M.2005.3740 RT Mechanical

M.2005.
3740
Mechanical Manual
Maintenance staff
HORIZONTAL BORING MILLS

PT, RT & MC Series
S/N 480
First Edition
MAG IAS – Fond du Lac

P.O. Box 590, 142 Doty Street
Fond du Lac, WI 54936, USA
tel +1 920 906-2437
fax +1 920 906 2243
www.mag-ias.com
SAFETY
RECOMMENDATIONS
IMPORTANT
DO NOT OPERATE, PROGRAM OR REPAIR THE MACHINE UNTIL
YOU HAVE READ THESE SAFETY RECOMMENDATIONS!
DO NOT OPERATE, PROGRAM OR REPAIR THE MACHINE UNTIL

YOU HAVE READ THE APPROPRIATE MANUALS!
‘‘Avertissement - Si vous ne lisez pas l’anglais, demandez à votre surveillant de vous donner les instructions de
sécurité!’’
‘‘Atención - Si no lee inglés, pregúntele a su supervisor para las instrucciónes de seguridad!’’
‘‘Vorsicht! - Wenn Sie kein englisch lesen, Ihren Vorgestellten um die Sicherheitsanweisungen bitten!’’
SAFETY RECOMMENDATIONS
>>>>>> SAFETY <<<<<<
IT’S EVERYBODY’S BUSINESS!
A metal cutting machine tool can be a very safe machine or it can be a very dangerous one. The difference depends
on you and the other personnel who are required to perform functions relating to the machine tool operation and
maintenance. Safely operating and maintaining the machine also depends on management and any others who may
be observers of the machine tool. Everybody must be safety conscious. When operating this machine, or in
association with it as an attendant, a maintenance person, or a supervisor, it is imperative that all individuals read,
understand, and follow the safety recommendations listed in this section and comply with the safety rules of the
individual’s own company. By adhering to these safety recommendations and your organization’s safety rules, a
number of needless accidents can be avoided. Under no circumstances are safety recommendations a substitute for
proper training. Correctly and safely operating and maintaining a machine tool demands a number of skills. MAG
offers training courses, but the responsibility for training remains with the owner of the machine tool.
Be it understood that these safety recommendations are a guideline. They cannot include all of the situations that
might arise in all companies, and in all types of operations on all types of metal cutting machine tools.
By following these rules, you can prevent serious personal injury and costly damage to equipment. So always think
SAFETY! It depends on YOU!
DEFINITION OF SAFETY NOTES
The following warnings with varying degrees of severity appear in this documentation. The type of note indicates the
hazard potential associated with the operation or event.
This symbol appears whenever death, serious personal injury or

substantial machine damage will occur if the appropriate precautions are
not taken.
This symbol appears whenever minor injury or major machine damage

might occur if the appropriate precautions are not taken.
This symbol appears whenever minor machine damage may occur if the
appropriate precautions are not taken.
SELECTION OF PERSONNEL
• Only qualified personnel, instructed in safety and all machine functions, should be entrusted to operate and/or
maintain this machine.
• All electrical/mechanical trouble-shooting and repair must be undertaken only by qualified personnel who are
properly trained and have adequate knowledge and skill.
• Operators and maintenance personnel should carefully read, understand, and fully comply with all machine
mounted warning and instruction plates. Do not paint over, alter, deface, or remove these plates from the
machine. Replace all plates that become unreadable.
• Clearly define the duties associated with setting up, operating, maintaining and servicing the machine.
• Personnel undergoing training on machine operations require continuous supervision by an experienced person.
• Clearly establish the responsibilities of the person operating the machine with the added authority to issue
warnings towards any individuals who may be involved in undesirable safety behavior.
• If multiple people are working on the machine, the responsibilities for individual tasks must be clearly defined and
observed.
PERSONAL PROTECTION (PROTECTIVE EQUIPMENT)
Clothing While operating and/or maintaining the machine, avoid neckties, long sleeve shirts, gloves,
wristwatches or other jewelry, which could become caught in moving machine parts. A suitable
head covering must be worn by personnel with long hair. Tight fitting clothes should be worn to
avoid accidents.
Shoes Wear safety shoes in proper condition to protect against rolling objects, falling objects, and
accidentally kicking sharp-edged materials.
Glasses Wear eye protection at all times.
Safety helmet Wear a safety helmet when carrying out maintenance and transport work.
Gloves Machining may cause the workpiece to have elevated temperature and sharp edges. Tools
and chips/shavings will also have sharp edges. Use gloves to handle workpiece, tools or when
removing chips. Make sure that the machine is not moving while wearing gloves.
Hearing protection Wear prescribed personal hearing protection.
Be mentally alert on the job. Avoid “horseplay”. Be serious about the job.
Alcohol and other drugs impair judgment and slow reaction times. Do not operate this machine while under their
influence or effects.
PRINCIPLES OF CORRECT OPERATION (APPROPRIATE USE)
• Think safety.
• Operate and maintain the machine only as set forth in the manuals supplied with the machine.
• Do not make any modification to the machine that could adversely affect safe operations. Changes or structural
modifications to the machine or its components, is not allowed.
• Spare parts must meet the technical requirements specified by the manufacturer.
• Safety limit switches, safety interlocks, and end of travel limit switches are provided for various machine units.
Do not remove them or bypass them in an effort to obtain more travel or take a “shortcut”. Serious damage to
the machine or personal injury may result. If the job requires greater range than the safety limit switches allow;
the work must be performed on a machine with greater travel.
• The machine should be kept in good operating condition at all times. Make sure to report any unusual sounds,
smoke, heat, etc., to the appropriate individual within your organization.
SAFETY INSTRUCTIONS FOR MACHINE OPERATION
• Do not operate the machine with safety guards, shields, covers, doors, or other protective devices disconnected,
removed, or out of place. Operate the machine only when they are in proper position and operating condition.
• If safety devices must be rendered functionless during set-up, maintenance or repair, ensure that once the
activity is completed that the safety devices are enabled and properly checked before operating the machine.
• At least once, per shift the machine should be inspected for visible damage and defects. Any observations
should be reported to the appropriate personnel without any delay. If necessary, immediately turn off power and
safeguard the machine.
• The area around the machine should be free of oil or coolant spills and as free as possible from obstructions.
• Ensure that the machine limits for work piece weight and size are not exceeded.
• Clamp all work and fixtures securely before beginning machining operations.
• Do not walk or stand on the machine way covers. When work platforms are used around the machine, they
should be sturdy, safe, and have anti-slip surfaces.
• Keep hands off the table and out of the path of moving units during machining operations.
• Do not remove chips from the work piece area with your hands or while the spindle/table is turning. Use a brush
to remove chips after the spindle/table has stopped. Dispose of chips frequently.
• All doors should be kept closed, especially on the control and electrical cabinets. Keep all covers in place.
• Work lamps should be directed towards the work piece, not the control or operator.
• Do not store tools, measuring equipment, etc. on the machine.
• Maintain tooling in good condition. Use only properly sharpened tools.
• Cutting tools are made for right or left hand rotation. Be sure the direction of spindle rotation is correct for the
tool being used.
• Use special care when handling or changing tools by hand. Do not place hands near a revolving cutting tool.
• Do not load or unload the machine unless the spindle is stopped.
• Do not adjust coolant delivery pipes or nozzles unless the spindle is stopped.
• Always use adequate lifting facilities, as well as have appropriate slings and hitches available, capable of lifting
within safe load limits. Employees using such equipment should be properly trained in its use.
SAFETY DISCONNECTION
EMERGENCY STOP BUTTONS
Emergency stop buttons (switches) are located in various locations on the machine. Since
these buttons can be unlocked mechanically, they do not provide absolute protection against
access by unqualified personnel. Use of the proper lockout/tagout procedure is required to
ensure absolute protection against access. The machine type and the optional equipment
provided with the machine will determine the number and location of these buttons. A typical
button is shown below - red button with yellow ring.
A noteplate specific to your machine has been located on the electrical control cabinet or enclosure. This noteplate
shows the various emergency stop button locations. Typical locations include:
• Pendant operator’s station
• Handheld stations (pendant and tool clamp/unclamp unit)
• Tool changer control box
• Optional production coolant system control box
• Optional pallet system control box
LOCKOUT / TAGOUT
A policy and procedure must be established outlining the requirements for the lockout of energy isolating devices
whenever maintenance or servicing is done on the machine. The procedure shall be used to ensure that before
employees perform any servicing or maintenance that the machine is stopped and isolated from all potentially
hazardous energy sources. In addition, the procedure will detail the method to lockout the machine thus preventing
the unexpected energizing or start-up of the machine and/or release of stored energy, which could cause injury and/or
damage to the machine.
GENERAL LOCKOUT PROCEDURE
1. Authorized personnel shall verbally notify all affected employees that servicing or maintenance is required on
the machine and that the machine must be shut down and locked out to perform the servicing or maintenance.
2. Authorized personnel should then refer to the appropriate policy to identify the type, location and magnitude of
the energy that the machine utilizes, understand the hazards associated with this energy, know the methods to
control this energy, and the verification process to ensure that the energy has been controlled. A noteplate
located on the electrical control cabinet or enclosure of the machine provides information concerning the
various forms of stored energy requiring control.
3. If the machine is operating, shut it down by the normal stopping procedure.
4. Engage the energy isolating device(s) so that the machine is isolated from the energy source.
5. Dissipate or restrain all sources of stored energy (pneumatic, electrical, hydraulic pressure, coolant pressure,
mechanical, elevated machine members-gravity, etc.) by the appropriate method.
6. Lockout the energy isolating device(s) with assigned lock(s), individual tags, and specialty equipment as
required.
7. Check the work area to ensure that all personnel have been safely positioned or removed from the area. Verify
the isolation of the equipment by attempting to operate the normal controls, ensuring that the machine does not
operate. Return operating controls to neutral or off position after verifying the isolation of the equipment.
8. The machine is now locked out.
SAFETY NOTES - SPECIFIC DANGERS
MECHANICAL SYSTEM
Types of danger are machine components and work piece movements with risk of body parts being caught or
crushed.
• Be aware of uncontrolled movements when personnel enter work area.
• Do not manually operate sensors and position recognition devices that otherwise prevent machine movements.
• Be aware of crush potential when using the machine in manual mode, during tool or pallet changes and while
performing maintenance work.
• Do not reach between the spindle and tool when the tool is being loaded.
• Always support suspended machine components, subject to potential gravitational movements, with wooden
wedge before working beneath these components.
• Do not operate if machine covers are open or disassembled. These covers serve to protect personnel from
movements of tool magazines, moving axes, and power transmission gears, belts and chains.
ELECTRICAL SYSTEM
Type of danger is high voltage with risk of shock to personnel and damage to property.
• Do not operate machine with the electrical control cabinet doors open.
• Do not operate machine with loose electrical connections, faulty insulation of cables, melted cables or other
faults, which interfere with the safety of the electrical system. If any of these conditions are noticed, the machine
should be shut down and may be operated again only after the fault has been eliminated.
• Work on electrical connections or machine electrical components may only be carried out by qualified
maintenance personnel.
HYDRAULIC AND PNEUMATIC SYSTEM
Types of danger include improper valve actuation and the release of fluids in high-pressure lines with the risk of
personnel injury or property damage.
• Do not manually operate directional control valves, since unintended movements could result.
• Periodically inspect for defects, such as chafe points or leaks, in pressure hoses, pressure pipes, and connection
fittings, especially after replacement or after putting a new system into operation. If any of these conditions are
noticed, the machine should be shut down and may only be operated again after the defect has been rectified.
• Improper tampering with hydraulic systems, such as modifying settings at pressure switches, can cause trapped
oil to escape at high speed from hydraulic lines, causing bodily injury or property damage.
• Pipes, hoses and machine parts can be damaged if the drain valve is not opened slowly to reduce pressure
before attempting service or repairs.
• Damage to the hydraulic system can occur if air is not removed from the system after repair.
CHIP DISPOSAL
Types of danger are moving parts in the conveyor and sharp or jagged edges on the chips. Risks of bodily injury
through body parts being caught and pulled in or crushed and/or cuts from sharp chips.
• When cleaning chip conveyors, make sure that the conveyor is turned off with lockout to prevent unintended
restart.
• Never reach into the chip ejection area while the machine is operational.
• Use safety gloves while removing chips. Remove gloves after conveyor and machine are operational.
COOLANT/HYDRAULIC OILS/LUBRICANTS
• Hydraulic oils and lubricants that leak onto the floor or machine components create a slippery condition. To
prevent accidents, cleanliness must be maintained.
• When working with oils, greases and other chemicals observe the safety regulations that apply to the product
(safety data sheets of the manufacturer).
• Oil mists are hazardous to health and should not be inhaled.
• Choose easily disposable coolants, observing waste disposal regulations.
FILTER MEDIA - HYDRAULIC/COOLANT
Types of danger are associated with the disposal process and include bodily injury and contamination of ground
water/earth.
• Avoid prolonged contact to dirty filter media that can irritate skin.
• Always wear eye protection.
• Make sure to not inhale vapors.
• Immediately clean even minor cut/abrasions thoroughly if they have been exposed to coolant or hydraulic fluids.
• When disposing of filter medium, make sure to comply with environmental protection and water resources laws.
FIRE PROTECTION
• Performing regular assessments and inspections at regular intervals.
• Assign and train staff for fighting fire.
• Establish fire protection rules, which include an alarm plan with planned escape routes, locations of emergency
switches, and the distribution of fire extinguishers.
• Keep combustible and inflammable substances away from the work area.
• Ensure that information is provided explaining the suitable methods of fire fighting.
• Fire prevention must be practiced and fire protection must be available to prevent loss of life, personal injury, and
property damage.
• Be aware of conditions that may be a fire hazard, such as volatile liquids and machining materials with a low flash
point.
M.2005.3740
S/N 480
MAG
Horizontal Boring Mills
PT, RT & MC Series
Mechanical Manual
This document is based on information available at the time of its publication. While
efforts have been made to render accuracy to its content, the information contained
herein does not purport to cover all details or variations in hardware and software, or to
provide for every possible contingency in connection with installation, operation,
programming, and maintenance. Features may be described herein which are not
present in all hardware and software systems. MAG assumes no obligation of notice to
holders of this document with respect to changes subsequently made.
MAG makes no representation or warranty, expressed, implied, or statutory with respect

to, and assumes no responsibility for the accuracy, completeness, sufficiency or
usefulness of the information contained in this manual.
Revision History
First Edition (05/2011)
© 2011 MAG IAS – Fond du Lac

PREFACE
This manual provides basic information about the machine and equipment. Instructions
and suggestions are given to insure proper installation and maintenance.
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A MACHINE TOOL IS A COMPLEX METAL REMOVING DEVICE,

EQUIPPED WITH MOVING MECHANICAL COMPONENTS, ALONG WITH
HYDRAULIC AND ELECTRICAL DEVICES OPERATING UNDER
PRESSURE AND HIGH VOLTAGE TO ACHIEVE THEIR INTENDED
PURPOSE. FOR THIS REASON OPERATION AND/OR REPAIR MUST BE
DONE ONLY BY QUALIFIED TECHNICIANS, TO PROVIDE FOR SAFE
AND RELIABLE OPERATION OF THIS EQUIPMENT.
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The machine and equipment illustrated and described in this manual is protected by
United States and foreign patents. These illustrations and specifications are not binding
in detail. We reserve the right to make changes and improvements and incorporate
them in the machine as conditions warrant.
Should problems arise or information not covered by this manual be required, contact
MAG IAS – Fond du Lac

142 Doty St., P.O. Box 590,
Fond du Lac, Wisconsin, 54936-0590 U.S.A.
TRAINING SERVICE PARTS

TELEPHONE .................................920-906-2437 800-934-0735 800-934-0735
FAX ................................................920-906-2243 920-906-2354 920-906-2634
WEBSITE............ www.mag-ias.com
Printed in U.S.A.
480 HBM
GENERAL TABLE OF CONTENTS
TITLE SECTION
SAFETY ............................................................................................................................................SAFETY
PREFACE ......................................................................................................................................PREFACE
DOCUMENTATION INTRODUCTION .................................................................................................... 1.10
MACHINE DESCRIPTION....................................................................................................................... 1.20
COLUMN ................................................................................................................................................. 4.10
BED.......................................................................................................................................................... 5.10
DAMPER ASSEMBLY............................................................................................................................. 5.20
WAY COVERS......................................................................................................................................... 5.30
HEADSTOCK-COMMON ...................................................................................................................... 12.10
HEADSTOCK-2 SPEED ........................................................................................................................ 12.20
HEADSTOCK-4 SPEED ........................................................................................................................ 12.30
DRAWBAR ............................................................................................................................................ 12.50
SADDLE ................................................................................................................................................ 13.10
ROTARY TABLE-COMMON................................................................................................................. 15.10
ROTARY TABLE-PLAIN TOP .............................................................................................................. 15.20
ROTARY TABLE-CLAMPING TOP ...................................................................................................... 15.30
PALLET CHANGER-COMMON............................................................................................................ 20.10
PALLET CHANGER-1250..................................................................................................................... 20.20
PALLET CHANGER-1600..................................................................................................................... 20.30
PALLET CHANGER R&R PROCEDURE............................................................................................. 20.40
PALLET CHANGER ALIGNMENT PROCEDURE ............................................................................... 20.50
PALLET CHANGER-MAINTENANCE.................................................................................................. 20.60
PALLET STANDS ................................................................................................................................. 22.10
PALLET STANDS-MAINTENANCE ..................................................................................................... 22.20
TOOL CHANGER .................................................................................................................................. 30.10
REFERENCE MATERIAL ..................................................................................................................... 69.10
CAMERA ............................................................................................................................................... 72.10
ENCODERS-FANUC ............................................................................................................................. 72.20
ENCODERS-SIEMENS ......................................................................................................................... 72.21
HYDRAULICS-COMMON ..................................................................................................................... 75.10
HYDRAULICS-2 SPEED ....................................................................................................................... 75.20
HYDRAULICS-4 SPEED ....................................................................................................................... 75.30
HYDRAULICS-SETUP .......................................................................................................................... 75.40
PNEUMATICS-COMMON ..................................................................................................................... 78.10
480 HBM
GENERAL TABLE OF CONTENTS
TITLE SECTION
PNEUMATICS-SETUP .......................................................................................................................... 78.20
LUBE SYSTEM-COMMON ................................................................................................................... 79.10
LUBE SYSTEM-2 SPEED ..................................................................................................................... 79.20
LUBE SYSTEM-4 SPEED ..................................................................................................................... 79.30
LUBE SYSTEM CHILLER ..................................................................................................................... 79.40
LUBE SYSTEM SETUP......................................................................................................................... 79.50
COOLANT SYSTEM.............................................................................................................................. 80.10
CHIP CONVEYOR ................................................................................................................................. 81.10
INSTALLATION..................................................................................................................................... 86.10
ATTACHMENTS-INTRODUCTION....................................................................................................... 92.10
AUTO ATTACHMENT CHANGER ....................................................................................................... 92.20
ATTACHMENTS.................................................................................................................................... 92.30
MAINTENANCE-NOTEPLATES ........................................................................................................... 96.10
MAINTENANCE-ALIGNMENTS ........................................................................................................... 96.20
SECTION 1.10
DOCUMENTATION DESCRIPTION
TABLE OF CONTENTS
TITLE PAGE
INTRODUCTION............................................................................................................................................................1
MACHINE DOCUMENTATION......................................................................................................................................2
MECHANICAL SERVICE MANUAL ........................................................................................................................2
MECHANICAL PRINT BOOKS ...............................................................................................................................2
ELECTRICAL SERVICE MANUAL .........................................................................................................................2
ELECTRICAL PRINTS............................................................................................................................................2
OPERATING INSTRUCTION MANUAL .................................................................................................................3

DOCUMENTATION DVD / CD AND VENDOR DOCUMENTATION ......................................................................3
INTRODUCTION
All manuals provided are made up of a Safety Section and sections of detailed information concerning all aspects of
the machine. Sections are separated by a colored sheet. Section title and numbers are identified at the bottom of
each page for ease of use.
A General Table of Contents, indicating what can be found in the various sections, is found at the front of the manual.
The first page(s) of each section is the Table of Contents for that particular section.
The individual sections cover the various areas of concern for the machine and the control. When appropriate,
references are made to other sections and other manuals sent with the machine. In all manuals you will find
DANGERS, WARNINGS, CAUTIONS and NOTES. Each is described below.
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DANGER INDICATES THAT THE PROCEDURE OR SITUATION COULD RESULT IN SEVERE

PERSONAL INJURY OR DEATH UNLESS THE INFORMATION PRESENTED IS FOLLOWED.
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WARNING INDICATES THAT THE PROCEDURE OR SITUATION COULD RESULT IN

PERSONAL INJURY UNLESS THE INFORMATION PRESENTED IS FOLLOWED.
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CAUTION INDICATES THAT IF THE INFORMATION PRESENTED IS NOT FOLLOWED THE

MACHINE OR THE WORKPIECE COULD BE DAMAGED.
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Note: Notes are messages (in bold type) indicating where to find additional information or are messages
providing helpful information of some kind.
DOCUMENTATION DESCRIPTION 1.10 - 1

MACHINE DOCUMENTATION
The following manuals and documentation is provided with each machine.

Note: All manuals, prints and vendor documentation are provided on a CD as standard format. Hard/Paper
copies are optional and may be ordered by the customer.
MECHANICAL SERVICE MANUAL
The purpose of the Mechanical Service Manual is for instruction and maintenance purposes and it covers the
mechanical and hydraulic systems for the machines. Material covered includes installation, machine alignments,
mechanical units, coolant, hydraulic, lubrication and pneumatic systems. Procedures for repair (of certain parts of the
machines) and troubleshooting are outlined with the interest of keeping machine downtime to a minimum.
The manual covers maintenance procedures with a brief overview but refers to the Print Books for complete and
detailed instructions and procedures.
MECHANICAL PRINT BOOKS
The drawings, sketches, and photographs included in this manual are for reference only. Each machine is shipped
with a specific set of machine drawings in large size format. These drawings or "prints" are referred to as Print Books.
The large prints are assembled in numerical order with the print number being shown in the lower right hand title box.
The Print Books are what should be used when performing maintenance procedures. This manual covers
maintenance procedures with a brief overview but refers to the Print Books for complete and detailed instructions and
procedures. The Print Books should be studied before beginning any maintenance procedures. Maintenance
procedures should be conducted by qualified maintenance personnel only.
Note: The Print Books should be studied before beginning any maintenance procedures. Maintenance
procedures should be conducted by qualified maintenance personnel only.
ELECTRICAL SERVICE MANUAL
The Electrical Service Manual is used for instructional purposes as well as a troubleshooting reference for these
machines.
The manual has been laid out to provide the electrical maintenance person with the information needed to maintain
and repair the machine. Details of the CNC control hardware and software are given as well as the application of
electronic devices used on the machine. Detailed instructions of setup and adjustments of devices, components, and
configuration can be found in the manual. Some examples of the information found include; software loading &
backup, feedback system debugging, axis drive troubleshooting and axis reference setup.
ELECTRICAL PRINTS
Two copies of the Machine Electrical Prints are provided with each machine. The prints are printed in the DIN format.
DIN prints are printed on A sized (8 ½ x 11) paper and are sharp and clear.
1.10 - 2 DOCUMENTATION DESCRIPTION

OPERATING INSTRUCTION MANUAL
The Operating Instruction Manual is used for instructional purposes as well as a reference for the programming and
operating the machine. The purpose of this manual is to bridge the application of the CNC control to a MAG machine
tool. This manual is to be used in conjunction with the control operation and programming manuals provided by the
control manufacturer.
The manual also provides information on the procedures required to prepare the machine for operation and also
provides information on the tooling, tool changing, programming, part program form and editing, work changing,
machine and part referencing, etc. Also included are the detailed instructions on the functions of the various control
panels used on the machine and on the format and function of the display screens used with each function of the
machine's operation.
DOCUMENTATION DVD / CD AND VENDOR DOCUMENTATION
There are several different pieces of documentation that is shipped with each machine. MAG puts together a DVD /
CD for each machine that contains all of the manuals listed above and also includes a large amount of vendor
documentation. Additionally, a CNC control DVD or CD ships with every machine that contains a library of the control
manufacturer's manuals.
MAG creates a ghost image of the hard drive that is burned to a DVD and is sent to the customer. The image can be
“ghosted” into a replacement hard drive should the hard drive in the operator station fail. The ghost image of the hard
drive is also stored on our own network so that if the DVD disk is lost or damaged, another disk can be obtained from
MAG.
A backup of the control’s battery backed memory of the CNC is output and burned to CD(s). The CD and backup
disks are normally kept in a plastic holder in the back of the binder that holds the printout of the ladder program.
DOCUMENTATION DESCRIPTION 1.10 - 3

SECTION 1.20
MACHINE DESCRIPTION
TABLE OF CONTENTS
TITLE PAGE
GENERAL ......................................................................................................................................................................1
MACHINE OVERVIEW ..................................................................................................................................................1
MACHINE AXES.....................................................................................................................................................1
HEADSTOCK..........................................................................................................................................................1
TOOL CHANGER ...................................................................................................................................................2
FEEDBACKS ..........................................................................................................................................................2
DRIVES AND MOTORS .........................................................................................................................................2

PALLET CHANGING ..............................................................................................................................................2
COMPENSATIONS ................................................................................................................................................2
MACHINE ILLUSTRATIONS .........................................................................................................................................3
PT 1500 / PT 1800..................................................................................................................................................3
RT 1250 / RT 1600 .................................................................................................................................................4
MC 1250 / MC 1600................................................................................................................................................5
MACHINE SPECIFICATIONS........................................................................................................................................6
PT SPECIFICATIONS ............................................................................................................................................6
RT SPECIFICATIONS ............................................................................................................................................7
MC SPECIFICATIONS ...........................................................................................................................................8
HORSEPOWER CHARTS .............................................................................................................................................9
TWO-SPEED HEADSTOCK 130MM SPINDLE DIAMETER ..................................................................................9
FOUR-SPEED HEADSTOCK 130MM SPINDLE DIAMETER.................................................................................9
FOUR-SPEED HEADSTOCK 155MM SPINDLE DIAMETER...............................................................................10

GENERAL
There are many variations of the horizontal spindle machines. The PT, RT and MC series machines are "table-type"
boring mills. These machines are available with or without rotary tables, coolant systems, and attachments
(contouring heads, right angle heads, etc.). There are a wide variety of different table configurations available
including removable and tilt rotary tables.
This section provides a general description of table-type horizontal machining centers.
MACHINE OVERVIEW
MACHINE AXES
X X-axis motion is accomplished by moving the table back and fourth on the saddle in front of the column.
X-axis plus motion is towards the operator, minus is toward the tool changer side of the machine.
Y Y-axis motion is the headstock moving vertically on the side of the column. Up is plus motion.
Z Z-axis motion is typically the spindle in and out of the headstock. The spindle moving into the headstock is
plus and out of the headstock is minus.
W W-axis is typically the saddle moving in toward the column (minus) and away from the column (plus).
Z and W-AXES
The standard configuration for the Z and W-axis on PT, RT, and MC Series Machines is:
Z-axis The SPINDLE in and out of the headstock.
W-axis The SADDLE motion to / from the column.
HOWEVER! To date several machines have had the Z and W-axis designations swapped.
On those machines, Z-axis was the saddle to / from the column while W-axis was the spindle
in / out of the headstock.
The spindle moving into the headstock is plus and out of the headstock is minus. The saddle
assembly moving toward the column is minus and away from the column is plus.
B With the RT and MC versions of the 480 machine, B-axis is a built in contouring rotary table. Counter-
clockwise rotation (when looking down at the table) is plus motion. This means that moving the table from 0°
to 90°, moves the table 1/4 revolution counter-clockwise. The PT version of the 480 machine can be ordered
with a removable B-axis table.
V V-axis is the optional contouring head attachment. The attachment mounts on the headstock. The spindle
motion in and out is converted to motion of a tool post in and out from the center of the spindle rotation.
Another type of attachment moves dual cutters in and out from the center of the spindle (CBS tooling).
A As an option, an A-axis rotary table, typically referred to as a "trunnion table", is available. Counter-
clockwise rotation (when viewed from X+ side) is plus motion. This means that moving the table from 0° to
90°, moves the table 1/4 revolution counter-clockwise. An A-axis rotary table is an "add-on" table and can be
mounted to the fixed table of a PT machine or mounted to the B-axis rotary table of a RT or MC machine
(table-on-table).
HEADSTOCK
There are three different headstocks available: a 130 mm / 5.1" two speed, a 130 mm / 5.1" four speed and a 155 mm
/ 6.1" four speed version.
MACHINE DESCRIPTION 1.20 - 1

TOOL CHANGER
Tool changers are available on all machines. There are several tool changer options available; 60, 90 and 120 tool
magazines. Each tool can weigh up to 50 kg / 110 lbs. Tools over 125 mm / 4.9" diameter require adjacent pockets
be kept empty. Maximum tool diameter is 280 mm / 11.0".
The vertical design of the tool changer uses a reliable, large link chain that has a minimum of parts. The double
gripper exchange arm mounts on a rail that makes the 90° turn around the corner of the column toward the spindle.
The spindle orient position is set where the spindle keys are level and the key toward the tool changer is further from
the center of the spindle. The keys are the same size but are not mounted the same distance to the spindle
centerline.
FEEDBACKS
The feedback systems used on the axes can vary. Typically X, Y, B and the saddle (typically the W-axis but
sometimes called Z-axis) axes use pulse distance coded Heidenhain encoders. The spindle axis (typically the Z-axis
but sometimes called W-axis) and sometimes the B-axis, use an absolute encoder feedback system.
Axes with pulse distance coded scales require machine referencing. Axes with absolute feedback encoders like the
spindle axis (typically Z-axis but sometimes W-axis) and sometimes the B-axis do not require machine referencing
(references are automatically "picked up" at power on).
Refer to the =DA area of the Machine Electrical Prints to see what encoders have been used on any of the machine
axes. There has been a great deal of variation in the type or number of the scales used.
Spindle position and speed feedback come from the spindle motor encoder and the BERO switch
DRIVES AND MOTORS
Highly responsive closed loop AC servo drives are used on these machines. The drives interface with the CNC
digitally, providing a very responsive and accurate system. A whole range of different motors are used based on the
table size and axis configurations. It is recommended that if a motor is changed, only the exact same motors be
used. Different axis use different motor sizes based on the loads of that axis.
PALLET CHANGING
A pallet changer option is available. This allows the machine to cut one part while a different part is loaded / unloaded
on a pallet on a stand next to the machine. Machines with pallet changing are designated MC machines.
COMPENSATIONS
There are several different compensation systems that can be applied to the horizontal machining centers.
• Backlash compensation is a standard feature which corrects for lost motion in an axis when the axis changes
direction.
• Pitch Error compensation is applied to all axes in the MAG shop at the time the machine is built. Straightness
compensation is an option that can be used to enhance the positioning accuracy of one axis when a second axis
is moved. (Another name for it could be "other axis based compensation".) As the first axis is moved, a second
axis is compensated to eliminate errors caused by machine misalignments.
• Thermal compensation is used to compensate the spindle axis (Z or W) positioning errors due to thermal
changes of the machines components.
1.20 - 2 MACHINE DESCRIPTION

MACHINE ILLUSTRATIONS
PT 1500 / PT 1800
The PT (plane table) version of this machine does not have a built in rotary table. The table size ranges from
1500 mm x 3000 mm / 59.05" x 18.1" for the PT 1500 machines and 1800 mm x 3600 mm / 70.9" x 141.7" and
1800 mm x 4200 mm / 70.9" x 165.4" for the PT 1800 version. Rotary tables are often purchased that are mounted
on the top of the table. Often these rotary tables can be connected and disconnected (this would be accomplished
using a special CUSTOM1 / MANUAL screen).
Automatic
Tool Changer Y-Axis
Spindle Axis
X-Axis
Saddle Axis
FIGURE 1.20 - 1
Illustration of PT 1500
Note: Machine / component specifications can vary depending on individual customer and / or machining
requirements.

RT 1250 / RT 1600
The RT (rotary table) version of this machine has a built in rotary table (B-axis). The table is always a contouring
table. The table incorporates a hydraulic clamp that locks the table in position when the table is commanded to a
position. The machine will typically include a tool changer.
Automatic
Tool Changer Y-Axis
Spindle Axis
B-Axis
X-Axis Saddle Axis
FIGURE 1.20 - 2
Illustration of RT1250
requirements.

MC 1250 / MC 1600
The MC (machining center) series machines are equipped with built-in B-axis rotary table and include pallet changing
and tool changing.
Automatic
Tool Changer
Y-Axis
Spindle Axis
B-Axis
X-Axis
Saddle Axis
FIGURE 1.20 - 3
Illustration of MC1600
requirements.

MACHINE SPECIFICATIONS
PT SPECIFICATIONS
Capacities - mm / in
PT 1500 PT 1800
X-axis travel 3000 / 118.1 3600 / 141.7
(165.4 / 4200)
Y-axis travel 2100 / 82.7 2100 / 82.7
(2600 / 102.4) (2600 / 102.4)
(3100 / 122.0) (3100 / 122.0)
(3600 / 141.7)
Y-axis travel below table top 0
Saddle-axis travel 59.1 / 1500
(78.7 / 2000)
(98.4 / 2500)
(137.8 / 3500)
Plain Table - mm / in
Table size 1500 x 3000 / 59 x 118.1 1800 x 3600 / 70.9 x 141.7
1800 x 4200 / 70.9 x 165.4
Allowable load 25,000 kg / 55,100 lb 40,000 kg / 88,200 lb
Spindle - mm / in
Power Spindle Speed
Spindle Diameter Spindle Travel
S1-100% / S6-40% Range Constant Torque Constant HP
40 / 60 hp Low 1 - 259 259 - 948
130 / 5.1 2 Speed 800 / 31.5
30 / 45 kW High 1 - 1038 1034 - 3791
40 / 60 hp Range 1 1 - 68 69 - 185
130 / 5.1 4 Speed 1000 / 39.4
30 / 45 kW Range 2 1 - 170 174 - 463
50 / 75 hp Range 3 1 - 437 446 - 1190
155 / 6.1 4 Speed 1250 / 49.2
37 / 56 kW Range 4 1 - 1285 1116 - 3500
Feeds / Traverse Rates (may be limited, based on travel)
X, Y, Z, W 25,000 mmpm / 984 ipm
B 6 rpm
Tool Changer - mm / in
Tool magazine capacity 60 - 90 - 120
Tool diameter adjacent pocket full 125 / 4.9
adjacent pocket empty 280 / 11
Tool length 750 / 29.5
Tool weight 37 - 50 kg / 82 lb - 110 lb
( ) = Optional
TABLE 1.20 - 1
PT Specifications
Note: Not all options / specifications may be listed, and / or options / specifications may change.

RT SPECIFICATIONS
RT 1250 RT 1600
X-axis travel 2500 / 98.4
(3600 / 141.7)
Y-axis travel 2100 / 82.7 2100 / 82.7
(2600 / 102.4) (2600 / 102.4)
(3100 / 122.0) (3100 / 122.0)
(3600 / 141.7)
Y-axis travel below table top 100 / 3.937 135 / 5.315
Saddle-axis travel 1500 / 59.1
(2000 / 78.7)
(2500 / 98.4)
(3500 / 137.8)
NC Rotary Table - mm / in
Table size 1250 x 1600 / 49.1 x 63 1600 x 2000 / 63 x 78.7
Optional 1600 x 1800 / 63 x 70.9) 1600 x 2500 / 63 x 98.4)
Allowable load 15,000 kg / 33,100 lb 25,000 kg / 55,100 lb
Number of positions 360,000
Index rate 6 rpm
Spindle - mm / in
Power Spindle Speed
30 / 45 kW Low 1 - 259 259 - 948
130 / 5.1 2 Speed 800 / 31.5
40 / 60 hp High 1 - 1038 1034 - 3791
30 / 45 kW Range 1 1 - 68 69 - 185
130 / 5.1 4 Speed 1000 / 39.4
40 / 60 hp Range 2 1 - 170 174 - 463
37 / 56 kW Range 3 1 - 437 446 - 1190
155 / 6.1 4 Speed 1250 / 49.2
50 / 75 hp Range 4 1 - 1285 1116 - 3500
X, Y, Z, W 25,000 mmpm / 984 ipm
B 6 rpm
Tool Changer - mm / in
( ) = Optional
TABLE 1.20 - 2
RT Specifications

MC SPECIFICATIONS
MC 1250 MC 1600
X-axis travel 2500 / 98.4
(3600 / 141.7)
Y-axis travel 2100 / 82.7 2100 / 82.7
(2600 / 102.4) (2600 / 102.4)
(3100 / 122.0) (3100 / 122.0)
(3600 / 141.7)
Y-axis travel below table top 100 / 3.937 135 / 5.315
Saddle-axis travel 1500 / 59.1
(2000 / 78.7)
(2500 / 98.4)
(3500 / 137.8)
NC Rotary Table - mm / in
Pallet Size 1250 x 1250 / 49.1 x 49.1 1600 x 1600 / 63 x 63
(1250 x 1600 / 49.1 x 63) (1600 x 2000 / 63 x 78.7)
(1250 x 1800 / 49.1 x 70.9) (1600 x 2500 / 63 x 98.4)
Allowable load On Pallet 70,000 kg / 15,430 lb 15,000 kg / 33,100 lb
On Machine 15,000 kg / 33,100 lb 25,000 kg / 55,100 lb
Number of positions 360,000
Index rate 6 rpm
Spindle - mm / in
Power Spindle Speed
30 / 45 kW Low 1 - 259 259 - 948
130 / 5.1 2 Speed 800 / 31.5
40 / 60 hp High 1 - 1038 1034 - 3791
30 / 45 kW Range 1 1 - 68 69 - 185
130 / 5.1 4 Speed 1000 / 39.4
40 / 60 hp Range 2 1 - 170 174 - 463
37 / 56 kW Range 3 1 - 437 446 - 1190
155 / 6.1 4 Speed 1250 / 49.2
50 / 75 hp Range 4 1 - 1285 1116 - 3500
X, Y, Z, W 25,000 mmpm / 984 ipm
B 6 rpm
Tool Changer - in / mm
( ) = Optional
TABLE 1.20 - 3
MC Specifications

HORSEPOWER CHARTS
TWO-SPEED HEADSTOCK 130MM SPINDLE DIAMETER
FOUR-SPEED HEADSTOCK 130MM SPINDLE DIAMETER

FOUR-SPEED HEADSTOCK 155MM SPINDLE DIAMETER

SECTION 4.10
COLUMN
TABLE OF CONTENTS
TITLE PAGE
COLUMN .......................................................................................................................................................................1
COLUMN MAINTENANCE..................................................................................................................................5
COLUMN
The column is a machined gray iron casting, which provides the support for the vertical Y-axis movement of the
headstock. The column is constructed with variable wall thickness and interior “X” bracing (FIGURE 4.10- 1). The
basic components of the column assembly consist of the machined column, a pair of heavy duty hardened and
ground preloaded roller guide ways, the Y-axis drive, and the linear encoder (all of which vary in length proportionally
to the available headstock travels). In addition, the column supports the mechanical & electrical services, which are
specific for either a two speed or four speed headstock and brackets for the tool changer.
Air & Lube Lines for Y-Axis Ballscrew Upper

Y-Axis Drive Bearing Support Y-Axis Servo Housing
Bottom View of Column Top View of Column Top View of Column with
Y-Axis Drive
FIGURE 4.10- 1
Top & Bottom of Column
The column provides the support for the Y-axis drive. The 80 mm (3.15”) diameter ballscrew is held in place on the
lower end by the damper assembly which is bolted to the column. Under the damper assembly are shims, which are
used to align the ballscrew with the linear rail system. If the shims are removed, they need to be reinstalled in the
exact same position. The damper assembly design ensures that the bearing preload is not lost due to ballscrew
thermal growth. System hydraulic pressure provides equal pressure on both sides of the bearings in the damper
assembly.
The other end of the ballscrew is held in place by bearings within a housing integrated into the column (FIGURE 4.10-
1). If bearing replacement is required, make sure to use the correct drawings for proper orientation (FIGURE 4.10- 2).
FIGURE 4.10- 2
Upper Y Axis Drive Bearing Thrust Orientation
COLUMN 4.10-1
2159 mm (85”)
M8 Cap Screw to
Temporarily Hold
Runner Block
Clamp Rail
1930 mm (76”)
1054 mm (41.5”)
FIGURE 4.10- 3
Column Ready for Headstock Installation
The Y-axis drive housing (FIGURE 4.10- 8), which is attached to the top of the column (FIGURE 4.10- 1), serves has
the mounting surface for the idler spur gear, lube components and the servo motor. The motor includes an integrated
brake. A 35T gear is assembled to the motor shaft. The gear and mounting method is dependent upon the motor
manufacturer (Siemens or Fanuc). After the housing is attached to the column, a keyed spur gear is installed onto
the ballscrew shaft, aligned with the idler gear. Air and oil spray assemblies provide lubrication to the motor drive/idler
and idler/ballscrew drive gear meshes.
4.10-2 COLUMN
The linear rail system used to attach the headstock to the column is similar to the system used for X-Axis movement.
The preloaded roller guide ways consist of a rail and a pair of runner blocks (also referred to as trucks) per side.
Each of the runner blocks contains four sets of recirculating roller bearings (FIGURE 4.10- 6). The bearing preload is
built into the runner blocks and is not adjustable.
Front Rail of Roller Rail System Rear Rail of Roller Rail System
Way Seat
Clamp Rail Clamp Rail
Guide Edge
Guide Edge
FIGURE 4.10- 4
Linear Rail System
The rails are screwed to an accurately machined rail seat which has been measured with a laser interferometer and
hand scraped to ensure straightness and flatness. Both of the rail seats have a locating shoulder (guide edge). The
parallelism of the locating shoulders is maintained within .01 mm (.0004” TIR). The ways are held in place by M16 X
60 socket head cap screws through the center of the way. Clamp rails are used to push the rails against the guide
edge (FIGURE 4.10- 4) machined into the column. A linear rail mounting procedure is included on the column
assembly drawing.
Runner Block
Column Guide Edge
Clamp Rail
Opposite Rail
Parallel to
Datum B within
0.01 mm
Tolerance Zone
FIGURE 4.10- 5
Linear Rail Mounting
COLUMN 4.10-3
Wedge Clamp
Guide Rail Recirculating

Roller Bearings
Guide Edge
FIGURE 4.10- 6
Linear Roller Rail System
After the mounting procedure is completed, a one piece steel strip is inserted in the rails to cover the cap screws
holding the rail to the column. The runner blocks are installed on the rails, with the guide edge of the runner block
(FIGURE 4.10- 5) facing towards the center of the column (side of rail that is against guide edge in column).
The column is bolted to the column base on the bed. At each of the four corners are a set of spacers (FIGURE 4.10-
7). The spacers are ground and marked during column alignment. If the column is removed, the spacers must be
returned to their marked position when the column is reinstalled.
Column
Shims must be
Installed before
Column Lowering
Base Column onto
Shims are Match Marked.

Position Shims in Proper
Location
FIGURE 4.10- 7
Column Spacers/Shims
Before the column weight is completely on the shims, install the column cap screws. When satisfied that the shims
are flush, slowly release the weight from the crane and recheck with a .001" feeler gauge. With most of the weight on
the column base, hand tighten the column cap screws until they just touch the column. At this point, it may be
necessary to use a bumping bar to ensure the column is tight against the alignment blocks. With all of the weight
resting on the column base but with the rigging still in place, tighten the alignment key bolts and then tighten all of the
column cap screws. Check the mating surfaces of the column & shims and base & shims with a .001" feeler gauge,
the joint must be feeler tight; feeler must not slide between the two.
4.10-4 COLUMN
Motor Drive Gear Lube Piston Motor Extends into
Distributors Inside of Column
Air/Oil
Idler Gear Spray
Nozzles
Servo Drive Motor
Ballscrew Drive Gear

FIGURE 4.10- 8
Y-Axis Drive Housing
COLUMN MAINTENANCE
The column consists of only a few parts and therefore it requires minimal maintenance. It is important to keep the
column clean and free from chips and dirt build-up. Monitor the condition of the ways and way wipers on the
headstock to make sure that no abnormal wear is occurring. Make sure the ways are receiving sufficient lubrication
and that they are not wearing abnormally from abrasions or chips caught in the wipers. The ballscrew nut should be
checked for chips in the nylon wipers.
Note: Occasionally run the headstock up and down the column full travel to lube the ways and ballscrew
and to prevent wear spots.
COLUMN 4.10-5
SECTION 5.10
BED
TABLE OF CONTENTS
TITLE PAGE
BED................................................................................................................................................................................1
BED
The bed is a machined gray iron casting, which provides the base for the saddle and the column. This one piece (bed
and column base) design provides superior vibration dampening, optimized structural stiffness and load carrying
capacity. It provides the saddle movement parallel to the spindle axis. For most machines this movement is
designated as the W-axis with spindle in/out being Z-axis, however, these designations can be reversed. The basic
components of the bed assembly consist of the machined bed, a pair of heavy duty hardened and ground preloaded
roller guide ways, the saddle-axis drive & ballscrew, and linear encoder (all of which vary in length proportionally to
the available saddle travels of 1500, 2000, 2500, 3000, or 3500 mm). The ballscrew diameter is 80mm (3.15”) for
1500, 2000 & 2500 mm travels, and 100mm (3.94”) for 3000 & 3500mm travels. The bed also supports one end of
the cable carrier that supplies the mechanical and electrical services used by the saddle and the rotary table/machine
center if so equipped. The bed is anchored to the floor by studs, which are set into the foundation.
Column Base
Saddle Axis Drive
Runner Blocks
(Trucks)
Oil Fill Port
FIGURE 5.10- 1
Bed Assembly
The preloaded roller guide ways consist of a rail (that depending upon length could be split into multiple pieces) and a
pair of runner blocks (also referred to as trucks). Each of the runner blocks contains four sets of recirculating roller
bearings. The bearing preload is built into the runner blocks and is not adjustable.
BED 5.10-1
Column Headstock Side of Column
Pair of Spacers at
being
Each Corner
lowered
onto Bed
Rear of Column
Leveling Setup Surface
Setscrews Used to Raise

Leveling Setup Pads Column for Spacer
Removal/Insertion
FIGURE 5.10- 2
Leveling Pads and Spacers on Column
The rails are bolted to an accurately machined rail seat which has been measured with a laser interferometer and
hand scraped to ensure straightness and flatness. Both of the rail seats have a locating shoulder, with a wedge
clamp used to find and maintain the correct rail position until the rail is bolted in place. The parallelism of the locating
shoulders is maintained within .013 mm (.0005”TIR). The ways are held in place by M16 socket head cap screws
through the center of the way.
FIGURE 5.10- 3
Column Base Surface
5.10-2 BED
The bed provides the support for the saddle axis drive, which moves the saddle in and out from the face of the
headstock (FIGURE 5.10- 4). The saddle axis and X-axis drives share a common design. They can be ordered in
18 M/min and 25 M/min rapid traverse with Siemens or Fanuc drive motors. One end of the saddle or X-axis
ballscrew is supported with a damper assembly, which is identical to the damper assembly used on Y-axis drive. See
damper assembly description in column.
Housing Axis Drive Damper

Assembly
Oil Fill Port
Drive Motor Cover Bearing Housing
Servo Motor
FIGURE 5.10- 4
Bed Axis Drive
The other end of ballscrew is supported by bearings contained within a housing that is integral to the bed. Note the
orientation of these bearings compared to Y-axis drive. Unlike the Y-axis drive, the saddle & X-axes drives do not
use an idler gear. Also, the gears are lubricated with an oil bath that must be manually filled to a level on a sight
gage. The motor shaft spur gear varies dependent upon both rapid traverse and drive motor type. Each motor shaft
gear has a corresponding drive motor cover. The cover accommodates the motor mount pattern and the shaft/gear
centerline.
BED 5.10-3
SECTION 5.20
BALLSCREW DAMPER ASSEMBLY
TABLE OF CONTENTS
TITLE PAGE
DAMPER ASSEMBLY ...................................................................................................................................................1
SETUP DAMPING ASSEMBLY ..........................................................................................................................2

DAMPER ASSEMBLY
The following procedure is for informational purposes only. It is intended to help one understand the functionality of
the damping assembly. The procedure assumes that the damping assembly is on the ballscrew and the ballscrew
locknuts have been torqued to the proper setting. See the appropriate axis drive drawing for the locknut torque
requirement. The centerline of the ballscrew has been aligned parallel to the linear ways within ± 0.05 mm (0.002”).
The two damper spacers between the column and damping assembly provide the adjustment.
The hydraulic pressure acts upon the two outer spacers to provide an equal but opposite force on the bearings outer
races. As the bearings length slowly changes due to thermal expansion, the hydraulic forces remain constant. The
damper assembly is initially setup with an equal gap between the outer spacers and the damper housing. A set of
orifices separates the hydraulic fluid acting on these spacers into two fluid chambers. The 0.2 mm (0.0079”) diameter
orifices effectively limit the movement of fluid at high frequencies, resulting in added damping forces.
Section A-A from Left Rotated 90°
Hydraulic
Ballscrew Bleed
A Port
Column
Mounting
Outer
Surface
Spacer
Damper
Spacer
Orifice Outer
Ø 0.2 mm Spacer
Special Connector
A with Orifice
Ø 0.2 mm
Main System
Hydraulic
Pressure Input
FIGURE 5.20- 1
Ballscrew Damping Assembly
BALLSCREW DAMPER ASSEMBLY 5.20-1

SETUP DAMPING ASSEMBLY
1. Ensure that the pipe plug for bleed port, the orifice inside the damping housing, and the connector (which
includes the second orifice) have been removed from the damping assembly, see FIGURE 5.20- 1. By
removing these fittings, any trapped air or fluid will not interfere in the gap setting process.
2. Set the damping gap. This step establishes an equal gap between the front and rear outer spacers and the
inside of the damping housing.
A. Slide the damping housing towards the bottom shoulder of the ballscrew, until there no longer is any
movement. Using a depth micrometer, measure from the end of ballscrew to the outside of the housing.
Record measurement.
B. Slide the damping housing away the bottom shoulder towards the bottom ballscrew nut, until there no
longer any movement Using a depth micrometer, measure from the end of ballscrew to the outside of
the housing in the same position as in step A. Record measurement.
C. Subtract measurement obtained in step B from step A. Divide result by 2.
D. Move the housing towards the bottom shoulder of ballscrew by the result of step C.
3. Hand tighten damping assembly to column with six M16 hex head cap screws and washers. Align centerline of
ballscrew parallel to length of linear guide rail (parallel to guide edge) within ± 0.05 mm (0.002”). Tighten M16
hex head cap screws.
4. Add orifice inside the damping housing and the special connector with orifice. Leave pipe plug, for bleed port,
out at this time.
5. Using a large bucket, bleed hydraulic supply hose until no air is in the line. Turn off hydraulics, attach the hose
to the feed line and feed line to damping assembly.
6. Turn on hydraulics and run until all air is gone from bleed port on damping assembly. With pipe plug for bleed
port available, turn off hydraulics and insert plug while hydraulic fluid (from residual pressure) is still leaving
bleed port.
Note: If an axis runs jittery, this may be a result of trapped air in the damping assembly or a blocked
orifice.
5.20-2 BALLSCREW DAMPER ASSEMBLY

SECTION 5.30
WAY COVERS
TABLE OF CONTENTS
TITLE PAGE
WAY COVERS...............................................................................................................................................................1
MAINTENANCE ..................................................................................................................................................1
WAY COVERS
Telescoping way covers are designed to protect your ways and ballscrews from hot chips, dirt, oils, and coolants as
well as from accidental damage caused by tools and work pieces.
Note: Way covers are not designed to be load bearing and should not be walked on for both safety and
functionality reasons
MAINTENANCE
• Way covers should be extended only after they have been installed on machine ways.
• Walking on way covers is not recommended. Damage to guide shoes (which ride on top of linear guide rails of
ways) and overloading may occur, especially if covers are walked on during column travel.
• Way covers should be inspected daily for dents and/or other damage to outside surface.
• Daily cleaning of the covers to remove chips and other debris is recommended. Frequency of cleaning
depends on work environment.
• Lubrication is the key to longevity of the covers. Extend cover to the fully extended position and then apply
lubricant after cleaning. The lubricant can be sprayed on or wiped on with a clean cloth. Standard hydraulic
oil, 5W motor oil, WD40, or similar products are recommended.
• If the machine has been idle or if the cover appears dry, the machine should be moved to both extended
positions and the right and left side covers lubricated.
• Periodic inspection of the machine way surfaces is recommended. Covers should be moved to the
compressed position, and the large box should be disconnected. Before reconnecting, spray bottom side of
covers with oil.
****************************************************************************************
REGULAR LUBRICATION IS THE KEY TO THE LONGEVITY OF YOUR WAY COVERS.
DO NOT USE COMPRESSED AIR FOR CLEANING.
****************************************************************************************
WAY COVERS 5.30-1

SECTION 12.10
HEADSTOCK COMMON FEATURES
TABLE OF CONTENTS
TITLE PAGE
HEADSTOCK INTRODUCTION ....................................................................................................................................1
COMMON HEADSTOCK FEATURES ................................................................................................................2

HEADSTOCK INTRODUCTION
This manual covers headstocks that are equipped with either two speed or four speed transmissions. The headstock
utilizes an independent variable speed electric motor that drives only the spindle. Infinitely variable spindle speeds
allow cutting tools to be run at optimum for increased tool life and improved work finish. The headstock contains a
live spindle, (meaning that the spindle is capable of travel in and out of the headstock). The spindle is a
programmable axis, (that may be designated as the “W” or “Z” axis), with complete control functions providing
movement for drilling and tapping operations. At the time of this writing, these headstocks had the following
specifications (TABLE 12.10- 1):
Two Speed Four Speed
Spindle Diameter 130 MM (5.1”) 130 MM (5.1”) 155 MM (6.1”)
Spindle Travel 800 MM (31.5”) 1000 MM (39.4”) 1250 MM (49.2”)
Spindle Taper #50 ANSI B5.50 #50 ANSI B5.50 #50 ANSI B5.50
Spindle Range 1 Constant 10 - 260 10 – 69

Speed Torque
(RPM)
Constant HP 260 - 999 70 - 185
Range 2 Constant 10 - 1060 10 – 173

Torque
Constant HP 1060 - 4000 174 - 463
Range 3 Constant N/A 10 – 445

Torque
Constant HP 446 - 1190
Range 4 Constant N/A 10 - 1115

Torque
Constant HP 1116 - 3500
Spindle S1-100 30 KW (40 HP) 30 KW (40 HP) 37 KW (50 HP)

Power
S6-40 45 KW (60 HP) 45 KW (60 HP) 56 KW (75 HP)
TABLE 12.10- 1
Spindle Specifications
HEADSTOCK – COMMON 12.10-1

COMMON HEADSTOCK FEATURES
The spindle is a precision ground nitrided forging made to hold ANSI B5.50, No. 50 taper, “V” flange tools. The
spindle rotates the tool (or attachment) which can perform a variety of cutting operations. The tool is held in the
spindle by a tool clamping system (drawbar). The power operated collet type tool retention and ejection system is
controlled by the hydraulically actuated drawbar. Collet fingers (which are available in various types to accept
different tool holder retention knobs) slide forward from the guide bushing to expand and except or release a tool
holder during a tool change cycle. Tool pull-in force ranges from 18,682 to 25,000 N (4200 to 5620 lb-force). Tool
changing can be accomplished via a program command which will do an automatic tool change to an optional tool
matrix. Manual tool changes can be performed using the selector switch located on the hand held pendant.
The spindle is extended or retracted by means of an electric servo motor. The motor transfers rotation to the
ballscrew using motor manufacturer dependent sprockets and a belt. The ballscrew, whose ballnut is in support on
the thrust bracket, rotates inside the rear housing (ram guide). The thrust bracket holds the rear spindle bearings and
moves linearly, guided by preloaded roller bearings that ride on linear ways. As the motor rotates the ballscrew, the
thrust bracket runs the spindle back and forth via the linear ways. The spindle is thus supported over its full range of
travel.
The headstock is mounted to an upright column (Y-axis). The column has a pair of linear guide ways, with each way
consisting of a guide rail (mounted to the column) and two runner blocks (trucks). The headstock attaches to the four
runner blocks of the linear ways. There are two spacers used to adjust the orientation of the headstock (spindle axis)
relative to the Y-axis. Wedge clamps are used to pull the headstock tight against the spacer and guide edge of the
runner blocks.
12.10-2 HEADSTOCK – COMMON

SECTION 12.20
2 SPEED HEADSTOCK
TABLE OF CONTENTS
TITLE PAGE
TWO SPEED HEADSTOCK FEATURES ......................................................................................................................1
TWO SPEED TRANSMISSION .....................................................................................................................................7
SHIFTER SOLENOID REPLACEMENT..............................................................................................................8
TWO SPEED GEARBOX LUBRICATION ...........................................................................................................9
REMOVING THE TWO SPEED HEADSTOCK SPINDLE CARTRIDGE .....................................................................10

TWO SPEED HEADSTOCK FEATURES
The two speed headstock (FIGURE 12.20- 1) is equipped with a ZF-DUOPLAN® two speed gearbox that transfers
the power from an electric drive motor to the spindle. The gearbox drives an output gear through an idler gear to a
bull gear, which is keyed and secured with a locknut onto the spindle sleeve. This precision spindle sleeve is
mounted in a set of four ball bearings inside the spindle cartridge. Two in the front of the spindle cartridge and two in
the back near the bull gear. The spindle cartridge is assembled to the cast iron headstock housing, providing the
spindle sleeve support. In the spindle sleeve are two drive keys, which are fixed in the sleeve by cap screws. They
protrude into the key ways located down the sides of the spindle. This allows the spindle to move in and out of the
headstock while the drive keys maintain contact with the spindle. ZF-DUOPLAN® = Trademark of ZF Industrial
Drives
The gearbox is lubricated with oil from the main hydraulic reservoir. A scavenger pump returns oil back to the
hydraulic unit. Lubrication to the rest of the headstock gears and bearings is supplied by a Vogel Lube System with
oil from the main hydraulic reservoir which also lubricates the linear ways and ballscrews.
Spindle Drive
Motor Headstock Services
Two-Speed Panel
Gearbox
Use Cap
Screw for
Manual
Extend/
Retract of
Spindle Spindle
Positioning Motor
(Fanuc Shown)
Spindle
Rear
Housing
FIGURE 12.20- 1
Two-Speed Headstock Assembly
HEADSTOCK – 2 SPEED 12.20-1

Output Gear Idler Gear Two Speed
Gearbox Thrust
Bracket
Spindle
Spindle
Sleeve
Cartridge
Bull Gear Spindle Drive Keys Rear Spindle

Spindle Sleeve
Bearings
Bearings
FIGURE 12.20- 2
Two-Speed Headstock Cross Section
Motor Drive
Cover
Motor Gear
Air/Oil
Spray
Nozzle
Pinion
Cover Idler Gear
Idler Gear
Spindle Shaft Front
Sleeve Bearing Lube
Spindle Headstock Housing Shown with

Motor Drive Cover Removed
Spindle Grease Fittings
Cap (SHC32 grease)
Spindle Cartridge
FIGURE 12.20- 3
Two Speed Headstock Front Housing
12.20-2 HEADSTOCK – 2 SPEED

Y-axis Ballscrew Nut
Mounting Surface
Spacer and
Wedge Clamp
as Shown
Below
Runner Block
Lube Lines
Headstock Gearbox Lube
Services Panel Return Hose Spindle
(Not Shown)
Spindle
Cartridge
Y-Axis Linear
Encoder Reader
Head Bracket
Mounting Surface
Column
Wedge
Spacer Clamp
Y-Axis Linear
Encoder Reader
Head Bracket
Runner Block
View from Bottom of Headstock (Truck)
Looking towards Top of Column
FIGURE 12.20- 4
Two Speed Headstock Column Attachment Surface

Spindle Cartridge Assembly
Spindle
Cartridge
Spindle Spindle Sleeve
Bull Gear
Thrust Cartridge
Cartridge
Thrust Cartridge Left and

Bull Gear Locknut Right Covers
Spindle Key Cover
Drive Key
Spindle Sleeve
Spindle Cap Front Bearing RTD Bearing Lube Line

Connector Fitting Tapped Holes
Spindle Key
FIGURE 12.20- 5
Two Speed Headstock Spindle Cartridge Assembly

Bottom View from Front Looking to Rear
Linear Rail
Spindle (Attaches to Rear Housing)
Runner Block
(1 of 4)
Linear Rail
(Attaches to Thrust Bracket
Rear (Attaches to Runner Blocks)
Housing)
Thrust Cartridge Covers

(Left and Right)
Runner Blocks and W-Axis

Ballscrew Lube Supply
Proximity Switch
Bracket
Coolant through Hydraulic Supply

Spindle Supply (Drawbar Unclamp)
Drawbar Unclamp
Proximity Switch
Drawbar Clamp
Proximity Switch
Spindle Orientation
(Bero) Switch
Bottom View from Rear Looking to Front
FIGURE 12.20- 6
Two Speed Headstock, Rear Housing Bottom View

Lube Metering Unit
For Front and Rear Spindle Bearings,
and Idler Gear Shaft Bearings
Headstock Lube
Pressure Switch
Headstock Lube Air
Pressure Switch
Gearbox Lube
Hydraulic Motor
Scavenger Pump
Profibus
Lube Distributors
for Gear Mesh
and Spindle OD
Spray Nozzles
Headstock
Gearbox Lube
Lube Enable
Pressure Gauge
Valve
Drawbar Unclamp
Pressure Gauge
Work Light Connections from Utility

Connector Carrier to Thrust Bracket
Drawbar Unclamp
Directional Control
Valve and Pressure
Reducing and Flow Spindle Orientation
Control Valves for Connector
Gearbox Lube
FIGURE 12.20- 7
Two Speed Headstock Service Panel

TWO SPEED TRANSMISSION
The transmission or “gearbox” as it is often referred to, used for the two speed headstock is purchased complete from
ZF Industries, Inc. Gearbox is type 2K300 with bearing on shifter fork, modified main housing with back spot faced
mounting holes and includes an adapter plate for Siemens 1PH7163 motor. Gearbox specifications include:
• Motor balancing type is full key, where the motor shaft is balanced with a fitted key, the hub without.
• Gearbox interface is closed with hub, hub bearing and radial shaft seal.
• Gear box type is for motor frame of h =160 mm (FIGURE 12.20- 8) and gear ratio of i = 4.00
• Output bearings are angular-contact ball bearings.
• Gearbox output type is with output flange of outside diameter = 130 mm.
• Installation position type is B5 (turned around longitudinal axis).
• Motor shaft diameter, d = 55 mm (FIGURE 12.20- 8).
• Torsional backlash on gearbox output is type “reduced backlash”, max. 20 arc/min.
The ZF transmission is a two-speed single planetary gearbox with electric shift. It was developed to meet strict
machine tool needs with respect to high running smoothness and low-noise operation. In contrast to conventional
gearboxes with spur gear trains, this planetary gearbox has the distinct advantage of allowing an extremely compact
and space-saving design since the power is split between 4 or 5 planet gears. Additionally, four simultaneously-
meshing planet gears with helical gearing assure low-noise operation at high rpm. See vendor manual on your CD
Shifter Solenoid Motor Adapter Plate Motor Frame Type
Spindle Motor
Output Flange
Spindle Gearbox Lube In

Headstock Gearbox
Housing
FIGURE 12.20- 8
Two Speed Gearbox

SHIFTER SOLENOID REPLACEMENT
For shifting solenoid faults, start by checking electrical connections. If there is a fault in the solenoid, the solenoid will
have to be replaced. The shift unit is maintenance free and does not contain adjustable components. Moving the
shift unit along the gearbox adjusts the shift forks. Re-adjust the shift fork position after renewing the shifter unit.
TO REMOVE THE SHIFTER SOLENOID:
1. Remove the electrical connections.
2. Remove the four socket head cap screws on adapter plate.
3. Lift and remove the solenoid with adapter plate.
TO INSTALL THE SHIFTER SOLENOID:
1. The sliding sleeve must be at the stop position for first gear.
2. Insert selector shaft into sliding sleeve and place the shift unit in the correct position on the gearbox housing.
3. Ensure the pin in the sliding sleeve engages in the recess in the selector shaft. To do this:
A. Move shift unit (don’t force) in oval mounting bolt holes toward gearbox output until it reaches the stop.
B. Move shift unit away from gearbox output approximately 0.5 ± 0.01 mm, secure shift unit in position.
C. Check the setting and adjust as necessary. See Sliding Sleeve Setting below.
D. Hook up electrical connections.
E. Check the unit by performing a test shift.
SLIDING SLEEVE SETTING
This check can only be performed with the gearbox removed from the motor.
1. Engage 2nd gear (1:1).
2. Measure the distance between the housing mating surface and the sliding sleeve on each of the segments
(FIGURE 12.20- 9; dimension “X”). The lower measured value must be equivalent to the desired value.
Reference dimension for gearbox type 2K300: 49.7 mm to 50.5 mm.
3. If the reference dimension is not as specified, check and adjust the shift unit as explained above.

Solenoid
Adapter Plate
Selector Shaft
Shift Fork
Sliding Sleeve
X
FIGURE 12.20- 9
ZF Gearbox Shifter Mechanism
TWO SPEED GEARBOX LUBRICATION
Lubrication for the ZF gearbox can be accomplished in a variety of ways, but in this application, recirculating oil is
used. DTE 26 from the main hydraulic unit is used as the lubricant. The incoming oil provides hydraulic pressure for
drawbar unclamp or lubrication of the gearbox. The incoming hydraulic oil, designated “hyd pressure” in FIGURE
12.20- 7, is routed to a manifold on the device panel. A directional control valve routes the oil to the drawbar during
tool unclamp cycle, otherwise the oil is routed through a hydraulic motor/pump set, before it is piped to the gearbox.
See “Lubrication System Setup” section for setting of pressure reducing and flow control valves within the valve stack.
The incoming oil turns the motor, which runs the pump that removes the oil from the gearbox. A proximity switch is
used to monitor the rotation of the motor/pump to be sure that it is working (FIGURE 12.20- 10). The lube return
connection used is designated as CONNECTION H (M42X1.5 threads) and the input connection is designated as
CONNECTION I (M22X1.5 threads) on the ZF gearbox.

Lube Return
(Opposite Side from Lube Input) Proximity Switch
See FIGURE 12.20- 4
Hydraulic
Lube Input Motor/Pump Set
Pump Mounted on Headstock Device

Panel (See FIGURE 12.20- 7)
Lube Return
FIGURE 12.20- 10
Two Speed Gearbox Lubrication
REMOVING THE TWO SPEED HEADSTOCK SPINDLE CARTRIDGE
The two speed headstock spindle cartridge is a complete assembly whose major components consists of the
cartridge, spindle sleeve, spindle and thrust cartridge (FIGURE 12.20- 5). Within the spindle is the tool clamping
system. A number of precision fit spacers in both the cartridge and thrust cartridge provide the proper bearing
preload. The spindle sleeve, which includes front and rear spindle bushings, is balanced as an in process assembly
along with keys, bull gear and the inner front bearing spacer (part of a matched set inner and outer spacer).
Note: Disassembly of the spindle cartridge in the field is not recommended.
If there is a need to remove the spindle cartridge, be sure to review your machine specific prints before disassembling
any components. Improper disassembly or handling can cause damage to the machine components. The following
procedure is for removing the spindle cartridge, including the tool clamping system (gripper assembly, drawbar, piston
cylinder, and rotary union) as a complete unit.
1. Remove ram guide guard and bottom headstock guard.
2. Ensure that drawbar has been clamped. This allows hydraulic pressure to go to tank.
3. Disconnect hydraulic and coolant hoses from drawbar rotary union.
4. Disconnect cables for clamp and unclamp proximity switches, and for spindle orientation switch (FIGURE
12.20- 6).
5. Disconnect both of the thrust cartridge lube lines (FIGURE 12.20- 11).

Thrust Cartridge Lube Lines
FIGURE 12.20- 11
Bottom View of Thrust Bracket
6. Remove (clamp/unclamp) switch bracket by taking out six M6X16 socket head screws. The three switches can
be left in the bracket, be careful not to hit the end of switches during bracket removal.
7. Remove twelve M10X35 socket head screws to release thrust cartridge from thrust bracket.
8. Two of the six tapped holes used to fasten the switch bracket to the thrust bracket are full thread. The fully
tapped holes are shown in (FIGURE 12.20- 12). Use two M6 full thread screws minimum 55mm long, inserted
into these tapped holes to push the thrust cartridge out of pilot bore in the thrust bracket.
Fully
Threaded
Holes
FIGURE 12.20- 12
Rear View of Thrust Bracket

9. Reposition spindle so front of cartridge is approximately 150 mm (6”) from end of spindle sleeve (FIGURE
12.20- 13). This will balance the spindle cartridge for easier lifting.
150 mm
FIGURE 12.20- 13
Position of Spindle in Preparation of Spindle Cartridge Removal (Shown Removed from Headstock)
10. Remove the six M10X16 button head screws from one of the spindle drive key covers. Leave the drive key in
the keyway. Place a M10 lock washer between the key and the spindle key cover and replace the screws to
drive the key into the spindle keyway, locking the spindle in position.
11. Remove cover on bottom of headstock (front housing). This will provide access to front bearing RTD cable
and four spindle sleeve bearing lube line connections.
12. Disconnect cable to front bearing RTD. Remove four spindle sleeve bearing lube lines. Unscrew Vogel socket
unions (requires M8 wrench) which connect the lube lines to the rear cartridge flange (FIGURE 12.20- 5).
13. Remove twelve M12X70 socket head screws on the front flange of the spindle cartridge.
14. Support spindle cartridge with a nylon strap attached to a crane before proceeding with the next steps.
15. Insert two M12X50 flat point setscrews into tapped holes in cartridge flange (FIGURE 12.20- 14). After
setscrews make contact with housing, turn in equally to push spindle cartridge out of the headstock housing.
After 20 mm, the spindle cartridge will be off the pilot OD and fall onto the clearance OD.
16. Move the spindle cartridge forward 100 mm out of the headstock housing bore. You will need to reposition the
nylon sling behind the cartridge flange to achieve the proper balancing point.
17. After the sling is repositioned, move the spindle cartridge out of the headstock cavity. Make sure not to bump
the exposed spindle surface or the drawbar rotary union.
18. Place the spindle cartridge in large wooden vee blocks, on the front and rear ends of the cartridge (FIGURE
12.20- 5). Make sure to protect the spindle’s precision ground outer diameter from any possible damage.
M12 Tapped
Holes Here &
180°. Used to
Push Spindle
Cartridge Out
of Headstock
Housing.
FIGURE 12.20- 14
View of Front of Spindle Cartridge

SECTION 12.30
4 SPEED HEADSTOCK
TABLE OF CONTENTS
TITLE PAGE
FOUR SPEED HEADSTOCK FEATURES ....................................................................................................................1
FOUR SPEED TRANSMISSION....................................................................................................................................7
SETTING THE SHIFTER CYLINDER PROXIMITY SWITCHES ......................................................................12
HYDRA-RIB BEARING .....................................................................................................................................13
REMOVING THE FOUR SPEED HEADSTOCK SPINDLE..........................................................................................14
REMOVING THE FOUR SPEED HEADSTOCK SPINDLE SLEEVE...........................................................................16

FOUR SPEED HEADSTOCK FEATURES
The four speed headstock consists of a series of precision bearings and hardened and ground helical gears, located
inside the headstock casting (gear housing), FIGURE 12.30- 1. Two internal-tooth clutches use electro-hydraulic
shifting to provide the four speed ranges. The transmission input shaft is connected to the electric spindle drive motor
output shaft using a motor coupling. A bull gear, which is keyed, threaded and locked onto a spindle sleeve, receives
the power from the output gear. The front support for the spindle sleeve is cast into the gear housing, (unlike the two
speed headstock, which has a separate spindle cartridge that provides the support and mounts to the headstock front
housing).
The spindle sleeve is mounted in two bearings. In the front of the spindle sleeve is a roller bearing. In the rear of the
spindle sleeve is a Hydra-Rib bearing. The Hydra-Rib bearing allows for variable spindle bearing preload pressure.
The bearing preload pressure is controlled by a hydraulic line plumbed directly to the bearing via a proportional
pressure reducing valve which is servo controlled. As the spindle RPM’s increase or decrease, the controls will
decrease or increase bearing preload respectively. The Hydra-Rib bearing is used to insure spindle accuracy and
bearing life.
The gear lines are lubricated by a set of six top mounted spray nozzles that receive oil from the head lube line. The
front bearings in gear lines “B”, “C”, “D”, & “E”, and the front and rear spindle sleeve bearings receive lube from the
head lube line. The head lube line also supplies a resistance fitting located in the top of sealing ring (FIGURE 12.30-
19). This fitting provides a medium slow flow of oil to the outside of the spindle in the area just aft of the spindle
sleeve. The head lube line oil is supplied by a separate chiller unit with a scavenger pump returning the oil to the
chiller. The hydraulic pressure required for the shifter hydraulic cylinders and for the Hydra-Rib bearing, as well as,
the lubrication oil supplied to the lube system for the ways and ballscrews is supplied from the main hydraulic
reservoir.
“E” Gear Line Motor

Coupling
“D” Gear Line

Gear Shift
Hydraulic
Cylinders
“C” Gear Line
“B” Gear Line Clutch Gears
Bearing Pre-Load
Hydraulic Supply
Bull Gear on Spindle Sleeve Spindle Drive Key & Hydra-Rib Bearing
Cover Location
FIGURE 12.30- 1
Four-Speed Transmission
Shown without Spindle and Shifter Shafts/Forks

Front Cover Gear Shift Cylinders Access Cover
Spindle (Drive)
Rotation Motor
Spindle Positioning Motor

(Fanuc Motor Shown)
Gear Housing Rear Housing
Rear Cover
Auto Coupler Chilled Oil (DTE 24)
Adapter Scavenger Pump & Motor
(Option)
FIGURE 12.30- 2
Four Speed Headstock Assembly (Shown with Optional Auto Coupler Adapter)
Clutch Gears Motor Coupling
Thrust Bracket
(Shown Extended and Retracted)
Spindle Sleeve
Rear of Spindle
Not Shown
Spindle Sleeve Front Spindle Sleeve Rear Bearing (Hydrostatic) Supported in
Bearing Thrust Bracket
FIGURE 12.30- 3
Four Speed Headstock Cross Section (Shown without Shift Cylinders, Shafts and Shift Forks)

Gear Shaft
Part Probe Covers
(Optional)
E
C
Gear Shaft
Covers
Spindle Cover
Gear Housing with Optional Auto

Coupler
Spindle Sleeve Spindle
FIGURE 12.30- 4
Four Speed Headstock Gear Housing

Y-axis Ballscrew Nut
Mounting Surface
Spacer and
Wedge Clamp
as Shown
Below
Runner Block
Lube Lines
Runner Block
Lube Lines
Auto Coupler
Adapter
(Option)
Y-Axis Linear
Encoder Reader
Head Bracket
Mounting Surface
Wedge
Spacer Clamp
Runner Block
(Truck)
FIGURE 12.30- 5
Four Speed Headstock Column Attachment Surface

Keyway for Spindle Key Rear Spindle Bearings
(Spindle Rotation)
Locknut
Drawbar Cylinder Rotary Union

Spindle Sensor Target Spacer
Hydra-Rib
Bearing
Gripper
Fingers
Spindle Drive
Key and Cover
Sleeve Retainer
Spindle
Sleeve
FIGURE 12.30- 6
Four Speed Headstock Spindle and Spindle Sleeve

Bottom View from Rear Looking to Front
Proximity Switch
Drawbar Clamped Bracket
Proximity Switch
Drawbar Unclamped
Proximity Switch
Coolant through
Spindle Supply Hydraulic Supply
(Drawbar Unclamp)
Spindle Orientation
(Bero) Switch
Runner Blocks, Spindle-Axis

Ballscrew, and Rear Spindle
Bearings Lube Supply
Spindle
Orientation
(Bero)
Lube Air Supply Switch
Rear Spindle
Bearings
Air/Oil Mixing
Blocks
Spindle
Rear Spindle Bearing

Thermocouple
Thrust Cartridge
Covers – Left & Right
Bottom View of Front of Thrust Bracket
FIGURE 12.30- 7
Four Speed Headstock Rear Housing (Bottom View)

Headstock Chilled Oil (DTE 24)
Hydra Rib Bearing Pressure Switch and Gauge
Pre-Load Pressure
Gear Shift Valves Gauge and
See FIGURE Proportional Valve
12.30- 10
Hydraulic Pressure
Profibus Headstock
Gauge
Lube
(DTE 26)
Pressure
Switch
Pressure Reducing
Valve
Work Light
Connector
Spindle Orientation
Connector
Drawbar Unclamp
Directional Control Headstock Lube
Valve Chilled Oil Return from Air Pressure
Scavenger Pump Switch
Connections from
Utility Carrier to
Thrust Bracket
FIGURE 12.30- 8
Four Speed Headstock Service Panel
FOUR SPEED TRANSMISSION
The four speed transmission, located within the gear housing, transfers the power from the electric spindle motor to
the spindle sleeve. The drive keys within the spindle sleeve rotate the spindle. Four gear lines are used to drive a
bull gear that is keyed to the spindle sleeve and locked into position with a threaded locknut. The gear lines are
identified as “B”, “C”, “D” and “E” as shown in FIGURE 12.30- 9. Each gear line consists of a shaft supported by
precision bearings, with spacers for locating the hardened and ground helical gears on the shaft. The “B” and “D”
lines each have a clutch gear on the shaft. A hydraulic cylinder coupled to a shifter shaft, with shift fork pinned to the
shaft, is used to move the clutch gear.

Gear Shafts
See FIGURE 12.30- 10 for Detail of
Front Bearing
this Area Showing Proximity Switches
Lube Line
“E” Gear Line
“D” Gear Line
Shift Forks
“C” Gear Line
Hydraulic Lines for

Optional Auto Coupler
“B” Gear Line Engage/Disengage
Clutch Gear
Spindle
Spindle Bearing Spindle Outer

RTD Access Spindle Sleeve Diameter Lube Line
Cover Bearings Lube Line
FIGURE 12.30- 9
Four Speed Transmission
Two magnetic proximity switches (FIGURE 12.30- 10) are mounted on each hydraulic cylinder to monitor cylinder
piston position. A pair of directional control valves, mounted on a manifold located on the headstock device panel
(FIGURE 12.30- 8), control the shifting. When solenoid DI-Y7 is energized, switch DI-S7 is set to output a “1”. The
remaining solenoids and switches follow this same numbering scheme. A procedure for setting the switches is
provided later is this section.

Motor Coupling
“D” Line High Range

Proximity Switch
(DI-S7)
4B
4A
Coupling
(Cylinder
Rod to Shift “D” Line Low Range
Shaft) Proximity Switch
(DI-S8) Aluminum Spacer
“B” Line High Range

Proximity Switch
(DI-S9)
Coupling
(Cylinder
Rod to Shift
Shaft)
“B” Line Low

Range Proximity
Switch (DI-S10)
4A 4B
TANK
(DI-Y8) (DI-Y7)
(DI-Y10) (DI-Y9) 3A 3B
PRESSURE
Valves on Headstock Device Panel View of Shift Cylinders from Bottom

(See FIGURE 12.30- 8) Looking towards Top of Headstock
(Proximity Switches not Shown)
FIGURE 12.30- 10
Four Speed Transmission Shift Cylinders and Valves

FIGURE 12.30- 11 shows that the two cylinders are piped differently. On the “D” line shifter, the “A” port from device
panel manifold is routed to the “4B” port on the cylinder. The “B” line shifter has the “A” port from device panel
manifold routed to the “3A” port on the cylinder. The hydraulic flow from the manifold to the cylinder ports is restricted
with .040” orifices. The orifices are located within the male connectors that tread into the reducers of the manifold
ports. Restricting flow slows the speed of the extend/retract cylinders, preventing excessive shock on couplers and
clutch gears.
DI-S7 DI-S8
DI-S10 DI-S9
D Gear Line
Shift Cylinder
B Gear Line
0.040” Orifice Shift Cylinder
Typical
D-Line Low Range D-Line High Range B-Line Low Range B-Line High Range
DI-Y8 DI-Y7 DI-Y10 DI-Y9
FIGURE 12.30- 11
Four Speed Shift Cylinder Schematic
TABLE 12.30- 1 lists the solenoids that are energized during a given speed range with the corresponding output from
the proximity switches.
SPINDLE SPEED
SOLENOID SWITCH RANGE 1 RANGE 2 RANGE 3 RANGE 4
D LINE HIGH DI-Y7 DI-S7 0 1 0 1
D LINE LOW DI-Y8 DI-S8 1 0 1 0
B LINE HIGH DI-Y9 DI-S9 0 0 1 1
B LINE LOW DI-Y10 DI-S10 1 1 0 0
PROGRAMMING M-CODE M41 M42 M43 M44
TABLE 12.30- 1
Four Speed Headstock Shifting Input/Output

FIGURE 12.30- 12 shows the gear train for each of the four ranges. The arrows in this figure show the position of the
clutch gears for each of the four spindle speed ranges.
SPINDLE SPEED RANGE 1 SPINDLE SPEED RANGE 2
MOTOR INPUT SHAFT

MOTOR INPUT SHAFT
D-High
D-Low
B-Low B-Low
MOTOR INPUT SHAFT MOTOR INPUT SHAFT
D-Low D-High
OUTPUT TO SPINDLE SLEEVE
B-High B-High
SPINDLE SPEED RANGE 3 SPINDLE SPEED RANGE 4
FIGURE 12.30- 12
Four Speed Headstock Gear Train Speed Ranges

SETTING THE SHIFTER CYLINDER PROXIMITY SWITCHES
The two shifter cylinders (for four speed headstock) each have a pair of magnetic proximity switches (FIGURE 12.30-
10). The switches are positioned to change state only at the very end of the cylinder stroke. This ensures that the
machine control receives the switch “high” digital input only when the shifter is fully engaged.
The following procedure only needs to be performed in the event of a repair or part replacement. If the shifting
cylinder proximity switches require set-up, the procedure should only be performed by qualified personnel.
The following procedure is performed with the gearbox cover removed, the control active and machine hydraulics
turned off. The cylinder part number includes the proximity switches, brackets and flexible tubes. A replacement
proximity switch is available, contact MAG parts department for the switch required for your machine. Use FIGURE
12.30- 10 for proximity switch designations.
1. In order to set the proximity switches for a shift cylinder, the cylinders must be manually positioned in the fully
extended and fully retracted positions. By opening the hydraulic supply lines at the cylinder connections
(FIGURE 12.30- 10), any residual pressure will be released. This allows the cylinders to be manually moved.
2. For “B” line shifter, lower cylinder within the gearbox, manually retract the cylinder. You may have to rock the
spindle motor coupling to ensure that “B” line clutch gear spline is fully engaged with the rear mating gear.
3. Set the “B” Line High Range Proximity Switch (DI-S9).
A. With cylinder fully retracted and proximity switch mounted on top of cylinder, slide switch from the
aluminum spacer towards the rod end of cylinder. Position switch just at the point where the RED light
comes on.
B. After the switch is set, manually move the shifter into and out of gear. Ensure that the RED light goes
on only when the shifter is within the last 2 mm of travel.
4. For “B” line shifter, lower cylinder within the gearbox, manually extend the cylinder. You may have to rock the
spindle motor coupling to ensure that “B” line clutch gear spline is fully engaged with the front mating gear.
5. Set the “B” Line Low Range Proximity Switch (DI-S10).
A. With cylinder fully extended and proximity switch mounted on bottom of cylinder, slide switch from the
rod end towards the aluminum spacer. Position switch just at the point where the RED light comes on.
6. For “D” line shifter, upper cylinder within the gearbox, manually retract the cylinder. You may have to rock the
spindle motor coupling to ensure that “D” line clutch gear spline is fully engaged with the rear mating gear.
7. Set the “D” Line Low Range Proximity Switch (DI-S8).
A. With cylinder fully retracted and proximity switch mounted on bottom of cylinder, slide switch from the
aluminum spacer towards the rod end of cylinder. Position switch just at the point where the RED light
comes on.
8. For “D” line shifter, upper cylinder within the gearbox, manually extend the cylinder. You may have to rock the
spindle motor coupling to ensure that “D” line clutch gear spline is fully engaged with the front mating gear.
9. Set the “D” Line High Range Proximity Switch (DI-S7).
A. With cylinder fully extended and proximity switch mounted on top of cylinder, slide switch from the rod
end towards the aluminum spacer. Position switch just at the point where the RED light comes on.

HYDRA-RIB BEARING
In the four speed headstock a special bearing is used that automatically adjusts bearing preload to prevent
overheating and maintain spindle accuracy and bearing life. Hydraulic pressure controls bearing preload in the
Timken Hydra-Rib bearing. This bearing allows changes of preload in the spindle system to obtain an optimum
preload setting. Once this optimum setting is obtained, the preload remains constant and is not affected by changes
in speed and load, which will produce temperature and thermal growth variations. Should cutting requirements
change, a new optimum preload is obtained by adjusting the hydraulic pressure supplied to the bearing. The
pressure is modulated by a proportional pressure reducing valve which is electronically servo controlled. A pressure
transducer is used to help maintain precise control. If this bearing is ever in need of replacement, please contact the
MAG service department.
Inlet Pressure Port
Snap Ring
Seal Retainer
Rib Chamber O-Ring
Seal
Rib
Roller
Locking Pin Cone Cup
FIGURE 12.30- 13
Timken Hydra-Rib Bearing
The Hydra-Rib bearing is mounted in the mid section of the gear housing and opposed by a single row tapered roller
bearing in the extended spindle support. The conventional tapered roller bearing has a fixed rib on the inner race or
“cone” in contact with the large end of the rollers. In the Hydra-Rib bearing, the rib is adjacent to the outer race and is
movable. See FIGURE 12.30- 13 for the proper Hydra-Rib bearing nomenclature. A pressure supply line is
connected to the inlet pressure port (FIGURE 12.30- 1) to pressurize the rib chamber, which is formed by the seal
retainer and seal. Oil pressure in the chamber transfers a force to the rib and from the rib to the rollers, thus
preloading the spindle bearings.
In the working mode, a gap exists between the rib and the cup shoulder. As thermal conditions in the bearing vary,
tending to increase or decrease the bearing preload, the floating rib will back off or advance to maintain a constant
preload force at all times. The pressure is changed during the operating cycle to handle a change in spindle load or
speed, thus increasing or decreasing the bearing preload as required. At the time of this writing, Hydra-Rib bearing
pressure is set at 8.3 bar (120 psi) for spindle speeds from 0-1200 rpm. The pressure decreases linearly to 3.4 bar
(50 psi) from 1200 to 2000 rpm. A constant 3.4 bar (50 psi) is held from 2000 to 3500 rpm. Always check your
specific machine engineering prints for exact pressures.

REMOVING THE FOUR SPEED HEADSTOCK SPINDLE
The spindle and spindle sleeve are part of a matched set of components identified as Sleeve Spindle Process
Assembly. There is a set of bushings inside the spindle sleeve that are machined to correspond to the exact
measured outside diameter of the spindle. For this reason, spindles are not interchangeable with spindle sleeves.
If there is a need to remove the spindle, be sure to review your machine specific prints before disassembling any
components. Improper disassembly or handling can cause damage to the machine components. This procedure is
for removing the spindle, including the tool clamping system (gripper assembly, drawbar, piston cylinder, and rotary
union).
1. Position the spindle at the “0” position or completely retracted into the headstock.
2. Remove the lower front and rear guard covers and pulley cover.
3. Ensure that drawbar has been clamped. This allows hydraulic pressure to go to tank.
4. Disconnect hydraulic and coolant hoses from drawbar rotary union.
Spindle Key
M5X0.8
Threaded Holes
Keyway Wiper & Spring

Wiper-Scraper
Adapter Key
FIGURE 12.30- 14
Removal of Keys and Wipers
5. Remove the two spindle keys. Note location of the keys, they will need to be installed in the same location on
reassembly (FIGURE 12.30- 14).
6. Remove the two adapter keys, which hold in the brass wiper-scraper. Note location of the keys, they will need
to be installed in the same location on reassembly (FIGURE 12.30- 14).
7. There are (2) M5X0.8 tapped holes in the brass wiper. Thread two screws in these tapped holes long enough
to pull the wiper-scraper from the spindle (FIGURE 12.30- 14). Pull equally on the screws to prevent the wiper-
scraper from jamming on the spindle.
8. Remove the two spring loaded keyway wipers (FIGURE 12.30- 14).
9. Loosen the two M5X20 flat head cap screws on the front retainer of the rubber spindle wiper (FIGURE 12.30-
15). Once these screws are loose, move the spindle forward so that the spindle wiper assembly can be
removed. Use M12 Allen wrench in socket head screw located in rear of ballscrew shaft to rotate ballscrew
and move spindle forward. Make sure to mark the spindle wiper assembly, so that the tabs will be inserted into
the same spindle keyway when reassembled.

FIGURE 12.30- 15
Spindle Wiper & Retainer Assembly
10. Remove the front cover (FIGURE 12.30- 2) from the gear housing. Note: the front cover has a bead of
Hylomar Gasket and Jointing Compound, applied at cover assembly. Before reassembly, this material must be
removed and a new bead applied. The front cover is being removed in order to access the spindle sleeve.
11. In the spindle sleeve are two drive key cover plates (FIGURE 12.30- 6). Remove the four corner M10X16
button head screws from the spindle key cover. Remove one of the two center screws and thread in a slide
hammer. Pull out the spindle key cover and spindle key as one unit. Keep this unit together and make sure to
note location and position. They must be reinserted into the spindle sleeve is the same location and position
upon reassembly.
12. Remove M6X8 nylok setscrew, located between the two mixing blocks, under thrust bracket (FIGURE 12.30-
16). Note: nylok setscrew is not reusable. Loosen M6X10 dog point setscrew which is beneath setscrew. This
dog point is used to orient spindle bearing spacer to receive lube from mixer blocks.
13. Remove twelve M10X25 socket heads screws that hold on the right and left thrust cartridge covers (FIGURE
12.30- 17). Note the orientation of slots in covers for reassembly. Once covers are removed, remove two
piece fitting spacer.
Setscrew and Dog Point

Location
FIGURE 12.30- 16
Spindle Bearing Spacer Lock Screw Location
14. Move the spindle so that it is at least 150 mm (6”) from face of spindle sleeve. Use the M10X1.5 threads (used
for spindle keys) to attach a metal bar across the front of the spindle. Place blocks between bar and spindle
sleeve. Use M12 Allen wrench in rear of ballscrew shaft to rotate ballscrew and move thrust bracket aft,
thereby, pulling spindle bearings from thrust bracket bore.

Note Orientation of
Right and Left Thrust Drain Slots in Covers
Cartridge Covers
FIGURE 12.30- 17
Thrust Cartridge Covers
15. Remove previous front of spindle setup. Install two eyebolts in M10X1.5 threads for the spindle keys. Place a
steel bar through the eyebolts and, by pulling on the bar; start to slide the spindle out of the spindle sleeve.
16. Continue to slide the spindle out of the spindle sleeve. The spindle should be supported with a flat nylon sling,
attached to a crane. Slide the spindle out of the spindle sleeve using the sling for support and balance. Do not
bump or pry the spindle side to side during withdrawal. Otherwise, damage could occur to the front and rear
spindle sleeve, precision ground bushings. Inspect these sleeve bushings after spindle removal.
17. Place the spindle in wooden vee blocks, using rust preventive paper between the spindle and wood. Make
sure to protect the spindle’s ground outer diameter from any possible damage.
REMOVING THE FOUR SPEED HEADSTOCK SPINDLE SLEEVE
In order to remove the spindle sleeve you must first remove the spindle. The spindle and spindle sleeve are part of a
matched set of components identified as Sleeve Spindle Process Assembly. There is a set of bushings inside the
spindle sleeve that are machined to correspond to the exact measured outside diameter of the spindle. For this
reason, spindle sleeves are not interchangeable with spindles. The spindle sleeve (with the matched set of
bushings); the bull gear, split spacer, key, setscrews & locknut; both sets of spindle drive keys & covers; the adapter
keys & rear retainer with spacers, and all the fasteners associated with these components are balanced as a
complete process assembly. If any of these components are removed, there exact location and orientation must be
recorded, so that at reassembly they are replaced as balanced. In addition, the Hydra-Rib bearing is precisely pre-
loaded during the headstock assembly process.
Note: Disassembly of the spindle cartridge in the field is not recommended.
If there is a need to remove the spindle sleeve, be sure to review your machine specific prints before disassembling
any components. Improper disassembly or handling can cause damage to the machine components. The following
procedure is for removing the spindle sleeve.
1. The front cover should already have been removed from the gear housing during spindle removal. Remove
the rear cover (FIGURE 12.30- 2) from the gear housing. Note: the front and rear covers have a bead of
Hylomar Gasket and Jointing Compound, (MAG part # A.1014.6403), applied at cover assembly. Before
reassembly, this material must be removed and a new bead applied.
2. Remove twelve M8X45 socket head screws from the spindle cover (FIGURE 12.30- 4). Remove the spindle
cover. There is a small O-ring near the bottom of the spindle cover and a large O-ring that fits on the spindle
cover OD.
3. Remove the spindle sleeve bearings lube lines (FIGURE 12.30- 9).

4. Remove cover by taking out two M6X10 button head screws (FIGURE 12.30- 18).
Hydraulic Lines for Optional Auto Coupler
Cover
Spacer
(Two
Pieces)
Sealing Ring
FIGURE 12.30- 18
Sealing Ring & Cover
5. Remove the spindle OD lube line (FIGURE 12.30- 19)
Resistance Fitting (CSA-00)
Spindle Outside
Diameter
FIGURE 12.30- 19
Spindle OD Lube Line
6. Support under side of sealing ring. Remove eight M8X45 socket head screws from flange of sealing ring.
Take out both pieces of spacer (FIGURE 12.30- 18). Slide sealing ring aft, to back of gear housing. Remove
sealing ring from gear housing cavity.

Spindle Sleeve Retainer
Seal Retainer
Rear Bearing
Inner Race
FIGURE 12.30- 20
Seal Retainer & Spindle Sleeve Retainer
7. Remove seal retainer from back of spindle sleeve retainer by taking out six M8X35 nylok socket head screws.
Remove the retainer and two piece spacer, (from the end of spindle sleeve), by taking out the remaining four
M8X35 nylok socket head screws (FIGURE 12.30- 20).
Split Spacers
beneath Gear Hub
FIGURE 12.30- 21
Bull Gear & Locknut
8. Remove wire from outside of bull gear locknut. Remove 3/8”-16X1/4” locking setscrews in three locations on
locknut. In location marked dog point, back out dog pt setscrew at least 6 mm. In other two locations, back out
3/8”-16X1/2” setscrews (FIGURE 12.30- 21). Turn off the locknut.
9. Pull the key out of the bull gear.
10. You must now separate the rear bearing inner race (FIGURE 12.30- 19) from the OD of the spindle sleeve.
Either push on the rear face of the spindle sleeve using a centrally located portable cylinder or use eyebolts in
the M20X2.5 threads located on front face of spindle sleeve to pull on the spindle sleeve. After enough force is
applied the inner race will “pop” loose. Remove inner race from spindle sleeve.
11. Remove the spindle sleeve from the gear housing. As you move the sleeve forward you will expose the split
spacers beneath the bull gear. Remove these spacers before continuing to move spindle sleeve from gear
housing.
12. When the end of the spindle sleeve is near the locknut, slide locknut off the spindle sleeve.
13. When the end of the spindle sleeve is near the bull gear, slide bull gear off spindle sleeve.
14. Place the spindle sleeve in wooden vee blocks, using rust preventive paper between the spindle sleeve and
wood.

SECTION 12.50
DRAWBAR
TABLE OF CONTENTS
TITLE PAGE
TOOL CLAMPING SYSTEM..........................................................................................................................................1
MOUNTING TOOL FOR THE GRIPPER ASSEMBLY........................................................................................2
FACTS TO REMEMBER WHEN WORKING WITH THE TOOL CLAMPING SYSTEM......................................2
REMOVING THE GRIPPER ASSEMBLY FROM THE DRAWBAR ....................................................................3
INSTALLING THE GRIPPER ASSEMBLY INTO THE SPINDLE........................................................................3
REMOVING THE TOOL CLAMPING SYSTEM (DRAWBAR) FROM THE SPINDLE.........................................4
INSTALLING THE TOOL CLAMPING SYSTEM (DRAWBAR) INTO THE SPINDLE .........................................5
TOOL CLAMPING SYSTEM TROUBLE SHOOTING GUIDE.............................................................................6
ADJUSTMENT PROCEDURE - TOOL CLAMPED/UNCLAMPED PROXIMITY SWITCHES ........................................7

TOOL CLAMPED – NORMALLY OPEN SWITCH ..............................................................................................7
TOOL UNCLAMPED – NORMALLY OPEN SWITCH .........................................................................................7

TOOL CLAMPING SYSTEM
The machines are equipped with a tool clamping system manufactured by OTT-JACOB Spanntechnik. The system
consists of an inside spindle drawbar and clamping springs, with an intensifying mechanism and piston built into a
cylinder outside of the spindle shaft. The nominal size of the tool interface is per SK-50 standards, which determines
the gripper configuration, as well as, the spindle inside contour. Gripper assemblies are available in a number of
styles that specifically accommodates steep taper tool standard DIN, ANSI and MAS retention knobs. The system
has central medium (coolant/air) transfer. Position indication (clamp/unclamp) is accomplished with a signal ring,
located on the piston cylinder. A dual-passage rotary union supplies the hydraulic fluid for unclamping of the power
drawbar and central coolant supply or cleaning of the tool interface with air. The rotary union is integrated behind the
cylinder. The drawbar length varies according to the length of the spindle. There is one length for the two speed
headstock and a longer length for the four speed headstock. On four speed headstocks, the same tool clamping
system is used for either a 130 mm or a 155 mm spindle diameter.
The tool clamping system mechanism works in the following manner, (FIGURE 12.50- 1). The tool is pulled into the
spindle taper by means of the gripper assembly, attached to the drawbar by the clamp adapter, and a Belleville spring
set. Within the working range, a nearly constant pull force is maintained. Safety is accomplished by a patented
wedge ring mechanism The clamping force on tool, due to force of intensifying mechanism, is 340% greater than
force of Belleville springs acting alone.
Note: If the hydraulic system would shut down, the tool will stay securely clamped.
Unclamping the tool is accomplished by means of hydraulic pressure working on a piston, which pushes a clamp
sleeve forward with push rods, and compresses the Belleville spring set, while it also unlocks the wedge-lock
mechanism. The forward movement of drawbar moves gripper assembly into a wider opening inside spindle and a
helical spring around top part of gripper assembly opens the gripping fingers and releases the tool. The front of the
gripper assembly contacts with the retention knob to eject the tool from spindle taper.
M45X1.5 External Thread Dual-passage Rotary Union

(Drawbar Assy to Spindle)
Belleville Spring Set
50 mm Wrench Flat Piston Cylinder &

Signal Ring
Spring Intensifier
Drawbar
Clamp Adapter
Gripper Assembly Drawbar Bushing and S-rings
(ANSI B.5.50 Shown) (added to drawbar assembly)
FIGURE 12.50- 1
Tool Clamping System Components
DRAWBAR 12.50-1
MOUNTING TOOL FOR THE GRIPPER ASSEMBLY
The gripper assembly consists of the gripper holder, socket head set screw, helical spring and four gripper fingers,
(FIGURE 12.50- 2). A mounting tool, MAG part # M.1301.5763 (OTT-JACOB #: 95.101.337.9.2), is available to
remove/install the gripper assembly. If the tool is not available, a large slotted screwdriver and 6 mm allen wrench
can be substituted. The slot machined in the front of the gripper holder is 2.38 mm (.094”) wide by 25.4 mm (1.0”)
long. Be sure to use the proper size screwdriver.
Setup
Dimension Grippers Helical Spring
Clamp Adapter
Socket Head
Gripper holder Set Screw
Mounting Tool
(M.1301.5763)
FIGURE 12.50- 2
Gripper Assembly and Adjustment Tool
FACTS TO REMEMBER WHEN WORKING WITH THE TOOL CLAMPING SYSTEM
• Run the spindle only when a tool is clamped in the taper with the drawbar. Failure to do this will cause the
back hydraulic seal to wear prematurely.
• The Belleville spring-pack is rated for check and/or replacement at 1-2 million cycles.
• The gripper fingers are matched sets and should not be mixed.
• The clamp force (pull-in-force) for ANSI & DIN gripper assemblies is 23000 N (5171 lb-force).
• The clamp force (pull-in-force) for MAS gripper assemblies is 23000 N (5171 lb-force).
• Hydraulic and coolant lines must be flexible and must not load the rotary union. The hydraulic pressure has to
be within the recommended range.
• The hydraulic pressure should not drop more than one bar (15 PSI) after being applied for 30 minutes.
• The series number of the rotary union is engraved into the outer diameter of the unit and this number as well
as the serial number should be recorded.
12.50-2 DRAWBAR
REMOVING THE GRIPPER ASSEMBLY FROM THE DRAWBAR
1. Remove tool from spindle and leave the drawbar in the unclamped position. Check the current setup
dimension by measuring from the front of the spindle to the front of the gripper holder. See mechanical prints
for proper setup dimension based on gripper type. Most machines are equipped with the ANSI B 5.50 – 78
tool standard.
2. Insert 6 mm Allen wrench into center of gripper holder, and loosen the setscrew by turning it CCW (viewed
from front of spindle) about two turns. If there is difficulty in loosening the setscrew, insert tool holder with
through hole (for coolant through spindle to tool) and clamp the drawbar. Insert the 6 mm Allen wrench
through tool holder and loosen the setscrew.
3. Once the setscrew is loose, unclamp the drawbar and remove tool holder.
4. Insert the mounting tool into the two holes in the front of the gripper holder. If mounting tool is not available
use screwdriver. Remove the gripper assembly by turning it CCW until it separates from the clamp adapter.
5. Pull the gripper assembly out the front of the spindle. If there is difficulty removing the gripper assembly, the
gripper holder is tapped to receive an 8 mm pin puller for easy removal from the spindle.
INSTALLING THE GRIPPER ASSEMBLY INTO THE SPINDLE
1. Place grease on outside of gripper assembly. Insert gripper assembly into front bore of spindle.
2. Insert a 4 mm diameter tube/rod through gripper assembly into the bore of the clamp adapter. If there is sag in
the drawbar shaft/clamp adapter, the rod will lift the shaft and aid in aligning external thread in clamp adapter
with internal thread in gripper assembly. Rotate the gripper assembly CW, (as viewed from front of spindle), to
start thread.
3. Once thread started, remove rod and insert mounting tool (or screwdriver) into front of gripper holder. Rotate
CW to tighten.
4. Measure from front of spindle to front of gripper holder, adjusting gripper holder position to match setup
dimension listed in your mechanical prints. After dimension is set, use the mounting tool to prevent gripper
holder from turning while the 6 mm tee handle allen wrench is used to lock it in place with socket head set
screw.
5. After approximately 100 clamp/unclamp cycles recheck gripper holder setup dimension. This is done with
drawbar unclamped.
6. Using a tool holder with coolant access, clamp the drawbar. Insert the 6 mm tee handle Allen wrench, and
retighten the socket head set screw with the drawbar clamped.
Drawbar for 2-Speed Headstock = 2112 mm (83”)
Drawbar for 4-Speed Headstock = 2947 mm (116”)
Shoulder that Contacts

Rear of Spindle
FIGURE 12.50- 3
Drawbar Length without Fingers (Shown in Tool Clamp and Unclamp Position)
DRAWBAR 12.50-3
REMOVING THE TOOL CLAMPING SYSTEM (DRAWBAR) FROM THE SPINDLE
The following procedure assumes that there is enough room behind the machine to allow for drawbar removal. For 2-
speed headstocks with (ANSI B5.50 or SK50 taper) and 800 mm spindle travel, the drawbar length is 2112 mm (83”).
For 4-speed headstocks with (ANSI B5.50 or SK50 taper) and 1000 or 1250 mm spindle travel, the drawbar length is
2947 mm (116”). This length is from front of clamp adapter (gripper assembly is removed) to back of rotary union
(FIGURE 12.50- 3).
1. Remove gripper assembly from drawbar, per procedure above.
2. Extend spindle approximately 250 mm (12”) from face of headstock.
3. Remove the covers on the back of the headstock to access the drawbar on the end of the spindle.
4. Position the headstock at a suitable height that allows one to stand beneath it. Use wood blocking between the
bottom of the headstock and the column base to prevent any headstock drift.
****************************************************************************************
DO NOT HOLD THE DRAWBAR ASSEMBLY IN THE AREA OF THE PISTON AND THE SIGNAL
RING (FIGURE 12.50- 1). THIS AREA MOVES DURING CLAMP/UNCLAMP CYCLE AND CREATES
A PINCH POINT.
****************************************************************************************
5. Clamp the drawbar and turn off main hydraulics. By clamping the drawbar, hydraulic pressure to the rotary
union will be allowed to flow to tank.
6. Disconnect hydraulic and coolant hoses from rotary union. Removing the 45° elbow fittings from rotary union
will make it easier to slide the drawbar over the spindle cable carrier, during the removal process.
7. Disconnect drawbar proximity switch cables. Cables should be identified, in order to reconnect in correct
position.
8. Remove switch bracket for drawbar proximity switches. Requires removing (5) M6 X 16 socket head cap
screws.
9. Have someone hold the spindle key at the front of the spindle to prevent the spindle from rotating. Using 50
mm wrench, break loose piston/intensifier mechanism (FIGURE 12.50- 1) from rear of spindle. There is a M45
X 1.5 thread in end of spindle. To remove, turn CCW (as viewed from rear of machine); will require about
seven revolutions.
10. Once the thread is disengaged, the entire drawbar must be removed out the back of the machine.
12.50-4 DRAWBAR
INSTALLING THE TOOL CLAMPING SYSTEM (DRAWBAR) INTO THE SPINDLE
The following procedure is for installing a drawbar when the spindle has not been removed from the machine. This
procedure is for two speed and four speed headstocks. The drawbar must be inserted into the rear of the spindle.
FIGURE 12.50- 3 shows the overall length of each type of drawbar.
1. The gripper assembly must be removed from the front of the drawbar.
2. If a new drawbar is being installed, make sure that the drawbar bushing (FIGURE 12.50- 1) is removed from
the existing drawbar and reinstalled on the new drawbar.
3. A new drawbar will require orientation of the end cap on the rotary union. Remove the three retaining screws
(FIGURE 12.50- 4) and rotate cap 120° CCW (as viewed from rear of rotary union). DO NOT REMOVE CAP -
ROTATE ONLY! Replace retaining screws.
4. Install the M10 and M6 45° elbow fittings into the rotary union of the drawbar. Do not put excessive amount of
side pressure on the rotary union.
5. Ensure that internal M45 threads of spindle and external M45 thread of drawbar are clean. Insert the drawbar
into the rear of the spindle. Apply removable thread lock, Loctite 243 to the last few threads of the drawbar.
Turn the drawbar in the CW direction until the shoulder between M45 X 1.5 thread and piston (FIGURE 12.50-
3) contacts the rear of the spindle.
6. Fully tighten drawbar.
Leakage Unclamp Hydraulic Locknut on Outside

Coolant Connection Connection Pressure Connection Rear of Spindle
(Initial Position)
120°
Coolant
Connection Sensor Target Spacer on
Outside of Spindle
Coolant Connection (Final Position)

Above View Shows End Cap Correctly Rotated
Rotate End Cap 120° CCW (Drawbar/Spindle Shown 180° Out of Machine Position)
(Shown as Received from Manufacturer)
FIGURE 12.50- 4
Tool Clamping Device (Drawbar) Inserted into Spindle
7. Reinstall switch bracket (for drawbar proximity switches), using (5) M6 X16 socket head cap screws. Ensure
that switches are not bumped during bracket installation. Ensure that bracket traps the fitting for hydraulic
unclamp supply, rotating rotary union as required.
8. Reattach coolant & hydraulic hoses. Ensure that hoses are free to move and do not apply side pressure to
rotary union. Reattach drawbar proximity switches cables.
9. Start machine and check for leaks or other problems.
10. Install gripper assembly into the spindle per above procedure “Installing Gripper Assembly into the Drawbar”.
11. Try a manual tool change and verify that tool clamp/unclamp proximity switches are set correctly. See
procedures listed below for resetting switches if necessary.
12. After the machine performs manual tool changes properly, perform automatic changes and replace covers.
DRAWBAR 12.50-5
TOOL CLAMPING SYSTEM TROUBLE SHOOTING GUIDE
TROUBLE POSSIBLE CAUSE REMEDY
Tool will not pull in. Setup dimension is not properly set Recheck setup dimension, readjust if
or is out of adjustment. necessary.
Counter screw got loose. Tighten counter screw.
Wrong gripper fingers were Install correct gripper fingers.

installed.
Wrong inside contour of spindle. Check inside contour of spindle.
Belleville spring broken, dirt in Disassemble, clean and check

intensifying unit.
Tool cannot be pulled in, tool Check tool changer.

position wrong.
Retention knob too big or not Install the correct size retention knob. Tighten
threaded in all the way on top of the knob.
tool
Tool will not release Dirt in hydraulic oil. Clean oil filters and flush oil lines.
Piston seals are defective. Replace piston and seals.
Rotary union leaks. Install new rotary union. Use flexible high
pressure oil lines so as to not to put excessive
load on the rotary union bearings.
Insufficient oil pressure. Check hydraulic system for proper setting.
Tool was left in spindle for Increase oil pressure momentarily to help
extended period of time. release tool.
Tool pulls out during Gripper fingers broken. Install new gripper fingers.
working cycle
Retention knob not concentric. Check tool holder retention knob.
Helical coil spring around gripper Remove gripper assembly from spindle,
fingers broken. disassemble and replace coil spring.
Retention knob too long or short. Replace or correct retention knob.
TABLE 12.50- 1
Tool Clamping System Trouble Shooting Guide
12.50-6 DRAWBAR
ADJUSTMENT PROCEDURE - TOOL CLAMPED/UNCLAMPED PROXIMITY SWITCHES
The proximity switches for sensing drawbar position are in either a two speed or four speed switch bracket, located in
the rear of the thrust housing/bracket. Each switch is mounted into an eccentric switch mount with a jam nut and the
switch mount is locked in position by a clamp (FIGURE 12.50- 5). To replace a switch, loosen the clamp and rotate
the flat on the clamp to allow for removal of the switch mount from the switch bracket. Remove jam nut and turn
switch to remove from switch mount. After turning in new switch and jam nut, follow adjustment procedure listed
below.
Clamp Switch Bracket
Jam Nut
Switch Mount
FIGURE 12.50- 5
Drawbar Clamp/ Unclamp Proximity Switches
TOOL CLAMPED – NORMALLY OPEN SWITCH
Use a tool holder that has been qualified to meet the gage dimension and retention knob dimensions of ANSI 5.50 V-
Flange #50 taper spindle. Insert tool holder in spindle and clamp drawbar. Adjust proximity switch so that end is
within (0.5 to 1.0 mm) of sensing area, shown in (FIGURE 12.50- 6). Remove switch mount and tighten jam nut.
Reinsert switch mount, lightly tighten clamp, and reconnect the cable to the proximity switch. Rotate switch mount so
that switch is not activated. Slowly turn the switch mount in opposite direction until the switch actuates. Switch
should be on rear half of flange. Tighten clamp without moving switch mount.
TOOL UNCLAMPED – NORMALLY OPEN SWITCH
Place the drawbar switch in the unclamped position. Pressure on main hydraulic gauge should be 152 to 186 bar
(2200 to 2700 psi.). Pressure on secondary system gauge should be 76 bar (1100 psi.). Adjust proximity switch so
that end is within (0.5 to 1.0 mm) of sensing area, shown in (FIGURE 12.50- 6). Remove switch mount and tighten
jam nut. Reinsert switch mount, lightly tighten clamp, and reconnect the cable to the proximity switch. Rotate switch
mount so that the switch is not activated. Slowly turn the switch mount in opposite direction until the switch actuates.
Switch should be on front half of flange. Tighten clamp without moving switch mount.
After both switches are adjusted, cycle the drawbar to each position and verify that the switches actuate properly.
Proximity Switch
Sensing Area Drawbar Unclamped Position
Drawbar Clamped Position
FIGURE 12.50- 6
Drawbar Rear End
DRAWBAR 12.50-7
SECTION 13.10
SADDLE
TABLE OF CONTENTS
TITLE PAGE
SADDLE.........................................................................................................................................................................1
SADDLE MAINTENANCE..............................................................................................................................................4
SADDLE
Saddle
Column Base of Bed
Saddle Axis
Drive
Bed X-Axis Drive

Runway Saddle
Support
FIGURE 13.10- 1
Saddle and Runway Supports
The saddle is a machined gray iron casting, which provides the base for the table. The saddle provides the support
for the X-axis movement of the table (perpendicular to the spindle axis). The basic components of the saddle
assembly consist of the machined saddle, a pair of heavy duty hardened and ground preloaded roller guide ways, the
X-axis drive & ballscrew, linear encoder, and saddle supports (support guide roller assembly).
SADDLE 13.10-1
Housing
Axis Drive -
Mounted to
Bearing
Housing of
Saddle
Sealed with
#2 Permatex Non
Hardening Sealer before
Drive Motor Cover Installed
Servo Motor
Drive Motor Cover
Servo Drive Motor with

Pinion Gear
(Siemens Motor Shown)
FIGURE 13.10- 2
Saddle Drive Components
The saddle axis and X-axis drives share a common design. They can be ordered in 18 M/min and 25 M/min rapid
traverse with Siemens or Fanuc drive motors. One end of the saddle or X-axis ballscrew is supported with a damper
assembly, which is identical to the damper assembly used on Y-axis drive, see damper assembly description.
The ballscrew diameter is 80mm (3.15”) for 2500 RT/MC & 3000 PT travels, and 100mm (3.94”) for all other travels.
The number of runway saddle supports required and the length of the other components vary based on total X-axis
travel and the type of table, (PT) plain table or (RT/MC) rotary table/machine center. In addition, the saddle provides
the support or mounting surfaces for the hydraulic, pneumatic and electrical services used by the rotary table and
pallets if so equipped.
The preloaded roller guide ways consist of a rail (that depending upon length could be split into multiple pieces) and a
pair of runner blocks (also referred to as trucks). Each of the runner blocks contains four sets of recirculating roller
bearings (FIGURE 13.10- 3). The bearing preload is built into the runner blocks and is not adjustable.
The rails are bolted to an accurately machined rail seat which has been measured with a laser interferometer and
hand scraped to ensure straightness and flatness. Both of the rail seats have a locating shoulder, with a wedge
clamp used to find and maintain the correct rail position until the rail is bolted in place (FIGURE 13.10- 3). The
parallelism of the locating shoulders is maintained within .013 mm (.0005”TIR). The ways are held in place by M16
socket head cap screws through the center of the way.
13.10-2 SADDLE
Wedge Clamp
Guide Rail
Recirculating
Roller Bearings
Guide Edge
FIGURE 13.10- 3
Linear Rail System
Saddle supports and runways are used to support the weight of the table when it is positioned out at the end of the
saddle (FIGURE 13.10- 1). Two saddle supports are used per runway. There are two to six runways per machine
with the number of runways dependent on table travel. Runway lengths increase for each of the available saddle
travels of 1500, 2000, 2500, 3000, or 3500 mm. As the table is positioned farther towards the end of the saddle, the
supports will carry more of the table load, keeping the saddle level. The saddle supports ride on a roller system,
which circulates around an oval shaped track (FIGURE 13.10- 4).
Chain and Roller

Saddle Support
Assembly
(Support Guide Roller Assembly)
Locking M10X35 Cap

Screw This Side
Height Adjustment Screws

Setscrew to Raise, Cap
Screws to Lower
Saddle Support
(Bottom View)
FIGURE 13.10- 4
Support Guide Roller Assembly
Note: The saddle supports are only for supporting the saddle while the table weight is positioned out from
center. They should never be used to raise or lower the saddle for alignment purposes.
These rollers are lubricated automatically by the lubrication system. Within the saddle support is a wedge
arrangement which is used to raise or lower the support. On the end of the support is a M16X40 setscrew used for
adjusting the wedge and two M10X50 cap screws used to lock wedge into position once adjusted (FIGURE 13.10- 4).
On the opposite end is a centered M10X35 cap screw, which must be loosened before attempting to adjust the
wedge. Once height adjustment is completed, tighten the screw to secure the lower wedge in the saddle support.
Refer to the mechanical print books for a cross sectional view of the saddle supports (support guide roller assembly).
SADDLE 13.10-3
SADDLE MAINTENANCE
Few parts make up the bed and saddle and therefore require minimal maintenance. It is important to keep the bed
and saddle clean and free from chips and dirt build-up. Monitor the condition of the roller guide ways to make sure
that no abnormal wear is occurring. Make sure they are receiving sufficient lubrication. Since the ways are covered
by way covers, this should protect the ways from daily exposure to chips and dirt, lengthening the intervals between
inspections. However, whenever the covers are removed for other maintenance, inspect the ways and way wipers. It
is good practice to occasionally run the axes at their full travel to lube the ways and ball screws and to prevent wear
spots.
Note: The X-axis and saddle-axis gear housings require manual fill with Mobil SHC 634. Reservoir should
be filled every three months as required.
13.10-4 SADDLE
SECTION 15.10
ROTARY TABLE COMMON
TABLE OF CONTENTS
TITLE PAGE
ROTARY TABLE INTRODUCTION ...............................................................................................................................1
ROTARY TABLE BASE .................................................................................................................................................3
TABLE DRIVE CONSTRUCTION ..................................................................................................................................5
HYDRAULIC SUPPLY AND TABLE CLAMPING COMPONENTS ................................................................................6
SETTING ROTOR LIFT .................................................................................................................................................8
REMOVING TABLE DIVE TRAIN ..................................................................................................................................9
INSTALLING THE TABLE DRIVE TRAIN ....................................................................................................................11
TABLE DRIVE BOX ASSEMBLY .................................................................................................................................11
CHECKING TABLE BACKLASH..................................................................................................................................12

ADJUSTING TABLE BACKLASH ................................................................................................................................13
DIRECT DRIVE............................................................................................................................................................14
RING BRAKE PRESSURE SWITCH ...........................................................................................................................15

ROTARY TABLE INTRODUCTION
This section of the manual covers rotary tables used with 1250/1600 plain rotary table and 1250/1600 clamping rotary
table. Examples of each type are shown in FIGURE 15.10 - 1. The rotary table provides an additional axis to the
machine, with 360° of rotation in both the clockwise and counterclockwise direction. This is designated as the B-axis.
The table can be programmed to position at 0.001° increments or 360,000 angular positions. Once positioned, a
hydraulically actuated ring brake clamps the table into position.
Plain Rotary Table Assembly (Rotary Table for RT1600 Shown)
Plain Table
Hydraulic Pump/Motor for

Worm Cover Hydrostatic Bearing & Brake
Pallet Clamp ‘T-Bars’
Clamp Ring
Electric Servo Motor

for Table Drive
Rotary Table 1600 Pallet Assembly (Rotary Table for MC1600 Shown)
FIGURE 15.10 - 1
Rotary Table Assemblies
ROTARY TABLE 15.10-1

The rotary table has full contouring capabilities. Complex part configurations can be machined by rotating the table
as the spindle is cutting the work piece. This type machining is possible because of the internal table design that
provides preloaded hydrostatic pressure on top and bottom of the rotor, along with the electric servo motor and
precision angular encoder working together to hold the table in position. In addition, the hydrostatics adds stiffness
and dampening, and allows for greater off center load carrying capacity.
The basic components of a rotary table are shown in the following cross sections. The components consist of the
rotary table base, rotor with worm gear, worm (table drive), ring band brake, angular encoder, stator (hydrostatic
thrust bearing), radial roller bearing, and the table. Additional components include servo motor and gearbox for table
drive, and hydraulic pump/motor for hydrostatic pressure supply (FIGURE 15.10 - 1).
Stator Ring, Band Angular Rotor Table

(Thrust Bearing) Brake Encoder
Radial Roller
Worm Gear Manifold Bearing Rotary Table Base
Worm
Ring, Band T-Bar Center Post Clamp Ring

Brake Cap
Stator Angular Rotor
(Thrust Bearing) Encoder
Worm Center Post

Worm Gear Rotary Table Base
Manifold Radial Roller
Bearing
FIGURE 15.10 - 2
Rotary Table Cross Sections
15.10-2 ROTARY TABLE

ROTARY TABLE BASE
The rotary table assembly prints were shipped with the machine. These prints will include the assembly procedures
and related information. Review the machine prints before starting any maintenance procedures.
The rotary table base serves as the support for hydraulic table brake, table drive, center manifold, center roller
bearing (rotor support), stator (hydrostatic thrust bearing), hydrostatic power supply, table brake hydraulic valve, linear
way and ballscrew lubrication components, and side manifold for incoming services.
The rotary table base has a hydraulic reservoir integral to the casting. The oil from this reservoir is used to pressurize
the hydrostatic thrust bearing, provide brake pressure, lubricate the center radial roller bearing for rotor, bathe the
table drive worm/ring gear mesh, and lubricate the worm gear shaft needle roller bearings and thrust bearings. The
rotary table must be filled to the “center to top” of sight glass with Mobil SHC 634 oil (FIGURE 15.10 - 6). Measure
the oil level with hydrostatic pump on for minimum of fifteen minutes. Earlier machines have fill plug in different
location and/or the sight gage at lower position. If your machine has the center of sight glass located at 211 mm
(8.3”) from top of table base (bottom of stator thrust bearing), make sure oil level is to the very top of sight glass.
Note: The table drive gearbox has a separate reservoir that must be filled with Mobil SHC 634 oil (FIGURE
15.10 - 11). An oil seal, between worm gear shaft needle bearing and 48T gear, separate the gearbox
reservoir from the table base reservoir.
Worm/Worm Gear
Mesh Area Rods for Locating
Manifold Hydrostatic Oil
(Gears Not Shown) Reservoir
Ring, Band Brake

(Rotary Table Clamp)
Groove for Pressurized

Oil to Hydrostatic
Bearing Pads
Access plugs for cap screws holding ring band brake to table
base. Four sets of four screws located 90°apart.
FIGURE 15.10 - 3
Rotary Table Base
A hydraulic motor and pump (FIGURE 15.10 - 5) make up the on board power source that furnishes the pressurized
oil for the hydrostatic thrust bearing, hydraulic pressure for table brake, and the lubrication to center radial roller
bearing. The table hydraulic motor is driven by oil supplied from the machine main hydraulic system. A pressure
reducing valve, which is located on the on the X-axis drive side of the saddle, is used to adjust the main system
pressure line into the hydraulic motor. The motor is connected to the pump with a coupling. The pump pulls oil from
the table reservoir and outputs the oil through a filter to the hydrostatics, brake and lube lines. A metering unit is
placed in the lube line to reduce the flow to center bearing.

The pressure into the hydraulic motor is adjusted to set the rotary table internal system pressure to 41 bar (600 psi).
A pressure gauge inserted in test port (FIGURE 15.10 - 5) is used to read output pressure of pump. The needle valve
should be fully open (full flow) (FIGURE 15.10 - 5). This needle valve is only used during rotary table construction, as
a means of adjusting pump output pressure.
The hydrostatic thrust bearing (stator) is supplied with oil through cross-drilled holes in the casting that feed a groove
on the top of the rotary table base (FIGURE 15.10 - 3). Outer and inner O-rings keep the oil in the groove. Twenty-
four access holes that are in the bottom of the stator and located above the table base groove, allow the oil to enter
cross-drilled holes to twelve upper and twelve lower pads in the stator. Restrictors (FIGURE 15.10 - 4) are inserted
between the access holes and pads to slow the oil flow, keeping it more constant. Different length restrictors are
used on upper vs. lower pads.
Upper Lower
Restrictor Restrictor
Table
Crossed Drilled Hole –

Plugged
(For Upper Pad Oil Drain to
Internal Reservoir)
Lower
Restrictor
Lower Test Upper
Port Restrictor
Upper Test
Port
FIGURE 15.10 - 4
Stator Hydrostatic Port Layout
The oil is distributed around the stator to the upper and lower pads for lift and separation between table or clamp ring
and stator (upper pads) and stator and rotor (lower pads). The spacing between these surfaces is what determines
the hydrostatic pressures. The table spacer (located between table or clamp ring and rotor) is ground to create the
spacing. Hydrostatic pressure test point readings for the upper bearing surfaces (pads) should read about 21 bar
(250 +/- 40 psi) and the bottom bearing surface should read about 28 bar (400 +/- 50 psi). These pressures can be
checked around the entire table at the upper and lower test ports with a pressure gauge. The order in which the ports
are laid out is shown in FIGURE 15.10 - 4. A hydraulic pump output pressure switch (FIGURE 15.10 - 5) indicates to
the control if the pump pressure is too high or too low. Individual pad pressures are not monitored.

Color Hydrostatic
Hydraulic Needle Valve
Indicator Pump
Pump Output
Pressure
Switch
Test Port
With Gauge
Installed
Hydraulic
Filter Motor
Table Brake Engage/Disengage

Directional Control Valve
FIGURE 15.10 - 5
Rotary Table Hydraulic Services
TABLE DRIVE CONSTRUCTION
The power source for table rotation is a machine control specific servo electric motor (Siemens or Fanuc). The motor
does not have an integrated brake. Through a toothed poly belt, a 28T pulley on the motor drive shaft drives a 60T
pulley mounted onto the shaft of a 21T gear. The 21T gear drives a 48T gear attached to the worm shaft. When the
motor rotates, it turns the worm, which turns a 100T worm gear bolted to the rotor. One rotation of the rotor requires
489.795 rotations of motor shaft.
Secured to the top of the rotor is the table or clamp ring (of a pallet clamping system). A large radial roller bearing
supports the rotor assembly. The hydrostatic thrust bearing (stator) applies opposing forces to the bottom of the table
and the top of the rotor.
The worm is supported by two (2) needle roller bearings on the drive end and a set of four thrust bearings, held within
a bearing support post, on the opposite end. The bearings are fitted inside the bearing support post with sufficient
preload to prevent the worm from moving axially.
The table drive worm is manufactured with a single thread, dual lead. The dual lead results in a thread that becomes
progressively heavier from leading to trailing end. Because the worm thread varies in thickness, it is possible to
remove the entire backlash between the worm and the worm gear attached to the table. This is done by engaging the
worm with the worm wheel at the point where the worm thread is just heavy enough to achieve this no lash condition,
without binding the worm wheel gear.
The table drive worm, worm gear, and worm shaft bearings are all kept lubricated by table base hydrostatic reservoir.
The reservoir should be filled with Mobil SHC 634 oil, pre-filtered to 5 micron. The oil fill point and the oil level sight
glass are shown in FIGURE 15.10 - 6.

A separate oil reservoir is located between the motor belt housing and the table base hydrostatic oil reservoir. This
reservoir lubricates the 21T to 48T gear mesh and the bearings on the 21T gear shaft. An oil seal on the worm shaft
keeps the reservoirs separated. An oil seal between 60T pulley and 21T gear shaft bearing keeps oil from entering
belt housing. Fill plug for gearbox reservoir is shown in FIGURE 15.10 - 11. Fill to top of plug with Mobil SHC 634 oil.
Later designed machines have a sight glass for this reservoir.
Earlier Design Current Design
Ring, Band
Brake Screw
Access
Oil Fill
198 mm
Oil Fill
211 mm
Drain Plug Sight Glass Drain Plug Sight Glass
FIGURE 15.10 - 6
Rotary Table Hydrostatic/Lube Reservoir Fill
HYDRAULIC SUPPLY AND TABLE CLAMPING COMPONENTS
The following components are located under covers or are part of the rotary table. Refer to FIGURE 15.10 - 5 &
FIGURE 15.10 - 7.
1. The hydrostatic table has its own on board hydraulic reservoir built into the table cavity. The rotary table must
be filled to the full mark on the sight glass with Mobil SHC 634 oil. This hydraulic oil supply provides
hydrostatic pressure, brake pressure and lubrication for the table drive worm, worm gear mesh, worm bearings,
and rotor radial roller bearing.
2. The oil can be drained from the table base reservoir by removing the pipe plug fitting near the sight glass
(FIGURE 15.10 - 6).
3. The system pressure of 41 bar (600 psi) is set by a pressure reducing valve located on the X-axis drive side of
the saddle. A pressure switch monitors the hydraulic pump output pressure (FIGURE 15.10 - 5). If pressure
increases or decreases beyond acceptable amounts, a fault is generated at the CNC operator station and the
machine shuts down. Individual upper and lower hydrostatic pad pressures are NOT monitored.
4. Oil is cycled through the table by a hydraulic motor and pump connected by a Lovejoy coupling. The oil is
circulated from the table base reservoir through the return line, into the pump and out through the filter. It is
then sent to the table base to provide hydrostatic pad pressure, to a directional control valve to supply brake
(table clamp) pressure, and through a lube meter inside a tee fitting (exit side of filter) to the rotor center radial
roller bearing.
5. The filter is a replaceable element type and is equipped with a color indicator. When clean and functioning, the
indicator is green. If dirty or blocked the indicator is red. The filter should be changed every 90 days even if
the color indicator is green. This frequency can be increased if conditions warrant.
6. There is an air inlet for air pressure to be supplied to an internal seal in the rotary table. This air pressure puts
a positive pressure across the seal to prevent the intrusion of dirt and/or coolant. The inlet is located near the
main services manifold, which is on the table base side opposite of the hydraulic pump & motor.

7. When the table is not moving, it is clamped in position. The clamp is a steel ring (ring, band brake) mounted
just inside the table base that presses on the OD of the rotor (FIGURE 15.10 - 3 & FIGURE 15.10 - 7). The
ring mounting surface has a groove between two o-rings. The ring is assembled to the table base during
machining operations. Sixteen M16 X 70 cap screws fasten the ring to the table base (FIGURE 15.10 - 3).
The uniquely designed ID of the ring is machined concentric with table base center bore and to size. When
table clamp is commanded, the directional control valve (FIGURE 15.10 - 5) allows hydraulic pressure from the
on board hydraulic pump to fill the groove behind the ring. The ring expands inboard making contact with the
OD of the rotor. There is a momentary drop in pressure, while the groove is filled with oil. The machine main
control ignores the pressure sensor for the few seconds it takes to rebuild pressure. When table unclamp is
commanded, the directional control valve reverses position allowing the oil in the groove to return to the table
base reservoir. The hydraulic pressure is released, allowing the ring to return to unclamped state. In
unclamped state, there is 0.08-0.15 mm (0.003”-0.006”) clearance between rotor OD and ring ID.
Rotor
Worm Gear
Ring, Band
Brake
Radial Roller Bearing
FIGURE 15.10 - 7
Assembling Rotor to Table

SETTING ROTOR LIFT
Calculate the table spacer and worm gear spacer dimensions (FIGURE 15.10 - 8). The table spacer thickness is
calculated so that there is 0.10 mm (.004”) clearance between bearing thrust stator and rotor, measured without
hydrostatic pressure. 0.10 mm is the total clearance and allows for 0.05 mm between top of stator and bottom of
table and 0.05 mm between bottom of stator and rotor surface beneath stator.
The worm gear spacer is calculated with 0.05 mm (.002”) clearance between bottom of stator and rotor.
Table spacer thickness = C + (0.10 mm) – D
Worm gear spacer thickness = A + (0.05 mm) - B – E
A dimension is stamped on the table base hub, (measured on CMM). E is ½ of worm gear thickness.
Grind the table spacer and worm gear spacer and set aside.
Install the center bearing onto rotary table manifold. The manifold is inserted into the center bore of table base.
Lower previously assembled worm gear, worm gear spacer and rotor in place. Clean surface of table casting that the
bearing thrust stator sits on and place sealant around air seal hole. Be sure to have the inner and outer o-rings in
place and lubricate with oil.
Lower hydrostatic bearing thrust stator, being sure slotted hole on bottom of stator lines up with air purge hole in the
table base. When stator is almost in contact with table base, start a few bolts for alignment. Lower all the way down.
Tighten bolts in a crisscross pattern, then torque to 60 Nm (44 lb-ft).
Table Spacer
Table or Clamp Ring
C D
Stator
Rotor
A
B
Table
Base
Worm Gear Spacer
FIGURE 15.10 - 8
Table Spacer & Worm Gear Spacer Calculation

REMOVING TABLE DIVE TRAIN
1. Turn off all machine power and drain the table base reservoir via the drain plug located on spindle side of base
(FIGURE 15.10 - 6). There is not a separate drain plug for the gearbox lubrication reservoir.
2. Disconnect the wiring cables to the rotary table drive motor.
3. Remove the tensioner bolt that threads into the housing cover (FIGURE 15.10 - 10).
4. While supporting with a lifting device, remove the rotary table motor and housing cover by removing the (6) cap
screws that hold the housing cover onto the belt housing. Must move the motor towards the large driven
pulley, so that, belt slips off motor drive pulley.
5. Remove the 60T belt pulley from the gear shaft. Remove the flange and inner seal (FIGURE 15.10 - 10).
6. Remove the drive box housing, (7) bolts and 2 taper pins. The oil that is in the gearbox reservoir behind the
belt housing will spill out. Remove the 48T gear off the end of the worm. It is held on to the shaft with a clamp
ring that is expanded with a gear flange.
7. Install a M12X1.75 threaded rod, acting as a guide/driver (approx. 1 meter long), into the end of the worm
shaft. [One method to make this rod would be to weld a long enough piece of bar stock to a cap screw. Grind
flats on the bar stock or weld a hex nut to the other end of the bar stock to use as a driver. Thread the cap
screw into the threaded hole in the end of the worm gear.]
8. To remove the worm gear, remove the cover plate and retainer from the end opposite the drive (FIGURE 15.10
- 1). The worm gear can be turned manually and fed out the end opposite the drive. Turn the previously
installed driver with a wrench until the worm gear is released from the ring gear. Support the shaft with a lifting
device. Then push out until free of the bore in the base.
9. Remove the clamp ring and bearing support post (FIGURE 15.10 - 9) from the end of the worm gear to expose
the worm gear bearings. Any necessary replacement of bearings can now be accomplished.
10. To release the bearing locknut, loosen each of the locking screws a little at a time in a crosswise pattern to
avoid binding the last screw. With the locking screws loose, the locknut can be easily loosened by means of a
standard radial spanner wrench.
Bearing Support Post Worm
Bearing
Clamp Ring Spacer
Worm Note Bearings

Orientation
FIGURE 15.10 - 9
Worm Gear

Rear View of Belt Front View of Belt Housing Taper Pin
Housing
21T Gear Shaft and Front Bearing in

Belt Housing
Oil Seal
48T Gear on
Worm Shaft
Flange
Taper Pin
21T Gear
Shaft Front
Bearing
Worm Needle
Bearings in
this Bore Housing Cover
60T Pulley on Gear

Shaft
21T Gear Shaft

Bearing Bore in Table
Base Casting
Gearbox Oil Fill
Plug
Remove Plug to
Check Belt Tension
21T Gear Shaft with
Rear Bearing
Belt Tensioner
Cap Screw
Housing
Cover Housing
Cover
FIGURE 15.10 - 10
Table Drive Components and Assembly

INSTALLING THE TABLE DRIVE TRAIN
Install the drive train in reverse of removal considering the following:
1. Replace all seals and remove any burrs and dirt.
2. Replacing the heavy duty adjustable locknut:
A. With the locking screws loose, turn the locknut onto the spindle thread until it is within 2.5 mm (0.100")
of the mating face.
B. Tighten the locking screws crosswise and uniformly while rotating the locknut back and forth until
clearance is nearly eliminated. In this condition the centerline of the locknut coincides with the spindle
centerline, mating face is perpendicular to the common centerline, and the thread flanks of the locknut
are in uniform contact over the full circumference in both the clamping and locking section.
C. Tighten the locknut against the mating face, with 160 Nm (118 ft. lbs.), the required preload to pre-
stretch the threads, eliminating any subsequent compaction of nut, spindle threads and contact
surfaces, then loosen the locknut and re-torque to 135 Nm (100 ft. lbs.).
3. Apply Loctite 518 on joint face of belt housing before reassembly.
4. If motor is removed from housing cover, coat motor flange with Loctite 518 when reattaching motor to housing
cover.
5. After table drive assembly is complete, fill gearbox cavity with Mobil SHC 634. Fill plug is shown in FIGURE
15.10 - 11, fill to top of plug.
TABLE DRIVE BOX ASSEMBLY
Reference FIGURE 15.10 - 11.
1. Heat the rear ball bearing to 71° C (160° F), assemble to the 21T gear shaft and install both into the bore of
table base casting.
2. Assemble 48T gear to the end of worm shaft using the locking element and gear flange.
3. Heat the front ball bearing to 71° C (160° F), and then assemble to the 21T gear shaft.
4. Assemble the belt housing to the main base casting with (6) M10X45 and (1) M10X100 cap screws and (2)
M12X50 taper pins. (Use Loctite 518 flange sealant on mating surfaces).
5. Assemble shaft seal and o-ring to flange. Slide flange assembly over gear shaft and bolt to the belt housing.
Assemble 60T pulley to gear shaft using the taper lock bushing and key. Position the pulley on shaft so the
teeth are approximately 9.5mm (3/8”) from the belt housing flange.
6. Assemble 28T pulley to the motor shaft. The method of assembly depends upon the motor being used
(Siemens or Fanuc).
7. Glue the housing gasket to housing cover using 3M gasket adhesive (M.1014.5943). Assemble the cover to
drive motor. See prints for proper orientation.
8. Install belt to 60T pulley that was previously mounted to the 21T gear shaft and install drive motor assembly to
the belt housing. Adjust belt to pulleys.
9. Install belt tensioner and set belt tension to deflect approx. 2.5mm (0.100") in the center with 10 lbs. of
downward force. Install 1.25” NPT pipe plug in belt housing cover and 1.5” NPTF pipe plug into belt tension
access hole in belt housing.
10. After table drive assembly is complete, fill gearbox cavity with Mobil SHC 634. Fill plug is shown in FIGURE
15.10 - 11, fill to top of plug.

CHECKING TABLE BACKLASH
Backlash or lost motion between the rotary table unit drive motor and the rotating table does not normally affect
positioning accuracy or repeatability. The rotary table position feedback unit (angular encoder) is independent of the
drive train, the feedback unit is mounted directly to the rotating segment of the table and its support is the table base.
As a result, the feedback unit reflects only the actual relationship of the table and the supporting unit and not the
driving mechanism. However, minimal backlash between the table's drive worm pinion and worm wheel gear is
important for servo stability. It is the snug engagement of the worm and worm gear that keeps the rotary table
stationary while cutting forces are applied to a workpiece secured to it. Excessive backlash between the worm and
the worm wheel may result in chatter marks in the workpiece finish. The following is a satisfactory method of
checking the backlash between the worm pinion and the worm wheel.
1. Clamp a ground parallel or gage block to the top face of the pallet or table near the center of a side. The gage
block should partially extend from the pallet surface to form a 90° angle with its slide, FIGURE 15.10 - 11.
2. Attach a 0.003 mm (0.0001") dial indicator to a good magnetic base indicator stand. Arrange the indicator
stand so that it is locked to the table base near the gage block and the indicator stylus is bearing against an
edge of the gage block. Preload the indicator to about .002" to .004".
3. Press machine start push button; hydraulic force is needed to maintain the pallet in a clamped position.
Note: Motor
Shown Out
of Position
FIGURE 15.10 - 11
Table Backlash Procedure
4. Attach a piece of flat bar stock, approximately 1.2m (4 feet) long to the pallet.
5. Pull firmly (100 ft lbs) on the bar in a manner that will tend to rotate the table clockwise.
6. Release the bar and allow the table to spring back of its own accord. Zero the indicator dial.
7. Pull firmly (100 ft lbs) on the bar in the opposite direction to rotate the table counterclockwise. Release the bar
and allow the table to spring back. Record the indicator reading, the difference represents backlash.
8. Repeat steps 1 - 7 three (3) more times. Backlash measured in this manner should be less then .0002".

ADJUSTING TABLE BACKLASH
The following procedure gives a very general outline of the steps required to adjust rotary table backlash. Moving the
worm closer to the worm drive will reduce backlash. Moving the worm to close to the worm drive will cause a binding
condition between the worm and worm gear. This procedure should only be attempted by highly qualified personnel
such as a MAG service representative.
Note: The table drive worm is manufactured with a single thread, dual lead. The dual lead results in a
thread that becomes progressively heavier from leading to trailing end. Because the worm thread
varies in thickness, it is possible to remove all backlash between the worm and the worm gear
attached to the table. This is done by engaging the worm with the worm gear at the point where the
worm thread is just heavy enough to achieve the proper backlash condition without binding the
worm gear.
1. Determine the existing lash from the test above.
2. Remove socket head cap screws and remove the cover. To remove backlash, either the fitting spacer or the
shoulder of the worm cover will have to be ground to allow the cover to push the worm into the worm gear.
The ratio is .005” per 1 inch of movement toward the drive end or .001” backlash removal take .200” off fitting
spacer. Example: measured backlash = .001”, grind off enough to move the shaft .200” in toward the motor
end.
3. A large movement of worm could require reposition of 48T gear on worm shaft.
4. When reassembling the cover, torque according to prints.
Fitting Spacer Worm Movement towards Worm

Drive Reduces Backlash
Worm
Worm Cover
48T Gear
FIGURE 15.10 - 12
Adjusting Worm Position to Reduce Backlash

DIRECT DRIVE
As of September 2010 the rotary table design has been modified to include a direct drive to replace the belt drive.
This eliminates the belt and therefore the need for belt tension maintenance or belt replacement.
The design includes the (control specific) servo drive motor together with a purchased gearbox and spline coupler
that slides directly onto the splined end of the worm drive gear.
FIGURE 15.10 - 13
Direct Drive Motor & Gearbox

RING BRAKE PRESSURE SWITCH
At the same time that the direct drive change was implemented, an additional pressure switch was also added to
monitor the engagement/disengagement of the ring brake (also referred to Rotary Table Clamp).
FIGURE 15.10 - 14
Ring Brake Pressure Switch

SECTION 15.20
ROTARY TABLE PLAIN
TABLE OF CONTENTS
TITLE PAGE
INSTALLING THE PLAIN TABLE TOP ..........................................................................................................................1
INSTALLING THE PLAIN TABLE TOP
1. Clean surface of bearing thrust stator and apply oil to top of stator before lowering table top down on to it. Set
table supply pressure to (41 bar) 600 psi using flow control and hydraulic power unit.
2. Install bearing spacer. Tighten center cover only enough to load the center bearing. Roll worm shaft to seat
rollers in bearing. The spacer then should be sized.
3. Remove the center cover and depth mic from spacer to the table surface that the cover is mounted. Measure
in 4 quadrants to be sure top is level. Grind center spacer to .04 to .07 mm (.0015 - .0025”) oversize from
measured dimension. Install rotary encoder on center post counterbore and bolt in place. Install o-ring on
center bearing spacer. Install center cover and indicate for run out under .001” TIR, tighten and pin. Depth
mic from counterbore in center cover to top of the encoder center hub. This dimension must be ground on the
encoder driver “A” dimension +/- .051 mm (.002”) (FIGURE 15.20- 1). Then, bolt fitted encoder driver to the
encoder and the center cover.
4. Mount a substantial bar radially from the center to the edge of the rotor. Place an indicator base on the table
weldment and position a .0001" indicator to measure vertical movement of the bar at the rotor's edge.
Measure the rotor rise as hydrostatic pressure is applied. Measure the rise at three equally spaced bar
positions around the rotor edge. The rise should be between 0.013 - 0.038 mm (.0005” - .0015”).
5. Install pressure gauge taps in the rotor and measure all the axial pad recess pressures. If the pressures are
incorrect:
Low pressure correction: You may have a plugged restrictor, check for that especially if only one pad is
bad. If all are bad: Grind stock off top set of shims.
High pressure correction: Top set of shims are too small. Start with a new set and increase thickness.
Grind this step to

+/-.002” of recorded
“ A “ dimension.
FIGURE 15.20- 1
Rotary Encoder Driver
(Plain Rotary Table)

SECTION 15.30
ROTARY TABLE CLAMPING
TABLE OF CONTENTS
TITLE PAGE
PALLET CLAMPING SYSTEM ......................................................................................................................................1
PALLET CLAMPING SYSTEM
The pallet clamping system requires hydraulic pressure to actuate the pallet clamping cylinders and air supply for
pallet present and unclamped sensing, and pallet locating surfaces blow-off. FIGURE 15.30- 2 shows the clamp ring,
which holds the hydraulic cylinders. The valves and piping mount to the rotor.
The manifold in a pallet clamping rotary table includes a center post, which acts as a rotary union to supply the
hydraulic fluid and air to the rotating pallet clamping system. The center post cap attaches to the rotor of the angular
encoder and to the rotary table rotor.
When a pallet is shuttled onto the table, it is held in place by a pair of 'T' shaped bars, which move up and down in
order to clamp the pallet to the table. The T-bars are actuated by hydraulic cylinders located under the T-bar
mounting bolts. A pair of locating pins is used to align the pallet side-to-side and front to back on the table. Ground
pads locate the pallet as it rests on the table and keeps the pallet flat. During the loading of the pallet, air is blown
across the locating pads to prevent any dirt from causing a misalignment or out of level condition. FIGURE 15.30- 1
shows the table with the pallet removed and points out the major components of the pallet clamping system.
Pallet Stop
Slow Down Plate Block
Slow Down Plate
Pallet Support
Rollers
Pallet Locating
Pins
T-Bar Mounting
Bolts
T-Bars
FIGURE 15.30- 1
Pallet Clamping System
FIGURE 15.30- 2 shows the table with the T-bars and the center cover removed. Upon reinstallation of the cover, the
old gasket material must be removed, surfaces cleaned and new oil & coolant resistant gasket (Loctite Red sealant or
Dow 735 black) put in place to seal the center cover.
Under the center cover are the valves for actuating the hydraulic clamping cylinders and the pneumatics for blowing
off the locating pads and pins. There are two pressure switches located under the way cover for the X-axis bed on
the tool changer side of the table (FIGURE 15.30- 4) which monitor pallet present and pallet clamping.

The hydraulics and pneumatics are supplied from the end of the bed, through the utility carrier to a manifold mounted
to the table base. From this manifold, lines are routed to the underside of the table base. The services then enter the
center manifold and up through the center post (which acts as a rotary union). Refer to the rotary table pallet
assembly drawings for cross sections of the manifold and center post.
Clamp Ring
8
5
6
4
(Bore for
Sleeve)
1
Center Post Cap

2
9 3
10
FIGURE 15.30- 2
Rotary Table with T-Bars and Center Cover Removed
The following is a list of the components shown in FIGURE 15.30- 2:

1. Pallet Clamp/Unclamp Hydraulic Cylinder. These cylinders (4 total) are used for raising and lowering the T-
bars for pallet clamping. To remove the cylinder, remove the 4 cap screws from the round locating plate and
lift up to pull the cylinder out.
2. Locating Pads (8 total) used to seat the pallet while clamped with the T-bars. They are precision ground and
should be inspected for wear, kept clean and free of nicks or burrs. Air is blown across the pads through holes
in the T-bars (supplied through 3) to clear the pads prior to clamping the pallet.
3. Pneumatic Supply Cylinder Sleeve (4 total) which supplies air (through 8) into the T-bar and then is channeled
out to the locating pads. In FIGURE 15.30- 3, item 3A shows the cylinder that slides into the sleeve (which is
bolted into the table by 3 cap screws). The Cylinder is threaded into the bottom side of the T-bar and an o-ring
seals the cylinder into the sleeve. Removal of the T-bar will pull the cylinder out of the sleeves.

4. T-bar Unclamped Pressure Switch Sleeve (1 total). Similar to the item at 3, this unit is used to indicate if the T-
bar is unclamped. In FIGURE 15.30- 3, item 4A shows the cylinder which slides into the sleeve (which is
bolted into the table by 3 cap screws) and is threaded into the bottom of the T-bar. It is supplied with air
pressure through 8. There are cross-holes drilled into the side of the cylinder. Depending on the position of
the cylinder in the sleeve (T-bar up or down position) will determine if the air pressure is released or blocked
off. If the T-bar is in the unclamped position, the holes will be blocked off and air pressure will increase to
make the pressure switch (FIGURE 15.30- 4) and indicate that the T-bar is unclamped.
Note: When removing the T-bar, the three sleeve cap screws must be removed and the cylinder (4A) and
sleeve (4) pulled up with the T-bar. This is not required with the four cylinders located at 3A. They
can be removed with the T-bar without loosening the sleeve.
4
4A
3
3A
FIGURE 15.30- 3
Pneumatic Supply Cylinder and Sleeve
T-Bar Clamp/Unclamp Pressure Switch Cylinder and Sleeve
5. Pallet Clamp Valve. Hydraulic pressure is supplied from the center post out to the valve. From there it is
distributed to the pallet clamp/unclamp cylinders. This valve will clamp the pallet by pulling down on the T-
bars.
6. Pallet Unclamp Valve. Hydraulic pressure is supplied from the center post out to the valve. From there it is
distributed to the pallet clamp/unclamp cylinders. This valve will unclamp the pallet by raising the T-bars.
7. Location of hydraulic lines supplying pressure to the cylinders for pallet clamp/unclamp.
8. Location pneumatic lines supplying air to the pneumatic supply cylinders for blowing off the pallet locating pads
and for supplying air to the locating pins (see 9).
9. Locating Pins. These pins locate the pallet on the table. An air blast to the pins clears them of debris before
the pallet is placed on the table. One pin is also hooked up to the pallet present pressure switch (FIGURE
15.30- 4). Air blows up through a center hole and when the pallet is present, the hole is sealed off and enough
backpressure is created to make the switch.
10. Stop Block. Is used to prevent the pallet from rolling off the table during shuttling.

FIGURE 15.30- 4 shows the bed on the right side of the table (tool changer side) with the cover pulled back.
On the right is the servo drive for the rotary table. In the center is the utility track and on the left is the ballscrew with
the pressure switch mounted above. Hydraulics and pneumatics are supplied to the center post in the table through
the manifold above the utility track. See the machine drawings for cross sectional views of the rotary table.
Pallet Present & Clamped

Pressure Switch
Pallet Unclamped Servo Drive Rotary

Pressure Switch Table
FIGURE 15.30- 4
Rotary Table Side View
(Tool Changer Side)

SECTION 20.10
PALLET CHANGER COMMON
TABLE OF CONTENTS
TITLE PAGE
INTRODUCTION............................................................................................................................................................1
PALLET CHANGER.......................................................................................................................................................2
COMMON PALLET CHANGER UNIT FEATURES.............................................................................................2

INTRODUCTION
The Machining Center (MC) type machines include automatic pallet changers with optional pallet stands. The pallet
changers are normally located in the front of the machine, but optionally, can be located on the side of the machine.
While the machine is performing operations on one part, the operator can safely setup/remove a part on another
pallet. A typical pallet exchange (shuttle) system consists of two pallet changers that transfer a pallet back and forth
to the machine rotary table (FIGURE 20.10- 1). The rotary table of a MC machine has a pallet clamping system that
is integral to the table. See “Rotary Table - Clamping” section for information on the pallet clamping system.
The pallet changer has optional rotational capabilities. Rotation helps facilitate setup of the work piece on the pallet
or provides the capability to transfer pallets to/from park stands. A pallet pool is the term used for multiple pallets
exchanged from/to park stands by the pallet changer.
Rotary Table with

Pallet Clamping
System
Bridge Unit
(Shown Retracted)
Pallet
Pallet Changer
Table with
Decking
Pallet Transfer
Base
FIGURE 20.10- 1
MC1250 Pallet Changer
There are two basic pallet changers, which are designed for either 1250 mm or 1600 mm width of the pallet (FIGURE
20.10- 2). The pallet changers have been designed to accommodate any of the available pallet lengths within a given
width. The pallet changer consists of a bridge unit that extends and retracts, mounted to a table that optionally
rotates. The table is mounted to a base that supports the hydraulic and electrical devices. A chain mechanism
powered by a servo motor is an integral to the bridge unit and is used to transfer the pallet back and forth from the
pallet changer to rotary table and/or park stands.
PALLET EXCHANGE 20.10-1

Various Lengths Available
1250 mm
or
1600 mm
Pallet to Table Latch Block

Clamping T-Slots
FIGURE 20.10- 2
Typical Pallet Bottom View
On a standard MC machine (no park stands), pallet exchanges occur in the following sequence. The X Axis, the
Saddle-Axis (table position relative to headstock) and the orientation of the rotary table are positioned at the
appropriate transfer location. The table then unclamps while the pallet exchange door is opening. After the door
motion is complete, the pallet changer bridge extends to close the gap between the pallet changer and the rotary
table receiver. On the outboard end of the bridge are roller supports that rest on hardened pads attached to the
rotary table base. The pallet is transferred on or off the table, using the chain link system with cam roller that
engages a latch block attached to the pallet. The bridge then retracts. When the bridge clearance switch is made,
the table clamps while the bridge completes its motion. The pallet exchange door then closes to complete the cycle.
PALLET CHANGER
The pallet changer or sometimes referred to as the pallet shuttle, allows a pallet mounted workpiece to be moved to
and from the machine table. The pallet changer can also used be to transfer pallets to and from park or setup stands.
COMMON PALLET CHANGER UNIT FEATURES
A pallet changer consists of the following basic components: the base, base rotation or non-rotation components, the
slide unit (bridge) components, transfer drive components, rotation drive components (if so equipped), hydraulic
assembly components, and the base decking. The 1250 & 1600 pallet changers have proximity switches that monitor
when the slide unit has cleared the exchange door, when slide cylinder is extended and when it is retracted. There is
also a mechanical switch, which senses pallet presence. Each of the servo motors, for transfer drive and rotation
drive, has built in encoders to relay exact positional information.
The pallet changer base supports the geared bearing (for rotating base) or spacers (for non-rotating base) that
support the slide unit table/frame. The gearbox mounting plate used for the rotational drive components attaches to
the base. The base serves as the mounting surface for the hydraulic valve assembly that controls the bridge
extension cylinder, the profibus for cable connections from hydraulic valve solenoids, proximity and mechanical
switches, and the connection between internal and external pallet transfer drive cables (FIGURE 20.10- 3).
20.10-2 PALLET EXCHANGE

Non-Rotational Pallet Changer
Spacers in Lieu of
Geared Bearing
Profibus
Cables for Chain Drive Motor

(Pallet Transfer)
Hydraulic Assembly for Bridge
Extend/Retract Cylinder
Rotational Pallet Changer
Shuttle Bridge Shuttle

Unit Table/Frame
Table Rotation
Drive Gear
Geared Bearing
(Between Table and Base) Gearbox Mounting
Plate
FIGURE 20.10- 3
1250 Pallet Changer without and with Rotation
The rotational drive components (if so equipped) consist of the geared bearing, gearbox mounting plate, drive gear,
gearbox and servo motor. The gearbox and motor may vary depending upon different drive components. The
gearbox mounting plate is designed to provide adjustment between the drive gear and ring gear of geared bearing.
The slide unit consists of the shuttle frame/table, the bridge unit, the bridge extension cylinder and the pallet transfer
drive (FIGURE 20.10- 4). The top of the shuttle frame/table serves as the mounting surface for the bridge extension
cylinder and the four runner blocks (trucks) of the linear ball rail system. The two linear rails are attached to the
bridge unit. The bottom of the shuttle frame/table serves as the mounting surface for the ring gear of the geared
bearing (for rotational pallet changers) or the spacers (for non-rotational pallet changers). For rotational pallet
changers, it is the shuttle frame/table, which rotates.

Bridge Unit Pallet
Transfer
Chain
Pallet Present
Switch
Bridge
Extension
Cylinder
Linear Rail
System
Pallet Transfer
(Chain) Drive
Shuttle Slide Clear

Frame/Table Proximity Switch
FIGURE 20.10- 4
1250 Pallet Changer Slide Unit
The bridge unit is a machined weldment, which supports the pallet, extends to span the gap between the pallet
changer and the machine table and/or pallet stand, and serves as the mounting surface for the pallet transfer
mechanism. Two linear rails mount to the underside of the bridge unit. The bridge extension cylinder rod is
connected to the underside of the bridge unit. Stroke adjustment is made at this connection point by adding or
removing hardened washers (FIGURE 20.10- 5). Stud type track rollers thread into the top runners of the bridge unit.
These rollers support the pallet and allow for pallet transfer.
Hardened Washers for Bridge Stoke Adjustment

Rod End Proximity Switch
(Cylinder Extended)
Cap End Proximity Switch

(Cylinder Retracted)
FIGURE 20.10- 5
Bridge Extension Cylinder with Proximity Switches

Mounted off center on the cross plate of the bridge unit is the pallet transfer mechanism. The transfer mechanism
consists of a double roller chain, idler sprocket, and drive sprocket driven by a gearbox and servo motor. Similar to
the rotational drive, the gearbox and motor may vary depending upon different drive components. The gearbox
mounts to the gearbox plate. The plate’s position is adjusted with a hex head screw that is in a thrust block mounted
between the sprockets. The latch roller mount acts as a link in the chain, connecting with one set of offset chain links.
When the chain turns, the cam roller will grab the latch block attached to the pallet and transport the pallet to and from
the pallet changer (FIGURE 20.10- 6).
Latch Roller at Bridge Retract

Position Pallet Latch Block
(After Pallet on Table)
Drive Sprocket
Latch Roller at 12:00

Latch Roller CW to O’clock Position Offset
Bridge Retract (Pallet Unload) Chain
Position and CCW Links
to 6:00 O’clock
Latch Roller Mount
Gearbox
Bearing Cup
Latch Roller
at 6:00 O’Clock Position Gearbox Plate
(Pallet on Changer) Servo Motor
FIGURE 20.10- 6
Pallet Transfer Mechanism
The chain is setup as a linear axis, see FIGURE 20.10- 6. The zero position is established at 12:00 o’clock (looking
from the top), which is the position that the pallet is fully loaded onto the table. The chain fully extended position is
CW past the zero position, where the latch roller is within 3 to 4 mm of entering the latch block. This is typically +72
mm on the linear axis. The latch roller is at the fully extended position when the bridge is retracted without a pallet.
The fully retracted position is located at the 6 o’clock position when viewed from the top. On the linear axis, this is
about -2190 mm for 1250 pallet changers and -2360 mm for 1600 pallet changers. The chain always rotates from the
fully extended position CCW (looking from the top) to the fully retracted position and from the fully retracted position
CW to the fully extended position.

SECTION 20.20
PALLET CHANGER 1250
TABLE OF CONTENTS
TITLE PAGE
1250 PALLET CHANGER FEATURES..........................................................................................................................1
1250 PALLET CHANGER FEATURES
The pallet changer used for 1250 mm width pallets requires a support stand. During the bridge extension to the
machine table or to a pallet stand, a height adjustable slide support stand supports the bridge unit until the bridge unit
is fully extended (FIGURE 20.20- 1).
Bridge Support Pad
Slide Support on Front Bridge Unit Fully

of Bridge Support Pad Extended
Jack Screws
FIGURE 20.20- 1
1250 Pallet Changer Slide Support
Once the bridge unit is fully extended, stud type track rollers contact rest pads attached to the rotary table or pallet
stand (FIGURE 20.20- 3). The track rollers are supported in eccentric bushings that fit into a bore in each of the
bridge rails. The eccentric bushings provide for roller height adjustment.
The 1250 rotational pallet changer has been designed with 360° of CW travel (looking from top view) from 0°, where
0° is defined as the pallet exchange position with the machine table. There is a mechanical rotational stop that allows
2.5° of overtravel CW (362.5°) and 2.5° of overtravel CCW (-2.5°). This rotational stop is fastened to the underside of
the shuttle table. The stop contacts one of the cap screws that are used to hold down the geared bearing to the base
(FIGURE 20.20- 2). A spacer is used to raise the head of this screw so that contact will be made with the stop.

Spacer to Raise
Head of Cap
Screw
Four Grease Fittings

90° Apart
Rotation Stop Mounted to Bottom of
Shuttle Frame/Table
Geared Bearing
(Bearing Fastened to Base)
(Ring Gear Fastened to Shuttle Table)
FIGURE 20.20- 2
1250 Pallet Changer Rotational Hard Stop
Track Roller with Eccentric Bushing Rest Pads Bridge Support Front Shuttle
FIGURE 20.20- 3
1250 Bridge Supports

SECTION 20.30
PALLET CHANGER 1600
TABLE OF CONTENTS
TITLE PAGE
1600 PALLET CHANGER FEATURES..........................................................................................................................1
1600 PALLET CHANGER FEATURES
Rotational pallet changers used for 1600 mm width pallets have base integrated roller support stands that add
support to the shuttle table during bridge extension to the machine table. If the pallet changer is used with pallet
stands, a pair of roller supports is used for each pallet stand in the array. The pair of rollers supports the shuttle table
during bridge extension to the pallet stand. For non-rotational pallet changers, the rollers are eliminated and
substituted with M16 hex head screws and jamb nuts.
Unlike the 1250 pallet changers, the track rollers that support the bridge on the machine table or pallet stands are not
integrated into the bridge runners. There is a separate pair of outriggers that attach to the bridge unit (FIGURE
20.30- 1). The track roller is supported in an eccentric bushing to provide for roller height adjustment.
Track Roller with Roller Support

Rest Pads Bridge Support for Side Shuttle Eccentric Bushing (Rotary Table Interface)
FIGURE 20.30- 1
1600 Bridge Support
The 1600 rotational pallet changer has been designed with 285° of CCW travel (looking from top view) from 0°, where
0° is defined as the pallet exchange position with the machine table. From 0° there is approximately 15° of CW travel.
Any rotation past these limits will result in damage to the hydraulic hoses within the cable carrier, as well as, the cable
carrier located inside the base. There are hard rotational stops that will be set at MAG. The rotational stop design
uses two 8 mm washers to raise the head of cap screws used to hold the geared bearing to the base. A dog point set
screw and jamb nut in the shuttle table are adjusted to make contact with the head of these screws. There are cap
screws located at 15° increments, with an access hole in the shuttle table to allow for resetting of these stops
(FIGURE 20.30- 2).
Dog Pt Set Screw

& Jamb Nut Bridge Cylinder
Access Hole to
Remove Cap Screw
Geared Bearing and Add Washers
FIGURE 20.30- 2
1600 PTU Rotational Stop Setup

SECTION 20.40
PALLET CHANGER R&R PROCEDURES
TABLE OF CONTENTS
TITLE PAGE
PALLET CHANGER BRIDGE REMOVAL......................................................................................................................1
PALLET TRANSFER DRIVE CHAIN REMOVAL ...........................................................................................................2

PALLET CHANGER BRIDGE REMOVAL
The pallet changer bridge unit is the part of the pallet changer, which extends to close the gap between the machine
table and/or pallet stand. The bridge unit is a machined weldment that is attached to the pallet shuttle table by the
runner blocks (trucks) of the linear guide system.
Note: Each of the four runner blocks has a grease fitting and should be greased quarterly or more often,
based on the frequency of use.
If the bridge unit should require removal from the pallet changer, a suggested removal procedure is listed below:
1. Turn off the hydraulics and relieve the pressure from both of the hoses connected to the hydraulic cylinder,
used to extend and retract the bridge. This cylinder is mounted to the shuttle table.
2. Remove the M20 cap screw to disconnect the cylinder rod from the bracket on the underside of the bridge unit.
3. Disconnect the power and encoder cables to the transfer drive motor and the cable to the pallet present switch.
Make sure that these cables are removed from any cable ties holding them to the bridge unit.
4. Remove the slide clear proximity switch from the shuttle table by removing the proximity switch bracket. This
will prevent accidental contact with the switch when bridge unit is removed.
5. Unfasten the cable carrier from the underside of the bridge unit.
6. Install lifting straps and hoisting equipment to the bridge unit. Ensure that the straps do not catch on the
cylinder or any other part of the shuttle table.
7. Scribe lines around the linear guide runner blocks attached to the shuttle table to aid in reinstallation. Remove
the interior cap screws on the four runner blocks. Manually push the bridge unit so that it is centered between
the runner blocks. Unscrew the remaining exterior cap screws on the four runner blocks. Lift the bridge unit
off the shuttle frame.

PALLET TRANSFER DRIVE CHAIN REMOVAL
The pallet transfer drive system consists of a double roller chain, idler sprocket, and drive sprocket driven by a
gearbox and servo motor. The 1250 pallet changer uses gearbox ratio of 58.25:1 and 1600 pallet changer uses
gearbox ratio of 78.89:1. The gearbox is purchased as an assembly that includes the gearbox, motor mounting
flange, and motor shaft coupling.
If there is a requirement to remove any of the drive components, other than the motor, the chain will need to be
removed first. Removal of the transfer chain is accomplished by the procedure listed below:
1. Position the latch roller mount in the pallet load position (opposite side from gearbox). This will allow for easy
access to the cotter pin in the clevis pin.
2. Loosen the six cap screws on the gearbox mounting plate.
3. Remove the chain cover to gain access to the thrust (anchor) block and the setscrew or hex head screw.
4. Back out the setscrew or hex head screw to allow gearbox mounting plate full forward movement.
5. Push the gearbox/motor assembly forward until contact is made with thrust (anchor) block.
6. Remove the cotter pin from the clevis pin that holds the offset chain links to the latch roller mount. Remove the
clevis pin. The chain will now be free to be removed.
Reassembly of the chain is the reverse of the removal process. The correct chain tension is achieved by turning the
setscrew or hex head in the thrust (anchor) block until the chain can be pried away from one side of the chain guide
by approximately 13 mm. If inconsistent pallet placement occurs, the chain tension is too loose.
Anchor Block &

Set Screw
1250 Chain Drive Sprocket

(MD.2000.7328 Ver. 4)
Thrust Block & Gearbox Mounting Plate

Hex Head Screw (1250 PTU Shown)
Bearing Retainer
Latch Roller Mount
1600 Chain Drive Sprocket

(MD.2001.1529 Ver. 0)
Cotter Pin
FIGURE 20.40- 1
Transfer Drive Chain Mechanism

SECTION 20.50
PALLET CHANGER ALIGNMENT
TABLE OF CONTENTS
TITLE PAGE
PALLET CHANGER ALIGNMENT .................................................................................................................................1
ALIGNING PALLET CHANGER TO ROTARY TABLE PALLET RECEIVER ......................................................1
ALIGNING PALLET CHANGER TO PALLET STAND ........................................................................................5

PALLET CHANGER ALIGNMENT
At initial installation, the pallet changer had been aligned with the machine table and the pallet stands (if so equipped).
If maintenance is required to the pallet changer, such as bridge unit removal, the pallet changer will need to be re-
aligned. If rough pallet shuttle operation develops, this could be a sign that the pallet changer and/or pallet stands
need to be re-aligned. Another factor that could require a pallet changer alignment is if the machine has been
involved in a collision.
ALIGNING PALLET CHANGER TO ROTARY TABLE PALLET RECEIVER
The following steps assume that the machine rotary table has been aligned per machine specifications and that a
pallet is currently on the rotary table. Use these steps to establish an exchange position, lineup the bridge to the
machine table and adjust the support rollers:
1. Establish the rotary table (B-axis) angular exchange position.
A. With a pallet clamped on the rotary table, rotate B-axis so that pallet stop bracket faces the column and
the pallet latch block is on the opposite side. Pallet hold down T-slots will be perpendicular to X-axis.
This is the normal B-axis absolute zero, and would be the proper angular exchange position for the
machine.
B. For a side pallet transfer machine, rotate so that the pallet latch block faces the pallet changer.
2. Set the cushions for the extend/retract cylinder.
A. Start by turning adjustment screw all the way in (which will produce the most cushion at end of cylinder
stroke) and then backing it out ¼ turn.
3. Set the pallet changer angular exchange position.
A. Use a straight edge clamped to the side of the pallet to lineup with the side of the rollers on the bridge
unit.
B. Jog pallet changer rotational axis until straight edge is parallel with the side of the bridge rollers. Do not
rotate machine B-axis. After rollers are parallel, set the pallet changer rotary zero location.
4. Rough level pallet changer with rotary table.
A. Have pallet stop block removed from rotary table. Place pallet on table if not already present.
B. Position the appropriate machine axis to move the rollers on table T-bar in line with the rollers on the
pallet changer bridge unit.
C. Unclamp pallet and carefully roll pallet away from pallet changer to expose the front rollers on the rotary
table T-bars.
Note: Since the pallet stop has been removed, ensure that pallet does not roll off table!
D. Using a precision level, adjust pallet changer base to level the bridge unit rollers front to back and side
to side. Using straight edge from bridge rollers to front T-bar rollers adjust pallet changer base so that
bridge rollers are the same height as the T-bar rollers. Bridge unit rollers must remain level.
5. Set chain drive zero.
A. Make sure bridge is fully retracted.
B. The transfer chain is setup as a linear axis. Zero is established when the pallet latch roller is at the
opposite end from the gearbox/motor. When looking at the pallet changer from a top view standing at
the rear, zero is at 12:00 and fully retracted is at 6:00.
C. Rotate the chain CW until latch roller is at 12:00 position. Set the rough zero for the chain.
PALLET CHANGER ALIGNMENT 20.50-1

6. Position X-axis and W-axis to a rough exchange position with pallet changer.
A. Turn the eccentric so the bridge track rollers are at their maximum clearance position.
B. Move appropriate machine axis so that pallet changer bridge can be fully extended without making
contact with rotary table.
C. Fully extend bridge unit.
D. Adjust machine axis as required to have bridge track rollers be positioned just short of the rest pads on
rotary table.
E. Adjust the other machine axis to ensure equal spacing between the inside edge of rest pad side guide
and the outside edge of the bridge rails (1250 pallet changer) or roller support (1600 pallet changer).
F. Make sure that the bridge support rollers have been adjusted to clear the rest pads. If bridge support
rollers have been adjusted for maximum clearance (step 6a) and pallet support rollers have been
adjusted to same height as table T-bar rollers (step 4), then the only way to gain additional clearance is
to remove material from rest pads, or for a 1600 pallet changer remove material from roller support at
mounting surface to bridge unit.
7. Finalize the height of pallet changer to rotary table.
A. Extend the bridge just short of the table rest pads.
B. Finalize height of bridge rollers to height of T-bar rollers by adjusting the pallet changer base height.
Ensure that bridge rollers remain level from front to back and side to side.
20.50-2 PALLET CHANGER ALIGNMENT

8. Finalize X-axis and W-axis exchange positions with pallet changer.
A. Ensure pallet is unclamped. Bridge unit is already fully extended from step 6.
B. Carefully adjust the machine axis which will move the table to bring the bridge support rollers onto the
table rest pads.
C. Adjust the eccentrics on the bridge support rollers until they just make contact with the table rest pads.
D. Extend and retract the bridge. Ensure that there is still equal spacing between inside guide edge on rest
pads and outside edge of bridge rails (1250 pallet changer) or roller support (1600 pallet changer).
Make final adjustment to machine axis as required.
E. With the bridge extended and empty, adjust the bridge support stand (1250 pallet changer only) so that
the roller just comes in contact with the mating support pad on underside of bridge unit.
F. Push the pallet by hand from the rotary table to the bridge and back to the rotary table. Verify smooth
operation. Leave pallet on rotary table.
G. Retract the bridge. With the pallet located correctly over locating pins, clamp pallet. Unclamp the pallet.
H. Rotate the transfer chain so that it is positioned at approximately 2:00 position. The override button will
be needed to rotate the chain with the bridge retracted.
I. Extend the bridge. Very slowly rotate pallet transfer chain CCW to the pallet latch block. Stop when the
latch roller on chain is 3-4 mm from pallet latch block (FIGURE 20.50- 1).
Pallet
Latch Roller
Pallet Latch
Block
3-4 mm
FIGURE 20.50- 1
Pallet Latch Block Clearance
J. Very slowly rotate pallet chain CCW towards the latch block. Stop before the roller contacts the latch
block. Shim the bridge cylinder using hardened washers so that the latch roller has equal gap on both
sides of the notch in the latch block. Be sure to limit the number of washers added so that the rear end
of the guide rails still extends beyond the end of the runner blocks (trucks). The pallet changer base
pushers can be used to locate the stand instead of or in conjunction with the cylinder washers.
K. Record the X-axis and W-axis exchange positions. These values will be entered in your control as
exchange parameters. (See electrical manual).

9. Using the setup pages extend slide at exchange position and manually push pallet from table to pallet changer
and back to ensure smooth operation.
10. Using the setup pages run pallet on and off table. Verify that as the pallet is taken from the machine table it
does move back and forth while the latch roller engages the pallet latch block. If forward/backward motion is
seen, reshim the slide cylinder (Step 8j).
11. Using the setup pages move the pallet back and forth between the table and pallet changer. The pallet
changer location is correct when the pallet is smoothly loaded and unloaded from the table without the pallet
being bumped back and forth.
FIGURE 20.50- 2
Pallet Stand Adjustment Pushers

ALIGNING PALLET CHANGER TO PALLET STAND
Note: Pallet stands should only be aligned after the pallet changer has been aligned with the machine
table.
The following steps assume that the pallet changer as been aligned with the machine rotary table. Use these steps to
establish a pallet changer exchange position with the pallet stand, lineup the bridge unit to the pallet stand and adjust
the support rollers:
1. Set the pallet changer angular exchange position.
A. Use a straight edge to lineup the side of the pallet support rollers on the bridge unit with the side of the
rollers on the pallet stand.
B. Jog pallet changer rotational axis until straight edge is parallel with the side of the bridge rollers. Use
the pushers on stand base to rotate stand in conjunction with pallet changer rotational axis (FIGURE
20.50- 2). After rollers are parallel, record the angular position. This value will be entered in your
control as an exchange parameter. (See electrical manual).
2. For 1600 pallet changer only, adjust support stands.
A. Make sure there is not a pallet on the pallet changer.
B. After establishing the rotational exchange position (step 1), adjust the two support stands. Stands
should be rotated to ensure that roller is centered under wear strip. Height of rollers should be adjusted
to just make contact with the wear strip. Only adjust the support stands (FIGURE 20.50- 3).
1600 Pallet
Changer
Table
Wear Strip
Support Stand
FIGURE 20.50- 3
1600 Pallet Changer Support Stands
3. Level pallet stand and set height with pallet changer bridge unit.
A. Without a pallet on the pallet stand or pallet changer unit, manually extend the bridge unit so that bridge
track rollers are positioned just short of the pallet stand rest pads.
B. Using a precision level, adjust pallet stand base to level the pallet support rollers front to back and side
to side. Using a straight edge from pallet stand rollers to front bridge unit rollers, adjust pallet stand
base so that the stand rollers are the same height as the bridge rollers. Make sure pallet stand rollers
remain level.

4. Set rest pads and bridge support stand.
A. Remove the support stand rest pads (FIGURE 20.50- 4).
B. Ensure that the sides of the bridge pallet support rollers are in line with the pallet stand support rollers.
Slowly extend the bridge unit to full stroke. The bridge support rollers should be on the rest pad area.
Measure from the bottom of the roller to rest pad mounting area. Adjust rest pads by adding a shim or
removing material as required.
C. With the bridge extended and empty, adjust the bridge support stand (1250 pallet changer only) so that
the roller just comes in contact with the mating support pad on underside of bridge unit.
D. Retract bridge and reinstall modified rest pads.
5. Using the setup pages extend slide at exchange position and manually push pallet from pallet changer to pallet
stand and back to ensure smooth operation.
6. Using the setup pages run pallet on and off stand. Verify that as the pallet is taken from the pallet stand it does
move back and forth while the latch roller engages the pallet latch block.
1600 Pallet Stand 1250 Pallet Stand
Roller Studs
Bridge
Bridge Alignment
Alignment Rollers
Rollers
Bridge Support
Bridge Support Wear Pads
Wear Pads
Pallet Latch Pallet Stop
Pallet Drag Strip
0.15 mm Gap
between Pallet Present
Screw Heads Switch
and Links
Pallet Locking Mechanism
FIGURE 20.50- 4
Pallet Stands with Detail of Locking Mechanism

SECTION 20.60
PALLET CHANGER MAINTENANCE
TABLE OF CONTENTS
TITLE PAGE
PALLET TRANSFER UNIT AND PALLET STAND MAINTENANCE .............................................................................1
LUBRICATION ...............................................................................................................................................................1
PALLET TRANSFER UNIT AND PALLET STAND MAINTENANCE
Pallet stands require minimal maintenance; however, a few guidelines are as follows:
1. Observe pallet shuttling to verify a smooth transition to and from the pallet changer. Rough shuttling could
indicate alignment problems. This may be more noticeable under heavy loads.
2. Check the pallet locking mechanism for proper engagement and release with the pallet. Make sure that there
is 0.15 mm gap between the three M20X35 cap screws and the link and latch plate. Use thread lock
compound on cap screws to ensure that gap is maintained.
3. Clean as needed to remove dirt and chips from chain, linear rails, and rotational drive gear.
4. Inspect the rollers for free wheeling. Inspect the bridge support wear pads for excessive wear which could be
an indication of an alignment problem.
5. Inspect the bearing retainer, which holds the bearing cup on the latch roller mount. Ensure that the three
M6X10 button head screws are kept tight. Thread lock compound is recommended if loosening is observed.
LUBRICATION
The following is a guideline for lubricating the pallet transfer unit and pallet stands. Frequent inspection will determine
if the pallet changer and pallet stand need more or less lubricant based on its use and environment.
1. Clean and inspect pallet support rollers and bridge support stand rollers for binding. They should roll freely.
Apply a light film of Mobil SAE 30 to the rollers quarterly.
2. Inspect the chain quarterly for cleanliness, clean as needed. Lubricate with a light film of Mobil SAE 30 oil.
Check chain tension and adjust if required. If inconsistent pallet placement occurs, the chain tension is too
loose.
3. Inspect the runner blocks (trucks) quarterly. Clean the linear rails as required. Grease the runner blocks with
general grease quarterly or as required. There is one grease fitting per runner block.
4. Check the pallet changer rotation gearbox (if so equipped) monthly. Remove side screw plug and fill to the
bottom of the plug hole with Mobil SHC 634.
5. There are four grease fitting on the geared bearing. The bearing is filled with grease at initial assembly. For
normal operations, no grease should be required.
PALLET CHANGER MAINTENANCE 20.60-1

SECTION 22.10
PALLET STANDS
TABLE OF CONTENTS
TITLE PAGE
PALLET STANDS ..........................................................................................................................................................1
1600 Pallet Stand 1250 Pallet Stand
Roller Studs
Bridge
Bridge Alignment
Alignment Rollers
Rollers
Bridge Support
Bridge Support Wear Pads
Wear Pads
Pallet Latch Pallet Stop
Pallet Drag Strip
0.15 mm Gap
between Pallet Present
Screw Heads Switch
and Links
Pallet Locking Mechanism
FIGURE 22.10- 1
Pallet Stands with Detail of Locking Mechanism
PALLET STANDS
A pallet stand is a heavy-duty steel weldment made to support the weight of the pallet and its load. Pallet stands are
available with and without rotation. They are designed to accommodate either 1250 mm or 1600 mm pallet widths.
While pallets are being setup for a job or sitting idle, they can be parked on a pallet stand.
When a pallet on a stand is required, the pallet changer will rotate into exchange position. The pallet changer bridge
will extend, with the roller studs being supported on the rest pads of the stand and the alignment rollers on the stand
ensuring that the bridge is in position. The front of the bridge will make contact with the pallet locking mechanism
front roller, causing the pallet latch to lower below the front of the pallet. The pallet is transferred on or off the pallet
stand using the pallet changer chain link system with cam roller that engages a latch block attached to the pallet.
After pallet transfer is completed, the bridge unit retracts allowing the pallet locking mechanism to latch, securing the
pallet to the stand. On the rear of a pallet stands is a mechanical pallet present switch, with a stop behind the switch
to prevent the pallet from rolling off the back of the stand.
PALLET STANDS 22.10-1

SECTION 22.20
PALLET STAND MAINTENANCE
TABLE OF CONTENTS
TITLE PAGE
PALLET STAND MAINTENANCE..................................................................................................................................1
LUBRICATION ....................................................................................................................................................1
PALLET STAND MAINTENANCE
Pallet stands require minimal maintenance; however, a few guidelines are as follows:
1. Observe pallet shuttling to verify a smooth transition to and from the pallet changer. Rough shuttling could
indicate alignment problems. This may be more noticeable under heavy loads.
2. Check the pallet locking mechanism for proper engagement and release with the pallet. Make sure that there
is 0.15 mm gap between the three M20X35 cap screws and the link and latch plate. Use thread lock
compound on cap screws to ensure that gap is maintained.
3. Clean as needed to remove dirt and chips.
4. Inspect the rollers for free wheeling. Inspect the bridge support wear pads for excessive wear which could be
an indication of an alignment problem.
LUBRICATION
The following is a guideline for lubricating the pallet stands. Frequent inspection will determine if the pallet stands
need more or less lubricant based on its use and environment.
1. Clean and inspect pallet support rollers and bridge support stand rollers for binding. They should roll freely.
Apply a light film of Mobil SAE 30 to the rollers quarterly.
2. Inspect the chain quarterly for cleanliness, clean as needed. Lubricate with a light film of Mobil SAE 30 oil.
Check chain tension and adjust if required. If inconsistent pallet placement occurs, the chain tension is too
loose.
3. Inspect the pallet support rollers quarterly. Grease the rollers with general grease quarterly or as required.
There is one grease fitting per roller.

SECTION 30.10
TOOL CHANGER
TABLE OF CONTENTS
TITLE PAGE
INTRODUCTION............................................................................................................................................................1
HYDRAULIC OPERATIONS ..........................................................................................................................................4
MANUAL TOOL LOAD/UNLOAD...................................................................................................................................7
HYDRAULIC CONTROL ELEMENTS............................................................................................................................9
MECHANICAL INSTALLATION AND SETUP..............................................................................................................12
INSTALLATION.................................................................................................................................................12
TOOL CHANGER SETUP.................................................................................................................................14

INTRODUCTION
Tool changers used on HBM, FT and FTR machines are purchased from Gifu Enterprise Co., LTD. The Gifu
operation manual is provided with your machine and includes assembly drawings, bills of materials, electrical control,
maintenance, and trouble shooting information. TABLE 30.10- 1 lists tool weight, length and diameter limits.
Automatic tool changers (ATC) provide a means of storing and retrieving tools used in part machining programs. An
ATC consists of three basic components: the tool changing mechanism, tool arm, and tool magazine (FIGURE 30.10-
1). The tool changing mechanism moves the tool arm between the tool magazine and the spindle. It also
extends/retracts the arm and rotates the arm 180° CW and return CCW. The tool arm has two grippers located on
each side of the arm. The tool arm grippers are spring loaded into the normally locked position. Plungers on the
back face of the arm lock/unlock the clamp mechanism (FIGURE 30.10- 2). When the arm is fully retracted, the
plunger may be depressed to unlock the gripper. Whether the plunger is depressed or not is a function of the where
the arm is in the tool changing cycle. When the arm is moved horizontally to grip/release a tool, from either the
spindle or the magazine, the plunger will be depressed against a block. This unlocks the gripper mechanism. The
horizontal motion of the gripper past the tool holder overcomes the gripper spring to open the gripper, closing at the
end of the stroke. The arm extends to extract the tool from the machine spindle or tool magazine tool pot, with the
plunger returning to normally extended (gripper locked position).
The standard tool magazine has 60 tool pots (storage locations). Optional tool changers can have 90, 110 (#60 ANSI
B5.50) or 120 tool pots. The tool pots are specifically designed for the tool taper and retention knob configuration
specified. The magazine design is similar to a roller chain, with the tool pots connected by a series of inner and outer
links. A servo motor provides the power for magazine rotation. A number of hydraulic cylinders are used to release
and eject the tools. For 90, 110 or 120 tool pot changers, a hydraulic cylinder is used to hold the chain during manual
or automatic tool exchange.
Except for the tool magazine drive motor and related parts the tool changer is purchased complete; the tool changing
mechanism rail support bracket which mounts on the machine column, the magazine bracket for 110 and 120 tool
magazines, the profibus block assembly and the tool change access platform and controls (FIGURE 30.10- 1).
Spindle Taper ANSI B5.50 #50 or ISO-50 (SK50) ANSI B5.50 #60
Quantity of Tools 60 90 120 110
Drive Ratio Tool Magazine 1/100 1/96 1/100
Power Supply of Magazine Electric (Servo)

Power Supply of ATC Hydraulic
Magazine Index Time 0.4 Sec./Pot
Tool Change Time 15 Sec.
Max. Tool Weight 50 kg (110 lbs.)
Max. Tool Length 750 mm (29.5”) 850 mm (33.5”)
Max. Tool Moment 110 Nm (1120 kg-cm) (81 lb-ft)

Max. Tool Diameter. 125 mm (4.9”) 170 mm (6.7”)
(All Pockets Full)
Max. Tool Diameter. 250 mm (9.8”) 350 mm (13.8”)
(Alternate Pockets Empty)
Max. Tool Diameter 280 mm (11”) 350 mm (13.8”)
TABLE 30.10- 1
Tool Changer Specifications
TOOL CHANGER 30.10-1

Tool Magazine Chain
Drive Motor
(Beneath Guard)
Tool Changing Mechanism

(See FIGURE 30.10- 5 for
Tool Magazine
Positioning
Mechanism
(Beneath Guard)
See FIGURE 30.10- 4
for Detail)
Tool Changing
Manual Tool Mechanism Rail
Load Controls Tool Arm Includes
(See Details in (See FIGURE 30.10- 2 for Transfer Chain
FIGURE 30.10- Detail)
7)
Tool Magazine
Tool Changer Platform

Manual Tool
(Access)
Load/Unload
Foot Pedals
FIGURE 30.10- 1
Tool Changer
30.10-2 TOOL CHANGER

Spring B16X90
Gripper Release Bar

(Plunger)
Spring G16X38
Gripper Release Bar Locating Pin

(Plunger) (Mounted in Tool Changing Mechanism)
Locating Pin Hole

(Locks Arm into Position during Load/Unload)
Tool Changing
Mechanism
Gripper Release Plunger
FIGURE 30.10- 2
Tool Arm Details & Assembled to Tool Change Mechanism

Bushing
Belt Servo Motor
Drive
Sprocket
Belt Tensioner
Motor Mount
Plate
Siemens Servo Motor Shown
Servo Motor Drive Sprocket (See

Cross Section Above)
Auto Tool Release

Cylinder
(This Location is for 60 Tool Pot Chain Drive Shaft Sprocket
Tool Magazines Only) (60 Tool Magazine Shown without Cover)
See FIGURE 30.10- 5
for 120 Tool Magazine
FIGURE 30.10- 3
Tool Magazine Drive Components
HYDRAULIC OPERATIONS
Hydraulic pressure from the machine’s main hydraulic unit supplies the tool changer. A ½” hydraulic hose, from the
X-services manifold (attached to the column), feeds a manifold mounted to the back of the tool magazine. A ½”
return hose connects to the same manifold. The normal hydraulic pressure is 76 bar (1100 psi). Hydraulic pressure
is used to operate a hydraulic motor and a number of hydraulic cylinders.
The hydraulic motor provides the tool changing mechanism’s movement from the tool magazine load/unload position
to the spindle load/unload position. (This is referred to as “parallel shifting”, in the vendor documentation). There are
two speeds used during the tool changing mechanism’s movement to/from spindle and tool magazine.
The tool changing mechanism uses an integrated hydraulic cylinder to provide the in/out movement for
removing/inserting a tool in the spindle or tool pot of magazine. A separate hydraulic cylinder driving a rack is used to
provide the 180° rotation of the tool arm for exchange of tools at the spindle; see FIGURE 30.10- 5 for a view of these
cylinders.

Cylinder Extended - Tool Chain Clamped Cylinder Retracted Tool Chain Unclamped
FIGURE 30.10- 4
Tool Magazine Positioning Cylinder & Mechanism
for 90 &120 Tool Pot Changers (Cover Removed)
For 90 & 120 tool pot magazines only, a hydraulic cylinder (FIGURE 30.10- 4) is used to actuate a “chain positioning”
device. This device holds the chain and accurately locates the required tool pot, during either a manual or automatic
tool exchange. The solenoid actuates during the clamp cycle, releasing to the normally unclamped position.
Two cylinders are used during the manual tool unload operation. One cylinder releases the tool (held by the retention
knob) from the tool pot. The second cylinder pushes the tool out of the tool pot (releasing the tool from the taper). A
pad mounted to the release cylinder makes contact with the shot pin mechanism on the rear of the tool pot. FIGURE
30.10- 6 shows a cross section of the tool pot and a view of the rear of the tool pot.
The tool magazine uses a hydraulic cylinder (FIGURE 30.10- 3 for 60 Tool, FIGURE 30.10- 6 for 90/120 Tool) to
release the tool from the tool pot during the automatic tool change cycle. A tool eject cylinder is not required during
automatic cycle; rather the tool arm is used to pull the tool from the tool pot.

Tool Arm in Extended Position Rear View of 120 Tool Magazine
Auto Tool Release

Cylinder
Tool Changing
Mechanism Rail
Tool Arm
CW/CCW
Rotation Cylinder
Tool Arm In/Out

Piston Rod
Manual Tool
Eject Cylinder
Manual Tool Release (Unlock
Tool) Cylinder
FIGURE 30.10- 5
Hydraulic Cylinder Locations

MANUAL TOOL LOAD/UNLOAD
A manual tool load/unload station is provided at the far end of the tool magazine (FIGURE 30.10- 1 and FIGURE
30.10- 7). There is an operator control panel with an emergency stop, tool magazine chain jog clockwise and counter
clockwise pushbuttons, and tool changer auto/manual mode lighted pushbutton. (Button is illuminated during
automatic mode). Next to the operator control panel is a separate chain rotation enable pushbutton.
Access to the tool magazine is inhibited while the machine FEED START is selected or the spindle is running. To
unlock the tool magazine door, one must first turn the selector switch located on the operator control panel to the
unlock position. The tool magazine door will unlock and should be left open during the manual tool load/unload
process. In order to manual jog the tool pot chain the manual/auto pushbutton must be in manual mode (light off). By
pressing the CHAIN ROTATION ENABLE pushbutton simultaneously with the appropriate chain jog pushbutton, the
magazine can be rotated. Rotate until the desired tool pot is in position at the manual load/unload location.
The “unload” foot pedal switch is used to release the tool from the tool pot. This pedal actuates a hydraulic cylinder
that has a pad connected to the cylinder FIGURE 30.10- 6. The pad contacts and drives a spring loaded rod, setting
the tool holder retention knob free (see tool pot cross section FIGURE 30.10- 6). After a very short delay, a second
hydraulic cylinder drives a eject pin into contact with the retention knob, pushing the tool out of the tool pot. The
“load” foot pedal switch only actuates the cylinder to drive in the spring-loaded rod, allowing the balls, shown in
FIGURE 30.10- 6 cross section, to accept the tool retention knob. The “load” foot pedal is depressed until the
properly aligned tool is firmly seated. Once foot petal is released, the spring-loaded rod returns to the extended
position, pushing the balls against the tool retention knob. The balls contact the retention knob, securely holding the
tool in the tool pot. The foot pedals only work with the tool magazine door open. The cables from the foot pedals
connect directly into the profibus on rear of tool magazine.
After manual tool load/unload is completed, press the tool changer auto/manual mode lighted pushbutton to select
Auto. Exit the tool changer access platform, closing the door. Turn the selector switch on the electrical cabinet to the
lock position.
Cross Section of Tool Pot

(Tool Locking Pin in Release Mode)
Tool Locking
Pin
Manual Release
Tool Pad
Manual Eject
Tool Pin
Rear View of Tool Pot
FIGURE 30.10- 6
Manual Load/Unload and Tool Pot Cross Section

Chain Tool Changer Auto/Manual
Rotation Lighted Pushbutton
Enable
Pushbutton
Jog Magazine
CCW
Pushbutton
Unload Tool Load Tool

Jog Magazine Foot Pedal Foot Pedal
CW Emergency Stop
Pushbutton Pushbutton
Tool
Magazine
Door Interlock
FIGURE 30.10- 7
Manual Tool Load/Unload Controls

HYDRAULIC CONTROL ELEMENTS
FIGURE Control Element Electrical Function GIFU Description

30.10- 9 Label
Position
1 Single Head Solenoid DP-Y12 Eject tool from tool pot after Forwarding for tool unloading
release. Manual operation
2 Single Head Solenoid DP-Y13 Manual release tool from tool pot Tool Unloading Release
or allow tool to be loaded
3 Single Head Solenoid DP-Y14 Auto release tool from tool pot Tool Changing Release
Only used with 90,110 & 120 Tool Magazines Engage cylinder to position & The movement of hydraulic
hold tool magazine chain during cylinder for positioning
4 Single Head Solenoid DP-Y15 tool change.
5 Right Twin Head Solenoid DP-Y7 Tool arm extend and adjust Hydraulic cylinder of tool pulling
speed tool arm extends retracting
and Throttling Valve
5 Left DP-Y8 Tool arm retract and adjust speed Hydraulic cylinder of tool pulling
tool arm retracts contracting
6 Right Twin Head Solenoid DP-Y9 Tool arm rotate 180° CW and Backwarding for tool changing
adjust rotation speed
and Throttling Valve
6 Left DP-Y10 Tool arm rotate 180° CCW and Forwarding for tool changing
adjust rotation speed
7 Right Twin Head Solenoid DP-Y4 Tool changing mechanism slow Tool arm parallel shifting to tool
movement at tool magazine magazine
7 Left DP-Y5 Tool changing mechanism slow Tool arm parallel shifting to
movement at spindle spindle
8 Twin Head Solenoid and DP-Y6 Tool changing mechanism fast Parallel shifting moving with high
Throttling Valve movement and adjust slow speed speed
(right side) and adjust fast speed
(left side)
TABLE 30.10- 2
Hydraulic Control Elements (Use with FIGURE 30.10- 8)

For 90 or 120 Tool Magazine For 60 Tool Magazine
8
8 7
6
7L 5
7R
3
6L 6R 2
1
5L
5R
3 Hydraulic Pressure
from X-services
Manifold Hydraulic Return to
2 X-services Manifold
FIGURE 30.10- 8
Hydraulic Solenoids Mounted on Rear of Tool Magazine

Means Fast Travel Means Slow Travel
FIGURE 30.10- 9
GIFU Flow Illustration

MECHANICAL INSTALLATION AND SETUP
The tool changer has been completely assembled, mounted to the machine and tested at the factory. It is
disassembled and shipped in a number of pieces. The tool changer platform and tool changer access platform are
shipped, separated from the column and tool magazine. The tool magazine, tool changing mechanism with tool arm
and one section of the transfer rail is shipped as a unit. The remaining two sections of the transfer rail, the tool
changing mechanism rail support bracket, and the tool storage retainer are shipped separately. For 90 & 120 tool
changers there is a bracket that supports the tool magazine to the column (FIGURE 30.10- 10), which is also shipped
separately.
Rear View of Tool Magazine

Tool
Magazine
Magazine Support
Bracket
Column
FIGURE 30.10- 10
Magazine Support Bracket (90, 110 & 120 Tool Magazines Only)
INSTALLATION
Begin the installation by attaching the tool changing mechanism rail support bracket to the column and attach the two
sections of tool changing mechanism transfer rail to the bracket. For 90 & 120 tool changers, assemble the tool
magazine bracket to the column, the six M16 X 40 cap screws with lock washers should be finger tight at this time.
The tool changer platform must be assembled to the column (). Assuming that the proper lifting equipment is
available, the tool magazine with tool changing mechanism should FIGURE 30.10- 11 to be mounted onto the tool
changer platform. To make the alignment process easier, make sure the M30 jack screws (FIGURE 30.10- 11) are
below the bottom of tool magazine by approximately 25 mm (1”) before putting tool magazine on tool changer
platform.

Bottom View of Tool Magazine on Tool Changer Platform
View in this
Direction
Below
M30 X 110 Hex

Head Screw
M30 Jam Nut
Tool Magazine
M20 X 100 Hex
Head Screw
M20 X 120 Hex
Head Screw

Column
M20 Jam Nut

FIGURE 30.10- 11
Jack Screws on Bottom of Tool Magazine
Tool Changing Mechanism Transfer Chain
Rail
Section
Splice
Locating Pin and

Bracket for Rail
Section Splice
FIGURE 30.10- 12
Aligning Tool Changing Mechanism Rail to Rail Section Attached to Column

Using jack screws (FIGURE 30.10- 11), adjust the position of the tool magazine on the tool changer platform so that
the transfer rail on the tool changing mechanism aligns with the transfer rail section mounted to the column. The
locating pin shown in FIGURE 30.10- 12 should be removed before connecting the rail sections and reinserted after
the splice has been made.
For 90 & 120 tool changers, assemble support bracket (FIGURE 30.10- 10) to rear of tool magazine with six M16 X
40 cap screws. Screws should only be finger tight at this time. The column must be aligned before these bolts and
those holding the bracket to the column are permanently fastened.
Once the transfer rail sections are spliced together, extend and fasten the tool changing mechanism transfer chain
(FIGURE 30.10- 12). There are eight cap screws, which hold the chain to the rail. On the opposite end, near tool
magazine is the chain-adjusting block (FIGURE 30.10- 13).
Transfer Chain Transfer Chain Spindle

Adjusting Block
This block is used to depress the plunger on tool

arm, unlocking the grippers
FIGURE 30.10- 13
Tool Changing Mechanism Transfer Chain
Connect all electrical wires and hydraulic hoses from the utility carriers to the manifolds or junction boxes. This will
vary with the type of equipment shipped with the machine. Always use the machine specific electrical and hydraulic
schematics that were shipped with your machine.
For 90 & 120 tool changers, after column alignments have been completed the tool magazine support bracket should
be permanently fastened. Apply “Loctite” to each of the bolts holding the bracket to the column and back of tool
magazine. Bolts should be threaded “finger tight”, so that column alignment is not altered.
TOOL CHANGER SETUP
The following procedures have been completed at the factory and should not need to be repeated. However, in the
case of a repair or part replacement, the procedures may have to be initiated again. The following steps are for
informational purposes only. If the tool changer requires set-up, it should be performed only by qualified personnel
such as a MAG service representative.
1. Using the exchange arm setup page (see tool changer section in electrical manual) verify tool exchange I/O
and motion of the tool changing mechanism.
A. Exchange arm extend (DP-S6) and retract (DP-S7)
B. Exchange arm CW (DP-S9) and CCW (DP-S10). (CW/CCW looking from behind tool arm towards
auxiliary table or floor plate)
C. Exchange arm back/forth motion – motion to magazine or to spindle

2. Using the exchange arm setup page (see tool changer section in electrical manual) verify limit switch I/O
locations by moving the exchange arm to proper locations. FIGURE 30.10- 14 shows location of limit switches
and the associated rail mounted detecting bars.
A. Exchange arm at magazine stop (DP-S12)
B. Exchange arm at magazine slowdown (DP-S14)
C. Exchange arm at park position (DP-S13)
D. Exchange arm at spindle slowdown (DP-S14)
E. Exchange arm at spindle stop (DP-S16)
F. Exchange arm in machine area (will go high when out of machining area) (DP-S15)
Exchange arm at magazine stop
Exchange arm at park position
Exchange arm slowdown
Exchange arm in machine area
Limit Switches
Exchange arm at spindle stop
Limit Switch Detecting Bars
FIGURE 30.10- 14
Tool Changing Mechanism Rail Position Limit Switches and Detecting Bars
3. Establish tool magazine zero location setting. Use the tool magazine setup page and exchange arm setup
page (see tool changer section in electrical manual). The tool arm and #1 tool pot must be aligned. After
alignment, the #1 tool pot will be set at 0.000 degree rotation. For 90 and 120 tool pot magazines, ensure that
the magazine is locked into position before attempting to find the zero location.
A. Tool Magazine CW & CCW motion. The tool pot numbers should count up on setup page as moved
CW looking through the magazine towards the column. Move magazine so tool pot #1 is in the
automatic tool load/unload position.
B. Use the tool changer alignment tools (FIGURE 30.10- 15 shows tools used with ANSI B5.50 tools) and
the exchange arm setup page to lineup tool pot #1 with arm. The taper bushing is loaded into tool pot.
Ring bushing is loaded into gripper of tool arm. (The tool arm operates mechanically to push in plunger
and unlock the gripper as the arm moves to the tool.) Guide bar is inserted through ring bushing into
taper bushing. When guide bar can be rotated 360°, arm will be aligned with tool pot (FIGURE 30.10-
18).

Retention Knob #50,A Ring Bushing
(M.1006.6560) (M.1006.7104)
Guide Bar
(M.1006.7103)
Taper Bushing
(M.1006.7105)
FIGURE 30.10- 15
Tool Changer Alignment Tools ANSI B5.50 (M.1007.0364)
C. Adjustments to horizontal arm position are made by modifying the hard stop and making sure the
slowdown plunger is not fully compressed (FIGURE 30.10- 16).
D. Vertical adjustments are made to the tool pot location. Use the incremental mode to move the tool pot
into position. Moves are made in units of degrees.
E. When the tool pot is aligned with the arm, see electrical manual for “setting the chain encoder offset”.
Slowdown Plunger
Spindle
Adjustment
Magazine
Adjustment
“Arm into Magazine” “Arm into Spindle”

Adjustment Bolt & Slowdown Plunger Adjustment Bolt & Slowdown Plunger (90 &120
(60 Tool Pot Changer) (60 Tool Pot Changer) Tool Pot Changer)
FIGURE 30.10- 16
Adjustment Bolt & Slowdown Plunger Locations
4. The following miscellaneous functions should be verified:
A. Tool changer Emergency Stop is functional (FIGURE 30.10- 7).
B. The Auto/Manual button (FIGURE 30.10- 7) is illuminated during automatic mode.
C. The tool load and tool unload foot pedals are operational. Door must be open. Manual mode button
depressed. Controls must be off manual page. Unload releases tool and ejects.
D. Magazine door closed registers on tool magazine setup page.

E. Magazine door lock/unlock selector switch located on the operator control panel.
F. Manual magazine movement CW & CCW using buttons (FIGURE 30.10- 7). Manual mode button
depressed. Magazine rotation enable pushbutton must be depressed. Controls must be off manual
page.
G. The tool in pocket registers on tool magazine setup page.

5. Set speeds of transfer motion. Use FIGURE 30.10- 17, which is a representation of the solenoid and flow
controllers mounted on back of tool magazine.
A. The transfer arm traverse speed between slowdowns (at spindle, park and magazine) is set with flow
controller labeled “Transfer Arm Speed (Fast)”. In the slowdown areas, speed is set by flow controller
labeled “Transfer Arm Speed (Slow)”. The flows are adjusted to meet a 15 second tool change.
B. For the exchange motion (arm rotation CW & CCW), flow controllers labeled “Adjust Speed Arm CCW”
and “Adjust Speed Arm CW” are opened fully CCW and then knob closed one full turn CW. Adjust for
balance if required.
C. For the arm extend/retract (removing or inserting a tool), flow controllers labeled “Adjust Speed Arm
Extend” and “Adjust Speed Arm Retract” are opened fully CCW and then knob closed half (0.5) turn
CW.
Tool Arm High Speed

Transfer Arm Transfer Arm
(Solenoid)
Speed (Fast) Speed (Slow)
DP-Y6
Tool Arm Low Speed

(Solenoid)
DP-Y5 DP-Y4
Tool Arm CW/CCW

Adjust Speed (Solenoid) Adjust Speed
Arm CCW DP-Y10 Arm CW
DP-Y9
Arm Extend/Retract
(Solenoid) Adjust Speed
Adjust Speed
Arm Retract DP-Y8 DP-Y7 Arm Extend
Tool Magazine
Position & Clamp NOT USED ON
60 TOOL POT
DP-Y15
CHANGERS
Auto Tool Release
DP-Y14
Manual Tool
Release
DP-Y13
Manual Tool
Unload
DP-Y12
FIGURE 30.10- 17
Solenoid & Flow Controller Layout
6. Move the Ram axis to machine coordinate zero position.

7. Establish Y-axis tool change position. Use the exchange arm setup page (see tool changer section in
electrical manual). The tool arm and spindle must be aligned.
A. The spindle must be oriented at 0.0 degrees, which will properly align arm with spindle.
B. Use the tool changer alignment tools (FIGURE 30.10- 15) and the exchange arm setup page to lineup
spindle with arm. The taper bushing is manually loaded into spindle. Ring bushing is loaded into
gripper of tool arm.
C. Adjustments to horizontal arm position are made by modifying the hard stop on tool changing
mechanism and making sure the slowdown plunger is not fully compressed (FIGURE 30.10- 16).
D. Jog Y-axis to align center of gripper arm. You must move arm towards tool magazine in order to use Y-
axis jog.
E. When guide bar, inserted into ring bushing and taper bushing, can be rotated 360° the arm is aligned to
spindle (FIGURE 30.10- 18). Rotate arm 180° and repeat alignment. Equalize any difference between
the two grippers.
F. Record the final Y-axis position and edit per electrical manual instructions.
8. Establish Z-axis (spindle in/out) tool change position.
A. Remove alignment equipment and insert a dummy tool into spindle.
B. Engage the exchange arm into the V-Flange of the dummy tool. The Z-axis must be adjusted until no
deflection is apparent in the exchange arm.
C. See tool changer section in electrical manual for complete procedure.
FIGURE 30.10- 18
Using Exchange Arm Alignment Tool
9. Try various automatic and manual tool changes to ensure reliability.
10. Apply grease to the flange of all tools to be cycled and on both tool arm gripper jaws.

SECTION 69.10
REFERENCE MATERIAL
TABLE OF CONTENTS
TITLE PAGE
BOLT TIGHTENING TORQUES-METRIC .....................................................................................................................1
BOLT TIGHTENING TORQUES-INCH ..........................................................................................................................2
CONVERSION CHART..................................................................................................................................................3
ANSI HYDRAULIC SYMBOLS.......................................................................................................................................4

BOLT TIGHTENING TORQUES-METRIC
Engineering suggested torque values for METRIC SOCKET HEAD CAP SCREWS. For Hex head, Button head, Flat
head, Shoulder screws, etc contact Engineering for proper torque values. The torque values listed also apply to cap
screws with pre-applied thread locker and manually applied Loctite.
Note: Torques noted on layouts or drawings supersede this chart.
METRIC Plain Finish and Yellow Zinc Plated

(Document: MD.2001.4524 REV 0 Issued: 5/14/1999)
NOMINAL PLAIN FINISH YELLOW ZINC PLATED
SIZE IN-LBS. FT-LBS. N-M IN-LBS. FT-LBS. N-M
M1.6 2.6 0.2 0.3 2.3 0.2 0.3
M2 5.3 0.4 0.6 4.8 0.4 0.5
M2.5 11.0 0.9 1.2 9.9 0.8 1.1
M3 19.0 1.6 2.1 17.1 1.4 1.9
M4 41.0 3.4 4.6 36.9 3.1 4.2
M5 85.0 7.1 9.6 76.5 6.4 8.6
M6 140 12 16 126 11 14
M8 350 29 40 315 26 36
M10 680 57 77 612 51 69
M12 1,200 100 136 1,080 90 122
M14 1,900 158 215 1,710 143 193
M16 2,900 242 328 2,610 218 295
M20 5,750 479 650 5,175 431 585
M24 9,700 808 1,096 8,730 728 986
M30 19,900 1,658 2,248 17,910 1,493 2,024
M36 34,100 2,842 3,853 30,690 2,558 3,468
M42 55,580 4,632 6,280 50,022 4,169 5,652
M48 75,800 6,317 8,564 68,220 5,685 7,708
REFERENCE MATERIAL 69.10 -1

BOLT TIGHTENING TORQUES-INCH
Engineering suggested torque values for INCH SOCKET HEAD CAP SCREWS. For Hex head, Button head, Flat
head, Shoulder screws, etc contact Engineering for proper torque values. The torque values listed also apply to cap
screws with pre-applied thread locker and manually applied Loctite.
Note: Torques noted on layouts or drawings supersede this chart.
INCH Plain Finish

(Document MD.2001.4524REV 0 Issued: 5/14/1999)
NOMINAL COARSE THREAD FINE THREAD
SIZE IN-LBS. FT-LBS. N-M IN-LBS. FT-LBS. N-M
#6 34 3 4 36 3 4
#8 59 5 7 60 5 7
#10 77 6 9 91 8 10
1/4" 200 17 23 240 20 27
5/16" 425 35 48 475 40 54
3/8" 750 63 85 850 71 96
7/16" 1,200 100 136 1,350 113 153
1/2" 1,850 154 209 2,150 179 243
9/16" 2,500 208 282 2,700 225 305
5/8" 3,400 283 384 3,820 318 432
3/4" 6,000 500 678 6,800 567 768
7/8" 8,400 700 949 9,120 760 1,030
1" 12,500 1,042 1,412 13,200 1,100 1,491
1-1/8" 14,900 1,242 1,683 16,600 1,383 1,876
1-1/4" 25,000 2,083 2,825 27,000 2,250 3,051
1-3/8" 33,000 2,750 3,728 35,000 2,917 3,954
1-1/2" 43,500 3,625 4,915 47,000 3,917 5,310
1-3/4" 71,500 5,958 8,078 82,500 6,875 9,321
2" 108,000 9,000 12,202 125,000 10,417 14,123
2-1/4" 155,000 12,917 17,513 186,000 15,500 21,015
2-1/2" 215,000 17,917 24,292 248,000 20,667 28,020
2-3/4" 290,000 24,167 32,766 330,000 27,500 37,285
3" 375,000 31,250 42,369 430,000 35,833 48,583
69.10 -2 REFERENCE MATERIAL

CONVERSION CHART
CONVERSION CHART
TO CHANGE METRIC TO ENGLISH (U.S.) DIVIDE BY
TO CHANGE ENGLISH (U.S.) TO METRIC MULTIPLY BY
PRESSURE Pounds per Square Inch (psi) Kilo Pascal (KPa) 6.895
Pounds per Square Inch (psi) Bar 0.0689
POWER Horsepower (HP) Kilowatts (kw) 0.746
TEMPERATURE Deg. Fahrenheit (°F) Deg. Celsius (°C) (°F-32) x 0.556
LENGTH Inches (in) Centimeters (cm) 2.54

Inches (in) Millimeters (mm) 25.40
Inches (in) Meters (m) 0.0254
Feet (ft) Meters (m) 0.305
FORCE Pounds (lbs) Newtons (N) 4.448

Inch pounds (in-lbs) Newton meters (Nm) 0.113
Foot rounds (ft-lbs) Newton meters (Nm) 1.356
VOLUME Pint (pt) Liters (L) 0.473

Gallons (G Liters (L) 3.785
Gallons Per Minute (GPM) Liters Per Minute (LPM) 3.785
Cubic inches (in3) Liters (L) 0.01639
Cubic inches (in3) Cubic meter (m3) 0.00001639
MASS Ounce (oz) Gram (g) 28.349

Pound (lb) Kilogram (kg) 0.454
AREA Square inches (in2) Square meters (m2) 0.0006451

ANSI HYDRAULIC SYMBOLS
LINE AND LINE FUNCTIONS PUMPS
LINE, WORKING PUMP, SINGLE
LINE, PILOT (L>20W) FIXED DISPLACEMENT
LINE, DRAIN (L<5W) PUMP, SINGLE
CONNECTOR VARIABLE DISPLACEMENT
LINE, FLEXIBLE MOTORS AND CYLINDERS
LINE, JOINING
MOTOR, ROTARY,
VARIABLE DISPLACEMENT
LINE, PASSING
DIRECTION OF FLOW MOTOR, ROTARY VARIABLE

DISPLACEMENT
HYDRAULIC
PNEUMATIC MOTOR, OSCILLATING
LINE TO RESERVOIR
ABOVE FLUID LEVEL CYLINDER, SINGLE ACTING
BELOW FLUID LEVEL
LINE TO VENTED MANIFOLD CYLINDER, DOUBLE ACTING
PLUG OR PLUGGED
CYLINDER, DIFFERENTIAL ROD
CONNECTION
CYLINDER, DOUBLE END ROD

RESTRICTION, FIXED
CYLINDER, CUSHIONS BOTH

RESTRICTION, VARIABLE ENDS
METHODS OF OPERATION METHODS OF OPERATION
PRESSURE COMPENSATOR LEVER

DETENT PILOT PRESSURE
MANUAL SOLENOID
SOLENOID CONTROLLED PILOT
MECHANICAL
PRESSURE OPERATED
PEDAL OR TREADLE SPRING
PUSH BUTTON SERVO
The symbols shown conform to the American National Standards (ANSI) Specifications. Basic symbols can be
used in any combination. No attempt has been made to show all combinations.
69.10 -4 REFERENCE MATERIAL

MISCELLANEOUS UNITS BASIC VALVE SYMBOLS (CONT.)
DIRECTION OF ROTATION VALVE, SINGLE FLOW PATH,

(ARROW IN FRONT OF SHAFT) NORMALLY OPEN
VALVE, MAXIMUM PRESSURE

COMPONENT ENCLOSURE
(RELIEF)
BASIC VALVE SYMBOL,

RESERVOIR, VENTED
MULTIPLE FLOW PATHS
FLOW PATHS BLOCKED IN
RESERVOIR, PRESSURIZED
CENTER POSITION
MULTIPLE FLOW PATHS (ARROW
PRESSURE GAGE
SHOWS FLOW DIRECTION)
TEMPERATURE GAGE VALVE EXAMPLES
FLOW METER (FLOW RATE) UNLOADING VALVE, INTERNAL

DRAIN, REMOTELY OPERATED
ELECTRIC MOTOR
DECELERATION VALVE.
NORMALLY OPEN
ACCUMULATOR, SPRING
LOADED
SEQUENCE VALVE, DIRECTLY
ACCUMULATOR, GAS OPERATED, EXTERNALLY
CHARGED DRAINED
FILTER OR STRAINER
PRESSURE REDUCING VALVE
HEATER
COUNTER BALANCE VALVE WITH
INTEGRAL CHECK
COOLER
TEMPERATURE AND PRESSURE
COMPENSATED FLOW CONTROL
TEMPERATURE CONTROLLER WITH INTEGRAL CHECK
DIRECTIONAL VALVE, TWO

INTENSIFIER
POSITION, THREE CONNECTION
DIRECTIONAL VALVE, THREE

PRESSURE SWITCH
POSITION, FOUR CONNECTION
BASIC VALVE SYMBOLS VALVE, INFINITE POSITIONING
(INDICATED BY HORIZONTAL
CHECK VALVE BARS)
MANUAL SHUT OFF VALVE
BASIC VALVE ENVELOPE
VALVE, SINGLE FLOW PATH,

NORMALLY CLOSED

SECTION 72.10
CAMERA SETUP
TABLE OF CONTENTS
TITLE PAGE
INTRODUCTION............................................................................................................................................................1
SYSTEM ........................................................................................................................................................................2
CAMERA COMPONENTS ..................................................................................................................................3
SETUP PROCEDURE ...................................................................................................................................................5
ON-SCREEN DISPLAY.......................................................................................................................................7
INTRODUCTION
The camera on your machine is a Costar model SI-C400N color CCD camera. Vendor documentation was supplied
with your machine. The purpose of this addendum is to provide an abbreviated setup procedure to aid you in
adjusting your system for a crisp and focused display on your monitor. The dimensions and settings listed in the
following setup were obtained on a test system in our factory. Your final dimensions and settings should be close to
what is listed but can vary from system to system. Therefore use our settings as a guide but adjust your system as
needed to obtain the best picture on your monitor.
FTR VTC
FIGURE 72.10 - 1
Camera
The camera is mounted to the headstock of your machine in a similar fashion to that shown in FIGURE 72.10 - 1.
CAMERA SETUP 72.10 -1

SYSTEM
The complete system consists of:
• Camera mounted in protective canister
• Monitor
• Control Console
FIGURE 72.10 - 2
System Components
72.10 -2 CAMERA SETUP

CAMERA COMPONENTS
The main components, shown in FIGURE 72.10 - 3 & FIGURE 72.10 - 4, of the camera system consist of:
• Camera
• C-Mount Adapter
• Spacer (may not be used)
• Camera Lens
Camera
C-Mount
Spacer
FIGURE 72.10 - 3
Camera Components

Mounting
Flange
FIGURE 72.10 - 4
Camera Lens

SETUP PROCEDURE
1. Remove protective canister (FIGURE 72.10 - 5) to access the camera and perform the setup procedure. It is
advisable to thoroughly clean the outside of canister prior to disassembly.
FIGURE 72.10 - 5
Camera Canister
2. Remove the two ¼-20 screws that mount the camera and lens to the enclosure arm.
3. If the 5 mm spacer (FIGURE 72.10 - 3) is installed it should be removed at this time.
4. Remove the camera lens.
5. Loosen two set screws on the C-Mount adapter.
6. Adjust the C-Mount adapter to obtain a dimension of .256” as shown in FIGURE 72.10 - 6.
7. Tighten two set screws on the C-Mount adapter.
8. Reattach the camera lens to the camera/adapter assembly.
9. Minor tweaking may be needed to ensure mount hole orientation on the camera body and camera lens with
respect to the enclosure mount arm.
10. Attach camera and lens to enclosure arm with two ¼-20 screws.
11. Access the On-Screen display using the buttons on the back of the camera body (FIGURE 72.10 - 7).
12. Navigate to the AGC setting; for button functions see FIGURE 72.10 - 8.
13. Set the AGC to 16dB.
14. Exit setup.
15. Test camera zoom, focus and clarity using the control console.
16. Make minor adjustments as needed.
17. Install canister when complete.
****************************************************************************************
SECURE CANISTER TIGHT ENOUGH TO PREVENT COOLANT INVASION BUT NOT SO TIGHT AS
TO BREAK GLASS.
****************************************************************************************

Adjust to
.256”
FIGURE 72.10 - 6
C-Mount Dimension

ON-SCREEN DISPLAY
To access the on screen displays for the system use the buttons on the back panel of the camera body. For button
locations see FIGURE 72.10 - 7. For button function see FIGURE 72.10 - 8.
FIGURE 72.10 - 7
Camera Back Panel

FIGURE 72.10 - 8
Setup Button Functions

SECTION 72.20
ENCODER FEEDBACKS – FANUC
TABLE OF CONTENTS
TITLE PAGE
ENCODER FEEDBACKS ..............................................................................................................................................1
ENCODER TYPES ........................................................................................................................................................2
HEIDENHAIN ENCODER INFORMATION ....................................................................................................................2
HOW LINEAR SCALES WORK ..........................................................................................................................3
GLASS SCALES .................................................................................................................................................3
STEEL TAPE SCALES .......................................................................................................................................3
PULSE DISTANCE CODED SCALES – HOW THEY WORK .............................................................................3
LS186C ...............................................................................................................................................................4
SPECIFICATIONS....................................................................................................................................4
LC191 F, LC192 F & LC193 F ENCODERS........................................................................................................5
SPECIFICATIONS....................................................................................................................................5
LB382 C ENCODER............................................................................................................................................6
SPECIFICATIONS....................................................................................................................................6
HEIDENHAIN LINEAR ENCODER PRE-INSTALLATION INFORMATION ...................................................................7
BUILDING THE LB382C STEEL TAPE SCALE ..................................................................................................7
SCALE MOUNTING TIPS .................................................................................................................................10
ANGULAR & ROTARY ENCODER INFORMATION....................................................................................................10
ERN 480 ROTARY ENCODER .........................................................................................................................10
ERN 480 SPECIFICATIONS ..................................................................................................................11
ERM 280 ...........................................................................................................................................................11
ERM 280 SPECIFICATIONS:.................................................................................................................12

MOUNTING / SERVICING THE ERM 280 ENCODER .....................................................................................12
SEPARATE DETECTORS...........................................................................................................................................13
ENCODER FEEDBACKS
These are the typical encoders used with each of the MAG machine series.
Machine Axis Typical feedback scale used.
X-axis 523 – LC193 F Absolute scale.

524 – 527 - LB382 C pulse distance coded scale.
Z-axis (ram) LC193 F absolute scale.
C-axis 523 – Table drive motor encoders (no separate C axis encoder).
VTC 524 – 527 - ERN 280 angular encoder.
V-axis & V1-axis (rail) LC183 glass absolute encoder. Optional.
Table Motor encoder(s) and a bero switch.
CS (spindle in ram) Machines since 2008 ERN 420 for orienting.

Before 2008, motor encoder and bero switch used for orienting.
Tool & pallet changers Motor encoders only.
X-axis LB382 C pulse distance coded scale.
Y-axis LB382 C pulse distance coded scale.
Spindle Motor encoder only.
HBM Saddle LB382 C glass or steel tape (depending on axis travel).
Ram LB382 C glass.
B-axis RCN 220 angular encoder. (This encoder varies.)
CS (spindle) Motor encoder and a bero switch used for orienting.
Tool & Pallet changer Motor encoders only.
X-axis LC193F glass absolute encoder.
Y-axis LC193F glass absolute encoder.
Z-axis (column axis) LC193F glass absolute encoder.
HMC W (optional live spindle) Motor encoder only – absolute feedback.
SPINDLE Motor encoder only.
B-axis RON 886C.
Tool Mag Motor encoder only.
Pallet changer Motor encoder only.
FIGURE 72.20 – 1
Typical encoders used.
ENCODER FEEDBACKS – FANUC 72.20 - 1

Note: Refer to the Machine Electrical Prints for the wiring connections used between the encoders and the
Fanuc control.
ENCODER TYPES
This section contains information on encoder feedback systems; however, the information contained in this section
does not pretend to cover all details or variations in the equipment nor to provide for every possible contingency to be
met in connection with installation, operation, or maintenance of encoders and transducers.
Encoders are made in a wide variety of configurations.
Linear encoders Linear scales are used on linear travel axes in various scale lengths and resolutions
to break a linear movement into a digital value.
Rotary & Angular encoders Used on rotary axes and positioners to break an angular movement into an angular
digital value, they can also be used for linear travel where it is impossible or
impracticable to use a linear encoder. Generally, rotary encoders are not as accurate
as angular encoders.
Incremental encoders Incremental encoders produce digital signals that increase or decrease the measured
position or value by incremental steps. These encoders typically have a fine
resolution that has a repeating pattern over a fixed distance.
Absolute encoders Absolute encoders produce a coded digital value which represents an absolute linear
or rotary magnitude or displacement. Absolute linear scales are now available in
lengths up to 4 meters. The feedback from an absolute encoder is a unique value for
any location of the reader head. This eliminates the need for a referencing cycle.
Pulse distance coded These scales are type of incremental scales that have a set of marker pulses that are
spaced at unequal distances from each other all the way along the scale length. A
control setup to use the pulse distance coded scales is referenced by hitting two or
three consecutive marker pulses. In this way, the axis can be referenced nearly
anywhere in its travel. The only point where referencing cannot be done is if the axis
is left at the extreme plus end of the axis travel.
HEIDENHAIN ENCODER INFORMATION
The Heidenhain linear encoder measuring system used on these VTC machines with the Fanuc control systems
consists of a scale, a scanning head and with some scales a Fanuc Separate Detector. The following are several
facts about these scales on these machines:
• The linear encoders used on these machines operate on the principle of photo-electrically scanning very fine
optical gratings. These gratings may be reflective (steel tapes) or transparent (glass).
• Incremental, pulse distance coded and absolute scales have all been used. Refer to SECTION 69.30 (Electrical
manual) for information on the referencing requirements of each different feedback system.
• The Separate Detector can interface with up to four feedbacks. + 5VDC Power is fed from the Separate Detector
to the scales.
• The scales used on these machines are typically pressurized with clean dry air to create a positive pressure in
the scale. Internal pressure of about .5 to 1 bar (about 7 to 14 psi) helps keep coolant and chips out of the
internal workings of the scale.
Note: Always make sure that the air dryer/filter is in good working order. Pumping dirty air into the scales
is much worse than not putting pressurized air into the scales.
72.20 - 2 ENCODER FEEDBACKS – FANUC

HOW LINEAR SCALES WORK
The Heidenhain linear scale can either be a DIADUR® glass scale with transmitted light grating or an AURODUR®
metal scale with reflected light grating. The scale is contained and protected within an aluminum or steel scale
housing. The scale units come in a variety of different fixed lengths and resolutions.
Scanning Reticle
GLASS SCALE
Incremental
Signals
Absolute
Light Signals
Source
Condenser
Lens
Solar Grating Period
Cells of Scale
FIGURE 72.20 - 2
Typical Heidenhain Absolute Linear Encoder
The absolute scale is made up a of a series of incremental scale patterns and a series of absolute scale patterns that
combined allow the control to auto reference the axes at power up.
The trick to how scales work is the fact that the width of the lines changes in a repeating pattern down the length of
the scale. The distance between the centers of the lines is constant. So as the reader head moves down the scale,
the amount of light that gets through (or is reflected on the steel scales) changes. The output of the solar cells varies
in a sine wave shape as the head moves down the scale. The distance moved to go through one sine wave varies
with the different scales. For some scales this distance is 20 mm, some are 32 mm, others are as much as 80 mm.
GLASS SCALES
Generally glass scales are typically limited to measuring about 3 meters (120") and some, depending upon the
specific encoder package, include error compensating devices every 100 mm (4"). Encoders which can measure
longer distances (up to 30,000 mm / 100') use a steel scale tape. Glass scales are mounted inside a one piece
aluminum extrusion body. All along one side of the body is an opening where the read head slides through a set of
rubber sealing lips that keep dirt out of the scale interior.
STEEL TAPE SCALES
Linear encoder packages with a steel scale tape are available in both single piece scale housing units and in
segmented scale housing units with a single tape for long measuring lengths. The scale tape for the segmented units
can be rolled into a coil for storage, and when mounted in the scale body, the tape and is stretched inside the
housing, and then "set" using a laser and finally clamped.
The steel tapes are typically about 0.3 mm (0.01") thick, with gold grating lines at a pitch of 100 micrometers or less.
The optical signals are picked up by reflection. The metal scale tape encoder units generally include error
compensating devices every 200 mm (8") depending upon the specific encoder package. Some compensation is also
possible by tensioning the scale tape as necessary.
PULSE DISTANCE CODED SCALES – HOW THEY WORK
Pulse distance coded scales are incremental scales so they provide a high degree of accuracy but axes with
incremental scales require referencing at power on. The pulse coded scale is a combination of both incremental and
absolute scales.

The output of the pulse coded scale is a sine and cosine waveform set. There are two series of marker pulses down
the length of the scale. One set of markers is evenly space down the length of the scale while the second set of
markers is spaced an increasing distance from each other along the length of the scale.
The axis only has to move between 10 and 20 mm to find where the slide is and pick up the incremental feedback.
Several different Heidenhain scales have been used on these machines. The following pages should include
information on the scales that have been used on your machine.
Each set of markers is longer by a fixed amount.
20 20 20
10.02
10.04
10.06
Incremental encoder
grating lines
20.02 20.02
FIGURE 72.20 - 3
Pulse Coded Scale Marker Pulse Layout
LS186C
The LS186C encoder is a pulse distance coded scale so an axis with this scale must be referenced when the
machine is first started. Anytime the scale number ends with a C, it is a pulse distance coded scale.
The feedback cable from this scale interfaces with the Separate Detector. The scale has a one piece aluminum body
with a single piece glass scale mounted inside. Rubber sealing lips help keep out dirt and coolant. The scale is
pressurized with .7 bar (about 10 psi).
When mounting the scale body be sure the scale is aligned parallel to the axis travel within .05 mm (.002 inches).
New scales will have two red clips that hold the reader head during shipping. Keep the two red clips holding the
reader head in place when mounting the reader head bracket to the reader head. Adjust the bracket to the scale so
there is no tension on the reader head when the clips are removed.
SPECIFICATIONS
Measuring standard .............................. DIADUR glass scale
Output signals ....................................... 1 Vpp
Signal period ......................................... 20 um
Accuracy grades .................................... ± 5 µm, ± 3 µm
Recommended measuring steps............ 1 µm, 0,5 µm
Measuring lengths.................................. 240 mm to 3040 mm

LC191 F, LC192 F & LC193 F ENCODERS
These scales are absolute feedback scales. If these scales are used, the control, when turned on, automatically
scans the scale and finds where the read head is in the scales travel. The axis position is then updated and the axis
is referenced.
These scales interface with the Fanuc control using a RS-485 serial communication link. The cables and connectors
come pre-wired and are interfaced into the CNC using the Separate Detector Unit (labeled SEPDET). There are no
test points where you can see the signals coming out of the scale.
The scale must be aligned When mounting the scale tighten
within .1 mm (.004"). the middle bolt first, then tighted
Check against this surface. the bolts as shown.
Tighten
Tighten fourth
Tighten
third
second
Tighten
Tighten fifth
Tighten sixth
last
To SEPDET
Be sure there is no pressure on the

head when mounted to the machine.
The scale is pressurized Tension on the head can cause pre-
to keep dirt & coolant out. mature failure of the scale.
FIGURE 72.20 - 4
LC191 F, LC192 F & L193 F Linear Encoders
SPECIFICATIONS
Incremental Signals Square wave signals (TTL) Ua1, U a2 and their inverted signals Ua1 and Ua2.
Reference Mark Signal Square wave pulse Ua0 and its inverted pulse Ua0.
Delay time: td ≤0.1 µs.

Pulse width 270° el. as special version.
Fault Detection Signal Square wave pulse Uas Pulse width: ts ≥20 ms
For special version reference pulse width 270° when Uas = Low output signals high
impedance.
Signal Levels Uhigh ≥ 20 mA
Ulow ≤ 20 mA
Load Capacity -Ihigh ≤ 20 mA
Ilow ≤ 20 mA
Cload ≤ 1000 pF
Switching Times Rise time t+ ≤ 100 ns
Fall time t- ≤ 100 ns

LB382 C ENCODER
This version of linear encoder is a pulse distance coded scale that outputs sinusoidal waveforms directly from the
scale to the Siemens drive (connector X421). The scale can be glass or steel tape.
For steel scales, the light is shined at an angle to the grating lines with a pickup head positioned to pickup a reflected
signal. Steel scales are used when axis travels are over 3 meters.
Several housings are bolted Reader head
Once the housing is set, the tape
together to cover the axis run. is stretched in the housing and
the reader head is added.
The output of the scale goes to the

An optional air line pressurizes the scale Siemens drive (connector X421).
to about 1 bar to keep dirt out of the scale.
FIGURE 72.20 - 5
LB382 C Linear Encoder
The steel scale is tensioned (stretched) initially using a special setup box from Heidenhain. Before the tension can be
adjusted, a small cover is removed from the face of the scale and a locking screw is loosened. An adjusting nut is
located at the end of the scale to adjust the tension. MAG uses a laser to verify the tension is correct. The laser is
setup at one end of the axis travel, the CNC and laser are zeroed, the axis is moved to the other end of the scale and
the tape tension is adjusted to put the same reading on the axis readout that is on the laser. Once the tension is set,
the clamping screw is tightened to keep the tension at the proper setting for the life of the machine. Refer to
BUILDING THE STEEL TAPE SCALE later in this section.
Linear compensation is then often used to bring the axis to the required accuracy specifications.
Note: Always turn power off before removing the power cable to any of the Heidenhain scale units. This is
true for any of the connectors into the Siemens control.
SPECIFICATIONS
Signal Levels A: 1 VPP with terminating resistor
B: 1 VPP with terminating resistor
R: 0.4 VPP with terminating resistor
Reference marks are placed every 50 mm.
Input power 5 VDC ± 5%
Operating temp. 0 to 50 degrees C
Max. Velocity 120 m/min.
Cable min. bend radius 6 mm cable 20 mm
10 mm cable 35 mm
8 mm cable 40 mm
Max cable length 150 m (492 feet).

HEIDENHAIN LINEAR ENCODER PRE-INSTALLATION INFORMATION
Before beginning the replacement of a Heidenhain linear encoder, the following items should be observed. On
machines where the encoder package is removed completely for machine shipment, the entire unit must be
reinstalled.
Note: New scales always ship with an instruction booklet from Heidenhain. Always refer to the booklet
first if you have any questions mounting the new scale. With most scales its best to tighten the
middle bolt first and then work out toward the ends of the scale.
1. Ensure that the mounting surfaces for the scale housing and the scanning head are properly cleaned before
proceeding. Never mount a scale on a pointed surface.
2. Use a dial indicator to check that the scale mounting surface is parallel to the machine guide way within 0.1
mm / 0.004") and square within 0.03 mm / 0.0012.
3. Also ensure that the connecting cable exit is at the correct side of the scanning head for the appropriate axis.
4. Never bend the reader head cable at a tight radius. The cable can be damaged.
5. If the scale is provided pressurized air, be sure to replace the air line into the end of the scale or onto the
reader head. Air is always put into the unit that is stationary.
6. There should be less than 1 ohm of resistance between the inside of the reader head cable connector and the
body of the scale. Don't measure to the outside of the connector, its coated with an insulating coating.
Note: For machine shipment, the connecting cables for the encoders for the axes are usually pulled back
to their respective packages and secured at machine tear down. Cable clips may be refitted and in
some cases a draw wire may be left in place for reinstallation of the cable.
Also, watch for transit clamps which may be fitted to the scanning head for shipment. These clamps must be
removed at installation before any axis motion is attempted.
BUILDING THE LB382C STEEL TAPE SCALE
The steel tape scales are assembled right on the machine.
1. The scale body sections are bolted to the machine. Each end section has one bolt hole that has no expansion
gaps. Make sure that you do not use washers that overlap the expansion gaps.
2. The three steel liners are installed first. These liners are used as bearing surfaces so that the transitions
between body segments is smoother.

FIGURE 72.20 - 6
Installing the Scale Liners
3. The photo below shows the gold plated steel tape is hooked to the red plastic clip and carefully fed through the
scale. Never touch the tape. The plastic liner that protects the tape for shipment should be saved in the event
the tape must be removed later.
FIGURE 72.20 - 7
Running the Steel Tape through the Scale Body
4. The end of the tape is anchored to the clip and the screws are tightened.
Note: Make sure that the block is pulled toward the end of the tape when tightening the two screws. You
don’t want the screws to shift in the holes when the tape is tensioned.

FIGURE 72.20 - 8
Mounting the Tape Anchor
5. Hook the steel tape to the end bracket and tighten the tape only so it is just snug. Do not over tighten.
A locking screw clamps the scale

in position once the tension is set.
FIGURE 72.20 - 9
Tightening the Scale
6. Once the tape is assembled, a laser is used to set the correct tension on the tape.
A. The axis is positioned at one end of its travel.
B. The laser is setup.
C. Both the control and laser are set to zero.
D. The axis is moved by the control to the other end of its travel.

E. The tension of the tape is adjusted so that the same readout is seen on both the laser and the CNC.
7. An axis with a steel tape scale will always use linear compensation. If a new tape is installed, the
compensation values should be redone.
SCALE MOUNTING TIPS
1. When mounting the scale, use washers with a small diameter on each bolt. Be sure the washer doesn't cover
the expansion cutout found on most of the bolt holes. Without a washer, the bolt can tweak the scale
alignment as the bolt is tightened.
2. Always mount the center hole (without the expansion cutout) firmly to the machine first. If the scale has two
solid mounting bolt holes (no expansion cutouts, bolt them both tightly if possible.
3. On long, multi segment scale units with the steel tape, make sure the end two segments are both firmly
mounted to the machine. The center segments are held by the expansion joints which allow some movement.
4. Only use the machined edge (shown in the figures above of the scales) when aligning the scale to the axis.
5. Leave the red plastic retention clips on the scale when mounting the reader head to ensure the reader bracket
is fit to the reader head. You don't want any tension on the reader head when the bracket is mounted. WHEN
MOUNTING IS DONE, REMOVE THE PLASTIC CLIPS! DON’T SLIDE THEM TO THE END OF THE SCALE.
Note: If there is tension on the read head, the stainless steel bearings on the read head will wear into the
aluminum extrusion and aluminum will flake off, damaging the scale beyond repair.
6. Plastic air lines are used because they will not condense moisture like a steel or copper line will. Change /
clean the air filters as often as needed to keep the air pumped into the scales clean and dry. It is better not to
put any air into the scales than it is to put in dirty air.
7. When replacing a scale on a machine with a new scale, you may find that the connector for the read head
comes out on the wrong side of the read head. The cable connector can be turned 180° on the head. Refer to
the Heidenhain manual that shipped with your documentation.
ANGULAR & ROTARY ENCODER INFORMATION
Rotary & Angular encoders are used to measure the position of spindle and rotary tables. Generally, rotary encoders
are not as accurate as angular encoders. The optional spindle in the ram, uses a rotary encoder while the C axis
position encoder is an angular encoder.
ERN 480 ROTARY ENCODER
The ERN 480 rotary encoder is used as the spindle feedback encoder for all these VTC machines with the rotating
spindle option. The encoder is mounted at the top of the ram and is driven by a cog belt. Machines that shipped
before 2008, used a bero switch for spindle orient. The encoder improves the positioning accuracy of the spindle.

FIGURE 72.20 - 10
ERN 480 - Rotating Spindle Encoder - All VTC Machines Since Late 2007
ERN 480 SPECIFICATIONS
Incremental signals 5 volt TTL A Quad B
Line count 250 to 5000
Operating power 5 VDC
Max Temp 100°C
ERM 280
The C axis angular encoders used on these machines are typically the Heidenhain ERM 280 encoder.
This encoder is an incremental feedback encoder and is typically mounted at the center of the table for machines with
the optional C axis table drive. The scale uses the magnetic scanning principle. The reader head is mounted on the
carrier and the ring is mounted on the table.
FIGURE 72.20 - 11
ERM 280 Axis Encoder & Reader Head All Machines

ERM 280 SPECIFICATIONS:
Power +5 VDC +/-5%.
Current draw 150 ma
Output 1 VPP sine wave - one reference mark per revolution
Interface Fanuc 01 serial interface
Operating temp. -10° to 100° C. (14° F to 212° F)
MOUNTING / SERVICING THE ERM 280 ENCODER
The ERM 280 scale is made up of two parts, a reader head and a ring. In this application, the reader head is
mounted on the carrier retention plate (on the base) and stays stationary while the encoder ring is mounted on and
spins with the carrier cover plate.
In this photo, the carrier cover has been removed and is sitting to the right of the table center. The reader head is on
the left side and the connector is at the bottom center.
FIGURE 72.20 - 12
Accessing The C Axis Encoder (viewed from front of machine)
Note: Before removing the carrier cover, be sure to have the reader head mounted as far away from the
center of the table as possible.
1. Remove the table from the carrier. Be sure to note the orientation of the table to the carrier. The table must
be reinstalled in the same relationship to the carrier.
2. An access cover on the carrier near the center is exposed. The cover allows access to the reader head
through a rectangular cover.
3. Remove the small access cover near the center of the carrier cover by removing the four small hex button
screws and pulling the cover.
4. Rotate the table (to about 8 o’clock) to inspect the reader head and the associated wiring to the reader head.
A connector is located under the carrier cover. The reader head can be replaced without removing the carrier
cover. Rotating the table moves the access hole on the carrier cover so you can access the connector (about 5
o’clock) and the cable tie downs.
5. Before removing the plate that holds the encoder ring, loosen the bolts holding the reader head and move the
reader head back away from the ring (away from the center of the table). It is easy to damage the reader head

when installing or removing the cover. The gap between the reader head and the ring is set using a clear
plastic shim that ships with the unit. The shim is 0.100 mm thick (close to .004 inches thick).
6. If you want to access the encoder ring, remove the encoder ring by removing the 12 bolts that hold the carrier
cover (M.1302.3072).
7. Carefully remove the carrier cover. O-rings mounted on the underside of the carrier cover will provide some
resistance to removing the cover. The cover itself weighs about 15 kg (35 pounds).
8. Carefully turn over the carrier cover over to view the encoder ring.
9. Service the encoder ring or reader head as required.

Note: Before placing the cover back on the machine. Make sure the cable is properly tied down by the
wire clips.
10. Carefully reinstall the carrier plate, making sure the reader head is not touching the encoder ring.
11. Align the carrier cover by sweeping an indicator on the center hole on the carrier cover and tighten the bolts.
12. Turn the carrier so the access cover is at the reader head.
13. Set the gap between the reader head and the encoder ring using the plastic shim.
Note: Never use a steel shim when setting the reader head gap.
14. Start the machine and check for feedback errors for the C axis.
15. Reinstall the small rectangular cover on the carrier cover.
16. Reinstall the machine table.
SEPARATE DETECTORS
A Separate Detector is used by the Fanuc control to read the feedbacks from the second encoder of the cutting axes
and for the rail feedback scales X1-axis, X2-axis. Z1-axis, Z2-axis, C-axis and V-axis and V1-axis. A single separate
detector can monitor one to four encoders. A second Separate Detector can be added for machines with more than
four 2nd encoders. The top four connectors on the face of the Separate Detector is used for the encoders (labeled
JF101 through JF104).
The bottom connector on the face of the Separate Detector (labeled JA4A) is used to tie an external battery to power
the scales (not used).
All Separate Detectors used through 2007 on MAG machines, required an A Quad B feedback signal. Starting in
2007, MAG started using a new Separate Detector from Fanuc that could read Sine / Cosign signals. This newer
Separate Detector eliminated the need to use IBV convertors and allowed the encoder cables to be run directly into
the Separate Detector. If swapping out a Separate Detector, be sure to check the part numbers of the Separate
Detectors and always use the correct replacement unit. There are no obvious physical differences between the old
and new versions of Separate Detectors.

FIGURE 72.20 - 13
Separate Detector
The encoder cables come back from the scales into the cabinet and are run directly to the separate detector. Fanuc
now manufactures a Separate Detector that can read the sine and cosine signals directly negating the need to use
IBV converter.
The Separate Detector is tied into the FSSB fiber optic link. The COP10_ connectors are located on the bottom of
the Separate Detector. If there are two Separate Detectors, a ribbon cable at the top of the units tie them together.
Note: Refer to the Machine Electrical Prints to see how the Separate Detector is wired for your machine.
If the encoder cable is ever changed, be sure to cut back the insulation on the cable and tie the cable to ground as
was done with the old cable. For machines with more than four 2nd feedbacks, a second Separate Detector is used.
The second Separate Detector ties to the first unit with a ribbon cable at the top of the units.

SECTION 72.21
ENCODER FEEDBACKS – SIEMENS
TABLE OF CONTENTS
TITLE PAGE
FEEDBACK INFORMATION..........................................................................................................................................1
ENCODER TYPES ........................................................................................................................................................2
LINEAR SCALES – HOW THEY WORK........................................................................................................................2
ABSOLUTE SCALES ..........................................................................................................................................3
PULSE DISTANCE CODED SCALES.................................................................................................................3
SPECIFIC SCALE DESCRIPTIONS ..............................................................................................................................4
LC181, LC182 & LC183 ENCODERS .................................................................................................................4
SCALE SPECIFICATIONS .......................................................................................................................4
LB302 C ENCODER............................................................................................................................................4
LB302 C SCALE SPECIFICATIONS ........................................................................................................5
LB382 C ENCODER............................................................................................................................................5
LB382 C SPECIFICATIONS.....................................................................................................................6
HEIDENHAIN LINEAR ENCODER PRE-INSTALLATION INFORMATION ...................................................................6
SCALE MOUNTING TIPS ...................................................................................................................................7
BUILDING THE STEEL TAPE SCALE................................................................................................................7
ANGULAR & ROTARY ENCODER INFORMATION....................................................................................................10
ERN 480 ROTARY ENCODER .........................................................................................................................11
ERN 480 SPECIFICATIONS ..................................................................................................................12
ANGULAR ENCODER SPECIFICATIONS .......................................................................................................12
RUNNING AN AXIS USING JUST THE MOTOR ENCODER......................................................................................12
AXES WITHOUT SAFETY INTEGRATED ........................................................................................................13

AXES WITH SAFETY INTEGRATED................................................................................................................14
FEEDBACK INFORMATION
These are the typical encoders used with each of the MAG machine series.
Machine Axis Typical feedback scale used.

Series
X-axis 523 – LC183 Absolute scale.
524 – 526 - LB382 C pulse distance coded scale.
Z-axis (ram) LC 183 absolute scale.
C-axis 523 – Table drive motor encoders.

VTC
524 – 526 - ERM 280 angular encoder.
Rail1 & Rail2 LC183 glass absolute encoders. Optional.
Table Motor encoder and a bero switch.
Spin1 (spindle in RH) Machines since 2008 use a ERN 480 for orienting.
Older machines, motor encoder and a bero switch for orienting.

Spin2 (spindle in LH)
Tool & pallet changers Motor encoders only.
X-axis LB382 C pulse distance coded scale.
Y-axis LB382 C pulse distance coded scale.
Spindle (usually Z-axis) Motor encoder only.
HBM Saddle (usually W-axis) LB382 C
B-axis RON 220 angular encoder. (This encoder varies.)
CS (spindle) Motor encoder and with some machines a bero switch for orienting.
Tool & Pallet changer Motor encoders only.
X-axis LC183 glass absolute encoder.
Y-axis LC183 glass absolute encoder.
Z-axis (column axis) LC183 glass absolute encoder.
HMC W-axis (opt. live spindle) Motor encoders only – absolute feedback.
SPINDLE Motor encoders only.
B-axis RON 886C. (This encoder varies.)
Tool & Pallet changers Motor encoders only.
FIGURE 72.21 – 1
Typical Encoders Used.
FEEDBACK INFORMATION – SIEMENS 72.21 - 1

Note: When replacing scales, always check the reader head to determine the correct hardware to order.
Tape scales are usually the steel tape version of the LB382 C scale. Often the body of the scale will
be labeled LB302, while the reader head and tape is the LB382 C model.
ENCODER TYPES
Most of the axes on these machines use encoder feedback although some rotary axes have used Encoders are made
in a wide variety of configurations. There are linear and rotary encoders which are further divided into incremental,
absolute and pulse distance coded measuring varieties.
Linear encoders Linear encoders are used on axes in various scale lengths and resolutions to change a
linear movement into a digital value.
Rotary encoders Rotary axes and positioners change an angular movement into an digital value, they can
also be used for linear travel where it is impossible or impracticable to use a linear
encoder.
Incremental encoders Incremental encoders output a very fine resolution and have a repeating cycle of output
that enables them to cover long distances. Axes with Incremental encoders require a
machine reference cycle be performed so that a special marker pulse or switch is found.
Stored offsets then are activated and the axis is referenced.
Absolute encoders Absolute encoders produce a coded digital output which represents an absolute linear or
rotary magnitude or displacement. An absolute encoder outputs a unique value for any
location in its travel. Axes with absolute encoders typically do not require referencing. (An
offset is created and stored for a machine zero location but the axis never is referenced.)
Pulse Distance Coded Pulse distance coded scales are incremental scales with a series of special marker pulses
that are absolute. When an axis using the scale is referenced, the axis is moved less than
100 mm (about 4 inches). Each set of marker pulses is a different distance from the
previous marker. Once two consecutive marker pulses are read, the control computes the
location on the scale, identifying where it is in its travel. The control then locks onto the
incremental signals and the axis is referenced.
LINEAR SCALES – HOW THEY WORK
The Heidenhain linear scale can either be a DIADUR® glass scale with transmitted light grating or an AURODUR®
metal scale with reflected light grating. These machines may utilize absolute and/or pulse distance coded scales. All
scales have a repeating pattern of fine lines that through the whole length of the scale. The distance between these
lines is called the grating period of the scale. The grating period determines the resolution of the scale.
The distance between the centers of the lines is constant but the thickness of the lines varies. So as the reader head
moves down the scale, the amount of light that gets through (or is reflected on the steel scales) changes. The output
of the solar cells varies in a sine wave shape as the head moves down the scale. The distance moved to go through
one sine wave varies with the different scales. For some scales this distance is 20 mm, some are 32 mm, others are
as much as 80 mm.
The Siemens 840D control is designed to monitor the sine / cosign signals directly. Scales that output square waves
are not used with the Siemens CNC. All linear scales run on +5 VDC that comes from the Siemens axis drive
encoder connectors X421 (X422).
72.21 -2 FEEDBACK INFORMATION – SIEMENS

ABSOLUTE SCALES
The scale is contained and protected within an aluminum or steel scale housing. The scale units come in a variety of
different fixed lengths and resolutions. Originally, Heidenhain had a manufacturing limit of 3 meters for absolute
scales that they have now have extended to a length of 4 meters.
The absolute scale is made up a of a series of incremental scale patterns and a series of absolute scale patterns that
combined allow the control to auto reference the axes at power up. The axis does not have to move at all for the
control to know the exact location of the reader head/ machine axis.
Scanning Reticle
GLASS SCALE
Incremental
Signals
Absolute
Light Signals
Source
Condenser
Lens
Solar Grating Period
Cells of Scale
FIGURE 72.21 - 1
Typical Heidenhain Absolute Linear Encoder
PULSE DISTANCE CODED SCALES
Pulse distance coded scales are incremental scales so they provide a high degree of accuracy. A problem with
incremental scales is that an axis with an incremental scale requires referencing. An absolute scale means you
wouldn't need to reference the axis but the resolution is typically too poor. The pulse coded scale is a combination of
both incremental and absolute scales.
Each set of markers is longer by a fixed amount.
20 20 20
10.02
10.04
10.06
Incremental encoder
grating lines
20.02 20.02
FIGURE 72.21 - 2
Pulse Coded Scale Marker Pulse Layout
The output of the pulse coded scale is a sine and cosine waveform set. There is also an output from the scale from a
two series of marker pulses that are spaced unequally along the length of the scale. One set of markers are evenly

spaced while the second set of markers are further apart as you move down the length of the scale. The control
calculates the distance between two sets of markers and software in the control calculates where the scale is in its
travel.
The axis has to move and see two consecutive markers to find where the slide is and pick up the incremental
feedback.
SPECIFIC SCALE DESCRIPTIONS
The scales that are described here are all manufactured by Heidenhain. Not all of them are used on each machine.
Refer to your electrical prints to determine what scale is used on your machine.
LC181, LC182 & LC183 ENCODERS
This version of linear encoder is an absolute scale that outputs sinusoidal waveforms directly to the Siemens drive
module (connector X421 or X422).
FIGURE 72.21 - 3
LC181. LC182 & LC183 Linear Encoder
Axes using the LC181 absolute scale, will be referenced as soon as the control is turned on.
SCALE SPECIFICATIONS
Signal Levels A: 1 VPP
B: 1 VPP
10 mm cable 35 mm
8 mm cable 40 mm
LB302 C ENCODER
Note: Normally the aluminum body sections that are bolted to the machine for axes with travels over three
meters will be labeled LB302. The tape and reader head mounted in the scale body will be the
LB382C scale.
Only a few machines that shipped prior to 2006 used the LB302 encoder. This version of linear encoder is a pulse
distance coded scale that outputs sinusoidal waveforms directly from the scale to the drive. The body of the scale
can be a single extrusion (glass unit) or can be made up of several segments that are bolted together (steel tape
unit). By bolting together multiple body sections, this scale can accommodate axes with lengths up to 30 meters.
For these steel tape scales, the light is shined at an angle to the grating lines with a pickup head positioned to pickup
a reflected signal.

Several housings are bolted Reader head
Once the housing is set, the tape
together to cover the axis run. is stretched in the housing and
the reader head is added.
The output of the scale goes to the

An optional air line pressurizes the scale Siemens Drive (connector X421).
to about 1 bar to keep dirt out of the scale.
FIGURE 72.21 - 4
The maximum distance required to reference the axis is 80 mm.

Note: Always turn power off before removing the power cable to any of the Heidenhain scale units.
LB302 C SCALE SPECIFICATIONS
Signal Levels 11 µApp/4-µm
11 µApp/4-µm
Max. Velocity 120 m/min
LB382 C ENCODER
This version of linear encoder is a pulse distance coded scale that outputs sinusoidal waveforms directly from the
scale to the Siemens drive (connector X421). The scale can be glass or steel tape.
For steel scales, the light is shined at the grating lines with a pickup head positioned to pickup a reflected signal.
Steel scales are used when axis travels are over 3 meters.
FIGURE 72.21 - 5

Linear compensation is then often used to bring the axis to the required accuracy specifications.
Note: Always turn power off before removing the power cable to any of the Heidenhain scale units. This is
true for any of the connectors into the Siemens control.
LB382 C SPECIFICATIONS
Signal Levels A: 1 VPP with terminating resistor
B: 1 VPP with terminating resistor
R: 0.4 VPP with terminating resistor

Reference marks are placed every 50 mm.
Max. Velocity 120 m/min.
10 mm cable 35 mm
8 mm cable 40 mm
Max cable length 150 m (492 feet).
HEIDENHAIN LINEAR ENCODER PRE-INSTALLATION INFORMATION
Before beginning the replacement of a Heidenhain linear encoder, the following items should be observed. On
machines where the encoder package is removed completely for machine shipment, the entire unit must be
reinstalled.
Note: New scales always ship with an instruction booklet from Heidenhain. Always refer to the booklet
first if you have any questions mounting the new scale. With most scales its best to tighten the
middle bolt first and then work out toward the ends of the scale.
1. Ensure that the mounting surfaces for the scale housing and the scanning head are properly cleaned before
proceeding. Never mount a scale on a pointed surface.
2. Use a dial indicator to check that the scale mounting surface is parallel to the machine guide way within 0.1
mm / 0.004") and square within 0.03 mm / 0.0012.
3. Also ensure that the connecting cable exit is at the correct side of the scanning head for the appropriate axis.
4. Never bend the reader head cable at a tight radius. The cable can be damaged.
5. If the scale is provided pressurized air, be sure to replace the air line into the end of the scale or onto the
reader head. Air is always put into the unit that is stationary.
6. There should be less than 1 ohm of resistance between the inside of the reader head cable connector and the
body of the scale. Don't measure to the outside of the connector, its coated with an insulating coating.

Note: For machine shipment, the connecting cables for the encoders for the axes are usually pulled back
to their respective packages and secured at machine tear down. Cable clips may be refitted and in
some cases a draw wire may be left in place for reinstallation of the cable. Also, watch for transit
clamps which may be fitted to the scanning head for shipment. These clamps must be removed at
installation before any axis motion is attempted.
SCALE MOUNTING TIPS
1. When mounting the scale, use washers with a small diameter on each bolt. Be sure the washer doesn't cover
the expansion cutout found on most of the bolt holes. Without a washer, the bolt can tweak the scale
alignment as the bolt is tightened.
2. Always mount the center hole (without the expansion cutout) firmly to the machine first. If the scale has two
solid mounting bolt holes (no expansion cutouts, bolt them both tightly if possible.
3. On long, multi segment scale units with the steel tape, make sure the end two segments are both firmly
mounted to the machine. The center segments are held by the expansion joints which allow some movement.
4. Only use the machined edge (shown in the figures above of the scales) when aligning the scale to the axis.
5. Leave the red plastic retention clips on the scale when mounting the read head to ensure the reader bracket is
fit to the reader head. You don't want any tension on the reader head when the bracket is mounted. Be sure
to remove the red clips when the reader is mounted to the machine.
Note: Once the reader head is mounted, pull the red alignment clips off of the scale, don’t just slide them
to the end of the scale. There may not be enough room for the clip when the axis is near its end of
travel.
Note: If the reader head is not mounted correctly, the rollers on the read head can cut into the aluminum
body and aluminum body will be grooved by the stainless steel rollers on the head, damaging the
scale beyond repair.
6. Plastic air lines are used because they will not condense moisture like a steel or copper line will. Change /
clean the air filters as often as needed to keep the air pumped into the scales clean and dry. It is better not to
put any air into the scales than it is to put in dirty air.
7. When replacing a scale on a machine with a new scale, you may find that the connector for the read head
comes out on the wrong side of the read head. The cable connector can be turned 180° on the head. Refer to
the Heidenhain manual that shipped with your documentation.
BUILDING THE STEEL TAPE SCALE
The steel tape scales are assembled right on the machine.
1. The scale body sections are bolted to the machine. Each end section has one bolt hole that has no expansion
gaps. Make sure that you do not use washers that overlap the expansion gaps.
2. The three steel liners are installed first. These liners are used as bearing surfaces so that the transitions
between body segments is smoother.

FIGURE 72.21 - 6
Installing the Scale Liners
3. The photo below shows the gold plated steel tape is hooked to the red plastic clip and carefully fed through the
scale. Never touch the tape. The plastic liner that protects the tape for shipment should be saved in the event
the tape must be removed later.
FIGURE 72.21 - 7
Running the Steel Tape through the Scale Body
4. The end of the tape is anchored to the clip and the screws are tightened.
Note: Make sure that the block is pulled toward the end of the tape when tightening the two screws. You
don’t want the screws to shift in the holes when the tape is tensioned.

FIGURE 72.21 - 8
Mounting the Tape Anchor
5. Hook the steel tape to the end bracket and tighten the tape only so it is just snug. Do not over tighten.
A locking screw clamps the scale

in position once the tension is set.
FIGURE 72.21 - 9
Tightening the Scale
6. Once the tape is assembled, a laser is used to set the correct tension on the tape.
A. The axis is positioned at one end of its travel.
B. The laser is setup.
C. Both the control and laser are set to zero.
D. The axis is moved by the control to the other end of its travel.

E. The tension of the tape is adjusted so that the same readout is seen on both the laser and the CNC.
7. An axis with a steel tape scale will always use linear compensation. If a new tape is installed, the
compensation values should be redone.
ANGULAR & ROTARY ENCODER INFORMATION
Angular and rotary encoders are used for measuring angles of rotation, angular velocities, and linear movements.
Encoders come in a variety of types and sizes, some with far better measuring capabilities than others. Every servo
motor and spindle motor has a rotary encoder mounted on the back end of the motor. Generally, angular encoders
used on rotary tables are low speed, high accuracy encoders that are more accurate than rotary encoders which are
high speed, lower accuracy encoders usually found on the back of the servo motors. The encoder used on Z axis is
an exception with over 1 million counts of resolution scaled over the spindle axis (typically Z) travel.
A wide variety of different angular encoders may be found on the rotary axes. The built in tables on the MC and RT
machines are designed and built by MAG MAG. Bolt on tables sometimes used with PT style machines are often
made by Demmeler or Ruckle.
C4
PZ (MARKER) C8
C2
PULSE
C1
PA , PB
(POSITION)
PULSES
0 1 2 3 4 5 6 7 8 9 A B C D E F 0
C1
C2
C4
C8
FIGURE 72.21 - 10
Typical Rotary Encoder Mask
Rotary encoders must be coupled to the driving shaft with a flexible precision coupling. Some encoders use a shaft
drive with an external coupling. The most accurate of rotary encoders mount over the end of the driving shaft and use

an integral stator side coupling which effectively eliminates the torsion encountered during acceleration and
deceleration.
The installation and adjustment procedures for rotary encoders, some or all of which may be fitted to any machine,
are described in the appropriate places in the MECHANICAL REPAIR MANUAL.
LENS AND
LIGHT SOURCE SCANNING RETICLE SOLAR CELLS
DISK WITH
GRATING LINES
FIGURE 72.21 - 11
Rotary Encoder Diagram (Typical)
ERN 480 ROTARY ENCODER
The ERN 480 rotary encoder is used as the spindle feedback encoder for all the VTC machines with the rotating
spindle option. The encoder is mounted at the top of the ram and is driven by a cog belt. Machines that shipped
before 2008, used a bero switch for spindle orient. The encoder improves the positioning accuracy of the spindle.
FIGURE 72.21 - 12
ERN 480 - Rotating Spindle Encoder - All Machines Since Late 2007

ERN 480 SPECIFICATIONS
Incremental signals 5 volt TTL A Quad B
Line count 250 to 5000
Operating power 5 VDC
Max Temp 100°C
ANGULAR ENCODER SPECIFICATIONS
Specification RON 220C RON 285C RCN 226
Accuracy +/- 2.5 angular seconds +/- 2.5 angular seconds +/- 2.5 angular seconds
Absolute counts/rev 1048576 (20 bit) 1048576 (20 bit) 67,108,864
Output signals 1 VPP 1 VPP 1 VPP
Power +5 VDC +/-5%. +5 VDC +/-5%. +5 VDC +/-5%.

Max current draw 250 ma Max current draw 250 ma Max current draw 250 ma
Operating temp 0° to 50° C. 0° to 50° C. 0° to 50° C.
Maximum rpm 3000 rpm 3000 rpm 3000 rpm
Interface Pulse Distance Coded Pulse Distance Coded Absolute
The output of these encoders runs directly to the X412 connector on the B axis drive.
TABLE 72.21 – 1
B-Axis Scale Specifications
****************************************************************************************
EXCESSIVE VIBRATION DURING MACHINING CAN CAUSE THE ROTARY ENCODER ON THE
SPINDLE AXIS TO SHIFT ITS ZERO POSITION. CHANGE THE PART PROGRAM TO PREVENT
THE EXCESSIVE VIBRATION!
IF THE SPINDLE AXIS POSITION (TYPICALLY Z BUT SOMETIMES W AXIS) IS INCORRECT, THE
REFERENCE OFFSET FOR THE AXIS MUST BE RESET. USE THE PROCEDURE FOR
ABSOLUTE ENCODERS IN SECTION 69 OF THE ELECTRICAL MANUAL.
****************************************************************************************
RUNNING AN AXIS USING JUST THE MOTOR ENCODER
It is sometime necessary, for maintenance reasons, to run an axis on just the motor encoder. If the linear scale has a
loss of feedback alarm, the axes are disabled. Often you must jog the axis to get at the scale (to allow covers to be
pulled back and to get access to the mounting bolts of the scale).
On machines that DO NOT use the Safety Integrated software feature, there IS a way to reconfigure the configuration
of the feedbacks to enable an axis to be moved. Several machine data values must be changed to reconfigure the
feedback configuration. If the machine has the Safety Integrated software feature you CANNOT run the axis on just
the motor encoder.

****************************************************************************************
WHEN RUNNING AN AXIS ON JUST THE MOTOR ENCODER, THE SOFT LIMITS AND
REFERENCING WILL NOT WORK. EXTRA CARE MUST BE TAKEN TO STAY CLEAR OF THE
END OF TRAVELS.
BE SURE TO RETURN THE FEEDBACK CONFIGURATION TO ITS ORIGINAL SETUP WHEN THE
NEW SCALE IS MOUNTED.
****************************************************************************************
AXES WITHOUT SAFETY INTEGRATED
1. Check to make sure you have a current backup of the NC and PLC archives. If you are not sure, go to
SECTION 21.10 of the electrical manual and make backups.
2. Enter the EVENING password.
A. Press the MENU SELECT key.
B. Press the STARTUP softkey.
C. Press the PASSWORD vertical softkey.
D. Enter the password EVENING and press the ENTER key (or press the OK vertical softkey).
3. Press the MACHINE DATA softkey.
4. Press the AXIS MD softkey.
5. Use the AXIS + or AXIS – vertical softkey to display the parameter set for the axis being worked on.
6. Search out and change MD30200 from a value of 2 to a value of 1. This parameter establishes which
feedback is used at power up. (A value of 1 selects the motor encoder and a value of 2 selects the second
feedback device.)
7. Access the CV Manager and change the measuring system of the axis from MeasSystem 2 to MeasSystem 1
as follows:
A. You should already be on the STARTUP area, so press the RECALL key.
B. Press the PLC softkey and then press the CV MANAGER softkey.
C. Press the EMERGENCY STOP push button.
D. Arrow down and highlight parameter dcAxis1SetMeasSystem2
E. Change the value of the parameter from 1 to a 0.
To use the axis scale as the primary feedback again, restore the values that were changed above. If this does not
work, restore the NC archive created in step 1.

AXES WITH SAFETY INTEGRATED
Make sure you write down the old values of each parameter and CV variable that you change, to make sure you can
get back to the original value when you need to.
These changes will allow you to run an axis with the linear encoder removed.
1. Go to the MACHINE DATA page.
2. Press the AXIS + vertical softkey to highlight the data set for the axis you are working on.
3. Press the AXIS MD softkey and search out and change the following parameters:
• 30200 Number of Encoders Change from a 2 to a 1.
• 30240 Encoder Type (Tab 1) Change to a value of 0. (Was a value of 1.)
• 36901 Safe Function Enable to a value of 0H (The value is typically 303H. The control puts in the H on its
own.)
4. Press the MOTOR MD softkey and change parameter 1301 Safe Function Enable to a value of 0H. (The value
was 303H).
5. Press the PLC softkey, then press the CV MANAGER softkey. The underscore in each variable is replaced by
the axis number. Change the following two CV Variables:
dcAxis_SetMeasSystem2 = 0 (the normal value is =1)
dcAxis_SafeCamEnable = 0 (the normal value is =1)
6. After the two variables have been changed, press the DOWNLOAD vertical softkey and then press the RESET
pushbutton.
The axes can be jogged in the mode, but you will not be able to run parts this way.
When done jogging the axes, make sure you reverse the changes to re enable the second feedback for that axis.

SECTION 75.10
HYDRAULIC SYSTEM - COMMON
TABLE OF CONTENTS
TITLE PAGE
THE HYDRAULIC SYSTEM ..........................................................................................................................................1
HYDRAULIC SYSTEM OPERATION..................................................................................................................1

THE HYDRAULIC SYSTEM
The hydraulic system consists of a central hydraulic power unit with services panel that supplies the hydraulic,
pneumatic and lubrication for the machine (FIGURE 75.10- 1 & FIGURE 75.10- 2). For machines with standard
coolant systems, a coolant filter and valves for diverting coolant through the spindle or for flood coolant is also part of
this unit (FIGURE 75.10- 3).
A 7.5 kW (10 HP) motor drives a variable displacement axial piston pump that supplies the main system pressure.
This same motor drives a fixed displacement vane pump which draws hydraulic fluid from the 167 liter (44 gal)
reservoir sending it through a heat exchanger, then a 10 micron filter element and back to the reservoir. There are
sensors which activate if the reservoir fluid level is low (EA-S1), temperature is too high (EA-S2), and if the filter is
clogged (EA-S4). See FIGURE 75.10- 4 for hydraulic services fluid diagram.
The main hydraulic unit provides pressure to the headstock and to the secondary hydraulic pressure circuit. Main
system pressure connects to the headstock device panel providing the hydraulic pressure for spindle drawbar
unclamp. Additional functions utilizing this pressure are dependent on if the headstock is a two-speed or four-speed.
The two-speed headstock reduces this pressure at the headstock services panel and uses the hydraulic fluid to
lubricate the ZF gearbox, also running a hydraulic motor/pump to return the gearbox lubricant to the main hydraulic
reservoir. The four-speed headstock uses normal mode system pressure to operate the cylinders that control gear
shifting and a proportional valve that varies the pressure supplied to the hydra-rib spindle sleeve rear bearing.
The secondary hydraulic pressure circuit supplies hydraulic pressure to operate the axis ballscrew bearing dampers,
tool changer, and accessories. This secondary pressure also feeds the devices that control the main lubrication
system. An additional reducing relieving valve on the main hydraulic services panel is set at 76 bar (1100 psi). This
valve prevents the secondary pressure circuit from feeling the high pressure required during a drawbar unclamp.
The main lubrication system devices are located on the hydraulic unit services panel. The devices consist of a
pressure reducing valve, directional control valve and pressure filter with 10 micron filter element that control the
lubrication pressure. Intermittent lubrication to the axis ways and ballscrews, the headstock bearings and gears, and
the Y-axis drive gears are supplied from this system.
HYDRAULIC SYSTEM OPERATION
The main hydraulic system operates in normal and high pressure modes. A pressure controller within the variable
displacement pump serves to maintain a constant pressure in the hydraulic system once the steady state has been
reached. A remote pressure relief valve (FIGURE 75.10- 5) is used to establish and control normal main system
pressure. The valve is set for 70 bar (1000 psi). A main system pressure relief valve (FIGURE 75.10- 1) is set at 165
bar (2400 psi). This valve limits pressure surges that occur when the system is first turned on, (before the remote
pressure relief valve is able to adjust the system to normal pressure mode of 70 bar (1000 psi).
Secondary circuit pressure is also 70 bar (1000 psi) in normal mode. A pressure reducing relieving valve (FIGURE
75.10- 6) is set slightly above normal mode pressure at 76 bar (1100 psi). This protects the secondary circuit during
high pressure mode. Setting this valve slightly above normal system pressure prevents a continuous dumping of fluid
to tank, which would result in excessive hydraulic fluid temperature.
When a spindle drawbar unclamp is initiated, a directional control valve turns off the flow to the remote pressure relief
valve, enabling high pressure mode. The variable pump is allowed to run at maximum pump pressure. A
compensator adjustment screw (FIGURE 75.10- 5), located on the pump body, is used to set the maximum pump
pressure at 150 bar (2200 psi). The machine control has a timer, which limits high pressure mode to maximum of
four minutes. (High pressure mode is time limited to prevent excessive hydraulic fluid temperature buildup).
HYDRAULIC SYSTEM - COMMON 75.10-1

Lubrication Controls
Clogging Indicator
Lube Filter “OK”
(HC-S4)
Lube Filter with 10

μm Filter Element Pneumatic
Components
Top View of this Area

See FIGURE 75.10- 5
Check Valve
Secondary Hydraulic Pressure

Components
See FIGURE 75.10- 6 for
Detailed View
Main System
Pressure Relief Valve
[Set @ 165-166 Bar (2400 psi)]
Fixed Displacement Vane

Pump (To Heat Exchanger) Variable Displacement
Axial Piston Pump
Hydraulic Pump Motor

Oil Filler (EA-M401)
Breather
Reservoir Assembly
166.5 Liter (44 Gallon)
Fill with ISO VG 68 (DTE 26)
FIGURE 75.10- 1
Hydraulic Power Unit with Services Panel
(Your Machine May Be Slightly Different)
75.10-2 HYDRAULIC SYSTEM - COMMON

To Tank
Profibus
To Lube
Filter
Oil Level “Not Low” (EA-S1)

Oil Temp “Not High” (EA-S2)
Main Reservoir Hydraulic Oil
Heat Exchanger
Hydraulic Oil Heat Exchanger

Main System Motor (EA-M400)
Hydraulic
Pressure to
Headstock Device
Panel
Return from Gearbox Lube

(Two Speed Headstock Only)
FIGURE 75.10- 2
Hydraulic Power Unit with Services Panel - Rear View

Floor Level View Top View
Mounting Bracket
For Std Coolant Filter
FIGURE 75.10- 3
Hydraulic Unit Services Panel (Rear View)

Y-Axis Damper
Accessory 2 Return
X-Axis Damper
Accessory 1 Return
Accessory 2 Tool Changer Return

Accessory 1
Headstock Pressure Return
Tool Changer - Pressure
Pressure to “Lube
Enable” Manifold
Hyd. Pressure “Not Low” (EA-S3)
Closes at 59 Bar (850 PSI) Rising
Opens at 50 Bar (720 PSI) Falling
Normal Mode: 70 Bar (1000 PSI)
High Mode: 76 Bar (1100 PSI)
Reducing Relieving Valve

Set at 76 Bar (1100 PSI)
To Tank from Adjust during High Pressure Mode
“Lube Enable”
Manifold
Headstock Pressure
High Pressure “Enable”
(HC-Y7) Main System Pressure
High Mode: 152 Bar (2200 PSI)
Return from Gearbox

Lube (Two Speed
Headstock Only)
Pressure Relief Valve for

Normal System Pressure
Set at 70 Bar (1000 PSI)
Main System
[Set @ 165-166 Bar (2400 psi)]
Variable Displacement
Axial Piston Pump
Fixed Displacement
Vane Pump
(To Heat Exchanger)
Oil Level “Not Low” (EA-S1) Clogging Indicator
Oil Temp “Not High” (EA-S2) Hyd. Oil Filter “OK”
(EA-S4)
FIGURE 75.10- 4
Hydraulic Unit Fluid Diagram

Remote Pressure Relief Valve
For Normal System Pressure
Set at 70 Bar (1000 PSI) High Pressure “Enable”
(HC-Y7)
Hydraulic Oil Filter

with 10 μm Filter
Element
Differential Pressure Adjustment

Screw (Factory Set @ 20 Bar)
Clogging Indicator
Hyd. Oil Filter “OK” Compensator Adjustment Screw
(EA-S4) (Maximum Main Hydraulic Pressure Adjustment)
FIGURE 75.10- 5
Top View of Hydraulic Unit Services Panel
Pressure Switch
Hyd. Oil Pressure “Not
Low” (EA-S3)
Pressure to Headstock
Device Panel

“Secondary Hyd. Pressure”
Right Side View of Reducing Relieving Valve
FIGURE 75.10- 6
Main Hydraulic Unit Secondary Hydraulic Pressure Components

SECTION 75.20
HYDRAULIC SYSTEM – 2 SPEED
TABLE OF CONTENTS
TITLE PAGE
2 SPEED HEADSTOCK HYDRAULICS.........................................................................................................................1
2 SPEED HEADSTOCK HYDRAULICS
unclamp.
The two-speed headstock reduces this pressure at the headstock services panel and uses the hydraulic fluid to
lubricate the ZF gearbox, also running a hydraulic motor/pump to return the gearbox lubricant to the main hydraulic
reservoir. See FIGURE 75.20- 1, which shows the schematic for two speed headstock hydraulic pressure.
valve, enabling high pressure mode at 150 bar (2200 psi). The machine control has a timer, which limits high
pressure mode to maximum of four minutes. (High pressure mode is time limited to prevent excessive hydraulic fluid
temperature buildup).
Additional controls located at the headstock device panel are used during the high pressure mode. In the two-speed
headstock, a directional control valve (FIGURE 75.20- 2) actuates allowing high pressure flow to the drawbar piston
and stopping the low pressure flow to the ZF gearbox. The low pressure flow to ZF gearbox is described in the
heading “Two Speed Headstock Gearbox Lube”.
HYDRAULIC SYSTEM – 2 SPEED 75.20-1

Proximity Switch (DI-S3) Proximity Switch (DI-S4)
Drawbar Clamped Drawbar Unclamped
Rotary Union
Gearbox Lube
Return Pump
3/8” Hose
Speed Sensing
Proximity Switch Through
(DI-S6) Headstock
“Lube Pump Running” Utility
Pressure Reducing Valve Carrier
(Pilot Oil from Port B)
Set at 27.5 Bar (400 psi)
Hydraulic Motor 5/8” Hose
No Pressure Reduction,
when Directional Control
Valve is in Position P to A
Drawbar Unclamp
Pressure Readings
of 2200-2500 psi
during Unclamp Only
Gearbox Lube
Pressure (After Flow
Set, Readings
between 90-150 psi)
Directional Flow Control Valve

Control Set to 2.5 L/min
Valve (DI- (0.65 gpm) after
Y3) Headstock Headstock Gearbox Spindle Spindle Air
Pressure Reducing Hydraulic
Drawbar Hydraulic Lube Coolant to Tool
Valve is Set Return
Unclamp Pressure Return
FIGURE 75.20- 1
Two Speed Headstock Drawbar Unclamp, Gearbox Lube & Coolant/Air through Spindle
75.20-2 HYDRAULIC SYSTEM – 2 SPEED

Hydraulic
Pressure
Hydraulic Pressure Lines Supply
Shown Highlighted
Optional Components for

Directional Control Valve Auto Coupler or To Rotary Union of Drawbar
“Drawbar Unclamp” (DI-Y3) Attachment Changer Drawbar Unclamp Pressure
FIGURE 75.20- 2
Two Speed Headstock Device Panel (Only Hydraulic Lines & Devices Shown)

SECTION 75.30
TABLE OF CONTENTS
TITLE PAGE
HYDRAULIC SYSTEM – 4 SPEED................................................................................................................................1
FOUR SPEED HEADSTOCK SHIFTING ............................................................................................................3
HYDRA-RIB BEARING CONTROL .....................................................................................................................5

unclamp.
The four-speed headstock uses normal system pressure to operate the cylinders that control gear shifting and a
proportional valve that varies the pressure supplied to the hydra-rib spindle sleeve rear bearing. See FIGURE 75.30-
2, which shows the schematic for four speed headstock hydraulic pressure.
valve, enabling high pressure mode at 150 bar (2200 psi). The machine control has a timer, which limits high
pressure mode to maximum of four minutes. (High pressure mode is time limited to prevent excessive hydraulic fluid
temperature buildup).
In the four-speed headstock, a directional control valve mounted to a manifold actuates, allowing high pressure flow to
the drawbar piston. A pressure reducing valve, set at 75 bar (1100 psi), ensures that gear shift cylinders and spindle
sleeve rear bearing proportional valve do not feel the effects of the high pressure.
Spindle Cartridge Rear Bearing Pre-load Pressure Gauge Headstock Chilled Oil (DTE 24)
Pressure Readings Vary from 8.3 Bar (120 psi) to 3.4 Bar Pressure Switch (DI-S11) and
(50 psi) Dependent upon Spindle Speed Gauge
Gear Shift Directional
Control Valves
Headstock Hydraulics
Pressure Gauge
Normal Mode: 70 Bar Axes Lube
(1000 psi) (DTE 26)
High Pressure Mode: Pressure
76 Bar (1100 psi) Switch
(HC-S1)
Profibus
Pressure Reducing Valve

Headstock Hyd. Pressure
Set at 76 Bar (1100 psi)
Drawbar Unclamp
Directional Control
Valve (DI-Y3)
Headstock Lube
Connections from Air “OK”
Utility Carrier to Pressure Switch
Thrust Bracket Chilled Oil Return from
Scavenger Pump (HC-S2)
FIGURE 75.30- 1
Four-Speed Headstock Services Panel Lubrication & Hydraulic Components

Hydra-Rib Bearing
Pre-Load Pressure from
Proximity Switch (DI-S4) Proportional Valve
Drawbar Unclamped (See FIGURE 75.30- 5)
Proximity Switch (DI-S3)

Drawbar Clamped
Rotary Union

Hydraulic Pressure Set at 76 Bar (1100 psi)
Return from Protects Shift Cylinders and
Proportional Valve and Hydra-Rib Bearing Pre-Load
Shift Cylinders Manifold Controls during High
(See FIGURE 75.30- 5) Pressure Mode
Hyd. Pressure to Proportional

Valve and Shift Cylinders
Manifold
(See Schematic Shown in
FIGURE 75.30- 5)
Headstock Hyd. Headstock Spindle Spindle Air

Pressure Hyd. Return Coolant to Tool
Directional Control Valve (DI-Y3)

Drawbar Unclamp
FIGURE 75.30- 2
Four Speed Headstock Drawbar Unclamp and Coolant/Air through Spindle

FOUR SPEED HEADSTOCK SHIFTING
FIGURE 75.30- 3 and FIGURE 75.30- 4 show the gear shifting function. During normal operation, system pressure at
70 bar (1000 psi) flows to a manifold with two directional control valves. Each valve controls flow to the shift cylinders
located within the headstock gear cavity. The valves each have two switched positions, two solenoids and a detent.
Both switched positions are fixed alternately and do not require that the solenoid be continually energized. In order to
minimize the shock to the shafts connected to the cylinders, 0.8 mm (0.030”) orifices have been inserted into the male
connectors of A & B ports of the manifold.
Proportional
Valve
“Bearing
Pre-Load
Directional pressure”
Control
Valves
“Gear Shift 0.03” Orifices
Cylinders” in Male
Pressure Connectors
Reducing Valve Hydraulic
Pressure
Lines Shown
Highlighted
Directional Control To Rotary Union

Valve of Drawbar
“Drawbar Unclamp” Drawbar Unclamp
(DI-Y3) Pressure
Hydraulic Pressure Supply
Device Panel Does Not Show Lines that
Connect to Headstock
FIGURE 75.30- 3
Four Speed Headstock Device Panel (Only Hydraulic Lines & Devices Shown)

Proximity Proximity Switch
Switch (DI-S8) (DI-S7) D Shaft
DI-Y8 D Shaft High Range D Shaft
D Shaft Low Range
Low Range
DI-Y7
D Shaft
High Range
(4) Orifices Clutch Gears
1 mm
DI-Y10 (0.04”)
B Shaft
Low Range
DI-Y9
B Shaft
High Range Proximity Proximity B Shaft
Switch (DI-S9) Switch (DI-S10)
B Shaft B Shaft
High Range Low Range
Note: Spindle Not Shown
Incoming Hyd. Pressure from

Pressure Reducing Valve on Device Panel
High Pressure Mode: 76 Bar (1100 PSI)
FIGURE 75.30- 4
Four Speed Headstock Shift Cylinders

HYDRA-RIB BEARING CONTROL
System pressure flows to a proportional pressure-reducing valve, FIGURE 75.30- 5. Hydraulic pressure is routed
from the valve to the spindle sleeve rear “Hydra-Rib” bearing. The pre-load bearing pressure is varied based on the
spindle speed. The machine control sends a D/A signal to drive the valve. Additionally, a pressure transducer
provides a proportional DC voltage output over its pressure range to provide closed loop feedback to the machine
control. This same pressure transducer is used to produce a fault if the pressure is above 8 bar (120 psi) or below
3.4 bar (50 psi).
Spindle Cartridge Rear “Hydra-Rib “Bearing

Drawbar Unclamp
Pressure
Pressure Gauge
Reading vary based on Coolant/Air
Spindle Speed (RPM) through
0-1200 = 8 Bar (120 psi) Spindle
1500 = 6.4 Bar (93 psi)
1750 = 5 Bar (73 psi)
Rotary Union
2000-3500 = 3.4 Bar (50 psi)
Ø 0.030” Orifice
Proportional Valve
(PPM001)
Spindle Bearing
Pressure Transducer Pressure Reducing Valve
(PSM014) Set at 76 Bar (1100 psi)
Protects Shift Cylinders and
Hydra-Rib Bearing Pre-Load
Controls during High
Four Speed Headstock Shift Cylinders Pressure Mode
Control
(See Schematic Shown in FIGURE
75.30- 4)
Pressure Gauge Readings
High Pressure Mode: 76 Bar (1100 PSI)
Directional Control Valve for Drawbar Unclamp

(See Schematic Shown in FIGURE 75.30- 2)
Headstock Hyd. Headstock Hyd.

Pressure Return
FIGURE 75.30- 5
Four Speed Headstock Hydra-Rib Bearing Pre-Load

SECTION 75.40
HYDRAULIC & PNEUMATIC SYSTEM SETUP
TABLE OF CONTENTS
TITLE PAGE
HYDRAULIC & PNEUMATIC SYSTEM SETUP ............................................................................................................1
HYDRAULIC & PNEUMATIC SYSTEM SETUP
informational purposes only. If the hydraulic/pneumatic system requires set-up, it should be performed only by
qualified personnel.
1. Set system air regulators & switches on hydraulic services panel (FIGURE 75.40- 1 & FIGURE 75.40- 3).
A. Ensure air is turned on at panel. Manual interlock must be parallel with air input line.
B. Pressure switch (HC-S5) “System Air Pressure OK”, has been set to at 4.5 bar (65 psi) falling pressure.
C. Main system air regulator should be set to 5.5 bar (80 psi). Read gauge on filter/regulator.
D. Linear scale air regulator should be set to 0.6-1.0 bar (8-15 psi).
E. Manually fire the headstock lube air solenoid valve (HC-Y2). Lube air regulator should be set to 5.5 bar
(80 psi) with lube air on. Close valve to turn off lube air.
F. Pressure switch (HC-S2) “Headstock Lube Air Pressure OK” on headstock services panel (for two-
speed headstock or for four-speed headstock) registers high in PLC when hydraulic unit is started. This
switch is factory set at 3 bar (44 psi).
2. Setup of standard (Rexroth) main hydraulic unit (FIGURE 75.40- 1).
A. Ensure that main hydraulic unit is filled to sight gauge with DTE-26 oil. For four-speed headstock,
ensure that oil cooler unit is filled to sight gauge with DTE-24 oil.
B. For four-speed headstock, ensure that the two ball valves on the Dimplex (Koolant Kooler) oil chiller are
open.
C. Press machine start. With hydraulics on ensure that main hydraulic unit and oil cooler unit (if applicable)
are running. Verify that the low flow light on oil cooler unit is not lit. Check for leaks.
D. Ensure that spindle drawbar is clamped. Adjust the main hydraulic system pressure relief valve, so that
main hydraulic pressure gauge is set to 70 bar (1000 psi). Valve is located beneath the “Hydraulic Oil
High Pressure Enable” valve (HC-Y7) on the top of the oil reservoir (FIGURE 75.40- 2).
E. Pressure switch (EA-S3) “Hydraulic Oil Pressure Not Low” has been set to open at 50 bar (735 psi). If
adjustment were required, use the reducing relieving valve (secondary hydraulic pressure) located on
services panel of main hydraulic unit, reading pressure on secondary hydraulic pressure gauge.
F. Using the drawbar selector switch, unclamp the drawbar. This will actuate “Hydraulic Oil High Pressure
Enable” valve (HC-Y7), bypassing the main hydraulic system pressure relief valve set in step 2D.
Adjust the maximum pressure compensator adjustment screw (FIGURE 75.40- 2) located on main
hydraulic pump for 150 bar (2200 psi), reading the main hydraulic pressure gauge. The maximum
pressure compensator adjustment screw is located closest to the pump body.
Note: The adjustment screw farthest from the pump body is for pilot valve differential pressure, which is
factory set and should not be adjusted!
HYDRAULIC & PNEUMATIC SYSTEM SETUP 75.40-1

G. The system is setup for a four minute maximum limit at high pressure. For this step one may have to
again unclamp drawbar to enable high pressure. Adjust reducing relieving valve from step 2E, so that,
secondary hydraulic pressure gauge reads 76 bar (1100 psi) while system is at high pressure. After
completing this step, clamp drawbar.
H. Verify main hydraulic unit services panel pressure gauge readings:
1. Drawbar Clamped: Main = 76 bar (1100 psi) & Secondary = 70 bar (1000 psi)
2. Drawbar Unclamped: Main = 150 bar (2200 psi) & Secondary = 76 bar (1100 psi)
I. The “Oil Temp Not High” (EA-S2) and “Oil Level Not Low” (EA-S1) are both register high in the PLC.
These switches are preset by the manufacturer.
J. The “Hyd. Oil Filter OK” (EA-S4) registers high in the PLC. This switch is preset by the manufacturer.
3. Hydraulic unit setup for four-speed headstock.
A. Unclamp the drawbar. With 150 bar (2200 psi) on main hydraulic pressure gauge, verify that the
headstock hydraulic pressure gauge on the headstock services panel (figures 8-10 or 8-25), reads 76
bar (1100 psi). Adjust pressure reducing valve on the headstock services panel as required. Drawbar
must be unclamped (main hydraulic in high pressure) during the adjustment.
B. Clamp the drawbar after pressure reducing valve adjustment completed.
C. Ensure incoming power to Turmoil oil chiller unit is checked for CW PHASING! The heat exchanger fan
blows air out of the unit. After starting hydraulics, verify that the LOW FLOW LIGHT is not lit. The oil
cooler setup is described in the lubrication section.
Note: Do not run longer than 15 seconds with low flow light on. Damage to seals will occur.
D. For machines with Dimplex (Koolant Koolers) oil chillers, remove cover/filter on side of the unit. The
flow meter will be above the filter, with flow adjustment right of the flow meter.
E. Turn the brass adjustment screw until you have 4.5 to 5 G.P.M. At this time, you should have
approximately 90 to 120 psi on the gauge on headstock device panel.
F. Verify that “Chiller Lube Pressure Switch” (DI-S11) on headstock device panel is high in the control.
The switch is set to open at 3.5 bar (50 psi) falling pressure.
4. Hydraulic unit setup for two-speed headstock.
A. Unclamp the drawbar. With 150 bar (2200 psi) on main hydraulic pressure gauge, verify that the
headstock drawbar pressure gauge on the headstock services panel is reading 150 bar (2200 psi).
Normal line pressure loss is acceptable.
B. The gearbox lube flow adjustment procedure is described in the lubrication section. See the heading
titled two-speed headstock gearbox lube.
75.40-2 HYDRAULIC & PNEUMATIC SYSTEM SETUP

Clogging Indicator
(HC-S4)
Lube Filter with 10

Components
See FIGURE
Top View of this Area 75.40- 3 for
See FIGURE 75.40- 2 Detailed View.
Check Valve

Components
Main System
[Set @ 165-166 Bar (2400 psi)]

Axial Piston Pump

Breather
Reservoir Assembly
FIGURE 75.40- 1
HYDRAULIC & PNEUMATIC SYSTEM SETUP 75.40-3

Remote Pressure Relief Valve
For Normal System Pressure
Set at 70 Bar (1000 PSI) High Pressure “Enable”
(HC-Y7)
Hydraulic Oil Filter

with 10 μm Filter
Element
Differential Pressure Adjustment

Screw (Factory Set @ 20 Bar)
Clogging Indicator
Hyd. Oil Filter “OK” Compensator Adjustment Screw
(EA-S4) (Maximum Main Hydraulic Pressure Adjustment)
FIGURE 75.40- 2
Top View of Hydraulic Unit Services Panel
Pressure Switch System Air Main System Regulator,

Pressure “OK” (HC-S5) Pressure Gauge & Filter
with 5 μm Filter Element
Lock-Out Valve
Solenoid Valve (HC-Y2)

Headstock Lube Air
Shop Air Inlet
Pressure Regulator & Gauge for

Headstock Lube Air Pressure
Set at 5.5 Bar (80 psi) Coalescing Filter with
0.01 μm Filter Element
Solenoid Valve
(HC-Y6) Air to
Spindle Collet
Pressure Regulator & Gauge for Linear Scale Air

Pressure Set at 0.6-1 Bar (8-15 psi)
FIGURE 75.40- 3
Pneumatic Components on Main Hydraulic Unit Services Panel
75.40-4 HYDRAULIC & PNEUMATIC SYSTEM SETUP

SECTION 78.10
PNEUMATIC SYSTEM
TABLE OF CONTENTS
TITLE PAGE
THE PNEUMATIC SYSTEM ..........................................................................................................................................1
THE PNEUMATIC SYSTEM
A pneumatic system is required to operate a number of mechanisms on the machine. Air is used to supply a positive
internal pressure in the housings of the X-axis & Y-axis linear encoders (scales), which prevents the ingress of
contamination. Air is mixed with oil to lubricate bearings and gears in the headstock and the Y-axis drive. Air can be
delivered through the spindle collet during a tool holder change. There is an extra connection at the main hydraulic
services panel to supply compressed air for any accessories.
The pneumatic system is located on the services panel of the main hydraulic unit (FIGURE 78.10- 1). The pneumatic
diagram is shown in FIGURE 78.10- 2. An air supply with maximum pressure of no more than 8.5 bar (125 psig) must
be connected to the system. The air supply passes through a filter/regulator where system pressure is set at 5.5-7
bar (80-100 psi). The filter/regulator has a 5 micron filter element followed by a coalescing filter with 0.01 micron filter
element to remove liquid aerosols and sub-micron particles. The filter bowls are equipped with automatic drains.
Pressures switch (HC-S5) monitor’s system air pressure. It is set to open at 4.5 bar (65 psi) falling pressure.

Lock-Out Valve

Headstock Lube Air
Shop Air Inlet

Solenoid Valve
(HC-Y6) Air to
Spindle Collet

FIGURE 78.10- 1
PNEUMATIC SYSTEM 78.10-1

The oil free, 5.5-7 bar (80-100 psi) air supply is routed to a manifold for Y-axis drive lube air and accessory air. This
air pressure is on, whenever main system air is activated. A secondary line feeds a set of manifolds with solenoid
valves. Valve HC-Y6 enables 5.5-7 bar (80-100 psi) air to the spindle collet for air blast during tool change. A
pressure regulator, set at 5.5 bar (80 psi), feeds valve HC-Y2. When the spindle is running, this valve is enabled,
supplying headstock lube air for the air + oil lube components. A line connected to these manifolds (separate from
the valves) feeds a pressure regulator set at 0.6-1 bar (8-15 psi). This line is routed to a manifold for linear scale air.
Pneumatic 5 Micron Filter and Regulator

with Pressure Gauge Coalescing Filter with
Lock-Out Valve 0.01 Micron Filter
Element
Shop Air Supply

Inlet 5.5-7 Bar
(80-100 psi)
(HC-S5) System Air Pressure “OK”

Open at 4.5 Bar (65 psi) Falling Pressure
HC-Y2
Headstock Lube Air
HC-Y6
Air through
Spindle Pressure Regulator and
Collet Gauge for “Headstock
Lube Air Pressure”
5.5 Bar (80 psi)
Pressure Regulator and Gauge

for Linear Scale Air Pressure
0.6-1.0 Bar (8-15 psi)
Headstock Lube Air

Spindle Air to Tool (To Headstock Device Panel)
(To Headstock Device Panel)
Accessory Air X-Axis Scale Air
Y-Drive Lube Air Y-Axis Scale Air
FIGURE 78.10- 2
Pneumatic Diagram
78.10-2 PNEUMATIC SYSTEM

SECTION 78.20
PNEUMATIC SYSTEM – SETUP
TABLE OF CONTENTS
TITLE PAGE
PNEUMATIC SYSTEM SETUP .....................................................................................................................................1
PNEUMATIC SYSTEM SETUP
informational purposes only. If the hydraulic/pneumatic system requires set-up, it should be performed only by
qualified personnel.
1. Set system air regulators & switches on hydraulic services panel (FIGURE 78.20- 1 & FIGURE 78.20- 2).
A. Ensure air is turned on at panel. Manual interlock must be parallel with air input line.
B. Pressure switch (HC-S5) “System Air Pressure OK”, has been set to at 4.5 bar (65 psi) falling pressure.
C. Main system air regulator should be set to 5.5 bar (80 psi). Read gauge on filter/regulator.
D. Linear scale air regulator should be set to 0.6-1.0 bar (8-15 psi).
E. Manually fire the headstock lube air solenoid valve (HC-Y2). Lube air regulator should be set to 5.5 bar
(80 psi) with lube air on. Close valve to turn off lube air.
F. Pressure switch (HC-S2) “Headstock Lube Air Pressure OK” on headstock services panel (FIGURE
78.20- 3 for two-speed headstock or FIGURE 78.20- 4 for four-speed headstock) registers high in PLC
when hydraulic unit is started. This switch is factory set at 3 bar (44 psi).
PNEUMATIC SYSTEM – SETUP 78.20-1

Clogging Indicator
(HC-S4)
Lube Filter with 10

Components
Check Valve
Secondary Hydraulic
Pressure Components
Main System
[Set @ 165-166 Bar (2400 psi)]

Axial Piston Pump

Breather
Reservoir Assembly
FIGURE 78.20- 1
78.20-2 PNEUMATIC SYSTEM – SETUP

Lock-Out Valve

Headstock Lube Air
Shop Air Inlet

Solenoid Valve
(HC-Y6) Air to
Spindle Collet

FIGURE 78.20- 2

Air + Oil Metering Unit for Lube Line to Y-Axis
Pressure Switch Pressure Switch Spindle Cartridge Bearings, Ways and Ballscrew
Headstock Lube “OK” Headstock Lube Air Rear Spindle Bearings, and
(HC-S1) “OK” (HC-S2) Idler Gear Shaft Bearings
Hydraulic Pump
for Gearbox
Lube Return
Lube Air for Gear &
Spindle Nozzles Proximity Switch
“Lube Pump Running”
(DI-Y6)
Piston Distributor for
Pressure Gauge Gear & Spindle Lube
Gearbox Lube Nozzles
Pressure Gauge
Drawbar Unclamp
Solenoid Valve “Headstock

Lube Enable” (HC-Y1)
Pressure Reducing Valve and
Directional Control Valve Flow Control Valve
“Drawbar Unclamp” “Gearbox Lube Control”
(DI-Y3)
FIGURE 78.20- 3
Two-Speed Headstock Device Panel Lubrication Components
78.20-4 PNEUMATIC SYSTEM – SETUP

Control Valves
Pressure Gauge
(1000 psi) (DTE 26)
(HC-S1)
Profibus

Drawbar Unclamp
Directional Control
Valve (DI-Y3)
Headstock Lube
FIGURE 78.20- 4

SECTION 79.10
LUBRICATION SYSTEM – COMMON
TABLE OF CONTENTS
TITLE PAGE
THE LUBRICATION SYSTEM .......................................................................................................................................1
LINEAR WAY AND BALLSCREW LUBE ............................................................................................................2
PISTON DISTRIBUTORS ...................................................................................................................................3
Y-AXIS DRIVE LUBE ..........................................................................................................................................4

THE LUBRICATION SYSTEM
The lubrication system uses reduced pressure and hydraulic reservoir DTE 26 oil from the central hydraulic unit to
supply non-recovered, total loss lubricant to the axis linear ways and ballscrews and the Y-axis drive gears. The two-
speed headstock use the main lubrication system to lubricate the spindle cartridge bearings, idler gear shaft bearings,
rear spindle bearings, drive gear mesh, and outside spindle diameter however, this lubricant is re-circulated. The
four-speed headstock uses the main lubrication system to provide rear spindle bearing lubricant, with a separate self-
contained oil cooler unit to supply lubricant to the gear train, spindle sleeve bearings and the outside of the spindle.
The X & W axis drive box has a gear drive that is immersed in SHC 634 oil bath.
Manifold Block X-Axis Lube
Y-Axis Drive Lube
Spindle-Axis, Y-Axis & Headstock Lube

(Connects to Headstock Device Panel)
Filter with 10 Micron

Filter Element
HC-S4: Lube Filter “OK”
Bypass: 6 Bar (87 PSID)
Switch Setting: 5 Bar (PSID)
Pressure Gauge
From Secondary
Pressure Readings of 26-28
Hydraulic Pressure
Bar (380-400 PSI) during
‘”Cycle On” ONLY
To Tank
Lubrication Pressure Pressure Reducing

Set At 26-28 Bar (380- Valve
400 PSI)
Check Valve
Directional Control
HC-Y1 Valve
Machine Lube Enable
FIGURE 79.10- 1
Lubrication Fluid Diagram from Main Hydraulic Unit to Main Lubrication Lines
LUBRICATION SYSTEM – COMMON 79.10-1

LINEAR WAY AND BALLSCREW LUBE
The main lubrication system is used to deliver lubricant to the linear way runner blocks and axes ballscrews. The
basic layout consists of pressure supplied by the main hydraulic system, piston distributors, main line (pump to piston
distributor), secondary line (piston distributor to lube point), 10 micron lube filter, controls and monitoring units.
The secondary hydraulic pressure line feeds the main lubrication system (FIGURE 79.10- 1). A pressure reducing
valve is used to lower the lubrication pressure to 26-28 bar (380-400 psi). A directional control valve enables lube, in
lieu of a separate lube pump.
Note: The lubrication pressure gauge on the main hydraulic services panel reads the pressure only during
lube enable cycle.
The lube cycle is initiated whenever machine hydraulics is turned on and every 720 seconds of total axes traverse
time. For machines with two-speed headstocks, the lube cycle is enabled every 720 seconds of spindle rotation.
Whenever the two-speed headstock lube is enabled, the axes lube is also enabled. The axes lube timer is reset after
every axes or headstock lube cycle. The two-speed headstock lube timer is reset after every headstock lube. See
FIGURE 79.10- 2 for lube components and FIGURE 79.10- 1 for lube fluid diagram to main lube line.
For machines with four speed headstocks, the lubrication of the rear spindle bearings is part of the axes lube cycle.
The line that feeds the spindle-axis piston distributors, also supplies the piston distributors for the rear spindle
bearings.
Pressure Reducing Valve Lubrication Pressure Gauge

“Lubrication System” Operating Pressure
Set @ 26-28 Bar (380-400 PSI) 26-28 Bar (380-400 psi)
During Lube “Cycle On”
Check
Valve

(HC-S4)
Directional
Control Valve
“Machine Lube
Enable”
(HC-Y1)

Lube Filter with “Secondary Hydraulic Pressure”
10 μm Filter Element Set @ 76 Bar (1100 psi)
FIGURE 79.10- 2
Main Hydraulic Unit Lubrication System Components
The main lube lines are connected to a manifold on the rear of the main hydraulic unit. These main lube lines
connect to piston distributors that are remotely positioned. When lube is enabled, a relatively small amount of lube oil
stored in the piston distributors is delivered to the intended lube point. Each of the runner blocks (trucks) of the X, Y
& Spindle-axes linear ways and the axes ballscrew nuts receive lube. In addition, the Y-axis drive gears receive lube
in the form of an air and oil mist. The Y-axis drive gears lube is described in detail in the later heading, “Y Axis Drive
Lube”. The lube line that connects to the headstock device panel provides lube to the Y and Spindle-axes ways, and
ballscrews plus other components dependent on whether it is a two speed or four speed. See appropriate later
headings, “Two Speed Headstock Lube” or “Four Speed Headstock lube”.
79.10-2 LUBRICATION SYSTEM – COMMON

PISTON DISTRIBUTORS
Piston distributors meter out and distribute the lube oil. The quantity of oil that the piston can deliver is determined by
exchangeable metering units. Distributor groups vary in their metering range and overall size. Different distributor
groups can be used in one installation (FIGURE 79.10- 3). The functional principle of the groups is the same, but
there are differences in design. The basic function is shown in FIGURE 79.10- 4 and described below:
1. The volume of oil allocated for the lube point is in front of the piston in the distributor.
2. When lube is enabled, the directional control valve (HC-Y1) opens to allow oil flow. The oil pressure pushes
the piston and the oil in front of it is fed to the lube point at main lube line pressure of 26-28 bar (380-400 psi).
3. After the pressure is relieved in the main lube line, the distributor’s piston returns to its initial position and once
again lets the designed quantity of oil flow into the space in front of the piston.
4. Pressure switch HC-S1 on the headstock device panel is monitored by the machine control. Once the lube
cycle is initiated, the switch must rise above 20 bar (290 psi) within a give time period. After the cycle ends,
the switch must fall below 20 bar (290 psi) within a give time period. A fault will occur in either case, if the time
period is exceeded.
Two Speed Spray Nozzle Supply

(Mounted on Headstock Device Panel)
FIGURE 79.10- 3
Example of Piston Distributor Arrangement
FIGURE 79.10- 4
Cutaway View of Piston Distribution
LUBRICATION SYSTEM – COMMON 79.10-3

Y-AXIS DRIVE LUBE
An oil + air system is used for the Y-axis drive lube (FIGURE 79.10- 5). The gear mesh surfaces at servo drive/idler
gear and idler gear/ballscrew drive are supplied with an even spray of lubricant with the help of air. This system is
used on all machines. One lube line from the manifold (Y drive lube) on the rear of the main hydraulic unit, supplies a
piston distributor attached inside the drive housing. Whenever the lube cycle is enabled, this piston distributor
delivers oil to each of the spray/mixing heads. The mixing heads are supplied with lube air that is filtered with 0.01
micron filter element at the main hydraulic unit. The air is delivered at 5.5 - 7 bar (80-100 psi). This is a separate air
line that is enabled whenever the pneumatic system is on.
Ballscrew Drive
Gear
Spray and Air/Oil Mixing Head
Lube Piston Motor Drive

Distributor Gear
FIGURE 79.10- 5
Y-Axis Drive Lube
79.10-4 LUBRICATION SYSTEM – COMMON

SECTION 79.20
LUBRICATION SYSTEM – 2 SPEED
TABLE OF CONTENTS
TITLE PAGE
TWO-SPEED HEADSTOCK LUBE................................................................................................................................1
OIL + AIR LUBE SYSTEM ..................................................................................................................................1
TWO-SPEED HEADSTOCK GEARBOX LUBE ..................................................................................................5

TWO-SPEED HEADSTOCK LUBE
The two-speed headstock makes use of an oil + air system with metering unit to supply lube to the spindle cartridge
bearings, rear spindle bearings, and idler gear shaft bearings. Lubrication of drive/idler & idler/bull gear meshing
points and the outer diameter of the spindle is accomplished with air + oil mixing unit with spray nozzle, located at the
lube point. One main lube line (labeled “head lube”) from the manifold on the rear of the main hydraulic unit connects
to the headstock device panel. This hose supplies the lubricant used to feed the Y and Spindle-axes ways and
ballscrews, & oil + air headstock lube.
A solenoid valve “Headstock Lube Enable” (HC-Y1) on the headstock device panel (FIGURE 79.20- 2) controls the
flow to the oil + air applications. After 720 seconds of spindle rotation, an axes lube cycle is initiated and the solenoid
valve (HC-Y1) energizes to allow flow to the metering unit and piston distributors on the headstock device panel.
OIL + AIR LUBE SYSTEM
Oil + air is minimal quantity metering. A drop of oil is pulled apart in streaks by a current of air in a narrow tube. The
oil drop is carried along the inner wall of a narrow tube in the direction of the lube point. Fine droplets of oil exit the
tube at the intended lube point. The carrier air leaves the lube point nearly free of oil.
The oil + air system utilized to lube the bearings on the two-speed headstock uses a metering unit (FIGURE 79.20- 2)
mounted on the headstock services panel. Lube oil from the main lube line connects at the headstock device panel.
It is routed to a solenoid valve that enables headstock lube. After the valve, the line passes through a piston
distributor and then into the metering unit. Also connected to the metering unit is a lube air line from the main
hydraulic unit services panel. The lube air is filtered with 0.01 micron filter element and pressure regulated at 5.5 bar
(80 psi). A solenoid valve at the main hydraulic unit enables air flow, whenever the spindle rotates. There is a
pressure switch mounted on the headstock services panel that monitors the minimum pressure requirement at the
metering unit of 3 bar (44 psi). See FIGURE 79.20- 2 for two-speed headstock services panel.
The metering unit has built in piston distributors with eight outlet ports. Within the unit are metering bores for each
port. Two ports supply lube to the rear spindle bearings and two to the idler gear shaft bearings. Four ports supply
double the lube to the spindle cartridge bearings. FIGURE 79.20- 3 shows various views of the metering unit.
LUBRICATION SYSTEM – 2 SPEED 79.20-1

Gearbox Lube
Return Pump
Speed Sensing
Proximity Switch
(DI-S6)
(Pilot Oil from Port B)
Set at 27.5 Bar (400 psi)
Hydraulic Motor
No Pressure Reduction,
when Directional Control
Valve is in Position P to A
Gearbox Lube
Pressure (After Flow
Set, Readings
between 90-150 psi)
Flow Control Valve

Set to 2.5 L/min
(0.65 gpm) after Headstock Headstock Gearbox
Pressure Reducing Hydraulic Hydraulic Lube
Valve is Set Pressure Return Return
FIGURE 79.20- 1
Two Speed Headstock Gearbox Lube
79.20-2 LUBRICATION SYSTEM – 2 SPEED

Air + Oil Metering Unit for Lube Line to Y-Axis
Pressure Switch Pressure Switch Spindle Cartridge Bearings, Ways and Ballscrew
Headstock Lube “OK” Headstock Lube Air Rear Spindle Bearings, and
(HC-S1) “OK” (HC-S2) Idler Gear Shaft Bearings
Hydraulic Pump
for Gearbox
Lube Return
Lube Air for Gear &
Spindle Nozzles Proximity Switch
(DI-Y6)
Piston Distributor for
Pressure Gauge Gear & Spindle Lube
Gearbox Lube Nozzles
Solenoid Valve “Headstock

Lube Enable” (HC-Y1)
Pressure Reducing Valve and
Flow Control Valve
“Gearbox Lube Control”
FIGURE 79.20- 2
Two-Speed Headstock Device Panel Lubrication Components

Pressure Alternate Oil Alternate
Measuring Ports Input Air Input
Air Adjustment
Screws
Secondary
Lines to Lube
Point
Screw Plugs
(Connections
for Additional
Metering
Units)
Air Input
Oil Input
FIGURE 79.20- 3
Two-Speed Headstock Lube Metering Unit
The oil + air system used to lube the two-speed headstock drive/idler gear mesh, idler/bull gear mesh, and spindle
outside diameter is different then that used to lube the bearings. Remote mixing units, which include spray nozzles,
are fed oil by the piston distributor located ahead of the metering unit. Branch air lines, which are part of the same air
line feeding the metering unit, are fed to these mixing units. When the headstock lube is enabled, the oil is pushed
from the distributor and mixes with the lube air to produce an even spray of lubricant. FIGURE 79.20- 4 shows one of
the two nozzles used for gear mesh lube and the nozzle used for spindle outside diameter lube.
Idler Gear
Nozzle
Spindle inside
Rear Housing
Drive Gear not Shown
FIGURE 79.20- 4
Spray Nozzle (Oil + Air Mix) Two-Speed Headstock

TWO-SPEED HEADSTOCK GEARBOX LUBE
The ZF gearbox is lubricated with a continuous flow of oil supplied from the main hydraulic pressure line. This main
line connects to the headstock services panel (referred to as headstock pressure), where it is routed to a combination
directional control valve, pressure reducing valve and flow control valve. The directional control valve is normally set
to direct the oil (from P to B), where it flows to a pump acting as a hydraulic motor (FIGURE 79.20- 5). The pressure
reducing valve is pilot operated, with pilot pressure taken from port B. The pressure is only reduced when the
directional control valve is not energized. The flow control valve only restricts flow in one direction, when pressure
flows through port B to the hydraulic motor.
The pressure and flow must be properly regulated to feed the correct amount of oil to the gearbox. The pressure
reducing valve is setup for 27.5 bar (400 psi) with the flow control valve fully open. The flow control valve is then
adjusted to produce 2.5 L/min (0.65 gpm) on a temporary flow gauge. This will produce a pressure drop, with
readings on the gearbox lube pressure gauge (located on the headstock device panel) of 6-10 Bar (90-150 psi). See
the setup procedure “Two-speed headstock ZF gearbox lubrication setup” in the “Lubrication System Setup” heading
later in this section.
Note: The oil flow is simultaneously powering the hydraulic motor coupled to the pump. The pump must
operate at the correct speed to remove the proper volume of oil from the gearbox.
A proximity switch (DI-S6) is mounted between the hydraulic motor (pump) and the return pump. This is a speed-
sensing switch that detects the rotational speed of the pump. The switch senses two high points per revolution on the
coupling connecting the hydraulic motor to return pump (FIGURE 79.20- 5). The first LED, when green indicates
power. This LED turns to orange when the output of the switch is on. A second LED flashes blue when there is
adequate pump speed.
When drawbar unclamp is initiated, the directional control valve is energized diverting the flow to the drawbar
hydraulic cylinder, thereby stopping lube to the ZF gearbox. Since the pressure reducing valve is pilot operated, it
allows the full 150 bar (2200 psi) of pressure to the drawbar. During a drawbar unclamp the spindle will not be
rotating; therefore, the gearbox lube stoppage is not an issue.

A: Gearbox Lube Pressure Gauge Lube Return
B: Drawbar Pressure Gauge Lube to Gearbox (Opposite Side from Input)
B Hydraulic Lube Return

Motor ZF Gearbox
Pump
E
C Proximity Switch
(Lube Pump
Running)
D (DI-S6)
Lube Input
Proximity Switch
C: Directional Control Valve (DI-Y3) (DI-S6) Set to
D: Pressure Reducing Valve this Surface.
E: Flow Control Valve
View of Coupling Connecting Hydraulic Motor

to Lube Return Pump.
FIGURE 79.20- 5
Two-Speed Headstock Gearbox Lube Components

SECTION 79.30
LUBRICATION SYSTEM – 4 SPEED
TABLE OF CONTENTS
TITLE PAGE
FOUR-SPEED HEADSTOCK LUBE ..............................................................................................................................1
FOUR-SPEED HEADSTOCK LUBE
On the four-speed headstock the Y and Spindle-axes ways and ballscrew nuts, and the rear spindle bearings are
lubricated using the pressure provided by the main hydraulic unit and lube oil from the main hydraulic unit reservoir.
A main lube line from the manifold on the rear of the hydraulic unit connects to the headstock device panel. This lube
line is routed both to the top of the headstock for Y-axis way and ballscrew lube, and through the headstock cable
carrier to provide Spindle-axis way and ballscrew lube, as well as, lube to the air + oil mixing blocks (FIGURE 79.30-
1) that lubricate the rear spindle bearings. A pressure switch on the headstock services panel monitors that “lube
pressure is OK”. This switch is factory set at 20 bar (290 psi).
The lube air line for the mixing blocks comes from the main hydraulic unit services panel. The lube air is filtered with
0.01 micron filter element and pressure regulated at 5.5 bar (80 psi). A solenoid valve at the main hydraulic unit
enables air flow whenever the spindle rotates. A pressure switch on the headstock services panel monitors that
“headstock lube air pressure is OK”. This switch is factory set at 3 bar (44 psi). On the four-speed headstock, lube
air is only used for the mixing blocks that lubricate the rear spindle bearings. FIGURE 79.30- 1 shows the mixing
blocks and piston distributors used for rear spindle bearings, Spindle-axis way and ballscrew lube. FIGURE 79.30- 2
shows the headstock services panel lubrication components.
Thrust Bracket (Shown Inverted)
Air + Oil Mixing Blocks
FIGURE 79.30- 1
Air + Oil Mixing Blocks for Rear Spindle Bearings
A completely self-contained closed-loop type oil cooler unit provides clean cooled oil to the headstock gear housing.
This cooled oil (DTE 24) provides lubrication to the front and rear spindle sleeve bearings, the four front gear shaft
bearings and an oil spray for gear to gear meshing. A branch line of this system feeds a resistance fitting that
provides one-way delivery of a small amount of oil to the outside diameter of the spindle.
The oil from the cooler connects to the headstock device panel. A pressure gauge and pressure switch (DI-S11) are
mounted on the headstock device panel. The pressure switch has been set to trip when the pressure falls below 3.5
bar (50 psi). The oil enters the top of the gear housing, branching to three separate lines. One line feeds a set of six
spray nozzles mounted at the top of the gear housing. The nozzles provide a shower of lube to the four gear shafts
and gear to gear mesh. Another line feeds the front and rear spindle sleeve bearings. The third line feeds lube into
the oil rings of the four gear shafts, lubricating the front gear shaft bearings.

Control Valves
Pressure Gauge
(1000 psi) (DTE 26)
(HC-S1)
Profibus

Drawbar Unclamp
Directional Control
Valve (DI-Y3)
Headstock Lube
FIGURE 79.30- 2
Resistance Fitting (CSA-00)
Spindle Outside Diameter
DTE 24 Lube to
Front and Rear
Spindle Sleeve
Bearings
Sealing Ring in Rear of Gear Housing
FIGURE 79.30- 3
Spindle OD Lube Line

The DTE 24 oil is collected by a set of dual scavenger pumps run by one two HP motor (FIGURE 79.30- 4). The
discharge ports of the pumps are internally piped together. The pump closest to the motor discharges the oil, with the
hose routed to the headstock device panel (labeled Chiller Return). The oil is returned to chiller unit reservoir. The
front pump suction line removes oil from the front spindle sleeve bearing. The second pump suction line removes the
remaining oil that collects on the bottom of the gear housing, discharging from its port.
View of Bottom of Headstock, Rotated 90°
Suction from
Bottom of Gear
Discharge to Housing
Headstock
Device Panel
(Then to Chiller
Reservoir)
Suction from
Front Spindle
Sleeve Bearing
Discharge
Front of Headstock
The Discharge Ports

of the Pumps are
Internally Piped
Together
Suction from Front Spindle

Suction from Bottom of Gear Housing Sleeve Bearing
FIGURE 79.30- 4
Four-Speed Headstock Scavenger Pump

SECTION 79.40
LUBRICATION CHILLER
TABLE OF CONTENTS
TITLE PAGE
FOUR-SPEED HEADSTOCK OIL COOLER UNIT ........................................................................................................1
OIL COOLER STARTUP.....................................................................................................................................3

FOUR-SPEED HEADSTOCK OIL COOLER UNIT
At the time of this writing, the oil chiller units used on four speed headstock machines are manufactured by Dimplex
Thermal Solutions - Koolant Kooler Brand (FIGURE 79.40- 1). Your machine may have been equipped with a unit
manufactured by Turmoil (FIGURE 79.40- 2). The vendor information include with you CD includes a manual for the
unit equipped with your machine.
The oil chiller unit consists of a separate 136 liter (40 gal) oil reservoir, filter with 10 micron filter element, digital
temperature controller, internal circulating pump, external circulating pump, and air cooled refrigeration system. The
cooler unit uses DTE 24 oil; where as, the main hydraulic unit uses DTE 26.
The unit draws in air through the air filters on the right and left side panels with fans exhaling the air from the top. The
flow of air cannot be impeded. Lack of adequate air flow will cause a reduction in cooling capacity and/or completely
shutdown the refrigeration compressor.
The unit is supplied with a digital ambient tracking temperature controller, mounted on the front of the door of the
electrical enclosure. The controller works to maintain the discharge oil at a constant temperature differential relative
to the air temperature. The oil sensor is mounted in the discharge line. The ambient air sensor is mounted on the
rear of the machine column (FIGURE 79.40- 1).
The discharge pressure gauge monitors oil pressure to the headstock. Pressure readings will range between 5-8.5
bar (75-125 psi). There are two pressure gauges that monitor the refrigerant (R134a). The suction pressure gauge
indicates the refrigerant pressure entering the compressor. The head pressure gauge indicates the refrigerant
pressure leaving the compressor. When refrigeration is not running, the gauges tend to equalize around 7 bar (100
psi). Total allowable gauge range during refrigeration: 1-4.5 bar (15-65 psi) for suction pressure, 4-17 bar (60-250
psi) for head pressure. Variations are dependent upon ambient temperature and whether system is cooling or hot
gassing.
LUBRICATION CHILLER 79.40-1

Ambient Air
Temperature
Sensor
Refrigerant
Pressure Gauges
Oil Discharge
Pressure Gauge
Lube Oil
Filler/Breather
Lube Oil Port
Return
Lube Oil
Discharge
Filter
Lube Oil
Discharge Machine Column
Left Side View

with Filter/Cover Front View
Removed
FIGURE 79.40- 1
Four-Speed Headstock Oil Chiller Unit – Dimplex Koolant Kooler
79.40-2 LUBRICATION CHILLER

Discharge Oil Filter
Ambient Air
Temperature Sensor
Refrigerant
Pressure Gauges
Discharge Flow Meter
(Right Access Panel)
Left Side View

Discharge Ambient Tracking
Pressure Gauge Temperature Controller
Lube Oil
Service Access Return
Panels
Lube Oil
Discharge
Lube Oil
Filler/Breather Port Machine Column
Front View
Discharge Flow Adjustment

(Left Access Panel)
FIGURE 79.40- 2
Four-Speed Headstock Oil Chiller Unit – Turmoil
OIL COOLER STARTUP
The oil cooler is designed for use indoors in a clean industrial environment. Ambient temperature should not fall
below 50° F (10° C) or rise above 113° F (42° C). The cooler is equipped with crankcase heater. The rotary
disconnect switch needs to be turned to the ON position to allow the crankcase heater to warm up the compressor for
at least four hours before starting refrigeration. If the oil cooler unit is in a relatively warm area, at least above 65° F
(16° C), it can be started sooner.
LUBRICATION CHILLER 79.40-3

SECTION 79.50
LUBE SYSTEM SETUP
TABLE OF CONTENTS
TITLE PAGE
LUBRICATION SYSTEM SETUP ..................................................................................................................................1
AXIS LUBE..........................................................................................................................................................1
TWO-SPEED HEADSTOCK ZF GEARBOX LUBRICATION SETUP .................................................................2
FOUR-SPEED HEADSTOCK OIL CHILLER SETUP FOR KOOLANT KOOLER UNIT ONLY ...........................3
FOUR-SPEED HEADSTOCK OIL CHILLER SETUP. FOR TURMOIL UNIT ONLY ..........................................3
LUBRICATION SYSTEM SETUP
informational purposes only. If the lubrication system requires set-up, it should be performed only by qualified
personnel such as a MAG service representative.
AXIS LUBE
1. Axis ways and ballscrews, and Y-axis drive lubrication setup. Includes two-speed headstock spindle cartridge
bearings, idler gear bearings, and rear spindle bearings lubrication. Includes four-speed headstock rear
spindle bearings lubrication.
A. With main hydraulic unit operational, manually fire control valve “Machine Lube Enable” HC-Y1.
B. Reading lubrication pressure gauge on main hydraulic unit services panel verify that lubrication pressure
is 26-28 bar (380-400 psi). Adjust pressure reducing valve under directional control valve from step A, if
required.
C. The “Lube Filter OK” (HC-S4) should be high in the PLC. The clogging indicator trip pressure is set by
the manufacture at 5 bar (73 psi).
D. The “Headstock Lube Pressure OK” (HC-S1) on either the two or four-speed headstock services panel
should be high in the PLC. The pressure switch is set by the manufacturer at 20 bar (290 psi).
LUBE SYSTEM SETUP 79.50-1

TWO-SPEED HEADSTOCK ZF GEARBOX LUBRICATION SETUP
1. With hydraulic system off, install a temporary 0 to 8 Lpm (0 to 2 gpm) flow gauge between the main hydraulic
pressure line and the headstock services panel connection (FIGURE 79.50- 1).
Gearbox Lube
Pressure Gauge
Temporary Flow
Gauge
FIGURE 79.50- 1
Two-Speed Headstock Device Panel with Temporary Flow Gauge
2. The pressure reducing valve on headstock services panel should first be adjusted (CCW) for zero pressure.
3. The flow control valve on headstock services panel should first be adjusted (CCW) for full flow.
4. Turn on machine hydraulics. Ensure there are no leaks.
5. Adjust pressure reducing valve CW to 27.5 bar (400 psi). Lock down pressure adjustment.
6. Adjust flow control valve to 2.5 Lpm (.65 gpm) flow on temporary flow gauge. Pressure will change once flow is
adjusted; however it is flow not pressure that is important. 6-13 bar (90-190 psi) lube pressure is normal.
7. Set the “Lube Pump Running” proximity switch (DI-S6) located between the hydraulic motor and pump. This is
a speed sensing pump, which detects the two high points on the coupling connecting the motor to pump.
A. Turn off hydraulics.
B. Turn in switch until it makes contact with the non-flat surface of the coupling.
C. Back off switch 2.5 -3.5 turns.
D. The switch has two LED’s. One is green indicating power. This LED turns to orange when the output of
the switch is on. The second LED flashes blue, when there is adequate pump speed.
E. Turn on hydraulics. Adjust the flow control valve for 1.5 Lpm (0.4 gpm) flow on temporary flow gauge.
F. Adjust the sensitivity potentiometer so that the green LED just turns orange.
G. Re-adjust the flow control valve for 2.5 Lpm (.65 gpm) on temporary flow gauge. Verify that the LED on
the switch is still orange. Lock down flow control adjustment.
8. Turn off machine hydraulics. Remove temporary flow gauge.
79.50-2 LUBE SYSTEM SETUP

FOUR-SPEED HEADSTOCK OIL CHILLER SETUP FOR KOOLANT KOOLER UNIT ONLY
1. Verify all hoses are connected and tight. Ensure oil filter is tight and that reservoir is filled with DTE 24 oil to
proper level. The filter should be hand tighten, and then turned an additional ¾ turn to seal.
2. Turn disconnect on and engage starter 239C momentarily to verify that unit rotation is correct. Air should be
blowing up and out of the top of the unit.
3. The chiller unit comes preprogrammed. Refer to the vendor documentation for the current settings and
operation of the controller.
FOUR-SPEED HEADSTOCK OIL CHILLER SETUP. FOR TURMOIL UNIT ONLY
1. Remove both service access panels on left side of unit. Break loose lock nut on oil discharge flow adjustment,
if required (FIGURE 79.50- 2).
FIGURE 79.50- 2
Ambient Tracking Temperature Controller (Turmoil Unit)
2. Start oil cooler unit. Verify that the red “Low Flow” light on the front of the unit goes out after the short time that
it takes to prime the internal pump and begin pumping oil through the internal circuit. If the flow of the oil in
internal circuit drops below 19 liter/min (5 gpm), the compressor will shut down and “Low Flow” light will come
on.
3. The pressure switch (DI-S11) beneath pressure gauge on headstock services panel has been adjusted to
close at 3.5 bar (50 psi).
4. Turn the oil discharge flow adjustment screw until there is 17-19 liter/min (4.5-5 gpm). Verify that there is 5-8.6
bar (75-125 psi) on “Headstock Lube Pressure” gauge from step C.
5. Tighten locknut and replace access panels.
6. Verify that ambient tracking temperature controller on oil cooler unit has been setup. Enter “Set-point Delta T”
which is temperature differential between oil at discharge and ambient air. Push “SET” once. The * and 1 LED
indicators will light and the display will show the current “Set-point Delta T” value. The value should be zero
(0). Use UP or DOWN to change. Enter “Limit Delta-T” which will signal an alarm when oil temperature (°F) is
this value above ambient air temperature. Push “SET” again. The * and 2 LED indicators will light and the
display will show the current “Limit Delta T” value. The value should be twenty (20). Pushing “SET” again will
return to the display mode. When in program mode, if no button is pushed for eight seconds, the controller will
automatically return to display mode.
LUBE SYSTEM SETUP 79.50-3

SECTION 80.10
COOLANT SYSTEMS
TABLE OF CONTENTS
TITLE PAGE
THE COOLANT SYSTEM..............................................................................................................................................1
COOLING LUBRICANTS ....................................................................................................................................2
ALTERATION OF COOLING LUBRICANT PROPERTIES .................................................................................3
CARE AND MONITORING OF THE COOLANT SYSTEM .................................................................................4
CLEANING THE COOLANT SYSTEM................................................................................................................4

THE COOLANT SYSTEM
The coolant system on a machine is used to dissipate heat between the cutting tool and workpiece. Coolant can be
delivered through the spindle and/or as a flood through the nozzles.
The standard machine uses a coolant sump built into the foundation with coolant capacity of 500 liter (132 gal). A 2.6
KW (3.5 HP) motor runs the coolant pump, delivering coolant at nominal supply capacity of 11.8 bar X 37 liter/min
(170 psi X 10 gpm) at 60 HZ. When the machine is on the coolant pump runs continuously. When coolant to the
machine is not required, a ¼” bypass tube connected to the pump returns coolant to the sump. Coolant from the
sump is pumped to a filter with 20 μm filter element mounted on the back of the main hydraulic unit. A pressure
switch is used to indicate a clogged filter. Skinner valves are used to enable flow either to “coolant thru spindle” or
flood coolant. The flood coolant line has a pressure regulator ahead of the skinner valve. Initial pressure setting for
flood coolant is 4 bar (60 psi), however, it can be adjusted as desired. The separate “coolant thru spindle” and “flood
coolant” lines are routed to the headstock services panel. FIGURE 80.10- 1 describes the standard coolant
components locate on the rear of the main hydraulic unit. FIGURE 80.10- 2 is the fluid diagram for a machine
equipped with a standard coolant system.
Pressure Switch Skinner Valve

“Coolant Filter OK” “Enable Coolant thru Spindle”
(IA-S1) (IA-Y1)
Coolant Supply from

Sump Pump
Pressure Regulator
(Flood Coolant)
Coolant Filter with

20 μm
Filter Element Skinner Valve
“Enable Flood Coolant”
(IA-Y3)
FIGURE 80.10- 1
Standard Coolant System Components Mounted on Rear of Main Hydraulic Unit
There are a number of optional coolant systems available. Higher coolant pressures can be achieved by using a
larger coolant pump. There are also above ground systems that are purchased as a complete assembly. These
systems have larger coolant tanks, higher coolant pressures, programmable coolant pressures, and paper filters as
some of the added enhancements. Refer to the Line and Foundation drawing and the vendor documentation included
on the CD for the particulars of these type coolant systems.
COOLANT SYSTEMS 80.10-1

COOLING LUBRICANTS
Cooling lubricants have a major influence on the cutting process. To optimize cutting conditions, thereby, lowering
total machining costs, cooling lubricants must be prepared and cleaned with care. The coolant system includes a
strainer at sump pump intake and inline filter with 20 μm filter element for removing chips and preparing the coolant.
Making the right selection of a suitable cooling lubricant can be difficult and requires a great deal of experience.
Health, accident prevention and the protection of the environment should be considered during the selection process.
All cooling lubricants (emulsions) which are miscible with water may be used. The manufactures of cooling lubricants
can provide the best information and advice for proper coolant lubricant selection.
Note: Coolants which contain nitrite must not be used.
Coolant Filter with Skinner

20 μm Filter Element Solenoid
Valve (IA-Y1)
Coolant
thru Spindle
Skinner
Pressure Switch “Coolant Solenoid
Filter OK” (IA-S1) Valve (IA-Y3)
Flood
Nominal Supply Capacity Coolant
8 Bar X 30 LPM (120 psi X 8 gpm) – 50 HZ

Pressure Regulator
11.8 Bar X 307.8 LPM (170 psi X 10 gpm) – 60 HZ
Set to 4 bar (60 psi)
FIGURE 80.10- 2
Standard Coolant System Fluid Diagram
Endless Paper Filter

Immersion Pump
Coolant through Flood Coolant

Tool Hose Hose Connection
Connection
Coolant Reservoir
1500 liter (396 gal.) Return Coolant Line from Machine
Foundation Sump Pump
FIGURE 80.10- 3
High Pressure Coolant System – Tank Assembly with Sump Pump
80.10-2 COOLANT SYSTEMS

ALTERATION OF COOLING LUBRICANT PROPERTIES
There are a number of factors that can alter the properties of cooling lubricants. Some of these factors are listed
below:
• The machining process in use
• The type of material being machined
• The machining of different materials (such as, aluminum & steel) on one machine with the same cooling
lubricant
• The preparation of the cooling lubricant
• The age of the cooling lubricant
• The type and amount of foreign oil taken up by the cooling lubricant
• The quality of the water (hardness, cleanness, etc.)
Some of the adverse effects include a reduction in the cooling and lubricating capacity of the cooling lubricant,
increased corrosion within the coolant system and germ production (fungus, bacteria, etc.).
A further unwanted alteration is foaming. For a given set of machining factors, different water hardness alone may
cause the cooling lubricant to foam. The water hardness can be altered and foaming eliminated or reduced by adding
appropriate agents.
MAG has no influence on any of these factors.
For this reason we recommend that any further information or advice be obtained directly from the cooling lubricant
manufacturer. These manufacturers offer comprehensive service facilities to assist in the selection of suitable cooling
lubricants.
COOLANT SYSTEMS 80.10-3

CARE AND MONITORING OF THE COOLANT SYSTEM
Regular care and monitoring are essential for maintaining the quality and longevity of the cooling lubricant. This also
helps to prevent the occurrence of unwanted alterations to the cooling lubricants properties. Inspection instruments
and quality-related products are available from cooling lubricant manufacturers. Some of these are listed below:
• Coolant system cleaning additives
• Preparation and addition of the emulsion (cooling lubricant)
• Care and monitoring of the emulsion (concentration monitoring), correcting the mix ratios, measures to deal
with foaming, measures to deal with preservation
• Storage and disposal
It is particularly important that regular testing is carried out in accordance with the hazardous materials ordnance (pH
value, nitrate and nitrite analysis, concentration analysis, colony count for yeast). If the limiting values are exceeded,
the complete system should be thoroughly cleaned and the cooling lubricant replaced.
CLEANING THE COOLANT SYSTEM
Over time, extremely fine particles of dirt deposit in the coolant system and eventually combine to form a tough layer
of dirt. The amount of fine particles deposited is dependent on the machining operation in use and the material being
cut. Regular checking and cleaning of the coolant system for contamination and deposits of dirt is required.
Eventually, it will become necessary to completely change the cooling lubricant.
Example of cleaning and exchanging the cooling lubricant:
• Fill the coolant system with system cleaner approximately 24 hours (or as directed by the system cleaner
manufacturer) before exchanging cooling lubricant. Normally production does not need to be suspended.
Follow the instruction per system cleaner manufacturer.
• Drain and dispose of cooling lubricant mixed with the system cleaner.
• Check the complete coolant system (sump, filters, outlets, tanks, etc.) and remove any deposits.
• Flush the coolant system thoroughly with water after cleaning.
• Repeat the process until the used rinsing water is free of foam.
• Refill the coolant system immediately with new cooling lubricant. To prevent corrosion, all pipes, containers,
etc. must be flushed and filled with coolant.
Note: This method is only intended as an example! Depending on the type of cooling lubricant in use, the
cooling lubricant manufacturer, the degree of coolant system contamination, etc., it may be
necessary to follow a different cleaning procedure.
80.10-4 COOLANT SYSTEMS

SECTION 81.10
CHIP CONVEYOR
TABLE OF CONTENTS
TITLE PAGE
GENERAL ......................................................................................................................................................................1
MAINTENANCE .............................................................................................................................................................1
SPECIAL REDUCER:..........................................................................................................................................1
MOTOR: ..............................................................................................................................................................1
CHAIN AND TORQUE LIMITER: ........................................................................................................................1
OPERATING DEVICES .................................................................................................................................................2
MANUAL / AUTO SWITCH .................................................................................................................................2
FORWARD LIGHTED PUSHBUTTON................................................................................................................2
REVERSE PUSHBUTTON..................................................................................................................................2
STOP PUSHBUTTON.........................................................................................................................................2
OPERATION..................................................................................................................................................................2
MANUAL MODE..................................................................................................................................................2
AUTO MODE.......................................................................................................................................................2
GENERAL
The chip conveyor option with the Universal Chip Management System gives more control over chip disposal and will
also monitor chip conveyor overload.
The following information will describe the controls and the manual and automatic operation of the conveyor.
MAINTENANCE
Depending on the model of chip conveyor, some maintenance tasks may not be necessary (sealed bearings, etc.).
SPECIAL REDUCER:
1. See vendor documentation for lubrication and maintenance.
MOTOR:
CHAIN AND TORQUE LIMITER:
Grease Fitting
FIGURE 81.10 - 1
Chip Conveyors
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IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT MACHINING CHIPS ARE

ADEQUATELY CONTROLLED. CHIPS SHOULD NOT BE ALLOWED TO ACCUMULATE IN THE
CONVEYOR BELT AS THIS CAN RESULT IN DAMAGE TO THE CHIP CONVEYOR.
****************************************************************************************
CHIP CONVEYOR 81.10 - 1

OPERATING DEVICES
The conveyor will be equipped with at least one manual control station. This station will be
mounted on or near the conveyor and has the buttons and switches to operate the
conveyor. The figure at the right shows the station and the devices located on it.
MANUAL / AUTO SWITCH
The MANUAL / AUTO switch is used to select the conveyor's mode of operation.
FORWARD LIGHTED PUSHBUTTON
The FORWARD pushbutton is a lighted pushbutton that will be lit when the conveyor is
moving in the forward direction.
REVERSE PUSHBUTTON
The REVERSE pushbutton is a momentary pushbutton that will direct the conveyor in the
reverse direction when pressed and held.
STOP PUSHBUTTON
The STOP pushbutton will halt all chip conveyor motion when pressed.
OPERATION
The chip conveyor can be controlled in the manual or auto modes as determined by the
Manual / Auto switch located on the manual control station. These modes are explained
here.
MANUAL MODE
The following occurs, in the Manual Mode, when the buttons on the control are used.
• FORWARD LIGHTED PUSHBUTTON - Pressing this button will start the conveyor in the forward direction and
the button will light.
• REVERSE PUSHBUTTON - Pressing this button will cause the conveyor to move in the reverse direction, only
while the button is depressed. If the FORWARD button is lit when REVERSE is pressed the conveyor will
reverse direction while the button is depressed. When released the conveyor will return to the forward direction.
Otherwise the conveyor will stop when the button is released.
• STOP PUSHBUTTON - Pressing this button will halt the forward or reverse motion of the chip conveyor. If this
button is held the FORWARD and REVERSE buttons are inhibited from starting.
AUTO MODE
With the MANUAL / AUTO switch in the Auto Mode, the following is possible using the buttons and M-codes.
• FORWARD LIGHTED PUSHBUTTON - No effect on the conveyor operation.
• REVERSE PUSHBUTTON - No effect on the conveyor operation.
• STOP PUSHBUTTON - Pressing this button when the conveyor is moving in the forward direction, will halt the
conveyor and cause the forward lighted pushbutton to blink on and off. Pressing the blinking FORWARD button
will then restart the forward motion of the conveyor. This is useful to briefly stop the conveyor to unload or
replace chip bins.
81.10 - 2 CHIP CONVEYOR

• M236 (FORWARD ACTIVE) - Programming the M236, with the machine in auto, will cause the conveyor to start
in the forward direction.
Note: The M236 M-code is only cancelled with M238. Pressing RESET or M02 or M30 will not cancel
the chip conveyor forward (M236).
• M238 (STOP ACTIVE) - Programming the M238, with the machine in auto, will cause the conveyor to stop and
extinguish the forward light.
CHIP CONVEYOR 81.10 - 3

SECTION 86.10
INSTALLATION
TABLE OF CONTENTS
TITLE PAGE
SHIPMENT AND UNLOADING......................................................................................................................................1
FOUNDATION ...............................................................................................................................................................3
INSTALLATION .............................................................................................................................................................7
MACHINE BED ..............................................................................................................................................................8
LEVELING .....................................................................................................................................................................9
INSTALLING THE COLUMN .......................................................................................................................................10
PREPARING THE HEADSTOCK FOR COLUMN INSTALLATION .............................................................................15
LIFTING THE TWO-SPEED HEADSTOCK ......................................................................................................16
LIFTING THE FOUR SPEED HEADSTOCK.....................................................................................................16

INSTALLING THE HEADSTOCK TO THE COLUMN ..................................................................................................19
INSTALLING THE TABLE AND SADDLE AS AN ASSEMBLY....................................................................................21
INSTALLING THE PLAIN TABLE AS A SEPARATE UNIT (IF REQUIRED) ...............................................................25
INSTALLING THE TOOL CHANGER ..........................................................................................................................31
INSTALLING THE CONTROL .....................................................................................................................................31
HYDRAULICS AND PNEUMATICS .............................................................................................................................32
INSTALL OPTIONS .....................................................................................................................................................34

SHIPMENT AND UNLOADING
Your MAG machine tool has been completely assembled and inspected at the factory. The size prevents shipment of
the machine fully assembled, and for this reason, it has been carefully dismantled. For domestic shipment, the major
machine units are placed on skids. Small parts are packed separately. All machined surfaces are coated with a
slushing compound and the entire machine is protected with waterproof paper and a plastic cover.
When removing the machine units from the trucks, or when lifting during assembly, heavy pads or wood blocks should
be placed at all points where lifting cables or chains could contact finished surfaces. Extra care is required to protect
scraped surfaces and machine components. Make sure no cables or chains exert strain on any projecting parts. The
"bill of lading" sent with the machine would provide detailed information on the weights of your specific machine. The
following are the weights of the major components (for reference only). Always refer to the "bill of lading" for specific
weights. Also major component weights can be found on the line and foundation prints.
Auxiliary Runways (each) 1,350 lbs. 612 kg
Bed 18,000 lbs. 8160 kg
Chip Conveyor 1,000 lbs. 453 kg
Column 21,000 lbs. 9520 kg
Control Cabinet 2,200 lbs. 997 kg
Headstock - 2 speed 7,600 lbs. 3445 kg
Headstock - 4 speed 8,550 lbs. 3855 kg
Hydraulic Unit 1,200 lbs. 544 kg
Miscellaneous Sheet Metal & Parts 6,000 lbs. 2720 kg
Saddle & Table 32,000 lbs. 14506 kg
Tool Changer (60-tool capacity) 7,050 lbs. 3196 kg
Way Covers 2,500 lbs. 1133 kg
Carefully check all parts of the machine against the packing list, as they are unpacked. All small parts should be
placed in parts racks or cabinets to guard against their loss or being misplaced. A careful check of all packing
material and bags should be made before disposal of this material.
Note: Carriers may refuse any damage claims if unpacking is continued to completion. When damage is
evident, it is necessary to discontinue further unpacking until authorized by the carrier. Immediately
report any damages or shortages to the carrier and to the MAG dealer representative from whom the
machine was purchased.
****************************************************************************************
BEFORE INSTALLATION, VERIFY ELECTRICAL POWER CONFIGURATION MATCHES MACHINE

SPECIFICATIONS. I.E. SOME SHOPS MAY USE ELECTRICAL CONFIGURATION THAT USES 230
DELTA INSTEAD OF THE 230 Y, WHICH IS WHAT IS USED WHEN THE MACHINE IS BUILT.
FAILURE TO CHECK THIS MAY RESULT IN SEVERE DAMAGE TO THE SYSTEM.
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INSTALLATION 86.10-1
Frame Works for Suspending Foundation Hardware until Concrete is Poured
Steel Reinforcing Rods

Hold-down Canisters Held in Place with
Metal & Wood Frame Works
Top Photo Shows Foundation before Concrete is Poured
Note: This Photo Shows a

Foundation for a Machine with Machine Column Mounts in
Multiple Auxiliary Runways on this Location of Bed
Each Side of Machine
Machine Bed Location Auxiliary Saddle

Photos for Reference Only: Support Runway
Always Refer to Certified Location
Machine Layout (Line &
Foundation) Drawings When
Building a Foundation Bottom Photo Shows Foundation Complete
Ready to Receive the Machine
FIGURE 86.10- 1
Machine Foundation
86.10-2 INSTALLATION
FOUNDATION
The foundation for your machine tool should be prepared in accordance with MAG approved specifications. Certified
Machine Layout (Line and Foundation) drawings are supplied in advance. These prints contain all the information
required to construct a proper foundation. Additional copies are available upon request.
The foundation should be concrete (34.5 MPa (5000 psi) compressive strength), with steel reinforcing bars per the
foundation plan. The minimum recommended concrete depth (depth taken from floor level) should be maintained
throughout the foundation. Soil borings should be made to determine the actual soil bearing capacity in the area to
be used. The soil bearing capacity must be capable of supporting the load specified on the Machine Layout (line and
foundation) drawing and meeting the desired settlement and accuracy requirements.
A smooth flat surface on the concrete is essential to allow the leveling plates (FIGURE 86.10- 2) to lie flat. A lot of
time at final leveling and alignment of the machine can be saved, if proper attention is paid to the foundation detail.
Foundation concrete should be flat and level within 6 mm.
The machine described in this manual is provided with a one-piece bed and column base of heavy box type, internally
ribbed construction. Regardless of the rigidity obtained from this type of construction, the foundation should be solid
and free from vibration. DO NOT place any anti-friction devices of either spring or rubber pad construction under the
machine.
All Dimensions in MM
FIGURE 86.10- 2
Bed and Runway Saddle Supports Foundation Hardware
The hold-down cans, for mounting bed and auxiliary saddle support runways can be located and hung from suitable
framing prior to the pouring of the concrete foundation (FIGURE 86.10- 1). If this method is used, the framing must
insure that the hold-down cans are accurately located per the coordinates specified on the Machine Layout (Line and
Foundation) drawing. The hold-down cans must remain perpendicular to the surface being poured and at the proper
depth. Ensure that the hold-down cans are fixed securely within the framing so as not to move during the pouring
process. Immediately before pouring concrete, setup leveling instrument and check all levels. If framing has sagged,
correct before starting pour.
Note: All hold-down bolts must be free floating; do not weld or grout in place.
Insert foam tubing, wood or plastic plug in top of hold-down cans before pouring concrete. This should stop concrete
from going into can, which would otherwise restrict bolt movement. The plugs will need to be removed before final
mounting of the machine components. See the Machine Layout (line and foundation) drawings for the specific
foundation hardware required for your machine. Example of hold-down cans used for bed and auxiliary saddle
support runways (FIGURE 86.10- 2), and foundation hardware used for tool changer (FIGURE 86.10- 3), pallet
changer stand (FIGURE 86.10- 4 & FIGURE 86.10- 5), and pallet changer slide support (FIGURE 86.10- 6) are
shown. Always refer to Certified Machine Layout (line & foundation) drawing for the specific hardware required for
your machine.
Note: The hold-down bolt cans must be flush to 1.5 mm below the concrete surface. This is essential to
allow the leveling plates to lie flat. If after foundation pour the cans are above the concrete surface,
grind the cans flush with concrete surface.
FIGURE 86.10- 3
Tool Changer Foundation Hardware
FIGURE 86.10- 4
Pallet Changer Stand Foundation Hardware
FIGURE 86.10- 5
Pallet Stand Kicker Assembly Foundation Hardware
Pallet Changer
Slide Support
FIGURE 86.10- 6
Pallet Changer Slide Support Foundation Hardware
INSTALLATION
Prior to installation of the machine components, they must first be prepared by removing the slushing compound from
each unit during assembly and thoroughly cleaning any machined surfaces. Use a nonflammable solvent to remove
the slushing compound. The solvent should be of a type that has no adverse effect on rubber or finished surfaces.
After cleaning, finished surfaces will still need to be protected. The use of light oil or spray rust preventive is
recommended.
Note: Do not use scrapers, knives, abrasive wheels, or any such devices to remove slushing compound
and/or shipping/packing material. These types of tools could scratch or gouge machined surfaces
and cause damage.
Ensure that the crane, chains, eyebolts and other lifting devices are rated to handle the load you are lifting.
Note: Care should be taken during the assembly of the machine to avoid any possible problems. If
something is unclear, check the prints or contact the MAG Service Department.
FIGURE 86.10- 7
Lifting the Machine Bed
MACHINE BED
To install the machine bed, proceed as follows: Hook up the bed as shown in FIGURE 86.10- 7 and raise the
assembly above the floor level. The bottom of the assembly should now be cleaned of all slushing compound and
foreign material. Be sure that foreign material is removed from the leveling screws and their threaded holes in the
bed. The leveling screws should be coated with an anti-seize lubricant before the bed is lowered onto the foundation.
The hold down bolts should be treated in the same manner. All leveling screws should be extended .250" below
bottom of the bed. This will allow the machine to set on the leveling pads with equal contact on all points. Make sure
the foundation and leveling plates are free from dirt and foreign material.
Note: Place all leveling plates over the hold down bolts. Measure all hold down bolts for their proper
length above the floor level, as shown on the Machine Layout (line and foundation) drawing. This
will assure that no bolts will be to short because of some cans being lower in the foundation than
others. Measure the centerline distance between all hold down bolts to ensure that none will
interfere with bolt position in the bed or auxiliary runway.
After all the above requirements have been met the bed should be ready for installation over the foundation hold
down bolts. Lower it over the hold down bolts. Bolts should be guided into the base using wooden sticks. NEVER
USE YOUR HANDS TO GUIDE THE BOLTS INTO THE BED! After the bed is resting on the leveling plates, it
should be completely leveled by using the proper leveling procedure explained in this section. After leveling is
complete, all the hold-down bolts should be tightened. Refer to the Machine Layout (line & foundation) drawing for
torque specifications.
LEVELING
The equipment used for leveling should consist of the following:
Two electronic levels or two precision spirit levels (make sure they have been properly calibrated).
One scraped or granite parallel that is long enough to span the runner blocks (trucks) on the bed linear ways. This
will permit setting the leveling equipment up so that levels can be placed at right angels to one another (FIGURE
86.10- 8).
Possibly two ground parallel blocks; these will be required to get the parallel bar above other components that may be
lower when setting up leveling equipment on various parts of the machine.
A list of suggested installation and alignment equipment can be found in the Alignment section of this manual.
Note: Final or finish leveling will be the first check when doing the alignments and will be done with the
machine under power and the hydraulics warmed up to operating temperature.
The parallel bar, ground blocks and the bed ways must be free from dirt, nicks, and burrs. Place the parallel across
the way surfaces above the leveling screws, at right angles to the bed length. If the parallel extends beyond the width
of the ways, it should be positioned so the extended amount is the same on both sides. After the parallel is in place
on the ways, place a level in the center of it. The second level should be placed on the bed ways between the
leveling screws in line with the bed length.
See FIGURE 86.10- 8 for general placement of levels, but verify their placement by checking the machines alignment
sheets.
Place Level on Parallel

and Fasten in Place
Set Runway Height

to 178.3 mm
(7.02”) below top
of Truck for rough
leveling. With
Truck Spacers
under Parallel, Set
Place Level on Runner Height at 184.2
Block (Truck) and Fasten mm (7.25”)
in Place
(Truck Shown out of
Position, should be next
to Parallel)
FIGURE 86.10- 8
Placement of Precision Levels on Bed
The surfaces near the ways should be marked with a pencil so that the parallel and the levels can be set at the same
relative position on the bed ways. Level adjustments should be made with the leveling screws on either side of the
machine bed assembly.
Bed should be raised or lowered gradually by using leveling screws nearest the level and the next several sets of
leveling screws. Never try to accomplish all the necessary adjustments on one leveling screw, as this will tend to
leave that particular section extremely high or low compared with the rest of the bed.
The parallel should then be moved to a position over the next pair of leveling screws and the level placed on it in the
same location. The other level should be moved farther down the bed way between the next pair of leveling screws
and appropriate adjustments made in each direction. This procedure should be repeated along the entire length of
bed. It will be necessary to repeat the leveling procedure two or three times or more, to correct errors that were
created in the continuous leveling procedure. When the bed is perfectly level, the locking nuts on all leveling screws
should be tightened. Locking nuts (M24) should be torqued to a maximum of 47 N-m (35 lb-ft). Do not over tighten
the locking nuts as this could affect the level condition of the bed.
Note: The auxiliary runways should be handled in the same manner as the machine bed. A dimension of
87.0 ± 0.3 mm (3.425”) must be maintained between top cast iron surface of auxiliary runways and
way seat of bed way per the print. A dimension of 178.3 mm (7.02”) should be maintained between
the top surface of the auxiliary runways and the top surface of the trucks or (7.250” with truck
spacers M.1301.8881) under parallel. This is done to allow for proper travel of saddle support
adjustment during machine leveling. Levels must be placed on the machined cast iron surface on
the auxiliary runways.
Be sure that the bed is perfectly level and that the hold-down bolts are all tightened before installing the rest of the
machine units. This will simplify final machine alignments.
Saddle Saddle Support Height

Adjustment Screw
Auxiliary Saddle
Support Runways
Column Mounting
Saddle Support
Surface of Bed
FIGURE 86.10- 9
Saddle Support (Not to be used for Major Leveling of Saddle or Table)
Note: Never use the adjustment screws (FIGURE 86.10- 9) in the saddle supports as the major leveling
adjustment of the table and saddle. Adjustment of the saddle is to be done with the leveling screws
on the bed and the auxiliary runways.
INSTALLING THE COLUMN
Some of the items you will need to install the column will be as follows:
• Crane and lifting chains rated to handle the weight of column.
• Lifting bar (rated to handle column weight), a couple of feet longer than the width of the column.
• Hardwood blocking.
• Bumping bar or timber for shifting large components.
• Stone or mill file for removing nicks and burrs.
• One torque wrench (rated so cap screws can be torqued to 245 N-m (180 lb-ft)
• Clean and check the column ways. They should be free of paint, slushing compound, nicks and burrs. After
cleaning, lightly oil the ways with Mobil DTE 26 (ISO VG 68).
Move the column to an area near the machine base if possible. Rig up the column as shown in FIGURE 86.10- 10,
FIGURE 86.10- 11, & FIGURE 86.10- 12. Completely clean the column, which includes the inside. To clean the
inside it is advisable to set it on hardwood blocks on the floor.
Use Chains around

Steel Bars to Lift
Make Sure to Support

Hoses/Cables while Lifting
FIGURE 86.10- 10
Setup for Lifting Column (Side View)
Two Wood Blocks on Three Wood Blocks on

Rear of Column Front of Column
Note: Wood Blocks are used to

Spread Chains So That during
Y-Axis Gearbox and Motor Lift, Chains are Clear of Linear
(Top of Column) Ways and Other Components
FIGURE 86.10- 11
Setup for Lifting Column
Hook up and carefully roll the column to a vertical position as shown in FIGURE 86.10- 13. Be sure you are rolling
the unit on hardwood or a non-marring surface. Again, the lift must be as straight and level as possible.
Then work through the top with an air hose and blow out any debris that may have collected on the inside. Once
clean then lift the column and inspect the bottom for nicks and burrs. If any nicks or burrs appear, they must be
removed with a stone or file. Completely clean the column base and remove any nicks and burrs that are found.
Locate and clean the column shims then place shims in position on top of column base. The shims are marked and
must be placed with their matching mark on the column base.
Ensure that the items used to lift the various machine components are of sufficient strength to maintain the load.
When satisfied that the column is straight and level, position it over the bed (FIGURE 86.10- 15). Line up the column
using extended studs screwed into the base at a couple locations. When the column is approximately 25 mm (1”)
above the column base, inspect the mating surfaces for dirt or lose material that may have fallen from the inside of
the column. This material must be removed before mating the two parts; if it is not removed, it will affect column
alignment.
With the column just touching the base, check the shims with a .001" feeler gauge (FIGURE 86.10- 14). Before the
column weight is completely on the shims, install the column cap screws. When satisfied that the shims are flush,
slowly release the weight from the crane and recheck with a .001" feeler gauge. With most of the weight on the
column base, hand tighten the column cap screws until they just touch the column. At this point, it may be necessary
to use a heavy timber or bumping bar to make sure the column is tight against the alignment blocks and spacers
(FIGURE 86.10- 16). With all of the weight resting on the column base but with the rigging still in place, tighten all of
the alignment key bolts and then tighten all of the column cap screws. Check the mating surfaces of the column,
spacers and base with a .001" feeler gauge, the joint must be feeler tight (feeler must not slide between the two).
FIGURE 86.10- 12
Lifting Column
Roll Column up
on to Steel Horse
with Hardwood
Top
Hardwood Blocks
on Floor
FIGURE 86.10- 13
Lifting Column to the Upright Position
Column
Shims must be
installed before
Lowering
Column onto Bed
Bed
Shims are Matched Marked.

Position Shims in Proper
Location
FIGURE 86.10- 14
Column Spacers (Shims)
Clean Bottom of Column and
Remove Any Burrs before
Setting Column on Bed
Place Column Spacers

at Each Corner of Bed
before Setting down
Column
Bed
FIGURE 86.10- 15
Column in Upright Position
Alignment Spacer
Column Spacers (Shims) Column Jack Screws, Used
to Lift Column for Spacer
Removal.
Alignment Spacer
Column Alignment Blocks. Do Not

Use to Push Excessively
FIGURE 86.10- 16
Column in Place on Machine Bed (Rear View Showing Alignment Blocks and Jack Screws)
FIGURE 86.10- 17
Column in Place on Machine Bed
PREPARING THE HEADSTOCK FOR COLUMN INSTALLATION
The 2-speed headstock weight is roughly 7600 pounds or 3445 kg.

The 4-speed headstock weight is roughly 8500 pounds or 3855 kg.
Remove the headstock from its shipping skid and clean thoroughly. Remove all slushing compound and packing
material.
If nicks and burrs are found on the bearing surfaces, use a small mill file or stone to clean them up. The headstock to
column bearing surfaces are located on the left side of headstock, where the runner blocks (trucks) of the Y-axis
linear ways attach; and the top of headstock, where the Y-axis ballscrew nut attaches. Remove nicks/burrs prior to
assembly of the headstock to the column. Clean out all cap screw clearance holes (for runner blocks and ballscrew
nut) and tapped holes used for wedge clamps and encoder bracket. The front linear way spacers (FIGURE 86.10-
18) should be checked for nicks and burrs. Each spacer is fastened to the headstock with M6 x 25 cap screw.
Ballscrew Nut
Mounting Surface Wedge
Clamp
Mounting
Surface
Spacer
Y-Axis
Runner
Block
Mounting
Y-Axis Surfaces
Runner
Block
Mounting
Surfaces Encoder Bracket
Mounting Surface
Wedge
Clamp
Spacer Mounting
Surface
FIGURE 86.10- 18
Left Side of Headstock (4-Speed Shown)
Check and clean the runner blocks (trucks) on the column. The mounting surface should be free of paint, slushing
compound, nicks and burrs. Stone surfaces and clean with solvent. The ballscrew nut and trucks should be
positioned on the column per FIGURE 86.10- 19. Temporarily hold runner blocks in position using a M8 cap screw in
one of the tapped holes found in the clamp rail FIGURE 86.10- 19.
LIFTING THE TWO-SPEED HEADSTOCK
Install three M16 x 2 eyebolts, (swivel type if possible) on headstock as shown in FIGURE 86.10- 20. Install a level
on the headstock, parallel to the spindle travel.
Using the M12 cap screw in the ballscrew shaft FIGURE 86.10- 22, move the spindle in and/or out to level the
headstock. Level crosswise also, if needed add a come along to roll headstock.
LIFTING THE FOUR SPEED HEADSTOCK
Install three M20 x 2.5 eyebolts, on headstock as shown in FIGURE 86.10- 21. Install a level on the headstock
parallel to the spindle travel.
Remove pulley cover. Using the M12 cap screw in the ballscrew shaft (FIGURE 86.10- 22), move the spindle in
and/or out to level the headstock. Level crosswise also, if needed add a come along to roll headstock.
2159 mm (85”)
M8 Cap Screw to
Temporarily Hold
Runner Block
Clamp Rail
1930 mm (76”)
1054 mm (41.5”)
FIGURE 86.10- 19
Column Prepared to Hang Headstock
Two-Speed Headstock Top of Headstock

(Shown Unassembled)
Use (3) M16X2 Eyebolts
FIGURE 86.10- 20
Lifting Two-Speed Headstock
Four-Speed Headstock
Use (3) M20X2.5

Eyebolts
FIGURE 86.10- 21
Lifting Four-Speed Headstock
Two-Speed Headstock Four-Speed Headstock
Use M10 Allen Wrench in Cap

Screw (of Ballscrew shaft) to
Extend/Retract Spindle.
Pulley Cover
Removed
FIGURE 86.10- 22
Manually Extend/Retract Spindle to Balance Headstock during Lifting
INSTALLING THE HEADSTOCK TO THE COLUMN
The headstock and column should have been prepared as described earlier. For the initial installation, the machine
should arrive with the ballscrew nut at the correct height (FIGURE 86.10- 19).
Level the headstock as well as possible before lifting into position.
Lift the headstock until the ballscrew nut mounting surface is about 150 mm (6”) the bottom of the ballscrew nut.
Slowly move headstock toward the column. Starting with lower runner blocks (trucks), move runner blocks into
position behind headstock. Start two M16X100 cap screws in each runner block.
The spacers (FIGURE 86.10- 18) on front upper and lower headstock bearing surface should have been installed.
Make sure that spacers are against locating side of runner blocks (FIGURE 86.10- 23).
Add remaining M16X100 cap screws to pull headstock against runner blocks. Install the wedge clamps to pull
headstock spacers tight against locating side of runner blocks. Use 0.025 mm (.001") feeler gauge to check top and
bottom of spacer for contact with runner block.
Using a star pattern, torque all M16 cap screws per specification called out on “Headstock Assembly” drawing.
Make sure the M8 cap screws that temporarily held the runner blocks in position have been removed. Using the
crane, slowly bring the headstock within approximately 25 mm (1”) of the bottom of the ballscrew nut (FIGURE 86.10-
24).
****************************************************************************************
DO NOT ALLOW THE HEADSTOCK TO MOVE UP AND BUMP THE BALLSCREW NUT. DAMAGE
TO BALLSCREW & BALLNUT INTERNAL PARTS MAY OCCUR.
****************************************************************************************
Clamp Rail
Wedge Clamp
Spacer
Locating Sides M8X25 Cap

Screws
Rear View of Runner Block Front View of Runner Block
FIGURE 86.10- 23
View of Lower Front Runner Block
Add a bottle jack with wood block rated to support the weight of the headstock to the underside of the headstock. Use
the bottle jack to move the headstock close enough to the bottom of the ballscrew nut, so that the (8) M12 X 35 cap
screws can be started by hand. Use the jack and cap screws to pull the headstock to seat against the ballscrew nut.
Use a removable thread lock compound (Loctite 242), to secure the M12 X 35 cap screws.
The headstock should now be securely attached to the column. Leave the jack under the headstock and remove the
lifting chains. The lube lines should be reattached to the four runner blocks and the ballscrew nut. The reader head
mounting bracket (FIGURE 86.10- 25), along with fitting spacer should be assembled to reader head with (2) M5 X 30
cap screws. Slide bracket up and assemble to headstock with (2) M8 X 40 cap screws.
FIGURE 86.10- 24
Using Crane to Move Headstock Close to Ballscrew Nut
(Four-Speed Headstock Shown)
Headstock
Reader Head Reader Head

Y-Axis Linear Mounting Bracket
Fitting Spacer
Encoder
View from Bottom of Headstock towards Top of Column
FIGURE 86.10- 25
Y-Axis Linear Encoder Reader Head Mounting Bracket Assembled to the Headstock
INSTALLING THE TABLE AND SADDLE AS AN ASSEMBLY
Level the bed & auxiliary runways before installing table & saddle.
Clean bed ways, roller packs, shims, the ballnut mounting surfaces and check for nicks or burrs if found they must be
removed. After checking bed ways, oil them with Mobil DTE 26 (ISO VG 68) just before installing the saddle. The
saddle support runways must be cleaned, checked and oiled in the same manner as the bed ways.
On most machines, the table and saddle will be shipped as one unit. However, on some machines due to their size
and/or customer lifting capacity, the table and saddle will be shipped as separate units. Assuming the saddle and
table are assembled together, lift the unit together as shown in FIGURE 86.10- 26. The unit must be level.
FIGURE 86.10- 26
Lifting Table and Saddle as an Assembly
Chain Length Varied to

Level Table/Saddle
Assembly during Lifting
Shipping Bracket
(M.2000.2794)
M36X4 Swivel Eyebolts M36X4 Swivel Eyebolts
FIGURE 86.10- 27
Lifting Table and Saddle (Side Views)
The table and saddle must be cleaned of all slushing compound and shipping material. Use a non-flammable solvent
to remove the slushing compound from each unit as needed during assembly.
and cause damage.
Shipping Bracket
(M.2000.2794)
This bracket must be

Rotary Table Drive secure until the table and
Motor saddle are set on the
runner blocks (trucks) of
bed linear ways
FIGURE 86.10- 28
Table to Saddle Shipping Bracket
If solvent is used, it should be of a type that has no adverse effect on rubber or painted surfaces. After cleaning,
finished surfaces will still need to be protected. The use of light oil or spray rust preventive is recommended.
If saddle wedges and shims were shipped removed from the saddle, they must be located, thoroughly cleaned, and
checked for nicks or burrs. In addition, the runner block mounting areas need to be cleaned and deburred.
The saddle support roller assemblies (FIGURE 86.10- 29) are normally shipped assembled to the saddle. They must
be cleaned and their chain & roller assembly oiled with Mobil DTE 26 (ISO VG 68).
Chain & Roller

Assembly Saddle
Support Roller Support Roller

Assembly Shown Assembly
Inverted (For View of
Chain & Roller
Assembly
Runway Saddle
Support
FIGURE 86.10- 29
Saddle Support Roller Assembly
Install the two spacers (side shims) on the “guide” linear way of the saddle, one for each runner block (truck) on the
linear rail (FIGURE 86.10- 30). Install the four truck spacers, one for each runner block. Each spacer is marked with
a number. This number must match with the same number marked on the saddle. Make sure you double-check the
number marked on the spacer (side shim), the truck spacer and the saddle location.
Saddle Set on Runner Blocks of Bed
Wedge Clamp Non-Guide

Truck Spacer Linear Way
Spacer “Guide”
(Side Shim) Linear Way
See FIGURE 86.10- 31 for
Details of this Area
Column Mounting Surface
FIGURE 86.10- 30
Guide vs. Non-Guide Linear Way
After the spacers are installed, move the table/saddle assembly over the bed ways. Line up the saddle pockets
(runner block mounting areas) with the bed ways. When you are satisfied the table/saddle assembly is lined up,
gently lower the unit over the ways. Be careful that the ballnut mounting pocket clears the ballscrew while lowering
the saddle. With the table/saddle assembly slightly above the runner blocks with truck spacers, move runner blocks
into position under the saddle and start the M16 cap screws. All six cap screws in each runner block should be
started. Lower table/saddle assembly just until the unit touches the runner blocks with truck spacers. Then push the
table/saddle assembly so that the two spacers (side shims) are up against the guide edge of the runner blocks.
Lower the table/saddle assembly onto runner blocks.
View of Saddle & Bed - Looking from Column Bottom View of Saddle on “Guide” Linear
Way
Saddle
Spacer for
Saddle
Alignment
Guide Edge of
“Truck” Runner Block
Spacer (Truck)
Wedge Clamp
Guide Edge of
Linear Rail
Runner Block Bed Spacer and Wedge Clamp used with both
(Truck) Runner Blocks of the “Guide” Way
FIGURE 86.10- 31
Detailed View of Bed to Saddle “Guide” Linear Way
When the table/saddle assembly is down on the runner blocks (trucks) and truck spacers, verify that the alignment
shims both top and side are snug.
Note: At this point use 0.025 mm (.001") feeler gauge to verify saddle is feeler tight to bed runner blocks on
all four corners and the two side spacers. Ensure that saddle supports are not holding saddle up off
the bed runner blocks.
Hand tighten all the M16 cap screws into runner blocks. Install the wedge clamps (FIGURE 86.10- 31) that pull the
saddle and spacers securely against the runner blocks of the “guide” linear way. Be sure, when you install the clamp
wedge that it does not bottom out on the saddle. (If it does, it will not hold the runner block securely against the
spacer. Remove the wedge and remove enough material so that it will not bottom out on the saddle). The wedge
clamp M8 X25 low head cap screws should be torqued to 11 N-m (8 lb-ft).
Check the spacers with 0.025 mm (0.001”) feeler gauge to ensure that they are tight to runner blocks. Then, check
the truck spacers to ensure that the saddle is still tight (making sure wedge clamp did not push up saddle). Torque
the runner block M16 cap screws to 195 N-m (145 lb-ft)
****************************************************************************************
DO NOT ALLOW THE MOUNTING SURFACE TO MOVE UP AGAINST AND "BUMP" THE
BALLSCREW NUT. DAMAGE TO BALLSCREW & BALLNUT INTERNAL PARTS MAY OCCUR.
****************************************************************************************
Align the ballscrew nut to the cavity in the saddle. To aid in alignment of the holes in the ballscrew nut and tapped
holes in saddle mounting surface, two (6" long) studs can be placed through the ballscrew nut and screwed into the
mounting surface to be used as guides. Move the unit until the mounting surface almost meets the ballnut and install
bolts by hand. When the unit is seated against the ballscrew nut, remove the two (2) studs and fasten the ballnut to
the mounting surface with the proper socket head cap screws. Then torque the bolts to 136 Nm (100 ft lbs.).
Note: Later be sure to check ballscrew alignment to linear way surfaces and adjust ballscrew nut position
if needed, by positioning near a bearing block and loosen then re-torque the bolts.
With the saddle in position on the bed and roller blocks, the crane can be released.
Remove the saddle shipping bracket and insert plugs in the holes. Store the bracket for possible use later.
Connect the ballnut lubrication and all other lubrication lines, saddle supports, etc.
Connect the reader head for the encoder to the mounting bracket.
Note 1: Bleeding the hydraulic hoses to the ballscrew damping blocks, all axes. Be prepared to catch some
oil. Also, have rags available. Bleed the hydraulic hoses to the damping blocks by opening the
bleeder screw on the screw side of the damping block with the hydraulics running until all the air is
out of the system. If an axis is jittery, air in the damper may be part of the problem. It may have air
in the system or a block orifice at the input. If bleeding does not improve the system, then check for
a blocked orifice (FIGURE 86.10- 32). The two orifices can be removed and cleaned, using a 0.2 mm
(.007”) diameter wire. (See “Setup of Axis Damping Assembly” section of this manual, for additional
information).
Note 2: If hydraulic line to ballscrew damping blocks has been disconnected and drained. This would allow
a large amount of air to enter the system. It may be necessary to bleed the line feeding the damping
block. With plug on end of hose, start the hydraulics running; be prepared to catch some oil. With
rags available, crack open the plug until all the air is out of the system. Shut down the hydraulics,
then, reinstall the hose onto the damping block. Restart hydraulics and bleed the damping block
using the bleeder screw.
Outer Spacer Outer Spacer

Hydraulic Bleed
Port
Axis
Ballscrew
Special
Connector with
Orifice
Ø 0.2 mm
Main System
Hydraulic
Damper Pressure Input
Spacer
Orifice
Bed, Saddle or Column
Ø 0.2 mm
Mounting Surface
FIGURE 86.10- 32
W, X, & Y -Axis Ballscrew Damping Assembly Cross-Section
INSTALLING THE PLAIN TABLE AS A SEPARATE UNIT (IF REQUIRED)
Level the bed, auxiliary runways and saddle before installing table. Install saddle as described in “Installing the
table/saddle as an assembly”.
Clean linear ways, runner blocks, spacers, ballscrew nut mounting surfaces and check for nicks or burrs, if found they
must be removed. After checking ways, oil them with Mobil DTE 26 (ISO VG 68) just before installing the table.
The table must be lifted as level as possible. Be sure your lifting equipment can safely handle the lift.
The table must be cleaned of all slushing compound and shipping material. Use a non-flammable solvent to remove
the slushing compound from each unit as needed during assembly.
and cause damage.
Holes for lifting on either end
Side of
Table Facing
Headstock
Shown
Spacer and
Spacer and
Wedge Clamp
Wedge Clamp
Runner Blocks (Trucks) on “Guide” Linear Way. Same Number on Non-Guide Way.
Only the End Runner Blocks of “Guide” Linear Way are used for aligning the Table.
Spacer and Wedge Clamp are used to turn the Table Axis.
FIGURE 86.10- 33
Plain Table (PT 1800 X 3600 MM Table Shown)
If table wedge clamps and spacers were shipped removed from the table, they must be located, thoroughly cleaned,
and checked for nicks or burrs. In addition, the runner block mounting areas need to be cleaned and deburred.
Install the spacers (side shims) on the “guide” linear way side of the table, one spacer at each end of the table
(FIGURE 86.10- 33). Place the “truck spacers” on top of each runner block. Each spacer is marked with a number.
This number must match with the same number marked on the table. Make sure you double-check the number
marked on the side spacers, the top spacers and the table location.
After the spacers are installed, move the table over the saddle linear ways. Line up the table pockets (runner block
mounting areas) with the ways. When you are satisfied the table is lined up, gently lower the unit over the ways. Be
careful that the ballnut mounting pocket clears the ballscrew while lowering the table. With the table above the runner
blocks with truck spacers, move runner blocks into position under the table and start the M16 cap screws. All six cap
screws in each runner block should be started. Lower table just until the unit touches the truck spacers on runner
blocks. Then push the table so that the two spacers (side shims) are up against the guide edge of the runner blocks.
Lower the table onto runner blocks.
When the table is down on the runner blocks (trucks) and truck spacers, verify that the alignment spacers are snug.
These alignment spacers will only be on the two corners of the table facing the column.
Note: At this point, use 0.025 mm (.001") feeler gage to verify table is feeler tight to roller pack top and side
shims on all roller pack positions.
Hand tighten all the M16 cap screws into runner blocks. Install the wedge clamps that pull the table and spacers
securely against the runner blocks of the “guide” linear way. Be sure, when you install the clamp wedge that it does
not bottom out on the saddle. (If it does, it will not hold the runner block securely against the spacer. Remove the
wedge and remove enough material so that it will not bottom out on the saddle). The wedge clamp M8 X25 low head
cap screws should be torqued to 11 N-m (8 lb-ft).
Check the spacers with 0.025 mm (0.001”) feeler gauge to ensure that they are tight to runner blocks. Then, check
the truck spacers to ensure that the saddle is still tight (making sure wedge clamp did not push table). Torque the
runner block M16 cap screws to 195 N-m (145 lb-ft)
****************************************************************************************
DO NOT ALLOW THE TABLE MOUNTING SURFACE TO MOVE UP AGAINST AND "BUMP" THE
BALLSCREW NUT. DAMAGE TO BALLSCREW & BALLNUT INTERNAL PARTS MAY OCCUR.
****************************************************************************************
Align the ballscrew nut to the cavity in the table. To aid in alignment of the holes in the ballnut and tapped holes in
the mounting surface, two (6" long) studs can be placed through the ballnut and screwed into the mounting surface to
be used as guides. Move the unit until the mounting surface almost meets the ballnut and install bolts by hand.
When the unit is seated against the ballnut, remove the two (2) studs and fasten the ballnut to the mounting surface
with the proper socket head cap screws. Then torque the M12 cap screws to 136 N-m (100 lb-ft.).
Note: Later be sure to check ball screw alignment to way surfaces and adjust ballnut position if needed by
positioning near a bearing block and loosen then re-torque the bolts.
Connect the ballnut lubrication and all other lubrication lines.
Installing the Rotary Table as a Separate Unit (if required)
Level bed, auxiliary runways, and saddle before installing Rotary Table (RT).
Clean linear ways, runner blocks, spacers, ballnut mounting surfaces and check for nicks or burrs, if found they must
be removed. After checking ways, oil them with Mobil DTE 26 (ISO VG 68) just before installing the rotary table.
The table must be lifted as level as possible (FIGURE 86.10- 34). Be sure your lifting equipment can safely handle
the lift.
Make the Lift as Level as

Possible. Use a Machine
Level at Center of Table to
Aid in Chain Adjustment
Use Wood Block or Other

Protection So that Chains
do not Mare the Table
Surface
FIGURE 86.10- 34
Lifting Rotary Table
The rotary table must be cleaned of all slushing compound and shipping material. Use a non-flammable solvent to
remove the slushing compound from each unit as needed during assembly.
and cause damage.
If rotary table runner block top spacers and adjuster blocks (FIGURE 86.10- 35) were shipped removed from the
table; they must be located, thoroughly cleaned, and checked for nicks or burrs. In addition, the rotary table runner
block mounting areas need to be cleaned and deburred.
Install the runner block top spacers (pair with lip and pair without lip) and the two adjuster blocks on the rotary table.
The adjuster blocks and spacers with lip are installed on runner blocks closest to column (FIGURE 86.10- 35). Each
runner block spacer and adjuster block is marked with a number. This number must match with the same number
marked on the rotary table runner block mounting areas. Make sure you double-check the number marked on the
runner block top spacers, adjuster blocks and the rotary table location.
After the runner block top spacers have been positioned on the runner blocks and the adjuster blocks have been
assembled to the rotary table, move the unit over the linear ways. Line up the rotary table pockets (runner block
mounting areas) with the ways. When you are satisfied the unit is lined up, gently lower the unit over the ways. Be
careful that the ballscrew nut mounting pocket clears the ballscrew while lowering the table. Just before the unit
touches the top spacers on the runner blocks, start all the M16 cap screws into the runner blocks.
After all cap screws are started, lower rotary table onto runner block spacers. Hand tighten all the M16 cap screws
into runner blocks. Start two M12 X 35 cap screws in each adjuster block and thread into spacer. With a 5 mm shim
between the adjuster block and the side of the runner block, use the M12 X 35 cap screws to pull the rotary table in
position against the runner block and 5 mm shim. (The 5 mm is a starting point for locating rotary table relative to
encoder reader head bracket and ballscrew nut mounting surface).
Move the rotary table until the mounting surface almost meets the ballscrew nut. Remove the 5 mm shims from
between the runner blocks and the adjuster blocks. Adjust the rotary table using the adjuster block cap screws and
setscrews (FIGURE 86.10- 36) until the threaded holes in the ballscrew nut mounting surface of the rotary table are
centered on the holes in the ballscrew nut. Install cap screws in the ballscrew nut one turn from snug. (See the
saddle assembly drawing for the proper socket head cap screws. For most applications, M12 X 45 cap screws are
required). Use both adjuster blocks to move rotary table until the ballscrew nut to its mounting surface is square,
using a feeler gage to check the gap. Then, move the rotary base until it makes contact with the mounting surface.
Be sure the surfaces are feeler tight. Then, snug up the ballscrew nut cap screws. Final torque for M12 X 45 cap
screws is 136 N-m (100 lb-ft).
Note: Later be sure to check ball screw alignment to way surfaces and adjust ballnut position if needed by
positioning near a bearing block and loosen then re-torque the bolts, if necessary.
Note: Once the adjuster block lock cap screws and setscrews have been adjusted and the cap screws to
the ballscrew nut and the runner blocks have been torqued to specification, do not readjust. This
adjustment is not intended to align the B axis table edge to the rest of the machine. It is for initial
alignment of the rotary table base to the ballscrew nut and ways.
Connect the ballscrew nut lubrication and all other lubrication lines.
Connect all electrical wires and hydraulic hoses from the utility carriers (FIGURE 86.10- 37) to the manifolds or
junction boxes. This will vary with the type of equipment shipped with the machine. Always use the machine specific
electrical and hydraulic schematics that were shipped with your machine.
Adjuster Block
Runner Block Spacer with
“Lip”
“Guide” Linear Way

Column/Headstock this
Side of Rotary Table
5 mm spacer used here

(and the other runner block
on this way) for initial table
alignment.
FIGURE 86.10- 35
Rotary Table Runner Block on “Guide” Linear Way
Cap Screws for

Fastening Adjuster
Block to Rotary Table
Cap Screws for Pulling

Setscrews for Pushing Table Away
Table to Runner Block.
from Runner Block (and Locking
(Screws Thread into
Final Position)
Runner Block Spacer)
FIGURE 86.10- 36
Rotary Table Adjuster Block
When Rotary Table in Place,
Attach Power Track Lines
and Services
Set the Rotary

Table on the
Runner Blocks
with Top Spacers,
at the Four
Corners of Rotary
Table
FIGURE 86.10- 37
Rotary Table in Position on Runner Blocks
Tool Changer Attachment

Surface
Rear of Hydraulic Unit
Column and Services Center
X-Axis Gearbox and Drive

Motor
Rotary Table Base Saddle Lube Piston

Distributors
Ballscrew Nut Mounting Surface
Saddle
Saddle
Linear Encoder Support
Saddle Support
Runway
W-Axis Drive Motor
(Fanuc Motor Shown) W-Axis Gearbox
FIGURE 86.10- 38
Rotary Table Assembled to Saddle
INSTALLING THE TOOL CHANGER
Refer to Tool Changer in this manual for information covering the installation.
INSTALLING THE CONTROL
The control base can now be placed in position according to the machine Layout (line and foundation) drawings.
FIGURE 86.10- 39 shows the control base and wiring coming in below the control, before it is set in place.
The photo also shows some of the other components behind the control.
Note: Care should be taken during the assembly of the machine to avoid any possible problems. If
something is unclear, check the prints or contact the MAG Service Department. Read and
understand the electrical and hydraulic startup procedures before attempting to bring the machine
on line.
The control enclosure then can be set in place on top of the base structure. Be sure to lift the enclosure only at the
specified lifting points or damage could occur to the unit.
All ductwork and cabling should be connected at this time, following the electrical diagrams supplied with your
machine. Also, refer to the Electrical Service Manual for detailed information about the machine's electrical
components, their function, and the proper installation and maintenance. All of the cables and wires were tagged at
the factory and should be connected to their proper terminal or plug.
The enclosure then can be finish wired. Be sure to tighten all of your connections and to verify all connections that
may have been done by someone else. Doing a tug and pull check is advised to help verify tight connections.
Oil Chiller Unit

(Four-Speed
Headstock Only)
Wire Way to Bed Rear of Tool

Changer Magazine
Hydraulic Unit and
Services Center
(Previous Design)
The Wiring Shown before

Setting the Control in Place
Set Control on this Surface
FIGURE 86.10- 39
Base of Control Cabinet
Operator Control
Station Shipped with
the Control
FIGURE 86.10- 40
Control Cabinet Hook Up
HYDRAULICS AND PNEUMATICS
In order for the machine to function, a factory supply of dry and lubricated air must be connected to the services panel
of the hydraulic unit. Typically, requirements are for supply of air at 6 Bar (87 psi) minimum and 34 cubic meters/ hr.
The number of pneumatic circuits is dependent on the number or various options that can be ordered with these
machines.
The hydraulic power unit with services panel should be installed according to the Machine Layout (line and
foundation) drawings. At the time of this writing, the standard hydraulic unit used on these MAG Horizontal Boring
Machines (HBM's) is the Rexroth Hydraulic unit. FIGURE 86.10- 41 shows the unit that is currently used on these
machines. This unit is equipped with a heat exchanger that is designed to keep the oil temperature below 49°C
(120°F). Thereby maintaining machine accuracy and increasing component life by dissipating heat.
The hoses and lines supplied for the machine were plugged and/or capped for shipment and tagged for reassembly.
When reassembling these hoses or lines, it is important that they are installed in their proper location by matching the
identification tags (FIGURE 86.10- 42). Before connecting any hoses, make certain there are no plugs or caps left in
the connections. Keep all the hoses clean, especially the connection points. It is very important that the hoses are
not contaminated during the reassembly of the machine. This could cause internal damage to machine components.
Shop Air Supply
Connection
FIGURE 86.10- 41
Hydraulic Power Unit and Services Panel
It is not recommended that the oil reservoirs (hydraulic, lube, etc.) be filled with their appropriate oils at this time. This
should be done just before the initial start up of the machine along with a complete grease and lubrication of the
machine. Refer to the Maintenance Noteplate section of this manual for information on grease and lube points,
reservoir location, types of oils and grease to be used and the frequency of lubrication.
Identification Tags
on Manifolds
Identification Tags
on Hoses
FIGURE 86.10- 42
Rear View of Hydraulic Unit
Assemble miscellaneous covers, guarding and shielding. This may include way covers, shielding on or around the
table or even an enclosure around the entire work area.
Also, add a Hook up to

these Eyebolts for Safety.
Do not Lift only by these
Eyebolts
Upper Brackets of
Headstock Shield, Lift with
a Strap Looped around
Each One Individually and
Centered above them at
this Location
Lower Brackets
of Headstock
Shield
FIGURE 86.10- 43
Headstock Shield
INSTALL OPTIONS
Optional Equipment must be placed in accordance with the machine Layout (line and foundation) drawings. The
wiring must be completed as shown on the electrical prints supplied with the machine.
Many machines have optional equipment such as:
• Four Speed Headstock Oil Chiller
• Indexers and Steady rests
• Production Coolant Systems
• Pallet Systems
• Enclosures
• Mist Collection Systems
• Fixtures and Clamping
• Right Angle Milling Attachments
• Spindle Supports
• Contouring Head Adapters
• Contouring Heads and Accessories
• Part and Tool Probes
• Auto Couplers
• Auto Attachment Changers (Latch Plate)
• Miscellaneous Other Options
FIGURE 86.10- 44, FIGURE 86.10- 45, & FIGURE 86.10- 46 show machines as they are being assemble and are
included for reference only. There can be various changes to any specific machines components and therefore the
reason for use as a reference only.
Access Covers
Various Covers
for Bed, Saddle
and Column
FIGURE 86.10- 44
Assembled RT (Rotary Table) Machine
Headstock
Services Panel
on Rear of
Headstock
Four-Speed
Headstock Oil
Chiller Typical
Location behind
Tool Changer
and Headstock
Tool Changer Guarding with Production Coolant System

Temporary Wood Support (Option) with Separate Coolant
Tank and Filter
FIGURE 86.10- 45
Rear Side View
Front Enclosure Doors

(Interlocked during
Enclosure Side Machining Operations)
Door (Interlocked Can be Opened using
during Machining Entrance Switches, if
Operations) Allowed.
FIGURE 86.10- 46
Machine with Enclosure Installed
SECTION 92.10
ATTACHMENTS – INTRODUCTION
TABLE OF CONTENTS
TITLE PAGE
INTRODUCTION............................................................................................................................................................1
INTRODUCTION
There are a number of optional attachments available that interface with the automatic attachment changer (latch
plate). Attachments include right angle heads, which may have automatic indexing and power drawbar capabilities,
feed out bar boring heads (contouring heads), spindle supports, other engineered attachments, auto attachment
changer cover, or oversized tooling. When these attachments are used with the auto attachment changer,
attachments storage racks are used to facilitate the automatic loading and unloading of the attachments.
Vertical tool racks are available to hold tools that are utilized by a right angle attachment. The tool rack will extend
and retract on linear ways powered by a hydraulic cylinder for automatic tool changes. These racks can be designed
to hold various tool tapers. Vertical tool racks are also available for storage of oversized tooling, which is not capable
of being stored in the normal tool changer. FIGURE 92.10- 1 shows an example of an attachment rack and a vertical
tool rack that accommodates SK50 tapered tooling.
Tool Rack
Tower
Tool Holder
Attachment
Rack Upper
Base
Base
Attachment
Rack Lower
Base
FIGURE 92.10- 1
Example of Tool Rack & Attachment Rack
ATTACHMENTS 92.10-1
SECTION 92.20
AUTO ATTACHMENT CHANGER
TABLE OF CONTENTS
TITLE PAGE
AUTO ATTACHMENT CHANGER (OPTION)................................................................................................................1
REMOVING THE AUTO ATTACHMENT CHANGER .........................................................................................2
ATTACHING THE AUTO ATTACHMENT CHANGER ........................................................................................4

AUTO ATTACHMENT CHANGER (OPTION)
The automatic attachment changer (also known as latch plate) is an optional device, which mounts to the front of the
headstock. This device allows for automatic clamping/unclamping of attachments, such as, right angle heads,
indexing heads, or other engineered attachments. During machining operations that do not require an attachment, a
cover is mounted to the changer. Attachments and the cover are stored in a rack/s located in the front of the
machine.
Four hydraulic cylinders that each includes a set of Belleville springs are used to clamp and unclamp the attachments.
The shaft of each cylinder has a four-jaw clamp mechanism that is designed to grab a retention knob. The retention
knobs are mounted to the attachment (or an adapter plate on the attachment). The jaws work similar to the tool
retention system used in the spindle. During clamping, the jaws are retracted by the piston. As the jaws are pulled
back into a sleeve, their shape forces them to close on to the retention knob. The piston continues its stroke pulling
the attachment securely to the face of the changer. Each retention knob includes a spacer that is used to set the
height of the retention knob relative to the face of the attachment. These heights are set at the factory.
When the auto attachment changer is in the clamp mode, the hydraulic pressure works in conjunction with the
Belleville springs to create over 45,000 Newton (10,000 lb) clamping force per cylinder. A 2X pressure intensifier is
used to boost normal system pressure to 152 bar (2200 psi). Check valves in the circuit prevent loss of hydraulic
pressure, with the springs serving has an added safety feature, in the case of total hydraulic pressure loss. During
unclamp mode, normal system pressure is used to overcome the springs and force the jaws into an open area. The
jaws release their hold on the retention knob, with the face of the jaw shaft pushing the retention knob (and
attachment) away from the changer.
The changer has a number of couplings to provide coolant, hydraulic pressure, and electrical connections into the
attachment. A set of three proximity sensors are used to determine the specific attachment mounted to the changer.
Latch Plate Cover Installed

Latch Plate without Cover
FIGURE 92.20- 1
Latch Plate
ATTACHMENTS 92.20-1
REMOVING THE AUTO ATTACHMENT CHANGER
In order to remove the auto attachment changer from the headstock, any attachment or cover must be unloaded to
the storage rack. Position the machine so that there is crane access to the changer.
1. To ensure that there is minimum hydraulic pressure in the hoses going to the attachment changer:
A. The attachment changer should be in unclamp attachment mode
B. For attachments with optional index head, the indexing head should be engaged
C. For attachments with optional drawbar (tool retention), the drawbar should be in clamp mode
2. Turn off the machine
3. Remove covers as required to access lines/hoses and cables.
4. Disconnect the hydraulic & coolant lines that are routed under the headstock. Add plugs on the end of all lines
that have been disconnected. Add plugs to attachment changer fittings. This will prevent any contaminants
from entering the system.
5. Disconnect the three attachment monitor proximity switch cables. For machines equipped with attachment
electrical connector/s, disconnect all the cables from the receptacle.
6. Add two M12 swivel eyebolts to the top of the attachment changer. Attach hooks from crane to eyebolts.
Minimal tension should be applied at this time.
7. Remove the four M12 tapered pull pins in the face of attachment changer.
8. With tapered pins removed, loosen eight M20 X 200 socket head cap screws. Make sure the changer is
supported by the crane before removing the screws.
9. With screws removed, move the changer away from the front of the headstock approximately 150 mm (6”). At
this time ensure that all hydraulic, coolant and electrical connections have been removed.
10. Lay the changer on wooden blocks and cover to protect its finish from damage.
92.20-2 ATTACHMENTS
Bolt #1 Bolt #8
Guide Bushing
Attachment
Bolt #2 Retention Clamps Bolt #7
Taper Pins Taper Pins
Bolt #3
Bolt #6
Guide Bushing
Bolt #4 Bolt #5
Service Connections
Proximity Switches
FIGURE 92.20- 2
Latch Plate Layout
ATTACHMENTS 92.20-3
ATTACHING THE AUTO ATTACHMENT CHANGER
The procedure to reattach the auto attachment changer is the reverse of removing, except for changer alignment to
spindle sleeve and bolt torque requirements. The face of the attachment changer must be perpendicular with spindle
sleeve axis of rotation. The attachment pilot diameter on front face of changer must be concentric with spindle sleeve
axis of rotation.
1. Add two 12 mm swivel eyebolts to the top of the attachment changer. Lift changer with crane.
2. Using mineral spirits clean the face of the headstock and the rear surface of the attachment changer.
3. Move the changer into position on the face of the headstock.
4. Mount the changer to the headstock with eight M20 X 200 cap screws. Hand tighten the cap screws.
5. Insert the four M12 tapered pins and drive to position. Ensure that there is some slack in the chain/strapping
holding the changer, so that the tapered pins can move the changer to proper location.
6. Torque the eight M20 X 120 cap screws to half of the torque specification in a criss cross sequence, (1-5-8-4-
2-6-7-3). Repeat the torque sequence, this time to the full torque specification.
7. Check and adjust as needed, the attachment pilot outside diameter must be concentric with axis of rotation of
the spindle sleeve. Sweep using a 0.0001” dial indicator or electronic indicator mounted on the spindle sleeve.
Concentricity reading must be within .0005" T.I.R.
8. Check and adjust as needed, the attachment mounting face of attachment changer must be perpendicular to
axis of rotation of spindle sleeve. Sweep mounting face using a 0.0001” dial indicator or electronic indicator
mounted on the spindle sleeve. Perpendicularity of face reading must be 0 - 0.0005” minus at top.
9. Connect the three attachment monitor proximity switch cables. For machines equipped with attachment
electrical connector/s, connect all the cables from the receptacle.
10. Connect the hydraulic & coolant lines that are routed under the headstock.
11. Replace any covers that were removed to facilitate removal and replacement of latch plate.
92.20-4 ATTACHMENTS
SECTION 92.30
ATTACHMENTS
TABLE OF CONTENTS
TITLE PAGE
ATTACHMENTS (OPTIONAL).......................................................................................................................................1
ATTACHMENTS (OPTIONAL)
There are a number of optional attachments available that interface with the automatic attachment changer (latch
plate). Attachments include right angle heads, which may have automatic indexing and power drawbar capabilities,
feed out bar boring heads (contouring heads), spindle supports, other engineered attachments, auto attachment
changer cover, or oversized tooling. The following are just a few examples of what is available. Consult vendor or
supplemental documentation for specifics of purchased attachments.
FIGURE 92.30- 1
Right Angle Attachment with Indexing Head
ATTACHMENTS 92.30-1
FIGURE 92.30- 2
Latch Plate Cover
FIGURE 92.30- 3
Boring Bar
92.30-2 ATTACHMENTS
SECTION 96.10
MAINTENANCE NOTEPLATES
TABLE OF CONTENTS
TITLE PAGE
PREVENTATIVE MAINTENANCE SCHEDULE ............................................................................................................1
VISUAL UPTIME MANAGEMENT SYMBOL AND COLOR GUIDE...............................................................................1
AUTONOMOUS MAINTENANCE CHECK POINTS ......................................................................................................2
PT 1500/1800 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER .................................2
RT 1250/1600 WITH 2-SPEED HEADSTOCK & TOOL CHANGER...................................................................4
MC 1250/1600 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER ................................6
EMERGENCY STOP BUTTON LOCATIONS................................................................................................................8
ENERGY CONTROL POINTS FOR MAINTENANCE....................................................................................................8

PREVENTATIVE MAINTENANCE SCHEDULE
The following preventative maintenance checks are suggestions based on a “typical” machine usage. These checks
should be tailored to your own shop conditions. Each machine needs to have a shop preventative maintenance
schedule with detailed and descriptive maintenance logs. Once setup, follow the requirements of the schedule.
Do not allow excessive accumulation of chips and cast iron dust to build up around way covers, moving members,
and other machine components. The entire machine and machine area should be cleaned every eight hour shift.
Cleaning the machine using high pressure air is not recommended. Brushing the machine or use of shop vacuum
cleaners is safer for the operator and the machine.
Note: Many components of this machine were supplied by other manufactures. Their manuals were
supplied with the machine documentation. Review these manuals for their specific instructions,
adjustments, maintenance procedures, and maintenance schedules.
VISUAL UPTIME MANAGEMENT SYMBOL AND COLOR GUIDE
The legend below describes the symbols and color schemes used in the autonomous maintenance check point
descriptions and visual management maps. A visual management noteplate, specifically compiled for your machine,
is attached to the electrical control panel. A number of these maps and descriptions are included in this manual.
Do not, Under Any Circumstances,

delay repair of machine components
even if they can be run under adverse
conditions.
This practice will lead to further
problems and even longer machine
downtime.
FIGURE 96.10- 1
Visual Uptime Management Noteplate Legend
MAINTENANCE NOTEPLATES 96.10-1

Note: The following diagrams and information are for reference only! Refer to the actual maintenance
schedule and emergency lockout placards attached to your machine.
AUTONOMOUS MAINTENANCE CHECK POINTS
A number of machine diagrams and periodic maintenance checks are included in this manual. As previously stated,
these are for reference only. The various machine types, equipped with typical options, are shown. A description of
the maintenance check, the recommended checking frequency and special instructions are mapped to the machine
shown. The maintenance checks vary dependent upon the following: If rotary table present (RT & MC machines),
type of headstock (two or four speed), type of coolant system which can include filter mounted on main hydraulic unit,
whether pallet changer present (MC machine), and whether tool changer present.
PT 1500/1800 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER
FIGURE 96.10- 2
Visual Management Map
96.10-2 MAINTENANCE NOTEPLATES

PT 1500/1800 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER
FIGURE 96.10- 3
Maintenance Check Points
(Use with FIGURE 96.10- 2)

RT 1250/1600 WITH 2-SPEED HEADSTOCK & TOOL CHANGER
39
FIGURE 96.10- 4

RT 1500/1600 WITH 2-SPEED HEADSTOCK & TOOL CHANGER
FIGURE 96.10- 5

MC 1250/1600 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER
39
FIGURE 96.10- 6

MC 1500/1600 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER
FIGURE 96.10- 7

EMERGENCY STOP BUTTON LOCATIONS
A noteplate has been included with the machine that shows the locations of the four emergency stop button locations.
The emergency stop buttons are located as follows:
1. Pendant operator’s station
2. Handheld station(s)
3. Tool changer control box (side of tool magazine)
4. Optional production coolant systems.
The emergency stop buttons are indicated by a red button with yellow ring.
ENERGY CONTROL POINTS FOR MAINTENANCE
When maintenance is required, make sure that any stored energy in the form of pneumatic, electrical, and gravity has
been controlled. The lockout location, control action to perform, and verification process for each type of stored
energy is listed in table below.
ENERGY LOCKOUT CONTROL VERIFICATION

SOURCE LOCATION ACTION PROCESS
Electrical Lockout Main electrical panel Place disconnect handle in Attempt to restart the system.
Primary off position. Attach multiple The system must not start.
Disconnect device, lock & tag. Visually verify.
Open disconnect and locking
device Installed.
Pneumatic Machine air inlet on Slowly close lockout valve Verify the valve Is closed
Lockout Primary main hydraulic unit to gradually shut off air and lockout device is properly
Air Supply pressure. Attach multiple attached.
device, lock & tag.
Control Gravity Headstock Bottom out, block, pin or Make sure vertical axis
chain vertical axis components are completely
components. secured and not capable of
movement.

SECTION 96.20
ALIGNMENTS
TABLE OF CONTENTS
TITLE PAGE
MACHINING ACCURACY..............................................................................................................................................1
SUGGESTED INSTALLATION & ALIGNMENT EQUIPMENT.......................................................................................3
INFORMATION REGARDING CYLINDER SQUARES AND PARALLELS ....................................................................5
THINGS TO KEEP IN MIND BEFORE DOING MACHINE ALIGNMENTS ....................................................................6
MACHINE ALIGNMENT CHECKS.................................................................................................................................6
INSTALLATION ALIGNMENT SPECIFICATIONS.........................................................................................................7

MACHINING ACCURACY
Machining accuracy depends on a number of things:
1. Work Piece Fixtures
2. Tooling and Workpiece
3. Measuring System
4. Positioning Servo
5. Thermal Factors
6. Machine Factors
The stability of the fixture must be considered when troubleshooting the machine accuracy. The fixture geometry
must be good, and its ability to resist load and thermal deflection must be appropriate.
Tool deflection and machining stress on the workpiece are other considerations that affect machining accuracy.
The measuring system and servo drive system has many electronic controls that have a bearing on machining
accuracy. The machines use Heidenhain linear encoders for independent feedback positioning of the drive system.
Thermal factors, whether ambient or machine temperature change, will influence machine accuracy. Temperature will
affect machine geometry as well as that of the fixture and workpiece. Extreme temperature can even have an
adverse effect on the electronic components of the positioning controls.
Machine factors covers things such as positioning lost motion because of backlash, deflections in the drive train, and
machine geometry.
The combined effect of the machine's measuring system, positioning servo backlash, and drive component
deflections determine the machine's slide positioning accuracy. If all of the positioning characteristics are excellent
but are coupled to the machine with poor geometric relationships, the result will be machining inaccuracy. The
following paragraphs deal with machine geometry.
In a multi-axis machine tool, the linear flatness of the ways, square checks, table orientation and spindle will concern
us. The Z-Axis must be perpendicular to the X-Axis, Y-Axis perpendicular to Z and X planes, and W-Axis parallel to
Z-Axis. The table surface must be parallel to the X and Z planes. The edge locators of the table should be parallel or
perpendicular to X, and so on. Checking these conditions is done with procedures often referred to as 'Square
Checks'. In addition, for machining accuracy each slide must travel with a minimum of roll, pitch, and yaw, resulting in
a straight line of motion. Among other things, this requires a solid foundation for the machine and a well-leveled
machine.
The following geometric procedures are a set of standard interactive instructions designed to assure that the machine
will perform as intended. Therefore, it is necessary that the geometric procedures are performed in a correct
sequence. The correct sequence of geometric procedures is provided in the following pages.
A machine whose beds appear to be perfectly level while its sliding members are stationary, may not remain so when
the slides are moved or moving. The weight shift that results with slide action is referred to as pitch, roll, and yaw.
These conditions are illustrated in the following figure.
ALIGNMENTS 96.20 -1
YAW
UPRIGHT
TOP VIEW
DIRECTION
OF TRAVEL
PITCH
DIRECTION
OF TRAVEL
UPRIGHT
ROLL
DIRECTION
OF TRAVEL
FIGURE 96.20 - 1
Yaw, Pitch, & Roll
96.20 -2 ALIGNMENTS
SUGGESTED INSTALLATION & ALIGNMENT EQUIPMENT
QTY. DESCRIPTION
1 2-1/2" x 8" x 60" precision parallel - granite or iron.
4 2" x 4" x 8" precision ground steel or cast iron riser blocks (ground matched sets)
2 Federal electronic levels and indicator heads.
2 Precision spirit levels (.00025" or .0005" per division accuracy).
2 .0001" dial indicators or electronic indicators.
2 Magnetic base for indicator.
1 36" alignment post or 45° granite square.
1 Electrical DVM.
1 Oscilloscope.
1 Surface gage.
1 *Laser interferometer or suitable equipment to check positioning accuracy.
1 Alignment laser or surveyor transit optical level.
1 12" radius tram bar and indicator extension rod (FIGURE 96.20 - 2).
1 Inch pound torque wrench.
1 Foot pound torque wrench.
1 5 to 10 micron filter buggy.
Basic hand tools and Allen wrenches. NOTE: Some machines may require metric (check with your
dealer).
Non-flammable cleaning solvent and cleaning rags.
Steel lifting bar (4" diameter, long enough to go thru column and provide pickup points). Wood
blocking and heavy pads.
Wire slings or nylon webbing. Miscellaneous eye bolts.
Lifting chains (if allowed).
Lubricants as specified by the machine lubrication charts.
* Needed to check positioning accuracy - not part of normal installation.
ALIGNMENTS 96.20 -3
For the best geometry checking results, the preliminary steps listed here should first be performed. When making a
correction, it is best to complete the entire group of checks that you intend to perform. If you record the results of
each check after it is completed, you will give yourself an opportunity to review a larger picture of the machine and
possibly eliminate unnecessary adjustments.
All geometry checks and corrections should be made only after the machine has been warmed up to normal operating
temperature to reduce the effect of the thermal factor on machine geometry. In addition, you may have to warm up
the machine again during the alignment checks to maintain the machine at the normal operating temperature.
Correct machine geometry is the relationship between the cutting tool held in the spindle and a workpiece supported
on the pallet and clamped to the table unit on the machine. Most geometry checks that are to be made will be
referenced to the pallet; therefore, make certain the pallet is clean and free of nicks, and ensure that the pallet locator
buttons on the table are also clean and without nicks.
FIGURE 96.20 - 2
Tram Bar & Extension Rod
96.20 -4 ALIGNMENTS
INFORMATION REGARDING CYLINDER SQUARES AND PARALLELS
The sample alignment checks on the following pages have been put in this manual to help establish the machine
alignments that are necessary to machine good parts. These checks do not represent all the checks that can be
made, but they do represent the most common checks used to determine if a machine is within alignment
specifications to produce good parts.
Before starting the alignment checks, do the following:
1. Bring the machine to operating temperature.
2. Check machine levelness.
3. Check gib settings (if applicable)
(1) When indicating the outside of a cylinder.
Precision indicator mounted

on "X" Axis moving from
right to left.
.015"
bandwidth
4" Dia.
The above sketch represents a 4" diameter cylinder square. If an indicator were mounted on the "X" axis and moved
from right to left to find the "high point", it would be seen that once the "high point" was reached that the "X" axis
would move .0075" (bandwidth of .015") before the indicator would pick up the curvature of the cylinder as it continued
to move to the left. For an 8" diameter cylinder the distance would double to .015" (bandwidth of .030"), a 12"
diameter cylinder the distance would be triple to .0225" (bandwidth of .045") and so on for larger cylinders.
(2) When supporting a precision parallel on precision blocks.
48"
Precision Parallel
precision blocks
FIGURE 96.20 - 3
Cylinder Squares & Parallels
The above sketch represents the proper method to use when supporting a precision parallel, when resting it on
precision blocks. The length of the parallel should be measured and then divided in half (24" in this example). Then
each of those halves should also be divided in half (12" in this example). The parallel should be marked in some
manner at these locations (e.g. the black arrows) and the precision blocks put under these locations to properly
support the parallel and lessen the possibility of sag and therefore erroneous measurements when using the parallel.
ALIGNMENTS 96.20 -5
THINGS TO KEEP IN MIND BEFORE DOING MACHINE ALIGNMENTS
When the machine has been completely installed and it is up and running the machine alignments can be done.
Alignments are very important regarding machine accuracy and repeatability and must be done properly. If you are
uncertain of the proper procedures for doing alignments, contact the MAG Service Department for assistance.
Alignments can be done as part of an annual preventative maintenance schedule. However, during the first year,
while the concrete foundation is curing and the machine is "settling in", alignment checks may need to be done more
often, perhaps as much as every 3 months. Another factor that could call for machine alignments to be done is if the
machine has been involved in a collision.
Note: The alignments shown in this section are general in nature and not specific to any one machine.
They are shown to display the types of inspection set-ups used to take specific alignments. The
tolerances are 0.0003" per foot.
Each machine's specifications and records are available upon request from the MAG Service
Department.
All alignment checks shall be conducted with machine erected on a MAG recommended foundation in a temperature
controlled room ±2° F. If these conditions are not met, the alignment and positioning accuracy of the machine may
exceed the tolerances herein.
All alignment checks shall be made with machine at stable operating temperature. This can be achieved by having
the hydraulics on for 8 hours. The spindle should not have been rotated faster than 100 RPM at any time during the 8
hours. All machine alignment tests shall be recorded with the spindle housing within ±2°F of ambient temperature.
A ±.0003"/ft. is defined to permit plus or minus variations within a 0.0006" band. Per foot tolerances cannot be
prorated for lengths less than one foot.
A ±.0003"/ft. total is defined to limit accumulated variations within the numerical value obtained by multiplying 0.0003"
by the length of travel in feet (i.e. 0.0003"/ft. X 3 = .0009").
The person conducting these checks should be familiar with the use and operation of metrology equipment. All
checks should be performed using electronic gauging whenever possible.
MACHINE ALIGNMENT CHECKS
Before any of the checks shown on the following pages can be performed, the machine's bed should be re-leveled to
support the fully assembled machine components as they traverse along their axes, thus minimizing the pitch and roll
of each axis.
Note: In the alignment sheets that follow, the Z-axis refers to the in/out movement of the spindle from the
headstock. The W-axis (if any) refers to the movement of the auxiliary slide towards or away from
the headstock. Your machine could have been ordered with the Z & W-axes designations reversed!
INSTALLATION ALIGNMENT SPECIFICATIONS
The following pages reflect a SAMPLE of alignment sheets used for aligning your machine. Copies of the completed
Installation Alignment Specifications were provided to your company at the time of installation.
Note: The alignments shown in this section are general in nature and not specific to any one machine.
They are shown to display the types of inspection set-ups used to take specific alignments. Each
machine's specifications and records are available upon request from the MAG Service Department.
96.20 -6 ALIGNMENTS
INSTALLATION ALIGNMENT SPECIFICATIONS
MC HORIZONTAL MACHINING CENTER

"480" SERIES MACHINE
(Specifications from MC Rev. 3, Jan. 23, 2007)
CUSTOMER:
SALES NO.: SERIAL NO.:
TYPE:
CHECKED BY
ACTUAL / DATE
ENVIRONMENT
All alignment tests shall be conducted with machine erected on a MAG

recommended foundation. The ambient air temperature of the machine
environment shall be controlled to ± 1°C (± 2°F) and the rate of change of
the environmental air shall not exceed 1°C (2°F) per hour. °F /
Avg. Ambient
Temperature
°F /
Spindle Housing
Temperature
OPERATING TEMPERATURE
All alignment checks shall be performed with the machine at a stable

operating temperature, which is the result of having had the hydraulics on
for 8 hours. The spindle shall not have been rotated above 10% of
maximum RPM at any time during the last hour.
Measure the temperature on the spindle housing. Temperature should be

within ± 1°C (± 2°F) of ambient.
If above conditions are not met, the alignment accuracy of the machine
may exceed the tolerances specified herein.
GAUGING
All checks are to be performed using electronic recording gauging

whenever possible. Attach all plots, charts, and graphs to this document.
ALIGNMENTS 96.20 -7
CHECKED BY
ACTUAL / DATE
TEST CONDITIONS
Perform the following tests only after the machine has become fully operational, has been properly tuned, after all
preliminary testing has been completed and all preliminary machine zeros have been set.
In addition, before any of the following tests are performed, the machine's W-bed should be re-leveled to support the
fully assembled machine components as they traverse along their axes, thus minimizing the pitch and roll of each
axis. In addition, all gibs should be properly adjusted to minimize yaw before continuing into the alignments.
NOTE: Machine should be leveled .0064 mm / 300 mm (.00025”/12”) maximum, both lengthwise and
crosswise.
1. PITCH & ROLL OF "X" AND "W" AXIS
Place two (2) electronic levels on rotary table top, one parallel to the "X" axis
ways and the other parallel to the "W" axis ways. Move the table throughout
the full travel of both axes.
TOLERANCE:
Up to 2500 mm travel on X or W axis - 4 Arc Seconds
Over 2500 mm travel on X or W axis - 6 Arc Seconds

Pitch /
Roll
2. CAPACITY DIMENSIONS
Refer to this machine's work order and enter specifications below.

Work Order Actual
Specification Capacity
Spindle Diameter /
Spindle Serial Number /
Spindle Travel /
Headstock Travel Above Pallet /
Table Travel /
Saddle Travel /
Fixture Locating Keyway Dimension /
Cross Slot Dimension /
Offset reference points stamped on center
of machined pallet face.
Pallet S/N /
Pallet S/N /
All (4) sides of pallets machined. /
96.20 -8 ALIGNMENTS
CHECKED BY
ACTUAL / DATE
3. PARALLELISM OF TOP SURFACE OF PALLET TO X AND W TRAVEL
Rotate the table to the 0° position. Mount an indicator in the spindle and
reference over corner #1 as shown. Use a precision gage block between the
top of pallet and the indicator tip. Lightly mark the pallet corners A, B, C and D
as shown below and mark the corners of the rotary table base 1, 2, 3, and 4 as
shown.
NOTE: Check to be taken at table ring diameter.
3.1 Set indicator zero at corner A-1. Slide the gage block out from under
the indicator, rotate the table 90° clockwise, slide the gage block back
under the indicator, take and record reading B-1. Similarly, take
readings C-1 and D-1.
3.2 Move X-axis to take (4) readings at corner 2, then move W-axis to take
(4) readings at corner 3 and so on until all (16) readings have been
recorded below and zero has been repeated within ±0.0025 mm
(±.0001").
TOLERANCE: 1250 mm 0.038 mm (.0015") TIR
1600 mm 0.050 mm (.002") TIR
TABLE BASE
#1 #2 #3 #4
A
PALLET
B
C
D
TABLE BASE
#1 #2 #3 #4
A
PALLET
B
C
D
Pallet S/N mm TIR /
Pallet S/N mm TIR /
ALIGNMENTS 96.20 -9
CHECKED BY
ACTUAL / DATE
4. EDGE OF COLUMN SQUARE WITH TOP OF WORK SURFACE
Perform test as shown using precision equipment with the post positioned on
center of rotary table.
TOLERANCE: 0.0064 / 300 mm (.00025"/12") (minus at top) /300 /
Leveling Pads Checked /
5. FACE OF COLUMN SQUARE WITH TOP OF WORK SURFACE
Perform test as shown using precision equipment with the post positioned in
center of rotary table.
TOLERANCE: 0.0064 / 300 mm (.00025"/12") /300 /
Leveling Pads Checked /
96.20 -10 ALIGNMENTS

CHECKED BY
ACTUAL / DATE
6. SPINDLE TRAVEL PARALLEL WITH SADDLE TRAVEL

(Z-W HORIZONTAL PARALLELISM)
Perform test as shown with the spindle rotating at low RPM and a precision test
arbor chucked in spindle indicating side of test arbor. Record the difference
between the mean runout at each position.
TOLERANCE: 0.005 mm / 600 (.0002"/24") /500 /
A. Spindle Retracted
W Axis Forward
B. Spindle Extended 600 mm (24")

TOP VIEW
W Move "Plus" 600 mm (24")
7. SPINDLE AXIS OF ROTATION PERPENDICULAR TO TABLE TRAVEL

(SPINDLE - X SQUARENESS)
Lay a master square flat on rotary table. Align front face of square parallel to X
axis travel. With sweep arm mounted on spindle sleeve, sweep front edge of
master square using spindle rotation and record results.
TOLERANCE: 0.010 mm / 500 mm (.0004"/20") /500 /
GRANITE GRANITE
MASTER MASTER
SQUARE SQUARE
(TOP VIEW) (TOP VIEW)
"0" X "0"
SPINDLE SPINDLE
ALIGNMENTS 96.20 -11

CHECKED BY
ACTUAL / DATE
8. SPINDLE AXIS OF ROTATION PERPENDICULAR TO HEADSTOCK

TRAVEL (SPINDLE - Y SQUARENESS)
Stand master square upright in the Y-Z plane. Align front of square parallel to
Y axis travel. Using sweep arm, set-up from test 7, sweep front edge of master
square using spindle sleeve rotation and record results.
TOLERANCE: -0.005 to -0.015 / 500 mm at top
(-.0002" to -.0006"/20") /500 /
GRANITE
"0" GRANITE
MASTER MASTER
SQUARE SQUARE
(SIDE VIEW) Y SPINDLE (SIDE VIEW) SPINDLE
"0"
9. SPINDLE TRAVEL PARALLEL WITH SADDLE TRAVEL

(W-Z VERTICAL PARALLELISM)
Perform test as shown with the spindle rotating at low RPM and a precision test
arbor chucked in spindle indicating bottom of test arbor. Record the difference
between the mean runout at each position.
TOLERANCE: 0.038 / 600 mm (.0015"/24") /600 /
A. Spindle Retracted
W Axis Forward
B. Spindle Extended 600 mm (24") SIDE VIEW

W Plus 600 mm (24")

CHECKED BY
ACTUAL / DATE
10. SPINDLE TAPER RUNOUT
Perform test using precision test arbor chucked in retracted spindle. Position
indicator 30 mm from spindle face and take reading while rotating spindle at
slow RPM. Move indicator out to 250 mm from spindle face and take reading.
Unchuck test arbor, rotate arbor 180°, rechuck it, and take another set of
readings. Record the algebraic average of the two readings at 30 mm and the
algebraic average of those at 250 mm below.
TOLERANCE: 0.010 mm TIR at 30 mm (.0004" TIR at 1.2") mm TIR /
0.020 mm TIR at 250 mm (.0008" TIR at 10") mm TIR
TOP VIEW
1.2"
10"
11. CROSS-SLOT PARALLEL TO WORK SURFACE TRAVEL
Perform test by tramming cross-slot.

TOLERANCE: 0.020 mm (.0008") TIR mm TIR /
Pallet S/N mm TIR /
Pallet S/N mm TIR /
Spindle Spindle

CHECKED BY
ACTUAL / DATE
12. PALLET CENTER PILOT BORE RUNOUT
Use indicator mounted in spindle to indicate back side of center bushing I.D.
while rotating table.
TOLERANCE: 0.025 mm (.001”) TIR
Pallet S/N mm TIR /
Pallet S/N mm TIR /
Spindle
PALLET
RECEIVER
13. CENTER PRECISION T-SLOT PARALLEL WITH TABLE TRAVEL (X-AXIS)
Tram back edge of T-slot at 0° position of rotary table as shown.

TOLERANCE: 0.025 mm (.001”) TIR up to 1500 mm
0.038 mm (.0015") 1500 mm to 2000 mm
0.050 mm (.002") over 2000 mm
Pallet S/N mm TIR /
Pallet S/N mm TIR /
Spindle Spindle

CHECKED BY
ACTUAL / DATE
14. CENTER PRECISION “T” SLOT SYMMETRICAL WITH TABLE ROTATION

(B AXIS)
Tram back edge of T-slot at 0° position of rotary table using X axis motion as
shown. Then rotate table to 180° position and tram back edge of T-slot.
TOLERANCE: 0.025 mm (.001”) TIR
Pallet S/N mm TIR /
Pallet S/N mm TIR /
Spindle Spindle
15. BACKLASH, HEADSTOCK
Move headstock up to a point; place an indicator and set it at "0". Scribe a line
on driving ball screw and bearing block. Move headstock up one revolution of
the ballscrew, stop, move headstock down one revolution of the ball screw, line
up scribe marks and take your reading on the indicator.
TOLERANCE: 0.050 mm (.002") Total mm Total /
CHECKED BY

ACTUAL / DATE
16. BACKLASH, SADDLE
Move saddle out to a point; place an indicator and set it at "0". Scribe a line on
driving ball screw and bearing block. Move saddle out one revolution of the
ball screw, stop, move saddle in one revolution of the ball screw, line up scribe
marks and take your reading on the indicator.
TOLERANCE: 0.050 mm (.002") Total SADDLE mm Total /
TABLE
BED Z
17. BACKLASH, TABLE
Move table right to a point; place an indicator and set it at "0". Scribe a line on
driving ball screw and bearing block. Move table right one revolution of the ball
screw, stop, move table left one revolution of the ball screw, line up scribe
marks and take your reading on the indicator.
TOLERANCE: 0.050 mm (.002") Total mm Total /

M.2005.3740 RT Mechanical

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M.2005.

HORIZONTAL BORING MILLS

MAG IAS – Fond du Lac

DO NOT OPERATE, PROGRAM OR REPAIR THE MACHINE UNTIL

‘‘Atención - Si no lee inglés, pregúntele a su supervisor para las instrucciónes de seguridad!’’

IT’S EVERYBODY’S BUSINESS!

DEFINITION OF SAFETY NOTES

This symbol appears whenever death, serious personal injury or

This symbol appears whenever minor injury or major machine damage

PERSONAL PROTECTION (PROTECTIVE EQUIPMENT)

Glasses Wear eye protection at all times.

Hearing protection Wear prescribed personal hearing protection.

SAFETY INSTRUCTIONS FOR MACHINE OPERATION

• Do not store tools, measuring equipment, etc. on the machine.

• Maintain tooling in good condition. Use only properly sharpened tools.

EMERGENCY STOP BUTTONS

• Pendant operator’s station

• Handheld stations (pendant and tool clamp/unclamp unit)

• Tool changer control box

• Optional production coolant system control box

• Optional pallet system control box

GENERAL LOCKOUT PROCEDURE

3. If the machine is operating, shut it down by the normal stopping procedure.

8. The machine is now locked out.

• Be aware of uncontrolled movements when personnel enter work area.

HYDRAULIC AND PNEUMATIC SYSTEM

• Oil mists are hazardous to health and should not be inhaled.

• Choose easily disposable coolants, observing waste disposal regulations.

FILTER MEDIA - HYDRAULIC/COOLANT

• Always wear eye protection.

• Make sure to not inhale vapors.

• Performing regular assessments and inspections at regular intervals.

• Assign and train staff for fighting fire.

MAG makes no representation or warranty, expressed, implied, or statutory with respect

© 2011 MAG IAS – Fond du Lac

A MACHINE TOOL IS A COMPLEX METAL REMOVING DEVICE,

MAG IAS – Fond du Lac

TRAINING SERVICE PARTS

MECHANICAL SERVICE MANUAL ........................................................................................................................2

MECHANICAL PRINT BOOKS ...............................................................................................................................2

ELECTRICAL SERVICE MANUAL .........................................................................................................................2

OPERATING INSTRUCTION MANUAL .................................................................................................................3

DANGER INDICATES THAT THE PROCEDURE OR SITUATION COULD RESULT IN SEVERE

WARNING INDICATES THAT THE PROCEDURE OR SITUATION COULD RESULT IN

CAUTION INDICATES THAT IF THE INFORMATION PRESENTED IS NOT FOLLOWED THE

DOCUMENTATION DESCRIPTION 1.10 - 1

The following manuals and documentation is provided with each machine.

MECHANICAL SERVICE MANUAL

MECHANICAL PRINT BOOKS

ELECTRICAL SERVICE MANUAL

1.10 - 2 DOCUMENTATION DESCRIPTION

DOCUMENTATION DVD / CD AND VENDOR DOCUMENTATION

DOCUMENTATION DESCRIPTION 1.10 - 3

MACHINE OVERVIEW ..................................................................................................................................................1

TOOL CHANGER ...................................................................................................................................................2

DRIVES AND MOTORS .........................................................................................................................................2

MACHINE ILLUSTRATIONS .........................................................................................................................................3

RT 1250 / RT 1600 .................................................................................................................................................4

HORSEPOWER CHARTS .............................................................................................................................................9

TWO-SPEED HEADSTOCK 130MM SPINDLE DIAMETER ..................................................................................9