OmniTurn GT-75 Guide

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Zip-Loader Installation, Operations,
and Technical Documentation for GT-75
(Including 1/16” Knife and Hopper Options)
Description
The OmniTurn Zip Loader is a multi-mode auto-loader that works as a short bar-loader or
as a part-loader.
Bars or parts are lifted one at a time from the tray (or hopper) onto a guide-trough, then
fed through the spindle liner into the collet.
Parts can be qualified from the face or from the rear, for overall length.
When the part is located, the collet is closed and the part is machined.
After machining, the part is ejected and the cycle begins again.
This document includes the hopper option and the 1/16” knife option.
The 1/16” knife is designed for loading parts or bars as small as 0.070” diameter.
The parts hopper option is designed to increase the number of parts that can be loaded
with the ZipLoader. The standard hopper accommodates parts from 1/2” diameter
to about 1/8”. For hopper operation with parts as small as 0.085” diameter some
modification would be necessary.
Dec 2019

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Table of Contents
Section 1: Component Descriptions
Zip Loader w/Hopper: Major Components. . . . . . . . . . 3
Component Parts, Overview . . . . . . . . . . . . . . . . . . . . 4
Component Parts, Sensors . . . . . . . . . . . . . . . . . . . . . 5
Component Parts, Air Panel . . . . . . . . . . . . . . . . . . . . 6
About Pressure & Speed. . . . . . . . . . . . . . . . . . . . . . . 6
Component Parts, Tray-guide Shoulders . . . . . . . . . . 7
Component Parts, Knife-down Jack-screws . . . . . . . . 7
Component Parts, Manual Control Box. . . . . . . . . . . . 7
Component Parts, Tray Pivot. . . . . . . . . . . . . . . . . . . . 8
Component Parts, Micrometer Adjustment . . . . . . . . . 8
Component Parts, Vee & Pushrod. . . . . . . . . . . . . . . . 9
Component Parts, Optional Hopper . . . . . . . . . . . . . . 9
Pusher and Push-rods. . . . . . . . . . . . . . . . . . . . . . . . . 10
Push-rods for small diameter parts . . . . . . . . . . . . . . . 10
Vee & 1/8” pushrod adjustment. . . . . . . . . . . . . . . . . . 11
1/8” Push-rod and Pushrod Adapter . . . . . . . . . . . . . . 11
Section 2: Setup and Alignment
Loader Setup and Alignment, Mechanical. . . . . . . . . . 12
Loader Setup and Alignment, Electrical. . . . . . . . . . . . 13
Loader Setup and Alignment, Air. . . . . . . . . . . . . . . . . 14
System Test, Manual. . . . . . . . . . . . . . . . . . . . . . . . . . 14
Loader Alignment and Changing Diameters . . . . . . . . 15
Aligning the Shuttle Plate Assembly . . . . . . . . . . . . . . 16
Aligning the loader for Small Diameter Parts. . . . . . . . 17
Section 3: Hopper
Hopper Operational Description . . . . . . . . . . . . . . . . . 18
Adjusting the Hopper. . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hopper Adjustments, 1/8” and 1/16” in Knife. . . . . . . . 19
Section 4: Operation
Using the Loader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
All Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bar Mode (M50). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Part Mode (M51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Stop Mode (M52). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2Part Mode (M53) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
PLC Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
M-Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
M97 - Jump to Sub-routine, Conditional . . . . . . . . . . . 36
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Air Panel Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Shuttle Components Parts List . . . . . . . . . . . . . . . . . . 38
Section 5: Technical Documents . . . . . . . . . . . . . . . 39
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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Zip Loader w/Hopper: Major Components
Before using your Zip Loader, become familiar with the component parts
PLC Cabinet
Air Panel
Home Stop
Shuttle
Stack Lamp Tray
Adjustable
Tray Guide
Manual
Control Box
Foundation
Brackets
Rear-stop
Shuttle stop
Loader
Air-line
Spindle Drive
Cabinet
Rodless Cylinder
Mounting
Bracket
Spindle
Liner
Cover Interlock Bypass
Keyswitch (cover removed
to show components)

Knee Adjust
Knob
Tray Lock Knob
Home Stop
Bearings
Shuttle
Knee Spindle
Liner Adjustable
Rear Stop
Tray-guide
Shoulder
Adjustable
Tray-guide
Pivot
Bracket
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Component Parts, Overview
Tray-guide Shoulders keep small diameter parts in tray from crawling over one another
Adjustable Tray Guide is set to accommodate the length of parts in tray
Knee is moved away from knife (not shown) as part diameter is increased
Spindle Liner To change spindle liner, remove pushrod from shuttle, loosen tray-lock knob and
remove micrometer lock knob,then pivot tray assembly out of the way.
Adjustable Rear Stop stops Shuttle Plate to qualify parts for overall length
Shuttle Plate carries the Pushrod on the rodless cylinder
Bearings give additional support to the Shuttle Plate (rodless cylinder has internal bearings)
Home Stop is set so end of Pushrod clears parts before load-cycle begins
Tray-Lock Knob allows tray to pivot to put different diameter parts at center of spindle liner
Knee Adjust Knob allows Knee to be set and locked
Adapter Plate connects pushrod to shuttle plate
NOTE: Cover removed to show parts; use bypass key-switch on PLC cabinet to run with cover open
Hopper and 1/16th
Knife options
The 1/16th knife option uses
1/8” pushrod to load parts
as small as 0.070” diameter.
Extreme care is required to
reliably load such small parts.
Standard ZipLoader
The standard ZipLoader
uses 1/4” pushrod with
pushers sized to accommo-
date parts from 1/4 to 1” in
diameter. Parts as small as
3/16” are routinely loaded.
Adjustable
Rear Stop
Knee
Hopper
Divider Spindle
Liner
Hopper
1/8” Pushrod
Adapter and
Pushrod
Hopper
Front Gate

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Component Parts, Sensors
There are five magnetic sensors on the rodless cylinder as follows:
Home: Mounted at left, farthest from collet closer, this sensor must light when the shuttle-
plate is at the adjustable home stop. Move the adjustable home stop and “home” sensor as
required to locate pusher just to left of part so as to minimize cycle-time.
Slow: The Slow sensor signals the PLC to change speed. Usually set to slow the shuttle
so bar or part does not hit stop too hard, but can be set faster for special applications.
Experiment with location of Slow sensor to best suit your particular application.
InPlace: When using the loader in Part Mode (M51) or Rear Stop Mode (M52) the InPlace
sensor signals the PLC that the part is in place and collet can be closed. Note that in Rear
Stop Mode, the Part Located sensor on the table-mounted stop must also be lit.
EoB (End of Bar): When using the loader in Bar Mode (M50), the EoB sensor signals the
CNC to execute “eject remnant and load new bar” subroutine.
Eject: Mounted nearest collet closer, this sensor must light when the shuttle is at the far right
of rodless cylinder. The push-rod should just clear the collet at this point, which allows the
finished part to fall free. Should never need adjustment.
When adjusting Limit Sensors, don’t overtighten.

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Component Parts, Air Panel
About Pressure & Speed
Set the “Push” regulator to 87psi. Speed is controlled by the “Pusher Speed” flow controls. Note that
the“Slow” designation carries over from obsolete air-pack. The “Slow” pusher speed can be set faster than
the initial pusher speed. The flow-control that is effective is determined as follows:
M47 (load new bar or part): speed is determined by the “Fast” flow-control setting. When shuttle crosses “Slow”
sensor, speed is determined by “Slow” flow control setting.
M11 (open collet and push): speed is determined by the “Slow” flow-control setting.
M48 (eject): speed is determined by “Pusher Speed” flow-control, except with M59 (below).
M59 (slow eject): speed is determined by “Slow” flow-control.
Delicate parts may need to be fed so slowly that ‘stiction’ prevents shuttle from starting. Accel pressure relief valve
can be set to overcome ‘stiction’ by allowing initial airflow to bypass flow-control, increasing accelleration. Turn-
ing grey knob CCW tends to bypass the flow-control; turning knob CW tends to bypass the pressure relief valve,
decreasing accelleration. Properly set, a “puff” of air will be felt at the output port (side opposite the ‘tee’) when
the manual “push” or “retract” buttons are pressed.
Observe the loader in operation, and adjust the controls as required to insure reliable operation.
1
10
3
2
2GO
ACCEL
PRESSURE
RELIEF
PUSHER
SPEED
INPUTS
(X)
PLC
OUTPUTS
(
ZL1
0
“Push” Regulator
Set at 87psi
Pusher Speed, Slow
Initial Setting:
Full CW then 1-3/4 CCW
Accel Pressure Relief
Initial setting:
Full CCW then 3-½ CW
Main Regulator/Filter
Set at 90-100psi
Pusher Speed, Fast
Initial Setting:
Full CW then 7 CCW
Misubishi PLC
FX3s-30MR
PLC Fuse (2) 3AG 1A
Air Valve: Rear Stop
Air Valve: Knife
Air Valve: Push
Air Valve: Slow
Air Valve: Retract
Stack-Lamp Relay (12V)
Knife Regulator
Set at 35psi
Cover Interlock Override Key
pn 790-16-001
pn 797-15-001
pn 790-15-001
pn 697-11-015
pn 797-11-002
pn 797-11-001
pn 797-11-002
pn 697-11-102
pn 697-11-102
pn 790-15-005

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Component Parts, Manual Control Box
The Manual Control Box allows manual operation of the
knife and the pushrod. Also provides reset after fault.
A key-switch on top selects manual or auto mode. When set
to manual mode, the green push-buttons are illuminated.
The loader will not respond to the load or eject commands
(M47 & M48) from the CNC when in manual mode.
If the loader or the CNC faults, the red “Reset/Initialize”
pushbutton will illuminate. Pressing Reset when lit will
open the collet on the GT-75, retract the rear-stop shot-pin
and table-mounted stop, and retract the shuttle to home.
When trouble-shooting loading issues, it is good practice to
issue M56 from MDI mode to force a loader fault, then re-
set/initialize before continuing.
Manual/Auto Switch
Knife Up
Push Shuttle (right)
Retract Shuttle (left)
Reset/Initialize
Component Parts, Tray-guide Shoulders
The Tray-guide shoulders are used with small diameter
parts to keep them flat on the tray. The height is set
to allow clearance for the parts to roll down the tray.
Note that as the shoulders are raised or lowered, the
front edge moves away from or toward the knife (hid-
den under the first rod in this picture). The front edge
of the shoulder must clear the rod resting on the knife.
Located under the knife support plate, two 10-32 jack-
screws allow precise adjustment of the knife when it’s
down. This adjustment is critical for parts with diam-
eter less than 3/16”. With these small diameter parts,
if the knife is set too low, the next part will tend to
crawl over the part on the knife; if the knife is set too
high, the next part will tend to burrow under the part
on the knife.
Component Parts, Knife-down Jack-screws

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Component Parts, Tray Pivot
For part diameters down to about 1/4”, the loader is aligned to the spindle by loosening Tray
Lock Knob and Micrometer Adjust Lock Knob and pivoting the tray to its lowest position.
Adjust as required for 1-1/8” dowel to be centered in the drawtube. The center of the tray pivot
is such that different diameters, down to about 1/4”, stay on center without lateral adjustment.
Component Parts, Micrometer Adjustment
Adjust knob
Lock-knob
Right-side Tray Lock Knob has been re-
placed by micrometer adjustment.
To adjust the tray height, loosen the left-
side tray lock knob and lock-knob on
micrometer adjustment. Use the adjust
knob to set the tray height, then tighten
lock-knobs.
RED=Tray at lowest position
GREEN=Tray raised for 1/4” part
1-1/8” alignment bar
Tray Lock Bracket
Pivot Bracket
1/4” part
As tray pivots, centers of different diameter parts align with pusher and spindle-liner.

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Component Parts, Vee & Pushrod
When aligning the ZipLoader for parts with diameters 1/8” or less, simply rotating the tray
assembly may not be satisfactory because the accuracy required to align the part with the
liner is much higher for small parts.
Spindle Liner
Vee Front
Shuttle Plate
PushrodAdapter
Pushrodw/Pusher
ShuttleBearings
KneeAdjust
Lock-knob
TrayAdjust
Lock-knob
Component Parts, Optional Hopper
DIVIDER
FRONT GATE
FLOOR
Gate Clearance
Adjustment
Floor Front-stop
Adjust
Front Gate to Knee
Adjustment
Floor Speed
Adjust
Lip Tray

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Pusher and Push-rods
Delrin pusher should be such that overall length of push-rod and pusher is about 30.25”.
Drawings below describe standard push-rod and typical pusher. The smallest diameter for this
combination is about 5/16”. For smaller diameters see list below drawings.
Push-rods for small diameter parts
The OmniTurn ZipLoader is capable of loading parts as small as 0.089” in diamter, but special
pushrods are necessary. For the smallest diameters, a thinner escapement knife is required. We
stock the necessary components, or you can fab your own from our drawings.
Standard pushrod, as shown in drawing above:
p/n 790-02-006 (standard pushrod w/barb)
For 1/4” parts, a plain 1/4” pushrod is used. It is as drawing above, except 30.25” long, no barb:
p/n 790-02-017 (plain 1/4” pushrod)
For parts 1/4” to 3/16”, the same 1/4” plain pushrod is used, except turned down a/r to clear collet:
p/n 790-02-016 (1/4” pushrod turned down)
For most parts 3/16” to 1/8”, a 3/16” pushrod is used, with 4-40 holes instead of 6-32. Must be
turned down a/r to clear collet. Requires 3/16” adapter plate:
p/n 790-02-020 (3/16” pushrod)
p/n 790-02-004 (adapter plate)
For some parts 3/16” to 1/8”, a plain 1/8” pushrod is used. Requires special adapter plate:
p/n 790-02-015 (1/8” pushrod) See next page for description
p/n 790-02-005 (adapter plate) See next page for description
For parts 1/8” to just under 3/32”, 1/8” pushrod and thin knife option is required:
p/n 790-09-101 (1/16” escapement knife assembly)
g
DETAIL (2X)
BARB TIP
DELRIN PUSHER, DIAMETER TO SUIT
0.204 x 0.80 DP
2.00
29.00
0.200 0.220
0.350
0.400
0.750
(ON CENTER LINE)
0.000
0.325
2.325
4.325
6-32 THRU (3 PLCS)

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1/8” Push-rod and Pushrod Adapter
The drawing below describes the adapter plate that holds the pushrod to the shuttle plate, and
the pushrod itself. The pushrod is any kind of 1/8” drillrod, bent to 90° as shown and cut to
about 25.5” long. The actual length is just sufficent for the pushrod tip to clear the collet when
the rodless cylinder shuttle is at the far right side of the loader (eject sensor lit).
Vee & 1/8” pushrod adjustment
Pushrod Adapter
Vee Front
Pushrod
Spindle Liner
Shuttle Plate
When aligning the ZipLoader for parts with diameters 1/8” or less, simply rotating the tray assembly
may not be satisfactory because the accuracy required to align the part with the liner is much higher
for small parts.
To align the loader: rotate the tray and adjust lateral position of loader to put part on center of
spindle liner. Put the pushrod in the vee by moving the shutlle plate and by adjusting height of
pushrod in pushrod adapter. NOTE: The bend of the pushrod should not quite rest in the vee; the
wieght of the rod will keep the tip in the vee.

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Loader Setup and Alignment, Mechanical
Setup the GT-75 and insure that it is fully operational and level
before attaching the Zip Loader.
The OmniTurn lathe was shipped with a Zip Loader mounting brack-
et attached. Foundation brackets on the Zip Loader are attached
to this mounting bracket. Attach the Zip Loader to the mounting
bracket as shown. Two 1/4-20 screws through slots in foundation
brackets secure the loader to the mount.
If the ZipLoader was shipped with the OmnTurn, no vertical alignment
adjustment should be necessary. Use a string along the back of the lathe
to align the loader parallel to the machine. Before tightening the screws
that hold the foundation brackets, adjust the loader as required to allow
your parts to pass smoothly from the guide-trough (‘vee’) into the spindle
liner. Use the shuttle as a handle and manually move the pushrod.
The much smaller parts used with the 1/16” knife require more attention to
alignment details. If the loader was aligned at the factory, the settings will
be pretty close, but may have changed during shipment. Pushrod speed
and the location of the ‘slow’ sensor (and setting of the ‘slow’ needle valve)
all affect reliable feeding of small diameter parts
Attach the stack lamp to the tray-side and connect it to the PLC
Cabinet at “Stack Lamp”.
Note cables and air line routed to back of CNC: these connec-
tions are discussed in item 6, on following page.
NOTE: If your ZipLoader shipped wih your OmniTurn, it was was aligned to the machine
at the factory. The front leveling mounts and foundation brackets are properly set. Only the
rear leveling mounts need adjustment to level the loader to the machine on your floor.
1. Attach to bracket
2a. Align to spindle, shipped with lathe from factory
3. Attach stacklamp
2b. Align to spindle, starting from scratch
To align a loader that wasn’t shipped with a lathe, loosen the tray lock
knobs and pivot the tray to its lowest position and set the height so the
1-1/8” alignment rod slides freely from
‘vee’ into drawtube. Pivot the tray all
the way up to install liner, then pivot
back down to allow smooth feeding of
your part.

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Loader Setup and Alignment, Electrical
Three cables connect the Zip Loader PLC cabinet to
the GT-75: A yellow and blue tagged cable from the
left side of the cabinet, and an unmarked cable from
the right side. The unmarked cable is paired with a
blue air-line.
The yellow-tagged connector goes to the spindle-drive
cabinet door and the blue-tagged connector goes to
the CNC back panel.
The unmarked cable is used for the spring-loaded
table-stop, required for parts that must be qualified
from the rear for overall length (see #6, below).
Route the yellow-tagged cable from the PLC cabi-
net to the spindle-drive cabinet door at connector
marked “Spindle Cab to PLC”;
Route the blue-tagged cable from the PLC cabinet to the CNC
back panel at connector marked “PLC”.
Connect the small in-line connector and blue air-line marked
“Table Stop” to the spring-loaded stop which is mounted on
the tooling plate (table) in the GT-75. The stop can be moved
to any location compatible with the other tooling.
The spring-loaded stop is certainly necessary for the second
op. to prevent damage to the chamfer on back-side of part.
4. Locate cables at Zip LoaderPLC Cabinet
5. Connect cable at Spindle Drive Cabinet
6. Connect cables at CNC Rear Panel

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Loader Setup and Alignment, Air
Main air for the loader connects to a
bulkhead fitting above the spindle drive
cabinet marked “Loader Air”.
Loader air main regulator should be set
for 90 - 100 psi.
7. Connect Loader Air
System Test, Manual
This test is for your benefit, to verify that nothing broke in shipping.
Perform this test after attaching loader to GT, and before doing any critical alignment of the
hopper and loader. The only alignment requirement is that the pushrod moves freely in the
spindle liner bushing. Do not put any parts in the hopper yet.
Set disconnect on spindle cabinet ON; set CNC control ON. After boot-up, set servos ON.
1. Verify that Auto/Manual keyswitch on Loader Manual Control is in Auto (switch lamps not lit).
2. Verify that green stacklamp is lit.
3. Push loader shuttle against adjustable home stop; verify that “Home” LED is lit.
4. Move the shuttle to “InPlace” sensor; the LED on sensor should light.
5. Move the shuttle to the “Slow” sensor; the LED on sensor should light.
6. Move the shuttle to “EoB” sensor (End of Bar); the LED on sensor should light.
7. Push the shuttle right, until “Eject” sensor LED lights.
8. Set Auto/Manual keyswitch on Loader Manual Control to Manual; three green push-buttons should light.
9. On knife cylinder, verify that LED on lower sensor is lit.
10. Press “Knife” switch; knife should rise smoothly. On knife cylinder, LED on upper sensor must light (LED
on lower switch should go out). Release switch; knife should fall back.
11. Press “Push” switch; shuttle should move to your right; press “Retract” until shuttle returns to home.
12. Set Auto/Manual switch to Auto. Home the CNC and go to MDI mode. Front door of GT-75 must be
closed or the door interlock bypass key-switch must be engaged; ziploader cover bypass key-switch on
PLC cabinet must also be engaged.
13. Issue M40; knife should rise; issue M41; knife should fall.
14. Issue M45: rear stop shot-pin and spring-loaded stop piston rod should extend; M46 to retract.
15. Issue M56; red stack-lamp should be lit. (This is a forced loader-fault; useful for reinitializing the loader).
16. Move the shuttle off the home sensor. Press Reset/Initialize switch on loader; shuttle should return to
home and green stack-lamp should be lit. This demonstrates that the PLC ladder is functioning.
This completes the manual system test.

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Loader Alignment and Changing Diameters
The procedure for aligning the “vee” of the loader to centerline of the spindle is critical
because the loader is designed so that different bar diameters will be on center by pivoting
the entire tray and ’vee’ assembly. With tray assembly is at its lowest position, set the load-
er height so that 1-1/8” bar will slide easily into draw-tube on OmniTurn. If a liner is in-
stalled, the same 1-1/8” bar can be used with tray assembly at lowest position, but a dowel
that closely fits liner must be installed on center in bar.
No other adjustment is necessary to put different diameters on center if this ini-
tial alignment is properly done. Parts with diameter less than 1/4” will probably
require some additional adjustment to insure consistent feeding.
To accommodate different bar diameters, adjust the distance of the ‘vee’ from the knife,
and pivot the entire tray to bring the new diameter on center. Knurled black-plastic adjust-
ment knobs on each side of tray lock the ‘vee’ in place, and a single steel tray-lock knob on
the left side locks the centerline adjustment.
For small diameter parts it may be necessary to ‘tweak’ the loader to insure reliable feeding.
See next page: “Aligning the OmniTurn ZipLoader for Small Diameter Parts”.
Special pushrods are necessary for parts less than 1/4” diameter. See pages 14 & 15 for
more information about these pushrods.
RED=Tray at lowest position
GREEN=Tray raised for 1/4” part
1-1/8” alignment bar
Tray Lock Bracket
Pivot Bracket
1/4” part
As tray pivots, centers of different diameter parts align with pusher and spindle-liner.

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Aligning the Shuttle Plate Assembly
The shuttle assembly and rodless cylinder should be periodically checked for correct align-
ment with the ‘vee’. This must be done if the rodless cylinder is replaced.
First verify that the rodless cylinder is parallel to the ‘vee’ front within about 1/32”. A six-
inch scale is adequate; measure from one edge of the band on top of the cylinder to the
edge of the Vee Front at two places about 24” apart.
If the cylinder is not parallel to the chassis, loosen the Pivot Bracket and Tray Lock Bracket
(see page 8) on one side and move the chassis assembly to make it parallel with the rodless
cylinder. The blocks are held in place with t-nuts.
After making the chassis parallel to the rodless cylinder, the shuttle plate assembly must be
aligned to the vee. There are ten screws in the top of the shuttle assembly: (shown below)
The four middle ones are M4 screws which hold the plate to the shuttle.
The two rows of two on either side of the four are 10-32 which attach the slide bearings.
The three 6-32 on the far end attach the push-rod to the plate. To align the assembly, first
loosen all these screws.
To properly align the shuttle assembly to the vee, it is easiest to use a plain 1/4” pushrod
(pn 790-02-017) which will lay flat in the vee. Pivot the tray so the pushrod lays in the vee.
Verify that the push-rod lays flat in the vee. Wiggle the pusher-plate as necessary to square
things up, then tighten the four M4 screws which hold the plate to the shuttle. Next, tighten
the three screws that hold the push-rod to the plate. Finally, squeeze the shuttle bearings
gently against the rodless cylinder and tighten the four screws which hold them in place.
Squeeze too tightly and the shuttle may not move fast enough to complete the cycle.
Shuttle Bearings
(4 Teflon screws)
McMaster 94701A308
Shuttle Plate
Knife
Knee
Vee Front
(Parts rest in ‘vee’
formed by Knee and
Vee Front.)
Shuttle Bearing
Clamp Screws (4)
Pushrod
Mounting Screws
Shuttle Plate Mounting
Screws (4 M4)
Pushrod Adapter
Tray
Pushrod
Rodless Cylinder
Shuttle

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Aligning the loader for Small Diameter Parts
See Page for 1/8” pushrod description (1/16” knife option)
When loading parts with diameters 5/16 and greater, the push-rod is fitted with a delrin push-
er which is the about the same diameter as the part, or a little smaller. Alignment is less crit-
cal because the push-rod doesn’t contact the ‘vee’: it is suspended between the adapter plate
(at the shuttle), and the pusher. The pusher rides in the vee to push the part into the liner.
Small diameter parts are 1/4” or less. For loading 1/4” parts or bars, use a 30-1/4” long push-
rod; for parts or bars down to about 3/16, turn down the end of the pusher to clear the collet
so part or remnant can be ejected. For smaller diameter parts, use a 3/16 or 1/8 pushrod. For
the 3/16 pushrod, put 4-40 holes in the pushrod at locations shown on page 14. Alignment is
very critical because the entire push-rod rests in the vee. For 1/8” pushrod, a different adapter
plate is required, and for parts less than 1/8” a different escapement knife may be necessary.
See page for more information about the various pushrods, including part numbers.
If the small diameter parts have sharp edge on face, it may be necessary to grind a small chamfer
inside the collet to insure reliable feeding. A die-grinder with a cone-shaped tool is adequate.
Speed of the pusher is also important, and the in-feed chamfer on the liner can be a factor.
Basic Alignment
The basic alignment procedure (as described on previous page) is to loosen the lock-knob
at left and lower the vee to bottom. Put 1-1/8” rod in the vee. Align the entire ziploader to
the drawtube with vee at lowest setting (bottom of pivot).
A 1-1/8” alignment rod ships with the loader. This rod is useful for setting the basic align-
ment, which is suitable for parts and bars 5/16 and greater. The vee stays on center for all
diameters because as vee is pivoted up, the center of different diameters passes through the
center of drawtube. The distance from the knife to the knee of the vee is adjusted for differ-
ent diameters by loosening the black knurled adjustment knobs on each side. The center of
each diameter should stay close enough to center of drawtube to load all diameters from 1”
to 5/16 by pivoting the tray. When loading smaller parts it gets much more critical.
Aligning the ‘vee’ (rotating the chassis)
After the basic alignment is done, and the correct liner is installed, loosen the tray-lock knob
and micrometer lock knob, then use micrometer adjust to rotate the chassis until parts to
freely move from ‘vee’ into the liner. With the smallest parts it may be necessary to relocate
the entire loader side-to-side to get perfect alignment. To do this, it may be easier to loosen
the pivot braket tee nuts and nudge the chassis assembly.

DIVIDER
FRONT GATE
FLOOR
Gate Clearance
Adjustment
Floor Front-stop
Adjust jam-nut
Loosen to slide
hopper toward knee
(both sides)
Floor Speed
Adjust
Lip Tray
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Hopper Operational Description
The parts hopper is designed to be used with the Omniturn Zip Loader to increase the
number of parts that can be loaded with the ZipLoader. The hopper allows small diameter
parts (1/2” - 1/8”) to be loaded in quantity in a 3-1/2”h x 11-3/4” x 24-1/8” wide box, the
quantity depending on the diameter of the part. The length of the part can be from ap-
proximately 2 inches, to 24 inches. The parts are then presented to the top of the knife in
the ZipLoader, and loaded into the rear of the spindle for machining. The hopper can be
mounted to any ZipLoader.
NOTE:
Refer to separate document “ZipLoader Hopper Kit Installation” for more detailed informa-
tion regarding the hopper.

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Hopper Adjustments, 1/8” and 1/16” in Knife
Hopper Adjustments
The hopper adjustment is very critical for parts with small diameters.
The height of the lip must be set to just barely allow parts to roll be-
tween lip and tray, and the distance between lip and knee must also
just barely allow one part to fit. The entire hopper is set to just clear
the knife, then the knee is moved away from the knife to barely allow
one part to fit between lip and knee.
Refer to separate document “ZipLoader Hopper Kit Installation” for
more detailed information regarding the hopper.
Hopper installed on standard
1/8” knife ZipLoader setup
for loading 5/8” parts.
Hopper installed on optional
1/16” knife ZipLoader setup for
loading 0.085” parts.
NOTE: Special modifications
are necessary to reliably load
parts this small.
FLOOR
TRAY
FRONT GATE
LIP to KNEE:
So back of part
just clears lip
as knife raises.
LIP to TRAY:
Only slightly
larger than
diameter 1/8” KNIFE
KNIFE to KNEE:
Can be as much as
1/2 the diameter
KNEE LIP ( )
Ø.625
parts
KNEE
TRAY
LIP
1/16”KNIFE
1/4” Floor to Front
FLOOR
LIP to TRAY:
Set hopper front just
slightly more than
diameter
NOTE: Hopper shown flat for clarity.
(Tray tipped about 20° in operation)
Ø.085
parts
(
(
KNIFE to KNEE:
For these tiny
parts this space
will be minimum.
1. Set knifetokneespacing to
minimum for reliable escape.
2. Adjust lip to tray so parts
just barely roll under.
3. Set lip to knee so part just
clears as knife raises.
LIP to KNEE: Position
hopper on tray so back of
part just clears lip as knife
raises. FRONT GATE

Pivot Bracket
Pushrod Adapter
Tray-guide
Shoulder
Tray Lock Knob
Home Stop
Shuttle Plate
Adjustable
Rear Stop
Spindle Liner
Adjustable
Tray Guide
Pusher
Micrometer
Adjust
Pushrod
Knee
Knee Adj Knob
Knee Adj Knob
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Using the Loader
Set the Adjustable Home Stop so that the pusher clears the bar or part when the shuttle is firmly against the stop.
The Home sensor must light when shuttle is firmly against the stop.
The In Place sensor is used in “part” and “stop” modes; it must light when part is at either front or rear stop.
The Eject sensor must light when the shuttle is at far right on rodless cylinder.
The Cover Interlock Bypass keyswitch (on PLC cabinet) allows testing setup with cover open.
Diameter change-over. For best results, liner id and pusher od should be appropriate for the part or bar od. To
change liners, remove pushrod from shuttle plate (three 6-32 SHCS), then loosen the tray-lock knob, and remove mi-
crometer lock knob. Swing entire tray assembly up and out of the way to clear flange on liner. Liner is held in place
with o-rings; it can take some effort to remove it. Liners come with three o-rings; remove one closest for easier removal.
To put the bar or part on center of the spindle, loosen steel tray lock knob and micrometer lock knob (lower knob).
Slide part by hand from vee into liner, moving tray up or down with micrometer adjust until part slides smoothly.
The pivot brackets are held with tee-nuts, and can be moved if fine-tuning for very small part diameters is necessary.
Plastic knurled knobs on each side of tray assembly lock the “knee” of the guide channel “vee” at correct distance
for different diameter bars. Loosen knee adjustment knobs at each side of tray to adjust knife-to-vee distance for new
size bar. Manually cycle knife to insure smooth delivery of the bar.
For best results, use push-rod / pusher assembly that has pusher about same diameter as your stock. Matching
pusher to stock insures that pusher follows stock in vee and into liner properly.
Programming: Detailed machine setup and programming information for the different modes starts on next page.