Note: The washers [1] and nuts [2] are installed during shipping and shold be saved for installation and not be discarded.

Note: The washer orentation [3] is important. the conical part of the washer should be against the casting, see illustration.

Connect the air aupple at the lube panel.

Note: For air requirements refer to the decal that is located on the lube cabinet door.

Initial Control Inspection

 Danger: At this point, there should be no electrical connection to the machine. Electrical panel must be closed and secured. When main switch is on, there is HIGH VOLTAGE throughout the electrical panel (including the circuit boards and logic circuits) and some components operate at high temperatures. Therefore, exercise extreme caution when working in the panel.

• Set the main breaker switch at the upper right of the electrical panel on the back of the machine to OFF.
• Using a screwdriver, unlock the two latches on the panel door, unlock the cabinet with the key and open the door.
• Take sufficient time to check all the components and connectors associated with the circuit boards. Look for any cables that have become disconnected, look for any signs damage and loose parts in the bottom of the panel box. If there are any signs that the machine was mishandled, call the factory before proceeding.

1-Phase Machines: Insert each power lead into the wire cover. Connect the two power leads to L1 and L3 terminals on top of the main circuit breaker.

3-Phase Machines: Insert each power lead into the wire cover. Connect the three power leads to L1, L2, and L3 terminals on top of the main circuit breaker.

Connect the separate ground line to the ground bus to the left of the terminals.

Note: Make sure that the leads actually go into the terminal-block clamps. (A poor connection will cause the machine to run intermittently or have other problems, such as servo overloads.) To check, simply pull on the wires after the screws are tightened.

After the line voltage is connected to the machine, make sure that the main circuit breaker (at top-right of rear cabinet) is OFF. Remove the Lockout/Tagout and turn ON the power at the source. Using a digital voltmeter and appropriate safety procedures:

1-Phase Machines: Measure the AC voltage across L1 & L3 at the main circuit breaker. The AC voltage must be between 220 - 250 voltage alarms.

Note: Lower or higher than this voltage can generate low/high voltage alarms.

3-Phase Machines: Measure the AC voltage between all three pair phases at the main circuit breaker. The AC voltage must be between 195 and 260 volts (360 and 480 volts for high voltage option).

  Note: Wide voltage fluctuations are common in many industrial areas; minimum and maximum voltage supplied to a machine while it is in operation must be known. U.S. National Electrical Code specifies that machines should operate with a variation of +5% to -5% around an average supply voltage. If problems with line voltage occur, or low line voltage is suspected, an external transformer may be used. If you suspect voltage problems, voltage should be checked every hour or two during a typical day to be sure it does not fluctuate more than +5% or -5% from an average.

Important: With the main circuit breaker turned OFF.

Check the transformer taps at the bottom-right corner of the rear cabinet.

1-Phase Machines: The input voltage cable must be moved to the connector which corresponds to the average voltage measured in the above step.

3-Phase Machines: The input voltage cables labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to the average voltage measured in the above step.

Transformer T5 supplies 24VAC used to power the main contactor. There are two versions of this transformer for use on a 240 and 400V machines. The 240V transformer has two input connectors located about two inches from the transformer, which allow it to be connected to either 180-220V or 221-240V. Users that have 220V-240V RMS input power should use the connector labeled 221-240V, while users with 190-220V input power should use the connector labeled 180-220V. Failure to use the correct input connector will result in either overheating of the main contactor or failure to reliably engage the main contactor.

The 480V (option) T5 transformer has three input connectors, labeled 340-380V, 381-440V and 441-480V. Users with 340-380V 50Hz power should use the 340-380V connector while users with 380V-440V 50Hz power should use the 381-440V connector.

 Important: Set the main circuit breaker to ON. Check for evidence of problems, such as the smell of overheating components or smoke. If such problems are indicated, immediately set the main circuit breaker to OFF and call the factory before proceeding.

After the power is on, measure the voltage across the bottom terminals on the main circuit breaker. It should be the same as the measurements where the input power connects to the main breaker. If there are any problems, check the wiring.

Apply power to the control by pressing the Power-On switch on the front panel.

Check the DC Voltage and AC Line Voltage gauges in Diagnostics. The DC Voltage gauge must read between 310 - 360V. The AC Line Voltage must be between 90 and 105 percent. If the voltage is outside these limits, turn off the power and recheck steps 2 and 3. If the voltage is still outside these limits, call the factory.

Remove the rear panel. 

Remove the column shipping bracket [1].

Remove the chip conveyor brackets [2].

Remove the operator door shipping bracket [3].

Reach in through the operator door and remove the red shipping bracket that is bolted to the rotary and H-frame [4]. 

Remove the load station door bracket [5].

Remove the load station pallet bracket. Remove the pallet plug that is bolted to the bracket. Place the plug in the center hole of the pallet and tap it in place with a mallet [6].

Set the machine height using the four corner leveling bolts [1,2,7,8] to 3"  (76.2 mm) above the floor. Turn each screw so they have equal tension.

Turn the four middle leveling screws [3,4,5,6] up off the middle pads.

Jog the X and Z axis to the middle of the travel.

Position the level at the center of the pallet, parallel to the X-axis.

Position the level at the center of the pallet, parallel to the Z-axis.

Adjust the corner leveling bolts [1,2,7,8] until both levels read +/- 0.0005"

Position the level at the center of the pallet, parallel to the X-axis.

Jog the Z axis towards the spindle and then away from the spindle and adjust the front left bolt [7] until the level reads +/- 0.0005"

Jog the X and Z axis to the middle of the travel.

Bring down the center leveling screws [3,4,5,6] with equal pressure.  

Position level at the center of the pallet, parallel to the Z-axis.

Jog the Z axis towards the spindle and then away from the spindle. Adjust the leveling screws [5,6,7,8] until the level reads +/- 0.0005"

Install tool T-2192 on the spindle.

Mount the bubble level on top of T-2192.

Jog the X-axis from left to right and adjust the leveling screws [3, 4] if necessary until the level reads +/- 0.0005"

Put a 8" test bar on the spindle.

Sweep the top and side of the bar about 6".     The indicator should not to exceed 0.0003 / 6".

 Note: If the spindle sweep is out make sure the level of the machine is correct.

Run the spindle run-in program.

Examine the sight glass, make sure the correct number of drops are fall through the sight glass.

Examine the fittings [1,2] on top of the oil pump tank.

The oil collects on top of the oil pump tank [3] either behind or in front of the sight glass bracket, underneath the leaking fitting.

Tighten any leaking fittings.

Go to the Maintenance tab.

Press [F2] to cycle an axis lubrication test.

Inspect the gauge on the grease lubrication system.  Make sure it holds pressure.

Install the support brackets onto the center brackets [3] using (4) SHCS 3/8-16 x 1 loctite [1] and (4) washers [2] on each corner.

Install the support brackets and center bracket assembly's [1] onto the enclosure panel.

Install (2) shoulder bolts [1] to secure the frame brackets [2] in place.

Attach the bottom enclosure panels to the center brackets [4] in the following order:

• Install the bottom left panel [1] first using (2) FBHCS 1/4-20 X 1/2 LOCTITE.
• Install the bottom center panel [2] next using (6) FBHCS 1/4-20 X 1/2 LOCTITE.
• Install the bottom right panel [3] using (8) FBHCS 1/4-20 X 1/2 LOCTITE.

Install the top enclosure panels to the center brackets [3] in the following order:

• Install the top left corner panel [1] using (14) FBHCS 1/4-20 X 1/2 LOCTITE.
• Install the top right corner panel [2] using (10) FBHCS 1/4-20 X 1/2 LOCTITE.
• Install the top center panel [3] using (30) FBHCS 1/4-20 X 1/2 LOCTITE.

Install and fasten the CAGE WINDOW INTERLOCK [1] using the provided hardware [2] onto the inside of the top center panel.

Install and fasten the INTERLOCK ASSEMBLY [3] with the provided hardware [4].

Reattach the TOOL CHANGER REMOTE SWITCH BOX [1] onto the enclosure panel [2].

Machines that come with the tool changer extension panels [2] will install them as shown in the image. 

NOTE: The sliding frame brackets [1] will need to be fully extended to install the extension panels [2].