#1 FADAL KILLER: LUBRICATION STARVATION

Preventing Fadal VMC Failure: Way Lubrication System Maintenance

The primary cause of mechanical failure in Fadal vertical machining centers (VMCs) is lubrication starvation. While general cleanliness extends machine life, inadequate oil delivery to the box ways and bearing surfaces accelerates Turcite wear, leading to severe geometric inaccuracies and premature machine failure.

Diagnostic Procedures

To verify proper oil distribution across all lubrication points, perform the following diagnostic steps:

1. Monitor Fluid Consumption

Track the consumption rate of the way lube reservoir daily and weekly. If the oil level does not drop consistently, the system is failing to distribute lubricant.

2. Inspect Way Surfaces

Remove the axis way covers and physically inspect the box ways. The surfaces must have a visible, consistent film of oil. Dry or poorly coated ways indicate a distribution failure.

System Overhaul and Flushing Protocol

If lubrication starvation is detected, perform a complete system overhaul:

Step 1: Replace Metering Units & Flush Lines

  1. Document the size and position of all metering units in the distribution manifolds.
  2. Remove and discard the old metering units.
  3. Fill the Bijur reservoir with mineral spirits.
  4. Flush the entire distribution network to clear varnish and debris.
  5. Install new metering units according to your documented layout.

    Step 2: Inspection and Pressure Testing

    • Inspect all manifolds, fittings, and lines for fractures or leaks. Repair as necessary
    • Test system pressure based on pump type:
      • Manual/Mechanical Plunger Pumps: Manually lift and release the plunger.
      • PDI (Positive Displacement Injector) Pumps: Cycle the machine power. Ensure the pressure gauge rises above 350 PSI, then drops to zero within approximately 10 seconds.

    Troubleshooting Pressure Diagnostics

    • No Pressure Rise (PDI): Replace the input filter (Part #LUB-0040) and the PDI choke valve (Part #LUB-0051) located above the intake filter. Verify pressure exceeds 350 PSI post-replacement.
    • Instant Pressure Drop to Zero: Indicates a downstream line break or major system leak that must be isolated and repaired.
    • Immediate Plunger Snap-Back (Non-PDI): Indicates a blockage at the pump inlet.

    Approved Lubricants

    Following service, fill the reservoir exclusively with Mobil Vactra No. 2.

    CRITICAL: Do not use paraffin-based lubricants (such as certain Chevron formulations). Paraffin precipitates out of solution, clogging new metering units within months and causing recurrent system starvation.

    Support and Parts

    We supply comprehensive replacement lines, metering units, filters, and valves to restore your Fadal lubrication system to factory specifications. Contact our technical support department for specialized component procurement and assistance. 208-888-9236 or CNCPros12@Gmail.com.

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