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MAINTENANCE MANUAL

QUEST®

GT27QUEST CHNC

®

Super-Precision®

CNC LatheEquipped with the Fanuc 32i-T Control

Revised: January 27, 2018

Original Instructions

Manual No. M-516A Litho in U.S.A.Part No. M A-0009500-0516 March, 2012

TP8252B

- NOTE -

Damage resulting from misuse, negligence, or accident is not covered by theHardinge Machine Warranty.

Information in this manual is subject to change without notice.

This manual covers the maintenance of QUEST® GT27 and QUESTCHNC® Super-Precision® CNC lathes equipped with the Fanuc 32i-T control.

In no event will Hardinge Inc. be responsible for indirect or consequentialdamage resulting from the use or application of the information in this man-ual.

Reproduction of this manual in whole or in part, without written permissionof Hardinge Inc. is prohibited.

CONVENTIONS USED IN MANUALS

DANGER

DANGER indicates a hazardous situation that, if not avoided, will result in death orserious injury.

WARNING

WARNING indicates a hazardous situation that, if not avoided, could result in deathor serious injury.

CAUTION

CAUTION indicates a hazardous situation that, if not avoided, could result in minoror moderate injury.

NOTICE

NOTICE indicates a situation that, if not avoided, could result in damage to themachine, tooling, or workpiece.

- NOTES -

Notes contain supplemental information.

© 2012, Hardinge Inc. M-516A

Table of Contents

Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Machine Description and Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Machine Electrical Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

General Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Safety Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

CHAPTER 1 - POWER-UP, POWER-DOWN, AND LOCK-OUT PROCEDURESPower-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Air and Electrical Lock-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Air Lock-Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Electrical Lock-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Clearing an Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Hour Run Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

CHAPTER 2 - LUBRICATIONIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Importance of Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Lubrication Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Grease Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Axis Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Lubrication Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Replacement Part Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Replacing a Lubrication Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Turret Lubrication (QUEST® CHNC® Lathe) . . . . . . . . . . . . . . . . . . . . . . . 2-6

CHAPTER 3 - AIR SYSTEMIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Adjusting the Main Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Air Receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Filter/Regulator and Coalescing Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Clean the Air System Bowls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Replace the Coalescing Filter(s) . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Air System Component Replacement or Adjustment . . . . . . . . . . . . . . . . . . . 3-6Main Air Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Replace the Main Air Pressure Switch . . . . . . . . . . . . . . . . . . . 3-6Adjusting the Main Air Pressure Switch . . . . . . . . . . . . . . . . . . . 3-9

Collet Close and Spindle Brake Air Pressure Switches . . . . . . . . . . . . . 3-10Collet Close Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . 3-10Spindle Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . 3-11Pressure Switch Setting. . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Replacing an Air Pressure Switch . . . . . . . . . . . . . . . . . . . . . 3-12Adjusting the Collet Close Air Pressure Switch . . . . . . . . . . . . . . . 3-14Adjusting the Spindle Brake Air Pressure Switch . . . . . . . . . . . . . . 3-15

M-516A i

Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16Replace the Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . 3-16

Replace or Clean the Manifold . . . . . . . . . . . . . . . . . . . . . . . . 3-17Collet Closer Pressure Regulator/Gauge Replacement . . . . . . . . . . . . . 3-18

Replacing the Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . 3-18Replacing the Pressure Regulator . . . . . . . . . . . . . . . . . . . . . 3-19

CHAPTER 4 - COOLANT SYSTEMIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Coolant Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Filling the Coolant Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Water-Based Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2pH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Chip Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Cleaning the Tank, Chip Screens, and Filter . . . . . . . . . . . . . . . . . . . . . . . 4-6

Coolant Nozzles and In-Line Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Adjusting the Nozzle Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Adjusting the Nozzle Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Replacing Coolant Nozzles or In-Line Valves . . . . . . . . . . . . . . . . . 4-12

Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Replacing the Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Machine with Standard Coolant System . . . . . . . . . . . . . . . . . . 4-13Machine with 125 psi [8.6 bar] Coolant System . . . . . . . . . . . . . . . 4-16

In-Line Coolant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

CHAPTER 5 - HEADSTOCK AND SPINDLE DRIVEIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Spindle Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Spindle Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Spindle Drive Motor Replacement and Alignment . . . . . . . . . . . . . . . . . . . . 5-7

Spindle Encoder Timing Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Spindle Encoder Timing Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . 5-14

Spindle Encoder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Headstock Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18Parallel Alignment Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18Aligning the Headstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Cleaning the Spindle Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

ii M-516A

CHAPTER 6 - COLLET CLOSERIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Free Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Collet Closer Draw Tube Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

ANSI A2-4 5C Collet Closer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Removing the Collet Closer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Installing the Collet Closer. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

ANSI A2-5 16C Collet Closer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Removing the Collet Closer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Installing the Collet Closer. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

CHAPTER 7 - AXIS DRIVE MOTORSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Carriage Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Setting the Z Axis Reference Position . . . . . . . . . . . . . . . . . . . . . 7-6

Cross Slide Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10Setting the X Axis Reference Position . . . . . . . . . . . . . . . . . . . . . 7-16

QUEST® GT27 Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16QUEST® CHNC® Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Turret Index Motor (QUEST CHNC Lathe) . . . . . . . . . . . . . . . . . . . . . . . 7-24Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24Setting the Turret Reference Position . . . . . . . . . . . . . . . . . . . . . 7-28

CHapter 8 - Control FunctionsOption Bit Change Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1Accessing the Option Bits Change Utility . . . . . . . . . . . . . . . . . . . . . . . 8-1Option Bits Page Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Changing the State of an Option Bit . . . . . . . . . . . . . . . . . . . . . . 8-3List of Protected Option Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3Password Access to the Protected Option Bits . . . . . . . . . . . . . . . . . 8-4

Input/Output Viewer Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6Accessing and Exiting rhe Input/Output Viewer Utility . . . . . . . . . . . . . . . . 8-6Standard Input Display Screens . . . . . . . . . . . . . . . . . . . . . . . . 8-7Standard Output Display Screens . . . . . . . . . . . . . . . . . . . . . . . 8-9Safety Input and Safety Output Display Screens . . . . . . . . . . . . . . . . 8-10

M-516A iii

CHAPTER 9 - MISCELLANEOUSCooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Fan Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1Cleaning the Foam Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Control and Axis Drive Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . 9-3Battery Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3Control Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3Axis Drive Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Part Chute [Option] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7Replacing the Part Chute Home Switch . . . . . . . . . . . . . . . . . . . . 9-8

APPENDIX ONE - PREVENTIVE MAINTENANCE SCHEDULE AND PRODUCTS APPLIEDIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1

Products Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-3Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-3Adhesives and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-3

APPENDIX TWO - ALARM AND OPERATOR MESSAGESAlarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-1

Operator Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-4

APPENDIX THREE - MACHINE TAGSTag Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-1

Tag Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7Tag Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7Individual Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7

APPENDIX FOUR - MACHINE PHOTOGRAPHS

DOCUMENT REVISION RECORD

iv M-516A

OFFICES

Global Headquarters

United States Hardinge Inc.One Hardinge DriveElmira, NY 14902-1507 USATelephone: 607-734-2281web site: www.hardinge.com

Hardinge Subsidiaries

England Jones & Shipman Hardinge Ltd.Murrayfield RoadLeicesterLE3 1UW EnglandTelephone: +44 (0)116 2013000website: www.hardinge.co.ukemail: [email protected]: www.jonesshipman.comemail: [email protected]

Germany Hardinge GmbHFichtenhain A 13 cD-47807 KrefeldGermanyTelephone: (49) 2151 496490

Switzerland L. Kellenberger & Co. AGHeiligkreuzstrasse 28PostfachCh-9009 St. GallenSwitzerlandTelephone: 41 071 242 91 11website: www.kellenberger.netemail: [email protected]

China Hardinge Machine (Shanghai) Co. Ltd.Hardinge China LimitedNo.1388 East Kang Qiao RoadPudong , Shanghai 201319Telephone : 0086 21 38108686web site: www.hardinge.com.cn

Taiwan Hardinge Taiwan Precision Machinery Ltd.4 Tzu Chiang 3rd RoadNan Tou City540 Taiwan, R.O.C.Telephone: 886-49-226-0536

M-516A v

MACHINE DESCRIPTION AND INTENDED USE

Applicable Machine: QUEST® GT27 and QUEST CHNC® Super-Precision® CNC Lathes

These lathes are numerically controlled machine tools designed to shape cold metal by the appli-cation of a cutting tool and rotating workpiece capable of performing two or more machining pro-cesses (e.g. turning, facing, drilling, grooving and boring) at one set-up of a workpiece andincorporating the following features:

• Select and change tools on the tool plate (QUEST GT27 lathe).

• Select and change tools on the turret top plate (QUEST CHNC lathe).

• Change the position of the tool plate relative to the spindle clamped workpiece.

• Select and apply spindle speeds and axis feeds.

• Control auxiliary services (e.g. coolant flow).

• Optional live tooling provide milling capabilities (QUEST GT27 lathe).

This lathe is designed to machine non-hazardous metals only.

Non-hazardous materials such as Tools Steels, Aluminum, and Brass may be machined.

DO NOT machine any flammable, explosive, toxic, or radioactive material.

DO NOT machine any material that produces a hazardous residue, dust, or gas.

DO NOT use any flammable, explosive, or toxic cutting fluids.

In all cases, if in doubt about the content of the material that you wish to machine, contact the mate-rial supplier.

MACHINE ELECTRICAL OPERATING RANGE

Ambient Temperature Range: +5° C to +40° C.

Humidity Range: Up to 40% at a maximum temperature of +40° C.

Altitude: Up to 1000 meters above sea level (minimum)

vi M-516A

GENERAL WARNINGS AND CAUTIONS

WARNING: California Residents

Product can expose you to chemicals including one or more listed chemicals whichare known to the State of California to cause cancer or birth defects or otherreproductive harm. For more information, go to www.P65Warnings.ca.gov

CHEMICAL WARNING:

Current laws and regulations require that information regarding chemicals usedwith this equipment be supplied to you. Refer to the applicable section of theSafety Data Sheets supplied with your machine when handling, storing, ordisposing of chemicals.

BAR FEED WARNING:

Machine should only be used with a bar feed approved by Hardinge Inc.

SPINDLE TOOLING WARNING:

Hardinge HQC (Quick-Change) collets MUST NOT be used in applications wherethe spindle is rotating without a bar or workpiece in the collet.

Rotating the spindle without a bar or workpiece in the collet can result in the collethead being expelled from the spindle.

Failure to comply with this warning can result in serious injury or death.

MAIN COOLANT GUARD WARNING:

The guards provided with the machine are intended to minimize the risks ofworkpiece ejection and not to eliminate them completely.

INTERLOCKED ACCESS PANEL CAUTION:

Opening an interlocked access panel while the machine is cutting a part will forcethe control into a dual check speed or position alarm, which can destroy theworkpiece and/or tooling.

M-516A vii

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 tooloperators be advised of the importance of safe maintenance, setup, and operation of Hardinge equip-ment. Our recommendations are described below. READ THESE SAFETY RECOMMENDATIONSBEFORE PROCEEDING ANY FURTHER.

READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation ormaintenance 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 neces-sary, wear respirator, helmet, gloves, and ear muffs or plugs.

DON’T OPERATE EQUIPMENT unless proper maintenance has been regularly performedand the equipment is known to be in good working order.

WARNING or INSTRUCTION TAGS are mounted on the machine for your safety and infor-mation. Do not remove them.

DON’T ALTER THE MACHINE to bypass any interlock, overload, disconnect, or other safetydevice.

DON’T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibration oc-curs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as any dam-aged parts.

REDUCE SPINDLE SPEED if vibration occurs. Bar stock straightness will have an effect onvibration and balance of the spindle system.

NEVER OPERATE THE MACHINE SPINDLE without a work-holding device if the draw tubeis in the spindle.

TIGHTEN ALL DRAW TUBE SCREWS before beginning spindle operation.

MAKE CERTAIN that the equipment is properly grounded. Consult National Electric Codeand all local codes.

DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance.

ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing electri-cal equipment.

DON’T REACH into any control or power case area unless electrical power is OFF.

viii M-516A

DON’T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a wetsurface.

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 beforerestarting the machine.

KEEP THE AREA AROUND THE MACHINE well lighted and dry.

KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating equip-ment.

HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combustiblematerial 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 andsecured.

TO REMOVE OR REPLACE the collet closer it is necessary to remove the guard door at theleft end of the machine. Make certain that the guard door is in place before starting the ma-chine.

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 de-vices 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 oper-ating the machine. Always check the machine and work area for loose tools and parts espe-cially 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 func-tions 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 OIL LEVEL and the status of the indicator lights before operat-ing the machine.

MAKE CERTAIN that all guards are in good condition and are functioning properly before op-erating the machine.

INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good con-dition and are functioning properly before the cycle is started.

M-516A ix

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 pushbutton.

CHECK SETUP, TOOLING, AND SECURITY OF THE WORKPIECE if the machine hasbeen 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 beforestarting the machine.

DON’T OPERATE any equipment while any part of the body is in the proximity of a poten-tially hazardous area.

DON’T REMOVE CHIPS with hands. Use a hook or similar device and make certain that allmachine movements have ceased.

BE CAREFUL of sharp edges when handling a newly machined workpiece.

DON’T REMOVE OR LOAD a workpiece while any part of the machine is in motion.

DON’T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing,neckties, or long hair not contained by a net or shop cap.

DON’T 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 amoving component of the machine.

DON’T CHECK finishes or dimensions of workpiece near running spindle or moving slides.

DON’T JOG SPINDLE in either direction when checking threads with a thread 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. Becareful of sharp edges on tools.

DON’T USE worn or defective hand tools. Use the proper size and type for the job being per-formed.

USE ONLY a soft-faced hammer on tooling and fixtures.

DON’T USE worn or broken tooling on machine.

MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools.

x M-516A

INSPECT ALL CHUCKING DEVICES daily to make certain that they are in good operatingcondition. Replace any defective chuck before operating the machine.

Hardinge high speed spindles are balanced to an ISO G1.0 standard. High speed spindlesrequire a work-holding device balanced to G2.5 or better.

USE MAXIMUM ALLOWABLE gripping pressure on the chuck. Consider weight, shape, andbalance of the workpiece.

USE LIGHTER THAN NORMAL feedrates and depth of cut when machining a workpiece di-ameter that is larger than the gripping diameter.

DON’T EXCEED the rated capacity of the machine.

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 withoutbeing 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 informa-tion.

MAKE CERTAIN that any bar feed mechanism is properly aligned with the spindle. If the barfeed is a floor-mounted type, it must be securely bolted to the floor.

DURING HIGH SPEED APPLICATIONS, the bar stock must be contained within the colletcloser and a bar feed not be used. Hardinge Inc. Recommends using a bar loader for feed-ing bar stock during high speed applications. Bar loaders feed the entire piece of bar stockinto the spindle; then, the pusher is disengaged from the bar stock.

UNLESS OTHERWISE NOTED, all operating and maintenance procedures are to be per-formed by one person. To avoid injury to yourself and others, be sure that all personnel areclear of the machine when opening or closing the coolant guard door and any access covers.

FOR YOUR PROTECTION - WORK SAFELY

M-516A xi

- NOTES -

xii M-516A

CHAPTER 1 - POWER-UP, POWER-DOWN,AND LOCK-OUT PROCEDURES

NOTICE

The recommended operating temperature range is 50° to 114° F [7° to 46° C].

- NOTE -

It is important that the power-up procedure is followed as described to ensure safe,accurate, and repeatable machine operation.

The air receiver should be drained approximately every 3 months unless excessivemoisture is present in the air supply system. Refer to Chapter 3 for information ondraining the air receiver.

POWER-UP PROCEDURE

1. Close the coolant guard door.

2. If necessary, drain the air receiver.

3. Turn main circuit breaker “A”, Figure 1.1, ON.

4. Turn main air valve “B”, Figure 1.2, ON.

- NOTE -

Refer to Chapter 4 for information on refilling the coolant tank.

5. Check the coolant level. Add coolant as required.

M-516A 1 - 1

Figure 1.1 - Main Circuit Breaker

TP8258A

A

Figure 1.2 - Main Air Valve

B

TP8248A

NOTICE

When turning the Control switch to ON, DO NOT press any push buttons or keysuntil the Position or Alarm screen is displayed. Some push buttons and keys haveother control maintenance or special operation functions.

6. Turn the Control ON/OFF switch to ON and wait until the CNC display screen is ON.

7. Pull the Emergency Stop push button out.

8. If the machine is equipped with an optional bar feed unit or chip conveyor, release anyadditional Emergency Stop push buttons.

9. Press the Emergency Stop Reset push button.

10. Press the Test Mode key to perform the MCC (motor control contactor) test.

- NOTE -

Press and hold the Door Unlock push button to disengage the guard door interlockand allow the door to be opened.

11. Open and close the coolant guard door to perform the guard door switch verification and clearthe verification alarm.

POWER-DOWN PROCEDURE

1. Be sure “Cycle Start” is not active. The Cycle Start push button light will be OFF.

2. Be sure the program has been completed and that the spindle and slides are stationary.

3. Press the Emergency Stop push button.

4. Turn the Control ON/OFF switch to OFF.

5. Turn main air valve “B”, Figure 1.2, OFF.

6. Turn main circuit breaker “A”, Figure 1.1, OFF.

7. If necessary, lock out the main air valve and main circuit breaker, as outlined in the next section.

1 - 2 M-516A

AIR AND ELECTRICAL LOCK-OUT PROCEDURES

AIR LOCK-OUT

1. Turn main air valve “C”, Figure 1.2, OFF.

2. Lock out the main air valve through tabs “D”, Figure 1.3.

ELECTRICAL LOCK-OUT

1. Turn main disconnect “A”, Figure 1.1, OFF.

2. Rotate the main disconnect switch to the Reset/Lock position.

3. Press tab “E”, Figure 1.4, to extend the lock-out lever.

4. Lock out the main disconnect handle, as shown in Figure 1.5

M-516A 1 - 3

Figure 1.3 - Lock-Out Tabson Main Air Valve

TP5095

D

Figure 1.4 - Lock-Out Lever Not Engaged

TP8245A

E

Figure 1.5 - Lock-Out Lever Engaged

TP8246A

CLEARING AN EMERGENCY STOP

- NOTE -

The operator must wait approximately ten seconds from the time the EmergencyStop push button is pressed before attempting to clear the Emergency Stop.

The Emergency Stop push button is located on the operator control panel.

1. Correct the condition that prompted the Emergency Stop condition.



HOUR RUN METER

Hour run meter “F”, Figure 1.6, is located on the side of the power case. It records the amount oftime that the control has been powered up.

1 - 4 M-516A

Figure 1.6 - Hour Run Meter

F

TP8248A

- NOTES -

M-516A 1 - 5

- NOTES -

1 - 6 M-516A

CHAPTER 2 - LUBRICATION

INTRODUCTION

The machine axes are grease lubricated at grease blocks mounted on the right side of the carriage.The grease system lubricates the ball screws and truck bearings on the linear guideways.

On QUEST® CHNC® lathes, the turret is lubricated with oil. Refer to page 2-6 for information on tur-ret lubrication.

When the grease lubrication system requires maintenance, the machine must be powered down.Refer to Chapter 1 for the power-up, power-down, and lock-out procedures.

IMPORTANCE OF LUBRICATION

Running conditions of the machine depend heavily upon the lubrication management. Make cer-tain that the lubrication system is checked frequently under severe operating conditions to keep themachine in proper working condition.

Fresh grease should be added every six months or 1000 hours of machine operation or more fre-quently under severe operating conditions.

On QUEST CHNC lathes, the oil in the turret should be replaced every two years or 4000 hours ofoperation.

RECOMMENDED LUBRICANTS

THK AFC grease is recommended for axis lubrication. (Hardinge part number: GC 0010994)

Mobil Delvac 75W-90 synthetic oil is recommended for turret lubrication on QUEST CHNC lathes.(Hardinge part number: CJ 0010912B)

Other lubricants may not contain certain additive packages needed for proper lubrication and per-formance. The additive packages may include rust inhibitors, corrosion inhibitors, and anti-wear com-pounds, which have been blended specifically for that application. Although many companies offersimilar greases, these may not contain the needed additives to ensure maximum performance andprotection of Hardinge machines.

LUBRICATION ALARM

The machine control issues a message every 1000 hours of operation. The lubrication message is“2000 Machine Lubrication Required”.

The lubrication message does not stop the machine, but will inhibit Cycle Start.

After lubricating the machine, clear the message as follows:

1. Press the Custom function key.

2. Press the Quick Operation soft key.

3. Press the Lubrication Reset soft key.

4. Press any other function key to exit.

M-516A 2 - 1

GREASE VOLUME

The grease volume presented is dependent upon the grease gun being used. Carefully measurethe amount of grease or count the grease gun strokes necessary to lubricate the guides and ballscrews. Be certain that all air is purged from any grease gun before use.

The required amount of grease is 5 cc.

When a LINCOLN #1147 grease gun is used, six (6) strokes supplies the correct amount of grease.(Available as an option from Hardinge Inc., Part Number TT 0010994-01)

Make certain that all the sliding surfaces are lubricated well by jogging the axes at 50% of the maxi-mum rapid traverse for a full 30 minutes before resuming automatic operation.

AXIS LUBRICATION

- NOTE -

Grease should be added when the linear guides are still warm from operation.

1. Wait for the cycle to end and that the spindles and slides are stationary.

- NOTE -

Refer to the operator’s manual (M-515) for information on using Rapid Referenceto move axes to the reference position.

2. Move the Z axis to the reference position.

3. Jog the X axis toward the front of the machine.

4. Power down and lock out the machine. Refer to the power-down procedure in Chapter 1.

5. Remove access cover “A”, Figure 2.1.

6. On QUEST® GT27 lathes, remove cover “B”, Figure 2.2, to access grease manifolds “C”,Figure 2.3.

On QUEST CHNC® lathes:

A) Remove cover "E", Figure 2.4, to access Zaxis grease manifold "G", Figure 2.5.

B) Remove cover "D" to access X axis greasemanifold "F".

7. Clean the grease fittings.

- NOTE -

Only use a manually operated grease gun.

8. Attach the grease gun nozzle to each greasefitting; slowly and evenly pump in the specifiedamount of grease.

9. Wipe the fittings clean of excess grease.

2 - 2 M-516A

Figure 2.1 - Right End of Machine

A

TP8247A

10. On QUEST® GT27 lathes, install cover “B”, Figure 2.2.


A) Install cover "D", Figure 2.4.

B) Install cover "E".

11. Install cover “A”, Figure 2.1.

12. Power up the machine. Refer to the power-up procedure in Chapter 1.

13. Clear the 1000 hour alarm by pressing the X1 and Rapid Traverse push buttons at the sametime.

14. Jog the axes at 50% of the maximum rapid traverse for a full 30 minutes before resumingautomatic machine operation.

M-516A 2 - 3

Figure 2.2 - Lubrication Access Cover(QUEST GT27 Lathe)

TP8355

B

Figure 2.3 - Grease Manifolds(QUEST GT27 Lathe)

TP5081A

C

Figure 2.4 - Lubrication Access Covers(QUEST CHNC Lathe)

D

E

TP7807

Figure 2.5 - Grease Manifolds(QUEST CHNC Lathe)

F

G

TP7806

LUBRICATION LINE REPLACEMENT

REPLACEMENT PART NUMBERS

Grease Manifold TT 0010234

Tubing TT 0007007

REPLACING A LUBRICATION LINE

1. Wait for the cycle to end and make certain that the spindle is stopped.


3. Remove access cover “A”, Figure 2.1.

4. On QUEST® GT27 lathes, remove cover “B”, Figure 2.2, to access the grease manifolds andlubrication lines.


A) Remove cover "E", Figure 2.4, to access the Z axis grease manifold and lubrication lines.

B) Remove cover "D" to access the X axis grease manifold and lubrication lines.

- NOTE -

Replace the lubrication lines one line at a time.

The ball screw lubrication lines connect to the middle fitting (marked “BS”) on eachgrease manifold.

5. Check each lubrication line for damage. Before disconnecting the line being replaced, measurethe length and check the route from the grease manifold to either the linear guide or ball screw.

6. Disconnect the lubrication line and compare the length of the old lubrication line and thereplacement lubrication line.

7. Before installing the replacement line, fill the line with THK AFC grease.

8. Install the replacement lubrication line:

A) Connect one end of the replacement lubrication line at the grease manifold.

B) Add the specified grease through its fitting until grease appears at the other end of thelubrication line.

C) Connect that end of the lubrication line.

2 - 4 M-516A

9. Wipe the fittings clean of excess grease.

10. On QUEST® GT27 lathes, install cover “B”, Figure 2.2.


A) Install cover "D", Figure 2.4.

B) Install cover "E".

11. Install cover “A”, Figure 2.1.


13. Jog the axes at 50% of the maximum rapid traverse for a full 30 minutes before resumingautomatic machine operation.

M-516A 2 - 5

TURRET LUBRICATION(QUEST® CHNC® Lathe)

The turret oil should be drained and refilled every 4000 hours of operation.

1. Move the cross slide toward the front of the machine to gain access to magnetic plug “H”,Figure 2.6.


3. Position a container with a minimum fluid capacity of 16 fluid ounces [0.5 liters] under themagnetic plug.

4. Remove the magnetic plug to drain the oil from the turret.

2 - 6 M-516A

Figure 2.6 - Turret Oil Drain Location

TI5650A

H Top View of Cross Slide

Front View of Cross Slide

- NOTE -

Inspection of the turret gear box may be necessary if metal fragments are presenton the magnetic plug.

5. Clean the magnetic plug.

6. Apply pipe sealant to the magnetic plug.

7. Install the magnetic plug in the cross slide.

CAUTION

Dispose of the used oil in accordance with all applicable government guidelines.

8. Dispose of the used oil.

9. Remove and clean plugs “I” and “J”, Figure 2.7.

- NOTE -

Mobil Delvac 75W-90 synthetic oil is recommended by Hardinge Inc. for turretlubrication on QUEST® CHNC® lathes.

10. Add oil to the turret at “I” until oil appears at “J”.

11. Install the plugs in the cross slide.


M-516A 2 - 7

Figure 2.7 - Oil Filler Locations

TI5651

I

J

Top View of Cross Slide

Right End View of Cross Slide

- NOTES -

2 - 8 M-516A

CHAPTER 3 - AIR SYSTEM

INTRODUCTION

Factory air to the machine goes through a filter/regulator system to set the air pressure and removecontaminants before they get into the machine air supply. A coalescing filter is mounted after the pres-sure switch manifold to remove additional water vapor and oil.

Machines not equipped with an X axis scale are equipped with one filter/regulator and one coalesc-ing filter. Refer to Figure 3.2.

Machines equipped with an X axis scale are equipped with one filter/regulator and two coalescingfilters. Refer to Figure 3.3.

Use a drip leg in the air line or, if the factory air has excessive moisture, add a heavy-duty air dryer tothe incoming air line. Connect the air supply line to the air valve “A”, Figure 3.1.

The incoming air line should have a minimum I.D. of 3/8 inch [9.5 mm]. If the air line is especiallylong, a larger inside diameter hose may have to be used.

Air is turned ON by turning air valve “A”, Figure 3.1, counterclockwise.

M-516A 3 - 1

Figure 3.1 - Valve CompartmentAccess Cover

TP8248A

A

B

ADJUSTING THE MAIN AIR PRESSURE

The proper operating range is 70 psi to 90 psi [4.9 to 6.3 bars]. Main air pressure switch “D”, Figure3.2 or 3.3, is preset at 60 psi [4.2 bars]. If the switch detects pressure below 60 psi [4.2 bars], an alarmmessage appears on the control display and the machine goes into Emergency Stop.

1. If necessary, turn main air valve “A”, Figure 3.1, ON

2. Remove cover “B”, Figure 3.1, to gain access to the valve compartment.

3. Pull up knob “C”, Figure 3.2 or 3.3, to allow the pressure to be adjusted.

4. Turn knob “C” clockwise or counterclockwise to adjust the pressure as necessary. Watch theair pressure gauge as the knob is turned to determine when the desired pressure level isachieved.

5. Press knob “C” down to lock the setting.

6. Replace cover “B”, Figure 3.1.

3 - 2 M-516A

Figure 3.2 - Air Panel Assembly:Machine Equipped with 5C Spindle

TP4995C

C

D

E

Figure 3.3 - Air Panel Assembly:Machine Equipped with

16C Spindle and X Axis Scale

TP7736A

C D

E

AIR RECEIVER

The air receiver, which maintains collet closer air pressure, is equipped with a manual screw valve.Drain the air receiver every three months to eliminate water and other contaminants. It may be neces-sary to install an air dryer in the air line if more frequent draining is required.

CAUTION

The air receiver is typically drained during machine power up BEFORE the mainair valve is turned ON.

DO NOT drain the air receiver when the main air valve is ON. Always turn themain air valve OFF before draining the air receiver.

1. Open manual screw valve “F”, Figure 3.4, a turn or two to drain the contaminants from the airreceiver.

2. Close the screw valve when draining is complete.

M-516A 3 - 3

Figure 3.4 - Air Receiver

TP8248A

F

FILTER/REGULATOR AND COALESCING FILTER

CLEAN THE AIR SYSTEM BOWLS

- NOTE -

Machines equipped with an X axis scale are equipped with two coalescing filters.

It is possible that after a period of time the air system bowls may need to be cleaned. Each bowl isheld in place by an outer protective shell (bowl guard). The filter/regulator has a different filter elementthan coalescing filter(s).


2. Remove access cover “B”, Figure 3.1.

- NOTE -

Clean one bowl at a time.

3. Clean the filter/regulator and filter bowls as follows:

A) Pull down on latch “E”, Figure 3.2 or 3.3, and rotate the shell counterclockwise to release thebowl from the filter head.

B) Pour any water present from the bowl.

C) Wipe the bowl clean with a lint-free cloth.

D) Check the bowl and O-ring for damage. Replace the bowl or O-ring if necessary.

E) Clean or replace the filter elements, as necessary:

1. Unscrew the nylon fixture to release the filter.

2. Thread the new filter on the nipple until it is tight.

4. Mount the bowl in the head as follows:

A) Put the plastic bowl into the shell.

B) Align the bowl in the head and press the shell up into place. Rotate the shell clockwise until itlatches to seat the O-ring.

C) Pull down on the bowl to confirm that the bowl is secure.

5. Replace access cover “B”, Figure 3.1.

6. Power up the machine and turn the main air valve ON. Refer to the power-up procedure inChapter 1.

7. Set the regulator to 80 psi [5.5 bars] and check it for air leaks. Seal any air leaks as necessary.

8. Check the air system bowl again for contamination, moisture, or air leaks. Correct anyproblems as necessary.

3 - 4 M-516A

REPLACE THE COALESCING FILTER(S)

- NOTE -

Machines not equipped with an X axis scale have one coalescing filter.

Machines equipped with an X axis scale have two coalescing filters.

The filter element should be changed at least every six months.



3. Pull down on latch “E”, Figure 3.2 or 3.3, and rotate the shell counterclockwise to release thebowl from the filter head.

4. Wipe the bowl clean with a lint-free cloth.

5. Check the bowl and O-ring for damage. Replace the bowl or O-ring if necessary.

6. Unthread the filter element from the threaded stem.

7. Thread the new filter element on the stem.

8. Mount the bowl in the head as follows

A) Put the plastic bowl into the shell.

B) Align the bowl in the head and press the shell up into place. Rotate the shell clockwise until itlatches to seat the O-ring.

C) Pull down on the bowl to confirm that the bowl is secure.


M-516A 3 - 5

AIR SYSTEM COMPONENT REPLACEMENT OR ADJUSTMENT

CAUTION

DO NOT perform these maintenance procedures until the machine is powereddown and locked out.

Any of the air control assembly components can be replaced if they become damaged. The air con-trol assembly can also be replaced as a unit. The components on the machine air panel can vary, de-pending on the options installed on the machine.

The air control assembly components are fastened together with taper-railed blocks.

MAIN AIR PRESSURE SWITCH

Replace the Main Air Pressure Switch

Main air pressure switch “D”, Figure 3.2 or 3.3, isconnected to terminal block 2200I/O-1TB with cable2316CBL.

1. Power down and lock out the machine. Refer tothe power-down procedure in Chapter 1.

2. Release three power case door locks “G” andopen power case door "H", Figure 3.5.

3. Release two door locks "J", Figure 3.6.

4. Lift lever "K" and open input/output case door"I".

5. Remove spindle compartment cover “M”,Figure 3.7.

3 - 6 M-516A

Figure 3.5 - Power Case Door

G

TP8258A

H

Figure 3.6 - Input/Output Case Door

TP8238

J

K

I

Figure 3.7 - Left End of Machine

TP8248A

M

L

6. Unscrew the hose clamp to release the coolant return hose fastened to the fitting on the coolantcatcher mounted inside spindle compartment cover “L”.

7. Remove spindle compartment cover “L”.


9. Disconnect the wires in cable 2316CBL from terminals 25 and 26 on terminal block2200I/O-1TB. Refer to Figure 3.8.

10. Pull cable 2316CBL from the power case, through the spindle drive compartment, and into thevalve compartment. Note the routing of cable 2316CBL for installation of the cable on the newpressure switch.

11. Loosen two screws “N”, Figure 3.9, on the top of the pressure switch.

12. Remove pressure switch “O”.

13. Verify that the new pressure switch is the same as the original switch.

14. Install the new switch and tighten the screws.

15. Route the cable for the new pressure switch as noted in step 10.

M-516A 3 - 7

Figure 3.8 - Input/Output Panel

TP8236

Terminal Block2200I/O-1TB

Figure 3.9 - Main Air Pressure Switch(Top View)

TP5108

N

P

O

16. Connect the wires in cable 2316CBL to terminal block 2200I/O-1TB as follows:

Wire Color Terminal Block Connection

Brown 25

Blue 26

17. Close and lock the input/output case door.

18. Close and lock the power case door.

19. Replace spindle compartment cover “L”, Figure 3.7.

20. Fasten the coolant return hose to the fitting on the coolant catcher mounted inside spindlecompartment cover “L”.

21. Replace spindle compartment cover “M”.

22. Check the setting of the new pressure switch and adjust as necessary. Refer to “Adjusting theMain Air Pressure Switch”, page 3-9.

3 - 8 M-516A

Adjusting the Main Air Pressure Switch

- NOTE -

The main air pressure switch should be set to energize at 60 psi [4.14 bar] on therise.




4. Turn knob “C” counterclockwise SLOWLY to reduce the air pressure. Watch the air pressuregauge as the knob is turned to determine the air pressure setting when the main air pressureswitch trips and puts the machine into Emergency Stop.

5. Press the System key.

6. Press the PMC Maintenance soft key.

7. Press the Status soft key.

8. Key in: X15.

9. Press the Search soft key.

10. View bit 15.0. Bit 15.0 will be set to “0”, indicating a low main air pressure fault condition.

11. Monitor bit 15.0 while turning knob “C” clockwise SLOWLY to increase the air pressure to 60 psi[4.14 bar], as viewed on the filter/regulator gauge.

12. If bit 15.0 does not change from “0” to “1” when the air pressure is approximately 60 psi [4.14bar], rotate adjustment screw “P”, Figure 3.9, counterclockwise until bit 15.0 changes from “0”to “1”.

If bit 15.0 changes from “0” to “1” when the air pressure is approximately 60 psi [4.14 bar],the switch is properly set.

- NOTE -

The proper operating range is 70 psi to 90 psi [4.9 to 6.3 bars].

13. Turn knob “C”, Figure 3.2 or 3.3, clockwise to increase the air pressure to the desired operatingpressure.



16. Power down the machine to clear the alarm. Refer to the power-down procedure in Chapter 1.

M-516A 3 - 9

COLLET CLOSE AND SPINDLE BRAKE AIR PRESSURE SWITCHES

Collet Close Pressure Switch

The purpose of collet close pressure switch “Q”, Figure 3.10, 3.11, or 3.12, is to detect air pressurewhen “Collet Close” has been activated by either of the following:

• Programming an M22

• Pressing a Collet Open/Close push button

3 - 10 M-516A

Figure 3.10 - Collet Closer and SpindleBrake Pressure Switches

(Machine Equipped with 5C Spindle)

TP5066

R

Q


(Machine Equipped with 16C Spindle)

TP5127

R

Q


(Machine Equipped with 5C Spindleand C-Axis Option)

TP5170

Q

R

Spindle Brake Pressure Switch

The purpose of main spindle brake pressure switch “R”, Figure 3.10, 3.11, or 3.12, is to detect airpressure whenever the spindle is not rotating and Spindle Free has not been activated from the opera-tor control panel.

Pressure Switch Setting

The pressure switches are factory set to energize when 20 psi [1.4 bar] or greater is detected. If aswitch fails to energize at 20 psi [1.4 bar], it should be adjusted. If a switch fails to energize during ad-justment, it must be replaced.

Refer to page 3-12 for information on replacing a collet close or spindle brake air pressureswitch.

Refer to page 3-14 for information on checking and adjusting a collet close air pressureswitch.

Refer to page 3-15 for information on checking and adjusting the spindle brake air pressureswitch.

M-516A 3 - 11

Replacing an Air Pressure Switch


2. Release three power case door locks “G” and open power case door "H", Figure 3.5.

3. Release two door locks "J", Figure 3.6.

4. Lift lever "K" and open input/output case door "I".

5. Remove spindle compartment cover “M”, Figure 3.7.

6. Unscrew the hose clamp to release the coolant return hose fastened to the fitting on the coolantcatcher mounted inside spindle compartment cover “L”.

7. Remove spindle compartment cover “L”.

8. If replacing the main spindle collet close air pressure switch, disconnect the wires in cable2314CBL from terminals 22 and 23 on terminal block 2200I/O-1TB. Refer to Figure 3.8.

If replacing the spindle brake air pressure switch, disconnect the wires in cable 2318CBL fromterminals 28 and 29 on terminal block 2200I/O-1TB. Refer to Figure 3.8.

9. Pull the pressure switch cable from the power case and into the spindle drive compartment.Note the routing of the cable for installation of the cable on the new pressure switch.

- NOTE -

Needle-nose pliers can be used to remove the old pressure switch. Position thepliers as shown in Figure 3.13 and GENTLY rock the pliers to apply pressure onthe retention ring to release the pressure switch.

10. Press the retention ring on the “Tee” fitting away from the pressure switch and pull the switchout of the fitting.

11. Verify that the new pressure switch is the same as the original switch.

3 - 12 M-516A

Figure 3.13 - Pressure Switch Removal

TP5128

12. Press the replacement switch into the “Tee” fitting.

13. Route the cable for the new switch as noted in step 9.

14. Connect the wires in the cable to terminal block 2200I/O-1TB as follows:

Switch Function Cable Number Wire Color Terminal Block Connection

Collet Close 2314CBLBrown 22

Blue 23

Spindle Brake 2318CBLBrown 28

Blue 29



17. Check the setting of the new pressure switch and adjust as necessary. Refer to page 3-14 or3-15 for the appropriate procedure to adjust the air pressure switch.

M-516A 3 - 13

Adjusting the Collet Close Air Pressure Switch

1. If spindle compartment covers “L” and “M”, Figure 3.7, are mounted on the machine:

A) Remove spindle compartment cover “M”.

B) Unscrew the hose clamp to release the coolant return hose fastened to the fitting on thecoolant catcher mounted inside spindle compartment cover “L”.

C) Remove spindle compartment cover “L”.


3. Press the Jog mode push button.

NOTICE

DO NOT operate the collet closer when a collet or step chuck is mounted in thespindle without first inserting a piece of stock or a plug of the correct size.

4. If a collet or step chuck is installed in the spindle, insert a piece of stock or a plug of the correctsize into the work-holding device.

5. Press the Collet Open/Close push button to close the work-holding device.

6. Turn regulator knob “T”, Figure 3.14, to set the collet closer air pressure to 20 psi [1.4 bar] , asviewed on gauge “S”.

7. Turn the adjustment screw on pressure switch “Q”, Figure 3.10, 3.11, or 3.12, clockwise untilthe indicator light on the pressure switch turns OFF.

8. Slowly turn the adjustment screw on thepressure switch counterclockwise until theindicator light on the pressure switch turns ON.The switch is now properly set.

9. Replace spindle compartment cover “L”,Figure 3.7.

10. Attach the coolant return hose to the fitting onthe coolant catcher mounted inside spindlecompartment cover “L” and secure with thehose clamp.


12. Turn regulator knob “T”, Figure 3.14, to set thecollet closer air pressure to the desired setting.

3 - 14 M-516A

Figure 3.14 - Collet CloserRegulator and Gauge

TP8252B

T

S

U

Adjusting the Spindle Brake Air Pressure Switch

1. If spindle compartment covers “L” and “M”, Figure 3.7, are mounted on the machine:

A) Remove spindle compartment cover “M”.

B) Unscrew the hose clamp to release the coolant return hose fastened to the fitting on thecoolant catcher mounted inside spindle compartment cover “H”.

C) Remove spindle compartment cover “L”.


3. Press the Jog mode push button.

- NOTE -

The spindle brake must be engaged to adjust the spindle brake air pressureswitch.

4. Check the indicator light next to the Spindle Free push button:

If the light is ON, press the Spindle Free push button to engage the spindle brake.

If the light is OFF, the spindle brake is engaged.



7. Turn knob “C” counterclockwise SLOWLY to reduce the air pressure to 20 psi [1.4 bar].

8. Turn the adjustment screw on pressure switch “R”, Figure 3.10, 3.11, or 3.12, clockwise untilthe indicator light on the pressure switch turns OFF.

9. Slowly turn the adjustment screw on pressure switch “R” counterclockwise until the indicatorlight on the pressure switch turns ON. The switch is now properly set.

10. Turn knob “C” , Figure 3.2 or 3.3, clockwise to increase the air pressure to the desired operatingpressure.



13. Replace spindle compartment cover “L”, Figure 3.7.

14. Attach the coolant return hose to the fitting on the coolant catcher mounted inside spindlecompartment cover “L” and secure with the hose clamp.


M-516A 3 - 15

SOLENOID VALVES

Solenoid valves at air manifolds “W” and “Z”, Figure 3.15, are horizontally stacked on the air panel.Most air system options are activated through solenoid valves and are available on the machine whenoriginally ordered or some of the options can be retrofitted when necessary. Main air manifold “W” haselectronic controlled valves and air blast manifold “Z” has air piloted solenoid valves.

Reference information is included in each air option retrofit kit and with each machine. Electricalconnections, air line connections, cable markings, routing through the machine, and location of theoption parts are on the option information sheets and on the tags on the machine.

Replace the Solenoid Valves

- NOTE -

Each solenoid block is mounted to a common air manifold.



- NOTE -

The two small valve mounting screws are diagonally placed on each valve block.

3. Unthread two small screws “X” and “Y”, Figure 3.15, from the front of the solenoid valve beingreplaced.

4. Lift the valve off the air manifold.

5. If there is an air line; press in the line, hold the fitting in and pull the line out.

6. Verify that the new solenoid valve is the same as the original valve.

7. Install the new valve and tighten the screws.

8. If there is an air line; press in the line, hold the fitting and line and pull them out until the air line issecure.


3 - 16 M-516A

Figure 3.15 - Air System Components

TP4997B

X

Z

W

V

Y

REPLACE OR CLEAN THE MANIFOLD

There are no moving parts in manifold “V”, Figure 3.15. The manifold only distributes the air. If it isnot dispersing air as it should or if it becomes damaged, it may need to be cleaned or replaced. Thereare additional ports in the air manifold for use when other air options are added to the machine.



3. To disconnect each air line; press in the line, hold the fitting in and pull the line out.

4. Unthread the screw from the front mounting block.

5. Remove the block and pull manifold “V”, Figure 3.15, from the sub-assembly.

6. Verify that the new manifold is the same as the original manifold.

7. Install the new manifold and tighten the screws.

8. To connect each air line; press in the line, hold the fitting and line and pull them out togetheruntil the air line is secure.


M-516A 3 - 17

COLLET CLOSER PRESSURE REGULATOR/GAUGE REPLACEMENT

The collet closer pressure regulator sets the collet close holding force. The collet closer pressure isadjusted by turning regulator knob “T” and observing the pressure on gauge “S”, Figure 3.14.

Collet closer air pressure should be set at approximately 40 psi [2.8 bar].

Replacing the Pressure Gauge


2. Open door “U”, Figure 3.14.

3. Disconnect the gauge air hose from the air pressure regulator by pressing the retention ring onthe fitting in the air pressure regulator and pulling the hose out of the fitting.

4. Loosen screws “A”, Figure 3.16.

5. Remove clamp “B” from the gauge.

6. Remove the gauge from the panel.

7. Remove the air line and fitting from the old gauge.

8. Apply Loctite® High Performance Pipe Sealant with Teflon® to the threads of the gauge air linefitting and install on the replacement gauge.

9. Mount the replacement gauge on the panel.

10. Install clamp “B” and two screws “A”.

11. Tighten the two screws to secure the gauge.

12. Press the loose end of the gauge air hose into the fitting on the air pressure regulator.

3 - 18 M-516A

Figure 3.16 - Collet CloserAir Pressure Gauge

TP5135

B

A

Replacing the Pressure Regulator


2. Open door “U”, Figure 3.14.

3. Disconnect the gauge air hose from the air pressure regulator by pressing the retention ring onthe fitting in the air pressure regulator and pulling the hose out of the fitting.

4. Remove the retaining ring from regulator knob “T”, Figure 3.14, to release the regulator fromthe panel.

5. If necessary, tag the regulator hoses for re-assembly.

6. Disconnect the hoses from the regulator fitting by pressing the retention ring on the fitting andpulling the hose out of the fitting.

7. Note the location of the fittings and pipe plug in relation to the air flow indicator (arrow) on thebase of the regulator, shown in Figure 3.17.

8. Remove the fittings and pipe plug from the old regulator.

9. Apply Loctite® High Performance Pipe Sealant with Teflon® to the threads of the fittings andpipe plug and install them on the replacement regulator.

10. Connect the hoses as tagged in step 5 to the regulator by pressing the loose end of the hosesinto the fittings.

NOTICE

The retaining ring can be damaged ifover-tightened.

11. Lift the air pressure regulator into position inthe panel and install the retaining ring removedin step 4.

12. Close door “U”, Figure 3.14.

13. Power up the machine. Refer to the power-upprocedure in Chapter 1.

14. Set the closer pressure to approximately 40 psi[2.8 bar]. Refer to “Adjusting the Main AirPressure”, page 3-2.

M-516A 3 - 19

Figure 3.17 - Air Flow Indicator onBase of Air Pressure Regulator

TI4989

Air FlowIndicator

AirIN

AirOUT

AirOUT

AirOUT

- NOTES -

3 - 20 M-516A

CHAPTER 4 - COOLANT SYSTEM

INTRODUCTION

CAUTION

When coolant system maintenance is required, the machine must be powereddown. Refer to Chapter 1 for the power-up, power-down, and lock-out procedures.

Hardinge machine tools are designed using the latest technology and highest quality materialsavailable. However, due to the ever increasing number of coolant selections available, it is impossibleto test material compatibility with each and every coolant. For additional information regarding thecoolant facilities on this machine, refer to the operator’s manual (M-515).

NOTICE

Whenever water soluble coolants are used it is important to use the manufacturer’srecommended mix ratio (concentration). It is also important to maintain the coolantby keeping the proper concentration level when coolant solution is added tocompensate 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 rustinhibitors in the coolant start depleting, which can result in corrosion of machinecomponents. Also, the quality of the water should be tested by the coolantmanufacturer so that the proper coolant additives can be administered. Failure tofollow these recommendations could result in damage to the machine, seals, andpaint.

If the coolant you have selected starts to react (cause material to rust, pit, swell,soften, crack, or blister) with any portion of the machine tool, Hardinge suggeststhat you discontinue use and contact your coolant representative for alternativecoolants.

It should also be noted that certain chemicals react with different metals. Hardingerecommends that you consult with your coolant representative to assure that thematerial 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 ensurethe best performance from the coolant and machine.

M-516A 4 - 1

SYSTEM DESCRIPTION

QUEST® GT27 and QUEST CHNC® lathes have a coolant recirculating system for either oil-basedor water-based coolant. The system consists of a coolant tank with filters, an electric pump, fully ad-justable directional nozzles in the work envelope, a chip flush block on the right side wall, and a cool-ant catcher on the cover of the spindle compartment. Coolant is fed to the tool tips and workpiecethrough the directional nozzles. Most of the fluid drains down into the tank; however, some liquid re-turns to the tank through a hose from the coolant catcher in the spindle drive compartment.

COOLANT TANK

CAPACITY

The coolant tank contains approximately 20 gallons [76 liters] of coolant.

FILLING THE COOLANT TANK

Open the front coolant guard door and pour the required amount of coolant directly into the chippan. Either water-based or oil-based coolant can be used.

WATER-BASED COOLANTS

Water-based coolants are a cutting fluid which, when improperly specified or maintained, can af-fect the life of a machine and the quality of the parts made on it. Water-based coolants are designed tosuppress rusting, enhance cutting, increase tool life, promote heat dissipation, and be economical touse.

Some water-based coolants may cause machine corrosion problems and be incompatible with ma-chine components, especially if the fluid is not maintained correctly. Water-based coolants must becorrectly specified according to the machined materials and ensure compatibility with the machine’scomponents.

It is important to follow the coolant manufacturer’s recommendations when using a water-basedcoolant. Maintaining coolants per the manufacture’s recommendations will increase the machine’suseful life and will minimize corrosion, rusting, staining, and health problems such as dermatitis. At aminimum, the coolant maintenance should include daily checks and correction of coolant concentra-tion, a measure of coolant pH.

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 accu-racy can be impaired by tramp oils, cleaners, and other contaminants.

Proper concentration control is essential for optimal tool life, corrosion control, and inhibiting bacte-rial growth. Water soluble coolants lose water by evaporation during normal operating conditionswhich tends to increase the coolant concentration over a normal work shift. The coolant concentrationmust be checked each day.

The coolant concentration must be kept within the specified range determined by the coolant man-ufacturer. Failure to maintain the coolant concentration within this range may result in poor perfor-mance from that fluid. Lean concentrations can lead to rust, rancidity, short tool life, and otherproblems. Rich concentrations can result in foam, residues, health problems such as dermatitis, andincreased coolant costs.

4 - 2 M-516A

pH

pH is a measure of a solution’s alkalinity or acidity. There are two common methods used to deter-mine pH. One method is the use of special pH test paper and the other is a pH meter.

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 indi-cates a growth of microbiological organisms (bacteria). Typically, the pH range is between 8.5 and9.2.

WATER QUALITY

The water quality is also an important factor toward achieving optimum coolant performance. Wa-ter that contains dissolved minerals, bacteria, and other impurities (hard water) can sometimes ad-versely affect the coolant selected. An indication of water related problems is the formation of a soaplike scum which adheres to sumps, filters, and other surfaces. It is best to consult with your coolantrepresentative to determine your requirements.

CARE AND MAINTENANCE

A daily check of the concentration and pH will help keep the coolant at its optimum performancelevel.

Make-up coolant should be added when needed and according to the manufacturer’s recommen-dation. This make-up coolant is necessary to provide additional fresh coolant which contains the es-sential additives required to keep the coolant performing properly.

Clean and replace the coolant per the coolant manufacturers recommendations. Proper cleaningof the machine is very important before refilling the tank with fresh coolant. Dispose of the used cool-ant properly. Bacteria live and cling to all wetted surfaces in the machine. Special cleaners, usuallyavailable from your coolant supplier, are recommended to flush the system before refilling. Thesecleaners will kill the bacteria left after draining the machine. It also is recommended that a thoroughcleaning, which includes scraping and removing any sludge found on the bottom and hidden in the toppanels of the coolant tank, be completed before circulating cleaner through the system.

M-516A 4 - 3

CHIP REMOVAL(Machine without Chip Conveyor)

The coolant tank is mounted on wheels and the coolant pump can be disconnected, allowing thecoolant tank to be moved out from under the machine.

CAUTION

Use a rake and suitable container to remove metal chips and shavings from thecoolant tank. Injury may result from attempting to remove chips by hand.

1. Open the guard door.


3. Allow the coolant to drain back into coolant tank “A”, Figure 4.1.

4. If the machine is equipped with a standard coolant system, pull back on the knurled ring torelease coupling “B”, Figure 4.2, to release the coolant hose from the coupling on the tank.

If the machine is equipped with a 125 psi [8.6 bar] coolant system:

A) Open valve "C", Figure 4.3, to allow thecoolant in the coolant hose to drain backtoward the coolant tank.

B) Close valve "C".

C) Disconnect the coolant tank hose fromcoolant filter “D” and drain any remainingcoolant from the hose into a container fordisposal.

4 - 4 M-516A

Figure 4.1 - Coolant Tank

A

TP8252B

Figure 4.2 - Quick-Disconnect Fitting

B

TP5016A

Figure 4.3 - Coolant Hose DrainValve at Right End of Machine

C

TP9612

D

5. Unlock casters “E”, Figure 4.4, to allow the coolant tank to be moved.

6. Roll the tank out to an area where it is convenient to remove the chips.

7. Rake the chips into a suitable container and dispose of them properly.

8. Roll the coolant tank into place under the front of the machine.

9. Position the entire length of the flexible splash shield inside the coolant tank. Refer to Figure4.5.

10. Lock casters “E” Figure 4.4, to secure the coolant tank in position.

11. If the machine is equipped with a standard coolant system, connect quick-disconnect coupling“B”, Figure 4.2, to the coolant tank.

If the machine is equipped with a 125 psi [8.6 bar] coolant system, connect the coolanthose to coolant filter "D", Figure 4.3.

M-516A 4 - 5

Figure 4.4 - Coolant Tank Casters

TP8366A

E

Figure 4.5 - Splash ShieldInside Coolant Tank

TP9614

CLEANING THE TANK, CHIP SCREENS, AND FILTER

Clean the coolant tank at least once every six months or more frequently if the coolant becomescontaminated by material being cut. Clean the coolant tank whenever changing the type or brand ofcoolant. The coolant catcher on the cover of the spindle compartment should also be cleaned at thesame time that the coolant tank is cleaned.



3. Allow the coolant to drain back into coolant tank “A”, Figure 4.1.

4. If the machine is equipped with a standard coolant system, pull back on the knurled ring torelease coupling “B”, Figure 4.2, to release the coolant hose from the coupling on the tank.

If the machine is equipped with a 125 psi [8.6 bar] coolant system:

A) Open valve "C", Figure 4.3, to allow the coolant in the coolant hose to drain back toward thecoolant tank.

B) Close valve "C".

C) Disconnect the coolant tank hose from coolant filter “D” and drain any remaining coolantfrom the hose into a container for disposal.

5. If necessary, unplug the chip conveyor electrical cable.

6. Unlock casters “E”, Figure 4.4, to allow the coolant tank to be moved.

7. Roll the tank out to an area where it is convenient to perform the required maintenance.

4 - 6 M-516A

8. If the machine is equipped with a chip conveyor:

WARNING

Use a hoist and lifting straps with a minimum lifting capacity of 1,000 pounds [454kg] to lift the chip conveyor.

NOTICE

The chip conveyor is equipped with one upper and lower attachment point on eachside. Use attachment points for lifting the chip conveyor. DO NOT attach a liftingdevice to any other part of the conveyor.

A) Attach lifting straps to the upper attachment points on the chip conveyor. Refer to Figure 4.6.

B) Remove chip deflector "F", Figure 4.7.

C) Remove two nuts "G", lock washers, and washers from the coolant tank.

D) Remove the chip conveyor from the coolant tank.

CAUTION

DO NOT remove chips with your bare hands. Wear gloves and use a rake orshovel to remove chips from the coolant tank.

9. Rake any chips present into a suitable container and dispose of them properly.

M-516A 4 - 7

Figure 4.6 - Attachment Pointson Chip Conveyor

UpperAttachment

Point

LowerAttachment

PointTP8361

Figure 4.7 - Chip Conveyor Coolant Tank

TP8331A

F

G

- NOTE -

When filled to the FULL line, the coolant tank contains approximately 20 gallons[76 liters] of coolant.

10. Pump the coolant from the tank.

11. Remove screens “H” and sump cover “I”, Figure 4.8 or 4.10, from the tank.

12. Remove filter “J”, Figure 4.9 or 4.10.

13. Remove any coolant remaining in the tank and wipe the tank clean.

14. Wash the filter, sump cover, screens, and coolant tank with a cleaner recommended by thecoolant manufacturer to remove any bacterial contamination.

4 - 8 M-516A

Figure 4.8 - Standard Coolant Tank

TP8327A

H

I

Figure 4.9 - Sump Filter(Standard Coolant Tank)

J

TP8330A

Figure 4.10 - Screens and Sump Filter(Chip Conveyor Coolant Tank)

TP8332A

H

I

J

15. Install the filter in the coolant sump.

16. Mount the sump cover and screens in the tank.

17. Clean the coolant catcher:

A) Position a container under surface "K", Figure 4.11, to collect coolant cleaner draining fromthe coolant catcher.

B) Press and turn the latches on draw tube access cover “L”, Figure 4.12.

C) Lift the draw tube access cover straight off.

D) Clean inside the spindle from outside to inside the work area.

E) Wipe any liquid and chips that remains in the coolant catcher.

F) Wash the coolant catcher and draw tube access cover with a cleaner recommended by thecoolant manufacturer.

G) Flush the coolant catcher to clean the return hose. Verify the cleaner flows through the hoseinto the container positioned in step 17A.

H) Clean the catcher and hose again.

I) Flush the coolant catcher and return hose.

J) Mount draw tube access cover “L” and secure the latches.

K) Remove the container positioned in step 17A.

18. If the machine is equipped with a chip conveyor:

A) Install the chip conveyor in the coolant tank.

B) Secure the chip conveyor with the two washers, lock washers, and nuts.

C) Install chip deflector "F", Figure 4.7, in the coolant tank.

M-516A 4 - 9

Figure 4.11 - Drain Surface

K

TP7322

Figure 4.12 - Draw Tube Access Cover

TP8248A

L

19. Roll the coolant tank into place under the front of the machine.

20. Position the entire length of the flexible splash shield inside the coolant tank. Refer to Figure4.5.

21. Lock casters “E” Figure 4.4, to secure the coolant tank in position.

22. If the machine is equipped with a chip conveyor, connect the chip conveyor electrical cable tothe machine.

23. If the machine is equipped with a standard coolant system, connect the coolant hose to thecoolant tank.

If the machine is equipped with a 125 psi [8.6 bar] coolant system, route the coolant tankhose through the round opening in the end of the machine and connect the hose to coolantfilter “D”, Figure 4.3.

24. Refill the tank with the desired coolant by pouring the fresh coolant directly into the coolant tank.

25. Close the guard door.

4 - 10 M-516A

COOLANT NOZZLES AND IN-LINE VALVES

LOCATIONS

There are coolant nozzles and in-line valves in two locations:

• The head wall, shown in Figure 4.13

• The tool slide coolant and air blast manifold, shown in Figure 4.14(QUEST® GT27 lathe)

ADJUSTING THE NOZZLE POSITION

The coolant nozzles can be adjusted to any angle by simply bending or forming the links until thedesired position is obtained.

ADJUSTING THE NOZZLE LENGTH



3. Separate ball links at one spot in nozzle “N”, Figure 4.13 or 4.14, by pulling it apart or rotating alink further than it normally goes.

4. Remove or add links to change the length of the nozzle as desired.

5. Re-attach the separated length by pressing the links together.

6. Adjust the angle and position of the nozzle to be certain that the length is correct.


M-516A 4 - 11

Figure 4.13 - Head Wall CoolantValves and Nozzles

TP5097

M

N

Figure 4.14 - Cross SlideCoolant Valves and Nozzles

(QUEST GT27 Lathe)

M

N

TP5120

REPLACING COOLANT NOZZLES OR IN-LINE VALVES



3. Unscrew the threaded link of nozzle “N” from valve “M”, Figure 4.13 or 4.14.

4. When the valve has to be removed, unthread it from the fitting on the head wall or from themanifold.

- NOTE -

Use hydraulic pipe sealant on the fitting threads when replacing either the valvesor adjustable nozzles.

5. Thread the valve into the fitting or manifold and then thread the nozzle into the valve.

6. Adjust the length and/or angle of the nozzle to direct the coolant.


8. Turn the coolant ON and adjust the coolant flow as necessary.

4 - 12 M-516A

COOLANT PUMP

INTRODUCTION

The coolant pump is located at the right rear of the machine. The coolant pump draws coolant fromthe tank and feeds it to the following locations:

• Head wall coolant nozzles

• Tool slide coolant manifold (QUEST® GT27 Lathe)

• Coolant guard chip flush

• Optional thru-spindle coolant

REPLACING THE COOLANT PUMP

Machine with Standard Coolant System



3. Flush any remaining coolant from the coolantlines:

A) Close valve “M”, Figure 4.13, on one of thehead wall coolant lines.

B) Aim the other head wall coolant line downtoward the coolant tank.

C) On QUEST GT27 lathes, close all but one ofthe tool slide coolant valves “M”, Figure4.14.

D) Verify chip flush coolant valve “O”, Figure4.15, is open.

E) Place a container under plug "R", Figure4.16.

F) Remove the plug to drain the coolant lines.

G) Pull back on the knurled ring to releasecoupling “B”, Figure 4.2, to release thecoolant hose from the coupling on the tank.

H) Lift the coolant hose as much as possible todrain coolant back toward the coolant pump.

I) Apply hydraulic pipe sealant and install theplug when draining is complete.

M-516A 4 - 13

Figure 4.15 - Valve forCoolant Guard Chip Flush

O

TP5021

Figure 4.16 - Coolant PumpUni-Directional Valve and Output Fittings

TP9620

Q

R

P

4. Loosen the hose clamps and pull the lower end of the coolant supply hoses "P", Figure 4.16,from the fittings.

5. Remove coolant pump access cover “S”, Figure 4.17.

6. Remove uni-directional valve “Q”, Figure 4.16, and associated fittings from the output side ofthe pump.

7. Remove fitting “T”, Figure 4.18, with hose and quick-disconnect coupling from the input side ofthe pump.

8. Remove two screws “U”, which secure the pump to the mounting plate.

9. Turn the pump enough to access the electrical junction box.

10. Remove the junction box cover.

11. Loosen the cord grip on the junction box.

12. Disconnect the ground wire from ground connection “V”, Figure 4.19.

- NOTE -

Cut the black power wires such thatthe splice connectors remain with theold pump.

13. Cut the black power wires and remove thecable from the junction box.

14. Lift the pump out through the access opening.

15. Cut the ring connectors off power wires “W” onthe new pump.

16. Strip pump power wires "W” for connectionusing 14 AWG splice connectors.

4 - 14 M-516A

Figure 4.17 - Coolant Pump Access Cover

TP8249A

S

Figure 4.18 - Coolant Pump

TP5111A

T

U

Figure 4.19 - Coolant Pump Wiring

TP5117

V

W

17. Place the new pump onto the mounting plate.

- NOTE -

The black power wires in the electrical cable are numbered 1, 2, and 3.

The black power wires in the junction box on the replacement pump are labeled U,V, and W. The black seal in the back of the junction box is also labeled for wireidentification.

18. Feed the electrical cable into the junction box and strip the black power wires for connectionusing 14 AWG splice connectors.

19. Use 14 AWG splice connectors to connect the black power wires as follows:

Wire 1 connects to wire U

Wire 2 connects to wire V

Wire 3 connects to wire W

20. Connect the ground wire to ground connection “V”.

21. Install the junction box cover.

22. Rotate the coolant pump into position on the platform and secure with two screws “U”, Figure4.18.

23. Apply hydraulic pipe sealant on the threads and install the fittings on the new pump.

24. Attach coolant hoses “P”, Figure 4.16, to the pump and tighten the clamps on the hoses.

25. Replace coolant pump access cover “S", Figure 4.17.

26. Connect the coolant hose to the coolant tank.

27. Check the level of coolant in the tank. Replenish as needed.


29. Prime the coolant pump:

A) Put a flexible piece of hose, approximately 16 to 18 inches [400 to 450 mm] long, over one ofthe head wall coolant nozzles.

B) Cut a 1 inch [25 mm] slot, 2 inches [50 mm] from the tip of the hose.

C) Put an air hose tip into the slot and point it toward the open end of the hose.

D) Activate the coolant in the head wall nozzle and turn the air on to create a vacuum to drawthe coolant through the system.

30. Activate the coolant and check the fittings for leaks. Correct as needed.

M-516A 4 - 15

Machine with 125 psi [8.6 bar] Coolant System


2. At the right end of the machine, open valve "C", Figure 4.3, to allow the coolant in the coolanthose to drain back toward the coolant tank.

3. Disconnect the coolant tank hose from coolant filter “D” and drain any remaining coolant fromthe hose into a container for disposal.

4. Position a container under filter "D".

5. Remove the plug from the bottom of the filter housing to drain the coolant.

6. Close valve "C" and replace the plug when draining is complete.

CAUTION

Spilling fluid on the floor can create a slipping hazard. Spilled fluid must be cleanedup immediately.

7. Disconnect union "X", Figure 4.20, and catch any coolant that may be present. Set the coolantfilter aside.

8. Disconnect union "Y" and catch any coolant that may be present.

9. Remove four screws "Z" and associated hardware to release the coolant pump from themounting platform.

10. Move the coolant pump to gain access to the coolant pump junction box.

11. Remove the cover from the coolant pump junction box.

- NOTE -

The power and suppressor wires are labeled 1, 2, and 3.

12. Record the connections for the power and suppressor wires. Refer to Figure 4.21.

4 - 16 M-516A

Figure 4.20 - Coolant Pump

TP9616

Z

X

Y

Figure 4.21 - Coolant Pump Junction Box

TP9618

1

2

3

Ground

13. Disconnect the power, ground, and suppressor wires from the junction box and carefully pullthe wires from the junction box.

- NOTE -

Have a container available to catch any coolant remaining in the pump.

14. Remove the coolant pump from the machine.

15. Remove the pipe fittings from the coolant pump and inspect for damage. Replace fittings asneeded.

- NOTE -

Apply hydraulic pipe sealant to all pipe threads.

16. Install the pipe fittings on the replacement coolant pump.

17. Route the power, ground, and suppressor wires into the junction box.

18. Connect the ground wire.

19. Connect the power and suppressor wires as recorded in step 12. Wire connections are alsogiven on the pump motor data tag.

20. Install the cover on the junction box.

21. Set the replacement coolant pump assembly on the machine and secure with the four mountingscrews and associated hardware.

22. Connect union "Y".

23. Hold the coolant filter in place and connect union "X".

24. Connect the coolant tank hose to the coolant filter.

M-516A 4 - 17

IN-LINE COOLANT FILTER

- NOTE -

The in-line coolant filter is only present on machines equipped with the 125 psi[8.6 bar] coolant pump.

Clean or replace the in-line filter element when any of the following occur:

• In-line filter gauge “A”, Figure 4.22, indicates between 4 to 6 in. Hg

• The coolant flow appears to be restricted

• Changing the type or brand of coolant

1. Power down the machine. Refer to the power-down procedure in Chapter 1.

2. Position a container under the in-line filter.

3. Remove the plug from the bottom of filter housing "D" to drain the coolant.

4. Install the plug when draining is complete.

NOTICE

Dispose of coolant in the filter housing in accordance with all applicablegovernment guidelines. DO NOT introduce the coolant back into the coolantsystem.

5. Properly dispose of the coolant collected in the container.

6. Wipe filter head “B” and filter housing “D” clean with a lint-free cloth.

7. Remove four screws “C” to release the filter housing from the filter head.

8. Remove the filter element from the filter head.

9. Clean or replace the filter element.

10. Clean the inside of the filter housing.

11. Verify the O-ring is in good condition and isproperly installed in the top of the filter housing.

12. Install the filter element on the filter head.

13. Mount the filter housing on the filter head.


15. Check for coolant leaks around the filterhousing. Tighten components as necessary.

4 - 18 M-516A

Figure 4.22 - In-Line Coolant Filter

A B

D

C

TP9612

- NOTES -

M-516A 4 - 19

- NOTES -

4 - 20 M-516A

CHAPTER 5 - HEADSTOCK AND SPINDLE DRIVE

INTRODUCTION

WARNING

When maintenance is required in the spindle compartment, the machine must bepowered down and locked out. Refer to Chapter 1 for the power-up, power-down,and lock-out procedures.

NOTICE

The headstock and spindle assembly must not be disassembled in the field.

Headstock and spindle assembly, “A”, Figure 5.1, is mounted on riser block “B”. The riser block ismounted to a cast iron insert in the machine base. The headstock is a solid, ribbed, cast-iron housingthat dissipates heat and supports the spindle assembly.

The ANSI A2-4 5C (27 millimeter) spindle provides 1116" [27mm] through spindle capacity.

The ANSI A2-5 16C (42 millimeter) spindle provides 158" [42mm] through spindle capacity.

The spindle motor requires minimal maintenance because it is fan cooled, brushless, and perma-nently sealed and lubricated. Drive vibration is minimized by the use of a vee-belt that transfers powerfrom the drive motor to the spindle.

M-516A 5 - 1

Figure 5.1 - Headstock and Riser Blockin Spindle Compartment

TP5178

A

B

SPINDLE DRIVE BELT TENSION ADJUSTMENT

The spindle drive belt tension is adjusted by moving the drive motor platform up or down.


2. Remove spindle compartment cover “D”, Figure 5.2.

3. Unscrew the hose clamp to release the coolant return hose fastened to the fitting on the coolantcatcher mounted inside spindle compartment cover “C”.

- NOTE -

The cable from the spindle access cover switch will remain attached to cover “C”.

4. Remove spindle compartment cover “C”.

5. Loosen, but do not remove, four screws “F”, Figure 5.3, that mount the drive motor platform tothe machine base. These four screws secure the platform once the spindle drive belt tensionhas been adjusted.

- NOTE -

Screw adjustment block “E” supports the drive motor platform and moves theplatform toward the spindle centerline for less belt tension or away from the spindlecenterline for more belt tension.

6. Adjust the drive belt tension to within specification by moving the drive motor platform toward oraway from the spindle centerline.

7. Check the drive belt tension with a sonic tension meter and adjust as needed. Refer to the belttension data tables on page 5-3.

5 - 2 M-516A


TP8248A

C

D

Figure 5.3 - Drive Motor Platform Boltsand Adjustment Block

TP5177

E

F

8. Secure the drive motor platform by tightening four locking screws “F”, to 230 lb-ft [312 N•m]torque.

9. Replace spindle compartment cover “C”, Figure 5.2.

10. Reconnect the coolant return hose to the bottom of the coolant catcher mounted inside spindlecompartment cover “C”.

11. Replace spindle compartment cover “D”.


13. Test the machine at various spindle speeds.

14. Make any adjustments as necessary.

QUEST® GT27 Lathe - Drive Belt Tension Data Table

8000 RPM(5C) Spindle

8000 RPM(5C) Spindle with C Axis


Meter Settings

Weight 0.84 g/cm 0.84 g/cm 52.99 g/m

Width 10 ribs 14 ribs 1mm / #R

Span 482 mm 469 mm 498 mm

Span FrequencyNew Belt 90.0 - 93.2 Hz 92.0 - 95.2 Hz 82 - 84 Hz

Used Belt 83.4 - 86.8 Hz 85.2 - 88.6 Hz 76 - 79 Hz

NOTE: Sonic Tension Meter Model 505C / 507C

QUEST CHNC® Lathe - Drive Belt Tension Data Table



Meter Settings

Weight 0.7 g/cm 60.9 g/m

Width 10 Ribs 1mm / #Rib

Span 534 mm 553 mm

Span FrequencyNew Belt 89 - 92.1 Hz 55 - 59 Hz

Used Belt 82.4 - 85.8 Hz 53 - 55 Hz

NOTE: Sonic Tension Meter Model 505C / 507C

M-516A 5 - 3

SPINDLE DRIVE BELT REPLACEMENT

Spindle drive belts are very reliable; however, belts should be checked for wear and tension every500 hours of operation.


2. Bleed off the air from the air receiver. Refer to Chapter 3 for information about the air receiver.



- NOTE -



6. Loosen, but do not remove, four screws “F”, Figure 5.3, that mount the drive motor platform tothe machine base.

- NOTE -


7. Turn the screw in adjustment block “E” to move the drive motor platform upward. Loosen thetension enough to allow the belt to be removed from the drive motor pulley.

8. Remove the belt from the drive motor pulley.

9. Tag for identification and disconnect the following:

• Collet open and collet close air lines at the 90° fitting on quick relief valves “G”,Figure 5.5.

• Spindle brake air line at fitting “J”.

- NOTE -

Needle-nose pliers can be used to re-move the pressure switch. Position thepliers as shown in Figure 5.4 andGENTLY rock the pliers to apply pres-sure on the retention ring to releasethe pressure switch.

10. Disconnect spindle brake pressure switch “I”.

5 - 4 M-516A

Figure 5.4 - Pressure Switch Removal

TP5128

- NOTE -

Turn plug “L” ¼ turn counterclockwise to release.

11. Disconnect plugs “K” and “L” from the Z axis drive motor.

12. Unfasten collet closer bracket “H”.

- NOTE -

Machines equipped with the C-axis option do not have a spindle encoder mountedon the headstock.

13. Remove the encoder assembly from the top ofthe headstock as follows:

A) Loosen two screws “M” and remove the beltfrom the pulley on encoder assembly “N”,Figure 5.6.

B) Remove two screws “M” and the encoderassembly. Lay the encoder assembly on theheadstock.

M-516A 5 - 5

Figure 5.5 - Air Line Connections

TP5170

I

H

L

K

J

G

Figure 5.6 - Spindle Encoder(16C Headstock Shown)

TP3538A

N

M

M

14. Remove the spindle drive belt from the spindle pulley and put the replacement belt on thispulley.

15. Place the belt in the grooves on the drive pulley. Adjust the drive belt tension by turning thescrew in adjustment block “E”, Figure 5.3, to move the spindle drive motor away from thespindle centerline.


17. Tighten four locking screws “F” to 230 lb-ft [312 N•m] torque after the spindle drive belt tensionspecification has been achieved.

18. Remount the encoder assembly on the headstock as follows:

A) Slip the spindle timing belt over the encoder pulley.

B) Mount encoder assembly “N” in place with two screws “M", Figure 5.6, but do not tighten thescrews.

- NOTE -

Check the spindle timing belt tension with a sonic tension meter. Refer to the belttension data table on page 5-13.

C) Pivot the encoder bracket to set the belt tension. Tighten screws “M” to 25 lb-ft[34 N•m] torque when the belt tension specification has been achieved.

19. Fasten collet closer bracket “H”, Figure 5.5.

20. Connect the collet closer and spindle brake air lines as tagged in step 9.

21. Press pressure switch “I” into the fitting in the spindle brake air line.

- NOTE -

Press self-locking plug “L” straight onto the motor receptacle.

22. Connect plugs “K” and “L”. Tighten the knurled nut on plug “K” to secure the connection.


24. Attach the coolant return hose to the fitting on the coolant catcher mounted inside spindlecompartment cover “C” and secure with the hose clamp.





5 - 6 M-516A

SPINDLE DRIVE MOTOR REPLACEMENT AND ALIGNMENT

The spindle drive motor is mounted to a plate that is mounted to the drive motor platform. This platehas four slots to allow belt alignment after the motor has been removed or replaced. Spindle drive belttension is adjusted by moving the drive motor platform upward or downward.




- NOTE -




- NOTE -



7. Remove the belt from the drive motor pulley.

8. Disconnect the cables from the drive motor as follows:

A) Remove cover “O”, Figure 5.7, from spindle motor junction box.

B) Record the wire connections.

- NOTE -

Observe how plug “P”, Figure 5.8, is installed in the plug bracket.

C) Lift plug “P”, Figure 5.8, from the plugbracket and press tabs “Q”, Figure 5.9, todisconnect.

D) Disconnect the wires in the junction box.

E) Release the nut from the 90° conduitconnector.

F) Carefully pull the 90° conduit connector andcables from the junction box.

M-516A 5 - 7

Figure 5.7 - Spindle Motor Junction Box

TP5180

O

9. Remove four bolts “R”, Figure 5.10, to release the motor from the plate.

10. Use a hoist to lift the motor from the drive compartment.

- NOTE -

Observe the orientation of the spindle motor pulley adapter in relation to thespindle motor.

11. Loosen 6 screws “S”, Figure 5.11, and slide the pulley and pulley adapter from the shaft of theold motor.

5 - 8 M-516A

Figure 5.8 - Spindle Motor Junction Box(Internal View)

TP5181

P

Figure 5.9 - Plug Connection

TP5182

Q

Figure 5.10 - Spindle Motor Mounting Bolts

TP5185

R

Figure 5.11 - Spindle MotorPulley and Adapter

S

TP5184

12. Slide the pulley and adapter onto the shaft of the new motor and position according to Figure5.12 and the following chart:

Machine Configuration Pulley Measurement

5C Spindle without C-Axis .25 inches [11 millimeters]

5C Spindle with C-Axis .41 inches [15 millimeters]

16C Spindle .13 inches [6.5 millimeters]

13. Check the adapter to be sure it is completely seated in the pulley.

M-516A 5 - 9

Figure 5.12 - Pulley Locationon the Motor Shaft

TI5953

PulleyMeasurement

IndicatorPosition

- NOTE -

The torque values listed in step 14 are based on a torque wrench applying torqueat the qualified length of the wrench. If an adapter is used on the torque wrench toaccess the screws on the pulley adapter, the torque value will change, based onthe change in the torque length.

If the torque length is modified due to the adapter, calculate new torque values asfollows:

Qualified Torque Length

Modified Torque Lengthx Original Torque Specification

Refer to Figure 5.13.

14. Tighten 6 screws “S”, Figure 5.11, in a diametrically opposing pattern as follows:

A) Tighten all screws finger tight.

B) Tighten all screws to 35 lb-in [4 N•m] or the value calculated as discussed above.

C) Tighten all screws to 50 lb-in [5.6 N•m] or the value calculated as discussed above.

D) Tighten all screws to 100 lb-in [11.3 N•m] or the value calculated as discussed above.

5 - 10 M-516A

Figure 5.13 - Modifying the Torque Length

TI4993



Modified Torque Length

Wrench with Adapter

Wrench with Socket

- NOTE -

Maximum pulley run-out is .005 inches [0.125 millimeters].

15. Position an indicator at the face of the pulley near the outer diameter and check the pulley forrun-out. Refer to Figure 5.12.

If the pulley run-out is with specification, proceed to step 16.

If the pulley run-out is not within specification, loosen screws “S”, Figure 5.11, and repeatsteps 13 and 14.

16. Lightly grease the contact surfaces and install the new motor on the mounting plate.

17. Thread four screws “R”, Figure 5.10, into the mounting plate, but do not tighten.

18. Slip the drive belt over the motor pulley and visually align the motor pulley with the spindlepulley.

19. Use a plumb bob to align a groove in the spindle motor pulley with the corresponding groove inthe spindle pulley.

20. Tighten the four screws “R” to 30 lb-ft [41 N•m] torque.

21. Use a plumb bob to check the pulley alignment.

22. If a fine adjustment is needed, proceed as follows:

A) Loosen four screws “U”, Figure 5.14.

B) Turn screw “T” to adjust the pulley alignment.

C) Tighten four screws “U” to 50 lb-ft [68 N•m] torque.

23. Adjust the belt tension by turning the screw in adjustment block “E”, Figure 5.3, to move thespindle drive motor away from the spindle centerline.


25. Tighten four locking screws “F” to 230 lb-ft [312 N•m] torque after the spindle drive belt tensionspecification has been achieved.

M-516A 5 - 11

Figure 5.14 - Motor Plate Adjusting Screw

TP5123

T

U

26. Connect the cables to the drive motor as follows:

A) Insert the 90° conduit connector and cables into the junction box.

B) Slide the nut for the 90° conduit connector over the cables and secure the conduit connector.

C) Connect plug “P”, Figure 5.8, and insert into the plug bracket.

D) Connect the wires as recorded in step 8.

E) Make certain that the gasket is in place to seal the junction box. Fasten the junction boxcover with its screws.




- NOTE -

The spindle is oriented when the spindle key in the spindle nose is at the 12o’clock (straight up) position.




5 - 12 M-516A

SPINDLE ENCODER TIMING BELT ADJUSTMENT

The spindle encoder is mounted in a bracket on top of the headstock. The bracket has a slottedopening for adjusting the timing belt tension.




- NOTE -



5. Locate encoder bracket “A”, Figure 5.15, andtest the spindle encoder timing belt tensionwith a sonic tension meter. Refer to the timingbelt tension data table shown below.

6. Loosen bracket screws “B”, Figure 5.15, toenable the bracket to be pivoted to set the belttension. Tighten the screws to 25 lb-ft [34 N•m]when the belt tension specification is met.

7. Replace spindle compartment cover “C”,Figure 5.2.

8. Attach the coolant return hose to the fitting onthe coolant catcher mounted inside spindlecompartment cover “C” and secure with thehose clamp.





Encoder Timing Belt Tension Data Table

Meter Settings

Weight 2.4 g/cm

Width 1 rib

Span 1 mm

Span FrequencyNew Belt 176 - 184 Hz

Used Belt 147 - 157 Hz

M-516A 5 - 13

Figure 5.15 - Spindle Encoder Pulleyand Bracket Screws

(16C Headstock Shown)

TP3538A

B

A

B

SPINDLE ENCODER TIMING BELT REPLACEMENT

The spindle encoder timing belt replacement requires that the spindle collet closer, and spindledrive belt be removed. Spindle compartment covers are removed and installed as in other spindle en-coder sections.




- NOTE -




- NOTE -



- NOTE -

Refer to Chapter 6 for information on removing the collet closer.

7. Remove the collet closer.

- NOTE -

The machine is equipped with twospindle brakes. Each spindle brake as-sembly will be in two parts when themounting screws are removed. Supportthe spindle brake assembly while re-moving the mounting screws.

Each spindle brake assembly has twoO-rings in the mating surfaces. TheseO-rings must be in place when thespindle brake assemblies are installedin the machine.

8. Remove spindle brake screws “C” to releasespindle brake assemblies “D”, Figure 5.16.

5 - 14 M-516A

Figure 5.16 - Spindle Brakes

TP5186

CD

E

9. Slide the belt from the spindle drive motor pulley and remove it from the spindle pulley.

10. Loosen screws “B”, Figure 5.15, and relieve the encoder belt tension.

11. Slip the timing belt from the encoder pulley and remove it from the spindle pulley.

12. Place the new spindle encoder timing belt on the pulleys.

- NOTE -

Check the spindle encoder timing belt tension with a sonic tension meter. Refer tothe belt tension data table on page 5-13.

13. Adjust the spindle encoder timing belt tension and tighten mounting screws “B”.

14. Slide the spindle drive belt onto the pulleys.

- NOTE -

Check the drive belt tension with a sonic tension meter. Refer to the belt tensiondata tables on page 5-3.

15. Adjust the spindle drive belt tension and tighten all four drive motor platform screws to 230 lb-ft[312 N•m] torque.

NOTICE

Be sure the O-rings are properly installed in each half of the spindle brakes beforemounting the spindle brakes.

16. Mount the spindle brake assemblies “D” using screws “C”, Figure 5.16. Tighten screws “C” to200 lb-in [22.6 N•m]

- NOTE -

Refer to Chapter 6 for information on installing the collet closer.

17. Install the collet closer.





M-516A 5 - 15

SPINDLE ENCODER REPLACEMENT

Spindle encoder “F”, Figure 5.17, is mounted in a bracket on top of the headstock. Remove themounting bracket and encoder to replace the encoder.




- NOTE -



5. Unfasten the knurled nut on the encoder electrical plug. Pull the plug straight out to release itfrom the encoder.

6. Unthread two screws “B” to remove mounting bracket “A”, Figure 5.15, the pulley, and encoderfrom the headstock.

7. Loosen the set screw in coupling “H”, Figure 5.17, to release the encoder from the pulley shaft.

8. Loosen three screws “G” and rotate the cam clamps to release the encoder from the mountingbracket.

9. Install the replacement 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 three screws “G” to 15 lb-in [1.7 N•m].

D) Tighten the set screw in coupling “H” to 11 lb-in [1.3 N•m].

5 - 16 M-516A

Figure 5.17 - Spindle Encoder Coupling

TP5188

HG

F

10. Slip the encoder timing belt over the pulley.

11. Mount the bracket on the headstock, but do not tighten screws “B”, Figure 5.15.

- NOTE -

Check the spindle encoder timing belt tension with a sonic tension meter. Refer tothe belt tension data table on page 5-13.

12. Pivot the encoder bracket to set the timing belt tension. Tighten screws “B” to 25 lb-ft [34 N•m]torque when the belt tension specification is met.





M-516A 5 - 17

HEADSTOCK ALIGNMENT

Headstock “A”, Figure 5.1, is mounted on riser block “B”, by four large screws. The headstock iscentered and can pivot on a dowel pin when the mounting screws are loosened.

PARALLEL ALIGNMENT SPECIFICATION

The parallel alignment specification, measured by indicating on the front of an arbor, is 0.0000 to-0.0001 inch [0.00000 to -0.00254 mm] with the outer end toward the front of the machine.

ALIGNING THE HEADSTOCK




- NOTE -



5. Loosen, but do not remove, the four screws mounting the headstock to the riser block.


7. Install a 6 inch [152 mm] long arbor in the spindle.

8. Mount an indicator on the tool slide to check the front of the arbor for parallel along the Z axis totest headstock alignment. Refer to Figure 5.18.

5 - 18 M-516A

Figure 5.18 - Indicator Position for Parallel Alignment(Top View)

TI4994

Front of Machine

Direction ofIndicator Movement

9. Turn the Setting Mode switch to JOG.

10. Press and hold the Drive Enable push button.

11. SLOWLY jog the Z axis to move the indicator the length of the arbor and watch the amount ofindicator movement.

12. If the headstock is within specification, proceed to step 13.

If the headstock is not within specification:

A) Using a dead-blow or soft-faced hammer, GENTLY tap the headstock in the appropriatedirection.

B) SLOWLY jog the Z axis to move the indicator the length of the arbor and watch the amount ofindicator movement.

C) Repeat steps A and B until the headstock alignment is within specification.


14. Tighten the four headstock mounting screws to 170 lb-ft [230 N•m] torque when the headstockis aligned.



17. SLOWLY jog the Z axis to move the indicator the length of the arbor and watch the amount ofindicator movement to verify the alignment of the headstock. Make any adjustments asnecessary.


19. Turn the Setting Mode switch to “0" (OFF).



M-516A 5 - 19

CLEANING THE SPINDLE BRAKE DISC

Check spindle brake disc “E”, Figure 5.16, every six months for contamination build-up. If contami-nation is present, use a cleaner to remove the contamination.




- NOTE -



- NOTE -

The machine is equipped with two spindle brakes. Each spindle brake assemblywill be in two parts when the mounting screws are removed. Support the spindlebrake assembly while removing the mounting screws.

Each spindle brake assembly has two O-rings in the mating surfaces. TheseO-rings must be in place when the spindle brake assemblies are installed in themachine.

5. Remove spindle brake screws “C” to release spindle brake assemblies “D”, Figure 5.16.

6. Determine what contamination is on the brake disc. Use a cleaner to completely remove thecontamination from the disc. Clean and wipe the disc dry with a lint-free cloth.

7. If possible, eliminate the source of contamination.

8. Clean each brake and make certain that they operate properly.

NOTICE

Be sure the O-rings are properly installed in each half of the spindle brakes beforemounting the spindle brakes.

9. Mount the spindle brake assemblies “D” using screws “C”, Figure 5.16. Tighten screws “C” to200 lb-in [22.6 N•m]


11. Test the brake as follows:

A) Press the Jog push button.

B) Press the Spindle Free push button to have the brake pads alternately engage anddisengage 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 arefunctioning. Make any adjustments as necessary.




5 - 20 M-516A

-NOTES -

M-516A 5 - 21

- NOTES -

5 - 22 M-516A

CHAPTER 6 - COLLET CLOSER

INTRODUCTION

The machine is equipped with a pneumatically (air) actuated collet closer. The entire collet closerassembly must be removed and returned to the factory if repairs are required.

The standard ANSI A2-4 5C collet closer provides a 1-1/16 inch [27 mm] through-spindlecapacity.

The optional ANSI A2-5 16C collet closer provides a 1-5/8 inch [42 mm] through-spindlecapacity.

Maintenance information for the collet closer pressure switch and air components is in Chapter 3.

FREE SPINDLE

A “Free Spindle” condition allows the spindle to be turned by hand. To obtain a free spindle condi-tion, proceed as follows:

- NOTE -

To obtain a free spindle, the control must be ON and the spindle must not berotating.


2. Press the control Reset key.

3. Press the Jog push button.

4. Press the Spindle Free push button.

- NOTE -

Free Spindle can also be obtained if Edit, Handle, or Zero Return mode is active.

COLLET CLOSER DRAW TUBE CLEANING

Depending on the job and material being cut, particularly if it is a bar stock job, the draw tube shouldbe removed from the collet closer and cleaned every 40 hours and between job setups to prevent chiploading between the draw tube and spindle bore. Refer to the operator’s manual (M-515) for informa-tion on cleaning the draw tube and spindle.

M-516A 6 - 1

ANSI A2-4 5C COLLET CLOSER

The collet closer should be removed only if repairs are required. The collet closer must be returnedto the factory for repair.

Contact the Hardinge Service Department for information on packaging and shipping the colletcloser and draw tube to the factory.

REMOVING THE COLLET CLOSER

1. Remove spindle compartment cover “B”, Figure 6.1.

2. Unscrew the hose clamp to release the coolant return hose fastened to the fitting on the coolantcatcher mounted inside spindle compartment cover “A”.

- NOTE -

The cable from the spindle access cover switch will remain attached to cover “A”.

3. Remove spindle compartment cover “A”.

4. Loosen three screws “C”, Figure 6.2, completely and pull them back flush with the snap rings.

5. Remove the spindle tooling.


7. Tag both air line connectors (collet open and collet close) for reassembly and disconnect themfrom the collet closer. Refer to Figure 6.2 for collet closer air connections.

8. Cap the air line connectors and the fittings on the collet closer to prevent contamination.

6 - 2 M-516A


TP8248A

A

B

Figure 6.2 - Spindle Draw Tube Nut

TP7005A

C

ColletOpen

ColletClose

CAUTION

Be ready to support the weight of the collet closer and draw tube as they arereleased from the spindle.

9. Loosen six screws “F” to release collet closer “D" from mounting plate “E”, Figure 6.3.

10. Pull the collet closer and draw tube straight out from the spindle and place on a clean levelsurface.

11. Clean the draw tube, the inside diameter of the collet closer, and the spindle bore.

12. Package the collet closer and draw tube for shipment as instructed by Hardinge Inc.

M-516A 6 - 3

Figure 6.3 - Collet Closerand Mounting Plate

TP7010

FED

INSTALLING THE COLLET CLOSER

1. Lightly stone and clean face "G" and counterbore "I", Figure 6.4.

2. Lightly stone and clean face "J" and locating diameter "K", Figure 6.5.

3. Apply Bostik Never-Seez® Anti-Seize Black Moly grease inside the end of diameter "H", Figure6.4.

4. Apply Bostik Never-Seez Anti-Seize Black Moly grease to the O-ring and collet closer neck "M",Figure 6.6.

5. Apply rust inhibitor to the inside diameter of the collet closer and spindle bore.

6. Grease the draw tube with a light coat of Mobiltemp SHC® 32 grease.

7. Insert the draw tube into the collet closer.

- NOTE -

Align the air line tubes with theanti-rotation bracket as the collet closeris pushed into position.

8. Center the draw tube in the spindle bore andpush the collet closer into position as far aspossible.

9. Lightly tighten screws "F" to secure colletcloser “D” to mounting plate “E”, Figure 6.3.

6 - 4 M-516A

Figure 6.4 - Collet Closer Mounting Plate

G

I

TP7009

H

Figure 6.5 - Collet Closer Faceand Locating Diameter

K

J

TP7014

Figure 6.6 - 5C Collet CloserNeck and O-Ring

M

TP7006

Collet OpenCollet Close

L

N

10. Set an indicator on the outer diameter of the collet closer housing, as shown in Figure 6.7.

11. Rotate the collet closer by hand and observe the total indicator runout.

NOTICE

When using a light deadblow or plastic hammer to adjust the collet closer runout,tap only on diameter "N", Figure 6.6. DO NOT tap on rotary union "L".

- NOTE -

The total indicator runout must not exceed 0.0005 inch [0.0127 mm].

12. If the runout is within specification, proceed to step 12.

If the runout is not within specification:

A) Use a light deadblow or plastic hammer to adjust the collet closer runout.

B) Continue to check the runout and adjust until the runout is within specification.

13. If using a standard length wrench, torque six screws “F”, Figure 6.3, to 120 Ib-in [13.6 N•m].

If using a 2 inch offset wrench, torque six screws “F” to 95 Ib-in [10.7 N•m].

14. Rotate the collet closer and check the total indicator runout again. Adjust the collet closerrunout as necessary.

NOTICE

DO NOT plug the vent holes in rotary union “L”, Figure 6.6, when applying rustinhibitor to the exterior of the collet closer.

15. Apply rust inhibitor on a clean cloth and wipethe exterior of the collet closer.

16. Purge the collet closer air lines

17. Connect the collet closer air lines as taggedduring collet closer removal. Refer to Figure6.6 for collet closer air connections.

18. Replace spindle compartment cover “A”,Figure 6.1.

19. Connect the coolant return hose to the bottomof the coolant catcher mounted inside spindlecompartment cover “A”.

20. Replace spindle compartment cover “B”.

M-516A 6 - 5

Figure 6.7 - Indicator Position forChecking Collet Closer Runout

TP7008

ANSI A2-5 16C COLLET CLOSER

The collet closer should be removed only if repairs are required. The collet closer must be returnedto the factory for repair.

Contact the Hardinge Service Department for information on packaging and shipping the colletcloser and draw tube to the factory.

REMOVING THE COLLET CLOSER

1. Remove spindle compartment cover “B”, Figure 6.1.

2. Unscrew the hose clamp to release the coolant return hose fastened to the bottom of thecoolant catcher mounted inside spindle compartment cover “A”.

- NOTE -

The cable from the spindle access cover switch will remain attached to cover “A”.


4. Loosen six screws "O”, Figure 6.8, completely and pull them back flush with the snap rings.

5. Remove the spindle tooling.


7. Tag both air line connectors (collet open and collet close) for reassembly and disconnect themfrom the collet closer. Refer to Figure 6.9 for collet closer air connections

8. Cap the air line connectors and the fittings on the collet closer to prevent contamination.

CAUTION

Be ready to support the weight of the collet closer and draw tube as they arereleased from the spindle.

9. Remove eight screws “Q” to release colletcloser “R” from the headstock assembly.

10. Pull the collet closer and draw tube straight outfrom the spindle and place on a clean levelsurface.

11. Clean the draw tube, the inside diameter of thecollet closer, and the spindle bore.

12. Package the collet closer and draw tube forshipment as instructed by Hardinge Inc.

6 - 6 M-516A

Figure 6.8 - Spindle Draw Tube Nut(16C Spindle)

O

TP9303

M-516A 6 - 7

Figure 6.9 - 16C Collet Closer Assembly

TI6183

Collet Close Collet Open

Collet Closer Mounted on the Pulley Assembly

Collet Closer Separated from the Pulley Assembly

P

Q

R

Indicate on this Diameter

Slide Collet CloserOut to Remove

INSTALLING THE COLLET CLOSER

1. Lightly stone and clean face "S" and bore "U", Figure 6.10.

2. Lightly stone and clean face "V" and locating diameter "W", Figure 6.11.

3. Apply Bostik Never-Seez® Anti-Seize Black Moly grease to plastic seal "T", Figure 6.10.

4. Grease the draw tube with a light coat of Mobiltemp SHC® 32 grease.

5. Insert the draw tube into the collet closer.

- NOTE -

Align the air line tubes with the anti-rotation bracket as the collet closer is pushedinto position.

6. Center the draw tube in the spindle bore and push it in as far as possible.

7. Lightly tighten screws "Q" to secure collet closer “R” to the pulley assembly.

8. Set an indicator on the collet closer diameter shown in Figure 6.9.

9. Rotate the collet closer by hand and observe the total indicator runout.

NOTICE

When using a light deadblow or plastic hammer to adjust the collet closer runout,tap only on diameter "R". DO NOT tap on rotary union "P".

- NOTE -

The total indicator runout must not exceed 0.0005 inch [0.0127 mm].

10. If the runout is within specification, proceed to step 11.

If the runout is not within specification:

A) Use a light deadblow or plastic hammer to adjust the collet closer runout.

B) Continue to check the runout and adjust until the runout is within specification.

6 - 8 M-516A

Figure 6.10 - Headstock Pulley Assembly

TP9305

U

S

T

Figure 6.11 - Collet Closer Faceand Locating Diameter

TP9306

V

W

11. Torque eight screws “Q” to 50 Ib-in [5.6 N•m].

12. Torque eight screws “Q” to 100 Ib-in [11.3 N•m].

13. Rotate the collet closer and check the total indicator runout again. Adjust the collet closerrunout as necessary.

NOTICE

DO NOT plug the vent holes in rotary union “P” when applying rust inhibitor to theexterior of the collet closer.

14. Apply rust inhibitor on a clean cloth and wipe the exterior of the collet closer.

15. Connect the collet closer air lines as tagged during collet closer removal. Refer to Figure 6.9 forcollet closer air connections.

16. Replace spindle compartment cover “A”, Figure 6.1.

17. Reconnect the coolant return hose to the bottom of the coolant catcher mounted inside spindlecompartment cover “A”.


M-516A 6 - 9

- NOTES -

6 - 10 M-516A

CHAPTER 7 - AXIS 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 the spindle (-Z) or away from the spindle (+Z).

The cross slide is a movable platform on the carriage that carries the dovetail top plate with toolingmounted on it. Control signals command the cross slide toward the back of the machine (-X) or towardthe front of the machine (+X).

Information covering ball screw and linear way lubrication appears in Chapter 2.

CARRIAGE DRIVE MOTOR

The carriage (Z axis) drive motor is located in the spindle drive compartment. Spindle compartmentcovers “A” and “B”, Figure 7.1, should both be removed.

The Z axis encoder is an integral part of the motor assembly and cannot be replaced separately.

MOTOR REPLACEMENT

1. Jog the Z axis to move the carriage to themiddle of its travel, if possible.

2. Remove any workpiece from the spindle tomaximize the work space.


4. Remove spindle compartment cover “B”,Figure 7.1.

5. Unscrew the hose clamp to release the coolantreturn hose fastened to the fitting on thecoolant catcher mounted inside spindlecompartment cover “A”.


M-516A 7 - 1

Figure 7.1 - Spindle Drive Compartmentand Valve Compartment Covers

TP8248A

A

B

C

7. Use a 5/8 inch hex wrench to remove pipe plug “D”, Figure 7.2.

8. Remove valve compartment cover “C”, Figure 7.1.

9. Remove coupling access cover “E”, Figure 7.3.

10. Use a flashlight and look into the headstock base to view coupling “F”, Figure 7.4.

11. If the screw in the coupling is accessible, proceed to step 12.

If the screw in the coupling clamp is not accessible, rotate the coupling as follows:

A) Remove access cover “G”, Figure 7.5.

B) Remove cover “H”, Figure 7.6, or cover "I", Figure 7.7.

C) Remove the four screws, washers, and ball screw end cover “J”, Figure 7.8.

D) Insert a wrench in the end of the ball screw and turn the ball screw until the head of the screwin the coupling can be accessed.

7 - 2 M-516A

Figure 7.2 - Pipe Plug forZ axis Drive Motor Coupling

D

TP5149

Figure 7.3 - Coupling AccessCover in Valve Compartment

TP5008

E

Figure 7.4 - Z Axis Coupling

F

TP5155

Figure 7.5 - Right End Access Door

TP8247A

G

12. Insert a 5 millimeter hex wrench in the access hole shown in Figure 7.4 and loosen the screw inthe coupling.

- NOTE -

Turn plug “L”, Figure 7.9, ¼ turn counterclockwise to release.

13. Disconnect plugs “K” and “L”, Figure 7.9, from the axis drive motor.

14. Note the orientation of the electrical connections.

M-516A 7 - 3

Figure 7.6 - Cross Slide Viewedfrom Right End of Machine

(QUEST® GT27 Lathe)

TP8355

H

Figure 7.7 - Cross Slide Viewedfrom Right End of Machine

(QUEST CHNC® Lathe)

I

TP7737

Figure 7.8 - Ball Screw End Cover

TP5143

J

Figure 7.9 - Z Axis Drive Motor

TP5144

L

MK

15. Remove four bolts “M” to release the motor from the motor mount.

NOTICE

Handle the motor with care. The encoder is extremely fragile. Do not hit the motorshaft or allow it to make contact with anything.

16. Carefully lift the motor from the spindle compartment.

17. BEFORE removing the coupling from the motor, measure the distance from the face of themotor to the near edge of the coupling. Refer to Figure 7.10.

18. Loosen screw “N” and slide the coupling from the motor shaft.

- NOTE -

DO NOT install the key provided with the replacement motor.

Orient the coupling such that the slot in the coupling DOES NOT align with thekeyway on the motor shaft. Refer to Figure 7.11.

19. Install the coupling on the shaft of the replacement motor. Set the position of the coupling asmeasured in step 17.

20. Tighten screw “N”, Figure 7.10, to 125 lb-in [14.0 N•m] torque.

21. Orient the motor to position the electrical connections as shown in Figure 7.9.

22. Rotate the motor shaft to orient screw “O” at a downward angle of approximately 45°.

23. Align the coupling with the end of the ball screw, orient the electrical connections as shown inFigure 7.9, and mount the motor. Tighten four screws “M” finger tight.

24. Use a flashlight and look into the headstock base to verify screw “O”, Figure 7.10, is accessible.

7 - 4 M-516A

Figure 7.10 - Axis Drive Motorand Z Axis Coupling

TP5147

O

N

Figure 7.11 - Incorrect Coupling Alignment

Keyway

TP5145

25. Tighten screws “M”, Figure 7.9, to 25 lb-ft [34 N•m] torque.

26. Insert the torque wrench in the access hole shown in Figure 7.4 and tighten coupling clampscrew “O”, Figure 7.10, to 125 lb-in [14.0 N•m] torque.

- NOTE -

Press self-locking plug “L”, Figure 7.9, straight onto the motor receptacle.

27. Connect plugs “K” and “L”, Figure 7.9. Tighten the knurled nut on plug “K” to secure theconnection.

28. Apply Loctite® High Performance Pipe Sealant with Teflon® to the threads and install pipe plug“D”, Figure 7.2.

29. Replace coupling access cover “E”, Figure 7.3.

30. Replace valve compartment cover “C”, Figure 7.1.

31. Replace spindle compartment cover “A”.

32. Attach the coolant return hose to the fitting on the coolant catcher mounted inside spindlecompartment cover “A” and secure with the hose clamp.


34. If it was necessary to manually rotate the ball screw:

A) Replace ball screw end cover “I”, Figure 7.8, and secure with four screws and washers.

B) Replace cover “H”, Figure 7.6, or cover "I", Figure 7.7.

C) Replace access cover “G”, Figure 7.5.

35. Proceed to “Setting the Z Axis Reference Position”, beginning on the next page.

M-516A 7 - 5

SETTING THE Z AXIS REFERENCE POSITION

1. Power up the machine as follows:

A) Unlock and turn the main disconnect switch ON.

B) Unlock and turn the main air valve ON.

C) Press and hold the “P” and Cancel keys.

D) Turn the Control ON/OFF switch to the ON (1) position.

E) Release the “P” and Cancel keys.

F) Pull the Emergency Stop push button out.

G) Press the Emergency Stop Reset push button.


3. Jog the Z axis approximately 1 inch [25 millimeters].


- NOTE -

Alarm 100 will be displayed when Parameter Write Enable is set to “1”.

5. Set Parameter Write Enable to “1”:

A) Press the Offset Setting key.

B) Press the Setting soft key.

C) Move the cursor to the PWE field.

D) Press the Manual Data Input mode push button.

E) Key in “1” and press the Input key.

- NOTE -

Alarm 000 will be displayed when Parameter 1815, Z Bit 4 (APZ) is set to “0”.

6. Set Parameter 1815, Z Bit 4 (APZ) to “0”:

A) Press the System key.

B) Press the Parameter soft key.

C) Press the Operator soft key.

D) Key in “1815” and press the Number Search soft key.

E) Move the cursor to the Parameter 1815 Z row.

F) Move the cursor to bit 4 (APZ)

G) Key in “0” and press the Input key.

7. Turn the Control ON/OFF switch to the OFF (0) position.

7 - 6 M-516A

8. Power up the control as follows:

A) Press and hold the “P” and Cancel keys.

B) Turn the Control ON/OFF switch to the ON (1) position.

C) Release the “P” and Cancel keys.

D) Pull the Emergency Stop push button out.

E) Press the Emergency Stop Reset push button.


10. Activate Jog mode.



13. Use the X and Z axis push buttons to jog the tooling top plate to within 2 inches [50 mm] of theface of the spindle.

14. Release the Drive Enable push button.

15. Turn the Setting Mode switch to MPG.

16. Activate Handle mode by pressing the Z Handle push button.

17. Press the appropriate push button (100X, 10X, 1X) to select the desired increment. Each markon the handwheel represents one unit increment.

18. Turn the handwheel in the negative (counterclockwise) direction to move the top plate to aposition in front of the face of the spindle.

19. If the machine is set to English mode, place a 1 inch gauge block against the face of the spindleand turn the handwheel in the negative direction to gently touch the top plate to the gauge blockso that a slight drag is felt when moving the gauge block. Refer to Figure 7.12 or 7.13.

If the machine is set to Metric mode, place a 25 millimeter gauge block against the face ofthe spindle and turn the handwheel in the negative direction to gently touch the top plate tothe gauge block so that a slight drag is felt when moving the gauge block. Refer to Figure7.12 or 7.13.

M-516A 7 - 7

Figure 7.12 - Setting the Z Axis(QUEST® GT27 Lathe)

TI4990

Gauge Block

Tooling Top Plate

Figure 7.13 - Setting the Z Axis(QUEST CHNC® Lathe)

Turret Top Plate

Gauge Block

TI5630

20. Preset the Z axis to zero:

A) Press the Position key.

B) Press the Relative soft key.

C) Press the W key.

D) Press the Origin key.

- NOTE -

The Z axis positions charted in step 15 are the Z axis Home positions minus thegauge block dimension.

21. Observing the Z axis Relative Position register, move the Z axis to the following position:

MachineModel

SpindleConfiguration

EnglishMode

MetricMode

QUEST® GT27 Lathe5C 10.2500 260.750

16C 9.6000 244.240

QUEST CHNC® Lathe 5C and 16C 11.0000 304.800

- NOTE -

Alarm 000 will be displayed when Parameter 1815, Z Bit 4 (APZ) is set to “1”.

22. Set Parameter 1815, Z Bit 4 (APZ) to “1”:

A) Press the Manual Data Input mode push button.

B) Press the System key.

C) Press the Parameter soft key.

D) Press the Operator soft key.

E) Key in “1815” and press the Number Search soft key.

F) Move the cursor to the Parameter 1815 Z row.

G) Verify the APC bit is set to “1”.

H) Move the cursor to bit 4 (APZ)

I) Key in “1” and press the Input key.



7 - 8 M-516A







26. Check the Z axis position:



C) Move the Z axis toward the spindle to position the tooling top plate at the following position:

English Mode: 1.0000

Metric Mode: 25.000

D) Using the gauge block, check for a slip fit between the face of the spindle and the face of thetooling top plate. Refer to Figure 7.12.

27. If the fit is not correct, repeat this procedure.

If the fit is correct, proceed to step 28.







F) Press the Reset key to cancel P/S alarm 100.


30. Reset the control as follows:

A) Press the Emergency Stop push button.

B) Turn the Control ON/OFF switch to the OFF (0) position.

C) Wait five seconds.


E) Pull the Emergency Stop push button out.

F) Press the Emergency Stop Reset push button.

M-516A 7 - 9

CROSS SLIDE DRIVE MOTOR

The cross slide (X axis) drive motor is located on the back of the cross slide.

The X axis encoder is an integral part of the motor assembly and cannot be replaced separately.

MOTOR REPLACEMENT

1. Jog the Z axis to center motor cover “B” with access cover “A”, Figure 7.14.

2. Jog the X axis to move the cross slide to the middle of its travel, if possible.

3. Remove any workpiece from the spindle to maximize the work space.

- NOTE -

DO NOT close the main coolant guard door.


5. At the rear of the machine, remove access covers “C” and “D”, Figure 7.15.

6. Wipe chips and coolant from the top plate and cross slide covers.

7 - 10 M-516A

Figure 7.14 - X Axis Motor CoverViewed from Front of Machine

BA

TP5166

Figure 7.15 - Rear Access Covers

TP8258A

C

D

7. Remove covers and manifold:

QUEST® GT27 LATHE

A) Remove manifold “E”, Figure 7.16, from the cross slide cover.

B) Remove cross slide cover “F”, Figure 7.17.

C) Remove upper motor cover “G”.

D) Remove the lower motor cover.

M-516A 7 - 11

Figure 7.16 - Cross Slide with Coolantand Air Blast Manifold(QUEST GT27 Lathe)

ETP3561

Figure 7.17 - Upper X Axis MotorCover at Rear of Machine

(QUEST GT27 Lathe)

TP5168

F

G

QUEST® CHNC® LATHE

A) Remove cross slide cover "H", Figure 7.18.

B) If the machine is equipped with optional air blast manifold "J", Figure 7.19, disconnect the airlines from the top and bottom of fitting "I".

C) Remove cross slide cover “K”, Figure 7.20.

D) Remove upper motor cover “L”.

E) Remove the lower motor cover.

7 - 12 M-516A

Figure 7.18 - Cross Slide CoversViewed from Right End of Machine

(QUEST CHNC Lathe)

H

TP8357A

Figure 7.19 - Optional Air Blast ManifoldViewed from Back of Machine

(QUEST CHNC Lathe)

I

TP8356

J

Figure 7.20 - Rear Cross Slide CoversViewed from Back of Machine

(QUEST CHNC Lathe)

K

L

TP8358A

8. Use a 5/8 inch hex wrench to remove pipe plug “M”, Figure 7.21, and gain access to the motorcoupling.

- NOTE -

Turn plug “P” ¼ turn counterclockwise to release.

9. Disconnect plugs “O” and “P” from the axis drive motor.

10. View the coupling to determine if screw “Q”, Figure 7.22, is accessible.

If the screw in the coupling is accessible, proceed to step 11.

If the screw in the coupling clamp is not accessible, rotate the coupling as follows:

A) At the front of the machine, remove the four screws, washers, and ball screw end cover “R”,Figure 7.23.

B) Insert a wrench in the end of the ball screw and turn the ball screw until the head of the screwin the coupling can be accessed.

M-516A 7 - 13

Figure 7.21 - X Axis Drive Motor

MP

TP5169

O

N

Figure 7.22 - X Axis Coupling

TP5153

Q

Figure 7.23 - X-Axis Ball ScrewCover Under Cross Slide

TP5142

R

11. Use a 5 millimeter hex wrench to loosen screw “Q”, Figure 7.22.

12. Note the orientation of the electrical connections.

13. Remove four screws “N”, Figure 7.21, to release the motor from the motor mount.

NOTICE

Handle the motor with care. The encoder is extremely fragile. Do not hit the motorshaft or allow it to make contact with anything.

14. Carefully remove the motor.

15. Remove O-ring “S”, Figure 7.24, from the motor.

16. If O-ring “S” is in good condition, install the O-ring on the replacement motor.

If O-ring “S” is in not good condition, install a new O-ring on the replacement motor.

17. Loosen screw “T”, Figure 7.25, and slide the coupling from the motor shaft.

- NOTE -

DO NOT install the key provided with the replacement motor.

Orient the coupling such that the slot in the coupling DOES NOT align with thekeyway on the motor shaft. Refer to Figure 7.11.

18. Install the coupling on the shaft of the replacement motor as follows:

A) Slide the coupling against the shoulder on the motor shaft.

B) Slide the coupling away from the shoulder on the motor shaft just far enough to eliminatecontact between the coupling and the shoulder.

19. Tighten screw “T”, Figure 7.25, to 125 lb-in [14.0 N•m] torque.

20. Orient the motor to position the electrical connections as shown in Figure 7.21.

21. Rotate the motor shaft to orient the clamp screw on the free end of the coupling at a upwardangle of approximately 45°.

7 - 14 M-516A

Figure 7.24 - O-Ring on X Axis Motor

S

TP5152

Figure 7.25 - Axis Drive Motorand X Axis Coupling

TP5146

T

22. Align the coupling with the end of the ball screw, orient the electrical connections as shown inFigure 7.21, and mount the motor. Tighten four screws “N” finger tight.

23. Verify coupling screw “Q”, Figure 7.22, is accessible.

24. Tighten screws “N”, Figure 7.21, to 25 lb-ft [34 N•m] torque.

25. Tighten coupling clamp screw “Q”, Figure 7.22, to 125 lb-in [14.0 N•m] torque.

- NOTE -

Press self-locking plug “P”, Figure 7.21, straight onto the motor receptacle.

26. Connect plugs “O” and “P”, Figure 7.21. Tighten the knurled nut on plug “O” to secure theconnection.

27. Apply Loctite® High Performance Pipe Sealant with Teflon® to the threads and install pipe plug“M”.

28. Replace covers and manifold:

QUEST® GT27 LATHE

A) Replace the lower motor cover.

B) Replace upper motor cover “G”, Figure 7.17.

C) Replace cross slide cover “F”.

D) Replace manifold “E”, Figure 7.16, on the cross slide cover.

QUEST CHNC® LATHE

A) Replace the lower motor cover.

B) Replace upper motor cover “L”, Figure 7.20.

C) Remove cross slide cover “K”.

D) If the machine is equipped with optional air blast manifold "J", Figure 7.19, connect the airlines to the top and bottom of fitting "I".

E) Replace cross slide cover "H", Figure 7.18.

29. At the rear of the machine, replace access covers “C” and “D”, Figure 7.15.

30. If it was necessary to manually rotate the ball screw, replace ball screw end cover “R”, Figure7.23, and secure with four screws and washers.

31. Proceed to “Setting the X Axis Reference Position”, beginning on the next page.

M-516A 7 - 15

SETTING THE X AXIS REFERENCE POSITION

QUEST® GT27 Lathe

- NOTE -

Refer to page 7-20 for setting the X axis reference position on a QUEST CHNC®

lathe.










3. Jog the X axis approximately 1 inch [25 millimeters].


- NOTE -








- NOTE -

Alarm 000 will be displayed when Parameter 1815, X Bit 4 (APZ) is set to “0”.

6. Set Parameter 1815, X Bit 4 (APZ) to “0”:





E) Move the cursor to the Parameter 1815 X row.



7 - 16 M-516A










11. If the machine is set to English mode, mount a collet and 1 inch diameter arbor in the spindle.

If the machine is set to Metric mode, mount a collet and 25 millimeter diameter arbor in thespindle.



14. Use the X and Z axis push buttons to move the back edge of the tooling top plate to within 4inches [100 mm] of the back side of the arbor mounted in the spindle.



17. Activate Handle mode by pressing the X Handle push button.


19. Place a piece of flat stock against the back edge of the tooling top plate.

20. If resetting a machine in English mode, place a 3 inch gauge block against the flat stockpositioned against the back edge of the tooling top plate. Refer to Figure 7.26.

If resetting a machine in Metric mode, place a 75 millimeter gauge block against the flatstock positioned against the back edge of the tooling top plate.

21. Turn the handwheel in the positive direction to gently touch the gauge block against the side ofthe arbor so that a slight drag is felt when moving the gauge block.

22. Preset the X axis to zero:



C) Press the U key.


M-516A 7 - 17

23. Observing the X axis Relative Position register, use the handwheel to move the X axis to thefollowing position:


Metric Mode: 37.4772

- NOTE -








F) Move the cursor to the Parameter 1815 X row.




7 - 18 M-516A

Figure 7.26 - Setting the X Axis Reference Position(QUEST® GT27 Lathe)

TI4991

Tooling Top Plate

Flat Stock

GaugeBlock

Arbor









28. Check the X axis position:



C) Move the X axis to position the top plate at the following position:



D) Using the gauge block, check for a slip fit between the side of the arbor and the flat stockpositioned against the back edge of the tooling top plate. Refer to Figure 7.26.










31. Turn the Setting Mode switch to "0" (OFF).








M-516A 7 - 19

QUEST® CHNC® Lathe

- NOTE -

Refer to page 7-16 for setting the X axis reference position on a QUEST GT27 lathe.










3. Jog the X axis approximately 1 inch [25 millimeters].


- NOTE -








- NOTE -







E) Move the cursor to the Parameter 1815 X row.




7 - 20 M-516A









11. If the machine is set to English mode, mount a collet and 1 inch diameter arbor in the spindle.

If the machine is set to Metric mode, mount a collet and 25 millimeter diameter arbor in thespindle.



14. Use the X and Z axis push buttons to jog the back edge of the turret top plate to within 2 inches[50 mm] of the back side of the arbor mounted in the spindle.



17. Activate Handle mode by pressing the X Handle push button.


19. Place a piece of flat stock against the back edge of the top plate.

M-516A 7 - 21

Figure 7.27 - Setting the X Axis Reference Position(QUEST® CHNC® Lathe)

TI5631

TurretTop Plate

Flat StockGaugeBlockArbor

20. If resetting a machine in English mode, place a 1 inch gauge block against the flat stockpositioned against the back edge of the turret top plate. Refer to Figure 7.27.

If resetting a machine in Metric mode, place a 25 millimeter gauge block against the flatstock positioned against the back edge of the turret top plate.

21. Turn the handwheel in the positive direction to gently touch the gauge block against the side ofthe arbor so that a slight drag is felt when moving the gauge block.

22. Preset the X axis to zero:



C) Press the U key.


23. Observing the X axis Relative Position register, move the X axis to the following position:



- NOTE -








F) Move the cursor to the Parameter 1815 X row.












7 - 22 M-516A

28. Check the X axis position:



C) Move the X axis to position the top plate at the following position:



D) Using the gauge block, check for a slip fit between the side of the arbor and the flat stockpositioned against the back edge of the tooling top plate. Refer to Figure 7.27.


















M-516A 7 - 23

TURRET INDEX MOTOR(QUEST® CHNC® Lathe)

MOTOR REPLACEMENT

1. Jog the Z axis to center cover “L”, Figure 7.20, with access cover “D”, Figure 7.15.

2. Jog the X axis to move the cross slide toward the front of the machine.

3. Open the main coolant guard door.

4. Remove any workpiece from the spindle to maximize the work space.


6. Remove access cover “G”, Figure 7.5.

7. Remove access cover “C”, Figure 7.15.

8. Clean all coolant and chips from the turret top plate, top plate mounting screws “A”, Figure 7.28,and all cross slide covers.

9. Remove the turret top plate:

A) Remove four top plate mounting screws “A” by loosening alternately and evenly.

B) Lightly tap on the top plate with a plastic or nylon hammer to free the top plate from thetapered mount.

- NOTE -

Be sure to retain the O-rings located at the four tapped holes in the key plate.

C) Lift the top plate from the key plate.

7 - 24 M-516A

Figure 7.28 - Turret Top Plates

Standard EightStation Top Plate

Optional FourStation Top Plate

A

TI5582

10. Remove cover “B”, Figure 7.29.

11. Remove pipe plug “C”, Figure 7.30, to gain access to the index shaft.

12. Check the orientation of the alignment mark on the end of the index shaft. Refer to Figure 7.31.

If the mark is NOT in the 12 o’clock position, use a hex wrench to rotate the index shaft toorient the mark to the 12 o’clock position.

If the mark is in the 12 o’clock position, proceed to the next step.

13. Apply pipe sealant and install pipe plug “C”, Figure 7.30.

14. Install cover “B”, Figure 7.29.

M-516A 7 - 25

Figure 7.29 - Front Index Shaft Cover

B

TI5655A

Figure 7.30 - Index Shaft Access Plug

C

TI5656A

Figure 7.31 - Mark on Index Shaft(Seal Plug Removed for Clarity)

TP7897

AlignmentMark

15. Remove cover “F”, Figure 7.32.

16. Remove covers “E” and “G”.

17. Remove cover “D” to gain access to the index motor.

18. Remove set screw “H”, Figure 7.33, to gain access to the rear clamp screw on the motorcoupling.

19. Loosen the rear clamp screw in the motor coupling.

20. Disconnect the two cables from the turret index motor “I”.

7 - 26 M-516A

Figure 7.32 - Cross Slide Covers Viewed from Right End of Machine

D

E

G

F

TI5652A

Figure 7.33 - Rear Access Screwfor Index Motor Coupling

H

I

TI5654A

21. Remove four bolts, lock washers, and the turret index motor.

22. Install the replacement turret index motor using the four screws and lock washers. Torque thescrews to 120 lb-in [14 N•m].

23. Tighten the rear clamp screw in the motor coupling. Torque to 12 lb-in [1.4 N•m].

24. Connect the two cables to the turret index motor.

25. Apply pipe sealant and install set screw “H”.

26. Install the turret top plate:

A) Using a paper towel, clean the surface of the key plate and the four keys.

B) Inspect the large lip seal around the diameter of key plate and the four O-rings. Replace theseal or O-rings if missing or damaged.

C) Lightly stone the flat mounting surface on the top of the key plate.

D) Lightly coat the lip seal, top of the key plate, and keys with Mobil 28 Grease.

E) Be sure inside of top plate is free of chips or any other debris.

F) Lightly coat the top plate sealing ring with Mobil 28 Grease.

G) Locate the keyways in the top plate directly over the keys in the mounting ring andCAREFULLY mount the turret top plate on the taper mount.

H) Clean and lightly oil four mounting screws A", Figure 7.28.

I) Install the four mounting screws and torque alternately and evenly to approximately 20 lb-ft[27 N•m].

27. Install cover “D”, Figure 7.32.

28. Install covers “E” and “G”.

29. Install cover “F”.

30. Install access cover “C”, Figure 7.15.

31. Install access cover “G”, Figure 7.5.


33. Proceed to "Setting the Turret Reference Position", on the next page.

M-516A 7 - 27

SETTING THE TURRET REFERENCE POSITION

1. Select Manual Data Input mode.

2. Select Offset/Settings.

3. Set PWE to “1".

4. Press the System key.

5. Press the PMC soft key.

6. Press the PMCPRM soft key.

7. Press the KEEPRL soft key.

8. Set TSETUP = 1 (K0.6). The Turret Setup Mode alarm will appear on the message screen.

9. Select JOG mode.

10. Press Collet Open/Close to unclamp the turret. The Collet Open light is ON when the turret isunclamped.

11. Press the 100X push button.

12. Press the Handwheel C Select push button.

13. Use the Handwheel to rotate the turret to station 8.

14. Press Collet Open/Close to clamp the turret.

15. Select Manual Data Input mode.

16. Set Parameter 1815.4 (APZ) to 0 (zero) for the turret (3rd Axis).

17. Press Emergency Stop.

18. Turn the machine OFF for a few seconds.

19. Turn the machine ON.

20. Set Parameter 1815.4 (APZ) to 1 (one) for the turret (3rd Axis).

21. Set PWE to “0".

22. Press Emergency Stop.

23. Turn the machine OFF for a few seconds.

24. Turn the machine ON.

7 - 28 M-516A

- NOTES -

M-516A 7 - 29

- NOTES -

7 - 30 M-516A

CHAPTER 8 - CONTROL FUNCTIONS

OPTION BIT CHANGE UTILITY

INTRODUCTION

This utility allows the user to change control option bits.

Some option bits cannot be changed without entering a password.

Refer to the list of protected option bits on page 8-3.

Refer to page 8-4 for information on entering the required password to change protectedoption bits.

ACCESSING THE OPTION BITS CHANGE UTILITY

1. Press the CUSTOM1 key to access the Custom Functions screen, shown in Figure 8.1.

2. Press the Auxiliary Functions soft key to access the Auxiliary Functions screen, shown inFigure 8.2.

M-516A 8 - 1

Figure 8.1 - Custom Functions Screen

TP8569A

Figure 8.2 - Auxiliary Functions Screen

TP9339A

3. Press the Option soft key to access the Option Bit screens, shown in Figures 8.3 through 8.6.

4. Use the PAGE soft keys to navigate between the Option Bit screens.

5. Press the EXIT soft key to return to the main Custom Functions screen.

6. Press the CNC soft key to exit the main Custom Functions screen.

OPTION BITS PAGE DESCRIPTION

Each line contains the option bit address, option bit name, and corresponding option bit state; “1"for ON or ”0" for OFF. The text cursor appears next to the option bit state that is being edited. Figure8.3 shows the text cursor next to the first option bit state.

8 - 2 M-516A

Figure 8.3 - Option Bits (Page 1)

TP9343


TP9344


TP9345


TP9346

CHANGING THE STATE OF AN OPTION BIT

1. Use the Page soft keys to access the required Option Bit page.

2. Use the arrow keys to move the text cursor to the desired option bit state.

3. Key in “1" (without quotes) to turn the option bit ON or a ”0" (without quotes) to turn the option bitOFF.

The number entered will appear next to the “NUM= >” prompt at the bottom left handcorner of the screen.

4. Press the INPUT key to enter the change into the control.

The option bit state should change to the desired state. If it does not change to the desiredstate, it may require a password. Refer to page 8-4 for information on entering the requiredpassword to change protected option bits.

LIST OF PROTECTED OPTION BITS

Option Bit Address Option Bit Name

K00.0 Service Mode

K00.1 Coolant Guard Switch Bypass

K00.6 Turret Setup Mode

K02.2 Allow Changing Macro Variables

K02.3 Allow Part Program Editing

K03.2 M21 (Open Chuck) Active With Spindle Running

K03.7 Does Not Clear Keep Relays K00.0 to K00.7 at Power Up

K04.0 Safe Spindle Stop Option

K04.3 Spindle Orient Setup

K05.2 C Axis Option

K05.3 Live Tool 1 Option

K05.4 Live Tool 2 Option

K06.5 Super Precision Handle Mode

K06.6 Turret Option

K06.7 8 Station Turret

K07.0 Coolant Guard Switch Bypass 2

K10.0 Write Parameters to Beta Servo Drive

K10.7 Automatic Guard Door Test Mode

K12.3 GM-Delphi Option

K15.4 New Door Closed Safety Switch

M-516A 8 - 3

PASSWORD ACCESS TO THE PROTECTED OPTION BITS

- NOTE -

Alarm 100 will be displayed when Parameter Write Enable is set to "1".

1. Set Parameter Write Enable to "1":





E) Key in "1" and press the Input key.

2. Press the SYSTEM key on the manual data input panel.

3. Press the expansion “+” soft key until the PMC MAINTE soft key is displayed.

4. Press the PMC MAINTE soft key.

5. Press the soft key expansion key (+) until the screen containing the DATA soft key is displayed.

6. Press the DATA soft key to access the data table control screen.

7. If necessary, set the data type to 2, as shown in Figure 8.7:

A) Move the cursor to the TYPE field.

B) Key in 2.

C) Press the Input key.

8. Press the OPRT soft key.

9. Press the ZOOM soft key. The screen shown in Figure 8.8 will be displayed.

8 - 4 M-516A

Figure 8.7 - Data Table 1 Control Screen

TP9351

Figure 8.8 - Data Table

TP9347

10. Key in 376.

11. Press the “SEARCH” soft key. The screen shown in Figure 8.9 will be displayed.

12. Key in 44238.

13. Press the Input key. The value will be loaded into address D0376, as shown in Figure 8.10.

You will now be able to modify the protected option bits.

The password remains in effect until the control is powered down.

14. Set Parameter Write Enable to "0":


B) Key in "0" and press the Input key.

C) Press the Reset key to cancel alarm 100.

M-516A 8 - 5

Figure 8.9 - D0376 Set to 0

TP9348

Figure 8.10 - D0376 Set to 44238

TP9349

INPUT/OUTPUT VIEWER UTILITY

INTRODUCTION

This utility allows the user to view the states of all of the control inputs and outputs.

The display screens are organized as follows:

• Standard inputs

• Standard outputs

• Safety inputs

• Safety outputs

ACCESSING AND EXITING THE INPUT/OUTPUT VIEWER UTILITY

1. Press the CUSTOM1 key to access the main Custom Functions screen, shown in Figure 8.1.

2. Press the Auxiliary Functions soft key to access the Auxiliary Functions screen, shown inFigure 8.2.

3. Press the ALL IO soft key to access the Input display screens. Refer to page 8-7 for additionalinformation on the Input display screens.

4. Use the soft keys to navigate between the display screens.

5. Press the EXIT soft key to return to the main Custom Functions screen.

6. Press the CNC soft key to exit the main Custom Functions screen.

8 - 6 M-516A

STANDARD INPUT DISPLAY SCREENS

Refer to Figures 8.11 through 8.16.

Press the OUTPTS soft key to access the standard Output display screens. Refer to page 8-9 foradditional information on the standard Output display screens.

Press the SAFETY soft key to access the Safety Input and Safety Output display screens. Refer topage 8-10 for additional information on the Safety Input and Safety Output display screens.

M-516A 8 - 7

Figure 8.11 - Standard Inputs (Page 1)

TP9357


TP9358


TP9359

8 - 8 M-516A


TP9360


TP9361


TP9362

STANDARD OUTPUT DISPLAY SCREENS

Refer to Figures 8.17 through 8.20.

Press the INPUTS soft key to access the standard Input display screens. Refer to page 8-7 for ad-ditional information on the standard Input display screens.

Press the SAFETY soft key to access the Safety Input and Output display screens. Refer to page8-10 for additional information on the Safety Input and Safety Output display screens.

M-516A 8 - 9

Figure 8.17 - Standard Outputs (Page 1)

TP9363


TP9364


TP9365


TP9366

SAFETY INPUT AND SAFETY OUTPUT DISPLAY SCREENS

Refer to Figures 8.21 and 8.22.

Use the OUTPTS and INPUTS soft keys to switch between the Safety Input and Safety Output dis-play screens.

Press the REG IO to return to page 1 of the standard input display screens.

- or -

Press the EXIT soft key to return to main Custom Functions screen, shown in Figure 8.1.

8 - 10 M-516A

Figure 8.21 - Safety Inputs (Page 1)

TP9368

Figure 8.22 - Safety Outputs (Page 1)

TP9369

- NOTES -

M-516A 8 - 11

- NOTES -

8 - 12 M-516A

CHAPTER 9 - MISCELLANEOUS

COOLING FANS

FAN LOCATIONS

QUEST® GT27 and QUEST CHNC® lathes areequipped with a headstock fan, a spindle compart-ment exhaust fan, and two power case plenum fans.The openings that allow air circulation through thespindle compartment and behind the power caseMUST NEVER BE BLOCKED.

The fans are active as soon as the machine ispowered up. When any of the fans require mainte-nance, the machine must be powered down.

Headstock fan "A", Figure 9.1, is located in thevalve compartment. This fan provides air for the spin-dle compartment.

Power case plenum fans "B", Figure 9.2, aremounted in the top of the power case. These fans ex-haust air from the top of the power case.

Spindle compartment fan "C" exhausts air out ofthe top to allow air circulation inside and vent warmerair.

M-516A 9 - 1

Figure 9.1 - Headstock Fan

TP7199

A

Figure 9.2 - Spindle Compartment and Power Case Plenum Fans(Top View)

TI5873

B

C

PowerCase Input/Output

Case

ControlCase

CLEANING THE FOAM AIR FILTERS

The headstock fan air filter is indicated as "D", Figure 9.3.

The power case plenum air filter is indicated as "E", Figure 9.4.


2. Clean each foam air filter as follows:

A) Grip the foam air filter and carefully pull it from the frame.

B) Wash the air filter clean in detergent and water. Squeeze out as much water as possible andallow it to air dry.

C) Make certain that the foam air filter is dry. Compress the filter and carefully fit it into theframe.


4. Check the fans to be sure they are drawing air.

9 - 2 M-516A

Figure 9.3 - Headstock Fan Air Filter

D

TP8252B

Figure 9.4 - Power Case Plenum Air Filter

TP8248A

E

CONTROL AND AXIS DRIVE BATTERY MAINTENANCE

NOTICE

New batteries must be installed at least once a year. Failure to perform thismaintenance will result in the loss of control information.

The recommended replacement interval for the control and axis drive batteries is once a year.Check the age of the control and axis drive batteries.

BATTERY LOCATIONS

• The control battery is behind the control display panel and on top of the controlunit

• A battery pack is on the X/Z axis servo drive unit in the power case

• A battery pack is on the T axis servo drive unit in the power case(QUEST® CHNC® lathe)

- NOTES -

Make certain that the replacement battery is like the battery being removed. Checkthe battery voltage and receptacle.

CONTROL BATTERY

NOTICE

Control battery replacement can be done with the control turned ON or OFF. If thepower is OFF, the change MUST be done within 30 minutes of when the powerwas turned OFF.

The control can temporarily maintain memory for approximately 30 minutes without the batterybackup.

Battery Specifications

Manufacturer: Sanyo Electric Corp.

Battery Number: CR17450SE-R

Voltage Rating: 3 volt

Battery Type: Lithium

Use the following procedure to check or replace the control battery.


2. After approximately 30 seconds, power down and lock out the machine. Refer to thepower-down procedure in Chapter 1.

NOTICE

Use care not to damage the gasket for the control display panel.

3. Remove the four mounting screws from control display panel “F”, Figure 9.5.

M-516A 9 - 3

4. Tilt the control display panel to gain access to control battery ”H”, Figure 9.6.

5. Press the battery latch down and remove the control battery from the holder.

6. Verify the new battery matches the battery being replaced.

7. Pull plug “G” straight off the battery connection.

8. Install the new battery.

9. Push the plug from the new battery onto the battery connection.

10. Set the control display panel back into the control housing.

11. Install the four mounting screws.

12. Dispose of the old battery properly.

9 - 4 M-516A

Figure 9.5 - Control Display Panel

F

TP8252B

Figure 9.6 - Control Battery

TP8242

G H

AXIS DRIVE BATTERY PACK

- NOTE -

QUEST® GT27 lathes require one axis drive battery pack.

QUEST CHNC® lathes require two axis drive battery packs.

Battery Pack Specifications

Manufacturer: Panasonic Corp.

Battery Number: BR-CCF2TH

Voltage Rating: 6 volt

Use the following procedure to check or replace the axis drive battery.



3. Release three power case door locks “I”, Figure 9.7.

4. Rotate interlock bypass “J” to allow the power case door to be opened.

DANGER

High voltage AC will be present in the power case when the main disconnectswitch is ON.

5. Open the power case door.

M-516A 9 - 5

Figure 9.7 - Power Case Door

I

TP8251A

J

NOTICE

Hold the battery cover by the top and bottom and squeeze the cover while pulling itoff.

6. Remove battery cover “K”, Figure 9.8 or 9.9.

7. Verify the new battery pack matches the battery pack being replaced.

8. Disconnect the old battery pack.

9. Connect the new battery pack.

10. Install the new battery pack and cover.




9 - 6 M-516A

Figure 9.8 - Battery Pack Cover(QUEST® GT27 Lathe)

TP8232

K

Figure 9.9 - Battery Pack Covers(QUEST CHNC® Lathe)

K

TP8329

PART CHUTE [Option]

DESCRIPTION

The part chute is located on rods that extend through the head wall. Part chute motion is limited tolinear motion between two positions:

• Home position, shown in Figure 9.10

• Extend position, shown in Figure 9.11

The extend/retract mechanism is in spindle compartment. The only adjustments to the part chuteare the extend position and the rate of travel. Refer to the operator’s manual (M-515) for informationon adjusting part chute positioning or rate of travel.

The part chute Home switch is connected to the power case terminal block 1I/O-1TB with cable1122CBL.

The part chute Home switch is active when the part chute is at the Home position (against the headwall). The part chute Home switch is located in the spindle compartment.

M-516A 9 - 7

Figure 9.10 - Part Chuteat the Home Position

TP5130

Figure 9.11 - Part Chuteat the Extend Position

TP5129

REPLACING THE PART CHUTE HOME SWITCH

1. If necessary, power up the machine. Refer to the power-up procedure in Chapter 1.

2. Close the main guard door.

3. Press and hold the Jog mode push button.

4. Press the Z axis Rapid Reference push button to move the Z axis to the reference position.

5. Release the Jog push button.

6. Press the Part Catch push button to extend the chute.


8. Release three power case door locks “I”, Figure 9.7, and the open power case door.

9. Release two door locks “M”, Figure 9.12.

10. Lift lever “N” and open input/output case door“L”.

11. Remove spindle compartment cover “P”,Figure 9.13.

12. Unscrew the hose clamp to release the coolantreturn hose fastened to the fitting on thecoolant catcher mounted inside spindlecompartment cover “O”.

13. Remove spindle compartment cover “O”.

14. Disconnect the wires in cable 2022CBL fromterminals 34 and 35 on terminal block1900I/O-1TB. Refer to Figure 9.14.

9 - 8 M-516A

Figure 9.12 - Input/Output Case Door

M

L

N

TP8238


TP8248A

P

O

Figure 9.14 - Input/Output Panels

TP8236

Terminal Block 1I/O-1TB

15. Pull the switch cable from the power case and into the spindle drive compartment. Note therouting of the cable for installation of the cable on the new switch.

16. Remove two screws “Q” and the switch from bracket “R”, Figure 9.15.

17. Compare the cable lengths of the old switch and the new switch and cut the replacement switchcable to length.

18. Mount the new switch to the bracket. Pull the switch all the way back in the slots and fasten thescrews finger tight.

19. Route the cable for the new switch as noted in step 15.

20. Connect the wires in cable 2022CBL to terminal block 1900I/O-1TB as follows:

Wire Color Terminal Block Connection

Black 34

White 35




24. If the part chute is not at Home, press the Reset key.

M-516A 9 - 9

Figure 9.15 - Mounting Bracketfor Part Chute Home Switch

TP5131

Q

S

R

- NOTE -

If the part chute Home switch is not energized when the part chute is commandedto the Home position, the following operator message will appear on the controldisplay:

“PART CATCHER NOT AT HOME”

25. If the part chute Home switch is not energized, adjust the switch as follows:

A) Press the Jog push button.

B) Press the Part Catch push button to extend the chute.

C) Loosen the screws; adjust the switch in toward end plate “S” and tighten the screws.

D) Press the Reset key to retract the part chute.

E) If the “PART CATCHER NOT AT HOME” message appears, repeat steps B, C, and D untilthe switch is energized.


27. Replace spindle compartment cover “O”, Figure 9.13.

28. Attach the coolant return hose to the fitting on the coolant catcher mounted inside spindlecompartment cover “O” and secure with the hose clamp.

29. Replace spindle compartment cover “P”.

9 - 10 M-516A

- NOTES -

M-516A 9 - 11

- NOTES -

9 - 12 M-516A

APPENDIX ONE - PREVENTIVE MAINTENANCESCHEDULE AND PRODUCTS APPLIED

INTRODUCTION

QUEST® GT27 and QUEST CHNC® Super-Precision® CNC lathes are designed to provide mini-mal downtime and insure long machine life when the following schedule of preventive maintenance isapplied. Modular construction and easy access to components help to monitor each of the systems ofthe machine. Monitoring sensors have been built into the machine for ease in troubleshooting prob-lems. Pressure sensors and control alarms alert the operator through the control display when sys-tems 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 re-moval when service is required. Open access covers and doors or remove panels to gain access tomachine components. There is no need to be cramped or extended when performing maintenance orservice on the machine. Any component can be easily removed when extensive service or replace-ment is necessary.

NOTICE

Do not use caustic or abrasive cleaners on this machine.

Maintaining a clean machine is part of any good maintenance program. Machines should be peri-odically wiped with a lint-free cloth soaked with mineral spirits. If the machine is operated in an atmo-sphere that causes surfaces to rust quickly, wipe these surfaces with a lint-free cloth soaked inmineral oil.

NEVER USE COMPRESSED AIR TO CLEAN DIRT OR CHIPS FROM THE MACHINE. Air pres-sure could force dirt particles and other foreign material past seals and wipers.

MAINTENANCE SCHEDULE

- NOTE -

A preventive maintenance check list (T-447) is provided on the document CDsupplied with the machine. Please print and use this check list to maintain a recordof the preventive maintenance procedures performed on the machine.

The following maintenance intervals are approximate. Components may require maintenancemore frequently depending on machine duty cycle and the level of environmental pollution present.

8 HOURS

Check the guard door vision panels . . . . . . . . . . . . . . . . Operator's Manual

Drain the air receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 3

Check the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 4

Check the coolant concentration and measure the coolant pH . . . . . . . Chapter 4

Remove chips and shavings . . . . . . . . . . . . . . . . . . . . . . . . Chapter 4

M-516A A1 - 1

40 HOURS

Check circulating fans for dirt and proper operation . . . . . . . . . . . . Chapter 9

Clean the foam air filters . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 9

Clean the spindle coolant catcher . . . . . . . . . . . . . . . . . . . . . Chapter 4

Clean and lubricate the spindle (collet closer) draw tube. . . . . . . . . . Chapter 6

Clean the chip conveyor. . . . . . . . . . . . . . . . . . . . Chip Conveyor Manual

Wash machine and wipe clean. . . . . . . . . . . . . . . . . . . . . Appendix One

500 HOURS

Check spindle drive belt for wear and tension . . . . . . . . . . . . . . . Chapter 5

Inspect and clean spindle motor . . . . . . . . . . . . . . . . . . . . . . Chapter 5

Check spindle encoder timing belt tension . . . . . . . . . . . . . . . . . Chapter 5

Clean spindle brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 5

Clean chip screens in the coolant tank . . . . . . . . . . . . . . . . . . . Chapter 4

1000 HOURS

Lubricate the ball screws and linear guides. . . . . . . . . . . . . . . . . Chapter 2

Replace the in-line air filters . . . . . . . . . . . . . . . . . . . . . . . . Chapter 3

Clean coolant tank and change coolant . . . . . . . . . . . . . . . . . . Chapter 4

Check and adjust the chip conveyor drive chain tension . . . Chip Conveyor Manual

2000 HOURS

Install new batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 9

4000 HOURS

Replace turret oil (QUEST® CHNC® lathe) . . . . . . . . . . . . . . . . . Chapter 2

A1 - 2 M-516A

PRODUCTS APPLIED

LUBRICANTS

(Use recommended product)

Product Manufacturer

Mobiltemp SHC® 32 Grease Mobil Oil Corp.

Mobil Delvac 75W-90 Synthetic Oil Mobil Oil Corp.

Molylube® Lubricant Bel-Ray Co., Inc.

Never-Seez Black Moly Grease Bostik Inc.

Parker Super Lube O-Ring Lubricant Parker Hannifin Corp.

THK AFC Grease THK Co., Ltd.

ADHESIVES AND SEALANTS

Product Manufacturer

3M Super Weather Strip and Gasket Adhesive 3M Automotive Aftermarket Division

737 Sealant Dow Corning Corporation

Loctite® Pipe Sealant with Teflon® (Item #592) Loctite Corporation

Loctite 222 Threadlocker Loctite Corporation



Loctite 569 Hydraulic Sealant Loctite Corporation

Scotch-Grip™ 847 Adhesive 3M Adhesive Division

V-711 Grease The Smith Group, Inc.

M-516A A1 - 3

- NOTES -

A1 - 4 M-516A

APPENDIX TWO - ALARM AND OPERATOR MESSAGES

ALARM MESSAGES

1000 Please Turn OFF Power

Machine Lock mode has been canceled. When Machine Lock mode is active there is nomachine motion during program execution, but the position registers indicate all motion dictatedby the part program. The machine power must be cycled to return the position registers to thecorrect values.

1001 Collet Pressure Switch Fault

Main spindle Collet Close or Open pressure switch is faulty. Spindle pressure switch inputindicates same state for more than 3.5 seconds. The control is put in an alarm condition.

1004 Main Spindle Brake Fault

Spindle brake pressure switch input contradicts the state of the brake solenoid valve.(Spindle free lamp indicates status of brake solenoid). The control is put in an alarm condition.

1005 Right Side Access Cover Open

The right side access cover is not in place. Executing a program in Automatic mode isinhibited. Install the cover and press Reset to allow machine operation.

1006 Bar Feed Fault Powerdown

The Automatic Power Down option is active and the main circuit breaker has failed to turnOFF when a bar feed fault is detected.

Refer to the operator's manual (M-515) for information on the Automatic Power Down option.

1007 Bar Feed Fault

Bar Feed out of position. Hydraulic motor protection relay trip condition.

Bar feed is placed in an Emergency Stop condition.

The control is put in an alarm condition.

1010 Spindle Unit Fault

Spindle drive/motor overload condition. The control is put in an alarm condition and themachine in Emergency Stop. (See drive alarm lamps on drive servo unit for cause of failure).

M-516A A2 - 1

1012 Turret Fault (QUEST® CHNC® Lathe)

Turret index was interrupted by Reset or low air pressure. To clear the fault:


2. Reset Emergency Stop, if necessary.

3. Select Jog mode.

4. Press a Turret Index push button.

1013 Turret Unclamped (QUEST CHNC Lathe)

The turret top plate is not properly seated or the turret unclamped proximity switch may befaulty.

1014 Coolant Overload

The overload on the coolant motor contactor has tripped. The control is put in an alarmcondition and the machine in Emergency Stop.

1015 Tool Probe Cover OFF

The tool probe receiver cover must be properly installed to allow automatic machineoperation. Install the probe receiver cover and press Reset to clear the alarm.

1016 Rear Access Cover Open

The rear access cover is not in place. Executing a program in Automatic mode is inhibited.Install the cover and press Reset to allow machine operation.

1026 End of Bar

End of bar condition exists. The control is put in an alarm condition.

1030 Low Main Air Pressure

Low air pressure to machine.

The control is put in an alarm condition and the machine in Emergency Stop.

The following alarms will also be displayed:

PWM0012 User I/O Cross Check Error (DCS PMC)

PWM0013 User I/O Cross Check Error (PMC)

SV1068 Dual Check Safety Alarm

Power down and power up the machine to clear the alarms. Refer to the power-down andpower-up procedures in Chapter 1.

1034 Collet Access Door Open

The collet access door is open. Executing a program in Automatic mode is inhibited. Closethe door and press Reset to allow machine operation.

A2 - 2 M-516A

1035 Verify Guard Door Switch

Machine power-up message. Open and close the main guard door to verify the interlockswitch operation.

1063 Turret Unclamped Switch (QUEST® CHNC® Lathe)

The turret unclamp solenoid is energized but the turret unclamped switch has not made.Either the turret has failed to unclamp or the unclamped switch has failed.

1082 T Code Invalid

The T word exceeds the maximum number of turret stations on the top plate.

T word format error.

1092 Robot Fault

A fault has occurred on the optional load/unload robot.

Refer to the documentation supplied with the robot for fault recovery.

1105 Main Chuck Failed to Close

A draw tube limit switch indicates the spindle draw tube has not moved to the Closedposition.

Verify collet closer operation.

Check the switch for adjustment or replacement.

1106 Main Chuck Failed to Grip Part

A draw tube limit switch indicates the spindle draw tube has moved from the Open position,past the Closed position, into a overtravel condition.

Check the machine spindle for a workpiece.

Check the switch for adjustment or replacement.

1141 Tool Group Life End

All of the tools in one or more tool groups have reached the life specified in the Tool LifeManagement program and an M30 (End of Program) has been read by the control.

Refer to the operator’s manual (M-515) for information on resetting the tool group counter(s).

1217 Alarm Live Tool Unit 1 (QUEST GT27 Lathe)

A drive fault has occurred on live tool attachment 1.

1237 Alarm Live Tool Unit 2 (QUEST GT27 Lathe)

A drive fault has occurred on live tool attachment 2.

M-516A A2 - 3

OPERATOR MESSAGES

2000 Machine Lubrication Required

Machine lubrication is required every 1000 hours of machine ON time. Cycle Start is inhibitedwhen this message is displayed.

Refer to Chapter 2 for information on machine lubrication.

2017 Part Catcher Not at Home

Part catcher is not in the up or home position. Cycle Start is inhibited until the part catcher isin the home position.

2023 Guard Door Open

Coolant guard door is open.

2024 Chuck Open

Spindle collet/chuck is open.

2032 Z Axis Overloaded, Please Adjust Feedrate

The Z axis thrust limit has been exceeded. The machine is put into a feed hold condition.

Turn the Feedrate Override switch down by 10% and press Cycle Start. Repeat until themessage clears. Adjust the feedrate in the part program by the percentage that was required toclear the message.

2033 Invalid M-Code Programmed

M word is programmed for an option not available/enabled on the machine.

M word is not defined in the control.

M word format error.

2036 Battery Voltage Low

Battery voltage for the control memory system is low. DO NOT POWER DOWN THEMACHINE.

Refer to Chapter 9 for instructions to replace the batteries.

A2 - 4 M-516A

2037 Jog Mode Required to Open Collet

For machines equipped with bar feed, JOG mode must be selected before manually openingthe collet.

2045 Invalid B-Code Programmed

B word is programmed for an option not available/enabled on the machine.

B word format error.

2050 Collet Open

Spindle operation in manual or automatic mode is not allowed with the work-holding deviceopen. The spindle will not be allowed to operate unless the work-holding device is closed.

Close the work-holding device to clear this message.

2051 High Pressure Coolant Motor Overload

The overload on the high pressure coolant motor contactor has tripped.

2052 High Pressure Coolant Filter Dirty

Check the high pressure coolant filter. Clean or replace the filter element, as needed.

2054 High Pressure Coolant Fault

The high pressure coolant unit has signaled a fault. Refer to the manufacturer’s servicemanual.

2056 Jog Setting Mode Required

The operator attempted to jog the axes or spindle with the door open and the setting mode isnot set to jog. The axes/spindle will not be allowed to jog unless the setting mode is set to jog.

2086 Part Count Satisfied

The part count specified has been completed. Part program execution is halted.

2090 Tool Slide Must be at Home in Z

A Rapid Reference must be performed on the Z axis before a Rapid Reference can beperformed on the X axis.

M-516A A2 - 5

2091 Pallet Done

The current pallet used by the optional load/unload robot is done.

Refer to the documentation supplied with the robot.

2093 Robot Entrance Door to Machine Open

The entrance door in the machine that is used by the optional load/unload robot is open.


2094 Robot Safety Gate Open

A robot safety gate is open.


2095 Tool Failed to Contact Probe

While using the probe cycle, the tool failed to contact the probe. Adjust the tool position andtry again. Press Reset to clear the message.

2100 Auto Door Drive Alarm, Please Press Reset

The auto door stepper motor drive unit has an alarm. Press Reset to clear this message.

2102 Auto Door Drive Alarm, Press Reset; Home Required

The auto door stepper motor drive unit has an alarm. Press Reset to clear this message. Thedrive will perform the homing operation when the door is next opened or closed.

2103 Auto Door Drive Alarm, Press the Reset Push Button

Press Reset to reset the stepper drive and clear this message. The drive will perform thehoming operation when the door is next opened or closed.

2126 Chip Conveyor Contactor Failed

This message occurs when either of the following conditions exist:

• the chip conveyor is turned OFF and the chip conveyor contactor stays ONfor more than one second.

• the chip conveyor is OFF and the chip conveyor contactor is ON for morethan one second.

A2 - 6 M-516A

2127 Coolant Pump Contactor Failed

This message occurs when either of the following conditions exist:

• the coolant pump is turned OFF and the coolant pump contactor stays ON formore than one second.

• the coolant pump is OFF and the coolant pump contactor is ON for more thanone second.

2140 New Tool Used on this Part

A tool in the currently active tool group has reached the tool life specified in the Tool LifeManagement program. The next tool in the active tool group has been selected.

Press Cycle Start or Reset to clear this message.

2200 Live Tool Alarm [__]:

Please refer to Fanuc Manual B-65245 for Alarm Documentation

2201 Live Tool Alarm [__]: A Parameter that Requires Power Down has been Specified


2202 Live Tool Alarm [__]: A Serial Pulse Coder Communication Error was Detected


2203 Live Tool Alarm [__]: Drive Motor Overheated


2204 Live Tool Alarm [__]: Excessive Position Error


2205 Live Tool Alarm [__]:Overcurrent


2206 Live Tool Alarm [__]: DC Link Overvoltage


M-516A A2 - 7

2207 Live Tool Alarm [__]: DC Link Low Voltage


2210 Live Tool Alarm [__]: The Cooling Fan has Stopped


2211 Live Tool Alarm [__]: Excessive Velocity Deviation


2220 Live Tool Alarm [__]:


2221 Live Tool Alarm [__]: A Parameter that Requires Power Down has been Specified


2222 Live Tool Alarm [__]: A Serial Pulse Coder Communication Error was Detected


2223 Live Tool Alarm [__]: Drive Motor Overheated


2224 Live Tool Alarm [__]: Excessive Position Error


2225 Live Tool Alarm [__]:Overcurrent


2226 Live Tool Alarm [__]: DC Link Overvoltage


2227 Live Tool Alarm [__]: DC Link Low Voltage


A2 - 8 M-516A

2230 Live Tool Alarm [__]: The Cooling Fan has Stopped


2231 Live Tool Alarm [__]: Excessive Velocity Deviation


2240 Door Closed Switch Fault -- Shorted

One of the two “door closed” switch contacts is ON all the time or the contacts are shortedtogether. Cycle Start is inhibited. Check the wiring.

When the problem is corrected, press Reset to clear the alarm.

2241 Door Closed Switch Fault -- Open

One of the two “door closed” switch contacts is disconnected. Cycle Start is inhibited. Checkthe wiring.


2242 Door Locked Switch Fault -- Shorted

One of the two “door locked” switch contacts is ON all the time or the contacts are shortedtogether. Cycle Start is inhibited. Check the wiring.


2243 Door Locked Switch Fault -- Open

One of the two “door locked” switch contacts is disconnected. Cycle Start is inhibited. Checkthe wiring.


2244 Door Failed to Lock

Cycle Start was pressed and the “door locked” switch indicates the door is not locked.

Check to be sure the door is completely closed.

Check the “door locked” switch.

M-516A A2 - 9

- NOTES -

A2 - 10 M-516A

APPENDIX THREE - MACHINE TAGS

TAG LOCATIONS

- NOTE -

Refer to the tables beginning on page A3-7 for tag part numbers.

M-516A A3 - 1

COLLET CLOSER

P/N AHB001152201CE

P/N FGA001036609 P/N FGA001036609

AIR INLET

DO NOT BLOCK.

CLEAN FILTER ONCE A WEEK.

MORE OFTEN, IF REQUIRED.

P/N FGA001036626

Crush Hazard

WARNING

P/N CQ 001036610

Could result in serious injury.

Stay clear of moving or rotating

parts.

All covers must be properly

installed before operating this

machine.

Tool or part ejection could result in deathor serious injury.Enclosure may not stop every type ofprojectile.

Step chucks must only be used with theappropriate step chuck closer. Follow safemachining practices.

Ejection Hazard

WARNING

P/N CQ 001036609

CAREFULLY WASH AND

DRY WINDOW WITH SOFT

CLEAN CLOTH TO AVOID

MARRING SURFACE

P/N FGA001036624

Figure A3.1 - Front of Machine

TI6276

2

3

4

5

66

1

A3 - 2 M-516A

AIR INLET

DO NOT BLOCK.

CLEAN FILTER ONCE A WEEK.

MORE OFTEN, IF REQUIRED.

P/N FGA001036626

WARNINGWhipping HazardWhipping bar stock could result in death

or serious injury.

Do not run machine with unsupported

stock extended betond rear of spindle.

P/N FGA001036601

NOTICE

Possible damage to machine, tooling, or workpiece.

All draw tube screws must be tightened before running

machine.

Torque to 120 lb-in [13.6 Nm].

Potential Machine Damage

FGA001036604

P/N FGA001036603

WARNINGCrush HazardCould result in serious injury.

Stay clear of moving or rotating parts.

All covers must be properly installed

before operating this machine.

P/N MGA0010366C05

PSIG / LBS Bar / daN

COLLET / CHUCK CLOSER

PRESSURE / FORCE - 5C SPINDLE

30 2.11047 467

40 2.81396 623

50 3.41745 778

60 4.12094 934

70 4.82443 1090

80 5.52792 1245

90 6.23141 1401

20 1.4698 311

WARNING

P/N FGA001036625

With this cover installed, the bar-feed and

its Emergency Stop button are disabled

and will not function.

Take appropriate action on the bar-feed

to tag or cover the Emergency Stop

button.

Bar-Feed Emergency Stop

Inoperable

ALWAYS CONNECT

RS 232 CABLE

BEFORE APPLYING

POWER TO THE

EXTERNAL DEVICE

P/N FGA001036623

DRAIN AIR RECEIVER

EVERY 3 MONTHS.

MORE OFTEN

IF REQUIRED.

P/N FGA001036619

Figure A3.2 - Left End of Machine

TI6277

7

1

8

9

10 11

12

13

M-516A A3 - 3

P/N CLC0008074

Model Supply Volts Phase

KVA Hertz Machine FLA

Control Volts Spindle Drive

Electrical Schematic

Control Model

Short Circuit Interrupting Capacity of

the Overcurrent Protective Device

Overcurrent Protection Provided

at Machine Supply Terminals

Machine Serial Number

Machine Weight, KG / LB

HARDINGE INC.

ONE HARDINGE DRIVE, ELMIRA, NY 14902 USA

TELEPHONE: +607-734-2281

Machine Group

Machine Designation

Year

Hydraulic System Pressure, BAR / PSIG

Maximum Spindle Speed, Sub-Spindle

Maximum Spindle Speed, Main Spindle

LCC0010302CE

"IMPORTANT"

DAMAGE RESULTINGFROM MISUSE,

NEGLIGENCE, ORACCIDENT IS NOTCOVERED BY THE

HARDINGE INC.MACHINE WARRANTY

P/N FGA001036622

LCC0010302CE

Figure A3.3 - Back of Machine

TI6278

14

15

14 16

A3 - 4 M-516A

Potential Machine Damage

Possible damage to turret top plate screws.

Machine must be in Emergency Stop to

change top plate. For instructions press

"CUSTOM1", then press soft key.

P/N GCC001030201CE

NOTICE

COLLET CLOSER

P/N AHB001152201CE

Figure A3.4 - Control Panel and Top of Coolant Guard

TI6279

Control Panel

Coolant Guard

17

2

18

M-516A A3 - 5

15 GALLONS

5 GALLONS

U.S.

U.S.

57 LITERS

19 LITERS

P/N HGA0010522

FULL

ADD

14 GALLONS

6 GALLONS

U.S.

U.S.

53 LITERS

23 LITERS

P/N HGA001036626

FULL

ADD

P/N HGA001036603

The rubber strips must be positioned such that both are

located inside coolant tank prior to using the coolant

system.

P/N HGA001036603

The rubber strips must be positioned such that both are

located inside coolant tank prior to using the coolant

system.

Figure A3.5 - Coolant Tanks

TI6280

19

20

19

21

A3 - 6 M-516A

Figure A3.6 - Turret Assembly(QUEST® CHNC® Lathe Only)

TI6281

22

TAG PART NUMBERS

TAG KITS

- NOTE -

The tag kits do not include the tags listed under the following identificationnumbers:

6, 14

Language Tag Kit Part Number

Dutch GGA0000100DU

English GGA0000100 E

French GGA0000100 F

German GGA0000100 G

Italian GGA0000100 I

INDIVIDUAL TAGS

- NOTE -

Refer to Figures A3.1 through A3.6 for tag identification.

IdentificationNumber

Description Language Tag Part Number

1 Tag, Inlet / Filter

DutchEnglishFrenchGermanItalian

FGA001036626DUFGA001036626FGA001036626FFGA001036626GFGA001036626I

2 Tag, Gauge Name


AHA001052201DUAHB001052201CEAHB001052201CFAHB001052201CGAHB001052201CI

3 Tag Window



M-516A A3 - 7

4 Tag, Warning, Ejection Hazard


CQ 001036609DUCQ 001036609CQ 001036609FCQ 001036609GCQ 001036609I

5Tag, Warning, Crush Hazard(Vertical)


CQ 001036610DUCQ 001036610CQ 001036610FCQ 001036610GCQ 001036610I

6 Tag, Fork Lift Right - FGA001036609

7 Tag, Drain Air Receiver



8 Tag, Notice, Draw Tube Screws



9Tag, Warning, Crush Hazard(Horizontal)



10 Tag, Warning, Whipping Hazard



11 Tag, RS-232



12 Tag, Warning, Bar Feed Emergency Stop


FGA001036625DUFGA001036625FGA001036625FFGB001036625GFGA001036625I

13

Tag, Closer Pressure(Machine with 27 Millimeter Spindle)

Tag, Closer Pressure(Machine with 42 Millimeter Spindle)



GGA00103665DUMGA0010366C05MGA00103665FMGA00103665GMGA00103665I

GGA001036616DUMGA0010366C16MGA001036616FMGA001036616GMGA001036616I

14 Tag, Electrical Hazard - LCC0010302CE

A3 - 8 M-516A

15 Tag, Misuse



16 Plate, Blank Data


CLC0008074DUCLC0008074CLC0008074 FCLD0008074 GCLC0008074 I

17Tag, Top Plate Change(QUEST® CHNC® Lathe Only)


GCA001030201DUGCC001030201CEGCB001030201CFGCB001030201CGGCB001030201CI

18 Tag, Glass Date



19 Tag, Coolant Tank Splash Shield


GGA001036611DUHGA001036603HGA001036603 FHGA001036603CGHGA001036603IT

20Tag, Coolant Level(Coolant Tank without Chip Conveyor)



21Tag, Coolant Level(Coolant Tank with Chip Conveyor)



22Tag, Gear Lubrication(QUEST CHNC Lathe Only)


GCA0010302GLDUGCA0010302GLGCA0010302GLFGCA0010302GLGGCA0010302GLI

M-516A A3 - 9

- NOTES -

A3 - 10 M-516A

APPENDIX FOUR - MACHINE PHOTOGRAPHS

M-516A A4 - 1

Figure A4.1 - Front View of Machine

TP8252B

A4 - 2 M-516A

Figure A4.2 - Left End of Machine

TP8248A

M-516A A4 - 3

Figure A4.3 - Right End of Machine

TP8247A

A4 - 4 M-516A

Figure A4.4 - Rear Access Covers and Power Case Door

TP8258A

M-516A A4 - 5

Figure A4.5 - Valve Compartment:Machine Not Equipped with an X Axis Scale

(Additional Valves for Options Shown)

TP4995C

A4 - 6 M-516A

Figure A4.6 - Valve Compartment:Machine Equipped with an X Axis Scale(Additional Valves for Options Shown)

TP7736A

M-516A A4 - 7

Figure A4.7 - Air Receiver

TP8256A

A4 - 8 M-516A

Figure A4.8 - Operator Control Panels

TP8254A

M-516A A4 - 9

Figure A4.9 - Internal View of Power Case: View 1(QUEST® GT27 Lathe)

A - Main Circuit Breaker (202CB)

B - Fanuc Power Supply (1PWS)

C - Spindle Drive (SPDR)

D - X/Z Axis Drive (X/ZDR)

TP8232

A

B C D

A4 - 10 M-516A

Figure A4.10 - Internal View of Power Case: View 1(QUEST® CHNC® Lathe)

A - Main Circuit Breaker (202CB)

B - Fanuc Power Supply (1PWS)

C - Spindle Drive (SPDR)

D - X/Z Axis Drive (X/ZDR)

E - Turret Drive (TDR)

TP8329

A

B C D E

M-516A A4 - 11

Figure A4.11 - Internal View of Power Case: View 2

A - Radio Frequency Interference Filter (201FIL)

B - Terminal Blocks (1TB)

C - Surge Suppressors (208SUP)

D - Ground Terminal Block (G0)

E - 230VAC Fuses (230FU, 216FU, 220FU, 224FU, 324FU)

F - Control ON Contactor (224M)

TP8233

AB

C

D

E

F

A4 - 12 M-516A


A - Line Reactor (1FIL)

B - Master Control Contactor (212M)

C - Emergency Stop Power Contactors (1211ES, 1214ES)

D - 230VAC Fuses (233FU, 237FU, 243FU, 301FU, 307FU, 314FU)

E - Coolant Contactor (233M) and Overload (233OL)

TP8234

A

B

C D

E

M-516A A4 - 13


A - 24VDC Power Supply (224PWS)

B - Safety Relays (1002CR, 1501CR, 1701CR, 1504CR, 1704CR,1507CR, 1707CR)

C - 24VDC Fuses (223FU, 224FU, 225FU, 226FU, 227FU, 228FU)

D - 115VAC Fuse (328FU)

E - 115VAC Terminal Blocks (2TB, 3TB)

F - Ground Terminal Blocks (G1, G2)

G - Safety Expansion Relays (1206SR, 1300SR)

H - 115VAC Control Transformer (327T)

TP8235

A

B

C

DE F

G

H

A4 - 14 M-516A


A - Fanuc Input/Output Modules (2520I/O, 2220I/O, 1920I/O,1640I/O, 1840I/O)

B - Input/Output Module (1900I/O)

C - Input/Output Module (2200I/O)Input/Output Module (2500I/O), Optional, Not Shown

D - Safety Input/Output Module (1700PCB)

E - Safety Input/Output Module (1500PCB)

F - 24VDC Terminal Blocks (6TB, 7TB, 8TB, 9TB, 10TB, 11TB)

TP8236

A

B C

DEF

- NOTES -

M-516A A4 - 15

- NOTES -

A4 - 16 M-516A

DOCUMENT REVISION RECORD

DateDocumentRevision

LevelDescription

December 26, 2011 - Initial Release.

March 22, 2012 A Updated manual to include QUEST® CHNC® lathe.

September 14, 2012 A Updated operator messages.

March 5, 2013 A Added grease and oil part numbers to Chapter 2.

November 12, 2013 A Updated Chapter 5, Headstock and Spindle Drive.

May 1, 2015 A Updated collet closer removal and installation procedures.

June 19, 2015 A Updated preventive maintenance schedule.

July 14, 2015 A Added Control Functions chapter.

June 28, 2016 AChanged Appendix Three - Machine Photographs to Appendix Four.

Added Appendix Three - Machine Tags.

September 29, 2016 A Corrected information for turret lubrication.

December 8, 2016 A Updated coolant system information.

February 27, 2018 AAdded warning for California residents to General Warnings andCautions.

M-516A R-1

Hardinge Inc.

Elmira, New York 14903 USAPhone: 607-734-2281 Fax: 607-734-8819

www.hardinge.com

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