Field Service Hurco1990 1999

FIELD SERVICE BULLETIN INDEX
FSBINDEX.DOC Revised May 9, 1997 FSB NUMBER DESCRIPTION

1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044 1045 MB1 TOOL CHANGER ALIGNMENT AND ADJUSTMENT. B INTERFACE BOARD RELIABILITY IMPROVEMENT. NUISANCE SHEAR PINING ON PARAJUST B DRIVE. INSTALLATION OF REPLACEABLE ENCODER DISKS. POWER DOWN MEMORY CIRCUIT ON B CONTROL MILLS. PROPER AXIS CURRENT ON KMB1 MILLS. MB1 SHOT PIN PROBLEM FIX. CHOPPER BOARDS ON PARAJUST B DRIVES. PARAJUST A SETUP AND ADJUSTMENT. CHATTER IN THE SPINDLE OF KMB1 KMB1m. INFO ON THE CRT BENT, B CONTROL FRONT PANEL BRD MOD RECOMMENDED WAY OIL FOR MILLS. MBII SHOT PIN ADJUSTMENT. VARIDRIVE BELT REPLACEMENT. MBII LIMIT SWITCH AND VALVE ADJUSTMENTS. MILL GROUND ROD USE INFORMATION. SNOW ON CRT OF MB1H MILLS. SHEAR PIN DURING TAPPING ON PARAJUST B DRIVES. MISSWIRED T2 TRANSFORMER ON MB3 MILLS. HIGH SPEED SPINDLE DIFFERENCES. MISPOSITION IN TOOLMASTER HMB1 BX RETROFIT. SET-UP OF BX SERVO CONTROL BOARD. PARAJUST 280V REFERENCE PROBLEM. RS232 DATA CARRIER LOST ERROR ON BX CONTROL. MB3/MD3 MOD. TO THE X5 BRD FOR MISPOSITION. KMB-1 SPLINE COUPLING REPLACEMENT. HURCO EDM SERVO AMP AND DIODE PUMP SETUP. EDM OPTITRON TRIP POINT SETTINGS. (MKII) SERIAL NUMBER ID ON ALL HURCO PRODUCTS. OIL LUBE REGULATOR KMB TYPE MACHINES. CONTROL TRANSFORMER REPLACEMENT SM1-CNC. MISCOUNT ON TOOL CHANGER OF MD1 AND MBX1. OIL FLOW INDICATOR RETROFIT MII. ORIENT TIME-OUT IN MBII MB3. MBXIH MD1 40V TOOL CHANGER SPRINGS WEAK. INTERMITTENT PROBLEMS ON B AND BX MILLS. B AND BX TAPE READER ADJUSTMENTS. VOLTAGE CONVERSIONS ON SM1-CNC AND KM3 MACHINES. BATTERY BACKUP ULTIMAX ONE CONTROL. PARAJUST VOLTAGE CONTROL BOARD PROBLEM. SM1-CNC Z AXIS PROBLEMS. ULTIMAX ONE TAPE FORMATTING PROBLEM. PARTS REPLACEMENT ON PARAJUST DRIVES. SM1-CNC BALL SCREW REPLACEMENT. MISSWIRED SPINDLE DAC ON MD1.
FSB NUMBER
DESCRIPTION
1046 1047 1048 1049 1050 1051 1052 1053 1054 1055 1056 1057 1058 1059 1060 1061 1062 1063 1064 1065-B 1066 1067 1068 1069 1070 1071 1072 1073 1074 1075 1076 1077 1078 1079 1080 1081 1082 1083 1084 1085 1086 1087 1088 1089 1090 1091 1092 1093 1094 1095 1096 1097 1098
MD3 Z AXIS SC FAULT PROBLEM WITH AUX BRIDGE. WIRING MAIN TRANSFORMER. SERVO DYNAMIC AMPLIFIER SET-UP. CIRCLE AND POSITIONING ACCURACY. SHOTPIN PROBLEMS AND ADJUSTMENTS ON MD3. MD3 FAULT LOGIC BOARD PROBLEM. SMI-CNC DOOR LATCH PROBLEM. LUBE OF SPLINE COUPLING KMB1 TYPE MACHINE. HONING KNEE MILL QUILL BORES. KNEE MILL SPINDLE REBUILDS. MISCOUNTS WITH MILLS USING HEIDNHAIN SCALES. AIR LINES POPPING OFF FITTINGS. MD1 CHIP REMOVAL BENEATH SADDLE. MD1 Y AXIS LEAD SCREW COVER. QUILLS FOR SMI-CNC. MD1-3 PARAJUST WIRING DRESS PROBLEM. SPINDLE ORIENT SPEED ADJUSTMENT MD1-3. TAPE TRANSPORT GROUNDING ULTIMAX 1. LUBE PRESSURE SWITCH SETUP ON MD3. ULTIMAX POWER SUPPLY CHECKOUT. Revised 3/17/93 ULTIMAX SWITCH SETTINGS. LUBE PROBLEMS ON SM1-CNC. CRTS SHORTING OUT ON ULTIMAX ONE. ENCODER DAMAGE. NEW REPLACEMENT FOR HEIDENHAIN X5 BOARDS. PARAJUST B DRIVE MAINTENANCE. GROUND FAULT ON HURCO AMPS. FRL UNIT BOWLS CRACKING. AUTOLUBE SYSTEMS ALL MILLS. ATC ERROR ON BMC-15 MILLS. INDEX MISSWIRE ON KM3/P. HI-LOW GEAR SWITCH PROBLEM MD3-BMC15. MISSWIRE ON RS232 ON KM3 TYPE MACHINES. MUTI-LOAD SCREENS ON B OR BX CONTROL MACHINES. KMC3-P SPINDLE SPEED AND ROTATION PROBLEMS. THREE PHASE POWER KVA-AMPERS AND WIRE SIZE. KM3P MOTOR BRUSH CONTAMINANT FIX (COVER). MACHINE INPUT VOLTAGE AND AIR REQUIREMENTS. MISSING SURGE SUPPRESSOR BMC 10-15. MISCOUNTS ON KM3 DUE TO SHIELDS MISSING. BMC AXIS BELT TENSION. USING DISTRIBUTOR STOCK. TAPE READER PROBLEMS TM5. RANDTRONICS CHASSIS WIRING PROBLEMS. OVER RATED HEATER ON BMC 15 CHIP CONVEYOR. TOOL CHANGER LIMIT SWITCH PROBLEM BMC 20. ULTIMAX LOCKUPS. BRAKE PACK PROBLEMS WITH MD1 AND MD3. MB3 SERVOMATE/RANDTRONIC TRANSFORMER. BX MISCOUNTING ON KNEE MILLS. DELTRON POWER SUPPLY ADJUSTMENT. CUSTOM CPU JUMPER CAUSES RS232 RS 232 PROBLEM. SOLENOID EXHAUST FILTERS CLOG MD3 THRU BMC 15.
REV. C
PAGE 2 OF 5 FSBINDEX.DOC 9-May-97
FSB NUMBER
DESCRIPTION
1099 1100-A 1101 1102 1103 1104 1105 1106 1107 1108 1109 1110 1111 1112 1113 1114 1115 1116 1117 1118 1119 1120 1121 1122 1123 1124 1125 1126 1127 1128 1129 1130 1131 1132 1133 1134 1135 1136 1137 1138-B 1139 1140 1141 1142 1143 1144 1145 1146-A 1147 1148 1149 1150 1151
BMC 10/10L TOOL SUPPORT PROBLEM. BMC 20 THRU 50 GIBS AND AXIS CURRENT ADJUSTMENT.REVISED 1/25/93 TM5 Z AXIS BOUNCING AT Z PLUS LIMIT SWITCH. SPIETH LOCKNUT INSTALLATION INSTRUCTIONS. MAX2 RS232 HARNESS MISSWIRE. SOFTWARE FOR YASKAWA MD3 MACHINES. ORIENT PROBLEM WITH YASKAWA RETROFIT. KMC3P PALL CHUCK REPLACEMENT. BMC AUTO LUBE WIRING IMPROPER SHIELDING. INSTALLATION OF THRUST BEARING'S. NONVOLATILE CPU/MEMORY PCB FOR ULTIMAX 1. TOOL CHANGER HEIGHT WITH 06F SOFTWARE. BMC DRAW ADJUSTMENT. BMC CLUTCH NOISE. BMC 20 THRU 50 GIB WEAR. AXIS END CAP PROBLEM KM3 MILLS. CONTROL RELAY PANEL PCB MAX 2 MACHINES. DELTRON POWER SUPPLY CHECK OUT. CONTROL GROUNDING IN ULTIMAX. RS232 CABLE HURCO REQUIREMENTS. PARAJUST A BRAKE BOARD REPLACEMENT. MISSWIRE ON YASKAWA RETROFIT. WRONG SPINDLE OVERLOADS ON KM3 TYPE MACHINES. GROUNDING OF INDUSTRIAL SERVO DRIVES. FANUC SPINDLE SPEED SENSOR INSTALL AND TROUBLINGSHOO DECKEL IND. SERVO DRIVE MODIFICATIONS. DELTRON POWER SUPPLY PROBLEMS. FERRITE BEADS AND TRANSIENT VOLTAGE PROTECTORS. BMC ATC JAMING (BUSHING PROBLEM) LEADSCREW MAPPING 7.24 BMC 20/50 CHIP DOOR INTERLOCK PROBLEM 7.24 SOFTWARE TAPPING T1 TRANSFORMER (BMC STAND ALONE) MAGAZINE JAMMED ERROR (ELECTRICAL) BIJUR WAY LUBE PUMP ADJUSTMENT MAX2 MEMORY BOARDS (DALLAS RAM) ENCODERS SHAFT MOUNT SPINDLE FIRMWARE FOR MD3 WITH YASKAWA DRIVE YASKAWA SPINDLE DRIVE RETROFIT KIT BMC20 V2 Z AXIS LUBRICATION LINE MISSROUTE DISK DRIVE RETROFIT, & FLOPPY DISK CONFIGURATION Revised 8/3/94 REV A VERTICLE HEAD LUBE RELAY ON DECKEL/MAX TURKITE DAMAGE BMC30 STRIKER PLATE SCREW PROBLEM YASKAWA SPINDLE DRIVE DOCUMENTATION PROBLEM GROUNDING IN ULTIMAX CONTROL CONSOLE GIB ADJUSTMENTS. Refer to FSB 1100-A REPLACING HURCO AMPS WITH SERVOMATE YASKAWA ORIENT MODIFICATION ATC STRIKER PLATE HOLD-DOWN SCREWS ATC MAGAZINE AIR CYLINDER SET SCREW ATC MAGAZINE AIR CYLINDER SET SCREW CONTROL RESIDENT DIAGNOSTICS (MAX) FLOOD FILTER (5 GAL)
FSB NUMBER
DESCRIPTION
1152 1153 1154 1155 1156 1157 1157-A 1158 1159 1160 1161 1162 1163 1164 1165-B 1166 1167 1168 1169 1170 1171 1172-A 1173 1174-A 1175 1176 1177 1178-A 1179 1180 1181 1182 1183 1184-A 1185 1186 1187 1188 1189-B 1190 1191 1192 1193-A 1194 1195 1196 1197 1198 1199 1200 1201 1202 1203
REPLACEMENT OF KNEE MILL MOTORS/ENCODERS (MTE ASSY) TRANSIENT ELIMINATOR (LINE POWER PROBLEMS) DUAL AXIS PCB (DAC OFFSET PCB) COUNTER WEIGHT RETROFIT BMC40 IP ISOLATION TRANSFORMER (BMC 20-50) CRT RELIABILITY IMPROVEMENT CRT GROUNDING BACKLASH MEASURING CIRCUIT PCB CLEANING FIELD SERVICE ACCURACY STANDARD OIL COOLER CONTACTOR MIS-WIRE (BMC 30-50) BEARING TORQUE SETTINGS TOOL RETENTION FORCES (ATC) SERVICE CALL CHECK LIST FUTABA CMK PARAMETER SETTINGS (EDM) Revised 3/3/92 REV. A KM5P DRAWBAR KM5P AXIS PULLEY LOCKING ELEMENTS KM5P DRAWBAR ROTARY TABLE ERRORS (BMC 20-50) YASKAWA SPINDLE DRIVE RETROFIT KIT (MB2-MD3) FAST FILL PROBLEMS TRM21 (EDM) CONTACTOR SUPPRESSION (BMC KM5P) LEADSCREW MAPPING INITIALIZATION v8.5 ULTIMAX SECRET (HIDDEN) SCREENS. Revised 3/17/93 BMC 20-50 SPINDLES CRT CONTROLER PCB, 26 PIN EDGE CONNECTOR VMC900 ORBITING UNIT (EDM) NOISE SUPPRESSION TRM21 W/ VMC 900 (EDM) ISOLATION TRANSFORMER KM5P UNCLAMP LIMIT SWITCH BMC 25-30K RS232 CABLES AXIS MISWIRE KM3/P MACHINE CONFIGURATION PROBLEMS (BCM 20-50 8.5 OR LATER) CRT CONTROLLER PCB-2. Revised 6/23/93 MAX 400 AMPLIFIER MODIFICATION. LEAD SCREW MAP INITIALIZATION v8.51 (BMC 20-50). CHAIN ROLLER, COUNTER WEIGHT (BMC 20-50. PARAJUST DIGITAL REVERSING PCB. (SPINDLE DRIVES) Z AXIS CRT ASSY. Revised 6/22/93 REV. A REV. C KNEE MILL PULLY CLUTCH SHAFT RETRO-FIT KIT. KM3/P UNCLAMP PUSH STUD LOCKNUT, LOCKTITE, BMC 20-50 SHAPE ELECTRONICS TRANSFORMER FUSES. MODIFICATION TO VOLTAGE DIVIDER PCB. ( TRM21/TRM39 ) TRANSFORMER COVER ( BMC 40SLV ). LUBE MODIFICATION KM5P. TYPE 1 ATC MODIFICATION FOR MAGAZINE OVERSHOOT. COUNTER WEIGHT NOISE ELIMINATION (BMC20-50 40SLV). ULTIMAX 3 DC POWER SUPPLY, REV. "C" NEW TERMINAL STRIP. CRP3 PCB MODIFICATION. BMC 20-50. OIL COOLER REPLACEMENT. BMC 30-50. 8-11-93 MAX 3 KEY BOARD BUTTON REPLACEMENT CHART. 10-29-93 CLAIREX SWITCH USED ON KM1/HM1 LIMIT SWITCHES. 1-4-94 TOOL RELEASE / KNOCK OUT LENGTH ON BMC'S.
FSB NUMBER
DESCRIPTION
1204 1205 1206 1207 1208 1209 1210 1211 1212 1213 1214 1215 1216 1217 1218-A 1219 1220 1221 1222 1223 1224 1225 1226-A 1227 1228 1229 1230 1231 1232 1233 1234-A 1235 1236 1237 1238 1239 1240 1241 1242 1243 1244 1245 1246 1247 1248 1249 1250
KM5D INPUT POWER, SOURCE FOR TRANSFORMER. KM3/3P MTE REMOVAL REPLACEMENT PROCEDURE. HAWK 5D MACHINE CONTROL PARAMETERS. HAWK 5D JO-BLOCK PROCEDURE FOR BACKLASH & LEADSCREW COMP. HAWK 5D SERVO AMP SET-UP PROCEDURE. HAWK 5D LIMIT SWITCH SET-UP PROCEDURE. HAWK 5M AUTO SPEED CONTROL PROM UPDATE. HAWK 5M I/O & CANBUS MAPPING. HAWK 5M SERVO AMP SET-UP. HAWK 5M PARAMETERS. HAWK 5M MONO CRT SETTINGS. REV. A HAWK 5M ADVANCED CMOS SET-UP. HAWK 5M LEAD SCREW MAP SET-UP. HAWK 5M & ISA HARD DRIVE SET-UP. YASKAWA AC SERVO SET-UP, MAX-2 & MAX-32 DUAL AXIS ACROLOC COOLANT PUMP LOW VOLUME HAWK 5M V1.51 HURCO.LDR FILE BMC SPINDLE HANDLING PRECAUTIONS HAWK 5M AXIS CURRENT SETUP ACCURACY STANDARD PROCEDURE HAWK 5M/5D TABLE T-SLOT ALIGNMENT HAWK 5M/5D DRAWBAR SET-UP KURT POWER DRAWBAR HAWK 5M/5D FLOOD COOLANT LEAKS POWER CABINET COOLANT LEAKS INCORRECT PARAMETER FOR WINDING CHANGE SERVO DYNAMICS DRIVE TUNE PROCEDURE DIGITAL SPINDLE CONTROLLER PCB MODIFICATIONS UPGRADE OF REMOTE SHUTDOWN RELAY (RSR) UPGRADE OF RS232C CABLES (COM1, COM2) KURT POWER HEADS & DRAWBAR SETUP RETROFIT OF DRIVE SPINDLES TO ACCEPT 18MM PROXIMITY SWITCHES MAX32 HARD DRIVES FRAME A FRL UNITS FRAME A Z AXIS CABLE DAMAGE ISA CARDRACK FAN REPLACEMENT ACROLOC 1540, 3030 OILING PROBLEMS BMC4020 NOISE PROBLEMS ISA CARDRACK TIPS 30SSM DAC SHIELD WORKLIGHT SUPPRESSION MODIFICATIONS SPINDLE AGREE FAULTS DURING RIGID TAP FUNCTIONS HARNESS BRACKET INSTALLATION ON BMC40/20 MACHINES. CANBUS CONTROLLER MODIFICATION SIEMENS DRIVE WIRING MODIFICATION COOLANT/OIL SEPARATOR RETROFIT SIEMENS FAST STOP SIGNAL MIS-WIRE
FSB NUMBER
DESCRIPTION
1251 1252 1253 1254 1255 1256 1257 1258 1259 1260 1261 1262 1263 1264 1265 1266 1267 1268 1269 1270 1271 1272 1273 1274 1275 1276 1277 1278 1279 1280 1281 1282 1283 1284 1285 1286 1287 1288 1289 1290 1291 1292 1293 1294 1295 1296 1297 1298 1299 1300 1301
V2.00 PARAMETER CHANGES M Code Mods for Frame "A" SPINDLE DRIVE FAULTS NOT REPORTED TO CONTROL FULL ENCLOSURE DOOR SLIDES 410-5001-002 AIR REQUIREMENTS / BMC3017, BMC4020 HAWK5M SERVO INHIBIT VERSION 2.0 PARAMETER CHANGES, BMC 4020 BMC3017SSM MODIFICATIONS MN3996
PAGE 6 OF 7 FSBINDEX.DOC 26-Jun-97
HURCO FIELD SERVICE BULLETIN

DATE: SUBJECT: AUGUST 24, 1981 TOOL CHANGER ALIGNMENT ISSUE NUMBER: 1001
SUPERSEDES NUMBER: 102 PAGE 1 OF 7
PRODUCT LINE: MB1
NOTE: DURING TC SET-UP, ENSURE TORQUE LIMITER NUT IS FULLY LOOSE UNTIL ALL OTHER ADJUSTMENTS ARE MADE. THIS PREVENTS THE ARM FROM SWINGING.
SHOT PIN ADJUSTMENT

1. 2. 3. 4. APPLY BLUEING TO LOWER SPINDLE COUPLING. ROTATE THE SPINDLE SO THE NOTCH IS NOT ALIGNED WITH THE SHOT PIN. ENERGIZE SHOT PIN MANUALLY, AND ROTATE SPINDLE. THE SHOT PIN SHOULD CONTACT LOWER SPINDLE COUPLING EVENLY. IF NOT, ADJUST SHOT PIN BRACKET AND REPEAT PROCEDURE. SHOT PIN LIMIT SWITCH ADJUSTMENT 1. INSTALL THE LIMIT SWITCH MOUNTING BRACKET USING LOCKTITE 242 ON THE B.H.C.S. NOTE: PLACE A TIE WRAP AROUND THE LIMIT SWITCH TO HOLD THE PLASTIC IN PLACE. 2. ROTATE THE SPINDLE UNTIL IT'S NOTCH IS DIRECTLY IN FRONT OF THE SHOT PIN CYLINDER. 3. ENERGIZE THE SHOT PIN MANUALLY (VALVE IN UPPER RIGHT SIDE OF SPINDLE HEAD CASTING). 4. WATCH FOR LIMIT SWITCH TO BE ACTUATED WHEN THE SHOT PIN IS ENERGIZED. 5. ORIENT THE SPINDLE TO THE POSITION WHERE THE SHOT PIN NOTCH IS NOT IN FRONT OF THE SHOT PIN. 6. ENERGIZE THE SHOT PIN. MAKE SURE THE SWITCH IS NOT ACTUATED, IF IT DOES, ADJUST THE LIMIT SWITCH, THEN REPEAT STEPS 3 AND 4. NO TOOL IN SPINDLE P.C. BRD MOUNTING AND ADJUSTMENT 1. ENSURE THE P.C. BOARD IS CORRECTLY COATED WITH HUMISEAL (BOTH SIDES. 2. INSTALL THE BOARD IN HEAD, USING B.H.C.S & LOCKTITE #242. 3. WATCH OPTICAL SWITCH WHILE ALTERNATING CLAMPING AND UNCLAMPING ENSURE THAT OPTICAL SWITCH DOES NOT RUB ON THE RING. 4. FINAL ADJUSTMENT IS MAKE AFTER THE OTHER LIMIT SWITCH ADJUSTMENTS ARE COMPLETE.
ORIGINATOR: REVISED BY:
WAYNE E. HAWKINS R. BRYANT
TC ARM SET UP
1. POSITION A PIECE OF WOOD PERPENDICULAR TO THE LEFT END OF THE TABLE. SET A SMALL HYDRAULIC JACK ON THE WOOD AND PLACE A BLOCK OF WOOD ON TOP OF THE JACK. RAISE JACK TO SUPPORT TC ASSEMBLY. 2. LOOSEN FOUR M12 S.H.C.S ADJUST JACK UNTIL TC ASSEMBLY IS LEVEL. POSITION LEVEL ON ARM WHEN ARM IS HALFWAY BETWEEN FULLY RETRACTED AND FULLY FORWARD. TIGHTEN SCREWS, REMOVE THE JACK, AND CHECK ARM AT FULLY RETRACTED, HALFWAY AND NEAR SPINDLE. THE ARM SHOULD NOT SWING BY ITSELF IN EITHER DIRECTION UPON RELEASE. 3. MOVE TC ARM UNDER SPINDLE AND RECHECK LEVEL. 4. MOVE ARM BACK, REMOVE SHOCK ABSORBER AND SCREW MECHANICAL STOP INTO ARM. 5. INSERT TOOL HOLDER IN SPINDLE. JOG Z-AXIS TO ALLOW THE TOOL CHANGER FINGERS TO ENGAGE THE TOOL HOLDER. DEPRESS THE EMERGENCY STOP. USING A TAPE MEASURE, MEASURE FROM THE LOWER SURFACE AT Z BALLNUT TO MATING AXIS STOP SURFACE. MB-1 MILLS REQUIRE 13.75". IF SLIGHTLY LESS, 13.6" OR GREATER, RAISE ARM FROM LEVEL POSITION A SMALL AMOUNT. RECHECK. 6. DEPRESS POWER ON TO RELEASE BRAKE. WHILE ACTIVATING SHOT PIN SOLENOID, ROTATE SPINDLE UNTIL SHOT PIN ENGAGES, DEPRESS EMERGENCY STOP. (THIS PROCEDURE WILL ALIGN THE TOOL HOLDER FOR A TOOL CHANGE ORIENTATION. 7. ENSURE THE GENEVA DRIVE ACTIVATES THE LIMIT SWITCH IN THE TOOL CAROUSEL THROUGHOUT THIS ADJUSTMENT PERIOD. POSITION TC ARM UNDER THE SPINDLE TO CHECK THE ALIGNMENT OF TC FINGER TO TOOL HOLD V SLOT. LOOK FOR DEFLECTION OF EACH FINGER. IF MISALIGNED, ADJUST FOUR M10 JACK SCREWS ON TC MOUNDING BRACKET SCREWS AND TIGHTENING M12A. BY ADJUSTING A SMALL AMOUNT AT A TIME, THE CORRECT ADJUSTMENT CAN BE DETERMINED. WHEN THE GENEVA DRIVE HAS EQUAL CW AND CCW MOTION, THE ARM IS CORRECTLY ADJUSTED. (ROTATING THE GENEVA DRIVE BY HAND WILL FORCE THE CAROUSEL TO ROTATE SLIGHTLY CW AND CCW UNTIL THE TOOL FINGERS TOUCH AGAINST IT'S NEIGHBORING FINGER. THE PHYSICAL AMOUNT OF GENEVA CW AND CCW MOTION SHOULD BE EQUAL FOR CENTER ADJUSTMENT.) 8. THE "CAROUSEL IN POSITION SWITCH-SHOULD BE ADJUSTED INTO ], (AND AS CLOSE AS POSSIBLE TO) THE GENEVA DRIVE TO ENSURE THE DRIVE STOPS ON THE FLAT READER PORTION. THIS SWITCH NOT ONLY ALLOWS TOOL POSITION TO BE READ, BUT MOST IMPORTANTLY COMMANDS THE TOOL CAROUSEL ROTATE MOTOR TO STOP ROTATING. THERE IS A SLIGHT MOTOR COASTING, SO THE SOONER THE SWITCH IS MADE THE SOONER THE MOTOR WILL STOP. (THE COASTING SHOULD LEAVE THE GENEVA DRIVE "FLAT" ON THE CENTER OF THE SWITCH. 9. WHEN ADJUSTMENTS ARE COMPLETE, USE LOCTITE # 242 ON ALL MOUNTING SCREWS. BY REMOVING AND LOCTITING ONE SCREW AT A TIME, THE ADJUSTMENTS WILL HOLD POSITION. TC ENCODER P.C. BOARD ADJUSTMENT 1. POWER ON TO RELEASE THE BRAKE. INSERT TOOL HOLDER IN SPINDLE, ACTIVATE THE SHOT PIN AND ROTATE THE SPINDLE UNTIL THE SHOT PIN ENGAGES THE NOTCH. 2. ROTATE CAROUSEL UNTIL TOOL #9 LINES UP WITH THE TOOL HOLDER IN THE SPINDLE. 3. DEPRESS THE EMERGENCY STOP. 4. POSITION ARM SO FINGERS ENGAGE THE TOOL HOLDER. NOTE: ENSURE THE GENEVA DRIVE ACTUATES THE LIMIT SWITCH. 5. THE NUMBER 9 SHOULD APPEAR ON THE CRT BESIDE COORDINATES. 6. IF NOT, ADJUST TC ENCODER BY LOOSENING THE BRACKET AND EITHER TURNING OR RAISING/LOWERING UNTIL #9 IS DISPLAYED. BY ROTATING THE PC BRD, THE # 8 WILL APPEAR IN ONE DIRECTION, AND #1 IN THE OTHER. ADJUST THE BOARD TO THE CENTER OF THIS BAND.
7. WHILE FINGERS ENGAGE THE TOOL HOLDER, GENTLY ROTATE GEAR IN BOTH DIRECTIONS TO THE PHYSICAL LIMIT. DEPRESS THE LIMIT SWITCH AT EACH LIMIT AND ENSURE #9 STILL APPEARS ON THE SCREEN. ID NOT, FINE ADJUST THE ENCODER BOARD. 8. MOVE THE ARM AWAY FROM THE TOOL. ROTATE GENEVA GEAR BY HAND TO ENSURE THE ENCODER BOARD PHOTO EYES DO NOT RUB ON THE ENCODER RINGS. 9. POWER ON, DEPRESS CHECK, OPERATE, ROTATE, AND WATCH THE SCREEN FOR EACH CORRECT TOOL NUMBER. 10. IF NO TOOL NUMBER IS DISPLAYED AS THE CAROUSEL MOVES INTO POSITION, THEN ADJUST TOOL CAROUSEL IN-POSITION LIMIT SWITCH. NOTE: IT MAY BE NECESSARY TO ADJUST THE TC ENCODER BOARD FOR ALL TOOL NUMBERS TO BE DISPLAYED. 11. IF THE WRONG TOOL NUMBER IS DISPLAYED, FINELY ADJUST THE TOOL CHANGER ENCODER BOARD. 12. USE LOCTITE #242 ON ALL MOUNTING SCREWS, REMOVING THEM ONE AT A TIME. MECHANICAL STOP ADJUSTMENT 1. POWER ON TO RELEASE THE BRAKE. INSERT TOOL HOLDER IN THE SPINDLE. ACTIVATE SHOT PIN AND ROTATE THE SPINDLE UNTIL SHOT PIN ENGAGES NOTCH. RELEASE THE SHOT PIN WITHOUT ROTATING THE SPINDLE. 2. DEPRESS THE EMERGENCY STOP. LOOSEN TORQUE LIMITER NUT. 3. MOVE ARM UNTIL FINGERS FULLY ENGAGE THE TOOL HOLDER. 4. ADJUST MECHANICAL STOP TO JUST "TOUCH OFF" THE STOP BLOCK. 5. TIGHTEN LOCKNUT (8mm) USING LOCTITE # 242. SHOCK ABSORBER INSTALLATION 1. INSTALL THE SHOCK ABSORBER IN THE ARM, SCREWING IN UNTIL BODY IS EVEN WITH THE ARM SURFACE. NOTE: DO NOT TIGHTEN LOCKNUT AT THIS TIME. 2. FINAL ADJUSTMENT WILL BE MADE IN LATER STEPS. TC HEIGHT ADJUSTMENT 1. DEPRESS POWER ON, CHECK OPERATE, TOOL CAL. 2. BRING THE HEAD DOWN WITH THE TOOL HOLDER CLAMPED IN THE SPINDLE TO PROPER ALIGNMENT WITH THE T/C FINGERS. (WHEN THE CAROUSEL IS MOVED INTO CONTACT WITH THE TOOL HOLDER). OBSERVE CAREFULLY THAT THE FINGERS ENGAGE THE "V" FLANGE OF THE HOLDER CENTRALLY UP AND DOWN AND RADIAL SO BOTH FINGERS OPEN APPROXIMATELY EQUALLY. 3. MOVE THE CAROUSEL BACK OUT OF THE WAY. IN DATE BLOCK "0", TOOL CALIBRATE, MOVE THE HEAD UP 2.4 INCHES. ADJUST THE ENCODER DISK ROTATION SO THE MARKER IS NOW ALIGNED AT THIS POINT. 4. YOU SHOULD NOW HAVE THE HEAD APPROXIMATELY .100 INCHES BELOW TOP LIMIT SWITCH SETTING. THIS .100 INCH MAY VARY AS THE T/C POSITION IS DETERMINED FROM THE FIRST MARKER PULSE/ ADJUST THE TOP LIMIT SWITCH UP OR DOWN AS NECESSARY TO STAY IN THE RANGE OF .075 TO .125. 5. USE LOCTITE #242 ON ALL MOUNTING SCREWS. 6. CHECK FOR Z TRAVEL (-16.050" TO -16.150". EMERGENCY STOP ARM DEFLECTION LIMIT SWITCH ADJUSTMENT. 1. MOUNT VEE BLOCK. POWER ON TO RELEASE THE BRAKE. INSERT TOOL HOLDER IN THE SPINDLE. ACTIVATE THE SHOT PIN AND ROTATE THE SPINDLE UNTIL SHOT PIN ENGAGES THE NOTCH. 2. DEPRESS THE EMERGENCY STOP. LOOSEN THE TORQUE LIMITER NUT. 3. MOVE THE ARM IN, UNTIL FINGERS ENGAGE THE TOOL HOLDER.
4. THIS STEP IS VERY IMPORTANT! ADJUST THE VEE BLOCK SO ANY ARM MOVEMENT INTERRUPTS THE SWITCH. 5. TEST ADJUSTMENT BY PERFORMING 10 TOOL CHANGES WITH NO TOOLS IN THE CAROUSEL. (NO TOOLS WILL ALLOW THE ARM TO FORWARD WITH MAXIMUM FORCE. IN SHOULD NOT TRIP SWITCH,) 6. USE LOCTITE #242 ON ALL MOUNTING SCREWS. ARM FORWARD LIMIT SWITCH ADJUSTMENT 1. POWER ON TO RELEASE THE BRAKE. INSERT TOOL HOLDER IN THE SPINDLE. ACTIVATE THE SHOT PIN AND ROTATE THE SPINDLE UNTIL THE PIN ENGAGES THE NOTCH. 2. DEPRESS THE EMERGENCY STOP. LOOSEN THE TORQUE LIMITED NUT. 3. MOVE THE ARM IN, UNTIL FINGERS FULLY ENGAGE THE TOOL HOLDER. 4. ADJUST ARM FORWARD SWITCH SO IT HAS JUST BEEN ACTIVATED. SWITCH SHOULD ACTIVATE SLIGHTLY BEFORE DESIRED FORWARD POSITION TO KEEP ARM FROM BANGING AT STOP. 5. USE LOCTITE # 242 ON SET SCREWS. ARM RETRACT 1. THE ARM RETRACT SWITCH IS ADJUSTED SO THE "COASTING" ACTION LEAVES THE ARM IN A SAFETY-RELATED POSITION, ALLOWING CLEARANCE FROM THE TC CARROUSEL TO THE HEAD OF THE MILL AND FROM THE CONDUIT TO CHAIN. (THERE IS NO MECHANICAL STOP IN THE RETRACT POSITION.) 2. USE LOCTITE # 242 ON SET SCREWS. CHAIN ADJUSTMENT 1. ADJUST CHAIN BY MOVING THE MOTOR BRACKET BACKWARDS OR FORWARD ON ITS SLOTS. 2. SLACK SHOULD BE TAKEN OUT, BUT THERE SHOULD BE NO PRESSURE APPLIED THROUGH CHAIN. THE DRIVE PACKAGE SHOULD BE HORIZONTAL, NOT AT AN ANGLE. 3. USE LOCTITE #242 ON ALL MOUNTING SCREWS AND SET SCREWS. TORQUE LIMITER ADJUSTMENT 1. MATE-IN THE TORQUE LIMITER BY TIGHTENING TO APPROXIMATELY FINAL TIGHTNESS, THEN ADDITIONAL 1/8 TURN. REQUEST TC WHILE HOLDING ARM STATIONARY. ALLOW THE LIMITER TO SPIN FOR 60 SECONDS. LOOSEN AND PROCEED. 2. USE A SMALL AMOUNT OF GREASE BETWEEN THE NUT AND LOCK WASHER TO PREVENT DAMAGE TO THE LOCK WASHER. 3. TIGHTEN THE NUT UNTIL THE ARM MOVEMENT BECOMES STIFF BY HAND. 4. DURING AN AUTOMATIC TOOL CHANGE, THE CLUTCH SHOULD SLIP APPROXIMATELY 1/4 TURN WHEN THE TOOL IS AT SPINDLE. 5. BEND TAB ON THE LOCK WASHER FULLY INTO GROOVE IN THE NUT TO PREVENT THE NUT FROM LOOSENING. DRY RUN THE CT WITH NO TOOL HOLDERS. SHOCK ADJUSTMENT 1. ADJUST SHOCK ABSORBER SO THE ARM HAS A SMALL AMOUNT OF "SLOW DOWN" WHEN TC FINGER ENGAGE THE TOOL HOLDER. BANGING NOISE SHOULD NOT OCCUR. AS MUCH OF THE SHOCK TRAVEL AS POSSIBLE SHOULD BE USED (APPROXIMATELY 3/4 " TO 7/8".) 2. TIGHTEN LOCKING NUT.
TOOL IN CAROUSEL LIMIT SWITCH NOTE: ENSURE ACTUATORS ARE LUBRICATED WITH OIL OR GREASE. 1. PLACE A TOOL IN EACH POSITION IN THE TOOL CAROUSEL. 2. ROTATE CAROUSEL AND STOP AT EACH POSITION. 3. ENSURE TOOL IN-CAROUSEL SWITCH IS ACTUATED AND THAT THE LIMIT SWITCH IS NOT ACTUATED WHEN THE TOOL IS REMOVED. NO TOOL IN-SPINDLE LIMIT SWITCH ADJUSTMENT WARNING: PLACE YOUR HAND NEAR THE EMERGENCY STOP BUTTON. 1. INSTALL TOOL HOLDER IN SPINDLE AND TOOL IN #1 SLOT IN CAROUSEL. IN DATA BLOCK 0, PROGRAM CUR TOOL 0 AND ATTEMPT TOOL CHANGE. CRT SHOULD READ ES TC ERROR. 2. OPTICAL SWITCH SHOULD BE MADE WITH NO TOOL IN SPINDLE AND NOT MADE WITH THE TOOL IN THE SPINDLE. ADJUST ACCORDINGLY. THE OPTIC SWITCH SHOULD NOT RUB THE ENCODER RING. 3. USE LOCTITE #242 ON THE MOUNTING SCREWS. FINE ADJUSTMENTS MAY BE REQUIRED THROUGHOUT TC, AS THE FIRST FEW AUTOMATIC TOOL CHANGES ARE MADE. HINT: ADJUSTING IN SMALL INCREMENTS AIDS IN FIND TUNING. SPINDLE ORIENT RPM 1. THE ORIENT RPM SHOULD BE 1 REVOLUTION PER 2 SECOND PERIOD. 2. JOG Z AXIS BELOW TOOL CHANGE HEIGHT (-2.4"0. CHANGE TOOL "VIA" DATA BLOCKS "0" AND DEPRESS MOTION HOLD BEFORE -2.4" IS REACHED. THE SPINDLE WILL TURN AT ORIENT SPEED AND R40 ON THE ISOLATION INTERFACE BOARD CAN BE ADJUSTED FOR THE CORRECT RPM RESEAL R40. Z AXIS TOOL CHANGER CURRENT LIMIT ADJUSTMENT 1. Z AXIS MUST RUN AT 250 IPM TOOL CHANGE SPEED. 2. TO ADJUST, RUN A LOOP DRILL FUNCTION, TOOL CAL AT 3.00", Z UP AND Z DOWN DIMENSION OF "0" INCHES. Z AXIS WILL THEN POSITION UP AND DOWN AT 250 IPM. INSTALLING A TEMPORARY JUMPER WIRE FROM +24 TO TB9-3 AND ANOTHER TEMPORARY JUMPER FROM IJ3-5 TO GROUND WILL ACTIVATE THE API RELAY AND THE 10K OHM POT, ON THE ATC RELAY PANEL WILL CONTROL THE Z AXIS CURRENT LIMIT. ADJUST THE Z AXIS CURRENT LIMIT POT ON THE ATC PANEL SO THE Z AXIS WILL JUST RUN RELIABLY. USE GLYPTOL ON THE POT. STEM TO HOLD IT'S POSITION. 3. PLACE PROTECTIVE STOCK BOX UNDER SPINDLE AND TC AREA TO SHIELD TABLE SURFACES FROM FALLING TOOLS. INSERT TOOL HOLDER IN SPINDLE. ATTEMPT AUTOMATIC TOOL CHANGE CAUTIOUSLY, BEING PREPARED TO DEPRESS EMERGENCY STOP OR MOTION HOLD. HINT: BY LOWERING THE RAPID TRAVERSE SPEED IN DATA BLOCK 0.1 TO 10 IPM, ANY TOOL DEFLECTION CAN BE SEEN AS THE TOOL IS RELEASED AND THE Z GOES UP, OR, WHEN Z AXIS COMES DOWN AND THE TOOL ENGAGES SPINDLE. BEFORE TC CYCLES 1. 2. 3. 4. RUN EACH TOOL POSITION AT LEAST TWICE IN AUTO TC. ENSURE TANG IS BENT TO LOCK NUT ON TORQUE LIMITER. ENSURE LOCKNUT IS TIGHT ON SHOCK ABSORBER. ENSURE SHOT PIN MOUNTING BOLTS ARE TIGHT.
5. ENSURE MOUNTING BOLTS FOR TOOL CHANGER ARM ARE TIGHT. 6. ENSURE LOCKNUT ON MECHANICAL STOP IS TIGHT. 7. ENSURE E.S. ARM DEFLECTION SWITCH IS CORRECTLY ADJUSTED AND OPERABLE. 8. ENSURE CHAIN HAS BEEN ADJUSTED. 9. ENSURE ALL MOUNTING SCREWS AND SET SCREWS HAVE BEN LOCTITED WITH #242. 10. ENSURE ALL TOOL HOLDERS TO BE USED FOR TC CYCLE DO NOT CONTAIN TOOLS. 11. PROCEED WITH CYCLING 12. AT LEAST THE LAST 250 TOOL CHANGES MUST HAVE THE COMPLETE COVERS MOUNTED DURING CYCLES. TOOL CHANGER PINNING THERE ARE TWO HOLES NEAR THE ARM MOUNTING BOLTS. DRILL THROUGH THESE HOLES INTO THE FRAME TO A DEPTH OF 3/4". DRILL SIZE Q, REAM SIZE IS .374" AND PIN SIZE IS PULL DOWEL 3/8 X 1 3/4 (HURCO PN 112-0013-001). SHOT PIN PINNING THERE ARE TWO HOLES NEAR THE MOUNTING BOLTS ON THE SHOT PIN BRACKET. DRILL INTO THE HEAD THROUGH THESE HOLES TO A DEPTH OF .50". USE DRILL SIZE 3/16" AND 3/16" X 1 1/4 SPRING PIN.

DATE: DEC. 22, 1981 ISSUE NUMBER: 1002
SUBJECT: RELIABILITY IMPROVEMENT B INTERFACE BRD SUPERSEDES NUMBER: 117 PRODUCT LINE: ALL B CONTROL MILLS PAGE 1 OF 1
THIS MODIFICATION SHOULD BE MADE WHEN A MACHINE EXHIBITS MANUAL JOG HAND WHEEL RESPONSE PROBLEMS. THIS MODIFICATION SHOULD BE ACCOMPLISHED PRIOR TO ORDERING A REPLACEMENT INTERFACE BOARD. REFERENCE SCHEMATIC AND PICTORIAL ATTACHED: 1. CUT LAND TO PIN 6 OF 14035 AT THE POINT SHOWN ON SHEET TWO WHICH IS MARKED BUY THE X. 2. ADD JUMPERS AS SHOWN ON THE NON COMPONENT SIDE OF THE BOARD, INSTALL ONE JUMPER FROM PIN 24 TO PIN 10 OF THE 7400. 3. ADD A 2K OHM RESISTOR FROM PIN 8 TO PIN 14 OF THE 7400 ON THE COMPONENT SIDE OF THE BOARD AS SHOWN ON SHEET THREE. PARTS REQUIRED: 1. ONE 2K OHM 1/4 WATT RESISTOR 407-0007-030. 2 EIGHT INCHES OF 28-30 GAUGE SOLID INSULATED WIRE. SHEET FIVE SHOWS THE SCHEMATIC OF THE INTERFACE BOARD. SHEET FOUR SHOWS THE MODIFICATION AS IT APPEARS ELECTRICALLY.
ORIGINATOR: WAYNE HAWKINS REVISED BY: R BRYANT

DATE: JANUARY 5, 1982 ISSUE NUMBER: 1003
SUBJECT:NUISANCE SHEAR PINNING ON PARAJUST B SUPERSEDES NUMBER: 119 PRODUCT LINE: ALL B AND BX BED MILLS PAGE 1 OF 1
WE HAVE RECENTLY FOUND THAT NUISANCE SHEAR PINNING IS NOT CAUSED BY THE ACTUAL SHEAR PIN CIRCUITRY BUT IS CAUSED BY THE SHEAR PIN RESET CIRCUITRY. THIS CIRCUIT DRAWN BELOW IS COMPOSED OF NORMALLY CLOSED SET OF K1 CONTACTS, CAPACITOR C12 ON THE FREQUENCY CONTROL BOARD AND K5 RELAY ON THE VOLTAGE CONTROL BOARD. WHENEVER WE TURN THE DRIVE OFF WE DROP OUT THE K1 RELAY WHICH IN TURN CLOSES THE K1 CONTACTS ALLOWING CURRENT TO FLOW THROUGH THE K5 RELAY COIL. THE K5 WILL THEN PICK UP AND SHOULD STAY PICKED UP UNTIL CAPACITOR C12 CHARGES AT WHICH POINT K5 THEN DROPS OUT. THIS IS THE REASON WHY, WHENEVER WE DO A TOOL CHANGE, IT APPEARS THAT WE GET A SHEAR PIN INDICATION. IF WE DISABLE THE CIRCUIT BY CLIPPING CAPACITOR C12 OUT THE NUISANCE SHEAR PIN WILL GO AWAY. WE CAN ALSO ATTRIBUTE THE K5 STICKING RELAY PROBLEM TO THIS SAME CIRCUIT IF CAPACITOR C12 IS LEAKY IT MIGHT ALLOW ENOUGH CURRENT TO FLOW EVEN WHEN CHARGED TO HOLD THE K5 RELAY ON. THIS WOULD BE SEEN AS A STUCK RELAY AND TAPPING THE RELAY USUALLY DROPS IT OUT. IF YOU SHOULD RUN INTO THIS PROBLEM TRY CLIPPING C12 AND RUNNING THE MACHINE TO SEE IF THE PROBLEM GOES AWAY. IF IT DOES NOT GO AWAY WHEN IT IS AN ACTUAL SHEAR PIN AND SHOULD BE INVESTIGATED TO FIND THE CAUSE OF THE PROBLEM.
ORIGINATOR: WAYNE HAWKINS REVISED BY:

DATE: JANUARY 18, 1982 SUBJECT: ENCODER INSTALLATION ISSUE NUMBER: 1004 SUPERSEDES NUMBER: 120 PAGE 1 REMOVAL 1. ACCESS THE ENCODER FOR THE Z AXIS BY REMOVING THE FIBERGLASS HALF- COVER, FOR THE X AXIS THE MOTOR COVER AND FOR THE Y AXIS, THE COVER ON THE Y MAIN FRAME. 2. REMOVE THE BLACK PLASTIC ENCODER CAP. 3. UNPLUG THE ENCODER. PULL APART THE PLUG BODIES ONLY. DO NOT PULL ON THE WIRES GOING INTO THE PLUGS. 4. REMOVE THE TWO SCREWS HOLDING THE ENCODER BODY TO THE LIMIT SWITCH BRACKET. REMOVE THE BODY BY PULLING IT AT A RIGHT ANGLE AWAY FROM THE DISK SHAFT. 5. LOOSEN THE TWO SCREWS HOLDING THE DISK TO THE SHAFT AND REMOVE THE DISK. THESE SET SCREWS MAY BE EITHER BRISTOL SPINE OR HEX. CAUTION: THE DISK CAN BE EASILY CHIPPED CRACKED OR SCRATCHED AND SHOULD BE HANDLED WITH CARE. INSTALLATION 1. CLEAN AREA ON LIMIT SWITCH ASSEMBLY BRACKET WHERE ENCODER MOUNTS. 2. PLACE THE ENCODER DISK ON THE ENCODER SHAFT. DO NOT TIGHTEN SET SCREWS. 3. CAREFULLY PLACE THE ENCODER BODY AROUND THE DISK, BEING CAREFUL NOT TO SCRATCH THE DISK. SCREW THE ENCODER BODY TO THE LIMIT SWITCH BRACKET. CAUTION: USE A THIN-BLADED SCREWDRIVER WHEN TIGHTENING THE MOUNTING SCREWS, A LARGE BLADED SCREWDRIVER CAN DAMAGE THE DISK BECAUSE OF THE PROXIMITY OF THE DISK EDGE TO THE SCREW HEAD. 4. INSERT THE .008" SHIM BETWEEN THE DISK AND THE READING HEAD ON THE ENCODER BODY. ADJUST THE DISK TO THE SHIM AND THE BODY AND TIGHTEN THE SET SCREWS. REMOVE THE SHIM. THE .008" DIMENSION IS THE CORRECT DISK-TO-READING HEAD GAP. 5. PLUG IN THE NEW ENCODER. 6. IF POSSIBLE SET UP A DUAL TRACE OSCILLOSCOPE TO PINS 1 AND 2 OF SJ 3,4 OR 5 ON THE SERVO CONTROL BOARD. JOG THE AXIS AT 50 INCHES PER MINUTE TO ENSURE THAT BOTH PHASES ARE CHANGING AND 90 DEGREES SHIFTED. OF 1
PRODUCT LINE: KM1
ORIGINATOR: UNKNOWN REVISED BY: R. BRYANT
DATE:FEBRUARY 10, 1982

SUBJECT: POWER DOWN MEMORY CIRCUIT PRODUCT LINE: B CONTROL MILLS
ISSUE NUMBER: 1005

SUPERSEDES NUMBER: 122 PAGE 1 OF 2
THIS BULLETIN IS TO CLARIFY THE BATTERY PROTECTION CIRCUIT USED IN THE B CONTROL MILLS. FIGURE 1 SHOWS THE BASIC HARDWIRING CIRCUIT BETWEEN THE DC POWER SUPPLY AND THE MPU AND THE MEMORY BOARDS. THIS DRAWING DOES NOT SHOW ALL THE WIRING, BUT ONLY THOSE INVOLVED WITH THE MEMORY BACKUP SUPPLY FOR POWER DOWN CONDITIONS. ALL MILL SUPPLIES ARE BASICALLY THE SAME, THE ONLY DIFFERENCE WOULD BE THAT OF SPECIFIC WIRE LOCATIONS. REFER TO THE OWNER'S MANUAL OF THE PARTICULAR MACHINE YOU ARE WORKING ON. FIGURE 2 SHOWS THE ACTUAL POWER CIRCUIT WHICH EXISTS ON THE MPU BOARD AND TIED TOGETHER WITH THE MEMORY BOARDS BY THE BACKPLANE CABLE J1-50. THE BATTERY PRESENTLY IS USED UP TO 3.7 VDC AND SLOWLY BLEED OFF POWER UNTIL IT REACHES APPROXIMATELY 2.0 VDC BELOW THIS LEVEL THE HARDWARE ON THE MEMORY BOARDS (U1, U3, U12) IS NOT RATED TO PERFORM AND A MEMORY FAILURE MAY OCCUR. IN TROUBLE-SHOOTING A SYSTEM, IT IMPERATIVE TO ASSURE ALL BOARDS HAVE THE CORRECT VOLTAGES PRESENT DURING A POWER DOWN CONDITION. UNTIL YOU DO THIS, BY MEASURING THE BOARDS PLUS VERIFYING WIRING, YOU CAN NOT ASSUME YOU HAVE A MEMORY OF MPU BOARD FAILURE.
ORIGINATOR: JERRY MC CLATCHEY REVISED BY: R. BRYANT

DATE: MARCH 30, 1982 SUBJECT: PROPER AXIS CURRENT DRAW FOR KMB-1 PRODUCT LINE: KMB-1 ISSUE NUMBER: 1006 SUPERSEDES NUMBER: 126 PAGE 1 OF 1
IT APPEARS THERE IS SOME CONFUSION WITH AXIS CURRENT READINGS AND ADJUSTMENT FOR THE KMB-1 X, Y AND Z AXIS. THE MACHINES ARE SET UP ON THE MANUFACTURING FLOOR TO DRAW BETWEEN 4.5 AND 5.5 AMPS AT 50 IPM. THIS ACCOMMODATES THE PRE-LOAD SETTINGS OF THE BEARING'S AND ALLOWS THE RIGIDITY OF THE MACHINE TO PASS SQUARENESS AND GEOMETRY TESTS. THE CURRENT DRAW IS NOT TAKEN INTO CONSIDERATION ON THE LAST ONE INCH OF POSITIVE Y AXIS TRAVEL BECAUSE OF THE CONSTRUCTION OF THE SADDLE ASSEMBLY AND THE FACT THAT THE WAYS HAVE A SLIGHT OUTWARD BOW BUILT INTO THEM. ALSO, THE LAST ONE INCH OF THE NEGATIVE X AXIS TRAVEL IS NOT CONSIDERED BECAUSE OF THE MOTOR MOUNTING BRACKET AND THE CRITICAL ALIGNMENT OF BALL SCREW. MANUFACTURING IS ALLOWING UP TO 7 AMPS INTERMITTENTLY ON THE AXIS WHEN THE MACHINE HAS THE MODERN STYLE BALL NUT. THE WAY YOU CAN TELL THE DIFFERENCE BETWEEN THE MODERN STYLE AND THE OLD NUT IS BY LOOKING AT THE BALL NUT ITSELF. THE MODERN NUT HAS TWO METAL BANDS IN PLACE AROUND BALL RETURN TUBES. ALSO, THESE RETURN TUBES ARE MUCH MORE PRONOUNCED ON THE MODERN BALL NUT, WHEREAS, THE OLD ONES WERE CONSTRUCTED WITHIN THE NUT ITSELF. THE NUT EASILY ACCESSIBLE ON THE Y AXIS BY SIMPLY REMOVING THE METAL PLATE ON THE RIGHT SIDE OF THE KNEE. TO GET TO THE X AXIS TO DETERMINE WHICH STYLE IT IS SIMPLY RUN THE X AXIS TO THE FULL POSITIVE POSITION, THEN LOOK UNDERNEATH THE TABLE AT THE NUT ITSELF. THE Z AXIS IS ACCESSIBLE BY JUST REMOVING THE FRONT COVER ON THE HEAD AND LOOKING IN AT THE NUT. TO ELIMINATE ANY CONFUSION INSETTING THESE CURRENTS, A NORMAL CURRENT DRAW IS TO BE BETWEEN 4.5 AND 5.5 AMPS ON THE OLD AS WELL AS THE NEW BALL NUT THE MODERN NUT CAN DRAW UP TO 7 AMPS INTERMITTENTLY. THESE CURRENT READINGS SHOULD BE TAKEN FROM THE FULL LIMITS OF AXIS TRAVEL WITH THE EXCEPTION OF THE LAST ONE INCH IN THE X AXIS AND THE LAST ONE INCH IN THE Y AXIS. THE READINGS SHOULD BE CONSISTENT OVER THE WHOLE LENGTH OF TRAVEL. WHEN THE AXIS IS STILL THE STANDING CURRENT IS TO BE A MAXIMUM OF 2.5 AMPS. TYPICAL STANDING CURRENT IS 1 TO 1.5 AMPS.
ORIGINATOR: RANDALL RENNEKAMP REVISED BY: R. BRYANT
DATE: MARCH 26, 1982 SUBJECT: MB1 SHOT PIN LIMIT SWITCH PRODUCT LINE: MB1 MILL
ISSUE NUMBER: 1007 SUPERSEDES NUMBER: 128 PAGE 1 OF 2
IN THE PAST WE HAVE EXPERIENCED MANY PROBLEMS WITH THE SHOT PIN LIMIT SWITCH ON THE MB1 MACHINES. THE NEW STYLE LIMIT SWITCH DESIGN THAT IS USED ON THE MB1H MACHINE SEEMS TO BE FAR SUPERIOR. THEREFORE IF YOU RUN INTO A MACHINE WITH PROBLEMS RELATED TO THE SHOT PIN LIMIT SWITCH, IT MAY BE A GOOD IDEA TO RETROFIT THE NEW STYLE PROXIMITY SWITCH. THIS CAN BE ACCOMPLISHED QUITE EASILY AND REQUIRES ONLY A FEW PARTS. 1) 802-0914-001 2) 117-0001-015 3) 101-0001-005 4) 110-1005-001 5) 423-1005-001 6) 406-2523-001 7) 406-0801-006 8) 406-0801-002 BRACKET 1 4-40 HEX NUT 2 4-40 X 3/4 SHCS 2 4 INTERNAL STARWASHER PROXIMITY SWITCH 1 20 GA RED WIRE MOLEX PINS 3 MOLEX BODY 1
2 12"
PROCEDURE 1. REMOVE POWER FROM THE MACHINE. 2. REMOVE BROWN AND WHITE WIRES FROM THE EXISTING SHOT PIN LIMIT SWITCH. THESE WILL BE USED LATER SO DO NOT CUT THEM OFF. 3. REMOVE OLD LIMIT SWITCH AND BRACKET BY REMOVING THE TWO BUTTON HEAD SCREWS. SAVE THESE SCREWS FOR FUTURE USE. 4. MOUNT NEW PROXIMITY SWITCH ONTO NEW BRACKET USING THE TWO STAR WASHERS AND THE TWO #4-40X3/4 SOCKET HEAD CAP SCREWS AND THE TWO 4-40 HEX NUTS. 5. MOUNT THE NEW SWITCH AND THE BRACKET TO THE SHOT PIN ASSEMBLY USING THE BUTTON HEAD SCREWS, WHICH WERE REMOVED IN STEP 2. 6. ATTACH A MOLEX PIN TO EACH OF THE BROWN AND THE WHITE WIRES, WHICH WERE REMOVED IN STEP 1. ALSO ATTACH A MOLEX PIN TO ONE END OF THE RED WIRE.
7. INSERT THE THREE MOLEX PINS INTO THE MOLEX BODY SUCH THAT PIN 1 IS RED, PIN 2 IS WHITE AND PIN 3 IS BROWN. WHEN THE SWITCH IS PLUGGED INTO THIS CONNECTOR, THE RED WIRES SHOULD CONNECT, THE WHITE WIRE SHOULD CONNECT TO THE BLACK WIRE FROM THE SWITCH AND THE BROWN WIRE SHOULD CONNECT TO THE WHITE WIRE FROM THE SWITCH. 8. CONNECT THE OTHER END OF THE RED WIRE TO PIN 1 OF THE TOOL IN SPINDLE PHOTO CELL SWITCH ASSEMBLY. THIS SHOULD SUPPLY +5VDC TO THE SWITCH. 9. UNPLUG THE PROXIMITY SWITCH AND APPLY POWER. CHECK FOR +5 WITH A METER AT THE MOLEX PLUG YOU JUST INSTALLED, FROM PIN 1 (RED WIRE) TO PIN 2 (WHITE WIRE). 10. PLUG THE PROXIMITY SWITCH IN AND LOAD THE MASTER TAPE. SELECT LANGUAGE AND PUT THE CONTROL IN EMERGENCY STOP. PUSH POWER ON BUTTON TO RELEASE SPINDLE BRAKE. MONITOR PIN 2 OF THE MOLEX CONNECTOR. 11. ROTATE SPINDLE BY HAND UNTIL NOTCH IN SPINDLE IS DIRECTLY IN FRONT OF SHOT PIN CYLINDER. 12. ENERGIZE SHOT PIN AIR VALVE IN UPPER RIGHT SECTION OF HEAD. WATCH SIGNAL FOR A LOW INDICATION WHEN THE SHOT PIN IS ENERGIZED. IF NOT LOW INDICATION APPEARS, ADJUST THE SWITCH UNTIL A LOW SIGNAL IS OBTAINED. 13. ROTATE THE SPINDLE UNTIL THE NOTCH IS NOT IN FRONT OF THE SHOT PIN CYLINDER. 14. ENERGIZE THE SHOT PIN AIR VALVE AND WATCH THE SIGNAL. A LOW INDICATION SHOULD NOT APPEAR. ID A LOW SIGNAL IS SEEN, ADJUST THE SWITCH UNTIL THE LOW SIGNAL IS NOT PRESENT. 15. REPEAT STEPS 11-14 UNTIL THE PROPER ADJUSTMENT ID OBTAINED. A LOW INDICATION SHOULD ONLY BE SEEN WHEN THE SHOT PIN IS IN THE NOTCH ON THE SPINDLE. 16. ONCE PROPER ADJUSTMENT IS OBTAINED. REMOVE THE BUTTON HEAD MOUNTING SCREWS ONE AT A TIME AND APPLY LOCTITE # 242 AND RE-INSTALL THE SCREWS. 17. SET THE MACHINE AND RUN AN AUTO TOOL CHANGE TO BE SURE THAT THE SWITCH IS WORKING PROPERLY. 18. THIS COMPLETES THE RETROFIT AND THE LAST STEP IS TO NOTE ON YOUR SERVICE REPORT THAT THIS RETROFIT HAS BEEN DONE. NOTE: THE MOUNTING BRACKET IS TAPPED FOR M2.5X.45 SCREWS SO IT MAY BE NECESSARY TO ENLARGE THE HOLES IN ORDER TO GET THE 4-40 SCREWS THROUGH.
DATE: APRIL 16, 1982 SUBJECT: PARAJUST B CHOPPER BOARDS
PRODUCT LINE: ALL BED MILLS USING B PARAJUST
RECENTLY WE HAVE BEEN MADE AWARE THAT THERE IS SOME CONFUSION PERTAINING TO THE CHOPPER BOARS FOR A PARAJUST B UNIT. THE QUESTION WAS ASKED IF THE MBII STYLE CHOPPER BOARD AND THE MBIH STYLE CHOPPER BOARD WERE THE SAME. THE MBII 10 AND 15HP PARAJUST UNITS USE A CHOPPER BOARD WITH THE PART NUMBER 402-6005-009; THE MBIH 7 1/2 HP PARAJUST UNITS USE A CHOPPER WITH PART NUMBER 402-5004-005. THE ONLY DIFFERENCE BETWEEN THESE TWO CHOPPER BOARDS IS THE VALVE OF RESISTOR R2. FOR 10HP AND 15 HP UNITS THE VALUE SHOULD BE 2.. OHMS, FOR THE 7 1/2 HP UNITS R2 VALUE IS 390 OHMS. IF YOU ARE IN THE FIELD AND SHOULD HAPPEN TO RECEIVE A CHOPPER BOARD FOR REPLACEMENT INTO A MACHINE IT MAY BE A WISE IDEA TO VERIFY THE VALUE OF R2, JUST TO BE SURE THAT YOU HAVE THE CORRECT CHOPPER BOARD FOR THE MACHINE YOU ARE WORKING ON. ALSO, IF YOU RECEIVE ONE STYLE BOARD AND FIND THAT R2 IS NOT WHAT YOU REALLY NEED YOU CAN SIMPLY CHANGE THE VALUE OF R2 TO MAKE THE CHOPPER WORK IN YOUR PARTICULAR MODEL OF MACHINE.
DATE: MAY 3, 1982 SUBJECT: PARAJUST A SETUP
PRODUCT LINE: ANY MILL USING PARAJUST A MATERIALS REQUIRED: DIGITAL TACHOMETER OSCILLOSCOPE DIGITAL MULTI-METER
1. TURN ODD DISCONNECT SWITCH TO REMOVE POWER. 2. CHECK ALL TERMINAL STRIPS FOR TIGHT SCREWS AND GOOD CRIMP CONNECTIONS. 3. VERIFY THE FOLLOWING. A. CAUTION HIGH VOLTAGE LABELS IN PROPER PLACE. B. GROUND WIRE FROM PARAJUST CHASSIS TO ITS, MECCA GROUND ASSEMBLY C. GROUND WIRE FROM SPINDLE MOTOR TO PARAJUST CABINET. D. POLARITY OF WIRING CORRECT .015 OHM CURRENT SENSE RESISTOR. (BLACK ON TOP, WHITE OR CLEAR ON BOTTOM). E. INSURE SLIDE SWITCH S1 ON THE ANALOG BOARD IS IN THE L POSITION. F. INSURE SLIDE SWITCH S2 ON THE ANALOG BOARD IS IN THE 5HP POSITION. G. INSURE ALL TERMINALS ON THE DC BUSS CAPACITORS ARE SOLDERED. H. INSURE RESISTANCE ON THE DYNAMIC BRAKE BOARD OUTPUT RESISTORS IS BETWEEN 11 AND 13 PHMS, AND WIRE INTO THE PARAJUST PROPERLY. 4. THE RESISTANCE MEASURED BETWEEN THE ISOLATION INTERFACE BOARD TERMINAL # 11 AND TERMINAL # 14 MUST BE GREATER THAN 19 MEG OHM. 5. INSURE THAT THE DIODES MARE MOUNTED CORRECTLY ON THE DYNAMIC BRAKING BOARD, (DIODES ARE IN5626 PART NUMBER 417-0001-017. NOTE DIODES MAY BE PREWIRED ON THE BRAKING BOARD). TWO LEADS OF THE DIODES COME FROM TB7-1, THE TOP DIODE HAS THE BANDED END COMING FROM TB7-1 THE BOTTOM AWAY FROM TB7-1 THE OTHER END OF THE TOP DIODE GOES TO TB6 NEG TERMINAL. THE OTHER END OF THE BOTTOM DIODE THE BANDED END GOES TO TB6 POSITIVE TERMINAL. ORIGINATOR: RANDAL RENNEKANP REVISED BY: R. BRYANT
DYNAMIC BRAKING BOARD DIODES:
6. SET THE FOLLOWING POTS AS SPECIFIED: ANALOG BOARD ACC/DEC V/HZ BOOST SHEAR PIN BRAKE BOARD GAIN FULL CCW FULL CCW,CW 1/4 T
FULL CW 50% THRESHOLD FULL CCW FULL CW
7. THE RESISTANCE BETWEEN TB1-10 AND TB1-11 MUST BE 0 OHMS. 8. CONFIRM THAT THE PARAJUST BRAKE BOARD C3 IS A .56 UFD 200 VDC CAPACITOR. 9. ISOLATION INTERFACE BOARD SETUP PROCEDURE: A. POSITION THE AUTO-MANUAL SWITCH TO THE AUTO POSITION. B. ROTATE R65 TO ITS' MAXIMUM CCW POSITION. C. APPLY POWER. MEASURE AC INPUT TO THE PARAJUST 218 TO 253 VAC. D. CHECK FOR 2.2 VDC INPUT AT TERMINAL #12 WITH RESPECT TO TERMINAL #13 WITH AN INPUT COMMAND OF 896 RPM ON THE CRT. (READ A JUST THE DAC INPUT ON THE CNC INTERFACE IF NEEDED). SEAL POT WITH TORQUE SEAL (HURCO PART NUMBER 348-0001-001). E. COMMAND AN INPUT OF 208 RPM ON THE CRT AND ADJUST R27 UNTIL THE SPINDLE RPM MEASURES 230-235 ON THE DIGITAL TACH. F. COMMAND AN INPUT OF 3408 RPM ON THE CRT AND ADJUST R26 UNTIL THE SPINDLE RPM MEASURES 3400 TO 3415. G. RE-CHECK 208 AND 3408 RPM AND INSURE BOTH ARE WITHIN THE TOLERANCE SPECIFIED. IF OUT OF SPECIFICATION, REPEAT STEPS E AND F. H. CHECK THE FOLLOWING RPM,S. PROGRAM ACCEPTABLE RANGE 144 163-175 240 250-270 496 500-530 1008 1000-1070 2016 1995-2110 3600 3540-3620 IF THE RPM FALLS BELOW 3540, SUBSTITUTE THE FOLLOWING VALUES FOR 18K RESISTOR R9 AND R17 ON THE ISOLATION INTERFACE BOARD. R9 - 13K R18 - 15K THESE WILL WORK ON 9 OUT OF TEN BOARDS. THE REMAINING BOARDS WILL REQUIRE DECADE BOXES TO TRIM. I. IF A TOOL CHANGER IS PRESENT, COMMAND A TOOL CHANGE AND ADJUST R40 UNTIL THE PROPER ORIENT SPEED ID REACHED. THIS IS TO BE 1 REVOLUTION /2 SECONDS. IN MOST CASES. J. CHECK TO SEE IF THE SCREWDRIVER ADJUSTMENT OF R56 AND R51 HAVE BEEN SEALED. IF THEY HAVE NOT. PROCEED THRU A-H IF THEY HAVE GOTO STEP 12
A. WITH A DIGITAL VOLTAGE METER, ADJUST R56 UNTIL PIN 3 OF IC12 EQUALS 5.4 VDC WITH RESPECT TO PHASE B. (OUTPUT SIGNAL COMMON, PIN 5 ISOLATION INTERFACE BOARD). B. REMOVE POWER. C. IMPORTANT TEMPORARILY REMOVE THE LEADS COMING FROM THE CURRENT SENSE RESISTOR INPUT TERMINALS NUMBER 6 AND 7. D. TEMPORARILY SHORT INPUT TERMINALS 5 AND 6 TOGETHER. E. TEMPORARILY CLIP LEAD INPUT TERMINAL # 7 TO PIN 3 OF IC8 AND SHORT OUT VRS. F. WHEN POWER IS NOW REAPPLIED THERE SHOULD EXIST AN INPUT OF ABOUT .138 VDC BETWEEN TERMINALS 6 AND 7. G. MONITORING PIN 6 OF IC11 WITH RESPECT TO PHASE B (OUTPUT SIGNAL COMMON, PIN #5 ISOLATION INTERFACE BOARD) WITH A DIGITAL VOLTMETER, ADJUST R51 UNTIL PIN 6 MEASURES 10.47 TIMES THE VDC BETWEEN TERMINALS 6 AND 7. H. REMOVE ALL CLIP LEADS, TEMPORARY SHORTS AND RECONNECT THE CURRENT SENSE RESISTOR TO INPUT TERMINALS 6 AND 7. CAREFULLY NOTING POLARITY. (WHITE OR CLEAR PIN 6, BLACK PIN 7). SEAL THE ADJUSTMENTS OF ALL POTS ON P.C. BOARD WITH TORQUE SEAL (HURCO PART NUMBER 348- 0001-001). 12. DISCONNECT POWER, BE SURE THAT THE LARGE FILTER CAPACITORS INSIDE THE PARAJUST ARE DISCHARGED. 13. POSITION THE AUTO/MANUAL SWITCH OF ISOLATION INTERFACE BOARD THE MANUAL POSITION. POSITION R38 FULL CCW THEN TURN CW 6 TURNS 14. RE-APPLY POWER. MEASURE AC INPUT TO PARAJUST, 218 TO 253 VAC. 15. ENERGIZE SPINDLE. A. POSITION R38 UNTIL SPINDLE RPM FALLS BETWEEN 200-208 RPM'S READING FROM THE DIGITAL TACH. ADJUST THE PARAJUST BOOST UNTIL THE SPINDLE MEASURES 72.2 TO 43.4 VDC ON THE DC BUSS CAPACITORS (BOTH LELAND AND G.E. MOTORS). 16. POSITION R38 UNTIL THE SPINDLE RPM FALLS BETWEEN 896-900 RPM ON THE DIGITAL TACH. ADJUST PARAJUST V/HZ POTENTIOMETER UNTIL PARAJUST DC BUSS VOLTAGE MEASURES 278 TO 282 VDC. (BOTH LELAND AND G.E. MOTORS) 17. REPEAT STEPS 15 AND 16 UNTIL NO FURTHER ADJUSTMENTS ARE NECESSARY. 18. ADJUST R38 UNTIL THE SPINDLE SPEED IS 2000 RPM, ON THE DIGITAL TACH, WILE SWITCHING THE AUTO-MANUAL SWITCH BETWEEN OFF AND MANUAL, SET THE RAMP UP AND DOWN WITH THE ACCEL/DECEL POTS, WHILE THE OSCILLOSCOPE IS CONNECTED AT TB1-12 AND TB1-13 (PARAJUST COMMON) FOR A RAMP OF 3 SECONDS FOR LELAND MOTOR AND A RAMP OF 1.4 SECONDS FOR A G.E. MOTOR NOTE: IF THIS ADJUSTMENT CANNOT BE SET LESS THAN OR EQUAL TO 3 SECONDS FOR LELAND MOTOR, CHECK THE SIZE OF C7 ON THE ANALOG BOARD AND REPLACE WITH A 10 UFD 25V CAPACITOR IF NEEDED. CAUTION: THE RED WIRE OF THE CAP BANK CAN BE FLOATING AT 300 VOLTS ABOVE CHASSIS. THE SCOPE CHASSIS WILL ALSO BE AT THIS POTENTIAL WHEN THE GROUND IS CONNECTED TO THE PARAJUST SIGNAL COMMON. DO NOT HAVE THE SAFETY GROUND ON THE SCOPE HOOKED UP ALSO THE METAL OF THE SCOPE WILL BE AT THIS VOLTAGE DO NOT TOUCH. THIS RAMP DOWN AND RAMP UP REFERS TO THE MAXIMUM SPINDLE MOTOR ACCELERATION FROM 9 TO 2000 RPM AND A MAXIMUM SPINDLE MOTOR DECELERATION FROM 2000 TO 0 RPM.

DATE: MAY 7, 1982 SUBJECT: CHATTER ON KMB-IM & KMB-I MILLS PRODUCT LINE: KONDIA STYLE KNEEL MILLS ISSUE NUMBER: 1010 SUPERSEDES NUMBER: 132 PAGE 1 OF 1
WHEN CUTTING FAIRLY MILD CUTS IN ALUMINUM OR STEEL, SOME MACHINES SEEM TO SHOW EXCESSIVE CHATTER IN THE SPINDLE. WHEN THERE IS A PROBLEM, THE NOISE IS USUALLY MORE PREVALENT WHEN AN AXIS IS MILLING IN ONE DIRECTION, WHILE THE OTHER DIRECTION SEEMS MUCH SMOOTHER. CHECK TO SEE ID THERE IS A GAP BETWEEN THE SPINDLE NUT AND THE QUILL. THE SPINDLE NUT HOLDS THE SPINDLE UP IN THE QUILL AND PUTS THE PRELOAD ON THE OUTER RACES OF THE SPINDLE BEARING'S. IF THERE IS NO GAP THIS MEANS THE QUILL NUT IS BOTTOMED OUT AND THERE PROBABLY WON'T BE SUFFICIENT PRELOAD ON THE BEARING'S. THE MINIMUM GAP IS .010 INCH. WE DON'T WANT A LARGE GAP BECAUSE IT COULD BE A CHIP TRAP AND DRAG CHIPS INTO THE BORE. IF YOU HAVE A MACHINE WHICH HAS NO CLEARANCE. THE NUT MUST BE REMOVED AND TURNED DOWN ON A LATHE. TO REMOVE THIS NUT YOU MUST FIRST REMOVE THE ERICHSON OR UNIVERSAL SPINDLE NUT. THEN LOOSEN THE ALLEN HEAD SCREW ON THE BACK OF THE QUILL (IT MAY BE COVER WITH PUTTY TO KEEP CHIPS OUT) THEN TURN THE NUT OFF THE QUILL. AFTER REINSTALLING THE NUT AND THE SET SCREW RE-PUTTY THE SET SCREW HOLE TO KEEP THE CHIP OUT OF THE BORE. NOTE: IF YOU HAVE TOO MUCH CLEARANCE THE THREADED PART OF THE NUT MUST BE TURNED DOWN.
ORIGINATOR: RANDAL RENNEKAMP REVISED BY: R. BRYANT
DATE: MAY 13, 1982 SUBJECT: FRONT PANEL BOARD MODIFICATIONS PRODUCT LINE: ANY B CONTROL MILL
IF YOU SHOULD RUN INTO A MACHINE THAT HAS BENDING OF THE VIDEO AT THE TOP OF THE SCREEN, THE FOLLOWING MODIFICATION TO THE FRONT PANEL BOARD SHOULD CURE THE PROBLEM. STEP 1 CUT THE LAND BETWEEN PIN 5 AND PIN 5 OF IC 33 (7430). STEP 2 ADD A JUMPER FROM PIN 6 OF IC 33 (7430) TO PIN 24 OF IC 28 (MCM66710P). STEP 3 REPLACE R80 WITH A 100 OHM 1/4 WATT 5 PERCENT RESISTOR. THIS MODIFICATION WILL MORE CLOSELY MATCH THE INPUT REQUIREMENTS OF THE CRT BY DECREASING THE VERTICAL SYNC SIGNAL TO 500 MICRO SECONDS AND DECREASING COMPOSITE VIDEO OUTPUT TO 1 VOLT PEAK TO PEAK.
FIELD SERVICE BULLETIN
DATE: MAY 26, 1982 SUBJECT: MILL AUTO LUBE OIL TYPE
PRODUCT LINE: MILLS
THE TYPE OF OIL WE RECOMMEND FOR USE IN OUR MACHINES IS MOBIL VACTRA 2 OR EQUIVALENT. HERE IS A SMALL CROSS LIST OF MANUFACTURERS. ALLUBE AMERICAN INDUSTRIAL AMERICAN INDUSTRIES INC. AMERICAN LUBRICANTS CO. AMOCO OIL CO. ANDERSON OIL & CHEMICAL CO. ASHLAND OIL INC. ATLANTIC RICHFIELD CO. BEL-RAY CO. INC. BROOKS TECHNOLOGY CO. CATA OIL & GREASE CO. CHEVRON USA INC. CITIES SERVICE CO. CONTINENTAL OIL CO. DARMEX INDUSTRIAL CORP. DAVIS HOWLAND OIL CORP DUBOIS CHEMICALS EXXON CO. USA FISKE BROS. REFININHG CO. GEORGE-CAROLINA OIL CO. GETTY REFINING & MARKETING GRAPHITE PRODUCTS CORP. GULF OIL CORP IMPERIAL OIL * GREASE CO. KENDALL REFINING CO. MOBIL OIL CORP. UNION OIL CO. OF CALIFORNIA MOLY SHIELD WAY OIL 315 REXLUBE #20 516 WAY LUBES #20 ALUCO MOLY WAY LUBE #40 WAYTAC OIL #31 WINSOR WAY OIL 1L WAULUBE W-30 TRUSLIDE S-315 RAYLENE EP OIL #2 BARCOTE 961 MED. HVY OIL FOR SLIDEWAYS CHEVRON OIL 68 CITGO SLIDERITE NO. 2 HD WAY LUBE 31 DARMEX 1050 WAY OIL 80 MPO-30 FEBIS K68 NO. 3-V G-C PRESS MEDIUM VEEDOL ATLINE 20 GP #350 WO GULFWAY 52 MOLUB-ALLOY M.W.O. 20 KENDALL 965 VACTRA NO. 2 WAY OIL HD 315
ORIGINATOR: RANDAL RENNEKANP REVISED BY: R. BRYANT
DATE: MAY 27, 1982 SUBJECT: MBII SPINDLE SHOT PIN LIMIT SWITCH OPTIMUM SETTING MB 2
ISSUE NUMBER: 1013 SUPERSEDES NUMBER: 138
PRODUCT LINE:
PAGE 1
OF 2
TO CLARIFY ANY MISCONCEPTIONS AND AS A REMINDER, THE FOLLOWING PROCEDURE SHOULD BE USED FOR ADJUSTING THE SPINDLE SHOT PIN (IN) LIMIT SWITCH FOR AN OPTIMUM SETTING: 1. PLACE CONTROL IN EMERGENCY STOP CONDITION. 2. MANUALLY ACTIVATE SHOT PIN IN SOLENOID AIR VALVE SO THAT THE SHOT PIN IS RIDING ON THE OUTSIDE OF THE ORIENTATION COLLAR. 3. THE PROPER "GAP" SHOULD BE BETWEEN .80 " TO .100" JUST AS THE SWITCH IS BEING MADE, OR STATED ANOTHER WAY, THE LOGIC "0) LEVEL IS DETECTED ACROSS THE SWITCH WIRES. IF THE .080" TO .100" GAP IS NOT CORRECT ADJUST THE L.S. ACTUATING DOG TO OBTAIN IT AND REMEMBER TO LOCKTITE THE ACTUATING DOG SET SCREW WHEN FINAL ADJUSTMENTS AREMADE. NOTE: SEE ATTACHED DRAWING FOR DETAILS.
ORIGINATOR: H.D. HUNT REVISED BY:

DATE: JUNE 3, 1982 SUBJECT: VARIDRIVE BELT REPLACEMENT ISSUE NUMBER: 1014 SUPERSEDES NUMBER: 139 PAGE 1 OF 1
PRODUCT LINE: KONDIA VARIDRIVE MACHINES
WHEN IN A SERVICE CALL TO A CUSTOMER WHO IS HAVING PROBLEMS WITH THE VARIDRIVE BELT. WE NEED TO CHECK THE VARIDRIVE PULLEYS FOR PITTING CAUSED BY RUST IN SHIPMENT FROM KONDIA TO HURCO IT IS POSSIBLE THAT THESE PULLEYS CAN ACQUIRE A SMALL RUST DEPOSIT ON THEM. THIS RUST CAN BECOME DEPOSITED IN THE VARIDRIVE BELT, AND CAUSE IT TO WERE OUT EXCESSIVELY FAST. IF ARE ON A CALL AND THE BELT IS WORN OR NEEDS REPLACING, MAKE SURE ANY RUST OR PITTING IS REMOVED FROM THE VARIDRIVE PULLEYS BEFORE THE NEW BELT IS INSTALLED. THIS CAN BE DONE BY SIMPLY RUBBING THE PULLEYS WITH STEEL WOOL AND MAKING SURE THEY ARE CLEAN.
ORIGINATOR: R. RENNEKAMP REVISED BY: R. BRYANT

DATE: JUNE 9, 1982 SUBJECT: MBII ATC LIMIT SWITCH & AIR VALVE SETTINGS ISSUE NUMBER: 1015 SUPERSEDES NUMBER: 141
PRODUCT LINE: MB2
PAGE 1
OF 1
AS AN ENDEAVOR TO OPTIMIZE THE MB-II ATC LIMIT SWITCHES AND AIR FLOW CONTROL VALVE SETTINGS, THE FOLLOWING SHOULD BE OBSERVED: PUSH BUTTON LIMIT SWITCH SHOULD HAVE .050 ADDITIONAL TRAVEL WHEN ACTIVATED BEFORE MECHANICAL STOP; ROLLER PUSH ACTUATE LIMIT SWITCHES SHOULD HAVE .100" TO .125" ADDITIONAL TRAVEL BEFORE MECHANICAL STOP. THE ATC AIR FLOW CONTROL VALVE ADJUSTMENT SCREWS SHOULD BE SET AS FOLLOWS: HI SPINDLE GEAR 1/2 TURN FROM CLOSED POSITION. LO SPINDLE GEAR " " TOOL ARM UP " " TOOL POT FORWARD 1 1/4 TO 1 1/2 TURNS FROM CLOSED POSITION. TOOL POT BACK " " " " SPINDLE SHOT PIN OUT " " " " CAROUSEL LOCATE IN " " " " CAROUSEL LOCATE OUT " " " " TOOL POT CLAMP " " " " TOOL POT UNCLAMP " " " " VERIFY AIR REGULATOR IS SET BETWEEN 5.5 AND 6.0 KG/CM2 AND DOES NOT DROP MORE THAN .5 KG/CM2 DURING AN AUTO TOOL CHANGE CYCLE.
ORIGINATOR: H.D. HUNT REVISED BY: R. BRYANT

DATE: AUGUST 31, 1982 SUBJECT: GROUND ROD USE IN HURCO MILLS ISSUE NUMBER: 1016 SUPERSEDES NUMBER: 146 PAGE 1 OF 1
PRODUCT LINE: ALL MILL LINES
IN THE PAST HURCO SUPPLIED GROUND RODS FOR THE CUSTOMER TO USE WITH THEE MILL. THIS PRACTICE WAS DISCONTINUED WITH THE ULTIMAX LINE OF CONTROL. IT WAS FOUND WITH THE GROUND ROD INSTALLED THE MACHINE WAS ACTING AS THE GROUNDING POINT FOR ALL MACHINES IN THE SHOP. CAUSING PROBLEMS WITH THE HURCO OF COURSE. SO DO NOT HAVE AN ULTIMAX CONTROL HOOKED TO A GROUND ROD. WITH THE B OR BX CONTROL THEY SHOULD BE HOOKED TO THE GROUND ROD THAT WAS SUPPLIED WITH THE MACHINE.
ORIGINATOR: R. BRYANT REVISED BY:
DATE: SEPTEMBER 3, 1982 SUBJECT: SNOW ON CRT
PRODUCT LINE: MB1H
THE FOLLOWING MODIFICATION SHOULD BE MADE TO ALL MB1H MACHINES TO ELIMINATE SNOW ON THE CRT. THIS SNOW IS CAUSED BY NOISE FROM THE SERVO SYSTEM. THE NOISE REACHES THE CRT VIA THE FRONT PANEL TO CONTROL WIRING HARNESS WHICH RUNS NEXT TO THE SERVO SYSTEM. MODIFICATION: 1. SPLICE THE TWO WHITE WIRES TOGETHER AT THE CRT CONNECTOR. THIS TIES THE VIDEO COMMON TO THE POWER SUPPLY COMMON. 2. MACHINES SHIPPED AFTER 6/2/82 SHOULD ALREADY HAVE THIS MODIFICATION DONE.

DATE: FEBRUARY 24, 1983 SUBJECT: SHEAR PIN DURING TAP ON PARAJUST B ISSUE NUMBER: 1018 SUPERSEDES NUMBER: 150 PAGE 1 OF 1
PRODUCT LINE: ALL MILLS USING PARAJUST B UNITS
IT HAS BEEN DISCOVERED THAT THE REVERSE RELAY CIRCUITY FOR THE PARAJUST CAN CAUSE A SHEAR PIN CONDITION DURING TAP. THIS WILL SHOW UP AS AND EMERGENCY STOP NO RPM AT THE BOTTOM OF A TAP. THIS CONDITION IS CAUSED BY A RELAY WITH EXCESSIVE BOUNCE. WE CAN PERFORM A SIMPLE MODIFICATION TO REMOVE THE REVERSE RELAY, AND TRIGGER THE PARAJUST WITH A DIRECT CONNECTION TO THE OPTO-ISOLATOR THAT CONTROLS THE REVERSE RELAY. THIS MODIFICATION WILL ONLY WORK ON PARAJUST B UNITS AND SHOULD NOT BE ATTEMPTED ON PARAJUST A UNITS. MODIFICATION: 1. REMOVE WIRE AT TB8-13. 2. REMOVE WIRE AT TB9-6. 3. SPLICE THESE TWO WIRE TOGETHER. 4. REMOVE REV RELAY. TRY DOING THIS MODIFICATION IF YOU RUN INTO A MACHINE THAT HAS HAD THIS PROBLEM BEFORE TRYING ANYTHING ELSE. ALL MACHINES BEING BUILT AFTER 2/15/83 WILL HAVE THIS MODIFICATION DONE. A SIMILAR SOLUTION IS BEING INVESTIGATED FOR MACHINES WITH PARAJUST A.
AGAIN I REPEAT. DO NOT PERFORM THIS MODIFICATION ON PARAJUST A UNITS.
DATE: MAY 2, 1983 SUBJECT:
ISSUE NUMBER: 1019
MISS-WIRED CONTROL TRANSFORMER (T2) SUPERSEDES NUMBER: 155 PAGE 1 OF 1
PRODUCT LINE: MB3
ON A MB3 INSTALLATION IT WAS DISCOVERED THAT THE PRIMARY SIDE OF THE T2 CONTROL TRANSFORMER WAS MISS-WIRED. THE 230 VAC INPUT SHOULD BE CONNECTED TO EITHER H1-H3 OR H1-H4. IN NO CASE SHOULD THE INPUT BE CONNECTED TO H1-H2. TO DETERMINE WHICH PRIMARY TAPS TO USE (H1-H3 OR H1- H4), MONITOR THE SECONDARY VOLTAGE AND WIRE THE PRIMARY TO ACHIEVE AS CLOSE TO THE 120 VAC AS POSSIBLE. NOTE: THE CONTROL MAGNETICS SCHEMATIC (DRAWING # 002-1653-001) IN THE MB3 OWNER'S MANUAL IS MISS-WIRED. STEPS ARE BEING TAKEN TO GET THAT CORRECTED.
DATE: OCTOBER 28, 1983 SUBJECT: HIGH SPEED SPINDLE
PRODUCT LINE: MILLS WITH HSS
HIGH SPEED SPINDLE MACHINE ARE NOW BEING PRODUCED AND THERE ARE SOME DIFFERENCES THAT YOU NEED TO BE AWARE OF. 1. A TAG IS BEING PLACED ON THE INSIDE OF THE PARAJUST DOOR TO HELP IDENTIFY A HSS MACHINE. 2. THE LETTERS "HSS" ARE BEING STAMPED ON THE IDENTIFICATION PLATE AFTER THE SERIAL NUMBER. 3. ONLY HSS MASTER TAPES SHOULD BE USED IN HSS MACHINES. 4. THE FREQUENCY BOARD OR ANALOG BOARD IS MODIFIED. 5. THE SETUP PROCEDURE IS SLIGHTLY DIFFERENT. 6. THE SPINDLE MOTOR IS DIFFERENT AND THE NEW PART NUMBER IS 401-6001- 613 7. THE SPINDLE ASSEMBLY IS ALSO DIFFERENT.

DATE: JANUARY 12, 1984 SUBJECT: BX RETROFIT TO TOOLMASTERS CONTROLS ISSUE NUMBER: 1021 SUPERSEDES NUMBER: 166 PAGE 1 OF 1
PRODUCT LINE: MB1
WE WERE RECENTLY ABLE TO SOLVE POSITIONING PROBLEM AT TWO DIFFERENT CUSTOMERS BY RE-ROUTING THE MOTOR WIRES AWAY FROM THE 5VDC CIRCUITRY AT TB7-X-Y-Z. IN BOTH CASES THE WIRES WERE RE-ROUTED ALONG THE RIGHT HAND SIDE OF THE POWER CABINET AWAY FROM THE 5VDC CIRCUITS. IF YOU ARE EXPERIENCING A POSITIONING PROBLEM WITH A BX RETROFIT TOOLMASTER CONTROL, TRY RE-ROUTING THE MOTOR WIRES.

DATE: JANUARY 12, 1984 SUBJECT: SET-UP OF BX SERVO CONTROL BOARD ISSUE NUMBER: 1022 SUPERSEDES NUMBER: 167 PAGE 1 OF 1
PRODUCT LINE: BX MILLS
ALIGNMENT PROCEDURE OF BX SERVO CONTROL BOARD THE SERVO CONTROL BOARD HAS ONLY THREE ADJUSTMENTS. THE +10 VOLT REFERENCE LEVEL, ADJUSTMENT R15 THE -10 VOLT REFERENCE LEVEL ADJUSTMENT, R16 THE +5 VOLTAGE REFERENCE ADJUSTMENT R14. THE LAST TWO ADJUSTMENTS ARE DEPENDENT IN THE +10 VOLTAGE ADJUSTMENT, THUS THE +10 VOLTAGE REFERENCE R15 SHOULD BE ADJUSTED FIRST. ADJUSTMENT PROCEDURE 1. APPLY +15, -15, AND +5 VOLTS TO THE SERVO CONTROL BOARD. 2. MONITORING THE VOLTAGE ON PIN 6 OF U33 ADJUST R15 FOR +10 VOLTS +- .01 VOLTS. 3. WILE MONITORING THE VOLTAGE ON PIN 14 OF U32 ADJUST R16 FOR -10 VOLTS +- .01V. 4. MANUALLY JOG AND AXIS AND TURN THE OVERRIDE POT TO FULL CW AND ADJUST R14 TO ACHIEVE A FEEDRATE OF 150.8. THE VOLTAGE ADJUSTMENTS NEED NOT BE DONE AGAIN AS LONG AS NOT IC,S ARE REPLACED ON THE BOARD. THE VOLTAGES WILL REMAIN STABLE EVEN IF THE +-15 V CHANGE AS WOULD BE THE CASE WHEN THE SERVO BOARD IS PLACED IN A DIFFERENT MILL.

DATE: SUBJECT: JANUARY 12, 1984 PARAJUST 280VDC BUSS VOLTAGE PROBLEM ISSUE NUMBER: 1023 SUPERSEDES NUMBER: 16 PAGE 1 OF 1
PRODUCT LINE: PARAJUST B MILLS
IF IN THE FIELD YOU FIND IT DIFFICULT TO OBTAIN 280VDC @ 900 RPM (PER MFG. DOCUMENT NO. 757-1001-003), THEN REMOVE TRIM RESISTOR R19. T R19 TRIM RESISTOR IS USED TO SET THE POINT ON THE DC HOLD ADJUSTMENT WHERE THE DC HOLD IS FIRST REALIZED. SINCE DC HOLD IS NOT USED IN OUR APPLICATION, REMOVING R19 WILL HAVE NO ADVERSE AFFECT ON THE OPERATION
DATE: JANUARY 18, 1984 SUBJECT: RS232 DATA CARRIER LOSS BX MPU BRD
PRODUCT LINE: BX CONTROL MILLS
IF YOU ARE WORKING ON A BX MILL USING RS232 AND GETTING DATA CARRIER LOST ERRORS TRY REMOVING RESISTORS R10 AND R6 330 OHM ON THE BX MPU. INPUTS J5-5,8 COULD BE ALLOWING NOISE TO BE RECEIVED. THIS MODIFICATION SHOULD ELIMINATE THIS PROBLEM.
ORIGINATOR: WAYNE HAWKINS REVISED BY: R BRYANT

DATE: JANUARY 19, 1984 SUBJECT: MOD TO X5 MOTHER BRD FOR MIS POSITIONING PRODUCT LINE: MB3/MD3 ISSUE NUMBER: 1025 SUPERSEDES NUMBER: 171 PAGE 1 OF 2
THIS MODIFICATION WILL HELP ELIMINATE NOISE FROM PHASE A AND B OF LINEAR SCALES. ADD 4 (407-0001-058) 10PF CAPACITORS TO NON COMPONENT SIDE OF X 5 MOTHER BOARD KEEP LEAD LENGTH SHORT (1/4" OR LESS). ADD CAPACITORS BETWEEN: 1. J1-1 AND J1-2 GROUND AND 5 VOLTS. 2. J2-1 AND J2-2 GROUND AND 5 VOLTS. 3. J3-1 AND J3-2 GROUND AND 5 VOLTS. 4. TB1-5 AND TB1-6 GROUND AND 5 VOLTS. VERIFY MACHINE CALIBRATION AND POSITIONING AFTER MODIFICATION.

DATE: May 9, 1984 SUBJECT: SPLINE COUPLING REPLACEMENT ISSUE NUMBER: 1026 SUPERSEDES NUMBER: 185 PAGE 1 OF 1
PRODUCT LINE: KMB-I /KMBX-I
Before any spline coupling is replaced, the following steps need to be followed. 1) Put ample grease on spline shaft and spline coupling. 2) Re-tram head. 3) Re-align "Z" axis ballscrew assembly. Then if noise persists, it can be determined that the spline coupling is bad and indeed should be replaced. When new spline coupling is received, make sure there is a good fit between it and the spline shaft by following the procedure outlined in Manufacturing Document #757-3012-011. If the fit is not good, a new spline coupling should be ordered.
ORIGINATOR: Wayne E. Hawkins REVISED BY:

DATE: MAY 30, 1084 SUBJECT: SERVO AMP BRD AND DIODE PUMP SETUP PRODUCT LINE: 425, 900, AND 1450 EDM,S ISSUE NUMBER: 1027 SUPERSEDES NUMBER: 187 PAGE 1 OF 2
RETRACT TIME ADJUSTMENTS STEPS 1-8 1. REMOVE ALL MATERIALS AND/OR FIXTURES FROM THE SURFACE OF THE WORK TABLE. 2. REMOVE ELECTRODE AND/OR HOLDER. 3. REMOVE DIAL INDICATOR AND MICROMETER FROM Z AXIS DEPTH GAGE RAIL. 4. TURN ON MAINS AT REAR OF MACHINE AND ON FRONT PANEL GENERATOR. 5. RELEASE FRONT PANEL EMERGENCY STOP. SELECT HEAD LOCK. USING FAST APPROACH CONTROL KNOB. CONFIRM PROPER AMOUNT OF Z AXIS TRAVEL ADJUST IF NECESSARY. 425 = Approximately 6" or 152mm 900 = Approximately 11" or 280mm 1450 = Approximately 11.8" or 300mm 6. PRESET COARSE FEED POT TO 0. PRESET FIND FEED POT TO 5 OR MID RANGE ON THE 425E. PRESET SENSITIVITY POT TO FULL "-" POSITION. 7. USING THE FAST APPROACH CONTROL KNOB POSITION THE Z AXIS ON THE MINUS LIMIT SWITCH. A. RELEASE HEAD LOCK AND START TIMING Z AXIS OVER FULL TRAVEL. RETRACT TIME SHOULD BE AS FOLLOWS. 425E & 425 MARK II 2 MINUTES + OR - 10 SEC. 900 MARK II 4 MINUTES + OR - 10 SEC. 1450 MARK II 4 MINUTES 30 + OR -10 SEC. 8. IF THE RETRACT TIMES ARE INCORRECT, CORRECTIONS SHOULD BE MAKE BY ADJUSTING THE AMPLIFIER GAIN POT MOUNT ON THE AMP CHASSIS ASSEMBLY. FIRST LOOSEN THE JAM NUT. A. CW TO REDUCE. B. CCW TO INCREASE TIME. DIODE PUMP OR SERVO GAIN ADJUSTMENTS 9-17
9. PRESET FINE FEED POT TO 5 (MID-RANGE ON THE 425E), COARSE FEED TO 0, SENSITIVITY POT TO MID RANGE. 10. REMOUNT DIAL INDICATOR ON Z AXIS DEPTH GAUGE RAIL. 11. APPLY HEAD LOCK, USING FAST APPROACH KNOB MOVE Z AXIS APPROXIMATE MIDDLE OF TRAVEL. 12. ZERO DIAL INDICATOR. 13. SELECT MAXIMUM CURRENT ( AMP, 50 AMP, OR 25 AMP DEPENDING ON MODEL OF GENERATOR. 14. TURN ON THE DIELECTRIC PUMP, ALLOW IT TO RUN UNTIL THE DIELECTRIC IS FLOWING ACROSS THE TABLE. CONFIRM THAT GENERATOR ON WILL LATCH ON. TURN GENERATOR OFF. 15. SELECT EDGE, FIND RELEASE HEAD LOCK AND ADJUST COARSE FEED POT TO BALANCE Z AXIS (NO MOVEMENT ON DIAL INDICATOR) 16. APPLY HEAD LOCK, DISENGAGE EDGE FIND, TURN ON GENERATOR. RELEASE HEAD LOCK. ADJUST HIGH CURRENT TRIM POT, TO BALANCE Z AXIS. NO MOVEMENT DIAL INDICATOR. 17. REPEAT STEPS 12 THROUGH 17 ON THE LOW CURRENT RANGE. USE LOW CURRENT TRIM POT TO BALANCE Z AXIS.
ORIGINATOR: B.J. STINSON REVISED BY:

DATE: MAY 29, 1984 SUBJECT: OPTITRON TRIP POINT SETTING ADJUSTMENTS PRODUCT LINE: EDM'S 1. JUMPER PINS S AND P ON THE RF BOARD (FIGURE 2). 2. APPLY POWER TO GENERATOR AND RELEASE EMERGENCY STOP AND ADJUST THE EFFICIENCY METER TO THE RED TRIP POINT GRADUATION. 3. WHILE WATCHING THE THRESHOLD RELAY (MOUNTED ON THE BIAS SUPPLY BOARD, FIGURE 1) ADJUST THE THRESHOLD POT ON THE RF BOARD (FIGURE 2) SO THE RELAY JUST PICKS UP. ISSUE NUMBER: 1028 SUPERSEDES NUMBER: 188 PAGE 1 OF
ORIGINATOR: B.J. STINSON REVISED BY:

DATE: JUNE 1, 1984 SUBJECT: SERIAL NUMBER ID ON HURCO PRODUCTS PRODUCT LINE: ALL HURCO PRODUCTS SCOPE: ISSUE NUMBER: 1029 SUPERSEDES NUMBER 18 PAGE 1 OF 15
All products, systems, etc., identified by Hurco serial number are to be marked according to the method prescribed in this specification. Information required for identification labels included. I. Serial Numbering Plan 1. Format Number each product line and each sub-assembly type sequentia as follows: All products are to use the same format with appropriate prefixes and suffixes. Sub-assemblies which are to have seri numbers will not use prefix letters.
---------------------- XXXX7 NNN MM8X Product Line Prefix -- ----(Letter(s) as listed in Table #1) ------ Consecutive numbering ------------- of products beginning each month (by major product line).
Year
Major Revision suffix from Table #2 Month First M is zero for numbers less than 10
B 1029 SERIAL NUMBER OF HURCO PRODUCTS
TABLE #1
Serial Number Prefix Letters - Product Identification
------------------------------------------------------------------Serial Numbers Are At- Ass Table #1 (Part 1) - CNC Millstached to Power Cabinet Location & --------------------------------------------------------------- Indpls.Read ITEM MODEL DESCRIPTION U.S.A. Engl ----------------------------------------------------------------____1_KM-1___Bridgeport_Knee_Mill_________________________B_____-_ ____2_KMB-1__Kondia_Knee_Mill_____________________________K____KM__ ____3_KMB-1s_Short_Axis_Travel_KMB-1_____________________KS_____-_ ____4_KMB-1m_Manual_Spindle_Speed_KMB-1__________________KM____MK_ ____5_KMBX-1_KMB-1_w/BX_Control__________________________KX_____-_ ____6_KMBX-1mKMB-1_w/BX_Control_&_Manual_Spindle_Speed__KMX_____-_ ____7_____________________________________________________________ ____8_____________________________________________________________ ____9_M1_____Toyama_______________________________________H_____M_ ___10_MB-1___M1-Improved_Size_&_Strength_________________HB____MB_ ___11_MB-1S__MB-1_With_Short_Axis_Travel________________MBS_____-_ ___12_MB-1H__Greater_Spindle_Power_MB-1__________________MH_____-_ ___13_MBX-1__BX_Control_on_MB-1H_________________________MX_____-_ ___14_MD-1___Toyama______________________________________MD_____-_ ___15_____________________________________________________________ ___16_M2_____Toyama_______________________________________T_____-_ ___17_MB-2___M2_With_Greater_Travel_&_Power______________TB_____-_ ___18_____________________________________________________________ ___19_____________________________________________________________ ___20_MBX-3__Toyama______________________________________JB_____-_ ___21_____________________________________________________________ ___22_MD-3___Toyama______________________________________JD_____-_ ___23_____________________________________________________________ ___24_TM-5___T-Bed_Mill_________________________________HTA_____-_ ___25_TMC-5__T-Bed_Mill_ATC_____________________________HTB_____-_ ___26_KM-3___SM1_CNC_MAX________________________________SDA_____-_ ___27_KM-3___SM1_CNC_MAX_SSC____________________________SDB_____-_ ___28_KMC-3__SM1_CNC_MAX_ATC_SSC________________________SDC_____-_ ___29_KM-3___SM1_CNC_BX_________________________________SXA*____-_ ___30_KM-3___SM1_CNC_BX_SSC_____________________________SXB_____-_ ___31_KMC-3__SM1_CNC_BX_ATC_SSC_________________________SXC_____-_ ___32_KM-3P__KMB1m_MAX__________________________________KDA_____-_ ___33_KM-3P__KMB1m_MAX_SSC______________________________KDB_____-_ ___34_KMC-3P_KMB1m_MAX_ATC_SSC__________________________KDC_____-_ ___35_KM-3P__KMB1m_BX___________________________________KXA_____-_ ___36_KM-3P__KMB1m_BX_SSC_______________________________KXB_____-_ ___37_KMC-3P_KMB1m_BX_ATC_SSC___________________________KXC_____-_
TABLE #1
------------------------------------------------------------------Serial Numbers Are At- Ass Table #1 (Part 1) - CNC Millstached to Power Cabinet Location & --------------------------------------------------------------- Indpls.Read ITEM MODEL DESCRIPTION U.S.A. Engl ----------------------------------------------------------------___38_BMC-10_Toyama_Bed_Mill_10HP_4000___________________BA_______ ___39_BMC-10_Toyama_Bed_Mill_10HP_6000___________________BB_______ ___40_BMC-10LToyama_Bed_Mill_10HP_4000__________________BLA_______ ___41_BMC-10LToyama_Bed_Mill_10HP_6000__________________BLB_______ ___42_BMC-15_Toyama_Bed_Mill_15HP_4000___________________BF_______ ___43_BMC-30_Taiwan_Bed_Mill_10HP_4000_(OEM_&_V1)________BC_______ ___44_BMC-40_Taiwan_Bed_Mill_10HP_4000_(OEM_&_V1)________BD_______ ___45_BMC-50_Taiwan_Bed_Mill_15HP_3000_(OEM_&_V1)________BE_______ ___46_BMC-30_Taiwan_Bed_Mill_10,000_RPM_(OEM_&_V1)_______BG_______ ___47_BMC-20_Taiwan_Bed_Mill___________(OEM_&_V1)________BH_______ ___48_FP3A___Deckel_Universal_Mill_4000_RPM_____________DHA_______ ___49_FP4A___Deckel_Universal_Mill_4000_RPM_____________DHB_______ ___50_BMC-20_Bed_Mill_BMC-20_V2__________________________BJ_______ ___51_BMC-30_Bed_Mill_BMC-30_V2__________________________BK_______ ___52_BMC-40_Bed_Mill_BMC-40_V2__________________________BL_______ ___53_BMC-50_Bed_Mill_BMC-50_V2__________________________BM_______ *Was SDX Suffix B (Rigidram); therefore, SDX Suffix B (Rigidram) and S
TABLE #1
Table #1 (Part 2) - Standard Mills ---------------------------------------------------------------- CN DESCRIPTION PREFIX PREFIX -----------------------------------------------------------------1 Standard 9 X 42 Table, Standard Ways SA -- -----------------------------------------------------------------1 Kondia 9 X 42 Table, Hardened Ways SB SBX -----------------------------------------------------------------1 Kondia 12 X 42 Table, Standard Ways SC -- -----------------------------------------------------------------1 Kondia 12 X 42 Table, Hardened Ways SD SDX -----------------------------------------------------------------1 Kondia 12 X 48 Table, Standard Ways SE -- -----------------------------------------------------------------1 Kondia 12 X 48 Table, Hardened Ways SF -- -----------------------------------------------------------------2 Kondia 58 X 11 Table, Hardened Ways SG -- -----------------------------------------------------------------Table #1 (Part 3) - Other Products ---------------------------------------------------------------- 1 DTP-1 Desk Top Programmer D ---------------------------------------------------------------- 2 DTP-2 Desk Top Programmer, Level 2 D2 ----------------------------------------------------------------Table #1 (Continued) - Serial Number Prefix Letters Table #1 (Part 4) - **Autobend 4 Gauges - Place Serial Numbers on P Mechanical Gauges ---------------------------------------------------------------- PRE- ITEM MODEL DESCRIPTION FIX SPECIAL INST ----------------------------------------------------------------_1__SD_______Single_Drive_ABIV_____________A__1)_The_prefix_"N"_i _2__DS_______Dual_Drive_ABIV_______________C_____units_with_diagn _3__DS/2_____1/2_Dual_Drive________________C______________________ _4__--_______Two_Axis_Drive________________E______________________ _5__P2_______Plate_Gauge___________________G______________________ _6__S1_______Shear_Gauge___________________I______________________
B 1029 SERIAL NUMBER OF HURCO PRODUCTS _7__SDHD2A___Single_Drive_Hydraulic_______AE__2)_Combination_of_u ________________2_Axis_ABIV______________________have_a_two,_thre _8__DSHD2A___Dual_Drive_Hydraulic_________CE_____letter_prefix_to_ ________________2_Axis_ABIV______________________system.__Example _9__SDPM2A___Single_Drive_Promecam________AE_____a)_Single_drive_ ________________2_Axis_ABIV______________________b)_Single_drive_ _10_SD/DS____Front/Rear,_Dual_Front-_______F________front/rear____ ________________Single_Rear______________________c)_Dual_drive/2_ _11_SD/DSHD2AFront/Rear,_Hyd._2_Axis______FC________rear_with_dia ________________Dual_Fnt.,_Dual_Rear_ABIV________Use_2,_3_or_4_le _12_DSPM2A___Dual_Drive_Promecam__________CE_____to_describe_syst ________________2_Axis_ABIV_______________________________________ _13_SDM2A____Single_Drive_Mech._Stop______AE______________________ ________________2_Axis_ABIV_______________________________________ _14_DSM2A____Dual_Drive_Mech._Stop________CE______________________ ________________2_Axis_ABIV_______________________________________ ** Vertical Control Unit (Autobend 2 Axis) requires the following: a) b) c) Serial Number - Identical to that of the Autobend Power Box Assembly Number - Hurco drawing number for the vertical control Contact Ratings - Maximum continuous current rating and voltage Relay Contacts if relay is used. (5A @ 240 VA
Table #1 (Continued) - Serial Number Prefix Letters -------------------------------------------------------------------- Table #1 (Part 5) - Autobend 5 Gauges --------------------------------------------------------------------------------------------------------------------------------------ITEM MODULE DESCRIPTION ------------------------------------------------------------------__1___Power_Cabinet_____Main_Power_Cabinet__________________________ ntrol_Head______Main_Control_Console______________________________AB_ l_#1__Smart_Control_for_S4_Type_Gauge___________________AC___ __4__ Type_Gauge_____________________________________AD___ __5___S7_Gaug _Type_Gauge__________________________AG___ __6___H7_Gauge_________ ___________________________AH___ __7___MDS_______________Multiple_ _________________AI___ __8___Multibend_________Multibend__________ _______AJ___ __9___Vert._Ctl._(Std.)_Hydraulic_and_Mechanical_Stop ___ _10___Vert._Ctl._(Up)___Promecam,_PRM_400,_Amada,_Adira,_SMT_P __Vert._Drive_(1)___Promecam________________________________________ rive_(2)___Promecam_(400)____________________________________AN___ _Amada_____________________________________________AP___ _14___Ve __________________________________________AQ___ _15___Vert._Drive_ ________________________________AR___ _16___S6,_S8_Gauge______Sin em____________________AS___
Table #1 (Continued) - Serial Number Prefix Letters ------------------------------------------------------------------- Table #1 (Part 6) - E.D.M.'s ------------------------------------------------------------------------------------------------------------------------------------ ITEM MODEL DESCRIPTION ----------------------------------------------------------------- 1 425E Combined Spark Unit & 30 Amp Generator ----------------------------------------------------------------- 2 425 Spark Unit (for 25 Amp) ----------------------------------------------------------------- 3 425 Spark Unit (for 50 Amp) ----------------------------------------------------------------- 4 900 Spark Unit (No Side Servo) ----------------------------------------------------------------- 5 900 Spark Unit (Side Servo) ----------------------------------------------------------------- 6 1450 Spark Unit ----------------------------------------------------------------- 7 25 AMP Generator, 25 Amp (for 425 or 400) ----------------------------------------------------------------- 8 50 AMP Generator, 50 Amp (for 425 or 900) ----------------------------------------------------------------- 9 50 AMP Generator, 50 Amp (for 1450) ----------------------------------------------------------------- 10 100 AMP Generator, 100 Amp (for 900) ----------------------------------------------------------------- 11 100 AMP Generator, 100 Amp (for 1450) ----------------------------------------------------------------- 12 CEC 200 Machine Tool (for 60 Amp) ----------------------------------------------------------------- 13 CEC 200 Filter Unit (for 60 Amp) ----------------------------------------------------------------- 14 CEC 200 Electronics Cabinet (for 60 Amp) ----------------------------------------------------------------- 15 425E Optitron Minor ----------------------------------------------------------------- 16 OPTIONAL EXTRA Programmable Digital Oscillator (MK1 Generators Only) ------------------------------------------------------------------
Table #1 (Continued) - Serial Number Prefix Letters ------------------------------------------------------------------- Table #1 (Part 6) - E.D.M.'s ------------------------------------------------------------------------------------------------------------------------------------ ITEM MODEL DESCRIPTION ----------------------------------------------------------------- 17 30/10 Generator ----------------------------------------------------------------- 18 60/10 Generator ----------------------------------------------------------------- 19 330 Spark Unit ----------------------------------------------------------------- 20 900 NC Spark Unit ----------------------------------------------------------------- 21 1450 NC Spark Unit ----------------------------------------------------------------- 22 1450/900 NC Spark Unit -----------------------------------------------------------------Table #1 (Continued) - Serial Number Prefix Letters ------------------------------------------------------------------- Table #1 (Part 6) - E.D.M.'s ------------------------------------------------------------------------------------------------------------------------------------ ITEM MODEL DESCRIPTION ----------------------------------------------------------------- 17 30/10 Generator ----------------------------------------------------------------- 18 60/10 Generator ----------------------------------------------------------------- 19 330 Spark Unit ----------------------------------------------------------------- 20 900 NC Spark Unit ----------------------------------------------------------------- 21 1450 NC Spark Unit ----------------------------------------------------------------- 22 1450/900 NC Spark Unit ------------------------------------------------------------------
Table #2 - Serial Number Suffix Letters ------------------------------------------------------------------- Table #2 (Part 1) - CNC Mills Major Change Notes ------------------------------------------------------------------------------------------------------------------------------------ITEM MODELS SUFFIX CHANGE & DATE ENTERED IN PRODUCT ----------------------------------------------------------------- 1 KMB-1, KMB-1m, A Change to Randtronics Servo Amp. (3/ ----------------------------------------------------------------- MB-1H, MB2 A Change to Randtronics Servo Amp. (3/ ----------------------------------------------------------------- 2 KMB-1 B Brake Board Change (3/82) ----------------------------------------------------------------- 3 KMB-1m B Support Cost Change (3/82) ----------------------------------------------------------------- 4 KMB-1 C Rigid Overarm (3/82) ----------------------------------------------------------------- 5 MB-1H, MB-2, B Change to HURCO FET Servo Amp ----------------------------------------------------------------- MB-3 B Change to HURCO FET Servo Amp ----------------------------------------------------------------- 6 KMB-1m C Change to HURCO FET Servo Amp ----------------------------------------------------------------- 7 KMB-1 D Rigid Overarm - HURCO FET Servo Amp ----------------------------------------------------------------- 8 KMB-1m E Moveable Overarm - HURCO FET Servo Am ----------------------------------------------------------------- 9 KMB-1 F Moveable Overarm - HURCO FET Servo Am ----------------------------------------------------------------- 10 KMB-1 G Rigid Overarm - HURCO FET Servo Amp ----------------------------------------------------------------- 11 KMB-1 H Moveable Overarm - Randtronics Servo ----------------------------------------------------------------- 12 KMB-1 J Rigid Overarm - Randtronics Servo Amp ----------------------------------------------------------------- 13 MB-1 C HURCO FET Servo Amp High Speed Spind ----------------------------------------------------------------- 14 MB-1 D Randtronics Servo Amp High Speed Spi ----------------------------------------------------------------- 15 SM1-CNC A SM1-CNC With NSK Ballscrews ----------------------------------------------------------------- 16 MD-1, MD-3 A Randtronics Servo Amp Low Speed Spin ----------------------------------------------------------------- 17 MD-1 B Randtronics Servo Amp High Speed Spi ------------------------------------------------------------------
Table #2 (Continued) - Serial Number Suffix Letters ------------------------------------------------------------------- Table #2 (Part 1) - CNC Mills Major Change Notes ------------------------------------------------------------------------------------------------------------------------------------ITEM MODELS SUFFIX CHANGE & DATE ENTERED IN PRODUCT ----------------------------------------------------------------- 18 MD-3 B HURCO FET Servo Amp ----------------------------------------------------------------- 19 MD-1 C HURCO FET Servo Amp Low Speed Spindl ----------------------------------------------------------------- 20 MD-1 D HURCO FET Servo Amp High Speed Spind ----------------------------------------------------------------- 21 TM-5 A HURCO Hybrid Servo Amp ----------------------------------------------------------------- 22 TM-5 B HURCO FET Servo Amp ----------------------------------------------------------------- 23 SM1-CNC B Rigid Overarm - (December 17, 1984) ----------------------------------------------------------------- 24 BMC-10(L) & 15 A Original Release ----------------------------------------------------------------- 25 KMC-3P D Has Kondia Tool Changer w/SSC ----------------------------------------------------------------- 26 KM-3P D Has Kondia SSC ----------------------------------------------------------------- 27 KM-3 C K Interface (Kondia Magnetics) ----------------------------------------------------------------- 28 KM-3 D K Interface - Left Hand Ball Screws ----------------------------------------------------------------- 29 BMC20-50 A Triple Axis Servo (One Piece Unit) ----------------------------------------------------------------- 30 BMC20-50 B Single Axis Servo ----------------------------------------------------------------- 31 BMC30-50 C Triple Axis Servo (Max 2) ----------------------------------------------------------------- 32 BMC20 C HURCO Built Tool Changer ----------------------------------------------------------------- 33 BMC30-50 D HURCO Built Pneumatics ----------------------------------------------------------------- 34 BMC20 D V1 Control AC 2 Motor ----------------------------------------------------------------- 35 BMC30-50 E V1 Control ----------------------------------------------------------------- 36 KM-3, KM-3P E MAX 2 Control ------------------------------------------------------------------
Table #2 (Continued) - Serial Number Suffix Letters ------------------------------------------------------------------- Table #2 (Part 1) - CNC Mills Major Change Notes ------------------------------------------------------------------------------------------------------------------------------------ITEM MODELS SUFFIX CHANGE & DATE ENTERED IN PRODUCT ----------------------------------------------------------------- 37 BMC-20 E OEM AC3S Spin Motor 4000 RPM ----------------------------------------------------------------- 38 BMC-20 F OEM AC3S Spin Motor 6000 RPM ----------------------------------------------------------------- 39 BMC-20 G V1 AC3S Spin Motor 4000 RPM ----------------------------------------------------------------- 40 BMC-20 H V1 AC3S Spin Motor 6000 RPM ----------------------------------------------------------------- 41 BMC-30-40 F OEM 18P Spin Motor 4000 RPM ----------------------------------------------------------------- 42 BMC-30-40 G OEM 18P Spin Motor 6000 RPM ----------------------------------------------------------------- 43 BMC-30-40 H V1 18P Spin Motor 4000 RPM ----------------------------------------------------------------- 44 BMC-30-40 J V1 18P Spin Motor 6000 RPM ----------------------------------------------------------------- 45 BMC-50 F OEM 22P Spin Motor ----------------------------------------------------------------- 46 BMC-50 G V1 22P Spin Motor 4000 RPM ----------------------------------------------------------------- 47 FP3A, FP4A A Original Release (MAX II With Disk S ----------------------------------------------------------------- 48 BMC-50 H V1 22P Spin Motor 3000 RPM ----------------------------------------------------------------- 49 BMC-20-30 A V2 Yaskawa 6000 RPM (Standard) ----------------------------------------------------------------- 50 BMC-40-50 A V2 Yaskawa 4000 RPM (Standard) ----------------------------------------------------------------- 51 BMC-20-40 B V2 Yaskawa 10000 RPM (Optional) ----------------------------------------------------------------- 52 BMC-30 C V2 Yaskawa 4000 RPM (Optional) ----------------------------------------------------------------- 53 BMC-40 C V2 Yaskawa 6000 RPM (Optional) ----------------------------------------------------------------- 54 KM-3, KM-3P F MAX 2 Control, Personality 2 ----------------------------------------------------------------- 55 BMC-20 J V1 AC3S Spin Motor 4000 RPM, Persona ------------------------------------------------------------------
Table #2 (Continued) - Serial Number Suffix Letters ------------------------------------------------------------------- Table #2 (Part 1) - CNC Mills Major Change Notes ------------------------------------------------------------------------------------------------------------------------------------ITEM MODELS SUFFIX CHANGE & DATE ENTERED IN PRODUCT ----------------------------------------------------------------- 56 BMC-20 K V1 AC3S Spin Motor 6000 RPM, Persona ----------------------------------------------------------------- 57 BMC-30-40 K V1 18P Spin Motor 4000 RPM, Personal ----------------------------------------------------------------- 58 BMC-30-40 L V1 18P Spin Motor 6000 RPM, Personal ----------------------------------------------------------------- 59 BMC-50 J V1 22P Spin Motor 3000 RPM, Personal ----------------------------------------------------------------- 60 BMC-50 K V1 22P Spin Motor 4000 RPM, Personal ----------------------------------------------------------------- 61 FP3A, FP4A B MAX II With Disk Standard, Personali ----------------------------------------------------------------- 56 BMC-20 K V1 AC3S Spin Motor 6000 RPM, Persona ----------------------------------------------------------------- 57 BMC-30-40 K V1 18P Spin Motor 4000 RPM, Personal ----------------------------------------------------------------- 58 BMC-30-40 L V1 18P Spin Motor 6000 RPM, Personal ----------------------------------------------------------------- 59 BMC-50 J V1 22P Spin Motor 3000 RPM, Personal ----------------------------------------------------------------- 60 BMC-50 K V1 22P Spin Motor 4000 RPM, Personal ----------------------------------------------------------------- 61 FP3A, FP4A B MAX II With Disk Standard, Personali -----------------------------------------------------------------Table #2 (Part 2) - Autobend ------------------------------------------------------------------- Table #2 (Part 1) - Autobend Major Change Notes -----------------------------------------------------------------ITEM MODELS SUFFIX CHANGE & DATE ENTERED IN PRODUCT ----------------------------------------------------------------- 1 Left Gauge L Identifies left half of an S5 gaugin ----------------------------------------------------------------- 2 Right Gauge R Identifies right half of an S5 gaugi ----------------------------------------------------------------- 3 1/2 Dual Drive R Identifies drive for reference purpo -----------------------------------------------------------------II. Special Identifying Features
B 1029 SERIAL NUMBER OF HURCO PRODUCTS Autobend IV 1) 2) 3) Rear Gauge, Dual Drive, Left/Right Identification - Stand at mounts to the press brake (opposite the motor end) and look t left gauge is to the left hand and the right gauge is to the Front Gauge, Dual Drive, Left/Right Identification - Use the above. One half dual drive - treat this as a right gauge.
III. Obsolete Serial Numbering System (for reference only) A. Autobend (Numbering used until near 2nd half of 1978) -----------------------YEAR 7 XXXX X 8 Consecutive numbering ---------- of gauges from the 1st ----Month gauge ever manufactured. This may be a one required to defin CNC Mills (Numbering used until near beginning of 1980) -----------------------YEAR 7 XXXX X 8 Consecutive numbering ---------- of mills from the 1st ----Month day of each new year. This may be a one required to defin B.
IV.
General Information & Warning Label Data (Information to be Adde Interrupt - Maximum short circuit overload current at which breaker may be expected to blow in a failsafe co for CNC Mills; 500 Amps for Autobend and DTP Pro Diagram Number - Hurco part number of the pertinent Owner's M the power cabinet assembly number for Autob Serial Number - Serial number derived from Standard (#715-40 AMPS: a) b) F.L. - Maximum continuous system operating current at nom voltage; Full load. (Product Standard 715-0000-0 Largest Motor - Maximum continuous operating current supp motor having the greatest current requir
AC VOLTS - Nominal machine supply voltage as designated by t consistent with Product Standard 715-0000-001. HZ - Supply voltage frequency as designated by the customer with Product Standard 715-0000-001.
Table #3 - Largest Motor Currents (Full Load) -------------------------------------------------------------------- CNC MILLS -------------------------------------------------------------------- KMB-1 G. E. Spindle Motor - 11 Amps KMB-1 Leland Spindle Motor - 12.6 Amps MB-1 G. E. Spindle Motor - 11 Amps MB-1 Leland Spindle Motor - 12.6 Amps MB-1H Leland Spindle Motor - 14 Amps MB-2 Leland Spindle Motor - 12 Amps MB-3 Leland Spindle Motor - 12 Amps KMB-1m Kondia Spindle Motor - 8.9 Amps KM-3P Kondia Spindle Motor - 8.9 Amps KM-3P Kondia Spindle Motor - 8.9 Amps KMC-3P Kondia Spindle Motor - 8.9 Amps -------------------------------------------------------------------- Autobend All Mills -------------------------------------------------------------------- TMD-5 Custom Spindle Motor - 15.5 Amps MD-1 Custom Spindle Motor - 14 Amps MD-3 G. E. Spindle Motor - 12 Amps BMC-10(L) Yaskawa - 43 Amps @ 200 VAC BMC-15 Yaskawa - 74 Amps @ 200 VAC KM-3 Kondia Spindle Motor - 8.9 Amps (SM1-CNC) ---------------------------------------------------------------------

DATE: JULY 10, 1984 SUBJECT: OIL LUBE AIR REGULATOR ISSUE NUMBER: 1030 SUPERSEDES NUMBER: 190 PAGE 1 OF 1
PRODUCT LINE: KMB-I KMBX-I KMB-Im
WE HAVE DISCOVERED THAT THE SET-UP PROCEDURE FOR OIL LUBE AIR REGULATOR THERE ARE NO SPECIFIC INSTRUCTIONS TO LOCK THE ADJUSTMENT KNOB. THIS OVERSIGHT HAS BEEN CORRECTED IN HOUSE. WHEN SERVICING A MILL THAT UTILITIES AN OIL LUBE REGULATOR A ROUTINE CHECK SHOULD BE MADE TO CONFIRM THE FOLLOWING: 1. THE LUBE REGULATOR IS SET TO 30 POUNDS PSI. 2. THE MAIN REGULATOR IS SET TO 80 POUNDS PSI. 3. THE ADJUSTMENT KNOBS ARE LOCKED IN PLACE. THERE ARE TWO TYPES OF OIL LUBE AIR REGULATORS. THEY ARE THE WILKERSON REGULATOR AND THE WATTS REGULATOR. THE WILKERSON IS LOCKED WITH A LOCKING RING THAT SNAPS UP AGAINST THE ADJUSTMENT KNOB. THE WATTS REGULATOR IS LOCKED BY TIGHTENING THE PHILLIPS HEAD SCREW ON TOP OF THE ADJUSTMENT KNOB.
ORIGINATOR: B.J. STINSON REVISED BY: R. BRYANT
DATE: Unknown SUBJECT: Control Transformer Replacement PRODUCT LINE: SM 1 CNC
ISSUE NUMBER: 1031 SUPERSEDES NUMBER: PAGE 1 OF 1
CONTROL MAGNETIC ASSEMBLY "002-2431-001 The current servo power transformer in the SM1- CNC is a single voltage input transformer. A PIN is in process to change this transformer to a 240 or 480/60 HZ input, 60V output. The part # for the new XFMR. is 413-0003-075. The new XFMR will be used in the KM1 (bridgeport), SM1 CNC. This transformer will enable a service engineer to change the taps of the XFMR to accommodate the customers power as opposed to ordering a new transformer.
ORIGINATOR: Joe Stinson REVISED BY:

PROPRIETARY INFORMATION
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR DISCLOSURE OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.

DATE: JULY 19, 1984 SUBJECT: ATC DECODER PINS MOVING ISSUE NUMBER: 1032 SUPERSEDES NUMBER: 200 PAGE 1 OF 1
PRODUCT LINE: MD1 / MBX1
WE HAVE SEEN SEVERAL TOOL CHANGER FAILURES IN THE FIELD CAUSED BY THE DECODING PINS IN THE TOOL CHANGER ASSEMBLY. THESE PINS NOT ONLY GIVE THE COUNT ON THE TOOL POSITION BUT ALSO HOLD THE FINGERS IN THE CAROUSEL. AS THE FINGERS WORK BACK AND FORTH WITH THE TOOLS BEING PUT IN THE SPINDLE THE PINS CAN MOVE DOWN. THIS INCREASES THE GAP BETWEEN THE PINS AND THE SENSORS CAUSING A TOOL MISCOUNT. THE FIX FOR THIS PROBLEM IS TO FIRST TAP THE PINS BACK TO THE RIGHT HEIGHT, (A GAP OF .01 TO .02") BETWEEN THE SENSORS AND THE PINS. THEN HAVE SPACERS MADE THAT WILL FIT UNDER THE PINS BETWEEN THE PINS AND THE BOTTOM PLATE OF THE TOOL CHANGER (THE PLATE THAT HOLDS THE FINGERS ON. THIS WILL KEEP THE PINS FROM WORKING DOWN AND IS A PERMANENT FIX DO NOT TRY TO LOCKTITE THE PINS IT DOES NOT HOLD.
ORIGINATOR: B.J. STINSON REVISED BY: R. BRYANT
DATE: July 7,1984 SUBJECT: Oil Flow Indicator Retrofit PRODUCT LINE: MII Gen I & II
The oil pump for MII Machines Generations I and II is driven by the spindle motor via a belt. If the belt brakes there is no signal to the control to shut off. Nor is there any alarm signal to warn the operator of the failure. With no lubrication to the gears in the head severe damage will occur. To correct this potential problem we are installing an OIL FLOW INDICATOR to notify the operator in the event of a failure with the oil flow system. The Assembly is available in a retrofit kit. For MII Generation 1 the part # for the kit is 0022059-001. For generation II the part # is 002-2059-002. The difference between the two kit is the 001 has an adapter plate and two 10/24 x 1.5" shcs. Page 2 thru 4 of this FSB will assist in the installation of this retrofit.
ORIGINATOR: BJ STINSON REVISED BY: L. Leffew 12/16/96

DATE:JULY 23, 1984 SUBJECT:ORIENT TIME-OUT ERR IN LOW GEAR PRODUCT LINE: MBII MBXII MB3
If a MBII, MBXII MB3 is getting an intermittent orient time out error during a tool change in low gear. Add a 18 gauge Green and Yellow wire from power supply terminal strip TB4-21 to power cabinet mecca ground. Also add a 18 gauge green and yellow wire from Parajust terminal strip TB7-4 to the Parajust cabinet mecca ground lug. This should reduce the ground potential between mecca ground and the dac return. Do several tool changes in low gear to confirm that problem has been resolved.
JOE STINSON

DATE: JULY 31, 1984 SUBJECT: 40V TOOL CHANGER ISSUE NUMBER: 1035 SUPERSEDES NUMBER: 198 PAGE 1 OF 2
PRODUCT LINE: HMBX1 / MD1 40V MACHINES
It has been determined that the spring tension of the die spring that supports the carousel is insufficient. This is especially evident if heavy tools are put in one side of the carousel. The carousel will tilt toward the heavier tools causing tool changer errors and or damage to the sensor switches. A PIN is being implemented to resolve this problem in house. The PIN consist of 1) Shorting the spacer from 2" to 1.700" to increase the die spring tension. 2) Readjusting the carousel in limit switch. 3) Readjusting the carousel down limit switch. 4) Readjusting the physical stop setscrew. The procedure for making these changes and adjustments in the field are as follows. 1) Remove all tools from the carousel 2) Remove all covers from the tool changer 3) Confirm that the setscrew and jam nut are tight (item #12 and #57). 4) While supporting the carousel remove the M6-10 x 65 mm bolt (item #9) NOTE!! The setscrew (item #12) should hold the carousel in position with the mounting bolt removed but care should be taken that the carousel doesn't drop down. 5) Remove the bearing cup, Spacer, and Spring (item #8,#10, and #105) 6) The spacer should be cut down from 2" to 1.7". NOTE!! do not discard the short piece of spacer it will be needed for reassembly.. 7) Use a lathe and a facing tool to clean and square the rough edge of each spacer. 8) Reassemble using the short piece of spacer as a washer against the head of the bolt. (use locktite #271 on the threads of the bolt) 9) With the carousel all the way back in home position adjust the Carousel down limit switch for a gap of .200" to .220". (FIGURE 1) 10) Clamp a tool in the spindle. Go into data block 0 program current tool #1. Command the computer to get tool #2. When Z axis gets to tool change height depress motion hold then hit Emergency stop. 11) Manually run the carousel in and adjust the carousel in limit switch to actuate .100" before physical stop. (FIGURE 2) 12) Run the carousel in so the fingers are engaging the tool. Adjust the physical stop setscrew to touch the rest button on the carousel
support casting. Lock down the setscrew locknut confirm that the setscrew is still touching the rest button with fingers fully engaging the tool. Apply loctite #271 to the setscrew threads. 13) Fill the carousel up with tools. Use a few heavy tools (Shell mill, large drills, etc). Run a minimum of 50 tool changes to confirm tool changer operation.
ORIGINATOR: J.B. STINSON REVISED BY: R.BRYANT

DATE: AUGUST 13, 1984 SUBJECT: INTERMITTENT PROBLEMS DUE TO POWER SUPPLY TRANSFORMER PRODUCT LINE: ALL B AND BX MILLS ISSUE NUMBER: 1036 SUPERSEDES NUMBER: 201
PAGE 1
OF 2
RECENTLY ON THREE DIFFERENT SERVICE CALLS ON MILLS THAT WERE DISPLAYING INTERMITTENT PROBLEMS, THE FINAL SOLUTION TO CORRECT THESE PROBLEM WAS CHANGING THE TAPS OF THE PRIMARY DC POWER SUPPLY TRANSFORMER. THIS FSB IS TO: 1, ALERT OUR SERVICE ENGINEERS OF THIS POTENTIAL PROBLEM. 2, A FEW OF THE SYMPTOMS TO LOOK FOR. 3, VOLTAGE MEASUREMENTS TO MAKE, THAT WILL HELP DETERMINE IF CHANGING TAPS SHOULD BE IMPLEMENTED. UNDER IDEAL CONDITIONS (MACHINE IS WIRE FOR 230 INPUT AND CUSTOMER POWER IS 230). THE INPUT VOLTAGE TO THE POWER SUPPLY TRANSFORMER IS 115 VAC. MILLS ARE SHIPPED FROM HURCO WITH THE PRIMARY OF THE POWER SUPPLY TRANSFORMER TAPPED FOR 115 VAC. IN THE CASE WERE A CUSTOMERS POWER IS LOW, SAY 218 VAC OR DURING TIMES OF PEAK USAGE THE CUSTOMERS POWER DROPS FROM 230 TO 218. THE INPUT TO THE POWER SUPPLY TRANSFORMER WILL BE REDUCED TO APPROXIMATELY 109 VAC. WITH 109 VAC INPUT ON THE 115V PRIMARY TAP THE SECONDARY CAN BE UNDER POWERED. THIS IN TURN REDUCES THE DC POTENTIAL APPLIED TO THE REGULATORS OF THE DC POWER SUPPLY. A FEW OF THE SYMPTOMS A MACHINE MIGHT DISPLAY ARE: 1, INTERMITTENT LOCKUPS. 2, LOSING THE MASTER PROGRAM FOR NO APPARENT REASON. 3, LOSING INFORMATION FROM THE PART PROGRAM. 4, MILLS WITH MANUAL SPINDLES (KMI, KMB1M), THESE SYMPTOMS MAY SEEM TO OCCUR WHEN THE SPINDLE IS STARTED. FOR SCHEMATICS AND PHYSICAL LAYOUTS SEE POWER SUPPLY SCHEMATICS OF SECTIONS 6 AND 7 OF THE CUSTOMER'S OWNER MANUAL. THE VOLTAGE MEASUREMENTS YOU SHOULD MAKE TO DETERMINE IS CHANGING THE INPUT TAPS ARE: 1, MEASURE THE CUSTOMER'S INPUT POWER TO THE MACHINE. CONFIRM THE MAIN INPUT TRANSFORMER IS WIRED ACCORDINGLY. THE INPUT POWER SHOULD BE + OR - 10% OF WHAT THE MACHINE IS WIRED FOR. 2, CONFIRM WHICH PRIMARY TAPS ARE BEING USED, 110, 115 OR 120.
3, MEASURE THE AC INPUT VOLTAGE TO THE PRIMARY TAP THAT IS BEING USED. 4, MEASURE THE DC POTENTIAL ACROSS THE FILTER CAPACITOR "C1" OF THE DC POWER SUPPLY AND WRITE IT DOWN. 5, IF THE 115V PRIMARY TAP IS BEING USED AND THE INPUT VOLTAGE IS 113 TO 118 VAC IT SHOULD BE OKAY. IF THE INPUT VOLTAGE IS ABOVE 118 VAC OR BELOW 113 PROCEED WITH STEPS 6 AND 7. 6, IF THE MACHINE VOLTAGE IS 118.1 VAC TURN OFF THE MAIN POWER TO THE MACHINE. CHANGE THE PRIMARY TAP TO THE 120 VAC INPUT. TURN POWER ON AND MEASURE THE DC POTENTIAL ACROSS C1, COMPARE IT TO THE FIRST MEASUREMENT, YOU SHOULD SEE A SMALL DECREASE. 7, IF THE INPUT VOLTAGE IS 103.5 TO 112.9 VAC. TURN OFF MAIN POWER TO THE MACHINE. CHANGE THE PRIMARY TAP TO THE 110 V TAP. TURN POWER BACK ON, MEASURE THE DC POTENTIAL ACROSS C1, COMPARE IT TO THE FIRST MEASUREMENT, YOU SHOULD SEE A SMALL INCREASE. IF THE INPUT POWER TO THE PRIMARY TAPS IS BELOW 103.5 OR_ABOVE 1126.5 THERE IS A PROBLEM WITH THE INPUT POWER. IT SHOULD BE NOTED THAT THIS FIX IS NOT THE ANSWER TO ALL INTERMITTENT MACHINE PROBLEMS. HOWEVER, IT IS SOMETHING YOU NEED TO KNOW ABOUT AND HOW TO LOOK FOR THE PROBLEM. IF YOU MAKE THIS CHANGE TO A MACHINE, DOCUMENT IT ON PAGE TWO OF THE SERVICE REPORT.
ORIGINATOR: J.B. STINSON REVISED BY:

DATE: SEPTEMBER 29, 1984 SUBJECT: TAPE READER ADJUSTMENT ISSUE NUMBER: 1037 SUPERSEDES NUMBER: 203 PAGE 1 OF 1
PRODUCT LINE: B AND BX MILLS
Tape Reader adjustment is no longer approved by HURCO. Research conducted by our Manufacturing Engineering Department has shown that there is no way that we can adjust them as accurately as Raymond. Raymond uses calibrated test tapes and test equipment that is calibrated and verified by the National Bureau of Standards. They only use their test tapes ten times before replacing them and their test equipment has a strict calibration schedule. Raymond says that if we do try to adjust them, then we can probably get them to read tapes but the tape drive will not be within specification. The more times we adjust them, the farther off the drive gets. If it then becomes necessary to replace the drive, the new drive will not read tapes written on the old drive. I admit that we did allow adjustment in the past but Raymond proved that we were causing more problems than we were correcting. If you run into a situation where there is incompatibility between tape readers then I recommend the following action. 1) Verify that the customer is using the latest software in all of his machines. The latest software utilizes an adaptive read program which is less susceptible to speed variations by adapting itself to the timing of the tape. A retry should always be performed if a tape fails to read in order to give the adaptive feature a second chance. This feature has been in all software released since the B series, C3 version. 2) If problems are still present, format a new tape on one of the units and write a part program on the tape. Then try to read the tape into one of the other units. 3) If trouble persists, then a tape reader replacement is in order and a determination must then be made whether one or all need replacement. In all cases the customer should be made aware of the fact that tapes are not going to last forever and the more a tape is used, the shorter its life will be. It should be common practice to make backup copies of all parts programs and periodic replacement of the working copy is necessary. Under no condition should you ever again adjust a tape reader.
ORIGINATOR: WAYNEHAWKINS REVISED BY:

DATE: JANUARY 21, 1985 SUBJECT: VOLTAGE CONVERSIONS PRODUCT LINE: SM1-CNC / KM3 ISSUE NUMBER: 1038 SUPERSEDES NUMBER: 206B PAGE 1 OF 1
ORIGINATOR: JERRY MC CLATCHEY

DATE: NOVEMBER 1, 1984 SUBJECT: MEMORY PCB BATTERY LED'S STAYING ON PRODUCT LINE: ALL ULTIMAX ONE MILLS ISSUE NUMBER: 1039 SUPERSEDES NUMBER: 208 PAGE 1 OF 1
A PROPERLY FUNCTIONING 415-0168-001 128K MEMORY BOARD OR A 414-0168-002 256 K MEMORY BOARD SHOULD NOT BE REPLACED OR CONSIDERED MARGINAL IF ONLY ONE OR TWO LED'S (LED1, LED2, LED3) STAY ON AFTER ONE HOUR OF RECHARGE TIME. IF ANY BATTERY LED IS OFF, THE MEMORY BOARD WILL PROVIDE A MINIMUM OF 72 HOURS OF POWER OFF MEMORY PROTECTION. THIS IS POSSIBLE DUE TO THE AMOUNT OF REDUNDANCY IN THE BATTERY BACKUP CIRCUIT AS IT APPLIES TO HURCO'S RETENTION SPECS. IT SHOULD BE NOTED THAT EACH OF THE THREE BATTERIES CONTAIN THREE SEPARATE CELL CONNECTED IN SERIES. ALTHOUGH, IT WOULD BE MARGINAL, JUST TWO OF THESE CELLS COULD MEET HURCO'S 72 HOUR REQUIREMENT . A BATTERY LED WILL STAY ON IF ONE OR MORE OF THE INDIVIDUAL CELLS SHORT; THEREFORE, THEN ALL THREE LED'S STAY ON THE MEMORY BOARD HAS NO GUARANTEE OF BATTERY BACKUP PROTECTION. BY THE WAY, LED4 INDICATES THAT THE CARD RACK COULD BE SUPPLYING LESS THAN 4.6 VDC. IF THE BOARD VOLTAGES ARE OKAY, THEN AN INTERNAL PROBLEM EXISTS ON THE MEMORY BOARD AND THE BOARD SHOULD BE REPLACED. TYPICAL BATTERY VOLTAGE RANGE SHOULD MEASURE 3.6 TO 4.2 VDC. IF A RED LED IS LIT ON THE HYBRID MPU/MEM BRD THE BATTERY IS DEAD IS WILL SHUT THE BOARD DOWN AND THE BATTERY AT LEAST MUST BE REPLACED. IF THE MPU BATTERY BOARD IS THE TWO BATTERY TYPE REPLACE THE BOARD IF IT IS A ONE BATTERY TYPE REPLACE THE BATTERY. REPLACEMENT BATTERIES FOR 128K BOARDS ARE 413-8001-008 REPLACEMENT BATTERIES FOR 256K BOARDS ARE 413-8001-009 REPLACEMENT BATTERIES FOR THE HYBRID MPU/MEM BOARDS ARE 450-0001-266
ORIGINATOR: MARK WHITCOMB REVISED BY: R. BRYANT
DATE: NOVEMBER 30, 1984 SUBJECT: PARAJUST VOLTAGE CONTROL BOARD PRODUCT LINE: BED MILLS WITH PARAJUST B
THE LATEST VERSION OF A PARAJUST B VOLTAGE CONTROL MODULE, 402-6005-021, CAN BE IDENTIFIED BY THE FACT THAT IT HAS A SOLDER MASK ON THE NON- COMPONENT SIDE OF THE BOARD. IN THIS LATEST VERSION, PARAMETRICS HAS MISTAKENLY LEFT IN TWO COMPONENT THAT IS SUPPOSED TO BE JUMPIER OUT IN THE HURCO VERSION. THE FIRST COMPONENT IS CAPACITOR C20, LOCATED NEAR PIN 5 OF MC9, ) LOWER RIGHT HAND QUARTER OF THE BOARD). C20 NEEDS TO BE REMOVED AND A JUMPER SOLDERED IN ITS PLACE. THE SECOND COMPONENT IS R25 A 3.3 K OHM RESISTOR LOCATED ADJACENT TO C20. R25 ALSO NEEDS TO BE REMOVED. WITH OUT THESE MODIFICATION, INTERMITTENT SHEARPINS COULD OCCUR DURING EITHER ACCEL OR DECELL. SPECIFICALLY ON ULTIMAX SERIES MACHINES, A FLICKERING SHEARPIN LAMP AT DRIVE AT DRIVE TURN OFF ONLY IS NOT A PROBLEM ACCORDING TO PARAMETRICS. IF THIS OCCURRENCE RESULTS IN A CRT MESSAGE OF SPINDLE DRIVE FAULT DETECTED THEN A PROBLEM DOES EXIST.
ORIGINATOR: MARK WHITCOMB REVISED BY:
DATE: NOVEMBER 30, 1984 SUBJECT: Z AXIS TRAVEL
PRODUCT LINE: SM1-CNC
WE HAVE RECENTLY EXPERIENCED OCCASIONS WHEN THE Z AXIS LIMIT SWITCHES HAVE BEEN ADJUSTED TO PROVIDE 4.75 INCHES OF Z AXIS TRAVEL AND WE HAVE OVER RUN THE SWITCH TO THE HARD STOP. THIS OVERRUN HAS CAUSED MACHINE DAMAGE IN AT LEAST TWO INSTANCES. THE Z AXIS TRAVEL SPECIFICATION HAS BEEN CHANGED TO 4.5 INCHES AND ALL PRODUCTION MILLS ARE ADJUSTED TO THIS DIMENSION. DO NOT, UNDER ANY CIRCUMSTANCES, ADJUST THE Z AXIS LIMIT SWITCH TO ANYTHING GREATER THAT 4.5 INCHES TRAVEL. WHEN THE Z AXIS HITS THE HARD STOP IT CAN CAUSE THE LOWER BEARING TO BREAK THRU THE HEAD CASTING. THIS CAN HAPPEN IN A AXIS RUNAWAY AS WILL TO FIX THE MACHINES THAT HAVE THIS PROBLEM A KIT HAS BEEN CREATED. THIS KIT HAS A STEEL INSERT AND NEW AXIS THRUST BEARING'S. THE PART NUMBER IS 0022482-001
ORIGINATOR: DAVE ROCH REVISED BY: R BRYANT
DATE: DECEMBER 17, 1984 SUBJECT: TAPE FORMATTING PROBLEM
PRODUCT LINE: ULTIMAX ONE MD1/MD3
THE PROBLEM WITH FORMATTING A TAPE APPEARS TO BE A RESULT OF RUNNING THE TAPE CONTROLLER BOARD AT TOO HIGH A CLOCK RATE. (I.E., THE 8085 AND 8255 PARALLEL CHIP ARE SPEC'ED AT A MAXIMUM CLOCK FREQUENCY OF 6 AND 3 , MHZ RESPECTIVELY. WITH THE 6.144 MHZ CRYSTAL IN THE CURRENT CONFIGURATION, THEY ARE RUNNING AT 6.144 AND 3.072 MHZ. THIS RESULTS IN NON-EXECUTION OF CERTAIN INSTRUCTIONS IN THE 8085 AND NOT-LATCHING OF DATA ON THE 8255 THAT INTERFACES TO THE TAPE DRIVE SYSTEM. THE REPLACEMENT CRYSTAL IS A 4.9152 MHZ PART NUMBER 407-0016-009 IF YOU FIND ANY THAT NEED CHANGING PLEASE DO SO WITH THIS NUMBER.
ORIGINATOR: DAVID PLATTS REVISED BY: R. BRYANT
DATE: DECEMBER 17, 1984 SUBJECT: SERVICE OF PARAMETRICS SPINDLE DRIVES PRODUCT LINE: ALL MILLS USING PARAJUST DRIVES
DRIVER MODULES DRIVER MODULES SHOULD ALWAYS BE REPLACED IN PAIRS THE PAIR BEING THE TWO SERIES-CONNECTED DRIVER MODULES. AS THE PAIR IS A SERIES CIRCUIT, FAILURE OF ONE DRIVE WILL ALWAYS OVERSTRESS THE REMAINING DRIVER MODULE IN THAT LEG. THIS OVERSTRESS MAY LEAD TO LATENT EFFECTS AND SUBSEQUENT RELIABILITY PROBLEMS IN THE DRIVER AND OR CHOPPER BOARD AREAS. CHOPPER BOARDS CHOPPER BOARDS SHOULD ALWAYS BE REPLACED IN PAIRS ON THE LARGE PARAJUST B DRIVERS/ AS THE PAIR OF CHOPPERS IS A PARALLEL CIRCUIT FAILURE OF ONE CHOPPER WILL ALWAYS OVERSTRESS THE REMAINING CHOPPER. THIS OVERSTRESS MAY LEAD TO LATENT DEFECTS AND SUBSEQUENT RELIABILITY PROBLEMS IN THE DRIVE UNIT. POWER MONITOR FAULTS IF THE POWER MONITOR FAULT REOCCURRS AFTER REPLACEMENT OF THE OF THE POWER MONITOR BOARD AN INCOMING POWER LINE EVALUATION SHOULD BE DONE AD SOON AS POSSIBLE, POWER MONITOR FAULTS OCCUR WHEN THE POWER LINE IS OUT OF THE HURCO SPECIFIED RANGE. OPERATION OF THE MILL WHEN POWER MONITOR FAULTS REPEATABLTY OCCUR MAY CAUSE SERIOUS RELIABILITY PROBLEMS WITH THE PARAMETRICS DRIVE AND WITH OTHER PARTS. (POWER MONITOR FAULTS MAY OCCUR AT THE INSTANT THE MAIN DISCONNECT IS TURNED ON, AND DURING THIS MANUAL TURN-ON ARE NOT A VALID FAULT. AFTER TURN-ON, FAULTS ARE ALWAYS CAUSE FOR CONCERN.)
ORIGINATOR: RICK GUNYON REVISED BY:
DATE: JANUARY 19, 1985 SUBJECT: Y AXIS BALLSCREW
PRODUCT LINE: SM1-CNC
THE NEW SM1-CNC RIGID RAM COULD HAVE LEFT OR RIGHT HAND BALL SCREWS IN THE Y AXIS. THIS WILL NOT CAUSE ANY PROBLEMS WITH THE MACHINE OPERATION BUT, IF WE EVER REPLACE ONE WITH THE OTHER, THEN THE MOTOR AND TACH WIRES WILL HAVE TO BE REVERSED TO MAKE THE AXIS MOVE IN THE RIGHT DIRECTION. THE ENCODER PHASE A AND B ALSO WILL NEED TO BE REVERSED.
ORIGINATOR: WAYNE E. HAWKINS REVISED BY:
DATE: JANUARY 10, 1985 SUBJECT: MISSWIRED SPINDLE DAC
PRODUCT LINE: MD1
A WIRING LIST ERR HAD MACHINES SHIPPING WITH THE DAC SHIELD WIRE BEING TIED TO THE DAC OUTPUT. THIS COULD CAUSE INTERMITTENT SPINDLE FAULTS. REMOVE DAC SHIELD WIRE FROM TB14-1 AND ATTACH TO TB14-13.
DATE: JANUARY 11, 1986 SUBJECT: RANDTRONICS AUX BRIDGE SC LED PRODUCT LINE: MD3 MD3 ONLY
OLD STYLE (ARTWORK AUX BRIDGE PCB'S WILL FALSELY SURGE CURRENT TRIP DUE TO A TEMPERATURE SENSITIVITY. IF THE CRT DISPLAYS SERVO AMP FAULT AND THE Z AXIS STATUS LED ON AC2 IS OUT, IN ADDITION TO THE AUX BRIDGE SC LED LATCHING ON, THEN THE OLD STYLE AUX BRIDGE NEEDS TO BE REPLACED WITH THE NEW STYLE. OLD STYLE IDENTIFICATION: COMPONENTS C10, R26 AND D16 ARE LOCATED JUST BELOW S1, THE HEAT SENSOR FOR THE PCB'S HEATSINK. NEW STYLE INDENTIFICATION: COMPONENTS C10, R26 AND A16 ARE LOCATED TO THE LEFT OF Q10 (LOCATED IN THE BOTTOM RIGHT HAND CORNER OF THE PCB). *NOTE: RANDTRONIC PCB PART NUMBER, REVISION LETTER OR SERIAL NUMBERS DO_NOT IDENTIFY OLD OR NEW STYLES IN ANY WAY!
DATE: JANUARY 25, 1985 SUBJECT: MAIN INPUT TRANSFORMER WIRING
PRODUCT LINE: ALL MILLS
WE RECENTLY EXPERIENCED EXCESSIVE HURCO SERVO AMP PROBLEMS ON AN MB3. BETWEEN AUGUST 20, 1984 AND DECEMBER 4, 1984 WE MADE TEN SERVICE CALLS. WE REPLACED 12 SERVO AMPS, 3 SERVO AMP POWER SUPPLIES, 2 BRIDGE RECTIFIERS AND THE COMPLETE SERVO AMP CHASSIS. AFTER REVIEWING THE HISTORY, WE NOTICED THAT THE MAIN INPUT TRANSFORMER HAD BEEN REWIRED ON A PREVIOUS SERVICE CALL. THE OUTPUT VOLTAGE MEASURED 233 VAC BUT THE TRANSFORMER WAS NOT WIRED PER THE VOLTAGE CONVERSION PRINT. ON DECEMBER 4, 1984, THE TRANSFORMER WAS REWIRED PER PRINT. AND THE OUTPUT VOLTAGE MEASURED 218 VAC. WE HAVE HAD NO FURTHER PROBLEMS WITH THIS MACHINE. FROM KNOW ON, WE SHOULD MAKE SURE THAT WE DO NOT WIRE A TRANSFORMER ANY WAY OTHER THEN TO PRINT.

DATE: SUBJECT: FEBRUARY 12, 1985 SERVO DYNAMIC SET-UP PROCEDURE ISSUE NUMBER: 1048 SUPERSEDES NUMBER: 229 PAGE 1 OF 1
PRODUCT LINE: MILLS USING WESTAMP DIRECT REPLACEMENT OF -006 WESTAMPS
WHEN PLUGGING THE J1 CONNECTOR ONTO THE SERVO DYNAMICS BOARD, ENSURE PIN J1 CONNECTOR PLUGS INTO PIN 1 ON J1 CONNECTOR OF THE NEW BRD. THE J2 CONNECTOR IS NOT USED ALSO NOTE THE PINS 12,13,15 ARE NOT USED ON THE J1 CONNECTOR. PRESETS 1: USING AN OHM METER, BETWEEN STATED POINTS, MAKE THESE PRESET ADJUSTMENTS PRIOR TO INSTALLING THE BOARD. ADJUST AUX POT: TP2 TO TP1 = SIG POT: TP3 TO TP1 = TAC POT: TP4 TO TP1 = *CMP POT: TP5 TO TP1 = 0.00K OHM. 2.67K OHM. 7.45K OHM. .72K OHM.
*NOTE: START WITH POT FULL CW AND TURN CCW FOR DESIRED READING. CL POT: J3-1 TO J3-3 = 0.87K OHM RMS POT: MAX C.W. (SHOULD BE PRESET ALREADY) POWER UP SETTINGS 2: POWER SERVOS UP, ADJUST SIG TO ACHIEVE .9 VDC B SERIES (.000") .65 VDC BX SERIES (.0000") OF DAC AT 25 IMP IN EITHER DIRECTION. IF AN IMBALANCE OF VOLTAGE OCCURS, ADJUST BAL TO GET BOTH DIRECTIONAL VOLTAGES WITHIN .050 VDC OF EACH OTHER. 3: NOW ZERO AXIS AND FINE TUNE BAL POT TO ACHIEVE CRT READINGS OF .0000.
ORIGINATOR: TERRY ROSENKOTTTER REVISED BY:
DATE: MARCH 20, 1989 SUBJECT: CIRCLE & POSITIONING ACCURACY PRODUCT LINE: ALL MILLS
MACHINE TYPE
SM1 CNC / KM3 MD1 / KM3P MD3
BMC 10 THRU 50
POSITIONING ACCURACY +/-.001 INCH +/- .0005 INCH +/-.0004 INCH REPEATABILITY +/-.0005 INCH +/- .0003 INCH +/-.0002 INCH CIRCLE T.I.R. .002 T.I.R. .0015 T.I.R. .0010 T.I.R
THE MACHINED CIRCLE SHOULD BE ROUND WITHIN THE T.I.R SPECIFICATION FOR THAT MACHINE TYPE. THE TRUE MEASURED CENTER OF A CIRCLE SHOULD FALL WITHIN THE ACCURACY SPECIFICATION FOR EACH MACHINE TYPE. VERIFICATION PROCEDURE: SWEEP THE MACHINED CIRCLE WITH AN INDICATOR INSERTED INTO THE SPINDLE. FIND THE TRUE CENTER OF THE CIRCLE BY MANUALLY JOGGING X AXIS TO OBTAIN EQUAL READINGS AT THE 3:00 AND 9:00 POSITIONS. MANUALLY JOG THE Y AXIS TO OBTAIN EQUAL READINGS AT THE 12:00 AND THE 6:00 POSITIONS. IDEALLY THE READINGS AT 12:00, 3:00, 6:00 AND 9:00 SHOULD BE EQUAL. ONCE THE CENTER IS ESTABLISHED, ZERO THE INDICATOR AT THE 12:00 POSITION, SWEEP THE CIRCLE AND RECORD THE READINGS AT VARIOUS POINTS. THE TOTAL INDICATOR READING (T.I.R.) SHOULD NOT EXCEED THE T.I.R. SPECIFICATION FOR THE MACHINE TYPE BEING CHECKED. NOTE: DO NOT USE AUTOMATIC POSITIONING TO DETERMINE TRUE CENTER AS ADDITIONAL POSITIONING VARIABLES MAY CAUSE GREATER THAN SPECIFIED T.I.R. READINGS. IT SHOULD ALSO BE NOTED THAT MACHINING PRACTICES CAN CAUSE EXCESSIVE T.I.R. READINGS. ID THE READINGS ARE ALL PLUS OR ALL MINUS, THE T.I.R. IS THE LARGEST MEASURED DEVIATION FROM INDICATOR ZERO. IF SOME READINGS ARE PLUS AND SOME ARE MINUS, THE T.I.R IS THE SUM OF THE LARGEST PLUS READING AND THE LARGEST MINUS READING IGNORING THE SIGNS. (THEIR ABSOLUTE VALUES.)
ORIGINATOR: WAYNE E. HAWKINS REVISED BY: R. BRYANT

DATE: MARCH 20, 1989 SUBJECT: CIRCLE & POSITIONING ACCURACY ISSUE NUMBER: 1049A SUPERSEDES NUMBER: 1049 PAGE 1 OF 1
PRODUCT LINE: ALL MILLS
DO NOT QUOTE THESE SPECIICATIONS TO CUSTOMERS
MACHINE TYPE
SM1 CNC / KM3 MD1 / KM3P BMC 10 THRU 50 MD3 POSITIONING ACCURACY +/-.001 INCH +/- .0005 INCH +/-.0004 INCH REPEATABILITY +/-.0005 INCH +/- .0003 INCH +/-.0002 INCH CIRCLE T.I.R. .002 T.I.R. .002 T.I.R. .002 T.I.R
THE MACHINED CIRCLE SHOULD BE ROUND WITHIN THE T.I.R SPECIFICATION FOR THAT MACHINE TYPE. CIRCLE TIR IN MOST CASES CAN BE SUBSTANTIALLY IMPROVED OVER THE ABOVE SPECIFICATIONS. THE TRUE MEASURED CENTER OF A CIRCLE SHOULD FALL WITHIN THE ACCURACY SPECIFICATION FOR EACH MACHINE TYPE. VERIFICATION PROCEDURE: SWEEP THE MACHINED CIRCLE WITH AN INDICATOR INSERTED INTO THE SPINDLE. FIND THE TRUE CENTER OF THE CIRCLE BY MANUALLY JOGGING X AXIS TO OBTAIN EQUAL READINGS AT THE 3:00 AND 9:00 POSITIONS. MANUALLY JOG THE Y AXIS TO OBTAIN EQUAL READINGS AT THE 12:00 AND THE 6:00 POSITIONS. IDEALLY THE READINGS AT 12:00, 3:00, 6:00 AND 9:00 SHOULD BE EQUAL. ONCE THE CENTER IS ESTABLISHED, ZERO THE INDICATOR AT THE 12:00 POSITION, SWEEP THE CIRCLE AND RECORD THE READINGS AT VARIOUS POINTS. THE TOTAL INDICATOR READING (T.I.R.) SHOULD NOT EXCEED THE T.I.R. SPECIFICATION FOR THE MACHINE TYPE BEING CHECKED. NOTE: DO NOT USE AUTOMATIC POSITIONING TO DETERMINE TRUE CENTER AS ADDITIONAL POSITIONING VARIABLES MAY CAUSE GREATER THAN SPECIFIED T.I.R. READINGS. IT SHOULD ALSO BE NOTED THAT MACHINING PRACTICES CAN CAUSE EXCESSIVE T.I.R. READINGS. ID THE READINGS ARE ALL PLUS OR ALL MINUS, THE T.I.R. IS THE LARGEST MEASURED DEVIATION FROM INDICATOR ZERO. IF SOME READINGS ARE PLUS AND SOME ARE MINUS, THE T.I.R IS THE SUM OF THE LARGEST PLUS READING AND THE LARGEST MINUS READING IGNORING THE SIGNS. (THEIR ABSOLUTE VALUES.) ORIGINATOR: WAYNE E. HAWKINS REVISED BY: MIKE GARLICK

DATE: APRIL 8, 1985 SUBJECT: SPINDLE HARDWARE FAULT PRODUCT LINE: MD3 ISSUE NUMBER: 1050 SUPERSEDES NUMBER: 228/233 PAGE 1 OF 1
DURING A RECENT SERVICE CALL ON AN MD3 WHICH WAS DISPLAYING INTERMITTENT SPINDLE HARDWARE FAULTS, WE FOUND THAT THE CLAMPING AND /OR UNCLAMPING OF THE SPINDLE CAUSED A TEMPORARY LOSS OF AIR PRESSURE TO THE SHOT PIN. THE SHOT PIN OUT STATE IS DRIVEN BY A SPRING. THIS TEMPORARY LOSS OF AIR ALLOWS THE SHOT PIN TO BACK OFF THE SHOT PIN LIMIT SWITCH CAUSING A SPINDLE HARD WARE FAULT. THIS PROBLEM WAS CORRECTED BY READJUSTING THE AIR FLOW RESTRICTORS FOR THE SPINDLE CLAMP AND UNCLAMP CYLINDERS. PRESET ADJUSTMENT IS, TURN THE RESTRICTOR ADJUSTMENT SCREWS ALL THE CW THEN BACK 1 1/2 TURNS CCW. RUN SEVERAL TOOL CHANGES, OBSERVE OPERATION OF THE SPINDLE CLAMP, UNCLAMP, AND SPINDLE SHOT PIN. IF ANY PROBLEMS WITH CLAMP OR UNCLAMP ARE NOTED ADDITIONAL ADJUSTMENTS OF 1/2 TURN CCW MAY BE REQUIRED. SHOT PIN IN LIMIT SWITCH ADJUSTMENT 1. ORIENT SPINDLE SO SHOT PIN IS ENERGIZED BUT NOT INTO SPINDLE SLOT. (ORIENTED SLOT) 2. PLACE SHIM OF .100 " THICKNESS BETWEEN SHOTPIN IN SWITCH AND ADJUSTABLE ACTUATOR DOG.. 3. ADJUST DOG UNTIL SWITCH IS JUST MADE. LOCK INTO POSITION. 4. ACTUATE SHOTPIN OUT-VALVE AND ADJUST DOG UNTIL SHOTPIN OUT-SWITCH IS MADE RELIABLY. 5. CYCLE 200 TOOL CHANGES AND OBSERVE PROPER OPERATION. 6. LOCKTITE ALL ADJUSTMENTS.
ORIGINATOR: RICK GUNYON REVISED BY: R BRYANT

DATE: April 16, 1985 SUBJECT: FAULT LOGIC BOARD 402 5001 035 PRODUCT LINE: MD3 ISSUE NUMBER: 1051 SUPERSEDES EUXBER: 234 PAGE 1 OF 1
HURCO RECENTLY MADE A PURCHASE OF FAULT LOGIC BOARDS FROM RANDTRONICS WHICH HAD A DIFFERENT 3 PHASE RECTIFIER THAN WE HAD ORIGINALLY USED. THIS NEW AND IMPROVED MODEL, WHICH HAS BEEN UNSUCCESSFUL, MUST BE REPLACED AND REPLACED AS A BOARD ASSEMBLY SINCE HURCO DOES NOT STOCK ONLY THE RECTIFIER. THE DEFECTIVE UNIT IS A SILICON POWER CUBE AND LOOKS EXACTLY LIKE A SQLID STATE RELAY. IT SAYS SILICON POWER ON THE UNIT. THE CORRECT RECTIFIER IS A BLACK AND SILVER CANISTER AND ONLY HAS NUMBERS ON IT AND IS CLEARLY LARGER THAE THE SILICON POWER TYPE. THIS MUST BE REPLACED. YOU MUST CHECK OUT EVERY MD3 YOU INSTALL MANUFACTURED IN FEBRUARY, MARCH AND APRIL. IT WOULD ALSO BE ADVISABLE TO DOUBLE CHECK ANY YOU SERVICE AND NOTE ON YOUR REPORT IF THE MACHIEE HAS THE CORRBCT RECTIFIER.
ORIGINATOR: JERRY MC CLATCHEY REVISED BY:
DATE: MAY 13, 1985 SUBJECT: DOOR LATCH INTERFACE PRODUCT LINE: SM1-CNC
THE ONE AC TRANSFORMER HAS BEEN FOUND TO INTERFERE VITH THE OPERATION OF THE DOOR LATCH ON SOME CONTROL CABINETS. THE SOLUTION IS TO MOVE THE ONEAC 3/'8" TQ 1/2" TOWARD THE REAR OF THE POWER CABINET BY DRILLIEG NEW HOLES IN THE ONE AC. THE INTERFERENCE ALLOWS THE LATCH HANDLE TO BE OPERATED WITHOUT OPERATING THE SCREW-DRIVER SLOT. ALL SMI-CNC'S SHOULD BE CHECKED FOR PROPER OPERATION OF THE LATCH AND REWORKED IN THE FIELD WHEN IMPROPER LATCH OPERATION IS FOUND. ALL SMI CNC MILLS SHIPPED VITH ONEACS PRIOR TO 3/ 30/'85 ARB BELIEVED TO REQUIRE THE REWORK.. ON 3/30/85 A MANUFACTURING NOTICE WAS ISSUED REQUIRING THIS RBWORK PRIOR TO SHIPMENT.
DATE: MAY 15, 1985 SUBJECT: LUBRICATION OF SPLINE COUPLING: PRODUCT LINE: KMB1, KMBX1, KMBX1 ATC
ISSUE NUMBER: 1053 SUPERSEDES NUMBER: 236/237 PAGE 1 OF 1
THE SPLINE COUPLING AND THE SPLINED AREA OF THE SPINDLE SHOULD BE PERIODICALLY LUBRICATED TO PREVENT THE OCCURRENCE OF EXCESSIVE NOISE DURING MACHINING OPERATIONS AND TO PROMOTE A LONGER LIFE EXPECTANCY. FREQUENCY OF LUBRICATION IS DEPENDENT UPON SEVERITY OF OPERATION AND AMOUNT OF MACHINE USE. (A GENERAL GUIDE MAY BE APPROXIMATELY EVERY 250 MACHINE HOURS. APPLY A LIGHT COATING OF N.L.G.I. #2 GENERAL PURPOSE LITHIUM-BASED HIGH TEMPERATURE GREASE TO THE SPLINED AREA OF THE SPINDLE AT BOTH SIDE OF THE COUPLING. DO NOT APPLY EXCESSIVE AMOUNTS OR GREASE THAT MAY BE SLUNG INTO THE DRIVE BELT AS THIS MAY CAUSE BELT SLIPPAGE. A LABEL HAS BEEN MADE AVAILABLE FOR FIELD RETROFIT. THE PART NUMBER IS 703-1005-297.
ORIGINATOR: FRANK PARROTT REVISED BY: R. BRYANT

DATE: JULY 9, 1985 SUBJECT: HONING QUILL BORES PRODUCT LINE: KNEE MILLS ISSUE NUMBER 1054 SUPERSEDES NUMBER: 246 PAGE 1 OF 1
THERE ARE (2) HONES LOCATED IN THE HURCO TOOL CRIB, HOWEVER ONLY ONE IS SUITABLE FOR USE IN HONING QUILLS IN KMB1-M THRU KM3 TYPE MACHINES. BECAUSE OF THE SLOT IN THE FRONT OF THE QUILL BORE, USE THE SUNNEN BRAND HONE. IT HAS STONES SPACED SO THIS SLOT WILL BE SPANNED AND THE STONES WILL NOT FALL INTO THE SLOT, REGARDLESS OF THE HONE RPM. DO NOT USE THE AMMCO HONE FOR THESE MACHINES. IT IS OKAY TO USE THE HONE FOR KMB1 TYPE QUILL BORES AS THEY ARE FULLY ROUND, WITH NO SLOT.
ORIGINATOR: JACK NANCE REVISED BY:
HURCO

DATE: NOVEMBER 4, 1985 SUBJECT: SPINDLE REBUILDS PRODUCT LINE: SPINDLE REBUILD KNEE MILLS
IF AT ALL POSSIBLE WHEN RETURNING SPINDLES FOR REBUILD, RETURN THE QUILL ALSO. THIS WILL ALLOW MANUFACTURING TO ASSURE THE SPINDLE IS PROPERLY SIZED FOR THE QUILL. IN SOME CASES SPINDLE BEARING'S HAVE BEEN LOOSE INSIDE THE QUILL DUE TO INTERNAL QUILL WEAR. IF THE QUILL IS RETURNED, MANUFACTURING CAN ASSURE A TIGHT FIT BETWEEN SPINDLE BEARING'S AND THE I.D. OF THE QUILL.
ORIGINATOR: R.J. JOHNSON REVISED BY:

DATE: JULY 10, 1985 SUBJECT: MISCOUNTS DUE TO WIRING IN X5 BOX ISSUE NUMBER: 1066 SUPERSEDES NUMBER: 250
PRODUCT LINE: MILLS USING HEIDENHEIN SCALES PAGE 1 OF 2
MISCOUNTS MAY OCCUR IF THE WIRE PAIRS FOR J4, J5, J6 TO TB4, TB5 AND TB6 WITHIN THE X5 BOX ARE NOT TIGHTLY TWISTED. TWIST AS MANY TURNS AS POSSIBLE WHILE ALLOWING CONNECTION TO WAGOS TB4-6. DO NOT TWIST TO THE POINT OF DOUBLE LEVELS OF TWIST, A SINGLE TIGHT TWIST IS REQUIRED. MILLS BEING INSTALL OR SERVICED SHOULD BE INSPECTED AND REWORKED TO THE ABOVE. MILLS NOT COMPLYING WITH THE ABOVE MAY BE EXPECTED T.O MISCOUNT SLIGHTLY, OR MAY NOT MISCOUNT AT ALL.

DATE:JULY 11, 1985 SUBJECT: AIR LINE FITTINGS POPPING OFF PRODUCT LINE: KMB1, MB1, MD1 ISSUE NUMBER: 1057 SUPERSEDES NUMBER: 252 PAGE 1 OF 1
THE FITTINGS BELOW CAN BE USED TO REPLACE THE FITTINGS SHIPPED WITH THE MILL ORIGINALLY TO REDUCE THE POSSIBILITY OF AIR LEAKS DUE TO AIR LINES POPPING OFF. 506-5060-002 FREE SWIVEL ELBOW O.D. 1/'4 PIPE THREAD 1/'4.
506-0002-013 STRAIGHT MALE CONNECTOR O.D. 1/2 THREAD 1/2
506-0002-014 STRAIGHT MALE CONNECTOR O.D. 1/'4 THREAD 1/8.
506-3012-016 UNION TEE TUBE O.D. 1/'4.
506-3009-036 MALE ELBOW O.D. 1/4 THREAD 1/4.
506-3009-037 MALE ELBOW O.D. 1/4 THREAD 1/8.
ORIGINATOR: ROBERT JOHNSON REVISED BY: R. BRYANT

DATE: JULY 23, 1985 ISSUE NUMBER: 1058
SUBJECT: CHIP REMOVAL FROM BENEATH SADDLE SUPERSEDES NUMBER: 255/253 PRODUCT LINE: MD1 PAGE 1 OF 1
REMOVAL OF THE CHIP BUILD-UP BENEATH THE SADDLE (AROUND THE BALL LEADSCREW) IS TO BE PERFORMED ON WEEKLY BASIS. THIS TO PREVENT THE POSSIBILITY OF BINDING And/or UNDUE WEAR ON THE LEADSCREW AND IMPROVE THE RETURN FLOW OF THE COOLANT. A STICKER PART NUMBER 703-1005-296 SHOULD BE INSTALLED ON THIS MACHINE TO INFORM THE CUSTOMER ABOUT THE CHIP REMOVAL.
ORIGINATOR: JACK NANCE REVISED BY: R. BRYANT

DATE: JULY 23, 1985 SUBJECT: Y AXIS LEADSCREW COVER PRODUCT LINE: MD1 ISSUE NUMBER: 1059 SUPERSEDES NUMBER: 256 PAGE 1 OF 1
WHEN THE WIDE Y AXIS WAY COVERS WERE ADDED TO THE MD1 MILLS, THE Y AXIS BALL SCREW COVER WAS DELETED. A BALLSCREW COVER IS AVAILABLE TO PROTECT THE BALL SCREW FROM CHIPS WHICH MAY GET UNDER THE SADDLE BY FALLING BEHIND THE TABLE. THE FOLLOWING PARTS ARE REQUIRED: 1, BALLSCREW COVER 902-0434-002 1 2, SPACER BAR 802-1661-001 2 3, M6 C 12 S.H.C.S 101-5008-003 2 A NOTCH MUST BE CUT IN THE SLIDIHG WAY COVER TO ALLOW CLEARANCE. SEE ATTACHED DRAWING FOR CUTOUT DIMENSIQNS. 802-1655-001, NOTE: ALL HOLES REQUIRED ARE ALREADY DRILLED AND TAPPED FOR THE BALLSCREW COVER, SPACER BAR ETC..
ORIGINATOR: ROBERT JOHNSON REVISED BY:

DATE: JULY 24, 1985 SUBJECT: QUILLS FOR KONDIA MILLS PRODUCT LINE: ALL SM1-CNC KILLS ISSUE NUMBER: 1060 SUPERSEDES NUMBER: 257 PAGE 1 OF 1
A) FIRST (21) SMI-CNC RETROFITS, MANUAL MILL TO CNC HAD KMB1M HEADS. THIS PART NUMBER IS 713-0016-001. QUILL TO BORE CLEARANCE IS .0008 TO . 0010" . B) UNTIL JANUARY 85, SM1 CNC MILLS WERE ALL SMI MANUAL MILLS CONVERTED TO CNC MILLS; THEREFORE WE TOOK MANUAL MILL, QUILLS PART NUMBER 7130012-108 RACK GEAR TYPE, AND MODIFIED IT, THUS NUMBER S01-1350-001. NOTE: THIS APPLIES ONLY TO CONVERTED SM1'S HURCO STYLE CNC CLEARANCE FOR QUILL TO BORE .0008-.0012". C) ON SM1-CNC'S BEGINNING WITH BUILDS IN JANUARY 1985, WE RECEIVED AND USED KONDIA'S RIGID OVERARM MODEL. THIS USED QUILL PART NUMBER 713- 0012-330. THIS WAS CHROME PLATED GROUND AND POLISHED QUILL. CLEARANCE WAS .0008-. 0010". D) IN FEBRUARY 1985, WE INSTITUTED AN INDUCTION HARDENED QUILL. THIS WAS THE SAME QUILL AS IN C BUT THE FINISH WAS CHANGED FROM CHROME INDUCTION HARDENED, GRIND AND POLISH FINISH. TO NO CHROME. HURCO PART NUMBER 713-0012-330. THESE QUILLS IN MILLS HAVE JUST ARRIVED THIS MONTH. CLEARANCES IS . 0004-.0006". E) REPLACEMENT QUILLS FOR ALL SMI-CNC'S WITH THE RIGID OVERARM ONLY SHOULD USE THIS LAST QUILL, AND THIS CLEARANCE. IN THE CASE OF OVERSIZE QUILLS, USE HARDENED QUILLS AHD CHROME PLATE AND GRIND TO OBTAIN THE DESIRED FIT OF .0004-.0006". F) REPLACEMENT QUILLS FOR THE EARLIER SM1-CNC'S HURCO STYLE, SHOULD USE QUILLS AS IN B ABOVE.
ORIGINATOR: DAVE ROCH REVISED BY:

DATE: AUGUST 27, 1985 SUBJECT: PARAJUST B WIRE DRESSING PRODUCT LINE: MD1-MD3 MILLS ISSUE NUMBER: 1061 SUPERSEDES NUMBER: 259 PAGE 1 OF 1
IT HAS BEEN FOUND THAT A PROBLEM COULD OCCUR IF THE PARAJUST WIRING IS NOT CORRECT. THE WIRING FROM THE PARAJUST CABINET TO THE PARAJUST DOOR (TB-1 AND THE BRAKE BOARD) CAN BECOME NICKED OR SEVERED IF IT IS NOT PROTECTED AND DRESSED PROPERLY. IT CAN ALSO CAUSE PROBLEMS CLOSING THE DOOR. THE PROPER DRESS SHOULD INCLUDE APPROXIMATELY 12" OF 1/'2" SPIRAL WRAP OVER THIS AREA OF WIRING FOR PROTECTION. IT SHOULD BE DRESSED SO AS TO PROTECT WIRING AND PARAJUST CIRCUIT BOARDS WHEN OPENING AND CLOSING PARAJUST DOORS.
THE PART NUMBER FOR SPIRAL WRAP IS 406-6241-001.
ORIGINATOR: K. PERKINS REVISED BY:

DATE: AUGUST 27, 1985 SUBJECT: ADJUSTABLE SPINDLE ORIENT SPEED PRODUCT LINE: MD1-3 PAGE 1 OF 1 ISSUE NUMBER: 1062 SUPERSEDES NUMBER: 260
D SERIES MILLS WITH A06 OR LATER SOFTWARE HAVE AN ADJUSTABLE ORIENT SPEED. SWITCH BLOCK S2 ON THE X SPINDLE DUAL AXIS BOARD. NORMAL SETTING IS S2 POSITIONS 1 TO 5. SPEED ADJUSTMENTS ARE AS FOLLOWS: LSB (BIT 1) POSITION 5 (BIT 2) 4 (BIT 3) 3 MSB (BIT 4) 2 SIGH BIT 1 FASTER = OPEN OR OFF/' SLOWER = CLOSED OR ON. THE SPEED ADJUSTMENT IS +- 50 '/ OF NOMINAL FOR MACHINE TYPE NOMINAL=40 RPM. SW2 POSITION 1 OPEN, AND 2 THRU 5 CLOSED = 50'/ FASTER. SW2 POSITION 1 CLOSED, AND 2 THRU 5 CLOSED = 50/ SLOWER. ANY COMBINATION MAY BE USED TO GET A WORKING ORIENT SPEED. AFTER ADJUSTING, CYCLE THE TOOL CHANGER USING HIGH AND LOW GEAR (RANGE) AND ENSURE RELIABLE OPERATION. FINE TUNE SPEED UNTIL HIGH AND LOW GEAR (RANGE) ARE BOTH RELIABLE. AFTER COMPLETION OF SETTING ORIENT SPEED, CYCLE THIS TOOL CHANGER 200 TIMES USING FULL RANGE OF RPM'S AND BOTH CW AND CCW ROTATION,
ORIGINATOR: KEITH PERKINS REVISED BY:
HURCO FIELD SRRVICE BULLETIN

DATE: AUGUST 27, 1985 SUBJECT: TAPE TRANSPORT GROUNDING PRODUCT LINE: ULTIMAX ONE ISSUE NUMBER: 1063 SUPERSEDES NUMBER: 262 PAGE 1 OF 2
ENSURE THAT THE CARTRIDGE GROUNDING CLIP IS PROPERLY INSTALLED IN THE TAPE TRANSPORT. THE GROUND CLIP SHOULD PROTRUDE THROUGH THE BOTTOM OF THE TRANSPORT SO AS TO TOUCH THE BOTTOM SO AS TO TOUCH THE BOTTOM OF THE CARTRIDGE WHEN INSERTED INTO THE TRAESPORT. NOTE : CLIP CAN BE SEEN TO THE RIGHT SIDE OF THE TAPE HEAD IN THE BQTTOM OF THE TRANSPORT AS VIEWED THROUGH THE CARTRIDGE QPENING. THERE IS ANOTHER GROUND WIRE TO BE CQNNECTED TO THE GRQUND LUG OH THE TAPE TRANSPORT. BOTH GROUND WIRES ARE TO BE CONNECTED ON THE OPPOSITE END TO THE CONSOLE GROUND AREA. LOCATED AT THE UPPER LEFT SIDE OF THE CABLE CONNECT BOARD ON THE BOTTOM OF THE ENCLOSURE. SEE THE ATTACHED DRAWING FOR THE LOCATION OF THE GROUND LUGS AND THE GROUND CLIP. NOTE: SOME EARLY TAPE TRANSPQRTS HAD A INFERIOR QUALITY GROUND CLIP THAT GETS CAUGHT ON THE BOTTOM OF THE TAPE CARTRIDGE AND WOULD GET BENT CAUSING THE TAPE NOT TO EJECT FULLY FROM THE TRANSPORT. IF THIS CONDITION IS SEEN, THE TAPE TRANSPORT SHOULD BE REPLACE WITH A NEW ONE OR A CURRENT PRODUCTION STYLE GROUND CLIP INSTALLED.

DATE: AUGUST 27, 1985 SUBJECT: LUBE PRESSURE SWITCH SETUP PRODUCT LINE: MD3 ISSUE NUMBER: 1064 SUPERSEDES NUMBER: 264 PAGE 1 OF 2
WITH A06 OR LATER SOFTWARE THAT MONITORS THE LUBE PRESSURE SWITCH. THE SWITCH SET UP IS AS FOLLOWS. 1. CONNECT VOLTMETER ACROSS LUBE PRESSURE SWITCH CONTACTS (N.O.) THE METER SHOULD BE IN THE 20 VDC SCALE. 2. SWITCH SHOULD BE OPEN (APPROXIMATELY 5 VDC READING). IF NOT, LOOSEN LUBE PRESSURE JAM NUT AND TURN ADJUSTMENT SCREW. 3. MANUALLY ACTIVATE LUBE SOLENOID. SWITCH SHOULD CLOSE (APPROXIMATELY 0 VDC). IF NOT ADJUST LUBE SWITCH. 4 MANUALLY ACTIVATE AND DEACTIVATE THE LUBE SOLENOID. VERIFY SWITCH CLOSES WHEN LUBE PUMP ACTIVATES AND THE SWITCH OPENS WHEN THE SOLENOID IS DEACTIVATED. 5. TIGHTEN LUBE SWITCH ADJUSTMENT JAM NUT BEING CAREFUL NOT TO ALTER SCREW SETTING. 6. RECHECK TO VERIFY CORRECT SWITCH ADJUSTMENT. 7. TO SIMULATE A SOFTWARE CONTROLLED OPERATION OF THE LUBE PUMP TURN OFF / ON POWER TO THE MILL. UPON POWER UP AND ENERGIZING SERVOS LUBE PUMP SHOULD BE ACTIVATED, FIRING SOLENOID AND CLOSING SWITCH. VERIFY NO ERROR IS REPORTED ON THE CRT SCREEN INDICATING "LUBE PRESSURE FAILURE". NOTE: SEE ATTACHED PAGE FOR LOCATION OF THE LUBE PRESSURE SWITCH AND SOLENOID.
DATE: November 2, 1992 SUBJECT: Ultimax Power Supply Adjustments. PRODUCT LINE: Ultimax Machines
ISSUE NUMBER: 1065-B SUPERSEDES NUMBER: 1065-A PAGE 1 OF 4
On Ultimax 1 thru 3 power supplies check at locations per type on the following pages. Output to be within the following spec.: 5 VDC 24 VDC - 12 VDC + 12 VDC = = = = +5.2 - 5.3 VDC +24.5 - 25.0 VDC -12.5 - -13 VDC +12.5 - +13 VDC
ALSO NOTE: THE 24 VOLT SUPPLY OUTPUT FROM THE POWERTEC IS ADJUSTABLE BUT NOT FOR THE POWERMATE. ALL ULTIMAX 1 THRU 2, SUPPLIES WILL BE REPLACED WITH THE DELTRON IF THEY ARE BAD, SO YOU MAY HAVE TO MOVE SOME WIRES AROUND TO MATCH HOOKUPS. SEE ATTACHED PAGES FOR DRAWINGS OF POWER SUPPLIES.
ORIGINATOR: Randall Bryant REVISED BY: Randall Bryant

G R O U N D
230VAC
Powermate DC Switching power supply Hurco part number 413-0008-001

+5VDC
All Pots are Interacting and should be verified after setup.
Caution: Use Non-metallic adjusting tool. As legs of pot

-12VDC +12VDC
are very near adjustment screw.
10 9 G + R 5 O V U D N C D
8 G R O U N D
7 + 24 V D C
6 G R O U N D
5 + 5 V D C
4 12 V D C
3 G R O U N D
2 G R O U N D
1 + 12 V D C
NONADJUSTABLE
+5VDC +24VDC
Powertec Power Supply Hurco Part number 413-0008-006

-12VDC

+12VDC
4 5 6
8 C O M M O N
9 10 11 C O M M O N + 5 V D C + 5 V D C
G V V + + - C R A A 12 24 12 O O C C V V V M U D D D M N C C C O N D
FSB 1065B Page 2 of 4
+12VDC -12VDC +24VDC
Deltron Power supply Hurco Part number 413-0008-011

+5VDC All Pots are Interacting and should be verified after setup.
Caution: Use Non-metallic adjusting tool. As legs of

pot are very near adjustment screw.
4 5 6
8 C O M M O N
9 10 11 C O M M O N + 5 V D C + 5 V D C
G V V + - + C R A A 12 12 24 O O C C V V V M U D D D M N C C C O D N
Fan Ground
Common 5VDC -12VDC 12VDC Common 24VDC
120 VAC
Ultimax 3 DC Power Supply. "REV A or B" Hurco Part number 413-0008-013 NOTE: refer to FSB 1198 for wiring code.
FSB 1065B Page 3 of 4
Ultimax 3 DC Power Supply. "REV C" Hurco Part number 413-0008-013 NOTE: refer to FSB 1198 for wiring code.
FSB 1065B Page 4 of 4 FSB XXX Page 4 of 4
DATE: December 7, 1993 SUBJECT: Ultimax Power Supply Adjustments Mod's. PRODUCT LINE: Ultimax Machines Revised Added Page 2 and Notes See page 2 for modification information.
ISSUE NUMBER: 1065-C SUPERSEDES NUMBER: 1065-B PAGE 1 OF 5
On Ultimax 1 thru 3 power supplies check at locations per type on the following pages. Output to be within the following spec.: 5 VDC 24 VDC - 12 VDC + 12 VDC = = = = +5.2 - 5.3 VDC +24.5 - 25.0 VDC -12.5 - -13 VDC +12.5 - +13 VDC
ALSO NOTE: THE 24 VOLT SUPPLY OUTPUT FROM THE POWERTEC IS ADJUSTABLE BUT NOT FOR THE POWERMATE. ALL ULTIMAX 1 THRU 2, SUPPLIES WILL BE REPLACED WITH THE DELTRON IF THEY ARE BAD, SO YOU MAY HAVE TO MOVE SOME WIRES AROUND TO MATCH HOOKUPS. SEE PAGE 2 FOR MORE INFORMATION ON REPLACEMENT SUPPLIES. SEE ATTACHED PAGES FOR DRAWINGS OF POWER SUPPLIES.
ORIGINATOR: Randall Bryant REVISED BY: L. Leffew

The MAX 2 Deltron supply has been replaced by a modified MAX 3 Deltron supply. This new supply is stocked under the old part number (413-0008-011). The modifications are for mounting only. This supply will mount in place of the original unit, except on KM3/3P machines that had the supply mounted behind the card rack. In this case the supply is moved to the left hand side wall. All cabling involved will reach to the new position. The 12 position Wago connector (406-4005-067) and directions on making the connections are included with the new supply. On early machines,(MD1's and MD3's possibly early OEM's) the supply was setup to operate on 230 vac, the new supply can not be changed to operate at this voltage. To install this new supply on a machine that is at 230 vac you will need to move the input voltage, to the power conditioner, from 230 vac to the 115 vac. Consult the wiring diagrams for proper connection points. The following information is supplied as an example only. It is not intended to be used to make wiring changes to the machine. On the MD1 the power conditioner is supplied from the primary side of T2 control voltage transformer. Locate the lines feeding the conditioner and move them to the secondary side of T2.
FSB 1065C Page 2 of 5
G R O U N D
230VAC
Powermate DC Switching power supply Hurco part number 413-0008-001

+5VDC

-12VDC +12VDC
10 9 G + R 5 O V U D N C D
8 G R O U N D
7 + 24 V D C
6 G R O U N D
5 + 5 V D C
4 12 V D C
3 G R O U N D
2 G R O U N D
1 + 12 V D C
NONADJUSTABLE
+5VDC +24VDC
Powertec Power Supply Hurco Part number 413-0008-006

-12VDC

+12VDC
4 5 6
8 C O M M O N
9 10 11 C O M M O N + 5 V D C + 5 V D C
G V V + + - C R A A 12 24 12 O O C C V V V M D D D M U C C C O N N D
FSB XXX Page 4 of 5
+12VDC -12VDC +24VDC
Deltron Power supply Hurco Part number 413-0008-011

+5VDC All Pots are Interacting and should be verified after setup.
Caution: Use Non-metallic adjusting tool. As legs of

pot are very near adjustment screw.
4 5 6
8 C O M M O N
9 10 11 C O M M O N + 5 V D C + 5 V D C
G V V + - + C R A A 12 12 24 O O C C V V V M U D D D M N C C C O D N
Fan Ground
Common 5VDC -12VDC 12VDC Common 24VDC
120 VAC
Ultimax 3 DC Power Supply. "REV A & B" Hurco Part number 413-0008-013 NOTE: refer to FSB 1198 for wiring code.
5V Adj
+24 V Adj +-12V Adj
Ultimax 3 DC Power Supply. "REV C" Hurco Part number 413-0008-013 NOTE: refer to FSB 1198 for wiring code.

DATE: MARCH 23, 1989 ISSUE NUMBER: 1066
SUBJECT: DIP SWITCH SETTINGS ON ULTIMAX MILLS SUPERSEDES NUMBER: 267 PRODUCT LINE: ALL ULTIMAX MILLS CONTROLS PAGE 1 OF 9
INTENT: TO PROVIDE UNIFORMITY IN SETTING SWITCH POSITIONS ON ALL ULTIMAX CONTROL MACHINES.
INDEX A. 128K MEMORY BOARD (415-0168-001) B. 256K MEMORY BOARD (415-0168-002) C. X/Y DUAL AXIS BOARD (415-0176-00X) D. Z/SPINDLE DUAL AXIS BOARD (415-0176-00X) E. MACHINE PERSONALITY BOARD (415-0176-001/002) F. CRT CONTROLLER BOARD (415-0174-001/002) G. MICRO MEMORY BOARD MAX II H. CONTROL RELAY PANEL NOTE: CONTROL MUST BE RESET (POWER DISCONNECTED) TO DETECT A CHANGE IN SWITCH CONFIGURATION.
ORIGINATOR: REVISED BY: R. BRYANT
A. 128K MEMORY BOARD: 415-0168-001 SWITCH AND JUMPER CONFIGURATION. FOR ANY BOARD WITH IT'S ADDRESS STARTING ABOVE 256K, A JUMPER MUST BE PRESENT BETWEEN E1 AND E2.
Brd 1 thru 4 Configurations 6 5 4 3 2 1 Battery Select
0 = OPEN S1 1 = CLOSED
Battery Select A. #1 CLOSED, #2 OPEN = MEMORY SUPPORTED BY +5V SUPPLY AND NOT BATTERY VOLTAGE BOARD B. #1 OPEN, #2 CLOSED = MEMORY SUPPORTED BY BATTERIES FOR DATE RETENTION. (NORMAL SETTING) Board # #1 #2 #3 #4 Switch Position 6 5 4 3 1 1 1 1 0 1 1 1 1 1 1 1 0 1 1 1
Jumper E1 to E2 Jumper E1 to E2
B. 256K MEMORY BOARD 415-0168-002 NOTE: 1= CLOSED = ON O= OPEN = OFF FUNCTION
SWITCH #
SW1 BANK SELECT SW2 READ TIME CLOCK (RTC) SELECT SW3 UPPER LIMIT BLOCK A SW4 LOWER LIMIT BLOCK A SW5 UPPER LIMIT BLOCK B SW6 LOWER LIMIT BLOCK B SW7 (1 THRU 3) BATTERY ENABLES SW7 (4) RTC WRITE PROTECT SW7 (5) +4 VDC RACK TO RAM ARRAY SW7 (6) VBB (BATTERIES) TO RAM ARRAY SW9 RTC SELECT
COMMON SWITCH SETTINGS (ALL 256K BOARDS) SWITCH # SW1 SW2 SW9 SW7 #1 SW7 #2 SW7 #3 SW7 #4 SW7 #5 SW7 #6 SETTINGS 1 THRU 4 = CLOSED 1 THRU 5, 7, 8 = CLOSED; 6= OPEN 1 THRU 4 = CLOSED CLOSED BATTERY 1 IN CIRCUIT CLOSED BATTERY 2 IN CIRCUIT CLOSED BATTERY 3 IN CIRCUIT CLOSED HARDWARE WRITE PROTECTED OPEN +5V FROM BUS DISABLED CLOSED BATTERY VOLTAGE TO RAM
COMMON WIRE JUMPERS (256K BOARDS) WIRE JUMPER REMOVE E28 TO E 27 REMOVE E24 TO E35 INSTALL E31 TO E32 INSTALL E29 TO E30 INSTALL E21 TO E22 FUNCTION DISABLES INTIALIZATION GEN. BY +5 MONT NEEDED FOR 16 BIT OPERATION NEEDED FOR 16 BIT OPERATION NEEDED FOR 16 BIT OPERATION XACK DELAY AT 310 NSEC
SWITCH SETTINGS TO MAKE PER BOARD FIRST 256K (MEMORY PCB #1) 0-3FFFF TOTAL SW3 1 2 3 4 5 6 0 0 0 1 1 1 SW4 1 2 3 4 1 1 1 1 SW5 1 2 0 0 SW6 1 2 1 1
5 1
6 1
3 0
4 0
5 1
6 1
3 1
4 5 6 0 1 1
SECOND 256K (MEMORY PCB #2) 4000-7FFFF SW3 1 2 3 4 5 6 0 0 0 1 0 1 SW4 1 2 3 4 1 1 1 1 SW5 1 2 0 0 SW6 1 2 1 1
5 0
6 1
3 0
4 0
5 0
6 1
3 1
4 5 6 0 0 1
WARNING: SW7 POSITIONS 1,2,3 MUST BE OPEN BEFORE PCB BATTERY OR BATTERY FUSES ARE DESOLDERED!
C. DUAL AXIS BOARD (X/Y) 415-0176-00X FOR ALL ULTIMAX MILLS
S1 NOTE: 1 = ON = CLOSED, O = OFF = OPEN BOARD ADDRESS STANDARD CONFIGURATION 1,2 AND 3 OPEN 4 CLOSED
3 4 On
Off LEADSCREW ERROR IS COMPENSATED OVER 20". SIGN BIT IN BACKLASH USED IN BMC 20-50 MACHINES ONLY.
S2
MSB LSB
S3
MSB LSB
Sign Bit On = Shorten Travel Off = Lengthen Travel
Scale/Encoder On = Rotary Encoder Off = Scale
Y axis Leadscrew Comp. S4

MSB LSB
Y axis Backlash Comp. S5

MSB LSB
Sign Bit On = Shorten Travel Off = Lengthen Travel
Scale/Encoder On = Rotary Encoder Off = Scale
X axis Leadscrew Comp.
X axis Backlash Comp.
SCALES = .000039" PER BIT (MD3, BMC 10 THRU 15) ROTARY ENCODERS = .00005" PER BIT (MD-1, KM3 & KM3P) ROTARY ENCODERS = .0000197 PER BIT (BMC 20-50) NOTE: BMC 10 THRU 15 USE A ROTARY ENCODER BUT ARE SET AT SCALE VALUES. SET SWITCHES IN BINARY CONFIGURATION FOR TOTAL ERROR COMPENSATION. FOR SCALES : ENCODERS : BMC 20-50 Max 1 & 2 until 7.24 POSITION 8 = .000039" 8 = .00005" 8 = .0000197" 7 = .000078" 7 = .00010" 7 = .0000394" 6 = .000156" 6 = .00020" 6 = .0000788" 5 = .000312" 5 = .00040" 5 = .0001576" 4 = .000624" 4 = .00080" 4 = .0003152" 3 = .001248" 3 = .00160" 3 = .0006304" 2 = .002496" 2 = .00320" 2 = .0012608" EXAMPLE: MD1 HAS .0005" OF BACKLASH. TO STRAP. FOR THIS YOU WOULD TURN ON POSITIONS 7 AND 5. FOR A DIFFERENT VALUE TURN ON OTHER SWITCHES. THE BIT VALUE ADDS AS THE SWITCHES ARE TURNED ON. NOTE: ON BMC 20-50, YOU MAY HAVE A TWO TO ONE PULLEY RATIO AND THE VALUES HAVE TO BE CUT IN HALF.
D. DUAL AXIS BOARD (Z/SPINDLE) 415-0176-001 USED IN MD1, MD3, BMC10 & 15 S1 NOTE: 1 = ON = CLOSED, O = OFF = OPEN BOARD ADDRESS STANDARD CONFIGURATION 1 2 3 4 1,2 AND 3 OPEN On 4 CLOSED LEADSCREW ERROR IS COMPENSATED OVER 20".
Off With 1 turned On 8-4 speeds up dwell. 1 turned Off 8-4 Slows down dwell. LSB
S2
On HSS Off LSS
On=Shot pin enabled S3 Off = Shot pin disabled
1 2 3 4 5 6 7 8 Orient Speed Adjust Mill type On=MD3 Off=MD1
1 2 3 4 5 6 7 8 8=LSB 4=MSB with a Max 70% Change with 4-8 on
Spindle Type/Shotpin Select
Tap / Dwell
SIGN BIT IN BACKLASH USED IN BMC 20-50 MACHINES ONLY.
S4
MSB LSB
S5
MSB LSB
1 2 3 4 5 6 7 8 Sign Bit On = Shorten Travel Off = Lengthen Travel
1 2 3 4 5 6 7 8 Scale/Encoder On = Rotary Encoder Off = Scale
Z axis Leadscrew Comp.
Z axis Backlash Comp.
SCALES = .000039" PER BIT (MD3, BMC 10/15) ROTARY ENCODERS = .00005" PER BIT (MD-1, KM3 & KM3P) ROTARY ENCODERS = .0000197 PER BIT (BMC 20-50) NOTE: BMC 10 /15 USE A ROTARY ENCODER BUT ARE SET AT SCALE VALUES. SET SWITCHES IN BINARY CONFIGURATION FOR TOTAL ERROR COMPENSATION. FOR SCALES : POSITION 8 = .000039" 7 = .000078" 6 = .000156" 5 = .000312" 4 = .000624" 3 = .001248" 2 = .002496" ENCODERS : 8 = .00005" 7 = .00010" 6 = .00020" 5 = .00040" 4 = .00080" 3 = .00160" 2 = .00320" BMC 20-50 Max 1 & 2 until 7.24 8 = .0000197" 7 = .0000394" 6 = .0000788" 5 = .0001576" 4 = .0003152" 3 = .0006304" 2 = .0012608"
NOTE: ON BMC 20-50, YOU MAY HAVE A TWO TO ONE PULLEY RATIO AND THE VALUES WILL HAVE TO BE CUT IN HALF.
E. MACHINE PERSONALITY BOARD 415-0177-00X NOTE: 1 = ON = CLOSED O = OFF = OPEN
S1
TO CHANGE A ULTIMAX ONE PERSONALITY BOARD TO A ULTIMAX TWO BOARD, REMOVE THE JUMPER ON TB 6 AND INSTALL IT TO PINS 4 AND 9. REMOVE THE JUMPER ON TB7 AND INSTALL IT TO PIN 12 ONLY. CHANGE THE PART NUMBER FROM 415-0177001 TO 415-0177-002.
1 2 3 4 5 6 7 8 Not used Spindle Type On = Hss Off= Standard Tool Changer On = Enabled Off = Disabled
Note: To turn off the Auto Spindle for a KM3P reverse pos# Language English German French Spanish 3 on S1
Machine Auto Spindle MD1 MD3 MD1 Manual Spindle Training Console BMC 10 BMC 10 L BMC 15 BMC 10N BMc 10NL KM3 Auto Spindle Speed KM3P Auto Spindle Speed KMC3P KM3 KM3P Manual Spindle
Pos:1 0 1 0 1 0 1 0 1 0 1 0 0 1 0
Pos:2 0 0 0 1 1 1 0 0 1 0 1 0 0 1
Pos:3 0 0 0 1 0 0 1 1 1 0 0 1 1 1
Pos:4 0 0 1 1 0 0 0 0 0 1 1 1 1 1
Pos 0 1 0 1
Pos 0 0 1 1
Pos 0 0 0 1
S2
Not used
1 2 3 4 5 6 7 8
Not used B Axis Select On = Present Off=Disable
A Axis Select On = Present Off=Disable
S3 STANDARD CONFIGURATION: POSITIONS 1 THRU 7 =OFF, POSITION 8 = ON
F. CRT CONTROLLER ONE BOARD (415-0174-001) SWITCH CONFIGURATIONS
S1
Not used
1 2 3 4 5 6 7 8
Normal / Local Mode On =Normal Off = Local or Test mode
1,2&3 OFF Baud rate 9600
50/60 Hz On = 60 Hz Off = 50 Hz Not used
NOTE: POSITIONS 4,6,7 ARE NOT CURRENTLY USED.
CRT CONTROLLER TWO BOARD (415-0174-002) SWITCH CONFIGURATIONS

Jumper X1B is jumpered1-2 = Normal mode, Jumper removed = local or test mode. Jumper X1A 1-2 = 60 Hz, Jumper removed = 50 Hz
G. MICRO MEMORY BOARD FOR MAX2

NOTE: 1 = CLOSED = ON O = OPEN = OFF Switch 1 2 3 SW1 1 1 1 SW2 1 1 0 SW3 0 0 1 SW4 0 0 0 4 1 1 1 0 5 1 1 1 1 6 1 1 1 1 7 1 1 1 1 8 1 1 1 1 Memory BLOCK A LO = $00000 BLOCK B LO = $40000 BLOCK A HI = $3FFFF BLOCK B HI = $FFFFF
H: CONTROL RELAY PANEL SW1

Frame type BMC 30 BMC 40 BMC 50 BMC 20 S1 0 0 1 1 S2 0 1 0 1 ATC type 20 Station 24 Station 30 Station 16 Station S3 0 0 1 1 S4 0 1 0 1
SW2
Spindle Speed 4000 RPM 6000 RPM 10000 RPM 3000 RPM S1 0 0 1 1 S2 0 1 0 1
SW3
ATC Solenoid type Single ended Double ended S1 0 1 Spindle Clutch Enable Disable S2 0 1
SW4
Rotary Axis Resolution 4000 Ticks/Degree 2000 Ticks/Degree 0 1
ATC Enable/Disable
Up Center Down Enabled Disabled Enable

DATE: SEPTEMBER 3, 1985 SUBJECT: LUBRICATION PROBLEMS PRODUCT LINE: SM1-CNC ISSUE NUMBER: 1067 SUPERSEDES NUMBER: 271 PAGE 1 OF 1
THE BALL NUT LUBE LINE OF SM1-CNC MACHINE MAY HAVE BEEN SUPER GLUED TO THE BALL NUT. THE GLUE MAY CAUSE A BLOCKAGE IN THE LUBE LINE WHICH WOULD CAUSE THE X AND Y AXIS BALL NUTS TO RUN DRY. WHEN PERFORMING SERVICE ON SM1-CNC'S THE X AXIS BALL SCREW SHOULD BE CHECKED FOR SIGNS OF LUBRICATION. IF THE SCREW LOOKS DRY OR HAS A DULL COLOR AND FEELS STICKY THIS COULD INDICATE IMPROPER LUBRICATION. IF THIS IS THE CASE, SLIDE THE TABLE AWAY AND VISUALLY VERIFY THE OPERATION OF THE LUBE SYSTEM. IF THE LINE APPEARS CLOGGED IT CAE BE CLEARED WITH EITHER A STOUT SAFETY PIN OR A SMALL DIAMETER DRILL. WHEN THE LINE HAS BEEN CLEARED, SUPER GLUE THE LINE BACK TO THE BALL NUT AND VERIFY PROPER OPERATION BY CYCLING THE LUBE PUMP.
ORIGINATOR: UNKNOWN REVISED BY:

DATE: OCTOBER 7, 1985 SUBJECT: CRTs SHORTING OUT PRODUCT LINE: ULTIMAX ONE CONTROLS ISSUE NUMBER: 1068 SUPERSEDES NUMBER: 275 PAGE 1 OF 1
RECENT INFORMATION FROM SERVICE INDICATES FAILURE OF TEXT AND GRAPHICS CRTs. IF THE FAILURE SYMPTOM IS NO DISPLAY, ONE OF THE CAUSE'S MAY BE THE PART LEADS OF THE CRTS ARE SHORTING TO THE MOUNTING PLATE THAT FORMS THE BACK OF THE CONSOLE. THIS COULD BE A RESULT OF INADVERTENTLY PRESSING THE CRT BOARD. IF THIS OCCURS THERE IS A FUSE ON BOTH THE TEXT AND GRAPHICS BOARDS WHICH CAN BE REPLACED. THE FUSE IS A 2 AMP PICO 125 VOLT, LOCATED AT F401 (PART NUMBER 409-1001-074). IN ORDER TO REDUCE THE POSSIBILITY OF LEADS SHORTING OUT ALL CRT BOARDS ARE BEING CLIPPED PRIOR TO MOUNTING. ADDITIONAL ACTION IS BEING PLANNED TO MINIMIZE THIS PROBLEM. TO REDUCE THE POSSIBILITY OF LEADS SHORTING OUT FOR FIELD MACHINES #4 NYLON WASHERS CAN BE INSTALLED BETWEEN THE CRT BOARDS AND THE MOUNTING PLATE STANDOFFS (PART NUMBER 220-0085-001), 7 WASHERS ARE NEEDED PER BOARD, OR 14 PER MACHINE.
ORIGINATOR: R.J. JOHNSON REVISED BY:

DATE: OCTOBER 9, 1985 SUBJECT: ENCODER DAMAGE DUE TO COUPLING ISSUE NUMBER: 1069 SUPERSEDES NUMBER: 2 76 PAGE 1 OF 1
PRODUCT LINE: ALL MILLS WITH ENCODER COUPLINGS
COMPRESSING OR TENSIONING THE FLEX COUPLING BETWEEN THE ENCODER AND THE SERVO MOTOR CAN CAUSE PREMATURE FAILURE OF THE ENCODER BEARING'S. RATHER THAN COMPRESSING THE FLEX COUPLING TO RESOLVE MISCOUNTS, YOU SHOULD REPLACE THE COUPLING WITH THE NEW ONE DESIGNED FOR DAMPENING TO ASSURE "CLEAN" OUTPUT OF PHASE A AND PHASE B. (NUMBER 205-0010-006 1/4" X 1/2" SHAFT DIAMETER), ALL SM1-CNC MILLS SHIPPED AFTER APRIL 1985 HAVE THE NEW COUPLING. 1/'4" X 1/4") ALL KMB1M (UK) MILLS SHIPPED AFTER SEPTEMBER 1985 HAVE THE NEW DAMPENED COUPLING (1/4" X 1/'2".
ORIGINATOR: R.J JOHNSON REVISED BY:

DATE: OCTOBER 16, 1985 SUBJECT: HEIDENHEIN 3P BOARDS PRODUCT LINE: MBX2 MB3 MD3 ISSUE NUMBER: 1070 SUPERSEDES NUMBER: 287/286 PAGE 1 OF 1
HEIDENHEIN HAS REDESIGNED THE X5 BOARD TO IMPROVE RELIABILITY. HOWEVER, THE NEW BOARDS ARE TALLER AND WILL NOT FIT INTO THE ENCLOSURE AND STILL ALLOW THE COVER TO BE REPLACED. IN ORDER TO OVERCOME THIS PROBLEM PERFORM THE FOLLOWING: 1. REMOVE THE MOTHBR BOARD FROM THE E1%CLOSURE SAVING THE SCREWS AND THE STANDOFFS. REMOVE THE ELECTRICAL PANEL. REMOVE THE ENCLOSURE FROM THE WALL OF THE POWER CABINET. USING THE ELECTRICAL PANEL AS A TEMPLATE DRILL FOUR HOLES IN THE BACK OF THE ENCLOSURE FOR THE FOUR HOLES IN THE MOTHER BOARD. REMOUNT THE MOTHER BOARD TO THE BACK OF THE ENCLOSURE USING SCREWS AND STANDOFFS FROM 1 ABOVE. ASSURE ALL WIRING IS RETURNED TO THE ORIGINAL CONDITION. REMEMBER WIRING IS RUNNING FROM THE MOTHER BOARD TO THE LINEAR SCALE CABLES INSIDE THE ENCLOSURES SHOULD HAVE A MINIMUM OF SIX TURNS. PART NUMBERS FOR OLD AND NEW X5 BOARDS ARE: PART NUMBER 415-0152-001 OLD X5 BOARD 415-0152-002 NEV X 5 BOARD DESCRIPTION DIMENSIONS 2. 5" X 2. 75" 2. 5" X 2. 87"
2. 3. 4.
5. 6.
ORIGINATOR: R.J JOHNSON REVISED BY:

DATE: DECEMBER 10, 1985 SUBJECT: PARAJUST MAINTENANCE PRODUCT LINE: ANY MILLS WITH PARAJUST ISSUE NUMBER: 1071 SUPERSEDES NUMBER: 290 PAGE 1 OF 2
THE FOLLOWING IS A LIST OF PREVENTIVE MAINTENANCE ITEMS WHICH CAN IMPROVE THE RELIABILITY AND REDUCE PART FAILURES TO THE PARAJUST SPINDLE SPEED DRIVE. 1. APPLY RTV ADHESIVE TO THE ORANGE CAPACITORS ON THE DRIVE MODULES TO REDUCE THE EFFECT OF VIBRATION. 2. DRESS THE CABLE LEADING FROM THE DQOR TO THE VOLTAGE CONTROL BOARD SUCH THAT IT DOES NOT PUSH AGAINST THE VOLTAGE CONTROL BOARD. WRAP SPIRAL BAND AROUND THE CABLE TO PREVENT ABRASION AND PINCHING THE CABLE IN THE DOOR. 3. TIGHTEN THE FEMALE PINS ON ALL MOLEX CONNECTORS TO ASSURE GOOD CONNECTION . EXAMINE THE MOLEX CONNECTOR (MC95) ON THE CHOPPER BOARD FOR BROWN COLOR. IF IT IS BROWN, IT IS A HIGH RESISTANCE POINT AND NEEDS TO BE CORRECTED. (LOOSE CONNECTIONS MAY ALSO BE FOUND BY WIGGLING THE CONNECTOR BODY AND NOTING TIGHTNESS.) 4. TIGHTEN ALL SCREWS ON BUSS CAPACITOR. IF SCREWS BOTTOM OUT, ADD WASHERS TO ASSURE TIGHTNESS. 5. TIGHTEN SCREWS ON ALL TERMINALS AND CONNECTION POINTS. 6. WIGGLE RING TONGUES TO ASSURE TIGHTNESS. 7. EXAMINE SOLDER JOINTS AROUND CONNECTORS TO ASSURE GOOD CONTACT AND NO COLD JOINTS. THIS WILL REDUCE THE EFFECT OF VIBRATION. 8. ASSURE THAT THE SHEAR PIN SENSE WIRE IS NOT COUPLED WITH THE BUS POWER VIRES. THIS IS APPLICABLE TO M-2 THROUGH MD-3 DRIVES. 9. ASSURE FANS ARE CLEAN AND OPERATIONAL FOR GOOD AIR FLOW. 10. ASSURE SCREW TERMINALS AND NUTS ARE TIGHT ON MAIN INPUT FUSES. 11. ASSURE MAIN INPUT FUSE CLIPS ARE TIGHT. THIS IS APPLICABLE TO M-1 THROUGH MD-1 DRIVES. ORIGINATOR: R.J. JOHNSON REVISED BY:
12. ASSURE EXTERNAL HEAT EXCHANGER SHEET METAL COVERS ARE IN PLACE THIS INCLUDES PERFORATED AND "L" SHAPED COVERS ON M-2 THROUGH MD-3 DRIVES.
FSB1071 PARAJUST MAINTENANCE

13. CLEAN CHIPS OFF THE TOP OF THE PARAJUST ENCLOSURE BEFORE OPENING DOOR. CLEAN CHIPS OFF ANY INTERNAL COMPONENTS. 14. EXAMINE THE BACK SIDE OF THE FREQUENCY AND VOLTAGE CONTROL MOTHER BOARDS FOR COLD SOLDER JOINTS OR CRACKED SOLDER TO THE MOLEX PLUGS MOUNTED TO THE BOARDS. 15. A CORRECTION IS NECESSARY REGARDING BRAKE BOARD ADJUSTMENT ON B DRIVES: ALL B DRIVES <EXCEPT 6000 RPM VERSION) ADJUST THE GAIN POT SO WHEN THE BRAKE IS ON THE OUTPUT HAS A 60'4 DUTY CYCLE. THE OUTPUT MUST NOT SWITCH ON AND REMAIN LOCKED TO THE BUS VOLTAGE. ALL B DRIVE WITH 6000 RPM VERSION MILLS, ADJUST THE GAIN POT SO WHEN THE BRAKE IS ON THE OUTPUT IS AT MAXIMUM AND THE BRAKE VOLTAGE REMAINS AT BUSS LEVEL FOR AS LONG AS POSSIBLE BEFORE PWM OCCURS. 16. SHEAR PINS ON DECEL AND OR BLOWN DRIVER AND CHOPPERS CAN RESULT FROM BREAKING RESISTOR BOX PROBLEM SUCH AS POOR SOLDER JOINTS, LOOSE CONNECTION, FAULTY RESISTORS. 17. JUST A REMINDER... THE INPUT VOLTAGE AT THE PARAJUST (NOT THE MAIN POWER TRANSFORMER) SHOULD NOT EXCEED 253 VAC. IF THE INPUT VOLTAGE AT THE PARAJUST IS AT 253 VAC OR SLIGHTLY LESS, NORMAL LINE POWER FLUCTUATIONS MAY EXCEED THE 253 LIMIT AND DOWNWARD ADJUSTMENT IS REQUIRED. 18. INSURE THE DC HOLD POT IS FULL CCW ESPECIALLY ON REPLACEMENT BOARDS. IMPROPERLY ADJUSTED DC HOLD POTS WILL CAUSE PREMATURE CHOPPER BOARD FAILURE.

DATE: DECEMBER 11, 1985 SUBJECT: GROUND FAULT ON HURCO AMPS PRODUCT LINE: ANY MILL USING HURCO AMPS ISSUE NUMBER: 1072 SUPERSEDES NUMBER: 292 PAGE 1 OF 1
THE PURPOSE OF THIS FSB IS TO CLARIFY THE MEANING OF A GROUND FAULT INDICATION ON THE HURCO FET SERVO AMP. A GROUND FAULT ON ANY AXIS INDICATES THAT THERE IS A GROUND FAULT SOMEWHERE IN THE TOTAL SERVO SYSTEM, NOT NECESSARILY THE AXIS IT IS INDICATED ON. FOR EXAMPLE, A GROUND FAULT IN THE Y AXIS MOTOR COULD FAULT THE X AXIS SERVO BOARD, THE Z AXIS SERVO BOARD OR ANY COMBINATION THEREOF, DEPENDING ON WHICH CIRCUITS HAPPEN TO BE MORE SENSITIVE, ONE CANNOT ASSURE THAT BECAUSE THE X AXIS INDICATED A GROUND FAULT CONDITION AND Y AND THE Z DO NOT, THE PROBLEM IS IN THE X AXIS. THE FAULT COULD BE IN THE Y OR Z AXIS ALSO.
ORIGINATOR: JOE BARESTEAD REVISED BY:

DATE: DECEMBER 9, 1985 SUBJECT: FRL PLASTIC BOWLS CRACKING PRODUCT LINE: ALL MILLS ISSUE NUMBER: 1073 SUPERSEDES NUMBER: 293 PAGE 1 OF 2
PLASTIC BOWL FAILURES (CRACKS IN BOWL) MAY OCCUR DUE TO INCOMPATIBILITY WITH MATERIALS IN THE COMPRESSED AIR LIME (INCLUDING CERTAIN COMPRESSOR OILS) OR MATERIALS USED TO CLEAN THE FRL BOWL OR USED NEAR THE BOWL. METAL BOWLS ARE AVAILABLE FROM THE FRL MANUFACTURE IN THE VENT OF REPEATED BOWL FAILURES OCCURRED OCCUR AND INCOMPATIBLE MATERIAL CANNOT BE ELIMINATED. THE MANUFACTURER'S STATEMENT REGARDING THESE MATERIALS IS LISTED BELOW: "CERTAIN COMPRESSOR OILS, CHEMICALS, HOUSEHOLD CLEANERS, SOLVENTS, PAINTS AND FUMES WILL ATTACK PLASTIC BOWLS AND CAN CAUSE BOWL FAILURE. DO NOT USE HEAR THESE MATERIALS. WHEN BOWL BECOMES DIRTY REPLACE BOWL OR WIPE ONLY WITH A CLEAN DRY CLOTH. REINSTALL METAL BOWL GUARD OR BUY AND INSTALL A METAL BOWL GUARD. IMMEDIATELY REPLACE ANY CRAZED, CRACKED, DAMAGED OR HOLED PLASTIC BOWL WITH A METAL BOWL OR A new PLASTIC BOWL AND METAL GUARD." SOME OF THE MATERIALS THAT WILL ATTACK POLYCARBONATE PLASTIC BOWLS: ACETALDEHYDE ACETIC ACID (CONC.) ACETONE ACRYLONITRILE AMMONIA AMMONIUM FLUORIDE AMMONIUM HYDROXIDE AMMONIUM SULFIDE CRESOL CYCLOHEXANOL CYCLQHEXANONE CYCLOHEXNE DIMETHLY FORMANIDE DIOXANE ETHANE TETRACHLORIDE ETHYL ACETATE METHYLENE SALICYLATE MILK OF LIME (CaOH) NITRIC ACID (CONC.) NITEOBENZENE NITROCELLULOSE LACQUER PHENOL PHOSPHOROUS HYDROXY CHLORIDE PHOSPHOROUS TRICHLORIDE
ANTIFREEZE BE]BENZENE BENZOIC ACID BENZYL ALCOHOL BRAKE FLUIDS BROMOBENZENE BUTYRIC ACID CARBOLIC ACID CARBON DISULFIDE TERAHYDRONAPHTHALENE CARBON TETRACHLORIDE CAUSTIC POTASH SOLUTION CAUSTIC SODA SOLUTION CHLORBENZENE CHLOROFORM
ETHYL ETHER ETHLAMINE ETHYLENE CHLOROHYRIN ETHLENE DICHLORIDE ETHYLENE GLYCOL FORMIC ACID (CONC.,) FREON GASOLINE HYDRAZINE HYDROCHLORIC ACID LACQUER THINNER METHYL ALCOHOL METHYLENE CHLORIDE PERCHLORETHYLENE
PROPIONIC ACID PYRIDINE SODIUM HYDROXIDE SODIUM SULFIDE STRENE SULFURIC ACID (CONC.) SULPHURAL CHLORIDE TANNERGAS
THIOPHENE TOLUENE TURPENTINE XYLENE
TRADE NAMES OP SOME COMPRESSOR, OILS RUBBER COMPOUNDS AND OTHER MATERIALS THAT WILL ATTACK POLYCARBONATE PLASTIC BOWLS:
ATLAS "PERMA GUARD" BUNA N CELLULUBE 4150 AND 4220 CRYLEX t5 CEMENT EASTMAN 910 GARLOCK # 98403 HASKEL 4568 023 HILGARD CO,'S HIL PHENE HOUGHTON 5 CO, OIL 0 1120, 1130,1055 HOUTOSAFE 1000 KANO KROIL KEYSTONE PENETRATING OIL #2 MARVEL MYSTERY OIL MINN. RUBBER 366Y NATIONAL COMPOUND #N11 NYLOCK VC 3
PARCO 4' 1306 NEOPRENE PETRON PD287 PRESTONE PYDRAUL AC SEARS REGULAR MOTOR OIL SINCLAIR OIL "LILY WHITE" SOME LOCTITE COMPOUNDS STAUFFER CHEMICAL FYRQUEL #150 STILLMAN 4SR 269 75 STILLMAN OSR513 70 TELAR TENNECO ANDER #495 AND #'500 OILS TITON ZEREX

DATE: JANUARY 14, 19S6 SUBJECT: OPERATION OF LUBE SYSTEMS PRODUCT LINE: ALL MILLS USING AUTOLUBE ISSUE NUMBER: 1074 SUPERSEDES NUMBER: 296 PAGE 1 OF 1
BELOW IS A SUMMARY OF THE WAY LUBE OPERATION BY MACHINE TYPE:
MD3: 20 MINUTES OFF TIME. PUMP ACTUATION IS ON FOR 5 SECONDS, THEN OFF FOR 5 SECONDS, THEN ON FOR 20 SECONDS AND CHECK FOR LUBE PRESSURE. TIMER CONTROLLED WHEN SERVOS ARE TURNED ON RESETS AND CYCLES, IF THE OFF TIME IS GREATER THAN 20 MINUTES. THE ERROR MESSAGE IS LUBE PRESSURE FAILURE. BMC 10-15: 30 MINUTES OFF TIME. RUN PUMP FOR 60 SECONDS AND CHECK FOR LUBE SWITCH MADE AT LEAST TWO TIMES. THE TIMER CONTROL IS THE SAME AS THE MD3 BUT USING 30 NOT 20 MINUTES. BMC 20-50: 12 MINUTES OFF TIME CONTROLLED BY AT TIMER BUILT INTO THE PUMP. PUMPS 3 TO 6 CC AND IS ADJUSTABLE. KM3: 60 MINUTES OFF TIME. ON FOR 8 SECONDS; NO SWITCH CHECKED. IT TURNS ON PUMP WHENEVER THE SERVOS ARE TURNED ON AND RESETS TIMER. PRE-ULTIMAX: USED A 15 MINUTE MOTOR DRIVEN CAM THAT IN SOME CASES TURNS ON THE PUMP AND IN OTHERS TURNED ON THE LUBE TIMER IN THE RELAY PANEL. THAT TIMED THE ON TIME. IN THE TYPE THAT DID NOT HAVE A DELAY RELAY THE ON TIME WAS CONTROLLED BY THE SPACING OF THE GAP IN THE CAM.
ORIGINATOR: RICK GUNYON REVISED BY: R. BRYANT

DATE: JANUARY 14, 1980 SUBJECT: ATC ERROR, CAROUSEL PRODUCT LINE: BMC-15 MILLS ISSUE NUMBER: 1075 SUPERSEDES NUMBER: 301 PAGE 1 OF 1
DURING RE-LAYOUT OF THE EXISTING ARTWORK FOR THE CONTROL RELAY PCB IT WAS NOTICED THAT SU1, LOCATED JUST BELOW J3, SHOULD BE A IN4002 DIODE NOT A SUPPRESSOR. REMOVE SU1 AND REPLACE IT WITH A 417-0001-003. FOR POLARITY SEE THE FIGURE BELOW:
DATE: JANUARY 24, 1986 SUBJECT: INDEX OPTION ULTIMAX PRODUCT LINE: KM3 KM3P
THE WIRING FOR THE INDEX OPTION INSIDE THE KM3 ULTIMAX POWER CABINET MAY BE WIRED INCORRECTLY. IF THE BLUE WIRE FOR ICR IS IN TB4-2, MOVE THIS WIRE TO TB6-2 LOCATED ON THE FAR RIGHT HAND SIDE OF TB6. SCHEMATICALLY, THE FOLLOWING WIRING SHOULD EXIST: INDEX CONNECTOR "B" TO TB6-2. TB6-2 TO MP-P3-25. PLEASE CHECK WIRING WHEN SERVICING ANY KM-3 ULTIMAX MACHINE.
ORIGINATOR: TERRY ROSENKOETTER REVISED BY:
DATE: 9/11/96 SUBJECT: HI-LO GEAR SWITCH PROBLEM PRODUCT LINE: MD3-BMC15
THE SWITCHES USED FOR THE HI/LO GEAR CHANGE (404-5202-005) ON THE MD3 AND BMC 10-15 MACHINES HAVE PROVED TO BE INTERMITTENT DURING HIGH VIBRATION CUTS. THE CONTACT ON THE CLOSED SWITCH MIGHT OPEN BRIEFLY CAUSING THE SPINDLE AXIS STATUS LIGHT TO GO OUT. IF SWITCH ADJUSTMENT DOES NOT SOLVE THE PROBLEM, PLACE A PIECE OF RUBBER APPROXIMATELY .125" THICK BETWEEN THE SWITCH AND IT'S MOUNTING BRACKET. THIS WILL ELIMINATE MUCH OF THE VIBRATION THAT THE SWITCH IS FEELING. BE SURE TO LOCKTITE THE MOUNTING SCREWS
DAVID PRICE Revived by L.Leffew & Wayne Kline
ORIGINATOR: Lonnie Leffew REVISED BY:


DATE: MARCH 18, 1986 SUBJECT: MIS-WIRE OF RS232 PORTS PRODUCT LINE: KM TYPE KNEEMILLS ISSUE NUMBER: 1078 SUPERCEDES NUMBER: 307 PAGE 1 OF 1
DUE TO A ERROR IN THE WIRING LIST SOME KM3 MILLS WITH ULTIMAX CONTROLS MAY HAVE SHIPPED WITH THE RS232 PORTS (1 AND 2) REVERSED. VERIFY PORT WIRING IS AS SHOWN BELOW. IF PORT 1 AND 2 ARE REVERSED ALL YOU NEED DO IS REMOVE THE PORT RECEPTACLES FROM THE MAIN ELECTRICAL CABINET AND SWITCH THEM.

DATE: MARCH 17, 1986 SUBJECT: MULTI-LOAD MASTERS ON CRT PRODUCT LINE: BX MILLS ISSUE NUMBER: 1079 SUPERSEDES NUMBER: 3 06 PAGE 1 OF 1
THIS FRONT PANEL BOARD MODIFICATION ELIMINATES MULTI-LOAD MASTER ON BX CRT'S AT POWER-UP. CONNECT A 20 Pf (CAPACITOR HURCO P/'N 407-0005-007) TO R76 (INPUT TO 7400) AND THE GROUND LAND NEAR R76.

DATE: MARCH 17, 1986 SUBJECT: SPEED SENSE SWITCH WIRING PRODUCT LIES: KMC3P ISSUE NUMBER: 1080 SUPERSEDES NUMBER: 309 / 310 PAGE 1 OF 1
ENSURE THERE IS A SHIELDED CABLE FROM THE SWITCH THAT SENSES SPINDLE RPM (4PRS) TO THE AUTOMATIC SPEED CONTROL PCB. THE SHIELD MUST BE CONNECTED TO GROUND AT THE TERMINAL BLOCK IN THE REMOTE STATION BOX. WIRE NUMBERS 194,195 AND 196 ARE 194 TO GROUND, 195 SIGNAL AND 196 TO + VCC. IF THE WIRING IS NOT DONE WITH SHIELDED CABLE, REMOVE AND REPLACE WITH BELDEN #' 8771 3 CONDUCTOR 20 AWG SHIELDED (HURCO PART NUMBER 406- 1441-001) THIS ELIMINATES NOISE THAT CAUSE ERRATIC ASC FUNCTION. IT IS IMPERATIVE THAT CORRECT INPUT LINE PHASING BE APPLIED TO THE KMC3P CONTROL BEFORE THE TOOL CHANGER IS CYCLED. VERIFY THE CORRECT PHASING BY RUNNING THE SPINDLE AND OBSERVE CORRECT ROTATION. (NOTE: REMEMBER THAT WHEN YOU RUN THE SPINDLE IN MANUAL THE CONTROL ASSUMES THAT YOU ARE IN HIGH GEAR SO CHECK TO MAKE SURE.) THE INCORRECT PHASING WILL CAUSE THE CLAMP/'UNCLAMP MOTOR TO JAM RESULTING IN DISASSEMBLY FOR REPAIR.
ORIGINATOR: T. ROSENKOETTER REVISED BY:

DATE: APRIL 3, 1986 SUBJECT: THREE PHASE POWER SERVICE PRODUCT LINE: ALL MILLS ISSUE NUMBER: 1081 SUPERSEDES NUMBER: 314 PAGE 1 OF 2
THE FOLLOWING CHART PROVIDES A CROSS REFERENCE BETWEEN THREE PHASE KVA AND LINE CURRENT IN AMPERES. THIS IS USEFUL BECAUSE ELECTRICAL SERVICE REQUIREMENTS ARE RATED IN TERMS OF KVA, AS IN THE CASE OF HURCO MACHINES. OCCASIONALLY, SERVICE REQUIREMENTS ARE RATED IN TERMS OF SUPPLY AMPERES. USING THIS CHART AND / OR THE FORMULA ALLOWS YOU TO CROSS BETWEEN THE TWO UNITS OF MEASURE. THE LAST CHART SHOWS THE MINIMAL WIRE SIZE BY CURRENT.
FSB1081 THREE PHASE POWER SERVICE

DATE: MAY 8, 1986 SUBJECT: MOTOR COVER PRODUCT LINE: KM3P, KMC3P ISSUE NUMBER: 1082 SUPERSEDES NUMBER: 315 PAGE 1 OF 1
A COVER HAS BEEN DESIGNED TO ENSURE THAT THE Y AXIS MOTOR AND TACH BRUSHES ON THE KMP TYPE MACHINES CANNOT BE CONTAMINATED WITH OIL. THIS COVER ALONG WITH 0-RINGS UNDER THE BRUSH CAPS PROVIDED ON THE MOTOR WILL ELIMINATE THE CHANCE OF OIL ON THE BRUSHES. PART NUMBERS FOR KIT ARE: 602 0002 008 HOSE CLAMP 802-1774 001 MOTOR COVER 8/ /2" X 81/'2" COVER NEOPRENE.

DATE: MAY 20, 1986 SUBJECT: INPUT VOLTAGE AND AIR PRESSURE PRODUCT LINE: ALL MILLS ISSUE NUMBER: 1083 SUPERSEDES NUMBER: 317 PAGE 1 OF 2
ORIGINATOR: DAVID PRICE REVISED BY: R. BRYANT

DATE: JULY 1, 1986 SUBJECT: MISSING SURGE SUPPRESSORS PRODUCT LINE: BMC 10 THRU 15 ISSUE NUMBER: 1084 SUPERSEDES NUMBER: 320 PAGE 1 OF 1
RECENTLY A SURGE SUPPRESSOR WAS FOUND MISSING FROM THE CONTROL RELAY PANEL ON A BMC 10. THE LACK OF THIS SUPPRESSER CAN CAUSE INTERMITTENT TOOL CHANGER ERRORS WHEN THE FLOOD COOLANT TURNS ON AND OFF. QE EVERY SERVICE CALL, CHECK TO BE SURE SU15 IS PRESENT ON THE CONTROL RELAY PANEL. THE SUPPRESSOR IS ORANGE, ABOUT THE SIZE OF A TWO WATT RESISTOR, AND IS LOCATED NEAR THE BOTTOM LEFT HAND CORNER OF THE BOARD. IF THE SUPPRESSOR IS NOT PRESENT, INSTALL A 417-6001-012 SUPPRESSOR AS SOON AS POSSIBLE.
ORIGINATOR: DAVID PRICE REVISED BY:

DATE: JULY 7, 1986 SUBJECT: MIS-WIRE ON KM3 BX TYPE MILLS PRODUCT LINE: KM3 BX TYPE ISSUE NUMBER: 1085 SUPERSEDES NUMBER: 322 PAGE 1 OF 2
DURING A REVISION TO SERVO CONDUIT HARNESSES ON THE BX KNEE MILLS IT WAS DISCOVERED THAT SHIELDS FOR THE MOTOR AND TACH. WERE NOT DOCUMENTED TO BE GROUNDED. THIS ERROR CAN FOUND ON KNEE MILLS WITH REMOVABLE SERVO CONDUIT HARNESSES. WITH THE SHIELDS NOT GROUNDED THE PROBABILITY FOR MISCOUNTING IS EVIDENT. THE CORRECTION TO THIS PROBLEM INVOLVES THE MOTOR SHIELDS TO GROUND AT THE RANDTRONICS TERMINAL STRIP (RTB1) AND CONNECTING THE TACH. SHIELDS TO TACH. RETURN AT RTB1. (THIS IS HOW THE ULTIMAX CONTROL IS WIRED.)
PARTS NEEDED:
HURCO PART NUMBER 406-4005-003 406-2005-029 406-6481-004 406-6481-006 DESCRIPTION GREEN /' YELLOW WAGO TERMINAL 16 AWG WHITE WIRE SHRINK SLEEVE 1/'4" SHRINK SLEEVE 1/'2" QUANTITY 1 18" 3" 3"
1. INSTALL ONE (1) ADDITIONAL GREEN/YELLOW WAGO TERMINAL ADJACENT TO EXISTING GREEN/'YELLOW TERMINAL AT RTB1-MGT. 2. USE 18 AWG WHITE WIRE TO CONNECT MOTOR SHIELD TO GREEN/YELLOW TERMINAL. SOLDER WHITE WIRE TO SHIELD AND USE 1/'2" SHRINK SLEEVE TO COVER CONNECTION. COMPLETE THIS ON X,Y AND Z. 3. CONNECT TACH. SHIELD TO TACH. RETURN AT RTB1. SOLDER BLACK WIRE (TACH, RETURN) TO SHIELD AND USE 1/'4" SHRINK SLEEVE TO COVER CONNECTION THIS CAN BE ACCOMPLISHED BY STRIPPING INSULATION OF BLACK WIRE ENOUGH TO ATTACH SHIELD, YET ALLOWING INSULATION TO REMAIN ALONG WIRE TO RTB1. COMPLETE THIS ON X,Y AND Z.
ORIGINATOR: T. ROSENKOETTER
X AXIS (EXAMPLE):
DATE: OCTOBER 15, 1986 SUBJECT: AXIS DRIVE BELT TENSION PRODUCT LINE: BMC MILLS
DUE TO THE BELT DRIVE SYSTEM FOR THE AXIS ON THE BMC 30, 40, AND 50 THE AMOUNT OF MOTOR BELT TENSION ON EACH AXIS AFFECTS THE BACKLASH IN THAT AXIS. AFTER THE LASER TEST HAS BEEN PERFORMED AND THE BACKLASH IS VERIFIED, THE GAP BETWEEN THE BELT HOUSING AND THE MOTOR MOUNTING PLATE WILL BE MEASURED WITH A FEELER GAUGE AND THAT VALUE WILL BE WRITTEN ON THE INSIDE OF THE POWER CABINET DOOR BELOW THE LASER COMPENSATION VALUES. WHEN INSTALLING MOTORS AT INSTALL, POSITION THE MOTOR TO ACHIEVE THE SAME GAP BETWEEN THE MOTOR MOUNTING PLATE AND THE BELT HOUSING THAT IS WRITTEN ON THE INSIDE OF THE CABINET.
ORIGINATOR: TIM CLOUD REVISED BY:

DATE: JANUARY 9, 1987 SUBJECT: USING DISTRIBUTOR STOCK PARTS PRODUCT LINE: ALL MILLS ISSUE NUMBER: 1087 SUPERSEDES NUMBER: 349 PAGE 1 OF 1
IF AND WHEN AN EMERGENCY SITUATION ARISES WHERE WE HAVE TO REMOVE PARTS FROM A DISTRIBUTORS STOCK MACHINE, THE FOLLOWING PROCEDURE MUST BE FOLLOWED. 1. THE DISTRIBUTOR MUST FIRST AUTHORIZE THE REMOVAL OF THE ITEMS AS THESE MACHINE ARE THE DISTRIBUTOR'S PROPERTY! 2. THE SERVICE ENGINEER MUST ENSURE THAT THE MACHINE IS NOT SCRATCHED OR DAMAGED IN ANY WAY AND THE CONDITION MUST BE NOTED ON THE SERVICE REPORT. 3. THE SERVICE ENGINEER MUST ORDER REPLACEMENT PARTS BEFORE LEAVING THE DISTRIBUTOR'S PLANT. 4. A SERVICE REPORT MUST BE FILLED OUT AND SIGNED BY THE AUTHORIZED INDIVIDUAL AT THE DISTRIBUTOR'S OFFICE. A NOTE ON THE SERVICE REPORT MUST BE MADE AS TO THE REPLACEMENT OF THE PARTS. NOTE WHO IS RESPONSIBLE FOR REPLACING THE PARTS AND IF WE HAVE TO RETURN TO DO IT; THE SCHEDULER FOR THE AREA MUST BE NOTIFIED SO A FOLLOW-UP CALL CAN BE MADE. 5. TO ELIMINATE ANY FUTURE CONFUSION; A DISTRIBUTOR AHD HIS STOCK MACHINE IS TO BE TREATED EXACTLY LIKE A CUSTOMER.
ORIGINATOR: RANDY RENEKAMP REVISED BY:

DATE: FEBRUARY 5, 1987 SUBJECT: TAPE READER PROBLEMS PRODUCT LINE: TM5 ISSUE NUMBER: 1088 SUPERSEDES NUMBER: 357 PAGE 1 OF 1
Upon investigation of the TM5 Tape Reader problems, a design error was found on the Front Panel Cable Connect PCB Serial LED Driver circuit (This PCB , 415-0201-001, is only used on the TM5.) The circuit that controls the LED brightness was incorrectly designed. A maximum current specification for this circuit is 750 micro amps. The circuit was operating with 850 micro amps causing the Serial LED Driver to operate extremely hot (140 degrees F.) The heat caused the reset line from the Serial LED Driver to operate incorrectly. This reset signal is received by the Tape Transport and CRT Controller PCB. The problem is solved by replacing R4, currently a 10K resistor, with a 39.2K resistor. This drops the worst case operating temperature to 109 degrees F. (this also dims the LED's , but not objectionably.) To further enhance this circuit, add a heat sink to the Serial LED Driver. The retrofit to field mills is two fold. 1) Replace R4 on the Front Panel Cable Connect PCB, (clearly marked and currently a 10K resistor) with a 39.2K resistor (HURCO P/M 407-0035441. ) 2) Mount a heat sink to U6 on the Front Panel Cable Connect PCB. This heat sink (HURCO P/N 420-0002-015) can be attached with a good thermal conductive cement such as Thermalbond Thermally Conductive Epoxy Adhesive. This fix will significantly improve the Tape Reader issue.
ORIGINATOR: T. ROSENKOETTER, W HAWKINS REVISED BY:

DATE: February 9, 1987 SUBJECT: RANDTRONICS CHASSIS WIRING PRODUCT LINE: Mills ISSUE NUMBER: 1089 SUPERSEDES NUMBER: 358 PAGE 1 OF 1
Some wiring problems have recently been discovered on the production floor with the Randtronics chassis wiring. These wiring problems have been in the Wago terminal strip wires which are done by Randtronics. In some cases the wires have not been stripped sufficiently to make a good connection. In other cases the wires were inserted into the Wago too far and the connection was through the insulation. The floor techs are watching out for this now but some may have gotten out into the field and might cause problems at a later date. Be aware of this possibility and check the wires going into the Wago terminal strip on the Randtronics chassis when on a service call whether it is for a servo related problem or not. Hopefully this will prevent a service call in the future if we can correct the wiring errors before they cause a problem.
ORIGINATOR: Wayne Hawkins REVISED BY:

DATE: MARCH 12, 1987 SUBJECT: CHIP CONVEYOR MOTOR HEATER PRODUCT LINE: BMC 15 ISSUE NUMBER: 1090 SUPERSEDES NUMBER: 364 PAGE 1 OF 1
IT HAS BEEN DETERMINED THAT THE HEATER FOR BMC 15 CHIP MOTOR IS NOT THE CORRECT VALUE. IT HAS AN ADJUSTABLE RANGE OF 1.6 TO 2.5 AMPS. THIS IS MUCH TOO HIGH SINCE THE MOTOR IS ONLY RATED AT 200 VAC. WHEN SERVICING A BMC 15 THIS SHOULD BE REPLACED. THE CORRECT HEATER HAS A RANGE OF .38 TO .62 AMP. THE HURCO PART NUMBER IS 403-5501-015. THE GE PART NUMBER IF CR4G1WD. IF THIS IS NOT REPLACED WITH THE CORRECT VALUE HEATER MOTOR DAMAGE COULD OCCUR IF THE MOTOR BECAME STALLED. ADJUST HEATER TO .5 TO .6 AMP AND ENSURE THAT CUSTOMER IS AWARE OF WHERE TO CHECK THIS IF HIS MOTOR STALLS.

DATE: MARCH 13, 1987 SUBJECT: TOOL CHANGE LIMIT SWITCH PRODUCT LINE: BMC 30 ISSUE NUMBER: 1091 SUPERSEDES NUMBER: 365 PAGE 1 OF 1
ON ALL BMC 30 MILLS PRIOR TO BC8005096B THE WIRE GOING TO THE HOME POSITION LIMIT SWITCH IS IN DANGER OF BEING CAUGHT ON THE SWITCH DOG AND TORN FROM THE MICRO SWITCH. TO PREVENT THIS DAMAGE SECURE THE WIRE WITH A JIFFY-CLAMP. THERE IS CURRENTLY AN M5 THREADED HOLE WHICH MAKES THE LOCATION AND MOUNTING OF THE JIFFY-CLAMP VERY EASY. IF YOU DO NOT HAVE THE PARTS AVAILABLE TO PERFORM THIS MODIFICATION, HERE ARE THE HURCO PART NUMBERS.
1 2 3
108-5003-003 110-0061-004 408-7501-009
M5 X.OBX10 BHSS #10 EXTERNAL STAR WASHER #125 JIFFY-CLAMP
THE JIFFY-CLAMP MODIFICATION WILL BE IN EFFECT UNTIL LEADVELL HAS PROVIDED THE NEW THROUGH HOLE. LEADWELL HAS BEEN NOTIFIED TO DRILL A THROUGH HOLE BESIDE THE MICRO SWITCH TO ROUT THE WIRE THROUGH; THEREFORE PREVENTING THE POSSIBILITY OF DAMAGE TO THE MICRO SWITCH WIRES.
ORIGINATOR: ERIC HUDSON REVISED BY:
DATE: MARCH 26, 1987 SUBJECT: ULTIMAX LOCKUP PRODUCT LINE: ULTIMAX MILLS
1. IT HAS BEEN DISCOVERED THAT INCORRECT ROUTING OF THE J-1 CABLE IN THE ULTIMAX CONSOLE CAN CAUSE MACHINE LOCKUPS. ROUTING THE CABLE ACROSS THE TOP OF THE CRT CONTROLLER BOARD IS NO LONGER ACCEPTABLE THIS CAN CAUSE THE CABLE TO BE PINCHED WHEN THE CARD CAGE IS SLID BACK INTO ITS NORMAL POSITION. ROUTE THE J1 CABLE TO THE SIDE OF THE CARD RACK TO ELIMINATE THIS PROBLEM. 2. RAPID BUTTON PUSHING AND MODE CHANGES HAVE BEEN KNOWN TO CAUSE LOCK-UPS. ENCOURAGE THE CUSTOMER TO USE ONLY ONE HAND WHILE PROGRAMMING THE MACHINE. 3. EMERGENCY STOP DEPRESSED WHILE IN THE TOOL SETUP MODE, THEN TRYING TO ACCESS PART PROGRAMMING MODE, WILL LOCKUP THE CONTROL VIRTUALLY EVERY TIME. 4. SWITCHING BETWEEN AUTO MODE AND SINGLE CYCLE MODE WILL LOCK THE CONTROL ON THE 20 MODE CHANGE . WE ARE NOT CLEARING THE BUFFER, THIS WILL BE FIXED
ORIGINATOR: RANDY RENNEKAMP, M. GARLICK REVISED BY: R, BRYANT
DATE: APRIL 1, 1987 SUBJECT: TOOL CHANGERS PRODUCT LINE: MD1 MD3
IT HAS BEEN NOTED THAT ON SOME CONTROL RELAY PANELS, 415-0189-001 AND 415-0189-002 THAT THE BRAKE PACK SOCKET HAS BEEN SOLDERED ONTO THE BOARDS INCORRECTLY. PLEASE NOTE WHEN AT A CUSTOMERS PLANT; THAT THE BRAKE PACK IS INSTALLED CORRECTLY. IF PIN NUMBER 1 OF THE BRAKE PACK SOCKET DOES NOT LINE UP WITH THE PCB SILKSCREEN NUMBER 1, REMOVE THE SOCKET AND CORRECT THE PROBLEM. IF THIS SITUATION IS FOUND, THE BRAKE PACK (PART NUMBER 412-0003-001) WILL REQUIRE REPLACEMENT DUE TO DAMAGE FROM BEING INCORRECTLY INSTALLED.
ORIGINATOR: RANDY RENNEKAMP REVISED BY:

DATE: APRIL 6, 1987 SUBJECT: SERVOMATE TRANSFORMER MIS-WIRED PRODUCT LINE: MB3 ISSUE NUMBER: 1094 SUPERSEDES NUMBER: 368 PAGE 1 OF 1
A PROBLEM HAS BEEN DISCOVERED IN THE FIELD WHICH NEEDS TO BE WATCHED FOR WHEN SERVICING THE MB3 MACHINES. THE 72 VAC INPUT TRANSFORMER CAN BE TAPPED FOR EITHER 72 VAC OR 88 VAC. THE CORRECT VOLTAGE FOR THE MH3 RANDTRONICS AMPLIFIERS IS 72 VAC. IF A MACHINE IS FOUND WITH A TRANSFORMER WIRED 88 VAC, PROMPTLY REWIRE IT FOR 72. THIS PROBLEM WILL NOT BE VERY VIDE SPREAD, BUT PLEASE LOOK FOR IT WHEN ALREADY ON AN MB3 CALL.
ORIGINATOR: RANDY RENNEKAMP REVISED BY:

DATE: April 6,1967 SUBJECT: BX Miscounting On Knee Mills PRODUCT LINE: BX Kneemills PAGE 1 OF 1 ISSUE NUMBER: 1095 SUPERCEDES NUMBER: 369
On some BX knee mills in the field we have been able to eliminate miscounting by adding a jumper from pin sixteen in the motor junction box to ground. The machine must have the new style servo conduits for this jumper to have a chance of working. The ground that we used was the head of the screw which holds the junction box to the motor. Ensure that the threads have no black paint in them so proper connection is made. The part number for this jumper is 423-6092-002 and has been released on P.I.N. 9335. This modification may cause the miscount to increase on some mills; however, on the majority of machines it corrected miscounting.
ORIGINATOR: Eric Hudson REVISED BY:

DATE: JUNE 11, 1987 SUBJECT: Deltron Power Supplies PRODUCT LINE: All ULTIMAX MILLS ISSUE NUMBER: 1096 SUPERSEDES NUMBER: 374 PAGE 1 OF 1
Effective with the June Mill Shipments, we will begin using a new Deltron switching power supply instead of the Powertec. The Deltron has Hurco part number 413-OOOB-010 and has the same mounting holes as the Powertec. The main difference is in the wiring, pins 5 and 6 on the Deltron are opposite the Powertec. Pin 5 on the Deltron is minus 12VDC and pin 6 is plus 24VDC. Pin 5 on the Powertec is plus 24VDC and pin 6 is minus 12VDC. If you are replacing a Powertec with a Deltron, make sure the wiring is correct before applying power. A sheet of paper with the wiring difference is being shipped with each Deltron. The Deltron is easily identified because it is gold in color and the Powertec is black. The adjustment pots are indicated below.
ORIGINATOR: WAYNE HAWKINS
DATE: JULY 29, 1987 SUBJECT: Custom CPU / Memory PCB PRODUCT LINE: All Ultimax Mills
ISSUE NUMBER: 1097 SUPERCEDES NUMBER: 377 PAGE 1 OF 1
It has been found that Custom CPU / Memory PCB's (415-0194-001,002,004) may have been shipped with a jumper installed that should have been removed if a Dual RS-232 PCB was installed. The jumper runs from J1-12 to J1-17. It is located on the non-component side of the PCB. If this jumper is installed the RS-232 PCB will not function. Note that the Schematic for the CPU/Memory PCB shows this jumper and refers to its removal on page 9 note 12 (REF. 415-0194-001,002,004 Rev.F). When making a Service call on a machine that has a Custom CPU/'Memory PCB make sure that this jumper has been removed if a RS-232 PCB is installed.
ORIGINATOR: Keith Perkins REVISED BY:

DATE: August 8, 1987 SUBJECT: Solenoid Exhaust Filters PRODUCT LINE: MB3, MD3, BMC10, BMC15 ISSUE NUMBER: 1098 SUPERCEDES NUMBER: 376 PAGE 1 OF 1
It has been found that if the solenoid exhaust filters become clogged that when the spindle clamp/unclamp cylinder operates back pressure can allow the shot pin to also move. This can cause an error since the shot pin may move enough to come off of the limit switch. To eliminate the problem will require one of the following; 1) Remove and clean filter. 2) Replace filter. 3) Remove filter from the pneumatic system.
ORIGINATOR: K. Perkins REVISED BY:
DATE: September 14,1987 SUBJECT: BMC 10 and 10L Tool Support PRODUCT LINE: BMC10, BMC10L
The BMC series of machines from Toyama utilize plastic tool support slides rather than the metal ones like the M2 and M3 series of machines. The BMC10L uses a clear plastic support (713-0008-320) which is the same size as the M2 and M3 support. The BMC10 uses a black plastic support (713-0008-696) which is quite a bit thicker. We have had several occurrences of breakage on these plastic tool supports. The breaks occur in the corner of the tool support where the roll pin is located. If you should find this condition on a BMC10L machine in the field, you need to order the following parts for each broken support. Qty 1 2 Description MD3 Steel Tool Support Roll Pin, 2 X 8 Part Number 713-0006-005 713-0008-313
If you should find this condition on a BMC10 machine in the field, you need to order the following retrofit kit. Qty 1 This kit includes: 24 48 48 48 Tool Support Repair Plate M3 X .5 X 10MM FHSCS M3 X .5 Std. Hex Nut M3 Int Teeth Lockwasher 802-2118-001 102-5001-003 117-5009-001 110-0067-004 Description BMC10 Tool Support Repair Kit Part Number 002-3133-001
This will give you enough parts to repair all 24 tool supports. See the attached drawing for attaching these plates. If any of the springs and balls are needed, their part numbers are, 713-0005-205 for the spring and 713-0008-299 far the ball.
DATE: September 14, 1987 SUBJECT: BMC 10 and 10L Tool Support PRODUCT LINE: BNC10, BMC10L
1) Remove the cover from the tool changer carousel. 2) Remove the tool support from the tool holder by removing the roll 1 pin from the corner of the tool support and sliding it out of the tool holder. Make sure you do not lose the steel ball or spring. 3) Drill two 9/64" holes through the end of the tool support. One hole should be 5/16" from the side with the tab and 3/16" up from the bottom. The other hole should be 13/16" from the side with the tab and 3/16" up from the bottom. 4) Slide the tool support back through the tool holder making sure the spring and steel ball are reinstalled. 5) Attach the repair plate to the tool support using two N3 X .5 X 10MM FHSCS, two M3 internal tooth lockwashers and two M3 X .5 standard hex nuts. 6) After all tool supports have been modified, rotate the carousel to each tool position and move each tool holder in and out of the holding station to make sure the repair plates clear all obstacles. In some cases, some of the ribs on the holding station casting will need to be ground down a small amount. 7) Reinstall the tool changer carousel cover.
ORIGINATOR: WAYNE E. Hawkins REVISED BY:
DATE: January 25, 1993 SUBJECT: AXIS AMPERAGE PRODUCT LINE: BMC 20 / 50
ISSUE NUMBER: 1100 A SUPERSEDES NUMBER: 1100 & 1144 PAGE 1 OF 2
It has been found that the gib adjustment screws on BMC mills can come loose in shipment and during normal use. It is important that these be checked on install as well as on service calls. Most BMC machines have tapered gibs with screws at both ends of the gib, one to adjust the gib pressure and one to lock the gib. Over tightening of these screws can damage the gib. The adjusting screws are on the top for the Z axis, the left hand end of the table for the X axis and the front of the saddle for the Y axis. The BMC 40/50 have gibs at both ends of X axis and do not have the lock screws. NOTE: The maximum rated current of the servo amplifiers must not be exceeded. The rated current for BMC 20/30 OEM/V1, FANUC MODEL 0/5, = 10 AMPS Peak. The rated current for BMC 40/50 OEM/V1, FANUC MODEL 10, = 15 AMPS Peak. The rated current for BMC 20 V2, (pre LR) YASKAWA AMPS, = 11 AMPS Peak. The rated current for BMC 20 LR/25/30 V2,YASKAWA AMPS, = 17 AMPS Peak. The rated current for BMC 40/50 V2, YASKAWA AMPS, = 42 AMPS Peak. The ULTIMAX 3 machines use the same amps as MAX 2 V2 machines.
SEE PAGE 2 FOR DETAILS ON GIB ADJUSTMENTS.

ORIGINATOR: Randall Bryant REVISED BY: Wayne E. Hawkins REVISED BY: KEITH PERKINS Revised by Lonnie Leffew 3-17-1993
THE PROCEDURE FOR MONITORING FANUC AXIS CURRENT IS AS FOLLOWS: 1 2 3 4 5 6 Connect a DVM positive lead to CH 10, 11, OR 12. Note: There are three sets of test points L, for X axis M for Y axis & N for Z axis. Connect negative lead to CH3. Set meter for VAC. Jog the axis at 100 IPM. The voltage reading on the meter is a VOLTS/AMP reading. EXAMPLE: The meter reads .255 VAC. This is equal to 2.55 AMPS of current. The axis being checked should be run full travel in both directions. Note The lowest and highest readings seen.
X axis Y axis Z+ axis Z- axis
BMC 20 2.5 to 3.5 2.5 to 3.5 4 to 5 3 to 4
BMC 20 LR 1 to 2 1 to 2 2 to 3 1 to 2
BMC 25/30 2 to 4 2 to 4 2 to 4 1 to 2
BMC 40/50 3 to 5 3 to 5 4 to 6 2 to 4
YASKAWA AXIS CURRENT CHECKS 1. 2. Check Axis Setup per Eng Doc # 757-4001-092. Check all axis. To check axis current draw, Connect a DVM with the positive lead to TM3-4 and the negative lead on the 0V of the appropriate axis amplifier. Note: Check all axes in both directions at 100 ipm over the full travel of the axis. Divide the meter reading by the appropriate value listed below. BMC 20 LR / 25 / 30=.484 VDC Acceptable values are:
BMC 20: X&Y= BMC 20: +Z= BMC 20: -Z= BMC 25/30 X&Y= BMC 25/30 +Z= BMC 25/30 -Z= 2.5-3.5 A 4-5 A 3-4 A 2-4 A 2-4 A 1-2 A 1.973 - 2.762 VDC 3.156 - 3.945 VDC 2.367 - 3.156 VDC 0.968 - 1.936 VDC 0.968 - 1.936 VDC 0.484 - 0.968 VDC BMC 20LR: X&Y= BMC 20LR: +Z= BMC 20LR: -Z= BMC 40/50 X&Y= BMC 40/50 +Z = BMC 40/50 -Z = 1-2 A 2-3 A 1-2 A 0.484 - 0.968 VDC 0.968 - 1.936 VDC 0.484 - 0.968 VDC
3.
1 amp on aBMC 20 = .789
BMC 40/50=.200 VDC
3 - 5 A 0.6 - 1.0 VDC 4 - 6 A 0.8 - 1.2 VDC 2 - 4 A 0.4 - 0.8 VDC
When adjusting gibs on any mill use caution. Do not tighten them too much. The BMC 20 box way machines may not be able to reach the currents specified. If you can not adjust for the recommended currents, ensure that you have gib pressure by loosening the gibs until you have the minimum current (no further drop) then tighten gibs to obtain an increase in current draw. Be sure to verify axis operation by a cutting test, ETC. RECORD THE INFORMATION ON THE SERVICE REPORT.
FSB 1100A Page 2 of 2
DATE: SEPTEMBER 16, 1987 SUBJECT: Z AXIS BOUNCING AT LIMIT SWITCH PRODUCT LINE: TM5
MOST IF NOT ALL TM5 MILLING MACHINES EXHIBIT THE PROBLEM OF BOUNCING ON AND OFF THE Z PLUS LIMIT SWITCH. THE REASON FOR THIS IS, LIKE OTHER MACHINES, THE AMP IS SHUT OFF ON A LIMIT. THE DIFFERENCE ON THE TM5 Z AXIS IS, THAT EXCEPT FOR THE BALL SCREW BRAKE WHICH IS ONLY ON WHEN THE S.E.R. RELAY IS OFF), THE AMP IS THE ONLY THING HOLDING THE Z AXIS UP. WHEN THE AMP IS SHUT OFF ON THE LIMIT SWITCH IT FALLS. WHEN IT FALLS OFF THE SWITCH, IT RESTARTS AND JUMPS BACK UP TO THE SWITCH. THIS CAUSES AN ANNOYING BOUNCING ON MOST MACHINES. THIS IS SOLVED BY CLIPPING THE WIRE J10-9 ON THE HURCO AMPLIFIER MOTHER BOARD AND J4-9 ON THE I/O BOARD THIS ALLOWS THE AMP TO REMAIN ENERGIZED WHILE ON THE Z PLUS LIMIT SWITCH.
ORIGINATOR: PAUL CHAMBERS REVISED BY:
DATE: September 16, 1987 SUBJECT: Knee Mill Bearing Locknut PRODUCT LINE: KM3, KM3P, KMC3, KMC3P
ISSUE NUMBER: 1102 SUPERCEDES NUMBER: 387 PAGE 1 OF
The new axis bearing locknuts used on the Knee Mills now should be installed in the following manner. 1) Loosen all clamp screws on the locknut. 2) Screw the locknut onto the Leadscrew until its contact face is approximately .1" from the mating face. 3) Uniformly tighten the clamp screws evenly and diagonally while turning the locknut until the thread clearance is removed as indicated by an increase in thread friction. The center line of the locknut is now in line with the center line of the Leadscrew and the locknut contact face is square with the common centerline of the locknut and the Leadscrew. 4) Tighten the locknut with the spanner wrench to 35 ft/'lbs. 5) Secure the position of the locknut by tightening the clamp screws to 25 in/lbs.
ASSEMBLY HINTS
1) Clamp screws should never be tightened before locknut is fully engaged on its mating male thread to avoid distortion. 2) During the disassembly process, it is important to loosen all clamp screws evenly and diagonally to prevent clamp screw jamming.
ORIGINATOR: Wayne Hawkins REVISED BY:

DATE: October 1, 1987 SUBJECT: New MAX2 RS232 Harness PRODUCT LINE: All MAX2 Controls ISSUE NUMBER: 1103 SUPERSEDES NUMBER: 369 PAGE 1 OF 1
It has been discovered that some of the RS232 Harnesses are not correctly wired. Steps have been taken to assure that they will be wired correctly from now on. Unfortunately some of the harnesses have already been shipped and will require checking in the field. On MAX2 controls prior to October of 1987, these harnesses need to be checked and corrected. The correct wiring is shown below.
ORIGINATOR: Wayne E. Hawkins
DATE: DECEMBER 11, 1987 SUBJECT: MD3 SOFTWARE FOR YASKAWA. DRIVE PRODUCT LINE: MD3 MILLS
ISSUE NUMBER: 1104 SUPERSEDES NUMBER: 396 PAGE 1 OF l
IT HAS BEEN FOUND THAT THE SPINDLE EPROM THAT IS INCLUDED WITH THE RETROFIT KIT DOES NOT WORK WITH SOFTWARE PRIOR TO D06E LEVEL. ANY MACHINE THAT RECEIVE THE YASKAWA DRIVE SHOULD HAVE VERSION D06E OR LATER SOFTWARE. THERE IS A PROBLEM WITH CUSTOMERS THAT USE NC SOFTWARE. CURRENTLY THE ONLY RELEASED VERSION OF NC SOFTWARE IS A06. SOFTWARE IS WORKING ON A VERSION THAT WILL WORK WITH THE YASKAWA SPINDLE PROM. ANY CUSTOMERS THAT HAVE THE YASKAWA ON THEIR MD3 AND THAT NEED THE NC SOFTWARE SHOULD WAIT FOR THE NEXT RELEASE (NOTE DO NOT ORDER 06F VERSION IT HAS A BUG IN IT THAT CAUSES MORE PROBLEMS THAN IT FIXES)
ORIGINATOR: KEITH PERKINS REVISED BY: R BRYANT
DATE: DECEMBER 1, 1987 SUBJECT: ORIENT PROBLEM WITH YASKAWA RETROFIT PRODUCT LINE: MB2, MB3, MD3
PAGE 1 OF 1
A RANDOM PROBLEM HAS BEEN SEEN WITH SOME MACHINE, PARTICULARLY MACHINE WITH LELAND SPINDLE MOTORS. THE PROBLEM IS BEING ABLE TO OBTAIN SMOOTH ORIENTATION IN BOTH OPERATING RANGES. THE MACHINE WILL OCCASIONALLY MISS THE SHOT PIN DUE TO CAMMING ACTION. ONE WAY TO ELIMINATE THIS IS TO RESET ONE OF THE SWITCH'S ON THE YASKAWA DRIVE. SWITCH 68 POSITION 1 IS NORMALLY SET TO ON. THIS SHOULD BE RESET TO OFF. THIS WILL ENABLE DYNAMIC BRAKING WHEN THE SPINDLE RAMPS DOWN TO l / 40 OF MAXIMUM FREQUENCY. TO MAKE THIS CHANGE FIRST TURN THE MACHINE POWER OFF CHANGE 68-1 FROM ON TO OFF THEN TURN MACHINE POWER BACK ON. SEVERAL TOOL CHANGES SHOULD BE RAN TO ENSURE CORRECT ORIENTATION IM BOTH LOW AND HIGH RANGES AND WITH BOTH CW AND CCW SPINDLE ROTATION. ORIENT SPEED MAY NEED TO BE READJUSTED.

DATE: MARCH 24, 1988 SUBJECT: BALL CHUCK REPLACEMENT PRODUCT LINE: KM3CP ISSUE NUMBER: 1106 SUPERSEDES NUMBER: 399 PAGE 1 OF 2
THE BALL CHUCK SHOULD BE REPLACED IN THE FOLLOWING MANNER. 1. REMOVE MOTOR/CLUTCH ASSEMBLY, THIS CAN BE DONE WITH LESS STRAIN ON CABLES IF THE Z AXIS IS MOVED TO THE MINUS LIMIT SWITCH. 2. CALIBRATE THE Z AXIS AFTER REMOVING MOTOR/CLUTCH ASSEMBLY. 3. REMOVE SNAP RING FROM SPINDLE SHAFT AND INSPECT FOR DAMAGE, IF DAMAGED REPLACE WITH PART NUMBER 113-0002-030. 4. UNSCREW QUILL DETECTOR FROM THE SPINDLE SHAFT (ITEM 019, PAGE 2) AND REMOVE, CHECK FOR DAMAGE, I.E. CRACKS OR BAD THREADS. 5. INSERT BALL CHUCK INTO SPINDLE TAPER WITH SPECIAL TOOL, TURN SPINDLE SHAFT CW TWO TURNS TO HOLD, INSERT DEPTH GAGE INTO TAPER AND ADJUST DISTANCE BETWEEN BALL CHUCK AND SPINDLE FACE TO 2.204" BY TURNING SPINDLE SHAFT CW. 6. WHEN 2.204H IS ACHIEVED REINSTALL QUILL DETECTOR AND TURN SPINDLE SHAFT CW 1 TURN, INSERT A TOOL HOLDER INTO SPINDLE AND CLAMP BY TURNING SPINDLE SHAFT BY HAND. 7. TURN SPINDLE SHAFT CCW UNTIL TOOL HOLDER IS RELEASED AND QUILL DETECTOR IS IN POSITION TO ACTIVATE THE UNCLAMP LIMIT SWITCH. 8. IT MAY BE NECESSARY TO ADJUST THE UNCLAMP LIMIT SWITCH TO SEE THE QUILL DETECTOR. IF THE LIMIT SWITCH IS DEFECTIVE REPLACE WITH PART NUMBER 713-0012-365. 9. REINSTALL SNAP RING AND MOTOR/CLUTCH ASSEMBLY. 10. CLAMP AND UNCLAMP A TOOL HOLDER USING MANUAL SWITCHES PRIOR TO RUNNING TC IN AUTO MODE. RUN 50-100 TOOL CHANGES IN THE AUTO MODE FOR FINAL CHECKOUT.
ORIGINATOR: FRED RAES REVISED BY:

DATE: SEPTEMBER 21, 1988 SUBJECT: BMC Auto Lube Wiring PRODUCT LINE: BMC 20-50 (OEM) ISSUE NUMBER: 1107 SUPERSEDES NUMBER: 400B PAGE 1 OF 1
It has been discovered that the wiring to the auto lube pump has not been properly shielded. This can cause intermittent false low lube errors. All machines shipping in May and some in April will have properly shielded wiring. If you wish to correct one in the field, the existing wiring will need to be replaced. You will need approximately 15 feet each of a three conductor non shielded 20 AWG cable (HURCO P/N 406-1247-007) and a two conductor with shield 22 AWG cable (HURCO P/N 406-1242-004). 1) Remove the 4 conductor cable to the auto lubricator. BMC 20 2) Add 3 conductor cable. BLACK 41 from Rly 16-5 to Lube -1. BLACK P2 from Rly 16-8 to Lube -2. YELLOW / GREEN from MECCA ground to Case Ground of the lube pump. 3) Add 2 conductor cable. CLEAR / SHIELD from T25 to Lube -3. BLACK from T26 to Lube -4. BMC 30 50 2) Add 3 conductor cable. YELLOW / GREEN from MECCA ground to Case Ground of the lube pump. with 10MA control (schematic 002-3210-004) BLACK 11 from Rly 9-4 to Lube -1. BLACK f2 from Rly 9-6 to Lube -2. with OMA control (schematic 002-3210-006) BLACK 11 from Rly 8-4 to Lube -1. BLACK #2 from Rly 8-6 to Lube -2. with HURCO 24VDC pneumatic (schematic 002-3210-055) BLACK #1 from Rly 16-4 to Lube -1. BLACK #2 from Rly 16-6 to Lube -2. 3) Add 2 conductor cable. CLEAR/SHIELD from T25 to Lube -3. BLACK from T24 to Lube -4. ORIGINATOR: Wayne E. Hawkins REVISED BY: Wayne E. Hawkins

DATE: JANUARY 6, 1989 SUBJECT: INSTALLATION OF THRUST BEARING'S PRODUCT LINE: ALL MILLS ISSUE NUMBER: 1108 SUPERSEDES NUMBER: 391A PAGE 1 OF 2
PURPOSE: TO PROVIDE A DEFINITIVE STATEMENT ON THE INSTALLATION OF THE AXIS THRUST BEARING'S IN HURCO MILL PRODUCTS. IN BRIEF THE AXIS BEARING'S IN ALL HURCO MILLS WILL BE MOUNTED IN THE DB NODE. IN THE PAST WE WERE MOUNTING THE QUAD SETS IN THE BMC 40 AND 50 MACHINES IN THE DF MODE, THIS WILL NO LONGER BE THE PRACTICE. THE MANUFACTURING FLOOR WILL START INSTALLING THE BEARING'S IN DB MODE FROM THIS DATE FORWARD. ALSO ANY MACHINE FROM THIS DATE FORWARD THAT MUST HAVE THE THRUST BEARING'S REPLACED WILL HAVE THEM INSTALLED IN THE DB MODE,
DB (BACK TO BACK) IN THE DB MODE THE STAMPED SIDES OR "BACKS" OF THE BEARING' S ARE MOUNTED TOGETHER. A GAP IS THEN LEFT BETWEEN THE INNER RINGS. TIGHTENING THE LOCK NUT ON THE BALL SCREW SHAFT CLOSES THIS GAP AND BRINGS THE BEARING'S INTO CONTACT WITH THE RACES UNDER A PREDETERMINED LOAD, AND THUS PRELOAD'S THE BEARING'S. BECAUSE THE LOAD LINES DIVERGE ON THE SHAFT THIS ARRANGEMENT PROVIDES EXCELLENT RIGIDITY WITH A MINIMAL AMOUNT OF BACKLASH IN THE SYSTEM.
ORIGINATOR: RANDALL BRYANT REVISED BY: RANDALL BRYANT

DATE: April 16, 1988 SUBJECT: Nonvolatile CPU / Memory PCB PRODUCT LINE: Ultimax I Mills ISSUE NUMBER: 1109 SUPERSEDES NUMBER: 401 PAGE 1 OF 2
The Nonvolatile CPU/Memory PCB (415-0194-70X) includes a completely redesigned power down and battery circuit which utilizes the latest technology in power down devices and Lithium energy sources. This new design requires an external voltage source which will provide an early warning that power is going down. This early warning will cause the microprocessor to: 1) complete the cycle it is on; 2) put everything away in memory; 3) deselect the memory devices; 4) reset the system; and 5) switch the memory devices over to the lithium energy source before power is too low for reliable operation. This new circuitry is located on a piggy-back board which is installed on the CPU board where the NiCad battery used to be. The external voltage is provided by the CCPU NMI Power Supply (002-3410-001) which is a black cylinder with two 2 conductor cables coming out of it. One of the cables is terminated with ring tongues and the other cable is terminated with a small connector. To install the new board and the external voltage source please follow these steps: (Remember to use the Static Safe Wrist strap) 1) Turn off main power to the Mill and remove the old CPU board and place it on an anti-static work area. 2) Remove the Graphics and RS-232 boards from the old CPU board by removing the nylon screws from the non-component side of the CPU board. 3) Unpack the new Nonvolatile CPU and place it on the anti-static work area. Note the location of the new piggy-back board and. the empty connector on the piggy-back board. 4) Install the Graphics and RS-232 boards onto the new CPU board. 5) Install the new CPU board into the card rack in the same location that the old board was in. 6) Take the CCPU MMI Power Supply and connect the cable with the ring tongues to a 115 VAC source in the control cabinet. This 115 VAC source can be found at the DC Switching Power Supply input on all Mills except MD1 and MD3. On ND1 and MD3 Mills the 115 VAC source can be found on the secondary of the T2 control transformer.
DATE: April 18, 1988 SUBJECT: Nonvolatile CPU / Memory PCB
ISSUE NUMBER: 1109 SUPERSEDES NUMBER:
PRODUCT LINE: Ultimax I Mill PAGE - OF 2 7) Turn on main power to the mill and check the voltage on the other cable of the CCPU NMI Power Supply. There should be approximately 50 VDC between the white and black wire with the black wire being positive. 8) Turn off main power to the mill and plug the connector into the empty connector on the piggy-back board of the new CPU board. 9) Dress the cables neatly and attach the CCPU MMI Power Supply to the cabinet by removing the paper from the double sided tape and sticking the power supply to the cabinet. 10) Installation is now complete. Turn on main power to the mill and load the master tapes.

DATE: May 12, 1988 SUBJECT: Tool Change Height and 06F PRODUCT LINE: BMC 30, 40, 50 MAX1 ISSUE NUMBER: 1110 SUPERSEDES NUMBER: 404 PAGE 1 OF 2
With the 06F version of Ultimax software, the Tool Change Height is handled with switch block Sl on the machine personality board instead of the EEPROM on the custom CPU board. This makes the tool change height handling the same as with MAX2. When updating to 06F software, you must set the tool change height on Sl. To obtain the correct height, enter the machine diagnostic mode using a tape version other than 06F. Use the ENTER, 4, 8, 8, ENTER sequence to read the correct height value and record it. After the value is recorded, turn the machine power off and set switches 1 through 6 of Sl o match the recorded value. The switches are a binary input with Sl-1 being the least significant bit and Sl-6 being the most significant with each bit representing 0.01 inches. The number must be rounded to the nearest 0.01 inch. See example below. After the switches are set correctly, load in the 06F version tape. The Tool Change Height now set on Sl will be the value that the machine will use for automatic tool changes.
ORIGINATOR: Wayne E. Hawkins REVISED BY:
ATC HEIGHT SETUP FOR BMC 20 TO 50 (INCLUDING BMC 25) (L06F Software h MAX 2 Machines to V8.0) ++++ NOTE +++~ Always use WRIST STRAP When working with any thing inside the Cabinet or Control Head on any HURCO PRODUCT. 1. Power up machine, Remove tool from spindle and from magazine tool load position. (You may need to remove tools from either side For visibility.) 2. Go to Manual Mode" Calibrate axis, & Tool Changer, Lock Spindle, Start ATC Diagnostics, move Magazine right. Enter the "Secret Code" by pressing Enter Button" 4,8,8"Enter Button. 3. Carefully move "Z" axis (HEAD), with the Jog Hand Wheel, down to achieve a gap of .5000" between the bottom of the "V" Flange and the bottom of the spindle. BMC 25 has fingers 5 reference the same. 4. Record Z axis position from CRT display as shown ie. (z axis) 0.0000" 5. Press EXIT soft key then move the Magazine left" press EM STOP. 6. Turn MAIN BREAKER off & pull Personality Board from computer card rack. The Personality Board can be identified by three cables that extend from its top , it is the first. board in the tall section. 7. Locate the block of switches labeled Sl (see Fig.1) Turn on the switches that add up to the value recorded in step 4. Example. Recorded value = .1834" Set switches # 5 and #2 to on 8. Reinstall board, power up machine and test Tool Changer for proper operation. Observe the Tool Changer as it engages the tool, if it pulls up increase SW1 settings by . .0100" and retry. Also if it. moves down decrease SW1 by . .0100" and retry Continue until TC engages as smoothly as possible.
DATE: JUNE 10, 1988 SUBJECT: DRAW BAR ADJUSTMENT
ISSUE NUMBER: 1111 SUPERSEDES NUMBER: 407A PAGE 1 OF 2
PRODUCT LINE: BMC 30 THRU 50
It has been discovered that in most cases the draw bar lock nuts have been backing off causing the tool to be held loosely in the spindle. These are identified as item #26 on the attached sheet. To determine if these are maladjusted remove the front cover from the head. Looking in from the right hand side, between the bottom of the knock out cylinder and the top of the RPM sensor switch mounting bracket, You will see the two lock nuts in question. If these are set properly you should see one half to one turn of thread showing above the top lock nut. To adjust these two nuts it is necessary to loosen the top nut by turning it CCW and then tighten the bottom nut by turning it CW. Then re-tighten the top nut to see if you have at least one half to one complete turn of thread showing above the tap lock nut. To insure the proper adjustment, this procedure may have to be repeated several times. After the proper adjustment has been achieved tighten the top nut down to maintain locking effect. See attached sheet for draw bar nut location.
DATE: JULY 16, 1988 SUBJECT: CLUTCH NOISE
ISSUE NUMBER 1112 SUPERSEDES NUMBER: 411 PAGE 1 OF 1
PRODUCT LINE: BMC MILLS WITH 2 SPEED BOX
In the BMC 30-50 two speed box clutch (a two part unit) we have found some cases of the guide pins out of true location. This can cause a bind or pinch when the two halves try to mesh. This binding can cause a loud popping noise when the machine tries to change gears. To determine if this has accrued look at the clutch where it meshes it will look like it is cocked to one side. If you are getting the popping sound you will have this problem. Some of the other symptoms are a grinding noise or spindle errors, (no RPM) due to both clutches engaged at the same time. At this time the only fix is to replace the clutch or the two speed box.
Dana Abshier Service Engineer
Randall Bryant Technical Specialist BMC

DATE: JULY 16, 1988 SUBJECT: GIB WEAR PRODUCT LINE: BMC 20 THRU 50 ISSUE NUMBER: 1113 SUPERSEDES NUMBER: 412 PAGE 1 OF 1
Information has been gathered by Barny Lewis that there are cases of excessive Gib wear in the BMC 40-50 machines. This is caused by a lack of lubrication to the Z axis, [due to long lube lines], The solution for this problem is in installing a separate lubrication system for the Z axis. This is done by interrupting the oil lines coming from the original oil pump and installing a 2nd oil pump for the z axis, The motor is paralleled off the first pumps wiring and installed above or below the original pump. The following part numbers are needed to perform this modification.
713-0020-091 713-0020-102 713-0020-551
Lube pump T junction Flex hose
ORIGINATOR: RANDALL BRYANT REVISED BY:

DATE: DECEMBER. 12, 1988 SUBJECT: X AXIS BED CAP ISSUE NUMBER: 1114 SUPERSEDES NUMBER: 416 PAGE 1 OF 1
PRODUCT LINE: KM3P
A PROBLEM WITH THE X AXIS END CAP HAS BEEN IDENTIFIED BY MANUFACTURING. WE BELIEVE THIS TO BE A ISOLATED PROBLEM AND DON'T EXPECT IT TO SHOW UP IN THE FIELD. HOWEVER THE CAP SHOULD BE INSPECTED IF WORKING ON A KM3P WITH HIGH X AXIS CURRENT. THE CAPS FLANGE MAY BE TO LONG, APPLYING UNWANTED PRELOAD ON THE AXIS BEARING, CAUSING HIGH AXIS CURRENT AND PREMATURE BEARING FAILURE. IF THE FLANGE IS CONTACTING THE BEARING THE FLANGE LENGTH SHOULD BE SHORTENED, OR REMOVED COMPLETELY, THIS CAP IS USED AS A COVER ONLY IN OUR APPLICATION. IF BEARING WAS DAMAGED REPLACE WITH 211-0009-007
ORIGINATED BY: FRED RABS
DATE: DECEMBER 30,1988 SUBJECT: CONTROL RELAY PANEL PCB PRODUCT LINE: BMC 20-50/' FP3A/4A MAX 2
BETWEEN THE MONTHS OF AUGUST 1988 AND NOVEMBER 1986 AN INCORRECT PART MAY HAVE BEEN USED ON THE RELAY CONTROL PANEL, PCB NUMBER 415-0224-001. THE CORRECT PART IS AN MID400 OPTOCOUPLER, PN 417-0004-015, USED IN THE U1 POSITION. THE INCORRECT PART, HCPL2531 WILL NOT WORK IN OUR APPLICATION. THIS OPTO IS USED FOR THE INDEX OPTION; SO IF WORKING ON ANY PROBLEM WITH INDEXER OPTION YOU MAY WANT TO CHECK U1 FIRST. IT IS BELIEVED THAT ALL BAD OPTOS WERE REPLACED, BUT THERE IS A POSSIBILITY THAT SOME MAY HAVE GOTTEN OUT THE DOOR. IF THE WRONG OPTO IS FOUND ,REPLACE WITH THE PN LISTED ABOVE.
DATE: DECEMBER 30, 1988 SUBJECT: Deltron Power Supply PRODUCT LINE: All Mills
Recently there has been an increasing number of Deltron Power supplies being returned from the field with no problem found. Deltron has informed us that starting immediately they will charge Hurco $75.00 per supply that is return to them and tests good. As you know the outputs of these supplies float and need to have a load on them to make them stable.
If one of the outputs from the power supply is low try to make sure that it is definitely because of the supply and not something in the system which is pulling it down. If you need to check the power supply with the outputs disconnected it is necessary to place a load on the output while testing. Below are the recommended resistor values needed to put a full load on each of the outputs.
5 VOLTS ----> .25 12 VOLTS ---> 3.3 24 VOLTS ---> 8
OHM 100 WATT OHM 48 WATT OHM 72 WATT
ORIGINATOR: MIKE GARLICK REVISED BY:

DATE: January 16, 1989 SUBJECT: GROUNDING IN CONTROL CONSOLE PRODUCT LINE: ALL ULTIMAX MILLS ISSUE NUMBER: 1117 SUPERSEDES NUMBER: 422 PAGE 1 OF 1
There are two grounding studs provided in the control console. However because the nutserts are glued into bottom of the console it is possible to have a large difference in potential or no continuity at all between them. If the two Mecca ground wires are installed on one stud and the board grounds are installed on the other it is possible that the boards will not be grounded. This has been traced as a cause of "lock-ups" on several machines. In the future when installing the console put all the grounds onto the same stud. On existing machines check to make sure this has been done and correct it if it has not.
ORIGINATOR: MIKE GARLICK REVISED BY:

DATE: JANUARY 7, 1989 SUBJECT: RS232 CABLE PRODUCT LINE: MILLS ISSUE NUMBER: 1118 SUPERSEDES NUMBER: 422 PAGE 1 OF 1
TO CLEAR UP SOME QUESTIONS ON THE SIZE AND LENGTH OF RS232 CABLES I AM PASSING ON THIS INFORMATION AS RECOMMENDED CABLE SIZE FROM HURCO MANUFACTURING. 1: SIX CONDUCTOR SHIELDED CABLE 2: 22 GAUGE STRANDED WIRE, AS THE MINIMAL WIRE SIZE. 3: 50 FEET OR LESS CAN BE SINGLE SHIELDED. 4: OVER 50 FEET THE CABLE MUST BE MULTI-SHIELDED. 5: A MAXIMUM OF 100 FEET POSSIBLE BUT 80 FEET OR LESS IS BEST. 6: DO NOT RUN THESE CABLES NEAR FLUORESCENT LIGHTING FIXTURES OR OTHER POSSIBLE ELECTRICAL NOISE SOURCES. EXP. POWER CABLES, CONTACTORS, TRANSFORMERS, ETC., ETC. 7: THE CABLE SHIELDS SHOULD BE CONNECTED AT ONE CONNECTOR DO NOT GROUND BOTH ENDS.
THE HURCO PART NUMBER FOR SIX WIRE RAW CABLE IS 406-1244-002.
ORIGINATOR: RANDALL BRYANT REVISED BY:
DATE: DECEMBER 20, 1988 SUBJECT: PARAJUST A BRAKING BOARDS
PRODUCT LINE: ALL MILLS WITH PARAJUST A
THERE HAS BEEN SOME CONFUSION ON REPLACING OLD STYLE BRAKING BOARDS (402-6002-007/'013) WITH THE NEW STYLE BOARD (402-6002-016), IT IS NOT NECESSARY TO UPGRADE TO THE NEW STYLE BOARD. HOWEVER IT CAN BE USED TO REPLACE THE OLD STYLE BOARDS. INSTALL THE NEW STYLE AS YOU WOULD THE OLD, THEN WIRE TB-6 AND TB-7 AS THEY WERE ON THE OLD BOARD, THEN WIRE TB-8 IN THE FOLLOWING MANNER. 1) REMOVE THE RED JUMPER WIRE FROM TERMINAL 1 OF DRIVER MODULE #2 THAT JUMPS TO TERMINAL 1 DRIVER MODULE #4 2) CONNECT THE SINGLE CONDUCTOR BLUE WIRE FROM TERMINAL 1 OF THE DRIVER MODULE # 2 TO TERMINAL 1 OF TB-8 ON THE NEW BRAKING BOARD. 3) CONNECT THE SINGLE CONDUCTOR RED WIRE FROM TERMINAL 1 OF DRIVER MODULE # 4 TO TERMINAL 2 OF TB-8 ON NEW STYLE BRAKING BOARD. 4) USE TIE WRAPS TO SECURE THE NEW WIRES TO THE EXISTING HARNESS. 5) FOLLOW NORMAL BRAKING BOARD SETUP. ***NOTE*** DIODES FOUND BETWEEN TB-6 AND TB-7 ON SOME OLD STYLE BOARDS SHOULD NOT BE INSTALLED ON THE NEW STYLE BRAKING BOARD.
DATE: NOVEMBER 7, 1988 SUBJECT: MIS-WIRE OF YASKAWA RETROFIT PRODUCT LINE: MB2 MB3
PAGE 1 OF 1
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
DATE: MAY 19, 1988 SUBJECT: SPINDLE MOTOR OVERLOAD PRODUCT LINE: KM3 AND KM3P
RECENTLY WE HAVE DISCOVERED THAT SOME MACHINES HAVE BEEN SHIPPED WITH THE WRONG SPINDLE MOTOR OVERLOAD. IN ORDER TO PREVENT ANY PREMATURE SPINDLE MOTOR FAILURES, IT IS IMPORTANT FOR YOU TO CHECK ALL KM3 AND KM3P'S WHEN YOU ARE IN ON INSTALL OR WORKING ON MACHINES. IF THE MACHINE IS WIRED FOR 230 VAC ADJUST EXISTING OVERLOADS FOR THE 10 AMP SETTING. IF THE MACHINE IS WIRED FOR 480 VAC AND HAS A 10-16 AMP OVERLOAD, REPLACE IT WITH A 6..3 TO 10 AMP OVERLOAD, PART NUMBER 403-5501-013 AND ADJUST FOR 6.3 AMP SETTING.

DATE: January 17, 1989 SUBJECT: INDUSTRIAL DRIVES GROUNDING PRODUCT LINE: DECKEL FP3A/'4A ISSUE NUMBER: 1122 SUPERSEDES NUMBER: 421A PAGE 1 OF 1
"EFFECTIVE IMMEDIATELY"
ALL INDUSTRIAL DRIVES SERVO AND SPINDLE DRIVES MUST HAVE A GROUND WIRE FROM THE MOTOR GROUND TERMINAL ON EACH DRIVE BACK TO THE SPARE GROUND TERMINAL ON THE PSR3 POWER SUPPLY (INDUSTRIAL DRIVE POWER SUPPLY). THE WIRE FOR THIS APPLICATION IS 12 AWG GREEN / YELLOW. WHEN INSTALLING THE ADDITIONAL GROUND VIRES ON THE DRIVES BE SURE THE MOTOR GROUND WIRE AND ADDED GROUND WIRE ARE TIGHT IN THE TERMINAL! THE ADDITION OF THESE WIRES IS NECESSARY FOR TO REASONS.
1. INDUSTRIAL DRIVES RECENTLY STARTED PAINTING ALL OF THEIR DRIVES AND THE UNITS ARE NO LONGER ADEQUATELY GROUNDED VIA THE CHASSIS MOUNTING HARDWARE. 2. THE ADDITION OF THE GROUND WIRES WILL HELP ELIMINATE THE POSSIBILITY OF MISCELLANEOUS DRIVE FAULTS WHICH COULD OCCUR WITHOUT PROPER GROUNDING.
ORIGINATOR: TOM MURDEN REVISED BY:
DATE: MARCH 1, 1989 SUBJECT: ORIENTATION SENSOR REPLACEMENT PRODUCT LINE: BMC 20-50
THERE HAS BEEN SOME QUESTION ON HOW TO TROUBLESHOOT AND REPLACE THE MAGNETIC SENSOR FOR FANUC SPINDLE DRIVES. WHEN ORIENTATION PROBLEMS OCCUR, THE FOLLOWING SHOULD BE CHECKED. 1. CONNECT A DUAL TRACE OSCILLOSCOPE TO OBSERVE THE MAGNETIC SENSOR OUTPUTS WHICH ARE SIGNAL A (MSA) AND SIGNAL B (LSA) ON THE ORIENT BOARD. 2. START THE SPINDLE AND RUN AT 120 RPM. (NOTE YOU MAY HAVE TO INCREASE THE RPM'S SO IT CAN BE SEEN ON THE SCOPE.) 3. IF THE MAGNETIC SENSOR AND MAGETIZER ARE MOUNTED CORRECTLY AS IN FIG. 2 THE OUTPUT WAVEFORMS SHOULD MATCH THE WAVEFORMS IN FIG. 1. 4. IF NOT REFER TO THE TROUBLESHOOTING TABLE ON PAGE 2 OF THIS BULLETIN. NOTE: WHEN INSTALLING A NEW SENSOR, LINE UP THE SLOT IN THE SENSOR HEAD AND THE REF HOLE ON THE MAGNETIZER . ALSO THEY SHOULD BE ON THE LOWER SIDE IN OUR SYSTEM, DO NOT HAVE THEM POINTED UP AS THE FANUC MANUAL TELLS YOU.
ORIGINATOR: FRED RAES REVISED BY: R, BRYANT

DATE: NOVEMBER 29, 1988 SUBJECT: INDUSTRIAL DRIVE PRODUCT LINE: DECKEL FP3A, FP4A ISSUE NUMBER: 1124 SUPERSEDES NUMBER: 415 PAGE 1 OF 1
ANY INDUSTRIAL DRIVES AXIS OR SPINDLE AMPLIFIER ORDERED FROM HURCO STOCK BEFORE MARCH 1, 1989 AS A REPLACEMENT UNIT WILL NEED MODIFICATIONS IN HOUSE BEFORE SHIPMENT AS NOTED BELOW. THESE MODIFICATIONS SHOULD ALSO BE VERIFIED UPON RECEIPT OF THE REPLACEMENT PART IN THE FIELD. 402-6003-007 X, Y AXIS DRIVE. THE ACS3 COMP1 BOARD NEEDS THE FOLLOWING CHANGES. X AXIS REMOVE THE 332K OHM R 60 AND REPLACE WITH A 226K OHM RESISTOR. Y AXIS REMOVE THE 332K OHM R 60 AND REPLACE WITH A 226K OHM RESISTOR. ALSO REMOVE JUMPER AT J-10 AND INSTALL A JUMPER AT J11. 403-6003-006 Z AXIS DRIVE. THE ACS3-COMP1 BOARD NEEDS THE FOLLOWING CHANGES. REMOVE THE TO 100PF CAPACITOR AT C25. REPLACE WITH TO 4700PF CAPACITORS. 402-6003-010 SPINDLE DRIVE. ALL DECKEL MACHINES SHOULD HAVE THE R/'D FLYER BOARD ON THE SPINDLE DRIVE REPLACED WITH THE OLD STYLE ANALOG DEVICES R/'D CERAMIC PACKAGE. THE R/'D FLYER BOARD IS LABELED ACS3-RDA1 AND IS LOCATED AT THE TOP OF THE AC3-MC2 BOARD. THE CERAMIC PACKAGE IS LABELED AP1750/'0416, 1524/'560.
ORIGINATOR: TOM MURDEN REVISED BY: R, BRYANT
DATE: APRIL 21, 1988 SUBJECT: PROBLEMS CAUSED BY VIBRATION IN DELTRON, POWER SUPPLY. PRODUCT LINE: ALL ULTIMAX MILLS
PAGE 1 OF 1
A PROBLEM WITH SOME DELTRON POWER SUPPLIES HAS BEEN IDENTIFIED; HURCO P/'N 413-0008-011. DUE TO A MANUFACTURING ERROR BY DELTRON, VIBRATION MAY CAUSE THE POWER SUPPLY TO DE-ENERGIZE MOMENTARILY. THIS IS CAUSED BY A FASTENER ON THE BACK OF THE CHASSIS CONTACTING THE ELECTRICAL CIRCUITRY. THIS PROBLEM MAY BE PRESENT IN ANY POWER SUPPLY MANUFACTURED BEFORE DECEMBER, 1987. THIS DOES NOT IMPLY THAT ALL PRE-DECEMBER SUPPLIES ARE DEFECTIVE. TO UNDER STAND WHAT HAS OCCURRED THE FOLLOWING EXPLANATION IS OFFERED. IN LATE 1987, DELTRON FOUND THAT A CLEARANCE HOLE FOR THE FASTENER IN QUESTION WAS COUNTERSUNK TO DEEP ALLOWING THE FASTENER TO CONTACT THE MAIN PRINTED CIRCUIT BOARD. THEY HAVE INCORPORATED AN INSULATOR ON ALL POWER SUPPLIES SINCE DATE CODE 5087 (5 WEEK OF 1987) TO ENSURE THAT THIS WILL NOT HAPPEN IN THE FUTURE. IT IS A FLAT SHEET OF MATERIAL THAT IS VISIBLE BETWEEN THE BASE AND THE MAIN CIRCUIT BOARD. ALTHOUGH THIS PROBLEM COULD EXIST ON ANY PRE-DECEMBER POWER SUPPLIES IT IS MOST PROBABLE TO EXIST IN ONLY A FEW. WE WILL BE WATCHING RETURNS CLOSELY. PLEASE BE AWARE OF THIS SITUATION WHEN TROUBLESHOOTING LOCK-UP PROBLEMS OF INTERMITTENT COMPUTER RESET. THE PROBLEM CAN BE INDUCED AND PROVEN BY TAPPING ON THE WAY OF THE POWER CABINET USED TO MOUNT THE POWER SUPPLY. IF THE PROBLEM OCCURS, REPLACE THE POWER SUPPLY.

DATE: MAY 11, 1989 SUBJECT: FERRITE BEADS AND TRANSIENT VOLTAGE PROTECTORS PRODUCT LINE: ALL PRODUCT ISSUE NUMBER: 1126 SUPERSEDES NUMBER:
PAGE 1 OF 3
IN RESPONSE TO RECENT INTEREST IN THIS SUBJECT, HERE IS A SHORT DISCUSSION OF THESE COMPONENTS AND HOW THEY CAN BE USED ON THE ATTACHED PAGES.
ORIGINATOR: RICK GUNYON, WAYNE E. HAWKINS
FERRITE BEADS AND TRANSIENT VOLTAGE PROTECTORS.

AS DISCUSSED IN THE RECENT SERVICE MEETING, THE ENGINEERING AND SERVICE GROUPS ARE PRESENTLY IN THE PROCESS OF DECIDING IF FERRITE BEADS WILL BE PLACED IN THE PRODUCTS AS A " STANDARD" PART. IN THE INTERIM FERRITE BEADS HAVE PROVEN EFFECTIVE, ON BOTH MILL AND AUTOBEND PRODUCTS, AT A NUMBER OF CUSTOMER SITES WHEN NOISE HAS CAUSED SYSTEM RELIABILITY PROBLEMS AND NORMAL " PREREQUISITE" STEPS HAVE NOT TOTALLY RESOLVED THE FAILURES. WHEN WIRE IS RAN THRU A FERRITE BEAD, THE BEAD WILL BLOCK OR ABSORB ELECTRICAL SIGNALS OF CERTAIN FREQUENCY RANGES AT THAT POINT IN THE WIRE. THIS CHARACTERISTIC CAN BE USED TO REDUCE NOISE AND INTERFERENCE THAT IS CONDUCTED INTO A CIRCUIT FROM THE EXTERNAL CABLES OR OTHER CIRCUITS. FERRITE BEADS ARE SPECIFIED BY DESCRIBING TWO MAIN CHARACTERISTICS, SIZE AND MATERIAL. BEADS MADE OF DIFFERENT COMPOSITIONS OF FERRITE MATERIALS WILL ABSORB DIFFERENT FREQUENCY RANGES. DC SIGNALS AND LOW FREQUENCY ( < 1mHZ) ARE NOT EFFECTED. FOR THE PURPOSE OF ABSORPTION OF ELECTROMAGNETIC INTERFERENCE (EMI OR NOISE), THE RISE TIME OF THE NOISE SHOULD BE CONSIDERED AS THE FREQUENCY WHICH NEEDS ATTENUATION; FOR MOST NOISE, THE MATERIAL ABSORBING THE HIGHER FREQUENCIES IS DESIRED. THE BEAD DOES NOT NEED TO FIT THE WIRE DIAMETER TIGHTLY; A GUIDELINE THE OPEN INTERNAL DIAMETER IN THE FERRITE BEAD CAN BE UP TO 5 TIMES THE CONDUCTOR DIAMETER AND STILL BE 100% EFFECTIVE. HIGHER LEVELS OF NOISE ATTENUATION CAN BE GAINED BY PASSING THE WIRE THRU THE BEAD MORE THAN ONCE; JUST LOOP THE WIRE AROUND THE BEAD, EACH TIME IT PASSES THROUGH THE BEAD IS LIKE ADDING ONE MORE BEAD SO, FOR EXAMPLE, 3 TURNS IS 3 TIMES THE ATTENUATION AS A SINGLE BEAD/SINGLE TURN. CABLES ARE TREATED JUST LIKE A SINGLE WIRE, IN THAT THE ENTIRE CABLE CAN PASS THROUGH A BEAD AND EACH WIRE IN THE CABLE WILL RECEIVE THE ATTENUATION JUST AS IF EACH WIRE RAN THROUGH IT'S OWN BEAD. WE HAVE USED "SPLIT BEADS" (FERRITE BEADS CUT IN HALF DURING THE MANUFACTURING PROCESS) SO THEY CAN BE PLACED AROUND A PRE-EXISTING CABLE AND IT'S CONNECTORS EASILY. EACH HALF OF THE SPLIT BEAD IS THEN TAPED TOGETHER TO FORM A WHOLE BEAD AND SECURED IN PLACE WITH A TIEWRAP. THESE SPLIT BEAD ARE AVAILABLE FOR ROUND CABLES AND FLAT LAY CABLES. MAXIMUM EFFECT IS GAINED WHEN THE BEAD IS PLACED AT THE POINT THE SIGNAL ENTERS THE PCB CIRCUITRY, AFTER THE EXTERNAL CABLING HAS PICKED UP ALL NOISE DUE TO ANTENNA EFFECT, AND BEFORE THE PCB PROCESSES THE SIGNALS FROM THE CABLE. ON MULTIPLE PCB SYSTEMS, A BEAD AT EACH PCB NAY BE NEEDED.
WE HAVE SOLVED PROBLEMS DUE TO EMI FROM OTHER INDUSTRIAL EQUIPMENT SUCH AS WELDERS; FROM CB RADIOS ON FORK TRUCKS IN THE PLANT, AND PROBLEMS DUE TO VARIOUS UNKNOWN SOURCES OF NOISE. IT IS IMPORTANT TO STRESS THAT THIS TECHNOLOGY IS NOT A CURE-ALL AND DOES NOT TAKE THE PLACE OF PROPER DESIGN AND INSTALLATION TECHNICS.
TRANSIENT VOLTAGE PROTECTORS

THE BRAND OF DEVICE ME PRESENTLY USE IS A TRANSZORB, MADE BY GENERAL SEMICONDUCTOR DEVICES. THESE ARE LIKE A FAST ACTING ZENER DIODE AND DESIGNED SPECIFICALLY FOR QUENCHING NOISE TRANSIENTS. THEY ARE INSTALLED FROM +5 VDC TO GROUND ON THE PCB TO BE PROTECTED, OR CAN BE INSTALLED ON INDIVIDUAL INPUT AND/OR OUTPUT LINES TO QUENCH NOISE AT THESE POINTS. THESE DEVICES ARE FOUND ON THE PERSONALITY 2 PCB ON MILL PRODUCTS AND HAVE BEEN ADDED TO EACH AUTOBEND PCB SINCE MARCH OF 1988, INCLUDING PCB'S RE-TESTED AND REPAIRED FROM CUSTOMER SITES. THESE DEVICES ARE OPEN AT THEIR OPERATING VOLTAGE (AVAILABLE IN 5.0 VOLT TO 45 VOLT MODELS) AND TURN ON TO CLAMP TRANSIENT SPIKES DURING THE TIME THE SPIKE IS SOMEWHAT ABOVE THIS OPERATING VOLTAGE. (FOR EXAMPLE, THE 5.0 VOLT TRANSZORB CLAMPS AT A 7.8 VOLT LEVEL.) THE CLAMPING ACTION TAKES PLACE IN LESS THAN 1 X 10 -12 SECONDS AND SO IS QUICK ENOUGH TO KNOCK DOWN EMI BEFORE THE CIRCUITRY ON THE PCB CAN REACT TO IT. THESE DEVICES ALSO HAVE A POWER RATING, AND IF THE EFFECTIVE POWER IN THE NOISE EXCEEDS THIS POWER RATING, THE DEVICE MILL INITIALLY FAIL SHORT AND TRIP THE SYSTEMS CIRCUIT BREAKER OR FUSE. IF THIS FAILS TO TRIP, AFTER SOME TIME THE DEVICE WILL OPEN DUE TO INTERNAL HEATING. THE DEVICES WE SPECIFY ARE RATED AT 1500 WATTS OF PEAK PULSE POWER AND 200 AMPS OF FORWARD SURGE CURRENT. DURING OUR TESTING TO DEFINE OUR ADDITION OF THESE DEVICES, WE COMPLETED TESTS IN OUR PLANT AND IN THE FIELD. AS A TYPICAL EXAMPLE OF THE RESULTS, AT A CUSTOMER SITE WE MEASURED 7 VOLT NOISE SPIKES ON THE 5.0 VOLT POWER AT THE PCB, WITH THE SYSTEM LOCKING UP, DATA CHANGING, ETC. DUE TO THIS NOISE. AFTER ADDING TRANSZORB ( NO OTHER CHANGES), THE MEASURED NOISE DECREASED TO A MAXIMUM OF .7 VOLTS AND ALL FAILURES WERE ELIMINATED. AGAIN, THESE TRANSZORBS ARE NOT A CURE-ALL BUT ONE MORE EFFECTIVE MEASURE WITHIN A RELIABLE SYSTEM DESIGN.
DATE: AUGUST 7, 1989 SUBJECT: BMC TOOL MAGAZINE JAMMING PRODUCT LINE: BMC 40/50
We have found that the brass thrust ring at the top of the tool magazine is spinning on the aluminum of the magazine causing the brass and aluminum to burr. This causes drag, to correct this situation the thrust ring must be pinned to the magazine and an oil groove added. This is only to be done on BMC 40/50, please notify technical specialist of this problem on a BMC 20/30. The procedure for pinning and grooving the thrust ring is as follows 1) Remove all tools from the magazine. 2) Remove the fiber glass covers on the tool changer and magazine. 3) Remove the black cover on the bottom of the magazine shaft. 4) Remove the Geneva drive assembly at this time. 5) Secure magazine with a hoist or jacks and then remove the bearing retainer plate on the bottom of the magazine shaft. (Caution: The bottom bearing is a three piece assembly, the lower and middle parts may fall out at this time. The shims should be removed at this time.) 6) Lover the magazine until it clears the shaft. 7) Remove and modify the thrust bearing at this time as per the enclosed drawings. You will need three roll pins (3/16x 1 1/2 inch) to pin it. 8) Pin the thrust ring to the magazine and reinstall the magazine on the shaft after it is well greased. (Caution: Place the pins as straight as possible so they can later be removed if needed.) 9) Install the bottom bearing and the shims, then the bearing retainer cap. The magazine should turn at this point with some resistance. if the magazine spins free or one man can't turn it you must re-shim it. ORIGINATOR: R.ARTHUR
10) Replace the Geneva drive and check that the flywheel to magazine you can just insert a .001" shim. 11) Check tool change rotation in both directions. If it rotates correctly install tools and do 25 tool changes. If no problems, now LOCTITE the bolts one at a time on the bearing retainer cap and the Geneva drive assembly. 12) Load and run 200 tool changes at this time. 13) Replace covers and run 50 tool changes.

DATE: JUNE 20, 1989 SUBJECT: Leadscrew Mapping 7.24 BMC 20\30\40\50 only ISSUE NUMBER: 1128 SUPERSEDES NUMBER: PAGE.1..... OF.1..... On the BMC 20/30/40/50 series machines the new 7.24 software includes Leadscrew mapping. Machines that were shipped with 7.24 software were Leadscrew mapped at the factory and this mapping will have to be loaded back into the memory whenever a memory board is changed. This can be done from the secret screen (642) by loading it from the mapping disk sent with each machine or manually through the keyboard using the MANUAL DATA ENTRY Softkey and the mapping charts in each machine. If this is not done no compensation will be taken into account. Because 7.24 software no longer looks to the dual axis boards for Leadscrew compensation on the current line of bed mil1s, machines using earlier versions of software will have to have the dip switch settings transferred into memory. This is done once again from the secret screen by selecting the DUAL AXIS DEFAULTS Softkey. This automatically takes the information stored in the dual axis boards and stores it in memory. The following procedure should be followed whenever a memory board with 7.24 or later software is installed. 1) Power up after installing the new board. 2) Use the EXIT Softkey to get out of- the machine configuration screen. 3) Select manual. 4) Turn on servo power and CALIBRATE the machine. 5) Go to the leadscrew setup screen by pressing: ENTER 6 4 2 ENTER from the tool change diagnostics screen. 6) If information is to be loaded from a disk select LOAD DATA FROM DISK Softkey. (The current storage device needs to be drive A selected under the AUXILIARY menu) 7) If data is to be transferred from the dual axis boards select the DUAL AXIS DEFAULTS Softkey. Backlash continues to be compensated for on the dual axis boards. ORIGINATOR: Mike Garlick

DATE: JUNE 21, 1989 SUBJECT: CHIP DOOR INTERLOCK 7.24 SOFTWARE PRODUCT LINE: BMC-20/30/40/50 ISSUE NUMBER: 1129 SUPERSEDES NUMBER: PAGE 1 OF 1
With version 7.24 software or later the chip door interlock is now looked at as a normally closed contact. When machines are upgraded to 7.24 1t will be necessary to install a jumper betveen terminals 9 and 10 of TB-3 on the Control Relay Panel. If this is not done a CHIP DOOR OPEN error will be displayed when the machine is put into AUTO mode and the program will be aborted.
ORIGINATOR: Hike Garlick REVISED BY:
DATE: JUNE 21, 1989 SUBJECT: TAPPING T1 TRANSFORMER (STAND ALONE) PRODUCT LINE: BMC 20 THRU 50 PAGE 1 OF 1
ISSUE NUMBER: 1130 SUPERSEDES NUMBER
IT HAS CAME TO MY ATTENTION THAT SOME OF THE BMC 20 THRU 50 MACHINES HAY HAVE' HAD THE T1 TRANSFORMER TAPPED FOR TOO HIGH A SECONDARY VOLTAGE OUTPUT. THIS MAY IN TURN CAUSE PREMATURE FAILURE OF THE FANUC AXIS AND SPINDLE DRIVE SYSTEM. IF THE VOLTAGE IS RUNNING ON THE HIGH SIDE OF THIS RANGE OR IF IT IS OVER THE LIMITS TRY MOVING THE OUTPUT TO THE 190VAC TAPS. REMEMBER THE RANGE IS FROM 180 TO 220VAC AND THE 190 IS CLOSER TO THE MIDDLE OF THIS RANGE WHEN THE INCOMING VOLTAGE IS ON THE HIGH SIDE. BE SURE TO CHECK ALL VOLTAGE LEVELS BEFORE AND AFTER MOVING THE TAPS. FROM THIS TIME ON, PLEASE CHECK ALL TRANSFORMERS ON ANY MACHINES YOU MAY BE WORKING ON THIS MAY SAVE A TRIP LATER TO REPLACE THE SPINDLE OR AXIS DRIVES. IF YOU HAVE ANY QUESTIONS PLEASE CALL ME DON'T GUESS BE SURE.
ORIGINATOR: RANDALL BRYANT, KEN BORGMEYER REVISED BY:
DATE: 06/21/89 SUBJECT: MAGAZINE JAMMED ERROR PRODUCT LINK: BMC-20/30/40/50
THIS BULLETIN SHOULD BE USED IN CONJUNCTION WITH FSB 1127 TO PROPERLY TROUBLE SHOOT AND CORRECT THE "MAGAZINE JAMMED" ERROR. We are beginning to get more and more reports of MAGAZINE JAMMED errors on machines in the field. FSB 1127 deals with the mechanical causes of this problem. However it is felt that the problem could also be caused by arcing in the ROTATE ENABLE (RE) and/or the TOOL MAGAZINE COUNTER CLOCKWISE (TMCC) relays. The BMC-20 appears to be the most susceptible to this arcing problem On newer V1 machines and all V2 machines the suppression in the Magazine motor circuit has been increased substantially. There are now 6 arc suppressors in the circuit which has helped reduce the arcing of the relay contacts. On older machines it may be necessary to place suppressors across the following contacts: ROTATE ENABLE (RE) 6-9 3-9 TOOL MAGAZINE COUNTER CLOCKWISE (TMCC) 9-3 9-6 8-5 8-2 It would be wise to replace the relays when the suppressors are installed as the contacts will probably have been badly pitted. PART NUMBER FOR SUPPRESSORS: 417-6001-010 PART NUMBER FOR RELAYS: 403-2001-013
ORIGINATOR: Mike Garlick REVISED BY:
DATE: 06/28/89 SUBJECT: BIJUR LUBE PUMP ADJUSTMENT PRODUCT LINE: BMC-20/30/40/50 PAGE 1 OF 1
The BIJUR lube pump adjustment procedure sent out to the field recently is incorrect. Please use the following procedure. 1) Remove the locking screw found inside the center of the manual hand pump to get to the adjusting screw. This could be a slotted or hex head set screw. 2) Using a depth micrometer measure the distance from the top of the pump handle to the top of the adjusting screw. This dimension should be set for .95 inches to allow 3cc of flow per cycle. However it may be necessary to use a different setting on some machines. Refer to the following chart for dimensions and outputs. INCHES DISCHARGE 1.03 2.5 cc .95 3.0 cc .87 3.5 cc .79 4.0 cc .71 4.5 cc .63 5.0 cc Each .080 of ad9ustment is equal to .5 cc. 3) Re-install locking screw.

DATE: 8/3/89 SUBJECT: MAX 2 MEMORY BOARDS PRODUCT LINE: ALL MAX 2 MILLS ISSUE NUMBER: 1133 SUPERSEDES NUMBER: PAGE 1 OF 1
THE NON VOLATILE STATIC RAM SITES ON THE MAX 2 MEMORY BOARDS WERE DALLAS DS1235 IC'S. THOSE DEVICES ARE TEMPORARILY UNAVAILABLE. THE RAM SITES MUST BE REWORKED BY OUR Vendor TO USE SMART SOCKETS AND STANDARD STATIC RAM IC'S. PREVIOUS TO THIS REWORK IT WAS POSSIBLE TO REMOVE THE DALLAS RAMS FROM A DEFECTIVE MEMORY BOARD AND INSTALL THEM INTO A NEW MEMORY BOARD. THIS WAS NORMALLY DONE TO SAVE A CUSTOMERS PROGRAMS WHEN THE MACHINE WASN'T EQUIPPED WITH THE DISK OPTION. THIS WILL NOT BE POSSIBLE WITH THE REWORKED MEMORY BOARDS.

DATE: 8-18-89 SUBJECT: SHAFT MOUNT ENCODERS PRODUCT LINE: ALL ISSUE NUMBER: 1134 SUPERSEDES NUMBER: PAGE 1 OF 1
ORIGINALLY, THE USE OF SHAFT MOUNT ENCODERS CAME ABOUT FOR TWO REASONS. 1) HIGH DEGREE OF DIFFICULTY IN ADJUSTING ENCODERS TO ACHIEVE PROPER QUADRATURE. 2) ENDPLAY IN SERVO MOTORS EXCEEDING ENCODER AIR GAP RESULTING IN A DAMAGED ENCODER DISK. ALL SHAFT MOUNT ENCODERS ARE ADJUSTED THEN SEALED BY OUR VENDOR. SERVICE ENGINEERS SHOULD NEVER DEFEAT THE FACTORY SEAL ON ANY SHAFT MOUNT ENCODER. IF THE MACHINE IS OUT OF WARRANTY REPLACE THE ENCODER, IF THE MACHINE IS STILL UNDER A PART WARRANTY ,THE MTE ASSEMBLY MUST BE REPLACED.
ORlGINATOR: FREDRICK RAES REVISED BY:

DATE: August 9, 1989 SUBJECT: Spindle Firmware PRODUCT LINE: MD3 with Yaskawa Spindle Drive ISSUE NUMBER: 1135 SUPERSEDES NUMBER: PAGE 1 OF 1
A new Spindle EPROM has been released for the MD3 type machines with the Yaskawa Spindle Drive (002-2060-001). The new EPROM is a 450-3001501 and replaces the 450-3001-439 EPROM. The changes in this new EPROM allow separate adjustments for Spindle Orient speed based upon the Spindle Gear Range (High or Low). Orient adjustments for this EPROM are listed below. Z / SPINDLE DUAL AXIS PCB
SWITCH BLOCK 2: LOW GEAR SPEED ADJUST POSITION ( S1 on D / A2 ) 1 2 3 4 5 6 7 8 ON = SLOWER OFF = FASTER MOST SIGNIFICANT BIT SPEED ADJUSTMENT SPEED ADJUSTMENT LEAST SIGNIFICANT BIT NOT USED ON = SHOT PIN ENABLED OFF SHOT PIN DISABLED ON = MD3 MACHINE TYPE OFF OFF = MD1 MACHINE TYPE SWITCH BLOCK 3: HIGH GEAR SPEED ADJUSTMENT POSITION (S2 on D/A2 ) 1 2 3 4 5. 6 7 8 ON = SLOWER OFF = FASTER MOST SIGNIFICANT BIT SPEED ADJUSTMENT SPEED ADJUSTMENT LEAST SIGNIFICANT BIT NOT USED NOT USED NOT USED
ORIGINATOR: K. PERKINS REVISED BY:

DATE: Auqust 11, 1989 SUBJECT: Yaskawa Spindle Drive Retrofit Kits PRODUCT LINE: MD3, MB2/3 (002-2060-001i002) ISSUE NUMBER: ll36 SUPERSEDES NUMBER: PAGE 1 OF 2
Effective September, 1989 the Yaskawa Retrofit Kits (002-2060-001,002) will change to different braking resistors. The new resistors eliminate the "Over Voltage" problem that has been seen during deceleration from a high RPM by providing more braking torque. The new resistors can be installed into existing drives in the field to eliminate the "OV" fault that could occur during deceleration from a high RPM. The new resistors have a part number of 407-0043-001. This. part number is for both the left and right hand resistor bank so only order a quantity of one (1) for each machine The resistors mount in the same location that the Yaskawa resistors did, but do not have overload contacts and connect in series as opposed to the parallel wiring of the Yaskawa resistors. Installation instructions are below: 1) Remove thermal overload wiring from the drive cabinet at TB8, positions 1 THRU 4 (blue and white vires). 2) Remove the resistor shields, save the BHCS for reuse. 3) Remove the cover plates from the Yaskawa resisters. 4) Disconnect the braking wires (black) from the Yaskawa resistors. 5) Remove the Yaskawa resistors, along with the overload wiring that was disconnected from TB8. Also remove the resistor spacers that are between the cabinet and the resistors. Save the BHCS for reuse. 6) Remove the conduit from the bottom of the Yaskawa resistors. 7) Mount the Post Glover resistors to the cabinet as the Yaskawa resistors were except do not install the spacers. 8) Connect the two (2) black braking wires to the posts on the new resistors. 9) Since these resistors connect in series, not parallel, remove one of the brake wires going to the drive at terminal "P" and one from terminal "B3".
10) At this point you should have a wire from one resistor bank to drive terminal "P" and one wire from the other bank to drive terminal "B3". 11) Connect the other two black wires, one from each resistor bank, to each other inside the drive cabinet. Use either a butt splice or wire nut to connect the wires. Assure a sound connection, and that the connection is not exposed and that the wiring is dressed neatly. 12) The total resistance of the two brake resistor units connected in series is 14 Ohms. l3) Power up the machine and program a series of spindle operations using both CW and CCW spindle rotations and both High and Low gear ranges. Also verify proper Orientation. 14) Verify the resistors are functioning properly by measuring the voltage being transferred to the resistors, during deceleration, from the drive at terminals "P" and "B3". 15) Re-install the brake shields and update the customers Yaskawa manual with the wiring changes that you have made. 16) If desired the accel and decel ramps of the drive can be set for a minimum time duration, (i.e. < 4 seconds) so as to confirm that the drive will follow the DAC ramps.
DATE: 09/07/89 SUBJECT: Z AXIS LUBRICATION LINES PRODUCT LINE: BMC 20 V2
ON SOME BMC 20,S THAT HAVE RECENTLY SHIPPED THE Z AXIS BALLSCREW NUT LUBRICATION LINE WAS ROUTED INCORRECTLY. ALL MACHINES NEED. TO BE CHECKED ON INSTALL AND ON SERVICE CALLS. IT MUST BE REPLACED IF WRONG! THIS IS THE RIGHT WAY. TO CHECK YOU MOST LOOK IN THE COLUMN, BEHIND THE SPINDLE MOTOR AT THE OIL DISTRIBUTION BLOCK. THERE SHOULD BE A HOLE FOR THIS OIL LINE TO PASS THRU AND ATTACH TO THE Z AXIS BALL NUT. THIS IS THE WRONG WAY! IF THE LINE IS ROUTED OVER THE TOP OF THE Z AXIS ASSY AND NOT THROUGH THIS HOLE, THE LINE CAN BE SHEARED OFF. IF THIS IS NOT NOTICED THIS CAN CAUSE SEVERE DAMAGE TO THE BALLSCREW. TO CORRECT THIS PROBLEM THE FOLLOWING PARTS WILL BE NEEDED: 1. 2. 3. 4. 5. 6. METER UNIT 713-0020-093 .2 COMPRESSION SLEEVES 713-0020-098 1 TUBE CLIP 713-0021-268 .10" 4MM TUBING 713-0021-269 COMPRESSION NIPPLE 713-0020-099 COMPRESSION NUT 713-0020-097
ORIGINATOR: BROCK REXING RANDALL BRYANT REVISED BY:
DATE: December 12, 1993 SUBJECT: Floppy Disk Drives, Max2/32/3 PRODUCT LINE: All Ultimax Controls
ISSUE NUMBER: 1138-A SUPERSEDES NUMBER: 1138 PAGE 1 OF 6
Revised and added Configuration of Max3 and Max32 HD (1.44 Mbyte) Floppy drives. Max2 NEC has got out of the business of making disk drives. We will therefore be using Teac and Sony drives in the future. However the pinout on these drives is located further to the right than on the NEC drives. Due to the shortness of the cable between plugs it will require replacing both drives in the event of one failing. A new part number has been issued for these drives. 426-0056-903. The 902 and 901 drives are still available in limited quantities and these should be used up before going to the 903 style. -If a machine has 901 style drives and one goes bad both drives will need to be replaced with two 002-3303-005 retrofit kits. -If a machine has 902 style drives and one goes bad both drives will have to be replaced with the 903 style. The physical size of these drives is the same so the retrofit kit is not needed. Max3 or 32 Teac has obsoleted two of the orginal Floppy drives used in the Max3 and 32 controls. Although the part number (426-0056-007) has remained unchanged, we have several different Teac drive configurations. The following 5 pages show the pinout and switch / jumper configuration of each of the drives and the retrofit kit.
ORIGINATOR: Mike Garlick REVISED BY: Brock Rexing

FSB 1138-A Page 2 of 6

SIZE DRAWING SHT.
1
OF
REV.
002-3303-005
3
FRONT SIDE
BOTTOM
1 4 4 1
QTY.
802-2300-039 101-0001-003 110-0002-022 426-0056-003

PART NUMBER
ADAPTER PLATE, DISK DRIVE 4-40 X 1/2 SHCS WASHER #4 DISK DRIVE, 3.5" FLOPPY, 1" BEZEL, CFG#2
ITEM DESCRIPTION PARTS LIST
4 3 2 1
ITEM
SURFACE TREATMENT
HEAT TREATMENT
CN 127
B 10378 A 10072
REV P.I.N. NO.
ITEM 1 WAS 426-0056-002 RELEASE

REVISION DESCRIPTION
17 FWG AUG 89 23 FWG JAN 89 REV DATE CHK DATE APPD DATE DF BY BY BY
FIRST USED ON
~ ~
EXCEPT AS NOTED: ALL DIMENSIONS HURCO IN INCHES TOLERANCE DECIMAL .0 .0300 DESCRIPTION .00 .0150 .000 .0050 .0000 .0005 ANGULAR 0ANGULAR 30' DRAWN BREAK ALL SHARP EDGES SCALE THIRD ANGLE PROJECTION
HURCO MANUFACTURING COMPANY, INC. INDIANAPOLIS, IN U.S.A.

R
ASSY, 3.5 INCH FLOPPY DRIVE RETROFIT KIT

DATE CHECKED DATE APPROVED DATE
F. GROSS
23JAN89
SIZE DRAWING SHT. REV.
1.25=1 PC
DISK OPTION
UNIT OF MEAS.
002-3303-005
OF

SIZE DRAWING SHT.
1
OF
REV.
426-0056-003
1.000
FRONT
4.000
ACTUAL APPEARANCE OF THE FRONTS MAY VARY BETWEEN VENDORS. HOWEVER, THE DIMESIONS OF THE BEZEL REMAIN 4" X 1" FOR ALL VENDORS UNDER THIS HURCO PART NUMBER.
SIGNAL PINOUT
PIN 2 PIN 1
TEAC FD-235
SONY MP-F11W-50L
MS IR RY DC D1 D0 FG
BACK
TOP
SIDE
SHUNT CONFIGURATION DRIVE A MS IR RY DC D1 D0 DRIVE B MS IR RY DC D1 D0 3 2 1
SWITCH CONFIGURATION DRIVE A DRIVE B
1
QTY.
426-0056-903 PART NUMBER
DISK DRIVE, 3.5" FLOPPY, 1" BEZEL, PINOUT #2

1
ITEM
SURFACE TREATMENT
HEAT TREATMENT
FIRST USED ON
~ ~
EXCEPT AS NOTED: ALL DIMENSIONS HURCO IN INCHES TOLERANCE DECIMAL .0 .0300 DESCRIPTION .00 .0150 .000 .0050 .0000 .0005 ANGULAR 0ANGULAR 30'DRAWN BREAK ALL F. GROSS SHARP EDGES THIRD ANGLE PROJECTION SCALE

R
3.5" MICROFLOPPY DISK DRIVE, 1" BEZEL

25JAN89
CN 129
A 10378 REL.
REV P.I.N. NO. REVISION DESCRIPTION
FWG
17 AUG 89
1.25=1
UNIT OF MEAS.
REV DATE CHK DATE APPD DATE DF BY BY BY
HURCO,DECKEL
EA.
426-0056-002
OF

SIZE DRAWING SHT.
1
OF
REV.
PROPRRIETARY INFORMATION
426-0056-001
MODEL FD1036A
P/N 134-500105-004-0
NEC
MODEL FD1036A
P/N 134-500105-004-0
NEC
MODEL FD1036A
P/N 134-500105-004-0
NEC
MODEL FD1037A NEC P/N 134-500474-954-0
FACTORY DEFAULT
CONFIGURED DRIVE 0
CONFIGURED DRIVE 1
TOP
SIGNAL PINOUT
PIN 1 PIN 2
MODEL FD1036A
P/N 134-500105-012-0
NEC
MODEL FD1036A
P/N 134-500105-012-0
NEC
MODEL FD1036A
P/N 134-500105-012-0
NEC
BACK
FACTORY DEFAULT
CONFIGURED DRIVE 0
CONFIGURED DRIVE 1 SWITCH SETTINGS FOR DRIVE CONFIGURATION
Pos. 1 Drive A
Pos. 2 Drive B
Pos. 3 Pos. 4 NOT USED
1
QTY.
DISK DRIVE, 3.5" FLOPPY, 1.25" BEZEL

1
ITEM
SURFACE TREATMENT
HEAT TREATMENT
FIRST USED ON
~ ~
EXCEPT AS NOTED: ALL DIMENSIONS HURCO IN INCHES TOLERANCE DECIMAL .0 .0300 DESCRIPTION .00 .0150 .000 .0050 .0000 .0005 ANGULAR 0ANGULAR 30' DRAWN BREAK ALL SHARP EDGES SCALE THIRD ANGLE

R
3.5" MICROFLOPPY DISK DRIVE

FWG
17AUG89
CN 130
A
REV
10378
P.I.N. NO.
ORIG. ISSUE
FWG
17 AUG 89
PROJECTION
FULL
UNIT OF MEAS.
426-0056-001
1
OF

SIZE DRAWING SHT.
1
OF
REV.
426-0056-002
NEC FD1037A-154
1.000
FRONT
4.000
BACK
SWITCH CONFIGURATION DRIVE A SIGNAL PINOUT DRIVE B
PIN 2 PIN 1
1 2 3 4 1 2 3 4
1
QTY.

1
ITEM
SURFACE TREATMENT
HEAT TREATMENT
FIRST USED ON
~ ~
EXCEPT AS NOTED: ALL DIMENSIONS HURCO IN INCHES TOLERANCE DECIMAL .0 .0300 DESCRIPTION .00 .0150 .000 .0050 .0000 .0005 ANGULAR 0ANGULAR 30'DRAWN BREAK ALL F. GROSS SHARP EDGES SCALE THIRD ANGLE PROJECTION

R

17AUG89
CN 131
A 10378 RELEASE
17 FWG AUG 89
REV DATE CHK DATE APPD DATE BY BY BY DF
1.25=1 EA.
HURCO,DECKEL
UNIT OF MEAS.
426-0056-002
OF

SIZE DRAWING SHT.
1
OF
REV.
426-0056-007
Teac FD 235HF-201 Teac FD 235HF-3201 /S G F E D C B A 4 3 2 1
Teac FD-235HF-4429 E D C B A 2 1
NOTES:
Jumper configuration for various HD Floppy Drives used on Ultimax 3 and Max32
Teac FD-235HF-5429
DS 0 1
SURFACE TREATMENT
HEAT TREATMENT
CN XXXX-X
FIRST USED ON
~ ~
EXCEPT AS NOTED: ALL DIMENSIONS HURCO IN INCHES TOLERANCE DECIMAL .0 .0300 DESCRIPTION .00 .0150 .000 .0050 .0000 .0005 ANGULAR 0ANGULAR 30' DRAWN BREAK ALL SHARP EDGES

R
1.44 HD FLOPPY DRIVE CONFIGURATION

B.R.R. NONE
12/8/93
A XXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
XX/XX
XX
Ultimax 3 Max 32
THIRD ANGLE PROJECTION
SCALE
UNIT OF MEAS.
PC
426-0056-007
OF
DATE: August 3, 1994 SUBJECT: Floppy Disk Drives, Max2/32/3 PRODUCT LINE: All Ultimax Controls
ISSUE NUMBER: 1138-B SUPERSEDES NUMBER: 1138 PAGE 1 OF 6
Revised and added Configuration of Max3 and Max32 HD (1.44 Mbyte) Floppy drives. (Rev A, 12-12-93) Revised Page 3 of 6, Add Sony MPF420-2 Max2 720K Floppy Drive Configuration (Rev B, 8-3-94) Max2 NEC has got out of the business of making disk drives. We will therefore be using Teac and Sony drives in the future. However the pinout on these drives is located further to the right than on the NEC drives. Due to the shortness of the cable between plugs it will require: 1) ordering another 34 pin connector (406-0802-047) to add to the existing disk control cable, or, 2) replacing both drives (426-0056-903) when one fails. Once both drives are the new -903 style they can be replaced individually. The 902 and 901 drives are still available in limited quantities and these should be used up before going to the 903 style. -If a machine has 901 style drives and one goes bad both drives will need to be replaced with two 002-3303-005 retrofit kits. -If a machine has 902 style drives and one goes bad both drives will have to be replaced with the 903 style. The physical size of these drives is the same so the retrofit kit is not needed. Max3 or 32 Teac has obsoleted two of the orginal Floppy drives used in the Max3 and 32 controls. Although the part number (426-0056-007) has remained unchanged, we have several different Teac drive configurations. The following 5 pages show the pinout and switch / jumper configuration of each of the drives and the retrofit kit.
ORIGINATOR: Mike Garlick REVISED BY: Brock Rexing

FSB 1138-A Page2 of 6

SIZE DRAWING SHT.
1
OF
REV.
002-3303-005
3
FRONT SIDE
BOTTOM
1 4 4 1
QTY.
802-2300-039 101-0001-003 110-0002-022 426-0056-003

PART NUMBER
ADAPTER PLATE, DISK DRIVE 4-40 X 1/2 SHCS WASHER #4 DISK DRIVE, 3.5" FLOPPY, 1" BEZEL, CFG#2
4 3 2 1
ITEM
SURFACE TREATMENT
HEAT TREATMENT
CN 127
B 10378 A 10072
REV P.I.N. NO.
ITEM 1 WAS 426-0056-002 RELEASE

17 FWG AUG 89 23 FWG JAN 89 REV DATE CHK DATE APPD DATE DF BY BY BY
FIRST USED ON
~ ~
EXCEPT AS NOTED: ALL DIMENSIONS HURCO IN INCHES TOLERANCE DECIMAL .0 .0300 DESCRIPTION .00 .0150 .000 .0050 .0000 .0005 ANGULAR 0ANGULAR 30' DRAWN BREAK ALL SHARP EDGES SCALE THIRD ANGLE PROJECTION

R
ASSY, 3.5 INCH FLOPPY DRIVE RETROFIT KIT

F. GROSS
23JAN89
1.25=1 PC
DISK OPTION
UNIT OF MEAS.
002-3303-005
OF

426-0056-003
OF
1.000
SONY MPF420-0
FRONT
4.000
BACK
SHUNT CONFIGURATION SIGNAL PINOUT
"A" Drive
"B" Drive
PIN 2 PIN 1 15 15 10 5 5 15 15 10 5 5
TEAC FD-235
SONY MP-F11W-50L
14
14
13
13
12
MS IR RY DC D1 D0 FG
12
BACK
11 11 6 1 1 11 11 6 1 1
TOP
SIDE
SHUNT CONFIGURATION DRIVE A MS IR RY DC D1 D0 DRIVE B MS IR RY DC D1 D0 3 2
SWITCH CONFIGURATION DRIVE A DRIVE B
1
QTY.
426-0056-903
PART NUMBER

1
ITEM
SURFACE TREATMENT EXCEPT AS NOTED: ALL DIMENSIONS IN INCHES TOLERANCE

R
HEAT TREATMENT
FIRST USED ON
~ ~
HURCO
DECIMAL .0 .00 .000 .0000 .0300 .0150 .0050 .0005 DRAWN DESCRIPTION
3.5" MICROFLOPPY DISK DRIVE, 1" BEZEL

ANGULAR 030' BREAK ALL SHARP EDGES THIRD ANGLE PROJECTION
F. GROSS
SCALE
25JAN89
CN 129
A 10378 REL.
17 AUG FWG 89
1.25=1
UNIT OF MEAS.
REV DATE CHK DATE APPDDATE BY BY BY
DF
HURCO,DECKEL
EA.
426-0056-002
OF

SIZE DRAWING SHT.
1
OF
REV.
PROPRRIETARY INFORMATION
426-0056-001
MODEL FD1036A
P/N 134-500105-004-0
NEC
MODEL FD1036A
P/N 134-500105-004-0
NEC
MODEL FD1036A
P/N 134-500105-004-0
NEC
MODEL FD1037A NEC P/N 134-500474-954-0
FACTORY DEFAULT
CONFIGURED DRIVE 0
CONFIGURED DRIVE 1
TOP
SIGNAL PINOUT
PIN 1 PIN 2
MODEL FD1036A
P/N 134-500105-012-0
NEC
MODEL FD1036A
P/N 134-500105-012-0
NEC
MODEL FD1036A
P/N 134-500105-012-0
NEC
BACK
FACTORY DEFAULT
CONFIGURED DRIVE 0
CONFIGURED DRIVE 1 SWITCH SETTINGS FOR DRIVE CONFIGURATION
Pos. 1 Drive A
Pos. 2 Drive B
Pos. 3 Pos. 4 NOT USED
1
QTY.
DISK DRIVE, 3.5" FLOPPY, 1.25" BEZEL

1
ITEM
SURFACE TREATMENT
HEAT TREATMENT
FIRST USED ON
~ ~

R
3.5" MICROFLOPPY DISK DRIVE

FWG
17AUG89
CN 130
A
REV
10378
P.I.N. NO.
ORIG. ISSUE
FWG
17 AUG 89
PROJECTION
FULL
UNIT OF MEAS.
426-0056-001
1
OF

SIZE DRAWING SHT.
1
OF
REV.
426-0056-002
NEC FD1037A-154
1.000
FRONT
4.000
BACK
SWITCH CONFIGURATION DRIVE A SIGNAL PINOUT DRIVE B
PIN 2 PIN 1
1 2 3 4 1 2 3 4
1
QTY.

1
ITEM
SURFACE TREATMENT
HEAT TREATMENT
FIRST USED ON
~ ~
EXCEPT AS NOTED: ALL DIMENSIONS HURCO IN INCHES TOLERANCE DECIMAL .0 .0300 DESCRIPTION .00 .0150 .000 .0050 .0000 .0005 ANGULAR 0ANGULAR 30'DRAWN BREAK ALL F. GROSS SHARP EDGES SCALE THIRD ANGLE PROJECTION

R

17AUG89
CN 131
A 10378 RELEASE
17 FWG AUG 89
REV DATE CHK DATE APPD DATE BY BY BY DF
1.25=1 EA.
HURCO,DECKEL
UNIT OF MEAS.
426-0056-002
OF

SIZE DRAWING SHT.
1
OF
REV.
426-0056-007
Teac FD 235HF-201 Teac FD 235HF-3201 /S G F E D C B A 4 3 2 1
Teac FD-235HF-4429 E D C B A 2 1
NOTES:
Jumper configuration for various HD Floppy Drives used on Ultimax 3 and Max32
Teac FD-235HF-5429
DS 0 1
SURFACE TREATMENT
HEAT TREATMENT
CN XXXX-X
FIRST USED ON
~ ~

R
1.44 HD FLOPPY DRIVE CONFIGURATION

B.R.R. NONE PC
12/8/93
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REV DATE CHK DATE APPD DATE BY BY BY
DF
Ultimax 3 Max 32
PROJECTION
UNIT OF MEAS.
426-0056-007
OF
DATE: October 5, 1989 SUBJECT: Vertical head lube relay PRODUCT LINE: FP3A/FP4A Ultimax 2
Effective immediately all FP3A and FP4A Ultimax machines should be checked f or proper wiring and. operation of the vertical head lube relay and solenoid. 1.) The wire from R101 pin 4 should connect to RLY4 terminal 6. This wire may currently be connected to RLY4 terminal 8 making the Vertical head lube solenoid non-functional. If the wire has been incorrectly connected to terminal 8, remove the wire from the relay and all wireways back to connector R101. The wire should be long enouqh to route up the riqht hand wireway and across to the top of RLY4 terminal 6. see 002-3730-012 +24VDC Unregulated Schematic for additional information. If RLY4 was mis-wired proceed to step 02. If RLY4 was correctly wired proceed to step 03. Remove the Vertical head lube solenoid connector and cover and inspect the wiring and diode connection. Terminal 01 should contain the black wire and the cathode end of the suppression diode. Terminal #2 should contain the clear wire and the anode end of the suppression diode. After checkinq wiring verify +24vdc on terminal 01 and qround on terminal 02 by manually requestinq a machine lube cycle. The solenoid is energized four times in succession following the way lube cycle. After verifyinq the proper wiring and voltage install the connector and proceed to step #3. 3.) Remove Vertical head lube line at the head connection and cover end of lube line with shop towel. Manually request a machine lube cycle and check for four shots of oil, one for each time the solenoid is energized. If no oil is present repeat machine lube Cycle until oil is seen in four shots for each manual lube cycle. Reconnect the oil line to the head and tighten fittings.

DATE: 9/29/89 SUBJECT: Turcite damage PRODUCT LINE: BMC. full enclosure machines ISSUE NUMBER: 1140 SUPERSEDES NUMBER: PAGE 1 OF 1
A number of machines have had damage done to the turcite on the X-Axis way surfaces. This is. being cause by the way cover extension brackets being mounted with the top edge above the way surface. The sharp edge of. the bracket peels the turcite from the underside of the table as it rides out over the end of the way. Due to the tact that all BMC-20 machines come with way extensions we have seen the problem mostly on this series machine. However it is possible for this to happen on any full enclosure machine old or new and has. It would be vise to check any of the above mentioned machine configurations for any damage that may have occurred. On BMC-30\40 full enclosure machines the extensions can and should be pinned to stop this from happening. The OEM BMC-50's the extensions were pinned and should not be a problem however they should be checked. The BMC-20 design does not allow pinning. Because it is mounted flat to the way surface any weight out on the way cover could cause the sharp edge of the extension to raise up and dig into the turcite as it passes under it. The only suggested solution is to remove the extensions and out a radius on the top edge of them where they mount to the casting. This will stop it from digging into the turcite. In some cases the extensions are physically to thick and when in place will be higher than the way surface. If this is found they will need to be ground down to be flush or lower than the way. This fix although not perfect can be done on a belt sander and needs to be done on all BMC-20's with slide ways covers. It does not take very long to do and could save weeks of down for a customer and a 3 to 4 day service call. If turcite is found to be damaged it will need to be repaired. However in most cases the damaged area can be cut out and the high spots stoned to allow the customer to at least run the machine until it can be repaired. As long as there is some turcite left it should not be a problem.

DATE: 9/28/89 SUBJECT: STRIKER PLATE HOLD-DOWN SCREWS PRODUCT LINE: BMC-30 V1 ATC ISSUE NUMBER: 1141 SUPERSEDES NUMBER: PAGE 1 OF 1
The shock absorbers on the BMC-30 Vl ATC make contact with steel "striker plates" to avoid direct contact with the soft aluminum casting. These are currently attached with quantity (4) 102-5003-002 FHSCS M5x0.8xlO which does not provide a sufficient depth of engagement. In the future these plates will be attached with quantity 4) 102-5003-004 SHCS M5x0.8xl6. these longer screws can be used for field service replacement and should work even if the first two or three threads are stripped in the aluminum casting.
ORIGINATOR: MICHAEL WATSON REVISED BY: RICHARD ARTHUR

DATE: October 19, 1989 SUBJECT: Yaskawa Spindle Drive Retrofit Kits PRODUCT LINE: MD3, MB3, MB2 ISSUE NUMBER: 1142 SUPERSEDES NUMBER: PAGE 1 OF 1
Recently some changes were to have been made to the Yaskawa Spindle Drive retrofit kits (002-2060-001, 002). These changes included changing the vendor for the Braking Resistors that are used from Yaskawa to Post Glover. This change eliminates the problem that was seen as an "OV" Fault during deceleration from a high RPM. The Post Glover resistors connect in series and do not have internal overload contacts, as opposed to the Yaskawa resistors that connected in parallel and had these contacts that connected thru the drive fault circuitry. Due to these differences. the interface schematics and Wago terminal layout of the spindle drive cabinet also changed, as did the manuals for these kits. The actual change to the Post Glover resistors has not yet been implemented because we are still waiting for the Post Glover resistors to arrive, but the manuals, schematics, etc. have been changed. Until the drive configuration is changed over to the Post Glover resistors the potential exists for the wrong documentation to be sent with the kit, or you may receive the new documentation and not be aware of which revision of the schematic matches what drive configuration. The past dive configuration is with the Yaskawa resistors, and you should use the REV. B schematics (002-2063-001 or -002). The Manuals for these kits have gray covers with a part number of 7040001-364 for MD3 and 704-0001-365 for NB2/3 and are dated April, 89. The new configuration, with the Post Glover resistors, will be implemented within the next two months or so, and for these you should use the REV. C schematics. The new manuals carry the same part number, are dated Sept. 89 and have blue plastic covers. 'The Yaskawa Braking resistors have a tan color enclosure and will have a pair of black vires along with a blue and white twisted pair connected to them. The Post Glover resistors are in a perforated aluminum enclosure and will not have the blue and white twisted pair. The Yaskawa resistors, when connected properly will have a resistance of 25 Ohms. The Post Glover resistors, when connected properly will have a resistance of 14 Ohms. ORIGINATOR: K. Perkins

DATE: 11/9/89 SUBJECT: GROUND ON ULTIMAX CONTROL CONSOLE PRODUCT LINE: ALL ULTIMAX CONTROLS ISSUE NUMBER: 1143 SUPERSEDES NUMBER:
PAGE 1 OF 1
Over the years We have had some problems vita the control locking up, jog buttons controlling the wrong axis and other various problems which are related to the CRT controller board. This board is in the process of being redesigned. but until this happens We must try to limit the situation as much as possible. The main cause of the Board being damaged is static electricity. The static and noise problem is made worse by the poor grounding found in the control head. To help solve this problem from now on any Ultimax control you are working on add a 5umper from the top half to the bottom half of the control head. This should be done on both sides of the control head. Use 2 small self tapping screws and a short piece of wire with two eyelets on the ends to insure the halves are conducting. Then run a wire to the main grounding post on the left hand side of the console.
ORIGINATOR: Randall Bryant REVISED BY:

DATE: 11/9/89 SUBJECT: Gib Adjustment PRODUCT LINE: BMC 20,30,40,50 V2 machine ISSUE NUMBER: 1144 SUPERSEDES NUMBER: PAGE 1 OF 1
In writing the BMC V2 Install Sheet I used the Engineering Document to find the information about adjusting the Gibs. Since that time I have found the current setting in the Engineering Document was wrong. and all the machines that have gone out have been adjusted to the wrong values. From this time on any time you are working on a BMC V2 machine adjust the Gibs for a current draw of 2 to 3 amperes on the BMC 20 and 30, and 3 to 4 amperes on the BMC 40 and 50 machines.

DATE: 11/10/89 SUBJECT: Replacing Hurco Amps with SERVOMATE PRODUCT LINE: Kmbx-1 Hmbx ISSUE NUMBER: 1145 SUPERSEDES NUMBER: PAGE 1 OF 4
At times we must Replace the Hurco amplifier chassis with SERVOMATE amplifier chassis. Whether this replacement is done due to the cost of the replacements or to improve the reliability of the machine. The following is a guide line we have used to make this replacement. The part number for the small SERVOMATE chassis is 402-5001-920. 1: 2: 3: Jog all axis to mid travel. Power off, Remove the three Hurco amplifiers from the chassis. Mark the motor leads and remove from TB1.
4: Mark the J connectors and unplug (P11-Z, P8-Y & P9-X). (TACH DAC LS + -) example Dwg #1 connection below. 5: Remove 115 VAC and 60 VAC red vires.
Dwg. #1 Hurco Amplifier J connectors. (P11-Z P8-Y & P9-X) Pin 1 is at the top with wires exiting to the right.
6: Unbolt the Hurco amplifier chassis and install the SERVOMATE chassis. Removing the boards makes this an easier Sob. 7: On Hurco Chassis get the vires for 115 VAC from T1, 5 6 T1,1; and the Buss voltage vires from FLB 2 & 4. Use Large Female spade terminals for (4) #10 awg vires and attach to the Fault logic board on J5 pins 1 E 2 (AC Servo Buss Voltage). The red and the white vires go to J4 1 E 2 {115 VAC). ORIGINATOR: Brock Rexing E Randall Bryant
Replacement of Hurco amplifiers with SERVOMATE.

8: Working with one axis at a time connect the wiring to match the SERVOMATE TB strip shown in DWG #2. DWG #2. SERVOMATE Terminal buss.
9: Add jumpers from TACH to DAC (9 to 12 for Z, 17 to 20 for Y, 25 to 28 for X). Amplifier ad1ustments: Note: Attempt to adjust only one amplifier at a time. Disconnect the other amplifiers as they all interact. 1: Starting with the X axis amplifier follow the standard BX pot presets. SIG 20 CW then CCW 5 turns Aux 20 CCW turns TACH 20 CW turns BAL 20 CW then 10 CCW turns GAIN 20 CW the 5 CCW turns CLM 20 turns 2: Verify correct motor lead polarity, power up, load the master. Push, Power On, Check, Enter and Operate with your hand on the Estop button in case of axis runaway. Helpful Hints: If the axis runs away try reversing the motor leads. If the axis Oscillates try reversing TACH leads. All machines may not be wired the same way, so you may have to find the correct combination of, TACH, DAC, and Motor wires. Note if the DAC is + the TACH is A Voltage they oppose each other. Use and Ohm meter to verify the polarity of the DAC wire to the servo control board J2-X J3-Y J4-Z pins 8 and 9 of each plug.
3: Before proceeding with the amplifiers fine tuning, verify that when the PLUS + LS is displayed on the CRT that the axis will move in the MINUS direction. Use a screwdriver to actuate the LS. Then check the LS for PLUS + movement only when the MINUS LS is shown. If this is not correct reverse LS +- at the SERVOMATE RTB. 4: Proceed with the standard BX SERVOMATE setup procedure, adjust the gain pot until axis oscillation starts the back off three to five turns, (use o'scope on the motor vires). 5: Adjust the SIG pot to measure .65vdc on pins 8 and 9 of SJ2-3-4. at 25ipm. Note you may have to adjust the TACH pot if you are are unable to achieve .65vdc with the SIG pot alone.
DATE: 12-01-89 SUBJECT: Yaskawa Orient Modification PRODUCT LINE: All V2-BMC Mills
ISSUE NUMBER: 1146A SUPERSEDES NUMBER:1146 PAGE 1 OF 5
In order to better monitor "Orient End" and prevent accidental damage to the machine or injury to the operator the following modifications should be made. Modification of the orient card will change the pull-up resistor on the "In Position" signal to a pull-down, allowing the spindle drive to recognize problems caused by intermittent connections between the orient sensor and the drive, or displacement of the spindle by the operator. A spindle axis firmware change is also required to continuously monitor the "Orient End" (ORE) signal. This firmware will correct the problem in BMC-50's when making a tool change from 600RPM. The dual winding machines will now orient in both high and low winding, requiring that the orient card setup be changed. To prevent the possibility of switching the cables for the spindle encoder (3CN) and the orient amplifier (5CN), a key will be added to the 5CN connector. Before starting this modification please verify that the ORIENT CARD has not been modified previously or is not the new style. See page 4 to determine if new style board. Parts required to complete this modification: 1 Spindle Axis PROM 450-3001-512 1 Resistor, 30.1K 1/4W 1% 407-0035-430 2" Heatshrink, 1/8" 406-6481-002 1 Contact, Male (Honda) 406-0811-008 Special Tools required: Honda Pin Extractor

Documentation Required: Spindle Drive Setup 757-4001-093 Rev. C What to do 1. Power off the machine and remove the Orient PCB from the spindle drive. Cut off R123 (located near 5CN - See drawing Page 5) from the PCB. Install a 30.1K Ohm, 1/4 Watt, 1%, "Metal Film" resistor to the solder side of the PCB from pin 16 of 5CN to the center pin of S23. Insure the leads are insulated with 1/8" heatshrink. 2. To distinguish modified boards, change the PCB number and type at the top of the PCB with a permanent marker as follows. "TYPE" JPAC-C345 change to JPAC-C345-YA "CODE NO." ETC008611 change to ETC503070 3. Remove the cover from connector 5CN, extract the female pin 13 (this pin should not have a wire in it) and replace it with a male pin (406-0811-008). Note that the mating pin on the PCB has already been cut off by Yaskawa. 4. Replace cover on connector and reinstall orient PCB. 5. Install new spindle axis firmware (450-3001-512). 6. Power on machine and follow the "Orient Setup" in the attached spindle drive setup (757-4001-093 Rev. C). Note: Check all drive Parameters (CN01 though CN40) to ensure they are correct. Power the machine off/on after changes have been made, to reload the Nonvolatile RAM. 7. Cycle the ATC (50 changes minimum) using several tools with the RPM set for both high and low winding ranges. Ensure that the orient position is correct for both windings. The new style Orient board looks very similar to the original board. The differences are, the new board has a shunt just above U38. U38 is in the lower right section of the board. See drawing "B" on page 4 of 5 and there is a resistor in the old R123 location. Also the identification numbers on the board have been changed. See below.
"TYPE" JAPC-C345 and "CODE" ETC008612
FSB XXX Page 2 of 5
There are some boards that have been modified by the manufacturers. These boards can be identified by R123 having been removed and by the type and code as listed below. "TYPE" JAPC-C345YA and "CODE" ETC503080
If you have problems or question please call me. EXT 2640
ORIGINATOR: Dale Clark REVISED BY: Lonnie Leffew DATE: MARCH 31,1991
FSB XXX Page 3 of 5
FSB xxxx Page 4 of 5
FSB XXX Page 5 of 5

DATE: 12/12/89 SUBJECT: ATC STRIKER PLATE HOLD-DOWN SCREWS PRODUCT LINE: BMC 30 V1 ATC ISSUE NUMBER: 1147 SUPERSEDES NUMBER:
PAGE 1 OF 1
The shock absorbers on the BMC-30 V1 ATC make contact with steel "striker plates" to avoid direct contact with the soft aluminum casting. These are currently attached with quantity (4) 102-5003-002 M5 X .8 X 10 which does not provide a sufficient length of thread. In the future these plates will be attached with quantity (4) 102-5003-004 FHSCS M5 X .8 X 16. These longer screws can be used for Field Service replacement and should work even if the first two or three threads are stripped in the aluminum casting.
ORIGINATOR: RICHARD ARTHUR TECHNICAL SPECIALIST REVISED BY:

DATE: 12/11/89 SUBJECT: TOOL CHANGER MAGAZINE AIR CYLINDER SET SCREW PRODUCT LINE: BMC 30 ISSUE NUMBER: 1149 SUPERCEDES NUMBER 1148
PAGE 1 OF 2
It has come to my attention that we use (3) different set screws on the BMC 30 tool magazine air cylinders. this is to try and clarify these different set screws. P/N8022324006: This 3 inch set screw has a counterbore and 1s used on any BMC ATC with an 8 inch stroke cylinder, prior to the V2 model tool changer. The V2 model tool changer will use the part number 80223244 001 three inch set screw. P/N8022324001: This 4 inch set screw is for Field Service use only and is used on tool changer with 7 1/2 inch stroke cylinder. P/N8022324001: This 3 inch set screw is currently used on the BMC 20 tool changer and does not have the counterbore. I, also am including 1nstructions for adjusting the cushions with this set screw. I hope this clarifies the confusion, if you have any questions please contact Technical Support.
ORIGINATOR: RICHARD ARTHUR TECHNICAL SPECIALIST REVISED BY:

DATE: 01/18/90 SUBJECT: CONTROL RESIDENT DIAGNOSTICS PRODUCT LINE: ALL ULTIMAX II MILLS ISSUE NUMBER: 1150 SUPERSEDES NUMBER: PAGE 1 OF 2
PURPOSE: The Control Resident Diagnostics Executive vas designed to execute within the normal operation of the ULTIMAX control. However, the Control Resident Diagnostics may only be accessed in mills with ULTIMAX II controls with version 8.00 or greater. This Field Service Bulletin explains how to use the Control Resident Diagnostics Executive in all other ULTIMAX II mills. Supplied with the Control Resident Diagnostics Field Service Kit (P/N 002-3417-002) are the following items: l. 2. 3. 4. 5. 6. 7. 8. 9. 10a. 10b. 704-0001-545 423-9000-001 423-9000-002 423-9000-003 423-9000-004 415-0196-001T 415-0197-001T 415-0198-001T 450-3001-vvv 415-0168-xxx 450-3002-yyy through zzz Note 1: Items 9, 10a, and 10b, Part Numbers are not completely provided because they will change with each new release of ULTIMAX II Software. Note 2: Items 10a and 10b can be used in any machine with an Ultimax II Control, but only to use the Control Resident Diagnostics. The Control Resident Diagnostics Manual provides instruction using the Test Connectors, the Test Cables and the Breakout Boards, but assumes that the control already has the Diagnostics resident in the Executive. Control Resident Diagnostics Manual RS-232 MIL Circle Test Connector RS-232 DB-25 Test Connector I/O Test Cable, MP/J1 to MP/J3 Dual Axis Test Cable 25-pin Breakout Board 37-oin Breakout Board 50-pin Breakout Board BMC 20-50 (VC) Axis Firmware BMC 20-50 STD/GER Memory Board BMC 20-50 STD/GER EPROM's
To set up a mill with the Control Resident Diagnostics Executive, power the mill to off and remove the MM8800C Memory PCB from the card rack. If the BMC 20-50 Memory Board (item 10a above) is provided, install the BMC 20-50 Memory Board in place of the current Memory Board. If the BMC 20-50 EPROM's (item 10b) are provided, remove the current Memory Board and replace the V65-V76 EPROM's with the BMC 20-50 EPROM's U65-U76; reinstall the Memory Board. CAUTION: Item 10a or 10b nay be installed in any other Ultimax II mill for the execution of the Control Resident Diagnostics only; remove the item from the Control when testing is complete. CONTROL RESIDENT DIAGNOSTICS FIRMWARE SETUP Within the Interactive Diagnostics of Control Resident Diagnostics are tests for the Dual Axis Boards and the Display of System Switch Settings; these tests require the new Axis Firmware. Since only one Firmware EPROM is provided, only one axis may be tested at any time. Remove the appropriate Dual Axis Board and replace the current Axis Firmware EPROM with the BMC 20-50 Axis Firmware EPROM (item 9) using the following Axis Chart : ZS DUAL axis PCB U45 U48 Spindle Axis Z Axis XY DUAL AXIS PCB Y Axis X Axis AB DUAL AXIS PCB B Axis A Axis
The BMC 20-50 Axis Firmware EPROM may also be used in place of the Spindle Axis Firmware EPROM. For the Display of System Switch Settings test, only one axis of the Dual Axis Board with the BMC 20-50 Axis Firmware EPROM installed will display the switch settings properly. Switch blocks S2 and S3 of the Dual Axis Board correlate to the U45 Axis Firmware EPROM while Switch blocks S4 and S5 correlate to the U48 Firmware EPROM. Note: When installing the BMC 20-50 Axis Firmware EPROM, make sure that all of the other current Firmware EPROM's are installed. Caution: Item 9 may be installed in any other ULTIMAX II mill type to execute the Dual Axis Tests only of the Control Resident Diagnostics; remove the item from the Control when testing is complete.
ORIGINATOR: DAVE SKRZYCZAK
DATE: 1-12-90 SUBJECT: 5 GALLON FLOOD FILTER PRODUCT LINE: BMC 20-50 V2
There have been some instances where the new style 5 gallon flood filters have caused the system to loose prime. If this occurs it will be necessary to verify that the filtering element is not clogged, that the PVC piping within the filter has been glued together properly, and the lid/fittings are sealed proper. A thin film of an oil based lubricant around the lid gasket, v111 aid in prolonging the life of the gasket and improve an air tight seal. Part no. 617-0008-002 Filter
If the system looses prime and the flood pump is allowed to run for a long period of time, the shaft seals on this pump may become damaged. If this happens the motor/pump will need to be replaced. Part no. 509-0002-001 Motor/pump
If the need arises to replace an older flood motor/pump use Part no. 002-3915-006 on the parts list doc. This is a field service replacement KIT for the early OEM system converting to the current production style.
ORIGINATOR: Brock Rexing REVISED BY:
DATE: 1-11-90 SUBJECT: REPLACEMENT OF KNEE MILL MOTORS AND ENCODERS PRODUCT LINE: KM3/3P
PAGE 1 OF 1
As of Oct. 1988 Electrocraft is supplying Hurco with an MTE ASSY. incorporatlnq an industrial qrade BEI encoder. To identify this motor, it has a Blue Label with a part no. 002-2490-005 on it. The encoder shaft is the coupling, there are no stand offs as the rear cover mounts directly to the back of the encoder. While customers are under WARRANTY, and the need arises to replace either the motor or encoder, use an MTE Assemblie. 002-2490-008 as this is the ONLY way HURCO can return the parts to Electrocraft per our warranty agreement with them. As the machines go out of warranty, and the need arises to replace only the Industrial BEI encoder use part no. 002-2490-007. The early style motor used on the KM3/3P, can be identified by a RED label and used an instrument qrade Litton, Datametrics, or BEI encoder. And has stand offs for the rear motor cover, a separate coupling, and a housing mounting bracket to attach the encoder to the motor. The Part Number for this encoder remains the same 002-2490-002. Be advised that we have two MTE assemblies in stock, both of which will have an Industrial grade BEI encoder in the assy. 1.) CUSTOMER REPLACEMENT ONLY* 002-2490-003R comes with a black pin pusher and a removal / installation procedure. 2.) SERVICE ENGINEER REPLACEMENT 002-2490-008 MTE ASSY as the service engineer has a pin pusher in his tool kit.
ORIGINATOR: Randall Bryant REVISED BY: Brock Rexing
DATE: 1/30/90 SUBJECT: CUSTOMER SUPPLY POWER RELATED PROBLEMS PRODUCT LINE: ALL MILLS
PAGE 1 OF 1
We have found that many ongoing problems with some mills are actually related to incoming power problems. These problems may show up as intermittent servo/spindle faults, computer lockups, and an unusual number of board failures. In the past we sent a serviceman in with a Dranetz Line Analyzer which vas installed, then we had to return to disconnect the device and evaluate the chart. In the future we will send the customer a Transient Suppression Unit with the understanding that he may try it for thirty days. If he does not feel it corrected the situation he may return it for a full refund. At the time the order is placed we will need a purchase order number. We do not consider this part of the machine warranty since the customer is responsible for furnishing acceptable power. We have two different Transient Eliminates devices, the first is a three phase unit and will normally be used with bed mills. This devise should be suggested if besides control lockups and unusual amount of board failures you also get axis and spindle drive failures. This unit is designed to protect the entire machine. The other device is a single phase unit and is used to protect the DC supply, this devise is suggested if you see constant control lockups or an unusual amount of PC board failures. this device is suggested for any mill. If you feel that power protect is advised, please consult with any Technical Specialist so the machine may be monitored as to the effectiveness of the devise. Listed are the Hurco part numbers and a description of each device. P/N 417-5001-017 Transient Eliminator TE110JR is a single phase 110 device used to protect the DC power supply. This is suggested for all knee mills and for bed mills that show control problems, but display no axis or spindle drive problems. P/N 417-5001-018 Transient Eliminator TE600 is a three phase device which should only be suggested for bed mills display axis and spindle drive problems in addition to control problems. ORIGINATOR: RICHARD E. ARTHUR TECHNICAL SPECIALIST
DATE: 11 January, 1990 SUBJECT: DAC Offset PCB Failures
PRODUCT LINE: Dual Axis Board with DAC Offset PCB attached
The Test and Repair department has reported a number of Dual Axis boards (equipped with the DAC Offset PCB) returned to them as failed boards. The problem with most was simply that the DAC Offset "Piggyback" board was loose. The assemblies were repaired by reseating this attached board. Please be aware of this and check the integrity of the connection before ordering or replacing this board when a failure is indicated. The machines this effects are BMC V2 Mills and all Deckel mills equipped with Ultimax controls. Also soon, this will include the OEM and Vl mills that have 8.0 software incorporated.
ORIGINATOR: Paul Chambers REVISED BY:

DATE: 4/20/90 SUBJECT: COUNTER WEIGHT (UPPER) ISSUE NUMBER: 1155 SUPERSEDES NUMBER:
PRODUCT LINE: BMC 40 IP PAGE 1 OF 3 Procedure to add an upper weight to the existing counter weight on BMC 40 IP machines. Note: All of these machines currently in the field have been flagged and each customer with a BMC-40-IP will receive this weight over the course of the next few weeks, THIS IS THE ONLY PROCEDURE TO FOLLOW AS DEVIATION TO THIS PROCEDURE MAY CAUSE DAMAGE TO THE MACHINE AND OR PERSONAL INJURY.
All directions are called out as if standing in the front, facing the Machine, as the operator would. 1. Jog the "Z" axis down to the minus limit switch, place a "steel" bar into the access hole located on the lower left side of the column, slowly jog the "Z" axis up until the counter weight will rest on the bar, see attached DWG, pg. 3. 2. Place support (wood 2X4) between the rear of the counter weight and the inside of column to support the counter weight from shifting during the next few steps, see attached DWG, pg. 4. **NOTE*
At this point make certain that the chains are still taught and the weight is resting on the bar. If the existing counter weight has an eye bolt, remove it. 3. Locate and remove the left bolt on the support bracket, {used to support the counter weight during shipment), pivot this bracket out of the way and reinstall same bolt using lock-tight 271, see attached DWG, pg. 4. 4. Remove the other (right) bolt holding the support bracket, discard bracket and bolt. From this point, remove and discard bolt located diagonally holding the plate to the counter weight, clean this surface, see attached DWG, pg. 4.
DATE: 5/24/90 SUBJECT: NEW ISOLATION TRANSFORMER PRODUCT LINE: BMC 20-50
ISSUE NUMBER: 1156 SUPERSEDES NUMBER: PAGE 1 OP 3
BED MILLS ARE PRESENTLY BEING BUILT WITH A NEW TRANSFORMER MOUNTED TO THE CABINETS. SHAPE TRANSFORMER MODEL Z-1321, 413-0003-1071 IS FOR BMC 20 AND MODEL Z-1322, 413-0003-1081 IS FOR BMC 30-50. SHAPE TRANSFORMER MODEL Z-1332i 413-0003-109i IS FOR ASIAN MACHINES WITH 380 AND 415VAC TAPS. REFER TO THE DRAWING NOTES FOR CONNECTIONS USING THE APPROPRIATE PRIMARY TAPS AND 208VAC SECONDARY TAPS. THE COOLANT PUMP MOTOR WILL BE CONNECTED TO THE 208VAC TAP.
ORIGINATOR: MATT WARNER REVISED BY:
DATE: 6/18/90 SUBJECT: CONSOLE CRT GROUNDING PRODUCT LINE: BMC20-50, MILLS, FP3A/4A
ISSUE NUMBER: 1157A SUPERSEDES NUMBER: 1157 PAGE 1 OF 1
Effective immediately, modifications to separate the console CRT grounds from their respective CRT PCB ground are to be discontinued (refer to original issue of FSB 1577 released 5/25/90). Separation of these grounds will result in any or all of the following problems, flyback circuit instability, increased console DC voltage noise levels, and masking of possible CRT defects caused during vendor manufacturing processes or through improper shipping and handling procedures. The CRT's should be wired as follows. The ground wire connected at the back of the tube should be connected to the CRT PCB at J401. The ground wire that connects to the console door ground stud between the CRT PCB's should be connected to CRT PCB J104. All Field Service engineers are requested to report customer names, machine types, and if possible serial numbers of machines on which this modification vas implemented. This information must be given to Hurco Indianapolis, Field Service schedulers. In addition, on any new machine shipped in April, May, and June console CRT wiring should be checked to insure that it is wired per the above instructions. If you have any questions concerning this bulletin please call the Field Service Technical Specialists.
ORIGINATOR: REVISED BY: TOM MURDEN
DATE: 06/01/90 SUBJECT: Measuring Backlash PRODUCT LINE: All Mills
ISSUE NUMBER: 1158 SUPERSEDES NUMBER: PAGE 1 OF
In order to establish a common method assuring the axes backlash the following is set forth as the only service approved standard for backlash measurement.
Required Equipment: .0001 inch indicator. Tool holder for indicator. A flat surface (i.e. vise). Definition: Backlash is the difference in axis travel that occurs when an axis direction is changed. This is usually do to mechanical looseness in the axis (i.e. worn thrust bearings or ballscrews). Remove all backlash strapping from the machine. It is required that you write a program of position blocks to do the test. Bring the indicator against the flat surface. Zero the indicator, then zero the machine reference at this point. Bring the indicator up from the surface and position the axis .5 inch further in the same direction. Reverse the travel and bring the axis back to the machine zero. Lower the indicator. The difference on the indicator is the backlash. Repeat this process four time and average the readings. This is the backlash in the axis. Use strapping charts to adjust the backlash to the new value.

DATE: 06/04/90 SUBJECT: Board Cleaning PRODUCT LINE: All Mills ISSUE NUMBER: 1159 SUPERSEDES NUMBER: PAGE 1 OF 2
One of the most important operations in a good preventive maintenance program is regular and thorough cleaning of the system. In any system dust builds up. Any smoke or other particulate or chemical matter that is in the environment is drawn into the system and collects on everything. This dust and garbage buildup can cause severe problems in a system if allowed to go unchecked. The dust layer acts as an insulator to heat, which prevents proper cooling of the system and may cause a system to overheat and damage components. The dust may contain other chemicals. These chemicals can conduct electricity, causing minor current shorts and electrical signal paths where they should not be. The chemicals also rapidly accelerate corrosion on any of the components in the system that are installed in sockets or where boards plug into slots. Cable connectors also can be affected by this corrosion. Floppy disk drives are another location where contamination can cause damage. To properly clean the system you need several items and tools. Beyond the tools that are normally required you will need the following.
Freon TF or Isopropyl alcohol. The cleaning material must be moisture and residue free. Pure Freon TF is best. Small brush. Gold wipes for cleaning the edge connectors. * Antistatic kit. * Vacuum cleaner. * 3.5 inch disk drive "wet" cleaning kit. Foam swabs
Reseating Socketed Chips: One of the primary preventive maintenance functions is to undo the effects of "chip creep." As the system heats and cools, it also expands and contracts. This physical expansion and contraction causes any components plugged into sockets to gradually work their way out of those sockets. For this reason, you need to find all the socketed components in the system and properly reseat them. Cleaning the Boards: The next step is to clean the boards and all connectors in the system. The first thing to do is clean the dust and debris off the board itself and then clean the edge connectors on the board. To clean the boards, first use the brush to gently wipe the boards, loosening and removing any dust and debris. You use the brush because simply blasting the board with compressed air does not remove all the dirt and dust There is also the possibility that you could drive the debris under the components. After you loosen the dirt and dust you can then use the "vacuum" to remove the debris. CAUTION: BE Careful OF STATIC WEAR THE STATIC STRAP AND USE ALL STATIC PRECAUTIONS. If at this point you still find dirt or debris on the board use the liquid cleaning solution and swabs to remove it. Then use the "Gold Wipes" to clean the edge connectors. Cleaning Connectors and Contacts: On the backplane you will want to clean the slot connectors. First vacuum the dirt and debris from the boards or cable. Then use the "Gold Wipes" or a swab with solution on it, to wipe the connector clean. Do not use a pink eraser to clean the board connectors as it removes the gold from the contact and this will then cause the contact to corrode faster. This in turn causes the contact to need cleaning more often. On the cable connectors use "Gold Wipes" where you can, then use the swabs to clean the other pins and places where the wipes will not reach. Disk Drives:
Use the brush to clean dust and debris from the drive then use the wet head cleaner kit to clean the disk heads. Don't forget to clean the cable plugs on the drives. Note: The Anti Static Vacuums will come after we have started the maintenance program, so use the brush to clean the boards.

DATE: 6/04/90 SUBJECT: New Field Service Accuracy Standard PRODUCT LINE: All Mill ISSUE NUMBER: 1160 SUPERSEDES NUMBER: PAGE 1 OF 1
You will soon be receiving a metal bar that has been measured on the CMM here at Hurco for its length. This dimension will be stamped into the metal. This standard will allow us to quickly and easily check a machine for accuracy. The length will be slightly over 13 inches. This size will allow you the ability to see the Leadscrew compensation in the older machines and still be small enough for use on the knee mills. To use the standard first allow it to reach the same temperature as the machine, this could take up to one hour. Take the time don't hurry! Place the standard perpendicular to the axis. It must be within .0001" from end to end. Using your indicator reference the part Zero on the end that does not have the tab (A). Program the axis to move the distance marked on the standard. Indicate the inside of the tab (B) the distance shown moved on the control should be the same as the distance marked on the standard taking into account the tolerances for the machine type.

DATE: 08/06/90 SUBJECT: Oil Cooler Contactor Mis-wire PRODUCT LINE: BMC 30 Thru 50 IP ISSUE NUMBER: 1161 SUPERSEDES NUMBER: PAGE 1 OF 4
We have recently changed from GE to Square D starter and heaters on BMC mills. Two problems must be corrected. Problem 1: On all mills with Square D (FCS A OCS) parts prior to August shipment the 115vac control line to the coil is connected at "A1" (white wire) and "96" (Red wire). 7he Red wire must be moved to "95" To provide over current protection.
To correct first find the cable from TB1-4,8,10 to OCS-1 (L1), 3 (L2), 5 (L3) (on machines with MRP & ARP boards TB 1 - 3,6,8 ) Remove the red wire at both ends insulate and leave in wireway, in case of 3 phase oil cooler replacement in the future. Connect white to OCS-1 (L1), black to OCS-3 (L2). Add 14 AWG black wire from OCS-5 (L3) to OCS-4 (T2). Connect cable to chiller, white OCS-2 (T1), black to OCS-6 (T3). Connect cable to suppressor board as follows, white to OCS-2 (T1), Black to OCS6 (T3), again leave the red wire in wireway. At the suppressor board TB 30-6 remove the red wire, black should be connected at TB 30-9 and white at TB 30-8.
Originator: Dale Clark

DATE: 13 SEPTEMBER 1990 SUBJECT: TORQUE SETTINGS FOR AXIS BEARINGS PRODUCT LINE: ALL HURCO MILLS ISSUE NUMBER: 1162 SUPERSEDES NUMBER: PAGE 1 OF 1
The following is a listing of all torque settings for axis bearings on the Hurco Milling machines:
MACHINE TYPE
AXIS
SETTING IN FT / LBS.
KM-1, KMB-1, 1m, KM-3/3P, SM1-CNC, MB-1, BMC-20, MD-1 MB-2, MB-3, MD-3, BMC-10, BMC-30 BMC-15, BMC-40, BMC-50 40 SLV
ALL
45-50
ALL
65
ALL ALL
85-90 55
DATE: 13 SEPTEMBER 1990 SUBJECT: TOOL RETENTION FORCES PRODUCT LINE: BMC MILLS
The following tool retention force specifications have been agreed to with LEADWELL. This applies to both Hurco Inc. and Hurco Ltd. MACHINE TYPE MAXIMUM MINIMUM
BMC-20 BMC-25 BMC-30 BMC-40 BMC-50
3.91 Kn. 8.12 Kn. 8.12 Kn. 8. 12 Kn. 13.7 Kn.
3. 6 Kn. 7.3 Kn. 7.3 Kn. 7.3 Kn. 12.3 Kn.
Specification may be exceeded slightly but must unclamp at 90 PSI. Settings must NOT be below minimum. Use the following formula to convert Kn. to Foot Lbs. 224.754 * Kn. = Ft. Lbs.
MEASURING RETENTION FORCE

1. Release the automatic draw in mechanism 2. Insert the DELTA CONTROL measuring system into the spindle by hand and operate the automatic draw-in mechanism. 3- Read off the draw-in force and record the figure. 4. Grip the DELTA CONTROL measuring system by hand and release the automatic draw-in mechanism. 5. Repeat the measurement in the 180 degree opposite position. 6. Repeat steps 2 to 5 another 3 times so that an average value can be obtained and any irregularities in the draw-in mechanism can be discovered. 7. Remove and clean the DELTA CONTROL measuring system after use and place it in its wooden box.

DATE: 01/09/89 SUBJECT: Service call check list PRODUCT LINE: All Machines ISSUE NUMBER: 1164 SUPERSEDES NUMBER: PAGE 1 OF 3
The following items should be checked on a machine on every service call whether they relate to the problem you were called in for or not. By doing these checks you may be able to save a future service call by spotting a potential problem.
SOFTWARE
Check to make sure the correct and latest software and firmware is installed in the machine.
VOLTAGE CHECKS
1) Incoming Power. +/-10% 2) 115U supply voltage. 110-130 3) Power supply voltages 4) Servo Bus supply voltage 5) Spindle and Servo drive voltages (BMC) On the BMC 20/50 series machines verify that the voltage to the spindle drive is as close to 200V as possible. Retap the main input transformer if necessary. Check the servo transformer for correct output voltage and correct if necessary.
CONNECTIONS
1) Check cabling to the card rack, relay panels and terminal strips for tightness. 2) Make sure all relays are properly seated. 3) Check all external wiring for looseness and or damage. On KM style machines verify that the cable clamps have been installed.
SETUP PROCEDURES
Go through the complete amplifier setup procedure. Verify smooth axis operation. Amplifiers which are out of adjustment can cause positioning and motion error problems.
MECHANICAL
1) Visually inspect the machine for excessive dirt and chip buildup. If the machine looks unkept and not properly maintained bring it to the customers attention and document it on your service report. Instruct the customer \ operator on critical areas to keep clean if this does not appear to be being done. (I.e. around limit switches, way covers, tool changer and ballscrews.) 2) Check all machine covers for damage or binding. 3) Verify all fans are running and check filters to make sure they are being regularly cleaned and changed.
LUBRICATION
1) Inspect all oiled surfaces for adequate lubrication. 2) Inspect all grease points for new and clean grease. (especially M1\MB1\MD1) 3) Check lube reservoir level and the type of oil they are using. Verify oiler and timer operation.
AIR
1) Verify correct air pressure to the machine. 2) Check air lube reservoir for oil. 3) Check water bowl for excessive water in air lines. All tool changers on Hurco machines almost exclusively use air pressure for tool changer operation. It is important to verify that the machine has a large volume of clean dry air supplied to it. It is the responsibility of the customer to provide this to the machine. If there is a problem with the air bring it to the customers attention and document it.
AIR HOSES
Hurco does not recommend the use of air hoses to clean chips from the machine. High pressure air can lodge chips in areas of the machine which can cause excessive damage. We can not stop customers from using them on the machines but we can recommend alternative methods. (vacuum systems). If you see situations where operators are blowing chips indiscriminately explain to them the problems which can arise from such action and instruct them to blow chips away from areas where the most damage can be done.
FINAL CHECK
Before turning a machine over to a customer it is important to verify proper machine operation. The only way to do this is to program the machine and allow it to run for a while in automatic mode. A simple program including drill, tap and mill routines with multiple tools, speeds and feeds will exercise all axis, the spindle, tool changer and control. Watch for smooth tool changer operation. After cycling for a while position the table to machine zero and verify positioning accuracy with the marker.
DATE: February 13, 1992 SUBJECT: Futaba Pulscale CMK Parameters PRODUCT LINE: Eltee TRM21/39 EP300CP
ISSUE NUMBER: 1165-A SUPERSEDES NUMBER:1165 PAGE 1 OF 2
Parameter settings for the Futaba CMK DRO in current production. Default settings 1. Hold down the Xo key, then turn on the power. Ready will appear on the display. Press Enter and the counter will take three steps to write-in the default settings. These steps are called Pass-1, Pass-2, and Pass-3 on the display. Changing a parameter setting 1. Hold the Unit key and turn power on. The display flashs SP. Press Xo key and the parameter data is displayed. Depressing the Xo key switches the display from Parameter #(ie..SP01) to Parameter Data(00000000). 2. With SP01 displayed depress 2, enter, and Parameter #2 is displayed. 3. To change data in a parameter, use the 0-9 keys and press Enter. Note:For SP#1,6,7,37, and 49 select the proper axis before keying in the data. 4. Data settings for steps 2-3 can be verified with chart on page 2. 5. Turn the power off/on. Parameter change is effective on power up.
ORIGINATOR: Brock Rexing REVISED BY: Richard Arthur

SP# 1 2 4 5 6 7 30 31 34 35 36 37 38 40 49
TRM21 PARAMETERS 00001001 X 00001001 Y 00001001 Z 0.000 0.000 0.000 +105.0000 X +100.0000 Y +160.0000 Z -105.0000 X -100.0000 Y -160.0000 Z 00000000 X 00000000 Y 00000001 Z 00000000 00000000 00100000 01111000 01000010 X 00000000 Y 00000000 Z 01001001 00000000 00000000 X 00000000 Y 00000000 Z
PARAMETER DESCRIPTION SCALE RESOLUTION REFERENCE POINT SHIFT EDGE SENSOR SHIFT LOST MOTION COMPENSATION + SOFTWARE LIMITS - SOFTWARE LIMITS SCALE POLARITY SMOOTHING PRINTER INTERFACE RS-232 BAUD RS-232C MODE DIRECTION TO RETURN POINT MODE/EDM DISPLAY POWER LOSS MEMORY INCH/MM OPERATION
NOTES 00001000=.5um 00001100=10um 00001001= 1um 00001101=25um 00001011= 5um 00001110=50um
MUST SET FOR EACH AXIS SCALE MUST SET FOR EACH AXIS SCALE NOTE Z POLARITY
DATA IS SET IN X AXIS
00000010= MM ONLY OPERATION 00000000= INCH/MM OPERATION
DATE: March 3, 1992 SUBJECT: Futaba Pulscale CMK Parameters PRODUCT LINE: Eltee TRM21/39 EP300CP
ISSUE NUMBER: 1165-B SUPERSEDES NUMBER:1165 & 1165A PAGE 1 OF 2
Parameter settings for the Futaba CMK DRO in current production. Default settings 1. Hold down the Xo key, then turn on the power. Ready will appear on the display. Press Enter and the counter will take three steps to write-in the default settings. These steps are called Pass-1, Pass-2, and Pass-3 on the display. Changing a parameter setting 1. Hold the Unit key and turn power on. The display flashs SP. Press Xo key and the parameter data is displayed. Depressing the Xo key switches the display from Parameter #(ie..SP01) to Parameter Data(00000000). 2. With SP01 displayed depress 2, enter, and Parameter #2 is displayed. 3. To change data in a parameter, use the 0-9 keys and press Enter. Note:For SP#1,6,7,37, and 49 select the proper axis before keying in the data. 4. Data settings for steps 2-3 can be verified with chart on page 2. 5. Turn the power off/on. Parameter change is effective on power up.
ORIGINATOR: Brock Rexing REVISED BY: Richard Arthur

SP# 1 2 4 5 6 7 30 31 34 35 36 37 38 40 49
PARAMETER DESCRIPTION SCALE RESOLUTION REFERENCE POINT SHIFT EDGE SENSOR SHIFT LOST MOTION COMPENSATION + SOFTWARE LIMITS - SOFTWARE LIMITS SCALE POLARITY SMOOTHING PRINTER INTERFACE RS-232 BAUD RS-232C MODE DIRECTION TO RETURN POINT MODE/EDM DISPLAY POWER LOSS MEMORY INCH/MM OPERATION
NOTES 00001000=.5um 00001100=10um 00001001= 1um 00001101=25um 00001011= 5um 00001110=50um
MUST SET FOR EACH AXIS SCALE MUST SET FOR EACH AXIS SCALE NOTE Z POLARITY
DATA IS SET IN X AXIS
00000010= MM ONLY OPERATION 00000000= INCH/MM OPERATION

DATE: 06 NOV. 90 SUBJECT: DRAWBAR PRODUCT LINE: KM5P ISSUE NUMBER: 1166 SUPERSEDES NUMBER: PAGE 1 OF 1
Manufacturing discovered that the Drawbar in the KM5P will create a loud noise and possible failure when in low gear. On two occasions the tool holder came loose during cutting. The Drawbar was almost to a complete stop with the spindle in motion when the loud noise was observed. The loud noise vas corrected by removing the nylon bushing from the Drawbar. Topwell uses a nylon bushing on the manual Drawbar; therefore, the power Drawbar was designed to use a nylon bushing. Engineering determined that the nylon bushing is not needed; moreover, Drawbar performance is increased when the nylon bushing is removed. Machines in the field that shipped prior to 31 0CT. 90 need to have the nylon bushing removed from the Drawbar.
ORIGINATOR: Gregg A. Wallace REVISED BY:
DATE: 11/30/90 SUBJECT: AXIS PULLEY LOCKING ELEMENTS PRODUCT LINE: KM5P
All KM5P machines need to have split locking elements in the axis pulleys. Some of the early machines were shipped with solid locking elements which will permit the pulley to slip on the ballscrew. As of September 28, 1990 all KM5P machines have split locking elements No. 219-0001-027. Two sets of split locking elements are needed for each of the three axis pulleys. The X-axis and Y-axis pulleys are easy to service; although, the head needs to be removed to service the Z-axis pulley.
ORIGINATOR: Gregg Wallace REVISED BY:

DATE: 12/11/90 SUBJECT: KM5P DRAWBAR PRODUCT LINE: KM5P ISSUE NUMBER: 1168 SUPERSEDES NUMBER: PAGE 1 OF 2
The KM5P drawbars are not piloting into the spindle shaft. The pilot diameter (.705 inches dia.) on the drawbar is not long enough which can lead to unthreading of the tool holder. The pilot diameter has been lengthened from .38 to .51 inches on PIN No. 11094. This revision effects the next order which will be seen on September 1991 machines for 5/8-11 threaded drawbars. This revision will be seen on March 1991 machines for M16x2 threaded drawbars. Until the new revision is shipped the drawbars will be modified for correct piloting. The bottom shoulder will be turned back .05 inches which will change the head length from 6.500 to 6.450 inches (shoulder to shoulder). The drawbar setup height (distance from the top of the drawbar spline to the top of the head casting bearing plate) will now be .95/.90 inches compared to the factory setting of 1.00/.95 inches. The following machines need to have the drawbars modified:
1. 2. 3. 4. 5. 6. 7. 8. 9.
KT9003090A KT9005090A KT9001080A KT9001100A KT9002100A KT9003100A KT9004100A KT9005100A KT9006100A ORIGINATOR: Gregg A. Wallace REVISED BY:

DATE: 12/14/90 SUBJECT: NUISANCE V2 ROTARY ERRORS DURING PARK MACHINE PRODUCT LINE: V2 BMC20-50 NON MRP/ARP WITH 4TH AXIS ROTARY OPTIONS ISSUE NUMBER: 1169 SUPERSEDES NUMBER:
PAGE 1 OF 1
The following applies to all V2 BMC machines with rotary options which have the rotary interface terminal strip and brake relay mounted on the DIN rail next to the machine relays. When a park machine command is executed and 24 VDC switched is dropped out a rotary clamp/unclamp may occur. This error is caused by the rotary brake changing state due to the loss of 24VDC switched and software detecting an unclamp state without a command being given to unclamp. This error may be a nuisance for some machine operators and can be eliminated by making a simple wiring change. Remove the 18 awg blue wire that runs from brake relay terminal "A" to brake relay terminal "9". Connect an 18 awg blue wire from brake relay terminal "9" to 24VDC at the TB4 terminal strip. This will power the rotary table brake on unswitched 24 VDC and should eliminate the nuisance unclamp error.

DATE: 01/07/91 SUBJECT: Yaskawa Spindle Drive Retrofit Kits PRODUCT LINE: 002-2060-001, 002 ISSUE NUMBER: 1170 SUPERSEDES NUMBER: PAGE 1 OF 1
Effective this month the inverter being used for these retrofit kits will appear slightly different. We are now receiving two styles of the inverter, both of which are functionally the same. The difference in the new style is in how the brake module and resistors connect to the -inverter. The connection is as shown below: NOTE: The Buss voltage was measured on P-n on old style drive on the new is now measured on +,.
DATE: 1-10-91 SUBJECT: FAST FILL PRODUCT LINE: TRM21
ISSUE NUMBER:1171 SUPERSEDES NUMBER: PAGE 1 OF 2
It has come to our attention that the fast fill on some recent TRM21'S has no effect on filling the work tank. Upon further investigation it was found that a plug, in the plumbing, in the dielectric unit is missing. All TRM21'S produced after 09/01/90 will need to be check for this problem. Approx. 12 machines. To check, pull up the gate in the work tank, turn on the dielectric unit and open the fill valve completely, press the fast fill button on the power supply, there should be a noticeable difference in the rate at which the work tank is filled, if not, proceed with the following steps. 1. Utilizing the following diagram locate the hose from the filter tank to a 1 1/4" to 3/4" reducing coupling (T). View of the dielectric tank with the top cover removed on page 2 of this FSB. This nipple is for support only and should contain a plug. If the plug is not in the nipple order part number 804-0024-001 and install in place of current nipple. This will restrict the flow to the 3/8" hose and thus allow the fast fill solenoid to function properly see page 3 for flow diagram. 2. Check for proper wiring of pump motor, jumper configuration is supplied on page 2.

DATE: January 30, 1991 SUBJECT: Contactor suppression PRODUCT LINE: KM-5P, BMC ISSUE NUMBER: 1172 SUPERSEDES NUMBER: PAGE 1 OF 1
The contactors used in the KM-5P and BMC lines have a build in suppression circuit for the coil. We have found that this varistor is marginal at best. The problem has become a major issue on the KM-5P, causing run away problems in the Z axis WHEN the spindle motor contactors turn off or on. Testing done at Hurco shows that the black 238v stranded lead suppressors carried by stores did the best job of noise suppression. All new KM-5P's and BMC's will have these suppressors installed across the coils of all contactors during assembly. We need to start placing these devices on all KM-5P and BMC machines in the field. It is critical that we get all the KM-5P's as soon as possible as this can cause serious damage. The BMC's we can work on as we come across them. Order some of these suppressors for your kits. HURCO PART NUMBER 417-6881-818
ORIGINATOR: Mike Garlick

DATE: January 29, 1991 SUBJECT: Lead Screw Mapping initialization V8.5 PRODUCT LINE: BMC 20-50 ISSUE NUMBER: 1173 SUPERSEDES NUMBER: PAGE 1 OF 1
DESCRIPTION: It has been recommended upon upgrading a customer to version 8.58 Executive software that the CLEAR RAMDISK (NVRAM) softkey in Interactive Diagnostics be selected to ensure that all of the battery-backed RAM is in a known state. However, as a result, the structure size for the Lead Screw Map is also cleared. Though the new Mapping data can be entered for both the Forward and Reverse Lead Screw Maps for each axis and the Memory will be retained, writing the Map to diskette will not record the information properly (even though no error message is displayed) so that subsequent readings of the Map from that diskette will corrupt the battery-backed RAM, including non Lead screw Map data. SOLUTION: With the version 8.58 Executive, the only way to reinitialize the Lead Screw Map is to load a previous Executive version's Lead Screw Map, either version 7.24 or 8.88. For machine's that are only receiving the version 8.58 upgrade and are not being LASER recertified, simply loading the existing Lead Screw Map diskette will properly initialize the Lead Screw Map and load the data properly into the Forward and Reverse Maps. If the machine does not have a Lead Screw Mapping diskette then selecting the DUAL AXIS DEFAULTS softkey in Lead Screw Setup will suffice; no Mapping diskette is to be made unless the machine is Laser certified. For machine's that are receiving both the version 8.58 upgrade and LASER certification, the old Lead Screw Map diskette must be loaded before beginning the LASER runs but after the battery-backed RAM is cleared. After loading the original Lead Screw Map data, selection of the DUAL AXIS DEFAULTS softkey will then overwrite zeros into the initialized Lead Screw Map. LASER certification can then begin. The STORE DATA ON DISKETTE softkey will then function properly in writing the Lead Screw Map data on the diskette. Always reload the Lead Screw Map from the Lead Screw Mapping diskette immediately after clearing the battery-backed RAM. ORIGINATOR: David J. Skrzypczak REVISED BY:
DATE: February 15, 1991 SUBJECT: Ultimax secret screens PRODUCT LINE: Ultimax II, 32, 3 Machines
ISSUE NUMBER: 1174-A SUPERSEDES NUMBER:1174 PAGE 1 OF 1
The following is a listing of the secret screens found in the Ultimax II control and the screens they are reached from. Some machine types and software versions do not have all of these screens. ie: knee mills and Deckels do not have the mapping screen.
Old Access Code 639 488 642 ** 527 **
Function/ Description
Access Screen Configuration Screen or (Auxillary Screen Max 32/3) Tool changer diagnostic Screen Tool change diagnostic Screen Tool change diagnostic Screen Auxilary Screen Tool change diagnostic Screen
New Access Code 100 101 102 103 200 300
Machine Configuration Edit Tool Changer Height, Axis & Spindle setup Leadscrew Map setup 8.60T Axis Accel Setup (Matrix 4 Axis Tune Diagnostics Max 32/3) Interactive Diagnostice 8.60T Manual Axis Initialization
ORIGINATOR: Mike Garlick REVISED BY: Brock Rexing 3/17/93


DATE: February 18, 1991 SUBJECT: BMC SPINDLES PRODUCT LINE: BMC 20 50 ISSUE NUMBER: 1175 SUPERSEDES NUMBER: PAGE 1 OF 1
All BMC 20 through 50 spindles now have a Hurco part number. This includes OEM machines. There is no longer any reason to disassemble spindles in the field to match pulleys. Spindles and pulleys are balanced as an assembly and the drawbar is installed and set prior to being shipped to a customer. By changing pulleys we run the risk of throwing the new spindle out of balance and possibly shortening its life span. Although there are only a few different spindles used in the BMC line, there are numerous configurations of spindle RPM ranges. To ensure a correct spindle is ordered for a customer it is important to take this into account. It may require the measurement of the spindle pulley and spindle length to select the correct one. Before ordering a spindle, part numbers should be verified with a Technical Specialist as they have the necessary information to help select the correct one. Spindle part numbers called out in manuals should not be assumed to be correct as they call out a standard number which may or may not match the actual spindle in the machine. A great deal of effort has gone into identifying and correcting problems with spindles. By making sure the correct spindle is ordered the failures seen in the past due to vibration will be eliminated.

DATE: 3-4-91 SUBJECT: Connector, card edge 26 pos. PRODUCT LINE: All Max II controls ISSUE NUMBER:1176 SUPERSEDES NUMBER: PAGE 1 OF 1
Item 406-0803-492 is an "AMP" 499560-5 card edge connector, 26 position that is connected to the CRT controller board. "AMP" changed their design from a high tension connector to a low tension connector without informing us. Because of the low tension connector, the Max II control may appear to be locked-up. If you have a machine that appears to be locked-up please check for the low tension "AMP" connector 111109-5 on the CRT controller board before determining other faults. A new vendor is being sourced but in the mean time you may order the 406-0803-492 in high tension form to fix any bad connection problems.
ORIGINATOR: Bill Baitinger REVISED BY:

DATE: April 29, 1991 SUBJECT: VCM900 Orbiting Unit PRODUCT LINE: TRM21 EP300CP ISSUE NUMBER: 1177 SUPERSEDES NUMBER: PAGE 1 OF 1
In the event you find problems with the, VMC900 Orbiting Unit, that is loose in one axis or the other, check the following areas: 1.) On the diagram below locate item number 41, these are cone point set screws (CPSHSS) that hold the leadscrew nut (item 37) in place. Check for tightness, if loose, remove and apply LOCTITE 609 and re-install the set screws. NOTE: The 3R chuck and the orbital unit will need to be removed to gain access to these screws. 2.) It is also possible that the locknut (item 47) has backed off.

DATE: January 31, 1992 SUBJECT: VMC 900 Noise Suppression PRODUCT LINE: TRM21 TRM39 EP300CP With VMC 900 ISSUE NUMBER: 1178A SUPERSEDES NUMBER: 1178 PAGE 1 OF 1
In an effort to reduce the noise susceptibility throughout the machine the following modification may need to be performed.
On all machines.
1. Adding four . 022uf Caps ( PART NUMBER ECH009 ) from TB1 pins 3 thru 6 to the ground plane on the circuit board. This can be accomplished by removing the PCB and soldering the caps from pins TB1-3 thru TB1-6 on the back side of the PCB. The solder mask around this connector is the ground plane of the board. This will need to be checked and verified on every machine as service is performed. Verify all connections and screw terminals are securely fastened. Secure the D04 diodes, CR6-CR8, (FR4D3R), on the Power Distribution PCB. If diodes are loose, remove nut, apply LOCTITE 242 to thread and reinstall. Verify FSB 1193 has been performed to machine.
Optional VMC900 only

2. For machines that have the Optional VMC900 Control, and are experiencing noise related problems such as, the Z axis position on the Futaba DRO and Z axis position on the VMC do not correspond to the same value, or the machine is experiencing communication errors, i.e.. ERROR 15. Order and install a new cable assy ( PART NUMBER 423-0311-002 ) . This new cable is a field service replacement part. It is only 60 inches long and utilizes improved shielding properties. When installing cable, ensure to route it away from the Gap Power leads on side panel. 3. If after installing new cable, the machine is still experiencing similar problems as described above, perform the following modification to the System PCB. Install a .01 Uf 100V ceramic capacitor on pin 49 (U18 68180) to DC common ORIGINATOR: Brock Rexing

SUBJECT: Isolation Transformer PRODUCT LINE: KM5P SUPERSEDES NUMBER: PAGE 1 OF 3
There have been two transformers used on the KM5P's. The original was part number 413-0003-105. This transformer supplied spindle motor power from taps on the secondary windings. This was soon discovered to cause the secondary voltage to sag approximately 50VAC. The cure was to change the transformer to another style. This new transformer is auto wound on its primary windings. This gives a constant 220VAC for the spindle motor. The part number is 413-0003-115. All machines shipped should have the 413-0003-115 transformer. If you are on a service call on a KM5P, please check the transformer part number. If it is incorrect, you will need to do one of two things. First determine their incoming power. If incoming power is 220/230VAC, then rewire so that the spindle is powered from line voltage. If the customer's power is some other voltage level, i.e. 208 or 460 VAC, order the correct transformer and replace it. Please take a look at the attached drawings. They show the transformers in question. Drawing number 002-4022-001 REV A is the control voltage schematic using the 413-0003-105 transformer. (NOTE this drawing is currently in the KM5P manual). This drawing shows one set of secondary leads from T1. When in reality there are two different voltage outputs, 200VAC and 220VAC. Drawing number 4130003-105 shows how the unit is wound. It also gives the connections for the different inputs voltages possible. For the correct information, use drawings 002-4022-001 REV B and 413-0003-115. The control voltage schematic shows the correct wiring. The terminal connections are also given. The spindle is powered from 220VAC and the rest of the machine is powered from 230VAC. Drawing 413-0003-115 shows how it is wound. The motor power is derived from taps on the primary side of the unit. If you suspect a bad transformer, please consult the wiring diagram while checking the resistance of the windings. A low resistance between the non isolated secondary and the primary is to be expected.
DATE: April 30, 1991 SUBJECT: Unclamp Switch PRODUCT LINE: BMC 25 & 30K
As most of you know we have a new style tool changer on the BMC 25 and 30K lines. This new tool changer uses a plastic tool finger. On occasion these have been known to break if the tool should stick in the spindle taper. As part of the solution to this problem engineering has created a three stage unclamp cylinder. This will knock the tool free of the taper. This revised set up procedure is a further precaution against breakage. To perform this set up you will need a shell end mill or similar large tool Insure that all cutters have been removed from the tool before you start. You will also need a piece of wood sturdy enough to support the head. (A 4" square block should do). Start by gaining access to the unclamp cylinder. Insert tool in to spindle then jog head down until tool rests on the wood block. You will have some pressure on the wood but do not let motion error activate. Then in ATC DIAGNOSTICS command the spindle to unclamp. This should simulate a stuck tool condition. If the unclamp cylinder lifts the head reduce the air pressure until it no longer lifts the head. You may have to bypass the air pressure switch to allow the servos to remain on. Once the machine is in a stuck tool condition set the unclamp switch so that it is on the edge of closing. Test the unclamp switch adjustment several times to insure that the switch does not close if tool is stuck. You can do this by commanding clamp and unclamp from ATC DIAGNOSTICS screen while monitoring the switch. When you are satisfied that adjustments are correct, return Machine to its normal operating condition. Be certain that the air pressure switch and regulator are set correctly.
ORIGINATOR: Lonnie Leffew Ken Borgmeyer REVISED BY:
DATE: MAY 16, 1991 SUBJECT: RS232 PRODUCT LINE: ALL
We have had several reports of RS232 cables having been plugged in the wrong direction. Gentlemen when HURCO ships a new machine the cables are disconnected from the printed circuit boards. This is done to prevent any undo strain on the boards during shipment to their new homes. When you are doing the install please insure that all connectors are plugged in correctly. Most are "D" style connectors and can not be installed backwards. This is not the case on the graphics and text CRT connectors nor the RS232 connector. The two CRT connectors will be obvious if they are wrong. You get blank displays. The RS232 will not function if in backwards. You will not know this until some one needs to use the communication feature. When you install a machine or are in on a service call please check to see if the RS232 is correct. If you examine the connector you will see an arrow on the pin 1 end of the plug and on the jack. These arrows will need to be aligned. This should help prevent problems if the customer decides to use his serial ports at a later date.
ORIGINATOR: Lonnie Leffew
DATE: JUNE 6, 1991 SUBJECT: AXIS MISWIRE PRODUCT LINE: KM3/P
A wiring mistake has been found on some of the machines made in the first half of this year. Please note not all machines have this problem, but the number that do is not known. If you have a machine that is miscounting over a long run of parts and it was made this year then this is more than likely what's wrong. In other cases check wile you are in the shop to ensure the wiring is correct. What happened was the shielding was not terminated correctly. Note: this only applies to the machine with the new max 400 amplifiers.
Please check and or do the following as needed:

1: At the amplifier (all three) a: At P1-1 (VCS+) The shield wire was hooked to P1-1, Disconnect the shield at this end and shorten and dress the cable. P3-1 (TG-) P3-2 (TG+) tachometer, P3-4 (MT-) P3-5 (MT+) Motor, Strip the cable jackets and solder the shield drain wire from both cables to an white wire. Connect the new drain wire to P3-3 (com). b:
18 ga
2:
At TB6: a: Remove the GRN/YEL wires. that go to TB7 as shown. TB6-1 to TB7-7 TB6-13 to TB7-6 TB6-26 to TB7-5 b: Add gray 14ga wires as shown. TB6-1 to TB4-34 TB6-13 to TB4-35 TB6-25 to TB4-36 c: Add two Wago jumpers to TB4-34-35-36 (part number 406-4006-003)
FSB1182 page 2 o
DATE: JUNE 13, 1991 SUBJECT: MACHINE CONFIGURATION PROBLEMS PRODUCT LINE: BMC 20-50 WITH 8.5 OR LATER
It has been found in manufacturing that if power is applied to the machine with the J1 connector for the personality board disconnected, the control will re-configure itself incorrectly. On power-up the control looks to the switch settings on the CRP board for verification of some of the parameters it has stored in memory. If it does not see these switches, ie. the cable to the CRP board is disconnected, it will configure the machine for just about any possible combination of machine options. In most cases when the cable is re-connected the control will NOT return to the correct configuration. To stop this from happening always make sure the cable from J1 on the personality board to J2 on the CRP board is connected prior to applying power to the machine. If it is necessary to disconnect this cable for trouble shooting purposes make sure you check the machine for correct configuration after reconnecting.
DATE: June 23, 1993 SUBJECT: CRT Controller PCB 2 PRODUCT LINE:
The CRT Controller PCB 1 (415-0174-001) when failing, is being replaced with the CRT Controller PCB 2 (415-0174-002). All connectors will correspond the same, except for the power supply "J4". You will also need to order this 6 Position Wago Plug PN 406-4005-061. To install: 1.) Cut the AMP female plug from the power supply harness. 2.) Strip 1/4" from each of the six wires. 3.) Insert the wires into the Wago terminal , as follows:
PIN 1 2 3 4 5 6 WIRE COLOR Gray Yellow Blue Brown Orange Gray SIGNAL GND +5V RST +12V -12V GND
Note: below is the jumper configuration. bold is standard configuration. EXAMPLE To go to "Local Mode" remove jumper 1-2 on X1B jumper.
Mode Line Local Mode X1B jumper 1-2 1-* X1A jumper
60Hz 50Hz
1-2 1-* ORIGINATOR: Fred Gross REVISED BY: Brock Rexing

DATE: July 18, 1991 SUBJECT: Max 400 Servo Amp PRODUCT LINE: KM3/P & Rebuilt machines
All amps in the field, including all KM3/P machines shipped between 12/90 thru 6/91 and also several of the rebuilt machines should be checked for this modification when making a service call. The mod is to remove C12 and C13 from the Power Amp PCB to correct a problem with output FETs ringing thus resulting in the amp blowing. All drives in machines shipped from July '91 have the lastest changes. Note that the current output signal (MCO) that is used to display the axis load bar on the CRT is not scaled properly. This problem is being investigated and will be corrected once a resolution has been found.
ORIGINATOR: Keith Perkins REVISED BY: Matt Warner
FSB 1185 PAGE 2 of 2
DATE: July 29, 1991 SUBJECT: Lead Screw Map Initialization, v8.51 PRODUCT LINE: BMC 20-50
DESCRIPTION:
A modification was made to the lead screw map structure in version 8.51. This change altered the lead screw map structure stored in memory. An upgrade to v8.51, therefore invalidates the v8.50 or earlier lead screw map stored in memory. The maximum axis travel supported by the lead screw map follow: X = 54" Y = 30" Z = 28" NOTE - AXIS TRAVEL SHOULD NOT EXCEED THE LEAD SCREW MAP LIMITS.
SOLUTION:
- Verify that you have a valid lead screw map on diskette. Compare the lead screw map with a hard copy printout. If one is not available make one from the current lead screw map residing on the machine. - Load lead screw map from disk, if it loads ok then you have a valid disk. Verify that the loaded map matches the printout made earlier. If the lead screw map does not load, then you will have to enter map manually after upgrade. - Install version 8.51. - If this is a new memory board then CLEAR RAM DISK - Load map from disk if valid or enter it manually. Verify that the loaded map matches printout. - Write lead screw file onto disk and update label with date, "V8.51", and name of person.
ORIGINATOR: Mark L. Kolp REVISED BY:
DATE: JULY 26 1991 SUBJECT: Chain Roller PRODUCT LINE: BMC 20 to 50
Gentlemen, I have received several questions and suggestions dealing with chain roller failures. We have found a problem with some of the shafts used on BMC machines. These shafts have been determined to be "soft". They should be hardened to a ROCKWELL C 50 - 55. If you experience a failure of these shafts you should replace all four shafts and the needle bearings. Also check for damage to the chain rollers. Replace them if necessary. Part numbers can be found in the manuals. If not, then call service. I have received several suggestions to add a grease fitting to the chain roller shafts. Although engineering feels that it is not necessary, we can add grease fittings if the customer wants them. Please follow the instructions on the drawing below.
DATE: July 30, 1991 SUBJECT: Parametrics Digital Reversing Card PRODUCT LINE: All with parametrics
We are currently using a new style digital reversing card in the parajust drives as the original style is no longer available. There has been some confusion on the proper installation of these new style boards. To help clarify this situation please refer to the following when replacing this card. 1. 2. 3. 4. 5. 6. Remove jumper between terminal 4 and 5 of TB-6. Remove white jumper on terminal 3 of TB-6. Adjust potientiometer R4 to full CW position. Connect reversing wire to terminal 2 of TB-6. If spindle runs backwards swap two motor output wires. Program several tap cycles and verify proper operation.
This will help clarify proper installation of the digital reversing card. Please note the following part numbers for reference: 402-6002-006 402-6005-006 Parajust "A" Parajust "B" (5 HP) (7.5/10 HP)
ORIGINATOR: Mark G. Bullington REVISED BY:
DATE: May 18, 1993 SUBJECT: Z AXIS CRT ASSEMBLY PRODUCT LINE: ALL MAX 2 CONTROLS
ISSUE NUMBER: 1189A SUPERSEDES NUMBER: FSB 1189

TIN 1007
PAGE 1 OF 2
Hurco now uses a new supplier for the 12 inch CRT's used in the Max 1 and 2 controls. The CRT's can be identified by a large rear panel, this will accommodate the Z Axis assembly. The part number for this larger rear CRT panel is 002-3994-004, and must be used with the Display Technology CRT's as well as the Z Axis CRT's. The part numbers for the Z Axis CRT's are as follows. TEXT CRT GRAPHICS CRT 425 0001 013 425 0001 014
If the control has Z Axis CRT's they may be adjusted using the following procedure. R-101 R-304 R-307 R-401 R-406 R-410 Contrast. Vert. SizeVert. SizesHorz. WidthHorz. CentHorz. FreqAdjust the display open and close vertically. Adjust vertical size of the characters at top and bottom of the display. Adjust the width of Horizontal position. This is a coil not a pot. Adjust the horizontal position of the display. This is fine adj. Adjust the horizontal position of the display. This is the coarse adjustment. Focus adjust. Adjust the brightness.
R-421 R-425
FocusBright-
ORIGINATOR: Richard Arthur REVISED BY: Richard Arthur

The only other difference is the Z Axis CRT has it's ribbon cable soldered on the PC board using the existing cable. Route the wires from the top of the board, through the holes and solder at the bottom. The following is the wire color code for the Z Axis CRT. 1) Red 2) n/c 3) n/c 4) n/c 5) Yellow 6) Violet 7) Brown and Orange (2 wires) 8) Green 9) White 10) Gray Remove the black and blue wires and attach them to the center stud as ground wires. The ribbon cable is attached to the PC board with a tie wrap, using the two holes at right side of the board.
CRT
DATE: June 22, 1993 SUBJECT: Z AXIS CRT ASSEMBLY PRODUCT LINE: ALL MAX 2 CONTROLS
ISSUE NUMBER: 1189B SUPERSEDES NUMBER: FSB 1189A

TIN 1007
PAGE 1 OF 2
The Max 1 & 2 Text and Graphics CRT's are now shipping with a 10 Pos Header Socket (P3) on the circuit PCB. In the past Customers and Field Service were instructed to cut the exsisting 10 Pin Plug from the ribbon cable and solder the wires direct to the CRT. This is no longer in effect with the new CRT's. If a Z-Axis CRT fails, and the wires were soldered to the PCB, you will need to order the customer a ribbon cable along with a replacement CRT. This allows for a relative simple removal and installation process in the future. 423-6141-001 423-6139-002 425 0001 013 425 0001 014 Note: Ribbon cable Assy, Text CRT to CRT Cnt'l PCB Ribbon Cable Assy, Graphics CRT to FPCC PCB Text CRT Graphics CRT
If replacing an orginal Elston CRT, you will need to order the Back Plate Mounting Assy Kit to accomodate the Z-Axis CRT into the console. Part Number 002-3994-004,
The Z-Axis CRT's may be adjusted using the following procedure and diagram on the following page.
R-101 R-304 R-307 L-401 R-406 R-410 R-421 R-425 Contrast. Vert. SizeVert. LinesHorz. WidthHorz. PhaseHorz. Freq.FocusBrightAdjust the display open and close vertically. Adjust vertical size of the characters at top and bottom of the display. Adjust the width of Horizontal position. This is a coil not a pot. Adjust the horizontal position fine adj. Adjust the horizontal position coarse adjustment. Focus adjust. Adjust the brightness.
ORIGINATOR: Richard Arthur REVISED BY: Brock Rexing

R406 P4 R410 L401 R421 R307 R304
F101
R425
P2 ** NOTE PIN #1
P3
R101
NOTE: The Brown wire on the Ribbon cable is oriented to Pin 1 (J3).
WARNING
Ensure Proper Connection and Orientation of Ribbon Cables. Damage may occur if cables are not plugged in properly! NOTE: Before turning on Power, check the other end of the Ribbon Cable, to ensure proper orientation, Brown to Pin 1. Text CRT J3 to CRT Controller PCB P1. Brown to Pin 1 each end. ! Graphics CRT J3 to Front Panel Cable Connect (FPCC) PCB P55. Brown to Pin 1 each end !
FSB 1189-B Page 2 of 2
DATE: December 1, 1993 SUBJECT: Z Axis CRT Assembly PRODUCT LINE: All Max 2 controls
ISSUE NUMBER: 1189C SUPERSEDES NUMBER:1189B/A &TIN 1007 PAGE 1 OF 3
The Max 1 & 2 Text and Graphics CRT's are now shipping with a 10 Pos Header Socket (P3) on the circuit PCB. In the past Customers and Field Service were instructed to cut the exsisting 10 Pin Plug from the ribbon cable and solder the wires direct to the CRT. This is no longer in effect with the new CRT's. If a Z-Axis CRT fails, and the wires were soldered to the PCB, you will need to order the customer a ribbon cable along with a replacement CRT. This allows for a relative simple removal and installation process in the future. 423-6141-001 423-6139-002 425 0001 013 425 0001 014 Note: Ribbon cable Assy, Text CRT to CRT Cnt'l PCB Ribbon Cable Assy, Graphics CRT to FPCC PCB Text CRT Graphics CRT
If replacing an orginal Elston CRT, you will need to order the Back Plate Mounting Assy Kit to accomodate the Z-Axis CRT into the console. Part Number 002-3994-004, this kit now contains ground wire to be added per print on page 3 of this FSB.
The Z-Axis CRT's may be adjusted using the following procedure and diagram on the following page.
R-101 R-304 R-307 L-401 R-406 R-410 R-421 R-425 Contrast. Vert. SizeVert. LinesHorz. WidthHorz. PhaseHorz. Freq.FocusBrightAdjust the display open and close vertically. Adjust vertical size of the characters at top and bottom of the display. Adjust the width of Horizontal position. This is a coil not a pot. Adjust the horizontal position fine adj. Adjust the horizontal position coarse adjustment. Focus adjust. Adjust the brightness.
ORIGINATOR: Richard Arthur REVISED BY: Brock Rexing

R406 P4 R410 L401 R421 R307 R304
F101
R425
P2
P3
R101
** NOTE PIN #1 NOTE: The Brown wire on the Ribbon cable is oriented to Pin 1 (J3).
WARNING
Ensure Proper Connection and Orientation of Ribbon Cables. Damage may occur if cables are not plugged in properly! NOTE: Before turning on Power, check the other end of the Ribbon Cable, to ensure proper orientation, Brown to Pin 1. Text CRT J3 to CRT Controller PCB P1. Brown to Pin 1 each end. ! Graphics CRT J3 to Front Panel Cable Connect (FPCC) PCB P55. Brown to Pin 1 each end !
SIZE
DRAWING
SHT.
1
OF
REV.
002-3822-051
UPPER HALF CONSOLE REAR PANEL
BLACK
Add Wire's
TO POWER CABINET LOWER HALF CONSOLE (SINGLE POINT)
BLACK
NOTES: 1. ALL CHASSIS GROUND CONNECTIONS ARE GREEN/YELLOW WIRE EXCEPT WHERE NOTED. 2. CHASSIS GROUND CONNECTIONS APPLY TO THE FOLLOWING ASSEMBLIES: a. 002-3994-004 b. 002-3301-012 c. 002-3301-011 d. 002-3301-010 e. 002-3301-009
MACHINE CONTROL PCB PROGRAM ENTRY PCB
SURFACE TREATMENT
HEAT TREATMENT
FIRST USED ON
~ ~
CN 7103
A
REV
12836
P.I.N. NO.
RELEASE
REVISION DESCRIPTION REV DATE CHK DATE APPD DATE DF BY BY BY
EXCEPT AS NOTED: ALL DIMENSIONS HURCO IN INCHES TOLERANCE DECIMAL .0 .0300 .00 .0150 DESCRIPTION .000 .0050 .0000 .0005 ANGULAR 0ANGULAR 30' DRAWN BREAK ALL SHARP EDGES SCALE THIRD ANGLE PROJECTION

R
SCHEMATIC, MAX 2 CONSOLE GROUNDING

FWG
21SEP93
NONE PC
MAX 2
UNIT OF MEAS.
002-3822-051
OF
DATE: September 16, 1991 SUBJECT: Knee mill pulley clutch shaft retrofit kit PRODUCT LINE: Knee mills
There are two styles of "timing belts" used in the head of knee mills. The old style belt has square groove teeth and the latest style belt is an HTD style (small round teeth). Because of the difference in belts, the pulley clutch shaft and timing pulley also have to match the tooth style. Since the only style pulley clutch shaft we can get is the HTD style, I have come up with a retrofit kit to convert the square groove machines to HTD (high torque drive). We will continue to sell square groove belts and square groove pulleys separately if a customer wants them but, we can not supply the square groove pulley clutch shaft # 7130016-042. If you are trying to order a 713-0016-042 pulley clutch shaft (square groove) a cross reference will tell you to order 0022542-001 ass'y K-mill timing belt retrofit kit. This kit contains the following 713-0016-145 Pulley clutch shaft 713-0016-146 Timing belt pulley 713-0016-147 Timing belt HTD HTD HTD
FYI: The HTD (high torque drive) belt is a positive drive belt with better power transmission characteristics and longer life. That is the reason our supplier only makes the HTD style now.
ORIGINATOR: Bill Baitinger REVISED BY:

INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTIONDISCLOUSURE OR OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
DATE: September 19, 1991 SUBJECT: Push Stud PRODUCT LINE: BMC 20 to 50
Gentlemen: Recently we have had several cases where the Push Stud and Lock Nut have come loose during operation of the spindle. When this happens the stud will work its way down against the top of the spindle and weld itself to the spindle. This then necessitates changing the draw bar and occasionally the spindle cartridge. Please locktite the pushstud into knock out cylindar shaft and locktite the locknut to the pushstud any time you are working on the head or doing an install of a machine. Record this in your service report

DATE: October 2, 1991 SUBJECT: Transformer fuses PRODUCT LINE: As noted in text
The Shape Electronics transformer, Z1301, p/n 413-0003-104 has three fuses on the output side. There have been reports of intermittent losses of power due to poor contact between the fuse and the contact point at the bottom of the fuse holder. Manufacturing is removing the springs and stretching them in order to increase the life of a good contact. It is recommended that the same be done on the machines with this type of transformer. Engineering will pursue a correction with the vendor. This unit is found in: CNC cabinets with MRP & ARP boards BMC/MAX 3 CNC cabinets BMC 40SX Prototype BMC 40SLV Power cabinets KM5P CNC cabinets MB-2 Rebuilds MB-1S to MD-1 Reworks MB-1 Rework
ORIGINATOR: Matt Warner REVISED BY:

INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR DISCLOUSURE OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
DATE: March 6, 1992 SUBJECT: Modification to Voltage Divider PCB E2104016 PRODUCT LINE: TRM21 TRM39 EP300CP EDM
The following inspection and modifications to the Voltage Divider PCB (E2104016) is to completed on ALL TRM21 / TRM39 EP300CP EDM machines with serial number prefix of PC or PE. This modification shall be preformed on the EDM machines as service is required. Refer to page 2 for the artwork layout of pcb. Add 2 links ( jumpers ) to either the front or back side of PCB as shown on page 2.

DATE: December 4, 1991 SUBJECT: Transformer Cover PRODUCT LINE: SLV 40
Recently a potential problem was discovered with the cover plate used on the SLV 40 transformer. There is a notch cut into the cover to allow the power cord to pass. This notch needs to be widened to approximately 2" for good clearance. At your first opportunity please correct this on the SLV40's in your area. Inspect the wiring for damage, and take corrective action as needed. As always please note the work done on a service report. This will be done on all machines under construction at HURCO MFG.

INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR DISCLOUSURE OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
DATE: January 31, 1992 SUBJECT: Lube Modification PRODUCT LINE: KM5P
The checking function of the meter units to the head assembly is not working properly. Therefore, it will be necessary to install an additional check valve to the line that feeds the head. Remove the line from the three port junction, at the left side of the machine base, that goes into the base to the head area. A compression nut and sleeve will be required in order to make the connection to the check valve. It has also been found that an excess of lube from the Z ballsleeve for the shift lever will wash the grease from the spindle bearings. It has been decided to remove the ballsleeve lube line from the five port manifold in the head and plug it. This plug has a standard thread that should thread into the manifold. The correct plug is metric and more costly. Use it if the stock on the other is depleted. Parts list: 502-0130-006 713-0020-097 713-0020-098 506-3023-005 713-0021-323 check valve compression nut compression sleeve closure plug closure plug (metric)
ORIGINATOR: Matt Warner REVISED BY:

DATE: June 9 1992 SUBJECT: TYPE 1 ATC OVER SHOOT FIX PRODUCT LINE: BMC 25 TO 30 and SLV 40
Some HURCO machines have experienced an overshoot problem on the magazine rotation on TYPE 1 ATC's. The Type 1 ATC has plastic fingers and no vertical movement of magazine. Engineering has a solution for this problem. The solution to this problem is as follows; 1. 2. Install new motor to new bracket with (2) M5 x 45 SHCS, (2) M5 nuts, and lock washers. Mount motor and bracket assembly to plate and Geneva drive using existing hardware and coupling. Use new drive key supplied with motor. Replace 12 mfd capacitor with 7.5 mfd cap.
3. 4. 5.
Remove brake pack and cover socket with label. Connect motor white wire to white wire of supply. This is common lead. Connect motor red wire to red wire of supply. Connect motor black wire to black wire of supply. If magazine runs backwards reverse red and black wires.
6.
Make a note on their ATC Relay PCB V2 Schematic of the changes. Include capacitor value, brake pack removal, and motor wire colors. Part Number of Retrofit Kit 002-4107-003 Part numbers (listed for reference only). ATC gear motor 401-3002-002 Bracket for new motor 802-2602-023 Capacitor 7.5 MFD 401-3002-003 ORIGINATOR: Lonnie Leffew REVISED BY:
Label No brake Pack required
703-1005-379
FSB XXX Page 2 of 3
DATE: June 23, 1992 SUBJECT: Counterweight Noise PRODUCT LINE: BMC 20 to 50, SLV40
On occasion a HURCO machining center counterweight will "BANG" against the column as the head travels. This is caused by the counterweight not hanging parallel to the column walls and as the head moves the weight will start swinging. To solve this problem you will need to determine which way the weight is out of parallel with the column; either left to right, front to back, or possibly both. Follow the appropriate instructions below.
LEFT to RIGHT. With the weight out left to right the preferred solution is to adjust the length of the chains to bring it square to column. This can be done with the "adjusting bolt" which attaches the chain to the top of the head. You must have as much of the adjusting bolt threaded into the head casting as possible. If this does not allow enough adjustment bring it as close as possible, and test the machine to see if a problem still exists. If it does, then follow the "rail mod" instructions on page two.
FRONT to BACK. If the counterweight is out front to back, determine if it is hitting at the front or the back of column. If it hits at the front of the column then change the rear chain roller sprocket to the next larger diameter sprocket. This will move the counterweight assembly about one quarter inch to the rear. If the weight is hitting at the rear of the column then follow the "rail mod" instructions on page two.

RAIL MODIFICATIONS After you have determined where the counterweight is hitting and the instructions given above do not cure the problem, then fabricate guide rails for the counter weight. First measure the inside height of the column. You will need two pieces (per side that needs the guides) of flat bar stock of this length. This stock needs to be thick enough to prevent the counterweight from swinging but not cause it to bind up. This stock is normally .25" - .375" thick and 1.5" or more wide. You will also need a 2" long piece of the same material per rail to attach these rails to the top of the column. Drill and tap two holes in one end of each rail. Drill two holes in the small pieces to attach them to the long rails. These pieces are attached at 90 degrees. Also drill two holes in the small pieces to attach the assembly to the top of the column. Don't forget to drill and tap the column top also. Insert the assemblies between the weight and the side of the column and bolt them in place. The rails need to be placed so that they guide the counterweight and prevent it from banging into the column or rails. Test the changes thoroughly. As with any work done on the machines include the information in the service report.
FSB 1197 Page 2 of 2
DATE: July 27, 1992 SUBJECT: Ultimax 3 DC Power Supply PRODUCT LINE: BMC20-50
Starting in August, the Deltron power supply (413-0008-013), used in all Ultimax 3 machines, will have a Wago connector in place of the screw terminals for the DC outputs. This version of the supply will be Rev. "C". When replacement of a Rev. "A" or "B" supply must be made using a Rev. "C" supply, the mating Wago connector will be required to modify the harness in that machine. Assembly 002-4107-004 has been created for Field use, this kit contains the power supply 413-0008-013 and one 12 position Wago connector 406-4005-067. Please see drawing 423-6807-003 page 2 for pin out information.
ORIGINATOR: Dale Clark REVISED BY:

DATE: July 21, 1993 SUBJECT: CRP3 PCB Modification PRODUCT LINE: BMC 20-50
On February 22, 1993 Manufacturing Notice 3788 reworked the CRP3 relay boards to revision E. This modification tied pin 1 of M2, M4, and M6 to 24 VDC return on pin 19 of M2, M4, and M6. It was later discovered that this induced an offset during the axis balance setup. On March 13, 1993 Manufacturing Notice 3792 came out with a new modification for CRP3 and rescinded Manufacturing Notice 3788. Basically the new modification removes 24 VDC return from the ground side of the load monitor input and instead ties the 12 VDC isolated voltage return in its place. Note, the revision letter for the 415-0224-004 CRP3 board was marked revision E for both modifications. Any MAX3 machines with erratic load meters and especially those shipped in February or March 1993 which are experiencing load meter problems or axis balance problems with a large offset should have the CRP modifications checked and reworked. This modification corrects an oversight from the original CRP3 board design. Functionally the CRP3 load meter circuit will be identical to CRP2 with the addition of this modification. Modification: 1. 2. 3. 4. 5. Use approximately 1/2" of wire wrap wire and solder pin 3 of U4 to C36 pin 2 (top). Tack Pack the wire to the PCB as required. Use approximately 1/2" of wire wrap wire and solder pin 10 of U4 to C35 pin 1 (top). Tack Pack the wire to the PCB as required. Use approximately 1/2" of wire wrap wire and solder pin 3 of U5 to C37 pin 1 (top). Tack Pack the wire to the PCB as required. Ensure that pins 1 and 19 of M2, M4 and M6 are not tied together as described on Manufacturing Notice 3788. Change the revision level to "E".
ORIGINATOR: Tom Murden REVISED BY:

DATE: August 11, 1993 SUBJECT: Replacement of Spindle Oil Cooler PRODUCT LINE: BMC 30-50
The following parts are needed for field installation of the new design oil cooler: ItemDescription 1) Fitting, 90 degree elbow (3/8T-1/4 M.P.) 2) Tubing, 3/8 O.D. 3) Oil Cooler 4) Brace, splash guard Field replacement of the new oil cooler requires the following steps: 1. The original mounting plate needs to be drilled to facilitate the new oil cooler. Due to inconsistency in hole location, it is best to set the new oil cooler in and mark the hole pattern from it. Then drill the original base and bolt on the new oil cooler. You may use your discretion on the mounting bolts. 2. The original oil lines will be of insufficient length and must be replaced. Fittings and tubing are listed with the parts above. 3. The original wiring should be of sufficient length and may be used. The new design oil unit is wired to receive 220 VAC single phase. On most of our machines 208 VAC single phase is the actual voltage supplied and is sufficient for this application. 4. The splash guard brace should be installed from the column to the splash guard using the one bolt hole end to any available screw on the column, as close to the level of the original brace as possible. The splash guard will need to have holes drilled to accommodate the two screws at its end of the brace. Part Number 506-3009-039 508-2001-005 504-5001-005 802-2618-004 Quantity 4 ea. 25 feet 1 ea. 1 ea.
ORIGINATOR: Richard Arthur REVISED BY:

DATE: October 29, 1993 SUBJECT: Max3 Keyboards PRODUCT LINE: Ultimax 3 Controls
Replacement keytops are now available for repairing Ultimax 3 keyboards. This will eliminate the need for a complete keyboard replacement when any of the keys break off. The part numbers for ordering the specific keytops required are listed below. Please note that when these keytops break, the plastic tang (shaped like an +) usually breaks off flush with the pushbutton actuator. This will require taking a needle and heating the tip so it can be inserted at an angle into the center of the broken + tang. When the needle cools the broken tang should easily pull out with the needle. Carefully snap the new keytop into place to complete the repair.
PART NUMBER 609-0514-001 609-0514-002 609-0514-003 609-0514-004 609-0514-005 609-0514-006 609-0514-007 609-0514-008 609-0514-009 609-0514-010
DESCRIPTION Keytop, Enter (1.25 x2) Dk.Gray Keytop, 0 (Zero) Keytop, (1 x 2) Dk.Gray Keytop, (1 x 2) Lt. Gray Keytop, 8 Keytop, 7 Keytop, 6 or 9 Keytop, 5 Keytop, 4 Keytop, 3
PART NUMBER 609-0514-011 609-0514-012 609-0514-013 609-0514-014 609-0514-015 609-0514-016 609-0514-017 609-0514-018 609-0514-019 609-0514-020
DESCRIPTION Keytop, 2 Keytop, 1 Keytop, . (Decimal Point) Keytop, X (Multiply Sign) Keytop, / (Divide Sign) Keytop, - (Minus Sign) Keytop, + (Plus Sign) Keytop, (Arrow) Keytop, (1 x 1) Dk.Gray Keytop, (1 x 1) Lt. Gray
ORIGINATOR: Mark Bullington REVISED BY:

DATE: January 4, 1994 SUBJECT: Clairex Switch PRODUCT LINE: KM1/HM1
The Clairex optical switch (418-0003-001) used on KM1/HM1 machines is no longer available. This switch was used for axis over travel and marker inputs on the KM1 machine, and for over travel on the M1. The only switches that are required for the machine to function are the marker switches and a switch for each axis to calibrate, (Z+, X-, Y-). If you encounter a machine that needs the switch replaced the following two (2) options exist. 1. Use one of the existing switches on the machine that are not required for machine operation, (Z-, X+, Y+). 2. A possible replacement that may be used is the magnetic proximity switch (418-5002-004) that was used on KMB1s thru KM3s. In order for this switch to be used an alternate mounting bracket and switch dog will need to be fabricated. Wire the switch as follows: SWITCH WIRE BLACK (-) COMMON RED (+) 5VDC WHITE (LOAD) KM1 LS PCB D OR E A OR B C M1 LS HARNESS P12-4 P12-5 P12-2(+LS) OR P12-3(-LS)
NOTE: IF OPTION 2 IS DONE, PLEASE FORWARD A COPY OF THE BRACKET AND SWITCH DOG DESIGN BACK TO HURCO, SO THAT WE MAY OFFER THIS AS PART OF A KIT IN THE FUTURE.

DATE: Jan. 4, 1994 SUBJECT: PRODUCT LINE:
1203 SUPERSEDES NUMBER: PAGE 1 OF 1
Tool release knock out " tool push out " can be measured and adjusted per the following information.
Push Out Amount. BMC 20 LR, 30, 40, 50. OEM 20 LR, 30, 40, 50 BMC's with the "TYPE 1" tool changer
.080" to .100 "
If the machine is working correctly with its present setup there is no need to adjust it.
Push out should be checked with an indicator. The air blast through the spindle will need to be disconnected and plugged during the check and adjustment. Do not forget to reconnect the air blast afterwards.
ORIGINATOR: L. Leffew REVISED BY:

RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
DATE: February 3, 1994 SUBJECT: KM5D Input Power PRODUCT LINE: Hawk KM5D
The new Knee Mill, KM5D HAWK can only be ordered from the factory as 230 VAC 3 Phase, 60 Hz. If your customer has a different incoming service, the distributor or customer needs to supply a 9KVA transformer that will convert their 3 phase plant line voltage to 230 VAC/3 Phase/60 Hz. Hurco suggests using a local supply suorce as an economical alternative. Example: G.E. Supply #9T21A4015. G.E. can be reached at 1-800-273-7313. Hurco will not be stocking any transformers for this purpose.


704-0001-589
DATE: February 7, 1994 SUBJECT: MTE Removal/Replacement PRODUCT LINE: KM3/3P
KM3/3P MOTOR/TACH/ENCODER REPLACEMENT PROCEDURE 1. 2. 3. If possible, move axis to a position providing easy access to the motor being removed. Switch the Main Disconnect Switch to OFF. Remove the servo conduit cable connector from the motor assembly. (Refer to Figure 1 for the location of the various components.) Remove the motor junction box cover. Locate pins L, S, K, and H on the motor receptacle. (Refer to Figure 1, View AA.) Using the pin extraction tool, remove the pins from the motor receptacle, being careful to note the color of the wire, and which location of the receptacle it was removed from. Also be extremely careful not to damage the pin or wire during removal. Remove the cord grip lock nut that secures the cord grip to the motor junction box. Carefully remove the cable from the junction box. Remove the motor. Install the new motor.
4. 5.
6.
7. 8. 9. 10.

11.
Install the limit switch cable and cord grip to the motor junction box, and tighten the cord grip lock nut. Using a small screwdriver to facilitate installation, insert the pins that were removed in step 6, into the motor receptacle. Be sure that the wire colors match the correct locations. Replace the junction box cover and reconnect the servo conduit cable to the motor. Switch the Main Disconnect Switch to ON. Check the motor, encoder, and limit switches for proper operation by SLOWLY jogging the axis to each switch. FIGURE 1
MOTOR CONNECTOR RECEPTACLE
A
12.
13. 14. 15.
JUNCTION BOX
A
CORD GRIP
VIEW A-A
L K M
A B
20-16 H R P D
G F
END VIEW
DATE: March 30, 1994 SUBJECT: Hawk 5D Machine Control Prameters PRODUCT LINE: Hawk 5D
The following table shows the default parameters for the 10M control when used for the Hawk 5D Knee Mill. Reference Part 3 of the Dynapath Installation Guide for Delta 10M/20M Computer Numerical Controls for Multi-Axes Milling Machines and Machining Centers for parameter descriptions and editing information.

Addr Hex 0000 0001 0002 0003 0004 0005 0006 0007 0008 0009 000A 000B 000C 000D 000E 000F 0010 0011 0012 0013 0014 0015 0016 0017 0018 0019 001A 001B 001C 001D 001E 001F 0020 0021 0022 0023 0024 0025 0026 0027 0028 0029 002A 002B 002C 002D 002E 002F 00F0 00F1
Value Byte 03 00 01 01 00 01 01 01 02 03 10 50 01 01 01 12 02 50 01 00 00 50 01 00 02 03 20 00 05 10 00 FF 02 50 01 00 00 50 01 00 02 03 20 00 05 10 00 FF FF FF
Addr Hex 0030 0031 0032 0033 0034 0035 0036 0037 0038 0039 003A 003B 003C 003D 003E 003F 0040 0041 0042 0043 0044 0045 0046 0047 0048 0049 004A 004B 004C 004D 004E 004F 0050 0051 0052 0053 0054 0055 0056 0057 0058 0059 005A 005B 005C 005D 005E 005F 0121 0122
Value Byte 01 50 01 00 00 50 01 00 04 06 40 00 05 10 00 FF 00 04 00 01 01 01 00 01 00 00 00 00 00 00 00 00 01 00 40 00 40 00 80 00 80 00 00 50 01 00 00 01 00 00
Addr Hex 0060 0061 0062 0063 0064 0065 0066 0067 0068 0069 006A 006B 006C 006D 006E 006F 0070 0071 0072 0073 0074 0075 0076 0077 0078 0079 007A 007B 007C 007D 007E 007F 0080 0081 0082 0083 0084 0085 0086 0087 0088 0089 008A 008B 008C 008D 008E 008F 0152 0153
Value Byte 00 31 02 00 10 00 02 00 00 00 02 00 10 13 77 00 00 00 02 00 10 06 02 00 00 00 10 00 10 00 10 00 00 00 10 00 10 00 10 00 00 00 10 00 10 00 10 00 00 00
Addr Hex 0090 0091 0092 0093 0094 0095 0096 0097 0098 0099 009A 009B 009C 009D 009E 009F 00A0 00A1 00A2 00A3 00A4 00A5 00A6 00A7 00A8 00A9 00AA 00AB 00AC 00AD 00AE 00AF 00B0 00B1 00B2 00B3 00B4 00B5 00B6 00B7 00B8 00B9 00BA 00BB 00BC 00BD 00BE 00BF 0183 0184
Value Byte 00 00 01 00 00 00 FF FF FF FF FF FF 01 50 FF FF 18 00 01 00 00 50 07 20 00 10 00 00 10 10 00 00 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF 00 00
Addr Hex 00C0 00C1 00C2 00C3 00C4 00C5 00C6 00C7 00C8 00C9 00CA 00CB 00CC 00CD 00CE 00CF 00D0 00D1 00D2 00D3 00D4 00D5 00D6 00D7 00D8 00D9 00DA 00DB 00DC 00DD 00DE 00DF 00E0 00E1 00E2 00E3 00E4 00E5 00E6 00E7 00E8 00E9 00EA 00EB 00EC 00ED 00EE 00EF 01B4 01B5
Value Byte 00 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF 00 00 FF 00 00 00 00 25 FF FF FF FF 00 00
00F2 00F3 00F4 00F5 00F6 00F7 00F8 00F9 00FA 00FB 00FC 00FD 00FE 00FF 0100 0101 0102 0103 0104 0105 0106 0107 0108 0109 010A 010B 010C 010D 010E 010F 0110 0111 0112 0113 0114 0115 0116 0117 0118 0119 011A 011B 011C 011D 011E 011F 0120 01E5 01E6 01E7 01E8 01E9
FF FF FF FF FF FF FF FF FF FF FF FF 01 00 00 00 00 01 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0123 0124 0125 0126 0127 0128 0129 012A 012B 012C 012D 012E 012F 0130 0131 0132 0133 0134 0135 0136 0137 0138 0139 013A 013B 013C 013D 013E 013F 0140 0141 0142 0143 0144 0145 0146 0147 0148 0149 014A 014B 014C 014D 014E 014F 0150 0151 0216 0217 0218 0219 021A
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0154 0155 0156 0157 0158 0159 015A 015B 015C 015D 015E 015F 0160 0161 0162 0163 0164 0165 0166 0167 0168 0169 016A 016B 016C 016D 016E 016F 0170 0171 0172 0173 0174 0175 0176 0177 0178 0179 017A 017B 017C 017D 017E 017F 0180 0181 0182 0247 0248 0249 024A 024B
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0185 0186 0187 0188 0189 018A 018B 018C 018D 018E 018F 0190 0191 0192 0193 0194 0195 0196 0197 0198 0199 019A 019B 019C 019D 019E 019F 01A0 01A1 01A2 01A3 01A4 01A5 01A6 01A7 01A8 01A9 01AA 01AB 01AC 01AD 01AE 01AF 01B0 01B1 01B2 01B3 0278 0279 027A 027B 027C
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
01B6 01B7 01B8 01B9 01BA 01BB 01BC 01BD 01BE 01BF 01C0 01C1 01C2 01C3 01C4 01C5 01C6 01C7 01C8 01C9 01CA 01CB 01CC 01CD 01CE 01CF 01D0 01D1 01D2 01D3 01D4 01D5 01D6 01D7 01D8 01D9 01DA 01DB 01DC 01DD 01DE 01DF 01E0 01E1 01E2 01E3 01E4 02A9 02AA 02AB 02AC 02AD
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
01EA 01EB 01EC 01ED 01EE 01EF 01F0 01F1 01F2 01F3 01F4 01F5 01F6 01F7 01F8 01F9 01FA 01FB 01FC 01FD 01FE 01FF 0200 0201 0202 0203 0204 0205 0206 0207 0208 0209 020A 020B 020C 020D 020E 020F 0210 0211 0212 0213 0214 0215 02DA 02DB 02DC 02DD 02DE 02DF 02E0 02E1
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 14 00 00 01 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
021B 021C 021D 021E 021F 0220 0221 0222 0223 0224 0225 0226 0227 0228 0229 022A 022B 022C 022D 022E 022F 0230 0231 0232 0233 0234 0235 0236 0237 0238 0239 023A 023B 023C 023D 023E 023F 0240 0241 0242 0243 0244 0245 0246 030B 030C 030D 030E 030F 0310 0311 0312
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
024C 024D 024E 024F 0250 0251 0252 0253 0254 0255 0256 0257 0258 0259 025A 025B 025C 025D 025E 025F 0260 0261 0262 0263 0264 0265 0266 0267 0268 0269 026A 026B 026C 026D 026E 026F 0270 0271 0272 0273 0274 0275 0276 0277 033C 033D 033E 033F 0340 0341 0342 0343
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
027D 027E 027F 0280 0281 0282 0283 0284 0285 0286 0287 0288 0289 028A 028B 028C 028D 028E 028F 0290 0291 0292 0293 0294 0295 0296 0297 0298 0299 029A 029B 029C 029D 029E 029F 02A0 02A1 02A2 02A3 02A4 02A5 02A6 02A7 02A8 036D 036E 036F 0370 0371 0372 0373 0374
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
02AE 02AF 02B0 02B1 02B2 02B3 02B4 02B5 02B6 02B7 02B8 02B9 02BA 02BB 02BC 02BD 02BE 02BF 02C0 02C1 02C2 02C3 02C4 02C5 02C6 02C7 02C8 02C9 02CA 02CB 02CC 02CD 02CE 02CF 02D0 02D1 02D2 02D3 02D4 02D5 02D6 02D7 02D8 02D9 039E 039F 03A0 03A1 03A2 03A3 03A4 03A5
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
02E2 02E3 02E4 02E5 02E6 02E7 02E8 02E9 02EA 02EB 02EC 02ED 02EE 02EF 02F0 02F1 02F2 02F3 02F4 02F5 02F6 02F7 02F8 02F9 02FA 02FB 02FC 02FD 02FE 02FF 0300 0301 0302 0303 0304 0305 0306 0307 0308 0309 030A 03CF 03D0 03D1 03D2 03D3 03D4 03D5 03D6 03D7 03D8 03D9
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0313 0314 0315 0316 0317 0318 0319 031A 031B 031C 031D 031E 031F 0320 0321 0322 0323 0324 0325 0326 0327 0328 0329 032A 032B 032C 032D 032E 032F 0330 0331 0332 0333 0334 0335 0336 0337 0338 0339 033A 033B 0400 0401 0402 0403 0404 0405 0406 0407 0408 0409 040A
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 01 00 00 10 01 00 00 10 01 00
0344 0345 0346 0347 0348 0349 034A 034B 034C 034D 034E 034F 0350 0351 0352 0353 0354 0355 0356 0357 0358 0359 035A 035B 035C 035D 035E 035F 0360 0361 0362 0363 0364 0365 0366 0367 0368 0369 036A 036B 036C 0431 0432 0433 0434 0435 0436 0437 0438 0439 043A 043B
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 FF FF FF FF FF FF FF FF FF FF FF
0375 0376 0377 0378 0379 037A 037B 037C 037D 037E 037F 0380 0381 0382 0383 0384 0385 0386 0387 0388 0389 038A 038B 038C 038D 038E 038F 0390 0391 0392 0393 0394 0395 0396 0397 0398 0399 039A 039B 039C 039D 0462 0463 0464 0465 0466 0467 0468 0469 046A 046B 046C
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 FF FF FF FF FF FF FF FF 01 01 01
03A6 03A7 03A8 03A9 03AA 03AB 03AC 03AD 03AE 03AF 03B0 03B1 03B2 03B3 03B4 03B5 03B6 03B7 03B8 03B9 03BA 03BB 03BC 03BD 03BE 03BF 03C0 03C1 03C2 03C3 03C4 03C5 03C6 03C7 03C8 03C9 03CA 03CB 03CC 03CD 03CE 0493 0494 0495 0496 0497 0498 0499 049A 049B 049C 049D
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 FF 00 00 00 00 FF FF FF FF FF FF
03DA 03DB 03DC 03DD 03DE 03DF 03E0 03E1 03E2 03E3 03E4 03E5 03E6 03E7 03E8 03E9 03EA 03EB 03EC 03ED 03EE 03EF 03F0 03F1 03F2 03F3 03F4 03F5 03F6 03F7 03F8 03F9 03FA 03FB 03FC 03FD 03FE 03FF 04C4 04C5 04C6 04C7 04C8 04C9 04CA 04CB 04CC 04CD 04CE 04CF 04D0 04D1
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 FF FF FF FF FF FF FF 01 00 10 00 10 00 10
040B 040C 040D 040E 040F 0410 0411 0412 0413 0414 0415 0416 0417 0418 0419 041A 041B 041C 041D 041E 041F 0420 0421 0422 0423 0424 0425 0426 0427 0428 0429 042A 042B 042C 042D 042E 042F 0430 04F5 04F6 04F7 04F8 04F9 04FA 04FB 04FC 04FD 04FE 04FF 0500 0501 0502
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF 50 49 43
043C 043D 043E 043F 0440 0441 0442 0443 0444 0445 0446 0447 0448 0449 044A 044B 044C 044D 044E 044F 0450 0451 0452 0453 0454 0455 0456 0457 0458 0459 045A 045B 045C 045D 045E 045F 0460 0461 0526 0527 0528 0529 052A 052B 052C 052D 052E 052F 0530 0531 0532 0533
FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF 00 01 00 01 00 01 FF FF FF FF 45 45 44 20 54 4F 20 42 45 20 52 45 46 45
046D 046E 046F 0470 0471 0472 0473 0474 0475 0476 0477 0478 0479 047A 047B 047C 047D 047E 047F 0480 0481 0482 0483 0484 0485 0486 0487 0488 0489 048A 048B 048C 048D 048E 048F 0490 0491 0492 0557 0558 0559 055A 055B 055C 055D 055E 055F 0560 0561 0562 0563 0564
00 01 00 00 01 01 00 00 00 FF FF FF FF FF FF 00 00 FF FF 18 00 01 00 00 50 07 20 00 10 00 00 10 10 00 00 FF FF FF 20 50 52 45 53 53 45 44 20 4D 41 43 48 49
049E 049F 04A0 04A1 04A2 04A3 04A4 04A5 04A6 04A7 04A8 04A9 04AA 04AB 04AC 04AD 04AE 04AF 04B0 04B1 04B2 04B3 04B4 04B5 04B6 04B7 04B8 04B9 04BA 04BB 04BC 04BD 04BE 04BF 04C0 04C1 04C2 04C3 0588 0589 058A 058B 058C 058D 058E 058F 0590 0591 0592 0593 0594 0595
FF FF FF FF 00 50 99 99 99 99 99 99 25 00 25 00 00 00 00 01 00 00 00 00 00 03 05 00 00 00 00 00 00 01 00 FF FF FF 50 55 54 20 48 41 53 20 43 48 41 4E 47 45
04D2 04D3 04D4 04D5 04D6 04D7 04D8 04D9 04DA 04DB 04DC 04DD 04DE 04DF 04E0 04E1 04E2 04E3 04E4 04E5 04E6 04E7 04E8 04E9 04EA 04EB 04EC 04ED 04EE 04EF 04F0 04F1 04F2 04F3 04F4 05B9 05BA 05BB 05BC 05BD 05BE 05BF 05C0 05C1 05C2 05C3 05C4 05C5 05C6 05C7 05C8 05C9
01 80 01 80 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 FF FF FF FF FF FF FF FF FF 56 45 4C 20 20 20 20 4D 4F 56 45 20 41 58 49 53 20
0503 0504 0505 0506 0507 0508 0509 050A 050B 050C 050D 050E 050F 0510 0511 0512 0513 0514 0515 0516 0517 0518 0519 051A 051B 051C 051D 051E 051F 0520 0521 0522 0523 0524 0525 05EA 05EB 05EC 05ED 05EE 05EF 05F0 05F1 05F2 05F3 05F4 05F5 05F6 05F7 05F8 05F9 05FA
20 52 45 56 49 53 49 4F 4E 20 23 30 30 35 20 2D 20 20 31 2F 31 34 2F 39 33 20 20 20 20 41 58 45 53 20 4E 49 54 43 48 20 49 53 20 54 55 52 4E 45 44 20 4F 46
0534 0535 0536 0537 0538 0539 053A 053B 053C 053D 053E 053F 0540 0541 0542 0543 0544 0545 0546 0547 0548 0549 054A 054B 054C 054D 054E 054F 0550 0551 0552 0553 0554 0555 0556 061B 061C 061D 061E 061F 0620 0621 0622 0623 0624 0625 0626 0627 0628 0629 062A 062B
52 45 4E 43 45 44 20 20 20 20 20 20 4F 4E 45 20 4F 52 20 4D 4F 52 45 20 4A 4F 47 20 42 55 54 54 4F 4E 53 49 56 45 20 20 53 50 49 4E 44 4C 45 20 53 57 49 54
0565 0566 0567 0568 0569 056A 056B 056C 056D 056E 056F 0570 0571 0572 0573 0574 0575 0576 0577 0578 0579 057A 057B 057C 057D 057E 057F 0580 0581 0582 0583 0584 0585 0586 0587 064C 064D 064E 064F 0650 0651 0652 0653 0654 0655 0656 0657 0658 0659 065A 065B 065C
4E 45 20 49 4E 50 55 54 20 48 41 53 20 43 48 41 4E 47 45 44 20 53 54 41 54 45 20 50 41 4E 45 4C 20 49 4E 53 57 20 49 4E 20 4F 46 46 20 50 4F 53 49 54 49 4F
0596 0597 0598 0599 059A 059B 059C 059D 059E 059F 05A0 05A1 05A2 05A3 05A4 05A5 05A6 05A7 05A8 05A9 05AA 05AB 05AC 05AD 05AE 05AF 05B0 05B1 05B2 05B3 05B4 05B5 05B6 05B7 05B8 067D 067E 067F 0680 0681 0682 0683 0684 0685 0686 0687 0688 0689 068A 068B 068C 068D
44 20 53 54 41 54 45 20 20 20 09 09 09 09 09 09 09 09 20 48 41 52 44 57 41 52 45 20 4F 56 45 52 54 52 41 45 41 52 53 50 4E 44 4C 45 20 4D 55 53 54 20 42 45
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0CF4 0CF5 0CF6 0CF7 0CF8 0CF9 0CFA 0CFB 0CFC 0CFD 0CFE 0DC3 0DC4 0DC5 0DC6 0DC7 0DC8 0DC9 0DCA 0DCB 0DCC 0DCD 0DCE 0DCF 0DD0 0DD1 0DD2 0DD3 0DD4 0DD5 0DD6 0DD7 0DD8 0DD9 0DDA 0DDB 0DDC 0DDD 0DDE 0DDF 0DE0 0DE1 0DE2 0DE3 0DE4 0DE5 0DE6 0DE7 0DE8 0DE9 0DEA 0DEB
4D 42 45 52 20 36 34 20 20 20 20 2D 2D 4F 4F 4C 20 43 48 41 4E 47 45 20 20 4D 35 30 2D 46 52 20 4F 56 52 3D 31 30 30 25 4D 30 37 2D 4D 49 53 54 20 43 4F 4F
0D25 0D26 0D27 0D28 0D29 0D2A 0D2B 0D2C 0D2D 0D2E 0D2F 0DF4 0DF5 0DF6 0DF7 0DF8 0DF9 0DFA 0DFB 0DFC 0DFD 0DFE 0DFF 0E00 0E01 0E02 0E03 0E04 0E05 0E06 0E07 0E08 0E09 0E0A 0E0B 0E0C 0E0D 0E0E 0E0F 0E10 0E11 0E12 0E13 0E14 0E15 0E16 0E17 0E18 0E19 0E1A 0E1B 0E1C
50 54 20 50 47 4D 20 53 54 50 20 2D 4D 34 39 20 26 20 4D 35 30 20 20 4D 30 38 2D 46 4C 4F 4F 44 20 43 4F 4F 4C 20 20 20 4D 36 30 3E 36 33 2D 54 4F 4F 4C 20
0D56 0D57 0D58 0D59 0D5A 0D5B 0D5C 0D5D 0D5E 0D5F 0D60 0E25 0E26 0E27 0E28 0E29 0E2A 0E2B 0E2C 0E2D 0E2E 0E2F 0E30 0E31 0E32 0E33 0E34 0E35 0E36 0E37 0E38 0E39 0E3A 0E3B 0E3C 0E3D 0E3E 0E3F 0E40 0E41 0E42 0E43 0E44 0E45 0E46 0E47 0E48 0E49 0E4A 0E4B 0E4C 0E4D
50 20 53 50 44 20 48 4F 4D 45 4D 4F 4F 4C 41 4E 54 20 4F 46 46 20 20 4D 36 37 2D 54 4C 20 43 41 52 20 48 4F 4D 45 4D 31 33 2D 4D 30 33 20 26 20 4D 30 38 20
0D8A 0D8B 0D8C 0D8D 0D8E 0D8F 0D90 0D91 0E56 0E57 0E58 0E59 0E5A 0E5B 0E5C 0E5D 0E5E 0E5F 0E60 0E61 0E62 0E63 0E64 0E65 0E66 0E67 0E68 0E69 0E6A 0E6B 0E6C 0E6D 0E6E 0E6F 0E70 0E71 0E72 0E73 0E74 0E75 0E76 0E77 0E78 0E79 0E7A 0E7B 0E7C 0E7D 0E7E 0E7F 0E80 0E81
45 20 43 43 57 20 20 4D 4E 43 4C 20 4D 38 31 2D 38 32 4D 31 34 2D 4D 30 34 20 26 20 4D 30 38 20 20 20 20 4D 38 31 2D 50 52 54 43 54 20 50 52 42 20 31 4D 31
0DBB 0DBC 0DBD 0DBE 0DBF 0DC0 0DC1 0DC2 0E87 0E88 0E89 0E8A 0E8B 0E8C 0E8D 0E8E 0E8F 0E90 0E91 0E92 0E93 0E94 0E95 0E96 0E97 0E98 0E99 0E9A 0E9B 0E9C 0E9D 0E9E 0E9F 0EA0 0EA1 0EA2 0EA3 0EA4 0EA5 0EA6 0EA7 0EA8 0EA9 0EAA 0EAB 0EAC 0EAD 0EAE 0EAF 0EB0 0EB1 0EB2
3D 31 30 30 25 4D 30 36 4C 20 4D 31 39 3E 32 33 20 20 4D 38 32 2D 50 52 54 43 54 20 50 52 42 20 32 4D 31 39 3E 32 33 2D 4F 52 49 45 4E 54 20 53 50 20 4D 39
0DEC 0DED 0DEE 0DEF 0DF0 0DF1 0DF2 0DF3 0EB8 0EB9 0EBA 0EBB 0EBC 0EBD 0EBE 0EBF 0EC0 0EC1 0EC2 0EC3 0EC4 0EC5 0EC6 0EC7 0EC8 0EC9 0ECA 0ECB 0ECC 0ECD 0ECE 0ECF 0ED0 0ED1 0ED2 0ED3 0ED4 0ED5 0ED6 0ED7 0ED8 0ED9 0EDA 0EDB 0EDC 0EDD 0EDE 0EDF 0EE0 0EE1 0EE2 0EE3
4C 20 20 20 20 4D 35 31 20 41 58 49 53 20 20 20 53 50 49 4E 44 4C 45 20 53 57 20 49 53 20 49 4E 20 43 43 57 20 50 4F 53 49 54 49 4F 4E 20 20 20 53 50 49 4E
0E1D 0E1E 0E1F 0E20 0E21 0E22 0E23 0E24 0EE9 0EEA 0EEB 0EEC 0EED 0EEE 0EEF 0EF0 0EF1 0EF2 0EF3 0EF4 0EF5 0EF6 0EF7 0EF8 0EF9 0EFA 0EFB 0EFC 0EFD 0EFE 0EFF 0F00 0F01 0F02 0F03 0F04 0F05 0F06 0F07 0F08 0F09 0F0A 0F0B 0F0C 0F0D 0F0E 0F0F 0F10 0F11 0F12 0F13 0F14
43 48 47 4D 30 39 2D 43 57 20 49 53 20 49 4E 20 41 55 54 4F 20 50 4F 53 49 54 49 4F 4E 20 20 53 50 49 4E 44 4C 45 20 53 57 20 49 53 20 49 4E 20 43 57 20 50
0E4E 0E4F 0E50 0E51 0E52 0E53 0E54 0E55 0F1A 0F1B 0F1C 0F1D 0F1E 0F1F 0F20 0F21 0F22 0F23 0F24 0F25 0F26 0F27 0F28 0F29 0F2A 0F2B 0F2C 0F2D 0F2E 0F2F 0F30 0F31 0F32 0F33 0F34 0F35 0F36 0F37 0F38 0F39 0F3A 0F3B 0F3C 0F3D 0F3E 0F3F 0F40 0F41 0F42 0F43 0F44 0F45
20 20 20 4D 38 30 2D 43 4F 4E 20 20 20 20 43 4F 4F 4C 41 4E 54 20 53 57 20 49 53 20 49 4E 20 4D 41 4E 55 41 4C 20 50 4F 53 49 54 49 4F 4E 43 4F 4F 4C 41 4E
0E82 0E83 0E84 0E85 0E86 0F4B 0F4C 0F4D 0F4E 0F4F 0F50 0F51 0F52 0F53 0F54 0F55 0F56 0F57 0F58 0F59 0F5A 0F5B 0F5C 0F5D 0F5E 0F5F 0F60 0F61 0F62 0F63 0F64 0F65 0F66 0F67 0F68 0F69 0F6A 0F6B 0F6C 0F6D 0F6E 0F6F 0F70 0F71 0F72 0F73 0F74 0F75 0F76 0F77 0F78 0F79
38 2D 43 4E 43 49 53 20 49 4E 20 41 55 54 4F 20 50 4F 53 49 54 49 4F 4E 20 20 4F 50 54 49 4F 4E 20 53 54 4F 50 20 41 43 54 49 56 45 20 53 57 49 54 43 48 20
0EB3 0EB4 0EB5 0EB6 0EB7 0F7C 0F7D 0F7E 0F7F 0F80 0F81 0F82 0F83 0F84 0F85 0F86 0F87 0F88 0F89 0F8A 0F8B 0F8C 0F8D 0F8E 0F8F 0F90 0F91 0F92 0F93 0F94 0F95 0F96 0F97 0F98 0F99 0F9A 0F9B 0F9C 0F9D 0F9E 0F9F 0FA0 0FA1 0FA2 0FA3 0FA4 0FA5 0FA6 0FA7 0FA8 0FA9 0FAA
30 2D 41 55 58 20 4F 4E 20 42 4C 4F 43 4B 20 44 45 4C 45 54 45 20 41 43 54 49 56 45 20 53 57 49 54 43 48 20 49 53 20 4F 4E 43 59 43 4C 45 20 4C 55 42 45 20
0EE4 0EE5 0EE6 0EE7 0EE8 0FAD 0FAE 0FAF 0FB0 0FB1 0FB2 0FB3 0FB4 0FB5 0FB6 0FB7 0FB8 0FB9 0FBA 0FBB 0FBC 0FBD 0FBE 0FBF 0FC0 0FC1 0FC2 0FC3 0FC4 0FC5 0FC6 0FC7 0FC8 0FC9 0FCA 0FCB 0FCC 0FCD 0FCE 0FCF 0FD0 0FD1 0FD2 0FD3 0FD4 0FD5 0FD6 0FD7 0FD8 0FD9 0FDA 0FDB
44 4C 45 20 53 53 54 45 4D 20 53 57 20 49 53 20 50 52 45 53 53 45 44 20 50 52 4F 54 45 43 54 20 50 52 4F 42 45 20 4E 4F 2E 20 31 20 53 57 49 54 43 48 20 49
0F15 0F16 0F17 0F18 0F19 0FDE 0FDF 0FE0 0FE1 0FE2 0FE3 0FE4 0FE5 0FE6 0FE7 0FE8 0FE9 0FEA 0FEB 0FEC 0FED 0FEE 0FEF 0FF0 0FF1 0FF2 0FF3 0FF4 0FF5 0FF6 0FF7 0FF8 0FF9 0FFA 0FFB 0FFC 0FFD 0FFE 0FFF 1000 1001 1002 1003 1004 1005 1006 1007 1008 1009 100A 100B 100C
4F 53 49 54 49 4F 4E 50 52 4F 54 45 43 54 20 50 52 4F 42 45 20 4E 4F 2E 20 32 20 53 57 49 54 43 48 20 49 53 20 4F 4E 4A 4F 47 20 35 54 48 20 41 58 49 53 20
0F46 0F47 0F48 0F49 0F4A 100F 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 101A 101B 101C 101D 101E 101F 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 102A 102B 102C 102D 102E 102F 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 103A 103B 103C 103D
54 20 53 57 20 4E 55 53 20 49 53 20 50 52 45 53 53 45 44 20 20 20 4A 4F 47 20 35 54 48 20 41 58 49 53 20 50 4C 55 53 20 49 53 20 50 52 45 53 53 45 44 20 20
0F7A 0F7B 1040 1041 1042 1043 1044 1045 1046 1047 1048 1049 104A 104B 104C 104D 104E 104F 1050 1051 1052 1053 1054 1055 1056 1057 1058 1059 105A 105B 105C 105D 105E 105F 1060 1061 1062 1063 1064 1065 1066 1067 1068 1069 106A 106B 106C 106D 106E 106F 1070 1135
49 53 54 4F 4F 4C 20 43 48 47 20 53 57 20 49 53 20 49 4E 20 4D 41 4E 20 50 4F 53 49 54 49 4F 4E 20 20 54 4F 4F 4C 20 43 48 47 20 53 57 20 49 53 20 49 4E 49
0FAB 0FAC 1071 1072 1073 1074 1075 1076 1077 1078 1079 107A 107B 107C 107D 107E 107F 1080 1081 1082 1083 1084 1085 1086 1087 1088 1089 108A 108B 108C 108D 108E 108F 1090 1091 1092 1093 1094 1095 1096 1097 1098 1099 109A 109B 109C 109D 109E 109F 10A0 10A1 1166
53 59 20 41 55 54 4F 20 50 4F 53 49 54 49 4F 4E 20 43 4F 4F 4C 41 4E 54 20 53 45 4C 45 43 54 20 53 57 20 41 54 20 46 4C 4F 4F 44 20 50 4F 53 27 4E 43 4F 49
0FDC 0FDD 10A2 10A3 10A4 10A5 10A6 10A7 10A8 10A9 10AA 10AB 10AC 10AD 10AE 10AF 10B0 10B1 10B2 10B3 10B4 10B5 10B6 10B7 10B8 10B9 10BA 10BB 10BC 10BD 10BE 10BF 10C0 10C1 10C2 10C3 10C4 10C5 10C6 10C7 10C8 10C9 10CA 10CB 10CC 10CD 10CE 10CF 10D0 10D1 10D2 1197
53 20 4F 4C 41 4E 54 20 53 45 4C 45 43 54 20 53 57 20 41 54 20 4D 49 53 54 20 50 4F 53 27 4E 20 44 52 41 57 20 42 41 52 20 4F 50 45 52 41 54 49 4F 4E 20 20
100D 100E 10D3 10D4 10D5 10D6 10D7 10D8 10D9 10DA 10DB 10DC 10DD 10DE 10DF 10E0 10E1 10E2 10E3 10E4 10E5 10E6 10E7 10E8 10E9 10EA 10EB 10EC 10ED 10EE 10EF 10F0 10F1 10F2 10F3 10F4 10F5 10F6 10F7 10F8 10F9 10FA 10FB 10FC 10FD 10FE 10FF 1100 1101 1102 1103 11C8
4D 49 50 42 20 49 53 20 50 52 45 53 53 45 44 53 45 54 55 50 20 4D 4F 44 45 20 49 4E 48 49 42 49 54 20 53 57 49 54 43 48 20 49 53 20 4F 4E 20 4D 54 42 20 43
103E 103F 1104 1105 1106 1107 1108 1109 110A 110B 110C 110D 110E 110F 1110 1111 1112 1113 1114 1115 1116 1117 1118 1119 111A 111B 111C 111D 111E 111F 1120 1121 1122 1123 1124 1125 1126 1127 1128 1129 112A 112B 112C 112D 112E 112F 1130 1131 1132 1133 1134 11F9
20 20 53 57 49 54 43 48 20 4E 55 4D 42 45 52 20 31 39 20 49 53 20 50 52 45 53 53 45 44 20 4D 54 42 20 53 57 49 54 43 48 20 4E 55 4D 42 45 52 20 32 30 20 52
1136 1137 1138 1139 113A 113B 113C 113D 113E 113F 1140 1141 1142 1143 1144 1145 1146 1147 1148 1149 114A 114B 114C 114D 114E 114F 1150 1151 1152 1153 1154 1155 1156 1157 1158 1159 115A 115B 115C 115D 115E 115F 1160 1161 1162 1163 1164 1165 122A 122B 122C 122D
53 20 50 52 45 53 53 45 44 20 4D 54 42 20 53 57 49 54 43 48 20 4E 55 4D 42 45 52 20 32 31 20 49 53 20 50 52 45 53 53 45 44 20 4D 54 42 20 53 57 20 4E 55 4D
1167 1168 1169 116A 116B 116C 116D 116E 116F 1170 1171 1172 1173 1174 1175 1176 1177 1178 1179 117A 117B 117C 117D 117E 117F 1180 1181 1182 1183 1184 1185 1186 1187 1188 1189 118A 118B 118C 118D 118E 118F 1190 1191 1192 1193 1194 1195 1196 125B 125C 125D 125E
54 43 48 20 4E 55 4D 42 45 52 20 32 32 20 49 53 20 50 52 45 53 53 45 44 20 4D 54 42 20 53 57 49 54 43 48 20 4E 55 4D 42 45 52 20 32 33 20 49 53 53 53 45 44
1198 1199 119A 119B 119C 119D 119E 119F 11A0 11A1 11A2 11A3 11A4 11A5 11A6 11A7 11A8 11A9 11AA 11AB 11AC 11AD 11AE 11AF 11B0 11B1 11B2 11B3 11B4 11B5 11B6 11B7 11B8 11B9 11BA 11BB 11BC 11BD 11BE 11BF 11C0 11C1 11C2 11C3 11C4 11C5 11C6 11C7 128C 128D 128E 128F
50 52 45 53 53 45 44 20 4D 54 42 20 53 57 49 54 43 48 20 4E 55 4D 42 45 52 20 32 34 20 49 53 20 50 52 45 53 53 45 44 20 4D 54 42 20 53 57 49 54 55 4D 42 45
11C9 11CA 11CB 11CC 11CD 11CE 11CF 11D0 11D1 11D2 11D3 11D4 11D5 11D6 11D7 11D8 11D9 11DA 11DB 11DC 11DD 11DE 11DF 11E0 11E1 11E2 11E3 11E4 11E5 11E6 11E7 11E8 11E9 11EA 11EB 11EC 11ED 11EE 11EF 11F0 11F1 11F2 11F3 11F4 11F5 11F6 11F7 11F8 12BD 12BE 12BF 12C0
48 20 4E 55 4D 42 45 52 20 32 35 20 49 53 20 50 52 45 53 53 45 44 20 4D 54 42 20 53 57 49 54 43 48 20 4E 55 4D 42 45 52 20 32 36 20 49 53 20 50 45 44 20 4D
11FA 11FB 11FC 11FD 11FE 11FF 1200 1201 1202 1203 1204 1205 1206 1207 1208 1209 120A 120B 120C 120D 120E 120F 1210 1211 1212 1213 1214 1215 1216 1217 1218 1219 121A 121B 121C 121D 121E 121F 1220 1221 1222 1223 1224 1225 1226 1227 1228 1229 12EE 12EF 12F0 12F1
45 53 53 45 44 20 4D 54 42 20 53 57 49 54 43 48 20 4E 55 4D 42 45 52 20 32 37 20 49 53 20 50 52 45 53 53 45 44 20 4D 54 42 20 53 57 49 54 43 48 41 47 45 20
122E 122F 1230 1231 1232 1233 1234 1235 1236 1237 1238 1239 123A 123B 123C 123D 123E 123F 1240 1241 1242 1243 1244 1245 1246 1247 1248 1249 124A 124B 124C 124D 124E 124F 1250 1251 1252 1253 1254 1255 1256 1257 1258 1259 125A 131F 1320 1321 1322 1323 1324 1325
42 45 52 20 32 38 20 49 53 20 50 52 45 53 53 45 44 20 4D 54 42 20 53 57 49 54 43 48 20 4E 55 4D 42 45 52 20 32 39 20 49 53 20 50 52 45 20 4D 54 42 20 46 41
125F 1260 1261 1262 1263 1264 1265 1266 1267 1268 1269 126A 126B 126C 126D 126E 126F 1270 1271 1272 1273 1274 1275 1276 1277 1278 1279 127A 127B 127C 127D 127E 127F 1280 1281 1282 1283 1284 1285 1286 1287 1288 1289 128A 128B 1350 1351 1352 1353 1354 1355 1356
20 4D 54 42 20 53 57 49 54 43 48 20 4E 55 4D 42 45 52 20 33 30 20 49 53 20 50 52 45 53 53 45 44 20 4D 54 42 20 53 57 49 54 43 48 20 4E 45 20 4E 55 4D 42 45
1290 1291 1292 1293 1294 1295 1296 1297 1298 1299 129A 129B 129C 129D 129E 129F 12A0 12A1 12A2 12A3 12A4 12A5 12A6 12A7 12A8 12A9 12AA 12AB 12AC 12AD 12AE 12AF 12B0 12B1 12B2 12B3 12B4 12B5 12B6 12B7 12B8 12B9 12BA 12BB 12BC 1381 1382 1383 1384 1385 1386 1387
52 20 33 31 20 49 53 20 50 52 45 53 53 45 44 20 4D 54 42 20 53 57 49 54 43 48 20 4E 55 4D 42 45 52 20 33 32 20 49 53 20 50 52 45 53 53 54 42 20 46 41 55 4C
12C1 12C2 12C3 12C4 12C5 12C6 12C7 12C8 12C9 12CA 12CB 12CC 12CD 12CE 12CF 12D0 12D1 12D2 12D3 12D4 12D5 12D6 12D7 12D8 12D9 12DA 12DB 12DC 12DD 12DE 12DF 12E0 12E1 12E2 12E3 12E4 12E5 12E6 12E7 12E8 12E9 12EA 12EB 12EC 12ED 13B2 13B3 13B4 13B5 13B6 13B7 13B8
54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 39 37 20 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 4E 55 4D 42 45 52 20
12F2 12F3 12F4 12F5 12F6 12F7 12F8 12F9 12FA 12FB 12FC 12FD 12FE 12FF 1300 1301 1302 1303 1304 1305 1306 1307 1308 1309 130A 130B 130C 130D 130E 130F 1310 1311 1312 1313 1314 1315 1316 1317 1318 1319 131A 131B 131C 131D 131E 13E3 13E4 13E5 13E6 13E7 13E8 13E9
4E 55 4D 42 45 52 20 39 38 20 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 39 39 20 20 20 20 20 46 41 55 4C 54 20
1326 1327 1328 1329 132A 132B 132C 132D 132E 132F 1330 1331 1332 1333 1334 1335 1336 1337 1338 1339 133A 133B 133C 133D 133E 133F 1340 1341 1342 1343 1344 1345 1346 1347 1348 1349 134A 134B 134C 134D 134E 134F 1414 1415 1416 1417 1418 1419 141A 141B 141C 141D
55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 30 30 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 4D 42 45 52 20 31 30 37 20 20
1357 1358 1359 135A 135B 135C 135D 135E 135F 1360 1361 1362 1363 1364 1365 1366 1367 1368 1369 136A 136B 136C 136D 136E 136F 1370 1371 1372 1373 1374 1375 1376 1377 1378 1379 137A 137B 137C 137D 137E 137F 1380 1445 1446 1447 1448 1449 144A 144B 144C 144D 144E
52 20 31 30 31 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 30 32 20 20 20 20 4D 41 55 4C 54 20 4D 45 53 53 41
1388 1389 138A 138B 138C 138D 138E 138F 1390 1391 1392 1393 1394 1395 1396 1397 1398 1399 139A 139B 139C 139D 139E 139F 13A0 13A1 13A2 13A3 13A4 13A5 13A6 13A7 13A8 13A9 13AA 13AB 13AC 13AD 13AE 13AF 13B0 13B1 1476 1477 1478 1479 147A 147B 147C 147D 147E 147F
54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 30 33 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 45 52 20 31 31 30 20 20 20 20
13B9 13BA 13BB 13BC 13BD 13BE 13BF 13C0 13C1 13C2 13C3 13C4 13C5 13C6 13C7 13C8 13C9 13CA 13CB 13CC 13CD 13CE 13CF 13D0 13D1 13D2 13D3 13D4 13D5 13D6 13D7 13D8 13D9 13DA 13DB 13DC 13DD 13DE 13DF 13E0 13E1 13E2 14A7 14A8 14A9 14AA 14AB 14AC 14AD 14AE 14AF 14B0
31 30 34 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 30 35 20 20 20 20 4D 54 42 4C 54 20 4D 45 53 53 41 47 45
13EA 13EB 13EC 13ED 13EE 13EF 13F0 13F1 13F2 13F3 13F4 13F5 13F6 13F7 13F8 13F9 13FA 13FB 13FC 13FD 13FE 13FF 1400 1401 1402 1403 1404 1405 1406 1407 1408 1409 140A 140B 140C 140D 140E 140F 1410 1411 1412 1413 14D8 14D9 14DA 14DB 14DC 14DD 14DE 14DF 14E0 14E1
4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 30 36 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 20 31 31 33 20 20 20 20 4D 54
141E 141F 1420 1421 1422 1423 1424 1425 1426 1427 1428 1429 142A 142B 142C 142D 142E 142F 1430 1431 1432 1433 1434 1435 1436 1437 1438 1439 143A 143B 143C 143D 143E 143F 1440 1441 1442 1443 1444 1509 150A 150B 150C 150D 150E 150F 1510 1511 1512 1513 1514 1515
20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 30 38 20 20 20 20 4D 54 42 20 46 20 4D 45 53 53 41 47 45 20 4E 55 4D 42
144F 1450 1451 1452 1453 1454 1455 1456 1457 1458 1459 145A 145B 145C 145D 145E 145F 1460 1461 1462 1463 1464 1465 1466 1467 1468 1469 146A 146B 146C 146D 146E 146F 1470 1471 1472 1473 1474 1475 153A 153B 153C 153D 153E 153F 1540 1541 1542 1543 1544 1545 1546
47 45 20 4E 55 4D 42 45 52 20 31 30 39 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 31 36 20 20 20 20 4D 54 42 20 46 41 55
1480 1481 1482 1483 1484 1485 1486 1487 1488 1489 148A 148B 148C 148D 148E 148F 1490 1491 1492 1493 1494 1495 1496 1497 1498 1499 149A 149B 149C 149D 149E 149F 14A0 14A1 14A2 14A3 14A4 14A5 14A6 156B 156C 156D 156E 156F 1570 1571 1572 1573 1574 1575 1576 1577
4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 31 31 20 20 20 20 4D 54 42 20 46 41 55 45 53 53 41 47 45 20 4E 55 4D 42 45 52
14B1 14B2 14B3 14B4 14B5 14B6 14B7 14B8 14B9 14BA 14BB 14BC 14BD 14BE 14BF 14C0 14C1 14C2 14C3 14C4 14C5 14C6 14C7 14C8 14C9 14CA 14CB 14CC 14CD 14CE 14CF 14D0 14D1 14D2 14D3 14D4 14D5 14D6 14D7 159C 159D 159E 159F 15A0 15A1 15A2 15A3 15A4 15A5 15A6 15A7 15A8
20 4E 55 4D 42 45 52 20 31 31 32 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 20 20 20 4D 54 42 20 46 41 55 4C 54
14E2 14E3 14E4 14E5 14E6 14E7 14E8 14E9 14EA 14EB 14EC 14ED 14EE 14EF 14F0 14F1 14F2 14F3 14F4 14F5 14F6 14F7 14F8 14F9 14FA 14FB 14FC 14FD 14FE 14FF 1500 1501 1502 1503 1504 1505 1506 1507 1508 15CD 15CE 15CF 15D0 15D1 15D2 15D3 15D4 15D5 15D6 15D7 15D8 15D9
42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 31 34 20 20 20 20 4D 54 42 20 46 41 55 4C 54 53 41 47 45 20 4E 55 4D 42 45 52 20 31
1516 1517 1518 1519 151A 151B 151C 151D 151E 151F 1520 1521 1522 1523 1524 1525 1526 1527 1528 1529 152A 152B 152C 152D 152E 152F 1530 1531 1532 1533 1534 1535 1536 1537 1538 1539 15FE 15FF 1600 1601 1602 1603 1604 1605 1606 1607 1608 1609 160A 160B 160C 160D
45 52 20 31 31 35 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53
1547 1548 1549 154A 154B 154C 154D 154E 154F 1550 1551 1552 1553 1554 1555 1556 1557 1558 1559 155A 155B 155C 155D 155E 155F 1560 1561 1562 1563 1564 1565 1566 1567 1568 1569 156A 162F 1630 1631 1632 1633 1634 1635 1636 1637 1638 1639 163A 163B 163C 163D 163E
4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 31 37 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 47 45 20 4E 55 4D 42 45 52 20 31 32 34 20 20 20
1578 1579 157A 157B 157C 157D 157E 157F 1580 1581 1582 1583 1584 1585 1586 1587 1588 1589 158A 158B 158C 158D 158E 158F 1590 1591 1592 1593 1594 1595 1596 1597 1598 1599 159A 159B 1660 1661 1662 1663 1664 1665 1666 1667 1668 1669 166A 166B 166C 166D 166E 166F
20 31 31 38 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 31 39 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47
15A9 15AA 15AB 15AC 15AD 15AE 15AF 15B0 15B1 15B2 15B3 15B4 15B5 15B6 15B7 15B8 15B9 15BA 15BB 15BC 15BD 15BE 15BF 15C0 15C1 15C2 15C3 15C4 15C5 15C6 15C7 15C8 15C9 15CA 15CB 15CC 1691 1692 1693 1694 1695 1696 1697 1698 1699 169A 169B 169C 169D 169E 169F 16A0
20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 32 30 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 20 4E 55 4D 42 45 52 20 31 32 37 20 20 20 20 4D
15DA 15DB 15DC 15DD 15DE 15DF 15E0 15E1 15E2 15E3 15E4 15E5 15E6 15E7 15E8 15E9 15EA 15EB 15EC 15ED 15EE 15EF 15F0 15F1 15F2 15F3 15F4 15F5 15F6 15F7 15F8 15F9 15FA 15FB 15FC 15FD 16C2 16C3 16C4 16C5 16C6 16C7 16C8 16C9 16CA 16CB 16CC 16CD 16CE 16CF 16D0 16D1
32 31 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 32 32 20 20 58 20 41 58 49 53 2D 20 58 20 41 58 49 53 2B 20
160E 160F 1610 1611 1612 1613 1614 1615 1616 1617 1618 1619 161A 161B 161C 161D 161E 161F 1620 1621 1622 1623 1624 1625 1626 1627 1628 1629 162A 162B 162C 162D 162E 16F3 16F4 16F5 16F6 16F7 16F8 16F9 16FA 16FB 16FC 16FD 16FE 16FF 1700 1701 1702 1703 1704 1705
41 47 45 20 4E 55 4D 42 45 52 20 31 32 33 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 54 48 20 41 58 2D 20 34 54 48 20 41 58 2B 20 35 54 48 20
163F 1640 1641 1642 1643 1644 1645 1646 1647 1648 1649 164A 164B 164C 164D 164E 164F 1650 1651 1652 1653 1654 1655 1656 1657 1658 1659 165A 165B 165C 165D 165E 165F 1724 1725 1726 1727 1728 1729 172A 172B 172C 172D 172E 172F 1730 1731 1732 1733 1734 1735 1736
20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 32 35 20 20 20 20 54 31 34 30 49 4E 53 52 54 31 34 31 49 4E 53 52 54 31 34
1670 1671 1672 1673 1674 1675 1676 1677 1678 1679 167A 167B 167C 167D 167E 167F 1680 1681 1682 1683 1684 1685 1686 1687 1688 1689 168A 168B 168C 168D 168E 168F 1690 1755 1756 1757 1758 1759 175A 175B 175C 175D 175E 175F 1760 1761 1762 1763 1764 1765 1766 1767
45 20 4E 55 4D 42 45 52 20 31 32 36 20 20 20 20 4D 54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 31 34 36 49 4E 53 52 54 31 34 37 49 4E 53 52 54 31 34 38
16A1 16A2 16A3 16A4 16A5 16A6 16A7 16A8 16A9 16AA 16AB 16AC 16AD 16AE 16AF 16B0 16B1 16B2 16B3 16B4 16B5 16B6 16B7 16B8 16B9 16BA 16BB 16BC 16BD 16BE 16BF 16C0 16C1 1786 1787 1788 1789 178A 178B 178C 178D 178E 178F 1790 1791 1792 1793 1794 1795 1796 1797 1798
54 42 20 46 41 55 4C 54 20 4D 45 53 53 41 47 45 20 4E 55 4D 42 45 52 20 31 32 38 20 20 20 20 2B 20 35 32 49 4E 53 52 54 31 35 33 49 4E 53 52 54 31 35 34 49
16D2 16D3 16D4 16D5 16D6 16D7 16D8 16D9 16DA 16DB 16DC 16DD 16DE 16DF 16E0 16E1 16E2 16E3 16E4 16E5 16E6 16E7 16E8 16E9 16EA 16EB 16EC 16ED 16EE 16EF 16F0 16F1 16F2 17B7 17B8 17B9 17BA 17BB 17BC 17BD 17BE 17BF 17C0 17C1 17C2 17C3 17C4 17C5 17C6 17C7 17C8 17C9
59 20 41 58 49 53 2D 20 59 20 41 58 49 53 2B 20 5A 20 41 58 49 53 2D 20 5A 20 41 58 49 53 2B 20 34 38 49 4E 53 52 54 31 35 39 49 4E 53 52 54 31 36 30 49 4E
1706 1707 1708 1709 170A 170B 170C 170D 170E 170F 1710 1711 1712 1713 1714 1715 1716 1717 1718 1719 171A 171B 171C 171D 171E 171F 1720 1721 1722 1723 17E8 17E9 17EA 17EB 17EC 17ED 17EE 17EF 17F0 17F1 17F2 17F3 17F4 17F5 17F6 17F7 17F8 17F9 17FA 17FB 17FC 17FD
41 58 2D 20 35 54 48 20 41 58 49 4E 53 52 54 31 33 38 49 4E 53 52 54 31 33 39 49 4E 53 52 49 4E 53 52 54 31 36 35 49 4E 53 52 54 31 36 36 49 4E 53 52 54 31
1737 1738 1739 173A 173B 173C 173D 173E 173F 1740 1741 1742 1743 1744 1745 1746 1747 1748 1749 174A 174B 174C 174D 174E 174F 1750 1751 1752 1753 1754 1819 181A 181B 181C 181D 181E 181F 1820 1821 1822 1823 1824 1825 1826 1827 1828 1829 182A 182B 182C 182D 182E
32 49 4E 53 52 54 31 34 33 49 4E 53 52 54 31 34 34 49 4E 53 52 54 31 34 35 49 4E 53 52 54 4E 53 52 54 31 37 31 49 4E 53 52 54 31 37 32 49 4E 53 52 54 31 37
1768 1769 176A 176B 176C 176D 176E 176F 1770 1771 1772 1773 1774 1775 1776 1777 1778 1779 177A 177B 177C 177D 177E 177F 1780 1781 1782 1783 1784 1785 184A 184B 184C 184D 184E 184F 1850 1851 1852 1853 1854 1855 1856 1857 1858 1859 185A 185B 185C 185D 185E 185F
49 4E 53 52 54 31 34 39 49 4E 53 52 54 31 35 30 49 4E 53 52 54 31 35 31 49 4E 53 52 54 31 53 52 54 31 37 37 49 4E 53 52 54 31 37 38 49 4E 53 52 54 31 37 39
1799 179A 179B 179C 179D 179E 179F 17A0 17A1 17A2 17A3 17A4 17A5 17A6 17A7 17A8 17A9 17AA 17AB 17AC 17AD 17AE 17AF 17B0 17B1 17B2 17B3 17B4 17B5 17B6 187B 187C 187D 187E 187F 1880 1881 1882 1883 1884 1885 1886 1887 1888 1889 188A 188B 188C 188D 188E 188F 1890
4E 53 52 54 31 35 35 49 4E 53 52 54 31 35 36 49 4E 53 52 54 31 35 37 49 4E 53 52 54 31 35 52 54 31 38 33 49 4E 53 52 54 31 38 34 49 4E 53 52 54 31 38 35 49
17CA 17CB 17CC 17CD 17CE 17CF 17D0 17D1 17D2 17D3 17D4 17D5 17D6 17D7 17D8 17D9 17DA 17DB 17DC 17DD 17DE 17DF 17E0 17E1 17E2 17E3 17E4 17E5 17E6 17E7 18AC 18AD 18AE 18AF 18B0 18B1 18B2 18B3 18B4 18B5 18B6 18B7 18B8 18B9 18BA 18BB 18BC 18BD 18BE 18BF 18C0 18C1
53 52 54 31 36 31 49 4E 53 52 54 31 36 32 49 4E 53 52 54 31 36 33 49 4E 53 52 54 31 36 34 54 31 38 39 49 4E 53 52 54 31 39 30 49 4E 53 52 54 31 39 31 49 4E
17FE 17FF 1800 1801 1802 1803 1804 1805 1806 1807 1808 1809 180A 180B 180C 180D 180E 180F 1810 1811 1812 1813 1814 1815 1816 1817 1818 18DD 18DE 18DF 18E0 18E1 18E2 18E3 18E4 18E5 18E6 18E7 18E8 18E9 18EA 18EB 18EC 18ED 18EE 18EF 18F0 18F1 18F2 18F3 18F4 18F5
36 37 49 4E 53 52 54 31 36 38 49 4E 53 52 54 31 36 39 49 4E 53 52 54 31 37 30 49 31 39 35 49 4E 53 52 54 31 39 36 49 4E 53 52 54 31 39 37 49 4E 53 52 54 31
182F 1830 1831 1832 1833 1834 1835 1836 1837 1838 1839 183A 183B 183C 183D 183E 183F 1840 1841 1842 1843 1844 1845 1846 1847 1848 1849 190E 190F 1910 1911 1912 1913 1914 1915 1916 1917 1918 1919 191A 191B 191B 191C 191C 191D 191D 191E 191E 191F 191F 1920 1920
33 49 4E 53 52 54 31 37 34 49 4E 53 52 54 31 37 35 49 4E 53 52 54 31 37 36 49 4E 30 31 49 4E 53 52 54 32 30 32 49 4E 53 52 52 54 54 32 32 30 30 33 33 49 49
1860 1861 1862 1863 1864 1865 1866 1867 1868 1869 186A 186B 186C 186D 186E 186F 1870 1871 1872 1873 1874 1875 1876 1877 1878 1879 187A 192D 192E 192F 1930 1931 1932 1933 1934 1935 1936 1937 1938 1939 193A 193B 193C 193D 193E 193F 1940 1941 1942 1943 1944 1945
49 4E 53 52 54 31 38 30 49 4E 53 52 54 31 38 31 49 4E 53 52 54 31 38 32 49 4E 53 32 30 35 49 4E 53 52 54 32 30 36 49 4E 53 52 54 32 30 37 49 4E 53 52 54 32
1891 1892 1893 1894 1895 1896 1897 1898 1899 189A 189B 189C 189D 189E 189F 18A0 18A1 18A2 18A3 18A4 18A5 18A6 18A7 18A8 18A9 18AA 18AB 195E 195F 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 196A 196B 196C 196D 196E 196F 1970 1971 1972 1973 1974 1975 1976
4E 53 52 54 31 38 36 49 4E 53 52 54 31 38 37 49 4E 53 52 54 31 38 38 49 4E 53 52 31 31 49 4E 53 52 54 32 31 32 49 4E 53 52 54 32 31 33 49 4E 53 52 54 32 31
18C2 18C3 18C4 18C5 18C6 18C7 18C8 18C9 18CA 18CB 18CC 18CD 18CE 18CF 18D0 18D1 18D2 18D3 18D4 18D5 18D6 18D7 18D8 18D9 18DA 18DB 18DC 198F 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 199A 199B 199C 199D 199E 199F 19A0 19A1 19A2 19A3 19A4 19A5 19A6 19A7
53 52 54 31 39 32 49 4E 53 52 54 31 39 33 49 4E 53 52 54 31 39 34 49 4E 53 52 54 37 49 4E 53 52 54 32 31 38 49 4E 53 52 54 32 31 39 49 4E 53 52 54 32 32 30
18F6 18F7 18F8 18F9 18FA 18FB 18FC 18FD 18FE 18FF 1900 1901 1902 1903 1904 1905 1906 1907 1908 1909 190A 190B 190C 190D 19C0 19C1 19C2 19C3 19C4 19C5 19C6 19C7 19C8 19C9 19CA 19CB 19CC 19CD 19CE 19CF 19D0 19D1 19D2 19D3 19D4 19D5 19D6 19D7 19D8 19D9 19DA 19DB
39 38 49 4E 53 52 54 31 39 39 49 4E 53 52 54 32 30 30 49 4E 53 52 54 32 49 4E 53 52 54 32 32 34 49 4E 53 52 54 32 32 35 49 4E 53 52 54 32 32 36 49 4E 53 52
1921 1921 1922 1922 1923 1923 1924 1924 1925 1925 1926 1926 1927 1927 1928 1928 1929 1929 192A 192A 192B 192B 192C 192C 19F1 19F2 19F3 19F4 19F5 19F6 19F7 19F8 19F9 19FA 19FB 19FC 19FD 19FE 19FF 1A00 1A01 1A02 1A03 1A04 1A05 1A06 1A07 1A08 1A09 1A0A 1A0B 1A0C
4E 4E 53 53 52 52 54 54 32 32 30 30 34 34 49 49 4E 4E 53 53 52 52 54 54 4E 53 52 54 32 33 30 49 4E 53 52 54 32 33 31 49 4E 53 52 54 32 33 32 49 4E 53 52 54
1946 1947 1948 1949 194A 194B 194C 194D 194E 194F 1950 1951 1952 1953 1954 1955 1956 1957 1958 1959 195A 195B 195C 195D 1A22 1A23 1A24 1A25 1A26 1A27 1A28 1A29 1A2A 1A2B 1A2C 1A2D 1A2E 1A2F 1A30 1A31 1A32 1A33 1A34 1A35 1A36 1A37 1A38 1A39 1A3A 1A3B 1A3C 1A3D
30 38 49 4E 53 52 54 32 30 39 49 4E 53 52 54 32 31 30 49 4E 53 52 54 32 53 52 54 32 33 36 49 4E 53 52 54 32 33 37 49 4E 53 52 54 32 33 38 49 4E 53 52 54 32
1977 1978 1979 197A 197B 197C 197D 197E 197F 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 198A 198B 198C 198D 198E 1A53 1A54 1A55 1A56 1A57 1A58 1A59 1A5A 1A5B 1A5C 1A5D 1A5E 1A5F 1A60 1A61 1A62 1A63 1A64 1A65 1A66 1A67 1A68 1A69 1A6A 1A6B 1A6C 1A6D 1A6E
34 49 4E 53 52 54 32 31 35 49 4E 53 52 54 32 31 36 49 4E 53 52 54 32 31 52 54 32 34 32 49 4E 53 52 54 32 34 33 49 4E 53 52 54 32 34 34 49 4E 53 52 54 32 34
19A8 19A9 19AA 19AB 19AC 19AD 19AE 19AF 19B0 19B1 19B2 19B3 19B4 19B5 19B6 19B7 19B8 19B9 19BA 19BB 19BC 19BD 19BE 19BF 1A84 1A85 1A86 1A87 1A88 1A89 1A8A 1A8B 1A8C 1A8D 1A8E 1A8F 1A90 1A91 1A92 1A93 1A94 1A95 1A96 1A97 1A98 1A99 1A9A 1A9B 1A9C 1A9D 1A9E 1A9F
49 4E 53 52 54 32 32 31 49 4E 53 52 54 32 32 32 49 4E 53 52 54 32 32 33 54 32 34 38 49 4E 53 52 54 32 34 39 49 4E 53 52 54 32 35 30 49 4E 53 52 54 32 35 31
19DC 19DD 19DE 19DF 19E0 19E1 19E2 19E3 19E4 19E5 19E6 19E7 19E8 19E9 19EA 19EB 19EC 19ED 19EE 19EF 19F0 1AB5 1AB6 1AB7 1AB8 1AB9 1ABA 1ABB 1ABC 1ABD 1ABE 1ABF 1AC0 1AC1 1AC2 1AC3 1AC4 1AC5 1AC6 1AC7 1AC8 1AC9 1ACA 1ACB 1ACC 1ACD 1ACE 1ACF 1AD0 1AD1 1AD2 1AD3
54 32 32 37 49 4E 53 52 54 32 32 38 49 4E 53 52 54 32 32 39 49 32 35 34 49 4E 53 52 54 32 35 35 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF
1A0D 1A0E 1A0F 1A10 1A11 1A12 1A13 1A14 1A15 1A16 1A17 1A18 1A19 1A1A 1A1B 1A1C 1A1D 1A1E 1A1F 1A20 1A21 1AE6 1AE7 1AE8 1AE9 1AEA 1AEB 1AEC 1AED 1AEE 1AEF 1AF0 1AF1 1AF2 1AF3 1AF4 1AF5 1AF6 1AF7 1AF8 1AF9 1AFA 1AFB 1AFC 1AFD 1AFE 1AFF 1B00 1B01 1B02 1B03 1B04
32 33 33 49 53 4E 52 54 32 33 34 49 4E 53 52 54 32 33 35 49 4E 00 99 99 01 00 00 50 00 01 00 99 99 FF FF 01 07 20 00 01 01 01 01 01 00 02 00 00 02 00 00 01
1A3E 1A3F 1A40 1A41 1A42 1A43 1A44 1A45 1A46 1A47 1A48 1A49 1A4A 1A4B 1A4C 1A4D 1A4E 1A4F 1A50 1A51 1A52 1B17 1B18 1B19 1B1A 1B1B 1B1C 1B1D 1B1E 1B1F 1B20 1B21 1B22 1B23 1B24 1B25 1B26 1B27 1B28 1B29 1B2A 1B2B 1B2C 1B2D 1B2E 1B2F 1B30 1B31 1B32 1B33 1B34 1B35
33 39 49 4E 53 52 54 32 34 30 49 4E 53 52 54 32 34 31 49 4E 53 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF
1A6F 1A70 1A71 1A72 1A73 1A74 1A75 1A76 1A77 1A78 1A79 1A7A 1A7B 1A7C 1A7D 1A7E 1A7F 1A80 1A81 1A82 1A83 1B48 1B49 1B4A 1B4B 1B4C 1B4D 1B4E 1B4F 1B50 1B51 1B52 1B53 1B54 1B55 1B56 1B57 1B58 1B59 1B5A 1B5B 1B5C 1B5D 1B5E 1B5F 1B60 1B61 1B62 1B63 1B64 1B65 1B66
35 49 4E 53 52 54 32 34 36 49 4E 53 52 54 32 34 37 49 4E 53 52 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF
1AA0 1AA1 1AA2 1AA3 1AA4 1AA5 1AA6 1AA7 1AA8 1AA9 1AAA 1AAB 1AAC 1AAD 1AAE 1AAF 1AB0 1AB1 1AB2 1AB3 1AB4 1B79 1B7A 1B7B 1B7C 1B7D 1B7E 1B7F 1B80 1B81 1B82 1B83 1B84 1B85 1B86 1B87 1B88 1B89 1B8A 1B8B 1B8C 1B8D 1B8E 1B8F 1B90 1B91 1B92 1B93 1B94 1B95 1B96 1B97
49 4E 53 52 54 32 35 32 49 4E 53 52 54 32 35 33 49 4E 53 52 54 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF
1AD4 1AD5 1AD6 1AD7 1AD8 1AD9 1ADA 1ADB 1ADC 1ADD 1ADE 1ADF 1AE0 1AE1 1AE2 1AE3 1AE4 1AE5 1BAA 1BAB 1BAC 1BAD 1BAE 1BAF 1BB0 1BB1 1BB2 1BB3 1BB4 1BB5 1BB6 1BB7 1BB8 1BB9 1BBA 1BBB 1BBC 1BBD 1BBE 1BBF 1BC0 1BC1 1BC2 1BC3 1BC4 1BC5 1BC6 1BC7 1BC8 1BC9 1BCA 1BCB
FF 00 00 10 00 01 00 00 50 00 10 00 00 40 96 00 10 10 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF
1B05 1B06 1B07 1B08 1B09 1B0A 1B0B 1B0C 1B0D 1B0E 1B0F 1B10 1B11 1B12 1B13 1B14 1B15 1B16 1BDB 1BDC 1BDD 1BDE 1BDF 1BE0 1BE1 1BE2 1BE3 1BE4 1BE5 1BE6 1BE7 1BE8 1BE9 1BEA 1BEB 1BEC 1BED 1BEE 1BEF 1BF0 1BF1 1BF2 1BF3 1BF4 1BF5 1BF6 1BF7 1BF8 1BF9 1BFA 1BFB 1BFC
50 00 18 00 00 18 00 00 01 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF
1B36 1B37 1B38 1B39 1B3A 1B3B 1B3C 1B3D 1B3E 1B3F 1B40 1B41 1B42 1B43 1B44 1B45 1B46 1B47 1C0C 1C0D 1C0E 1C0F 1C10 1C11 1C12 1C13 1C14 1C15 1C16 1C17 1C18 1C19 1C1A 1C1B 1C1C 1C1D 1C1E 1C1F 1C20 1C21 1C22 1C23 1C24 1C25 1C26 1C27 1C28 1C29 1C2A 1C2B 1C2C 1C2D
FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF
1B67 1B68 1B69 1B6A 1B6B 1B6C 1B6D 1B6E 1B6F 1B70 1B71 1B72 1B73 1B74 1B75 1B76 1B77 1B78 1C3D 1C3E 1C3F 1C40 1C41 1C42 1C43 1C44 1C45 1C46 1C47 1C48 1C49 1C4A 1C4B 1C4C 1C4D 1C4E 1C4F 1C50 1C51 1C52 1C53 1C54 1C55 1C56 1C57 1C58 1C59 1C5A 1C5B 1C5C 1C5D 1C5E
1B98 1B99 1B9A 1B9B 1B9C 1B9D 1B9E 1B9F 1BA0 1BA1 1BA2 1BA3 1BA4 1BA5 1BA6 1BA7 1BA8 1BA9 1C6E 1C6F 1C70 1C71 1C72 1C73 1C74 1C75 1C76 1C77 1C78 1C79 1C7A 1C7B 1C7C 1C7D 1C7E 1C7F 1C80 1C81 1C82 1C83 1C84 1C85 1C86 1C87 1C88 1C89 1C8A 1C8B 1C8C 1C8D 1C8E 1C8F
1BCC 1BCD 1BCE 1BCF 1BD0 1BD1 1BD2 1BD3 1BD4 1BD5 1BD6 1BD7 1BD8 1BD9 1BDA 1C9F 1CA0 1CA1 1CA2 1CA3 1CA4 1CA5 1CA6 1CA7 1CA8 1CA9 1CAA 1CAB 1CAC 1CAD 1CAE 1CAF 1CB0 1CB1 1CB2 1CB3 1CB4 1CB5 1CB6 1CB7 1CB8 1CB9 1CBA 1CBB 1CBC 1CBD 1CBE 1CBF 1CC0 1CC1 1CC2 1CC3
1BFD 1BFE 1BFF 1C00 1C01 1C02 1C03 1C04 1C05 1C06 1C07 1C08 1C09 1C0A 1C0B 1CD0 1CD1 1CD2 1CD3 1CD4 1CD5 1CD6 1CD7 1CD8 1CD9 1CDA 1CDB 1CDC 1CDD 1CDE 1CDF 1CE0 1CE1 1CE2 1CE3 1CE4 1CE5 1CE6 1CE7 1CE8 1CE9 1CEA 1CEB 1CEC 1CED 1CEE 1CEF 1CF0 1CF1 1CF2 1CF3 1CF4
1C2E 1C2F 1C30 1C31 1C32 1C33 1C34 1C35 1C36 1C37 1C38 1C39 1C3A 1C3B 1C3C 1D01 1D02 1D03 1D04 1D05 1D06 1D07 1D08 1D09 1D0A 1D0B 1D0C 1D0D 1D0E 1D0F 1D10 1D11 1D12 1D13 1D14 1D15 1D16 1D17 1D18 1D19 1D1A 1D1B 1D1C 1D1D 1D1E 1D1F 1D20 1D21 1D22 1D23 1D24 1D25
1C5F 1C60 1C61 1C62 1C63 1C64 1C65 1C66 1C67 1C68 1C69 1C6A 1C6B 1C6C 1C6D 1D32 1D33 1D34 1D35 1D36 1D37 1D38 1D39 1D3A 1D3B 1D3C 1D3D 1D3E 1D3F 1D40 1D41 1D42 1D43 1D44 1D45 1D46 1D47 1D48 1D49 1D4A 1D4B 1D4C 1D4D 1D4E 1D4F 1D50 1D51 1D52 1D53 1D54 1D55 1D56
1C90 1C91 1C92 1C93 1C94 1C95 1C96 1C97 1C98 1C99 1C9A 1C9B 1C9C 1C9D 1C9E 1D63 1D64 1D65 1D66 1D67 1D68 1D69 1D6A 1D6B 1D6C 1D6D 1D6E 1D6F 1D70 1D71 1D72 1D73 1D74 1D75 1D76 1D77 1D78 1D79 1D7A 1D7B 1D7C 1D7D 1D7E 1D7F 1D80 1D81 1D82 1D83 1D84 1D85 1D86 1D87
1CC4 1CC5 1CC6 1CC7 1CC8 1CC9 1CCA 1CCB 1CCC 1CCD 1CCE 1CCF 1D94 1D95 1D96 1D97 1D98 1D99 1D9A 1D9B 1D9C 1D9D 1D9E 1D9F 1DA0 1DA1 1DA2 1DA3 1DA4 1DA5 1DA6 1DA7 1DA8 1DA9 1DAA 1DAB 1DAC 1DAD 1DAE 1DAF 1DB0 1DB1 1DB2 1DB3 1DB4 1DB5 1DB6 1DB7 1DB8 1DB9 1DBA 1DBB
1CF5 1CF6 1CF7 1CF8 1CF9 1CFA 1CFB 1CFC 1CFD 1CFE 1CFF 1D00 1DC5 1DC6 1DC7 1DC8 1DC9 1DCA 1DCB 1DCC 1DCD 1DCE 1DCF 1DD0 1DD1 1DD2 1DD3 1DD4 1DD5 1DD6 1DD7 1DD8 1DD9 1DDA 1DDB 1DDC 1DDD 1DDE 1DDF 1DE0 1DE1 1DE2 1DE3 1DE4 1DE5 1DE6 1DE7 1DE8 1DE9 1DEA 1DEB 1DEC
1D26 1D27 1D28 1D29 1D2A 1D2B 1D2C 1D2D 1D2E 1D2F 1D30 1D31 1DF6 1DF7 1DF8 1DF9 1DFA 1DFB 1DFC 1DFD 1DFE 1DFF 1E00 1E01 1E02 1E03 1E04 1E05 1E06 1E07 1E08 1E09 1E0A 1E0B 1E0C 1E0D 1E0E 1E0F 1E10 1E11 1E12 1E13 1E14 1E15 1E16 1E17 1E18 1E19 1E1A 1E1B 1E1C 1E1D
1D57 1D58 1D59 1D5A 1D5B 1D5C 1D5D 1D5E 1D5F 1D60 1D61 1D62 1E27 1E28 1E29 1E2A 1E2B 1E2C 1E2D 1E2E 1E2F 1E30 1E31 1E32 1E33 1E34 1E35 1E36 1E37 1E38 1E39 1E3A 1E3B 1E3C 1E3D 1E3E 1E3F 1E40 1E41 1E42 1E43 1E44 1E45 1E46 1E47 1E48 1E49 1E4A 1E4B 1E4C 1E4D 1E4E
1D88 1D89 1D8A 1D8B 1D8C 1D8D 1D8E 1D8F 1D90 1D91 1D92 1D93 1E58 1E59 1E5A 1E5B 1E5C 1E5D 1E5E 1E5F 1E60 1E61 1E62 1E63 1E64 1E65 1E66 1E67 1E68 1E69 1E6A 1E6B 1E6C 1E6D 1E6E 1E6F 1E70 1E71 1E72 1E73 1E74 1E75 1E76 1E77 1E78 1E79 1E7A 1E7B 1E7C 1E7D 1E7E 1E7F
1DBC 1DBD 1DBE 1DBF 1DC0 1DC1 1DC2 1DC3 1DC4 1E89 1E8A 1E8B 1E8C 1E8D 1E8E 1E8F 1E90 1E91 1E92 1E93 1E94 1E95 1E96 1E97 1E98 1E99 1E9A 1E9B 1E9C 1E9D 1E9E 1E9F 1EA0 1EA1 1EA2 1EA3 1EA4 1EA5 1EA6 1EA7 1EA8 1EA9 1EAA 1EAB 1EAC 1EAD 1EAE 1EAF 1EB0 1EB1 1EB2 1EB3
1DED 1DEE 1DEF 1DF0 1DF1 1DF2 1DF3 1DF4 1DF5 1EBA 1EBB 1EBC 1EBD 1EBE 1EBF 1EC0 1EC1 1EC2 1EC3 1EC4 1EC5 1EC6 1EC7 1EC8 1EC9 1ECA 1ECB 1ECC 1ECD 1ECE 1ECF 1ED0 1ED1 1ED2 1ED3 1ED4 1ED5 1ED6 1ED7 1ED8 1ED9 1EDA 1EDB 1EDC 1EDD 1EDE 1EDF 1EE0 1EE1 1EE2 1EE3 1EE4
1E1E 1E1F 1E20 1E21 1E22 1E23 1E24 1E25 1E26 1EEB 1EEC 1EED 1EEE 1EEF 1EF0 1EF1 1EF2 1EF3 1EF4 1EF5 1EF6 1EF7 1EF8 1EF9 1EFA 1EFB 1EFC 1EFD 1EFE 1EFF 1F00 1F01 1F02 1F03 1F04 1F05 1F06 1F07 1F08 1F09 1F0A 1F0B 1F0C 1F0D 1F0E 1F0F 1F10 1F11 1F12 1F13 1F14 1F15
1E4F 1E50 1E51 1E52 1E53 1E54 1E55 1E56 1E57 1F1C 1F1D 1F1E 1F1F 1F20 1F21 1F22 1F23 1F24 1F25 1F26 1F27 1F28 1F29 1F2A 1F2B 1F2C 1F2D 1F2E 1F2F 1F30 1F31 1F32 1F33 1F34 1F35 1F36 1F37 1F38 1F39 1F3A 1F3B 1F3C 1F3D 1F3E 1F3F 1F40 1F41 1F42 1F43 1F44 1F45 1F46
1E80 1E81 1E82 1E83 1E84 1E85 1E86 1E87 1E88 1F4D 1F4E 1F4F 1F50 1F51 1F52 1F53 1F54 1F55 1F56 1F57 1F58 1F59 1F5A 1F5B 1F5C 1F5D 1F5E 1F5F 1F60 1F61 1F62 1F63 1F64 1F65 1F66 1F67 1F68 1F69 1F6A 1F6B 1F6C 1F6D 1F6E 1F6F 1F70 1F71 1F72 1F73 1F74 1F75 1F76 1F77
1EB4 1EB5 1EB6 1EB7 1EB8 1EB9 1F7E 1F7F 1F80 1F81 1F82 1F83 1F84 1F85 1F86 1F87 1F88 1F89 1F8A 1F8B 1F8C 1F8D 1F8E 1F8F 1F90 1F91 1F92 1F93 1F94 1F95 1F96 1F97 1F98 1F99 1F9A 1F9B 1F9C 1F9D 1F9E 1F9F 1FA0 1FA1 1FA2 1FA3 1FA4 1FA5 1FA6 1FA7 1FA8 1FA9 1FAA 1FAB
FF FF FF FF FF FF FF 00 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF
1EE5 1EE6 1EE7 1EE8 1EE9 1EEA 1FAF 1FB0 1FB1 1FB2 1FB3 1FB4 1FB5 1FB6 1FB7 1FB8 1FB9 1FBA 1FBB 1FBC 1FBD 1FBE 1FBF 1FC0 1FC1 1FC2 1FC3 1FC4 1FC5 1FC6 1FC7 1FC8 1FC9 1FCA 1FCB 1FCC 1FCD 1FCE 1FCF 1FD0 1FD1 1FD2 1FD3 1FD4 1FD5 1FD6 1FD7 1FD8 1FD9 1FDA 1FDB 1FDC
1F16 1F17 1F18 1F19 1F1A 1F1B 1FE0 1FE1 1FE2 1FE3 1FE4 1FE5 1FE6 1FE7 1FE8 1FE9 1FEA 1FEB 1FEC 1FED 1FEE 1FEF 1FF0 1FF1 1FF2 1FF3 1FF4 1FF5 1FF6 1FF7 1FF8 1FF9 1FFA 1FFB 1FFC 1FFD 1FFE 1FFF
FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF EA 00 80 FF FF FF FF FF
1F47 1F48 1F49 1F4A 1F4B 1F4C
FF FF FF FF FF FF
1F78 1F79 1F7A 1F7B 1F7C 1F7D
FF FF FF FF FF FF
1FAC 1FAD 1FAE
FF FF FF
1FDD FF 1FDE FF 1FDF FF
DATE: April 16, 1994 SUBJECT: Hawk 5D JO-BLOCK PROCEDURE PRODUCT LINE: Hawk 5D Knee Mill
The following procedure will provide a standardized procedure for testing and compensating for the leadscrew and backlash error for the Hawk 5D Knee Mill. Note that the programs are designed for use with a 19.5 Jo Block for the X axis and a 10 Jo Block for the Y axis. The tables are designed to be used as the indicator reads. (EXAMPLE: If the indicator reads minus error, then you would use the minus table). EQUIPMENT Obtain the following equipment required to perform Jo Block test: 19.5 inch Jo Block 10 inch Jo Block 3 End Blocks 2 Toe Clamps 2 Tee Nuts 2 Bolts Tool Holder Dial Indicator X AXIS PROCEDURE 1. Load program XJB. Reference program listed below: N0000.5(9)E1$ N0001(0)X0Y0Z0$ N0002(1)X.03F5C0G0$ N0003(1)Y-.25F5C0G0$ N0004(1)X4.03F100C0G0$ N0005(1)X.03F100C0G0$ N0006(1)Y0F5$ N0007(0)X0$ N0008(1)X.03F5$ ORIGINATOR: Keith Perkins REVISED BY:
N0009(1)Y-.25F5C0G0$ N0010(1)X4.03F100C0G0 N0013(0)X0Y0Z0$ N0014(1)X.03F5C0G0$ N0015(0)X19.5Z1$ N0016(1)Z0F100C0G0$ N0017(1)X19.53F5C0G0$ N0018(0)X0Z1$ N0011(1)X.03F100C0G0$ N0019(1)Z0F100C0G0$ N0020(1)X.03F5C0G0$ N0021(0)X19.5Z1$ N0022(1)Z0F100C0G0$ N0023(1)X19.53F5C0G0$ N0024(0)X0Y0Z1$ N0025(1)Z0F100C0G0$ N0026(1)X.03F5C0G0$ N0027(0)Z2$ N0028(9)M0E0$ N0029(9)M30$ Reference the machine. Mount the 19.5 inch Jo Block with end blocks attached in the center slot using the toe clamps to hold the Jo Block in place. 4. Install the tool holder and indicator in the spindle. 5. Zero the indicator on the outside left surface of the left end block, centered 1/8 inch from top of block. 6. Back X off of the block 0.0030 inches and ZERO SET X, Y, and Z. 7. Run the program in Single Event. (The first part of the program is backlash) 8. Press CYCLE START until the indicator touches the Jo Block and check the indicator for zero. 9. Continue with the program until the indicator touches the Jo Block again. Take the first reading and record it. ___________________inches 10. Continue with the program. Backlash is rechecked for verification. 11. Continue with the program until the indicator touches the right end block.. Take and record the reading. This reading is the leadscrew error. ___________________inches 12. Continue with the program. The program repeats to verify the reading. 13. Load presets per Table 1. 14. Load the compensation into the parameters. (Table 2) 15. Load backlash into the parameters. (Table 4) 14. Repeat the procedure to verify compensation is accurate. Y AXIS PROCEDURE 1. Load program YJB. Reference program listed below: N0000.5(9)E1T1$ N0001(0)X0Y0Z0$ N0002(1)Y.03F5C0G0$
2
2. 3.
N0003(1)X-.25F5C0G0$ N0004(1)Y4.03F100C0G0$ N0005(1)Y.03F100C0G0$ N0006(1)X0F5$ N0007(0)Y0$ N0008(1)Y.03F5$ N0009(1)X-.25F5C0G0$ N0010(1)Y4.03F100C0G0$ N0011(1)Y.03F100C0G0$ N0012(1)X0F5C0G0$ N0013(0)X0Y0Z0$ N0014(1)Y.03F5C0G0$ N0015(0)X0Y10Z1$ N0016(1)Z.2F100C0G0$ N0017(1)Y10.03F5C0G0$ N0018(0)X0Y0Z1$ N0019(1)Z0F100C0G0$ N0020(1)Y.03F5C0G0$ N0021(0)Y10Z1$ N0022(1)Z.2F100C0G0$ N0023(1)Y10.03F5C0G0$ N0024(0)X0Y0Z1$ N0025(1)Z0F100C0G0$ N0026(1)Y.03F5C0G0$ N0027(0)Z2$ N0028(9)M0E0$ N0029(9)M30$ 2. 3. Reference the machine. Mount the 10 inch Jo Block, with one end block attached, in the center of the table situated with the end block toward the column and 1/2 inch of the Jo Block extending over the front table pad. Use the toe clamp to hold the Jo Block in position. 4. Zero the indicator on the front surface of the Jo Block, centered 1/8 inch from top of block. 5. Back Y off of the block 0.0030 inches and ZERO SET X, Y, and Z. 6. Run the program in Signal Event. (The first part of the program is backlash) 7. Press CYCLE START until the indicator touches the Jo Block and check the indicator for zero. 8. Continue with the program until the indicator touches the Jo Block again. Take the first reading and record it. ___________________inches 9. Continue with the program. Backlash is rechecked for verification. 10. Continue with the program until the indicator touches the end block. Take and record the reading. This reading is the leadscrew error. ___________________inches 11. Continue with the program. The program repeats to verify the reading. 12. Load the compensation into the parameters. (Table 3) 13. Load backlash into the parameters. (Table 4)
3
14. Repeat the procedure to verify compensation is accurate.
LOADING PARAMETERS 1. Depress EMERGENCY STOP. 2. Toggle the WRITE PROTECT SWITCH on the Processor PCB to the DOWN position to enable the EEPROMs. NOTE: ANY DATA THAT IS CHANGED WILL AFFECT THE OPERATION OF THE MACHINE. BE EXTREMELY CAREFUL WHEN SELECTING THE ADDRESS TO BE CHANGED. Press RESET, "P" to enter the Parameter mode. Select the address to be changed by typing "A", then the address number, ENTER. NEXT EVENT will move to the next address. After all parameters are changed, toggle the WRITE PROTECT SWITCH to the UP position. Press RESET, then release the EMERGENCY STOP BUTTON.
3. 4. 5,
TABLE #1 - Presets: ADDR. 0005 0047 100 101 102 103 104 105 200 201 202 203 204 205 DATA 01 01 00 00 00 02 54 00 35 60 00 02 54 00 TABLE #4: BACKLASH AXIS ADDR X 0048 0049 Y 004A 004B DATA NOTE: Values are loaded in millimeters Example: 0.014mm X 0048 00 0049 14
TABLE # 2: X AXIS Error is in ten thousandths of an inch (0.0001) ADDR 0106 0107 0108 0109 010A 010B 010C 010D 010E 010F 0110 0111 0112 0113 0114 0115 0116 0117 0118 0119 011A 011B 011C 011D 011E 011F 0120 0121 0122 0123 +1 00 00 00 00 11 00 00 00 00 11 00 00 00 00 11 00 00 00 00 11 00 00 00 00 11 00 00 00 00 11 +2 00 11 00 00 11 00 11 00 00 11 00 11 00 00 11 00 11 00 00 11 00 11 00 00 11 00 11 00 00 11 +3 00 11 11 00 11 00 11 11 00 11 00 11 11 00 11 00 11 11 00 11 00 11 11 00 11 00 11 11 00 11 +4 00 11 11 11 11 00 11 11 11 11 00 11 11 11 11 00 11 11 11 11 00 11 11 11 11 00 11 11 11 11 +5 00 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 12 +6 00 11 11 11 12 11 11 11 11 12 11 11 11 11 12 11 11 11 11 12 11 11 11 11 12 11 11 11 12 12 +7 00 12 11 11 12 11 12 11 11 12 11 12 11 11 12 11 12 11 11 12 11 12 11 11 12 11 12 11 12 12 +8 00 12 12 11 12 11 12 12 11 12 11 12 12 11 12 11 12 12 11 12 11 12 12 11 12 11 12 12 12 12 +9 +10 +11 +12 +13 +14 +15 +16 +17 +18 +19 +20 +21 +22 +23 +24 +25 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15 11 12 12 12 12 13 13 13 13 13 14 14 15 15 14 15 16 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 12 12 12 12 13 13 13 13 13 14 14 15 14 14 15 15 15 12 12 12 12 12 13 14 13 13 13 14 14 14 14 15 15 15 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15 11 13 12 12 12 12 13 13 13 13 13 14 14 14 14 14 16 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 12 12 13 13 13 13 13 14 14 14 14 15 15 15 15 15 15 11 12 12 12 12 12 13 13 13 13 14 14 14 14 14 15 16 12 12 12 13 13 13 14 13 14 14 14 14 14 15 15 15 15 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15 11 13 12 12 12 12 13 13 13 13 13 14 14 14 14 15 16 12 12 12 13 13 13 13 13 14 14 14 15 14 15 15 15 15 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 12 12 12 12 12 13 13 14 13 14 14 14 15 14 15 15 15 12 12 13 13 13 13 14 14 14 14 14 14 15 15 15 15 15 12 12 12 12 12 13 13 13 14 13 14 14 14 15 14 15 16 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 12 12 13 13 13 13 13 14 14 14 14 15 15 15 15 15 15 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
TABLE # 2: X AXIS (continued) Error is in ten thousandths of an inch (0.0001) ADDR 0106 0107 0108 0109 010A 010B 010C 010D 010E 010F 0110 0111 0112 0113 0114 0115 0116 0117 0118 0119 011A 011B 011C 011D 011E 011F 0120 0121 0122 0123 -1 00 00 00 00 01 00 00 00 00 01 00 00 00 00 01 00 00 00 00 01 00 00 00 00 01 00 00 00 00 01 -2 00 01 00 00 01 00 01 00 00 01 00 01 00 00 01 00 01 00 00 01 00 01 00 00 01 00 01 00 00 01 -3 00 01 01 00 01 00 01 01 00 01 00 01 01 00 01 00 01 01 00 01 00 01 01 00 01 00 01 01 00 01 -4 00 01 01 01 01 00 01 01 01 01 00 01 01 01 01 00 01 01 01 01 00 01 01 01 01 00 01 01 01 01 -5 00 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 02 -6 00 01 01 01 02 01 01 01 01 02 01 01 01 01 02 01 01 01 01 02 01 01 01 01 02 01 01 01 02 02 -7 00 02 01 01 02 01 02 01 01 02 01 02 01 01 02 01 02 01 01 02 01 02 01 01 02 01 02 01 02 02 -8 00 02 02 01 02 01 02 02 01 02 01 02 02 01 02 01 02 02 01 02 01 02 02 01 02 01 02 02 02 02 -9 00 02 02 02 02 01 02 02 02 02 01 02 02 02 02 01 02 02 02 02 01 02 02 02 02 02 02 02 02 02 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05 02 02 02 02 03 03 03 03 03 04 04 05 05 04 05 06 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 02 02 02 03 03 03 03 03 04 04 05 04 04 05 05 05 02 02 02 02 03 04 03 03 03 04 04 04 04 05 05 05 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05 03 02 02 02 02 03 03 03 03 03 04 04 04 04 04 06 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 02 03 03 03 03 03 04 04 04 04 05 05 05 05 05 05 02 02 02 02 02 03 03 03 03 04 04 04 04 04 05 06 02 02 03 03 03 04 03 04 04 04 04 04 05 05 05 05 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05 03 02 02 02 02 03 03 03 03 03 04 04 04 04 05 06 02 02 03 03 03 03 03 04 04 04 05 04 05 05 05 05 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 02 02 02 02 03 03 04 03 04 04 04 05 04 05 05 05 02 03 03 03 03 04 04 04 04 04 04 05 05 05 05 05 02 02 02 02 03 03 03 04 03 04 04 04 05 04 05 06 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 02 03 03 03 03 03 04 04 04 04 05 05 05 05 05 05 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
FSB XXX Page 6 of 7
TABLE # 3: Y AXIS Error is in ten thousandths of an inch (0.0001) ADDR 0206 0207 0208 0209 020A 020B 020C 020D 020E 020F 0210 0211 0212 0213 0214 ADDR 0206 0207 0208 0209 020A 020B 020C 020D 020E 020F 0210 0211 0212 0213 0214 +1 00 00 00 11 00 00 00 00 11 00 00 00 00 11 00 -1 00 00 00 01 00 00 00 00 01 00 00 00 00 01 00 +2 00 11 00 00 11 00 00 11 00 00 11 00 00 11 00 -2 00 01 00 00 01 00 00 01 00 00 01 00 00 01 00 +3 00 00 11 00 11 11 00 11 00 11 11 00 11 11 00 -3 00 00 01 00 01 01 00 01 00 01 01 00 01 01 00 +4 00 11 11 11 00 11 11 11 00 11 11 11 00 11 11 -4 00 01 01 01 00 01 01 01 00 01 01 01 00 01 01 +5 00 11 11 11 11 00 11 11 11 00 11 11 11 11 11 -5 00 01 01 01 01 00 01 01 01 00 01 01 01 01 01 +6 00 11 11 11 11 11 11 12 11 11 11 11 11 11 11 -6 00 01 01 01 01 01 01 02 01 01 01 01 01 01 01 +7 00 11 11 12 11 11 12 11 11 12 11 11 12 11 11 -7 00 01 01 02 01 01 02 01 01 02 01 01 02 01 01 +8 00 12 11 11 12 11 12 11 11 12 11 12 11 11 12 -8 00 02 01 01 02 01 02 01 01 02 01 02 01 01 02 +9 +10 +11 +12 +13 +14 +15 +16 +17 +18 +19 +20 +21 +22 +23 +24 +25 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 12 12 12 12 12 12 12 13 13 13 13 13 14 14 14 14 15 11 12 12 12 13 13 13 13 13 14 14 14 14 14 14 15 14 12 12 12 13 12 12 13 13 13 13 14 13 14 14 14 14 15 12 12 12 12 12 13 12 13 13 13 13 14 13 14 14 14 14 11 11 12 12 12 12 13 12 13 13 14 14 14 14 15 15 15 12 12 12 12 13 13 13 13 13 13 13 13 14 14 14 14 14 11 12 12 13 12 12 12 13 13 14 13 14 14 14 14 14 15 12 12 12 12 12 13 13 13 13 13 14 13 13 14 14 14 14 12 11 12 12 13 12 13 12 13 13 13 14 14 14 15 15 15 11 12 12 12 12 13 12 13 13 13 13 14 14 14 14 14 14 12 12 12 12 12 12 13 13 13 14 14 13 14 14 14 14 15 12 12 12 13 12 13 13 13 13 13 13 14 13 14 14 14 14 11 12 12 12 13 12 12 13 13 13 14 13 14 14 14 15 15 12 12 12 12 12 13 13 13 13 13 13 14 14 14 14 14 14 -9 00 02 01 02 02 01 02 01 02 02 01 02 02 01 02 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 02 02 02 02 02 02 03 03 03 03 03 04 04 04 04 05 02 02 02 03 03 03 03 03 04 04 04 04 04 04 05 04 02 02 03 02 02 03 03 03 03 04 03 04 04 04 04 05 02 02 02 02 03 02 03 03 03 03 04 03 04 04 04 04 01 02 02 02 02 03 02 03 03 04 04 04 04 05 05 05 02 02 02 03 03 03 03 03 03 03 03 04 04 04 04 04 02 02 03 02 02 02 03 03 04 03 04 04 04 04 04 05 02 02 02 02 03 03 03 03 03 04 03 03 04 04 04 04 01 02 02 03 02 03 02 03 03 03 04 04 04 05 05 05 02 02 02 02 03 02 03 03 03 03 04 04 04 04 04 04 02 02 02 02 02 03 03 03 04 04 03 04 04 04 04 05 02 02 03 02 03 03 03 03 03 03 04 03 04 04 04 04 02 02 02 03 02 02 03 03 03 04 03 04 04 04 05 05 02 02 02 02 03 03 03 03 03 03 04 04 04 04 04 04 FSB XXX Page 7 of 7
DATE: April 11, 1994 SUBJECT: Hawk 5D Servo Amplifier Setup Procedure PRODUCT LINE: Hawk 5D
The following procedure will assist in the adjustment and setup of the Servo Dynamics DC servo drives used in the Hawk 5D Knee Mill. AMPLIFIER PRE-SETS 1) Assure control power is OFF and that the J1 connector has been removed from the servo amp that is to be adjusted. 2) Connect an Ohm meter between TP1 and TP3 (Reference Servo Dynamics manual for location of test points). 3) Adjust the SIGNAL pot for a reading of 2.5 Kohms. 4) Connect the meter between TP1 and TP4 and adjust the TACH pot for a reading of 4Kohms. 5) AUX. pot - Set full CCW. 6) CMP. pot - Set full CCW, then 10 turns CW. 7) CL. pot - Set full CW 8) BALANCE pot - Set mid-range (20 turn pot). 9) Reconnect the J1 connector. FINAL SETTINGS 1) Enable the Servos and adjust the CMP pot CW till the motor starts to oscillate, then CCW until the oscillation stops, and then an additional 3 turns CCW. 2) Enable the LAG display on the control (axis setup screen), and then select Medium Jog speed with the override set at max. This will jog the axis at 15 IPM. 3) Adjust the SIGNAL pot to achieve 0.0150 of Lag. 4) Adjust the BALANCE to minimize the difference between the lag when the jog direction is changed. 5) Motion Hold, and adjust the BALANCE for 0.0000 of Lag. 6) Run a program to move all the axes at rapid, full travel to assure that no errors occur.

DATE: April 11, 1994 SUBJECT: Hawk 5D Limit Switch Setup Procedure PRODUCT LINE: Hawk 5D
The following procedure will assist in the setup of the Axis Limit Switches on the Hawk 5D Knee Mill. Z AXIS 1) Move the Z axis so that the Quill extends 1 inch (as measured between the bottom of the Head casting and the top of the Quill locknut ring). 2) Adjust the Reference Switch to be made at this point. Note that the switch activates off the top of the dog. 3) Home Z or jog it to ZERO. 4) Adjust the Z Reference Switch so that the DRAW BAR height is 0.90 to 1.00 as measured from the top of the DRAW BAR to the Bearing surface, when Z is at ZERO. 5) Set the Over Travel switches for 0.100 of over travel. In order to do this you will need to open up the software travel limits. Z (+) = 0.100 Z (-) = (-) 6.100 6) Set software travel limits to: Z (+) = 0.020 Z (-) = (-) 6.020 7) Set Z Home for 0.0000. Y AXIS 1) Reference the Y axis. 2) E-Stop to disable the servos. 3) Move the Y axis by hand, noting the position display on the control, until the Y is at the positive hard stop. 4) Set the Reference switch dog for 0.300 from the Y ZERO. 5) Set the Over Travel switches for 0.100 of over travel. Y (+) = 0.100 Y (-) = (-) 14.100 ORIGINATOR: Keith Perkins REVISED BY:
FSB 1209 PAGE 2 OF 2 6) Set the software limits to: Y (+) = 0.020 Y (-) = (-) 13.77 Set Y Home for (-) 1.000
7)
X AXIS 1) Reference the X axis. 2) Jog to near each hard stop and then E-Stop and verify that there is a minimum of 0.300 on both ends, to hard stop. 3) Adjust the Reference Switch dog to achieve this. 4) Set the Over Travel switches for 0.100 of over travel. X (+) = 31.100 X (-) = (-)0.100 5) Set the software limits for: X (+) = 31.020 X (-) = 0.020 6) Set Home for (+) 1.000 For all axes, assure that the axis will run full travel at rapid without hitting a over travel switch. For Z axis, assure that the Draw Bar functions properly.
DATE: July 7, 1994 SUBJECT: Auto Speed Control Prom Update PRODUCT LINE: KM5P/KM5M
There has been a new ASC Prom released for the KM5P or KM5M machines that fixes two problems. The part number is 450-3010-104. The first problem effects the 5M only. During tapping extraneous interrupts were processed as real commands and would be seen as a speed change command at the top and bottom of the tap cycle. The new Prom uses Switch 2 position 2 to enable a 130msec delay for each new command. The second problem effects all machine types and would cause the speed control to runaway to hard stop. With this Prom, in order to maintain compatibility with older versions of executive software, the debounce switch can be switched ON/OFF. Switch 2-2 controls the debounce enable. The chart below details the switches and their functions: ASC SWITCH 2 POSITION 1 POSITION 2 OPEN BYPASS SOFTWARE LIMITS ENABLE 130mSEC DEBOUNCE * CLOSED USE SOFTWARE LIMITS NO DEBOUNCE **
* - Use with Max 32, Max 3 version 1.51 or above software ** - Use with all Max 2 and Max 32, Max 3 version 1.50 or below software.

DATE: May 13, 1994 SUBJECT: Hawk 5M I/O & CANbus Mapping PRODUCT LINE: Hawk 5M INPUTS FUNCTION CRP4 WAY LUBE LEVEL J1-45 INDEXER IN POSITION J1-29 CHIP ENCLOSURE INTERLOCK #1 J1-44 CONTROL POWER STATUS J1-28 SPINDLE OVERLOAD TRIP J1-43 SPINDLE SPEED CONTROL 0 J1-27 SPINDLE SPEED CONTROL 1 J1-42 SPINDLE SPEED CONTROL 2 J1-26 CHIP ENCLOSURE INTERLOCK #2 J1-41 AXIS FAULT (X/Y/Z/a/b) J1-40 AXIS MOTOR OVERTEMP J1-24 OUTPUTS FUNCTION CRP4 AXIS ENABLE RELAY J1-17 SPINDLE ENABLE RELAY J1-16 INDEXER COCK RELAY J1-15 FLOOD COOLANT RELAY J1-32 MIST COOLANT SOLENOID J1-49 SPINDLE FWD. STARTER J1-48 SPINDLE REV. STARTER J1-47 SPINDLE BRAKE SOLENOID J1-46 CONTROL ON RELAY J1-2 SPINDLE SPEED CHANGE ENABLE J1-35 SERVO FAULT RELAY J1-34 AUTO MODE RELAY J1-33
I/O INTERFACE J1-45 J1-29 J1-44 J1-28 J1-43 J1-27 J1-42 J1-26 J1-41 J1-40 J1-24
CANBUS J3-1 J3-2 J3-3 J3-4 J3-6 J3-7 J3-8 J3-9 J3-11 J3-13 J3-14
I/O INTERFACE J1-17 J1-16 J1-15 J1-32 J1-49 J1-48 J1-47 J1-46 J1-2 J1-35 J1-34 J1-33
CANBUS J3-17 J3-18 J3-19 J3-20 J3-22 J3-23 J3-24 J3-25 J3-31 J3-32 J3-33 J3-34

FSB 1212 PAGE 1 OF 3
DATE:
May 13, 1994
ISSUE NUMBER: 1212-A SUPERSEDES NUMBER: PAGE 1 OF 3
SUBJECT: Servo Drive Setup PRODUCT LINE: Hawk 5M
The following procedure will assist in the adjustment and setup of the Servo Dynamics DC drives used in the Hawk 5M Knee Mill. AMPLIFIER PRE-SETS 1. Ensure that the (2) 0 Ohm shunts labeled W1 and W2 have been removed from the drive (only required on a replacement drive installation & setup). Reference the Figure shown below for location.
W1 & W2
2. Assure that the machine is in Emergency Stop. 3. Remove the J1 connector from the drive to be adjusted.
ORIGINATOR: Keith Perkins REVISED BY: David Skrzypczak

4. Connect an Ohm meter between TP1 and TP3 on the drive and adjust the SIGNAL pot for a reading of 5,000 Ohms. 5. Connect the Ohm meter between TP1 and TP4 and adjust the TACH pot for a reading of 7,000 Ohms. 6. Adjust the CMP pot full CCW, then 10 turns CW. 7. Adjust the CL pot full CW. 8. Adjust the BAL pot mid-range (20 turn pot). 9. Reconnect the J1 connector to the drive.
AXIS BALANCE ADJUSTMENTS 1. Set the RAPID DETENT parameter on the control for: 1016 mmpm for X or Y axis adjustment 635 mmpm for Z axis adjustment 2. Jog the axis to be adjusted to mid-travel. 3. Connect a DVM set to DC Millivolts to J1-1 with respect to J1-2 of the drive to be adjusted. 4. Enable the servo power by depressing Manual Mode, Power ON, Start. 5. Enter the 101 screen and enable the LOAD BAR DISPLAY, FOLLOWING ERROR DISPLAY, and ACTUAL POSITION DISPLAY. 6. Select AXIS BALANCE, then depress Motion Hold, select the Softkey for the axis to be adjusted, and depress Start. 7. Do not adjust the pots on the Matrix 4 DSP board (if the pots are not sealed then use TIN 1074 to null the DSP boards before balancing the amplifiers). Adjust the BAL pot of the respective drive until a reading of 0.0 Millivolts is obtained. 8. Verify the balance by observing the Encoder Count display (the right-most column) with Motion Hold depressed; a properly balanced axis will not be counting. Do not balance by the Most Positive and Most Negative Count displays.
9. Once the servo drive has been balanced, exit the axis balance test and return to the Manual Mode screen. 10. Jog the axis at rapid (1016 mmpm for X or Y axis, 635 mmpm for Z) and adjust the SIGNAL pot on the drive to obtain a reading of 0.95 VDC. This reading must be .95 or less. 11. Program a 45 degree vectored move for XY of 300 mm length at 5000 mmpm velocity. The following error should be 0.700 mm with no more than a difference between X and Y of 0.06 mm.
DIGITAL SPEED CONTROLLER BALANCE ADJUSTMENTS 1. Connect a DVM set to DC Millivolts to TB1-1 (DAC IN) with respect to TB1-2 (DAC RTN) of the Digital Speed Controller Board. 2. Enter the 101 screen and select AXIS BALANCE, then depress Motion Hold; select SPINDLE and depress Start. 3. Adjust the VR4 pot on the DSP Board...
DATE: May 13, 1994 SUBJECT: HAWK 5M PARAMETERS PRODUCT LINE: HAWK 5M
The following figures show the default parameters for the Hawk 5M Knee Mill and should be used to aid in the machine configuration. Access the secret screens as follows: Function/Description Machine Configuration & Axis/Spindle Setup Axis Balance Leadscrew Mapping Matrix 4 DSP Axis Tune Interactive Diagnostics Access Screen Power-Up Configuration or from Auxiliary Mode Manual Mode ATC Diagnostics Manual Mode ATC Diagnostics Manual Mode ATC Diagnostics Auxiliary Mode Access Code ENTER,100,ENTER ENTER,101,ENTER ENTER,102,ENTER ENTER,103,ENTER ENTER,527,ENTER

The figures shown are as follows: Figure 1 Machine Configuration screen in Metric as seen at machine power-up Figure 2 Machine Configuration screen in Inch as seen during power-up (Note 100 access code entered) Figure 3 Machine Configuration screen seen after 100 code and ENTER depressed Figure 4 X Axis Physical Parameters Figure 5 X Axis Vertical Parameters Figure 6 Y Axis Physical Parameters Figure 7 Y Axis Vertical Parameters Figure 8 Z Axis Physical Parameters Figure 9 Z Axis Vertical Parameters Figure 10 - Spindle Physical Parameters Figure 11 - More Spindle Physical Parameters Figure 12 - Spindle Vertical Parameters Figure 13 - Configuration Parameter Screen for Machine Parameters & Tool Changer Parameters Figure 14 - Machine Parameters Figure 15 - Tool Changer Parameters Figure 16 - System Parameters screen as seen in Auxiliary Mode Figure 17 - Text Color Parameters for Mono CRT Figure 18 - Graphics Color Parameters for Mono CRT Figure 19 - Storage Functions Color Parameters for Mono CRT Figure 20 - ATC Diagnostics Screen Figure 21 - ATC Diagnostics Screen showing 103 code to access Axis Tuning for DSP Figure 22 - Axis Tune Screen after entry of 103 code Figure 23 - X Axis Tuning Parameters Figure 24 - Y Axis Tuning Parameters Figure 25 - Z Axis Tuning Parameters
FIGURE 1
FIGURE 2
FIGURE 3
FIGURE 4
FIGURE 5
FIGURE 6
FIGURE 7
FIGURE 8
FIGURE 9
FIGURE 10
FIGURE 11
FIGURE 12
FIGURE 13
FIGURE 14
FIGURE 15
FIGURE 16
FIGURE 17
FIGURE 18
FIGURE 19
FIGURE 20
FIGURE 21
FIGURE 22
FIGURE 23
FIGURE 24
FIGURE 25
DATE: May 13, 1994 SUBJECT: Monochrome CRT Settings PRODUCT LINE: Hawk 5M
The color settings on a Monochrome system must be set properly in order for the information to be seen on the CRTs. It is very easy to change these parameters from the default settings and get the control into a state in which you can not see anything on the CRTs. If this occurs there are two ways to get back the default settings. 1) 2) Reload the machine configuration parameters from the backup disk (assuming you can see enough on the CRT to do this). Know the keystrokes for the color parameters to get back to the default settings.
Below are listed the Softkey strokes required from a machine power-up state to reset the color settings. F8 EXIT AUXILIARY MODE F4 MACHINE CONFIGURATION F3 SET COLOR PARAMETERS F1 TEXT COLOR PARAMETERS F1 BLACK F7 MORE F2 LIGHT GRAY F7 MORE F7 MORE F4 WHITE F7 MORE F7 MORE F4 WHITE F7 MORE F7 MORE F4 WHITE F7 MORE F7 MORE

F4 F7 F7 F4 F7 F7 F4 F8 F2 F7 F7 F4 F4 F7 F2 F7 F2 F7 F7 F4 F7 F7 F4 F7 F7 F4 F8 F3 F7 F2 F7 F7 F4 F1 F7 F7 F4 F1 F7 F7 F4 F7 F2 F7 F2 F1 F8
WHITE MORE MORE WHITE MORE MORE WHITE EXIT GRAPHICS COLORS MORE MORE WHITE CYAN MORE LIGHT GRAY MORE LIGHT GRAY MORE MORE WHITE MORE MORE WHITE MORE MORE WHITE EXIT STORAGE FUNCTION COLORS MORE LIGHT GRAY MORE MORE WHITE BLACK MORE MORE WHITE BLACK MORE MORE WHITE MORE LIGHT GRAY MORE LIGHT GRAY BLACK EXIT FSB 1214 PAGE 2 OF 2
DATE:
January 23, 1997
ISSUE NUMBER: 1214-A
SUBJECT: Monochrome (and Color) CRT Settings PRODUCT LINE: Ultimax 3 PAGE 1 OF 2
The color settings on a Monochrome system must be set properly in order for the information to be seen on the CRTs. Early software versions enabled the SET COLOR PARAMETER softkey. This was removed in V1.52 to prevent customers from inadvertently changing colors on a monochrome system; however, V1.61 has reenabled this softkey (due to the incorrect setting of some of the monochrome colors during a software upgrade, the softkey now allows the customer to reset the colors to their default). COLOR PARAMETER DEFAULTS A. TEXT COLOR PARAMETERS 1. Background Color 2. Reverse Background Color 3. Data Display Area 4. Prompt Area Color 5. Softkey Label Color 6. Softkey Text Color 7. Softkey Line Delimiter 8. Cursor Color Monochrome Black Light Gray White White White White White White Color Black Light Gray White Light Red Light Red Light Cyan White Blue
NOTE: Reverse Background Color is also used for the Cursor Color in the NC Part Program editor. B. GRAPHICS COLORS 1. Part Path Color 2. Cutter Path Color 3. Rapid Path Color 4. Axes Color 5. Character Color 6. Box Color 7. Pointing Device Cursor Color White Monochrome Light Gray White White White White White Yellow Color Light Cyan Light Red Yellow Light Green White Light Cyan
ORIGINATOR: Keith Perkins REVISED BY: David Skrzypczak

8. DXF Line Color 9. DXF Highlight Color 10. DXF Branch Color 11. DXF Calculator Display Color 12. DXF Calculator Buttons Color 13. DXF Calculator Grid Color C. STORAGE FUNCTION COLORS 1. Directory Background Color 2. Highlighted Directory Color 3. Unhighlighted Directory Color 4. Current Directory Color 5. File Background Color 6. Highlighted File Color White 7. Unhighlighted File Color 8. Line Border Color 9. Page Up/Page Down Arrow Color
Light Gray White White White White Light Gray Monochrome Light Gray White Black White Black White Light Gray Light Gray Black
Green Yellow Red Light Green White Green Color Red White Black Yellow Blue Light Gray Light Gray Black
If the monochrome colors are all changed then there are several ways to get back the default settings: 1. Delete the SYSINT.SYS file from the C:\CONFIG\V1.xx directory (this will force the software to reload the default color settings). 2. Reload the Machine Configuration parameters from the Machine Configuration Disk (assuming that enough of the CRT can be seen to do this). 3. Boot the Executive from floppy disk and allow the default Machine Configuration to be loaded. Then copy the SYSINT.SYS file created on the last Executive disk to C:\CONFIG\V1.xx 4. If the screen is completely blank and it is suspected that the colors have been changed, enter the following keystrokes to restore enough of the screen to set the remaining defaults. After machine power up, press: F8 (EXIT) Auxiliary Mode F4 (MACHINE CONFIGURATION) F3 (SET COLOR PARAMETERS) F1 (TEXT COLOR PARAMETERS) F1 (BLACK for Background Color) F7 (MORE) F2 (LIGHT GRAY for Reverse Background Color) F7 twice (MORE) F4 (WHITE for Data Display Area) F7 twice (MORE) F4 (WHITE for Prompt Area Color) F7 twice (MORE) F4 (WHITE for Softkey Label Color) F7 twice (MORE) F4 (WHITE for Softkey Text Color) F7 twice (MORE) F4 (WHITE for Softkey Line Delimiter Color) F7 twice (MORE) F4 (WHITE for Cursor Color) F8 (EXIT; required to activate color settings) FSB 1214-A, Page 2 of 2
DATE: May 13, 1994 SUBJECT: Hawk 5M Advanced CMOS Setup Options PRODUCT LINE: Hawk 5M
The following tables list the default settings for the AMI BIOS Setup for the ISA control used on the Hawk 5M Knee Mill. In order to access the BIOS Setup Utilities you will need to connect a standard AT keyboard to the keyboard connector located on the bottom of the ISA Card Rack. Then reboot the control and depress the (DEL) key during the power-up. This will bring up the screen shown below: AMI BIOS SETUP PROGRAM - AMI BIOS SETUP UTILITIES 1992 American Megatrends, Inc., All Rights Reserved STANDARD CMOS SETUP ADVANCED CMOS SETUP ADVANCED CHIPSET SETUP AUTO CONFIGURATION WITH BIOS DEFAULTS ADVANCED PERIPHERAL SETUP OPTIONS CHANGE PASSWORD HARD DISK AUTO DETECT HARD DISK UTILITY WRITE TO CMOS AND EXIT DO NOT WRITE TO CMOS AND EXIT
Advanced CMOS Setup for configuring System Options : SEL
ESC: EXIT
F2/F3: COLOR
F10: Save and Exit

The following tables list the settings for: 1) 2) 3) ADVANCED CMOS SETUP ADVANCED CHIPSET SETUP ADVANCED PERIPHERAL SETUP TABLE 1: ADVANCED CMOS SETUP Typematic Rate Programming Disabled Typematic Rate Delay (msec.) 500 Typematic Rate (Char/Sec) 15 Above 1MB Memory Test Disabled Memory Test Tick Sound Disabled Memory Parity Error Check Enabled Hit <DEL> Message Display Enabled Hard Disk Type 47 RAM Area 0:300 Wait For <F1> If Any Error Enabled System Boot-Up Num Lock On Numeric Processor Test Enabled Weitek Processor Absent Floppy Drive Seek At Boot Enabled System Boot-Up Sequence A:, C: System Boot-Up CPU Speed High External Cache Memory Enabled Internal Cache Memory Enabled Fast Gate A20 Option Enabled Turbo Switch Function Enabled Password Checking Option Setup Video ROM Shadow C000, 16K Enabled Video ROM Shadow C400, 16K Enabled Adapter ROM Shadow C800, 16K Disabled Adapter ROM Shadow CC00, 16K Disabled Adapter ROM Shadow D000, 16K Disabled Adapter ROM Shadow D400, 16K Disabled Adapter ROM Shadow D800, 16K Disabled Adapter ROM Shadow DC00, 16K Disabled Adapter ROM Shadow E000, 16K Disabled Adapter ROM Shadow E400, 16K Disabled Adapter ROM Shadow E800, 16K Disabled Adapter ROM Shadow EC00, 16K Disabled System ROM Shadow E000, 64K Disabled System ROM Shadow F000, 64K Enabled Boot Sector Virus Protection Disabled
Table 2: ADVANCED CHIPSET BIOS SETUP Hidden Refresh Enabled Slow Refresh Disabled Single ALE Enable No Keyboard Reset Control Disabled Master Mode Byte Swap Disabled AT Cycle Wait State Enabled AT Cycle Between I/O Cycles 3 AT Bus Clock Selection CLKI/5 Fast Decode Enable Disabled Memory Read Wait State 2 W/S Memory Write Wait State 3 W/S Cache Read Cycle 3-2-2-2 Cache Write Wait State 1 W/S Non-Cacheable Block-1 Size Disabled Non-Cacheable Block-1 Base 0 KB Non-Cacheable Block-2 Size Disabled Non-Cacheable Block-2 Base 0 KB Cacheable RAM Address Range 64 MB Video BIOS Area Cacheable Yes
Table 3: ADVANCED PERIPHERAL SETUP Programming Option Auto On-Board Floppy Drive Disabled On-Board IDE Drive Disabled First Serial Port Address Disabled Second Serial Port Address Disabled Parallel Port Address Disabled IRQ Active State High Parallel Port Mode Normal
DATE: May 16, 1994 SUBJECT: Lead Screw Mapping PRODUCT LINE: Hawk 5M Knee Mill
In order to compensate for leadscrew and backlash error the control incorporates a forward and reverse map for each axis. This map will allow compensation in millionths of an inch (i.e. 0.0001 inches = 100 millionths of an inch) for each inch of axis travel, for full travel of the axis. It will also allow a single backlash entry that will alter the reverse map data by the back lash value entered. Refer to Figures 9 thru 12. The method you will use to enter the error values will depend upon the method used to check the accuracy of the axis. If you are using a Laser Interferometer or a Webber bar that will allow you to check the axis every inch full travel, then you can simply enter the error seen in millionths of an inch in the forward map screen, and the errors seen on the return run in the reverse screen. If you are using a JO-Block of a given dimension as a standard, you will then need to determine the error per inch in millionths of an inch and calculate the values to be entered into the table. The same values will need to be entered into both the forward and reverse map and then the backlash value could be entered in to alter the reverse map. Refer to Figures 9 thru 12. Figure 1 shows the screen you will see when you enter Machine Diagnostics, which you will need to go to access the mapping screens. Note the 102 at the bottom of the screen. This is the secret code to access the mapping screens. The key sequence once you have entered the diagnostics screen is ENTER, 102, ENTER. This will then display the screen shown in Figure 2. Figure 2 is the main screen for mapping. From this screen you can: 1) Manually enter compensation, 2) Load axis mapping from disk (floppy or hard disk) that was previously saved, 3) Load defaults (Note that this will reset all map data to zeros, i.e. no mapping information), 4) Save mapping compensation to disk (floppy or hard drive)

Figures 3 thru 8 show typical forward and reverse screens for the X, Y, and Z axes. Example: The X axis was checked using a JO-Block that was 19.5 inches long. The error seen at 19.5 inches was 0.0002925 inches (292.5 millionths). The error per inch would be 0.0002925 ' 19.5 which would equal 0.000015 inches (15 millionths). This error per inch was then entered for each entry in the forward table (Figure 3) and the reverse table. Prior to the back lash value being entered the screens had the same values entered for both forward and reverse mapping. The backlash error was 0.0003 inches (300 millionths) and this was added as a single entry using the reverse compensation softkey, to the reverse compensation and the result displayed in the reverse table shown in Figure 4. The Y axis was checked with a 10 inch JO-Block. The error was (-) 0.0004 inches (400 millionths) and the backlash was 0.0008 inches (800 millionths). Refer to Figures 5 and 6. The Z axis screens (Figures 7 and 8) show 0.00001 inches (10 millionths) per inch error and 0.0001 inches (100 millionths) of backlash. Figures 9 and 10 show an example of a Z axis prior to entering backlash compensation. The Z axis leadscrew error is 0.0001 inches (100 millionths of an inch) per inch. Figure 11 shows entering 100 millionths (0.0001 inches) of backlash compensation. Figure 12 shows the result of the backlash compensation on the reverse map.
FIGURE 1
FIGURE 2
FIGURE 3
FIGURE 4
FIGURE 5
FIGURE 6
FIGURE 7
FIGURE 8
FIGURE 9
FIGURE 10
FIGURE 11
FIGURE 12
Once the mapping is completed and all data is entered and confirmed valid, you should save the leadscrew map to both the hard drive and to the customers configuration floppy disk. Note that as with all types of accuracy checks that the axes should be allowed to warm up to minimize the effect of thermal expansion and that the more accurate the measuring device the more accurate the machine will perform. The accuracy and repeatability specs for the 5M are: Accuracy ) 0.0005 inches Repeatability ) 0.0003 inches
DATE: May 20, 1994 SUBJECT: ISA HARD DISK SETUP PRODUCT LINE: Hawk 5M
The following steps are required to setup a hard drive to boot the Ultimax software. It is assumed that the drive will be low level formatted from the manufacturer. 1) You must have a DOS bootable floppy disk with the following files: FDISK.EXE, FORMAT.COM, BOOTMERG.EXE, AND BOOTSTRP.BIN.
NOTE: It is also handy to have some form of disk utility such as NU.EXE from the Norton Utilities. 2) Create the C: and D: partitions by using FDISK.EXE and setup the primary partition for 10 megabytes, and make this the active (boot) partition. The second partition (D:) should use the remainder of the space on the drive. Use FORMAT.COM and format the C: drive. Enter EXECUTIVE_1 as the volume label. Format the D: partition, no volume label is needed. Put the Hurco bootstrap on the boot sector of the drive by typing the following: bootmerg bootstrp.bin c: NOTE THE SPACES, SYNTAX IS EVERYTHING
3)
4)

5)
Copy the HURCO.LDR file onto C:
NOTE: This must be the first file copied onto the C: partition. The reason is that the HURCO.LDR must start at cluster 2 and must be contiguous. It must be the first or second entry in the root directory, the volume label is the other. The bootstrap is a small program that assumes that these conditions exist. The Norton utilities are useful for checking these conditions. NU.EXE can be used to look at the root directory and verify that the volume label and the hurco.ldr are the first two entries. Also check the start cluster for hurco.ldr and make sure it is 2. Then select the FAT and verify that the chain of clusters is contiguous. 6) 7) Copy all other files in any order to C: Reboot the control by cycling the power OFF and ON.
DATE: July 29, 1994
ISSUE NUMBER: 1218-A
SUBJECT: Yaskawa AC Servo Set-up, Max 2 & Max32 Dual Axis SUPERSEDES NUMBER: PRODUCT LINE: BMC20-50, KM5 PAGE 1 OF 5
Revised Engineering Doc 757-4002-092: To reflect KM5 & BMC20LR X & Y Axis Jumper setting on SW2
SUBJECT:
Ultimax II BMC 20-50 IP/V2 and KM5 Yaskawa Servo Amplifier Set-up Procedure
II. APPLICABILITY:
Applicable to all Ultimax II and Max 32 BMC 20/50 IP/V2 Machine Centers and KM5 Knee Mills. This procedure to be used by Manufacturing during build process and by Customer Service when installing or servicing the above machine types.
III. INDEX:
Page 2 Page 2Page 3 Page 4 Page 5 Servopack Configuration ** INFORMATION ADDED ** DAC Offset PCB Adjustment procedure Linear Axis Servo Setup procedure Yaskawa Servopack PCB layout Diagram Amplifier Information and Fault Codes
Tools Required:
Digital Volt Ohm Meter (DVM) Small Screwdriver

IV. LINEAR AXIS YASKAWA SERVOPACK CONFIGURATION:

NOTE: A) Normally the factory settings of VR1 thru VR6 will not need to be altered. Verify that the Yaskawa Servopack for each Axis is configured as follows:
LINEAR AXES Refer to Page 4 for location Shunt SW1 SW2 SW3 SW4 Pots VR1 VR3 VR4 VR5 VR6 Settings Jumpers on 4 & 8 Jumpers on 2 thru 8 1:2 Ratio/ All BMC Jumpers on 1 thru 8 1:1 Ratio BMC20LR X & Y Axis Direct Drive Jumpers on 3 thru 8 1:4 Ratio KM5 Jumpers on 1 & 4. Add jumper to #7 if machine exhibits an axis oscillation in manual and / or automatic. Will be heard as a rumble. Jumpers on 1 thru 4 & 8 Setting Mid range Mid range Mid range Full CW Mid range Scale 5 of 10 Scale 5 of 10 Scale 5 of 10 Scale 10 of 10 Scale 5 of 10 Scale
IN-B ZERO FINE CUR LOOP
V. DAC FLYER PCB SETUP PROCEDURE:

AXIS CONTROLLER ONE (AC1) Top pot Z axis DAC offset adjustment Bottom pot Spindle DAC offset adjustment (Used on KM5 Only) AXIS CONTROLLER TWO (AC2) Top pot X axis DAC offset adjustment Bottom pot Y axis DAC offset adjustment A) B) Ensure machine is Calibrated and the Axis are positioned to center of travel. Depress the Change Tool or Diagnostics Softkey then ATC & Machine Diagnostics softkey, to display the diagnostic screen. Depress Enter, 488, Enter, (Note: may be 101 on later software versions) to display the Spindle/Servo Diagnostic Setup screen. Depress Axis Balance Adjustment softkey. This commands an open-loop routine that outputs four bits of DAC, both plus and minus, at a three second duty cycle. This will produce an approximate +/- 9.7mVDC command signal to the servo amplifier. Use the Axis Jog buttons to select the axis to adjust, then depress the Start button. Connect a Digital Volt Meter, set on the Millivolt DC scale, to TM3-2 (Positive Lead) and 0V (Negative lead) of the approiate servo amplifier. Adjust the approiate DAC Offset Adjustment pot to obtain a symmetrical reading within 0.0001 VDC (0.1mVDC). Note the actual voltage value may vary slightly from one Dual Axis PCB to another, however it will usually be around +/- 9.7mVDC. Return the axis to the closed-loop servo mode by depressing the Exit softkey and the Manual Mode key.
C)
D) E)
F)
G)
FSB XXX Page 2 of 5
VI. LINEAR AXIS SERVO SETUP PROCEDURE:

1. Confirm the Control is in Metric Mode and enter the following programs for the Axis to be adjusted: X Axis: Part Setup: X = 0, Y = 0, Z = 0 Tool Setup: Tool 1 = Any type, Any Diameter, Length = 0, RPM = 100. Program Parameters: Rapid Traverse = 1016 mm/Min. Part Program: Data block 1 = Pattern Loop Rectangular, 10 x 10 with no offsets. Data block 2 = Position Tool 1 to X of 0, Y of 0. Data Block 3 = Position Tool 1 to X of 100 mm, Y to 0 mm. Data Block 4 = Pattern End. Y Axis: Same as above except exchange X and Y coordinates in Data Block 3. Z Axis: Part and Tool Setup same as above. Program Parameters same as above. Part Program: Data Block 1 = Drill Holes with Tool 1, Z Start and Z Bottom = -100 mm, Feed = 1016 mm/Min., RPM = 100. Bolt Circle of 100 holes with 0 Radius. Connect DVM to Yaskawa TM3-2 (Positive Lead), and 0V (Negative lead) of the axis to be setup. Set Meter on 2 VDC scale. While running the correct program for the axis being set, adjust VR1 to obtain .945 to .955 VDC in both directions. Use VR3 to minimize difference in signal when changing direction of the axis. Adjust VR4 to obtain .950 to .952 VDC in both directions. After VR4 is set for .950 to .952 VDC in both directions depress Motion Hold button. Verify that signal is 0.000 VDC. If not adjust VR3 for 0.000 VDC or as close as possible to zero. Repeat above steps for All Axes. Calibrate Axes and observe position display on CRT. CRT should display 0.000MM for all axes and Marker Dot should be either on solid or flashing on & off. If not, fine tune VR3 for the selected Axis. Run Axes thru a few short position moves, then recheck the axis balance by Calibrating Axes as in step above. Program Full Travel, Rapid Traverse moves of 10160 mm/Min. and verify axes run smoothly and that no Motion Error occurs. Repeat this ten times.
A)
B)
C)
2.
3.
4.
5. 6.
7.
8.
FSB XXX Page 3 of 5
CACR-SRCA REV B
OV
TM5 TM3 1 SW1 1 T O 8 SL4 T O 8 TM4 1 1 T O 8 T O 8
SW4 1 T O 8 SW2 1 T O 8 VR9 VR2 VR10 VR11 VR12 VR13 IN-B SW3 1 LOOP T O 8 ZERO 5VP RESET PUSHBUTTON
TROUBLE LED INDICATION (7-SEGMENT)
IN P MP
VR7 VR4 8 TO 1 TM2 8 TO 1 TM1 VR8
CUR
SL6 SL7 SL5
2CN
1CN
FSB XXX Page 4 of 5
MAX TWO V2 AXIS AMPLIFIER INFORMATION

GREEN LED STATUS INDICATORS
LED NAME ILLUMINATED INDICATION
MAIN BUS INPUT VOLTAGE IS PRESENT. (AXIS BUS STARTER [ABS] IS ACTIVATED) AMPLIFIER CONTROL VOLTAGE IS PRESENT. (INTERNAL +5VDC)
MP P IN
A DAC COMMAND IS CURRENTLY APPLIED.
AXIS AMPLIFIER SEVEN-SEGMENT LED DISPLAY

LED INDICATION BASE CURRENT IS BLOCKED NORMAL OPERATION TIME OF INDICATION
GOES ON WHEN THE MAIN DISCONNECT IS TURNED ON. GOES ON AFTER THE START PUSH BUTTON IS DEPRESSED. GOES ON WHEN THE MAIN DISCONNECT IS TURNED ON. GOES ON WHEN THE START PUSH BUTTON IS DEPRESSED AND MCCB DOES NOT TRIP.
PROBABLE CAUSE
MACHINE IS IN EMERGENCY STOP.
AXES ARE READY TO MOVE.
DEFECTIVE AMPLIFIER CONTROL CIRCUIT BOARD (1 PWB). DEFECTIVE CURRENT FEEDBACK CIRCUIT. DEFECTIVE MAIN CIRCUIT TRANSISTOR MODULE. DEFECTIVE MOTOR GROUNDING. DEFECTIVE MAIN CIRCUIT TRANSISTOR MODULE. DEFECTIVE AMPLIFIER CONTROL CIRCUIT BOARD (1 PWB). DEFECTIVE AMPLIFIER CONTROL CIRCUIT BOARD (1 PWB). DEFECTIVE MAIN CIRCUIT THYRISTOR DIODE MODULE. DEFECTIVE AMPLIFIER CONTROL CIRCUIT BOARD (1 PWB). DEFECTIVE REGEN TRANSISTOR OR REGEN RESISTOR.
OVERCURRENT
GOES ON WHEN THE START PUSH BUTTON IS DEPRESSED AND MCCB DOES TRIP. GOES ON WHEN THE AXIS STARTS OR SLOWS DOWN. GOES ON WHEN THE MAIN DISCONNECT IS TURNED ON. GOES ON WHEN THE START PUSH BUTTON IS DEPRESSED. GOES ON WHEN THE MAIN DISCONNECT IS TURNED ON. GOES ON AFTER THE START PUSH BUTTON IS DEPRESSED.
CIRCUIT
PROTECTOR TRIPPED
REGENERATIVE TROUBLE
4 5 6
OVERVOLTAGE OVERSPEED
DEFECTIVE REGEN CIRCUIT. GOES ON AFTER THE START PUSH BUTTON IS DEPRESSED. GOES ON AFTER THE START PUSH BUTTON IS DEPRESSED. GOES ON WHEN THE MAIN DISCONNECT IS TURNED ON.
DEFECTIVE REGENERATIVE CIRCUIT.
MOTOR/ENCODER CONNECTION ERROR OR MOTOR/ENCODER FAILURE. DEFECTIVE MAIN CIRCUIT THYRISTOR DIODE MODULE. DEFECTIVE AMPLIFIER CONTROL CIRCUIT BOARD (1 PWB). RESULT OF POSSIBLE OVERHEAT, ALLOW SYSTEM TO COOL FOR 30 MINUTES. CONTINUOUS MACHINE OPERATION ABOVE 100% RATED LOAD. RESULT OF POSSIBLE OVERHEAT, ALLOW SYSTEM TO COOL FOR 30 MINUTES. CONTINUOUS MACHINE OPERATION ABOVE 100% RATED LOAD. DEFECTIVE AMPLIFIER CONTROL CIRCUIT BOARD (1 PWB). DEFECTIVE AMPLIFIER CONTROL CIRCUIT BOARD (1 PWB). MOTOR/ENCODER CONNECTION ERROR OR MOTOR/ENCODER FAILURE. DEFECTIVE AMPLIFIER CONTROL CIRCUIT BOARD (1 PWB). MISSING THREE PHASE INPUT SOURCE. CHECK AXIS BUS STARTER (ABS). DEFECTIVE AMPLIFIER CONTROL CIRCUIT BOARD (1 PWB).
VOLTAGE DROP
OVERLOAD
GOES ON WHEN THE START PUSH BUTTON IS DEPRESSED. GOES ON DURING MACHINE OPERATION. GOES ON WHEN THE MAIN DISCONNECT IS TURNED ON.
OVERHEAT
GOES ON DURING MACHINE OPERATION.
A/D ERROR
GOES ON WHEN THE MAIN DISCONNECT IS TURNED ON. GOES ON WHEN THE MAIN DISCONNECT IS TURNED ON. MOTOR STARTS MOMENTARILY, THEN C. ERROR GOES ON. GOES ON WHEN THE MAIN DISCONNECT IS TURNED ON. GOES ON AFTER THE START PUSH BUTTON IS DEPRESSED. GOES ON DURING MACHINE OPERATION.
OVERRUN PROTECTION
OPEN PHASE
CPU ERROR
ERROR STATUS IS RELEASED BY PRESSING THE AMPLIFIER RESET BUTTON
703-0006-169 Rev.A
FSB XXX Page 5 of 5
DATE: August 29, 1994 SUBJECT: Low Volume from Coolant Pumps. PRODUCT LINE: Acroloc 1540, 1550, 3030 Twin Spindles
This FSB covers any Acroloc 1540, 1550, or 3030 Twin Spindle with the 200 gallon coolant reservoir. The low coolant volume that we are experiencing has been found to be caused by a filter screen directly in front of the coolant pump. To rectify this problem, remove the screen from in front of the pump. The filter basket is sufficient to keep chips and debris from damaging the Pump. This could also be why we are experiencing such a high rate of Coolant Pump failures, as the motor must work harder to pump coolant.
ORIGINATOR: Don Schmedake REVISED BY:

DATE: November 10, 1994 SUBJECT: Executive Disk V1.51 PRODUCT LINE: Hawk 5M
The Executive Diskettes V1.51 that were shipped with all Hawk 5M machines have a defective HURCO.LDR file. The control will not be able to boot off of these floppy diskettes, as the control will continually reboot. Also, do not attempt to execute an UPGRADE EXECUTIVE with these diskettes as this will transfer the defective HURCO.LDR file to the Hard Drive. This will result in the control continuously rebooting. If a customer needs to use the Executive Diskettes, a new V1.51 (or a V1.52 with a new Software Protection Key) will be required.

DATE: November 28, 1994 SUBJECT: Spindle Handling Precaution PRODUCT LINE: All BMCS (Cartridge Type)
HURCO MANUFACTURING has had our spindle rebuilders investigate the causes for failures. One cause for failures is supporting the weight of the spindle cartridge assembly on the spindle nose instead of the cartridge mounting flange. This will lead to premature bearing failure. Whenever you are replacing the spindle cartridge in any machine that has a cartridge assembly. the weight of the assembly is to be supported by the mounting flange. This can be accomplished by using wood blocks of sufficient height and width to keep the spindle nose clear of the table. As always use caution when moving heavy objects. After installing but, before running the new spindle, be sure to completely check it out. Do the following geometry checks and procedures. 1. Verify machine is level. Correct as necessary. 2. X to Z, Y to Z & X to Y squareness. Correct as necessary. You may have to sacrifice level to obtain proper squareness 3. Check table flatness. (The preceding three (3) items can cause an apparent spindle problem.) 4. Check spindle sweep. Correct as necessary. 5. Set drive belt tension per engineering document # 757 4001 117 rev B. 6. Perform Spindle Run In per engineering document # 757 4001 118 rev A.

DATE: January 19, 1995 SUBJECT: Proper Axis Current Set-Up PRODUCT LINE: Hawk 5M
The proper axis currents for the Hawk 5M mill are as follows: 1) 2) The X/Y Axis current should be between 3 to 6 Amps; in both plus and minus directions. The Z Axis current should be between 1.5 to 3 amps; in both plus and minus directions.
The axis currents are to be set by adjusting Gib tension per normal procedure.


R
DATE: SUBJECT: PRODUCT LINE:
January 16, 1995 Accuracy Standard Procedure All Mills
ISSUE NUMBER: 1223
PAGE 1 OF 5
INTENT: To have a standard procedure in using the accuracy standard to setup the leadscrew compensation and backlash on all machines. Following is a step by step procedure to assist you in this endeavor: 1. Allow the 13.1 inch standard to reach the same temperature as the machine, which could take up to one hour or more depending on the initial temperature of the standard. 2. Stone the table to remove small nicks in order to provide a smooth surface. 3. Level the machine and check geometry to insure the machine is within specifications. 4. Place the standard on the table parallel to the axis you intend to measure. The standard should be directly over the leadscrew and not to one side of the table. If it is off to one side, a small kick in the table will affect the outcome of your measurements. Align the standard with a .0001 indicator in order to ensure absolute parallelism with the axis, usually .0001 from end to end. If the standard has a slight bow, align the ends and disregard the center. Placing a magnetic base along side the standard is sufficient to hold the standard in place. If you must use clamps to hold the standard, DO NOT over tighten; if debris is under the standard or the table is not flat then the standard may be damaged. 5. Refer to the following Fig. 1 and the program ACCRCSTD.HD3 in checking the machine. The Part Zero and Tool Zero is at Position 1 and should be near the center of the tab. Data Block 1 is a Parameter Block to slow the Rapid Traverse, setup Retract Clearance, and increase Drill Dwell. By using a Data Block for the parameters, it allows you to jog at normal feedrates in the manual mode. Data Block 2 sets up a loop for a continuous run. Data Blocks 3 and 4 provides for Drill Positions 1 through 6. Please note that Z Start in Data Block 4 is at a -.5000. A similar program can be written for the B/BX machines.
ORIGINATOR: Ken Borgmeyer REVISED BY:

Pos. 2
Pos. 1 & 3 Pos. 4 & 6 Pos. 5
13.1 INCH STANDARD
FIG. 1
6. The program should be ran in the Dry Run of Test Mode with a Minimum Z of -0.5000. On the B/BX, a Dry Run is done by depressing Operate, Auto On, Check, Start, and Head Down for each movement. The Spindle On and Auto tool Change are not used. A couple of runs should be done to check the measurements to insure that the Standard is not moving and that the indicator is giving good readings. For example, the reading at Position 3 should be the same on all runs. 7. The difference between Position 3 and Position 4 is the leadscrew error. The difference between Positions 1 and 3 is the backlash at that position. Likewise, the difference between Positions 4 and 6 is the backlash at that end of the Standard. Record this information. 8. Leadscrew error should be corrected first, thus making the backlash checks easier. To compute leadscrew error, take the difference between Positions 3 and 4 and divide by 13.1. Round off the result to the nearest ten-millionths and add to each inch value in the Forward Map. For example, if you have a difference of 0.0008 (or 800 millionths) between Positions 3 and 4, dividing by 13.1 results in 61.07 millionths which is rounded to 60 millionths per inch. In the Forward Map (102 screen), enter the following numbers:
0 inch 1 inch 2 inch 3 inch 4 inch 0 60 120 180 240
and so on. In the Reverse Map, enter the same numbers in each location. For the above example, 0 inch will be 0, 1 inch will be 60, etc. Note: this is before you enter any backlash in the Reverse Map! The program should be run again to verify the leadscrew error has been corrected and only then should the backlash error be recorded. 9. If the backlash is approximately the same on bothe readings, an average can be used. For example, if the differences between Positions 1 and 3 is 0.0004 and Positions 4 and 6 is 0.0006 then 0.0005 would be sufficient to bring the machine into specification. In this case, 500 millionths would be added to all locations in the Reverse Map. If the backlash varies over the lenght of the leadscrew, different backlash can be added at those locations.
FSB1223.DOC Page 2 of 5
10. The numbers in the Leadscrew Compensation screen corresponds to the machine location from table zero. If you have large differences in backlash from one inch to the next (greater than 0.0002) then you have a serious problem with the leadscrew or other major problems. This procedure should allow you to setup a machine to specification. If the customer insists the machine be setup under closer standards then a laser must be done.
HURCO ULTIMAX PART PROGRAM ACCRCSTD.HD3 PART SETUP PART ZERO OFFSET X Y Z 1.2345 6.7890 0.0000 SAFETY WORK REGION Z TOP (+) 99.0000 Z BOTTOM (-) -99.0000 X LEFT (-) -99.0000 X RIGHT (+) 99.0000 Y FRONT (-) -99.0000 Y BACK (+) 99.0000
INCH STANDARD
GENERAL PARAMETERS RETRACT CLEARANCE RAPID TRAVERSE PECK CLEARANCE PLANE CHORD ERROR DEPLETION RETRACT 99.0000 IN 400.0 IPM 0.0500 IN 0.0001 IN 0.0050 IN
HOLES PARAMETERS BORE ORIENT RETRACT DRILL DWELL BORE DWELL 0.0200 IN 0.5 SEC 1.0 SEC
MILLING PARAMETERS BLEND OFFSET BLEND OVERLAP FINISH FEED FINISH SPEED FINISH XY FINISH Z MILLING DIRECTION POCKET OVERLAP CUTTER COMP PARAMETER 0.1250 IN 0.1250 IN 100 % 100 % 0.0100 IN 0.0050 IN CLIMB 10 % INSERT ARC
PROGRAM PARAMETERS OVERRIDE LOCKOUT PROGRAM PROTECT TOOL CHANGE POSITION OFF PARTIAL NO
TOOL SETUP 1 TYPE DIAMETER ZERO CALIBRATION SPEED (RPM) COOLANT DRILL 0.1000 12.3456 0 OFF
CW
DATA BLOCKS 1 CHANGE GENERAL PARAMETERS RETRACT CLEARANCE RAPID TRAVERSE PECK CLEARANCE PLANE CHORD ERROR DEPLETION RETRACT HOLES PARAMETERS BORE ORIENT RETRACT DRILL DWELL BORE DWELL MILLING PARAMETERS BLEND OFFSET BLEND OVERLAP FINISH FEED FINISH SPEED FINISH XY FINISH Z MILLING DIRECTION POCKET OVERLAP PATTERN LOOP RECTANGULAR X NUMBER 10 Y NUMBER 10 X DISTANCE 0.0000 Y DISTANCE 0.0000 HOLES DRILL TOOL Z START Z BOTTOM PLUNGE FEED SPEED (RPM) PECK DEPTH PECK TYPE LOCATIONS 1 2 3 HOLES DRILL TOOL Z START Z BOTTOM PLUNGE FEED SPEED (RPM) PECK DEPTH PECK TYPE LOCATIONS 1 2 3 PATTERN END
0.5000 IN 40.0 IPM 0.0500 IN 0.0001 IN 0.0050 IN 0.0200 IN 1.0 SEC 1.0 SEC 0.1250 IN 0.1250 IN 100 % 100 % 0.0100 IN 0.0050 IN CLIMB 10 %
1 0.0000 0.0000 5.0 0 0.0000 STANDARD X Y 0.0000 0.0000 -1.0000 0.0000 0.0000 0.0000
1 -0.5000 -0.5000 5.0 0 0.0000 STANDARD X Y 13.1000 0.0000 14.1000 0.0000 13.1000 0.0000
DATE: March 24, 1995 SUBJECT: Table T-Slot Alignment PRODUCT LINE: Hawk 5M / Hawk 5D
The T-Slot parallel alignment to X Axis is measured from the center to each end of the table, not from one end to the other. This measurement should be 15 inches from center in each direction and the tolerance is 0.0008 inches over 12 inches of travel. The center T-Slot is the only one measured or specified. See diagram below.
15
15 15

DATE: JUNE 13, 1995 SUBJECT: HAWK 5M/5D DRAWBAR SETUP PRODUCT LINE: HAWK 5M/5D
The following is the procedure for setting the drawbar height on all HAWK 5 machines. There have been several reports of power heads failing in the field and the possible cause could be inproper drawbar setup.
1) Calibrate machine. 2) Remove cover and power head assembly. . 3) Measure from top of retainer cap to top of drawbar and set to .950 to 1.00 with machine at home position 4) Adjust Z+ limit switch if necessary to achieve .950 to 1.00.
ORIGINATOR: KOSTAS EVDOKIOU REVISED BY:

DATE: August 16, 1995
ISSUE NUMBER: 1226
SUBJECT: Kurt Power Drawbars-Hawk 5 M and Hawk 5 D SUPERSEDES NUMBER: PRODUCT LINE: Hawk 5 M-5D PAGE 1 OF 1
It has been discovered that some of the Kurt Power Drawbars were supplied to HURCO with out the O-ring being greased. This results in the Kurt Power drawbar either not engaging every time or not returning to the normal disengaged position (It sticks in the down position.). TO RESOLVE THIS PROBLEM; GREASE THE O-RING 1) Remove Kurt power head from machine. 2) Remove power cover (4 screws). 3) Remove the spring clip and snap the collet out. 4) This exposes the O-ring, coat with a lithium grease 5) Preload the spring clamp tension 6) Replace the power cover. 7) Mount Power Head back on machine and verify that Kurt Power Head engages and disengages the cleanly every time. NOTE: IF THE TOP OF THE DRAW BAR IS DAMAGED THE DRAWBAR MUST BE REPLACED ALSO. PART #802-2706-001 The washer part number if needed is 604-0742-013. The part # for the Kurt Power Drawbar is 002-4005-001
ORIGINATOR: Steven Artz REVISED BY:

DATE: July 21, 1995 SUBJECT: Flood Coolant Leaks PRODUCT LINE: Frame "A" Machines
The Frame A machines described below need to have the wipers and covers for the Y-axis checked for wear, gaps and excessive weld build up which can cause wiper failure. Machines 1-73 were modified per the Frame A machine addendum and will not have the wiper shown in figure 1. Machines 74 and later must be inspected and corrected. Any machine with a May 1995 or later serial number falls into this group. Frame numbers are located on the lower right when viewing from the back of the machine. Please review the following drawings for locations of points to be inspected.

figure 1 The neoprene wiper seen here against the Y-axis cover may have become damaged by running back and forth over heavy welding . Inspect the Y-axis with a flashlight from the back of the machine. Black rubber flakes on the Y-axis cover indicates further inspection of the wipers should be done.
During your inspection watch for gaps during axis movement over the full travel of Y. Some mounting bolts may need to be loosened to adjust the covers up or down to eliminate gaps. But to not bind the way covers when the Y- axis moves to the negative limit. IF YOU HAVE ANY QUESTIONS CALL HURCO TECHNICAL SERVICE.
DATE: August 23, 1995 SUBJECT: Power Cabinet Coolant Leaks. PRODUCT LINE: Hawk 5M
Gentlemen; The purpose of this FSB is to notify you of a possible invasion of coolant into the Power Cabinet. We have had 3 incidents where coolant has leaked into the Power Cabinet past the mounting bolts for the transformer located on top of the Power Cabinet and shorting out either the Servo Dynamics axis drive, or the I/O board and Backplane in the ISA Card Rack. After close inspection of the mounting flange on the transformer, it appears that the only way to resolve the problem is to silicone the threads of the bolts, the nutsert, and between the mounting flange and Power Cabinet. ( Due to the slotted holes on 1 side of the transformer mounting bracket.) If you have a Hawk 5M in your territory, it will be necessary to resolve this problem before any damage can occur. You can find a 4.7 oz. tube of silicone under the Hurco part number 702-0001-004. We do have this silicone in stock at this time.

DATE: November 9, 1995 SUBJECT: Incorrect parameter for Winding Change PRODUCT LINE: BMC 30/HT/D
We have had some instances of BMC 30/HT/D machines not changing windings in the field due to an incorrect parameter being installed. Please check to make sure that the BMC 30/HT/D Machines in your region changes windings at your next visit to the customers facility. The symptoms of this problem would be lack of torque, and difficulty setting up Rigid Tapping as the spindle is always in high gear. To check to see if your machine is changing windings is to simply program a spindle speed of 1999 rpm, and than a spindle speed of 2003 rpm. Since the winding change occurs at 2001 rpm, you should hear the Dual Winding contactor change states and also see the Load Meter jump at the same time. If you determine that this problem does exist, follow the procedure in the Dynapath Delta 20 Installation Guide to access parameters, and verify that parameter address 4AE is set to 04. Change this parameter to a value of 05. If this parameter is set to a value other than mentioned, please call Technical Support for further instructions. This parameter is used to turn on options located in the PIC Ladder Instructions, so it must be set correctly.!!!

DATE: November 9, 1995 SUBJECT: Servo Dynamics Drive Tune Procedure. PRODUCT LINE: BMC 30/D, Hawk 5D, Hawk 5M
If it becomes necessary to change a Servo Dynamics Drive Board or Drive Chassis Assembly, use the following procedure to assure proper tuning of the replacement board or boards. 1. Disconnect all plugs from the board or boards. 2. Attach the common of your volt meter to TP1 on a good drive Board. 3. Measure and document the Ohms between TP1 (common) and TP2, (Aux Pot) TP3, (Sig Pot) TP4. (Tach Pot) and TP5 (Cmp Pot). 4. Adjust the Potentiometers on the new Drive Board to match your documented readings from the good board. This will tune the new board to the correct specifications. 5. Double check your Axis Balance and Axis Lag before leaving and adjust as necessary.

DATE: Nov. 28, 1995 SUBJECT: Digital Spindle Controler PCB Modifications PRODUCT LINE: Hawk 5 ssm
This modification is to remedy the spindle not at speed error on the SINGLE SCREEN MAX Hawk 5s. On the digital speed controller (415-0252-901)solder a 330 ohm 1/4w resistor in parallel with the resistor element at RN1 pin 5. All new boards should have a 270 ohm resistor pack (407-0010-070) not the 2.2 K resistor pack. Machines shipped after Jan 01, 1996 should already have this modification done. Machines shipped in 1995 may not have had board modified. PLEASE CHECK.
RESISTOR, 330 OHM 1/4 W 5%
RN 1
..........
SOLDER SIDE
ORIGINATOR: J. Steven Artz REVISED BY:

DATE: Jan. 16, 1996 SUBJECT: Upgrade of Remote Shutdown Relay. (RSR) PRODUCT LINE: BMC 30/D, BMC 30/HT/D Delta 20 and Delta 40 Controls
The purpose of this FSB is to upgrade the Remote Shut Down Relay to enable the Servo Dynamics Drive to brake the Axis to a stop when Emergency Stop is depressed. To perform this upgrade, it will be necessary to order a Hurco Part Number # 407-0002-078 50 VDC., 220 Micro Farrad Radial Polarized Capacitor, and install it across the coil of Remote Shutdown Relay. This will cause the Servo Dynamics Drive to remain ready long enough after the DAC Signal is cut off to allow braking before the Drive is Inhibited. Remember to observe the Polarity of the Capacitor. Keep in mind that the Silver Stripe on the Diode is the plus side of the relay coil.

DATE: Jan. 24, 1996 SUBJECT: Upgrade of RS232C Cables. (Com 1, Com 2 ) PRODUCT LINE: BMC 30/M, BMC 30/HT/M
The purpose of this FSB is to upgrade the Com 1, Com 2 RS232C cables located on the back door of the Electrical Cabinet. To do this upgrade you will need to order 2 of a part # 423-4405-080, and 4 threaded stand-offs, part # 110-0134-051. Remove the existing Ribbon Cable Harness going to Com 1 and Com 2, taking care to note where Com 1 and Com 2 plug into the ISA Card Rack, so as not to unintentionally swap the two ports. Attach the new shielded Cables to their respective ports on the ISA Card Rack, and secure the Female ends of the Cables to the back door of the Electrical Cabinet using the Thumb Screws already in the new cable assembly and the Female Stand Offs to secure it to the Com Panel, using Loctite 601 to prevent these from coming loose. This is being done to solve a noise problem that occurs during long transfers of files VIA RS232C.

DATE: 02/21/96 SUBJECT: Kurt Power Heads & Drawbar Set-up
PRODUCT LINE: KM5P, Hawk 5M, Hawk 5D, & Hawk 5SSM PAGE 1 OF 2 DISASSEMBLY OF CHICAGO PNEUMATIC OR KURT POWER DRAWBAR VOIDS THE ONE (1) YEAR MANUFACTURERS WARRANTY. If suspected failure and under warranty then replace. Complete Power Drawbar Assemblies (Powerhead, with base plate,switches, & fittings, Drawbar, and Head Cover) can now be ordered. PART NUMBER 002-4208-003 002-4208-004 002-4208-005 002-4208-006 DESCRIPTION Metric Power Drawbar Assy. Inch Power Drawbar Assy. Metric Power Drawbar Assy. Inch Power Drawbar Assy. DRAWBAR PART # 802-2906-003 802-2906-002 802-2706-002 802-2706-001 WHERE USED Current Hawk Mills Current Hawk Mills KM5P & Early Hawk Mills KM5P & Early Hawk Mills
PROBLEMS TO BE ADDRESSED 1. Washer coming loose from mounting plate and hanging up on drawbar. Solution: Insure that tool change height is set to 1.00 to 0.95 (FSB 1225) Set-up: Need 0.050 to 0.100 clearance between top of drawbar shoulder and bottom of thrust washer. 2. Air ratchet catching and binding up when moving up/down. Solution: Fill (there is a level check plug on rear of air ratchet and this is where you fill the air ratchet) with air tool oil (5wt) when installing a new machine or power drawbar head. Check to make sure that the guide rods are straight and parallel. NOTE: If Chicago Pneumatic Air Ratchet is under or over oiled, the ratchet loses power. 3. Air ratchet coming loose from mounting base. Solution: Loc Tite the 4 bolts holding the head to plate. This is to be done any time servicing or replacing unit.
ORIGINATOR:Steven Artz REVISED BY:

4. Top end of drawbar being chewed up. Solution: Make sure height set correctly. 5. Tools coming loose in spindle. Solution: Refer to FSB 1166, 1168, 1225, TIN 1024A, & 1065. 6. Air motor starts before head is down in spline. Solution:#1 Check spring (Spring-Plunger) inside powerhead (REF. Page 15 Item # 18 in Kurt manual) it maybe weak and need replaced. ONLY DISASSEMBLE IF NON-WARR. #2 FSB 1226 #3 Guide rods are not parallel. Replace unit. 7. Air motor runs in one direction only or doesnt run at all. Solution: #1 Disconnect the 2 air lines (1/4) from powerhead that come from IN/OUT valve and make sure air is coming through each line when appropriate button selected. If no air, check button assembly (Page 11 of Kurt Manual) #2 Disassemble upper block (Page 5 in Kurt Manual) and check O- Rings items #3 & #7 #3 Check Mist Lube Unit to make sure that we are not over lubing and causing valve in powerhead to stick. If this is the case adj. the mist lube unit and cycle the powerhead to free up. ONLY DISASSEMBLE IF NON-WARRANTY. 8. Powerhead Assembly Sticks in down position. Solution: #1 Check drawbar spline for damage. If damaged replace and set-up correctly. #2 Check drawbar/head alignment (float in if needed). #3 FSB 1226A (O-Ring not greased Item # 18, page 5 in Kurt Manual) #4 Air lines binding in cover. Reroute, open slot in cover and reapply protective edging. #5 Spring to weak or adjusted incorrectly (No preload). Ref. Item #13 on page 5 of Kurt Manual. #6 Air Line Retro (TIN 1024), use 3/8 line @80psi (Head needs minimum of 70 psi) #7 Guide rods bent. HURCO SERVICE ENGINEERS ARE NOT TO CALL KURT MFG FOR TECHNICAL SUPPORT
FSB XXX Page 2 of 4
DATE: March 3, 1996 SUBJECT: Retro-fit of Drive Spindles to accept 18 MM Proximity Switches. PRODUCT LINE: Acroloc 15-32, 15-40 Machining Centers
PAGE 1 OF 1
Our current supplier of 300-577 14 mm Proximity Switches has notified us that they are discontinuing these switches. We have no choice but to go to a larger diameter switch as they were the only ones who manufactured this switch. The replacement switch will be part # 418-5002-016, and has a diameter of 18mm. The Acroloc machines that will be most affected by this change will be the 1980 to 1990 15-32 and 1540 machines with the following controls: Fanuc 6 M to 11 M, Yasnac MX 1, GE Mark 2000, and Siemens 810 Controls. To perform this retro-fit when replacing this switch, it will be necessary to remove and disassemble the drive spindle, remove and disassemble the orient plunger assembly, and drill out existing switch holes with a 15.5 mm drill, and than tap these holes with an 18 x 1 mm tap. When resetting the proximity switches in the drive spindle, be sure to leave enough clearance for the button head screw in the orient sensing ring to clear the switch. (When the head of the button head screw just clears the proximity switch, back the switch off 1 full turn before locking it into place.)


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Feb. 08, 1996 Max32 Hard Drives All Max32 machines
ISSUE NUMBER: 1236
PAGE 1 OF 1
There have been several reported problems with Max32 upgrades not allowing the servos to power up. The following is to be done to all Max32 Snooper PCBs. When doing a Max32 upgrade to any machine with any Hard Drive type(Ex. Conner, Seagate, Quantum...) you must make sure that the Hard Drive is mounted on the back side of the Snooper PCB. Reroute the power cable if needed. You might have to unsolder the cable from the front side and solder to the back side to make it work being careful not to cross any wires. Also, you must reroute the ribbon cable for the Hard Drive to make it work. When reinstalling the Hard Drive into the card rack be sure that the Snooper PCB is nearest to the Personality Board and the Hard Drive is facing the CPU. All Snooper PCB assemblies in Max32 kits will be modified this way at Hurco Mfg Co starting in May96. Please verify any Snooper PCB that you install in a Max32 machine is done this way.
ORIGINATOR: K. Evdokiou REVISED BY:

DATE: April 4 1996 SUBJECT: FRL Units PRODUCT LINE: All 30 A Frames
Gentleman; The purpose of this FSB is to remind you that the Water Trap Filter on the FRL Units is NOT an Automatic Self Dumping Unit. There has been some confusion as to which type of Water Trap Filter is being used, as some of the documentation implies, but does not specifically say that it is or is not an Automatic Dumping Unit. The current Water Trap Filter must be drained periodically to insure that no water is able to infiltrate the Machine air system. This is done by squeezing the two tabs located on the bottom of the Water Trap Filter Bowl. Please instruct your customers at install or your next Service Call to drain this unit daily, to prevent damage to the air driven tool change motor, valves, and pneumatic cylinders, thus preventing down time. We are currently trying to source a Self Dumping Water Trap Filter replacement for the Manual units. We will offer this replacement as a Non Warranty replacement Option if the customer prefers the Automatic Self Dumping Unit.

DATE: SUBJECT:
April 29, 1996 Z AXIS Cable Damage
ISSUE NUMBER:
1238
SUPERSEDES NUMBER: PAGE 1 OF 1
PRODUCT LINE: BMC 30M/ HTM/ D
This bulletin is to correct machines that have had damage to some of the cables going to the HEAD area. These cables run through the Z AXIS CABLE HOUSING and into the Z AXIS CABLE CARRIER. As it passes from the housing to the carrier it rubs on a rough edge of the housing. HURCOS sub-contract manufacturers will start adding a plastic conduit to protect the cables with their MARCH shipments. This is an interim fix. The long term correction will be for manufacturers to weld a round bar at the rough edge to give a smooth surface to protect the cables. Manufacturing has been adding a NEOPRENE SHEET to protect the cables. This should be done in the field to any machine that has not been remedied yet. You should be able to purchase NEOPRENE at a local industrial supply house, i.e.( W.W. GRAINGERS ). The Z AXIS CABLE HOUSING can be seen from the right side. It is between the cabinet and the Z AXIS CABLE CARRIER (flexible metal tube). It has two access plates on it.

DATE: June 17, 1996 SUBJECT: Fan Replacement / ISA Card Racks PRODUCT LINE: All ISA machines
Card rack with integrated power supply: To replace fans on this ISA card rack you will need to order one piece of 002-4428-017 for each new 24VDC fan. 1. 2. 3. 4. Power off the machine. Remove the fan housing screws. Carefully remove the plastic fasteners that are holding each fan. Unplug and replace with the new fan or fans and reassemble.
Card rack with power distribution board: If you are working on the old style card rack with the power distribution pcb on the side you will need to convert the fan wiring from 12VDC to 24VDC when replacing the fans. Order two of the 002-4428-017 fans and proceed as follows. 1. 2. 3. 4. Power off the machine. Remove the four mounting screws holding each fan. Unplug and replace with the new fans and reassemble. Locate the 423-4400-009 ISA Fan /Backplane power harness. This harness is internal to the card rack and the J1 end of the harness plugs through the card rack and into the back side of the power distribution board at TB7. Locate the 12VDC brown wire on J1-10. Remove this wire from the J1 wago connector. Remove a blue 24VDC wire from either J1-11, or J1-12. Splice the brown fan wire to the 24VDC wire and insert back into the respective J1 terminal. This completes the modification. You should now have 24VDC supplied to the new fans.
5. 6. 7. 8. 9.

DATE: August 13, 1996 SUBJECT: Oiling Problems PRODUCT LINE: Acroloc 1540, 3030
This bulletin is to inform you to inspect the oil line which goes across the y-axis ways on all Acroloc 1540 and 3030 machines. This oil line can be found inside the saddle, and goes across the y-axis ballscrew. One of the x-axis telescopic covers must be pulled back to inspect.
Some machines had the oil line stretched too tight at assembly. Some of the oil lines are pulling out of the compression nut and ferrule. When re-installing oil line leave slack in the line, but ensure that the oil line is clear of the y-axis ballscrew rotation. Recommended parts for correction: 1. 350112 2. 508-2001-001 Ferrule 5/32 Bijur Tubing Qty 2 Qty 3 ft.
ORIGINATOR: Tim Cloud REVISED BY:

DATE: September 4, 1996 SUBJECT: Possible Noise Problems PRODUCT LINE: BMC4020/HT/M, BMC4020SSM
The purpose of this FSB is to prevent potential noise problems to the ISA Control caused by the close proximity of the Commutation Reactor wiring harness and the main Wire Way located in the center of the Electrical Cabinet. To correct this problem, you will need to remove the Commutation Reactor harness from the Wire Way, unfasten the Commutation Reactor from the back wall of the cabinet, and rotate the reactor 180 deg., so that the harness is going out towards the Siemens Drive Package. Secure the wires to the back wall of the cabinet using cable ties and self adhesive tie downs. (See attached drawing for details. ) If after doing this procedure, the machine is still experiencing noise related anomalys , (control lock ups, tool change errors etc. ) try to move as many of the of the wires from the main wire way to the smaller wire way located on the left side of the cabinet, as cable length will allow. Also verify that all required suppressers and diodes are installed.

FSB xxxx Page 3 of 2
DATE: Sept. 6, 1996 SUBJECT: ISA CARD RACK DIAGNOSTIC TIPS PRODUCT LINE: ALL ISA MACHINES
This document was created to help diagnose problems within the ISA card rack. This document will be updated when additional helpful information is available. If you discover a unique way to diagnose a card rack problem, write detailed steps down and it will be reviewed for validity and possibly added to this document.
1.
Dont hesitate to SCAN the hard drive for a virus before trying any other tests on a card rack you may save yourself a lot of frustration. CMOS settings and motherboard jumpers are also crucial. I wouldnt recommend making any changes before consulting your documentation first; dont guess. If your card rack boots and the Ultimax screens come up and you suspect an I/O and or peripheral or functional type problem; Install your ISA test harnesses and run the ISATEST diagnostic software which came with the harness kit (refer to your blue ISA manual for instructions). Dont forget that there are some interactive diagnostic functions available through the Auxiliary screen using Enter, 200, Enter. If you are having video problems i.e. no video displayed: Power off the rack, remove the Canbus controller card and power up the rack again. The Canbus controller has been known to cause video problems. You may have to wait 30-45 seconds before the screens come up if you are booting the executive. For intermittent problems such as rebooting. Check the power connections at the motherboard and the Power Good (PG) signal. Especially on the old style racks the power connector on the motherboard has one pin with two wires crimped in it. This is the 12VDC for ORIGINATOR: Tom Murden REVISED BY:
2.
3.
4.
5.
the Power Good chip. If this wire is loose and intermittent the rack will reboot. 6. Check the fans on the card rack for slow movement or no movement. If needed replace the fans. If you are replacing 12VDC fans refer to FSB1239. If the fans are OK, and you have a new style rack remove the power supply cover and check for loose connections. Also, check the fuse block connections in the integrated power switch. If you have the old style card rack with the separate power supply, check the fan on the power supply. Is it moving slowly or not at all? If the fan on the supply isnt working replace the power supply. While you are at the power supply dont forget to check the supply voltages. If you suspect an I/O Interface, DC I/O, or Canbus controller board lockup, go into the machine diagnostic screen from manual mode and try running the ATC functions, unclamp, etc. Try jogging the axis. Try spindle on in manual mode. If some of these functions dont work, your I/O interface, D/C I/O, or Canbus controller may be locked up. Try cycling power on the machine. If this clears up the problem, you need to try all diagnostics functions one at a time. Also, check the washdown and coolant functions. One of these is probably improperly suppressed. If the rack wont boot the Executive software and displays errors like missing loader etc. Try booting a DOS disk. You can remove all the boards except the Video card and the Floppy Drive Transceiver board if you need to and still boot the card rack with a DOS bootable disk. Then diagnose the hard drive etc.
7.
8.
Page 2 of 2
DATE: September 5, 1996 SUBJECT: Spindle twitch @ Null setup. PRODUCT LINE: BMC30SSM
The first group of production BMC30 SSM bedmills (from Quaser) were affected by a spindle noise problem not seen in previous, similar Frame A bedmills. The severity of the noise varied from machine-to-machine, and manifested itself as a twitchy spindle at 0 rpm conditions, during the spindle balance portion of the machine acceptance test. Depending on the machine, it was difficult to null the spindle. Once (an unstable!) null was established, it then became more difficult to adjust the spindles high speed parameters so that our set up specifications could be met. A few machines with noise symptoms that were not as prevalent , were able to be set up satisfactorily and shipped, and must now be repaired in the field. This problem is created by having the DAC shield tied at both ends, and also having the DAC cable stripped back too far at the TB1 strip. The suggested repair is to remove the shield ground from the S1CN connector, Pin 2 at the spindle drive, and to remove the excess DAC wire inside the wire way at the TB1 strip. In some cases, there was found to be as much as 3 Ft. of unshielded wire on either side of the TB1 connector. Please trim this and any harness back so that no more than 4 inches of DAC wires are left outside of the cable. Please refer to Drawing # 423-4401-073 for details.

Drawing Number 423-4401-073
Remove
Page 2 of 2
DATE: September 9, 1996 SUBJECT: Work Light Suppresser Modification PRODUCT LINE: BMC30SSM, BMC30/M with Siemens, BMC4020/HT/M, BMC4020SSM
ISSUE NUMBER: 1244 SUPERSEDES NUMBER: PAGE 1 of 2
The purpose of this FSB is to make you aware of a problem that we are experiencing with the Work Light on off switch located on the Communications panel. If the Work Light is turned on or off there is a chance that the control will lock up, making it necessary to reboot the control. To rectify this problem, you will need (2) # 417-6001-010 Surge suppressers. Refer to the attached schematic and install a Part Number 417-6001-010 surge suppresser across each ballast and work light.

417-6001-010
417-6001-010
DATE: September 4, 1996 SUBJECT: Spindle Agree Faults during Rigid Tap Functions PRODUCT LINE: BMC4020HT/M, BMC4020SSM, BMC30HT/M (Siemens Drive Only)
We have been experiencing Spindle Agree Fault errors during Rigid Tap Functions on BMC4020/HT/M, BMC4020SSM, and BMC30/HT/M mills that use the Siemens Drive package. Changing the following Parameters in the Ultimax 3 ISA control and the Siemens Spindle Drive module will prevent these errors from occurring.
1) Tap Deceleration, on the 103 screen will be decreased from 120,000 rev/min/min to 80,000 rev/min/min. 2) Siemens Spindle Drive Parameter # P-027, will be increased from 20 RPM to 30 RPM.

DATE: September 26, 1996 SUBJECT: Harness Bracket Installation PRODUCT LINE: BMC4020/HT/M, BMC4020/SSM
The purpose of this FSB is to install bracket assemblies on the harness coming into the bottom the electrical cabinet, and on the wire harness exiting the cattrack above the electrical cabinet. This modification will remove the foam insulation currently packed in around these harness entry / exit locations, and must be done to help seal the cabinet from external contamination. (Coolant, oil, dust, etc.) Enclosed in the kit you will find assorted grommets, a 7. inch piece of H channel, (8) M5 x 12 mm screws and flat washers, and (2) two piece brackets that need to be installed according to the attached pictures. The grommets will have to be cut in one place in order to fit over the cables. This will prevent having to remove the cable ends. Note: Use the H channel to seal between the holes in the 2 piece plate.

Cattrack Harness Installation
Cabinet Bottom Installation
DATE: October 3, 1996 SUBJECT: Canbus Controller Modification PRODUCT LINE: All ISA machines
This modification may help eliminate some lock-up situations on 486 based systems especially during screen updates. The modification is mandatory for all Pentium based systems to correct an ISA bus conflict, caused by the I/F circuit responding to non-specific addressing. Modification: U36, pin 1 is to be cut at the PCB and pulled out perpendicular to the side of the IC. Using 30 GA. Wire (insulated wirewrap wire), solder one end to the floating pin 1 on U36, and the other end to the via as shown below. Change the revision letter from B to C. Verification: Continuity between gold finger A11(AEN) and U36 pin 1, and no continuity between U36 pin 1 and ground.
U36
U37
Pin 1
Ground

DATE: October 9, 1996 SUBJECT: Siemens Drive wiring change. PRODUCT LINE: BMC4020/HT/M, BMC4020/SSM
The purpose of this FSB is to initiate a wiring change to the Enable circuits of the Siemens Drive Package to leave "Pulse Enable" active at Emergency Stop for a greater time period to allow for regeneration of axis motor voltage, and proper braking of the axis. The symptoms that would lead to this wiring change would be a slight drift of the of the axis after Emergency Stop is depressed. In order to make this modification, you will need to do the following steps. 1) Remove the Wago jumper bar between TB2 - 50 and TB2 - 51. ( This TB strip is located at the back wall of the control cabinet, on the left side. If in doubt as to the location, please refer to the cabinet lay out drawing, number 003-2007-002 and 003-2007-003 located in the BMC4020 manual, part # 704-0001-748.) 2) Disconnect the wires that run from CRP4 TB1 - 5, and X321 Pin 663 on the dual axis drive module, and X321 Pin 663 on the Single axis drive module. 3) Add a jumper wire (24AWG) between X321 Pin 663 and Pin 9 on the dual axis drive module and on X321 Pin 663 and Pin 9 on the single axis drive module. This change will keep the Pulse Enable Signal on till the regeneration for braking is complete. 4) Add a wire (18AWG) from CRP4 / TB1 - 5 to TB2 - 50. This is for the Axis Enable Relay signal.

Please Reference Sheet 8 of 12 on Drawing # 003-2022-002 in the BMC4020 Manual, Rev "A", Part # 704-0001-748 for more detail.
Please Reference Sheet 9 of 12 on Drawing # 003-2022-002 in the BMC4020 Manual, Rev "A", Part # 704-0001-748 for more detail.
FSB 1248 Page 3of 3
DATE: October 11, 1996 SUBJECT: Coolant/Oil Separator Modification PRODUCT LINE: 30D/HT/M/SSM, 4020SSM/HTM
There are a few Frame A machines still having problems with coolant run off from the back of the machine casting. In order to try to correct this problem a replacement Coolant/Oil Separator Tank has been designed. This design replaces the current separator tank and will catch any run off from almost the entire width of the machine base. This should correct any of the problem machines we still have in the field. This new design can also be retrofitted to the new 4020 machines if necessary. This modification should only be done if FSB1227 has been completed and the machine still has coolant leakage. Retrofit Parts: 003-1008-012 Assembly Coolant/Oil Separator (consists of parts listed below). 1pc 9pc 9pc 6ft. 24in. 1pc 1pc 4pc 803-1049-004 Tank Coolant/Oil Separator 101-5008-003 SHCS, M6 X 1.0 P X 12 LG 110-0046-007 Lockwasher, M6 Helical Spring 507-0001-002 Low Pressure Hose I.D. 507-1203-002 Low Pressure Hose I.D. 702-0001-004 RTV, 4.7oz Clear 506-5008-003 Plug 3/8 602-0002-006 Clamp, #16 Aeroseal
Retrofit procedure: 1. Remove the existing Coolant/Oil separator tank from the back of the machine frame. 2. Using the old tank and wooden blocks etc., locate the new tank centered on the back of the machine frame to transfer the mounting holes. Locate the tank approximately down from the Y axis servo motor (this will allow for easier motor removal and belt adjustment). See figure 1. 3. Transfer the top right and top left hole locations from the tank and drill and tap these two holes first. Temporarily mount the tank with two fasteners and transfer the remaining holes. ORIGINATOR: Tom Murden REVISED BY:
4. Thoroughly clean the back of the machine frame to help bond the RTV sealant used on the tank mounting flange. 5. Apply a generous bead of RTV to the tank mounting flange and install the tank with the fasteners provided. 6. Remove any excess RTV. 7. Remove the old drain tube and fitting from the flood coolant tank and install the 3/8 plug into the flood coolant tank. See figure 2. 8. Drill and tap PT holes in the flood motor mounting plates (locations are approximate). See figure2. 9. Install the elbow fittings in each of the two holes. 10. Install hose between each of the flood coolant fittings and each side of the new Coolant/Oil separator tank (use hose clamps provided). 11. Install hose between Coolant/Oil separator tank and oil catch tank (use hose clamps from old Coolant/Oil separator tank). 12. Run washdown system and check for leaks.
Rear view of machine base Figure 1
Top view of machine.
Figure 2
DATE: December 5, 1996 SUBJECT: Re-Wire of Fast Stop signal to Siemens Drive
PRODUCT LINE: BMC30/HT/M, BMC4020/SSM, BMC4020/HT/M PAGE 1 OF 2
There is a chance that Frame "A" mills with Siemens Drive packages (BMC30/HT/M's and BMC4020's ) have a mis-wire in the Fast Stop circuit. Fast Stop has been found to be tied into the Spindle Purge Relay, ( RLY 2 ) at Pin 7, instead of being attached to TB10, Pin 3, on the CRP4 Brd. as shown in the current electrical schematics, causing the Drive to be disabled when Spindle Purge times out, and causing the following alarm message. "Spindle Fault Agree Error", when the machine is put back in cycle or programmed with a spindle speed. Please do not hesitate to check the Fast Stop circuit if your customer notifies you of this symptom on their Siemens driven mill. Please reference the following page for correct wiring information.


HURCO MANUFACTURING COMPANY One Technology Way Indianapolis, IN 46268-0180
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June 26, 1997 V2.00 PARAMETER CHANGES ULTIMAX 3 ISA
ISSUE NUMBER: 1251
PAGE 1 OF 4
PURPOSE: To correct parameters that were incorrectly listed on the Engineering Documents and the Machine Parameter Diskettes issued with V2.00 Field Installation Software Kit, 007-4123-009.
DESCRIPTION: Please update the following Engineering Documents in the V2.00 Field Installation Software Kit (these documents will be distributed upon their release): 757-4002-125 Rev B, Ultimax V2.xx Software Field Installation Procedure page 7, step 21, change the Machine S/N Prefix for 427-0004-014 from B3M to B3HM change the Machine S/N Suffix for 427-0004-014 from B to C change the Machine S/N Prefix for 427-0004-015 from B3HM to B3M change the Machine S/N Suffix for 427-0004-015 from C to B 757-4005-001 Rev A, Parameters for BMC30SSM (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-002 Rev A, Parameters for BMC30SSM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-003 Rev A, Parameters for BMC30M (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-004 Rev A, Parameters for BMC30HTM (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-005 Rev A, Parameters for BMC30M (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-006 Rev A, Parameters for BMC30HTM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-007 Rev A, Parameters for BMC4020SSM with Ultimax 3 ISA Software V2.X 757-4005-008 Rev A, Parameters for BMC4020HTM with Ultimax 3 ISA Software V2.X page 6, General Parameters, change Configuration Parameter Units from Inch to Metric General Parameters, change Max. Programmable Contour Feedrate from 300.0 to 7620.0 page 5, Axes, Physical Parameters, change Distance per Revolution from 0.4724in to 12.0mm for X, Y, and Z Axes NOTE: This corrects an axis misposition problem in which the Inch value of 0.4724 was being being converted to 11.99896mm; the correct value is 12.0mm or 0.47244095in.
ORIGINATOR: David Skrzypczak REVISED BY:

757-4005-001 Rev A, Parameters for BMC30SSM (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-002 Rev A, Parameters for BMC30SSM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-003 Rev A, Parameters for BMC30M (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-004 Rev A, Parameters for BMC30HTM (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-005 Rev A, Parameters for BMC30M (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-006 Rev A, Parameters for BMC30HTM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X page 5, Axes, Vertical Parameters, change Plus Direction Travel Limit from 30.0in to 762.0mm for X Axis Axes, Vertical Parameters, change Plus Direction Travel Limit from 18.0in to 432.0mm for Y Axis Axes, Vertical Parameters, change Minus Direction Travel Limit from -24.0in to -609.0mm for Z Axis 757-4005-001 Rev A, Parameters for BMC30SSM (Siemens Spindle) with Ultimax 3 ISA Software V2.X page 5, Axes, Physical Parameters, change Maximum Feedrate from 500.0ipm to 12700.0mmpm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 590.0ipm to 15000.0mmpm for X and Y Axes page 11, change N95:211 from 0 to 1 757-4005-002 Rev A, Parameters for BMC30SSM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X page 5, Axes, Physical Parameters, change Maximum Feedrate from 394.0ipm to 10000.0mmpm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 590.0ipm to 15000.0mmpm for X and Y Axes 757-4005-003 Rev A, Parameters for BMC30M (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-004 Rev A, Parameters for BMC30HTM (Siemens Spindle) with Ultimax 3 ISA Software V2.X page 5, Axes, Physical Parameters, change Maximum Feedrate from 563.0ipm to 16000.0mmpm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 945.0ipm to 24000.0mmpm for X and Y Axes 757-4005-005 Rev A, Parameters for BMC30M (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-006 Rev A, Parameters for BMC30HTM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X page 5, Axes, Physical Parameters, change Maximum Feedrate from 590.0ipm to 15000.0mmpm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 945.0ipm to 24000.0mmpm for X and Y Axes 757-4005-007 Rev A, Parameters for BMC4020SSM with Ultimax 3 ISA Software V2.X page5, Spindle, Physical Parameters, change Maximum DAC Volts from 9.350 to 9.500 NOTE: this change is required for initial startup only; it will be reset for Spindle Balance
757-4005-007 Rev A, Parameters for BMC4020SSM with Ultimax 3 ISA Software V2.X 757-4005-008 Rev A, Parameters for BMC4020HTM with Ultimax 3 ISA Software V2.X page 5, Axes, Vertical Parameters, change Plus Direction Travel Limit from 40.0in to 1016.0mm for X Axis Axes, Vertical Parameters, change Plus Direction Travel Limit from 20.0in to 508.0mm for Y Axis Axes, Vertical Parameters, change Minus Direction Travel Limit from -24.0in to -609.0mm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 530.0ipm to 13450.0mmpm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 787.0ipm to 20000.0mmpm for X and Y Axes
INSTRUCTIONS: Please update the following Machine Parameters Diskettes in the V2.00 Field Installation Software Kit: Machine Parameters Diskette, BMC 30SSM Siemens Spindle, 427-0004-011 1. Using DOS Edit (or other ASCII editor), load the INTCFG.SYS file from the 30SSMS.MCD directory. 2. Search for N95:211; the line will read N95:211= SPINDLE DRIVE TYPE = 0. 3. At the end of the line, change the 0 to 1. 4. Exit and save the file. The following steps must be done at a machine for the following diskette: Machine Parameters Diskette, BMC 30SSM Siemens Spindle, 427-0004-011 1. After V2.00 has been loaded with the correct parameters per the Installation Procedure, access the Integrator Support Services screen from Auxiliary by pressing <Enter> 100 <Enter>. 2. Select the CNC CONFIG PARAMETERS softkey. 3. Select the SPINDLE softkey 4. Select the VERTICAL PARAMETERS softkey. 5. Select the GEAR TABLE PARAMETERS softkey. 6. Change the Minimum RPM from 100 to 1. 7. Select the EXIT softkey (may require multiple selections) to return to the Integrator Support Services screen.. 8. Select the MISCELLANEOUS SERVICES softkey. 9. Select the YES softkey to change the D: Drive Access Enable. 10. Select the EXIT softkey(may require multiple selections) to return to Auxiliary mode. 11. Select the STORAGE FUNCTIONS softkey. 12. Select the DISK OPERATIONS LIST DIRECTORY softkey. 13. Select the SELECT CURRENT STORAGE DRIVE softkey. 14. Select the HARD DRIVE D softkey. 15. Highlight the 30SSMS.MCD directory and select the CHANGE TO DIRECTORY softkey. 16. Highlight the SPINDLE.SYS file and select the COPY PROGRAM softkey. 17. Insert the 427-0004-011 diskette into the floppy disk drive (make sure the disk is not Write Protected). 18. Enter A: to copy the file to the Machine Parameters Diskette. 19. Reenter Integrator Support Services and disable the D:Drive Access Enable. 20. In Auxiliary, backup the modified parameters to the Ultimax 3 Version 2.xx Parameter Backup diskette. The following steps must be done at a machine for each of the following diskettes: FSB1251.DOC Page 3 of 4
Machine Parameters Diskette, BMC 30SSM Siemens Spindle, 427-0004-011 Machine Parameters Diskette, BMC 30HTM Siemens Spindle, 427-0004-012 Machine Parameters Diskette, BMC 30SSM Yaskawa Spindle, 427-0004-013 Machine Parameters Diskette, BMC 30M Siemens Spindle, 427-0004-014 Machine Parameters Diskette, BMC 30M Yaskawa Spindle, 427-0004-015 Machine Parameters Diskette, BMC 30HTM Yaskawa Spindle, 427-0004-016 Machine Parameters Diskette, BMC 4020SSM Siemens, 427-0004-017 Machine Parameters Diskette, BMC 4020HTM Siemens, 427-0004-018 1. After V2.00 has been loaded with the correct parameters per the Installation Procedure, access the Integrator Support Services screen from Auxiliary by pressing <Enter> 100 <Enter>. 2. Select the CNC CONFIG PARAMETERS softkey. 3. Select the SPINDLE softkey. 4. Change the Maximum DAC Volts from 9.35 to 9.5 volts. 5. Select the EXIT softkey. 6. Select the GENERAL PARAMETERS softkey. 7. Change the Configuration Parameter Units from Inch to Metric. 8. Enter the Max. Programmable Contour Feedrate as 7620.0. 9. Select the EXIT softkey. 10. Select the X AXIS softkey. 11. Enter the Distance per Revolution as 12.0. 12. Enter the Maximum Feedrate per the revised Engineering Document for each machine type. 13. Select the VERTICAL PARAMETERS softkey. 14. Enter the Plus and Minus Direction Travel Limit for each machine type. 15. Repeat steps 10-14 for the Y and Z Axes. 16. Select the EXIT softkey to return to the Integrator Support Services menu. 17. Select the MISCELLANEOUS SERVICES softkey. 18. Select the YES softkey to change the D: Drive Access Enable. 19. Select the EXIT softkey(may require multiple selections) to return to Auxiliary mode. 20. Select the STORAGE FUNCTIONS softkey. 21. Select the DISK OPERATIONS LIST DIRECTORY softkey. 22. Select the SELECT CURRENT STORAGE DRIVE softkey. 23. Select the HARD DRIVE D softkey. 24. Highlight the appropriate .MCD directory and select the CHANGE TO DIRECTORY softkey. 25. Highlight the SYSFIX.SYS file and select the COPY PROGRAM softkey. 26. Insert the 427-0004-01x diskette into the floppy disk drive (make sure the disk is not Write Protected). 27. Enter A: to copy the file to the Machine Parameters Diskette. 28. Reenter Integrator Support Services and disable the D: Drive Access Enable. 29. In Auxiliary, backup the modified parameters to the Ultimax 3 Version 2.xx Parameter Backup diskette.
Network: The correct INTCFG.SYS, SPINDLE.SYS, and SYSFIX.SYS files for each of the machine types are located on the service network in the following subdirectory: \COMMON\SERVICE\EXEC\MAX3_OEM\PARAM There is one zip file for every machine type which contains the replacement Configuration files discussed in this FSB.

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June 26, 1997 V2.00 PARAMETER CHANGES ULTIMAX 3 ISA
ISSUE NUMBER: 1251b
PAGE 1 OF 4
PURPOSE: To correct parameters that were incorrectly listed on the Engineering Documents and the Machine Parameter Diskettes issued with V2.00 Field Installation Software Kit, 007-4123-009.
DESCRIPTION: Please update the following Engineering Documents in the V2.00 Field Installation Software Kit (these documents will be distributed upon their release): 757-4002-125 Rev B, Ultimax V2.xx Software Field Installation Procedure page 7, step 21, change the Machine S/N Prefix for 427-0004-014 from B3M to B3HM change the Machine S/N Suffix for 427-0004-014 from B to C change the Machine S/N Prefix for 427-0004-015 from B3HM to B3M change the Machine S/N Suffix for 427-0004-015 from C to B 757-4005-001 Rev A, Parameters for BMC30SSM (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-002 Rev A, Parameters for BMC30SSM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-003 Rev A, Parameters for BMC30M (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-004 Rev A, Parameters for BMC30HTM (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-005 Rev A, Parameters for BMC30M (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-006 Rev A, Parameters for BMC30HTM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-007 Rev A, Parameters for BMC4020SSM with Ultimax 3 ISA Software V2.X 757-4005-008 Rev A, Parameters for BMC4020HTM with Ultimax 3 ISA Software V2.X page 6, General Parameters, change Configuration Parameter Units from Inch to Metric General Parameters, change Max. Programmable Contour Feedrate from 300.0 to 7620.0 page 5, Axes, Physical Parameters, change Distance per Revolution from 0.4724in to 12.0mm for X, Y, and Z Axes NOTE: This corrects an axis misposition problem in which the Inch value of 0.4724 was being being converted to 11.99896mm; the correct value is 12.0mm or 0.47244095in.
ORIGINATOR: David Skrzypczak REVISED BY: Tom Murden

757-4005-001 Rev A, Parameters for BMC30SSM (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-002 Rev A, Parameters for BMC30SSM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-003 Rev A, Parameters for BMC30M (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-004 Rev A, Parameters for BMC30HTM (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-005 Rev A, Parameters for BMC30M (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-006 Rev A, Parameters for BMC30HTM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X page 5, Axes, Vertical Parameters, change Plus Direction Travel Limit from 30.0in to 762.0mm for X Axis Axes, Vertical Parameters, change Plus Direction Travel Limit from 18.0in to 460.0mm for Y Axis Axes, Vertical Parameters, change Minus Direction Travel Limit from -24.0in to -610.0mm for Z Axis NOTE: Changing travel limits on existing V2.00 machines will erase the leadscrew map for that axis. On upgrades from V1.XX to V2.00 use the travel limits from V1.XX (write them down before doing the upgrade). 757-4005-001 Rev A, Parameters for BMC30SSM (Siemens Spindle) with Ultimax 3 ISA Software V2.X page 5, Axes, Physical Parameters, change Maximum Feedrate from 500.0ipm to 12700.0mmpm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 590.0ipm to 15000.0mmpm for X and Y Axes page 11, change N95:211 from 0 to 1 757-4005-002 Rev A, Parameters for BMC30SSM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X page 5, Axes, Physical Parameters, change Maximum Feedrate from 394.0ipm to 10000.0mmpm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 590.0ipm to 15000.0mmpm for X and Y Axes 757-4005-003 Rev A, Parameters for BMC30M (Siemens Spindle) with Ultimax 3 ISA Software V2.X 757-4005-004 Rev A, Parameters for BMC30HTM (Siemens Spindle) with Ultimax 3 ISA Software V2.X page 5, Axes, Physical Parameters, change Maximum Feedrate from 630.0ipm to 16000.0mmpm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 945.0ipm to 24000.0mmpm for X and Y Axes 757-4005-005 Rev A, Parameters for BMC30M (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X 757-4005-006 Rev A, Parameters for BMC30HTM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X page 5, Axes, Physical Parameters, change Maximum Feedrate from 590.0ipm to 15000.0mmpm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 945.0ipm to 24000.0mmpm for X and Y Axes 757-4005-007 Rev A, Parameters for BMC4020SSM with Ultimax 3 ISA Software V2.X page5, Spindle, Physical Parameters, change Maximum DAC Volts from 9.350 to 9.500 NOTE: this change is required for initial startup only; it will be reset for Spindle Balance
757-4005-007 Rev A, Parameters for BMC4020SSM with Ultimax 3 ISA Software V2.X 757-4005-008 Rev A, Parameters for BMC4020HTM with Ultimax 3 ISA Software V2.X page 5, Axes, Vertical Parameters, change Plus Direction Travel Limit from 40.0in to 1016.0mm for X Axis Axes, Vertical Parameters, change Plus Direction Travel Limit from 20.0in to 508.0mm for Y Axis Axes, Vertical Parameters, change Minus Direction Travel Limit from -24.0in to -610.0mm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 530.0ipm to 13462.0mmpm for Z Axis Axes, Physical Parameters, change Maximum Feedrate from 787.0ipm to 20000.0mmpm for X and Y Axes
INSTRUCTIONS: Please update the following Machine Parameters Diskettes in the V2.00 Field Installation Software Kit: Machine Parameters Diskette, BMC 30SSM Siemens Spindle, 427-0004-011 1. Using DOS Edit (or other ASCII editor), load the INTCFG.SYS file from the 30SSMS.MCD directory. 2. Search for N95:211; the line will read N95:211= SPINDLE DRIVE TYPE = 0. 3. At the end of the line, change the 0 to 1. 4. Exit and save the file. The following steps must be done at a machine for the following diskette: Machine Parameters Diskette, BMC 30SSM Siemens Spindle, 427-0004-011 1. After V2.00 has been loaded with the correct parameters per the Installation Procedure, access the Integrator Support Services screen from Auxiliary by pressing <Enter> 100 <Enter>. 2. Select the CNC CONFIG PARAMETERS softkey. 3. Select the SPINDLE softkey 4. Select the VERTICAL PARAMETERS softkey. 5. Select the GEAR TABLE PARAMETERS softkey. 6. Change the Minimum RPM from 100 to 1. 7. Select the EXIT softkey (may require multiple selections) to return to the Integrator Support Services screen.. 8. Select the MISCELLANEOUS SERVICES softkey. 9. Select the YES softkey to change the D: Drive Access Enable. 10. Select the EXIT softkey(may require multiple selections) to return to Auxiliary mode. 11. Select the STORAGE FUNCTIONS softkey. 12. Select the DISK OPERATIONS LIST DIRECTORY softkey. 13. Select the SELECT CURRENT STORAGE DRIVE softkey. 14. Select the HARD DRIVE D softkey. 15. Highlight the 30SSMS.MCD directory and select the CHANGE TO DIRECTORY softkey. 16. Highlight the SPINDLE.SYS file and select the COPY PROGRAM softkey. 17. Insert the 427-0004-011 diskette into the floppy disk drive (make sure the disk is not Write Protected). 18. Enter A: to copy the file to the Machine Parameters Diskette. 19. Reenter Integrator Support Services and disable the D:Drive Access Enable. 20. In Auxiliary, backup the modified parameters to the Ultimax 3 Version 2.xx Parameter Backup diskette. The following steps must be done at a machine for each of the following diskettes: FSB1251.DOC Page 3 of 4
Machine Parameters Diskette, BMC 30SSM Siemens Spindle, 427-0004-011 Machine Parameters Diskette, BMC 30HTM Siemens Spindle, 427-0004-012 Machine Parameters Diskette, BMC 30SSM Yaskawa Spindle, 427-0004-013 Machine Parameters Diskette, BMC 30M Siemens Spindle, 427-0004-014 Machine Parameters Diskette, BMC 30M Yaskawa Spindle, 427-0004-015 Machine Parameters Diskette, BMC 30HTM Yaskawa Spindle, 427-0004-016 Machine Parameters Diskette, BMC 4020SSM Siemens, 427-0004-017 Machine Parameters Diskette, BMC 4020HTM Siemens, 427-0004-018 1. After V2.00 has been loaded with the correct parameters per the Installation Procedure, access the Integrator Support Services screen from Auxiliary by pressing <Enter> 100 <Enter>. 2. Select the CNC CONFIG PARAMETERS softkey. 3. Select the SPINDLE softkey. 4. Change the Maximum DAC Volts from 9.35 to 9.5 volts. 5. Select the EXIT softkey. 6. Select the GENERAL PARAMETERS softkey. 7. Change the Configuration Parameter Units from Inch to Metric. 8. Enter the Max. Programmable Contour Feedrate as 7620.0. 9. Select the EXIT softkey. 10. Select the X AXIS softkey. 11. Enter the Distance per Revolution as 12.0. 12. Enter the Maximum Feedrate per the revised Engineering Document for each machine type. 13. Select the VERTICAL PARAMETERS softkey. 14. Enter the Plus and Minus Direction Travel Limit for each machine type. 15. Repeat steps 10-14 for the Y and Z Axes. 16. Select the EXIT softkey to return to the Integrator Support Services menu. 17. Select the MISCELLANEOUS SERVICES softkey. 18. Select the YES softkey to change the D: Drive Access Enable. 19. Select the EXIT softkey(may require multiple selections) to return to Auxiliary mode. 20. Select the STORAGE FUNCTIONS softkey. 21. Select the DISK OPERATIONS LIST DIRECTORY softkey. 22. Select the CHANGE PROGRAM MASK softkey and change to *.*. 23. Select the SELECT CURRENT STORAGE DRIVE softkey. 24. Select the HARD DRIVE D softkey. 25. Highlight the appropriate .MCD directory and select the CHANGE TO DIRECTORY softkey. 26. Highlight the SYSFIX.SYS file and select the COPY PROGRAM softkey. 27. Insert the 427-0004-01x diskette into the floppy disk drive (make sure the disk is not Write Protected). 28. Enter A: to copy the file to the Machine Parameters Diskette. 29. Reenter Integrator Support Services and disable the D: Drive Access Enable. 30. In Auxiliary, backup the modified parameters to the Ultimax 3 Version 2.xx Parameter Backup diskette. Network: The correct INTCFG.SYS, SPINDLE.SYS, and SYSFIX.SYS files for each of the machine types are located on the service network in the following subdirectory: \COMMON\SERVICE\EXEC\MAX3_OEM\PARAM There is one zip file for every machine type which contains the replacement Configuration files discussed in this FSB.
DATE: November 20, 1997 SUBJECT: M-CODE MODIFICATIONS PRODUCT LINE: YASKAWA ISA BEDMILLS
The M-Code modifications that were incorporated into V2.01 on production machines may be required by customers when upgrading their older ISA bedmills to V2.XX. The following MCode modifications can be added to either older Yaskawa ISA bedmills or older Siemens ISA bedmills that dont have terminal strips.
**If a customer has probing on the machine that is to be upgraded to V2.XX and he wants the M-Code modifications, then a second DC I/O board will need to be added to the card rack. If the customer has Probing and also has a Rotary Table option, then the M-Code modification can be added to their existing second DC I/O board.
A.
M-Code modifications for Siemens ISA machines without TB1, TB2 terminal strips. Materials required: 1 PC 20 position terminal strip (406-4005-323). 2 PC 5 conductor 24 AWG cable 30 inches in length (406-1325-008). 1 PC 2 conductor 22 AWG cable 96 inches in length (406-2006-050). 1. 2. Mount the 20 position terminal strip on the main panel near the cardrack. Modify the following terminations of the DCI/O J2 Harness, 423-4401-068: a) At the DC I/O J2-22 remove the gray wire. Heatshrink and fold back. b) At the DC I/O J2-37 remove the blue wire. Heatshrink and fold back. Install the first piece of 5-conductor cable as show below. c) Black wire to DC I/O J2-22 (OUT 9). d) Brown wire to DC I/O J2-6 (OUT 10). e) Red wire to DC I/O J2-38 (OUT 11). f) Green wire to DC I/O J2-23 (OUT 23). ORIGINATOR: TOM MURDEN REVISED BY:
g)
h) i) j) k) l) 3.
White wire to DC I/O J2-37 (OCOM 3). Also add a jumper from DC I/O J2-37 to DC I/O J2-7 (+24 VDC). Terminate the other end of this cable at the new terminal strip as follows: White wire to new terminal strip at terminal 11 and jumper to 12,13,14, and 15 (+24VDC). Black wire to terminal 16 (AUX OUT 1). Brown wire to terminal 17 (AUX OUT 2). Red wire to terminal 18 (AUX OUT 3). Green wire to terminal 19 (AUX OUT 4).
Modify the following terminations of the I/O to Infeed I/R Module Harness, 423-4405-077: a) Remove the wires attached to Siemens drive X141 connector terminal 15 and R. Trace the wires back into the wireway to the 2 position mate n loc connector disconnect and discard. b) Install the clear wire of the new 2 conductor cable at X141-R. c) Install the black wire of the new 2 conductor cable at X141-15. Continue termination of the other end of the two conductor cable in step 4. Modify the following terminations of the I/O IF J1 Harness, 423-4401-065: a) Remove the wire at I/O IF J1-48, heatshrink and fold back. Install the other end of the new 2 conductor clear wire at I/O IF J1-48. b) Install the other end of the new 2 conductor black wire and shield at I/O IF J1-7. You will need to splice into the wire currently at I/O IF J1-7. Modify the following terminations of the DC I/O J1 Harness, 423-4401-067. Install the second 5-conductor cable as show below. a) Black wire to DC I/O J1-39 (GND). You will need to splice into the wire currently at DC I/O J1-39. This wire should already be tied to ground. b) Brown wire to DC I/O J1-24 (INP13). c) Red wire to DC I/O J1-8 (INP14). d) Green wire to DC I/O J1-40 (INP15). e) White wire to DC I/O J1-25 (INP16). Terminate the other end of this cable at the new terminal strip as follows: f) Black wire to new terminal strip at terminal 5 and jumper to 4,3,2, and 1. g) Brown wire to terminal 6 (AUX OUT 1 OFF). h) Red wire to terminal 7 (AUX OUT 2 OFF). i) Green wire to terminal 8 (AUX OUT 3 OFF). j) White wire to terminal 9 (AUX OUT 4 OFF).
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B.
M-Code modifications for Yaskawa ISA machines without TB1, TB2 terminal strips. Materials required: 1 PC 20 position terminal strip (406-4005-323). 2 PC 5 conductor 24 AWG cable 30 inches in length (406-1325-008). 1. 2. Mount the 20 position terminal strip on the main panel near the cardrack Modify the following terminations of the DCI/O J2 Harness, 423-4405-008: Install the first piece of 5-conductor cable as show below. a) Black wire to DC I/O J2-22 (OUT 9). b) Brown wire to DC I/O J2-6 (OUT 10). c) Red wire to DC I/O J2-38 (OUT 11). d) Green wire to DC I/O J2-23 (OUT 23). e) Remove the existing wire at DC I/O J2-37. Heatshrink and fold back. Install the White wire to DC I/O J2-37 (OCOM 3). Also add a jumper from DC I/O J2-37 to DC I/O J2-7 (+24 VDC). Terminate the other end of this cable at the new terminal strip as follows: f) White wire to new terminal strip at terminal 11 and jumper to 12,13,14, and 15 (+24VDC). g) Black wire to terminal 16 (AUX OUT 1). h) Brown wire to terminal 17 (AUX OUT 2). i) Red wire to terminal 18 (AUX OUT 3). j) Green wire to terminal 19 (AUX OUT 4). Modify the following terminations of the DC I/O J1 Harness, 423-4401-067. Install the second 5-conductor cable as show below. a) Black wire to DC I/O J1-39 (GND). ). You will need to splice into the wire currently at DC I/O J1-39. This wire should already be tied to ground. b) Brown wire to DC I/O J1-24 (INP13). c) Red wire to DC I/O J1-8 (INP14). d) Green wire to DC I/O J1-40 (INP15). e) White wire to DC I/O J1-25 (INP16). Terminate the other end of this cable at the new terminal strip as follows: f) Black wire to new terminal strip at terminal 5 and jumper to 4,3,2, and 1. g) Brown wire to terminal 6. h) Red wire to terminal 7. i) Green wire to terminal 8. j) White wire to terminal 9.
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M-Code modifications for current production BMC30, and BMC4020 machines with TB1 and TB2 terminal strips 1. Modify the following terminations of the I/O to Infeed I/R Module Harness, 423-4405-077: a) Find the two conductor shielded cable that runs from TB2-45, 55, and 56 to the Siemens I/R module at X141-15, and R. Remove the wires from TB2-45, 55, and 56 and reroute the cable in the wireways to go to TB1-55, and 56. b) Connect the wire from I/R module X141-R to TB1-55. c) Connect the wire from I/R module X141-15 and the cable shield to TB1-56. This removes the I/R Module reset at the DC I/O board and makes TB2-45 available as M-code output 1. d) Update Harness Revision to C. Modify the following terminations of the I/O IF J1 Harness, 423-4401-065: a) Delete OUTP6 (spare) signal from I/O IF/J1-48 to CRP4/J1-48. Remove the Honda pin from I/O IF/J1-48 with a pin pusher or unsolder the wire and fold back and heatshrink. b) Using a piece of 24 AWG blue wire externally route a new connection from I/O IF J148 to TB1-55. This reconnects the I/R module reset at the I/O IF board. c) Update Harness Revision to C. Modify the following terminations of the DCI/O J2 Harness, 423-4401-068: a) Find the wire from DC I/O J2-5 to TB2-55 bottom. Move the wire end at DC I/O J25 to DC I/O J2-23. Move the other end that was at TB2-55 bottom to TB2-35 bottom. This sets up OUTP12 at TB2-35 and disconnects the GND reference from OCOM3 at TB2-55. b) The OCOM3 output source for outputs 9,10,11, and 12 is currently connected from DC I/O J2-37 to TB2-55. Move the TB2-55 end to TB2-52. This sets up the outputs to send out 24V when active. c) Find OUTP24 which is connected from DC I/O J2-44 to TB2-47. Move the DC I/O J2-44 end to DC I/O J2-38. This sets up OUTP11 at TB2-47 and does away with the old probe reset. d) Modify Harness Revision to D. Using the 24AWG Blue Wire and two Ferrules, add a MGND signal from TB1-7 to TB1-56 bottom. This reconnects the ground reference between the I/O IF board and the Seimens I/R module.
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Version 2.00 Specifications for Auxiliary M-Codes Overview Hurco has defined 4 outputs and 4 inputs as auxiliary M-Code functions. These active high I/O points will aid in eliminating noise related problems. The operator may use Hurco defined M-Codes to perform unique machine functions from within a part program. The operator may use these M-Codes in NC or conversational part program. The configuration table allows the integrator to define the M-Codes, assign an average time to the function for estimated run time purposes, and to display a string on the auto screen when the M-Code is executed.
I/O Specifications Outputs (LH1510 device): 24VDC solid state relays with SPST normally open outputs. Absolute maximum continuous load: IL = 150mA. Damage to outputs will occur if operated 200mA IL < 360mA. Current limit: ILMT = 360mA. Current limit at > 360mA will cause current foldback condition. Absolute maximum voltage: VL = 200VDC. On-resistance: 10 at load current 50mA. Off-resistance: 3,300G The outputs are configured as a bank of 4, active high 24VDC. 24VDC supply maximum load: Isupply = 500mA. Outputs are disabled at power-up and in case of embedded E-Stop condition (Host Watchdog Time-out) Inputs (PS2505 device): Inputs are Bi-directional optocouplers with a 24VDC +/-10% signal range. Maximum input source current: Isource = 2mA. The inputs are configured as a bank of 4, active high 24VDC.
External Signal Conditioning If the integrator chooses to incorporate external devices such as relays, solenoids, contactors, etc. diodes and surge suppressors must be placed in the integrators circuit (typically across relay, contactor, or solenoid coils) to protect the I/O boards from any high voltage spikes and/or noise conditions.
Predefined M-Codes Each of the Aux Outputs are controlled by a pair of pre-defined M-Code functions, as follows: M52 M53 M54 M55 Enables Aux Output 1 Enables Aux Output 2 Enables Aux Output 3 Enables Aux Output 4 M62 M63 M64 M65 Disables Aux Output 1 Disables Aux Output 2 Disables Aux Output 3 Disables Aux Output 4
Connection of Physical I/O Connection points for utilizing M-Codes on machines with TB1 and TB2 terminal strips installed at the factory. Outputs Aux Out 1 Aux Out 2 Aux Out 3 Aux Out 4 I/O Description OUT09 OUT10 OUT11 OUT12 Terminal Block TB2 - 45 TB2 - 46 TB2 - 47 TB2 - 35
Confirmation Inputs Aux In 1 Aux In 2 Aux In 3 Aux In 4
I/O Description INP13 INP14 INP15 INP16
Terminal Block TB2 - 21 TB2 - 22 TB2 - 23 TB2 - 24
Connection points for utilizing M-Codes on machines with field installed 20 position M-Code terminal strip. Outputs Aux Out 1 Aux Out 2 Aux Out 3 Aux Out 4 Confirmation Inputs Aux In 1 Aux In 2 Aux In 3 Aux In 4 I/O Description OUT09 OUT10 OUT11 OUT12 I/O Description INP13 INP14 INP15 INP16 Terminal Block TB1 - 16 TB1 - 17 TB1 - 18 TB1- 19 Terminal Block TB1 - 6 TB1 - 7 TB1 - 8 TB1 - 9
In addition to the inputs and outputs above, +24 VDC is available for inputs at TB1-11,12,13,14, and 15. VDC Return is also available at TB1-1,2,3,4, and 5 (field installed terminal strip only).
Configuration of M-Code Parameters The integrator defined M-Codes are found in Integrator Support Services under: F1 - CNC Configuration Parameters General Parameters M-Code Table Page Down M Code Table (0-255) 52 53 54 55 62 63 64 65 Status Integrator Defined Integrator Defined Integrator Defined Integrator Defined Integrator Defined Integrator Defined Integrator Defined Integrator Defined Time (sec) 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 Program Operation Label Aux Out #1 Aux Out #2 Aux Out #3 Aux Out #4 Aux Out #1 Off Aux Out #2 Off Aux Out #3 Off Aux Out #4 Off
In the fields of the table you can put the time required for each specific M-Code and this time will be added in the program estimated run time. Also, The Program Operation Label can be edited. The text will be displayed on the screen when the M-Code is called in the program (conversational only).
The M-Code confirmation enable is found in the Integrator Support Services under: F2 - Integrator Configuration parameters F2 - Integer parameters F1 - Jump to parameter 250 Integer Parameters N95:250 Description Aux Output CF Enable Value 0
To make use of the Aux Inputs, the Auxiliary M-Code Confirmation Enable Mask parameter (N95:250 in the Integrator Config Parameters) must be set. The value to be entered in for N95:250 is determined as follows: Aux Input 1 Aux Input 2 Aux Input 3 Aux Input 4 2 4 8 16 (Value to activate this input only) (Value to activate this input only) (Value to activate this input only) (Value to activate this input only)
For more than one Aux Input in use, simply add the value for the respective Aux Inputs (for example, using Aux Inputs 1, 2, and 3, enter 14 for N95:250). If the Auxiliary M-Code Confirmation Enable Mask is set then every occurrence of an Aux Output will require a corresponding Aux Input confirming that the Aux Output request is completed.
Examples of M-Code Use Example without Confirming input: A simple configuration would be to wire a relay to one of the Aux Outputs. If the coil of a relay were wired to the Aux Output 1 then commanding an M52 will enable the relay and an M62 will disable the relay. The Aux Inputs are not used in this configuration because the Confirmation parameter is not set. If the user needs a time delay for the M52 (or M62) function to be completed then a dwell would have to be added to the program (in NC, use G04). Example with Confirming input: The following example uses Aux Output 1, Aux Input 1, with N95:250 set to 2. Commanding an M52 will enable Aux Output 1; this will stop the program until the Aux Input 1 is TRUE (or high) before proceeding with the program. The Aux Output 1 will stay enabled until an M62 is commanded; this will then disable Aux Output 1 and will stop the program until the Aux Input 1 is FALSE (or low) before proceeding with the program. You may have to wire a set of normallyopened contacts from the relay with the Finish signal input so that when the Aux Output is disabled with the M62, the Aux Input will be disabled. In this example, the user may also want to define the Time (in sec) in the M-Code Table (in General Parameters of CNC Config Parameters) that is required for the Aux Input 1 to be active (with an M52) or inactive (with an M62). Note that these times are only for computing estimated run-time and will not control any delay in program execution of the respective M-Codes. IMPORTANT: If you are using a relay, solenoid, contactor, etc with the Aux Outputs, be sure to use diodes or surge suppressors in the circuit to protect the DC I/O board from any high voltage spikes and/or noise conditions. Documentation Reference for M-Code changes 003-2022-004 (CAD 8385 REV. C) Interconnect Diagram, BMC4020 with Siemens 003-2022-002 (CAD 8278 REV. E) Electrical Diagrams for BMC4020 with Siemens 003-1022-016 (CAD 8397 REV. C) Interconnect Diagram, BMC30HT/M with Siemens 003-1022-014 (CAD 8277 REV. E) Electrical Diagrams for BMC30HT with Siemens 003-1022-013 (CAD 8401 REV. D) Interconnect Diagram, BMC30M with Siemens 003-1022-007 (CAD 8399 REV. D) Electrical Diagrams for BMC30M with Siemens 003-1022-018 (CAD 8477 REV. D) Interconnect Diagram, BMC30/SSM with Siemens 003-1022-017 (CAD 8476 REV. E) Schematics, Electrical, BMC30/SSM with Siemens 423-4401-065 (CAD 8337 REV. C) 423-4401-067 (CAD 8339 REV. D) 423-4401-068 (CAD 8340 REV. D) 423-4405-077 (CAD 8298 REV. C) Harness, I/O IF J1 Harness, DC I/O J1 Harness, DC I/O J2 Harness, I/O to Infeed I/R Module
DATE: September 5, 1997 SUBJECT: Spindle Drive Faults not reported to Control PRODUCT LINE: BMC 40/50, BMC 50/50
Due to an error in the DC I/O harness wiring some BMC40/50 and BMC50/50 machines may not be reporting spindle drive faults. If you suspect a machine has this problem inspect the 423-4405035 DC I/O J1 harness. There should be jumpers between pins 3, 35, and 37 at the DC I/O J1 end of the harness (SEE the attached drawings, 423-4405-035, 002-4122-044 Pg. 3 of 6). The problem with most of the machines is DC I/O pin 37 has not been tied to +24vdc with pin 3 and 35. This supplies the reference voltage for the spindle fault input.

DATE: September 08, 1997 SUBJECT: Full Enclosure Door Slides 410-5001-002 PRODUCT LINE: BMC40, BMC50
Due to limited availability and higher cost the C3301-27 full enclosure door slide is no longer being used. It has been replaced with the C3301-28 under the same Hurco part number. This door slide is one inch longer than the original and may require some mounting modifications. See sheet two which shows mounting hole locations.

DATE: September 29, 1997 SUBJECT: Air Requirements PRODUCT LINE: All BMC30 and BMC40/20
It is the customers responsibility to assure the following air requirements are met and maintained. 1. A continuous supply of 5 CFM @ 80-100 PSI (0.14 CMM @ approximately 5.5-7.0 bar). 2. The air pressure drop during an ATC cycle must not exceed 10 PSI (approximately 0.75 bar). 3. The minimum air supply line ID is 0.5 in (12mm). Do not use quick connect fittings due to their restrictive nature.
Note 1: Service representatives should assure that the Low Air Pressure Switch is set at 60 PSI (approximately 4 bar). Note 2: V1.XX software will disable Control Power if a Low Air Pressure fault is detected. The operator must correct the error and enter ATC Diagnostics to clear the error message. Note 3: V2.0X software will activate the Interrupt Cycle Mode if a Low Air Pressure fault is detected. The error prompt will be automatically cleared when the error is corrected. If the fault occurs during an ATC cycle, then the control will complete the ATC cycle (if possible) before beginning the Interrupt Cycle. The program can be resumed when the Air Pressure is restored and the operator selects Auto and presses Start. Note 4: V2.1X will work the same as V2.0X except the error message will not be cleared until the operator selects another operation or selects auto to resume the program.

DATE: October 8, 1997 SUBJECT: Hawk5M Servo Inhibit PRODUCT LINE: Hawk5M W/Wago Servo Dynamic
In the event of an unexpected power failure the Hawk5M machines may exhibit axis movement of to while the servo bus capacitor discharges. This problem can be corrected by using the AER signal to control the servo inhibit inputs as well as the solid state relay that enables the bus voltage. This problem was corrected on the redesigned Hawk5M. The machines which can benefit from this modification are the early Hawk5M machines. These machines were all dual screen with the transformer on top of the power cabinet and orange Wago connectors on the servo drives. If you have trouble determining whether a machine is a candidate for this modification Call the Hurco Service Department. Material needed: 3 pc 20 in. 2.7K ohm watt resistors 407-0035-331 or 407-0036-079 20 awg wire
Modification: 1. Locate Q15 on each servo drive board (see figure 1). Carefully unsolder and remove Q15 from the component side of the board. Install the 2.7K resistor (at old Q15 location) as shown in figure 1 on the component side of the board. Keep the resistor leads short to prevent shorting out on the heatsink/ mounting bracket. 2. Install wire jumpers to tie each drive together at J1 pin 9 (Wago connector). Install an additional jumper from the X axis servo board J1 pin 9 and tie to the Servo drive chassis TB201 pin 1 or CRP4 TB1-5 (AER 24VDC enable signal, see figure 2). This will enable and disable the servo drives with the enable signal.

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October 15, 1997 V2.00 Parameter Changes BMC 4020SSM
ISSUE NUMBER: 1257
PAGE 1 OF 1
PURPOSE: To recommend a change to one of the Siemens Spindle parameters to correct a problem where the Spindle could orient with the magazine in the right position. DESCRIPTION: For BMC4020SSM Machining Centers running V1.64 Executive software, the Siemens Spindle parameter P-149, Startup parameter C axis/position, is set to 29H per Engineering Document 7574002-097. This sets the orient direction to unidirectional so that when an orient is required, the Spindle will always orient in the same direction. However during an Auto Tool Change operation when the Tool Magazine is in the Right position and the Head is in the Down position completing the tool change sequence, the Spindle is clamped which re-enables Spindle Enable Relay (SER). As the Tool Magazine moves back to the Left position, if SER has not yet been energized to hold the Spindle in orient position, it is possible for the movement of the magazine to rotate the Spindle slightly. Once SER is energized, the Spindle Drive senses that the Spindle is no longer oriented so it reissues an Orient command. This occurs in a fraction of a second, before the Tool Magazine has fully disengaged from the Head on its way left. With the P-149 parameter set to 29H, the Spindle could orient one full revolution thereby damaging the Spindle Key or the Tool Fingers. Testing has shown that the proximity switch for sensing Orient Position on BMC4020SSM Machining Centers is capable of handling a bidirectional orient command (that is, the orient will take the shortest direction to reach Orient Position). Changing P-149 to 21H for BMC4020SSM Machining Centers establishes bidirectional orient so that in the above scenario, the Spindle will still orient to the Orient Position but will not do a full revolution asit will take the shortest path. MATERIALS: Siemens I/R Module, Servo Drive, and Spindle Drive Setup Procedure with Ultimax 3 ISA Control. Applicable Machining Centers: BMC30M, BMC30HT, BMC30SSM, BMC4020HT and BMC4020SSM. Engineering Document 757-4002-097
INSTRUCTIONS: Modify Engineering Document, 757-4002-097, Attachment B, BMC4020SSM, change P149 from 29H to 21H. Also modify section XVI, paragraph A, step 1 from 29H to 21H.
ORIGINATOR: David Skrzypczak REVISED BY:

DATE: October 16, 1997 SUBJECT: BMC30SSM Modifications MN3996 PRODUCT LINE: BMC30SSM
In June of 1996 Manufacturing Notice #3996 was released. This document specifically documented several changes needed on the early machines which would be added in the field and integrated into manufacturing as new machines were built. Recently we have found that some of these changes are still not being included on the new production machines. Please review the following list of changes on any BMC30SSM and verify that these changes have indeed been added to each machine. The frames which we know need to be checked are Q376-Q379, Q392-Q399, and Q404-Q415. Newer machines should be checked during any service call. Some of these machines may have been upgraded to dual screen (Be sure to check frame and serial numbers).
CHECKLIST: 1. Servo Dynamics amplifiers not modified. Check Q15, it should have been removed and replaced with a resistor and the amplifiers should have several white opto-couplers on the boards. Also, these amplifiers should be labeled as SDFPO 1525 type drives (402-5001-087) and a Shunt Regulator assemble, (402-5001-074) should be mounted to the chassis near the bus capacitor. 2. There should be a 16 AWG green/yellow ground wire from the cabinet ground bus bar to the ISA cardrack wing nut. 3. The keyboard port harness located on the SSM console assemble is incorrectly wired. Please verify wiring per drawing 423-4401-064. 4. TB1 and TB2 terminal strips sag in the middle. Double sided tape should be added to the back of this assembly to correct this problem. Later production units used an aluminum mounting rail to correct this problem.

5. The Flood coolant contactor was installed without the overload relay. Install the overload relay #403-5503-010 and adjust for 1 amp. 6. The Flood coolant contactor is also missing noise suppressors (417-6001-010). Add suppressors to the coil and from phase to phase on the overload. The suppressors should be implemented at frame #Q566. 7. The CB3 20A and CB4 32A circuit breakers for the primary (220 VAC) and secondary (90VAC) windings of the Control transformer (Servo Dynamics taps) should be replaced due to nuisance tripping caused by high inrush current. These changes should be implemented on frame #Q578. a) The new CB3 breaker (20A) is a 404-9081-059 Klockner Moeller #FAZN C20-2, or ABB S272-K20. b) The new CB4 breaker (40A) is a 404-9081-058 Klockner-Moeller # FAZN C40-2, or ABB S272-K40 8. In addition at the release of V2.00 the Z axis rapid was increased from 394 ipm (10008 mmpm) to 500 ipm (12700 mmpm). a) It is important that the DAC is reset to 0.950 @ 50 ipm on the Z axis drive when the rapid has been increased to 500 ipm. b) Since this change could affect Rigid Tapping it would be beneficial to check Z and Spindle axis parameters and verify that Rigid Tapping functions correctly (refer to parameter document 757-4005-001, CAD DP0001 REV D).

Field Service Hurco1990 1999

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FIELD SERVICE BULLETIN INDEX

FSBINDEX.DOC Revised May 9, 1997 FSB NUMBER DESCRIPTION

PAGE 2 OF 5 FSBINDEX.DOC 9-May-97

PAGE 3 OF 5 FSBINDEX.DOC 9-May-97

PAGE 4 OF 5 FSBINDEX.DOC 9-May-97

PAGE 5 OF 5 FSBINDEX.DOC 9-May-97

PAGE 6 OF 7 FSBINDEX.DOC 26-Jun-97

HURCO FIELD SERVICE BULLETIN

SUPERSEDES NUMBER: 102 PAGE 1 OF 7

PRODUCT LINE: MB1

SHOT PIN ADJUSTMENT

ORIGINATOR: REVISED BY:

WAYNE E. HAWKINS R. BRYANT

HURCO FIELD SERVICE BULLETIN

ORIGINATOR: WAYNE HAWKINS REVISED BY: R BRYANT

HURCO FIELD SERVICE BULLETIN

ORIGINATOR: WAYNE HAWKINS REVISED BY:

HURCO FIELD SERVICE BULLETIN

PRODUCT LINE: KM1

ORIGINATOR: UNKNOWN REVISED BY: R. BRYANT

HURCO FIELD SERVICE BULLETIN

DATE:FEBRUARY 10, 1982

ISSUE NUMBER: 1005

ORIGINATOR: JERRY MC CLATCHEY REVISED BY: R. BRYANT

HURCO FIELD SERVICE BULLETIN

ORIGINATOR: RANDALL RENNEKAMP REVISED BY: R. BRYANT

HURCO FIELD SERVICE BULLETIN

ISSUE NUMBER: 1007 SUPERSEDES NUMBER: 128 PAGE 1 OF 2

ORIGINATOR: WAYNE HAWKINS REVISED BY:

HURCO FIELD SERVICE BULLETIN

DATE: APRIL 16, 1982 SUBJECT: PARAJUST B CHOPPER BOARDS

ISSUE NUMBER: 1008 SUPERSEDES NUMBER: 128 PAGE 1 OF 1

PRODUCT LINE: ALL BED MILLS USING B PARAJUST

ORIGINATOR: WAYNE HAWKINS REVISED BY:

HURCO FIELD SERVICE BULLETIN

DATE: MAY 3, 1982 SUBJECT: PARAJUST A SETUP

ISSUE NUMBER: 1009 SUPERSEDES NUMBER: 131 PAGE 1 OF 3

DYNAMIC BRAKING BOARD DIODES:

FULL CW 50% THRESHOLD FULL CCW FULL CW

HURCO FIELD SERVICE BULLETIN

ORIGINATOR: RANDAL RENNEKAMP REVISED BY: R. BRYANT

HURCO FIELD SERVICE BULLETIN

ISSUE NUMBER: 1011 SUPERSEDES NUMBER: 134 PAGE 1 OF 1

ORIGINATOR: WAYNE HAWKINS REVISED BY:

FIELD SERVICE BULLETIN

ISSUE NUMBER: 1012 SUPERSEDES NUMBER: 137 PAGE 1 OF 1

PRODUCT LINE: MILLS

ORIGINATOR: RANDAL RENNEKANP REVISED BY: R. BRYANT

HURCO FIELD SERVICE BULLETIN

ISSUE NUMBER: 1013 SUPERSEDES NUMBER: 138

ORIGINATOR: H.D. HUNT REVISED BY:

HURCO FIELD SERVICE BULLETIN

PRODUCT LINE: KONDIA VARIDRIVE MACHINES

ORIGINATOR: R. RENNEKAMP REVISED BY: R. BRYANT

HURCO FIELD SERVICE BULLETIN

PRODUCT LINE: MB2

ORIGINATOR: H.D. HUNT REVISED BY: R. BRYANT

HURCO FIELD SERVICE BULLETIN

PRODUCT LINE: ALL MILL LINES

ORIGINATOR: R. BRYANT REVISED BY:

HURCO FIELD SERVICE BULLETIN

DATE: SEPTEMBER 3, 1982 SUBJECT: SNOW ON CRT

ISSUE NUMBER: 1017 SUPERSEDES NUMBER: 148 PAGE 1 OF 1

PRODUCT LINE: MB1H