Key lock switch on control cabinet - ALL axes moved 2=) - Program test without axis motions Suppression of SPINDLE ON and COOLANT ON ase Electronic _handwheel 26 Handwheel OFF 27 0.01 mm increments ON/OFF 28 Handwheel for axis motions 29 Axis selectors fx axis TH ¥ axis © 2 axis Handbox 5 Mushroom head EMERGENCY STOP button 18 Feed stop 19 Feed start 20 Program cycle start 21 Tool change/acknowledgement 25 Tool clamp 8 © S| © Q—s-e io). Lge @ ‘Oo TT ‘ey PD10.83Main assemblies and.controls Nachine base Angular table (standard equipment, version 1) Column Vertical spindle head Headstock Knee Table slide Coolant tank Feed motor Y axis Plug connector for machine lamp and centring microscope Feed motor X axis Connectors for universal table, rotary index table and NC rotary table | | } | -Main assemblies of machine ' | | = Controls Screw for quill adjustment Y axis (horizontal spindle) Locating pin for vertical spindle head Screw for quill adjustment Z axis (vertical spindle) Locating pin for adjustments of vertical spindle head Handwheel Y axis Handwheel Z axis Control console Emergency stop push button Portable hand control Handwhee1 X axis ~wozE=rRzane i Apart from a few minor deviations with respect to design and application, the main assemblies and controls are identical on the three machines covered by this manual. The table slides and worktables are of different size to suit the different machine models.| i | : I 1. Technical data It should be noted that non-metric values are approximations. Spindle drive system FP2_NC FP3 NC FPA NC Pole-changing 3-phase ac motor with brake ki 1.6/2.0 2.0/3.0 2.0/4.0 21 spindle speeds CW and CCH, 7 programmable min’! 31.5...3150 31.5...3150 31.5...3150 Spindle taper (ST = standard taper) sT 40 st 40 st 40 Quill stroke (manual control), horizontal/vertical om 65/60 80/80 (3") 80/80 (3") Power tool clamping unit, (2 172") switch-operated Feed drive system Separate de motors and ball screws in all axes Feed rates, programmable wim /min 1...2000 (0.04"...80") Rapid traverse rate X, Y, Z mm/min 4000 (160") Incremental feed Ranges of traverse X (right/Teft) mm 300 (12") 400 (16") 560 (22") Y (forward/back) om 220 (9") 315 (12") 450 (18") Z (vertical) mm 400 (16") 400 (16") 450 (18") Vertical spindle head adjustment (on headstock, chain drive) mm 100 (4") 150 (6") 150 (6") Table slide, number of T-slots 4 4 5 width of T-slots ™ 14H7 14H7 147 (9/16") distance of T-slots mm 63 63 63 (2 1/2") Measuring system Direct, smallest increment mm/deg 0.001/0.001 Input resolution mm/deg/ inch 0.001/0,001/0.0001 Control unit: SINUMERIK 3M 3D contouring control, keyboard-programmable, with central display screen showing all positions and active machine condition data in program-controlled as well as in manual and setup modes, with Vinear interpolation, circular interpolation, drilling cycles, 4th axis, playback operation, 32 tool compensation pairs, program store, interface for terminal for program input and output. Electrical data Total connected load i KVA approx 19 approx 22. approx 25 Weight of machine Complete, in operating condition (with cabinet, without table) kg (1b) 1190(2620) 1520(3350) 2070 (4560) 0-4 wrFP2NC ovenrRavee (oy) Qvearrave. ‘a od (9) le” ate et a Dimensions in mm (inch approximations) 4.2FP3NC 2reRArEL ey cay mem ( OfBarabree Soft ete, a Oleic i fa sep (7) ovenraave. 0) geesrenra. 18 Webel py mensions in mm (inch approximations) 1.3FP4NC on) =, Dimensions in mm (inch approximations) 442. Transport and assembly i | | i Transport of machine i | | i | Delivery conditions | Within Germany the machine is delivered 1 unpacked, bolted to a transport pallet. \ | Make certain that the support surface is as large as possible (move prongs of ! forklift truck apart and extend if i necessary), otherwise the machine might tip over. 1 Foreign customers will receive the ma~ chine in a sturdy transport crate bolted to the bottom pallet. + FP2NC FP3NC FRANC “] Crate dimensions } Bottom panel 209 x 181 cm }217 x 207 cm] 242 = 201 cm rf Height of crate 184 cm. 200 cm 208 cm | Weight ce with angular table =” (kg)/ 1295 1655 2330 with universal table (kg)| 1380 1745 2295 with rotary index table (kg) 1340 1820 2370 with NC rotary table (kg) 1375 1870 2420 The machine is bolted to the bottom panel i of the transport crate. Caution: the | crate also contains the accessories, so } the weight might not be uniformly dis- | tributed. Transport the crate cautious- i ly, making certain that the transport ropes (when using a crane) or the prongs of the forklift truck are applied as far to the outside as possible because the centre of gravity is not in the middle of the crate. Caution - machine might otherwise tip over. Move and deposit machine cautiously. Please inspect the machine for damage in transit and check i completeness of accessories as specified in delivery note. i2. Transport and assembly Transport of machine Preparing the machine for transport Transport equipment: ‘two support props. To prevent damage during transport manoeuvres proceed as follows: Disconnect power line at connector blocks in control cabinet. Screw off cable duct from control cabinet and attach to machine in protected position. Soe Lock swivel-mounted control console (b) in desired position by means of Clamping screws (c). Remove clamping fixtures such as angu- Tar table etc from table slide (e) and transport separately. Place support props (f) with base plates on machine base. Use handwheel (d) to move knee down- wards until it rests on wooden props. [Use hendwheel (a) to move headstock 100 mm forward from rear end position. Pee Transport of machine without crate other delicate parts. Use utmost care in transporting the uncrated machine. pushing or lifting force to handwheels, controls, control panel or Never apply2. Transport and assembly Transport of machine Transport equipment: | Bars or tubes | Endless rope . FP2NC Length/dia | 1 «800 mm/50 mm | 3000 mm/30. mm (32"72") (10 ft/1 174") | FP3NC Length/dia | 2 * 800 mm/50 mm | 5000 mm/30 mm (32"/2") (17Ft/4 1/4") FRANC Length/dia | 2 * 800 mm/60 mm | 5000 mm/30 mm (32"72 1/2") (17 Ft/4 1/4") Two support props, two spacers (g). To prevent damage proceed as follows: Prepare the machine for transport (page 2-2). EEE EEE EE Pe ee EEE EE EEE EEE EEE <4 Cautiously pull plastic caps (h) out of openings in machine column and keep for later re-use. STIL cen Cec Insert transport rod(s) (i) into and through opening(s) in colum. Sling endless rope around rods as shown. | Attach rope to crane hook or arm of | forklift truck. To prevent damage do not tension rope before placing spacers (9) between rope and machine. 2p Move slowly by means of crane or fork- lift truck, avoid shocks and vibration, deposit cautiously. Transport on round.bars or poles Crowbars to be applied to recesses in machine base only. Use utmost care in transporting the machine. Never apply Pushing or lifting force to handwheels, controls, control panel or other delicate parts.‘2. Transport and assembly Transport of machine Transport in crate [Prepare the machine for transport (page 2-2). | | Tilt vertical spindle head J} through about 90° and clamp (page 3-2}. Attach arbor support bearing bracket (k) and clamp. | [Fit support prop (1) underneath con- trol console arm and lock arm by means of screws (c). Bolt machine to bottom panel of trans- port crate. Protect machine and accessories from moisture by means of = anti-corrosion grease = suitable covers = noisture-absorbing agents. Transport of contro! cabinet Transport equipment: 2 steel bars, 800 mm long (32"), 30 mm diameter (1 1/4") {endless rope, 4m long (13 ft) Insert steel rods through eyes (m) on control cabinet. Sling endless rope around rods as shown, then lift cabinet. Transport the crate cautiously, making certain that the trans- port ropes (when using a crane) or the prongs of the forklift truck are applied as far to the outside as possible because the centre of gravity is not in the middle of the crate. forklift truck. Avoid excessive vibration when transporting cabinet by means of aa ro2. Transport and assembly i Installation of machine Installation of machine For dimensions see foundation diagram. To level the machine, place spirit level on table slide or headstock. In general, the machine need not be anchored if in stalled on level ground. However, if heavy workpieces with substantial ‘over- hang have to be machined, the machine base should be fixed by means of 4 anchoring bolts (see information leaflet ‘Erection and installation of machines’ supplied with the machine). A special foundation is not required, but the shop floor should have a load capacity of at least three tonnes/n®. The place of erection should be protected from excessive temperature Fluctuations and should be free of reson- ant vibration caused by neighbouring ma- chines. If this is not possible, inter- pose vibration-damping material (see in- formation leaflet cited above). Upon depositing and, if required, anchor- ing the machine at the place of erection, remove transport equipment. Proceed as Follows: Move knee upwards by means of hand- |wheel and remove support props. EEStor eee Loosen clamping screws on control con- | sole, then retighten sufficiently to permit the use of push buttons and keys without control console moving away. Remove anticorrosive agent with par- affin oil (kerosene) or cleansing oi]. Residues of anticorrosive agent are subject to resinification and may thus affect the proper lubrication of traversing screws and guide ways. Never use aggressive solvents such as trichlorcethyl- ene, acetone or the like: they would attack the paint.Foundation and floor space diagram (including safety area) FP2NC Y cr | 4 eae pry it \ 8 -—1200-—-} im 5004\ 2 4 i Q | a 19 ta} 1 g ! 8 ? © t z ° | f 2 St) | ire) i } 175}. 8 lige oe X--@-LP 14 x So 3h =] £ 5 t -——— 30! Y += Power convection DIMENSIONS IN MM (1 INCH = 25.4 MM)Foundation and floor space diagram (including safety area) FP3NC count L—min.1700 — DIMENSIONS IN MM (1_INCH = 25.4 MM) ee a 6 1 | Y POWER CONNECTION 2 3 N q 27| Foundation and floor space diagram (including safety area) FP4NC | aes E on Le Tiss 2B ye - 8 s==|~ CD | 3 8 S = 560s =F AL (2 3! 8 | peta | ARES | wolf > 2 | x, Be pe BL ° | g a 130_ eo I cf — ee 217, ves 3700 Y qF POWER CONNECTION DIMENSIONS IN MM_(1_INCH = 25.4 MM) 282. Transport and assembly Electrical connection Installation of control cabinet The control cabinet is equipped with a cooling fan provided in the rear wall. Proper cooling is only ensured if the rear side of the cabinet is duly screened from external heat sources (radiators, sunlight). Electrical connection Always set main disconnect switch (b) to zero before opening control cabinet. The rating plate of the control cabi- net shows important data such as type of control, serial number etc. Use this information for connection to power supply and provision of suitable fuses. Quote these data in all in- quiries relating to electrical equip- ment. See also ‘Technical data’, Machine to be connected to power supply by qualified electrician only. Max permissible voltage fluctuations 5 x. Check for correct direction of rota~ tion. If wrong, reverse rotation by ‘interchanging the wires at the terminals. 2.92. Transport and assembly Electrical connection Initial lubrication O Mounting the machine lamp | Screw lamp holder (1) into vertical spindle head mounting arm. SES eee Fit tubular lamp support to lamp holder and tighten nut (n). j Fit lamp cable to connector on verti- cal spindle head. { | To switch on the lamp, depress lamp button (0) 1 or 2 seconds: tubes should be illuminated when button is released. When a tube starts flicker- ing replace both fluorescent tubes. Initial lubrication Make certain to fill reservoirs of centralized lubrication systen cutter spindle gearing hydraulic unit with the prescribed oils (see ‘Maintenance schedule’ p 9-2). Assemble coolant reservoir and attach to machine as described in Information Leaflet JF 728 supplied with the machine. Fil] coolant tank (approx 40 1tr), Lubricate the machine as specified in this manual (‘Maintenance schedule’ p 9-2) and check al] lubricating points.i 1 | | 3. Preparatory operations Preparing the machine for operation Starting the machine Set main disconnect switch on control |, { Control, progranme and data stores, cabinet to 1. and measuring systens will be oper | ative, machine drives blocked. R & Operate button LA [AIT systems and drives operative. “Control on’. Green lamp ‘Control on! iTTumi- lv nated. a Ht Stopping the machine a Operate button Ly [AN drives will stop. Programme, Ax “Control off". position data and tool compensation | | © values will remain stored. Signal | lamp illuminated. | t : tt [Set main disconnect switch to 0. Signal lamp extinguished, machine | and contro} will be de-energized. I eee Emergency stop. In the event of danger, the machine can be stopped in any mode of operation by means of one of the emergency stop but- tons: all drive motors will stop dead. Emergency stops have the same effect as "Control off" button (4). To restart the machine, reset ‘Emergency stop’ button by turning it clockwise, then operate ‘Control on‘ button (3): al] machine systems will again be ready for operation. 3-13. Preparatory operations _ Preparing the machine for operation Milling with vertical spindle The vertical spindle head slides on the headstock and always remains on the machine. To extend the working range, the spindle head is adjustable by 100 mm (4") on the FP2NC and 150 mm (6") on the FP3NC and FP4NC. To mount attachments, the spindle head can be moved to a rear rest position. To save space we show only one machine in the illustrations, but operation and adjustments are the same on all three models. It should be noted that the tempera~ ture of the vertical spindle head and the headstock will rise to approx 35° C above ambient temperature during operation. Quill axial adjustment [Release clamp (a). i {Use drum (b) or handle (d) to move quill to the desired position. LW N Retighten clamp (a), otherwise spindle will be moved back to starting posi- tion by built-in return spring. The downfeed limit stop can be ad- justed by means of screw (g). Spindle head adjustments Vertical and horizontal positions Two locating blocks (e) and (f) in con-| junction with an index pin (g) locate | the front section of the spindle head | in vertical and horizontal positions.3. Preparatory operations Preparing the machine for operation Proceed as follows: Release clamping screws (h) on face side of spindle head. XY Pull out index pin and turn spindie | head through 90°. ey Allow index pin to snap in and move into contact with locating block. Retighten clamping screws. Tilting the vertical spindle head Release clamping screws (h) on face side of spindle head. Pull out index pin. Ua et Ta Piped For obtaining an angular position first set spindle head to scale, then retighten clamping screws (h) finger-tight. NZ Mount centring tester or test arbor on spindle and disengage spindle fron transmission. Gee os Gauge table surface with centring tester or adjust spindle head using test arbor and air gap method. Correct as required. eee oe Retighten clamping screws (h) firmly. PEE eee EEE eee It should be noted that a smal] quan- tity of oi] will flow out when spindle head is tilted to 90° position.3. Preparatory operations Preparing the machine for operation Moving vertical spindle head to opel ating position Release clamping screws Ki to K3. pe ee Pull up index pin (1) and move spindle head to desired position (front or rear snap lock): = on FP2NC by hand, = on FP3NC and FP4NC by applying ratchet spanner to (m). Remember that gears will enter into mesh when moving spindle head forward from rear rest position or back from front end position. To facilitate gear engagenent proceed as follows: Release spindle brake (button 112) and move spindle slightly back and forth by hand. Allow index pin (1) to snap in and | move into contact with front surface of locating block. Reclamp vertical spindle head by means of Ki and K2. Do not use clamping screw K3 except for clamping the spindie head in rest position. For production reasons, the vertical spindle is slightly offset relative to the horizontal spindle. Determine and record this offset and make a suitable allowance in high-accuracy operations when changing fron vertical to hori~ zontal spindle and vice versa. mie3. Preparatory operations ~ Preparing the machine for operation Milling with horizontal spindle wWithou-arbor Support bearing Move spindle head to position of 97° | (p 3-3 5 index mark on scale) and Ra ] Fit splash guard (n), move spindle head back to rest position (see il]us- tration) and tighten clamps Ki to K3. A small quantity of oi] will flow out from the vertical spindle and the hole for the downfeed limit stop when the spindle head is moved back to vertical position. Milling with horizontal cutter spindle and arbor support bearing Set vertical spindle head to horizon- tal position (p 3-3) and clamp, > Release clamps K1 and K2, pull up index pin (1) and move vertical spindle head forward up to stop (0). ore Apply clamps Ki and K2. Fret cer eNeeee Insert cutter arbor into horizontal | | cutter spindie Attach arbor support bracket (p) to spindle head ways and clamp by means of screw, Lubricate arbor support bearing sleeve (oi1 can), repeat several times a da Mounting of tables or indexing a equipment, Detailed instructions for each table and for the index head witl be found under the respective headings in Chapter 10 (‘Attachments and accessories’).FD 10.83 Electric controls and connections on control cabinet The following items will be found on the right-hand side wall of the contro? cabinet: tee Nain disconnect switch th = Key lock switch for program test | ° Connector for signal cable 4-4FD 10.83 Sequence of operations for starting the machine 1. Main disconnect switch to ON. 2. Operate push button @) NC AND DRIVE ON. 3. Operate button (2) RESET. 4. If machine has been gut of use for some length of time, operate push button (6) MANUAL LUBRICATION once. | | | |Explanatory notes on M addresses (4 functions are described in the SINUMERIK 3M programming manual.) Ic should be noted that only one M address is permissible in each block. MOO - Programmed stop (unconditional) The block containing MOO will first be completed before the program is ineerrupted. spindle and coolant flow vill stop. Use button 40) NC | START to continue the program. Spindle will start automatically. MO1 - Optional stop Same as MOO, but program will stop only if toggle switch OPTIONAL STOP ACTIVE is operated, MO2 ~ End of program End of program without tape rewind. Spindle and coolant flow will be stopped. | | M03 - Spindle ON clockwise MO4 - Spindle ON counterclockwise MOS - Spindle OFF M06 - Tool change Buttons (2i) TOOL CHANGE will start flashing. Upon completion of tool change operate button again (acknowledge function). Program will not be resumed until button (20) NC START has been operated. Tool change without MO Operate button @ TOOL CHANGE while spindle is standing still: button will start flashing. In addition, button ((9) FEED STOP will light up: in program tool can now be changed. Operate button (i) T00L CHANGE again. To deactivate | the feed stop operate button (J) FEED START. MOT - Additional lube pulse Use MO7 in programs containing numerous small feed increments. Tf M07 is programmed in blocks containing G01, G02 or G03, the lube pulse will not be released until the next block with 600.| M08 - Coolant ON When M08 is programed, coolant flow will start automatically. Button (G) COOLANT ON/OFF Lights up. M09 - Coolant OFF When MO9 is programmed, coolant flow will stop automatically. Coolant supply can also be switched on and off by manual control using button @® coowanr on/orF. M22 ~ Mirror imaging X axis By programming M22, the X axis will be mirror imaged: all signs with be changed. Example: 100 22 N101 G00 X-100 Machine will move to X+100 in block N101. Lamp @) MIRROR IMAGING X AXIS will be illuminated. M23 - Mirror imaging Y axis Same procedure as described under M22; lanp Qi) MIRROR IMAGING ¥ AKIS will be illuminated. x and ¥ axes may be mirror imaged simultaneously. Example: 200 M22 201 N23 N202 X17 Y+I2 Machine will move to X#17 and Y-12 in block N202. Lamps 2) will be illuminated. N29 - Cancel mirror imaging M29 will cancel M22 and M23. N30 _- End of program Same as MO2 but with tape rewind to start. 56M84 - Spindle stop upon operating button (18) FEED STOP (tapping operations) Address M84 is used for tapping operations with a compensation chuck, In eubroutines it is written "8400". Function M84 causes the spindle to stop immediately when button is operated. To restart the spindie and continue the program operate button ({9) FEED START. M85 ~ Spindle stop upon operating button (8) PEED STOP (milling operations) M85 will first stop the feed motion when button is operated and then, after a short dwell, the spindle will stop as well. This feature can be used for the tool to clear itself in the workpiece. MBO - Cancel M64 and M85Spindle speeds on FP2NC, EP3NC, FP4NC machines Spindle speeds to be programmed directly using address S. 800 (zero) 8125 $800 si60 $1000 $31 8200 $1250 S40 $250 $1600 50 $315 $2000 863 8400 82500 80 3500 $3150 S100 $630 Always use one of the spindle speeds Listed above (to be programmed directly). Example: N10 GOO X31 ¥14.5 $500 MO3 If intermediate values are programmed, the control will use the nearest lower spindle speed value. Example: N150 $74 M03 Control will use spindle speed $63. Actually programmed: N150 $63 MO3 Exception If @ value below 31 is programmed, the control will use $31. Examplet N100 $23 Mo3 Control will use spindle speed $31. Actually programmed: N100 $31 M03 5Explanatory notes on indicating lamp Qa) fal when the control is switched on, the hydraulic pump starts operating until the required system pressure is attained, If this is not the case within 30 seconds, indicating Lamp @4) will Light up. The axis slides of the machine cannot be moved. Check for the following possible causes: no oil in reservoir; leaking oil lines pressure switch in hydraulic unit defective. Baits stan ae sastetc@) ti) The slideways of the machine are lubricated at intervals of two hours. Blocks with G01 will first be completed before a lube pulse is released, Button (6) will Light up during lubrication and also if an additional lube pulse is programmed by means of M07. If very small feed increments are used, button (6) may be used for re~ leasing additional lube pulses (even though MO7 may not have been prom grammed. In the event of a lube failure, button (6) will start flashing. In most cases this is due to Lack of oil in the reservoir. First remedy the fault, then acknowledge by operating button (6) and finally operate button CYCLE START to continue the program.| Explanatory notes on key lock selector (see also SINUMERIK 3M operating instructions, page ) he key lock switch for tape tests will be found on the control cabinet (wight-hand side viewed from operator's position). - Key lock switch = spinate ox ana cootane of suppressed ey ~ AM axes moved 2=) ~ Program test without axis motions Normal position for machining operations: gb Suppression of SPINDLE ON and COOLANT ON ‘The key lock switch can be used for marking out @ contour by suppressing NO3 and M08. Turn key to position fj :Lamp (@2)will Light up briefly. The ‘conmand will only be performed if the program had been started with the spindle standing still. To continue the program turn key back to oh Machine Lock When the key is turned to position 7p the program is obtainable without axis notions. Button (2)will be Elashing. This feature may be used for detecting parity errors, circular interpolation errors ete. upon releasing the machine lock move to reference point (datum) in a11 axes. To continue the program turn key back to dh.9. Maintenance General information General_information Make certain that the maintenance opera- tions specified in the maintenance sched- uleare performed regularly to keep the machine in good condition for many years of service. The lubrication intervals specified should be reduced if the machine is constantly used under heavy load condi- tions. The proper selection of lubricants is of vital importance. We recommend that only the lubricants listed in the ‘Table of lu- bricants' (page 9-1) be used, since other- wise reliable operation of the machine might be jeopardized and your warranty claims. might be forfeited. Once a brand of lubricant has been selected this. should always be used again. Do not change over to another brand without pre- viously cleaning the machine thoroughly. Another important point is the careful stor- age and handling of your lubricants. Keep storage tanks or containers clean and close covers tightly after removing oi1 or grease. Use only lint-free materials (never cotton waste) for cleaning the oi1 reservoirs of the machine. Sludge, residues and sediments can easily be removed with cleansing oil. Take care that none of the cleansing fluid is left in the reservoirs. Always set main disconnect switch on control cabinet to 0 when doing any maintenance work on the machine. Pree Recommend Iabeigénts fubricants, 7 ran © Hiitine [0 BREE. [0 Hay [Ama | |/O*= = — 7a room ry os or Seehaus? cee ee | Se ee eS far cesra ‘eae onan] SEEN] esses a Se9. Maintenance Maintenance schedule Compulsory maintenance Flest use or after long periods of nancuse weekly Tyereuiic unit @ Fit) tank at €2 (p 3-8) Libe pone 2 na Oo isa" ve de transnis- Fiona oft ang hydrautie Ov approx 5 Ver Centralizes Worteation @ FiT task at £3 (p 3:4) une 150-V6 220 bedway' of ee point 3 Ippros fo) Ver coolant untz @EIN cctane tank (9 2-5) Lube point 4 ica approx 40 Ite YerticaT spindle head @ Four in ofl st €/A6 (p 9-6) Gavel gate HOP"1sh ¥e-46 transalsston Lube point & Spindie drive transe\saton be paint? ond hydraulic oF! FON) of chaser 7 bd ‘to about middle of sight siete t Sh 7 Ae Tae Ne erarsaseston and hydrate oft Spprox t'to 8 ee ® toply oft gun to nipple BREN See Heanehssion td hydrate ot Remove transport fixture fron EOSGH anpt fiers ror support Deering Ube poine 16 contro! cabinet AIS tine intervals apply to siegle-shift operation In the event of nore frequent use reduce lube intervals accerdinaly Centralized Wuorcation @ Check oi! level at $3 ang wnt replenish if-raq'd (p38) | USD YG 220 bed may oF1 Brain oil pane DM Tevel Ehouie never rise : Seyond"Tower cape of Fier @ check of) tered at 97 ane repienish 1 req'd (p 96) P'TSO Va 46" teanset ss son ahd hydraulic ott Wie point 3 | sotnare drive transetssion Lobe point? @ cheer of) Neve), ree Hydreuiic unit Lone paint’? plentsh {¢ req'd (p 9-4) 4 AuP"1S0 V5 46 transmis~ Sion and fygraulie 081 cootant vats @ drain coolant reservotry clean and refitl (p 9-5] Unbutton betlaws, clean | Uibe'poine = Protective 2eVTows aan a a eae wes nen cg ae tten ‘Lube point 2 e (9 9-3), Ee Gens eee eee eer eeeeeee eee spine vnenasion @ Otay oft t AIA? | Ratt? On) eS) a6 eansnis: Feed motors and \Gheck carbon brushes | | teresa spite nad | {sehageneratore for wear, replace if {ibe point 8 req'd ("3-85 @cnange ott at €/86 {bevel gears) (pe) Lae point i> 180 ve 46 transmis SHoa'and tyarautic 981 go9. Maintenance Maintenance schedule Yearly or as specified & @ hs Ee iMonthly E = filler hole S = sight glass A= drain plug (point A7 on FP 4NC only) The vertical spindle head is supplied from the spindle trans- mission by means of a pump of its oun. The automatic centralized lubrication unit (lube point 3) only supplies the guide ways and elevating screw. For this reason, all other lube instructions for the machine and at~ tachments (see items concerned) should be carefully observed. For the remaining lube points proceed as follows: Horizontal and vertical spindle Lube point 1 Taper gibs Lube point 11 Tool clamping units Contact Technical Service (in horizontal and for inspection at inter-\_—1 vertical spindles) vals of 2 years. Earlier @ Spindles provided with permanent lubrication; if defective contact Technical Service. ISOFLEX SUPER TEL special grease. inspection required if, due to frequent tool changes {over 100 000 clamping oper- ations) the clamping force should diminish (noticeable by increased rust formation in spindle taper. @Have clearance of quide ways checked by Technical Service at least once a year. :9. Maintenance Maintenance instructions Automatic centralized lubrication unit The unit, which is switched on together with the main disconnect switch, is fac- tory-set for lubrication intervals of minutes and supplies the central- ized lubrication system with bed way oi7. If ‘Lube fault’ Tights up on >perator control panel, the machine will continue operating up to next tool change and then stop. Replenish oi]. Filling the unit ‘Lift off perspex cover ($3) and enove filler screw (E3). | | | | | Ea | | | se funnel and hose to pour in oi] up ‘0 upper ‘index mark on transparent reservoir (capacity approx 2.7 Itr). | io 'To continue cycle first operate button O47 level should never drop below 19 and then button 20: program will : atin units sere Mibtoe vate : ‘index mark on perspex window. ~ Check of1 level at Teast once a Hydraulic unit: week and replenish as required. The hydraulic unit is provided under- neath a cover on the maintenance side of the machine. Insufficient pressure caused by a leak in the oi] lines or too low an of] level will cause an , engrgency stop: control will be switched | off. Filling the unit Remove cover on maintenance side of ma~ chine (6 screws). Remove filler screw | (>) with air filter and of] dipstick. | “Pour in oi]. Make certain oi1 level a i l never drops below 30mm fromupper rim. | | rarer eaereceeeccee Restart the machine by ‘Control on’ button (3). | Check 017 level at Jéast once a week and replenish as required.9, Maintenance Maintenance instructions Coolant unit Filling the reservoir Remove cover (a) and pour in coolant (capacity approx 40 Itr). scha Jet pipe (b). ge hose OF svarf pan to Hn Drain coolant reservoir about once a month, clean and flush thoroughly with hot 1'8 calzined soda solution. Remove flushing liquid completely (do NOT use compressed air). Clean screen (c) and insert (d) in reservoir of swarf and sludge. Protective bellows and guide ways The protective bellows should be re- moved at least once a month to clean and service the guide ways, The bel- Jows are attached by patent fasteners and can be removed by applying suitable tool immediately adjacent to each fastener. Headstock bellows To clean the V guide and the headstock feed screw move headstock to its rear end position. Open fasteners (a) on bearing shield (b) only and push bel- lows against machine column.TELE ELLE Pee eee I 1 i 9, Maintenance Maintenance instructions | | Cautiously back off clamping screw | Cleaning the elevating screw [Clean elevating screw and lubricate by hand, using bed way ofl. user att (#) and allow cover (g) to move slowly back to upper position by spring | force. Move knee to upper end position. First clean cover (g) externally, then cautiously push all the way down. Fix [in that position by advancing screw(*). Spindle drive transmission Filling transmission with ofl first use and oi7 change) Pour in oil through screen-covered bore (a). hanging the oil (at yearly intervals) Move headstock to its rear end posi- tion. Unbutton bellows (b) from bear- ing shield (c) and push back. [Remove screw (d), on FP 4NC also screw | (A7) (see page 9-3), and drain of]. Ty9. Maintenance Maintenance instructions Drive belt Check tension of drive belt once a month, proceeding as follows: Set spindle speed of 2500 min”! we | Start main drive motor. If belt produces a whistling sound during starting or braking the motor, the belt should be tensioned: Pee eee eee eet {Loosen motor mounting screws (e). < San nar Sere VerencEnrrarcTuSEnRRAATG| Tension the belt until whist} ing sound is no longer heard. ae Retighten screws (e). Replacing the belt Pa Move motor downwards until belt can be removed. Fit new belt (without using tools) and ‘adjust belt tension.9. Maintenance Collisions Collisions with an obstacle In the event of a collision of a machine slide with an obstacle, the protective clutch will slip with a creaking noise. he machine wit stop dead. To restart the machine proceed as follows: oT] Back away machine slide. SEE SPE Sere | [Perform the routine checks listed be~ | low. ECE cS eee i Restart the control and resume the | |work cycle, | EEE Ee Ee Ee EE EEE EEE EEE ; -— Routine checks Collision of headstock with table Loosen and retighten mounting screws on table slide. | GPA Ae ere rete Use dial indicator to check parallel- | | ism of table surface to Y axis. Universal table: Check all clamps. Rotate table through one or two full | [turns to check for proper function. Re-align table. NC rotary table and rotary index table: << Check operating noise (on NC rotary table in both directions). a | {Check table top for axial runout and centre bore for radial runout. x we Re-align table. 3-969. Maintenance Collisions Collision with horizontal cutter spindle Perform all routine checks for colli- | sions with tables (p 9-10). | In | addition: Check spindle quill for easy movability. HEE Eee [Mount test arbor (300 ma) on spindle Jand check for radial runout at at Least two points. [Check parallelism of headstock motion | ‘and spindle quill using test arbor | (300 mn) | Collisions with vertical spindle head [Perform 311 routine checks for colli- jSions with tables (p 9-10. In addition: check testi [Check locating blocks for rotation | | of spindle head (a) and adjustments ock (b)- | of hea10. Attachments and accessories _ Tool mounts wee Ef: —f—-1 1.1 Stub orbor {combination arboe) i | 1.2 Cutter arbor 1.3 Calis chuck ‘ith length edjustmant a U = a Any I 1.3 Spring coer 1.4 Bate holder ea 20 Acuxing seve 1.5 Taper adagter wes |} ima 2.1 Adjusting sleeve 16 Base holder Giese 20 Soring coier ————') <= 2.2 Clamping sleeve wie | os 26 boing tot HEH pene eae aaah 24 Tapping chuck 25 Tapping insert10. Attachments and accessories Standard tools and accessories Measuring tools Centring microscope ‘S740 shank; for work-to-too! alignment by scribed reference lines or points or by reference mark on edge finder. Machine will be immobilized when microscope is connected to control cabinet. Centrieator CHII and CO precision centring testers Dial indicator stationary while feeler is rotating. ST 40 shank ‘or cylindrical shank 16 mm (5/8") diameter. Measuring ranges: cu. co op 200mm (12%) 125mm (5") 10 400mm (16") 125mm (5") Surfaces 480mm (19") 160mm (6) Clamping fixtures ‘Machine vices Size't Size 2 Clamping capacity 85mm (21/8"| 80mm (3 1/8") Wideh of jaws 85mm (3 3/8") 110mm (4 3/8") Swivel range 360° Height with swivel base 85mm (3.3/8") 115mm (4 1/2”) For T-slots of 14mm 9/16") Weight 7.8kg (1716) 21 kg (46 1b) Hydraulie views Specially designed for rapid and safe clamping of plain- parallel workpieces. Sie Size Size 2 Clamping capacity 160mm 16") 200mm (8) 300mm (127 wisth of Jews 100mm fa") 128mm 5") 160mm (6") Shivel range 360" 360" 360" ‘eit wlth swivel bese 126mm 16") 135mm (5") 158mm (6") Talor width 12/14 me 12/14/16rem (1/2""-9/16"-5/8") Max clamp: ing force 25k (560016) 95kN (7700%b1) 50 KN (1100076) Weight 23g (4808) 47Kg (HOT To) 87 kg (14810) Procision angle gauge for setting attachments, work holding and indexing fixtures ‘or workpieces at any angle with the aid of slip gauges (gage blocks) by tabular values. Helix clamps For safe and raliable clamping of workpieces, Set of 6 x 2 clamps (2 of each size), ranging from 0... 255 mm (10) For detailed information see our catalogue 'Too! mounts standard taper ST 40 and tools’ Centring cone ‘S740 shank; for rapid coarse alignment of spindle exis and ‘workpiece bore; max centring diameter 46 mm (1 3/4”) Test arbor ‘S740 shank: for angular positioning of tilting attachments Scribing equipment Circular scribing device 'ST40 shank; fine adjustment with slip gauges (gage blocks}: radius up to 150 mm (6), Seribing pins ‘$740 shank: or oylindrical shank 12mm (1/2" dia; spring-loaded needle. | |10. Attachments and accessories Swart pans and splash guard equipment 2280 000472 2280 000482 2280 000492_ 2280 000470 2280 000480 2280 000490_ Swarf_pans | Stock numbers FR2 NC: 2280 000872 FP3 NC: 2280 000482 Fea nc: 2280 090492 Swarf pans with splash guard A swarf pan with splash guard is indispensable for operations with copious use of coolant and high | stock removal rates. The swarf pans and splash guards Visted below can de used for all | work clamping tables of the ma- | chines concerned. FP2NC: Stock No 2280 000470 “ Weight 70 kg (155 1b) FP3NC: Stock No 2280 000480 Weight 90 kg (200 1b) FP4NC: Stock No 2280 000490 Weight 130 kg (290 1b) In operations with the universal table an additional insert plate is required. Stock No 2280 000475, fitting all 3 machine models. For assembly instructions see special leaflet supplied with | the equipment. | The splash guard wall panel can be folded up and down as required. If the table slide moves up to the end of its range to the right or left and the vertical spindle head is in 90° tilted position, the lat~ eral wall panels must be folded down. To remove the swarf, tip dumping box in a downward direction. x ssiaeseaeee10. Attachments and accessories Angular table 2230 001200.(FP2 NC) Angular table 2230 001300 (FP3 NC) Angular table 2230 001400 (FP4 NC) Version 1 of the machines if sup- plied with the angular table as standard equipment. Angular_tables FR2NC FP3NC FRANC Stock No 2230 001200 2230 001300 2230 001400 Clamping surface 610 x 335mm(24"x 13") 70x 460nm(28" x18") 900% S30mm(36" x 21") Teslots, number 5 1 8 | | width 14 mm H7 (9/16") 14mm H7 (9/16") 14 mm H7 (9/16") | distance 63 mm (2 1/2") 63 mm (2 1/2") 63 mm (2 1/2") | Max vertical clearances 520 nm (20") 560 mm (22") 633 mm (25") | (vertical spindle/ | table surface) | Max table load 250 kg (550 1b) 380 kg (770 1b) 450 kg (990 1b) | Weight 405 kg (230 1b) 136 kg (300 1b) 260 kg (570 1b) * manually controlled operation res ey It should be noted that non-metric values are approximations. Mounting the table on the machine First fit two T-siot bolts without nuts to the upper T-slot of the table slide. Insert guide blocks of table cautious- it ly into T-slots of table slide. baa T another 4 T-slot bolts with nuts. Sea a Table may be mounted one T-slot Tower ‘on table slide. Dimensions in mm ee; 10. Attachments and accessories Retrofitting of tables For retrofitting the universal table, rotary index table or NC rotary table i to a machine originally supplied with | the angular table, the upper fixed stop and the trip dog for the axis Vimit switch have to be exchanged, otherwise there will be danger of collisions with the headstock. The fixed stop and the trip dog are supplied with the table units con- cerned. To exchange the trip dog proceed as Follows: eee een | Remove handwheels (a) and mounting = | | screw (b)- I [Remove mounting screws (c) and take off wall panel (d). waa [Remove screws (e) and take off plate f). Move knee downwards until mounting ] screws for upper trip dog (g) are lo- | cated in the aperture of the frame | | Aperture in i i i casting. frame casting ae aa Exchange trip dog (g). To reassemble the parts, reverse the above procedure. 70-510. Attachments and accessories Retrofitting of tables To exchange the fixed stop proceed as follows: (a) FP2NC, FP3NC Remove mounting screws (h) and take off wall panel (j). CEE ee see eee ESE eet ee Exchange fixed stop (k). SBE oe eee eee ee To reassemble the parts, reverse the above procedure. (b) FRANC Move knee to lower end position. Poe Remove screws (1) and take off stop (m). K Insert stop rail (n) into knee from below. | fae Refit stop (m) by means of screws (1).10. Attachments and accessories Universal table 2038 000800 Universal table 2038 001100 with digital position readout Version 2 of the machine is equipped with a universal table. For retrofitting of universal tadles see p 10-5. Universal tables with digital position readout 2 sizes Table swivel range 360° Tilting angle towards machine 15° away fron machine 45° Tilting range to right and left 945° Measuring system direct, resolution 360 009 x 0.0012 Reduction ratios 60:1/120:1/240:1 | Size 1 Size 2 j for FP2NC for FP3NC_+ FP4NC | Stock No 2038 00800 2038 001100 | Clamping surface 600 x 320mm (24" x 13") 740 x 450mm (28"« 18") | T-slots, number 5 7 | width 40mm H7 (216") 4am H7 (9/16") | distance 3 mm (2 1/2") 3 mm (2 1/2") | Centre bore dia 63 mm HE (2 1/2") 63 mm HG (2 1/2") | depth 8 mm (s/s) 8 mm (5/16") I Distance, centre 1 to mounting surface 205 mm (8") 260 mm (10") j Max vertical clearance* (vertical spindle/ FPSNC: 457 mm (18") table surface) 452 mm (18") FPANC: 530 mm (21") Max table load 480 kg (400 1b) 300 kg (660 1b) Weight 485 kg (410 1b) 230 kg (510 1b) It should be noted that non-metric values *manually controlled operation are approximations. - gt cai gpa | AS rs pote Sacer a: STETUTUS e | gy] = © yt 7 Xt | ‘O i e \ { | Dimensions in m| 10. Attachments and accessories Universal table 2038 000800 Universal table 2038 001100 with digital position readout Mounting the table on the machine For lifting the table preferably use a hoisting chain with special T-slot blocks as shown in the i1lustration (not supplied by DECKEL). Insert central clamping screw for | , clamping lever (3) into upper T-slot of table slide. pissteeet [Attach table to clamping surface of | \ table slide, cautiously inserting the | | clamping screw into and through the [Dore in the table. Fit T-slot blocks | into upper T-slot. NZ Attach nut of clamping lever (j) to | Slanping screw (from below, through | opening HES Zt | Fix table by means of at least 6 | T-slot bolts. See | Tighten clamping nut and fit lever to serration in such a position that safe clamping is ensured after tilting. NZ Connect plug of table measuring system to socket on knee of machine. | a cos)10. Attachments and accessories Universal table 2038 000800 Universal table 2038 001100 with digital position readout | pa table by means of ratchet span- Aligning the table Tilting the table about axis A = setting the table parallel to Y axis of machine. | Release clamping nuts (h) - five nuts | on each side. ner applied to adjusting screw (0). Adjust table coarsely to zero or de | sired angular position using scale Lia. To eliminate reversing play, first move slightly beyond the desired angular po- sition before final adjustment. Adjust table to accurate zero position place straightedge on table and gauge | with dial indicator in direction of | Y axis of machine. Remove cover of built-in dial indica- tor (p) and set dial indicator to zero, for future positioning operations. Adjust dial indicator in retaining bore in such a way that zero reading is in coloured sector, then clamp dial indi- cator by means of knurled screw. Refit cover to protect built-in dial | indicator from swarf, coolant and | unauthorized tampering. !10. Attachments and accessories Universal table 2038 000800 Universal table 2038 001100 with digital position readout Tilting the table about axis B = setting the table parallel to X axis of machine TRelease 8 clamping nuts (t). | | See eE EEE Ne [Release clamping lever (j), slightly releasing nuts of lever if required. aos Adjust table by applying ratchet span-, ner to adjusting screw (k). Pee eee ec an Adjust table coarsely to zero or de~ “sired angular position using scale (1). See EEE EEEE EEE nse coer e eee eee [Adjust table to agcurate zero position by means of dial indicator (i) as de scribed on preceding page. Sw ECEEHEEEEEHEEE Retighten clamping nuts and lever. | | Aligning ‘the table ¢ axis with the vertical spindle axis Set vertical spindle to exactly verti-| cal position, then mount centring tester on spindle. | Basses Remove protective cap from centre bore of table top by means of suitable tool SEEESDACe aS tasnEPSOSEEsEEEPEEESEES Depending on location of reference | jpoint, first move to reférence points | lin X and Y, then use centring tester | to align table axis with spindle axis. | }10. Attachments and accessories Universal table 2038 000800 Universal table 2038 001100 with digital position readout Swivelling the table about C axis [fetes 4 clamping nuts (e). 2 TRetighten clamping nuts for milling | operations without table rotation. Selection of reduction gear rat: | Select desired ratio by setting asso- | jciated symbol to the vertically upward | [position,‘ 10, Attachments and accessories Universal table 2038 000800 Universal table 2038 001100 with digital position readout axis po! jon_readout on CRT The universal table is not power-driven and can only be rotated by manual hand- wheel control. The position readout for the C axis corresponds to the read- outs for the other axes. IMPORTANT: clamped condition of C axis | 4s NOT shown on CRT. Resolution of position readout 0.001° = 3.6 seconds of arc. Keying in zero position of screen readout Zero can be placed at any point, simi- Jar to the other axes. | Manual control of table Table position will be shown on additional readout. Set table to desired position by hand wheel control. Program -controlled operation If a program requires a C-axis motion | proceed as follows Blocks without C axis to be pro- ] grammed as usual. | eee peecere Ee Pee Input of C values in manual mode or playback is NOT possible. Stop progran by programming MOO in b lock preceding a C axis motion. | j Fess Continue programming as usual.he 10. Attachments and accessories A Universal table 2038 000800 i Universal table 2038 001100 | with digital position readout | l Pree I | Automatic operation Move machine to program zero point. eee | Clamp C axis (p 10-11). | | | wa | ‘Start program, EEE eee eee eo Work cycle will be interrupted at M00. i. ~ | [Release C axis clamp. gH ee EEECSEE Eee sees Perform indexing operation by manual “\{ Table position will control. | be shown on addi- _/ | tional readout. Operate ‘Cycle start’ but- a Automatic program will continue. ton- rf | 10-1310, Attachments and accessories Universal table 2038 000800 Universal table 2038 001100 with digital position readout Maintenance | 209800110010. Attachments and accessories Universal table 2038 000800 Universal table 2038 001100 with digital position readout Maintenance No Lube point Instructions 8 @ @ @ Worm gear drive Reduction gearing Table top bearings Initial quantity 750 cm Check sight glass. Change oi] at least once a year. 1S0 VG 220 bed way oi7 Initial quantity 500 cm* Check sight glass. Change oii at least once a year. HLP SO VG 46 transmission and hydraulic of1 2-3 strokes of oi] gun as required 1S0 YG 220 bedway 077 For ‘Table of lubricants’ and symbols of lubricants see page 9-1. 10-110. Attachments and accessories Universal table 2038 000800 Universal table 2038 001100 with digital position readout Adjusting end play of worm bearing For good access to part tilt table 15° forward and remove table top. [Remove screw (a). } | < Lift off cap (c) and release locking screw (b). | Bee Fa eg SC UE cece Use ring nut (d) to adjust bearing end| play. 7 Ne Retighten locking screw (b). | PEEL se Leech Refit cap (c), making certain that O-ring is not damaged. Refit screw i. Adjusting backlash in worm gearing Release screw (a). | Use the two studs (e) for accurate and | uniform backlash adjustment. | Accessories to universal tables Clamping chuck with flange Stock No 2240 000500 Three-jaw chuck with flange 200 mm (8") Stock No 2240 900300 Faur-jaw chuck with flange 200 mm (8") Stock No 2240 00040010, Attachments and accessories Rotary index table 2238 004000 Rotary index table 2238 002800 - | Version 3 of the machine is equipped | with a rotary index table. { For retrofitting of tables see p 10-5. | Rotary index tables | Indexing steps obtainable: 5° - 15° - 30° - 45° - 90° - 180° | | FP2_NC* £2 NC/FP3_NC FPa_NC Stock No 2238 004000 2238 002700 2238 002800 Table diameter 400 mm (16") 500 mm (20") 500 mm (20") T-slots, number 5 7 7 \ . width 14 nim H? (9/16") 14 pm H7 (9/16") 14 am HT (9/16") distance 63/90. ma 63 mm (2 1/2") 63 mm (2 172") (2 4/2" - 3 1/2") | | Centre bore, diameter 63 mm H6 (2.1/2") 63 mm HE (2 1/2") 63 mm HE (2 1/2") | depth 8 am (5/16") 8 mn (5/16") 8 mm (5/16") : | Distance, table centre/ | mounting surface 475 mm (7") 271 mm (11") 271 mm (11") | Max vertical clearance (vertical spindle/ | table surface) 452 mm (18") 487 mm (19") 535 mm (21") Max table load 480 kg (400 1b) 180 kg (400 1b) 300 kg (660 1b) Wei ght 150 kg (330 Tb) 175 kg (385 1b) 370 kg (810 1b) It should be noted that non-metric values are approximations. | ‘when table 2238 004000 (to be discontinued) is no | jonger available, table 2238 002700 will be supplied for FP2 NC and FP3 NC machines. FP2 NC/FP3 NC FP4NC | = e-|" & Pee eeeee er eeey | i US EUS 1 | (Rees | 1] £ I i q | | | 1 | [| at 2 | =| ee a L HEEL c I | || Dimensions in mn 10-1710. Attachments and accessories Rotary index table 2238 004000 Rotary index table 2238 002800 The rotary index table on machines of version 3 is mounted at the factory. A machine supplied with this table is ready for immediate operation. If the rotary index table is supplied separately, the following preparatory operations are required for retrofit~ ting the table: For transport by crane or forklift leruck attach either eyebolts with | {Teslot blocks or sturdy steel bars to | T-slots of table top. Fit rope or | chain Lee ee ee eee SSE Transport and mounting of table | | | Lift table cautiously and insert guide blocks into a T-slot of table slide. Crown gear teeth of table top will be disengaged from mating teeth in table base, so that base may turn relative to sus- pended table top. {Attach table by means of 6 bolts. | Electrical connection | [Switch off main disconnect switch on control cabinet of machine. j Connect cable (a) to associated con- nector. Lee 1048Pneumatic connection [Attach pneumatic hose to fitting (b). \ “\ Cables, hose lines, connectors and Vv 10. Attachments and accessories Rotary index table 2238 004000 Rotary index table 2238 002800 » fittings are colour-coded for correct connection. [Usless provided, mount maintenance unit in accordance with Information 1 \Leaflet IF-736 or IF-737 supplied with | the table. [Set maintenance unit (pressure con- [troller (c) and oi] mist lubricator | ({d)) as set forth in accompanying | ‘operating instructions. ! Connecting the unit to ain supply ‘Connect compressed-air supply line to | maintenance unit (system pressure min 16 bar). | SU {Turn handle (c) of pressure control | lvaive counterclockwise up to stop (reduction of pressure). i SCH ete ster eet eee [Open shut-off valve of air supply | Tine. 4 Turn handle (c) of pressure control valve clockwise until desired oper- ating pressure is obtained. eae Use screwdriver to turn oi] throttle (d) of oi] mist lubricator to right or; left until disired quantity (1 drop | per 8-10 switching operations is ob- tained (right: less oi]; left: more 011). Pressure drop during operation In the event of a pressure drop during an indexing operation move table top slightly back and forth until it drops into its mating teeth by its own weight. ow \ 70-42i | i : | | 10. Attachments and accessories Rotary index table 2238 004000 Rotary index table 2238 002800 Preparing the table for operation Set pressure switch to drawing OP-3512 ‘and manufacturer's operating instruc- tions. ed Set throttle screws (e and f) to draw- ‘ing 8 10-1420 and manufacturer's oper- [ating instructions. ESE erere eee eereeeee ee . Fill.with oi] (see ‘Maintenance’ Setting the indexing increments Press push button (i) and hold in de~ pressed condition, NZ Use handle (h) to set the desired in- dexing increment: desired value to be in vertically upward position. Pease Release push button. IMPORTANT ‘is standing still. Setting the table top Set smallest indexing increment (5°) as described above. Be enter Operate rotary index table until table top is in desired position. ST RAL Set indexing increment required for j Job on hand. Never set indexing increments except while rotary table10. Attachments and accessories Rotary index table 2238 004000 Rotary index table 2238 002800 Aligning the table C axis with the vertical spindle axis Proceed as described for universal table (p 10-10). Removing the table from the machine Clamp table top and remove rotary in- dex table by reversing the mounting procedure (p 10-18). The bottom sur- face of the table base can be used for placing the table on the floor. Maintenance Weekly O41 mist Tubricator Daily, Filter, water separator and pressure contro} valve Visual inspection (riser pipe must always be imersed in oi1) 180 VG 10 spindle of1 Clean reservoir (only use water and commercial detergents) Visual inspection Drain condensate water Clean filter elements in paraffin oil (kerosene) and clean by air blasting. Clean plastic parts with water only, | 0-2110. Attachments and accessories Rotary index table 2238 004000 Rotary index table 2238 002800 As required Hydraulic damper, Check of] level in damping unit, if it fails to respond Replenish oi] (up to 2 mm below to adjustment of set screws upper rim of reservoir) as and when required. o HLP ISO VG 46 hydraulic and transmission oil | | Table maintenance and lubrication For details see manufacturer's operating instructions. Accessories to rotary index tables jaw chuck with flange 200 mm (8") Stock No 2240 000300 j-Jaw chuck with flange 200 mm (8") Stock No 2240 000400 {oo510. Attachments and accessories NC rotary table 2238 003600 NC rotary table 2238 001900 NC rotary table 2238 002000 Version 4 of the machine is equipped For retrofitting of tables see p 10-5. with an NC rotary table. NC rotary tables Table controlled by 'Sinumerik 3M’ control (4th axis = C axis) Indexing increments: 0.001° Measuring system: direct Resolution: 360 000 x 0.0012 FP2 NC FP2_NC/FP3 NC Fea NC | Stock No 2238 003600 2238 001900 2238 002000 Table diameter 400 mm (16") 500 mm (20") 500 ma (20") T-slots, number 5 7 7 width 14 mm H7 (9/16") 14 mm H7 (9/16") 14 mm H7 (9/16") distance 63/90_mm 63 mm (2 1/2") 63 mm (2 1/2") (2 1/2" - 3 1/2") Centre bore, diameter 63 om HE (2 1/2") 63 mm H6 (2 1/2") 63 mm (2 1/2") depth 8 mm (5/16") 8 mm (5/16") 8 mm (5/16") Distance, table centre/ mounting surface 175 mm (7") 274 mm (14") 274 mm (11") Max vertical clearance* (vertical spindles clamping surface) 452 mm (18") 487 mm (19") 535 mm (21") Max table load 150 kg (330.1b) 300 kg (660 1b) 300 kg (660 1b) Weight 240 kg (530 1b) 240 kg (530 1b) 385 kg (850 1b) Speed of rotation 0.004 to 7.4 min”! Incremental feed 0.01% It [FP2 NC/FP3 NC | | | | i | | Dimensions in mm j ‘when table 2238 003600 (to be discontinued) is no longer available, table 2238 001900 will be supplied for FP2 NC and FP3 NC machines. Joa| 10, Attachments and accessories | NC rotary table 2238 003600 NC rotary table 2238 001900 NC rotary table 2238 002000 | Apply table clamp. Fit 3 eyebolts (a) with T-slot blocks (b) (supplied by manufacturer) to | Teslots of table top. | | | | Mounting the table on the machine For transport see above. | Attach table to clamping surface of | | table slide. Cautiously insert guide blocks into lone of the T-slots of the table | | slide. | | Secure rotary table by at least 4 'T-slot bolts. Connecting the table to the control | Switch off main disconnect switch on | control cabinet of the machine, Fit plugs and connectors to associated counterparts and lock in position, a) Connection for table feed motor b) Hydraulic connection C) Connection for axis counter 'd) Connection of control line Gneba10. Attachments and accessories NC rotary table 2238 003600 NC rotary table 2238 001900 NC rotary table 2238 002000 | Removing the table from the machine ' | Apply table clamp and remove NC rotary | | | table, reversing the procedure | | | described on page 10-24. The bottom i | surface of the table base can be used for placing the table on the floor. | Deposit cautiousty. | Maintenance and lubrication For details see manufacturer's operating ‘instructions. Accessories to NC rotary table 3-jaw chuck with flange 200 mm (8") Stock No 2240 000300 4-jaw chuck with flange 200 mm (8") — Stock No 2240 000400 | {0-2i | | 10. Attachments and accessories Index head ST 40 with overarm and tailstock 2212 000750 Technical data | Internal taper of indexing spindie st 40 | Centre height above clamping surface 90 mm (3 1/2") Centre height up to overarm 100 mn (4") Swivel range about axis B 360° Tilting range to/away from machine 15°/6° Reduction ratio 40:1 Direct indexing by graduation 12 Direct indexing by index plate 24 registers Index circles for indirect indexing 27 - 31-34 - 41 - 43 (3 index plates) 33 - 38 - 39 - 42 - 46 36 - 37 - 40 - 58 Max indexing error, direct indexing 1" 30" indirect indexing J min of are Wei ght 64 kg (140 1b) Mounting the index head on the machine | | Preferably suspend the index head by | the two bores provided in the housing. Insert guide blocks into T-slots of clamping surface. | Secure by means of T-slot bolts. | Swivelling and tilting the index head | Release associated 3 clamping screws, | i swivel or tilt index head as re- quired and retighten clamping screws.10. Attachments and accessories Index head ST 40 with overarm and tailstock 2212 000750 Aligning the index head Mount test arbor on index head. | jSet desired angular or zero position | ‘coarsely to scale (see preceding page). | Fit dial indicator to holder on head- | i |stock or to cutter spindle and gauge | | |test arbor with dial indicator for | | |fine adjustment in desired axis 1 \ | | Mounting the overarm | Remove cover. | Attach overarm, | Engaging and disengaging the index feed Wore | | Release clamps (a) and (b). L : XRF : j ;—_ [Swivel worm housing into or out of en- | SEEEEEeE | Igagement up to stop (to the right = IN, pee ® to the left = OUT). ] — oS ___ | 7 | |Engage with care to prevent damage to 7 / | worm gearing, Move worm shaft slight- ly back and forth (by index crank) to | e | [facilitate engagement. 70-27Index head ST 40 with overarm and tailstock 2212 000750 Clamping the indexing head spindle ———— | Use clamp (b), making certain that | “spindle is always clamped for heavy | 10. Attachments and accessories | i | | i | Ecurs| . | Direct indexing with 24-register index plate ~ 1 ‘Engage index pin in desired register. Release clamp (b) and loosen 4 screws | Kee LES See eee Rees [Adjust workpiece to desired position | (» turning the index head spindle. He ——— Retighten the 4 screws (c). Rotating the index head spindle {Release spindle clamp (c). i [Disengage index pin. IEEE eee eee | Turn index head spindle with workpiece i into desired position and re-engage index pin. u 16.3810. Attachments and accessories Index head ST 40 with overarm and tailstock 2212 000750 Use measuring instrument (in cutter spindle) to sight,clamped and centred workpiece. . [Clamp index head s| clamp (b). L | Indirect indexing by graduated scale | [Engage index pin (d). If pin is not lexactly in alignment with a hole in che plate (e), release clamp (f) and rotate index plate until pin is in lregister. Retighten clamp (f). Set scale to zero or other desired | position. [Reclamp scale ring. < [For indexing operation, release clamp (b) and rotate index head shaft up to desired angular position on scale. [— | Bae TELE EEE ta 1 revolution of scale = 9° 1 division of scale = 1 min of arc | || | I | | : | . | é = 7 ee i ES10. Attachments and accessories Index head ST 40 with overarm and tailstock 2212 000750 { | | | Indirect indexing by means of perforated index plates Consult ‘Chart of indexing values and mount. index plate required {numerals BEHIND stroke in table indicate index circle). Proceed as follows: Remove hand crank (h). | | i | lH ipa aes 1 | | I | eee eee “Force off index plate (k) by means of | 2 studs. | [Fit desired index plate, apply clamp (1) and mount sector {j) and crank (h). | | Os Use measuring instrument (in vertical spindle) to sight clamped and centred | |workpiece. | Engage index pin (d). a | eect We [TF index pin is not exactly in align- [nent with'a hole in index plave (his [release clamp (1) and rotate index || [plate with scale drum until pin (d) || Lis in register. | | Ca | > | [Retighten clamp (1). | PoP10. Attachments and accessories Index head ST 40 with overarm and tailstock 2212 000750 Indexing operation | Loosen screw (m). N Zo ee at Obtain number of holes from ‘Chart of | indexing values’ (numerals AHEAD OF stroke indicate number of holes). | Userpkezind muraber-o7 ine 62 Hee EEtE SO Adjust sector (j) in such a way that | [one of its arms rests against index pin (4) and the required number of | 7 7 holes is between the arms (NOT | | | counting the hole engaged by the pin. | fee Ree PEEEEEeEEEEE Disengage index pin (d). | | First rotate crank through required number of full turns and, in addition, through the angle enclosed by the sector arms. Pee bet Engage index pin (4). | | SHEE EH eee eee new Advance sector (j) for next operation. |10. Attachments and accessories Index head ST 40 with overarm and tailstock 1 FP/KF3S: 2212 - 00/2212 -600/ 2312 - 600 : : oo iean- 2319 goolezia Lean Chart of indexing values for indirect indexing | jurnbar of crank turns "Number of eeank turns Number ot [5] -£g [Number of een fre Ganctome | 38] $8 [Conese j full) frasora full | tection! fun] tectonat {23 | 8 | tai tae w 1 + aay T= as Te] > as 2] 1227] 1 | Siar] ae | Bae = gies i te/baay | + | 3133]°°°) =|'887| | 3 2 ir aan | : = Jerse) | 580 ~ |888 48 12/27 : = | iete) | Se = |s9 18 8107 i = |rom6! | $0 = |aia3 is [gar : = Heke) | a0 = las 13/2829) = i | = frog) | 420 = ie | 13 [63 |savaz araeles | = | = }ioe! | 339 = ls j | 87 ea = | = [fapt) | ao = lass | naar, | fas we | 32098 = Jrage! | S69 arr | 10 re 2 = |"S86) | See 2 Biss 8 | 24727 re = 20708 = hrs) | $8 = aise 8 [8/37 | 442} rae 60 = = |'e3) | 520 = 388 | 3 et 20198 = |g) | St dar | Fleya7 = | = |"eros) | Se = ae 2|“ei27 i = | 1043 | 580 = 5158 8 | 18/77 |asaearao | = [digs | = | "e/23| eras} 620 = ist 8| ‘a7 = aoe) | = | sts | °°) 80 = ids | 012 = |aorse| | = |Tes| | 660 = [Bie | 5 )8i27 | = /i8) | iso =| ese) | 50 = lise | 5 =ipe] | hss =| gee! | Yao =e | & | 122 s6i06 = 383] | feo | | = | ao | 60 ae i = | Zar 08 =| gm) | too = 388 3|2aa7 = |ioss| | fro =| ee) | &o = [dao 3) = | farsa 18 =| are) | S20 2 Bat 3 {aay | sara] 204 = ita "8 =| ga | Bao = Bal | 3) Baa 2 | s°| = | ist27/20r38) B20 =} ga) | 860 = ag 2 |era2 | > [3813 ° =| gas) | S20 = diss i ae] 3 |r | 2 [ose Fae =] seis! | 080 = ie } as | 2°) 3) S077 recto | = lore a = | 782) eras] ine = |e i 8 3 | tae) 2a1a5 be = | fae| zorasaorssaeo = | diss) °°} :2s0 = 8s " 3] tae 2 = | abit pes =| S83) [i220 = | a | i 1 | 2] 3] ‘6r29| eras) |e = | Borer 70 =| fer) | i380 = Yee | 19 2| 4/38 ss = | terse 50 = | gaz 1440 = | 36 | wel 2 es = | os =| fee) seo) | = [vas | $e | i] aver es = | is| 0 =| sss) | is20 = [igs i 2 1 aaa eo | «| = [437/16 Bee =| 88) ie) = fae 2 1 | a3 le = | sora fos = | fae] |soo = |iia0 \ a 3 bares Ee = | ie 10 =| Mat fies = |aiat Ze | 15°) | Serer] zoraloarselos = | Sas 33 =| fas} | isso = java 3 +) a9 0 = 81 28 =| Se) |588 mar 3 +) rsa ce = | i839 3 =| Slat) [ero = | Mas z + | taey 08 = | ier E30 =| Sas | ast = [ses] |, \ 2 4 tra <8 = | fora =| sie) ey 2 1 arse 0 = | 333] fo =| isa } 30 | 120] 4) “9/a7| saraajrarach 12 = | s6ya2| aa = | 53) a 4) $31 his = | setae 3 = | SF] ae] 2 1} Sfae|roro] fs = | 20068 =| day 3 1} 33 hae | 2°] = | e137] vad 2706 = | 288 a i] gee Nae = | e8t i = | iar L Pool10. Attachments and accessories Index head ST 40 with overarm and tailstock 2212 000750 Maintenance Eliminating backlash between work ‘and worm gear | Remove screw (n) and either grind off a few hundredths of a mm from its point or insert shims. | [Refit screw (n) and check for backlash with the-worm engaged (preferably with a faceplate mounted). A | Lubrication fp | /* | Monthy & I | Lubricate index head spindle and worm bearings (with Worm engaged) by means of grease gun. 10-43