These are quick-reference instructions, not an actual manual. Do not attempt to use
these instructions without an in-person intro.
To turn it on:
- You may need to turn on the top breaker in the panel over by the garage door. (labeled Shear)
- Throw the Big Switch (tm) on the wall.
- Throw the breaker on the right side of the machine (black lever)
- Fans will start, but not much else.
- Press "Master Start"
- The computer will boot and run diagnostics.
- At this point you can play with the computer, but it will not move.
- Press "Master Start" again.
- More fans will start, /now/ it can move.
And don't forget to tie the AC busses together before an SPS burn.
- Atomic batteries to power
- Turbines to speed
To turn it off:
- Press "power off", its under the molly guard.
- The computer will shut down, but fans will continue to run. It is in the state of just after the breaker was turned on.
- Turn the breaker off.
- Fans will stop.
- Throw the Big Switch (tm) on the wall.
- Press the big mushroom button.
- It will stop, but has not actually misplaced its marbles yet.
- If you press power off within 5 seconds of emergency stop, you will force
it into the "Initialization Required" state. This may be needed if it has
been incorrectly initialized.
- To clear the emergency stop, rotate the knob.
- It will probably say "master start required". (So press it...)
If it says Initialization Required, or axes are unaligned
If the power fails, it looses track of where all its bits are, and so must be
Press master start, if it starts, continue. Otherwise double check previous
steps and try again. It will probably complain about what is wrong.
- Chuck Jaws: press ID Grip or OD grip to match its position, press low pressure
- Quill: turn tail stock return or advance to match its position
- Part catcher: Park (not actually present)
The machine will then move slightly so the pointers are not aligned. This
is expected, the encoders are absolute position, but repeat every motor
revolution, grid align just tells them which revolution they are on. It
then reads the absolute encoders, and twitches to its calibrated location.
- Use the jog controls to align the pointer on the tool turret with the pointer
on the top of the machine.
- Press turret jog to make sure tool 1 is in the active position.
- Press grid-align.
While you're at 4.2x10 hit TC Set to define where tool changes happen and
home set for where the lathe goes to when you hold down the home button.
Going that far away from the work for a tool change is perhaps overkill, but
the cost of a crash is very high.
To load your Gcode into the lathe:
Your Gcode will probably need some milacron-isms. (will be covered in a
separate document.) This describes transferring your file into the lathe's
To Run your Gcode, press cycle start while on the machine setup screen. If you
press it on the program management screen it will say its inhibited.
- On the host computer, run the upload script with your Gcode file. (This will be replaced with a print queue or something)
- Press program-management
- Press control-load. (hold down control...)
- Press Line
- Press Start
- Verify the file transfers (the upload script will report percent complete)
- The screen will blank for a few seconds, and then show Gcode. Make sure
its your Gcode! (insert a comment or operator message so you can easily identify it.)
- Press machine setup to get to the usual screen.
If dry run is selected, the Gcode will be run at jog speed without the spindle
running. Make sure you have no stock in the chuck! If dry run is selected, it will
prompt you to press cycle start again.
To manually enter Gcode:
- Press MDI
- Type your Gcode
- Press cycle start
If dry-run is selected, it will prompt you to press cycle start again, and will then
run the program ignoring all the feed rates (and going at 200 fpm) without the spindle
running. Make sure there is no stock in the chuck!
To Adjust Tool length numbers:
Hopefully you will not need to do this. Do not move tools, you will break other people's
Gcode. If you need a tool which is not on the turret, post on the mailing list and we'll
get consensus on how to rearrange things.
If you press data-reset, it will clear any current tool offsets and you will not have
the correct delta.
- Make sure the turret is clear of any work and the chuck.
- use MDI to enter "M6Txx" where xx is the tool you want to correct.
- Touch something or make a cut, to get your X or Z number.
- Observe the delta between the displayed location and the actual position.
- If you are adjusting X, multiply the delta by 2. (radius)
- Add that delta to the X or Z number on the Tool Length screen, and then enter the new value and press return.
- Note that nothing happened.
- Use MDI to enter "M6Txx" a second time.
- When you press cycle start, the position numbers will jump. Since you're
entering the same tool number, the turret will not rotate, so you can just
sit where you touched or cut, and make sure the new number is correct.
BUT if you enter the wrong tool number on the second MDI step, it will
rotate and probably crash. Double-check the T display on the MDI screen.
If it says...
"Cycle start inhibited"
You can't press cycle start on the program management screen. Press machine-setup and try again.
Select tool pos ##"
You jogged the turret and then issued a tool change command. It wants you to put the turret back where you found it.
Initialize chuck jaws
It wants the jaws gripping before it will run your program or MDI. Press the foot switch to close the jaws.
Watch the ID/OD grip toggle button on the left panel. You'll need to open the door (see next note).
The chuck jaws won't move
The chuck jaws will not move with the door closed. Which is interesting, since nothing else will move with
the door open...
Alert No TC Set
You need to set a location for doing tool changes. Jog the machine to somewhere safe, and then
on the machine setup screen press "Set TC" (on the function keys).
Alert 10672 Spindle error T setter
The tool setter (tool calibration arm with the button on it) is not completely in the up position.
80 Spare Alert nn
From the manual: "An alert report has been made with an alert ID not correctly defined." The remedy (again from the manual) is "Do not do whatever you did."
To change jaws
Loosen the bolts (2 per jaw), then remove the two bolts completely to free the jaw.
Swap them one at at a time, rotating the chuck so you're only removing the jaw in the
"top dead center" position. This will prevent the retaining piece (which the bolts
thread into) from falling into the conveyor. You don't want to go fishing around in the
chips and coolant...
The jaw positions are numbered on the chuck, the jaws are also numbered.
I believe the jaws are actually interchangeable, but its not hard to just keep them matched.
- Carbide Insert Multipurpose, Long-Life, Style CNMG-431 1
- Carbide Insert Multipurpose, Long-Life, Style DNMG-432 1
- Carbide Insert Multipurpose, Long-Life, Style TNMG-432 1
- Carbide Insert for Aluminum, Brass & Bronze, Style TCMT-32.51 1
- auto-lube: manual says P-47, someone wrote "68 oil" on the back, mailling list says vactra #2. (auto-lube on the right-back corner (when facing the front of the machine))
- Headstock: manual says P-38, someone wrote in "dryduo oil parodene 32R0" and "DTE LITE VATRO LITE" (maybe, the hand writing is marginal.)
- Chuck: MolyKote BR2 plus (2 shots to each fitting)
- Hydraulic reservoir: manual says P-38
- Coolant: Kool Mist #77, KoolRite 2290, Trim Sol
The chuck jaws are 1.5mm 60 degree bevel teeth. Ask the google for things which fit a
B-208 style chuck. For example http://www.ebay.com/itm/360284089050?_trksid=p2060353.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
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