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    FANUC MAINTENANCE MANUAL GE FANUC CONTROL MAINTENANCE MANUAL FADAL MACHINING CENTERS, LLCCorporate Office ...................................... phone...

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    AUGUST 2005FADAL MACHINING CENTERS

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    AUGUST 2005TABLE OF CONTENTS iFANUC MAINTENANCE MANUAL TABLE OF CONTENTSactionGoToR:1.0 SPECIFICATactionGoToR:IONS actionGoToR:. . . . . . actionGoToR:. . . . . . actionGoToR:. . . . . . actionGoToR:. . . . . . actionGoToR:. . . . . . actionGoToR:. . . . . ...

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    iiTABLE OF CONTENTSMAN-0121 R1FADAL MACHINING CENTERS 2.6.8 CONDUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403.0 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

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    AUGUST 2005TABLE OF CONTENTS iiiFANUC MAINTENANCE MANUAL 4.3.3 RESTARTING THE CHIP CONVEYOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 794.3.4 OBSERVANCE AND INSPECTION . . ....

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    ivTABLE OF CONTENTSMAN-0121 R1FADAL MACHINING CENTERS 6.3.4 TOOL OFFSET 999 PAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1346.4 MULTI STEP SKIP . . . . . . . . . . . . . . . . . . . . . . . . ....

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    AUGUST 2005TABLE OF CONTENTS vFANUC MAINTENANCE MANUAL 7.6.7 DUAL ARM TOOL CHANGER - ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1947.6.8 INSERTING THE ARM ASSEMBLY . . . . . . . . ...

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    viTABLE OF CONTENTSMAN-0121 R1FADAL MACHINING CENTERS 10.0 SPINDLE DRIVE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23110.1 BELT DRIVE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

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    AUGUST 2005TABLE OF CONTENTS viiFANUC MAINTENANCE MANUAL 10.9.2 INSTALL COMPONENT PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26010.10 40 TAPER BT & CAT PULL ST...

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    viiiTABLE OF CONTENTSMAN-0121 R1FADAL MACHINING CENTERS

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    AUGUST 2005SPECIFICATIONS1 FANUC MAINTENANCE MANUAL 1.0 SPECIFICATIONSThis section provides dimensions/specifications of machines (VMCs 2216, 3016, 4020, 6030, 8030, 3020, 4525, and 6535). Dimensions represent in inches and millimeters.

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    FADAL MACHINING CENTERS 2SPECIFICATIONSMAN-0121 R11.1 ILLUSTRATIONS & DATA FOR ALL VMC MODELS1.1.1 VMC 2216Figure 1-1: VMC 2216NOTE Dimensions represented in inches and [millimeters].

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    AUGUST 2005SPECIFICATIONS3 FANUC MAINTENANCE MANUAL *Rated Peak ValueTable 1-1: VMC 2216 Specifications2216 SPECIFICATIONS2216 STANDARD2216 METRICTable Size39" x 16"750 mm x 406 mmFloor to Table31"787 mmT-Slots (No. x Width x Span)3 x .562" x 4.33"3 x 14 mm x 110 mmCuttin...

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    FADAL MACHINING CENTERS 4SPECIFICATIONSMAN-0121 R11.1.2 VMC 3016Figure 1-2: VMC 3016NOTE Dimensions represented in inches and [millimeters].

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    AUGUST 2005SPECIFICATIONS5 FANUC MAINTENANCE MANUAL *Rated Peak ValueTable 1-2: VMC 3016 Specifications3016 SPECIFICATIONS3016 STANDARD3016 METRICTable Size39" x 16"750 mm x 406 mmFloor to Table31"787 mmT-Slots (No. x Width x Span)3 x .562" x 4.33"3 x 14 mm x 110 mmCuttin...

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    FADAL MACHINING CENTERS 6SPECIFICATIONSMAN-0121 R11.1.3 VMC 4020Figure 1-3: VMC 4020NOTE Dimensions represented in inches and [millimeters]. Optional Very High Torque Motor 30 Peak Horsepower, 32 Amps continuous current in WYE mode, 56, Amps continuous current in DELTA mode, Peak current may ru...

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    AUGUST 2005SPECIFICATIONS7 FANUC MAINTENANCE MANUAL *Rated Peak ValueTable 1-3: VMC 4020 Specifications4020 SPECIFICATIONS4020 STANDARD4020 METRICTable Size48" x 20"1,219mm x 508 mmFloor to Table32"813 mmT-Slots (No. x Width x Span)5 x .687" x 3.75"5 x 17.5 mm x 95.3 mmCu...

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    FADAL MACHINING CENTERS 8SPECIFICATIONSMAN-0121 R11.1.4 VMC 6030Figure 1-4: VMC 6030NOTE Dimensions represented in inches & [millimeters].Optional Very High Torque Motor 30 Peak Horsepower, 32 Amps continuous current in WYE mode, 56 Amps continuous current in DELTA mode, Peak current may run...

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    AUGUST 2005SPECIFICATIONS9 FANUC MAINTENANCE MANUAL *Rated Peak ValueTable 1-4: VMC 6030 Specifications6030 SPECIFICATIONS6030 STANDARD6030 METRICTable Size62.5 x 30"1,588mm x 762 mmFloor to Table36"914 mmT-Slots (No. x Width x Span)5 x .687" x 5.5"5 x 17.5 mm x 139.7 mmCuttin...

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    FADAL MACHINING CENTERS 10SPECIFICATIONSMAN-0121 R11.1.5 VMC 8030Figure 1-5: VMC 8030NOTE Dimensions represented in inches & [millimeters].Optional Very High Torque Motor 30 Peak Horsepower, 32 Amps continuous current in WYE mode, 56 Amps continuous current in DELTA mode, Peak current may ru...

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    AUGUST 2005SPECIFICATIONS11 FANUC MAINTENANCE MANUAL *Rated Peak ValueTable 1-5: VMC 8030 Specifications8030 SPECIFICATIONS8030 STANDARD8030 METRICTable Size82.5" x 30"2,096 mm x 762 mmFloor to Table36"914 mmT-Slots (No. x Width x Span)5 x .687" x 5.5"5 x 17.5 mm x 139.7 ...

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    FADAL MACHINING CENTERS 12SPECIFICATIONSMAN-0121 R11.1.6 VMC 3020Figure 1-6: VMC 3020NOTE Table and head shown at cold start position. Top of head cover at cold start position. Add 18” for max operating height. Subtract 2” for install height. Dimensions represented in inches & [millimete...

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    AUGUST 2005SPECIFICATIONS13 FANUC MAINTENANCE MANUAL *Rated Peak ValueTable 1-6: VMC 3020 Specifications3020 SPECIFICATIONS3020 STANDARD3020 METRICTable Size40.5" x 20"1,029 mm x 508 mmFloor to Table31"787 mmT-Slots (No. x Width x Span)5 x .709" x 3.75"5 x 18 mm x 95.3 mm...

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    FADAL MACHINING CENTERS 14SPECIFICATIONSMAN-0121 R11.1.7 VMC 4525Figure 1-7: VMC 4525NOTE Table and head shown at cold start position. Top of head cover at cold start position. Add 18” for max operating height. Subtract 2” for install height. Dimensions represented in inches & [millimete...

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    AUGUST 2005SPECIFICATIONS15 FANUC MAINTENANCE MANUAL *Rated Peak ValueTable 1-7: VMC 4525 Specifications4525 SPECIFICATIONS4525 STANDARD4525 METRICTable Size53.5" x 25"1,359mm x 635mmFloor to Table31"787mmT-Slots (No. x Width x Span)5 x .709" x 4.92"5 x 18mm x 125mmCuttin...

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    FADAL MACHINING CENTERS 16SPECIFICATIONSMAN-0121 R11.1.8 VMC 6535Figure 1-8: VMC 6535NOTE Dimensions represented in inches & [millimeters].SIDE VIEWFRONT VIEWTOP VIEW - BASESCALE 2:1TOP VIEW

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    AUGUST 2005SPECIFICATIONS17 FANUC MAINTENANCE MANUAL *Rated Peak ValueTable 1-8: VMC 6535 Specifications6535 SPECIFICATIONS6535 STANDARD6535 METRICTable Size74.8" x 26.5"1,899mm x 673.1mmFloor to Table40.3"1024mmT-Slots (No. x Width x Span)5 x .709" x 4.92"5 x 18mm x 125m...

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    FADAL MACHINING CENTERS 18SPECIFICATIONSMAN-0121 R11.2 FADAL BOLT TORQUE SPECIFICATIONSTable 1-9: Fadal Bolt Torque SpecificationsCOMPONENTMODELLOCATIONBOLT SIZETORQUEUNITCOLUMNALLCOLUMN TO BASE5/8"-11 X X.50 HHB175FT-LBSCOLUMNALLCOUPLER SET SCREW1/4"-20 X 0.50 SHSS 70IN-LBSCOLUMNALLZ B...

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    AUGUST 2005SPECIFICATIONS19 FANUC MAINTENANCE MANUAL 1.2.1 2216 & 3016 TABLEFigure 1-9: 2216 & 3016 TableABCDDEETable 1-10: 2216 & 3016 Table DimensionsVMCS 2216 & 3016A16.00" (406.4 mm)B40.50" (1028.7 mm)C36.00" (914.4 mm)D3.67" (93.22 mm)E4.33" (109.98 mm)

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    FADAL MACHINING CENTERS 20SPECIFICATIONSMAN-0121 R11.2.2 3020 & 4525 TABLEFigure 1-10: 3020 & 4525 TableABCDEEEEFTable 1-11: 3020 & 4525 Table DimensionsVMC 3020VMC 4525A20.00” (508 mm)A25.00” (635 mm)B41.75” (1060.45 mm)B54.76” (1390.90 mm)C36.00” (914.40 mm)C49.00” (124...

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    AUGUST 2005SPECIFICATIONS21 FANUC MAINTENANCE MANUAL 1.2.3 4020 TABLEFigure 1-11: 4020 TableABCDDEEEETable 1-12: 4020 Table DimensionsVMC 4020A20.00” (508 mm)B49.00” (1244.66 mm)C43.50” (1104.9 mm)D2.52” (64 mm)E3.740” (95 mm)

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    FADAL MACHINING CENTERS 22SPECIFICATIONSMAN-0121 R11.2.4 6030 TABLEFigure 1-12: 6030 TABLEABCDDEEEETable 1-13: 6030 Table DimensionsVMC 6030A30.00” (762 mm)B63.50” (1612.9 mm)C58.00” (1473.2 mm)D3.976” (101 mm)E5.512” (140 mm)

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    AUGUST 2005SPECIFICATIONS23 FANUC MAINTENANCE MANUAL 1.2.5 8030 TABLE Figure 1-13: 8030 TableABCDEEEEDTable 1-14: 8030 Table DimensionsVMC 8030A30.00” (762 mm)B83.50” (1612.9 mm)C78.00” (1473.2 mm)D3.976” (101 mm)E5.512” (140 mm)

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    FADAL MACHINING CENTERS 24SPECIFICATIONSMAN-0121 R11.2.6 6535 TABLEFigure 1-14: 6535 TableABCDEEEEDTable 1-15: 6535 Table DimensionsVMC 6535A35.00” (889 mm)B74.76” (1899 mm)C69.50” (1765 mm)D2.74” (70 mm)E4.92” (125 mm)

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    AUGUST 2005SPECIFICATIONS25 FANUC MAINTENANCE MANUAL 1.2.7 T-SLOTS FOR ALL TABLESFigure 1-15: T-Slots for All TablesTable 1-16: Metric T-Slot Dimensions for All TablesT-SLOT DIMENSIONSE0.7086” - 0.7093 ” (17.998 mm - 18.016 mm)F1.190” - 1.250” (30.22 mm - 31.75 mm)G0.482” - 0.542” (1...

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    FADAL MACHINING CENTERS 26SPECIFICATIONSMAN-0121 R11.3 RECOMMENDED MAINLINE FUSES / CIRCUIT BREAKERSNOTE VHT with Fadal control runs only on 220-240V. External transformer required for any other voltage.VHT with Siemens Control only runs on 400V. External transformer required for any other voltag...

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    AUGUST 2005PRE-INSTALLATION PROCEDURES27 FANUC MAINTENANCE MANUAL 2.0 PRE-INSTALLATION PROCEDURES

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    FADAL MACHINING CENTERS 28PRE-INSTALLATION PROCEDURESMAN-0121 R12.1 FOUNDATIONWARNING!The VMC MUST be placed on a surface that will support the combined weight of the VMC, options, fixtures, and tooling, etc. (refer to the VMC Specifications section at the beginning of this manual for VMC weights...

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    AUGUST 2005PRE-INSTALLATION PROCEDURES29 FANUC MAINTENANCE MANUAL Installation). For high performance machines, the machine must be bolted to achieve maximum performance.Figure 2-2: Anchor Stud Installation Anchor stud installation:1. Wear safety goggles.2. Use 7/8 carbide tipped drill for the...

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    FADAL MACHINING CENTERS 30PRE-INSTALLATION PROCEDURESMAN-0121 R14. Use proper eye and hearing protection while performing this step. Remove dust and rubble from the hole with compressed air and brush.5. Insert capsule in the hole, either end first.6. Select proper 1/2” SQ. drive socket and atta...

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    AUGUST 2005PRE-INSTALLATION PROCEDURES31 FANUC MAINTENANCE MANUAL thicker with # 4 rebar 18” on center three inches off the ground. For stress lines in the concrete make sure they are such that they do not go under any of the machines. (If they do, this will eventually defeat the purpose of...

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    FADAL MACHINING CENTERS 32PRE-INSTALLATION PROCEDURESMAN-0121 R12.2 SHIPPING DIMENSIONSNOTE All VMCs 6535 and 8030 do not get crated. (Unless specified by customer or distributor.) They are placed on pallets and vacuum sealed.Table 2-2: VMC Shipping DimensionsVMCLENGTHWIDTHHEIGHTWEIGHTZ MTR DWN8...

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    AUGUST 2005PRE-INSTALLATION PROCEDURES33 FANUC MAINTENANCE MANUAL 2.3 POSITIONING1. Place the VMC so that skylights or air vents are NOT directly overhead. Do not expose the machine to direct sunlight, or any other heat source. Do not place the machine in an area that will expose the machine to m...

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    FADAL MACHINING CENTERS 34PRE-INSTALLATION PROCEDURESMAN-0121 R12.4 AIR SUPPLYWARNING!Air pressure required: 120psi before regulator, 80 psi after regulator, 15 scfm (stan-dard cubic feet per minute) momentary.1. From the main air supply line attach a 3/8” air supply line for the VMC. The dista...

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    AUGUST 2005PRE-INSTALLATION PROCEDURES35 FANUC MAINTENANCE MANUAL 2.5 ELECTRICAL GROUNDINGWARNING!The importance of proper grounding CANNOT be over-emphasized! Improper grounding will result in a wide range of hard-to-diagnose problems in communica-tions, positioning, spindle motion, etc.2.5.1 PR...

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    FADAL MACHINING CENTERS 36PRE-INSTALLATION PROCEDURESMAN-0121 R1•intermediate metal conduit•electrical metallic tubing or cable armor4. One end of the supplemental grounding conductor shall be attached to the VMC’s ground bus. The other end shall be effectively bonded to a copper cold water...

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    AUGUST 2005PRE-INSTALLATION PROCEDURES37 FANUC MAINTENANCE MANUAL 2.6 CHECKING GROUNDING INTEGRITY OF FADAL VMCS2.6.1 SPECIFICATION -GROUNDING FOR THE FADAL MACHINE1. MUST conferm to NEC code as stated in the Maintenance Manual.2. MUST be a continuous wire 8 AWG or larger between the VMC's ground...

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    FADAL MACHINING CENTERS 38PRE-INSTALLATION PROCEDURESMAN-0121 R14. Turn off the VMC and measure the ground voltages (AC and DC) again. Record these readings. Voltages should be OV to .005V.5. Voltages (AC or DC) across the ground wire will cause false resistance readings. If the ground voltages w...

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    AUGUST 2005PRE-INSTALLATION PROCEDURES39 FANUC MAINTENANCE MANUAL 2.6.7 WIRINGTable 2-5: Wiring Requirements40 Taper240 VAC 3 Ø8 AWG (10 mm2) stranded THHN copper within 100 ft. of panel. For VHT 4AWG6 AWG (16 mm2) stranded THHN copper 100 ft. or more from panel.For VHT 3 AWG40 Taper480 VAC 3 Ø...

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    FADAL MACHINING CENTERS 40PRE-INSTALLATION PROCEDURESMAN-0121 R12.6.8 CONDUIT1. The number and size of conductors in any raceway shall not be more than will permit dissipation of the heat.2. The conduit must allow ready installation or withdrawal of the conductors without damage to the conductors...

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    AUGUST 2005INSTALLATION PROCEDURE41 FANUC MAINTENANCE MANUAL 3.0 INSTALLATION PROCEDUREWARNING!Before beginning the Machine Installation & Hook-Up it is important to review the entire Installation Procedure section.

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    FADAL MACHINING CENTERS 42INSTALLATION PROCEDUREMAN-0121 R13.1 MACHINE INSTALLATION & HOOK-UP3.1.1 UNPACKINGTools Required Hammer, 15/16” socket or wrench and knife1. Remove the crate and/or protective material from around the VMC.2. Remove the strapping material from the front doors.3. Unl...

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    AUGUST 2005INSTALLATION PROCEDURE43 FANUC MAINTENANCE MANUAL 3. At this point the VMC is ready for power and air connections.Figure 3-1: Placing the VMC3.1.3 AIR SUPPLYWARNING!AIR PRESSURE REQUIRED: 120 psi before regulator, 80 psi after regulator, 15 scfm (standard cubic feet per minute) moment...

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    FADAL MACHINING CENTERS 44INSTALLATION PROCEDUREMAN-0121 R12. Check the pressure gauge for 120 psi and adjust the regulator on the VMC if necessary.3. Check for air leaks at the fitting and around the air regulator.4. It is important that the air compressor turns on when the pressure drops to app...

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    AUGUST 2005INSTALLATION PROCEDURE45 FANUC MAINTENANCE MANUAL Verify the MOV Surge Suppressor Board1. Locate the MOV Surge Suppressor Board (see 55,Figure 3-2: MOV Surge Suppressor Board).Figure 3-2: MOV Surge Suppressor Board2. Find the part number on the board.a. If your incoming voltage is un...

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    FADAL MACHINING CENTERS 46INSTALLATION PROCEDUREMAN-0121 R1Figure 3-3: Figure 3-4:

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    AUGUST 2005INSTALLATION PROCEDURE47 FANUC MAINTENANCE MANUAL Figure 3-5: The VMC is Ready for the Initial Power on Procedure1. Move the main disconnect switch to the ON (up) position. 2. Measure the voltage at the transformers secondary between A12-B12, A12-C12, B12-C12. 3. For single phase meas...

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    FADAL MACHINING CENTERS 48INSTALLATION PROCEDUREMAN-0121 R13.2 TRANSFORMER TAPPING1. With the machine main power switch turned OFF, verify that the chart on the door of the cabinet is the one for the transformer in the machine. 2. Measure the input voltage to the machine on the chart (Measure leg...

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    AUGUST 2005INSTALLATION PROCEDURE49 FANUC MAINTENANCE MANUAL 3.3 SINGLE PHASE INPUT POWERThe Fadal VMC line is designed for three phase input power. However, three-phase power is not always available. If this is the case, Fadal offers a single-phase input power option. Most Fadal machines are cap...

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    FADAL MACHINING CENTERS 50INSTALLATION PROCEDUREMAN-0121 R13.4 PHASE CONVERTER ROTARYThe normal Fadal VMC requires three phase-input power. The machines are also configured in a single-phase power configuration when requested. Some customers prefer to use rotary phase converters. However, Fadal d...

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    AUGUST 2005INSTALLATION PROCEDURE51 FANUC MAINTENANCE MANUAL 3.5 LEVELINGLeveling is an important first step in setting up the VMC. All calibration and squareness performed on the assembly line is done with the machine leveled. It is important to follow the sequence below precisely to ensure prop...

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    FADAL MACHINING CENTERS 52INSTALLATION PROCEDUREMAN-0121 R18. Place the level on the right hand way (the outer right hand way on the 6535) of the base with the small bubble towards the column. Take an accurate reading. (See 62,Figure 3-6: Leveling Box Way.)Figure 3-6: Leveling Box Way. 9. Now p...

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    AUGUST 2005INSTALLATION PROCEDURE53 FANUC MAINTENANCE MANUAL 13. Verify the spindle tram and, if necessary, adjust by slightly changing only the two front leveling screws.

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    FADAL MACHINING CENTERS 54INSTALLATION PROCEDUREMAN-0121 R13.6 HOLD DOWN CLAMPSLarger machines may vibrate, bump on reversals, and degrade floor finish.This may indicate that the base casting needs to be clamped to floor.Larger machines need to be clamped to the floor to prevent movement between ...

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    AUGUST 2005INSTALLATION PROCEDURE55 FANUC MAINTENANCE MANUAL 3.7 OPTICAL FIBER CABLE HANDLINGCareful handling of Optical Fiber Cable:1. Even though reinforcing cover used on the optical fiber code has enough mechani-cal strength, be sure not to be damaged by heavy materials drop.2. Detaching and ...

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    FADAL MACHINING CENTERS 56INSTALLATION PROCEDUREMAN-0121 R13.8 COUPLER INSTALLATION ON AXIS MOTOR OR BALLSCREWNOTE Motor and Ball Screw shaft must be clean and oil free.Follow the next procedure:1. Loozen both coupler HUB screws. 2. Mark coupler HUBs and SPIDER before disassembling to insure coup...

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    AUGUST 2005INSTALLATION PROCEDURE57 FANUC MAINTENANCE MANUAL 6. Install the SPIDER and set the tolerance on all 4 RAISED BOSSes to 0.015”-0.030” from the HUB using 2 (two) 0.015”(0.381mm) and 0.030” (0.762mm) feeler gages.Figure 3-8: Gages 7. Install Ball Screw coupler HUB on the SPIDER...

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    FADAL MACHINING CENTERS 58INSTALLATION PROCEDUREMAN-0121 R1 Figure 3-10: Motors Table 3-1: CouplersMACHINEX AXISY AXIS Z AXISEMCKTR ROTEX GS 24.625x24mmKTR ROTEX GS 24.625x24mmKTR ROTEX AI GS 24.625x19mm221630164020603080305020A4020A3016LKTR ROTEX GS 24.625x24mm2016LKTR ROTEX AI GS 24.625...

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    AUGUST 2005INSTALLATION PROCEDURE59 FANUC MAINTENANCE MANUAL 3.9 PENDANT INSTALLATIONIn order to install pendant, follow the next procedure:VMC 65351. Carefully remove shipping crate, with pendant inside, from machine and place it close to the right side of the machine.2. Remove second (smaller)...

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    FADAL MACHINING CENTERS 60INSTALLATION PROCEDUREMAN-0121 R18. Pull all the cables coming from the machine through the upper pivot support and the hole on the right top side of the pendant housing.9. Connect these cables to appropriate positions according wiring diagram.10. Connect remote bulk-hea...

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    AUGUST 2005INSTALLATION PROCEDURE61 FANUC MAINTENANCE MANUAL 7. Connect these cables and wires to appropriate positions according wiring diagram.Figure 3-12: 2216, 3016, 6030, 8030 Fanuc controlCables through the hole

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    FADAL MACHINING CENTERS 62INSTALLATION PROCEDUREMAN-0121 R13.10 GENERAL Dettach column breaks from spindle head and tool changer arm.Figure 3-13: Column breaksPlace the cable carrier (black flexible arc on top of the machine) onto appropriate screws and tight them with nuts. Figure 3-14: Cable ...

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    AUGUST 2005INSTALLATION PROCEDURE63 FANUC MAINTENANCE MANUAL 3.11 CHIP CONVEYOR3.11.1 INSTALLATION PROCEDURE1. Place the chip conveyor in the coolant tank.2. Measure the height to the top of the conveyor sheet metal (should be approximately the height of the coolant tank).3. Set the machine heigh...

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    FADAL MACHINING CENTERS 64INSTALLATION PROCEDUREMAN-0121 R17. Adjust the machine height (during leveling and installation) to minimize the gap (or overlap) between the coolant tank face and the machine sheet metal, (Figure 3-17: Minimize Gap of Overlap).Figure 3-17: Minimize Gap or Overlap8. Coo...

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    AUGUST 2005INSTALLATION PROCEDURE65 FANUC MAINTENANCE MANUAL 3. The control also has a variable speed control for the belt speed. The belt speed can be controlled from 2.60 ft./min. to 10.80ft/min. Figure 3-18: Control Operating PositionsFigure 3-19: Emergency Stop (CE machines only)

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    FADAL MACHINING CENTERS 66INSTALLATION PROCEDUREMAN-0121 R1

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    AUGUST 2005MACHINE MAINTENANCE67 FANUC MAINTENANCE MANUAL 4.0 MACHINE MAINTENANCE

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    FADAL MACHINING CENTERS 68MACHINE MAINTENANCEMAN-0121 R14.1 SCHEDULED MAINTENANCE4.1.1 MAINTENANCE & LUBRICATION SCHEDULEDaily1. Check air pressure: Right regulator 120 psi. max. (Tool Out Only). Left Regulator80-90 psi.2. Check way lube level. Use Castrol Magna BD68, Shell Tonna 68V or Mobi...

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    AUGUST 2005MACHINE MAINTENANCE69 FANUC MAINTENANCE MANUAL 10. Grease Geneva wheel and gear using Kopr-Kote.11. For high torque machines, check fluid level in the hydraulic actuator reservoir.Refill, if needed, with Mobil DTE Heavy Medium.12. Inspect all cooling fans, clean screens if necessary.Ev...

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    FADAL MACHINING CENTERS 70MACHINE MAINTENANCEMAN-0121 R13. Remove the oil line that is between the way lube pump and the three port junction Tthat is located near the pump mount.4. Verify that the flush pump air regulator is fully counterclockwise.5. Attach an air line to the flush pump.WARNING!V...

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    AUGUST 2005MACHINE MAINTENANCE71 FANUC MAINTENANCE MANUAL WARNING!Wear safety glasses!If the fan is turning slowly or not at all, it may require cleaning or replacement. The fan on the bottom of the junction box has a screen that requires periodic inspection and removal for cleaning.4.1.4 SPINDLE...

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    FADAL MACHINING CENTERS 72MACHINE MAINTENANCEMAN-0121 R14.1.6 TANK RESERVOIRThe tank reservoir is located next to the motor pump assembly in the chiller cabinet. The tank has a 2 1/2 gallon capacity. Visually check the fluid level with the machine powered on. If the fluid level is le...

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    AUGUST 2005MACHINE MAINTENANCE73 FANUC MAINTENANCE MANUAL 4.1.7 FLUIDSTable 4-1: FluidsRESERVOIRFILL WITHWaylubeCASTROL MAGNA BD68SHELL TONNA 68Vor MOBIL VACTRA #2Spindle Cooling SystemDOWFROST™ CLEAR(Mixed 50/50 with de-ionized water or sodium free distilled water)Rotary TablesMOBIL GEAR 626Hy...

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    FADAL MACHINING CENTERS 74MACHINE MAINTENANCEMAN-0121 R14.1.8 DUAL ARM TOOL CHANGERThe causes of abnormal wear and fractures will be apparent when the tool changer is used without lubricant. It is very important to grease all moving parts of the tool changer at least once a week.LubricantThe lubr...

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    AUGUST 2005MACHINE MAINTENANCE75 FANUC MAINTENANCE MANUAL 2. Inspection:a. Check the parts of the tool falling mechanism for damage and wear. Addgrease to the sliding base of the tool falling mechanism and the pull rod. b. Check the parts of the tool pots, tool discs, and snap rings for damage an...

  • Page 86

    FADAL MACHINING CENTERS 76MACHINE MAINTENANCEMAN-0121 R14.2 TESTS FOR CE SAFEGUARDS ON FADAL MACHINESThese tests should be done when machine is first installed and after servicing when any components are replaced.1. Power on machine but do reference. Start spindle. (Press Shift-Spindle on)•Spin...

  • Page 87

    AUGUST 2005MACHINE MAINTENANCE77 FANUC MAINTENANCE MANUAL Daily & Weekly Safety Tests for CE Safety CircuitsTo ensure proper functioning of safety circuits, the following tests should be performed on a regular basis.DailyFront Door Lock Daily Test for 2030-OA1. Close all doors. Make sure mach...

  • Page 88

    FADAL MACHINING CENTERS 78MACHINE MAINTENANCEMAN-0121 R14.3 CHIP CONVEYOR4.3.1 MAINTENANCE SCHEDULE CHIP CONVEYORPlease carry out daily, monthly, and yearly inspection according to the following directions.Daily Inspection1. Always keep oil in the speed reducer at the specified oil level.2. Chec...

  • Page 89

    AUGUST 2005MACHINE MAINTENANCE79 FANUC MAINTENANCE MANUAL 1. At the initial running, confirm the following before turning power on.a. Inspect for and remove any article other than material (chip, etc.) to be trans-ported on conveyor link belt portion.WARNING!Make sure hands, feet and clothing are...

  • Page 90

    FADAL MACHINING CENTERS 80MACHINE MAINTENANCEMAN-0121 R1Figure 4-3: Adjust Take-Up Bearing3. Check roller chain between motor and conveyor for proper alignment and correcttension.Figure 4-4: Check Roller Chain4. The greatest care should be exercised to keep friction surface of torque limiter fr...

  • Page 91

    AUGUST 2005FANUC CONTROL81 FANUC MAINTENANCE MANUAL 5.0 FANUC CONTROLThis chapter covers those items, displayed on the screen, that are related to maintenance. It describes how to display various screens by the function keys.

  • Page 92

    FADAL MACHINING CENTERS 82FANUC CONTROLMAN-0121 R15.1 SCREEN DISPALYED IMMEDIATELY AFTER POWER IS TURNED ON5.1.1 SLOT STATUS DISPLAYIf a hardware trouble or an incorrect mounting is found, the following screen is displayed.Slot state screen 1. ...

  • Page 93

    AUGUST 2005FANUC CONTROL83 FANUC MAINTENANCE MANUAL Software ID40 : Main CPU41 : C language43 : Sub CPU49 : CAP II4A : Remote buffer4F : PMC-RE53 : Loader control59 : RISC board for high-precision contour control5E : HSSB interface (with PC)5.1.2 SETTING MODULE SCREEN 1-slot number 2-modu...

  • Page 94

    FADAL MACHINING CENTERS 84FANUC CONTROLMAN-0121 R15.1.3 CONFIGURA-TION DISPLAY OF SOFTWARE 1-CNC control 2-digital servo ROM 3-sub CPU (remote buffer 4-order made macro/macro compiler 5-PMC B0H1-01COPYRIGHT FANUC LTD 1996-2001 SERVO : 90B0-01 SUB : xxxx-xx OMM : yy...

  • Page 95

    AUGUST 2005FANUC CONTROL85 FANUC MAINTENANCE MANUAL 5.2 SYSTEM CONFIGURATION SCREENAfter the system has been installed correctly, you can find the PCBs installed and thesoftwares integrated on the system configuration screen.5.2.1 DISPLAY METHODFollow the next steps:1. Press SYSTEM key.2. Press s...

  • Page 96

    FADAL MACHINING CENTERS 86FANUC CONTROLMAN-0121 R1Module ID5.2.3 MODULLE CON-FIGURATION SCREENConfiguration of the modules displayed on PCB. 1-slot number (the number is correspoinding to PCB configuration screen) 2-typr of PCB mounted 3-name of card PCB or DIMM module 4-hardware ID of mounte...

  • Page 97

    AUGUST 2005FANUC CONTROL87 FANUC MAINTENANCE MANUAL 5.3 SCREEN DISPLAYDisplaying the operation history.1. Press the SYSTEM function key.2. Press the continue menue key . The [OPEHIS] (operation history) soft key are dis-played.3. Press the [OPEHIS] soft key twice. The operation history screen is ...

  • Page 98

    FADAL MACHINING CENTERS 88FANUC CONTROLMAN-0121 R1•Page/cursor key: •Soft key: [SF1], [SF2], etc.•Other key <RESET>, <CAN>, etc.•Key pressed at power-on 2. Input and output signalsGeneral signals are displayed in the following format:Some signals are indicated by their symbol ...

  • Page 99

    AUGUST 2005FANUC CONTROL89 FANUC MAINTENANCE MANUAL 3. NC alarmsNC akarms are displayed in reverse video.P/S alarms system alarms, and external alarms are displayed together with their numbers.For other types of alarms, only the alarm type is displayed. (No details are dis-played.)For two-path co...

  • Page 100

    FADAL MACHINING CENTERS 90FANUC CONTROLMAN-0121 R1OP_HIS SIGNAL SELECT 01000 N02000NO. ADDRESS SIGNAL01020304050607080910> X0000 X0004 X0008 X0009 X0012 Y0000 Y0004 Y0007 Y0008 Y0010000010001000000000001100001110000000111101000000001100000...

  • Page 101

    AUGUST 2005FANUC CONTROL91 FANUC MAINTENANCE MANUAL 1. 2. 3. 4. 7. 8. 5.5.4 CNC STATE DISPLAY - display example and explanation. -indicates the current status of the CNC. ...

  • Page 102

    FADAL MACHINING CENTERS 92FANUC CONTROLMAN-0121 R1* * * : Other status4. Auxiliary function statusFIN: The completion signal FIN for an auxiliary function is being awaited.* * * : Other status5. Emergency stop and reset status (displayed at the location of items mentioned in (3) and (4)).E...

  • Page 103

    AUGUST 2005FANUC CONTROL93 FANUC MAINTENANCE MANUAL 5.5 OPERATING MONITORLoad meter of the servo axis and the serial spindle and speed meter can be displayed.5.5.1 DISPALY METHOD1. Set a parameter to display operating monitor. (Bit 5 (OPM) of parameter No.3111)2. Press the POS key to display the...

  • Page 104

    FADAL MACHINING CENTERS 94FANUC CONTROLMAN-0121 R15.6 MAINTENANCE INFORMATION SCREENThe maintenance information screen is provided to record the history of maintenance performed by a service person of Fadal.The screen has the following features:•MDI alphabetical input is allowed•the recording...

  • Page 105

    AUGUST 2005FANUC CONTROL95 FANUC MAINTENANCE MANUAL Screen operationThe maintenance information screen has view mode and edit mode which are selected by pressing the [END] or [EDIT] soft key.Initially view mode is selcted. To start editing select edit mode by pressing the ([OPRT)] and [EDIT] keys...

  • Page 106

    FADAL MACHINING CENTERS 96FANUC CONTROLMAN-0121 R1Operation of the soft keys5.6.2 MAINTENANCE INFORMATION INPUT/OUTPUTThe maintenance can be read and punched:When the maintenance information is input from or output to a memory card a file name MAINTINFDAT is used.1. Format(1) View mode(2) ...

  • Page 107

    AUGUST 2005FANUC CONTROL97 FANUC MAINTENANCE MANUAL 2. ReadingWhen a MAINTINFDAT file generated in the format shown above is read the data is added at the end of the exisiting maintenance information.NOTE A TAB code is converted to one to four blanks depending on the input position. Control code...

  • Page 108

    FADAL MACHINING CENTERS 98FANUC CONTROLMAN-0121 R15.7 POWER MOTION MANAGERWhen the Power Motion series is used as an additional axis (slave) of the CNC the power motion manager allows the slave data to be displayed and set by the CNC.The power motion manager enables the following display and sett...

  • Page 109

    AUGUST 2005FANUC CONTROL99 FANUC MAINTENANCE MANUAL SLPWE - - Settings of slave parameters0 Can be made by Power mate CNC manager regardless of the PWE setting1 Are made according to the PWE settingASG - - Whether or not the number of bytes allocated to the input/output destination of the β...

  • Page 110

    FADAL MACHINING CENTERS 100FANUC CONTROLMAN-0121 R1Alternative termination method is to select another function while this function is enables. To do this press an MDI funciton key (POS, PROG, ...)NOTE After another screen is displayed by pressing a function key pressing the function key restore...

  • Page 111

    AUGUST 2005FANUC CONTROL101 FANUC MAINTENANCE MANUAL 2. Press the [PARAM] soft key. The parameter screen appears.The screen displays just the bit and decimal data. Searching can be made for the parameter to be displayed.1. Select the active slave.2. Press the [(OPRT)] soft key. The following soft...

  • Page 112

    FADAL MACHINING CENTERS 102FANUC CONTROLMAN-0121 R1Diagnosis screenThis screen shows the current status of the slave.1. Press the [SYSTEM] function selection soft key. The following soft keys appear:2. Press the [DGNOS] soft key. The diagnosis screen appears. The displayed data is basically the s...

  • Page 113

    AUGUST 2005FANUC CONTROL103 FANUC MAINTENANCE MANUAL 1. Press the [MSG] function selection soft key. just the error code is displayed on the screen.Up to forty (40) codes can be displayed on the screen.Operating the active slaveThe active slave is subjected to the ZOOM function, which will be des...

  • Page 114

    FADAL MACHINING CENTERS 104FANUC CONTROLMAN-0121 R1The figure above shows a sample four-slave display screen on a display unit with twelve soft keys. A unit with seven soft keys can also display the four-slave display screen.The figure above shows a sample single-slave display screen on a display...

  • Page 115

    AUGUST 2005FANUC CONTROL105 FANUC MAINTENANCE MANUAL When the soft keys are displayed as shown above SELECT ACTIVE SLAVE is displayed.Key-in fieldWhen the [(OPRT)] soft key is pressed the message line may turn into a key-in field as require. The numeric data input by using DMI ke...

  • Page 116

    FADAL MACHINING CENTERS 106FANUC CONTROLMAN-0121 R14. Press the [READ] soft key.5. Press the [EXEC] soft key.During input INPUT blinks in the message field.Writting parametersThe data file of parameters saved in CNC memory or a memory card as a program is written into the slave determined by the...

  • Page 117

    AUGUST 2005FANUC CONTROL107 FANUC MAINTENANCE MANUAL 5.8 PERIODIC MAINTENANCE SCREENSUsing the periodic maintenance screens makes it easy to manage consumable (such as LCD unit backlight and backup battery) that are to be replaced periodically.5.8.1 OVERVIEWThe following configurationThe followin...

  • Page 118

    FADAL MACHINING CENTERS 108FANUC CONTROLMAN-0121 R15.8.3 STATUS SCREEN DISPLAY AND SET-TINGUp to 10 consumable items can be registered for management. Their remaining service time and count status are displayed on the status screen.Item nameThe name of an item to be subjected to periodic m...

  • Page 119

    AUGUST 2005FANUC CONTROL109 FANUC MAINTENANCE MANUAL (a). Program-based registration. Executing a program in the following format enables item names to be registered on the machine system menu screen.(b). MDI keypad-based registration. An item name can be registered on the machin...

  • Page 120

    FADAL MACHINING CENTERS 110FANUC CONTROLMAN-0121 R1[Machine system] menu screen: [NC system] menu screen:PERIODICAL MAINTENANCE O0001 N12345 (MACHINE) ITEM NAME01020304050607080910>_ EDIT * * * * * * * * * * * * * * * ...

  • Page 121

    AUGUST 2005FANUC CONTROL111 FANUC MAINTENANCE MANUAL NOTE On the CNC system screen no item name can be registered erased input or output.2. MDI keypad-based setting.An item name can be registered on the status screen by first entering it in the following format using keys then pressing sof...

  • Page 122

    FADAL MACHINING CENTERS 112FANUC CONTROLMAN-0121 R14. Count status.The count status is displayed at the left of the corresponding item number as listed below:DISPLAYCOUNT STATUSBlankCount suspended@Count inder wayThe service life has expired

  • Page 123

    AUGUST 2005FANUC CONTROL113 FANUC MAINTENANCE MANUAL 5.9 LANGUAGE SETUP1. Change the language setting in the macro variable table.- Press [OFFSET/SETTING] key on the MDI panel.- Press once or twice on the LCD screen until MACRO soft key comes out.- Press [MACRO] soft key on the LCD screen.- Input...

  • Page 124

    FADAL MACHINING CENTERS 114FANUC CONTROLMAN-0121 R14. Check the following screen on the CNC. If screen displays with the right language, the software insatallation is successful. Otherwise, repeat steps above all over again.Follow these step to setup any language.EXAMPLE:ENGLISHJAPANESE

  • Page 125

    AUGUST 2005FANUC CONTROL115 FANUC MAINTENANCE MANUAL GERMANFRENCH

  • Page 126

    FADAL MACHINING CENTERS 116FANUC CONTROLMAN-0121 R1CHINESEITALIAN

  • Page 127

    AUGUST 2005FANUC CONTROL117 FANUC MAINTENANCE MANUAL KOREANSPANISH

  • Page 128

    FADAL MACHINING CENTERS 118FANUC CONTROLMAN-0121 R1DUTCHPORTUGUESE

  • Page 129

    AUGUST 2005FANUC CONTROL119 FANUC MAINTENANCE MANUAL 5.10 FINAL FILES BACKUP PROCEDUREFollow these steps:I STEP:Prepare operation1. Smoothly put the COMPACT FLASH CARD inside the M-CARD slot of LCD.2. Press EDIT PB. to change edit mode.3. Press SYSTEM on the MDI panel until parameter screen comes...

  • Page 130

    FADAL MACHINING CENTERS 120FANUC CONTROLMAN-0121 R118. Press PITCH.19. Press OPRT.20. Press PUNCH.21. Press EXEC.II STEP:Backup the PLC software1. Put the flash card into the slot on the LCD.2. Press EDIT PB. to change edit mode.3. Press SYSTEM on the MDI panel until parameter screen comes out.4....

  • Page 131

    AUGUST 2005FANUC CONTROL121 FANUC MAINTENANCE MANUAL III STEP:Sram backup procedure1. Power of the machine.2. Put the flash card into the slot.3. Press the most right side two soft key on the LCD screen and hold.4. Wait until the CNC system screen comes out.5. Wait until the CNC system screen dis...

  • Page 132

    FADAL MACHINING CENTERS 122FANUC CONTROLMAN-0121 R1

  • Page 133

    AUGUST 2005OPTIONS SETUP123 FANUC MAINTENANCE MANUAL 6.0 OPTIONS SETUP

  • Page 134

    FADAL MACHINING CENTERS 124OPTIONS SETUPMAN-0121 R16.1 FANUC SOFTWARE INSTALLATION PROCEDURE6.1.1. OPTION INSTAL-LATION PROCESSFind the activation key from the Fanuc SFT-xxxx floppy disk. The activation key is located at the A disk: SFT-0095.txt second paragraph. Write down this number on your pa...

  • Page 135

    AUGUST 2005OPTIONS SETUP125 FANUC MAINTENANCE MANUAL - Press NO.SRH soft key on the LCD screen, the program will display on the screen.- Press DOOR OVR (the light above the DOOR OVR should flick).- Press AUTO key on the pendant.- Press CYCLE START key to run the program.- Make sure the program i...

  • Page 136

    FADAL MACHINING CENTERS 126OPTIONS SETUPMAN-0121 R1 NOTE ACTIVATION KEY is located in the A disk file: SFT-0095.txt second paragraph. 44A728229-G01 EZOPT(TM) CNC OPTION INSTALLATION UTILITY for GE Fanuc series 0C, 15A/B, 16B/C, 18B/C, and all series i controls. Prepared: 02/01/05 12:50:...

  • Page 137

    AUGUST 2005OPTIONS SETUP127 FANUC MAINTENANCE MANUAL 13. Verify wether series cable is connected from PC to Fanuc CNC, then press “Y” on the PC.14. Check the download link:- Quickly press following keys and soft keys on the Fanuc control:- Until the PC displays press MDI and RESET, then press...

  • Page 138

    FADAL MACHINING CENTERS 128OPTIONS SETUPMAN-0121 R123. Run the program O8851 to recover the communication parameter to original one.- Press EDIt key on the pendant.- Press PROG key on the MDI panel.- Press DIR soft key on the LCD screen.- Input O8851.- Press NO.SRH soft key on the LCD screen, the...

  • Page 139

    AUGUST 2005OPTIONS SETUP129 FANUC MAINTENANCE MANUAL 6.2 MACHINE COLD START SETUPFadal Fanuc VMC comes with absolute encoders which is setup at Fadal already. The machine will remember the position even if it is powered off. We need to remake the cold start position if the alarm No.300 appears o...

  • Page 140

    FADAL MACHINING CENTERS 130OPTIONS SETUPMAN-0121 R1 3.3 Use MPG move the X axis to the X axis middle potion mark. 3.4 Record the X coordinate displayed on the CNC screen as A. 3.5 Press MDI push button on the operator panel A. 3.6 Press SYSTEM key on the MDI panel. 3.7 Press PARAMETER soft key b...

  • Page 141

    AUGUST 2005OPTIONS SETUP131 FANUC MAINTENANCE MANUAL 5. Find out Z axis zero position manually, make the cold start. 5.1 Install tool on the arm (DATC) or Magazine (ATC). 5.2 Measure the height of the tool. 5.3 Install the tool on the spindle. 5.4 Use MPG move the Z axis to the same height as the...

  • Page 142

    FADAL MACHINING CENTERS 132OPTIONS SETUPMAN-0121 R16.3 TOOL OFFSET SETUPFanuc Software option related with tool offset.6.3.1 TOOL OFFSET 200 PAIRS1. Update the software option from EZOPT disk according to Fanuc Software Option Installation Procedure. (See Option Installation process, section 6.1...

  • Page 143

    AUGUST 2005OPTIONS SETUP133 FANUC MAINTENANCE MANUAL - Press PAGE UP key once on the MDI pane.- Check the following screen on the CNC. If 400 pairs offset appears on the screen, the software installation is successful. Otherwise, repeat all the steps above all over again.6.3.3 TOOL OFFSET 499 P...

  • Page 144

    FADAL MACHINING CENTERS 134OPTIONS SETUPMAN-0121 R1 over again.6.3.4 TOOL OFFSET 999 PAIRS1. Update the software option form EZOPT disk according to Fanuc Software Option Installation Procedure. (See section 6.1, MAN-0121 R1)2. Cycle the CNC power.3. Follow these steps to display the following sc...

  • Page 145

    AUGUST 2005OPTIONS SETUP135 FANUC MAINTENANCE MANUAL

  • Page 146

    FADAL MACHINING CENTERS 136OPTIONS SETUPMAN-0121 R16.4 MULTI STEP SKIPFollow the next procedure:1. Update the software option from EZOPT disk according to the Fanuc Software Option Installation Procedure. (See section 6.1, MAN-0121 R1)2. Install the probe hardware and make sure that signal is wor...

  • Page 147

    AUGUST 2005OPTIONS SETUP137 FANUC MAINTENANCE MANUAL 6.5 OPTION SETUP PROCEDURE FOR K BITS1. Setup the machine type. 1.1 Push the OFFSET/setting key to select offset screen, push the “+” soft key below the LCD to find out MACRO soft key, and then select it. 1.2 Input 599. 1.3 Pres...

  • Page 148

    FADAL MACHINING CENTERS 138OPTIONS SETUPMAN-0121 R1Table 6-1: (Continued) Option Data SheetVARIABLE NO.VARIABLE VALUE MACHINE TYPE REMARKS#601 TOOL CHANGER POCKET NUMBER16ATC(*#601=24 MAGZINE POCKET NO.), ATC/DATC21ATC30ATC20DATC24DATC32DATC62DATC40HMC DATC92HMC D...

  • Page 149

    AUGUST 2005OPTIONS SETUP139 FANUC MAINTENANCE MANUAL #605 SPINDLE MAX CLAMP SPEED75007500RPM7.5K Spindle1000010000RPM15KSpindle 7.5 k1500015000RPM15K Spindle#606SPINDLE SHIFT SPEED (*spare parameter)2501Mech HI/LO=2501. Electrical HI/LO=2501#610A AXIS SELECTION0No A axis 1A axis exists#611B AXI...

  • Page 150

    FADAL MACHINING CENTERS 140OPTIONS SETUPMAN-0121 R1#615A AXIS SCALE SELECTION0No A axis scale EAK-00411A axis existsEAK-0041#616B AXIS SCALE SELECTION0No B axis scale 1B axis exists#617A AXIS TYPE SELECTION1VH165A4/5000is, EAK-00422TR165A4/5000is, EAK-00433V300/V400B8/3000is, EAK-00444SMW-175A2/5...

  • Page 151

    AUGUST 2005OPTIONS SETUP141 FANUC MAINTENANCE MANUAL 1.8 Run the option program from O8800 to O8805 one by one to active all the options.1.8.1 Press EDIT key to select edit mode, and push PROGRAM key on the MDI keyboard untilprogram directory is displayed on the CNC screen..1.8.2 Use PAGE UP/P...

  • Page 152

    FADAL MACHINING CENTERS 142OPTIONS SETUPMAN-0121 R1- Press PMC soft key- Press PMCPRM soft key- Press KEEPLY soft key- Move to the cursor to K4- Move to the bit 6 using cursor- Change the K4.6=1- Cycle the power- The alarm 1050 will disappear 1.11 ***Run the M84 when the spindle assembly is read...

  • Page 153

    AUGUST 2005OPTIONS SETUP143 FANUC MAINTENANCE MANUAL 6.6 MACHINE TIME STAMPFollow the next procedure:1. Update the software option from EZOPT disk according to Fanuc software option installation procedure. 2. Input the testing program P5006 from EDIT mode.3. Run the testing program O5006 from AUT...

  • Page 154

    FADAL MACHINING CENTERS 144OPTIONS SETUPMAN-0121 R1O5006G21G91G02 X3.0Y5.0R3.1234567M30

  • Page 155

    AUGUST 2005OPTIONS SETUP145 FANUC MAINTENANCE MANUAL 6.7 MOUNTING AND REMOVING OPTION BOARDWARNING! The replacement described here should be performed by a person fully trained in maintenance and safety. If the care not to touch any high–voltage area. If the area is uncovered, direct contact wi...

  • Page 156

    FADAL MACHINING CENTERS 146OPTIONS SETUPMAN-0121 R12. Connect the removed cables to correct positions. 6.7.2 MOUNTING AND REMOVING A MINI–SLOT OPTION BOARD (EXCEPT DEVICENET BOARD) Removing the board1. Remove cables connected to the target mini–slot option board. Remove other cables that wou...

  • Page 157

    AUGUST 2005OPTIONS SETUP147 FANUC MAINTENANCE MANUAL 6.7.3 MOUNTING AND REMOVING THE BACK PANEL WARNING!The replacement described here should be performed by a person fully trained in maintenance and safety. If the care not to touch any high–voltage area. If the area is uncovered, direct conta...

  • Page 158

    FADAL MACHINING CENTERS 148OPTIONS SETUPMAN-0121 R12. Pull up the back panel until the latch is engaged.3. Connect the fan connector to the back panel. 4. Mount the main CPU board and option boards. 6.7.4 REPLACING THE FUSE OF THE CONTROL UNITWARNING! Before starting the replacement of a f...

  • Page 159

    AUGUST 2005OPTIONS SETUP149 FANUC MAINTENANCE MANUAL Mounting position of the fuse of the control unit The fuse of the control unit is mounted on the main CPU board.6.7.5 REPLACING THE BATTERY Part programs, offset data, and system parameters are stored in CMOSmemory in the control unit. The powe...

  • Page 160

    FADAL MACHINING CENTERS 150OPTIONS SETUPMAN-0121 R1Replacing the batteryIf a lithium battery is used, have A02B–0200–K102 (FANUC internal code: A98L–0031–0012) handy. 1. Turn the CNC on. About 30 seconds later, turn the CNC off. 2. Remove the battery from the top area of the CNC unit. Dis...

  • Page 161

    AUGUST 2005OPTIONS SETUP151 FANUC MAINTENANCE MANUAL be completed within 30 minutes, save the whole contents of the CMOS memory to a memory card. The contents of the memory can be easily restored with the memory card in case the memory loses the contents. Discard the dead battery, observing appro...

  • Page 162

    FADAL MACHINING CENTERS 152OPTIONS SETUPMAN-0121 R13. Remove the lid from the battery case. 4. Replace the old dry cells with new ones. Mount the dry cells in a correct orientation. 5. Replace the lid on the battery case. In the power–off state, the battery should be replaced as in the case of...

  • Page 163

    AUGUST 2005OPTIONS SETUP153 FANUC MAINTENANCE MANUAL 2. Pull the fan unit to be replaced. 3. Lift the pulled fan unit until the fan unit is detached from the cabinet. 4. Place a new fan unit on the cabinet. 5. Push the new unit as far as it goes. When a click is heard, the unit is connected to th...

  • Page 164

    FADAL MACHINING CENTERS 154OPTIONS SETUPMAN-0121 R1Mounting position of the fuse•Information of the fuse Ordering information: A02B–0265–K101 Rating: 2.0 A Individual information: A60L–0001–0290#LM20C 6.7.8 REPLACING THE LCD BACKLIGHTWARNING! The replacement described here should be pe...

  • Page 165

    AUGUST 2005OPTIONS SETUP155 FANUC MAINTENANCE MANUAL Replacing the backlight1. Remove soft key cable connector CK2, then remove the escutcheon from the LCD unit. If the unit has a touch panel, remove touch panel signal cable connector CN1 as well.

  • Page 166

    FADAL MACHINING CENTERS 156OPTIONS SETUPMAN-0121 R12. Disconnect inverter cable connector CP1 and video signal cable connector CN8, then remove the LCD panel from the unit. 3. For 9.5. monochrome LCD

  • Page 167

    AUGUST 2005OPTIONS SETUP157 FANUC MAINTENANCE MANUAL 4. After replacing the backlight, assemble the unit, reversing the disassembly proce-dure of steps (1) to (3). During the assembly, take care to keep dust out. 6.7.9 HEAT GENERA-TION OF THE UNITS Table 6-2: Heat GenerationUNITHEART GENERATIONR...

  • Page 168

    FADAL MACHINING CENTERS 158OPTIONS SETUPMAN-0121 R1NOTE 1 The values are taken when 50% of the module inputs are turned on. 2 The heat generated in the separate detector is not included.

  • Page 169

    AUGUST 2005AUTOMATIC TOOL CHANGERS159 FANUC MAINTENANCE MANUAL 7.0 AUTOMATIC TOOL CHANGERSVMC models 3020, 4525, 6535 come standard with the Dual Arm Tool Changer. VMC models 2216, 3016, 4020, 6030, 8030 (DATC optional) come standard with a 21 tool capacity (30 tool capacity optional for 4020, 60...

  • Page 170

    FADAL MACHINING CENTERS 160AUTOMATIC TOOL CHANGERSMAN-0121 R17.1 OPERATION7.1.1PROGRAMMINGTo make an automatic tool change, an M6 code is used. This code can be used in a program or in Manual Data Input (MDI) mode.In a ProgramWhen another tool is needed, an M6 followed by a tool location. (T_) is...

  • Page 171

    AUGUST 2005AUTOMATIC TOOL CHANGERS161 FANUC MAINTENANCE MANUAL 16. Activate the turret motor and the turret reverse (if the reverse direction is required)circuit(s).17. Count the turret sensor signals, with a dwell time for coasting as set by the turretfactor, until the requested tool position is...

  • Page 172

    FADAL MACHINING CENTERS 162AUTOMATIC TOOL CHANGERSMAN-0121 R17.2 ADJUSTMENTSThere are four motions that influence the automatic tool changer alignment. These motions are:•Z-axis up & down.•Spindle orientation.•Turret in & out.•Turret rotation.7.2.1 Z AXIS COLD START ADJUSTMENT1. R...

  • Page 173

    AUGUST 2005AUTOMATIC TOOL CHANGERS163 FANUC MAINTENANCE MANUAL Figure 7-2: Move ATC Slide Toward Spindle5. Measure the distance from the ATC carriage to the nose of the spindle with athickness gauge. Adjust the Z axis until the nose of the spindle is .050” [1.27mm]above the turret carriage fo...

  • Page 174

    FADAL MACHINING CENTERS 164AUTOMATIC TOOL CHANGERSMAN-0121 R17.2.2 SPRING CONFIG-URATION 16, 21 & 30 TOOL CHANGERSFigure 7-4: Spring Configuration7.2.3 ATC TURRET SLIDE ADJUSTMENT1. Position the Z-axis to the machine zero.2. Orient the spindle using M190 from MDI mode. 3. Insert a tool holde...

  • Page 175

    AUGUST 2005AUTOMATIC TOOL CHANGERS165 FANUC MAINTENANCE MANUAL Figure 7-5: Loosen Hex Bolts / Move Slide to Spindle Until EngagedFigure 7-6: ATC Cylinder5. Give the slide a firm push toward the spindle. Retighten the 2 bolts.6. If the slide does not fully engage, loosen each of the six 3/8&qu...

  • Page 176

    FADAL MACHINING CENTERS 166AUTOMATIC TOOL CHANGERSMAN-0121 R17. Tighten all bolts on tool carrier and upper Geneva slot. If the slide still does notengage, check the spindle orientation.8. Disconnect the air to the machine.9. Move the ATC slide back.10. Switch the air lines connected to the air c...

  • Page 177

    AUGUST 2005AUTOMATIC TOOL CHANGERS167 FANUC MAINTENANCE MANUAL 7.3 ATC MOTOR REPLACEMENT PROCEDURE7.3.1 REPLACING THE TURRET MOTOR ON A GENEVA WHEEL ATC 1. Remove the ATC cover.2. Remove the Motor cover. 3. Disconnect the Molex connector with the motor wires.4. Disconnect the ground wire.5. Remov...

  • Page 178

    FADAL MACHINING CENTERS 168AUTOMATIC TOOL CHANGERSMAN-0121 R17.3.2 TURRET FACTOR SETTINGThis parameter is set at the factory. This parameter should not be changed unless the turret motor has been replaced or the tool turret rotation is over or under shooting. NOTE VMCs equipped with the Servo Tu...

  • Page 179

    AUGUST 2005AUTOMATIC TOOL CHANGERS169 FANUC MAINTENANCE MANUAL Figure 7-11: Fadal Spindle PulleysNOTCH NO.DESCRIPTION1ATC 16T, 21T, 30T, except 4020, 4020A, 5020A, 2ATC 30T, 4020, 4020A, 5020A3DATC 24T, 65354DATC 24T, except 65356DATC 3016DBalance positions

  • Page 180

    FADAL MACHINING CENTERS 170AUTOMATIC TOOL CHANGERSMAN-0121 R17.4 DUAL ARM TOOL CHANGER7.4.1 TOOL CHANGER SPECIFICATIONSTable 7-1: DATC Tool Changer SpecificationsSPECIFICATIONS2216301640206030803045256535/40TType of ToolCAT-40/BT-40Number of Tools202421/62Maximum Tool DiameterAll Pockets Fu...

  • Page 181

    AUGUST 2005AUTOMATIC TOOL CHANGERS171 FANUC MAINTENANCE MANUAL 7.4.2 SUB-ASSEM-BLIESFigure 7-12: Index MechanismTable 7-2: Index MechanismNo.Part Description1Cam Base2Cylindrical Cam3Sensor Block4Proximity Switch Bracket5Motor Base6Driving Shaft7Gear8Gear Plate 2

  • Page 182

    FADAL MACHINING CENTERS 172AUTOMATIC TOOL CHANGERSMAN-0121 R1Figure 7-13: Tool ArmTable 7-3: Tool ArmNo.Part Description1Tool Arm2Tool Draw3Tool Holding Rod4Spring Cover5Plunger6Positioning Key7Positioning Screw8Self Lubricating Bearing9Self Lubricating Bearing10Spring Pin

  • Page 183

    AUGUST 2005AUTOMATIC TOOL CHANGERS173 FANUC MAINTENANCE MANUAL Figure 7-14: Tool Falling MechanismTable 7-4: Tool Falling MechanismNo.Part Description1Tool Rod2Sliding Block3Sliding Block Cover Plate4Positioning Block Stand5Positioning Sliding Block (1)6Positioning Sliding Block (2)7Fixing Base ...

  • Page 184

    FADAL MACHINING CENTERS 174AUTOMATIC TOOL CHANGERSMAN-0121 R1Figure 7-15: Tool Turret7.4.3 INSTALLATION & TESTINGDual Arm ATC Installation and Alignment:1. Verify that all bolts are properly tightened.2. Remove the main cover surrounding the ATC arm and falling mechanism.3. Remove the oil in...

  • Page 185

    AUGUST 2005AUTOMATIC TOOL CHANGERS175 FANUC MAINTENANCE MANUAL 4. Install the ATC onto the machine using: 8 1/2 – 13 X 1 ¾ inch UNC-2B HHC hexcap screws with eight split lock washers. 5. Do not tighten the mount bolts completely. They will need to remain loose to allowfor the front to back and...

  • Page 186

    FADAL MACHINING CENTERS 176AUTOMATIC TOOL CHANGERSMAN-0121 R116. JOG the Z-axis down and position the head and spindle fixture at or near thenormal Z-axis cold start position. this will put the tool holder up inside the fixture. Donot allow the sides of the tool holder to touch the Inner Diameter...

  • Page 187

    AUGUST 2005AUTOMATIC TOOL CHANGERS177 FANUC MAINTENANCE MANUAL 25. Recheck the level and alignment of the ATC for front to back and side to side. Ifnecessary, re-adjust the alignment and tighten the ATC into position. See 189,Figure 7- 189,18:.26. Repeat above steps for the opposite tool gripper...

  • Page 188

    FADAL MACHINING CENTERS 178AUTOMATIC TOOL CHANGERSMAN-0121 R132. Remove the spindle fixture from the head.Figure 7-16: Manual Rotation of Tool ArmFigure 7-17: Pull Motor Brake Switch

  • Page 189

    AUGUST 2005AUTOMATIC TOOL CHANGERS179 FANUC MAINTENANCE MANUAL Figure 7-18: ATC Movement

  • Page 190

    FADAL MACHINING CENTERS 180AUTOMATIC TOOL CHANGERSMAN-0121 R1Figure 7-19: Engage Gripper Key Way7.4.4 SCHEDULED MAINTENANCEThe maintenance schedule is based on machine usage of eight hours a day, five days a week.Daily Maintenance Perform the following daily:1. Cleaninga. Remove the chips and de...

  • Page 191

    AUGUST 2005AUTOMATIC TOOL CHANGERS181 FANUC MAINTENANCE MANUAL b. Remove the chips and debris that have accumulated on the inverted movingbody of the tool pot.c. Clear the tool changing mechanism of all debris before any operation.2. Inspection:a. Check the parts of the tool falling mechanism for...

  • Page 192

    FADAL MACHINING CENTERS 182AUTOMATIC TOOL CHANGERSMAN-0121 R17.5 DATC TOOL CHANGER ADJUSTMENT PROCEDURE***Verify the cold start position.****First, should finish the M84 spindle belt calibration and spindle orientation setup before setup the tool changer.***Preparation: Verity the spindle orienta...

  • Page 193

    AUGUST 2005AUTOMATIC TOOL CHANGERS183 FANUC MAINTENANCE MANUAL active displayed when any Keep Relays are set to “1”. All settings are always to be set to “0” for use of machine by Auto/MDI commands.K0030.0 Z axis Tool Changer Position Proximity SwitchBypass door open proximity switch. Int...

  • Page 194

    FADAL MACHINING CENTERS 184AUTOMATIC TOOL CHANGERSMAN-0121 R1K5.7=1-- DATC 405. Spindle Orientation M codeM190

  • Page 195

    AUGUST 2005AUTOMATIC TOOL CHANGERS185 FANUC MAINTENANCE MANUAL 7.6 50 TAPER DUAL ARM TOOL CHANGER7.6.1 TOOL CHANGER SPECIFICATIONS7.6.2 SUB-ASSEM-BLIESFigure 7-20: Index MechanismTable 7-6: Tool Changer SpecificationsSPECIFICATIONS6535/50TType of ToolCAT-50/BT-50Number of Tools32Maximum Tool Dia...

  • Page 196

    FADAL MACHINING CENTERS 186AUTOMATIC TOOL CHANGERSMAN-0121 R1Figure 7-21: 50 Taper Tool ArmTable 7-7: Index MechanismNo.Part Description1Cam Base2Cylindrical Cam3Driving Spindle4Gear5Motor Base6Proximity Switch Base7Gear’s Locking Basket8Proximity Switch Block9Gear

  • Page 197

    AUGUST 2005AUTOMATIC TOOL CHANGERS187 FANUC MAINTENANCE MANUAL Figure 7-22: Tool Falling MechanismTable 7-8: 50 Taper Tool ArmNo.Part DescriptionNo.Part Description1Tool Arm Body12Counter Sunk Screw2Gripper13Female Hexagon Bolt3Tool Holding Rod14Spring(2)4Spring Cover15Spring(1)5Fixing Rod16Loc...

  • Page 198

    FADAL MACHINING CENTERS 188AUTOMATIC TOOL CHANGERSMAN-0121 R1Table 7-9: Tool Falling MechanismNo.Part DescriptionNo.Part Description1Tool Falling Pull Rod9Cylinder Base 2Sliding Block10Positioning Slide Block 3Sliding Block Cover Plate11Connecting Block4Positioning Block 12R-Fixing Plate 5Positio...

  • Page 199

    AUGUST 2005AUTOMATIC TOOL CHANGERS189 FANUC MAINTENANCE MANUAL Figure 7-23: Control ElementsTable 7-10: Control ElementsNo.Part Description1Tool Changing Mechanism Motor2Index Mechanism Motor3Proximity Switch 14Reed Switch 2

  • Page 200

    FADAL MACHINING CENTERS 190AUTOMATIC TOOL CHANGERSMAN-0121 R17.6.3 INSTALLATION1. Check if all the bolts and parts are affixed tightly (they might be loose duringtransportation). If not; fasten them tightly.2. Check if the automatic tool changer has any interference with the column ofmachining ce...

  • Page 201

    AUGUST 2005AUTOMATIC TOOL CHANGERS191 FANUC MAINTENANCE MANUAL 10. If the trial running of single action is not smooth, stop running to check, in order toavoid any damage.11. If it is necessary, prolong the time between each related action.12. When performing the successive running, be careful no...

  • Page 202

    FADAL MACHINING CENTERS 192AUTOMATIC TOOL CHANGERSMAN-0121 R17.6.5 TROUBLESHOOTINGTable 7-12: TroubleshootingSYMPTOMPOSSIBLE REASONSSOLUTIONTool disk is not rotating while tool selecting1) Proximity switch of tool counting and positioning of tool disc is not sensed2) Proxim...

  • Page 203

    AUGUST 2005AUTOMATIC TOOL CHANGERS193 FANUC MAINTENANCE MANUAL Table 7-12: (Continued) TroubleshootingSYMPTOMPOSSIBLE REASONSSOLUTIONCylinder is not acting1) Reed switch of tool falling (contracting of cylinder) is out of order2) Reed switch of tool returning (protruding of cylinder) is out of or...

  • Page 204

    FADAL MACHINING CENTERS 194AUTOMATIC TOOL CHANGERSMAN-0121 R17.6.6 MAINTENANCE1. The lubricant inside the lubricant container of the tool changing mechanism shouldbe changed after working for 2400 hours. When the cam, rollers and the bevel gear are in use without lubricant, abnormal wear and frac...

  • Page 205

    AUGUST 2005AUTOMATIC TOOL CHANGERS195 FANUC MAINTENANCE MANUAL 7.6.7 DUAL ARM TOOL CHANGER - ARM INSTALLATIONWARNING!The arm of the dual arm tool changer moves suddenly and with great force. Make sure that while performing the following procedure you and others are out of range of the arm. 7.6.8 ...

  • Page 206

    FADAL MACHINING CENTERS 196AUTOMATIC TOOL CHANGERSMAN-0121 R15. Insert a tool holder into the spindle and the lowered tool pot.6. Jog the Z axis to correct tool change position.7. Lock the spindle with the M190 command.8. Again enter the Dual Arm Tool Changer Menu and select number 4 (Move ArmRev...

  • Page 207

    AUGUST 2005AXES DRIVE SYSTEM197 FANUC MAINTENANCE MANUAL 8.0 AXES DRIVE SYSTEM

  • Page 208

    FADAL MACHINING CENTERS 198AXES DRIVE SYSTEMMAN-0121 R18.1 ROTARY TABLES, 4TH AXISFigure 8-1: Rotary Table8.1.1 PRE-INSTALLA-TIONRemove the top of the shipping crate:1. With a large screwdriver gently pry the clips from the bottom of the crate.2. Remove the crate top.Install all items except the...

  • Page 209

    AUGUST 2005AXES DRIVE SYSTEM199 FANUC MAINTENANCE MANUAL 8.1.2 REMOVE THE ROTARY TABLE FROM THE SHIPPING CRATEWARNING!Wear Safety goggles, steel toe shoes and gloves to reduce the risk of injury.The VMC table, or any surface on which the rotary table rests, must be free of chips, or anything else...

  • Page 210

    FADAL MACHINING CENTERS 200AXES DRIVE SYSTEMMAN-0121 R11. The Higgins nut pre-load should be no more than hand tight.Figure 8-2: Higgins Nut2. Secure the Higgins nut to the worm shaft by tightening the set screw.Figure 8-3: Tighten Set ScrewHiggins Nut

  • Page 211

    AUGUST 2005AXES DRIVE SYSTEM201 FANUC MAINTENANCE MANUAL 3. The bolts holding the worm pivot plate must be loose to allow setup for theadjustments.Figure 8-4: Loosen Bolts Holding Worm Pivot Plate4. The pivot adjustment screws should be set to zero (pivot plate resting on pin A)before starting t...

  • Page 212

    FADAL MACHINING CENTERS 202AXES DRIVE SYSTEMMAN-0121 R15. Turn the top pivot adjusting screw one turn on the side opposite of the motor. Turnthe screw on the motor side two turns. (A turn for this procedure is as far as thewrench will move from one side of the pocket to the opposite side). Figure...

  • Page 213

    AUGUST 2005AXES DRIVE SYSTEM203 FANUC MAINTENANCE MANUAL 7. Move the indicator to the opposite side and take a reading off of the motor sidepivot plate. Adjust the motor side pivot plate so that it is +.001 or -.0002 (+.0254mmor -.0508mm). Figure 8-8: Move Indicator and Take Reading8. Keep check...

  • Page 214

    FADAL MACHINING CENTERS 204AXES DRIVE SYSTEMMAN-0121 R111. Install motor plate o-ring and set motor on housing with two bolts at oppositecorners.Figure 8-10: Install Motor Plate O-Ring and Set on Housing12. Connect power leads to the motor.13. Listen to the operation of worm gear. Any knocking o...

  • Page 215

    AUGUST 2005AXES DRIVE SYSTEM205 FANUC MAINTENANCE MANUAL 16. Zero the indicator. Using a flat aluminum plate in the slots of the chuck, place forceup and down on the plate. If there is movement indicated, the worm gearadjustment is off. If there is no movement the motor gear backlash is the cause...

  • Page 216

    FADAL MACHINING CENTERS 206AXES DRIVE SYSTEMMAN-0121 R18.2 MAINTENANCE8.2.1 GEAR OILThe gear oil is the primary concern in rotary table maintenance. The oil should be changed every six to twelve months, depending on usage.1. Remove the 1/8-27 NPT plug from the cover plate opposite the motor.2. T...

  • Page 217

    AUGUST 2005AXES DRIVE SYSTEM207 FANUC MAINTENANCE MANUAL 8.3 A & B AXIS SETUPFollow the next procedure:1. Power off the machine. Install the A & B axis drive inside the cabinet and install the A axis rotary table.• Hardware:A axis drive for VH165 A06B-6114-H103 SERVO AMP SVM1-20iA&...

  • Page 218

    FADAL MACHINING CENTERS 208AXES DRIVE SYSTEMMAN-0121 R1•Reference all the axes•Double check the pitch compensation data if necessaryO4014(PITCH_A_SETUP)(*STEPOVER=10 FOR V300(*STEPOVER=20 FOR VH65, TR65(*N3605 BITO=0.UNIDIRECTIONAL PITCH COMP.(*N3620 p4R600(*N3621 p4R600(*N3622 p4R618(*N3623 ...

  • Page 219

    AUGUST 2005AXES DRIVE SYSTEM209 FANUC MAINTENANCE MANUAL N10624 R0N10625 R0N10626 R0N10627 R0N10628 R0N10629 R0N10630 R0N10631 R0N10632 R0N10633 R0N10634 R0N10635 R0N10636 R0N3620 P4R600N3621 P4R600N3622 P4R636N3623 P4R10N3624 P4R10000N3625 P4R360000N3626 P4R0N3627 P4R0G11GOTO70N60(*STEPOVER=20DE...

  • Page 220

    FADAL MACHINING CENTERS 210AXES DRIVE SYSTEMMAN-0121 R1N3621 P4R600N3622 P4R618N3623 P4R10N3624 P4R20000N3625 P4R360000N3626 P4R0N3627 P4R0N70M30%4. Make a cold start for A & B axis•Press MDI key on the operator panel•Press SYSTEM key on the MDI•Press PARAM soft key on LCD •Input 1850...

  • Page 221

    AUGUST 2005AXES DRIVE SYSTEM211 FANUC MAINTENANCE MANUAL Parameter:1851A______B______6. Check the A & B axis brake•Install the indicator on the table and touch the chuck of the A axis•Use M code to brake/release the A & B axis and check if the A & B axis is off from the original p...

  • Page 222

    FADAL MACHINING CENTERS 212AXES DRIVE SYSTEMMAN-0121 R18.4 DIGITAL AXIS DRIVE SYSTEM8.4.1 SETUP BACKLASH PROCEDURE***Prepare: In MDI mode, input G21 to change machine to Metric display.Follow the next procedure:1. Reference all the axes.Push Reference mode key and select referen...

  • Page 223

    AUGUST 2005AXES DRIVE SYSTEM213 FANUC MAINTENANCE MANUAL 1. Update the software option from EZOPT disk according to Fanuc software option installation procedure. (See Options Setup, Section 6.0)2. Cycle the CNC power.3. Following the procedure go to the next screen- press [OFFSET/SETTING] key on ...

  • Page 224

    FADAL MACHINING CENTERS 214AXES DRIVE SYSTEMMAN-0121 R1- press [PMC] soft key on the LCD screen- press [PMCDGN] soft key on the LCD screen- press [STATUS] soft key on the LCD screen- input [F110] from the MDI panel- press [SEARCH] soft key on the LCD screen4. Check the following screen on the CNC...

  • Page 225

    AUGUST 2005PALLET CHANGER215 FANUC MAINTENANCE MANUAL 9.0 PALLET CHANGER

  • Page 226

    FADAL MACHINING CENTERS 216PALLET CHANGERMAN-0121 R19.1 INSTALLATION OF PALLET CHANGER1. The left, front, lower edge of the base must be a minimum of 2” from the floor. Levelthe machine on the 1.5” leveling pads that were shipped with the machine (see theFadal Maintenance Manual Pre-Installat...

  • Page 227

    AUGUST 2005PALLET CHANGER217 FANUC MAINTENANCE MANUAL 8) Slide the Pallet Changer receiver base into position. Line up the floor plate railswith the bolt holes on the main casting base.Figure 9-2 Slide Pallet Changer Receiver Base into Position9. Install the bolts for the floor plate rails. Check...

  • Page 228

    FADAL MACHINING CENTERS 218PALLET CHANGERMAN-0121 R116. Move pallet A onto the machine by hand. Check for a smooth transition. If bindingoccurs, return the pallet to the receiver and check the alignment (Steps 12 and 13).17. Once the A pallet travels across the rails smoothly, return it to the re...

  • Page 229

    AUGUST 2005PALLET CHANGER219 FANUC MAINTENANCE MANUAL 23. Tighten the 5/16” socket head pallet arm bolt to 35-40 foot pounds.24. Store pallet A.a. In the ENTER NEXT COMMAND mode, type UT and press the ENTER button.b. Select option #5 PALLET CHANGERc. Select option #4 SERVICE UTILITYd. Select op...

  • Page 230

    FADAL MACHINING CENTERS 220PALLET CHANGERMAN-0121 R1f. Verify that the arm is lined up with the groove in pallet B. If the arm is not linedup with the groove, move the pallet forward or backward to allow the arm toenter the groove.g. Press the manual button to return to the utility menu. Press Op...

  • Page 231

    AUGUST 2005PALLET CHANGER221 FANUC MAINTENANCE MANUAL 9.2 INSTALLATION OF LIGHT CURTAIN1. Attach the front and rear base plates to the pallet receiver (A).2. Fasten the front and back light curtain mirror assemblies to the front and rear baseplates. Verify that both mirrors are level (B).3. Attac...

  • Page 232

    FADAL MACHINING CENTERS 222PALLET CHANGERMAN-0121 R13. Adjust mirror #2 until the receiver can be seen when looking in mirror #1. 4. Repeat the above steps while standing on the receiver side. If the mirrors arealigned properly, the transmitter will be viewed while looking in mirror #2 from there...

  • Page 233

    AUGUST 2005PALLET CHANGER223 FANUC MAINTENANCE MANUAL 9.3 SETTING THE SENSOR ON THE 1840 BOARD9.3.1 PURPOSEDuring a pallet change, the table will move to the table limits. If there is anything blocking the progress of the Y-axis, the current of the motor will be too high. The 1840 board senses wh...

  • Page 234

    FADAL MACHINING CENTERS 224PALLET CHANGERMAN-0121 R18. Make a pallet change In the MANUAL DATA INPUT mode (do not make a palletchange from the UTILITIES menu; a pallet change from the UTILITIES menu doesnot utilize all of the functions of a complete pallet change).In the MANUAL DATA INPUT mode:a....

  • Page 235

    AUGUST 2005PALLET CHANGER225 FANUC MAINTENANCE MANUAL 9.4 OPERATIONThe pallet changer may be operated within the program or by use of the UT (Utilities) command.9.4.1 PALLETSThere are 2 pallets on the pallet changer. They are identified as Pallet A and Pallet B. Pallet A is the closest pallet to ...

  • Page 236

    FADAL MACHINING CENTERS 226PALLET CHANGERMAN-0121 R19.5 MAINTENANCE SCHEDULE9.5.1 EACH PART CYCLE1. Use an M20 in the program to make it automatic. Frequent washing out of chipsprevents them from building up into difficult-to-remove piles.2. Blow away any chips that may lodge underneath Pallet in...

  • Page 237

    AUGUST 2005PALLET CHANGER227 FANUC MAINTENANCE MANUAL 5. Remove all tools from tool changer, and clean out any chip buildup found. Whenreturning tools to ATC, inspect retention ring tension on tool holders for excessivelooseness, replacing rings, if necessary.6. Disconnect front Y-axis way cover ...

  • Page 238

    FADAL MACHINING CENTERS 228PALLET CHANGERMAN-0121 R19.6 MIDACO PALLET CHANGER9.6.1 REQUIREMENTSPower requirementsThe pallet changer requires a 230V/Single Phase/30AMP power feed. The power is to be connected to the top of the power disconnect located in the pallet changer’s electrical enclosure...

  • Page 239

    AUGUST 2005PALLET CHANGER229 FANUC MAINTENANCE MANUAL Monthly1. Check the air pressure level. Maintain a constant supply of 90-120 PSI.2. Check the cam followers to make sure they move freely.For more detailed information see Midaco Pallet Changer Servo Drive Manual.

  • Page 240

    FADAL MACHINING CENTERS 230PALLET CHANGERMAN-0121 R12.6.3 PALLET

  • Page 241

    AUGUST 2005SPINDLE DRIVE SYSTEMS231 FANUC MAINTENANCE MANUAL 10.0 SPINDLE DRIVE SYSTEMS

  • Page 242

    FADAL MACHINING CENTERS 232SPINDLE DRIVE SYSTEMSMAN-0121 R110.1 BELT DRIVE SYSTEMS10.1.1 POSI-DRIVE BELT SYSTEMThe Posi-Drive Belt System features two belts that run on a 1-2 and 2-1 reduction pulley arrangement.Spindle Belts Replacement on Auto Hi/low SystemThe spindle drive belts are Gates 315...

  • Page 243

    AUGUST 2005SPINDLE DRIVE SYSTEMS233 FANUC MAINTENANCE MANUAL 6. Remove six each of the 1/4” hex bolts holding the Drawbar Cylinder assembly.Figure 10-2: Remove Hex Bolts Holding Drawbar Cylinder Assembly7. Remove the Drawbar Cylinder assembly. 8. Disconnect the Orientation Bridge/Drawbar hall ...

  • Page 244

    FADAL MACHINING CENTERS 234SPINDLE DRIVE SYSTEMSMAN-0121 R19. Remove three each of the 3/8” socket head cap screws holding the OrientationBridge assembly.Figure 10-5: Remove Socket Head Cap Screws10. Remove the Orientation Bridge assembly and front belt guide.Figure 10-6: Remove Orientation B...

  • Page 245

    AUGUST 2005SPINDLE DRIVE SYSTEMS235 FANUC MAINTENANCE MANUAL Figure 10-8: Remove Spindle Motor Bolt13. Swing the spindle motor forward and remove the rear belt guide from the left side.Figure 10-9: Remove Rear Belt Guide14. Remove the 2 spindle drive belts.15. Replace the 2 spindle drive belts....

  • Page 246

    FADAL MACHINING CENTERS 236SPINDLE DRIVE SYSTEMSMAN-0121 R110.1.2 MOTOR PLATE TENSIONER CABLEMachines equipped with a motor plate tensioner cable system (10K), as shown in the figure below, will need adjusting when belts are replaced.Adjustment procedure:1. Disconnect the air supply from the mac...

  • Page 247

    AUGUST 2005SPINDLE DRIVE SYSTEMS237 FANUC MAINTENANCE MANUAL 10.2 HYDRAULIC HI/LOW SYSTEMThe hydraulic hi/low system requires very little maintenance. It is an air over oil system with check valves. Periodically check that you can see fluid in the 1/4 inch lines that go to the rear of the cylinde...

  • Page 248

    FADAL MACHINING CENTERS 238SPINDLE DRIVE SYSTEMSMAN-0121 R110.2.1 7,500 RPM POLY CHAIN BELTThis system features a single belt that runs on a 1-1 pulley arrangement.Spindle Belt ReplacementThe spindle drive belt is a Gates Poly-chain. Gates manufactures the belt to Fadal specification. When replac...

  • Page 249

    AUGUST 2005SPINDLE DRIVE SYSTEMS239 FANUC MAINTENANCE MANUAL 6. Remove each of the six 1/4” hex bolts to the Drawbar assembly.Figure 10-12: Remove Hex Bolts to Drawbar Assembly7. Remove the Drawbar assembly.8. Remove each of the four 3/8” cap bolts to the Orientation Bridge assembly.Figure 1...

  • Page 250

    FADAL MACHINING CENTERS 240SPINDLE DRIVE SYSTEMSMAN-0121 R110. Loosen each of the two 1/2” hex bolts to the Spindle motor.Figure 10-14: Loosen Hex Bolts to Spindle Motor11. Swing the Spindle motor forward.12. Remove the Spindle drive belt.13. Install the new Spindle drive belt.14. Mount a Mag ...

  • Page 251

    AUGUST 2005SPINDLE DRIVE SYSTEMS241 FANUC MAINTENANCE MANUAL 10.3 TOOLS STICKING IN THE SPINDLE DURING A CHANGE CYCLEThere are many different solutions to problems leading to sticking tools, and although most machines experiencing a sticking tool problem will exhibit only one or two of these symp...

  • Page 252

    FADAL MACHINING CENTERS 242SPINDLE DRIVE SYSTEMSMAN-0121 R110.3.2 DRAWBAR CYLINDER HALL EFFECTS SWITCHTool "Popping" can be reduced on machines equipped with Drawbar Cylinder Hall Effects switches, by checking the adjustment on the switch. If the switch is up too high, then the Z-axis ...

  • Page 253

    AUGUST 2005SPINDLE DRIVE SYSTEMS243 FANUC MAINTENANCE MANUAL correct location of the magnet for the Hall Effects switch, and avoid cutting the large O-ring accidentally.10.3.8 AIR LEAKS: HYDRAULIC ACTUA-TOR ASSEMBLY BOLTSTwo of the 1/4-20 bolts used to mount the Hydraulic Actuator assembly penet...

  • Page 254

    FADAL MACHINING CENTERS 244SPINDLE DRIVE SYSTEMSMAN-0121 R1indicate galling of the surface. Recently the Knock-Out Cap was redesigned to provide a capturing ridge to contain the upper points of the crown of the spring pilot. With the increased tool retention forces, we have seen some distortion o...

  • Page 255

    AUGUST 2005SPINDLE DRIVE SYSTEMS245 FANUC MAINTENANCE MANUAL 10.3.19 MEASURING DRAWBAR PERFOR-MANCEIn order to measure the amount of push force that the Drawbar Cylinder has upon the tool, place a tool holder into the spindle (without a tool in it) and Jog the machine slowly downward in Z-axis o...

  • Page 256

    FADAL MACHINING CENTERS 246SPINDLE DRIVE SYSTEMSMAN-0121 R110.3.20 DRB-0024 STICKING TOOLS KIT, 10K LDB, DRB-0025 STICKING TOOLS KIT, 10K LDB-CT=Figure 10-17: Drawbar Kit

  • Page 257

    AUGUST 2005SPINDLE DRIVE SYSTEMS247 FANUC MAINTENANCE MANUAL 10.4 SPINDLE DRAWBAR AND BELLEVILLE SPRING REPLACEMENT10.4.1 DRAWBAR REMOVAL1. Remove the Drawbar Cylinder Assembly.2. Remove the Orientation Bridge Assembly.3. Place a long 3/8 inch drive extension or similar item in the spindle and jo...

  • Page 258

    FADAL MACHINING CENTERS 248SPINDLE DRIVE SYSTEMSMAN-0121 R110.4.3 REMOVE FLOATER1. Remove the drawbar (See Drawbar Removal, Section 10.4.1, MAN-0121 R1)2. The floater has two ball bearings that hold it in place. Using a floater removal tool ora magnet pull the ball bearing toward the center and...

  • Page 259

    AUGUST 2005SPINDLE DRIVE SYSTEMS249 FANUC MAINTENANCE MANUAL 10.5 SPINDLE PRE-LOAD10.5.1 MEASURING THE SPINDLE PRE-LOAD1. Place a Pressure Gage (SVT-0066) on the table and align it with the Spindle nose. 2. Set an indicator on the Head and touch the indicator tip on the nose of th...

  • Page 260

    FADAL MACHINING CENTERS 250SPINDLE DRIVE SYSTEMSMAN-0121 R110.6 SPINDLE DUTY CYCLEThe Fadal Engineering Department in conjunction with the bearing manufacturers recommend that the following procedures be followed to increase spindle life under extreme operating conditions.Spindles operating under...

  • Page 261

    AUGUST 2005SPINDLE DRIVE SYSTEMS251 FANUC MAINTENANCE MANUAL 10.7 AIR POSITIVE FLOW SYSTEMFigure 10-18: Air Positive Flow System

  • Page 262

    FADAL MACHINING CENTERS 252SPINDLE DRIVE SYSTEMSMAN-0121 R110.8 SPINDLES10.8.1 10K GREASE PACKED SPINDLESComponentsThe 10K grease packed spindles are self contained units.Functional DescriptionThese spindles are belt driven and require no maintenance. There is air supplied to the spindle on the t...

  • Page 263

    AUGUST 2005SPINDLE DRIVE SYSTEMS253 FANUC MAINTENANCE MANUAL 10.8.3 SPINDLE/LUBE PUMP/CONTROLSpindleBearingsCeramic Steel HybridLubricationAir and oil pressure feed back controlOperating temp.Ambient +20°F during steady state operationMotor Power15 HPMax. Speed15,000 RPMMax. Cut3/8” Max. Dept...

  • Page 264

    FADAL MACHINING CENTERS 254SPINDLE DRIVE SYSTEMSMAN-0121 R14. Remove the head cover by removing the four 1/4 -20 socket head cap screws.5. Disconnect the electrical connection to the orientation bridge assembly at the sixpin connector plug.6. Disconnect the two 1/4” air lines from the orientati...

  • Page 265

    AUGUST 2005SPINDLE DRIVE SYSTEMS255 FANUC MAINTENANCE MANUAL 10.8.4 COMPONENT INSTALLATIONRegulator/ Separation Block Mounting The regulator should be installed at the same location that it was at when the machine was originally installed.Installing Spindle Lubrication PumpMount the spindle lubr...

  • Page 266

    FADAL MACHINING CENTERS 256SPINDLE DRIVE SYSTEMSMAN-0121 R15. Above items must be checked properly or spindle tram test may be invalid.Figure 10-19: Granite Block for Spindle Tram Test6. Establish X,Y plane by mounting an indicator in spindle. Touch off granite block atpoints A,B,C, and D by mov...

  • Page 267

    AUGUST 2005SPINDLE DRIVE SYSTEMS257 FANUC MAINTENANCE MANUAL 10.8.6 ADJUSTING SPINDLE TRAMIf spindle is to be installed, follow this procedure. Clean all surfaces and replace O-rings. Mount spindle in head using 6 SoCap bolts. Check tram as described above. Determine which position shows t...

  • Page 268

    FADAL MACHINING CENTERS 258SPINDLE DRIVE SYSTEMSMAN-0121 R110.9 15K AIR/OIL SPINDLE INSTALLATION1. Verify that the lower spindle O-ring is in good condition (not cut, torn or pinched).2. Position the 15K spindle in the head with O-ring seal.3. Install six socket head cap screws and evenly tighten...

  • Page 269

    AUGUST 2005SPINDLE DRIVE SYSTEMS259 FANUC MAINTENANCE MANUAL 18. Install the orientation bridge assembly and front belt guide with the three 3/8”socket head cap screws, and tighten them snugly.19. Install the draw bar cylinder plate with the six hex head bolts, and tighten the bolts.20. Connec...

  • Page 270

    FADAL MACHINING CENTERS 260SPINDLE DRIVE SYSTEMSMAN-0121 R110. Connect the inlet line, stamped “AIR/OIL IN” (23) on the lower flange, to the singleend of the Y-fitting.11. Connect the other air/oil PDI line (22) and the other pressure switch line (26) to thedouble end of the second Y-fitting....

  • Page 271

    AUGUST 2005SPINDLE DRIVE SYSTEMS261 FANUC MAINTENANCE MANUAL NOTE Observe the color of the oil coming out of the oil pressure line. If the color is DARK BROWN, there is way lube oil in the pump. Prime the line until the way lube oil is flushed out. The spindle oil color is LIGHT YELLOW, prime th...

  • Page 272

    FADAL MACHINING CENTERS 262SPINDLE DRIVE SYSTEMSMAN-0121 R110.10 40 TAPER BT & CAT PULL STUDSFigure 10-22: 40-Taper BT & CAT Pull StudsFigure 10-23: 40-Taper BT & CAT Pull Studs

  • Page 273

    AUGUST 2005FUSES263 FANUC MAINTENANCE MANUAL 11.0 FUSESBefore replacing a blown fuse, it is necessary to locate and remove the cause of the blown fuse.For this reason, only those personnel who have received approved safety and maintenance training may perform this work.WARNING!Before starting the...

  • Page 274

    FADAL MACHINING CENTERS 264FUSESMAN-0121 R1 11.1 REPLACING THE FUSE OF LCD UNIT Mounting position of the fuseFigure 11-1: Fuse of LCD unit•Information of the fuse Ordering information: A02B–0265–K101 Rating: 2.0 A Individual information: A60L–0001–0290#LM20C

  • Page 275

    AUGUST 2005FUSES265 FANUC MAINTENANCE MANUAL 11.2 PANEL FUSESFuses are GMA-1, GMA-2, GMA-3, GMA-5.LocationTable 11-1: Panel FusesTERMINAL BLOCKPOSITIONFUSET.B.1180F124V 5AMP180F224V 3AMP180F324V 1AMP180F424V 5AMPT.B.3170FU1120V 2AMP170FU2120V 2AMP170FU3120V 2AMP173FU1120V 3AMPT.B.4850FU124V 1A...

  • Page 276

    FADAL MACHINING CENTERS 266FUSESMAN-0121 R1Table 11-1: (Continued) Panel FusesTERMINAL BLOCKPOSITIONFUSET.B 4 (cont)853FU524V 5AMP853FU624V 5AMP853FU724V 5AMP853FU824V 5AMP854FU124V 2AMP854FU224V 2AMP854FU324V 2AMP854FU424V 2AMP854FU524V 2AMP854FU624V 2AMP854FU724V 2AMP854FU824V 2AMP855FU124V 2...

  • Page 277

    AUGUST 2005FUSES267 FANUC MAINTENANCE MANUAL 11.3 REPLACING THE FUSE OF THE CONTROL UNIT Mounting position of the fuse of the control unit The fuse of the control unit is mounted on the main CPU board.Figure 11-2: Fuse of the control unit

  • Page 278

    FADAL MACHINING CENTERS 268FUSESMAN-0121 R1 11.4 REPLACING FUSES ON VARIOUS UNITSFuse mounting location on the connector panel I/O modulesFigure 11-3: Fuses on various unitsNOTE No fuse is provided on the expansion modules. A fuse is provided on the basic module only.

  • Page 279

    AUGUST 2005FUSES269 FANUC MAINTENANCE MANUAL Fuse mounting location on the operator’s panel I/O modulesFigure 11-4: Fuse on the operator’s panelFuse mounting location on the operator’s panel connection units Figure 11-5: Fuse on the operator’s panel

  • Page 280

    FADAL MACHINING CENTERS 270FUSESMAN-0121 R1 Fuse mounting locations on the machine operator’s panel interface unit Figure 11-6: Fuse on the machine operator’s panelFU1: Fuse for +24V (for protection of general–purpose DO and the power supply of this printed circuit board) FU2: Fuse for +5V...

  • Page 281

    AUGUST 2005FUSES271 FANUC MAINTENANCE MANUAL Fuse mounting location on the distributed I/O machine operator’s panelsFigure 11-7: Fuse the distributed I/O panelFuse mounting location on the separate detector interface unit Figure 11-8: Fuse on the separate ditector

  • Page 282

    FADAL MACHINING CENTERS 272FUSESMAN-0121 R1

  • Page 283

    AUGUST 200512.0 GENERAL INFORMATION273 FANUC MAINTENANCE MANUAL 12.0 GENERAL INFORMATION

  • Page 284

    FADAL MACHINING CENTERS 27412.0 GENERAL INFORMATIONMAN-0121 R112.1 HELPFUL FORMULAS12.1.1 TEMPERATUREDegrees Fahrenheit (F) = (9/5 x degrees C) + 32Degrees Celsius (C) = 5/9 x (degrees F-32)12.1.2 CONVERSION FACTORSInch (in) = millimeter x 0.03937Inch (in) = centimeter x 0.3937Millimeter (m...

  • Page 285

    AUGUST 200512.0 GENERAL INFORMATION275 FANUC MAINTENANCE MANUAL Three-PhaseKilovolt-Amperes (KVA) = (Volts x Amperes x 1.73) / 100012.1.4 EXPANSION COEFFICIENTSFormulaExpansion amount = Coefficient x distance x degree of temperature change (Fahrenheit)CoefficientsSteel=.00000633Cast Iron=.0000065...

  • Page 286

    FADAL MACHINING CENTERS 27612.0 GENERAL INFORMATIONMAN-0121 R112.2 THERMAL EXPANSION12.2.1 OVERVIEWThermal expansion is a natural occurrence in materials subject to heat, and there are several sources of heat in any machining operation. In addition, different materials react to heat at different...

  • Page 287

    AUGUST 200512.0 GENERAL INFORMATION277 FANUC MAINTENANCE MANUAL 12.2.5 HEAT SOURCESIt comes as no surprise that the primary source of heat in machining is friction; however, some of the sources of friction, and all of the areas affected by a given friction source, may not be readily apparent. Ad...

  • Page 288

    FADAL MACHINING CENTERS 27812.0 GENERAL INFORMATIONMAN-0121 R1of carrying away the heat of the cut and minimizing the effects of thermal expansion resulting from that heat.Yet another practice that deserves mentioning is machining parts at temperatures significantly different from those at which ...

  • Page 289

    AUGUST 200512.0 GENERAL INFORMATION279 FANUC MAINTENANCE MANUAL 12.3 NON-UNIFORM EXPANSION12.3.1 MATERIAL DIFFERENCESThe differing rates of expansion by unlike materials further complicate the problems created by the heat generated in the machining process. This applies both to parts stock, li...

  • Page 290

    FADAL MACHINING CENTERS 28012.0 GENERAL INFORMATIONMAN-0121 R1on the table. Because of its large size, the table seems less affected by the heat of machining. It will expand, but it takes longer to heat or cool the entire table. In addition, the use of coolant tends to stabilize the temperature o...

  • Page 291

    AUGUST 200512.0 GENERAL INFORMATION281 FANUC MAINTENANCE MANUAL 12.4 SOLVING THE THERMAL EXPANSION PROBLEM12.4.1 GENERAL CONSIDERATIONSA simplified description of the thermal environment in machining would state that heat is generated through friction, and also input through ambient factors. Th...

  • Page 292

    FADAL MACHINING CENTERS 28212.0 GENERAL INFORMATIONMAN-0121 R112.5 READING STATUS GROUPReading a status in a computer can be very helpful for troubleshooting. Status is usually a byte or a word. The status is normally represented in hexadecimal. To demonstrate how a status byte is decoded, the co...

  • Page 293

    AUGUST 200512.0 GENERAL INFORMATION283 FANUC MAINTENANCE MANUAL 12.6 VMC MAINTENANCE12.6.1 CABINET FANSThe fans in the cabinets must be functioning properly. The purpose of the fans in the cabinets is to cool the electronics and to move the heat out the vents. An excessive amount of heat in the c...

  • Page 294

    FADAL MACHINING CENTERS 28412.0 GENERAL INFORMATIONMAN-0121 R1This process is also effective for inspecting parts. By cooling the part prior to the finish cuts, the temperatures at final cut and at inspection can be brought closer. In this situation, the target temperature should also be close to...

  • Page 295

    AUGUST 200512.0 GENERAL INFORMATION285 FANUC MAINTENANCE MANUAL ProbeA probe in the spindle can be used as a part of the program to discover what adjustments are required to compensate for thermal expansion. The probe can be used to pick up the new home position at the beginning of each program, ...

  • Page 296

    FADAL MACHINING CENTERS 28612.0 GENERAL INFORMATIONMAN-0121 R112.6.5 CONCLUSIONThermal expansion is a natural occurrence in any machining operation, and, when ignored, can significantly impact positioning repeatability. By identifying and eliminating unwanted heat sources, by calculating or meas...

  • Page 297

    AUGUST 2005INDEX287 FANUC MAINTENANCE MANUAL INDEX10K GREASE PACKED SPINDLES 25215K AIR/OIL SPINDLE 25215K AIR/OIL SPINDLE INSTALLATION 2582216 & 3016 TABLE 193020 & 4525 TABLE 2040 TAPER BT & CAT PULL STUDS 2624020 TABLE 2150 TAPER DUAL ARM TOOL CHANGER .1856030 TABLE 226535 TABLE...

  • Page 298

    FADAL MACHINING CENTERS 288INDEXMAN-0121 R1CCABINET FANS 283CHECKING GROUNDING INTEGRITY OF FADAL VMCS37CHIP CONVEYOR 63CHIP CONVEYOR 78CHIP CONVEYOR POWER AND CONTROLS64CNC STATE DISPLAY 91COMPONENT INSTALLATION 255CONCLUSION 286CONDUIT 40CONFIGURATION DISPLAY OF SOFTWARE 84CONFIGURATION OF P...

  • Page 299

    AUGUST 2005INDEX289 FANUC MAINTENANCE MANUAL FINAL FILES BACKUP PROCEDURE 119FIXTURES / SUB PLATES 279FLUIDS 73FOR ALL BOX WAY VMCS51FOUNDATION 28FRICTION 277FUSES 263GGEAR OIL 206GENERAL 62GENERAL CONSIDERATIONS 281GENERAL INFORMATION 273HHEAT GENERATION OF THE UNITS 157HEAT SOURCES 277HEL...

  • Page 300

    FADAL MACHINING CENTERS 290INDEXMAN-0121 R1MMACHINE ASSEMBLIES 279MACHINE COLD START SETUP 129MACHINE INSTALLATION & HOOK-UP 42MACHINE MAINTENANCE 67MACHINE TIME STAMP 143MACHINING PRACTICES 277MACHINING PRACTICES 283MAINTENANCE 194MAINTENANCE 206MAINTENANCE 228MAINTENANCE & LUBRICAT...

  • Page 301

    AUGUST 2005INDEX291 FANUC MAINTENANCE MANUAL PPALLET CHANGER 215PALLET 230PALLETS 225PANEL FUSES 265PARAMETER 98PARAMETER INPUT/OUTPUT105PENDANT INSTALLATION 59PERIODIC MAINTENANCE SCREENS 107PHASE CONVERTER ROTARY 50PLACING THE VMC 42PLUMBING SPINDLE 259POSI-DRIVE BELT SYSTEM 232POSITIONIN...

  • Page 302

    FADAL MACHINING CENTERS 292INDEXMAN-0121 R1SCREEN DISPLAY 99SCREEN DISPLAY AND OPERATION 94SCREEN DISPLAY AND SETTING 107SERIALIZED MATCHED SETS 206SETTING MODULE SCREEN 83SETTING THE SENSOR ON THE 1840 BOARD 223SETTING THE VH-65 WORM GEAR BACKLASH 199SETUP BACKLASH PROCEDURE 212SHIPPING D...

  • Page 303

    AUGUST 2005INDEX293 FANUC MAINTENANCE MANUAL UUNPACKING 42VVERIFICATION - CHECK GROUNDING INTEGRITY WITH FLUKE METER 37VMC 2216 2VMC 3016 4VMC 3020 12VMC 4020 6VMC 4525 14VMC 6030 8VMC 6535 16VMC 8030 10VMC MAINTENANCE283VMC OPTIONS 284WWEEKLY MAINTENANCE 226WIRING 39WORK COORDINATE SETUP 212...

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