Field Service Hurco1990 1999 PDF

FIELD SERVICE BULLETIN
INDEX
FSBINDEX.DOC Revised May 9, 1997
FSB NUMBER DESCRIPTION
1001 MB1 TOOL CHANGER ALIGNMENT AND ADJUSTMENT.

1002 B INTERFACE BOARD RELIABILITY IMPROVEMENT.
1003 NUISANCE SHEAR PINING ON PARAJUST B DRIVE.
1004 INSTALLATION OF REPLACEABLE ENCODER DISKS.
1005 POWER DOWN MEMORY CIRCUIT ON B CONTROL MILLS.
1006 PROPER AXIS CURRENT ON KMB1 MILLS.
1007 MB1 SHOT PIN PROBLEM FIX.
1008 CHOPPER BOARDS ON PARAJUST B DRIVES.
1009 PARAJUST A SETUP AND ADJUSTMENT.
1010 CHATTER IN THE SPINDLE OF KMB1 KMB1m.
1011 INFO ON THE CRT BENT, B CONTROL FRONT PANEL BRD MOD
1012 RECOMMENDED WAY OIL FOR MILLS.
1013 MBII SHOT PIN ADJUSTMENT.
1014 VARIDRIVE BELT REPLACEMENT.
1015 MBII LIMIT SWITCH AND VALVE ADJUSTMENTS.
1016 MILL GROUND ROD USE INFORMATION.
1017 SNOW ON CRT OF MB1H MILLS.
1018 SHEAR PIN DURING TAPPING ON PARAJUST B DRIVES.
1019 MISSWIRED T2 TRANSFORMER ON MB3 MILLS.
1020 HIGH SPEED SPINDLE DIFFERENCES.
1021 MISPOSITION IN TOOLMASTER HMB1 BX RETROFIT.
1022 SET-UP OF BX SERVO CONTROL BOARD.
1023 PARAJUST 280V REFERENCE PROBLEM.
1024 RS232 DATA CARRIER LOST ERROR ON BX CONTROL.
1025 MB3/MD3 MOD. TO THE X5 BRD FOR MISPOSITION.
1026 KMB-1 SPLINE COUPLING REPLACEMENT.
1027 HURCO EDM SERVO AMP AND DIODE PUMP SETUP.
1028 EDM OPTITRON TRIP POINT SETTINGS. (MKII)
1029 SERIAL NUMBER ID ON ALL HURCO PRODUCTS.
1030 OIL LUBE REGULATOR KMB TYPE MACHINES.
1031 CONTROL TRANSFORMER REPLACEMENT SM1-CNC.
1032 MISCOUNT ON TOOL CHANGER OF MD1 AND MBX1.
1033 OIL FLOW INDICATOR RETROFIT MII.
1034 ORIENT TIME-OUT IN MBII MB3.
1035 MBXIH MD1 40V TOOL CHANGER SPRINGS WEAK.
1036 INTERMITTENT PROBLEMS ON B AND BX MILLS.
1037 B AND BX TAPE READER ADJUSTMENTS.
1038 VOLTAGE CONVERSIONS ON SM1-CNC AND KM3 MACHINES.
1039 BATTERY BACKUP ULTIMAX ONE CONTROL.
1040 PARAJUST VOLTAGE CONTROL BOARD PROBLEM.
1041 SM1-CNC Z AXIS PROBLEMS.
1042 ULTIMAX ONE TAPE FORMATTING PROBLEM.
1043 PARTS REPLACEMENT ON PARAJUST DRIVES.
1044 SM1-CNC BALL SCREW REPLACEMENT.
1045 MISSWIRED SPINDLE DAC ON MD1.
1046 MD3 Z AXIS SC FAULT PROBLEM WITH AUX BRIDGE.

1047 WIRING MAIN TRANSFORMER.
1048 SERVO DYNAMIC AMPLIFIER SET-UP.
1049 CIRCLE AND POSITIONING ACCURACY.
1050 SHOTPIN PROBLEMS AND ADJUSTMENTS ON MD3.
1051 MD3 FAULT LOGIC BOARD PROBLEM.
1052 SMI-CNC DOOR LATCH PROBLEM.
1053 LUBE OF SPLINE COUPLING KMB1 TYPE MACHINE.
1054 HONING KNEE MILL QUILL BORES.
1055 KNEE MILL SPINDLE REBUILDS.
1056 MISCOUNTS WITH MILLS USING HEIDNHAIN SCALES.
1057 AIR LINES POPPING OFF FITTINGS.
1058 MD1 CHIP REMOVAL BENEATH SADDLE.
1059 MD1 Y AXIS LEAD SCREW COVER.
1060 QUILLS FOR SMI-CNC.
1061 MD1-3 PARAJUST WIRING DRESS PROBLEM.
1062 SPINDLE ORIENT SPEED ADJUSTMENT MD1-3.
1063 TAPE TRANSPORT GROUNDING ULTIMAX 1.
1064 LUBE PRESSURE SWITCH SETUP ON MD3.
1065-B ULTIMAX POWER SUPPLY CHECKOUT. Revised 3/17/93 REV. C
1066 ULTIMAX SWITCH SETTINGS.
1067 LUBE PROBLEMS ON SM1-CNC.
1068 CRTS SHORTING OUT ON ULTIMAX ONE.
1069 ENCODER DAMAGE.
1070 NEW REPLACEMENT FOR HEIDENHAIN X5 BOARDS.
1071 PARAJUST B DRIVE MAINTENANCE.
1072 GROUND FAULT ON HURCO AMPS.
1073 FRL UNIT BOWLS CRACKING.
1074 AUTOLUBE SYSTEMS ALL MILLS.
1075 ATC ERROR ON BMC-15 MILLS.
1076 INDEX MISSWIRE ON KM3/P.
1077 HI-LOW GEAR SWITCH PROBLEM MD3-BMC15.
1078 MISSWIRE ON RS232 ON KM3 TYPE MACHINES.
1079 MUTI-LOAD SCREENS ON B OR BX CONTROL MACHINES.
1080 KMC3-P SPINDLE SPEED AND ROTATION PROBLEMS.
1081 THREE PHASE POWER KVA-AMPERS AND WIRE SIZE.
1082 KM3P MOTOR BRUSH CONTAMINANT FIX (COVER).
1083 MACHINE INPUT VOLTAGE AND AIR REQUIREMENTS.
1084 MISSING SURGE SUPPRESSOR BMC 10-15.
1085 MISCOUNTS ON KM3 DUE TO SHIELDS MISSING.
1086 BMC AXIS BELT TENSION.
1087 USING DISTRIBUTOR STOCK.
1088 TAPE READER PROBLEMS TM5.
1089 RANDTRONICS CHASSIS WIRING PROBLEMS.
1090 OVER RATED HEATER ON BMC 15 CHIP CONVEYOR.
1091 TOOL CHANGER LIMIT SWITCH PROBLEM BMC 20.
1092 ULTIMAX LOCKUPS.
1093 BRAKE PACK PROBLEMS WITH MD1 AND MD3.
1094 MB3 SERVOMATE/RANDTRONIC TRANSFORMER.
1095 BX MISCOUNTING ON KNEE MILLS.
1096 DELTRON POWER SUPPLY ADJUSTMENT.
1097 CUSTOM CPU JUMPER CAUSES RS232 RS 232 PROBLEM.
1098 SOLENOID EXHAUST FILTERS CLOG MD3 THRU BMC 15.
PAGE 2 OF 5
FSBINDEX.DOC 9-May-97
1099 BMC 10/10L TOOL SUPPORT PROBLEM.

1100-A BMC 20 THRU 50 GIBS AND AXIS CURRENT ADJUSTMENT.REVISED 1/25/93
1101 TM5 Z AXIS BOUNCING AT Z PLUS LIMIT SWITCH.
1102 SPIETH LOCKNUT INSTALLATION INSTRUCTIONS.
1103 MAX2 RS232 HARNESS MISSWIRE.
1104 SOFTWARE FOR YASKAWA MD3 MACHINES.
1105 ORIENT PROBLEM WITH YASKAWA RETROFIT.
1106 KMC3P PALL CHUCK REPLACEMENT.
1107 BMC AUTO LUBE WIRING IMPROPER SHIELDING.
1108 INSTALLATION OF THRUST BEARING'S.
1109 NONVOLATILE CPU/MEMORY PCB FOR ULTIMAX 1.
1110 TOOL CHANGER HEIGHT WITH 06F SOFTWARE.
1111 BMC DRAW ADJUSTMENT.
1112 BMC CLUTCH NOISE.
1113 BMC 20 THRU 50 GIB WEAR.
1114 AXIS END CAP PROBLEM KM3 MILLS.
1115 CONTROL RELAY PANEL PCB MAX 2 MACHINES.
1116 DELTRON POWER SUPPLY CHECK OUT.
1117 CONTROL GROUNDING IN ULTIMAX.
1118 RS232 CABLE HURCO REQUIREMENTS.
1119 PARAJUST A BRAKE BOARD REPLACEMENT.
1120 MISSWIRE ON YASKAWA RETROFIT.
1121 WRONG SPINDLE OVERLOADS ON KM3 TYPE MACHINES.
1122 GROUNDING OF INDUSTRIAL SERVO DRIVES.
1123 FANUC SPINDLE SPEED SENSOR INSTALL AND TROUBLINGSHOO
1124 DECKEL IND. SERVO DRIVE MODIFICATIONS.
1125 DELTRON POWER SUPPLY PROBLEMS.
1126 FERRITE BEADS AND TRANSIENT VOLTAGE PROTECTORS.
1127 BMC ATC JAMING (BUSHING PROBLEM)
1128 LEADSCREW MAPPING 7.24 BMC 20/50
1129 CHIP DOOR INTERLOCK PROBLEM 7.24 SOFTWARE
1130 TAPPING T1 TRANSFORMER (BMC STAND ALONE)
1131 MAGAZINE JAMMED ERROR (ELECTRICAL)
1132 BIJUR WAY LUBE PUMP ADJUSTMENT
1133 MAX2 MEMORY BOARDS (DALLAS RAM)
1134 ENCODERS SHAFT MOUNT
1135 SPINDLE FIRMWARE FOR MD3 WITH YASKAWA DRIVE
1136 YASKAWA SPINDLE DRIVE RETROFIT KIT
1137 BMC20 V2 Z AXIS LUBRICATION LINE MISSROUTE
1138-B DISK DRIVE RETROFIT, & FLOPPY DISK CONFIGURATION Revised 8/3/94 REV A
1139 VERTICLE HEAD LUBE RELAY ON DECKEL/MAX
1140 TURKITE DAMAGE
1141 BMC30 STRIKER PLATE SCREW PROBLEM
1142 YASKAWA SPINDLE DRIVE DOCUMENTATION PROBLEM
1143 GROUNDING IN ULTIMAX CONTROL CONSOLE
1144 GIB ADJUSTMENTS. Refer to FSB 1100-A
1145 REPLACING HURCO AMPS WITH SERVOMATE
1146-A YASKAWA ORIENT MODIFICATION
1147 ATC STRIKER PLATE HOLD-DOWN SCREWS
1148 ATC MAGAZINE AIR CYLINDER SET SCREW
1149 ATC MAGAZINE AIR CYLINDER SET SCREW
1150 CONTROL RESIDENT DIAGNOSTICS (MAX)
1151 FLOOD FILTER (5 GAL)
PAGE 3 OF 5
1152 REPLACEMENT OF KNEE MILL MOTORS/ENCODERS (MTE ASSY)

1153 TRANSIENT ELIMINATOR (LINE POWER PROBLEMS)
1154 DUAL AXIS PCB (DAC OFFSET PCB)
1155 COUNTER WEIGHT RETROFIT BMC40 IP
1156 ISOLATION TRANSFORMER (BMC 20-50)
1157 CRT RELIABILITY IMPROVEMENT
1157-A CRT GROUNDING
1158 BACKLASH MEASURING
1159 CIRCUIT PCB CLEANING
1160 FIELD SERVICE ACCURACY STANDARD
1161 OIL COOLER CONTACTOR MIS-WIRE (BMC 30-50)
1162 BEARING TORQUE SETTINGS
1163 TOOL RETENTION FORCES (ATC)
1164 SERVICE CALL CHECK LIST
1165-B FUTABA CMK PARAMETER SETTINGS (EDM) Revised 3/3/92 REV. A
1166 KM5P DRAWBAR
1167 KM5P AXIS PULLEY LOCKING ELEMENTS
1168 KM5P DRAWBAR
1169 ROTARY TABLE ERRORS (BMC 20-50)
1170 YASKAWA SPINDLE DRIVE RETROFIT KIT (MB2-MD3)
1171 FAST FILL PROBLEMS TRM21 (EDM)
1172-A CONTACTOR SUPPRESSION (BMC KM5P)
1173 LEADSCREW MAPPING INITIALIZATION v8.5
1174-A ULTIMAX SECRET (HIDDEN) SCREENS. Revised 3/17/93
1175 BMC 20-50 SPINDLES
1176 CRT CONTROLER PCB, 26 PIN EDGE CONNECTOR
1177 VMC900 ORBITING UNIT (EDM)
1178-A NOISE SUPPRESSION TRM21 W/ VMC 900 (EDM)
1179 ISOLATION TRANSFORMER KM5P
1180 UNCLAMP LIMIT SWITCH BMC 25-30K
1181 RS232 CABLES
1182 AXIS MISWIRE KM3/P
1183 MACHINE CONFIGURATION PROBLEMS (BCM 20-50 8.5 OR LATER)
1184-A CRT CONTROLLER PCB-2. Revised 6/23/93
1185 MAX 400 AMPLIFIER MODIFICATION.
1186 LEAD SCREW MAP INITIALIZATION v8.51 (BMC 20-50).
1187 CHAIN ROLLER, COUNTER WEIGHT (BMC 20-50.
1188 PARAJUST DIGITAL REVERSING PCB. (SPINDLE DRIVES)
1189-B Z AXIS CRT ASSY. Revised 6/22/93 REV. A REV. C
1190 KNEE MILL PULLY CLUTCH SHAFT RETRO-FIT KIT. KM3/P
1191 UNCLAMP PUSH STUD LOCKNUT, LOCKTITE, BMC 20-50
1192 SHAPE ELECTRONICS TRANSFORMER FUSES.
1193-A MODIFICATION TO VOLTAGE DIVIDER PCB. ( TRM21/TRM39 )
1194 TRANSFORMER COVER ( BMC 40SLV ).
1195 LUBE MODIFICATION KM5P.
1196 TYPE 1 ATC MODIFICATION FOR MAGAZINE OVERSHOOT.
1197 COUNTER WEIGHT NOISE ELIMINATION (BMC20-50 40SLV).
1198 ULTIMAX 3 DC POWER SUPPLY, REV. "C" NEW TERMINAL STRIP.
1199 CRP3 PCB MODIFICATION. BMC 20-50.
1200 OIL COOLER REPLACEMENT. BMC 30-50. 8-11-93
1201 MAX 3 KEY BOARD BUTTON REPLACEMENT CHART. 10-29-93
1202 CLAIREX SWITCH USED ON KM1/HM1 LIMIT SWITCHES. 1-4-94
1203 TOOL RELEASE / KNOCK OUT LENGTH ON BMC'S.
PAGE 4 OF 5
1204 KM5D INPUT POWER, SOURCE FOR TRANSFORMER.

1205 KM3/3P MTE REMOVAL REPLACEMENT PROCEDURE.
1206 HAWK 5D MACHINE CONTROL PARAMETERS.
1207 HAWK 5D JO-BLOCK PROCEDURE FOR BACKLASH & LEADSCREW COMP.
1208 HAWK 5D SERVO AMP SET-UP PROCEDURE.
1209 HAWK 5D LIMIT SWITCH SET-UP PROCEDURE.
1210 HAWK 5M AUTO SPEED CONTROL PROM UPDATE.
1211 HAWK 5M I/O & CANBUS MAPPING.
1212 HAWK 5M SERVO AMP SET-UP.
1213 HAWK 5M PARAMETERS.
1214 HAWK 5M MONO CRT SETTINGS. REV. A
1215 HAWK 5M ADVANCED CMOS SET-UP.
1216 HAWK 5M LEAD SCREW MAP SET-UP.
1217 HAWK 5M & ISA HARD DRIVE SET-UP.
1218-A YASKAWA AC SERVO SET-UP, MAX-2 & MAX-32 DUAL AXIS
1219 ACROLOC COOLANT PUMP LOW VOLUME
1220 HAWK 5M V1.51 HURCO.LDR FILE
1221 BMC SPINDLE HANDLING PRECAUTIONS
1222 HAWK 5M AXIS CURRENT SETUP
1223 ACCURACY STANDARD PROCEDURE
1224 HAWK 5M/5D TABLE T-SLOT ALIGNMENT
1225 HAWK 5M/5D DRAWBAR SET-UP
1226-A KURT POWER DRAWBAR HAWK 5M/5D
1227 FLOOD COOLANT LEAKS
1228 POWER CABINET COOLANT LEAKS
1229 INCORRECT PARAMETER FOR WINDING CHANGE
1230 SERVO DYNAMICS DRIVE TUNE PROCEDURE
1231 DIGITAL SPINDLE CONTROLLER PCB MODIFICATIONS
1232 UPGRADE OF REMOTE SHUTDOWN RELAY (RSR)
1233 UPGRADE OF RS232C CABLES (COM1, COM2)
1234-A KURT POWER HEADS & DRAWBAR SETUP
1235 RETROFIT OF DRIVE SPINDLES TO ACCEPT 18MM PROXIMITY SWITCHES
1236 MAX32 HARD DRIVES
1237 FRAME A FRL UNITS
1238 FRAME A Z AXIS CABLE DAMAGE
1239 ISA CARDRACK FAN REPLACEMENT
1240 ACROLOC 1540, 3030 OILING PROBLEMS
1241 BMC4020 NOISE PROBLEMS
1242 ISA CARDRACK TIPS
1243 30SSM DAC SHIELD
1244 WORKLIGHT SUPPRESSION MODIFICATIONS
1245 SPINDLE AGREE FAULTS DURING RIGID TAP FUNCTIONS
1246 HARNESS BRACKET INSTALLATION ON BMC40/20 MACHINES.
1247 CANBUS CONTROLLER MODIFICATION
1248 SIEMENS DRIVE WIRING MODIFICATION
1249 COOLANT/OIL SEPARATOR RETROFIT
1250 SIEMENS FAST STOP SIGNAL MIS-WIRE
PAGE 5 OF 5
1251 V2.00 PARAMETER CHANGES

1252 M Code Mods for Frame "A"
1253 SPINDLE DRIVE FAULTS NOT REPORTED TO CONTROL
1254 FULL ENCLOSURE DOOR SLIDES 410-5001-002
1255 AIR REQUIREMENTS / BMC3017, BMC4020
1256 HAWK5M SERVO INHIBIT
1257 VERSION 2.0 PARAMETER CHANGES, BMC 4020
1258 BMC3017SSM MODIFICATIONS MN3996
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
PAGE 6 OF 7
FSBINDEX.DOC 26-Jun-97
HURCO FIELD SERVICE BULLETIN
DATE: AUGUST 24, 1981 ISSUE NUMBER: 1001
SUBJECT: TOOL CHANGER ALIGNMENT SUPERSEDES NUMBER: 102
PRODUCT LINE: MB1 PAGE 1 OF 7
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. APPLY BLUEING TO LOWER SPINDLE COUPLING.

2. ROTATE THE SPINDLE SO THE NOTCH IS NOT ALIGNED WITH THE SHOT PIN.
3. ENERGIZE SHOT PIN MANUALLY, AND ROTATE SPINDLE.
4. 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: WAYNE E. HAWKINS

REVISED BY: 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. RUN EACH TOOL POSITION AT LEAST TWICE IN AUTO TC.

2. ENSURE TANG IS BENT TO LOCK NUT ON TORQUE LIMITER.
3. ENSURE LOCKNUT IS TIGHT ON SHOCK ABSORBER.
4. 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.

REVISED BY:
SUBJECT: ENCODER INSTALLATION SUPERSEDES NUMBER: 120
PRODUCT LINE: KM1 PAGE 1 OF 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.
ORIGINATOR: UNKNOWN
DATE:FEBRUARY 10, 1982 ISSUE NUMBER: 1005
SUBJECT: POWER DOWN MEMORY CIRCUIT SUPERSEDES NUMBER: 122
PRODUCT LINE: B CONTROL MILLS 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

DATE: MARCH 30, 1982 ISSUE NUMBER: 1006
SUBJECT: PROPER AXIS CURRENT DRAW FOR KMB-1 SUPERSEDES NUMBER: 126
PRODUCT LINE: KMB-1 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

SUBJECT: MB1 SHOT PIN LIMIT SWITCH SUPERSEDES NUMBER: 128
PRODUCT LINE: MB1 MILL 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 BRACKET 1
2) 117-0001-015 4-40 HEX NUT 2
3) 101-0001-005 4-40 X 3/4 SHCS 2
4) 110-1005-001 4 INTERNAL STARWASHER 2
5) 423-1005-001 PROXIMITY SWITCH 1
6) 406-2523-001 20 GA RED WIRE 12"
7) 406-0801-006 MOLEX PINS 3
8) 406-0801-002 MOLEX BODY 1
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.

REVISED BY:
DATE: APRIL 16, 1982 ISSUE NUMBER: 1008
SUBJECT: PARAJUST B CHOPPER BOARDS SUPERSEDES NUMBER: 128
PRODUCT LINE: ALL BED MILLS USING B PARAJUST PAGE 1 OF 1
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.

REVISED BY:
DATE: MAY 3, 1982 ISSUE NUMBER: 1009
SUBJECT: PARAJUST A SETUP SUPERSEDES NUMBER: 131
PRODUCT LINE: ANY MILL USING PARAJUST A PAGE 1 OF 3
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 PRE-
WIRED 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

DYNAMIC BRAKING BOARD DIODES:
6. SET THE FOLLOWING POTS AS SPECIFIED:
ANALOG BOARD BRAKE BOARD
ACC/DEC FULL CW GAIN FULL CCW

V/HZ 50% THRESHOLD FULL CCW,CW 1/4 T
BOOST FULL CCW
SHEAR PIN 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.
SUBJECT: CHATTER ON KMB-IM & KMB-I MILLS SUPERSEDES NUMBER: 132
PRODUCT LINE: KONDIA STYLE KNEEL MILLS 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

SUBJECT: FRONT PANEL BOARD MODIFICATIONS SUPERSEDES NUMBER: 134
PRODUCT LINE: ANY B CONTROL MILL PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: MILL AUTO LUBE OIL TYPE SUPERSEDES NUMBER: 137
PRODUCT LINE: MILLS PAGE 1 OF 1
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 MOLY SHIELD WAY OIL 315

AMERICAN INDUSTRIAL REXLUBE #20
AMERICAN INDUSTRIES INC. 516 WAY LUBES #20
AMERICAN LUBRICANTS CO. ALUCO MOLY WAY LUBE #40
AMOCO OIL CO. WAYTAC OIL #31
ANDERSON OIL & CHEMICAL CO. WINSOR WAY OIL 1L
ASHLAND OIL INC. WAULUBE W-30
ATLANTIC RICHFIELD CO. TRUSLIDE S-315
BEL-RAY CO. INC. RAYLENE EP OIL #2
BROOKS TECHNOLOGY CO. BARCOTE 961
CATA OIL & GREASE CO. MED. HVY OIL FOR SLIDEWAYS
CHEVRON USA INC. CHEVRON OIL 68
CITIES SERVICE CO. CITGO SLIDERITE NO. 2
CONTINENTAL OIL CO. HD WAY LUBE 31
DARMEX INDUSTRIAL CORP. DARMEX 1050
DAVIS HOWLAND OIL CORP WAY OIL 80
DUBOIS CHEMICALS MPO-30
EXXON CO. USA FEBIS K68
FISKE BROS. REFININHG CO. NO. 3-V
GEORGE-CAROLINA OIL CO. G-C PRESS MEDIUM
GETTY REFINING & MARKETING VEEDOL ATLINE 20
GRAPHITE PRODUCTS CORP. GP #350 WO
GULF OIL CORP GULFWAY 52
IMPERIAL OIL * GREASE CO. MOLUB-ALLOY M.W.O. 20
KENDALL REFINING CO. KENDALL 965
MOBIL OIL CORP. VACTRA NO. 2
UNION OIL CO. OF CALIFORNIA WAY OIL HD 315
ORIGINATOR: RANDAL RENNEKANP

SUBJECT: MBII SPINDLE SHOT PIN LIMIT SWITCH SUPERSEDES NUMBER: 138
OPTIMUM SETTING
PRODUCT LINE: MB 2 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 ISSUE NUMBER: 1014
SUBJECT: VARIDRIVE BELT REPLACEMENT SUPERSEDES NUMBER: 139
PRODUCT LINE: KONDIA VARIDRIVE MACHINES PAGE 1 OF 1
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
SUBJECT: MBII ATC LIMIT SWITCH & AIR VALVE SUPERSEDES NUMBER: 141
SETTINGS
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

SUBJECT: GROUND ROD USE IN HURCO MILLS SUPERSEDES NUMBER: 146
PRODUCT LINE: ALL MILL LINES PAGE 1 OF 1
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 ISSUE NUMBER: 1017
SUBJECT: SNOW ON CRT SUPERSEDES NUMBER: 148
PRODUCT LINE: MB1H PAGE 1 OF 1
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.

REVISED BY:
DATE: FEBRUARY 24, 1983 ISSUE NUMBER: 1018
SUBJECT: SHEAR PIN DURING TAP ON PARAJUST B SUPERSEDES NUMBER: 150
PRODUCT LINE: ALL MILLS USING PARAJUST B UNITS PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: MISS-WIRED CONTROL TRANSFORMER (T2) SUPERSEDES NUMBER: 155
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.
ORIGINATOR:
REVISED BY:
DATE: OCTOBER 28, 1983 ISSUE NUMBER: 1020
SUBJECT: HIGH SPEED SPINDLE SUPERSEDES NUMBER: 159
PRODUCT LINE: MILLS WITH HSS PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: BX RETROFIT TO TOOLMASTERS CONTROLS SUPERSEDES NUMBER: 166
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.

REVISED BY:
SUBJECT: SET-UP OF BX SERVO CONTROL BOARD SUPERSEDES NUMBER: 167
PRODUCT LINE: BX MILLS PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: PARAJUST 280VDC BUSS VOLTAGE PROBLEM SUPERSEDES NUMBER: 16
PRODUCT LINE: PARAJUST B MILLS PAGE 1 OF 1
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

REVISED BY:
SUBJECT: RS232 DATA CARRIER LOSS BX MPU BRD SUPERSEDES NUMBER: 168
PRODUCT LINE: BX CONTROL MILLS PAGE 1 OF 2
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.

SUBJECT: MOD TO X5 MOTHER BRD FOR MIS POSITIONING SUPERSEDES NUMBER: 171
PRODUCT LINE: MB3/MD3 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.
4. TB1-5 AND TB1-6 GROUND AND 5 VOLTS.
VERIFY MACHINE CALIBRATION AND POSITIONING AFTER MODIFICATION.

REVISED BY:
DATE: May 9, 1984 ISSUE NUMBER: 1026
SUBJECT: SPLINE COUPLING REPLACEMENT SUPERSEDES NUMBER: 185
PRODUCT LINE: KMB-I /KMBX-I PAGE 1 OF 1
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:
SUBJECT: SERVO AMP BRD AND DIODE PUMP SETUP SUPERSEDES NUMBER: 187
PRODUCT LINE: 425, 900, AND 1450 EDM,S 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:
SUBJECT: OPTITRON TRIP POINT SETTING ADJUSTMENTS SUPERSEDES NUMBER: 188
PRODUCT LINE: EDM'S PAGE 1 OF
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.

REVISED BY:
SUBJECT: SERIAL NUMBER ID ON HURCO PRODUCTS SUPERSEDES NUMBER 18
PRODUCT LINE: ALL HURCO PRODUCTS PAGE 1 OF 15
SCOPE: 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.
----------------------- Year

XXXX7 NNN MM8X

Product Line Prefix -- ----- Major Revision
(Letter(s) as listed suffix from
in Table #1) Table #2
------- Month
First M is zero
Consecutive numbering ------------- for numbers less
of products beginning than 10
each month (by major
product line).
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_____-_
-------------------------------------------------------------------
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 (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______________________
_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) Serial Number - Identical to that of the Autobend Power Box

b) Assembly Number - Hurco drawing number for the vertical control
c) Contact Ratings - Maximum continuous current rating and voltage
Relay Contacts if relay is used. (5A @ 240 VA
---------------------------------------------------------------------
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 (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)
------------------------------------------------------------------
------------------------------------------------------------------
------------------------------------------------------------------
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)
------------------------------------------------------------------
--------------------------------------------------------------------
--------------------------------------------------------------------
------------------------------------------------------------------
------------------------------------------------------------------
17 30/10 Generator
------------------------------------------------------------------
18 60/10 Generator
------------------------------------------------------------------
19 330 Spark Unit
------------------------------------------------------------------
20 900 NC Spark Unit
------------------------------------------------------------------
------------------------------------------------------------------
22 1450/900 NC Spark Unit
------------------------------------------------------------------
--------------------------------------------------------------------
--------------------------------------------------------------------
------------------------------------------------------------------
------------------------------------------------------------------
17 30/10 Generator
------------------------------------------------------------------
18 60/10 Generator
------------------------------------------------------------------
19 330 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
--------------------------------------------------------------------
--------------------------------------------------------------------
------------------------------------------------------------------
------------------------------------------------------------------
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
------------------------------------------------------------------
--------------------------------------------------------------------
--------------------------------------------------------------------
------------------------------------------------------------------
------------------------------------------------------------------
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
------------------------------------------------------------------
--------------------------------------------------------------------
--------------------------------------------------------------------
------------------------------------------------------------------
------------------------------------------------------------------
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
------------------------------------------------------------------
------------------------------------------------------------------
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

Autobend IV
1) 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
2) Front Gauge, Dual Drive, Left/Right Identification - Use the
above.
3) 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
B. 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
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) F.L. - Maximum continuous system operating current at nom

voltage; Full load. (Product Standard 715-0000-0
b) 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 ISSUE NUMBER: 1030
SUBJECT: OIL LUBE AIR REGULATOR SUPERSEDES NUMBER: 190
PRODUCT LINE: KMB-I KMBX-I KMB-Im PAGE 1 OF 1
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.

DATE: Unknown ISSUE NUMBER: 1031
SUBJECT: Control Transformer Replacement SUPERSEDES NUMBER:
PRODUCT LINE: SM 1 CNC 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.
SUBJECT: ATC DECODER PINS MOVING SUPERSEDES NUMBER: 200
PRODUCT LINE: MD1 / MBX1 PAGE 1 OF 1
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.

DATE: July 7,1984 ISSUE NUMBER: 1033
SUBJECT: Oil Flow Indicator Retrofit SUPERSEDES NUMBER:
PRODUCT LINE: MII Gen I & II PAGE 1 OF 4
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 002-
2059-001.
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 ISSUE NUMBER: 1034
SUBJECT:ORIENT TIME-OUT ERR IN LOW GEAR SUPERSEDES NUMBER: 196
PRODUCT LINE: MBII MBXII MB3 PAGE 1 OF 1
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.
ORIGINATOR: JOE STINSON

REVISED BY:
SUBJECT: 40V TOOL CHANGER SUPERSEDES NUMBER: 198
PRODUCT LINE: HMBX1 / MD1 40V MACHINES PAGE 1 OF 2
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
SUBJECT: INTERMITTENT PROBLEMS DUE TO POWER SUPERSEDES NUMBER: 201

SUPPLY TRANSFORMER
PRODUCT LINE: ALL B AND BX MILLS 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:
SUBJECT: TAPE READER ADJUSTMENT SUPERSEDES NUMBER: 203
PRODUCT LINE: B AND BX MILLS PAGE 1 OF 1
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:
SUBJECT: VOLTAGE CONVERSIONS SUPERSEDES NUMBER: 206B
PRODUCT LINE: SM1-CNC / KM3 PAGE 1 OF 1

DATE: NOVEMBER 1, 1984 ISSUE NUMBER: 1039
SUBJECT: MEMORY PCB BATTERY LED'S STAYING ON SUPERSEDES NUMBER: 208
PRODUCT LINE: ALL ULTIMAX ONE MILLS 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

SUBJECT: PARAJUST VOLTAGE CONTROL BOARD SUPERSEDES NUMBER: 210
PRODUCT LINE: BED MILLS WITH PARAJUST B PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: Z AXIS TRAVEL SUPERSEDES NUMBER: 214
PRODUCT LINE: SM1-CNC PAGE 1 OF 1
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 002-
2482-001
ORIGINATOR: DAVE ROCH

DATE: DECEMBER 17, 1984 ISSUE NUMBER: 1042
SUBJECT: TAPE FORMATTING PROBLEM SUPERSEDES NUMBER: 217
PRODUCT LINE: ULTIMAX ONE MD1/MD3 PAGE 1 OF 1
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

SUBJECT: SERVICE OF PARAMETRICS SPINDLE DRIVES SUPERSEDES NUMBER: 219
PRODUCT LINE: ALL MILLS USING PARAJUST DRIVES PAGE 1 OF 1
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:
SUBJECT: Y AXIS BALLSCREW SUPERSEDES NUMBER: 223
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.

REVISED BY:
SUBJECT: MISSWIRED SPINDLE DAC SUPERSEDES NUMBER: 225
PRODUCT LINE: MD1 PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: RANDTRONICS AUX BRIDGE SC LED SUPERSEDES NUMBER:
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!

REVISED BY:
SUBJECT: MAIN INPUT TRANSFORMER WIRING SUPERSEDES NUMBER: 227
PRODUCT LINE: ALL MILLS PAGE 1 OF 1
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.
SUBJECT: SERVO DYNAMIC SET-UP PROCEDURE SUPERSEDES NUMBER: 229
PRODUCT LINE: MILLS USING WESTAMP PAGE 1 OF 1
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 = 0.00K OHM.

SIG POT: TP3 TO TP1 = 2.67K OHM.
TAC POT: TP4 TO TP1 = 7.45K OHM.
*CMP POT: TP5 TO TP1 = .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:
SUBJECT: CIRCLE & POSITIONING ACCURACY SUPERSEDES NUMBER: 230
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. .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.)

DATE: MARCH 20, 1989 ISSUE NUMBER: 1049A
SUBJECT: CIRCLE & POSITIONING ACCURACY SUPERSEDES NUMBER: 1049
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.)

REVISED BY: MIKE GARLICK
SUBJECT: SPINDLE HARDWARE FAULT SUPERSEDES NUMBER: 228/233
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.

DATE: April 16, 1985 ISSUE NUMBER: 1051
SUBJECT: FAULT LOGIC BOARD 402 5001 035 SUPERSEDES EUXBER: 234
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.

REVISED BY:
SUBJECT: DOOR LATCH INTERFACE SUPERSEDES NUMBER: 235
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.

REVISED BY:
SUBJECT: LUBRICATION OF SPLINE COUPLING: SUPERSEDES NUMBER: 236/237
PRODUCT LINE: KMB1, KMBX1, KMBX1 ATC 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

DATE: JULY 9, 1985 ISSUE NUMBER 1054
SUBJECT: HONING QUILL BORES SUPERSEDES NUMBER: 246
PRODUCT LINE: KNEE MILLS 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:
SUBJECT: SPINDLE REBUILDS SUPERSEDES NUMBER: 282
PRODUCT LINE: SPINDLE REBUILD KNEE MILLS PAGE 1 OF 1
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:
SUBJECT: MISCOUNTS DUE TO WIRING IN X5 BOX 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.

REVISED BY:
DATE:JULY 11, 1985 ISSUE NUMBER: 1057
SUBJECT: AIR LINE FITTINGS POPPING OFF SUPERSEDES NUMBER: 252
PRODUCT LINE: KMB1, MB1, MD1 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

SUBJECT: CHIP REMOVAL FROM BENEATH SADDLE SUPERSEDES NUMBER: 255/253
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

SUBJECT: Y AXIS LEADSCREW COVER SUPERSEDES NUMBER: 256
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:
SUBJECT: QUILLS FOR KONDIA MILLS SUPERSEDES NUMBER: 257
PRODUCT LINE: ALL SM1-CNC KILLS 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 713-
0012-108 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:
SUBJECT: PARAJUST B WIRE DRESSING SUPERSEDES NUMBER: 259
PRODUCT LINE: MD1-MD3 MILLS 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:
SUBJECT: ADJUSTABLE SPINDLE ORIENT SPEED SUPERSEDES NUMBER: 260
PRODUCT LINE: MD1-3 PAGE 1 OF 1
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
SUBJECT: TAPE TRANSPORT GROUNDING SUPERSEDES NUMBER: 262
PRODUCT LINE: ULTIMAX ONE 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.

REVISED BY:
SUBJECT: LUBE PRESSURE SWITCH SETUP SUPERSEDES NUMBER: 264
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.

REVISED BY:
DATE: November 2, 1992 ISSUE NUMBER: 1065-B
SUBJECT: Ultimax Power Supply Adjustments. SUPERSEDES NUMBER: 1065-A
PRODUCT LINE: Ultimax Machines 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 = +5.2 - 5.3 VDC

24 VDC = +24.5 - 25.0 VDC
- 12 VDC = -12.5 - -13 VDC
+ 12 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
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.
G 230VAC
R
O
U
N
D
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

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

+5VDC Hurco Part number 413-0008-006
+24VDC
-12VDC Caution: Use Non-metallic adjusting tool. As legs of pot

+12VDC
1 2 3 4 5 6 7 8 9 10 11
G V V + + - C C C + +
R A A 12 24 12 O O O 5 5
O C C V V V M M M V V
U D D D M M M D D
N C C C O O O C C
D N N N
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.
1 2 3 4 5 6 7 8 9 10 11
G V V + - + C C C + +
R A A 12 12 24 O O O 5 5
U D D D M M M D D
N C C C O O O C C
D N N N
Fan Common
5VDC
Ground
-12VDC
12VDC
Common
120 VAC
24VDC
Ultimax 3 DC Power Supply. "REV A or B"

Hurco Part number
413-0008-013
NOTE: refer to FSB 1198 for wiring code.

Ultimax 3 DC Power Supply. "REV C"
Hurco Part number
413-0008-013
FSB XXX Page 4 of 4

DATE: December 7, 1993 ISSUE NUMBER: 1065-C
SUBJECT: Ultimax Power Supply Adjustments Mod's. SUPERSEDES NUMBER: 1065-B
PRODUCT LINE: Ultimax Machines PAGE 1 OF 5
Revised Added Page 2 and Notes

See page 2 for modification information.
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 = +5.2 - 5.3 VDC

24 VDC = +24.5 - 25.0 VDC
- 12 VDC = -12.5 - -13 VDC
+ 12 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.

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 230VAC
R
O
U
N
D
Powermate DC Switching power supply

Hurco part number 413-0008-001
+5VDC
Caution: Use Non-metallic adjusting tool. As legs of pot

-12VDC +12VDC
10 9 8 7 6 5 4 3 2 1
G + G + G + - G G +
R 5 R 24 R 5 12 R R 12
O V O V O V V O O V
U D U D U D D U U D
N C N C N C C N N C
D D D D D
NONADJUSTABLE

Powertec Power Supply
+5VDC Hurco Part number 413-0008-006
+24VDC
-12VDC Caution: Use Non-metallic adjusting tool. As legs of pot

+12VDC
1 2 3 4 5 6 7 8 9 10 11
G V V + + - C C C + +
R A A 12 24 12 O O O 5 5
U D D D M M M D D
N C C C O O O C C
D N N N
FSB XXX Page 4 of 5

+12VDC
-12VDC
+24VDC
Deltron Power supply
+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.
1 2 3 4 5 6 7 8 9 10 11
G V V + - + C C C + +
R A A 12 12 24 O O O 5 5
U D D D M M M D D
N C C C O O O C C
D N N N
Fan Common
5VDC
Ground
-12VDC
12VDC
Common
120 VAC
24VDC
Ultimax 3 DC Power Supply. "REV A & B"


5V Adj
+24 V Adj
+-12V Adj
Ultimax 3 DC Power Supply. "REV C"

Hurco Part number
413-0008-013

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:
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.
Battery Select
0 = OPEN
Brd 1
thru 4
S1
Configurations
6 5 4 3 2 1 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 # Switch Position

6 5 4 3
#1 1 1 1 1
#2 0 1 1 1
#3 1 1 1 1 Jumper E1 to E2
#4 0 1 1 1 Jumper E1 to E2
B. 256K MEMORY BOARD 415-0168-002
NOTE: 1= CLOSED = ON
O= OPEN = OFF
SWITCH # FUNCTION
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 # SETTINGS
SW1 1 THRU 4 = CLOSED

SW2 1 THRU 5, 7, 8 = CLOSED; 6= OPEN
SW9 1 THRU 4 = CLOSED
SW7 #1 CLOSED BATTERY 1 IN CIRCUIT
SW7 #4 CLOSED HARDWARE WRITE PROTECTED
SW7 #5 OPEN +5V FROM BUS DISABLED
SW7 #6 CLOSED BATTERY VOLTAGE TO RAM
COMMON WIRE JUMPERS (256K BOARDS)
WIRE JUMPER FUNCTION
REMOVE E28 TO E 27 DISABLES INTIALIZATION GEN. BY +5 MONT

REMOVE E24 TO E35 NEEDED FOR 16 BIT OPERATION
INSTALL E31 TO E32 NEEDED FOR 16 BIT OPERATION
INSTALL E29 TO E30 NEEDED FOR 16 BIT OPERATION
INSTALL E21 TO E22 XACK DELAY AT 310 NSEC
SWITCH SETTINGS TO MAKE PER BOARD
FIRST 256K (MEMORY PCB #1) 0-3FFFF TOTAL
SW3 SW4 SW5 SW6

1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
0 0 0 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 1 0 1 1
SECOND 256K (MEMORY PCB #2) 4000-7FFFF
SW3 SW4 SW5 SW6

1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
0 0 0 1 0 1 1 1 1 1 0 1 0 0 0 0 0 1 1 1 1 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 3 4
1,2 AND 3 OPEN
4 CLOSED On
LEADSCREW ERROR IS COMPENSATED OVER 20". Off

SIGN BIT IN BACKLASH USED IN BMC 20-50 MACHINES ONLY.
S2 S3
MSB LSB MSB LSB
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Sign Bit Scale/Encoder

On = Shorten Travel On = Rotary Encoder
Off = Lengthen Travel Off = Scale
Y axis Leadscrew Comp. Y axis Backlash Comp.
S4 S5
MSB LSB MSB LSB
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

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
4 CLOSED On
LEADSCREW ERROR IS COMPENSATED OVER 20". Off
S2 On HSS On=Shot pin enabled S3 With 1 turned On 8-4 speeds up dwell.

Off LSS Off = Shot pin disabled 1 turned Off 8-4 Slows down dwell.
LSB
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Orient Speed Mill type
Adjust On=MD3 8=LSB 4=MSB with a
Off=MD1 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 S5
MSB LSB MSB LSB
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
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 : 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"
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 1 2 3 4 5 6 7 8
Not used
IT TO PINS 4 AND 9. REMOVE THE JUMPER ON
TB7 AND INSTALL IT TO PIN 12 ONLY. Spindle Type
CHANGE THE PART NUMBER FROM 415-0177- On = Hss
Off= Standard
001 TO 415-0177-002.
Tool Changer
On = Enabled
Off = Disabled
Machine Pos:1 Pos:2 Pos:3 Pos:4

Auto Spindle MD1 0 0 0 0
MD3 1 0 0 0
MD1 Manual Spindle 0 0 0 1
Training Console 1 1 1 1
BMC 10 0 1 0 0
BMC 10 L 1 1 0 0
BMC 15 0 0 1 0
BMC 10N 1 0 1 0
BMc 10NL 0 1 1 0
KM3 Auto Spindle Speed 1 0 0 1
KM3P Auto Spindle Speed 0 1 0 1
KMC3P 0 0 1 1
Note: To turn off the KM3 1 0 1 1
Auto Spindle for a KM3P Manual Spindle 0 1 1 1
KM3P reverse pos#
Language Pos Pos Pos S2

Not used
English 0 0 0
German 1 0 0
French 0 1 0
Spanish 1 1 1 1 2 3 4 5 6 7 8 Not used
3 on S1
B Axis Select
A Axis Select On = Present
On = Present Off=Disable
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
Normal / Local Mode

1 2 3 4 5 6 7 8 On =Normal
Off = Local or Test mode
50/60 Hz On = 60 Hz
Off = 50 Hz
1,2&3 OFF Not used
Baud rate 9600
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 4 5 6 7 8 Memory
SW1 1 1 1 1 1 1 1 1 BLOCK A LO = $00000
SW2 1 1 0 1 1 1 1 1 BLOCK B LO = $40000
SW3 0 0 1 1 1 1 1 1 BLOCK A HI = $3FFFF
SW4 0 0 0 0 1 1 1 1 BLOCK B HI = $FFFFF
H: CONTROL RELAY PANEL

SW1
Frame type S1 S2 ATC type S3 S4
BMC 30 0 0 20 Station 0 0
SW2 SW3
Spindle Speed S1 S2 ATC Solenoid type S1 Spindle Clutch S2
4000 RPM 0 0 Single ended 0 Enable 0
6000 RPM 0 1 Double ended 1 Disable 1
10000 RPM 1 0
3000 RPM 1 1
SW4 ATC Enable/Disable

Rotary Axis Resolution Up Enabled
4000 Ticks/Degree 0 Center Disabled
2000 Ticks/Degree 1 Down Enable
SUBJECT: LUBRICATION PROBLEMS SUPERSEDES NUMBER: 271
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:
SUBJECT: CRTs SHORTING OUT SUPERSEDES NUMBER: 275
PRODUCT LINE: ULTIMAX ONE CONTROLS 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.

REVISED BY:
SUBJECT: ENCODER DAMAGE DUE TO COUPLING SUPERSEDES NUMBER: 2 76
PRODUCT LINE: ALL MILLS WITH ENCODER COUPLINGS PAGE 1 OF 1
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:
SUBJECT: HEIDENHEIN 3P BOARDS SUPERSEDES NUMBER: 287/286
PRODUCT LINE: MBX2 MB3 MD3 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.
2. REMOVE THE ELECTRICAL PANEL.
3. REMOVE THE ENCLOSURE FROM THE WALL OF THE POWER CABINET.
4. USING THE ELECTRICAL PANEL AS A TEMPLATE DRILL FOUR HOLES IN

THE BACK OF THE ENCLOSURE FOR THE FOUR HOLES IN THE MOTHER
BOARD.
5. REMOUNT THE MOTHER BOARD TO THE BACK OF THE ENCLOSURE USING

SCREWS AND STANDOFFS FROM 1 ABOVE.
6. 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 DESCRIPTION DIMENSIONS

415-0152-001 OLD X5 BOARD 2. 5" X 2. 75"
415-0152-002 NEV X 5 BOARD 2. 5" X 2. 87"
ORIGINATOR: R.J JOHNSON

REVISED BY:
SUBJECT: PARAJUST MAINTENANCE SUPERSEDES NUMBER: 290
PRODUCT LINE: ANY MILLS WITH PARAJUST 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.

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.
SUBJECT: GROUND FAULT ON HURCO AMPS SUPERSEDES NUMBER: 292
PRODUCT LINE: ANY MILL USING HURCO AMPS 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:
SUBJECT: FRL PLASTIC BOWLS CRACKING SUPERSEDES NUMBER: 293
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 CRESOL METHYLENE SALICYLATE

ACETIC ACID (CONC.) CYCLOHEXANOL MILK OF LIME (CaOH)
ACETONE CYCLQHEXANONE NITRIC ACID (CONC.)
ACRYLONITRILE CYCLOHEXNE NITEOBENZENE
AMMONIA DIMETHLY FORMANIDE NITROCELLULOSE LACQUER
AMMONIUM FLUORIDE DIOXANE PHENOL
AMMONIUM HYDROXIDE ETHANE TETRACHLORIDE PHOSPHOROUS HYDROXY CHLORIDE
AMMONIUM SULFIDE ETHYL ACETATE PHOSPHOROUS TRICHLORIDE

REVISED BY:
ANTIFREEZE ETHYL ETHER PROPIONIC ACID
BE]BENZENE ETHLAMINE PYRIDINE
BENZOIC ACID ETHYLENE CHLOROHYRIN SODIUM HYDROXIDE
BENZYL ALCOHOL ETHLENE DICHLORIDE SODIUM SULFIDE
BRAKE FLUIDS ETHYLENE GLYCOL STRENE
BROMOBENZENE FORMIC ACID (CONC.,) SULFURIC ACID (CONC.)
BUTYRIC ACID FREON SULPHURAL CHLORIDE
CARBOLIC ACID GASOLINE TANNERGAS
CARBON DISULFIDE HYDRAZINE
TERAHYDRONAPHTHALENE
CARBON TETRACHLORIDE HYDROCHLORIC ACID THIOPHENE
CAUSTIC POTASH SOLUTION LACQUER THINNER TOLUENE
CAUSTIC SODA SOLUTION METHYL ALCOHOL TURPENTINE
CHLORBENZENE METHYLENE CHLORIDE XYLENE
CHLOROFORM PERCHLORETHYLENE
TRADE NAMES OP SOME COMPRESSOR, OILS RUBBER COMPOUNDS AND OTHER

MATERIALS THAT WILL ATTACK POLYCARBONATE PLASTIC BOWLS:
ATLAS "PERMA GUARD" PARCO 4' 1306 NEOPRENE

BUNA N PETRON PD287
CELLULUBE 4150 AND 4220 PRESTONE
CRYLEX t5 CEMENT PYDRAUL AC
EASTMAN 910 SEARS REGULAR MOTOR OIL
GARLOCK # 98403 SINCLAIR OIL "LILY WHITE"
HASKEL 4568 023 SOME LOCTITE COMPOUNDS
HILGARD CO,'S HIL PHENE STAUFFER CHEMICAL FYRQUEL #150
HOUGHTON 5 CO, OIL 0 1120, 1130,1055 STILLMAN 4SR 269 75
HOUTOSAFE 1000 STILLMAN OSR513 70
KANO KROIL
KEYSTONE PENETRATING OIL #2 TELAR
MARVEL MYSTERY OIL TENNECO ANDER #495 AND #'500 OILS
MINN. RUBBER 366Y TITON
NATIONAL COMPOUND #N11 ZEREX
NYLOCK VC 3
DATE: JANUARY 14, 19S6 ISSUE NUMBER: 1074
SUBJECT: OPERATION OF LUBE SYSTEMS SUPERSEDES NUMBER: 296
PRODUCT LINE: ALL MILLS USING AUTOLUBE 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:
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:
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.

SUBJECT: ATC ERROR, CAROUSEL SUPERSEDES NUMBER: 301
PRODUCT LINE: BMC-15 MILLS 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:

REVISED BY:
SUBJECT: INDEX OPTION ULTIMAX SUPERSEDES NUMBER: 303
PRODUCT LINE: KM3 KM3P PAGE 1 OF 1
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 ISSUE NUMBER: 1077
SUBJECT: HI-LO GEAR SWITCH PROBLEM SUPERSEDES NUMBER:
PRODUCT LINE: MD3-BMC15 PAGE 1 OF 1
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:
SUBJECT: MIS-WIRE OF RS232 PORTS SUPERCEDES NUMBER: 307
PRODUCT LINE: KM TYPE KNEEMILLS 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.

REVISED BY:
SUBJECT: MULTI-LOAD MASTERS ON CRT SUPERSEDES NUMBER: 3 06
PRODUCT LINE: BX MILLS 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.

REVISED BY:
SUBJECT: SPEED SENSE SWITCH WIRING SUPERSEDES NUMBER: 309 / 310
PRODUCT LIES: KMC3P 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 KMC-

3P 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:
SUBJECT: THREE PHASE POWER SERVICE SUPERSEDES NUMBER: 314
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
SUBJECT: MOTOR COVER SUPERSEDES NUMBER: 315
PRODUCT LINE: KM3P, KMC3P 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.

REVISED BY:
SUBJECT: INPUT VOLTAGE AND AIR PRESSURE SUPERSEDES NUMBER: 317
ORIGINATOR: DAVID PRICE

SUBJECT: MISSING SURGE SUPPRESSORS SUPERSEDES NUMBER: 320
PRODUCT LINE: BMC 10 THRU 15 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:
SUBJECT: MIS-WIRE ON KM3 BX TYPE MILLS SUPERSEDES NUMBER: 322
PRODUCT LINE: KM3 BX TYPE 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 DESCRIPTION QUANTITY

406-4005-003 GREEN /' YELLOW WAGO TERMINAL 1
406-2005-029 16 AWG WHITE WIRE 18"
406-6481-004 SHRINK SLEEVE 1/'4" 3"
406-6481-006 SHRINK SLEEVE 1/'2" 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):
SUBJECT: AXIS DRIVE BELT TENSION SUPERSEDES NUMBER: 336
PRODUCT LINE: BMC MILLS PAGE 1 OF 1
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:
SUBJECT: USING DISTRIBUTOR STOCK PARTS SUPERSEDES NUMBER: 349
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:
SUBJECT: TAPE READER PROBLEMS SUPERSEDES NUMBER: 357
PRODUCT LINE: TM5 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 407-0035-
441. )
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 ISSUE NUMBER: 1089
SUBJECT: RANDTRONICS CHASSIS WIRING SUPERSEDES NUMBER: 358
PRODUCT LINE: Mills 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:
SUBJECT: CHIP CONVEYOR MOTOR HEATER SUPERSEDES NUMBER: 364
PRODUCT LINE: BMC 15 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.

REVISED BY:
SUBJECT: TOOL CHANGE LIMIT SWITCH SUPERSEDES NUMBER: 365
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.
1 108-5003-003 M5 X.OBX10 BHSS

2 110-0061-004 #10 EXTERNAL STAR WASHER
3 408-7501-009 #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:
SUBJECT: ULTIMAX LOCKUP SUPERSEDES NUMBER: 366
PRODUCT LINE: ULTIMAX MILLS PAGE 1 OF 1
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
SUBJECT: TOOL CHANGERS SUPERSEDES NUMBER: 367
PRODUCT LINE: MD1 MD3 PAGE 1 OF 1
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:
SUBJECT: SERVOMATE TRANSFORMER MIS-WIRED SUPERSEDES NUMBER: 368
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 ISSUE NUMBER: 1095
SUBJECT: BX Miscounting On Knee Mills SUPERCEDES NUMBER: 369
PRODUCT LINE: BX Kneemills PAGE 1 OF 1
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:
SUBJECT: Deltron Power Supplies SUPERSEDES NUMBER: 374
PRODUCT LINE: All ULTIMAX MILLS 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.

SUBJECT: Custom CPU / Memory PCB SUPERCEDES NUMBER: 377
PRODUCT LINE: All Ultimax Mills 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 ISSUE NUMBER: 1098
SUBJECT: Solenoid Exhaust Filters SUPERCEDES NUMBER: 376
PRODUCT LINE: MB3, MD3, BMC10, BMC15 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 ISSUE NUMBER: 1099
SUBJECT: BMC 10 and 10L Tool Support SUPERSEDES NUMBER: 379
PRODUCT LINE: BMC10, BMC10L PAGE 1 OF 2
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 Description Part Number
1 MD3 Steel Tool Support 713-0006-005
2 Roll Pin, 2 X 8 713-0008-313
If you should find this condition on a BMC10 machine in the field, you
need to order the following retrofit kit.
Qty Description Part Number

1 BMC10 Tool Support Repair Kit 002-3133-001
This kit includes:
24 Tool Support Repair Plate 802-2118-001

48 M3 X .5 X 10MM FHSCS 102-5001-003
48 M3 X .5 Std. Hex Nut 117-5009-001
48 M3 Int Teeth Lockwasher 110-0067-004
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 ISSUE NUMBER: 1099
SUBJECT: BMC 10 and 10L Tool Support SUPERSEDES NUMBER:
PRODUCT LINE: BNC10, BMC10L PAGE 2 OF 2
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 ISSUE NUMBER: 1100 A
SUBJECT: AXIS AMPERAGE SUPERSEDES NUMBER: 1100 & 1144
PRODUCT LINE: BMC 20 / 50 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.

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 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.
2 Connect negative lead to CH3.
3 Set meter for VAC.
4 Jog the axis at 100 IPM.
5 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.
6 The axis being checked should be run full travel in both directions.
Note The lowest and highest readings seen.
BMC 20 BMC 20 LR BMC 25/30 BMC 40/50

X axis 2.5 to 3.5 1 to 2 2 to 4 3 to 5
Y axis 2.5 to 3.5 1 to 2 2 to 4 3 to 5
Z+ axis 4 to 5 2 to 3 2 to 4 4 to 6
Z- axis 3 to 4 1 to 2 1 to 2 2 to 4
YASKAWA AXIS CURRENT CHECKS
1. Check Axis Setup per Eng Doc # 757-4001-092. Check all axis.
2. 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.
3. Divide the meter reading by the appropriate value listed below.
1 amp on aBMC 20 = .789 BMC 20 LR / 25 / 30=.484 VDC BMC 40/50=.200 VDC

Acceptable values are:
BMC 20: X&Y= 2.5-3.5 A 1.973 - 2.762 VDC BMC 20LR: X&Y= 1-2 A 0.484 - 0.968 VDC
BMC 20: +Z= 4-5 A 3.156 - 3.945 VDC BMC 20LR: +Z= 2-3 A 0.968 - 1.936 VDC
BMC 20: -Z= 3-4 A 2.367 - 3.156 VDC BMC 20LR: -Z= 1-2 A 0.484 - 0.968 VDC
BMC 25/30 X&Y= 2-4 A 0.968 - 1.936 VDC BMC 40/50 X&Y= 3 - 5 A 0.6 - 1.0 VDC
BMC 25/30 +Z= 2-4 A 0.968 - 1.936 VDC BMC 40/50 +Z = 4 - 6 A 0.8 - 1.2 VDC
BMC 25/30 -Z= 1-2 A 0.484 - 0.968 VDC BMC 40/50 -Z = 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

SUBJECT: Z AXIS BOUNCING AT LIMIT SWITCH SUPERSEDES NUMBER: 385
PRODUCT LINE: TM5 PAGE 1 OF 1
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:
SUBJECT: Knee Mill Bearing Locknut SUPERCEDES NUMBER: 387
PRODUCT LINE: KM3, KM3P, KMC3, KMC3P 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 ISSUE NUMBER: 1103
SUBJECT: New MAX2 RS232 Harness SUPERSEDES NUMBER: 369
PRODUCT LINE: All MAX2 Controls 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
SUBJECT: MD3 SOFTWARE FOR YASKAWA. DRIVE SUPERSEDES NUMBER: 396
PRODUCT LINE: MD3 MILLS 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)

SUBJECT: ORIENT PROBLEM WITH SUPERSEDES NUMBER: 396

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.

REVISED BY:
SUBJECT: BALL CHUCK REPLACEMENT SUPERSEDES NUMBER: 399
PRODUCT LINE: KM3CP 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:
SUBJECT: BMC Auto Lube Wiring SUPERSEDES NUMBER: 400B
PRODUCT LINE: BMC 20-50 (OEM) 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.
CLEAR / SHIELD from T25 to Lube -3.
BLACK from T26 to Lube -4.
BMC 30 50

YELLOW / GREEN from MECCA ground to Case Ground of the lube pump.
with 10MA control (schematic 002-3210-004)
BLACK f2 from Rly 9-6 to Lube -2.
with OMA control (schematic 002-3210-006)
BLACK #2 from Rly 8-6 to Lube -2.
with HURCO 24VDC pneumatic (schematic 002-3210-055)
CLEAR/SHIELD from T25 to Lube -3.
BLACK from T24 to Lube -4.

REVISED BY: Wayne E. Hawkins
SUBJECT: INSTALLATION OF THRUST BEARING'S SUPERSEDES NUMBER: 391A
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
SUBJECT: Nonvolatile CPU / Memory PCB SUPERSEDES NUMBER: 401
PRODUCT LINE: Ultimax I Mills 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.
SUBJECT: Nonvolatile CPU / Memory PCB 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.
SUBJECT: Tool Change Height and 06F SUPERSEDES NUMBER: 404
PRODUCT LINE: BMC 30, 40, 50 MAX1 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.

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.
SUBJECT: DRAW BAR ADJUSTMENT SUPERSEDES NUMBER: 407A
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 ISSUE NUMBER 1112
SUBJECT: CLUTCH NOISE SUPERSEDES NUMBER: 411
PRODUCT LINE: BMC MILLS WITH 2 SPEED BOX PAGE 1 OF 1
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 Randall Bryant

Service Engineer Technical Specialist BMC
SUBJECT: GIB WEAR SUPERSEDES NUMBER: 412
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 Lube pump

713-0020-102 T junction
713-0020-551 Flex hose

REVISED BY:
DATE: DECEMBER. 12, 1988 ISSUE NUMBER: 1114
SUBJECT: X AXIS BED CAP SUPERSEDES NUMBER: 416
PRODUCT LINE: KM3P PAGE 1 OF 1
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 ISSUE NUMBER: 1115
SUBJECT: CONTROL RELAY PANEL PCB SUPERSEDES NUMBER: 416
PRODUCT LINE: BMC 20-50/' FP3A/4A MAX 2 PAGE 1 OF 1
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 OPTO-
COUPLER, 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.

REVISED BY:
SUBJECT: Deltron Power Supply SUPERSEDES NUMBER: 419
PRODUCT LINE: All Mills PAGE 1 OF 1
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 OHM 100 WATT

12 VOLTS ---> 3.3 OHM 48 WATT
24 VOLTS ---> 8 OHM 72 WATT
ORIGINATOR: MIKE GARLICK

REVISED BY:
DATE: January 16, 1989 ISSUE NUMBER: 1117
SUBJECT: GROUNDING IN CONTROL CONSOLE SUPERSEDES NUMBER: 422
PRODUCT LINE: ALL ULTIMAX MILLS 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:
SUBJECT: RS232 CABLE SUPERSEDES NUMBER: 422
PRODUCT LINE: MILLS 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.

REVISED BY:
SUBJECT: PARAJUST A BRAKING BOARDS SUPERSEDES NUMBER: 417
PRODUCT LINE: ALL MILLS WITH PARAJUST A PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: MIS-WIRE OF YASKAWA SUPERSEDES NUMBER: 413

RETROFIT
PRODUCT LINE: MB2 MB3 PAGE 1 OF 1
DURING TWO MB2 YASKAWA RETROFITS, WE FOUND THAT A MISTAKE WAS

MADE ON THE INTERNAL WIRING OF THE YASKAWA. THE 1 K OHM RESISTOR
FEEDING THE 100 OHM LOW AND HIGH GEAR ORIENT POTS WERE PARALLEL
SOLDERED ON THE 5V FEED WIRE BUT THE WIRE WAS NOT CUT OUT (FIGURE 1)
WHEN INSTALLING THE MB2 / 3 RETROFITS THIS SHOULD BE CHECK AND THE
WIRE CUT OUT AS SHOWN IN FIGURE 2.
ALSO ON ANY SERVICE CALL CHECK THIS RESISTOR TO MAKE SURE THE
RESISTOR IS WIRED IN RIGHT.
THIS WILL GIVE FULL ADJUSTMENT POTENTIAL TO THE ORIENT POTS. IF YOU
HAVE MADE THIS RETROFIT AND HARD TIME ADJUSTING THESE POTS THIS MAY
HAVE BEEN YOUR PROBLEM, PLEASE ADVISE YOUR REGIONAL MANAGER IF YOU
RECALL ANY YASKAWA INSTALLS WHERE THIS WAS A PROBLEM. FOLLOW UP
WILL BE REQUIRED.

REVISED BY:
SUBJECT: SPINDLE MOTOR OVERLOAD SUPERSEDES NUMBER: 406
PRODUCT LINE: KM3 AND KM3P PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: INDUSTRIAL DRIVES GROUNDING SUPERSEDES NUMBER: 421A
PRODUCT LINE: DECKEL FP3A/'4A 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:
SUBJECT: ORIENTATION SENSOR REPLACEMENT SUPERSEDES NUMBER: 424
PRODUCT LINE: BMC 20-50 PAGE 1 OF 3
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.

SUBJECT: INDUSTRIAL DRIVE SUPERSEDES NUMBER: 415
PRODUCT LINE: DECKEL FP3A, FP4A 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.

SUBJECT: PROBLEMS CAUSED BY VIBRATION IN SUPERSEDES NUMBER: 402

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.

REVISED BY:
SUBJECT: FERRITE BEADS AND TRANSIENT SUPERSEDES NUMBER:

VOLTAGE PROTECTORS
PRODUCT LINE: ALL PRODUCT 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 TIE-
WRAP. 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.
SUBJECT: BMC TOOL MAGAZINE JAMMING SUPERSEDES NUMBER:
PRODUCT LINE: BMC 40/50 PAGE 1 OF 3
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.

SUBJECT: Leadscrew Mapping 7.24 SUPERSEDES NUMBER:

BMC 20\30\40\50 only
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
SUBJECT: CHIP DOOR INTERLOCK 7.24 SOFTWARE SUPERSEDES NUMBER:
PRODUCT LINE: BMC-20/30/40/50 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:
SUBJECT: TAPPING T1 TRANSFORMER SUPERSEDES NUMBER

(STAND ALONE)
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:
SUBJECT: MAGAZINE JAMMED ERROR SUPERSEDES NUMBER:
PRODUCT LINK: BMC-20/30/40/50 PAGE 1 OF 1
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:
SUBJECT: BIJUR LUBE PUMP ADJUSTMENT SUPERSEDES NUMBER:
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.

REVISED BY:
SUBJECT: MAX 2 MEMORY BOARDS SUPERSEDES NUMBER:
PRODUCT LINE: ALL MAX 2 MILLS 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.

REVISED BY:
DATE: 8-18-89 ISSUE NUMBER: 1134
SUBJECT: SHAFT MOUNT ENCODERS SUPERSEDES NUMBER:
PRODUCT LINE: ALL 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:
SUBJECT: Spindle Firmware SUPERSEDES NUMBER:
PRODUCT LINE: MD3 with Yaskawa Spindle Drive 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 450-3001-
501 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 ON = SLOWER OFF = FASTER

2 MOST SIGNIFICANT BIT
3 SPEED ADJUSTMENT
4 SPEED ADJUSTMENT
5 LEAST SIGNIFICANT BIT
6 NOT USED
7 ON = SHOT PIN ENABLED OFF SHOT PIN DISABLED
8 ON = MD3 MACHINE TYPE OFF OFF = MD1 MACHINE TYPE
SWITCH BLOCK 3: HIGH GEAR SPEED ADJUSTMENT

POSITION (S2 on D/A2 )
1 ON = SLOWER OFF = FASTER

2 MOST SIGNIFICANT BIT
3 SPEED ADJUSTMENT
4 SPEED ADJUSTMENT
5. LEAST SIGNIFICANT BIT
6 NOT USED
7 NOT USED
8 NOT USED
ORIGINATOR: K. PERKINS
REVISED BY:
DATE: Auqust 11, 1989 ISSUE NUMBER: ll36
SUBJECT: Yaskawa Spindle Drive Retrofit Kits SUPERSEDES NUMBER:
PRODUCT LINE: MD3, MB2/3 (002-2060-001i002) 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.
SUBJECT: Z AXIS LUBRICATION LINES SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20 V2 PAGE 1 OF 2
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. METER UNIT 713-0020-093

2. .2 COMPRESSION SLEEVES 713-0020-098
3. 1 TUBE CLIP 713-0021-268
4. .10" 4MM TUBING 713-0021-269
5. COMPRESSION NIPPLE 713-0020-099
6. COMPRESSION NUT 713-0020-097
ORIGINATOR: BROCK REXING

RANDALL BRYANT
REVISED BY:
DATE: December 12, 1993 ISSUE NUMBER: 1138-A
SUBJECT: Floppy Disk Drives, Max2/32/3 SUPERSEDES NUMBER: 1138
PRODUCT LINE: All Ultimax Controls 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.

REVISED BY: Brock Rexing
FSB 1138-A Page 2 of 6
SIZE DRAWING SHT. REV.
1 PROPRIETARY INFORMATION
C 002-3303-005 OF
1 B 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.
FRONT SIDE
1 802-2300-039 ADAPTER PLATE, DISK DRIVE 4

4 101-0001-003 4-40 X 1/2 SHCS 3
4 110-0002-022 WASHER #4 2
1 426-0056-003 DISK DRIVE, 3.5" FLOPPY, 1" BEZEL, CFG#2 1
BOTTOM
QTY. PART NUMBER ITEM DESCRIPTION ITEM
PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
ALL DIMENSIONS HURCO MANUFACTURING COMPANY, INC.
HURCO
IN INCHES
TOLERANCE INDIANAPOLIS, IN U.S.A.
R
DECIMAL
.0 .0300
HEAT TREATMENT .00 .0150 DESCRIPTION
~
.000 .0050
.0000 .0005 ASSY, 3.5 INCH FLOPPY DRIVE RETROFIT KIT
ANGULAR 0ANGULAR 30' DRAWN DATE CHECKED DATE APPROVED DATE
BREAK ALL
17 SHARP EDGES F. GROSS 23JAN89
B 10378 ITEM 1 WAS 426-0056-002 FWG AUG
89
FIRST USED ON THIRD ANGLE SCALE SIZE DRAWING SHT. REV.
1.25=1 1
C B
23 PROJECTION
CN A 10072 RELEASE FWG JAN
REV P.I.N. REVISION DESCRIPTION
89
REV DATE CHK DATE APPD DATE DF DISK OPTION UNIT OF MEAS. 002-3303-005 OF
1
127 NO. BY BY BY PC
SIZE DRAWING SHT.
REV.
D 426-0056-003 OF
1 A INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR
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
BACK
RY
DC
D1
D0
FG
TOP
SIDE
SHUNT CONFIGURATION SWITCH CONFIGURATION

DRIVE A DRIVE B DRIVE A DRIVE B
MS MS
IR IR
RY RY
DC DC
3 2 1 0 3 2 1 0
D1 D1
D0 D0
1 426-0056-903 DISK DRIVE, 3.5" FLOPPY, 1" BEZEL, PINOUT #2 1

PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
ALL DIMENSIONS
HURCO HURCO MANUFACTURING COMPANY, INC.
IN INCHES
TOLERANCE
INDIANAPOLIS, IN U.S.A.
R
DECIMAL
.0 .0300
~
.000 .0050
.0000 .0005 3.5" MICROFLOPPY DISK DRIVE, 1" BEZEL
ANGULAR 0ANGULAR 30'DRAWN DATE CHECKED DATE APPROVED DATE
BREAK ALL
SHARP EDGES F. GROSS 25JAN89
1.25=1 1
D
17 PROJECTION
CN
129
A 10378 REL.
REV P.I.N.
NO.
REVISION DESCRIPTION
FWG AUG
89
REV DATE CHK DATE APPD DATE DF
BY BY BY
HURCO,DECKEL UNIT OF MEAS.
EA.
426-0056-002 OF
1 A
SIZE DRAWING SHT.
REV.
1 PROPRRIETARY INFORMATION
D 426-0056-001 OF
MODEL FD1036A NEC MODEL FD1036A NEC MODEL FD1036A NEC
P/N 134-500105-004-0 P/N 134-500105-004-0 P/N 134-500105-004-0 MODEL FD1037A NEC

FACTORY DEFAULT CONFIGURED DRIVE 0 CONFIGURED DRIVE 1 P/N 134-500474-954-0
TOP
SIGNAL PINOUT
PIN 1
PIN 2

BACK
P/N 134-500105-012-0 P/N 134-500105-012-0 P/N 134-500105-012-0
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
1 426-0056-901 DISK DRIVE, 3.5" FLOPPY, 1.25" BEZEL 1

PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
ALL DIMENSIONS
IN INCHES
R
DECIMAL
.0 .0300
~
.000 .0050
.0000 .0005 3.5" MICROFLOPPY DISK DRIVE
BREAK ALL
SHARP EDGES FWG 17AUG89
FULL 1
D A
PROJECTION
CN A 10378 ORIG. ISSUE FWG
17
AUG
89
UNIT OF MEAS. 426-0056-001 OF
1
130 REV P.I.N.
NO.
REVISION DESCRIPTION REV DATE CHK DATE APPD DATE DF
BY BY BY
SIZE DRAWING SHT.
REV.
D 426-0056-002 OF
NEC FD1037A-154
1.000
FRONT
4.000 BACK

SWITCH CONFIGURATION
DRIVE A DRIVE B
SIGNAL PINOUT
PIN 2
PIN 1
1 2 3 4 1 2 3 4

PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
ALL DIMENSIONS
IN INCHES
R
DECIMAL
.0 .0300
HEAT TREATMENT
.00 .0150 DESCRIPTION
~
.000 .0050
.0000 .0005 DISK DRIVE, 3.5" FLOPPY, 1" BEZEL, PINOUT #1
BREAK ALL
SHARP EDGES F. GROSS 17AUG89
1.25=1 1
D
17 PROJECTION
CN
131
A 10378 RELEASE
REV P.I.N.
NO.
FWG AUG
89
REV DATE CHK DATE APPD DATE
BY BY BY
DF
EA.
426-0056-002 OF
1 A
SIZE DRAWING SHT.
REV.
D 426-0056-007 OF
1
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR
Teac FD 235HF-201
Teac FD 235HF-3201 /S
Teac FD-235HF-4429
G E
F D
E C
D B
C A
B 2 1
A
4 3 2 1
NOTES:
Teac FD-235HF-5429
Jumper configuration for various HD Floppy Drives
used on Ultimax 3 and Max32
DS
0 1
SURFACE TREATMENT
EXCEPT AS NOTED:
~
ALL DIMENSIONS
IN INCHES
R
DECIMAL
.0 .0300
HEAT TREATMENT
~
.000 .0050
.0000 .0005 1.44 HD FLOPPY DRIVE CONFIGURATION
BREAK ALL
SHARP EDGES B.R.R. 12/8/93
FIRST USED ON SCALE SIZE DRAWING SHT. REV.
CN Ultimax 3
THIRD ANGLE
NONE 1
D
PROJECTION
A XXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X XX/XX
X
XXXX-X XX
Max 32 UNIT OF MEAS. 426-0056-007 OF

REV P.I.N.
NO.
BY BY BY PC 1
DATE: August 3, 1994 ISSUE NUMBER: 1138-B
SUBJECT: Floppy Disk Drives, Max2/32/3 SUPERSEDES NUMBER: 1138
PRODUCT LINE: All Ultimax Controls 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.

FSB 1138-A Page2 of 6
C 002-3303-005 OF
1 B INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR
FRONT SIDE
1 802-2300-039 ADAPTER PLATE, DISK DRIVE 4

4 101-0001-003 4-40 X 1/2 SHCS 3
4 110-0002-022 WASHER #4 2
1 426-0056-003 DISK DRIVE, 3.5" FLOPPY, 1" BEZEL, CFG#2 1
BOTTOM
PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
HURCO
IN INCHES
R
DECIMAL
.0 .0300
~
.000 .0050
.0000 .0005 ASSY, 3.5 INCH FLOPPY DRIVE RETROFIT KIT
BREAK ALL
17 SHARP EDGES F. GROSS 23JAN89
B 10378 ITEM 1 WAS 426-0056-002 FWG AUG
89
1.25=1 1
C B
23 PROJECTION
CN A 10072 RELEASE FWG JAN
89
REV DATE CHK DATE APPD DATE DF DISK OPTION UNIT OF MEAS. 002-3303-005 OF
1
127 NO. BY BY BY PC
SHT.
SIZE DRAWING REV.
D 426-0056-003 OF
1 A DISCLOSURE OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT
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 9 4 14 9 4
13 8 3 13 8 3
12 7 2 12 7 2
MS
IR
BACK
RY
DC
D1
11 11 6 1 1 11 11 6 1 1
D0
FG
TOP
SIDE
SHUNT CONFIGURATION SWITCH CONFIGURATION
DRIVE A DRIVE B DRIVE A DRIVE B
MS MS
IR IR
RY RY
DC DC
3 2 1 0 3 2 1 0
D1 D1
D0 D0

PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
ALL DIMENSIONS
~
IN INCHES
R
DECIMAL
.0 .0300
HEAT TREATMENT
.000 .0050
3.5" MICROFLOPPY DISK DRIVE, 1" BEZEL
~
.0000 .0005
ANGULAR 030'
DRAWN DATE CHECKED DATE APPROVED DATE
BREAK ALL
F. GROSS 25JAN89
SHARP EDGES
THIRD ANGLE
17 PROJECTION 1.25=1 1
CN A 10378 REL.
D
FWGAUG
129 REV P.I.N.

NO.
89
REV DATE CHK DATE APPDDATE
BY BY BY
DF HURCO,DECKEL
UNIT OF MEAS.
EA.
426-0056-002 OF
1 A
SIZE DRAWING SHT.
REV.
1 PROPRRIETARY INFORMATION
D 426-0056-001 OF
P/N 134-500105-004-0 P/N 134-500105-004-0 P/N 134-500105-004-0 MODEL FD1037A NEC

FACTORY DEFAULT CONFIGURED DRIVE 0 CONFIGURED DRIVE 1 P/N 134-500474-954-0
TOP
SIGNAL PINOUT
PIN 1
PIN 2

BACK
P/N 134-500105-012-0 P/N 134-500105-012-0 P/N 134-500105-012-0
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
1 426-0056-901 DISK DRIVE, 3.5" FLOPPY, 1.25" BEZEL 1

PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
ALL DIMENSIONS
IN INCHES
R
DECIMAL
.0 .0300
~
.000 .0050
.0000 .0005 3.5" MICROFLOPPY DISK DRIVE
BREAK ALL
SHARP EDGES FWG 17AUG89
FULL 1
D A
PROJECTION
CN A 10378 ORIG. ISSUE FWG
17
AUG
89
UNIT OF MEAS. 426-0056-001 OF
1
130 REV P.I.N.
NO.
BY BY BY
SIZE DRAWING SHT.
REV.
D 426-0056-002 OF
NEC FD1037A-154
1.000
FRONT
4.000 BACK

SWITCH CONFIGURATION
DRIVE A DRIVE B
SIGNAL PINOUT
PIN 2
PIN 1
1 2 3 4 1 2 3 4

PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
ALL DIMENSIONS
IN INCHES
R
DECIMAL
.0 .0300
HEAT TREATMENT
~
.000 .0050
.0000 .0005 DISK DRIVE, 3.5" FLOPPY, 1" BEZEL, PINOUT #1
BREAK ALL
SHARP EDGES F. GROSS 17AUG89
1.25=1 1
D
17 PROJECTION
CN
131
A 10378 RELEASE
REV P.I.N.
NO.
FWG AUG
89
REV DATE CHK DATE APPD DATE
BY BY BY
DF
EA.
426-0056-002 OF
1 A
SIZE DRAWING SHT.
REV.
D 426-0056-007 OF
1
Teac FD 235HF-201
Teac FD 235HF-3201 /S
Teac FD-235HF-4429
G E
F D
E C
D B
C A
B 2 1
A
4 3 2 1
NOTES:
Teac FD-235HF-5429
Jumper configuration for various HD Floppy Drives
used on Ultimax 3 and Max32
DS
0 1
SURFACE TREATMENT
EXCEPT AS NOTED:
~
HURCO
IN INCHES
R
DECIMAL
.0 .0300
HEAT TREATMENT
~
.000 .0050
.0000 .0005 1.44 HD FLOPPY DRIVE CONFIGURATION
BREAK ALL
SHARP EDGES B.R.R. 12/8/93
CN THIRD ANGLE
PROJECTION NONE 1
X Ultimax 3
D
XX/XX
XXXX-X AXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X

XX
REV DATE CHK DATE APPD DATE DF Max 32 UNIT OF MEAS. 426-0056-007 OF
1
NO. BY BY BY PC
SUBJECT: Vertical head lube relay SUPERSEDES NUMBER:
PRODUCT LINE: FP3A/FP4A Ultimax 2 PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: Turcite damage SUPERSEDES NUMBER:
PRODUCT LINE: BMC. full enclosure machines 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.

REVISED BY:
SUBJECT: STRIKER PLATE HOLD-DOWN SCREWS SUPERSEDES NUMBER:
PRODUCT LINE: BMC-30 V1 ATC 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
PRODUCT LINE: MD3, MB3, MB2 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 704-
0001-364 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
SUBJECT: GROUND ON ULTIMAX SUPERSEDES NUMBER:

CONTROL CONSOLE
PRODUCT LINE: ALL ULTIMAX CONTROLS 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.

REVISED BY:
SUBJECT: Gib Adjustment SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20,30,40,50 V2 machine 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.

REVISED BY:
SUBJECT: Replacing Hurco Amps with SERVOMATE SUPERSEDES NUMBER:
PRODUCT LINE: Kmbx-1 Hmbx 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: Jog all axis to mid travel.
2: Power off, Remove the three Hurco amplifiers from the chassis.
3: 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 ISSUE NUMBER: 1146A
SUBJECT: Yaskawa Orient Modification SUPERSEDES NUMBER:1146
PRODUCT LINE: All V2-BMC Mills 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

REVISED BY:
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
SUBJECT: ATC STRIKER PLATE SUPERSEDES NUMBER:

HOLD-DOWN SCREWS
PRODUCT LINE: BMC 30 V1 ATC 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:
SUBJECT: TOOL CHANGER MAGAZINE SUPERCEDES NUMBER 1148

AIR CYLINDER SET SCREW
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

REVISED BY:
SUBJECT: CONTROL RESIDENT DIAGNOSTICS SUPERSEDES NUMBER:
PRODUCT LINE: ALL ULTIMAX II MILLS 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. Control Resident Diagnostics Manual 704-0001-545

2. RS-232 MIL Circle Test Connector 423-9000-001
3. RS-232 DB-25 Test Connector 423-9000-002
4. I/O Test Cable, MP/J1 to MP/J3 423-9000-003
5. Dual Axis Test Cable 423-9000-004
6. 25-pin Breakout Board 415-0196-001T
7. 37-oin Breakout Board 415-0197-001T
8. 50-pin Breakout Board 415-0198-001T
9. BMC 20-50 (VC) Axis Firmware 450-3001-vvv
10a. BMC 20-50 STD/GER Memory Board 415-0168-xxx
10b. BMC 20-50 STD/GER EPROM's 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.
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 XY DUAL AXIS PCB AB DUAL AXIS PCB
U45 Spindle Axis Y Axis B Axis

U48 Z Axis X 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

SUBJECT: 5 GALLON FLOOD FILTER SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20-50 V2 PAGE 1 OF 1
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:
SUBJECT: REPLACEMENT OF KNEE MILL MOTORS SUPERSEDES NUMBER: 405

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.

SUBJECT: CUSTOMER SUPPLY POWER SUPERSEDES NUMBER:

RELATED PROBLEMS
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

DATE: 11 January, 1990 ISSUE NUMBER: 1154
SUBJECT: DAC Offset PCB Failures SUPERSEDES NUMBER:
PRODUCT LINE: Dual Axis Board with DAC Offset PAGE 1 OF 1

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:
SUBJECT: COUNTER WEIGHT (UPPER) 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.
SUBJECT: NEW ISOLATION TRANSFORMER SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20-50 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 ISSUE NUMBER: 1157A
SUBJECT: CONSOLE CRT GROUNDING SUPERSEDES NUMBER: 1157
PRODUCT LINE: BMC20-50, MILLS, FP3A/4A 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
SUBJECT: Measuring Backlash SUPERSEDES NUMBER:
PRODUCT LINE: All Mills 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.

REVISED BY:
SUBJECT: Board Cleaning SUPERSEDES NUMBER:
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

REVISED BY:
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.
SUBJECT: New Field Service Accuracy Standard SUPERSEDES NUMBER:
PRODUCT LINE: All Mill 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.

REVISED BY:
SUBJECT: Oil Cooler Contactor Mis-wire SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30 Thru 50 IP 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 OCS-
6 (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 ISSUE NUMBER: 1162
SUBJECT: TORQUE SETTINGS FOR AXIS BEARINGS SUPERSEDES NUMBER:
PRODUCT LINE: ALL HURCO MILLS 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 ALL 45-50
MB-2, MB-3, MD-3,

BMC-10, BMC-30 ALL 65
BMC-15, BMC-40,
BMC-50 ALL 85-90
40 SLV ALL 55

REVISED BY:
DATE: 13 SEPTEMBER 1990 ISSUE NUMBER: 1163
SUBJECT: TOOL RETENTION FORCES SUPERSEDES NUMBER:
PRODUCT LINE: BMC MILLS PAGE 1 OF 2
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 3.91 Kn. 3. 6 Kn.
BMC-25 8.12 Kn. 7.3 Kn.
BMC-30 8.12 Kn. 7.3 Kn.
BMC-40 8. 12 Kn. 7.3 Kn.
BMC-50 13.7 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.

REVISED BY:
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.
SUBJECT: Service call check list SUPERSEDES NUMBER:
PRODUCT LINE: All Machines 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 ISSUE NUMBER: 1165-A
SUBJECT: Futaba Pulscale CMK Parameters SUPERSEDES NUMBER:1165
PRODUCT LINE: Eltee TRM21/39 EP300CP 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.

REVISED BY: Richard Arthur
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.
TRM21 TRM39 PARAMETER
SP# PARAMETERS PARAMETERS DESCRIPTION NOTES
00001001 X 00001001 X 00001000=.5um 00001100=10um
1 00001001 Y 00001001 Y SCALE RESOLUTION 00001001= 1um 00001101=25um
00001001 Z 00001001 Z 00001011= 5um 00001110=50um
2 0.000 0.000 REFERENCE POINT
SHIFT
4 0.000 0.000 EDGE SENSOR
SHIFT
5 0.000 0.000 LOST MOTION
COMPENSATION
+105.0000 X +148.250 X + SOFTWARE
6 +100.0000 Y +101.600 Y LIMITS MUST SET FOR EACH AXIS SCALE
+160.0000 Z +108.000 Z
-105.0000 X -148.250 X - SOFTWARE
7 -100.0000 Y -101.600 Y LIMITS MUST SET FOR EACH AXIS SCALE
-160.0000 Z -108.000 Z
00000000 X 00000000 X
30 00000000 Y 00000000 Y SCALE POLARITY NOTE Z POLARITY
00000001 Z 00000001 Z
31 00000000 00000000 SMOOTHING
34 00000000 00000000 PRINTER
INTERFACE
35 00100000 00100000 RS-232 BAUD
36 01111000 01111000 RS-232C MODE
01000010 X 01000010 X DIRECTION TO
37 00000000 Y 00000000 Y RETURN POINT DATA IS SET IN X AXIS
00000000 Z 00000000 Z
38 01001001 01001001 MODE/EDM DISPLAY
40 00000000 00000000 POWER LOSS
MEMORY
00000000 X 00000000 X INCH/MM 00000010= MM ONLY OPERATION
49 00000000 Y 00000000 Y OPERATION 00000000= INCH/MM OPERATION
00000000 Z 00000000 Z

DATE: March 3, 1992 ISSUE NUMBER: 1165-B
SUBJECT: Futaba Pulscale CMK Parameters SUPERSEDES NUMBER:1165 & 1165A
PRODUCT LINE: Eltee TRM21/39 EP300CP 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.

TRM21 TRM39 PARAMETER
SP# PARAMETERS PARAMETERS DESCRIPTION NOTES
00001001 X 00001001 X 00001000=.5um 00001100=10um
1 00001001 Y 00001001 Y SCALE RESOLUTION 00001001= 1um 00001101=25um
00001001 Z 00001001 Z 00001011= 5um 00001110=50um
2 0.000 0.000 REFERENCE POINT
SHIFT
4 0.000 0.000 EDGE SENSOR
SHIFT
5 0.000 0.000 LOST MOTION
COMPENSATION
+105.0000 X +148.250 X + SOFTWARE
6 +100.0000 Y +101.600 Y LIMITS MUST SET FOR EACH AXIS SCALE
+160.0000 Z +108.000 Z
-105.0000 X -148.250 X - SOFTWARE
7 -100.0000 Y -101.600 Y LIMITS MUST SET FOR EACH AXIS SCALE
-160.0000 Z -108.000 Z
00000000 X 00000000 X
30 00000000 Y 00000000 Y SCALE POLARITY NOTE Z POLARITY
00000001 Z 00000001 Z
31 00000000 00000000 SMOOTHING
34 00000000 00000000 PRINTER
INTERFACE
35 00100000 00100000 RS-232 BAUD
36 01111000 01111000 RS-232C MODE
01000010 X 01000010 X DIRECTION TO
37 00000000 Y 00000000 Y RETURN POINT DATA IS SET IN X AXIS
00000000 Z 00000000 Z
38 01001001 01001001 MODE/EDM DISPLAY
40 00000000 00000000 POWER LOSS
MEMORY
00000000 X 00000000 X INCH/MM 00000010= MM ONLY OPERATION
49 00000000 Y 00000000 Y OPERATION 00000000= INCH/MM OPERATION
00000000 Z 00000000 Z

DATE: 06 NOV. 90 ISSUE NUMBER: 1166
SUBJECT: DRAWBAR SUPERSEDES NUMBER:
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:
SUBJECT: AXIS PULLEY LOCKING ELEMENTS SUPERSEDES NUMBER:
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:
SUBJECT: KM5P DRAWBAR SUPERSEDES NUMBER:
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. KT9003090A
2. KT9005090A
3. KT9001080A
4. KT9001100A
5. KT9002100A
6. KT9003100A
7. KT9004100A
8. KT9005100A
9. KT9006100A
ORIGINATOR: Gregg A. Wallace
REVISED BY:
SUBJECT: NUISANCE V2 ROTARY ERRORS DURING SUPERSEDES NUMBER:

PARK MACHINE
PRODUCT LINE: V2 BMC20-50 NON MRP/ARP PAGE 1 OF 1

WITH 4TH AXIS ROTARY OPTIONS
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.

REVISED BY:
PRODUCT LINE: 002-2060-001, 002 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 +,.

REVISED BY:
DATE: 1-10-91 ISSUE NUMBER:1171
SUBJECT: FAST FILL SUPERSEDES NUMBER:
PRODUCT LINE: TRM21 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.

REVISED BY:
SUBJECT: Contactor suppression SUPERSEDES NUMBER:
PRODUCT LINE: KM-5P, BMC 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

SUBJECT: Lead Screw Mapping initialization V8.5 SUPERSEDES NUMBER:
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 re-
initialize 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 ISSUE NUMBER: 1174-A
SUBJECT: Ultimax secret screens SUPERSEDES NUMBER:1174
PRODUCT LINE: Ultimax II, 32, 3 Machines 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 New
Access Function/ Description Access Screen Access
Code Code
Configuration Screen or
639 Machine Configuration Edit (Auxillary Screen Max 32/3) 100
Tool Changer Height, Axis &
488 Spindle setup Tool changer diagnostic Screen 101
642 Leadscrew Map setup Tool change diagnostic Screen 102
8.60T Axis Accel Setup
** (Matrix 4 Axis Tune Tool change diagnostic Screen 103
Diagnostics Max 32/3)
527 Interactive Diagnostice Auxilary Screen 200
8.60T Manual Axis
** Initialization Tool change diagnostic Screen 300

REVISED BY: Brock Rexing 3/17/93
SUBJECT: BMC SPINDLES SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20 50 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.

REVISED BY:
DATE: 3-4-91 ISSUE NUMBER:1176
SUBJECT: Connector, card edge 26 pos. SUPERSEDES NUMBER:
PRODUCT LINE: All Max II controls 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:
SUBJECT: VCM900 Orbiting Unit SUPERSEDES NUMBER:
PRODUCT LINE: TRM21 EP300CP 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 ISSUE NUMBER: 1178A
SUBJECT: VMC 900 Noise Suppression SUPERSEDES NUMBER: 1178
PRODUCT LINE: TRM21 TRM39 EP300CP PAGE 1 OF 1

With VMC 900
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
SUBJECT: Isolation Transformer SUPERSEDES NUMBER:
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 413-
0003-105 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.

REVISED BY:
SUBJECT: Unclamp Switch SUPERSEDES NUMBER:
PRODUCT LINE: BMC 25 & 30K PAGE 1 OF 1
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.

Ken Borgmeyer
REVISED BY:
SUBJECT: RS232 SUPERSEDES NUMBER:
PRODUCT LINE: ALL PAGE 1 OF 1
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.

SUBJECT: AXIS MISWIRE SUPERSEDES NUMBER:
PRODUCT LINE: KM3/P PAGE 1 OF 2
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.
b: 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 18 ga
white wire. Connect the new drain wire to P3-3 (com).

REVISED BY:
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
SUBJECT: MACHINE CONFIGURATION PROBLEMS SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20-50 WITH 8.5 OR LATER PAGE 1 OF 1
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.

REVISED BY:
DATE: June 23, 1993 ISSUE NUMBER: 1184-A
SUBJECT: CRT Controller PCB 2 SUPERSEDES NUMBER: 1184
PRODUCT LINE: PAGE 1 OF 1
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 WIRE COLOR SIGNAL
1 Gray GND
2 Yellow +5V
3 Blue RST
4 Brown +12V
5 Orange -12V
6 Gray 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 X1B jumper
Line 1-2
Local 1-*
Mode X1A jumper
60Hz 1-2
50Hz 1-*
ORIGINATOR: Fred Gross

DATE: July 18, 1991 ISSUE NUMBER: 1185
SUBJECT: Max 400 Servo Amp SUPERSEDES NUMBER:
PRODUCT LINE: KM3/P & Rebuilt machines PAGE 1 OF 2
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.

REVISED BY: Matt Warner
FSB 1185 PAGE 2 of 2
SUBJECT: Lead Screw Map Initialization, v8.51 SUPERSEDES NUMBER:
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 ISSUE NUMBER: 1187
SUBJECT: Chain Roller SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20 to 50 PAGE 1 OF 2
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.

REVISED BY:
SUBJECT: Parametrics Digital Reversing Card SUPERSEDES NUMBER:
PRODUCT LINE: All with parametrics PAGE 1 OF 1
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. Remove jumper between terminal 4 and 5 of TB-6.

2. Remove white jumper on terminal 3 of TB-6.
3. Adjust potientiometer R4 to full CW position.
4. Connect reversing wire to terminal 2 of TB-6.
5. If spindle runs backwards swap two motor output wires.
6. 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 Parajust "A" (5 HP)

402-6005-006 Parajust "B" (7.5/10 HP)
ORIGINATOR: Mark G. Bullington

REVISED BY:
DATE: May 18, 1993 ISSUE NUMBER: 1189A
SUBJECT: Z AXIS CRT ASSEMBLY SUPERSEDES NUMBER: FSB 1189

TIN 1007
PRODUCT LINE: ALL MAX 2 CONTROLS 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 425 0001 013

GRAPHICS CRT 425 0001 014
If the control has Z Axis CRT's they may be adjusted using the following procedure.
R-101 Contrast.
R-304 Vert. Size- Adjust the display open and close vertically.
R-307 Vert. Sizes- Adjust vertical size of the characters at top and bottom of the display.
R-401 Horz. Width- Adjust the width of Horizontal position. This is a coil not a pot.
R-406 Horz. Cent- Adjust the horizontal position of the display. This is fine adj.
R-410 Horz. Freq- Adjust the horizontal position of the display. This is the coarse
adjustment.
R-421 Focus- Focus adjust.
R-425 Bright- Adjust the brightness.
ORIGINATOR: 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 ISSUE NUMBER: 1189B
SUBJECT: Z AXIS CRT ASSEMBLY SUPERSEDES NUMBER: FSB 1189A

TIN 1007
PRODUCT LINE: ALL MAX 2 CONTROLS 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 Ribbon cable Assy, Text CRT to CRT Cnt'l PCB

423-6139-002 Ribbon Cable Assy, Graphics CRT to FPCC PCB
425 0001 013 Text CRT
425 0001 014 Graphics CRT
Note: 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 Contrast.
R-307 Vert. Lines- Adjust vertical size of the characters at top and bottom of the display.
L-401 Horz. Width- Adjust the width of Horizontal position. This is a coil not a pot.
R-406 Horz. Phase- Adjust the horizontal position fine adj.
R-410 Horz. Freq.- Adjust the horizontal position coarse adjustment.

R406
P4 R421
R410 R307
L401 R304
F101
R425
R101
P2 1 P3
** 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 !
FSB 1189-B Page 2 of 2

DATE: December 1, 1993 ISSUE NUMBER: 1189C
SUBJECT: Z Axis CRT Assembly SUPERSEDES NUMBER:1189B/A

&TIN 1007
PRODUCT LINE: All Max 2 controls 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 Ribbon cable Assy, Text CRT to CRT Cnt'l PCB

423-6139-002 Ribbon Cable Assy, Graphics CRT to FPCC PCB
425 0001 013 Text CRT
425 0001 014 Graphics CRT
Note: 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 Contrast.
R-307 Vert. Lines- Adjust vertical size of the characters at top and bottom of the display.
L-401 Horz. Width- Adjust the width of Horizontal position. This is a coil not a pot.
R-406 Horz. Phase- Adjust the horizontal position fine adj.
R-410 Horz. Freq.- Adjust the horizontal position coarse adjustment.

R406
P4 R421
R410 R307
L401 R304
F101
R425
R101
P2 1 P3
** 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 !

C 002-3822-051 OF
1
UPPER HALF
CONSOLE
REAR PANEL
BLACK
Add Wire's
LOWER HALF BLACK
TO POWER CABINET CONSOLE NOTES:

(SINGLE POINT) 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
EXCEPT AS NOTED:
~
HURCO
IN INCHES
TOLERANCE
INDIANAPOLIS, IN U.S.A.
R
DECIMAL
.0 .0300
~
.000 .0050
.0000 .0005 SCHEMATIC, MAX 2 CONSOLE GROUNDING
ANGULAR 0ANGULAR 30'
DRAWN DATE CHECKED DATE APPROVED DATE
BREAK ALL
SHARP EDGES FWG 21SEP93
FIRST USED ON THIRD ANGLE
SCALE SIZE DRAWING SHT. REV.
NONE 1
C
PROJECTION
CN A 12836 RELEASE
REV P.I.N. REVISION DESCRIPTION REV DATE CHK DATE APPD DATE DF MAX 2 UNIT OF MEAS. 002-3822-051 OF
1
7103 NO. BY BY BY PC

SUBJECT: Knee mill pulley clutch shaft retrofit kit SUPERSEDES NUMBER:
PRODUCT LINE: Knee mills PAGE 1 OF 1
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 # 713-
0016-042.
If you are trying to order a 713-0016-042 pulley clutch shaft

(square groove) a cross reference will tell you to order 002-
2542-001 ass'y K-mill timing belt retrofit kit. This kit
contains the following
713-0016-145 Pulley clutch shaft HTD

713-0016-146 Timing belt pulley HTD
713-0016-147 Timing belt 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.
SUBJECT: Push Stud SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20 to 50 PAGE 1 OF 1
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

REVISED BY:
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
SUBJECT: Transformer fuses SUPERSEDES NUMBER:
PRODUCT LINE: As noted in text PAGE 1 OF 1
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
DATE: March 6, 1992 ISSUE NUMBER: 1193-A
SUBJECT: Modification to Voltage Divider PCB E2104016 SUPERSEDES NUMBER: 1193
PRODUCT LINE: TRM21 TRM39 EP300CP EDM PAGE 1 OF 2
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.

REVISED BY:
DATE: December 4, 1991 ISSUE NUMBER: 1194
SUBJECT: Transformer Cover SUPERSEDES NUMBER:
PRODUCT LINE: SLV 40 PAGE 1 OF 1
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.

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
SUBJECT: Lube Modification SUPERSEDES NUMBER:
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 check valve

713-0020-097 compression nut
713-0020-098 compression sleeve
506-3023-005 closure plug
713-0021-323 closure plug (metric)
ORIGINATOR: Matt Warner

REVISED BY:
DATE: June 9 1992 ISSUE NUMBER: 1196
SUBJECT: TYPE 1 ATC OVER SHOOT FIX SUPERSEDES NUMBER:
PRODUCT LINE: BMC 25 TO 30 and SLV 40 PAGE 1 OF 1
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. Install new motor to new bracket with (2) M5 x 45 SHCS, (2) M5

nuts, and lock washers.
2. Mount motor and bracket assembly to plate and Geneva drive

using existing hardware and coupling. Use new drive key
supplied with motor.
3. Replace 12 mfd capacitor with 7.5 mfd cap.
4. Remove brake pack and cover socket with label.
5. 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

REVISED BY:
Label No brake Pack required 703-1005-379
FSB XXX Page 2 of 3

DATE: June 23, 1992 ISSUE NUMBER: 1197
SUBJECT: Counterweight Noise SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20 to 50, SLV40 PAGE 1 OF 2
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.

REVISED BY:
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

SUBJECT: Ultimax 3 DC Power Supply SUPERSEDES NUMBER:
PRODUCT LINE: BMC20-50 PAGE 1 OF 1
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:
SUBJECT: CRP3 PCB Modification SUPERSEDES NUMBER:
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. 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.
4. Ensure that pins 1 and 19 of M2, M4 and M6 are not tied together as described on Manufacturing
Notice 3788.
5. Change the revision level to "E".
ORIGINATOR: Tom Murden

REVISED BY:
SUBJECT: Replacement of Spindle Oil Cooler SUPERSEDES NUMBER:
The following parts are needed for field installation of the new design oil cooler:
ItemDescription Part Number Quantity

1) Fitting, 90 degree elbow (3/8T-1/4 M.P.) 506-3009-039 4 ea.
2) Tubing, 3/8 O.D. 508-2001-005 25 feet
3) Oil Cooler 504-5001-005 1 ea.
4) Brace, splash guard 802-2618-004 1 ea.
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.

REVISED BY:
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.
SUBJECT: Max3 Keyboards SUPERSEDES NUMBER:
PRODUCT LINE: Ultimax 3 Controls PAGE 1 OF 1
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 DESCRIPTION PART NUMBER DESCRIPTION
609-0514-001 Keytop, Enter (1.25 x2) Dk.Gray 609-0514-011 Keytop, 2

609-0514-002 Keytop, 0 (Zero) 609-0514-012 Keytop, 1
609-0514-003 Keytop, (1 x 2) Dk.Gray 609-0514-013 Keytop, . (Decimal Point)
609-0514-004 Keytop, (1 x 2) Lt. Gray 609-0514-014 Keytop, X (Multiply Sign)
609-0514-005 Keytop, 8 609-0514-015 Keytop, / (Divide Sign)
609-0514-006 Keytop, 7 609-0514-016 Keytop, - (Minus Sign)
609-0514-007 Keytop, 6 or 9 609-0514-017 Keytop, + (Plus Sign)
609-0514-008 Keytop, 5 609-0514-018 Keytop, (Arrow)
609-0514-009 Keytop, 4 609-0514-019 Keytop, (1 x 1) Dk.Gray
609-0514-010 Keytop, 3 609-0514-020 Keytop, (1 x 1) Lt. Gray
ORIGINATOR: Mark Bullington

REVISED BY:
SUBJECT: Clairex Switch SUPERSEDES NUMBER:
PRODUCT LINE: KM1/HM1 PAGE 1 OF 1
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 KM1 LS PCB M1 LS HARNESS

BLACK (-) D OR E P12-4
COMMON
RED (+) A OR B P12-5
5VDC
WHITE C P12-2(+LS) OR P12-3(-LS)
(LOAD)
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.

REVISED BY:
DATE: Jan. 4, 1994 1203
SUBJECT: SUPERSEDES NUMBER:
PRODUCT LINE: 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:
SUBJECT: KM5D Input Power SUPERSEDES NUMBER:
PRODUCT LINE: Hawk KM5D PAGE 1 OF 1
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.

REVISED BY:
704-0001-589
SUBJECT: MTE Removal/Replacement SUPERSEDES NUMBER:
PRODUCT LINE: KM3/3P PAGE 1 OF 2
KM3/3P MOTOR/TACH/ENCODER REPLACEMENT PROCEDURE
1. If possible, move axis to a position providing easy access to the motor being removed.
2. Switch the Main Disconnect Switch to OFF.
3. Remove the servo conduit cable connector from the motor assembly. (Refer to Figure 1 for
the location of the various components.)
4. Remove the motor junction box cover.
5. Locate pins L, S, K, and H on the motor receptacle. (Refer to Figure 1, View

AA.)
6. 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.
7. Remove the cord grip lock nut that secures the cord grip to the motor junction box.
8. Carefully remove the cable from the junction box.
9. Remove the motor.
10. Install the new motor.

REVISED BY:
11. Install the limit switch cable and cord grip to the motor junction box, and tighten the cord
grip lock nut.
12. 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.
13. Replace the junction box cover and reconnect the servo conduit cable to the motor.
14. Switch the Main Disconnect Switch to ON.
15. Check the motor, encoder, and limit switches for proper operation by SLOWLY jogging the
axis to each switch.
FIGURE 1
MOTOR CONNECTOR RECEPTACLE

A
JUNCTION BOX
A
CORD GRIP
VIEW A-A
L A
K B
M
J S N C
20-16
H D
R P
G E
F
END VIEW

DATE: March 30, 1994 ISSUE NUMBER: 1206
SUBJECT: Hawk 5D Machine Control Prameters SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5D PAGE 1 OF 35
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.

REVISED BY:
Addr Value Addr Value Addr Value Addr Value Addr Value
Hex Byte Hex Byte Hex Byte Hex Byte Hex Byte
0000 03 0030 01 0060 00 0090 00 00C0 00
0001 00 0031 50 0061 31 0091 00 00C1 FF
0002 01 0032 01 0062 02 0092 01 00C2 FF
0003 01 0033 00 0063 00 0093 00 00C3 FF
0004 00 0034 00 0064 10 0094 00 00C4 FF
0005 01 0035 50 0065 00 0095 00 00C5 FF
0006 01 0036 01 0066 02 0096 FF 00C6 FF
0007 01 0037 00 0067 00 0097 FF 00C7 FF
0008 02 0038 04 0068 00 0098 FF 00C8 FF
0009 03 0039 06 0069 00 0099 FF 00C9 FF
000A 10 003A 40 006A 02 009A FF 00CA FF
000B 50 003B 00 006B 00 009B FF 00CB FF
000C 01 003C 05 006C 10 009C 01 00CC FF
000D 01 003D 10 006D 13 009D 50 00CD FF
000E 01 003E 00 006E 77 009E FF 00CE FF
000F 12 003F FF 006F 00 009F FF 00CF FF
0010 02 0040 00 0070 00 00A0 18 00D0 FF
0011 50 0041 04 0071 00 00A1 00 00D1 FF
0012 01 0042 00 0072 02 00A2 01 00D2 FF
0013 00 0043 01 0073 00 00A3 00 00D3 FF
0014 00 0044 01 0074 10 00A4 00 00D4 FF
0015 50 0045 01 0075 06 00A5 50 00D5 FF
0016 01 0046 00 0076 02 00A6 07 00D6 FF
0017 00 0047 01 0077 00 00A7 20 00D7 FF
0018 02 0048 00 0078 00 00A8 00 00D8 FF
0019 03 0049 00 0079 00 00A9 10 00D9 FF
001A 20 004A 00 007A 10 00AA 00 00DA FF
001B 00 004B 00 007B 00 00AB 00 00DB FF
001C 05 004C 00 007C 10 00AC 10 00DC FF
001D 10 004D 00 007D 00 00AD 10 00DD FF
001E 00 004E 00 007E 10 00AE 00 00DE FF
001F FF 004F 00 007F 00 00AF 00 00DF FF
0020 02 0050 01 0080 00 00B0 FF 00E0 FF
0021 50 0051 00 0081 00 00B1 FF 00E1 FF
0022 01 0052 40 0082 10 00B2 FF 00E2 FF
0023 00 0053 00 0083 00 00B3 FF 00E3 FF
0024 00 0054 40 0084 10 00B4 FF 00E4 00
0025 50 0055 00 0085 00 00B5 FF 00E5 00
0026 01 0056 80 0086 10 00B6 FF 00E6 FF
0027 00 0057 00 0087 00 00B7 FF 00E7 00
0028 02 0058 80 0088 00 00B8 FF 00E8 00
0029 03 0059 00 0089 00 00B9 FF 00E9 00
002A 20 005A 00 008A 10 00BA FF 00EA 00
002B 00 005B 50 008B 00 00BB FF 00EB 25
002C 05 005C 01 008C 10 00BC FF 00EC FF
002D 10 005D 00 008D 00 00BD FF 00ED FF
002E 00 005E 00 008E 10 00BE FF 00EE FF
002F FF 005F 01 008F 00 00BF FF 00EF FF
00F0 FF 0121 00 0152 00 0183 00 01B4 00
00F1 FF 0122 00 0153 00 0184 00 01B5 00
00F2 FF 0123 00 0154 00 0185 00 01B6 00
00F3 FF 0124 00 0155 00 0186 00 01B7 00
00F4 FF 0125 00 0156 00 0187 00 01B8 00
00F5 FF 0126 00 0157 00 0188 00 01B9 00
00F6 FF 0127 00 0158 00 0189 00 01BA 00
00F7 FF 0128 00 0159 00 018A 00 01BB 00
00F8 FF 0129 00 015A 00 018B 00 01BC 00
00F9 FF 012A 00 015B 00 018C 00 01BD 00
00FA FF 012B 00 015C 00 018D 00 01BE 00
00FB FF 012C 00 015D 00 018E 00 01BF 00
00FC FF 012D 00 015E 00 018F 00 01C0 00
00FD FF 012E 00 015F 00 0190 00 01C1 00
00FE 01 012F 00 0160 00 0191 00 01C2 00
00FF 00 0130 00 0161 00 0192 00 01C3 00
0100 00 0131 00 0162 00 0193 00 01C4 00
0101 00 0132 00 0163 00 0194 00 01C5 00
0102 00 0133 00 0164 00 0195 00 01C6 00
0103 01 0134 00 0165 00 0196 00 01C7 00
0104 00 0135 00 0166 00 0197 00 01C8 00
0105 00 0136 00 0167 00 0198 00 01C9 00
0106 00 0137 00 0168 00 0199 00 01CA 00
0107 00 0138 00 0169 00 019A 00 01CB 00
0108 00 0139 00 016A 00 019B 00 01CC 00
0109 00 013A 00 016B 00 019C 00 01CD 00
010A 00 013B 00 016C 00 019D 00 01CE 00
010B 00 013C 00 016D 00 019E 00 01CF 00
010C 00 013D 00 016E 00 019F 00 01D0 00
010D 00 013E 00 016F 00 01A0 00 01D1 00
010E 00 013F 00 0170 00 01A1 00 01D2 00
010F 00 0140 00 0171 00 01A2 00 01D3 00
0110 00 0141 00 0172 00 01A3 00 01D4 00
0111 00 0142 00 0173 00 01A4 00 01D5 00
0112 00 0143 00 0174 00 01A5 00 01D6 00
0113 00 0144 00 0175 00 01A6 00 01D7 00
0114 00 0145 00 0176 00 01A7 00 01D8 00
0115 00 0146 00 0177 00 01A8 00 01D9 00
0116 00 0147 00 0178 00 01A9 00 01DA 00
0117 00 0148 00 0179 00 01AA 00 01DB 00
0118 00 0149 00 017A 00 01AB 00 01DC 00
0119 00 014A 00 017B 00 01AC 00 01DD 00
011A 00 014B 00 017C 00 01AD 00 01DE 00
011B 00 014C 00 017D 00 01AE 00 01DF 00
011C 00 014D 00 017E 00 01AF 00 01E0 00
011D 00 014E 00 017F 00 01B0 00 01E1 00
011E 00 014F 00 0180 00 01B1 00 01E2 00
011F 00 0150 00 0181 00 01B2 00 01E3 00
0120 00 0151 00 0182 00 01B3 00 01E4 00
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105A 54 108B 45 10BC 53 10ED 48 111E 44
105B 49 108C 43 10BD 27 10EE 49 111F 20
105C 4F 108D 54 10BE 4E 10EF 42 1120 4D
105D 4E 108E 20 10BF 20 10F0 49 1121 54
105E 20 108F 53 10C0 44 10F1 54 1122 42
105F 20 1090 57 10C1 52 10F2 20 1123 20
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1061 4F 1092 41 10C3 57 10F4 57 1125 57
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1063 4C 1094 20 10C5 42 10F6 54 1127 54
1064 20 1095 46 10C6 41 10F7 43 1128 43
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106A 57 109B 50 10CC 52 10FD 4F 112E 42
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106D 53 109E 27 10CF 49 1100 4D 1131 20
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106F 49 10A0 43 10D1 4E 1102 42 1133 30
1070 4E 10A1 4F 10D2 20 1103 20 1134 20
1135 49 1166 49 1197 20 11C8 43 11F9 52
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1137 20 1168 43 1199 52 11CA 20 11FB 53
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113A 45 116B 4E 119C 53 11CD 4D 11FE 44
113B 53 116C 55 119D 45 11CE 42 11FF 20
113C 53 116D 4D 119E 44 11CF 45 1200 4D
113D 45 116E 42 119F 20 11D0 52 1201 54
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113F 20 1170 52 11A1 54 11D2 32 1203 20
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1149 48 117A 45 11AB 4E 11DC 53 120D 4D
114A 20 117B 53 11AC 55 11DD 45 120E 42
114B 4E 117C 53 11AD 4D 11DE 44 120F 45
114C 55 117D 45 11AE 42 11DF 20 1210 52
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122A 20 125B 53 128C 55 12BD 45 12EE 41
122B 4E 125C 53 128D 4D 12BE 44 12EF 47
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1250 52 1281 54 12B2 33 12E3 20 1314 4D
1251 20 1282 42 12B3 32 12E4 46 1315 42
1252 32 1283 20 12B4 20 12E5 41 1316 45
1253 39 1284 53 12B5 49 12E6 55 1317 52
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131F 20 1350 45 1381 54 13B2 4E 13E3 20
1320 4D 1351 20 1382 42 13B3 55 13E4 46
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1322 42 1353 55 1384 46 13B5 42 13E6 55
1323 20 1354 4D 1385 41 13B6 45 13E7 4C
1324 46 1355 42 1386 55 13B7 52 13E8 54
1325 41 1356 45 1387 4C 13B8 20 13E9 20
1326 55 1357 52 1388 54 13B9 31 13EA 4D
1327 4C 1358 20 1389 20 13BA 30 13EB 45
1328 54 1359 31 138A 4D 13BB 34 13EC 53
1329 20 135A 30 138B 45 13BC 20 13ED 53
132A 4D 135B 31 138C 53 13BD 20 13EE 41
132B 45 135C 20 138D 53 13BE 20 13EF 47
132C 53 135D 20 138E 41 13BF 20 13F0 45
132D 53 135E 20 138F 47 13C0 4D 13F1 20
132E 41 135F 20 1390 45 13C1 54 13F2 4E
132F 47 1360 4D 1391 20 13C2 42 13F3 55
1330 45 1361 54 1392 4E 13C3 20 13F4 4D
1331 20 1362 42 1393 55 13C4 46 13F5 42
1332 4E 1363 20 1394 4D 13C5 41 13F6 45
1333 55 1364 46 1395 42 13C6 55 13F7 52
1334 4D 1365 41 1396 45 13C7 4C 13F8 20
1335 42 1366 55 1397 52 13C8 54 13F9 31
1336 45 1367 4C 1398 20 13C9 20 13FA 30
1337 52 1368 54 1399 31 13CA 4D 13FB 36
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1339 31 136A 4D 139B 33 13CC 53 13FD 20
133A 30 136B 45 139C 20 13CD 53 13FE 20
133B 30 136C 53 139D 20 13CE 41 13FF 20
133C 20 136D 53 139E 20 13CF 47 1400 4D
133D 20 136E 41 139F 20 13D0 45 1401 54
133E 20 136F 47 13A0 4D 13D1 20 1402 42
133F 20 1370 45 13A1 54 13D2 4E 1403 20
1340 4D 1371 20 13A2 42 13D3 55 1404 46
1341 54 1372 4E 13A3 20 13D4 4D 1405 41
1342 42 1373 55 13A4 46 13D5 42 1406 55
1343 20 1374 4D 13A5 41 13D6 45 1407 4C
1344 46 1375 42 13A6 55 13D7 52 1408 54
1345 41 1376 45 13A7 4C 13D8 20 1409 20
1346 55 1377 52 13A8 54 13D9 31 140A 4D
1347 4C 1378 20 13A9 20 13DA 30 140B 45
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134A 4D 137B 32 13AC 53 13DD 20 140E 41
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134C 53 137D 20 13AE 41 13DF 20 1410 45
134D 53 137E 20 13AF 47 13E0 4D 1411 20
134E 41 137F 20 13B0 45 13E1 54 1412 4E
134F 47 1380 4D 13B1 20 13E2 42 1413 55
1414 4D 1445 41 1476 45 14A7 4C 14D8 20
1415 42 1446 55 1477 52 14A8 54 14D9 31
1416 45 1447 4C 1478 20 14A9 20 14DA 31
1417 52 1448 54 1479 31 14AA 4D 14DB 33
1418 20 1449 20 147A 31 14AB 45 14DC 20
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141E 20 144F 47 1480 4D 14B1 20 14E2 42
141F 20 1450 45 1481 54 14B2 4E 14E3 20
1420 4D 1451 20 1482 42 14B3 55 14E4 46
1421 54 1452 4E 1483 20 14B4 4D 14E5 41
1422 42 1453 55 1484 46 14B5 42 14E6 55
1423 20 1454 4D 1485 41 14B6 45 14E7 4C
1424 46 1455 42 1486 55 14B7 52 14E8 54
1425 41 1456 45 1487 4C 14B8 20 14E9 20
1426 55 1457 52 1488 54 14B9 31 14EA 4D
1427 4C 1458 20 1489 20 14BA 31 14EB 45
1428 54 1459 31 148A 4D 14BB 32 14EC 53
1429 20 145A 30 148B 45 14BC 20 14ED 53
142A 4D 145B 39 148C 53 14BD 20 14EE 41
142B 45 145C 20 148D 53 14BE 20 14EF 47
142C 53 145D 20 148E 41 14BF 20 14F0 45
142D 53 145E 20 148F 47 14C0 4D 14F1 20
142E 41 145F 20 1490 45 14C1 54 14F2 4E
142F 47 1460 4D 1491 20 14C2 42 14F3 55
1430 45 1461 54 1492 4E 14C3 20 14F4 4D
1431 20 1462 42 1493 55 14C4 46 14F5 42
1432 4E 1463 20 1494 4D 14C5 41 14F6 45
1433 55 1464 46 1495 42 14C6 55 14F7 52
1434 4D 1465 41 1496 45 14C7 4C 14F8 20
1435 42 1466 55 1497 52 14C8 54 14F9 31
1436 45 1467 4C 1498 20 14C9 20 14FA 31
1437 52 1468 54 1499 31 14CA 4D 14FB 34
1438 20 1469 20 149A 31 14CB 45 14FC 20
1439 31 146A 4D 149B 31 14CC 53 14FD 20
143A 30 146B 45 149C 20 14CD 53 14FE 20
143B 38 146C 53 149D 20 14CE 41 14FF 20
143C 20 146D 53 149E 20 14CF 47 1500 4D
143D 20 146E 41 149F 20 14D0 45 1501 54
143E 20 146F 47 14A0 4D 14D1 20 1502 42
143F 20 1470 45 14A1 54 14D2 4E 1503 20
1440 4D 1471 20 14A2 42 14D3 55 1504 46
1441 54 1472 4E 14A3 20 14D4 4D 1505 41
1442 42 1473 55 14A4 46 14D5 42 1506 55
1443 20 1474 4D 14A5 41 14D6 45 1507 4C
1444 46 1475 42 14A6 55 14D7 52 1508 54
1509 20 153A 31 156B 45 159C 20 15CD 53
150A 4D 153B 36 156C 53 159D 20 15CE 41
150B 45 153C 20 156D 53 159E 20 15CF 47
150C 53 153D 20 156E 41 159F 20 15D0 45
150D 53 153E 20 156F 47 15A0 4D 15D1 20
150E 41 153F 20 1570 45 15A1 54 15D2 4E
150F 47 1540 4D 1571 20 15A2 42 15D3 55
1510 45 1541 54 1572 4E 15A3 20 15D4 4D
1511 20 1542 42 1573 55 15A4 46 15D5 42
1512 4E 1543 20 1574 4D 15A5 41 15D6 45
1513 55 1544 46 1575 42 15A6 55 15D7 52
1514 4D 1545 41 1576 45 15A7 4C 15D8 20
1515 42 1546 55 1577 52 15A8 54 15D9 31
1516 45 1547 4C 1578 20 15A9 20 15DA 32
1517 52 1548 54 1579 31 15AA 4D 15DB 31
1518 20 1549 20 157A 31 15AB 45 15DC 20
1519 31 154A 4D 157B 38 15AC 53 15DD 20
151A 31 154B 45 157C 20 15AD 53 15DE 20
151B 35 154C 53 157D 20 15AE 41 15DF 20
151C 20 154D 53 157E 20 15AF 47 15E0 4D
151D 20 154E 41 157F 20 15B0 45 15E1 54
151E 20 154F 47 1580 4D 15B1 20 15E2 42
151F 20 1550 45 1581 54 15B2 4E 15E3 20
1520 4D 1551 20 1582 42 15B3 55 15E4 46
1521 54 1552 4E 1583 20 15B4 4D 15E5 41
1522 42 1553 55 1584 46 15B5 42 15E6 55
1523 20 1554 4D 1585 41 15B6 45 15E7 4C
1524 46 1555 42 1586 55 15B7 52 15E8 54
1525 41 1556 45 1587 4C 15B8 20 15E9 20
1526 55 1557 52 1588 54 15B9 31 15EA 4D
1527 4C 1558 20 1589 20 15BA 32 15EB 45
1528 54 1559 31 158A 4D 15BB 30 15EC 53
1529 20 155A 31 158B 45 15BC 20 15ED 53
152A 4D 155B 37 158C 53 15BD 20 15EE 41
152B 45 155C 20 158D 53 15BE 20 15EF 47
152C 53 155D 20 158E 41 15BF 20 15F0 45
152D 53 155E 20 158F 47 15C0 4D 15F1 20
152E 41 155F 20 1590 45 15C1 54 15F2 4E
152F 47 1560 4D 1591 20 15C2 42 15F3 55
1530 45 1561 54 1592 4E 15C3 20 15F4 4D
1531 20 1562 42 1593 55 15C4 46 15F5 42
1532 4E 1563 20 1594 4D 15C5 41 15F6 45
1533 55 1564 46 1595 42 15C6 55 15F7 52
1534 4D 1565 41 1596 45 15C7 4C 15F8 20
1535 42 1566 55 1597 52 15C8 54 15F9 31
1536 45 1567 4C 1598 20 15C9 20 15FA 32
1537 52 1568 54 1599 31 15CA 4D 15FB 32
1538 20 1569 20 159A 31 15CB 45 15FC 20
1539 31 156A 4D 159B 39 15CC 53 15FD 20
15FE 20 162F 47 1660 4D 1691 20 16C2 58
15FF 20 1630 45 1661 54 1692 4E 16C3 20
1600 4D 1631 20 1662 42 1693 55 16C4 41
1601 54 1632 4E 1663 20 1694 4D 16C5 58
1602 42 1633 55 1664 46 1695 42 16C6 49
1603 20 1634 4D 1665 41 1696 45 16C7 53
1604 46 1635 42 1666 55 1697 52 16C8 2D
1605 41 1636 45 1667 4C 1698 20 16C9 20
1606 55 1637 52 1668 54 1699 31 16CA 58
1607 4C 1638 20 1669 20 169A 32 16CB 20
1608 54 1639 31 166A 4D 169B 37 16CC 41
1609 20 163A 32 166B 45 169C 20 16CD 58
160A 4D 163B 34 166C 53 169D 20 16CE 49
160B 45 163C 20 166D 53 169E 20 16CF 53
160C 53 163D 20 166E 41 169F 20 16D0 2B
160D 53 163E 20 166F 47 16A0 4D 16D1 20
160E 41 163F 20 1670 45 16A1 54 16D2 59
160F 47 1640 4D 1671 20 16A2 42 16D3 20
1610 45 1641 54 1672 4E 16A3 20 16D4 41
1611 20 1642 42 1673 55 16A4 46 16D5 58
1612 4E 1643 20 1674 4D 16A5 41 16D6 49
1613 55 1644 46 1675 42 16A6 55 16D7 53
1614 4D 1645 41 1676 45 16A7 4C 16D8 2D
1615 42 1646 55 1677 52 16A8 54 16D9 20
1616 45 1647 4C 1678 20 16A9 20 16DA 59
1617 52 1648 54 1679 31 16AA 4D 16DB 20
1618 20 1649 20 167A 32 16AB 45 16DC 41
1619 31 164A 4D 167B 36 16AC 53 16DD 58
161A 32 164B 45 167C 20 16AD 53 16DE 49
161B 33 164C 53 167D 20 16AE 41 16DF 53
161C 20 164D 53 167E 20 16AF 47 16E0 2B
161D 20 164E 41 167F 20 16B0 45 16E1 20
161E 20 164F 47 1680 4D 16B1 20 16E2 5A
161F 20 1650 45 1681 54 16B2 4E 16E3 20
1620 4D 1651 20 1682 42 16B3 55 16E4 41
1621 54 1652 4E 1683 20 16B4 4D 16E5 58
1622 42 1653 55 1684 46 16B5 42 16E6 49
1623 20 1654 4D 1685 41 16B6 45 16E7 53
1624 46 1655 42 1686 55 16B7 52 16E8 2D
1625 41 1656 45 1687 4C 16B8 20 16E9 20
1626 55 1657 52 1688 54 16B9 31 16EA 5A
1627 4C 1658 20 1689 20 16BA 32 16EB 20
1628 54 1659 31 168A 4D 16BB 38 16EC 41
1629 20 165A 32 168B 45 16BC 20 16ED 58
162A 4D 165B 35 168C 53 16BD 20 16EE 49
162B 45 165C 20 168D 53 16BE 20 16EF 53
162C 53 165D 20 168E 41 16BF 20 16F0 2B
162D 53 165E 20 168F 47 16C0 2B 16F1 20
162E 41 165F 20 1690 45 16C1 20 16F2 34
16F3 54 1724 54 1755 31 1786 35 17B7 38
16F4 48 1725 31 1756 34 1787 32 17B8 49
16F5 20 1726 34 1757 36 1788 49 17B9 4E
16F6 41 1727 30 1758 49 1789 4E 17BA 53
16F7 58 1728 49 1759 4E 178A 53 17BB 52
16F8 2D 1729 4E 175A 53 178B 52 17BC 54
16F9 20 172A 53 175B 52 178C 54 17BD 31
16FA 34 172B 52 175C 54 178D 31 17BE 35
16FB 54 172C 54 175D 31 178E 35 17BF 39
16FC 48 172D 31 175E 34 178F 33 17C0 49
16FD 20 172E 34 175F 37 1790 49 17C1 4E
16FE 41 172F 31 1760 49 1791 4E 17C2 53
16FF 58 1730 49 1761 4E 1792 53 17C3 52
1700 2B 1731 4E 1762 53 1793 52 17C4 54
1701 20 1732 53 1763 52 1794 54 17C5 31
1702 35 1733 52 1764 54 1795 31 17C6 36
1703 54 1734 54 1765 31 1796 35 17C7 30
1704 48 1735 31 1766 34 1797 34 17C8 49
1705 20 1736 34 1767 38 1798 49 17C9 4E
1706 41 1737 32 1768 49 1799 4E 17CA 53
1707 58 1738 49 1769 4E 179A 53 17CB 52
1708 2D 1739 4E 176A 53 179B 52 17CC 54
1709 20 173A 53 176B 52 179C 54 17CD 31
170A 35 173B 52 176C 54 179D 31 17CE 36
170B 54 173C 54 176D 31 179E 35 17CF 31
170C 48 173D 31 176E 34 179F 35 17D0 49
170D 20 173E 34 176F 39 17A0 49 17D1 4E
170E 41 173F 33 1770 49 17A1 4E 17D2 53
170F 58 1740 49 1771 4E 17A2 53 17D3 52
1710 49 1741 4E 1772 53 17A3 52 17D4 54
1711 4E 1742 53 1773 52 17A4 54 17D5 31
1712 53 1743 52 1774 54 17A5 31 17D6 36
1713 52 1744 54 1775 31 17A6 35 17D7 32
1714 54 1745 31 1776 35 17A7 36 17D8 49
1715 31 1746 34 1777 30 17A8 49 17D9 4E
1716 33 1747 34 1778 49 17A9 4E 17DA 53
1717 38 1748 49 1779 4E 17AA 53 17DB 52
1718 49 1749 4E 177A 53 17AB 52 17DC 54
1719 4E 174A 53 177B 52 17AC 54 17DD 31
171A 53 174B 52 177C 54 17AD 31 17DE 36
171B 52 174C 54 177D 31 17AE 35 17DF 33
171C 54 174D 31 177E 35 17AF 37 17E0 49
171D 31 174E 34 177F 31 17B0 49 17E1 4E
171E 33 174F 35 1780 49 17B1 4E 17E2 53
171F 39 1750 49 1781 4E 17B2 53 17E3 52
1720 49 1751 4E 1782 53 17B3 52 17E4 54
1721 4E 1752 53 1783 52 17B4 54 17E5 31
1722 53 1753 52 1784 54 17B5 31 17E6 36
1723 52 1754 54 1785 31 17B6 35 17E7 34
17E8 49 1819 4E 184A 53 187B 52 18AC 54
17E9 4E 181A 53 184B 52 187C 54 18AD 31
17EA 53 181B 52 184C 54 187D 31 18AE 38
17EB 52 181C 54 184D 31 187E 38 18AF 39
17EC 54 181D 31 184E 37 187F 33 18B0 49
17ED 31 181E 37 184F 37 1880 49 18B1 4E
17EE 36 181F 31 1850 49 1881 4E 18B2 53
17EF 35 1820 49 1851 4E 1882 53 18B3 52
17F0 49 1821 4E 1852 53 1883 52 18B4 54
17F1 4E 1822 53 1853 52 1884 54 18B5 31
17F2 53 1823 52 1854 54 1885 31 18B6 39
17F3 52 1824 54 1855 31 1886 38 18B7 30
17F4 54 1825 31 1856 37 1887 34 18B8 49
17F5 31 1826 37 1857 38 1888 49 18B9 4E
17F6 36 1827 32 1858 49 1889 4E 18BA 53
17F7 36 1828 49 1859 4E 188A 53 18BB 52
17F8 49 1829 4E 185A 53 188B 52 18BC 54
17F9 4E 182A 53 185B 52 188C 54 18BD 31
17FA 53 182B 52 185C 54 188D 31 18BE 39
17FB 52 182C 54 185D 31 188E 38 18BF 31
17FC 54 182D 31 185E 37 188F 35 18C0 49
17FD 31 182E 37 185F 39 1890 49 18C1 4E
17FE 36 182F 33 1860 49 1891 4E 18C2 53
17FF 37 1830 49 1861 4E 1892 53 18C3 52
1800 49 1831 4E 1862 53 1893 52 18C4 54
1801 4E 1832 53 1863 52 1894 54 18C5 31
1802 53 1833 52 1864 54 1895 31 18C6 39
1803 52 1834 54 1865 31 1896 38 18C7 32
1804 54 1835 31 1866 38 1897 36 18C8 49
1805 31 1836 37 1867 30 1898 49 18C9 4E
1806 36 1837 34 1868 49 1899 4E 18CA 53
1807 38 1838 49 1869 4E 189A 53 18CB 52
1808 49 1839 4E 186A 53 189B 52 18CC 54
1809 4E 183A 53 186B 52 189C 54 18CD 31
180A 53 183B 52 186C 54 189D 31 18CE 39
180B 52 183C 54 186D 31 189E 38 18CF 33
180C 54 183D 31 186E 38 189F 37 18D0 49
180D 31 183E 37 186F 31 18A0 49 18D1 4E
180E 36 183F 35 1870 49 18A1 4E 18D2 53
180F 39 1840 49 1871 4E 18A2 53 18D3 52
1810 49 1841 4E 1872 53 18A3 52 18D4 54
1811 4E 1842 53 1873 52 18A4 54 18D5 31
1812 53 1843 52 1874 54 18A5 31 18D6 39
1813 52 1844 54 1875 31 18A6 38 18D7 34
1814 54 1845 31 1876 38 18A7 38 18D8 49
1815 31 1846 37 1877 32 18A8 49 18D9 4E
1816 37 1847 36 1878 49 18A9 4E 18DA 53
1817 30 1848 49 1879 4E 18AA 53 18DB 52
1818 49 1849 4E 187A 53 18AB 52 18DC 54
18DD 31 190E 30 192D 32 195E 31 198F 37
18DE 39 190F 31 192E 30 195F 31 1990 49
18DF 35 1910 49 192F 35 1960 49 1991 4E
18E0 49 1911 4E 1930 49 1961 4E 1992 53
18E1 4E 1912 53 1931 4E 1962 53 1993 52
18E2 53 1913 52 1932 53 1963 52 1994 54
18E3 52 1914 54 1933 52 1964 54 1995 32
18E4 54 1915 32 1934 54 1965 32 1996 31
18E5 31 1916 30 1935 32 1966 31 1997 38
18E6 39 1917 32 1936 30 1967 32 1998 49
18E7 36 1918 49 1937 36 1968 49 1999 4E
18E8 49 1919 4E 1938 49 1969 4E 199A 53
18E9 4E 191A 53 1939 4E 196A 53 199B 52
18EA 53 191B 52 193A 53 196B 52 199C 54
18EB 52 191B 52 193B 52 196C 54 199D 32
18EC 54 191C 54 193C 54 196D 32 199E 31
18ED 31 191C 54 193D 32 196E 31 199F 39
18EE 39 191D 32 193E 30 196F 33 19A0 49
18EF 37 191D 32 193F 37 1970 49 19A1 4E
18F0 49 191E 30 1940 49 1971 4E 19A2 53
18F1 4E 191E 30 1941 4E 1972 53 19A3 52
18F2 53 191F 33 1942 53 1973 52 19A4 54
18F3 52 191F 33 1943 52 1974 54 19A5 32
18F4 54 1920 49 1944 54 1975 32 19A6 32
18F5 31 1920 49 1945 32 1976 31 19A7 30
18F6 39 1921 4E 1946 30 1977 34 19A8 49
18F7 38 1921 4E 1947 38 1978 49 19A9 4E
18F8 49 1922 53 1948 49 1979 4E 19AA 53
18F9 4E 1922 53 1949 4E 197A 53 19AB 52
18FA 53 1923 52 194A 53 197B 52 19AC 54
18FB 52 1923 52 194B 52 197C 54 19AD 32
18FC 54 1924 54 194C 54 197D 32 19AE 32
18FD 31 1924 54 194D 32 197E 31 19AF 31
18FE 39 1925 32 194E 30 197F 35 19B0 49
18FF 39 1925 32 194F 39 1980 49 19B1 4E
1900 49 1926 30 1950 49 1981 4E 19B2 53
1901 4E 1926 30 1951 4E 1982 53 19B3 52
1902 53 1927 34 1952 53 1983 52 19B4 54
1903 52 1927 34 1953 52 1984 54 19B5 32
1904 54 1928 49 1954 54 1985 32 19B6 32
1905 32 1928 49 1955 32 1986 31 19B7 32
1906 30 1929 4E 1956 31 1987 36 19B8 49
1907 30 1929 4E 1957 30 1988 49 19B9 4E
1908 49 192A 53 1958 49 1989 4E 19BA 53
1909 4E 192A 53 1959 4E 198A 53 19BB 52
190A 53 192B 52 195A 53 198B 52 19BC 54
190B 52 192B 52 195B 52 198C 54 19BD 32
190C 54 192C 54 195C 54 198D 32 19BE 32
190D 32 192C 54 195D 32 198E 31 19BF 33
19C0 49 19F1 4E 1A22 53 1A53 52 1A84 54
19C1 4E 19F2 53 1A23 52 1A54 54 1A85 32
19C2 53 19F3 52 1A24 54 1A55 32 1A86 34
19C3 52 19F4 54 1A25 32 1A56 34 1A87 38
19C4 54 19F5 32 1A26 33 1A57 32 1A88 49
19C5 32 19F6 33 1A27 36 1A58 49 1A89 4E
19C6 32 19F7 30 1A28 49 1A59 4E 1A8A 53
19C7 34 19F8 49 1A29 4E 1A5A 53 1A8B 52
19C8 49 19F9 4E 1A2A 53 1A5B 52 1A8C 54
19C9 4E 19FA 53 1A2B 52 1A5C 54 1A8D 32
19CA 53 19FB 52 1A2C 54 1A5D 32 1A8E 34
19CB 52 19FC 54 1A2D 32 1A5E 34 1A8F 39
19CC 54 19FD 32 1A2E 33 1A5F 33 1A90 49
19CD 32 19FE 33 1A2F 37 1A60 49 1A91 4E
19CE 32 19FF 31 1A30 49 1A61 4E 1A92 53
19CF 35 1A00 49 1A31 4E 1A62 53 1A93 52
19D0 49 1A01 4E 1A32 53 1A63 52 1A94 54
19D1 4E 1A02 53 1A33 52 1A64 54 1A95 32
19D2 53 1A03 52 1A34 54 1A65 32 1A96 35
19D3 52 1A04 54 1A35 32 1A66 34 1A97 30
19D4 54 1A05 32 1A36 33 1A67 34 1A98 49
19D5 32 1A06 33 1A37 38 1A68 49 1A99 4E
19D6 32 1A07 32 1A38 49 1A69 4E 1A9A 53
19D7 36 1A08 49 1A39 4E 1A6A 53 1A9B 52
19D8 49 1A09 4E 1A3A 53 1A6B 52 1A9C 54
19D9 4E 1A0A 53 1A3B 52 1A6C 54 1A9D 32
19DA 53 1A0B 52 1A3C 54 1A6D 32 1A9E 35
19DB 52 1A0C 54 1A3D 32 1A6E 34 1A9F 31
19DC 54 1A0D 32 1A3E 33 1A6F 35 1AA0 49
19DD 32 1A0E 33 1A3F 39 1A70 49 1AA1 4E
19DE 32 1A0F 33 1A40 49 1A71 4E 1AA2 53
19DF 37 1A10 49 1A41 4E 1A72 53 1AA3 52
19E0 49 1A11 53 1A42 53 1A73 52 1AA4 54
19E1 4E 1A12 4E 1A43 52 1A74 54 1AA5 32
19E2 53 1A13 52 1A44 54 1A75 32 1AA6 35
19E3 52 1A14 54 1A45 32 1A76 34 1AA7 32
19E4 54 1A15 32 1A46 34 1A77 36 1AA8 49
19E5 32 1A16 33 1A47 30 1A78 49 1AA9 4E
19E6 32 1A17 34 1A48 49 1A79 4E 1AAA 53
19E7 38 1A18 49 1A49 4E 1A7A 53 1AAB 52
19E8 49 1A19 4E 1A4A 53 1A7B 52 1AAC 54
19E9 4E 1A1A 53 1A4B 52 1A7C 54 1AAD 32
19EA 53 1A1B 52 1A4C 54 1A7D 32 1AAE 35
19EB 52 1A1C 54 1A4D 32 1A7E 34 1AAF 33
19EC 54 1A1D 32 1A4E 34 1A7F 37 1AB0 49
19ED 32 1A1E 33 1A4F 31 1A80 49 1AB1 4E
19EE 32 1A1F 35 1A50 49 1A81 4E 1AB2 53
19EF 39 1A20 49 1A51 4E 1A82 53 1AB3 52
19F0 49 1A21 4E 1A52 53 1A83 52 1AB4 54
1AB5 32 1AE6 00 1B17 FF 1B48 FF 1B79 FF
1AB6 35 1AE7 99 1B18 FF 1B49 FF 1B7A FF
1AB7 34 1AE8 99 1B19 FF 1B4A FF 1B7B FF
1AB8 49 1AE9 01 1B1A FF 1B4B FF 1B7C FF
1AB9 4E 1AEA 00 1B1B FF 1B4C FF 1B7D FF
1ABA 53 1AEB 00 1B1C FF 1B4D FF 1B7E FF
1ABB 52 1AEC 50 1B1D FF 1B4E FF 1B7F FF
1ABC 54 1AED 00 1B1E FF 1B4F FF 1B80 FF
1ABD 32 1AEE 01 1B1F FF 1B50 FF 1B81 FF
1ABE 35 1AEF 00 1B20 FF 1B51 FF 1B82 FF
1ABF 35 1AF0 99 1B21 FF 1B52 FF 1B83 FF
1AC0 FF 1AF1 99 1B22 FF 1B53 FF 1B84 FF
1AC1 FF 1AF2 FF 1B23 FF 1B54 FF 1B85 FF
1AC2 FF 1AF3 FF 1B24 FF 1B55 FF 1B86 FF
1AC6 FF 1AF7 00 1B28 FF 1B59 FF 1B8A FF
1AC7 FF 1AF8 01 1B29 FF 1B5A FF 1B8B FF
1AC8 FF 1AF9 01 1B2A FF 1B5B FF 1B8C FF
1AC9 FF 1AFA 01 1B2B FF 1B5C FF 1B8D FF
1ACA FF 1AFB 01 1B2C FF 1B5D FF 1B8E FF
1ACB FF 1AFC 01 1B2D FF 1B5E FF 1B8F FF
1ACC FF 1AFD 00 1B2E FF 1B5F FF 1B90 FF
1ACD FF 1AFE 02 1B2F FF 1B60 FF 1B91 FF
1ACE FF 1AFF 00 1B30 FF 1B61 FF 1B92 FF
1ACF FF 1B00 00 1B31 FF 1B62 FF 1B93 FF
1AD0 FF 1B01 02 1B32 FF 1B63 FF 1B94 FF
1AD1 FF 1B02 00 1B33 FF 1B64 FF 1B95 FF
1AD2 FF 1B03 00 1B34 FF 1B65 FF 1B96 FF
1AD3 FF 1B04 01 1B35 FF 1B66 FF 1B97 FF
1AD4 FF 1B05 50 1B36 FF 1B67 FF 1B98 FF
1AD5 00 1B06 00 1B37 FF 1B68 FF 1B99 FF
1AD6 00 1B07 18 1B38 FF 1B69 FF 1B9A FF
1AD7 10 1B08 00 1B39 FF 1B6A FF 1B9B FF
1AD8 00 1B09 00 1B3A FF 1B6B FF 1B9C FF
1AD9 01 1B0A 18 1B3B FF 1B6C FF 1B9D FF
1ADA 00 1B0B 00 1B3C FF 1B6D FF 1B9E FF
1ADB 00 1B0C 00 1B3D FF 1B6E FF 1B9F FF
1ADC 50 1B0D 01 1B3E FF 1B6F FF 1BA0 FF
1ADD 00 1B0E FF 1B3F FF 1B70 FF 1BA1 FF
1ADE 10 1B0F FF 1B40 FF 1B71 FF 1BA2 FF
1ADF 00 1B10 FF 1B41 FF 1B72 FF 1BA3 FF
1AE0 00 1B11 FF 1B42 FF 1B73 FF 1BA4 FF
1BAA FF 1BDB FF 1C0C FF 1C3D FF 1C6E FF
1BAB FF 1BDC FF 1C0D FF 1C3E FF 1C6F FF
1BAC FF 1BDD FF 1C0E FF 1C3F FF 1C70 FF
1BAD FF 1BDE FF 1C0F FF 1C40 FF 1C71 FF
1BAE FF 1BDF FF 1C10 FF 1C41 FF 1C72 FF
1BAF FF 1BE0 FF 1C11 FF 1C42 FF 1C73 FF
1BB0 FF 1BE1 FF 1C12 FF 1C43 FF 1C74 FF
1BB6 FF 1BE7 FF 1C18 FF 1C49 FF 1C7A FF
1BB7 FF 1BE8 FF 1C19 FF 1C4A FF 1C7B FF
1BB8 FF 1BE9 FF 1C1A FF 1C4B FF 1C7C FF
1BB9 FF 1BEA FF 1C1B FF 1C4C FF 1C7D FF
1BBA FF 1BEB FF 1C1C FF 1C4D FF 1C7E FF
1BBB FF 1BEC FF 1C1D FF 1C4E FF 1C7F FF
1BBC FF 1BED FF 1C1E FF 1C4F FF 1C80 FF
1BBD FF 1BEE FF 1C1F FF 1C50 FF 1C81 FF
1BBE FF 1BEF FF 1C20 FF 1C51 FF 1C82 FF
1BBF FF 1BF0 FF 1C21 FF 1C52 FF 1C83 FF
1BC0 FF 1BF1 FF 1C22 FF 1C53 FF 1C84 FF
1BC6 FF 1BF7 FF 1C28 FF 1C59 FF 1C8A FF
1BC7 FF 1BF8 FF 1C29 FF 1C5A FF 1C8B FF
1BC8 FF 1BF9 FF 1C2A FF 1C5B FF 1C8C FF
1BC9 FF 1BFA FF 1C2B FF 1C5C FF 1C8D FF
1BCA FF 1BFB FF 1C2C FF 1C5D FF 1C8E FF
1BCB FF 1BFC FF 1C2D FF 1C5E FF 1C8F FF
1BCC FF 1BFD FF 1C2E FF 1C5F FF 1C90 FF
1BCD FF 1BFE FF 1C2F FF 1C60 FF 1C91 FF
1BCE FF 1BFF FF 1C30 FF 1C61 FF 1C92 FF
1BCF FF 1C00 FF 1C31 FF 1C62 FF 1C93 FF
1BD0 FF 1C01 FF 1C32 FF 1C63 FF 1C94 FF
1BD6 FF 1C07 FF 1C38 FF 1C69 FF 1C9A FF
1BD7 FF 1C08 FF 1C39 FF 1C6A FF 1C9B FF
1BD8 FF 1C09 FF 1C3A FF 1C6B FF 1C9C FF
1BD9 FF 1C0A FF 1C3B FF 1C6C FF 1C9D FF
1BDA FF 1C0B FF 1C3C FF 1C6D FF 1C9E FF
1C9F FF 1CD0 FF 1D01 FF 1D32 FF 1D63 FF
1CA0 FF 1CD1 FF 1D02 FF 1D33 FF 1D64 FF
1CA6 FF 1CD7 FF 1D08 FF 1D39 FF 1D6A FF
1CA7 FF 1CD8 FF 1D09 FF 1D3A FF 1D6B FF
1CA8 FF 1CD9 FF 1D0A FF 1D3B FF 1D6C FF
1CA9 FF 1CDA FF 1D0B FF 1D3C FF 1D6D FF
1CAA FF 1CDB FF 1D0C FF 1D3D FF 1D6E FF
1CAB FF 1CDC FF 1D0D FF 1D3E FF 1D6F FF
1CAC FF 1CDD FF 1D0E FF 1D3F FF 1D70 FF
1CAD FF 1CDE FF 1D0F FF 1D40 FF 1D71 FF
1CAE FF 1CDF FF 1D10 FF 1D41 FF 1D72 FF
1CAF FF 1CE0 FF 1D11 FF 1D42 FF 1D73 FF
1CB0 FF 1CE1 FF 1D12 FF 1D43 FF 1D74 FF
1CB6 FF 1CE7 FF 1D18 FF 1D49 FF 1D7A FF
1CB7 FF 1CE8 FF 1D19 FF 1D4A FF 1D7B FF
1CB8 FF 1CE9 FF 1D1A FF 1D4B FF 1D7C FF
1CB9 FF 1CEA FF 1D1B FF 1D4C FF 1D7D FF
1CBA FF 1CEB FF 1D1C FF 1D4D FF 1D7E FF
1CBB FF 1CEC FF 1D1D FF 1D4E FF 1D7F FF
1CBC FF 1CED FF 1D1E FF 1D4F FF 1D80 FF
1CBD FF 1CEE FF 1D1F FF 1D50 FF 1D81 FF
1CBE FF 1CEF FF 1D20 FF 1D51 FF 1D82 FF
1CBF FF 1CF0 FF 1D21 FF 1D52 FF 1D83 FF
1CC0 FF 1CF1 FF 1D22 FF 1D53 FF 1D84 FF
1CC6 FF 1CF7 FF 1D28 FF 1D59 FF 1D8A FF
1CC7 FF 1CF8 FF 1D29 FF 1D5A FF 1D8B FF
1CC8 FF 1CF9 FF 1D2A FF 1D5B FF 1D8C FF
1CC9 FF 1CFA FF 1D2B FF 1D5C FF 1D8D FF
1CCA FF 1CFB FF 1D2C FF 1D5D FF 1D8E FF
1CCB FF 1CFC FF 1D2D FF 1D5E FF 1D8F FF
1CCC FF 1CFD FF 1D2E FF 1D5F FF 1D90 FF
1CCD FF 1CFE FF 1D2F FF 1D60 FF 1D91 FF
1CCE FF 1CFF FF 1D30 FF 1D61 FF 1D92 FF
1CCF FF 1D00 FF 1D31 FF 1D62 FF 1D93 FF
1D94 FF 1DC5 FF 1DF6 FF 1E27 FF 1E58 FF
1D95 FF 1DC6 FF 1DF7 FF 1E28 FF 1E59 FF
1D96 FF 1DC7 FF 1DF8 FF 1E29 FF 1E5A FF
1D97 FF 1DC8 FF 1DF9 FF 1E2A FF 1E5B FF
1D98 FF 1DC9 FF 1DFA FF 1E2B FF 1E5C FF
1D99 FF 1DCA FF 1DFB FF 1E2C FF 1E5D FF
1D9A FF 1DCB FF 1DFC FF 1E2D FF 1E5E FF
1D9B FF 1DCC FF 1DFD FF 1E2E FF 1E5F FF
1D9C FF 1DCD FF 1DFE FF 1E2F FF 1E60 FF
1D9D FF 1DCE FF 1DFF FF 1E30 FF 1E61 FF
1D9E FF 1DCF FF 1E00 FF 1E31 FF 1E62 FF
1D9F FF 1DD0 FF 1E01 FF 1E32 FF 1E63 FF
1DA0 FF 1DD1 FF 1E02 FF 1E33 FF 1E64 FF
1DA6 FF 1DD7 FF 1E08 FF 1E39 FF 1E6A FF
1DA7 FF 1DD8 FF 1E09 FF 1E3A FF 1E6B FF
1DA8 FF 1DD9 FF 1E0A FF 1E3B FF 1E6C FF
1DA9 FF 1DDA FF 1E0B FF 1E3C FF 1E6D FF
1DAA FF 1DDB FF 1E0C FF 1E3D FF 1E6E FF
1DAB FF 1DDC FF 1E0D FF 1E3E FF 1E6F FF
1DAC FF 1DDD FF 1E0E FF 1E3F FF 1E70 FF
1DAD FF 1DDE FF 1E0F FF 1E40 FF 1E71 FF
1DAE FF 1DDF FF 1E10 FF 1E41 FF 1E72 FF
1DAF FF 1DE0 FF 1E11 FF 1E42 FF 1E73 FF
1DB0 FF 1DE1 FF 1E12 FF 1E43 FF 1E74 FF
1DB6 FF 1DE7 FF 1E18 FF 1E49 FF 1E7A FF
1DB7 FF 1DE8 FF 1E19 FF 1E4A FF 1E7B FF
1DB8 FF 1DE9 FF 1E1A FF 1E4B FF 1E7C FF
1DB9 FF 1DEA FF 1E1B FF 1E4C FF 1E7D FF
1DBA FF 1DEB FF 1E1C FF 1E4D FF 1E7E FF
1DBB FF 1DEC FF 1E1D FF 1E4E FF 1E7F FF
1DBC FF 1DED FF 1E1E FF 1E4F FF 1E80 FF
1DBD FF 1DEE FF 1E1F FF 1E50 FF 1E81 FF
1DBE FF 1DEF FF 1E20 FF 1E51 FF 1E82 FF
1DBF FF 1DF0 FF 1E21 FF 1E52 FF 1E83 FF
1DC0 FF 1DF1 FF 1E22 FF 1E53 FF 1E84 FF
1E89 FF 1EBA FF 1EEB FF 1F1C FF 1F4D FF
1E8A FF 1EBB FF 1EEC FF 1F1D FF 1F4E FF
1E8B FF 1EBC FF 1EED FF 1F1E FF 1F4F FF
1E8C FF 1EBD FF 1EEE FF 1F1F FF 1F50 FF
1E8D FF 1EBE FF 1EEF FF 1F20 FF 1F51 FF
1E8E FF 1EBF FF 1EF0 FF 1F21 FF 1F52 FF
1E8F FF 1EC0 FF 1EF1 FF 1F22 FF 1F53 FF
1E90 FF 1EC1 FF 1EF2 FF 1F23 FF 1F54 FF
1E96 FF 1EC7 FF 1EF8 FF 1F29 FF 1F5A FF
1E97 FF 1EC8 FF 1EF9 FF 1F2A FF 1F5B FF
1E98 FF 1EC9 FF 1EFA FF 1F2B FF 1F5C FF
1E99 FF 1ECA FF 1EFB FF 1F2C FF 1F5D FF
1E9A FF 1ECB FF 1EFC FF 1F2D FF 1F5E FF
1E9B FF 1ECC FF 1EFD FF 1F2E FF 1F5F FF
1E9C FF 1ECD FF 1EFE FF 1F2F FF 1F60 FF
1E9D FF 1ECE FF 1EFF FF 1F30 FF 1F61 FF
1E9E FF 1ECF FF 1F00 FF 1F31 FF 1F62 FF
1E9F FF 1ED0 FF 1F01 FF 1F32 FF 1F63 FF
1EA0 FF 1ED1 FF 1F02 FF 1F33 FF 1F64 FF
1EA6 FF 1ED7 FF 1F08 FF 1F39 FF 1F6A FF
1EA7 FF 1ED8 FF 1F09 FF 1F3A FF 1F6B FF
1EA8 FF 1ED9 FF 1F0A FF 1F3B FF 1F6C FF
1EA9 FF 1EDA FF 1F0B FF 1F3C FF 1F6D FF
1EAA FF 1EDB FF 1F0C FF 1F3D FF 1F6E FF
1EAB FF 1EDC FF 1F0D FF 1F3E FF 1F6F FF
1EAC FF 1EDD FF 1F0E FF 1F3F FF 1F70 FF
1EAD FF 1EDE FF 1F0F FF 1F40 FF 1F71 FF
1EAE FF 1EDF FF 1F10 FF 1F41 FF 1F72 FF
1EAF FF 1EE0 FF 1F11 FF 1F42 FF 1F73 FF
1EB0 FF 1EE1 FF 1F12 FF 1F43 FF 1F74 FF
1EB6 FF 1EE7 FF 1F18 FF 1F49 FF 1F7A FF
1EB7 FF 1EE8 FF 1F19 FF 1F4A FF 1F7B FF
1EB8 FF 1EE9 FF 1F1A FF 1F4B FF 1F7C FF
1EB9 FF 1EEA FF 1F1B FF 1F4C FF 1F7D FF
1F7E FF 1FAF FF 1FE0 FF
1F7F 00 1FB0 FF 1FE1 FF
1F80 FF 1FB1 FF 1FE2 FF
1F88 FF 1FB9 FF 1FEA FF
1F89 FF 1FBA FF 1FEB FF
1F8A FF 1FBB FF 1FEC FF
1F8B FF 1FBC FF 1FED FF
1F8C FF 1FBD FF 1FEE FF
1F8D FF 1FBE FF 1FEF FF
1F8E FF 1FBF FF 1FF0 FF
1F8F FF 1FC0 FF 1FF1 FF
1F90 FF 1FC1 FF 1FF2 FF
1F96 FF 1FC7 FF 1FF8 EA
1F97 FF 1FC8 FF 1FF9 00
1F98 FF 1FC9 FF 1FFA 80
1F99 FF 1FCA FF 1FFB FF
1F9A FF 1FCB FF 1FFC FF
1F9B FF 1FCC FF 1FFD FF
1F9C FF 1FCD FF 1FFE FF
1F9D FF 1FCE FF 1FFF FF
1F9E FF 1FCF FF
1F9F FF 1FD0 FF
1FA0 FF 1FD1 FF
1FA1 FF 1FD2 FF
1FA2 FF 1FD3 FF
1FA3 FF 1FD4 FF
1FA4 FF 1FD5 FF
1FA5 FF 1FD6 FF
1FA6 FF 1FD7 FF
1FA7 FF 1FD8 FF
1FA8 FF 1FD9 FF
1FA9 FF 1FDA FF
1FAA FF 1FDB FF
1FAB FF 1FDC FF
1FAC FF 1FDD FF
1FAD FF 1FDE FF
1FAE FF 1FDF FF
SUBJECT: Hawk 5D JO-BLOCK PROCEDURE SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5D Knee Mill PAGE 1 OF 7
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$

REVISED BY:
1
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$
2. Reference the machine.

3. 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
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. Reference the machine.

3. 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.
3. Press RESET, "P" to enter the Parameter mode.

4. Select the address to be changed by typing "A", then the address number, ENTER.
NEXT EVENT will move to the next address.
5, After all parameters are changed, toggle the WRITE PROTECT SWITCH to the UP
position. Press RESET, then release the EMERGENCY STOP BUTTON.
TABLE #1 - Presets:
ADDR. DATA TABLE #4: BACKLASH

0005 01
0047 01 AXIS ADDR DATA NOTE: Values are
100 00 X 0048 loaded in millimeters
101 00 0049 Example: 0.014mm
102 00 Y 004A X 0048 00
103 02 004B 0049 14
104 54
105 00
200 35
201 60
202 00
203 02
204 54
205 00
4
TABLE # 2: X AXIS
Error is in ten thousandths of an inch (0.0001)

ADDR +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11 +12 +13 +14 +15 +16 +17 +18 +19 +20 +21 +22 +23 +24 +25
0106 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0107 00 11 11 11 11 11 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
0108 00 00 11 11 11 11 11 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
0109 00 00 00 11 11 11 11 11 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
010A 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
010B 00 00 00 00 11 11 11 11 11 12 12 12 12 13 13 13 13 13 14 14 15 15 14 15 16
010C 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
010D 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 15 14 14 15 15 15
010E 00 00 00 11 11 11 11 11 12 12 12 12 12 13 14 13 13 13 14 14 14 14 15 15 15
010F 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
0110 00 00 00 00 11 11 11 11 11 13 12 12 12 12 13 13 13 13 13 14 14 14 14 14 16
0111 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
0112 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
0113 00 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15
0114 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 15 15 15 15 15 15
0115 00 00 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 14 14 14 14 14 15 16
0116 00 11 11 11 11 11 12 12 12 12 12 13 13 13 14 13 14 14 14 14 14 15 15 15 15
0117 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
0118 00 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15
0119 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
011A 00 00 00 00 11 11 11 11 11 13 12 12 12 12 13 13 13 13 13 14 14 14 14 15 16
011B 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 15 14 15 15 15 15
011C 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
011D 00 00 00 11 11 11 11 11 12 12 12 12 12 13 13 14 13 14 14 14 15 14 15 15 15
011E 11 11 11 11 11 12 12 12 12 12 13 13 13 13 14 14 14 14 14 14 15 15 15 15 15
011F 00 00 00 00 11 11 11 11 12 12 12 12 12 13 13 13 14 13 14 14 14 15 14 15 16
0120 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
0121 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
0122 00 00 00 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 15 15 15 15 15 15
0123 11 11 11 11 12 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
TABLE # 2: X AXIS (continued)

ADDR -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25
0106 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0107 00 01 01 01 01 01 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
0108 00 00 01 01 01 01 01 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
0109 00 00 00 01 01 01 01 01 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
010A 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
010B 00 00 00 00 01 01 01 01 01 02 02 02 02 03 03 03 03 03 04 04 05 05 04 05 06
010C 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
010D 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 05 04 04 05 05 05
010E 00 00 00 01 01 01 01 01 02 02 02 02 02 03 04 03 03 03 04 04 04 04 05 05 05
010F 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
0110 00 00 00 00 01 01 01 01 01 03 02 02 02 02 03 03 03 03 03 04 04 04 04 04 06
0111 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
0112 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
0113 00 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05
0114 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 05 05 05 05 05 05
0115 00 00 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 04 04 04 04 04 05 06
0116 00 01 01 01 01 01 02 02 02 02 02 03 03 03 04 03 04 04 04 04 04 05 05 05 05
0117 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
0118 00 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05
0119 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
011A 00 00 00 00 01 01 01 01 01 03 02 02 02 02 03 03 03 03 03 04 04 04 04 05 06
011B 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 05 04 05 05 05 05
011C 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
011D 00 00 00 01 01 01 01 01 02 02 02 02 02 03 03 04 03 04 04 04 05 04 05 05 05
011E 01 01 01 01 01 02 02 02 02 02 03 03 03 03 04 04 04 04 04 04 05 05 05 05 05
011F 00 00 00 00 01 01 01 01 02 02 02 02 02 03 03 03 04 03 04 04 04 05 04 05 06
0120 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
0121 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
0122 00 00 00 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 05 05 05 05 05 05
0123 01 01 01 01 02 02 02 02 02 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

ADDR +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11 +12 +13 +14 +15 +16 +17 +18 +19 +20 +21 +22 +23 +24 +25
0206 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0207 00 11 00 11 11 11 11 12 12 12 12 12 12 12 12 13 13 13 13 13 14 14 14 14 15
0208 00 00 11 11 11 11 11 11 11 12 12 12 13 13 13 13 13 14 14 14 14 14 14 15 14
0209 11 00 00 11 11 11 12 11 12 12 12 13 12 12 13 13 13 13 14 13 14 14 14 14 15
020A 00 11 11 00 11 11 11 12 12 12 12 12 12 13 12 13 13 13 13 14 13 14 14 14 14
020B 00 00 11 11 00 11 11 11 11 11 12 12 12 12 13 12 13 13 14 14 14 14 15 15 15
020C 00 00 00 11 11 11 12 12 12 12 12 12 13 13 13 13 13 13 13 13 14 14 14 14 14
020D 00 11 11 11 11 12 11 11 11 12 12 13 12 12 12 13 13 14 13 14 14 14 14 14 15
020E 11 00 00 00 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 13 13 14 14 14 14
020F 00 00 11 11 00 11 12 12 12 11 12 12 13 12 13 12 13 13 13 14 14 14 15 15 15
0210 00 11 11 11 11 11 11 11 11 12 12 12 12 13 12 13 13 13 13 14 14 14 14 14 14
0211 00 00 00 11 11 11 11 12 12 12 12 12 12 12 13 13 13 14 14 13 14 14 14 14 15
0212 00 00 11 00 11 11 12 11 12 12 12 13 12 13 13 13 13 13 13 14 13 14 14 14 14
0213 11 11 11 11 11 11 11 11 11 12 12 12 13 12 12 13 13 13 14 13 14 14 14 15 15
0214 00 00 00 11 11 11 11 12 12 12 12 12 12 13 13 13 13 13 13 14 14 14 14 14 14
ADDR -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25
0206 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0207 00 01 00 01 01 01 01 02 02 02 02 02 02 02 02 03 03 03 03 03 04 04 04 04 05
0208 00 00 01 01 01 01 01 01 01 02 02 02 03 03 03 03 03 04 04 04 04 04 04 05 04
0209 01 00 00 01 01 01 02 01 02 02 02 03 02 02 03 03 03 03 04 03 04 04 04 04 05
020A 00 01 01 00 01 01 01 02 02 02 02 02 02 03 02 03 03 03 03 04 03 04 04 04 04
020B 00 00 01 01 00 01 01 01 01 01 02 02 02 02 03 02 03 03 04 04 04 04 05 05 05
020C 00 00 00 01 01 01 02 02 02 02 02 02 03 03 03 03 03 03 03 03 04 04 04 04 04
020D 00 01 01 01 01 02 01 01 01 02 02 03 02 02 02 03 03 04 03 04 04 04 04 04 05
020E 01 00 00 00 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 03 03 04 04 04 04
020F 00 00 01 01 00 01 02 02 02 01 02 02 03 02 03 02 03 03 03 04 04 04 05 05 05
0210 00 01 01 01 01 01 01 01 01 02 02 02 02 03 02 03 03 03 03 04 04 04 04 04 04
0211 00 00 00 01 01 01 01 02 02 02 02 02 02 02 03 03 03 04 04 03 04 04 04 04 05
0212 00 00 01 00 01 01 02 01 02 02 02 03 02 03 03 03 03 03 03 04 03 04 04 04 04
0213 01 01 01 01 01 01 01 01 01 02 02 02 03 02 02 03 03 03 04 03 04 04 04 05 05
0214 00 00 00 01 01 01 01 02 02 02 02 02 02 03 03 03 03 03 03 04 04 04 04 04 04
FSB XXX Page 7 of 7

SUBJECT: Hawk 5D Servo Amplifier Setup Procedure SUPERSEDES NUMBER:
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.

REVISED BY:
SUBJECT: Hawk 5D Limit Switch Setup Procedure SUPERSEDES NUMBER:
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

REVISED BY:
FSB 1209 PAGE 2 OF 2
6) Set the software limits to:

Y (+) = 0.020
Y (-) = (-) 13.77
7) Set Y Home for (-) 1.000
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.

SUBJECT: Auto Speed Control Prom Update SUPERSEDES NUMBER:
PRODUCT LINE: KM5P/KM5M PAGE 1 OF 1
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 OPEN CLOSED

2
POSITION 1 BYPASS SOFTWARE LIMITS USE SOFTWARE
LIMITS
POSITION 2 ENABLE 130mSEC NO DEBOUNCE **
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.

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

REVISED BY:
DATE: May 13, 1994 ISSUE NUMBER: 1212-A
SUBJECT: Servo Drive Setup SUPERSEDES NUMBER:
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.

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...

SUBJECT: HAWK 5M PARAMETERS SUPERSEDES NUMBER:
PRODUCT LINE: HAWK 5M PAGE 1 OF 15
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 Access Screen Access Code

Machine Configuration & Power-Up Configuration ENTER,100,ENTER
Axis/Spindle Setup or from Auxiliary Mode
Axis Balance Manual Mode ENTER,101,ENTER
ATC Diagnostics
Leadscrew Mapping Manual Mode ENTER,102,ENTER
ATC Diagnostics
Matrix 4 DSP Axis Tune Manual Mode ENTER,103,ENTER
ATC Diagnostics
Interactive Diagnostics Auxiliary Mode ENTER,527,ENTER

REVISED BY:
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

SUBJECT: Monochrome CRT Settings SUPERSEDES NUMBER:
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) Reload the machine configuration parameters from the backup disk (assuming you can see
enough on the CRT to do this).
2) 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

REVISED BY:
F4 WHITE
F7 MORE
F7 MORE
F4 WHITE
F7 MORE
F7 MORE
F4 WHITE
F8 EXIT
F2 GRAPHICS COLORS
F7 MORE
F7 MORE
F4 WHITE
F4 CYAN
F7 MORE
F2 LIGHT GRAY
F7 MORE
F2 LIGHT GRAY
F7 MORE
F7 MORE
F4 WHITE
F7 MORE
F7 MORE
F4 WHITE
F7 MORE
F7 MORE
F4 WHITE
F8 EXIT
F3 STORAGE FUNCTION COLORS
F7 MORE
F2 LIGHT GRAY
F7 MORE
F7 MORE
F4 WHITE
F1 BLACK
F7 MORE
F7 MORE
F4 WHITE
F1 BLACK
F7 MORE
F7 MORE
F4 WHITE
F7 MORE
F2 LIGHT GRAY
F7 MORE
F2 LIGHT GRAY
F1 BLACK
F8 EXIT
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 Monochrome Color

1. Background Color Black Black
2. Reverse Background Color Light Gray Light Gray
3. Data Display Area White White
4. Prompt Area Color White Light Red
5. Softkey Label Color White Light Red
6. Softkey Text Color White Light Cyan
7. Softkey Line Delimiter White White
8. Cursor Color White Blue
NOTE: Reverse Background Color is also used for the Cursor Color in the NC Part Program editor.
B. GRAPHICS COLORS Monochrome Color

1. Part Path Color Light Gray Light Cyan
2. Cutter Path Color White Light Red
3. Rapid Path Color White Yellow
4. Axes Color White Light Green
5. Character Color White White
6. Box Color White Light Cyan
7. Pointing Device Cursor Color White Yellow

REVISED BY: David Skrzypczak
8. DXF Line Color Light Gray Green
9. DXF Highlight Color White Yellow
10. DXF Branch Color White Red
11. DXF Calculator Display Color White Light Green
12. DXF Calculator Buttons Color White White
13. DXF Calculator Grid Color Light Gray Green
C. STORAGE FUNCTION COLORS Monochrome Color

1. Directory Background Color Light Gray Red
2. Highlighted Directory Color White White
3. Unhighlighted Directory Color Black Black
4. Current Directory Color White Yellow
5. File Background Color Black Blue
6. Highlighted File Color White White
7. Unhighlighted File Color Light Gray Light Gray
8. Line Border Color Light Gray Light Gray
9. Page Up/Page Down Arrow Color Black 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

SUBJECT: Hawk 5M Advanced CMOS Setup Options SUPERSEDES NUMBER:
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
ESC: EXIT : SEL F2/F3: COLOR F10: Save and Exit

REVISED BY:
The following tables list the settings for:
1) ADVANCED CMOS SETUP

2) ADVANCED CHIPSET SETUP
3) 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 DC00, 16K Disabled
Adapter ROM Shadow E000, 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

SUBJECT: Lead Screw Mapping SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5M Knee Mill PAGE 1 OF 8
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)

REVISED BY:
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
SUBJECT: ISA HARD DISK SETUP SUPERSEDES NUMBER:
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.
3) Use FORMAT.COM and format the C: drive. Enter EXECUTIVE_1 as the volume label.
Format the D: partition, no volume label is needed.
4) 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

REVISED BY:
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) Copy all other files in any order to C:
7) 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 - Servopack Configuration ** INFORMATION ADDED **

Page 2- - DAC Offset PCB Adjustment procedure
Page 3 - Linear Axis Servo Setup procedure
Page 4 - Yaskawa Servopack PCB layout Diagram
Page 5 - Amplifier Information and Fault Codes
Tools Required:
Digital Volt Ohm Meter (DVM)
Small Screwdriver

REVISED BY:
IV. LINEAR AXIS YASKAWA SERVOPACK CONFIGURATION:
NOTE: Normally the factory settings of VR1 thru VR6 will not need to be altered.
A) Verify that the Yaskawa Servopack for each Axis is configured as follows:
LINEAR AXES Refer to Page 4 for location
Shunt Settings
SW1 Jumpers on 4 & 8
Jumpers on 2 thru 8 1:2 Ratio/ All BMC
SW2 Jumpers on 1 thru 8 1:1 Ratio BMC20LR X & Y Axis Direct Drive
Jumpers on 3 thru 8 1:4 Ratio KM5
SW3 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.
SW4 Jumpers on 1 thru 4 & 8
Pots Setting Scale

VR1 IN-B Mid range 5 of 10 Scale
VR3 ZERO Mid range 5 of 10 Scale
VR4 FINE Mid range 5 of 10 Scale
VR5 CUR Full CW 10 of 10 Scale
VR6 LOOP Mid range 5 of 10 Scale
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) Ensure machine is Calibrated and the Axis are positioned to center of travel.
B) 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.
C) 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.
D) Use the Axis Jog buttons to select the axis to adjust, then depress the Start button.
E) 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.
F) 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.
G) Return the axis to the closed-loop servo mode by depressing the Exit softkey and the Manual
Mode key.
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:
A) 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.
B) Y Axis:
Same as above except exchange X and Y coordinates in Data Block 3.
C) 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.
2. Connect DVM to Yaskawa TM3-2 (Positive Lead), and 0V (Negative lead) of the axis to be
setup. Set Meter on 2 VDC scale.
3. 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.
4. 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.
5. Repeat above steps for All Axes.
6. 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.
7. Run Axes thru a few short position moves, then recheck the axis balance by Calibrating Axes as
in step above.
8. 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.
FSB XXX Page 3 of 5

CACR-SRCA
REV B
OV
TM5
TM3 TM4
1
1 1
T
SW1 T T O
O O
1 8
8 8
T
O
SL4
8
SW4
RESET PUSHBUTTON
1
T
O
TROUBLE LED INDICATION
8 (7-SEGMENT)
SW2
VR9 IN
1 VR2 P
T VR10 MP
O VR11
VR12 5VP
8
VR13
IN-B
SW3 1
LOOP
T
O
8 ZERO
CUR
VR7
VR4
8 TO 1
VR8 SL6
TM2
8 TO 1 SL7
TM1
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.

MP (AXIS BUS STARTER [ABS] IS ACTIVATED)
AMPLIFIER CONTROL VOLTAGE IS PRESENT.

P (INTERNAL +5VDC)
IN A DAC COMMAND IS CURRENTLY APPLIED.
AXIS AMPLIFIER SEVEN-SEGMENT LED

DISPLAY
LED INDICATION TIME OF INDICATION PROBABLE CAUSE
BASE CURRENT GOES ON WHEN THE MAIN MACHINE IS IN EMERGENCY STOP.

- IS BLOCKED DISCONNECT IS TURNED ON.
NORMAL GOES ON AFTER THE START AXES ARE READY TO MOVE.

OPERATION PUSH BUTTON IS DEPRESSED.
GOES ON WHEN THE MAIN DEFECTIVE AMPLIFIER CONTROL CIRCUIT

DISCONNECT IS TURNED ON. BOARD (1 PWB).
GOES ON WHEN THE START DEFECTIVE CURRENT FEEDBACK CIRCUIT.

PUSH BUTTON IS DEPRESSED DEFECTIVE MAIN CIRCUIT TRANSISTOR
AND MCCB DOES NOT TRIP. MODULE.
1 OVERCURRENT
GOES ON WHEN THE START DEFECTIVE MOTOR GROUNDING.
PUSH BUTTON IS DEPRESSED DEFECTIVE MAIN CIRCUIT TRANSISTOR
AND MCCB DOES TRIP. MODULE.
GOES ON WHEN THE AXIS DEFECTIVE AMPLIFIER CONTROL CIRCUIT

STARTS OR SLOWS DOWN. BOARD (1 PWB).

CIRCUIT BOARD (1 PWB).
DISCONNECT IS TURNED ON.
2 PROTECTOR
GOES ON WHEN THE START DEFECTIVE MAIN CIRCUIT THYRISTOR
TRIPPED DIODE MODULE.
PUSH BUTTON IS DEPRESSED.

REGENERATIVE
3 TROUBLE GOES ON AFTER THE START DEFECTIVE REGEN TRANSISTOR OR REGEN
PUSH BUTTON IS DEPRESSED. RESISTOR.
4 OVERVOLTAGE DEFECTIVE REGEN CIRCUIT. DEFECTIVE REGENERATIVE CIRCUIT.
GOES ON AFTER THE START MOTOR/ENCODER CONNECTION ERROR

5 OVERSPEED PUSH BUTTON IS DEPRESSED. OR MOTOR/ENCODER FAILURE.
GOES ON AFTER THE START DEFECTIVE MAIN CIRCUIT THYRISTOR

6 VOLTAGE DROP PUSH BUTTON IS DEPRESSED. DIODE MODULE.

GOES ON WHEN THE START RESULT OF POSSIBLE OVERHEAT, ALLOW

7 OVERLOAD PUSH BUTTON IS DEPRESSED. SYSTEM TO COOL FOR 30 MINUTES.
GOES ON DURING MACHINE CONTINUOUS MACHINE OPERATION ABOVE

OPERATION. 100% RATED LOAD.
GOES ON WHEN THE MAIN RESULT OF POSSIBLE OVERHEAT, ALLOW

DISCONNECT IS TURNED ON. SYSTEM TO COOL FOR 30 MINUTES.
A OVERHEAT
GOES ON DURING MACHINE CONTINUOUS MACHINE OPERATION ABOVE
OPERATION. 100% RATED LOAD.

b A/D ERROR

OVERRUN DISCONNECT IS TURNED ON. BOARD (1 PWB).
C PROTECTION
MOTOR STARTS MOMENTARILY, MOTOR/ENCODER CONNECTION ERROR
THEN C. ERROR GOES ON. OR MOTOR/ENCODER FAILURE.

OPEN DISCONNECT IS TURNED ON. BOARD (1 PWB).
F PHASE GOES ON AFTER THE START MISSING THREE PHASE INPUT SOURCE.
PUSH BUTTON IS DEPRESSED. CHECK AXIS BUS STARTER (ABS).
GOES ON DURING MACHINE DEFECTIVE AMPLIFIER CONTROL CIRCUIT

CPU ERROR
OPERATION. BOARD (1 PWB).
ERROR STATUS IS RELEASED BY PRESSING THE AMPLIFIER RESET BUTTON
703-0006-169 Rev.A
FSB XXX Page 5 of 5

SUBJECT: Low Volume from Coolant Pumps. SUPERSEDES NUMBER:
PRODUCT LINE: Acroloc 1540, 1550, 3030 Twin Spindles PAGE 1 OF 1
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 ISSUE NUMBER: 1220
SUBJECT: Executive Disk V1.51 SUPERSEDES NUMBER:
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.

REVISED BY:
SUBJECT: Spindle Handling Precaution SUPERSEDES NUMBER:
PRODUCT LINE: All BMCS (Cartridge Type) PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: Proper Axis Current Set-Up SUPERSEDES NUMBER:
The proper axis currents for the Hawk 5M mill are as follows:
1) The X/Y Axis current should be between 3 to 6 Amps; in both plus and minus directions.
2) 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.

REVISED BY:
R
SUBJECT: Accuracy Standard Procedure
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 0
1 inch 60
2 inch 120
3 inch 180
4 inch 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.
FSB1223.DOC
Page 3 of 5
HURCO ULTIMAX PART PROGRAM INCH
ACCRCSTD.HD3 STANDARD
PART SETUP
PART ZERO X 1.2345 SAFETY WORK REGION

Y 6.7890 Z TOP (+) 99.0000
OFFSET Z 0.0000 Z BOTTOM (-) -99.0000
X LEFT (-) -99.0000
X RIGHT (+) 99.0000
Y FRONT (-) -99.0000
Y BACK (+) 99.0000
GENERAL PARAMETERS
RETRACT CLEARANCE 99.0000 IN

RAPID TRAVERSE 400.0 IPM
PECK CLEARANCE PLANE 0.0500 IN
CHORD ERROR 0.0001 IN
DEPLETION RETRACT 0.0050 IN
HOLES PARAMETERS
BORE ORIENT RETRACT 0.0200 IN

DRILL DWELL 0.5 SEC
BORE DWELL 1.0 SEC
MILLING PARAMETERS
BLEND OFFSET 0.1250 IN

BLEND OVERLAP 0.1250 IN
FINISH FEED 100 %
FINISH SPEED 100 %
FINISH XY 0.0100 IN
FINISH Z 0.0050 IN
MILLING DIRECTION CLIMB
POCKET OVERLAP 10 %
CUTTER COMP PARAMETER INSERT ARC
PROGRAM PARAMETERS
OVERRIDE LOCKOUT OFF

PROGRAM PROTECT PARTIAL
TOOL CHANGE POSITION NO
TOOL SETUP
1 TYPE DRILL
DIAMETER 0.1000
ZERO CALIBRATION 12.3456
SPEED (RPM) CW 0
COOLANT OFF
FSB1223.DOC
Page 4 of 5
DATA BLOCKS
1 CHANGE GENERAL PARAMETERS

RETRACT CLEARANCE 0.5000 IN
RAPID TRAVERSE 40.0 IPM
PECK CLEARANCE PLANE 0.0500 IN
CHORD ERROR 0.0001 IN
DEPLETION RETRACT 0.0050 IN
HOLES PARAMETERS
BORE ORIENT RETRACT 0.0200 IN
DRILL DWELL 1.0 SEC
BORE DWELL 1.0 SEC
MILLING PARAMETERS
BLEND OFFSET 0.1250 IN
BLEND OVERLAP 0.1250 IN
FINISH FEED 100 %
FINISH SPEED 100 %
FINISH XY 0.0100 IN
FINISH Z 0.0050 IN
MILLING DIRECTION CLIMB
POCKET OVERLAP 10 %
2 PATTERN LOOP RECTANGULAR

X NUMBER 10
Y NUMBER 10
X DISTANCE 0.0000
Y DISTANCE 0.0000
3 HOLES
DRILL
TOOL 1
Z START 0.0000
Z BOTTOM 0.0000
PLUNGE FEED 5.0
SPEED (RPM) 0
PECK DEPTH 0.0000
PECK TYPE STANDARD
LOCATIONS X Y
1 0.0000 0.0000
2 -1.0000 0.0000
3 0.0000 0.0000
4 HOLES
DRILL
TOOL 1
Z START -0.5000
Z BOTTOM -0.5000
PLUNGE FEED 5.0
SPEED (RPM) 0
PECK DEPTH 0.0000
PECK TYPE STANDARD
LOCATIONS X Y
1 13.1000 0.0000
2 14.1000 0.0000
3 13.1000 0.0000
5 PATTERN END
FSB1223.DOC
Page 5 of 5
SUBJECT: Table T-Slot Alignment SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5M / Hawk 5D PAGE 1 OF 1
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

REVISED BY:
SUBJECT: HAWK 5M/5D DRAWBAR SETUP SUPERSEDES NUMBER:
PRODUCT LINE: HAWK 5M/5D PAGE 1 OF 1
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:
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:
SUBJECT: Flood Coolant Leaks SUPERSEDES NUMBER:
PRODUCT LINE: Frame "A" Machines PAGE 1 OF 2
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.

REVISED BY:
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.

SUBJECT: Power Cabinet Coolant Leaks. SUPERSEDES NUMBER:
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.

REVISED BY:
SUBJECT: Incorrect parameter for Winding Change SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30/HT/D PAGE 1 OF 1
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.!!!

REVISED BY:
SUBJECT: Servo Dynamics Drive Tune Procedure. SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30/D, Hawk 5D, Hawk 5M PAGE 1 OF 1
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.

REVISED BY:
DATE: Nov. 28, 1995 ISSUE NUMBER: 1231
SUBJECT: Digital Spindle Controler PCB Modifications SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5 ssm PAGE 1 OF 1
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 ISSUE NUMBER: 1232
SUBJECT: Upgrade of Remote Shutdown Relay. (RSR) SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30/D, BMC 30/HT/D PAGE 1 OF 1

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.

REVISED BY:
DATE: Jan. 24, 1996 ISSUE NUMBER: 1233
SUBJECT: Upgrade of RS232C Cables. (Com 1, Com 2 ) SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30/M, BMC 30/HT/M PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: Kurt Power Heads & Drawbar Set-up SUPERSEDES NUMBER:
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 DESCRIPTION DRAWBAR PART # WHERE USED

002-4208-003 Metric Power Drawbar Assy. 802-2906-003 Current Hawk Mills
002-4208-004 Inch Power Drawbar Assy. 802-2906-002 Current Hawk Mills
002-4208-005 Metric Power Drawbar Assy. 802-2706-002 KM5P & Early Hawk Mills
002-4208-006 Inch Power Drawbar Assy. 802-2706-001 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

SUBJECT: Retro-fit of Drive Spindles to SUPERSEDES NUMBER:

accept 18 MM Proximity Switches.
PRODUCT LINE: Acroloc 15-32, 15-40 Machining PAGE 1 OF 1

Centers
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 15-
40 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.)

REVISED BY:
DATE: Feb. 08, 1996 ISSUE NUMBER: 1236
SUBJECT: Max32 Hard Drives
PRODUCT LINE: All Max32 machines 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 ISSUE NUMBER: 1237
SUBJECT: FRL Units SUPERSEDES NUMBER:
PRODUCT LINE: All 30 A Frames PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: Z AXIS Cable Damage SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30M/ HTM/ D PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: Fan Replacement / ISA Card Racks SUPERSEDES NUMBER:
PRODUCT LINE: All ISA machines PAGE 1 OF 1
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. Power off the machine.

2. Remove the fan housing screws.
3. Carefully remove the plastic fasteners that are holding each fan.
4. 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. Power off the machine.

2. Remove the four mounting screws holding each fan.
3. Unplug and replace with the new fans and reassemble.
4. 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.
5. Locate the 12VDC brown wire on J1-10.
6. Remove this wire from the J1 wago connector.
7. Remove a blue 24VDC wire from either J1-11, or J1-12.
8. Splice the brown fan wire to the 24VDC wire and insert back into the respective J1
terminal.
9. This completes the modification. You should now have 24VDC supplied to the new fans.
REVISED BY:
SUBJECT: Oiling Problems SUPERSEDES NUMBER:
PRODUCT LINE: Acroloc 1540, 3030 PAGE 1 OF 1
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 Ferrule Qty 2

2. 508-2001-001 5/32 Bijur Tubing Qty 3 ft.
ORIGINATOR: Tim Cloud

REVISED BY:
SUBJECT: Possible Noise Problems SUPERSEDES NUMBER:
PRODUCT LINE: BMC4020/HT/M, BMC4020SSM PAGE 1 OF 2
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.

REVISED BY:
FSB xxxx Page 3 of 2
DATE: Sept. 6, 1996 ISSUE NUMBER: 1242
SUBJECT: ISA CARD RACK DIAGNOSTIC TIPS SUPERSEDES NUMBER:
PRODUCT LINE: ALL ISA MACHINES PAGE 1 OF 2
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.
2. CMOS settings and motherboard jumpers are also crucial. I wouldnt recommend making
any changes before consulting your documentation first; dont guess.
3. 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.
4. 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.
5. 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

REVISED BY:
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.
7. 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.
8. 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.
Page 2 of 2
SUBJECT: Spindle twitch @ Null setup. SUPERSEDES NUMBER:
PRODUCT LINE: BMC30SSM PAGE 1 OF 2
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.

REVISED BY:
Drawing Number 423-4401-073
Remove
Page 2 of 2
SUBJECT: Work Light Suppresser Modification SUPERSEDES NUMBER:
PRODUCT LINE: BMC30SSM, BMC30/M with Siemens, PAGE 1 of 2

BMC4020/HT/M, BMC4020SSM
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.

REVISED BY:
417-6001-010 417-6001-010

SUBJECT: Spindle Agree Faults during Rigid Tap Functions SUPERSEDES NUMBER:
PRODUCT LINE: BMC4020HT/M, BMC4020SSM, BMC30HT/M PAGE 1 OF 1

(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.

REVISED BY:
SUBJECT: Harness Bracket Installation SUPERSEDES NUMBER:
PRODUCT LINE: BMC4020/HT/M, BMC4020/SSM PAGE 1 OF 2
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.

REVISED BY:
Cattrack Harness Installation Cabinet Bottom Installation

SUBJECT: Canbus Controller Modification SUPERSEDES NUMBER:
PRODUCT LINE: All ISA machines PAGE 1 OF 1
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

REVISED BY:
SUBJECT: Siemens Drive wiring change. SUPERSEDES NUMBER:
PRODUCT LINE: BMC4020/HT/M, BMC4020/SSM PAGE 1 OF 3
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.

REVISED BY:
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

SUBJECT: Coolant/Oil Separator Modification SUPERSEDES NUMBER:
PRODUCT LINE: 30D/HT/M/SSM, 4020SSM/HTM PAGE 1 OF 3
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 803-1049-004 Tank Coolant/Oil Separator

9pc 101-5008-003 SHCS, M6 X 1.0 P X 12 LG
9pc 110-0046-007 Lockwasher, M6 Helical Spring
6ft. 507-0001-002 Low Pressure Hose I.D.
24in. 507-1203-002 Low Pressure Hose I.D.
1pc 702-0001-004 RTV, 4.7oz Clear
1pc 506-5008-003 Plug 3/8
4pc 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.

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 ISSUE NUMBER: 1250
SUBJECT: Re-Wire of Fast Stop signal to Siemens Drive SUPERSEDES NUMBER:
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.

REVISED BY:
HURCO MANUFACTURING COMPANY
One Technology Way
Indianapolis, IN 46268-0180
R
SUBJECT: V2.00 PARAMETER CHANGES
PRODUCT LINE: ULTIMAX 3 ISA 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:
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
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
for Z Axis
for X and Y Axes
for Z Axis
for X and Y Axes
for Z Axis
for X and Y Axes
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
FSB1251.DOC
Page 2 of 4
for X Axis
for Y Axis
for Z Axis
for Z Axis
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:
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 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
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.
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.
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.
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).
28. Reenter Integrator Support Services and disable the D: Drive Access Enable.
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.
FSB1251.DOC
Page 4 of 4
One Technology Way
R
DATE: June 26, 1997 ISSUE NUMBER: 1251b
SUBJECT: V2.00 PARAMETER CHANGES
PRODUCT LINE: ULTIMAX 3 ISA 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
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.

REVISED BY: Tom Murden
for X Axis
for Y Axis
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).
for Z Axis
for X and Y Axes
page 11, change N95:211 from 0 to 1
for Z Axis
for X and Y Axes
for Z Axis
for X and Y Axes
for Z Axis
for X and Y Axes
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
FSB1251.DOC
Page 2 of 4
for X Axis
for Y Axis
for Z Axis
for Z Axis
for X and Y Axes
INSTRUCTIONS: Please update the following Machine Parameters Diskettes in the V2.00 Field
Installation Software Kit:

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:
3. Select the SPINDLE 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..
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).
19. Reenter Integrator Support Services and disable the D:Drive Access Enable.
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 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
3. Select the SPINDLE softkey.
4. Change the Maximum DAC Volts from 9.35 to 9.5 volts.
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.
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.
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.
22. Select the CHANGE PROGRAM MASK softkey and change to *.*.
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).
29. Reenter Integrator Support Services and disable the D: Drive Access Enable.
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.
FSB1251.DOC
Page 4 of 4
SUBJECT: M-CODE MODIFICATIONS SUPERSEDES NUMBER:
PRODUCT LINE: YASKAWA ISA BEDMILLS PAGE 1 OF 8
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 M-
Code 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. Mount the 20 position terminal strip on the main panel near the cardrack.
2. 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).

REVISED BY:
g) 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:
h) White wire to new terminal strip at terminal 11 and jumper to 12,13,14, and 15
(+24VDC).
i) Black wire to terminal 16 (AUX OUT 1).
j) Brown wire to terminal 17 (AUX OUT 2).
k) Red wire to terminal 18 (AUX OUT 3).
l) Green wire to terminal 19 (AUX OUT 4).
3. 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.
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.
5. 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).
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).

B. M-Code modifications for Yaskawa ISA machines without TB1, TB2 terminal strips.
Materials required:
1 PC 20 position terminal strip (406-4005-323).
1. Mount the 20 position terminal strip on the main panel near the cardrack

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).
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).
3. 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).
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.

C. 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.
2. 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 J1-
48 to TB1-55. This reconnects the I/R module reset at the I/O IF board.
c) Update Harness Revision to C.

a) Find the wire from DC I/O J2-5 to TB2-55 bottom. Move the wire end at DC I/O J2-
5 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.
4. 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.

D. 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 Enables Aux Output 1 M62 Disables Aux Output 1

Connection of Physical I/O
Connection points for utilizing M-Codes on machines with TB1 and TB2 terminal strips installed at
the factory.
Outputs I/O Description Terminal Block
Aux Out 1 OUT09 TB2 - 45
Confirmation Inputs I/O Description Terminal Block

Aux In 1 INP13 TB2 - 21
Connection points for utilizing M-Codes on machines with field installed 20 position M-Code
terminal strip.
Outputs I/O Description Terminal Block
Aux Out 4 OUT12 TB1- 19
Confirmation Inputs I/O Description Terminal Block

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) Status Time (sec) Program Operation

Label
52 Integrator Defined 0.0000 Aux Out #1
62 Integrator Defined 0.0000 Aux Out #1 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 Description Value

N95:250 Aux Output CF Enable 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 2 (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 normally-
opened 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) Harness, I/O IF J1

423-4401-067 (CAD 8339 REV. D) Harness, DC I/O J1
423-4401-068 (CAD 8340 REV. D) Harness, DC I/O J2
423-4405-077 (CAD 8298 REV. C) Harness, I/O to Infeed I/R Module

SUBJECT: Spindle Drive Faults not reported to Control SUPERSEDES NUMBER:
PRODUCT LINE: BMC 40/50, BMC 50/50 PAGE 1 OF 3
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 423-4405-
035 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.

REVISED BY:
SUBJECT: Full Enclosure Door Slides 410-5001-002 SUPERSEDES NUMBER:
PRODUCT LINE: BMC40, BMC50 PAGE 1 OF 2
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.

REVISED BY:
SUBJECT: Air Requirements SUPERSEDES NUMBER:
PRODUCT LINE: All BMC30 and BMC40/20 PAGE 1 OF 1
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.

REVISED BY:
SUBJECT: Hawk5M Servo Inhibit SUPERSEDES NUMBER:
PRODUCT LINE: Hawk5M W/Wago Servo Dynamic PAGE 1 OF 3
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 2.7K ohm watt resistors 407-0035-331 or 407-0036-079

20 in. 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.

REVISED BY:
FSB 1256 2 of 3
FSB 1256 3 of 3
One Technology Way
SUBJECT: V2.00 Parameter Changes
PRODUCT LINE: BMC 4020SSM 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 757-
4002-097. 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.

REVISED BY:
SUBJECT: BMC30SSM Modifications MN3996 SUPERSEDES NUMBER:
PRODUCT LINE: BMC30SSM PAGE 1 OF 1
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.

REVISED BY:
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).

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FIELD SERVICE BULLETIN

1001 MB1 TOOL CHANGER ALIGNMENT AND ADJUSTMENT.

1046 MD3 Z AXIS SC FAULT PROBLEM WITH AUX BRIDGE.

1099 BMC 10/10L TOOL SUPPORT PROBLEM.

1152 REPLACEMENT OF KNEE MILL MOTORS/ENCODERS (MTE ASSY)

1204 KM5D INPUT POWER, SOURCE FOR TRANSFORMER.

1251 V2.00 PARAMETER CHANGES

DATE: AUGUST 24, 1981 ISSUE NUMBER: 1001

SUBJECT: TOOL CHANGER ALIGNMENT SUPERSEDES NUMBER: 102

PRODUCT LINE: MB1 PAGE 1 OF 7

SHOT PIN ADJUSTMENT

1. APPLY BLUEING TO LOWER SPINDLE COUPLING.

SHOT PIN LIMIT SWITCH ADJUSTMENT

NO TOOL IN SPINDLE P.C. BRD MOUNTING AND ADJUSTMENT

ORIGINATOR: WAYNE E. HAWKINS

TC ENCODER P.C. BOARD ADJUSTMENT

MECHANICAL STOP ADJUSTMENT

SHOCK ABSORBER INSTALLATION

ARM FORWARD LIMIT SWITCH ADJUSTMENT

TORQUE LIMITER ADJUSTMENT

1. MATE-IN THE TORQUE LIMITER BY TIGHTENING TO APPROXIMATELY FINAL TIGHTNESS,

NO TOOL IN-SPINDLE LIMIT SWITCH ADJUSTMENT

SPINDLE ORIENT RPM

1. THE ORIENT RPM SHOULD BE 1 REVOLUTION PER 2 SECOND PERIOD.

Z AXIS TOOL CHANGER CURRENT LIMIT ADJUSTMENT

1. Z AXIS MUST RUN AT 250 IPM TOOL CHANGE SPEED.

1. RUN EACH TOOL POSITION AT LEAST TWICE IN AUTO TC.

TOOL CHANGER PINNING

DATE: DEC. 22, 1981 ISSUE NUMBER: 1002

SUBJECT: RELIABILITY IMPROVEMENT B INTERFACE BRD SUPERSEDES NUMBER:

PRODUCT LINE: ALL B CONTROL MILLS PAGE 1 OF 1

THIS MODIFICATION SHOULD BE MADE WHEN A MACHINE EXHIBITS MANUAL JOG

REFERENCE SCHEMATIC AND PICTORIAL ATTACHED:

1. CUT LAND TO PIN 6 OF 14035 AT THE POINT SHOWN ON SHEET TWO

1. ONE 2K OHM 1/4 WATT RESISTOR 407-0007-030.

SHEET FIVE SHOWS THE SCHEMATIC OF THE INTERFACE BOARD.

ORIGINATOR: WAYNE HAWKINS

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

ORIGINATOR: WAYNE HAWKINS

SUBJECT: ENCODER INSTALLATION SUPERSEDES NUMBER: 120

PRODUCT LINE: KM1 PAGE 1 OF 1

CAUTION: THE DISK CAN BE EASILY CHIPPED CRACKED OR SCRATCHED AND

1. CLEAN AREA ON LIMIT SWITCH ASSEMBLY BRACKET WHERE ENCODER MOUNTS.

CAUTION: USE A THIN-BLADED SCREWDRIVER WHEN TIGHTENING THE

DATE:FEBRUARY 10, 1982 ISSUE NUMBER: 1005

SUBJECT: POWER DOWN MEMORY CIRCUIT SUPERSEDES NUMBER: 122

PRODUCT LINE: B CONTROL MILLS PAGE 1 OF 2

THIS BULLETIN IS TO CLARIFY THE BATTERY PROTECTION CIRCUIT USED IN THE B

IN TROUBLE-SHOOTING A SYSTEM, IT IMPERATIVE TO ASSURE ALL BOARDS HAVE THE

ORIGINATOR: JERRY MC CLATCHEY

DATE: MARCH 30, 1982 ISSUE NUMBER: 1006

PRODUCT LINE: KMB-1 PAGE 1 OF 1

IT APPEARS THERE IS SOME CONFUSION WITH AXIS CURRENT READINGS AND

ORIGINATOR: RANDALL RENNEKAMP

DATE: MARCH 26, 1982 ISSUE NUMBER: 1007

SUBJECT: MB1 SHOT PIN LIMIT SWITCH SUPERSEDES NUMBER: 128

PRODUCT LINE: MB1 MILL PAGE 1 OF 2

1. REMOVE POWER FROM THE MACHINE.

NOTE: THE MOUNTING BRACKET IS TAPPED FOR M2.5X.45 SCREWS SO IT MAY BE

ORIGINATOR: WAYNE HAWKINS