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SAFETY NOTICE - BRIDGEPORT SER!ES I! INTERACT 2

PERFORM ALL ACTIONS IN THE MANNER STATED IN THIS MANUAL.

NEVER OPERATE THE MACHINE WITHOUT PROPER CUTTER GUARDING.

ENSURE YOU KNOW HOW TO STOP YOUR MACHINE.

DO NOT TAMPER WITH THE MACHINE

KEEP MACHINE AND SURROUNDING AREA CLEAN AND TIDY.

GUARDING

The guard supplied as standard equipment with the Bridgeport Series ll lnteract 2 (pictured above) is made of a clear
material (Lexan or equivalent) having high impact resistance to provide operator safety and a clear unobstructed view of
the component and cutter. A door at the front allows easy access for tool changing or loading of components. This guard
lS NOT SUITABLE FOR ALL OPERATIONS of which the machine is capable, and great care should be taken to ensure
the guard you use is safe for the operation being performed.

I
 Attention is drawn to the requirements of the
Health and Safety at Work Act 1974 which applies
to the U K. Similarly in other countries the machine
should always be operated to conform with the
appropriate regu lations.

is

I.

All machines in the Bridgeport range, together with their accessories are designed and produced to ensure safety to the
operator as far as is reasonably practicable.

Every machine and where appropriate, the attachments, are
provided with a cutter guard which will satisfy statutory
requirements for a large number of applications. However,
as the machine and attachments are designed for general
engineering applications the guard supplied will not cover
every possible requirement for effective guarding of the
cutter. Under no circumstances should any machine from
the Bridgeport range of machines be used without the
correct safety guard for the operation to be performed. As
we have no control over the end use of our machines, it is
the user's responsibility to ensure that the machine is
properly used and guarded for every operation.

i
(.- otlt 253t(22-.
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I

, Bridgeport Machines Division of Textron Limited,

P.O. Box 22, Forest Road,
Leicester LE5 0FJ, England
Telephone: ( 531122; Telex: 34598
ollb
 PART NO. 0596351

INSTALLATION & MAINTENANCE

MANUAL

FOR THE

SERIES II INTERACT 2

MILLING, DRILLING & BORING MACHINE

,l
I

This manual provides information which is proprietary to Bridgeport Machines

and its suppliers and is made available for the use and maintenance of our
products. Any use, reproduction or disemination of this information for any
other purpose wittrout written permission is prohibited.

The information in this document is subject to change without notice and does
not constihrte a commitment by Bridgeport Textron.

October 1982
 LIST OF CONTENTS

Section Page

MACHINE INSTALLATION 7-2

1.1 Preparation of the Machine Location 7-2

7.2 Electricd Service 7-2

II PREPARATION FOR OPERATION 2-l

2.7 Cleaning the Machine 2-l

2.2 Lubrication 2-7

III MACHINE COMMISSIONING 3-1

3.1 General 3-1

3.2 CommissioningProcedure 3-7

IV MACHINE MAINTENANCE - THEORY OF OPERATION 4-1

4.7 The XY Servo Motor Drive 4-r

+.2 Knee Drive 4-r
+.3 Lubricating System +l
4.+ TheZ Axis Drive 4-2
4.5 The Milling, Drilling and Boring Head +-3
4.6 Specification +-4

V POWER DISTRIBUTION 5-1

5.1 Power Disuibution 5-1

VI CONTROL AND AXIS DRIVES 6-7

6.1 Axis Drive Unit System Description 6-7

6.2 Replacement of Axis Drive Unit 6-7
6.3 Conuol System Description 6-3
6.4 Fitting a New Controller 6-3
6.5 Sofrware Limits 64
6.6 Controller Buffer Battery Replacement 6-5

VII BASE ASSEMBLY AND MAINTENANCE 7-7

7.1 Drive Belt Replacement 7-7

7.2 XtA V Axis Diive Motor Replacement 7-3
7.3 Table and Saddle Removal 7-8
7.4 X&YAxisBallscrew 7-9
7.5 Air Assist Pedestal 7-12
7.6 Limit Switch Replacement 7-1+
7.7 Lubrication 7-17
7.8 X&YAxisGibs 7-20
7.9 Lost Motion & Backlash Compensation 7-22

BT/%M/10A2
 LIST OF CONTENTS (Cont'd)

Section Page
SERIES II INTERACT 2 HEAD ADJUSTMENT
vm AND MAINTENANCE 8-1

8.1 Lubrication 8-1

8.2 Power Transmission 8-1
8.3 Quill and Spindle 8-8
8.4 Quill Limit Switches 8-15
8.5 Alignment of Quill Housing Assembly to Drive Motor
Housing Assembly 8-16
8.6 Bdl Quill Extension Inspection 8-17

Ix SPARE PARTS LIST 9-1

9.1 Electrical Parts List 9-1

9.2 Mechanical Parts List 9-2

x PREVENTIVE MAINTENAI{CE 10-1

10.1 Warranty 10-1

lO.2 Singte Shift Operation and Using Coolant on all Operations 1Gl
10.3 Multiple Shift Operations and Punitive Environments 1G2
10.4 MaintenanceSummary 104

XI FAULT FINDING 1 1-1

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f.
 I,IS'I' O F' I LLUS'I'RA'TIONS

lrigure Page

l-l Series II lnteract 2 Milling Machine I -1

t-2 Machine Base Layout I -3
l-3 lnstallation Plan View I -4

2-l Lubrication System 2-7

6-l Axis l)rive Unit Connections & Adjustments 6-2

6-2 Rear of Conrrol System Showing Connections 6-6
6-' System Wiring Diagrrm 6-7

7-l 'l'able and Saddle Arrangemcnt 7-4

7-2 Knee Arrangement (2 sheets) 7-5 to
7-6
7-3 I)ual l)ial La1'out 7-7
74 Elevating Screlv Assembly 7-13
7-5 Limir Srvitch & 1'rip Dog Arrangement 7-18
74 fuyout of Services 7-19
7-7 Knee Lubrication System 7-20
7-8 Saddle to'l'able Gib Setting 7 -22
7-9 Saddle to Knee Gib Setting 7-22

8-l Milling Head Assembly 8-3

Special
-l'ool 5'l'6921 Head Lift Bracket 84
8-2
8-3 Z Axis Assembly 8-7
84 Spindlc Brake antl Back Cear Assembly 8-11
8-5 Quick Change Locknut Assembly 8-13
86 Quill Limit Srvitch Setting 8-14
8-7 llall Quill Extension 'l'orque on Nut Set-up 6-re
8-8 Ball Quill & Nur l"lushing 8-19
8-9 Ball Quill Extension t;lushing 8-20
LEVELS OF MAINTENANCE

Level 1 (Opera tor) Maintenance

The machine operator (or other customer representative) is not assumed to have any detailed
knowledge of the equipment. He is not assumed to have any (electrical) tools for maintenance.

Level 1 maintenance consists of keeping the equipment clean, lubricating (and ensuring that
lubricant reservoirs are full), making sure that power is turned on, and that proper start-up and
operating procedures are being followed.

Lwel 1 personnel are not auttrorised to make adjustment or replace comPonents.

Level2 Maintenance

The level 2 service man is assumed to have a fair knowledge of ttre equipment.

He is assumed to have a VOM, spare fuses, printed circuit boards etc.

Level2 maintenance consists of all level 1 procedures plus adjustment of power supply voltages
and replacement of major sub-assemblies, such as seryo motors, cables, drive boards, fuses etc.,
plus certain individual components such as contactors, power switches and relays.

Level2 personnel are not recommended to replace individual components other than those
enumerated above.

Level 3 Maintenance (Bridgeport Field Service or Specially Trained Dealer Service)

For all level 3 maintenance such as replacement of individual electronics p,rts etc., it is strongly
recommended that this be carried out only by Bridgeport Field Service Engineers, or their
Trained Deder Service Staff.
Figure 1-1 Series II Interact 2 Milling Machine

1-1
 SECTION I

MACHINE INSTALLATION

1.1 PREPARATION OF THE MACHINE LOCATION

1.1.1 Foundation and Clearances

When setting the machine on a prepared foundation of concrete (optional) or on the shop floor,
use shim plates, adjustable mounting pads or thin grouting to compensate for unevenness in the
floor.

Figure 1-2 shows the base dimensions and the 17 mm (27132") diameter clearance holes for
16 mm (S/a':;.6o1,s, should it be required to bolt the machine to t}re floor.

Figure 1-3 shows the necessary clearances around the machine for access door opening for
maintenance and to continue the remainder of the installation.

1.2 ELECTRICAL SERVICE

1.2.7 Referencelnformation

The machine is wired f.or 27O,22O,2+O,380 v or 4OO, 42O,44O, 460,480 v and all fused 20
amps. Check the label on the outside of the Power Equipment Enclosure on the side of the
machine to determine the exact figures for your installation.

The electrical service entry is at the rear of the Power Equipment Enclosure (see Figure 1-3)
where a 20 mm diameter hole has been provided for electrical conduit fittings.

WARNING: DO NOT CONNECT ELECTRICAL SUPPLY AT THIS STAGE

7-2
(4) LEVELLING
BOSSES ON BASE

LEVEL POSITION
CROSS AND LENGTH WISE
-

108 mm
(4ll+")

1180 mm 965 mm
(46 712"\ (39")

FOR 16 mm (5/8") BOLTS

660 mm
(26")

787 mm
(31")

Figure 1-2 Machine Base Layout

t-3
20 mm DIA HOLE FOR
314" DIA CONDUIT FITTING

559 mm' 279 mm

(22") (11")+

508 mm
(20")
1194 mm
(47")

691 mm
(27Y2")

1638 mm
(64Y2"')

1346 mm
(53")

-
II

Figure 1-3 Installation Plan View

74
 SECTION II

PREPARATION FOR OPERATION

2.7 CLEANING THE MACHINE

After final acceptance testing at the factory, nvo major operations are carried out which must
be fully understood in order to do an effective job of cleaning the machine:

1. Masking and Spray Painting.

2. Cosmolene rust preventative application with a Spray Gun.

Clean all rust preventative from the machine with kerosene .

WARNING: DO NOT USE GASOLINE, CHLORINATED HYDROCARBONS OR ANY

OTHER INFLAM]VIABLE OR TOXIC CLEANING AGENT.

Clean and lubricate all exposed sections of the table, saddle and knee ways. This includes the
underside of all ways. It also includes the possible necessity to scrape paint from some of the
hidden surfaces where the masking may not have been completely effective.

2,2 LUBRICATION

There are two classes of lubrication systems:

1. Those areas lubricated for life such as spindle bearings, transmission gearbox etc.

2. The forced lubrication system from the automatic one-shot pump to supply ways, gibs and
ballscrews including the Z axis (see Figure 2-1).

Figure 2-1 Lubrication System

2-7
 SECTION III

MACHINE COMMISSIONING

3.7 GENERAL

Initial machine commissioning MUST be carried out by Bridgeport Field Service or their trained
Dealer Service.

Electrical power must not be applied to the machine until requested by the Engineer carrying
out the commissioning.

3.2 COMMISSIONINGPROCEDURE

3.2.1 PreliminaryInspection

The following checks are to be carried out before the machine main isolator is switched on

3 .2.1.7 Visual Inspection

a. Check the machine for any transit damage and check that all hardware fixings are secure.

b. Check that all fuses are installed and are secure .

c. Check that the lubrication reservoir has been filled with the correcr grade of oil and operate
the plunger to check that the system is pumping the lubricant.

3.2.7.2 Wire Checks

a. Check that ALL terminal strip screws in the power cabinet are secure.

b. Check that the D.C. feed motor connections are secure.

c. Check that the connections to the head limit switches are secure.

3.2.2 Mains Su Checks

a. Measure the incoming 3 phase supply on the supply side of the main isolator and record rhese
readings below:

Lines L1 to L2 ....... volts A.C.

ii. Lines Ll to L3 ....... ......... volts A.C.

iii. Lines L2 to L3 ....... ......... volts A.C.

b. Check with the customer for any known, regular variations of supply voltage which are
widely different from the nominal values measured in (a) above.

3-1
c. Check that transformers T7,T2 (located in the power cabinet) and the spindle motor are
wired for the correct supply voltage and record this below:

T1 wire numbers 1 06 and 7O7 , T2 wire numbers 11 1 md 172

Equipment wired for volts A.C. oPeration

d. Check that the spindle motor overload O/L is correct for the operating voltage selected.

3.2.3 ElectricalChecks

Switch the main isolator ON and carry out the following electrical tests:

a. Measure the A.C. voltage between wire numbers 8 and 9, and check that it falls within the
range 110 volt A.C. +. 5 volt.

Voltage reads ........ volts A.C.

b. Measure the D.C. voltage between wire numbers 116 and 90 and check that it falls within the
range 24 volts D.C. to 28 volts D.C.

Voltage reads ........ volts D.C.

c. Measure the smoothed D.C. voltage terminals 65 and 90 and check that it falls within the
range 22 volts D.C. to 26 volts D.C.

Voltage reads . volts D.C.

3.2.4 Pneumatics

Set the respective pressure regulators to provide a nominal pressure of 80 psi (5.62 kglcm2) to

a. The spindle brake and speed change pneumatics.

b. The air assisted knee.

3.2.5 SpindleOperation

Switch ON, REF machine and carry out the following checks

a. Spindle brake

i. With the brake switch set to OFF, check that the brake is not applied.

ll Operate the spindle starter switch and check that the spindle rotation is correct. If
necessary interchange lines Ll and L2 to provide the correct rotation.

lll. Check that the spindle runs both forward and reverse.

IV With the brake switch set to AUTO, check that when the spindle is switched off, the
brake is applied and when the spindle is started, the brake is released.

3-2
b. Spindle speed changer

With the spindle running, check that:

i. When INCREASE is depressed, spindle speed increases.

ii. When DECREASE is depressed, spindle speed decreases.

3.2.6 Final Checks

Briefly carry out checks to ensure that the following facilities are functional:

3.2.6.1 MpI
Check that the machine responds correcdy to MDI commands.

3.2.6.2 Lube

Check that the automatic, centralised lubricating system is working correctly and that the oil is
getting onto the slideways.

3.2.6.3 Coolant

Check that the coolant qystem(s) fitted function correcdy.

3.2.6.4 Low Voltage Light

If a low volt light is fitted, check that this functions correcdy

3-3
 SECTION IV

MACHINE MAINTENANCE

THEORY OF OPERATION

+.1 THE XY SERVO MOTOR DRIVE

4.7.7 Servo Motors

The feed motors are of the permanent magnet rype driven by silicon controlled rectifier &ive
cards situated in the electrical cabinet.

A l25linerrevolutiorr encoder is mounted on the back of each motor and provides the position
feed back signal.

4.7.2 Transmission

The X and Y motions of the table are accomplished by means of hardened and preloaded 5 mm
pitch ballscrews with recirculating ball nuts. On the X axis the ball nut is fixed to the saddle and
the D.C. motor turns the screw through a2:7 reduction timing belt drive.

The Y a.xis is similar, the drive being to the rear of the screw to give operator access to the work
Ltea.

4.2 KNEE DRIVE

4.2.7 Raising and Lowering Knee

The knee is elevated by an Acme screw. A friction type dual dial, calibrated in increments of
.01 mm (.001") is provided.

To change knee elevation push the knee eievating crank in until the clutch meshes, then turn the
crank clockwise to elevate the knee, or counter-clockwise to lower it.

NOTE: Two knee lock leaers wbicb control clamps on tbe knee-column uays must be
released prior to raisi.ng and lowering tbe knee.

4.2.2 Clamping the Knee

To clamp the knee, turn the knee lock levels firmly upwards. To release, turn them the other
way. Keep the knee clamped while cutting.

4.3 LUBRICATING SYSTEM

All moving members are fed from a central lubricating tank containing a filter and motorised
timed plunger lubricating pump. Each pump discharges (5 cc every 30 minutes) metered amount
of fluid as follows:

X axis 8 orifices
Y axis 6 orifices
Z axis 6 orifices
XY and Z axis ballscrews 1 orifice each

4-r
Lubrication between the ouside of the quill and the bore in which it rides is effected by waste
oil from the Z axis ballscrew.

To distribute and retain the oil on the table, saddle and knee, grooves are cut into the face of
the ways and through holes in the gib so that both sides of the dovetail get full lubrication.
Excess oil exudes over the edge of the ways between the moving members.

Spindle bearings are grease-packed and require no additional lubrication for the life of the
machine. Low level lube will not stop a job in progress but it will prwent the feed from
being started for the next job.

4.3.7 RequiredLubricants

The following lubricants are approved for use in the Series II Interact 2 automatic lubrication
system:
American Oil Co Way Oil No. 31
(Standard Oil Co. - Division of American Oil Co.)
Adantic Richfield Co ...... Richway Oil No. 3

Dominion 5315 and

Truslide 300 Oil'Sinclair'
Boron Oil Co Factoray 5O

BP Trading Ltd. & it's Affiliated Companies ............. BP Energo HP 20-C

Chevron oil Co Chewon Vistac Oil 15 W
Cities Service Oil Co .. Citgo Slide Rite 2
Fiske Bros. Refining Co .. Lubriplate 3W
Gulf Oil Corp & Subsidiaries Gulfway 52
E. F. Houghton Co Waylube 297
Humble Oil & Refining Co
and its Esso-Affiliated Co's Oyerseas Febis K-5 3

Mobil Oil Corp Mobil Vactra Oil No.2

Petrofina Group Fina Artac EP 37
Shell Oil Co ........ Tonna 68
Sinclair Refining Co See Atlantic Richfield Co.
Standard Oil Co. (Ohio) Factoway 50
Sun Oil Corp ........ Sunoco Way Lubricant 80
Sunray D-X Oil Co ........ D-X Wayclingl32O
Texaco Inc Way Lubricant D
Arthur C. Withrow Co Withrolube 629

4.4 THE Z AXIS DRIVE

The quill is drivpn by the same type of D.C. feed motor as used on the X and Y u<is. A timing
belt is used to connect the D.C. feed motor and the ball quill extension because of its excellent
performance characteristics for this application. The ball quill extension is hardened and ground
with a 5 mm pitch thread carryng a recirculating ball type nut with suitable internal preload
with proper adjustment of the timing belt lost motion is virnrally eliminated. The ball quill
extension drives the quill through a working travel of.725 mm (4 59/6+").

4-2
 4,5 THE MILLING, DRILLING AND BORING HEAD

4.5.1 Transmission

The prime mover is a 3 phase, 2 h.p. (t.5 kw) A.C. induction motor.

The motor incorporates Bridgeport's unique patented reverse flow air cooling system. This
system ensures that the heat build up in the spindle bearings, belt and quill area is kept to an
absolute minimum. Distortion is thereby avoided by maintaining the operating temPerature to
within 20oF of ambient resulting in increased belt and bearing life and maintained accuracy.

The speed changer control is provided by factory balanced, cast iron varidiscs. Each varidisc
assembly is precision dynamically balanced. The careful balancing diminishes vibration and
promotes long belt life.

When the high/low shifter is in high, the output varidiscs drives the spindle directly through the
clutch. Shifting into back gear (low) disengages the clutch and engages the bull gear. The power
travels through a toothed belt drive to a counter shaft and back to the spindle through the bull
gear.

4.5.2 The Quill and Spindle

The quill is an 86 mm (3 3/8") diameter steel tube ground and chrome plated to a tolerance of
.005 mm (.0002"). The quill secures the outer races of the angular contact Class 7 preloaded
bearings mounted to the spindle. The spindle itself is alloy steel hardened and ground with an
involute spline at its upper end to slide internally in the power transmission train. At the lower
end of the spindle a taper is ground for Erickson No. 30 Quick Change Tool Holders.

CAUTION: Because of tbe matcbed fit of quill to quill bousing and because tbe spindle taper
isground in its own bearings any field cbange of spindle must be performed as a
spindle cartridge sub assembly consisting of spindle, bearings, spdcers and locknuts

+-3
 4.6 SPECIFICATION

METRIC INCH
RANGE
Table travel (X axis) 760 mm 29 77 132"
Saddle travel (Y axis) 370 mm t+ |U64"
Quill travel (Z axis) 125 mm 4 5916+"
Knee travel 335 mm 73 3/16"
Throat distance 395 mm 75 9n6"
Table to spindle 178 mm 7"
Maximum component weight, centrally loaded 450 Kg 990Ib

TABLE
Overall size ll94 x 422 mm 47 x 76 518"
Working surface 965 x 380 mm 38 x 15"
Tee slots (3) - centres ,11.1 mm + 3/8"
- width 15.9 mm 518"
Height above floor - max. 2260 mm gg"

SPINDLE
Motor 1.5 kW 2h.p
Taper # 30 Quick Change
Speed range (infinitely variable 50 - 3750 r.p.m.
Transmission ratios 1:1 and 8.3:1

FEED DRIVE
D.C. permanent magnet motors - stall torque 3.2 Nm 2.4lbft
Ballscrews - pitch 5mm o.79685"
Manual feedrate range lO-750mm/min. O.4 - 30 inlmin.
Rapid feed rate 5000 mm/min. 200 inlmh.
Programmable feedrate ran ge I - 5000 mm/min. 0.1 - 200 in/min
Feedrate increments 1mm/min. 0.1 in/min.

CONTROL AND MACHINE PERFORMANCE

System resolution - linear 0.001 mm 0.0001"
- angular 0.0010
Display resolution 0.005 mm 0.0002"
Positioning repeatability r 0.010 mm +-0.0005"
Positioning accuracy *.0.025 mm *.0.001"
Drilling capacity - mild steel 20 mm dia. 314" dia'.
Milling capacity - mild steel 25 cm3/min. t.s in3/min.
Boring - max dia. 100 mm dia. 4" dia.

44
 SECTION V

POWER DISTRIBUTION

5.1 Prime power to the system is 3 phase, 50160 Hz. A.C. input voltage is selected by the
customer when ordering the rnachi:ae. Minor voltage adjustment can be made in the field to
cope with local differences from the specified voltage. Available input voltages are 21O,22O,
23O, 38O, +OO,42O,44O, 460 and 480 v.

5.1.1 Three ptrase power enters the system through the main system disconnect located on
the electrical cabinet and feeds the 3 phase distribution wiring.

Items connected to the 3 phase distribution wiring are

1. The spindle motor.

2. Control voltage uansformer (T1).

3. Axis ririve power transformer (T2)

5.1..2 Single Phase Power

The 110 volt single phase output from Tl feeds the single phase distribution wiring. Items fed
from the single phase distribution are as follows:

1. Spindle and feed contactors.

2. Lube pump motor.

3. Coolant pump motor.

5.7.3 24Yolt D.C. Power

24 volt D.C. power is used for general purpose switching and control functions in which close
voltage regulation is not important. These include:

1. The 24 volt D.C. regulator which produces the smooth ed 24 volt D.C. for the MDI control.

5-1
 SECTION VI

CONTROL AND AXIS DRIVES

6.1 AXIS DRIVE UNIT SYSTEM DESCRIPTION

Power to each feed motor is provided by an S.C.R. feed drive unit situated in the elecuical
cabinet.

The main power input to the feed drive unit is a 180-0-180 volts A.C. supply derived from trans-
former T2 and applied to terminals U and V on the drive card via smoothing chokes LL, L2, L3
for X, Y , Z axis drives respectively

Each drive unit produces a D.C. supply which appears at terminals C and D. The D.C. motor
armature is connected between these terminals and the zero volt tapping of. T2. Control of the
D.C. voltage to the motor is by means of the input command voltage from the MDI control
which is fed to the drive unit on terminals 7 and 9 for each of the three axes.

Each motor has an integral tachometer whose signal is input to the respective drive at terminals
4 and 6 to close the velocity feedback loop.

6.2 REPLACEMENT OF AXIS DRIVE UNIT

1. Switch off and isolate the machine

2. Remove the old drive unit after remorring the plug-in terminal strip connector, the push-on
power cable connectors and the screw down earth cable connection.

3. Reverse the procedure to fit the new drive unit ensuring that all elecuical connections are
correct to the circuit diagram.

The new drive must now be adjusted

4. Remove wires 5, 6,7 from overload 3 in electrical panel

5. Switch on isolator, press [CE] b,r,.on on control unit. Display will show "Pass Over Reference
Points".

6. Enter figure 95748 and . control unit will transfer into Machine Paramerer Mode
@
Alter parameter 17 to:

0 for setting X axis drive

3 for setting Y axis drive
5 for setting Z axis drive

DEL
Press D button on control to change back to Pass Over Reference Points mode.

7. Set current limit on drive.

Turn the feedrate control ando/o override control on pendant fully clockwise.

Connect a D.C. voltmeter between test point 5 and ground on the drive being set.

6-r
 MAIN POWER MAIN ARMATURE
TERMINALS TERMINALS

380 V U C D v

L1 L2 0v

CURRENT LIMIT
POT.

-1
-2 R30
-3
TEST -+
-5 R26
POINTS
-1415 +
-
-76GND
OFFSET - R9 R2s
POT.
OFFSET

COMPENSATION
BOARD 1 6 t2

TACHOMETER TACH,INHIBIT
GAIN POT. AND COMMAND
TERMINALS

Figure 6-1 Axis Drive Unit Connections and Adjustments

6-2
 Press programme start button on pendant and adjust R30 potentiometer on drive until the
voltage reads:

r 4.8 volts for 50 Hz machine

*. 5.9 volts for 60 Hz machine

8. Press programme stop button, alter parameter 77 back to 5, switch off at isolator, remove
the D.C. voltmeter and reconnect wires 5 , 6,7 to overload 3 .

9. Switch on and reference inachine as normal.

Alter machine parameter 37 to ON

The display will alter to 1um resolution. Set display to zEro. Adjust offset potentiometer R9 on
drive until the display figure reads 0.000 or the last figure oscillates from 0 to t 1. Change
machine parameter 37 to off.

10. Change machine parameter 7 to 3O;8 to 30;21 to OFF; and22 to ON. Set up programme
to rapid the relevant axis and set cycling.

With the % override control to fully clockwise adjust tacho. potentiometer R23 on drive until
D.R.O. reading is approximately balanced about 5.000 for both directions.

Alter machine parameter back as previously. 7 to 2;8 to 70;21 to ON; and 22 to OFF.

Drive is now set up.

6.3 CONTROL SYSTEM DESCRIPTIO

The control unit has faciiities for automatic cycling of the machine from the stored programme
and for interlocking of the power feed controls.

It is a closed loop feedback system. This faciliry being achieved using a digital encoder on rhe
rear of each motor.

Boundary parameters such as slide rapid traverse rates, slide lost motion values and software
limits to trayerses must be entered into the cotltrol at machine build and are retained even with
the machine power off by abattery back-up system.

NOTE: Tbe batteries are boused bebind a cooer pldte on tbe front of tbe unit. Batteries must
only be remoaed if tbe macbine power is ON. Otberwise tbe boundaryl parameters are
lost.

6.+ FITTING A NEW CONTROLLER

Before removing the old controller, check that the Machine Software Parameter Record sheet is
correct (this can be found in the door pocket of the electrical cabinet). With the controller in its
manual mode enter the figure 95148 md step through the machine parameter figures using the
cursor button + If necessary amend the record sheet.

1. Switch off the machine and isolate it.

2. Remove the pendant box rear cover to expose the back of the controller. Remove the 110 volt
supply (wire numbers 8 and 9) and earth wires from the 3 way terminal block. After removing

6-3
 the terminal box cover plate gently prise away the 6 terminal strips together with their
associated wiring. Unplug the 4 encoders leads marking them for ease of replacement viz.
top is X oris, second is Y a:<is, third is Z axis (quill), bottom is electronic handwheel. Unplug
the programme storage interface lead and VDU lead.

3. Carefully support the controller and remove the 4 mounting screws.

4. Withdraw the controller from the front of the pendant.

5. Offer up the new controller and whilst supporting it replace the 4 mounting screws.

6. Fit the I amp fuse supplied with the new conuoller.

7. Set the voltage selector on the rear of t}te new controller to 120 volts.

8. Replace the 110 volt supply and earth wires in the 3 way terminal block being careful to
ensure the correct polarity.'Plug in the 6 termind strip connectors.

9. Replace the 4 encoders in their colrect sockets.

10. Replace the programme storage interface and VDU leads.

11. Switch on, the machine will now request Machine Parameters. If not then input 95148 and
press [Eh-l
' l\--lt

12. The control will then display machine Parameters.

13. Enter the values as recorded on the Machine Software Parameter Record.

For oN pt.tt l@land oFF press NO

ENT

6.5 SOFTWARE LIMITS

After changing a feed motor, a feed drive belt, or an axis limit switch it is necessary to reset the
software limits on the a:ris concerned.

Proceed as follows:

1. Switch on the isolator and pass over reference points in the normal manner. If during ref-
erence procedure the control unit displays "Wrong Reference Point" then switch off and
rotate the relevant a:<is motor pulley by 180o on motor shaft and re-reference.

Set the control unit in meuic and reference mode by

REF
and @
2. For the relevant axis only, increase the Machine Parameter below by 5 mm:

For the X a<is increase parameter 31

For the Y a"xis increase parameter 33
For the Z axis increase parameter 35

Using the electronic handwheel, gently feed the axis in the positive direction until it just trips
the extreme limit (i.e. the Power Enable light goes out).

Make a note of the figure on display

64
 To get off the exueme limit, hold down the Power Enable pushbutton while turning the
handwheel.

3. Deduct 0.4 mm from the noted <iisplay figure and enter the result as the Machine
Parameter for the relevant axis.

i.e. Parameter 31 for the X axis

Parameter 33 for the Y o<is
Parameter 35 for the Z axis

Deduct this entered figure from 750.1 for the X axis

from 360.1 for the Y axis
from 125.1 for the Z axis znd

enter the result, as a negative value, for the second Machine Parameter of the relevant axis

i.e. Parameter 32 for the X axis

Parameter 34 f.or the Y a;<is
Parameter 36 for the Z axis

4. Using joysticks, check that axis can be run on to its software limits, in rapid and off again
without operating the extreme limits.

Check that the axis stroke between software limits is at least:

X=750mm
Y=360mm
Z=l25mm
Record the new figures on the Machine Software Parameter Record which can be found in
the door pocket of the electrical cabinet.

6.6 CONTROLLER BUFFER BATTERY REPLACEMENT

r{
When the dialogue display reads "EXCHANGE BUFFER BATTERY" the barteries should be
replaced by new ones as soon as possible. MAINS POWER MUST BE MAINTAINED UNTIL
THIS EXCHANGE IS COMPLETED. The programme memory is supplied by the mains power
supply when the buffer batteries are discharged. Continued operation of the machine is
therefore possible. However, the memory content will be erased in the event of a mains power
failure.

CAUTION: Batteries must be replaced witb mains power supplied to tbe macbine. Failure to
obserue tbis principle will result in a partial loss of tbe executiae software.

The battery compartment which is located beneath the cover plate on the control panel,
contains a special battery carrier. When inserting new batteries, care should be taken that the
polarity conforms to the polariry signs shown on the carrier.

The batteries to be used have IEC designation "LRG" and must be of the leak-proof type.
we especially recommend the use of Mallory Alkaline Batteries Type MN1500.

6-5
o o
o
o o x
AXIS rl

z(,
U
Y o
AXIS r!
z
Ft
C
-l
(,
( Z
o AXIS

o o
HANDWHEEL
ENCODER

VDU CABLE
o

o o
oo o o
o
oo
o fr- o

110 V A.C VOLTAGE TERMINAL PROGRAMME

SUPPLY SELECTOR STRIPS (5) STORAGE
SET TO 12OV INTERFACE
SOCKET

Figure 6'2 Rear of Control System Showing Connections

6-6
I
SECTION VII

BASE ASSEMBLY AND MAINTENANCE

/

7.7 DRIVE BELT REPLACEMENT

7.7.7 X Axis Drive Belt Replacement

To make the task of re-assembly easier the table needs to be towards the left hand end of its
stroke. Depending upon whether the belt is broken or not determines the sequence in which the
job is done.

If the belt is not broken

1. Traverse the machine to the left hand end

WARNING; D/SCONNECT POWER TO THE MACHINE BY THROWING THE MAIN

CIRCUIT BREAKER TO THE 'OFF'POSITION.

2. Remove the eight screws securing the L.H. end table sliding guard and remove. It may be
necessary to remove the fixing screws of the lubrication junction on the rear of the table. Do
not disturb the lubrication fittings.

3. Remove the rwo screws securing the motor bracket cover and remove the cover.

4. Remove the four screws securing the saddle end cover and remove the cover (continued in
paragraph 4).

If the belt is broken

WARNING: DISCONNECT THE POWER TO THE MACHINE BY THROWING THE MAIN

CIRCUIT BREAKER TO THE'OFF' POSITION.

1. Remove the eight screws securing the L.H. end table sliding guard and remove. It may be
necessary to remove the fixing screw of the lubrication junction on the rear of the table .
Do not disturb the lubrication fittings.

2. Remove the two screws securing the motor bracket cover and remove the cover.

3. Remove the four screws securing the saddle end cover'and remove the cover. This gives access
to the leadscrew and the driven pulley. Rotate the leadscrew manually to bring the table to
the left hand end.

4. Remove two screws securing motor cover and remove cover.

5. Support the motor and remove the four screws securing the motor and remove the motor

6. Remove the old belt and refit the new belt on the driven pulley.

7. Refit the motor, inclining the motor to re-engage the drive pulley. Refit the four securing
screws.

I 7-l
 \
8. Adjust the belt tension so it is tensioned by a force of approximately 1 3 5N (3 0 lbf). If no belt
tension meter is available an approximate guide is that at mid position between the pulleys
the belt will deflect 6 mm (7/4") from its mean position when a force of 70N (16 lbf) is I
exerted on the belt.

9. Reset the machine software limits as per Section 7 .6.3 .

7 .1.2 Y Axis Drive Belt Replacement

To ensure that no damage occurs to the Y axis ballscrew during this procedure, two people are
required, one to withdraw the knee front bracket and maintain the alignrr.ent of the assembly,
whilst the second person slips the old belt from the pulley and over the end of the leadscrew
and replaces it with a new one.

WARNING: DISCONNECT POWER TO THE MACHINE BY THROWING THE MAIN

CIRCUIT BREAKER TO THE'OFF' POSITION.

1. Remove the owo neoprene covers on the top of the knee.

2. Remove ttre stop pin on knee front bracket and slide covers forward.

3. Remove the T inspection plate at the rear of the top of the knee.

4. Remove t}re access hole cover on the left hand side of the knee.

5. Remove the motor bracket cover.

6. Remove the motor cover.

7. Slacken the belt tension screw on the motor bracket above the motor flange

8. Support t}le motor and remove the four screws securing the motor and remove the motor
The dowel pin, underneath the tension screw, will be released so make sure this item is
located.

9. Remove the rwo fixing screws from the top corners of the knee front bracket and replace
with two screws 5/16 UNC x 5" long. These new screws will allow the front bracket,
complete with the Y axis ballscrew to be slid forward to give clearance to remove the drive
belt.

10. From the access hole in the knee remove the formed copper lubrication pipe from the top of
the ballnut. Remove the four screws securing the ballnut from its nut bracket.

11. Withdraw the front bracket dowels and remaining fixing screws and carefully pull forward the
front bracket complete with the ballscrew assembly. The second person should guide the rear
of the leadscrew to maintain its position and avoid damage.

12. The old belt can now be slipped off the pulley and clear of the rear of the leadscrew. Fit the
new belt on the leadscrew pulley and relocate the leadscrew in its rear bearing. This bearing
is a shell needle roller bearing and care must be taken to ensure no damage occurs to the
needle bearing or the return tubes of the ballscrew assembly. Ensure the copper lubrication
pipe is not uapped.

1 3. Realign the ballnut and loosely fit the four screws.

7-2

I
4. Refit the screws and dowels securing the front bracket.

5. Rotate the leadscrew anti-clockwise to bring the face of the ballnut hard in contact with the
nut bracket.

6. Tighten the four screws in the nut bracket to a torque of 9 Nm (80lbin) and refit the copper
pipe into the top of the ballnut flange.

7. Refit the motor, inclining to engage the motor pulley in the belt and fit the four fixing
screws, ensuring that the belt tension screw and pin are correctly fitted.

8. Adjust the belt tension so it is tensioned by a force of 135 N (lO lbf). If no belt tension
meter is available an approximate guide is that at the mid point between the pulleys the belt
will deflect 6 mm (114") from its mean position when a force of 70 N (16 lbf) is exerted on
the belt.

9. Reset the machine software limits per section 7 .6.7.

7.2 X AND Y AXIS DRIVE MOTOR REPLACEMENT

7.2.1 X Axis Drive Motor Replacement

WARNING: D/SCONNECT POWER TO THE MACHINE BY THROWING THE MAIN

CIRCUIT BREAKER TO THE 'OFF'POSITION BEFORE BEGINNING THIS
PROCEDURE.

1. Remove the two screws securing the motor bracket cover and remove the cover.

2. Support t}le motor and remove the four screws securing the motor and remove the motor.

3. Remove rear cover from pendant box, and the cover plates from the external cable exit of
the pendant arm.

4. Remove the cable ties from the X a:<is resolver cable and unwrap the spiroband sleeve.

5. Disconnect the X a.xis resolver cable from the rear of the Heidenhain unit and pull the cable
out of the pendant arm.

6. Disconnect the motor wiring to the motor ar the terminal box.

7. Remove the drive pulley and fit to the new motor.

8. Install replacement motor by reversing steps 3 - 6 above.

9. After the motor is installed, set the belt tension as described in Section 7.1.1 item 8. Check
the reference limit as per Section 7 .6.2 and re{et the sofrware limits as per Section T .6.3.

7.2.2 Y Axis Drive Motor Replacement

WARNINGI DISCONNECT POWER TO THE MACHINE BY THROWING THE MAIN

CIRCUIT BREAKER TO THE'OFF'POSITION BEFORE BEGINN/NG THIS
. PROCEDURE.

1. Remove the rwo screws securing the motor bracket cover and remove the cover

7-3
 2t59779 21520t9 1572493 r577592 2152002 1700390 2159716

2t597 36 2152018

21597 39 r57 85 54 t57 7 59

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r57799+ 2t52t9t
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I 879r8t4 700392

879t877
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2159855 2t59853
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Figure 7-1 Table

2L52039 1540530

21597 40

1705559
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L700392

o
1700754

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2159864 2159867
1700335

1553590 t572733

Saddle Arrangement

74
 215200r

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2r52llr t572493 1577592
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21597 38

2t52At6
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2t52l12 2I5OO35 RIGHT SIDE

I 705068 2150036 LEFT SIDE
1705556 2150013

I 2150012
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I Figure 7-2Knee Arrangernent (Sheet I of.2)

I 7-5
 l- -t
1700371 1577592 2t597t7 1572493 lt
l1
Ir
'l-J
'lll

2t52tO7

1700369

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2t52r72 1705086 2L5986t 2t52LO8
t572788 2152078

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- - --1

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Figure 7-2 Knee Arrangement (Sheet 2 of 2)

7-6
 )
2t5027t 2t597+2 110 t7052AO

I
2r5 2L570L8

I
_l

Figure 7-3 Dtal Dial Layout

7-7
 7. Remove the five screws securing the thrust bearing cap and bearing assembly. The ballscrew
assembly can now be withdrawn from the left hand end of the saddle. Remove the bearings
from the ballscrew.

8. To replace a new ballscrew, reverse the disassembly procedure, paying particular attention to
the following:

a. The ballscrew assembly is supplied from the original manufacturer protected in lanolin, and
this must be completely removed. Wash the assembly by completely immersing in CLEAN
white spirit (NOT PARAFFIN) and brushing well. Run the ballnut up the full length of the
screw to ensure complete removal. Allow the screw to drain for an hour and blow dry using a
water-free airline. Lighdy oil with a mineral based lubrication oil (Mobil DTE 24 or similar)
ensuring all moving parts are lubricated. Fit a plastic ball (BM part number 8303822) to plug
the radial lubrication hole not used - refer to the old screw for its correct position.

b. When refitting the axis thrust bearings ensure that the bearings are back-to-back, on Fafnir
bearings, this is with the stamped faces of the outer rings together. To ensure best results the
high points of eccentriciry should be together so ensure the round burnish mark on each
bearing is axially in line. If there is any doubt about the condition of these bearings they
should be replaced.

c. The alignment of the ballscrew with the bedface and master guideway is critical and must be
within 0.050 (0.002") along the full length of the ballscrew. When the screw alignment
requirement has been set tighten the bearing cap screws to 9 Nm (80 lbin). Recheck the
alignment of the ballscrew.

d. Wind the ballnut to the right hand end of the saddle prior to refitting the table. Ensure the
ballnut is positioned with the lubrication hole uppermost, ready to refit the lubrication pipe

e. Always refit the saddle end covers as soon as is practical and never run the machine under
power without the saddle end covers in position.

9. Adjust the X axis belt tension as per Section 7.7.1.

10. Reset the software limits as per Section 7.6.3

11. Set the X axis gib strip and keep plate and check lost motion as per Section 7.9.1

12. Reset the X axis backlash compensation as per Section 7.9.2

7.4.2 Y Axis Ballscrew Assembly Removal

To ensure that no damage occurs to the Y axis ballscrew during this procedure, two people are
required, one to withdraw the knee front bracket and maintain the alignment of the assembly,
whilst the second person removes the pulley and guides the ballscrew from the knee.

WARNING: DISCONNECT POWER TO THE MACHINE BY THROWING THE MA]N

CIRCUIT' BREAKER TO THE'OFF' POSITION.

1. Remove the two neoprene covers on the top of the knee.

2. Remove the drive belt housing cover and handwind the saddle forward.

3. Remove the stop pin on the knee front bracket and slide covers forward

7-to
 4. Remove the T inspection plate at the rear of the top of the knee.

5. Remove the access hole cover on the left hand side of the knee.

6. Slacken the belt tension screw on the motor bracket above the motor flange.

7. Support the motor and remove the four screws securing the motor and remove the motor
The dowel pin, underneath the tension screw, will be released so:nake sure this item is
located.

8. Remove the two fixing screws from the top corners of the knee front bracket and replace
with two screws 5/16 UNC x 5" long. These new screws will allow the front bracket,
complete with the Y axis ballscrew to be slid forward to give clearance to remove the drive
belt.

9. From the access hole in the knee remove the tormed copper lubrication pipe from the top of
the ballnut. Remove the four screws securing -"he ballnut from its nut bracket.

10. Measure and record the distance from the ballscrew pulley to the bearing housing. On
re-assembly this figure will be used to fix the pulley in its original position. Release the taper
lock holding the pulley.

11. Withdraw the front bracket dowels and remaining fixing screws and carefully pull forward the
front bracket complete with the ballscrew assembly. The second person should guide the rear
of the leadscrew to maintain its position and avoid damage.

12. The drive belt and pulley is now slid off the rear of the leadscrew. Support the front bracket
and remove the rwo support screws. The ballscrew assembly can be withdrawn from thc'. frcnt
of the knee. Disassemble the ballscrew from the front bracket.

1 3. To replace a new ballscrew reverse the disassembly procedurc, paying particular attention to
the following:

a. The ballscrew assembly is supplied from the original manufacturer protected in lanolin, and
this must be completely removed. Wash the assembly by completely immersing in CLEAN
white spirit (NOT PARAFFIN) and brushing well. Run the ballnut up the full length of the
screw to ensure complete removal. Allow the screw to drain for an hour and blow dry using
a mineral based lubricating oil (Mobil DTE 2+ or similar) ensuring all moving parts are
lubricated. Fit a plastic batl (BM part number 8303822) to plug the radial lubrication hole
not used - refer to the old screw for its corect position.

b. When refitting the axis thrust bearings ensure that the bearings are back-to-back, on Fafnir
bearings, this is with the stamped faces of the outer rings together. To ensure best results the
high points of eccentricity should be together so ensure the round burnish mark on each
bearing is axially in line. If there is any doubt about the condition of these bearings, they
should be replaced.

The fixing screws on the bearing cap should be tightened to a torque of 34 Nm (25 lbft).

c. As long the rear bearing remains untouched in the knee, the alignment of the ballscrew
as
should be maintained. If the alignment is lost then it is necessary to remove the saddle, as
described in Section 7 .3.2 and the alignment reset. The alignment of the ballscrew with the
bedface and master guideway is critical and must be within 0.030 (0.0012") along the full
length of the ballscrew. Recheck the alignment when the fixing screws have been tightened.

7-tt
14. Adjust the Y axis belt tension as per Section 7.1.2.

15. Reset the software limits as per Section 7 .6.7 .

7.5 AIR ASSIST PEDESTAL

7 .5.1 Removal

NOTE: Due to tbe requirement for tbe cylinder to be air tigbt, tbe cylinder sleeoe is
considered an integral part of tbe pedestal assembly and is remoaed as a unit.

1. Raise the knee to a sufficient height (not the total trarrel) to allow access to the pedestal and
elevating nut. Lock the knee in that position and in addition support the knee with a rope
sling.

CAUTION: Tbe assembled knee weigbs 8't5 kg (i930lb). Use aPpropriate care to preoent
equipment darnage and personal injury.

2. Discharge the air from the cylinder and disconnect the air hose and lubrication line from the
top of the pedestal.

3. Remove the screws securing the leadscrew nut mount from the pedestal

4. Hoist the knee to full travel height, pulling the leadscrervr/ out of the pedestal along with the
oacking cup, packing retainer, leadscrew bumper, thrust bearing and bearing retainer.

5. Remove the two pedestal mounting screws and remove the pedestal from the base

7 .5.2 linder Gasket Removal

1. Raise the knee to a position close to the topmost working position. Lock the knee in that
position and in addition support the knee with a rope sling.

CAUTION: Tbe assembled knee ueigbs 875 kg (19301b). Use dppropridte care to preaent
equipment damage and personal injury.

2. Remove the pedestal mounting screws and handwind the elevating screw to withdraw the
pedestal from the base to gain access to the bottom fixing screws.

3. Remove the screws securing the cylinder bottom cover and replace the cylinder cover gasket.

4. To assemble reverse the disassembly proc(dure.

7 .5.3 Packing Cup Replacement

1 . Remove the pedestal as described in Section 7 .5.1.

2. Remove the screws securing the packing retainer, remove the retainer and packing.

3. Replace with Bridgeport supplied packing (BM part number 2152721).It is important that
this packing has been soaked in a mineral based lubricant (Mobil DTE 24 or equivalent) for
at least 12 hours prior to assembly. Care must be taken to ensure that the coil spring is in
position during assembly.

7-72
1 7003 88 1705556
2150012 2150013
1720549
2152737
2150554

21500t4
2.157018
2159700
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1515I59 HOSE FITTING

2t552tt
I5I5I60 HOSE FITTING
I5IO253 VINYL TUBING 2L52tt9
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Figure 74 Elevating Screw Assembly

7-73
 7.6 LIMIT SWITCH REPLACEMENT

7.6.1 X Axis Extreme Limit Do

The available stroke of the table is determined by the software limits set in the machine control.
The extreme limit dogs exist only as an additional safeguard to shut off power to the axis drive
in the event of a control or drive malfunction which causes the table to go outside its software
limits.

1. In order to set the extreme limit dogs it is necessary to override the software limits.

Change machine paxameter 31 to +1000

Change machine parameter 32 to -1000

CAUTION: Tbe X axis software limits are nou inactiae. Use the bandwbeel only. Approacb the
ballscrew positioe stops at d creep feed rate.

2. Using the handwheel, position display and the power enable lamp, set the dogs to give an axis
suoke of 7 5l mm to 7 52 mm central to the traverse between positive ballscrew stops.

3. Reset the X axis reference dog as per Section 7.6.2.

4. Reset the mechine software limits as per Section 7 .6.3 .

7.6.2 X Axis Reference Dog

The axis reference dog is used in conjunction with the encoder on the motor shaft to determine
the machine datum following an intemrption of mains power.

1. When resetting the reference dog first temporarily set it to operate between 8 mm and 10 mm
before the extreme .

2. Switch off the main isolator. Switch on the machine isolator and pass over the axis reference
points as normal.

3. Place the control in reference mode by pressing the key and then
REF
@
4. Re-adjust the axis reference dog to operate the reference switch at between -1.0 mm and
-1.5 mm as read on the position readout display.
5. Reset the machine software limits as per Section 7 .6.3 .

7.6.3 X Axis Software Limits

After changing a feed motor, a feed drive belt, or an axis limit switch, it is necessary to reset
the software limits.

1. Temporarily override the software limits

Chaage machine parameter 35 to +1000

Change machine parameter 36 to -1000

CAUTION: Tbe X axis software limits are now inactiae. Use the bandwbeel only. Approacb tbe
ballscrew positioe stops at a creep feed rate.

7-74
 2. Place the control in reference mode by pressing the key ancl then
REF
@
3. Slowly handwind the axis and record the position display figure as the positive extrerne limit
switch just operates.

4. Deduct 0.4 mm from the reading, to obtain the positive software limit figure.

5. Deduct 750.i mm from the positive software limit figure to obtain the negative software
limit figure "

6. Enter these values as follows'

Machine parameter 31 Positive software limit (X a<is)

Machine parameter 32 Negative software limit (X axis)

7. Using the joystick in rapid, check hat the table can be run onto its software limits, and off
again,without tripping the extreme limits.

8. Exit from the control reference mode by pressing then

REF
@
9. Check that at least 750 mm of stroke can be achieved

10. Record the new software limits on the Machine Software Parameter Record which may be
found in the door pocket of the elecuical cabinet.

7.6.4 X Axis Limit Switch Replacement

To remove an X axis limit switch (located on the rear surface of the saddle) turn off the power
and proceed as follows,

1. Remove the bottom cover plate from the limit switch.

2. Unscrew the large hexagon nut(s) on the electrical cable connection and disconnect the cable
from the limit switch.

3. Remove the t'wo screws securing the limit switch to the mounting plate on the saddle.

Install the new limit switch by reversing the above procedure. Verticd adjustment of the limit
switch may be achieved by slackening the two screws securing the mounting plate to the
saddle.

NOTE After installation of tbe limit switcb cbeck the X avis reference dog adjustment ds per
Section 7.6.2 steps 2 to 5. If necessary,reset tbe X axis ercfieme limit dogs as per
Section 7.6.1.

7.6.5 Y Axis Extreme Limit Dogs

The available stroke of the saddle is determined by the software limits set in the machine
control. The extreme limit dogs exist only as an additional safeguard to shut off power to the
axis drive in the event of a control or drive malfunction which causes the table to go outside its
software limits.

1. In order to set the extreme limit dogs it is necessary to'override the software limits.

7-15
 Change machine parameter 33 to +1000
Change machine parameter 34 to -1000

CAUTION: Tbe Y axis software limits are nou inactioe. Use tbe bandwbeel only. Approacb tbe
ballscrew positioe stops at a creep feed rate.

2. Using the handwheel, position display and the power enable lamp, set the dogs to give an axis
stroke of. 361mm to 362 mm central to the traverse between positive ballscrew stops.

3. Reset the Y axis reference dog as per Section 7.6.6.

4. Reset the machine software limits as per Section 7.6.7

7.6.6 Y Axis Reference Dog

The axis reference dog is used in conjunction with the encoder on the motor shaft to determine
the machine datum following an interruption of mains power.

1. When resetting the reference dog first temporarily set it to operate between B mm and 10 mm
before the extreme.

2. Switch off the machine isolator. Switch on the machine isolator and pass over the axis
reference points as normal.

3. Place the control in reference mode by pressing the 8EF key and then

4. Re-adjust the axis reference dog to operate the reference switch at between -1.0 mm and
-1.5 mm as read on the position readour display.
5. Reset the machine software limits as per Section 7.6.7.

7.6.7 Y Axis Software Limits

After changing a feed motor, an encoder, or feed drive belt on an axis limit switch, it is
necessary to reset the software limits.

1. Temporarily override the software limits

Change machine parameter 35 to +1000

Change machine parameter 36 to -1000

CAUTION: Tbe Y axis software limits are now inactiae. (lse tbe bandwheel only. Approach tbe
ballscreu positioe sto")s at a creep feed rate.

2. Place the control in reference mode by pressing the key and then
REF

@
3. Slowly handwind the axis and record the position display figure as the positive extreme limit
switch just operates.

4. Deduct 0.4 mm from the reading, to obtain the positive sofrware limit figure.

5. Deduct 360.1 mm from the positive software limit figure to obtain the negative sofrware
limit figure.

7 -76
6. Enter these values as follows

Machine parameter 33 Positive software limit (Y axis)

Machine parameter 34 Negative software limit (Y axis)

7. Using the joystick in rapid, check the saddle can be run onto its software limits, and off again
without tripping the extreme limits.

8. Exit from the control reference mode by pressing then

REF
@
9. Check that at least 360 mm of stroke can be achieved

0. Record the new software limits on the Machine Software Parameter Record which may be
found in the door pocket of the electrical cabinet.

7.6.8 Y Axis Limit Switch Replacement

To remove the Y axis limit switch (located underneath the saddle at the right hand side of the
knee ) turn off the power and proceed as follows,

1. Remove the cover plate from the rear of the limit switch.

2. Unscrew the large hexagon nut on the electrical cable connector and disconnect the cable
from the limit switch.

3. Remove the two screws securing the limit switch to the mounting plate on the saddle

Install the new limit switch by reversing the above procedure.

Adjustment of the limit switch may be achieved by slackening the two screws securing the
mounting plate to the saddle.

NOTE: After installation of tbe limit switcb cbeck the Y axis reference dog adjusnnent as per
Section 7.6.6 steps 2 to 5. If necessary reset tbe Y axis ex*eme limit dogs ds per
Section 7.6.5.

7.7 LUBRICATION

7.7.7 X, Y and Z Axes

The table, saddle and head quill are lubricated by an automatic system that operates whenever
the power enable lamp is lit.

The oil reservoir and pump are located in a cabinet at the rear of the machine column.

A float switch in the oil reservoir prevents restart of the feed drive if the oil level is too low.

NOTE: Tbe switcb will not stop the macbine while it is in operation but it will protect against
startin g witb ou t su ffi c ie n t lu bric ati on.
re

Oil distributors for the table and saddle are located inside the saddle and can be exposed by
removing the table. For instructions on table removal see Section 7.3.1. Oil distributors for the
head quill are located on the left side of the column.

7 -17
 SIDE ELEVATION
POSITION OF LIMIT SWITCH
ON SADDLE AND TRIP DOGS
ON SIDE OF KNEE I

2L52028
q

L7OO475 (4)

17034OO (3)
lO - 32 UNF x 5/8"
HEX HD SCREWS

8791850
t705603
3/16" WASHER (3)
L70034
1/4" UNC x 518"
SOCKET CAP SCREW
ll r.
21598s9 (2)

1700355
1/4" UNC x 314"
SOCKET CAP SCREW
2152003
SADDLE

17005604 (4)
1/4" WASHER

Figure 7-5 Limit Switch & Trip

 DOGS ON SADL.'-

1705603 (3)
2r598s7 (2) 2159859 Q) 3/r6" WASHER

1703400
LO - 32 UNF x 5/8" HEla ;:D. (3)
2t59858

1700+7 2152045 (2')

I
5

@ @ lO-32 UNFx 1"

SOCKET CAP SCREW

879L85
STOP (3)

2159858

1553672 t70560+ 1/4" WASHER (2)

LIMIT SWITCH
1700355
1/4" UNC x 314" SOCKET CAP
Dog Arrangement scREw (2)
I

7-78
I

80L464L
s.S
802801 1

\
2L59897
\ t702589
156t77t

r570687
r570655

8300207
1700471
15702t8 t57 5269
15r5165
REGULATOR
'A' t570655
8300623
830365 3 1570687
t705623
t570567
r570565
8303879 t5t517l
I L561770
I
I
15 10502 8303607
I t570640 8303617
t570768 t700471
t r570625 t579740
I
t I

I
l
!
8303628

t700357
1561785
8303874
r570548
I I
8 303605 REGULATOR
I
T I

I
I

I
I
It r 5 10504
'B'
I
r570628
I

I
.// r570644
15 70800 8028001
I
1703 181
J 2159894

I 1701597
t705039

r57 5246
15 10501 1700353
t700357 2t59898
8303607 1701038 NOTE:
83036t7 1515161 +6+90LO 17050+3 REGULATOR'A'TO BE SET AT 80 p.s.i.g.
8303629
t570549
1705605 REGULATOR'B'TO BE SET AT 4O p.s.i.g.
157 5279
Figure 7-6 Layottt of Services

7-19
T

I 8303604 8303604 8303627 LUBRICATION ITEMS NOT ANNOTATED

8 3036r 5 METER UNIT FJB{O
rf_ f.i 830360r
8303603
METER
METER
UNIT FJB{
UNIT FJB-1
I
830t628 UNIT FJB-2
,r -I
_. I METER
8 30 3821 CLOSURE PLUG
I 8303607 COMPRESSION BUSHING

l
L- '--l- 8303606
830361 3
COMPRESSION SLEEVE
DRIVE BUSHING

t57 5297 -
ir tol oo+

8303612
157 5290 -1
8303627
It
+ e ce

t r57 5292 \
+ctt
I

T t- 8303604 8 30 3608
+ ++
I I
+

I \

\
\ I

_)
\ I

t _l

Figure 7-7 Knee Lubrication System

7-20
CA\ITION: Use only Mobil Vacta No. 2 or equioalent to ensure max'imum effectiueness of tbe
lubrication system.

All other moving parts such as bearings, gears etc., are prepacked with lifetime grease at the
factory and should not require further servicing for their full service life.

7.7.2 Knee Lubrication

The knee ways are lubricated by automatic system from a distributor located inside the knee.
External feeder hoses are attached to the left side of the knee. All bearings are greased for life
Lubrication of the knee elevating screw is through a grease fitting at the top of the pedestal.

7.8 X AND Y AXIS GIBS

7 .8.1 Adjustment of Table and Saddle Gibs

At the factory all the gibsare given an initial setting, the machine is cycled for approximately
50 hours and then the gibs are given a final setting. Therefore they should not require
re-adjusting if proper maintenance of automatic lube system is provided. In the event that gib
adjustment is required, however, proceed as follows in Section 7 .8.2 or 7 .8.3.

7.8.2 Saddle to Table Gib Setting (see Figure 7-8)

1. Set up indicators in position no. 1.

2. Push end of table and release, pull end of table and release. Note the total indicator reading
less the spring back.

3. Adjust the gib, by turning the adjusting screw to obtain a maximum indicator reading (less
spring back) of .0005".

4. After gib is set, move indicator to position no.2.

5. Push and pull on end of the table. Note the total indicator reading less spring back.

6. Total indicator reading in position no. 1 (after gib is set) should equal the total indicator
reading in position no. 2 within.*- .0002", if not, remove and scrape the gib and repeat
setting.

7. Check lost motion as per Section 7 .9.1.

7.8.3 Saddle to Knee Gib Setting (see Figure 7-9)

1. Move the saddle to position no. I and set up indicator.

2. Push the end of the table and release, pull the end of the table and release. Note the total
indicator reading less spring back.

3. Adjust the gib by turning the adjusting screw, to obtain a maximum indicator reading less
spring back of .0005".

4. After the gib is set, move the saddle to position no. 2 and set up the indicator.

5. Push and pull on the end of the table. Note the total indicator reading less spring back.

7 -21
 PUSH & PULL
FORCE ON
TABLE
TABLE

SADDLE
a

I
POSITION NO.2 POSITION NO. 1

t
INDICATOR SET-UP:
330 mm mm INDICATOR ON TABLE
BASE ON SADDLE
(13") (13")
Figure 7-8 Saddl' able Gib Setting

POSITION NO. 1 POSITION NO.2

SADDLE IN FULL BACK SADDLE,IN FULL FRONT
POSITION ON KNEE POSITION ON KNEE
fa;
'r-

PUSH & PULL

FORCE ON
TABLE
SADDLE

KNEE

Figure 7-9 Saddle to Knee Gib Setting

INDICATOR SET-UP:
TNDTCATOR ON SADDLE 7-22
END BASE ON KNEE
6. The total indicator reading in position no. 1 (after the gib is set) should equal the total
indicator reading in position no. 2 within i .0002", if not, remove and scrape the gib and
repeat the setting.

7. Check lost motion as per Section 7.9.1

7.8.4 Knee to Column Gib Setting

1. Remove the way wiper cover (3005096) and wiper (3005099) to expose the knee to column
gib.

2. Manually, using the crank handle, raise and lower the knee and turn the adjusting screw
(8005088) until a smooth movement is attained.

7.9 LOST MOTION AND BACKLASH COMPENSATION

NOTE: ln serting tbe gib stripS. extrente, cgre.must b'e taken to ensure tbat tbey are not ooer-
tigbtered o* i':r *i ' axis stdlls may occur; similarly if tbe grb sffips are left too
slack,lostntolit:,,, - )ot sE Jnce j;.:'ish andpoorrepeatability may result. Itis essential
tberefore tbat, wben adjusting tbe gib stips, tbe correct procedure is followed, and
lost motion is checked to ensure tbat tbe optimam settingbas been acbieoed. Lost
rnotion should be less tban .025 mm (.001"); if tbis fiyrt is exceeded, slacken the gib
strtp btt one quarter of a rurn and recbeck. It sbould also be noted tbat lost motion
may be promoted if an inappropriate slideway lubicant is used.

7 .9.7 To Check Lost Motion

Pre-requisites

1. Gib strips set as perSection 7.8.1 ,7 .8.2 or 7 .8.3 .

2. Zerc backlash compensation has been entered into the TNC software parameters 39 f.or X
axis or 40 for Y axis. (Follow procedure as per Section 7.9.2, but enter zero).

Equipment

Dial gauge (reading to .002 mm or better and having a travel greater thalrr 2 mm), clock stand
with magnetic base.

Measurement procedure

1. Apply knee locks.

2. Move the axis to be checked to its mid position.

3. Atign the dial gauge along the a^:<is to be checked as shown in Figure 7-8 or 7-9.

4. Using handwind, bring the dial gauge into contact with the quill and move to the mid stroke
of the gauge.

5. Zero the axis DRO and the dial gauge.

6. Using manual data input, move to +1 mm at a feed rate of 1000 mm/min and back to 0.
Check that the DRO reading is zero, and note the dial gauge reading (ignoring the sign).

7-23
7. Rapid to -1 mm and back to 0.

8. If the DRO does not read zero, or the dial gauge reads zero within .002 mm repeat steps 5 to
7.

9. Enter backlash compensation into the control unit as per Section 7 .9 .2. The lost motion
should not exceed 0.025 mm (.001").

7 .9.2 Backlash Compensation

The lost motion remaining after the above gib setting procedure has been followed, may be
virtually eliminated by means of the backlash compensation facility built into the control.
To compensate for backlash, proceed as follows,

1. Measure lost motion as per Section 7.9.1above.

2. In manual mode, key in 95748 and ENTER.

Screen displays "Machine Parameter 0".

3. Key in 39 GO TO.

Screen displays "Machine Parameter 39".

4.Kq in value of X axis lost motion (expressed in mm) and ENTER.

5. Page to line 40 and enter Y axis lost motion.

6. Page to line 41 and etter Z axis lost motion.

OEL
7. Press o and the parameter indication will go out.

8. Record the new figures on the Machine Software Parameter Record which can be found in
the door pocket of the electrical cabinet.

7-2+
 SECTION VIII

SERIES II INTERACT 2 HEAD ADJUSTMENT AND MAINTENANCE

(Refer to Figures 8-2,8-3 and 8-4)

8.1 LUBRICATION

All bearings and gears in the head are lubricated for life, bearings and quill feed pinion with
BRB lifetime grease and back gears with Sunoco No. 741 E.P. grease or Mobil Lux No. 1 E.P.

The automatic lubrication system used to lubricate the table, saddle and knee also lubricates the
ball quill extension. The reservoir should be filled periodically and is located in a cabinet at the
rear of the column. Mobil Vactra No. 2 or equivalent should be used.

The HI-LO sleeve is connected to the automatic lubrication system and therefore needs no
special attention.

8.2 POWER TRANSMISSION

8.2.7 Resetting Speed Control

NOTE: Excess uear on tbe Vari-drioe beltwill cause a sligbt increase in acrual speed as
compared to tbdt sbown on tbe dial. Tbe speed control can be reset b)/ tbe follouing
procedure:

turn the variable speed control snugly against the high speed stop
1. With the spindle rotating,
(3750 readingon dial). Loosen the jam nut (8300351) and turn the adjusting screw
(8025526) at the top of the head. Using a tachometer set the spindle speed at 3750 r.p.m.
Tighten the jam nut.

2. Loosen the acorn nut (8300365) in the centre of the speed dial (8025517) a;nd reposition the
dial to match the tachometer reading. Tighten the acorn nur.

|';OTE: Wben tbe belt is worn to the e?ctent tbat accurate speed adjustment is no longer
possible, tbe belt must be replaced, per Section 8.2.4.

8.2.2 Head Removal

1. Disconnect power to the machine and remove the electrical cable from the motor. This dis-
assembly is done at the motor by removing the cover of the electrical connecrion box and
disconnecting the wires. Be sure that the wires are properly labelled to ensure correct
reassembly.

2. Remove the quill feed motor as per Section 8.3.2

3. Remove two screws from the push button housing (3730063).

NOTE Oil is likely to dip out from under coaer (8050233). Tbis oil sbould be discarded and
need not be replaced upon reassembly.

4. The wires should be disconnected from the microswitches.

NOTE: Refer to tbe wiring diagram for reassembly

8-1
 5. Remove two screws which support the right hand cover and joystick housing (8797904) and
put the cover out of the way.

6. Disconnect the nylon tubing that comes out of the back of the ram from the centralised
lubricator and its hose clamp.

7. From under the previously removed cover (8791904), pull the nylon tubing through the ram,
coil and tie.

NOTE: To retbread tbe nylon tubing, remoae tbe nameplate on eacb side of the ram.

8. Remove the two screws retaining the left hand side cover (8050165) and place this cover,
complete with the push button housing, out of the way.

NOTE: Tbe bead sbould now be clear of all elec*ical connections.

9. Attach the head lifting tool (ST{921) to the belt housing bearing cap (8025601) using three
Y+ - 20 x .7 50 screws. The loop in the lifting tool should be over the centre of gravity of the
head.

10. Support the head by an overhead hoist through the loop of the lifting tool

11. Remove the remaining four bolts that secure the head to the ram.

12. After reassembly trammel the spindle and set'

a. Quill drive belt as per Section 8.3.3.

b. Extreme limit switches as per Section 8.4.1.

c. Z axis reference switch as per Section 8.4.2.

d. Z axis software limits as per Section 8.4.3.

8.2.3 Motor Removal

1. With rlre motor running, adjust the variable speed control to the top of the speed range. The
speed changer should be adjusted into the red zone and until the mechanical stop in the speed
changer is reached. This adjustment may be made in either the high or low speed range. The
variable speed belt is now in the proper position for motor removal.

CAUTION: The speed range adjustrnent is oery important.

2. Shut down the motor.

3. Disccnnect power to the machine and remove the elecuical cable from the motor

4. Remove the head, per Section 8.2.2.

r. -5. Remove the motor pulley cover (8050195).

8-2
 I r ' - r

2J-601 CAP 802560I 2J-587 BRC 8025587

sT-l60 SCREW (l) 83oO160 2J-552 S WASHER 11|o25552

2J-555 RET R|NC 8025555

2J-5O7 PLA^|E REF 8O25507
-7 sizs33
I
2J-588 BRG 8025588 2J-sO5 HOUSTNG 8025505 I
2J-546 SLEEVE (2) 8o2s546 2J-533 PULLEY Aoal}'+a --J
2J{6s BUSH (2\ EO2s665 sr-1935 scR (2) 83o1935 2)-663 (1-t8-2l22) KEY 8025663
2J-551 RET RING 6025553
B:ofZ13 2l'668 BELr 8e.566&
- zl-s34 PULt.EY 8025534
77-0164 BI)LT HSG 8050164 2l-536 KEy 8o2s536
2J-506 CAP 8025506
2J-s88 BRG 8025588
sT-159 SCR (2) 8J00159
77-0163 BEL7. HSG BASE 8050163
2J-5lO SPACER (l) 802553O
774162CBAR HSG 8050162 2)-707 HUB 8025707
BELT 8303791

2J-513 SLEEVE 8025513

77.0192 PLATE 8050192

sT-499 S H.C S (4) 880499
sT-1919 SCR (4) 83ol9l9
J-t 18 WASHER (4) 80073 18
77.0161 MOTOR MTG BRKT
8050161

sT-I67 S.H.C.S. (4) 810O167 JUNCTICN 81O36M

sT-I925 WASHER (4) 83o1925 coMP BUSH (l) r130J607
r-19-196s WASHER (4) coMP SLEEVT (4) 8l0l6l7
I
I
ELBOW I i03608
NYLON TUBiI.!G 8303603
COPPER 7 UPIN(, 83O36IO
,AA sr-soo B.rr c s 8ioo566
METER UNI'I 830360T
CCMP NUT 830J506

sT-157 S.H.C.S (2) 83oot57

77{1A2 ItIIACKET 8050i82
,'N swt rcH 8o758o9
sT.l(r4r R H M S (2) 8101941
r-()1 i961 WASHER (2) 8301943
1'66-i458 WAST]ER (2) 83Ul944
s1'-33r NUT (2) 83ool36

BOL1 i )i 5897
r551205 MOTOR sT-19i IU't 8iOl931
83Ot925 WASHER (4)
ST i57 I .l C-S.83oo157
8300167 S.H.C.S. (4) 77 018: HOE 8050187

swtT(rF 2) 8o75105
sT-194' l H M.S. (4) 8301941
El r-01-r' WASHER (4) 8301943
\ 1-66-54 , wAsrrER (4) 8301944
oa sT,336 JUT (4) 83OO336
d
Ft
.D
77-018t |RK'r (2) 805o1Es
o sr-158 'r.c s. (4) 830o158
I o
3
ods EI
r4). ' oc

o
Fl _T
o. I

a
o
rD +
E
77-O191 CONTROL COVER 8050191
GASKET 830395 1
1-77-0216 H.H B (4) 8301946
sT-1075 WASHER (4) 830lO75
21 59865 COVER
1700365 SCREW (2)

8791808 PULLEY
8791816 PLATE
t7oo337 (4) SCREW
77O5552 (4) NYLTITE INSERT

I +

77-0166 COVER 8050166

sr-1914 s H c s. (1) 83o1e34
8050165 COVER ST-164 S-H C.S. (l) 830o1rr4
8301934 S.H.C.S.
8300164 S.H.C.S. 77-0159 QUtLr. HSC 8050159

2-20-OtO2 THUMB SCR 81109051

BLOCK 8050264

1-01-1O36 (2)S H CS 83O0162

' ,-t- i 77,0218 ROD 8050218

i,"gz<'t
 I

NOTE Tbis drawing is provided for field fabrication of tbis

part.

83 mm
(3.281")

# H DRILL (3)
oc
r-t
,!
o 10 mm
(3 /8"1
o I
co WELD
t''J
(A
(a
o 96 mm
F: (3.789")
-l 32 mm 121 mm
o (7 t/4")
o (4 3t+")
@u)
L*I
o( 48 mm
\o
fJ (1.995")
o 44 mm
F)
o- (7 3/4") 6mm
t- (t/+")
Fb
d
mm
EE
rl
F:
n
7f
o
.+
101 mm
16 mm (4")
(5 /8") 32 mm
_+
(7 u4")
124 mm
(4 7 /8")
NOTE: If step (1) was done correctly tbe drioe belt (5025668) will ride towards tbe outside
edge of tbe pulleys (7012642 and 7012643). If tbis condition does not exist,
reassemble tbe bead and repeat step 1.

6. Remove retaining ring (8300610).

7. Loosen the socket ser screw and remove pulley (7012643). Be prepared for the pulley to
spring up approxim ately ahalf inch when the socket screw is loosened.

8. Compress t}re lower pulley (70126+2) on the motor shaft until the oressure is relieved from
the rltaining ring (8050084), and remove the ring. Lift the lower rulley assembly (7012642)
(comprisingp"Uey IAOZS 642),compression spring (8025661) .-i'., collar (8025664)) off the
motor shaft.

9. Support the motor and remove the t'wo screws (8301930) that secure the motor to the
variable speed housing. Remove the motor from the housing.

CAUTION: Tbe motor weigbs approximately 28 kg 60lb). Take aPpropriLte precautions to

preoent equipment damage and possible personal iniury.

NOTE Reassembly witl be dccomplisbed by reoersing tbe disassembly procedure. Retaining

ring (8050084) is easily damaged on remoaal and may need replacement. Difficulty
may be encountered wben assernbling pulleys. First work tbe belt as far forward
towards tbe cente of tbe drioen pulleys (5025533 and 8025534) as possible. Next,
work tbe belt as far as possible towards tbe peripbery of tbe driae pulleys (7012642
and 7012643). Witb band pressure and a small plastic mallet,lower pulley (7012643)
until retdiningring (5300610) may be assembled.

8.2.4 VariDrive Belt lacement

control to thc top of the speed range. The

1. With rhe moror running, adjust the variable speed
speed changer should be adjusted into the red zone and rintil the mechanical stop in the speed
changer is reached. This adjustment may be made in either the high or low speed range.

2. Shut down the motor.' n

3. Disconnect power to the machine.

4. Remove the motor pulley cover (8050195).

5. Remove retaining ring (8300610).

6. [,oosen socket ser screw and remove pultey (7012643). Be prepatGh8or the pulley to spring
up approximately half an inch when the socket set screw is loosened.

7. Remove the top bearing cry (8O25601) and the two screws (S301935) and two bushings that
secure the speed changer plate (8025507) to the bearing housing (8025505).

8. Remove the two screws under the speed changer dial that secures the speed changer housing
(8050176) to the belt housing base (8050163).

9. Remove rhe screws ((2) 830014+ (l) AiOOf g3) securing the belt housing (8050164) to the
belt housing base (3050163). The belt housing is now held in place by two taper pins.

8-5
10. Lift the belt housing, with the speed changer bracket attached, off the taper pins and separate
it from the belt housing base. To facilitate this step, tap upward on the speed changer housing
(8050176) with a plastic mallet. Several blows may be necessary to loosen the two housings.

11. Remove the old belt and replace it with a new one.

CAUTION: Do not substitute a belt purcbased from otber tban a Bridgeport dealer. Vibration
and ooerbeating could result from the use of a wrong belt.

NOTE Reassembly will be accornplisbed by reaersingtbe disassembly procedure. Difficulty

may be encounterc'| wben assemblingpulley (7012643). First work tbe belt as far
toward tbe centre tttiib; e.drioen pulleys (8025533 and 8025534) aspossible. Next,
work tbe belt as far a.. possible toward tbe peripbery of tbe drfue pulleys (1012643
and 7012642). Witb band pressure and a small plastic rnallet,lower pulley (7012643)
until retaining ring (8300610) may be assembled.

8.2.5 Timing Belt Replacement

1. With the motor running, adjust the variable speed control to the top of the speed range. The
speed changer should be?djusted into the red zone and until the mechanical stop in the speed
changer is reached. This adjustment may be made in either the high or low speed range.

2. Shut down the motor

3. Lower the quill.

4. Disconnect power to the machine.

5. Remove the motor pulley cover (8050195).

6. Remove retaining ring (9300610).

7. Loosen socket set screw and remove pulley (7012643). Be prepared for the pulley to spring
up approximately one half inch when the socket set screw is loosened.

8. Compress the lower pulley <lOtZe+Dlt )nd remove retaining ring (8050084).
t,
NOTE: This retaining ring is easily darnaged and may need replacing.

9. Lift the lower pulley assembly (70126+2) comprising pulley (8025642), compression spring
(8025661) and the collar (8025644) off the motor shaft.

10. Put the HI-NEUTRAL-LO lever on the right side of the head in the LO position.

11. Remove the two lower screws (8300612) in the speed changer housing (8050176).

12. Remove the two screws (8300168) and three screws (8301937) holding the belt housing
base (80501 63) to the gear housing (8050162). There are two dowel pins still holding these
parts together. To facilitate this step, tap upward on the speed changer housing (8050176)
with a plastic mallet. Several blows may be necessary to loosen the two housings.

13. The two upper screws (8300612) on the speed changer housing should be loosened after the
belt housing has been loosened from the gear housing.

8-6
 IIIIIII
sT-2r3 SSS REF 8300213

774020 KEy REF 8050200 77{I8I PULLEY REF 8O50181

2159865 COVER

L.HS COVER 8050165 @

66-5897 STOP BOLT REF 8075897

ST-1931 HEX NUT REF 830193I
,t
HINGE 8080065
'.::.,IYIf

553589 JOYSTICK
77-O187 SHOE REF 8050187
s'f-I57 SHCS REF 8300157

VIEW C{ Z.AXIS ASSEMBLY 8780063 COVEE

I

TAPER PrN (4) 8025677

"J477

77Arc4BEUI HOUSING REF

El 8050164
oa
d
>.t
o
oo
I

N
co
{
I
t<
lh
774163 RELT HOUSING BASE
REF 8050163
lu
o
-
77.OI62 GEAR HOUSING
8050762

sT-227 SSS J140 GE i, {

8

77-0184 ADJ. SCREW

8050180

ST{7 KEY
J r44 GEAR REF 8300067
8007t44
-1 -,.i

77-0159 HSG. REF

VIEW D.D HEAD ROTATION ASSY 80501 5 it
14. Gendy disengage the timing belt (8303791) from pulley (8O257O7) as the belt housing is
being raised.

15. Remove the old belt and replace with a new one.

NOTE Reassembly will be accomplisbed by reoersing tbe disassembly procedure. Dfficulty

may be encountered wben assembling pulley (7012643). First work tbe belt as far
toward the centre of tbe drioen pulleys (8025533 and 8025534) as possible. Next,
work tbe belt as far as possible toward tbe peripbery of tbe drioe pulley (7012643
and 701264D. Witb band pressure and a small plastic mallet,louer pulley (7012643)
until retdining ring (8300610) may be assembled.

8.3 QUILL AND SPINDLE

8.3.1 Quill Drive Motor Replacement

WARNING: DISCONNECT POWER TO THE MACHINE BY THROWING THE MAIN

,OFF,POSITION BEFORE BEGINN/NG THIS
CIRCUIT BREAKER TO THE
PROCEDURE.

1. Remove the nvo screws securing the motor pulley cover and remove the cover.

2. Slacken, but do not yet remove, the four screws holding the drive motor to the motor
mounting housing.

3. Slide ttre timing belt (8800072) off the motor pulley.

4. Remove the drive pulley (8791808) and fit to new motor.

5. Remove the rear cover from the pendant box, and the cover plates from the external cable
exit of the pendant arm.

6. Remove the cover (2159897) from the rear of the machine column.

7. Remove the cable ties from the Z aris resolver cable and unwrap the spiroband sleeve.

8. Disconnect the Z axs resolver from the rear of the Heidenhain unit and pull the cable
through the pendant arm and the ram.

9. Disconnect the motor wiring at the motor terminal box.

10. Remove the four screws, previously slackened in step 2, and remove the motor (complete
with encoder and encoder cable).

11. Install new motor by reversing steps 2 - 10.

NOTE: To facilitate threading the encoder cable tbrougb tbe rdrn tbe namepldtes sbould be
rernoaed from tbe sides of the ram.

72. After the motor is installed adjust the belt tension as per Section 8.3.2., check the setting of
the reference dog is per Section 8.4.2 and reset the software limits as per Section 8.4.3.

8-8
 8.3.2 Qu ill Drive Belt Adiustment

1. Remove screws (8301929) and lift pulley cover (2759865) off the mounting housing
(8050161).

2. Loosen, do not remove, tbur screws (8300167) securing thc drive motor to mounting housing
(80s0161).

3. Pulling the motor away from the head will increase the belt tension. Pushing the motor
toward the head will decrease the tension.

4. Tighten the four motor mounting screws when the proper tension is obtained.

5. The beit should have a tension of.294 N (66 lb) or should deflect in the middle on one side,
3 rnm with 22 N force applied (1/8" with 15 lb force).

8.3.3 Quill Drive Belt Removal

1. Disconnect power to the machine.

2. Remove rwo screws (8301929) and lift the pulley cover (2 1 59865) off the motor mounting
housing (8050161).

3. Remove four screws (8300167), holding the drive motor to the motor mounting housing.

4. Slide the timing belt (8800012) off. the motor pulley (8050142).

5. Loosen the four screws and pull the motor pulley (879180S) off the motor shaft.

6. Lift the drive motor off the motor mounting housing (8050161).

7. Remove two socket head cap screws from the hinged push button housing (8780063).

8. Carefully note and record the colour and location of all six limit switch wires.

9. Remove the six wires from the three limit switches.

10. Remove two socket head cap screws and remove the right side cover and joystick housing
(8791904).

1 1. Attach head removal tool (5T-6921) (Figure 8-2) to bearing cap (8025601) using three % - 2O
x .7 50 screws.
I
12. Support the head with a hoist attached to tool (5T-6921).

13. Remove four socket head cap screws (3800499) connecting quill housing (8050159) to
motor mounting housing (8050161).

14. Lift the upper head assembly 2 - 2 112".

15. Disconnect the oil line to the left of the meter unit (8303601).

16. Remove the upper head assembly.

8-9
17. Support the spindle in the UP position.

18. Remove four bearing retainer screws (8300171)

19. Remove metering unit (8303601) from lower bearing support (8O5O177)

20. Rotate ball nut assembly on the ballscrew, only enough to raise pulley (8050181) above quill
housing (8050159).

WARNING: IF THE BALLNUT IS ROTATED OFF THE BALLSCREW, THE BALLSCREW

ASSEMBLY WILL BE DESTROYED. A NEW BALLSCREW ASSEMBLY WILL
THEN BE NEEDED.

27. Belt may now be lifted up over the spindle and out of the machine.

NOTE: Tbe area must be kept free of any contaminating elements.

22. Assemble the machine in the opposite order of disassembly. A special assembly procedure for
the quill housing (8050159) and drive motor housing (8050161) are given in Section 8.5.1.

23. Set the quill feed belt (8800012) tension, per Section 8.3.3.

24. Check reference switch setting as per Section 8.4.2 znd rcset Z a><is software limits as per
Section 8.4.3.

8.3.4 BaIl Quill Extension Removal (Figure 8-1)

Special tools - 3T-6927 (Figure 8-2)

2" adjustable spanner wrench.

3 l/2" diameter adjustable hook spanner wrench.

1. Follow the disassembly procedure for the Quill Drive Belt Removal, per Section 8.3.3 steps 1

thru 19.

2. The ball quill extension has a total travel of 5".

WARNING: SHOULD THIS DISTANCE BE EXCEEDED, THE BALLS WILL FALL OUT OF
THE ASSEMBLY AND A NEW BALL QUILL EXTENSION WILL HAVE TO BE
PURCHASED.

3. Rotate the ball quill extension nut far enough up to remove six socket head cap screws
(83OO572), but not to exceed 5" of travel.

4. Rotate the ball quill extension back down and remove from the spindle.

5. Remove the bearing retainer (8O5O177) and bearings (83 02 80) by removing lock washer
(8303950) and nut. Use a 2" adjustable spanner wrench and a 3 ll2" adjustable hook
spanner wrench.

6. Remove two snap rings (8301939) znd pulley (8050181).

T.Before installation, inspect and clean theball quill extension assembly, per Section 8.6.2

8-10
 2J-52s BRAKE SHOE ASSY. (2) 77{163 CASTNG 8050163
8025525

2l-s2+

t7

2J-szz ausurNc so2s5z2'

WASHERS (4) 8OO7O9r

4H-20At

2l-579 CAM 8Ot4699

sT-22 PtN A300022
77{176 SUB.ASSY. SPEED CHANGER
4J-3O2 HANDLE 8303953
8050176 sT-22 PtN 8300648
El
oa
d 774194 LOCK SHAFT 8050194
Fl l-284 BALL 8OO7284
2J-556 SNAP RING 8025556
o
€ 2J-571 S.S.S.8025571
2J-556 SNAP R|NG 83O0rO2
s 2J-523 FTNGERS (2t 8025523
U)
rJ
a- 2l-571 S.S.S.802557r
o J93 DOWEL 8OO7o93
TE
r_t 2J-535 SHAFT 8O255 15

?r
li
Hi,
st

$)

o
EE 77-Or9l.SLEEVE 8050r93
E: VIEW A.A
o sT-2r3 S.S.S.83002r3
,f BRAKE ASSEMBLY
4J-3O2 HANDLE 8303953
(1
tr
t_l

>
rA
0
o
C'

77{215 SHIFTER 8050215

zl4o4 PLATE 8025604-

I
sr-I53 s.H.c.s. (2) 8300153
i
sT-1936 S.H.C.S. (2) 8301936 2J-603 BLOCK 8025603
I

C
\ 2J-605 PLATE 8O25605
1 o\ I 2J-582 SPR. 8/025582

l 2J{07 PLUNGER 802s5o7

s'l:216 s.s s. E300216 (8300217)

2J{07 PLUNGER ao256o7

I sT-I6 PtN 8300016

2J.606 HANDLE
802 5606
J28+ BALL
8007284

77-O16l MOTOR MTG BRKT 8050161

VIT]W B-B I-II.LCI SHIFTF-R 3IIEIViBII

NOTE: CLEANLINESS is of great importance. Be sure tbat no cbips or dirt will get to tbe
quill or ball quill extension.

8. After the assembly is complete, perform the following settings:

a. Align rhe motor mounting housing (8050161) to the quill housing (8050159) per Section
8.5.1.

b. Set the quill feed belt (8303952) tension per Section 8.3.3.

c. Check and if necessary reset the quill limit switches.

i. Extreme limit switches, as per Section 8.3.1.

ii. Quill reference switch, as per Section 8.3.2.

iii. Set the software limits, as per Section 8.4.

NOTE: Tbe bearings need to be installed in tbe same orientation as they were. Use tbe V on
tbe outside diameter as a guide for correct orientation of tbese bearings. As a
reference note tbat tbe shields of tbe bearings are to tbe outside.

8.3.5 Quill Removal

1. Follow the procedure for the ball quill extension removal, Section 8.3.4 steps 1 thru 4.

2. The quill will fall out of the housing when the blocks supporting it are removed.

3. For installation notes and settings see Section 8.3.4 steps 7 and 8.

CA\ITION: Tbe only occasion on wbicb a quill sbould be remoaed is in tbe eoent of seoere
damage by scoring tbrougb lack of lubrication or otber damage. The quill outside
diameter and tbe quill bousing bore are a matched fit.

8.3.6 Spindle Removal

1. LOWER the quill 25 mm from the upper position (Z +ve software limit)

2. Remove the spindle nose set screw (8300218) located on the quill outside diameter

3. Move the quill to the upper position (Z +ve software limit). Lower the knee to the full down
position.

4. Place blocks under the spindle to prevent it from dropping when loosened from the quill.
Remove the spindle nose locknut (8007514) from the quill (Figure 8-1). The spindle is now
free to be removed from the quill.

5. If the spindle
does not drop out, then tap on the end of the spindle with a soft mallet
through the opening on the top of the variable speed assembly. This will force the spindle
bearing out of the bore of the quill.

WARNING DO NOT HAVE HANDS BETWEEN THE SPINDLE AND SUPPORT BLOCKS,
WHEN THE SPINDLE BEARINGS CLEAR THE BORE IN THE QUILL THE
SPINDLE WILL DROP OUT OF THE QUILL RAPIDLY.

8-72
1. Remove three screws from locknut

@ @

2. Screw on nut assembly as far as possible - then back

off 1 turn.

3. Insert standard Quick Change Adaptor and tighten

locknut until tight.

4. Screw in longest button head screw (dog pt.) in hole

that permits greatest amount of rotation for unlocking
(This is usually the hole closest to a locking ear).

5. Rotate nut back to load position. This is when locking

ears and keys are in line.

KEYS

LOCKING EARS
\-\___--t
ROTATE
TO UNLOCK
6. Insert cadmium plated screw in hole that is in line
with locking ear. This is identifying screw so oPerator
knows how to load adaptors.

7. Put remaining screw in only open hole. Spindle is

now ready to use.

Figure 8-5 Quick Change Locknut Assembly

8-13
 TOP POSITION SWITCH

BOTTOM POSITION SWITCH

LrMrr swrTCH (8075809) SWITCH TRIPPED

(FrxED) AT 1.5 mm (.060")
GAP
TRIP DOG AND
TRrP DOG (8050179) q QUILL AT TOP
r POSITION
El LOCKNUT (8301931) PLACE 1.500 mm QUILL HOUSING
oa
Ft (.060") SHIM HERE T
o
a ADJUSTING STOP
o\ scREw (8o7s897)
QUILL TRrP DOG (8050187)
OoH
rL.
MAX. QUrLL
+1. d LIMIT SWITCH DOWN TRAVEL
qi
{
d
REFERENCE SWITCH (8075 10s) 126/127 mm
r)
CN
rD
-t
Ft TRrP DOG(8050187)
oq SWITCH ADJUSTMENT

LIMIT SWITCH
(8075 1 o5) LOCKING SCREWS (2)
(8301941)

SWITCH QUILL QUILL HOUSING

ADJUSTMENT

LOCKING SCREWS (2)

(8301941) QUILL QUILL HOUSING
 8.4 QUILL LIMIT SWITCHES

8.4.1 Z Axis Extreme Limit Switches

The available stroke of the quill is determined by the software limits set in the machine control.
The extreme limit dogs exist only as an additional safeguard to shut off power to the axis drive
in the event of a contiol or drive malfunction which causes the quill to go outside its software
limits.

1. In order to set the extreme limit switches it is necessary to override the software limits'

Change machine parameter 35 to +1000

Change machine parameter 36 to -1000

CAUTION: Tbe Z axis software limits are nou inactioe. Use the bandwbeel only. Approach tbe
bump stoPs at a creeq feed rate.

2. Lower the quill approximately 25 mm.

3. Remove rwo screws from the hinged push button housing (8780063) to give access to the
limit switches.

4. Loosen the hex nut (8301931) on the positive stop adjustment screw (8O75897).

5. Place a 1.5 mm (.060") shim on the top of the trip stop (8050179) in the quill housing slot
and up to the quill.

6. Carefully use rhe handwheel to raise the quill until a slight resistance is felt on the shim.

7. Turn the positive stop screw (8O75897) until the switch (8075S09) is actuated. Flold this
position and lock the hex locknut (8301931).

8. Remove the shim.

9. Carefully. using the handwheel, position display and the power e"labie button, set the bottom
position switch (8075105) to give a stroke of.726 mm to 127 t;lt-

10. Reset the Z axis refererice dog as per Section 8.4-2-

11. Reset the Z axis softwre lin:.its as per Section 8.4.3.

8.4.2 Z Axis Reference Switch

The axis reference switch is used in conjunction with the encoder on the motor shaft to
determine the machine datum following an interruption of mains Power.

1. When resetting the reference switch first temporarily set it to operate between 8 mm and 10
mm from the top position switcti.

2. Switch off the machine isolator. Switch on the machine isolator and pass over tlte reference
points as normal.

3. Place the control in reference mode by pressing the REF key then @

8-1 5
 4. Readjust the axis r.fer..fce switch to operate at between -1.0 mm and -1.5 mm as read on
the position readout display.

5. Reset the machine sofcware limits as per Section 8.4.3.

8.4.3 Z Axis Software Limits

After changing a feed motor, an encoder, a feed drive belt or an axis limit switch, it is necessary
to reset the software limits.

1. Temporarily override the sofrware limits.

Change machine parameter 35 to +1000

Change machine parameter 36 to -1000

CAUTION: The Z axis software limits are nou) inactiae. Use tbe bandwbeel only. Approach tbe
bump stops at a creep feed rate.

2. Place the control in reference mode by pressing the REF key and then

3. Slowly handwind the axis and record the position display figure as the top position switch
just operates.

4. Deduct 0.4 mm from the reading to obtain the positive software limit figure

5. Deduct 125.1 mm from the positive software limit figure to obtain the negative software
limit figuie.

6. Enter these values as foiiows:

Machine paranreter 35 I'ositive sofrware limit (Z a-xis)

Machine paramei:cr 3fi J.)egative software limit (Z axis)

7. Using the joysti':k clieck that the quill can be run into the positive software limit at rapid and
the negative soti.-,rrare li:"r.it at maximum feed rate, and off again without tripplng the extreme
limits.

8. Exit from the control reference mode by pressing REF then l@

9. Check that at least 125 mm of stroke can be achicycc

10. Record the new software limits on the Machine Software Parameter Record which may be
found in the door pocket of the electrical cabinet.

8.5 ALIGNMENT OF QUILL HOUSING ASSEMBLY TO DRIVE MOTOR HOUSING

ASSEMBLY

8.5.1 Alignment of Quill Housing Assembly to Drive Ivlotor Housing Assembly (Drive Belt
Pull)

This setting should be done as a reassembly procedure of the ball quill extension assembly to
the quill housing (8050159) and the motor mounting housing (3050161) to the quill housing
(8oso1s9).

8-16
1. The four screws (8300171) securing the bearing support (S05017',1 and bearing supPort
cover (8050178) to the quill housing (S050159) should be installed, but left loose.

2. Use belt (83039 52) to move the quill up and down along its travel and return to home
position. This should allow the bearing support (8050177) to float and align itself with the
quill housing (8050159). Tighten the four screws (8300171).

NOTE: Cbeck for proper alignment as follows.

3. Tie a string around the belt and tie a measuring scale on the end of the string. Pull on the
scale, moving the quill up or down to obtain a reading.

4. Repeat this procedure to obtain a reading over the entire up and down travel of the quill.

5. The reading on the scale should be minimized by repeating steps 2 and 4.

6. Tighten four sockethead cap screws (8300171) securingthe bearings to the quill housing
(80501s9).

7. The motor mounting housing (8050161) mounted to a complete variable speed assembly,
should be mounted on to the quill housing (3050159). Take care not to damage the splines
on the spindle (S050109) or gear hub (8025998).

8. Install four screws (S300499) but leave them loose.

9. Repeat step 2 ro float motor mounting housing (3050161) into place. Tighten the four
screws (8300499).

10. Repeat step 3. The reading on the scale with the quill moving up should not exceed 40 ozs
maximum pull.

The reading on the scale with the quill moving down should not exceed 28 ozs. maxlmum
pull.

8.6 BALL QUILL EXTENSION INSPECTION

CA1TION: CLEANLINESS is of great importance in tbis operation. Operator's bands and

clotbing must be free of any dirt and oil. Test equipment, fixtures and tables must
be free of dirt, dust cbips and oil. Tbe inspection area orroom must be free of any
air contaminating equipment, sucb as grinding macbines, exbaust blowers etc.

8.6.1 Ball Qu ill Extension Preload Torque on Nut (Fizure 8-7)

1. The ball quill extension shaft and nut must be free of. zny foreign material.

2. Set the ball quill extension assembly (5780465) in an upright position, with the ball threads
facing upward and the mounting flange downwards.

3. Wrap a srring around the ballnut's large outside diameter (pulley mounting diameter).

4. Tie a measuring scale on the end of the string.

5. Pull on the scale, rotatingthe quill nut to obtain a reading.

8-r7
 QUILL SCALE
NU'I' READING
TRAVEL (PULL)
510 g
UP (18 ozs) MAX
510 g
DOWN (18 ozs) MAX

QUILL THREAD
UPWARD

PULL SCALE'fO
ROTA'fE NUT

Jrurlde
NUT
TRAVEL SCALE

BALL QUILL STRING WRAPPEI)

EXTENSION ASSEMBLY AROUND NUT
(878046s)

Figure 8-7 Ball Quill Extension Torque on Nut Set-up

8-18
6. Repeat this procedure to obtain a reading over the entire up and down travel of the ballnut
on the ball shaft.

7. The reading on the scale with the nut moving up should not exceed 510 g (1 8 oz.) maximum
pull.

The reading on the scale with the nut moving down should not exceed 510 g (18 oz.)
maximum pull.

8. If the scale readings exceed the limits or if there is any excessive drag or nut hang up on the
shaft, then clean and flush the ballnut and shaft, per Section 8.6.2.

9. If after cleaning the nut, the scale readings are still over the limits or a drag or hang up still
exist, replace the ball quill extension assembly (8780465).

8.6-2 Cleaning and Flushin s the Ball Quill Extension Assembly 8-8 and 8-9)

1 . Set the ball quill extension assembly (87 80465) in a horizontal position and place over a
flushing tank, per Figure 8-9.

2. Pour an oil dissolving solvent over the ball threads and ballnut. This will remove any contam-
inated oil, chips or foreign material from the ball quill extension assembly. Remove from the
flushing tank.

3. Set in an upright position, with the ball threads facing upward and the mounting flange
downward in a container, per Figure 8-8.

4. Pour an oil dissolving solvent over the ball threads and into the top of the nut, at the same
time rotate the nut over its total travel. This will remove any contaminated oil on the threads
and flush any chips or foreign material lodged in the ballnut tracks.

5. After cleaning apply a film of light machine oil over the threads and into the ballnut.
QUILL THREADS POUR CLEAN SOLVENT
UPWARD INTO THE NUT AT THE TOP
(FLUSHING NUT)

NUT
TRAVEL
BALL QUILL AND NUT I.'LUSHING

BALL QUILL
EXTENSION
ASSEMBLY (8780465) CONTAINER

Figure 8-8 Ball Quill and Nut Flushing

8.79
 BALL QUILL EXTENSION
ASSEMBLY (8780465) rN
HORIZONTAL POSITION

POUR CLEAN SOLVENT

OVER BALL QUILL EXTENSION
EXTERIOR

ililil i tiil
|ll
uuul
ffillt FLUSHING
TANK

CLEAN SOLVENT

Figure 8-9 Ball Quill Extension Flushing

8-20
+-8.

PrtvtXY FN..t^^-
.-aJr:E-rl A\ - <?a
^rt g\,r.t
,v - o C,)

I I

D(s3s s3 t,1 2z
la

.uo I l(' .-

- ,lri

,is-- i -rZ- t
-
 SECTION IX

SPARE PARTS LIST

9.7 ELECTRICAL PARTS LIST

Computer No. Part No. Description

1. Pendant Parts

1553367 Heidenhain VDU

7553360 Heidenhain TNC 145
1550494 Pushbutton Black
7550487 Pushbutton Red
1550495 Coolant Switch
7550489 Pushbutton Emergency Stop
1555552 Feedrate Potentiometer
7550442 Illuminated Pushbutton
1555309 Resistor 1OOR 1W
7555776 Resistor 3 3R
1555204 Iiesistoi: +70R
7550440 "PDwci Cn" Bulb

2. Electrical Panel

1551338 2O Amp Fuse

t557348 1O Amp Fuse
1s57392 2 Amp Fuse
7557394 5 Amp Fuse
1552533 ZO - 3.7'A Overload
7552535 ZO-6.7AOverload
1557423 Axis Drive Unit (Bosch)
1553903 Auto Transformer (Bosch)
1553883 Choke (Bosch)
1555390 Resistor 3R3 12W
1553957 Transformer
7554300 Rectifier
75557 5t Capacitor 0. 1 Microfarad
1555304 Resistor 10 OHM
7555374 Resistor 1.2 KOHM
1555607 Capacitor 100 Microfarad 24 v Regulator Board
1555005 Diode 1N4002 Complete 4648770
1556550 Transistor TIP 31,{
7557018 24 v Zener Diode
15 51819 Isolator
1552921 110 v Relay
7552922 24v D.C. Relay
7553256 DIL OO52 Contactor

3. Machine Mounted Elecuical Items

1553590 X/Y Joystick Euchner

1s53589 Z Joystick Euchner

9-1
 3. Machine Mounted Electrical Items (cont'd)

Computer No Part No. Description

1553672 X & Y Axis Limit Switch

8520004 Spindle & Brake Conuol Panel
1553359 Handwheel Encoder
1553+7 7 Z Limit Switch
807 5809 Z Limit Switch
1504761 "spindle Off" Bulb

4. Motors

1551205 Axis Drive Motor SEM MT30R4/58 + Encoder

1552697 Coolant Pump
8600770 Spindle Motor 2h.p.

9.2 MECHANICAL PARTS LIST

1. Base Machine

X AXIS FEED DRIVE ASSEMBLY €

21597 t6 Ballscrew
7579779 Driven Pulley
2759760 Motor Pulley
* 1577994 Belt
1572+93 Bearing (PR)
1705558 Bearing Locknut
1577 592 Bearing Seal
\
Y AXIS FEED DRIVE'ASSEMBLY

21597 t7 Ballscrew
2159779 Drivefi'P.rttey
21s97 60 Motor Pulley
'+ 7577989 Belt
7572493 Bearing (PR)

Z AXIS FEED DRIVE ASSEMBLY

8780465 Ballscrew
8050149 770149 Locknut
8302800 Bearing Fafnir 9114 PD
8303950 Lockwasher
8050181 770781 Driven Pulley
8797808 Motor Pulley
8800012 Belt

9-2
Computer No Part No. Description gE Where Used

BEARINGS

7572620 Bearing 2 Elevating straft assembly

7720508 Bearing 1 Knee pedestal location

MISCELLANEOUS

2152070 Rubber Front Cover 7 Secured to front of saddle

2752077 Rubber Rear Chipguard Cover 1 Secured between column
and table rear
8303600 D2990 TM5 Pump Bijur 1 One shot lubrication
8303616 83533 Hose Assembly Type SS 27" 1 One shot lubrication
8303618 84870 Hose Assembly Type 5C27" 1 One shot lubrication
8600005 110 v Coolant Pump 5O Hz 1 Coolant system
8303820 Coolant Nozzle & Tap Assembly 1 Coolant system
8028001 BSMl Spraymist Pr-p 1 Spraymist system
802801 1 BSM11 Spraymist Nozzle 1 Spraymist system
2750014 Bevel Gear ) send togetrer 7 Pedestal to elevating
8300086 sr86 3/16 Sq. K.y i 1 shaft
7224004 Dual Dial , 1 Dial for elevating shaft
8005088 H88 Gib Adj. Screw 3 Securing all gib keys
2150015 Pinion Gear 1 Elwating shaft assembly
7572620 Bearing 2 Elevating shaft assembly
2750777 Clutch Sleeve 1 Elevating shaft assembly
8300068 5T68 No. 7 Woodruff Key 1 Elevating shaft assembly
4649815 Chip & Coolant Shield 1

27s9767 Splash Tray for Base

2. MDI Milling Head

7075079 UII,L - SPINDLE S/ASSY - RETRO

8007169 1169 Spindle Dirt Shield 1

8007170 J17O Bearing Spacer 877339 1
8007777 lt7 t Bearing Spacer inc. in 8OO777O 1
8007776 J176 Bearing Sleeve 1
8007272 J272 Locknut WO6 1

8007273 1273 Lockwasher W-06 1

8007 51+ 1514 Spindle Bearing Locknut 1

8050076 Bearing Fafnir M2O6 KDD

8050077 Bearing Fafnir JM 207 KDD
8050109 770109 150 - 30 Bristol Erickson Spindle
805021 3 770273 Quill

BEARINGS

8025587 2Js87 Bearing DN107 YR TR250 J702 1 ln2J6O7 bearing cap

8025 5 88 21s88 Bearing DN220 YR TR250 J702 2 On varidisc assembly
8025589 21s89 Bearing M9308 PP TR25O J7O2 2 On 21511 bull gear
8025590 2lsgo Bearing M203 NPP 2 On 21529 bull gear

9-3
Computer No. Part No Description gE. Where Used

BELTS

8025668 21668 Variable Drive Belt 1 Varidrive assembly

8303797 2J791 Timing Belt 1 Inside head i,

VARIDISCS

7072533 21s33 Adj. Driven Vari-Disc I Varidrive ,assernhlI.

8025534 21s34 Stat Driven Vari-Disc I Vari-drive-asembly
7012642 2J642 Adj. Motor Vari-Disc 1 Varidrive. assembl5,
8050082 770082 Stat Motor Vari-Disc 1 Vari-drive assembly

MISCELLANEOUS

8025505 2H505 Bearing Housing Pulley 1 Varidrive assembly

8025506 21506 Brake Bearing Cap I Varidrive assembly
8025524 21524 Brake Spring 2 Brake assembly
8025525 2J52s Brake Shoe 1pr Brake assembly
8025603 2J603 Hi-Lo Pinion Block 1 Hi-Lo assembly
8025607 2J607 Hi-Lo Detent Plunger I Hi-Lo assembly
8025577 21577 318" x 3" x 1/76" C/Spring 3 Lifting bull gear
8050176 770r76 Speed Changer Assembly 1 Speed change
8025663 21663 Plastic Key for 2J533 1 Vari-drive assembly

.L

94
I
t SECTION X

PREVENTIVE N{AINTENANCE

10.1 WARRANTY

As quotcd in Bridgeport's terms and conditions:

"Bridgeporl warrants to the original purchaser only that all products manufactured by it will be
free t'rorn defects in materials or workmanship for a period of trvelve (12) months from date of
shipment to such purchaser, such warran to remain in effect if and if such ucts are
used in accordance with all rnstrucuons as to tenance set ln
lnstructron eets

7O.2 SINGLE SHIFT OPERATION USING COOLANT ON ALL OPERATIONS

70.2.7 DailyMaintenance MAINTENANCE LEVEL 1

T 1. Check automatic lubricating system oil level and fill as necessary.

CAUTION: (Ise only Mobil Vactra No. 2 or equioalent to ensure maximum effectiaeness of tbe
lubrication sJlstem.

2. Clean dirt and chips from ways. (DO NOT USE AN AIR HOSE).
T
70.2.2 Weekly Maintenance MAINTENANCE LEVEL I
In addition to daily maintenance:

l. Clean chips and dirt from the entire machine and wipe down.

2.. Check that oil is reaching all slideways.

3. Clean and apply light coat of oil to steel chip guards on knee and to the guards between the
table and saddle.

10.2.3 Yearly Maintenance MAINIENANCE LEVEL 2

In addition to weekly maintenance:

1. Lower spindle motor fan cover and-olean.

2. Remove cover (8050195) on spindle drive belt housing. Clean housing and cover.

3. Remove automatic lubricator filter and clean.

4. Remove two screws and open hinged control cover (8780063) over quill switches. Inspect for
dirt and grease on ballscrew and clean as necessary.

5. Check spindle speed and adjust as per Section 8.2.1.

6. Check feed drive belt tensions on all axes as per Sections 7.1.1, 7.7.2 and 8.3.2.

10-1
 7. Check the slidervay gib settings and adjust if necessary as per Section,7.8.

8. Check lost motion a1irer,Section7.9.

9. Check axis drive motor brushes for wear. Replace if less than 5 mm (0.20") of carbon
remains.

10.3 MULTIPLE SHIFT OPERATIONS AND PUNITIVE ENVIRONMENTS

10.3 .1 Definitions

Bridgeport is defining 3 shift operation, 5 or more days per week, as a multiple shift operation.

Punitive Environments are considered to be those in which the workpiece iq,cut dry or when
cutting Magnesium or Carbon.
t
If the workpiece is cut dry (Cast Iron, Carbon or Magnesium) extra-ordinary precautions should
be taken by the customer. The foilowing recommendations are made as a guidet

1. The (212) head has a patented cooling system to minimise spindle growth. The spindle motor
draws air from behind the speed indicator plate over the equipment in the belt housing and
exhausts around the motor shroud. THE AIR INLET SHOULD BE FILTERED FOR
PUNITIVE ENVIRONMENTS.

2. Specially designed vacuum systems at the cutting tool are recommended

hoses must not be used to clean the machine, use industrial vacuum cleaners.

filters should be considered if clean air cannot be ducted to the 2J2head.

Daily Maintenance MAINTFNANCE LEVEL 1

.r XU tomatic lubricating system oil level and fJl as necessary.

CAUTION: Use only Mobil Vactq No. 2 or equioalent to ensure maximum effectiaeness of tbe
lubication $/stem.

2. Clean dirt and chips from way surfaces and apron. Use industrial vacuum cleaner.

3. Clean and apply a light coat of oil to way surfaces.

10.3.3 48 Hour Maintenance MAINTENANCE LEVEL 1

I
rl

t In addition to daily maintenance:

I
1. Clean the entire machine using an industrial vacuum cleaner.

i
2. Check that oil is reaching all slideways.
I

) 3. Clean and apply light coat of oil to steel chip guards on knee and to guards between the table
and saddle.
:

to-2
I
{
7o.3.4 Weekly ( 144 Hour) Maintenance MAINTENANCE LEVEL 2

In addition to 48 hour maintenance,

1. Lower spindle motor fan cover and clesn.

2. Remove cover (8050195) on spindle drive belt housing. Clean housing and cover.

3. Remove two screws and open hinged control cover (8780063) over quill switches. Inspect for
dirt and grease on ballscrew. Clean as necessary.

10.3.5 6 Monthly Maintenance MAINTENANCE LEVEL 2

In addition to weekly inaintenance:

1. Remove automauc lubricator filter and clean.

2. Check spindle speed and adjust as per Section 8.2.7.

3. Check feed drive belt tensions on all axes as per Section s7.7.7;7.7.2 and 8.3.2.

4. Check the slideway gib settings and adjust if necessary as per Sections 7.8.

5. Check lost motion as per Section 7.9.

6. Check drive mot^r brushes for wear. The minimum recommended length of carbon,
ar<is
before brush replacement is 6 mm (O.24").

10-3
 IO,4 MAINTENANCE SUMT4.ARY T
Machine Duty & Environment Single Shift, Coolant Multiple Shift & Punitive

Maintenance Interval Daily Weekly Yearly Daily 40 Hr, L44 }tr. 6 Mthly

Check auto lubricator level x x x x x x x

Clean dirt and chips from ways x x x x x x x

Clean and apply oil to ways x x x x

Clean entire machine x x x x x

Check that oil is reaching

slideways x x x x

Check and apply oil to sliding

guards x x x x x

Clean spindle motor fan cover x I x x

Clean spindle drive belt housing x x x

Clean quill housing

Clean auto lubricator filter

x

x
x x

x
I
Check spindle speed x x

Check feed drive belt tension x x

Check slideway gib settings x x I

Check feed drive motor brushes x x
I
t

I
I
t04
 I
1

SECTION XI. l

I FAULT FINDING .i

This section is a brief guide to enable simple electricd faults to be readily identified and to
localise any problem area due to the more obscure faults that cannot be dealt with individually
in this chapter.

The procedure has been written in a logical sequence which must be followed from the
beginning. The results of this procedure will also be most useful in any further dialogue should
the fault not be located.

WARNING

Parts of tbis procedure inzsoloe a:orking

witb elec*ically liue circuits and must

only be perfortned by personnel qualified
T
to do so.

F
I
T
1 1-1
 Can the spindle be YES Turn to the next page but one
started manually?

Is the 'SPINDLE OFF' Check fuses MF1, MF2, MF3,

lamp illurninated? TFU1 ,TFUZ & CFU3

YES

Are the control displays Check fuse CFU1 and fuse at

illuminated? back of control. Also check
11Ov AC supply to control
between wire 8 and 9

YES
i

Is the VDU display ON? efi.rrt brightness & contrasr

;
.on display. Check lead
between control & VDU
connected. If display still not
wo,pking - then faulty VDU
if {* I'

l. e

{
Does the coftrol display read
.POWER INTERRUPTED'?
.YES Press E on control
3

-tl*

Turn to next page

77-2
 Does the control display read YES Verify operation of 24v DC
.RELAY EXT D.C. VOLTAGE regulator board by checking
MISSING'? 24v (t- 2v) berween earth &
terminal block 65

NO

",1 .'
Does control display YES Switch off at isolator and
'CoNTROL ELECTR9NICS DEFECTIVE if fault clears then
resta^rt,
.EMERGENCY
CUT OUT DEFECTIVE' ". carry on otherwise faulty
'PROGRAMIIE.IUEMORY DE FECTIVE' control unit

.i.. c

Check for 11Ov A.C. benveen earth and

the following terminal block numbers:

1r ,"o ... Emergency stop

-* r ' latched in on pe
YES

|}
72 Emergency stop pushbutton
.{ s latched in on spindle control
. YES panel

* 'Spindle motor O/L1 tripped

18 I
t' iJx- (manual reset)
*
END OF CHECKS +
ur,
+

1 1-3
 Does POWER ENABLE button YES Turn to the next page
illuminate on being pressed?

Does control display read

.POWER INTERRUPTED'
YES Press
E button on control
tr

,t
+

Check 11ov A.C5etween earth grd NO Feed motor overload O/L3

and terminal 22 t Qrranual rs#.t)
I ffr .+
+' t

YES

HoId'POWER ENABLE' pushbutrcn IN

and check 11Or/ A.C. between earth and
the following termind block numberq-:
t ,.
27 F?tulty POWER ENABLE
svitch f*
+
rlt YES lr
tl
t 'r*. '
28 Thermal overloadjnside X axis
Motor (auto reset)
51 ,}-'
{ 't
+
*--
-?b:
429 .Therind overload inside Y"axis
Motor (auto rese!)
YES

30 Thermal overload inside.Z a:<is

, Motor (auto reset) i

YES C
*
T.ury.tb next page
7t-4
 f
if Does Contactor 5FC pull IN

YES

Faulty POWER ENABLE bulb

END OF CHECKS

I -)

* f

+
* t

I
t 77-5
 Does POWER ENABLE button Turn to the next page
extinguish on being released?

YES

One of the three otes is on an AXIS

LIMIT SWITCH. With POWER ENABLE
button pressed, drive off a:cis limit by
using electronic handwheel or joysticks
or reference

END OF CHECKS

77-6
r

Does the control display read YES

.REF: PASS OVER REFERENCE
POINTS' when @ pushbutton
Pressed?

Does control display read

.MACHINE PARAMETER O'?

YES

Input machine parameter into control

unit. Machine parameter for machine
are inside electrical panel

END OF CHECKS

77-7
 Does the machine pass over YES Turn to the next page but one
it's reference poina when the
.PROGRAMME START'
pushbutton is operated?

Is there 11Ov A.C. between Check lubrication oil level

eafth and main terminal block
number 17?

YES

Are the t'uyo small green LED's NO Check the two small 160 mA
marked 'BTB'illuminated at the fuses mounted in clips at the
top right hand corner of the feed bottom right hand corner of
drive card?

YES

(z)
Does the (Y) axis NO Faulty relay
(x)
(14)
relay (13) CR pull IN ?
(12)

YES

Turn to the next page

11-8
 (z)
Does the (Y) Axis drive green Faulty drive
(x)
LED's marked'FG' illuminate?

YES

Faulty drive
Faulty drive motor
Faulry control

END OF CHECKS

7t-9
 Do the joystick axis controls YES Turn to the next page
operate correcdy?

NO

Does the control display read: YES Faulty encoder or associated

.DEFECT ON* _ MEASURING cable on the indicated* aris
SYSTEM'?

Does the control disPlaY read t YES Faulty control unit

.CONTROL _ ELECTRONICS DEFECTIVE'
or 'PROGRAMME MEMORY
DEFECTIVE'?

NO

Does the conuol displaY read, YES Axis slide tight - check that
.GROSS POSITIONING ERROR'? a,xis is free by winding ares via
belts. Feed drive card correctly
adjusted or faulty

Do the joysticks controls operate YES Neutral microswitch on rear of

correctly in the rapid mode? joystick incorrectly adjusted or
faulty

Turn to next page

1 1-10
Joystick rapid pushbutton faulty.
Joyitick directional microswitches faulty.
END OF CHECKS

11-1 1

-J
 Does the machine run and
position correcdy in programme?

Does the control display read: YES Faulty conuol unit

.CONTROL
- ELECTRONICS DEFECTIVE'
or'PROGRAMNIE MEMORY
DEFECTIVE'?

Does machine attempt to move Does conuol displaY read YES Programming
to programmed position? .LIMIT SWITCH,? error

YES Feedrate override control atzero.

Miscellaneous function in programme
block not completed e.g. M03 - spindle
start, M51 - indexer (if fitted)

Do the position readout display Tool length or diameter

figures correspond to the programmed compensation in operation,
axis positions to within *.0.01 mm Feed drive card incorrectly
(0.0004")? adjusted or faulry

YES

If the position readout figures correspond to the programmed axis positions, but the machine is
not positioning as indicated, check the tightness of the belt pulley on the o<is motor shaft and the
tightness of the rotary encoder coupling on the other end of the a><is motor.

END OF CHECKS

7t-12
 -A-n (

6/L2/92 L2-39-36) rr?<34-AcT 2 S"'5o ou€og

0 s000 t.
1 s000 t

2 s000 l!
3 750
4 9 ,000
5 0 ,500
6 0 ,300
7 2 ,000
I 1 0,000 "t
9 0, 010 i
10 0
11 0 .l
L2 0
13 0 ,7 30
L4 0 ,7 30
15 0 ,7 30
16 2000
L7 5
18 ON
19 ON
20 ON
2L ON
MP 22 OFF
23 ON
24 OFF
25 OFF
'26 ON
27 0
28 0
29 0199 1
30 0, 100
3L +9 r700
32 -7 40,.400
33 +5 r 800
34 -354,300
35 +5,900
35 -119 ,200
37 OFF
38 0, 150
39 0,022
40' 0r045
4L o,005
42.. 1
"43 1
44 1
45 2
46 0,000
47 OFF
,48 oN.
49 3
50 3r000
51 0
52 OFF
53 0,000
54 1,300
TAM
-_ -----: 1T--l ..'.'=-:-----.' =-r
I

I
I

\( - ''
Bridg"port Machines Diiision of Textron Limited
t-*.+
O

P.O. BAX 22, FOREST ROAD, LEICESTER Lfr

Telephone:. (0533) 531 122
*r

Bridgeport Texnon reseroe tbe igbt to amepd specification witbou notbe

t:, :+i'
1 ,i-

Prlnted in England

^i
[, )