CONQUEST GT27 and GT27SP AUTOLOAD SYSTEM

Transcription

1 MAINTENANCE MANUAL TP3436. CONQUEST GT27 and GT27SP AUTOLOAD SYSTEM Revised: April, 2000 Manual No. M-371 Litho in U.S.A. Part No. M May, 1999

2 SAFETY INFORMATION Refer to the Programmer s, Operator s and this Maintenance manual supplied with the machine tool for Hardinge Safety recommendations. Refer to the following documents for additional safety requirements: American National Standard for Machine Tools - Manufacturing Systems/Cells Safety Requirements for Construction, Care, and Use ANSI B American National Standard for Industrial Robots and Robot Systems - Safety Requirements ANSI R 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 maintenance of the Hardinge CONQUEST GT27 and CONQUEST GT27SP CNC lathes with Autoload system. 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 or 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-371

3 READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE STARTING MAINTENANCE OR REPAIR ON THE MACHINE, LOAD/UNLOAD AUTOMATION, OR BAR FEED. 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 Conquest machine. When machine maintenance is performed by persons not familiar with the operation of this equipment, the Operator s Manual (M-370) must be consulted when instructions require that the machine be run. - WARNING - Occupational Safety and Health Administration (OSHA) Hazard Communication Standard , effective May 25, 1986, and various state employee right-to-know laws require that information regarding chemicals used with this equipment be supplied to you. A complete list of the chemicals used with this machine, their reference data sheet numbers, and their suppliers appears as an insertion at the end of this manual. Refer to the applicable section of the Material Safety Data Sheets supplied with your machine when handling, storing, or disposing of chemicals. Machine should only be used with a bar feed approved by Hardinge Inc. HARDINGE SAFETY RECOMMENDATIONS Your Hardinge machine is designed and built for maximum ease and safety of operation. However, some previously accepted shop practices may not reflect current safety regulations and procedures, and should be re-examined to insure compliance with the current safety and health standards. Hardinge Inc. recommends that all shop supervisors, maintenance personnel, and machine tool operators be advised of the importance of safe maintenance, setup, and operation of Hardinge-built equipment. Our recommendations are described below. READ THESE SAFETY RECOMMENDATIONS BEFORE PROCEEDING ANY FURTHER. READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation or maintenance of the machine. Make certain that you understand all instructions. DON T ALLOW the operation or repair of equipment by untrained personnel. CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job. WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. When necessary, wear respirator, helmet, gloves, and ear muffs or plugs. DON T OPERATE EQUIPMENT unless proper maintenance has been regularly performed and the equipment is known to be in good working order. WARNING or INSTRUCTION TAGS are mounted on the machine for your safety and information. Do not remove them. DON T ALTER THE MACHINE to bypass any interlock, overload, disconnect, or other safety device. DON T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibration occurs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as any damaged parts. M-371 i

4 MAKE CERTAIN that the equipment is properly grounded. Consult National Electric Code and all local codes. DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance. ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing electrical equipment. DON T REACH into any control or power case area unless electrical power is OFF. DON T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a wet surface. REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished. ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters before restarting the machine. KEEP THE AREA AROUND THE MACHINE well lighted and dry. KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating equipment. HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combustible material and keep chips clear of the work area. DON T USE a toxic or flammable substance as a solvent cleaner or coolant. MAKE CERTAIN THAT PROPER GUARDING is in place and that all doors are closed and secured. TO REMOVE OR REPLACE the collet closer it is necessary to remove the guard door at the left end of the machine. Make certain that the guard door is in place before starting the machine. DON T OPEN GUARD DOORS while any machine component is in motion. MAKE SURE chucks, closers, fixture plates and all other spindle-mounted work-holding devices are properly mounted and secured before starting the machine. MAKE CERTAIN all tools are securely clamped in position before starting the machine. REMOVE ANY LOOSE PARTS OR TOOLS left on machine or in the work area before operating the machine. Always check the machine and work area for loose tools and parts especially after work has been completed by maintenance personnel. REMOVE CHUCK WRENCHES before starting the machine. BEFORE PRESSING THE CYCLE START PUSH BUTTON, make certain that proper functions are programmed and that all controls are set in the desired modes. KNOW WHERE ALL stop push buttons are located in case of an emergency. CHECK THE LUBRICATION and the status of the indicator lights before operating the machine. INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good condition and are functioning properly before operating the machine. ii M-371

5 CHECK THE POSITION of the tool top plate before pressing the Cycle Start push button. CHECK THE POSITION of any load/unload automation before pressing the Cycle Start push button. CHECK SETUP, TOOLING, AND SECURITY OF THE WORKPIECE if the machine has been OFF for any length of time. DRY CYCLE a new setup to check for programming errors. MAKE CERTAIN that you are clear of any pinch point created by moving slides before starting the machine. DON T OPERATE any equipment while any part of the body is in the proximity of a potentially hazardous area. DON T REMOVE CHIPS with hands. Use a hook or similar device and make certain that all machine movements have ceased. BE CAREFUL of sharp edges when handling newly machined workpieces. DON T REMOVE OR LOAD workpieces while any part of the machine and/or Autoload system is in motion. DON T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing, neckties or long hair not contained by a net or shop cap. DON T ADJUST tooling or coolant hoses while the machine is running. DON T LEAVE tools, workpieces or other loose items where they can come in contact with a moving component of the machine and/or Autoload system. DON T CHECK finishes or dimensions of workpiece near running spindle or moving slides. DON T JOG SPINDLE in either direction when checking threads with a thread gage. DON T ATTEMPT to brake or slow the machine with hands or any makeshift device. ANY ATTACHMENT, TOOL OR MACHINE MODIFICATION not obtained from Hardinge Inc. must be reviewed by a qualified safety engineer before installation. USE CAUTION around exposed mechanisms and tooling especially when setting up. Be careful of sharp edges on tools. DON T USE worn or defective hand tools. Use the proper size and type for the job being performed. USE ONLY a soft-faced hammer on turret tools and fixtures. DON T USE worn or broken tooling and/or grippers on machine. MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools. INSPECT ALL CHUCKING/GRIPPING DEVICES daily to make certain that they are in good operating condition. Replace any defective chuck before operating the machine. USE MAXIMUM ALLOWABLE gripping pressure. Consider weight, shape, and balance of the workpiece. M-371 iii

6 USE LIGHTER THAN NORMAL feedrates and depth of cut when machining a workpiece diameter that is larger than the gripping diameter. DON T EXCEED the rated capacity of the machine and/or autoload system. DON T LEAVE the machine unattended while it is operating. DON T CLEAN the machine with an air hose. KEEP TOTE PANS a safe distance from the machine. Don t overfill the tote pans. DON T LET STOCK project past the back end of the collet closer or machine spindle without being adequately covered and properly supported. FOLLOW each bar feed manufacturer s guidelines. For performance and safe application, size and use feed tube bushings, pushers, and spindle liners according to bar feed information. MAKE CERTAIN that any bar feed mechanism is properly aligned with the spindle. If the bar feed is a floor-mounted type, it must be securely bolted to the floor. 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 and Autoload system when opening or closing the coolant guard door and any access cover. - WARNING - Before activating a new program, turn the control OFF. Wait approximately 10 seconds; then, turn the control ON. This will set the collet closer timer to the default setting of 4.9 seconds and will assure safe operation of the control. FOR YOUR PROTECTION - WORK SAFELY iv M-371

7 Table Of Contents CHAPTER 1 - REFERENCES and INSTALLATION Machine Serial Number CNC Control Serial Number Machine Foundation Installation Leveling the Machine Cleaning the Machine Air Connection Grounding the Machine Earth Ground System Grounding Power Connection Power Case Door CHAPTER 2 - POWER-UP PROCEDURE Basic Machine Power-Up Power Down and Lock Out Procedure Clearing an Emergency Stop Hour Run Meter Review Control Status CHAPTER 3 - LUBRICATION Introduction Lubricator Consumption Guidelines Lubricator Refill Lubricator Reservoir and In-Line Filter Purge LubricationSystem Replace the Lubricator Clean Tramp Oil Trough CHAPTER 4 - AIR FACILITY Introduction Drain the Filter/Regulator Unit Daily Drain the Filter Bowls and Air Receiver Clean the Air System Bowl Replace Coalescing Filter Replace the Collet Closer (GT27, Big-Bore) Filter Replace Air Control Assembly Components Replace the Pressure Switch(es) Replace or Clean Manifold(s) Solenoid Valves Air Blast Options M-371 v Revised: April, 2000

8 CHAPTER 5 - COOLANT FACILITIES Introduction Water-Based Coolants Concentration ph Water Quality Care and Maintenance Removing Chips and Shavings Cleaning the Reservoir and Filters Coolant In-Line Valves and Hoses Replacing the Coolant Pump Coolant Catcher CHAPTER 6 - PART LOAD/UNLOAD GANTRY Introduction Gantry Lubrication Gantry Pneumatic (Air) Panel Gantry Axes Drive Motors CHAPTER 7 - HEADSTOCK and SPINDLE DRIVE Introduction Spindle Draw Tube Plug Spindle Drive Belt Adjustment Spindle Drive Belt Replacement Spindle Drive Motor Replacement and Alignment Spindle Encoder Timing Belt Adjustment Spindle Encoder Replacement Spindle Encoder Timing Belt Replacement Headstock Alignment Cleaning the Spindle Brake Disc CHAPTER 8 - COLLET CLOSER Introduction Free Spindle Collet Closer Draw Tube Cleaning Standard ANSI A2-4 5C Collet Closer ANSI A2-4 16C Big-Bore Collet Closer Pressure Regulator/Gauge Replacement Pressure Switch Replacement vi M-371

9 CHAPTER 9 - AXES DRIVE MOTORS Introduction Carriage Drive Motor Replacement Cross Slide Drive Motor Replacement CHAPTER 10 - MISCELLANEOUS Air Fan and Heat Exchanger Battery Replacement Drive Battery Control Battery Part Catcher To Adjust the Part Catcher Position To Adjust the Part Catcher Travel Rate To Replace the Solenoid(s) To Replace the Valve To Replace the Pressure Regulator and/or Gauge To Replace the Part Catcher (Chute) Home Switch (LS 6) Worklight, Worklight Starter/Ballast Live Tool Holder Bearings Stacker Table Torque Limiter APPENDIX ONE PREVENTIVE MAINTENANCE SCHEDULE and PRODUCTS APPLIED Introduction Pg.1 Maintenance Schedule Pg.1 8 Hours Pg.1 40 Hours Pg Hours Pg Hours Pg Hours Pg.2 Yearly Pg.2 Lubricants Pg.3 Adhesives and Sealants Pg.3 APPENDIX TWO - PHOTOGRAPHS CONQUEST GT27/GT27SP Autoload Photographs M-371 vii Revised: January, 2000

10 - NOTES - viii M-371

11 CHAPTER 1 - INSTALLATION MACHINE SERIAL NUMBER The serial number for the CONQUEST GT27 and CONQUEST GT27SP Autoload system is stamped on plate A, Figure 1.1, which is located on the upper right corner of the power case door. This serial number should be included in all correspondence regarding this machine. CNC CONTROL SERIAL NUMBER The CNC control serial number is located on tag B, Figure 1.2, inside the control case. The CRT and operator s control panel are mounted on the control case door. Unthread the screws and rotate the door open; the tag is located on the control housing. This serial number should be included in all correspondence regarding the control. A B Figure Machine Serial Number TP3516. Figure Control Serial Number TP3533. MACHINE FOUNDATION The CONQUEST GT27/GT27SP Autoload system machines require a substantial foundation. Do not locate the machine near equipment that causes vibration. Poor surface finishes or damage to the control may result from any vibration transmitted to the machine. The legs are set at approximately 3 inches [76 mm] creating a minimum 1 inch [25.4 mm] machine clearance. It is not necessary that the machine be set perfectly level unless a bar feed is to be used with the machine. However, the machine should be reasonably level, within ±.13 inch [3.3 mm] in the machine footprint, to allow the way lube oil to be collected at the end of the machine away from the spindle. Shim the support legs with metal plates if necessary. - NOTES - Refer to Figure 1.3 to locate the feet in the machine s base. Use the dimensions to locate the concrete pads. The pads must be level with each other within ±.13 inch [±3.3 mm] or the floor must be level within ±.13 inch in 5 feet [±3.3 mm in 1524 mm] and be constructed of 3000 psi [207 bars] concrete or better. Avoid placing the machine over floor expansion joints. M

12 Harcrete Base Outline 34.5 [876] 13.6 [346] Two Adjustable Screws (Number 4 and 5) 15.25[387] [494] Measurements are inch [metric] Width of Machine is 65.0 [1651] Machine and Stacker Table is 91.5[2324] 5 Top View of Machine [1001] Figure Pad Placement for Machine Support [907] 5.0 [127] 34.0 [864] 51.5 [1308] TI4479. Verify that the foundation for the machine meets the specifications. Hardinge suggests that the foundation be as follows: RECOMMENDED a 4 inch [102 mm] thick concrete floor as large as the machine footprint. The machine s footprint is the overall dimensions, length and width, of the machine. ACCEPTABLE concrete pads 14 x 14 x 4 inches [356 x 356 x 102 mm] centered under each of the machine s feet. INSTALLATION - NOTES - The weight of the standard CONQUEST GT27/GT27SP Autoload system machines is approximately 8,100 pounds [3674 kg]; the weight of the chip conveyor with empty coolant tank is approximately 630 pounds [286 kg]; and, the weight of the skid is approximately 900 pounds [408 kg]. Use a fork lift truck with a minimum lifting capacity of 12,000 pounds [5443 kg] or use two lift bars a minimum of 3.0 inch [Ø76 mm] diameter, made of 8620 alloy steel that are approximately 120 inches [3048 mm] long when rigging. To set the machine in place: 1. Leave the machine on the skid and move it to the installation site. 2. Remove the coolant tank, ground rod, and any parts boxes from the skid. 3. Gain access to the forklift slots by unthreading the screws and lifting off lower spindle access cover C, Figure 1.4; reach inside along the edge of front cover D, unthread the three screws and pull the cover straight out to the left. 1-2 M-371

13 4. Remove the screws that secure the four machine hold-down brackets (two brackets on each end of the machine base) to the skid. Loosen the screws that fasten the hold-down brackets to the machine and raise the brackets all the way up to clear the skid. Tighten the screws just enough to hold the brackets up. - CAUTION - To avoid damage to the machine, only lift the machine from the front. C E D - NOTES - There are two forklift or rigging slots, approximately 40 inches (1012 mm) center to center, under the machine. Figure Spindle (Left) End of the Machine Refer to Figure 1.3 to locate the support legs numbered 1 through 3. The only legs that are adjustable are the fourth leg which is located near the front left forklift slot and fifth leg located behind the power case near the corner of the Harcrete base (under the spindle). 5. Make certain that the adjustable fourth and fifth legs are threaded all the way up for clearance and that each has a disc (pad) attached. - WARNING - Raise the machine high enough to make certain that the machine s legs and hold-down brackets clear the skid. 6. Use a fork lift truck or rigging to lift the machine from the skid. Lift the machine slowly while making certain that it remains balanced. 7. Carefully lower the machine in place. The machine is initially supported by three legs. - WARNING - Any bar feed used with the Hardinge CONQUEST GT27/GT27SP Autoload system machines should be approved by Hardinge Inc. 8. If there is no bar feed, place a bubble indicator on top of the tooling top plate parallel to the spindle and level the machine within.13 inch [3.3 mm] in the machine footprint; turn the bubble indicator 90 degrees to level within specification. Use metal plates as shims. However; if the machine will have the bar feed option, use a tighter specification to level the machine and secure it to the floor. Level the machine for a bar feed as follows: A. At the spindle end of the machine, unthread the four screws to release spindle draw tube access cover E, Figures 1.4, 1.5, and 1.6. Rotate or remove the access cover from the machine, Figure NOTE - Hardinge suggests using a 1 inch [Ø 25 mm] diameter ground bar approximately 3 feet [1 meter] long and straight within inch [0.125 mm]. B. If necessary, remove coolant plug F, from the end of the spindle draw tube. Insert the bar into the spindle draw tube but leave 1 foot [305 mm] of the bar exposed. C. Make certain that the bar is resting evenly at the bottom of the draw tube radius and then put a bubble indicator or other leveling device on the exposed bar parallel to the spindle centerline. TP3531. M

14 E F Figure Spindle Draw Tube Access Cover TP3539. E Figure Draw Tube End and Coolant Plug TP CAUTION - Use metal plates as shims to level the machine. Do NOT attempt to move (thread) the three legs that are not adjustable to level the machine. -NOTE - Level the machine within inch per foot [0.635 mm per 305 mm]. D. Use metal plates as shims to level the machine within specification. 9. Thread the adjustable fourth and fifth legs down as follows until the machine is firmly supported. A. Thread the adjustable legs down until the disc just makes contact with the floor. B. Only thread each leg one-sixteenth to one-eighth turn more. C. Check to make certain that the machine is level within specification. Adjust level as necessary. - NOTE - It may be more convenient to move the machine to drill the holes and mount the expansion shields after the floor has been marked. 10. Secure the machine to the floor as follows: A. Loosen the screws that fasten the hold down brackets and lower the brackets to the floor. Tighten the screws just enough to hold the brackets. B. Mark the floor at the center of the hold-down bracket slots. C. Remove the hold-down brackets from the machine. D. Drill a.75 inch [Ø19 mm] diameter hole, 4 inches [102 mm] deep at the mark. E. Drive an expansion shield down into the hole until it bottoms. F. Mount the hold-down brackets to the machine. G. Put a washer on the lag screw. Put the lag screw through the hold-down bracket and thread it into the expansion shield until it is tight. 1-4 M-371

15 11. Tighten the lock nut against the base to set the adjustable fourth and fifth legs. Check to make certain that the machine is level within its specification. 12. Unthread the screws to unlatch right end access cover G, Figure 1.7, in two places and remove it from the machine (the tender system or optional stacker table should not be in place yet). Reach up inside and unthread the screw that fastens the red coolant guard door bracket in place. Remove the bracket and open the G door. - NOTE - If the machine has the Auto door option, the field service engineer will mount the coolant door interlock air cylinder. 13. Remove all tape, foam, and other packing material from the machine. 14. At the rear of the machine, roll the coolant tank into place and fasten the coolant hose, Figure 1.8. Adjust the skirting and make certain that the coolant will drain into the coolant chip pan. 15. Put the tramp oil pan in place. TP Check that all electric cables are connected or plugged in. - CAUTION - Do not apply power to the machine. Start up of the machine must be conducted by a Hardinge service engineer. 17. Place and align the stacker table or other tending system to be used. 18. Mount all access covers; close and fasten all doors. If this is the initial installation, call the Hardinge service department at (800) or (607) to schedule the final installation and inspection of this machine. A Hardinge Field Service Engineer will visit your plant, at no charge, to test run this machine. He runs a designed test program but will not set-up or make parts. Figure Machine Right End Access Cover (in Stacker Table) Figure Coolant Reservoir and Tramp Oil Pan TP3430. Otherwise, this information is intended to be a guide should the machine be moved or put in storage. M

16 CLEANING THE MACHINE - CAUTION - Do not use compressed air to clean chips from the machine. Air pressure forces dirt particles and other foreign matter past the seals and covers into the slides, ball screw, and bearings. This will cause additional wear and will reduce the life and accuracy of the machine. After the machine has been properly located and leveled, remove all shipping grease, oil, and dirt accumulated in transit. USE A CLOTH OR BRUSH WITH A GOOD GRADE OF OIL BASE GREASE SOLVENT TO CLEAN THE MACHINE. Insert a shim of approximately.030 inch [.76 mm] thick plastic shim between the spindle and headstock front cap. Run the shim completely around the spindle several times to remove the shipping grease. If this grease is not removed, the spindle may run hot. Use Clorox 409 cleaner to clean the coolant guard windows. Do not use benzene, leaded gasoline, acetone, or chlorinated solvents. AIR CONNECTION The machine is equipped with filter/regulator H, Figure 1.9, and coalescing filter I. Machines with the big-bore option also have an air receiver and air receiver filter. The air should be OFF when the machine is not in use. Connect the input air line to air valve J. The air line should have a minimum I.D. of 3/8 inch [9.5 mm] or the machine will not function properly. Use the knob on top of the air valve to turn the air system ON. Use knob K, to set the regulator at a constant pressure between 70 psi minimum and 90 psi maximum [4.9 and 6.3 bars]. The air valve must be ON before Cycle Start can be energized. If the air pressure is below 60 psi [4.2 bars], an error message will be displayed on the CRT screen and the program goes into E-Stop. To drain the air filter/regulator: 1. Turn ON main air valve J, by turning the knob counterclockwise and aligning the lock tabs. 2. Press the valve at the bottom of filter bowl H, sideways until the bowl is drained. K - CAUTION - Drain the filter/regulator at least once a day by pressing the manual FLEX-DRAIN petcock, on the bottom of the bowl sideways. If an excessive moisture problem exists, J add a heavy-duty air dryer to the incoming air line. H I Figure Air Panel TP M-371

17 To adjust the air system pressure: 1. Make certain that main air valve J, Figure 1.9, is turned ON. 2. Loosen the lock knob on top of knob K of most machines to allow the pressure to be adjusted. Some machines have a pressure knob that must be lifted to be adjusted. 3. Turn knob K clockwise or counterclockwise to adjust the pressure as necessary. Read the air pressure gauge as the knob is turned to determine how much adjustment is necessary. 4. Tighten the lock knob on top of the adjustment knob to set the pressure on most machines. The other pressure knobs must be pressed down to be set. To drain the air receiver filter and air receiver only on big-bore option machines: 1. The main air valve must be ON. 2. Unthread the manual screw drain on the air receiver filter until the contaminants are drained from the filter. Thread the drain tight enough to seat the drain. 3. Then, unthread the manual screw drain a turn or two to drain the contaminants from the air receiver. Tighten the screw drain valve to seat the drain. GROUNDING THE MACHINE - WARNING - Improper grounding of the Hardinge CONQUEST GT27/GT27SP Autoload system could result in damage to the control and severe electrical shock to personnel in the event of an electrical fault. To properly ground the machine an Earth Ground and a System Ground are required. The minimum ground wire size for all machines is 8 AWG. In general, there are two requirements for system grounding. They are as follows: Earth Ground: An earth ground assures that all voltages have the same reference base and that voltage potential, in the event of circuit shorts or other malfunctions, is limited. This is accomplished by having a neutral reference wire common to all voltage sources within the system. Since safety requirements vary with locality, consult local codes which take precedence over the following guidelines. Earth ground connections in their order of effectiveness are as follows: 1. Effectiveness of continuous water pipe when properly buried will depend on conditions of soil. When installed below permanent moisture level, the impedance of this type ground is typically below 3 OHMS. 2. Effectiveness of man-made, driven or buried electrodes will depend on condition of soil. When installed below permanent moisture level, the impedance of this type ground is typically below 5 OHMS. 3. Other available electrodes, such as metal frames of buildings or metal well castings must be well chosen, since they are substantially below 25 OHMS but exceed 5 OHMS. Ground connections, wire, and electrodes should not exceed 5 OHMS, as measured from the equipment ground stud through the primary electrode, through earth, to another independent electrode, separated by 20 feet of earth. Additional ground should be installed when necessary to insure that the impedance does not exceed 5 OHMS. The ohmic measurement should be made in terms of a voltage-current relation, such as the current of a 120 volt, 100 watt lamp bulb. M

18 The ground conductor connecting the ground stud to the chosen electrode should be of braid or welding cable (equivalent to AWG #8 or larger). Braid or welding cable minimizes the resistance at higher frequencies. When longer lengths are required, use a larger size cable, so that the resistance of the cable is less than OHMS. In general, the size must be rated to carry peak short-circuited current for maximum time duration without degrading the ground system, and must withstand any mechanical abuse to which it may be exposed. Interconnect all separate enclosures, control stations, pendant stations, conduits, and the like, to implement and maintain safe ground continuity throughout all metallic components of the system. This is always considered good practice and a locally regulated requirement. System Grounding: A proper grounding arrangement prevents equipment damage and personal injury caused by an electrical fault such as a short circuit. To accomplish this, the grounding setup must assure that all voltages have the same reference base; and that, in the event of an electrical fault, the voltage potential is limited. The National Electrical Code recommends that: Effective Grounding Path. The path to ground from circuits, equipment, and metal enclosures for conductors shall (1) be permanent and electrically continuous, (2) have capacity to conduct safely any fault current likely to be imposed on it, and (3) have sufficiently low impedance to limit the voltage to ground and to facilitate the operation of the circuit protective devices. The earth shall not be used as the sole equipment grounding conductor.*1 On the CONQUEST GT27 and GT27SP Autoload system, all electrical circuits and all non-current carrying metal parts of the control and the machine tool are interconnected by a series of ground wires attached to ground terminal strip L, Figure 1.10, which is located near the bottom of the power case. Attached to the shipping crate is an eight foot long, 5/8 inch round copper-covered steel rod, which is the system grounding electrode, and a ground clamp. The ground connector used to connect the machine ground block to the electrode must be a braid or welding cable equivalent to AWG #8 or larger. (Braid or welding cable minimizes the resistance at higher frequencies). When longer lengths are required, use a larger size cable so that the total resistance of the cable is less than.075 OHMS. In general, the size must be rated to carry peak short-circuited current of maximum time duration without degrading the ground systems, and must withstand any mechanical abuse to which it may be exposed. To establish an earth ground, the electrode must be driven into the ground to a depth of eight feet. If the bottom is encountered at a depth of less than four feet, the electrode may be buried horizontally in a trench. * 1 National Fire Protection Association, National Electrical Code Handbook 1996, Fifth Edition, Section L Figure Machine Ground Terminal Strip TP M-371

19 POWER CONNECTION The electrical requirements for the CONQUEST GT27 and GT27SP Autoload system are listed in Table NOTES - The wire sizes listed below are for reference only. Due to the variation of local electrical codes, Hardinge recommends that the local utility supply company be consulted to determine exact service and wiring requirements. Machines that require 380, 415, 460, and 575 voltage supply must have a supplementary transformer. It is recommended that machines with 208 voltage supply also have a supplementary transformer. Machine Supply Voltage Frequency (Hz) Full Load Amps (FLA) Service Requirement (Minimum 115% of FLA) Recommended AC Incoming Wire Size * No. 4 AWG No. 4 AWG * No. 8 AWG * No. 8 AWG * No. 8 AWG Table Conquest GT Autoload System To access the power case and connect the power supply: - WARNING - Make certain that the main disconnect switch is in the OFF position when working in the power case or the control case. 1. Turn disconnect switch M, Figure 1.11, to OFF before opening the power case door. 2. Turn off the power source to the machine. If the machine is to be reconnected to another power line, make certain that the power to that line is OFF. 3. Unlock the power case door; turn the disconnect switch while pulling the door open. M Figure Main Disconnect Switch TP3516 M

20 4. Check that the line side of the disconnect switch and the ground stud inside the case are set to have the power source and ground line connected. If the line side of the disconnect switch has wire clamps, they must be open so that the wires can be inserted and fastened. - NOTE - If this is the initial installation, a Hardinge field service engineer will visit the plant to make the power connections and test run the machine. Local codes and company policy may require that special personnel make the power connection to the machine. Have the proper personnel available, if necessary, to make this connection when the Hardinge service engineer is scheduled to be at the machine site. Refer to the Hardinge CONQUEST GT27 and GT27SP AUTOLOAD system Installation Instructions, manual M-372, for complete installation information before the service engineer visits. 5. Route the power cable into the power case far enough to reach the switch and ground stud near it. Use a cable clamp to secure N the cable at the entrance to the power case. If the line side of the disconnect switch has screws without wire clamps, fasten a ¼ inch [6.5 mm] ring clamp to each of the wires. - NOTE - If this is the initial installation, do not connect the wires to the main disconnect switch. Do not apply power to the machine. The service engineer or the special personnel will connect the ground wire and power leads. If this is not the initial installation, proceed with the instructions below. Figure Disconnect Switch and Ground Stud Inside the Power Case 6. Connect the electrical power supply to the line side of the disconnect switch and the ground wire to ground stud N, Figure Do not turn disconnect switch M, Figure 1.11, ON until all electrical connections have been checked by a Hardinge service technician. TP M-371

21 POWER CASE - WARNING - To avoid possible electrical hazard to the worker or damage to the machine, allow only authorized personnel to have access to enclosures containing electrical equipment. The power case cannot be opened while the machine is powered up. The machine must be power down before the power case can be opened. DO NOT have the power case open while the machine is powered up unless an authorized person is trouble shooting the control electronics. - WARNING - Be extremely carefully when working in the power case. To open the power case door: 1. Power down the machine as follows: A. Make certain that the cycle has ended and that the spindle has stopped. B. Press the Emergency (E-Stop) Stop pushbutton. C. Turn the Control power switch to OFF. D. Turn main disconnect switch M, Figure 1.11, to OFF. 2. Use the hex key to unlatch power case door. 3. Pull the tab at the upper right on the main disconnect switch down while turning the disconnect switch lever and pulling the door open. - WARNING - People are exposed to electrical hazard when the machine is turned ON with the power case open. 4. To power up the machine while the power case door is open, use a wrench on the main disconnect bar to turn the bar clockwise to ON. 5. Turn the Control power switch to ON and bring the control out of E-Stop. 6. The machine must be powered down again to close and latch the power case door before operating the machine. M

22 - NOTES M-371

23 CHAPTER 2 - POWER-UP PROCEDURE - CAUTION - The recommended operating temperature range is 50 to 114 F [7 to 46 C]. - NOTE - Follow the power-up procedure exactly as described in the steps which follow to ensure safe, accurate, and repeatable machine operation. BASIC MACHINE POWER-UP 1. Turn main disconnect switch A, Figure 2.1, ON. 2. Turn main air valve B, Figure 2.2, ON. - CAUTION - Any accumulated water must be drained from the air system at least once a day. If more frequent draining is required, it may be necessary to install an air dryer in the air line. - NOTE - Coalescing filter E is equipped with an automatic drain. 3. Drain filter bowl C by pressing valve D sideways. Release when draining is complete. B A C D E TP3516 TP3426 Figure Main Disconnect Switch Figure Main Air Panel 4. On machines equipped with a big-bore (16C) spindle option: A. Drain the air receiver filter bowl by unthreading the drain valve. Close when draining is complete. B. Drain the air receiver by unthreading the drain valve. Close when draining is complete. 5. Check lubricant and coolant levels. Add lubricant and coolant as required. (continued on the next page) M

24 - CAUTION - When turning the Control switch to ON, DO NOT press any pushbuttons or keys until the Position or Alarm screen is displayed. Some pushbuttons and keys have other control maintenance or special operation functions. 6. Turn the Control OFF/ON switch to ON and wait until the control display screen is ON. 7. Pull the gantry pendant and stacker table Emergency Stop pushbuttons outward; then release. 8. Pull the front panel Emergency Stop pushbutton outward; then, release. 9. Press the Emergency Stop Reset pushbutton [3]. 10. Open and close the coolant guard door to perform the guard door switch verification and clear the verification alarm. The machining system is now ready for operation. POWER-DOWN PROCEDURE To power down the control: 1. Be sure Cycle Start is not active. The Cycle Start pushbutton [47] will not be illuminated. 2. Be sure program execution has been completed and that all axes are stationary. 3. Press the front panel Emergency Stop pushbutton. 4. Turn the Control OFF/ON switch to OFF. 5. Turn main air valve B, Figure 2.2, OFF. 6. Turn main disconnect switch A, Figure 2.1, OFF. CLEARING AN EMERGENCY STOP There are three Emergency Stop pushbuttons, located as follows: Under the operator control panel Above the stacker table access door On the gantry pendant To clear an E-Stop condition: 1. Correct the condition that prompted the Emergency Stop (E-Stop) condition. 2. Pull the Emergency Stop pushbutton that was pressed to initiate the Emergency Stop outward; then, release. 3. Pull the Emergency Stop pushbutton located under the operator control panel outward; then, release. 4. Press the Emergency Stop Reset pushbutton [3]. 2-2 M-371

25 HOUR RUN METER The hour run meter is located on the side of the power case which is also the left (spindle) end of the machine. It records the amount of time that the control has been powered up. TP3524. Figure Hour Run Meter REVIEW CONTROL STATUS The following descriptions refer to the control status displays. POSITION KEY There are three pages of position display data. After the Position key is pressed, the position display page that was last active will appear on the control display screen. To access the other position display pages, press the appropriate soft key. The three position display pages are as follows: 1. ALL (Overall Position Display): This page shows the active program number and block number are displayed in the upper right-hand corner of the control display screen if the control is in Automatic mode. A. Relative: The axis position on the Relative Coordinate System. Position is displayed as U and W coordinates. B. Absolute: Axis position on the Work Coordinate System. After power-up, the origin of the Work Coordinate System is the intersection of the spindle face and the spindle centerline. Position is displayed as X and Z coordinates. This origin can be relocated by any one of the following: Active set of tool offsets Position Reset operation Workshift offset C. Machine: Displays the axis position in relation to the Reference Zero position. The X-Axis Reference Zero position is inches [298 mm] from the spindle centerline, as measured on the diameter. The Z-Axis Reference Zero position on machines equipped with a 5C spindle is inches [ mm] from the face of the spindle. The Z-Axis Reference Zero position on machines equipped with a 16C spindle is inches [ mm] from the face of the spindle. (continued on the next page) M

26 D. Distance to Go: This is the distance remaining between current axis position and the programmed axis position. This register is displayed only while the control is in Automatic or Manual Data Input mode. 2. ABS (Absolute Position Display). Refer to part b under ALL (Overall Position Display). 3. REL (Relative Position Display). Refer to part a under ALL (Overall Position Display). PROGRAM KEY Press the Program key to display the active program number, and active block sequence number and eleven blocks of the active program on the control display screen. To display other pages of the program, select Edit mode and use the page keys to read through the program. During execution of the active part program, the cursor will be positioned under the sequence number of the active block. If necessary, press the Reset ket to return to the start of the program. OFFSET SETTING KEY When the Offset Setting key is pressed, the Offset and Setting soft keys are displayed. From the first Offset Setting screen, press the soft key expansion key once to display the Macro Program soft key. From the first Offset Setting screen, press the soft key expansion key twice to display the Work Shift soft key. OFFSET soft key Press the Offset soft key to access the geometry and wear soft keys. Geometry: Consists of four pages of Geometry offsets, eight offsets on each page. Wear: Consists of four pages of Wear offsets, eight offsets on each page. One of the two chapters will be displayed on the control display screen. The displayed page will be the page which was active when the Offset display was last deactivated. To display the other chapter, press the corresponding soft key. Use the page keys to view other pages within a chapter. The tool geometry and wear offset chapters each consist of four pages, which display the following information: X and Z Tool Offsets (32 pair) Tool nose radius values Tool nose orientation numbers Use the page keys to view other pages. The Tool Offset pages are formatted as follows: Offset Page 01: Offset Numbers Offset Page 02: Offset Numbers Offset Page 03: Offset Numbers Offset Page 04: Offset Numbers M-371

27 SETTING Soft Key Press the Setting soft key to access the system variables page, which allows the operator or programmer to assign the system variables listed below. To modify these variables, move the cursor to the variable which is to be modified, enter the desired value, and press the INPUT key. PARAMETER WRITE = _ (0:DISABLE 1: ENABLE) TV CHECK = _ (0:OFF 1:ON) PUNCH CODE = _ (0:EIA 1:ISO) INPUT UNIT = _ (0:MM 1:INCH) I/O CHANNEL = _ (0-3:CHANNEL NO.) SEQUENCE NO. = _ (0:OFF 1:ON) TAPE FORMAT = _ (0:NO CNV 1:ON) SEQUENCE STOP = _ (PROGRAM NO.) SEQUENCE STOP = _ (SEQUENCE NO.) PARAMETER WRITE This parameter allows the control parameters to be edited. When set to 0", parameter editing is disabled. When set to 1", parameter editing is enabled. Refer to Chapter 3 for information on editing machine parameters. TV CHECK This parameter allows the activation or deactivation of parity checking. When set to 1", parity is checked from the beginning of each block to the beginning of the next block. When set to 0", vertical parity checking is disabled. PUNCH CODE This parameter allows the selection of either EIA or ISO data input format through the RS-232 serial port. When set to 0", the data input format is set to EIA. When set to 1", the data input format is set to ISO. INPUT UNIT This parameter allows the selection of metric or inch operating mode. When set to 0", the operating mode is Metric. When set to 1", the operating mode is set to Inch. I/O CHANNEL This parameter allows the selection of the logical I/O to be used by the control. The valid selections for the I/O port assignments are 0, 1, or 2. Refer to Chapter 6 for a complete explanation of I/O port selection. SEQUENCE NO. This parameter allows the selection of automatic sequence number insertion. When active, sequence numbers will be automatically inserted into a program which is entered into memory from the Manual Data Input keyboard. When set to 0", automatic sequence number insertion is inactive. When set to 1", automatic sequence number insertion is active. TAPE FORMAT Not Active M

28 SEQUENCE STOP (2 entries) These two entries are used together to provide the machine operator with the capability of stopping automatic part program execution after the program block specified has been completed. The first entry (Program No.) identifies the program to be monitored. The second entry (Sequence No.) identifies the sequence number (N word) of the last block to be executed by the CNC control during normal automatic operation. Once this block is executed, the CNC control will stop program execution. Press the Cycle Start pushbutton [47] to resume program execution. MACROS Soft Key Press the MACROS soft key to display the macro variable registers. WORK SHIFT Soft Key Press the Work Shift soft key to display the workshift offset registers. SYSTEM KEY Press the System key to access the following information: - Machine parameters and diagnostics - PMC parameters, ladder, and diagnostics - Control system configuration One of four chapters will be displayed on the control display screen. The displayed page will be the page which was active when the key was last deactivated. If necessary, press the soft key to display the desired chapter. Use the page keys to view other pages within the chapter. PARAMETER Soft Key Press the Parameter soft key to display machine parameters. These parameters establish many of the characteristics, specifications, and functions of the machine tool. The page that was active when the parameter chapter was last exited will be displayed. Use the page keys to view other pages within the chapter. Refer to Chapter 3 for information on editing machine parameters. DIAGNOSTICS Soft Key Press the Diagnostics soft key to display the machine diagnostics chapter. The page that was active when the diagnostics chapter was last exited will be displayed. Use the page keys to view other pages within the chapter. PMC Soft Key Press the PMC soft key to display the PMC information screen. The purpose of this screen is to view the PMC ladder, parameters, and diagnostics. SYSTEM Soft Key Press the System soft key to display the control system information screen. 2-6 M-371

29 MESSAGE KEY If ALM is displayed at the bottom right-hand corner of the control display screen during machine operation, press the Message key. After the Message key is pressed, one of the three chapters will be displayed. To display one of the other chapters, press the appropriate soft key. ALARM Soft Key Alarm Message chapter. This chapter displays alarms that create a feed hold condition. One alarm will be displayed on the control display screen at a time. The display is formatted to indicate which tool station has generated the alarm. Descriptions of each alarm are given in the alarm list in Appendix Two. MESSAGE Soft Key Operator Message chapter. Operator messages do not initiate a feed hold condition. They call the operator s attention to a particular condition that exists. HISTORY Soft Key The GE Fanuc series 18i-T control is capable of storing the last 25 alarms generated by the machine control. There are a maximum of five pages, with up to five alarms per page. Use the page keys to display next or previous page. - NOTE - Alarm and Operator messages caused by an error generated in Background Edit will have no affect on a part program which is executing in foreground. - NOTES - M

30 - NOTES M-371

31 CHAPTER 3 - LUBRICATION Introduction The lubricator is mounted at the rear of the machine, Figure 3.1. Lubrication is accomplished through a LUBRIQUIP distribution system, A, for the ball screws and the bearings on the linear guideways. The cross slide ball screw, the carriage ball screw, and the 8 linear way bearing cartridges are lubricated automatically; the gantry and any load/unload system have, if necessary, their own separate lubrication. Tramp (waste) oil container (pan) B, Figure 3.2, should be emptied once per shift. It is located on the floor at right end of the machine near the back. When the machine has the optional Stacker Table or other load/unload system on the right end of the machine, the tramp oil pan is accessed through an opening near the floor. The lubrication system will complete 4 cycles of pumping oil during power up. If the cycle is not completed, an alarm is generated and the machine goes into an Emergency Stop (E-Stop) condition. Correct the emergency, i.e. add oil or whatever corrects the A situation, and, then, pull the E-Stop pushbutton out to clear the alarm and initiate the power-up lubrication cycle or at any time the lubrication system needs to be tested. Lubricator Consumption Guidelines The run time for one full lubricator tank is approximately 220 hours. All times are approximate and variations on an individual machine could be up to ±20% from the time listed. If actual lubrication consumption is greater or less than the acceptable range given, then check the system for the type of oil being used and for leaks or kinked hoses. Figure Lubricator Location The reservoir contains about 1.6 gallons [6 liters] of Mobil Vactra #2 oil when filled. The LUBRIQUIP feeders limit the amount of oil used per cycle. The actuator switch is activated to indicate that the cycle is completed once the distributor block sequentially sends oil to the 4 cross slide linear guide blocks, 4 carriage linear guide blocks, and both ball nuts. The pump cycle time is controlled by machine software and is preset at Hardinge. The lubrication pump cycles every 3.33 minutes; however, when the machine is idle, it cycles once every 50 minutes (30 cycles). If the axes move intermittently, the lubrication time will be greater than minutes and less than 50 minutes. The lubricator is active any time the CNC control is on. When the lubrication system requires maintenance, the machine must be powered down. A detailed procedure to power it down appears in Chapter 2 - POWER-UP PROCEDURE. B TP3525. TP3430. Figure Tramp Oil Pan and Trough M

32 Power-Down Procedure 1. Make certain that Cycle Start is not active. The pushbutton light should be off. 2. Make sure that the program has been completed and that the spindle, slides, and any load/unload system are stationary. 3. Press Emergency Stop pushbutton. 4. Turn the Control OFF/ON switch to the OFF (0) position. 5. Turn main air lock out valve OFF. 6. Turn main disconnect switch OFF. Lubrication Oil The lubrication oils that Hardinge, Inc. recommends for use on the machines have been thoroughly tested and qualified. Other oils may not contain certain additive packages needed for proper lubrication and performance from the oil. The additive packages may include rust and corrosion inhibitors, anti-wear compounds, defoamants, etc., which have been blended specifically for that application. Although many companies offer similar oils, these oils may not contain the needed additives to ensure maximum performance and protection of the Hardinge machines. Lubricator Refill Check the oil level daily. The oil level can be seen in the reservoir and compared to the sight gauge. The lubricator tank can be refilled at anytime that oil is needed, even while the machine is in operation. If the lubricator is low on oil, the following conditions exist: A. Lube Low Refill is displayed and single mode LED will flash but automatic operation is still allowed. B. When the tank is not refilled within the next 25 minutes, the machine is forced into Block by Block operation. C. If the tank is not filled after 5 more minutes, the machine will shut down with the JOG mode locked on and the Lube System Failure message displayed. D. When the machine is powered up and the Low Lube Refill message is displayed, the JOG mode is locked on. Fill the lubricator tank to clear this message and re-activate the lubrication system. Figure LUBRIQUIP Lubricator To fill the lubricator tank: 1. Wipe away any chips, oil, and dirt from the tank cover. - NOTE - Leave the filler tube screen in place. 2. Unthread filler cap C, Figure 3.3, and fill the tank with Mobil Vactra #2 oil. 3. Thread the cap on and continue with maintenance or operation. C TP M-371

33 To correct the low lubricator condition: 1. Fill the lubricator tank. 2. Press the E-Stop Reset (3) and Zero Return (6) pushbuttons at the same time to remove the alarm condition and re-activate the lubrication system. Other lubrication control conditions can be cleared just by pressing the RESET button on the CRT/MDI panel. To empty the tramp oil pan: 1. Locate tramp oil pan B, Figure 3.2, on the floor at right end of the machine near the back. If the machine has the optional Stacker Table or other load/unload system access the pan through an opening near the floor. 2. Pull the tramp oil pan from under the tramp oil trough. 3. Pour the oil from the pan; dispose of the oil in an environmentally safe manner. Clean the tramp oil pan with a lint-free cloth, if necessary. 4. Slide the pan in place aligned under the trough so that it will catch the oil. Lubricator Reservoir and In-Line Filter The in-line filter should be inspected every six months; it is located under and behind the lubricator reservoir bracket. Clean or replace the filter as necessary. It is also recommended that the reservoir be cleaned at least once a year. Efficient lubrication, clean valves and feeders, and long bearing life depend on clean lubricant. The filter cleans the oil before it goes into the lube lines and valves. To change the system filter element: 1. Power down the machine. Locate the in-line filter below the reservoir bracket. 2. Unthread plug D, Figure 3.4, from the filter housing. The plug has the filter mounted to it. 3. Replace the filter by unthreading it from the plug and installing a fresh, clean filter. 4. If necessary, clean the lubricator tank. Wipe it with a lint-free cloth. 5. Unthread the filler cap and fill the lubricator reservoir. Re-install the filler cap. 6. Power up the machine and check the lubrication system for oil leaks. D Figure In-Line Filter TP3429. M

34 To prefill and purge (prime) the lubrication system of air before operation: Anytime that the lubrication system has air contamination, the air must be purged from the lines and feeder block. Detailed information to purge the LUBRIQUIP system is contained in LUBRIQUIP literature bulletin Lubricator feeder block E, Figure 3.5, is mounted up underneath the rear of the cross slide on the carriage. The ports in the castings can be located by following the oil lines from the feeder block; ports 1 through 5 are for the cross slide with port 3 the ball screw lubrication and ports 6 through 10 are for the carriage with port 8 for its ball screw. 1. Make certain that the machine is powered down. 2. Access the feeder block. Unthread the screws and lift off the rear cross slide way E cover. 3. Fill and purge the feeder block and lubrication lines as follows: A. Remove the alternate outlet pipe plug(s) TP3534. from the feeder block. Figure LUBRIQUIP Feeder Block B. Connect an oil-filled hand pump to the outlet opening. C. Disconnect the lubrication line from its destination; manually pump the oil while making certain that oil is filling the line and reaching its lubrication point. D. Reconnect the lubrication line at the destination but do not thread in the alternate outlet plugs at this time. E. Repeat steps A through D for all lines from the feeder to their lubrication point(s). 4. Last, fill the feeder block with oil using the following procedure: A. Verify that all alternate outlet pipe plug(s) have been removed from the feeder block. B. Connect the LUBRIQUIP lubrication system pump to the inlet of the feeder block. C. Turn just the control ON and cycle the lubrication system pump until oil flows freely (is discharged) from the feeder block valve alternate outlet opening(s). D. Thread in the alternate outlet pipe plug(s) tight on the feeder block. Check all other lubrication system fittings to verify that they are tight and free of leaks. 5. When the lubrication system has been purged and other work completed, mount the way covers and fill the lubricator tank. 6. Power up the machine. 3-4 M-371

35 Replace the Lubricator Replace the lubricator as a unit if any of the lubricator mechanisms such as the motor and pump fail or become damaged. 1. Power down the machine. 2. Disconnect the oil line from the lubricator. 3. Unthread the nut that secures the grommet which seals the electrical cable and unthread the fitting that secures the sensor cable. 4. Loosen the screws that fasten the cover to electrical junction box E, Figure 3.6, and lift F off the cover. 5. Make a diagram of the electrical wire connections and connection for the sensor wire. G This will be important to follow when reconnecting the replacement lubricator. 6. Disconnect the wires and remove the cables from the junction box and fittings. TP Unthread two screws that mount the lubricator to the bracket. Replace the lubricator and Figure Top of Lubricator mount the new lubricator to the bracket. 8. Feed the cables into the junction box and connect the wires per step #5. Cover the junction box; connect the sensor wire. Make certain that the grommets are in place and then seal them by tightening the nuts. - CAUTION - Use just enough pipe sealant to secure the fittings. Do not apply sealant to the first few threads. Excess sealant may be pushed into the lube line and cause it to malfunction. 9. Reconnect the lube line to the lubricator. 10. Power up the machine and check the lubrication flow. To clean the oil reservoir: 1. Power down the machine. 2. Unthread the six screws from the top of the tank. The lubricator top has all the lubrication mechanisms and reservoir (tank) mounted to it. 3. Carefully loosen the tank and lower it from the lubricator top. Drain the oil. 4. Wipe the tank clean with a lint-free cloth. 5. Inspect and clean or replace the suction filter on the inlet tube. 6. Re-align the tank with the lubricator top and fasten it in place with its screws. 7. Unthread filler cap C, Figure 3.3, and fill the reservoir. Thread the filler cap on tight. 8. Power up the machine and check the tank seal for leaks. M

36 Clean Tramp Oil Trough The lubrication waste oil gravitates into the carriage ball screw cavity; drains down through the Harcrete base via a short hose into a trough which drains to the tramp oil pan at the right end of the machine. When the machine has the optional Stacker Table or other load/unload system on the right end of the machine, tramp oil and coolant may drain from the parts and gripper into a drain pan, through a hose and back into the tramp oil pan. To clean the tramp oil opening: 1. Move the axes away from Home toward the spindle. 2. Power down the machine. 3. Lift out and empty tramp oil pan B, Figure 3.2. Place the empty container back in place. 4. Gain access to the carriage ball screw cavity at the right side of the cross slide. -WARNING - Always blow the waste oil down through the line into an empty container. NEVER LOOK into the opening while air pressure is applied. 5. Use an air hose with moderate air pressure to clean waste oil or chips down through the opening. A flexible tube may have to be attached to the nozzle and shaped to fit under the way cover and into the waste oil opening. 6. Unthread the waste oil hose elbow and use a piece of wire up through the oil line if chips still block the waste oil opening. Work the wire up through the opening and push the chips up into the trough. - CAUTION - Use a cloth to remove the chips from the trough. Never use an air blast and do not use bare hands to remove the chips. 7. Wipe the chips from the trough with a rag and put the oil pan under the machine base. 8. Use an air hose with moderate air pressure to clean the waste oil opening again after using the wire to clear it. 9. Thread the waste oil hose elbow into the Harcrete base. 10. Remove the oil pan and clean any debris from it. Replace the pan under the trough. 11. Check the oil level in the lubrication reservoir. Fill the reservoir, if necessary. 12. Power up the machine. 3-6 M-371

37 - NOTES - M

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39 CHAPTER 4 - AIR FACILITIES INTRODUCTION Factory air to the CONQUEST GT27 and GT27SP AUTOLOAD series machines goes through a filter/regulator system to set the air pressure and remove contaminants before they get into the machine air supply. A coalescing filter is mounted after the pressure switch manifold to remove additional water vapor and oil. The system distributes air to: 1) the collet closer open and close, 2) the air options, and 3) the collet closer air receiver on machines with the Big Bore option or GT27 machines. Other valves B C and switches are added to this assembly as air options are added to the machine. A If the factory air has excessive moisture, add a heavy-duty air dryer to the incoming air line. Connect the air supply line to the air valve on the filter/regulator. The incoming air line should have a minimum I.D. of 3/8 inch [9.5 mm]; however, if the air line is especially long, a larger inside diameter hose may have to E be used. D Air is turned on by turning air valve knob A, Figure 4.1, counterclockwise and aligning the lock tabs. Regulator knob B, adjusts the air pressure range from 70 psi to 90 psi [4.9 to 6.3 bars]. Air pressure switch, C, is preset at 60 psi [4.2 bars]. If the switch detects pressure below 60 psi [4.2 bars], an alarm TP3426. message appears on the CRT and the program goes into E-Stop. Figure Air Panel with Cover - WARNING - Do not attempt to block or look into the port at the bottom of the air F G valve while releasing air from it. The air valve may be used to purge the factory air of contaminates before they get into the filter/regulator by rotating valve A, to any of the three positions other than the ON or OFF location over the lock rings. Drain the Filter/Regulator Unit Daily Drain filter/regulator daily by pressing manual FLEX-DRAIN petcock D, sideways; coalescing filter and collet closer filter bowls have manual (twist, unthread a turn or two) drains. If an excessive moisture problem exists, add a heavy-duty air dryer to the incoming air line. Figure Air Panel without Cover TP M

40 Power-Down Procedure When the air system requires maintenance, the machine must be powered down. A detailed procedure to power down the machine appears in Chapter 2 - POWER-UP PROCEDURE. 1. Be certain that Cycle Start is not active. Pushbutton light is OFF. 2. Make sure that the program has been completed and that the spindle, slides, and any load/unload system are stationary. 3. Press Emergency Stop (E-Stop) pushbutton. 4. Turn the Control OFF/ON switch to the OFF (0) position. 5. Turn off and lock out the main air valve. 6. Turn off and lock out the main disconnect switch. - CAUTION - The filter/regulator bowl and air receiver 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. Drain the Filter Bowls and Air Receiver The filter/regulator filter bowl has a manual flex drain valve; the coalescing filter and collet closer filter bowls have manual twist (unthread) drains to remove contaminants from the system; the air receiver, which maintains collet closer air pressure, has a petcock. - NOTE - The filter/regulator filter has a manual FLEX-DRAIN petcock D, Figure 4.1, that must be pressed sideways to open the drain valve. 1. Make certain that the air source is connected and turned ON. 2. Press the manual drain valve sideways on the bottom of filter/regulator A, enough to empty the bowl. Release the manual drain valve to seal the drain. 3. Check that any moisture in the coalescing filter and collet closer (GT27) filter bowls is below the level indicator line. Unthread the manual drain a turn or two if necessary. 4. Unthread the petcock counterclockwise on the bottom of the air receiver, Figure 4.3, just enough to drain. Thread the petcock closed to seal the air receiver. Drain the Air Receiver - CAUTION - Unthread, i.e. open, petcock H, Figure 4.3, on the end (bottom) of the air receiver whenever working on the air system or its components. This releases any air pressure. The air receiver is mounted under the machine tray and air panel at the rear of the machine. It should be drained of contaminants daily or possibly when draining the filter/regulator bowl. H Tp4017. Figure Air Receiver (Big Bore and GT27 Machines) 4-2 M-371

41 - WARNING - Do not look up under the machine tray while draining contaminants from the air receiver. Air exhausts rapidly from the air receiver. To drain the air receiver, turn petcock H, Figure 4.3, on the end (bottom) of the air receiver counterclockwise until any contaminants are exhausted. Again, if excessive moisture is in the air system, an air dryer must be installed. Seal the petcock by turning it clockwise until it is closed. Clean the Air System Bowl It is possible that after a period of time the air system bowl may need to be cleaned. The bowl is held in place by an outer protective shell (bowl guard). 1. Power down the machine. Drain any water from the filter/regulator bowl by pressing FLEX-DRAIN petcock D, Figures 4.1 and 4.4, to the side. 2. Pull down on black latch I, Figure 4.4, on the side of the outer shell. Rotate the shell counterclockwise to release the bowl from the filter/regulator head. Do not use excessive force to remove the bowl. Twist the bowl gently to release it from the head. 3. 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. 4. Clean or replace the filter on the regulator as necessary. To release the filter, unscrew the nylon fixture. The filter will drop out when the fixture is released. Clean or replace the filter and remount it. I J 5. Mount the bowl in the head as follows: put the plastic bowl into the shell. Align the bowl and shell in the air system head, press the D shell up into place and rotate it clockwise until the latch on the shell clicks to seat the TP3526. O-ring and bowl. Check to confirm that the Figure Coalescing Filter Unit bowl is in place before turning ON the main air valve. 6. Power up the machine and turn the main air valve ON. Set the regulator to 80 psi [5.5 bars] and check it for air leaks. Seal any air leaks as necessary. 7. Set the regulator below 60 psi [4.2 bars] to test the pressure switch to make certain that the whole system is functioning properly. When satisfied with the switch, manifold, and air unit, return the regulator pressure to an operating pressure from 70 psi to 90 psi [4.9 to 6.3 bars]. 8. Check the air system bowl again for contamination, moisture, or air leaks. Correct any problems as necessary. M

42 Replace the Coalescing Filter The machine is equipped with coalescing air filter J, Figure 4.4. This filter drains automatically when the sight indicator on the head turns orange. Make certain that the drain nipple on the bottom of the bowl is not covered or blocked. The filter element (Hardinge part number CN E) should be changed at least every six months. To change the coalescing filter element: 1. Power down the machine. Make certain that the air lock-out valve is OFF; align the lock-out valve tabs and lock the valve in the OFF position. 2. Pull down on the black latch and rotate the shell counterclockwise to release the bowl from the filter head. Wipe the bowl clean and check the O-ring. 3. Unthread the filter element from the threaded stem. 4. Thread the new filter element on the stem. 5. Put the plastic bowl in the shell. Align the bowl and shell in the filter head slots, press the shell up into place and rotate it clockwise until the latch on the shell clicks to seat the O-ring and bowl. 6. Power up the machine. Replace the Collet Closer (GT27, Big-Bore) Filter The GT27 machine and big-bore machine are each equipped with a collet closer air filter, Figure 4.5. This filter should be manually drained each day and when the moisture level is near the level indicator line. Make certain that the drain nipple on the bottom of the bowl is not covered or blocked. The filter element (Hardinge part number LC ) should be changed at least every six months. To change the coalescing filter element: 1. Power down the machine. Make certain that the air lock-out valve is OFF; align the lock-out valve tabs and lock the valve in the OFF position. 2. Relieve system air pressure by opening the air receiver petcock. When the air pressure is reduced, tighten the petcock. 3. Press (lift) the shell slightly up into the filter head and, then, rotate the shell counterclockwise to release the bowl from the head. Wipe the bowl clean and check the O-ring. 4. Unthread the filter element from the threaded nipple. Replace the filter element and thread it on snug. 5. Align the bowl and shell in the filter head; press the shell up into place and rotate it clockwise until it seats the O-ring and shell. 6. Unlock the air lock-out valve. Power up the machine. Tp4019. Figure GT27 and Big-Bore Collet Closer Air Filter 4-4 M-371

43 Replace the Air Control Assembly Components Any of the air control assembly components can be replaced if they become damaged. The air control assembly can also be replaced as a unit. 1. Power down the machine. Make certain that the air lock-out valve is OFF. Align the lock-out valve tabs and lock the valve in the OFF position. 2. Disconnect the main air line from the air lock out valve. 3. Unthread the screw and pull the electric plug straight up from the top of pressure switch C, Figure Disconnect the air line(s) from the air manifold. 5. Unthread the screws and remove the air assembly unit from the panel. - NOTE - The air control assembly components are fastened together with taper-railed blocks. 6. Loosen, but do not remove, the screws in the taper-railed block on either side of the component being replaced. Carefully slide the component out of the blocks. 7. Make certain that the O-rings are in place and mount the new component between the taper-railed blocks. Tighten the screw in each block. 8. Mount the air assembly unit on the panel. Tighten the screws that fasten it in place. - NOTE - Use just enough sealant to secure the fitting when fastening the air lines to the manifold((s). Do not apply sealant to the first few threads. 9. Fasten the air line(s) to the manifold. 10. Connect the electric plug to the top of the of pressure switch. Thread the screw into the pressure switch to secure the plug. 11. Connect the main air line and turn the air source on. 12. Remove the lock from the lock-out tab and power up the machine. Set the regulator to an operating pressure between 70 psi and 90 psi [4.9 to 6.2 bars]. 13. Press the E-STOP RESET pushbutton if it is still necessary to clear 1017 Main Air Pressure Low alarm message from the CRT. 14. Check the air system bowl for contamination, moisture, or air leaks and correct any problems as necessary. Replace the Pressure Switch(es) Pressure switch C, Figure 4.1, and/or collet pressure switches F and G, Figure 4.2, is designed to send a signal to the control and an alarm message appears on the CRT when the main air pressure falls below 60 psi [4.2 bars]. 1. Power down the machine. Make certain that the air lock out valve is OFF. Align the lock-out valve tabs and lock the valve in the OFF position. 2. Unthread the screw that holds the electrical plug to the top of the pressure switch. Pull the plug straight up to remove it from the switch. (continued on the next page) M

44 3. Unthread the pressure switch from the manifold. The switch is tightened to the manifold with light torque pressure, however, a wrench may be necessary to unthread it. - NOTE - Use just enough sealant to secure the fitting when fastening the pressure switch to the manifold. Do not apply sealant to the first few threads. 4. Thread a new pressure switch on the manifold and only tighten it to 50 in/pounds [5.6 Nm]. 5. Connect the electric plug to the pressure switch. Secure the plug with the screw. 6. Remove the lock from the lock-out tab and power up the machine. Set the regulator to an operating pressure between 70 psi to 90 psi [4.9 to 6.2 bars]. 7. Press the E-Stop Reset pushbutton if it is still necessary to clear 1017 Main Air Pressure Low alarm message from the CRT. 8. Check the air system bowl for contamination, moisture, or air leaks and correct any problems as necessary. Replace or Clean the Manifold(s) Main air manifold K, Figure 4.6, and collet closer manifold L, have no moving parts, but if they are not dispersing air as they should or if they become damaged, they may need to be replaced or cleaned. There are additional ports in the main air manifold for use when other air options are added to the machine. 1. Power down the machine. Make certain that the air lock out valve is OFF. Align the lock-out valve tabs and lock the valve in the OFF position. 2. Disconnect the air lines from whichever manifold requires work. 3. Unthread the manifold and fitting from the air panel. The air fitting may have to be removed from the manifold if the manifold is to be replaced. - NOTE - L Use just enough sealant to secure the fitting when fastening the air system components together. Do not apply sealant to the first few threads. 4. Thread the plugs and air line fittings into the new manifold and mount it on the air assembly unit. K 5. Attach the air lines to the fittings on the manifold. 6. Remove the lock from the lock-out tab and power up the machine. Set the regulator to an operating pressure between 70 psi and 90 psi [4.9 to 6.2 bars]. TP3427. Figure Air Manifolds and Solenoid Valves 4-6 M-371

45 7. Press the E-Stop Reset pushbutton if it is still necessary to clear 1017 Main Air Pressure Low alarm message from the CRT. 8. Check the air system bowl for contamination, moisture, or air leaks and correct any problems as necessary. Solenoid Valves Solenoid valves at both manifolds K and L, Figure 4.6, are horizontally stacked when mounted on the air panel. Most air system options are activated through solenoid valves and are available on the machine when originally ordered or some of the options can be retrofitted when necessary. Reference information is included in each air option retrofit kit and with each machine. Electrical connections, air line connections, cable markings, routings (ducting) through the machine, and location of the option parts are on the option information sheets and on the tags on the machine. To replace or add a solenoid valve: 1. Power down the machine. Make certain that the air lock out valve is OFF. Align the lock-out valve tabs and lock the valve in the OFF position. 2. Refer to the schematic chart on the panel to identify which valve needs to be replaced. If a valve is to be added, make certain that an identification stamp is placed on the chart. 3. Unthread the screw and remove the end plate from the stack of solenoid valves. 4. Unscrew the two fasteners that mount the end cap and each valve to its adjacent valve until the valve to be replaced is removed or until the new valve can be added to the stack of valves. - NOTE - It is not necessary to remove the electrical connection or air line from valves that are not being replaced. 5. Unthread the screw that secures the electrical connection to the solenoid valve being replaced. Pull the connection straight up to release it from the valve. 6. Unthread the air line from the fitting on the bottom of the valve being replaced. If necessary, remove the pneumatic fitting from the valve. 7. Thread an air fitting to the new valve. Use sealant to secure the fitting but do not apply it to the first few threads. 8. Mount the new valve to the end piece or adjacent valve on the panel. Check the valve gaskets and replace any that are worn. Fasten each valve and gasket in place. 9. Check the gaskets and mount the other valves and end plate to the new valve. 10. Support the new valve and fit the electrical connection to it. Secure the connection with its screw. 11. Refer to the information sheet for connections if an option is being added. 12. Fasten the air line to the fitting on the bottom of the valve. 13. Remove the lock from the lock-out tab and power up the machine. Set the regulator to an operating pressure between 80 psi to 90 psi [5.5 to 6.3 bars]. 14. Press the E-Stop Reset pushbutton if it is still necessary to clear 1017 Main Air Pressure Low alarm message from the CRT. M

46 Air Blast Options There are two air blast system options on the machine. One air blast system is on the headwall and the other system is on the cross slide coolant/air blast manifold. Each air blast system carries a force of air from the machine air supply system and directs it wherever necessary. When the machine s air system is active, an air blast can clean chips from the workholding device or from tooling. Flexible copper tubing mounted in standard brass fittings directs air at any position desired by the operator. TP186. Figure Headwall Air Blast TP185. Figure Cross Slide Air Blast and Coolant Nozzles The air blast system can be activated by programmed M codes. The headwall air blast is program activated by an M36 code and deactivated by an M37 code. The cross slide air blast is activated by an M46 code and deactivated by an M47 code. Both air blast locations can also be activated by the AIR BLAST pushbutton near the middle of the main control panel. If the air blast has been activated by a programmed code, pressing the AIR BLAST pushbutton will turn the air blast off and vice versa. When the pushbutton is pressed, both locations are activated unless there are plugs in the fittings. The thru-headwall air blast line is added to the existing manifold assembly in the valve compartment. Two copper tubes, Figure 4.7, are mounted in standard elbow fittings from a Tee fitting. The tubing can be replaced with a pipe plug to seal either fitting. The cross slide coolant and air blast manifold is controlled by another valve and solenoid in the valve compartment. Three copper tubes are mounted in standard straight fittings in the cross slide coolant and air blast manifold. These tubes can also be replaced with pipe plugs when any of them are not needed. If the air blast options are to be retrofitted to a machine, information for the electrical connections of the solenoids and mounting instructions are included in the kit. 4-8 M-371

47 - NOTES - M

48 - NOTES M-371

49 CHAPTER 5 - COOLANT FACILITIES Hardinge machine tools are designed using the latest technology and highest quality materials available. However, due to the ever increasing number of coolant selections available, it is impossible to test material compatibility with each and every coolant. For additional information regarding the coolant facilities on this machine, refer to the Operator s Manual (M-370). - CAUTION - Whenever water soluble coolants are used it is important to use the manufacturer s recommended mix ratio (concentration). It is also important to maintain the coolant by keeping the proper concentration level when coolant solution is added to compensate for evaporation. Another important factor is coolant Ph (acidity). Typically, the coolant Ph range is between 8.5 and 9.2. Below 8.5 the rust inhibitors in the coolant start depleting, which can result in corrosion of machine components. Also, the quality of the water should be tested by the coolant manufacturer so that the proper coolant additives can be administered. Failure to follow these recommendations could result in damage to the machine, seals, and paint. If the coolant you have selected starts to react (cause material to rust, pit, swell, soften, crack, blister etc.) with any portion of the machine tool, Hardinge suggests that you discontinue use and contact your coolant representative for alternative coolants. It should also be noted that certain chemicals react with different metals. Hardinge recommends that you consult with your coolant representative to assure that the material you are cutting does not react with the coolant you have selected. - NOTE - A properly selected and maintained coolant, either oil or water based, will ensure the best performance from the coolant and machine. INTRODUCTION The CONQUEST GT27 and CONQUEST GT27SP Autoload systems have a coolant recirculating module for either oil-based or water-based coolant. The module consists of a reservoir (tank) with filters, a five-eighth horsepower electric pump, fully adjustable directional hoses on the headwall and cross slide, a chip flush block with hoses on the right side wall, and a coolant catcher on the cover of the spindle compartment. Coolant is fed to the tool tips and workpiece through the directional hoses. Most of the fluid drains down into the tank through the chip pan, however, some liquid returns to the tank through a hose from the coolant catcher in the spindle drive compartment. At the beginning of each shift, clean the pan of most of its chips and then pour coolant directly into the pan. Fill the coolant reservoir to the FULL line (28 gallon [106 liter]) of the sight gauge on the tank. M

50 The coolant module is ready when the machine is powered up. The control panel pushbutton acts counter to the program; that is, when the program calls for coolant and coolant is not wanted at that time, the coolant can be shut off by pressing the COOLANT pushbutton. The opposite is also true. If the program does not call for coolant and it is needed, coolant can be activated by pressing the Coolant pushbutton. If coolant flow is not activated by a programmed M08, M13, or M14, pressing the Coolant pushbutton will start coolant flow. However, each time the program is repeated, the pushbutton must be pressed again to activate the coolant when it is needed. The adjustable nozzles direct coolant wherever they are set. Each in-line valve regulates flow to the nozzles and connects the directional hoses to the headwall fitting or to the manifold mounted on the cross slide. WATER-BASED COOLANTS Water-based coolants are a popular 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. Some coolants may cause machine corrosion problems and be incompatible with machine components. Poorly maintained coolants may result in rancidity, poor tool life, staining, rusting, foaming, etc., 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 compatibility with machine components. Refer to the list of common materials used in machine tool assembly at the end of this section. It is very important to follow the coolant manufacturer s recommendations when using a water based coolant. Maintaining coolants will increase the machine s useful life and will minimize corrosion, rusting, staining, etc., and health problems such as dermatitis, that are normally exhibited with used coolants. This maintenance should include a minimum of daily checks and correction of coolant concentration, a measure of coolant ph (acidity), and removal of any tramp oil from the machine sump. Concentration: The coolant concentration should be checked and corrected on a daily basis using a refractometer. The refractometer is a hand held optical device that gives a fairly reliable reading. However, its accuracy can be impaired by tramp oils, cleaners, and other contaminants. 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. ph: 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. 5-2 M-371

51 Water based coolants are designed to run within the ph range determined by the manufacturer. 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, filters, etc. It is best to consult with your coolant representative to determine your requirements. Care and Maintenance: A daily check of the concentration and ph will help keep the coolant at its 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 coolant 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. Proper cleaning of the machine is very important before refilling the reservoir with fresh coolant. Dispose of the used coolant properly. 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 reservoir, be completed before circulating cleaner through the system. When the coolant facilities require maintenance, the machine must be powered down. A detailed procedure to power down the machine appears in Chapter 2 - POWER-UP PROCEDURE. Power-Down Procedure 1. Be certain that Cycle Start is not active. The pushbutton light will be OFF. 2. Be sure the program has been completed and that the spindle, slides, and gantry are stationary. 3. Press the Emergency Stop pushbutton. 4. Turn the Control OFF/ON switch to the OFF (0) position. 5. Turn main air lock out valve OFF. 6. Turn main disconnect switch OFF and lock it out. M

52 Removing Chips and Shavings The chip pan/coolant reservoir is mounted on wheels and the coolant pump is removable, so that the reservoir may be moved straight out from under the machine. - 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. To remove chips from the chip pan/coolant reservoir: 1. Power down the machine. 2. Wait a minute to allow the coolant to drain into the tank. A 3. Locate coolant pump A, Figure 5.1, mounted near the left end of tank B, as viewed from the rear of the machine. Unthread the screws from the coolant pump flange and carefully lift the pump from the tank. B If necessary, unplug the chip conveyor electrical cable. 4. Roll the tank straight back to an area where it is most convenient to remove the metal chips or shavings. 5. Rake the chips into a suitable container and C TP3430 dispose of them properly. Figure Coolant Pump and Reservoir 6. Return the tank to its opening under the machine. 7. Place the coolant pump in its opening in the tank. Align the mounting holes in the pump flange with the threaded holes in the tank; thread in and tighten the screws. 8. Check inside the work area to see that coolant will drain into the chip pan. Correct any problems before powering up the machine and turning the coolant on. Cleaning the Reservoir and Filters Clean the coolant reservoir (tank) at least once every six months or more frequently if the coolant becomes contaminated by material being cut. Clean the reservoir whenever changing the type or brand of coolant. The coolant catcher on the cover of the spindle compartment should also be cleaned at the same time that the reservoir is cleaned. To clean the reservoir and filters: 1. Follow directions 1 through 5, in Removing Chips and Shavings, this chapter, to remove the tank and clean the chip pan. - 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. 5-4 M-371

53 2. Place a shallow pan under tank drain spigot C, on the left end. Remove the pipe plug to drain the coolant from the reservoir. 3. Lift the chip deflector from the chip pan or chip conveyor and lift the covers off the coolant reservoir filter assemblies. - CAUTION - Be careful, wear protection against metal slivers and cuts, when removing metal chips or shavings with the coolant from the reservoir. 4. Remove any coolant still in the reservoir. Wipe the reservoir clean. 5. Be aware of how each filter assembly is mounted in the frame in the reservoir. Lift the filter assemblies from the tank, one at a time. 6. Shake out the metal chips and then clean the filter assembly. Wipe the assembly clean. 7. Wash the reservoir and filter assemblies with a cleaner recommended by the coolant manufacturer to remove bacterial contamination. Flush the cleaner from the reservoir and clean it as recommended by the coolant manufacturer. 8. Apply pipe sealant to the pipe plug and thread it in to seal drain spigot C, Figure Align each filter assembly in its frame and fit it into the tank. Do not force the filter assembly into the frame, each will fit only one way and should not be altered to fit differently. 10. Fit the tank covers in place and install the chip deflector. 11. Return the tank to its space under the machine. 12. Place the coolant pump in its opening in the tank. Align the mounting holes in the pump flange with the threaded holes in the tank; thread in and tighten the screws. 13. Check inside the work area to see that coolant will drain into the chip pan. 14. Pour coolant directly into the chip pan. Refill the reservoir with the desired coolant. Coolant In-line Valves and Hoses The adjustable Snap-Loc hoses can be adjusted to any angle by simply bending or forming the links until the desired position is obtained. There are coolant valves and hoses on the headwall and on the cross slide coolant/air manifold. To adjust the nozzle length and position: 1. Power down the machine. 2. Separate ball links at one spot in nozzle D, Figure 5.2, by pulling it apart or rotating a link further than it normally goes. 3. Remove or add links to change the length of the hose as desired. 4. Re-attach the separated length by pressing the links together. 5. Adjust the angle and position of the hose to be certain that the length is correct. 6. Power up the machine. E D Figure Headwall Coolant Valves and Nozzles TP191 M

54 To replace coolant hoses or in-line valves: 1. Power down the machine. 2. Unscrew the threaded link of the hose from headwall valve E, Figure 5.2, and/or from cross slide coolant/air manifold valve F, Figure When the valve has to be removed, unthread it from the fitting on the headwall or from the manifold. - NOTE - Use pipe thread sealant on the fitting threads when replacing either the valves or adjustable hoses. 4. Thread the valve into the fitting or manifold and then thread the hose into the valve. 5. Adjust the length and/or angle of the hose to direct the coolant. 6. Power up the machine and adjust the coolant flow as necessary. TP192 Figure Cross Slide Coolant Valves and Hoses F Replacing the Coolant Pump Coolant pump G, Figure 5.4, is located on the reservoir at the left as viewed from behind the machine. The five-eighth horsepower motor draws coolant from the reservoir and pushes it to the headstock and cross slide hoses and the chip flush block. To replace the coolant pump: 1. Power down the machine. 2. Wait a minute to allow the coolant to drain into the tank. 3. At the rear of the machine, unthread the screws from the coolant pump flange and carefully lift the pump from the tank. 4. Follow the electrical cable from the pump to the side of the power case; unplug the coolant pump cable from the connection. 5. Loosen the clamps to the hoses so that the brass fittings can be unfastened to release the pump. Do not cut the hoses unless the fittings will not turn within the hoses when the clamps are loosened. There is enough hose if it is necessary to trim the hose to release the fittings. H G Figure Coolant Pump, Coolant Plumbing and Hoses TP M-371

55 6. Remove any plumbing fittings that might be necessary for re-installation of the hoses on the replacement pump. Some check valves may be located located vertically as in Figure 5.4 or they might be on a straight nipple and lay horizontally. Use pipe thread sealant on the threads when installing the fittings on the new pump. 7. Attach the coolant hoses to the pump. Tighten the clamps on the hoses. 8. Feed the pump electrical cable to the side of the power case and plug it in. 9. Make certain that the coolant hoses are not kinked when placing the pump in the reservoir. Align the mounting holes in the pump flange with the threaded holes in the tank; thread in and tighten the screws. - NOTE - If the pump needs to be primed, place a flexible piece of hose, approximately 16 [406.4mm] to 18 [457.2mm] inches long, over a coolant nozzle on one of the hoses mounted on the headwall. Cut a hole 2 [50.8mm] inches from the end of the hose where the coolant comes out of the hose. Make the hole large enough to insert an air hose tip to create a vacuum when the air is turned on to help draw the coolant through the system when it is activated. 10. Power up the machine and activate the coolant. Check the fittings for leaks. Coolant Catcher The coolant catcher returns coolant that flows through the rear of the spindle to the reservoir. The catcher is part of spindle compartment cover I, Figure 5.5. The coolant returns from the catcher to the tank through a hose that is mounted in the headwall. If the rest of the coolant system is being cleaned, the catcher and return hose should also be cleaned. 1. Make certain that the power is OFF. 2. Turn the main disconnect switch OFF. 3. Remove spindle compartment cover I, at the left end of the machine as follows: A. Unthread four panhead screws and rotate the left end of the cover, when facing the cover, out for enough clearance to disconnect the coolant return hose. B. Locate the hose fastened to the nipple on the bottom of the coolant catcher mounted on the spindle compartment cover. Unscrew the hose clamp to release the hose. C. Rotate the cover further and pull it straight I out of the tab in the lower right corner. 4. Access the coolant catcher on the cover; wipe out any liquid that remains in the catcher. 5. Wash the catcher with a cleaner recommended by the coolant manufacturer. TP2343. Figure Spindle Compartment Covers M

56 6. Insert the compartment cover in the tab at the lower right corner and connect the hose to the nipple on the catcher. 7. Mount the cover and tighten the screws. 8. Flush the coolant catcher to clean the return hose. Check the reservoir to see that the cleaner flows through the hose into the tank. 9. Clean the catcher and hose again. Flush the catcher and hose. 10. Fasten the cover in place with its screws. 11. Do what is necessary to clean and ready the coolant reservoir as described earlier in this chapter. 12. Pour coolant directly into the chip pan. Refill the reservoir with the desired coolant. Power up the machine and test the coolant flow. Figure Spindle Coolant Catcher TP NOTES M-371

57 CHAPTER 6 - PART LOAD/UNLOAD GANTRY Introduction The GÜDEL gantry in the machine cell with the CONQUEST GT27 and GT27SP series machine is a parts load/unload system. It is an integral part of this machine being aligned on towers that are mounted directly to the Harcrete machine base. For detailed gantry maintenance refer to the GÜDEL Operation Manual provided with the machine. Gantry system A, Figure 6.1, on top of the machine requires little routine maintenance with the exception of the repair-by-replace part-gripping fingers and lubrication of rollers and rails, and gear teeth. The part-gripping fingers are replaced when there is a change in the workpiece being made or when they become so worn that they no longer safely grip the workpiece; they must be replaced as a set. Each month or as required, add lubrication to the gantry grease blocks. Or if the gantry has the optional grease packs (automatic lubricators), replace them every six months or when signs of tribocorrosion begin. Gantry Lubrication - NOTES - Move the gantry to a convenient work position in front of the main coolant door and retract the gantry arm (up). Make certain that the spindle, machine axes and gantry are stationary before opening the main coolant door. Tribocorrosion is red coloration of the running track indicating direct metal to metal contact and insufficient lubrication. There are four grease blocks for each gantry axis; B, Figure 6.2, for the Y-axis and C, Figure 6.3, for the Z-axis. To grease the gantry axes: Figure Gantry Location Above Machine A TP Position the gantry and open the main coolant door. 2. Power down the machine. 3. Locate the four Y-axis grease blocks, Figure 6.2. Wipe the grease nipples clean with a lint-free cloth. B (continued on the next page) TP3554. Figure Gantry Y-Axis Grease Blocks M

58 - NOTE - Hardinge recommends KLÜBER NCA 15 (Hardinge part number TT NCA) grease in the gantry axes grease blocks. 4. Align the grease gun nozzle on the grease block nipple; pump the specified grease into C the block until fresh grease can be seen near each grease block grease opening. 5. Locate the four Z-axis grease blocks, Figure 6.3; the lower left grease block is up in front of the proximity switch block bracket. Wipe the grease nipples clean with a lint-free cloth. If this gantry position is too difficult to reach the Z-axis grease nipples, power up the machine to jog the gantry to the far right (+Z) TP3558. and power the machine down again. At the right rear of the machine, remove the guard Figure Z-Axis Grease Blocks to access the grease nipples. 6. Align the grease gun nozzle on the grease block nipple; pump the specified grease into the block until fresh grease can be seen near each grease block grease opening. 7. Check the condition of the part-gripping fingers while being in that close to the gantry; replace them as necessary. 8. Close the door and power up the machine. Move each gantry axis its full travel distance several times. Gantry Pneumatic (Air) Panel Solenoid valves D, Figures 6.4 and 6.5, mounted on the air panel on the gantry platform activate air cylinders to maneuver the gantry wrist and grippers. To replace a solenoid valve: 1. Power down the machine. Make certain that the air lock out valve is OFF. Align the lock-out valve tabs and lock the valve in the OFF position. 2. Refer to the schematic chart on the panel to identify which valve needs to be replaced. 3. Unthread the screw and remove the end plate from the stack of solenoid valves. 4. Unscrew the two fasteners that mount the end cap and each valve to its adjacent valve until the valve to be replaced is removed or until the new valve can be added to the stack of valves. D TP3556. Figure Gantry Pneumatic (Air) Panel 6-2 M-371 Revised: January, 2000

59 - NOTE - It is not necessary to remove the electrical connection or air line from valves that are not being replaced. 5. Unthread the screw that secures the electrical connection to the solenoid valve being replaced. Pull the connection straight up to release it from the valve. 6. Unthread the air line from the fitting on the valve being replaced. If necessary, remove the pneumatic fitting from the valve. 7. Thread an air fitting to the new valve. Use sealant to secure the fitting but do not apply it to the first few threads. 8. Mount the new valve to the end piece or adjacent valve on the panel. Check the valve gaskets and replace any that are worn. Fasten each valve and gasket in place. Figure Gantry Air Panel 9. Check the gaskets and mount the other valves and end plate to the new valve. 10. Support the new valve and fit the electrical connection to it. Secure the connection. 11. Remove the lock from the lock-out tab and power up the machine. Set the regulator to an operating pressure between 80 psi to 90 psi [5.5 to 6.3 bars]. 12. Press the E-Stop Reset pushbutton if it is still necessary to clear 1017 Main Air Pressure Low alarm message from the CRT. Gantry Axes Drive Motors The gantry is a two axes parts load/unload system. Each axis has a drive motor and gear box to move the gripper in the Y-axis and Z-axis directions. The drive motor/encoder assembly is an integral unit that must NOT be separated from the motor. The motor drive shaft uses a coupling on a splined shaft for direct drive and the axis drive motor flange mounts the motor directly to the gear box. To replace the gantry axes drive motor(s): - NOTES - Although it is best to work on the gantry drive motor(s) when the gantry is at the Home position, it may be necessary to replace/work on it anywhere along the gantry travel. Depending on the type of load/unload system, it may be necessary to remove the canopy from the top front right of the machine or stand on a platform at the rear to access the gantry axes drive motor(s). 1. If possible, Home the gantry axes; or, jog the gantry arm up and out of the machine workarea. 2. Power down the machine. (continued on the next page) D TP3557. M

60 3. Gain access to the gantry axes drive motor(s). F Unthread the screws and remove the canopy from the top front right of the machine or build a platform to act as a staging to work on the drive motors. It may be necessary to E use an approved ladder if the gantry drive motor is in other positions. 4. Tag the electrical connections to the encoder and motor for re-assembly. Note the position of the electrical connection outlets in relation to the gantry platform before unfastening the motor. 5. Unscrew each screw and pull the cable connector straight out from the encoder connection and from motor connection. NOTE - TP3554. The drive motor weighs approximately 30 pounds [13.6 kg]. Figure Z-Axis Drive Motor 6. Unthread four screws that mount the motor to the gear box. Carefully lift the motor and attached coupling from the gear shaft and platform. 7. Loosen the clamp screws in the coupling shoulder and unfasten the coupling from the motor drive shaft. 8. Mount the coupling to the drive shaft on the F new motor as follows: A. Place the coupling all the way on the drive shaft of the new motor. B. Tighten the coupling screws to 12 lb-in torque. 9. Lift the axis replacement motor; carefully align the coupling with the splined end of the gear box; position the electrical connection TP3557. outlets per step #4 and loosely mount the drive motor to the gear box with four screws Figure Y-Axis Drive Motor D, Figures 2.4 and 2.5, finger tight. 10. Make certain that lockwashers are in place and tighten the four screws that mount the drive motor to 85 lb-in torque. 11. Connect the motor and encoder electrical sources per step #4. Tighten the screws to secure the connections. 6-4 M-371

61 - NOTE - Because the motor/encoder assembly has been disconnected from the gear box, the control does not know the position of the gantry axes. This may cause a SOFTWARE OVERTRAVEL message to be displayed when the control is powered up even though an overtravel condition does not exist. 12. Mount the gantry home fixture to the top (tool) plate. The fixture is a standard HG5 tool holder with.50 inch [12.7 mm] collet bushing and a pointed, line-scribed and numbered, homing bar. Center the fixture on the 0 on the top plate; then, insert the homing bar 30 to 40 millimetres into the fixture collet bushing. 13. Power up the machine. If information is necessary to power up the machine refer to Hardinge Operator s manual M-370. Zero return (Home) both machine axes. The X Home position puts the homing bar at the spindle centerline. 14. Clear the feed hold (alarm) condition and reset the gantry as follows: A. Press the F1 key until PATH soft key is present; press the F10 key to activate the path setting sub screen. The sub screen will display GANTRY or MTOOL (machine); if MTOOL is displayed, press the directional up or down arrow directional keys to change to GANTRY. B. Press the E-Stop pushbutton and make certain that it remains down. C. Press OFFSET SETTING key to display the Setting (HANDY) page. D. Press the PAGE down ( )orup( ) until the cursor is at Parameter WRITE. E. Change Parameter WRITE from 0 to 1 (enable). Press key 1 and then the INPUT soft key or INPUT key. F. Press the SYSTEM key and PARAMETER soft key. Enter and press the No.SRCH (search) soft key. G. At 1850 Z, key in 0 and press the INPUT soft key. An alarm may be displayed; if an alarm is displayed, power down and, then, power up the control. H. Press the SYSTEM key and PARAMETER soft key. Enter and press the No.SRCH (search) soft key. I. At 1815 bit 4 Z (APZ), key in 0 and press the INPUT soft key. J. Press the Control OFF [O] [55PB] pushbutton and wait momentarily; press Control ON [ l ] [56PB] pushbutton (power down and power up). K. Pull the E-Stop pushbutton out and, then, pull it further out and hold it momentarily to release the Emergency Stop. L. Open both the main guard door and coolant guard door to the work area. M. Rotate the wrist in the clockwise position and, then, move the shuttle to the IN position. Jog the gantry in front of the spindle. (continued on the next page) M

62 N. Slide the homing bar toward the spindle until it makes contact with the gripper. Jog the gantry Z axis in the plus (+) direction to the scribed line flush with the collet bushing as referenced by the brass tag numbers on the chart inscribed on the fixture. (The gripper moves the homing bar back into the gantry home fixture.) This is the gantry Z axis home position. O. Set the gantry axis as follows: 1. Remove (pull) the homing bar from the gantry home fixture. 2. Make certain that the control is in JOG mode. If necessary, quick page to MODE; press JOG soft key. 3. Press POS pushbutton, then, REL soft key. 4. Press W and then press the ORIGIN soft key. The gantry Z axis will change to 0. Press U and then press the ORIGIN soft key. The gantry Y axis will change to Jog the Y axis up until the position display reads This positions both the Z and Y axes at their Home position. 6. Press SYSTEM key and the PARAMETER soft key. 7. Enter 1815andpress the No.SRCH soft key. 8. At 1815 bit 4 Z (APZ), key in 1 and press the INPUT soft key. And, at 1815 bit 4 Y (APZ), key in 1 and press the INPUT soft key. P. Press the Control OFF [O] [55PB] pushbutton and wait momentarily; press Control ON [ l ] [56PB] pushbutton (power down and power up). Q. Change Parameter WRITE back to 0 as follows: 1. Press the E-Stop pushbutton and make certain that it remains down. 2. Press OFFSET SETTING key to display the Setting (HANDY) page. 3. Press the PAGE down ( )orup( ) until the cursor is at Parameter WRITE. 4. Change Parameter WRITE from 1 to 0. Press key 0 and then the INPUT soft key or INPUT key. 15. Close both the coolant guard door and main guard door. 16. Turn the MACHINE/BOTH/GANTRY [6SS Path Select] selector switch to GANTRY and reset the Y and Z gantry axes. 17. Turn the MACHINE/BOTH/GANTRY [6SS Path Select] selector switch to MACHINE. Press the Zero Return [6] pushbutton to reset the X and Z machine axes. 18. If necessary, install the canopy or remove any platform or ladders from the work area. 6-6 M-371

63 - NOTES - M

64 - NOTES M-371

65 CHAPTER 7 - HEADSTOCK AND SPINDLE DRIVE Introduction The headstock, A, Figure 7.1, and spindle assembly are mounted on riser block B. The riser block is mounted to a cast iron insert in the Harcrete polymer composite base. The headstock is a solid, ribbed, cast-iron housing that dissipates heat and supports the spindle assembly. The standard collet spindle is an ANSI A2-4 5C collet design that permits bar work up to 1-1/16" [27mm] diameter. It is also possible to use a 4 inch chuck on this spindle nose. The headstock and spindle assembly must not be disassembled in the field. After the headstock is assembled, the spindle nose is ground to center and then the pulley is ground. The runout on the face of the pulley should be no more than.0001" [.0025 mm] maximum, Figure 7.2. Check this runout when mounting the adapter plate and collet closer. A The AC digital spindle drives and motors are reliable. They require minimal maintenance because B they are fan cooled, brushless, and permanently sealed and lubricated. Drive vibration is minimized by the use of a vee-belt that transfers power from the drive motor to the spindle. When anything in the spindle compartment requires maintenance, the machine must be powered down. A detailed procedure to power down and lock out the machine appears in Chapter 2 - Power-Up Procedure. Power-Down Procedure 1. Be certain that Cycle Start is not active. The pushbutton light will be OFF. 2. Make sure the program has been completed and that the spindle, slides, and gantry are stationary. 3. Press the Emergency Stop pushbutton. 4. Turn the Control switch to the OFF (0) position. 5. Turn the air valve OFF and lock it out. 6. Turn the main disconnect switch OFF and lock it out..0001" [.0025mm] T.I.R. maximum.0001" [.0025mm] T.I.R. maximum TP3536. Figure Headstock and Riser Block in Spindle Compartment TI2167 Figure Runout on Lip and Face of the Spindle Pulley M

66 Spindle Draw Tube Plug The spindle draw tube plug is inserted in the rear opening of the draw tube to contain coolant and/or chips when a bar feed is not being used. Put the plug into the tube up to the flange, insert a small rod or allen wrench to turn the plug shaft clockwise and expand the rubber seal within the tube. Remove the rod or wrench immediately after seating the plug in the tube. Spindle Drive Belt Adjustment Figure Spindle Draw Tube (without Plug) The spindle drive belt tension is adjusted by moving the drive motor platform up or down. Belt adjustment can be made with just the lower cover of the spindle compartment off. However, to accurately test the belt deflection, also remove the upper cover. 1. Power down the machine. 2. Remove the spindle compartment covers at the left end of the machine as follows: A. Unthread the panhead screws and lift off lower spindle compartment cover D, Figure 7.4. B. Unscrew the hose clamp to release the coolant return hose fastened to the bottom of the coolant catcher mounted inside upper spindle compartment cover C. C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. 3. Loosen, but do not remove, four screws E, Figure 7.5, that mount the drive motor platform to the Harcrete base. These four screws secure the platform once the vee-belt has been adjusted. C - NOTE - The belt tension specification is.30" [7.6 mm] belt deflection at 6.7 to 9 pounds [3 to 4 kg] force when using a spring gauge. The static tension read on an OPTIBELT gauge is 100 to 105 D pounds [45.4 to 47.6 kg] force. TP3540. TP3531. Figure Spindle Drive Compartment Covers 7-2 M-371

67 4. Adjust the drive belt tension by moving the drive motor platform toward or away from the spindle centerline. The screw in adjustment block F, Figure 7.5, supports the platform and moves it toward the centerline for less belt tension or away from the centerline for more belt tension. 5. Secure the platform after setting the belt tension specification. Tighten four locking screws E, to 230 lb-ft [312 Nm] torque. 6. Power up the machine and test the machine at various rpm. Power down the machine and mount the compartment covers as follows: A. Mount the upper compartment cover on the machine. B. Connect the hose to the fitting on the coolant catcher. C. Mount the lower spindle drive compartment cover and fasten it in place with its screws. E F E TP3536. Figure Drive Motor Platform Bolts and Adjustment Block Spindle Drive Belt Replacement Spindle drive belts are very reliable; however, belts should be checked for wear and tension every 500 hours of operation. 1. Power down the machine. Make certain that the main air valve is locked out and, if the machine has the big bore optional spindle, bleed off the air from the air receiver (unthread the drain on the bottom). 2. Remove the spindle compartment covers at the left end of the machine as follows: A. Unthread the panhead screws and lift off lower spindle compartment cover D, Figure 7.4. B. Unscrew the hose clamp to release the coolant return hose fastened to the bottom of the coolant catcher mounted inside upper spindle compartment cover C. C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. 3. Loosen, but do not remove, four screws E, Figure 7.5, that mount the drive motor platform to the Harcrete base. These four screws secure the platform once the vee-belt has been adjusted. 4. Belt tension can be released by threading the screw in adjustment block F, Figure 7.6, toward the spindle centerline. Loosen the tension enough to allow the belt to be removed from the drive motor pulley. (continued on the next page) M

68 5. Disconnect and remove the following to allow the belt to be removed: A. Tag the following lines for identification and disconnect them from the spindle, collet closer and Z-axis drive motor: 1. Disconnect air brake hose J, and disconnect collet open line H, and collet close line I. 2. Unthread the knurled nuts and disconnect electric lines K to the axis motor by pulling them straight off. B. Unfasten collet closer bracket G. C. Unthread screws R and remove the encoder assembly from the top of the headstock as follows: 1. Loosen two screws R, and loosen the belt from the encoder. 2. Unthread the screws and remove the encoder assembly. Lay the encoder assembly on the headstock. 6. Remove the spindle drive belt from the spindle pulley and put the replacement belt on this pulley. - NOTE - The belt tension specification is.30" [7.6 mm] belt deflection at 6.7 to 9 pounds [3 to 4 kg] force when using a spring gauge. The static tension read on an OPTIBELT gauge is 100 to 105 pounds [45.4 to 47.6 kg] force. 7. Place the belt in the grooves on the drive pulley. Adjust the belt tension by turning the screw in adjustment block F away from the spindle centerline. 8. Tighten four locking screws E to 230 lb-ft [312 Nm] torque after the platform is in place. 9. Fasten collet closer bracket G, in place with its screws. 10. Connect lines H, I, J, and K to their respective connectors. 11. Remount the encoder assembly on the headstock as follows: A. Slip the spindle timing belt over the encoder pulley. B. Mount the bracket in place but do not tighten screws R". - NOTE - The belt tension specification is 0.10" [2.5 mm] belt deflection measured at the midpoint between pulleys at an applied force from.35 to.42 pound [.16 to.19 kg]. C. Pivot the encoder bracket to set the belt tension. Retighten screws R to 25 lb-ft [34 Nm] torque when the belt tension specification is met. H G J I K E R F L O Figure Spindle Drive Belt and Hydraulic Lines R M N E TP M-371

69 12. Power up the machine. - NOTE - The spindle is oriented when the spindle key in the spindle nose is at the 12 o clock (straight up) position. 13. Test the new spindle belt at various rpm. 14. Power down the machine and mount the spindle compartment covers. Spindle Drive Motor Replacement and Alignment The spindle drive motor is mounted to a plate that is mounted to the drive motor platform. This plate has four slots to allow belt alignment after the motor has been removed or replaced. Spindle drive belt tension is adjusted by moving the drive motor platform. The drive motors are very reliable and require minimal maintenance because they are fan cooled, brushless, and permanently sealed and lubricated. To replace and align the drive motor: 1. Power down the machine and lock out the main disconnect switch. 2. Follow steps #1 through 5 in Spindle Drive Belt Replacement to remove the spindle compartment covers and releasing the belt tension. 3. Disconnect the power cable from the drive motor as follows: A. Remove the screws and take the cover from electrical junction box L. B. Make a diagram of the wire connections and what lead cables enter the box through which cord grip. C. Release the knurled nut from each cord grip and pull the grommet and nut back on the lead cables. D. Unfasten the wires from the terminal strips in the junction box. Carefully pull the wires from the box. 4. Remove four bolts M to release the motor from the plate. Do not loosen four screws N that mount the plate to the platform. 5. Lift the motor from the drive compartment with the help of another person or a hoist. 6. Unfasten, if necessary, the pulley from the old motor and mount it on the new motor. 7. Lightly grease the contact surfaces and install the new motor on the plate. Thread four bolts M into the plate but do not tighten them. 8. Slip the drive belt over the motor pulley and visually align the motor pulley with the spindle pulley. 9. Tighten the four bolts to 30 lb-ft [41 Nm] torque. - NOTE - The belt tension specification is.30" [7.6 mm] belt deflection at 6.7 to 9 pounds [3 to 4 kg] force when using a spring gauge. If the static tension is read with an OPTIBELT gauge, the force is 100 to 105 pounds [45.4 to 47.6 kg]. 10. Adjust the belt tension by moving the drive motor platform away from the spindle centerline. Tighten four locking screws, E to 230 lb-ft [312 Nm] torque to secure the platform. (continued on the next page) M

70 11. Loosen four screws N to move the plate on the platform if further belt alignment is necessary. Loosen or tighten platform alignment screw O, after the belt is aligned. Align the belt and retighten the screws to 50 lb-ft [68 Nm] torque. 12. Feed the lead cables through the cord grips to the junction box and connect the power cable to the drive motor as follows: A. Follow the diagram made in step #3.B to fasten the wires to the terminal strips. B. Slide the grommets in place on the cables in the cord grips. Tighten the knurled nut on each grip to seal the cables. C. Make certain that the gasket is in place to seal the junction box. Fasten the junction box cover with its screws. 13. Power up the machine and test the machine at various rpm. 14. Power down the machine and mount the compartment covers as follows: A. Mount the upper compartment cover on the machine. B. Connect the hose to the fitting on the coolant catcher. C. Mount the lower spindle drive compartment cover and fasten it in place. Spindle Encoder Timing Belt Adjustment Spindle encoder P, Figures 7.7 and 7.8, is mounted in a bracket on top of the headstock. The bracket has slotted openings for adjusting the timing belt tension. 1. Power down the machine. 2. Remove the spindle compartment covers at the left end of the machine as follows: A. Unthread the panhead screws and lift off lower spindle compartment cover D, Figure 7.3. B. Unscrew the hose clamp to release the coolant return hose fastened to the bottom of the coolant catcher mounted inside upper spindle compartment cover C. C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. R Q P 3. Locate encoder bracket Q, Figure 7.7, and test the belt tension. - NOTE - R The belt tension specification is 0.10" [2.5 mm] belt deflection measured at the midpoint between pulleys with an applied force of.35 to.42 pound [.16 to.19 kg]. 4. Loosen bracket screw(s) R, Figures 7.7 and 7.8, to enable the bracket to be pivoted to set the belt tension. Retighten the screw(s) to 25 lb-ft [34 Nm] when the belt tension specification is met. 5. Power up the machine and observe the belt tension at various rpm. 6. Power down the machine and mount the compartment covers. TP2364. Figure Spindle Encoder Pulley and Bracket Screws 7-6 M-371

71 Spindle Encoder Replacement Spindle encoder P, Figure 7.8, is mounted in a bracket on top of the headstock. Remove the mounting bracket and encoder to replace the encoder. 1. Power down the machine. 2. Remove the spindle compartment covers at S the left end of the machine as follows: A. Unthread the panhead screws and lift off Q lower spindle compartment cover D, Figure 7.3. P B. Unscrew the hose clamp to release the coolant return hose fastened to the bottom R of the coolant catcher mounted inside upper spindle compartment cover. C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. TP Unfasten the knurled nut on the encoder electrical plug. Pull the plug straight out to Figure Spindle Encoder release it from the encoder. 4. Unthread two screws R to remove mounting bracket Q, Figures 7.7 and 7.8, the pulley and encoder from the headstock. 5. Loosen the set screw in coupling S, that fastens the encoder to the pulley shaft. 6. Loosen the three screws that fasten the cam clamps that hold the encoder to the mounting bracket. 7. Replace the encoder on the mounting bracket as follows: A. Align the encoder shaft in the coupling opening. B. Hold the encoder on the bracket and rotate the cam clamps into place. C. Tighten the three screws to 15 lb-in [1.7 Nm] torque. D. Tighten the coupling set screw to 11 lb-in [1.3 Nm] torque. 8. Remount the encoder assembly on the headstock. Slip the spindle timing belt over the pulley. Mount the bracket in place but do not tighten screws R. - NOTE - The belt tension specification is 0.10" [2.5 mm] belt deflection measured at the midpoint between pulleys at an applied force of.35 to.42 pound [.16 to.19 kg] 9. Pivot the encoder bracket to set the belt tension. Retighten screws R to 25 lb-ft [34 Nm] torque when the belt tension specification is met. - WARNING - Make certain that NO ONE is near the operator s control panel and that the machine cycle is complete before working in the spindle compartment area with the machine powered up. 10. Power up the machine and test the machine at various rpm. Power down the machine and mount the compartment covers. M

72 Spindle Encoder Timing Belt Replacement The spindle encoder timing belt replacement requires that the spindle collet closer, and spindle drive belt be removed. Spindle compartment covers are removed and installed as in other spindle encoder sections. 1. Power down the machine and lock out the main disconnect switch. 2. Remove the spindle compartment covers at the left end of the machine. 3. Loosen, but do not remove, four screws E, Figure 7.6, that mount the drive motor platform to the Harcrete base. 4. Turn the screw in adjustment block F clockwise to relieve tension on the spindle drive belt. Enough tension should be off the belt to allow it to be removed from the spindle pulley in step 11, below. 5. Disconnect air brake hose J, and both collet open line H and collet close line I. 6. Follow detailed directions in Chapter 8 to remove the closer. Loosen the six screws through the adapter plate and pull the closer assembly out as far as it comes. Unthread the screws fully until the closer assembly is released. 7. Remove the belt from the drive motor pulley and slide it from the spindle pulley. Turn the screw in adjustment block F, Figure 7.6, clockwise if the belt needs to be loosened more to removed the belt. 8. Loosen screws R, Figures 7.7 and 7.8, and relieve the encoder belt tension. 9. Slip the timing belt from the encoder pulley and remove it from the spindle pulley. Remove the belt from the spindle assembly. - NOTE - The encoder timing belt tension specification is 0.10" [2.5 mm] belt deflection measured at the midpoint between pulleys at a force of.35 to.42 pound [.16 to.19 kg]. 10. Replace the spindle timing belt on the pulleys. Adjust the belt tension and tighten mounting screws R. - NOTE - The belt tension specification is.30" [7.6 mm] belt deflection at 6.7 to 9 pounds [3 to 4 kg] force when using a spring gauge. The static tension read on an OPTIBELT gauge is 100 to 105 pounds [45.4 to 47.6 kg] force. 11. Slide the drive belt onto the pulleys. Adjust the belt tension and tighten all four drive motor platform screws to 230 lb-ft [312 Nm] torque. 12. Install the collet closer as follows: A. Clean the spindle bore and use a light coat of Bel-Ray Molylube Anti-Seize molybdenum disulfide on the bore and on the outside diameter of the collet closer sleeve. B. Center the draw tube in the spindle and push it in as far as it will go. Align the air line tubes in their bracket as the collet closer is pushed into place. C. Thread the six screws from the adapter into the collet closer hand tight. D. Push the assembly in further and tighten the screws by hand. E. Tighten the collet closer screws to 100 lb-in [12 Nm] torque. 13. Connect the collet open/close air lines and air brake hose unfastened in step # Power up the machine. 7-8 M-371

73 Headstock Alignment Headstock T, Figure 7.9, is mounted on riser block U, by four large screws. It is centered and can pivot on a dowel pin when the mounting screws are loosened. The alignment blocks and jack screws are packaged separately and must be mounted to the riser block before starting the headstock alignment. To align the headstock: 1. Power down the machine. 2. Remove the spindle compartment covers at the left end of the machine per Spindle Drive Belt Adjustment page Mount the jack screws in the alignment blocks. Use two screws in each block and mount the alignment blocks to the front of riser block U. 4. Power up the machine. 5. Install a 6 inch [152 mm] long arbor. 6. Mount an indicator on the top plate. - NOTE - The headstock alignment specification is within to inch [ to mm] toward the head when measured parallel to the T ways. The perpendicular specification, measured by indicating on top of the arbor, is within to inch [ to mm] with the outer U end low. 7. Locate the indicator on the top plate to check the edge of the arbor for parallel along the Z-axis to test headstock alignment. 8. Move the indicator to check along the top of the arbor for headstock alignment perpendicular to the ways. Figure Headstock and Riser Block in Spindle Compartment - WARNING - Shut down the power to the machine each time adjustments are to be made in the spindle drive compartment. 9. Power down the machine. 10. Loosen, but do not remove, the four screws mounting the headstock to the riser block if the headstock needs to be aligned in either direction. TP3537. (continued on the next page) M

74 - NOTE - One jack screw must be loosened as the other jack screw is tightened. The head pivots on a center dowel pin and is held by the jack screws until the mounting screws are tightened. 11. Loosen or tighten the jack screws in the alignment blocks as necessary to move the headstock within its alignment specifications. 12. Tighten the four headstock mounting screws to 170 lb-ft [230 Nm] torque when the headstock is aligned. 13. Power up the machine and follow steps #7 through 11 to recheck the alignment of the headstock. Make any adjustments as necessary. 14. Power down the machine. 15. Unthread both jack screws away from the headstock. The alignment blocks can remain on the headstock. 16. Mount the compartment covers. Cleaning the Spindle Brake Disc Every six months open the spindle compartment covers and check spindle brake disc V, Figure 7.10, for contamination build-up on the brake contact sides of the disc. If contamination is present, use a cleaner to remove the contaminant; then, clean and dry the disc. Clean the spindle brake disc as follows: 1. Power down the machine and lock out (disable) the main disconnect switch. 2. Remove the spindle compartment covers as follows: A. Unthread the screws and lift off the lower spindle compartment cover. B. Loosen the clamp and disconnect the coolant hose from the coolant catcher drain. C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. 3. Unthread both screws mounting each spacer block X, to the riser block. 4. Slide brake assemblies W, from the brake disc. 5. Determine what contamination is on the brake disc. Use a cleaner to completely remove the contamination from the disc. Clean and wipe the disc dry with a lint-free cloth. 6. If possible, eliminate the source of contamination. V 7. Clean each brake and make certain that they W operate properly. 8. Slide the brake assemblies on the brake disc X and mount them to the riser block. Tighten TP3537. the four screws finger tight. Figure Spindle Brakes 7-10 M-371

75 - NOTE - The gap between each brake pad and the brake disc is a minimum of.005 inch [.13 mm]. The gaps on each side of the disc do not have to be equal. 9. Measure the gap between the brake pad and disc on each side of the disc. 10. If there is interference or not enough clearance, remove the screws mounting the black spacer block(s) to the riser block and add shim(s) or remove material from the spacer block as necessary to create the proper brake gaps. 11. Slide the brake(s) on the brake disc and re-attach the spacer block(s) to the riser block with the screws finger tight. Check the gap again; then, when the gap is within specification, alternately tighten the screws to 25 Ib.-ft. [34 N-m] torque. 12. Check the screws that mount the brakes to the spacer blocks by making certain that each is at 200 Ib-in [23 N-m] torque. 13. Power up the machine. 14. Test the brake as follows: A. Press the JOG pushbutton; although, any control mode can be used. B. Press the SPINDLE FREE pushbutton to have the brake pads disengage the disc. Press it again to engage the disc. When the light is off, the brake is engaged. C. Watch the gap between the brake pad and brake disc to make certain that both brakes are functioning. Make any adjustments as necessary. 15. Power down the machine and mount the spindle compartment covers. 16. Power up the machine. -NOTES - M

76 -NOTES M-371

77 CHAPTER 8 - COLLET CLOSER Introduction The CNC lathe is equipped with a pneumatically (air) actuated collet closer. If repairs to the collet closer are required, the ENTIRE ASSEMBLY must be removed and returned to the factory. The standard collet closer is an ANSI A2-4 5C which accepts work up to 1-1/16 inch [26.98 mm]. The optional A2-4 16C Big-Bore general precision spindle uses the same maintenance information; however, the spindles are NOT interchangeable. Detailed maintenance information for the collet closer pressure switch and air components is in Chapter 4 - AIR FACILITIES. Free Spindle The Free Spindle condition allows the spindle to be turned by hand. If the machine is still powered up, press the Collet/Chuck pushbutton to open the spindle workholding device and remove any stock from the collet or chuck. Power down the machine. Power-Down Procedure: 1. Be certain that Cycle Start is not active. The pushbutton light will be OFF. 2. Look inside the work compartment to make sure that the program has been completed and that the spindle, slides, and gantry are stationary. 3. Press the Emergency Stop (E-Stop) pushbutton. 4. Turn the Control switch to the OFF (0) position. 5. Turn the main air valve OFF and lock it out. 6. Turn the main disconnect switch OFF and lock it out. Collet Closer Draw Tube Cleaning Depending on the job and material being cut, particularly if it is a bar stock job, the draw tube should be removed from the collet closer and cleaned every 40 hours and between job setups to prevent chip loading between the draw tube and spindle bore; it should also be removed when cleaning the collet closer monthly. Always clean from the spindle compartment end in toward the work area. To remove the draw tube: 1. Press the Collet/Chuck pushbutton to open the spindle workholding device and remove any stock. Power down the machine. 2. Unthread the four panhead screws on access cover B, Figure 8.1, on upper spindle compartment cover A, and remove it. If more room is needed to remove and clean the spindle draw tube and/or collet closer, remove the spindle compartment covers as follows: A. Unthread the panhead screws and lift off the lower spindle compartment cover. B. Unscrew the hose clamp to release the coolant return hose fastened to the bottom of the coolant catcher mounted inside upper spindle compartment cover A. C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. (continued on the next page) M

78 - NOTE - The adjusting nut may be warm if the spindle has been run continuously just before power down. 3. Remove the draw tube from the collet or chuck as follows: A. Unthread three screws C, Figure 8.2, in the edge of the knurled adjusting nut. B. Lightly pull back on the adjusting nut and unthread the draw tube from the collet or chuck. C. Remove the collet from the spindle or unthread the screws and remove the chuck from the chuck adapter. 4. Pull the draw tube assembly straight out from the spindle. - CAUTION - Always wipe the draw tube and spindle interior from the spindle compartment end toward the work compartment. 5. Wipe the draw tube and the inside of the spindle free of coolant, chips, and dirt. 6. Check the condition of the grooves on the draw tube. Thoroughly clean each groove. - NOTE - Use Mobiltemp SHC 32 grease or the military specified Mobilgrease Use a light coat of the specified grease to cover the outside diameter of the draw tube and the inside of the spindle bore. If the machine is a big-bore, make certain that there is grease in the grooves. 8. Slide the draw tube into the spindle and push it in all the way. 9. Remount the collet or chuck as follows: A. Pull the draw tube back slightly. Figure Collet Closer Access Door and Upper Spindle Compartment Cover B. Put a collet into the spindle and hold it with the collet retainer or mount a chuck on the chuck adapter. C. Push the draw tube into the spindle until it makes contact with the rear of the collet or chuck. Turn the draw tube and fully thread it onto the collet or chuck. 10. Power up the machine. D C E A Figure Draw Tube End and Collet Closer B TP3531. TP M-371

79 - CAUTION - DO NOT close the collet closer without gripping a workpiece or piece of stock in the collet or chuck. 11. Adjust the collet or chuck holding force as follows: A. Put a workpiece or piece of stock in the collet or chuck. B. Push the Collet/Chuck pushbutton to close the collet. C. Thread the draw tube on the collet or chuck tight. D. Unthread the tube a quarter to a half a turn while aligning three screws C, Figure 8.2, with the three holes in the collet closer. Thread the screws in tight. 12. Test run the spindle. Open and close the collet or chuck several times. Replace the access cover and/or spindle compartment covers before cutting parts. Standard ANSI A2-4 5C Collet Closer The collet closer should be removed monthly or approximately 160 hours of operation. If repairs to the collet closer are required, the ENTIRE ASSEMBLY must be returned to the factory. To remove the collet closer: 1. Remove the spindle compartment covers as follows: A. Unthread the panhead screws and lift off the lower spindle compartment cover. B. Unscrew the hose clamp to release the coolant return hose fastened to the bottom of the coolant catcher mounted inside upper spindle compartment cover A. C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. 2. Set the machine for a Free Spindle and press the Collet/Chuck OPEN pushbutton. 3. Unthread three screws C, Figure 8.2, in the knurled adjusting nut and remove the collet or chuck from the draw tube as follows: A. Press the COLLET OPEN pushbutton and remove any stock. B. Hold the collet or chuck from turning. C. Grip the knurled adjusting nut and unthread the draw tube from the collet or chuck. D. Remove the collet from the spindle or unthread the screws and remove the chuck from the chuck adapter. 4. Power down the machine and make certain that the air valve is OFF. 5. Tag air-line connectors D and E, Figure 8.2, for re-assembly and disconnect them from the collet closer. (continued on the next page) M

80 6. Scribe a mark from the collet closer mounting plate to the collet closer as in Figure Unthread six screws F, Figure 8.3, to release collet closer H", from adapter G, as follows: A. Unthread the screws until they stop against the brake disc. B. Pull the collet closer back the length of the unthreaded screws. C. Unthread the screws the rest of the way out. 8. Pull the collet closer and draw tube assembly straight out from the spindle. 9. Unthread three mounting screws C, Figure 8.2, to release the draw tube from the collet closer. Pull the draw tube assembly straight out from the closer. 10. Wipe clean the draw tube, the inside diameter of the collet closer, and the spindle bore. To install the collet closer: 1. Check the condition of the O-ring on the collet closer neck. Replace the O-ring (part number OR V) if necessary. - NOTE - Use Mobiltemp SHC 32 grease or the military specified Mobilgrease Grease the draw tube with a light coat of the specified grease; insert the draw tube into the collet closer and thread in three mounting screws C, lightly. 3. Clean the spindle bore and use a light coat of Bostik Never-Seez Black Moly (part number HG ) grease on the O-ring and collet closer neck (back pilot O.D. of the collet closer). 4. Center the draw tube in the spindle and push it in as far as it will go. Align the scribed line and insert the air line tubes in the bracket as the collet closer is pushed into place. 5. Mount the collet closer to adapter G, Figure 8.3, as follows: A. Align the six screws in the adapter with the threads in the collet closer openings and thread them in hand tight. B. Push the assembly further in toward the adapter and tighten the screws by hand. C. Put an indicator at the arrow on the bearing housing in Figure 8.3. Rotate collet closer H by hand and align the collet closer on the adapter to inch [ mm] or less fluctuation. D. Tighten the six screws to 95 Ib-in [10.7 N m] torque. E. Check the fluctuation again and adjust the collet closer as necessary. Again, tighten the collet closer mounting screws to 95 lb-in [10.7 N m] torque. H G Figure Collet Closer and Mounting Plate F TP M-371

81 6. Remount a collet or chuck as follows: A. Unthread three screws C, and pull the draw tube back slightly. B. Put a collet into the spindle and hold it with the collet retainer or mount a chuck on the chuck adapter. C. Push the draw tube into the spindle until it makes contact with the rear of the chuck or collet. Turn the draw tube and fully thread it onto the chuck or collet. 7. Reconnect air lines D and E, Figure 8.2, as noted in step #5 when removing the collet closer. 8. Power up the machine. - CAUTION - DO NOT close the collet closer without gripping a workpiece or piece of stock in the collet or chuck. 9. Adjust the collet or chuck holding force as follows: A. Put a workpiece or piece of stock in the collet or chuck. B. Push the COLLET OPEN pushbutton and make certain that it is lit. C. Thread the draw tube on the collet or chuck tight. D. Unthread the tube a quarter to a half a turn while aligning three screws C, Figure 8.2, with the three holes in the collet closer. Thread the screws in tight. 10. Test run the spindle. Open and close the collet or chuck several times. Replace the spindle compartment covers before cutting parts. ANSI A2-4 16C Big Bore Collet Closer The collet closer should be removed and cleaned once a month or if it is damaged. Replace the quad ring (small interior ring) occasionally or when it becomes worn. The collet closer assembly must be returned to the factory when repairs are required. Remove the draw tube with the collet closer. To remove the collet closer: 1. Press the Collet/Chuck pushbutton to open the spindle workholding device and remove any stock. 2. Power down the machine. 3. Remove the spindle compartment covers as follows: A. Unthread the panhead screws and lift off the lower spindle compartment cover. B. Unscrew the hose clamp to release the coolant return hose fastened to the bottom of the coolant catcher mounted inside upper spindle compartment cover A. C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. 4. Scribe a mark from the collet closer mounting plate to the collet closer as in Figure 8.4. (continued on the next page) M

82 - NOTE - Mount an indicator on the side wall and indicate the bearing housing near L. 5. Rotate the collet closer by hand and record the bearing housing movement. This movement figure will be necessary for collet closer re-alignment. 6. Remove the collet or chuck as follows: A. Unthread three screws C, Figure 8.2, in the knurled adjusting nut. B. Hold the collet or chuck from turning. C. Grip the knurled adjusting nut and unthread the draw tube. D. Remove the collet from the spindle or unthread the screws and remove the chuck from the chuck adapter. 7. Tag air-line connectors D (collet open), E (collet close), and if there is an air receiver line for re-assembly and disconnect the air lines from the collet closer. 8. Unthread screws I, Figure 8.4, to release collet closer K from collet closer mounting plate J, as follows: A. Unthread screws I. - CAUTION - Be ready to support the weight of the collet closer and draw tube as they are released from the spindle. B. Work (pull) the collet closer and draw tube assembly straight out from the spindle. C. Unthread three mounting screws C, Figure 8.2, to release the draw tube. D. Pull the draw tube assembly straight out from the closer. - CAUTION - Always wipe the draw tube from the knurled end and the spindle interior from the spindle compartment end toward the work compartment. 9. Wipe the draw tube clean. And, wipe clean the collet closer and spindle bore. 10. Check the condition of the O-ring on the mounting plate and the quad ring on the nose in the collet closer. Replace either ring as necessary. L K Figure Collet Closer and Mounting Plate I J TP M-371

83 To install the collet closer: 1. Use a light coat of Bostik Never-Seez Black Moly (part number HG ) to grease the inside lip of the collet closer where it mounts over the O-ring. Also, put a light coat of grease on the nose (quad ring area). - NOTE - Use Mobiltemp SHC 32 grease or the military specified Mobilgrease Use a light coat of the specified grease to cover the outside diameter of the draw tube and the inside of the spindle bore. Make certain that there is grease in the grooves. 3. Insert the draw tube into the collet closer. 4. Center the draw tube in the spindle and push it in as far as it will go. Align the scribed line and align the interior pin in its hole; also, align the air line tubes in their bracket as the collet closer is pushed into place. 5. Mount the collet closer to collet closer mounting plate J, Figure 8.4, as follows: A. Align the scribed mark on the collet closer with the scribed mark on the collet closer mounting plate; align the screws in the mounting plate with the threads in the collet closer openings and thread them in hand tight. Push the assembly further toward the adapter and tighten the screws by hand. B. Indicate the fluctuation at L in Figure 8.4 and align the collet closer on the adapter to the original fluctuation figure as noted in step #5 when removing the collet closer or as close to the number as possible. If there was no reading at step #5 when removing the collet closer, align the collet closer on the adapter to inch [ mm] or less fluctuation. C. Tighten the collet closer mounting screws to 100 lb-in [12 N m] torque. 6. Remount a collet or chuck as follows: A. Pull the draw tube back slightly. B. Put a collet into the spindle and hold it with the collet retainer or mount a chuck on the chuck adapter. C. Push the draw tube into the spindle until it makes contact with the rear of the chuck or collet. Turn the draw tube and fully thread it onto the chuck or collet. 7. Reconnect the air lines as noted in step #7 of the collet closer removal instructions. 8. Unlock the air lock out valve and power up the machine. - CAUTION - DO NOT close the collet closer without gripping a workpiece or piece of stock in the collet or chuck. 9. Adjust the collet or chuck holding force as follows: A. Put a workpiece or piece of stock in the collet or chuck. B. Push the Collet/Chuck pushbutton to open the collet. C. Thread the draw tube on the collet or chuck tight. D. Unthread the tube a quarter to a half a turn while aligning three screws C, Figure 8.2, with the three holes in the collet closer. Thread the screws in tight. E. Test run the spindle. Open and close the collet or chuck several times. 10. Replace the spindle compartment covers before cutting parts. M

84 Pressure Regulator/Gauge Replacement A collet closer pressure regulator sets the collet close holding force. The collet closer pressure is adjusted by turning regulator knob O, Figures 8.5 and 8.6, and observing the pressure on gauge N. The collet closer air pressure should be set at approximately 40 psi [2.8 bar]. To replace the pressure regulator: 1. Power down the machine and make certain that the main air valve is OFF. 2. Unthread the screws and remove air panel cover M, Figure 8.5. O 3. Make a diagram of the direction of the air flow arrow on the regulator. Tag the regulator hose(s) for re-assembly 4. Disconnect the hose(s) from the regulator. N 5. Unthread the regulator with gauge from the air manual and lift it off. 6. Remove the fittings and pipe plug from the M old regulator. Unthread the gauge from the old regulator; or, if the gauge is to be replaced, just leave it with the old regulator. TP Apply Loctite High Performance Pipe Sealant with Teflon (Item No ) to the Figure Collet Closer Pressure Gage threads of the fittings, pipe plug and, if necessary, the gauge. Install them on the replacement regulator. - NOTE - The arrow on the back of the regulator O indicates the direction of air flow. 8. Thread the regulator with gauge onto the air manual making sure that the knob is up. Make certain that the air flow arrow is pointed per step #3. 9. Attach the hoses to the regulator per information as noted also in step # Mount air panel cover M. Power up the machine and set the closer pressure to approximately 40 psi [2.8 bar]. Lift the knob on the top of the regulator, set the air pressure and press the knob down to set collet closer air pressure and secure the setting. Figure Collet Closer Regulator and Air Panel without Cover TP M-371

85 Pressure Switch Replacement Collet closer pressure switch Q, Figure 8.7, is designed for 20 psi [1.4 bar]. If the switch fails, the collet may not close. There are two conditions which may cause this to occur: If the collet closer air regulator O, Figure 8.6, is set lower than the pressure switch, a close collet command will not close the collet. The Collet Open light will flash and an E-Stop condition will stop the axis motion. If the pressure switch pressure is lower than the collet closer air regulator and the air regulator is not set high enough to close the collet closer, a close collet command will cause the Collet Open light to go out and will permit axis motion even though the collet is not closed. There are two other pressure switches; main air pressure switch R, 60 psi [4.2 bars] and spindle brake pressure switch P, 20 psi [1.4 bar]. Additional pressure switches may be installed as other air options are added to the machine. To replace the pressure switch: 1. Power down the machine and make certain that the main air valve is OFF. 2. Unthread the screws and remove air panel R cover M, Figure Remove the screw that holds the electrical connector to the top of the switch. Pull the plug straight up to remove it from the switch. 4. Remove the pressure switch from the manifold. The switch is only hand tightened; however, Q P a wrench may be necessary to unthread it. 5. Replace the switch on the manifold and tighten it to 50 lb-in [5.6 N m] torque. 6. Align the openings with the prongs and push TP3517. the electrical connector straight down on top of the switch. Fasten the electrical connector Figure Pressure Switches in place with its screw. 7. Power up the machine. Set the regulator to 80 psi [5.5 bars] and check it for air leaks. Correct it as necessary. 8. Set the regulator below 20 psi [1.4 bars] to test the switch at low pressure. 9. When satisfied with the switch, return the regulator pressure to a consistent operating pressure from 70 psi to 90 psi [4.9 to 6.3 bars]. 10. Mount air panel cover M. M

86 - NOTES M-371

87 CHAPTER 9 - AXES DRIVE MOTORS Introduction The carriage is a movable platform that carries the cross slide with a dovetail top plate for tooling. Control signals command the carriage toward (-Z) or away (+Z) from the spindle. The cross slide is a movable platform on the carriage that carries the dovetail top plate with tooling mounted on it. Control signals command the cross slide toward (-X) or away (+X) from the spindle centerline. Detailed information covering the ball screw and linear way lubrication appears in Chapter 3-LU- BRICATION of this maintenance manual. Carriage Drive Motor Replacement The drive motor is located in spindle drive compartment A, Figure 9.1. It is connected to the ball screw with a coupling. The motor has an encoder that is an integral part of the motor assembly and cannot be replaced separately. To replace the carriage drive motor: 1. Jog the Z-axis to move the carriage to the middle of its travel, if possible. Remove any workpiece from the spindle to maximize the work space. 2. Power down the machine as follows: put the machine into E-stop, turn the Control OFF, turn the main disconnect switch and air valve OFF. 3. Access the ball screw coupling as follows: A. Unthread the three screws and swing open control panel B. B. Unthread four nuts and lift off access cover D, Figure 9.2. C. Reach through the opening and unthread the pipe plug from the headstock base. D. Use a flashlight and look into the headstock base to view the coupling. 4. If the screw in the coupling clamp cannot be accessed, turn the coupling as follows: A. Gain entrance to access cover E, Figure 9.3, on the right end of the machine; A unthread the screws and lift off the access B cover. B. Unthread the screws and remove the way cover from the right side of the carriage and the bed. C. Unthread four screws and remove ball screw end cover F, Figure 9.4. C D. Use a wrench in the end of the ball screw and turn it until the head of the screw in the coupling clamp can be accessed in the headstock base. E. Loosen the screw in the coupling. TP3531. Figure Spindle Drive Compartment and Valve Compartment Covers M

88 D E TP3560. Figure Headstock Pipe Plug Access Cover Behind Control Panel 5. Remove the spindle compartment covers at the left end of the machine as follows: A. Unthread the panhead screws and lift off lower spindle compartment cover C, Figure 9.1. B. Unscrew the hose clamp to release the TP3562. hose from the coolant catcher mounted inside upper spindle compartment cover A. Figure Right End Access Door C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. 6. Locate electrical connections H, and G, (behind connector H ) on motor I, Figure 9.5; unscrew the knurled nut and pull the F connectors straight out. - NOTE - Handle the motor with care. The encoder is extremely fragile. Do not hit Figure Ball Screw End Cover TP224. the motor shaft or allow it to make contact with anything. 7. Note the position of the electrical connections; unthread the four bolts that fasten the motor to the motor mount. Carefully lift the motor from the spindle compartment. 8. Remove and install the coupling on the motor as follows: A. Note that the curved face of the washers are toward the flex elements. Disassemble the coupling by unfastening two screws opposite each other on the coupling. B. Unthread the lock nut fastening the coupling to the tapered shaft on the motor. C. Use a gear puller if necessary to remove the coupling from the motor shaft. Do not tap or jar the coupling from the shaft. D. Make certain that the key is in place on the replacement motor shaft and mount the coupling. Tighten the coupling lock nut to 25 lb-ft [34 N m] torque. 9-2 M-371

89 - NOTE - When assembling the coupling, the curved face of the washers are toward the flex elements. Assemble the coupling and tighten the mounting screws to 96 lb-in [11 N m] torque. E. Assemble the coupling. 9. Align the coupling with the end of the ball I screw, position the electrical connections per G step #7 and mount the motor with the H screws finger tight. 10. Tighten the four screws that fasten the motor to 25 lb-ft [34 N m] torque. 11. Tighten the coupling clamp screw to 60 lb-in [7 N m] torque. 12. Connect motor cable G and encoder cable H. Tighten the knurled nuts to secure the connections. - NOTE - Because the motor has been unfastened from the ball screw, the control TP3536. for Z-axis motor cannot position the carriage accurately. This might cause the CRT to display Software Figure Z-Axis Motor Overtravel when the control is powered up even though an overtravel condition does not exist. 13. Clear the feed hold (alarm) condition and reset the Z axis as follows: A. Make certain that the control is on or turn the Control switch to the ON [l]position and then make sure the machine is in MDI mode. B. Press the E-Stop pushbutton and make certain that it remains down. C. Press OFFSET SETTING key to display the Setting (HANDY) page. D. Press the PAGE down ( )orup( ) until the cursor is at Parameter WRITE. E. Change Parameter WRITE from 0 to 1 (enable). Press key 1 and then the INPUT soft key or INPUT key. F. Press the SYSTEM key and PARAMETER soft key. Enter and press the No.SRCH (search) soft key. G. At 1850 Z, key in 0 and press the INPUT soft key. An alarm may be displayed; if an alarm is displayed, power down and, then, power up the control. H. Press the SYSTEM key and PARAMETER soft key. Enter and press the No.SRCH (search) soft key. I. At 1815 bit 4 Z, key in 0 and press the INPUT soft key. J. At 1815 bit 5 Z, key in 1 and press the INPUT soft key. (continued on the next page) M

90 K. Turn the Control switch to OFF [ O] andwait momentarily. While pressing and holding the CAN (cancel) and O p [/// and Op] keys, turn the Control switch ON [l]. L. Pull the E-Stop pushbutton out and, then, pull it further out and hold it momentarily to release the Emergency Stop. M. Set the axis as follows: - CAUTION - Be certain that no interference of axis travel exists when the Zero Return (Reference Home) procedure is used. 1. Press POS key and then PAGE down ( ) to read the relative axes position. Actual Position Relative is displayed with the X and Z position. - NOTE - Make certain that there are no offsets or workshifts active. Axes Home positions are as follows: X = (Inch mode) (Metric mode) (diameter) Z = (Inch mode) (Metric mode) 2. Set Feedrate % Override [F WW %] switch to between 20% and 40%. - WARNING - Some work and alignment testing on the carriage requires that access covers are off and doors are open while the machine is powered up. Be extremely careful when working on the machine with the covers off and doors open. - NOTE - If the control alarm + Software Overtravel appears, it is necessary to turn the Control switch OFF to power down the control. Press and hold both the CAN and the O p [/// and Op] keys while turning the Control switch ON until the machine is powered up. This procedure allows the control to ignore the overtravel alarms when Zero Returning (Home) the axes. 3. Put the control into JOG mode. Quick page to MODE; press JOG soft key. 4. Move Z axis [4 key] to bring the front face of the top plate approximately inch from the spindle face. While moving the carriage, increase the % Feedrate as necessary. 5. At HANDLE (press POS pushbutton, then, REL soft key), press the HZ (handle Z) soft key and use the MPG hand wheel to move the axis until a 1 inch JO block has a slip fit between the face of the spindle and the front face of the top plate (not the front edge of the top plate dovetail). 6. Press W and then press the ORIGIN soft key. The Z axis will change to Jog the Z axis until the position display reads (calculate JO block = ). 8. Press SYSTEM key and the PARAMETER soft key. 9. Enter 1815 andpress the No.SEARCH soft key. 10. At 1815 bit 4 Z, key in 1 and press the INPUT soft key. 9-4 M-371

91 N. Turn the Control switch to OFF [ O] andwait momentarily. While pressing and holding the CAN (cancel) and O p [/// and Op] keys, turn the Control switch ON [l]. O. Change Parameter WRITE back to 0 as follows: 1. Press the E-Stop pushbutton and make certain that it remains down. 2. Press OFFSET SETTING key to display the Setting (HANDY) page. 3. Press the PAGE down ( )orup( ) until the cursor is at Parameter WRITE. 4. Change Parameter WRITE from 1 to 0. Press key 0 and then the INPUT soft key or INPUT key. 14. Put the control into JOG mode. Quick page to MODE; press JOG soft key. 15. Test run each axis to make certain that they are moving properly. 16. Check that the Z-axis position is when positioned for a 1 inch JO slip fit between the face of the spindle and the front face of the top plate. 17. Power down the machine; mount the covers and close the control panel as follows: A. The spindle compartment (left end of machine): 1. Mount the upper spindle compartment cover on the machine. 2. Connect the hose to the fitting on the coolant catcher. 3. Mount the lower spindle drive compartment cover and fasten it in place. B. The control panel (front of machine): 1. Thread the pipe plug into the headstock base. 2. Mount access cover D, Figure 9.2, in the compartment. 3. Close control panel B, Figure 9.1, and thread in the three screws. C. Cover the right end of the ball screw and mount the access cover as follows: 1. Put ball screw end cover F, Figure 9.4, on and fasten it with its screws. 2. Mount the Z-axis way covers. 3. Mount the slide cover. 4. Mount the coolant and air blast manifold. 5. Install access cover E, Figure 9.3, and secure it by threading in the screws. 18. Power up the machine. M

92 Cross Slide Drive Motor Replacement - NOTE - Some photographs are shown without covers, the chip and coolant guard, and other components in place. They have been removed to show components. The drive motor is located on the front of the carriage in the main compartment, Figure 9.6. It is connected to the cross slide ball screw with a coupling. The motor has an encoder that is an integral part of the assembly and cannot be replaced separately. To replace the cross slide drive motor: 1. Jog the Z-axis to move the carriage to a convenient work position in front of the main coolant guard door. 2. Power down the machine as follows: put the machine into E-stop, turn the Control OFF, turn the main disconnect switch and air valve OFF. 3. Open the main coolant guard door and wipe chips and coolant from the top plate and cross slide covers. 4. At the rear of the machine, unthread the screws and lift off rear access cover J. It may be necessary to remove the coolant tank/coolant tank and chip conveyor K, to have more access room at the rear of the machine. 5. Unthread the screws and remove the cross slide rear cover. 6. At the front of the machine, gain access to the X-axis drive motor and adapter mount as follows: A. Remove coolant and air blast manifold L, Figure 9.8, from the cross slide cover. Unthread the screws and remove cover M. Figure Cross Slide Drive Motor Cover B. Unthread a screw low on each side and the front screw, Figure 9.6, so that the bottom cover (tray) can drop down from the motor cover. C. Unthread the screws and remove the drive motor cover to gain access to the motor and adapter mount. 7. Loosen the ball screw coupling clamp from the ball screw as follows: A. Reach up underneath the adapter mount and feel for the ball screw coupling screw. B. If the coupling screw cannot be felt, go to the rear of the machine and unthread four screws to remove ball screw end cover N, Figure 9.9. C. Use a hex wrench (8 mm) in the end of the ball screw and turn it until the head of the screw in the coupling clamp can be accessed through the adapter mount opening. D. Loosen the screw in the coupling clamp. 8. Tag for re-assembly and then remove the electrical connections from the motor. Unscrew each knurled nut and pull the connectors straight out. J K Figure Rear Access Cover TP3552. TP M-371

93 N L M Figure Cross Slide with Coolant and Air Blast Manifold TP3564. TP235. Figure X-Axis Ball Screw Cover Under Carriage 9. Note the position of the electrical connections on the drive motor before unfastening it from the motor mount. - NOTE - Handle the motor with care. The encoder is extremely fragile. Do not hit the motor shaft or allow it to come into contact with anything. 10. Unthread the four bolts that fasten the motor to the motor adapter mount and carefully pull the motor from the main compartment. 11. Remove and install the coupling on the motor shaft as follows: A. Note that the curved face of the washers are toward the flex elements. Disassemble the coupling by unfastening two screws opposite each other on the coupling. B. Unthread the lock nut fastening the coupling to the tapered shaft on the motor. C. Use a gear puller if necessary to remove the coupling from the motor shaft. Do not use a hammer to tap the coupling from the shaft. D. Make certain that the key is in place on the replacement motor shaft and mount the coupling. Tighten the coupling lock nut to 25 lb-ft [34 N m] torque. - NOTE - When assembling the coupling, the curved face of the washers are toward the flex elements. Assemble the coupling and tighten the coupling screws to 96 lb-in [11 N m] torque. E. Assemble the coupling. 12. Align the coupling with the end of the ball screw, position the electrical connections per step #9 and mount the motor with the screws finger tight. 13. Tighten the four screws that fasten the motor to 25 lb-ft [34 N m] torque. 14. Reach up underneath the adapter mount and tighten the coupling clamp screw to 60 lb-in [7 N m] torque. 15. Connect the motor cable and the encoder cable as noted from step #8. Tighten the knurled nuts to secure the connections. (continued on the next page) M

94 - NOTE - Because the motor has been unfastened from the ball screw, the control for X-axis motor cannot position the cross slide accurately. This might cause the CRT to display Software Overtravel when the control is powered up even though an overtravel condition does not exist. 16. Clear the feed hold (alarm) condition and reset the X axis as follows: A. Make certain that the control is on or turn the Control switch to the ON [l]position and, then, make sure that the machine is in MDI mode. B. Press the E-Stop pushbutton and make certain that it remains down. C. Press OFFSET SETTING key to display the Setting (HANDY) page. D. Press the PAGE down ( )orup( ) until the cursor is at Parameter WRITE. E. Change Parameter WRITE from 0 to 1 (enable). Press key 1 and then the INPUT soft key or INPUT key. F. Press the SYSTEM key and PARAMETER soft key. Enter and press the No.SEARCH soft key. G. At 1850 X, key in 0 and press the INPUT soft key. An alarm may be displayed; if an alarm is displayed, power down and, then, power up the control. H. Press the SYSTEM key and PARAMETER soft key. Enter and press the No.SRCH (search) soft key. I. At 1815 bit 4 X, key in 0 and press the INPUT soft key. J. At 1815 bit 5 X, key in 1 and press the INPUT soft key. K. Turn the Control switch to OFF [ O] andwait momentarily. While pressing and holding the CAN (cancel) and O p [/// and Op] keys, turn the Control switch ON [l]. L. Pull the E-Stop pushbutton out and, then, pull it further out and hold it momentarily to release the Emergency Stop. M. Set the axis as follows: - CAUTION - Be certain that no interference of axis travel exists when the Zero Return (Reference Home) procedure is used. 1. Press POS key and then PAGE down ( ) to read the relative axes position. Actual Position Relative is displayed with the X and Z position. - NOTE - Make certain that there are no offsets or workshifts active. Axes Home positions are as follows: X = (Inch mode) (Metric mode) (diameter) Z = (Inch mode) (Metric mode) 2. Set Feedrate % Override [F WW %] switch to between 20% and 40%. - WARNING - Some work and alignment testing on the cross slide requires that access covers are off and doors are open while the machine is powered up. Be extremely careful when working on the machine with the covers off and doors open. 9-8 M-371

95 - NOTE - If the control alarm + Software Overtravel appears, it is necessary to turn the Control switch to OFF to power down the control. Press and hold both the CAN (cancel) and the O p [/// and Op] keys while turning the Control switch to ON until the machine is powered up. This procedure allows the control to ignore the overtravel alarms when Zero Returning (Home) the axes. 3. Put the control into JOG mode. Quick page to MODE; press JOG soft key. 4. Mount a 1 inch [25.4 mm] arbor in a collet. 5. Mount a flat stock at the back end of the dovetail tool or use magnets to attach the flat stock to the back of the dovetail tool. 6. Use the 1 inch [25.4 mm] arbor, the flat piece of stock and a inch [55.56 mm] JO block to reset the control as follows: a. Move the Z axis [4 key] within range to have a slip fit of the JO block between the side of the arbor and the flat stock. b. Move the X axis [2 # and/or 8 keys] to have an approximate fit of the JO block. c. At HANDLE (press POS pushbutton, then, REL soft key), set the HX (handle X axis, cursor with directional pushbuttons) soft key. Use the MPG hand wheel to move the cross slide for a slip fit of the JO block between the side of the arbor and the flat stock. d. Use the MPG dial to move the cross slide to obtain a slip fit of the inch [55.56 mm] JO block between the round edge of the arbor and the flat piece of stock. 7. Press SYSTEM key and the PARAMETER soft key. 8. Enter 1815andpress the No.SEARCH soft key. 9. At 1815 bit 4 X, key in 1 and press the INPUT soft key. N. Turn the Control switch to OFF [ 0 ] and wait momentarily. While pressing and holding the CAN (cancel) and O p [/// and Op] keys, turn the Control switch ON [l]. O. Change Parameter WRITE back to 0 as follows: 1. Press the E-Stop pushbutton and make certain that it remains down. 2. Press OFFSET SETTING key and then the SETING soft key to display the Setting (HANDY) page. 3. Press the PAGE down ( )orup( ) until the cursor is at Parameter WRITE. 4. Change Parameter WRITE from 1 to 0. Press key 0 and then the INPUT soft key or INPUT key. 17. Put the control into JOG mode. Quick page to MODE; press JOG soft key. 18. Slide the main compartment door closed. Stay clear of any moving components and test run each axis to make certain that they are moving properly. (continued on the next page) M

96 19. Power down the machine and mount the covers as follows: A. Mount the drive motor cover on the front of the cross slide, Figure 9.6, and fasten it in place. B. Align the screws in either side of the tray with the slots in the drive motor cover and hold the tray in place. Thread the screw into the tray near the bottom edge of the drive motor cover. Tighten all the screws. C. At the rear of the machine, if necessary, mount ball screw end cover N, Figure 9.9, under the front of the cross slide. Tighten the four screws. D. Mount the cross slide rear cover and tighten the screws. E. Fasten rear access cover J, Figure 9.7, in place with its screws. If necessary, roll the coolant tank/coolant tank and chip conveyor in place under the machine. F. Mount cross slide cover M, Figure 9.8, on the cross slide. Tighten the screws. G. Fasten coolant and air blast manifold L, on the cross slide cover. 20. Power up the machine. - NOTES M-371

97 CHAPTER 10 - MISCELLANEOUS AIR FAN and HEAT EXCHANGER There is a headstock fan and a power case heat exchanger installed on this CNC lathe. The openings that allow air circulation through the spindle compartment and in the power case and MUST NEVER BE BLOCKED. The fans are active as soon as the machine is powered up. The headstock fan is located low on the left end of the machine and the spindle compartment is vented at the top to allow air circulation inside and air to exhaust out. The air fan has a foam filter mounted in the lower spindle compartment cover. The power case has a heat exchanger mounted on the door. It stabolizes the case air temperature while sealing out potentially contaminated, external air. When either the fan and/or heat exchanger require maintenance, the machine must be powered down. A detailed procedure to power down the machine appears in Chapter 2 - Power-Up Procedure. Power-Down Procedure 1. Be certain that Cycle Start is not active. The pushbutton light will be OFF. 2. Be sure the program has been completed and that the spindle, slides, and gantry are stationary. 3. Press the Emergency Stop pushbutton. 4. Turn the Control OFF/ON switch to the OFF (0) position. 5. Turn the main air valve OFF 6. Turn the main disconnect switch OFF and lock it out. To clean the foam filter: 1. Power down the machine. - NOTE - Foam air filter B, Figure 10.1, is in a frame that has a slotted support back. 2. Clean the foam air filter as follows: A. Grip the foam air filter and carefully pull it from the lower compartment cover. B. Wash the air filter clean in detergent and water. Squeeze out as much water as possible and allow it to air dry. C. Make certain that the foam air filter is dry. Compress it enough and carefully fit it in the cover opening. 3. Power up the machine and make certain that the fan draws air. B A TP3535. Figure Headstock Fan on Spindle Compartment Cover M

98 To clean the heat exchanger filter: 1. Power down the machine. 2. Loosen, but do not remove, the screw in the top filter runner. Grasp one side of heat exchanger filter C, Figure 10.2, and pull it straight out the side runners. 3. Clean the heat exchanger filter as follows: A. Brush dirt from the face of the filter element to remove much of the dirt. B. Safely use an air gun to blow the remaining contaminants from the filter. C. Carefully wash the air filter clean in detergent and water. D. Rinse the filter in clean water. E. Carefully wipe the filter dry and, then, allow it to air dry. F. Make certain that the foam air filter is dry. Align the filter element in the runners and slide it all the way in until it fully covers the opening. G. Tighten the screw in the top runner. 4. Power up the machine and make certain that the exterior top fans draw air through the filter. C Figure Heat Exchanger TP3527. BATTERY REPLACEMENT Battery units are located in the middle section (drive section) of the power case on each drive and on top of the CPU inside the control. The batteries supply power to maintain axes memory and control memory when the machine is not turned ON. The drive battery units are a battery pack and the control is a single battery. Although the batteries should be replaced at least once a year, there is also a Low Battery alarm. Check the age of the batteries and replace them as necessary. E - WARNING - D High voltage AC will be present in the power case when the main disconnect switch is ON and when the control is ON (powered up). - CAUTION - Battery replacement can be done with the control turned ON or OFF. Figure Drive Battery Units TP M-371 Revised: January, 2000

99 - NOTE - The drive contains a lithium battery pack. Make certain that the replacement pack is like those being removed. Check the battery voltage and receptacle. To change the drive battery: 1. Make certain that the machine has been powered up. Turn the control switch to the ON(l)position if necessary. 2. Power down the machine or turn the door interlock key (switch) on the power case to the OFF position. 3. Unlatch the power case door and open it. Figure Drive BatterywithReceptacle F on a Plug and Second Plug G 4. Remove battery cover E, Figure 10.4, on the front panel of the power unit. Hold the battery cover by the top and bottom and squeeze the cover while pulling it off. 5. Do not disconnect the battery; pry out the old battery and verify that the new battery is like the battery being replaced. Put tape on or somehow mark the old battery. 6. Install the fresh battery while the old battery is still connected, Figure 10.5, as follows: A. Pry the cap from the second (free) plug G, Figure The free plug does not have a battery receptacle attached to it (unoccupied). The plugs are near each other and are labeled; either can be the free plug. B. Push the receptacle from the new battery onto the second plug as H, Figure 10.5, while the old battery is still connected. 7. Pull the old battery receptacle straight off the plug. Put the cap from step #6.A on. F Dispose of the old battery properly. 8. Put the new battery in place and fasten the H battery cover on the front panel. 9. Repeat the procedure for the batteries in all the drives. 10. Close the power case door and latch it. If necessary, power up the machine. E Figure Both Battery Packs Connected at Plugs F G Tp3737. Tp3738. M Revised: January, 2000

100 To change the control battery: - WARNING - Be extremely careful when releasing the LCD (display, screen) from the operator s control panel. Gain access over the top; there are plugs and connections along the bottom that should not be stretched. - CAUTIONS - Control battery replacement must done within 30 minutes of the control being turned OFF. A fresh battery must be installed at least once a year. Failure to perform this maintenance will result in the loss of control information. 1. Make certain that the machine has been powered up. Turn the control switch to the ON ( l ) position or press the CONTROL ON pushbutton if necessary. 2. Power down the machine. Make sure that the main disconnect switch on the power case is turned to the OFF position and locked out. 3. The operator s control panel swings open; unthread the screws and open the panel. Then, unthread the screws and remove the back cover to the operator s control panel to gain access to the top of the CPU (control unit). However, if it is easier to just unthread the CPU, unthread the four screws and carefully tilt the top of the LCD out to gain access to the top of the CPU. 4. Locate the control battery on top of the control housing. Hold yellow plastic battery latch I, Figure 10.6, to the side while pulling the battery out. 5. Carefully lift the wires from around the battery holder to extend the wires and reach the I connector pin (plug). - 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. 6. Verify that the new battery is like the battery being replaced. Put tape on or somehow mark the old battery. Figure Control Battery on Top of the CPU 7. Pull the old battery receptacle straight off its plug on the control unit wire. 8. Install the fresh battery. Push the new battery receptacle on the plug. Put the battery in place and fasten the plastic battery latch. Dispose of the old battery properly. 9. If the operator s control panel swings open, mount the back cover to the operator s control panel. Swing the operator s control panel closed and thread in the screws. If the top of the LCD is pulled out, carefully place the LCD in the operator s control panel and mount the frame to the panel. 10. Unlock the main disconnect switch and power up the machine. Tp M-371 Revised: January, 2000

101 PART CATCHER The part catcher is located on rods out of the headwall. The catcher extend/retract mechanism is in spindle compartment J, Figure The only adjustments to the part catcher are the extend and retract positions and their travel rate. Parts can be removed from the machine through the access door in the guard door without interrupting the cycle. To adjust the part catcher position: 1. Put part catcher K, Figure 10.8, in the desired position for adjustment - either the extend or retract position. Program an M26 to extend the catcher or press the RESET key near the CRT to retract the catcher. 2. Power down the machine as follows: put the machine into E-Stop, turn the control to the J OFF (0) position, turn the main disconnect switch and air valve OFF. 3. Remove the spindle compartment covers as follows: A. Unthread the screws and lift off the lower spindle compartment cover. B. Unscrew the hose clamp to release the coolant return hose fastened to the bottom TP3531. of the coolant catcher mounted inside the upper spindle compartment cover. Figure Drive Compartment Cover C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. 4. Adjust the part catcher position as follows: A. Loosen the set screw in collars L, Figure 10.9, on both support rods. B. Position the part catcher. C. Slide the collars against piston plate M, K and tighten the set screw to secure them. 5. Turn the fine adjustment knob, Figure 10.9, clockwise or counterclockwise to slightly adjust the part catcher to the final desired position. TP Power up the machine and return the part catcher to the retracted position if it was put Figure Part Catcher in the extended position. 7. Power up the machine and test the extend and retract function several times to make certain that the part catcher goes to the desired position. Adjust the position of the part catcher as necessary by powering down the machine and following steps #4 through #8. (continued on the next page) M Revised: January, 2000

102 8. Power down the machine and mount the compartment covers as follows: A. Mount the upper compartment cover on the machine. B. Connect the hose to the fitting on the coolant catcher. C. Mount the lower spindle drive compartment cover and fasten it in place. O N L L M Knob L To adjust the part catcher travel rate: Part catcher motion is actuated by a two-way valve. The solenoids activate the valve to shift from one position to the other. The two-way air valve applies air pressure through the air regulators to extend TP248. or retract the air cylinder. Extend regulator N, and Figure Part Catcher Mechanism retract regulator O, have a screw on top that controls the amount of air to the cylinder to control the rate of travel. 1. Program an M26 to extend the catcher or press the RESET key near the CRT to retract the catcher. 2. Power down the machine as follows: put the machine into E-Stop, turn the control OFF, turn the main disconnect switch and air valve OFF. 3. Remove the spindle compartment covers as follows: A. Unthread the screws and lift off the lower TP249. spindle compartment cover. B. Unscrew the hose clamp to release the Figure Part Catcher Access Door coolant return hose fastened to the bottom of the coolant catcher mounted inside the upper spindle compartment cover. C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. 4. Adjust the screw in either extend valve N, or retract valve O, Figure 10.9, as necessary to adjust the travel rate of either or both functions. 5. Power up the machine and test the extend and retract travel rate. Adjust whichever screw as necessary to set the rate. 6. Power down the machine and mount the compartment covers as follows: A. Mount the upper compartment cover on the machine. B. Connect the hose to the fitting on the coolant catcher. C. Mount the lower spindle drive compartment cover and fasten it in place M-371 Revised: January, 2000

103 To replace the solenoid(s): - NOTE - Refer to Chapter 4 - AIR FACILITIES for additional information about the solenoids, valves, or pressure regulators. 1. Power down the machine. 2. Remove the air panel access cover. Identify the component(s) that needs to be replaced in the part catcher assembly. P 3. Replace the extend solenoid and/or retract solenoid as follows: A. Unthread the screw that holds the solenoid to the valve. B. Pull the solenoid straight out to remove it from the valve. C. Follow the wires from the solenoid to the TP3525. terminal block. D. Make a diagram to identify the wires for Figure Main Air Panel with Cover reassembly. E. Remove the wires from their terminal. F. Replace the solenoid and fasten the wires per step #3.D, above. G. Push the solenoid straight down on the valve. Fasten it in place with its screw. 4. Power up the machine. 5. Make certain that the main air pressure regulator is set between 70 psi and 90 psi [4.9 and 6.3 bars]. Turn the fine adjustment knob and set the part catcher pressure regulator to 40 psi [2.7 bar]. Check for air leaks in the part catcher air system and correct any leaks as necessary. 6. Replace the air panel cover. To replace the valve: 1. Power down the machine. 2. Remove air panel cover P, Figure 10.11, and identify the component(s) that needs to be replaced in the part catcher assembly. 3. Replace the two-way valve as follows: A. Unthread the screw that holds each of the solenoids to the valve. B. Pull each solenoid straight out to remove them from the valve. C. Make a diagram to identify the air lines for reassembly. D. Unthread the fittings and remove the air lines from the valve. E. Unthread the screws and remove the valve, with the pressure regulator and gauge assembly attached to it, from the manifold. (continued on the next page) M Revised: January, 2000

104 3. (continued... ) - NOTE - Use sealant on fitting threads when they are mounted to new components. F. Unthread the regulator and gauge assembly from the old valve and replace the valve. Thread the regulator and gauge to the new valve. G. Replace the valve, make certain that the O-rings are in place, and fasten the valve on the manifold. H. Fasten the air lines to the valve and tighten the fittings. I. Push the solenoids straight down on the valve. Fasten each in place with its screw. 4. Power up the machine. 5. Make certain that the main air pressure regulator is set between 70 psi and 90 psi [4.9 and 6.3 bars]. Turn the fine adjustment knob, Figure 10.6, and set the part catcher pressure regulator to 40 psi [2.7 bar]. Check for air leaks in the part catcher air system and correct any leaks as necessary. 6. Replace the valve compartment cover. To replace the pressure regulator and/or gauge: 1. Power down the machine. 2. Remove the valve compartment cover and identify the component(s) that needs to be replaced in the part catcher assembly. 3. Replace the pressure regulator as follows: A. Unthread the gauge from the valve. If just the gauge is to be replaced, use sealant on the threads and thread the new gauge in place on the valve. Continue with step #4 below. If the regulator is being replaced, continue with step B. B. Disconnect the air line from the fitting on the regulator. C. Unthread the regulator from the stem fitting. D. Unthread the air line fitting from the side of the old regulator, use sealant on the threads, and mount it on the new regulator. E. Use sealant on the threads and thread the new regulator on the stem fitting. F. Use sealant on the threads and fasten the gauge to the new regulator. G. Reconnect the air line to the fitting on the regulator. 4. Power up the machine. 5. Make certain that the main air pressure regulator is set between 70 psi and 90 psi [4.9 and 6.3 bars]. Turn knob at Figure 10.9, and set the part catcher pressure regulator to 40 psi [2.7 bar]. Check for air leaks in the part catcher air system and correct any leaks as necessary. 6. Replace the valve compartment cover M-371 Revised: January, 2000

105 To replace the part catcher (chute) Home switch (LS 6): Part catcher Home switch Q, Figure 10.12, is active when the chute is at home against the headwall. Refer to Figure 10.8 to see the part catcher at Home. The switch is located in the spindle compartment on a bracket and is activated by the end plate. 1. Extend the part catcher to move the end plate off the switch roller as follows: A. Press the MDI pushbutton. B. Press the PRGRM key. C. Enter M26andpress the INPUT key. D. Press the CYCLE START pushbutton to extend the catcher. 2. Power down the machine as follows: put the machine into E-Stop, turn the control to the OFF (0) position, turn the main disconnect switch and air valve OFF. 3. Remove the spindle compartment covers as follows: Q A. Unthread the screws and lift off the lower spindle compartment cover. B. Unscrew the hose clamp to release the coolant return hose fastened to the bottom of the coolant catcher mounted inside the upper spindle compartment cover. Figure Part Catcher Switch in Spindle Compartment C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out and pull straight back to release the cover. 4. Open the power case door to gain access to the terminal boards. 5. Follow the electrical cable from part catcher Home switch Q, Figure 10.12, into the power case. 6. Make a diagram of the cable wires to each of the terminal boards. 7. Disconnect the wires from the terminal boards. 8. Unthread two screws and remove the switch from the bracket. 9. Compare the cable lengths of the old switch and the replacement switch and cut the replacement switch cable to length. 10. Mount the switch to the bracket. Pull the switch all the way back in the slots and fasten the screws finger tight. 11. Feed the cable through the compartment and into the power case. 12. Strip the cable and wires and connect the wires to the terminal boards per step #6, above. 13. Power up the machine. If the part catcher is not at Home, press the RESET [ // ] key. If the parts catcher Home switch is not made, a PARTS CATCHER NOT HOME (#2015) message will appear on the CRT. When the switch is made, tighten the screws. (continued on the next page) TP251. M Revised: January, 2000

106 14. Set the switch as follows: A. Program an M26 to extend the catcher as follows: 1. Press the MDI pushbutton. 2. Press the PRGRM key. 3. Enter M26andpress the INPUT key. 4. Press the CYCLE START pushbutton to extend the catcher. B. Loosen the screws; adjust the switch in toward the end plate and tighten the screws. C. Press the RESET [ // ] key to retract the catcher. D. Read the display on the CRT. If the PARTS CATCHER NOT HOME message appears, extend the parts catcher and repeat steps B, C, and D until the switch is made. E. Extend and retract the part catcher several times to make certain that bit 5 changes each time the end plate leaves the switch roller and each time it returns. F. Adjust the switch as necessary. 15. Power down the machine and mount the spindle compartment covers as follows: A. Mount the upper compartment cover on the machine. B. Connect the hose to the fitting on the coolant catcher. C. Mount the lower spindle drive compartment cover and fasten it in place. 16. Power up the machine and test the part catcher. WORKLIGHT The worklight is mounted on the ceiling of the coolant guard. It is a 20 Watt fluorescent lamp (TL20W/33RS) and has a starter and ballast assembly mounted in a Waldmann (Type DWDV-120) fixture. - WARNING - DO NOT perform any work on electrical components while the electrical power is ON. To replace the lamp and/or starter/ballast assembly: 1. Power down the machine. 2. Open the coolant guard door. However, since the worklight is located near the back of the work area, it may be more convenient to access the worklight through the rear access cover. 3. Wipe the worklight, worklight brackets R, R R Figure 10.13, and worklight cable clean. TP Unthread two wing screws which hold the Figure Worklight worklight brackets closed. Open the worklight brackets and remove the worklight. 5. Loosen, but do not remove, the three screws in the left end (cable end) cap (right end cap if approaching the worklight through the rear access opening). Hold the worklight assembly securely and slide the guard tube from the assembly M-371 Revised: January, 2000

107 6. Replace the fluorescent lamp and/or starter/ballast assembly, as necessary. - NOTE - During re-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 I.D. 7. Hold the worklight assembly and slide the guard tube up on the assembly. Fasten it by tightening the three screws snug. Secure the screws but do not overtighten them. 8. Mount the worklight in the worklight bracket and fasten two wing screws in loosely. 9. Power up the machine. The light will come on when the machine powers up. 10. Adjust the worklight by turning the guard tube. Thread two wing screws in tight to secure the worklight. Close the coolant guard door. LIVE TOOL HOLDER BEARINGS The live tool holder has a tool spindle that is supported by a set of bearings near the front of the spindle and a single bearing at the rear. The front bearing set is DB mounted on the spindle. The live tool holder bearings must be cleaned and re-greased once a year. To disassemble, clean and grease the bearings: 1. Power down the machine. 2. Disconnect the live tool holder cable. 3. Remove the live tool holder from the tool plate and put it on a clean work bench. 4. Unthread the screws and remove plate S, Figure Unthread the set screw; unthread the jam nut and remove pulley T, and key. The drive Y X motor may need to be loosened if the drive belt requires less tension. T 6. Unthread four screws U, fastening spindle housing V, to the live tool drive belt housing. Lift off the spindle housing. S - NOTE - Usually rear bearing X, remains in W the spindle housing. Sometimes the V U bearing is removed with the spindle. TI Unthread the screws and slide the spindle assembly out while removing spindle retaining Figure Live Tool Holder cap W. 8. Unthread bearing jam nut Y, and work the front bearing set from the spindle. The bearings are DB mounted. (continued on the next page) M Revised: January, 2000

108 - NOTES - Keep the inner race and outer race in the same orientation at all times during cleaning. Do not rotate the bearing in either direction during cleaning. Do not use forced air to clean the bearings. 9. Clean the bearings and wipe them clean with a lint-free cloth as follows: A. Clean the bearings in bearing cleaning solution. Or, clean the bearings with fresh kerosene and then clean them with fresh naptha. B. Wipe the bearings dry with a lint-free cloth and let them air dry. 10. Lubricate the bearings as follows: A. Load the front bearing set with 1.5 grams of KLUBER Isoflex NCA 15 grease (Hardinge grease cartridge part number TT NCA). B. Load the rear bearing with 0.5 grams of ANDOK C grease. 11. Mount the front bearings (DB order) on the spindle and torque bearing jam nut Y, Figure 10.14, to 28 lb-ft.. Loosen this bearing jam nut and, then, re-torque it to 28 lb-ft again. 12. Mount the rear bearing in the spindle housing. 13. Align the spindle and put the spindle into spindle housing V. Align spindle retaining cap W mounting openings and evenly torque the screws to 35 lb/in. 14. Mount the spindle housing to the live tool drive belt housing. Torque four screws U, to 120 lb/in Put the key in the spindle keyway and slip pulley T, on the spindle. Torque the jam nut to 100 lb/in. and tighten the set screw. 16. Mount and align the drive belt on the pulley. Adjust the belt tension if necessary. 17. Install plate S, and tighten the screws. 18. Mount the live tool holder on the tool plate and connect the live tool holder cable. 19. Power up the machine. 20. Run in the live tool holder bearings as follows: A. Run live tool at 400 rpm for 4 minutes. B. Reverse the rotation; run live tool again at 400 rpm for 4 minutes. C. Run live tool in the same direction as step A, above, at 1200 rpm for 4 minutes. D. Reverse the rotation; run live tool again at 1200 rpm for 4 minutes. E. Run live tool in the same direction as step A, at 2400 rpm for 4 minutes. F. Reverse the rotation; run live tool again at 2400 rpm for 4 minutes. G. And finally, run live tool in the same direction as step A, at 4000 rpm for 4 minutes. H. Reverse the rotation; run live tool again at 4000 rpm for 4 minutes. 21. Power down the machine and set up tooling on the tool plate M-371 Revised: January, 2000

109 STACKER TABLE TORQUE LIMITER The stacker table option has a torque limiter between the gear box and the table to protect the table and parts rods from damage. To reset the stacker table torque limiter: - CAUTION - DO NOT attempt to index the stacker table with the elevator(s) in the up position; damage to the rods will occur. 1. Check inside the stacker table booth to verify if the elevator(s) is up or down. If both elevators are down, proceed with step #2. If either or both elevators are in the up position, move the elevator(s) to the down position as follows: A. Activate JOG mode. B. On the gantry pendant, press and hold the Elevator Down pushbutton until the stacker table elevator(s) is down. 2. Press the stacker table booth E-Stop (Emergency Stop) pushbutton. 3. Press the Table Index pushbutton; torque limiter may reset and table drops down. 4. If nothing happens when the Table Index pushbutton is activated; open the stacker table access door, reach down to the right and turn the gear box knob until the torque limiter resets (a click will be heard and table drops down). - NOTES - M Revised: January, 2000

110 - NOTES M-371

111 APPENDIX ONE Preventive Maintenance Schedule and Products Applied Introduction The CONQUEST GT27 and GT27SP AUTOLOAD CNC lathes 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 lubrication and control system for ease in troubleshooting problems. Pressure sensors and control alarms alert the operator through the CRT display when systems malfunction. Circuit breakers provide visual confirmation of the electrical status of each circuit. The plug-in relays have LED s for verification of switch condition. The access covers and doors along with the sheet metal housings have been design for ease of removal when service is required. Open access covers and doors or remove panels to gain access to modules. There is no need to be cramped or extended when performing maintenance or service on the machine. Any module can be easily removed from the frame when extensive service or replacement is necessary. - 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 kerosene. 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. Maintenance Schedule The following maintenance times are approximate and components may need attention more frequently if excessive environmental pollution is present. 8 Hours Check oil level Empty tramp oil reservoir Drain air line filter unit (bowl) Check red pop up indicator on air filter Coolant level Remove chips and shavings (continued on the next page) M-371 Appendix One-Page 1

112 Maintenance Schedule (continued) 40 Hours Check circulating fans for dirt and proper operation Clean the spindle coolant catcher Clean and lubricate the spindle (collet closer) draw tube (The draw tube should also be cleaned between job setups.) Wash machine and wipe clean App. One-Page1 160 Hours Check spindle belt tension Check power and control cases for contaminants Ch. 10 Gantry lubrication Check the air filter and heat exchanger filter (Clean more frequently if necessary; replace either filter when necessary) Clean and lubricate the collet closer (The collet closer should also be cleaned between job setups.) Check lubricator system Ch Hours Check spindle drive belt for wear and tension Inspect and clean spindle motor Check spindle encoder timing belt tension Clean spindle brake disc Clean chip screens in the coolant reservoir Hours Clean air line lubricant bowl Clean or replace the lubricator in-line filter Clean coolant reservoir and change coolant (Coolant reservoir should also be cleaned when changing the type or brand of coolant.) Clean lubricant reservoir Replace optional gantry grease packs (automatic lubricators) Yearly Install fresh batteries Clean and re-grease the live tool holder bearings Appendix One-Page 2 M-371

113 Lubricants (Use recommended product) Product Vendor Vactra Oil # Mobil Oil Corp. Velocite Oil # Mobil Oil Corp. Mobiltemp SHC 32 Grease Mobil Oil Corp. Mobilgrease 28 Grease Mobil Oil Corp. Molykote 55M Silicone O-Ring Lubricant Dow Corning Corp. 111 Compound Silicone Lubricant Dow Corning Corp. Molylube Lubricant Bel-Ray Co.,Inc. Never-Seez Black Moly Bostik Inc. KLÜBER NBU KLÜBER Lubrication Adhesives and Sealants Loctite Pipe Sealant with Teflon (Item #592) Loctite Corp. Loctite Threadlocker # Loctite Corp. Loctite Threadlocker # Loctite Corp. Permatex Sealant Loctite Corp. RTV Silicone Rubber Adhesive Sealant General Electric RT-108 Sealing Adhesive General Electric Vactra and Velocite are registered trademarks of Mobil Oil Corporation. Mobilgrease and Mobiltemp SHC are registered trademarks of Mobil Oil Corporation. Molykote is a registered trademark of Dow Corning Corporation. Loctite and Permatex are registered trademarks of Loctite Corporation. Teflon is a registered trademark of Dupont Corporation. M-371 Appendix One-Page 3

114 - NOTES - Appendix One-Page 4 M-371

115 APPENDIX TWO - PHOTOGRAPHS CONQUEST GT27 and GT27SP AUTOLOAD Lathe TP3436. Figure A2.1 - Front of Machine and Operator's Panel A C B TP3409. Figure A2.2 - Machine and Autoload System without "Canopy or Phone Booth" A - Gantry B - Load/Unload Area C - Control Panel M-371 Appendix 2-Page 1

116 D C B A TP3531. Figure A2.3 - Spindle Drive Compartment End View A - Lower Spindle Compartment Cover B - Coolant Catcher Access Door C - Upper Spindle Compartment Cover D - RS232 Serial Port (Front of Control Panel) Appendix 2-Page 2 M-371

117 TP3530. Tp4020. Figure A2.4A - GT27SP Power Case Interior Figure A2.4B - GT27 Power Case Interior M-371 Appendix 2-Page 3 Revised: January, 2000

118 TP3528. Figure A2.5 - Upper Part of the Power Case Appendix 2-Page 4 M-371

119 TP3529. Figure A2.6 - Lower Part of the Power Case M-371 Appendix 2-Page 5

120 TP3533. Figure A2.7 - Operator's Control Panel Interior Appendix 2-Page 6 M-371

121 TP3536. Figure A2.8 - Spindle Compartment M-371 Appendix 2-Page 7

122 Figure A2.9 - Air Panel and Lubricator TP3525. TP3517. Figure A Air Panel with Cover Off Appendix 2-Page 8 M-371

123 TP3430. Figure A Coolant Pump and Reservoir M-371 Appendix 2-Page 9

124 TP3410. Figure A Gantry Arm in Workarea TP3412. Figure A Gantry View from Right with Arm Extended Appendix 2-Page 10 M-371

125 Figure A Gantry Air Panel Viewed from Left TP3556. TP3557. Figure A Gantry Air Panel Viewed from Right M-371 Appendix 2-Page 11

126 TP3553. Figure A Gantry Overall Front View TP3558. Figure A Gantry Z-Axis Motor and Grease Boxes Appendix 2-Page 12 M-371

127 TP3411. Figure A Right End of Machine Ready for Load/Unload System TP3433. Figure A Right End with Stacker Table M-371 Appendix 2-Page 13

128 Figure A Stacker Table without Covers TP3432. TP3434. Figure A Stacker Table Control Boxes Appendix 2-Page 14 M-371