Quest 6/42 QUEST 8/51 QUEST 10/65: Operator'S Manual

OPERATOR’S MANUAL
TP6793
®
QUEST 6/42
QUEST 8/51
QUEST 10/65
MULTI-TASKING CNC Lathes
Equipped with the
GE Fanuc 16i-T, 18i-T, or 21i-T Control
Revised: January 18, 2008
Manual No. M-392D Litho in U.S.A.

Part No. M D-0009500-0392 June, 2007
- NOTICE -
Damage resulting from misuse, negligence, or accident is not covered by the
Hardinge Machine Warranty.
Information in this manual is subject to change without notice.

This manual covers the operation of Hardinge QUEST® 6/42, 8/51, and
10/65 Multi-Tasking CNC lathes equipped with the of the following GE
Fanuc controls:
16i-T
18i-T
21i-T
In no event will Hardinge Inc. be responsible for indirect or consequential
damage resulting from the use or application of the information in this man-
ual.
Reproduction of this manual in whole or in part, without written permission
of Hardinge Inc., is prohibited.
CONVENTIONS USED IN THIS MANUAL
- WARNINGS -
Warnings must be followed carefully to avoid the possibility of personal injury
or damage to the machine, tooling, or workpiece.
- CAUTIONS -
Cautions must be followed carefully to avoid the possibility of damage to the
machine, tooling, or workpiece.
- NOTES -
Notes contain supplemental information.
- TRADEMARK NOTICE -
Windows is a registered trademark of Microsoft Corporation.
Hardinge Inc.
One Hardinge Drive
P.O. Box 1507
Elmira, New York 14902-1507 U.S.A.
www.hardinge.com
© 2007, Hardinge Inc. M-392D

READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE OPERATING
MACHINE, LOAD/UNLOAD AUTOMATION, OR BAR FEED SYSTEM
When this instruction book was printed, the information given was current. However, since we are
constantly improving the design of our machine tools, automation, and bar feed systems, it is possible
that the illustrations and descriptions may vary from the machine, automation, or bar feed system you
received.
- WARNING -
Occupational Safety and Health Administration (OSHA) Hazard Communica-
tion Standard 1910.1200, effective May 25, 1986, and various state “employee
right-to-know laws” require that information regarding chemicals used with
this equipment be supplied to you. Refer to the applicable section of the Mate-
rial Safety Data Sheets supplied with your machine when handling, storing, or
disposing of chemicals.
Machine should only be used with a bar feed approved by Hardinge Inc.
- SPINDLE TOOLING WARNING -

Hardinge HQC (Quick-Change) collets MUST NOT be used in applications
where the spindle is rotating without a bar or workpiece in the collet.
Rotating the spindle without a bar or workpiece in the collet can result in the
collet head being expelled from the spindle.
Failure to comply with this warning can result in serious injury or death.
HARDINGE SAFETY RECOMMENDATIONS

Your Hardinge machine is designed and built for maximum ease and safety of operation. However,
some previously accepted shop practices may not reflect current safety regulations and procedures,
and should be re-examined to insure compliance with the current safety and health standards.
Hardinge Inc. recommends that all shop supervisors, maintenance personnel, and operators be
advised of the importance of safe maintenance, setup, and operation of machine tools. Our recom-
mendations are described below. READ THESE SAFETY RECOMMENDATIONS BEFORE PRO-
CEEDING ANY FURTHER.
READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation or
maintenance of the machine. Make certain that you understand all instructions.
DON’T ALLOW the operation or repair of equipment by untrained personnel.
CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job.
WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. When necessary,
wear respirator, helmet, gloves, and ear muffs or plugs.
DON’T OPERATE EQUIPMENT unless proper maintenance has been regularly performed and
the equipment is known to be in good working order.
WARNING or INSTRUCTION TAGS are mounted on the machine for your safety and informa-
tion. Do not remove them.
DON’T ALTER THE MACHINE to bypass any interlock, overload, disconnect, or other safety
device.
M-392D i
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 on vi-
bration and balance of the spindle system.
NEVER OPERATE THE MACHINE SPINDLE without a work-holding device if the draw tube is
in the spindle.
TIGHTEN ALL DRAW TUBE SCREWS before beginning spindle operation.
MAKE CERTAIN that the equipment is properly grounded. Consult National Electric Code and
all local codes.
DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance.
ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing electrical
equipment.
DON’T REACH into any control or power case area unless electrical power is OFF.
DON’T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a wet
surface.
REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished.
ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters before re-
starting the machine.
KEEP THE AREA AROUND THE MACHINE well lighted and dry.
KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating equipment.
HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combustible
material and keep chips clear of the work area.
DON’T USE a toxic or flammable substance as a solvent cleaner or coolant.
MAKE CERTAIN THAT PROPER GUARDING is in place and that all doors are closed and se-
cured.
TO REMOVE OR REPLACE the collet closer it is necessary to remove the guard door at the
left end of the machine. Make certain that the guard door is in place before starting the 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 operat-
ing the machine. Always check the machine and work area for loose tools and parts especially
after work has been completed by maintenance personnel.
REMOVE CHUCK WRENCHES before starting the machine.
ii M-392D
BEFORE PRESSING THE CYCLE START PUSH BUTTON, make certain that proper functions
are programmed and that all controls are set in the desired modes.
KNOW WHERE ALL stop push buttons are located in case of an emergency.
CHECK THE LUBRICATION OIL LEVEL and the status of the indicator lights before operating
the machine.
MAKE CERTAIN that all guards are in good condition and are functioning properly before oper-
ating the machine.
INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good condi-
tion and are functioning properly before the cycle is started.
CHECK THE POSITION of the tool top plate before pressing the Cycle Start push button.
CHECK THE POSITION of any load/unload automation before pressing the Cycle Start push
button.
CHECK SETUP, TOOLING, AND SECURITY OF THE WORKPIECE if the machine has been
OFF for any length of time.
DRY CYCLE a new setup to check for programming errors.
MAKE CERTAIN that you are clear of any “pinch point” created by moving slides before starting
the machine.
DON’T OPERATE any equipment while any part of the body is in the proximity of a potentially
hazardous area.
DON’T REMOVE CHIPS with hands. Use a hook or similar device and make certain that all
machine movements have ceased.
BE CAREFUL of sharp edges when handling a newly machined workpiece.
DON’T REMOVE OR LOAD a workpiece while any part of the machine is in motion.
DON’T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing, neck-
ties, or long hair not contained by a net or shop cap.
DON’T ADJUST tooling or coolant hoses while the machine is running.
DON’T LEAVE tools, workpieces or other loose items where they can come in contact with a
moving component of the machine.
DON’T CHECK finishes or dimensions of workpiece near running spindle or moving slides.
DON’T JOG SPINDLE in either direction when checking threads with a thread gage.
DON’T ATTEMPT to brake or slow the machine with hands or any makeshift device.
ANY ATTACHMENT, TOOL, OR MACHINE MODIFICATION not obtained from Hardinge Inc.
must be reviewed by a qualified safety engineer before installation.
USE CAUTION around exposed mechanisms and tooling especially when setting up. Be care-
ful 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.
M-392D iii
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.
INSPECT ALL CHUCKING DEVICES daily to make certain that they are in good operating con-
dition. Replace any defective chuck before operating the machine.
Hardinge high speed spindles are balanced to an ISO G1.0 standard. High speed spindles re-
quire a work-holding device balanced to G2.5 or better.
USE MAXIMUM ALLOWABLE gripping pressure on the chuck. Consider weight, shape, and
balance of the workpiece.
USE LIGHTER THAN NORMAL feedrates and depth of cut when machining a workpiece diam-
eter 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 without
being adequately covered and properly supported.
FOLLOW each bar feed manufacturer’s guidelines. For performance and safe application, size
and use feed tube bushings, pushers, and spindle liners according to bar feed information.
MAKE CERTAIN that any bar feed mechanism is properly aligned with the spindle. If the bar
feed is a floor-mounted type, it must be securely bolted to the floor.
DURING HIGH SPEED APPLICATIONS, the bar stock must be contained within the collet
closer and a bar feed not be used. Hardinge Inc. Recommends using a bar loader for feeding
bar stock during high speed applications. Bar loaders feed the entire piece of bar stock into the
spindle; then, the pusher is disengaged from the bar stock.
UNLESS OTHERWISE NOTED, all operating and maintenance procedures are to be per-
formed by one person. To avoid injury to yourself and others, be sure that all personnel are
clear of the machine when opening or closing the coolant guard door and any access covers.
FOR YOUR PROTECTION - WORK SAFELY
iv M-392D
Table of Contents
CHAPTER 1 - OPERATOR CONTROL PANELS

Control Display Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manual Data Input Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Special Key Functions for Windows Operation . . . . . . . . . . . . . . . . . . . . . . 1-7
Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Control Interface Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Standard Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
PC-Based Operator Interface [Option] . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Stack Light [Option]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
On-Line Help System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
P/S Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Methods of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Accessing the On-Line Help System . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Alarm Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Operation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Exiting the On-Line Help System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
CHAPTER 2 - POWER-UP AND CONTROL STATUS

Power-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Machine Warm-Up Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Machine Warm-Up Program Structure . . . . . . . . . . . . . . . . . . . . . . . . 2-3
QUEST® 8/51 Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
QUEST 8/51 Lathe with Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . . 2-3
QUEST 10/65 Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
QUEST 10/65 Lathe with Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . 2-4
Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Reviewing Control Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Position Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Program Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Offset Setting Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
System Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Message Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
M-392D v
CHAPTER 3 - OPERATIONAL MODES AND EDITING
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Single Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Edit Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Word Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Word Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Editing a Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Altering a Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Inserting a Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Deleting a Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Deleting Up to an End of Block . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Deleting Data Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Deleting a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Edit Slow Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Continuous Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Incremental Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Manual Data Input Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Safe Start Subprograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Main Spindle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Sub-Spindle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Entering a Program from the Keyboard . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Activating a Stored Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Running a Part Program for the First Time . . . . . . . . . . . . . . . . . . . . . . 3-11
Stopping a Program Running in Automatic Mode. . . . . . . . . . . . . . . . . . . 3-12
Restarting a Stopped Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Dry Run and Machine Lock Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Activating Dry Run and Machine Lock . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Exiting Dry Run and Machine Lock . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Background Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Activating Background Edit Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Editing an Existing Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Creating a New Program from the Keyboard . . . . . . . . . . . . . . . . . . . . . 3-14
Ending Background Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Extended Part Program Editing [Option] . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Copy an Entire Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Copy Part of a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Move Part of a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Merge a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Search and Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Editing Machine Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Displaying the Program Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
vi M-392D
CHAPTER 4 - VDI TURRET TOP PLATE TOOLING
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Top Plate Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
QUEST® 6/42 & 6/42SP Lathe Turret Tooling Consideration. . . . . . . . . . . . . . . 4-2
Tool Holder or Tool Station Plug Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Tool Station Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Left-Hand / Right-Hand Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Square Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Reversible Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Installing Square Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Round Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Tool Holder Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Installing Round Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Removing Round Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
CHAPTER 5 - ESA TURRET TOP PLATE TOOLING

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Top Plate Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Tool Holder or Tool Station Plug Removal . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Tool Station Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Tool Station Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Left-Hand / Right-Hand Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Reversible Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Maximum Tool Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Installing Square Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Tool Holder Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Maximum Z Axis Tool Extension for Sub-Spindle Operation . . . . . . . . . . . . . 5-9
Installing Round Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
M-392D vii
CHAPTER 6 - HARDINGE TURRET TOP PLATE TOOLING
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Main Spindle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Qualified Tool Holders for Main Spindle Operation . . . . . . . . . . . . . . . . 6-1
Left-Hand / Right-Hand Tool Selection . . . . . . . . . . . . . . . . . . . . . . 6-2
Installing Square Shank Tooling. . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Between-Center Turning on QUEST® 6/42 Lathes . . . . . . . . . . . . . . . . 6-4
Sub-Spindle Operation [Option]. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Maximum Tool Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Cut-Off Tool Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Tooling Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Tooling Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Tool Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Tool Shank Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Mounting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Round Shank Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Tool Setting Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Installing Round Shank Tools for Main Spindle Operation . . . . . . . . . . . . . . 6-10
Installing Round Shank Tools for Sub-Spindle Operation. . . . . . . . . . . . . . . 6-12
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
CHAPTER 7 - WORK SHIFT

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Manually Establishing Z Axis Work Shift . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
VDI or ESA Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Hardinge Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
CHAPTER 8 - TOOL OFFSETS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Storing Tool Geometry Offsets in Memory . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Setting Tool Offsets for Non-Center Working Tools on the Turret . . . . . . . . . . 8-9
Setting Tool Offsets for Center-Working Tools on the Turret . . . . . . . . . . . . . 8-12
Tool Probe [Option]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Manual Tool Probe Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Semi-Automatic and Automatic Tool Probe Operation . . . . . . . . . . . . . . . . 8-16
Datuming the Tool Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Tool Probe Datum Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Semi-Automatic Tool Probe Operation . . . . . . . . . . . . . . . . . . . . . . 8-19
Automatic Tool Probe Operation . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Tool Probe Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Entering Tool Nose Radius Value and Orientation Code . . . . . . . . . . . . . . . . . 8-22
Adjusting Tool Wear Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Adjusting X and Z Axis Tool Wear Offsets . . . . . . . . . . . . . . . . . . . . . . 8-23
Rules for Adjusting Wear Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
viii M-392D
CHAPTER 9 - MAIN SPINDLE AND COLLET CLOSER
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Spindle Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Free Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Hydraulic Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Adjusting the Main Spindle Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . 9-2
Main Collet Closer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Chucking Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Switching the Chucking Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Cleaning the Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Removing Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Installing Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Collet or Step Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Jaw Chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Spindle Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Spindle Liner Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Boring a Bushing to Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Installing or Removing the Spindle Liner . . . . . . . . . . . . . . . . . . . . . . . 9-14
CHAPTER 10 - TAILSTOCK
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Travel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Tailstock Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Fixed Home Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Adjustable Home Position (Retract). . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Rapid-to-Feed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Overtravel Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Tailstock Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Cycle Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Overtravel Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Tailstock Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Manual Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Initiating Manual Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Stopping Manual Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Programmed Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Initiating Programmed Movement . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Stopping Programmed Movement. . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Checking and Adjusting Tailstock Feedrate . . . . . . . . . . . . . . . . . . . . . . . 10-8
Checking and Adjusting Tailstock Force . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Removing and Installing a Live Center . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Removing a Live Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Installing a Live Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
M-392D ix
CHAPTER 11 - INPUT/OUTPUT DEVICES
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Input/Output Device Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Input/Output Device Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
I/O Channel 0, 1, or 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
I/O Channel 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Standard Operator Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
PC-Based Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Selecting the Input/Output Device . . . . . . . . . . . . . . . . . . . . . . . 11-5
RS-232 Serial Port (NC Data) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Data Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Tape Parity Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Baud Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Stop Bits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Checking and Modifying Communications Parameters . . . . . . . . . . . . . . . . 11-7
RS-232 Port Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Baud Rate Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Stop Bit Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
RS-232 Serial Port (NC Data). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Uploading Data through the RS-232 Port . . . . . . . . . . . . . . . . . . . . . 11-9
Uploading Control Parameters into Control Memory. . . . . . . . . . . . . . 11-9
Uploading Part Programs into Control Memory . . . . . . . . . . . . . . . . 11-10
Uploading Tool Offsets into Control Memory . . . . . . . . . . . . . . . . . 11-11
Downloading Data through the RS-232 Port . . . . . . . . . . . . . . . . . . . 11-12
Downloading Control Parameters from Control Memory. . . . . . . . . . . . 11-12
Downloading Part Programs from Control Memory . . . . . . . . . . . . . . 11-13
Downloading Tool Offsets from Control Memory . . . . . . . . . . . . . . . 11-14
Integrated Input/Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Standard Operator Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
PC-Based Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18
CHAPTER 12 - OPERATOR MAINTENANCE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Machine Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Draining the Air Filter Bowls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Adjusting the Machine Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Standard Hydraulic Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Filling the Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Hydrostatic Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Filling the Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Coolant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Tramp Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Chip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
x M-392D
CHAPTER 13 - OPTIONS AND MISCELLANEOUS FEATURES
Machine Run Time Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Accessing the Run Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Resetting the Run Time Counter to Zero . . . . . . . . . . . . . . . . . . . . . . . 13-1
Machine Cycle Time Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Accessing the Cycle Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Clock Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Resetting the Clock Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Parts Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Accessing the Parts Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Resetting the Parts Counter to Zero . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Thread Cutting Cycle Retract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
High Pressure Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Bar Feed Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
English / Metric Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Establishing English / Metric Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Axis Thrust Limitation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Monitoring Axis Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Accessing the Axis Servo Tune Page. . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Adjusting Axis Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Part Catchers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Main Spindle Part Catcher [Option] . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Typical Part Unload Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Adjusting the Part Catcher for Part Length . . . . . . . . . . . . . . . . . . . . 13-10
Adjusting the Part Catcher Extend / Retract Speeds . . . . . . . . . . . . . . . 13-10
Adjusting the Part Basket Extend / Retract Speeds . . . . . . . . . . . . . . . . 13-11
Conveyor-Style Sub-Spindle Part Catcher [Option] . . . . . . . . . . . . . . . . . . 13-12
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Part Catcher M Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Part Catcher Gripper Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
Boring the Gripper Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
Changing the Gripper Pads . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Thru- Sub-Spindle Part Catcher [Option] . . . . . . . . . . . . . . . . . . . . . . . 13-17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Part Catcher Component Identification . . . . . . . . . . . . . . . . . . . . . . 13-18
Selecting Part Catcher Components . . . . . . . . . . . . . . . . . . . . . . . 13-18
Changing Part Catcher Components . . . . . . . . . . . . . . . . . . . . . . . 13-22
Changing Sub-Spindle Draw Tubes . . . . . . . . . . . . . . . . . . . . . . . . 13-25
Installing the Standard Draw Tube. . . . . . . . . . . . . . . . . . . . . . . 13-25
Installing the Part Catcher Draw Tube . . . . . . . . . . . . . . . . . . . . . 13-27
M-392D xi
Part Probe [Option] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29
Set-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29
Datuming the Part Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-31
Datuming the Part Probe on the X Axis . . . . . . . . . . . . . . . . . . . . . . 13-31
Datuming the Part Probe on the Z Axis . . . . . . . . . . . . . . . . . . . . . . 13-32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33
Cleaning Probe and OMM Unit Windows . . . . . . . . . . . . . . . . . . . . . . . 13-34
Changing the Probe Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-35
Sub-Spindle Part Present Detector [Option] . . . . . . . . . . . . . . . . . . . . . . . 13-36
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-36
Extending the Part Present Detector . . . . . . . . . . . . . . . . . . . . . . . . . 13-37
Range of Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-37
CHAPTER 14 - VDI LIVE TOOLING [Option]

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Types of Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Adjustable Dead Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Live Tooling Collets and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
VDI 30 Live Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
VDI 40 Live Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Live Tooling RPM Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Live Tooling Attachment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
Mounting the Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
Installing / Removing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
Live Tooling Attachment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-12
Live Tooling Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Cross-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
End-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
VDI 30 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
VDI 40 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Setting Tool Offsets for Live Tooling . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
Setting Offsets for End-Working Tools . . . . . . . . . . . . . . . . . . . . . . 14-14
Setting Offsets for Cross-Working Tools . . . . . . . . . . . . . . . . . . . . . 14-16
Tool Nose Radius Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
Live Tooling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
Live Tooling Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-18
Lubricating the Live Tooling Attachment . . . . . . . . . . . . . . . . . . . . . . . 14-18
Lubricating the Live Tooling Pinion Gears . . . . . . . . . . . . . . . . . . . . . . 14-19
Lubrication Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
VDI 30 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
VDI 40 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
Lubricating the Turret Index Shaft and Live Tooling Drive Shaft . . . . . . . . . . . 14-20
xii M-392D
CHAPTER 15 - ESA LIVE TOOLING [Option]
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Types of Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Live Tooling Collets and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Live Tooling Attachment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Mounting the Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Installing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Tool Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Live Tooling Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Cross-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
End-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Setting Tool Offsets for Live Tooling . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Setting Offsets for End-Working Tools . . . . . . . . . . . . . . . . . . . . . . 15-7
Setting Offsets for Cross-Working Tools . . . . . . . . . . . . . . . . . . . . . 15-9
Tool Nose Radius Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Live Tooling Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Live Tooling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
CHAPTER 16 - TOOL LIFE MANAGEMENT

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Tool Life Measurement Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Number of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Amount of Machining Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Tool Life Management Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
Bar Feed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
Determining Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . . . . 16-3
Verifying Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . . . . 16-3
Setting Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . . . . . 16-3
Determining the Measurement Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5
Verifying the Measurement Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5
Switching the Measurement Unit . . . . . . . . . . . . . . . . . . . . . . . . . 16-5
Resetting a Tool Group Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6
M-392D xiii
CHAPTER 17 - SUB-SPINDLE AND COLLET CLOSER [Option]
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
Cycle Start Safety Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
Free Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
Controlling Sub-Spindle Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
Automatic, Manual Data Input, or Single Mode . . . . . . . . . . . . . . . . . . . . 17-2
E Data Word. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
Feedrate Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Axis Direction Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Feedrate Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Rapid Traverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Moving the Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Handwheel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Moving the Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Sub-Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
Removing Sub-Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
Installing Sub-Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-6
Collet or Step Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-6
Jaw Chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-8
Sub-Spindle Collet Closer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-10
Hydraulic Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-10
Adjusting the Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 17-11
Sub-Spindle Collet Closer Operation . . . . . . . . . . . . . . . . . . . . . . . . . 17-12
Automatic Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-12
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-12
Chucking Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-12
Switching the Chucking Mode . . . . . . . . . . . . . . . . . . . . . . . . . 17-12
Main and Sub-Spindle Machining Set-Up and Operation. . . . . . . . . . . . . . . . . 17-13
Sample Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-14
Set Up and Machine Main Spindle Operation . . . . . . . . . . . . . . . . . . . 17-14
Set Up and Machine Sub-Spindle Operation . . . . . . . . . . . . . . . . . . . 17-15
APPENDIX ONE
Turret Travel Specifications
X and Z Axes
VDI 30 Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1
VDI 40 Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-2
ESA Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-3
Hardinge Turret Top Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
Y Axis [Option] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-5
Tailstock Travel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-6
Sub-Spindle Travel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-6
Work Envelope
Machine Equipped with Tailstock and VDI 30 Turret Top Plate. . . . . . . . . . . . A1-7
Machine Equipped with Tailstock and VDI 40 Turret Top Plate. . . . . . . . . . . . A1-8
Machine Equipped with Tailstock and ESA Turret Top Plate . . . . . . . . . . . . . A1-9
Machine Equipped with Tailstock and Hardinge Turret Top Plate . . . . . . . . . . A1-10
Machine Equipped with Sub-Spindle and VDI 30 Turret Top Plate . . . . . . . . . . A1-11
Machine Equipped with Sub-Spindle and VDI 40 Turret Top Plate . . . . . . . . . . A1-12
Machine Equipped with Sub-Spindle and ESA Turret Top Plate . . . . . . . . . . . A1-13
Machine Equipped with Sub-Spindle and Hardinge Turret Top Plate. . . . . . . . . A1-14
xiv M-392D
Sample Tooling Layouts
10 Station VDI 30 Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . A1-15
10 Station VDI 30 Turret Top Plate with Live Tooling . . . . . . . . . . . . . . . . . A1-16
12 Station ESA Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-23
12 Station ESA Turret Top Plate with Live Tooling . . . . . . . . . . . . . . . . . . A1-24
12 Station Hardinge Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . A1-25
Spindle Torque and Horsepower Curves
Main Spindle
QUEST® 6/42 Lathes
Standard Spindle Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-26
QUEST 8/51 Lathes
High Speed Spindle Drive, High Speed Range . . . . . . . . . . . . . . . . A1-28
High Speed Spindle Drive, Low Speed Range. . . . . . . . . . . . . . . . . A1-29
QUEST 10/65 Lathes
High Speed Spindle Drive, High Speed Range . . . . . . . . . . . . . . . . A1-31
High Speed Spindle Drive, Low Speed Range. . . . . . . . . . . . . . . . . A1-32
Sub-Spindle [Option]
Standard Spindle Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
High Speed Spindle Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-34
Live Tooling
VDI 30 and ESA Top Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-35
VDI 40 Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-36
Spindle Draw Tube Configurations
QUEST® 6/42 Lathes with Standard Spindle Drive . . . . . . . . . . . . . . . . . . A1-37
QUEST 8/51 Lathes with Standard Spindle Drive . . . . . . . . . . . . . . . . . . A1-38
QUEST 10/65 Lathes with Standard Spindle Drive . . . . . . . . . . . . . . . . . . A1-39
APPENDIX TWO
G Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-1
M Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-7
Operator Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-15
M-392D xv
- NOTES -
xvi M-392D
CHAPTER 1 - OPERATOR CONTROL PANELS
CONTROL DISPLAY PANEL
The control display panel is shown in Figure 1.1. The panel consists of the display screen with as-
sociated soft keys.
- NOTE -
The optional PC-based operator interface is equipped with a touch screen display.
The operator can select Windows functions by touching the display screen.
The operator can select CNC soft key functions through the use the soft keys or di-
rectly by touching the soft key functions displayed on the screen.
SOFT KEYS
The ten unlabeled soft keys have various functions, depending on which function key is
active. The function keys are located on the Manual Data Input panel. The soft key functions
are displayed at the bottom of the control display screen.
LEFT-HAND SOFT KEY
This key is used to return to the initial state after a function has been accessed by press-
ing a soft key.
RIGHT-HAND SOFT KEY
This key is used to display further soft key functions which are not currently displayed.
TI4154
Figure 1.1 - Control Display Panel

(18i-T Control Shown)
M-392D 1-1
MANUAL DATA INPUT KEYBOARD
The available Manual Data Input panels are shown in Figures 1.2 through 1.5. This panel consists
of keys relating to data input, data editing, and monitoring control functions.
Refer to page 1-7 for information on special key functions relating to the Windows operating system
on machines equipped with the optional PC-based operator interface.
ALTER
This key permits changes to an existing entry in an active program while in Edit mode.
Refer to Edit mode in Chapter 3.
This key is also used as the Tab key in the Windows environment on the optional
PC-based operator interface.
CAN (Cancel)
This key is used to cancel or delete the last character or symbol which has been entered
into the input buffer. It is also used, together with the appropriate function key, to clear the
Data displayed on the screen.
This key is also used as the Backspace key in the Windows environment on the optional
CURSOR CONTROL KEYS
The è and ç cursor control keys will shift the cursor forward or backward through the
program one Data word at a time.
The ê and é cursor control keys will shift the cursor forward or backward through the
program one Data block (program line) at a time.
CUSTOM
This key has no function on the standard operator interface.

This key is used as the Control key in the Windows environment on the optional Windows
based operator interface.
DATA INPUT KEYS
- NOTE -
Most alphabetic keys on the Manual Data Input keyboard are used to input more
than one character. The input from an alphabetic key is switched through the use of
the Shift key.
These keys are used to manually enter Data into the control. These keys input alphabetic,
numeric, and other characters. In addition to these keys, the Alter, Insert, Delete, Input, EOB
(End of Block), and Cancel keys are active. Data entered with the Data input keys is indi-
cated on a line near the bottom of the display screen.
1-2 M-392D
DELETE
This key causes the selected Data to be deleted. Refer to Edit mode in Chapter 3 for in-
formation on using the delete function.
EOB
This key is used to input an End of Block (;) character.
GRAPH
This key is used to graphically display the tool path while the program is being executed.
Machine motion will occur unless Machine Lock mode is active.
Refer to the GE Fanuc operator’s manual for a description of the graphics feature.
INPUT
This key is used to set Data, which has been entered into the input buffer area, into the
appropriate area in the control memory. Refer to Manual Data Input mode in Chapter 3.
INSERT
This key allows additional commands to be inserted in a program line while in Edit mode.
Refer to Edit mode in Chapter 3.
HELP
This key allows the operator to access the machine on-line help system. Refer to page
1-22 for information relating to the on-line help system.
This key is also used as the Escape key in the Windows environment on the optional
MESSAGE
This key allows the operator to display alarm messages and operator messages issued
by the machine control due to NC programming errors or machine hardware failures.
OFFSET SETTING
This key allows the setting and display of offset values. Refer to:
Reviewing Control Status, in Chapter 2
Chapter 7 - Work Shift
Chapter 8 - Tool Offsets
M-392D 1-3
TI3818
Figure 1.2 - Manual Data Input Panel

(Non-CE Mark Machines with Standard Operator Interface)
TI3874

(CE Mark Machines with Standard Operator Interface)
1-4 M-392D
Blank
Key
TI4730

(Non-CE Mark Machines with Optional PC-Based Operator Interface)
TI4731

(CE Mark Machines with Optional PC-Based Operator Interface)
M-392D 1-5
PAGE UP KEYS
PAGE DOWN KEYS
The Page keys are used to display information which requires more than one display
page. Pressing Page é or Page ê causes the control the display the previous or next page,
respectively.
POS (Position)
Pressing the Position key will display the position Data in one of three ways:
1. In the absolute mode of the work coordinate system by pressing the Absolute soft key.
2. In the relative coordinate system by pressing the Relative soft key.
3. In the overall mode, indicating relative, absolute, machine coordinate, and distance to go, by
pressing the All soft key.
Use the Page keys to switch between the various position display screens. Refer to
Chapter 2 for more information on the position display screens.
PROG (Program)
The Program function key allows the operator to perform the following:
In Edit mode - Edit and display program memory.
In Manual Data Input mode - Input and display Manual Data Input Data.
In Automatic mode - Display the active part program.
RESET
This key can be activated any time while a part program is being executed. When the Re-
set key is pressed, axis and spindle motion are stopped. The M and G codes are reset to
the power-up default status. The Reset key is also used to clear an alarm state after a fault
has been corrected.
- NOTE -
To return to the start of a main part program, select Edit mode and press Reset.
SYSTEM
This key allows the setting and display of parameters and diagnostic Data. Refer to Chap-
ter 2 for more information on the diagnostic and parameter screens.
1-6 M-392D
SPECIAL KEY FUNCTIONS FOR WINDOWS OPERATION
- NOTE -
The descriptions in this section relate only to machines equipped with the optional
The functions described in this section are discussed in terms of how they relate to the use of the
CNC Manual Data Input keyboard in the Windows environment. Refer to your Microsoft Windows
manual for additional information relating to the Windows operating system.
Refer to Figures 1.4 and 1.5 for key locations.
Alter Key This key is used as the Tab key
Blank Key This key is used as the Alternate key
Cancel Key This key is used as the Backspace key
Custom Key This key is used as the Control key
Help Key This key is used as the Escape key
Shift + 1 Inputs the left brace symbol: {
Shift + 2 Inputs the right brace symbol: }
Shift + R Inputs the caret symbol: ^
Shift + S Inputs the backslash symbol: \
Shift + T Inputs the tilde symbol: ~
Shift + U Inputs the underscore symbol: _
Shift + Graph Access a Windows pop-up menu (equivalent to right click on a mouse)
Custom + Help Toggles between the CNC display screen and the Windows Start Menu
When using the Custom/Help key combination to toggle from the Windows
Start Menu back to the Fanuc CNC screen, press the “CNC Screen Display
Function” icon at the bottom of the display to clear the Windows tool bar.
M-392D 1-7
OPERATOR CONTROL PANEL
- NOTE -
The functions described in this section are listed according to location on the opera-
tor control panel, from left to right. Refer to Figure 1.6.
SPECIAL MODES
BLOCK SKIP
Press this push button to alternately activate and deactivate Block Skip mode. When this
mode is active, the control will ignore any Data block preceded by a slash (/) code. The indi-
cator light is illuminated when Block Skip is active.
DRY RUN
- NOTE -
This mode must be OFF for normal machine operation.
Press this push button to alternately activate and deactivate Dry Run mode. When this
mode is active, programmed feedrates are ignored and cutting moves are performed at a
Jog feedrate of 50 inches per minute. The indicator light is illuminated when Dry Run is ac-
tive. Refer to Chapter 3 for information on using Dry Run mode.
G00
This push button is a momentary switch. Pressing this push button releases the Edit Slow
feature. Refer to Chapter 3 for information on Edit Slow mode.
MACHINE LOCK
- NOTE -
This mode must be OFF for normal machine operation.
Press this push button to alternately activate and deactivate Machine Lock mode. When
this mode is active, all axis and spindle motion is inhibited. M, S, and T functions are also
inhibited. The indicator light is illuminated when Machine Lock is active. Refer to Chapter 3
for information on using Machine Lock.
1-8 M-392D
AUTOMATION 1 2
MAIN SUB CCW CW
1+2
1 BOTH 2
MACH AUX
BLOCK OPTION MACHINE COOLANT PART
SKIP STOP LOCK ON/OFF CATCHER INC
1 2
G00 AUX
DRY REPEAT TOOL MAIN SUB
RUN MODE PROBE FREE DEC FREE
X Y 10X 100X
80
7 8 9 10 MDI EDIT 1X 25 50 60
100
6 11
5 12 Z E LOW 100 40
4 13 SINGLE RAPID REF 120
3 14 C1 C2 20
AUTO JOG
2 15 140
RAPID
1 16 REF 0% 150
F %
TURRET STATION MACHINE MODES % RAPID OVERRIDE % FEED RATE OVERRIDE F %
MANUAL AXIS MOVEMENT
INDEX
0
OPEN/ FEED CYCLE
A X/Y
- +
CLOSE HOLD START
MACHINE PROGRAM
POWER PROTECT Z/E Z/E GE/Fanuc
RAPID
0 1 TRAV
0 1 1
0 OPEN/
CLOSE
X/Y
B
C
Figure 1.6 - Operator Control Panel TI4666A
OPTION STOP
- CAUTION -
It is the responsibility of the part programmer to program the appropriate com-
mand to restart the spindle and coolant when program execution is resumed
after an Option Stop.
Press this push button to alternately activate and deactivate Option Stop mode. This func-
tion causes the control to stop execution of the part program AFTER executing an active
block which contains an M01 code. The M01 code is ignored when Option Stop is not ac-
tive. This function may be activated before or during execution of the block containing the
M01 code. The indicator light is illuminated when Option Stop is active. When a block con-
taining an M01 code is encountered and this function is active, the following occurs:
The block is executed.
All slide motion and spindle motion stops.
The coolant pump turns OFF and Feed Hold turns ON.
Option Stop can be activated in Dry Run mode. To resume program execution, press the
Cycle Start push button. The Feed Hold push button light will turn OFF.
REPEAT MODE
Press this push button to alternately activate and deactivate Repeat mode. This function
causes the active part program to cycle continuously. The indicator light is illuminated when
Repeat is active.
M-392D 1-9
MISCELLANEOUS FUNCTIONS
AUX (Auxiliary)
No Function.
COOLANT ON/OFF
This push button controls standard coolant operation. If coolant flow has been activated
by a programmed M08 (Coolant ON), M13 (Spindle Forward/Coolant ON), or M14 (Spindle
Reverse/Coolant ON), pressing this push button will stop the coolant flow. If coolant flow has
not been activated by the program, pressing this push button will start coolant flow even
though an M08, M13 or M14 has not been programmed. However, if the program is re-
peated the push button will not be active. The indicator light is illuminated when this function
is active.
PART CATCHER
This push button allows the operator to alternately extend and retract the main spindle
part catcher when the machine is in Jog mode. The indicator light is illuminated when the
part catcher is extended toward the spindle.
Refer to page 13-9 for additional information on the main spindle part catcher.
TOOL PROBE
This push button allows the operator to alternately deploy and stow the optional tool
probe when the machine is in Jog mode.
Refer to page 8-14 for additional information on the tool probe.
AUTOMATION
Option not available.
1-10 M-392D
SPINDLE CONTROL
MAIN SPINDLE / SUB-SPINDLE 1 2
When Jog mode is active, this switch allows the operator to select the main spindle or
sub-spindle as the spindle to be controlled by the push buttons in the Spindle area of the
machine control panel.
MAIN SPINDLE FREE 1
Press this push button to alternately activate and deactivate Main Spindle Free. When
Main Spindle Free is activated, the spindle brake is released and the operator may rotate
the main spindle by hand when Cycle Start is NOT active. The indicator light is illuminated
when Main Spindle Free is active.
SPINDLE CCW / SPINDLE CW
This switch allows the operator to select the direction for non-programmed spindle mo-
tion (as viewed from the main spindle end of the machine) when the machine is in Jog
mode. The spindle speed is controlled with the Spindle Increase Override and Spindle
Decrease Override push buttons. The push button indicator light is illuminated when one of
these functions is active.
SPINDLE INCREASE OVERRIDE
SPINDLE DECREASE OVERRIDE
These push buttons have two applications:

1. Controlling spindle speed for non-programmed clockwise or counterclockwise spindle mo-
tion:
a) Set the machine mode selector switch to Jog mode.
b) Use the Main Spindle / Sub-Spindle switch to select the appropriate spindle.
c) Use the Spindle CCW / Spindle CW switch to select the desired direction of rotation.
d) Initiate spindle rotation by pressing the Spindle Increase Override push button and release
to begin spindle motion. The first time this switch is pressed and released, the spindle
speed will begin rotating at approximately 25 rpm.
Use the Spindle Increase Override push button to increase spindle speed. The spindle
speed will increase by approximately 25 rpm each time this key is pressed.
Press the Spindle Decrease Override push button to slow the spindle.
e) To stop spindle motion, press the Reset key or press and hold the Spindle Decrease
Override push button until spindle motion ceases.
M-392D 1-11
2. Override programmed spindle speed while spindle is active in Auto mode:
Press the Spindle Decrease Override push button and release to decrease the spindle
speed in ten percent increments to a minimum of 50%. This push button is illuminated
when actual spindle speed is lower than the programmed spindle speed.
Press the Spindle Increase Override push button and release to increase the spindle
speed in ten percent increments to a maximum of 120%. This push button is illuminated
when actual spindle speed is higher than the programmed spindle speed.
Press the Spindle Increase Override and Spindle Decrease Override push buttons simul-
taneously to cancel the override function. The spindle speed will return to the pro-
grammed rate.
SUB-SPINDLE FREE 2
Press this push button to alternately activate and deactivate Secondary Spindle Free.
When Secondary Spindle Free is activated, the spindle brake is released and the operator
may rotate the secondary spindle by hand when Cycle Start is NOT active. The indicator
light is illuminated when Secondary Spindle Free is active.
1-12 M-392D
TURRET CONTROL
TURRET STATION
This rotary switch enables the operator to select the turret station to be indexed to the ac-
tive position when the Turret Index push button is pressed.
INDEX
- CAUTION -
The operator must be sure no interference exists within the machine work en-
velope before manually indexing the turret.
- NOTE -
The control must be in Jog mode to allow the Index push button to function.
Press the Index push button to command the turret to index to the station selected with
the Turret Station rotary switch.
MACHINE POWER
Switch “A”, Figure 1.6, turns the CNC control OFF when set to “0" and turns the CNC
control ON when set to ”1".
PROGRAM PROTECT
This switch is a two position, key operated switch. For normal operation, this switch
should be turned to the ON position. When this switch is turned to ON, parameters cannot
be edited and part programs cannot be edited or deleted. When this switch is turned to
OFF, parameters can be edited and part programs can be edited or deleted. The key should
be removed except when part program or parameter editing is required. The key cannot be
removed from the switch when Program Protect is turned OFF.
M-392D 1-13
MANUAL AXIS MOVEMENT
- NOTE -
Refer to Figures 1.7 and 1.8 for illustrations showing axis definitions.
MANUAL AXIS MOVEMENT SELECTOR SWITCH
C1 Selects the C1 axis for manual axis control. The C1 axis is radial motion of the main
spindle.
Z Selects the Z axis for manual axis control. The Z axis is linear motion of the turret paral-
lel with the spindle centerline.
X Selects the X axis for manual axis control. The X axis is linear motion of the turret par-
allel with the spindle face and parallel with the machine bed.
Y Selects the Y1 axis for manual axis control. The Y1 axis is linear motion of the turret
parallel with the spindle face and perpendicular with the machine bed.
E Selects the E axis for manual axis control. The E axis is linear motion of the tailstock or
sub-spindle parallel with the spindle centerline.
C2 Selects the C2 axis for manual axis control. The C2 axis is radial motion of the sub-spin-
dle.
-Z +Z
+X
Turret
-X
Main Spindle Sub-Spindle
-E +E TI4642A
Figure 1.7 - E, X, and Z Axis Definitions

(Shown with Optional Sub-Spindle)
1-14 M-392D
Z/E
The Z/E push buttons are momentary type switches that allow the operator to jog the se-
lected axis in the indicated direction. The axis to be jogged is selected through the use of
the Manual Axis Movement selector switch. Refer to Figure 1.7 for axis definitions. Active in
Jog mode.
X/Y
The X/Y push buttons are momentary type switches that allow the operator to jog the se-
lected axis in the indicated direction. The axis to be jogged is selected through the use of
the Manual Axis Movement selector switch. Refer to Figures 1.7 and 1.8 for axis definitions.
Active in Jog mode.
RAPID TRAV (Rapid Traverse)
This push button is a momentary type switch. Pressing this push button while simulta-
neously pressing one of the Jog directional push buttons causes the selected axis to move
at approximately 150 in/min [3800 mm/min]. Refer to Jog Mode, in Chapter 3.
MANUAL PULSE GENERATOR
Manual pulse generator “B”, Figure 1.6, allows the operator to jog the selected axis by
specific increments. The axis to be jogged is selected with the Manual Axis Movement
switch and the increment is selected with the Rapid Override switch.
+Y
+X
-Y
-X
d
Be
ne
hi
Spindle Centerline
ac
M
TI4656
Figure 1.8 - X and Y Axis Definitions

(Viewed from the Tailstock/Sub-Spindle End of the Machine)
M-392D 1-15
MACHINE MODES
AUTO
Automatic mode allows execution of the active part program and modification of part pro-
grams using the Back Edit function. The indicator light is illuminated when automatic mode
is active. Refer to Chapter 3 for an explanation of Automatic mode.
SINGLE (Single Block)
Single mode provides the operator with the ability to execute one block of Data each time
the Cycle Start push button is pressed. Canned cycles are executed one pass at a time. The
indicator light is illuminated when Single mode is active. Refer to the programmer’s manual
(M-391) for descriptions of the Canned Cycles.
MDI (Manual Data Input)
Manual Data Input mode allows manual input of a temporary program block. The indicator
light is illuminated when Manual Data Input mode is active. Refer to Chapter 3 for an expla-
nation of Manual Data Input mode.
EDIT
Edit mode allows the operator or programmer to edit a stored program when the Program
Protect key switch is in the OFF position. To deactivate Edit mode, select another operating
mode. The indicator light is illuminated when Edit mode is active. Refer to Chapter 3 for an
explanation of Edit mode.
RAPID REFERENCE
Rapid Reference mode allows the operator to move the machine axes to their respective
reference positions through the use of the Rapid Reference push button.
The X axis must be moved to the reference position before the Y1 or Z axis can be com-
manded to the reference position through the use of the Rapid Reference push button.
The Rapid Reference push button allows the machine operator to move the selected axis
to the reference position. The axis to be moved is selected through the use of the Manual
Axis Movement selector switch. Active in Rapid Reference mode.
The X axis must be moved to the reference position before the Y1 or Z axis can be
moved to the reference position.
JOG
Jog mode allows non-programmed movement of the axes. The indicator light is illumi-
nated when Jog mode is active. Refer to Chapter 3 for an explanation of Jog mode.
1-16 M-392D
% RAPID OVERRIDE F %
The Rapid Override switch has a dual function. Depending on which mode has been se-
lected, the functions are as follows:
In Jog mode, the operator can select the jog increment to be active when moving an
axis with the manual pulse generator. The movement distance per division on the manual
pulse generator is:
LINEAR AXES (E, X, Y1, Z)
X1 = .0001 inches [.001 millimeters]
ROTARY AXES (C1, C2)
X1 = .001 degree
X10 = .01 degree
X100 = .1 degree
In all other modes, the operator can modify the machine Rapid Traverse rate in steps
from Low to 100%. It is active in Positioning Mode (G00). The Rapid Override switch con-
trols the E, X, Y, and Z axes.
% FEEDRATE OVERRIDE F %
The Feedrate Override switch has a dual function. Depending on which mode has been
selected, the functions are as follows:
In Jog mode, the jog feedrate can be modified in predefined steps from 0 - 50 in/min
[1270 mm/min].
In all other modes, the operator can modify programmed feedrates from 0% - 150%. A
setting of “0" will stop G01, G02, & G03 motion.
M-392D 1-17
SUB OPEN / CLOSE 2
Pressing this push button while Cycle Start is NOT active will cause the work-holding de-
vice in the secondary spindle to alternately open and close. The push button will be illumi-
nated when the work-holding device is closed and will blink when the work-holding device is
open.
MAIN OPEN / CLOSE 1
Pressing this push button while Cycle Start is NOT active will cause the work-holding de-
vice in the main spindle to alternately open and close. The push button will be illuminated
when the work-holding device is closed and will blink when the work-holding device is open.
FEED HOLD
This push button is a latching type switch that allows the operator to stop all programmed
slide motion. However, the active spindle speed is not affected. Feed Hold can be activated
while in Automatic, Single Block, or Dry Run modes. Cycle Start turns OFF when Feed Hold
is activated. To resume normal operation after a feed hold, press Cycle Start. This push but-
ton is illuminated when Feed Hold is active.
CYCLE START
This push button is a latching type switch that initiates program execution when the con-
trol is in Automatic mode or Single mode. An additional function of this switch is to execute
Manual Data Input commands. This push button is illuminated when Cycle Start is active.
EMERGENCY STOP
- CAUTION -
DO NOT use the Emergency Stop push button to stop spindle rotation unless
an emergency actually exists.
- NOTE -
The operator must wait approximately ten seconds from the time the Emergency
Stop push button is pressed before attempting to clear the Emergency Stop.
Emergency Stop push button “C”, Figure 1.6, is a latching type switch. When pressed,
programmed slide motion and spindle rotation are stopped. The message “Emergency Stop”
is displayed on the control screen. To return to normal operation:
1. Correct the problem that prompted the Emergency Stop condition.
2. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the
push button out to the end of travel and release.
1-18 M-392D
CONTROL INTERFACE PORTS
STANDARD OPERATOR INTERFACE
The standard operator interface, shown in Figure 1.9, is equipped with 2 Data input/output ports:
• ATA Flash Card Port
• RS-232 Serial Port (25 pin)
Refer to Chapter 11 for information on using these input/output ports.
ATA Flash
Card Port
RS-232
Serial Port
TP4090
Figure 1.9 - Data Input/Output Ports

(Standard Operator Interface)
M-392D 1-19
PC-BASED OPERATOR INTERFACE [Option]
- CAUTION -
It is recommended that the control
be powered down before connecting
a keyboard or mouse to the CNC
control. ATA Flash
Card Port
- NOTE -
The universal serial bus (USB) ports Data Port
are not active on machines using the Cover
Microsoft Windows NT operating sys-
tem.
The PC-based operator interface is equipped with
the following:
• RS-232 Serial Port (15 pin) for PC Data RS-232 Port
for NC Data
• RS-232 Serial Port (25 pin) for NC Data TP4623A
• Universal Serial Bus (USB) Ports Figure 1.10 - Data Input/Output Ports
(Overall View)
• Keyboard Port
• Mouse Port
Refer to Figure 1.10 for the location of the ATA
flash card port and the RS-232 port used for NC Data
Keyboard
input/output.
Open the Data port cover, Figure 1.10, to gain ac- RS-232 Port
cess to the PC Data RS-232, universal serial, key- for PC Data
board, and mouse ports. Refer to Figure 1.11 for port
identification.
Mouse
Refer to Chapter 11 for information on using the
ATA flash card and RS-232 serial ports.
USB Port 1
USB Port 2
TP4624A
Figure 1.11 - PC and Data

Input/Output Ports
1-20 M-392D
STACK LIGHT [Option]
The optional stack light, shown in Figure 1.12, is located at the left end of the lathe. The stack light is
used to visually indicate the current status of the lathe.
The colors and definitions are listed below:
RED
Emergency Stop or alarm condition. Automatic cycle is stopped.
AMBER
The lathe is in Automatic mode, but automatic cycle is not active.
GREEN
Automatic cycle active. Normal operation.
TP4955
Figure 1.12 - Optional Stack Light
M-392D 1-21
ON-LINE HELP SYSTEM
GENERAL DESCRIPTION
The on-line help system provides information and instructions relating to P/S alarms, methods of
operation, and parameter tables.
P/S Alarms
- NOTE -
Only the more difficult to understand P/S alarms are supported by the on-line help
system.
Information and remedies concerning specific P/S alarms is supplied.
Methods of Operation
Information concerning CNC machining operations.
Parameter Table
Displays ranges of parameter numbers based on parameter functions.
ACCESSING THE ON-LINE HELP SYSTEM

Press the HELP key to access the on-line help system. The following menu will be displayed:
1. Alarm Detail
2. Operation Method
3. Parameter Table
- NOTE -
When viewing “Operation Method” or “Parameter Table” screens, the help system
will display two numbers in the upper right-hand corner of the screen; for example,
“¼". The upper number indicates the current page number and the lower number in-
dicates the total number of pages for that particular topic.
Alarm Detail
1. Press the “1 Alm” soft key.
2. Key in the alarm number and press the Select soft key. The alarm number and a detailed ex-
planation will be displayed.
3. Repeat step 2 as needed.
4. Exit the on-line help system. Refer to “Exiting the On-Line Help System”.
1-22 M-392D
Operation Method
1. Press the “2 Opr” soft key.
2. Key in the topic number and press the Select soft key. The selected topic and a detailed ex-
planation will be displayed.
3. Repeat step 2 as needed.
Parameter Table
1. Press the “3 Para” soft key. Page 1 of 4 will be displayed.
2. Use the page keys to view the various pages, as needed.
EXITING THE ON-LINE HELP SYSTEM
Press the Help key again or press any of the following function keys to exit the on-line help system:
- Message
- Offset / Setting
- Position
- Program
- System
M-392D 1-23
- NOTES -
1-24 M-392D
CHAPTER 2 - POWER-UP AND CONTROL STATUS
- CAUTION -
The recommended operating temperature range is 50° to 95° F [7° to 35° C].
POWER-UP PROCEDURE
- NOTE -
It is important that the power-up procedure is followed as described to ensure safe,
accurate, and repeatable machine operation.
1. Turn main disconnect switch “A”, Figure 2.1, ON.
2. Turn the main air valve on pressure regulator “B”,
Figure 2.2, ON.
- NOTE -
Refer to Chapter 12 for information on
draining the air filter bowls and refilling
A
the coolant tank.
3. Drain air filter bowls “C” and “D”.
4. Check the coolant level. If necessary, add coolant.
- CAUTION -
When turning the Control ON/OFF
switch to ON, DO NOT press any TP4109A
other push buttons or keys until the
position or alarm screen is dis- Figure 2.1 - Power Case Door
played. Some push buttons and keys
are used for control maintenance or
special operation commands.
5. Turn the Control ON/OFF switch to ON and wait B
until the CNC display screen is ON.
6. Pull the Emergency Stop push button out to the
first detent, wait two seconds; then, pull the push
button out to the end of travel and release.
7. Verify that the coolant guard door is closed.
8. Set the Machine Modes selector switch to Jog.
9. Set the Axis Selector switch to “E”.
10. Press the right-hand Z/E push button to move the C D
tailstock or optional sub-spindle to the reference
position. TP4101
Figure 2.2 - Air Control Assembly
M-392D 2-1
11. Open and close the coolant guard door to perform the guard door switch verification and clear
the verification alarm.
12. If the machine is equipped with a high-speed spindle and has been powered down for more
than 4 hours, proceed to Machine Warm-Up Program.
MACHINE WARM-UP PROGRAM

- CAUTION -
Factory-installed machine warm-up program O9000 will run the main spindle
and sub-spindle (if equipped) for 3 minutes intervals at the following speeds:
QUEST® 8/51 Lathes: 2000, 4000, 6000, and 8000 rpm.
QUEST 10/65 Lathes: 2000, 4000, and 6000 rpm.
If the tooling installed in the main spindle is NOT capable of these spindle
speeds, it will be necessary to copy and modify machine warm-up program
O9000 to reduce the spindle speed to the maximum rating of the spindle tool-
ing.
If the machine is NOT equipped with the optional Extended Part Program
Editing, refer to page 3-10 for information on entering a program from the key-
board.
If the machine is equipped with the optional Extended Part Program Editing,
refer to page 3-15 for information on copying part programs.
Refer to page 3-2 for information on editing a program.
- NOTE -
The factory-installed machine warm-up programs begin on page 2-3.
The machine warm-up program is only used on a machine that is equipped with a
high-speed spindle and has been powered down for more than 4 hours.
1. Set the Machine Modes selector switch to Automatic mode.
- NOTE -
The factory-installed machine warm-up program is O9000.
2. Select the machine warm-up program:
A) Key in:
“O9000” (Factory-installed machine warm-up program)
- or -
The number for the modified machine warm-up program (Refer to caution above)
B) Press the Cursor ê key.
3. Press the Cycle Start push button to execute the machine warm-up program.
2-2 M-392D
MACHINE WARM-UP PROGRAM STRUCTURE
- NOTE -
Refer to the appropriate warm-up program, based on the machine model and if the
machine is equipped with the optional sub-spindle.
QUEST® 8/51 LATHE
O9000 (WARM UP Q51) ;
G97 M3 S2000 P1 ;
G4 X180. ;
S4000 ;
G4 X180. ;
S6000 ;
G4 X180. ;
S8000 ;
G4 X180. ;
M30 ;
QUEST 8/51 LATHE WITH SUB-SPINDLE

O9000 (WARM UP Q51 WITH SUB) ;
G97 M3 S2000 P1 ;
M33 S2000 P2 ;
G4 X180. ;
S4000 P1 ;
S4000 P2 ;
G4 X180. ;
S6000 P1 ;
S6000 P2 ;
G4 X180. ;
S8000 P1 ;
S8000 P2 ;
G4 X180. ;
M30 ;
M-392D 2-3
QUEST® 10/65 LATHE
O9000 (WARM UP Q65) ;
G97 M3 S2000 P1 ;
G4 X180. ;
S4000 ;
G4 X180. ;
S6000 ;
G4 X180. ;
M30 ;
QUEST 10/65 LATHE WITH SUB-SPINDLE

O9000 (WARM UP Q65 WITH SUB) ;
G97 M3 S2000 P1 ;
M33 S2000 P2 ;
G4 X180. ;
S4000 P1 ;
S4000 P2 ;
G4 X180. ;
S6000 P1 ;
S6000 P2 ;
G4 X180. ;
M30 ;
2-4 M-392D
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 the main air valve on pressure regulator “B”, Figure 2.2, OFF
6. Turn main disconnect “A”, Figure 2.1, OFF.

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 and hold the Custom key; then, press the Help key to display the Windows Start menu.
4. Release the Custom key.
5. On the touch screen, press “Shut Down” to display the shut-down menu.
6. Select “Shut Down the Computer”.
7. Press “Yes” and wait for the Windows shut-down to be completed. The following message will
be displayed:
“It is now safe to turn off your computer”
9. Turn the Control ON/OFF switch to OFF.
10. Turn the main air valve on pressure regulator “B”, Figure 2.2, OFF
11. Turn main disconnect “A”, Figure 2.1, OFF.
M-392D 2-5
REVIEWING CONTROL STATUS
The following descriptions refer to the control status displays. Refer to Chapter 1 for additional in-
formation on the manual Data input keyboard:
POSITION KEY
There are three (3) pages of position display Data. After the Position key is pressed, the po-
sition display page that was last active will appear on the control display screen. To access the
other position display pages, press the appropriate soft key. The three position display pages
are as follows:
1. ALL (Overall Position Display): This page shows the active program number and block number
are displayed in the upper right-hand corner of the control display screen if the control is in
Automatic mode.
A) Relative: The axis position on the Relative Coordinate System. Position is displayed as U
and W coordinates.
B) Absolute: Axis position on the Work Coordinate System. After power-up, the origin of the
Work Coordinate System is the intersection of the spindle face and the spindle centerline.
Position is displayed as X and Z coordinates. This display can be modified by any one of the
following:
Active set of tool offsets
Position Reset operation
Work Shift offset
C) Machine: Displays the turret reference position in relation to the origin of the Work
Coordinate System, which is the intersection of the spindle face and the spindle centerline.
D) Distance to Go: This is the distance remaining between current axis position and the
programmed axis position. This register is displayed only while the control is in Automatic or
Manual Data Input mode.
2. Absolute Position Display. Refer to part “b” under “ALL (Overall Position Display)”.
3. Relative Position Display. Refer to part “a” under “ALL (Overall Position Display)”.
PROGRAM KEY
Press the Program soft key to display the active program number, and active block se-
quence number and eleven blocks of the active program on the control display screen. To dis-
play other pages of the program, select Edit mode and use the page keys to read through the
program.
During execution of the active part program, the cursor will be positioned under the se-
quence number of the active block.
If necessary, press the Reset key to return to the start of the program.
2-6 M-392D
OFFSET SETTING KEY
When the Offset Setting key is pressed, the Offset and Setting soft keys are displayed. From the
first Offset Setting screen, press the soft key expansion key once to display the Macro soft key. From
the first Offset Setting screen, press the soft key expansion key twice to display the Work Shift soft
key.
OFFSET SOFT KEY
Press the Offset soft key to access the geometry and wear soft keys.
One of the two chapters will be displayed on the control display screen. The displayed page
will be the page which was active when the Offset display was last viewed. To display the other
chapter, press the corresponding soft key. Use the Page keys to view other pages within a
chapter.
The tool geometry and wear offset chapters display the following information:
X and Z Tool Offsets (32 pair)
Tool nose radius values
Tool nose orientation numbers
SETTING SOFT KEY

Press the Setting soft key to access the system variables pages, which allows the operator
or programmer to assign the system variables listed below. To modify these variables, use the
page and cursor keys to move the cursor to the variable which is to be modified, enter the de-
sired value, and press the Input key.
Parameter Write = _(0:Disable 1: Enable)
TV Check = _(0:OFF 1:ON)
Punch Code = _(0:EIA 1:ISO)
Input Unit = _(0:MM 1:Inch)
I/O Channel = _(0-4:Channel No.)
Sequence No. = _(0:OFF 1:ON)
Tape Format = _(0:No CNV 1:ON)
Sequence Stop = _(Program No.)
Sequence Stop = _(Sequence No.)
Parameter Write
This parameter allows the control parameters to be edited. When set to “0", parameter
editing is disabled. When set to ”1", parameter editing is enabled. Refer to Chapter 3 for
information on editing machine parameters.
TV Check
This parameter allows the activation or deactivation of parity checking. When set to “1",
parity is checked from the beginning of each block to the beginning of the next block.
When set to ”0", vertical parity checking is disabled.
M-392D 2-7
Punch Code
This parameter allows the selection of EIA or ISO Data input format through the
RS-232 serial port. When set to “0", the Data input format is set to EIA. When set to ”1",
the Data input format is set to ISO.
Input Unit
This parameter allows the selection of metric or inch operating mode. When set to “0",
the operating mode is Metric. When set to ”1", the operating mode is set to Inch.
I/O Channel
This parameter allows the selection of the logical I/O to be used by the control. The
valid selections for the I/O port assignments are 0, 1, 2, or 4.
I/O port assignments 0, 1, and 2 are used to select the RS-232 serial port and
specify the port configuration.
I/O port assignment 4 is used to select the ATA Flash Card port on the standard
operator interface.
I/O port assignment 4 is used to select the following group of input/output devices
provided with the optional PC-based operator interface.
ATA Flash Card Port
RS-232 Serial Port
3½” Disk Drive
Internal Hard Disk
CD-ROM Drive
Refer to Chapter 11 for additional information on Data input/output.
Sequence No.
This parameter allows the selection of “automatic sequence number insertion”. When
active, sequence numbers will be automatically inserted into a program which is entered
into memory from the manual Data input keyboard. When set to “0", automatic sequence
number insertion is inactive. When set to ”1", automatic sequence number insertion is ac-
tive.
Tape Format
Not Active
Sequence Stop (2 entries)
These two entries are used together to provide the machine operator with the capabil-
ity of stopping automatic part program execution after the program block specified has
been completed.
The first entry (Program No.) identifies the program to be monitored.
The second entry (Sequence No.) identifies the sequence number (N word) of the last
block to be executed by the CNC control during normal automatic operation. Once this
block is executed, the CNC control will stop program execution.
Press the Cycle Start push button to resume program execution.
2-8 M-392D
MACROS SOFT KEY
Press the Macros soft key to display the macro variable registers.
WORK SHIFT SOFT KEY
Press the Work Shift soft key to display the work shift offset registers.
SYSTEM KEY
Press the System key to access the following information:
• Machine parameters and diagnostics
• PMC parameters, ladder, and diagnostics
• Control system configuration
One of four chapters will be displayed on the control display screen. The displayed page will be the
page which was active when the key was last deactivated. If necessary, press the soft key to display
the desired chapter. Use the page keys to view other pages within a chapter.
PARAMETER SOFT KEY
Press the Parameter soft key to display machine parameters. These parameters establish
many of the characteristics, specifications, and functions of the machine tool. The page that
was active when the parameter chapter was last exited will be displayed. To view other pages
within the chapter, press the Page key to move to the desired page. Refer to Chapter 3 for in-
formation on editing machine parameters.
DIAGNOSTIC SOFT KEY
Press the Diagnostic soft key to display the machine diagnostics chapter. The page that was
active when the diagnostics chapter was last exited will be displayed. Use the Page keys to
view other pages within the chapter.
PMC SOFT KEY
Press the PMC soft key to display the PMC information screen. The purpose of this screen is
to view the PMC ladder, parameters, and diagnostics.
SYSTEM SOFT KEY
Press the System soft key to display the control system information screen.
M-392D 2-9
MESSAGE KEY
If “ALM” is displayed at the bottom right-hand corner of the control display screen during machine
operation, press the Message key. After the Message key is pressed, one of the three chapters will be
displayed. To display one of the other chapters, press the appropriate soft key.
ALARM SOFT KEY
Alarm Message chapter. This chapter displays alarms that create a feed hold condition. One
alarm will be displayed on the control display screen at a time. The display is formatted to indi-
cate which tool station has generated the alarm. Descriptions of each alarm are given in the
alarm list in Appendix 2.
MESSAGE SOFT KEY
Operator Message chapter. Operator messages do not initiate a feed hold condition. They
call the operator’s attention to a specific machine condition.
HISTORY SOFT KEY
The control is capable of storing the last 25 alarms generated by the machine control. There
are a maximum of five pages, with up to five alarms per page. Use the Page keys to display
next or previous page.
- NOTE -
Alarm and Operator messages caused by an error generated in Background Edit
mode will have no affect on a part program that is executing in the foreground.
2-10 M-392D
- NOTES -
M-392D 2-11
- NOTES -
2-12 M-392D
CHAPTER 3 - OPERATIONAL MODES AND EDITING
AUTOMATIC MODE
- CAUTION -
Before executing any part program in Automatic mode, it is recommended that
the program be cycled through one time in Single mode. Refer to the instruc-
tions for “Running a Part Program for the First Time”, page 3-11.
Automatic mode allows selection and execution of the active part program. When Automatic mode
is active and the Program key is pressed, the following soft keys are displayed on the control display
screen:
Program
Check
Current
Next
Operator
Automatic mode is activated by the mode selector switch.
SINGLE MODE
Single mode allows the operator to execute one block of Data each time the Cycle Start push button
is pressed. Canned cycles are executed one pass at a time. Single mode is activated by the mode se-
lector switch.
Refer to the programmer’s manual (M-391) for descriptions of the Canned Cycles.
EDIT MODE
Edit mode allows creation of new part programs or modification of existing part programs held in
memory. There are two ways to search through the program: Word Scan and Word Search.
WORD SCAN
The Word Scan function permits the operator to search through the program one word or one line at
a time.
- NOTE -
The cursor is displayed below the address character of the selected word.
1. Use the cursor ç and è keys to move the cursor word by word on the screen.
2. Use the cursor é and ê keys to move the cursor line by line on the screen.
3. Continue pressing the cursor keys to make a continuous search.
4. Press the Page é or Page ê key to display the preceding or following pages and search for the
first word of that page.
M-392D 3-1
WORD SEARCH
Word Search permits a specified word to be searched for from the current cursor position using the
following procedure:
1. Key in the Data word to be searched for.
2. Press the cursor ê key to search forward or cursor é to search backward. If the Data word
entered in step 1 is located, the cursor will be displayed below the first character in the Data
word.
EDITING A PROGRAM
- NOTE -
When Edit mode is active and the Program Protect key is turned OFF, Edit Slow
mode is automatically activated. Refer to page 3-4 for information on Edit Slow
mode.
1. Set the mode selector switch to Edit mode.
- NOTE -
The Program Protect key MUST be turned to OFF to allow creating, editing, or delet-
ing of part programs.
2. Turn the Program Protect key to OFF.
3. Press the Reset key.
4. Activate the program as follows:
a) Press the Program key.
b) Key in the letter “O” followed by the number for the desired program.
Example: O1111
c) Press the cursor ê key.
5. Search for the word to be modified using the Word Scan or Word Search function.
6. Alter, insert, or delete the word/block/program as described in the sections that follow.
- CAUTION -
If the Reset key is not pressed before selecting Automatic mode and the part
program is executed, the program will begin executing at the point in the pro-
gram where the cursor was located when Edit mode was exited.
7. Press the Reset key to “rewind” the part program back to the beginning.
8. Turn the Program Protect key to ON.
3-2 M-392D
Altering a Word
- NOTE -
The cursor MUST be positioned under the word to be altered.
1. Use the Word Scan or Word Search function to locate the Data word to be changed.
2. Key in the letter address and the new value.
3. Press the Alter key.
Inserting a Word
- NOTE -
The cursor MUST be positioned under the word immediately preceding the location
of the new Data word.
1. Use the Word Scan or Word Search function to find the Data word or End of Block immedi-
ately preceding the point in the program where the new Data word will be inserted.
2. Key in the Data word to be inserted.
3. Press the Insert key.
Deleting a Word
- CAUTION -
The cursor MUST be positioned under the word which is to be deleted.
1. Use the Word Scan or Word Search function to find the Data word which is to be deleted.
2. Press the Delete key.
Deleting Up to an End of Block

1. Position the cursor at the point where the deletion is to begin.
2. Press the EOB (End of Block) key; then, press the Delete key.
- NOTE -
The Data between the cursor and the next End of Block character will be deleted.
The cursor will move to the address character of the next Data word in the program.
M-392D 3-3
Deleting Data Blocks
- NOTE -
In the procedure which follows, all Data from the cursor to, and including, the block
specified by the sequence number will be deleted. The cursor will move to the next
sequence number in the program.
1. Position the cursor at the point where the deletion is to begin.
2. Key in the sequence number (N word) where the deletion is to end.
3. Press the Delete key.
Deleting a Program
1. Press the Program key.
2. Key in the letter “O” and the number of the program to be deleted.
Example: O1111
3. Press the Delete key. The selected program will be deleted.
EDIT SLOW MODE

Edit Slow mode disables the Rapid Override switch and forces G00 positioning moves to be per-
formed at 39 in/min [990 mm/min]. This will occur whenever Edit mode is selected and the Program
Protect key is in the OFF position.
This mode will remain active until the G00 push button is pressed or an M30 (End of Program) is
read by the machine control
JOG MODE
- NOTE -
Refer to Spindle Control, beginning on page 1-11, for information on non-pro-
grammed spindle motion.
The Y1 axis controls the optional Y axis on the turret.
The E axis controls the tailstock or optional sub-spindle.
Jog mode permits non-programmed movement of the axes. Jog mode is activated by setting the
mode selector switch to Jog. While in Jog mode, use the axis direction push buttons or the manual
pulse generator to obtain the desired X, Y, Z, or E axis movement.
CONTINUOUS JOG
The Feedrate Override switch has a direct affect on the X, Y, Z, and E axis jog speeds. The jog
feedrate for the X, Y, Z, and E axes is approximately 25 in/min [635 mm/min] when the feedrate over-
ride switch is set to 100% and approximately 37.5in/min [952 mm/min] when the corresponding switch
is set to 150%. The Traverse push button will increase normal jog speeds. When the Traverse push
button is pressed along with one of the axis push buttons, the feedrate override switch is ignored and
the selected axis moves at approximately 236 in/min [6000mm/min]. Refer also to Incremental Jog.
3-4 M-392D
INCREMENTAL JOG
The manual pulse generator permits the cross slide or carriage to be moved incrementally when-
ever Jog mode is active. The axis to be moved is selected by using the selector switch in the Manual
Axis Movement section of the operator control panel. The movement increment is selected with the
Rapid Override switch. The selected axis will move incrementally when the handwheel is rotated. The
direction and distance is determined by the direction and amount of rotation of the handwheel.
- NOTE -
When moving the X axis with the machine in diameter mode, physical axis motion
will be one half the selected increment.
EXECUTING AN INCREMENTAL JOG
1. Set the mode selector switch to Jog mode.
- NOTE -
The X/Y and Z/E axis direction keys are also active and may be used to jog the
axes. Refer to Continuous Jog.
2. In the Manual Axis Movement section of the operator control panel, use the selector to select
the desired axis.
3. Set the Rapid Override switch to select the desired increment. Refer to Rapid Override, page
1-17, for information on increment selection.
4. To view axis position on the control display screen:
a) Press the Position key.
b) Press the Page key until the desired position display appears on the control display
screen.
5. Turn the handwheel in the desired direction (+ or -). Observe the axis position registers to
determine when the axis has been moved the required distance.
If the X axis was selected in step 2, turn the handwheel in the plus direction to move the
cross slide away from the spindle centerline and turn the handwheel in the minus direction
to move the cross slide toward the spindle centerline.
If the Y1 axis was selected in step 2, turn the handwheel in the plus direction to move the
turret away from the machine bed and turn the handwheel in the minus direction to move
the turret toward the machine bed.
If the Z axis was selected in step 2, turn the handwheel in the plus direction to move the
carriage away from the face of the main spindle and turn the handwheel in the minus direc-
tion to move the carriage toward the face of the main spindle.
If the E axis was selected in step 2, turn the handwheel in the plus direction to move the
tailstock or sub-spindle away from the face of the main spindle and turn the handwheel in
the minus direction to move the tailstock or sub-spindle toward the face of the main spin-
dle.
M-392D 3-5
MANUAL DATA INPUT MODE
Manual Data Input mode allows the operator to input a single block of non-stored Data into the
Manual Data Input memory. The Data can then be executed by pressing the Cycle Start push button.
Once the Data in the Manual Data Input memory has been executed, it is erased from memory.
USING MANUAL DATA INPUT
- NOTE -
Pressing the Reset key clears the Manual Data Input buffer.
1. Set the mode selector switch to Manual Data Input mode.
4. Enter the Data into the Manual Data Input buffer using the Data input keys. Each Data block
must end with a valid End of Block character.
- NOTE -
If an error is made while keying in the Data and the Insert key has not been pressed,
press the Cancel key and key in the correct Data.
5. Press the Insert key to input and display the Data from step 4 into the Manual Data Input
memory.
- NOTE-
To alter Data after it has been entered into the Manual Data Input memory, place the
cursor on the word, key in the correct Data, and press the Alter key. If it is necessary
to delete a word, place the cursor on the word and press the Delete key.
The collet closer must be in the closed position before an Manual Data Input com-
mand can be executed.
6. Close the coolant guard door and press the Cycle Start push button to execute the Data.
3-6 M-392D
SAFE START SUBPROGRAMS
Safe Start subprograms O1, O2, O3, O4, O998, and O999 have been developed by Hardinge Inc.
to provide machine safety and to help simplify programming. These programs are loaded perma-
nently into the control memory. The purpose of these programs is to reactivate start-up modes, for ex-
ample: positioning mode, deactivate Tool Nose Radius Compensation, establish ipm feed, and move
the turret to the safe index position.
Refer to the programmer’s manual (M-391) for more information on the Safe Start programming
format.
- CAUTION -
If the machine is to be run in metric mode, the Z entry (pullback) in
subprogram O2 must be converted to a metric value.
The operator should be aware that program O999 is used for the main spindle
ONLY. To avoid crash situations, program O998 must be used for the
sub-spindle.
(Continued on next page)
M-392D 3-7
MAIN SPINDLE OPERATION
- CAUTION -
The Z axis coordinate defined in subprogram O999 MUST be programmed as a
POSITIVE number.
When machining on the main spindle, the safe index coordinates are defined by subprogram O999.
The X axis safe index coordinate should be set to the X axis reference position and the Z axis safe in-
dex coordinate should be set to the length of the longest tool PLUS 1 inch [25.4 mm].
Refer to Figure 3.1 or 3.2.
Subprogram O1 is used to exit the workpiece after performing an external machining operation on
the workpiece.
Subprogram O2 is used to exit the workpiece after performing an internal machining operation on
the workpiece.
Subprogram O999 is not called directly from the part program. Subprograms O1 and O2 call
subprogram O999, which is used to deactivate the tool offset and command the turret to the safe index
position.
+X
+X
+Z
+Z
Safe Index = Z + 1” [25.4 mm] Safe Index = Z + 1” [25.4 mm]

TI4691 TI4743
Figure 3.1 - Z Axis Safe Index Value Figure 3.2 - Z Axis Safe Index Value
for Main Spindle Operations for Main Spindle Operations
(VDI Turret Top Plate) (Hardinge Turret Top Plate)
3-8 M-392D
SUB-SPINDLE OPERATION
- CAUTION -
The Z axis coordinate defined in subprogram O998 MUST be programmed as a
NEGATIVE number.
When machining on the sub-spindle, the safe index coordinates are defined by subprogram O998.
The X axis safe index coordinate should be set to the X axis reference position and the Z axis safe in-
dex coordinate should be set to the length of the longest tool PLUS 1 inch [25.4 mm].
Refer to Figure 3.3 or 3.4.
Subprogram O3 is used to exit the workpiece after performing an external machining operation on
the workpiece.
Subprogram O4 is used to exit the workpiece after performing an internal machining operation on
the workpiece.
Subprogram O998 is not called directly from the part program. Subprograms O3 and O4 call
subprogram O998, which is used to deactivate the tool offset and command the turret to the safe index
position.
+X
+X
+Z
+Z
Z Z
Safe Index = Z + 1” [25.4 mm] Safe Index = Z + 1” [25.4 mm]

TI4692 TI4744
Figure 3.3 - Z Axis Safe Index Value Figure 3.4 - Z Axis Safe Index Value
for Sub-Spindle Operations for Sub-Spindle Operations
(VDI Turret Top Plate) (Hardinge Turret Top Plate)
M-392D 3-9
PROGRAMS
ENTERING A PROGRAM FROM THE KEYBOARD
- NOTE-
Refer to Chapter 1 of the programmer’s manual (M-391) for a description of the Data
words used with this machine.
Refer to Chapter 11 of this manual for information on loading part programs from
tape, disk, or ATA flash card.
4. Key in the letter and the program number at the Manual Data Input panel.
Example: O1111
6. Press the EOB (End of Block) key.
8. Enter each Data block as follows:
A) Key in the letter addresses and values.
B) Press the EOB (End of Block) key.
C) Press the Insert key.
9. Turn the Program Protect key to ON.
ACTIVATING A STORED PROGRAM

1. Set the mode selector switch to Automatic mode.
3. Key in the letter “O” followed by the number for the desired program.
Example: O100
4. Press the cursor ê key.
3-10 M-392D
RUNNING A PART PROGRAM FOR THE FIRST TIME
- CAUTION -
Before executing any part program, be sure that all offsets are correct and that
no interference exists in the working area of the machine tool.
Operator should check and if necessary alter the coordinate values pro-
grammed in Safe Index Subprogram O998 or O999 to be certain that they are
sufficient. Refer to “Editing a Program”, page 3-2, for instructions to edit an
active program.
When Cut-off and Feed Stock are the first operations on bar work, the operator
must make certain that the stock face is placed flush with the collet face be-
fore starting the cycle. This will ensure that the turret tooling will not come in
contact with workpiece and cause damage to either the turret tooling or the
workpiece.
When testing an operation that uses a self-releasing tap or die holder, activate
Automatic mode immediately before the block containing the spindle reversal.
After the Option Stop (M01) is read at the end of the tap or die operation, acti-
vate Single mode to test the remainder of the program.
3. Activate the desired program.
4. Set the mode selector switch to Single mode.
5. Close the guard door.
6. Press the Check soft key.
- NOTE -
Program Check displays the Absolute Position and Distance to Go to complete the
move.
7. Press the Option Stop push button.
- NOTE -
Single mode is used for first part set up (Block-by-Block execution). Automatic mode
is used to run part programs in automatic mode.
8. Turn the Rapid Override switch to LOW.
9. Turn the Feedrate Override switch to 10%.
- NOTE -
Setting the Rapid Override switch to LOW causes non-cutting linear moves (G00) to
be made at 39 in/min [990 mm/min].
Turning Feedrate Override switch to “0" stops X, Y, Z, and E axis motion. When the
switch is turned to another setting axis motion will resume.
10. Press the Cycle Start push button to execute each block of Data.
M-392D 3-11
STOPPING A PROGRAM RUNNING IN AUTOMATIC MODE
- CAUTION -
Pressing either the Reset key or the Emergency Stop push button while a pro-
gram is running in Automatic mode will leave the tool against the workpiece if
performed at the wrong time. DO NOT stop the program with a tool against the
workpiece unless absolutely necessary. Damage to the workpiece and/or tool-
ing may result.
There are several ways to stop a program running in Automatic mode:
1. Program a stop command in the part program where it is to be stopped.
2. Press the Feed Hold push button.
- NOTE -
Automatic operation can be restarted by pressing the Cycle Start push button when
the Feed Hold push button has been used.
4. Press the Emergency Stop push button
RESTARTING A STOPPED PROGRAM

If the program was stopped by pressing the Emergency Stop push button, perform steps 1 through
5.
If the program was stopped by pressing the Reset key, perform steps 4 through 6.
3. Key in the letter “O”; then, press the cursor é key. The control will go to the beginning of the
program.
4. If it is necessary to restart the program at a point other than the beginning:
- CAUTION -
Be sure the block selected in the next step is a safe starting point for the de-
sired operation.
A) Key in the letter “N” and the block number for the restart point. For example, “N5".
B) Press the cursor ê key. The control will search the program for the block specified in the
previous step.
5. Press the Cycle Start push button. Program execution will resume at the block specified in step
4.
3-12 M-392D
DRY RUN AND MACHINE LOCK MODES
- CAUTION -
If Machine Lock is not activated with Dry Run, slide motion will occur at a jog
feedrate that is controlled using the Feedrate Override switch. The operator
must make certain that no interference exists between the tooling, workpiece,
or spindle before running the machine in Dry Run.
- NOTE -
Feedrate override has a direct affect on the Dry Run feedrate. When Dry Run mode
is active, axis motion will occur at a feedrate of 100 in/min [2540 mm/min] when the
feedrate override is set to 100%. When the feedrate override is set to zero, axis mo-
tion and program execution are inhibited.
Cycle Start must be inactivate before Dry Run and Machine Lock modes can be activated. Acti-
vating Dry Run and Machine Lock modes together allows the operator to execute part programs with-
out axis or spindle motion.
ACTIVATING DRY RUN AND MACHINE LOCK

1. Set the mode selector switch to Automatic mode.
2. Activate the program.
3. Press the Machine Lock push button and Dry Run push button.
4. Close the coolant guard door.
5. If it is desired to run the program block-by-block, set the mode selector switch to Single
mode.
- NOTE -
If Single mode is active, the Cycle Start push button must be pressed for each pro-
gram block.
6. Press the Cycle Start push button.
EXITING DRY RUN AND MACHINE LOCK
1. Press the Machine Lock push button and Dry Run push button to deactivate Dry Run and
Machine Lock modes.
2. Turn the control OFF, wait a few seconds; then, turn the control ON.
M-392D 3-13
BACKGROUND EDIT
The Background Edit function enables the operator or programmer to edit or create a part program
while a second program is being executed by the machine tool. An alarm or warning in Background
Edit mode does not affect the program being executed in the foreground or vice-versa.
ACTIVATING BACKGROUND EDIT MODE

1. Turn the Program Protect key to the OFF position.
3. Press the Operator soft key.
4. Press the Background Edit soft key.
- NOTE -
The editing functions which may be performed in Background Edit mode are the same as the fore-
ground editing functions. Descriptions of the foreground editing functions begin on page 3-3.
EDITING AN EXISTING PROGRAM

1. Activate Background Edit mode.
2. Key in the letter “O” and the desired program number.
3. Press the cursor ê key.
CREATING A NEW PROGRAM FROM THE KEYBOARD
1. Activate Background Edit mode.
2. Key in the letter “O” and the desired program number.
6. Refer to “Entering a Part Program from the Keyboard”, page 3-10.
ENDING BACKGROUND EDITING
- CAUTION -
If the Reset key is pressed while Background Edit is active, the part program
that is being executed will stop and the offset will be canceled. The operator
must escape Background Edit (Press the Background End soft key) to return
to the main program. With the main program displayed, the operator must jog
the turret to a safe area and restart the program at the beginning of the tool
operation.
1. Press the Background End soft key.
2. Turn the Program Protect key to the ON position.
3-14 M-392D
EXTENDED PART PROGRAM EDITING [Option]
INTRODUCTION
Extended Part Program Editing provides the following capabilities:
• Copy or move all or part of a program to another program
• Merge a program at any location within another program
• Search for or replace a Data word in a program
COPY AN ENTIRE PROGRAM

This procedure creates a new program by duplicating an existing program.
1. Select Edit mode.
4. If necessary, activate the source program as follows:
b) Key in the letter O followed by the number for the desired program.
Example: O1111
c) Press the Cursor ê key.
6. Press the right-hand soft key.
7. Press the Extended Edit soft key.
8. Press the Copy soft key.
9. Press the All soft key.
10. Key in only the number for the new program. DO NOT key in the letter “O”.
11. Press the Input key.
12. Press the Execute soft key.
13. If editing is complete, turn the Program Protect key to the ON position.
M-392D 3-15
COPY PART OF A PROGRAM
This procedure creates a new program by duplicating part of an existing program.
Example: O1111
8. Press the Copy soft key.
9. Select the beginning of the range to be copied by moving the cursor to the beginning of the
range and pressing the CRSL~ soft key.
10. Select the end of the range to be copied by:
Moving the cursor to the end of the range and pressing the ~CRSL soft key.
- or -
Pressing the ~BTTM soft key to indicate the end of the program as the end of the range to
be copied.
3-16 M-392D
MOVE PART OF A PROGRAM
This procedure creates a new program by extracting part of an existing program. The selected
range will be removed from the original program.
Example: O1111
8. Press the Move soft key.
9. Select the beginning of the range to be moved by moving the cursor to the beginning of the
range and pressing the CRSL~ soft key.
10. Select the end of the range to be moved by:
Moving the cursor to the end of the range and pressing the ~CRSL soft key.
- or -
Pressing the ~BTTM soft key to indicate the end of the program as the end of the range to
be moved.
M-392D 3-17
MERGE A PROGRAM
This procedure inserts a copy of the specified existing program within the currently active program.
Example: O1111
8. Press the Merge soft key.
9. Select the location where the specified program will be inserted by:
Moving the cursor to the position where the program is to be inserted and pressing the
~CRSL soft key.
- or -
Pressing the ~BTTM soft key to indicate the end of the program as the position where the
program is to be inserted.
10. Key in only the number for the program to be inserted. DO NOT key in the letter “O”.
3-18 M-392D
SEARCH AND REPLACE
This procedure locates or replaces the specified Data.
4. If necessary, activate the program as follows:
Example: O1111
- NOTE -
Be sure the cursor is located at the appropriate position in the program. The search
or replace function will begin at the cursor position.
8. Move the cursor to the desired position in the program.
9. Press the Change soft key.
- NOTE -
A maximum of 15 characters can be input when specifying the Before or After Data.
Data words specified as Before or After Data must be valid Data words.
10. Key in the Data word to be replaced.
11. Press the Before soft key.
12. Key in the new Data word.
13. Press the After soft key.
14. Press the Execute soft key to replace all occurrences of the specified Data word.
- or -
Press the Execute Single soft key to individually replace each occurrence the specified
Data word.
- or -
Press the Skip soft key to search for the first occurrence of the specified Data word.
15. When editing is complete, turn the Program Protect key to the ON position.
M-392D 3-19
EDITING MACHINE PARAMETERS
- CAUTION -
Use extreme caution when editing machine parameters. Making incorrect
changes in the parameter table may disable the machine or cause undesirable
machine behavior.
1. Press the Offset Setting key.
2. Press the Setting soft key.
3. If necessary, use the page up/down keys to display the Setting page that contains the Pa-
rameter Write field.
4. If necessary, use the cursor keys to move the cursor to the Parameter Write field.
5. Set the mode selector switch to Manual Data Input mode.
7. Key in the number “1" to enable parameter editing.
- NOTE -
The control is placed in P/S alarm No. 100.
9. Press the System key.
10. Press the Parameter soft key.
11. Use the page and/or cursor keys to position the cursor on the parameter to be modified.
12. Key in the new parameter value.
14. Repeat steps 11 through 13 as needed.
17. If necessary, use the page up/down keys to display the Setting page that contains the Pa-
rameter Write field.
18. If necessary, use the cursor keys to move the cursor to the Parameter Write field.
19. Key in the number “0" (zero) key to disable parameter editing.
21. Turn the Program Protect key to the ON position.
3-20 M-392D
22. Press the Reset key to cancel P/S alarm No. 100 .
- NOTE -
Depending on which parameters have been modified, the control may output P/S
alarm No. 000. If this alarm message is displayed, it will be necessary to re-initialize
the control using the following procedure:
A) Press the Emergency Stop push button.
B) Press the Control OFF push button.
C) Wait approximately ten seconds.
D) Press the Control ON push button.
E) Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the
DISPLAYING THE PROGRAM DIRECTORY

Use the following procedure to display program memory:
3. Press the Library soft key. The program library (directory) will be displayed.
M-392D 3-21
- NOTES -
3-22 M-392D
CHAPTER 4 - VDI TURRET TOP PLATE TOOLING
INTRODUCTION
®
QUEST series lathes are available with VDI ESA, or Hardinge turret top plates.
Refer to Chapter 5 for information on tooling for ESA turret top plates.
Refer to Chapter 6 for information on tooling for Hardinge turret top plates.
TOP PLATE CONFIGURATIONS

- CAUTION -
Refer to page 4-2 for information concerning turret tooling for QUEST 6/42 &
6/42SP lathes equipped with the following combination of options:
• 12 or 16 station VDI 30 top plate
• Tool probe
• Sub-spindle part present detector
QUEST series lathes are available with the following VDI top plate configurations:
QUEST 6/42 & 6/42SP lathes
• 12 station VDI 30 top plate
QUEST 8/51, 8/51SP, 10/65 & 10/65SP lathes
A live tooling option is available for the VDI top plate. Refer to Chapter 14 for information on live
tooling for the VDI top plate.
M-392D 4-1
QUEST® 6/42 & 6/42SP LATHE TURRET TOOLING CONSIDERATION
- CAUTION -
A potential interference condition exists on QUEST 6/42 & 6/42SP lathes
equipped with the following combination of options:
• Tool probe
The retract position of the sub-spindle part present detector on machines equipped with this combi-
nation of options has been adjusted to avoid interference with the tool probe during part transfer be-
tween the main spindle and the optional sub-spindle. Refer to Figure 4.1.
When machining on the sub-spindle, the new position of the part present detector could cause in-
terference with the tool in the turret station immediately above the active turret station. It is possible to
avoid this potential interference condition by doing either of the following:
• Install a short tool holder in the turret station immediately above the active turret station
if all turret stations are required for tooling
• Install a tool plug in the turret station immediately above the active turret station if all
turret stations are not required
Refer to page 13-36 for additional information relating to the optional part present detector.
4-2 M-392D
Potential Interference
with this Tool Holder
Part Present Detector Retracted
(Adjusted Position)
Turret Top Plate
Part Present Detector Retracted
(Standard Position)
Tool Probe Mounted

on Machine Headwall
Active Turret Station
Sub-Spindle
TI5348
Figure 4.1 - Sub-Spindle Part Present Detector and

Tool Probe Viewed from Left End of Machine
M-392D 4-3
TOOL HOLDER OR TOOL STATION PLUG REMOVAL
- WARNING -
When removing a tool holder or tool station plug from a top plate, have a firm
grip on the tool holder or tool station plug while loosening the clamp screw in
the top plate.
The turret is pressurized to prevent fluid contaminants from entering the turret assembly. The air
pressure in the turret may cause the tool holder or tool station plug to begin moving out of the top plate
when the clamp screw is loosened.
TOOL STATION PLUGS

- CAUTION -
Failure to install tool station plugs at turret tool stations not equipped with
tooling can result in damage to the machine tool.
DO NOT use the plastic tool station plugs when operating a machine equipped
with high pressure coolant.
All QUEST® series lathes are shipped with plastic
tool station plugs installed in the turret top plate.
Lathes equipped with the high pressure coolant
option are also supplied with steel tool station plugs.
The steel tool station plugs must be used in place of
the plastic plugs on machines equipped with high
pressure coolant.
Install a tool station plug at each turret tool station
not equipped with tooling. Refer to Figure 4.2 for an il-
lustration of a tool station plug. TI4263A
Figure 4.2 - Tool Station Plug

PLUG INSTALLATION
1. Thoroughly clean the top plate and tool station
plug. A B
2. Clean and check the O-ring on the tool station
plug to be sure the O-ring is in good condition.
3. Aligning tool station plug “B” with coolant
button “C”, insert the plug into the turret top C
plate as shown in Figure 4.3.
4. Tighten clamp screw “A”.
TI4681
Figure 4.3 - Installing a Tool Station Plug
4-4 M-392D
LEFT-HAND / RIGHT-HAND TOOL SELECTION
Hardinge Inc. recommends that all cutting forces be directed into the machine base. Directing the
cutting forces into the machine base will result in maximum tool life.
Making the selection between left-hand or right-hand tooling should be based on:
• the position of the tool in relation to the spindle
• the direction of spindle rotation
TOOL HOLDERS
Hardinge Inc. offers tool holders in various lengths as measured from the edge of the turret top
plate. The standard tool holders can be mounted in any of the top plate tool positions; however, if the
machine has the Y axis option and it is programmed to be moved below the spindle centerline, a
shorter Y-axis tool holder MUST be mounted in the top plate tool position nearest the way cover to
maintain tooling clearance.
SQUARE SHANK TOOLS

BASIC CONFIGURATION
Square shank tool holders obtained from Hardinge Inc. that are designed for QUEST® series lathes
are available for ¾", 1”, 20 mm, or 25 mm tooling.
Square shank tools are held in the tool holder by clamping block “G”, Figure 4.4. Clamp screws “D”
and “F” apply force to the clamp block to secure the tool in the tool holder. Spring-loaded screw “E” is
used to hold the clamp block in place when tension is removed from the clamping screws.
When installing or removing square shank tooling, do not remove spring-loaded screw “E”.
Clamping block “G” is held in the tool holder by the spring-loaded screw.
REVERSIBLE TOOL HOLDERS

Square shank tool holders obtained from
Hardinge Inc. that are designed for QUEST series
lathes are capable of using left-hand or right hand D E F G
tooling. Refer to “Left-Hand / Right-Hand Tool Selec-
tion”, above.
1. Carefully remove screw “E”, the spring, and
clamp block “G”.
2. Remove clamp screws “D” and “F”.
3. Thoroughly clean the tool holder body and all
components that were removed.
4. Install clamp block “G”, the spring, and screw TI4158
“E” on the upper or lower side of the tool holder,
as needed. Figure 4.4 - Basic Square
Shank Tool Holder
5. Install clamp screws “D” and “F”.
M-392D 4-5
INSTALLING SQUARE SHANK TOOLS
- CAUTION -
Refer to the Maximum Tool Extension table shown below.
Refer also to Figures 4.5 and 4.6.
Maximum Tool Extension

Turret Top Plate Maximum Tool Extension
Y Axis Option
Configuration Inches [Millimeters]
No 6.985 [177.4]
VDI 30
Yes 5.605 [142.4]
No 7.575 [192.4]
VDI 40
Yes 6.195 [157.4]
- NOTE -
Hardinge recommends that tooling be selected that will direct all cutting forces into
the machine base. Refer to Left-Hand / Right-Hand Tool Selection, page 4-5.
The recommended tool mounting position is to have the tool seated against the edge
of the tool holder, as shown in Figures 4.5 and 4.6.
1. Thoroughly clean the top plate, tool holders, and tooling.
2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition.
- CAUTION -
Be sure the tool holder is mounted flush against the side of the turret top
plate, as shown in Figure 4.8.
3. Aligning tool holder “H” with coolant button “I”, insert the tool holder shank into the turret top
- NOTE -
Maximum torque for the clamp screw is 17 lb-ft [23 N•m] on VDI 30 top plates and
33 lb-ft [45 N•m] on VDI 40 top plates.
4. Tighten clamp screw “J”.
- CAUTION -
Be sure the tool sits squarely in the slot of the tool holder.
5. Mount the tool in the tool holder and tighten two clamp screws “K”, Figure 4.8.
4-6 M-392D
Inches [Millimeters]
Turret
Top Plate
Standard Turret: 6.985 [177.4]

Y-Axis Turret: 5.605 [142.4]
Recommended Tool
Main Mounting Position
Spindle
TI4673A
Figure 4.5 - Square Shank Tool Installation

(Main Spindle Operation)
Turret
Top Plate

Y-Axis Turret: 5.605 [142.4]
Recommended Tool
Mounting Position Optional
Sub-Spindle
TI4684A
Figure 4.6 Square Shank Tool Installation

(Sub-Spindle Operation)
M-392D 4-7
J
TI4674
Figure 4.7 - Mounting a Square Shank Tool Holder
Be sure the tool holder is flush against

the side of the turret top plate.
TI4675
Figure 4.8 - Square Shank Tool Holder with Tool

(Viewed from the Main Spindle)
4-8 M-392D
ROUND SHANK TOOLS
TOOL HOLDER CAPACITIES
- NOTE -
Refer to the appropriate tooling catalog for information on tool holders and bushings.
Round shank tool holders for QUEST® series lathes are available from Hardinge Inc. in the follow-
ing capacities:
Turret Top Plate English Metric
Configuration Capacities Capacities
¾ inch 20 millimeters
VDI 30 1 inch 25 millimeters
1¼ inch 32 millimeters
VDI 40 1½ inch 40 millimeters
When using round shank tooling with a diameter equal to the capacity hole of the tool holder, the
tool can be mounted directly in the tool holder. When using round shank tooling with a diameter other
than the sizes specified above, it will be necessary to use a tool holder bushing.
INSTALLING ROUND SHANK TOOLS
- CAUTION -
When installing round shank tooling for sub-spindle operations, maximum
tool extension is 8.375 inches [212.73 mm] from the centerline of the turret top
plate tool mounting location. Refer to Figure 4.9.
1. 1Thoroughly clean the turret top plate, tool holders, and tooling.
3. If it is necessary to index the turret:
A) Move the turret to a safe index position.
B) Index the turret to the desired tool station.
C) Move the turret to a convenient position for installing tools.
- CAUTION -
Be sure the tool holder is mounted flush against the side of the turret top
plate.
- NOTE -
the machine base, resulting in maximum tool life. Refer to Left-Hand / Right-Hand
Tool Selection, page 4-5.
4. Loosen two screws “M”, Figure 4.10.
M-392D 4-9
Inches
Turret [Millimeters]
Top Plate
6.997
[177.73]
8.375
[212.73]
Optional
Sub-Spindle
TI4685A
Figure 4.9 - Maximum Round Shank Tool

Extension for Sub-Spindle Operations
TI4677
Figure 4.10 - Mounting a Round Shank Tool Holder

(Viewed from the Main Spindle)
4-10 M-392D
VIEW #1 VIEW #2
Q P
R
Q P
S
T U
R S T U
TI4678
Figure 4.11 - Tool Setting Gauge Oriented for Main Spindle Tooling
5. Aligning tool holder “L” with coolant button “N”, insert the tool holder shank into the turret top
6. Press the tool holder against the turret top plate and tighten two screws “M”.
- NOTE -
7. Tighten clamp screw “O”.
8. Place setting bar “S”, Figure 4.11 or 4.12, in the tool holder and tighten set screws “U” so
that there is a slight drag on the setting bar when it is rotated in the holder.
9. Loosen thumb screw “R” enough to allow locating bar “Q” to slide.
10. Place the machined side of tool setter support “P” flat against the side of the tool holder.
11. Rotate setting bar “S” until the machined flat is in line with the flat surface of locating bar “Q”,
as shown in view #2.
12. Tighten thumb screw “R” when the following conditions are met:
a) The machined side of tool setter support “P” is flat against the side of the tool holder.
b) The flat on setting bar “S” is perpendicular to locating bar “Q”. Refer to view #2.
13. Loosen set screws “U” and remove gauge “S”.
14. If required, install the appropriate tool bushing in the round shank tool holder.
M-392D 4-11
VIEW #1 VIEW #2
P Q R
P Q
S
U T
U T S R
TI4686
Figure 4.12 - Tool Setting Gauge Oriented for Sub-Spindle Tooling
15. Install and adjust the tool for length.

16. Properly align the tool shank and tool bushing, if used, with the set screws in the tool holder.
17. Tighten set screws “U” just enough to apply a slight drag on the tool shank.
18. Place the machined side of tool setter support “P” against the side of tool holder.
19. Rotate the tool until the tool tip touches locating bar “Q”.
20. Tighten set screws “U” to secure the setting.
21. Repeat steps 1 through 20 for additional tools, as necessary.
REMOVING ROUND SHANK TOOLS
- WARNING -
When removing a tool holder from a top plate, have a firm grip on the tool
holder while loosening clamp screw “O”, Figure 4.10.
1. Loosen two screws “M”, Figure 4.10.
2. Loosen clamp screw “O”.
3. Remove the tool holder from the turret top plate.
4. Install a tool station plug if another tool holder is not to be installed. Refer to page 4-4 for
information on tool station plugs.
5. Repeat steps 1 through 3 for additional tool holders, as necessary.
4-12 M-392D
- NOTES -
M-392D 4-13
- NOTES -
4-14 M-392D
CHAPTER 5 - ESA TURRET TOP PLATE TOOLING
INTRODUCTION
®
QUEST series lathes are available with ESA, VDI, or Hardinge turret top plates.
Refer to Chapter 4 for information on tooling for VDI turret top plates.
Refer to Chapter 6 for information on tooling for Hardinge turret top plates.
TOP PLATE CONFIGURATION

The ESA turret top plate is a 12 station top plate.
A live tooling option is available for the ESA top plate. Refer to Chapter 15 for information on live
tooling for the ESA top plate.
TOOL HOLDER OR TOOL STATION PLUG REMOVAL

- WARNING -
When removing a tool holder or tool station plug from a top plate, have a firm
grip on the tool holder or tool station plug when releasing the tool holder from
the top plate.
pressure in the turret may cause the tool holder or tool station plug to begin moving out of the top plate
when the tool holder is released from the top plate.
M-392D 5-1
TOOL STATION PLUGS
INTRODUCTION
- CAUTION -
tooling can result in damage to the machine tool.
Install a tool station plug at each turret tool station not equipped with tooling. Refer to Figure 5.1 for
an illustration of a ESA tool station plug.
TOOL STATION PLUG INSTALLATION

1. Thoroughly clean the top plate and blanking plug.
2. Check the O-ring on the blanking plug to be sure the O-ring is in good condition.
3. Press and hold button "A", Figure 5.2.
4. Insert blanking plug "B" into the turret top plate as shown in Figure 5.2.
5. Release button "A" to clamp the blanking plug.
6. Tighten rear clamp screw "D", Figure 5.3.
7. Install and tighten four face screws “C”, Figure 5.2.
TI5413
Figure 5.1 - Blanking Plug
5-2 M-392D
A
C C
TI5435
Figure 5.2 - Blanking Plug Installed on Top Plate
TP7130
Figure 5.3 - Rear Clamping Screw
M-392D 5-3
LEFT-HAND / RIGHT-HAND TOOL SELECTION
Hardinge Inc. recommends that all cutting forces be directed into the machine base. Directing the
cutting forces into the machine base will result in maximum tool life.
Making the selection between left-hand or right-hand tooling should be based on:
• the position of the tool in relation to the spindle
• the direction of spindle rotation
SQUARE SHANK TOOLS

BASIC CONFIGURATION
Square shank ESA tool holders obtained from Hardinge Inc. that are designed for QUEST® series
lathes are available for ¾", 1”, 20 mm, or 25 mm tooling.
Square shank tools are held in the tool holder by clamping block “H”, Figure 5.4. Clamp screws “E”
and “G” apply force to the clamp block to secure the tool in the tool holder. Spring-loaded screw “F” is
used to hold the clamp block in place when tension is removed from the clamping screws.
When installing or removing square shank tooling, do not remove spring-loaded screw “F”.
Clamping block “H” is held in the tool holder by the spring-loaded screw.
REVERSIBLE TOOL HOLDERS

Square shank ESA tool holders obtained from Hardinge Inc. that are designed for QUEST series
lathes are capable of using left-hand or right hand tooling. Refer to “Left-Hand / Right-Hand Tool Se-
lection”, above.
1. Carefully remove screw “F”, the spring, and
clamp block “H”.
E F G H
2. Remove clamp screws “E” and “G”.
3. Thoroughly clean the tool holder body and all
components that were removed.
4. Install clamp block “H”, the spring, and screw
“F” on the upper or lower side of the tool holder,
as needed.
5. Install clamp screws “E” and “G”.
TI5415
Figure 5.4 - Basic Square

Shank Tool Holder
5-4 M-392D
MAXIMUM TOOL EXTENSION
- CAUTION -
When installing square shank tooling, the maximum X axis tool extension
must not exceed the values listed in the table shown below. Refer also to Fig-
ure 5.5.

Y Axis Option
No 3.639 [92.43]
Yes 2.259 [57.38]
Tool Oriented for Tool Oriented for

Main Spindle Operation Sub-Spindle Operation
Maximum Tool Maximum Tool

Extension Extension
Recommended Tool Recommended Tool

Mounting Position Mounting Position
TI5459
Figure 5.5 - Maximum Square Shank Tool Extension
M-392D 5-5
I
TI5418
Figure 5.6 - Mounting a Square Shank Tool Holder
TI5419
Figure 5.7 - Square Shank Tool Holder with Tool
5-6 M-392D
INSTALLING SQUARE SHANK TOOLS
- NOTE -
the machine base. Refer to Left-Hand / Right-Hand Tool Selection, page 5-4.
The recommended tool mounting position is to have the tool seated against the edge
of the tool holder, as shown in Figure 5.5.

4. Press and hold button "I", Figure 5.6.
5. Insert the tool holder into the turret top plate as shown in Figure 5.6.
6. Release button "I" to clamp the tool holder.
8. Install and tighten four face screws “J”, Figure 5.7.
- CAUTION -
Be sure the tool sits squarely in the slot of the tool holder.
Refer to the maximum tool extension table on page 5-5. Refer also to Figure
5.5.
9. Mount the tool in the tool holder and tighten two clamp screws “K”, Figure 5.7.
10. Repeat as needed for additional tooling.
M-392D 5-7
ROUND SHANK TOOLS
TOOL HOLDER CAPACITIES
- NOTE -
Refer to the appropriate tooling catalog for information on tool holders and bushings.
Round shank ESA tool holders obtained from Hardinge Inc. that are designed for QUEST® series
lathes are available with the following maximum tool shank capacities:
English Tool Holder: 1¼ inches
Metric Tool Holder: 32 or 40 millimeters
When using round shank tooling with a diameter equal to the capacity hole of the tool holder, the
tool can be mounted directly in the tool holder. When using round shank tooling with a diameter other
than the sizes specified above, it will be necessary to use a tool holder bushing.
5-8 M-392D
MAXIMUM Z AXIS TOOL EXTENSION FOR SUB-SPINDLE OPERATION
- CAUTION -
DO NOT exceed the maximum Z axis tool extension defined in this section.
When installing round shank tooling for sub-spindle operations, the maximum Z axis tool extension
is 8.375 inches [212.73 mm] from the centerline of the turret top plate tool mounting location. Refer to
Figure 4.9.
Inches
[Millimeters]
5.481
[139.22]
8.375
[212.73]
TI5420A

M-392D 5-9
INSTALLING ROUND SHANK TOOLS
- CAUTION -
tool extension is 8.375 inches [212.73 mm] from the centerline of the turret top
plate tool mounting location. Refer to Figure 5.8.
- NOTE -
the machine base, resulting in maximum tool life. Refer to Left-Hand / Right-Hand
Tool Selection, page 5-4.
4. Press and hold button "L", Figure 5.9.
5. Insert the tool holder into the turret top plate as shown in Figure 5.9.
6. Release button "L" to clamp the tool holder.
8. Install and tighten four face screws “M”, Figure 5.10.
9. Place setting bar “Q”, Figure 5.11 or 5.12, in the tool holder and tighten set screws “S” so that
there is a slight drag on the setting bar when it is rotated in the holder.
10. Loosen thumb screw “P” enough to allow locating bar “O” to slide.
11. Place the machined side of tool setter support “N” flat against the side of tool holder "R".
12. Rotate setting bar “Q” until the machined flat is in line with the flat surface of locating bar “O”, as
shown in view #2.
13. Tighten thumb screw “P” when the following conditions are met:
A) The machined side of tool setter support “N” is flat against the side of the tool holder.
B) The flat on setting bar “Q” is perpendicular to locating bar “O”. Refer to view #2.
5-10 M-392D
L
TI5421
Figure 5.9 - Mounting a Round Shank Tool Holder
TI5436
Figure 5.10 - Round Shank Tool Holder Mounted on Top Plate
M-392D 5-11
VIEW #1 VIEW #2
O
N
P
O N
Q
R S
P Q R S TI5437
Figure 5.11 - Tool Setting Gauge Oriented for Main Spindle Tooling
VIEW #1 VIEW #2
N O P
N O
Q
S R
S R Q P TI5438
Figure 5.12 - Tool Setting Gauge Oriented for Sub-Spindle Tooling
5-12 M-392D
14. Loosen set screws “S” and remove gauge “Q”.
15. If required, install the appropriate tool bushing in the round shank tool holder.
- CAUTION -
When installing tooling for sub-spindle operation, DO NOT exceed the maxi-
mum tool extension specified on page 5-9.
16. Install and adjust the tool for length.
17. Properly align the tool shank and tool bushing, if used, with the set screws in the tool holder.
18. Tighten set screws “S” just enough to apply a slight drag on the tool shank.
19. Place the machined side of tool setter support “N” against the side of tool holder "R".
20. Rotate the tool until the tool tip touches locating bar “O”.
21. Tighten set screws “S” to secure the setting.
22. Repeat steps 3 through 21 for additional tools, as necessary.
M-392D 5-13
- NOTES -
5-14 M-392D
CHAPTER 6 - HARDINGE TURRET TOP PLATE TOOLING
INTRODUCTION
®
QUEST series lathes are available with ESA, VDI, or Hardinge turret top plates.
Refer to Chapter 4 for information on tooling for VDI turret top plates.
Refer to Chapter 5 for information on tooling for ESA turret top plates.
SQUARE SHANK TOOLS

MAIN SPINDLE OPERATION
Hardinge turret top plates are designed to use qualified square shank tool holders. Since these
tools are length, width, and height qualified, both set-up time and downtime due to tool replacement
are greatly reduced.
Qualified Tool Holders for Main Spindle Operation

Qualified tool holder dimensions are held to ±.003 inch [.076 mm]. A left-hand square shank quali-
fied tool holder is illustrated in Figure 6.1. Refer to Table 6.1 for qualified tool holder dimensions.
A
F
B H
TI2701A
Figure 6.1 - Qualified Tool Holder
Dimension English (in.) Metric (mm)

A 1.000 25.00
B 1.000 25.00
C 6.000 150.00
E 1.250 36.00
F 1.250 32.00
H 1.000 25.00
Table 6.1 - Qualified Tooling Dimensions
M-392D 6-1
Left-Hand / Right-Hand Tool Selection
- CAUTION -
Read this section thoroughly before mounting square shank tooling for main
spindle operations on the turret top plate.
When using square shank tooling, Hardinge recommends the exclusive use of left-hand tools for
the following reasons:
1. The use of left-hand tools insures that all
cutting forces will be directed into the machine
base and will result in maximum tool life.
2. In the event that a right-hand tool and a
left-hand tool are mounted in adjacent tool
stations, as shown on Figure 4., an
interference situation is created. Both tools 1.500
WILL NOT be able to locate against the tool [38.10]
stop on the turret. Refer to the close-up in
Figure 6.3. This could create a potential safety
hazard and MUST be avoided.
Right-hand tooling can be used IF A CHAMFER IS
MACHINED ON THE CORNER OF THE English 1.500
RIGHT-HAND TOOL HOLDER. Figure 6.4 shows [Metric] [38.10]
TI2499
the location and minimum size of the chamfer re-
quired to allow for safe use of right-hand tooling. Figure 6.2 - Tool Interference Illustration
0.063
0.063 [1.60]
[1.60]
45° CH x 0.011 [2.8] Flat

English English
[Metric] [Metric]
TI2500 TI2501
Figure 6.3 - Interference Close-Up Figure 6.4 - Tool Shank Chamfer
6-2 M-392D
Installing Square Shank Tools
- CAUTION -
The shank of the tool holder should be positioned firmly against the tool stop
on the turret top plate, as shown in Figure 6.5. The notable exception is out-
lined in “Between-Center Turning on QUEST® 6/42 Lathes”, on the next page.
- NOTE -
When using square shank tooling, Hardinge recommends the exclusive use of
left-hand tools. This insures that all cutting forces will be directed into the machine
base, resulting in maximum tool life.
The wedge clamp can be located on either side of the tool slot centerline to accommodate both
right-hand and left-hand tools. Referring to Figure 6.6, note that the larger side of the upper wedge
should bear against the tool shank with the arrow pointing toward the tool shank.
1. Mount the wedge clamp on the top plate in the correct orientation for the tool to be installed.
2. Install the tool holder on the top plate and tighten the wedge clamp screws. This will
automatically set the tool tip to the correct height as long as qualified tooling is used.
Tool Wedge Tool

Shank Clamp Shank
Tool Shank Against

Tool Stop
TI4936 TI1908
Figure 6.5 - Tool Shank Positioned Figure 6.6 - Tool Clamp Orientation
Against the Tool Stop
M-392D 6-3
Between-Center Turning on QUEST® 6/42 Lathes
- CAUTION -
Read this section thoroughly before Coolant
mounting square shank tooling for Ring
between-center turning operations.
Tailstock
- NOTE - Enclosure
The information in this section applies
only to QUEST 6/42 lathes.
When using a standard live center for be-
tween-center turning near the tailstock, a potential in-
terference condition exists between the coolant ring
TP4982
on a Hardinge turret top plate and the tailstock enclo-
sure. Refer to Figure 6.7. Figure 6.7 - Turning Near the Tailstock
with a Standard Live Center
The minimum diameter that can be turned is 2 18
inches [54 millimeters].
If it is necessary to turn a smaller diameter near the Coolant
tailstock, two solutions are available: Ring
1. Use an extended nose center, as shown in Tailstock

Figure 6.8. Enclosure
- or -
2. Extend the tool away from the tool stop a
distance equal to:
2.125 - Finished Diameter
Tool Extension =
2 TP4983
Refer to Figure 6.9. Figure 6.8 - Turning Near the Tailstock

with an Extended Nose Live Center
Example: Finished Diameter = 1.75 inches
2.125 - 1.75
Tool Extension = = .1875
2
Tool
Extension
TI4937
Figure 6.9 - Extending the Tool

Away from the Tool Stop
6-4 M-392D
SUB-SPINDLE OPERATION [Option]

- CAUTION -
Turret tooling for sub-spindle operation MUST NOT extend more than 4¼
inches [108 mm] from the turret top plate on the X axis.
An interference condition can exist if sub-spindle turret tooling extends more than 4¼ inches
[108 mm] from the turret top plate on the X axis. Be sure all sub-spindle turret tooling does not extend
beyond this limit
Cut-Off Tool Operating Limits

When using a cut-off tool during a cut-off and transfer operation from the main spindle to the
sub-spindle, the following operating limits must be observed:
• the tip of the cut-off tool MUST extend 3.94 inches [100 millimeters] from the
edge of the turret top plate.
• the face of the sub-spindle must be at least 1.80 inches [45.7 millimeters] from
the face of the main spindle.
Refer to Figure 6.10.
Refer to the chart on the next page to identify the correct square shank cut-off tool holder.
Inches [millimeters]
Turret
Top Plate
Square Shank Cut-Off
Tool Holder Required
3.94
[100]
Main Spindle Optional Sub-Spindle
1.80 [45.7]
TI4925
Figure 6.10 - Cut-Off Tool Operating Limits
M-392D 6-5
Model Numbers for Square Shank Cut-Off Tool Holders
Machine Model English Top Plate Metric Top Plate

QUEST® 6/42 Lathe SG-CE SG-CEM
QUEST 8/51 & 10/65 Lathes CL-CE CL-CM
Tooling Configuration
Sub-spindle operations require ¾ inch square shank tooling on English top plates and 20 millimeter
square shank top plates on Metric machines.
Tooling Location
Square shank tooling for sub-spindle operations can only be mounted at odd numbers tool stations.
6-6 M-392D
Tool Mounting Position
Square shank tooling for main spindle operations is mounted on the -Z face of the turret top plate
and square shank tooling for sub-spindle operations is mounted on the +Z face of the turret top plate.
Toward Main Spindle Away from Main Spindle
-Z Turret Top +Z Turret Top

Plate Face Plate Face
Square Shank Tool Square Shank Tool

Slots for Main Spindle Slots for Sub-Spindle
Operations Operations
(Odd Numbered Tool
Stations Only)
TI2737A
Figure 6.11 - Hardinge Turret Top Plate

(Sub-Spindle Machines Only)
M-392D 6-7
Tool Shank Modification
1.81
- CAUTION - [46.0]
Failure to modify the length of the
tool holder shank may result in poor
surface finish.
The length of the tool slots used for sub-spindle 1.25
[38.1]
operations is 1-13/16 inches [46 mm]. Due to the
length of the tool slots, it will be necessary to shorten
the shank of the tool holder to position the tool tip at a
distance of 1-1/4 inches [31.8 mm] from the edge of
the turret top plate. The final length of the tool, after
modification, will be 3-1/16 inches [77.8 mm] from the
tool tip to the end of the tool shank. Refer to Figure
6.12. English
[Metric]
TI2774
Figure 6.12 - Tool Length Modification
Mounting Tools
- NOTE -
When using square shank tooling for sub-spindle operations, Hardinge recommends
the exclusive use of right-hand tools. This insures that all cutting forces will be di-
rected into the machine base, resulting in maximum tool life.
The wedge clamp can be located on either side of the tool slot centerline to accommodate both
right-hand and left-hand tools. Referring to Figure 6.6, note that the larger side of the upper wedge
should bear against the tool shank with the arrow pointing toward the tool shank.
1. Mount the wedge clamp on the top plate in the correct orientation for the tool to be installed.
2. Install the tool holder on the top plate and tighten the wedge clamp screws.
6-8 M-392D
ROUND SHANK TOOLS
Round shank tools 1½ inches or 40 millimeters in diameter can be mounted directly into the op-
tional English or Metric round shank tool holders, respectively. Round shank tools in specific sizes
ranging from 1/32 inch [1 millimeter] up to ¾ inch [20 millimeters] can be mounted in the round shank
tool holders using the Hardinge Double-Angle Tool Holder Collet and Tool Holder System.
Round shank tools in specific sizes ranging from ½ inch [12 millimeters] up to 1¼ inch [32 millime-
ters] can be mounted in the round shank tool holders using Hardinge HDC-12 bushings.
ROUND SHANK TOOL HOLDERS

QUEST® 6/42 LATHE
Hardinge drill holders are qualified at 1.250 inches [31.75 mm] from the hole center to the
turret face. Hardinge boring bar holders are qualified at 2.000 inches [50.80 mm] from the hole
center to the turret face.
QUEST 8/51 and 10/65 LATHES
Hardinge drill holders are qualified at 1.500 inches [38.10 mm] from the hole center to the
turret face. Hardinge boring bar holders are qualified at 2.813 inches [71.44 mm] from the hole
center to the turret face.
Refer to the appropriate Hardinge tooling catalog for additional information.
TOOL SETTING GAUGES
- NOTE -
Two separate tool setting gauges are supplied with QUEST series lathes. One
gauge is used to set tools for main spindle operation. The other gauge is used to set
tools for sub-spindle operation.
Tool setting gauges are used to place the tool nose of round shank tools such as boring bars and in-
ternal threading tools on center with the spindle centerline.
The tool slot centerline of the active station and the spindle centerline are the same distance from
the top surface of the machine ways. Therefore, if the tool nose is positioned on the tool slot centerline,
it will be on center with the spindle centerline.
The tool setting gauge for main spindle operation mounts in the tool slot and provides a
physical projection of the tool slot centerline. Once the tool setting gauge is mounted on the
turret, the tool is rotated to bring the tool nose against the gauge.
The tool setting gauge for sub-spindle operation is held against the side of the tool holder
and provides a physical projection of the tool slot centerline. Once the tool setting gauge is
properly set up, the tool is rotated to bring the tool nose against the gauge.
M-392D 6-9
INSTALLING ROUND SHANK TOOLS FOR MAIN SPINDLE OPERATION
1. If not already installed, loosely mount wedge clamp “A”, Figure 6.13, on the top plate in the
correct orientation for the tool to be installed.
2. Mount the round shank tool holder on the turret.
3. If required, install the appropriate tool cartridge in the round shank tool holder.
4. Insert the tool in the holder or tool cartridge and adjust the tool to length. Align the flat on the
Hardinge Double-Angle Tool Holder Collet or the slot in Hardinge HDC-12 bushings and the flat
on the tool shank with one of the groups of three set screws “C”, Figure 6.14.
- NOTE -
Orientation of the gauge for setting left-hand tools is shown in Figure 6.13.
5. Insert tool setting gauge “B”, Figures 6.13 and 6.14, in the turret tool slot with one of the
chamfered edges toward the bottom of the slot.
+X
+Y
Spindle Centerline
C
TI1908 TI2410
Figure 6.13 - Tool Setting Gauge Figure 6.14 - Tool Setting Gauge
(Front View) (Side View)
6-10 M-392D
6. Carefully position the tool setting gauge so the tool nose can be rotated to touch the inner face
of the gauge; then, tighten wedge clamp “A”, Figure 6.13.
- CAUTION -
Be careful not to damage the tool nose.
7. Rotate the tool until the tool nose touches the inner face of the tool setting gauge.
- CAUTION -
When the set screws are fully tightened there is the possibility that the tool
may rotate. This will damage the tool nose if it is against the tool setting
gauge.
- NOTE -
To secure the tool, tighten the group of three set screws that align with the tool and
tool holder as described in step 4.
8. Snug, but do not fully tighten any group of three set screws “C”, Figure 6.14, to hold the tool in
place.
9. Loosen wedge clamp “A”, Figure 6.13, swing the tool setting gauge out of the way, and tighten
the wedge clamp.
10. Fully tighten three set screws “C”, Figure 6.14, to secure the tool.
11. Loosen the wedge clamp and carefully position the tool setting gauge to check that the tool
nose is still on center. If it has moved, repeat steps 6 through 10.
12. Remove the tool setting gauge from the turret and tighten the wedge clamp.
M-392D 6-11
INSTALLING ROUND SHANK TOOLS FOR SUB-SPINDLE OPERATION
- CAUTION -
DO NOT use round shank tool holder adapter plates on machines equipped
with the sub-spindle option. Use of the adapter plates may result in interfer-
ence between the round shank tool holders and the sub-spindle.
The operator must make certain that no interference exists between the turret
tooling and the main spindle, workpiece, or sub-spindle before manually in-
dexing the turret.
Operating Limits
- CAUTION -
tool extension is 7.25 inches [184.1 mm] from the surface of the tool holder.
When installing a drill or boring bar for sub-spindle operation, the following operating limits must be
observed:
• maximum tool extension is 7.25 inches [184.1 millimeters] from the surface of the
tool holder. Refer to Figure 6.15.
• tool extension must provide a minimum of 1.25 inches [32 millimeters] clearance
between the tool holder and the face of the sub-spindle at the end of the cut. Re-
fer to Figure 6.16.
Inches
[Millimeters]
Turret
Top Plate
7.25 Optional
[184.1] Sub-Spindle
Maximum
Tool Extension
TI4740A

6-12 M-392D
Inches [millimeters]
Turret
Top Plate
Optional
Sub-Spindle
Tool Holder
1.25 [32.0]
TI4926
Figure 6.16 - Minimum Tool Holder Clearance

for Round Shank Tool Holders
M-392D 6-13
Installation Procedure
1. Index the turret to the desired station.
2. Mount tool holder “E” on the turret, as shown in view #1 of Figure 6.17.
3. Refer to the illustration and complete steps 4 through 14.
4. Place setting bar “I” in the tool holder and tighten set screws “D” so that there is a slight drag on
the setting bar when it is rotated in the holder.
5. Loosen thumb screw “H” enough to allow locating bar “G” to slide.
6. Place the machined side of tool setter support “F” flat against the side of the tool holder.
7. Rotate setting bar “I” until the machined flat is in line with the flat surface of locating bar “G”, as
shown in view #2.
8. Tighten thumb screw “H” when the following conditions are met:
A) The machined side of tool setter support “F” is flat against the side of the tool holder.
B) The flat on setting bar “I” is perpendicular to locating bar “G”. Refer to view #2.
9. Loosen set screws “D” and remove gauge “I”.
VIEW #1 VIEW #2
+X
+Z
F
H
I
E
I
H
G
E F
TI2773
Figure 6.17 - Tool Setting Gauge for Sub-Spindle Tooling

(Hardinge Turret Top Plate)
6-14 M-392D
- CAUTION -
Be sure that there is sufficient clearance between the sub-spindle tooling and
the turret.
10. Place the tool in the tool holder at the desired length.
11. Tighten set screws “D” just enough to apply a slight drag on the tool shank.
12. Place the machined side of tool setter support “F” against the side of tool holder.
13. Rotate the tool until the tool tip touches locating bar “G”.
14. Tighten set screws “D” to secure the setting.
15. Repeat steps 1 through 14 for additional tools as necessary.
M-392D 6-15
- NOTES -
6-16 M-392D
CHAPTER 7 - WORK SHIFT
INTRODUCTION
The work shift offset shifts the origin of the work coordinate system. Work Shift values (Z) are
stored in the Work Shift file. The value stored in this file is active at all times.
- CAUTION -
The Work Shift file contains an X and a Z shift register. The X axis register in
the Work Shift file should be set to zero at all times.
The value entered into the Z axis Work Shift file must be a negative number.
The values stored in the Work Shift file are added to the Absolute Position registers, thus shifting
the origin of the work coordinate system by the amount stored in the Work Shift file. For example, if the
Z axis is at 14 inches and the operator stores Z-2.5 in the Work Shift file, the Absolute Position regis-
ters would then display Z11.5 [14 +(- 2.5)].
Immediately after a Work Shift value is stored, the control adds it to the Absolute Position registers.
The registers will remain modified until the Work Shift offset values are set to zero by the operator or
from the part program.
Typically, the part length is stored as the Z Work Shift offset and the X Work Shift offset IS NOT
USED (set to zero). Since the Work Shift value is added to the Absolute Position registers, the part
length is stored as a negative Z value. With the part length stored in the Work Shift file, the origin of the
Absolute coordinate system is the intersection of the part face and the spindle centerline.
- NOTE -
Refer to the programmer’s manual (M-391) for information on storing a work shift
from the part program.
M-392D 7-1
MANUALLY ESTABLISHING Z AXIS WORK SHIFT
VDI OR ESA TURRET TOP PLATE
- NOTE -
This procedure is used to set the work shift on QUEST® series lathes equipped with
a VDI or ESA turret top plate. Refer to page 7-6 for the procedure that applies to
QUEST series lathes equipped with a Hardinge turret top plate.
1. Load a workpiece into the collet or step chuck at the desired length.
2. Activate Jog mode.
3. Jog the turret to a safe position for indexing.
- CAUTION -
The machine operator must make certain that no interference exists between
the spindle, spindle tooling, turret, turret tooling, tailstock, sub-spindle, or
workpiece before manually indexing the turret.
- NOTE -
If an square shank tool holder is not available, install a tool holder at any convenient
station.
4. Turn the Station switch to the number of a turret station equipped with a square shank tool
holder.
5. Press the Turret Index push button to index the turret to the selected turret station.
6. Set the Feedrate Override switch to the desired setting. A setting of 150% will equal a jog
feedrate of approximately 37.5 in/min [952 mm/min].
7. Jog the tool holder to within 1 inch [25 mm] of the face of the workpiece.
8. Use the Manual Axis Movement switch to select the Z axis.
- NOTE -
Refer to page 1-17 for information on using the Rapid Override switch to select
handwheel increments.
9. Use the Rapid Override switch to select the desired handwheel increment.
10. Place a shim or scale against the face of the workpiece; then, turn the handwheel in the
appropriate direction to move the turret toward the face of the workpiece until a slight drag is felt
when moving the shim between the tool holder and workpiece. Refer to Figure 7.1, 7.2, 7.3, or
7.4.
11. Press the Offset Setting key to display the offset pages.
12. Press the right hand soft key until the Work Shift soft key is displayed.
13. Press the Work Shift soft key to display the Work Shift registers.
7-2 M-392D
Turret Position
Work Shift
Main
Spindle
Shim
Thickness
Tool Holder
Offset Value
TI4682A
Figure 7.1 - Establishing the Main Spindle Work Shift

(VDI Turret Top Plate)
Turret Position
Optional
Tool Holder Offset Value Sub-Spindle
Main
Spindle
Shim Thickness
Work Shift
TI4683B
Figure 7.2 - Establishing the Sub-Spindle Work Shift

(VDI Turret Top Plate)
M-392D 7-3
Turret Position
Work Shift
Main
Spindle
Shim
Thickness
Tool Holder
Offset Value
TI5443

(ESA Turret Top Plate)
Main
Spindle
Optional
Sub-Spindle
Turret Position
Tool Holder Offset Value
Shim Thickness
Work Shift
TI5444

(ESA Turret Top Plate)
7-4 M-392D
14. If not already set to “0" (zero), set the X value under Shift Value to ”0" as follows:
A) Use the cursor keys to move the cursor to the X Data field under Shift Value.
B) At the Manual Data Input keyboard, key in the number “0" (zero).
C) Press the Input key.
15. Use the cursor keys to move the cursor to the Z Data field under Measurement.
- NOTE -
The tool holder offset value is the Z axis distance from the tool station centerline to
the tool holder surface used to set the work shift.
Refer to the appropriate tooling catalog for the tool holder offset value.
16. If setting work shift at the main spindle, key in:
+(Tool Holder Offset Value + shim thickness)
If setting work shift at the sub-spindle, key in:
-(Tool Holder Offset Value + shim thickness)
17. Press the Input key. The Z axis Work Shift will be recorded in the Z Shift Value register.
18. Turn the handwheel in the appropriate direction to move the tool holder at least 1 inch [25 mm]
from the face of the workpiece.
M-392D 7-5
HARDINGE TURRET TOP PLATE
- NOTE -
This procedure is used to set the work shift on QUEST® series lathes equipped with
a Hardinge turret top plate. Refer to page 7-2 for the procedure that applies to
QUEST series lathes equipped with a VDI or ESA turret top plate.
1. Load a workpiece into the collet or step chuck at the desired length.
- CAUTION -
The machine operator must make certain that no interference exists between
the spindle, spindle tooling, turret, turret tooling, tailstock, sub-spindle, or
workpiece before manually indexing the turret.
4. Turn the Station switch to the number of an empty turret station.
5. Press the Turret Index push button to index the turret to the selected turret station.
6. Set the Feedrate Override switch to the desired setting. A setting of 150% will equal a jog
feedrate of approximately 37.5 in/min [952 mm/min].
7. Jog the turret top plate to within 1 inch [25 mm] of the face of the workpiece.
8. Use the Manual Axis Movement switch to select the Z axis.
- NOTE -
Refer to page 1-17 for information on using the Rapid Override switch to select
handwheel increments.
9. Use the Rapid Override switch to select the desired handwheel increment.
10. Place a shim or scale against the face of the workpiece; then, turn the handwheel in the
appropriate direction to move the turret toward the face of the workpiece until a slight drag is felt
when moving the shim between the turret top plate and workpiece. Refer to Figure 7.5 or 7.6.
12. Press the right hand soft key until the Work Shift soft key is displayed.
13. Press the Work Shift soft key to display the Work Shift registers.
14. If not already set to “0" (zero), set the X value under Shift Value to ”0" as follows:
A) Use the cursor keys to move the cursor to the X Data field under Shift Value.
B) At the Manual Data Input keyboard, key in the number “0" (zero).
C) Press the Input key.
7-6 M-392D
Turret Position
Work Shift
Main
Spindle
Shim
Thickness
TI4733

Work Shift
Turret Position
Main
Spindle
Optional
Sub-Spindle
4.7875 inches
[121.603 mm]
Shim Thickness
TI4734A

M-392D 7-7
15. Use the cursor keys to move the cursor to the Z Data field under Measurement.
16. If setting work shift at the main spindle, key in the shim thickness as a positive (+) value.
If setting work shift at the sub-spindle, key in:
-(4.7875” [121.603 mm] + shim thickness)
17. Press the Input key. The Z axis Work Shift will be recorded in the Z Shift Value register.
18. Turn the handwheel in the appropriate direction to move the tool holder at least 1 inch [25 mm]
from the face of the workpiece.
7-8 M-392D
- NOTES -
M-392D 7-9
- NOTES -
7-10 M-392D
CHAPTER 8 - TOOL OFFSETS
INTRODUCTION
The Tool Offset file is made up of two types of offsets: Tool Geometry Offsets and Tool Wear Off-
sets. The control has the capacity to store 32 sets of each offset type (Offsets 01 through 32) in sepa-
rate files.
- NOTE -
Information stored in the Geometry and Wear Offset files is automatically converted
into the correct units when a programmed G20 or G21 command is used to switch
between inch and metric mode.
Tool offsets are illustrated in Figures 8.1 through 8.12.
Machines equipped with an ESA turret top plate have the same X axis reference po-
sition and travel specifications as a machine equipped with a VDI 30 turret top plate.
As indicated in Figures 8.5 through 8.8, the diameter of the ESA turret top plate is
1.378 inches [35.00 millimeters] smaller per side than the VDI 30 turret top plate.
Refer to the programmer’s manual (M-391) for:
• a description of turret reference point and the tool nose reference point.
• information on activating and canceling tool offsets
The following information is stored in the Tool Geometry Offset file:

X Tool Dimension
Diameter distance from the X axis tool touch-off point to the turret X axis reference
point. Sign is determined by the direction from the tool nose reference point to the turret
reference point.
Z Tool Dimension
Distance from the Z axis tool touch-off point to the turret Z axis reference point. Sign is
determined by the direction from the tool nose reference point to the turret reference
point.
Tool Orientation:
The orientation code describes the location of the center of the tool nose in relation to
the tool nose reference point.
Tool Nose Radius Value:
The distance from the cutting edge to the center of the tool nose radius.
M-392D 8-1
Turret Z Axis Reference Position
Turret X Axis Reference Position
This distance equals ½

the X Axis Tool Offset
Z Axis Tool Offset
Main Spindle
+X Axis Tool Offset

+Z Axis Tool Offset
TI4679A
Figure 8.1 - Square Shank Tool Offsets

for Main Spindle Operation (VDI Top Plate)

Z Axis Tool Offset
Optional
Sub-Spindle
+X Axis Tool Offset

-Z Axis Tool Offset
TI4687A

for Sub-Spindle Operation (VDI Top Plate)
8-2 M-392D
Z Axis Tool Offset

Main Spindle
+X Axis Tool Offset

+Z Axis Tool Offset
TI4680A
Figure 8.3 - Round Shank Tool Offsets

for Main Spindle Operation (VDI Top Plate)
Z Axis Tool Offset

+X Axis Tool Offset

-Z Axis Tool Offset
TI4688A

for Sub-Spindle Operation (VDI Top Plate)
M-392D 8-3
1.378 [35.00]

(Refer to the note on page 8-1)
Z Axis Tool Offset
Main Spindle
+X Axis Tool Offset

+Z Axis Tool Offset
TI5439A

for Main Spindle Operation (ESA Top Plate)
1.378 [35.00]

Refer to the note on page 8-1)

Z Axis
Tool Offset
Optional
Sub-Spindle
+X Axis Tool Offset

-Z Axis Tool Offset
TI5440A

for Sub-Spindle Operation (ESA Top Plate)
8-4 M-392D
Z Axis Tool Offset
1.378 [35.00]


Main Spindle
+X Axis Tool Offset

+Z Axis Tool Offset
TI5441A

for Main Spindle Operation (ESA Top Plate)
Z Axis Tool Offset
1.378 [35.00]


Optional
Sub-Spindle
+X Axis Tool Offset

-Z Axis Tool Offset
TI5442A

for Sub-Spindle Operation (ESA Top Plate)
M-392D 8-5
Z Axis Tool Offset

Main Spindle
+X Axis Tool Offset

+Z Axis Tool Offset
TI4736

for Main Spindle Operation (Hardinge Top Plate)

Z Axis Tool Offset

Optional
Sub-Spindle
+X Axis Tool Offset

-Z Axis Tool Offset
TI4737

for Sub-Spindle Operation (Hardinge Top Plate)
8-6 M-392D
Z Axis Tool Offset

Main Spindle
+X Axis Tool Offset

+Z Axis Tool Offset
TI4738

for Main Spindle Operation (Hardinge Top Plate)

Z Axis
Tool Offset
+X Axis Tool Offset

-Z Axis Tool Offset
TI4739

for Sub-Spindle Operation (Hardinge Top Plate)
M-392D 8-7
The Tool Wear Offset file allows the operator to enter minor dimensional changes for each tool to
compensate for tool wear. The Tool Wear Offset files coincide with the Geometry Offset files. When a
tool offset is activated, the control looks at the corresponding Tool Wear offset and performs the nec-
essary corrections to compensate for tool wear.
The Tool Offset files allow the operator to easily make corrections resulting from tool changes,
eliminating the need for large-scale modifications to the part programs.
The Data word format for the T word is T4. Tool Offsets are activated by the last two digits in the T
word. The first two digits specify the turret station
8-8 M-392D
STORING TOOL GEOMETRY OFFSETS IN MEMORY
- NOTE -
Tool offset values can be entered using the following methods:
Manually from the keyboard.
Through the part program or a separate program. Refer to the programmer’s
manual (M-391) for information on storing tool offsets from a program.
SETTING TOOL OFFSETS FOR NON-CENTER WORKING TOOLS ON THE TURRET

1. Load a workpiece of known diameter and length into the collet or chuck.
2. If it has not already been done, determine the Work Shift Offset following the appropriate
procedure in Chapter 7.
- NOTE -
The work shift value must be in the Z axis work shift register to accurately set the
tool offsets.
3. Enter the work shift value into the Z axis work shift register.
5. Set the Feedrate Override switch to the desired setting.
- CAUTION -
The machine operator must be sure that no interference exists between the
spindle, spindle tooling, turret, turret tooling, or workpiece before indexing a
turret.
7. Index the turret to the selected station.
8. Mount the tool holder and tool onto the turret.
9. Jog the tool tip to within 1 inch [25 mm] of the face of the workpiece held in the spindle.
10. Place a shim or scale against the face of the workpiece and use the handwheel to move the
turret on the Z axis to gently touch the tool tip to the shim so that a slight drag is felt when
moving the shim, as shown in Figure 8.13 or 8.14.
12. Press the Offset soft key to access the Tool Offset pages.
M-392D 8-9
O.D. Tool
Shim
Workpiece Workpiece
Shim
I.D. Tool
TI4689A
Figure 8.13 - Tool Touch-Off Points at Main Spindle

(VDI Turret Top Plate Shown)
TI4690A
Figure 8.14 - Tool Touch-Off Points at Optional Sub-Spindle

(VDI Turret Top Plate Shown)
13. If not already displayed, press the Geometry soft key to display the Tool Geometry Offset
pages.
14. Use the page and cursor keys to position the cursor at the Z axis field for the desired offset.
15. If touching off on the main spindle, key in the letter Z and the thickness of the shim as a positive
value.
If touching off on the optional sub-spindle, key in the letter Z and the thickness of the shim
as a negative value.
8-10 M-392D
16. Press the Measure soft key. The Z axis offset value for the tool will now be displayed under the
appropriate offset number, as selected in step 14.
17. If touching off an O.D. working tool, jog the turret on the Z axis to clear the workpiece.
If touching off an I.D. working tool, use the handwheel to position the tool tip approximately
.125 inch [3.2 mm] from the face of the workpiece.
18. Use the cursor keys to position the cursor at the X axis field for the desired offset.
19. If touching off an O.D. working tool, jog the turret on the X axis to place the tool tip beyond the
O.D. of the part as shown in Figure 8.13 or 8.14.
20. If touching off an O.D. working tool, use the handwheel to move the turret on the Z axis until the
tool tip is past the face of the workpiece.
21. Place the shim against the O.D. of the workpiece and turn the handwheel in the appropriate
direction until the tool tip gently makes contact with the shim, as shown in Figure 8.13 or 8.14.
22. Key in the diameter of the workpiece as a positive value.
Example: Diameter = 2.125
Input = X2.125
- NOTE -
Using the Measure soft key to set a tool geometry offset automatically resets the
corresponding wear offset to zero.
23. Press the Measure soft key. The X axis offset value for the tool will now be displayed under the
appropriate offset number.
24. Compensate for shim thickness:
If touching off an O.D. working tool and the control is set for diameter programming, enter
twice the shim thickness as a negative (-) value and press the Input+ soft key.
If touching off an O.D. working tool and the control is set for radius programming, enter the
shim thickness as a negative (-) value and press the Input+ soft key.
If touching off an I.D. working tool, no shim compensation is needed.
25. Jog the turret in the +X direction to clear the diameter of the workpiece by at least 1 inch [25
mm] in the +X direction.
26. Jog the turret in the +Z direction to clear the face of the workpiece by at least 1 inch [25 mm] in
the +Z direction.
28. Index the turret to the next tool station that is to be set.
29. Repeat steps 8 through 28 as required for other tools.
M-392D 8-11
SETTING TOOL OFFSETS FOR CENTER-WORKING TOOLS ON THE TURRET
- CAUTION -
This procedure is to be used for center-working tools such as drills, taps, and
reamers ONLY.
The X axis Wear Offset must always set to zero for center-working tools.
1. Load a workpiece of known diameter and length into the collet or chuck.
- NOTE -
tool offsets.
- CAUTION -
spindle, spindle tooling, turret, turret tooling, or workpiece before indexing a
turret.
8. Mount the tool in the tool holder at the length desired.
9. Jog the tool tip to within 1 inch [25 mm] of the face of the workpiece held in the spindle.
10. Place a shim against the face of the workpiece and use the handwheel to move the turret in the
appropriate direction to gently touch the tool tip to the shim until a slight drag is felt when moving
the shim.
13. Press the Geometry soft key to access the Geometry Offset pages.
14. Use the page and cursor keys to position the cursor at the X axis field for the desired offset.
8-12 M-392D
- NOTE -
Refer to the appropriate tooling catalog for information on tool holder dimensions.
15. If the control is set for diameter programming, enter twice the tool holder dimension as a
positive (+) value and press the Input key.
If the control is set for radius programming, enter the tool holder dimension as a positive
(+) value and press the Input key.
16. Use the cursor keys to position the cursor at the Z axis field for the desired offset.
17. Key in the letter Z and the thickness of the shim as a positive value.
- NOTE -
19. Move the turret in the appropriate Z direction to clear the workpiece.
20. Repeat steps 6 through 19 as required for other center-working tools.
M-392D 8-13
TOOL PROBE [Option]
INTRODUCTION
The tool probe allows the operator to set tool geometry offsets quickly and accurately. The tool
probe has been calibrated at the factory and is ready to use without further adjustment. Refer to “Tool
Probe Calibration”, on page 8-21, for additional information.
The tool probe has three available operating modes:
• Manual Mode
• Semi-Automatic Mode
• Automatic Mode
MANUAL TOOL PROBE OPERATION
- NOTE -
The axis jog push buttons will not produce axis motion when the tool probe is acti-
vated and deployed. Axis motion is obtained through the use of the manual pulse
generator.
The optional sub-spindle must be at the E axis reference position before the tool
probe can be activated and deployed.
Once a tool has been probed, the X axis must be moved to the Reference Position
before the turret can be indexed.
This procedure assumes that all required turret tooling has been installed. Refer to:
Chapter 4 for information on installing tooling on a VDI turret top plate.
Chapter 5 for information on installing tooling on an ESA turret top plate.
Chapter 6 for information on installing tooling on a Hardinge turret top plate.
- CAUTION -
spindle, spindle tooling, tool probe, turret, turret tooling, or workpiece before
indexing the turret.
1. Activate Rapid Reference mode.
2. Set the Manual Axis Movement switch to “X”.
3. Press the Rapid Reference push button to move the turret to the X axis reference position.
8-14 M-392D
4. If the machine is equipped with the sub-spindle option:
A) Set the Manual Axis Movement switch to “E”.
B) Press the Rapid Reference push button to move the sub-spindle to the reference position.
- CAUTION -
When the tool probe is turned ON, do not touch the probe with any object
other than the tool that is being set.
- NOTE -
Activating the tool probe will cause the control to automatically display the tool ge-
ometry offset registers.
6. Press the Tool Probe push button to activate and deploy the tool probe.
8. Use the page and cursor keys to position the cursor at the desired offset number.
- CAUTION -
The machine operator must exercise care when approaching the tool probe
stylus with the tool. DO NOT impact the tool probe stylus with the tool.
9. Set the Rapid Override switch to an appropriate value to safely approach the tool probe stylus
with the tool.
10. Use the manual pulse generator to move the tool tip to a position near the appropriate side of
the tool probe stylus.
11. Press the appropriate axis push button to choose which side of the tool probe stylus will be
used. Refer to Figure 8.15.
12. Set the Rapid Override switch to the “1x” position for manual pulse generator control.
X/Z
+X
Tool
X/Z Probe X/Z
Stylus
+Z
X/Z
CL
TI4716
Figure 8.15 - Axis Push Buttons
M-392D 8-15
13. Turn the manual pulse generator one increment at a time to move the tool tip carefully against
the tool probe stylus until the probe is tripped. The offset will register on the display screen
14. Move the tool away from the tool probe stylus.
15. Repeat steps 8 through 14 if touching the tool off on another axis.
20. Repeat steps 7 through 19 if touching off additional tools.
21. Press the Tool Probe push button to deactivate and retract the tool probe.
SEMI-AUTOMATIC AND AUTOMATIC TOOL PROBE OPERATION
Datuming the Tool Probe

- CAUTION -
The tool probe must be correctly calibrated in manual mode before semi-auto-
matic or automatic operation is performed.
All tools that are to be updated through semi-automatic or automatic tool
probe operation MUST have an offset value that is approximately equal to the
actual tool offset Data. This can be accomplished by either of the following
methods:
• Manually touching off the tools
• Using the tool probe in manual mode
- NOTE -
It is recommended that a standard turning tool be used to datum the probe.
The semi-automatic and automatic tool probe functions require that a master tool be used to datum
the probe prior to use. A master tool is defined as a tool that has known offset values defined in the tool
offset file.
The process of datuming the tool probe for semi-automatic or automatic operation is not to be con-
fused with calibrating the probe for manual operation.
When the probe is calibrated for manual operation, parameters 5015 through 5018 are
used to record the position of the probe stylus. Refer to “Tool Probe Calibration”, on page
8-21, for additional information.
When the probe is datumed for semi-automatic or automatic operation, macro variables
522 through 531 are used to record the position of the probe stylus. Refer to “Tool Probe
Datum Procedure”, on the next page.
8-16 M-392D
TOOL PROBE DATUM PROCEDURE
- NOTE -
Refer to “Entering a Program from the Keyboard”, page 3-10, for information on en-
tering a program through the manual Data input keyboard.
1. Enter the following program into the control memory:
O____ (Datum Auto Tool Probe) ; Program Number (Operator Message)
#509=1 ; Specifies that Geometry and Wear Offsets are to be used
#530=.785 ;
#531=.3925 ;
G98 ; Inch/Millimeter per Minute Feedrate
M91 ; Enable Automatic Mode with Probe Extended
G65 P9011 K2. T_. H_. ; Call Macro Program 9011,
K2. = Sets all Probe Faces for Datum
T_. = Tool Station and Offset for Master Tool,
H_. - Tool Quadrant (Tool Orientation Code)
M30 ; End of Program
7. Index the turret to the station with the master tool.
- CAUTION -
with the tool.
10. Use the manual pulse generator to move the tool tip within 1 inch [25 millimeters] of the corner
of the two sides of the probe stylus to be used for datuming.
11. Activate Automatic mode.
M-392D 8-17
- NOTE -
Refer to “Activating a Stored Program”, page 3-10, for information on activating a
program.
12. Verify the datum program entered in step 1 is active.
13. Press the Cycle Start push button to datum the probe. After datuming is complete, the tool will
return to the position it was jogged to in step 10.
17. Press the Tool Probe push button to retract the tool probe.
8-18 M-392D
Semi-Automatic Tool Probe Operation
- CAUTION -
The tool probe must be correctly calibrated before semi-automatic operation is
performed.
The probe must be datumed before semi-automatic operation is performed.
Refer to “Datuming the Tool Probe”, page 8-16 for information on datuming
the probe for semi-automatic operation.
- NOTE -
Refer to “Entering a Program from the Keyboard”, page 3-10, for information on en-
tering a program through the manual Data input keyboard.
1. Enter the following program into the control memory:
O____ (Semi-Automatic Tool Probe Cycle) ; Program Number (Operator Message)
#509=1 ; Specifies that Geometry and Wear Offsets are to be used
G98 ; Inch/Millimeter per Minute Feedrate
M91 ; Enable Automatic Mode with Probe Extended
G65 P9011 T_. H_. ; Call Macro Program 9011,
T_. = Offset Location for Tool Data (1 - 32),
H_. - Tool Quadrant (Tool Orientation Code)
- CAUTION -
with the tool.
10. Use the manual pulse generator to move the tool tip within 1 inch [25 millimeters] of the corner
of the two sides of the probe stylus to be used for datuming.
11. Activate Automatic mode.
M-392D 8-19
- NOTE -
program.
12. Verify the program entered in step 1 is active.
13. Press the Cycle Start push button to probe the tool. After probing is complete, the tool will return
to the position it was jogged to in step 10.
17. Press the Tool Probe push button to retract the tool probe.
- NOTE -
If probing additional tools, modify the values for the T and H words in program
O3333 as needed for each tool to be probed.
18. Repeat steps 6 through 17, as needed, to probe additional tools.
Automatic Tool Probe Operation

- CAUTION -
The tool probe must be correctly calibrated before automatic operation is per-
formed.
The probe must be datumed before automatic operation is performed. Refer to
“Datuming the Tool Probe”, page 8-16 for information on datuming the probe
for automatic operation.
Automatic tool probe operation can be performed by using either of the following methods:
• Execute automatic tool probe operation from within the part program
• Call a subprogram to execute automatic tool probe operation
Refer to the programmer’s manual (M-391) for information on programming automatic operation of
the tool probe.
8-20 M-392D
TOOL PROBE CALIBRATION
The tool probe parameters are set at the factory when the probe is calibrated. Normally, it is not
necessary to re-calibrate the probe unless one of the following occurs:
• The probe tip has been replaced.
• The turning center is operating at a temperature that is significantly different than that
which the tool probe was calibrated at.
- NOTE -
The values for parameters 5015 and 5016 are set as diameter values.
Parameters 5015 through 5018 define the locations of the stylus contact surfaces used to set tool
offsets. Refer to Figure 8.16.
CALIBRATION PROCEDURE
1. Mount sufficient tooling on each turret to be able to probe all 4 surfaces on each tool probe
stylus.
2. Set tool offsets for the tooling installed in step 1 using the procedure outlined under “Setting
Tool Offsets for Non-Center Working Tools on the Turret”, starting on page 8-9.
3. Probe one of the tools installed in step 1 and observe any difference between the tool offset
obtained in step 2 and the tool offset established by the tool probe.
- NOTE -
Refer to Chapter 3 for information on editing machine parameters.
4. Modify the associated parameters (5015 through 5018) as needed to produce the same offset
using both steps 2 and 3.
5. Repeat steps 2 through 4 as needed until identical results are obtained when using both steps 2
and 3.
+X
Parameter 5018
+Z
Parameter 5017
Probe Parameter
Stylus Parameter 5016
5015
CL
TI4717A
Figure 8.16 - Tool Probe Parameter Definitions
M-392D 8-21
ENTERING TOOL NOSE RADIUS VALUE AND ORIENTATION CODE
- NOTE -
If Tool Nose Radius Compensation is to be used, the tool nose radius value and the
tool quadrant must be entered for each tool which uses Tool Nose Radius Compen-
sation.
3. Press the Geometry soft key to display the tool geometry offsets.
4. Use the page and cursor keys to position the cursor at the R Data field for the desired offset.
5. Enter the tool nose radius value and press the Input key.
- NOTE-
The “T” value defines the orientation of the tool tip and has a range from 0 through 9.
6. Use the cursor keys to position the cursor at the T Data field for the desired offset.
7. Enter the tool orientation code number and press the Input key.
8. Repeat steps 4 through 7 for each tool, as required.
4 3
+X
5 7
+Z
1 2
6
Main Spindle Tailstock / Sub-Spindle
TI2376
Figure 8.17 - Tool Orientation Codes
8-22 M-392D
ADJUSTING TOOL WEAR OFFSETS
Tool wear offset adjustments are made by adding to or subtracting from an existing offset value us-
ing positive or negative values and the Input+ soft key.
Tool Wear Offsets that are intended to adjust the position of the tool nose in the -X or -Z direction
are entered as NEGATIVE values. Tool Wear Offsets that are intended to adjust the position of the
tool nose in the +X or +Z direction are entered as POSITIVE values.
ADJUSTING X AND Z AXIS TOOL WEAR OFFSETS

3. Press the Wear soft key to display the Wear Offset page.
5. Enter the X axis wear value as follows:
If the control is set for Diameter Programming, enter the wear offset as a diameter value.
If the control is set for Radius Programming, enter one half the measured (diameter) wear
offset value.
6. Press the Input+ soft key.
8. Enter the Z axis wear value.
9. Press the Input+ soft key.
10. Repeat steps 4 through 9 for each tool as required.
RULES FOR ADJUSTING WEAR OFFSETS

1. Negative (-) offset values MUST be signed.
2. Wear Offset values may not exceed .5000 inch [12.700 mm].
M-392D 8-23
- NOTES -
8-24 M-392D
CHAPTER 9 - MAIN SPINDLE AND COLLET CLOSER
- WARNING -
Tighten all draw tube screws before beginning spindle operation.
- CAUTION -
Never operate the main spindle without a work-holding device if the draw tube
is in the spindle.
INTRODUCTION
The main spindle is equipped with a .875 inch [22.2 mm] stroke, hydraulically actuated collet closer.
The hydraulic collet closer can be programmed for bar feed operation or it can be operated manually
for machine setup and chucking operations. If repairs to the collet closer assembly are required, the
ENTIRE ASSEMBLY must be removed and returned to the factory. Refer to the maintenance manual
(M-393) for information on removing or installing the collet closer assembly.
SPINDLE CAPACITIES
- CAUTION -
When machining bar stock that extends back into the spindle draw tube on a
machine equipped with a high-speed spindle, spindle liners MUST be used
when machining bar stock below the minimum size listed in the following ta-
ble.
Refer to “Spindle Liners”, page 9-13, for additional information.
QUEST® series lathes have the following maximum through-spindle capacities:
Machine Maximum Through-Spindle Minimum Bar Stock

Model Capacity Diameter for Operation
Inch [Millimeter] without a Spindle Liner
QUEST 6/42 Lathe 1.625 [41.27] 1.500 [38.10]
QUEST 8/51 Lathe 2.000 [50.80] 1.875 [47.63]
QUEST 10/65 Lathe 2.500 [63.50] 2.375 [60.33]
M-392D 9-1
FREE SPINDLE
A “Free Spindle” condition allows the main spindle to be turned by hand. To obtain a free spindle,
proceed as follows:
- NOTE -
To obtain a free spindle, the control must be ON and the spindle must not be rotat-
ing.
1. Power up the machine as described in Chapter 2.
2. Press the control Reset key.
3. Press the Main Spindle Free push button.
HYDRAULIC PRESSURE CONTROL

The collet closer draw bar force is controlled by hydraulic oil pressure. The hydraulic pressure con-
trols are located at the back of the machine.
Knob “A”, Figure 9.1, 9.2, 9.3, or 9.4 is used to adjust the hydraulic pressure applied to the collet
closer draw bar.
Gauge “B”, Figure 9.1, 9.2, 9.3, or 9.4 registers the collet closer hydraulic pressure in psig and bars.
Refer to Table 9.1, 9.2, or 9.3 to determine the approximate force that will be applied to the collet
closer draw bar for a given pressure.
A check valve system positively holds the closer open or closed, whichever is active, in the event of
an hydraulic pressure failure.
- CAUTION -
DO NOT exceed the maximum pressure setting, as shown in Tables 9.1, 9.2,
and 9.3.
The collet closer hydraulic pressure should be maintained at 500 psi [34.5 bar]
when operating at spindle speeds above 4,200 rpm.
- NOTE -
It is the responsibility of the machine operator or set-up person to properly adjust the
collet closer hydraulic pressure, based on the type of material to be machined and
the configuration of the workpiece.
ADJUSTING THE MAIN SPINDLE HYDRAULIC PRESSURE

1. Loosen the knurled lock nut behind adjustment knob “A”, Figure 9.1, 9.2, 9.3, or 9.4.
2. Turn the adjustment knob clockwise or counterclockwise to decrease or increase the collet
closer hydraulic pressure.
3. Tighten the knurled lock nut to secure the setting.
9-2 M-392D
B
TP4285
Figure 9.1 - Main Collet Closer Pressure Adjustment

(Machine Equipped with Standard Spindle Drive and Tailstock)
TP4196
(Machine Equipped with Standard Spindle Drive and Sub-Spindle)
M-392D 9-3
B
TP4815

(Machine Equipped with High Speed Spindle Drive and Tailstock)
TP4816

(Machine Equipped with High Speed Spindle Drive and Sub-Spindle)
9-4 M-392D
English Metric
Gauge Pressure Draw Bar Force Gauge Pressure Draw Bar Force
(psig) (lbs) (bar) (daN)
100 1,206 6.9 538
200 2,412 13.8 1,076
300 3,619 20.7 1,615
400 4,826 27.6 2,152
500 6,000 34.5 2,678
Table 9.1 - Main Spindle Collet Closer Draw Bar Force

(QUEST® 6/42 Lathes)
English Metric
100 2,000 6.9 890
200 4,000 13.8 1,780
300 6,000 20.7 2,670
400 8,000 27.6 3,560
500 10,000 34.5 4,450

(QUEST 8/51 Lathes)
English Metric
100 2,533 6.9 1,127
200 5,066 13.8 2,253
300 7,599 20.7 3,380
400 10,132 27.6 4,507
500 12,665 34.5 5,634

(QUEST 10/65 Lathes)
M-392D 9-5
MAIN COLLET CLOSER OPERATION
AUTOMATIC OPERATION
For automatic operation, program M21 to open the collet and M22 to close the collet. The M21
(Open Collet) command may be executed while the spindle is running. M21 will remain active until it is
canceled by an M22 (Close Collet) command. While M21 is active, the Main Open/Close push button
will not be active. A programmed M22 (Collet Close) command will remain active until it is canceled by
an M21 (Open Collet) command.
MANUAL OPERATION
- NOTE -
Manual operation of the collet closer is not possible while Cycle Start is active.
When the bar feed option is turned OFF, the collet closer can be manually operated in any mode.
When the bar feed option is turned ON, the machine must be in Jog mode to manually operate the col-
let closer. Use the Main Open/Close push button to operate the collet closer manually.
CHUCKING MODES
There is no default chucking mode. The current chucking mode will remain active until canceled by
the appropriate command (M27 or M28).
External chucking mode permits the use of work-holding fixtures that grip the workpiece externally.
Internal chucking mode permits the use of work-holding fixtures that grip the workpiece internally.
SWITCHING THE CHUCKING MODE

1. Check to be sure the Main Open/Close indicator light is ON. Place a workpiece in the collet and
press the Main Open/Close push button, if necessary.
2. Activate Manual Data Input mode.
3. Press the Program soft key.
4. At the manual Data input keyboard:
Key in “M28” for External Chucking
Key in “M27” for Internal Chucking
8. Close the machine guard door and press the Cycle Start push button.
9. Press the control Reset key. The selected chucking mode will be active
9-6 M-392D
CLEANING THE SPINDLE
As a general rule, the spindle and spindle draw tube should be cleaned between setups or monthly
if a long-run job is on the machine. However, when the machine is run more than one shift per day or
certain types of materials are being machined, it may be necessary to clean the spindle and spindle
draw tube more often. Use the spindle tooling removal and installation procedures that follow for
cleaning the spindle and draw tube.
SPINDLE TOOLING
- CAUTION -
Read and follow all safety recommendations and operating limits for any
work-holding device installed in the spindle. DO NOT EXCEED the rated ca-
pacity of the work-holding device.
QUEST® series machines are available with a standard or high speed main spindle. The high
speed spindle is balanced to the ISO G1.0 standard and requires a work-holding device balanced to
ISO G2.5 or better.
All work-holding devices, other than Hardinge collets, should be carefully reviewed for speed limi-
tations and balance specifications.
Hardinge Inc. offers chucks balanced to G2.5 or better for high speed applications.
REMOVING SPINDLE TOOLING
- CAUTION -
Do not operate the collet closer
when a collet or step chuck is
mounted in place without gripping a
piece of stock or a plug of the cor-
rect size. C
1. Power the machine up using the procedure
outlined in Chapter 2.
4. If necessary, press the Main Open/Close push
button to open work-holding device in the collet
closer.
5. At the left end of the machine, remove draw
tube access cover “C”, Figure 9.5.
TP4088
6. If present, remove the plug from the end of the
spindle draw tube. Figure 9.5 - Main Spindle Draw
Tube Access Cover
M-392D 9-7
7. Completely loosen six screws “D”, Figure 9.6.
- NOTE -
Six screws “D”, Figure 9.6, must be
completely disengaged from the collet
F
closer liner before draw tube nut “E” D
can be rotated.
Removal of a jaw chuck or step chuck
may require the assistance of a second E
person.
8. Rotate draw tube nut “E”, Figure 9.6,
counterclockwise to disengage the draw tube
from the work-holding device.
- WARNING -
Be prepared to accept the weight of
the work-holding device. TP4821
9. Remove the work-holding device from the Figure 9.6 - Main Spindle Draw Tube Nut
spindle.
10. If the machine is equipped with the optional
sub-spindle, cover the sub-spindle to protect it from chips while the main spindle is being
cleaned.
11. Close the main coolant guard door.
12. From the collet closer end of the draw tube, use an air line to blow chips and coolant out of the
spindle.
- WARNING -
The draw tube may be HOT when running aggressive duty cycles on machines
equipped with a high speed spindle.
13. Completely remove the draw tube from the back of the spindle.
14. From the collet closer end of the draw tube, use an air line to blow chips and coolant out of the
spindle a second time.
15. Clean the spindle and draw tube.
16. Lightly lubricate the bearing surfaces of the draw tube with Molylube® Anti-Seize grease.
17. Lightly coat the remaining exterior surfaces of the draw tube with Mobiltemp® SHC 32 grease.
18. Carefully replace the draw tube in the spindle.
19. If spindle tooling is to be installed at this time, proceed to “Installing Spindle Tooling”, beginning
on page 9-9.
If spindle tooling is not to be installed at this time:
A) Replace the draw tube plug.
B) Replace draw tube access cover “C”, Figure 9.5.
9-8 M-392D
INSTALLING SPINDLE TOOLING
- NOTE -
For the best surface finish and part roundness, the main spindle and draw tube have
been balanced together at the factory. Although the spindle and draw tube can be
run in other positions, the best balance is when etched mark “F”, Figure 9.6, and
spindle drive button “G”, Figure 9.7, are aligned.
Two procedures are outlined in this section. The first procedure, which begins below, covers the in-
stallation of collets and step chucks. The second procedure, beginning on page 9-11, covers the in-
stallation of jaw chucks.
Collet or Step Chuck

This procedure assumes that any previously used spindle tooling has already been removed. If
there is spindle tooling to be removed, perform the steps outlined under “Removing Spindle Tooling”,
beginning on page 9-7.
If previously used spindle tooling has just been removed, proceed to step 6.
- CAUTION -
Do not operate the collet closer when a collet or step chuck is mounted in
place without gripping a piece of stock or a plug of the correct size.
1. Power the machine up using the procedure outlined in Chapter 2.
4. Remove draw tube access cover “C”, Figure 9.5.
5. If present, remove the plug from the end of the spindle draw tube.
- NOTE -
The collet and spindle bore MUST be clean.
6. Clean the spindle bore and the collet or step
chuck and closer to be installed. G
7. Press the Main Spindle Free push button to

release the spindle brake and allow the spindle
to be rotated.
8. Manually position spindle drive button “G”,
Figure 9.7, to the top dead center (12 o’clock)
position.
9. Press the Main Spindle Free push button again
to have the brake secure the spindle drive
button at 12 o’clock.
TP4820
Figure 9.7 - Main Spindle Nose with

Drive Button at Top Dead Center
M-392D 9-9
- WARNING -
To insure operator safety:
- DO NOT use cast iron step chucks.
- DO NOT use a step chuck without a step chuck closer.
- NOTE -
Installation of a step chuck may require the assistance of a second person.
10. If installing a step chuck in the spindle, place the step chuck closer against the spindle and
install the mounting screws securely.
11. Align the keyway in the collet with the key in the spindle and slide the collet into the spindle until
it makes contact with the draw tube.
12. Carefully push the draw tube against the back of the collet while rotating the draw tube
clockwise to start the threads of the collet into the threads of the draw tube.
- NOTE -
Adjustment of the collet or step chuck may require the assistance of a second per-
son.
13. Select the largest diameter workpiece which is to be chucked and position this part in the collet
or step chuck.
14. Rotate draw tube nut “E”, Figure 9.6, clockwise until the workpiece is gripped tightly; then, back
the draw tube nut off ¼ to ½ turn.
15. Rotate the draw tube the shortest distance to locate etched mark “F” at top dead center (12
o’clock) position.
16. Tighten six draw tube screws “D”.
17. Press the Main Open/Close push button to close the collet and test the gripping force on the
workpiece.
If the gripping force is satisfactory, then go to step 14.
If the gripping force is more or less than desired, adjust knob “A”, Figure 9.1, 9.2, 9.3, or
9.4, to any setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table 9.1, 9.2,
or 9.3.
- CAUTION -
If the machine will not be operated with a bar feed system, the draw tube plug
should be installed in the end of the spindle draw tube to prevent coolant and
chips from entering the spindle drive motor compartment.
18. Install the plug in the end of the spindle draw tube if a bar feed system will not be used.
19. Replace draw tube access cover “C”, Figure 9.5.
9-10 M-392D
Jaw Chuck
there is spindle tooling to be removed, perform the steps outlined under “Removing Spindle Tooling”,
beginning on page 9-7.
- CAUTION -
- NOTE -
The jaw chuck and spindle bore MUST be clean.
6. Clean the jaw chuck and spindle bore.
7. Press the Main Spindle Free push button to release the spindle brake and allow the spindle to
be rotated.
8. Manually position spindle drive button “G”, Figure 9.7, to the top dead center (12 o’clock)
position.
9. Press Main Spindle Free push button again to have the brake secure the spindle drive button at
12 o’clock.
10. Place the chuck in the spindle and install the mounting screws securely.
11. Carefully push the draw tube against the back of the chuck while rotating the draw tube
clockwise to start the threads of the chuck into the threads of the draw tube.
12. Thread the draw tube onto the 3 jaw chuck as far as possible.
13. Rotate the draw tube counterclockwise to locate etched mark “F”, Figure 9.6, at top dead center
(12 o’clock) position.
14. Tighten six draw tube screws “D”.
M-392D 9-11
15. Place a workpiece into the chuck and press the Main Open/Close push button to close the
chuck and test the gripping force on the workpiece.
If the gripping force is more or less than desired, adjust knob “A”, Figure 9.1, 9.2, 9.3, or
9.4, to any setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table 9.1, 9.2,
or 9.3.
- CAUTION -
9-12 M-392D
SPINDLE LINERS
INTRODUCTION
- CAUTION -
When machining bar stock that extends back into the spindle draw tube on a
machine equipped with a high-speed spindle, spindle liners MUST be used
when machining bar stock below the minimum size listed in the table shown
on page 9-1.
The spindle liner supports and aligns the bar stock in the spindle draw tube. Each spindle liner con-
sists of four nylon spindle liner bushings, three spindle liner spacers, and one spindle liner nut. Bore
the four spindle liner bushings to the appropriate size and install the spindle liner components in the
spindle draw tube.
SPINDLE LINER BUSHING
- NOTE -
A spindle liner requires four spindle liner bushings bored to the same size.
A round capacity hole will always be used in the spindle liner bushing, regardless of
the profile of the bar stock to be machined (round, square, hex, ...).
Referring to Figure 9.8, the dimensions of the spindle liner bushings are as follows:
Machine Dimension “A” Dimension “B” Dimension “C”

Model Inch [Millimeter] Inch [Millimeter] Inch [Millimeter]
QUEST® 6/42 Lathe 1.673 2.677 .250
QUEST 8/51 Lathe 2.080 3.203 .250
QUEST 10/65 Lathe 2.628 4.816 .468
B
TP4838
Figure 9.8 - Spindle Liner Bushing

(Cross Section View)
M-392D 9-13
Boring a Bushing to Size
1. Install a 3 jaw chuck or step check in the machine spindle that will accommodate the O.D. of
the spindle liner bushing.
2. Insert the spindle liner bushing into the selected work-holding device and press the Main
Open/Close push button to close the work-holding device.
- CAUTION -
If drilling the capacity hole for clearance purposes, be sure to drill the capacity
hole undersize.
3. If necessary, use a drill to open up the capacity hole to accommodate the boring bar.
4. Bore the capacity hole in the spindle liner bushing to a diameter that is .020 inch [.5 millime-
ter] larger than the bar stock to be machined.
INSTALLING OR REMOVING THE SPINDLE LINER
- NOTE -
The spindle, draw tube, and spindle liner components must be cleaned before
installation.
3. If the collet closer is in the closed position, press the Main Open/Close push button to set the
collet closer to the open position.
4. On the machine, press the Emergency Stop push button.
5. On the bar feed unit or bar loader, press the Emergency Stop push button.
6. If necessary, move the bar feed unit or bar loader away from the machine.
8. Install or remove the spindle liner bushings components. Refer to Figure 9.9.
Installation:
A) Install the spindle liner bushings and spacers.
B) Install the spindle liner nut and tighten the three screws.
Removal:
A) Loosen the three screws and remove the spindle liner nut.
B) Remove the spindle liner bushings and spacers.
9-14 M-392D
Spindle Liner Nut Spindle Liner Spacers
Spindle Liner Bushings
TP4806
Figure 9.9 - Spindle Liner Components Installed in Spindle Draw Tube

10. Position the bar feed unit or bar loader in operating position.
11. Clear the Emergency Stop on the bar feed unit or bar loader.
12. Pull the Emergency Stop push button on the machine out to the first detent, wait two seconds;
then, pull the push button out to the end of travel and release.
M-392D 9-15
- NOTES -
9-16 M-392D
CHAPTER 10 - TAILSTOCK
INTRODUCTION
®
QUEST series lathes feature a hydraulically operated, programmable tailstock. The hydraulic
system is located at the rear of the machine. The tailstock gives added support when machining long
parts and reduces part deflection. This allows for closer tolerances, better surface finishes, and higher
speeds and feeds than would otherwise be possible.
- WARNING -
Be sure all personnel are clear of the tailstock before initiating tailstock mo-
tion.
- CAUTION -
Always make certain the turret is in a safe index position before moving the
tailstock toward the machine spindle.
Check and, if necessary, adjust the tailstock feedrate before using the
tailstock for machining operations. Refer to “Checking and Adjusting
Tailstock Feedrate”, page 10-8.
Check and, if necessary, adjust the tailstock force before using the tailstock
for machining operations. Refer to “Checking and Adjusting Tailstock Force”,
page 10-9.
The tailstock assembly is advanced and retracted by means of a hydraulic cylinder. Tailstock mo-
tion can be controlled automatically from the part program or manually using push buttons on the op-
erator control panel.
There are two rates of motion:
• The rapid traverse rate (approximately 300 in/min [7620 mm/min])
• The adjustable feedrate.
The tailstock incorporates a “safety shear” feature to prevent damage to the tooling, turret,
tailstock, and linear ways in the event that the turret contacts the tailstock. If contact is made between
the tailstock and turret, the “safety shear” feature allows the tailstock to be pivoted away from the tur-
ret. Refer to the maintenance manual (M-393) for instructions on aligning the tailstock.
Tailstock overtravel protection in the forward direction is provided by macro program 9130. If the
tailstock reaches the overtravel coordinate programmed in macro program 9130, tailstock motion will
stop and the machine is put into a feed hold condition.
M-392D 10-1
TRAVEL SPECIFICATIONS
The tailstock travel specifications are shown in Figure 10.1. Tailstock Home (Retract) is a fixed po-
sition. The forward (extend) position can be adjusted to suit the workpiece length.
+X Z0
28.75 [730.3]
+Z 7.25
Dependent on Tailstock Center used
[184.2]
CL
Main Tailstock at Tailstock at Fixed

Spindle Forward Position Home Position
NOTE: All dimensions are shown in inches [millimeters]

TI4651A
Figure 10.1 - Tailstock Travel Specifications
10-2 M-392D
TAILSTOCK POSITIONS
Four tailstock positions are recognized by the control:
• Fixed Home Position
• Adjustable Home Position (Retract)
• Rapid-To-Feed Position
• Overtravel Position
- NOTE -
The programmer establishes the adjustable home, rapid-to-feed, and overtravel po-
sitions, as needed, through macro program 9130. When the tailstock is commanded
to one of these positions, the tip of the tailstock center will be moved to the com-
manded position.
Refer to the programmer’s manual (M-391) for information on setting the adjustable
home, rapid-to-feed, and overtravel positions through macro program 9130.
FIXED HOME POSITION

The fixed home position is at the maximum tailstock travel away from the machine spindle. Refer to
“Tailstock Movement”, page 10-5, for information on moving the tailstock to this position. This position
is NOT adjustable. Refer to Figure 10.1.
ADJUSTABLE HOME POSITION (RETRACT)

The adjustable home position is located between the rapid-to-feed position and the fixed home po-
sition. This position is intended to minimize tailstock motion, resulting in lower cycle times.
When the tailstock is commanded to the adjustable home position, the tip of the live center is posi-
tioned at the adjustable home position.
RAPID-TO-FEED POSITION
The rapid-to-feed position is the coordinate at which the rapid forward motion of the tailstock is re-
duced to provide acceptable contact with the workpiece.
OVERTRAVEL POSITION
The overtravel position is the coordinate at which the forward motion of the tailstock is stopped and
the machine is put into a feed hold condition.
M-392D 10-3
TAILSTOCK SAFETY INTERLOCKS
There are two safety interlocks associated with the tailstock. These interlocks are designed to re-
duce the possibility of crashes that result from incorrect tailstock positioning.
CYCLE START INTERLOCK

To activate Cycle Start while in Automatic, Manual Data Input, or Single mode, the tailstock MUST
be in one of the following positions:
• Fixed Home position
• Adjustable Home Position (Retract)
• Forward Position (Any coordinate between the rapid-to-feed and the overtravel posi-
tions)
If the tailstock is not in one of these three positions, an alarm will be generated by the control when
the Cycle Start push button is pressed.
To clear the alarm, move the tailstock to the fixed home position. Refer to “Tailstock Movement”,
page 10-5, for information on moving the tailstock.
OVERTRAVEL INTERLOCK
While in Automatic, Manual Data Input, or Single mode, M84 commands RAPID tailstock motion
toward the machine spindle. Macro program 9130 MUST be executed to set the rapid-to-feed position
so that the tailstock center will FEED onto the workpiece. If no workpiece is present, the tailstock will
continue to move toward the machine spindle, resulting in an overtravel condition.
Tailstock overtravel protection in the forward direction is provided by the overtravel coordinate pro-
grammed in macro program 9130. If the tailstock reaches the overtravel coordinate, an alarm will be
generated and the machine will be put into a feed hold condition.
To clear the alarm:
2. Press the right-hand Z/E push button to move the tailstock to the fixed home position at the
rapid traverse rate.
10-4 M-392D
TAILSTOCK MOVEMENT
- NOTE -
Refer to the programmer’s manual (M-391) for information on programming tailstock
operation.
Generally, the machine control must be in Jog mode to manually control tailstock motion. The nota-
ble exception is during “between-center” work. If M30 (End of Program) is active while in Automatic
mode, it is possible to manually jog the tailstock without switching to Jog mode. Be aware that activat-
ing Jog mode will cancel this feature until another M30 is read by the control while in Automatic mode.
The Z/E push buttons are used to jog the tailstock in the indicated direction.
While in manual mode, the tailstock will always FEED toward the machine spindle and RAPID
away from the machine spindle.
MANUAL MOVEMENT
Initiating Manual Movement

2. Set the Manual Axis Movement switch to “E” to select the tailstock.
3. Move the tailstock as follows:
TOWARD THE MACHINE SPINDLE
When the tailstock is to the right of the rapid-to-feed position:
Press the left-hand Z/E push button to FEED the tailstock toward the machine spindle
(-Z direction).
Press the left-hand Z/E push button and the Rapid Traverse push button to RAPID the
tailstock toward the machine spindle (-Z direction).
TOWARD THE FIXED HOME POSITION
Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position.
Stopping Manual Movement

Manual tailstock motion can be stopped by pressing the Emergency Stop push button, Hold push
button, or control Reset key.
EMERGENCY STOP
To initiate tailstock motion after an Emergency Stop:
4. Press a Z/E push button to move the tailstock in the desired direction.
HOLD or RESET
To initiate tailstock motion after a Hold or control Reset, press a Z/E push button to move
the tailstock in the desired direction.
M-392D 10-5
PROGRAMMED MOVEMENT
Initiating Programmed Movement

- NOTE -
The machine control MUST be in Automatic, Manual Data Input, or Single mode to
command tailstock motion using M codes.
M84 Tailstock Forward
When an M84 is read by the control, the tailstock will RAPID forward (toward the machine
spindle) until the rapid-to-feed position is reached. At that point, the tailstock will slow to
the preset feedrate and feed onto the workpiece.
M85 Tailstock Retract
When an M85 is read by the control, the tailstock will move to the first home position en-
countered at RAPID TRAVERSE rate.
M86 Tailstock Home
When an M86 is read by the control, the tailstock will move to the fixed home position at
the RAPID TRAVERSE rate.
Stopping Programmed Movement

Programmed tailstock motion can be stopped by pressing the Emergency Stop push button, Feed
Hold push button, or control Reset key.
EMERGENCY STOP
To initiate programmed tailstock motion after an Emergency Stop:
4. Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position.
5. Reset the program to the beginning of the current operation.
6. Activate Automatic mode and press the Cycle Start push button.
10-6 M-392D
FEED HOLD
To initiate programmed tailstock motion after a Feed Hold, press the Cycle Start push but-
ton.
RESET
To initiate programmed tailstock motion after a control Reset:
2. Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position.
3. Reset the program to the beginning of the current operation.
4. Activate Automatic mode and press the Cycle Start push button.
M-392D 10-7
CHECKING AND ADJUSTING TAILSTOCK FEEDRATE
2. Press the right-hand Z/E push button to Home the tailstock.
3. Press the left-hand Z/E push button to move the tailstock toward the machine spindle and
observe the current tailstock feedrate. The tailstock will move toward the machine spindle at the
adjustable feedrate.
4. If the tailstock feedrate needs to be changed, turn knob “C”, Figure 10.2 or 10.3, in the required
direction to increase or decrease the feedrate as desired.
5. Repeat steps 2 through 4 until the desired feedrate is achieved.
B
B
A A
C
TP4285 TP4815
Figure 10.2 - Hydraulic System Figure 10.3 - Hydraulic System

(Machine with Standard Spindle) (Machine with High Speed Spindle)
10-8 M-392D
CHECKING AND ADJUSTING TAILSTOCK FORCE
The force applied to the workpiece is controlled by hydraulic oil pressure which is regulated by
valve “A”, Figure 10.2 or 10.3. Gauge “B” indicates the force in pounds per square inch and bars. Ta-
ble 10.1 lists the approximate force in pounds and dekanewtons which will be applied to the workpiece
for a given gauge pressure.
2. Use the left-hand Z/E push button to engage the tailstock with the workpiece.
3. Check the tailstock hydraulic pressure on gauge “B”, Figure 10.2 or 10.3.
If the tailstock hydraulic pressure needs to be adjusted, go to step 4.
If the tailstock hydraulic pressure does not need to be adjusted, go to step 6.
English Metric
Gauge Pressure Applied Force Gauge Pressure Applied Force
200 630 13.8 280
300 940 20.7 420
400 1,260 27.6 560
500 1,570 34.5 700
Table 10.1 - Applied Tailstock Force
M-392D 10-9
- CAUTION -
Recommended tailstock pressure is 350 psig (24 bars). For maximum operat-
ing safety and to ensure that the hydraulic tailstock functions correctly, never
set the tailstock pressure below 200 psig [13.8 bars].
4. Loosen the knurled lock nut on valve “A” and turn the adjusting nut in the required direction until
the desired pressure registers on gauge “B”. Refer to Table 10.1.
5. Tighten the lock nut on valve “A”.
6. Press the right-hand Z/E push button to move the tailstock to the fixed home position.
REMOVING AND INSTALLING A LIVE CENTER

REMOVING A LIVE CENTER
- NOTE -
Release nut "E", Figure 10.4, requires a 2 inch wrench, which is supplied with the
machine. The wrench part number is QC 0009189.
Remove the live center by rotating release nut "E", Figure 10.4, outward to push live center "D" from
the tailstock bushing.
INSTALLING A LIVE CENTER

1. Rotate the release nut inward before installing a live center.
2. Insert the live center into the tailstock bushing.
The live center will be seated in the bushing the first time it contacts a workpiece.
TI5362
Figure 10.4 - Live Center

and Release Nut
10-10 M-392D
- NOTES -
M-392D 10-11
- NOTES -
10-12 M-392D
CHAPTER 11 - INPUT/OUTPUT DEVICES
INTRODUCTION
®
QUEST series lathes are available with either the standard operator interface or the optional
PC-based operator interface. When indicated, refer to the specific information relating to the appro-
priate operator interface.
The purpose of this chapter is to explain the transfer of data between the various input/output de-
vices and the CNC control.
INPUT/OUTPUT DEVICE LOCATIONS

- NOTE -
The RS-232 port supplied with the standard operator interface is a 25 pin connec-
tion.
The standard operator interface is equipped with one ATA Flash Card port and one physical
RS-232 port, shown in Figure 11.1.
ATA Flash
Card Port
RS-232
Serial Port
TP4090
Figure 11.1 - Data Input/Output Ports

(Standard Operator Interface)
M-392D 11-1
- NOTE -
The RS-232 port supplied with the PC-based operator interface is a 15 pin connec-
tion.
The PC-based operator interface is equipped with the following devices for data input/output:
• RS-232 Serial Port (15 pin) for PC Data
• RS-232 Serial Port (25 pin) for NC Data
• 3½” Disk Drive
• Internal Hard Disk
• CD-ROM Drive
Refer to Figures 11.2, 11.3, and 11.4.
Open the Data port cover, Figure 11.2, to gain access to the PC Data RS-232, universal serial, key-
board, and mouse ports.
Cover for
3½” Disk Drive and ATA Flash
CD-ROM Drive Card Port
Data Port
Cover
RS-232 Port
for NC Data
TP4623A
Figure 11.2 - ATA Flash Card Port

and Cover for RS-232 Port
(PC-Based Operator Interface)
11-2 M-392D
RS-232 Port
for PC Data
TP4624A
Figure 11.3 - RS-232 Port

CD-ROM
Drive
3½” Disk
Drive
TP4622
Figure 11.4 - 3½” Disk Drive

and CD-ROM Drive
M-392D 11-3
INPUT/OUTPUT DEVICE SELECTION
The input/output device to be used is selected through the I/O Channel setting, which is discussed
on page 2-8. The valid settings for the I/O Channel are 0, 1, 2, and 4.
I/O CHANNEL 0, 1, OR 2
Three independent port assignments are available to allow the operator or programmer to estab-
lish three different I/O port configurations for the same physical RS-232 port. These three configura-
tions are designated as channels 0, 1, and 2.
Instead of changing the associated parameters to reassign the baud rate and stop bits, it is possible
to select a different I/O port configuration and have the changes implemented by the control automati-
cally.
Setting the I/O Channel to 0, 1, or 2 selects the RS-232 port and selects which configuration will be
active.
Refer to page 11-6 for information on the RS-232 port.
Refer to page 11-8 for information on the RS-232 port parameter settings.
11-4 M-392D
I/O CHANNEL 4
Standard Operator Interface

Setting the I/O Channel to 4 selects the ATA Flash Card port. Refer to page 11-15 for information on
using the ATA Flash Card port.
PC-Based Operator Interface

Setting the I/O Channel to 4 allows the operator to select any of the following devices for data in-
put/output:
• 3½” Disk Drive (Drive A:)
• Internal Hard Disk (Drive C: and D:)
• CD-ROM Drive (Drive E:)
• ATA Flash Card Port (Drive F:)
SELECTING THE INPUT/OUTPUT DEVICE
- NOTE -
If the ATA flash card is to be used on the PC-based operator interface, it must be
plugged into the flash card port BEFORE the control is turned ON.
1. Press Shift + Graph.
2. Select “Data Input/Output Device” from the menu.
3. If the desired device is already selected, press OK
or
Proceed to step 4.
4. Press Browse.
5. Select the desired device (A, C, D, E, or F). Refer to the following device definitions:
A: 3½” disk drive
C: hard disk, partition 1
D: hard disk, partition 2
E: CD-ROM drive
F: ATA flash card port
6. Press OK to exit the device selection display.
7. Press OK to exit to the CNC display.
M-392D 11-5
RS-232 SERIAL PORT (NC DATA)
DATA COMMUNICATIONS PROTOCOL
Data communications protocol consists of three basic types of information: parity, baud rate, and
stop bits. The baud rate and stop bits are controlled by parameters, which may be modified as re-
quired.
Tape Parity Check

Tapes punched in EIA format (EIA Standard RS-244-B) contain an odd number of holes in each
character and tapes punched in ASCII (ISO), (EIA Standard RS-358-B) contain an even number of
holes in each character. This characteristic of having an odd or even number of holes punched in ev-
ery character is called parity.
The control accepts tape punched in either code, but each tape must be programmed in only one of
the accepted codes.
The control automatically determines the particular type of coding by decoding the first End of
Block (;) character on the tape. Each character is checked for parity as it is read by the tape reader or
computer.
Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired par-
ity.
Baud Rate
Baud rate is the speed at which data is transmitted from one device to another. To successfully
transmit data between two devices, it is necessary to have both devices set to the same baud rate.
The baud rate is set by three different parameters, depending on which I/O port is active. Refer to
the I/O setting on Setting Page #1 to determine which I/O port is active. Refer to ”Input/Output Device
Selection”, page 11-4.
Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired baud
rate.
Stop Bits
The control is capable of operating with 1 or 2 stop bits, depending on the requirement. The number
of stop bits active in the machine control is controlled by three different parameters, depending on
which I/O port is active. These parameters may be modified as required. Refer to ”Input/Output De-
vice Selection”, page 11-4.
Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired
number of stop bits.
11-6 M-392D
CHECKING AND MODIFYING COMMUNICATIONS PARAMETERS
Use the following procedure to check communications protocol parameters:
3. Use the Page keys to display the parameter page to be viewed.
Use the following procedure to check and modify communications protocol parameters as needed:
3. If necessary, use the Page keys to display the Setting page that contains the Parameter Write
field.
4. If necessary, use the cursor keys to position the cursor at the Parameter Write field.
6. Key in the number 1 (one).
7. Press the Input key. Parameter editing will be enabled.
10. Use the Cursor and Page keys to position the cursor on the parameter to be modified.
11. Key in the new parameter value.
13. Repeat steps 10 through 12, as needed.
17. Key in the number 0 (zero).
18. Press the Input key. Parameter editing will be disabled.
M-392D 11-7
RS-232 PORT PARAMETER SETTINGS
Refer to “Checking and Modifying Communications Parameters”, starting on page 11-7, for infor-
mation on modifying the parameter settings for the three I/O ports. These parameters may be modi-
fied as required.
Baud Rate Parameter Settings
I/O Port Parameter Number

0 103
1 113
2 123
The valid parameter settings are as follows:
Setting Baud Rate

1 50
2 100
3 110
4 150
5 200
6 300
7 600
8 1200
9 2400
10 4800
11 9600
12 19200
Stop Bit Parameter Settings
I/O Port Parameter Number Bit Number

0 101 0
1 111 0
2 121 0
The valid parameter settings are “0" for 1 Stop Bit and ”1" for 2 Stop Bits.
- NOTE -
The Stop Bit parameter settings are displayed as one bit in an 8 bit binary number (0
or 1). The bits are read “0" to ”7", from right to left.
11-8 M-392D
DATA TRANSFER
RS-232 SERIAL PORT (NC DATA)
Uploading Data through the RS-232 Port

UPLOADING CONTROL PARAMETERS INTO CONTROL MEMORY
- CAUTION -
Always connect the RS-232 cable before applying power to the external device
and always remove power from the external device before disconnecting the
RS-232 cable.
1. Verify the machine control communications protocol as outlined under “Checking and
Modifying Communications Parameters”, page 11-7.
2. Refer to the appropriate manual to set the tape reader or computer to the desired
communications protocol.
3. Connect the interface cable from the tape reader or computer to the serial port.
field.
14. Activate Edit mode.
15. Press the soft key expansion key until the Read soft key is displayed.
16. Press the Read soft key.
18. Set the tape reader or computer to transmit data to the machine control.
19. After the control parameters have been uploaded, activate Manual Data Input mode.
20. Press the Offset Setting soft key.
M-392D 11-9
23. Remove power from the external device; then, disconnect the RS-232 cable from the machine
control.
24. Close the serial port cover.
25. Turn the control OFF and wait approximately 10 seconds.
26. Turn the control ON.
UPLOADING PART PROGRAMS INTO CONTROL MEMORY
- CAUTION -
RS-232 cable.
2. Refer to the appropriate manual to set the tape reader or computer to the desired
- NOTE -
If the program has no program number or if the program number is to be altered, key
in the letter “O” and the desired program number.
8. Key in the letter “O” and the program number. Example: O1111
- NOTE -
When the program has been completely loaded into the control, it will appear as the
active program on the control display screen.
12. After the part programs have been uploaded, turn the Program Protect key to ON.
control.
11-10 M-392D
UPLOADING TOOL OFFSETS INTO CONTROL MEMORY
- CAUTION -
RS-232 cable.
2. Refer to the appropriate manual to set the tape reader, or computer to the desired
6. Press the Offset soft key.
- NOTE -
The offset data will load directly into the offset registers.
control.
M-392D 11-11
Downloading Data through the RS-232 Port
DOWNLOADING CONTROL PARAMETERS FROM CONTROL MEMORY
- CAUTION -
RS-232 cable.
2. Refer to the appropriate manual to set the tape punch or computer to the desired
4. Connect the interface cable to the output device and the serial port on the control.
5. Set the tape punch or computer to receive data.
10. Press the soft key expansion key until the Punch soft key is displayed.
11. Press the Punch soft key.
12. Press the ALL soft key to download all parameters
- or -
Press the NON ZERO soft key to download only parameters with non-zero values.
- NOTE -
To stop the parameters from downloading, press the Reset key. Once the Reset key
has been pressed, it is not possible to download the remaining parameters. It will be
necessary to download all of the parameters.
14. After the control parameters have been downloaded, remove power from the external device
and disconnect the RS-232 cable from the machine control.
11-12 M-392D
DOWNLOADING PART PROGRAMS FROM CONTROL MEMORY
- CAUTION -
RS-232 cable.
8. Key in the letter “O” and the program number. Example: O1111
10. Press the Punch key.
- NOTE -
When outputting to a tape punch, the control will automatically output 3 feet of leader
and trailer tape. To shorten the leader or trailer length, press the Cancel push button
while the leader or trailer is being punched, respectively.
To stop the part program from downloading, press the Reset key. Once the Reset
key has been pressed, it is not possible to download the rest of the part program. It
will be necessary to download the entire part program.
12. After the part programs have been downloaded, remove power from the external device and
disconnect the RS-232 cable from the machine control.
M-392D 11-13
DOWNLOADING TOOL OFFSETS FROM CONTROL MEMORY
- CAUTION -
RS-232 cable.
8. Press the Offset soft key.
9. Press the Geometry soft key to display the Geometry offset page.
12. Press the Punch key.
- NOTE -
To stop the tool offsets from downloading, press the Reset key. Once the Reset key
has been pressed, it is not possible to download the remaining tool offsets. It will be
necessary to download all of the tool offsets.
14. After the tool offsets have been downloaded, remove power from the external device and
disconnect the RS-232 cable from the machine control.
11-14 M-392D
INTEGRATED INPUT/OUTPUT DEVICES
Standard Operator Interface

Machines with the standard operator interface are equipped with an integrated ATA Flash Card
Port.
- NOTES -
Any flash card used must be an ATA Flash Card.
I/O Channel 4 must be selected. Refer to page 11-5 for information on selecting I/O
Channel 4.
FILE MANAGEMENT
1. Insert the ATA flash card into the flash card port.
2. Set the I/O Channel to 4.
3. If copying a program to the machine control, turn the Program Protect key to OFF.
4. If copying parameters to the machine control:
A) Press the Offset Setting key.
B) Press the Setting soft key.
C) If necessary, use the Page keys to display the Setting page that contains the Parameter
Write field.
D) If necessary, use the cursor keys to position the cursor at the Parameter Write field.
E) Activate Manual Data Input mode.
F) Key in the number 1 (one).
G) Press the Input key. Parameter editing will be enabled.
7. Press the soft key expansion key until the ALL IO soft key is displayed.
8. Press the ALL IO soft key.
9. Press the appropriate soft key, based on the type of file to be copied to the control memory:
Program: This function is used to transfer a program between the I/O device and control
memory.
Parameter: This function is used to transfer a parameter file between the I/O device and
control memory.
Offset: This function is used to transfer an offset file between the I/O device and con-
trol memory.
M-392D 11-15
10. Press the Operator soft key. The following soft key functions will be displayed:
FILE This function is used to search the selected input/output device for a specific
SEARCH file name.
A) Press the File Search soft key.
B) Key in the number of the file, NOT a program name.
C) Press the File Set soft key.
D) Press the Execute soft key. If the specified file is found, it will be displayed at the top of the
file listing.
FILE This function is used to copy the selected file from the input/output device to
READ the machine control.
A) Press the File Read soft key.
D) Press the Execute soft key. The selected file will be copied to the control memory.
PUNCH This function is used to copy the machine parameters, offset register data, or
the active program from the machine control to the input/output device
A) If necessary, activate the program to be copied. Refer to Chapter 3 for information on
activating programs.
B) Press the Punch soft key.
C) If a file name is to be assigned, key in the file name and press the File Name soft key.
D) If a program name is to be changed, key in the new program name and press the O Set soft
key.
E) Press the Execute soft key. The selected file will be copied from the control memory to the
input/output device.
DELETE This function is used to delete a selected file from the input/output device.
A) Press the Delete soft key.
D) Press the Execute soft key. The specified file will be deleted from the input/output device.
11-16 M-392D
11. If a program was copied to the machine control, turn the Program Protect key to ON.
12. If control parameters were copied to the machine control:
A) Activate Manual Data Input mode.
B) Press the Offset Setting soft key.
C) Key in the number 0 (zero).
D) Press the Input key. Parameter editing will be disabled.
14. Remove the ATA flash card and close the cover.
M-392D 11-17
PC-Based Operator Interface
Machines with the PC-based operator interface are equipped with the following integrated in-
put/output devices:
• 3½” disk drive
• Internal Hard Disk
• CD-ROM Drive
- NOTES -
Any flash card used must be an ATA Flash Card.
I/O Channel 4 must be selected. Refer to page 11-5 for information on selecting I/O
Channel 4.
If an ATA flash card is to be used, the flash card must be plugged into the flash card
port BEFORE the control is turned ON.
FILE MANAGEMENT
1. If the ATA flash card port is to be used, insert the ATA flash card into the flash card port before
the control is turned ON.
2. Turn the machine control ON.
3. Set the I/O Channel to 4.
4. Select the input/output device to be used:
A: 3½” disk drive
C: internal hard disk, partition 1
D: internal hard disk, partition 2
E: CD-ROM drive
F: ATA flash card port
Refer to page 11-5 for information on the selecting the input/output device.
5. If copying a program to the machine control, turn the Program Protect key to OFF.
6. If copying parameters to the machine control:
A) Press the Offset Setting key.
B) Press the Setting soft key.
C) If necessary, use the Page keys to display the Setting page that contains the Parameter
Write field.
D) If necessary, use the cursor keys to position the cursor at the Parameter Write field.
E) Activate Manual Data Input mode.
F) Key in the number 1 (one).
G) Press the Input key. Parameter editing will be enabled.
11-18 M-392D
9. Press the soft key expansion key until the ALL IO soft key is displayed.
10. Press the ALL IO soft key.
11. Press the appropriate soft key, based on the type of file to be copied to the control memory:
Program: This function is used to transfer a program between the I/O device and control
memory.
Parameter: This function is used to transfer a parameter file between the I/O device and
control memory.
Offset: This function is used to transfer an offset file between the I/O device and con-
trol memory.
12. Press the Operator soft key. The following soft key functions will be displayed:
FILE This function is used to search the selected input/output device for a specific
SEARCH file name.
A) Press the File Search soft key.
D) Press the Execute soft key. If the specified file is found, it will be displayed at the top of the
file listing.
FILE This function is used to copy the selected file from the input/output device to
READ the machine control.
A) Press the File Read soft key.
D) Press the Execute soft key. The selected file will be copied to the control memory.
M-392D 11-19
PUNCH This function is used to copy the machine parameters, offset register data, or
the active program from the machine control to the input/output device
A) If necessary, activate the program to be copied. Refer to Chapter 3 for information on
activating programs.
B) Press the Punch soft key.
C) If a file name is to be assigned, key in the file name and press the File Name soft key.
D) If a program name is to be changed, key in the new program name and press the O Set soft
key.
E) Press the Execute soft key. The selected file will be copied from the control memory to the
input/output device.
DELETE This function is used to delete a selected file from the input/output device.
A) Press the Delete soft key.
D) Press the Execute soft key. The specified file will be deleted from the input/output device.
13. If a program was copied to the machine control, turn the Program Protect key to ON.
14. If control parameters were copied to the machine control:
A) Activate Manual Data Input mode.
B) Press the Offset Setting soft key.
C) Key in the number 0 (zero).
D) Press the Input key. Parameter editing will be disabled.
16. Remove the ATA flash card and close the cover.
11-20 M-392D
- NOTES -
M-392D 11-21
- NOTES -
11-22 M-392D
CHAPTER 12 - OPERATOR MAINTENANCE
INTRODUCTION
Operator maintenance is normally confined to cleaning the machine and maintaining the hydraulic
fluid and coolant levels. It is a good practice to check all fluid levels at the beginning of each shift. The
operator should also check the cooling fans periodically to see that they are free of obstructions and
functioning properly. Refer to the maintenance manual (M-393) for more extensive maintenance pro-
cedures.
MACHINE AIR SYSTEM

The machine is equipped with a regulator and two-stage filter system to regulate and filter the in-
coming air supply. The filter/regulator assembly is located at the back of the machine.
- CAUTION -
The air filter bowl should be drained at least once a day. If more frequent
draining is required, it may be necessary to install an air dryer in the air line.
DRAINING THE AIR FILTER BOWLS
1. Turn the main air valve on regulator “B”, Figure 12.1, ON.
2. Unscrew drain valve “C” only enough to drain the bowl of the standard air filter. Close the valve
when the air filter bowl has finished draining.
3. Unscrew drain valve “D” only enough to drain the bowl of the coalescing air filter. Close the
valve when the air filter bowl has finished draining.
D
C
TP4101
Figure 12.1 - Air Filter/Regulator
M-392D 12-1
ADJUSTING THE MACHINE AIR PRESSURE
Regulator “B”, Figure 12.1, is equipped with a pressure gauge that indicates the air pressure deliv-
ered to the machine. The recommended range for machine air pressure is 70 psig [4.8 bars] to 90 psig
[6.2 bars]. If necessary, adjust the regulator to set the machine air pressure to within the recom-
mended range.
- NOTE -
The machine is equipped with an air pressure sensor that will force the machine into
Emergency Stop if the air pressure falls below 60 psig [4.1 bars].
1. Turn main air valve on regulator “B”, Figure 12.1, ON.
2. Lift knob “A”, then turn the knob clockwise or counterclockwise to increase or decrease
machine air pressure, respectively.
3. Press knob “A” down to lock the setting.
HYDRAULIC SYSTEM
STANDARD HYDRAULIC UNIT
- NOTE -
®
Use only Mobil DTE-13M hydraulic fluid in the standard hydraulic unit.
The standard hydraulic unit provides hydraulic oil under pressure to operate the collet closer, spin-
dle brake, and turret. The reservoir should be filled whenever the hydraulic fluid level drops below
sight gauge “E”, Figure 12.2 .
The reservoir should be drained, cleaned, and filled with fresh hydraulic fluid after every 1000 hours
of operation. Refer to the maintenance manual (M-393) for instructions on draining and cleaning the
standard hydraulic unit.
Filling the Oil Reservoir

- NOTE -
It is recommended that the machine not
be powered up for at least 10 minutes
after oil has been added to the hydrau-
lic tank. This will allow any air bubbles
present in the oil to dissipate.
It is recommended that the hydraulic oil
be pre-filtered to 5 micron maximum
particle size before being added to the
hydraulic tank.
1. Power down the machine as outlined in E F
Chapter 2.
2. Remove cap “F”, Figure 12.2, and SLOWLY fill
the reservoir with Mobil DTE-13M hydraulic TP4105
fluid until sight gauge ”E” is filled. Figure 12.2 - Standard Hydraulic Unit
3. Replace cap “F”. (Shown with Cover Removed)
12-2 M-392D
HYDROSTATIC HYDRAULIC UNIT
- NOTE -
The hydrostatic hydraulic unit is only used on machines equipped with the
HydroGlide® hydrostatic linear guideway option.
Use only Mobil® DTE-18M® hydraulic fluid in the hydrostatic hydraulic unit.
The hydrostatic hydraulic unit provides hydraulic oil under pressure to the linear guideway trucks.
The reservoir should be filled whenever the hydraulic fluid level drops below sight gauge “H”, Figure
12.3.
The reservoir should be drained, cleaned, and filled with fresh hydraulic fluid after every 1000 hours
of operation. Refer to the maintenance manual (M-393) for instructions on draining and cleaning the
hydrostatic hydraulic unit.
Filling the Oil Reservoir

- NOTE -
It is recommended that the machine not be powered up for at least 10 minutes after
oil has been added to the hydraulic tank. This will allow any air bubbles present in
the oil to dissipate.
It is recommended that the hydraulic oil be pre-filtered to 5 micron maximum particle
size before being added to the hydraulic tank.
1. Power down the machine as outlined in Chapter 2.
2. Remove cap “G”, Figure 12.3, and SLOWLY fill the reservoir with Mobil DTE-18M hydraulic
fluid until sight gauge ”H” is filled.
3. Replace cap “G”.
TP5765
Figure 12.3 - Hydrostatic Hydraulic Unit

(Shown with Cover Removed)
M-392D 12-3
COOLANT SYSTEM
Hardinge machine tools are designed using the latest technology and highest quality materials
available. However, due to the ever-increasing number of coolant selections available, it is important
to test material compatibility with each and every coolant. For additional information regarding coolant
selection, coolant maintenance, and the coolant facilities on this machine, refer to the maintenance
manual (M-393).
- CAUTION -
Whenever water-soluble coolants are used, it is important to use the manufac-
turer’s recommended mix ratio (concentration). It is also important to maintain
the coolant by keeping the proper concentration level when coolant is added
to compensate for evaporation. Another important factor is coolant pH (acid-
ity). Typically, the coolant pH should be in the range of 8.5 to 9. When the pH
drops below 8.5 the rust inhibitors in the coolant start depleting, which can re-
sult in corrosion of machine components. Also, the quality of the water should
be tested by the coolant manufacturer so that the proper coolant additives can
be administered. Failure to follow these recommendations could result in dam-
age to the machine, seals, and paint.
If the coolant you have selected starts to react (cause material to rust, pit,
swell, soften, crack, blister, etc.) with any portion of the machine tool,
Hardinge suggests that you discontinue use and contact your coolant repre-
sentative for alternative coolants.
It should also be noted that certain chemicals react with different metals.
Hardinge recommends that you consult with your coolant representative to as-
sure that the material you are cutting does not react with the coolant you have
selected.
The coolant level should not be allowed to fall below the sight gauge on the coolant tank. The cool-
ant tank should be drained and cleaned at least every six months or whenever the type or brand of
coolant is changed. More frequent cleaning may be required if the material being machined contami-
nates the coolant. Refer to the maintenance manual (M-393) for instructions on draining and cleaning
the coolant system.
To fill the coolant tank, open the front coolant guard door and pour the required amount of coolant
directly into the chip pan. Fill the coolant tank to the “FULL” line on the sight gauge tag. Either wa-
ter-based or oil-based coolant may be used.
The coolant tank fluid capacity is 40 gallons [152 liters].
12-4 M-392D
TRAMP OIL PAN
- WARNING -
Dispose of waste oil in accordance with all applicable government guidelines.
DO NOT introduce the waste oil into the hydraulic system.
- NOTE -
The tramp oil pan is only used on machines equipped with the HydroGlide® hydro-
static linear guideway option.
The machine has been designed to keep contamination of the coolant by the oil used for the hydro-
static linear guideways to a minimum. The oil drains from the machine and is collected in the tramp oil
pan. The pan should be removed and emptied once a day. Empty the pan and place it back into posi-
tion.
1. Slide tramp oil pan “I”, Figure 12.4, under the hydraulic units platform.
2. Insert the end of tramp oil return line “J”, Figure 12.5, into the pan.
J
I
TP5780 TP5782
Figure 12.4 - Tramp Oil Pan Figure 12.5 - Tramp Oil Pan Completely in
Partially in Position Position with Return line in Place
(Viewed from Side of Machine)
M-392D 12-5
CHIP REMOVAL
(Machines Without an Optional Chip Conveyor)
1. Power down the machine as outlined in Chapter 2.
2. If coolant was ON, wait a few minutes to allow any coolant that was in use to drain back into the
tank.
3. Move the coolant tank as needed to gain access to the chips.
- WARNING -
Do not remove chips with your bare hands.
4. Rake or shovel the chips into a suitable container.
5. Return the coolant tank to its opening under the front of the machine.
6. Check inside the work area to make certain that coolant will drain back into the coolant tank
properly.
12-6 M-392D
- NOTES -
M-392D 12-7
- NOTES -
12-8 M-392D
CHAPTER 13 - OPTIONS AND
MISCELLANEOUS FEATURES
MACHINE RUN TIME COUNTER
The machine Run Time counter shows the total run time during automatic operation. The Run Time
counter does not count during a feed hold or programmed stop condition.
ACCESSING THE RUN TIME DISPLAY

Press the Position function key. The Run Time is displayed at the bottom of the page.
RESETTING THE RUN TIME COUNTER TO ZERO

2. If the Setting (Timer) page is not displayed:
A) Press the Setting soft key.
B) Use the page keys to display the Setting (Timer) page.
4. Turn the Program Protect key switch to the OFF position.
6. Move the cursor to the number to be reset.
7. Key in “0" (zero) and press the Input key.
8. Repeat steps 6 and 7 as needed.
9. Turn the Program Protect key switch to the ON position.
MACHINE CYCLE TIME COUNTER

The machine Cycle Time counter shows the time of one automatic operation. The Cycle Time
counter starts counting when Cycle Start is pressed and stops counting when an End of Program
(M02/M30) is encountered. The Cycle Time counter does not count during a feed hold or programmed
stop condition.
The Cycle Time counter is automatically reset to zero when the Cycle Start push button is pressed,
or when the control is turned OFF.
ACCESSING THE CYCLE TIME DISPLAY

Press the Position key. The Cycle Time is displayed at the bottom of the page.
M-392D 13-1
CLOCK FUNCTION
The clock function is displayed in the lower right corner of all screens. The clock function is dis-
played as a 24 hour clock.
RESETTING THE CLOCK DISPLAY

6. Move the cursor to the number to be corrected.
- NOTE -
The display will not be updated if an invalid value is entered. Negative numbers are
considered invalid values.
7. Enter the correct value and press the Input key. Refer to the following chart.
ITEM MAXIMUM VALUE

Year 2085
Month 12
Day 31
Hour 23
Minute 59
Second 59

13-2 M-392D
PARTS COUNTER
The Parts Counter shows the total number of times a program has been run during automatic oper-
ation. The Parts Counter is increased by one (1) each time an M97 command is read by the control.
- NOTE -
The Part Required register is located on the same display screen as the Parts Coun-
ter register.
When Part Required is set to any non-zero number and the machine is running in Repeat mode,
program execution will stop when the number in the Part Counter register is equal to the number in the
Part Required register.
ACCESSING THE PARTS COUNTER DISPLAY

Press the Position key. The Parts Counter is displayed at the bottom of the page.
RESETTING THE PARTS COUNTER TO ZERO

6. Move the cursor to the number to be reset.
7. Key in “0" (zero) and press the Input key.
- NOTE -
Part Required must be set to zero for continuous cycling of bar work.
M-392D 13-3
THREAD CUTTING CYCLE RETRACT
- NOTE -
Thread Cutting Cycle Retract is NOT functional during G32 Threadcutting.
This feature allows the operator to retract the tool from the workpiece during a threading pass. The
tool retracts to an X coordinate equal to the X coordinate of the start point of the threading cycle and
moves to the start point. The tool will follow the same basic retract movement that it would follow at the
end of the thread.
To retract the tool, press the Feed Hold push button. The tool will be retracted from the workpiece
when the current lead is completed. The tool will NOT finish the threading pass.
To restart the threading cycle, press the Cycle Start push button. The control will execute the
threading cycle as programmed. The tool will re-execute the pass which was interrupted by Feed
Hold.
The CNC control will synchronize the re-entry of the tool with the thread on the workpiece. This will
assure the thread will be properly formed when the threading cycle is completed.
HIGH PRESSURE COOLANT SYSTEM

The High Pressure coolant system option is used when special coolant-fed tools are mounted on
the turret. When the High Pressure coolant system is operating, the standard machine coolant system
is disabled. The pump unit is located externally from the machine and draws coolant from the ma-
chine’s coolant reservoir. The coolant is then pumped to the special tools when they are in the cutting
position.
The spindle must be running before activating High Pressure coolant. When the option turned ON,
the High Pressure coolant can be controlled manually by pressing the HP Coolant ON/OFF push but-
ton. The High Pressure coolant can also be activated and deactivated from the part program using the
M10 and M11 commands, respectively.
BAR FEED INTERFACE

- NOTE -
The bar feed interface must be activated for bar work and deactivated for slug work.
- NOTE -
The Block Skip push button indicator light will be ON when the bar feed interface is
activated.
2. Press and hold the Spindle Increase and Spindle Decrease push buttons.
3. Press the Block Skip push button to activate or deactivate the bar feed interface.
4. Release the Spindle Increase and Spindle Decrease push buttons.
13-4 M-392D
ENGLISH / METRIC MODE
One of the purposes of the Setting page is used to establish whether the control is to power-up and
operate in English mode or Metric mode. This section outlines the procedure for selecting the desired
operating mode.
Through the use of the G20 (Inch Mode) and G21 (Metric Mode) commands, It is possible to oper-
ate in either mode regardless of which mode has been selected on the Setting page. However, the use
of these two G codes will not automatically adjust the position registers to display the position values
in the proper units (inches vs millimeters).
- CAUTION -
Part programs should usually be written in the same format as selected on the
Setting page. Programs not written in the same format as established on the
Setting page MUST contain the appropriate English / Metric G code, G20/G21
respectively. When required, this G code must be programmed by itself in the
first Data block following the program number.
The work shift values are NOT automatically changed to the appropriate units
when the operating mode is changed.
- NOTE -
The tool offsets are automatically changed to the appropriate units when the operat-
ing mode is changed.
ESTABLISHING ENGLISH / METRIC MODE

1. Press the Offset Setting function key.
3. If necessary, use the Page keys to display the Setting page that contains the Input Unit field.
4. If necessary, use the cursor keys to position the cursor at the Input Unit field.
6. Key in the appropriate number (0:MM 1:INCH).
8. Turn the Control ON / OFF switch to OFF.
9. Wait a few seconds; then, turn the Control ON / OFF switch to ON and wait until the control
display screen is ON. The machine will power up in the desired operating mode.
M-392D 13-5
AXIS THRUST LIMITATION
INTRODUCTION
The E and Z axis servo drives are capable of delivering levels of thrust that exceed the limits of the
machine tool. Therefore, axis thrust must be limited or machine life may be reduced. There is refer-
ence material available for the programmer that provides approximate thrust values based on drill di-
ameter, spindle speed, feedrate, and the type of material being machined. Hardinge Inc.
recommends the MACHINING DATA HANDBOOK from Metcut Research Associates, Inc.
- NOTE -
Thrust limits are not easily exceeded unless large diameter twist drills are being run
with aggressive feedrates.
Axis thrust is limited to the following:
THRUST LIMIT
AXIS
English (Pounds-Force) Metric (Newtons)
E 1,500 6,670
Z 2,250 10,000
MONITORING AXIS THRUST

It is possible to monitor axis thrust as a percentage of how much current the E or Z axis servo motor
is drawing compared to the maximum amount of current that the motor should draw.
- CAUTION -
The percentage of maximum current must not exceed the following limits:
AXIS LIMIT VALUE

E 107
Z 132
If the percentage of maximum current on the E or Z axis exceeds the limit value, an alarm
message will be displayed.
The percentage of maximum current is displayed under “CURRENT (%)” on the associated axis
Servo Tune page. Refer to the position indicator shown in Figure 13.1.
13-6 M-392D
S E R VO MOT OR T U NING O____ N____
Z AXIS
(PAR AME T E R ) (MONIT OR )
F U NC. B IT ~ AL AR M 1 ~
L OOP GAIN ~ AL AR M 2 ~
T U NING S T ~ AL AR M 3 ~
S E T P E R IOD ~ AL AR M 4 ~
INT GAIN ~ AL AR M 5 ~
P R OP. GAIN ~ L OOP GAIN ~
F ILT E R ~ P OS E R R OR ~
V E L OC. GAIN ~ CU R R E NT %
S P E E D (R P M) ~
NU M. AU T O
(S V. S E T ) (S V. T U N) ( ) ( ) ( )
TI4179
Figure 13.1 - Servo Tune Screen

(Z axis page shown)
ACCESSING THE AXIS SERVO TUNE PAGE

- CAUTION -
DO NOT modify any of the parameters displayed on the “Servo Setting” and
“Servo Motor Tuning” screens. If any of the parameters are modified, reload
the machine parameters from the diskette supplied with the machine tool. Re-
fer to Chapter 11 for information on loading machine parameters.
3. If necessary, press the right hand soft key to display the Servo Parameter soft key.
4. Press the Servo Parameter soft key.
5. Press the Servo Tune soft key.
6. If necessary, use the Page keys to access the appropriate “Servo Motor Tuning” screen.
7. Observe the value shown to the right of “CURRENT (%)”. Refer to the position indicator shown
in Figure 13.1.
M-392D 13-7
ADJUSTING AXIS THRUST
- NOTE -
This procedure is to be performed during the operation that causes the axis over-
load.
When performing machining operations where axis thrust is a concern, it is possible
to minimize cycle time by adjusting the programmed feedrate to bring the value un-
der “CURRENT (%)” as close to the limit without exceeding the limit.
If the value displayed under “CURRENT (%)” on the appropriate axis Servo Tune page exceeds
the limit, reduce axis thrust according to the following procedure:
1. Turn the Feedrate Override switch down by 10%.
2. Run the operation that caused the axis overload and observe the value displayed under
“CURRENT (%)” on the axis Servo Tune page.
If the value displayed under “CURRENT (%)” on the Servo Tune page still exceeds the
limit, repeat steps 1 and 2.
If the value displayed under “CURRENT (%)” on the Servo Tune page is under the limit,
adjust the programmed feedrate in the part program according to the setting of the Feed-
rate Override switch.
EXAMPLE
Assuming that the Feedrate Override switch had to be set to 80% to allow the operation to be per-
formed:
1. Multiply the programmed feedrate by “.8".
2. Modify the programmed feedrate for the operation to match the number calculated in step 1.
13-8 M-392D
PART CATCHERS
MAIN SPINDLE PART CATCHER [Option]
Introduction
The main spindle part catcher is controlled from the operator panel through the use of the Part
Catcher push button when the machine is in Jog mode.
The main spindle part catcher is controlled from the part program through the use of the following M
codes:
M25 - PART CATCHER RETRACT
The M25 command rotates the part catcher arm to the spindle centerline for part pickup.
M26 - PART CATCHER EXTEND
The M26 command causes the following to occur:
1. The part catcher arm rotates toward the front of the machine and the part basket extends to
receive the part.
2. The part basket retracts after a fixed period of time.
Typical Part Unload Sequence

1. The part catcher arm rotates inward to a position under the spindle (M26).
2. The collet/chuck opens, ejecting the part onto the arm (M21).
3. The arm rotates outward and the basket extends to receive the part (M25).
4. The part falls from the arm into the basket.
5. The basket retracts.
6. The operator can open cover “A”, Figure 13.2, and remove the part from the basket by hand.
A
B
TP4612
Figure 13.2 - Main Spindle Part Catcher

(External View)
M-392D 13-9
Adjusting the Part Catcher for Part Length
1. Loosen the screw in locking collar “C”, Figure
13.3.
C
2. Slide the part catcher toward or away from the
machine headwall to adjust the position, as
needed.
3. Tighten the screw in locking collar “C”.
Adjusting the Part Catcher

Extend / Retract Speeds
TP4610
The part catcher extend and retract speeds are Figure 13.3 - Position Adjustment
controlled by separate flow control valves and can be Locking Collar
adjusted independently.
Remove sheet metal cover “D”, Figure 13.4,
from the front of the machine to gain access to
the part catcher flow control valves.
D
Flow control valve “E”, Figure 13.5, is used to
adjust the speed at which the part catcher ex-
tends (moves toward the spindle centerline).
Flow control valve “F” is used to adjust the
speed at which the part catcher retracts (moves
toward the front of the machine).
Rotate the knob on a flow control valve clock-
wise to reduce speed.
Rotate the knob on a flow control valve coun-
TP4158
terclockwise to increase speed.
Figure 13.4 - Front Cover
TP4613
Figure 13.5 - Part Catcher

Extend/Retract Adjustments
13-10 M-392D
Adjusting the Part Basket Extend / Retract Speeds
The part basket extend and retract speeds are controlled by separate flow control valves and can
be adjusted independently.
Remove sheet metal cover “B”, Figure 13.2, to gain access to the part basket flow control
valves.
Flow control valve “G”, Figure 13.6, is used to adjust the speed at which the part catcher ex-
tends (moves toward the spindle centerline).
Flow control valve “H” is used to adjust the speed at which the part catcher retracts (moves
toward the front of the machine).
Rotate the knob on a flow control valve clockwise to reduce speed.
Rotate the knob on a flow control valve counterclockwise to increase speed.
G H
TP4605
Figure 13.6 - Part Basket

Extend/Retract Adjustments
M-392D 13-11
CONVEYOR-STYLE SUB-SPINDLE PART CATCHER [Option]
Introduction
The sub-spindle part catcher is a multiple axis part removal system designed to remove a
workpiece from the sub-spindle and deposit the workpiece on a conveyor, which will carry the
workpiece to an unload ramp located at the right end of the machine tool.
- NOTE -
It is the operator’s responsibility to provide a suitable container or surface to receive
the finished workpiece when it leaves the unload ramp.
The lower edge of the unload ramp, shown in Figure 13.7, is approximately 23¾ inches from the
floor.
TP4644
Figure 13.7 - Sub-Spindle Part

Catcher Unload Ramp
(Covers Removed for Clarity)
13-12 M-392D
Part Catcher M Codes
The sub-spindle part catcher is controlled through
the use of the following six M codes:
M221 PART CATCHER SLIDE EXTEND
M221 commands the part catcher to slide
OUT from the sub-spindle headwall to the
fixed part pick-up position.
M222 PART CATCHER SLIDE RETRACT
M222 commands the part catcher to slide
IN to the part drop-off position over the part
conveyor.
M225 PART CATCHER ARM ROTATE DOWN
M225 commands the part catcher arm to
swing down to allow the part catcher to be re-
tracted.
M226 PART CATCHER ARM ROTATE UP
M226 commands the part catcher arm to TP4654
swing up to the part retrieve position at the Figure 13.8 - Part Catcher Extended,
spindle centerline. Arm Rotated to Down Position
M227 PART CATCHER GRIPPER CLOSE
M227 commands the part catcher gripper to
close and grip the workpiece.
M228 PART CATCHER GRIPPER OPEN
M228 commands the part catcher gripper to
open and release the workpiece.
TP4655
Figure 13.9 - Part Catcher Extended,

Arm Rotated to Up Position
M-392D 13-13
Interlocks
1. M221 must be active (Part Catcher Slide Extend) before M226 (Part Catcher Arm Rotate Up)
can be commanded.
2. The sub-spindle must be at the reference position before M225 (Part Catcher Arm Rotate
Down) can be commanded.
3. M225 (Part Catcher Arm Rotate Down) must be active before M222 (Part Catcher Slide
Retract) can be commanded.
Capacity
The part catcher has the following workpiece capacity:
Category English Units Metric Units

Maximum Length 6 inches 152.4 millimeters
Maximum Diameter 2.5 inches 63.5 millimeters
Maximum Weight 7 lb 3.18 Kg
13-14 M-392D
Part Catcher Gripper Pads
The part catcher grippers are designed to be equipped with nylon pads. The nylon pads are bored
to the outer diameter of the workpiece to be machined.
BORING THE GRIPPER PADS
The gripper pad fixture, shown in Figure 13.10, is used to hold the gripper pads when they are
bored to the required size.
1. Install a work-holding device capable of holding a 3½ inch workpiece in the machine spindle.
2. Insert blank gripper pads into the fixture and secure with four M3 x .5 x 10mm screws, supplied
with the fixture.
3. Insert the gripper pad fixture into the spindle and close the work-holding device.
4. Bore the gripper pads to the required diameter.
5. Remove the gripper pad fixture from the spindle.
6. Remove the gripper pads from the gripper pad fixture.
7. Install the gripper pads on the part catcher gripper. Refer to “Changing the Gripper Pads”, page
13-16.
Gripper Pad
Fixture
Gripper Pads
TI4745
Figure 13.10 - Gripper Pad Fixture

with Blank Gripper Pads
M-392D 13-15
CHANGING THE GRIPPER PADS
1. If necessary, bore the gripper pads as outlined in the preceding section.
6. Set the Manual Axis Movement switch to “E”.
7. Press the Rapid Reference push button to move the sub-spindle to the reference position.
- NOTE -
Refer to Chapter 3 for information on using Manual Data Input mode.
The guard door must be closed to execute commands in Manual Data Input mode.
8. Use Manual Data Input mode to:
A) Extend the part catcher slide (M221).
B) Rotate the part catcher arm to the up position (M226).
9. Open the guard door.
10. If necessary, loosen screws “I”, Figure 13.11,
to remove the gripper pads currently installed
on the grippers.
11. Clean the part catcher grippers.
12. Thoroughly clean the replacement gripper I
pads.
13. Install the replacement gripper pads.
15. Use Manual Data Input mode to:
A) Rotate the part catcher arm to the down
position (M225).
B) Retract the part catcher slide (M222). TP4656
Figure 13.11 - Gripper Pad

Mounting Screws
13-16 M-392D
THRU- SUB-SPINDLE PART CATCHER [Option]
- CAUTION -
Observe the sub-spindle operating limitations outlined in the programmer’s
manual (M-391) when running a sub-spindle equipped with the thru- sub-spin-
dle part catcher.
- NOTE -
The thru- sub-spindle part catcher is capable of handling parts with diameters that
fall within the following range:
³ 3
16 " « £ 1"
Introduction
The thru- sub-spindle part catcher provides the capability of feeding parts through the part catcher
draw tube, which is installed in the sub-spindle, and out the right end of the machine.
During part transfer from the main spindle to the sub-spindle, the part currently in the sub-spindle
collet is pushed from the collet by the part being delivered from the main spindle. As subsequent parts
are delivered from the main spindle to the sub-spindle, the parts in the part catcher draw tube are
pushed toward the right end of the machine, out the exit tube, and down the ramp to a receptacle pro-
vided by the machine operator.
Refer to Figure 13.12 for an overall view of the thru- sub-spindle part catcher assembly.
NOTE: Sub-spindle assembly not shown.

Refer to Figure 13.17
for close-up view.
Collet and
Guide Bushing
Draw Tube
Assembly
Part Catcher
Guard
Exit Tube
Safety Switch Clamp
Safety Switch
Part Catcher
Ramp
TI4788
Figure 13.12 - Isometric View of Thru- Sub-Spindle Part Catcher Assembly
M-392D 13-17
Part Catcher Component Identification
COLLET GUIDE BUSHINGS
Three collet guide bushings, each machined for a different capacity, are supplied with the
thru- sub-spindle part catcher. A collet guide bushing is always installed in the sub-spindle col-
let when the thru- sub-spindle part catcher is to be used. Refer to “Selecting Part Catcher Com-
ponents” for information on selecting the correct collet guide bushing.
One blank collet guide bushing is also included with the thru- sub-spindle part catcher. The
blank collet guide bushing can be used for the following:
• Replace a worn or damaged collet guide bushing
• Produce a custom size collet guide bushing for the part to be machined
PART CATCHER DRAW TUBE ASSEMBLY
One draw tube assembly is supplied with the thru- sub-spindle part catcher. This draw tube
assembly will replace the standard sub-spindle draw tube when the thru- sub-spindle part
catcher is to be used.
PART CATCHER DRAW TUBE LINERS
Two draw tube liners are supplied with the thru- sub-spindle part catcher. A draw tube liner
must be installed in the part catcher draw tube when the thru- sub-spindle part catcher is to be
used for parts that are 9/16 inch or less in diameter. Refer to “Selecting Part Catcher Compo-
nents” for information on selecting the correct draw tube liner.
EXIT TUBES
Three exit tubes are supplied with the thru- sub-spindle part catcher. An exit tube is always
installed when the thru- sub-spindle part catcher is to be used. Refer to “Selecting Part Catcher
Components” for information on selecting the correct exit tube.
Selecting Part Catcher Components

The following part catcher components will be selected based on the diameter of the part to be ma-
chined.
• Collet Guide Bushing
• Part Catcher Draw Tube Liner
• Exit Tube
Collet Guide Bushing Draw Tube

Part Size Ranges Exit Tube Size
Capacity Hole Liner Size
³3/16”, *5/16” Small Small Small
$5/16”, *9/16” Medium Medium Medium
$9/16”, *1” Large None Large
The three configurations are shown in Figures 13.13, 13.14, and 13.15.
13-18 M-392D
Collet Guide
Bushing
Collet
Draw Tube Assembly
Draw Tube Nut
Draw Tube
Retaining Screws
1/16”
[1.6 mm] Exit Tube
Anti-Rotation
Bracket
TI4789
Figure 13.13 - Section View Showing Components

for 1 Inch Maximum Part Diameter
M-392D 13-19
Draw Tube
Liner
Collet Guide
Bushing
Collet
Draw Tube Assembly
Draw Tube Nut
Draw Tube
Retaining Screws
1/16”
[1.6 mm] Exit Tube
Draw Tube Liner
Anti-Rotation
Bracket
TI4790

for 9/16 Inch Maximum Part Diameter
13-20 M-392D
Draw Tube
Liner
Collet Guide
Bushing
Collet
Draw Tube Assembly
Draw Tube Nut
Draw Tube
Retaining Screws
1/16”
[1.6 mm]
Exit Tube
Draw Tube Liner
Anti-Rotation
Bracket
TI4791

for 5/16 Inch Maximum Part Diameter
M-392D 13-21
Changing Part Catcher Components
Part catcher components will be changed for either of the following reasons:
• Accommodate a different part size
• Replace a worn component
- CAUTION -
Do not operate the collet closer when a collet is mounted in place without
gripping a piece of stock or a plug of the correct size.
4. If necessary, press the Sub Open/Close push button to open work-holding device in the collet
closer.
5. At the right end of the machine, pull safety switch clamp “K” to disengage safety switch “L”,
Figure 13.16.
6. Loosen the mounting nuts and remove part catcher guard “J”.
7. Remove four thumbscrews “O” and tube clamps “P”, Figure 13.17.
8. Remove exit tube “Q”.
9. Remove two insert blocks “N”.
10. If a draw tube liner is in the draw tube:
A) Remove the two M4 screws and lock washers located at “T”.
B) Slide the liner out of the draw tube.
11. Remove the collet from the sub-spindle:
- NOTE -
J
The six draw tube retaining screws
must be completely disengaged from
the collet closer liner before draw tube K
nut can be rotated.
A) Using the T-handle hex wrench provided,
completely loosen the six draw tube
retaining screws, shown in Figures 13.13,
L
13.14, and 13.15.
B) Rotate the draw tube nut counterclockwise
to disengage the draw tube from the collet. M
TP4717
C) Remove the collet from the sub-spindle.
Figure 13.16 - Part Catcher Guard
13-22 M-392D
Refer to Figure 13.12 for an overall view of the part catcher.
T
S
Q
U
P
O
V
X
W
N
TI4796
Figure 13.17 - Exit Tube Clamps and Anti-Rotation Bracket
12. Remove the guide bushing from the collet.

13. Clean the collet and guide bushing; then, place in storage.
14. Cover the main spindle to protect it from contaminants while the sub-spindle is being cleaned.
16. From the collet closer end of the draw tube, use an air line to blow any contaminants present out
of the sub-spindle.
17. Press the Sub Open/Close push button to set the collet closer to the closed position.
M-392D 13-23
18. If necessary, install the appropriate draw tube liner, based on the diameter of the part to be
produced, in the draw tube. Secure the draw tube liner with the two M4 screws and lock
washers provided.
Refer to “Selecting Part Catcher Components”, page 13-18, for additional information on
component selection.
19. Install two insert blocks “N”.
- NOTE -
There should be approximately 1/16” clearance between the end of the draw tube or
draw tube liner and the end of the exit tube. Refer to Figures 13.13, 13.14, and
13.15.
20. Install the appropriate exit tube “Q”, based on the diameter of the part to be produced.
21. Install two exit tube clamps “P” and secure with four thumbscrews “O”.
22. Press the Sub Open/Close push button to set the collet closer to the open position.
23. Install the appropriate collet guide bushing, based on the diameter of the part to be produced, in
the collet to be used.
24. Install the collet in the sub-spindle using the basic information provided in “Installing
Sub-Spindle Tooling”, beginning on page 17-6.
25. Replace part catcher guard “J”, Figure 13.16, and secure the mounting nuts.
26. Use clamp “K” to engage safety switch “L”.
27. Position a part receptacle under ramp “M”.
13-24 M-392D
Changing Sub-Spindle Draw Tubes
INSTALLING THE STANDARD DRAW TUBE
This procedure is used when it is necessary to change from the part catcher draw tube to the stan-
dard draw tube.
- CAUTION -
closer.
Figure 13.16.
7. Remove four thumbscrews “O” and tube clamps “P”, Figure 13.17.
8. Remove exit tube “Q”.
9. Remove two insert blocks “N”.
- CAUTION -
DO NOT remove two alignment blocks “R”.
10. Remove four screws “X” and two tube support blocks “Y”.
11. If a draw tube liner is in the draw tube:
A) Remove the two M4 screws and lock washers located at “T”.
B) Slide the liner out of the draw tube.
12. Clean all items removed in steps 7 through 11; then, place in storage.
13. Remove the collet from the sub-spindle:
- NOTE -
The six draw tube retaining screws must be completely disengaged before the draw
tube nut can be rotated.
A) Completely loosen the six draw tube retaining screws, shown in Figures 13.13, 13.14, and
13.15.
B) Rotate the draw tube nut counterclockwise to disengage the draw tube from the collet.
C) Remove the collet from the sub-spindle.
M-392D 13-25
14. Remove the guide bushing from the collet.
15. Clean the collet and guide bushing; then, place in storage.
of the sub-spindle.
19. Remove screw “W” and two bushings “V” from anti-rotation bracket “U”.
20. Completely remove the draw tube from the back of the sub-spindle.
21. Use an air line to blow any contaminants present out of the sub-spindle a second time.
22. Clean the sub-spindle, standard draw tube, and part catcher draw tube.
23. Lightly coat all exterior surfaces of the part catcher draw tube with Mobiltemp® SHC 32 grease;
then, place in storage.
24. Lightly lubricate the bearing surfaces of the standard draw tube with Molylube® Anti-Seize
grease.
25. Lightly coat the remaining exterior surfaces of the standard draw tube with Mobiltemp SHC 32
grease.
26. Carefully slide the standard draw tube into the sub-spindle.
27. If spindle tooling is to be installed at this time, install the tooling according to the procedure
outlined in “Installing Sub-Spindle Tooling”, beginning on page 17-6.
If spindle tooling is not to be installed at this time, install the draw tube plug.
28. Replace part catcher guard “J”, Figure 13.16, and tighten the mounting nuts.
13-26 M-392D
INSTALLING THE PART CATCHER DRAW TUBE
This procedure is used when it is necessary to change from the standard draw tube to the part
catcher draw tube.
closer.
Figure 13.16.
- NOTE -
Six screws “A”, Figure 13.18, must be completely disengaged before draw tube nut
“B” can be rotated.
Removal of a jaw chuck or step chuck may require the assistance of a second per-
son.
7. Completely loosen six screws “A”, Figure 13.18.
8. Rotate draw tube nut “B” counterclockwise to disengage the draw tube from the work-holding
device.
- WARNING -
Be prepared to accept the weight of the work-holding device.
9. Remove the work-holding device from the sub-spindle.
10. Clean the work-holding device; then, place in storage.
13. From the collet closer end of the draw tube, use
an air line to blow any contaminants present
out of the sub-spindle.
B
14. Completely remove the draw tube from the
back of the sub-spindle.
15. Use an air line to blow any contaminants
present out of the sub-spindle a second time.
16. Clean the sub-spindle, standard draw tube,
and part catcher draw tube.
A
17. Lightly coat all exterior surfaces of the standard
draw tube with Mobiltemp® SHC 32 grease;
then, place in storage.
18. Lightly lubricate the bearing surfaces of the TP4133
part catcher draw tube with Molylube® Figure 13.18 - Standard Draw Tube Nut
Anti-Seize grease.
M-392D 13-27
19. Lightly coat the remaining exterior surfaces of the part catcher draw tube with Mobiltemp® SHC
32 grease.
20. Carefully slide the part catcher draw tube into the sub-spindle.
- CAUTION -
Be sure bushings “V”, and screw “W” extend through the hole in bracket “S”.
21. Install two bushings “V”, and screw “W” into anti-rotation bracket “U”, as shown in Figure 13.17.
Torque screw “W” to 60 lb-in [6.8 N•m].
22. Press the Sub Open/Close push button to set the collet closer to the closed position.
23. If necessary, install the appropriate draw tube liner, based on the diameter of the part to be
produced, in the draw tube. Secure the draw tube liner with the two M4 screws and lock
washers provided.
24. Thoroughly clean the two mounting surfaces for brackets “Y”.
25. Thoroughly clean two alignment blocks “R”.
- NOTE -
Locate brackets “Y” against alignment blocks “R” before securing with screws “X”.
26. Install two brackets “Y” using four screws “X”. Torque screws “X” to 25 lb-ft [33.9 N•m].
27. Install two insert blocks “N”.
- NOTE -
There should be approximately 1/16” clearance between the end of the draw tube or
draw tube liner and the end of the exit tube. Refer to Figures 13.13, 13.14, and
13.15.
28. Install the appropriate exit tube “Q”, based on the diameter of the part to be produced.
29. Install two exit tube clamps “P” and secure with four thumbscrews “O”.
30. Press the Sub Open/Close push button to set the collet closer to the open position.
31. Install the appropriate collet guide bushing, based on the diameter of the part to be produced, in
the collet to be used.
32. Install the collet in the sub-spindle using the basic information provided in “Installing
Sub-Spindle Tooling”, beginning on page 17-6.
33. Replace part catcher guard “J”, Figure 13.16, and secure the mounting nuts.
35. Position a part receptacle under ramp “M”.
13-28 M-392D
PART PROBE [Option]
INTRODUCTION
- CAUTION -
Although overtravel protection is built into the probe, the probing velocity
must not exceed 18 inches/minute to insure that the machine stopping dis-
tance does not exceed the probe overtravel.
The optional part probe extends the versatility of the machines by providing automatic size check-
ing and updating of tool offsets. Outside diameters, inside diameters, and lengths can be checked
when a cutting operation is not active.
The system consists of a measuring probe which is datumed in reference to a known surface. The
probe is a multi-directional switch that is programmed to contact the workpiece at the desired inspec-
tion point. Contact can be made from any direction. When the probe stylus makes contact, a signal is
generated which is relayed to the interface where it is converted into a form the machine control will
accept. The control compares the inspection point to the calibration point and offsets are automati-
cally corrected when required. The slide then backs off and a second signal is relayed to the interface,
indicating the stylus has reseated and the probe is ready for the next measurement.
SET-UP PROCEDURE
- NOTE -
The probe holder installs in the same manner as a standard round shank tool holder.
Refer to Chapter 4, 5, or 6 for information on installing tool holders.
1. Mount probe holder “F”, Figure 13.19 or 13.20, on the turret at the desired station.
2. Place OMP unit “E” in the probe holder and tighten mounting screws “G” just enough to hold the
probe in position.
3. Screw probe “A” into OMP unit “E” and tighten at “D” using the spanner wrench provided with
the probe.
4. Position the turret midway between the reference position and the spindle face and spindle
centerline.
A
G
B
G F
C D E F
TP4688 TP4693A
Figure 13.19 - Part Probe Mounted Figure 13.20 - Part Probe Mounted
on a Hardinge Top Plate on a VDI Top Plate
M-392D 13-29
5. Adjust OMP unit “E”, Figure 13.19, and OMM unit “I”, Figure 13.21, so that the optical window
on the OMP unit and the window on the OMM unit are aligned.
6. Tighten mounting screws “G”, Figure 13.19 or 13.20.
7. Tighten screw “H”, Figure 13.21.
- NOTE -
The probe stylus has a 360 degree rotational capability. However, it is important that
the center of the stylus ball coincides with the X axis centerline of the turret.
8. Mount probe stylus “C”, Figure 13.19, on the probe with screw “B” so that the center of the
stylus ball is approximately on line with the X axis center line of the turret top plate.
9. Index the turret to the station with the probe mounted on it.
10. Place a center in the spindle work-holding device.
11. Jog the turret to position the center of the stylus ball on center with the spindle centerline.
12. Adjust the probe stylus until the center of the ball is on the spindle centerline. This will place the
center of the ball on the X axis centerline of the turret.
13. Tighten screw “B” using the wrench provided.
14. Datum the part probe, as outlined on the next page.
H
TP4689
Figure 13.21 - Part Probe OMM Unit

on the Main Spindle Headwall
13-30 M-392D
DATUMING THE PART PROBE
- CAUTION -
The part probe must be correctly datumed before automatic operation is per-
formed.
When the probe is datumed for automatic operation, macro variables 500 and 501 are used to re-
cord the position of the probe stylus.
Datuming the Part Probe on the X Axis

- NOTE -
The program in step 1 is only an example to illustrate program structure. Turret sta-
tion, tool offset, and coordinate Data may vary, depending on workpiece geometry
and probe location on the turret top plate.
If necessary, refer to “Entering a Program from the Keyboard”, page 3-10, for infor-
mation on entering a program through the manual Data input keyboard.
In this example, a piece of bar stock has been turned to a diameter of 1.7500 inches for the purpose
of datuming the probe on the X axis.
1. Enter a program similar to the following into the control memory:
O____ (Radial Datum X Axis Part Probe) ; Program Number (Operator Message)
G10 P0 Z___ ; Set Work Shift, if Required
G0 G40 G98 X16.5 Z6. T0 ; Positioning Mode, Cancel Tool Nose Radius Compensation,
Inch/Millimeter per Minute Feedrate,
Move Turret to Safe Index Position,
Cancel Tool Offset
T0800 ; Index to Probe Station, No Tool Offset Active
X3. Z.5 T0808 ; Move to Position Probe as Required, Activate Probe Offset
M90 ; Part Probe ON
G4 X1. ; Dwell to Allow Probe ON
X1.76 Z-.375 ; Position Probe for X Axis Datuming as Required
G65 P9013 X1.75 ; Call Macro Program 9013,
X1.75 = Known Diameter of the Bar stock
G0 X3. Z.5 ; Move to Clear Bar stock in Spindle
X16.5 Z6. T0 ; Move Turret to Safe Index Position, Cancel Tool Offset
2. Activate Automatic Mode.
- NOTE -
program.
4. Press the Cycle Start push button to datum the probe on the X axis.
5. Proceed to “Datuming on the Z Axis”, on the next page.
M-392D 13-31
Datuming the Part Probe on the Z Axis
- NOTE -
The program in step 1 is only an example to illustrate program structure. Turret sta-
tion, tool offset, and coordinate Data may vary, depending on the Z axis surface to
be used for datuming and probe location on the turret top plate.
If necessary, refer to “Entering a Program from the Keyboard”, page 3-10, for infor-
mation on entering a program through the manual Data input keyboard.
In this example, the spindle face will be used for datuming the probe on the Z axis.
1. Enter a program similar to the following into the control memory:
O____ (Datum Z Axis Part Probe) ; Program Number (Operator Message)
G10 P0 Z___ ; Set Work Shift, if Required
G0 G40 G98 X16.5 Z6. T0 ; Positioning Mode, Cancel Tool Nose Radius Compensation,
Inch/Millimeter per Minute Feedrate,
Move Turret to Safe Index Position,
Cancel Tool Offset
T0800 ; Index to Probe Station, No Tool Offset Active
X5. Z.5 T0808 ; Move to Position Probe as Required, Activate Probe Offset
M90 ; Part Probe ON
G4 X1. ; Dwell to Allow Probe ON
X3.625 Z.05 ; Position Probe for Z Axis Datuming as Required
G65 P9017 Z0. T8. ; Call Macro Program 9017,
Z0. = Known Z Position,
T8. = Offset Location for Part Probe
G0 X5. Z.5 ; Move to Clear Spindle
X16.5 Z6. T0 ; Move Turret to Safe Index Position, Cancel Tool Offset
2. Activate Automatic Mode.
- NOTE -
program.
4. Press the Cycle Start push button to datum the probe on the Z axis.
The probe is now datumed and is ready for automatic operation. Refer to the programmer’s manual
(M-391) for information on programming automatic operation of the part probe.
13-32 M-392D
MAINTENANCE
- CAUTION -
Only a minimum amount of maintenance can be done by user. Dismantling of
Renishaw equipment is a highly specialized operation and must be carried out
by an authorized service center. Equipment requiring repair that is still under
warranty should be returned to Hardinge Inc.
Adjustment to the stylus spring pressure may affect probe repeatability. Refer
to the Renishaw LP2 Probe document supplied with the probe.
Do not use sharp cleaning tools.
Do not use a degreasing agent when washing the probe cavity.
The probe system requires minimum maintenance. Approximately once a month the cavity be-
tween front cap “K”, Figure 13.22, and inner seal “Q”, Figure 13.23, should be checked for contami-
nants. A build-up of dirt or fine chips could eventually cause the probe to malfunction.
1. Use the hex pin wrench supplied with probe to remove screw “L” and stylus “J”, Figure 13.22.
2. Remove cap “K”, using spanner wrench supplied with the probe.
3. Remove seal “N”, Figure 13.23, and compression spring “O”.
4. Wash out cavity “P” and all parts with a jet of coolant.
J K
P
M
N O
Q
L
TP754 TP751
Figure 13.22 - Probe and Stylus Assembly Figure 13.23 - Probe Disassembled
M-392D 13-33
5. Check rear O-ring “R”, Figure 13.24, for damage or wear and replace if necessary.
6. If inner seal “Q”, Figure 13.23, is pierced or damaged, return the probe to Hardinge Inc.
7. Reverse the procedure to reassemble. Front cap “K”, Figure 13.22, need only be finger tight.
TP755
Figure 13.24 - Rear O-Ring
CLEANING PROBE AND OMM UNIT WINDOWS

The optical windows on the probe and OMM units should be checked several times during each
work shift for any accumulation of dirt or chips which might interfere with probe operation. Use glass
cleaner and a rag to clean the windows at least once per shift. More frequent cleaning may be required
depending on the material being machined.
13-34 M-392D
CHANGING THE PROBE BATTERIES
- NOTE -
The probe unit is supplied with four 3 volt lithium batteries. Two 3 volt lithium batter-
ies are required for probe operation.
1. Loosen screws “G”, Figure 13.19 or 13.20, and remove the probe assembly from probe holder
“F”.
2. Remove cap “S”, Figure 13.25, using a coin or screwdriver.
3. Remove battery retractor “T” and the old batteries.
4. Install the battery retractor and two fresh batteries in the probe, positive end first. Refer to
Figure 13.26 for the correct position of the battery retractor.
5. Install cap “S”.
6. Re-install the probe assembly on the top plate. Refer to page 13-29.
7. Re-calibrate the probe.
TP4694
Figure 13.25 - Battery Orientation
Battery Retractor
TP4695
Figure 13.26 - Battery Retractor Position
M-392D 13-35
SUB-SPINDLE PART PRESENT DETECTOR [Option]
- CAUTION -
Refer to page 4-2 for information concerning turret tooling for QUEST 6/42 &
6/42SP lathes equipped with the following combination of options:
• Tool probe
INTRODUCTION
Sub-spindle part present detector "U", Figure 13.27, is commanded from the part program to check
the sub-spindle for a part. Refer to the programmer’s manual (M-391) for an explanation of the M
codes used to command the sub-spindle part present detector.
TP6968
Figure 13.27 - Part Present Detector
13-36 M-392D
EXTENDING THE PART PRESENT DETECTOR
An extension is provided in the event an application requires positioning the part present detector
arm further from the face of the sub-spindle.
- CAUTION -
Care must be used to avoid an impact between the part present detector and
the main machine headwall when the part present detector extension is in-
stalled.
1. Note the radial position of part present detector arm "V", Figure 13.28.
2. Loosen two screws "W".
3. Remove the part present detector arm from main shaft "Z".
4. Thread extension "X" into the main shaft.
5. Tighten set screw "Y".
6. Install the part present detector arm and position radially as noted in step 1.
7. Tighten two screws "W".
RANGE OF MOTION
The range of motion for the part present detector is 120. Refer to View "B", Figure 13.28.
M-392D 13-37
Extension Not Installed Extension Installed
W X Y Z
VIEW "A"
VIEW "B"
120°
TP5349
Figure 13.28 - Part Present Detector Extension and Range of Motion
13-38 M-392D
- NOTES -
M-392D 13-39
- NOTES -
13-40 M-392D
CHAPTER 14 - VDI LIVE TOOLING [Option]
INTRODUCTION
A live tooling option is available on QUEST® series lathes equipped with a VDI top plate. The live
tooling attachments are not included with the machine tool and must be purchased separately.
VDI 30 live tooling attachments have a maximum spindle speed of 8000 rpm, as measured at the
tool tip, and can be operated at 30 percent of the total duty cycle at 8000 rpm.
VDI 40 live tooling attachments have a maximum spindle speed of 6000 rpm, as measured at the
tool tip, and can be operated at 30 percent of the total duty cycle at 6000 rpm.
TYPES OF ATTACHMENTS
- CAUTION -
Live tooling attachments are available with or without through-tool coolant ca-
pability.
Live tooling attachments without through-tool coolant capability can be run
with or without coolant, as the machining process requires.
Live tooling attachments with through-tool coolant capability MUST be run
with coolant turned ON.
Refer to page 14-3 for information on live tooling RPM limits for through-tool
coolant attachments, based on coolant pressure.
The live tooling attachments are identified by axis of operation and if they have internal (thru-tool)
coolant.
VDI 30 live tooling attachments are designed to use ER 25 collets to grip the tools.
VDI 40 live tooling attachments are designed to use ER 32 collets to grip the tools.
Cross-Working Attachment:
This attachment locates the center of the drill or milling tool on the centerline of the tool sta-
tion, with the spindle of the attachment aligned with the X axis.
End-Working Attachment:
This attachment locates the center of the drill or milling tool on the centerline of the tool sta-
tion, with the spindle of the attachment aligned with the Z axis.
M-392D 14-1
ADJUSTABLE DEAD STOP
Each live tooling attachment is equipped with an adjustable dead stop. The dead stop can be ad-
justed against the end of the tool to prevent the tool from sliding in the tool holder during high-thrust
machining operations.
The adjustable dead stop is threaded and can be adjusted using a small common-blade screw-
driver.
The adjustable dead stop for all cross-working live tooling attachments is accessed through the
front of the tool holder. Refer to Figure 14.1.
The adjustable dead stop for end-working live tooling attachments equipped with internal coolant is
accessed through the front of the tool holder. The adjustable dead stop for end-working live tooling at-
tachments NOT equipped with internal coolant is accessed through the back of the tool holder. Refer
to Figure 14.2.
Access to
Dead Stop
TI4811
Figure 14.1 - Cross-Working Live Tooling Attachment
Access to Dead Stop

(Attachment without internal coolant)
Access to Dead Stop

(Attachment with internal coolant)
TI4812
Figure 14.2 - End-Working Live Tooling Attachment
14-2 M-392D
LIVE TOOLING COLLETS AND CAPACITIES
- NOTE -
ER 25 and ER 32 collets conform to DIN 6499.
VDI 30 LIVE TOOLING

ER 25 collets are capable of employing English tools with a shank size from 0.02 inches up to and
including 0.63 inches.
ER 25 collets are capable of employing Metric tools with a shank size from 0.5 millimeters up to and
including 16 millimeters.
VDI 40 LIVE TOOLING

LIVE TOOLING RPM LIMIT

- CAUTION -
DO NOT exceed the RPM limits for through-tool coolant live tooling attach-
ments, as indicated in graphs 14.1 and 14.2.
- NOTE -
The RPM limits DO NOT apply to live tooling attachments without through-tool cool-
ant capability
Live tooling attachments with through-tool coolant capability are subject to an RPM limit, based on
the pressure of the coolant supplied to the attachment. The coolant pump delivers approximately 187
psi [12.9 bar].
Refer to graphs 14.1 and 14.2 for RPM limits.
M-392D 14-3
End-Working Toolholder
Internal Coolant
400
Maximum Coolant Pressure,
350
300
250
(PSI)
200
150
100
50
0
3000 4000 5000 6000 7000 8000
Spindle Speed, (RPM)
TI4750A
Graph 14.1 - End-Working Attachments
Cross-Working Toolholder
Internal Coolant
400
350
Maximum Coolant
Pressure, (PSI)
300
250
200
150
100
50
0
1000 3000 5000 7000
Spindle Speed, (RPM)
TI4751A
Graph 14.2 - Cross-Working Attachments
14-4 M-392D
LIVE TOOLING ATTACHMENT INSTALLATION
- NOTE -
All turret tool stations can be used for live tooling applications.
MOUNTING THE ATTACHMENT

1. Power-up the machine according to the procedure outlined in Chapter 2.
- CAUTION -
spindle, spindle tooling, turret, turret tooling, or workpiece before manually in-
dexing the turret.
4. Move the turret to a safe position for indexing.
- WARNING -
Stay clear of the turret and turret tooling when indexing the turret. Physical in-
jury can result.
5. Manually index the turret to position the desired tool station:
a) Set the Turret Station switch to the tool station to be indexed to the active position.
b) Press the Index push button.
6. Thoroughly clean the turret top plate and the live tooling attachment.
7. Clean and check the O-ring on the live tooling attachment to be sure the O-ring is in good
condition.
8. If mounting an end-working attachment, loosen two screws “D”, Figure 14.4 or 14.6.
- CAUTION -
NEVER force the live tooling attachment into the turret top plate.
Be sure the live tooling attachment is mounted flush against the side of the
turret top plate, as shown in Figure 14.3, 14.4, 14.5, or 14.6.
- NOTE -
When installing a VDI 40 live tooling attachment, the flats on the end of the drive
shaft must be oriented 90° (perpendicular) to the gear rack on the shaft, as shown in
Figures 14.5 and 14.6.
If necessary, rotate the spindle of the VDI 40 live tooling attachment to allow the at-
tachment to seat properly.
9. Aligning live tooling attachment “A” with coolant button “C”, mount the live tooling attachment
on the turret top plate, as shown in Figure 14.3, 14.4, 14.5, or 14.6.
M-392D 14-5
10. If mounting an end-working attachment, press the tool holder against the turret top plate and
tighten two screws “D”, Figure 14.4 or 14.6.
- NOTE -
11. Tighten clamp screw “B”.
12. If necessary, remove cap “E”, Figure 14.11, or cap “F”, Figure 14.12, and install the proper
collet for the tool to be used. Replace the cap, but DO NOT TIGHTEN.
14-6 M-392D
A
B
1
10
9
3
8
4
7
5
6
TI4714A
Figure 14.3 - Mounting a VDI 30 Cross-Working Live Tooling Attachment
B
1
10
D
2
C
3
8
4
5
6
TI4872
Figure 14.4 - Mounting a VDI 30 End-Working Live Tooling Attachment
M-392D 14-7
Be sure the tool holder is flush against
the side of the turret top plate Gear Rack for A
Clamp Screw
1
10
9
C
8
1
Note the Orientation
of the Flats on the
4
Drive Shaft
7
5
6
TI47886
Figure 14.5 - Mounting a VDI 40 Cross-Working Live Tooling Attachment
A
Be sure the tool holder is flush against Gear Rack for
the side of the turret top plate Clamp Screw
1
10
2
D
9
3
C
8
Note the Orientation

4
1 of the Flats on the

Drive Shaft
7
5
6
TI4885
Figure 14.6 - Mounting a VDI 40 End-Working Live Tooling Attachment
14-8 M-392D
INSTALLING / REMOVING TOOLS

- WARNING -
DO NOT exceed these maximum tool extension values. Personal injury and
damage to the tooling and machine can result.
- NOTE -
All dimensions are shown in inches [millimeters].
Cross-working live tooling attachments have the following maximum tool extension from the edge
of the turret top plates:
VDI 30 Turret: 6.985 [177.4]
VDI 30 Turret with Y-Axis Option: 5.605 [142.4]
VDI 40 Turret: 7.575 [192.4]
VDI 40 Turret with Y-Axis Option: 6.195 [157.4]
Refer to Figures 14.7 and 14.8.
Inch [Millimeter] Inch [Millimeter]
Maximum Maximum
Tool Tool
Extension Extension
Standard Turret: 6.985 [177.4] Standard Turret: 7.575 [192.4]
Y-Axis Turret: 5.605 [142.4] Y-Axis Turret: 6.195 [157.4]
TI4715 TI4715
Figure 14.7 - Maximum Tool Extension Figure 14.8 - Maximum Tool Extension
for VDI 30 Cross-Working Attachments for VDI 40 Cross-Working Attachments
M-392D 14-9
End-working live tooling attachments oriented for sub-spindle operation have a maximum tool ex-
tension of 8.375 inches [212.73 mm] from the centerline of the turret top plate tool mounting location.
Refer to Figures 14.9 and 14.10.
Inch [Millimeter] Inch [Millimeter]
Maximum Tool Maximum Tool

Extension Extension
6.997 6.997
[177.73] [177.73]
2.756 3.543
[70.00] [90.00]
8.375 8.375
[212.73] [212.73]
Maximum Tool Extension Maximum Tool Extension
TI4704 TI4704
Figure 14.9 - Maximum Tool Extension Figure 14.10 - Maximum Tool Extension
for VDI 30 End-Working Attachments for VDI 40 End-Working Attachments
(Oriented for Sub-Spindle Operation) (Oriented for Sub-Spindle Operation)
14-10 M-392D
Procedure
- NOTE -
Wrenches are supplied with the live tooling attachments.
1. Insert the tool into the attachment and set to length.
2. Secure the tool:
On cross-working attachments, mount a wrench on spindle “E”, Figure 14.11, and use a
second wrench to turn cap “F” in the clockwise direction to tighten.
On end-working attachments, mount a wrench on spindle “H”, Figure 14.12, and use a
spanner wrench to turn cap “G” in the clockwise direction to tighten.
Reverse the procedure to remove the tooling.
E G
F
H
TI4209 TI4210
Figure 14.11 - Cross-Working Attachment Figure 14.12 - End-Working Attachment
M-392D 14-11
LIVE TOOLING ATTACHMENT REMOVAL
- WARNING -
When removing a live tooling attachment from the top plate, have a firm grip
on the attachment while loosening the clamp screw in the top plate.
pressure in the turret may cause the tooling attachment to begin moving out of the top plate when the
clamp screw is loosened.
1. If removing an end-working attachment, loosen two screws “D”, Figure 14.4 or 14.6.
2. Loosen clamp screw “B”, Figure 14.3 or 14.4, 14.5, or 14.6.
3. Remove the tool holder from the turret top plate.
4. Install a tool station plug if another tool holder is not to be installed. Refer to page 4-4 for in-
formation on tool station plugs.
5. Repeat steps 1 through 4 for additional tool holders, as necessary.
14-12 M-392D
LIVE TOOLING OFFSETS
Live tooling offsets are set in the same manner as standard tooling. However, there are some con-
siderations to be aware of that will simplify setting the tool offsets for tools mounted in live tooling at-
tachments. These considerations are outlined below.
Refer to page 14-14 for information on setting live tooling offsets.
CROSS-WORKING ATTACHMENTS
Cross-working attachments are qualified on the Z axis. The centerline of the spindle in the
cross-working attachment will always be located at the Z axis reference position of the turret top
plates. Therefore, the Z axis tool offset will always be “0".
Figures 14.7 and 14.8 illustrate a cross-working drill/mill attachment mounted on the turret top
plate.
END-WORKING ATTACHMENTS
End-working attachments are qualified on the X axis.
Figures 14.9 and 14.10 illustrate an end-working drill/mill attachment mounted on the turret top
plate.
VDI 30 Attachments
The centerline of the spindle in the VDI 30 end-working attachment will be located 2.756 inches
[70.0 mm] from the side of the turret top plate.
On machines set for diameter programming, this will result in an X tool geometry offset of 5.512
inches [140.00 mm]. On machines set for radius programming, this will result in an X tool geometry off-
set of 2.756 inches [70.00 mm].
VDI 40 Attachments
The centerline of the spindle in the VDI 40 end-working attachment will be located 3.543 inches
[90.0 mm] from the side of the turret top plate.
On machines set for diameter programming, this will result in an X tool geometry offset of 7.086
inches [180.00 mm]. On machines set for radius programming, this will result in an X tool geometry off-
set of 3.543 inches [90.00 mm].
M-392D 14-13
SETTING TOOL OFFSETS FOR LIVE TOOLING
The live tooling feature allows milling, drilling, and tapping operations to be performed on either the
diameter or face of the workpiece. The method used to establish the tool offset values for live tooling
are similar to the method used for standard tooling. Live tooling attachments can be mounted at any
tool station on the turret top plate.
Setting Offsets for End-Working Tools

- NOTE-
VDI 30 end-working live tooling attachments place the tool centerline 2.756 inches
[70.0 mm] from the X axis turret face. When establishing tool offsets, this dimension
must be doubled for machines that have been set for Diameter Programming.
VDI 40 end-working live tooling attachments place the tool centerline 3.543 inches
[90.0 mm] from the X axis turret face. When establishing tool offsets, this dimension
must be doubled for machines that have been set for Diameter Programming.
This procedure assumes that the live tooling attachment has already been mounted
on the turret top plate and the tooling has been installed in the attachment. Refer to
page 14-5 for information on installing live tooling attachments.
1. Load a workpiece of known diameter and length into the collet closer or chuck.
- NOTE -
tool offsets.
- CAUTION -
dexing the turret.
7. Select the desired turret station using the Turret Station switch.
8. Press the Index push button to index the turret to the selected station.
9. Jog the tool to within 1 inch [25 mm] of the workpiece being held in the spindle.
14-14 M-392D
10. Place a shim against the part face and use the handwheel to move the turret on the Z axis to
gently touch the tool tip to the shim so that a slight drag is felt when moving the shim.
13. Press the Geometry soft key to display the Tool Geometry Offset pages.
15. Key in the appropriate value from the following table:
Programming Programming Value to Enter as Offset

Mode Unit VDI 30 Top Plate VDI 40 Top Plate
Inch 5.512 7.086
Diameter
Millimeter 140.00 180.00
Inch 2.756 3.543
Radius
Millimeter 70.00 90.00

17. Use cursor keys to position the cursor at the Z axis field for the desired offset.
19. Key in the letter Z and the thickness of the shim as a negative value.
- NOTE -
21. Turn the handwheel in the appropriate direction to clear the workpiece.
M-392D 14-15
Setting Offsets For Cross-Working Tools
- NOTE -
Cross-working live tool attachments place the tool centerline at the Z axis turret ref-
erence position. Therefore, the Z axis tool offset will be equal to “0” (zero).
- NOTE -
tool offsets.
- CAUTION -
dexing the turret.
9. Jog the tool until it is positioned over the workpiece O.D.
10. Press the X push button.
11. Press the desired handwheel increment push button.
12. Place a shim against the part O.D. and use the handwheel to move the turret on the X axis to
14-16 M-392D
Input = X2.125
- NOTE -
18. Press the Measure soft key.
If the control is set for diameter programming, enter twice the shim thickness as a negative
(-) value.
If the control is set for radius programming, enter the shim thickness as a negative (-)
value.
20. Press the Input+ soft key. The X Offset will be decreased by the amount specified in step 19.
22. Key in “0" (zero).
TOOL NOSE RADIUS COMPENSATION

For typical live tooling applications, Tool Nose Radius Compensation is not required. Tool Nose
Radius Compensation may be required for live tooling during C-Axis operations. Refer to the pro-
grammer’s manual (M-391) for information on Tool Nose Radius Compensation or C-Axis.
LIVE TOOLING ALIGNMENT

The live tooling attachments are factory set to be on center and should require no further adjust-
ment.
M-392D 14-17
LIVE TOOLING MAINTENANCE
LUBRICATING THE LIVE TOOLING ATTACHMENT
- NOTES -
Each live tooling attachment must be removed from the turret top plate at least once
per month to be inspected and lubricated.
1. Move the turret to a safe index position.
2. Index the turret top plate to a convenient position for removing the live tooling attachment.
3. Open the main coolant guard door.
5. Wipe coolant, chips, and other contaminants J
from the live tool attachment and turret top
plate.
6. Unthread the clamp screw just enough to be I
able to remove the live tooling attachment. Pull
the live tooling attachment straight out from the
top plate.
7. Inspect the live tooling attachment for wear and
the amount of grease on spline “I”, Figure
14.13, or flats “K”, Figure 14.14. TP4221
8. Lightly coat spline “I” or flats “K” with Molylube®

Figure 14.13 - VDI 30 Cross-Working
Anti-Seize grease.
Live Tooling Attachment
9. Check O-ring “J” or “L” to be sure that it is in
good condition.
10. Mount the live tooling attachment on the turret
top plate.
- NOTE -
Maximum torque for the clamp screw is
17 lb-ft [23 N•m] on VDI 30 top plates
and 33 lb-ft [45 N•m] on VDI 40 top
plates. L
11. Tighten the clamp screw.
K
13. Pull the Emergency Stop push button out to the
first detent, wait two seconds; then, pull the
push button out to the end of travel and TP4864
release.
Figure 14.14 - VDI 40 End-Working
14. Repeat steps 2 through 13, as needed, for Live Tooling Attachment
additional live tooling attachments.
14-18 M-392D
LUBRICATING THE LIVE TOOLING PINION GEARS
Lubrication Frequency
VDI 30 TURRET
If the live tooling is generally run at less than 5000 rpm, the live tooling pinion gears must be
inspected and lubricated every 500 hours of operation.
If the live tooling is generally run at 5000 rpm or faster, the live tooling pinion gears must be
VDI 40 TURRET
If the live tooling is generally run at less than 4000 rpm, the live tooling pinion gears must be
If the live tooling is generally run at 4000 rpm or faster, the live tooling pinion gears must be
Lubrication Procedure
1. Move the turret to a convenient position for accessing top plate cover “M”, Figure 14.15.
4. Wipe coolant, chips, and other contaminants from the turret top plate.
5. Remove six screws “N” and the associated lock washers to remove turret cover “M”.
6. Apply KLÜBER® ISOFLEX Topas NCA 152 grease to pinion gears “O”, Figure 14.16.
7. Replace turret cover “M” using lock washers and screws “N”, Figure 14.15. Torque screws
“N” to 120 lb-in [162 N•m].
N
P
TP4227 TP4218
Figure 14.15 - Turret Top Plate Cover Figure 14.16 - Live Tooling Pinion Gears
(VDI 30 Turret Shown) (VDI 30 Turret Shown)
M-392D 14-19
LUBRICATING THE TURRET INDEX SHAFT AND LIVE TOOLING DRIVE SHAFT
The turret index shaft and live tooling drive shaft must be inspected and lubricated every 2000
hours of operation.
1. Move the turret to a convenient position for accessing top plate cover “M”, Figure 14.15.
4. Wipe coolant, chips, and other contaminants from the turret top plate.
5. Remove six screws “N” and the associated lock washers to remove turret cover “M”.
- CAUTION -
Use only a manually operated grease gun.
- NOTE -
A manually operated grease gun will require approximately 4½ strokes to deliver the
required amount of grease.
6. Using a manually operated grease gun, apply 4.0 cc of KLÜBER® ISOFLEX Topas NCA 15
grease to grease fittings “P” and “Q”.
7. Replace turret cover “M” using lock washers and screws “N”, Figure 14.15. Torque screws
“N” to 120 lb-in [162 N•m].
14-20 M-392D
- NOTES -
M-392D 14-21
- NOTES -
14-22 M-392D
CHAPTER 15 - ESA LIVE TOOLING [Option]
INTRODUCTION
A live tooling option is available on QUEST® series lathes equipped with a ESA top plate. The live
tooling attachments are not included with the machine tool and must be purchased separately.
ESA live tooling attachments have a maximum spindle speed of 8000 rpm, as measured at the tool
tip, and can be operated at 30 percent of the total duty cycle at 8000 rpm.
TYPES OF ATTACHMENTS
- CAUTION -
Live tooling attachments are available with or without through-tool coolant ca-
pability.
Live tooling attachments without through-tool coolant capability can be run
with or without coolant, as the machining process requires.
Live tooling attachments with through-tool coolant capability MUST be run
with coolant turned ON.
The live tooling attachments are identified by axis of operation and if they have internal (thru-tool)
coolant.
Cross-Working Attachment:
This attachment aligns the centerline of the tool with the X axis.
End-Working Attachment:
This attachment aligns the centerline of the tool with the Z axis.
LIVE TOOLING COLLETS AND CAPACITIES

- NOTE -
ER 25 collets conform to DIN 6499.
ESA live tooling attachments are designed to use ER 25 collets to grip the tools.
M-392D 15-1
LIVE TOOLING ATTACHMENT INSTALLATION
- CAUTION -
tooling can result in damage to the machine tool. Refer to page 5-2 for infor-
mation on ESA tool station plugs.
- NOTE -
All turret tool stations can be used for live tooling applications.
MOUNTING THE ATTACHMENT

1. Thoroughly clean the top plate, live tooling attachments, and tooling.
4. Press and hold button "A", Figure 15.1.
5. Insert the tool holder into the turret top plate as shown in View B.
6. Release button "A" to clamp the tool holder.
B
A
VIEW A VIEW B
Live Tool Attachment Live Tool Attachment
Aligned for Installation Installed on Top Plate
TI5451
Figure 15.1 - Live Tooling Attachment Installation

(Cross-Working Attachment Shown)
15-2 M-392D
7. Tighten rear clamp screw "C", Figure 15.2.
8. Install and tighten four face screws “B”, Figure
15.1. C
9. If necessary, remove cap “D”, Figure 15.3, and
install the proper collet for the tool to be used.
Replace the cap, but DO NOT TIGHTEN.
TP7130
Figure 15.2 - Rear Clamping Screw
Cross-Working End-Working
Live Tooling Attachment Live Tooling Attachment
D
TI5452
Figure 15.3 - Collet Caps on Live Tool Attachments
M-392D 15-3
INSTALLING TOOLS

- WARNING -
DO NOT exceed these maximum tool extension values. Personal injury and
damage to the tooling and machine can result.
- NOTE -
All dimensions are shown in inches [millimeters].
Cross-working live tooling attachments have the following maximum tool extension from the edge
of the turret top plates:
Turret with Y-Axis Option: 6.983 [177.37]
End-working live tooling attachments oriented for sub-spindle operation have a maximum tool ex-
tension of 8.375 inches [212.73 millimeters] from the centerline of the turret top plate tool mounting lo-
cation.
Cross-Working Live Tooling Attachment End-Working Live Tooling Attachment

Oriented for Sub-Spindle Operation
5.481
[139.22]

Y-Axis Turret: 6.983 [177.37]
8.375
Inch [Millimeter] [212.73]
TI5453
Figure 15.4 - Maximum Tool Extensions
15-4 M-392D
Tool Installation Procedure
- NOTE -
Wrenches are supplied with the live tooling attachments.
1. Insert the tool into the attachment and set to length.
2. Mount a spanner wrench on spindle “E”, Figure 15.5.
3. Use a wrench to tighten cap “F”.
Cross-Working End-Working
Live Tooling Attachment Live Tooling Attachment
E
F
TI5454
Figure 15.5 - Tools Installed in Live Tool Attachments
M-392D 15-5
LIVE TOOLING OFFSETS
Live tooling offsets are set in the same manner as standard tooling. However, there are some con-
siderations to be aware of that will simplify setting the tool offsets for tools mounted in live tooling at-
tachments. These considerations are outlined below.
Refer to page 15-7 for information on setting live tooling offsets.
CROSS-WORKING ATTACHMENTS
Cross-working attachments are qualified on the Z axis. The centerline of the spindle in the
cross-working attachment will always be located at the Z axis reference position of the turret top
plates. The Z axis tool offset will always be “0".
END-WORKING ATTACHMENTS
- NOTE -
Machines equipped with an ESA turret top plate have the same X axis turret refer-
ence position and travel specifications as a machine equipped with a VDI 30 turret
top plate. As indicated in Figure 15.6, the diameter of the ESA turret top plate is
1.378 inches [35.00 millimeters] smaller per side than the VDI 30 turret top plate.
End-working attachments are qualified on the X axis. The centerline of the spindle in the end-work-
ing attachment will be located 2.7559 inches [70.00 millimeters] from the X axis turret reference posi-
tion.
On machines set for radius programming, the X tool geometry offset will be 2.7559 inches
[70.00 millimeters].
On machines set for diameter programming, the X tool geometry offset will be 5.5118 inches
[140.00 millimeters].
Inch [Millimeter]
1.378
[35.00]

(Refer to the note on this page)
2.7559
[70.0]
TI5455A
Figure 15.6 - X Axis Tool Offset for

End-Working Live Tooling Attachments
15-6 M-392D
SETTING TOOL OFFSETS FOR LIVE TOOLING
The live tooling feature allows milling, drilling, and tapping operations to be performed on either the
diameter or face of the workpiece. The method used to establish the tool offset values for live tooling
are similar to the method used for standard tooling. Live tooling attachments can be mounted at any
tool station on the turret top plate.
Setting Offsets for End-Working Tools

- NOTE-
ESA end-working live tooling attachments place the tool centerline 2.7559 inches
[70.00 millimeters] from the X axis turret reference position. When establishing tool
offsets, this dimension must be doubled for machines that have been set for Diame-
ter Programming.
- NOTE -
tool offsets.
- CAUTION -
dexing the turret.
9. Jog the tool to within 1 inch [25 millimeters] of the workpiece being held in the spindle.
M-392D 15-7
10. Place a shim against the part face and use the handwheel to move the turret on the Z axis to
15. Key in the appropriate value from the following table:
Programming Programming Value to Enter

Mode Unit as Offset
Inch 5.5118
Diameter
Millimeter 140.00
Inch 2.7559
Radius
Millimeter 70.00

17. Use cursor keys to position the cursor at the Z axis field for the desired offset.
19. Key in the letter Z and the thickness of the shim as a negative value.
- NOTE -
15-8 M-392D
Setting Offsets for Cross-Working Tools
- NOTE -
Cross-working live tool attachments place the tool centerline at the Z axis turret ref-
erence position. Therefore, the Z axis tool offset will be equal to “0” (zero).
- NOTE -
tool offsets.
- CAUTION -
dexing the turret.
9. Jog the tool until it is positioned over the workpiece O.D.
10. Press the X push button.
11. Press the desired handwheel increment push button.
12. Place a shim against the part O.D. and use the handwheel to move the turret on the X axis to
M-392D 15-9
Input = X2.125
- NOTE -
18. Press the Measure soft key.
If the control is set for diameter programming, enter twice the shim thickness as a negative
(-) value.
If the control is set for radius programming, enter the shim thickness as a negative (-)
value.
20. Press the Input+ soft key. The X Offset will be decreased by the amount specified in step 19.
22. Key in “0" (zero).
TOOL NOSE RADIUS COMPENSATION

For typical live tooling applications, Tool Nose Radius Compensation is not required. Tool Nose
Radius Compensation may be required for live tooling during C-Axis operations. Refer to the pro-
grammer’s manual (M-391) for information on Tool Nose Radius Compensation or C-Axis.
LIVE TOOLING MAINTENANCE

Refer to the maintenance manual (M-393) for information on live tooling maintenance.
LIVE TOOLING ALIGNMENT

Live tooling alignment is set at the factory and should require no further adjustment.
15-10 M-392D
- NOTES -
M-392D 15-11
- NOTES -
15-12 M-392D
CHAPTER 16 - TOOL LIFE MANAGEMENT
INTRODUCTION
The basic concept of Tool Life Management is that after a specific number of parts or a specific
amount of machining time, the control will automatically begin using another tool in place of the cur-
rent tool being used for a particular operation.
Tools are assigned to specific groups, as designated by the programmer. The control will monitor
the measurement value assigned to each tool group and automatically switch to the next tool in the
group when the counter for that tool group reaches the measurement value specified by the program-
mer.
TOOL LIFE MEASUREMENT UNITS

Tool life can be measured using one of the two following methods:
1. Number of parts (machined by the tool)
2. Amount of machining time (on the tool)
Only one of these methods may be used at a time. “Number of parts” will be the active measure-
ment unit when the machine is shipped from the factory. Refer to Determining the Measurement Unit,
page 16-5, for information on verifying or switching the active measurement unit.
An alarm message will be displayed when any tool group has reached its programmed tool life and
an “M30" (End of Program) is read by the control. At that point, the machine operator will replace the
tooling and reset the counter relating to the affected tool group. Refer to Resetting a Tool Group Coun-
ter, page 16-6.
NUMBER OF PARTS
When this type of measurement is used, the control will increment the tool group counter for the ac-
tive tool each time the tool group is called by the part program.
AMOUNT OF MACHINING TIME

When this type of measurement is used, the control will run the tool group counter for the current
tool whenever G01, G02, or G03 is active.
M-392D 16-1
TOOL LIFE MANAGEMENT PROGRAM
When using Tool Life Management, tools and offsets are assigned to specific groups. These
groups are established by the programmer through the use of a Tool Life Management program,
which is independent of the part program. The Tool Life Management program will define the parame-
ters required for Tool Life Management.
The Tool Life Management program defines the following parameters:
• Group numbers.
• Tool life value for each group.
• Tool stations and offsets for each group.
- CAUTION -
When the Tool Life Management program is executed, all Tool Life Manage-
ment counters will be reset to 0 (zero).
When using Tool Life Management, the machine operator MUST load and execute the Tool Life
Management program BEFORE executing the part program for the first time.
Refer to the programmer’s manual (M-391) for information on the Tool Life Management program
and how to incorporate Tool Life Management information in the part program.
BAR FEED OPERATION

There are no special considerations for running bar jobs. When running a bar job and using Tool
Life Management, the programmer will program an M30 at the end of the part program and the ma-
chine operator will activate Repeat mode to cause the part program to loop.
Refer to page 1-9 for information on Repeat mode.
16-2 M-392D
OPERATION
DETERMINING MAXIMUM GROUPS AND GROUP SIZES
The maximum number of tool groups and maximum number of tools per group are established by
parameter 6800, bits 0 and 1. Be sure that bits 0 and 1 are set to appropriate values to allow for the
necessary number of tool groups and tools per group to be programmed in the Tool Life Management
Program.
The bits in parameter 6800 are numbered as follows:
7 6 5 4 3 2 1 0
Set bits 0 and 1 according to the following chart:
Bit 1 Bit 0 Max No. of Groups Max Tools per Group

0 0 16 16
0 1 32 8
1 0 64 4
1 1 16 16
When the machine is shipped from the factory, the maximum number of groups and maximum tools
per group will be set to 16.
Verifying Maximum Groups and Group Sizes

3. Use the Page keys to display the page that contains parameter 6800.
4. Compare bits 0 and 1 to chart above to determine the maximum groups and group sizes.
Setting Maximum Groups and Group Sizes

field.
M-392D 16-3
10. Use the Page and Cursor keys to position the cursor at parameter 6800.
11. Record the current number in parameter 6800.
12. Key in the entire parameter value with bits 0 and 1 set to the appropriate values.
16-4 M-392D
DETERMINING THE MEASUREMENT UNIT
The two types of measurement units available are “Number of Parts” and “Amount of Machining
Time”. To verify which measurement unit is active, it is necessary to view parameter 6800, bit 2. To
switch the type of measurement unit to be used with Tool Life Management, it is necessary to modify
parameter 6800, bit 2.
The bits in parameter 6800 are numbered as follows:
7 6 5 4 3 2 1 0
Verifying the Measurement Unit

3. Use the Page keys to display the page that contains parameter 6800.
If parameter 6800, bit 2 is set to 0, “Number of Parts” is active.
If parameter 6800, bit 2 is set to 1, “Amount of Machining Time” is active.
Switching the Measurement Unit

field.
10. Use the Page and Cursor keys to position the cursor at parameter 6800.
11. Record the current number in parameter 6800.
12. Key in the entire parameter value with bit 2 set to the appropriate value.
M-392D 16-5
RESETTING A TOOL GROUP COUNTER
Resetting the control or turning the control OFF will have NO AFFECT on the tool group counters.
When all of the tools in a tool group have reached the tool life specified in the Tool Life Management
program and an M30 “End of Program” is read, the following alarm message will be displayed:
1006 TOOL GROUP LIFE END
The expired tool groups will be listed near the bottom of the Tool Life Management screen on the
control display. The control can display more than one tool group number at a time, when applicable.
Resetting the counter for the expired tool group(s) will clear the alarm and allow machine operation.
- NOTE -
It is not necessary to change machine modes to reset tool group counters.
Use the following procedure to reset the tool group counter(s):
3. Press the Tool Life soft key.
- NOTE -
Each time a cursor control key is pressed, the cursor will move to the next tool group
in the corresponding direction.
4. Use the cursor control keys to move the cursor to the desired tool group.
6. Press the Clear soft key.
7. Press the Execute soft key. The tool group counter at the cursor position will be reset to 0
(zero).
8. Repeat steps 4 through 7 to reset additional tool group counters, as needed.
16-6 M-392D
- NOTES -
M-392D 16-7
- NOTES -
16-8 M-392D
CHAPTER 17 - SUB-SPINDLE AND
COLLET CLOSER [Option]
- WARNING -
Tighten all draw tube screws before beginning spindle operation.
- CAUTION -
Never operate the sub-spindle without a work-holding device if the draw tube
is in the spindle.
INTRODUCTION
The sub-spindle allows parts to be machined at both ends without stopping the machine to
end-for-end the workpiece. This reduces cycle times by eliminating part handling by the operator.
Drilling, boring, turning and facing operations can be performed on parts which are chucked in the
sub-spindle.
Depending on the machining sequence which is selected, the first side of the workpiece is ma-
chined in either the main spindle or the sub-spindle. The workpiece is then transferred to the other
spindle to complete machining of the second side. The sub-spindle travel specifications are shown in
Appendix One.
CYCLE START SAFETY INTERLOCK

Cycle Start is inhibited when the main spindle and sub-spindle work-holding devices are both open.
At least one work-holding device must be closed before Cycle Start can be activated.
FREE SPINDLE
A “Free Spindle” condition allows the sub-spindle to be turned by hand. To obtain a free spindle,
proceed as follows:
- NOTE -
To obtain a free spindle, the control must be ON and the sub-spindle must not be ro-
tating.
1. Power up the machine as described in Chapter 2.
3. Press the Sub Spindle Free push button.
M-392D 17-1
CONTROLLING SUB-SPINDLE MOVEMENT
AUTOMATIC, MANUAL DATA INPUT, OR SINGLE MODE
- NOTE -
When E axis motion is programmed by itself, the sub-spindle moves at the pro-
grammed feedrate. When E axis motion is programmed with X and/or Z axis motion,
the sub-spindle moves at a compensated feedrate to cause the sub-spindle to com-
plete the move at the same time as the other axes.
Linear motion of the sub-spindle assembly, designated the E axis, is performed by a servo drive
system that is controlled by the CNC control. The E Data word is used to command direction and dis-
tance when moving the ball screw driven sub-spindle in Automatic, Manual Data Input, or Single
mode. The face of the sub-spindle is the sub-spindle reference point.
The maximum programmable feedrate (G01 active) is 394 in/min [10,000 mm/min].
The machine is forced into a Feed Hold condition when Automatic, Manual Data Input, or Single
mode is active and any interlocked door is opened or cover removed. The Feed Hold condition is re-
leased when the door is closed or cover replaced. Press the Cycle Start push button to resume pro-
gram execution.
E Data Word
The E Data word commands an absolute move referenced against the Z0 (zero) position of the ma-
chine coordinate position. Positive E coordinates are to the right of Z0 and negative E coordinates are
to the left of Z0. The Z0 position will be equal to the face of the main spindle unless modified through
the Work Shift offset. Refer to Chapter 7 for information on the Work Shift offset.
Feedrate Override Switch

The Feedrate Override switch allows the machine operator to adjust the programmed feedrate of
the sub-spindle from 0% to 150%, up to a maximum feedrate of 394 in/min [10,000 mm/min].
17-2 M-392D
JOG MODE
Axis Direction Keys

When a Z/E push button is pressed while Jog mode is active and the Manual Axis Motion switch is
set to the E axis, the servo drive system causes the sub-spindle to move in the selected direction at a
jog feedrate of 25 in/min [635 mm/min] when the Feedrate Override switch is set to 100%. Refer to
“Feedrate Override Switch”, below.
FEEDRATE OVERRIDE SWITCH
The Feedrate Override switch allows the machine operator to adjust the jog feedrate of
the sub-spindle from 0 to 37.5 in/min [952 mm/min].
RAPID TRAVERSE
The Traverse push button allows the machine operator to jog the sub-spindle on the E
axis at approximately 150 in/min [3810 mm/min], regardless of the setting of the Feedrate
Override switch.
MOVING THE SUB-SPINDLE
2. Use the Manual Axis Motion switch to select the E axis.
4. Press the appropriate Z/E push button to jog the sub-spindle in the desired direction.
Handwheel Control
The handwheel can be used to move the sub-spindle incrementally on the E axis whenever Cycle
Start is not active. The E axis is selected with the Manual Axis Motion switch. The movement incre-
ment is selected by with the Rapid Override switch. The sub-spindle will move incrementally when the
handwheel is rotated. The direction and distance is determined by the direction and amount of rotation
of the handwheel.
MOVING THE SUB-SPINDLE
2. Use the Manual Axis Motion switch to select the E axis.
3. Use the Rapid Override switch to select the desired increment.
4. To view axis position on the control display:
A) Press the Position key.
B) Press the Page key until the desired position display appears on the control display.
5. Turn the handwheel in the desired direction (+ or -). Observe the axis position display to
determine when the axis has been moved the required distance.
• Turn the handwheel in the plus (+) direction to move the sub-spindle away from
the face of the main spindle.
• Turn the handwheel in the minus (-) direction to move the sub-spindle toward the
face of the main spindle.
M-392D 17-3
SUB-SPINDLE TOOLING
This section covers the removal and installation of spindle tooling, such as collets, step chucks,
and jaw chucks.
- CAUTION -
Read and follow all safety recommendations and operating limits for any
work-holding device installed in the spindle. DO NOT EXCEED the rated ca-
pacity of the work-holding device.
QUEST® series machines are available with a standard or high speed sub-spindle. The high speed
spindle is balanced to the ISO G1.0 standard and requires a work-holding device balanced to ISO
G2.5 or better.
All work-holding devices, other than Hardinge collets, should be carefully reviewed for speed limi-
tations and balance specifications. Hardinge Inc. offers chucks balanced to G2.5 or better for high
speed applications.
REMOVING SUB-SPINDLE TOOLING

- CAUTION -
closer.
5. At the right end of the machine, remove draw tube access cover “A”, Figure 17.1.
7. Completely loosen six screws “B”, Figure 17.2.
A
D
C
B
TP4135A TP4133A
Figure 17.1 - Draw Tube Access Figure 17.2 - Spindle Draw Tube
Cover at Right End of Machine
17-4 M-392D
- NOTE -
Six screws “B”, Figure 17.2, must be completely disengaged from the collet closer
liner before draw tube nut “C” can be rotated.
Removal of a jaw chuck or step chuck may require the assistance of a second per-
son.
8. Rotate draw tube nut “C” counterclockwise to disengage the draw tube from the work-holding
device.
- WARNING -
Be prepared to accept the weight of the work-holding device.
9. Remove the work-holding device from the spindle.
10. Cover the main spindle to protect it from chips while the sub-spindle is being cleaned.
of the spindle.
- WARNING -
The draw tube may be HOT when running aggressive duty cycles on machines
equipped with a high speed sub-spindle.
13. Completely remove the draw tube from the back of the spindle.
of the spindle a second time.
15. Clean the spindle and draw tube.
16. Lightly lubricate the bearing surfaces of the draw tube with Molylube® Anti-Seize grease.
17. Lightly coat the remaining exterior surfaces of the draw tube with Mobiltemp® SHC 32 grease.
18. Carefully replace the draw tube in the spindle.
19. If spindle tooling is to be installed at this time, proceed to “Installing Spindle Tooling”, beginning
on page 17-6.
If spindle tooling is not to be installed at this time:
A) Replace the draw tube plug.
B) Replace draw tube access cover “A”, Figure 17.1.
M-392D 17-5
INSTALLING SUB-SPINDLE TOOLING
- NOTE -
For the best surface finish and part roundness, the sub-spindle and draw tube have
been balanced together at the factory. Although the spindle and draw tube can be
run in other positions, the best balance is when etched mark “D”, Figure 17.2, and
spindle drive button “E”, Figure 17.3, are aligned.
Two procedures are outlined in this section. The first procedure, which begins below, covers the in-
stallation of collets and step chucks. The second procedure, beginning on page 17-8, covers the in-
stallation of jaw chucks.
Collet or Step Chuck

there is spindle tooling to be removed, perform the steps outlined under “Removing Sub-Spindle
Tooling”, beginning on page 17-4.
- CAUTION -
4. Remove draw tube access cover “A”, Figure 17.1.
- NOTE -
The collet and spindle bore MUST be clean.
6. Clean the spindle bore and the collet or step
chuck and closer to be installed.
E
7. Press the Sub-Spindle Free push button to
release the spindle brake and allow the spindle
to be rotated.
8. Manually position spindle drive button “E”,
Figure 17.3, to the top dead center (12 o’clock)
position.
9. Press the Sub-Spindle Free push button again
to have the brake secure the spindle drive
TP5785
Figure 17.3 - Sub-Spindle Nose with

Drive Button at Top Dead Center
17-6 M-392D
- WARNING -
To insure operator safety:
- DO NOT use cast iron step chucks.
- DO NOT use a step chuck without a step chuck closer.
- NOTE -
Installation of a step chuck may require the assistance of a second person.
10. If installing a step chuck in the spindle, place the step chuck closer against the spindle and
install the mounting screws securely.
11. Align the keyway in the collet with the key in the spindle and slide the collet into the spindle until
it makes contact with the draw tube.
12. Carefully push the draw tube against the back of the collet while rotating the draw tube
clockwise to start the threads of the collet into the threads of the draw tube.
- NOTE -
Adjustment of the collet or step chuck may require the assistance of a second per-
son.
13. Select the largest diameter workpiece which is to be chucked and position this part in the collet
or step chuck.
14. Rotate the draw tube nut “C”, Figure 17.2, clockwise until the workpiece is gripped tightly; then,
back the draw tube off ¼ to ½ turn.
15. Rotate the draw tube the shortest distance to locate etched mark “D” at top dead center (12
16. Tighten six draw tube screws “B”.
17. Press the Sub Open/Close push button to close the collet and test the gripping force on the
workpiece.
If the gripping force is more or less than desired, adjust knob “F”, Figure 17.4 or 17.5, to
any setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table 17.1.
- CAUTION -
19. Replace draw tube access cover “A”, Figure 17.1.
M-392D 17-7
Jaw Chuck
there is spindle tooling to be removed, perform the steps outlined under “Removing Sub-Spindle
Tooling”, beginning on page 17-4.
- CAUTION -
4. Remove draw tube access cover “A”, Figure 17.1.
- NOTE -
The jaw chuck and spindle bore MUST be clean.
6. Clean the jaw chuck and spindle bore.
7. Press the Sub-Spindle Free push button to release the spindle brake and allow the spindle to
be rotated.
8. Manually position spindle drive button “E”, Figure 17.3, to the top dead center (12 o’clock)
position.
9. Press the Sub-Spindle Free push button again to have the brake secure the spindle drive
10. Place the chuck in the spindle and install the mounting screws securely.
11. Carefully push the draw tube against the back of the chuck while rotating the draw tube
clockwise to start the threads of the chuck into the threads of the draw tube.
12. Rotate draw tube nut “C”, Figure 17.2, to thread the draw tube onto the 3 jaw chuck as far as
possible.
13. Rotate the draw tube counterclockwise to locate etched mark “D” at top dead center (12
14. Tighten six draw tube screws “B”.
17-8 M-392D
15. Place a workpiece into the chuck and press the Sub Open/Close push button to close the chuck
and test the gripping force on the workpiece.
If the gripping force is more or less than desired, adjust knob “F”, Figure 17.4 or 17.5, to
any setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table 17.1.
- CAUTION -
17. Replace draw tube access cover “A”, Figure 17.1.
M-392D 17-9
SUB-SPINDLE COLLET CLOSER
The sub-spindle on QUEST® series lathes is equipped with a .5 inch [12.7 mm] stroke, hydraulically
actuated collet closer. If repairs to the collet closer assembly are required, the ENTIRE ASSEMBLY
must be removed and returned to the factory. Refer to the QUEST series lathe maintenance manual
(M-393) for information on removing or installing the sub-spindle collet closer assembly.
HYDRAULIC PRESSURE CONTROL

- NOTE -
The sub-spindle collet closer has an operational pressure range of 60 psig [4.14
bars] to 500 psig [34.5 bars].
The sub-spindle collet closer draw bar force is controlled by hydraulic oil pressure. The hydraulic
pressure controls are located at the back of the machine. Sub-spindle collet closer pressure is con-
trolled with adjustment knob “F”, Figure 17.4 or 17.5.
Gauge “G” registers the collet closer hydraulic pressure in psig and bars. Refer to Table 17.1, page
17-11, to determine the force that will be applied to the collet closer draw bar for a given pressure. A
check valve system positively holds the closer open or closed, whichever is active, in the event of a hy-
draulic pressure failure.
- CAUTION -
DO NOT exceed the maximum pressure setting, as shown in Table 17.1 .
- NOTE -
It is the responsibility of the machine operator or set-up person to properly adjust the
collet closer hydraulic pressure, based on the type of material to be machined and
the configuration of the workpiece.
F
G
TP4196
Figure 17.4 - Sub-Spindle Collet Closer Pressure Adjustment

(Machine with Standard Spindle Drive)
17-10 M-392D
G
TP4816
Figure 17.5 - Sub-Spindle Collet Closer Pressure Adjustment

(Machine with High Speed Spindle Drive)
Adjusting the Hydraulic Pressure

1. Loosen the knurled lock nut behind pressure adjustment knob “F”, Figure 17.4 or 17.5.
2. Turn pressure adjustment knob “D” clockwise or counterclockwise to decrease or increase the
collet closer hydraulic pressure.
3. Tighten the knurled lock nut to secure the setting.
English Metric
100 1,206 6.9 538
200 2,412 13.8 1,076
300 3,619 20.7 1,615
400 4,826 27.6 2,152
500 6,000 34.5 2,678
Table 17.1 - Sub-Spindle Collet Closer Draw Bar Force
M-392D 17-11
SUB-SPINDLE COLLET CLOSER OPERATION
- CAUTION -
Do not operate the sub-spindle collet closer when a collet or step chuck is
mounted in place without gripping a piece of stock or a plug of the correct
size.
Automatic Operation
For automatic operation, program M56 to open the collet and M57 to close the collet. The M56
(Open Collet) and M57 (Collet Close) commands may be executed while the spindle is running. M56
will remain active until it is canceled by an M57 (Close Collet) command. A programmed M57 (Collet
Close) command will remain active until it is canceled by an M56 (Open Collet) command.
Manual Operation
The collet closer can be manually operated whenever the machine is in a Reset or program stop
(M00, M01, or M30) condition. Use the Sub Open/Close push button to operate the sub-spindle collet
closer manually.
Chucking Modes
There is no default chucking mode. The current chucking mode will remain active until canceled by
the appropriate command (M68 or M69).
External chucking mode permits the use of work-holding fixtures that grip the workpiece externally.
Internal chucking mode permits the use of work-holding fixtures that grip the workpiece internally.
SWITCHING THE CHUCKING MODE
1. Check to be sure the Sub Open/Close indicator light is ON. Place a workpiece in the collet and
press the Sub Open/Close push button, if necessary.
3. Press the Program soft key.
4. At the manual Data input keyboard:
Key in “M68” for External Chucking
Key in “M69” for Internal Chucking
8. Close the machine guard door and press the Cycle Start push button.
9. Press the control Reset key. The selected chucking mode will be active
17-12 M-392D
MAIN AND SUB-SPINDLE MACHINING SET-UP AND OPERATION
Main and sub-spindle machining involves the following procedures:
• Set offsets and machine the first side.
• Set offsets and machine the second side.
- CAUTION -
WORK SHIFT When machining operations involving both spindles are per-
formed, two work shifts must be called out through the part pro-
gram. Both the main and sub-spindle work shifts must be recorded
for insertion into the part program.
Z AXIS VALUES For sub-spindle machining, negative Z values will be clearing
moves outside the workpiece face. Positive Z values will be inside
the workpiece face.
SAFE START AND The operator should be aware that programs O1 and O2 are used
SAFE END for the main spindle ONLY. To avoid crash situations, programs
PROGRAMS O3 and O4 must be used for the sub-spindle.
O3 must be used to start all sub-spindle tool operations and to end
all outside diameter work.
O4 must be used to end all sub-spindle inside diameter work.
SAFE INDEX The operator should be aware that program O999 is used for the
PROGRAMS main spindle ONLY. To avoid crash situations, program O998
must be used for the sub-spindle.
Prerequisites:
Control is turned ON and part program is loaded and active. Refer to Chapters 3
and 11.
Safe Start and Safe End Programs O1, O2, O3, and O4 are loaded into the
control and are called out in the part program.
Safe Index Programs O998 and O999 are entered into the control.
Operator knows how to edit part programs. Refer to Chapter 3.
Work-holding device is installed on the main spindle and adjusted to grip the
workpiece properly. Refer to Chapter 9.
Work-holding device is installed on the sub-spindle and adjusted to grip the
workpiece properly. Refer to Chapter 17.
Tools are mounted on the turret top plate at the correct stations. Refer to
Chapter 4, 5, or 6.
Operator knows how to establish the work shift offset and tool offsets for the
main spindle. Refer to Chapters 7 and 8.
Operator knows how to establish the work shift offset and tool offsets for the
sub-spindle. Refer to Chapters 7 and 8.
M-392D 17-13
SAMPLE MACHINE SET-UP
The sample machine set-up on pages 17-14 through 17-16 illustrates how a machine could be set
up for main spindle machining, followed by sub-spindle machining.
- CAUTION -
If the machine is to be operated in Metric mode, the Z pull back value in pro-
gram O4 must be converted to the metric value.
When a bar feed is being used, the face of the bar should be flush with the col-
let face since the program begins with a feed stock operation.
Set Up and Machine Main Spindle Operation
1. Place a workpiece of the correct size in the main spindle work-holding device at the desired
length.
2. Press the Main Open/Close push button to close the work-holding device.
3. Establish the work shift offset for the main spindle. Record this dimension.
4. Find the tool geometry offsets for the turret tooling used for the main spindle.
5. Subtract the shim thickness and face stock to be removed from the value recorded in step 3 and
record this dimension for insertion into the part program.
- CAUTION -
The X Safe Index coordinate defined in subprogram O999 should be equal the
X Home position. The Z Safe Index coordinate should equal the LONGEST tool
plus 1.000 inch [25.4 mm] minimum. Refer to Chapter 8 for additional informa-
tion.
The Z Safe Index coordinate defined in subprogram O999 MUST be pro-
grammed as a POSITIVE number.
6. Check the coordinates in Safe Index Sub-Program O999 to be sure that they are adequate.
If Then
Adequate Go to step 7.
Inadequate Edit sub-program O999 to provide extra clearance.
Refer to Chapter 3.
7. If necessary, select the part program that is to be executed.
8. If a bar job is being run, press the Repeat Mode push button.
If a bar job is not being run, go to step 9.
17-14 M-392D
- CAUTION -
For safe operation, the main spindle work shift must be programmed at the
start of each main spindle operation.
9. Enter the work shift in the program at the start of each main spindle operation.
- NOTE -
The work shift is entered in the G10 P0 Z-____ block.
10. Press the control Reset key and make certain the program is at the beginning.
- NOTE -
This will cause the active program to be displayed as well as the Distance To Go to
complete the move.
12. Set the Rapid Override switch to LOW.
13. Adjust the Feedrate Override switch to the desired percentage.
- CAUTION -
Do not use Single Block for a releasing Tap and Die Holder Operation.
14. Activate Single mode.
17. Press the Cycle Start push button for each block and machine the first side.
Set Up and Machine Sub-Spindle Operation

18. Execute the part transfer operation.
19. Establish the work shift offset for the sub-spindle. Record this dimension.
20. Establish the X and Z tool geometry offsets for the sub-spindle tooling on the turret.
- CAUTION -
To insure safe operation, the work shift for the sub-spindle must be entered at
the start of each Sub-Spindle operation.
The Z SHIFT VALUE defined in subprogram O998 must be programmed as a
NEGATIVE value.
21. Subtract the shim or scale thickness and face stock from the value recorded in step 19.
Program this dimension as the Z axis work shift at the beginning of each sub-spindle operation.
The work shift is entered in the G10 P0 Z-____ block.
M-392D 17-15
- CAUTION -
The X Safe Index coordinate defined in subprogram O998 should be equal the
X Home position. The Z Safe Index coordinate should equal the LONGEST tool
plus 1.000 inch [25.4 mm] minimum. Refer to Chapter 8 for additional informa-
tion.
The Z Safe Index coordinate defined in subprogram O998 MUST be pro-
grammed as a NEGATIVE number.
22. Check the Sub-Spindle Safe Index coordinates in subprogram O998.
They should read X19.5 Z-____ . Refer to page 3-7 for information on calculating the Z
safe index coordinate.
If the coordinates are: Then:
Correct Go to step 23.
Incorrect Edit the program to enter the correct values.
24. Activate the main workpiece program.
28. Key in the letter N and the sequence number of the first sub-spindle machining operation.
29. Press Cursor ê.
30. Activate Single mode.
32. Set the Feedrate Override switch to the desired percentage.
33. Set the Rapid Override switch to LOW.
35. Press the Cycle Start push button to execute each block of data.
17-16 M-392D
- NOTES -
M-392D 17-17
- NOTES -
17-18 M-392D
APPENDIX ONE
Z0
25.630 [651.00] +Z Software Limit
Main Spindle Headwall
25.380 [644.65] Z Axis Reference Position
1.378 [35.00]
0.500 [12.70] -Z Software Limit
Turret Top Plate
5.000 [127.00]
+X
+Z
Main 19.770 [502.15]

Spindle +X Software Limit
4.870 [123.70] 19.500 [495.30]

-X Software Limit X Axis
Reference Position
CL
NOTES:
1. All dimensions are shown in inches [millimeters].
2. All measurements for X are diameter values measured from the spindle centerline.
3. All measurements for Z are measured from the face of the main spindle.
4. Full programmable travel on the X axis is 14.900 [378.46], measured on the diameter.
5. Full programmable travel on the Z axis is 25.130 [638.30].
TI4649A
Figure A1.1 - Turret Travel Specifications: X and Z Axes

(Lathes equipped with a VDI 30 Turret Top Plate)
M-392D A1-1
Z0
1.634 [41.50]
Turret Top Plate
5.000 [127.00]
+X
+Z
Main 20.950 [532.13]

Spindle +X Software Limit
20.700 [525.78]
6.050 [153.67] X Axis
-X Software Limit Reference Position
CL
NOTES:
TI4881

(Lathes equipped with a VDI 40 Turret Top Plate)
A1-2 M-392D
Z0
Main Spindle

Headwall
5.000 [127.00]
Turret Top Plate
X and Z Axis Reference Position
(Refer to Note 6)
1.378 [35.00]
+X (Refer to Note 6)
+Z
Main
Spindle 19.500 [495.30]
19.770 [502.15]
X Axis
4.870 [123.70] +X Software Limit
Reference Position
-X Software Limit
CL
NOTES:
2. All X axis travel specifications are diameter values measured from the spindle centerline.
3. All Z axis travel specifications are measured from the face of the main spindle.
TI5430A

(Lathes equipped with an ESA Turret Top Plate)
M-392D A1-3
Z0
Turret Top Plate

5.000 [127.00]
+X
+Z
Main
17.362 [441.00]
Spindle
+X Software Limit
17.330 [440.18]
2.316 [58.83] X Axis
-X Software Limit Reference Position
CL
NOTES:
TI4735

(Lathes equipped with a Hardinge Turret Top Plate)
A1-4 M-392D
NOTE: All dimensions are shown in inches [millimeters].
+Y
2.000 [50.80]
+X
13.780 -Y
[350.00]
-X
1.377
7.450 [34.98]
[189.23]
2.435
[61.85]
2.854 [72.50]
Spindle
Centerline
2.879 [73.13]
14.000
[355.60] 0.126
[3.18]
TI4643
Figure A1.5 - Turret Travel Specifications: Y Axis Option

(VDI or ESA Top Plate)
(Viewed from the Tailstock/Sub-Spindle End of the Machine)
M-392D A1-5
+X
Z0
28.75 [730.3]
+Z 7.25
Dependent on Tailstock Center used
[184.2]
CL
Main
Tailstock at Tailstock at Fixed
Spindle
Forward Position Home Position
NOTE: All dimensions are shown in inches [millimeters].

TI4651A
Figure A1.6 - Tailstock Travel Specifications
+X
Z0
23.500 [596.90] Software Limit
+Z
23.25 [590.55] Reference Position
CL
Main
Spindle
0.500 [12.70] Software Limit
NOTE: All dimensions are shown in inches [millimeters]. TI4650B
Figure A1.7 - Sub-Spindle Travel Specifications
A1-6 M-392D
-Z Software +Z Software
Limit Limit
25.130 [638.30]
(Z Axis Travel)
5.500
[139.70]
0.500 [12.70]
+X Software Limit
Turret
7.450 Reference
[189.23] Position
(X Axis Travel)
3.120 [79.25]
-X Software Limit
CL
2.435 [61.85]
Machine Reference Position
NOTES:
2. All measurements for X are radius values.
3. The work envelope is shown with NO tool offset active.
4. The work envelope shown will be shifted by an active offset.
5. The tailstock is shown at the Reference position.
TI4719
Figure A1.8 - Work Envelope: Machine Equipped with

Tailstock and VDI 30 Turret Top Plate
M-392D A1-7
Limit Limit
24.625 [625.48]
(Z Axis Travel)
5.500
[139.70]
0.500 [12.70]
+X Software Limit
Turret
7.450 Reference
[189.23] Position
(X Axis Travel)
3.625 [92.08]
-X Software Limit
CL
3.025 [76.84]
NOTES:
TI4882

Tailstock and VDI 40 Turret Top Plate
A1-8 M-392D
Maximum Turn Diameter = 10.55 [267.9]
1.250
[31.75]
5.275 7.450 5.70

[133.99] [189.23] [144.8]
(X Axis Travel)
CL
23.054 [585.57]
(Maximum Turn Length)
25.130 [638.30]
(Z Axis Travel)
NOTES:
3. The turret is shown at the +X and +Z software limits.
TI5431A

Tailstock and ESA Turret Top Plate
M-392D A1-9
Limit Limit
22.660 [575.56]
(Z Axis Travel)
5.250
[133.35]
0.250 [6.35]
+X Software Limit
Turret
7.523 Reference
[191.08] Position 5.840
(X Axis Travel) [148.34]
-X Software Limit
CL
1.158 [29.41]
NOTES:
TI4741

Tailstock and Hardinge Turret Top Plate
A1-10 M-392D
Limit Limit
25.130 [638.30]
(Z Axis Travel)
5.500
[139.70]
0.500 [12.70]
+X Software Limit
Turret
7.450 Reference
[189.23] Position
(X Axis Travel)
2.380 [60.45]
-X Software Limit
CL
2.435 [61.85]
NOTES:
5. The sub-spindle is shown at the Reference position.
TI4718A

Sub-Spindle and VDI 30 Turret Top Plate
M-392D A1-11
Limit Limit
24.625 [625.48]
(Z Axis Travel)
5.500
[139.70]
0.500 [12.70]
+X Software Limit
Turret
Reference
7.450
Position
[189.23]
(X Axis Travel)
1.875 [47.63]
-X Software Limit
CL
3.025 [76.84]
NOTES:
TI4883

Sub-Spindle and VDI 40 Turret Top Plate
A1-12 M-392D
Maximum Turn Diameter = 10.55 [267.9] 1.250
[31.75]
5.275 7.450
[133.99] [189.23]
(X Axis Travel)
CL
3.006 [76.34]
0.196 [4.98]
23.054 [585.57]
(Maximum Turn Length)
25.130 [638.30]
(Z Axis Travel)
NOTES:
3. The turret is shown at the +X and +Z software limits.
TI5432A

Sub-Spindle and ESA Turret Top Plate
M-392D A1-13
Limit Limit
22.660 [575.56]
(Z Axis Travel)
5.250
[133.35]
0.250 [6.35]
+X Software Limit
Turret
Reference Position
7.523 0.340 [8.64]
[191.08]
(X Axis Travel)
-X Software Limit
CL
1.158 [29.41]
NOTES:
TI4742

Sub-Spindle and Hardinge Turret Top Plate
A1-14 M-392D
11.17 [283.72] Dia.
Centerline at 88 mm 11.53 Centerline at 88 mm
[292.86]
Dia. 11.53 [292.86] Dia.
Centerline at 70 mm
11.17 [283.72] Dia.
11.17 [283.72] Dia.
9.84 [249.94] Dia.
.750” Tool Centerline at 70 mm

Holder
11.17
1.25 [283.72]
Dia.
11.47 10.66
[291.34] [270.76]
Dia. Dia.
11.76
[298.70]
Dia.
Centerline
11.10 [281.94] Dia. at 70 mm
.88
Centerline at 88 mm
10.66
[270.76]
Dia.
11.17
Cut-Off Tool Holder [283.72]
Centerline Dia.
at 88 mm
Centerline at 70 mm
11.17 [283.72] Dia. 11.17 [283.72] Dia.
NOTES:
1. All single dimensions are shown in inches.
2. All dual dimensions are shown in inches [millimeters].
TI4710
Figure A1.16 - Sample Tooling Layout:

10 Station VDI 30 Turret Top Plate
M-392D A1-15
10.66 [270.76] Dia.
End Mill/Drill Attachment
Centerline at 70 mm
Cross Mill/Drill Attachment
10.25 [260.35] Dia.
9.82 [249.43] Dia.

End Mill/Drill
.750” Tool Double Spindle
Holder Attachment
1.25
10.63
[270.00]
Dia.
11.47
[291.34]
Dia.
11.76
[298.70]
Dia.
Centerline
11.10 [281.94] Dia. at 70 mm
.88
9.99
[253.75]
Dia.
Centerline at 88 mm
11.17
[283.72]
Centerline Dia.
at 88 mm
Cut-Off Tool Holder
Centerline at 70 mm
11.17 [283.72] Dia.
11.17 [283.72] Dia.
NOTES:
TI4711

10 Station VDI 30 Turret Top Plate with Live Tooling
A1-16 M-392D
9.18 [233.17] Dia. 9.46 [240.28] Dia. Centerline at 88 mm
9.46 [240.28] Dia.

Centerline at 88 mm
9.18 [233.17] Dia.
Centerline at 70 mm
9.18 [233.17] Dia. 9.18 [233.17] Dia.
Centerline at 70 mm
.750” Tool
Holder Centerline
at 88 mm
1.25 9.18
[233.17]
Dia.
9.39
[238.51]
Dia.
Centerline
at 70 mm
Centerline at 88 mm .88 9.18

[233.17]
Dia.
Centerline
9.36 [237.74] Dia. at 88 mm
Cut-Off Tool Holder

9.18
[233.17]
Centerline at 70 mm Dia.
Centerline at 70 mm
8.71
8.71 [221.23] Dia. [221.23]
Dia.
NOTES:
TI4712

M-392D A1-17
End Mill/Drill Attachment
8.72 [221.49] Dia. Cross Mill/Drill Attachment
9.18 [233.17] Dia.
Centerline at 70 mm End Mill/Drill

Double Spindle
8.13 [206.50] Dia. Attachment
8.32 [211.33] Dia.
9.18
[233.17]
.750” Tool Dia.
Holder
8.53
1.25
[216.66]
Dia.
9.41
Centerline
[239.01]
at 88 mm
Dia.
9.66
[245.36]
Dia.
Centerline
at 70 mm
Centerline at 88 mm .88
9.18
9.36 [237.74] Dia. [233.17]
Dia.
Centerline
at 88 mm
Cut-Off Tool Holder 9.18

[233.17]
Centerline at 70 mm Dia.
7.90 [200.66] Dia. 8.06

[204.72]
Dia. 9.18 [233.17] Dia.
8.70 [220.98] Dia. End Mill/Drill Double Spindle Attachment
NOTES:
TI4713

A1-18 M-392D
6.69
[169.93] 1-1/4” Boring Bar
6.95 Dia.
[176.53]
Dia.
¾” Square
Turning Tool
8.19 [208.03]
Dia.
6.61
[167.89]
1.25 Dia.
1” Square [31.75]
Turning Tool
8.29
[210.57]
Dia.
6.29
[159.77]
Dia.
6.63
6.76 [168.40]
[171.70] Dia.
Dia.
6.46
40mm Boring Bar [164.08]
Dia.
NOTES:
TI4832

M-392D A1-19
End-Working
6.68 Live Tool
[169.67]
Dia.
1-1/4” Boring Bar
6.68 6.69 [169.93] Dia.
[169.67]
Dia.
27.80 [706.12] Dia.

Swing-Over Way Cover
Non-Y Axis
¾” Square
Turning Tool
6.67
7.70 [169.42]
[195.58] Dia.
Dia.
7.82
[198.63]
Dia.
6.55 Cross-Working
[166.37] Live Tool
Dia.
1.79 [45.47]
3.19 [81.03]
6.69 [169.93] Dia. 25.00 [635.00] Dia.

Swing-Over Way Cover
Y Axis
40mm Boring Bar 6.46 [164.08] Dia.
6.41
[162.81]
Dia.
NOTES:
TI4833

A1-20 M-392D
10.80 [274.3] 25” Diameter Maximum
Dia. Swing over Way Cover
2” Boring Bar
1-9/16” Drill
36°
8.90 [226.1]
Dia.
9.45 [240.0]
Dia.
1” Square Turning Tool

with 1-1/4” Overhang 19.75
[501.7]
Dia.
18.30 [464.8]
Dia. 9.35 [237.5]
Dia.
20.20 [513.1]
Dia.
10.80 [274.3] 1.25

Dia.
21.80 [553.7]
Dia.
1” Square Axial
Turning Tool
12.80 [325.1]
Dia.
10.90 [276.9]
Dia.
NOTES:
2. All dual dimensions are shown in inches [millimeters]. TI4879

M-392D A1-21
2” Boring Bar
18.30 [464.8]
Dia.
1-9/16” Drill
25” Diameter Maximum
Swing over Way Cover
9.45 [240.0] Dia.
8.90 [226.1] Dia.

25/32” Drill
Live Tool
1” Square Turning Tool

with 1-1/4” Overhang
10.80 [274.3]
2-1/2” Face Mill
Dia.
Live Tool
10.35 [262.9]
Dia.
1.25
¾” Drill
Live Tool
12.80 [325.1]
Dia. 10.45 [265.4]
Dia.
36°
1” End Mill
11.85 [301.0]
Dia.
21.80 [553.7]
Dia.
NOTES:
2. All dual dimensions are shown in inches [millimeters]. TI4880

A1-22 M-392D
Ø 20.7087 [526.0] Ø 9.48 [240.8]
Ø 8.88 [225.6]
Ø 9.48 [240.8]
Ø 8.96 [227.6] Ø 1.25 Drill
Ø 9.14 [232.2]
Ø 1.25
Boring Bar
0.88 [22.4]
Ø 9.57 [243.1]
Ø 9.06 [230.1]
Ø 11.02
[280.0]
Ø 8.85 [224.8]
0.75 Turning
Tool
Cut-Off 1.25 [31.8]

Tool Holder
Ø 0.63 Drill in ER Collet
Ø 9.46 [240.3]
Ø 8.85 [224.8]
Ø 9.46 [240.3] Ø 9.46 [240.3]
NOTES:
TI5433

12 Station ESA Turret Top Plate
M-392D A1-23
Cross-Working Mill/Drill Attachment
End-Working Mill/Drill Attachment

Ø 9.11 [231.4] Ø 9.26 [235.2]
Ø 9.10 [231.1] Ø 9.27 [235.5]
Ø 8.86 [225.0] Ø 9.48

[240.8]
Ø 19.2915 [490.0]
Ø 20.7087 [526.0]
Ø 9.48
0.75 Turning [240.8]
Tool
Ø 8.96 [227.6] Ø 1.25

Drill
Ø 1.25 Boring Bar
0.88 [22.4]
Ø 9.47
Ø 9.49 [241.0] [240.5]
Ø 0.63 Drill in ER Collet
Cut-Off Tool Holder

Ø 9.46 [240.3]
Ø 9.25 [235.0]
Ø 11.19 [284.2]
NOTES:
TI5434

12 Station ESA Turret Top Plate with Live Tooling
A1-24 M-392D
9.510 [241.55] Dia. 8.530 [216.66] Dia.
8.530 [216.66] Dia.
9.514 Centerline at 1.500

[241.66]
Dia.
1.125
9.510
8.567 [241.55]
[217.60] Dia.
Dia.
Centerline
9.510 at 2.813
[241.55]
Dia.
F = 1.250
(Worst Case) 9.510
[241.55]
9.510 Dia.
[241.55]
.060
Dia.
Past Center
9.046 [229.77] Dia.
1.438
8.859 [225.02] Dia.
9.510 [241.55] Dia.
NOTES:
TI4732

12 Station Hardinge Turret Top Plate
M-392D A1-25
HP (cont)
Quest 42 Belted (cont.)
Torque (cont)
12.0 50.0
45.0
10.0 40.0
Horsepower (HP)
35.0
Torque (ftlbs)
8.0
30.0
6.0 25.0
20.0
4.0
15.0
2.0 10.0
5.0
0.0 0.0
0
300
600
900
1200
1500
1800
2200
2500
2800
3100
3400
3700
4000
4300
4600
4900
5200
5500
5800
Speed (RPM)
TI4630
Figure A1.27 - Main Spindle Torque/Horsepower Curves,

Standard Drive, Continuous Rating (QUEST® 6/42 Lathe)
HP (30 min.)
Quest 42 Belted (30 min.)
Torque (30 min)
16.0 80.0
14.0 70.0
12.0 60.0
Horsepower (HP)
Torque (ftlbs)
10.0 50.0
8.0 40.0
6.0 30.0
4.0 20.0
2.0 10.0
0.0 0.0
0
300
600
900
1200
1500
1800
2200
2500
2800
3100
3400
3700
4000
4300
4600
4900
5200
5500
5800
Speed (RPM)
TI4831

Standard Drive, 30 Minute Rating (QUEST 6/42 Lathe)
A1-26 M-392D
HP (cont)
Torque (cont)
16.0 160.0
14.0 140.0
12.0 120.0
Torque (ftlbs)
Horsepower
10.0 100.0
(HP)
8.0 80.0
6.0 60.0
4.0 40.0
2.0 20.0
0.0 0.0
0
0
0
0
00
00
00
00
00
00
00
00
00
00
30
60
90
12
15
18
22
25
28
31
34
37
40
Speed (RPM)
TI4752

HP (30 min.)
Quest 51 Belted (30min)
Torque (30 min)
25.0 250.0
20.0 200.0
Torque (ftlbs)
Horsepower
15.0 150.0
(HP)
10.0 100.0
5.0 50.0
0.0 0.0
0
0
0
0
00
00
00
00
00
00
00
00
00
00
30
60
90
12
15
18
22
25
28
31
34
37
40
Speed (RPM) TI4753

M-392D A1-27
Quest 51 Wrap HS winding (cont.) HP (cont)
Torque (cont)
16.0 120.0
14.0
100.0
12.0
Torque (ftlbs)
Horsepower
10.0 80.0
(HP)
8.0 60.0
6.0 40.0
4.0
2.0 20.0
0.0 0.0
0
500
1000
1500
2100
2600
3100
3600
4100
4600
5100
5600
6100
6600
7100
7600
Speed (RPM)
TI4760
Figure A1.31 - Main Spindle Torque/Horsepower Curves, High-Speed Drive,

High Speed Range, Continuous Rating (QUEST® 8/51 Lathe)
HP (30 min.)
Quest 51 Wrap HS winding (30min)
Torque (30 min)
25.0 140.0
120.0
20.0
Torque (ftlbs)
Horsepower
100.0
15.0 80.0
(HP)
10.0 60.0
40.0
5.0
20.0
0.0 0.0
0
0
00
00
00
00
00
00
00
00
00
00
00
00
00
00
50
10
15
21
26
31
36
41
46
51
56
61
66
71
76
Speed (RPM) TI4761

High Speed Range, 30 Minute Rating (QUEST 8/51 Lathe)
A1-28 M-392D
Quest 51 Wrap LS winding (cont.) HP (cont)
Torque (cont)
16.0 160.0
14.0 140.0
12.0 120.0
Torque (ftlbs)
Horsepower
10.0 100.0
(HP)
8.0 80.0
6.0 60.0
4.0 40.0
2.0 20.0
0.0 0.0
0 100 200 300 450 500 600 700 800
Speed (RPM)
TI4762

Low Speed Range, Continuous Rating (QUEST® 8/51 Lathe)
HP (30 min.)
Quest 51 Wrap LS Winding (30min)
Torque (30 min)
25.0 250.0
20.0 200.0
Torque (ftlbs)
Horsepower
15.0 150.0
(HP)
10.0 100.0
5.0 50.0
0.0 0.0
0 100 200 300 450 500 600 700 800
Speed (RPM) TI4763

Low Speed Range, 30 Minute Rating (QUEST 8/51 Lathe)
M-392D A1-29
HP (cont)
Torque (cont)
35.0 200.0
30.0
150.0
Torque (ftlbs)
25.0
Horsepower
20.0
(HP)
100.0
15.0
10.0 50.0
5.0
0.0 0.0
0
0
00
00
00
00
00
00
00
00
30
60
90
12
15
18
22
25
28
31
34
Speed (RPM)
TI4754

HP (30 min.)
Quest 65 Belted (30min)
Torque (30 min)
40.0 250.0
35.0
200.0
30.0
Torque (ftlbs)
Horsepower
25.0 150.0
(HP)
20.0
15.0 100.0
10.0
50.0
5.0
0.0 0.0
0
200
400
600
857
1000
1200
1400
1600
1800
2100
2300
2500
2700
2900
3100
3300
Speed (RPM) TI4755

A1-30 M-392D
Quest 65 Wrap HS winding (cont.) HP (cont)
Torque (cont)
16.0 120.0
14.0 100.0
12.0
Torque (ftlbs)
Horsepower
10.0 80.0
(HP)
8.0 60.0
6.0 40.0
4.0
2.0 20.0
0.0 0.0
0
0
0
00
00
00
00
00
00
00
00
00
00
00
00
40
80
12
16
21
25
29
33
37
41
45
49
53
57
Speed (RPM)
TI4768

High Speed Range, Continuous Rating (QUEST® 10/65 Lathe)
HP (30 min.)
Quest 65 Wrap HS winding (30min)
Torque (30 min)
25.0 140.0
120.0
20.0
Torque (ftlbs)
Horsepower
100.0
15.0 80.0
(HP)
10.0 60.0
40.0
5.0
20.0
0.0 0.0
0
0
0
00
00
00
00
00
00
00
00
00
00
00
00
40
80
12
16
21
25
29
33
37
41
45
49
53
57
Speed (RPM) TI4769

High Speed Range, 30 Minute Rating (QUEST 10/65 Lathe)
M-392D A1-31
Quest 65 Wrap LS winding (cont.) HP (cont)
Torque (cont)
16.0 200.0
14.0
12.0 150.0
Torque (ftlbs)
Horsepower
10.0
(HP)
8.0 100.0
6.0
4.0 50.0
2.0
0.0 0.0
0 100 200 300 450 500 600 700 800
Speed (RPM)
TI4770

Low Speed Range, Continuous Rating (QUEST® 10/65 Lathe)
HP (30 min.)
Quest 65 Wrap LS Winding (30min)
Torque (30 min)
25.0 250.0
20.0 200.0
Torque (ftlbs)
Horsepower
15.0 150.0
(HP)
10.0 100.0
5.0 50.0
0.0 0.0
0 100 200 300 450 500 600 700 800
Speed (RPM) TI4771

Low Speed Range, 30 Minute Rating (QUEST 10/65 Lathe)
A1-32 M-392D
HP (cont)
Standard Speed Sub-Spindle (Continuous)
Torque (cont)
8.0 30.0
7.0
25.0
6.0
20.0
Horsepower (HP)
Torque (ftlbs)
5.0
4.0 15.0
3.0
10.0
2.0
5.0
1.0
0.0 0.0
0
0
0
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
40
80
12
16
21
25
29
33
37
41
45
49
53
57
61
65
69
73
77
Speed
TI4758
Figure A1.41 - Standard Speed Sub-Spindle Torque/Horsepower Curves,

Continuous Rating
Standard Speed Sub-Spindle (30 Minute) HP (30 min.)

Torque (30 min)
12.0 40.0
35.0
10.0
30.0
8.0
Horsepower (HP)
Torque (ftlbs)
25.0
6.0 20.0
15.0
4.0
10.0
2.0
5.0
0.0 0.0
0
0
0
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
40
80
12
16
21
25
29
33
37
41
45
49
53
57
61
65
69
73
77
Speed
TI4759
Figure A1.42 - Standard Speed Sub-Spindle Torque/Horsepower Curves,

30 Minute Rating
M-392D A1-33
HP (cont)
High Speed Sub-Spindle (Continuous)
Torque (cont)
8.0 30.0
7.0
25.0
6.0
20.0
Horsepower (HP)
5.0
Torque (ftlbs)
4.0 15.0
3.0
10.0
2.0
5.0
1.0
0.0 0.0
0
0
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
50
10
15
21
26
31
36
41
46
51
56
61
66
71
76
81
86
91
96
Speed TI4869
Figure A1.43 - High Speed Sub-Spindle Torque/Horsepower Curves,

Continuous Rating
High Speed Sub-Spindle (30 Minute) HP (30 min.)

Torque (30 min)
12.0 40.0
35.0
10.0
30.0
8.0
Horsepower (HP)
Torque (ftlbs)
25.0
6.0 20.0
15.0
4.0
10.0
2.0
5.0
0.0 0.0
0
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
0
50
10
15
21
26
31
36
41
46
51
56
61
66
71
76
81
86
91
96
Speed TI4870
Figure A1.44 - High Speed Sub-Spindle Torque/Horsepower Curves,

30 Minute Rating
A1-34 M-392D
HP (cont)
Quest VDI 30 and ESA
Torque (cont)
Live Tooling (cont.)
3.5 12.0
Horsepower (HP)
3.0 10.0
Torque (ftlbs)
2.5 8.0
2.0
6.0
1.5
1.0 4.0
0.5 2.0
0.0 0.0
0
0
0
00
00
00
00
00
00
00
00
00
00
0
30
60
90
12
15
18
22
25
28
31
34
37
40
Speed (RPM)(Q65SP is limited to 3429)
TI4766A
Figure A1.45 - Live Tooling Torque/Horsepower Curves,

Continuous Rating (VDI 30 and ESA Top Plates)
HP (30 min.)
Quest VDI 30 and ESA Torque (30 min)
Live Tooling (30min)
6.0 20.0
Horsepower (HP)
5.0
Torque (ftlbs)
15.0
4.0
3.0 10.0
2.0
5.0
1.0
0.0 0.0
0
0
00
00
00
00
00
00
00
00
00
00
30
60
90
0
12
15
18
22
25
28
31
34
37
40

TI4767A

30 Minute Rating (VDI 30 and ESA Top Plates)
M-392D A1-35
HP (cont)
Quest VDI 40 Live Tooling (cont.)
Torque (cont)
6.0 20.0
5.0
Torque (ftlbs)
15.0
Horsepower
4.0
(HP)
3.0 10.0
2.0
5.0
1.0
0.0 0.0
0
0
0
0
00
00
00
00
00
00
00
00
00
00
30
60
90
12
15
18
22
25
28
31
34
37
40
TI4764

Continuous Rating (VDI 40 Top Plate)
HP (30 min.)
Quest VDI 40 Live Tooling (30min)
Torque (30 min)
8.0 30.0
7.0 25.0
Torque (ftlbs)
6.0
Horsepower
5.0 20.0
(HP)
4.0 15.0
3.0 10.0
2.0
1.0 5.0
0.0 0.0
0
0
00
00
00
00
00
00
00
00
00
00
30
60
90
12
15
18
22
25
28
31
34
37
40
Speed (RPM)(Q65SP is limited to 3429) TI4765

30 Minute Rating (VDI 40 Top Plate)
A1-36 M-392D
Figure A1.49 - Spindle Draw Tube Configuration:
QUEST® 6/42 Lathe with Standard Spindle Drive
M-392D A1-37
A1-38 M-392D
M-392D A1-39
- NOTES -
A1-40 M-392D
APPENDIX TWO
G CODES
G Code Group Definition
G00 1 Rapid Traverse Positioning Mode
G01 1 Linear Interpolation
G02 1 Clockwise Circular Interpolation
G03 1 Counterclockwise Circular Interpolation
G04 0 Dwell
G10 0 Offset Value Setting
G17 16 X,C Work Plane Selection
G18 16 X,Z Work Plane Selection
G19 16 Z,C Work Plane Selection
G20 6 Inch Data Input
G21 6 Metric Data Input
G22 9 Stored Stroke Limits ON
G23 9 Stored Stroke Limits OFF
G28 0 Return to Reference Position
G31 0 Skip Function
G32 1 Threadcutting Routine (Constant Lead)
G34 1 Threadcutting Routine (Variable Lead)
G40 7 Cancel Tool Nose Radius Compensation
G41 7 Tool Nose Radius Compensation (Part Right)
G42 7 Tool Nose Radius Compensation (Part Left)
G50 0 Maximum RPM Limit for Constant Surface Speed
G65 0 User Macro Call
G70 0 Automatic Finishing Cycle
G71 0 Automatic Rough Turning Cycle
G72 0 Automatic Rough Facing Cycle
M-392D A2-1
G Code Group Definition
G73 0 Automatic Rough Pattern Repeat Cycle
G74 0 Automatic Drilling Cycle
G76 0 Automatic Threading Cycle
G80 10 Cancel G80 Series Cycle
G83 10 Z Axis Drilling Cycle
G84 10 Z Axis Tapping Cycle
G85 10 Z Axis Boring Cycle
G87 10 X Axis Drilling Cycle
G88 10 X Axis Tapping Cycle
G89 10 X Axis Boring Cycle
G90 1 Canned Turning Cycle
G92 1 Canned Threading Cycle
G94 1 Canned Facing Cycle
G96 2 Constant Surface Speed
G97 2 Direct RPM Programming
G98 5 Inches/mm per Minute Feedrate
G99 5 Inches/mm per Revolution Feedrate
G107 0 Activate Cylindrical Interpolation
G112 21 Activate Polar Interpolation
G113 21 Cancel Polar Interpolation
A2-2 M-392D
M CODES
M Code Definition Standard / Option
M00 Program Stop Standard

M01 Option Stop Standard
M03 Main Spindle Forward Rotation Standard
M04 Main Spindle Reverse Rotation Standard
M05 Main Spindle Stop / Coolant OFF Standard
M07 Spindle Phase Synchronization Option
M08 Coolant ON Standard
M09 Coolant OFF Standard
M10 High Pressure Coolant ON Option
M11 High Pressure Coolant OFF Option
M13 Main Spindle Forward Rotation / Coolant ON Standard
M14 Main Spindle Reverse Rotation / Coolant ON Standard
M15 Thru-Spindle Coolant ON, Main Spindle Option
M16 Thru-Spindle Coolant OFF, Main Spindle Option
M20 Speed Arrival Check ON Standard
M21 Main Spindle Collet / Chuck Open Standard
M22 Main Spindle Collet / Chuck Close Standard
M23 Main Spindle Contouring Mode ON Option
M24 Main Spindle Contouring Mode OFF Option
M25 Part Catcher Retract Option
M26 Part Catcher Extend Option
M27 Main Spindle Internal Chucking Mode Standard
M28 Main Spindle External Chucking Mode Standard
M29 Rigid Tapping Mode Standard
M30 Program End, Optional Auto Door Open Standard
M32 Spindle Synchronization Option
M33 Sub-Spindle Forward Rotation Option
M-392D A2-3
M34 Sub-Spindle Reverse Rotation Option

M35 Sub-Spindle Stop Option
M36 Main Spindle Air Blast ON Option
M37 Main Spindle Air Blast OFF Option
M38 Auto Door Open Option
M40 Low Speed Range Option
M41 High Speed Range Option
M42 No Corner Rounding - Exact Stop Standard
M43 Corner Rounding Standard
M44 Enable Turret Bi-Directional Index Standard
M45 Disable Turret Bi-Directional Index Standard
M46 Sub-Spindle Air Blast ON Option
M47 Sub-Spindle Air Blast OFF Option
M48 Enable Feedrate and Spindle Override Standard
M49 Disable Feedrate and Spindle Override Standard
M51 Live Tooling Rotation Option
M52 Live Tooling Rotation Option
M53 Live Tooling Rotation / Coolant ON Option
M54 Live Tooling Rotation / Coolant ON Option
M55 Live Tooling Stop / Coolant OFF Option
M56 Sub-Spindle Collet / Chuck Open Option
M57 Sub-Spindle Collet / Chuck Close Option
M58 Feed Bar Stock Option
M59 Cancel Feed Bar Stock Option
M60 Speed Arrival Check OFF Standard
M61 Bar Change Option
M62 Activate C Axis Spindle Synchronization Option
M63 Cancel C Axis Spindle Synchronization Option
A2-4 M-392D
M64 Spindle Feedback from Main Spindle (Default) Standard

M65 Spindle Feedback from Sub-Spindle Option
M66 Spindle Feedback from Live Tool Spindle Option
M68 Sub-Spindle External Chucking Mode Option
M69 Sub-Spindle Internal Chucking Mode Option
M70 Spindle Orient Commands to Sub-Spindle Option
M71 Spindle Orient Commands to Main Spindle Option
M72 Chamfering OFF Standard
M73 Chamfering ON Standard
M76 Sub-Spindle Drive OFF Option
M77 Sub-Spindle Drive Low Torque Option
M78 Sub-Spindle Drive Normal Torque Option
M80 Check Part Missing Option
M81 Check Part Present Option
M84 Tailstock Advance Standard
M85 Tailstock Retract Standard
M86 Tailstock Retract to Fixed Home Position Standard
M90 Part Probe ON Option
M91 Tool Probe Enable Option
M92 Tool Probe Deploy Option
M93 Tool Probe Stow Option
M97 Increment Part Counter Standard
M98 Sub-Program Call Standard
M99 Return from Sub-Program Standard
M215 Thru-Spindle Coolant ON, Sub-Spindle Option
M216 Thru-Spindle Coolant OFF, Sub-Spindle Option
M221 Sub-Spindle Part Catcher Slide Extend Option
M222 Sub-Spindle Part Catcher Slide Retract Option
M-392D A2-5
M223 Sub-Spindle Contouring Mode ON Option

M224 Sub-Spindle Contouring Mode OFF Option
M225 Sub-Spindle Part Catcher Arm Rotate Down Option
M226 Sub-Spindle Part Catcher Arm Rotate Up Option
M227 Sub-Spindle Part Catcher Gripper Close Option
M228 Sub-Spindle Part Catcher Gripper Open Option
A2-6 M-392D
ALARM MESSAGES
1000 Air Pressure Low

Low air pressure to machine. The control is put in an alarm condition and the machine in
E-stop.
Increase the air pressure to within the recommended range and press Reset to clear the
alarm.
1002 Verify Operator Door Switch

Machine Power-Up Message. Open and close the main guard door to verify interlock switch
operation.
1006 Tool Group Life End

All of the tools in one or more tool groups have reached the tool life specified in the Tool Life
Management program and an M30 “End of Program” has been read by the control.
Refer to Chapter 16 for instructions on resetting the tool group counter(s).
1007 Barfeed Fault Powerdown

The automatic power down feature of the machine has been selected and the conditions for
shutdown have been met.
1013 Tool Probe Arm Timeout

The tool probe arm remained in between the active and stowed positions for more than ten
seconds. Clear any obstruction. Select Jog mode. Move the probe arm to one position or the
other using the probe push button. Press Reset to clear the alarm.
1014 Tool Probe Not Enabled

Program M91 to enable the tool probe when it is deployed for use with the machine in
Automatic mode. Failing to enable the probe with M91 causes this alarm to be displayed when
the machine moves. Press Reset to clear the alarm.
1015 Tool Probe Switch Fault

Both the probe stowed and probe active limit switches are activated. This may indicate that a
switch has failed. When the problem is fixed, press Reset to clear the alarm.
1016 Spindle Fault

The spindle coolant chiller temperature is too high or too low, spindle coolant chiller flow is
too low, or the collet drain overflow sensor indicates the collet drain pump has failed. When one
of these conditions has been true for four minutes or more, the machine will stop. When the
problem is fixed, press Reset to clear the alarm.
M-392D A2-7
1026 Hydraulic Pressure Too Low
The hydraulic pressure switch indicated that the pressure was too low for machine operation.
To restart, press the Emergency Stop push button to put the machine in emergency stop state.
After a few seconds, clear the Emergency Stop. If the pump starts and stays ON, press Reset to
clear the alarm.
1035 Hydraulic Pump Overload

The hydraulic pump motor overload has tripped. Reset the overload to restart the motor and
clear this message.
1036 Hydraulic Fan Overload

The hydraulic fan motor overload has tripped. Reset the overload to restart the motor and
clear this message.
1050 X1 Torque Limiter Fault

The X axis torque limiter has tripped. The control is put into an alarm condition and the
machine in Emergency Stop.
Refer to the maintenance manual (M-393) for information on resetting the torque limiter.
1051 Z1 Torque Limiter Fault

The Z axis torque limiter has tripped. The control is put into an alarm condition and the
1053 E Torque Limiter Fault

The E axis torque limiter has tripped. The control is put into an alarm condition and the
1056 Live Tool Torque Limit

The live tool torque limiter has tripped. The control is put into an alarm condition and the
1057 Live Tool Fault

The live tooling disengaged proximity switch does not give the expected signal. The live
tooling spline may have failed to engage or the live tooling disengaged proximity switch may be
faulty. Press Reset to clear the alarm.
A2-8 M-392D
1060 Turret Fault
Turret index was interrupted by Reset or Emergency Stop.
To clear the fault:
1. Reset Emergency Stop.
2. Select Jog mode.
3. Select a station and press the Turret Index push button.
4. The turret will index to the selected station.
1061 Turret Unclamped

The turret top plate is not properly seated. Turret index time exceeds two seconds. Turret
proximity switch may be faulty. The control is put in an alarm condition.
1062 Please Press Reset

Turret index is not allowed when the live tool drive is engaged. Press Reset to disengage the
live tool drive. Try to index the turret.
1063 Turret Unclamped Switch

The turret unclamp solenoid is energized but the turret unclamped switch has not been
activated. Either the turret has failed to unclamp or the unclamped switch has failed.
1067 Turret Station Switch Fault

The turret station selector switch indicates an invalid station. The control is put into an alarm
condition.
1072 Please Turn Off Power

After operating the machine with the Machine lock feature active, power down is required to
reset the machine position. Power OFF the machine, wait a few seconds, and then restart the
machine.
1075 Bar Feed Fault

Bar feed signals a fault. The control is put in an alarm condition.
Adjust the bar feed and press Reset to clear the alarm.
1076 End of Bar

End of bar condition exists. The control is put in an alarm condition.
Press Reset to clear the alarm.
1082 T Code Invalid

The T word exceeds the maximum number of turret stations on the top plate.
T word format error.
M-392D A2-9
1083 M Code Invalid
M word is programmed for an option not available/enabled on the machine.
M word is not defined in the control.
M word format error.
1085 B Code Invalid

B word orient angle is invalid.
B word is programmed for an option not available/enabled on the machine.
B word format error.
1100 Part Catcher Must be Retracted

The main spindle part catcher must be retracted before starting a program in Automatic
mode or deploying the optional tool probe in any mode.
1110 Left Collet Access Door

The main spindle collet access door is open. Automatic mode is inhibited. Close the door and
press Reset to allow machine operation.
1111 Right Collet Access Door

The sub-spindle collet access door is open. Automatic mode is inhibited. Close the door and
press Reset to allow machine operation.
1113 Main Collet Limit Switch

One or both of the main collet Open/Close pressure switches are faulty. Both switches
indicate the same state. The control is put into an alarm condition.
1114 Main Spindle Orient Fault

Spindle orient failed to complete in five seconds. Press Reset to clear the alarm.
1115 Main Spindle Brake Fault

Main spindle brake switch input contradicts the state of the solenoid valve.
1120 Tailstock Past Limit Position

The tailstock has traveled past the position defined by the A word in macro program 9130.
Refer to the programmer’s manual (M-391) for information on macro program 9130.
A2-10 M-392D
1121 Move Tailstock to Mid or Home
The tailstock is out of position. Move the tailstock to either the mid-point or the fixed Home
position. Cycle Start is inhibited.
1123 Please Home Tailstock

Power Up Message. Home the tailstock.
Refer to Chapter 10 for information on homing the tailstock.
1131 Main Collet Reservoir Full

Hydraulic fluid has filled the overflow reservoir. This indicates that a fault may exist in the
main spindle collet drain pump system. Possible causes are:
• Level sensor in the overflow reservoir is faulty
• Faulty air valve on the drain pump
• Drain pump is faulty
Refer to Appendix Three of the maintenance manual (M-393) to identify the collet reservoir
pump.
1140 Part Catcher Must Be Retracted

The sub-spindle part catcher slide is not retracted and program execution was attempted.
Retract the sub-spindle part catcher slide and press Reset to clear the alarm.
1170 Hydraulic Temperature Too High

- NOTE -
This alarm applies only to machines equipped with HydroGlide® hydrostatic linear
guideways.
The fluid temperature in the hydraulic unit for the HydroGlide hydrostatic linear guideways
exceeds the high limit. Possible causes for hydraulic fluid high temperature are:
• Ambient temperature is in excess of the recommended maximum operating
temperature, which is 95°F [35°C]
• Hydraulic unit pump motor is running hot
• Hydraulic unit heat exchanger fan has malfunctioned
• Hydraulic unit heat exchanger coils need to be cleaned
1174 Hydrostatic Pressure Fault

Hydrostatic pressure is too low to support the slides. Emergency stop is applied. Determine
the cause of the problem. Restart the machine and Press Reset to clear this message.
M-392D A2-11
1180 CH1 Temperature Out of Range
This message applies to Super-Precision® machines only.
Thermocouple channel 1 indicates an improbable value. The thermocouple needs to be
replaced. Refer to Appendix Three of the maintenance manual (M-393) for thermocouple
locations.
1181 CH1 Thermocouple Disconnected

This message applies to Super-Precision machines only.
Thermocouple channel 1 appears to be open-circuited. Check the thermocouple connection.
Refer to Appendix Three of the maintenance manual (M-393) for thermocouple locations.

locations.

1184 Cold Junction Compensation Fault 1

The temperature measurement system has a fault. Refer to the GE Fanuc temperature
measurement system documentation.
1185 Thermocouple System Fault 1

1186 Thermocouple Module Fault 1

A2-12 M-392D
1187 Temperature Compensation Out of Range
The temperature compensation calculated by the control is too large. Temperature
compensation is disabled.

locations.


locations.

1194 Cold Junction Compensation Fault 2

1195 Thermocouple System Fault 2

M-392D A2-13
1196 Thermocouple Module Fault 2
1210 Part Missing

The sub-spindle part detector did not find a part in the sub-spindle.
1211 Part Present

The sub-spindle part detector found a part in the sub-spindle.
1212 Part Detector Failed to Retract

The sub-spindle part detector is actuating the extended switch or not actuating the home
switch.
1213 Opposite Collet Limit Switch

One or both of the sub-spindle collet Open/Close pressure switches are faulty. Both switches
indicate the same state. The control is put into an alarm condition.
1214 Opposite Spindle Orient Fault

Sub-spindle orient failed to complete in five seconds. Press Reset to clear the alarm.
1215 Opposite Spindle Brake Fault

Sub-spindle brake switch input contradicts the state of the solenoid valve.
1231 Opposite Collet Reservoir Full

Hydraulic fluid has filled the overflow reservoir. This indicates that a fault may exist in the
sub-spindle collet drain pump system. Possible causes are:
• Level sensor in the overflow reservoir is faulty
• Drain pump is faulty
Refer to Appendix Three of the maintenance manual (M-393) to identify the collet reservoir
pump.
1400 Part Catcher, See Message

The sub-spindle part catcher has a fault. Refer to the message display for detailed
information.
A2-14 M-392D
OPERATOR MESSAGES
2001 1000 Hour Lube Required

Machine lubrication is required every 1000 hours of machine ON time. Cycle Start is inhibited
while this message is displayed.
Refer to the maintenance manual (M-393) for information on machine lubrication.
After lubricating the machine, press the Reset and Feed Hold push buttons at the same time
to clear this message.
2005 New Tool Used on this Part

A tool in the currently active tool group has reached the tool life specified in the Tool Life
Management program. The next tool in the active tool group has been selected.
Press Cycle Start or Reset to clear this message.
2021 Lamp Output Disconnected

An output module driving the panel lamps is overloaded. Turn the machine OFF to clear this
message.
2022 Operator Door Open

The coolant guard door is open. Cycle Start is inhibited until the guard door is closed.
2023 Battery Low

Low voltage condition on control memory battery back-up. DO NOT POWER DOWN THE
MACHINE!
Refer to the maintenance manual (M-393) for instructions to replace the battery.
2024 Part Probe Battery Low

The part probe battery is nearly discharged.
Refer to Chapter 13 for instructions to replace the battery. After the battery is replaced, press
Reset to clear this message.
2030 Coolant Pump Overload

The coolant pump motor overload on the coolant pump contactor in the machine power case
has tripped. Repeat mode is canceled.
Correct the cause of the overload. Locate the coolant pump contactor in the power case and
reset the overload. When the overload is reset, press Reset to clear this message.
M-392D A2-15
2031 Coolant Chiller Flow
The flow switch in the coolant chiller unit has opened, indicating low coolant flow. This may
be due to a clogged coolant filter.
After proper coolant flow is restored, press Reset to clear this message.
2034 X Scale Air Purge Pressure Fault

The scale air purge pressure switch indicates a loss of pressure. Repeat mode is canceled.
Cycle Start is inhibited.
Correct the cause of the pressure loss and press Reset to clear this message.
2047 Air Conditioner Fault

The optional air conditioner has failed. Machine operation can continue unless the machine
gets too hot. The user must decide if it is cool enough in the shop to run the machine without the
air conditioner.
2054 E Axis Thrust Limit Exceeded, Please Adjust Feedrate

The E axis thrust limit has been exceeded. The machine is put into a feed hold condition.
Turn the Feedrate Override switch down by 10% and press Cycle Start. Repeat until the
message clears. Adjust the feedrate in the part program by the percentage that was required to
clear the message.
2055 Turret Thrust Limit Exceeded, Please Adjust Feedrate

The Z axis thrust limit has been exceeded. The machine is put into a feed hold condition.
Turn the Feedrate Override switch down by 10% and press Cycle Start. Repeat until the
message clears. Adjust the feedrate in the part program by the percentage that was required to
clear the message.
2071 Y Too Low to Jog E1 or Z1

The turret is positioned below Y0. Move the turret to Y0 before attempting to move the E1 or
Z1 axis.
2077 Open Collet Only in Jog Mode

For machines equipped with the bar feed option and the option is turned ON, the control must
be in Jog mode to manually open the collet or chuck. Press Reset or select Jog mode to clear
this message.
2086 Part Count Satisfied

The part count specified has been completed. Repeat mode is canceled. Press Cycle Start
or Reset to clear this message.
A2-16 M-392D
2090 Turret Must be at X Axis Home Position
The tool probe was commanded to deploy and the turret is not at the X axis reference
position. Move the turret to the X axis reference position before deploying the tool probe.
When the tool probe is deployed, the turret can only be indexed when it is positioned at the X
axis reference position.
2091 Opposite Spindle Must be at Home Position

The tool probe was commanded to deploy and the sub-spindle is not at the reference
position. Move the sub-spindle to the reference position before deploying the tool probe.
2092 Tailstock Must be at Home Position

The tool probe was commanded to deploy and the tailstock is not at the reference position.
Move the tailstock to the reference position before deploying the tool probe.
2093 Tool Probe Must be Stowed

The tool probe is not stowed and Cycle Start was pressed with Automatic mode active. The
tool probe must be stowed to start a part program in Automatic mode.
The tool probe is not stowed and the part catcher was commanded to extend. The tool probe
must be stowed before the part catcher can be extended in any mode.
2096 Spindle Chiller Temperature

The spindle chiller temperature is too high or low or the spindle coolant chiller flow is too low
on machines equipped with built-in spindle motors. This fault cancels Repeat mode. The
machine will stop with alarm 1016 after four minutes. Press Reset to clear this message.
2097 Collet Drain Pump Fault

The collet drain reservoir overflow sensor indicates the main or sub-spindle collet drain pump
has failed. Repeat mode is canceled. The machine will stop with alarm message 1016 after four
minutes. Press reset to clear this message.
2101 Part Catcher Timeout

The main spindle part catcher took too much time to complete the commanded motion. The
arm or basket may be stuck or obstructed. Press Reset to clear this message.
M-392D A2-17
2102 Part Catcher Limit Switch Fault
One of the following conditions exists:
• The main spindle part catcher arm extended and retracted limit switches are
both activated.
• The main spindle part catcher basket extended and retracted limit switches
are both activated.
• This may indicate that one of the limit switches has failed.
Refer to the maintenance manual (M-393) for information on replacing limit switches.
2103 Please Close Part Catcher Cover

The main spindle part catcher cover is open. Program execution is inhibited. Close the cover
to allow program execution.
2133 Main Collet Open

The main spindle collet/chuck is open. Cycle Start and manual spindle operation are
inhibited. Close the Collet/chuck to allow Cycle Start and manual spindle operation.
Press Reset to clear this message
2134 Main Spindle Contouring Mode

The manual axis movement selector switch is set to C1 and the operator is attempting to
manually operate the main spindle through the use of the spindle control functions on the
operator panel.
Set the manual axis movement selector switch to another setting.
2141 Opposite Spindle Part Catcher Timeout

The sub-spindle part catcher took too long to complete the commanded motion. The slide,
arm, or gripper may be stuck. Correct the problem and press Reset to clear the alarm.
2142 Opposite Spindle Part Catcher Limit Switch Fault

The sub-spindle part catcher slide, arm, or gripper limit switches indicate the same state.
This may indicate that one of the switches has failed. Correct the problem and press Reset to
clear the alarm.
2143 Opposite Spindle Part Catcher Slide Must be Extended

The sub-spindle part catcher slide must be extended before the arm can be rotated up to the
spindle centerline.
2144 Opposite Spindle Must be Home

The sub-spindle must be at the reference position before the sub-spindle part catcher arm
can be rotated up or down.
A2-18 M-392D
2145 Opposite Spindle Part Catcher Arm Must be Down
The sub-spindle part catcher arm must be rotated down before the part catcher slide can be
retracted.
2146 Opposite Spindle Parts Catcher Gripper Fault

The parts catcher grippers are closed without gripping a part.
2147 Part Conveyor Motor Overload

The part conveyor motor overload in the machine power case has tripped.
Correct the cause of the overload. Reset the overload in the power case. When the overload
is reset, press Reset to clear this message.
2150 High Pressure Coolant Filter Clogged

The high pressure coolant filter pressure drop is too high. This message cancels Repeat
mode, but allows machine operation. Check the condition of the filter.
Press the Reset key to clear this message from the screen.
2151 High Pressure Coolant Motor Overload

The high pressure coolant motor is overloaded. Correct the cause of the problem.
Press the Reset button on the high pressure coolant unit to reset the alarm.
Press the control Reset key to clear this message from the screen.
2152 High Pressure Coolant Level Low

The level switch in the high pressure coolant tank indicates that the coolant level is too low.
Check the operation of the pump. Find and correct the cause of the problem.
Press the Reset button on the high pressure coolant unit to reset the alarm.
Press the control Reset key to clear this message from the screen.
2153 One Spindle Must be Running

The active spindle must be running before the high pressure coolant pump can be started.
The active spindle is selected by M64 or M65. The main spindle is the default.
Revise the part program is necessary.
Press Reset to clear this message.
M-392D A2-19
2154 High Pressure Coolant Not Ready
The high pressure coolant unit is not ready.
Verify the high pressure coolant unit is ON.
Check the fuses in the machine power case.
Find and correct the cause of the problem.
Press Reset to clear this message.
2155 Lower Axis Thrust Limit

The lower axis thrust limit has been exceeded. The machine is put into a feed hold condition.
Press Cycle Start or Reset to clear this message.
2170 Hydrostatic Fluid Level too Low

The hydrostatic fluid level is below the full mark. The machine goes into Emergency Stop. Fill
the tank and restart the machine. Press Reset to clear this message.
2171 Hydrostatic Fluid Level Low, Refill

The hydrostatic fluid level is below the full mark. The tank should be filled soon. Filling the
tank clears this message.
2172 Hydrostatic Pump Overload

Hydrostatic pump circuit breaker tripped. Determine the cause of the problem. Reset the
circuit breaker and press Reset to clear this message.
2173 Hydrostatic Fan Overload

Hydrostatic cooling fan circuit breaker tripped. Determine the cause of the problem. Reset
the circuit breaker and press Reset to clear this message.
2175 Hydrostatic Temperature Fault

Hydrostatic temperature is too high. Determine the cause of the problem and correct it. Press
2176 Excessive Flow

Hydrostatic fluid flow is excessive. Determine the cause of the problem and correct it. Press
2200 Parameter Write Fault 1: Please Turn Off Power and Restart Machine
The control has failed to write a parameter correctly. Restarting the machine may clear the
problem. Contact the Hardinge Service Department if necessary.
A2-20 M-392D
2201 Parameter Write Fault 2: Please Turn Off Power and Restart Machine
The control has failed to write a parameter correctly. Restarting the machine may clear the
problem. Contact the Hardinge Service Department if necessary.
2220 Axis Thrust Limit X Axis

The optional programmable X axis thrust limit has been exceeded. Refer to the
programmable thrust limit documentation.
2221 Axis Thrust Limit Y Axis

The optional programmable Y axis thrust limit has been exceeded. Refer to the
2222 Axis Thrust Limit Z Axis

The optional programmable Z axis thrust limit has been exceeded. Refer to the
2223 Axis Thrust Limit E Axis

The optional programmable E axis thrust limit has been exceeded. Refer to the
2233 Opposite Collet Open

The sub-spindle collet/chuck is open. Cycle Start and manual spindle operation are inhibited.
Close the Collet/chuck to allow Cycle Start and manual spindle operation.
Press Reset to clear this message
2234 Opposite Spindle Contouring Mode

The manual axis movement selector switch is set to C2 and the operator is attempting to
manually operate the sub-spindle through the use of the spindle control functions on the
operator panel.
Set the manual axis movement selector switch to another setting.
2240 Door Closed Switch Fault — Shorted

One of the two door closed switch contacts is ON all the time or the two contacts are shorted
together. Cycle Start is inhibited. Check the switch wiring.
When the problem is corrected, press Reset to clear this message.
2241 Door Closed Switch Fault — Open

One of the two door closed switch contacts is disconnected. Cycle Start is inhibited. Check
the switch wiring.
M-392D A2-21
2242 Door Locked Switch Fault — Shorted
One of the two door locked switch contacts is ON all the time or the two contacts are shorted
together. Cycle Start is inhibited. Check the switch wiring.
2243 Door Locked Switch Fault — Open

One of the two door locked switch contacts is disconnected. Cycle Start is inhibited. Check
the switch wiring.
2246 Please contact Hardinge at 800/635-0192 extension 2227, or at

tpc@hardinge.com, and provide the key code shown below.
You will be given a four digit password. You have 45 Days To
obtain your password. Key Code: [Xxxx]
Contact Hardinge Inc. as instructed.
2247 Your warning period has expired. Please contact Hardinge at

800/635-0192 extension 2227, or at tpc@hardinge.com, and provide
the key code shown below.
Key Code: [Xxxx]
Contact Hardinge Inc. as instructed.
5305 Illegal Spindle Number

A spindle command (S word) was issued without an active P word. Program P1, P2, or P3 to
specify the active spindle.
Refer to the programmer’s manual (M-391) for information on programming the P word for
spindle selection.
A2-22 M-392D
- NOTES -
M-392D A2-23
Hardinge Inc.
Elmira, New York 14902-1507 USA
Phone: 607-734-2281 Fax: 607-734-8819
www.hardinge.com

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OPERATOR’S MANUAL

Revised: January 18, 2008

Manual No. M-392D Litho in U.S.A.

Information in this manual is subject to change without notice.

CONVENTIONS USED IN THIS MANUAL

© 2007, Hardinge Inc. M-392D

- SPINDLE TOOLING WARNING -

HARDINGE SAFETY RECOMMENDATIONS

FOR YOUR PROTECTION - WORK SAFELY

CHAPTER 1 - OPERATOR CONTROL PANELS

CHAPTER 2 - POWER-UP AND CONTROL STATUS

CHAPTER 5 - ESA TURRET TOP PLATE TOOLING

CHAPTER 7 - WORK SHIFT

CHAPTER 8 - TOOL OFFSETS

CHAPTER 12 - OPERATOR MAINTENANCE

CHAPTER 14 - VDI LIVE TOOLING [Option]

CHAPTER 16 - TOOL LIFE MANAGEMENT

Figure 1.1 - Control Display Panel

CURSOR CONTROL KEYS

This key has no function on the standard operator interface.

DATA INPUT KEYS

This key is used to input an End of Block (;) character.

Figure 1.2 - Manual Data Input Panel

Figure 1.3 - Manual Data Input Panel

Figure 1.4 - Manual Data Input Panel

Figure 1.5 - Manual Data Input Panel

PAGE DOWN KEYS

Alter Key This key is used as the Tab key

Blank Key This key is used as the Alternate key

Cancel Key This key is used as the Backspace key

Custom Key This key is used as the Control key

Help Key This key is used as the Escape key

Shift + 1 Inputs the left brace symbol: {

Shift + 2 Inputs the right brace symbol: }

Shift + R Inputs the caret symbol: ^

Shift + S Inputs the backslash symbol: \

Shift + T Inputs the tilde symbol: ~

Shift + U Inputs the underscore symbol: _

MANUAL AXIS MOVEMENT

Figure 1.6 - Operator Control Panel TI4666A

Option not available.

MAIN SPINDLE / SUB-SPINDLE 1 2

MAIN SPINDLE FREE 1

SPINDLE CCW / SPINDLE CW

SPINDLE INCREASE OVERRIDE

SPINDLE DECREASE OVERRIDE

These push buttons have two applications:

Main Spindle Sub-Spindle

Figure 1.7 - E, X, and Z Axis Definitions

RAPID TRAV (Rapid Traverse)

MANUAL PULSE GENERATOR

Figure 1.8 - X and Y Axis Definitions

SINGLE (Single Block)

MDI (Manual Data Input)

MAIN OPEN / CLOSE 1

Figure 1.9 - Data Input/Output Ports

Figure 1.11 - PC and Data

Figure 1.12 - Optional Stack Light

ACCESSING THE ON-LINE HELP SYSTEM

Figure 2.2 - Air Control Assembly

MACHINE WARM-UP PROGRAM

QUEST 8/51 LATHE WITH SUB-SPINDLE

QUEST 10/65 LATHE WITH SUB-SPINDLE