MAINTENANCE MANUAL - hardingeservice.com

1 MAINTENANCE MANUALCONQUEST GT27 and GT27 SPAUTOLOAD SYSTEMR evised: April, 2000 MANUAL No. M-371 Litho in No. M -0009500-0371 May, INFORMATIONR efer to the Programmer s, Operator s and this MAINTENANCE MANUAL supplied withthe machine tool for Hardinge Safety recommendations. Refer to the following doc-uments for additional safety requirements:American National Standard for Machine Tools -Manufacturing Systems/CellsSafety Requirements for Construction, Care, and UseANSI National Standard for Industrial Robots and Robot Systems -Safety RequirementsANSI NOTICE -Damage resulting from misuse, negligence, or accident is not covered by theHardinge Machine in this MANUAL is subject to change without MANUAL covers the MAINTENANCE of the Hardinge CONQUEST GT27and CONQUEST GT27SP CNC lathes with Autoload no event will Hardinge Inc. be responsible for indirect or consequentialdamage resulting from the use or application of the information in this of this MANUAL in whole or in part, without written permission ofHardinge Inc.

2 Is 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 CAUTIONS -Cautions must be followed carefully to avoid the possibility of damage to themachine, tooling, or NOTES -Notes contain supplemental Hardinge Box 1507 Elmira, New York 14902-1507 1999, Hardinge COMPLETE INSTRUCTIONS CAREFULLY BEFORE STARTING MAINTENANCEOR REPAIR ON THE MACHINE, LOAD/UNLOAD AUTOMATION, OR BAR technicians who use this MANUAL should have a general knowledge of machine maintenanceand repair. This general knowledge coupled with the following MANUAL will greatly reduce or eliminatedowntime of the Conquest 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 machinebe WARNING -Occupational Safety and Health Administration (OSHA) Hazard Communica-tion Standard , effective May 25, 1986, and various state employeeright-to-know laws require that information regarding chemicals used withthis equipment be supplied to you.

3 A complete list of the chemicals usedwith this machine, their reference data sheet numbers, and their suppliersappears as an insertion at the end of this MANUAL . Refer to the applicablesection of the Material Safety Data Sheets supplied with your machine whenhandling, storing, or disposing of should only be used with a bar feed approved by Hardinge SAFETY RECOMMENDATIONSYour 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 Inc. recommends that all shop supervisors, MAINTENANCE personnel, and machine tooloperators be advised of the importance of safe MAINTENANCE , setup, and operation of Hardinge-builtequipment. Our recommendations are described THESE SAFETY RECOMMENDATIONS BEFORE PROCEEDING ANY THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operationor MAINTENANCE of the machine.

4 Make certain that you understand all T ALLOW the operation or repair of equipment by untrained YOUR SUPERVISOR when in doubt as to the correct way to do a SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. When nec-essary, wear respirator, helmet, gloves, and ear muffs or T OPERATE EQUIPMENT unless proper MAINTENANCE has been regularly per-formed and the equipment is known to be in good working or INSTRUCTION TAGS are mounted on the machine for your safety and in-formation. Do not remove T ALTER THE MACHINE to bypass any interlock, overload, disconnect, or othersafety T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibrationoccurs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as anydamaged CERTAIN that the equipment is properly grounded. Consult National Electric Codeand all local MAIN ELECTRICAL POWER before attempting repair or ONLY AUTHORIZED PERSONNEL to have access to enclosures containingelectrical T REACH into any control or power case area unless electrical power is T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on awet BLOWN FUSES with fuses of the same size and type as originally AND CORRECT the cause of a shutdown caused by overload heaters be-fore restarting the THE AREA AROUND THE MACHINE well lighted and CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combus-tible material and keep chips clear of the work T USE a toxic or flammable substance as a solvent cleaner or CERTAIN THAT PROPER GUARDING is in place and that all doors are closedand REMOVE OR REPLACE the collet closer it is necessary to remove the guard door atthe left end of the machine.

5 Make certain that the guard door is in place before startingthe T OPEN GUARD DOORS while any machine component is in SURE chucks, closers, fixture plates and all other spindle-mounted work-holdingdevices are properly mounted and secured before starting the CERTAIN all tools are securely clamped in position before starting the ANY LOOSE PARTS OR TOOLS left on machine or in the work area beforeoperating the machine. Always check the machine and work area for loose tools andparts especially after work has been completed by MAINTENANCE CHUCK WRENCHES before starting the PRESSING THE CYCLE START PUSH BUTTON, make certain that properfunctions are programmed and that all controls are set in the desired WHERE ALL stop push buttons are located in case of an THE LUBRICATION and the status of the indicator lights before operating ALL SAFETY DEVICES AND GUARDS to make certain that they are in goodcondition and are functioning properly before operating the THE POSITION of the tool top plate before pressing the Cycle Start push THE POSITION of any load/unload automation before pressing the Cycle Startpush SETUP, TOOLING.

6 AND SECURITY OF THE WORKPIECE if the machine hasbeen OFF for any length of CYCLE a new setup to check for programming CERTAIN that you are clear of any pinch point created by moving slides beforestarting the T OPERATE any equipment while any part of the body is in the proximity of a po-tentially hazardous T REMOVE CHIPS with hands. Use a hook or similar device and make certain thatall machine movements have CAREFUL of sharp edges when handling newly machined T REMOVE OR LOAD workpieces while any part of the machine and/or Autoloadsystem is in T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing,neckties or long hair not contained by a net or shop T ADJUST tooling or coolant hoses while the machine is T LEAVE tools, workpieces or other loose items where they can come in contactwith a moving component of the machine and/or Autoload T CHECK finishes or dimensions of workpiece near running spindle or T JOG SPINDLE in either direction when checking threads with a thread T ATTEMPT to brake or slow the machine with hands or any makeshift ATTACHMENT, TOOL OR MACHINE MODIFICATION not obtained from HardingeInc.

7 Must be reviewed by a qualified safety engineer before CAUTION around exposed mechanisms and tooling especially when setting up. Becareful of sharp edges on T USE worn or defective hand tools. Use the proper size and type for the job ONLY a soft-faced hammer on turret tools and T USE worn or broken tooling and/or grippers on CERTAIN that all tool mounting surfaces are clean before mounting ALL CHUCKING/GRIPPING DEVICES daily to make certain that they are ingood operating condition. Replace any defective chuck before operating the MAXIMUM ALLOWABLE gripping pressure. Consider weight, shape, and balance ofthe LIGHTER THAN NORMAL feedrates and depth of cut when machining a workpiecediameter that is larger than the gripping T EXCEED the rated capacity of the machine and/or autoload T LEAVE the machine unattended while it is T CLEAN the machine with an air TOTE PANS a safe distance from the machine. Don t overfill the tote T LET STOCK project past the back end of the collet closer or machine spindlewithout being adequately covered and properly each bar feed manufacturer s guidelines.

8 For performance and safe application,size and use feed tube bushings, pushers, and spindle liners according to bar feed CERTAIN that any bar feed mechanism is properly aligned with the spindle. If thebar feed is a floor-mounted type, it must be securely bolted to the 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 personnelare clear of the machine and Autoload system when opening or closing the coolant guarddoor and any access WARNING -Before activating a new program, turn the control OFF. Wait approximately 10seconds; then, turn the control ON. This will set the collet closer timer to thedefault setting of seconds and will assure safe operation of the YOUR PROTECTION - WORK SAFELYivM-371 Table Of ContentsCHAPTER 1 - REFERENCES and INSTALLATIONM achine Serial Control Serial the the the Case 2 - POWER-UP PROCEDUREB asic Machine Down and Lock Out an Emergency Run Control 3 - Consumption Reservoir and In-Line the Tramp Oil 4 - AIR the Filter/Regulator Unit the Filter Bowls and Air the Air System Coalescing the Collet Closer (GT27, Big-Bore) Air Control Assembly the Pressure Switch(es).

9 4-5 Replace or Clean Manifold(s)..4-6 Solenoid Blast : April, 2000 CHAPTER 5 - COOLANT and Chips and the Reservoir and In-Line Valves and the Coolant 6 - PART LOAD/UNLOAD Pneumatic (Air) Axes Drive 7 - HEADSTOCK and SPINDLE Draw Tube Drive Belt Drive Belt Drive Motor Replacement and Encoder Timing Belt Encoder Encoder Timing Belt the Spindle Brake 8 - COLLET Closer Draw Tube ANSI A2-4 5C Collet A2-4 16C Big-Bore Collet Regulator/Gauge Switch 9 - AXES DRIVE Drive Motor Slide Drive Motor 10 - MISCELLANEOUSAir Fan and Heat Adjust the Part Catcher Adjust the Part Catcher Travel Replace the Solenoid(s)..10-7To Replace the Replace the Pressure Regulator and/or Replace the Part Catcher (Chute) Home Switch (LS 6)..10-9 Worklight, Worklight Tool Holder Table Torque ONEPREVENTIVE MAINTENANCE SCHEDULE and PRODUCTS and TWO - PHOTOGRAPHSCONQUEST GT27/GT27SP Autoload PhotographsM-371viiRevised: January, 2000- NOTES -viiiM-371 CHAPTER 1 - INSTALLATIONMACHINE SERIAL NUMBERThe serial number for the CONQUEST GT27 and CONQUEST GT27SP Autoload system isstamped on plate A , Figure , which is located on the upper right corner of the power case serial number should be included in all correspondence regarding this CONTROL SERIAL NUMBERThe CNC control serial number is located on tag B , Figure , inside the control case.

10 The CRTand operator s control panel are mounted on the control case door. Unthread the screws and rotatethe door open; the tag is located on the control housing. This serial number should be included in allcorrespondence regarding the FOUNDATIONThe CONQUEST GT27/GT27SP Autoload system machines require a substantial foundation. Donot locate the machine near equipment that causes vibration. Poor surface finishes or damage to thecontrol may result from any vibration transmitted to the legs are set at approximately 3 inches [76 mm] creating a minimum 1 inch [ mm] machineclearance. It is not necessary that the machine be set perfectly level unless a bar feed is to be usedwith the machine. However, the machine should be reasonably level, within .13 inch [ mm] in themachine footprint, to allow the way lube oil to be collected at the end of the machine away from thespindle. Shim the support legs with metal plates if NOTES -Refer to Figure to locate the feet in the machine s base.