Maintenance Manual

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

Part No. M -0009500-0371 May, 1999
SAFETY INFORMATION
Refer to the Programmer’s, Operator’s and this Maintenance manual supplied with
the machine tool for Hardinge Safety recommendations. Refer to the following doc-
uments for additional safety requirements:
American National Standard for Machine Tools -
Manufacturing Systems/Cells
Safety Requirements for Construction, Care, and Use ANSI B11.20-1997
American National Standard for Industrial Robots and Robot Systems -
Safety Requirements ANSI R15.06-1992
- NOTICE -
Damage resulting from misuse, negligence, or accident is not covered by the
Hardinge Machine Warranty.
Information in this manual is subject to change without notice.

This manual covers the maintenance of the Hardinge CONQUEST® GT27
and CONQUEST GT27SP CNC lathes with Autoload™ system.
In no event will Hardinge Inc. be responsible for indirect or consequential
damage resulting from the use or application of the information in this manual.
Reproduction of this manual in whole or in part, without written permission of
Hardinge Inc. is prohibited.
CONVENTIONS USED IN THIS MANUAL

- WARNINGS -
Warnings must be followed carefully to avoid the possibility of personal in-
jury or damage to the machine, tooling, or workpiece.
- CAUTIONS -
Cautions must be followed carefully to avoid the possibility of damage to the
machine, tooling, or workpiece.
- NOTES -
Notes contain supplemental information.
Hardinge Inc.
One Hardinge Drive
P.O. Box 1507
Elmira, New York 14902-1507 U.S.A.
www.hardinge.com
© 1999, Hardinge Inc. M-371

READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE STARTING MAINTENANCE
OR REPAIR ON THE MACHINE, LOAD/UNLOAD AUTOMATION, OR BAR FEED.
The technicians who use this manual should have a general knowledge of machine maintenance
and repair. This general knowledge coupled with the following manual will greatly reduce or eliminate
downtime of the Conquest machine.
When machine maintenance is performed by persons not familiar with the operation of this equip-
ment, the Operator’s Manual (M-370) must be consulted when instructions require that the machine
be run.
- WARNING -
Occupational Safety and Health Administration (OSHA) Hazard 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. A complete list of the chemicals used
with this machine, their reference data sheet numbers, and their suppliers
appears as an insertion at the end of this manual. Refer to the applicable
section of the Material Safety Data Sheets supplied with your machine when
handling, storing, or disposing of chemicals.
Machine should only be used with a bar feed approved by Hardinge Inc.
HARDINGE SAFETY RECOMMENDATIONS

Your Hardinge machine is designed and built for maximum ease and safety of operation. However,
some previously accepted shop practices may not reflect current safety regulations and procedures,
and should be re-examined to insure compliance with the current safety and health standards.
Hardinge Inc. recommends that all shop supervisors, maintenance personnel, and machine tool
operators be advised of the importance of safe maintenance, setup, and operation of Hardinge-built
equipment. Our recommendations are described below.
READ THESE SAFETY RECOMMENDATIONS BEFORE PROCEEDING ANY FURTHER.
READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation
or maintenance of the machine. Make certain that you understand all instructions.
DON’T ALLOW the operation or repair of equipment by untrained personnel.
CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job.
WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. When nec-
essary, wear respirator, helmet, gloves, and ear muffs or plugs.
DON’T OPERATE EQUIPMENT unless proper maintenance has been regularly per-
formed and the equipment is known to be in good working order.
WARNING or INSTRUCTION TAGS are mounted on the machine for your safety and in-
formation. Do not remove them.
DON’T ALTER THE MACHINE to bypass any interlock, overload, disconnect, or other
safety device.
DON’T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibration
occurs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as any
damaged parts.
M-371 i
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 be-
fore restarting the machine.
KEEP THE AREA AROUND THE MACHINE well lighted and dry.
KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating equip-
ment.
HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combus-
tible material and keep chips clear of the work area.
DON’T USE a toxic or flammable substance as a solvent cleaner or coolant.
MAKE CERTAIN THAT PROPER GUARDING is in place and that all doors are closed
and secured.
TO REMOVE OR REPLACE the collet closer it is necessary to remove the guard door at
the left end of the machine. Make certain that the guard door is in place before starting
the machine.
DON’T OPEN GUARD DOORS while any machine component is in motion.
MAKE SURE chucks, closers, fixture plates and all other spindle-mounted work-holding
devices are properly mounted and secured before starting the machine.
MAKE CERTAIN all tools are securely clamped in position before starting the machine.
REMOVE ANY LOOSE PARTS OR TOOLS left on machine or in the work area before
operating the machine. Always check the machine and work area for loose tools and
parts especially after work has been completed by maintenance personnel.
REMOVE CHUCK WRENCHES before starting the machine.
BEFORE PRESSING THE CYCLE START PUSH BUTTON, make certain that proper
functions are programmed and that all controls are set in the desired modes.
KNOW WHERE ALL stop push buttons are located in case of an emergency.
CHECK THE LUBRICATION and the status of the indicator lights before operating the
machine.
INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good
condition and are functioning properly before operating the machine.
ii M-371
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 po-
tentially hazardous area.
DON’T REMOVE CHIPS with hands. Use a hook or similar device and make certain that
all machine movements have ceased.
BE CAREFUL of sharp edges when handling newly machined workpieces.
DON’T REMOVE OR LOAD workpieces while any part of the machine and/or Autoload
system is in motion.
DON’T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing,
neckties or long hair not contained by a net or shop cap.
DON’T ADJUST tooling or coolant hoses while the machine is running.
DON’T LEAVE tools, workpieces or other loose items where they can come in contact
with a moving component of the machine and/or Autoload system.
DON’T CHECK finishes or dimensions of workpiece near running spindle or moving
slides.
DON’T JOG SPINDLE in either direction when checking threads with a thread gage.
DON’T ATTEMPT to brake or slow the machine with hands or any makeshift device.
ANY ATTACHMENT, TOOL OR MACHINE MODIFICATION not obtained from Hardinge
Inc. must be reviewed by a qualified safety engineer before installation.
USE CAUTION around exposed mechanisms and tooling especially when setting up. Be
careful of sharp edges on tools.
DON’T USE worn or defective hand tools. Use the proper size and type for the job being
performed.
USE ONLY a soft-faced hammer on turret tools and fixtures.
DON’T USE worn or broken tooling and/or grippers on machine.
MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools.
INSPECT ALL CHUCKING/GRIPPING DEVICES daily to make certain that they are in
good operating condition. Replace any defective chuck before operating the machine.
USE MAXIMUM ALLOWABLE gripping pressure. Consider weight, shape, and balance of
the workpiece.
M-371 iii
USE LIGHTER THAN NORMAL feedrates and depth of cut when machining a workpiece
diameter that is larger than the gripping diameter.
DON’T EXCEED the rated capacity of the machine and/or autoload system.
DON’T LEAVE the machine unattended while it is operating.
DON’T CLEAN the machine with an air hose.
KEEP TOTE PANS a safe distance from the machine. Don’t overfill the tote pans.
DON’T LET STOCK project past the back end of the collet closer or machine spindle
without being adequately covered and properly supported.
FOLLOW each bar feed manufacturer’s guidelines. For performance and safe application,
size and use feed tube bushings, pushers, and spindle liners according to bar feed infor-
mation.
MAKE CERTAIN that any bar feed mechanism is properly aligned with the spindle. If the
bar feed is a floor-mounted type, it must be securely bolted to the floor.
UNLESS OTHERWISE NOTED, all operating and maintenance procedures are to be per-
formed by one person. To avoid injury to yourself and others, be sure that all personnel
are clear of the machine and Autoload system when opening or closing the coolant guard
door and any access cover.
- WARNING -
Before activating a new program, turn the control OFF. Wait approximately 10
seconds; then, turn the control ON. This will set the collet closer timer to the
default setting of 4.9 seconds and will assure safe operation of the control.
FOR YOUR PROTECTION - WORK SAFELY
iv M-371
Table Of Contents
CHAPTER 1 - REFERENCES and INSTALLATION

Machine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CNC Control Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Machine Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Leveling the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Grounding the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Earth Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
System Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Power Case Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
CHAPTER 2 - POWER-UP PROCEDURE

Basic Machine Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Power Down and Lock Out Procedure . . . . . . . . . . . . . . . . . . . . . . . 2-2
Clearing an Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hour Run Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Review Control Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
CHAPTER 3 - LUBRICATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lubricator Consumption Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lubricator Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lubricator Reservoir and In-Line Filter . . . . . . . . . . . . . . . . . . . . . . . 3-3
Purge LubricationSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Replace the Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Clean Tramp Oil Trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
CHAPTER 4 - AIR FACILITY

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Drain the Filter/Regulator Unit Daily . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Drain the Filter Bowls and Air Receiver . . . . . . . . . . . . . . . . . . . . . . 4-2
Clean the Air System Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Replace Coalescing Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Replace the Collet Closer (GT27, Big-Bore) Filter . . . . . . . . . . . . . . . . . 4-4
Replace Air Control Assembly Components . . . . . . . . . . . . . . . . . . . . 4-5
Replace the Pressure Switch(es) . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Replace or Clean Manifold(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Air Blast Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
M-371 v
Revised: April, 2000
CHAPTER 5 - COOLANT FACILITIES
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Water-Based Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Concentration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
pH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Removing Chips and Shavings . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cleaning the Reservoir and Filters. . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Coolant In-Line Valves and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Replacing the Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Coolant Catcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
CHAPTER 6 - PART LOAD/UNLOAD GANTRY

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Gantry Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Gantry Pneumatic (Air) Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Gantry Axes Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
CHAPTER 7 - HEADSTOCK and SPINDLE DRIVE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Spindle Draw Tube Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Spindle Drive Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Spindle Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Spindle Drive Motor Replacement and Alignment. . . . . . . . . . . . . . . . . . 7-5
Spindle Encoder Timing Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . 7-6
Spindle Encoder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Spindle Encoder Timing Belt Replacement . . . . . . . . . . . . . . . . . . . . . 7-8
Headstock Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Cleaning the Spindle Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
CHAPTER 8 - COLLET CLOSER

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Free Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Collet Closer Draw Tube Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Standard ANSI A2-4 5C Collet Closer . . . . . . . . . . . . . . . . . . . . . . . 8-3
ANSI A2-4 16C “Big-Bore” Collet Closer . . . . . . . . . . . . . . . . . . . . . . 8-5
Pressure Regulator/Gauge Replacement. . . . . . . . . . . . . . . . . . . . . . 8-8
Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
vi M-371
CHAPTER 9 - AXES DRIVE MOTORS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Carriage Drive Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Cross Slide Drive Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . 9-6
CHAPTER 10 - MISCELLANEOUS
Air Fan and Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Drive Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Control Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Part Catcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
To Adjust the Part Catcher Position . . . . . . . . . . . . . . . . . . . . . . . . 10-5
To Adjust the Part Catcher Travel Rate . . . . . . . . . . . . . . . . . . . . . . 10-6
To Replace the Solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
To Replace the Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
To Replace the Pressure Regulator and/or Gauge . . . . . . . . . . . . . . . . . 10-8
To Replace the Part Catcher (Chute) Home Switch (LS 6) . . . . . . . . . . . . . 10-9
Worklight, Worklight Starter/Ballast . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Live Tool Holder Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Stacker Table Torque Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
APPENDIX ONE
PREVENTIVE MAINTENANCE SCHEDULE and PRODUCTS APPLIED
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg.1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg.1
8 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg.1
40 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg.2
160 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg.2
500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg.2
1000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg.2
Yearly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg.2
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg.3
Adhesives and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg.3
APPENDIX TWO - PHOTOGRAPHS

CONQUEST® GT27/GT27SP Autoload™ Photographs
M-371 vii
Revised: January, 2000
- NOTES -
viii M-371
CHAPTER 1 - INSTALLATION
MACHINE SERIAL NUMBER
The serial number for the CONQUEST® GT27 and CONQUEST GT27SP Autoload™ system is
stamped on plate “A”, Figure 1.1, which is located on the upper right corner of the power case door.
This serial number should be included in all correspondence regarding this machine.
CNC CONTROL SERIAL NUMBER

The CNC control serial number is located on tag “B”, Figure 1.2, inside the control case. The CRT
and operator’s control panel are mounted on the control case door. Unthread the screws and rotate
the door open; the tag is located on the control housing. This serial number should be included in all
correspondence regarding the control.
B
A
TP3516. TP3533.
Figure 1.1 - Machine Serial Number Figure 1.2 - Control Serial Number
MACHINE FOUNDATION
The CONQUEST GT27/GT27SP Autoload system machines require a substantial foundation. Do
not locate the machine near equipment that causes vibration. Poor surface finishes or damage to the
control may result from any vibration transmitted to the machine.
The legs are set at approximately 3 inches [76 mm] creating a minimum 1 inch [25.4 mm] machine
clearance. It is not necessary that the machine be set perfectly level unless a bar feed is to be used
with the machine. However, the machine should be reasonably level, within ±.13 inch [3.3 mm] in the
machine footprint, to allow the way lube oil to be collected at the end of the machine away from the
spindle. Shim the support legs with metal plates if necessary.
- NOTES -
Refer to Figure 1.3 to locate the feet in the machine’s base. Use the dimensions to
locate the concrete pads.
The pads must be level with each other within ±.13 inch [±3.3 mm] or the floor
must be level within ±.13 inch in 5 feet [±3.3 mm in 1524 mm] and be constructed
of 3000 psi [207 bars] concrete or better.
Avoid placing the machine over floor expansion joints.
M-371 1-1
34.5 [876]
Harcrete® Base Outline
13.6 [346]
3
5
15.25[387]
51.5 [1308]
1
35.7 [907]
19.5[494]
Two Adjustable Screws Top View of Machine
4
(Number 4 and 5)
2
Measurements are inch [metric]
Width of Machine is 65.0 [1651] 5.0 [127] TI4479.
Machine and Stacker Table is 91.5[2324] 39.4 [1001] 34.0 [864]
Figure 1.3 - Pad Placement for Machine Support
Verify that the foundation for the machine meets the specifications. Hardinge suggests that
the foundation be as follows:
RECOMMENDED a 4 inch [102 mm] thick concrete floor as large as the machine
footprint. The machine’s footprint is the overall dimensions,
length and width, of the machine.
ACCEPTABLE concrete pads 14 x 14 x 4 inches [356 x 356 x 102 mm] cen-
tered under each of the machine’s feet.
INSTALLATION
- NOTES -
The weight of the standard CONQUEST® GT27/GT27SP Autoload™ system ma-
chines is approximately 8,100 pounds [3674 kg]; the weight of the chip conveyor
with empty coolant tank is approximately 630 pounds [286 kg]; and, the weight of
the skid is approximately 900 pounds [408 kg].
Use a fork lift truck with a minimum lifting capacity of 12,000 pounds [5443 kg] or
use two lift bars a minimum of 3.0 inch [Ø76 mm] diameter, made of 8620 alloy
steel that are approximately 120 inches [3048 mm] long when rigging.
To set the machine in place:
1. Leave the machine on the skid and move it to the installation site.
2. Remove the coolant tank, ground rod, and any parts boxes from the skid.
3. Gain access to the forklift slots by unthreading the screws and lifting off lower spindle ac-
cess cover “C”, Figure 1.4; reach inside along the edge of front cover “D”, unthread the
three screws and pull the cover straight out to the left.
1-2 M-371
4. Remove the screws that secure the four ma-
chine hold-down brackets (two brackets on E
each end of the machine base) to the skid.
Loosen the screws that fasten the hold-down
brackets to the machine and raise the brack- D
ets all the way up to clear the skid. Tighten
the screws just enough to hold the brackets
up.
- CAUTION - C
To avoid damage to the machine,
only lift the machine from the front.
- NOTES -
TP3531.
There are two forklift or rigging slots,
approximately 40 inches (1012 mm) Figure 1.4 - Spindle (Left) End of the
center to center, under the machine. Machine
Refer to Figure 1.3 to locate the support legs numbered 1 through 3. The only legs
that are adjustable are the fourth leg which is located near the front left forklift slot
and fifth leg located behind the power case near the corner of the Harcrete® base
(under the spindle).
5. Make certain that the adjustable fourth and fifth legs are threaded all the way up for clear-
ance and that each has a disc (pad) attached.
- WARNING -
Raise the machine high enough to make certain that the machine’s legs and
hold-down brackets clear the skid.
6. Use a fork lift truck or rigging to lift the machine from the skid. Lift the machine slowly while
making certain that it remains balanced.
7. Carefully lower the machine in place. The machine is initially supported by three legs.
- WARNING -
Any bar feed used with the Hardinge CONQUEST® GT27/GT27SP Autoload
system machines should be approved by Hardinge Inc.
8. If there is no bar feed, place a bubble indicator on top of the tooling top plate parallel to the
spindle and level the machine within .13 inch [3.3 mm] in the machine footprint; turn the
bubble indicator 90 degrees to level within specification. Use metal plates as shims.
However; if the machine will have the bar feed option, use a tighter specification to level
the machine and secure it to the floor. Level the machine for a bar feed as follows:
A. At the spindle end of the machine, unthread the four screws to release spindle draw
tube access cover “E”, Figures 1.4, 1.5, and 1.6. Rotate or remove the access cover
from the machine, Figure 1.6.
- NOTE -
Hardinge suggests using a 1 inch [Ø 25 mm] diameter ground bar approximately 3
feet [1 meter] long and straight within 0.005 inch [0.125 mm].
B. If necessary, remove coolant plug “F”, from the end of the spindle draw tube. Insert the
bar into the spindle draw tube but leave 1 foot [305 mm] of the bar exposed.
C. Make certain that the bar is resting evenly at the bottom of the draw tube radius and
then put a bubble indicator or other leveling device on the exposed bar parallel to the
spindle centerline.
M-371 1-3
E F
TP3539
.
E TP3559.
Figure 1.5 - Spindle Draw Tube Figure 1.6 - Draw Tube End
Access Cover and Coolant Plug
- CAUTION -
Use metal plates as shims to level the machine. Do NOT attempt to move
(thread) the three legs that are not adjustable to level the machine.
-NOTE -
Level the machine within 0.025 inch per foot [0.635 mm per 305 mm].
D. Use metal plates as shims to level the machine within specification.
9. Thread the adjustable fourth and fifth legs down as follows until the machine is firmly sup-
ported.
A. Thread the adjustable legs down until the disc just makes contact with the floor.
B. Only thread each leg one-sixteenth to one-eighth turn more.
C. Check to make certain that the machine is level within specification. Adjust level as nec-
essary.
- NOTE -
It may be more convenient to move the machine to drill the holes and mount the
expansion shields after the floor has been marked.
10. Secure the machine to the floor as follows:
A. Loosen the screws that fasten the hold down brackets and lower the brackets to the
floor. Tighten the screws just enough to hold the brackets.
B. Mark the floor at the center of the hold-down bracket slots.
C. Remove the hold-down brackets from the machine.
D. Drill a .75 inch [Ø19 mm] diameter hole, 4 inches [102 mm] deep at the mark.
E. Drive an expansion shield down into the hole until it bottoms.
F. Mount the hold-down brackets to the machine.
G. Put a washer on the lag screw. Put the lag screw through the hold-down bracket and
thread it into the expansion shield until it is tight.
1-4 M-371
11. Tighten the lock nut against the base to set the adjustable fourth and fifth legs. Check to
make certain that the machine is level within its specification.
12. Unthread the screws to unlatch right end ac-
cess cover “G”, Figure 1.7, in two places and
remove it from the machine (the “tender” sys-
tem or optional stacker table should not be in
place yet).
Reach up inside and unthread the screw that
fastens the red coolant guard door bracket in
place. Remove the bracket and open the
G
door.
- NOTE -
If the machine has the “Auto” door op-
tion, the field service engineer will
mount the coolant door interlock air
cylinder.
13. Remove all tape, foam, and other packing
material from the machine.
14. At the rear of the machine, roll the coolant
tank into place and fasten the coolant hose,
Figure 1.8. Adjust the skirting and make cer-
tain that the coolant will drain into the coolant
chip pan.
15. Put the tramp oil pan in place. TP3562.
16. Check that all electric cables are connected Figure 1.7 - Machine Right End Access
or plugged in. Cover (in Stacker Table)
- CAUTION -
Do not apply power to the machine.
Start up of the machine must be
conducted by a Hardinge service
engineer.
17. Place and align the stacker table or other
tending system to be used.
18. Mount all access covers; close and fasten all
doors.
If this is the initial installation, call the
Hardinge service department at (800)
424-2440 or (607) 734-2281 to schedule the
final installation and inspection of this ma- TP3430.
chine. A Hardinge Field Service Engineer will Figure 1.8 - Coolant Reservoir
visit your plant, at no charge, to test run this and Tramp Oil Pan
machine. He runs a designed test program
but will not set-up or make parts.
Otherwise, this information is intended to be a guide should the machine be moved or put
in storage.
M-371 1-5
CLEANING THE MACHINE
- CAUTION -
Do not use compressed air to clean chips from the machine. Air pressure
forces dirt particles and other foreign matter past the seals and covers into
the slides, ball screw, and bearings. This will cause additional wear and will
reduce the life and accuracy of the machine.
After the machine has been properly located and leveled, remove all shipping grease, oil, and dirt
accumulated in transit. USE A CLOTH OR BRUSH WITH A GOOD GRADE OF OIL BASE GREASE
SOLVENT TO CLEAN THE MACHINE.
Insert a shim of approximately .030 inch [.76 mm] thick plastic shim between the spindle and
headstock front cap. Run the shim completely around the spindle several times to remove the ship-
ping grease. If this grease is not removed, the spindle may run hot.
Use Clorox 409® cleaner to clean the coolant guard windows. Do not use benzene, leaded gaso-
line, acetone, or chlorinated solvents.
AIR CONNECTION
The machine is equipped with filter/regulator “H”, Figure 1.9, and coalescing filter “I”. Machines with
the “big-bore” option also have an air receiver and air receiver filter. The air should be OFF when the
machine is not in use.
Connect the input air line to air valve “J”. The air line should have a minimum I.D. of 3/8 inch [9.5
mm] or the machine will not function properly. Use the knob on top of the air valve to turn the air system
ON. Use knob “K”, to set the regulator at a constant pressure between 70 psi minimum and 90 psi
maximum [4.9 and 6.3 bars]. The air valve must be ON before Cycle Start can be energized. If the air
pressure is below 60 psi [4.2 bars], an error message will be displayed on the CRT screen and the pro-
gram goes into E-Stop.
To drain the air filter/regulator:
1. Turn ON main air valve “J”, by turning the knob counterclockwise and aligning the lock
tabs.
2. Press the valve at the bottom of filter bowl
“H”, sideways until the bowl is drained. K
- CAUTION -
Drain the filter/regulator at least
once a day by pressing the manual
FLEX-DRAIN® petcock, on the bot-
tom of the bowl sideways. If an ex-
cessive moisture problem exists, J
add a heavy-duty air dryer to the in- H
coming air line.
I
TP3517
Figure 1.9 - Air Panel
1-6 M-371
To adjust the air system pressure:
1. Make certain that main air valve “J”, Figure 1.9, is turned ON.
2. Loosen the lock knob on top of knob “K” of most machines to allow the pressure to be ad-
justed. Some machines have a pressure knob that must be lifted to be adjusted.
3. Turn knob “K” clockwise or counterclockwise to adjust the pressure as necessary. Read
the air pressure gauge as the knob is turned to determine how much adjustment is neces-
sary.
4. Tighten the lock knob on top of the adjustment knob to set the pressure on most machines.
The other pressure knobs must be pressed down to be set.
To drain the air receiver filter and air receiver only on “big-bore” option machines:
1. The main air valve must be ON.
2. Unthread the manual screw drain on the air receiver filter until the contaminants are
drained from the filter. Thread the drain tight enough to seat the drain.
3. Then, unthread the manual screw drain a turn or two to drain the contaminants from the air
receiver. Tighten the screw drain valve to seat the drain.
GROUNDING THE MACHINE

- WARNING -
Improper grounding of the Hardinge CONQUEST® GT27/GT27SP Autoload™
system could result in damage to the control and severe electrical shock to
personnel in the event of an electrical fault. To properly ground the machine
an Earth Ground and a System Ground are required.
The minimum ground wire size for all machines is 8 AWG.
In general, there are two requirements for system grounding. They are as follows:
Earth Ground:
An earth ground assures that all voltages have the same reference base and that voltage potential,
in the event of circuit shorts or other malfunctions, is limited. This is accomplished by having a neutral
reference wire common to all voltage sources within the system.
Since safety requirements vary with locality, consult local codes which take precedence over the
following guidelines. Earth ground connections in their order of effectiveness are as follows:
1. Effectiveness of continuous water pipe when properly buried will depend on conditions of
soil. When installed below permanent moisture level, the impedance of this type ground is
typically below 3 OHMS.
2. Effectiveness of man-made, driven or buried electrodes will depend on condition of soil.
When installed below permanent moisture level, the impedance of this type ground is typi-
cally below 5 OHMS.
3. Other available electrodes, such as metal frames of buildings or metal well castings must
be well chosen, since they are substantially below 25 OHMS but exceed 5 OHMS.
Ground connections, wire, and electrodes should not exceed 5 OHMS, as measured from the
equipment ground stud through the primary electrode, through earth, to another independent elec-
trode, separated by 20 feet of earth. Additional ground should be installed when necessary to insure
that the impedance does not exceed 5 OHMS. The ohmic measurement should be made in terms of a
voltage-current relation, such as the current of a 120 volt, 100 watt lamp bulb.
M-371 1-7
The ground conductor connecting the ground stud to the chosen electrode should be of braid or
welding cable (equivalent to AWG #8 or larger). Braid or welding cable minimizes the resistance at
higher frequencies.
When longer lengths are required, use a larger size cable, so that the resistance of the cable is less
than 0.075 OHMS. In general, the size must be rated to carry peak short-circuited current for maxi-
mum time duration without degrading the ground system, and must withstand any mechanical abuse
to which it may be exposed.
Interconnect all separate enclosures, control stations, pendant stations, conduits, and the like, to
implement and maintain safe ground continuity throughout all metallic components of the system.
This is always considered good practice and a locally regulated requirement.
System Grounding:
A proper grounding arrangement prevents equipment damage and personal injury caused by an
electrical fault such as a short circuit. To accomplish this, the grounding setup must assure that all
voltages have the same reference base; and that, in the event of an electrical fault, the voltage poten-
tial is limited. The National Electrical Code recommends that:
250-51. Effective Grounding Path. The path to ground from circuits, equipment,
and metal enclosures for conductors shall (1) be permanent and electrically contin-
uous, (2) have capacity to conduct safely any fault current likely to be imposed on
it, and (3) have sufficiently low impedance to limit the voltage to ground and to fa-
cilitate the operation of the circuit protective devices.
The earth shall not be used as the sole equipment grounding conductor.*1
On the CONQUEST ® GT27 and GT27SP
Autoload™ system, all electrical circuits and all
non-current carrying metal parts of the control and
the machine tool are interconnected by a series of
ground wires attached to ground terminal strip “L”,
Figure 1.10, which is located near the bottom of the
power case.
Attached to the shipping crate is an eight foot
long, 5/8 inch round copper-covered steel rod, which L
is the system grounding electrode, and a ground
clamp. The ground connector used to connect the
machine ground block to the electrode must be a
braid or welding cable equivalent to AWG #8 or
larger. (Braid or welding cable minimizes the resis-
tance at higher frequencies). When longer lengths
are required, use a larger size cable so that the total
resistance of the cable is less than .075 OHMS. In
general, the size must be rated to carry peak
TP3529
short-circuited current of maximum time duration
without degrading the ground systems, and must Figure 1.10 - Machine Ground
withstand any mechanical abuse to which it may be Terminal Strip
exposed.
To establish an earth ground, the electrode must be driven into the ground to a depth of eight feet. If
the bottom is encountered at a depth of less than four feet, the electrode may be buried horizontally in
a trench.
*1 National Fire Protection Association, National Electrical Code Handbook 1996, Fifth Edition, Section 250-51.
1-8 M-371
POWER CONNECTION
The electrical requirements for the CONQUEST® GT27 and GT27SP Autoload™ system are listed
in Table 1.1.
- NOTES -
The wire sizes listed below are for reference only. Due to the variation of local
electrical codes, Hardinge recommends that the local utility supply company be
consulted to determine exact service and wiring requirements.
Machines that require 380, 415, 460, and 575 voltage supply must have a supple-
mentary transformer. It is recommended that machines with 208 voltage supply
also have a supplementary transformer.
Machine Frequency Full Load Service Requirement Recommended

Supply (Hz) Amps (Minimum 115% of FLA) AC Incoming
Voltage (FLA) Wire Size
* 208 60 48 60 No. 4 AWG

230 60 43 60 No. 4 AWG
* 380 50 27 30 No. 8 AWG
* 415 50 24 30 No. 8 AWG
* 460 60 22 30 No. 8 AWG
Table 1.1 - Conquest GT Autoload System
To access the power case and connect the power supply:

- WARNING -
Make certain that the main discon-
nect switch is in the OFF position
when working in the power case or
the control case. M
1. Turn disconnect switch “M”, Figure 1.11, to

OFF before opening the power case door.
2. Turn off the power source to the machine. If
the machine is to be reconnected to another
power line, make certain that the power to
that line is OFF.
3. Unlock the power case door; turn the dis-
connect switch while pulling the door open. TP3516
Figure 1.11 - Main Disconnect Switch
M-371 1-9
4. Check that the line side of the disconnect switch and the ground stud inside the case are
set to have the power source and ground line connected. If the line side of the disconnect
switch has wire clamps, they must be open so that the wires can be inserted and fastened.
- NOTE -
If this is the initial installation, a Hardinge field service engineer will visit the plant
to make the power connections and test run the machine. Local codes and com-
pany policy may require that special personnel make the power connection to the
machine. Have the proper personnel available, if necessary, to make this connec-
tion when the Hardinge service engineer is scheduled to be at the machine site.
Refer to the Hardinge CONQUEST® GT27 and GT27SP AUTOLOAD™system In-
stallation Instructions, manual M-372, for complete installation information before
the service engineer visits.
5. Route the power cable into the power case
far enough to reach the switch and ground
stud near it. Use a cable clamp to secure N
the cable at the entrance to the power case.
If the line side of the disconnect switch has
screws without wire clamps, fasten a ¼ inch
[6.5 mm] ring clamp to each of the wires.
- NOTE -
If this is the initial installation, do not con-
nect the wires to the main disconnect
switch. Do not apply power to the machine.
The service engineer or the special per-
sonnel will connect the ground wire and
power leads. TP3421
Figure 1.12 - Disconnect Switch and

If this is not the initial installation, proceed Ground Stud Inside the Power Case
with the instructions below.
6. Connect the electrical power supply to the line side of the disconnect switch and the
ground wire to ground stud “N”, Figure 1.12.
Do not turn disconnect switch “M”, Figure 1.11, ON until all electrical connections have
been checked by a Hardinge service technician.
1 - 10 M-371
POWER CASE
- WARNING -
To avoid possible electrical hazard to the worker or damage to the machine,
allow only authorized personnel to have access to enclosures containing
electrical equipment.
The power case cannot be opened while the machine is powered up. The machine must be power
down before the power case can be opened.
DO NOT have the power case open while the machine is powered up unless an authorized person
is trouble shooting the control electronics.
- WARNING -
Be extremely carefully when working in the power case.
To open the power case door:
1. Power down the machine as follows:
A. Make certain that the cycle has ended and that the spindle has stopped.
B. Press the Emergency (E-Stop) Stop pushbutton.
C. Turn the Control power switch to OFF.
D. Turn main disconnect switch “M”, Figure 1.11, to OFF.
2. Use the hex key to unlatch power case door.
3. Pull the tab at the upper right on the main disconnect switch down while turning the discon-
nect switch lever and pulling the door open.
- WARNING -
People are exposed to electrical hazard when the machine is turned ON with
the power case open.
4. To power up the machine while the power case door is open, use a wrench on the main
disconnect bar to turn the bar clockwise to ON.
5. Turn the Control power switch to ON and bring the control out of E-Stop.
6. The machine must be powered down again to close and latch the power case door before
operating the machine.
M-371 1 - 11
- NOTES -
1 - 12 M-371
CHAPTER 2 - POWER-UP PROCEDURE
- CAUTION -
The recommended operating temperature range is 50° to 114° F [7° to 46° C].
- NOTE -
Follow the power-up procedure exactly as described in the steps which follow to
ensure safe, accurate, and repeatable machine operation.
BASIC MACHINE POWER-UP

1. Turn main disconnect switch “A”, Figure 2.1, ON.
2. Turn main air valve “B”, Figure 2.2, ON.
- CAUTION -
Any accumulated water must be drained from the air system at least once a
day. If more frequent draining is required, it may be necessary to install an
air dryer in the air line.
- NOTE -
Coalescing filter “E” is equipped with an automatic drain.
3. Drain filter bowl “C” by pressing valve “D” sideways. Release when draining is complete.
C
E
D
A
TP3516 TP3426
Figure 2.1 - Main Disconnect Switch Figure 2.2 - Main Air Panel
4. On machines equipped with a “big-bore” (16C) spindle option:

A. Drain the air receiver filter bowl by unthreading the drain valve. Close when draining is
complete.
B. Drain the air receiver by unthreading the drain valve. Close when draining is complete.
5. Check lubricant and coolant levels. Add lubricant and coolant as required.
(continued on the next page)
M-371 2-1
- CAUTION -
When turning the Control switch to ON, DO NOT press any pushbuttons or
keys until the Position or Alarm screen is displayed. Some pushbuttons and
keys have other control maintenance or special operation functions.
6. Turn the Control OFF/ON switch to ON and wait until the control display screen is ON.
7. Pull the gantry pendant and stacker table Emergency Stop pushbuttons outward; then re-
lease.
8. Pull the front panel Emergency Stop pushbutton outward; then, release.
9. Press the Emergency Stop Reset pushbutton [3].
10. Open and close the coolant guard door to perform the guard door switch verification and
clear the verification alarm.
The machining system is now ready for operation.
POWER-DOWN PROCEDURE
To power down the control:
1. Be sure “Cycle Start” is not active. The Cycle Start pushbutton [47] will not be illuminated.
2. Be sure program execution has been completed and that all axes are stationary.
3. Press the front panel Emergency Stop pushbutton.
4. Turn the Control OFF/ON switch to OFF.
5. Turn main air valve “B”, Figure 2.2, OFF.
6. Turn main disconnect switch “A”, Figure 2.1, OFF.
CLEARING AN EMERGENCY STOP

There are three Emergency Stop pushbuttons, located as follows:
• Under the operator control panel
• Above the stacker table access door
• On the gantry pendant
To clear an E-Stop condition:
1. Correct the condition that prompted the Emergency Stop (E-Stop) condition.
2. Pull the Emergency Stop pushbutton that was pressed to initiate the Emergency Stop out-
ward; then, release.
3. Pull the Emergency Stop pushbutton located under the operator control panel outward;
then, release.
4. Press the Emergency Stop Reset pushbutton [3].
2-2 M-371
HOUR RUN METER
The hour run meter is located on the side of the
power case which is also the left (spindle) end of the
machine. It records the amount of time that the con-
trol has been powered up.
TP3524.
Figure 2.3 - Hour Run Meter
REVIEW CONTROL STATUS

The following descriptions refer to the control status displays.
POSITION KEY
There are three pages of position display data. After the Position key is pressed, the position dis-
play 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 center-
line. Position is displayed as X and Z coordinates. This origin can be relocated by any
one of the following:
Active set of tool offsets
Position Reset operation
Workshift offset
C. Machine: Displays the axis position in relation to the Reference Zero position.
The X-Axis Reference Zero position is 11.75 inches [298 mm] from the spindle cen-
terline, as measured on the diameter.
The Z-Axis Reference Zero position on machines equipped with a 5C spindle is
11.250 inches [285.00 mm] from the face of the spindle.
The Z-Axis Reference Zero position on machines equipped with a 16C spindle is
10.600 inches [268.49 mm] from the face of the spindle.
M-371 2-3
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 Auto-
matic or Manual Data Input mode.
2. ABS (Absolute Position Display). Refer to part “b” under “ALL (Overall Position Display)”.
3. REL (Relative Position Display). Refer to part “a” under “ALL (Overall Position Display)”.
PROGRAM KEY
Press the Program key to display the active program number, and active block sequence number
and eleven blocks of the active program on the control display screen. To display other pages of the
program, select Edit mode and use the page keys to read through the program.
During execution of the active part program, the cursor will be positioned under the sequence num-
ber of the active block.
If necessary, press the Reset ket to return to the start of the program.
OFFSET SETTING KEY
When the Offset Setting key is pressed, the Offset and Setting soft keys are displayed. From the
first Offset Setting screen, press the soft key expansion key once to display the Macro Program soft
key. From the first Offset Setting screen, press the soft key expansion key twice to display the Work
Shift soft key.
OFFSET soft key
Press the Offset soft key to access the geometry and wear soft keys.
Geometry: Consists of four pages of Geometry offsets, eight offsets on each page.
Wear: Consists of four pages of Wear offsets, eight offsets on each page.
One of the two chapters will be displayed on the control display screen. The displayed
page will be the page which was active when the Offset display was last deactivated. To
display the other chapter, press the corresponding soft key. Use the page keys to view
other pages within a chapter.
The tool geometry and wear offset chapters each consist of four pages, which display the
following information:
X and Z Tool Offsets (32 pair)
Tool nose radius values
Tool nose orientation numbers
Use the page keys to view other pages. The Tool Offset pages are formatted as follows:
Offset Page 01: Offset Numbers 01-08
2-4 M-371
SETTING Soft Key
Press the Setting soft key to access the system variables page, which allows the operator
or programmer to assign the system variables listed below. To modify these variables,
move the cursor to the variable which is to be modified, enter the desired value, and press
the INPUT key.
PARAMETER WRITE = _ (0:DISABLE 1: ENABLE)
TV CHECK = _ (0:OFF 1:ON)
PUNCH CODE = _ (0:EIA 1:ISO)
INPUT UNIT = _ (0:MM 1:INCH)
I/O CHANNEL = _ (0-3:CHANNEL NO.)
SEQUENCE NO. = _ (0:OFF 1:ON)
TAPE FORMAT = _ (0:NO CNV 1:ON)
SEQUENCE STOP = _ (PROGRAM NO.)
SEQUENCE STOP = _ (SEQUENCE NO.)
PARAMETER WRITE
This parameter allows the control parameters to be edited. When set to “0", parameter edit-
ing is disabled. When set to ”1", parameter editing is enabled. Refer to Chapter 3 for infor-
mation on editing machine parameters.
TV CHECK
This parameter allows the activation or deactivation of parity checking. When set to “1",
parity is checked from the beginning of each block to the beginning of the next block.
When set to ”0", vertical parity checking is disabled.
PUNCH CODE
This parameter allows the selection of either EIA or ISO data input format through the
RS-232 serial port. When set to “0", the data input format is set to EIA. When set to ”1",
the data input format is set to ISO.
INPUT UNIT
This parameter allows the selection of metric or inch operating mode. When set to “0", the
operating mode is Metric. When set to ”1", the operating mode is set to Inch.
I/O CHANNEL
This parameter allows the selection of the logical I/O to be used by the control. The valid
selections for the I/O port assignments are 0, 1, or 2. Refer to Chapter 6 for a complete ex-
planation of I/O port selection.
SEQUENCE NO.
This parameter allows the selection of “automatic sequence number insertion”. When ac-
tive, 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 num-
ber insertion is inactive. When set to ”1", automatic sequence number insertion is active.
TAPE FORMAT
Not Active
M-371 2-5
SEQUENCE STOP (2 entries)
These two entries are used together to provide the machine operator with the capability of
stopping automatic part program execution after the program block specified has been
completed.
The first entry (Program No.) identifies the program to be monitored.
The second entry (Sequence No.) identifies the sequence number (N word) of the last
block to be executed by the CNC control during normal automatic operation. Once this
block is executed, the CNC control will stop program execution.
Press the Cycle Start pushbutton [47] to resume program execution.
MACROS Soft Key
Press the MACROS soft key to display the macro variable registers.
WORK SHIFT Soft Key
Press the Work Shift soft key to display the workshift offset registers.
SYSTEM KEY
Press the System key to access the following information:
- Machine parameters and diagnostics
- PMC parameters, ladder, and diagnostics
- Control system configuration
One of four chapters will be displayed on the control display screen. The displayed page
will be the page which was active when the key was last deactivated. If necessary, press
the soft key to display the desired chapter. Use the page keys to view other pages within
the chapter.
PARAMETER Soft Key
Press the Parameter soft key to display machine parameters. These parameters establish
many of the characteristics, specifications, and functions of the machine tool. The page
that was active when the parameter chapter was last exited will be displayed. Use the
page keys to view other pages within the chapter. Refer to Chapter 3 for information on ed-
iting machine parameters.
DIAGNOSTICS Soft Key
Press the Diagnostics soft key to display the machine diagnostics chapter. The page that
was active when the diagnostics chapter was last exited will be displayed. Use the page
keys to view other pages within the chapter.
PMC Soft Key
Press the PMC soft key to display the PMC information screen. The purpose of this screen
is to view the PMC ladder, parameters, and diagnostics.
SYSTEM Soft Key
Press the System soft key to display the control system information screen.
2-6 M-371
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 format-
ted to indicate which tool station has generated the alarm. Descriptions of each alarm are
given in the alarm list in Appendix Two.
MESSAGE Soft Key
Operator Message chapter. Operator messages do not initiate a feed hold condition. They
call the operator’s attention to a particular condition that exists.
HISTORY Soft Key
The GE Fanuc series 18i-T control is capable of storing the last 25 alarms generated by
the machine control. There are a maximum of five pages, with up to five alarms per page.
Use the page keys to display next or previous page.
- NOTE -
Alarm and Operator messages caused by an error generated in Background Edit
will have no affect on a part program which is executing in foreground.
- NOTES -
M-371 2-7
- NOTES -
2-8 M-371
CHAPTER 3 - LUBRICATION
Introduction
The lubricator is mounted at the rear of the machine, Figure 3.1. Lubrication is accomplished
through a LUBRIQUIP® distribution system, “A”, for the ball screws and the bearings on the linear
guideways. The cross slide ball screw, the carriage ball screw, and the 8 linear way bearing cartridges
are lubricated automatically; the gantry and any load/unload system have, if necessary, their own
separate lubrication.
Tramp (waste) oil container (pan) “B”, Figure 3.2,
should be emptied once per shift. It is located on the
floor at right end of the machine near the back. When
the machine has the optional Stacker Table or other
load/unload system on the right end of the machine,
the tramp oil pan is accessed through an opening
near the floor.
The lubrication system will complete 4 cycles of
pumping oil during power up. If the cycle is not com-
pleted, an alarm is generated and the machine goes
into an Emergency Stop (E-Stop) condition. Correct
the emergency, i.e. add oil or whatever corrects the A
situation, and, then, pull the E-Stop pushbutton out to
clear the alarm and initiate the power-up lubrication
cycle or at any time the lubrication system needs to
be tested.
TP3525
.
Lubricator Consumption Guidelines
Figure 3.1 - Lubricator Location
The run time for one full lubricator tank is approxi-
mately 220 hours. All times are approximate and vari-
ations on an individual machine could be up to ±20%
from the time listed. If actual lubrication consumption
is greater or less than the acceptable range given,
then check the system for the type of oil being used
and for leaks or kinked hoses.
The reservoir contains about 1.6 gallons [6 liters]
of Mobil Vactra® #2 oil when filled. The LUBRIQUIP
feeders limit the amount of oil used per cycle. The ac- B
tuator switch is activated to indicate that the cycle is
completed once the distributor block sequentially
TP3430
.
sends oil to the 4 cross slide linear guide blocks, 4
carriage linear guide blocks, and both ball nuts. The Figure 3.2 - Tramp Oil Pan and Trough
pump cycle time is controlled by machine software
and is preset at Hardinge. The lubrication pump cy-
cles every 3.33 minutes; however, when the machine is idle, it cycles once every 50 minutes (30 cy-
cles). If the axes move intermittently, the lubrication time will be greater than 3.333 minutes and less
than 50 minutes.
The lubricator is active any time the CNC control is on. When the lubrication system requires main-
tenance, the machine must be powered down. A detailed procedure to power it down appears in
Chapter 2 - POWER-UP PROCEDURE.
M-371 3-1
Power-Down Procedure
1. Make certain that “Cycle Start” is not active. The pushbutton light should be off.
2. Make sure that the program has been completed and that the spindle, slides, and any
load/unload system are stationary.
3. Press Emergency Stop pushbutton.
4. Turn the Control OFF/ON switch to the OFF (0) position.
5. Turn main air lock out valve OFF.
6. Turn main disconnect switch OFF.
Lubrication Oil
The lubrication oils that Hardinge, Inc. recommends for use on the machines have been thoroughly
tested and qualified. Other oils may not contain certain additive packages needed for proper lubrica-
tion and performance from the oil. The additive packages may include rust and corrosion inhibitors,
anti-wear compounds, defoamants, etc., which have been blended specifically for that application.
Although many companies offer “similar” oils, these oils may not contain the needed addi-
tives to ensure maximum performance and protection of the Hardinge machines.
Lubricator Refill
Check the oil level daily. The oil level can be seen
in the reservoir and compared to the sight gauge. The
lubricator tank can be refilled at anytime that oil is
needed, even while the machine is in operation. If the
lubricator is low on oil, the following conditions exist:
A. “Lube Low Refill” is displayed and single
mode LED will flash but automatic opera- C
tion is still allowed.
B. When the tank is not refilled within the
next 25 minutes, the machine is forced
into Block by Block operation.
C. If the tank is not filled after 5 more min-
utes, the machine will shut down with the
JOG mode locked on and the “Lube Sys-
tem Failure” message displayed.
D. When the machine is powered up and the
“Low Lube Refill” message is displayed, TP3525
.
the JOG mode is locked on. Fill the lubri- Figure 3.3 - LUBRIQUIP® Lubricator
cator tank to clear this message and
re-activate the lubrication system.
To fill the lubricator tank:
1. Wipe away any chips, oil, and dirt from the tank cover.
- NOTE -
Leave the filler tube screen in place.
2. Unthread filler cap “C”, Figure 3.3, and fill the tank with Mobil Vactra #2 oil.
3. Thread the cap on and continue with maintenance or operation.
3-2 M-371
To correct the low lubricator condition:
1. Fill the lubricator tank.
2. Press the E-Stop Reset (3) and Zero Return (6) pushbuttons at the same time to remove
the alarm condition and re-activate the lubrication system.
Other lubrication control conditions can be cleared just by pressing the RESET button on
the CRT/MDI panel.
To empty the tramp oil pan:
1. Locate tramp oil pan “B”, Figure 3.2, on the floor at right end of the machine near the back.
If the machine has the optional Stacker Table or other load/unload system access the pan
through an opening near the floor.
2. Pull the tramp oil pan from under the tramp oil trough.
3. Pour the oil from the pan; dispose of the oil in an environmentally safe manner.
Clean the tramp oil pan with a lint-free cloth, if necessary.
4. Slide the pan in place aligned under the trough so that it will catch the oil.
Lubricator Reservoir and In-Line Filter

The in-line filter should be inspected every six months; it is located under and behind the lubricator
reservoir bracket. Clean or replace the filter as necessary. It is also recommended that the reservoir
be cleaned at least once a year.
Efficient lubrication, clean valves and feeders, and long bearing life depend on clean lubricant. The
filter cleans the oil before it goes into the lube lines and valves.
To change the system filter element:
1. Power down the machine. Locate the in-line
filter below the reservoir bracket.
D
2. Unthread plug “D”, Figure 3.4, from the filter
housing. The plug has the filter mounted to
it.
3. Replace the filter by unthreading it from the
plug and installing a fresh, clean filter.
4. If necessary, clean the lubricator tank. Wipe
it with a lint-free cloth.
5. Unthread the filler cap and fill the lubricator
reservoir. Re-install the filler cap.
6. Power up the machine and check the lubrica-
tion system for oil leaks.
TP3429.
Figure 3.4 - In-Line Filter
M-371 3-3
To prefill and purge (prime) the lubrication system of air before operation:
Anytime that the lubrication system has air contamination, the air must be purged from the lines and
feeder block. Detailed information to purge the LUBRIQUIP® system is contained in LUBRIQUIP liter-
ature bulletin 30103.
Lubricator feeder block “E”, Figure 3.5, is mounted
up underneath the rear of the cross slide on the car-
riage. The ports in the castings can be located by fol-
lowing the oil lines from the feeder block; ports 1
through 5 are for the cross slide with port 3 the ball
screw lubrication and ports 6 through 10 are for the
carriage with port 8 for its ball screw.
1. Make certain that the machine is powered
down.
2. Access the feeder block. Unthread the
screws and lift off the rear cross slide way E
cover.
3. Fill and purge the feeder block and lubrica-
tion lines as follows:
A. Remove the alternate outlet pipe plug(s) TP3534.
from the feeder block.
Figure 3.5 - LUBRIQUIP Feeder Block
B. Connect an oil-filled hand pump to the
outlet opening.
C. Disconnect the lubrication line from its destination; manually pump the oil while making
certain that oil is filling the line and reaching its lubrication point.
D. Reconnect the lubrication line at the destination but do not thread in the alternate outlet
plugs at this time.
E. Repeat steps A through D for all lines from the feeder to their lubrication point(s).
4. Last, fill the feeder block with oil using the following procedure:
A. Verify that all alternate outlet pipe plug(s) have been removed from the feeder block.
B. Connect the LUBRIQUIP lubrication system pump to the inlet of the feeder block.
C. Turn just the control ON and cycle the lubrication system pump until oil flows freely (is
discharged) from the feeder block valve alternate outlet opening(s).
D. Thread in the alternate outlet pipe plug(s) tight on the feeder block. Check all other lubri-
cation system fittings to verify that they are tight and free of leaks.
5. When the lubrication system has been purged and other work completed, mount the way
covers and fill the lubricator tank.
6. Power up the machine.
3-4 M-371
Replace the Lubricator
Replace the lubricator as a unit if any of the lubricator mechanisms such as the motor and pump fail
or become damaged.
1. Power down the machine.
2. Disconnect the oil line from the lubricator.
3. Unthread the nut that secures the grommet
which seals the electrical cable and unthread
the fitting that secures the sensor cable.
4. Loosen the screws that fasten the cover to
electrical junction box “E”, Figure 3.6, and lift F
off the cover.
5. Make a diagram of the electrical wire con-
G
nections and connection for the sensor wire.
This will be important to follow when recon-
necting the replacement lubricator.
6. Disconnect the wires and remove the cables
from the junction box and fittings.
TP3426.
7. Unthread two screws that mount the lubrica-
tor to the bracket. Replace the lubricator and Figure 3.6 - Top of Lubricator
mount the new lubricator to the bracket.
8. Feed the cables into the junction box and connect the wires per step #5. Cover the junction
box; connect the sensor wire. Make certain that the grommets are in place and then seal
them by tightening the nuts.
- CAUTION -
Use just enough pipe sealant to secure the fittings. Do not apply sealant to
the first few threads. Excess sealant may be pushed into the lube line and
cause it to malfunction.
9. Reconnect the lube line to the lubricator.
10. Power up the machine and check the lubrication flow.
To clean the oil reservoir:
2. Unthread the six screws from the top of the tank. The lubricator top has all the lubrication
mechanisms and reservoir (tank) mounted to it.
3. Carefully loosen the tank and lower it from the lubricator top. Drain the oil.
4. Wipe the tank clean with a lint-free cloth.
5. Inspect and clean or replace the suction filter on the inlet tube.
6. Re-align the tank with the lubricator top and fasten it in place with its screws.
7. Unthread filler cap “C”, Figure 3.3, and fill the reservoir. Thread the filler cap on tight.
8. Power up the machine and check the tank seal for leaks.
M-371 3-5
Clean Tramp Oil Trough
The lubrication waste oil gravitates into the carriage ball screw cavity; drains down through the
Harcrete® base via a short hose into a trough which drains to the tramp oil pan at the right end of the
machine. When the machine has the optional Stacker Table or other load/unload system on the right
end of the machine, tramp oil and coolant may drain from the parts and gripper into a drain pan,
through a hose and back into the tramp oil pan.
To clean the tramp oil opening:
1. Move the axes away from Home toward the spindle.
3. Lift out and empty tramp oil pan “B”, Figure 3.2. Place the empty container back in place.
4. Gain access to the carriage ball screw cavity at the right side of the cross slide.
-WARNING -
Always blow the waste oil down through the line into an empty container.
NEVER LOOK into the opening while air pressure is applied.
5. Use an air hose with moderate air pressure to clean waste oil or chips down through the
opening. A flexible tube may have to be attached to the nozzle and shaped to fit under the
way cover and into the waste oil opening.
6. Unthread the waste oil hose elbow and use a piece of wire up through the oil line if chips
still block the waste oil opening. Work the wire up through the opening and push the chips
up into the trough.
- CAUTION -
Use a cloth to remove the chips from the trough. Never use an air blast and
do not use bare hands to remove the chips.
7. Wipe the chips from the trough with a rag and put the oil pan under the machine base.
8. Use an air hose with moderate air pressure to clean the waste oil opening again after us-
ing the wire to clear it.
9. Thread the waste oil hose elbow into the Harcrete base.
10. Remove the oil pan and clean any debris from it. Replace the pan under the trough.
11. Check the oil level in the lubrication reservoir. Fill the reservoir, if necessary.
3-6 M-371
- NOTES -
M-371 3-7
- NOTES -
3-8 M-371
CHAPTER 4 - AIR FACILITIES
INTRODUCTION
Factory air to the CONQUEST® GT27 and GT27SP AUTOLOAD™ series machines goes through
a filter/regulator system to set the air pressure and remove contaminants before they get into the ma-
chine air supply. A coalescing filter is mounted after the pressure switch manifold to remove additional
water vapor and oil. The system distributes air to: 1) the collet closer open and close, 2) the air options,
and 3) the collet closer air receiver on machines with
the Big Bore option or GT27 machines. Other valves B C
and switches are added to this assembly as air op- A
tions are added to the machine.
If the factory air has excessive moisture, add a
heavy-duty air dryer to the incoming air line. Connect
the air supply line to the air valve on the filter/regula-
tor. The incoming air line should have a minimum I.D.
of 3/8 inch [9.5 mm]; however, if the air line is espe-
cially long, a larger inside diameter hose may have to E
be used. D
Air is turned on by turning air valve knob “A”, Fig-
ure 4.1, counterclockwise and aligning the lock tabs.
Regulator knob “B”, adjusts the air pressure range
from 70 psi to 90 psi [4.9 to 6.3 bars]. Air pressure
switch, “C”, is preset at 60 psi [4.2 bars]. If the switch
detects pressure below 60 psi [4.2 bars], an alarm TP3426.
message appears on the CRT and the program goes
into E-Stop. Figure 4.1 - Air Panel with Cover
- WARNING -
Do not attempt to block or look into G
the port at the bottom of the air F
valve while releasing air from it.
The air valve may be used to purge the factory air
of contaminates before they get into the filter/regula-
tor by rotating valve “A”, to any of the three positions
other than the ON or OFF location over the lock
rings.
Drain the Filter/Regulator Unit Daily

Drain filter/regulator daily by pressing manual
FLEX-DRAIN® petcock “D”, sideways; coalescing fil-
ter and collet closer filter bowls have manual (twist,
unthread a turn or two) drains. If an excessive mois-
ture problem exists, add a heavy-duty air dryer to the
incoming air line.
TP342
7.
Figure 4.2 - Air Panel without Cover
M-371 4-1
When the air system requires maintenance, the machine must be powered down. A detailed proce-
dure to power down the machine appears in Chapter 2 - POWER-UP PROCEDURE.
1. Be certain that “Cycle Start” is not active. Pushbutton light is OFF.
2. Make sure that the program has been completed and that the spindle, slides, and any
load/unload system are stationary.
3. Press Emergency Stop (E-Stop) pushbutton.
5. Turn off and lock out the main air valve.
6. Turn off and lock out the main disconnect switch.
- CAUTION -
The filter/regulator bowl and air receiver must be drained once a day. If more
frequent draining is required, it may be necessary to install an air dryer in
the air line.
Drain the Filter Bowls and Air Receiver

The filter/regulator filter bowl has a manual flex drain valve; the coalescing filter and collet closer fil-
ter bowls have manual twist (unthread) drains to remove contaminants from the system; the air re-
ceiver, which maintains collet closer air pressure, has a petcock.
- NOTE -
The filter/regulator filter has a manual FLEX-DRAIN® petcock “D”, Figure 4.1, that
must be pressed sideways to open the drain valve.
1. Make certain that the air source is connected and turned ON.
2. Press the manual drain valve sideways on the bottom of filter/regulator “A”, enough to
empty the bowl. Release the manual drain valve to seal the drain.
3. Check that any moisture in the coalescing filter and collet closer (GT27) filter bowls is be-
low the level indicator line. Unthread the manual drain a turn or two if necessary.
4. Unthread the petcock counterclockwise on the bottom of the air receiver, Figure 4.3, just
enough to drain. Thread the petcock closed to seal the air receiver.
Drain the Air Receiver
- CAUTION -
Unthread, i.e. open, petcock “H”,
Figure 4.3, on the end (bottom) of
the air receiver whenever working
on the air system or its compo-
H
nents. This releases any air pres-
sure.
The air receiver is mounted under the machine
tray and air panel at the rear of the machine. It should
be drained of contaminants daily or possibly when
draining the filter/regulator bowl.
Tp4017.
Figure 4.3 - Air Receiver (Big Bore and

GT27 Machines)
4-2 M-371
- WARNING -
Do not look up under the machine tray while draining contaminants from the
air receiver. Air exhausts rapidly from the air receiver.
To drain the air receiver, turn petcock “H”, Figure 4.3, on the end (bottom) of the air receiver coun-
terclockwise until any contaminants are exhausted. Again, if excessive moisture is in the air system,
an air dryer must be installed. Seal the petcock by turning it clockwise until it is closed.
Clean the Air System Bowl

It is possible that after a period of time the air system bowl may need to be cleaned. The bowl is held
in place by an outer protective shell (bowl guard).
Drain any water from the filter/regulator bowl by pressing FLEX-DRAIN® petcock “D”, Fig-
ures 4.1 and 4.4, to the side.
2. Pull down on black latch “I”, Figure 4.4, on the side of the outer shell. Rotate the shell
counterclockwise to release the bowl from the filter/regulator head. Do not use excessive
force to remove the bowl. Twist the bowl gently to release it from the head.
3. Wipe the bowl clean with a lint-free cloth and
check the O-ring for damage. Replace the
O-ring and/or bowl if necessary.
4. Clean or replace the filter on the regulator as
necessary. To release the filter, unscrew the
nylon fixture. The filter will drop out when the
fixture is released. Clean or replace the filter
and remount it.
I J
5. Mount the bowl in the head as follows: put
the plastic bowl into the shell. Align the bowl
and shell in the air system head, press the D
shell up into place and rotate it clockwise un-
til the latch on the shell “clicks” to seat the TP3526.
O-ring and bowl. Check to confirm that the Figure 4.4 - Coalescing Filter Unit
bowl is in place before turning ON the main
air valve.
6. Power up the machine and turn the main air valve ON. Set the regulator to 80 psi [5.5
bars] and check it for air leaks. Seal any air leaks as necessary.
7. Set the regulator below 60 psi [4.2 bars] to test the pressure switch to make certain that
the whole system is functioning properly. When satisfied with the switch, manifold, and air
unit, return the regulator pressure to an operating pressure from 70 psi to 90 psi [4.9 to 6.3
bars].
8. Check the air system bowl again for contamination, moisture, or air leaks. Correct any
problems as necessary.
M-371 4-3
Replace the Coalescing Filter
The machine is equipped with coalescing air filter “J”, Figure 4.4. This filter drains automatically
when the sight indicator on the head turns orange. Make certain that the drain nipple on the bottom of
the bowl is not covered or blocked. The filter element (Hardinge part number CN -0010779-3E) should
be changed at least every six months.
To change the coalescing filter element:
1. Power down the machine. Make certain that the air lock-out valve is OFF; align the
lock-out valve tabs and lock the valve in the OFF position.
2. Pull down on the black latch and rotate the shell counterclockwise to release the bowl from
the filter head. Wipe the bowl clean and check the O-ring.
3. Unthread the filter element from the threaded stem.
4. Thread the new filter element on the stem.
5. Put the plastic bowl in the shell. Align the bowl and shell in the filter head slots, press the
shell up into place and rotate it clockwise until the latch on the shell “clicks” to seat the
O-ring and bowl.
Replace the Collet Closer (GT27, Big-Bore) Filter
The GT27 machine and big-bore machine are each equipped with a collet closer air filter, Figure
4.5. This filter should be manually drained each day and when the moisture level is near the level indi-
cator line. Make certain that the drain nipple on the bottom of the bowl is not covered or blocked. The
filter element (Hardinge part number LC -0011614) should be changed at least every six months.
To change the coalescing filter element:
1. Power down the machine. Make certain that
the air lock-out valve is OFF; align the
lock-out valve tabs and lock the valve in the
OFF position.
2. Relieve system air pressure by opening the
air receiver petcock.
When the air pressure is reduced, tighten the
petcock.
3. Press (lift) the shell slightly up into the filter
head and, then, rotate the shell counterclock-
wise to release the bowl from the head. Wipe
the bowl clean and check the O-ring. Tp4019
.
4. Unthread the filter element from the threaded Figure 4.5 - GT27 and Big-Bore Collet
nipple. Closer Air Filter
Replace the filter element and thread it on
snug.
5. Align the bowl and shell in the filter head; press the shell up into place and rotate it clock-
wise until it seats the O-ring and shell.
6. Unlock the air lock-out valve. Power up the machine.
4-4 M-371
Replace the Air Control Assembly Components
Any of the air control assembly components can be replaced if they become damaged. The air con-
trol assembly can also be replaced as a unit.
1. Power down the machine. Make certain that the air lock-out valve is OFF. Align the
2. Disconnect the main air line from the air lock out valve.
3. Unthread the screw and pull the electric plug straight up from the top of pressure switch
“C”, Figure 4.1.
4. Disconnect the air line(s) from the air manifold.
5. Unthread the screws and remove the air assembly unit from the panel.
- NOTE -
The air control assembly components are fastened together with taper-railed
blocks.
6. Loosen, but do not remove, the screws in the taper-railed block on either side of the com-
ponent being replaced. Carefully slide the component out of the blocks.
7. Make certain that the O-rings are in place and mount the new component between the
taper-railed blocks. Tighten the screw in each block.
8. Mount the air assembly unit on the panel. Tighten the screws that fasten it in place.
- NOTE -
Use just enough sealant to secure the fitting when fastening the air lines to the
manifold((s). Do not apply sealant to the first few threads.
9. Fasten the air line(s) to the manifold.
10. Connect the electric plug to the top of the of pressure switch. Thread the screw into the
pressure switch to secure the plug.
11. Connect the main air line and turn the air source on.
12. Remove the lock from the lock-out tab and power up the machine. Set the regulator to an
operating pressure between 70 psi and 90 psi [4.9 to 6.2 bars].
13. Press the E-STOP RESET pushbutton if it is still necessary to clear “1017 Main Air Pres-
sure Low” alarm message from the CRT.
14. Check the air system bowl for contamination, moisture, or air leaks and correct any prob-
lems as necessary.
Replace the Pressure Switch(es)

Pressure switch “C”, Figure 4.1, and/or collet pressure switches “F” and “G”, Figure 4.2, is designed
to send a signal to the control and an alarm message appears on the CRT when the main air pressure
falls below 60 psi [4.2 bars].
1. Power down the machine. Make certain that the air lock out valve is OFF. Align the
2. Unthread the screw that holds the electrical plug to the top of the pressure switch. Pull the
plug straight up to remove it from the switch.
M-371 4-5
3. Unthread the pressure switch from the manifold. The switch is tightened to the manifold
with light torque pressure, however, a wrench may be necessary to unthread it.
- NOTE -
Use just enough sealant to secure the fitting when fastening the pressure switch to
the manifold. Do not apply sealant to the first few threads.
4. Thread a new pressure switch on the manifold and only tighten it to 50 in/pounds
[5.6 Nm].
5. Connect the electric plug to the pressure switch. Secure the plug with the screw.
operating pressure between 70 psi to 90 psi [4.9 to 6.2 bars].
7. Press the E-Stop Reset pushbutton if it is still necessary to clear “1017 Main Air Pressure
Low” alarm message from the CRT.
lems as necessary.
Replace or Clean the Manifold(s)

Main air manifold “K”, Figure 4.6, and collet closer manifold “L”, have no moving parts, but if they
are not dispersing air as they should or if they become damaged, they may need to be replaced or
cleaned. There are additional ports in the main air manifold for use when other air options are added to
the machine.
the air lock out valve is OFF. Align the
OFF position.
2. Disconnect the air lines from whichever man-
ifold requires work.
3. Unthread the manifold and fitting from the air
panel. The air fitting may have to be re-
moved from the manifold if the manifold is to
be replaced.
- NOTE - L
Use just enough sealant to secure the
fitting when fastening the air system
components together. Do not apply
sealant to the first few threads.
4. Thread the plugs and air line fittings into the
new manifold and mount it on the air assem- K
bly unit.
5. Attach the air lines to the fittings on the man-
ifold.
6. Remove the lock from the lock-out tab and
power up the machine. Set the regulator to
an operating pressure between 70 psi and TP3427.
90 psi [4.9 to 6.2 bars].
Figure 4.6 - Air Manifolds and Solenoid
Valves
4-6 M-371
lems as necessary.
Solenoid Valves
Solenoid valves at both manifolds “K” and “L”, Figure 4.6, are horizontally stacked when mounted
on the air panel. Most air system options are activated through solenoid valves and are available on
the machine when originally ordered or some of the options can be retrofitted when necessary.
Reference information is included in each air option retrofit kit and with each machine. Electrical
connections, air line connections, cable markings, routings (ducting) through the machine, and loca-
tion of the option parts are on the option information sheets and on the tags on the machine.
To replace or add a solenoid valve:
1. Power down the machine. Make certain that the air lock out valve is OFF. Align the
2. Refer to the schematic chart on the panel to identify which valve needs to be replaced. If a
valve is to be added, make certain that an identification stamp is placed on the chart.
3. Unthread the screw and remove the end plate from the stack of solenoid valves.
4. Unscrew the two fasteners that mount the end cap and each valve to its adjacent valve un-
til the valve to be replaced is removed or until the new valve can be added to the stack of
valves.
- NOTE -
It is not necessary to remove the electrical connection or air line from valves that
are not being replaced.
5. Unthread the screw that secures the electrical connection to the solenoid valve being re-
placed. Pull the connection straight up to release it from the valve.
6. Unthread the air line from the fitting on the bottom of the valve being replaced. If neces-
sary, remove the pneumatic fitting from the valve.
7. Thread an air fitting to the new valve. Use sealant to secure the fitting but do not apply it to
the first few threads.
8. Mount the new valve to the end piece or adjacent valve on the panel. Check the valve gas-
kets and replace any that are worn. Fasten each valve and gasket in place.
9. Check the gaskets and mount the other valves and end plate to the new valve.
10. Support the new valve and fit the electrical connection to it. Secure the connection with its
screw.
11. Refer to the information sheet for connections if an option is being added.
12. Fasten the air line to the fitting on the bottom of the valve.
M-371 4-7
Air Blast Options
There are two air blast system options on the machine. One air blast system is on the headwall and
the other system is on the cross slide coolant/air blast manifold. Each air blast system carries a force
of air from the machine air supply system and directs it wherever necessary. When the machine’s air
system is active, an air blast can clean chips from the workholding device or from tooling. Flexible cop-
per tubing mounted in standard brass fittings directs air at any position desired by the operator.
TP186.
TP185. Figure 4.8 - Cross Slide Air Blast and

Figure 4.7 - Headwall Air Blast Coolant Nozzles
The air blast system can be activated by programmed M codes. The headwall air blast is program
activated by an M36 code and deactivated by an M37 code. The cross slide air blast is activated by an
M46 code and deactivated by an M47 code. Both air blast locations can also be activated by the AIR
BLAST pushbutton near the middle of the main control panel. If the air blast has been activated by a
programmed code, pressing the AIR BLAST pushbutton will turn the air blast off and vice versa. When
the pushbutton is pressed, both locations are activated unless there are plugs in the fittings.
The thru-headwall air blast line is added to the existing manifold assembly in the valve compart-
ment. Two copper tubes, Figure 4.7, are mounted in standard elbow fittings from a “Tee” fitting. The
tubing can be replaced with a pipe plug to seal either fitting.
The cross slide coolant and air blast manifold is controlled by another valve and solenoid in the
valve compartment. Three copper tubes are mounted in standard straight fittings in the cross slide
coolant and air blast manifold. These tubes can also be replaced with pipe plugs when any of them are
not needed.
If the air blast options are to be retrofitted to a machine, information for the electrical connections of
the solenoids and mounting instructions are included in the kit.
4-8 M-371
- NOTES -
M-371 4-9
- NOTES -
4 - 10 M-371
CHAPTER 5 - COOLANT FACILITIES
Hardinge machine tools are designed using the latest technology and highest quality materials
available. However, due to the ever increasing number of coolant selections available, it is impossible
to test material compatibility with each and every coolant. For additional information regarding the
coolant facilities on this machine, refer to the Operator’s Manual (M-370).
- CAUTION -
Whenever water soluble coolants are used it is important to use the manu-
facturer’s recommended mix ratio (concentration). It is also important to
maintain the coolant by keeping the proper concentration level when coolant
solution is added to compensate for evaporation. Another important factor is
coolant Ph (acidity). Typically, the coolant Ph range is between 8.5 and 9.2.
Below 8.5 the rust inhibitors in the coolant start depleting, which can result
in corrosion of machine components. Also, the quality of the water should be
tested by the coolant manufacturer so that the proper coolant additives can
be administered. Failure to follow these recommendations could result in
damage to the machine, seals, and paint.
If the coolant you have selected starts to react (cause material to rust, pit,
swell, soften, crack, blister etc.) with any portion of the machine tool,
Hardinge suggests that you discontinue use and contact your coolant 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
assure that the material you are cutting does not react with the coolant you
have selected.
- NOTE -
A properly selected and maintained coolant, either oil or water based, will ensure
the best performance from the coolant and machine.
INTRODUCTION
The CONQUEST® GT27 and CONQUEST GT27SP Autoload™ systems have a coolant recircu-
lating module for either oil-based or water-based coolant. The module consists of a reservoir (tank)
with filters, a five-eighth horsepower electric pump, fully adjustable directional hoses on the headwall
and cross slide, a chip flush block with hoses on the right side wall, and a coolant catcher on the cover
of the spindle compartment. Coolant is fed to the tool tips and workpiece through the directional
hoses. Most of the fluid drains down into the tank through the chip pan, however, some liquid returns
to the tank through a hose from the coolant catcher in the spindle drive compartment.
At the beginning of each shift, clean the pan of most of its chips and then pour coolant directly into
the pan. Fill the coolant reservoir to the FULL line (28 gallon [106 liter]) of the sight gauge on the tank.
M-371 5-1
The coolant module is ready when the machine is powered up. The control panel pushbutton acts
counter to the program; that is, when the program calls for coolant and coolant is not wanted at that
time, the coolant can be shut off by pressing the COOLANT pushbutton. The opposite is also true. If
the program does not call for coolant and it is needed, coolant can be activated by pressing the Cool-
ant pushbutton. If coolant flow is not activated by a programmed M08, M13, or M14, pressing the
Coolant pushbutton will start coolant flow. However, each time the program is repeated, the
pushbutton must be pressed again to activate the coolant when it is needed.
The adjustable nozzles direct coolant wherever they are set. Each in-line valve regulates flow to the
nozzles and connects the directional hoses to the headwall fitting or to the manifold mounted on the
cross slide.
WATER-BASED COOLANTS
Water-based coolants are a popular cutting fluid which, when improperly specified or maintained,
can affect the life of a machine and the quality of the parts made on it. Water-based coolants are de-
signed to suppress rusting, enhance cutting, increase tool life, promote heat dissipation, and be eco-
nomical. Some coolants may cause machine corrosion problems and be incompatible with machine
components. Poorly maintained coolants may result in rancidity, poor tool life, staining, rusting, foam-
ing, etc., which affect machine performance and may cause health problems such as dermatitis. Wa-
ter-based coolants must be correctly specified according to the machined materials and compatibility
with machine components. Refer to the list of common materials used in machine tool assembly at the
end of this section.
It is very important to follow the coolant manufacturer’s recommendations when using a water
based coolant. Maintaining coolants will increase the machine’s useful life and will minimize
corrosion, rusting, staining, etc., and health problems such as dermatitis, that are normally
exhibited with “used” coolants. This maintenance should include a minimum of daily checks and
correction of coolant concentration, a measure of coolant pH (acidity), and removal of any tramp oil
from the machine sump.
Concentration:
The coolant concentration should be checked and corrected on a daily basis using a refractometer.
The refractometer is a hand held optical device that gives a fairly reliable reading. However, its accu-
racy can be impaired by tramp oils, cleaners, and other contaminants.
Proper concentration control is essential for optimal tool life, corrosion control, and inhibiting bacte-
rial growth. Water soluble coolants lose water by evaporation during normal operating conditions
which tends to increase the coolant concentration over a normal work shift. The coolant concentration
must be checked each day.
The coolant concentration must be kept within the specified range determined by the coolant man-
ufacturer. Failure to maintain the coolant concentration within this range may result in poor perfor-
mance from that fluid. Lean concentrations can lead to rust, rancidity, short tool life, and other
problems. Rich concentrations can result in foam, residues, health problems such as dermatitis, and
increased coolant costs.
pH:
pH is a measure of a solution’s alkalinity or acidity. There are two common methods used to deter-
mine pH. One method is the use of special pH test paper and the other is a pH meter.
5-2 M-371
Water based coolants are designed to run within the pH range determined by the manufac-
turer. The pH of water based coolants typically runs on the alkaline side of the pH scale. A drop in pH
indicates a growth of microbiological organisms (bacteria). These anaerobic bacteria live on the
tramp oils and additives found in the coolants. When these bacteria feed on the oils they release an
acidic by-product which eventually drives the coolant towards a lower pH level. Typically, the pH
range is between 8.5 and 9.2.
Water Quality:
The water quality is also an important factor toward achieving optimum coolant performance. Wa-
ter that contains dissolved minerals, bacteria, and other impurities (hard water) can some-
times adversely affect the coolant selected. An indication of water related problems is the
formation of a soap like scum which adheres to sumps, filters, etc. It is best to consult with your coolant
representative to determine your requirements.
Care and Maintenance:
A daily check of the concentration and pH will help keep the coolant at its optimum performance
level. In addition to these checks, any tramp oil must be removed from the coolant. Frequent removal
of tramp oils will limit the growth of anaerobic bacteria which cause the rancid odors and feed on the
additives in the coolants.
Make-up coolant should be added when needed and according to the manufacturer’s recommen-
dation. This make-up coolant is necessary to provide additional fresh coolant which contains the es-
sential additives required to keep the coolant performing properly.
Clean and replace the coolant per the coolant manufacturers recommendations. Proper cleaning
of the machine is very important before refilling the reservoir with fresh coolant. Dispose of
the used coolant properly. Bacteria live and cling to all wetted surfaces in the machine. Special
cleaners, usually available from your coolant supplier, are recommended to flush the system before
refilling. These cleaners will kill the bacteria left after draining the machine. It also is recommended
that a thorough cleaning, which includes scraping and removing any sludge found on the bottom and
hidden in the top panels of the coolant reservoir, be completed before circulating cleaner through the
system.
When the coolant facilities require maintenance, the machine must be powered down. A detailed
procedure to power down the machine appears in Chapter 2 - POWER-UP PROCEDURE.
1. Be certain that “Cycle Start” is not active. The pushbutton light will be OFF.
2. Be sure the program has been completed and that the spindle, slides, and gantry are sta-
tionary.
3. Press the Emergency Stop pushbutton.
5. Turn main air lock out valve OFF.
6. Turn main disconnect switch OFF and lock it out.
M-371 5-3
Removing Chips and Shavings
The chip pan/coolant reservoir is mounted on wheels and the coolant pump is removable, so that
the reservoir may be moved straight out from under the machine.
- WARNING -
Use a rake and suitable container to remove metal chips and shavings from
the chip pan. Injury may result from attempting to remove chips without a
rake.
To remove chips from the chip pan/coolant reservoir:
2. Wait a minute to allow the coolant to drain
into the tank. A
3. Locate coolant pump “A”, Figure 5.1,

mounted near the left end of tank “B”, as
viewed from the rear of the machine.
Unthread the screws from the coolant pump
flange and carefully lift the pump from the
tank. B
If necessary, unplug the chip conveyor elec-
trical cable.
4. Roll the tank straight back to an area where
it is most convenient to remove the metal
chips or shavings.
5. Rake the chips into a suitable container and C TP3430
dispose of them properly. Figure 5.1 - Coolant Pump and Reservoir

6. Return the tank to its opening under the ma-
chine.
7. Place the coolant pump in its opening in the tank. Align the mounting holes in the pump
flange with the threaded holes in the tank; thread in and tighten the screws.
8. Check inside the work area to see that coolant will drain into the chip pan. Correct any
problems before powering up the machine and turning the coolant on.
Cleaning the Reservoir and Filters
Clean the coolant reservoir (tank) at least once every six months or more frequently if the coolant
becomes contaminated by material being cut. Clean the reservoir whenever changing the type or
brand of coolant. The coolant catcher on the cover of the spindle compartment should also be cleaned
at the same time that the reservoir is cleaned.
To clean the reservoir and filters:
1. Follow directions 1 through 5, in “Removing Chips and Shavings”, this chapter, to remove
the tank and clean the chip pan.
- WARNING -
Use a rake and suitable container to remove metal chips and shavings from
the chip pan. Injury may result from attempting to remove chips without a
rake.
5-4 M-371
2. Place a shallow pan under tank drain spigot “C”, on the left end. Remove the pipe plug to
drain the coolant from the reservoir.
3. Lift the chip deflector from the chip pan or chip conveyor and lift the covers off the coolant
reservoir filter assemblies.
- CAUTION -
Be careful, wear protection against metal slivers and cuts, when removing
metal chips or shavings with the coolant from the reservoir.
4. Remove any coolant still in the reservoir. Wipe the reservoir clean.
5. Be aware of how each filter assembly is mounted in the frame in the reservoir. Lift the filter
assemblies from the tank, one at a time.
6. Shake out the metal chips and then clean the filter assembly. Wipe the assembly clean.
7. Wash the reservoir and filter assemblies with a cleaner recommended by the coolant man-
ufacturer to remove bacterial contamination. Flush the cleaner from the reservoir and clean
it as recommended by the coolant manufacturer.
8. Apply pipe sealant to the pipe plug and thread it in to seal drain spigot “C”, Figure 5.1.
9. Align each filter assembly in its frame and fit it into the tank. Do not force the filter assem-
bly into the frame, each will fit only one way and should not be altered to fit differently.
10. Fit the tank covers in place and install the chip deflector.
11. Return the tank to its space under the machine.
12. Place the coolant pump in its opening in the tank. Align the mounting holes in the pump
flange with the threaded holes in the tank; thread in and tighten the screws.
13. Check inside the work area to see that coolant will drain into the chip pan.
14. Pour coolant directly into the chip pan. Refill the reservoir with the desired coolant.
Coolant In-line Valves and Hoses
The adjustable Snap-Loc® hoses can be adjusted to any angle by simply bending or forming the
links until the desired position is obtained. There are coolant valves and hoses on the headwall and on
the cross slide coolant/air manifold.
To adjust the nozzle length and position:
2. Separate ball links at one spot in nozzle “D”,
Figure 5.2, by pulling it apart or rotating a
link further than it normally goes. E
3. Remove or add links to change the length of

the hose as desired. D
4. Re-attach the separated length by pressing
the links together.
5. Adjust the angle and position of the hose to
be certain that the length is correct.
TP191
Figure 5.2 - Headwall Coolant Valves

and Nozzles
M-371 5-5
To replace coolant hoses or in-line valves:
2. Unscrew the threaded link of the hose from
headwall valve “E”, Figure 5.2, and/or from
cross slide coolant/air manifold valve “F”,
Figure 5.3.
3. When the valve has to be removed, unthread
it from the fitting on the headwall or from the
manifold.
- NOTE - F
Use pipe thread sealant on the fitting
threads when replacing either the
valves or adjustable hoses.
4. Thread the valve into the fitting or manifold
and then thread the hose into the valve.
TP192
5. Adjust the length and/or angle of the hose to
direct the coolant. Figure 5.3 - Cross Slide Coolant Valves
and Hoses
6. Power up the machine and adjust the coolant
flow as necessary.
Replacing the Coolant Pump

Coolant pump “G”, Figure 5.4, is located on the reservoir at the left as viewed from behind the ma-
chine. The five-eighth horsepower motor draws coolant from the reservoir and pushes it to the
headstock and cross slide hoses and the chip flush block.
To replace the coolant pump:
2. Wait a minute to allow the coolant to drain
into the tank.
3. At the rear of the machine, unthread the G
screws from the coolant pump flange and
carefully lift the pump from the tank.
4. Follow the electrical cable from the pump to H
the side of the power case; unplug the cool-
ant pump cable from the connection.
5. Loosen the clamps to the hoses so that the
brass fittings can be unfastened to release
the pump. Do not cut the hoses unless the
fittings will not turn within the hoses when TP3429
the clamps are loosened. There is enough
hose if it is necessary to trim the hose to re- Figure 5.4 - Coolant Pump, Coolant
lease the fittings. Plumbing and Hoses
5-6 M-371
6. Remove any plumbing fittings that might be necessary for re-installation of the hoses on
the replacement pump. Some check valves may be located located vertically as in Figure
5.4 or they might be on a straight nipple and lay horizontally.
Use pipe thread sealant on the threads when installing the fittings on the new pump.
7. Attach the coolant hoses to the pump. Tighten the clamps on the hoses.
8. Feed the pump electrical cable to the side of the power case and plug it in.
9. Make certain that the coolant hoses are not kinked when placing the pump in the reservoir.
Align the mounting holes in the pump flange with the threaded holes in the tank; thread in
and tighten the screws.
- NOTE -
If the pump needs to be primed, place a flexible piece of hose, approximately 16
[406.4mm] to 18 [457.2mm] inches long, over a coolant nozzle on one of the hoses
mounted on the headwall. Cut a hole 2 [50.8mm] inches from the end of the hose
where the coolant comes out of the hose. Make the hole large enough to insert an
air hose tip to create a vacuum when the air is turned on to help draw the coolant
through the system when it is activated.
10. Power up the machine and activate the coolant. Check the fittings for leaks.
Coolant Catcher
The coolant catcher returns coolant that flows through the rear of the spindle to the reservoir. The
catcher is part of spindle compartment cover “I”, Figure 5.5. The coolant returns from the catcher to
the tank through a hose that is mounted in the headwall. If the rest of the coolant system is being
cleaned, the catcher and return hose should also be cleaned.
1. Make certain that the power is OFF.
2. Turn the main disconnect switch OFF.
3. Remove spindle compartment cover “I”, at
the left end of the machine as follows:
A. Unthread four panhead screws and rotate
the left end of the cover, when facing the
cover, out for enough clearance to discon-
nect the coolant return hose.
B. Locate the hose fastened to the nipple on
the bottom of the coolant catcher mounted
on the spindle compartment cover. Un-
screw the hose clamp to release the hose.
C. Rotate the cover further and pull it straight I
out of the tab in the lower right corner.
4. Access the coolant catcher on the cover;
wipe out any liquid that remains in the
catcher.
5. Wash the catcher with a cleaner recom-
mended by the coolant manufacturer.
TP2343.
Figure 5.5 - Spindle Compartment Covers
M-371 5-7
6. Insert the compartment cover in the tab at
the lower right corner and connect the hose
to the nipple on the catcher.
7. Mount the cover and tighten the screws.
8. Flush the coolant catcher to clean the return
hose. Check the reservoir to see that the
cleaner flows through the hose into the tank.
9. Clean the catcher and hose again. Flush the
catcher and hose.
10. Fasten the cover in place with its screws.
11. Do what is necessary to clean and ready the
coolant reservoir as described earlier in this
chapter.
12. Pour coolant directly into the chip pan. Refill TP3540.
the reservoir with the desired coolant. Figure 5.6 - Spindle Coolant Catcher
Power up the machine and test the coolant
flow.
- NOTES -
5-8 M-371
CHAPTER 6 - PART LOAD/UNLOAD GANTRY
Introduction
The GÜDEL gantry in the machine cell with the
CONQUEST® GT27 and GT27SP series machine is
a parts load/unload system. It is an integral part of A
this machine being aligned on towers that are
mounted directly to the Harcrete® machine base. For
detailed gantry maintenance refer to the GÜDEL
“Operation Manual” provided with the machine.
Gantry system “A”, Figure 6.1, on top of the ma-
chine requires little routine maintenance with the ex-
ception of the “repair-by-replace” part-gripping
fingers and lubrication of rollers and rails, and gear
teeth. The part-gripping fingers are replaced when
there is a change in the workpiece being made or
when they become so worn that they no longer safely
grip the workpiece; they must be replaced as a set. TP3409
.
Each month or as required, add lubrication to the Figure 6.1 - Gantry Location Above
gantry grease blocks. Or if the gantry has the optional Machine
grease packs (automatic lubricators), replace them
every six months or when signs of tribocorrosion be-
gin.
Gantry Lubrication
- NOTES -
Move the gantry to a convenient work position in front of the main coolant door and
retract the gantry arm (up). Make certain that the spindle, machine axes and gantry
are stationary before opening the main coolant door.
Tribocorrosion is red coloration of the running track indicating direct metal to metal
contact and insufficient lubrication.
There are four grease blocks for each gantry axis; “B”, Figure 6.2, for the Y-axis
and “C”, Figure 6.3, for the Z-axis.
To grease the gantry axes:
1. Position the gantry and open the main cool-
ant door. B
3. Locate the four Y-axis grease blocks, Figure
6.2. Wipe the grease nipples clean with a
lint-free cloth.
TP3554
.
Figure 6.2 - Gantry Y-Axis Grease Blocks
M-371 6-1
- NOTE -
Hardinge recommends KLÜBER NCA
15 (Hardinge part number TT
00010994NCA) grease in the gantry
axes grease blocks.
4. Align the grease gun nozzle on the grease
block nipple; pump the specified grease into C
the block until fresh grease can be seen near
each grease block grease opening.
5. Locate the four Z-axis grease blocks, Figure
6.3; the lower left grease block is up in front
of the proximity switch block bracket. Wipe
the grease nipples clean with a lint-free cloth.
If this gantry position is too difficult to reach
the Z-axis grease nipples, power up the ma-
chine to jog the gantry to the far right (+Z) TP3558.
and power the machine down again. At the

right rear of the machine, remove the guard Figure 6.3 - Z-Axis Grease Blocks
to access the grease nipples.
6. Align the grease gun nozzle on the grease block nipple; pump the specified grease into the
block until fresh grease can be seen near each grease block grease opening.
7. Check the condition of the part-gripping fingers while being in that close to the gantry; re-
place them as necessary.
8. Close the door and power up the machine. Move each gantry axis its full travel distance
several times.
Gantry Pneumatic (Air) Panel
Solenoid valves “D”, Figures 6.4 and 6.5, mounted on the air panel on the gantry platform activate
air cylinders to maneuver the gantry wrist and grippers.
To replace a solenoid valve:
the air lock out valve is OFF. Align the
OFF position.
2. Refer to the schematic chart on the panel to
identify which valve needs to be replaced.
3. Unthread the screw and remove the end
plate from the stack of solenoid valves.
4. Unscrew the two fasteners that mount the
end cap and each valve to its adjacent valve
until the valve to be replaced is removed or
until the new valve can be added to the D
stack of valves.
TP3556.
Figure 6.4 - Gantry Pneumatic (Air) Panel
6-2 M-371
- NOTE -
It is not necessary to remove the elec-
trical connection or air line from valves
that are not being replaced.
5. Unthread the screw that secures the electri-
cal connection to the solenoid valve being re-
placed. Pull the connection straight up to re-
lease it from the valve. D
6. Unthread the air line from the fitting on the

valve being replaced. If necessary, remove
the pneumatic fitting from the valve.
7. Thread an air fitting to the new valve. Use
sealant to secure the fitting but do not apply
it to the first few threads.
8. Mount the new valve to the end piece or ad-
jacent valve on the panel. Check the valve TP3557
.
gaskets and replace any that are worn. Fas-
ten each valve and gasket in place. Figure 6.5 - Gantry Air Panel
9. Check the gaskets and mount the other
valves and end plate to the new valve.
10. Support the new valve and fit the electrical connection to it. Secure the connection.
Gantry Axes Drive Motors
The gantry is a two axes parts load/unload system. Each axis has a drive motor and gear box to
move the gripper in the Y-axis and Z-axis directions. The drive motor/encoder assembly is an integral
unit that must NOT be separated from the motor. The motor drive shaft uses a coupling on a splined
shaft for direct drive and the axis drive motor flange mounts the motor directly to the gear box.
To replace the gantry axes drive motor(s):
- NOTES -
Although it is best to work on the gantry drive motor(s) when the gantry is at the
Home position, it may be necessary to replace/work on it anywhere along the gan-
try travel.
Depending on the type of load/unload system, it may be necessary to remove the
canopy from the top front right of the machine or stand on a platform at the rear to
access the gantry axes drive motor(s).
1. If possible, Home the gantry axes; or, jog the gantry arm up and out of the machine
workarea.
M-371 6-3
3. Gain access to the gantry axes drive mo-
tor(s). F
Unthread the screws and remove the canopy
from the top front right of the machine or
build a platform to act as a staging to work
on the drive motors. It may be necessary to
E
use an approved ladder if the gantry drive
motor is in other positions.
4. Tag the electrical connections to the encoder
and motor for re-assembly. Note the position
of the electrical connection outlets in relation
to the gantry platform before unfastening the
motor.
5. Unscrew each screw and pull the cable con-
nector straight out from the encoder connec-
tion and from motor connection.
NOTE - TP3554.
The drive motor weighs approximately
30 pounds [13.6 kg]. Figure 6.6 - Z-Axis Drive Motor
6. Unthread four screws that mount the motor
to the gear box. Carefully lift the motor and
attached coupling from the gear shaft and
platform.
7. Loosen the clamp screws in the coupling
shoulder and unfasten the coupling from the
motor drive shaft.
8. Mount the coupling to the drive shaft on the F
new motor as follows:
A. Place the coupling all the way on the drive
shaft of the new motor.
B. Tighten the coupling screws to 12 lb-in
torque.
9. Lift the axis replacement motor; carefully
align the coupling with the splined end of the
gear box; position the electrical connection TP3557.
outlets per step #4 and loosely mount the
drive motor to the gear box with four screws Figure 6.7 - Y-Axis Drive Motor
“D”, Figures 2.4 and 2.5, finger tight.
10. Make certain that lockwashers are in place and tighten the four screws that mount the
drive motor to 85 lb-in torque.
11. Connect the motor and encoder electrical sources per step #4. Tighten the screws to se-
cure the connections.
6-4 M-371
- NOTE -
Because the motor/encoder assembly has been disconnected from the gear box,
the control does not know the position of the gantry axes. This may cause a
SOFTWARE OVERTRAVEL message to be displayed when the control is powered
up even though an overtravel condition does not exist.
12. Mount the gantry home fixture to the top (tool) plate. The fixture is a standard HG5 tool
holder with .50 inch [12.7 mm] collet bushing and a pointed, line-scribed and numbered,
homing bar.
Center the fixture on the 0 on the top plate; then, insert the homing bar 30 to 40 milli-
metres into the fixture collet bushing.
13. Power up the machine. If information is necessary to power up the machine refer to
Hardinge Operator’s manual M-370.
Zero return (Home) both machine axes. The X Home position puts the homing bar at the
spindle centerline.
14. Clear the feed hold (alarm) condition and reset the gantry as follows:
A. Press the F1 key until PATH soft key is present; press the F10 key to activate the path
setting sub screen. The sub screen will display GANTRY or MTOOL (machine); if
MTOOL is displayed, press the directional up or down arrow directional keys to change
to GANTRY.
B. Press the E-Stop pushbutton and make certain that it remains down.
C. Press OFFSET SETTING key to display the Setting (HANDY) page.
D. Press the PAGE down ( ⇓ ) or up ( ⇑ ) until the cursor is at Parameter WRITE.
E. Change Parameter WRITE from 0 to 1 (enable). Press key 1 and then the INPUT soft
key or INPUT key.
F. Press the SYSTEM key and PARAMETER soft key. Enter 1 8 5 0 and press the
No.SRCH (search) soft key.
G. At 1850 Z, key in 0 and press the INPUT soft key. An alarm may be displayed; if an
alarm is displayed, power down and, then, power up the control.
H. Press the SYSTEM key and PARAMETER soft key. Enter 1 8 1 5 and press the
I. At 1815 bit 4 Z (APZ), key in 0 and press the INPUT soft key.
J. Press the Control OFF [O] [55PB] pushbutton and wait momentarily; press Control ON [
l ] [56PB] pushbutton (power down and power up).
K. Pull the E-Stop pushbutton out and, then, pull it further out and hold it momentarily to re-
lease the Emergency Stop.
L. Open both the main guard door and coolant guard door to the work area.
M. Rotate the wrist in the clockwise position and, then, move the shuttle to the IN position.
Jog the gantry in front of the spindle.
M-371 6-5
N. Slide the homing bar toward the spindle until it makes contact with the gripper.
Jog the gantry Z axis in the plus (+) direction to the scribed line flush with the collet
bushing as referenced by the “brass tag” numbers on the chart inscribed on the fix-
ture. (The gripper moves the homing bar back into the gantry home fixture.) This is
the gantry Z axis home position.
O. Set the gantry axis as follows:
1. Remove (pull) the homing bar from the gantry home fixture.
2. Make certain that the control is in JOG mode. If necessary, quick page to MODE;
press JOG soft key.
3. Press POS pushbutton, then, REL soft key.
4. Press W and then press the ORIGIN soft key. The gantry Z axis will change to 0.
Press U and then press the ORIGIN soft key. The gantry Y axis will change to 0.
5. Jog the Y axis up until the position display reads 546.100. This positions both the Z
and Y axes at their Home position.
6. Press SYSTEM key and the PARAMETER soft key.
7. Enter 1 8 1 5 and press the No.SRCH soft key.
8. At 1815 bit 4 Z (APZ), key in 1 and press the INPUT soft key.
And, at 1815 bit 4 Y (APZ), key in 1 and press the INPUT soft key.
P. Press the Control OFF [O] [55PB] pushbutton and wait momentarily; press Control ON [
l ] [56PB] pushbutton (power down and power up).
Q. Change Parameter WRITE back to 0 as follows:
1. Press the E-Stop pushbutton and make certain that it remains down.
2. Press OFFSET SETTING key to display the Setting (HANDY) page.
3. Press the PAGE down ( ⇓ ) or up ( ⇑ ) until the cursor is at Parameter WRITE.
4. Change Parameter WRITE from 1 to 0. Press key 0 and then the INPUT soft key or
INPUT key.
15. Close both the coolant guard door and main guard door.
16. Turn the MACHINE/BOTH/GANTRY [6SS Path Select] selector switch to GANTRY and re-
set the Y and Z gantry axes.
17. Turn the MACHINE/BOTH/GANTRY [6SS Path Select] selector switch to MACHINE.
Press the Zero Return [6] pushbutton to reset the X and Z machine axes.
18. If necessary, install the canopy or remove any platform or ladders from the work area.
6-6 M-371
- NOTES -
M-371 6-7
- NOTES -
6-8 M-371
CHAPTER 7 - HEADSTOCK AND SPINDLE DRIVE
Introduction
The headstock, “A”, Figure 7.1, and spindle assembly are mounted on riser block “B”. The riser
block is mounted to a cast iron insert in the Harcrete™ polymer composite base. The headstock is a
solid, ribbed, cast-iron housing that dissipates heat and supports the spindle assembly.
The standard collet spindle is an ANSI A2-4 5C
collet design that permits bar work up to 1-1/16"
[27mm] diameter. It is also possible to use a 4 inch
chuck on this spindle nose.
The headstock and spindle assembly must not be
disassembled in the field. After the headstock is as-
sembled, the spindle nose is ground to center and
then the pulley is ground. The runout on the face of
the pulley should be no more than .0001" [.0025 mm]
maximum, Figure 7.2. Check this runout when
mounting the adapter plate and collet closer. A
The AC digital spindle drives and motors are reli-

able. They require minimal maintenance because B
they are fan cooled, brushless, and permanently
sealed and lubricated. Drive vibration is minimized by
the use of a vee-belt that transfers power from the
drive motor to the spindle.
When anything in the spindle compartment re-
quires maintenance, the machine must be powered
down. A detailed procedure to power down and lock
out the machine appears in Chapter 2 - Power-Up
Procedure.
Power-Down Procedure TP3536.
1. Be certain that Cycle Start is not active. The Figure 7.1 - Headstock and Riser Block
pushbutton light will be OFF. in Spindle Compartment
2. Make sure the program has been completed
and that the spindle, slides, and gantry are
stationary.
.0001" [.0025mm]
3. Press the Emergency Stop pushbutton. T.I.R. maximum
4. Turn the Control switch to the OFF (0) posi-
tion.
5. Turn the air valve OFF and lock it out.
6. Turn the main disconnect switch OFF and
lock it out. .0001" [.0025mm]
T.I.R. maximum
TI2167
Figure 7.2 - Runout on Lip and Face

of the Spindle Pulley
M-371 7-1
Spindle Draw Tube Plug
The spindle draw tube plug is inserted in the rear
opening of the draw tube to contain coolant and/or
chips when a bar feed is not being used. Put the plug
into the tube up to the flange, insert a small rod or
allen wrench to turn the plug shaft clockwise and ex-
pand the rubber seal within the tube. Remove the rod
or wrench immediately after seating the plug in the
tube.
TP3540.
Figure 7.3 - Spindle Draw Tube

(without Plug)
Spindle Drive Belt Adjustment
The spindle drive belt tension is adjusted by moving the drive motor platform up or down. Belt ad-
justment can be made with just the lower cover of the spindle compartment off. However, to accurately
test the belt deflection, also remove the upper cover.
2. Remove the spindle compartment covers at the left end of the machine as follows:
A. Unthread the panhead screws and lift off lower spindle compartment cover “D”, Figure
7.4.
B. Unscrew the hose clamp to release the
coolant return hose fastened to the bot-
tom of the coolant catcher mounted inside
upper spindle compartment cover “C”.
C. Unthread the panhead screws on the up-
per compartment cover. Pivot the left side
out and pull straight back to release the
cover.
3. Loosen, but do not remove, four screws “E”,
Figure 7.5, that mount the drive motor plat-
form to the Harcrete base. These four
screws secure the platform once the
vee-belt has been adjusted. C
- NOTE -
The belt tension specification is .30"
[7.6 mm] belt deflection at 6.7 to 9
pounds [3 to 4 kg] force when using a
spring gauge. The static tension read
on an OPTIBELT gauge is 100 to 105 D
pounds [45.4 to 47.6 kg] force.
TP3531.
Figure 7.4 - Spindle Drive Compartment

Covers
7-2 M-371
4. Adjust the drive belt tension by moving the
drive motor platform toward or away from the
spindle centerline. The screw in adjustment
block “F”, Figure 7.5, supports the platform
and moves it toward the centerline for less
belt tension or away from the centerline for
more belt tension.
5. Secure the platform after setting the belt ten-
sion specification. Tighten four locking
screws “E”, to 230 lb-ft [312 Nm] torque.
6. Power up the machine and test the machine
at various rpm.
Power down the machine and mount the E
compartment covers as follows: E
A. Mount the upper compartment cover on

the machine. F
B. Connect the hose to the fitting on the TP3536
.
coolant catcher. Figure 7.5 - Drive Motor Platform Bolts

C. Mount the lower spindle drive compart- and Adjustment Block
ment cover and fasten it in place with its
screws.
Spindle Drive Belt Replacement
Spindle drive belts are very reliable; however, belts should be checked for wear and tension every
500 hours of operation.
1. Power down the machine. Make certain that the main air valve is locked out and, if the ma-
chine has the big bore optional spindle, bleed off the air from the air receiver (unthread the
drain on the bottom).
7.4.
B. Unscrew the hose clamp to release the coolant return hose fastened to the bottom of
the coolant catcher mounted inside upper spindle compartment cover “C”.
C. Unthread the panhead screws on the upper compartment cover. Pivot the left side out
and pull straight back to release the cover.
3. Loosen, but do not remove, four screws “E”, Figure 7.5, that mount the drive motor plat-
form to the Harcrete base. These four screws secure the platform once the vee-belt has
been adjusted.
4. Belt tension can be released by threading the screw in adjustment block “F”, Figure 7.6, to-
ward the spindle centerline. Loosen the tension enough to allow the belt to be removed
from the drive motor pulley.
M-371 7-3
5. Disconnect and remove the following to allow
R
the belt to be removed:
R
A. Tag the following lines for identification
and disconnect them from the spindle, col-
let closer and Z-axis drive motor:
G
1. Disconnect air brake hose “J”, and dis-
connect collet open line “H”, and collet H
close line “I”.
2. Unthread the knurled nuts and discon-
nect electric lines “K” to the axis motor I
by pulling them straight off.
B. Unfasten collet closer bracket “G”.
C. Unthread screws “R” and remove the en- J
coder assembly from the top of the
headstock as follows: K
1. Loosen two screws “R”, and loosen the
belt from the encoder.
2. Unthread the screws and remove the
encoder assembly. Lay the encoder as-
sembly on the headstock. L
6. Remove the spindle drive belt from the spin-

dle pulley and put the replacement belt on
this pulley.
- NOTE -
M
The belt tension specification is .30" [7.6
mm] belt deflection at 6.7 to 9 pounds [3 to
4 kg] force when using a spring gauge. N
The static tension read on an OPTIBELT
gauge is 100 to 105 pounds [45.4 to 47.6
kg] force. O E
E
7. Place the belt in the grooves on the drive
pulley. Adjust the belt tension by turning the
F
screw in adjustment block “F” away from the TP3536.
spindle centerline.
Figure 7.6 - Spindle Drive Belt and
8. Tighten four locking screws “E” to 230 lb-ft
[312 Nm] torque after the platform is in Hydraulic Lines
place.
9. Fasten collet closer bracket “G”, in place with its screws.
10. Connect lines “H”, “I”, “J”, and “K” to their respective connectors.
11. Remount the encoder assembly on the headstock as follows:
A. Slip the spindle timing belt over the encoder pulley.
B. Mount the bracket in place but do not tighten screws “R".
- NOTE -
The belt tension specification is 0.10" [2.5 mm] belt deflection measured at the
midpoint between pulleys at an applied force from .35 to .42 pound [.16 to .19 kg].
C. Pivot the encoder bracket to set the belt tension. Retighten screws “R” to 25 lb-ft
[34 Nm] torque when the belt tension specification is met.
7-4 M-371
- NOTE -
The spindle is oriented when the spindle key in the spindle nose is at the 12
o’clock (straight up) position.
13. Test the new spindle belt at various rpm.
14. Power down the machine and mount the spindle compartment covers.
Spindle Drive Motor Replacement and Alignment
The spindle drive motor is mounted to a plate that is mounted to the drive motor platform. This plate
has four slots to allow belt alignment after the motor has been removed or replaced. Spindle drive belt
tension is adjusted by moving the drive motor platform.
The drive motors are very reliable and require minimal maintenance because they are fan cooled,
brushless, and permanently sealed and lubricated.
To replace and align the drive motor:
1. Power down the machine and lock out the main disconnect switch.
2. Follow steps #1 through 5 in “Spindle Drive Belt Replacement” to remove the spindle com-
partment covers and releasing the belt tension.
3. Disconnect the power cable from the drive motor as follows:
A. Remove the screws and take the cover from electrical junction box “L”.
B. Make a diagram of the wire connections and what lead cables enter the box through
which cord grip.
C. Release the knurled nut from each cord grip and pull the grommet and nut back on the
lead cables.
D. Unfasten the wires from the terminal strips in the junction box. Carefully pull the wires
from the box.
4. Remove four bolts “M” to release the motor from the plate. Do not loosen four screws “N”
that mount the plate to the platform.
5. Lift the motor from the drive compartment with the help of another person or a hoist.
6. Unfasten, if necessary, the pulley from the old motor and mount it on the new motor.
7. Lightly grease the contact surfaces and install the new motor on the plate. Thread four
bolts “M” into the plate but do not tighten them.
8. Slip the drive belt over the motor pulley and visually align the motor pulley with the spindle
pulley.
9. Tighten the four bolts to 30 lb-ft [41 Nm] torque.
- NOTE -
The belt tension specification is .30" [7.6 mm] belt deflection at 6.7 to 9 pounds [3
to 4 kg] force when using a spring gauge. If the static tension is read with an
OPTIBELT gauge, the force is 100 to 105 pounds [45.4 to 47.6 kg].
10. Adjust the belt tension by moving the drive motor platform away from the spindle center-
line. Tighten four locking screws, “E” to 230 lb-ft [312 Nm] torque to secure the platform.
M-371 7-5
11. Loosen four screws “N” to move the plate on the platform if further belt alignment is neces-
sary. Loosen or tighten platform alignment screw “O”, after the belt is aligned. Align the belt
and retighten the screws to 50 lb-ft [68 Nm] torque.
12. Feed the lead cables through the cord grips to the junction box and connect the power ca-
ble to the drive motor as follows:
A. Follow the diagram made in step #3.B to fasten the wires to the terminal strips.
B. Slide the grommets in place on the cables in the cord grips. Tighten the knurled nut on
each grip to seal the cables.
C. Make certain that the gasket is in place to seal the junction box. Fasten the junction box
cover with its screws.
13. Power up the machine and test the machine at various rpm.
14. Power down the machine and mount the compartment covers as follows:
A. Mount the upper compartment cover on the machine.
B. Connect the hose to the fitting on the coolant catcher.
C. Mount the lower spindle drive compartment cover and fasten it in place.
Spindle Encoder Timing Belt Adjustment
Spindle encoder “P”, Figures 7.7 and 7.8, is mounted in a bracket on top of the headstock. The
bracket has slotted openings for adjusting the timing belt tension.
7.3.
the coolant catcher mounted inside upper spindle compartment cover “C”.
cover. Q
R P
3. Locate encoder bracket “Q”, Figure 7.7, and
test the belt tension.
- NOTE - R
The belt tension specification is 0.10"
[2.5 mm] belt deflection measured at
the midpoint between pulleys with an
applied force of .35 to .42 pound [.16
to .19 kg].
4. Loosen bracket screw(s) “R”, Figures 7.7 and
7.8, to enable the bracket to be pivoted to
set the belt tension. Retighten the screw(s) TP2364.
to 25 lb-ft [34 Nm] when the belt tension
specification is met. Figure 7.7 - Spindle Encoder Pulley and
Bracket Screws
5. Power up the machine and observe the belt
tension at various rpm.
6. Power down the machine and mount the compartment covers.
7-6 M-371
Spindle Encoder Replacement
Spindle encoder “P”, Figure 7.8, is mounted in a bracket on top of the headstock. Remove the
mounting bracket and encoder to replace the encoder.
2. Remove the spindle compartment covers at
S
the left end of the machine as follows:
A. Unthread the panhead screws and lift off
Q P
lower spindle compartment cover “D”, Fig-
ure 7.3.
coolant return hose fastened to the bottom
R
of the coolant catcher mounted inside up-
per spindle compartment cover.
cover.
TP209
3. Unfasten the knurled nut on the encoder
electrical plug. Pull the plug straight out to Figure 7.8 - Spindle Encoder
release it from the encoder.
4. Unthread two screws “R” to remove mounting bracket “Q”, Figures 7.7 and 7.8, the pulley
and encoder from the headstock.
5. Loosen the set screw in coupling “S”, that fastens the encoder to the pulley shaft.
6. Loosen the three screws that fasten the cam clamps that hold the encoder to the mounting
bracket.
7. Replace the encoder on the mounting bracket as follows:
A. Align the encoder shaft in the coupling opening.
B. Hold the encoder on the bracket and rotate the cam clamps into place.
C. Tighten the three screws to 15 lb-in [1.7 Nm] torque.
D. Tighten the coupling set screw to 11 lb-in [1.3 Nm] torque.
8. Remount the encoder assembly on the headstock. Slip the spindle timing belt over the pul-
ley. Mount the bracket in place but do not tighten screws “R”.
- NOTE -
The belt tension specification is 0.10" [2.5 mm] belt deflection measured at the
midpoint between pulleys at an applied force of .35 to .42 pound [.16 to .19 kg]
9. Pivot the encoder bracket to set the belt tension. Retighten screws “R” to 25 lb-ft [34 Nm]
torque when the belt tension specification is met.
- WARNING -
Make certain that NO ONE is near the operator’s control panel and that the
machine cycle is complete before working in the spindle compartment area
with the machine powered up.
10. Power up the machine and test the machine at various rpm.
Power down the machine and mount the compartment covers.
M-371 7-7
Spindle Encoder Timing Belt Replacement
The spindle encoder timing belt replacement requires that the spindle collet closer, and spindle
drive belt be removed. Spindle compartment covers are removed and installed as in other spindle en-
coder sections.
1. Power down the machine and lock out the main disconnect switch.
2. Remove the spindle compartment covers at the left end of the machine.
3. Loosen, but do not remove, four screws “E”, Figure 7.6, that mount the drive motor plat-
form to the Harcrete base.
4. Turn the screw in adjustment block “F” clockwise to relieve tension on the spindle drive
belt. Enough tension should be off the belt to allow it to be removed from the spindle pulley
in step 11, below.
5. Disconnect air brake hose “J”, and both collet open line “H” and collet close line “I”.
6. Follow detailed directions in Chapter 8 to remove the closer. Loosen the six screws
through the adapter plate and pull the closer assembly out as far as it comes. Unthread the
screws fully until the closer assembly is released.
7. Remove the belt from the drive motor pulley and slide it from the spindle pulley. Turn the
screw in adjustment block “F”, Figure 7.6, clockwise if the belt needs to be loosened more
to removed the belt.
8. Loosen screws “R”, Figures 7.7 and 7.8, and relieve the encoder belt tension.
9. Slip the timing belt from the encoder pulley and remove it from the spindle pulley. Remove
the belt from the spindle assembly.
- NOTE -
The encoder timing belt tension specification is 0.10" [2.5 mm] belt deflection mea-
sured at the midpoint between pulleys at a force of .35 to .42 pound [.16 to .19 kg].
10. Replace the spindle timing belt on the pulleys. Adjust the belt tension and tighten mounting
screws “R”.
- NOTE -
The belt tension specification is .30" [7.6 mm] belt deflection at 6.7 to 9 pounds [3
to 4 kg] force when using a spring gauge. The static tension read on an OPTIBELT
gauge is 100 to 105 pounds [45.4 to 47.6 kg] force.
11. Slide the drive belt onto the pulleys. Adjust the belt tension and tighten all four drive motor
platform screws to 230 lb-ft [312 Nm] torque.
12. Install the collet closer as follows:
A. Clean the spindle bore and use a light coat of Bel-Ray Molylube Anti-Seize® molybde-
num disulfide on the bore and on the outside diameter of the collet closer sleeve.
B. Center the draw tube in the spindle and push it in as far as it will go. Align the air line
tubes in their bracket as the collet closer is pushed into place.
C. Thread the six screws from the adapter into the collet closer hand tight.
D. Push the assembly in further and tighten the screws by hand.
E. Tighten the collet closer screws to 100 lb-in [12 Nm] torque.
13. Connect the collet open/close air lines and air brake hose unfastened in step #5.
7-8 M-371
Headstock Alignment
Headstock “T”, Figure 7.9, is mounted on riser block “U”, by four large screws. It is centered and can
pivot on a dowel pin when the mounting screws are loosened.
The alignment blocks and jack screws are packaged separately and must be mounted to the riser
block before starting the headstock alignment.
To align the headstock:
2. Remove the spindle compartment covers at the left end of the machine per “Spindle Drive
Belt Adjustment” page 7-2.
3. Mount the jack screws in the alignment blocks. Use two screws in each block and mount
the alignment blocks to the front of riser block “U”.
5. Install a 6 inch [152 mm] long arbor.
6. Mount an indicator on the top plate.
- NOTE -
The headstock alignment specification
is within 0.0000 to -0.0001 inch
[0.00000 to -0.00254 mm] toward the
head when measured parallel to the T
ways. The perpendicular specification,
measured by indicating on top of the
arbor, is within 0.0000 to 0.0004 inch
[0.0000 to 0.0102 mm] with the outer U
end low.
7. Locate the indicator on the top plate to check
the edge of the arbor for parallel along the TP3537.
Z-axis to test headstock alignment. Figure 7.9 - Headstock and Riser Block
8. Move the indicator to check along the top of in Spindle Compartment
the arbor for headstock alignment perpendic-
ular to the ways.
- WARNING -
Shut down the power to the machine each time adjustments are to be made
in the spindle drive compartment.
10. Loosen, but do not remove, the four screws mounting the headstock to the riser block if the
headstock needs to be aligned in either direction.
M-371 7-9
- NOTE -
One jack screw must be loosened as the other jack screw is tightened. The head
pivots on a center dowel pin and is held by the jack screws until the mounting
screws are tightened.
11. Loosen or tighten the jack screws in the alignment blocks as necessary to move the
headstock within its alignment specifications.
12. Tighten the four headstock mounting screws to 170 lb-ft [230 Nm] torque when the
headstock is aligned.
13. Power up the machine and follow steps #7 through 11 to recheck the alignment of the
headstock. Make any adjustments as necessary.
15. Unthread both jack screws away from the headstock. The alignment blocks can remain on
the headstock.
16. Mount the compartment covers.
Cleaning the Spindle Brake Disc

Every six months open the spindle compartment covers and check spindle brake disc “V”, Figure
7.10, for contamination build-up on the brake contact sides of the disc. If contamination is present, use
a cleaner to remove the contaminant; then, clean and dry the disc.
Clean the spindle brake disc as follows:
1. Power down the machine and lock out (disable) the main disconnect switch.
2. Remove the spindle compartment covers as follows:
A. Unthread the screws and lift off the lower spindle compartment cover.
B. Loosen the clamp and disconnect the coolant hose from the coolant catcher drain.
3. Unthread both screws mounting each spacer
block “X”, to the riser block.
4. Slide brake assemblies “W”, from the brake
disc.
5. Determine what contamination is on the
brake disc. Use a cleaner to completely re-
move the contamination from the disc. Clean
and wipe the disc dry with a lint-free cloth.
6. If possible, eliminate the source of contami-
nation. V
7. Clean each brake and make certain that they W
operate properly.
8. Slide the brake assemblies on the brake disc X
and mount them to the riser block. Tighten
TP3537.
the four screws finger tight.
Figure 7.10 - Spindle Brakes
7 - 10 M-371
- NOTE -
The gap between each brake pad and the brake disc is a minimum of .005 inch
[.13 mm]. The gaps on each side of the disc do not have to be equal.
9. Measure the gap between the brake pad and disc on each side of the disc.
10. If there is interference or not enough clearance, remove the screws mounting the black
spacer block(s) to the riser block and add shim(s) or remove material from the spacer
block as necessary to create the proper brake gaps.
11. Slide the brake(s) on the brake disc and re-attach the spacer block(s) to the riser block
with the screws finger tight. Check the gap again; then, when the gap is within specifica-
tion, alternately tighten the screws to 25 Ib.-ft. [34 N-m] torque.
12. Check the screws that mount the brakes to the spacer blocks by making certain that each
is at 200 Ib-in [23 N-m] torque.
14. Test the brake as follows:
A. Press the JOG pushbutton; although, any control mode can be used.
B. Press the SPINDLE FREE pushbutton to have the brake pads disengage the disc. Press
it again to engage the disc. When the light is off, the brake is engaged.
C. Watch the gap between the brake pad and brake disc to make certain that both brakes
are functioning. Make any adjustments as necessary.
15. Power down the machine and mount the spindle compartment covers.
-NOTES -
M-371 7 - 11
-NOTES -
7 - 12 M-371
CHAPTER 8 - COLLET CLOSER
Introduction
The CNC lathe is equipped with a pneumatically (air) actuated collet closer. If repairs to the collet
closer are required, the ENTIRE ASSEMBLY must be removed and returned to the factory. The stan-
dard collet closer is an ANSI A2-4 5C which accepts work up to 1-1/16 inch [26.98 mm]. The optional
A2-4 16C “Big-Bore” general precision spindle uses the same maintenance information; however,
the spindles are NOT interchangeable.
Detailed maintenance information for the collet closer pressure switch and air components is in
Chapter 4 - AIR FACILITIES.
Free Spindle
The “Free Spindle” condition allows the spindle to be turned by hand. If the machine is still powered
up, press the Collet/Chuck pushbutton to open the spindle workholding device and remove any stock
from the collet or chuck. Power down the machine.
Power-Down Procedure:
1. Be certain that Cycle Start is not active. The pushbutton light will be OFF.
2. Look inside the work compartment to make sure that the program has been completed and
that the spindle, slides, and gantry are stationary.
3. Press the Emergency Stop (E-Stop) pushbutton.
4. Turn the Control switch to the OFF (0) position.
5. Turn the main air valve OFF and lock it out.
6. Turn the main disconnect switch OFF and lock it out.
Collet Closer Draw Tube Cleaning
Depending on the job and material being cut, particularly if it is a bar stock job, the draw tube should
be removed from the collet closer and cleaned every 40 hours and between job setups to prevent chip
loading between the draw tube and spindle bore; it should also be removed when cleaning the collet
closer monthly. Always clean from the spindle compartment end in toward the work area.
To remove the draw tube:
1. Press the Collet/Chuck pushbutton to open the spindle workholding device and remove any
stock. Power down the machine.
2. Unthread the four panhead screws on access cover “B”, Figure 8.1, on upper spindle com-
partment cover “A”, and remove it.
If more room is needed to remove and clean the spindle draw tube and/or collet closer, re-
move the spindle compartment covers as follows:
A. Unthread the panhead screws and lift off the lower spindle compartment cover.
the coolant catcher mounted inside upper spindle compartment cover “A”.
M-371 8-1
- NOTE -
The adjusting nut may be warm if the
spindle has been run continuously just B
before power down.
3. Remove the draw tube from the collet or A
chuck as follows:
A. Unthread three screws “C”, Figure 8.2, in
the edge of the knurled adjusting nut.
B. Lightly pull back on the adjusting nut and
unthread the draw tube from the collet or
chuck.
C. Remove the collet from the spindle or
unthread the screws and remove the
chuck from the chuck adapter. TP3531.
4. Pull the draw tube assembly straight out from Figure 8.1 - Collet Closer Access Door and
the spindle.
Upper Spindle Compartment Cover
- CAUTION -
Always wipe the draw tube and
spindle interior from the spindle
compartment end toward the work
compartment.
C
5. Wipe the draw tube and the inside of the
spindle free of coolant, chips, and dirt.
6. Check the condition of the grooves on the
draw tube. Thoroughly clean each groove.
- NOTE -
Use Mobiltemp® SHC 32 grease or the E
military specified Mobilgrease® 28. D
7. Use a light coat of the specified grease to

cover the outside diameter of the draw tube
and the inside of the spindle bore.
TP3537
If the machine is a “big-bore”, make certain
that there is grease in the grooves. Figure 8.2 - Draw Tube End
and Collet Closer
8. Slide the draw tube into the spindle and
push it in all the way.
9. Remount the collet or chuck as follows:
A. Pull the draw tube back slightly.
B. Put a collet into the spindle and hold it with the collet retainer or mount a chuck on the
chuck adapter.
C. Push the draw tube into the spindle until it makes contact with the rear of the collet or
chuck. Turn the draw tube and fully thread it onto the collet or chuck.
8-2 M-371
- CAUTION -
DO NOT close the collet closer without gripping a workpiece or piece of
stock in the collet or chuck.
11. Adjust the collet or chuck holding force as follows:
A. Put a workpiece or piece of stock in the collet or chuck.
B. Push the Collet/Chuck pushbutton to close the collet.
C. Thread the draw tube on the collet or chuck tight.
D. Unthread the tube a quarter to a half a turn while aligning three screws “C”, Figure 8.2,
with the three holes in the collet closer. Thread the screws in tight.
12. Test run the spindle. Open and close the collet or chuck several times.
Replace the access cover and/or spindle compartment covers before cutting parts.
Standard ANSI A2-4 5C Collet Closer

The collet closer should be removed monthly or approximately 160 hours of operation. If repairs to
the collet closer are required, the ENTIRE ASSEMBLY must be returned to the factory.
To remove the collet closer:
2. Set the machine for a “Free Spindle” and press the Collet/Chuck OPEN pushbutton.
3. Unthread three screws “C”, Figure 8.2, in the knurled adjusting nut and remove the collet
or chuck from the draw tube as follows:
A. Press the COLLET OPEN pushbutton and remove any stock.
B. Hold the collet or chuck from turning.
C. Grip the knurled adjusting nut and unthread the draw tube from the collet or chuck.
D. Remove the collet from the spindle or unthread the screws and remove the chuck from
the chuck adapter.
4. Power down the machine and make certain that the air valve is OFF.
5. Tag air-line connectors “D” and “E”, Figure 8.2, for re-assembly and disconnect them from
the collet closer.
M-371 8-3
6. Scribe a mark from the collet closer mount- H G
ing plate to the collet closer as in Figure 8.3.
7. Unthread six screws “F”, Figure 8.3, to re-
lease collet closer “H", from adapter “G”, as F
follows:
A. Unthread the screws until they stop
against the brake disc.
B. Pull the collet closer back the length of the
unthreaded screws.
TP3576.
C. Unthread the screws the rest of the way
out. Figure 8.3 - Collet Closer
8. Pull the collet closer and draw tube assembly and Mounting Plate
straight out from the spindle.
9. Unthread three mounting screws “C”, Figure 8.2, to release the draw tube from the collet
closer.
Pull the draw tube assembly straight out from the closer.
10. Wipe clean the draw tube, the inside diameter of the collet closer, and the spindle bore.
To install the collet closer:
1. Check the condition of the O-ring on the collet closer neck. Replace the O-ring (part num-
ber OR 0003034V) if necessary.
- NOTE -
Use Mobiltemp SHC 32 grease or the military specified Mobilgrease® 28.
®
2. Grease the draw tube with a light coat of the specified grease; insert the draw tube into the
collet closer and thread in three mounting screws “C”, lightly.
3. Clean the spindle bore and use a light coat of Bostik “Never-Seez” Black Moly (part num-
ber HG 0010440) grease on the O-ring and collet closer neck (back pilot O.D. of the collet
closer).
4. Center the draw tube in the spindle and push it in as far as it will go. Align the scribed line
and insert the air line tubes in the bracket as the collet closer is pushed into place.
5. Mount the collet closer to adapter “G”, Figure 8.3, as follows:
A. Align the six screws in the adapter with the threads in the collet closer openings and
thread them in hand tight.
B. Push the assembly further in toward the adapter and tighten the screws by hand.
C. Put an indicator at the arrow on the bearing housing in Figure 8.3. Rotate collet closer
“H” by hand and align the collet closer on the adapter to 0.001 inch [0.0254 mm] or less
fluctuation.
D. Tighten the six screws to 95 Ib-in [10.7 N•m] torque.
E. Check the fluctuation again and adjust the collet closer as necessary. Again, tighten the
collet closer mounting screws to 95 lb-in [10.7 N•m] torque.
8-4 M-371
6. Remount a collet or chuck as follows:
A. Unthread three screws “C”, and pull the draw tube back slightly.
chuck adapter.
C. Push the draw tube into the spindle until it makes contact with the rear of the chuck or
collet. Turn the draw tube and fully thread it onto the chuck or collet.
7. Reconnect air lines “D” and “E”, Figure 8.2, as noted in step #5 when removing the collet
closer.
- CAUTION -
B. Push the COLLET OPEN pushbutton and make certain that it is lit.
10. Test run the spindle. Open and close the collet or chuck several times.
Replace the spindle compartment covers before cutting parts.
ANSI A2-4 16C “Big Bore” Collet Closer

The collet closer should be removed and cleaned once a month or if it is damaged. Replace the
quad ring (small interior ring) occasionally or when it becomes worn. The collet closer assembly must
be returned to the factory when repairs are required. Remove the draw tube with the collet closer.
To remove the collet closer:
1. Press the Collet/Chuck pushbutton to open the spindle workholding device and remove any
stock.
4. Scribe a mark from the collet closer mounting plate to the collet closer as in Figure 8.4.
M-371 8-5
- NOTE -
Mount an indicator on the side wall and in- I
dicate the bearing housing near “L”.
L J
5. Rotate the collet closer by hand and record
the bearing housing movement. This move-
ment figure will be necessary for collet closer
re-alignment. K
6. Remove the collet or chuck as follows:
A. Unthread three screws “C”, Figure 8.2, in
the knurled adjusting nut.
B. Hold the collet or chuck from turning.
C. Grip the knurled adjusting nut and
unthread the draw tube.
D. Remove the collet from the spindle or
unthread the screws and remove the
chuck from the chuck adapter.
7. Tag air-line connectors “D” (collet open), “E” TP2368.
(collet close), and if there is an air receiver

line for re-assembly and disconnect the air Figure 8.4 - Collet Closer
lines from the collet closer. and Mounting Plate
8. Unthread screws “I”, Figure 8.4, to release
collet closer “K” from collet closer mounting
plate “J”, as follows:
A. Unthread screws “I”.
- CAUTION -
Be ready to support the weight of the collet closer and draw tube as they are
released from the spindle.
B. Work (pull) the collet closer and draw tube assembly straight out from the spindle.
C. Unthread three mounting screws “C”, Figure 8.2, to release the draw tube.
D. Pull the draw tube assembly straight out from the closer.
- CAUTION -
Always wipe the draw tube from the knurled end and the spindle interior
from the spindle compartment end toward the work compartment.
9. Wipe the draw tube clean. And, wipe clean the collet closer and spindle bore.
10. Check the condition of the O-ring on the mounting plate and the quad ring on the nose in
the collet closer. Replace either ring as necessary.
8-6 M-371
To install the collet closer:
1. Use a light coat of Bostik “Never-Seez” Black Moly (part number HG 0010440) to grease
the inside lip of the collet closer where it mounts over the O-ring. Also, put a light coat of
grease on the nose (quad ring area).
- NOTE -
Use Mobiltemp SHC 32 grease or the military specified Mobilgrease® 28.
®
2. Use a light coat of the specified grease to cover the outside diameter of the draw tube and
the inside of the spindle bore. Make certain that there is grease in the grooves.
3. Insert the draw tube into the collet closer.
4. Center the draw tube in the spindle and push it in as far as it will go. Align the scribed line
and align the interior pin in its hole; also, align the air line tubes in their bracket as the col-
let closer is pushed into place.
5. Mount the collet closer to collet closer mounting plate “J”, Figure 8.4, as follows:
A. Align the scribed mark on the collet closer with the scribed mark on the collet closer
mounting plate; align the screws in the mounting plate with the threads in the collet
closer openings and thread them in hand tight. Push the assembly further toward the
adapter and tighten the screws by hand.
B. Indicate the fluctuation at “L” in Figure 8.4 and align the collet closer on the adapter to
the original fluctuation figure as noted in step #5 when removing the collet closer or as
close to the number as possible.
If there was no reading at step #5 when removing the collet closer, align the collet
closer on the adapter to 0.001 inch [0.0254 mm] or less fluctuation.
C. Tighten the collet closer mounting screws to 100 lb-in [12 N•m] torque.
6. Remount a collet or chuck as follows:
A. Pull the draw tube back slightly.
chuck adapter.
C. Push the draw tube into the spindle until it makes contact with the rear of the chuck or
collet. Turn the draw tube and fully thread it onto the chuck or collet.
7. Reconnect the air lines as noted in step #7 of the collet closer removal instructions.
8. Unlock the air lock out valve and power up the machine.
- CAUTION -
B. Push the Collet/Chuck pushbutton to open the collet.
E. Test run the spindle. Open and close the collet or chuck several times.
10. Replace the spindle compartment covers before cutting parts.
M-371 8-7
Pressure Regulator/Gauge Replacement
A collet closer pressure regulator sets the collet close holding force. The collet closer pressure is
adjusted by turning regulator knob “O”, Figures 8.5 and 8.6, and observing the pressure on gauge “N”.
The collet closer air pressure should be set at approximately 40 psi [2.8 bar].
To replace the pressure regulator:
1. Power down the machine and make certain that the main air valve is OFF.
2. Unthread the screws and remove air panel
cover “M”, Figure 8.5. O
3. Make a diagram of the direction of the air

flow arrow on the regulator. Tag the regulator
hose(s) for re-assembly
4. Disconnect the hose(s) from the regulator. N
5. Unthread the regulator with gauge from the

air manual and lift it off.
6. Remove the fittings and pipe plug from the M
old regulator.
Unthread the gauge from the old regulator;
or, if the gauge is to be replaced, just leave it
with the old regulator. TP3526.
®
7. Apply Loctite High Performance Pipe Seal-
ant with Teflon® (Item No. 59241) to the Figure 8.5 - Collet Closer Pressure Gage
threads of the fittings, pipe plug and, if nec-
essary, the gauge. Install them on the re-
placement regulator.
- NOTE -
The arrow on the back of the regulator O
indicates the direction of air flow.
8. Thread the regulator with gauge onto the air
manual making sure that the knob is up.
Make certain that the air flow arrow is
pointed per step #3.
9. Attach the hoses to the regulator per infor-
mation as noted also in step #3.
10. Mount air panel cover “M”.
Power up the machine and set the closer
pressure to approximately 40 psi [2.8 bar]. TP3517.
Lift the knob on the top of the regulator, set

the air pressure and press the knob down to Figure 8.6 - Collet Closer Regulator
set collet closer air pressure and secure the and Air Panel without Cover
setting.
8-8 M-371
Pressure Switch Replacement
Collet closer pressure switch “Q”, Figure 8.7, is designed for 20 psi [1.4 bar]. If the switch fails, the
collet may not close. There are two conditions which may cause this to occur:
If the collet closer air regulator “O”, Figure 8.6, is set lower than the pressure switch, a close collet
command will not close the collet. The Collet Open light will flash and an E-Stop condition will stop the
axis motion.
If the pressure switch pressure is lower than the collet closer air regulator and the air regulator is not
set high enough to close the collet closer, a close collet command will cause the Collet Open light to go
out and will permit axis motion even though the collet is not closed.
There are two other pressure switches; main air pressure switch “R”, 60 psi [4.2 bars] and spindle
brake pressure switch “P”, 20 psi [1.4 bar]. Additional pressure switches may be installed as other air
options are added to the machine.
To replace the pressure switch:
1. Power down the machine and make certain
that the main air valve is OFF.
2. Unthread the screws and remove air panel R
cover “M”, Figure 8.5.
3. Remove the screw that holds the electrical Q
P
connector to the top of the switch. Pull the
plug straight up to remove it from the switch.
4. Remove the pressure switch from the mani-
fold. The switch is only hand tightened; how-
ever, a wrench may be necessary to
unthread it.
5. Replace the switch on the manifold and
tighten it to 50 lb-in [5.6 N•m] torque.
TP3517.
6. Align the openings with the prongs and push
the electrical connector straight down on top Figure 8.7 - Pressure Switches
of the switch. Fasten the electrical connector
in place with its screw.
7. Power up the machine. Set the regulator to 80 psi [5.5 bars] and check it for air leaks. Cor-
rect it as necessary.
8. Set the regulator below 20 psi [1.4 bars] to test the switch at low pressure.
9. When satisfied with the switch, return the regulator pressure to a consistent operating pres-
sure from 70 psi to 90 psi [4.9 to 6.3 bars].
10. Mount air panel cover “M”.
M-371 8-9
- NOTES -
8 - 10 M-371
CHAPTER 9 - AXES DRIVE MOTORS
Introduction
The carriage is a movable platform that carries the cross slide with a dovetail top plate for tooling.
Control signals command the carriage toward (-Z) or away (+Z) from the spindle.
The cross slide is a movable platform on the carriage that carries the dovetail top plate with tooling
mounted on it. Control signals command the cross slide toward (-X) or away (+X) from the spindle cen-
terline.
Detailed information covering the ball screw and linear way lubrication appears in Chapter 3 - LU-
BRICATION of this maintenance manual.
Carriage Drive Motor Replacement

The drive motor is located in spindle drive compartment “A”, Figure 9.1. It is connected to the ball
screw with a coupling. The motor has an encoder that is an integral part of the motor assembly and
cannot be replaced separately.
To replace the carriage drive motor:
1. Jog the Z-axis to move the carriage to the middle of its travel, if possible. Remove any
workpiece from the spindle to maximize the work space.
2. Power down the machine as follows: put the machine into E-stop, turn the Control OFF,
turn the main disconnect switch and air valve OFF.
3. Access the ball screw coupling as follows:
A. Unthread the three screws and swing
open control panel “B”.
B. Unthread four nuts and lift off access
cover “D”, Figure 9.2.
C. Reach through the opening and unthread
the pipe plug from the headstock base.
D. Use a flashlight and look into the
headstock base to view the coupling.
4. If the screw in the coupling clamp cannot be
accessed, turn the coupling as follows:
A. Gain entrance to access cover “E”, Figure
9.3, on the right end of the machine; A
unthread the screws and lift off the access B
cover.
B. Unthread the screws and remove the way
cover from the right side of the carriage
and the bed.
C. Unthread four screws and remove ball
screw end cover “F”, Figure 9.4. C
D. Use a wrench in the end of the ball screw

and turn it until the head of the screw in
the coupling clamp can be accessed in
the headstock base. TP3531.
E. Loosen the screw in the coupling. Figure 9.1 - Spindle Drive Compartment
and Valve Compartment Covers
M-371 9-1
D
E
TP3560
.
Figure 9.2 - Headstock Pipe Plug Access

Cover Behind Control Panel
5. Remove the spindle compartment covers

at the left end of the machine as follows:
A. Unthread the panhead screws and lift off
lower spindle compartment cover “C”,
Figure 9.1.
hose from the coolant catcher mounted TP3562.
inside upper spindle compartment cover

“A”. Figure 9.3 - Right End Access Door
C. Unthread the panhead screws on the
upper compartment cover. Pivot the left
side out and pull straight back to release
the cover.
6. Locate electrical connections “H”, and “G”,
(behind connector “H”) on motor “I”, Figure
9.5; unscrew the knurled nut and pull the
F
connectors straight out.
- NOTE -
Handle the motor with care. The en- TP224.
coder is extremely fragile. Do not hit Figure 9.4 - Ball Screw End Cover
the motor shaft or allow it to make con-
tact with anything.
7. Note the position of the electrical connections; unthread the four bolts that fasten the motor
to the motor mount. Carefully lift the motor from the spindle compartment.
8. Remove and install the coupling on the motor as follows:
A. Note that the curved face of the washers are toward the flex elements. Disassemble the
coupling by unfastening two screws opposite each other on the coupling.
B. Unthread the lock nut fastening the coupling to the tapered shaft on the motor.
C. Use a gear puller if necessary to remove the coupling from the motor shaft. Do not tap
or jar the coupling from the shaft.
D. Make certain that the key is in place on the replacement motor shaft and mount the cou-
pling. Tighten the coupling lock nut to 25 lb-ft [34 N•m] torque.
9-2 M-371
- NOTE -
When assembling the coupling, the
curved face of the washers are toward
the flex elements. Assemble the cou-
pling and tighten the mounting screws
to 96 lb-in [11 N•m] torque.
E. Assemble the coupling.
9. Align the coupling with the end of the ball I
screw, position the electrical connections per G
step #7 and mount the motor with the H
screws finger tight.
10. Tighten the four screws that fasten the motor
to 25 lb-ft [34 N•m] torque.
11. Tighten the coupling clamp screw to 60
lb-in [7 N•m] torque.
12. Connect motor cable “G” and encoder cable
“H”. Tighten the knurled nuts to secure the
connections.
- NOTE -
Because the motor has been unfas-
tened from the ball screw, the control
TP3536.
for Z-axis motor cannot position the
carriage accurately. This might cause
the CRT to display “Software Figure 9.5 - Z-Axis Motor
Overtravel” when the control is pow-
ered up even though an overtravel
condition does not exist.
13. Clear the feed hold (alarm) condition and reset the Z axis as follows:
A. Make certain that the control is on or turn the Control switch to the ON [ l ] position and
then make sure the machine is in MDI mode.
key or INPUT key.
G. At 1850 Z, key in 0 and press the INPUT soft key. An alarm may be displayed; if an
I. At 1815 bit 4 Z, key in 0 and press the INPUT soft key.
J. At 1815 bit 5 Z, key in 1 and press the INPUT soft key.
M-371 9-3
K. Turn the Control switch to OFF [ O ] and wait momentarily. While pressing and holding
the CAN (cancel) and Op [/// and Op] keys, turn the Control switch ON [ l ].
L. Pull the E-Stop pushbutton out and, then, pull it further out and hold it momentarily to re-
M. Set the axis as follows:
- CAUTION -
Be certain that no interference of axis travel exists when the Zero Return
(Reference Home) procedure is used.
1. Press POS key and then PAGE down ( ⇓ ) to read the relative axes position. “Actual
Position Relative” is displayed with the X and Z position.
- NOTE -
Make certain that there are no offsets or workshifts active. Axes Home positions
are as follows:
X = 23.50000 (Inch mode) 596.0000 (Metric mode) (diameter)
Z = 11.25000 (Inch mode) 286.0000 (Metric mode)
2. Set Feedrate % Override [F WW %] switch to between 20% and 40%.

- WARNING -
Some work and alignment testing on the carriage requires that access covers
are off and doors are open while the machine is powered up. Be extremely
careful when working on the machine with the covers off and doors open.
- NOTE -
If the control alarm “+ Software Overtravel” appears, it is necessary to turn the
Control switch OFF to power down the control. Press and hold both the CAN and
the Op [/// and Op] keys while turning the Control switch ON until the machine is
powered up. This procedure allows the control to ignore the overtravel alarms
when Zero Returning (Home) the axes.
3. Put the control into JOG mode. Quick page to MODE; press JOG soft key.
4. Move Z axis [4 ⇐ key] to bring the front face of the top plate approximately 1.000
inch from the spindle face. While moving the carriage, increase the % Feedrate as
necessary.
5. At HANDLE (press POS pushbutton, then, REL soft key), press the HZ (handle Z)
soft key and use the “MPG” hand wheel to move the axis until a 1 inch JO block has
a slip fit between the face of the spindle and the front face of the top plate (not the
front edge of the top plate dovetail).
6. Press W and then press the ORIGIN soft key. The Z axis will change to 0.
7. Jog the Z axis until the position display reads 10.2500 (calculate 11.2500 - 1.0000
JO block = 10.2500).
9. Enter 1 8 1 5 and press the No.SEARCH soft key.
10. At 1815 bit 4 Z, key in 1 and press the INPUT soft key.
9-4 M-371
N. Turn the Control switch to OFF [ O ] and wait momentarily. While pressing and holding
O. Change Parameter WRITE back to 0 as follows:
2. Press OFFSET SETTING key to display the Setting (HANDY) page.
INPUT key.
15. Test run each axis to make certain that they are moving properly.
16. Check that the Z-axis position is 1.0000 when positioned for a 1 inch JO slip fit between
the face of the spindle and the front face of the top plate.
17. Power down the machine; mount the covers and close the control panel as follows:
A. The spindle compartment (left end of machine):
1. Mount the upper spindle compartment cover on the machine.
2. Connect the hose to the fitting on the coolant catcher.
3. Mount the lower spindle drive compartment cover and fasten it in place.
B. The control panel (front of machine):
1. Thread the pipe plug into the headstock base.
2. Mount access cover “D”, Figure 9.2, in the compartment.
3. Close control panel “B”, Figure 9.1, and thread in the three screws.
C. Cover the right end of the ball screw and mount the access cover as follows:
1. Put ball screw end cover “F”, Figure 9.4, on and fasten it with its screws.
2. Mount the Z-axis way covers.
3. Mount the slide cover.
4. Mount the coolant and air blast manifold.
5. Install access cover “E”, Figure 9.3, and secure it by threading in the screws.
M-371 9-5
Cross Slide Drive Motor Replacement
- NOTE -
Some photographs are shown without covers, the chip and coolant guard, and
other components in place. They have been removed to show components.
The drive motor is located on the front of the carriage in the main compartment, Figure 9.6. It is con-
nected to the cross slide ball screw with a coupling. The motor has an encoder that is an integral part of
the assembly and cannot be replaced separately.
To replace the cross slide drive motor:
1. Jog the Z-axis to move the carriage to a con-
venient work position in front of the main
coolant guard door.
2. Power down the machine as follows: put the
machine into E-stop, turn the Control OFF,
turn the main disconnect switch and air valve
OFF.
3. Open the main coolant guard door and wipe
chips and coolant from the top plate and
cross slide covers. TP3552.
4. At the rear of the machine, unthread the Figure 9.6 - Cross Slide Drive Motor Cover
screws and lift off rear access cover “J”.
It may be necessary to remove the coolant
tank/coolant tank and chip conveyor “K”, to
have more access room at the rear of the
machine.
5. Unthread the screws and remove the cross J
slide rear cover.
6. At the front of the machine, gain access to
the X-axis drive motor and adapter mount as
follows: K
A. Remove coolant and air blast manifold “L”,
TP3561
.
Figure 9.8, from the cross slide cover.
Unthread the screws and remove cover Figure 9.7 - Rear Access Cover
“M”.
B. Unthread a screw low on each side and the front screw, Figure 9.6, so that the bottom
cover (tray) can drop down from the motor cover.
C. Unthread the screws and remove the drive motor cover to gain access to the motor and
adapter mount.
7. Loosen the ball screw coupling clamp from the ball screw as follows:
A. Reach up underneath the adapter mount and feel for the ball screw coupling screw.
B. If the coupling screw cannot be felt, go to the rear of the machine and unthread four
screws to remove ball screw end cover “N”, Figure 9.9.
C. Use a hex wrench (8 mm) in the end of the ball screw and turn it until the head of the
screw in the coupling clamp can be accessed through the adapter mount opening.
D. Loosen the screw in the coupling clamp.
8. Tag for re-assembly and then remove the electrical connections from the motor. Unscrew
each knurled nut and pull the connectors straight out.
9-6 M-371
N
L
M
TP3564. TP235.
Figure 9.8 - Cross Slide with Coolant Figure 9.9 - X-Axis Ball Screw Cover
and Air Blast Manifold Under Carriage
9. Note the position of the electrical connections on the drive motor before unfastening it from
the motor mount.
- NOTE -
Handle the motor with care. The encoder is extremely fragile. Do not hit the motor
shaft or allow it to come into contact with anything.
10. Unthread the four bolts that fasten the motor to the motor adapter mount and carefully pull
the motor from the main compartment.
11. Remove and install the coupling on the motor shaft as follows:
A. Note that the curved face of the washers are toward the flex elements. Disassemble the
coupling by unfastening two screws opposite each other on the coupling.
B. Unthread the lock nut fastening the coupling to the tapered shaft on the motor.
C. Use a gear puller if necessary to remove the coupling from the motor shaft. Do not use
a hammer to tap the coupling from the shaft.
D. Make certain that the key is in place on the replacement motor shaft and mount the cou-
pling. Tighten the coupling lock nut to 25 lb-ft [34 N•m] torque.
- NOTE -
When assembling the coupling, the curved face of the washers are toward the flex
elements. Assemble the coupling and tighten the coupling screws to 96 lb-in [11
N•m] torque.
E. Assemble the coupling.
12. Align the coupling with the end of the ball screw, position the electrical connections per
step #9 and mount the motor with the screws finger tight.
13. Tighten the four screws that fasten the motor to 25 lb-ft [34 N•m] torque.
14. Reach up underneath the adapter mount and tighten the coupling clamp screw to 60 lb-in
[7 N•m] torque.
15. Connect the motor cable and the encoder cable as noted from step #8. Tighten the knurled
nuts to secure the connections.
M-371 9-7
- NOTE -
Because the motor has been unfastened from the ball screw, the control for X-axis
motor cannot position the cross slide accurately. This might cause the CRT to dis-
play “Software Overtravel” when the control is powered up even though an
overtravel condition does not exist.
16. Clear the feed hold (alarm) condition and reset the X axis as follows:
A. Make certain that the control is on or turn the Control switch to the ON [ l ] position and,
then, make sure that the machine is in MDI mode.
key or INPUT key.
No.SEARCH soft key.
G. At 1850 X, key in 0 and press the INPUT soft key. An alarm may be displayed; if an
I. At 1815 bit 4 X, key in 0 and press the INPUT soft key.
J. At 1815 bit 5 X, key in 1 and press the INPUT soft key.
K. Turn the Control switch to OFF [ O ] and wait momentarily. While pressing and holding
L. Pull the E-Stop pushbutton out and, then, pull it further out and hold it momentarily to re-
M. Set the axis as follows:
- CAUTION -
Be certain that no interference of axis travel exists when the Zero Return
(Reference Home) procedure is used.
1. Press POS key and then PAGE down ( ⇓ ) to read the relative axes position. “Actual
Position Relative” is displayed with the X and Z position.
- NOTE -
Make certain that there are no offsets or workshifts active. Axes Home positions
are as follows:
X = 23.50000 (Inch mode) 596.0000 (Metric mode) (diameter)
Z = 11.25000 (Inch mode) 286.0000 (Metric mode)
2. Set Feedrate % Override [F WW %] switch to between 20% and 40%.
- WARNING -
Some work and alignment testing on the cross slide requires that access
covers are off and doors are open while the machine is powered up. Be ex-
tremely careful when working on the machine with the covers off and doors
open.
9-8 M-371
- NOTE -
If the control alarm “+ Software Overtravel” appears, it is necessary to turn the
Control switch to OFF to power down the control. Press and hold both the CAN
(cancel) and the Op [/// and Op] keys while turning the Control switch to ON until
the machine is powered up. This procedure allows the control to ignore the
overtravel alarms when Zero Returning (Home) the axes.
4. Mount a 1 inch [25.4 mm] arbor in a collet.
5. Mount a flat stock at the back end of the dovetail tool or use magnets to attach the
flat stock to the back of the dovetail tool.
6. Use the 1 inch [25.4 mm] arbor, the flat piece of stock and a 2.1875 inch [55.56 mm]
JO block to reset the control as follows:
a. Move the Z axis [4 ⇐ key] within range to have a slip fit of the JO block between
the side of the arbor and the flat stock.
b. Move the X axis [2 ⇓ # and/or 8 ⇑ keys] to have an approximate fit of the JO
block.
c. At HANDLE (press POS pushbutton, then, REL soft key), set the HX (handle X
axis, cursor with directional pushbuttons) soft key. Use the MPG hand wheel to
move the cross slide for a slip fit of the JO block between the side of the arbor
and the flat stock.
d. Use the MPG dial to move the cross slide to obtain a “slip fit” of the 2.1875 inch
[55.56 mm] JO block between the round edge of the arbor and the flat piece of
stock.
8. Enter 1 8 1 5 and press the No.SEARCH soft key.
9. At 1815 bit 4 X, key in 1 and press the INPUT soft key.
N. Turn the Control switch to OFF [ 0 ] and wait momentarily. While pressing and holding
O. Change Parameter WRITE back to 0 as follows:
2. Press OFFSET SETTING key and then the SETING soft key to display the Setting
(HANDY) page.
INPUT key.
18. Slide the main compartment door closed. Stay clear of any moving components and test
run each axis to make certain that they are moving properly.
M-371 9-9
19. Power down the machine and mount the covers as follows:
A. Mount the drive motor cover on the front of the cross slide, Figure 9.6, and fasten it in
place.
B. Align the screws in either side of the tray with the slots in the drive motor cover and hold
the tray in place. Thread the screw into the tray near the bottom edge of the drive motor
cover. Tighten all the screws.
C. At the rear of the machine, if necessary, mount ball screw end cover “N”, Figure 9.9, un-
der the front of the cross slide. Tighten the four screws.
D. Mount the cross slide rear cover and tighten the screws.
E. Fasten rear access cover “J”, Figure 9.7, in place with its screws. If necessary, roll the
coolant tank/coolant tank and chip conveyor in place under the machine.
F. Mount cross slide cover “M”, Figure 9.8, on the cross slide. Tighten the screws.
G. Fasten coolant and air blast manifold “L”, on the cross slide cover.
- NOTES -
9 - 10 M-371
CHAPTER 10 - MISCELLANEOUS
AIR FAN and HEAT EXCHANGER
There is a headstock fan and a power case heat exchanger installed on this CNC lathe. The open-
ings that allow air circulation through the spindle compartment and in the power case and MUST
NEVER BE BLOCKED. The fans are active as soon as the machine is powered up.
The headstock fan is located low on the left end of the machine and the spindle compartment is
vented at the top to allow air circulation inside and air to exhaust out. The air fan has a foam filter
mounted in the lower spindle compartment cover.
The power case has a heat exchanger mounted on the door. It stabolizes the case air temperature
while sealing out potentially contaminated, external air. When either the fan and/or heat exchanger re-
quire maintenance, the machine must be powered down. A detailed procedure to power down the ma-
chine appears in Chapter 2 - Power-Up Procedure.
1. Be certain that Cycle Start is not active. The pushbutton light will be OFF.
2. Be sure the program has been completed and that the spindle, slides, and gantry are sta-
tionary.
3. Press the Emergency Stop pushbutton.
5. Turn the main air valve OFF
6. Turn the main disconnect switch OFF and lock it out.
To clean the foam filter:

- NOTE -
Foam air filter “B”, Figure 10.1, is in a
frame that has a slotted support back.
2. Clean the foam air filter as follows:
A. Grip the foam air filter and carefully pull it
from the lower compartment cover. A
B. Wash the air filter clean in detergent and
water. Squeeze out as much water as
possible and allow it to air dry.
C. Make certain that the foam air filter is dry.
Compress it enough and carefully fit it in
the cover opening. B
3. Power up the machine and make certain that
the fan draws air.
TP3535.
Figure 10.1 - Headstock Fan on Spindle

Compartment Cover
M-371 10 - 1
To clean the heat exchanger filter:
2. Loosen, but do not remove, the screw in the
top filter runner. Grasp one side of heat
exchanger filter “C”, Figure 10.2, and pull it
straight out the side runners.
3. Clean the heat exchanger filter as follows:
A. Brush dirt from the face of the filter ele-
ment to remove much of the dirt.
B. Safely use an air gun to blow the remain-
ing contaminants from the filter.
C. Carefully wash the air filter clean in deter-
gent and water.
D. Rinse the filter in clean water.
E. Carefully wipe the filter dry and, then, al-
low it to air dry.
F. Make certain that the foam air filter is dry. C
Align the filter element in the runners and
slide it all the way in until it fully covers
the opening.
G. Tighten the screw in the top runner.
4. Power up the machine and make certain that
the exterior top fans draw air through the fil- TP3527.
ter. Figure 10.2 - Heat Exchanger
BATTERY REPLACEMENT
Battery units are located in the middle section (drive section) of the power case on each drive and
on top of the CPU inside the control. The batteries supply power to maintain axes memory and control
memory when the machine is not turned ON. The drive battery units are a battery pack and the control
is a single battery.
Although the batteries should be replaced at least
once a year, there is also a “Low Battery” alarm.
Check the age of the batteries and replace them as
necessary.
E
- WARNING - D
High voltage AC will be present in
the power case when the main dis-
connect switch is ON and when the
control is ON (powered up).
- CAUTION -
Battery replacement can be done
with the control turned ON or OFF.
TP3528.
Figure 10.3 - Drive Battery Units
10 - 2 M-371
- NOTE -
The drive contains a lithium battery
pack. Make certain that the replace-
ment pack is like those being removed. F
Check the battery voltage and recepta- E
cle.
G
To change the drive battery:
1. Make certain that the machine has been
powered up. Turn the control switch to the
ON ( l ) position if necessary.
Tp3737.
2. Power down the machine or turn the door in-
terlock key (switch) on the power case to the Figure 10.4 - Drive BatterywithReceptacle
OFF position. “F” on a Plug and Second Plug “G”
3. Unlatch the power case door and open it.
4. Remove battery cover “E”, Figure 10.4, on the front panel of the power unit. Hold the bat-
tery cover by the top and bottom and squeeze the cover while pulling it off.
5. Do not disconnect the battery; pry out the old battery and verify that the new battery is like
the battery being replaced. Put tape on or somehow mark the old battery.
6. Install the fresh battery while the old battery is still connected, Figure 10.5, as follows:
A. Pry the cap from the second (free) plug “G”, Figure 10.4. The free plug does not have a
battery receptacle attached to it (unoccupied). The plugs are near each other and are la-
beled; either can be the free plug.
B. Push the receptacle from the new battery
onto the second plug as “H”, Figure 10.5,
while the old battery is still connected.
7. Pull the old battery receptacle straight off the
plug. Put the cap from step #6.A on. F
Dispose of the old battery properly.
8. Put the new battery in place and fasten the H
battery cover on the front panel.
9. Repeat the procedure for the batteries in all
the drives.
10. Close the power case door and latch it.
If necessary, power up the machine.
Tp3738.
Figure 10.5 - Both Battery Packs

Connected at Plugs
M-371 10 - 3
To change the control battery:
- WARNING -
Be extremely careful when releasing the LCD (display, screen) from the oper-
ator’s control panel. Gain access over the top; there are plugs and connec-
tions along the bottom that should not be stretched.
- CAUTIONS -
Control battery replacement must done within 30 minutes of the control be-
ing turned OFF.
A fresh battery must be installed at least once a year. Failure to perform this
maintenance will result in the loss of control information.
1. Make certain that the machine has been powered up. Turn the control switch to the ON
( l ) position or press the CONTROL ON pushbutton if necessary.
2. Power down the machine. Make sure that the main disconnect switch on the power case is
turned to the OFF position and locked out.
3. The operator’s control panel swings open; unthread the screws and open the panel. Then,
unthread the screws and remove the back cover to the operator’s control panel to gain ac-
cess to the top of the CPU (control unit).
However, if it is easier to just unthread the CPU, unthread the four screws and carefully tilt
the top of the LCD out to gain access to the top of the CPU.
4. Locate the control battery on top of the con-
trol housing. Hold yellow plastic battery latch
“I”, Figure 10.6, to the side while pulling the
battery out.
5. Carefully lift the wires from around the bat-
tery holder to extend the wires and reach the I
connector pin (plug).
- NOTE -
The control unit contains a lithium bat-
tery. Make certain that the replacement
battery is like the battery being re-
moved. Check the battery voltage and Tp3335.
receptacle. Figure 10.6 - Control Battery

6. Verify that the new battery is like the battery on Top of the CPU
being replaced. Put tape on or somehow
mark the old battery.
7. Pull the old battery receptacle straight off its plug on the control unit wire.
8. Install the fresh battery. Push the new battery receptacle on the plug. Put the battery in
place and fasten the plastic battery latch.
Dispose of the old battery properly.
9. If the operator’s control panel swings open, mount the back cover to the operator’s control
panel. Swing the operator’s control panel closed and thread in the screws.
If the top of the LCD is pulled out, carefully place the LCD in the operator’s control panel
and mount the frame to the panel.
10. Unlock the main disconnect switch and power up the machine.
10 - 4 M-371
PART CATCHER
The part catcher is located on rods out of the headwall. The catcher extend/retract mechanism is in
spindle compartment “J”, Figure 10.7. The only adjustments to the part catcher are the extend and re-
tract positions and their travel rate. Parts can be removed from the machine through the access door
in the guard door without interrupting the cycle.
To adjust the part catcher position:
1. Put part catcher “K”, Figure 10.8, in the de-
sired position for adjustment - either the ex-
tend or retract position. Program an M26 to
extend the catcher or press the RESET key
near the CRT to retract the catcher.
machine into E-Stop, turn the control to the J
OFF (0) position, turn the main disconnect
switch and air valve OFF.
3. Remove the spindle compartment covers as
follows:
A. Unthread the screws and lift off the lower
spindle compartment cover.
coolant return hose fastened to the bottom TP3531.
of the coolant catcher mounted inside the
upper spindle compartment cover. Figure 10.7 - Drive Compartment Cover
cover.
4. Adjust the part catcher position as follows:
A. Loosen the set screw in collars “L”, Figure
10.9, on both support rods.
B. Position the part catcher.
C. Slide the collars against piston plate “M”, K
and tighten the set screw to secure them.
5. Turn the fine adjustment knob, Figure 10.9,
clockwise or counterclockwise to slightly ad-
just the part catcher to the final desired posi-
tion.
TP247.
6. Power up the machine and return the part
catcher to the retracted position if it was put Figure 10.8 - Part Catcher
in the extended position.
7. Power up the machine and test the extend and retract function several times to make cer-
tain that the part catcher goes to the desired position. Adjust the position of the part
catcher as necessary by powering down the machine and following steps #4 through #8.
M-371 10 - 5
8. Power down the machine and mount the O
compartment covers as follows: N
A. Mount the upper compartment cover on

the machine.
M
B. Connect the hose to the fitting on the
coolant catcher.
L
C. Mount the lower spindle drive compart- Knob
ment cover and fasten it in place. L
L
To adjust the part catcher travel rate:
Part catcher motion is actuated by a two-way
valve. The solenoids activate the valve to shift from
one position to the other. The two-way air valve ap- TP248.
plies air pressure through the air regulators to extend

or retract the air cylinder. Extend regulator “N”, and Figure 10.9 - Part Catcher Mechanism
retract regulator “O”, have a screw on top that con-
trols the amount of air to the cylinder to control the
rate of travel.
1. Program an M26 to extend the catcher or
press the RESET key near the CRT to re-
tract the catcher.
machine into E-Stop, turn the control OFF,
turn the main disconnect switch and air valve
OFF.
follows:
spindle compartment cover. TP249.
B. Unscrew the hose clamp to release the Figure 10.10 - Part Catcher Access Door
coolant return hose fastened to the bottom
upper spindle compartment cover.
4. Adjust the screw in either extend valve “N”, or retract valve “O”, Figure 10.9, as necessary
to adjust the travel rate of either or both functions.
5. Power up the machine and test the extend and retract travel rate. Adjust whichever screw
as necessary to set the rate.
6. Power down the machine and mount the compartment covers as follows:
10 - 6 M-371
To replace the solenoid(s):
- NOTE -
Refer to Chapter 4 - AIR FACILITIES
for additional information about the so-
lenoids, valves, or pressure regulators.
2. Remove the air panel access cover. Identify
the component(s) that needs to be replaced
in the part catcher assembly. P
3. Replace the extend solenoid and/or retract
solenoid as follows:
A. Unthread the screw that holds the sole-
noid to the valve.
B. Pull the solenoid straight out to remove it
from the valve.
C. Follow the wires from the solenoid to the
terminal block. TP3525.
D. Make a diagram to identify the wires for Figure 10.11 - Main Air Panel with Cover
reassembly.
E. Remove the wires from their terminal.
F. Replace the solenoid and fasten the wires per step #3.D, above.
G. Push the solenoid straight down on the valve. Fasten it in place with its screw.
5. Make certain that the main air pressure regulator is set between 70 psi and 90 psi
[4.9 and 6.3 bars]. Turn the fine adjustment knob and set the part catcher pressure regula-
tor to 40 psi [2.7 bar]. Check for air leaks in the part catcher air system and correct any
leaks as necessary.
6. Replace the air panel cover.
To replace the valve:

2. Remove air panel cover “P”, Figure 10.11, and identify the component(s) that needs to be
replaced in the part catcher assembly.
3. Replace the two-way valve as follows:
A. Unthread the screw that holds each of the solenoids to the valve.
B. Pull each solenoid straight out to remove them from the valve.
C. Make a diagram to identify the air lines for reassembly.
D. Unthread the fittings and remove the air lines from the valve.
E. Unthread the screws and remove the valve, with the pressure regulator and gauge as-
sembly attached to it, from the manifold.
M-371 10 - 7
3. (continued ..... )
- NOTE -
Use sealant on fitting threads when they are mounted to new components.
F. Unthread the regulator and gauge assembly from the old valve and replace the valve.
Thread the regulator and gauge to the new valve.
G. Replace the valve, make certain that the O-rings are in place, and fasten the valve on
the manifold.
H. Fasten the air lines to the valve and tighten the fittings.
I. Push the solenoids straight down on the valve. Fasten each in place with its screw.
[4.9 and 6.3 bars]. Turn the fine adjustment knob, Figure 10.6, and set the part catcher
pressure regulator to 40 psi [2.7 bar]. Check for air leaks in the part catcher air system and
correct any leaks as necessary.
6. Replace the valve compartment cover.
To replace the pressure regulator and/or gauge:
2. Remove the valve compartment cover and identify the component(s) that needs to be re-
placed in the part catcher assembly.
3. Replace the pressure regulator as follows:
A. Unthread the gauge from the valve. If just the gauge is to be replaced, use sealant on
the threads and thread the new gauge in place on the valve. Continue with step #4 be-
low. If the regulator is being replaced, continue with step B.
B. Disconnect the air line from the fitting on the regulator.
C. Unthread the regulator from the stem fitting.
D. Unthread the air line fitting from the side of the old regulator, use sealant on the threads,
and mount it on the new regulator.
E. Use sealant on the threads and thread the new regulator on the stem fitting.
F. Use sealant on the threads and fasten the gauge to the new regulator.
G. Reconnect the air line to the fitting on the regulator.
[4.9 and 6.3 bars]. Turn knob at Figure 10.9, and set the part catcher pressure regulator to
40 psi [2.7 bar]. Check for air leaks in the part catcher air system and correct any leaks as
necessary.
6. Replace the valve compartment cover.
10 - 8 M-371
To replace the part catcher (chute) Home switch (LS 6):
Part catcher Home switch “Q”, Figure 10.12, is active when the chute is at home against the
headwall. Refer to Figure 10.8 to see the part catcher at Home. The switch is located in the spindle
compartment on a bracket and is activated by the end plate.
1. Extend the part catcher to move the end
plate off the switch roller as follows:
A. Press the MDI pushbutton.
B. Press the PRGRM key.
C. Enter M 2 6 and press the INPUT key.
D. Press the CYCLE START pushbutton to
extend the catcher.
machine into E-Stop, turn the control to the
OFF (0) position, turn the main disconnect
switch and air valve OFF.
follows:
Q
spindle compartment cover. TP251.
B. Unscrew the hose clamp to release the Figure 10.12 - Part Catcher Switch in
coolant return hose fastened to the bottom Spindle Compartment
upper spindle compartment cover.
4. Open the power case door to gain access to the terminal boards.
5. Follow the electrical cable from part catcher Home switch “Q”, Figure 10.12, into the power
case.
6. Make a diagram of the cable wires to each of the terminal boards.
7. Disconnect the wires from the terminal boards.
8. Unthread two screws and remove the switch from the bracket.
9. Compare the cable lengths of the old switch and the replacement switch and cut the re-
placement switch cable to length.
10. Mount the switch to the bracket. Pull the switch all the way back in the slots and fasten the
screws finger tight.
11. Feed the cable through the compartment and into the power case.
12. Strip the cable and wires and connect the wires to the terminal boards per step #6, above.
13. Power up the machine. If the part catcher is not at Home, press the RESET [ // ] key.
If the parts catcher Home switch is not made, a “PARTS CATCHER NOT HOME” (#2015)
message will appear on the CRT. When the switch is made, tighten the screws.
M-371 10 - 9
14. Set the switch as follows:
A. Program an M26 to extend the catcher as follows:
1. Press the MDI pushbutton.
2. Press the PRGRM key.
3. Enter M 2 6 and press the INPUT key.
4. Press the CYCLE START pushbutton to extend the catcher.
B. Loosen the screws; adjust the switch in toward the end plate and tighten the screws.
C. Press the RESET [ // ] key to retract the catcher.
D. Read the display on the CRT. If the “PARTS CATCHER NOT HOME” message ap-
pears, extend the parts catcher and repeat steps B, C, and D until the switch is made.
E. Extend and retract the part catcher several times to make certain that bit 5 changes
each time the end plate leaves the switch roller and each time it returns.
F. Adjust the switch as necessary.
15. Power down the machine and mount the spindle compartment covers as follows:
16. Power up the machine and test the part catcher.
WORKLIGHT
The worklight is mounted on the ceiling of the coolant guard. It is a 20 Watt fluorescent lamp
(TL20W/33RS) and has a starter and ballast assembly mounted in a Waldmann (Type DWDV-120)
fixture.
- WARNING -
DO NOT perform any work on electrical components while the electrical
power is ON.
To replace the lamp and/or starter/ballast assembly:
2. Open the coolant guard door.
However, since the worklight is located near R R
the back of the work area, it may be more
convenient to access the worklight through
the rear access cover.
3. Wipe the worklight, worklight brackets “R”,
Figure 10.13, and worklight cable clean. TP3566.
4. Unthread two wing screws which hold the Figure 10.13 - Worklight
worklight brackets closed. Open the worklight
brackets and remove the worklight.
5. Loosen, but do not remove, the three screws in the left end (cable end) cap (right end cap
if approaching the worklight through the rear access opening). Hold the worklight assembly
securely and slide the guard tube from the assembly.
10 - 10 M-371
6. Replace the fluorescent lamp and/or starter/ballast assembly, as necessary.
- NOTE -
During re-assembly, be certain that the end cap is seated tightly against the guard
tube when the three screws are tightened. Tightening these screws causes the
rubber seal to expand and grip the guard tube I.D.
7. Hold the worklight assembly and slide the guard tube up on the assembly. Fasten it by
tightening the three screws snug. Secure the screws but do not overtighten them.
8. Mount the worklight in the worklight bracket and fasten two wing screws in loosely.
9. Power up the machine. The light will come on when the machine powers up.
10. Adjust the worklight by turning the guard tube. Thread two wing screws in tight to secure
the worklight. Close the coolant guard door.
LIVE TOOL HOLDER BEARINGS

The live tool holder has a tool spindle that is supported by a set of bearings near the front of the spin-
dle and a single bearing at the rear. The front bearing set is DB mounted on the spindle.
The live tool holder bearings must be cleaned and re-greased once a year.
To disassemble, clean and grease the bearings:
2. Disconnect the live tool holder cable.
3. Remove the live tool holder from the tool
plate and put it on a clean work bench.
4. Unthread the screws and remove plate “S”,
Figure 10.14.
5. Unthread the set screw; unthread the jam nut Y X
and remove pulley “T”, and key. The drive
motor may need to be loosened if the drive
belt requires less tension. T
6. Unthread four screws “U”, fastening spindle

housing “V”, to the live tool drive belt hous-
ing. Lift off the spindle housing. S
- NOTE -
Usually rear bearing “X”, remains in W
the spindle housing. Sometimes the V U
bearing is removed with the spindle. TI3958.
7. Unthread the screws and slide the spindle Figure 10.14 - Live Tool Holder
assembly out while removing spindle retain-
ing cap “W”.
8. Unthread bearing jam nut “Y”, and work the front bearing set from the spindle. The bear-
ings are DB mounted.
M-371 10 - 11
- NOTES -
Keep the inner race and outer race in the same orientation at all times during
cleaning. Do not rotate the bearing in either direction during cleaning.
Do not use forced air to clean the bearings.
9. Clean the bearings and wipe them clean with a lint-free cloth as follows:
A. Clean the bearings in bearing cleaning solution. Or, clean the bearings with fresh kero-
sene and then clean them with fresh naptha.
B. Wipe the bearings dry with a lint-free cloth and let them air dry.
10. Lubricate the bearings as follows:
A. Load the front bearing set with 1.5 grams of KLUBER Isoflex® NCA 15 grease (Hardinge
grease cartridge part number TT 0010994NCA).
B. Load the rear bearing with 0.5 grams of ANDOK C® grease.
11. Mount the front bearings (DB order) on the spindle and torque bearing jam nut “Y”, Figure
10.14, to 28 lb-ft.. Loosen this bearing jam nut and, then, re-torque it to 28 lb-ft again.
12. Mount the rear bearing in the spindle housing.
13. Align the spindle and put the spindle into spindle housing “V”. Align spindle retaining cap
“W” mounting openings and evenly torque the screws to 35 lb/in.
14. Mount the spindle housing to the live tool drive belt housing. Torque four screws “U”, to
120 lb/in..
15. Put the key in the spindle keyway and slip pulley “T”, on the spindle. Torque the jam nut to
100 lb/in. and tighten the set screw.
16. Mount and align the drive belt on the pulley. Adjust the belt tension if necessary.
17. Install plate “S”, and tighten the screws.
18. Mount the live tool holder on the tool plate and connect the live tool holder cable.
20. Run in the live tool holder bearings as follows:
A. Run live tool at 400 rpm for 4 minutes.
B. Reverse the rotation; run live tool again at 400 rpm for 4 minutes.
C. Run live tool in the same direction as step A, above, at 1200 rpm for 4 minutes.
D. Reverse the rotation; run live tool again at 1200 rpm for 4 minutes.
E. Run live tool in the same direction as step A, at 2400 rpm for 4 minutes.
F. Reverse the rotation; run live tool again at 2400 rpm for 4 minutes.
G. And finally, run live tool in the same direction as step A, at 4000 rpm for 4 minutes.
H. Reverse the rotation; run live tool again at 4000 rpm for 4 minutes.
21. Power down the machine and set up tooling on the tool plate.
10 - 12 M-371
STACKER TABLE TORQUE LIMITER
The stacker table option has a torque limiter between the gear box and the table to protect the table
and parts rods from damage.
To reset the stacker table torque limiter:
- CAUTION -
DO NOT attempt to index the stacker table with the elevator(s) in the up posi-
tion; damage to the rods will occur.
1. Check inside the stacker table booth to verify if the elevator(s) is up or down.
If both elevators are down, proceed with step #2.
If either or both elevators are in the up position, move the elevator(s) to the down position
as follows:
A. Activate JOG mode.
B. On the gantry pendant, press and hold the Elevator Down pushbutton until the stacker
table elevator(s) is down.
2. Press the stacker table booth E-Stop (Emergency Stop) pushbutton.
3. Press the Table Index pushbutton; torque limiter may reset and table drops down.
4. If nothing happens when the Table Index pushbutton is activated; open the stacker table
access door, reach down to the right and turn the gear box knob until the torque limiter re-
sets (a “click” will be heard and table drops down).
- NOTES -
M-371 10 - 13
- NOTES -
10 - 14 M-371
APPENDIX ONE
Preventive Maintenance Schedule and Products Applied
Introduction
The CONQUEST® GT27 and GT27SP AUTOLOAD™ CNC lathes are designed to provide minimal
downtime and insure long machine life when the following schedule of preventive maintenance is ap-
plied. Modular construction and easy access to components help to monitor each of the systems of
the machine. Monitoring sensors have been built into the machine’s lubrication and control system for
ease in troubleshooting problems. Pressure sensors and control alarms alert the operator through the
CRT display when systems malfunction. Circuit breakers provide visual confirmation of the electrical
status of each circuit. The plug-in relays have LED’s for verification of switch condition.
The access covers and doors along with the sheet metal housings have been design for ease of re-
moval when service is required. Open access covers and doors or remove panels to gain access to
modules. There is no need to be cramped or extended when performing maintenance or service on
the machine. Any module can be easily removed from the frame when extensive service or replace-
ment is necessary.
- CAUTION -
Do not use caustic or abrasive cleaners on this machine.
Maintaining a clean machine is part of any good maintenance program. Machines should be peri-
odically wiped with lint-free cloths soaked with kerosene. If the machine is operated in an atmosphere
that causes surfaces to rust quickly, wipe these surfaces with a lint-free cloth soaked in mineral oil.
NEVER USE COMPRESSED AIR TO CLEAN DIRT OR CHIPS FROM THE MACHINE. Air pres-
sure could force dirt particles and other foreign material past seals and wipers.
Maintenance Schedule
The following maintenance times are approximate and components may need attention more fre-
quently if excessive environmental pollution is present.
8 Hours
Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Empty tramp oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Drain air line filter unit (bowl) . . . . . . . . . . . . . . . . . . . . . . . 4-1
Check red “pop up” indicator on air filter . . . . . . . . . . . . . . . . . 4-3
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Remove chips and shavings . . . . . . . . . . . . . . . . . . . . . . . 5-4
M-371 Appendix One-Page 1

Maintenance Schedule (continued)
40 Hours
Check circulating fans for dirt and proper operation . . . . . . . . . . . . 10-1
Clean the spindle coolant catcher . . . . . . . . . . . . . . . . . . . . 5-7
Clean and lubricate the spindle (collet closer) draw tube. . . . . . . . . . 8-1
(The draw tube should also be cleaned between job setups.)
Wash machine and wipe clean . . . . . . . . . . . . . . . App. One-Page1
160 Hours
Check spindle belt tension . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Check power and control cases for contaminants . . . . . . . . . . . Ch. 10
Gantry lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Check the air filter and heat exchanger filter. . . . . . . . . . . . . . . 10-1
(Clean more frequently if necessary; replace either filter when necessary)
Clean and lubricate the collet closer . . . . . . . . . . . . . . . . . . . 8-3
(The collet closer should also be cleaned between job setups.)
Check lubricator system . . . . . . . . . . . . . . . . . . . . . . . . Ch. 3
500 Hours
Check spindle drive belt for wear and tension . . . . . . . . . . . . . . . 7-2
Inspect and clean spindle motor . . . . . . . . . . . . . . . . . . . . . 7-5
Check spindle encoder timing belt tension. . . . . . . . . . . . . . . . . 7-6
Clean spindle brake disc . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Clean chip screens in the coolant reservoir . . . . . . . . . . . . . . . . 5-4
1000 Hours
Clean air line lubricant bowl . . . . . . . . . . . . . . . . . . . . . . . 4-2
Clean or replace the lubricator in-line filter . . . . . . . . . . . . . . . . 3-3
Clean coolant reservoir and change coolant . . . . . . . . . . . . . . . . 5-4
(Coolant reservoir should also be cleaned when changing the type or brand of coolant.)
Clean lubricant reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Replace optional gantry grease packs (automatic lubricators). . . . . . . . 6-1
Yearly
Install fresh batteries. . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Clean and re-grease the live tool holder bearings. . . . . . . . . . . . . 10-6
Appendix One-Page 2 M-371

Lubricants
(Use recommended product)
Product Vendor
Vactra® Oil #2 . . . . . . . . . . . . . . . . . . . . . . . Mobil Oil Corp.
Velocite® Oil #6. . . . . . . . . . . . . . . . . . . . . . . Mobil Oil Corp.
Mobiltemp SHC® 32 Grease . . . . . . . . . . . . . . . . . Mobil Oil Corp.
Mobilgrease® 28 Grease . . . . . . . . . . . . . . . . . . Mobil Oil Corp.
Molykote® 55M Silicone O-Ring Lubricant . . . . . . . . . . Dow Corning Corp.
111 Compound Silicone Lubricant . . . . . . . . . . . . . . Dow Corning Corp.
Molylube® Lubricant. . . . . . . . . . . . . . . . . . . . . Bel-Ray Co.,Inc.
Never-Seez Black Moly . . . . . . . . . . . . . . . . . . . Bostik Inc.
KLÜBER NBU 15 . . . . . . . . . . . . . . . . . . . . . . KLÜBER Lubrication
Adhesives and Sealants

Loctite® Pipe Sealant with Teflon® (Item #592) . . . . . . . . Loctite Corp.
Loctite Threadlocker #222 . . . . . . . . . . . . . . . . . Loctite Corp.
Loctite Threadlocker #242 . . . . . . . . . . . . . . . . . Loctite Corp.
Permatex® Sealant . . . . . . . . . . . . . . . . . . . . . Loctite Corp.
RTV Silicone Rubber Adhesive Sealant . . . . . . . . . . . General Electric
RT-108 Sealing Adhesive . . . . . . . . . . . . . . . . . . General Electric
Vactra and Velocite are registered trademarks of Mobil Oil Corporation.

Mobilgrease and Mobiltemp SHC are registered trademarks of Mobil Oil Corporation.
Molykote is a registered trademark of Dow Corning Corporation.
Loctite and Permatex are registered trademarks of Loctite Corporation.
Teflon is a registered trademark of Dupont Corporation.
M-371 Appendix One-Page 3

- NOTES -
Appendix One-Page 4 M-371

APPENDIX TWO - PHOTOGRAPHS
CONQUEST® GT27 and GT27SP AUTOLOAD™ Lathe
TP3436.
Figure A2.1 - Front of Machine and Operator's Panel
TP3409.
Figure A2.2 - Machine and Autoload System

without "Canopy or Phone Booth"
A - Gantry
B - Load/Unload Area
C - Control Panel
M-371 Appendix 2-Page 1

D
B
C
TP3531.
Figure A2.3 - Spindle Drive Compartment End View
A - Lower Spindle Compartment Cover

B - Coolant Catcher Access Door
C - Upper Spindle Compartment Cover
D - RS232 Serial Port (Front of Control Panel)
Appendix 2-Page 2 M-371

TP3530. Tp4020.
Figure A2.4A - GT27SP Power Case Interior Figure A2.4B - GT27 Power Case Interior

TP3528.
Figure A2.5 - Upper Part of the Power Case

TP3529.
Figure A2.6 - Lower Part of the Power Case

TP3533.
Figure A2.7 - Operator's Control Panel Interior

TP3536.
Figure A2.8 - Spindle Compartment

TP3525.
Figure A2.9 - Air Panel and Lubricator
TP3517.
Figure A2.10 - Air Panel with Cover Off

TP3430.
Figure A2.11 - Coolant Pump and Reservoir

TP3410.
Figure A2.12 - Gantry Arm in Workarea
TP3412.
Figure A2.13 - Gantry View from Right with Arm Extended

TP3556.
Figure A2.14 - Gantry Air Panel Viewed from Left
TP3557
.
Figure A2.15 - Gantry Air Panel Viewed from Right

TP3553.
Figure A2.16 - Gantry Overall Front View
TP3558.
Figure A2.17 - Gantry Z-Axis Motor and Grease Boxes

TP3411.
Figure A2.18 - Right End of Machine Ready

for Load/Unload System
TP3433.
Figure A2.19 - Right End with Stacker Table

TP3432.
Figure A2.20 - Stacker Table without Covers
TP3434.
Figure A2.21 - Stacker Table Control Boxes

- NOTES -

“Performance Has Established Leadership for Hardinge”®
Hardinge Inc.
Elmira, New York 14902-1507 USA
Phone: 607-734-2281 Fax: 607-734-8819
www.hardinge.com

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Maintenance Manual - SP - M-0009500-0371

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Revised: April, 2000

Manual No. M-371 Litho in U.S.A.

Information in this manual is subject to change without notice.

CONVENTIONS USED IN THIS MANUAL

© 1999, Hardinge Inc. M-371

HARDINGE SAFETY RECOMMENDATIONS

FOR YOUR PROTECTION - WORK SAFELY

CHAPTER 1 - REFERENCES and INSTALLATION

CHAPTER 2 - POWER-UP PROCEDURE

CHAPTER 4 - AIR FACILITY

CHAPTER 6 - PART LOAD/UNLOAD GANTRY

CHAPTER 7 - HEADSTOCK and SPINDLE DRIVE

CHAPTER 8 - COLLET CLOSER

APPENDIX TWO - PHOTOGRAPHS

CNC CONTROL SERIAL NUMBER

Machine and Stacker Table is 91.5[2324] 39.4 [1001] 34.0 [864]

Figure 1.3 - Pad Placement for Machine Support

Figure 1.9 - Air Panel

GROUNDING THE MACHINE

Machine Frequency Full Load Service Requirement Recommended

* 208 60 48 60 No. 4 AWG

Table 1.1 - Conquest GT Autoload System

To access the power case and connect the power supply:

1. Turn disconnect switch “M”, Figure 1.11, to

Figure 1.11 - Main Disconnect Switch

Figure 1.12 - Disconnect Switch and

BASIC MACHINE POWER-UP

4. On machines equipped with a “big-bore” (16C) spindle option:

CLEARING AN EMERGENCY STOP

Figure 2.3 - Hour Run Meter

REVIEW CONTROL STATUS

Lubricator Reservoir and In-Line Filter

Figure 3.4 - In-Line Filter

Drain the Filter/Regulator Unit Daily

Figure 4.2 - Air Panel without Cover

Drain the Filter Bowls and Air Receiver

Figure 4.3 - Air Receiver (Big Bore and

Clean the Air System Bowl

Replace the Pressure Switch(es)

Replace or Clean the Manifold(s)

TP185. Figure 4.8 - Cross Slide Air Blast and

3. Locate coolant pump “A”, Figure 5.1,

dispose of them properly. Figure 5.1 - Coolant Pump and Reservoir

3. Remove or add links to change the length of

Figure 5.2 - Headwall Coolant Valves

Replacing the Coolant Pump

Figure 5.5 - Spindle Compartment Covers

(continued on the next page)

Figure 6.2 - Gantry Y-Axis Grease Blocks

and power the machine down again. At the

Figure 6.4 - Gantry Pneumatic (Air) Panel

6. Unthread the air line from the fitting on the

The AC digital spindle drives and motors are reli-

Figure 7.2 - Runout on Lip and Face

Figure 7.3 - Spindle Draw Tube

Figure 7.4 - Spindle Drive Compartment

A. Mount the upper compartment cover on

coolant catcher. Figure 7.5 - Drive Motor Platform Bolts

(continued on the next page)

6. Remove the spindle drive belt from the spin-

(continued on the next page)

Cleaning the Spindle Brake Disc