Fanuc Maintenance Manual 2006

FADAL MACHINING CENTERS
GE FANUC 0i MC
MAINTENANCE MANUAL
FADAL MACHINING CENTERS, LLC
Corporate Office............................................. phone (818) 407-1400 ............................. fax (818) 407-0020

Service / Parts................................................ phone (818) 727-2100 ............................. fax (818) 407-1004
Programming Support .................................... phone (818) 727-2100 ............................. fax (818) 407-0061
[email protected]
20701 Plummer Street, Chatsworth, California 91311 USA
MAN-0140_B
TABLE OF CONTENTS
TABLE OF CONTENTS ......................................................................................................... i
1.0 MACHINE MAINTENANCE ............................................................................................. 1

1.1 WAYS LUBRICATION .................................................................................................................2
1.2 COOLANT TRAY .........................................................................................................................3
1.3 SPINDLE .....................................................................................................................................3
1.3.18K (10K OPT) GREASE PACKED SPINDLES .......................................................................................3
1.3.2AIR OIL SPINDLE (OPT) ........................................................................................................................3
1.4 AUTOMATIC TOOL CHANGER (ATC) .......................................................................................4
1.5 FUSES .........................................................................................................................................5
1.6 CE DOOR ....................................................................................................................................5
1.7 SPINDLE COOLING SYSTEM (OPT) .........................................................................................7
1.7.1PUMP FILTER .........................................................................................................................................8
1.7.2TANK RESERVOIR .................................................................................................................................8
1.8 CONVEYOR (OPT) .....................................................................................................................9
1.9 CHILLER COOLANT (OPT) ........................................................................................................9
1.9.1CUTTING FLUIDS ...................................................................................................................................9
1.10 ROTARY TABLE (OPT) ..........................................................................................................10
1.10.1SCHEDULE .........................................................................................................................................10
1.11 COOLANT THROUGH SPINDLE (OPT) .................................................................................12
2.0 GENERAL ...................................................................................................................... 13

2.1 MAINTENANCE LABEL ............................................................................................................14
2.2 WARM UP .................................................................................................................................14
2.3 ROUGH CUT/COOL DOWN/FINISH CUT ................................................................................15
2.4 MONITORING POSITION CHANGES ......................................................................................15
2.5 FLUIDS ......................................................................................................................................15
2.6 MAINTENANCE CHART ...........................................................................................................15
3.0 OPTIONS ....................................................................................................................... 19

3.1 CONVEYOR ...............................................................................................................................20
3.2 CHILLER COOLANT ..................................................................................................................20
3.2.1CUTTING FLUID ....................................................................................................................................20
3.3 TOOL CHANGER.......................................................................................................................21
3.3.1AUTOMATIC TOOL CHANGER (A.T.C.)...............................................................................................21
3.3.2 DUAL ARM TOOL CHANGER (D.A.T.C.).............................................................................................22
MAN-0140_B TABLE OF CONTENTS i

GE FANUC 0i MC MAINTENANCE MANUAL
3.4 ROTARY TABLE ........................................................................................................................23

3.4.1 GEAR OIL .............................................................................................................................................23
3.4.2 REMOVAL AND STORAGE..................................................................................................................26
3.5 PROBE .......................................................................................................................................27
3.6 COOLANT THROUGH SPINDLE...............................................................................................27
4.0 INDEX ............................................................................................................................. 31
ii TABLE OF CONTENTS 2006

1.0 MACHINE MAINTENANCE
MAN-0140_B MACHINE MAINTENANCE 1

1.1 WAYS Lubrication is essential for the free motion of the balls, saddle, and head, as
LUBRICATION well as for the nut on each ballscrew. Each way and ballscrew must be lubri-
cated to minimize both the wear on the machine and the excess heat gener-
ated by friction. The lubrication system must be inspected and serviced
regularly. Inspect all of the ways to confirm that each way is getting lubricated.
The lubrication system may need to be flushed by a qualified service person to
remove any contaminants on the inside of the tubes and joints.
Waylube System
USE WAYLUBE TYPE Castrol Magna BD68, Shell Tonna 68V or Mobil Vactra
Oil #2.
Figure 1-1: Waylube system
The Positive Displacement Injection (PDI) lube system is a solenoid-controlled

pneumatic system. When the solenoid is activated, the pump sends oil to the
junction block assemblies, which may contain several different size valves, at a
pressure ratio of 5:1. The pump is activated for 10 seconds, within a 4 minute
cycle, during which oil is distributed to all of the valves on the junction block
assemblies. When the solenoid is deactivated the oil flow stops and creates
back pressure which escapes through a relief valve. When the pressure on the
valve drops below 50 psi, a spring inside the valve is then able to inject oil into
the lines.
The CNC has direct control of the automatic lube system. The cycle is acti-
vated by executing an axis motion in a CNC program, commanding an axis
move in MDI mode or pressing the JOG key. Once activated it monitors the oil
level to be sure the reservoir is above the minimum level. In addition, it shuts
the oil system down if the machine sits idle longer than one cycle of the lube
system.
Frequently clogging filters indicate that the wrong waylube is being used.
Replace the External filter on the BIJUR PDI way lube pump.
2 MACHINE MAINTENANCE 2006

1.2 COOLANT TRAY Remove all the chips from the coolant tray (located on the back side of the x-
axis) regularly.
Figure 1-2: Coolant Tray
1.3 SPINDLE It is the recommendation of the Engineering Department in conjunction with the
bearing manufacturers that the following procedure be followed to increase
spindle life under extreme operating conditions.
Spindles operating under 8,000 RPMs need no cool down period regardless of
on time or load to the tool.
1.3.1 8K (10K OPT) Fadal recommends that Spindles operating at over 8,000 RPMs for extended
GREASE PACKED periods of time should be shut down for a period of at least 20 minutes after
SPINDLES every 5 hours of continuous operation. This will allow cooling of the races and
re-lubrication of the grease lubricated bearings. The actual load to the spindle
is not a factor at higher RPMs. The time period should be monitored as closely
as possible to increase spindle life.
The 8K and 10K grease packed spindles are self contained units.
These spindles are belt driven and require no maintenance. There is air sup-
plied to the spindle on the top and bottom for positive pressure.
These spindles are self-contained, therefore they should be replaced when

bad. The 8K spindle has a locking drawbar and the 10K has a locking drawbar.
1.3.2 AIR OIL SPINDLE Fadal Air/Oil Lubricating System delivers high-efficiency lubrication and cooling
(OPT) for high-speed spindles and other surfaces requiring accurate oil deliveries.
The advanced design delivers precise amounts of lubricant and eliminates
residual drift of “oil fog” or mist during operation. The 16K air/oil system con-
sists of a spindle, a spindle lubricating oil supply pump, a vacuum pump, a pos-
itive displacement injector (PDI) block, a coalescent filter, four pressure
switches (2-15psi, 1-80psi, 1-265psi) mounted on a pressure switch manifold,

an electronic control board with wire harness, and various standard plumbing
parts. This spindle is also belt driven. The electronic control board controls the
ON time of solenoids for oil and air while monitoring:
• Supply oil pressure

• Oil reservoir level
• Air filter
• Supply air pressure
• Air/oil pressure to the upper and lower bearings of the spindle
The pump pressurizes oil to the PDI block. Oil pressure is monitored by an oil
pressure switch. Air is supplied to the PDI block through a coalescing filter from
a solenoid valve. Air pressure to the machine is monitored by an air pressure
switch. The PDI block mixes air and oil. The two lines carry the air/oil mixture to
the upper and lower bearings. The pressure of each line is monitored by a
pressure switch. A vacuum pump is used to remove any oil that blows by the
upper or lower bearings, to reduce oil leakage.
Figure 1-3: Air Oil System
1.4 AUTOMATIC The maintenance schedule is based on machine usage of eight hours a day,
TOOL CHANGER five days a week:
(ATC)
Daily
1. Clean the tool changing mechanism off all debris before any operation.
2. Tool in spindle blow chips from around A.T.C. and slide. NEVER blow chips
from around these areas during automatic tool change or without a tool in
the spindle. (Do not use regular water to clean inside mechanism of A.T.C.
3. Wash A.T.C. area.
Weekly

1. Clean A.T.C. slide.
2. Inspect the parts of the tool pockets and tool retention rings for damage
and tightness.
Monthly
1. Clean carriage plate bearing track

from the chips.
2. Lubricate carriage plate with grease.
Figure 1-4: Carriage Plate Bearing Track
1.5 FUSES
Fuses
Figure 1-5: Fuses
There are only 5 (five) fuses located in the electrical cabinet. Check them regu-
larly.
1.6 CE DOOR To ensure the proper function of Safety Circuits, perform the following tests on
a regular bases:
Daily
1. Close the front doors. Make sure VMC is not in emergency stop.
2. Start spindle at slow speed.
3. Open front door; the spindle should stop immediately (fully stopped from
any speed in less than 5 seconds). Five to ten seconds after the door is

opened, the spindle contactor will open. (Five to ten seconds delay allows
the spindle to come to a controlled stop.)
4. Close the front doors. The spindle contactor should immediately re-
energize.
Weekly
1. Close the front doors. Make sure VMC is not in emergency stop.
2. Open the electrical cabinet containing Door Interlock Board and examine
LEDs and relays on the board.
• Heart LED should be blinking.

• Red door LEDs should be off.
• Yellow door LEDs should be off.
• Green “Doors Closed” LED should be on.
• Red Slidehold LEDs should be off.
• Estop relay (K7) should be on (LED lit).
• Green “Spindle Enable” LED should be on.
• “Spindle” relay for spindle contactor (K5) should be on (LED lit).
3. Press the Emergency Stop switch.
• Heart LED should stop blinking.

• E-stop relay should go off immediately.
• Spindle Enable LED and Spindle relay should go off after 5 to 10 seconds.
Spindle contactor should then release.
4. Release the Emergency Stop switch and clear the emergency stop
condition by pressing Jog.
5. Open the front door.

• Front door red LEDs should be on.
• Green “Doors Closed” LED should be off.
• The yellow LED for the front door should flash at the instant the door is
opened.
• Spindle Enable LED and Spindle relay should go off and Spindle contactor
should release after 5 to 10 seconds.
6. Close the front door and open left side door.

• Left door red LED's should be on.
• Yellow door LED should flash at the instant the one door is closed and
when the other door is opened.

should release after 5 to 10 seconds.
7. Close the left side door and open right side door.

• Right door red LED's should be on.
• Yellow door LED should flash at the instant the one door is closed and
when the other door is opened.
should release after 5 to 10 seconds
1.7 SPINDLE The spindle cooling system is made up of

COOLING SYSTEM a motor pump assembly, ambient-liquid
(OPT) temperature sensor assembly and a DP5P
chiller. As long as there is power to the
machine the chiller pump is circulating
Dowfrost through the system. The ambient
sensor is used to measure casting/air tem-
perature and the liquid sensor to measure
Dowfrost temperature in the return line.
When there is a one degree temperature
differential between the two sensors the
chiller is then powered on. A refrigeration
unit, coupled to a thermostat, is used to
control the temperature of the fluid, which
consequently conditions the temperature
of spindle as the fluid flows through.
Figure 1-6: Spindle Cooling System

1.7.1 PUMP FILTER There is a small filter and pressure gauge

located on the pump head assembly. Normal
pressure is 3-5 pounds. If the pressure gauge
shows a pressure above normal the filter
should be inspected and cleaned.
Figure 1-7: Pump Filter
1.7.2 TANK RESERVOIR The tank reservoir is located next to the

motor pump assembly in the chiller cabinet.
The tank has a 2 1/2 gallon capacity. Visu-
ally check the fluid level with the machine
powered on. If the fluid level is less than 1/2
of the tank, mix the Dowfrost to a 50:50
solution, with deionized water, or sodium
free distilled water and fill to fill level indica-
tor.
Figure 1-8: Tank Reservoir
Source for Dowfrost:
GOLDENWEST LUBRICANTS
1816 POTRERO AVE., SOUTH EL MONTE, CA 91733
(626) 443 - 3441; (800) 540 - 5823
Do not accept any substitutes for DOWFROST!
Pressure
The cooling system should maintain a constant pressure of 3 to 5 psi.
If the pressure rises, the following conditions may exist:
• clogged pump filter;

• pinched coolant lines.

If the machine is losing pressure and the Dowfrost level keeps dropping, the
following conditions may exist:
• there is a hole in one of the lines;

• loose fitting.
1.8 CONVEYOR Please carry out daily, monthly, and yearly inspection according to the following
(OPT) directions.
1. Check motor for abnormal operation, i.e. noise, heat, excessive current,
etc.
2. Discard chips on the surface of the belt and inside of frame (place a rag on
the belt and reverse until the rag is discarded).
1.9 CHILLER The configuration, the coolant and the amount of coolant will affect the cooling
COOLANT (OPT) process. If the tank is full the tem
perature swings are larger then if the tank is low because more fluid is required
to cool and larger temperatures range from top to bottom of the tank.
1.9.1 CUTTING FLUIDS Some types of coolant have a tendency to swell the motor cover gasket and
attack the sealing compound. If this occurs, we recommend switching coolants.
Wynns 941 has shown to be a satisfactory coolant.
Using soluble and synthetic coolants that are mixed with water is the single
most effective factor in removing the heat generated during cutting. Coolant is
formulated specifically to absorb a great deal of heat within its molecular struc-
ture without having to radiate that heat onto the next material it contacts. Cut-
ting oils are formulated for cutting, and lack the cooling quality of soluble and
synthetic coolants mixed with water. Flood coolant is a better choice than either
mist coolant or cutting oils because it benefits the cutting process in addition to
providing heat removal.
The temperature of the coolant can be conditioned further through any of a few
simple actions. Bags of ice floating in the coolant tank can be used to maintain
the temperature. Pumping the coolant through a radiator, or through a copper
coil in the coolant tank, or through a copper coil placed in a small refrigerator
can all be used to condition the temperature of the coolant.
One side benefit of coolant is its cooling effect on the table as well as the part.
As it is splashed around, the coolant's direct contact and its evaporation tends
to keep the table at or near the temperature of the coolant, directly compensat-
ing for the effect of hot chips falling on the table. If the coolant temperature is
being conditioned through some of the steps just mentioned, the thermal stabil-
ity of the table benefits even more.

NOTE
Some types of coolant have tendency to swell the motor cover gasket and
attack the sealing coupound. If this occurs, we recommend switching
coolants. WYNNS 941 has shown to be satisfactory coolant.
1.10 ROTARY TABLE Face Plate

(OPT)
The rotary table face plate and any tooling must be free from chips and dings.
Stone both surfaces and wipe clean.
Serialized Matched Sets
Rotary tables heads are serialized. FADAL maintains a record of the center line
height of all serialized heads and tail stocks. If a customer desires at a later
date to purchase a matching component, this may be easily accomplished.
1.10.1 SCHEDULE Daily
Clear away chips and debris from face plate.
Weekly
Check oil level.
6-12 Months (depending on usage).l
Check oil and change if necessary.
As a replacement oil use:
MOBILGEAR 626
LUBRICATION OIL
ISO VG 68
WARNING!
Do not attempt to perform maintenance until you have read and completely
understood the contents of the following instructions. Maintenance
depends on the rotary table model. Disassemble and remove rotary table
for the maintenace purposes.
The gear oil is the primary concern in rotary table maintenance. A small
amount of oil can be trapped in bottom of sight gage making it appear that the
appropriate oil level is in the unit when actually the oil level may be danger-
ously low.

To change the gear oil , follow these steps:

VH 175, VH 225
1
1-Oil fill plug
2-Oil drain plug
2
Figure 1-9: Rotary table
1. Remove the pipe plug located on the back side of the rotary table.
2. Drain oil completely.
3. Install drain plug.
4. Remove the pipe plug located on the top of the rotary table.
5. Add oil to the indexer.
6. Re-install the pipe plug.
7. Check the oil level.
The oil level is checked by viewing the oil level sight gage on side of the unit.
VH 165
1
1-A-axis Trunnion
2-Side Plate 3
3-Oil drain plug
Figure 1-10: Rotary Table
1. Remove the pipe plug located on the side plate of the rotary table.
3. Use teflon tape to tape the pipe plug 2.5 turns.
4. Re-install the pipe plug back to it’s appropriate position.

5. Remove 1/2-14 NPT pipe plug located on the top of the A-axis.
6. Fill it with recommended oil.
9. Check the oil level. The oil level is checked by viewing the oil level sight
gage.
1.11 COOLANT FADAL's Coolant Through Spindle 1

THROUGH option is designed to work in con- 2
SPINDLE (OPT) junction with specific tooling (with a
hole in the center) to allow coolant
to be pumped deep into the part,
where normally coolant does not
reach. This significantly improves
the rate at which heat is removed
from the area of the cut, reducing
the expansion of the part material.
In addition, there is less heat to be 3
1-250 PSI
transferred through the tool to the
4 2-Vacuum Indicator
spindle and the head, so expansion 3-Coolant Filter
of the spindle and the head is also 4-Gear pump filter
significantly reduced, improving Z
axis positioning and accuracy.
Figure 1-11: Coolant through pump
Coolant through spindle requires the following maintenance:
1. If vacuum indicator shows above 20Hg, change the coolant filter.
2. Check and make sure the coolant tank is at least 3/4 full; if coolant is low,
this can damage the pump.
3. If Machining ceramic or Material with a very small and abrasive chips, it is

recommended to use 10µ (micron) filter instead of 100µ, which is Factory
installed.
4. Pump comes with Factory sitting and 250PSI, changing it might cause the
damage of the seal system.
5. Clean gear pump filter strainer weekly. (Lift the pump and rinse it.)


2.0 GENERAL
MAN-0140_B GENERAL 13
2.1 MAINTENANCE Refer to maintenace and lubrication label for proper maintenance.
LABEL
Figure 2-1: Maintenance Label
2.2 WARM UP The first step in combating thermal expansion effects is also the simplest. Run
the machine through a series of moves, at feeds and speeds equivalent to what
will be encountered in the production run, long enough to reach an equilibrium;
that is, where the amount of heat being generated is balanced by the amount of
heat being removed (via convection, evaporation, or absorption through
expansion of material). After that point is reached, the effect of thermal
expansion in the VMC stabilizes.
Locate fixture offsets and establish tool length offsets after the machine has
attained the optimum operating temperature. Avoid using moves or spindle
speeds that exceed those used in the part program.
In addition to running a warm up routine at the beginning of the production shift,

the same kind of routine can be run during breaks. This will maintain the VMC
at operating temperature, especially the two subsystems that heat up or cool
down the most (the spindle and the ball screws).
14 GENERAL 2006
2.3 ROUGH CUT/ A complement to the warm up of the VMC is the use of a rough cut to remove
COOL DOWN/ most of the material from the part. Although the part material heats up, the
FINISH CUT material can then be cooled to a stable temperature. Then, a series of finish
cuts can complete the part in a short time, so that the material doesn't have
time to expand beyond acceptable tolerance.
This 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 tem-
perature at which the gauge is calibrated.
2.4 MONITORING The home position of the part will change as the temperature of the ballscrews
POSITION change. The operator can follow the home position changes throughout the
CHANGES production run and change the fixture home position and offsets accordingly.
2.5 FLUIDS Recommended fluids
SECTION USE
Waylube CASTROL MAGNA BD68
SHELL TONNA 68V
or MOBIL VACTRA #2
Spindle Cooling System DOWFROST CLEAR
(Mixed 50/50 with de-ionized water or sodium free
distilled water)
Rotary Tables MOBIL GEAR 626
Hydraulic Hi/Low MOBIL DTE HEAVY MEDIUM
Hydraulic Brake HYDRAULIC OIL 32
Dual Tool Changer SAE 90-140,
(approximately 1.3 gallons, (5 liters))
2.6 MAINTENANCE WARNING!

CHART Before carrying out any maintenance operations, ensure that the machine
is safe to work on and electrical power is switched OFF.
Maintenance Chart
SCHEDULE
2216 & 3016
• Check way lube system for adequate oil flow to all way
surfaces.
• Check way lube level. Use Castrol Magna BD68, Shell
Tonna 68V or Mobil Vactra #2 or equivalent.
• Check coolant level.
• Clean coolant screen.
• With tool in spindle blow chips from around A.T.C. and
slide. NEVER blow chips from around these areas
during automatic tool change or without a tool in the
spindle.
• Wash A.T.C. and machine work area.
• Clear the tool changing mechanism of all debris before
DAILY
any operation.
• Inspect the parts of the tool pockets, tool carrier, and
tool retention rings for damage and tightness.
• Remove heavy chip build up from guards and way
covers.
• Check air pressure (air pressure depends on VMC
model)
• Clean the area around the machine.
• Immediately clean any spills in the area.
• Remove the chips and debris surrounding the proxim-
ity switch inducing box.
• Remove the chips and debris that have accumulated
on the inverted moving body of the tool pot.
16 GENERAL 2006
Maintenance Chart
SCHEDULE
2216 & 3016
• Check spindle cooler pump and refrigeration unit for

proper operation.
• Check fluid level of chiller tank and refill, if needed,
with a 50/50 mix of Dowfrost clear and de-ionized
water. If de-ionized water is not available, sodium-free
distilled water can be substituted. Do not accept any
substitutes for DOWFROST CLEAR!
• Activate Thru-Tool coolant system for 2-3 minutes (if
machine has this option).
• For high torque and high speed machines, check fluid
WEEKLY
level in the hydraulic actuator reservoir. Refill, if

needed, with Mobil DTE Heavy Medium.
• Clean A.T.C. slide.
• Grease axis way cover using molygraph.
• Grease retention rings using molygraph.
• Grease Geneva wheel and gear using Copr-Kote.
• Check air regulator.
• Drain and clean water separator.
• Inspect all cooling fans, clean screens if necessary.
Maintenance Chart
SCHEDULE
2216 & 3016
• Keep correct tension of conveyor chain by adjusting

take-up bearing.
• Check roller chain between motor and conveyor for
proper alignment and correct tension.
• The greatest care should be exercised to keep friction
surface of torque limiter free from oil when lubricating
roller chain.
MONTHLY
• Change conveyor oil at 100 hours initially, every 1,500

to 2,000 hours thereafter.
• Check motor for abnormal operation, i.e. noise, heat
excessive current, etc.
• EVERY 4 MONTHS. Replace service way lube filter.
Machines with an external filter require less frequent
replacement; however, do not exceed 4 months.
When replacing the external filter, fill the new filter with
way lube prior to installation.
• Carry out all monthly inspection items.

• Check bolts for looseness.
YEARLY
• Check electrical connections for looseness.

• Check friction disk for abrasion, and replace if neces-
sary.
18 GENERAL 2006
GE FANUC 0i MAINTENANCE MANUAL
3.0 OPTIONS
MAN-0140_B OPTIONS 19
3.1 CONVEYOR Please carry out daily, monthly, and yearly inspection according to the following
directions.
1. Check motor for abnormal operation, i.e. noise, heat, excessive current, etc.
2. Discard chips on the surface of the belt and inside of frame (place a rag on the belt
and reverse until the rag is discarded).
3.2 CHILLER Different models of the VMC have different coolant configurations.
COOLANT
The configuration, the coolant and the amount of coolant will affect the cooling process.
If the tank is full the temperature swings are larger then if the tank is low because more
fluid is required to cool and larger temperatures range from top to bottom of the tank.
VMC 2216 / 3016 / 4020 Metric balls-crews, 10,000 RPM Spindle Configuration
The coolant flow path is coolant tank to pump to coolant sensor to X axis ballscrew to Z
axis ballscrew to spindle to Y axis ballscrew to chiller and back to coolant tank.
VMC 6030 / 8030 10,000 RPM Spindle Configuration
The coolant flow path is coolant tank to pump to spindle to Y axis ballscrew to coolant
sensor to chiller and back to coolant tank.
3.2.1 CUTTING FLUID Some types of coolant have a tendency to swell the motor cover gasket and attack the
sealing compound. If this occurs, we recommend switching coolants. Wynns 941 has
shown to be a satisfactory coolant.
Using soluble and synthetic coolants that are mixed with water is the single most
effective factor in removing the heat generated during cutting. Coolant is formulated
specifically to absorb a great deal of heat within its molecular structure without having
to radiate that heat onto the next material it contacts. Cutting oils are formulated for
cutting, and lack the cooling quality of soluble and synthetic coolants mixed with water.
Flood coolant is a better choice than either mist coolant or cutting oils because it
benefits the cutting process in addition to providing heat removal.
One side benefit of coolant is its cooling effect on the table as well as the part. As it is
splashed around, the coolant's direct contact and its evaporation tends to keep the
table at or near the temperature of the coolant, directly compensating for the effect of
hot chips falling on the table. If the coolant temperature is being conditioned through
some of the steps just mentioned, the thermal stability of the table benefits even more.
20 OPTIONS 2006
NOTE
Some types of coolant have tendency to swell the motor cover gasket and attack
the sealing compound. If this occurs, we recommend switching coolants. WYNNS
941 has shown to be satisfactory coolant.
3.3 TOOL CHANGER
3.3.1 AUTOMATIC The maintenance schedule is based on machine usage of eight hours a day, five days a
TOOL CHANGER week:
(A.T.C.)
Daily
1. Clean the tool changing mechanism of all debris before any operation.
2. Tool in spindle blow chips from around A.T.C. and slide. NEVER blow chips from
around these areas during automatic tool change or without a tool in the spindle.
(Do not use regular water to clean inside mechanism of A.T.C.
3. Wash A.T.C. area.
Weekly
1. Clean A.T.C. slide.
2. Inspect the parts of the tool pockets and tool retention rings for damage and
tightness.
Monthly
1. Clean carriage plate bearing track from the

chips.
2. Lubricate carriage plate with grease.
Yearly
1. Check tension on A. T. C. belt.

Figure 2-1: Carriage Plate Bearing Track
3.3.2 DUAL ARM TOOL The lubricant inside the lubricant container of the tool
CHANGER (D.A.T.C) changing mechanism should be changed after working for
2400 hours. When the cam, rollers and the bevel gear are
in use without lubricant, abnormal wear and fractures will
occur. Appropriate quantity of lubricant should be a little
more than half of the lubricant container.
The lubricant should be changed annually or when the

lubricant becomes contaminated. Recommended
lubricants viscosity: SAE 90-140.
Figure 2-2: DATC Oil Glass Gage
Follow the instructions from the maintenance (yellow) label below the DATC oil glass
gage. Amount of lubricant:
• 40 Taper - fill oil to the middle line of oil glass about 6 liters.
• 50 Taper - fill oil to the middle of oil glass about 10 liters.
The maintenance schedule is based on machine usage of eight hours a day, five days a
week:
The parts which should be checked and replenished with grease periodically:
Daily
1. Remove the chips around all the proximity switches and reed switches.
2. Remove the chips inside the tool pot.
3. Clean the tool changing mechanism so that the chips can not stick on it.
4. Check the pocket mechanism parts.
Weekly
1. Grease tool arm gripper.
2. Grease tool arm holding rod (head) sliding block of pocket mechanism.
3. Grease positioning block of pocket mechanism.
4. Grease tool magazine.
5. Check the parts of tool pots and tool disc and also check if “C” snap rings are tight
22 OPTIONS 2006
Monthly
1. Check tool arm plunger.
2. Check tool arm wear-resistant hold down plate.
Every 6 months
1. Check tool arm plunger.
2. Check too arm tool holding rod.
3. Replenish with grease tool pot roller wheel.
4. Replenish with grease tool magazine driving roller.
5. Replenish with grease index mechanism cylindrical cam.
3.4 ROTARY TABLE Face Plate
The rotary table face plate and any tooling must be free from chips and dings. Stone
both surfaces and wipe clean.
Serialized Matched Sets
Rotary tables heads are serialized. FADAL maintains a record of the center line height
of all serialized heads and tail stocks. If a customer desires at a later date to purchase a
matching component, this may be easily accomplished.
3.4.1 GEAR OIL Daily
Clear away chips and debris from face plate.
Weekly
Check oil level.
6-12 Months (depending on usage).
Check oil and change if necessary.
As a replacement oil use:
MOBILGEAR 626
LUBRICATION OIL
ISO VG 68
WARNING!
Do not attempt to perform maintenance until you have read and completely
understood the contents of the following instructions. Maintenance may very
depending on the rotary table model. Disassemble and remove the rotary
table for maintenance purposes.
The gear oil is the primary concern in rotary table maintenance. A small amount of oil
can be trapped in bottom of sight gage making it appear that the appropriate oil level is
in the unit when actually the oil level may be dangerously low.
To change gear oil, follow these steps:
V300/V400
1
1-Oil fill plug
2-Oil drain plug
Figure 2-3: V400
1. Remove 7/8-14 UNF pipe plug located on the side of the rotary table.
4. Remove the 7/8-14 UNF pipe plug located on the top of the rotary table.
5. Add oil.
7. Check the oil level. The oil level is checked by viewing the oil level sight gage.
24 OPTIONS 2006
V175, V225, and V275

1
1-Oil fill plug
2-Oil drain plug
2
Figure 2-4: V275
1. Remove the pipe plug located on the back side of the rotary table.
4. Remove the pipe plug located on the top of the rotary table.
5. Add oil to the indexer.
7. Check the oil level.
The oil level is checked by viewing the oil level sight gage on side of the unit.
VH165
1
1-A-axis Trunnion
2-Side Plate 3
3-Oil drain plug
Figure 2-5: V165
1. Remove the pipe plug located on the side plate of the rotary table.
4. Re-install the pipe plug back to it’s appropriate position.
5. Remove 1/2-14 NPT pipe plug located on the top of the A-axis.
6. Fill it with recommended oil.
9. Check the oil level. The oil level is checked by viewing the oil level sight gage.
3.4.2 REMOVAL AND 1. Wipe any coolant, chips or dirt from the rotary table, motor cable, connector and
STORAGE any fixtures.
2. Jog the table for best access to the rotary table.
3. Turn off the power and lock out the main power box.
4. Unscrew the motor cable connector from the 4th axis receptacle, place a plastic
bag around the connector for protection, and replace the dummy plug in the
receptacle (for D.C. servo rotary motors).
5. Coil up the cable and wire tie it in a loop.
6. Make sure there are no chips between mating connections.
7. Remove any fixtures that are attached to the face plate. The fixtures will add extra
weight and make the rotary table awkward to lift.
8. Loosen the 1/2-13 hex bolts that mount the unit to the table.
9. Carefully slide the unit to the edge of the table.
10. Screw in the 1/2-13 eyebolts.
11. Ease the rotary table off of the table using the proper lifting procedure.
12. Wipe off the bottom of the unit and place it on a clean flat surface.
13. Lightly coat with a protective oil to keep it from rusting. The unit may be stored in
the original container for protection.
14. Power on the machine.
15. Type SETP <<ENTER>> to bring up the parameters.
16. Change the axes selection from X,Y,Z,A to X,Y,Z (from 4 to 3).
17. Exit the parameter screen.
18. Power the machine off and then back on. This will reset the parameters.
26 OPTIONS 2006
3.5 PROBE A probe in the spindle can be used as a part of the program to discover what
adjustments are required. The probe can be used to pick up the new home position at
the beginning of each program, or even at various times within the program. A probe
can quantify the rate of expansion in the Z axis and a change can then be made to the
tool table. The probe can also track the Y axis and X axis growth and, by using a macro,
the fixture offsets can be altered without operator intervention. Because the amount of
expansion differs depending on where the fixture is located on the table, each fixture
should be relocated with the probe. A consideration when using a probe is that if a chip
is in the spindle or on the probe's holder the probe will indicate an incorrect position.
Probe requires the following maintenance:
1. Clean all the chips from the probe.
2. Change the batteries every 3 months (MP12), depending on usage.
3. Constantly verify the alignment of the switch face (TS27R).
3.6 COOLANT FADAL's Coolant Through Spindle option is 1

THROUGH designed to work in conjunction with specific 2
SPINDLE tooling (with a hole in the center) to allow
coolant to be pumped deep into the part,
where normally coolant does not reach. This
significantly improves the rate at which heat
is removed from the area of the cut,
reducing the expansion of the part material.
In addition, there is less heat to be
transferred through the tool to the spindle
and the head, so expansion of the spindle 3
1-250 PSI
and the head is also significantly reduced,
4 2-Vacuum Indicator
improving Z axis positioning and accuracy. 3-Coolant Filter
4-Gear pump filter
Figure 2-6: Coolant through pump
Coolant through spindle requires the following maintenance:
1. If vacuum indicator shows above 20Hg, change the coolant filter.
2. Check and make sure the coolant tank is at least 3/4 full; if coolant is low, this can
damage the pump.
3. If Machining ceramic or Material with a very small and abrasive chips, it is

recommended to use 10µ (micron) filter instead of 100µ, which is Factory installed.
4. Pump comes with Factory sitting and 250PSI, changing it might cause the damage
of the seal system.
5. Clean gear pump filter strainer weekly. (Lift the pump and rinse it.)
28 OPTIONS 2006
30 OPTIONS 2006
INDEX
0-9
8K (10K OPT) GREASE PACKED SPINDLES 3
A
AIR OIL SPINDLE (OPT) 3
AUTOMATIC TOOL CHANGER (ATC) 4
C
CE DOOR 5
CHILLER COOLANT (OPT) 9
CONVEYOR (OPT) 9
COOLANT THROUGH SPINDLE (OPT) 12
COOLANT TRAY 3
CUTTING FLUIDS 9
F
FLUIDS 15
FUSES 5
G
GENERAL 13
M
MACHINE MAINTENANCE 1
MAINTENANCE CHART 15
MAINTENANCE LABEL 14
MONITORING POSITION CHANGES 15
P
PUMP FILTER 8
MAN-0140_B INDEX 31
R
ROTARY TABLE (OPT) 10
ROUGH CUT/COOL DOWN/FINISH CUT 15
S
SCHEDULE 10
SPINDLE 3
SPINDLE COOLING SYSTEM (OPT) 7
T
TANK RESERVOIR 8
W
WARM UP 14
WAYS LUBRICATION 2
32 INDEX 2006

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FADAL MACHINING CENTERS

FADAL MACHINING CENTERS, LLC

Corporate Office............................................. phone (818) 407-1400 ............................. fax (818) 407-0020

TABLE OF CONTENTS ......................................................................................................... i

1.0 MACHINE MAINTENANCE ............................................................................................. 1

2.0 GENERAL ...................................................................................................................... 13

3.0 OPTIONS ....................................................................................................................... 19

MAN-0140_B TABLE OF CONTENTS i

3.4 ROTARY TABLE ........................................................................................................................23

4.0 INDEX ............................................................................................................................. 31

ii TABLE OF CONTENTS 2006

1.0 MACHINE MAINTENANCE

MAN-0140_B MACHINE MAINTENANCE 1

Figure 1-1: Waylube system

The Positive Displacement Injection (PDI) lube system is a solenoid-controlled

2 MACHINE MAINTENANCE 2006

Figure 1-2: Coolant Tray

These spindles are self-contained, therefore they should be replaced when

MAN-0140_B MACHINE MAINTENANCE 3

• Supply oil pressure

Figure 1-3: Air Oil System

3. Wash A.T.C. area.

4 MACHINE MAINTENANCE 2006

1. Clean A.T.C. slide.

1. Clean carriage plate bearing track

2. Lubricate carriage plate with grease.

Figure 1-4: Carriage Plate Bearing Track

Figure 1-5: Fuses

2. Start spindle at slow speed.

MAN-0140_B MACHINE MAINTENANCE 5

• Heart LED should be blinking.

3. Press the Emergency Stop switch.

• Heart LED should stop blinking.

5. Open the front door.

• Heart LED should stop blinking.

6. Close the front door and open left side door.

• Heart LED should stop blinking.

6 MACHINE MAINTENANCE 2006

• Heart LED should stop blinking.

1.7 SPINDLE The spindle cooling system is made up of

Figure 1-6: Spindle Cooling System

MAN-0140_B MACHINE MAINTENANCE 7

1.7.1 PUMP FILTER There is a small filter and pressure gauge

Figure 1-7: Pump Filter

1.7.2 TANK RESERVOIR The tank reservoir is located next to the

Figure 1-8: Tank Reservoir

Source for Dowfrost:

1816 POTRERO AVE., SOUTH EL MONTE, CA 91733

(626) 443 - 3441; (800) 540 - 5823

Do not accept any substitutes for DOWFROST!

The cooling system should maintain a constant pressure of 3 to 5 psi.

If the pressure rises, the following conditions may exist:

• clogged pump filter;

8 MACHINE MAINTENANCE 2006

• there is a hole in one of the lines;

MAN-0140_B MACHINE MAINTENANCE 9

1.10 ROTARY TABLE Face Plate

Serialized Matched Sets

1.10.1 SCHEDULE Daily