SECTION SIX

ROTARY TABLE

TABLE OF CONTENTS
TITLE PAGE
HYDROSTATIC TABLE ............................................................................................................................6-1
TABLE DRIVE CONSTRUCTION .............................................................................................................6-2
HYDRAULIC SUPPLY AND CLAMPING SYSTEM COMPONENTS.......................................................6-3
SETTING ROTOR LIFT .............................................................................................................................6-4
INSTALLING THE TABLE TOP ................................................................................................................6-5
REMOVING TABLE DRIVE TRAIN ..........................................................................................................6-6
INSTALLING THE TABLE DRIVE TRAIN ................................................................................................6-6
TABLE DRIVE BOX ASSEMBLY .............................................................................................................6-7
CHECKING TABLE BACKLASH..............................................................................................................6-7
ADJUSTING TABLE BACKLASH ............................................................................................................6-8
PALLET CLAMPING SYSTEM .................................................................................................................6-9
HYDROSTATIC TABLE
The rotary table assembly prints were shipped with the machine. These prints will include the assembly
procedures and related information. Review the machine prints before starting any maintenance
procedures.
The hydrostatic table has its own on board hydraulic reservoir. The rotary table must be filled to the full
mark with 21L (5.5 gallons) of Mobil SHC 634 oil. The table hydrostatic pump is driven by oil supplied
from the machine hydraulic system to the rotary table motor/pump combination. The inner table
hydrostatics is supplied with oil through cross drilled holes in the casting and between the oil seals on the
upper portion of the rotary table base, which goes into the lower oil feed hole on the hydrostatic ring. This
oil is then distributed around the ring to the upper and lower ports for lift and separation between
surfaces. The spacing between these surfaces is what determines your hydrostatic pressures.
The hydraulic motor and pump make up the on board power source to furnish the fluid for the hydrostatic
table. The needle valve should be fully open (full flow) (Figure 6-2). This valve is only used during rotary
table construction. A pressure reducing valve, which is located on the on the X-axis drive side of the
saddle, is used to adjust the main system pressure line into the hydraulic motor. The pressure is adjusted
to set the rotary table internal system pressure to 41 bar (600 psi). A pressure gauge inserted in test port
(Figure 6-2) is used to read internal system pressure. Hydrostatic pressure test point readings for the
upper bearing surface should read about 21 bar (250 +/- 40 psi) and the bottom bearing surface should
read about 28 bar (400 +/- 50 psi). These pressures can be checked around the entire table at the upper
and lower test ports with a pressure gauge. The order in which the ports are laid out is shown in figure 6-
1. Pressure switches will also indicate at the control if the system pressure is too high or too low.

Crossed Drilled Hole

-Plugged

Lower
Restrictor Lower Test Upper
Port Restrictor
Upper Test
Port

Figure 6-1
Hydrostatic Port Lay Out

6-1
 Color Hydrostatic Ensure Needle Valve Is
Hydrostatic Indicator Pump Fully Open
Pressure (All Color Bands Showing)
Electrical
Indicator

Test Port
With Gauge
Installed

Filter

Hydraulic
Motor

Figure 6-2
Rotary Table Hydraulic Services

TABLE DRIVE CONSTRUCTION

The power source for table rotation is an electric motor. The motor is connected to the worm pinion
through a belt and coupling. When the motor turns, it will turn the worm which will turn a large ring gear
bolted to the rotor. Secured to the rotor are the pallet base and a large bearing on which the whole
assembly rotates. There is no brake on the rotary table motor. The drive motor has four mounting bolts.
To access these bolts, remove the housing cover.
The worm is supported by two (2) thrust bearings and one (1) radial support bearing. The bearings are
fitted inside the bearing carrier with sufficient preload to prevent the worm from moving axially within the
bearing carrier.
The table drive worm is manufactured with a single thread, dual lead. The dual lead results in a thread
that becomes progressively heavier from leading to trailing end. Because the worm thread varies in
thickness, it is possible to remove all the backlash between the worm and the worm wheel gear attached
to the table. This is done by engaging the worm with the worm wheel at the point where the worm thread
is just heavy enough to achieve this no lash condition without binding the worm wheel gear.
The table drive worm, worm gear, and bearings are all kept lubricated by filling the drive train cavity with
Mobil SHC 634 oil, pre-filtered to 5 micron. The oil fill point and the oil level sight glass are shown in
Figure 6-3.

6-2
 Oil Fill
Sight Gauge

Drain Plug

Figure 6-3
Rotary Table Hydraulic Reservoir/Lube Fill

HYDRAULIC SUPPLY AND CLAMPING SYSTEM COMPONENTS

The following components are located under covers or are part of the rotary table. Refer to Figure 6-2, 3.
1. The hydrostatic table has its own on board hydraulic reservoir built into the table cavity. The rotary
table must be filled to the full mark on the sight gauge with 21L (5.5 gallons) of Mobil SHC 634 oil.
This hydraulic oil supply provides hydrostatic pressure and lubrication for the table drive worm,
worm gear, and bearings.
2. The oil can be drained from the reservoir by either removing the plug to the right of the pickup point
or if equipped, remove the pipe plug fitting near the sight glass to drain the reservoir.
3. The system pressure of 41 bar (600 psi) is set by a pressure reducing valve in the circuit. An
electrical indicator switch monitors the hydrostatic pressure. If pressure increases or decreases
beyond acceptable amounts, a fault is generated at the CNC operator station and the machine
shuts down.
4. Oil is cycled through the table by a hydraulic motor and pump connected by a Lovejoy coupling.
The oil is circulated back from the table through the return line, into the pump and out through the
filter. It is then sent back to the table.
5. The filter is a replaceable element type and is equipped with a color indicator. When clean and
functioning, the indicator is green. If dirty or blocked the indicator is red. The filter should be
changed every 90 days even if the color indicator is green. This frequency can be increased if
conditions warrant.
6. There is an air inlet for air pressure to be supplied to an internal seal in the rotary table. This air
pressure puts a positive pressure across the seal to prevent the intrusion of dirt and/or coolant.
7. When the table is not moving, it is clamped in position. The clamp is a steel ring mounted just
inside the table base that presses on the OD of the rotor (Figure 6-4). The clamp is actuated by
hydraulic pressure supplied by the table clamp pressure valve. When the clamp pressure is
released, the braking force is removed.

6-3
 Rotor
The inside of the
table is the oil
reservoir

Clamp Ring

Center Bearing

Figure 6-4
Lowering Rotor Assembly into Table

SETTING ROTOR LIFT

Calculate the table spacer dimension so that .089 mm (.0035 +/- .0005) looseness exists between
bearing thrust stator and the table top. Grind the table spacer and set aside.
Install the center bearing on to rotary table manifold (center post). Lower previously assembled ring gear
and rotor in place. Clean surface of table casting that the bearing thrust stator sits on and place sealant
around air seal hole. Be sure to have the inner and outer o-rings in place and lubricate with oil.
Lower hydrostatic bearing thrust stator, being sure slotted hole on bottom lines up with air hole in the
casting. When close to being down start a few bolts for alignment. Lower all the way down. Tighten
bolts in a crisscross pattern then torque to 60NM.

6-4
INSTALLING THE TABLE TOP
1. Clean surface of bearing thrust stator and apply oil to top of bearing before lowering table top down
on to it. Set table supply pressure to (41 bar) 600 psi using flow control and hydraulic power unit.
2. Install bearing spacer. Tighten center cover only enough to load the center bearing. Roll worm
shaft to seat rollers in bearing. The spacer then should be sized.
3. Remove the center cover and depth mic from spacer to the table surface that the cover is mounted.
Measure in 4 quadrants to be sure top is level. Grind center spacer to .04 to .07mm (.0015 -
.0025”) oversize from measured dimension. Install rotary encoder on center post counterbore and
bolt in place. Install o-ring on center bearing spacer. Install center cover and indicate for run out
under .001” TIR, tighten and pin. Depth mic from counterbore in center cover to top of the encoder
center hub. This is the dimension that must be ground on the encoder driver (M.1300.8130) “A”
dimension +/- .051mm (.002”) (Figure 6-5). Then, bolt fitted encoder driver to the encoder and the
center cover.
Mount a substantial bar radially from the center to the edge of the rotor. Place an indicator base on
the table weldment and position a .0001" indicator to measure vertical movement of the bar at the
rotor's edge. Measure the rotor rise as hydrostatic pressure is applied. Measure the rise at three
equally spaced bar positions around the rotor edge. This should be .0005 - .0015
4. Install pressure gauge taps in the rotor and measure all the axial pad recess pressures. If the
pressures are incorrect:
Low pressure correction: You may have a plugged restrictor, check for that especially if only one
pad is bad. If all are bad: Grind stock off top set of shims.
High pressure correction: Top set of shims are too small. Start with a new set and increase
thickness.

Grind this step to +/-

.002” of recorded “
A “ dimension.

Figure 6-5
Rotary Encoder Driver

6-5
REMOVING TABLE DRIVE TRAIN
1. Turn off all power to the machine and drain the table lubrication through the pipe plug drain hole
located under the drive train cavity.
2. Remove the housing cover and gasket. Disconnect the wiring cables to the rotary table drive
motor.
3. Loosen the four socket head cap screws holding the motor in place and remove the tensioner bolt.
4. While supporting with a lifting device, remove the rotary table motor and drive cover plate by
removing the (6) cap screws that hold the drive cover plate onto the base.
5. Remove the pulley that the motor drives from the shaft. Remove the inner seal.
6. Remove the drive box housing, (7) bolts and 2 taper pins. Remove the gear off the end of the
worm. It is held on with a taper lock to the shaft.
7. Install a threaded rod acting as a guide/driver (approx. 1 meter long) into the end of the worm shaft.

[One method to make this rod would be to weld a long enough piece of bar stock to a cap screw.
Grind flats on the bar stock or weld a hex nut to the other end of the bar stock to use as a driver.
Thread the cap screw into the threaded hole in the end of the worm gear.]
8. To remove the worm gear, remove the cover plate and retainer from the end opposite the drive.
The worm gear can be turned manually and fed out the end opposite the drive. Turn the previously
installed driver with a wrench until the worm gear is released from the ring gear. Support the shaft
with a lifting device. Then push out until free of the bore in the base.
9. Remove the clamp ring and bearing support sleeve from the end of the worm gear to expose the
worm gear bearings. Any necessary replacement of bearings can now be accomplished.
10. To release the adjustable locknut, loosen each of the locking screws a little at a time in a crosswise
pattern to avoid binding the last screw. With the locking screws loose, the locknut can be easily
loosened by means of a standard radial spanner wrench.

INSTALLING THE TABLE DRIVE TRAIN

Install the drive train in reverse of removal considering the following:
1. Replace all seals and remove any burrs and dirt.
2. Replacing the heavy duty adjustable locknut:
a. With the locking screws loose, turn the locknut onto the spindle thread until it is within 0.100"
of the mating face.
b. Tighten the locking screws crosswise and uniformly while rotating the locknut back and forth
until clearance is nearly eliminated. In this condition the centerline of the locknut coincides
with the spindle centerline, mating face is perpendicular to the common centerline, and the
thread flanks of the locknut are in uniform contact over the full circumference in both the
clamping and locking section.
c. Tighten the locknut against the mating face, with 160 Nm (118 ft. lbs.), the required preload to
pre-stretch the threads, eliminating any subsequent compaction of nut, spindle threads and
contact surfaces, then loosen the locknut and torque to 135 Nm (100 ft. lbs.).
3. To secure the bearing, torque the M6 screws in a crosswise pattern to 15 Nm (136 in lbs).

6-6
TABLE DRIVE BOX ASSEMBLY
(Reference Layout MD.2000.6671)
1. Heat the bearing M.1001.4877 to 160° Fahrenheit, assemble to the gear shaft M.1001.2499 and
install both into the base casting.
2. Assemble gear M.1001.2498 to the end of worm shaft using the locking element and gear flange.
3. Heat the bearing M.1001.4896 to 160° Fahrenheit, then assemble to the gear shaft M.1001.2499.
4. Assemble and pin the belt housing to the main base casting. (Use Loctite 518 flange sealant on
mating surfaces).
5. Assemble shaft seal and o-ring to flange. Slide flange assembly over gear shaft and bolt to the belt
housing. Assemble belt sprocket to gear shaft using the taper lock bushing and key. Position the
sprocket on shaft so the teeth are approximately 3/8 inch from the belt housing flange.
6. Assemble sprocket to the motor shaft using a spacer, locking element, another spacer and cap as
per print.
7. Glue housing gasket to housing cover using 3M gasket adhesive (M.1014.5943). Assemble the
cover to drive motor. See prints for proper orientation.
8. Install belt to driven sprocket that was previously mounted to the gear shaft and install drive motor
assembly to the drive housing. Adjust belt to pulleys.
9. Install belt tensioner and set belt tension to deflect approx. 0.100” in the center with 10 lbs. of
downward force. Install pipe plug M.1200.1039 in belt housing cover and belt tension access hole.
10. Fill gear housing with oil SHC 630 and pipe plug holes.

CHECKING TABLE BACKLASH

Backlash or lost motion between the rotary table unit drive motor and the rotating table does not normally
affect positioning accuracy or repeatability. The rotary table position feedback unit is independent of the
drive train, the feedback unit is mounted directly to the rotating segment of the table and its support is the
table base. As a result, the feedback unit reflects only the actual relationship of the table and the
supporting unit and not the driving mechanism. However, minimal backlash between the table's drive
worm pinion and worm wheel gear is important for servo stability. It is the snug engagement of the worm
and worm wheel that keeps the rotary table stationary while cutting forces are applied to a workpiece
secured to it. Excessive backlash between the worm and the worm wheel may result in chatter marks in
the workpiece finish.
The following is a satisfactory method of checking the backlash between the worm pinion and the worm
wheel.
1. Clamp a ground parallel or gage block to the top face of the pallet near the center of a side. The
gage block should partially extend from the pallet surface to form a 90° angle with its slide (see
figure 6-6).
2. Attach a 0.003mm (0.0001") dial indicator to a good magnetic base indicator stand. Arrange the
indicator stand so that it is locked to the table base near the gage block and the indicator stylus is
bearing against an edge of the gage block. Preload the indicator to about .002" to .004".
3. Press the machine start push button turning on the main hydraulic unit. Hydraulic force is needed
to maintain the pallet in a clamped position. If your machine is equipped with pallets.
4. Attach a piece of flat bar stock, approximately 1.2m (4 feet) long to the pallet.
5. Pull firmly (100 ft lbs) on the bar in a manner that will tend to rotate the table clockwise.
Release the bar and allow the table to spring back of its own accord. Zero the indicator dial.

6-7
 Figure 6-6
Checking Table Backlash

6. Pull the bar firmly (100 ft lbs) on the bar in the opposite direction to rotate the table
counterclockwise. Release the bar and allow the table to spring back of its own accord. Record
the indicator reading, the difference represents backlash.
7. Temporarily remove the indicator and stand to allow clearance for rotating the table.
8. Repeat steps 1 through 7 three (3) more times, rotating the table about 90° from each other.
Backlash measured in this manner should be less then .0002".

ADJUSTING TABLE BACKLASH

To reduce rotary table backlash, follow the steps below.
Note: The table drive worm is manufactured with a single thread, dual lead. The dual lead
results in a thread that becomes progressively heavier from leading to trailing end.
Because the worm thread varies in thickness, it is possible to remove all the backlash
between the worm and the worm wheel gear attached to the table. This is done by
engaging the worm with the worm wheel at the point where the worm thread is just heavy
enough to achieve this no lash condition without binding the worm wheel gear.
1. Determine the existing lash from the test above.
2. Remove socket head cap screws and remove the cover. To remove backlash, the cover will have
to be ground to allow the cover to push the worm into the worm wheel. The ratio is .005” per 1 inch
of movement toward the drive end or .001” backlash removal take .200” off fitting spacer.
Example: measured backlash = .001”, grind off enough to move the shaft .200” in toward the motor
end.
3. When reassembling the cover torque the cap screws to 55 nm (40 ft lbs).

6-8
PALLET CLAMPING SYSTEM
When a pallet is shuttled onto the table it is held in place by a pair of 'T' shaped bars which move up and
down in order to clamp the pallet to the table. The T-bars are actuated by hydraulic cylinders located
under the T-bar mounting bolts. A pair of locating pins is used to align the pallet side to side and front to
back on the table. Ground pads locate the pallet as it rests on the table and keeps the pallet flat. During
the loading of the pallet, air is blown across the locating pads to prevent any dirt from causing a
misalignment or out of level condition. Figure 6-7 shows the table with the pallet removed and points out
the major components of the pallet clamping system.

Slow Down Pallet Stop

Plate Block Slow Down
Plate

Pallet Support
Rollers

Pallet Locating
Pins

T-Bar Mounting
Bolts

T-Bars

Figure 6-7
Pallet Clamping System

Figure 6-8 shows the table with the T-bars and the center cover removed. Upon reinstallation of the
cover, the old gasket material must be removed, surfaces cleaned and new oil & coolant resistant gasket
(Loctite Red sealant or Dow 735 black) put in place to seal the center cover.
Under the center cover are the valves for actuating the hydraulic clamping cylinders and the pneumatics
for blowing off the locating pads and pins. There are two pressure switches located under the way cover
for the X axis bed on the toolchanger side of the table (see figure 6-10) which monitor pallet present and
pallet clamping.
The hydraulics and pneumatics are supplied from the end of the bed, through the utility carrier, then into
the table and up through the center post (refer to the machine drawings for cross sections of the table).

6-9
 H

F E

D
(Bore for
A Sleeve)

I
C

Figure 6-8
Rotary Table with T-Bars and Center Cover Removed

The following is a list of the components shown in Figure 6-8:

A. Pallet Clamp/Unclamp Hydraulic Cylinder. These cylinders (4 total) are used for raising and
lowering the T-bars for pallet clamping. To remove the cylinder, remove the 4 cap screws from the
round locating plate and lift up to pull the cylinder out.
B. Locating Pads (8 total) used to seat the pallet while clamped with the T-bars. They are precision
ground and should be inspected for wear, kept clean and free of nicks or burrs. Air is blown across
the pads through holes in the T-bars (supplied through C) to clear the pads prior to clamping the
pallet.
C. Pneumatic Supply Cylinder Sleeve (4 total) which supplies air (through H) into the T-bar and then is
channeled out to the locating pads. In Figure 6-9, item Cc shows the cylinder that slides into the
sleeve (which is bolted into the table by 3 cap screws). The Cylinder is threaded into the bottom
side of the T-bar and an o-ring seals the cylinder into the sleeve. Removal of the T-bar will pull the
cylinder out of the sleeves.

6-10
D. T-bar Unclamped Pressure Switch Sleeve (1 total). Similar to the item at C, this unit is used to
indicate if the T-bar is unclamped. In Figure 6-9, item Dd shows the cylinder which slides into the
sleeve (which is bolted into the table by 3 cap screws) and is threaded into the bottom of the T-bar.
It is supplied with air pressure through H. There are cross-holes drilled into the side of the cylinder.
Depending on the position of the cylinder in the sleeve (T-bar up or down position) will determine if
the air pressure is released or blocked off. If the T-bar is in the unclamped position, the holes will
be blocked off and air pressure will increase to make the pressure switch (see Figure 6-10) and
indicate that the T-bar is unclamped.
Note: When removing the T-bar, the (3) sleeve cap screws must be removed and the cylinder
(Dd) and sleeve (D) pulled up with the T-bar. This is not required with the (4) cylinders
located at Cc. They can be removed with the T-bar without loosening the sleeve.

Dd

Figure 6-9
Pneumatic Supply
Cylinder and Sleeve

T-Bar Clamp/Unclamp
Pressure Switch
C
Cc

E. Pallet Clamp Valve. Hydraulic pressure is supplied from the center post out to the valve. From
there it is distributed to the pallet clamp/unclamp cylinders. This valve will clamp the pallet by
pulling down on the T-bars.
F. Pallet Unclamp Valve. Hydraulic pressure is supplied from the center post out to the valve. From
there it is distributed to the pallet clamp/unclamp cylinders. This valve will unclamp the pallet by
raising the T-bars.
G. Location of hydraulic lines supplying pressure to the cylinders for pallet clamp/unclamp.
H. Location pneumatic lines supplying air to the pneumatic supply cylinders for blowing off the pallet
locating pads and for supplying air to the locating pins (see I).
I. Locating Pins. These pins locate the pallet on the table. An air blast to the pins clears them of
debris before the pallet is placed on the table. One pin is also hooked up to the pallet present
pressure switch (see Figure 6-10). Air blows up through a center hole and when the pallet is
present, the hole is sealed off and enough backpressure is created to make the switch.
J. Stop Block. Is used to prevent the pallet from rolling off the table during shuttling.

6-11
Figure 6-10 shows the bed on the right side of the table (toolchanger side) with the cover pulled back.
On the right is the servo drive for the rotary table. In the center is the utility track and on the left is the
ballscrew with the pressure switch mounted above. Hydraulics and pneumatics are supplied to the center
post in the table through the manifold above the utility track. See the machine drawings for cross
sectional views of the rotary table.

Pallet Present &

Clamped Pressure
Switch

Pallet Unclamped Servo Drive

Pressure Switch Rotary Table

Figure 6-10
Rotary Table Side View
(Side Closest to Toolchanger)

6-12