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    OCTOBER 2005SIEMENS MAINTENANCE MANUAL SIEMENS SINUMERIK 840D CONTROL MAINTENANCE MANUAL FADAL MACHIN...

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    FADAL MACHINING CENTERS MAN_0126_R1

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    OCTOBER 2005TABLE OF CONTENTSi SIEMENS MAINTENANCE MANUAL actionGoToR:TABLE OF CONTENTS1.0 SPECIFICATIONS .....................................................................................................................................1actionGoToR:1.1 ILLUSTRATIONS & DATA FOR ALL VMC MODE...

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    FADAL MACHINING CENTERS iiTABLE OF CONTENTSMAN-0126_R1actionGoToR:3.1.4 POWER CHECK actionGoToR:.................................................................................................................................44actionGoToR:3.2 TRANSFORMER actionGoToR:TAPPING actionGoToR:............

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    OCTOBER 2005TABLE OF CONTENTSiii SIEMENS MAINTENANCE MANUAL actionGoToR:5.3.2 FIXTURES / SUB PLATES actionGoToR:...................................................................................................................85actionGoToR:5.3.3 MACHINE ASSEMBLIES actionGoToR:......................

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    FADAL MACHINING CENTERS ivTABLE OF CONTENTSMAN-0126_R1

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    OCTOBER 2005SPECIFICATIONS1 SIEMENS 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-0126_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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    OCTOBER 2005SPECIFICATIONS3 SIEMENS 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 .708" x 4.33"3 x 18 mm x 110 mmCut...

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    FADAL MACHINING CENTERS 4SPECIFICATIONSMAN-0126_R11.1.2 VMC 3016Figure 1-2: VMC 3016NOTE Dimensions represented in inches and [millimeters].

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    OCTOBER 2005SPECIFICATIONS5 SIEMENS 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 .708" x 4.33"3 x 18 mm x 110 mmCut...

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    FADAL MACHINING CENTERS 6SPECIFICATIONSMAN-0126_R11.1.3 VMC 4020Figure 1-3: VMC 4020NOTE Dimensions represented in inches and [millimeters].

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    OCTOBER 2005SPECIFICATIONS7 SIEMENS 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 .708" x 3.74"5 x18 mm x 95 mmCut...

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    FADAL MACHINING CENTERS 8SPECIFICATIONSMAN-0126_R11.1.4 VMC 6030Figure 1-4: VMC 6030NOTE Dimensions represented in inches & [millimeters].

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    OCTOBER 2005SPECIFICATIONS9 SIEMENS 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 .708" x 5.512"5 x 18 mm x 140 mmCutti...

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    FADAL MACHINING CENTERS 10SPECIFICATIONSMAN-0126_R11.1.5 VMC 8030Figure 1-5: VMC 8030NOTE Dimensions represented in inches & [millimeters].

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    OCTOBER 2005SPECIFICATIONS11 SIEMENS 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 .708" x 5.512"5 x 18 mm x 140...

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    FADAL MACHINING CENTERS 12SPECIFICATIONSMAN-0126_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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    OCTOBER 2005SPECIFICATIONS13 SIEMENS 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 .708" x 3.74"5 x 18 mm x 95 ...

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    FADAL MACHINING CENTERS 14SPECIFICATIONSMAN-0126_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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    OCTOBER 2005SPECIFICATIONS15 SIEMENS 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 .708" x 4.92"5 x 18mm x 125mmCut...

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    FADAL MACHINING CENTERS 16SPECIFICATIONSMAN-0126_R11.1.8 VMC 6535Figure 1-8: VMC 6535NOTE Dimensions represented in inches & [millimeters].SIDE VIEWFRONT VIEWTOP VIEW - BASETOP VIEW

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    OCTOBER 2005SPECIFICATIONS17 SIEMENS 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 .708" x 4.92"5 x 18mm x 1...

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    FADAL MACHINING CENTERS 18SPECIFICATIONSMAN-0126_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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    OCTOBER 2005SPECIFICATIONS19 SIEMENS 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....

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    FADAL MACHINING CENTERS 20SPECIFICATIONSMAN-0126_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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    OCTOBER 2005SPECIFICATIONS21 SIEMENS 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-0126_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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    OCTOBER 2005SPECIFICATIONS23 SIEMENS 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-0126_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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    OCTOBER 2005SPECIFICATIONS25 SIEMENS 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”...

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    FADAL MACHINING CENTERS 26SPECIFICATIONSMAN-0126_R11.3 RECOMMENDED MAINLINE FUSES / CIRCUIT BREAKERSTable 1-17: Circuit Breakers for the New Sheet MetalSPINDLETYPE380-415 V3 PHASE480 V3 PHASE5 HP30A30A10 HP35A30AHT35A40AVHT70A70A50 Taper70A70 A

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    OCTOBER 2005PRE-INSTALLATION PROCEDURES27 SIEMENS MAINTENANCE MANUAL 2.0 PRE-INSTALLATION PROCEDURES

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    FADAL MACHINING CENTERS 28PRE-INSTALLATION PROCEDURESMAN-0126_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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    OCTOBER 2005PRE-INSTALLATION PROCEDURES29 SIEMENS 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 ...

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    FADAL MACHINING CENTERS 30PRE-INSTALLATION PROCEDURESMAN-0126_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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    OCTOBER 2005PRE-INSTALLATION PROCEDURES31 SIEMENS 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...

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    FADAL MACHINING CENTERS 32PRE-INSTALLATION PROCEDURESMAN-0126_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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    OCTOBER 2005PRE-INSTALLATION PROCEDURES33 SIEMENS 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 t...

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    FADAL MACHINING CENTERS 34PRE-INSTALLATION PROCEDURESMAN-0126_R12.4 AIR SUPPLYWARNING!Air pressure required: 120 psi 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 dist...

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    OCTOBER 2005PRE-INSTALLATION PROCEDURES35 SIEMENS 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...

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    FADAL MACHINING CENTERS 36PRE-INSTALLATION PROCEDURESMAN-0126_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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    OCTOBER 2005PRE-INSTALLATION PROCEDURES37 SIEMENS 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 gro...

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    FADAL MACHINING CENTERS 38PRE-INSTALLATION PROCEDURESMAN-0126_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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    OCTOBER 2005PRE-INSTALLATION PROCEDURES39 SIEMENS MAINTENANCE MANUAL 2.6.7 WIRINGTable 2-5: Wiring Requirements40 Taper480 VAC 3 Ø10 AWG (6 mm2) stranded THHN copper within 100 ft. of panel. For VHT 6 AWG8 AWG (10 mm2) stranded THHN copper 100 ft. or more from panel.For VHT 4 AWG50 Taper480 VAC ...

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    FADAL MACHINING CENTERS 40PRE-INSTALLATION PROCEDURESMAN-0126_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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    OCTOBER 2005INSTALLATION PROCEDURE41 SIEMENS 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-0126_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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    OCTOBER 2005INSTALLATION PROCEDURE43 SIEMENS 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) mom...

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    FADAL MACHINING CENTERS 44INSTALLATION PROCEDUREMAN-0126_R12. Check the pressure gauge for 120 psi and adjust the regulator on the VMC ifnecessary.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 toappro...

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    OCTOBER 2005INSTALLATION PROCEDURE45 SIEMENS MAINTENANCE MANUAL Verify the MOV Surge Suppressor Board1. Locate the MOV Surge Suppressor Board (see 51,Figure 3-2: MOV Surge SuppressorBoard).Figure 3-2: MOV Surge Suppressor Board2. Find the part number on the board.a. If your incoming voltage is ...

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    FADAL MACHINING CENTERS 46INSTALLATION PROCEDUREMAN-0126_R1Figure 3-3: Figure 3-4:

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    OCTOBER 2005INSTALLATION PROCEDURE47 SIEMENS MAINTENANCE MANUAL Figure 3-5: Figure 3-6:

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    FADAL MACHINING CENTERS 48INSTALLATION PROCEDUREMAN-0126_R1Figure 3-7:

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    OCTOBER 2005INSTALLATION PROCEDURE49 SIEMENS MAINTENANCE MANUAL 3.2 TRANSFORMER TAPPING1. With the machine main power switch turned OFF, verify that the chart on the door ofthe cabinet is the one for the transformer in the machine. 2. Measure the input voltage to the machine on the chart (Measure...

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    FADAL MACHINING CENTERS 50INSTALLATION PROCEDUREMAN-0126_R13.3 PHASE CONVERTER ROTARYThe normal Fadal VMC requires three phase-input power. Some customers prefer to use rotary phase converters. However, Fadal does not recommend the use of rotary phase converters. Rotary phase converters input sin...

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    OCTOBER 2005INSTALLATION PROCEDURE51 SIEMENS MAINTENANCE MANUAL 3.4 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 p...

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    FADAL MACHINING CENTERS 52INSTALLATION PROCEDUREMAN-0126_R18. Place the level on the right hand way (the outer right hand way on the 6535) of thebase with the small bubble towards the column. Take an accurate reading. (See 58,Figure 3-8: Leveling Box Way.)Figure 3-8: Leveling Box Way. 9. Now put...

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    OCTOBER 2005INSTALLATION PROCEDURE53 SIEMENS MAINTENANCE MANUAL 13. Verify the spindle tram and, if necessary, adjust by slightly changing only the twofront leveling screws.

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    FADAL MACHINING CENTERS 54INSTALLATION PROCEDUREMAN-0126_R13.5 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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    OCTOBER 2005INSTALLATION PROCEDURE55 SIEMENS MAINTENANCE MANUAL 3.6 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 a...

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    FADAL MACHINING CENTERS 56INSTALLATION PROCEDUREMAN-0126_R13.7 COUPLER INSTALLATION ON AXIS MOTOR OR BALLSCREWNOTE Motor and Ball Screw shaft must be clean and oil free.Follow the next procedure:1. Loosen both coupler HUB screws. 2. Mark coupler HUBs and SPIDER before disassembling to insure coup...

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    OCTOBER 2005INSTALLATION PROCEDURE57 SIEMENS 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 3-10: Gages 7. Install Ball Screw coupler HUB on the SPI...

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    FADAL MACHINING CENTERS 58INSTALLATION PROCEDUREMAN-0126_R1 Figure 3-12: Motors Table 3-1: CouplersMACHINEX AXISY AXIS Z AXIS2216KTR ROTEX GS24 .625x24mmKTR ROTEX GS24 .625x24mmKTR ROTEX AI GS24 .625x19mm301630204020452560308030Table 3-2: CouplersMACHINEX AXISY AXIS Z AXIS6535/40TKTR ROTEX...

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    OCTOBER 2005INSTALLATION PROCEDURE59 SIEMENS MAINTENANCE MANUAL 3.8 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 (smalle...

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    FADAL MACHINING CENTERS 60INSTALLATION PROCEDUREMAN-0126_R13.9 GENERAL Detach 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 ca...

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    OCTOBER 2005INSTALLATION PROCEDURE61 SIEMENS MAINTENANCE MANUAL 3.10 CHIP CONVEYOR3.10.1 INSTALLATION PROCEDURE1. Place the chip conveyor in the coolant tank.2. Measure the height to the top of the conveyor sheet metal (should beapproximately the height of the coolant tank).3. Set the machine hei...

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    FADAL MACHINING CENTERS 62INSTALLATION PROCEDUREMAN-0126_R17. Adjust the machine height (during leveling and installation) to minimize the gap (oroverlap) between the coolant tank face and the machine sheet metal, (Figure 3-17:Minimize Gap of Overlap).Figure 3-17: Minimize Gap or Overlap8. Coola...

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    OCTOBER 2005INSTALLATION PROCEDURE63 SIEMENS MAINTENANCE MANUAL 2. The control also has a variable speed control for the belt speed. The belt speed canbe 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 64INSTALLATION PROCEDUREMAN-0126_R1

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    OCTOBER 2005MACHINE MAINTENANCE65SIEMENS MAINTENANCE MANUAL 4.0 MACHINE MAINTENANCE

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    FADAL MACHINING CENTERS 66MACHINE MAINTENANCEMAN-0126_ 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 Mob...

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    OCTOBER 2005MACHINE MAINTENANCE67SIEMENS 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....

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    FADAL MACHINING CENTERS 68MACHINE MAINTENANCEMAN-0126_ 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!...

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    OCTOBER 2005MACHINE MAINTENANCE69SIEMENS 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 SPIND...

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    FADAL MACHINING CENTERS 70MACHINE MAINTENANCEMAN-0126_ 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 l...

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    OCTOBER 2005MACHINE MAINTENANCE71SIEMENS 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 626...

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    FADAL MACHINING CENTERS 72MACHINE MAINTENANCEMAN-0126_ 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 lub...

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    OCTOBER 2005MACHINE MAINTENANCE73SIEMENS 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 ...

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    FADAL MACHINING CENTERS 74MACHINE MAINTENANCEMAN-0126_ 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)•Spi...

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    OCTOBER 2005MACHINE MAINTENANCE75SIEMENS 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 ma...

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    FADAL MACHINING CENTERS 76MACHINE MAINTENANCEMAN-0126_ 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. Che...

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    OCTOBER 2005MACHINE MAINTENANCE77SIEMENS 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 a...

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    FADAL MACHINING CENTERS 78MACHINE MAINTENANCEMAN-0126_ 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 f...

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    OCTOBER 2005GENERAL INFORMATION79SIEMENS MAINTENANCE MANUAL 5.0 GENERAL INFORMATION

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    FADAL MACHINING CENTERS 80GENERAL INFORMATIONMAN-0126_ R15.1 HELPFUL FORMULAS5.1.1 TEMPERATUREDegrees Fahrenheit (F) = (9/5 x degrees C) + 32Degrees Celsius (C) = 5/9 x (degrees F-32)5.1.2 CONVERSION FACTORSInch (in) = millimeter x 0.03937Inch (in) = centimeter x 0.3937Millimeter (mm) = inc...

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    OCTOBER 2005GENERAL INFORMATION81SIEMENS MAINTENANCE MANUAL Three-PhaseKilovolt-Amperes (KVA) = (Volts x Amperes x 1.73) / 10005.1.4 EXPANSION COEFFICIENTSFormulaExpansion amount = Coefficient x distance x degree of temperature change (Fahrenheit)CoefficientsSteel=.00000633Cast Iron=.00000655Alum...

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    FADAL MACHINING CENTERS 82GENERAL INFORMATIONMAN-0126_ R15.2 THERMAL EXPANSION5.2.1 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 rates,...

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    OCTOBER 2005GENERAL INFORMATION83SIEMENS MAINTENANCE MANUAL 5.2.5 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. Additio...

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    FADAL MACHINING CENTERS 84GENERAL INFORMATIONMAN-0126_ 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 the p...

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    OCTOBER 2005GENERAL INFORMATION85SIEMENS MAINTENANCE MANUAL 5.3 NON-UNIFORM EXPANSION5.3.1 MATERIAL DIF-FERENCESThe 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, like a...

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    FADAL MACHINING CENTERS 86GENERAL INFORMATIONMAN-0126_ 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 of the...

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    OCTOBER 2005GENERAL INFORMATION87SIEMENS MAINTENANCE MANUAL 5.4 SOLVING THE THERMAL EXPANSION PROBLEM5.4.1 GENERAL CON-SIDERATIONSA simplified description of the thermal environment in machining would state that heat is generated through friction, and also input through ambient factors. That he...

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    FADAL MACHINING CENTERS 88GENERAL INFORMATIONMAN-0126_ R15.5 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 command ...

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    OCTOBER 2005GENERAL INFORMATION89SIEMENS MAINTENANCE MANUAL 5.6 VMC MAINTENANCE5.6.1 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 cabinet...

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    FADAL MACHINING CENTERS 90GENERAL INFORMATIONMAN-0126_ 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 the ...

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    OCTOBER 2005GENERAL INFORMATION91SIEMENS MAINTENANCE MANUAL 5.6.4 VMC OPTIONSThere are options that can be added to a standard VMC to help manage the thermal expansion problems.ProbeA probe in the spindle can be used as a part of the program to discover what adjustments are required to compensate...

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    FADAL MACHINING CENTERS 92GENERAL INFORMATIONMAN-0126_ R15.6.5 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 measuring e...

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    OCTOBER 2005INDEX79SIEMENS MAINTENANCE MANUAL actionGoToR:INDEX2216 & 3016 TABLE 193020 & 4525 TABLE 204020 TABLE 216030 TABLE 226535 TABLE 248030 TABLE 23AACCURACY AND REPEATABILITY 82AIR SUPPLY 34AIR SUPPLY 43ALTERNATE SERVICE 38AMBIENT SOURCES 87AMBIENT TEMPERATURE 83CCABINET FANS 89CH...

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    FADAL MACHINING CENTERS 80INDEXMAN-0126_ R1GGENERAL 60GENERAL CONSIDERATIONS 87GENERAL INFORMATION 79HHEAT SOURCES 83HELPFUL FORMULAS 80HOLD DOWN CLAMPS 54IILLUSTRATIONS & DATA FOR ALL VMC MODELS 2INSPECTION - CHECK GROUND WIRE COMING INTO VMC 37INSTALLATION PROCEDURE 41INSTALLATION PROCEDURE...

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    OCTOBER 2005INDEX81SIEMENS MAINTENANCE MANUAL RESTARTING THE CHIP CONVEYOR 77SSCHEDULED MAINTENANCE 66SCHEDULED MAINTENANCE FOR DUAL ARM TOOL CHANGER 72SHIPPING DIMENSIONS 32SOLVING THE THERMAL EXPANSION PROBLEM 87SPECIFICATION -GROUNDING FOR THE FADAL MACHINE 37SPECIFICATIONS 1SPINDLE & BALL...

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    FADAL MACHINING CENTERS 82INDEXMAN-0126_ R1

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