INSTALLATION INSTRUCTIONS VMC Series P3 Vertical Machining Centers

Transcription

1 INSTALLATION INSTRUCTIONS VMC Series P3 Vertical Machining Centers ATTENTION READ THE ENCLOSED INFORMATION BEFORE REMOVING THE MACHINE FROM THE SKID.

2 - NOTICE - Damage resulting from misuse, negligence, or accident is not covered by the Hardinge Machine Warranty. Information in this manual is subject to change without notice. This manual covers the installation and extended storage of Hardinge Series P 3 Vertical Machining Centers equipped with a Fanuc or Siemens control. In no event will Hardinge Inc. be responsible for indirect or consequential damage resulting from the use or application of the information in this manual. Reproduction of this manual in whole or part, without written permission of Hardinge Inc. is prohibited. CONVENTIONS USED IN THIS MANUAL - WARNINGS - Warnings must be followed carefully to avoid the possibility of personal injury and damage to the machine, tooling, or workpiece. - CAUTIONS - Cautions must be followed carefully to avoid the possibility of damage to the machine, tooling, or workpiece. - NOTES - Notes contain supplemental information. i

3 Table of Contents CHAPTER 1 - INSTALLATION INSTRUCTIONS Machine Serial Number CNC Control Serial Number Fanuc Control Siemens Control Hard Disk Option Tool Changer Eye Bracket Machine Footprint VMC600 P 3, 800 P 3, and 1000 P 3 Machining Centers VMC1250 P 3 and 1500 P 3 Machining Centers VMC480 P 3, and 710 P 3 Machining Centers DT480 P 3, 710 P 3 and 300 P 3 Machining Centers Machine Foundation Preparing the Machine Foundation Foundation Requirements Weight Specifications Shipping Weight Machine Weight Setting the Machining Center in Place Mount the Z Axis Drive Motor Cleaning the Machine Grounding the Machine Supplemental Earth Ground System Ground Electrical Power Connection Machine Power Requirements Making the Electrical Connection Checking the Electrical Phase Pneumatic Connection Removing the Shipping Restraints Removing the Spindle Shipping Cradle Removing the Counterweight Rods Removing the Shipping Brackets X and Y Axes Tool Changer Operator Control Panel Precision Leveling the Machining Center Cutting Fluid (Coolant) Water-Based Coolants Coolant Tank Capacity ii

4 Preparing the Coolant System Care and Maintenance Installing the Chip Conveyor Option CHAPTER 2 - EXTENDED STORAGE INSTRUCTIONS Power-Up and Power-Down Procedures Machine Equipped with a Fanuc Control Power-Up Procedure Zero Return (Home) Procedure Power-Down Procedure Machine Equipped with a Siemens Control Power-Up Procedure Power-Down Procedure Spindle Warm-Up Procedures Short Term Spindle Warm-Up Long Term Spindle Warm-Up Machine with Oil-Air Spindle Lubrication Machine with Grease Spindle Lubrication Change the Control Battery Pack (Fanuc Control Only) Apply Rust Inhibitor Clean the Tools and Spindle Support the Spindle/Headstock Clean the Air Filter/Regulator/Lubricator Clean the Heat Exchanger Air Filter Clean the Coolant Tank Assembly and Screens Clean or Replace the Coolant In-Line Filters Grease the Axes Add Oil to the Lubrication Cup Oil Specification Adding Oil to the Lubrication Cup iii

5 - NOTES - iv

6 - NOTES - v

7 CHAPTER 1 - INSTALLATION INSTRUCTIONS MACHINE SERIAL NUMBER The serial number (listed as Mfg.No.) for the VMC600 P 3, VMC800 P 3 and VMC1000 P 3 machines is stamped on plate A, Figure 1.1. The serial number plate is mounted on the power case door. The serial number should be included in all correspondence regarding this machine. Figure Machine Serial Number CNC CONTROL SERIAL NUMBER FANUC CONTROL The CNC control serial number (listed as No.) is located on tag B, Figure 1.2. This tag is located in the power case on the flange above the CPU control master board. The serial number should be included in all correspondence regarding the control. SIEMENS CONTROL Siemens controls have two serial numbers (listed as Unique Copy Number in the Siemens manual). The serial number format is S T-Nnnnnnn. Control serial number tag D, Figure 1.3, is located on the back of the operator s control panel (PCU 50). Drive serial number tag E, Figure 1.4, is located in the power case on the CPU (CCU). These serial numbers should be included in all correspondence regarding the control. 1-1

8 Figure Control Serial Number Tag (Fanuc Control) Figure Control Serial Number Tag (Siemens Control) Figure Drive Serial Number Tag (Siemens Control) HARD DISK OPTION VMC machining centers equipped with the Siemens 810D control are available with an optional hard disk for increased program storage. If this is the initial installation and because the machine still needs to be moved and adjusted, be aware that hard disk C, Figure 1.3, at the back of the operator s control panel, is at the lock or transport position. The hard disk must be set to the Operating position before the control can be activated. Refer to the information on the front of the machine. TOOL CHANGER EYE BRACKET Eye bracket F, Figure 1.5, is located on the top of the machine. Machines equipped with one tool changer will have one Eye bracket. Machines equipped with the optional second tool changer will have two Eye brackets. 1-2

9 - CAUTION - DO NOT use the Eye bracket(s) for lifting the machine. Figure Tool Changer Eye Bracket 1-3

10 MACHINE FOOTPRINT VMC600 P 3, 800 P 3, AND 1000 P 3 MACHINING CENTERS The footprint for VMC600 P 3, 800 P 3, and 1000 P 3 machining centers is shown in Figure 1.6.a. Figure 1.6.a - Machine Base and Foot Locations (VMC600 P 3, 800 P 3, and 1000 P 3 Machines) 1-4

11 VMC1250 P 3, AND 1500 P 3 MACHINING CENTERS The footprint for VMC1250 P 3 and 1500 P 3 machining centers is shown in Figure 1.6.b Figure 1.6.b - Machine Base and Foot Locations (VMC1250 P 3 and 1500 P 3 Machines) 1-5

12 VMC480P 3, 710P 3,AND MACHINING CENTERS DT480P 3, DT710P 3,AND DT300P 3 MACHINING CENTERS The footprint for VMC480P 3, 710P 3, DT300P 3, DT480P 3, and DT710P 3 machining centers is shown in Figure 1.7. Figure Machine Base and Foot Locations (VMC480P 3, 710P 3, DT300P 3, DT480P 3,and DT710P 3 ) 1-6

13 MACHINE FOUNDATION Hardinge Series P 3 Vertical Machining Centers require a solid foundation. Do not locate the machine near equipment that causes vibration. Poor cuts or damage to the control may result from vibration transmitted to the machine. The foundation must be level within.31 inch in 5 feet [7.9 mm in 1.52 m] and be constructed of 3000 psi [207 bar] concrete or better. The legs are at approximately 1 inch [25 mm] height when the machining center is shipped from the factory. The machining center will be set within final precision level specifications, which is within inches per foot [ mm per 305 mm] or within 5 seconds of a degree. The front lip of the coolant guard skirt must be at least 12 inches [305 mm] from the floor to provide sufficient clearance for the coolant tank. PREPARING THE MACHINE FOUNDATION Avoid placing the machining center over floor expansion joints. The soil under the foundation for the machining center must be compacted to a safe bearing capacity of 4 tons per square foot [0.38 MPa]. The foundation must be level within.31 inch in 5 feet [7.9 mm in 1524 mm] and be constructed of 3000 psi [207 bar] concrete or better. Refer to Figure 1.6 or 1.7 to locate the legs in the machining center s base. Use these dimensions to locate the pads shipped with the machine. Verify that the foundation for the machining center meets the following specifications. These foundation specifications cover a broad range of customer applications. If your application is unique, please contact Hardinge engineers to be advised of the acceptable foundation for your specific application. FOUNDATION REQUIREMENTS RECOMMENDED a 6 inch [152 mm] thick concrete floor as large as the machine footprint. The machine s footprint is the overall dimensions (length and width) of the machine base ACCEPTABLE a 4 inch [102 mm] thick concrete floor as large as the machine footprint. The machine s footprint is the overall dimensions (length and width) of the machine base. 1-7

14 WEIGHT SPECIFICATIONS The shipping weight and machine weight for VMC1250 P 3 and 1500 P 3 machining centers are the same because no skid is used for shipment. SHIPPING WEIGHT The shipping weight is the combined weight of the machine, skid, and any additional components on the skid. Machine Model VMC480II, DT480P 3 VMC710II, DT710P 3 DT300P 3 Standard and High Speed Machines High Torque Machines 5798 lb [2630Kg] 5908 lb [2680Kg] 5467 lb [2480Kg] VMC600 P 3 10,030 lb [4550 Kg] 10,263 lb [4655 Kg] VMC800 P 3 10,471 lb [4749 Kg] 10,704 lb [4855 Kg] VMC1000 P 3 10,803 lb [4900 Kg] 11,035 lb [5005 Kg] VMC1250 P 3 19,550 lb [8868 Kg] 19,617 lb [8898 Kg] VMC1500 P 3 20,051 lb [9095 Kg] 20,117 lb [9125 Kg] MACHINE WEIGHT Machine Model Standard and High Speed Machines High Torque Machines DT480P 3, VMC480P lb [2400Kg] DT710P 3, VMC710P lb [2450Kg] DT300P lb [2250Kg] VMC600 P 3 9,524 lb [4320 Kg] 9,756 lb [4425 Kg] VMC800 P 3 9,855 lb [4470 Kg] 10,086 lb [4575 Kg] VMC1000 P 3 10,186 lb [4620 Kg] 10,417 lb [4725 Kg] VMC1250 P 3 19,550 lb [8868 Kg] 19,617 lb [8898 Kg] VMC1500 P 3 20,051 lb [9095 Kg] 20,117 lb [9125 Kg] 1-8

15 LZ.HAND-1 HARDINGE Lift the machines carefully and at proper position, which lifting tags on. Lifting point. 1-9

16 SETTING THE MACHINING CENTER IN PLACE VMC1250 P 3 and 1500 P 3 machining centers are not shipped on a skid. 1. Leave the machine on the shipping skid and move it to the installation site. 2. Remove the coolant tanks, ground rod, motor, and any parts boxes from the skid. 3. Be careful of the rear of the machine, where the coolant pumps are mounted, when the machine is lifted from the skid and moved in place. 4. Unthread the legs that secure the machining center to the skid. Remove the blocking from around the machine. VMC600 P 3, 800 P 3, and 1000 P 3 machining centers are equipped with four legs on the base and two legs on the tower at the rear of the machine. VMC1250 P 3 and 1500 P 3 machining centers are equipped with six legs on the base and three legs on the tower at the rear of the machine. Each leg is adjustable and has a locking Figure Machine Legs Under Table nut. (VMC1000 P 3 Machine Shown) Refer to G, Figures 1.8, 1.9, and Loosen the locking nut and thread the nut all the way up to the leg adjustment hex. Figure Tower Support Legs at Rear of Machine (VMC1000 P 3 Machine Figure Tower Support Legs at Rear of Machine (VMC1500 P 3 Machine - WARNING - DO NOT use the Eye bracket(s) on top of the machine to lift the machine. Raise the machining center high enough to make certain that the legs, frame, and guards clear the shipping skid. The forklift truck will require fork extensions and must have the capacity to 1-10

17 safely lift the specified weight at 48 inches [1.22m] from the truck. Refer to the weight specifications on page Use a forklift truck or rigging to lift the machining center from the skid. Lift it slowly while making certain that it remains balanced during alignment over the installation site. 7. Wipe the floor clean and place the pads supplied with the machine, under each of the machine legs. Refer to Figure 1.6a, 1.6b,or Carefully and slowly lower the machining center in place on the pads. 9. Verify that each leg is centered over its pad and that the legs on the machine base make contact and are supported in their pads. Adjust the legs as necessary. The coarse level specification for the machining center is when its machining table is level within half a division on a inch per foot [0.127 mm per 305 mm] per division improved level along both the X and Y axes. However, because the shipping cradle for the head is still mounted, place a bubble indicator or other leveling device on the machine table. 10. Place a bubble indicator or other leveling device on the machine table. Coarse level the machining center within specification by adjusting the following legs: DT480P 3, 710 P 3, and 300 P 3 machines: 1, 2, 3, 4 VMC480P 3 and 710 P 3 machines: 1, 2, 3, VMC600 P 3, 800II, and 1000 P 3 machines: 1, 2, 3, 4 VMC1250 P 3 and 1500 P 3 machines: 1, 2, 3, 4, 5, 6 Precision level the machining center after mounting the Z axis drive motor and powering up the machine. MOUNTING THE Z AXIS DRIVE MOTOR When mounting the Z axis drive motor, it may be more convenient to remove the Z axis motor guard. VMC1250 P 3 and 1500 P 3 machining centers are not equipped with Z axis counterweights. 1. Align scribed lines on coupling H, Figure 1.11 or 1.12, and fasten the coupling mounting screws. 2. Put drive motor electrical connection fittings toward the rear of the machine; align the mounting holes on the motor flange, and put the mounting screws in place. 3. Tighten the motor mounting screws to 70 lb-ft [95 N m] torque. 1-11

18 4. Connect the motor cables and thread the knurled nut onto the fittings to secure the electrical connections. 5. Align the holes and mount the Z-axis cable carrier to the bolt pad on the column. When the wooden shipping cradle is in place, there is slack in the counterweight chains. After the machine is powered up, the spindle (Z axis) can be lowered to increase the slack in the chains or be raised to remove the shipping cradle. 6. Verify that the counterweight chains are aligned on both sets of pulleys. If the chain is off a pulley, carefully maneuver the chain until it is aligned on the pulley before starting a machine cycle. 7. Mount the Z axis motor guard, if necessary. Figure Z Axis Motor Coupling and Counterweight Chains (VMC600 P 3, 800 P 3, & 1000 P 3 Machines) Figure Z Axis Motor Coupling (VMC1250 P 3 & 1500 P 3 Machines) (DT480P 3, 710 P 3, and 300 P 3 machines) (VMC480P 3 and 710 P 3 machines) CLEANING THE MACHINE - CAUTION - Do not use compressed air to clean the machining center. Air pressure forces dirt and other foreign matter past the seals and covers into the slides, ball screws, and bearings. This causes additional wear and will reduce the life and accuracy of the center. After the machining center has been properly located and leveled, remove all tape and other packing material. Also, remove the shipping grease, oil, and dirt accumulated in transit. USE A CLOTH OR BRUSH WITH A GOOD GRADE OF OIL BASE GREASE SOLVENT TO CLEAN THE MACHINING CENTER. Then, apply a coat of light oil to 1-12

19 lubricate and protect items such as the table, spindle, tool changer, etc.. Use Clorox 409 cleaner to clean the coolant guard windows. Do not use benzene, leaded gasoline, acetone or chlorinated solvents. GROUNDING THE MACHINE - WARNING - Improper grounding of any Hardinge Machining Center could result in damage to the control and severe electrical shock to personnel in the event of an electrical fault. To properly ground the machining center an Earth Ground and a System Ground are required. The minimum ground wire size for all machining centers is #8 AWG. If a supplemental earth ground is to be installed, the customer must supply and install the ground rod, ground rod clamp, and ground conductor according to all applicable electrical codes. All electrical components should have the same reference base to assure that voltage potential, in the event of circuit shorts or other malfunctions, is limited. This is accomplished by having a neutral reference wire common to all voltage sources within the system. Since safety requirements vary with locality, consult local codes that will take precedence over the following guidelines. SUPPLEMENTAL EARTH GROUND Earth ground connections in their order of effectiveness are as follows: 1. Effectiveness of continuous water pipe when properly buried will depend on conditions of soil. When installed below permanent moisture level, the impedance of this type of ground is typically below 3 OHMS. 2. Effectiveness of man-made, driven or buried electrodes will depend on condition of soil. When installed below permanent moisture level, the impedance of this type of ground is typically below 5 OHMS. 3. Other available electrodes, such as metal frames of buildings or metal well castings must be well chosen, since they are substantially below 25 OHMS, but exceed 5 OHMS. Ground connections, wires, and electrodes should not exceed 5 OHMS, as measured from the equipment ground stud through the primary electrode through earth, to another independent electrode separated by 20 feet of earth. Additional grounding should be installed when necessary, to insure that the impedance does not exceed 5 OHMS. The ohmic measurement should be made in terms of a voltage-current relation, such as the 1-13

20 current of a 120 volt, 100 watt lamp bulb. The ground conductor connecting the ground stud to the ground rod should be 8 AWG or larger. When longer lengths are required, use a larger size cable, so that the resistance of the cable is less than OHMS. The ground conductor must be rated to carry peak short-circuited current for maximum time duration without degrading the ground system. The ground conductor must withstand any mechanical abuse to which it may be exposed. To establish an earth ground, the ground rod must be driven into the ground to a depth of eight feet. If the bottom is encountered at a depth of less than four feet, the electrode may be buried horizontally in a trench. SYSTEM GROUND A proper grounding arrangement prevents equipment damage and personal injury caused by an electrical fault such as a short circuit. To accomplish this, the grounding setup must assure that all voltages have the same reference base; and that, in the event of an electrical fault, the voltage potential is limited. The National Electrical Code recommends that: Effective Grounding Path. The path to ground from circuits, equipment, and metal enclosures for conductors shall (1) be permanent and electrically continuous, (2) have capacity to conduct safely any fault current likely to be imposed on it, and (3) have sufficiently low impedance to limit the voltage to ground and to facilitate the operation of the circuit protective devices. The earth shall not be used as the sole equipment grounding conductor.1 All electrical circuits and all non-current carrying metal parts of the control and the machine tool are interconnected by a series of ground wires attached to the ground bar located in the bottom of the control case. 1 National Fire Protection Association, National Electrical Code Handbook 1996, Fifth Edition, Section ELECTRICAL POWER CONNECTION Due to the variation of local electrical codes, Hardinge recommends that the local utility supply company be consulted to determine exact service and wiring requirements for your area. MACHINE POWER REQUIREMENTS The following full load amp (FLA) requirements are at 30 minute rating. Machine Model Control Type Full Load Amp Rating 1-14

21 Machine Model Control Type Full Load Amp Rating VMC480P 3 and 710 P 3 DT 300 P 3, 480P 3, and 710 P 3 Fanuc 59 Amps VMC600 P 3, 800 P 3, 1000P 3 Fanuc 67 Amps Siemens 35 Amps VMC1250 P 3, 1500 P 3 Fanuc 123 Amps Siemens 58 Amps MAKING THE ELECTRICAL CONNECTION - WARNING - Make certain that the main disconnect switch is in the OFF position when working in the power case. 1. Make certain that the power source to the electric cable that leads to the machine is turned OFF and locked out. 2. Open the power case door. 3. If main disconnect switch I, Figure 1.13, has been removed for shipment, find it in the bottom of the power case and mount it, with cutout J as shown, on the switch bracket. 4. Turn the disconnect switch to OFF position. 5. Make certain that the line side (upper side) of the disconnect switch and the Figure Main Disconnect ground stud are set to have the power source and ground line connected. 6. Route the power cable into the bottom of the power case and far enough to easily reach the switch connections and the ground stud next to them. Use a cable clamp to secure the cable at the entrance. 7. Prepare the power cable wires to be fastened to the disconnect switch. If the switch requires that the wires have lugs, make certain that the lugs are suitable for the wire gauge. The ground connection must be an AWG #8 or larger cable. 8. Connect the ground wire and power leads. 9. Close and lock the power case door. CHECKING THE ELECTRICAL PHASE Turn only main disconnect switch F, Figure 1.13, ON and check the spindle drive motor fan on top of the machine by comparing the motor fan direction with the directional arrow on the fan cover. The electrical phase is correct if the direction of the fan matches the arrow. 1-15

22 When the fan direction does not match the arrow, the electrical phase is wrong and the incoming wiring at the main disconnect switch must be changed. CHANGING THE ELECTRICAL PHASE 1. Turn the main disconnect switch OFF. 2. Turn OFF the power source to the incoming power cable and lock out the switch. 3. Open the power case door. 4. Disconnect and exchange any two wires on the line side of the disconnect switch. 5. Close and lock the power case door. 6. Unlock the incoming power switch and turn the power source ON. 7. Turn just the main disconnect switch ON. 8. Verify the electrical phase is correct. PNEUMATIC CONNECTION The pneumatic filter/regulator/lubricator, shown in Figure 1.14, is mounted at the rear of the machine center, on the side of the tower. Supply an air line with proper fittings to the machining center. Factory air to the machining center goes through the filter/regulator to control the air supply for the machine. A heavy-duty air dryer may have to be added in the air line if the factory air has excessive moisture. The air volume requirement for a machining center is approximately 16 scfm [453 lm]. Some machines with air options may require a larger air volume. Machining centers equipped with the high-speed spindle require 23 scfm [650 lm] at 75 psi [5.2 bars]. The incoming air line should have a minimum inside diameter of 3/8 inch [9.5 mm]. A larger diameter hose may have to be installed if the air line is especially long. Connect the air line to the machine. Do not turn the air source ON. Check the incoming air line connection, turn the air valve ON, and set the regulator at a consistent pressure from 59 to 73 psi [4.1 to 5 bar]. The air pressure switch is preset at 58.8 psi [4 bar]. If the air pressure falls below this setting, an alarm message appears on the control display screen and the control stays in Emergency Stop. Figure Air Filter/Regulator and Air Lubricator 1-16

23 REMOVING THE SHIPPING RESTRAINTS VMC1250II and 1500II machining centers are not equipped with Z axis counterweights. The shipping brackets and counterweight rods must be removed before the axes can be moved and the machine precision leveled. Remove all the fixtures listed below before precision leveling the machine. 1. Remove the wooden spindle shipping cradle from under the headstock. 2. Remove the counterweight rods (steel rods) from the tower. 3. Remove the X and Y axis shipping bracket(s) holding the work table. Some machines have two brackets near the front of the table and other machines have one shipping bracket centered on the tower at the rear of the table. 4. Remove the shipping bracket(s) from the tool changer(s). 5. Remove the operator control panel shipping bracket. 6. Remove the bubble wrap and free the operator control pendant. REMOVING THE SPINDLE SHIPPING CRADLE 1. Make certain that the machine is ON and bring the control out of Emergency Stop. If necessary, free the main door handles but do not open the doors at this time. Keep shipping cradle K, Figure 1.15, for future use to support the headstock when moving the machining center or to block the spindle whenever working on the Z axis. 2. Make certain that the control is in Jog mode. 3. Press the +Z push button to raise the spindle enough to release the cradle. 4. Open the doors and carefully remove the shipping cradle. Figure Spindle Support Cradle 1-17

24 REMOVING THE COUNTERWEIGHT RODS -NOTE - The rods are removed from the right side of the tower as viewed from the rear. 5. Unthread the screws fastening washers L, Figure 1.16, that secure the counterweight rods. Remove the screws and the washers drop from the slots in the rods. 6. Press the -Z push button to slowly lower the spindle just enough to align the openings closer and loosen the rods. 7. Rattle the rods to shake them loose; then, pull the rods straight out from the tower. 8. Put the washers on the screws and thread the screws back into their holes. 9. Press the +Z push button to move the Z axis straight up. Figure Counterweight Support Rods REMOVING THE SHIPPING BRACKETS X and Y Axes Some machines have a separate shipping bracket for the X and Y axes. Both brackets are located near the front of the table, as shown in Figure Other machines have one shipping bracket centered on the tower at the rear of the table, as shown in Figure If the machine has two shipping brackets at the front of the table, Figure 1.17, remove the brackets as follows: - CAUTION - DO NOT thread any of the screws back into their holes after removing the shipping brackets. 1. Unthread the screws and remove X axis shipping bracket M. 1-18

25 2. Unthread the screws and remove Y axis shipping bracket N. If the machine has just one axes shipping bracket O, Figure 1.18, remove the brackets as follows: 1. Reach up under the lower Z axis way cover (front of tower) and unthread two screws that fasten the bracket 2. Unthread two screws through the bracket into the back of the table and remove the bracket. Figure Separate X Axis and Y Axis Shipping Brackets Figure One X and Y Axes Shipping Bracket Figure Carousel (Tool Magazine) Shipping Bracket Figure Operator Control Panel Shipping Bracket and Pendant Tool Changer 1. Unlatch and pull open the left side access door; unthread the screws and remove tool carousel (changer) shipping bracket P, Figure If the machine has the optional second tool changer to the right side of the spindle, unlatch and pull open the right side access door to unthread the screws and remove its shipping bracket. 2. Close and latch the side access door(s). 1-19

26 Operator Control Panel 1. At the front of the machine near the operator control panel, remove the screws and shipping bracket Q, Figure 1.20, to allow the control panel to pivot. Thread the screws back into the pendant support and tighten them. Keep shipping bracket Q, for future use to secure the operator control panel when moving the machining center. 2. Below the operator control panel, remove the bubble wrap from operator control pendant R and remove the fasteners used to secure the pendant during shipping. 3. Pull the operator control panel out and rotate it to various positions. PRECISION LEVELING THE MACHINING CENTER 1. Rough fit the coolant tank under the machining center to assure clearance before precision leveling the center. If there is not enough space for the coolant tank: A) Raise the machine until there is clearance by adjusting the following legs: DT300 P 3, 480P 3, and 710 P 3 machines: 1, 2, 3, 4 VMC480P 3 and 710 P 3 machines: 1, 2, 3, VMC600 P 3, 800II, and 1000 P 3 machines: 1, 2, 3, 4 VMC1250 P 3 and 1500 P 3 machines: 1, 2, 3, 4, 5, 6 B) Coarse level the machining center again. 2. Activate Jog mode. 3. Use the Z axis push buttons to position the spindle face 10 inches [254 mm] above the table. 4. Use the X and Y axis push buttons to center the table in both axes on the spindle. In general; raising the base is preferred when adjusting the legs during leveling of the machine. The coarse level specification of machining center is when a inch per foot [0.127mm per 305 mm] per division improved level is placed on the machining table and it indicates level within half a division along both the X and Y axes. 5. Wipe the machine table and improved level(s) clean. 6. Place the improved level(s) on the machine table as shown in Figure Figure Levels on the Machining Table 1-20

27 Make certain hat the machining center is still within coarse level specification. If necessary, adjust the legs while maintaining clearance between the base and the floor for the coolant tank. A master precision level is a level that has divisions that indicate at least inch per foot [ mm per 305 mm]. When precision leveling the machining center, make certain that the front of the machine (+Y direction) is low, but still within specification. The secondary precision level specification is when the machine table is within two divisions on the master precision level along both axes. The final precision level specification is when the machine table is level within half of one division on the master precision level along both axes. This specification is within inch per foot [ mm per 305 mm] or 5 seconds. 7. Wipe the machine table and master precision level clean. Place the master precision level(s) on the machine table. 8. Adjust the legs until the precision level is within the secondary precision level specification along both the X and Y axes. This specification is within inch per foot [ mm per 305 mm]. 9. Thread the tower legs down until they just touch the floor. 10. Tighten the tower legs while keeping the level within the secondary precision leveling specification. 11. Adjust the legs until the X and Y axes are both within the final precision level specification. Refer to the note at the top of this page for the specification. Movement on the Y axis will start at about a half turn after foot contact has been made with the floor. 12. Check each leg to make certain that the foot is in full contact with the floor. Physically try to move the foot. If large parts are the primary function on this machine, check the precision level specification throughout the full travel of the table. Adjust the legs as necessary. 13. When the machining table is level within the final precision level specification, tighten the locking nuts. 14. Check the final precision level specification again. If the machining center is not level within its specification, loosen the locking nut(s) and repeat the directions beginning with step

28 CUTTING FLUID (COOLANT) VMC Series II machining centers are designed using the latest technology and highest quality materials available. Due to the ever increasing number of cutting fluid (coolant) selections available, it is impossible to test material compatibility with each and every coolant. Refer to the maintenance manual (M-379) for information regarding the coolant facilities on this machine. The two most popular types of cutting fluids are cutting oils and water-based coolants. Be prepared to fill the tank assembly with the approved coolant to the FULL line of the sight gauge after the Hardinge service engineer assembles the coolant tank, mounts the coolant pump, and has the assembly in place. - CAUTION - Whenever cutting fluids are used, it is essential to follow the manufacturer s recommendations on the selection and maintenance for that particular fluid. WATER-BASED COOLANTS Water-based coolants are a cutting fluid which, when improperly specified or maintained, can affect the life of a machine and the quality of the parts made on it. Water-based coolants are designed to suppress rusting, enhance cutting, increase tool life, promote heat dissipation, and be economical to use. Some water-based coolants may cause machine corrosion problems and be incompatible with machine components, especially if the fluid is not maintained correctly. Poorly maintained coolants may result in rancidity, poor tool life, staining, rusting, and foaming, which affect machine performance and may cause health problems such as dermatitis. Water-based coolants must be correctly specified according to the machined materials and ensure compatibility with the machine s components. Refer to the list of common materials used in the manufacture of Hardinge machines which follows this section. It is extremely critical to follow the coolant manufacturer s recommendations when using a water- based coolant. Maintaining coolants per the manufacture s recommendations will increase the machine s useful life and will minimize corrosion, rusting, staining, etc., and health problems such as dermatitis. At a minimum, the coolant maintenance should include daily checks and correction of coolant concentration, a measure of coolant ph, and removal of any tramp oil from the machine sump. COOLANT TANK CAPACITY Approximate coolant tank capacities are shown in the following chart: Machine Models Coolant Tank Capacity VMC480P 3 and 710 P 3 machines 27 gallons [100 liters] DT300 P3, 480P3, and 710 P3 machines VMC600II, 800II, and 1000II Machines 40 gallons [150 liters] 1-22

29 VMC1250II and 1500II Machines 80 gallons [300 liters] PREPARING THE COOLANT SYSTEM The following procedure is used if the machining center has been moved after the initial start-up visit and the coolant tanks have been emptied. 1. Roll coolant tank S, Figure 1.22, into the opening under the front of the machining center. 2. Adjust the skirting and check inside the work area to see that coolant will drain back into the coolant tank chip pan. 3. Install the coolant hose and tighten the clamps. 4. Pour the coolant directly into the chip pan of the coolant tank. Fill the tank with the approved coolant to the FULL line of the sight gauge. Always check for cutting fluid leaks and correct them as necessary. Make any adjustments before powering up the machine and turning the coolant ON. A properly selected and maintained coolant, either oil or water based, will ensure the best performance from the coolant and machining center. Figure Coolant Tank CARE AND MAINTENANCE A daily check of the concentration and ph will help keep the coolant at its optimum performance level. Limit the growth of anaerobic bacteria which cause the rancid odors and feed on the additives in the coolants. Make-up coolant should be added when needed and according to the manufacturer s recommendation. This make-up coolant is necessary to provide additional fresh coolant which contains the essential additives required to keep the coolant performing properly. 1-23

30 INSTALLING THE CHIP CONVEYOR OPTION 1. Move the coolant tank near the front of the machine. 2. Lift out the chip trays, chip pan and filters (screens) from the coolant tank. 3. Set the chip conveyor into the coolant tank. 4. If the electrical cable is not plugged into the connector on the chip conveyor, plug one end of the cable into the chip conveyor connector. 5. Roll the coolant tank with chip conveyor into the opening under the front of the machine. Refer to Figure Attach the coolant hose to the coolant tank. 7. Plug the other end of the chip conveyor cable into the connector located on the bottom of the power case. 8. DT300 P 3, 480P 3, 710 P 3, VMC480P 3 and 710 P 3 machines do not offer chip conveyor. Figure Machine with Chip Conveyor 1-24

31 - NOTES

32 CHAPTER 2 - EXTENDED STORAGE INSTRUCTIONS - CAUTION - These recommended procedures should be used when the machining center will sit idle or be stored for a period of one or more months. Attach this document, or a copy of this document, to the machine being stored. Refer to the maintenance manual for additional information. POWER-UP AND POWER-DOWN PROCEDURES MACHINE EQUIPPED WITH A FANUC CONTROL Power-Up Procedure Information relating to machines equipped with a Siemens control begins on page 2-4. It is important that the power-up procedure is followed as described to ensure safe, accurate, and repeatable machine operation. 1. Turn main disconnect switch A, Figure 2.1, ON. 2. At the rear of the machine, slide valve E, Figure 2.2, upward to turn the machine air ON. 3. Check the air filter bowl; it drains automatically but may need to be cleaned. 4. Check the coolant level. Add coolant, if necessary. Figure Main Disconnect Switch Figure Air Filter/Regulator/Lubricator - CAUTION - When pressing the Control ON push button, DO NOT press any other push buttons or keys until the position or alarm screen is displayed. Some push buttons and keys are used for control maintenance or special operation commands. 2-1

33 5. Press the Control ON push button and wait until the control display screen is ON. 6. Pull the Emergency Stop push button OUT to release the Emergency Stop condition. 7. If necessary, release the Emergency Stop push button that is located next to the manual index push buttons for the tool changer magazine(s). 8. Be sure that the coolant guard doors are closed. 9. Zero Return (Reference Home) the machine axes, as outlined below. High-performance high-speed machines require additional spindle and oil-air start up procedures. Refer to Spindle Warm-Up Procedures, on page 2-6. Zero Return (Home) Procedure - CAUTION - When zeroing the axes with the Zero Return (Reference Home) procedure, be certain that no interference exists between the machine table, workpiece on the table, and spindle tooling. DO NOT attempt to Home the machine axes if the tool changer magazine(s) is (are) not at the Home position. If necessary, switch to Jog mode to move the axes to a safe location for axes motion; then, switch back to Zero Return mode to perform the Homing procedure. 1. Verify that the tool magazine is at the Home (retracted) position. If there is a second tool magazine, verify that it is at Home also. 2. Select Jog mode. 3. If necessary, move the axes to a safe location for axes motion. 4. Set the Jog Feedrate switch to the desired feedrate. Each axis must travel continuously at least one full inch [25.4 mm] before it returns to Home. The Zero Return (Home) position is not the same as the tool change position. 5. Use the -Z push button to jog the spindle at least 1 inch [25.4mm] toward (minus, downward) the table. 6. Use the +X push button to jog the table approximately 1 inch [25.4mm] in the plus direction. 7. Use the -Y push button to jog the table approximately 1 inch [25.4mm] in the minus direction. 8. Select Zero Return mode. 9. Press the +Z push button; the spindle will move to the spindle HOME position. 2-2

34 10. Press the -X push button; the table will move to the X HOME position. 11. Press the +Y push button; the table will move to the Y HOME position. 12. If the machine is equipped with an optional rotary table, press the +B push button to index the rotary table to the Home position. Power-Down Procedure - CAUTION - DO NOT power down the machine while Edit mode is active. Powering down the machine while Edit mode is active will result in the loss of all macro programs and machine parameters. If data is lost, all macro programs and parameters must be loaded into the control memory from the backup disc supplied with the machine. 1. Be certain that Cycle Start is not active. The Cycle Start push button light will be OFF. 2. Be sure the program has been completed and that the spindle and slides are stationary. 3. Press the Emergency Stop push button. 4. Press the Control OFF push button. - CAUTION - If the machine is a high-performance high-speed machine, make certain that the Labyrinth air seal air pressure C, Figure 2.3, is left ON for 15 minutes after the spindle has stopped to allow the spindle interior to cool to room temperature without drawing in coolant and contaminants. 5. At the rear of the machine, slide valve B, Figure 2.2, downward to turn the machine air OFF. 6. Turn main disconnect switch A, Figure 2.1, OFF. MACHINE EQUIPPED WITH A SIEMENS CONTROL Information relating to machines equipped with a Fanuc control begins on page 2-1. Power-Up Procedure 1. If equipped, verify the optional hard disk at the back of the operator s control panel is set to the Operating position as follows: A) Swing the control panel out to gain access to the back of the panel. B) Unthread the screws to lift off the cover at the back of the panel. C) Rotate the hard disk to the Operating position (counterclockwise to vertical). D) Install the cover before trying to power up the machine. The guard door must be closed when jogging an axis or Homing the machine axes. 2-3

35 2. Close the main guard door. 3. Turn main disconnect switch A, Figure 2.1, ON. 4. At the rear of the machine, slide valve E, Figure 2.2, upward to turn the machine air ON. 5. Check the air filter bowl; it drains automatically but may need to be cleaned. The machine will power up in the ShopMill mode. Wait for alarm 3000 Emergency Stop to be displayed before proceeding to step Pull the Emergency Stop push button out and release it to allow the machine to power up. 7. On the operator control panel, press the Reset push button to clear the Emergency Stop condition. The Feed Stop indicator light will be ON when Feed Stop is active. 8. Press the Feed Stop push button to deactivate the Feed Stop function. 9. Press the Axis Home push button to Zero Return all the axes at the same time. The Axis Home indicator light will start flashing and the X, Y and Z axes will automatically Home (go to the Home position for each axis). 10. Press the Manual push button to put the machine in ShopMill manual mode. High-performance high-speed machines require additional spindle and oil-air start up procedures. Refer to Spindle Warm-Up Procedures, on page 2-6. Power-Down Procedure 1. Press the Emergency Stop push button. 2. Turn main disconnect switch A, Figure 2.1, OFF. - CAUTION - If the machine is a high-performance high-speed machine, make certain that the Labyrinth air seal air pressure F, Figure 2.3, is left ON for 15 minutes after the spindle has stopped to allow the spindle interior to cool to room temperature without drawing in coolant and contaminants. 3. Pull main air valve B, Figure 2.2, downward to turn the machine air supply OFF. SPINDLE WARM-UP PROCEDURES - CAUTION - Failure to properly warm up the spindle can result in spindle failure. 2-4

36 Never run the spindle over 50 percent of the maximum rated speed without a tool holder installed in the spindle. Spindle warm-up is only required on High Speed machining centers. High Speed machining centers are equipped with an automatic timer that will inhibit spindle operation for 5 minutes after the machining center has been powered up. The purpose is to ensure proper lubrication of the spindle bearings. Perform the appropriate spindle warm-up after the 5 minute period has expired. High Speed machining centers equipped with a 12,000 RPM spindle are available with either grease lubrication or oil-air lubricator F, Figure On machining centers equipped with oil/air spindle lubrication, make certain that oil-air lubricator F, Figure 2.3, is ON. Allow 5 minutes BEFORE proceeding to step On machining centers equipped with oil/air spindle lubrication, turn spindle labyrinth air seal pressure valve G ON. The recommended pressure setting is 7.4 psi [0.5 bar]. 3. Perform the appropriate spindle warm-up, depending on how long the machining center has been idle. SHORT TERM SPINDLE WARM-UP - CAUTION - Short term spindle warm-up should only be used if the machining center has been idle LESS than 2 weeks. Refer to Long Term Spindle Warm-Up if the machine has been idle 2 weeks or more. Use Manual Data Input mode to run the spindle at 25 percent of the maximum spindle speed for 15 minutes. Once the spindle warm-up is completed, the machine is ready for operation. Figure 2.3- High-Speed Spindle Lubrication System - Air and Oil LONG TERM SPINDLE WARM-UP Use the appropriate procedure in this section if the machine has been idle 2 weeks or more. 2-5

37 Machine with Oil-Air Spindle Lubrication Use Manual Data Input mode to run the spindle at 25 percent of the maximum spindle speed for 30 minutes; then, 50 percent of the maximum spindle speed for 60 minutes. Once the spindle warm-up is completed, the machine is ready for operation. Machine with Grease Spindle Lubrication Use Manual Data Input mode to run the spindle at 25 percent of the maximum spindle speed for 20 minutes; then, 50 percent of the maximum spindle speed for 30 minutes. Once the spindle warm-up is completed, the machine is ready for operation. - CAUTION - Battery replacement must be done with the control turned ON. It is possible that parameters, programs, macros, and offsets will be lost if the power is OFF and the batteries are removed. 2. Check the age of the batteries and replace them if necessary. Fresh batteries must be installed at least once a year. - NOTES - The control battery unit supplies power to maintain the control memory when the control is not ON. The control unit contains three standard D sized batteries. CHANGE THE CONTROL BATTERY PACK (Fanuc Control Only) - CAUTION - A fresh battery pack must be installed at least once a year. Failure to perform this maintenance will result in the loss of control information. Battery Specifications Manufacturer: Sanyo Battery Number CR17450SE-R Voltage Rating: 3 volt Battery Type: Lithium 1. Power up the machine. Refer to the power-up procedure beginning on page WARNING - High voltage AC will be present in the power case when the main disconnect switch is ON. 2. Turn interlock bypass H, Figure 2.4, as indicated to allow the power case door to be opened with the power ON. 2-6

38 3. Open the power case door. - WARNING - Hold the battery cover by the top and bottom and squeeze the cover while pulling it off. 4. Remove battery cover I, Figure 2.5. Figure Door Interlock Bypass Figure CNC Control Unit 5. Verify the replacement battery pack matches the battery pack being removed. 6. Disconnect the old battery pack from receptacle J, Figure Connect the new battery pack. 8. Install the battery pack and cover. 9. Close and secure the power case door. 10. Properly dispose of the old battery pack. Figure Control Battery Pack 2-7

39 APPLY RUST INHIBITOR 1. Move the Y axis as far as possible in the minus ( - ) direction and, then, the X axis as far as possible in the plus ( + ) direction. 2. On the slide with the most space, remove the way cover screws and slide the way covers back to expose the ball screws and linear guide rails. 3. Use a lint-free cloth to wipe the ball screws and linear guide rails clean. 4. Apply a rust inhibitor to the ball screws and linear guide rails. 5. Reposition the way covers, install and tighten the way cover screws. 6. Return both axes to their Home position. 7. On the other sides of the table, remove the way cover screws and slide the way covers back to expose the ball screws and linear guide rails. 8. Use a lint-free cloth to wipe the ball screws and linear guide rails clean. 9. Apply a rust inhibitor to the ball screws and linear guide rails. 10. Reposition the way covers and install the way cover screws. 11. Clean the inside of the machine. Apply rust inhibitor to all exposed metal surfaces. - CAUTION - Protect the machine table surface by covering it with a piece of plywood or thick cardboard when loading or unloading tool holders in the spindle. CLEAN THE TOOLS AND SPINDLE 1. Open the main coolant guard door if necessary. - WARNING - A cutting tool could cause personal injury. DO NOT attempt to grasp the tool and tool holder by the cutting tool. Be sure to have a firm grip on the tool holder. 2. Remove the tool holder and tool by grasping the tool holder with one hand and pressing the Tool Release push button mounted on the headstock with the other hand. 3. Wipe the spindle and spindle nose clean with a lint-free cloth. Apply rust inhibitor to thespindle. 4. Clean the tool holder and apply rust inhibitor. 5. Manually cycle the tool magazine and clean it. 2-8

40 SUPPORT THE SPINDLE/HEADSTOCK 1. Center the machine table under spindle. 2. Use the Tee bolts in the table and mount spindle shipping cradle K, Figure 2.7, to the table. 3. Make certain that the % Feedrate Override switch is set between 20% and 40%. 4. Press -Z push button until the spindle is close but not touching the cradle. 5. Activate MPG mode. Watch the Load Meter while lowering the spindle/headstock onto the shipping cradle. 6. Align the spindle nose on the cradle and use the MPG (manual pulse generator) to ease the spindle/headstock into the cradle. Stop MPG motion when the Load Meter approaches the 0 (zero) load reading. Figure Spindle Shipping Cradle CLEAN THE AIR FILTER/REGULATOR/LUBRICATOR 1. Make certain that the machine is powered down and that the air lock-out valve is OFF or disconnected. 2. Twist ring C, Figure 2.2, above the outer shell on the filter/regulator counterclockwise to release the shell and bowl from the head. Drain any water and contaminants from the bottom of the bowl. 3. Wipe the bowl clean with a lint-free cloth and check the O-ring for damage. Replace the O-ring and/or bowl if necessary. 4. Clean or replace the filter as necessary. To release the filter, unscrew the nylon fixture. Thread the new filter on the nipple until it is tight. 5. Mount the bowl on the head as follows: A) Put the plastic bowl into the shell. B) Align the bowl in the head and press the shell up into place. Rotate the ring on the outer shell clockwise until it latches to seat the O-ring. 2-9

41 C) Pull down on the bowl to confirm that the bowl is in place. 6. Remove screw D, Figure 2.2, and fill the lubricator with the appropriate oil, as listed below. Thread the screw on and tighten it. OIL CHARACTERISTICS Viscosity : ISO VG32 Viscosity index: above 95 Anti-oxidation, Anti-rust, Good Stability RECOMMENDED OILS CPC Circulation Oil R32 Mobil D.T.E. Heavy Medium Esso Auto A68 Shell Turbo Oil T68 Daphne Super Multi Oil 68 CLEAN THE HEAT EXCHANGER AIR FILTER 1. Power down the machine. 2. Clean power case heat exchanger air filter B, Figure 2.1, as follows: A) Use the tab on the filter to lift the air filter up, slide the bottom out and pull it down to remove the air filter from its frame. B) Wash the air filter clean in detergent and water. Blow it out with compressed air and allow it to air dry. C) Put the filter, with tab down, up into the top of its frame, press it in and drop it into the bottom of the frame. 3. Power up the machine. CLEAN THE COOLANT TANK ASSEMBLY AND SCREENS - CAUTION - Be sure to remove and drain the coolant pump along with the rest of the coolant system. Failure to drain the coolant pump could result in damage to the pump if the temperature in the storage area goes below 32 F [0 C]. 1. Make certain that the machine is powered down. 2. Allow the coolant to drain back into the coolant tank assembly. 3. Loosen the clamp and unthread the coolant hoses from the coolant pumps. 4. Blow coolant from the hoses and coolant pump as follows: A) Fasten an air line to the coolant hose. B) Turn the air ON and set the pressure near 80 psi for 2 minutes to blow coolant from the coolant hoses. Turn the air OFF. C) Unthread the plug on the elbow fitting near the coolant pump or if there is a coolant 2-10

42 plug in the bottom of the pump, remove it. Wait 1 minute to allow any coolant to drain back. D) Turn the air ON again for 15 to 20 seconds to remove any coolant that may have settled. Turn the air OFF. E) Put pipe sealant on the plug and thread it into the elbow or coolant pump tight. F) Unfasten the air line from the coolant hose. - WARNING - Wear protection and be careful when removing coolant, metal chips, and shavings from the tank assembly. Move the coolant tank assembly from under the machining center if it can be moved without force. The weight of the coolant and chips may prohibit the coolant tank assembly from being moved at this time. 5. Pump the coolant from the coolant tank assembly or unthread the pipe plugs on both sides of the coolant tank to drain the coolant. - WARNING - Use a rake and suitable container to remove metal chips and shavings from the chip trays. Injury may result from attempting to remove chips without a rake. Dispose of the chips and shavings in an environmentally safe manner. 6. Rake the chips into a suitable container and dispose of them properly. 7. Roll the coolant tank assembly from under machining center. 8. Lift the screen cover from the left tank and remove the plate covering the screen filter in the right tank. 9. Remove any coolant still in the tanks and wipe them clean. 10. Be aware of how the filter weld assembly is mounted in the tank. Lift the filter assembly from its frame. 11. Shake the metal chips out of the filter assembly, screen cover, and plate. Wipe them clean. 12. Wash the tank, screen, plate, and filter assembly with a cleaner recommended by the coolant manufacturer to remove any bacterial contamination. 13. Flush the cleaner from the tanks and clean them as necessary. Do not force the filter assembly into its frame. There is only one way for it to fit. 14. Replace the filter weld assembly in the frame in the tanks. 15. Put the screen cover in the left tank and the plate cover in the right tank. 16. Roll the tank into place under the machine. Slide the chip trays into place 17. Connect the coolant hoses to the coolant pumps. Check the coolant hoses for kinks or 2-11

43 distortion; correct any problems as necessary. Check that the hoses are secure on the pump and tighten the clamps as necessary. CLEAN OR REPLACE THE COOLANT IN-LINE FILTERS Maintenance should also be performed on the coolant filters once a week while the machine is in service or whenever there appears to be restricted coolant flow. 1. Power down the machine and wait a minute to allow most of the coolant to drain back into the tank and to allow the coolant pressure to drop. 2. At the rear of the machine near the coolant pump, wipe the Y-filter cap clean and wipe the spin-on canister filter clean. 3. Unthread the Y-filter cap and lift out the filter screen. Inspect the screen and clean it as necessary. 4. Put the Y-filter screen all the way down into the filter housing and thread the cap in to seal the filter. 5. Replace the spin-on canister filter: A) Wrap a rag around the spin-on canister filter head to catch any coolant and unthread the filter from its mounting nipple. B) Wipe the nipple clean and make certain that the filter seal is removed from the mounting surface. C) Half fill the replacement filter with coolant. Wipe a light coat of oil completely around the seal on top of the filter. D) Thread the filter on the mounting nipple until contact is made; then, thread it on two-thirds of a turn further. GREASE THE AXES 1. Make certain that the axes and spindle are stopped. Viewed from the front of the machine, the Z axis cover is just above the coolant guard, Figure 2.8. The X and Y axes cover is located on the front of the way cover inside the coolant guard doors, Figure 2.9. Use Kluber ISOFLEX NCA 15 grease to lubricate the X, Y, and Z axes. 2. Remove the covers to gain access to the axes grease fittings. VMC1250II and 1500II machines are equipped with two sets of Y axis grease fittings. The two sets of fittings are positioned approximately 39 inches [990 millimeters] 2-12

44 apart. 3. Jog the X axis until the Y axis grease fittings (lower set Figure 2.9) are uncovered. The X axis grease fittings are attached and move with the X axis jog. 4. Attach a grease gun (supplied) to the grease nipple and pump in grease until resistance is felt, then, one more pump of grease. Repeat the process for each grease nipple on all three axes. 5. Wipe the nipples clean of excess grease. 6. Replace the access covers. Figure 2.8.a - Z Axis Grease Fittings Figure 2.8.b - Z Axis Grease Fittings (For DT300P 3 /DT480P 3 /DT710P 3 / VMC480P 3 /VMC710P 3 ) Figure 2.9.a - X and Y Axes Grease Fittings at Front of Way Cover X AXES GREASE Y AXES GREASE Figure 2.9.b - X and Y Axes Grease Fittings at Front of Way Cover (FOR DT300P 3 /DT480P 3 /DT710P 3 /VMC480P 3 /VMC710P 3 ) 2-13

45 ADD OIL TO THE LUBRICATION CUP Add the specified oil to the air/oil tool-knockout piston oil cup L, Figure 2.10, located on the knockout piston near the top of the machine. OIL SPECIFICATION CHARACTERISTICS Viscosity : ISO VG68 Viscosity index: above 95 Anti-oxidation, Anti-corrosion, Anti-rust, Anti-emulsion RECOMMENDED OILS B.P. Energol NT 68 Mobil Vactra Oil No.2 Esso Febis K68 Shell Tonna Oil T68 Chevron Way Lubrica NT68 Figure Spindle Lubricator Cup ADDING OIL TO THE LUBRICATION CUP 1. Wait for the cycle to end and make certain that the spindle is stopped. 2. Power down the machine. 3. Locate the oil cup at the top of the machine. 4. Inspect the cover to be sure the vent hole is not plugged. 5. Unfasten the cover of the oil cup and fill the cup. Install the cover. - WARNING - If the machine is going to be moved, make certain that the incoming electrical power is turned OFF before disconnecting the electrical supply cable from the machine. Shut off and lock out the air supply. - CAUTION - DO NOT use the Eye bracket(s) on top of the machine to lift the machine. If data is lost, all macro programs and parameters must be loaded into the control memory from the backup disc supplied with the machine. Attach this document, or a copy of this document, to the machine being stored. 2-14