Scanned and converted by Vince Callahan

MAINTENANCE MANUAL
and
P A R T S CATALOG
NO. 3352A

1-22 MASTERMIL

T h i s I s A Maintenance Manual And P a r t s C a t a l o g Only.

F o r O p e r a t i n g I n s t r u c t i o n s R e f e r T o Manual No. 3353.

T h i s Manual Contains Maintenance I n s t r u c t i o n s And T h e

P a r t s L i s t F o r The G o r t o n Model 1-22 M a s t e r m i l .

The machine to which this manual applies h a s been carefully assembled, in-
spected and test- run under maximum load at the Gorton factory. It i s i n
satisfactory operating condition. Routine operations and adjustments a r e
explained herein, but the manufacturer will not be held responsible for satis-
f a c t o r y o p e r a t i o n if u n a u t h o r i z e d m o d i f i c a t i o n s . a l t e r a t i o n s o r m a j o r r e p a i r s
a r e a t t e m p t e d w i t h o u t s p e c i f i c i n s t r u c t i o n s f r o m t h e f a c t o r y . One o f t h e s e
manuals i s furnished with each machine. Additional copies may be purchased
d i r e c t f r o m t h e G o r t o n M a c h i n e C o r p o r a t i o n a t $5. 00 e a c h .

T h e right i s r e s e r v e d to im p r o v e . c h a n g e , modify o r d i s c o n t i n u e a n y G o r t o n m a c h i n e , a t t a c h m e n t o r
a c c e s s o r y without obligation to m a k e s u c h i m p r o v e m e n t , c h a n g e o r modification o n e q u i p m e n t p r e v i o u s l y
sold or on order.

Patent Notice: T h e m a c h i n e s a n d a t t a c h m e n t s to which t h e s e i n s t r u c t i o n s apply a r e p r a t e c t e d by i s s u e d

and pending United S t a t e s a n d f o r e i g n p a t e n t s .

S U B S I D I A R Y O F K E A R N E Y & T R E C K E R CORPORATION

RACINE W I S C O N S I N 53403 U S A
 WARRANTY

T h e GORTON MACHINE CORPORATION w a r r a n t s t h a t t h e

equipment which it supplies will fulfill the specifi-
c a t i o n s c o n t a i n e d i n t h e c o n t r a c t of sale. If either
the workmanship o r material is not a s agreed, such
defect shall be remedied by Gorton. No allowance
w i l l b e m a d e f o r a n y e x p e n s e i n c u r r e d by t h e p u r c h a s e r
in r e p a i r i n g defective p a r t s o r in supplying any mis-
sing parts, except on Gorton's written consent. The
w a r r a n t y on a l l c o m p o n e n t s p u r c h a s e d by G o r t o n f r o m
other vendors shall be in accordance with the warranty
given by s u c h vendor. Gorton s h a l l not be liable f o r
a n y l o s s of p r o f i t s o r a n y o t h e r c o n s e q u e n t i a l d a m a g e s
w h a t s o e v e r a r i s i n g f r o m a n y b r e a c h of w a r r a n t y , d e -
lays in shipment, o r from any other cause(s) whatso-
ever. No o t h e r w a r r a n t y s h a l l b e i m p l i e d , o r a t t a c h
b y o p e r a t i o n of l a w . This warranty i s limited to twelve
( 1 2 ) m o n t h s a f t e r d a t e of s h i p m e n t f r o m G o r t o n ' s p l a n t
( s i x (6) m o n t h s if u s e d o n a t w o s h i f t o p e r a t i o n ) , a n d
i s void if the original equipment has been altered. This
warranty is limited to the f i r s t purchaser and is not
transferable.

GORTON MACHINE CORPORATION

RACINE, WISCONSIN, U. S. A.
 TABLE OF CONTENTS
MAINTENANCE INFORMATION

DESCRIPTION PAGE

PRELIMINARY OPERATIONS --------------------------------------

ELECTRICAL -------------------------------------------------------
COLUMN --------------------------------------------------------------------
KNEE- ADJUSTMENTS -----------------------------------------------
KNEE- REMOVING AND RE PLACING PARTS ------------------
SADDLE-ADJUSTMENTS ---------------------------------------------
SADDLE- REMOVING AND REPLACING PARTS ---------------
TABLE-ADJUSTMENTS --------------------------------------------
TABLE-REMOVING AND REPLACING PARTS ----------------
SPINDLE-ADJUSTMENTS ------------------------------------------
SPINDLE-REMOVING AND REPLACING PARTS -------------
VARIABLE SPEED HEAD --------------------------------------------
STANDARD HEAD -------------------------------------------------------
RAM AND TURRET ----------------------------------------------
HORIZONTAL SPINDLE -------------------------------------------
MAINTENANCE CHECK LIST ------------------------------------
LUBRICATION ---------------------------------------------------------

PARTS O R D E R I N G LISTS
SERVICE POLICY ----------------------------------------------------
COLUMN- PARTS LIST ----------------------------------------------
KNEE- PARTS LIST ----------------------------------------------------
SADDLE- PARTS LIST ------------------------------------------------
SADDLE LUBRICATION- PARTS LIST ---------------------------
TABLE- PARTS LIST ------------------------------------------------
RAM AND TURRET-PARTS LIST ---------------------------------
HORIZONTAL SPINDLE-PARTS LIST ----------------------------
VARIABLE SPEED HEAD-PARTS LIST --------------------------
STANDARD HEAD AND SPINDLES-PARTS LIST --------------
SPINDLE DOWN FEED- PARTS LIST ------------------------------
SPRAY MIST COOLANT-PARTS LIST ---------------------------
FLOOD COOLANT- PARTS LIST ----------------------------------
ELECTRICAL- PARTS LIST -----------------------------------------
STYLE "B" ARBOR SUPPORT- PARTS LIST --------------------
DYNA DRIVE II-PARTS LIST -------------------------------------

iii
 PRELIMINARY OPERATIONS

1. UNCRATING 4. CLEANING

Remove crating with c a r e s o that machine and Do not operate any moving part of this ma-
parts a r e not marred, scratched o r damaged. Exa- chine until it i s thoroughly clean and has been gi-
mine carefully for evidence of shipping damage. Re- ven a coating of oil. Remove shipping grease with
port a t once to transportation company and to Gorton clean olium spirits, o r other grease solvent. Use
representative any evidence of such damage. Check lintless rags, not cotton waste. Never use an air
shipment carefully against itemized packing list for hose. When machine i s clean, give it a light coat of
possible shortages. a good grade clean machine oil to prevent r u s t spots
and other corrosion. For lubrication s e e LUBRI-
2. FOUNDATION CATION page 41.
I

Before moving the machine be s u r e the lo-

cation has a solid footing and i s level a s possible.
Have steel shims ready for leveling. steel shims
should be used because softer metals a r e not stable
enough to maintain level of the machine. Use vi-
bration pads under all four corners of the machine.

The machine does not have to be bolted to the

floor.

3. MOVING THE MACHINE (See figure 1)

This machine i s easily moved by shop hoist

o r crane. Be s u r e that r a m i s in operating posi-
tion and that r a m i s securely held by r a m clamp-
ing nuts. Position the table with its center direct-
ly below the spindle and place table clamping lever
in clamp position.

Insert lifting hook into the eye bolt on top of

r a m and carefully move machine to desired location.
If machine does not lift evenly, change the c r o s s po-
sition of table. Figure 1. Moving The Machine
DO NOT USE CHAINS UNDER TABLE OR RAM.
This could damage the bearing surfaces causing mis- 1. Ram 4. Clamping Nut
alignment. 2. Clamping Nut 5. Lifting Hook
3. Serial Number
The machine can also be moved by using a
lift truck as shown in figure 1. Use wood spacers 5 . LEVELING
between the forks and bearing surfaces to prevent
damage. After machine has been installed and cleaned,
it must be carefully leveled. Make sure it is at room
CAUTION temperature before beginning to level. Use a sen-
sitive, graduated spirit level (10 seconds per grad-
Make s u r e that r a m i s securely clam- uation) for best results. Level machine by placing
ped to t u r r e t with front and r e a r r a m spirit level f i r s t lengthwise, then crosswise on the
clamping bolts (figure 1). Place lif- table, and change the position of the table several
ting hook in eye bolt on top of r a m and times during the process. Remember that this ma-
move machine to its permanent loca- chine must be re-leveled from time to time due to
tion. floor settlement.
 ELECTRICAL

6. HOOK-UP PROCEDURE Maximum efficiency requires full power.

Check input voltage while machine is running and
This machine and control equipment have been while a l l other electrical equipment on the s a m e line
wired, phased, inspected and test run in our factory is operating. The input voltage to the machine must
to insure c o r r e c t performance in the customer's be within plus o r minus 8% of the voltage marked on
plant. the electrical cabinet nameplate to insure proper op-
eration of controls.
If machine was shipped with spindle motor
dismounted, the motor must f i r s t be mounted and 8. POWER FEED (DYNA-DRIVE, OPTIONAL)
connected. To connect spindle motor, open motor
terminal box cover and match color coded "tattle Power feed to the table and spindle downfeed
tail" lead wires of the motor to the s a m e color wire a r e supplied by D. C. shunt wound motors. If the
of the power supply line. In some cases, wires a r e direction of rotation does not conform with the set-
marked with l e t t e r s and numbers. If motor leads ting of the downfeed toggle switch o r the longitudinal
a r e accidentally disarranged, consult motor speci- direction engagement lever, the a r m a t u r e leads must
fication plate f o r proper lead wire connection. be r e v e r s e d a t the corresponding motor.
Proceed to connect the power input line t o the 9. POWER ELEVATE (OPTIONAL)
t e s t leads marked L1, L2 and L3 on the terminal
s t r i p in the control cabinet. Make certain the cor- The power elevate motor is a 3-phase in-
r e c t voltage and phase is used. duction motor operated by a drum-type reversing
switch located in Dyna Drive II control panel a t the
7. MOTOR ROTATION front of the saddle. If the direction of movement
controlled by the switch is wrong, c o r r e c t by chang-
Place spindle reversing switch a t "FOR- ing power supply leads on the motor.
WARD" position and check spindle motor operating
direction. The rotation direction of a standard ma- 10. DIAGRAMS
chine is clockwise, when looking down a t the spindle.
One of each of the following will be found in
CAUTION the pocket on the inner wall of the control cabinet
door: elementary connection diagram, panel lay-
If spindle has c o r r e c t rotation, a l l out diagram, sequence of operations and feed mo-
other power feed controls will be di- t o r instructions. Location of fuses, hook-up of ac-
rectional. If power feed controls a r e tuators and controls is provided. This data should
directional, but spindle rotation i s in- remain with the machine a t all times for efficient
correct, CHANGE LEADS TO SPIN- s e r v i c e and maintenance.
DLE MOTOR.
11. D. C. POWER SUPPLY
If it rotates counter-clockwise, r e v e r s e the
power leads to the cabinet. All other motors which The spindle downfeed and table feed power
require counter-clockwise operation will be s o mar- supply provides the means of operating D. C. drive
ked with an a r r o w on the motor end bell. motors from an A. C. line. The function of the D. C.
control panel, located in the main electrical cabinet, 8. Advance the downfeed rate selector t o . 5 .
i s to supply power to the armature and fields on the 9. Engage the downfeed direction selector
two D. C. feed motors. The armature voltage i s (toggle switch). The quill should move at a low feed
controlled so that the motor speed may be varied rate.
from minimum to maximum rating. Maximum horse- 10. Advance feed rate control to maximum
power is delivered at maximum speed. At speeds and note that downfeed rate increases smoothly.
below maximum, the torque i s constant and the horse- 11. At conclusion of tests, declutch levers
power i s directly proportional to the s e t running and return downfeed rate selector to the zero "click
speed. off" position.

The complete power drive system consists

of the following units: (1) the power supply, (2) the 13. POTENTIOMETER CONTROLS
D. C. drive motors and (3) the operator control po-
tentiometers. The power supply is mounted in a The table feed and spindle downfeed poten-
vertical position within the cabinet for proper ven- tiometer controls (I. P. M. selectors) a r e connected
tilation of the heat sink. The power supply contains in parallel. WHEN NOT IN USE, BOTH SHOULD BE
the circuits for converting A. C. single phase to D. C. TURNED OFF (spindle downfeed in "click-off ").
to control the feed motors. The motor field i s sup- When either table feed o r spindle downfeed control
plied with a half-wave rectified D. C. voltage. Var- i s engaged, the remaining control i s automatically
iable armature voltage (controlled f r o m operator's disconnected through an electrical interlock relay.
potentiometer control) i s supplied from a half-wave
silicon control rectifier circuit. 14. GENERAL

12. D. C. OPERATIONAL CHECK If it i s necessary to disconnect any motor,

actuator o r control, it i s advisable to tag o r mark
The system should be placed in operation a s the lead wires.
follows:
If for any reason the drawings have been mis-
1. Set table and spindle feed rate selectors placed, consult the nameplate on the control cabinet
(potentiometers) to their zero "click off" positions, for EE and E P drawing numbers.
2. Close line disconnect switch on machine
electrical control cabinet. Reserve fuses for D. C. power supply a r e
3. Advance the table feed rate selector to .6. shipped with the machine. Only fuses of the same
4. Engage the table direction selector. The specification a r e to be used in the corresponding
table should move at a low feed rate. component. DO NOT USE SUBSTITUTE FUSES.
5. Advance feed rate control to maximum
and note that table feed rate increases smoothly. All electrical components a r e standard. In
6. Return table feed rate selector to the zero case of component fatigue o r breakdown, the r e -
"click off" position. placement should be of the same model and manu-
7. Engage the spindle downfeed clutch lever facture.
and operating lever on the downfeed gear box (turn
depth stop down to low position).
 COLUMN

15. SERIAL NUMBER LOCATION (figure 1) 17. SPRAY MIST COOLANT

The s e r i a l number of each machine i s loca- The s p r a y m i s t coolant s y s t e m is a i r opera-

ted on the front of the column just above the left way. ted and is mounted on the r e a r of the column. A 1/4
When ordering p a r t s and when writing to the factory inch pipe tap on the left side of the unit connects to a
always include the s e r i a l number of the machine. s h o p a i r l i ne a n d p r e s s u r e s hould not exceed 125 lbs.
Air and coolant lines connect to the right s i d e of the
16. FLOOD COOLANT unit. The nozzle h a s a magnetic holder for efficient
positioning relative to the cutter, and a thumbscrew
The flood coolant system i s a gusher type of needle control on the nozzle is used to control the
package unit in which the r e s e r v o i r , motor and pump amount of coolant in the spray. When the thumbscrew
a r e located in the back, lower p a r t of the column. is closed, only a i r comes out of the nozzle.
The coolant tank h a s a capacity of 2-1/2 gallons.
The motor and pump a r e integral and must be r e - A slotted screw, under the a c o r n nut on the
placed a s a unit. Rotation of the pump is counter- top left of the unit, can be turned to regulate out-
clockwise (looking down f r o m top), and is indica- going a i r pressure. A gage is supplied for visually
ted by an a r r o w on the pump housing. checking this pressure.

The coolant r e t u r n line is connected to the left The filler cap on the top, right of the unit,
table bracket and runs through the left side of the should not be removed while the unit is activated.
column into the r e s e r v o i r . The outlet line h a s a The unit is activated by electrical interlock be-
flexible, nozzle and shutoff valve. tween the spindle motor and the solenoid on top of
the s p r a y m i s t unit. Coolant flow will s t a r t o r stop
A s c r e e n is provided in the table to remove with spindle motor control. Air flow will continue
chips and other foreign material f r o m the coolant. with coolant off.
However, we suggest that periodically the r e s e r v o i r
be removed and inspected f o r foreign material. If A sight gage on the front of the unit provides
any is present it should be removed to prevent dam- a visual means of checking coolant level when filling
age to the coolant pump. the unit, and directly below the sight gage is the drain
plug.
Fill re s e r v o i r to level m a r k before starting
pump. Water soluble oils a r e used in this unit and the
mixture should be to manufacturer's specification and
Before stopping the pump, s e t the shutoff on consistency to insure non r u s t and non clogging con-
the nozzle to the O F F position s o the " prime" will ditions. Multi nozzle manifold blocks a r e available
not be lost. To keep the r e t u r n line open, remove s o m o r e than one nozzle can be used for g r e a t e r cut-
and clean the s c r e e n on the left end of the table and ting efficiency.
the r e t u r n line.

The spindle motor and coolant pump a r e elec-

trically interlocked.
 KNEE - ADJUSTMENT

18. TAPERED GIB (figure 2) 19. VERTICAL TRAVEL MICROSWITCH, POWER

ELEVATE (figure 3).
Adjust the tapered gib a s follows:
This microswitch (1) stops the knee at its lim-
1. Remove the right wiper (4). its of travel when power operated. The limit stops
2. Back off the bottom gib screw (2) and take (2) a r e fixed and cannot be adjusted. If the limit stops
up the same amount on top gib screw (1). a r e reached the power elevate stops.
3. When the tapered gib is properly adjusted
the knee will move down of its own weight. This can To check operation of the microswitch, turn
be checked by raising the knee with the handwheel, the elevate handwheel to move the knee up and down.
clamping the knee, and rotating the handwheel coun- Listen for the relay dropout and the click of the mic-
ter-clockwise to take up any backlash in the elevate roswitch a s i t reaches the limit stops. Approxima-
train. By releasing the clamp the knee should drop tely four complete turns of the handwheel, after you
and not hang". hear the click, should move the knee to its top o r
bottom limits.

It i s necessary to manually operate the knee

until the switch roller (3) moves off the stop and the
power elevate a s s i s t i s re-activated.

Figure 2. Knee Gib Figure 3. Left Side Of Knee

1. Top Gib bcrew 4. Right Wiper 1. Vertical Travel Microswitch

2. Bottom Gib Screw 5. Wiper Screw 2. Limit Stops
3. Tapered Gib 3. Switch Roller
20. ANTI-BACKLASH NUT (CROSS, 12" KNEE)
(figure 4).

To eliminate backlash between the c r o s s feed

s c r e w and nut f o r climb milling, the anti-backlash
nut should be adjusted a s follows:

1. Move the saddle as f a r a s possible to the

r e a r of the machine, and lift up the front apron (1).
2. Loosen the two socket head s c r e w s (2)
holding the adjustable nut (3).
3. To eliminate backlash, rotate the adjus-
table nut counterclockwise (as you face it).
4. I f n u t i s too tight (no backlash) rotate it
clockwise.
5. Retighten the two socket head s c r e w s (2)
and drop the apron back into position.

NOTE

The 10" c r o s s feed knee has a single

fixed nut, s o no backlash adjustment
is possible.

Figure 4. Adjusting Anti-Backlash Nut-Cross

12" Knee

1. Front Apron
2. Socket Head Screws
3. Adjustable Nut

KNEE - REMOVING AND REPLACING PARTS

21. CROSS FEED SCREW NUTS AND BEARINGS 8. Remove the bearing locknut (17) and take
(figure 5) out the ball bearings (9) and two spacers (10 and 11).
9. Take out the two capscrews (12) and r e -
Remove the c r o s s f eed screw, nuts and bear- move the front adjustable nut (13).
ings a s follows: 10. Lightly tap the r e a r stationary nut (14)
to remove it.
1. Move the saddle to i t s forward position.
2. Take out the r o l l pin (1) and pull off the NOTE
handwheel (2).
3. Unscrew the thumb s c r e w (3) and remove The 10" knee does not have an adjus-
the micrometer dial (4). table nut. To remove the stationary
4. Remove the three capscrews (5) and take nut, move the saddle forward. Re-
off the bearing plate (6). move the locknut (15) and tap out the
5. Replace the handwheel (2) and the r o l l pin stationary nut (16).
(1) holding the handwheel to the shaft.
6. Turn the handwheel until the c r o s s feed 11. Reassemble the p a r t s in r e v e r s e order.
s c r e w (7) backs out of the c r o s s feed nut. Be s u r e the dog point in the s e t s c r e w mates with the
7. Remove the roll pin (1) and again take off slot in the stationary nut. It may be necessary to
the handwheel (2), s o the other p a r t s can be remov- rotate the adjustable nut s o that the s c r e w p a s s e s
ed. through the nuts without binding.
 Figure 5. Removing Cross Feed Screw Nuts And
Bearings

1. Roll Pin 11. Spacer

2. Handwheel 12. Spacer
3. Thumb Screw 13. Adjustable Nut
4. Micrometer Dial 14. Stationary Nut
5. Capscrews 15. Locknut
6. Bearing Plate 16. Stationary Nut
7. Cross Feed Screw 17. Bearing Locknut
8. Bearing Locknut NOTE: Items 12 to 15 a r e
9. Ball Bearing in saddle.
10. Spacer
Figure 6. Elevate Feed Screw Nut And Bearing, Power and Manual Elevate

1. Capscrews 8. Elevate Gear Bracket Assembly

2. Power Elevate Assembly 9. Screws
3. Setscrew 10. Elevate Nut
4. Handwheel- Power 11. Elevate Screw
5. Capscrews 12. Locknut
6. Manual Elevate Assembly 13. Roller Bearings
7. Screws 14. Hand Crank Manual
22. ELEVATE FEED SCREW, NUT AND BEARINGS 9. Remove the locknut (12) and remove the
POWER ELEVATE (figure 6) elevate screw (11) from the gear and bearing assem-
bly.
Remove the elevate feed screw, nut and bear- 10. Access holes a r e provided so the two ta-
ings a s follows: pered roller bearings (13) can be tapped out.
11. Reassemble in r e v e r s e order of disas-
1. Elevate knee to uppermost position, us- sembly. Do not tighten the three screws holding
ing a 4 x 4 o r car jack, block up knee so i t cannot the gear bracket until the power elevate motor and
move downward. manual elevate assembly a r e in assembled position.
2. Take out the three screws (1) holding the Use extreme c a r e when attaching the elevate nut to
power elevate assembly and slide out the complete be s u r e vertical alignment of feed screw to column
power elevate assembly (2). ways i s maintained s o no binding occurs.
3. Loosen the setscrew (3) in the c r o s s feed
handwheel and remove the handwheel (4). 23. ELEVATE FEEDSCREW, NUT AND BEARINGS
4. Remove the c r o s s feed handwheel, s e e MANUAL ELEVATE (figure 6)
step 2, paragraph 21.
5. Take out the three capscrews (5) holding 1. Elevate knee to uppermost position, us-
the manual elevate assembly (6) and remove the com- ing a 4 x 4 o r c a r jack, block up knee s o i t cannot
plete assembly. move downward.
6. Remove the three screws (7) holding the 2. Remove the elevate hand crank (14).
elevate gear bracket assembly (8) in knee. These 3. Follow procedure outlined in steps 5
screws can be reached through access hole in bot- through 10 in paragraph 22.
tom of knee. 4. Reassemble in r e v e r s e order of disas-
7. Remove the two screws (9) and rotate the sembly. Use extreme c a r e when attaching the el-
elevate screw ( l l ) , clockwise, looking down f r o m evate support to be s u r e vertical alignment of feed
the top, until the elevate gear bracket, elevate screw screw to column ways i s maintained s o no binding
and nut can be removed. occurs.
8. Unscrew the elevate nut (10) from the
elevate screw (11).

SADDLE-ADJUSTMENTS
24. FLAT GIBS (figure 7)

To adjust the flat gibs, they must be r e -

moved from the machine. Do so as follows:
1. Turn off all electric power to the ma-
chine.
2. Remove the two capscrews (1 and 2) and
the cover (3).
NOTE

The next step will allow removal of the

complete Dyna Drive II assembly f r o m
the saddle. Be s u r e to support this
assembly before proceeding.

3. Remove capscrew (4), capscrew (5) and

two capscrews (6) and lift off the complete Dyna
II assembly (7). Figure 7. Adjusting Flat Gibs
4. Remove the eight capscrews (8) holding
the guide plates (9) and guide plate spacers (10) on
each side of the saddle, and remove the plates and
spacers. 1. Capscrews 8. Capscrews
5. Take a micrometer measurement of the 2. Capscrews 9. Guide Plates
two knee ways (11). 3. Cover 10. Guide Plate Spacers
6. Machine the two spacers to the dimen- 4. Capscrew 11. Knee Ways
sion of the knee ways +.001 inch f o r oil space. 5, Capscrew 12. Pipe Plug
7. Reassemble, being s u r e that left and right 6. Capscrew 13. Clamp Handle
gibs a r e in correct location. 7. Dyna Drive II Assembly
 Figure 8. Adjusting Tapered Gib

1. Front Apron 4. Rear Gib Screw

2. Rear Apron 5. Front Gib Screw
3. Tapered Gib

25. TAPERED GIB (figure 8) 26. SADDLE AND QUILL GIB CLAMPS (figures 11
and 14).
Adjust the tapered gib a s follows
If the saddle and quill gib clamp handles a r e
1. The tapered gib is on the left side of the misused, they will eventually become inoperative
narrow guide of the knee. Lift up the front and r e a r and will not be usable. If this occurs they can be
aprons (1 and 2) to gain access to the gib screws. adjusted a s follows:
2. Back off the r e a r gib screw (4) and take
up on the front gib screw (5) the s a m e number of 1. Back off the pipe plug in the clamp screw
turns. shaft.
2. Move the clamp handle to desired posi-
NOTE tion and retighten the pipe plug.

Any time a gib i s removed the clamp 27. BIJUR ONE SHOT SYSTEM
for that particular slide should be held
in extreme "off" position by using rub- The Bijur lubrication pump (5, figure 11) lo-
ber band, string, etc. This will pre- cated on the left side of the saddle, is operating pro-
vent the gib clamping rod f r o m moving perly when the handle returns slowly after i t i s pull-
into the space normally occupied by ed back. If the handle snaps back, the ball check i s
gib. If this should happen, i t i s very stuck open and oil i s returned to the reservoir in-
difficult to re-position the clamping stead of going to the lubrication fittings.
rod s o gib can be inserted.
If pump is not operating properly, remove i t
and i m m e r s e i t in solvent. Operate the plunger un-
til the plunger operates slowly instead of snapping
back to the closed position. Reinstall the pump and
check its operation.
 1. Setscrew 17. Adjustable Nut
2. Handwheel 18. Adapter
3. Roll Pin 19. Fixed Nut
4. Handwheel 20. Feed Screw
5. Roll Pin 21. T h r u s t Bearing
6. Clutch 22. Thrust Bearing
7. Thumbscrew 23. Bearing T h r u s t Plate
8. Micrometer Dial 24. Capscrew
9. Spring 25. Bearing Locknut
10. Snap Ring 26. Spring
11. Left End Radial Bearing 27. Micrometer Dial
12. Left End Table Bracket 28. Thumbscrew
13. Capscrews 29. Handwheel
14. Left Adjustable Stop 30. Setscrew
15. Capscrews NOTE: Items 16 to 19
16. Capscrews
17. Fixed Nut
18. Adapter
19. Adjustable Nut

Handfeed

Figure 9. Longitudinal Feed Screw, Bearings and Saddle Nuts

SADDLE - REMOVING AND REPLACING PARTS

28. LONGITUDINAL FEED SCREW, BEARINGS 2. Drive out the r o l l pin (5) and remove the
AND SADDLE NUTS--POWER FEED (figure 9) clutch (6).
3. Loosen the thumbscrew (7) and take off
Remove the longitudinal feed screw, bearings the micrometer dial (8).
and saddle nuts a s follows: 4. Remove the spring (9), and take off the
snap ring (10).
1. Loosen the s e t s c r e w (1) in the left hand- 5. Loosen the s e t s c r e w (30) in the right
wheel (2) and remove the handwheel. handwheel (29) and remove the handwheel.
6. Loosen the thumbscrew (28) and remove
the micrometer dial (27) and spring (26).
NOTE 7. Remove the t h r e e capscrews (24) and the
thrust plate (23).
On handfeed machines, remove the 8. Replace the right handwheel on the feed
r o l l pin (3) and take off the handwheel s c r e w and lock i t i n position with the s e t s c r e w (27).
(4). 9. Unscrew the bearing locknut (25).
 10. Rotate the feed s c r e w (20) to remove it 30. ELECTRONIC D. C. DRIVE (figure 10).
and the t h r u s t bearings (21 and 22) f r o m the right
side of the machine. Remove the bearings f r o m the In the event of a Dyna Drive failure, the fol-
feed screw. lowing procedure should be used to isolate the trouble.

NOTE NOTE

We recommend replacement of the The following checks should be made

longitudinal feed s c r e w and both ad- by a qualified electrician as electri-
justable and fixednuts a s a unit, r a t h e r c a l shock can r e s u l t if standard safety
than replacing separate p a r t s , precautions a r e not followed.

11. When reassembling these p a r t s be s u r e 1. Check for 115 volts A. C. on t e r m i n a l s 1

the clutch i s turned s o the key is a t the bottom. and 2 of the D. C. power supply located within the
12. The left end radial bearing (11) can now main control enclosure. Absence of 115 volts may
be removed f r o m the l e f t table end bracket (12). be a r e s u l t of:
13. To remove the saddle nuts p r o c e e d a s fol- The power to the machine being turned
lows: (figure 9). off.
A. Take out the four capscrews (13) Blown fuse in the main disconnect
and remove the left table end bracket (12). switch.
B, Remove the left adjustable stop Blown fuse on the control transfor-
(14) by taking out the capscrew (15). This will allow mer. This f u s e i s mounted on the
the table to be moved to the right to expose the fixed t r a n s f o r m e r inside of the control en-
(19) and adjustable (17) nuts. closure,

NOTE 2. With 115 volts A. C. a t t e r m i n a l s 1 and 2,

check for 115 volts A. C. on t e r m i n a l s 1 and 13 of the
It i s good practise to support the right D. C. power supply. Absence of this voltage indi-
end of table so excessive overhang will cates a blown fuse in the D. C. power supply.
not disturb the ways.
NOTE

C. Remove the adjustable nut (17) by If this fuse blows as soon a s i t i s r e -

taking out the two capscrews (16) and sliding adjus- placed, this indicates a s h o r t in either
table nut out of the adapter (18). the motor o r the D. C. control. To
D. Remove fixed nut (19) f r o m oppo- isolate this condition, disconnect the
s i t e end of adapter. leads in the motor connection box a t
E. Reassemble p a r t s in r e v e r s e o r - the motor and insulate the exposed
d e r of disassembly. leads with electricians tape o r equi-
valent.
NOTE
BE SURE TO MARK ALL LEADS PRI -
When installing the fixed nut (19), the OR TO DISCONNECTING SO THAT
dog point s e t s c r e w should be positi- THEY CAN BE RECONNECTED PRO-
oned s o i t slides into the slot on the PERLY.
nut. It may be necessary, when in-
stalling the feed screw, to rotate the Install a new fuse in the D. C. power
adjustable nut (17) s o the threads of supply and check for 115 volts A. C.
the two nuts and the s c r e w line up pro- a t t e r m i n a l s 2 and 13 of the D. C. pow-
perly with no binding. e r supply. If this now is present, this
would indicate a shorted motor wind-
ing and in such case, the motor should
be replaced o r rewound by a n author-
29. REMOVING DYNA DRIVE II
ized s e r v i c e agent. If this fuse blows
with the motor disconnected, this in-
To remove the Dyna Drive II for r e p a i r o r r e - dicates a defective motor control am-
placement, proceed a s follows: plifier which should be replaced.
1. Follow steps 1 through 3 in paragraph 24.
2. Disconnect leadwires and m a r k them for
proper matching a t reassembly. 3. With 115 volts A. C. at t e r m i n a l s 2 and
3. Reassemble in r e v e r s e o r d e r of disas- 13 of the D. C. power supply, check f o r 0 t o 75 volts
sembly. D.C. on t e r m i n a l s 2 and 4 of the D. C. power supply.
With the feed rate control set for 0 speed, the D. C. b. A brush which is stuck or hung up in
voltage should be 0, with the feed rate control set the brush holder. In this case, the
for maximum speed, the D. C. voltage should be 75 brush holder and brushes should be
volts. If this voltage is not present, the D. C. con- cleaned and replaced.
trol should be replaced. c. An open armature winding within the
4. With 115 volts A. C. on terminals 2 and motor which should be corrected by
13 and 0 to 75 volts D. C. on terminals 2 and 4 of the either replacing or rewinding the mo-
D. C. control, check for 50 volts D. C. on terminals tor.
2 and 5 of the D. C, power supply. d. An open field winding in the motor
which should be corrected by rewind-
5. If all of the above conditions are met and ing of the motor.
the Dyna Drive still does not operate, this would in- The diagram in Figure 10 will give additional
dicate an open field or armature circuit in the motor, information to the electronically oriented technician
which could be caused from: should he desire to service the control assembly.
a. Worn brushes in the motor which We recommend that if there is a malfunction in this
should be replaced. control that the entire power supply be replaced.

M-13
 TABLE - ADJUSTMENTS

31. ANTI-BACKLASH NUT (figure 11)

Adjust the anti-backlash nut a s follows:

1. Move the table to a point near center o r

left of center to gain a c c e s s to the adjustable nut
(1).
2. To remove backlash in lead screw, loosen
the two socket capscrews (2), turn the adjustable nut
(1) clockwise until snug and retighten the two socket
capscrews.

32. HOW TO CHECK BACKLASH

Check c r o s s and longitudinal backlash a s fol-

lows: Figure 11. Adjusting Anti- Backlash Nut
1. Move saddle and table all to their mid-
range positions, and tighten the clamps. 1. Adjustable Nut 4. Clamp Handle
2. Turn the handwheels back and forth to de- 2. Capscrews 5. Bijur Pump
termine the amount of backlash. 3. Pipe Plug
3. If work .has constantly been machined in
the s a m e a r e a of the table, excessive backlash will
occur in that area of the screw.In areas of the s c r e w
not normally used the fit between the feed s c r e w and
nut will be tight (zero backlash). Therefore, in o r -
der to establish near uniform backlash throughout
s c r e w length, the backlash adjustment should be made
on the little-used a r e a of the screw.

TABLE - REMOVING AND REPLACING PARTS

33. GIB (figure 12) 3. Remove the right and left adjustable stops
(9 and 11) by taking out the capscrews (10 and 12).
Adjust the tapered gib a s follows: 4. Take out the four capscrews (14) and re-
move the left end table bracket (13).
1. Move the table to a point somewhere near 5. Remove the gib s c r e w (3) on the right end
center to gain a c c e s s to the gib screws. of the table and take out the gib (1). (See NOTE, par-
2. To tighten gib, back off the gib screw (2) agraph 25).
on the left end of the gib (1) and tighten the gib screw 6. Use a hoist to remove the table, o r slide
(3) on the right end the s a m e amount. the table out and onto "horses". Raise o r lower the
34. TABLE (figure 12) knee s o table height matches height of the "horses".
7. Reassemble in r e v e r s e o r d e r of disas-
To remove the table proceed a s follows: sembly.

1. Follow steps 1 through 8 under paragraph 35. TABLE FEEDSCREW, BEARINGS AND SADDLE
28, page M-11 . NUTS
2. Rotate the feed s c r e w (4) to remove it and
the thrust bearings (5 and 7) f r o m the right side of To remove table feed screw, bearings and
the machine. saddle nuts, follow procedure in paragraph 28.
 Figure 12. Table Exploded View

1. Tapered Gib 9. Right Adjustable Stop

2. Left Gib Screw 10. Capscrews
3. Right Gib Screw 11. Left Adjustable Stop
4. Feed Screw 12. Capscrews
5. T h r u s t Bearing 13. Left End Table Bracket
6. Spacer 14. Capscrews
7. Thrust Bearing 15. Dowel Pin
8. Tee Slot
 SPINDLE-ADJUSTMENTS
36. ADJUSTING QUILL RETRACT SPRING (figure
13)
The quill r e t r a c t spring can be adjusted to ob-
tain desired sensitivity of vertical spindle movement.
Make the adjustment a s follows:

1. To obtain a "soft feel" loosen the s e t s c r e w

(1) and slide the collar (2) to the right.
2. Place a pin spanner wrench in the housing
(3).
3. Back off s e t s c r e w (4) s o housing can be
rotated counter-clockwise, a s you face it.

NOTE

The housing (3) has detent holes every

45 o . Be s u r e s e t s c r e w (4) e n t e r s one
of these holes to prevent housing f r o m
slipping after adjustment.

Figure 13. Adjusting Quill Retract Spring And 4. To obtain a "heavy feel" rotate the housing
Guide Ring clock-wise.
5. Retighten both s e t s c r e w s (1 and 4).
Setscrew 6. Spindle Sleeve Bushing
Collar 7. Spindle Feed Hand
Housing Lever 37. ADJUSTING QUILL GUIDE RING (figure 13)
Setscrew 8. Sleeve
Clamp Ring Adjusting 9. Setscrew The adjustable quill guide ring i s a feature
Screw of the Mastermil head. It i s to be adjusted for vary-
ing spindle loads--tighter f o r heavier cuts- - looser
for lighter cuts.

To adjust the quill guide ring s o quill moves

freely, proceed a s follows:

1. When tightening the clamp ring adjusting

s c r e w (5), be s u r e that the spindle sleeve bushing
(6) i s all the way up in spindle housing nose.
2. With spindle feed hand lever (7), bring
quill down 2 o r 3 inches. Tighten s c r e w s o that quill
s t a y s in place.
3. Now tap Allen wrench lightly until s c r e w
(5) loosens just enough to p e r m i t quill to r e t r a c t
freely. If this clamp ring adjusting s c r e w i s too
tight, the quill will bind. If too loose, heavy cut-
ting will cause chatter and perhaps "cocking" of
spindle sleeve bushing.

38. SPINDLE DOWN FEED (figure 14)

If t h e r e i s excessive float in the spindle hand

feed crank, check and tighten the s e t s c r e w (1) i n the
housing below the hand feed shaft and the s e t s c r e w
Figure 14. Adjusting Spindle Down Feed (2) in the collar behind the crank.

1. Setscrew (Housing) 6. Microswitch The torque output, using the power down feed
2. Setscrew (Collar) 7. Pin should be sufficient to drill a 3/4 inch hole in c a s t
3. Setscrew 8. Shifter Handle iron. If this i s not possible the over- riding slip
4. Dog Pt. Setscrews 9. Spindle Clamp Handle clutch may have lost i t s torque output due to lengthy
5. Brake Screw usage. Replace the s l i p clutch (paragraph 43).
 The direction selector toggle switch must be 5. Retighten the setscrew.
in the "OFF" position and the feed r a t e selector must
be in "CLICK-OFF" position when the unit i s not in NOTE
use, since the unit is electrically interlocked with
table feed. If table i s moving, and power down feed When properly adjusted, the knob will
switch i s activated, the table will stop. "snap" into the engaged (high) position.

39. ADJUSTING BACK GEAR SHIFTER CLUTCH

(figure 13) 40. ADJUSTING SPINDLE BRAKE (figure 14)

In the spindle high speed range, a clutch i s Adjust the spindle brake a s follows:
used between the bull g e a r and the timing gear. This
clutch must engage s o there i s "zero" backlash. Any 1. Loosen the setscrew (3) and the two dog
backlash between clutches will cause spindle rattle, point s c r e w s (4).
excessive backlash and poor cutting perfo-rmance. 2. With a screwdriver, turn the slotted end
of the brake s c r e w (5) clockwise, a s you face it.
To adjust the back g e a r shifter clutch proceed
a s follows: CAUTION

1. Be s u r e spindle i s turned off (not rotating) It i s extremely important that the mi-
and brake lever is in forward position. croswitch (6) i s contacted by the pin
2. Move the back g e a r shifter knob to the high (7), s o the switch cuts off electrical
range. power to the spindle motor BEFORE
3. Place a p i n (not supplied) in one of the two the brake shoes contact the sheave.
holes on the sleeve (8).
4. Loosen the setscrew (9) and, with the pin, When the brake i s properly adjusted, a n elec-
rotate the sleeve clockwise, a s you face it, until you t r i c a l interlock prevents starting the spindle when
feel a slight resistance. the brake i s engaged.

SPINDLE - REMOVING AND REPLACING PARTS

41. REMOVING SPINDLE (figure 15) 1. Loosen pipe plug (1) s o the locking handle
(2) can be removed.
The cutter spindle requires no adjustment.
The bearings a r e permanently g r e a s e -sealed and r e - 2. Remove the clamping s t u d (3) and locking
quire no lubrication. If an i r r e g u l a r pattern de- slug (4).
velops during face milling, o r if play should de-
velop after a long period of service, the super-
precision ball bearings which a r e fixed pre- load NOTE
should be replaced by bearings of the s a m e type f r o m
the Gorton Machine Corporation, which will put the Locking slug mates with spindle quill
spindle in "like new" condition. (6) through hole in quill ring (5). On
reassembly it i s necessary to align
NOTE hole in ring and tapped hole in cast-
ing s o spindle clamp will work free-
It i s strongly recommended that spin- ly.
dles requiring s e r v i c e be returned to
the factory for expert attention. How- 3. Remove the capscrew (12) and drive a
ever, if it i s necessary to replace soft metal wedge in slot at r e a r of spindle housing
bearings in the field, do so a s follows: thereby releasing quill guide ring.
 4. Engage the clutch in hand feed box by
moving the shifter handle (8, figure 14) to the right.
This will hold the spindle in the vertical position
while the tension spring is being released.
5. Mark the nose of the spindle shaft (20)
and the pulley (21), s o that the splines can be r e -
mated in the s a m e position during reassembly.
6. Remove the two capscrews (8) and the
complete micrometer depth stop assembly (9).
7. Remove the two button head s c r e w s (14)
and slot cover shield (13). Remove the two cap-
s c r e w s (l0), the depth stop cover plate (7) and brac-
ket (11).
8. Loosen the s e t s c r e w s (18) and slide the
feed shaft collar (17) t o the right.
9. Place a pin spanner wrench in two holes
of the retainer (16) so the spindle spring (15) will
not recoil rapidly when the setscrew (4, figure 13)
is released.
NOTE

See figure 16 f o r the following steps.

10. Place wood blocks (1) on the table, below

the spindle, to protect the table surface.
11. Grasp the nose (2) of the spindle and slowly
turn the hand feed crank (3) to lower the spindle and
completely disengage the rack and pinion g e a r teeth.

CAUTION

This assembly is quite heavy and will

require more than one hand to support
it a s it moves down.

12. This procedure allows the complete spin-

dle assembly and guide ring (4) to be removed to-
gether. It may be necessary to re-position the wedge
s o the assembly does not have to be forced out.
13. Reassemble in r e v e r s e o r d e r of disas-
sembly and adjust the guide ring (see paragraph 37).

Figure 15. Removing Spindle Exploded View

1. Pipe Plug 11. Stop Key

2. Locking Handle 12. Capscrew
3. Clamping Stud 13. Slot Cover Shield
4. Locking Slug 14. Button Head Screw
5. Quill Ring 15. Spindle Spring Figure 16. Removing Spindle
6. Spindle Quill 16. Retainer
7. Depth Stop Cover Plate 17. Feed Shaft Collar 1. Wood Block 5. Setscrew (Shaft)
8. Capscrews 18. Setscrew 2. Spindle Nose 6. Capscrews
9. Micrometer Depth Stop 19. Setscrew 3. Hand Feed Crank 7. Setscrew
Assembly 20. Spindle 4. Spindle Assembly and
10. Capscrews 21. Pulley Guide Ring
42. REPLACING SPINDLE BEARINGS (figure 17)

To replace the spindle bearings proceed a s

follows:

1. Mark the spindle and pulley s o the splines

will match on reassembly.
2. Move the shifter knob to the high range.

CAUTION

This assembly is quite heavy and will

require more than one hand to sup-
port it a s it moves downward.

3. Remove the nut ( 2 ) a t the nose of spindle.

This nut has a left-hand thread.
4. Release tang on lockwasher (8) and r e -
move locknut (9). Tap top of spindle (3) with a soft
mallet arld remove spindle (3). This will allow r e -
moval of lower bearings (4), upper bearings (7) and
spacer (5).

NOTE

If these p a r t s a r e not marked for r e -

assembly, i t may cause excessive
spline-end or nose-end runout causing
poor operation.

NOTE

It i s recommended that replacement

of spindle bearings be done a t the
Gorton factory. However, if done in
the field, the faces marked "Thrust"
should face each other with the match
marks aligned.

Figure 17. Removing Spindle Bearings

The bearings (4 and 7) used a r e fixed pre- 1. Quill Ring 6. G r e a s e Retainer

load, and therefore the locknut (9) should not be 2. Nut (L. H. Thread) 7. Bearings
tightened excessively. 3. Spindle 8. Lockwasher
6. Reassemble t h e p a r t s in r e v e r s e o r d e r of 4. Bearings 9. Locknut
disassembly. 5. Spacer
43. REPLACING SLIP CLUTCH (figure 16) 8. Slide the new spring (1) into the retainer
sleeve (2) and discard the retainer ring which slides
Replace the slip clutch a s follows: off the spring.
9. Install the e n t i r e assembly onto the down-
1. Back off the s e t s c r e w (5) on motor g e a r feed shaft (5) s o the bent end of the spring is in the
box shaft. s l o t on the shaft.
2. Remove the four capscrews (6) holding 10. Rotate the retainer sleeve (2) to align the
motor to bracket and move motor back. hole in spring and the hole in the sleeve.
3. Loosen s e t s c r e w (7) in s l i p clutch and 11. Replace s e t s c r e w (3).
remove the clutch. 12. Remove the spring and sleeve assembly.
13. Insert the end of a punch between the out-
CAUTION er coil and the next coil of the spring directly i n line
with the s e t s c r e w (3). Tap the punch until the outer
In reassembly a few thousandths mis- coil conforms to the radius of the sleeve and the
alignment i s permissible and will be spring i s firmly held by the setscrew.
compensated for by the slip clutch. 14. Adjust tension of the spring (see para-
G r e a t e r misalignment will load the graph 36).
clutch s o output torque will be dimin-
ished.

44. REPLACING QUILL RETRACT SPRING (figure

18)
Remove the quill r e t r a c t spring (1) as follows:

1. If the hand feed lever (8) is on the right

side of the downfeed shaft (5), remove the lever,
2. Loosen the s e t s c r e w (7) and remove the
collar (6).
3. Clamp the quill with the locking handle.
4. Place a pin spanner wrench in the retain-
e r sleeve (2) and loosen the s e t s c r e w (4).
5. Turn the spanner wrench counter-clock-
wise to relieve a l l tension on the spring.
6. Slide the r e t a i n e r sleeve with its enclosed
p a r t s off of the downfeed shaft.
7, Remove the slotted spring keeper s c r e w
(3) and pull out the old quill r e t r a c t spring.

NOTE Figure 18. Replacing Quill Retract Spring

The new spring is held in a coiled po-

sition with a retainer ring. Do not 1. Quill Retract Spring 5. Downfeed Shaft
remove the retainer. It will slide off 2. Retainer Sleeve 6. Collar
when the spring is installed in the 3. Setscrew 7. Setscrew
housing. 4. Setscrew 8. Hand Feed Lever

VARIABLE SPEED HEAD

45. REPLACING BULL GEAR BEARINGS (figure 19) s c r e w s (2) and the two s h o r t e r socket head capscrews
(1) f r o m the cover (3) and take off the cover.
To replace the bull gear bearings on the vari- 5. Loosen the s e t s c r e w (5) and remove the
able speed head, proceed as follows: pulley locknut (6).
6. Loosen the s e t s c r e w (7) and remove the
1. Turn the spindle speed control knob to i t s speed adjusting a r m shaft (8).
lowest r.p.m. setting. 7. Remove the r o l l pin (12) and, while r e -
2. Remove the draw bar (4) and adapters. moving it, place fingers inside of the sleeve (17) to
3. Turn off a l l power to the machine. catch r o l l pin s o i t doesn't drop into spindle spline.
4. Remove the two long socket head cap-
 Figure 19. Replacing Bull Gear Bearings--Variable Speed Head
1. Capscrews 9. Shifter 18. Spindle Drive Belt
2. Capscrews 10. Front Variable Sheeve 19. Hex Bolt
3. Cover 11. Lower Sheave 20. Washer
4. Draw Bar 12. Roll Pin 21. Motor Variable
5. Setscrew 13. Bearing Retaining Nut Pulley Assembly
6. Pulley Locknut 14. Bearings 22. Motor
7. Setscrew 15. Spacer 23. Washers
8. Speed Adjusting Arm 16. Spacer 24. Hex Head Bolts
Shaft 17. Sleeve
 1'
Capscrews
Setscrew
Timing Belt Pulley
Counter Shaft Nut
Timing Belt
Spacer
Bull Gear Assembly
Bull Gear
Bull Gear Retainer
Bearings
Bearing Nut
Bearing
Spindle Pulley Housing
Pulley Sleeve \ I
\
\I
Figure 20. Replacing Bull Gear Bearings-- Variable Speed Head

8. Remove the two hex head bolts (24) and (See figure 20 f o r the following steps).
washers (23). Tilt the motor (22) back and wedge it
in position s o the front variable sheave (10) can be 13. Remove the four socket capscrews (1)
lifted off. holding the spindle pulley housing (13) to the spindle
9. Lift off the variable sheave (10). It may head.
be necessary to rotate the speed knob s o the shif- 14. Lift the pulley housing off of the machine.
t e r (9) disengages and can be removed. It may be necessary to rotate spindle to disengage
10, Lift the spindle drive belt (18) off of the the timing belt (5). If the pulley sleeve (14) does not
spindle upper drive section. disengage f r o m the bearing (12), tap on top of pulley
11. Remove motor, variable pulley and drive sleeve and remove it from the bearing. This sleeve
belt, Release the electric cable clamps s o cable will should have a light push fit through the bearings for
be f r e e and motor can be s e t on the floor o r a bench. e a s e of reassembly.
To remove motor variable pulley assembly (21), r e - 15. Remove the counter shaft nut (4) and the
move hex bolt (19) and washer (20) and slide off the timing belt pulley (3).
variable pulley assembly (21).
12. Remove the lower sheave (10). NOTE
NOTE
On reassembly u s e one drop of Lock-
It may be necessary to use a wheel tite on the counter shaft nut (4) to s e -
puller to remove pulley sheaves. c u r e it.
 Setscrew 8. Guide Pin
Setscrew 9. Brake Screw
Handle Assembly 10. Brake Shoe Assy's.
Button Head Screws 11. Brake Shoes
Switch Plate Cover 12. Setscrew
Capscrews 13. Gear
Brake Switch Housing 14. Speed Dial

Figure 21. Spindle Brake And Speed Dial--Variable Speed Head

16. Loosen the setscrewm(2) in the back g e a r NOTE

shifter assembly, and lift off the bull g e a r assembly
.(7).
, When variable pulleys and shifter a r e
17. Remove the bearing nut (11) and remove removed, i t may be necessary to r e -
the bull g e a r (8) f r o m the bull g e a r r e t a i n e r (9). Take t i m e the spindle speed dial (See figure
out the bearings (10) and s p a c e r (6) f r o m the retain- 21). Do this by running the spindle a t
er. i t s lowest r. p. m. and check it with a
18. When reassembling, the bull g e a r should tachometer. Loosen the s e t s c r e w (12)
be in the high speed position, with the clutch on sleeve in g e a r (13), rotate the speed dial (14)
(14) mated with the bull g e a r clutch. The timing belt to the c o r r e c t speed and retighten the
(5) can then be placed in position. setscrew.

Slide the pulley housing (13) over the sleeve

(14) and r e a s s e m b l e the other p a r t s in r e v e r s e o r -
d e r of disassembly. See paragraph 39 f o r adjus- 49. REPLACING SPINDLE BRAKE SHOES
ting the back g e a r clutch. (figure 21)

46. REMOVING/RE PLACING SPINDLE DRIVE To replace the spindle brake shoes proceed
BELT as follows:

To remove o r replace spindle drive belt (17, 1. Follow s t e p s 1 through 12 under para-
figure 19), follow s t e p s 1 through 10, paragraph 45. graph 45, REPLACING BULL GEAR BEARINGS.
2. Loosen the s e t s c r e w (1) and the two set-
47. REMOVING/REPLACING TIMING BELT s c r e w s (2) s o the spindle brake handle assembly
(3) can be removed.
To remove o r replace timing belt (5, figure 3. Remove the four button head s c r e w s (4)
20), follow s t e p s 1 through 14, paragraph 45. and take off the switch plate cover (5).
4. Remove the t h r e e capscrews (6) s o the
48. REMOVING PULLEY HOUSING BEARINGS brake switch housing (7) can be removed.
(figure 19) 5. Take out the guide pin (8) and pull out the
brake s c r e w (9) and the two brake shoe a s s e m b l i e s
To remove the pulley housing bearings pro- (10).
ceed a s follows:

1. Follow s t e p s 1 through 14 under para- NOTE

graph 45, REPLACING BULL GEAR BEARINGS.
2. Remove the bearing retaining nut (13) and If only the brake shoes (11) a r e to be
remove the bearings (14) and the two s p a c e r s (15 replaced, cement them in place with
and 16). Pliobond No. 20 cement.
3. Follow procedure in s t e p 18, paragraph
45, REPLACING BULL GEAR BEARINGS f o r r e a s - 6. Reassemble the p a r t s in r e v e r s e o r d e r of
sembling. disassembly.
 Figure 22. Replacing Bull Gear Bearings--Standard Head
1. Draw Bar 10. Spacer 18. Clamp Handle Nut 27. Bull Gear Retainer
2. Locknut 11. Bull Gear Assembly 19. Washer 28. Bearing Nut
3. Lockwasher 12. Pulley Sleeve 20. Nut 29. Capscrew
4. Spindle Drive Belt 13. Timing Belt Spindle 21. Locknut 30. Spindle Head
5. Key Pulley 22. Washer 31. Counter Shaft
6. Spindle Pulley 14. Motor 23. Capscrew 32. Timing Belt Pulley
7. Ball Bearing Locknut 15. Knob 24. Bearings 33. Counter Shaft Nut
8. Bearings 16. Clamp Handle 25. Spacer 34. Timing Belt
9. Spacer 17. Setscrew 26. Spacer
 STANDARD HEAD
50. REPLACING BULL GEAR BEARINGS-- 52. REPLACING BRAKE SHOES--STANDARD
STANDARD HEAD (figure 22) HEAD (figure 23)

To remove the bull g e a r bearings f r o m the To replace the brake shoes on the standard
standard head proceed a s follows: head, proceed a s follows:

1. Turn off a l l power to the machine. 1. Remove the spindle drive belt (16) move
2. Remove the draw bar (1) and any tooling the motor back a s f a r a s possible and clamp it
in the spindle. 2. Remove the bearing locknut (15) and lock-
3. Take off the electrical cable clamps on washer (14).
the ram. 3. Loosen the s e t s c r e w (3) and the two set-
4. Remove the capscrew (23) and washer s c r e w s (2) s o the spindle brake handle assembly (1)
(22). Remove the nut (20). can be removed.
5. Loosen s e t s c r e w s (17) and with knob (15) 4. Remove the four button head s c r e w s (4)
loosen the clamp nut (18). and take off the switch plate cover (5).
6. Remove the knob (15) and handle (16)) un- 5. Remove the t h r e e capscrews (6) s o the
s c r e w the clamp handle nut (18) an d r e m o v e the wa- brake switch housing (7) can be removed.
s h e r (19). 6. Remove the guide pin (10).
7. Move the motor forward and remove the 7. Lift up the spindle pulley (13) s o the bra-
spindle drive belt (4). king flange will c l e a r the brake shoe assembly (12).
8. Lift the motor (14) off of the machine. 8. Slide the brake s c r e w (8) and brake shoe
9. Remove the ball bearing locknut (2) and assemblies (9 and 12) f r o m the housing.
ball bearing lockwasher (3).
10. Remove the four capscrews (29) holding NOTE
the spindle pulley housing (21) to the spindle head
(30). If only the brake shoes (11) are to be
11. Release the spindle brake if it is not al- replaced, they should be cemented in
ready released. place with Goodyear Pliobond No. 20
12. Remove the spindle pulley (6) and key cement.
(5).
13. Lift the spindle pulley housing (21) off of 9. Reassemble in r e v e r s e order.
the machine. If the pulley sleeve (12), does not r e -
main in i t s position, it may be necessary to rotate Handle
the spindle s o timing belt (34) will disengage f r o m Setscrew
timing belt spindle pulley (13). Setscrew
14. Unscrew the counter shaft nut (33) and take Button Head Screws
off the timing belt (34). Lift the timing belt pulley Switch Plate Cover
(32) off of the counter shaft (31). Capscrews ---
15. The bull g e a r assembly (11) can now be Brake Switch Housing
removed over the top of spindle. 14-----
Brake Screw l!J --
16. Take off the bearing nut (28) and slide the Brake Shoe Assembly
bull g e a r r e t a i n e r (27) and bearings (24) f r o m the Guide Pin
bull gear. Brake Shoes
17. P r e s s out the bearings (24) and the two Brake Shoe Assembly
0
s p a c e r s (25 and 26). Spindle Pulley
18. Reassemble the p a r t s in r e v e r s e o r d e r of Lockwasher
disassembly. Bearing Locknut
Spindle Drive Belt

51. REPLACING PULLEY HOUSING BEARINGS-- 5

STANDARD HEAD (figure 22)

Replace the pulley housing bearings a s follows:

1. Follow steps 1 through 13 in paragraph 50,

REPLACING BULL GEAR BEARINGS.
2. Remove the bearing r e t a i n e r nut (7).
3. Invert the spindle pulley housing (21) and
p r e s s out the bearings (8) and two s p a c e r s (9 and
10).

Figure 23. Replacing Brake Shoes--Standard Head

M-25
 RAM AND TURRRET

53. REMOVING SWIVEL HEAD (figure 24) If electrical cables must be disconnected,
mark each individual wire, and make a sketch of con-
To remove the swivel head proceed as follows: nections for aid in re-connecting.

1. Turn off all electrical power to the ma- When re- assembling, the alignment of the pi-
chine. lot on swivel head and the bore in r a m must be pre-
2. Move the knee to i t s lowest position, and cisely made. It i s a l s o necessary to physically a s -
move the saddle completely forward. s i s t the head to obtain engagement of worm and worm
3. Move the r a m to the r e a r s o the motor wheel.
will not s t r i k e the table when the head is rotated.
NOTE
NOTE
If the swivel head turns under normal
It is good practice to support the swi- cutting p r e s s u r e , it is possible that
vel head while it is being inverted. foreign material is between the cutting
J u s t before the head i s completely in- f a c e s of head and ram. If this hap-
verted, the worm and worm wheel will pens, follow s t e p s 1 through 5 in this
disengage. Wood supports can be used paragraph. Clean off both faces and
under the inverted head to stabilize it be s u r e they a r e d r y before r e a s s e m -
on the machine table. bling.

4. Loosen the three nuts (1) and invert the

head using worm and worm wheel (3).
5. Remove the three nuts (1). Use hand ele-
vation s o the machine table will support the head.
6. Loosen the two hex clamping nuts (2) and
move the r a m back with wrench until i t i s completely
disengaged from swivel head.

Figure 24. Removing Swivel Head Figure 25. Removing T u r r e t

1. Hex Nuts 1. Spider Clamp Screw 4. Washer

2. Hex Clamping Nuts 2. Setscrew 5. Spider Clamp
3. Worm And Worm Wheel 3. Hex Nut 6. Spider Bolt
54. REMOVING RAM AND HEAD ASSEMBLY 2. Loosen the setscrew (2) and remove the
(figure 24) large hex nut (3) and washer (4). The spider clamp
(5) will drop, and the turret can then be lifted off of
To remove the r a m proceed a s follows: column with a sling.

1. Remove the two hex nuts (2). 56. ADJUSTING SPIDER CLAMP FOR TURRET
2. With a hoist and sling, lift the r a m straight (figure 25)
up off guide keys and rack. Use caution, as assembly
i s off center load. Set it on wood blocks to protect If the turret turns under normal cutter pres-
the way surfaces. sure, check the spider clamp f o r the turret, and, if
necessary, adjust it a s follows:
On reassembly be s u r e that the rack and gear
teeth a r e engaged a s r a m i s lowered into position. 1. Loosen the spider clamp screw (1) so ap-
proximately 1/2" to 3/4" of thread i s exposed below
55. REMOVING TURRET (figure 25) the spider clamp (5). This screw i s reached through
access hole in back of column.
To remove the turret proceed a s follows: 2. Loosen the setscrew (2) and rotate the hex
nut (3) until the ball nose on the spider clamp screw
1. Loosen the spider clamp screw (1). This (1) contacts the casting.
screw and the following parts can be reached through 3. Re-lock the setscrew (2) and re-clamp the
the access hole in the r e a r of column. spider (5) with the spider clamp screw (1).

HORIZONTAL SPINDLE
57. REMOVING BEARINGS FROM STYLE "B" 3. Install new needle bearings by pressing
ARBOR SUPPORT (figure 26) into the housing (4) from either end, s o the outside
face of the bearings i s just past the shoulder in the
Remove the bearings from the style "B" a r - casting. This will allow clearance between the bear-
bor support a s follows: ings and the seals when the seals a r e installed.

1. Remove the arbor support bearing (1). CAUTION

2. Insert a rod between the needle bearings
(2 and 3) and tap out one of the bearings. The other Do not p r e s s needle bearings s o far
bearing can then be pressed out. that they meet in the middle of the
casting. This would block off lubri-
NOTE cation holes.

When bearings a r e replaced, the seals

should also be replaced.

Figure 26. Removing Bearings From Style "B" Arbor Support

1. Bearing 3. Needle Bearing
2. Needle Bearing 4. Housing
 Figure 27. Removing Horizontal Spindle And Bearings

1. Setscrew 13. Spacer

2. Timing Pulley 14. Capscrews
3. Taper Lock Bushing 15. Gear Box
4. Capscrews 16. Capscrews
5. Bearing Retainer 17. Bearing Retaining Ring
6. Pulley Shaft 18. Spindle Shaft
7. Helical Gear 19. Setscrews
8. Capscrews 20. Pre- load Nut
9. Gear Box Cover 21. Bearing
10. Retaining Ring 22. Bearing
11. Setscrews 23. Needle Bearing
12. Helical Gear
58. REMOVING HORIZONTAL SPINDLE AND 8. Take out the six capscrews (16) and bear-
BEARINGS (figure 27) ing retainer ring (17).
9. Tap the back end of spindle shaft (18) and
To remove the horizontal spindle and bearings remove the spindle through the front end of machine.
proceed a s follows:

1. Carefully label all fitting washers and NOTE

shims when they a r e removed, s o they will be re-
placed in the correct location. It i s strongly recommended that spin-
2. Remove setscrew (1), so the timing pul- dles requiring service be returned to
ley (2) can be removed along with the taper lock bu- the factory for expert attention. How-
shing (3). ever, if it is necessary to replace
3. Take out the four capscrews (4) and the bearings in the field do s o a s follows:
bearing retainer (5). This will allow removal of the
pulley shaft (6).
4. Remove the helical gear (7). A. Loosen the setscrews (19) and r e -
5. Take out the six capscrews (8) and gear move the pre-load nut (20).
box cover (9). B. Remove the bearings (21 and 22).
6. Remove the retaining ring (10). Loosen Use a bearing puller to remove bearing (21) on the
the setscrew (11) and remove the helical gear (12) narrow end of spindle.
and spacer (13).
7. Take out the four capscrews (14). Remove 10. Reassemble the parts in reverse order of
the gear box (15) and needle bearing (23). disassembly.

MAINTENANCE CHECK LIST

1. No coolant o r inadequate supply. Plugged lines o r table screen. Clean out reservoir and table
(Flood type) screen (par. 16).
Pump rotation is wrong. Check rotation (par. 16) and cor-
rect by reversing leads to pump.
Prime i s lost. Re-prime.

2. No coolant or inadequate supply. No air, or low pressure. (See par. 17).

(Spray mist type) Low coolant level. Add coolant (par. 17).

3. Knee binds Tapered gib too tight. Adjust tapered gib (par. 18).
Knee clamp is "on". Release clamp.

4. Knee movement is too loose Tapered gib too loose. Adjust tapered gib (par. 18).
Elevate screw and nut worn. Replace screw and nut (par. 22
and 23).

5. No power elevate. Microswitch has moved past li- Manually operate knee (par. 19).
mit stop.
Microswitch worn out. Replace switch.
Relay inoperative. Use wiring diagram and check
relay.
Power elevate motor burned out. Replace motor (par. 22).

6. Inadequate supply of lubricant Check Bijur One-Shot pump. Clean pump if necessary (par.
21).

7. Too much or too little backlash Anti-backlash nut needs adjust- Adjust (par. 20).
ing. (12" cross on1y),
 MAINTENANCE CHECK LIST

8. No power to table. Feed motor burned out. Replace motor (par. 30).
Feed r a t e potentiometer faulty. Replace potentiometer.
D. C. Power supply fuse blown. Replace fuse.
Shifting shoes broken. Check and replace, using ex-
ploded view f o r reference.
Electrical failure o r disconnect. Check f u s e s and connections
using wiring diagram furnished.
Spindle downfeed switch in "on" Turnfeed dial to "click-off" po-
position. sition (par. 13).

9. E r r a t i c c r o s s feed movement. C r o s s feed s c r e w and nut worn. Replace c r o s s feed s c r e w and

nut (par. 21).

10. Saddle binds. Tapered gib too tight. Adjust tapered gib. (par. 25).

11. Saddle movement too loose. Knee ways worn. Adjust flat gib (par. 24).

12. Table binds. Tapered gib too tight. Adjust gib (par. 31).
Lack of lubrication. Fill and check reservoir.

13. Too much o r too little backlash Anti-backlash nut needs adjusting. Adjust (par. 32).
in table feed.

14. E r r a t i c table movement. Table lead s c r e w and saddle nuts Replace s c r e w and nuts (par.
worn. 35).

15. Excessive float in spindle hand Setscrew loose. Tighten (par. 38).
feed lever.

16. Spindle torque output inadequate. Worn s l i p clutch. Replace the clutch. (par. 44).
(Power feed). Misalignment of motor and g e a r Align.
box.

17. No power to spindle feed. D. C. power supply fuse blown. Replace fuse.
Feed r a t e potentiometer faulty. Replace potentiometer.
Table feed r a t e dial in "on" po- Turn dial t o "off" position.
sition.

18. Spindle brake not operating pro- Brake lever needs adjustment. Adjust (par. 40).
perly. Brake shoes worn. Replace brake shoes (par. 47 o r
50).

19. Irregular pattern during f a c e mil- Spindle ball bearings worn. Return spindle to factory, o r if
ling, o r play in spindle. this is not possible, replace
bearings (par. 42 o r 55).
Cutting tool improperly sharp- Re-sharpen tool.
ened.

20. Quill binds. Clamp ring adjustment too tight. Loosen s c r e w (par. 37).

21. Heavy cutting causes chatter. Clamp ring adjustment too loose. Tighten s c r e w (par. 37).
 MAINTENANCE CHECK LIST

22. Vernac optics inaccurate. Reader out of focus. Re-focus.

Scales misaligned. Re-align scales.
Scales dirty. Clean with tissue. (No solvent).

23. T u r r e t turns under normal cut- Spider clamp too loose. Tighten (par. 54).
ter pressure.

24. Head turns under normal cutter Foreign material between mating Clean (par. 51).
pressure, surfaces.

25. Cutter spindle does not rotate Shifter knob in neutral position. Place in "High o r Low" position.
under power. Main electric switch open. Close switch on electric cabinet.
Drive belt broken. Replace belt (par. 46).
"Forward-Reverse" switch in Place in proper position.
neutral position.
Spindle brake "On". Release brake.
Main fuse blown. Replace fuse.
Heater coil activated. Push reset.

FOR LUBRICATION DATA AND DRAWINGS SEE PAGES M-30 AND M-31 FOLLOWING.
 LUBRICATION

59. LUBRICATION 3,4. SADDLE/TABLE AND KNEE/COLUMN

The 1-22 Mastermil must be properly lubri- Saddle/table slide lubrication pump and r e s -
cated before placing in operation and during opera- ervoir unit is located on left side of saddle. Hand
tion to insure continued trouble- free operation. The pump should be operated once, twice daily. Pull
illustrations locate lubrication points on the machine out handle and allow pump to r e t u r n slowly. The oil
and the lubrication plate. Due to the advanced de- level of the r e s e r v o i r should be checked daily and
sign, a minimum number of units r e q u i r e daily at- kept filled a t all times.
tention. However, adherence to the lubrication
schedule i s of major importance in obtaining maxi- Knee/column slide lubrication is through oil
mum performance and long life of the machine. cups on knee. Check daily and keep filled. Use
Socony Vactra #2 o r Sun Oil SWL #80.

1. SPINDLE DOWNFEED MOTOR 5. POWER ELEVATE MOTOR

Spindle downfeed motor bearings a r e lubri- Power elevate motor bearings a r e perma-
cated a t factory- - for two (2) year period. When nently grease packed and do not require replenish-
repacking u s e Socony BRB #4 or Sun Oil Prestige ment o r charge.
#42. Repeat at two (2) year intervals.
2. SPINDLE DOWNFEED MOTOR GEAR CASE 6. POWER ELEVATE GEAR BOX
Spindle downfeed gear c a s e lubricated a t fac- The power elevate g e a r box is filled a t fac-
tory--for two (2) year period. When repacking u s e tory for two (2) year period. When repacking the
Socony Mobilplex EP-24 o r Sun Oil Prestige 740 AEP. g e a r housing, cover must be dismantled. Use Socony
Repeat a t two (2) year intervals. Mobilplex EP-24 o r Sun Oil Prestige 740 AEP.
 LUBRICATION

7. DNYA-DRIVE I1
a t factory. Requires no additional lubrication.
Dyna- Drive I1 motor bearings a r e g r e a s e
packed a t factory. Repack after three (3) y e a r s of 10. LUBRICATION PLATE
operation--under s e v e r e conditions, after approxi-
mately 18 months. Use Socony Mobilux No. 2 o r Sun The lubrication plate which indicates type and
Oil Prestige #42, frequency of lubrication a s outlined above, is located
on r e a r curved section of column.
8. SPINDLE BARREL AND DEPTH STOP
For maximum efficiency and minimum down-
The spindle b a r r e l and depth stop should be time, always follow the directions a s outlined. It is
thoroughly cleaned and lightly oiled once per week. Use important t o u s e fresh, clean lubricants a t a l l t i m e s
Socony Velocity #10 o r Sun Oil Solnus #70. and to follow the specifications. Specific lubricants
have been developed through extensive testing. Do
NOTE: At s a m e time lubricate the spindle not substitute unless equivalent product is available.
splines with Fisk Refinery Lubriplate. 11. SPINDLE HEAD

9. SPINDLE DRIVE MOTOR Lubricate the spindle head through the g r e a s e

fitting at the back of the head once per week. Use three
Spindle drive motor bearings a r e lubricated (3) shots of Keystone #122 grease.