o S o a o S
e c l
Rua Coriolano, 710
: P ul
05.047 - 900 So PauloP - SP - Brasil

Telefone (11
- P
S 3-3388
o) 3- 87
Telefone +55 19 3455-9000 Fax P(a11 ) 38 65-9510
lift eyebolts, and safe devices and methods.

o
ul
il
Fax +55 19 3455-2499 Internet o: :Swww .romi.-cBr omas.br
c ia
Eliz-mano
ail, 7:m
10aqfer SP i.com.br
ulo@-rom88
er la So Pa3873-33510
om io ) 865-9
Rua.0C47 - 90 (11
C or 0
S. A. 05 e ( 11 ) 3com.br r
mi Telef
on mi. i.com.b
st ri as Ro , 56 il Fax ne t :w ww.ro r @ ro m
In d z ingt
on
- Bras000 Interail:maqfe
M at. riProla By ste- SP 55-9-2499 E-m
Av .453-900ara d'Oe5 19 34 55
13 a Brb +5 5 19 34
Sant one +5
Telef
Fax

2.21. 72 POSITIONS INDEXING (ACCESSORY)
The indexing assembly is placed behind the headstock and it provides the spindle locking during
a pre-determined machining plan thru CNC program. The spindle program should be done in 5
to 5 degrees for the corret indexing position for locking. After the angular positioning there is M22
comand to actuate the piston and M23 comand to turn the piston off.
Piston is hydraulically actuated and its return occurs thru a spring system.
See adjusting parameter in electrical diagram to provide the angular adjusting for the correct piston
fitting to the gear.
Remark:
In case of a different angle program than 5 to 5 degrees spindle will be located in a wrong angle for
the piston fitting to the gear.
4
2
Indexing
Components description
N Description
1 Piston for indexing locking
2 72-teeth gear
3 Valve (V45) / Solenoid (Y161)
4 Sensors (S161 /S162)
ATTENTION!
When the machine is equipped with indexing a limit pressure valve is added on hydraulic line
which should be adjusted in 15 bar to limit the working pressure of the indexing.
For additional information of hydraulic system please see the chapter Hydraulic System .

This system monitoring is performed by two sensors. In case of sensors replacement the following
procedures should be followed:
A - Replacement of Spindle Locked sensor S161 (1)
Put the piston (2) forward Locked Indexing system;

Replace the damaged sensor. For new sensor mounting observe the indicated distant on below figure;
Move the new sensor (1) from left to right until the LED is lit. In this position tighten the clamping nuts;
Make sure LED is off upon piston in backward position.
0,5 mm
B - Replacement of Spindle Unlocked sensor S162 (3)
Put the piston (2) backward - Unlocked Indexing system;

Replace the damaged sensor. For new sensor mounting observe the indicated distant on below figure;
Move the new sensor (1) from right to left until the LED is lit. In this position tighten the clamping nuts;
Make sure LED is off upon piston in backward position.
0,5 mm
ATTENTION
Both sensors should never be turned on/off simultaneously. In this case previous procedures
should be performed again.

2.22. RS232 CONNECTION AND ELECTRICAL POWER OUTLET
Power outlet
Port RS232
Do neither connect nor disconnect the RS-232 serial cable without switching the machine main
switch off. Otherwise, the serial port could be damaged.
Do not use supply form other equipment when the serial cable is connected to the machine. Such action
could damage the CNC serial port. Always use supply from the machine to which it is connected.
Care must be taken when connecting any instrument to the electrical power socket.
Ensure that the instrument connected to the power socket would not exceed the current provided
by the socket.
Ensure that the instrument is set to the electrical power socket voltage.
Voltage would always be present at the socket while the main switch will be switched on. Be careful
before connecting any instruments to the socket.
Do not connect any instruments other than those indicated for use.
VOLTAGE 220VAC
CURRENT (Maximum): 1A
IMPORTANT
The Control panel and Electrical Cabinet have been designed in optimized manner aiming at occupying
small volume space in the machine layout, in addition to having IP54 protection degree. Therefore,
to prevent any type of damage to electric-electronic components do not install any type of equipment
to these assemblies.
Romi understands that for installing any type of equipment, drilling and threading operations would
be required to the Control Panel and/or Electrical Cabinet Casing, making possible the infiltration of
filings and small chips, in addition to modifying the protection degree, thus promoting contamination,
and consequently, compromising the proper machine functioning. Attention:
Romi would not be liable for damages occurred due to modifications made to these assemblies.

2.23. ELECTRICAL PANEL - VENTILATION AREA
Always switch the Main Switch off prior to accessing this area, observing the safety procedures
for electrical installations and works with electricity.
Periodically cleaning/replacing the ventilation filter is mandatory. The time for cleaning the filter
shall be accessed in accordance with the working environment where the machine is installed.
The customer shall access the time interval required for cleaning the filter. This time interval could
be changed on the CNC "Customer" screen (default value = 192 hours). The customer shall be
effectively alerted about the filter change periodicity (preventive maintenance). After this time count,
an alarm would occur: "Check the electrical panel filters cleanliness".
When changing the filter pay attention that the sealing foam would be properly fixed to the filter
metallic frame. For ordering this filter from Romi, please check the code in the Parts Catalog (see
Chapter "Plate-works").
Never leave the panel switched on without the filter at the air intake.
Check that all parts related to the electrical panel are properly attached and sealed. The electrical
panel inside must be a clean location; therefore, if during periodical inspections, dirt would be
found in it, dirt must be removed.
2.24. CHECKING ALL ELECTRICAL CONNECTIONS
Always switch the main switch off before accessing the electrical cabinet.
Never attempt to access any components within the cabinet while the machine is powered-up. Serious
accident risks would exist.
Ensure that the proper procedures for electrical connections have been obeyed prior to power-up the
machine for the first time.
It is highly recommendable all electrical connections to be checked and re-tightened, using proper tool,
during the machine installation procedure. Always check for loose wiring or connections. Check all connectors
used. It is recommended to check for loose components inside or outside the electrical cabinet.

2.25. PREVENTIVE MAINTENANCE CHART
NOTE
This chart has the purpose of guiding the machine user on periodically inspection for the key
components
The periodicity recommended must be reduced in function of the environment severity and work conditions,
which the machine will be exposed to. This hypothesis must be analyzed by the maintenance department
via follow-up of the operation and conditions of the internal machine components.
Period
Fortnightly
Monthly
Weekly
Daily
ITEMS TO BE INSPECTED BY THE OPERATOR
Warm up the machine
Check lubricant oil level
Clean filters (strainer) in the coolant tank
Remove chips excess in the machining area
Check leaks in lubrication system
Inspect chip wipers
Check leaks in coolant system
Clean door glass
Grease chuck (AUTOBLOK)
Lubricate the tailstock quill
Check coolant level and quality
Clean operation panel externally
Clean filters and fans in electrical panel
Clean coolant tank

Semiannually
Quarterly
Annually
Monthly
1.5 year
Weekly
ITEMS TO BE INSPECTED BY QUALIFIED TECHNICIANS
Clean air conditioner filter (accessory)
Inspect lubrication of guides and ballscrews
Check operation of drive fans
Inspect chip wipers
Check and clean headstock area (belts, pulleys, sensors)
Inspect piping and flow units of the lubrication system
Check coolant lubricant valve for wear and leakage (see turret manual) (4000 hs)
Check oil of the turret gearbox chamber (see turret manual) (4000 hs)
Inspect and clean the heat exchange of hydraulic unit (accessory)
Check toothed belts of X and Z axes
Check spindle belt and encoder toothed belt
Check and clean the main motor fan (4000 hs)
Perform internal cleaning of the electrical panel
Inspect machine leveling
Dismount and clean chuck (AUTOBLOK)
Check gaps on X and Z axes
Check functioning of the main motor (vibration, noise)
Lubricate chip conveyor belt (*)
Change the oil of the turret gearbox chamber (see turret manual) (8000 hs)
Check cylinder safety valves (AUTOBLOK)
Replace flow units in the lubrication system
Replace line and suction filters in the lubrication system
Change oil in hydraulic unit (1st change after 3 months) (*)
Check and tighten wiring in electrical panel
Check and clean hydraulic unit filter (*)
Inspect and lubricate the bearings of the X and Z axes (10.000 hs)
Check electrical lines and connections of the turret (see turret manual)
(*) = Considering 8-hour shift / 5 days a week

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Maintenance

CHAPTER 2 GENERAL MAINTENANCE __________________________ 3

T54125A Maintenance Manual - ROMI C620 v3.0

2.11. Coolant System and Chip Conveyor connectors ........................................................................ 47

T54125A Maintenance Manual - ROMI C620 v3.0

T54125A Maintenance Manual - ROMI C620 v3.0 1

1.2. GENERAL NOTE

Machine powered-up Machine switched off for maintenance activities

Main Switch Apply padlock to

2 Maintenance Manual - ROMI C620 v3.0 T54125A

T54125A Maintenance Manual - ROMI C620 v3.0 3

4 Maintenance Manual - ROMI C620 v3.0 T54125A

This service could be bought from Romi, as it is

TRANSVERSAL TOLERANCE ALLOWED FOR LEVELING: 0,04 mm/m

LONGITUDINAL TOLERANCE ALLOWED FOR LEVELING: 0,02 mm/m

T54125A Maintenance Manual - ROMI C620 v3.0 5

a. Adjust all leveling screws until they touch the ground.

6 Maintenance Manual - ROMI C620 v3.0 T54125A

Consider "X" as the tolerance value specified in table 1

If the following conditions would occur, proceed as follows

=> For 1.000mm machine version:

1.000mm Machine Version

T54125A Maintenance Manual - ROMI C620 v3.0 7

Consider "X" as the tolerance value specified in table 1

Large Middle Small

2.000mm Machine Version

8 Maintenance Manual - ROMI C620 v3.0 T54125A

Machine can be equipped with 2 types of headstocks:

DIRECT DRIVE HEADSTOCK

Spindle shaft is mounted on high precision bearings, permanently lubricated. Unless it is

Geared headstock is comprised of a set of gears enabling a two manually selected

2.2.1. Position Encoder

Toothed Belt Encoder assembly Encoder assembly Toothed Belt

Direct Drive Headstock Geared Headstock

T54125A Maintenance Manual - ROMI C620 v3.0 9

Direct Drive Headstock Geared Headstock

2.2.2. Lubrication (Direct Drive Headstock and Geared Headstock)

10 Maintenance Manual - ROMI C620 v3.0 T54125A

b) 0.020mm upward only

Roundness recommended for

2.2.3.2. Vertical Plan

T54125A Maintenance Manual - ROMI C620 v3.0 11

Direct Drive Headstock

- Loosen the cartridge bolts (2);

After aligning, keep all bolts secured to headstock and

3 Direct Drive Headstock

12 Maintenance Manual - ROMI C620 v3.0 T54125A

Loosen the 4 bolts (4) that fix the support (5).

Geared Headstock machine version

T54125A Maintenance Manual - ROMI C620 v3.0 13

If needing to transport/lift the electrical motor,

Motor Weight (approx.)

Main Motor - Fan

Cleaning the motor fan at every 4000 hours is recommended.

14 Maintenance Manual - ROMI C620 v3.0 T54125A

The 3 chuck settings informed to CNC are:

Function of solenoids and sensors on hydraulic chuck

T54125A Maintenance Manual - ROMI C620 v3.0 15