17.1 UMC - Hydraulic Workholding Ready

UMC Hydraulic Workholding Ready - Installation

AD0499

Introduction

This procedure will explain how to install the hydraulic workholding assembly on UMC reboot machines. 

This procedure applies to the following kits:

93-1000455 HYD WORKHOLDING  FIELD INSTALL UMC 500
93-1000456 HYD WORKHOLDING  FIELD INSTALL UMC 750
93-1000457 HYD WORKHOLDING  FIELD INSTALL UMC 1000

Prerequisites

  • Software Version 100.20.000.1110 or higher
  • This procedure applies to reboot machines only.
  • A hinge door over the I/O PCB.
    Important: 93-1000573 I/O DOOR ASSY HINGED order the hinge door if it did not come in the kit.

Installation

1

Assemble the hydraulic manifold as shown:

[1] FITG POLY3/8F NPT1/4M 90 BRASS

[2]  FITG ORB6M JIC6M STR STL (2x)

[3] O-Ring 2-212 (4x)

 

2

Connect the staff to the staff extension using [2] SHCS 1/4-20 X 5/8 make sure the O-Ring 2-011 [1] are seated in the cavaties of the shaft.

Torque the bolts to their required specs.

 

3

Press the dowel pin [1] into the anti-rotation block [2] until it bottoms out. 

4

Assemble the platter coupler by installing the SHCS 5/16-18 X 1/2 [1] and O-Ring 2-011 [2] these will serve as plugs to the hydraulic lines until the workholding is installed. 

Finish assembling the coupler by installing O-Ring 2-031 [3] into the groove of the coupler [4].

5

Rotate the B-axis +90 degrees and remove the cover [1]. Return the B-axis to its original position at 0 degrees.

6

Remove the platter by following the removal section of the UMC C-Axis Platter Replacement linked below.

 WARNING: IF YOU DO NOT DISENGAGE THE BRAKE AND DISCONNECT THE LINES YOU CAN PERMANENTLY DAMAGE THE BRAKE BY REMOVING THE PLATTER.

UMC C-Axis Platter Replacement
UMC Rotary Unit – Weight Reference Guide

7

Place the platter on a bench and bolt the coupler [1] to the platter using SHCS 1/4-20 X 5/8 [2].

While the platter is on the bench insert the felt strip included in the kit in the groove [3]

NOTE: If the UMC is not exchanging platters reuse the felt strip already in the groove. 

Torque the bolts to their required specs.

8

Install the coupler onto the shaft assembly [1] by using 1/4-20 X 1 1/4 bolts [3]. Make sure the O-Rings 2-011 [2] are in the cavaties of the shaft and not where the bolts attach.

Torque the bolts to their required specs.

9

Install the coupler and platter assembly [2] back onto the rotary using M12 bolts [1].

Tighten the bolts, but do not torque them down yet.

Follow the installation section of the UMC C-Axis Platter Replacement linked below for the full instruction on how to correctly reinstall the platter.

UMC C-Axis Platter Replacement

10

Rotate the B-axis 90 degrees [1].

11

Attach the anti-rotation block [3] to the gearbox using the M6 bolts [4].

If the read head is in configuration [1] you will need to clock it to position [2]  this will require you to redo the compensations on the machine.

If the read head is in configuration [2] the compensations will not need to be redone.

Torque the bolts to their required specs.

Please contact service about borrowing a swivel checker.

12

Install the shaft and manifold assembly [1] by pressing the dowel pin [2] into the hydraulic manifold.

13

Install the shaft assembly to the hydraulic manifold make sure to install the snap ring [2] to the shaft groove [1].

 

14

The HPU cables will be routed to a box under the control cabinet from there the HPU will have a 6 foot placement radius [1] so that the customer has the freedom to place it where they like. This section of cables will be contained in a conduit.

15

Install the pallet air blast solenoid [1] to the lube panel as shown, route the hose from the solenoid over the top of the machine and into the sheet metal.

16

Follow the wiring diagram  for the electrical components all of the wiring will make its way through the box under the control cabinet and to the I/O board.

If the machine does not come with a I/O HINDGED DOOR you will need to install it, follow the I/O HINGED DOOR PROCEDURE for instructions on how to install it.

A food pedal cable will also be routed from the front skirt [1] of the machine along the side skirt into the box under the control cabinet and connected to the I/O board as shown.

17

Install the side of the hose with the filters [1]  to the HPU, there are zip ties indicating which hose is clamp and unclamp.

The RED zip tie indicates the CLAMP hydraulic hose.

The GREEN zip tie indicates the UNCLAMP hydraulic hose.

18

Route the hydraulic lines from the HPU [1] through the center thru bore of the B-axis body. The air line [2] will also be routed along with the hydraulic lines.

19

Pull the hoses through the B-axis body and to the hydraulic manifold as shown. Use the zip ties and cable clamps to neatly route the cables to the hydraulic manifold.

The unclamp denoted in green [1] goes the fittings as shown, and the clamp hose denoted in red [2] is also as shown. The airline [3] will attach to the elbow fitting on the manifold. 

NOTE: Make sure to match the clamp and unclamp hose with the same color zip ties on the manifold fittings. 

20

Add the decal to the tank of the HPU as shown.

21

Reinstall the new cover [2] and return the rotary [1] to 0 degree's on the B axis.

22

Attach the decal [1] (PN: 29-1171) that shows the correct method for cleaning the platter and rotary union port on the front of the UMC.

23

Please refer to the link to install the Hydraulic Vise option.

UMC Hydraulic Vise - Installation/Removal - AD0514
Option - Activation Code + Patch - NGC

24

Please refer to the link to verify/load any patches involved with the installation.

17.2 UMC - Hydraulic Vise Installation

UMC Hydraulic Vise - Installation/Removal

AD0514

Introduction

1

This procedure will explain how to install the hydraulic vise option on the UMC series machines. 

Please refer to the hydraulic workholding procedure to install the HPU, hydraulic manifold, and the other components that drive the hydraulic vise.

Pre-requisites: 

  • Software version 100.20.000.1110 or higher.

Kits applied:

  • 93-1000517 HYDRAULIC VISE-6.0 FIELD INSTALL
  • 93-1000518 HYDRAULIC VISE-8.0 FIELD INSTALL
  • 93-1000519 HYDRAULIC VISE-10 FIELD INSTALL

2

This section is for hydraulic vises with 2 mounting bollts.

Blank platters have a no drill zone [1] of  Ø7.25 in. and ↧1.75 in. for custom workholding on these platters.  

Machines sold with a blank platter also have the option of purchasing the Haas hydraulic vise. 

To install the vise the user will need to drill mounting holes outside the no drill zone [1].  Home the B & C-Axis and drill using the hole pattern that follows:

  • Haas Hydraulic Vise: (2x) 1/2-13 holes at 9 in. (on center) [2]

for the mounting bolts, the mounting bolt. Use the brake bleed access hole for reference [3].

NOTE: Pictured is a UMC-500 blank platter but the no drill zone and Haas hydraulic vise hole pattern will be the same throughout all UMC models. 

3

This section is for hydraulic vises with 4 mounting bollts.

Blank platters have a no drill zone [1] of  Ø7.25 in. and ↧1.75 in. for custom workholding on these platters.  

Machines sold with a blank platter also have the option of purchasing the Haas hydraulic vise. 

To install the vise the user will need to drill mounting holes outside the no drill zone [1].  Home the B & C-Axis and drill using the hole pattern that follows:

  • 6 & 8 in. Hydraulic Vise  – 4x ½-13 at 103.6mm [2] x 63mm [3] (on center)
  • 10 in. Hydraulic Vise – 4x ½-13 at 124.7mm [2] x 63mm [3] (on center)

For the mounting bolts, the mounting bolt. Use the brake bleed access hole for reference [3].

NOTE: Pictured is a UMC-500 blank platter but the no drill zone and Haas hydraulic vise hole pattern will be the same throughout all UMC models. 

Installation

1

In the position shown the air line is the hole denoted [2] use the brake bleed access port [1] as a reference.

2

This section is for hydraulic vises with 2 mounting bollts.

Set the C-axis to its home position.

Clean the mating surface inside the center bore and on the spud of the hydraulic vice for chips and left over oil. Make sure the screws and washers are removed as well

To install the vise [1] carefully place the vise into the bore, make sure to align the hydraulic holes [2] inside the bore with the hydraulic holes on the vise [3]. Be sure that the O-rings [4] are in the grooves of the hydraulic holes, if they are ripped or damage, replace them immediately 

NOTE: The coupler on the platter can only be installed in one orientation.  The hydraulic holes [2] can only be oriented in one way, be sure to match the holes on the coupler to those on the spud.

Use the SHCS and washer [5] to bolt the vise to the T-nuts [6] in the slot shown in the image. 

 While placing the vise make sure the DOWELS [7] are in the T-slots positioned above the left T-nut and under the right T-nut. They should sit diagonally across from each other.  

NOTE: Always clean inside the center bore for chips before installing the hydraulic vise.

3

This section is for hydraulic vises with 4 mounting bollts

Set the C-axis to its home position.

Clean the mating surface inside the center bore and on the spud of the hydraulic vice for chips and left over oil. Make sure the screws and washers are removed as well

To install the vise [1] carefully place the vise into the bore, make sure to align the hydraulic holes [2] inside the bore with the hydraulic holes on the vise. Be sure that the O-rings [3] are in the grooves of the hydraulic holes, if they are ripped or damage, replace them immediately 

NOTE: The coupler on the platter can only be installed in one orientation.  The hydraulic holes [2] can only be oriented in one way, be sure to match the holes on the coupler to those on the spud.

Use the SHCS and washer [4] to bolt the vise to the T-nuts [5] in the slot shown in the image. 

 While placing the vise make sure the aligning block [6] are in the center T-slots.  

NOTE: Always clean inside the center bore for chips before installing the hydraulic vise.

4

To activate the vise, press [CURRENT COMMANDS] and under the workholding tab [1] select workholding type [2] to Custom Hydraulic Vise. 

Adjust Clamp Force

1

Determine the type of Hydraulic Vise is installed on the machine.  LMC or Autogrip.

Use the Hydraulic Vise Clamp Force Chart decal to find the PSI to achive the desired clamp force.

Adjust the Hydraulic Unit pressure valve to the correct PSI.

2

Finally, make sure the vice actuates, to do so press the foot pedal. 

Removing the Vise

1

To physically remove the hydraulic vise press [CURRENT COMMANDS] and disable the vise by going to the workholding tab under the device tab. Change the value of the workholding from Custom Hydraulic Vise to None.

De-pressurize the HPU  by pressing [F3] on the maintenance tab.

Remove the vise and plug the three port holes with the 5/16-18 screws provided in the kit.

Re-activate the HPU by pressing [F4] on the maintenance tab.

2

After the vice is removed plug the hydaulic ports with the 5-/16 screws and washers.

 NOTE: Make sure there are O-rings in the grooves before plugging with the screws.

17.3 UMC - Hydraulic Working Ready

Introduction

The UMC series machines have two types of workholding and vises: hydraulic [1] and pneumatic [2]. This troubleshooting guide will have information in regards to the hydraulic workholding [1]. 

For further information on how to install the hydraulic or pneumatic workholding mechanisms/vises please refer to the links below:

Hydraulic Workholding Links: 

Symptom Table

Symptom Probable Casue Corrective Action
Hydraulic fluid is coming out of the air blast port. Verify orientation of the ports between the coupler and the spud of the vise. The open and close ports may be lined up with the air blast port.  Remove the vise from the platter and verify if the orientation is correct. Newer versions of the coupler will have the air port labeled "AIR" 
Vise jaws are not closing when commanded and HPU is functioning properly.
Hydraulic lines are clogged.  Debris may have been introduced when installing or removing the hydraulic vise from the machine. 

If the system has a the hydaulic filter fitting on the side attached to the HPU, check the filter fittings to see if any debris is present. 

If debris is present clean the fitting off, replace the hydruaulic oil and continuously check the fitting so it does not get clogged. Replace the fittings as needed
Clamp and unclamp solenoids have failed due to debris present in the hydraulic oil.

If the system does not have the hydraulic filter fitting on the side attached to the HPU, update the system by ordering two 58-2127 FILTER 65 MICRON HYD 6ORBM 6JICM STR STL and replace the two 58-0038 FITG ORB6M JIC6M STR STL that were already installed on the hose. 

Replace the hydraulic oil and continuously check the fitting so it does not get clogged. Replace the fittings as needed
HPU - Hydraulic Vise Pressure on the gauges page is dropping . The pressure sensor is monitoring the accumulator pressure not the vise pressure. Visit the Hydraulic Vise -  HPU Dial and Valve section for futher information
Hydraulic Vise - Part is moving while clamped . The clamping force is not set correctly .  Adjust the valve on the HPU to the correct pressure using the decal posted on the HPU. Visit the Hydraulic Vise -  HPU Dial and Valve section for futher information.
Message: Foot pedal 1 is locked out. The foot pedal is pressed when in the EDIT mode or LIST PROGRAM mode. Navigate off of the EDIT mode or LIST PROGRAM mode.
Alarm 391 FEATURE DISABLED Workholding is not setup on Workholding Tab. Enable the workholding on the Workholding tab. See the Programmable Air - Installation procedure for more information.
Broken dove tail jaw. Incorrect part setup on jaws. Refer to the Proper Dovetail Usage reference document. 
Unable to set pressure consistently. Faulty cartridge valve.
 Check cartridge valve for any leaks. If there are no leaks, replace cartridge valve. 
Can not reach above 100 psi 

Machines with a Blank Platter

1

This section is for hydraulic vises with 2 mounting bollts.

Blank platters have a no drill zone [1] of  Ø7.25 in. and ↧1.75 in. for custom workholding on these platters.  

Machines sold with a blank platter also have the option of purchasing the Haas hydraulic vise. 

To install the vise the user will need to drill mounting holes outside the no drill zone [1].  Home the B & C-Axis and drill using the hole pattern that follows:

  • Haas Hydraulic Vise: (2x) 1/2-13 holes at 9 in. (on center) [2]

for the mounting bolts, the mounting bolt. Use the brake bleed access hole for reference [3].

NOTE: Pictured is a UMC-500 blank platter but the no drill zone and Haas hydraulic vise hole pattern will be the same throughout all UMC models. 

2

This section is for hydraulic vises with 4 mounting bollts.

Blank platters have a no drill zone [1] of  Ø7.25 in. and ↧1.75 in. for custom workholding on these platters.  

Machines sold with a blank platter also have the option of purchasing the Haas hydraulic vise. 

To install the vise the user will need to drill mounting holes outside the no drill zone [1].  Home the B & C-Axis and drill using the hole pattern that follows:

  • 6 & 8 in. Hydraulic Vise  – 4x ½-13 at 103.6mm [2] x 63mm [3] (on center)
  • 10 in. Hydraulic Vise – 4x ½-13 at 124.7mm [2] x 63mm [3] (on center)

For the mounting bolts, the mounting bolt. Use the brake bleed access hole for reference [3].

NOTE: Pictured is a UMC-500 blank platter but the no drill zone and Haas hydraulic vise hole pattern will be the same throughout all UMC models. 

Hydraulic Vise - HPU Dial and Valve

1

Pressure drop on the controller gauge page is normal as it is monitoring the accumalator pressure [1]. Pressure on the controller should always be higher than on the dial for the system to keep clamping force consistent.

 NOTE: 100 psi/5 minutes is what is considered normal pressure drop.

2

The HPU dial [1] located on the HPU will display the pressure applied to the vise, the controller HPU pressure found on the gauge page will display the pressure monitored from the accumulator [2].

 NOTE: The pressure may vary within 10 psi as long as the accumulator is funtioning properly. 

3

To make adjustments to the pressure applied to the vise, the knob denoted as [1] is used to make the adjustment while knob denoted as [2] is used to lock the adjustment in place.

NOTE: If the pressure value is drifting more than 10 psi on the dial check if knob [2] is locked in place and check for any leaks from the vise or the system. 

 

4

Haas hydraulic vises will have a hydraulic vise clamp force chart that can be used to achieve the correct clamp force in relation to the pressure on the dial. 

NOTE: This chart will NOT apply to third party vises. 

 

Electrical Diagram

1

When running the wires, make sure there isnt excess strain on the cables. Check to make sure all connections are secure and in the correct location based on the diagram above.