Nakanishi NR4040-AQC User manual

取扱説明書 / OPERATION MANUAL
日本語 : P1 - P14 / English : P17 - P32
NR4040 -AQC
エアークイックチェンジスピンドル / Air Quick Change Spindle
002OM-K0659

17
ENGLISH
CONTENTS
1. CAUTIONS FOR HANDLING AND OPERATION ………………………………… P18
2. BASIC PACKAGE ……………………………………………………………………… P21
3. WARRANTY ……………………………………………………………………………… P21
4. CONTACT US …………………………………………………………………………… P22
5. FEATURES ……………………………………………………………………………… P22
6. SPECIFICATIONS AND DIMENSIONS……………………………………………… P23
7. CONNECTION OF THE SPINDLE TO THE MOTOR …………………………… P24
8. CONNECTION OF AIR HOSE AND AIR SUPPLY………………………………… P25
9. CHANGING THE TOOL AND REPLACING THE COLLET……………………… P26
10. REPLACING THE COLLET HOLDER ……………………………………………… P28
11. INSTALLATION OF THE SPINDLE ………………………………………………… P29
12. BREAK-IN PROCEDURE……………………………………………………………… P30
13. CAUTIONS WHEN USING GRINDSTONES AND TOOLS ……………………… P30
14. TROUBLESHOOTING ………………………………………………………………… P31
15. DISPOSAL OF THE SPINDLE ……………………………………………………… P32
Thank you for purchasing the " NR4040 - AQC " Air Quick Change Spindle. This Spindle
features easy replacement of the collet holder by ON / OFF air operation. The Spindle is
designed for grinding, small diameter drilling and milling, etc..
The E4000 CONTROLLER, E4000 Series Brushless Motor, and Air Line Kit are required
to drive this Spindle. Read this and all the associated component Operation Manuals
carefully before use. Always keep this Operation Manual in a place where a user can
referred to for reference at any time.

18
1. CAUTIONS FOR HANDLING AND OPERATION
■Read these warnings and cautions carefully and only use in the manner intended.
■These warnings and cautions are intended to avoid potential hazards that could result
in personal injury to the operator or damage to the device. These are classi¿ed as
follows in accordance with the seriousness of the risk.
①This Spindle is not a hand tool. It is designed to be used on CNC
machines or special purpose machines.
②Do not touch the cutting tool while it is running. It is very dangerous.
③Wear safety glasses, dust mask and use a protective cover around the
Spindle whenever the Spindle is rotating.
④Never connect, disconnect or touch the Power Cord Plug or Motor Cord
Plug with wet hands. This may cause an electric shock.
⑤Do not replace the collet holder while the brushless motor is rotating.
Contact with internal components will damage the Spindle.
⑥When the collet holder is clamped in the Spindle, do not cycle the clamp
air ON / OFF. This will cause damage to the Spindle and loss of precision.
⑦Never operate or handle the Spindle and brushless motor until you have
thoroughly read the Operation Manuals and safe operation has been
con¿rmed.
1) To prevent injuries / damages, check the Spindle and brushless motor
and cutting tool for proper installation, before operating the brushless
motor and Spindle.
2)
Before disconnecting the Spindle and brushless motor, always turn the
control power off and turn the compressed air supply to the CONTROLLER
off. Then it is safe to remove the Spindle and brushless motor.
⑧When installing a Spindle to a ¿xed base, make sure the ¿xed base is
grounded in order to avoid the risk of an electric shock.
⑨ When installing a tool in the collet holder, tighten the collet correctly then
re-check the collet and collet nut before operating. Do not overtighten the
collet. This may cause damage to the collet holder.
WARNING
Class Degree of Risk
WARNING
A safety hazard could result in bodily injury or
damage to the device if the safety instructions are not
properly followed.
CAUTION
A hazard that could result in light or moderate
bodily injury or damage to the device if the safety
instructions are not followed.
INFORMATION
Be sure to keep the usage for your safety.

19
ENGLISH
⑩Ensure that of the collet holder is correctly mounted in the Spindle before
rotating the Spindle.
⑪Do not use bent, broken, chipped, out of round or sub-standard tools, as
this may cause them to shatter or explode. Tools with fractures or a bent
shank will cause injury to the operator. When using a new tool, rotate it in
a low speed and increase speed gradually for safety.
⑫Do not exceed the maximum recommended allowable tool speed. For your
safety, use speeds below the maximum allowable speed.
⑬Do not apply excessive force. This may cause tool slippage, tool damage,
injury to the operator or loss of concentricity and precision.
WARNING
①Do not drop or hit this Spindle, as shock can damage to the internal
components.
②Protect the collet holder taper from the ground particles, dust, metal chips
or coolant spray when using the automatic tool change in the machine.
Should ground particles, dust, metal chips or coolant spray adhere to
the taper, remove them with an air blow before they are inserted into the
spindle.
③Make sure the inner face of the Spindle and the taper surface of the collet
holder are clean (Clean them if debris is found) before replacing the collet
holder.
Ground particles or metal chips stuck to the surface will cause run-out or
damage to the collet and spindle. Loss of concentricity will cause spindle
damage due to the lack of precision.
④ When cleaning a Spindle, stop the brushless motor and remove debris with
a soft brush or a cloth. Do not blow air into the dust proof cover area (refer
to contents of page number P23 " 6 - 2 Outside View " ) with compressed
air as foreign particles or cutting debris may get into the ball bearing.
⑤When replacing the tool, make sure the tool shank, collet, collet nut, and
inner face of the collet holder are clean. If ground particles or metal chips
stick to the inside of the collet, damage to the collet holder or spindle can
occur due to the loss of precision.
⑥Always clean the tool shank before installing the tool in the Spindle.
⑦When sizing the correct collet size to the tool shank diameter, a tolerance
of +0 〜
-
0.01mm is strongly recommended. A tool shank within the +0 〜
-
0.1mm range is mountable, however, this may cause poor concentricity
and or insuf¿cient tool shank gripping force.
⑧Select suitable products or tools for all applications. Do not exceed the
capabilities of the Spindle or tools.
CAUTION

20
⑨When replacing the collet holder, the air supply pressure must be 0.6MPa
to the Clamp / Unclamp air inlet joint of the spindle. If insuf¿cient air
pressure is supplied, the collet holder may not be released.
⑩ Do not stop the supply cooling air for motor during operation of the machine.
Removing the air pressure from the Motor / Spindle causes a loss of
purging, allowing the Motor / Spindle to ingest coolant. This will cause
damage to the Motor / Spindle.
⑪ Carefully direct coolant spray to the tool. Do not spray directly on the Spindle
body. If large amount spray directly on the Spindle, it may cause excess load
of the motor rotation with loss of durability to the Motor / Spindle.
⑫Stop working immediately when abnormal rotation or unusual vibration
are observed. Afterwards, please check the contents of page number
P31 " 14. TROUBLESHOOTING ".
⑬Always check if the tool, collet, collet nut, collet holder, connection hose
and supply air hose are not damaged before and after operating.
⑭If the collet, collet nut or the collet holder show signs of wear or damage,
replace them before a malfunction or additional damage occurs.
⑮The Duty Cycle for opening / closing the collet holder is approximately
150,000 tool changes. Inspection and repair may be necessary if 150,000
cycles are exceeded. Return to a NAKANISHI dealer for service.
⑯After installation, repair, initial operation, or long periods of non operation,
please refer to contents of page number P30 " 12. BREAK-IN PROCEDURE "
detailed in Table. 2. When checking the Spindle, no vibration or unusual
sound should be observed during rotation.
⑰Do not disassemble, modify or attempt to repair this Spindle. Additional
damage will occur to the internal components. Service must be performed
by NSK NAKANISHI or an authorized service center.
⑱When using this Spindle for mass production, please consider the
purchase the another Spindle as a spare in case of an emergency.
⑲Securely connect the compressor supply connection hose and the air
hose to the Air Line Kit and the motor and Spindle to avoid accidental
disconnection during use.
CAUTION

21
ENGLISH
3. WARRANTY
We provide a limited warranty for our products. We will repair or replace the products if the
cause of failure is due to the following manufactures defects. Please contact us or your
local distributor for details.
(1) Defect in manufacturing.
(2) Any shortage of components in the package.
(3) Where damaged components are found when initially opening the package.
(This shall not apply if the damage was caused by the negligence of a customer.)
When opening the package, check if it includes all items listed in " Table.1 Packing List
Contents ".
In the event of any shortage, please contact either NAKANISHI (see the " 4. CONTACT US "
section) or your local dealer.
2. BASIC PACKAGE
NR4040 - AQC Spindle・・1pc. ȭ6mm Filter with Air Hose・・1pc.
Wrench (36mm)・・1pc. Inspection Card・・1pc.
Operation Manual・・1set
Table. 1 Packing List Contents
*The collet holder, collet, and collet nut are sold separately.
36
᳨ᰝᡂ⦼⾲
Inspection Card
ྲྀᢅㄝ󰩣᭩
OPERATION MANUAL

22
5. FEATURES
①The collet holder can be replaced automatically by putting ON / OFF the air.
②The Spindle housing is made from precision ground, hardened, stainless steel (SUS).
③There are 2 types of collet holders. Various sizes of mounting collets are available
depending on the collet holder used (CHK 0.5mm - 6.35mm or CH16 ȭ3.0mm,
ȭ3.175mm, ȭ4.0mm, ȭ6.0mm, ȭ6.35mm, ȭ8.0mm and ȭ10.0mm).
4. CONTACT US
For your safety and convenience when purchasing our products, we welcome your questions.
If you have any questions about operation, maintenance and repair of the product, please
contact us.
Company Name
Business Hours
U.S. Toll Free No.
Telephone No.
Fax No.
Web Address
:Industrial Div.
: 8:30am to 17:00pm (CST)
(closed Saturday, Sunday and Public Holidays)
: 800-585-4675
: 847-843-7664
: 847-843-7622
: www.nskamericacorp.com
Contact UsContact Us
For U.S. Market
Company Name
Business Hours
Telephone No.
e-mail Address
:
: 8:00am to 17:00pm
(closed Saturday, Sunday and Public Holidays)
: [phone]
: [email protected]
For Other Markets

23
ENGLISH
6 - 2 Outside View
Fig. 1
※
Air Inlet Joint
※Dust Proof Cover AreaQC5 - 16
4 - M4 X 0.7 depth 10
ȭ15.9
ȭ18.8
ȭ40 0
-0.01
0.5 (3.8)(54)70 9
(25.2)
133
ȭ23
ȭ25.8
0.5 3.8
(36.9)
ȭ68
QC5 - K
18.3
ȭ52
ȭ40 0
-0.01
45°
90°
27
ȭ10
4 - M6 X 1 depth 7
※
ȭ55
Collet Holder QC5 - K QC5 - 16
Collet CHK - □□ CH16 - □□
ȭ0.5mm - 6.0mm in 0.1mm
increments and ȭ2.35mm,
ȭ3.175mm and ȭ6.35mm
ȭ3.0mm, ȭ3.175mm, ȭ4.0mm,
ȭ6.0mm, ȭ6.35mm, ȭ8.0mm and
ȭ10.0mm
Collet Nut K - 265 CHN - 16
Wrench 12 x 14 (2 pcs. Required.）17 x 22 (2 pcs. Required.)
Preset Adapter QC5 - K ADP QC5 - 16 ADP
＜Options ＞
Model NR4040 - AQC
Maximum Motor Rotation Speed 40,000min-1 (rpm)
Spindle Accuracy Less than 1ȝm
Supply Air Pressure at the Replacing
the Collet Holder
0.6MPa (87psi)
Applicable Motor EM-4020, EM-4020A, EM-4040, EM-4040A
Applicable Collet Holder QC5 - K (For Collet CHK Type)
QC5 - 16 (For Collet CH16 Type)
Weight 2,160g
6. SPECIFICATIONS AND DIMENSIONS
6 - 1 Speci¿cations

24
Fig. 2
7. CONNECTION OF THE SPINDLE TO THE MOTOR
CAUTION
・Make sure your hands and all interlocking parts of the Spindle and
brushless motor are clean before connecting the brushless motor to the
Spindle. This is critical in preventing contaminants from entering the
brushless motor or Spindle.
・When connecting the Spindle to the brushless motor, it is best to hold the
brushless motor and Spindle in a vertical position. Carefully connect by
threading the brushless motor on the Spindle and avoid mis-alignment, as
this will cause damage to the brushless motor and or Spindle drive.
Align the threads on the front end of
the brushless motor and the rear end
of the Spindle, then turn the Spindle
clockwise.
If the drive shaft of the brushless motor
does not engage the drive dog on the
Spindle smoothly, DO NOT FORCE
THEM TO SEAT. Tighten the Spindle
after rotating the Dust Proof Cover by
hand to engage the drive shaft and
the drive dog. Use the provided 36mm
wrenches for ¿nal tightening of the
Spindle to the brushless motor.
36
Tighten
36
Turn
Transmission Clutch
Dust Proof Cover

25
ENGLISH
8. CONNECTION OF AIR HOSE AND AIR SUPPLY
CAUTION
Securely connect the air hose to the brushless motor and air line kit to avoid
accidental disconnection and injury to the operator during use.
CAUTION
Ensure that the pressure at the spindle ATC Inlet is 0.6MPa (87psi).
As illustrated in the picture, measure the pressure as close to the spindle as
possible.
(1) Connect the provided ȭ6mm air hose with ¿lter and 3-way valve to Air Inlet Joint
shown in Fig. 3.
(2) Supply clean air from air compressor through air ¿lter or air dryer to the 3-way valve
at the air pressure : 0.6MPa (87psi).
Dry Air
Filter 3 - Way Valve ȭ6mm Hoseȭ6mm Hose
Air Release
Air Supply
(Supply Side)
Fig. 3
Air Supply (Supply Side)
Pressure Gauge
T-Type Joint
ȭ6 One - Touch Joint
Fig. 4

26
9 - 1 How to Replace Collets using the Provided Wrenches
(1) Attach the collet to the collet nut. Be sure to fully engage the latch inside the collet nut
to the groove on the collets outer circumference area (Fig. 5, Fig. 6) (Install the collet
in the collet nut by positioning the collet in the collet nut and pressing down on Àat
surface (Fig. 7)).
(2) Attach the collet and collet nut to the collet holder and lightly ¿nger tighten.
(Do not completely tighten until the end) (Fig. 8).
(3) Insert the tool in to the collet and position the wrench on the collet holder.
Position the wrench on the collet nut, then tighten the collet nut by turning clockwise
(Fig .9).
(4) When removing the tool, set the wrench on the collet nut and turn it counterclockwise
to loosen the collet and remove the tool (The ¿rst turn will loosen the collet nut,
but the tool will not release and turning will become stiff. Keep turning through the
stiffness and the collet will open.).
(5) When removing the collet, the collet and collet nut are secured by a groove in the
collet and a Àange in the collet nut. To remove the collet hold the collet nut in one
hand and push diagonally down on the collet. The collet should be released (Fig. 7).
Fig. 5 Fig. 6 Fig. 7
Groove
Latch Collet
Collet Nut
Latch
Push
Collet Nut
Wrench Seat
Collet
9. CHANGING THE TOOL AND REPLACING THE COLLET
CAUTION
・Do not tighten the collet without inserting a tool or dummy bur, as this will
damage the collet, collet holder or collet nut, causing dif¿culty removing
the collet.
・When installing the collet in the collet nut, make sure to fully engage the
latch inside the collet nut to the groove on the collets outer circumference
area. In addition, remember that if the collet is attached without being
engaged with the latch of the collet nut, the collet cannot be removed and
this may cause damage to the collet or the collet holder.
RECOMMENDATION
Please minimize the tool overhang amount to maintaining high accuracy.

27
ENGLISH
Fig. 8 Fig. 9
Tighten Loosen
Tool
Collet Holder
Collet Nut
Wrench
Wrench
Tool Loosen
Tighten
Collet Nut
Collet Holder
9 - 2 Tool Replacement using a Preset Adapter
(1) Af¿x the preset adapter to the tool holder (ȭ20mm) etc.
(2) Align the collet holder to the drive dog notch of the preset adapter, and insert the
collet holder (Fig. 10).
(3) Attach the collet and collet nut to the collet holder, and lightly ¿nger tighten.
(Do not tighten until the end) (Fig. 11).
(4) Insert the tool into the collet and set the wrench on the collet holder. Set the wrench
on the collet nut, and tighten the collet nut by turning clockwise (Fig .12).
Wrench Loosen
Tighten
Collet Holder
QC5-□
Preset Adapter
Collet Nut
Tighten Loosen
Fig. 10 Fig. 11 Fig. 12
RECOMMENDATION
Adjust the tool extension length using the preset adapter.

28
(1) Stop the motor rotation and con¿rm the rotation has stopped.
(2) Supply air pressure : 0.6MPa (87psi) to Air Inlet Joint through 3-way valve. Then, the
collet holder will be removed.
Have a tool holder ready beforehand, protect the tool from damage.
(3) Replace the collet holder.
(4) Exhaust the air through 3-way valve. The collet holder will be ¿xed ¿rmly.
(5) When installing the collet holder into the spindle, set the collet holder a distance of
1.2 - 1.8mm from the face of the spindle.
Before Mounting
Dimensions
1.2 - 1.8 （3.8）
After Mounting
Dimensions
0.5 （3.8）
Fig. 13 Before Clamping Fig. 14 After Clamping
10. REPLACING THE COLLET HOLDER
WARNING
・ When replacing the collet holder, be sure to stop the Motor. If the collet holder
replaced while the motor is rotating, the Spindle will incur internal damage.
・ When collet holder is not attached to the Spindle, do not turn ON / OFF of the air
operation. Because this will cause damage to the Spindle or loss of precision.
CAUTION
・When the air is supplied to the inlet joint of the Spindle, the collet holder
will be pushed out by exhausting the coolant air of brushless motor from
the edge of Spindle. Be careful not to be damaged to the tool or be injured.
・Use the air ON / OFF valve through which the air can be exhausted. Do not
use 2 way valve, because the 2 way valve is not exhausted and the collet is
not closed.

29
ENGLISH
11. INSTALLATION OF THE SPINDLE
(1) Insert the Spindle housing diameter (ȭ40mm) area into the ¿xed base holder of the
machine.
Insert the rear side of the Spindle housing diameter (ȭ40mm) area into the holder, in
consideration of the position of the Air Inlet Joint.
(2) Secure the Spindle into the holder by using the bolts (4pcs.) and the Mounting Screw
Hole ( 4 locations ) on the Spindle as shown in Fig. 16 and 17.
WARNING
Whenever connecting a Spindle to a brushless motor, or when installing a
Spindle to a ¿xed base, ensure that the ¿xed base is grounded in order to
avoid risk of an electric shock.
CAUTION
When installing a Spindle, do not hit, drop or cause shock to the Spindle. This
may cause damage to internal components and result in malfunctions.
Fig. 15
* After installing the Collet Holder to the
Spindle, the Collet Holder alignment can
be checked utilizing a Laser Displacement
Sensor as illustrated in Fig. 15.
Laser Displacement Sensor
NR4040 - AQC
M4 Bolt
Holder
M6 Bolt
Air Inlet Joint
NR4040 - AQC
Holder
Fig. 16 Front side Fig. 17 Rear side

30
The maximum surface speed or rpm is always speci¿ed for a grindstone. Do
not exceed the maximum speed with reference to the calculating chart below.
Always follow the grindstone manufacturer's recommendations.
Surface Speed (m / s)=
13. CAUTIONS WHEN USING GRINDSTONES AND TOOLS
3.14 x Diameter (mm) x Rotation Speed (min-1) (rpm)
1,000 x 60
CAUTION
12. BREAK-IN PROCEDURE
Steps 1 2 3 4
Rotation Speed
(min-1) (rpm) 10,000 20,000 30,000 40,000
Rotation Time (min) 15 10 10 15
Items to Check
No Abnormal
Noises. The Spindle housing temperature during the break-in process
should not exceed 20 degrees
C (36 degrees F) above ambient
temperature. Should the Spindle
exceed this limit, rest the Spindle
for at least 20 minutes and re-start
the break in procedure from the
beginning. If the housing temperature
rises again and exceeds 20 degrees
C (36 degrees F) above ambient
temperature, check the Spindle and
motor for proper installation.
The Spindle
housing
temperature
during the break-
in process should
not exceed
20 degrees C
(36 degrees F)
above ambient
temperature.
During transportation, storage or installation, the grease inside the bearings will settle. If
the spindle is suddenly run at high-speed, the grease will be ejected from the bearings,
causing excessive heat that will cause bearing damage.
After installation, repair, initial operation, or long periods of non operation, please follow the
break-in procedure detailed in Table. 2.
Table. 2
(1) The proper surface speed for general grindstones is 10 - 30m / s.
(2) Do not exceed 13mm of overhang for mounted grindstones as shown in Fig. 18. If the
overhang must exceed 13mm, reduce the motor speed in accordance with Table. 3.
(3) Dress the grindstone prior to use.
(4) Do not use cutting tools with bent or broken shanks, cracks or excessive run-out.

31
ENGLISH
Fig. 18
Table. 3 Overhang and Speed
Overhang (mm) Max. Speed (min-1) (rpm)
20 N x 0.5
25 N x 0.3
50 N x 0.1
* N = Max. Operating Speed with 13mm overhang.
(5) For grinding, the maximum depth of cut should not exceed 0.01mm radially or axially.
Reciprocate the tool several times after each pass to eliminate tool pressure.
(6) Always operate cutting tools within the allowable recommended speed of the cutting
tools. Use of a cutting tool outside of the allowable speed of the cutting tools could
cause damage to the Spindle and injury to the operator.
(7) When replacing the tool, make sure the tool shank, collet, collet nut, and inner face of
the collet holder are clean. If ground particles or metal chips stick to the inside of the
collet, damage to the collet holder or Spindle can occur due to the loss of precision.
(8) Do not strike or disassemble the Spindle.
(9) Please set the cutting tools to minimize the overhang amount. 13mm is the maximum
amount of overhang to maintain high accuracy and safety.
13
Grind Stone
If a problem or concern occurs, please check the following prior to consulting your dealer.
14. TROUBLESHOOTING
Trouble Cause Inspection / Corrective Action
Spindle does not
rotate or rotate
smoothly.
The spindles ball bearings
have been damaged.
Replace the ball bearings.
(Return to NAKANISHI dealer service.)
The motor has been damaged. Replace the motor.
(Return to NAKANISHI dealer service.)
Overheating
during rotation.
Cutting debris has contaminated
the ball bearings, and the ball
bearings are damaged.
Replace the ball bearings.
(Return to NAKANISHI dealer service.)
Abnormal
vibration or noise
during rotation.
The tool shank is bent. Replace the tool.
Cutting debris has
contaminated the ball bearing.
Replace the ball bearings.
(Return to NAKANISHI dealer service.)
The spindles ball bearings
have been damaged.
Collet holder
slippage. The collet holder is worn or damaged. Replace the collet holder.
The internal components
of the Spindle are worn or
damaged.
Replace the internal components of the
Spindle.
(Return to NAKANISHI dealer service.)

32
When disposal of a Spindle is necessary, follow the instructions from your local government
agency for proper disposal of industrial components.
Refer to Brushless Motor and E4000 CONTROLLER Operation Manuals.
15. DISPOSAL OF THE SPINDLE
Trouble Cause Inspection / Corrective Action
Cannot clamp a
collet holder. Poor the air hose connection. Check all threaded joints and re-tighten if necessary.
The air hose has been damaged. Replace the air hoses.
Low air pressure. Check the Compressor, Air Circuit, and
Regulator.
Tool slippage. Collet or collet nut are not
correctly installed. Check and clean the collet and collet nut. Reinstall the collet and collet nut.
The collet and the collet nut are
worn. Replace the collet, collet nut and collet holder.
High run-out. The tool is bent. Change the tool.
Collet nut is not correctly
installed. Secure the collet and the collet nut correctly.
The collet, collet nut or collet
holder are worn. Replace the collet, collet nut or collet holder.
Inside of the Spindle is worn. Replace the Spindle shaft.
(Return to NAKANISHI dealer service.)
Contaminants inside the collet,
collet nut and collet holder or
the Spindle.
Clean the collet, collet nut and collet
holder or the Spindle.
The Spindle ball bearings are
worn.
Replace the ball bearings.
(Return to NAKANISHI dealer service.)

2017.03.14 001