RS 42, RS 51, RS 65, SR 150, SR 200, and SR 200 Big Bore MULTI-TASKING CNC LATHES

Transcription

1 MAINTENANCE MANUAL TP7485 RS 42, RS 51, RS 65, SR 150, SR 200, and SR 200 Big Bore MULTI-TASKING CNC LATHES Equipped with a GE Fanuc 18i-T, GE Fanuc 21i-T or Siemens SINUMERIK 840D SL Control Revised: February 4, 2009 Manual No. M-490B Litho in U.S.A. Part No. M B August, 2008

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 RS and SR CNC Lathes equipped with the GE Fanuc 18i-T, GE Fanuc 21i-T, or Siemens SINUMERIK 840D SL 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. Hardinge Inc. One Hardinge Drive P.O. Box 1507 Elmira, New York U.S.A , Hardinge Inc. M-490B

3 READ THIS INFORMATION CAREFULLY BEFORE STARTING MACHINE OPERATION, MAINTENANCE, OR REPAIR The technicians who use this manual should have a general knowledge of machine maintenance and repair. This general knowledge coupled with the following manual will greatly reduce or eliminate downtime of the lathe machine. When machine maintenance is performed by persons not familiar with the operation of this equipment, the appropriate operator s manual must be consulted: Machine with GE Fanuc 18i-T or 21i-T Control Operator s Manual M-489 Machine with Siemens SINUMERIK 840D SL Control Operator s Manual M WARNING - Occupational Safety and Health Administration (OSHA) Hazard Communication Standard , effective September 23, 1987, and various state employee right-to-know laws require that information regarding chemicals used with this machine be supplied to you. The list of chemicals appears in manual M-179, the Material Safety Data Sheets. Refer to the applicable section of the Material Safety Data Sheets supplied with your machine when handling, storing, or disposing of chemicals. Store Material Safety Data Sheets of other chemicals used with this Hardinge machine in the same packet with manual M-179. Any bar feed system to be used with these machines must be approved by Hardinge Inc. HARDINGE SAFETY RECOMMENDATIONS Your Hardinge machine is designed and built for maximum ease and safety of operation. Because some previously accepted shop practices may not reflect current safety regulations and procedures, they should be re-examined to insure compliance with the current safety and health standards. 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 all equipment. Our recommendations are described below. READ THESE SAFETY RECOMMENDATIONS BE- FORE PROCEEDING ANY FURTHER. READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation, programming, or maintenance of the machine. Make certain that you understand all instructions. CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job. Do NOT OPERATE EQUIPMENT unless proper maintenance has been regularly performed and the equipment is known to be in good working order. WARNING and INSTRUCTION TAGS are mounted on the machine for your safety and information. Do not remove them. Do NOT ALTER THE MACHINE to bypass any interlock, overload, disconnect switch, or other safety device. Do NOT ALLOW the operation or repair of equipment by untrained personnel. M-490B i

4 Do NOT OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing, and/or neckties. Long hair must be contained by a net or shop cap for safety. WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. Wear a respirator, helmet, gloves, and ear muffs or plugs when necessary. Do NOT OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibration occurs. Report any excessive or unusual conditions as well as any damaged parts to your supervisor. ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing electrical equipment. DISCONNECT and LOCKOUT MAIN ELECTRICAL POWER before attempting repair or maintenance. Do NOT REACH into any control or power case area unless electrical power is OFF. MAKE CERTAIN that the equipment is properly grounded. Consult and comply with the National Electric Code and all local codes. Do NOT 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 any shutdown before restarting the machine. KEEP THE AREA AROUND THE MACHINE well lighted and dry. KEEP CHEMICALS AND FLAMMABLE MATERIAL away from operating equipment. HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combustible material and keep the chips clear of the work area. Do NOT USE a toxic or flammable substance as a solvent cleaner or coolant. INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good condition and are functioning properly. MAKE CERTAIN THAT PROPER GUARDS are in place and that all doors and covers are in place and secured before starting a machining cycle. Do NOT OPEN GUARDS while any machine component is in motion. Make certain that all people in the area are clear of the machine when opening the guard door. MAKE SURE that chucks, closers, fixture plates, and all other spindle-mounted work-holding devices are properly mounted. MAKE CERTAIN that all tooling is secured in position before starting the machine. Do NOT USE worn or defective hand tools. Use the proper size and type tool for the job being performed. USE CAUTION around exposed mechanisms and tooling especially when setting up. Be careful of sharp edges on tools. USE ONLY a soft-faced hammer on turret tools and fixtures. MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools. Do NOT USE worn or broken tooling on the machine. ii M-490B

5 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; the high-speed spindles require a WORK-HOLDING TOOL BALANCED to G2.5 or better. ANY ATTACHMENT, TOOL, OR MACHINE MODIFICATION not obtained from Hardinge Inc., must be reviewed by a qualified safety engineer before installation. USE MAXIMUM ALLOWABLE gripping pressure on the chuck. Consider the weight, shape, and balance of the workpiece. USE LIGHTER THAN NORMAL feedrates and depth of cut when machining a workpiece diameter that is larger than the gripping diameter. Do NOT EXCEED the rated capacity of the machine and work-holding device. REDUCE SPINDLE SPEED if vibration occurs; bar straightness will have an effect on vibration and balance of the spindle system. Do NOT LEAVE tools, workpieces or other loose items where they can come in contact with a moving component of the machine. REMOVE ANY LOOSE PARTS OR TOOLS from the work area. Always clear the machine and work area of tools and parts especially after work has been completed by maintenance personnel. REMOVE CHUCK WRENCHES before starting the machine. CHECK THE SETUP, TOOLING, AND SECURE THE WORKPIECE if the machine has been turned OFF for any length of time. CHECK THE LUBRICATION AND COOLANT LEVELS and the status of control indicator lights before operating the machine. KNOW where all EMERGENCY STOP push buttons are located. MAKE CERTAIN THAT PROPER FUNCTIONS are programmed and that all controls are set in the desired modes before pressing the Cycle Start push button. CHECK THE TURRET POSITION before pressing the Cycle Start push button. DRY CYCLE a new setup to check for programming errors. Do NOT ADJUST tooling or coolant hoses while the machine is running. KEEP CLEAR of any pinch point and any potentially hazardous situation. Do NOT LEAVE the machine unattended while it is operating. Do NOT REMOVE OR LOAD workpieces while any part of the machine is in motion. BE CAREFUL of sharp edges when handling newly machined workpieces. Do NOT CHECK the finish or dimension of a workpiece near a running spindle or moving slide. Do NOT JOG SPINDLE in either direction when checking threads with a thread gage. Do NOT ATTEMPT to brake or slow the machine with hands or any makeshift device. Do NOT REMOVE CHIPS with hands. Make certain that all machine movement has stopped and then use a hook or similar device to remove chips and shavings. M-490B iii

6 Do NOT CLEAN the machine with an air hose. KEEP TOTE PANS a safe distance from machine. Don t overfill the tote pans. Do NOT LET STOCK project past the back end of the collet closer or machine spindle without being adequately contained and properly supported. When a bar feed system is used, make certain that it is properly ALIGNED with the spindle. If the bar feed is a floor-mounted type, it must be securely fastened to floor. When a bar feed system is used, follow the bar feed manufacturer s guidelines. For performance and safe application - SIZE and USE feed tube bushings, pushers, and spindle liners according to the bar feed manufacturer s information. During high-speed applications, the bar stock must be contained within the collet closer and a bar feed not be used. Hardinge recommends using a bar loader for high-speed applications of feeding stock to the work-holding device. Bar loaders feed the entire bar stock into the spindle and, then, the pusher is disengaged from the bar. 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. FOR YOUR PROTECTION - WORK SAFELY iv M-490B

7 Table of Contents CHAPTER 1 - AIR SYSTEM Introduction Air Control Assembly Setting the Machine Air Pressure Drain the Filter Bowl Clean the Filter Bowls Replace the Filters Replace Air Control Assembly Components Replacing the Filter/Regulator or Coalescing Filter Replacing the Pressure Switch Thru-Spindle Air Blast [Option] Adding Oil to the Rotary Union or Removing the Air Blast Shaft from the Spindle. 1-7 Mounting the Air Blast Shaft in the Spindle CHAPTER 2 - COOLANT SYSTEM Introduction Cutting Fluid (Coolant) Water-Based Coolants Coolant Maintenance Chip Flush Cleaning the Coolant Filter Cleaning the Coolant Tank VDI Turret Coolant Facilities Spindle Coolant Catcher Cleaning the Spindle Coolant Catcher Installing the Draw Tube Plug Thru-Spindle Coolant [Option] Removing the Coolant Tube from the Spindle Mounting the Coolant Tube in the Spindle Live Tooling Tramp Oil Pan CHAPTER 3 - STANDARD HYDRAULIC SYSTEM Introduction System Specifications Hydraulic Heat Exchanger Hydraulic Tank Maintenance Filling the Hydraulic Tank Hydraulic Filter Replacement M-490B v

8 CHAPTER 4 - HYDROSTATIC HYDRAULIC SYSTEM Introduction Operating Pressure System Specifications Hydraulic Heat Exchanger Hydraulic Tank Maintenance Filling the Hydraulic Tank Replacing the By-Pass Filter Replacing the System Filter CHAPTER 5 - LUBRICATION Introduction Importance of Lubrication Lubrication Alarm Axes Grease Lubrication Grease Volumes Lubrication Procedure Replacing a Grease Lubrication Line Z Axis Way Cover Guide Rod Grease Lubrication Oil Lubrication System Introduction Checking the Oil Level and Filling the Lubricator Checking and Adjusting the Oil Flow Checking and Adjusting the Lubricator Air Pressure Oil Seepage Turret Lubrication Live Tool Holder Lubrication CHAPTER 6 - SPINDLE DRIVES Main Spindle Drive Belt Tension Adjustment Sub-Spindle Drive Belt Tension Adjustment [Option] CHAPTER 7 - MISCELLANEOUS Battery Replacement GE Fanuc Control Siemens Control Work Light Replacing the Lamp or Starter Replacing the Ballast Sub-Spindle Parts Catcher [Option] Adjusting the Arm Swing (Rotate) Position Adjusting the Arm Swing (Rotate) Speed Adjusting the Part Present Sensor Headstock Fans Air Filter vi M-490B

9 CHAPTER 8 - TORQUE LIMITER RESET PROCEDURES (GE Fanuc Control) Introduction Turret Top Plates Editing Machine Parameters Machines with VDI Turret Top Plates Resetting the Z Axis Torque Limiter Resetting the X Axis Torque Limiter Machines with Hardinge Turret Top Plates Resetting the Z Axis Torque Limiter Resetting the X Axis Torque Limiter Machines with ESA Turret Top Plates Resetting the Z Axis Torque Limiter Resetting the X Axis Torque Limiter Turret Top Plate Zero Return Procedure Live Tool Torque Limiter Sub-Spindle E Axis Torque Limiter Torque Limiters on Super-Precision Machines Resetting the X or Z Axis Torque Limiter CHAPTER 9 - TORQUE LIMITER RESET PROCEDURES (Siemens Control) Introduction Turret Top Plates X Axis Torque Limiter Reset Z Axis Torque Limiter Reset E Axis Torque Limiter Reset Live Tool Torque Limiter Reset Turret Top Plate Zero Return Procedure APPENDIX ONE - PREVENTIVE MAINTENANCE SCHEDULE Introduction A1-1 Standard Maintenance Schedule A1-1 8 Hours A Hours A Hours A Hours A Hours A Hours A1-2 Maintenance Schedule for Options A1-3 8 Hours A Hours A Hours A Hours A Hours A1-3 Non-Metallic Materials Typically Found in Hardinge Machine Construction A1-4 M-490B vii

10 APPENDIX TWO - ALARM AND OPERATOR MESSAGES (GE Fanuc Control) Alarm Messages A2-1 Operator Messages A2-8 APPENDIX THREE - ALARM AND OPERATOR MESSAGES (Siemens Control) Alarm Messages A3-1 Operator Messages A3-15 APPENDIX FOUR - MACHINE PHOTOGRAPHS viii M-490B

11 - NOTES - M-490B ix

12 - NOTES - x M-490B

13 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 Remove access cover "A", Figure 1.1, to gain access to the air control assembly, shown in Figure 1.2. The air control assembly consists of a filter/regulator, coalescing filter, air manifold, and pressure switch. Connect the air supply line directly to filter/regulator B, Figure 1.2. Install a quick-disconnect coupling to the filter/regulator or add an air lock-out valve as required. 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. A C B E D Figure Access Covers at Rear of Machine TP7384 Figure Air Panel TP7464 M-490B 1-1

14 SETTING THE MACHINE AIR PRESSURE 1. Remove access cover "A", Figure Turn the air supply to the machine ON. 3. Pull regulator knob C, Figure 1.2, 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. 4. Replace access cover "A", Figure 1.1. DRAIN THE FILTER BOWL - WARNING - If an air lock-out valve has been installed, do not attempt to block or look into the air port at the bottom of the valve while releasing air. - CAUTION - Air filter/regulator bowl on the bottom of B, Figure 1.2, must be drained once a day. If more frequent draining is required, it may be necessary to install an air dryer in the air line. The bowl on filter/regulator B, Figure 1.2, has a manual drain valve to remove contaminants from the system. Drain the filter bowl daily. Some bowls may have an automatic drain similar to coalescing filter D. - NOTE - The manual drain valve on the bottom of filter/regulator B has right-hand threads. 1. Make certain that the air source is connected and turned ON. 2. Remove access cover "A", Figure Unthread the manual drain valve on the bottom of the filter/regulator counterclockwise enough to drain the bowl. Thread the drain valve closed to seal the drain. 4. Check the drain on the bottom of coalescing filter D. Clean the bowls and valves as necessary. 5. Replace the access cover. 1-2 M-490B

15 CLEAN THE FILTER BOWLS 1. Power down the machine. 2. Remove access cover "A", Figure Turn the air supply to the machine OFF. 4. 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. 5. Pour out contaminants that are present in the filter bowls. 6. Wipe the bowls clean with a lint-free cloth and change the filter if necessary. 7. Insert each bowl under a filter head and tighten the sleeve clockwise to seat the bowl O-ring. 8. Grasp the sleeve and pull down to verify that the bowl is secure. 9. Turn the air supply to the machine ON. 10. Replace the access cover. M-490B 1-3

16 REPLACE THE FILTERS Drain the filter bowls on filter/regulator B, Figure 1.2, and coalescing filter D. Check the filter bowls daily for contaminants. Change the filters once a month or if the sight gauge on the coalescing filter head is red. 1. Power down the machine. 2. Remove access cover "A", Figure Turn the air supply to the machine OFF. 4. Replace the filter/regulator filter (Hardinge part number LC K) or coalescing filter (Hardinge part number LC ) 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. 5. Turn the air supply to the machine ON. 6. Power up the machine. 7. Set the regulator to 85 psi [5.9 bars] and check for air leaks. Correct any air leaks as necessary. 8. Set the regulator below 60 psi [4.2 bars] to test the pressure switch. The control will go into an Emergency Stop condition. 9. Set the regulator to an operating pressure between 70 psi to 90 psi [4.9 to 6.2 bars]. 10. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 11. Press the Reset key if it is still necessary to clear the alarm message from the control display. 12. Check the air system bowl for contamination, moisture, or air leaks. Correct any problems as necessary. 13. Replace the access cover. 1-4 M-490B

17 REPLACE AIR CONTROL ASSEMBLY COMPONENTS Filter/regulator B, Figure 1.2, or coalescing filter D 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. Remove access cover "A", Figure Turn the air supply to the machine OFF. 4. Remove the air assembly unit from the air panel. 5. Loosen the fittings and other components, as needed. 6. 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. 7. Replace the air control assembly or disassemble and replace the faulty component. 8. Mount the air control assembly to the air panel. 9. Fasten the drain tube(s) to the component drain(s). 10. If any air lines have been removed, connect the air lines. 11. Turn the air supply to the machine ON. 12. Power up the machine. 13. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 14. Press the Reset key if it is still necessary to clear the alarm message from the control display. 15. Set the regulator to an operating pressure between 70 and 90 psi [4.9 to 6.2 bars]. 16. Check the air system bowls for contamination, moisture, or air leaks. Correct any problems as necessary. 17. Replace the access cover. M-490B 1-5

18 REPLACING THE PRESSURE SWITCH Pressure switch F, Figure 1.3, 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. Remove access cover "A", Figure Turn the air supply to the machine OFF. 4. Disconnect the pressure switch cable from input/output module "G", Figure Press the retention ring on the fitting away from pressure switch "F" and pull the switch out of the fitting on the air manifold. 6. Disassemble the plug on the pressure switch cable and record the wire connections. 7. Mount the plug on the cable of the new pressure switch. 8. Press the replacement pressure switch into the fitting on the air manifold. 9. Connect the pressure switch cable to input/output module "G". 10. Turn the air supply to the machine ON. 11. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 12. Press the Reset key if it is still necessary to clear the alarm message from the control display. 13. Check the air system bowl for contamination, moisture, or air leaks. Correct any problems as necessary. 14. Replace the access cover. F G Figure Main Air Pressure Switch and Input/Output Module TP M-490B

19 THRU-SPINDLE AIR BLAST [Option] The thru-spindle air blast option carries air through the spindle(s) from the standard air system. It can be used on either the main spindle or the sub-spindle or it can be used on both spindles at the same time. When the machine s air system is active, air is directed from inside the spindle to clean chips from the spindle(s) and gripping surface(s). - NOTE - The thru-spindle air blast rotary union requires lubrication once a week. The spindle air blast carrier tube is sized for the inside diameter of the spindle and can be used with at a maximum speed of 5,000 rpm and a maximum air pressure of 150 psi [10 bar]. It is mounted and sealed within the spindle shaft, but can be removed when necessary. The thru-spindle air line is equipped with standard air fittings. ADDING OIL TO THE ROTARY UNION OR REMOVING THE AIR BLAST SHAFT FROM THE SPINDLE 1. Power down the machine. 2. Turn the air supply to the machine OFF. 3. Remove the spindle compartment cover to gain access to the thru-spindle air tube and air fitting. -OR- Remove the right end cover of the machine to gain access to the sub-spindle thru-spindle air tube and air fitting. 4. Disconnect the air line from the air fitting on the rotary union, as follows: A) Push the air line into the fitting I, Figure 1.4, and hold the compression ring IN. B) Pull the air line out of the fitting. I K J H Figure Spindle Collet Closer with Thru-Spindle Air Blast TP3707 M-490B 1-7

20 5. Secure thru-spindle bearing housing J and remove four screws K. 6. Carefully pull on the bearing housing to pull the air tube out just enough to turn the rotary union until the air fitting is on the bottom and the oil port (near the manufacturer s tag) is accessible on top. -OR- Continue to carefully pull on the bearing housing while supporting the air tube as it is removed from the spindle - NOTE - Lubricate rotary union H with light machine oil. Add oil through the spring-loaded oil port near the manufacturer s tag. MOUNTING THE AIR BLAST SHAFT IN THE SPINDLE 1. Put a light coat of grease on the air shaft O-rings. 2. Insert the thru-spindle air blast shaft into the spindle as follows: A) Align the nose of the air tube in the spindle opening and push the air tube into the spindle. B) As the rotary union approaches the bracket, turn it until the air fitting is aligned up and in the bracket slot. C) Continue to carefully push on the bearing housing until the air tube is all the way into the spindle. 3. Rotate the bearing housing to align the screws on the threaded holes. 4. Thread the screws in and torque to 120 lb-in. [14 N m] to secure the tube. 5. Push the air line into nylon compression ring on fitting I, Figure 1.4. Tug on the air line to seat the air line while making certain that it is secure. 6. Mount the spindle drive compartment cover or right end cover in place. 7. Turn the air supply to the machine ON. 8. Power up the machine. 9. Test and adjust the air flow as necessary. 1-8 M-490B

21 - NOTES - M-490B 1-9

22 - NOTES M-490B

23 CHAPTER 2 - COOLANT SYSTEM INTRODUCTION - WARNING - The machine must be powered down when the coolant system requires maintenance. - CAUTION - DO NOT plug the coolant line that provides chip flush between the turret and the tailstock or sub-spindle. Refer to page 2-4 for additional information. RS and SR 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 both turret top plates or through tool holders to directional balls, an optional thru-spindle coolant with separate pump 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/or the directional balls. Coolant drains into the tank through the chip pan. 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 with selected coolant. The coolant tank capacity is approximately 50 gallons [189 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. Coolant is delivered to the tip of the cutting tool through two holes in each station of the turret top plate. The direction is set by loosening the flathead socket screw and rotating the brass ball to a convenient position, then tighten the screw to hold the ball in place. These two holes also supply coolant to a drill or boring bar when mounted in an applicable tool holder. M-490B 2-1

24 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-490B

25 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-490B 2-3

26 CHIP FLUSH The chip flush feature delivers coolant to the area between the turret and tailstock or optional sub-spindle for the purpose of removing chips. The chip flush feature is active whenever the coolant pump is turned ON. DO NOT plug chip flush coolant nozzle "A", Figure 2.1, or coolant line "B", Figure 2.2. A B TP7114 Figure Chip Flush Coolant Nozzle Figure Chip Flush Coolant Line (Inside Right End of Machine) TP M-490B

27 CLEANING THE COOLANT FILTER The coolant filter element should be replaced when a pressure differential of 10 psi or greater is observed between the coolant filter gauges shown in Figure 2.3 or 2.4. The coolant filter housing should be cleaned whenever the filter element is replaced. The coolant filter will be mounted in one of the following locations at the right end of the machine: Externally, as shown in Figure 2.3. Internally, as shown in Figure 2.6. The coolant filter pressure gauges can be viewed from the right end of the machine. 1. Verify the machine is powered down. 2. If the coolant filter is mounted internally, remove access cover "C", Figure Wipe the filter housing and filter head, shown in Figure 2.3 or 2.6, clean with a lint-free cloth. Filter Head Filter Housing Pressure Gauges Figure Externally Mounted Coolant Filter TI7380 Figure Pressure Gauges for Internally Mounted Coolant Filter TI7463 C Filter Head Filter Housing Figure Access Covers at Rear of Machine TI7384 Figure Internally Mounted Coolant Filter TI7462 M-490B 2-5

28 - CAUTION - Use care not to spill the coolant contained in the filter housing. 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 filter element and the coolant in the filter housing. 8. Clean the inside of the filter housing. - NOTE - The Hardinge part number for the replacement filter element is SR T. 9. Install the new filter element in the filter body. 10. Slide the filter housing up into mounting position on the filter head. 11. Install the nut on the top of the filter unit to secure the filter housing to the filter head. 12. If the coolant filter is mounted internally, replace access cover "C", Figure M-490B

29 CLEANING THE COOLANT TANK 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 filter on the coolant pump 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. Disconnect the coolant hose from the coolant tank. 4. If the machine is equipped with a chip conveyor: - CAUTION - Exercise care not to lose the two washers located behind the mounting tabs on chip deflector "E", Figure 2.7. A) Remove the nuts and washers from mounting studs "D", Figure 2.7. B) Remove chip deflector "E". C) Remove the washers behind the chip deflector mounting tabs. 5. Move the tank into an area that is convenient to remove the metal chips and shavings. - WARNING - Use a rake and suitable container to remove metal chips and shavings from the chip pan. Injury may result from attempting to remove chips without a rake. Dispose of the chips and shavings in an environmentally safe manner. 6. Rake any chips present into a suitable container and dispose of them properly. 7. Pump the coolant from the tank. -or- Place a shallow pan under the tank drain on the right end of the tank and remove the pipe plug to drain the coolant from the tank. D E TI5403 Figure Chip Deflector at Left End of Coolant Tank (Machine with Chip Conveyor Only) M-490B 2-7

30 F G TI5529 Figure Coolant Tank without Chip Conveyor 8. If the machine is NOT equipped with a chip conveyor: - NOTE - Observe the position and orientation of covers "F" and the chip baskets located under cover "G", Figure 2.8. A) Remove covers "F", Figure 2.8. B) Remove cover "G". C) Remove the two chip baskets located under cover "G". 2-8 M-490B

31 H I K J TI5530 Figure Coolant Tank with Chip Conveyor If the machine is equipped with a chip conveyor: - NOTE - Chip deflectors "H", Figure 2.9, are located on both sides of the coolant tank. Observe the position and orientation of the two long covers located under the chip conveyor. Observe the position and orientation of the chip baskets located under cover "K", Figure 2.9. A) Remove two chip deflectors "H", Figure 2.9. B) Remove back support "I". C) Remove the screws, nuts, and washers located at "J" to release the chip conveyor from the coolant tank. D) Lift the chip conveyor out of the coolant tank. E) Remove the two long covers located under the chip conveyor. F) Remove cover "K". G) Remove the two chip baskets located under cover "K". M-490B 2-9

32 - WARNING - Wear protection and be careful when removing coolant, metal chips, and shavings from the tank. 9. Remove any coolant remaining in the tank and wipe it clean. 10. Shake out the metal chips from the chip screen (standard tank) and chip baskets. 11. Wipe the chip screen and chip baskets clean. 12. Wash the coolant tank, chip screen, and chip baskets with a cleaner recommended by the coolant manufacturer to remove any bacterial contamination. Flush the cleaner from the coolant tank and clean as recommended. 13. If necessary, apply pipe sealant to the pipe plug and thread it into the tank drain. 14. If the machine is NOT equipped with a chip conveyor: - CAUTION - DO NOT force the chip screen into the support frame. There is only one way for the screen to fit. A) Replace covers "F", Figure 2.8, on the support frame in the tank. B) Replace the two chip baskets. C) Replace cover "G". If the machine is equipped with a chip conveyor: A) Replace the two long covers. Orient as noted earlier in this procedure. B) Replace the two chip baskets. C) Replace cover "K", Figure 2.9. D) Set the chip conveyor into the coolant tank and position against the front wall of the coolant tank. E) Secure the chip conveyor to the coolant tank by installing the screws, nuts, and washers at "J". F) Install back support "I". G) Install two chip deflectors "H" M-490B

33 15. Position the tank under the machine. 16. Connect the coolant hose to the coolant tank. 17. Check inside the work area and make certain that coolant will drain into the chip pan. 18. If the machine is equipped with a chip conveyor: A) Install washers on mounting studs "D", Figure 2.7. B) Install chip deflector "E" and secure with washers, lock washers, and nuts. 19. Pour the coolant directly into the chip pan of the coolant tank. Fill the coolant tank to the covers. 20. Make adjustments to the coolant level and tank position as necessary before powering up the machine and turning the coolant ON. M-490B 2-11

34 VDI TURRET COOLANT FACILITIES Each tooling station has an opening at the back of the VDI turret top plate which aligns with the coolant bushing L, Figure 2.10, to carry coolant to the tool holders or nozzles. Coolant to the turret top plate stations is routed through a distribution block, turret base, coolant bushing, and the turret top plate to adjustable directional balls or to live tool holders with thru-tool coolant. 1. Move the turret to a convenient position toward the spindle centerline. 2. Power down the machine. 3. Remove the turret covers from the turret. 4. Leave the rear cover on the turret unless the machine has live tooling. If the machine has live tooling, remove the screws, loosen the silicone bead, and lift the cover from the live tooling drive motor. 5. Remove the universal fitting to disconnect the coolant hose. 6. Wash all the parts in cleaner recommended by the coolant manufacturer. 7. Clean the coolant path through the turret base and remove any obstructions. 8. Wipe each part dry with a lint free cloth and check them for burrs. Stone the parts smooth and clean as necessary. 9. Thread the coolant hose universal fitting to the connector. Tighten the fitting. 10. Seal the gap between the cover and turret sheet metal with a bead of silicone and remount the turret covers. Tighten the screws. 11. Power up the machine, Activate the turret coolant flow. Check the turret area for coolant leaks and correct them as necessary. L Figure Turret Coolant Bushing TP M-490B

35 SPINDLE COOLANT CATCHER The coolant catcher returns coolant that flows through the rear of the spindle. A hose connected to the coolant catcher drain returns coolant to the coolant tank through an opening in the headwall. If the rest of the coolant system is being cleaned, the catcher and return hose should also be cleaned. CLEANING THE SPINDLE COOLANT CATCHER 1. Power down the machine. - CAUTION - Spindle access cover "M", Figure 2.11, must be taken straight off when it is removed. Remove the bottom two screws; support the cover while removing the top left screw and, then, the top right screw. Lift the cover straight off. 2. Release coolant catcher cover M, Figure 2.11, and lift it off. 3. Wipe out any coolant and chips. 4. Wash the coolant catcher with a cleaner recommended by the coolant manufacturer. 5. Flush and then check the coolant tank to see that the cleaner flows into the tank. 6. Clean again and/or remove the hose at the connector to clean it if necessary. 7. Mount the coolant catcher cover in place. 8. Clean and then ready the coolant tank as described earlier in this chapter. 9. Fill the tank with coolant. 10. Power up the machine and test the coolant flow. M Figure Spindle Coolant Catcher Access Cover TP7298 M-490B 2-13

36 INSTALLING THE DRAW TUBE PLUG The spindle draw tube plug can be inserted into the end of the spindle, as shown in Figure It stops coolant and chips when a bar feed is not used with the machine. Power down the machine; remove the coolant catcher cover; place the spindle draw tube plug into the draw tube all the way up to the flange; insert a small rod or hex wrench through the plug shaft hole and turn it clockwise to expand the rubber seal until the plug is secure within the draw tube. Remove the rod or wrench before mounting the cover on the coolant catcher and powering up the machine. TP4263 Figure Spindle Coolant Catcher 2-14 M-490B

37 THRU-SPINDLE COOLANT [Option] The thru-spindle coolant option carries coolant through the spindle from an additional coolant system. When the machine coolant system is active, coolant can be directed from inside the spindle to clean chips from the spindle and gripping surface(s). - CAUTION - Never run the spindle with the thru-spindle coolant tube in place and the coolant turned OFF. - NOTE - The thru-spindle coolant tube does not require lubrication other than coolant going through the tube while the spindle is turning. The spindle coolant carrier tube is sized for the inside diameter of the spindle. It is mounted and sealed within the spindle, but can be removed when necessary. The thru-spindle coolant line is tapped into the turret coolant line and has an in-line quick-disconnect coupling. The ½-20 threaded coolant tube tip makes it possible to create and mount specialized nozzles. REMOVING THE COOLANT TUBE FROM THE SPINDLE 1. Power down the machine. - CAUTION - Spindle access cover M, Figure 2.11, must be taken straight off when it is removed. 2. Remove cover "M", Figure 2.11, to gain access to the thru-spindle coolant tube and quick-disconnect coupling. 3. Pull back on the knurled ring and unfasten the quick-disconnect coupling in the coolant line. 4. Secure the thru-spindle bearing housing and unthread the four screws. 5. Carefully pull on the bearing housing to pull the coolant tube from the spindle. Continue to pull on the bearing housing while supporting the coolant tube as it is removed. M-490B 2-15

38 MOUNTING THE COOLANT TUBE IN THE SPINDLE 1. Put a light coat of grease on the coolant tube O-rings. 2. Align the nose of the coolant tube in the spindle opening and push the tube into the spindle. As the rotary union approaches the bracket, turn it until the coolant plumbing is aligned in the bracket slot. Continue to carefully push on the bearing housing until the coolant tube is all the way into the spindle. 3. Rotate the bearing housing to align the screws with the threaded holes. 4. Install the screws and torque to 120 lb-in. [14 N m] to secure the coolant tube in the spindle. 5. Pull back on the knurled ring and fasten the quick-disconnect coupling. Check the coupling to make certain that it is fastened securely. 6. Install cover "M", Figure Power up the machine. 8. Test and adjust the coolant flow as necessary. LIVE TOOLING The live tooling attachments require grease each month. Refer to Chapter 5 for information on lubricating live tooling attachments M-490B

39 TRAMP OIL PAN - WARNING - Dispose of waste oil in accordance with all applicable government guidelines. DO NOT introduce the waste oil into the hydraulic system. - NOTE - The tramp oil pan is only used on machines equipped with the HydroGlide hydrostatic linear guideway option. The machine has been designed to keep contamination of the coolant by the oil used for the hydrostatic linear guideways to a minimum. The oil drains from the machine and is collected in the tramp oil pan. The pan should be removed and emptied once a day. Empty the pan and place it back into position. 1. Slide the tramp oil pan under the hydraulic units platform. Refer to Figure Insert the end of tramp oil return line into the pan. Pan Location Figure Tramp Oil Pan Partially in Position TP7395 M-490B 2-17

40 - NOTES M-490B

41 CHAPTER 3 - STANDARD HYDRAULIC SYSTEM INTRODUCTION - WARNING - The machine must be powered down when the hydraulic system requires maintenance. - NOTE - This chapter covers the maintenance of the standard hydraulic system. Refer to Chapter 4 for information relating to the additional hydrostatic hydraulic system on machines equipped with the HydroGlide hydrostatic linear guideway system. The standard hydraulic system is located at the rear of the machine on a platform. Hydraulic pressure is used to operate the main collet closer, spindle brake, turret, and either tailstock carriage or sub-spindle collet closer. The hydraulic pressure is controlled, as required by each function, at the right end of the machine. The hydraulic system is equipped with a 5-micron filter. Refer to page 3-4 for information on filter replacement. SYSTEM SPECIFICATIONS Hydraulic Oil: Mobil DTE-13M oil Approximate Hydraulic Tank Capacities Machine equipped with a Tailstock: 15 gallons [57 liters] Machine equipped with a Sub-Spindle: 20 gallons [76 liters] M-490B 3-1

42 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 should be cleaned every 160 hours of operation to ensure maximum heat dissipation. MACHINES EQUIPPED WITH HYDROSTATIC LINEAR GUIDEWAYS Machines equipped with hydrostatic linear guideways are equipped with two hydraulic units and two heat exchangers. The standard hydraulic unit and associated heat exchanger are located to the left of the hydrostatic units, as viewed from the back of the machine. Remove access cover "A", Figure 3.1, to gain access to the heat exchanger for the standard hydraulic unit. MACHINES EQUIPPED WITH STANDARD LINEAR GUIDEWAYS Machines equipped with standard linear guideways are equipped with one hydraulic unit and one heat exchanger. Remove access cover "B", Figure 3.1, to gain access to heat exchanger "D", Figure 3.2. A B D C Figure Access Covers at Rear of Machine TP7384 TP7399 Figure Hydraulic Heat Exchanger 3-2 M-490B

43 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. Remove access cover "C", Figure Wipe filler cap E, Figure 3.3, and the area around the cap clean with a lint-free cloth. - 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-13M hydraulic fluid until sight gauge F is filled. 5. Replace the cap when filling is completed. 6. Replace the access cover. 7. Wait 10 minutes to allow any air in the oil to escape before powering up the machine. E F Figure Hydraulic Tank Filler Cap (Machine With Tailstock or High Speed Sub-Spindle) TP7394 M-490B 3-3

44 HYDRAULIC FILTER REPLACEMENT The filter should be checked by viewing red indicator G, Figure 3.4. Filter Replacement Interval Machines Not Equipped with a Sub-Spindle 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. Machines Equipped with a Sub-Spindle Replace the filter element after 2000 hours of operation or if the red indicator has tripped. Replacing the Filter Element 1. Power down the machine. 2. Remove access cover "C", Figure Check red indicator G, Figure 3.4 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. - CAUTION - The filter bowl contains hydraulic oil. Exercise care not to spill the oil. 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. G H I Figure Hydraulic Filter TP M-490B

45 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. 9. Thread the filter bowl onto the filter head hand tight. 10. Reset the red indicator by pressing down on the flexible dome. 11. Fill the tank with hydraulic fluid. 12. Wait 10 minutes for air in the oil to dissipate and power up the machine. 13. Check for hydraulic fluid leaks around the filter bowl. Tighten the bowl if necessary. 14. Replace the access cover. M-490B 3-5

46 - NOTES M-490B

47 CHAPTER 4 - HYDROSTATIC HYDRAULIC SYSTEM INTRODUCTION - WARNING - The machine must be powered down when the hydrostatic hydraulic system requires any type of maintenance. DO NOT repair leaks or tighten fittings until the machine is powered down. Serious personal injury can result if maintenance is attempted while the machine is powered up. - NOTE - The hydrostatic hydraulic system is only on machines equipped with the optional HydroGlide hydrostatic linear guideway system. This additional hydraulic system does not replace the standard hydraulic system. Refer to Chapter 3 for information relating to standard hydraulic systems. The hydrostatic hydraulic system is located on a platform at the rear of the machine. The hydrostatic hydraulic unit provides hydraulic oil under pressure to the linear guideway trucks on the X and Z axes. OPERATING PRESSURE The recommended operating pressure is 1000 psi [69 bar]. If the hydraulic pressure supplied to the hydrostatic linear guideways falls below 800 psi [55 bar], an alarm message appears on the control display and the control goes into Emergency Stop. Possible causes for low hydraulic pressure are: System filter needs to be replaced. Refer to page 4-5. Hydraulic unit pump motor is faulty. SYSTEM SPECIFICATIONS Hydraulic Oil: Mobil DTE-18M oil Approximate Hydraulic Tank Capacity: 10 gallons [38 liters] M-490B 4-1

48 HYDRAULIC HEAT EXCHANGER The hydrostatic hydraulic unit is equipped with a heat exchanger to reduce and stabilize the temperature of the hydraulic oil. The heat exchanger should be cleaned every 160 hours of operation to ensure maximum heat dissipation. Remove cover "A", Figure 4.1, to gain access to the heat exchanger shown in Figure 4.2. A B Figure Access Covers at Rear of Machine TP7384 Figure Hydrostatic Hydraulic System Heat Exchanger TP M-490B

49 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 The tank should be filled whenever the hydraulic fluid level drops below sight gauge B, Figure NOTE - Use only Mobil DTE-18M hydraulic fluid in the hydrostatic hydraulic unit. It is recommended that the machine not be powered up for at least 10 minutes after oil has been added to the hydraulic tank. This will allow any air bubbles present in the oil to dissipate. It is recommended that the hydraulic oil be pre-filtered to 5 micron maximum particle size before being added to the hydraulic system. The fluid capacity of the tank is approximately 10 gallons [38 liters]. 1. Power down the machine. 2. Remove cover "B", Figure Remove cap C, Figure 4.3, and SLOWLY fill the tank with Mobil DTE-18M hydraulic fluid until sight gauge D is filled. 4. Replace cap C. 5. Replace cover "B", Figure 4.1. C D Figure Top View of Hydraulic System TP5765 M-490B 4-3

50 REPLACING THE BY-PASS FILTER The hydraulic system by-pass filter is located on the right side of the hydraulic tank. Check the filter pressure daily by viewing red indicator E, Figure 4.4. If the red indicator has popped up (extended), try to reset it by gently pressing down on the dome. Replace the filter element after 1000 hours of operation or if the indicator doesn t reset. 1. Power down the machine. 2. Remove cover "B", Figure Check red indicator E, Figure 4.4, 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. 4. Unthread filter bowl E from the filter head until it drops from the head. - WARNING - 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. Pour 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 shop cloth 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. - NOTE - It is recommended that the hydraulic oil be pre-filtered to 5 micron maximum particle size before being added to the hydraulic system. 9. Thread the filter bowl onto the filter head hand tight. 10. Reset the red indicator by pressing it down. E 11. If necessary, fill the tank with hydraulic fluid. - NOTE - It is recommended that the machine not be powered up for at least 10 minutes after oil has been added to the hydraulic tank. This will allow any air bubbles present in the oil to dissipate. 12. Power up the machine. 13. Check for hydraulic fluid leaks around the filter bowl. Tighten the bowl if necessary. 14. Replace cover "B", Figure 4.1. F Figure Hydraulic System By-Pass Filter (Right Side View) TP M-490B

51 REPLACING THE SYSTEM FILTER - NOTE - The machine will issue an alarm message if the hydraulic pressure to the linear guideway trucks drops below 800 psi [55 bar]. The hydraulic system filter is located at the front of the hydraulic tank. This filter will need to be replaced when the difference in pressure between gauges G and H, Figure 4.5, is 150 psi [10.4 bar] or greater. 1. Power down the machine. 2. Remove cover "B", Figure Unthread filter bowl I, Figure 4.6, from the filter head until it drops from the head. - WARNING - Dispose of oil in the filter bowl in accordance with all applicable government guidelines. DO NOT introduce the oil back into the hydraulic system. 4. Pour the oil from the filter bowl. Wipe the bowl clean with a lint free cloth. 5. Clean the bowl with solvent recommended by the hydraulic oil manufacturer. Wipe it dry with a lint free cloth. 6. Wrap the filter element in a shop cloth and pull it straight down to release it from the nipple in the filter head. 7. Install a new filter element by gently pressing it onto the nipple. G H I Figure 4.5 Hydraulic System Pressure Gauges TP5787 Figure Hydrostatic Hydraulic Unit TP5766 M-490B 4-5

52 8. Thread the filter bowl onto the filter head hand tight. - NOTE - It is recommended that the hydraulic oil be pre-filtered to 5 micron maximum particle size before being added to the hydraulic system. 9. If necessary, fill the tank with hydraulic fluid. - NOTE - It is recommended that the machine not be powered up for at least 10 minutes after oil has been added to the hydraulic tank. This will allow any air bubbles present in the oil to dissipate. 10. Power up the machine. 11. Check for hydraulic fluid leaks around the filter bowl. Tighten the bowl if necessary. 12. Replace cover "B", Figure M-490B

53 - NOTES - M-490B 4-7

54 - NOTES M-490B

55 CHAPTER 5 - LUBRICATION INTRODUCTION - WARNING - The machine must be powered down when the grease lubrication system requires maintenance. - NOTE - In additional to the grease lubrication system, machines equipped with the live tooling option are also equipped with an oil lubricator. The oil lubricator supplies Mobil DTE 24 oil to the live tooling drive shaft and pinion gears in the turret. Refer to page 5-7 for information on the oil lubrication system. RS and SR machines are equipped with a grease lubrication system, which supplies grease to the following machine components: All axis ball screws X and Z axis truck bearings on machines equipped with the standard linear guideways Y axis truck bearings on machines equipped with Y axis [Option] Tailstock truck bearings on machines equipped with a tailstock [standard] Sub-spindle truck bearings on machines equipped with a sub-spindle [option] 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-490B 5-1

56 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. Machines equipped with HydroGlide hydrostatic linear guideways are not equipped with grease manifolds for the X and Z axes. The X and X axes each have a single grease fitting to lubricate the associated ball screw. The center port on the grease manifolds (labeled BS ) feeds the ball screw for the associated axis. KLÜBER Isoflex NCA 15 or NBU 15 grease (Hardinge grease cartridge part number TT NCA or HS SL) 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 Standard Linear Guideway Grease Volume X Axis 4 cc 7 cc Y Axis 3 cc 7 cc Z Axis 10 cc 7 cc E Axis (Sub-Spindle) 10 cc 7 cc Tailstock (no ball screw) 3.5 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 Standard Linear Guideway Lube X Axis 4½ strokes 8 strokes Y Axis strokes 8 strokes Z Axis 11.5 strokes 8 strokes E Axis (Sub-Spindle) 11.5 strokes 8 strokes Tailstock (no ball screw) 4 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. 5-2 M-490B

57 LUBRICATION PROCEDURE 1. Wait for the cycle to end and that the spindles and slides are stationary. 2. Open the right end of the machine to gain access to the grease manifolds and fittings shown in Figures 5.1 through At the back of the machine, remove the upper service cover to gain access the grease manifold shown in Figure Jog the axes until the grease fittings on the manifolds are accessible. YAxis Manifold Sub-Spindle Manifold XAxis Manifold TP5062 Figure 5.1 -X&Y Axes Grease Manifolds (Machine Equipped with Standard Linear Guideways) TP4823 Figure Sub-Spindle Grease Manifold Tailstock Manifold Figure Tailstock Grease Manifold TP4098 M-490B 5-3

58 5. Power down the machine. 6. Wipe each grease fitting clean. - NOTE - Only use a manually operated grease gun. The tailstock grease manifold, shown in Figure 5.3, has four grease fittings. There is no ball screw on the tailstock. 7. 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. 8. Wipe the fittings clean of excess grease. 9. Install the service covers. 10. Power up the machine. 11. Press the Reset and Feed Hold push buttons simultaneously to clear the lubrication alarm. 12. Jog the axes at 50% of the maximum rapid traverse for a full 30 minutes before resuming automatic machine operation. XAxis Fitting ZAxis Fitting ZAxis Manifold TP5764 Figure X and Z Axis Grease Fittings (Machine Equipped with HydroGlide Hydrostatic Linear Guideways) Figure Z Axis Grease Manifold (Machine Equipped with Standard Linear Guideways) TP M-490B

59 REPLACING A GREASE LUBRICATION LINE 1. Wait for the cycle to end and make certain all machine motion has stopped. 2. Open the right end of the machine to gain access to the grease manifolds and fittings shown in Figures 5.1 through or- At the back of the machine, remove the upper service cover to gain access the grease manifold shown in Figure Jog each axis until the grease/lubrication lines are accessible. 4. Power down the machine. - NOTE - Replace the grease lubrication lines one line at a time. 5. Check each grease lubrication line for damage. Before disconnecting the line being replaced, measure the length and check the route to either linear guide or ball screw. The ball screw lubrication line connects to the middle fitting on the grease manifold marked BS. There is no middle fitting on the tailstock manifold because the tailstock is not equipped with a ball screw. 6. Disconnect the grease lubrication line and compare the length to be sure the replacement line is the same length as the original line. 7. Before installing the replacement line, fill the line with KLÜBER Isoflex NCA 15 or NBU 15 grease. 8. Connect one end of the replacement line at the grease manifold and add the specified grease through the fitting until grease appears at the other end of the truck or ball screw line; then, connect that end of the line. Repeat the process for each grease lubrication line being replaced. 9. Wipe the fittings clean of excess grease. 10. Close any access doors that were opened and install any access covers that were removed. 11. Power up the machine. 12. Jog the axes at 50% of the maximum rapid traverse for a full 30 minutes before resuming automatic machine operation. M-490B 5-5

60 Z AXIS WAY COVER GUIDE ROD GREASE LUBRICATION Grease is used to lubricate Z axis way cover guide rod A, Figure 5.6, on top of the machine. Black Molylube Anti-Seize grease (Hardinge grease cartridge part number HG ) is recommended. - NOTE - The Z axis way cover guide rod must be inspected and lubricated every 160 hours (once a month) of operation. 1. Move the turret to the Z axis reference position (turret far right in work area, guide bushings far left as viewed from rear of machine in Figure 5.6). - NOTE - It may be more convenient to remove the rear sheet metal cover. 2. At the rear of the machine, stand on a ladder or substantial support to gain access to the Z axis way cover guide rod A, and guide bushings B. 3. Use a lint-free cloth to wipe chips and debris from the rod and bushings. - NOTE - If the guide bushings have a grease fitting, only use a manually operated grease gun. 4. Apply a light coat of grease the entire length of the guide rod. If there are grease fittings, attach the grease gun nozzle to a grease fitting; slowly and evenly pump in the specified grease until it is viewed around the bushing near the rod. 5. If necessary, wipe the fittings clean of excess grease and, then, mount the rear sheet metal cover. 6. Resume machine maintenance or operation. B B A TP4264 Figure Z Axis Way Cover Guide Rod 5-6 M-490B

61 OIL LUBRICATION SYSTEM INTRODUCTION The oil lubrication system is present on all RS and SR machines equipped with the live tooling option. This lubrication system automatically supplies oil to the live tooling pinion gears in the turret whenever the control is ON. The lubrication system is designed to use Mobil DTE 24 oil. Oil introduced into this lubrication system must be clean and free of moisture. Lubricator oil consumption will vary, depending on machine usage. To minimize oil consumption, put the machine into Emergency Stop or turn the control OFF whenever the machine is not in operation. C The oil lubrication system is mounted in one of the following locations Externally mounted at the right end of the machine, as shown in Figure 5.7. D Internally mounted at the back of the machine, as shown in Figure 5.8. The internally mounted lubricator is located behind access cover "F", Figure 5.9. E Figure Externally Mounted Oil Lubrication System TP7378 C F D E Figure Internally Mounted Oil Lubrication System TP7467 Figure Access Covers at Rear of Machine TP7384 M-490B 5-7

62 CHECKING THE OIL LEVEL AND FILLING THE LUBRICATOR - WARNING - The oil lubricator is pressurized. Turn the machine control OFF before attempting to remove threaded filler plug "H", Figure 5.10, from the top of the reservoir. - CAUTION - Do not overfill the lubricator. The maximum oil level is approximately ½ inch [12 millimeters] from the top of the sight gauge. - NOTE - The lubricator oil level should be checked at least once per month. View the oil level in sight gauge "E", Figure 5.7 or 5.8. If it is necessary to fill the lubricator: 1. Turn the machine control OFF. 2. Slowly remove threaded plug "H", Figure 5.10, from the top of the lubricator. 3. Insert a small funnel into the filler hole and fill the lubricator to within ½ inch [12 millimeters] of the top of the sight gauge. 4. Install the threaded plug. F G H Figure Top of Oil Lubricator TP M-490B

63 CHECKING AND ADJUSTING THE OIL FLOW The correct drip rate is once every five to seven seconds. View the drip rate at "G", Figure If it is necessary to adjust the drip rate: Turn knob "F" clockwise to decrease the drip rate. Turn knob "F" counterclockwise to increase the drip rate. CHECKING AND ADJUSTING THE LUBRICATOR AIR PRESSURE The correct lubricator air pressure is 15 psi [1 bar]. View the air pressure on gauge "C", Figure 5.7 or 5.8. If it is necessary to adjust the air pressure: 1. Pull knob "D" downward to unlock. 2. Rotate the knob to set the air pressure to 15 psi [1 bar]. 3. Press the knob upward to lock the setting. OIL SEEPAGE The O-ring has been removed from some of the clamp screws on VDI turret top plates to allow for a minimal amount of oil seepage. Refer to Figure The O-ring has been removed from some of the clamp buttons on ESA turret top plates to allow for a minimal amount of oil seepage. Refer to Figure Clamp Screw Clamp Button TI5483 TI5484 Figure VDI Turret Top Plate Figure ESA Turret Top Plate M-490B 5-9

64 TURRET LUBRICATION Live tooling is an optional feature. - NOTE - The turret index shaft and live tooling drive shaft must be lubricated every 2000 hours of operation. KLÜBER Isoflex NCA 15 or NBU 15 grease (Hardinge grease cartridge part number TT NCA or HS SL) is recommended for the index shaft and live tooling drive shaft. 1. Move the turret to a convenient position to access top plate cover I, 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. 6. Remove six screws J and the associated lock washers to remove turret cover I. I J Figure Turret Top Plate Cover TP M-490B

65 K K L Figure Non-Live Tooling Turret TP7213 Figure Live Tooling Turret TP7212A - NOTE - Use a manually operated grease gun. Use KLÜBER Isoflex NCA 15 or NBU 15 grease. 7. Grease the turret index shaft: A) Attach the grease gun nozzle to grease fitting "K", Figure 5.14 or B) Slowly and evenly pump in 4.0 cc (4.5 strokes) of the specified grease. 8. If the machine is equipped with live tooling, grease the live tool drive shaft: A) Attach the grease gun nozzle to grease fitting "L", Figure B) Slowly and evenly pump in 4.0 cc (4.5 strokes) of the specified grease. 9. Wipe any excess grease from the fitting(s). 10. Install top plate cover I, Figure 5.13, using six screws J and the associated lock washers. Torque the screws to 120 Ib-in [13.6 N m]. M-490B 5-11

66 LIVE TOOL HOLDER LUBRICATION The live tool holders are factory set to be on center and should require no further adjustment. Verify the drive shaft spline is lightly lubricated with Molylube Anti-Seize grease and that the tool holder is flush or seated flat against the live tooling drive block. - NOTE - Do not disassemble the live tool holder. Return the entire assembly to Hardinge Inc. if repairs are necessary. The live tool holder must be removed from the turret top plate each 160 hours to be inspected and lubricated. Apply a light coat of Molylube Anti-Seize grease to the live tool holder spline when mounting in the drive block. 1. Move the turret and index the turret top plate to a convenient position where the live tool holder can be removed. 2. Open the coolant guard door. 3. Wipe coolant, chips, and other contaminants from the live tool holder and turret top plate. 4. Remove the live tool holder from the turret top plate. 5. Inspect the live tool holder for wear and the amount of grease on spline M, Figure Check O-ring N to be sure it is in good condition. 7. Mount the live tool holder on the turret top plate. 8. Close the coolant guard door. N M Figure VDI Cross-Working Live Tool Holder Shown TP M-490B

67 - NOTES - M-490B 5-13

68 - NOTES M-490B

69 CHAPTER 6 - SPINDLE DRIVES - NOTE - This chapter applies only to machines equipped with standard spindle drives. Machines equipped with high speed spindle drives are not equipped with drive belts or external spindle drive motors. MAIN SPINDLE DRIVE BELT TENSION ADJUSTMENT - WARNING - The machine must be powered down when the main spindle drive requires maintenance. DO NOT attempt to perform maintenance until the machine is powered down. Serious personal injury can result if main spindle drive maintenance is attempted while the machine is powered up. 1. Power down the machine. 2. Remove draw tube access cover "B", Figure Remove spindle compartment cover "A". 4. Loosen, but do not remove, four screws "C", Figure 6.2 or 6.3, that secure the motor mounting plate to the machine base. A B Figure Left End of Machine TP7298 M-490B 6-1

70 D D C C Figure Main Spindle Motor Mounting Plate (RS 42 Lathes) TP6014 Figure Main Spindle Motor Mounting Plate (RS 51, RS 65, SR 150, and SR 200 Lathes) TP NOTE - Check belt tension across all strands of the drive belt simultaneously. 5. Check the drive belt tension on one side of the belt at a point midway between the spindle pulley and the drive motor pulley. Refer to the following chart for belt tension values: Machine Model New Belt Tension Used Belt Tension RS 42 Lathes RS 51 / SR 150 Lathes RS 65 / SR 200 Lathes.266 Inch deflection at to lb [6.76 mm deflection at 7.48 to 7.98 Kg].285 Inch deflection at to lb [7.24 mm deflection at to Kg].296 Inch deflection at to lb [7.52 mm deflection at to Kg].266 Inch deflection at to lb [6.76 mm deflection at 6.48 to 6.98 Kg].285 Inch deflection at to lb [7.24 mm deflection at to Kg].296 Inch deflection at to 50.0 lb [7.5 mm deflection at to Kg] 6-2 M-490B

71 6. Rotate adjusting screw "E", Figure 6.4, to move the motor mounting plate as needed to obtain the proper drive belt tension. 7. Secure the motor mounting plate to the machine base by tightening four screws "C", Figure 6.2 or 6.3, to 200 lb-ft [271 N m]. 8. Replace spindle compartment cover "A", Figure Replace draw tube access cover "B". E Figure Adjusting Screw for Main Spindle Motor TP5955 M-490B 6-3

72 SUB-SPINDLE DRIVE BELT TENSION ADJUSTMENT [Option] - WARNING - Be sure all personnel are clear of the machine when moving the machine axes. - NOTE - The machine will be powered up during this procedure. This procedure requires the use of a sonic belt tension meter. 1. If necessary, power up the machine. 2. Release the latch and remove access cover "A", Figure Move the sub-spindle (E axis) toward the right end of the machine to gain access to the rear screws on covers "B", Figure 6.6. Refer to the following procedure: A) Set the Machining Modes selector switch to Jog mode. B) Set the Manual Axis Movement selector switch to the E axis. C) Set the Feedrate Override switch to the desired setting. D) Press the appropriate Z/E push button to jog the sub-spindle in the desired direction. 4. Remove the rear screws from covers "B", Figure Move the sub-spindle (E axis) toward the main spindle as far as possible. The control will display an overtravel alarm. B A Figure Right End Access Door TP7375 TP6001 Figure Rear of Sub-Spindle Covers 6-4 M-490B

73 B D C TP6004 Figure Front of Sub-Spindle Covers Figure Bracket for Sub-Spindle Cable Carrier TP WARNING - Failure to put the machine into an Emergency Stop condition could result in severe personal injury. 6. Press the Emergency Stop push button. 7. Remove the front screws from covers "B", Figure NOTE - It is recommended to place a shop cloth on the machine where cable carrier bracket "D", Figure 6.8, will rest after the screws are removed. 8. At the right end of the machine, remove the screws from cable carrier bracket "D", Figure 6.8, to allow cable carrier "E", Figure 6.9, to be lowered to provide clearance for removing the sub-spindle covers. 9. Slide covers "B", Figure 6.6, out the end of the machine. E Figure Sub-Spindle Cable Carrier TP5999 M-490B 6-5

74 10. Loosen, but do not remove, four screws "G", Figure NOTE - Access to the sub-spindle drive belt is through opening "H", Figure Belt tension is checked with a sonic belt tension meter 11. Rotate adjusting screw "F", Figure 6.10, to move the motor mounting plate as needed to obtain the proper drive belt tension. Proper belt tension is as follows: Force: 813 to 871 Newtons Frequency: 195 to 202 Hertz Mass:.470 grams/cm 2 Belt Width: 12 millimeters Belt Span: 308 millimeters 12. Tighten four screws "G", Figure 6.10, to 85 lb-ft [115 N m]. 13. Replace covers "B", Figure Replace the front screws in covers "B", Figure Apply silicone grease to the front edges of the sub-spindle covers, indicated as "C", to seal the seams. 16. Lift cable carrier "E", Figure 6.9, back into position and secure cable carrier bracket "D", Figure 6.8, in position. 17. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 18. Press the control Reset key. 19. Move the sub-spindle toward the right end of the machine to gain access to covers "B", Figure Replace the rear screws in covers "B". 21. Install access cover "A", Figure 6.5, and secure the latch. F G Figure Sub-Spindle Motor Plate and Adjusting Screw H Figure Drive Belt Access TP5991 TP M-490B

75 - NOTES - M-490B 6-7

76 - NOTES M-490B

77 CHAPTER 7 - MISCELLANEOUS BATTERY REPLACEMENT GE FANUC CONTROL 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 battery units 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 battery units are a battery pack. - WARNING - High voltage AC will be present in the power case when the main disconnect switch is ON and when the control is ON. - CAUTION - 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. - NOTE - The control unit contains a lithium battery. Make certain that the replacement battery is like the battery being removed. Check the battery voltage and receptacle. M-490B 7-1

78 Replacing the 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 Specifications Manufacturer: Sanyo Electric Corp. Battery Number: CR17450SE-R Voltage Rating: 3 volt Battery Type: Lithium Use the following procedure to check or replace the control battery. 1. Power up the machine. 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 7.2, 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. C A B TP7373 Figure Upper Left End of Machine Figure Control Battery Unit TP M-490B

79 Replacing the Drive Unit Batteries - CAUTION - A fresh battery 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 Manufacturer: Panasonic Corp. Battery Number: BR-CCF2TH Voltage Rating: 6 volt Use the following procedure to check or replace the axis drive batteries. 1. Power down the machine. 2. Unlock and open the power case door. 3. Remove battery covers D, Figure 7.3, on the front panel of the drive units. Hold the battery cover by the top and bottom and squeeze the cover while pulling it off. - CAUTION - Do not disconnect the old battery until instructed. 4. Remove the old battery from the holder and verify that the new battery is like the battery being replaced. Mark the old battery for identification. D Figure Drive (Axes) Battery Units (Sub-Spindle Machine Shown) TP7397 M-490B 7-3

80 - NOTE - Each drive unit has two plugs for battery connection. 5. Install the fresh battery while the old battery is still connected, as follows: A) Remove the cap from the second (unoccupied) plug. The unoccupied plug does not have a battery receptacle attached to it. The plugs are near each other and are labeled. Either plug can be unoccupied. B) Connect the plug from the new battery to the second receptacle while the old battery is still connected. Refer to Figure 7.4. C) Disconnect the old battery and cap the receptacle. 6. Put the new battery in the battery holder and replace the battery cover. 7. Repeat the procedure for additional axis drive units. 8. Close and latch the power case door. 9. Dispose of the old battery properly. Figure Both Battery Packs Connected to Axis Drive Unit TP M-490B

81 SIEMENS CONTROL - 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. Check the age of the SRAM battery. Replace the battery if necessary: The control can temporarily maintain memory for approximately 30 minutes without the battery backup. Battery Specifications Manufacturer: Siemens AG Battery Number: 6FC5247-0AA18-0AA0 Voltage Rating: 3 volt Battery Type: Lithium Use the following procedure to check or replace the SRAM battery. 1. Power down the machine. 2. Unlock and open the power case door. 3. Gently press fan/battery module "E", Figure 7.5, backwards. This detaches the module E from the front interlock. 4. Tilt the fan/battery module forwards at an angle and pull out the plastic guide from the control unit cutout. 5. Remove battery "F", Figure 7.6, by first TP7459 removing the plug connector and then taking out the battery. Figure Fan/Battery Module 6. Connect the cable plug connector of the new battery to the mating connector in the fan/battery module and insert the battery. 7. Tilt the fan/battery module forwards at an angle with the open side facing up (battery visible). F 8. Push the plastic guide into the cutouts on the underside of the control unit. 9. Tilt the fan/battery module up until the front interlock snaps into place. 10. Close and latch the power case door. 11. Dispose of the old battery properly. Figure SRAM Backup Battery TP7460 M-490B 7-5

82 WORK LIGHT The work light is mounted on the right side wall above the main spindle. The work light is designed to use a 36 Watt (DWDC-136 B) fluorescent lamp. - WARNING - NEVER perform any work on the electrical components of this machine tool while the electrical power is ON. REPLACING THE LAMP OR STARTER 1. Power down the machine. 2. Open the coolant guard door. 3. Wipe the work light, work light brackets, and work light cable clean. 4. Remove two wing screws G, Figure 7.7, on the work light brackets, open the brackets, and remove the work light. 5. Loosen, but do not remove, the three screws in the right end cap. Hold the work light assembly and slide the guard tube from the assembly. 6. Replace the fluorescent lamp or starter, as necessary. - NOTE - During assembly, be certain that the end cap is seated tightly against the guard tube when the three screws are tightened. Tightening these screws causes the rubber seal to expand and grip the guard tube. 7. Hold the work light assembly and slide the guard tube up on the assembly. Fasten it by tightening the three screws. Secure the G screws, but do not over-tighten. 8. Mount the work light in the work light bracket and install both wing screws loosely. 9. Power up the machine. The light will turn ON when the machine powers up. 10. Adjust the work light by turning the guard tube. 11. Tighten the two wing screws to secure the work light. Figure Work Light TP M-490B

83 REPLACING THE BALLAST 1. Power down the machine. 2. Open the power case door. - NOTE - The ballast are located on the back of the hinged panel. 3. Loosen nut "H", Figure 7.8, and "I", Figure Swing the hinged panel open to gain access to ballast J, Figure 7.10 or Follow the wires from the ballast to the terminal block 6. Record the terminal block connections. 7. Disconnect the ballast wires from the terminal blocks. 8. Remove the ballast. 9. Mount the new ballast. 10. Connect the wires per step Swing the hinged panel into position and secure with nuts "H", Figure 7.8, and "I", Figure Close and lock the power case door. H Figure Top of Hinged Panel I Figure Bottom of Hinged Panel TP7402 TP7404 J J Figure Work Light Ballast (Machine with GE Fanuc Control) TP7403 Figure Work Light Ballast (Machine with Siemens Control) TP7471 M-490B 7-7

84 SUB-SPINDLE PARTS CATCHER [Option] The sub-spindle parts 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. There is limited adjustment that can be made in the event of a mishap. 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. When the parts grip arm requires maintenance or adjustment, the main door must be open and the machine powered up with the air turned OFF. - WARNING - All operating and maintenance procedures are to be performed by one person. Because 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. ADJUSTING THE ARM SWING (ROTATE) POSITION 1. The air-actuated arm rotate has several adjustments to position gripper K, Figure Mount a test part in the sub-spindle. Verify the position of the gripper in relation to the part and determine what direction, if any, the gripper needs to be moved. 3. If a set of gripper inserts (pads) needs to be bored for a part: A) Obtain a representative sample of the part that is going to be gripped. Measure the maximum outside diameter to be used. B) Mount a blank set of nylon gripper pads (Hardinge part number QC FPAD) K in the boring fixture. C) Mount the fixture with pads in the main spindle. D) Use the sub-spindle to bore the gripper pads. Bore the inside diameter of the pads to match the outside diameter of the part to be gripped. E) Remove the fixture and new pads from the main spindle and mount the pads to the gripper arm. Gripper Arm Figure Sub-Spindle Parts Catcher Gripper TP M-490B

85 4. Adjust the arm position as follows: A) With the air OFF, rotate the arm up to access the mounting screws in the slotted gripper arm. Loosen the screws just enough to be able to move the arm with light drag while positioning the gripper. B) 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. C) Adjust the length of the arm position and tighten the screws. Rotate the arm down. D) Power up the machine and turn the air ON. E) Check that the workpiece is in position with the sub-spindle collet closed. F) Use Manual Data Input mode to move the arm up to put the gripper in position. G) Jog the E axis (sub-spindle) holding the workpiece into the gripper. - NOTE - The gripper should not vibrate or move to accommodate the workpiece being gripped. There should be some clearance between the workpiece and gripper. H) Watch the gripper and workpiece while closing the gripper on the piece. Adjust the arm position as necessary. I) Turn the air OFF. Gently shake the arm assembly to seat the gripper on the part. Tighten the screws to secure the arm and the gripper. J) Turn the air ON. Open and close the gripper several times to verify the gripper fit on the workpiece. Make any arm or gripper adjustments as necessary. K) Open the gripper and jog the E axis back (retract) to Home position. Use Manual Data Input mode to move the arm down to the retract position. L) Test the arm and gripper position several times and make any adjustments as necessary. There should be no part drag on the workpiece. M-490B 7-9

86 5. Adjust the arm swing as follows: - NOTE - Stem L, Figure 7.13, is used to set the arm swing down (Home) position and usually does not require any adjustment. Threading stems L and M IN reduces the stroke, which shortens the arm rotation distance. Threading the stems OUT increases the stroke, which lengthens the rotation. A) Loosen the jam nut on stem L or M. Loosen the nut only enough to be able to adjust the stem. B) Adjust the stem. C) Tighten the jam nut to set the arm rotation position. D) Test the arm rotation travel several times using the M codes to rotate and retract the arm. Adjust the stem as necessary. 6. Remove the test part from the machine. N L Proximity (Sensor) Switch Arm Up/Gripper Extend Proximity (Sensor) Switch Arm Down/Gripper Home M O Figure Parts Gripper Mechanism TP M-490B

87 ADJUSTING THE ARM SWING (ROTATE) SPEED The air-actuated arm rotate speed is adjusted at valves N and O, Figure These valves control the amount of air applied to the piston in the air cylinder. Threading a valve IN reduces the swing speed. Valve "N" controls the arm down speed. Valve "O" controls the arm up speed. 1. Adjust the arm position as previously described. 2. Loosen the jam nut at valve N or O. 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 the valve as necessary. ADJUSTING THE PART PRESENT SENSOR The part present sensor is a proximity switch located on a slotted bracket on the gripper hand. When adjusted properly, it detects when a part is located in the gripper. As part production and part size change, the part present sensor must be adjusted. - NOTE - Be aware that because of the light torque specification and location of the switch, the bracket must be removed each time it requires adjustment in the bracket. 1. Locate where the part present sensor is on the bracket on the gripper. 2. Make certain that the new part will fit in the gripper. 3. Mount a test part in the sub-spindle exactly where a part would be located during the machine cycle. Verify that the arm and gripper have been adjusted to receive the new part. 4. Check the part present sensor in relation to the part and determine what direction, if any, the proximity switch needs to be moved. 5. Loosen the screws fastening the sensor s slotted bracket just enough to be able to adjust the bracket. 6. Set the proximity switch at or within.030 in. [.76 mm] from the test part. 7. Tighten the screws that mount the bracket to the gripper. 8. Check distance between the test part and the switch per step Adjust the bracket as necessary. 10. Return the arm to the Home position and remove the test part before running the machine. M-490B 7-11

88 HEADSTOCK FANS AIR FILTER The headstock fans have a filter on the front of machine that should be visually checked weekly or more frequently if the air is heavily contaminated because of the proximity to the floor. Failure to clean the air filter will cause a reduction in efficiency and lead to an increase in the headstock temperature. When installed, the foam air filter is located at "P", Figure CLEANING THE AIR FILTER 1. If the machine is equipped with the sliding filter frame shown in Figure 7.15: A) Move the coolant tank away from the machine. B) Slide the filter frame out far enough to remove foam air filter "Q". If the machine is equipped with filter cover "R", Figure 7,16, remove the cover. 2. Remove the foam filter from the machine. P Figure Air Filter Location TP7387 Q R Figure Air Filter Frame Partially Removed from Machine TP7388 Figure Air Filter Cover TP M-490B

89 3. Clean the foam air filter as follows: A) Wash the air filter clean in detergent and water. B) Squeeze out as much water as possible and allow it to air dry. 4. Install the foam filter. 5. If the machine is equipped with the sliding filter frame: A) Slide the filter frame back into position, as shown in Figure B) Move the coolant tank back into operating position under the machine. If the machine is equipped with filter cover "R", Figure 7,16, replace the cover. M-490B 7-13

90 - NOTES M-490B

91 CHAPTER 8 - TORQUE LIMITER RESET PROCEDURES (GE Fanuc Control) - NOTE - This information in this chapter is intended for machines equipped with a GE Fanuc control. 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 (sub-spindle option) Live tooling drive shaft (optional) in the turret - NOTE - Super-Precision machines may display GEF alarm message 345x Soft Disconnect. This alarm prevents moving the axis to reset the torque limiter. Refer to page 8-24 for information on resetting the axes on Super-Precision machines. TURRET TOP PLATES RS and SR series machines are available with the following types of turret top plates: Machine Series ESA Top Plate VDI Top Plate Hardinge Top Plate RS Standard Optional Optional SR Optional Standard Optional Reset procedures are presented according to the type of top plate. Refer to the appropriate torque limiter reset procedure, based on the configuration of the machine: VDI top plate, page8-3 Hardinge top plate, page 8-8 ESA top plate, page 8-14 M-490B 8-1

92 EDITING MACHINE PARAMETERS - CAUTION - Use extreme caution when editing machine parameters. Making incorrect changes in the parameter table may disable the machine or cause undesirable machine behavior. To change parameter settings during the torque limiter reset procedures, the Program Protect key must be set to 0 and Parameter Write Enable set to 1, as follows: 1. Press the Offset Setting key. 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 field. 4. If necessary, use the cursor keys to move the cursor to the Parameter Write field. 5. Set the mode selector switch to Manual Data Input mode. 6. Turn the Program Protect key to the OFF position. 7. Key in the number 1" to enable parameter editing. 8. Press the Input key. After the torque limiter has been reset, set the Parameter Write Enable to 0 and Program Protect key to M-490B

93 MACHINES WITH VDI TURRET TOP PLATES - NOTE - The torque limiter reset procedures in this section are intended for general precision machines. Refer to page 8-24 for information on resetting X and Z axis torque limiters on a Super-Precision machine. RESETTING THE Z AXIS TORQUE LIMITER After a collision, an axis alarm will be displayed stating which torque limiter has tripped. In Jog mode, use the MPG handle to move the Z axis away from the collision. 1. This procedure uses the face of the main spindle as the reference for resetting the Z axis. 2. Set the Mode Selector switch to Jog mode. 3. Use the MPG handle to move the Z axis away from the collision. 4. Mount a Hardinge TT or TT 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. 5. Set the Mode Selector switch to Manual Data Input mode. - NOTE - Refer to Editing Machine Parameters, page 8-2 for information on setting Parameter Write Enable. 6. Set the Program Protect key to 0 and Parameter Write Enable to Press the System key. 8. Press the Parameter soft key. 9. Key in Press the Number Search soft key. 11. Set parameter 1815 bit 4 Z to Press the Emergency Stop push button. 13. Turn the control OFF. 14. Wait a few seconds; then, turn the control ON. 15. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 16. Set the Mode Selector switch to Jog mode. M-490B 8-3

94 17. If the machine is set to inch mode, place a 3 inch gage block against the face of the spindle. If the machine is set to metric mode, place a 75 millimeter gage block against the face of the spindle. 18. Use the MPG handwheel to position the turret top plate for a slip fit of the gage block between the face of the tool holder and the face of the spindle. Refer to Figure Press the Position key. 20. Press the Relative soft key to display the relative position page. 21. Press the W key. 22. 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. 23. Press the Preset soft key. 24. Use the MPG handwheel to move the Z axis so that the Z Axis Relative Position is as follows: Inch Mode: W Metric Mode: W Set the Mode Selector switch to Manual Data Input mode. 26. Press the System key. 27. Press the Parameter soft key. 28. Key in Inches [Millimeters] 29. Press the Number Search soft key. Z Axis Position (See Note Below) 30. Set parameter 1815 bit 4 Z to Set the Parameter Write Enable to 0 and Program Protect key to Press the Reset key. 33. Press the Emergency Stop push button. 34. Turn the control OFF. 35. Wait a few seconds; then, turn the control ON. 36. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release [42.00] Tool Holder Main Spindle Gage Block NOTE: Z Axis Position = Gage Block + Tool Holder TT Tool Holder Figure VDI Top Plate, Reset Z Axis from the Main Spindle Face TI4797A 8-4 M-490B

95 RESETTING THE X AXIS TORQUE LIMITER After a collision, an axis alarm will be displayed stating what torque limiter is tripped. In Jog mode, use the MPG handle to move the X axis away from the collision. This procedure uses the edge of a known part or arbor as the reference for resetting the X axis. - NOTE - This procedure uses a sample part diameter of: 2 inches for the inch calculations 50 millimeters for the metric calculations 1. Set the Mode Selector switch to Jog mode. 2. Use the MPG handle to move the X axis away from the collision. 3. Mount a Hardinge TT or TT 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. 4. Set the Mode Selector switch to Manual Data Input mode. - NOTE - Refer to Editing Machine Parameters, page 8-2 for information on setting Parameter Write Enable. 5. Set the Program Protect key to 0 and Parameter Write Enable to Press the System key. 7. Press the Parameter soft key. 8. Key in Press the Number Search soft key. 10. Set parameter 1815 bit 4 X to Press the Emergency Stop push button. 12. Turn the control OFF. 13. Wait a few seconds; then, turn the control ON. 14. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 15. Set the Mode Selector switch to Jog mode. 16. If the machine is set to inch mode, place a 3 inch gage block against the edge of the part. If the machine is set to metric mode, place a 75 millimeter gage block against the edge of the part. M-490B 8-5

96 17. Use the MPG handwheel to position the turret top plate for a slip fit of the gage block between the edge of the tool holder and the edge of the part. Refer to Figure Calculate the X axis position: Inch Mode: [2 x (gage block )] + part diameter Metric Mode: [2 x (gage block )] + part diameter 19. Press the Position key. 20. Press the Relative soft key to display the relative position page. 21. Press the U key. 22. Key in the X axis position calculated in step 18 as a positive value. 23. Press the Preset soft key. 24. Use the MPG handwheel to move the X axis so that the X Axis Relative Position is as follows: Inch Mode: U Metric Mode: U Set the Mode Selector switch to Manual Data Input mode. 26. Press the System key. 27. Press the Parameter soft key. Inches [Millimeters] [65.00] Tool Holder TT (Radius Value) or [165.00] or [50.00] Gage Block Main Spindle Workpiece TI4800A Figure VDI Top Plate, Reset X Axis from Edge of Part 8-6 M-490B

97 28. Key in Press the Number Search soft key. 30. Set parameter 1815 bit 4 X to Set the Parameter Write Enable to 0 and Program Protect key to Press the Reset key. 33. Press the Emergency Stop push button. 34. Turn the control OFF. 35. Wait a few seconds; then, turn the control ON. 36. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. M-490B 8-7

98 MACHINES WITH HARDINGE TURRET TOP PLATES - NOTE - The torque limiter reset procedures in this section are intended for general precision machines. Refer to page 8-24 for information on resetting X and Z axis torque limiters on a Super-Precision machine. RESETTING THE Z AXIS TORQUE LIMITER After a collision, an axis alarm will be displayed stating which torque limiter has tripped. In Jog mode, use the MPG handle to move the Z axis away from the collision. This procedure uses the face of the main spindle as the reference for resetting the Z axis. Wipe clean the face and edge of the top plate that will be used to reset the turret. Index these cleaned surfaces toward the spindle centerline. 1. Set the Mode Selector switch to Jog mode. 2. Use the MPG handle to move the Z axis away from the collision. 3. Set the Mode Selector switch to Manual Data Input mode. - NOTE - Refer to Editing Machine Parameters, page 8-2 for information on setting Parameter Write Enable. 4. Set the Program Protect key to 0 and Parameter Write Enable 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 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 to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 14. Set the Mode Selector switch to Jog mode. 15. If the machine is set to inch mode, place a 3 inch gage block against the face of the spindle. If the machine is set to metric mode, place a 75 millimeter gage block against the face of the spindle. 8-8 M-490B

99 16. Use the MPG handwheel to position the turret top plate for a slip fit of the gage 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. 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: Inch Mode: W Metric Mode: W Set the Mode Selector switch to Manual Data Input mode. 24. Press the System key. 25. Press the Parameter soft key. Inches [Millimeters] or [75.00] Spindle Gage Block TI4856A Figure Hardinge Top Plate, Reset Z Axis from Spindle Face M-490B 8-9

100 26. Key in Press the Number Search soft key. 28. Set parameter 1815 bit 4 Z to Set the Parameter Write Enable to 0 and Program Protect key 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 to the first detent, wait two seconds; then, pull the push button out to the end of travel and release M-490B

101 RESETTING THE X AXIS TORQUE LIMITER This procedure uses the edge of a known part or arbor as the reference for resetting the X axis. - NOTE - This procedure uses a sample part diameter of: 2 inches for the inch calculations 50 millimeters for the metric calculations 1. Set the Mode Selector switch to Jog mode. 2. Use the MPG handle to move the X axis away from the collision. 3. Set the Mode Selector switch to Manual Data Input mode. - NOTE - Refer to Editing Machine Parameters, page 8-2 for information on setting Parameter Write Enable. 4. Set the Program Protect key to 0 and Parameter Write Enable 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 X 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 to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 14. Set the Mode Selector switch to Jog mode. 15. If the machine is set to inch mode, place a 3 inch gage block against the edge of the part. If the machine is set to metric mode, place a 75 millimeter gage block against the edge of the part. M-490B 8-11

102 16. Use the MPG handwheel to position the turret top plate for a slip fit of the gage block between the edge of the turret top plate and the edge of the part. Refer to Figure Calculate the X axis position: (2 x gage block) + part diameter 18. Press the Position key. 19. Press the Relative soft key to display the relative position page. 20. Press the U key. 21. Key in the X axis position calculated in step 17 as a positive value. 22. Press the Preset soft key. 23. Use the MPG handwheel to move the X axis so that the X Axis Relative Position is as follows: Inch Mode: U Metric Mode: W Set the Mode Selector switch to Manual Data Input mode. 25. Press the System key. 26. Press the Parameter soft key. (Radius Value) or [100.00] Gage Block Spindle Workpiece Figure Hardinge Top Plate, Reset X Axis from Edge of Part or [50.00] TI4858A 8-12 M-490B

103 27. Key in Press the Number Search soft key. 29. Set parameter 1815 bit 4 X to Set the Parameter Write Enable to 0 and Program Protect key 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 to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. M-490B 8-13

104 MACHINES WITH ESA TURRET TOP PLATES - NOTE - The torque limiter reset procedures in this section are intended for general precision machines. Refer to page 8-24 for information on resetting X and Z axis torque limiters on a Super-Precision machine. RESETTING THE Z AXIS TORQUE LIMITER After a collision, an axis alarm will be displayed stating which torque limiter has tripped. In Jog mode, use the MPG handle to move the Z axis away from the collision. This procedure uses the face of the main spindle as the reference for resetting the Z axis. 1. Set the Mode Selector switch to Jog mode. 2. Use the MPG handle to move the Z axis away from the collision. 3. Set the Mode Selector switch to Manual Data Input mode. - NOTE - Refer to Editing Machine Parameters, page 8-2 for information on setting Parameter Write Enable. 4. Set the Program Protect key to 0 and Parameter Write Enable 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 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 to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 14. Set the Mode Selector switch to Jog mode. 15. If the machine is set to inch mode, place a 3 inch gage block against the face of the spindle. If the machine is set to metric mode, place a 75 millimeter gage block against the face of the spindle M-490B

105 16. Use the MPG handwheel to position the turret top plate for a slip fit of the gage 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. 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: Inch Mode: W Metric Mode: W Set the Mode Selector switch to Manual Data Input mode. 24. Press the System key. 25. Press the Parameter soft key. Inches [Millimeters] 26. Key in Press the Number Search soft key. 28. Set parameter 1815 bit 4 Z to Set the Parameter Write Enable to 0 and Program Protect key 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 to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. Z Axis Position (See Note Below) Gage Block Main Spindle NOTE: Z Axis Position = Gage Block [35.00) [35.00] Figure ESA Top Plate, Reset Z Axis from the Main Spindle Face TI5567 M-490B 8-15

106 RESETTING THE X AXIS TORQUE LIMITER After a collision, an axis alarm will be displayed stating what torque limiter is tripped. In Jog mode, use the MPG handle to move the X axis away from the collision. This procedure uses the edge of a known part or arbor as the reference for resetting the X axis. - NOTE - This procedure uses a sample part diameter of: 2 inches for the inch calculations 50 millimeters for the metric calculations 1. Set the Mode Selector switch to Jog mode. 2. Use the MPG handle to move the X axis away from the collision. 3. Set the Mode Selector switch to Manual Data Input mode. - NOTE - Refer to Editing Machine Parameters, page 8-2 for information on setting Parameter Write Enable. 4. Set the Program Protect key to 0 and Parameter Write Enable 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 X 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 to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 14. Set the Mode Selector switch to Jog mode. 15. If the machine is set to inch mode, place a 3 inch gage block against the edge of the part. If the machine is set to metric mode, place a 75 millimeter gage block against the edge of the part M-490B

107 16. Use the MPG handwheel to position the turret top plate for a slip fit of the gage block between the edge of the turret top plate and the edge of the part. Refer to Figure Calculate the X axis position: Inch Mode: [2 x (gage block )] + part diameter Metric Mode: [2 x (gage block )] + part diameter 18. Press the Position key. 19. Press the Relative soft key to display the relative position page. 20. Press the U key. 21. Key in the X axis position calculated in step 17 as a positive value. 22. Press the Preset soft key. 23. Use the MPG handwheel to move the X axis so that the X Axis Relative Position is as follows: Inch Mode: U Metric Mode: U Set the Mode Selector switch to Manual Data Input mode. 25. Press the System key. 26. Press the Parameter soft key. Inches [Millimeters] Gage Block [35.000] (Diameter Value) or [130.00] Main Spindle Workpiece or [50.00] Turret Reference Position TI5568 Figure ESA Top Plate, Reset X Axis from Edge of Part M-490B 8-17

108 27. Key in Press the Number Search soft key. 29. Set parameter 1815 bit 4 X to Set the Parameter Write Enable to 0 and Program Protect key 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 to the first detent, wait two seconds; then, pull the push button out to the end of travel and release M-490B

109 TURRET TOP PLATE ZERO RETURN PROCEDURE - NOTE - This section applies to all turret top plates. The turret top plate must be zero returned (synchronized with the machine control) if the turret top plate is interrupted while indexing. Top plate indexing can be interrupted by the following: Electrical outage Pressing the Reset key while the top plate is in motion Pressing the Emergency Stop push button while the top plate is in motion Faulty turret proximity switch When zero returning the turret, the top plate will continue to the original station during interruption or to the selected station. The following procedure is used when the turret top plate fails to seat properly and the control is put into an alarm condition: 1. Clear the Emergency Stop condition or power down the machine and replace the turret proximity switch as necessary. 2. Power up the machine. 3. Activate Jog mode. 4. Set the Turret Station selector switch as needed. 5. Press the Turret Index push button to index the turret. The turret will index to the station selected in step 4 and seat (clamp down). The alarm will clear. 6. Reset the program to the beginning of the current tool operation. M-490B 8-19

110 LIVE TOOL TORQUE LIMITER 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 too 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. Activate Manual Data Input mode. 4. Press the System key. 5. Press the PMC soft key. 6. Press the PMCPRM soft key. 7. Press the KEEPRL soft key. 8. Change K00, bit 7, to "1": A) Position the cursor on K00, bit 7. B) Key in 1 and press the Input key. The Live Tool Setup Mode alarm will be displayed. 9. Activate Jog mode. 10. Press the Main Spindle Collet Open/Close push button ONCE. The live tool drive motor will be engaged. 11. Press the Reset key. If the live tool torque limit alarm is NOT cleared from the display, proceed to step 12. If the live tool torque limit alarm is cleared from the display, proceed to step If resetting on a machine equipped with a VDI top plate, position an adjustable wrench on the flats of the live tool attachment nut. If resetting on a machine equipped with an ESA top plate, position the spanner wrench supplied with the ESA live tool attachment on the live tool attachment nut. 13. Rotate the live tool attachment until the torque limiter resets. 14. Press the Reset key. The live tool torque limit alarm will be cleared from the display. 15. Press the System key. 16. Press the PMC soft key. 17. Press the PMCPRM soft key. 18. Press the KEEPRL soft key. 19. Change K00, bit 7, to "0". The Live Tool Setup Mode alarm will be cleared from the display M-490B

111 SUB-SPINDLE E AXIS TORQUE LIMITER There is a torque limiter on the sub-spindle E axis drive. 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. Set the Mode Selector switch to Jog mode. 2. Use the MPG handle to move the sub-spindle (E axis) away from the collision. 3. Set the Mode Selector switch to Manual Data Input mode. - NOTE - Refer to Editing Machine Parameters, page 8-2 for information on setting Parameter Write Enable. 4. Set the Program Protect key to 0 and Parameter Write Enable 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 to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 14. Set the Mode Selector switch to Jog mode. - NOTE - Any convenient gage block can be used. This procedure assumes a 3 inch gage block for machines set to inch mode and a 75 millimeter gage block for machines set to metric mode. 15. If the machine is set to inch mode, place a 3 inch gage block against the face of the spindle. If the machine is set to metric mode, place a 75 millimeter gage block against the face of the spindle. M-490B 8-21

112 16. Use the MPG handwheel to position the turret top plate for a slip fit of the gage block between the face of the main spindle and the face of the sub-spindle. Refer to Figure Press the Position key. 18. Press the Relative soft key to display the relative position page. 19. Press the E key. 20. 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. 21. Press the Preset soft key. 22. Use the MPG handwheel to move the E axis so that the E Axis Relative Position is as follows: Inch Mode: E Metric Mode: E Set the Mode Selector switch to Manual Data Input mode. 24. Press the System key. 25. Press the Parameter soft key. Gage Block Main Spindle Sub-Spindle TI4803 Figure Reset E Axis (Sub Spindle) from Main Spindle 8-22 M-490B

113 26. Key in Press the Number Search soft key. 28. Set parameter 1815 bit 4 E to Set the Parameter Write Enable to 0 and Program Protect key 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 to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. M-490B 8-23

114 TORQUE LIMITERS ON SUPER-PRECISION MACHINES - NOTE - The torque limiter reset procedure in this section is intended for Super-Precision machines. Refer to the following sections for information on resetting X and Z axis torque limiters on a general precision machine: Machines with VDI Top Plates, page 8-3 Machines with Hardinge Top Plates, page 8-8 Machines with ESA Top Plates, page 8-14 Super-Precision machines may display GEF alarm message 345x Soft Disconnect. This alarm prevents moving the axis to reset the torque limiter. RESETTING THE X OR Z AXIS TORQUE LIMITER 1. Set the Mode Selector switch to Manual Data Input mode. - NOTE - Refer to Editing Machine Parameters, page 8-2 for information on setting Parameter Write Enable. 2. Set the Program Protect key to 0 and Parameter Write Enable to Press the System key. 4. Press the Parameter soft key. 5. Key in Press the Number Search soft key. 7. Set the X AND Z data fields for parameter 2064 to : A) Position the cursor on the desired data field. B) Key in C) Press the Input key. 8. Press the Parameter soft key. 9. Key in Press the Number Search soft key. 11. Depending on which torque limiter tripped, set the X OR Z value for parameter 2003, bit 1 to 1 : 12. Set the Mode Selector switch to Jog mode. 13. Set the MPG handwheel increment to the lowest setting (1X / LOW). 14. Turn the MPG handwheel until the torque limiter is reset. 15. Set the Mode Selector switch to Manual Data Input mode M-490B

115 16. Press the Parameter soft key. 17. Key in Press the Number Search soft key. 19. Depending on which torque limiter was reset, set the X OR Z value for parameter 2003, bit 1 back to 0 : 20. Set Parameter Write Enable to Set the Program Protect key to Press the Reset key. M-490B 8-25

116 - NOTES M-490B

117 CHAPTER 9 - TORQUE LIMITER RESET PROCEDURES (Siemens Control) - NOTE - This information in this chapter is intended for machines equipped with a Siemens control. 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 (sub-spindle option) Live tooling drive shaft (optional) in the turret TURRET TOP PLATES RS and SR series machines are available with the following types of turret top plates: Machine Series ESA Top Plate VDI Top Plate Hardinge Top Plate RS Standard Optional Optional SR Optional Standard Optional M-490B 9-1

118 X AXIS TORQUE LIMITER RESET 1. Activate Jog mode. 2. Move the X axis to engage the torque limiter. 3. Move the turret in the +X direction to provide clearance. 4. Install a inch arbor in the machine spindle. 5. If the machine is equipped with an ESA turret top plate, install a Home Position gage (Hardinge Part Number QC AF) on the top plate. 6. Press the X Handwheel key. 7. Press the appropriate Handwheel Increment key. 8. Use the MPG handwheel to position the turret top plate as follows: If resetting the Home position on a machine equipped with an ESA turret top plate, position the top plate for a slip fit of a 4 inch gage block between the arbor in the spindle and the Home Position gage. Refer to Figure 9.1. If resetting the Home position on a machine equipped with a VDI or Hardinge turret top plate, position the top plate for a slip fit of a 4 inch gage block between the arbor in the spindle and the side of the turret top plate. Refer to Figure Press the MENU SELECT key. 10. Press the START-UP soft key 11. Press the MACHINE DATA soft key. 12. Press the AXIS MD soft key. 13. Press the FIND soft key. 14. Key in Press the OK soft key. 16. Select the X axis using the AXIS+ or AXIS- soft key. - NOTE - Two lines are displayed for parameter The line displaying a value of "2" is the line to be modified. 17. Select the line for parameter that displays the value "2". 18. Key in Press the Input key. 20. Close the main coolant guard door 21. Press the REF POINT key. 22. Press the X+ key. The X axis Home position will be reset. This procedure is complete. 9-2 M-490B

119 NOTE: All dimensions shown in inches. ESA Turret Top Plate Home Position Gage (QC AF) 4 Inch Gage Block VDI Top Plate 4 Inch Gage Block Hardinge Turret Top Plate 4 Inch Gage Block TI5639 Figure X Axis Reference Reset M-490B 9-3

120 Z AXIS TORQUE LIMITER RESET 1. Activate Jog mode. 2. Move the Z axis to engage the torque limiter. 3. Move the turret in the +Z direction to provide clearance. 4. If the machine is equipped with an ESA turret top plate, install a Home Position gage (Hardinge Part Number QC AF) on the top plate. If the machine is equipped with a VDI turret top plate, install a gage bar or tool of known diameter on the top plate. 5. Press the Z Handwheel key. 6. Press the appropriate Handwheel Increment key. 7. Use the MPG handwheel to position the turret top plate as follows: If resetting the Home position on a machine equipped with an ESA turret top plate, position the top plate for a slip fit of a 4 inch gage block between the face of the spindle and the Home Position gage. Refer to Figure 9.2. If resetting the Home position on a machine equipped with a VDI turret top plate, position the top plate to locate the tool station centerline 4 inches from the face of the spindle. The size of the gage block will depend on the diameter of the arbor or tool mounted on the turret. Refer to Figure 9.2. If resetting the Home position on a machine equipped with a Hardinge turret top plate, position the turret top plate for a slip fit of a 4 inch gage block between the face of the spindle and the face of the turret top plate. Refer to Figure Press the MENU SELECT key. 9. Press the START-UP soft key 10. Press the MACHINE DATA soft key. 11. Press the AXIS MD soft key. 12. Press the FIND soft key. 13. Key in Press the OK soft key. 15. Select the Z axis using the AXIS+ or AXIS- soft key. 9-4 M-490B

121 NOTE: All dimensions shown in inches. 4 Inch Gage Block ESA Turret Top Plate Home Position Gage (QC AF) VDI Top Plate Gage Block Inch Gage Block Hardinge Turret Top Plate TI5640 Figure Z Axis Reference Reset M-490B 9-5

122 - NOTE - Two lines are displayed for parameter The line displaying a value of "2" is the line to be modified. 16. Select the line for parameter that displays the value "2". 17. Key in Press the Input key. 19. Close the main coolant guard door 20. Press the REF POINT key. 21. Press the Z+ key. The Z axis Home position will be reset. This procedure is complete. 9-6 M-490B

123 E AXIS TORQUE LIMITER RESET 1. Activate Jog mode. 2. Move the E axis to engage the torque limiter. 3. Jog the sub-spindle toward the main spindle. 4. Press the E Handwheel key. 5. Press the appropriate Handwheel Increment key. 6. Use the MPG handwheel to position the sub-spindle for a slip fit of a 4 inch gage block between the face of the main spindle and the face of the sub-spindle. Refer to Figure Press the MENU SELECT key. 8. Press the START-UP soft key 9. Press the MACHINE DATA soft key. 10. Press the AXIS MD soft key. 11. Press the FIND soft key. 12. Key in Press the OK soft key. 14. Select the E axis using the AXIS+ or AXIS- soft key. 4 Inch Gage Block Main Spindle Sub-Spindle TI4803 Figure E Axis Reference Reset M-490B 9-7

124 - NOTE - Two lines are displayed for parameter The line displaying a value of "2" is the line to be modified. 15. Select the line for parameter that displays the value "2". 16. Key in Press the Input key. 18. Close the main coolant guard door 19. Press the REF POINT key. 20. Press the E+ key. The E axis Home position will be reset. This procedure is complete. 9-8 M-490B

125 LIVE TOOL TORQUE LIMITER RESET 1. Open the coolant guard door. 2. Wipe coolant, chips, and other contaminants from the live tool attachment in the active position. 3. If resetting on a machine equipped with a VDI top plate, position an adjustable wrench on the flats of the live tool attachment nut. If resetting on a machine equipped with an ESA top plate, position the spanner wrench supplied with the ESA live tool attachment on the live tool attachment nut. 4. Rotate the live tool attachment until the torque limiter resets. 5. Press the Alarm Cancel key. The live tool torque limit alarm will be cleared from the display. TURRET TOP PLATE ZERO RETURN PROCEDURE - NOTE - This section applies to all turret top plates. The turret top plate must be zero returned (synchronized with the machine control) if the turret top plate is interrupted while indexing. 1. Activate Jog mode. 2. Press and hold either Turret Index push button to obtain slow top plate rotation in the corresponding direction. 3. Release the push button when the turret top plate is at the correct position. M-490B 9-9

126 - NOTES M-490B

127 APPENDIX ONE - PREVENTIVE MAINTENANCE SCHEDULE INTRODUCTION RS and SR 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 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 Check the headstock fan air filter Chapter 7 M-490B A1-1

128 40 HOURS Remove the chips from the coolant tank Chapter 2 Wash the machine and wipe clean Appendix One 160 HOURS Check and clean the air line filter Chapter 1 Check the coolant pump 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.) Clean and refill the hydraulic system(s) Chapter 3 Check all hydraulic hoses for cracks, bad fittings, and kinks Chapter 3 Check the hydraulic system wiring for deterioration; check LED s..... Chapter 3 Add axes way grease lubrication Chapter HOURS Replace the standard hydraulic system filter element Chapter 3 Lubricate the turret index shaft Chapter HOURS Check the seal on hydraulic tank filler cap Chapter 3 Install a fresh control back-up battery Chapter 7 (Hardinge Inc. recommends installing a fresh battery each 2000 hours) Install fresh drive battery units Chapter 7 (Hardinge Inc. recommends installing a fresh battery each 2000 hours) A1-2 M-490B

129 8 HOURS Check the barfeed oil level. Clean chips from the tool probe. Clean chips from the part catcher. Clean the tool touch probe. Grease the chuck master jaws. MAINTENANCE SCHEDULE FOR OPTIONS 40 HOURS Clean the chip conveyor. Check the part catcher. Check the live tool oil lubricator, fill as needed. Check the hydrostatic hydraulic unit system filter pressure gauges. Check the filter(s) on the power case air conditioner. Clean or replace according to manufacturer recommendations. Empty the tramp oil pan (Machines with HydroGlide hydrostatic guideways). Lubricate the thru-spindle air blast. 160 HOURS Disassemble and clean the chuck. Grease the live tooling holders. Grease the Z axis way cover guide rod 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. Replace the by-pass filter element on machines equipped with hydrostatic guideways HOURS Lubricate the live tooling drive shaft. M-490B A1-3

130 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-490B

131 APPENDIX TWO - ALARM AND OPERATOR MESSAGES (GE Fanuc Control) 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 Verify Operator Door Switch Machine Power-Up Message. Open and close the main guard door to verify interlock switch operation 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-489) 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 Tool Probe Arm Timeout The tool probe arm remained in between the active and stowed positions for more than ten seconds. Clear any obstruction. Select Jog mode. Move the probe arm to one position or the other using the probe push button. Press Reset to clear the alarm Tool Probe Not Enabled Program M91 to enable the tool probe when it is deployed for use with the machine in Automatic mode. Failing to enable the probe with M91 causes this alarm to be displayed when the machine moves. Press Reset to clear the alarm Tool Probe Switch Fault Both the probe stowed and probe active limit switches are activated. This may indicate that a switch has failed. When the problem is fixed, press Reset to clear the alarm. M-490B A2-1

132 1016 Spindle Fault The spindle coolant chiller temperature is too high or too low, spindle coolant chiller flow is too low, or the collet drain overflow sensor indicates the collet drain pump has failed. 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 Hydraulic Pump Overload The hydraulic pump motor overload has tripped. Reset the overload to restart the motor and clear this message Hydraulic Fan Overload The hydraulic fan motor overload has tripped. Reset the overload to restart the motor and clear this message X1 Torque Limiter Fault The X axis torque limiter has tripped. The control is put into an alarm condition and the machine in Emergency Stop Z1 Torque Limiter Fault The Z axis torque limiter has tripped. The control is put into an alarm condition and the machine in Emergency Stop 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 Live Tool Torque Limit The live tool torque limiter has tripped. The control is put into an alarm condition and the machine in Emergency Stop Live Tool 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. A2-2 M-490B

133 1060 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 Please Press Reset Turret index is not allowed when the live tool drive is engaged. Press Reset to disengage the live tool drive. Try to index the turret 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 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 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. M-490B A2-3

134 1082 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 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 Part Catcher Must be Retracted The main spindle part catcher must be retracted before starting a program in Automatic mode or deploying the optional tool probe in any 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 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. A2-4 M-490B

135 1120 Tailstock Past Limit Position The tailstock has traveled past the position defined by the A word in macro program Refer to the programmer s manual (M-488) for information on macro program Move Tailstock to Mid or Home The tailstock is out of position. Move the tailstock to either the mid-point or the fixed Home position. Cycle Start is inhibited Please Home Tailstock Power Up Message. Home the tailstock. Refer to the operator's manual (M-489) for information on homing the tailstock Part Catcher, See Messages The sub-spindle part catcher slide has a fault. Refer to the message display page for detailed information Hydraulic Temperature Too High - NOTE - This alarm applies only to machines equipped with HydroGlide hydrostatic linear guideways. The fluid temperature in the hydraulic unit for the HydroGlide hydrostatic linear guideways exceeds the high limit. Possible causes for hydraulic fluid high temperature are: Ambient temperature is in excess of the recommended maximum operating temperature, which is 95 F [35 C] Hydraulic unit pump motor is running hot Hydraulic unit heat exchanger fan has malfunctioned Hydraulic unit heat exchanger coils need to be cleaned M-490B A2-5

136 1174 Hydrostatic Pressure Fault Hydrostatic pressure is too low to support the slides. Emergency stop is applied. Determine the cause of the problem. Restart the machine and Press Reset to clear this message CH1 Temperature Out of Range This message applies to Super-Precision machines only. Thermocouple channel 1 indicates an improbable value. The temperature monitoring system needs to be checked. Refer to Appendix Three for temperature sensor locations CH3 Temperature Out of Range This message applies to Super-Precision machines only. Thermocouple channel 3 indicates an improbable value. The temperature monitoring system needs to be checked. Refer to Appendix Three for temperature sensor locations Temperature Compensation Out of Range This message applies to Super-Precision machines only. The temperature compensation calculated by the control is too large. Temperature compensation is disabled CH2 Temperature Out of Range This message applies to Super-Precision machines only. Thermocouple channel 2 indicates an improbable value. The temperature monitoring system needs to be checked. Refer to Appendix Three for temperature sensor locations CH4 Temperature Out of Range This message applies to Super-Precision machines only. Thermocouple channel 4 indicates an improbable value. The temperature monitoring system needs to be checked. Refer to Appendix Three for temperature sensor locations Part Missing The sub-spindle part detector did not find a part in the sub-spindle Part Present The sub-spindle part detector found a part in the sub-spindle. A2-6 M-490B

137 1212 Part Detector Failed to Retract The sub-spindle part detector is actuating the extended switch or not actuating the home switch 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 Failed to Lock The main guard door failed to lock when the part program was started. M-490B A2-7

138 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 5 for information on machine lubrication. After lubricating the machine, press the Reset and Feed Hold push buttons at the same time to clear this message Live Tool Lube Oil Level Low. Refill with Mobil DTE 24. The oil level in the reservoir is low. Cycle Start is inhibited. Refill the reservoir with Mobil DTE 24 oil. Press Reset to clear this message 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 this message 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 7 for instructions to replace the battery Part Probe Battery Low The part probe battery is nearly discharged. Refer to the operator's manual (M-489) for instructions to replace the battery. After the battery is replaced, press Reset to clear this message. A2-8 M-490B

139 2030 Coolant Pump Overload The coolant pump motor overload on the coolant pump contactor in the machine power case has tripped. Repeat mode is canceled. Correct the cause of the overload. Locate the coolant pump contactor in the power case and reset the overload. When the overload is reset, press Reset to clear this 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 this message 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 this 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 Turret 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 Y Too Low to Jog E1 or Z1 The turret is positioned below Y0. Move the turret to Y0 before attempting to move the E1 or Z1 axis 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 this message. M-490B A2-9

140 2086 Part Count Satisfied The part count specified has been completed. Repeat mode is canceled. Press Cycle Start or Reset to clear this message Turret Must be at X Axis Home Position The tool probe was commanded to deploy and the turret is not at the X axis reference position. Move the turret to the X axis reference position before deploying the tool probe. When the tool probe is deployed, the turret can only be indexed when it is positioned at the X axis reference position Opposite Spindle Must be at Home Position The tool probe was commanded to deploy and the sub-spindle is not at the reference position. Move the sub-spindle to the reference position before deploying the tool probe Tailstock Must be at Home Position The tool probe was commanded to deploy and the tailstock is not at the reference position. Move the tailstock to the reference position before deploying the tool probe Tool Probe Must be Stowed The tool probe is not stowed 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 not stowed and the part catcher was commanded to extend. The tool probe must be stowed before the part catcher can be extended in any mode Spindle Chiller Temperature The spindle chiller temperature is too high or low or the spindle coolant chiller flow is too low on machines equipped with built-in spindle motors. This fault cancels Repeat mode. The machine will stop with alarm 1016 after four minutes. Press Reset to clear this message Collet Drain Pump Fault The collet drain reservoir overflow sensor indicates the main or sub-spindle collet drain pump has failed. Repeat mode is canceled. The machine will stop with alarm message 1016 after four minutes. Press reset to clear this message 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 this message. A2-10 M-490B

141 2102 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. The main spindle part catcher basket extended and retracted limit switches are both activated. This may indicate that one of the limit switches has failed Please Close Part Catcher Cover The main spindle part catcher cover is open. Program execution is inhibited. Close the cover to allow program execution 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 this message 2134 Main Spindle Contouring Mode The manual axis movement selector switch is set to C1 and the operator is attempting to manually operate the main spindle through the use of the spindle control functions on the operator panel. Set the manual axis movement selector switch to another setting 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 alarm 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 alarm Opposite Spindle Part Catcher Slide Must be Extended The sub-spindle part catcher slide must be extended before the arm can be rotated up to the spindle centerline. M-490B A2-11

142 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 up or down 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 Parts Catcher Gripper Fault The parts catcher grippers are 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 this 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 this message from the screen High Pressure Coolant Motor Overload The high pressure coolant motor is overloaded. 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 this message from the screen 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 this message from the screen 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 is necessary. Press Reset to clear this message. A2-12 M-490B

143 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 this message Lower Axis Thrust Limit The lower axis thrust limit has been exceeded. The machine is put into a feed hold condition. Press Cycle Start or Reset to clear this message Hydrostatic Fluid Level too Low The hydrostatic fluid level is below the full mark. The machine goes into Emergency Stop. Fill the tank and restart the machine. Press Reset to clear this message Hydrostatic Fluid Level Low, Refill The hydrostatic fluid level is below the full mark. The tank should be filled soon. Filling the tank clears this message Hydrostatic Pump Overload Hydrostatic pump circuit breaker tripped. Determine the cause of the problem. Reset the circuit breaker and press Reset to clear this message Hydrostatic Fan Overload Hydrostatic cooling fan circuit breaker tripped. Determine the cause of the problem. Reset the circuit breaker and press Reset to clear this message Hydrostatic Temperature Fault Hydrostatic temperature is too high. Determine the cause of the problem and correct it. Press Reset to clear this message Excessive Flow Hydrostatic fluid flow is excessive. Determine the cause of the problem and correct it. Press Reset to clear this message Parameter Write Fault 1: Please Turn Off Power and Restart Machine The control has failed to write a parameter correctly. Restarting the machine may clear the problem. Contact the Hardinge Service Department if necessary. M-490B A2-13

144 2201 Parameter Write Fault 2: Please Turn Off Power and Restart Machine The control has failed to write a parameter correctly. Restarting the machine may clear the problem. Contact the Hardinge Service Department if necessary Axis Thrust Limit X Axis The optional programmable X axis thrust limit has been exceeded. Refer to the programmable thrust limit documentation Axis Thrust Limit Y Axis The optional programmable Y axis thrust limit has been exceeded. Refer to the programmable thrust limit documentation Axis Thrust Limit Z Axis The optional programmable Z axis thrust limit has been exceeded. Refer to the programmable thrust limit documentation Axis Thrust Limit E Axis The optional programmable E axis thrust limit has been exceeded. Refer to the programmable thrust limit documentation 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 this message 2234 Opposite Spindle Contouring Mode The manual axis movement selector switch is set to C2 and the operator is attempting to manually operate the sub-spindle through the use of the spindle control functions on the operator panel. Set the manual axis movement selector switch to another setting Door Closed Switch Fault Shorted One of the two door closed switch contacts is ON all the time or the two contacts are shorted together. Cycle Start is inhibited. Check the switch wiring. When the problem is corrected, press Reset to clear this message Door Closed Switch Fault Open One of the two door closed switch contacts is disconnected. Cycle Start is inhibited. Check the switch wiring. When the problem is corrected, press Reset to clear this message. A2-14 M-490B

145 2242 Door Locked Switch Fault Shorted One of the two door locked switch contacts is ON all the time or the two contacts are shorted together. Cycle Start is inhibited. Check the switch wiring. When the problem is corrected, press Reset to clear this message Door Locked Switch Fault Open One of the two door locked switch contacts is disconnected. Cycle Start is inhibited. Check the switch wiring. When the problem is corrected, press Reset to clear this message Please contact Hardinge at 800/ extension 2227, or at and provide the key code shown below. You will be given a four digit password. You have 45 Days To obtain your password. Key Code: [Xxxx] Contact Hardinge Inc. as instructed Your warning period has expired. Please contact Hardinge at 800/ extension 2227, or at tpc@hardinge.com, and provide the key code shown below. Key Code: [Xxxx] Contact Hardinge Inc. as instructed Illegal Spindle Number A spindle command (S word) was issued without an active P word. Program P1, P2, or P3 to specify the active spindle. Refer to programmer s manual (M-488) for information on programming the P word for spindle selection. M-490B A2-15

146 - NOTES - A2-16 M-490B

147 APPENDIX THREE - ALARM AND OPERATOR MESSAGES (Siemens Control) Supply Phase Sequence Incorrect ALARM MESSAGES Main supply phase sequence is wrong. 3 phase auxiliary motors are not started. Correct main supply phase sequence. Reset to clear alarm X Axis Torque Limit Fault X axis torque limit coupling has tripped. Axes are in a Feed Stop condition and Cycle Start is inhibited. Axis brake is applied and measuring system is switched to motor encoder. Alarm remains active until the coupling is re-engaged and the measuring systems are re-aligned. Reset to clear alarm Z Axis Torque Limit Fault - NOTE - The Z axis linear scale is present on all Super-Precision machines. Z axis torque limit coupling has tripped. Axes are in a Feed Stop condition and Cycle Start is inhibited. Axis measuring system is switched to motor encoder if a linear scale is fitted. Without a linear scale, the coupling must be re-engaged and then the absolute position reset. Reset to clear alarm. With a linear scale fitted, the coupling must be re-engaged and the measuring systems re-aligned. Reset to clear alarm Main Spindle Fan Motor Overload Main spindle fan motor is overloaded. Main spindle motor is stopped. Reset main spindle fan motor overload. Reset to clear alarm Main Spindle Not Referenced for C Axis Operation Main spindle is not referenced for operation as the C axis. Program execution is stopped. Reset to clear alarm and reference main spindle before re-running the program. Main spindle will reference while running in spindle operation or with M19 or can be referenced in axis mode with G74 C0. M-490B A3-1

148 Main Spindle Warmup Cycle Not Completed! The main spindle warmup cycle was aborted by the operator. Main spindle warmup cycle has not been executed. Reset to clear alarm Turret Unclamp Timeout Fault Turret has not returned unclamped within the allowed time. Axes are in Feed Stop condition and Cycle Start is inhibited. Check unclamp system for faults in the switches or valves. Reset to clear alarm Turret Clamp Timeout Fault Turret has not returned clamped within the allowed time. Axes are in Feed Stop condition and Cycle Start is inhibited. Check clamp system for faults in the switches or valves. Reset to clear alarm Turret Clamp/Unclamp Switch State Fault Turret is not indicating clamp or unclamp position. Axes are in Feed Stop condition and Cycle Start is inhibited. Check clamp/unclamp system for faults in the switches or valves. Reset to clear alarm Turret Cannot Index With Y Axis Below Home Position Turret cannot index unless the Y axis is at Home position or above. Turret index is blocked and programmed tool is not activated. Reset to clear alarm and correct program to allow turret index only with Y axis in correct position. Alarm occurs when Y axis position is incorrect when turret index is programmed with T-Code Turret Cannot Index With X Axis Below Home Position Turret cannot index unless the X axis is at Home position or above. Turret index is blocked and programmed tool is not activated. Reset to clear alarm and correct program to allow turret index only with X axis in correct position. Alarm occurs when X axis position is incorrect when turret index is programmed with T-Code. A3-2 M-490B

149 Live Tool Spindle Fan Motor Overload Live tool spindle fan motor is overloaded. Live tool spindle motor is stopped. Reset live tool spindle fan motor overload. Reset to clear alarm Live Tool Spindle Torque Limit Fault Live tool spindle torque limit coupling has tripped. Live tool spindle motor is stopped. Axes are in a Feed Stop condition and Cycle Start is inhibited. Manually re-engage the coupling. Reset to clear alarm Live Tool Spindle Lubrication Level Low Live tool spindle lubrication oil reservoir level is low. Live tool spindle is stopped, axes are in a Feed Stop condition and Cycle Start is inhibited. Refill the live tool spindle lubrication oil reservoir. Reset to clear alarm Sub-Spindle Fan Motor Overload Sub-spindle fan motor is overloaded. Sub-spindle motor is stopped. Reset Sub-spindle fan motor overload. Reset to clear alarm Sub-Spindle Not Referenced for C Axis Operation Sub-spindle is not referenced for operation as the A axis. Program execution is stopped. Reset to clear alarm and reference sub-spindle before re-running the program. Sub -spindle will reference while running in spindle operation or with M19 or can be referenced in axis mode with G74 A E Axis Torque Limit Fault - NOTE - The E axis linear scale is present on all Super-Precision machines. E axis torque limit coupling has tripped. Axes are in Feed Stop condition and Cycle Start is inhibited. Axis measuring system is switched to motor encoder if a linear scale is fitted. The coupling must be re-engaged and then the absolute position reset. Reset to clear alarm. Axis can be traversed with the handwheel to allow the coupling to be reset. M-490B A3-3

150 Drives Main Contactor Not Energized Main supply contactor for Sinamics drives is not energized. Drives are not enabled. Check integrity of the emergency stop circuit as the main contactor is hardware controlled. Reset to clear alarm Drives Not Ready Sinamics drives are not ready for operation. Drives are not enabled. Check integrity of the emergency stop circuit as the 'drives ready' signal to the NCU is hardware controlled. Check drive system for any faults or missing connections. Reset to clear alarm Drives Not Enabled Sinamics drives are ready for operation but are not enabled. Check drive system for any faults or missing connections. Reset to clear alarm Main Air Pressure Low Main air pressure is missing or pressure is too low. Axes are in a Feed Stop condition and Cycle Start is inhibited. Restore air pressure. Reset to clear alarm Main Hydraulic Pump Motor Overload The main hydraulic pump motor is overloaded. Main hydraulic pump is stopped. Axes are in a Feed Stop condition and Cycle Start is inhibited. Reset main hydraulic overload. Reset to clear alarm Main Hydraulic Pressure Low Main hydraulic pressure is low. Axes are in a Feed Stop condition and Cycle Start is inhibited. Restore main hydraulic pressure. Reset to clear alarm Main Hydrostatic Pump Motor Overload The main hydrostatic pump motor is overloaded. Main hydrostatic pump is stopped. Axes are in a Feed Stop condition and Cycle Start is inhibited. Reset main hydrostatic overload. Reset to clear alarm. A3-4 M-490B

151 Main Hydrostatic Pressure Low Main hydrostatic pressure is low. Axes are in a Feed Stop condition and Cycle Start is inhibited. Restore main hydrostatic pressure. Reset to clear alarm Main Spindle Collet/Chuck Open Timeout Fault Main spindle collet/chuck has not opened within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check main spindle collet/chuck for blockages. Check the integrity of the relevant pressure switch and solenoid. Reset to clear alarm Main Spindle Collet/Chuck Close Timeout Fault Main spindle collet/chuck has not closed within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check main spindle collet/chuck for blockages. Check the integrity of the relevant pressure switch and solenoid. Reset to clear alarm Main Spindle Collet/Chuck Pressure Switch State Fault Main Spindle collet/chuck opened and closed pressure switches are both ON. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the switches for wiring faults; for example, the non-activated switch has a short circuit. -or- Check the switches for false triggering; for example, incorrect pressure setting Main Spindle Collet Access Door Open Main spindle collet access door has been opened during program execution. Main spindle is stopped, axes are in a Feed Stop condition, and Cycle Start is inhibited. Close main spindle collet access door. Reset to clear alarm Main Spindle Collet Drain Level High Main spindle collet drain level is high. Main spindle is stopped, axes are in Feed Stop condition and Cycle Start is inhibited. Reset to clear alarm. M-490B A3-5

152 Coolant Pump Motor #1 Overload Coolant pump #1 motor is overloaded. Coolant pump #1 and #2 are stopped. Axes are in a Feed Stop condition and Cycle Start is inhibited. Reset coolant pump #1 overload. Reset to clear alarm Coolant Pump Motor #2 Overload Coolant pump #2 motor is overloaded. Coolant pump #1 and #2 are stopped. Axes are in a Feed Stop condition and Cycle Start is inhibited. Reset coolant pump #2 overload. Reset to clear alarm Part Catcher #1 Extend Timeout Fault Part catcher #1 has not extended within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check part catcher #1 for blockages or wire-breaks in the input or output for the Extend circuit. Reset to clear alarm Part Catcher #1 Retract Timeout Fault Part catcher #1 has not retracted within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check part catcher #1 for blockages or wire-breaks in the input or output for the Retract circuit. Reset to clear alarm Part Catcher #1 Switch Off State Fault Part catcher #1 extend and retract proximity switches are both OFF. Axes are in a Feed Stop condition and Cycle Start is inhibited. If part catcher #1 is not extended or retracted, it must be moved to either end of stroke. If part catcher #1 is extended, check the extend proximity switch for a fault or broken wire. If part catcher #1 is retracted, check the retract proximity switch for a fault or broken wire. Reset to clear alarm. A3-6 M-490B

153 Part Catcher #1 Switch On State Fault Part catcher #1 extend and retract proximity switches are both ON. Axes are in a Feed Stop condition and Cycle Start is inhibited Part Conveyor Motor Overload Part conveyor motor is stopped. Axes are in a Feed Stop condition and Cycle Start is inhibited. Reset the part conveyor motor overload. Reset to clear alarm Part Catcher Conveyor Cover Switch Off State Fault Part conveyor cover extend and retract proximity switches are both OFF. Axes are in a Feed Stop condition and Cycle Start is inhibited. If part conveyor cover is not extended or retracted, it must be moved to either end of stroke. If part conveyor cover is extended, check the extend proximity switch for a fault or broken wire. If part conveyor cover is retracted, check the retract proximity switch for a fault or broken wire. Reset to clear alarm. Check the switches for wiring faults; for example, the non-activated switch has a short circuit. -or- Check the switches for false triggering; for example, a broken activation cam Part Catcher Conveyor Cover Switch On State Fault Part conveyor cover extend and retract proximity switches are both ON. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the switches for wiring faults; for example, the non-activated switch has a short circuit. -or- Check the switches for false triggering; for example, a broken activation cam." M-490B A3-7

154 Safety Door Open/Close Monitor Error #1 Both the safety door opened and closed switches are ON. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the safety door switch for possible short circuit of one of the opened or closed inputs Safety Door Open/Close Monitor Error #2 Safety door closed switch is ON during cyclic test. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the safety door closed switch for possible short circuit Safety Door Open/Close Monitor Error #3 Safety door opened switch is ON during cyclic test. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the safety door opened switch for possible short circuit Safety Door Open/Close Monitor Error #4 Safety door switch is indicating an open or not closed state while the door is indicating locked. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the safety door switch for a mechanical failure of the locking system Safety Door Unlock/Lock Monitor Error #1 Both the safety door locked and unlocked switches are ON. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the safety door switch for possible short circuit of one of the locked or unlocked inputs Safety Door Unlock/Lock Monitor Error #2 Safety door locked switch is ON during cyclic test. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the safety door locked switch for possible short circuit. A3-8 M-490B

155 Safety Door Unlock/Lock Monitor Error #3 Safety door unlocked switch is ON during cyclic test. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the safety door unlocked switch for possible short circuit Safety Door Unlock/Lock Monitor Error #4 Both the safety door locked and unlocked switches are OFF. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the safety door switch for possible open circuit of one of the locked or unlocked inputs Sub-Spindle Collet/Chuck Open Timeout Fault Sub-spindle collet/chuck has not opened within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check sub-spindle collet/chuck for blockages. Check the integrity of the relevant pressure switch and solenoid. Reset to clear alarm Sub-Spindle Collet/Chuck Close Timeout Fault Sub-spindle collet/chuck has not closed within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check sub-spindle collet/chuck for blockages. Check the integrity of the relevant pressure switch and solenoid. Reset to clear alarm Sub-Spindle Collet/Chuck Pressure Switch State Fault Sub-spindle collet/chuck opened and closed pressure switches are both ON. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the switches for wiring faults; for example, the non-activated switch has a short circuit. -or- Check the switches for false triggering; for example, incorrect pressure setting Sub-Spindle Collet Access Door Open Sub-spindle collet access door has been opened during program execution. Sub-spindle is stopped, axes are in a Feed Stop condition and Cycle Start is inhibited. Close Sub-spindle collet access door. Reset to clear alarm. M-490B A3-9

156 Sub-Spindle Collet Drain Level High Sub-spindle collet drain level is high. Sub-spindle is stopped, axes are in a Feed Stop condition, and Cycle Start is inhibited. Reset to clear alarm Part Catcher Conveyor Cover Retract Timeout Fault Part conveyor has not retracted within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check part conveyor for blockages or wire-breaks in the input or output for the Retract circuit. Reset to clear alarm Part Catcher Conveyor Cover Extend Timeout Fault Part conveyor has not extended within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check part conveyor for blockages or wire-breaks in the input or output for the Extend circuit. Reset to clear alarm High Pressure Coolant Unit Fault High pressure coolant unit is indicating a fault condition. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check manufacturer's documentation for details. Reset to clear alarm High Pressure Coolant Fault High pressure coolant unit is indicating a coolant fault condition. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check manufacturer's documentation for details. Reset to clear alarm High Pressure Coolant Unit Not Ready High pressure coolant unit is indicating a not ready state. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check manufacturer's documentation for details. Reset to clear alarm. A3-10 M-490B

157 Part Detect - Switch State Fault Part Detect Arm In and Out proximity switches are both OFF. Axes are in a Feed Stop condition and Cycle Start is inhibited. If part detect arm is not IN or OUT, it must be moved to either end of stroke. If part detect is IN, check the in proximity switch for a fault or broken wire. If part detect is OUT, check the out proximity switch for a fault or broken wire. Reset to clear alarm Part Detect - Part Missing Part is not present in sub-spindle after checking with M81. Axes are in a Feed Stop condition and Cycle Start is inhibited. Reset to clear alarm Part Detect - Part Present Part is present in sub-spindle after checking with M80. Axes are in a Feed Stop condition and Cycle Start is inhibited. Reset to clear alarm Part Detect Arm Out Timeout Fault Part detect arm has not reached the "home" or Out position within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check part detect arm for blockages or wire-breaks in the input or output for the Arm Out circuit. Reset to clear alarm Tool Probe Active Timeout Fault Tool probe has not reached the active or deployed position within the allowed time. Tool probe active output is blocked. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check tool probe for blockages or wire-breaks in the input or output for the Tool Probe Active circuit. Reset to clear alarm. M-490B A3-11

158 Tool Probe Stow Timeout Fault Tool probe has not reached the stowed position within the allowed time. Tool probe stow output is blocked. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check tool probe for blockages or wire-breaks in the input or output for the Tool Probe Stow circuit. Reset to clear alarm Part Probe Error Part probe interface device has an error condition. Axes are in a Feed Stop condition and Cycle Start is inhibited. Refer to the manufacturer's documentation for details. Reset to clear alarm Part Probe Battery Low Part probe battery charge level is low. Axes are in a Feed Stop condition and Cycle Start is inhibited. Refer to the manufacturer's documentation for details. Reset to clear alarm Part Catcher #2 Slide In Timeout Fault Part catcher #2 slide has not reached the IN position within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check part catcher #2 slide for blockages or wire-breaks in the input or output for the In circuit. Reset to clear alarm Part Catcher #2 Slide Out Timeout Fault Part catcher #2 slide has not reached the Out position within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check part catcher #2 slide for blockages or wire-breaks in the input or output for the Out circuit. Reset to clear alarm Part Catcher #2 Slide Switch Off State Fault Part catcher #2 slide In and Out proximity switches are both OFF. Axes are in a Feed Stop condition and Cycle Start is inhibited. If the Part Catcher #2 Slide is not In or Out, it must be moved to either end of the stroke. If part catcher #2 is Out, check the Out proximity switch for a fault or broken wire. If part catcher #2 is In, check the In proximity switch for a fault or broken wire. Reset to clear alarm. A3-12 M-490B

159 Part Catcher #2 Slide Switch On State Fault Part catcher #2 slide In and Out proximity switches are both ON. Axes are in a Feed Stop condition and Cycle Start is inhibited Part Catcher #2 Rotate Up Timeout Fault Part catcher #2 rotate has not reached the Up position within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check part catcher #2 rotate for blockages or wire-breaks in the input or output for the Up circuit. Reset to clear alarm Part Catcher #2 Rotate Down Timeout Fault Part catcher #2 rotate has not reached the Down position within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check part catcher #2 rotate for blockages or wire-breaks in the input or output for the Down circuit. Reset to clear alarm Part Catcher #2 Rotate Switch Off State Fault Part catcher #2 rotate Up and Down proximity switches are both OFF. Axes are in a Feed Stop condition and Cycle Start is inhibited. If part catcher #2 rotate is not Up or Down, it must be moved to either end of stroke. If part catcher #2 rotate is Up, check the Up proximity switch for a fault or broken wire. If part catcher #2 rotate is down, check the Down proximity switch for a fault or broken wire. Reset to clear alarm. Check the switches for wiring faults; for example, the non-activated switch has a short circuit. -or- Check the switches for false triggering; for example, a broken activation cam Part Catcher #2 Rotate Switch On State Fault Part catcher #2 rotate Up and Down proximity switches are both ON. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check the switches for wiring faults; for example, the non-activated switch has a short circuit. -or- Check the switches for false triggering; for example, a broken activation cam. M-490B A3-13

160 Part Catcher #2 Gripper Open Timeout Fault Part catcher #2 grip has not opened within the allowed time. Axes are in a Feed Stop condition and Cycle Start is inhibited. Check part catcher #2 grip for blockages or wire-breaks in the input or output for the Open circuit. Reset to clear alarm Number of Temperature Sensors Not Defined Temperature compensation is enabled, but the number of sensors as '2' or '4' is not defined. Cycle Start is inhibited. Disable temperature compensation or correctly define the number of sensors Temperature Sensor 1 Value Out Of Range Temperature sensor 1 value is too low or too high. Cycle Start is inhibited. Check the sensor and connecting wiring Temperature Sensor 2 Value Out Of Range Temperature sensor 2 value is too low or too high. Cycle Start is inhibited. Check the sensor and connecting wiring Temperature Sensor 3 Value Out Of Range Temperature sensor 3 value is too low or too high. Cycle Start is inhibited. Check the sensor and connecting wiring Temperature Sensor 4 Value Out Of Range Temperature sensor 4 value is too low or too high. Cycle Start is inhibited. Check the sensor and connecting wiring Temperature Compensation Value Out Of Range Resulting temperature compensation value is too high. Cycle Start is inhibited. Check the individual sensors and connecting wiring or the offset adjustment and constant settings. A3-14 M-490B

161 OPERATOR MESSAGES Feed Disable - Feedhold [MCP] Feedhold is active from machine control panel. All axes are in feedhold. Press FEED RELEASE to cancel FEEDHOLD Feed Disable - Feed Override at 0 [MCP] Feedrate override on the machine control panel is at 0%. All axes are in Feed Stop condition. Set feedrate override to position other than 0% NC Read-In Disable - Machine Safety Door Not Locked Machine safety door is closed but did not lock when cycle was started. Program execution is stopped until the door is both closed and locked. Push door fully closed to allow lock mechanism to engage or check door lock system NC Read-In Disable - User M-Code A user M code has not returned complete. Program execution is stopped until user M code returns complete. Check connection of the user M code driven device or check configuration of the user M code Cycle Start Inhibit - X/Z Not Referenced The X and/or Z axis absolute reference positions are not set. Cycle Start is inhibited in AUTO mode. Set absolute position for both the X and Z axes Cycle Start Inhibit - Turret Not Referenced Turret absolute reference position is not set. Cycle Start is inhibited in AUTO mode. Set absolute position for the turret Cycle Start Inhibit - Main Sp Collet/Chuck Not Closed The main spindle collet or chuck is not closed. Cycle Start is inhibited. Close the main spindle collet or chuck. M-490B A3-15 Revised: February 4, 2009

162 Cycle Start Inhibit - Main/Sub Sp Collet/Chuck Not Closed The main spindle or sub-spindle collet or chuck is not closed. Cycle Start is inhibited. Close the main spindle or sub-spindle collet or chuck Z Axis Thrust Limit Z axis continuous thrust (torque) load has been exceeded. Cycle stop is applied. Press Cycle Start to resume the cycle. If the condition persists the program cutting load needs to be reduced Main Spindle Warmup Required (Insert Part, Close Collet, Close Door & [Spindle Start]) The main spindle warmup cycle is ready to run. With the collet/chuck closed and the safety door closed press Spindle Start to start the main spindle warmup cycle Main Spindle Warmup Stage 1/2 - Please Wait Main spindle warmup cycle stage 1 of 2 is running. Main spindle runs at 2000 rpm for 3 minutes. Main spindle warmup cycle can be interrupted with Reset or Spindle Stop Main Spindle Warmup Stage 2/2 - Please Wait... Main spindle warmup cycle stage 2 of 2 is running. Main spindle runs at 4000 rpm for 3 minutes. Main spindle warmup cycle can be interrupted with Reset or Spindle Stop Turret Cannot Index With Y Axis Below Home Position Turret cannot index unless the Y axis is at home position or above. Turret index is blocked. Move Y axis to correct position before indexing turret Turret Cannot Index With X Axis Below Home Position Turret cannot index unless the X axis is at home position or above. Turret index is blocked. Move X axis to correct position before indexing turret. A3-16 M-490B Revised: February 4, 2009

163 Turret Cannot Index With Live Tool Not Disengaged Turret cannot index with the live tool spindle engaged. Turret index is blocked. In MDI mode, orient live tool spindle with SPOS[2]=0 to disengage Machine Safety Door Open Machine safety door is open. Cycle Start is inhibited. Spindle operation is inhibited. Axis jog rapid is inhibited. Turret index speed is reduced. Close safety door Main Spindle Collet Access Door Open Main spindle collet access door is open. Main spindle cannot run and Cycle Start is inhibited. Close main spindle collet access door Sub Spindle Collet Access Door Open Sub-spindle collet access door is open. Sub-spindle cannot run and Cycle Start is inhibited. Close sub-spindle collet access door High Pressure Coolant Filter Clogged High pressure coolant unit is indicating that the filter is clogged. Check manufacturer's documentation for exact details Tailstock Not Referenced Hydraulic tailstock is not referenced. Cycle Start is inhibited. Reference the tailstock. Tailstock can be referenced in JOG REF Mode with the E+ key Tailstock Overtravel Hydraulic tailstock has reached the overtravel limit. Cycle Start is inhibited. Check for a part in the collet/chuck or, if necessary, correct the overtravel position Tailstock Limit Position Incorrect Hydraulic tailstock Limit position must be set less than the Decel position. Cycle Start is inhibited. Correct the Limit or Decel position. M-490B A3-17 Revised: February 4, 2009

164 Tailstock Decel Position Incorrect Hydraulic tailstock Decel position must be set less than the Mid position. Cycle Start is inhibited. Correct the Decel or Mid position Tailstock Mid Position Incorrect Hydraulic tailstock Mid position must be set less than the reference position. Cycle Start is inhibited. Correct the Mid position Tailstock Not In Position For NC Start Hydraulic tailstock is not at one of the defined positions to allow Cycle Start. Cycle Start is inhibited. Move the tailstock to one of the defined positions to allow Cycle Start X or E Axis Not Home for Tool Probe Active/Stow Tool probe cannot be deployed or stowed unless the X and E axes are at their home positions. Tool probe cannot be deployed or stowed. Move the X and E axes to the respective home positions Tailstock Not Home for Tool Probe Active/Stow Tool probe cannot be deployed or stowed unless tailstock is at the home positions. Tool probe cannot be deployed or stowed. Move the tailstock to the home position. A3-18 M-490B Revised: February 4, 2009

165 - NOTES - M-490B A3-19

166 - NOTES - A3-20 M-490B

167 APPENDIX FOUR - MACHINE PHOTOGRAPHS Figure A4.1 - Operator Control Pendant (Machine with GE Fanuc Control) TP7405 Figure A4.2 - Operator Control Pendant (Machine with Siemens Control) TP7452 M-490B A4-1

168 A B D C E TP7223 Figure A4.3 - Overall View of Machine A - Spindle Compartment Cover B - Side of Power Case C - Main Spindle Draw Tube Access Cover D - Operator Control PENDANT (GE Fanuc Control Shown) E - Coolant Tank A4-2 M-490B

169 TP4100A Figure A4.4 - Main Air Filter / Regulator M-490B A4-3

170 Figure A4.5 - Standard Hydraulic Unit TP7406 Figure A4.6 - Hydrostatic Hydraulic Unit (Machine with HydroGlide Hydrostatic Linear Guideway System) TP5766 A4-4 M-490B

171 Figure A4.7 - Main Disconnect Switch and Tags on Power Case Door (Machine with GE Fanuc Control) TP4109A Figure A4.8 - Main Disconnect Switch and Tags on Power Case Door (Machine with Siemens Control) TP7611 M-490B A4-5

172 TP4201 Figure A4.9 - Main Spindle Drive, RS 51, RS 65, SR 150, and SR 200 Machines (RS 42 Machines have the Spindle Brake on Top) A4-6 M-490B

173 Figure A Externally-Mounted Primary Coolant Pump and Coolant Filter TP7408 M-490B A4-7

174 Figure A Internally-Mounted Primary Coolant Pump TP7407A Figure A Internally-Mounted Coolant Filter and Turret Coolant Pump TP7462 A4-8 M-490B

175 Machine Base Thermal Sensor Figure A Machine Base Thermal Sensor Location Behind Pedestal Fan Unit, Viewed from Left End of Machine (Super-Precision Machine or Machine Equipped with Hydrostatic Linear Guideways) TP5908 Headstock Riser Thermal Sensor Figure A Headstock Riser Thermal Sensor Location (Super-Precision Machine) TP5909 M-490B A4-9

176 Temperature Sensor Temperature Sensor Figure A Thermal Sensor Locations, Carriage Viewed from the Tailstock/Sub-Spindle End of the Machine (Machine Equipped with Hydrostatic Linear Guideways) TP7398 A4-10 M-490B

177 C A B Figure A Y-Axis, Turret Index, and Live Tooling Motors TP5870 A - Y-Axis Motor B - Turret Index Motor C - Live Tooling Motor M-490B A4-11

178 - NOTES - A4-12 M-490B

179 - NOTES - M-490B A4-13

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