3.1 Installation

The knee mill is shipped with the head tilted to one side. To bring the head upright, break loose the four bolts [1]. Do not loosen all the way. 

Use the pivot bolt [2] to rotate the head, until the angle indicator [3] reaches zero. 

Remove the shipping bolts [1] and replace with leveling bolts [2]. Tighten down leveling bolts until they touch the pallet. 

Use forklift to lift knee mill off of pallet. Place forks under knee mill base. Lift knee mill from the front. Moving table and ram head towards the forklift may increase stability. 

Lower knee mill onto leveling pads. 

Install handles on the X-axis cranks [1], y-axis cranks [2], and knee crank [3]. Use wrench to tighten. 

Note: The x-axis handles are located in the coolant troughs of the Knee Mill table. Remove the shipping paper from the table to locate them. 

Adjust leveling screw heights until the casting is 1.25 in (32 mm) above the ground [1]. 

Move the table until it is in the center of travel in the X and Y axes. Place the level parallel to the t-slots. Adjust leveling screws until the bubble is centered. 

Place the level perpendicular to the t-slots. Adjust the leveling screws until the bubble is centered. Turn the level parallel to the t-slots, and adjust if necessary. Continue adjusting until knee mill is level. 

With the level parallel to the t-slots, jog the table through its full y-axis of travel. Note the bubble positioning at each end of travel. Adjust the feet to remove twist from the y-axis. 

With the level perpendicular to the t-slots, jog the table through its full x-axis of travel. Note the bubble positioning at each end of travel. Adjust the feet to remove twist from the x-axis.

Tighten the lock nuts [1] to fix the level of the casting in place. 

Note: If the lock nut cannot be fully tightened due to the shape of the casting, use the beveled washers included in the install kit. Install beveled washers underneath the lock nuts, then tighten the lock nuts. 

Move the gauge block under the indicator stylus from the rear of the indicator. Record the value. Repeat at each 90-degree interval.

 To adjust the spindle tilt, break loose the three bolts behind the head [1]. Use the adjustment bolt [2] to alter the angle of the head. 

 To adjust the spindle tilt, break loose the four bolts on the front of the head [1]. Use the adjustment bolt [2] to alter the angle of the head. 

Remove two bolts on the table [1] and the front of the knee [2]. Install the front way cover.

Remove two bolts from the column [1] and underneath the table [2]. Install the back way cover. 

Screw the threaded end of the drain tubes into table [1]. Move the table to the front right corner of travel and secure the right drain tube to the catch tray with the drain tube bracket [2]. 

Move the table to the front left corner of travel and repeat with the left drain tube. Ensure that neither tube has looping or excess slack at any position of table movement. Adjust hose positioning as necessary. Trim excess hose [1]. 

Screw in the feed direction plunger [1]. Use the hand wheel to provide additional leverage. 

Connect air supply behind the column [1]. The air connection may need to be replaced with a standard quick connect fitting to be compatible with your air supply. The regulator has a 1/4 NPT inlet port [2].

Open the electrical cabinet door. Main breaker must be switched off to open the electrical cabinet. Route the power cables through the bottom of the electrical cabinet. Connect the other end of the power cables to a high voltage plug. 

Connect the yellow and green ground cable [1] to ground. 

Connect the brown wire labelled R to the port labelled R [1]. Connect the blue wire labelled S to the port labelled S [2]. Connect the black wire labelled T to the port labelled T [3].

The machine is wired as 220VAC upon arrival. To wire the machine for 380VAC instead, move the black wire labeled S1 to the 380 V connection. 

Attention: Do not connect S1 to the 380 connection if your power source is 220VAC, or vice versa. Doing so will cause permanent damage to the machine. 

Attention: The spindle motor and coolant pump are designed for 220/380V power only. Do not connect S1 to the 415 or 440 connections. Doing so will cause permanent damage to the machine. 

Note: An external transformer is required for 415/440VAC incoming voltage. 

Remove the cap [1] to access lubrication fill port. Pour oil slowly, giving it time to pass through the filter. Fill until oil approaches max fill line. 

Lubrication tank should be filled with 93-4578 SYNTHETIC GEAR/BEARING OIL 1GL/3.78L, or 93-2365 SYNTHETIC GEAR/BEARING OIL 1QT/0.94L, or an ISO VG68 Oil. About 2 quarts is needed to fill the tank.

To modify the discharge volume of lube, loosen the set screw [2]. Turn the nut counterclockwise to decrease volume and clockwise to increase volume. The increments [3] on the post indicate discharge volume.  

The lubrication system must be manually primed. Pull up on the plunger [1] and release it. Wait until the plunger returns to it's initial position. Pull and release at least twice more. Do not press on the plunger. 

Remove the coolant tank cover from the back of the knee mill column by unscrewing the four bolts [1]. Fill the coolant tank.

Note: Ensure that coolant tank is clean and free of chips before filling coolant. 

For more information about coolant mixing and concentrations, see Coolant - Overview and Coolant -Maintenance .

It may be necessary to check that the RPM placard correctly displays the spindle RPM. 

Turn the machine to low gear. Once in low gear, slowly turn up spindle RPM until placard no longer rotates, and turning hand wheel does not increase spindle RPM any further. 

Turn off motor. If the placard does not indicate that the machine is at 500 RPM [1], the placard should be adjusted. 

Loosen the bolt [2] on the placard and rotate it until the indicator arrow points to 500 RPM on the low-gear range. Tighten the bolt. 

Move the table all the way to the right, stopping before the power table feed hits the table. 

Examine the position of the right hard stop. If the hard stop is not in a position to trigger the limit switches, move the hard stop to the correct location.