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Use these numbers to identify which foot to adjust.

• Prerequisites:

Adjust each leveling screw until the base is 4" (10 cm) above the floor (3" (76 mm) leveling pad height plus 1" (25 mm) of screw below the bottom of the pad).

 Note: The condition of the foundation may require different heights at some leveling screws to make the machine level.

  Important: it is required that the machine be anchored. Refer to the following link: ANCHORING INSTRUCTIONS.

• Using the anchor pattern from Machine Layout to mark the machine location.
• Print the anchor footprint from AD0456 to mark anchor location.
  • Important: Footprint must be printed at 1:1 ratio
    

Tools Required:

• Electronic differential level, precision bubble level, calibrated to show 0.0005 inch per 10"
• Test indicator (0.0005")
• Two ¾" hex wrenches (one open end or box and one ratchet)
•  600 #  TORQUE  WRENCH , ¾ DRIVE w/ 1.5" Socket
• 50T X 8” PREC SPINDLE ALIGNMEN TOOL
•  3 x 4 x 40  GRANITE PARALLEL
•  3 x 12 x 18  GRANITE TRI SQUARE
•  2 x 6 x 6  GRANITE PARALLEL 
  
• 50T Alignment Split Tool

Important: Depending on the available space and equipment it may be simpler to relocate the tool changer assembly before moving the Column Base into the facility

Remove the side panels from under the tool changer.

Clean the mating surface for the tool changer [1].

Place a piece of cardboard between the spindle head and the tool changer to prevent scratching the spindle head covers.

Note: Some components of the Carousel where removed for illustration purpose only.

Using the proper lifting equipment and lifting straps (2x) as shown to support the tool changer (aprox. 2670 lbs / 1211 kg).

Unbolt [2] the tool changer from the shipping location and lift it into position on the column and tighten the (6) bolts to 80 ft-lb (108 Nm).

Important: Ensure the anchoring preparations are in accordance with the anchoring instructions prior to setting the machine in place. Image [1] Anchor hole [2] Leveling Pad

Place the column base assembly in position on the following leveling screws.

• 1 - 2
• 4 - 26
• 6 - 24

Rough level by measuring from the floor to the bottom of the base 3". (4 - 4 1/2 inches for Conveyor Option). 

This will ensure that the final leveling procedure will go more quickly and that the coolant tank will properly fit beneath the coolant discharge. Loosely screw the jam nuts onto the leveling screws.

Place the table base assembly in position on the following leveling screws.. When placing the table base in position with respect to the column base, it is important that the two mating flanges be as parallel as possible (vertically and horizontally).

Rough level by measuring from the floor to the bottom of the base 3" (4 - 4 1/2 inches for Conveyor Option).  This will ensure that the final leveling procedure will go more quickly.

After rough leveling, verify that each of the screws are actually engaged in the threads, and that when the column base is in place and the mating surfaces are in contact that each.

Be certain that the connecting screws are still free to rotate (do not leave the connecting bolts tight at this time because the machine still must be final leveled and squared)

Note: The counterbalance cylinders have been removed (for overhead clearance during shipping), and they must be reinstalled and recharged with dry nitrogen prior to enabling the column axis

Re-install alignment collar and thrust bearing

• Note orientation of alignment collar - deep shoulder faces rod end.

Insert the cylinder down between the spindle head casting and Column casting.

Slide the top of cylinder into the Rod Bracket until the bottom clears the Mount Block

Install cylinder assembly into mounting block on column 

From the rear of the Column casting, extend cylinder rod and re- connect to the Rod End that is mounted on spindle head. 

WARNING : Use appropriate PPE equipment (face shield, gloves, etc.) when filling the hydraulic tanks.

Make sure all tank valves are closed before beginning. 

Attach nitrogen tank fill nozzle

Begin filling counterbalance tank by SLOWLY cracking open the valve

Fill tank until gauge reads 750psi.

Wiring the Column Base

• On the electrical cabinet side, Locate the bundle of wires (Purple Line) containing 
  • Right Door sensor cable
  • Air line (Right Door Interlock)
  • Right Side work light
  • RJ45 SHIELDED CABLE
  • USB 2.0 CABLE
  • CBL740/770/+12V&GND-SKBIF EXT VS
  • Work light
• Route cable through the cable channel along the base of the Column and Table assembly.
• Continue up the rear panel of the Table assembly and over the top of the enclosure in the cable channel.
• Connect the work light cable into the splitter connector 
• Insert the air into the right Door Interlock and connect the Right Door Sensor
• From the Front Panel connect the RJ45 SHIELDED CABLE, USB 2.0 CABLE and CBL740/770/+12V&GND-SKBIF EXT VS 
• route the Air Line into Front Panel and connect to the quick connect for the air nozzle.

• On the Tool Changer Side locate the bundle of wires containing
  • Coolant Electrical connection bracket (Blue Line)
  • Left Door Sensor cable (Orange Line)
  • Air Line (Left Door Interlock) (Orange Line)
  • Left side work light (Orange Line)
• Route cable and coolant lines through the cable channel along the base of the Column and Table assembly.
• Split the Door and work light cable from the coolant lines, continue routing the door and work light cables up the rear panel of the Table assembly and over the top of the enclosure in the cable channel.
• Connect the work light cable into the splitter connector 
• Insert the air into the Left Door Interlock and connect the Left Door Sensor
• Continue routing the Coolant Line through the cable channel and mount the coolant electrical connection bracket to the back of the enclosure panel
  

Wiring the Table Base

• On the Table Base locate the bundle of cable (Red Line) containing 
  • X - axis motor / encoder cable
  • X - axis Linear Scale cable
  • X - axis lube lines (2x)
• Route the cables through the cable channel located on the side of the Column base and into the bottom control wire box.
• In the wire box find the X-axis linear scale interpolation box and connect the X axis linear scale cable
• Route the X-axis motor / encoder cable up into the Electrical Cabinet 
• Connect the X axis motor cable the Amplifier and route the X axis encoder cable up to the Main Processor (P1)
• Locate the Chip Auger motor cable (Green line) in the cable channel  and route to the electrical cabinet. 
• Connect auger motors to open locaion on QUAD CHIPC  PBC  (P4 - P7)

Unblocking the Column Base

CAUTION: Before unblocking machine ensure that counterbalance cylinder charging hose is attached to nitrogen tank and nitrogen tank is fully charged to 750 psi.

• Remove the shipping bracket and hardware completely from the side of column base on the Tool Changer side.
• Handle jog (without zero return) the spindle head to the up position and support the bellows.
• Remove the spindle shipping bracket 

Unblocking the Table Base

• Remove the shipping bracket and hardware completely from the front of Table base 

Leveling the Machine

At this point the machine is completely unblocked and all axes are enabled. The process of leveling can now begin. The following criteria should have already been met at this point:

• The machine correctly placed with respect to the anchoring points.
• The rough leveling has taken place, ensuring that the bottom of the two bases are very close to 4 inches off the floor
• The mating flanges of the two bases have been pulled into contact.
• The screws that connect the two bases have been backed off and can rotate freely

Rough leveling the Column Base

• Zero return all axes 3.
• Move the Y-axis to the center of travel. 
• With four leveling screws on the corners on the column base.
  • 1 - 2
  • 6 - 24
• With the column at approximately center of travel, using gauge blocks lay one granite parallel across the linear guides as close to the table as possible and another granite parallel across the linear guides as near the rear of the machine as possible.
• Place a level on each parallel and adjust the level of the column from side to side.
• Check the freedom of the mating flange screws to be certain there is no binding.
• On the guide nearest the control, place one level on the linear guide in front of the column and one level on the linear guide to the rear of the column. Adjust the level of the machine in the direction of Y-axis travel. Move the levels to the opposite linear guide and complete the process.
• When the column base is level to earth in both directions, the six center leveling screws should be lowered to touch the leveling pads.
• Remove the granite parallels from the column base.

Level of the Column Base

• Handle jog the column to the rear.
• Place a single level (T-2181 and T-2192) on the spindle, parallel to the X-axis of the machine. It is very unlikely that this surface will read zero; do not expect it to. Make note of the reading that is present.
• While monitoring the level, move the column all the way forward and check if there is a change in the level reading. If there is no change in reading, then the column base has no twist. If there is a twist in the base, this must be corrected by using leveling feet 1,2,4 and 26.

Rough leveling the Table Base

• Move the X-axis to the center of travel.
•  Place two levels at right angles to each other as close as possible to the center of the table. One will show the level across the width of the table and the other will show the level along the length of the table.
• Focus on leveling the table only in this X-axis position to establish a primary datum for the machine. Adjust only the four leveling screws: 7, 14, 16 and 23. 
• When the table level is close to zero in both directions, the four very end leveling screws (10, 11, 19 and 20) may be brought down to touch the leveling pads.
•  Continue to level the table base until both levels on the table read zero.

Sweeping the Table

• Mounting the indicator on the spindle, first verify that the table is flat to the Y-axis plane.
• Place a parallel granite (32") on the table surface. Sweep the granite in the Y-axis to determine, and correct column / table flatness in the Y-axis direction. This is a very sensitive measurement method and corrections to this flatness should be made in conservative steps.
• Raise or lower the front of the table to get the flatness within specification using leveling screws 14 and 16.
• Move the levels to the table and place them as close to the center as possible.
• One level should be parallel to the X-axis and one level should be perpendicular to the X-axis.
• Once the Column to Table flatness has been established, jog the X-axis and adjust the remaining leveling screws to maintain the current level reading.

level the Table 

• Focus on leveling the table only in this X-axis plane to establish a primary datum from the granite. 
• Make note of the reading that is present. 
  
• While monitoring the level, jog the table all the way to left and check if there is a change in the level reading.
• While monitoring the level, jog the table all the way to right and check if there is a change in the level reading.
•  If there is no change of reading, then the column base has no twist. If there is a twist in the table, this must be corrected.
•  the remaining leveling screws should be lowered to touch the leveling pads.

Every point of inspection must be verified to be within the tolerances specified for the machine. 

• 1A. FLATNESS OF COLUMN TRAVEL MOVEMENTS
• 1B. FLATNESS OF TABLE TRAVEL MOVEMENTS
• 2. INSPECT SQUARENESS OF X-AXIS TO Y-AXIS
• 3. TABLE STRAIGHTNESS
• 4A. SQUARENESS OF Z-AXIS MOTION TO X-AXIS
• 4B. SQUARENESS O F Z-AXIS MOTION TO Y AXIS
• 5. SPINDLE SWEEP
• 6A. SPINDLE RUNOUT AT TAPER
• 6B. SPINDLE RUNOUT ON TEST TOOL BAR
• 7. PARALLELISM OF TABLE TO X - Y MOTION

Two fundamental geometry checks need to be made. The first is the perpendicularity of the X-axis to the Y-axis, and the second is to verify the sweep of the Z-axis.

• The sweep of the X-axis to the Y-axis is accomplished using a granite square. Set zero by sweeping the Y-axis on one side of the square, and then to verify that the motion of the X-axis is perpendicular by sweeping the adjacent side of the square. If the X-axis and Y-axis are not found to be within tolerance, between the mating flange surfaces that is creating this error.

Observe readings and adjust base to saddle perpendicularity as follows:

• Route ratchet straps from both sides of base to ends of saddle, looping through casting holes.
• Remove slack from both straps without over tightening.
• Gently tighten the appropriate strap observing reading changes on indicator.
• Continue making slight adjustments with straps and repeat granite sweeps until perpendicularity reading is within traveler specifications - record readings.

Verify the sweep of the Y/Z-axis:

• Sweeping the Z-axis is accomplished using a cylinder square. 
• The line of motion of the Z-axis will be checked by comparing it to the line of intersection of the two most convenient relative planes, that of the X-Z plane and the Y-Z plane.
•  By assuring that each of these planes are perpendicular to the X-Y plane within specification, the machine geometry will be preserved. 

Observe readings and adjust the needed Column Base leveling screws:

• X-Z plane: 
  • Adjust the left / right leveling screw evenly up or down to bring the reading within specification.
• Y-Z plane:
  • Adjust the rear leveling screw evenly up or down to bring the reading within specification.

• Before tightening all the connecting screws, recheck the table level to be certain that the squaring process of the column base did not affect table level.
• Torque the connecting screws with lock washers in place to 400 ft-lb. 

• Complete the machine installation, install the anchor bolts and tightening to 25 ft-lb. 
• Repeat of the basic leveling procedure and a recheck of the geometry to be done. All criteria must be met.