T-42 T-51 T-65 Multi-Tasking CNC Lathes

Transcription

1 MAINTENANCE MANUAL TP7878A T-42 T-51 T-65 Multi-Tasking CNC Lathes Equipped with a Fanuc 31i-T Control Revised: May 29, 2012 Original Instructions Manual No. M-506A Litho in U.S.A. Part No. M A February, 2012

2 - NOTICE - Damage resulting from misuse, negligence, or accident is not covered by the Hardinge Machine warranty. Information in this manual is subject to change without notice. This manual covers the routine maintenance of Hardinge T-42, T-51, and T-65 Multi-Tasking CNC lathes equipped with a Fanuc 31i-T control. In no event will Hardinge Inc. be responsible for indirect or consequential damage resulting from the use or application of the information in this manual. Reproduction of this manual in whole or in part, without written permission of Hardinge Inc., is prohibited. CONVENTIONS USED IN THIS MANUAL - WARNINGS - Warnings must be followed carefully to avoid the possibility of personal injury and damage to the machine, tooling, or workpiece. - CAUTIONS - Cautions must be followed carefully to avoid the possibility of damage to the machine, tooling, or workpiece. - NOTES - Notes contain supplemental information. 2012, Hardinge Inc. M-506A

3 Table of Contents Offices Iii Machine Description and Intended Use Iv Machine Electrical Operating Range Iv Warnings V Safety Recommendations vi CHAPTER 1 - AIR SYSTEM Introduction Air Control Assembly Setting the Machine Air Pressure Turret Air Bearing Pressure Regulator Clean the Air Filter Bowls Replace the Air Filter Elements Replace Air Control Assembly Components Replacing the Filter/Regulator or Coalescing Filter Replacing the Pressure Switch CHAPTER 2 - COOLANT SYSTEM Introduction Cutting Fluid (Coolant) Water-Based Coolants Coolant Maintenance Cleaning the Coolant Filter Cleaning the Chip Basket Cleaning the Coolant Tank Spindle Coolant Catcher CHAPTER 3 - HYDRAULIC SYSTEM Introduction System Specifications Hydraulic Tank Maintenance Filling the Hydraulic Tank Hydraulic Oil Filter Replacement Hydraulic Heat Exchanger Hydraulic System Relief Valve Replacement CHAPTER 4 - LUBRICATION Introduction Importance of Lubrication Lubrication Alarm Axes Grease Lubrication Grease Volumes Lubrication Procedure Turret Lubrication Live Tool Holder Lubrication M-506A i

4 CHAPTER 5 - MISCELLANEOUS Control and Axis Drive Battery Replacement Control Battery Axis Drive Batteries Sub-Spindle Part Catcher Alignment [Option] Introduction Verifying the Gripper Position Adjusting the Gripper Extension Adjusting the Arm Swing Positions Adjusting the Arm Swing Speed Air Filters Cleaning an Air Filter Service Access Panels Left Service Access Panel Right Service Access Panel Checking the Turret Top Plate Alignment (Live Tool Machines Only) CHAPTER 6 - TORQUE LIMITER RESET AND AXIS POSITION RESET PROCEDURES Introduction Linear Scales Enabling Parameter Edit Resetting the X, Z, or E Axis Torque Limiter Resetting an Axis Position Z Axis Not Equipped with a Linear Scale E Axis Live Tool Torque Limiter Reset Turret Setup Mode Setting Turret Home APPENDIX ONE - PREVENTIVE MAINTENANCE SCHEDULE Introduction A1-1 Standard Maintenance Schedule A1-1 Maintenance Schedule for Options A1-3 Non-Metallic Materials Typically Found in Hardinge Machine Construction A1-4 APPENDIX TWO - ALARM AND OPERATOR MESSAGES Alarm Messages A2-1 Operator Messages A2-8 APPENDIX THREE - MACHINE PHOTOGRAPHS ii M-506A

5 APPENDIX FOUR - MACHINE TAGS Tag Locations A4-1 Tag Part Numbers A4-10 Tag Kits A4-10 Individual Tags A4-10 APPENDIX FIVE - RECOMMENDED SPARE PARTS T-42 Lathe A5-1 T-51 and T-65 Lathes A5-3 DOCUMENT REVISION RECORD M-506A iii

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7 Global Headquarters United States Hardinge Subsidiaries England Germany China Taiwan Distributor France OFFICES Hardinge Inc. One Hardinge Drive Elmira, NY USA Telephone: web site: Bridgeport Hardinge Machine Tools, Ltd. Whiteacres Cambridge Road Whetstone Leicester LE8 6BD England Telephone: +44 (0) web site: Hardinge GmbH Saalestrasse Krefeld Germany Telephone: (49) Hardinge Machine (Shanghai) Co. Ltd. Hardinge China Limited No.1388 East Kang Qiao Road Pudong, Shanghai Telephone : web site: Hardinge Taiwan Precision Machinery Ltd. 4 Tzu Chiang 3rd Road Nan Tou City 540 Taiwan, R.O.C. Telephone: Delta Machines 3 Rue du Docteur Charcot F Morangis Cedex France Telephone: +33 (0) web site: delta-machines@delta-machines.fr M-506A iii

8 MACHINE DESCRIPTION AND INTENDED USE Applicable Machines: T-42, T-51, T-65 CNC Lathes This lathe is a numerically controlled machine tool designed to shape cold metal by the application of a cutting tool and rotating workpiece capable of performing two or more machining processes (e.g. turning, facing, drilling, grooving and boring) at one set-up of a workpiece and incorporating the following features: Select and change tools from a turret. Change the position of the turret relative to the spindle clamped workpiece. Select and apply spindle speeds and axis feeds. Control auxiliary services (e.g. coolant flow). Tailstock provides added support when machining long parts and reduces part deflection. Optional sub-spindle provides capability of back side tuning. Optional live tooling provide milling capabilities. This lathe is designed to machine non-hazardous metals only. Non-hazardous materials such as Tools Steels, Aluminum, and Brass may be machined. DO NOT machine any flammable, explosive, toxic, or radioactive material. DO NOT machine any material that produces a hazardous residue, dust, or gas. DO NOT use any flammable, explosive, or toxic cutting fluids. In all cases, if in doubt about the content of the material that you wish to machine, contact the material supplier. MACHINE ELECTRICAL OPERATING RANGE Ambient Temperature Range: +5 C to +40 C. Humidity Range: Up to 40% at a maximum temperature of +40 C. Altitude: Up to 1000 meters above sea level (minimum) iv M-506A

9 CHEMICAL WARNING WARNINGS AND CAUTIONS Current laws and regulations require that information regarding chemicals used with this equipment be supplied to you. Refer to the applicable section of the Material Safety Data Sheets supplied with your machine when handling, storing, or disposing of chemicals. BAR FEED WARNING Machine should only be used with a bar feed approved by Hardinge Inc. SPINDLE TOOLING WARNING Hardinge HQC (Quick-Change) collets MUST NOT be used in applications where the spindle is rotating without a bar or workpiece in the collet. Rotating the spindle without a bar or workpiece in the collet can result in the collet head being expelled from the spindle. Failure to comply with this warning can result in serious injury or death. ENTRAPMENT WARNING DO NOT climb into the machine guard! You may become entrapped. Due to the compact size of the Hardinge lathes and the provision of side access doors to allow servicing of the machine, it is not necessary to climb into the machine guard. In the unlikely event that this warning is ignored and the main access door is closed, the door will latch shut and cannot be opened from the inside. Another person must release the door lock. Refer to Chapter 15 of the Operator's Manual (M-505) for information on releasing the door lock. MAIN COOLANT GUARD WARNING The guards provided with the machine are intended to minimize the risks of workpiece ejection and not to eliminate them completely. INTERLOCKED ACCESS PANEL CAUTION Opening an interlocked access panel while the machine is cutting a part will force the control into a dual check speed or position alarm, which can destroy the workpiece and/or tooling. TURRET TOP PLATE ALIGNMENT CAUTION (Live Tool Machines Only) Check the alignment of the turret top plate with the live tool drive shaft in the event that any of the following events have occurred: Static tool breakage Live tool breakage Live tool torque limiter trip Machine crash Refer to Chapter 5 for information on checking the alignment of the turret top plate. M-506A vii

10 SAFETY RECOMMENDATIONS Your Hardinge machine is designed and built for maximum ease and safety of operation. However, some previously accepted shop practices may not reflect current safety regulations and procedures, and should be re-examined to insure compliance with the current safety and health standards. When this instruction book was printed, the information given was current. However, since we are constantly improving the design of our machine tools and bar feed systems, it is possible that the illustrations and descriptions may vary from the machine or bar feed system you received. Hardinge Inc. recommends that all shop supervisors, maintenance personnel, and machine tool operators be advised of the importance of safe maintenance, setup, and operation of Hardinge equipment. Our recommendations are described below. READ THESE SAFETY RECOMMENDATIONS BEFORE PROCEEDING ANY FURTHER. Read the appropriate manual or instructions before attempting operation or maintenance of the machine. Make certain that you understand all instructions. Don t allow the operation or repair of equipment by untrained personnel. Consult your supervisor when in doubt as to the correct way to do a job. Wear safety glasses and proper foot protection at all times. When necessary, wear respirator, helmet, gloves, and ear muffs or plugs. Don t operate equipment unless proper maintenance has been regularly performed and the equipment is known to be in good working order. Warning or instruction tags are mounted on the machine for your safety and information. Do not remove them. If a tag comes off, re-attach the tag at the original position. Replace any warning or instruction tag if it becomes unreadable. Refer to Appendix Four for tag identification. Don t alter the machine to bypass any interlock, overload, disconnect, or other safety device. Don t operate equipment if unusual or excessive heat, noise, smoke, or vibration occurs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as any damaged parts. Reduce spindle speed if vibration occurs. Bar stock straightness will have an effect on vibration and balance of the spindle system. Machining an unbalanced workpiece may create an ejection hazard. Minimize the risk by counter-balancing or machining at reduced speeds. Never operate the machine spindle without a work-holding device if the draw tube is in the spindle. Tighten all draw tube screws before beginning spindle operation. Make certain that the equipment is properly grounded. Consult National Electric Code and all local codes. Disconnect main electrical power before attempting repair or maintenance. vi M-506A

11 Allow only authorized personnel to have access to enclosures containing electrical equipment. Don t reach into any control or power case area unless electrical power is OFF. Don t touch electrical equipment when hands are wet or when standing on a wet surface. Replace blown fuses with fuses of the same size and type as originally furnished. Ascertain and correct the cause of a control alarm before restarting the machine. Keep the area around the machine well lighted, dry, and free of obstructions. Keep chemical and flammable material away from electrical or operating equipment. Keep chips clear of the work area. Don t use a toxic or flammable substance as a solvent cleaner or coolant. Make certain that proper guarding is in place and that all doors are closed and secured. To remove or replace the collet closer it is necessary to remove the guard door at the left end of the machine. Make certain that the guard door is in place before starting the machine. Don t open guard doors while any machine component is in motion. Make sure chucks, closers, fixture plates, and all other spindle-mounted work-holding devices are properly mounted and secured before starting the machine. Make certain all tools are securely clamped in position before starting the machine. Remove any loose parts or tools left on machine or in the work area before operating the machine. Always check the machine and work area for loose tools and parts especially after work has been completed by maintenance personnel. Remove chuck wrenches before starting the machine. Before pressing the cycle start push button, make certain that proper functions are programmed and that all controls are set in the desired modes. Know where all Emergency Stop push buttons are located in case of an emergency. Check the lubrication oil level and the status of the indicator lights before operating the machine. Make certain that all guards are in good condition and are functioning properly before operating the machine. Inspect all safety devices and guards to make certain that they are in good condition and are functioning properly before the cycle is started. DO NOT power up the machine until the guard door vision panel has been inspected and determined to be in satisfactory condition. Failure to inspect the vision panel can result in unsafe operating conditions. M-506A vii

12 Check the position of the tool top plate before pressing the Cycle Start push button. Check the position of any load/unload automation before pressing the Cycle Start push button. Check setup, tooling, and security of the workpiece if the machine has been OFF for any length of time. Dry cycle a new setup to check for programming errors. Make certain that you are clear of any pinch point created by moving slides before starting the machine. Don t operate any equipment while any part of the body is in the proximity of a potentially hazardous area. Don t remove chips with hands. Use a hook or similar device and make certain that all machine movements have ceased. Be careful of sharp edges when handling a newly machined workpiece. Don t remove or load a workpiece while any part of the machine is in motion. Don t operate any machine while wearing rings, watches, jewelry, loose clothing, neckties, or long hair not contained by a net or shop cap. Don t operate any machine while under the influence of drugs and/or alcohol. Don t adjust tooling or coolant hoses while the machine is running. Don t leave tools, workpieces or other loose items where they can come in contact with a moving component of the machine. Don t check finishes or dimensions of workpiece near running spindle or moving slides. Don t jog spindle in either direction when checking threads with a thread gauge. Don t attempt to brake or slow the machine with hands or any improvised device. Any machine modification must be reviewed by Hardinge Inc. before implementation. Use caution around exposed mechanisms and tooling especially when setting up. Be careful of sharp edges on tools. Don t use worn or defective hand tools. Use the proper size and type for the job being performed. Use only a soft-faced hammer on tooling and fixtures. Don t use worn or broken tooling on machine. Make certain that all tool mounting surfaces are clean before mounting tools. viii M-506A

13 Inspect all chucking devices daily to make certain that they are in good operating condition. Replace any defective chuck before operating the machine. Hardinge high speed spindles are balanced to an ISO G1.0 standard. High speed spindles require a work-holding device balanced to G2.5 or better. Use maximum allowable gripping pressure on the chuck. Consider weight, shape, and balance of the workpiece. Check the workpiece for distortion. Use lighter than normal feedrates and depth of cut when machining a workpiece diameter that is larger than the gripping diameter. Don t exceed the rated capacity of the machine or tooling. Don t leave the machine unattended while it is operating. Don t clean the machine with an air hose. Keep tote pans a safe distance from the machine. Don t overfill the tote pans. Don t let stock project past the back end of the collet closer or machine spindle without being adequately covered and properly supported. Follow each bar feed manufacturer s guidelines. For performance and safe application, size and use feed tube bushings, pushers, and spindle liners according to bar feed information. Make certain that any bar feed mechanism is properly aligned with the spindle. If the bar feed is a floor-mounted type, it must be securely bolted to the floor. During high speed applications, the bar stock must be contained within the collet closer and a bar feed not be used. Hardinge Inc. recommends using a bar loader for feeding bar stock during high speed applications. Bar loaders feed the entire piece of bar stock into the spindle; then, the pusher is disengaged from the bar stock. Unless otherwise noted, all operating and maintenance procedures are to be performed by one person. To avoid injury to yourself and others, be sure that all personnel are clear of the machine when opening or closing the coolant guard door and any access covers. Because there are so many things that either cannot be done or must not be done when using the machine, that is impossible to cover all of them in the documentation. Assume that something is impossible unless the manual specifically states that it can be done. FOR YOUR PROTECTION - WORK SAFELY M-506A ix

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15 CHAPTER 1 - AIR SYSTEM INTRODUCTION - WARNING - The machine must be powered down when the air system s components require maintenance. Factory air goes through a filter/regulator system to control the air pressure and remove contaminants before they get into the machine air supply. If the factory air has excessive moisture, a heavy-duty air dryer must be added to the incoming air line. The incoming air line must have a minimum inside diameter of 3/8 inch [9.5 mm]. A larger diameter hose may be required if the air line is especially long. The air volume requirement for a machine is approximately 8 to 9 scfm [226 to 255 lm]. AIR CONTROL ASSEMBLY The air control assembly, shown in Figure 1.1, consists of a main air shut-off valve, filter/regulator, coalescing filter, air manifold, and pressure switch. Main air lock-out valve "A" turns the air supply to the machine ON or OFF. The bowls on filter/regulator "B" and coalescing filter "D" are equipped with automatic drains. Main air pressure switch E is preset at 60 psi [4.1 bars]. If the pressure falls below this level, an alarm message appears on the control display and the control goes into Emergency Stop. C D E B F A Figure Air Control Assembly TP7857B M-506A 1-1

16 SETTING THE MACHINE AIR PRESSURE 1. Turn the air supply to the machine ON. 2. Pull regulator knob C, Figure 1.1, up and set the machine air pressure at a constant pressure from 70 psi to 90 psi [4.9 to 6.2 bars]. Press the knob down when adjustment is complete. TURRET AIR BEARING PRESSURE REGULATOR Regulator "F", Figure 1.1, controls the turret air bearing pressure. Check the gauge on the regulator to be sure the pressure is within 18 to 22 psi [1.25 to 1.5 bar]. If necessary, pull the regulator knob down and set the turret air bearing pressure within the specified range. Push the knob up when adjustment is complete. CLEAN THE AIR FILTER BOWLS Clean the bowls on Filter/regulator "B" and coalescing filter "D", Figure 1.1, every three months or more frequently, if necessary: 1. Power down the machine. 2. Turn main air lock-out valve "A", Figure 1.1, OFF. 3. Lift and unthread the bowl sleeve counterclockwise just enough, approximately one eighth of a turn, to release the sleeve and bowl from the filter head. 4. Pour out contaminants that are present in the filter bowls. 5. Wipe the bowls clean with a lint-free cloth and change the filter if necessary. 6. Insert each bowl under a filter head and tighten the sleeve clockwise to seat the bowl O-ring. 7. Grasp the sleeve and pull down to verify that the bowl is secure.. 8. Turn the main air lock-out valve ON. 9. Power up the machine. 10. Set filter/regulator "B" to 85 psi [5.9 bars] and check for air leaks. Correct any air leaks as necessary. 11. Set the filter/regulator below 60 psi [4.2 bars] to test the pressure switch. The control will go into an Emergency Stop condition. 12. Set the filter/regulator to an operating pressure between 70 psi to 90 psi [4.9 to 6.2 bars]. 13. Press the Emergency Stop Reset push button. 14. Press the Reset key if it is still necessary to clear the alarm message from the control display. 15. Check the air system bowl for contamination, moisture, or air leaks. Correct any problems as necessary. 1-2 M-506A

17 REPLACE THE AIR FILTER ELEMENTS Replace the following air filter elements every month or more frequently, if necessary: Filter element for filter/regulator "B", Figure 1.1 (Part Number QC SMC1) Filter element for coalescing filter "D" (Part Number QC SMC2) 1. Power down the machine. 2. Turn main air lock-out valve "A", Figure 1.1, OFF. 3. Replace each filter element as follows: A) Lift the filter bowl sleeve and turn it counterclockwise about one eighth of a turn to release it from the filter head. Do not use excessive force to remove a filter bowl. B) Wipe the bowl clean with a lint-free cloth and check the O-ring for damage. Replace the O-ring and/or bowl if necessary. C) To release the filter, unscrew the nylon fixture on the bottom of the filter from the stem. Align the replacement filter on the nylon fixture and thread the fixture on the stem until it is tight. D) Mount the bowl by aligning the bowl and sleeve on the head and turning it clockwise about one eighth of a turn to tighten it in place. Pull down on the sleeve to confirm that the bowl is in place. 4. Turn the main air lock-out valve ON. 5. Power up the machine. 6. Set filter/regulator "B" to 85 psi [5.9 bars] and check for air leaks. Correct any air leaks as necessary. 7. Set the filter/regulator below 60 psi [4.2 bars] to test the pressure switch. The control will go into an Emergency Stop condition. 8. Set the filter/regulator to an operating pressure between 70 psi to 90 psi [4.9 to 6.2 bars]. 9. Press the Emergency Stop Reset push button. 10. Press the Reset key if it is still necessary to clear the alarm message from the control display. 11. Check the air system bowl for contamination, moisture, or air leaks. Correct any problems as necessary. M-506A 1-3

18 REPLACE AIR CONTROL ASSEMBLY COMPONENTS Filter/regulator B or coalescing filter D, Figure 1.1, can be replaced if they become damaged or the air control assembly can be replaced as a unit. The air control components are assembled with standard fittings and components. REPLACING THE FILTER/REGULATOR OR COALESCING FILTER 1. Power down the machine. 2. Turn main air lock-out valve "A", Figure 1.1, OFF. 3. Remove the air assembly unit from the air panel. 4. Loosen the fittings and other components, as needed. 5. Compare the components to be replaced or complete air assembly unit to make certain that the replacements are the same as the original parts. - NOTE - Use just enough sealant to secure the component and fitting. Do not apply sealant to the first few threads. 6. Replace the air control assembly or disassemble and replace the faulty component. 7. Mount the air control assembly to the air panel. 8. Fasten the drain tube(s) to the component drain(s). 9. If any air lines have been removed, connect the air lines. 10. Turn the main air lock-out valve ON. 11. Power up the machine. 12. Press the Reset key if it is still necessary to clear the alarm message from the control display. 13. Set the regulator to an operating pressure between 70 and 90 psi [4.9 to 6.2 bars]. 14. Check the air system bowls for contamination, moisture, or air leaks. Correct any problems as necessary. 1-4 M-506A

19 REPLACING THE PRESSURE SWITCH Pressure switch E, Figure 1.1, is designed to send a signal to the control when the main air system pressure falls below 60 psi [4.2 bars]. An alarm message will appear on the control display when the main air system pressure falls below 60 psi [4.2 bars]. 1. Power down the machine. 2. Turn main air lock-out valve "A", Figure 1.1, OFF. 3. Unlatch and open access doors "G", Figure Follow the pressure switch cable to the plug connection. 5. Disconnect the plug on the pressure switch cable. 6. Press the retention ring on the fitting away from pressure switch "E", Figure 1.1, and remove the pressure switch and cable from the machine. 7. Press the replacement pressure switch into the fitting on the air manifold. 8. Route the cable to the plug connection. 9. Connect the pressure switch cable. 10. Close and latch the access doors. 11. Turn the main air lock-out valve ON. 12. Power up the machine. 13. Press the Reset key if it is still necessary to clear the alarm message from the control display. 14. Check the air system bowl for contamination, moisture, or air leaks. Correct any problems as necessary. G Figure Rear Access Doors TP7863 M-506A 1-5

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21 CHAPTER 2 - COOLANT SYSTEM INTRODUCTION - WARNING - The machine must be powered down when the coolant system requires maintenance. T-42, T-51, and T-65 machines have a coolant recirculating system for either oil-based or water-based coolant. The system consists of a coolant tank with filter screens, a pump, openings through the turret top plate or through tool holders to directional balls, and a coolant catcher on the rear of the main spindle. Some machines may have other coolant options. Coolant is fed to the work area through the hoses and the directional balls. Coolant drains directly from the work envelope into the coolant tank. Coolant and chip management is very important. Clean the pan of most of the chips and then pour the coolant directly into the pan. Fill the coolant tank to 1 inch [25 millimeters] above the screen in the chip basket. Approximate coolant tank capacity is: T-42 lathe without chip conveyor: 55 gallons [208 liters] T-42 lathe with chip conveyor: 50 gallons [189 liters] T-51 and T-65 lathes: 65 gallons [246 liters] If standard coolant has been activated by the program, pressing the Coolant push button will stop coolant flow. If standard coolant has not been activated by the program, pressing the Coolant push button will start coolant flow. However, if the program is repeated, the Coolant push button must be pressed again to activate the coolant each time the program is run. M-506A 2-1

22 CUTTING FLUID (COOLANT) Hardinge machine tools are designed using the latest technology and highest quality materials available. However, due to the ever increasing number of cutting fluid (coolant) selections available, it is impossible to test material compatibility with each and every coolant. The two most popular types of cutting fluids are cutting oils and water-based coolants. - CAUTION - Whenever cutting fluids are used, it is essential to follow the manufacturer s recommendations on the selection and maintenance for that particular fluid. WATER-BASED COOLANTS Water-based coolants are a cutting fluid which, when improperly specified or maintained, can affect the life of a machine and the quality of the parts made on it. Water-based coolants are designed to suppress rusting, enhance cutting, increase tool life, promote heat dissipation, and be economical to use. Some water-based coolants may cause machine corrosion problems and be incompatible with machine components, especially if the fluid is not maintained correctly. Poorly maintained coolants may result in rancidity, poor tool life, staining, rusting, foaming, which affect machine performance and may cause health problems such as dermatitis. Water-based coolants must be correctly specified according to the machined materials and ensure compatibility with the machine s components. Refer to the list of common materials used in the manufacture of Hardinge machines at the end of Appendix One. It is extremely critical to follow the coolant manufacturer s recommendations when using a water-based coolant. Maintaining coolants per the manufacture s recommendations will increase the machine s useful life and will minimize corrosion, rusting, staining, etc., and health problems such as dermatitis. At a minimum, the coolant maintenance should include daily checks and correction of coolant concentration, and a measure of coolant ph. Coolant Concentration Proper concentration control is essential for optimal tool life, corrosion control, and inhibiting bacterial growth. Water soluble coolants lose water by evaporation during normal operating conditions which tends to increase the coolant concentration over a normal work shift. The coolant concentration must be checked each day. The coolant concentration must be kept within the specified range determined by the coolant manufacturer. Failure to maintain the coolant concentration within this range may result in poor performance from that fluid. Lean concentrations can lead to rust, rancidity, short tool life, and other problems. Rich concentrations can result in foam, residues, health problems such as dermatitis, and increased coolant costs. 2-2 M-506A

23 Coolant ph - NOTE - Water based coolants are designed to run within the ph range determined by the manufacturer ph is a measure of a solution s alkalinity or acidity. There are two common methods used to determine ph. One method is the use of special ph test paper and the other is a ph meter. The ph of water based coolants typically runs on the alkaline side of the ph scale. A drop in ph indicates a growth of microbiological organisms (bacteria). These anaerobic bacteria live on the tramp oils and additives found in the coolants. When these bacteria feed on the oils they release an acidic by-product which eventually drives the coolant towards a lower ph level. Typically, the ph range is between 8.5 and 9.2. Water Quality The water quality is also an important factor toward achieving optimum coolant performance. Water that contains dissolved minerals, bacteria, and other impurities (hard water) can sometimes adversely affect the coolant selected. An indication of water related problems is the formation of a soap like scum which adheres to sumps and filters. It is best to consult with your coolant representative to determine your requirements. COOLANT MAINTENANCE - NOTE - A properly selected and maintained coolant, either oil or water based, will ensure the best performance from the coolant and machine. Proper cleaning of the machine is very important before refilling the tank with fresh coolant. Dispose of the used coolant properly. A daily check of the concentration and ph will help keep the coolant at optimum performance level. In addition to these checks, any tramp oil must be removed from the coolant. Frequent removal of tramp oils will limit the growth of anaerobic bacteria which cause the rancid odors and feed on the additives in the coolants. Make-up cutting fluid should be added when needed and according to the manufacturer s recommendation. This make-up coolant is necessary to provide additional fresh coolant which contains the essential additives required to keep the coolant performing properly. Clean and replace the coolant per the coolant manufacturers recommendations. Bacteria live and cling to all wetted surfaces in the machine. Special cleaners, usually available from your coolant supplier, are recommended to flush the system before refilling. These cleaners will kill the bacteria left after draining the machine. It also is recommended that a thorough cleaning, which includes scraping and removing any sludge found on the bottom and hidden in the top panels of the coolant tank, be completed before circulating cleaner through the system. M-506A 2-3

24 CLEANING THE COOLANT FILTER The needle on coolant filter pressure gauge "A", Figure 2.1, should be in the GREEN zone when the coolant is ON. The coolant filter element and filter housing should be cleaned when the needle is in the RED zone when the coolant is ON. 1. Verify the machine is powered down. 2. Release latch "B", Figure 2.2, and open the access doors. 3. Wipe filter head "C" and filter housing "D", Figure 2.3, clean with a lint-free cloth. A B Figure Coolant Filter Gauge TP7857B Figure Rear Access Doors TP7863 C D Figure Coolant Filter TP7889A 2-4 M-506A

25 - CAUTION - Use care not to spill the coolant contained in the filter housing. Spilling coolant on the floor can result in a slipping hazard. Spilled coolant must be cleaned up immediately. Dispose of coolant in the filter housing in accordance with all applicable government guidelines. DO NOT introduce the coolant back into the coolant system. 4. Remove the nut on the top of the filter unit to release the filter housing from the filter head. 5. Remove the filter element from the filter body. 6. Allow the coolant in the filter element to drain into the filter housing. 7. Properly dispose of the coolant in the filter housing. 8. Wash the filter element and the inside of the filter housing with a cleaner recommended by the coolant manufacturer. 9. Verify the rubber seal is properly seated in the filter head. 10. Install the filter element in the filter body. 11. Slide the filter housing up into mounting position on the filter head. 12. Install the nut on the top of the filter unit to secure the filter housing to the filter head. 13. Close and latch the access doors. M-506A 2-5

26 CLEANING THE CHIP BASKET (Machines without Chip Conveyor) Clean the coolant tank chip basket every forty hours of machine operation or more frequently if necessary. - NOTE - Open cover "E", Figure 2.4, to access the chip basket on T-42 lathes not equipped with a chip conveyor. 1. Remove the screws and chip basket "G", Figure 2.5 or Wash the chip basket with a cleaner recommended by the coolant manufacturer. 3. Use the screws to install the chip basket in the coolant tank. E F Figure Right End of Coolant Tank TP7952 G G Figure Coolant Tank Chip Basket (T-42 Lathe) TP7893A Figure Coolant Tank Chip Basket (T-51 and T-65 Lathes) TP M-506A

27 CLEANING THE COOLANT TANK - WARNING - Wear protection and be careful when removing coolant, metal chips, and shavings from the tank. Spilling fluid on the floor can create a slipping hazard. Spilled fluid must be cleaned up immediately. Use a rake and suitable container to remove metal chips and shavings from the coolant tank. Injury may result from attempting to remove chips without a rake. Dispose of chips and shavings in an environmentally safe manner. Clean the coolant tank at least once every four months or more frequently if the materials being cut contaminate the coolant. Clean the tank whenever changing the type or brand of coolant. The coolant catcher on the spindle compartment end and the coolant filter should also be cleaned whenever the tank is cleaned. 1. Power down the machine. 2. Wait a sufficient amount of time to allow the coolant to drain into the tank. 3. At the right end of the machine, remove access cover "H", Figure Release the locking handles and disconnect coolant hose coupling "J", Figure If the coolant tank is equipped with a coolant level sensor, disconnect cable "I" from the receptacle on the coolant tank. 6. Release coolant tank clamp "K", Figure 2.9. Figure Access Covers at Right End of Machine H TP7948 K I J Figure Coolant Hose Coupling TP8220 Figure Right Coolant Tank Clamp TP7942 M-506A 2-7

28 L N M Figure Left End Skirt Mounted on Machine TP7871A Figure Left Coolant Tank Clamp TP7870A 7. Release two latches "M" and remove left end skirt "L", Figure 2.10, from the machine. 8. Release coolant tank clamp "N", Figure Move the coolant tank from under the machine. 10. If cleaning a coolant tank equipped with a chip conveyor: A) Remove four screws "O", Figure B) Support the left end of the chip conveyor. C) Roll the chip conveyor out of the coolant tank. -or- If cleaning a coolant tank without a chip conveyor on a T-51 or T-65 lathe: A) Remove four screws "P", Figure B) Remove tank liner "Q". 11. Rake any chips present into a suitable container and dispose of them properly. 12. Remove the chip basket, Figure 2.12, 2.13, or Remove the coolant tank covers, Figure 2.14 or Pump the coolant from the tank. 2-8 M-506A

29 Chip Basket Support this end of the chip conveyor during removal and installation. O NOTE: Two screws "O" located on each side of the chip conveyor. TI5789 Figure Coolant Tank with Chip Conveyor (T-42, T-51, and T-65 Lathes) Chip Basket P Q NOTE: Two screws "P" located on each side of the tank liner. TI5864 Figure Coolant Tank without Chip Conveyor (T-51 and T-65 Lathes) M-506A 2-9

30 Coolant Tank Covers TI5791 Figure Coolant Tank Covers (T-42 Lathe with Chip Conveyor, T-51 and T-65 Lathes) Chip Basket Coolant Tank Covers TI5710A Figure Coolant Tank Covers (T-42 Lathe without Chip Conveyor) 2-10 M-506A

31 15. If the machine is equipped with a coolant chiller: A) Disconnect the chiller RETURN hose from the coolant tank. Refer to Figure B) Disconnect the chiller RETURN hose from the port on the chiller unit. Refer to Figure C) Apply air pressure (30 psi / 2 bar maximum) at the RETURN port to purge the coolant from the chiller unit back into the coolant tank. D) Connect the chiller RETURN hose to the chiller unit. E) Disconnect the chiller DISCHARGE hose from the coolant tank. F) If necessary, place a shallow pan under the coolant filter housing. G) Loose the fitting on the bottom of the filter housing to drain any remaining coolant from the housing. H) Tighten the fitting when draining is complete. I) Replace the coolant filter element according to the chiller installation and maintenance manual supplied with the coolant chiller unit. 16. If necessary, place a shallow pan under drain "F", Figure 2.4, and remove the plug to drain any remaining coolant from the tank. Coolant Chiller RETURN Port Hose connected to coolant chiller RETURN port Coolant Filter Housing Hose connected to coolant chiller DISCHARGE port TI5796 TP8082 Figure Coolant Chiller Hose Connections on the Coolant Tank Figure Coolant Chiller Ports M-506A 2-11

32 Coolant Channels Channel Plug Coolant Nipple TI5792 Figure Coolant Tank with Covers Removed (T-42 Lathe with Chip Conveyor, T-51 and T-65 Lathes) 17. If it is necessary to flush the coolant channels, Figure 2.18 or 2.19: A) Remove the fittings from the coolant nipple, Figure 2.18 or B) Remove the channel plug, Figure 2.18 or C) Use a hose to feed coolant into the coolant nipple and the channel plug opening to flush chips and shavings from the coolant channels. D) Remove any chips or shavings flushed from the coolant channels. E) Drain any coolant present from the coolant tank. F) Install the channel plug. G) Install the fittings on the coolant nipple M-506A

33 Channel Plug Coolant Nipple Coolant Channels TI5790 Figure Coolant Tank with Covers Removed (T-42 Lathe without Chip Conveyor) 18. Clean the permanent screen filter mounted in the coolant tank. 19. Clean the coolant tank. 20. Shake out the metal chips from the chip basket. 21. Wash the coolant tank, chip basket, and covers with a cleaner recommended by the coolant manufacturer. Flush the cleaner from the coolant tank and clean as recommended. 22. Apply pipe sealant to the drain plug and thread it into the tank drain. 23. Replace the coolant tank covers. 24. Install the chip basket in the coolant tank. 25. If working with a coolant tank equipped with a chip conveyor: A) Support the left end of the chip conveyor. B) Roll the chip conveyor into the coolant tank. C) Secure the chip conveyor with four screws "O", Figure or- If working with a coolant tank without a chip conveyor on a T-51 or T-65 lathe: A) Set tank liner "Q", Figure 2.13, into position. B) Secure the tank liner with four screws "P". M-506A 2-13

34 26. Position the tank under the machine. 27. Engage the coolant tank clamps. 28. Install left end skirt "L" and engage latches "M", Figure Connect coolant hose coupling "J", Figure 2.8, and engage the locking handles. 30. If the coolant tank is equipped with a coolant level sensor, connect cable "I" to the receptacle on the coolant tank. 31. Replace access cover "H", Figure Power up the machine. 33. Open the main guard door. - WARNING - Spilling coolant on the floor can result in a slipping hazard. Spilled coolant must be cleaned up immediately. 34. Pour the coolant directly into the chip pan or chip conveyor. Fill the coolant tank to 1 inch [25 millimeters] above the chip basket M-506A

35 SPINDLE COOLANT CATCHER The coolant catcher returns coolant that flows through the rear of the spindle. A drain system connected to the coolant catcher returns coolant to the coolant tank. CLEANING THE SPINDLE COOLANT CATCHER 1. Power down the machine. - CAUTION - Spindle access cover "O", Figure 2.20, must be taken straight off when it is removed. 2. Release the two latches and remove spindle access cover R, Figure Wipe out any coolant and chips. 4. Wash the coolant catcher with a cleaner recommended by the coolant manufacturer. 5. Install the access cover. 6. Clean and install the coolant tank as described earlier in this chapter. 7. Fill the tank with coolant. 8. Power up the machine and test the coolant flow. R Figure Spindle Access Cover at Left End of Machine TP7947 M-506A 2-15

36 - NOTES M-506A

37 CHAPTER 3 - HYDRAULIC SYSTEM INTRODUCTION - WARNING - The machine must be powered down when the hydraulic system requires maintenance. The hydraulic system is located at the rear of the machine on a platform. Hydraulic pressure is used to operate hydraulic collet closers, spindle brakes, and clamping the turret top plate. The hydraulic system is equipped with a 5-micron oil filter. Refer to page 3-3 for information on oil filter replacement. SYSTEM SPECIFICATIONS Hydraulic Oil: Mobil DTE 10 EXCEL 32 oil (ISO VG32) Hydraulic Tank Capacity: Minimum Oil Level: 10 gallons [38 liters] Maximum Oil Level: 12 gallons [45 liters] M-506A 3-1

38 HYDRAULIC TANK MAINTENANCE The oil level should be maintained at full or near full to ensure good system cooling, good air dissipation, and overall system performance. FILLING THE HYDRAULIC TANK 1. Power down the machine. 2. Open access doors "A", Figure Wipe filler cap C, Figure 3.2, and the area around the cap clean with a lint-free cloth. - WARNING - Exercise care not to spill the oil. Spilled oil must be cleaned up immediately. - NOTE - It is recommended that the hydraulic oil be pre-filtered to 5 micron maximum particle size before being added to the hydraulic system. 4. Remove the filler cap and SLOWLY fill the tank with Mobil DTE 10 EXCEL 32 oil until sight gauge F is filled. 5. Replace the cap when filling is completed. 6. Close the access doors. 7. Wait 10 minutes to allow any air in the oil to escape before powering up the machine. Figure Rear Access Doors A TP7863 B C F D E Figure Hydraulic System Relief Valve Adjustment TP M-506A

39 HYDRAULIC OIL FILTER REPLACEMENT The oil filter should be checked by viewing red indicator G, Figure 3.3. Oil Filter Replacement Interval If the red indicator has tripped, try to reset it by gently pressing down on the dome. Replace the filter element after 2000 hours of operation or if the red indicator does not reset. Replacing the Oil Filter Element 1. Power down the machine. 2. Open access doors "A", Figure Check red indicator G, Figure 3.3 to determine the condition of the filter or check the hour-run meter to verify the number of hours that the machine has been run. - WARNING - Exercise care not to spill the hydraulic oil in filter bowl. Spilling oil on the floor can create a slipping hazard. Spilled oil must be cleaned up immediately. 4. Unthread filter bowl I from filter head H. - CAUTION - Dispose of oil in the filter bowl in accordance with all applicable government guidelines. DO NOT introduce the oil back into the hydraulic system. 5. Dispose of the oil from the filter bowl. Wipe the bowl clean with a lint free cloth. 6. Clean the bowl with solvent recommended by the hydraulic oil manufacturer. Wipe it dry with a lint free cloth. 7. Wrap the filter element in a rag and pull it straight down to release it from the nipple in the filter head. 8. Install a new filter element by gently pressing it onto the nipple. G 9. Thread the filter bowl onto the filter head hand tight. 10. Reset the red indicator by pressing down on H the flexible dome. 11. Fill the tank with hydraulic fluid. 12. Wait 10 minutes for air in the oil to dissipate. I 13. Power up the machine. 14. Check for hydraulic fluid leaks around the filter bowl. Tighten the bowl if necessary. TP7864 Figure Hydraulic Oil Filter 15. Close the access doors. M-506A 3-3

40 HYDRAULIC HEAT EXCHANGER The hydraulic unit is equipped with a heat exchanger to reduce and stabilize the temperature of the hydraulic oil. The heat exchanger is located in the top of the coolant and hydraulic system enclosure. The heat exchanger should be cleaned every 160 hours of operation to ensure maximum heat dissipation. The heat exchanger air filter should be cleaned every 40 hours of operation to ensure maximum heat dissipation. 1. Power down the machine. 2. Open access doors "A", Figure 3.1, to gain access to heat exchanger "J" and heat exchanger air filter "L", Figure Clean the hydraulic heat exchanger. 4. Press release "K" to remove the air filter. 5. Wash the air filter in detergent and hot water. 6. Allow the filter to air dry. 7. Install the filter. 8. Close the access doors. J K L TP7894A Figure Hydraulic Heat Exchanger 3-4 M-506A

41 HYDRAULIC SYSTEM RELIEF VALVE REPLACEMENT 1. Power down the machine. 2. Remove access cover "M", Figure Replace relief valve "N", Figure Replace the access cover. 5. Adjust the new relief valve as follows: A) Power up the machine. B) Open access doors "A", Figure 3.1. C) Wipe filler cap C, Figure 3.2, and the area around the cap clean with a lint-free cloth. D) Remove the filler cap. E) Remove strainer collar "D" and the strainer to gain access to the lock nut on the main pressure control valve adjustment screw. F) Loosen the lock nut on the main pressure control valve adjustment screw. G) Remove plug "E" to gain access to the main pressure control valve adjustment screw. H) Use a hex wrench to adjust the main hydraulic pressure to 850 psi [58.6 bar], as viewed on gauge "B". I) Loosen the lock nut on the relief valve adjustment screw. J) Rotate the relief valve pressure control adjustment screw counterclockwise to reduce the valve setting until flow is audibly detected through the relief valve. M N Figure Hydraulic System Side Access Cover TP8067 Figure Hydraulic System Relief Valve TP8065 M-506A 3-5

42 K) Rotate the relief valve pressure control adjustment screw clockwise to increase the valve setting until the flow through the relief valve is stopped. L) Hold the relief valve pressure control adjustment screw and tighten the lock nut. M) Adjust the main hydraulic pressure to 750 psi [51.7 bar]. N) Hold the main pressure control valve adjustment screw and tighten the lock nut. O) Install plug "E". P) Install the strainer and strainer collar. Q) Install the filler cap. 6. Close the access doors. 7. Press Reset to clear the alarm message. 3-6 M-506A

43 - NOTES - M-506A 3-7

44 - NOTES M-506A

45 CHAPTER 4 - LUBRICATION INTRODUCTION - WARNING - The machine must be powered down when the grease lubrication system requires maintenance. The lubrication system supplies grease to the following machine components: All axis ball screws X and Z axis truck bearings Y axis truck bearings on machines equipped with Y axis E axis truck bearings on machines equipped with a tailstock or sub-spindle Fresh grease should be added every six months or 1000 hours of machine operation or more frequently under severe operating conditions. IMPORTANCE OF LUBRICATION Running conditions of this machine depend heavily upon the lubrication management. Make certain that the lubrication system is checked frequently under severe operating conditions to keep this machine in proper working condition. LUBRICATION ALARM The control issues a lubrication alarm message after every 1000 hours of operation. This alarm message does not stop the machine; however, Cycle Start is inhibited. After the required lubrication maintenance has been performed, press the Reset and Feed Hold push buttons simultaneously to clear the alarm. M-506A 4-1

46 AXES GREASE LUBRICATION - NOTE - The grease volume presented is dependent upon the grease gun being used; carefully measure the amount of grease or count the grease gun strokes necessary to lubricate the guides and ball screws. Be certain that all air is purged from any grease gun before use. The center port on the grease manifolds (labeled BS ) feeds the ball screw for the associated axis. KLÜBER Isoflex NCA 15 grease (Hardinge part number TT NCA) is recommended for machine lubrication. Grease should be added when the linear guides are still warm from operation. GREASE VOLUMES Check the grease lubrication system every 6 months (approximate 1000 hours of operation) and add grease according to the following table: Location Ball Screw Grease Volume Linear Guideway Grease Volume X Axis 4cc 7cc Y Axis 3cc 7cc Z Axis 10 cc 7 cc E Axis (Tailstock or Sub-Spindle) 10 cc 7 cc When a LINCOLN #1147 grease gun is used (Hardinge Option Part Number TT ), the following number of strokes supplies the correct amount of grease: Location Ball Screw Lube Linear Guideway Lube X Axis 4½ strokes 8 strokes Y Axis strokes 8 strokes Z Axis 11.5 strokes 8 strokes E Axis (Tailstock or Sub-Spindle) 11.5 strokes 8 strokes Make certain that all the sliding surfaces are lubricated well by jogging the axes at 50% of the maximum rapid traverse for a full 30 minutes before resuming automatic machine operation. 4-2 M-506A

47 LUBRICATION PROCEDURE - NOTE - The Y axis is an optional feature. 1. Wait for the cycle to end and that the spindles and slides are stationary. 2. If necessary, jog the turret to a safe position to perform a reference return for the X and Z axes. 3. Press the Rapid Reference mode push button. 4. Press the X Axis Select push button. 5. Press the upper X/Y push button to move the X axis the reference position. 6. Press the Z Axis Select push button. 7. Press the right Z/E push button to move the Z axis the reference position. 8. Press the Jog mode push button. 9. Press the E Axis Select push button. 10. Press the Z/E push buttons to move the E axis (tailstock or sub-spindle) toward the main spindle to gain access to cover "A", Figure Open the main guard door. 12. Power down the machine. 13. Remove cover "A", Figure 4.1, to gain access to E axis grease manifold "B", Figure 4.2. A B Figure Access Cover for E Axis Grease Manifold TP7945 Figure E Axis Grease Manifold TP7946 M-506A 4-3

48 14. Open door "C", Figure 4.3, to gain access the X, Y and Z axis grease manifolds. Refer to Figure Wipe each grease fitting clean. - NOTE - Only use a manually operated grease gun. 16. Attach the grease gun nozzle to the grease fitting; slowly and evenly pump in the specified amount of grease. Repeat the process for each grease fitting on all grease manifolds. 17. Wipe the fittings clean of excess grease. - CAUTION - Do not overtighten the screws for cover "A", Figure 4.1. Cover distortion and leakage could result. 18. Install cover "A", Figure 4.1, as follows: A) Install and tighten the four screws next to the bend in the cover. B) Install and tighten the remaining six screws. 19. Close and latch door "C", Figure Power up the machine. 21. Press the Reset and Feed Hold push buttons simultaneously to clear the lubrication alarm. 22. Jog the axes at 50% of the maximum rapid traverse for a full 30 minutes before resuming automatic machine operation. Figure Rear Access Doors C TP7863 YAxis Grease Manifold XAxis Grease Manifold ZAxis Grease Manifold Figure X, Y, and Z Axis Grease Manifolds TP M-506A

49 TURRET LUBRICATION - NOTE - Grease is used to lubricate the live tooling drive shaft. The live tooling drive shaft must be lubricated every 2000 hours of operation. Use KLÜBER Isoflex NCA 15 grease (Hardinge part number TT NCA). 1. Move the turret to a convenient position to access top plate cover E, Figure Open the main coolant guard door. 3. Press the Emergency Stop push button. 4. Power down the machine. 5. Wipe coolant, chips, and other contaminants from the turret top plate. - NOTE - Two of the clearance holes for screws "D", Figure 4.5, are tapped for M10 screws. Long M10 screws can be threaded into these holes to aid in removal and installation of the turret cover. 6. Remove ten M8 screws D and the associated lock washers to remove turret cover E. - NOTE - Use a manually operated grease gun. 7. Attach the grease gun nozzle to grease fitting F, Figure Slowly and evenly pump in approximately 2.0 cc (2 strokes) of the specified grease. 9. Wipe any excess grease from the fitting. 10. Install top plate cover E, Figure 4.5, using ten screws D and the associated lock washers. Torque the screws to 120 Ib-in [13.6 N m]. D E F Figure 4.5 -Turret Top Plate Cover TI5713 Figure Live Tooling Drive Shaft Grease Fitting TP7944 M-506A 4-5

50 LIVE TOOL ATTACHMENT LUBRICATION Verify the drive shaft tang is lightly lubricated with Molylube Anti-Seize grease and that the live tool attachment is properly seated on the turret top plate. - CAUTION - The live tool attachment must be removed from the turret top plate each 160 hours to be inspected and lubricated. Failure to lubricate the drive shaft tang will result in damage to the live tool drive system and the live tool attachment. - NOTE - Refer to the operator's manual (M-505) for information on installing live tooling attachments. Do not disassemble the live tool attachment. Return the entire assembly to Hardinge Inc. if repairs are necessary. Apply a light coat of Molylube Anti-Seize grease to the drive shaft tang before mounting the live tool attachment on the turret top plate. 1. Move the turret and index the turret top plate to a convenient position where the live tool attachment can be removed. 2. Open the coolant guard door. 3. Wipe coolant, chips, and other contaminants from the live tool attachment and turret top plate. 4. Remove the live tool attachment from the turret top plate. 5. Inspect O-ring H, Figure 4.7, to be sure it is in good condition. 6. Inspect the live tool attachment for wear. 7. Apply a light coat of Molylube Anti-Seize grease to tang "G". 8. Mount the live tool attachment on the turret top plate. 9. Close the coolant guard door. G H TP7854 Figure Live Tool Attachment Lubrication Points (Angular Adjustable Live Tool Attachment Shown) 4-6 M-506A

51 - NOTES - M-506A 4-7

52 - NOTES M-506A

53 CHAPTER 5 - MISCELLANEOUS CONTROL AND AXIS DRIVE BATTERY REPLACEMENT The recommended replacement interval for the control and axis batteries is once a year. Battery units are located in two places on the machine: The control battery is behind the control display panel and on top of the control unit The drive batteries are on the drive units in the power case The batteries supply power to maintain control and axes memory when the machine is not turned ON. The control battery is one special lithium battery and the drive batteries are battery packs. CONTROL BATTERY - CAUTION - A fresh battery must be installed at least once a year. Failure to perform this maintenance will result in the loss of control information. Battery replacement can be done with the control turned ON or OFF. If the power is OFF, the change MUST be done within 30 minutes of when the power was turned OFF. Battery Specifications Hardinge Part Number: Voltage Rating: Battery Type: TB 3 volt Lithium M-506A 5-1

54 Battery Replacement Procedure 1. Power up the machine for a minimum of 30 seconds. 2. Power down the machine. 3. Remove access cover A, Figure Hold the battery latch to the side of the battery while pulling battery B, Figure 5.2, out. 5. Verify that the new battery is like the battery being replaced. 6. Disconnect the battery from connector C. 7. Connect the new battery. 8. Put the new battery into the battery slot. The battery latch will snap into place. 9. Dispose of the old battery properly. 10. Mount the access cover. B A C Figure Back of Operator Pendant TP7937 Figure Control Unit Battery TP M-506A

55 AXIS DRIVE BATTERIES - CAUTION - Fresh batteries must be installed at least once a year. Failure to perform this maintenance will result in the loss of drive position information. - NOTE - The number of axis drive units to be checked will vary, depending on the machine configuration. Battery Pack Specifications Hardinge Part Number: Voltage Rating: 6 volt Battery Type: Lithium D Battery Replacement Procedure 1. Power down the machine. 2. Release six latches "D", Figure Open the left power case door. 4. Lift door release "F", Figure 5.4, and open the right power case door. E - WARNING - High voltage AC will be present in the power case when the main circuit breaker switch is ON. Figure Power Case Doors 5. Move main circuit breaker switch "E", Figure 5.3, to the ON position. TI5695 F Figure Power Case Door Release TP7939 M-506A 5-3

56 6. Remove battery cover G, Figure 5.5: A) Squeeze the battery cover on the sides. B) Tip the top of the cover outward. 7. Disconnect the battery plug from the receptacle. 8. Connect the plug from the new battery to the receptacle. 9. Put the new battery in the battery holder and replace the battery cover. 10. Repeat steps 6 through 9 for additional axis drive units. 11. Move main circuit breaker switch "E", Figure 5.3, to the OFF position. 12. Close and latch the power case doors. 13. Dispose of the old batteries properly. G Figure Axis Drive Batteries TP M-506A

57 INTRODUCTION SUB-SPINDLE PART CATCHER ALIGNMENT [Option] The sub-spindle part catcher allows safe part removal from the optional sub-spindle without machine cycle interruption. It must be factory installed and cannot be retrofitted. The arm and conveyor are aligned at the factory. The gripper arm is UP in position with the gripper OPEN before the sub-spindle brings the workpiece into the gripper pads. The workpiece should be gripped without any arm vibration. The air-actuated arm has several adjustments to properly position gripper H, Figure 5.6, in relation to the part. Check the arm to determine if it should be replaced. It is possible that during a crash the arm might be bent, distorted or cracked. - WARNING - Operating and maintenance procedures are to be performed by one person. Since the machine is powered up while making the arm position adjustments, be extremely careful that no one else is near the control panel while these adjustments are being made and the positions are being set. - NOTE - Refer to the operator's manual (M-505) for information on changing gripper pads. H Gripper Arm Figure Sub-Spindle Part Catcher Gripper TP7934A M-506A 5-5

58 VERIFYING THE GRIPPER POSITION 1. Mount a test part in the sub-spindle. 2. Close the guard door. 3. Activate Rapid Reference mode. 4. Press the X Axis Select push button. 5. Press the Rapid Reference push button to move the turret to the X axis reference position. 6. Press the E Axis Select push button. 7. Press the Rapid Reference push button to move the sub-spindle to the reference position. 8. Activate Jog mode. 9. Press the Part Catcher S2 push button to extend the part catcher slide. 10. Press the Part Catcher S2 push button to rotate the part catcher arm to the up position. 11. Press the Part Catcher S2 push button to open the gripper. 12. Carefully jog the sub-spindle forward to position the part inside the gripper pads. - NOTE - Observe the gripper while executing the Gripper Close command to determine in which direction, if any, the gripper needs to be adjusted. The gripper should not vibrate or move to accommodate the part being gripped. There should be some clearance between the part and gripper. 13. Close the gripper on the part: A) Activate Manual Data Input mode. B) Close the gripper: C) Key in M227 (Gripper Close). D) Press the EOB (End of Block) key. E) Press the Insert key. F) Press the Cycle Start push button to execute the command. 14. Open the gripper with the M228 command. 15. Activate Rapid Reference mode. 16. Press the E Axis Select push button. 17. Press the Rapid Reference push button to move the sub-spindle to the reference position. If gripper position or speed adjustment is required, refer the following sections: Adjusting the Gripper Extension, page 5-7 Adjusting the Arm Swing Positions, page 5-8 Adjusting the Arm Swing Speed, page M-506A

59 ADJUSTING THE GRIPPER EXTENSION 1. Verify the arm is in the Up position. 2. Verify the gripper is in the Open position. 3. Carefully jog the sub-spindle forward to position the part inside the gripper pads. 4. Loosen screw "I", Figure Adjust the gripper extension as needed. 6. Close the guard door. 7. Close the gripper on the part: A) Activate Manual Data Input mode. B) Close the gripper: C) Key in M227 (Gripper Close). D) Press the EOB (End of Block) key. E) Press the Insert key. F) Press the Cycle Start push button to execute the command. 8. Tighten screw "I" to secure the setting. I Figure Gripper Extension Adjustment TP8080 M-506A 5-7

60 ADJUSTING THE ARM SWING POSITIONS - NOTE - The sub-spindle must be at the Reference position to allow the part catcher arm to rotate. Stem J, Figure 5.8, is used to set the arm swing down (Home) position and usually does not require any adjustment. Stem L, Figure 5.9, is used to set the arm swing up position. Threading stems J and L IN reduces the stroke, which shortens the arm rotation distance. Threading the stems OUT increases the stroke, which lengthens the rotation. 1. Loosen the jam nut on stem J or L. Loosen the nut only enough to be able to adjust the stem. 2. Adjust the stem. 3. Tighten the jam nut to set the arm swing position. 4. Test the arm rotation several times. Adjust as necessary. Remove the test part from the machine when adjustment is complete. J K L M TP7958 Figure Arm Swing Down Adjustments TP7959 Figure Arm Swing Up Adjustments 5-8 M-506A

61 ADJUSTING THE ARM SWING SPEED The arm down rotate speed is adjusted at valve K, Figure 5.8. The arm up rotate speed is adjusted at valve "M", Figure 5.9. These valves control the amount of air applied to the piston in the air cylinder. Threading a valve IN reduces the swing speed. 1. Adjust the arm position as previously described. 2. Loosen the jam nut at valve K or M. Loosen the nut only enough to be able to adjust the valve. 3. Adjust the valve. 4. Tighten the jam nut to set the speed of the arm rotation. 5. Test the arm rotation travel several times using the M codes to rotate and retract the arm. Adjust each valve as necessary. M-506A 5-9

62 AIR FILTERS The power case air filter and the spindle drive motor air filter should be visually checked weekly or more frequently if the air is heavily contaminated. The power case air filter is located at "N", Figure The spindle drive motor air filter is located at "O". CLEANING AN AIR FILTER 1. Remove the air filter. 2. Wash the air filter in detergent and hot water. 3. Squeeze out as much water as possible and allow the air filter to air dry. 4. Install the air filter. N O Figure Left End of Machine TP7956A 5-10 M-506A

63 SERVICE ACCESS PANELS The machine is equipped with two front-mounted service access panels. These panels provide easy access to internal machine components. - WARNING - A minimum of two people are required to remove or install left access panel "Q", Figure LEFT SERVICE ACCESS PANEL Removing the Access Panel 1. Close main guard door "R", Figure Power down the machine. 3. Release three latches "P". 4. Disengage the key from interlock switch "S", Figure Release two latches "T". 6. Carefully tilt panel "Q", Figure 5.11, outward. 7. Lift the panel to remove. P Q R Installing the Access Panel 1. Aligning the pins in the bottom of the access panel with the mounting holes in the machine, set the panel in place. 2. Tilt the panel back into position. 3. Engage two latches "T", Figure Insert the key into interlock switch "S". 5. Engage three latches "P", Figure Figure Left End Latches S TP7991 T Figure Top Latches TP7992A M-506A 5-11

64 RIGHT SERVICE ACCESS PANEL Opening the Access Panel 1. If necessary, power up the machine. 2. Open main guard door "R", Figure Power down the machine. - NOTE - Guard step "V", Figure 5.14, can be used to reach door stop bracket "U", Figure Remove the four flange nuts and door stop bracket "U". 5. Remove guard step "V", Figure Release three latches "X", Figure Open access panel "W" by sliding it to the left. Closing the Access Panel 1. Close access panel "W", Figure 5.15, by sliding it to the right. 2. Engage three latches "X". 3. Install guard step "V", Figure Use the four flange nuts to install door stop bracket "U", Figure U Figure Door Stop Bracket TP7995 W X V Figure Guard Step TP7993 Figure Right End Latches TP M-506A

65 CHECKING THE TURRET TOP PLATE ALIGNMENT (LIve Tool Machines Only) - CAUTION - Failure to check the turret top plate alignment can result in damage to the live tool drive system and live tooling attachments. It is important to check the alignment of the turret top plate with the live tool drive shaft in the event that any of the following events have occurred: Static tool breakage Live tool breakage Live tool torque limiter trip Machine crash - NOTE - Use a cross-working live tool attachment only. A false backlash check will occur if an end-working live tool attachment is used. Refer to the operator's manual (M-505) for information on installing turret tooling and indexing the turret top plate. 1. If the top plate is equipped with a cross-working live tooling attachment, index the cross-working live tool attachment to the active station. -or- If the top plate is not equipped with a cross-working live tooling attachment, install a cross-working live tool attachment at the active station on the turret top plate. 2. Open the main guard door, if necessary. 3. Press the control Reset key. - WARNING - Exercise extreme care while working near cutting tools mounted on the turret top plate. 4. Rotating the live tool attachment one full revolution by hand, check the forward and reverse backlash at 90 degree intervals. Refer to Figure If slight backlash is felt, the alignment of the turret top plate to the live tool drive shaft is acceptable. If no backlash is felt or binding is detected, the turret top plate is out of alignment. Figure Checking the Backlash TP8333 M-506A 5-13

66 5. If the alignment of the turret top plate to the live tool drive shaft is acceptable, reset turret tooling as needed and continue with machine operation. If the turret top plate is out of alignment, contact your local machine distributor or Hardinge Inc. to schedule a service technician to have the turret top plate realigned M-506A

67 - NOTES - M-506A 5-15

68 - NOTES M-506A

69 CHAPTER 6 - TORQUE LIMITER RESET AND AXIS POSITION RESET PROCEDURES INTRODUCTION Torque limiters are safety couplings that release when excessive pressure is applied to an axis ball screw or the turret drive shaft. When resistance is great enough to trip a torque limiter in the event of a collision, the control goes into an Emergency Stop condition to protect the machine tool from further damage. Torque limiters are installed on the following: Z and X axis ball screws E axis ball screw (tailstock or sub-spindle) Live tooling drive shaft in the turret (Machine with BMT 45 turret top plate only) LINEAR SCALES - NOTE - Axes equipped with linear scales will display the following alarm message when a torque limiter is tripped: 445 _ Axis: Soft Disconnect Alarm An axis equipped with a linear scale will retain position data if the torque limiter is tripped. An axis not equipped with a linear scale will not retain position data if the torque limiter is tripped. It will be necessary to reset the axis position according to the procedures beginning on page 6-5. Refer to the following table to determine if the axis to be reset is equipped with a linear scale: Axis High Performance Machine Super-Precision Machine X Yes Yes Z No Yes E No No M-506A 6-1

70 ENABLING PARAMETER EDIT - CAUTION - Use extreme caution when editing machine parameters. Making incorrect changes in the parameter table may disable the machine or cause undesirable machine behavior. Parameter Write Enable (PWE) must be set to 1 to enable parameter editing. 1. Press the Offset Setting key until the Setting (Handy) page is displayed. 2. Press the Setting soft key. 3. If necessary, use the page up/down keys to display the Setting page that contains the Parameter Write Enable field. 4. If necessary, use the cursor keys to move the cursor to the Parameter Write Enable field. 5. Press the Manual Data Input mode push button. 6. Key in the number 1" to enable parameter editing. 7. Press the Input key. Set Parameter Write Enable (PWE) to 0 when parameter editing is complete. 6-2 M-506A

71 RESETTING THE X, Z, OR E AXIS TORQUE LIMITER - NOTE - Refer to Enabling Parameter Edit, page 6-2 for information on setting Parameter Write Enable. 1. Set Parameter Write Enable (PWE) to Select Jog mode. 3. Select the axis related to the torque limiter that has tripped. 4. Set the Rapid Override switch to X Rotate the MPG handwheel in the positive (+) direction until the software limit is encountered. 6. Press the System key. 7. Press the Parameter soft key. 8. Key in 1320 and press the Number Search soft key. 9. Record the number in the E, X, or Z register, depending on the axis to be reset. 10. Use the cursor keys to position the cursor on the number that was recorded. 11. Key in a very large number and press the Input key. 12. Press the System key. 13. On the control display panel, press the right arrow key until the PMC Maintenance soft key is displayed. 14. Press the PMC Maintenance soft key. 15. Key in the PMC Signal number and press the Number Search soft key. If the X axis is being reset, search for PMC Signal X10 and observe bit 0. If the Z axis is being reset, search for PMC Signal X30 and observe bit 5. If the E axis is being reset, search for PMC Signal X30 and observe bit 6. A value of "0" means the torque limiter is properly engaged. A value of "1" means the torque limiter is tripped. - NOTE - The torque limiter alarm will automatically clear when the torque limiter engages if the axis is equipped with a linear scale. If resetting the X axis, press and hold the Enable switch (T-42 lathe) or Enable push button (T-51 and T-65 lathes) while using the MPG handwheel. 16. SLOWLY rotate the MPG handwheel in the + direction until the observed value changes from 1 to Move the axis in the negative ( ) direction to a position within the normal software limits for that axis. M-506A 6-3

72 18. Press the System key. 19. Press the Parameter soft key. 20. Key in 1320 and press the Number Search soft key. 21. Use the cursor keys to position the cursor on the E, X, or Z register, depending on the axis that was reset. 22. Key in the number recorded in step 8 and press the Input key. 23. Set Parameter Write Enable (PWE) to If the axis is equipped with a linear scale, power the machine down and power the machine up to clear the Soft Disconnect alarm. If the axis is not equipped with a linear scale, proceed to "Resetting an Axis Position", beginning on page M-506A

73 RESETTING AN AXIS POSITION Z AXIS NOT EQUIPPED WITH A LINEAR SCALE Machine with BMT Turret Top Plate This procedure uses the face of the main spindle as the reference for resetting the Z axis. 1. Mount a Hardinge CQ SQD tool holder at the active turret station. If a tool fitting this description is already on the turret, index that tool to the active station. 2. Clean the main spindle and the tool holder. 3. Press the Manual Data Input mode push button. - NOTE - Refer to Enabling Parameter Edit, page 6-2 for information on setting Parameter Write Enable. 4. Set Parameter Write Enable (PWE) to Press the System key until the Parameter page is displayed. 6. Press the Parameter soft key. 7. Key in Press the Number Search soft key. 9. Set parameter 1815 bit 4 Z to Press the Emergency Stop push button. 11. Turn the control OFF. 12. Wait a few seconds; then, turn the control ON. 13. Pull the Emergency Stop push button out. 14. Press the Emergency Stop Reset push button. 15. Press the MPG mode push button. M-506A 6-5

74 16. If the machine is set to inch mode, place a 3 inch gauge block against the face of the spindle. If the machine is set to metric mode, place a 75 millimeter gauge block against the face of the spindle. 17. Use the MPG handwheel to position the turret top plate for a slip fit of the gauge block between the face of the tool holder and the face of the spindle. Refer to Figure Press the Position key. 19. Press the Relative soft key to display the Relative Position page. 20. Press the W key. 21. If the machine is set to inch mode, key in as the Z axis position. If the machine is set to metric mode, key in as the Z axis position. 22. Press the Preset soft key. 23. Use the MPG handwheel to move the Z axis so that the Z Axis Relative Position is as follows: Mode T-42 Lathe T-51 and T-65 Lathes Inch W W Metric W W Press the Manual Data Input mode push button. 25. Press the System key. Inches [Millimeters] CQ SQD Tool Holder Gauge Block Main Spindle [68.50] Tool Holder Z Axis Position (See Note Below) NOTE: Z Axis Position = Gauge Block + Tool Holder TI5706 Figure BMT 45 Turret Top Plate, Reset Z Axis from the Main Spindle Face 6-6 M-506A

75 26. Press the Parameter soft key. 27. Key in Press the Number Search soft key. 29. Set parameter 1815 bit 4 Z to Set Parameter Write Enable (PWE) to Press the Reset key. 32. Press the Emergency Stop push button. 33. Turn the control OFF. 34. Wait a few seconds; then, turn the control ON. 35. Pull the Emergency Stop push button out. 36. Press the Emergency Stop Reset push button. M-506A 6-7

76 Machine with Hardinge Turret Top Plate This procedure uses the face of the main spindle as the reference for resetting the Z axis. Clean the main spindle face and the turret top plate. 1. Press the MPG mode push button. 2. Press the Manual Data Input mode push button. - NOTE - Refer to Enabling Parameter Edit, page 6-2 for information on setting Parameter Write Enable. 3. Set Parameter Write Enable (PWE) to Press the System key. 5. Press the Parameter soft key. 6. Key in Press the Number Search soft key. 8. Set parameter 1815 bit 4 Z to Press the Emergency Stop push button. 10. Turn the control OFF. 11. Wait a few seconds; then, turn the control ON. 12. Pull the Emergency Stop push button out. 13. Press the Emergency Stop Reset push button. 14. Press the MPG mode push button. 15. If the machine is set to inch mode, place a 3 inch gauge block against the face of the spindle. If the machine is set to metric mode, place a 75 millimeter gauge block against the face of the spindle. 16. Use the MPG handwheel to position the turret top plate for a slip fit of the gauge block between the face of the turret top plate and the face of the spindle. Refer to Figure Press the Position key. 18. Press the Relative soft key to display the Relative Position page. 19. Press the W key. 20. If the machine is set to Inch mode, key in as the Z axis position. If the machine is set to metric mode, key in as the Z axis position. 6-8 M-506A

77 21. Press the Preset soft key. 22. Use the MPG handwheel to move the Z axis so that the Z Axis Relative Position is as follows: Mode T-42 Lathe T-51 and T-65 Lathes Inch W W Metric W W Press the Manual Data Input mode push button. 24. Press the System key. 25. Press the Parameter soft key. 26. Key in Press the Number Search soft key. 28. Set parameter 1815 bit 4 Z to Set Parameter Write Enable (PWE) to Press the Reset key. 31. Press the Emergency Stop push button. 32. Turn the control OFF. 33. Wait a few seconds; then, turn the control ON. 34. Pull the Emergency Stop push button out. 35. Press the Emergency Stop Reset push button. Inches [Millimeters] or [75.00] Main Spindle Gauge Block TI5708 Figure Hardinge Top Plate, Reset Z Axis from Spindle Face M-506A 6-9

78 E AXIS The E axis drive provides linear motion of the tailstock or sub-spindle. When resistance is great enough to trip the limiter in the event of a collision, the program goes into an Emergency Stop condition to protect the machine from further damage and alarm E Axis Torque Limit is displayed. This procedure uses the face of the main spindle as the reference for resetting the E axis. 1. Press the MPG mode push button. 2. Use the MPG handwheel to move the tailstock or sub-spindle (E axis) away from the collision. 3. Press the Manual Data Input mode push button. - NOTE - Refer to Enabling Parameter Edit, page 6-2 for information on setting Parameter Write Enable. 4. Set Parameter Write Enable (PWE) to Press the System key. 6. Press the Parameter soft key. 7. Key in Press the Number Search soft key. 9. Set parameter 1815 bit 4 E to Press the Emergency Stop push button. 11. Turn the control OFF. 12. Wait a few seconds; then, turn the control ON. 13. Pull the Emergency Stop push button out. 14. Press the Emergency Stop Reset push button. 15. Press the MPG mode push button. - NOTE - Any convenient gauge block can be used. This procedure assumes a 3 inch gauge block for machines set to inch mode and a 75 millimeter gauge block for machines set to metric mode. 16. If the machine is set to inch mode, place a 3 inch gauge block against the face of the main spindle. If the machine is set to metric mode, place a 75 millimeter gauge block against the face of the main spindle M-506A

79 17. Use the MPG handwheel to position the tailstock or sub-spindle for a slip fit of the gauge block between the two surfaces. Refer to Figure Press the Position key. 19. Press the Relative soft key to display the Relative Position page. 20. Press the E key. 21. If the machine is set to Inch mode, key in as the E axis position. If the machine is set to metric mode, key in as the E axis position. 22. Press the Preset soft key. 23. Use the MPG handwheel to move the E axis so that the E Axis Relative Position is as follows: Mode T-42 Lathe T-51 and T-65 Lathes Tailstock Sub-Spindle Tailstock Sub-Spindle Inch E E E E Metric E E E E Press the Manual Data Input mode push button. 25. Press the System key. 26. Press the Parameter soft key. Gauge Block Main Spindle Tailstock or Sub-Spindle TI5785 Figure Reset E Axis from Main Spindle M-506A 6-11

80 27. Key in Press the Number Search soft key. 29. Set parameter 1815 bit 4 E to Set Parameter Write Enable (PWE) to Press the Reset key. 32. Press the Emergency Stop push button. 33. Turn the control OFF. 34. Wait a few seconds; then, turn the control ON. 35. Pull the Emergency Stop push button out. 36. Press the Emergency Stop Reset push button M-506A

81 LIVE TOOL TORQUE LIMITER RESET The turret is equipped with a torque limiter to protect live tooling. When resistance is great enough to trip any one or multiple torque limiters in the event of a collision or excessively aggressive machining, the live tooling drive motor will stop to protect tooling from further damage and alarm 1056 Live Tool Torque Limit is displayed. 1. Open the coolant guard door. 2. Wipe coolant, chips, and other contaminants from the live tool attachment in the active position. 3. Press the Manual Data Input mode push button. 4. Press the Offset/Setting key. - NOTE - Refer to Enabling Parameter Edit, page 6-2 for information on setting Parameter Write Enable. 5. Set Parameter Write Enable (PWE) to "1". 6. Press the System key. 7. Press the PMC soft key. 8. Press the PMCMAINTE soft key. 9. Press the far right arrow soft key once. 10. Press the KEEP RELAY soft key. 11. Move the cursor to K0000, bit Press "1" and Input. EX1066 Live Tool Setup Mode alarm will be displayed. 13. Remove the tool attachment mounted at the active tool station, 14. Mount the torque limiter reset tool (Hardinge part number TG BMT-AB), shown in Figure 6.4, at the active turret station using four M8 x 16 socket head cap screws. The tang on the reset tool will engage the live tool drive shaft in the turret. 15. Press the Jog mode push button. The Spindle Decrement indicator light will turn ON. Figure Live Tool Torque Limiter Reset Tool TP8086 M-506A 6-13

82 16. Press the Spindle Decrement push button. The live tool drive motor will rotate slowly. The live tool drive motor will stop rotating and the Spindle Decrement indicator light will turn OFF when the torque limiter engages. 17. Press the Reset key. The live tool torque limit alarm will be cleared from the display. 18. Change K00, bit 7, to "0". 19. Set Parameter Write Enable (PWE) to "0". 20. Remove the torque limiter reset tool. 21. Install the tool attachment at the active station M-506A

83 TURRET SETUP MODE Turret Setup mode is used to set the turret Home position (synchronized with the machine control) if the turret top plate is interrupted while indexing. When Turret Setup is active: The main collet pushbutton clamps and unclamps the turret. The DRYRUN light flashes when the turret should be unclamped and lights solid if it is unclamped. The REPEAT light flashes when the turret should be clamped and lights solid if it is clamped. SETTING TURRET HOME 1. If the turret top plate is clamped, this is a good time to mark the position. 2. Press the Manual Data Input mode push button. 3. Press the Offset/Setting key. 4. Set Parameter Write Enable (PWE) to "1". 5. Press the System soft key. 6. Press the PMC soft key. 7. Press the PMCPRM soft key. 8. Press the KEEPRL soft key. 9. Set K0.6 (TSETUP) = 1. The Turret Setup mode alarm will appear on the message screen. 10. Press the Jog mode push button. 11. Press Main Collet Open to unclamp the turret. The Repeat Mode light is on when the turret is unclamped. 12. Use the Handwheel to rotate the turret top plate to the highest numbered whole station (10, 12, or 16). 13. Press Main Collet Open/Close to clamp the turret top plate. The Dry Run light is on when the turret top plate is clamped. 14. Press the Manual Data Input mode push button. 15. Set Parameter (APZ) to "0" for the turret (3rd Axis). 16. Turn the machine control OFF for a few seconds. 17. Turn the machine control ON. 18. Set Parameter (APZ) to "1" for the turret (3rd Axis). 19. Set Parameter Write Enable (PWE) to "0". 20. Turn the machine control OFF for a few seconds. 21. Turn the machine control ON. M-506A 6-15

84 - NOTES M-506A

85 APPENDIX ONE - PREVENTIVE MAINTENANCE SCHEDULE INTRODUCTION RS series machines are designed to provide minimal downtime and insure long machine life when the following schedule of preventive maintenance is applied. Modular construction and easy access to components help to monitor each of the systems of the machine. Monitoring sensors have been built into the machine s hydraulic and control system for ease in troubleshooting problems. Pressure sensors and control alarms alert the operator through the control display when systems malfunction. Circuit breakers provide visual confirmation of the electrical status of each circuit. The plug-in Input/Output modules in the power case have LED s for verification of circuit status. - CAUTION - Do not use caustic or abrasive cleaners on this machine. Maintaining a clean machine is part of any good maintenance program. Machines should be periodically wiped with lint-free cloths soaked with mineral spirits. If the machine is operated in an atmosphere that causes surfaces to rust quickly, wipe these surfaces with a lint-free cloth soaked in mineral oil. NEVER USE COMPRESSED AIR TO CLEAN DIRT OR CHIPS FROM THE MACHINE. Air pressure could force dirt particles and other foreign material past seals and wipers. STANDARD MAINTENANCE SCHEDULE The following maintenance times are approximate and components may need attention more frequently if excessive environmental pollution is present. Preventive maintenance frequency is for single shifts and should be increased proportionally when work is for two or three shifts per day. 8 HOURS Check the guard door vision panel Operator's Manual Drain the air filter/regulator bowls Chapter 1 Check the coolant level Chapter 2 Check the coolant concentration and measure the coolant ph Chapter 2 Check the coolant filter, replace filter element if necessary Chapter 2 Check the chips in coolant tank; remove as necessary Chapter 2 Check the hydraulic heat exchanger fan Chapter 3 Check the hydraulic pressure gauges Chapter 3 Check the hydraulic fluid level in the tank; check hydraulic fluid leaks... Chapter 3 Check the red pop up indicator; hydraulic system filter Chapter 3 M-506A A1-1

86 40 HOURS Check the turret air bearing pressure gauge Chapter 1 Remove the chips from the coolant tank Chapter 2 Clean the coolant tank chip basket Chapter 2 Clean the air filters Chapter 5 Wash the machine and wipe clean Appendix One 160 HOURS Replace air line filters Chapter 1 Check the coolant pump Chapter HOURS Clean the air filter/regulator and coalescing filter bowls Chapter HOURS Clean and flush the coolant system and change the coolant Chapter 2 (Coolant tank should also be cleaned when changing the type or brand of coolant. Follow coolant manufacturer s recommendations.) Check all hydraulic hoses for cracks, bad fittings, and kinks Chapter 3 Check the hydraulic system wiring for deterioration; check LED s..... Chapter 3 Lubricate the machine axes Chapter HOURS Replace the hydraulic system filter element Chapter 3 Lubricate the turret index shaft Chapter 4 Install a fresh control back-up battery Chapter 5 (Hardinge Inc. recommends installing a fresh battery each 2000 hours) Install fresh drive unit batteries Chapter 5 (Hardinge Inc. recommends installing a fresh battery each 2000 hours) 4000 HOURS Check the seal on hydraulic tank filler cap Chapter 3 A1-2 M-506A

87 8 HOURS Check the barfeed oil level. Clean the tool probe. Clean chips from the part catcher. Grease the chuck master jaws. MAINTENANCE SCHEDULE FOR OPTIONS 40 HOURS Clean the chip conveyor. Check the part catcher. Check the filter(s) on the power case air conditioner. Clean or replace according to manufacturer recommendations. 160 HOURS Disassemble and clean the chuck. Grease the live tooling holders HOURS Check the warning lights. Check the barfeed-in-position switch. Tighten the electrical plug connections in power case and control case. Check and fill the chip conveyor gearbox oil. Check and adjust the chip conveyor drive belt tension HOURS Lubricate the live tooling drive shaft. M-506A A1-3

88 NON-METALLIC MATERIALS TYPICALLY FOUND IN HARDINGE MACHINE CONSTRUCTION nitrile neoprene fluorocarbon rubber urethane silicone rubbers cork-nitrile composites polyurethane enamel acetal plastics polycarbonates nylons phenolic plastics polyethylene PVC PTFE (polytetrafluoroethylene) - NOTES - A1-4 M-506A

89 APPENDIX TWO - ALARM AND OPERATOR MESSAGES ALARM MESSAGES 1000 Air Pressure Low Low air pressure to machine. The control is put in an alarm condition and the machine in E-stop. Increase the air pressure to within the recommended range and press Reset to clear the alarm Tool Group Life End All of the tools in one or more tool groups have reached the tool life specified in the Tool Life Management program and an M30 End of Program has been read by the control. Refer to the operator's manual (M-505) for information on resetting a tool group counter Barfeed Fault Powerdown The automatic power down feature of the machine has been selected and the conditions for shutdown have been met Spindle Chiller Temperature Or Flow Fault The spindle coolant chiller temperature is too high or too low, or the spindle coolant chiller flow is too low. When one of these conditions has been true for four minutes or more, the machine will stop. When the problem is fixed, press Reset to clear the alarm Hydraulic Pressure Too Low The hydraulic pressure switch indicated that the pressure was too low for machine operation. To restart, press the Emergency Stop push button to put the machine in emergency stop state. After a few seconds, clear the Emergency Stop. If the pump starts and stays ON, press Reset to clear the alarm Turret Setup Mode Turret Setup mode is active. Cycle Start is disabled. Deactivate Turret Setup mode to clear this alarm. Refer to page 6-15 for information on Turret Setup mode. M-506A A2-1

90 1035 Hydraulic Pump Overload The hydraulic pump motor overload has tripped. Reset the overload to restart the motor and clear the alarm Hydraulic Fan Overload The hydraulic fan motor overload has tripped. Reset the overload to restart the motor and clear the alarm Turret Air Fault Low air pressure to the turret air bearing. The control is put in an alarm condition and the machine in E-stop. Increase the air pressure to within the recommended range and press Reset to clear the alarm. Refer to Chapter 1 for information on adjusting the air pressure for the turret air bearing E-Stop Not OFF At Power Up Emergency Stop was not active when the control is turned ON. Test the Emergency Stop circuit as follows: 1. Press the Emergency Stop push button IN. 2. Pull the Emergency Stop push button OUT. 3. Press the Emergency Stop Reset push button X Torque Limiter Fault The X axis torque limiter has tripped. The control is put into an alarm condition and the machine in Emergency Stop. Refer to Chapter 6 for information on resetting torque limiters Z Torque Limiter Fault The Z axis torque limiter has tripped. The control is put into an alarm condition and the machine in Emergency Stop. Refer to Chapter 6 for information on resetting torque limiters. A2-2 M-506A

91 1052 Live Tool Disengage Fault The live tooling disengaged proximity switch does not give the expected signal. The live tooling spline may have failed to engage or the live tooling disengaged proximity switch may be faulty. Press Reset to clear the alarm E Torque Limiter Fault The E axis torque limiter has tripped. The control is put into an alarm condition and the machine in Emergency Stop. Refer to Chapter 6 for information on resetting torque limiters Turret Fault Turret index was interrupted by Reset or Emergency Stop. To clear the fault: 1. Reset Emergency Stop. 2. Select Jog mode. 3. Select a station and press the Turret Index push button. 4. The turret will index to the selected station Turret Unclamped The turret top plate is not properly seated. Turret index time exceeds two seconds. Turret proximity switch may be faulty. The control is put in an alarm condition Turret Unclamped Switch The turret unclamp solenoid is energized but the turret unclamped switch has not been activated. Either the turret has failed to unclamp or the unclamped switch has failed Turret Switches May Be Swapped The two turret clamp/unclamp switches are wired incorrectly or one of the switches is faulty Y Axis Too Low To Index Turret The turret is positioned below Y0. Move the turret to Y0 or above before attempting to index the turret top plate. M-506A A2-3

92 1066 Live Tool Torque Limiter Fault The live tool torque limiter has tripped. The control is put into an alarm condition and the machine in Emergency Stop. Refer to Chapter 6 for information on resetting torque limiters Turret Station Switch Fault The turret station selector switch indicates an invalid station. The control is put into an alarm condition Please Turn Off Power After operating the machine with the Machine lock feature active, power down is required to reset the machine position. Power OFF the machine, wait a few seconds, and then restart the machine No Live Tooling At Half-Station Live tooling was commanded while the turret top plate is positioned at station 17 through 32. Live tooling can only be commanded at station 1 through 16. Press Reset to clear the alarm Bar Feed Fault Bar feed signals a fault. The control is put in an alarm condition. Adjust the bar feed and press Reset to clear the alarm End of Bar End of bar condition exists. The control is put in an alarm condition. Press Reset to clear the alarm T Code Invalid The T word exceeds the maximum number of turret stations on the top plate. T word format error M Code Invalid M word is programmed for an option not available/enabled on the machine. M word is not defined in the control. M word format error. Press Reset to clear the alarm. A2-4 M-506A

93 1084 Y Axis Brake Failed The Y axis brake was commanded to engage and the control detects movement on the Y axis. Replace the Y axis motor or drive belt, as needed B Code Invalid B word orient angle is invalid. B word is programmed for an option not available/enabled on the machine. B word format error. Press Reset to clear the alarm X Axis Brake Failed The X axis brake was commanded to engage and the control detects movement on the X axis. Replace the X axis brake Tool Probe Must Be Stowed The tool probe is active and Cycle Start was pressed with Automatic mode active. The tool probe must be stowed to start a part program in Automatic mode. The tool probe is active and the part catcher was commanded to extend. The tool probe must be stowed before the part catcher can be extended in any mode. Refer to the operator's manual (M-505) for information on the tool probe Part Catcher Must be Retracted The main spindle part catcher must be retracted before starting a program in Automatic mode. Press Reset to clear the alarm Left Collet Access Door The main spindle collet access door is open. Automatic mode is inhibited. Close the door and press Reset to allow machine operation Right Collet Access Door The sub-spindle collet access door is open. Automatic mode is inhibited. Close the door and press Reset to allow machine operation. M-506A A2-5

94 1112 Rear Access Door Open The rear access door is open. Close the door and press Reset to allow machine operation Main Collet Limit Switch One or both of the main collet Open/Close pressure switches are faulty. Both switches indicate the same state. The control is put into an alarm condition Main Spindle Orient Fault Spindle orient failed to complete in five seconds. Press Reset to clear the alarm Main Spindle Brake Fault Main spindle brake switch input contradicts the state of the solenoid valve Front Access Cover Open The left front access cover is not properly mounted on the machine. Machine operation is inhibited. Properly mount the door on the machine and press Reset to allow machine operation Tailstock Force Too Low The force exerted by the tailstock against the part has fallen to an unacceptable value. Cycle Start is inhibited. Press Reset to clear this alarm Tailstock Motion Fault The tailstock has been commanded to move in the +E or -E direction and has not reached the programmed position within 2½ seconds Part Catcher, See Messages The sub-spindle part catcher slide has a fault. Refer to the message display page for detailed information Part Missing A part should be in the sub-spindle and the part present detector did not find a part Part Present A part should not be in the sub-spindle and the part present detector found a part. A2-6 M-506A

95 1213 Opposite Collet Limit Switch One or both of the sub-spindle collet Open/Close pressure switches are faulty. Both switches indicate the same state. The control is put into an alarm condition Opposite Spindle Orient Fault Sub-spindle orient failed to complete in five seconds. Press Reset to clear the alarm Opposite Spindle Brake Fault Sub-spindle brake switch input contradicts the state of the solenoid valve Door Did Not Lock The guard door failed to lock and program execution was attempted Tailstock Overtravel Limit The tailstock has traveled past the E axis position specified by the A word in the M82 command line. Refer to the programmer's manual (M-504) for information on programming the tailstock Programmed Force Too High The force programmed by the F word in the M82 command line is above the allowable range. Refer to the programmer's manual (M-504) for information on programming the tailstock Programmed Force Too Low The force programmed by the F word in the M82 command line is below the allowable range. Refer to the programmer's manual (M-504) for information on programming the tailstock A Limit Missing The A word is missing from the M82 command line. The A word must be programmed. Refer to the programmer's manual (M-504) for information on programming the tailstock B Setting Missing Or Incorrect The B word is missing from the M82 command line or is programmed with an invalid value. B1 or B2 must be programmed. Refer to the programmer's manual (M-504) for information on programming the tailstock. M-506A A2-7

96 OPERATOR MESSAGES Hour Lube Required Machine lubrication is required every 1000 hours of machine ON time. Cycle Start is inhibited while this message is displayed. Refer to Chapter 4 for information on machine lubrication. After lubricating the machine, press the Reset and Feed Hold push buttons at the same time to clear the message Press and Hold the Unlock Button. Open and Close Guard Door to Verify the Door Switch. Machine power-up message. Press and hold the Unlock push button. Open and close the guard door to verify interlock switch operation Tool Probe Cover Off The tool probe receiver cover must be properly installed to allow automatic machine operation. Install the probe receiver cover and press Reset to clear the alarm New Tool Used on this Part A tool in the currently active tool group has reached the tool life specified in the Tool Life Management program. The next tool in the active tool group has been selected. Press Cycle Start or Reset to clear the message Spindle Warm-Up Active Machine power-up message. The spindle warm-up cycle is active Ready To Warm Up Spindle(s)? Press Cycle Start Again To Continue, Reset To Cancel. Machine power-up message Spindle Warm-Up Bypassed. Running The Main Spindle At High Speed Without Warmup May Damage The Spindle. See Manual For Warning Notice. Machine power-up message. The machine operator has by-passed the recommended spindle warm-up cycle. A2-8 M-506A

97 2020 Check Spindle Tooling Speed Limits. Insert Part(s), Close Collet(s), Close Door. When Safe, Press Cycle Start To Warm Up Spindle(s). Machine power-up message. Refer to the operator's manual (M-505) for information spindle tooling speed limits Lamp Output Disconnected An output module driving the panel lamps is overloaded. Turn the machine OFF to clear this message Operator Door Open The coolant guard door is open. Cycle Start is inhibited until the guard door is closed Control Battery Low Low voltage condition on control memory battery back-up. DO NOT POWER DOWN THE MACHINE! Refer to Chapter 5 for instructions to replace the battery Protect Key Must Be OFF To Bypass Warm-Up Machine power-up message. The Program Protect key must be OFF before the machine operator can by-pass the recommended spindle warm-up cycle Coolant Pump OL The coolant pump motor overload on coolant pump 1 contactor in the machine power case has tripped. Repeat mode is canceled. Correct the cause of the overload. Locate the coolant pump 1 contactor in the power case and reset the overload. When the overload is reset, press Reset to clear the message Coolant Chiller Flow The flow switch in the coolant chiller unit has opened, indicating low coolant flow. This may be due to a clogged coolant filter. After proper coolant flow is restored, press Reset to clear the message. M-506A A2-9

98 2032 Coolant Pump 2 Motor OL The coolant pump motor overload on coolant pump 2 contactor in the machine power case has tripped. Repeat mode is canceled. Correct the cause of the overload. Locate the coolant pump 2 contactor in the power case and reset the overload. When the overload is reset, press Reset to clear the message Incorrect Power Phase Sequence The phasing of the incoming 3-phase power to the machine is incorrect. 1. Power down the machine. 2. Turn OFF the electrical power to the machine. 3. Open the power case doors. 4. Swap the connection of any two wires on the line side of the main circuit breaker. 5. Close and latch the power case doors. 6. Turn ON the electrical power to the machine X Scale Air Purge Pressure Fault This message applies to Super-Precision machines only. The scale air purge pressure switch indicates a loss of pressure. Repeat mode is canceled. Cycle Start is inhibited. Correct the cause of the pressure loss and press Reset to clear the message Enable Switch ON at Power Up Power up message. The hand-held Enable switch is ON (center position) at power-up. Release the Enable switch or replace if faulty Setting Mode: Enable Switch ON T-42 Lathe: Setting mode has been activated and the hand-held Enable switch is ON (center position). Release the Enable switch or replace if faulty. T-51 and T-65 Lathes: Setting mode has been activated and the Enable push button is active. Release the Enable push button or replace if faulty. A2-10 M-506A

99 2043 Setting Mode: Verify Enable Switch Setting mode has been activated. Cycle the hand-held Enable switch through all positions to clear the message Open And Close Left Access Door To Verify Door Interlock Switch Machine power-up message. Remove and replace the collet access cover at the left end of the machine to verify interlock switch operation Open And Close Right Access Door To Verify Door Interlock Switch Machine power-up message. Remove and replace the large access cover at the right end of the machine to verify interlock switch operation Wiring Fault: Check +24B Wiring Emergency Stop is active and +24 volts is detected on the +24B circuit. The +24B circuit should be zero volts when Emergency Stop is active. Referring to the electrical schematic supplied with the machine, check the wiring in the +24B circuit Air Conditioner Overload The overload on the air conditioner contactor in the machine power case has tripped. Correct the cause of the overload. Locate the air conditioner contactor in the power case and reset the overload. When the overload is reset, press Reset to clear the message E Axis Thrust Limit Exceeded, Please Adjust Feedrate The E axis thrust limit has been exceeded. The machine is put into a feed hold condition. Turn the Feedrate Override switch down by 10% and press Cycle Start. Repeat until the message clears. Adjust the feedrate in the part program by the percentage that was required to clear the message Z Axis Thrust Limit Exceeded, Please Adjust Feedrate The Z axis thrust limit has been exceeded. The machine is put into a feed hold condition. Turn the Feedrate Override switch down by 10% and press Cycle Start. Repeat until the message clears. Adjust the feedrate in the part program by the percentage that was required to clear the message. M-506A A2-11

100 2056 Setting Mode Required T-42 Lathe: Setting mode is required to use the enable switch. Turn the setting mode switch to "1" (ON). T-51 and T-65 Lathes: Setting mode is required to use the Enable push button. Turn the setting mode switch to MPG or JOG Feedrate Override Set To Zero The Feedrate Override switch is set to zero and a Rapid Reference move was attempted. Set the Feedrate Override switch to any non-zero value to allow the Rapid Reference move. Set the Feedrate Override switch to any non-zero value or press the Reset key to clear the message Please Press Reset It is not allowed to open the guard door or operate the part catcher manually with a part program active. If necessary, press Reset to stop the part program Y Too Low To Jog E Or Z The turret is positioned below Y0. Move the turret to Y0 or above before attempting to move the E or Z axis Please Turn Setting Mode OFF Power up message. Turn the Setting Mode switch to "0" (OFF) Open Collet Only In Jog Mode For machines equipped with the bar feed option and the option is turned ON, the control must be in Jog mode to manually open the collet or chuck. Press Reset or select Jog mode to clear the message Part Count Satisfied The part count specified has been completed. Repeat mode is canceled. Press Cycle Start or Reset to clear the message Guard Door Switch Fault Two Inputs Must Agree The two inputs on the guard door switch must indicate the same condition (door open or door closed). Check the switch wiring or replace the switch, if necessary. A2-12 M-506A

101 2090 Turret Must Be At X Axis Home Position When the tool probe is active, the turret can only be indexed when it is positioned at the X axis reference position Tool Failed To Contact Probe While using the probe cycle, the tool failed to contact the probe. Adjust the tool position and try again. Press Reset to clear the message Please Check Axis Selector Switch While using the probe cycle, the axis jog button pressed is for an axis that does not match the Axis Select push button that is active. Press the correct axis jog push button or change the axis selection. Press Reset to clear the message Spindle Chiller Temperature Or Flow Fault The spindle chiller temperature is too high or low or the spindle coolant chiller flow is too low. This fault cancels Repeat mode. The machine will stop with alarm 1016 after four minutes. Press Reset to clear the message Turret Must Be At Required Z Axis Position The turret Z axis position must be greater than 15.4 in [ mm] to allow the tool probe to deploy without danger of collision E-Axis Must Be Homed The sub-spindle must be at the reference position to allow the automatic tool probe to deploy Low Coolant Low coolant level. Refer to the operator's manual (M-505) for information on refilling the coolant tank Part Catcher Timeout The main spindle part catcher took too much time to complete the commanded motion. The arm or basket may be stuck or obstructed. Press Reset to clear the message Part Catcher Limit Switch Fault One of the following conditions exists: The main spindle part catcher arm extended and retracted limit switches are both activated. This may indicate that one of the limit switches has failed. M-506A A2-13

102 2103 Part Conveyor Out Of Position. Close Door, Press Reset, Press Part Catc S2" Button On Operator Panel To Recover The part catcher slide is not on the home switch and not on the extended switch. Follow the instructions in the message Auto Door Drive Alarm, Please Press Reset The automatic guard door stepper motor drive unit has an alarm. Press Reset to clear this message Auto Door Collision Detected, Press E-S Reset Button To Reset The automatic door is equipped with a collision detector; a sensitive rubber boot at the leading edge of the door. If the door hits something when moving, it will stop. To reset the collision detector mechanism, press the Emergency Stop Reset button Auto Door Drive Alarm, Press Reset; Home Required The automatic door stepper motor drive unit has an alarm. Press Reset to clear this message. The drive will perform the homing operation the next time the door is opened or closed Auto Door Drive Alarm, E-Stop Required To Reset Put the machine in Emergency Stop push button to reset the automatic door stepper drive Main Chuck Failed To Close Main spindle Collet Close has been commanded and the main spindle draw tube is still in the Open position Main Chuck Did Not Grip Part Main spindle Collet Close has been commanded and the main spindle draw tube has traveled past the closed position, indicating that no workpiece is in the spindle Can't Apply Tailstock Brake With Spindle Running The brake was not applied. Stop the spindle before applying the brake. Reset clears the message. A2-14 M-506A

103 2125 Spindle Speed Exceeds Limit, Main Spindle - CAUTION - When modifying the programmed spindle speed or the spindle speed limit, be sure to select values that will not create an unsafe operating condition. The spindle speed programmed for the main spindle exceeds the limit set on the Spindle Speed Limit screen. Modify the programmed spindle speed or the value on the Spindle Speed Limit screen. Refer to the operator's manual (M-505) for information on the Spindle Speed Limit screen Spindle Speed Exceeds Limit, Opposite Spindle - CAUTION - When modifying the programmed spindle speed or the spindle speed limit, be sure to select values that will not create an unsafe operating condition. The spindle speed programmed for the sub-spindle exceeds the limit set on the Spindle Speed Limit screen. Modify the programmed spindle speed or the value on the Spindle Speed Limit screen. Refer to the operator's manual (M-505) for information on the Spindle Speed Limit screen Spindle Speed Exceeds Limit, Live Tooling - CAUTION - When modifying the programmed spindle speed or the spindle speed limit, be sure to select values that will not create an unsafe operating condition. The spindle speed programmed for the live tool spindle exceeds the limit set on the Spindle Speed Limit screen. Modify the programmed spindle speed or the value on the Spindle Speed Limit screen. Refer to the operator's manual (M-505) for information on the Spindle Speed Limit screen Main Collet Open The main spindle collet/chuck is open. Cycle Start and manual spindle operation are inhibited. Close the Collet/chuck to allow Cycle Start and manual spindle operation. Press Reset to clear the message. M-506A A2-15

104 2134 Main Spindle Contouring Mode The C1 Axis Select push button is active and the operator is attempting to manually operate the main spindle through the use of the spindle control functions on the operator panel. Press another Axis Select push button Main Spindle Pole Position Not Set. Close Door And Press Test Pushbutton. Machine power-up message. Close the guard door and press the Test push button Test Not Performed. Main Spindle May Be Running Or Have Alarm The MCC contactor test or spindle pole positioning was attempted and failed. Main spindle drive has not indicated the main spindle is stationary. If the main spindle is not running, check for alarms on the spindle drive. Press Reset and, if needed, power down the machine to clear spindle alarms Test Not Performed. Opposite Spindle May Be Running Or Have Alarm The MCC contactor test or spindle pole positioning was attempted and failed. Sub-spindle drive has not indicated the sub-spindle is stationary. If the sub-spindle is not running, check for alarms on the spindle drive. Press Reset and, if needed, power down the machine to clear spindle alarms Opposite Spindle Part Catcher Timeout The sub-spindle part catcher took too long to complete the commanded motion. The slide, arm, or gripper may be stuck. Correct the problem and press Reset to clear the message Opposite Spindle Part Catcher Limit Switch Fault The sub-spindle part catcher slide, arm, or gripper limit switches indicate the same state. This may indicate that one of the switches has failed. Correct the problem and press Reset to clear the message Opposite Spindle Part Catcher Slide Must Be Extended The sub-spindle part catcher slide must be extended before the arm can be rotated out to the spindle centerline. A2-16 M-506A

105 2144 Opposite Spindle Must Be Home The sub-spindle must be at the reference position before the sub-spindle part catcher arm can be rotated Opposite Spindle Part Catcher Arm Must Be Down The sub-spindle part catcher arm must be rotated down before the part catcher slide can be retracted Opposite Spindle Part Catcher Gripper Fault The part catcher gripper is closed without gripping a part Part Conveyor Motor Overload The part conveyor motor overload in the machine power case has tripped. Correct the cause of the overload. Reset the overload in the power case. When the overload is reset, press Reset to clear the message High Pressure Coolant Filter Clogged The high pressure coolant filter pressure drop is too high. This message cancels Repeat mode, but allows machine operation. Check the condition of the filter. Press the Reset key to clear the message High Pressure Coolant Level Low The level switch in the high pressure coolant tank indicates that the coolant level is too low. Check the operation of the pump. Find and correct the cause of the problem. Press the Reset button on the high pressure coolant unit to reset the alarm. Press the control Reset key to clear the message One Spindle Must be Running The active spindle must be running before the high pressure coolant pump can be started. The active spindle is selected by M64 or M65. The main spindle is the default. Revise the part program as necessary. Press Reset to clear the message. M-506A A2-17

106 2154 High Pressure Coolant Not Ready The high pressure coolant unit is not ready. Verify the high pressure coolant unit is ON. Check the fuses in the machine power case. Find and correct the cause of the problem. Press Reset to clear the message MCC Contactor Status Fault The actual contactor output does not match the anticipated output. Check the contactor and replace, if necessary E-Stop Contactor Status Fault The actual contactor output does not match the anticipated output. Check the contactor and replace, if necessary Main Guard Door Lock Contactor Status Fault The actual contactor output does not match the anticipated output. Check the contactor and replace, if necessary Air Supply Contactor Status Fault The actual contactor output does not match the anticipated output. Check the contactor and replace, if necessary Hydraulic Supply Contactor Status Fault The actual contactor output does not match the anticipated output. Check the contactor and replace, if necessary Auto Door Air Supply Contactor Status Fault The actual contactor output does not match the anticipated output. Check the contactor and replace, if necessary Main Guard Closed Contactor Status Fault The actual contactor output does not match the anticipated output. Check the contactor and replace, if necessary. A2-18 M-506A

107 2164 X Axis Brake Contactor Status Fault The actual contactor output does not match the anticipated output. Check the contactor and replace, if necessary Y Axis Brake Contactor Status Fault The actual contactor output does not match the anticipated output. Check the contactor and replace, if necessary Chip Conveyor Contactor Status Fault The actual contactor output does not match the anticipated output. Check the contactor and replace, if necessary Barfeed Power Contactor Status Fault The actual contactor output does not match the anticipated output. Check the contactor and replace, if necessary Hydraulic Pump Contactor Status Fault Or Overload Trip The actual contactor output does not match the anticipated output or the associated overload has tripped. Check the contactor and overload. Reset the overload or replace the contactor, if necessary Coolant Pump 1 Contactor Status Fault Or Overload Trip The actual contactor output does not match the anticipated output or the associated overload has tripped. Check the contactor and overload. Reset the overload or replace the contactor, if necessary Coolant Pump 2 Contactor Status Fault Or Overload Trip The actual contactor output does not match the anticipated output or the associated overload has tripped. Check the contactor and overload. Reset the overload or replace the contactor, if necessary High Pressure Coolant Pump Contactor Status Fault Or Overload Trip The actual contactor output does not match the anticipated output or the associated overload has tripped. Check the contactor and overload. Reset the overload or replace the contactor, if necessary. M-506A A2-19

108 2174 Live Tool Fan Motor Contactor Status Fault Or Overload Trip The actual contactor output does not match the anticipated output or the associated overload has tripped. Check the contactor and overload. Reset the overload or replace the contactor, if necessary Mist Collector Contactor Status Fault Or Overload Trip The actual contactor output does not match the anticipated output or the associated overload has tripped. Check the contactor and overload. Reset the overload or replace the contactor, if necessary Part Conveyor Contactor Status Fault Or Overload Trip The actual contactor output does not match the anticipated output or the associated overload has tripped. Check the contactor and overload. Reset the overload or replace the contactor, if necessary Parameter Write Fault 1: Please Turn Off Power and Restart Machine The control has failed to write a parameter correctly. Cycling control power OFF and ON may clear the problem. Contact the Hardinge Service Department if necessary Parameter Write Fault 2: Please Turn Off Power and Restart Machine The control has failed to write a parameter correctly. Cycling control power OFF and ON may clear the problem. Contact the Hardinge Service Department if necessary Parameter Write Fault 3: Please Turn Off Power and Restart Machine The control has failed to write a parameter correctly. Cycling control power OFF and ON may clear the problem. Contact the Hardinge Service Department if necessary Parameter Write Fault 4: Please Turn Off Power and Restart Machine The control has failed to write a parameter correctly. Cycling control power OFF and ON may clear the problem. Contact the Hardinge Service Department if necessary Macro Variable Write Fault 5. Please Turn Off Power And Restart Machine The control has failed to write a macro variable correctly. Cycling control power OFF and ON may clear the problem. Contact the Hardinge Service Department if necessary. A2-20 M-506A

109 2205 Macro Variable Write Fault 6. Please Turn Off Power And Restart Machine The control has failed to write a macro variable correctly. Cycling control power OFF and ON may clear the problem. Contact the Hardinge Service Department if necessary Opposite Chuck Failed To Close Sub-spindle Collet Close has been commanded and the sub-spindle draw tube is still in the Open position Opposite Chuck Did Not Grip Part Sub-spindle Collet Close has been commanded and the sub-spindle draw tube has traveled past the closed position, indicating that no workpiece is in the spindle Opposite Collet Open The sub-spindle collet/chuck is open. Cycle Start and manual spindle operation are inhibited. Close the Collet/chuck to allow Cycle Start and manual spindle operation. Press Reset to clear the message 2234 Opposite Spindle Contouring Mode The C2 Axis Select push button is active and the operator is attempting to manually operate the main spindle through the use of the spindle control functions on the operator panel. Press another Axis Select push button Opposite Spindle Pole Position Not Set. Close Door And Press Test Pushbutton. Machine power-up message. Close the guard door and press the Test push button Close Door. Then Press Test Pushbutton To Execute Main Contactor (MCC) Test Machine power-up message. Close the guard door and press the Test push button Test Not Performed. Door May Be Open, Live Tool Spindle Running, Live Tool Spindle Alarm The MCC contactor test or spindle pole positioning was attempted and failed. Guard door may be open or the live tool drive has not indicated the live tool spindle is stationary. If the live tooling is not running, check for alarms on the live tool drive. Press Reset and, if needed, power down the machine to clear spindle alarms. M-506A A2-21

110 2241 CNC External Input Fault The CNC has rejected external data. If this problem persists, please contact the factory Spindle Error - Diagnostic 710 Gives Details See A.4 ERROR CODES in Fanuc 31i Model A Maintenance Manual for an explanation of error codes displayed in diagnostic Spindle Fault - Diagnostic 712 Gives Details See Section in Fanuc 31i Model A Maintenance Manual for an explanation of warning codes displayed in diagnostic 712. A2-22 M-506A

111 - NOTES - M-506A A2-23

112 - NOTES - A2-24 M-506A

113 APPENDIX THREE - MACHINE PHOTOGRAPHS A C D B E F G Figure A3.1 - Main Air Control and Coolant Pressure Gauge TP7857B A - Coolant Pressure Gauges B - Main Air Filter/Regulator C - Coalescing Filter D - Main Air Pressure Switch E - Turret Air Bearing Pressure Regulator F - Turret Air Purge Pressure Regulator (BMT 45 Top Plate only) G - Main Air Shut-Off Valve M-506A A3-1

114 B A TP7889A Figure A3.2 - Coolant Pump (Stage 2) and Coolant Filter A - Coolant Pump (Stage 2) B - Coolant Filter A3-2 M-506A

115 B A Figure A3.3 - Hydraulic Unit and Coolant Pump (Stage 1) TP7864B A - Hydraulic Unit B - Coolant Pump (Stage 1) M-506A A3-3

116 Figure A3.4 - Main Disconnect Switch Handle and Tags on Power Case Door TP7938 A3-4 M-506A

117 A B C Figure A3.5 - Internal View of Power Case TP7964 A - Fanuc Input/Output Modules B - Linear Scales Input C - Safety Output Relays (Channel 2) M-506A A3-5

118 A B C D Figure A3.6 - Internal View of Power Case TP7965 A - Safety Input/Output Module (Channel 1) B - Safety Input/Output Module (Channel 2) C - Safety Output Relays (Channel 1) D - X Axis Brake Resistors A3-6 M-506A

119 B A C Figure A3.7 - Internal View of Power Case: Tool Probe Interface, Thermal Compensation Modules, and Safety Expansion Relays TP8299 A - Tool Probe Interface B - Thermal Compensation Modules C - Safety Expansion Relays M-506A A3-7

120 Figure A3.8 - Internal View of Power Case: Upper Input/Output Module (5000 I/O) TP7979 A3-8 M-506A

121 A B C D Figure A3.9 - Internal View of Power Case: Lower Input/Output Modules TP7980 A I/O B I/O C I/O D I/O M-506A A3-9

122 Figure A Internal View of Power Case: Axis Servo and Spindle Drive Units TP7966A A3-10 M-506A

123 Figure A Internal View of Power Case: 24 Volt Fuse Blocks, Contactors, and Terminal Blocks TP7974A M-506A A3-11

124 Figure A Internal View of Power Case: 110 Volt Fuse Blocks, Terminal Blocks, Relays, and Ground Strip (G3) TP7976 A3-12 M-506A

125 TP7977B Figure A Internal View of Power Case: 200 volt (50 Hz) / 230 volt (60 Hz) Fuse Blocks, Contactor, and Overload (T-42 Lathes) M-506A A3-13

126 Figure A Internal View of Power Case: 200 volt (50 Hz) / 230 volt (60 Hz) Fuse Blocks (T-51 and T-65 Lathes) TP78300 A3-14 M-506A

127 A B C Figure A Internal View of Power Case: Main Spindle and Sub-Spindle SSM Modules and Line Reactor (T-42 Lathes) TP7967 A - Sub-Spindle SSM Module B - Main Spindle SSM Module C - Line Reactor M-506A A3-15

128 A B C D Figure A Internal View of Power Case: Main Spindle and Sub-Spindle SSM Modules, Line Reactor, and MCC Contactor (T-51 and T-65 Lathes) TP8304 A - Sub-Spindle SSM Module B - Main Spindle SSM Module C - Line Reactor D - MCC Contactor A3-16 M-506A

129 Figure A Internal View of Power Case: 400 volt (50Hz) / 460 volt (60Hz) Fuse Blocks and Contactors TP7968 M-506A A3-17

130 Figure A Internal View of Power Case: 400 volt (50Hz) / 460 volt (60Hz) Fuse Blocks, Contactors, and Overloads (T-42 Lathe) TP7969A A3-18 M-506A

131 TP8303 Figure A Internal View of Power Case: 400 volt (50Hz) / 460 volt (60Hz) Fuse Blocks, Contactors, and Overloads (T-51 and T-65 Lathes) M-506A A3-19

132 A B Figure A Internal View of Power Case: 24 Volt Power Supply and Control Transformer (T-42 Lathes) TP7970 A - 24 Volt Power Supply B - Control Transformer A3-20 M-506A

133 A B Figure A Internal View of Power Case: 24 Volt Power Supply and Control Transformer (T-51 and T-65 Lathes) TP8301 A - 24 Volt Power Supply B - Control Transformer M-506A A3-21

134 B C A TP7971 Figure A Internal View of Power Case: Main Circuit Breaker, Main PE (Ground) Connection, and Line Reactor (T-42 Lathes) A - Main Circuit Breaker B - Main PE (Ground) Connection C - Line Reactor A3-22 M-506A

135 D B A C Figure A Internal View of Power Case: Main Circuit Breaker and Main PE (Ground) Connection (T-51 and T-65 Lathes) TP8210 A - Main Circuit Breaker B - Main PE (Ground) Connection C - Surge Suppressor D - MCC Contactor M-506A A3-23

136 A Figure A Internal View of Power Case: Line Reactor (T-51 and T-65 Lathes) TP8302 A - Line Reactor (located behind main circuit breaker mounting plate) A3-24 M-506A

137 A B C TP7972 Figure A Internal View of Power Case: MCC Contactor, Surge Suppressor, and Ground Terminal (T-42 Lathes) A - MCC Contactor B - Surge Suppressor C - Ground Terminal M-506A A3-25

138 TP7973 Figure A Internal View of Power Case: Ground Strip (G2) (T-42 Lathes) A3-26 M-506A

139 Figure A Internal View of Power Case: Ground Strip (G2) (T-51 and T-65 Lathes) TP8305 M-506A A3-27

140 A B C D E F G Figure A Interface Receptacles on the Side of the Power Case TP7960A A - Main Spindle Foot Switch B - Tailstock or Sub-Spindle Foot Switch C - High Pressure Coolant Power D - High Pressure Coolant Control E - Bar Feed Control F - Bar Feed Power G - Chip Conveyor Power A3-28 M-506A

141 C B A D E Figure A X, Y, and Z Axis Grease Manifolds, X Axis Drive Motor, and Live Tooling Drive Motor TP7936 A - X Axis Grease Manifold B - Live Tooling Motor C - Y Axis Grease Manifold D - X Axis Motor E - Z Axis Grease Manifold M-506A A3-29

142 B A Figure A Turret Index Motor and Y Axis Drive Motor TP7987 A - Turret Index Motor B - Y Axis Drive Motor A3-30 M-506A

143 - NOTES - M-506A A3-31

144 - NOTES - A3-32 M-506A

145 WHEN MACHINE IN OPERATION, AIR GAP OF POWER CASE TO MACHINE BASE SHOULD BE 1.00" [25.4mm] TO 2.00" [50.8mm] P/N CQ ARGP HAZARDOUS AREA! DO NOT TOUCH MOVING OR ROTATING PARTS DO NOT RUN MACHINE WITH STOCK EXTENDED BEYOND REAR R OF SPINDLE PROPERR BARFEED COVER MUST BE USED WITH CORRESPONDING BARFEED UNIT MAIN COLLET CLOSER HYDRAULIC VALVE ASSEMBLY-MAIN COLLET CLOSER 500 PSI MAX B A CLOSER DRAIN B P T A MAIN SPINDLE BRAKE P/N CQ MHV PRESSURE ADJUSTMENT SOLENOID FOR COLLET OPEN SOLENOID FOR BRAKE DISENGAGE SOLENOID FOR COLLET CLOSE APPENDIX FOUR - MACHINE TAGS TAG LOCATIONS - NOTE - Refer to the tables beginning on page A4-10 for tag part numbers. NOTE: INSIDE VALVE COMPARTMENT DOOR TI5776B Figure A4.1 - Left End of Machine M-506A A4-1

146 CAREFULLY WASH AND DRY WINDOW WITH SOFT CLEAN CLOTH TO AVOID MARRING SURFACE P/N CSA WCE -NOTICE- MAXIMUM SPINDLE RPM MAIN SPINDLE 6,000 RPM SUBSPINDLE 6,000 RPM IMPORTANT DAMAGE RESULTING FROM MISUSE, NEGLIGENCE, OR ACCIDENT IS NOT COVERED BY THE HARDINGE INC. MACHINE WARRANTY CLASS 2 LASER PRODUCT DO NOT STARE INTO BEAM PULSE POWER <2.6 mw nm, 2kHz, 15.5 us PULSE. COMPLIES WITH 21 CFR & EN :2001 EXCEPT FOR DEVIATIONS PURSUANT TO LASER NOTICE NO. 50, DATED P/N CQA C2LR DANGER FAILURE TO FOLLOW SAFE MACHINING PRACTICES CAN RESULT IN EJECTED PARTS AND SERIOUS INJURY. ENCLOSURE MAY NOT STOP EVERY TYPE OF PROJECTILE. P/N BL EJ VISION PANEL INSTALLATION DATE YEAR 11 INSTALLED CHANGE BEFORE MONTH IF DAMAGED REPLACE IMMEDIATELY, OTHERWISE REPLACE AFTER A MAXIMUM OF 10 YEARS. SEE OPERATOR'S SAFETY MANUAL. P/N BL GC SERVICE ACCESS COVER PLACE THE CONTROL IN E-STOP BEFORE REMOVING THIS COVER TO ELIMINATE POSSIBLE PINCH POINTS. THIS COVER IS TO BE REMOVED FOR SERVICE ACCESS BY AUTHORIZED PERSONNEL ONLY. COVER MUST BE PROPERLY SECURED BEFORE OPERATING THIS EQUIPMENT. P/N CSA CE TI5777C Figure A4.2 - Front of Machine A4-2 M-506A

147 20 PSI MIN SUB SPINDLE CHUCK OPEN A IN B P T SUB SPINDLE CHUCK CLOSE B SUB SPINDLE CHUCK CYLINDER A BRAKE DISENGAGE SOLENOID SPINDLE BRAKE P/N CQ SSB SUB SPINDLE CHUCK CLOSE SUB SPINDLE CHUCK OPEN REGULATOR P/N CQ SSPV SOLENOID FOR COLLET OPEN SOLENOID FOR COLLET CLOSE WHEN MACHINE IN OPERATION, AIR GAP OF POWER CASE TO MACHINE BASE SHOULD BE 1.00" [25.4mm] TO 2.00" [50.8mm] P/N CQ ARGP NOTE: INSIDE VALVE COMPARTMENT DOOR PNEUMATIC VALVE ASSEMBLY-COLLET CLOSER * 31 HYDRAULIC VALVE ASSEMBLY- BRAKE * 32 ** 33 * 2 2 * * 7 * * * Sub-Spindle Machines Only 5 ** Tailstock Machines Only TI5778A Figure A4.3 - Right End of Machine M-506A A4-3

148 CLEAN FILTER ONCE A WEEK MORE OFTEN IF REQUIRED P/N AD CE SERVICE ACCESS COVER PLACE CONTROL IN E-STOP BEFORE REMOVING THIS COVER TO ELIMINATE POSSIBLE PINCH POINTS. THIS COVER IS TO BE REMOVED FOR SERVICE ACCESS BY AUTHORIZED PERSONNEL ONLY. COVER MUST BE PROPERLY SECURED BEFORE OPERATING EAUIPMENT. P/N CSA CE AIR INLET DO NOT BLOCK P/N CCA CE MODEL SUPPLY VOLTS PHASE KILOWATTS HERTZ MACHINE FLA CONTROL VOLTS SPINDLE DRIVE WIRING DIAGRAMS POWER NC SHORT CIRCUIT INTERRUPTING CAPACITY OF THE OVERCURRENT PROTECTIVE DEVICE OVERCURRENT PROTECTION PROVIDED AT MACHINE SUPPLY TERMINALS NOTE - ADDITIONAL DATA PLATES IN CONTROL CASE P/N CL MACHINE SERIAL NO. HARDINGE INC ONE HARDINGE DR, PO BOX 1507, ELMIRA,NY, ,USA TEL: MACHINE WEIGHT P/N LCA CE THIS ENCLOSURE CONTAINS ELECTRICAL EQUIPMENT AUTHORIZED PERSONNEL ONLY P/N CSB CE THIS ENCLOSURE CONTAINS ELECTRICAL EQUIPMENT AUTHORIZED PERSONNEL ONLY P/N CSB CE * 40 ** 41 * CE Machines Only 11 ** Non CE Machines Only TI5779C Figure A4.4 - Back of Machine A4-4 M-506A

149 36 TI5781 Figure A4.5 - Main Spindle Compartment M-506A A4-5

150 36 TI5782A Figure A4.6 - Lower Axis with Sub-Spindle A4-6 M-506A

151 22 TI5783 Figure A4.7 - Optional Sub-Spindle Part Present Detector M-506A A4-7

152 IMPORTANT: TAILSTOCK OR SUBSPINDLE CAN COLLIDE WITH BASKET IF ADJUSTED IMPROPERLY. SEE OPERATOR'S MANUAL BEFORE ADJUSTING. LIVE TOOL HOLDER INSTRUCTIONS WHEN LIVE TOOL HOLDER NUT IS TIGHTENED HOLDER MUST BE ON NON-ACTIVE TURRET STATION. USE PROVIDED WRENCHES TO HOLD SHAFT AND NUT. DAMAGE COULD OCCUR TO DRIVE TANG IF INSTRUCTIONS ARE NOT FOLLOWED. MAINTAINCE WHEN LIVE TOOL HOLDERS ARE REMOVED APPLY GREASE (HARDINGE P/N HG ) MOLYLUBE, OR EQUIVALENT. EVERY 1,000 HRS (MORE FREQUENT IF TOOL EXCEEDS 5,000RPM) P/N CQ LIVE Hydraulic Unit Top View Control Pendant Rear View Main Spindle Headwall Turret Top Cover TI5780A Figure A4.8 - Miscellaneous Views A4-8 M-506A

153 P/N: CQ FS1 P/N: CQ FS2 P/N: CQ FS TI5801 Figure A4.9 - Foot Switches M-506A A4-9

154 TAG PART NUMBERS TAG KITS Language Czech Dutch English German Italian Polish Spanish Tag Kit Part Number CQ CZ CQ DU CQ E CQ G CQ I CQ PO CQ SP INDIVIDUAL TAGS - NOTE - Refer to Figures A4.1 through A4.9 for tag identification. Identification Number Tag Description Language Tag Number 1 Instruction Tag: Air Gap Czech Dutch English German Italian Polish Spanish CQ ARCZ CQ ARDU CQ ARGP CQ ARG CQ ARI CQ ARPO CQ ARSP 2 Tag Kit: Gauge Overlay Czech Dutch English German Italian Polish Spanish CQ TKCZ CQ TKDU CQ TK CQ TKG CQ TKI CQ TKPO CQ TKSP 3 Component Identification: Hydraulic Valve Assembly Czech Dutch English German Italian Polish Spanish CQ MHCZ CQ MHDU CQ MHV CQ MHVG CQ MHVI CQ MHPO CQ MHSP A4-10 M-506A

155 Identification Number Tag Description Language Tag Number Data Tag: 16C Main Spindle Closer Pressure / Force (T-42 Lathe, 42 Millimeter Spindle) Czech Dutch English German Italian Polish Spanish SR L1CZ SR L1DU SR L1CE SRA L1CG SR L1CI SR L1CP SR L1CS 4 Data Tag: 20C Main Spindle Closer Pressure / Force (T-42 Big-Bore or T-51 Lathe, 51 Millimeter Spindle) Czech Dutch English German Italian Polish Spanish DQ MCZ DQ MDU DQ MCE DQ MCG DQ MCI DQ MCP DQ MCS Data Tag: 25C Main Spindle Closer Pressure / Force (T-65 Lathe, 65 Millimeter Spindle) Czech Dutch English German Italian Polish Spanish EQ MCZ EQ MDU EQ MCE EQ MCG EQ MCI EQ MCP EQ MCS 5 Warning Tag: Service Access Czech Dutch English German Italian Polish Spanish CSA CZ CS DU CSA CE CSB CG CSA CI CSA CP CSA CS 6 Warning Tag: Chuck Pressure Limit Czech Dutch English German Italian Polish Spanish SR CHCZ SR CHDU SR CH SRA CHG SR CHI SR CHPO SR CHSP 7 Warning Tag: Draw Tube Screws (T-42 Lathe) Warning Tag: Draw Tube Screws (T-42 Big-Bore or T-51 Lathe, 51 Millimeter Spindle) (T-65 Lathe, 65 Millimeter Spindle) Czech Dutch English German Italian Polish Spanish Czech Dutch English German Italian Polish Spanish CQ CZ CQ DU CQ CE CQ CG CQ CI CQ CP CQ CS DQ CZ DQ DU DQ CE DQ CG DQ CI DQ CP DQ CS M-506A A4-11

156 Identification Number Tag Description Language Tag Number 8 Warning Tag: Barfeed Operation Czech Dutch English German Italian Polish Spanish QC WACZ QC WADU QC WARN QCA WACG QC WARI QC WACP QC WACS 9 Warning Tag: Pinch Point Area Czech Dutch English German Italian Polish Spanish CS CZ CS DU CS CE CSA CG CS CI CS CP CS CS 10 Instruction Tag: Air Filter Cleaning Czech Dutch English German Italian Polish Spanish AD CZ AD DU AD CE ADA CG AD CI AD CP AD CS 11 Instruction Tag: Air Inlet Czech Dutch English German Italian Polish Spanish CCA CZ CC DU CCA CE CCB CG CCA CI CCA CP CCA CS 12 Instruction Tag: Drain Accumulator Czech Dutch English German Italian Polish Spanish CQ DACZ CQ DADU CQ DA CQ DAG CQ DAI CQ DAPO CQ DASP Identification Tag: 400PL Identification Tag: 405PL Identification Tag: 512PL Identification Tag: 7303PL Receptacle Identification: 7007PL Receptacle Identification: 5701PL - CQ CQ CQ CQ CQ CQ A4-12 M-506A

157 Identification Number Tag Description Language Tag Number 19 Receptacle Identification: 5705PL - CQ Instruction Tag: Shipping Bracket Czech Dutch English German Italian Polish Spanish SR BFCZ SR BFDU SR BFSH SR BFG SR BFI SR BFPO SR BFSP 21 Instruction Tag: Window Cleaning Czech Dutch English German Italian Polish Spanish CSA WCZ CS WDU CSA WCE CSB WCG CSA WCI CSA WCP CSA WCS 22 Warning Tag: Class 2 Laser Czech Dutch English German Italian Polish Spanish CQ C2CZ CQ C2DU CQA C2LR CQA C2LG CQ C2LI CQ C2PO CQ C2SP 23 Warning Tag: Moving / Rotating Parts Czech Dutch English German Italian Polish Spanish CNA CZ CN DU CNA CE CNB CG CNA CI CNA CP CNA CS M-506A A4-13

158 Identification Number Tag Description Language Tag Number Instruction Tag: Maximum Spindle RPM (T-42 Lathe, 42 Millimeter Main Spindle) Czech Dutch English German Italian Polish Spanish CQ MSCZ CQ MSDU CQ MSP CQ MSPG CQ MSPI CQ MSPO CQ MSSP 24 Instruction Tag: Maximum Spindle RPM (T-42 Big-Bore Lathe, 51 Millimeter Main Spindle) Instruction Tag: Maximum Spindle RPM (T-51 Lathe, 51 Millimeter Main Spindle) Czech Dutch English German Italian Polish Spanish Czech Dutch English German Italian Polish Spanish CQ MBCZ CQ MBDU CQ MSPB CQ MSBG CQ MSBI CQ MBPO CQ MBSP DQ MSCZ DQ MSDU DQ MSP DQ MSPG DQ MSPI DQ MSPO DQ MSSP Instruction Tag: Maximum Spindle RPM (T-65 Lathe, 65 Millimeter Main Spindle) Czech Dutch English German Italian Polish Spanish EQ MSCZ EQ MSDU EQ MSP EQ MSPG EQ MSPI EQ MSPO EQ MSSP 25 Notice Tag: Machine Warranty Czech Dutch English German Italian Polish Spanish CSA CZ CS DU CSA CE CSC CG CSA CI CSA CP CSA CS 26 Data Tag: Glass Date Czech Dutch English German Italian Polish Spanish BL GCCZ BL GCDU BL GC BL GCGE BL GCIT BL GCPO BL GCSP 27 Warning Tag: Ejected Part Czech Dutch English German Italian Polish Spanish BL EJCZ BL EJDU BL EJ BL EJGE BL EJIT BL EJPO BL EJSP A4-14 M-506A

159 Identification Number Tag Description Language Tag Number 28 Warning Tag: Bar Stock Czech Dutch English German Italian Polish Spanish SBA CZ SB DU SBA CE SBB CG SBA CI SBA CP SBA CS 29 Data Tag: Sub-Spindle Closer Pressure / Force (T-42 Lathe, 42 Millimeter Sub-Spindle) Data Tag: Sub-Spindle Closer Pressure / Force (T-51 or T-65 Lathe, 51 Millimeter Sub-Spindle) Czech Dutch English German Italian Polish Spanish Czech Dutch English German Italian Polish Spanish CQ CZ CQ DU CQ CE CQ CG CQ CI CQ CPO CQ CSP DQ CZ DQ DU DQ CE DQ CG DQ CI DQ CP DQ CS 30 Instruction Tag: RS-232 Port Czech Dutch English German Italian Polish Spanish CSA R2CZ CS R2DU CSA R2CE CSB R2CG CSA R2CI CSA R2CP CSA R2CS 31 Component Identification: Pneumatic Valve Assembly Czech Dutch English German Italian Polish Spanish CQ SSCZ CQ SSDU CQ SSPV CQ SSPG CQ SSPI CQ SSPO CQ SSSP 32 Component Identification: Sub-Spindle Hydraulic Brake Valve Assembly Czech Dutch English German Italian Polish Spanish CQ SBCZ CQ SBDU CQ SSB CQ SSBG CQ SBI CQ SBPO CQ SBSP 33 Component Identification: Sub-Spindle Hydraulic Brake Valve Assembly Czech Dutch English German Italian Polish Spanish CQ TSCZ CQ TSDU CQ TSB CQ TSBG CQ TSBI CQ TSPO CQ TSSP M-506A A4-15

160 Identification Number Tag Description Language Tag Number 34 Instruction Tag: Coolant Filter Replacement Czech Dutch English German Italian Polish Spanish SR FCZ SR FDU SR FE SR FG SR FI SR FPO SR FSP 35 Machine Data Tag Czech Dutch English German Italian Polish Spanish CL CZ CL DU CL CLA G CL I CL CP CL SP 36 Warning Tag: Electrical Hazard - LCA CE 37 Warning Tag: Electrical Enclosure Czech Dutch English German Italian Polish Spanish CSB CZ CS DU CSB CE CSD CG CSA IT CSB CP CSB CS 38 Machine Serial Number Tag Czech Dutch English German Italian Polish Spanish CN CZ CN DU CN CNA CG CN CI CN CP CN CS Identification Tag: Company Address and Telephone Number (CE) Identification Tag: Company Address and Telephone Number (Non CE) - CQ CQ Data Tag: Machine Weight Czech Dutch English German Italian Polish Spanish CQ CZ CQ DU CQ CQ G CQ I CQ PO CQ SP 42 Data Tag: Hydraulic Oil Czech Dutch English German Italian Polish Spanish CQ CZ CQ DU CQ CE CQ CG CQ CI CQ CPO CQ CSP A4-16 M-506A

161 Identification Number Tag Description Language Tag Number 43 Instruction Tag: Part Catcher Czech Dutch English German Italian Polish Spanish SR PCCZ SR PCDU SR PC SRA PCG SR PCI SR PCPO SR PCSP 44 Instruction Tag: Live Tool Holders Czech Dutch English German Italian Polish Spanish CQ LICZ CQ LIDU CQ LIVE CQ LIVG CQ LII CQ LIPO CQ LISP Identification Tag: Main Spindle Collet Closer Foot Switch Identification Tag: Sub-Spindle Collet Closer Foot Switch Identification Tag: Tailstock Foot Switch - CQ FS1 - CQ FS2 - CQ FS3 M-506A A4-17

162 - NOTES - A4-18 M-506A

163 APPENDIX FIVE - RECOMMENDED SPARE PARTS T-42 LATHES Part Number Description Quamtity Specification LP Fuse, 6A Class CC 3 SG Fuse, 10A Class CC 3 SG Fuse, 30A Class CC 3 SG Fuse, 2-1/2A Class CC 3 SG Fuse, 5A Class CC 3 SG Fuse, 2A Class CC 3 SG Fuse, 7A Class CC 3 SG Fuse, 3A Class CC 3 SG Fuse, 1A Class CC 3 SG Fuse, 1-6/10A Class CC 3 VL CC04 Fuse, 4A Class CC 3 LC Relay, Mini 24VDC 2 CQ Relay, FG Safety, 2NO/2NC 2 TT Switch, Proximity 1 TT Switch, Proximity 1 SR M Filter Element, 100 M Cleanable 1 NV Switch, Part Catcher Cylinder 1 QC Switch, Pressure 1 GOULD ATDR6 GOULD ATDR10 GOULD ATDR30 SHAWMUT ATDR2-1/2 GOULD ATDR5 GOULD ATDR2 GOULD ATDR7 GOULD ATDR3 GOULD ATDR1 GOULD ATDR1-6/10 GOULD ATDR4 IDEC RH1B-U-DC24V OMRON G7SA-2A2B TURCK BI 1-GS880-AP6X-0.6M-RS4T TURCK BI1.5-EG08K-AP6X-V1131 TRUMPLER-CLANCY TC P-B-DOE-597 LIANG YI LY-D73L RW EARL UE10F12M201400R M-506A A5-1

164 Part Number Description Quamtity Specification CQA SV1 Air Valve SV2A00 1 CQA SV2 Air Valve SV LP Z1 Belt, Y-Axis Drive 1 QC Switch, Proximity 1 QC Switch, Proximity 1 TG LTY Belt, Live Tool 1 TT SOL Valve, Spindle Brake 1 VL CCDV Valve, Collet Closer / Turret 1 SMC SV2A00-5FU SMC SV2200-5FU GATES 8MGT TURCK BI1.5EG08AP6X-V11 TURCK BI1EG05AP6X-V1331 CONTINENTAL SYNCHROCHAIN C8M VICKERS DG4V3S2AMUH560 VICKERS DG4V3S-2N-MUH5-60 CQA DCS Pressure Switch, Dual Check Safety 1 SMC ISE40A-N01-Y-X531 SB F Filter, Hydraulic 1 TT NCA Grease, Kluber 1 TT Gun, Grease 1 PALL HC9020FKN4H/Q=37720 KLUBER ISOFLEX NCA LINCOLN 1147 CQ FPAD Pad, Fingers 4 Hardinge Inc. A5-2 M-506A

165 T-51 AND T-65 LATHES Part Number Description Quamtity Specification LP Fuse, 6A Class CC 3 SG Fuse, 10A Class CC 3 SG Fuse, 30A Class CC 3 SG Fuse, 2-1/2A Class CC 3 SG Fuse, 5A Class CC 3 SG Fuse, 2A Class CC 3 SG Fuse, 7A Class CC 3 SG Fuse, 3A Class CC 3 SG Fuse, 1A Class CC 3 SG Fuse, 1-6/10A Class CC 3 VL CC04 Fuse, 4A Class CC 3 LC Relay, Mini 24VDC 2 CQ Relay, FG Safety, 2NO/2NC 2 TT Switch, Proximity 1 TT Switch, Proximity 1 SR M Filter Element, 100 M Cleanable 1 NV Switch, Part Catcher Cylinder 1 QC Switch, Pressure 1 CQA SV1 Air Valve SV2A00 1 GOULD ATDR6 GOULD ATDR10 GOULD ATDR30 SHAWMUT ATDR2-1/2 GOULD ATDR5 GOULD ATDR2 GOULD ATDR7 GOULD ATDR3 GOULD ATDR1 GOULD ATDR1-6/10 GOULD ATDR4 IDEC RH1B-U-DC24V OMRON G7SA-2A2B TURCK BI 1-GS880-AP6X-0.6M-RS4T TURCK BI1.5-EG08K-AP6X-V1131 TRUMPLER-CLANCY TC P-B-DOE-597 LIANG YI LY-D73L RW EARL UE10F12M201400R SMC SV2A00-5FU M-506A A5-3

166 Part Number Description Quamtity Specification CQA SV2 Air Valve SV CQA SV3 Air Valve SV DQ Y Belt, Y-Axis Drive 1 QC Switch, Proximity 1 QC Switch, Proximity 1 DQ LTY Belt, Live Tool 1 TT SOL Valve, Spindle Brake 1 VL CCDV Valve, Collet Closer / Turret 1 SMC SV2200-5FU SMC SV2300-5FU GATES 8MGT / TURCK BI1.5EG08AP6X-V11 TURCK BI1EG05AP6X-V1331 CONTINENTAL SYNCHROCHAIN 20G-C3-8PC VICKERS DG4V3S2AMUH560 VICKERS DG4V3S-2N-MUH5-60 CQA DCS Pressure Switch, Dual Check Safety 1 SMC ISE40A-N01-Y-X531 SB F Filter, Hydraulic 1 TT NCA Grease, Kluber 1 TT Gun, Grease 1 PALL HC9020FKN4H/Q=37720 KLUBER ISOFLEX NCA LINCOLN 1147 DQ FPAD Pad, Fingers 4 Hardinge Inc. A5-4 M-506A

167 - NOTES - M-506A A5-5

168 - NOTES - A5-6 M-506A

169 DOCUMENT REVISION RECORD Date Document Revision Level Description October 29, Initial release. November 2, Added German language tag numbers to Appendix Four. November 3, Moved tag #23 from page A4-2 to page A4-1. November 15, Added hydraulic heat exchanger air filter, reformatted Hydraulic System chapter. Added spindle drive motor air filter to Miscellaneous chapter. November 17, Updated cleaning procedures in Coolant chapter. December 8, Added alarm message 1112 to Appendix Two. December 16, Added clearance hole note to turret lubrication procedure. January 10, March 11, Added hydraulic system relief valve adjustment procedure. Added spilled fluid warnings to Chapters 2 and 3. Added operator message 2097 to Appendix Two. Added alarm messages 3010 through 3014 to Appendix Two. Added coolant chiller information. Updated sub-spindle part catcher alignment. Updated power case photo in Appendix Three. Updated Appendix Four. March 17, Updated coolant filter cleaning procedure. April 15, Updated torque limiter reset procedures. Updated machine tag data. Removed hydraulic and pneumatic schematics. February 1, 2012 A Added T-51 and T-65 lathes. Added Appendix Five. February 20, 2012 A Updated the X, Z, E axis torque limiter reset procedure. April 30, 2012 A Added turret top plate alignment caution. Added turret top plate alignment check to Chapter 5. May 29, 2012 A Updated live tool attachment lubrication. M-506A R-1

170 Hardinge Inc. Elmira, New York USA Phone: Fax: