11.1 DC-Series Maintenance Schedule

DC Tool Changer
Maintenance Item Interval
Clean the chips from the tool changer.
 Weekly
Inspect motor and gearbox.
 Monthly
Grease the guide rails.
 Monthly
Grease the extractor fingers.
 Monthly
Auxiliary Filter
Maintenance Item Interval
Replace the filter bag.
 Check the Gauge
Inspect the hoses for cracking.
 Six Months
Electrical Cabinet
Maintenance Item Interval
Clean vector drive air vents / filter.
 Monthly
Enclosure
Maintenance Item Interval
Inspect windows for damage.
 Daily
Inspect the door interlock operation.
 Daily
Inspect waycovers and lubricate.
 Monthly
Pneumatics
Maintenance Item Interval
Inspect the spindle air regulator pressure.
 Weekly
Inspect the hoses for cracking.
 Six Months
Clean the Air Purge Solenoid.
 Annually
Air Regulator
Maintenance Item Interval
Inspect Outgoing Air Pressure.
 Weekly
Inspect/Refill Air Lubrication Level.
 Monthly
Clean/Replace Air Filter
 Six Months
Probe System
Maintenance Item Interval
Check the probe batteries.
 Six Months
Check probe calibration.
 Six Months
Rotary
Maintenance Item Interval
Inspect the oil level.
 Annually
Replace the oil.
 Two Years
Inspect the A-Axis counterbalance cylinder for oil leaks. Two Years
Replace the A-Axis counterbalance cylinder.
 Four Years
Standard Coolant System
Maintenance Item Interval
Clean the filter screen.
 As Required
Inspect the coolant level.
 Weekly
Inspect the coolant concentration. Fill out the Mixture - Maintenance Log sheet.
 Weekly
Completely clean the coolant tank and replace the coolant.
 Six Months
Clean the standard coolant filter.
 Six Months
Verify coolant refill is operating correctly.

 Six Months
Through Spindle Coolant (TSC) 300/1K PSI
Maintenance Item Interval
Clean the TSC-300 / 1K Pump Filter
 Six Months
Inspect the hoses for cracking.
 Six Months
Verify the Auto Clean system is operating correctly.
 Six Months
Spindle Chiller 
Maintenance Item Interval
Inspect Fluid Tank Level.
 Daily
Fill Fluid Tank. As Required
Clean Air Inlet Filter.
 Weekly
Inspect/Clean Air Outlets.
 Weekly
Spindle
Maintenance Item Interval
Clean and lubricate the spindle taper.

 As Required
Spindle drawbar force measurement.
 Annually
Axis Lubrication Pump
Maintenance Item Interval
Inspect lubrication tank level.
 Monthly
Perform Axis Lubrication Test.
 Six Months
Clean the filter inside the oil reservoir.
 Annually
Clean the Auxiliary Filter Annually
Tooling
Maintenance Item Interval
Grease Pull Studs.
 As Required

11.2 DC-Series - Axis Lubrication Pump Maintenance

Introduction

  1. Oil Tank Cap
  2. Oil Inlet Filter
  3. Reservoir
  4. Level Switch
  5. Gear Pump
  6. Pressure Relief Valve
  7. Dump Valve
  8. Elbow Adapter
  9. Pressure Gauge
  10. Power Indicator

DC-Series - Axis Lubrication Pump Maintenance

Axis Lubrication Pump
Maintenance Item Interval
Inspect lubrication tank level.
 Monthly
Perform Axis Lubrication Test.
 Six Months
Clean the filter inside the oil reservoir.
 Annually
Clean the Auxiliary Filter. Annually

1

Fill the tank with 93-2365 OIL SYNTHETIC 75W-90 to the MAX fill line[1].

 Note: You must fill the reservoir tank to the fill line [1] each time you fill the tank.

2

The filter for the axis lubricant must be cleaned. To access the filter, unfasten the bottom of the axis lubricant filter [1] from the top cap [2] that is mounted in the lube panel. Then, remove the filter element [3] and clean. If it cannot be cleaned sufficiently, replace the filter element.

11.3 DC-Series - Air Regulator Maintenance

Introduction

The air regulator requires monitoring and maintenance of the following parts:

  1. Pressurized air filter
  2. Pressurized air canister
  3. Air lubrication canister
  4. Air inlet
  5. Air outlet

 

DC-Series Air Regulator Maintenance

Air Regulator
Maintenance Item Interval
Inspect Outgoing Air Pressure.
 Weekly
Inspect/Refill Air Lubrication Level.
 Monthly
Clean/Replace Air Filter. Six Months

1

The pressurized air filter needs to be cleaned whenever the air lubrication is refilled. To remove the air filter, unfasten the air canister [1] and the umbrella base [2]. Clean the filter or have it replaced if cannot be cleaned sufficiently.

NOTE: When re-installing the filter, the narrow end must be oriented up as shown in the image.

2

Prior to refilling the air lubrication canister, clean out the canister [3] using a non-organic solvent such as dishwashing soap. Once cleaned, refill the canister with air lubricant. Use Mobil DTE 24 Ultra as lubricant for the air regulator - (93-2546)

Inspect the inlet and outlet ports for leaks or damage whenever the air regulator is disconnected from the air supply.

11.4 DC-Series - Spindle Chiller Maintenance

Introduction

This section gives details about the required maintenance for the Spindle Chiller unit [1]. 

Spindle Chiller 
Maintenance Item Interval
Inspect Fluid Tank Level.
 Daily
Fill Fluid Tank. As Required
Clean Air Inlet Filter.
 Weekly
Inspect/Clean Air Outlets.
 Weekly

DC-Series Spindle Chiller Maintenance

1

This image shows the key components of the Spindle Chiller:

Front of Chiller:

  • Temperature Control
  • Flow Indicators
  • Air Inlet Filter

Back of Chiller:

  • Fluid Tank Inlet
  • Alarm Terminal
  • Cooling Inlet/Outlet
  • Fluid Level Gauge
  • Air Outlets

2

Inspect the fluid tank level by looking at the fluid level gauge located on the back of the spindle chiller [2]. To add fluid to the tank, remove the cap to the inlet at the top of the unit, and fill the tank with a mixture of 30% ethylene glycol and 70% dionized water until the gauge reads the level is at the top of the NORMAL [3] or at the FULL level.

3

To clean the air inlet filter, remove the grate to gain access to the filter unit. From there, remove the filter screen so that any dust or debris can be picked out of the filter. If necessary, wash the filter using water to get rid of contaminants. 

4

Make sure that the air outlets are clear of dust and debris. It is also recommended to allow a clear area of 12 inches directly behind the air outlet vents. This will allow for proper air circulation in the system.

11.5 DC-Series - Service Parts List

Part Number Description Applies to Machines
93-4412 Coupling X and Y axis DC-1 DC-1
93-4413 Coupling Z-axis DC-1 DC-1
93-4405 Bearing Angular Contact X and Y axis DC-1 DC-1
93-4406 Bearing Deep Groove X and Y axis DC-1 DC-1
93-4407 Bearing Angular Contact Z-axis DC-1 DC-1
93-4408 Bearing Deep Groove Z-axis DC-1 DC-1
93-4455 Tool Changer Cam Follower DC-1 DC-1
93-3945 Spindle 30T Inline 20K With Drawbar DC-1 DC-1/30T and DC-2/30T
93-4454 Bearing Tool Changer Needle DC-1 DC-1/30T and DC-2/30T
93-4456 Bearing Tool Changer Roller DC-1 DC-1/30T and DC-2/30T
93-4415 Linear Guide X-axis DC-1 DC-1
93-4416 Linear Guide Y-axis DC-1 DC-1
93-4417 Linear Guide Z-axis DC-1 DC-1
93-4418 Ballscrew X-axis DC-1 DC-1
93-4419 Ballscrew Y-axis DC-1 DC-1
93-4424 Ballscrew Z-axis DC-1 DC-1
93-4409 Telescoping Waycover X-axis Left DC-1 DC-1
93-4425 Telescoping Waycover X-axis Right DC-1 DC-1
93-4410 Telescoping Waycover Y-axis Front DC-1 DC-1
93-4426 Telescoping Waycover Y-axis Rear DC-1 DC-1
93-4402 Lube Pump DC-1 DC-1 and DC-2
93-4403 Air Regulator Unit DC-1 DC-1 and DC-2
93-4457 Tool Changer 30T Tool Holder Assembly DC-1 DC-1/30T and DC-2/30T
93-4458 Tool Changer Motor Replacement DC-1/30T and DC-2/30T
59-2245 Spindle Chiller DC-1 DC-1 and DC-2
93-4404 Oil Distribution Manifold DC-1 DC-1 and DC-2
93-4460 Conduit X-axis Motor Cable Braided DC-1 DC-1
93-4610 Gearbox Assembly 30T Service Kit DC-1/30T and DC-2/30T
93-4685 Enclosure Roof DC-1 DC-1
93-4629 Coolant Tank Mesh Plate DC-1**************** DC-1
93-4630 Ferrule Lube Line DC-1 DC-1
93-4631 Fitting 4NPT to JIC 12 Adapter Coolant DC-1*************** DC-1
93-4632 BT40 Magazine Reducer DC*******  
93-4633 Spindle Drive Dog DC-1 DC-1/30T and DC-2/30T
93-4707 Lube Filter Straight Fitting DC-1 DC-1 and DC-2
93-4708 Lube Pump 90 Degree Fitting DC-1 DC-1 and DC-2
93-4709 X-axis Conduit Mount DC-1 DC-1
93-4762 Coolant Tank Thermometer/Level Sensor DC-1/2 DC-1/30T and DC-2/30T
93-4763 Tool Changer Front Plastic Cover DC-1/2 DC-1/30T and DC-2/30T
93-4764 Hose 3/4 ID Hydraulic Steel Wire Braided DC-1  
93-4830 Window Side Piece DC-1/2 DC-1/30T and DC-2/40T
93-4977 Door Magnet DC-1/2 DC-1/30T and DC-2/30T
93-4978 Leveling Pad DC-1/2 DC-1/30T and DC-2/30T
93-5066 Telescoping Waycover Z-axis DC-1 DC-1/30T
93-5068 Tool Changer Rear Plastic Cover DC-1/2 DC-1/30T and DC-2/30T
93-4972 Spindle 40T Inline 15K with Drawbar DC-1 DC-1/40T and DC-2/40T
93-4979 Tool Holder Assembly 40T Tool Changer DC-1 DC-1/40T and DC-2/40T
93-4872 Coupling X and Y and Z axis DC-2 DC-2 
93-4873 Linear Guide X-axis DC-2 DC-2
93-4874 Linear Guide Y-axis DC-2 DC-2
93-4875 Linear Guide Z-axis DC-2 DC-2
93-4876 Ballscrew X-axis DC-2 DC-2
93-4877 Ballscrew Y-axis DC-2 DC-2
93-4878 Ballscrew Z-axis DC-2 DC-2
93-4673 Telescoping Waycover X-axis Left DC-2 DC-2
93-4674 Telescoping Waycover X-axis Right DC-2 DC-2
93-4765 Hose 3/4 ID Hydraulic Steel Wire Braided DC-2 DC-2