wto 4201 User manual

Type 4201
Type 4205
B80000-0-ENG
Driven Toolholders
with QuickFlex®
Operating Instruction

www.wto-tools.comB80000-0 ENG2
Introduction
© 2019 WTO Werkzeugeinrichtungen GmbH. All rights reserved. This document may not be
copied or reproduced in whole or in part, or transferred to any other media or language, by
any means, without the prior written permission of WTO Werkzeugeinrichtungen GmbH.
General
WTO Driven Precision Toolholders (DTH) are high quality products with low maintenance
requirements. Please follow these instructions to maintain a high accuracy and a long
service life.
This manual contains important safety directions and instructions for product setup and
operation.
Keep for further reference
Product identification
Product type and article numbers are printed on the product.
Refer to this when contacting WTO.
Validity of this manual
This manual applies to the Driven Toolholders with QuickFlex®, Chapter 2 describes the nam-
ing rules.
Driven Toolholders with QuickFlex®Operating Instruction
can be downloaded in several languages:

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Content
1 Safety 4
1.1 General 4
1.2 Purpose 5
1.3 Limits of use 5
1.4 Areas of responsibility 6
1.5 Hazard of use 7
1.6 Unpacking 8
2 Product Description 9
3 Operation 10
3.1 Installation and operation advices 10
3.2 Break in period 11
3.3 Changing the cutting tool 12
3.4 Changing the QuickFlex®adapter 13
3.5 DTH with internal coolant supply 14
3.6 Plug DTH coolant nozzle to use for IC only 14
3.7 Ball nozzle options 15
3.8 Copper pipe fitting options 15
3.9 Collet solutions for DTH’s with internal coolant supply 16
3.10 Adjusting the projection length of the cutting tool 16
3.11 One-hand wrench 16
3.12 Available ER collet nuts for QuickFlex®17
3.13 Turret centerreline alignment 18
3.14 Duty cycle ratio 19
3.15 Service interval 19
4 Care and Cleaning 20
5 Storage and Transport 21
5.1 Storage 21
5.2 Shipment 21
5.3 Shipping claims 21
6 Warranty 22
7 Disposal 22
8 DTH tolerances 23

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1 Safety
1.1 General
Description
The following instructions should enable the person responsible for the product and the
person who actually uses the equipment to anticipate and avoid operational hazards.
The person responsible for the product must ensure that all users understand these
instructions and adhere to them.
Generalities
When operating and using our DTH, observe the safety regulations of the regional associations
and the safety laws and guidelines of the respective state and/or the European Union.
Above such regulations, observe the safety instructions of the manufacturer of your machine
tool.
About warning messages
Warning messages are an essential part of product safety. They appear wherever hazards or
hazardous situations can occur.
For user safety, all safety instructions and safety messages shall be strictly observed and fol-
lowed. Therefore, the manual must always be available to all product users.
DANGER, WARING, CAUTION an NOTICE are standardized signal words for identifying levels
of hazards and risks related to personal injury and property damage. For your safety it is
important to read and fully understand the table below with the different signal words and
their definitions. Supplementary safety information symbols may be placed within a warning
message as well as supplementary information.
DANGER
WARNING
CAUTION
NOTICE
Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous situation or an unintended use
which, if not avoided, could result in death or serious injury
Indicates a potentially hazardous situation or an unintended use which, if
not avoided, may result in minor or moderate injury.
Important information which must be adhered to in practice as it
enables the product to be used in a technically correct and efficient
manner.

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WARNING
Adverse use can lead to injury, malfunction and damage. It is the task of the person respon-
sible for the equipment to inform the user about hazards and how to counteract them. The
product is not to be operated until the user has been instructed on how to work with it.
1.2 Purpose
Permitted use
To prepare Driven Toolholders with QuickFlex®for operation.
Adverse use
• Use of the product without instruction
• Use outside of the intended limits
• Disabling safety systems
• Removal of hazard notices
• Opening the product using tools, e.g., screwdriver, unless specifically instructed for certain
functions
• Modification or conversion of the product
• Use after misappropriation
• Use of products with obviously recognizable damages or defects
• Use with accessories from other manufacturers without the prior approval of WTO
1.3 Limits of use
Environment
Suitable for use under rough conditions, ref. technical data. Not suitable for use in aggressive
or explosive environments.

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1.4 Areas of responsibility
Manufacturer of the product
WTO is responsible for supplying the product, including the operating instruction and original
accessories, in a completely safe condition.
Manufacturers of non-WTO Accessories
The manufacturers of non-WTO accessories are responsible for developing, implementing and
communicating safety concepts for their products, and are also responsible for the effective-
ness of those safety concepts in combination with the WTO product.
Person in charge of the product
The person in charge of the product has the following duties:
• To understand the safety instructions on the product and the instructions in the manual
• To be familiar with local regulations relating to safety and accident prevention
• To inform WTO immediately if the product becomes unsafe

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1.5 Hazard of use
WARNING
The absence of instruction, or the inadequate imparting of instruction, can lead to incorrect or
adverse use, and can give rise to accidents with far-reaching human, material, financial and
environmental consequences.
Precautions: All users must follow the safety instructions given by the manufacturer and the
directions of the person responsible for the product.
WARNING
This tool is intended for use by skilled persons with knowledge on the use of this tool who
understand the resulting risks.
Precautions: Read all instructions before using the tool system.
WARNING
Use all appropriate safety guards or machine encapsulations to securely collect particles such
as chips or cutting elements that may spin off.
Precautions: Always use appropriate personal protective equipment such as safety gloves,
safety shoes and workwear with tight fitting sleeves.
CAUTION
The user must use the tool as intended.
Precautions: Only WTO owned service centers and authorized service workshops are permitted
to repair these products.
CAUTION
Check important components for damage prior to every operation.
Precautions: DO NOT USE or operate damaged tool or product. Return the product to the
appropriate location for repair, replacement or recycling.

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WARNING
For safety reasons it is recommend to use lifting equipment for lifting DTH’s heavier than
18kg/40lb. Lifting slings are recommended.
CAUTION
Check the center of gravity before lifting.
1.6 Unpacking
When unpacking the product, make sure that no accessories are missing and that none of the
package contents have been damaged.
If you detect any transport damages please contact your sales representatives.
NOTICE
Keep the packaging for safe storage of tools.

n1 = n2 n1 # n2
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DTH type label
Rotating direction
Ratio
1:2, 1:3 => speed increaser
2:1, 3:1 => torque increaser
Max. output RPM
Product Code
Serial No.
Important for DTH
identification (e.g.
for spare part
request)
Rotating direction
Equal Opposite
Rotating direction stated on DTH dimensional drawing
A dimensional drawing is delivered with each DTH stating the technical specifications and the
DTH outside dimensions.
Access the WTO Online Catalog to download the dimensional drawing at
www.wto-tools.com
Equal Opposite
2 Product description

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3 Operation
3.1 Installation and operation advices
Avoid damage and dirt at the contact surfaces of the DTH and turret.
Rotate DTH spindle by hand before mounting on turret. In case of problems like roughness,
backlash or visual runout, do not use the DTH and contact WTO immediately for repair.
NOTICE
Never operate DTH beyond the maximum design torque and/or output RPM which are stated
on the DTH dimensional drawing.
Overloading the DTH will cause high wear and possibly gear
breakage, and warranty will not cover damages caused by overloading.
WARNING
Remove or at least cover the cutting tool when handling, transporting or storing the DTH.
Otherwise the danger of injury increases.
WARNING
Consider the operating instructions of the machine tool manufacturer.

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WARNING
Never change cutting tool or QuickFlex®adapter without holding the spindle! Use one-hand
wrench for holding the spindle!
3.2 Break in period
Break in period is essential for long life of the DTH.
Break in removes intensified friction of internal components, especially bearings and gears,
and helps to distribute the lubrication applied during assembly.
NOTICE
Run the DTH at 50 % of the maximum output RPM for 30 minutes without load during first
start-up. Maximum RPM is stated on the DTH dimensional drawing.
In case of error put DTH out of operation. Check if DTH is installed correctly, if necessary
and possible, correct the error. Let potential errors be repaired by WTO. Vibrations of the
DTH, excessive noises, high heat generation or excessive coolant leakage are signs of an
error.
During break in period DTH body temperature 75°C (167°F) must not be exceeded.
WARNING
Never change cutting tool or QuickFlex®adapter in turret positions other than the operation
position when turret drive is released.

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3.3 Changing the cutting tool
Rotate turret into machining position
(released machine drive)
Put on one-hand wrench and rotate DTH
spindle by hand until it locks into the
spindle nose
Release clamping nut with spanner
wrench
Change cutting tool
Tighten clamping nut with spanner
wrench. Follow torque recommendation!
Remove spanner wrench and
one-hand wrench
NOTICE
Never clamp oversize tool shanks. Never use a ø 12-11 mm collet to clamp a shank
ø 12.2mm. Rather use the next bigger collet, in that case ø 13-12 mm!
Improper handling causes poor runout and damage of the clamping nut!
WARNING
Tighten the clamping nut only when holding the spindle!
ER-20QF ER-25QF ER-32QF ER-40QF ER-50QF
80 Nm 110 Nm 140 Nm 180 Nm 240 Nm
59 ft-lb 81 ft-lb 103 ft-lb 133 ft-lb 177 ft-lb
Recommended tightening torque for the collet clamping nut

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ER-20QF ER-25QF ER-32QF ER-40QF ER-50QF
70 Nm 90 Nm 110 Nm 150 Nm 180 Nm
52 ft-lb 66 ft-lb 81 ft-lb 111 ft-lb 133 ft-lb
Recommended tightening torque of the clamping nut for adapters
3.4 Changing the QuickFlex®adapter
Rotate turret into machining position
(released machine drive)
Put on one-hand wrench and rotate DTH
spindle by hand until it locks into the
spindle nose
Release clamping nut with spanner
wrench
Change QuickFlex®adapter
Tighten clamping nut with spanner
wrench. Follow torque recommendation!
Remove spanner wrench and one-hand
wrench
Watch video:

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Designed to supply coolant both through spindle (internal coolant supply) and external cool-
ant supply port. External coolant port can be plugged.
3.5 DTH with internal coolant supply
NOTICE
Must not be operated without coolant. Coolant must be switched on and available before
tool rotation. Running dry might damage the internal seals. Seal damage is not covered under
warranty.
NOTICE
To avoid excess wear and/or damage to the internal sealing system, coolant fluid must
be filtered to a particle size less than 50 µm. If not available on the machine, install an
additional filtration system.
NOTICE
For machining Gray Cast Iron, use only DTH’s with external coolant design.
3.6 Plug DTH coolant nozzle to use for IC only
Ball nozzle
Copper pipe fitting

Ø 12
14
Ø 12
38
Ø 12
55
M6
70
M6
70
Ø 12
M6
Ø d
Ø D
M
M
Ø d
Ø D
M
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3.7 Ball nozzle options
One-piece ball nozzles
Item No. 59145 45168 79542
Straight pipe Angular pipe Straight adaptor
Item No. 111128 111129 111126
3.8 Copper pipe fitting options
Modular ball nozzles
Item No. MØD Ød
30549 M 10 x 1 64.8
31638 M 12 x 1 8 6
Item No. MØD Ød
55753 M 8 x 1 64,8
47997 M 10 x 1 64,8
Angular type
Item No. MItem No.
97184 M 8 x 1 -
18483 M 10 x 1 26263
18529 M 12 x 1 26264
Plug screw
Straight type
Sealing ring
Dimensions in mm

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3.9 Collet solutions for DTH’s with internal
coolant supply
For DTH’s with internal coolant supply use:
Sealed ER collets (WTO type 1910…) or Standard ER collets (WTO type 1900…)
in combination with seal washer
(WTO type 2101…)
3.10 Adjusting the projection length of the cutting tool
Turn screw inside the DTH spindle to adjust
the projection length of the cutting tool.
NOTICE
Remove stop screw from spindle when using
QuickFlex®adapter.
3.11 One-hand wrench
Size Item No.
20 107720000
25 107725000
32 107732000
40 107740000
50 107750000
For driven toolholders: to
hold the QuickFlex®spindle
when tightening.

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3.12 Available ER collet nuts for QuickFlex®
Size Item No. e M Recommended
torque [Nm]
Seal washer
ER-20QF 207020000 7.5 M 32 x 1.50 80 210120… 107520020
ER-25QF 207025000 8M 40 x 1.50 110 210125… 107525020
ER-32QF 207032000 8M 50 x 1.50 140 210132… 107532020
Collet nut ERQF
For external and internal coolant supply using seal washers
For collets DIN 6499, ISO 15488
Size Item No. e M Recommended
torque [Nm]
Seal washer
ER-40QF 208040001 9M 62 x 1.50 180 210140… 107540020
ER-50QF 208050001 17 M 68 x 1.50 240 210150… 107550020
Collet nut ERQF-BC
With ball bearing
For external and internal coolant supply using seal washers
For collets DIN 6499, ISO 15488
Collet nut ERQF-A – short
For external and internal coolant supply using sealed collets
For collets DIN 6499, ISO 15488
Size Item No. e M Recommended
torque [Nm]
SW
ER-20QF 202120001 2.4 M 32 x 1.50 75 107525101 107525104 20
ER-25QF 202125001 2.0 M 40 x 1.50 100 107532101 107532104 21
ER-32QF 202132001 2.3 M 50 x 1.50 130 107540101 107540104 24
ER-40QF 202140001 3.0 M 62 x 1.50 150 107540101 107540104 24
Size Item No.
Single parts
Item No. Com-
plete set
d
min.
d
max.
Range per
seal washer
Number
per set
No. included
per set
ER 16 210116…[d*10] 210116000 3.0 10 0.5 14 3.0-10
ER 20 210120…[d*10] 210120000 3.0 13 0.5 20 3.0-13
ER 25 210125…[d*10] 210125000 3.0 16 0.5 26 3.0-16
ER 32 210132…[d*10] 210132000 3.0 20 0.5 34 3.0-20
ER 40 210140…[d*10] 210140000 3.0 26 0.5 46 3.0-26
ER 50 210150…[d*10] 210150000 6.0 25 0.5 11 6, 8, 10, 12,
14, 19, 20, 21,
23, 24, 25
Ordering example: 210116040 suits to ER 16 and shank d = 4.0 - 3.5
Dimensions in mm
Seal washer for collet nuts ERQF, ERQF-BC
For internal coolant supply

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3.13 Turret centerline alignment
Using orientation pin on turret: Using turret surface:
Using eccentric pin on DTH:

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3.14 Duty cycle ratio
NOTICE
Operating the DTH beyond the recommended duty cycle ratio can cause excessive heat
generation and damages to the DTH like bearing failures. DTH body temperature should not
exceed 65°C (149°F) when operating under normal conditions.
3.15 Service interval
DTH life time depends on cutting application and operation conditions.
Wear items such as bearings and seals need to be replaced periodically.
Recommended service interval is
• 12 months under normal conditions in 2 shifts.
• 6 months when operating under 3 shifts or heavy conditions or high RPM.
• 6 months for DTH with internal coolant supply.
Maintenance includes cleaning the inside of the DTH and lubricating the bearings and gears.
Maintenance work must be performed by WTO factory owned service centers or by staff who
are trained by WTO.
Recommended duty cycle ratio
(operating under normal conditions)

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NOTICE
DTH must be cleaned frequently in order to maintain the high quality and accuracy.
Chips, grease, oil, coolant, etc. must be removed after every 24 hours of operation.
Cleaning must be performed only by using a clean rag.
NOTICE
Never use compressed air to clean the DTH.
Compressed air forces chips and coolant through the sealing system causing premature
failure of the DTH.
Clean and check the DTH once per week, rotate spindle several times by hand.
Clean carefully the spindle area when removing the cutting tool.
4 Care and Cleaning