3 - Haas Knee Mill - Installation

Unpacking

1

Remove plastic wrap from knee mill.

Remove paper covers from ways. Remove protective plastic sheets from decals.

Removal of Rust Inhibitor

For ease of removal, first use a plastic scraper to remove most of the rust inhibitor and then use either a heavy duty citrus cleaner or Simple Green to spray all the way covers and other non-painted surfaces that have been coated with rust inhibitor. Let it soak for a few minutes before removing it using a shop towel. It is recommended to apply mineral spirit or WD-40 to all exposed metal surfaces for rust proofing.

Important: Do not use scotch-brite or metal scrapers, these will scratch the way covers. Furthermore, to avoid any contamination of the way cover seals with the sticky residue. Do not move any of the axes until all the rust inhibitor has been removed.

Note: The product is not hazardous and can typically be disposed of similarly to used oil.

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2

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.

3

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

4

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.

5

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

Levelling

1

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

2

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.

3

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.

4

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.

5

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.

Spindle Squaring

Two ways of squaring the spindle are described below. They can be used interchangeably, depending on the tools available.

1

Add a granite square to the table on jacks [1]. Use a magnetic base to attach an indicator to the spindle. Indicate across the face of the granite as you jog the table in x and y. Adjust the jacks until the granite is level. Place a cylinder square on top of the granite square.

2

Place the indicator on the cylinder square as shown. Jog the table incrementally in the y-axis to find the high point of the cylinder.

Without moving the indicator, jog the knee up and down. 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.

3

Place the indicator on the cylinder square as shown. Jog the table incrementally in the x-axis to find the high point of the cylinder.

Without moving the indicator, jog the knee up and down. 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.

Spindle Sweep

If you do not have the tools available for spindle squaring, as described above, a spindle sweep can be performed as an alternative.

3

Put a magnetic base with a 0.0005" (0.01 mm) indicator on the spindle.

Note: Make sure the indicator base cannot move or turn with the spindle.

Move a gauge block below the indicator stylus from the rear of the indicator. Set the indicator to 0. Remove the gauge block.

Examine the table every 10 inches (25.4 cm) on the X and Y Axis. Move the table to the next location. Move the gauge block under the indicator stylus from the rear of the indicator. Record the value.

Note: The maximum permitted error is 0.0012" (0.03 mm) at a distance of 10" (25.4 cm).

4

Move the spindle to the center of the area with the smallest error.

Move the magnetic indicator base onto the spindle nose. Put the stylus 5" (12.7 cm) from the spindle centerline.

Note: The magnetic indicator base must turn with the spindle.

Move the gauge block under the stylus from the rear of the indicator.

Jog the Z Axis to set the indicator to 0.

1

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

2

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.

3

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.

Component Installation

1

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

2

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

3

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].

4

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].

5

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

Air Connection

1

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].

Electrical Installation

1

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.

2

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

3

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].

4

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.

Fill Coolant and Lubrication

Note: Machine does not come with oil or coolant. Oil and coolant must be purchased seperately.

1

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.

2

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.

3

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 .

Note: Be sure to maintain your coolant mixture to keep the coolant concentrate at acceptable levels. Improperly maintained coolant mixtures can allow machine components to rust. Rust damage is not covered by your warranty. Ask your HFO or your coolant dealer if you have questions about the specific coolant you plan to use.

Grease and Oil Head

1

The three ports [1] on the head of the machine should be filled with 93-4575 SYNTHETIC GEAR/BEARING OIL 1GL/3.78L, 93-2365 SYNTHETIC GEAR/BEARING OIL 1QT/0.94L, or other ISO VG68 Oil.

The grease port [2] should be filled with 93-3891 GREASE MOBIL XHP 322 5% MOLY or other EP32 grease.

Verify RPM Placard Alignment

1

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.

2

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.