Lathe Maintenance r0214-201.pdf

8/9/2019 Lathe Maintenance r0214-201.pdf

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April 2005 704-0214-201 Revision A

MAINTENANCEANDSAFETY

MANUAL

for Turning Centers


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ii - Maintenance and Safety Manual 704-0214-201 Lathe Turning Centers

The information in this document is subject to change without notice and does notrepresent a commitment on the part of Hurco Companies, Inc. (Hurco). The softwaredescribed in this document is furnished under the License Agreement to customers. It isagainst the law to copy the software on any medium except as specifically allowed in thelicense agreement. The purchaser may make copies of the software for backup purposes.No part of this document may be reproduced or transmitted in any form or by any means,

electronic or mechanical, including photocopying, for any purpose without the expresswritten permission of the Hurco machine tool owner.

Hurco Manufacturing Company reserves the right to incorporate any modification orimprovements in machines and machine specifications which it considers necessary, anddoes not assume any obligation to make any said changes in machines or equipmentpreviously sold.

Hurco products and services are subject to Hurcos then current prices, terms, andconditions, which are subject to change without notice.

2005 Hurco Companies, Inc. All rights reserved.

Patents: U.S. Patents B14,477,754; 5,453,933; Canadian Patent 1,102,434;

Japanese Patents 1,649,006 and 1,375,124; other Patents pending.

Hurco, Max, Ultimax, and WinMax are Registered Trademarks of Hurco Companies, Inc.

AutoCAD, Autodesk, and DXF are registered trademarks of Autodesk, Inc.

MS-DOS, Microsoft, and Windows are registered trademarks of Microsoft Corporation.

Many of the designations used by manufacturers and sellers to distinguish their productsare claimed as trademarks. Hurco has listed here all trademarks of which it is aware. Formore information about Hurco products and services, contact:

Hurco Companies, Inc.

One Technology WayP.O. Box 68180Indianapolis, IN 46268-0180Tel (317) 293-5309 (products)

(317) 298-2635 (service)Fax (317) 328-2812 (service)

For Hurco subsidiary contact information, go to Hurcos Web site:w w w .h u r c o .c o m


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Lathe Maintenance and Safety Manual 704-0214-201 Table of Contents iii

TABLEOFCONTENTS

Maintenance and Safety Manual

Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiSample Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiScreen Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiConsole Buttons and Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Using the Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiiPrinting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiiIcons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xDaily (Every 8-10 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xWeekly (Every 40-50 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

Monthly (Every 150-200 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xEvery 3 Months (Every 500 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xEvery 6 Months (Every 1000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . xAnnually (Every 2000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3

Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3Guideways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3Switches and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4Spindle and Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6AC Spindle Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7Spindle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7

Axes Motion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8Servo Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11Ballscrews and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11Feedback Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11

Machine Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12Safety Procedures for Electrical Service . . . . . . . . . . . . . . . . . . . . . . . 1 - 12Electrical Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13

Operator Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19Flat Panel Node PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19

Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 20Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 21

Operation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1Safe Installation of Guarding System and Machine . . . . . . . . . . . . . . . . . . 2 - 2Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3

Training for Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3Safety Messages and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3


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Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 6Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 6Safe Working Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7

Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9Persons Trapped in Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 10

Machine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1Daily Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2

Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3Floppy Disk Drive and Diskettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3Exterior Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4Autolube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 7Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 7

Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8

Selecting Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8Preparing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 9Maintaining the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 9Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 10

Limit Switches and Dogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 10Machine Electrical Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 10Machine Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 10Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 11Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 12

Power-Up Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 12Initialization Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 13Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 13Common Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 15

Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 21Information Required for Parts Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 21Returning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 21

Machine Operations and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2Bar Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3Chip Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3

Chip Conveyor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3Chip Conveyor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5

Chuck Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 6Operating Dimension Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 8Optional Chuck Footswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 8Chuck Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 8Chuck Hydraulic Pressure Gauge Settings . . . . . . . . . . . . . . . . . . . . . . .4 - 10Chuck Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 11

Parts Catcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 12Parts Catcher Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 12Parts Catcher Pneumatic System Filter and Regulator Unit . . . . . . . . . . .4 - 14


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Lathe Maintenance and Safety Manual 704-0214-201 Table of Contents v

Tailstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16Tailstock Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16Optional Tailstock Footswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17Tailstock Hydraulic Pressure Gauge Settings . . . . . . . . . . . . . . . . . . . . 4 - 17

Tool Setter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18Tool Setter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18

Tool Setter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19

Record of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

LISTOFFIGURES

Figure 11. Hurco TM8 Turning Center with the Max for Lathe Consoleand Options 1 - 2

Figure 12. Full Chip and Coolant Enclosure with Side Door Open . . . . . . . . . . 1 - 4Figure 13. Communication Port Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16Figure 14. Male 9-Pin D-Type Connector . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17Figure 15. Max for Lathe Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19

Figure 21. Locations of Safety Warning and Decals . . . . . . . . . . . . . . . . . . . 2 - 4Figure 22. Warning Decals and Instruction Plates . . . . . . . . . . . . . . . . . . . . 2 - 5

Figure 31. Autolube Pump and Tank Assembly . . . . . . . . . . . . . . . . . . . . . . 3 - 5

Figure 41. Hurco TM8 Turning Center with the Max for Lathe Consoleand Options 4 - 2

Figure 42. Manual screen with Chip Conveyor softkeys . . . . . . . . . . . . . . . . 4 - 4Figure 43. Auto Run screen with Chip Conveyor softkeys . . . . . . . . . . . . . . . 4 - 4Figure 44. External Closed, Internal Closed, and Collet chucks . . . . . . . . . . . 4 - 6Figure 45. Chuck Operations softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7Figure 46. Grease Zerk Fittings on Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10Figure 47. Accessory Operations softkeys . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11Figure 48. Cutoff Block with Parts Catcher fields . . . . . . . . . . . . . . . . . . . . . 4 - 12Figure 49. Filter and Regulator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13Figure 410. Accessory Operations softkeys 4 - 15Figure 411. Accessory Operations softkeys 4 - 17Figure 412.Tool Setter Stylus Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18

Figure 413.Positioning the Stylus Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19Figure 414.Hardware Configurations screen . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20Figure 415.Tool Setter Calibration screen . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21Figure 416.Boring Block and Test Bar in Turret . . . . . . . . . . . . . . . . . . . . . . 4 - 22Figure 417.Starting Position for X- Calibration . . . . . . . . . . . . . . . . . . . . . . . 4 - 23Figure 418.Test Plate Secured to Turret with Magnet . . . . . . . . . . . . . . . . . . 4 - 24Figure 419.Test Plate Positioned at Tool Setter Head . . . . . . . . . . . . . . . . . . 4 - 25
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vi - Table of Contents 704-0214-201 Lathe Maintenance and Safety Manual

LISTOFTABLES

Table 11. TM Spindle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Table 12. Draw Tube Thru-Hole Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6Table 13. Draw Tube Sroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6Table 14. Draw Pull Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6Table 15. Spindle Drive Belt Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7Table 16. TM Axes Motion Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10Table 17. Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16Table 18. RS-232-C Signals Available at Serial Port . . . . . . . . . . . . . . . . . . . 1 - 17Table 19. TM6, TM8, TM10 Coolant Capacity and Pump Rating . . . . . . . . . . . 1 - 20Table 110. TM Tooling Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 22

Table 21. Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9

Table 31. Lubrication for Lathes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4

Table 32. Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8Table 33. Missing or Faulty Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 15Table 34. Power Fluctuation Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 3 - 16Table 35. Coolant System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17Table 36. Motion and Spindle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 3 - 19Table 37. Environmental Factors Troubleshooting . . . . . . . . . . . . . . . . . . . . 3 - 20

Table 41. Chuck Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7Table 42. Maximum Chuck Hydraulic Operating Pressure Settings . . . . . . . . . 4 - 10Table 43. Maximum Tailstock Hydraulic Pressure Settings . . . . . . . . . . . . . . . 4 - 17


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Lathe Maintenance and Safety Manual 704-0214-201 Using This Manual vii

USINGTHISMANUAL

Sample ScreensSample screens in this manual were taken from a Max Control for Lathe. All screens aresubject to change. The screens on your system may vary slightly. The sample screen hereillustrates softkeys and includes the software version.

SoftkeysSoftkeys are located on the side of the screen. You can set the softkeys to appear oneither the right or left side of the screen. Refer to the Getting Started with Max for TurningCentersmanual for information about making this selection. Softkeys may change uponfield entries or other softkey selection. References to softkeys in the documentationappear in all caps followed by the softkeys corresponding F-key. For example, the PartSetup softkey from the Input screen above is referenced as the PART SETUP F1 softkey.

Screen AreasThe screens are divided into the following four areas, in addition to the row of softkeys:

Data EntryThe data entry area is located on the opposite side of the screen from the softkeys. Fieldsin the data entry area display or receive information. Refer to Using the Touch Screen, onpage viiifor information on entering information in fields.

Prompts

Status Bar

Error/Status Area

Softkeys

F1 to F8

Data Entry Area


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viii - Using This Manual 704-0214-201 Lathe Turning Centers

Prompts and Error/Status AreaThe bottom portion of the screen is reserved for prompts, program status and errormessages.

Prompts provide help on data entry selections based on the field with the blinking cursor.

Errors and status messages can occur anytime the status or error is true. They are notbased on the field with the blinking cursor. These messages provide machine informationto the operator and error messages may also stop and/or prevent machine operations. Anexample of a status message is Way Lube is Low.

Status BarThe status bar contains

The name of the open, selected program.

A calculator iconselect the icon to display a working, on-screen calculator.

Units of measure (Inch or Millimeters). When Inch is displayed, you can selectit in the status bar to change to Millimeters, and vice versa.

Programming mode (R for Radius; D for Diameter). When Radius is displayed,you can select it in the status bar to change to Diameter, and vice versa.

A yellow icon indicating when the feed hold is on.

A red icon indicating that the Emergency Stop button has been pressed.

Console Buttons and KeysReferences to console buttons and keys appear in bold text throughout thedocumentation. For example, the Start Cycle button appears as the Start Cyclebuttonand the Manual key appears as the Manualkey in text.

Refer to the Getting Started with Max Control for Turning Centers manual for informationabout console buttons and keys, in addition to other information about using softkeys andthe pop-up text entry window.

Using the Touch Screen

The console Max Control for Lathes has a touch screen for entering programming data.Tap the screen on a softkey, field, or drop-down list using the stylus attached to the sideof the console or another suitable pointing device to make selections.

Printing

To print part or all of this manual from the CD, select File/Printto print this document.Be sure to review the Print Rangeselections and make the appropriate choice for pages.Select Properties/Paper/Qualityand adjust the Tray Selection/Paper Sourceifnecessary.


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Lathe Maintenance and Safety Manual 704-0214-201 Using This Manual ix

Icons

This manual may contain the following icons:

Caution/Warning

Hints and Tricks

Important

Troubleshooting

Where can we go from here?

Table of Contents

The operator may be injured and the turning center severely damaged if thedescribed procedure is not followed.

Useful suggestions that show creative uses of the Lathe Max features.

Ensures proper operation of the machine and control.

? Steps that can be taken to solve potential problems.

Lists several possible options the operator can take.

To assist with onscreen viewing, this icon is located on the cover page. Clickthe icon to access the Table of Contents.

You can also access many of the same TOC entries from the Adobe Readerbookmarks located on the left side of the PDF page.


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Lathe Maintenance and Safety Manual 704-0214-201 Machine Components1-1

MACHINECOMPONENTS

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4

Spindle and Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Axes Motion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8

Machine Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12

Operator Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19

Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 20

Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 21


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1 - 2 Machine Components 704-0214-201 Lathe Maintenance and Safety Manual

Overview

Before using the machine, you should become familiar with its components. Because ofEuropean Committee (CE) requirements, Hurco machines sold in Europe may differ fromthose sold elsewhere. The figure below identifies some of the easily recognized

components of a machine. The location of some components may differ on other models.

Figure 11. Hurco TM8 Turning Center with the Max for Lathe Console and Options

Hurco machines are available with several hardware and software options.

Hurco turning centers use microprocessor-based, computer numerical control (CNC)

digital control systems. Part programs are entered in either Conversational orConventional NC (G-Code) format.

All machining centers described in this manual have a horizontal spindle withprogrammable spindle speeds, and a multi-tool turret and two axes. Options are availableto accommodate various turning applications.

1 Machine Frame or Base

2 Console

3 Turret

4 Parts Catcher option

5 Conveyor option

6 Coolant Drip Tray

7 Enclosure Door. The spindle is located inside the

machine behind this door.

8 Power cabinet (rear)

9 Communications panel (side)

10 Tailstock and chuck gauges

11 Way lube pump (may also be located on the right sideof the machine frame)

12 Bar Feeder option

Information about options is available from Hurco or your Hurcodistributor.


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Closed loop servo drive systems and motors with rotary encoders power the mechanicaldrives that position the axes. The rotary encoders provide positioning feedbackinformation to the control. Limit switches mounted on each axis determine end-of-traveland establish reference points for initial machine zeros.

The control positions an axis by sending a command to the appropriate servo drive, whichin turn supplies voltage to the connected axis servomotor.

Refer to the Parts Listings and Wiring Diagrams Manualfor mechanical and electricalcomponent drawings for your machine.

The TM6, TM8, and TM10 machines are described in this manual.

FrameThe major structural assemblies of each Hurco machine are constructed of thick-walled,fine-grain cast iron. This construction provides strength and excellent dampeningcharacteristics, keeping deflection and resistance at a minimum during turning.

The machine base (including leveling bolts) is the substructure for the column and table.The column is a rigid box type, and allows for machining a variety of part sizes. The basesupports the table and preserves table flatness.

Head

The cast iron head assembly is designed to produce superior cutting accuracy.

Guideways

The X and Z axes guideways are oversized, precision linear rails.

Switches and Sensors

Limit switches, proximity switches, and electrical sensors monitor machine functions.These devices report their state to the control. If a malfunction is detected, a stopcondition will shut off power to the servo systems and spindle.

Machine linear positioning accuracy was set at the factory, in anambient temperature of 68 F (20 C). Continual operation athigher or lower temperatures may require that you re-compensate the linear positioning accuracy.


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Enclosure

Full chip enclosures are standard in Hurco turning centers.

Figure 12. Full Chip and Coolant Enclosure with Side Door Open

Standard features include a flood coolant system with chip pan. An optional chipconveyor may be installed.


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Spindle and Drive System

The spindle and drive system consists of a spindle, motor with encoder, pulleyarrangement and drive unit. Different size spindles, motors and pulleys gives eachmachine its unique cutting power specification.

Table 11. TM Spindle Specifications

TM6 Spindle Specifications

Max RPM 6000 rpm

Base Speed RPM 1090 rpm

Motor HP - Continuous 7.5 kW 10 hp

Motor HP - Peak (1 min. rating) 11 kW 15 hp

Spindle Torque - Continuous 65 Nm @ 1090 rpm 48 ft-lb @1090 rpm

Spindle Torque - Peak (1 min. rating) 98 Nm @ 1090 rpm 72 ft-lb. @ 1090 rpm


Max RPM 4800 rpm


Motor HP - Continuous 11 kW 15 hp

Motor HP - Peak (1 min. rating) 14 kW 19 hp

Spindle Torque - Continuous 123 Nm @ 870rpm 91 ft-lb @ 870 rpm

Spindle Torque - Peak (1 min. rating) 155 Nm @ 870 rpm 114 ft-lb. @ 870 rpm


Max RPM 3000 rpm


Motor HP - Continuous 15 kW 20 hp

Motor HP - Peak (1 min. rating) 18.6 kW 25 hp

Spindle Torque - Continuous 249 Nm @ 572 rpm 184 ft-lb @ 572 rpm

Spindle Torque - Peak (1 min. rating) 311 Nm @ 572 230 ft-lb. @ 572 rpm


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Spindle

TM lathes have a cartridge type spindle. This spindle is precision balanced, and made ofhigh-grade alloy steel. The spindle shaft (inside the cartridge) is supported by ABEC-7class angular contact bearings. The bearings are grease packed.

The workpiece or material is held in either a three-jaw chuck or collet chuck clamped bya hydraulically actuated draw tube. The following table contains the draw tube thru-holediameter for each machine type:

Table 12. Draw Tube Thru-Hole Diameter

The following table contains the draw tube stroke measurements:

Table 13. Draw Tube Sroke

The following table contains the maximum draw pull force measurements:

Table 14. Draw Pull Force

Pressure is adjusted through a valve located under an access panel at the lower left sideof the front of the machine. Clamping by external, internal, or collet type workholdingcan be set through the manual mode. The chuck is opened or closed by pressing the footpedal. Maximum clamping pressure is approximately 400 psi.

Draw Tube Thru-Hole Diameter

Model mm inches

TM6 46 1.8

TM8 52 2

TM10 75 2.9

Draw Tube Stroke

Model mm inches

TM6 15 0.6

TM8 22 0.9

TM10 25 1.0

Maximum Draw Pull Force

Model kN lb

TM6 33 7419

TM8 56 12589

TM10 69 15512


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AC Spindle Drive Unit

The spindle drive uses Flux Vector control method for precise speed and torque controlover a wide range of motor speeds. The spindle system also requires an encoder forfeedback. A microprocessor along with programming parameters governs the closed-loopcontrol and monitoring.

The following messages are output at terminals via relay contacts:

Speed Agree

Spindle Fault

When the spindle drive detects a fault or alarm, the fault information is displayed on theDigital Operator (i.e., OC, or Overcurrent), the fault contact closes, and the motor stops.

Spindle Motor

The spindle motor and spindle are coupled using a no-slippage gear belt. The motor isfully enclosed, uses forced-air cooling, and has no brushes to inspect or replace.

Table 15. Spindle Drive Belt Ratio

To allow the machining of a variety of parts, the spindle RPM is specified in the partprogram. A manual spindle speed override on the control console permits fine-tuning ofthe spindle RPM for a specific machining cycle, without changing the part program.

Machine Spindle Drive/Belt Ratio

TM6 1.33 :1

TM8 1.67 :1

TM10 1.67 :1


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Axes Motion System

AC servo drive systems power the X and Z axes in Hurco turning centers. Approximatepositioning specifications appear below.

TM6

X Axis Specifications Metric Inch

Motor TorqueContinuous 5.4 N m 48 lb-in.

Motor TorquePeak 13.8 N m 122 lb-in.

Axis ThrustContinuous 2.9 kN 650 lbs.

Axis ThrustPeak 7.4 kN 1655 lbs.

Rapid Feed Rate 19 m/min. 750 ipm

Maximum Travel (45 incline) 177 mm 7 in.

Z Axis Specifications Metric Inch






Maximum Travel (horizontal) 356 mm 14 in.


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TM8
















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Table 16. TM Axes Motion Specifications

TM10
















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Servo Motors

The CNC controls axes velocity and travel direction using AC servomotors. These motorsare enclosed, transistor-driven, and self-cooled. Because they are designed withoutbrushes, the motors are free from flashover and commutation loss.

Ballscrews and Bearings

The precision ballscrews are the double ballnut type. The ballscrews are hardened andground to minimize drag torque and reduce backlash.

The axes positioning drives are supported at the drive-ends by ABEC-7 class bearings.

Feedback Systems

Each drive has circuitry to detect conditions in the servos closed-loop system.

Each axis motor is equipped with a rotary encoder that provides velocity and positionfeedback signals for each closed-loop system. These signals are required for motorcontrol and accurate positioning.

Limit switches mounted on each axis are used to establish reference points for initialmachine zeros and for determining end-of-travel.


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Machine Electrical Cabinet

The machines electrical control cabinet contains CNC-related electronics and power-related circuitry.

Safety Procedures for Electr ical Service

Before removing or working on any printed circuit board (PCB), cables, fuses, breakers,or other machine components, make sure that the main disconnect switch on theelectrical cabinet door is in the OFF position. Whenever work will be performed in an areaaway from the main disconnect switch, post a warning at the switch informing others thatthe machine is being serviced and the power must remain OFF.

Handling Printed Circui t Boards

The following procedures should be taken to prevent damage when removing printedcircuit boards (PCB), or when checking the boards for proper and secure connections.

Avoid flexing PCBs. Rough handling can result in hairline cracks in the printed circuitetching. Problems caused by cracks in PC boards can be hard to isolate. Avoid touchingthe components on a PCB because they can be damaged by static electricity.

Always put on a static safe handling wrist strap before touching PCBassemblies inside the cabinets, and before removing replacement boardsfrom their static protective packaging.

Visually inspect the wrist strap every time you put it on, making sure that thesnap fasteners are properly connected.

Be sure the strap fits snug to the wrist. Taking off the wrist strap should bethe last thing you do when finished inside the cabinet.

After the replacement PCB is properly mounted in the cabinet, place thedefective PCB assembly into the static shielding and return to Hurco.

High voltages inside of the electrical cabinet can cause serious injuryor death. Only qualified personnel may service the machine, andmust follow all safety rules and precautions. The line-side of themain disconnect switch is hot, unless the AC source is disconnected.


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Electr ical Cabinet Components

The electrical cabinet contains power circuitry and CNC electronics. The cabinet isattached to the machine column and connects to the machine systems via cable andharness assemblies.

Power-related circuitry distributes power, while CNC-related electronics control machineoperation (e.g., spindle speed and axis positioning).

Electrical Cabinet Operating Temperature

The electronics inside of the electrical cabinet are designed to tolerate reasonably highambient temperatures. Fans on some of the electronic assemblies and a heat exchangeron the cabinet door circulate warm air away from components.

The cabinet contains a temperature sensor, mounted on the CANbus control board in theISA control board rack. This sensor is preset to a high temperature limit. If thetemperature exceeds the limit, the machine will enter an emergency stop condition.

Hurco Turning Centers that are not equipped with the air conditioning option may be

operated in ambient temperatures up to 95 F (35 C), and in relative humidity (non-condensing) up to 95%.

Electrical Cabinet Layout

Electrical cabinet layouts may vary from machine to machine. See the Parts Listings andWiring Diagrams Manual for your machine model.

Power Supply

The DC switching power supply mounted on the ISA control card rack converts the 115VAC input power to the regulated DC voltages distributed by the DC distribution board.The DC distribution board supplies regulated DC voltages to all printed circuit boardassemblies in the card cage, console, and control relays.


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CNC Electronics

The primary CNC-related PC boards that are located in the machines electrical cabinetare described below.

ISA Control Card Rack

The ISA Control Card Rack contains the following microprocessor control PCBs:

Main CPU (Single Board CPU and Passive Backplane)

Peripheral Interface

Dual VGA Board

Motion Controller

CANbus Controller

CANbus DC I/O Backplane

I/O Interface

Main CPU Board

The main CPU board is a single board computer with a microprocessor CPU.

The CPU board uses a passive backplane that provides both ISA and PCI buses, and isjumper-configurable to permit system performance enhancements. Since the boardsmemory requirements are based upon the application requirements, memory isupgradeable.

Peripheral Interface

The control supports standard AT-compatible peripherals including:

Hard disk

Serial interfaceCOM1

Floppy disk

The interface for the hard disk is an integrated disk electronics (IDE) interface. It isconsidered integrated because the hard disk controller resides on the drive itself and theinterface resides on the motherboard. The connector for this interface is typically a dualrow, 40-pin header.

The main CPU board supports a standard, 34-pin, PC/AT style, floppy disk interface. Thebase level system has at least one 1.44 MB drive.

VGA Board

The VGA board enables the CPU board to display text and graphics on the display. TheVGA board connects to the CPU board via the PCI bus.


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Motion Control Board

The motion control subsystem uses a PCI servo transducer card to pass velocitycommands from the soft motion system to the servo drive and spindle pack. Thetransducer card also converts A quad B encoder feedback to position data that in turn isread by the motion software. The PCI servo transducer supports S, X, Z, C, Y, and S axes.

CANbus Controller BoardThe CANbus is a multi-master serial bus developed for the controller area network (CAN).This bus is the input/output (I/O) center of the Ultimax ISA platform.

The CANbus controller board and the DC I/O interface board handle the I/O controlfunctions within the CNC controller. The external node used by the machining center isthe console interface.

The CANbus controller board is an intelligent AT bus board for executing logic controlprograms, controlling CANbus I/O, controlling local 24-volt I/O, and monitoring the on-board A/D converter.

CANbus DC I/O Backplane

The CANbus DC I/O backplane distributes power and CANbus signals to the I/O interfaceboard. The basic voltage levels are +5VDC, +/-12VDC, +24VDC. There are three isolatedgrounds: digital GND, machine GND, and analog GND. The backplane slot determines thenode address of the board.

I/O Interface Board

The CANbus I/O interface board forms the interface between the motion subsystem andthe CANbus controller I/O. The I/O signals on this board are buffered and then routedwithin the enclosure over a ribbon cable to the motion or CANbus subsystems. The boarduses Honda connectors.

CANbus DC I/O Node

The CANbus DC I/O Node board mounts on the CANbus DC I/O backplane in theextension enclosure to the ISA card rack. This board communicates with the machinethrough 32 input and 32 output connections, and transfers information through thebackplane to the CANbus controller.

The 24 volt solid state outputs are current limited to 150mA. Outputs are disabled atpower up and when the E-Stop button is depressed.

Multiple boards may be used to provide additional I/O. The extension enclosure acceptstwo of these boards in addition to the I/O interface board; all are connected to theCANbus DC I/O backplane. Expansion for other boards is possible.


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Communication Ports

All communication ports are located on the Comm Port panel assembly on machinecontrol cabinet. The following connectors are available:

Table 17. Communication Ports

The communication ports are typically arranged as follows:

Figure 13. Communication Port Assembly

Port Connector Type Use

PORT 1 9-pin RS-232 C Serial Communications

10-base T RJ45 Network (Ethernet)

USB USB Printer and jump drive connection


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RS-232-C Serial Port

The RS-232-C serial port can be used to connect peripherals to the machine. This portmay be addressed separately. The standard baud rates are software-selectable. The portcan be used as an output or input, depending upon the software.

The connector pin designated for the RS-232-C signal is shown below:

Figure 14. Male 9-Pin D-Type Connector

While the signals present at the serial port conforms to the RS-232-C standard, not allstandard RS-232-C signals are available. Some peripheral devices may provide RS-232-Ccontrol signals that are not available at the port described here. However, such devicescan usually be adapted to the port. In some cases, it may be necessary to add jumpers tothe connector. Signals available at the serial port are:

Table 18. RS-232-C Signals Available at Serial Port

COM 1 Signal Name Signal on this Pin

1 Data Carrier Detect (DCD) Not used by the control.

2 Receive Data (RXD) Data received (by machine) in serial format

from peripheral device.

3 Transmit Data (TXD) Data transmitted (by machine) to peripheral

device in serial format.

4 Data Terminal Ready (DTR) Not used by the control.

5 Signal Ground (SG) Line establishing the common ground

reference potential for all interface lines

6 Data Set Ready (DSR) Signal to notify printer that transmitter is

ready for transmission.

7 Request to Send (RTS) Line used by control to instruct peripheral

device to get ready to receive data. Data canbe transmitted after the Clear-To-Send signal

is received from connected peripheral device.

8 Clear to Send (CTS) Control line used by peripheral device to

indicate that it is ready to receive data frommachine.

9 Ring Indicator (RI) Signal indicates modem has received the ringof an incoming call.

1 2 3 4 5

6 7 8 9


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To connect a peripheral to the machine, fabricate an adapter cable. If a properly shieldedlow capacitance cable is used, cable lengths of up to 100 feet are permissible.

Be certain that you use the correct cabling before connecting the device to the machine.Consult the peripheral manual to determine whether the peripheral is a Data TerminalEquipment (DTE) or Data Communication Equipment (DCE) device. The Hurco machine isa DTE device, and in most cases, so is a personal computer. A printer may be either a

DTE or DCE device.

Network Ports

The 10baseT (RJ45) connector is used with the Ultinet option. This option requires anethernet card, cabling from the ethernet card to the communications panel, and anoptikey diskette to enable the option.

USB Port

The USB Port (Universal Serial Bus) is a high-speed port that allows you to connectdevices, such as printers and jump drives to the panel. You can use a jump drive totransfer files.


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Operator Control Console

Hurco Lathes come with a Max Control for Lathes console. Contact your full servicedistributor or Hurco for more information about features.

For operating and programming information, refer to the Getting Started Manual,Conversational Part Programming Manual,and the NC Part Programming Manualshippedwith the machine.

A Max for Lathe console is pictured below:

Figure 15. Max for Lathe Control Console

Flat Panel Node PCB

The CANbus Flat Panel Node PCB is an intelligent slave that processes the operatorinterface I/O functions related to the console. This PCB is located in the control consoleand has the following features:

An 8 x 8 keyboard matrix for scanning, decoding and debouncing of keys.

Outputs to control 16 discrete LEDs and three 24-volt status lamps.

Emergency stop hardware contacts and software input.

Green Run LED and red system fail Sysfail LED.


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Coolant System

A flood coolant system is standard on each machining center. A washdown hose andnozzle to clean chips from inside the enclosure are also included.

Table 19. TM6, TM8, TM10 Coolant Capacity and Pump Rating

The flood coolant system cleans swarf from the cut and protects the part and tool. Thesystem is self-contained. The operator can control the coolant system using consolepushbuttons.

TM6

Tank Capacity Flood Pump Rating Flood Pump Size

94.5 L 41 L/Min. 0.66 kW

25 Gal. 11 Gal./min. 0.89 hp

TM8


113 L 41 L/Min. 0.66 kW

30 Gal. 11 Gal./min. 0.89 hp

TM10


113 L 41 L/Min. 0.66 kW

30 Gal. 11 Gal./min. 0.89 hp


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Turret

The Lathe uses hydraulics and switches to rotate and position OD (outer diameter) and ID(inner diameter) tools around the slotted disc turret. A hydraulic pump pressure gauge islocated at the rear of the machine, along with a thermometer and sight gauge. The

maximum hydraulic pressure setting for the turret is 32 kg/cm2(455 psi). You canincrease or decrease the pressure for clamp and unclamp for smooth operation using theknob located near the pump assembly and turret solenoids.

The table below lists tooling specifications:

TM6

Specifications Units

Tool Stations 12

Tool Holder Type 30 VDI

Adjacent Turret Rotation .5 sec.

Farthest Turret Rotation 1.5 sec.

Turret Positioning Accuracy +/- 2 arc sec.

Turret Repeatability Accuracy +/- 0.5 arc sec.

Tool Shank Width 19 mm x 19 mm .75 in. x .75 in.

Boring Bar Diameter 31 mm 1.25 in.

TM8


Tool Stations 10






Tool Shank Width 25 mm x 25 mm 1.0 in. x 1.0 in.

Boring Bar Diameter 38 mm 1.5 in.


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Table 110. TM Tooling Specifications

The basic sequence of operation, assuming that the magazine is positioned to the nexttool required, is as follows:

1. Start the tool change process with the turret at Home position and the spindleoriented.

2. The turret rotates from the Up position to the Down position.

3. The tool indexer rotates CCW direction

4. The spindle clamps the tool in the spindle.

5. The tool indexer rotates back to the 0 degree position.

6. The turret rotates back to the Up position.

TM10


Tool Stations 12






Tool Shank Width 25 mm x 25 mm 1.0 in. x 1.0 in.

Boring Bar Diameter 50.8 mm 2.0 in.

Keep tool clearances in mind during tool setup to avoid tools comingin contact with the chuck or the rear of the tool indexer.


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Lathe Maintenance and Safety Manual 704-0214-201 Operation Requirements2-1

OPERATIONREQUIREMENTS

This chapter contains the following requirements for operating the turning center.

Safe Installation of Guarding System and Machine . . . . . . . . . . . . . . . . . . . . . . 2 - 2

Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3

Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9

Noise Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9

Persons Trapped in Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10


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2 - 2 Operation Requirements 704-0214-201 Lathe Maintenance and Safety Manual

Safe Installation of Guarding System and

Machine

Inspect the machining center to ensure that all parts are included and intact. The owner

is responsible for proper site preparation before the machine is installed. A Hurco FieldService Engineer must install the machine in the prepared location. This location mustnot subject the machine to uncontrolled cabinet temperatures or unfavorable workenvironment conditions that could cause electronic component failure.

If the owner decides later to move the machining center from its installed location, it is

recommended that the owner call Hurco for assistance.

Each machining center has a self-contained guarding system. Inspect the machine toensure the guarding system is intact. The chip doors on the front of the machine lock

during Automatic Run Mode to prevent access to the moving parts of the machine.

Safety Circuits

If the owner or operator modifies the hardware or software by removing, altering,disabling, or tampering with any safety circuit, safety switch, or other safety operationand operates the turning center with those modifications, such operation is extremelyhazardous and is a foreseeablemisuseof the machine, and voids the Hurco warranty. Ifsuch modifications are discovered, the turning center must be immediately shut off andnot used. Contact a Hurco-Certified Engineer for assistance in restoring the machine to

safe operation.

The Hurco turning centers safety circuit is designed to provide safe and reliableoperation. Tamper-resistant fasteners are used to hold combination door lock/switches inplace and to prevent access to internal wiring. Here are basic rules governing operation:

The spindle cannot operate unless all enclosure doors are closed, excludingdoors that are fastened shut with bolts or screws.

Enclosure doors must be closed and locked during automatic execution,warm-up cycle, calibration cycle, automatic tool changes, probing, or whenrunning the spindle.

In the event that the enclosure door is opened during automatic operation, or

any time the doors are locked, an immediate command to stop all motion willbe executed and control power will be removed.

Redundancy is included in electrical design to detect single point failures.

When the Emergency Stop button is pressed, power is cut off to the spindle,after allowing for deceleration.

Turret electrical circuits will be isolated from source power when any door isopen.

Improper moving of the machine may result in personal injury ordamage to the machine.


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Safe Operation

This section addresses the safe operation of the machining center. The informationpresented here is not a substitute for operator training, skill, and good judgment. Hurcodoes not accept any liability for operator error.

Training for Operators

Hurco or a Hurco authorized distributor must train all machining center operators. Hurcooffers classes to demonstrate the programming capabilities of its CNC system. Thetraining classes provide hands-on development of part programs.

Safety Messages and Decals

Study this manual before attempting to operate the turning center and become familiarwith machine functions and safety features. Review all caution and warning messages, as

well as all warning and instruction plates or decals on the turning center.


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Safety Warnings and Decal Locations

Figure 21. Locations of Safety Warning and Decals


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Safety Warning and Decal Definitions

1. Arm Entanglement/Roller Shaft Label

6. Tailstock/Pressure Label

with factory setting

11. Chip Conveyor Label/

12. Coolant Pump Label

2. Hand Entanglement/

Belt Drive Label

7. Hydraulic Chuck/Pressure Label with

factory setting

13. Industrial Certification

Label

3. Technical Manual Label 8. Hand Entanglement/

Rotating Shaft Label

14. Electrical Shock Caution

Label

4. Cutting of Hand Label

9. CE Label

15./16.Machine

Identification Label/Pop

Rivet

5. Hand Crush/Side ForceLabel

10. Burn Hazard/HotSurface Label

17./18. Blanking Plate/

M3.5 x6.35 LG DriveScrews

Figure 22. Warning Decals and Instruction Plates


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Setup

Follow these precautions during machine and production setup:

Perform all setup work with the Emergency Stop engaged. Never put yourhands near a part being machined.

Clamp the work piece securely before starting the machine. Loose objectssuch as wrenches and chuck keys can become flying projectiles if notremoved before starting the machine.

Wear gloves or use a shop cloth when handling tooling.

Inspect tools and tool holders frequently. Use tools that are properlysharpened and in good condition.

Never start the machine when the cutter is in contact with the work piece.Make sure the direction of spindle rotation is correct to prevent cutterbreakage. Rotate the spindle clockwise for right-hand tools, andcounterclockwise for left-hand tools.

Keep the work area well lighted. Adjust lamps so that light does not shinedirectly into the operators eyes.

Operation and Maintenance

Know where the Emergency Stop pushbuttons are located.

Do not leave the machine unattended, but stand away while it is running.Never lean on the machine.

Be aware of all pinch points caused by the motion of the axes, turret, and anyindexing options. Be aware of protruding machine parts.

Keep the electrical cabinet doors closed while power is on. Before opening theelectrical cabinet doors, verify that the main disconnect switch has been

turned Off.

Do not remove or bypass safety limit switches, interlocks and othersafeguards.

Do not start the machine unless all systems contain the proper amount andtype of lubricant.

Make certain that all necessary guards and protective devices are in placebefore operating the machine.

If unusual sounds, smoke, heat or damaged parts occur, turn off themachine.

High voltages present in the machines electrical system can causeserious injury or even death.


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Safe Working Practices

Follow the correct service and repair procedures to ensure safe operation of themachining center, and to reduce the likelihood of serious operator injury.

Observe these basic safety precautions when working near a machine:

Responsible Conduct

Follow the instructions provided when performing a maintenance task.

Keep all parts of your body away from moving parts.

Be alert and keep safety in mind.

Never attempt to operate or repair a machine if you have taken strongmedication, used a prescription drug, or consumed an alcoholic beverage.

Do not attempt to operate or repair a machine until you have read andunderstood all information that pertains to the machine, including all warningand instruction plates or decals mounted on the machine.

Know how the machine functions, and understand its safety features.

Personal Care

Avoid frequent or prolonged skin contact with fresh or used cutting fluids and oils. Ifmachining chemicals come in contact with your skin, wash the area immediately. Washyour hands thoroughly before eating. Change clothing that has become contaminatedwith machining fluids and oils.

For complete information about handling industrial chemicals used in machining, refer tothe international Control of Substances Hazardous to Health (COSHH) materials from thechemical suppliers.

Wearing Apparel Wear eye protection and safety shoes while in the machining center work

area. Safety glasses with side shields are recommended. Safety shoes shouldbe in good condition, with steel reinforced toes and oil-resistant soles.

Remove clothing and jewelry that could get caught in the machines movingparts. Do not wear loose-fitting clothing. Long shirt sleeves are notrecommended.

Keep long hair tied-back so that vision is not obstructed and hair cannotbecome caught in moving parts.

Heavy Lifting

Do not attempt to lift more than you can safely handle. When lifting, keepyour back straight and use your legs.

Use a hoist for heavy lifting, making sure that the load is evenly balanced andis raised slowly.

Do not raise a large load over aisles and make certain that the landing area isclear and level.


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Housekeeping

Maintain a clean and orderly workspace around the machine. The floor mustbe free of spills and obstructions.

Use only sturdy work platforms with anti-slip surfaces around the machine.

Do not store tools, shop cloths, and miscellaneous parts on the machine.

When removing chips, make certain the spindle is completely stopped. Use abrush or chip scraper to remove chipsdo not use compressed air to blowchips from the spindle, controls, cabinet or floor. Do not remove chips byhand, or while the spindle is turning. Dispose of chips frequently.


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Control Systems

Circuit diagrams for electrical, hydraulic, and pneumatic systems are available in themachining centers Parts Listings and Wiring Diagram Manual.

Noise Levels

The following noise level readings were taken in the vicinity of the turning center, 1.6meters from the floor and 1 meter from the machines enclosure. The maximum ambientnoise level reading taken for each machine at the time was 60 dB.

Measurements were made with background noise present using a dB meter set on A-rated scale. The sensor head was placed vertical to the floor.

Table 21. Noise Levels

Readings Measured From CNC

Machine dB Reading

TM6 max 82 dB

TM8 max 82 dB

TM10 max 82 dB

The noise emission levels in the previous table are for reference only,

and are not necessarily safe working levels. While there is acorrelation between the emission and exposure levels, this cannot beused to determine whether further precautions are required. Factorsthat influence the actual level of exposure of the workforce includecharacteristics of the workroom, other sources of noise, the numberof machines and other adjacent processes. Also the permissibleexposure level can vary from country to country. This information,however, will enable the user of the machine to make a betterevaluation of the hazard and risk.


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Persons Trapped in Machine

If all safety circuits are intact, it is not possible to run a machining center while in directcontact with any axis, the turret or chip conveyor.

To release a person trapped in the machine, press the Emergency Stop button

With machine power off, the relief valves will depressurize, allowing manualmovement of machine components.

With machine power on, counter motions can be activated using the control.In addition, power-piloted valves can be activated by pressing corresponding

buttons.

Enclosure doors should not be closed while performing maintenance inside the machineenclosure.

Personnel should not perform maintenance inside the machine enclosure withoutsomeone else present.

To release locked enclosure doors, you must power On the machine:

1. Press the Manual console key.

2. Turn the machine power On. The enclosure doors automatically unlock.

Pressing the Emergency Stop button will lock enclosure doors.


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Lathe Maintenance and Safety Manual 704-0214-201 Machine Maintenance3-1

MACHINEMAINTENANCE

The maintenance schedule in this chapter is a based on normal use (8 hours of operation

per day). Your machines maintenance schedule may vary. Machines operated for longerperiods each day, or in warm or humid environments, should be serviced more often.

This chapter contains the following machine maintenance information:

Daily Operational Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4

Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8

Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8

Limit Switches and Dogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10

Machine Electrical Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10

Machine Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12

Ordering Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21

Information Required for Parts Orders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21

Returning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21


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3 - 2 Machine Maintenance 704-0214-201 Lathe Maintenance and Safety Manual

Daily Operational Checks

The operator should perform the following each day:

Check that all shields, covers and doors operate properly.

Jog each axis through its full travel, watching for smooth operation.

Ensure that all axis limit switches are functioning correctly and are adjustedto their proper travel limits.

Inspect the guideways for scratches or excessive wear.

Check that the way wipers are not damaged.

Touch the guideways to check for proper lubrication. All axis guidewaysshould have a thin film of lubricant.

Run the spindle at various speeds, including the minimum and maximumRPM, while observing for proper start, stop and spindle operation.

Turn power off and rotate the spindle by hand. It should rotate easily.

Check that all console control buttons and keys light when pressed, andactivate the intended functions.

Clean chips from way covers, enclosure, turret, and chip conveyor.

Wipe spindle with a lint-free cloth dipped in clean, light oil.


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Cleaning the Machine

Follow these recommendations when cleaning the turning center:

Machined and unpainted surfaces should be wiped clean with a lint-free clothdipped in a clean, light machine oil.

Exterior painted surfaces may be cleaned with a soft cloth dampened withwater and a mild detergent.

The control consoles exterior may be cleaned with a soft cloth moistened(not wet) with water and a mild detergent.

The console screens may be wiped with a damp, soft, lint-free cloth.

The machine enclosure should be thoroughly cleaned annually, or as needed.

Floppy Disk Drive and Diskettes

Follow the recommendations below for diskettes and the disk drive:

Keep dirt, dust, coolant and oils away from the floppy drive.

Keep the drive door closed when not inserting or removing a diskette.

Keep diskettes away from heat, extreme cold and electromagnetic fields. Donot touch the diskette surface. Store diskettes in closed containers to protectthem from dust and dirt.

Heat Exchanger

The heat exchanger removes heat from the control cabinet. Filters inside the heatexchanger become dirty with dust, and must be cleaned weekly.

Exterior Wiring

Inspect conduit, connectors, cabling and wiring external to the machine every month forevidence of fraying, cracking and looseness.


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Lubrication

Periodically check and maintain all lubricant levels to keep the machine in good operatingcondition. Lubrication points and recommended lubricants appear in the table below. Thislist is not exhaustive. Lubricants that meet the same specifications as those listed below

may be substituted. Local suppliers should be able to cross reference recommendedlubricants.

Lubrication points and recommended lubricants appear in the table below. This list is notexhaustive. Lubricants that meet the same specifications as those listed below may besubstituted.

Table 31. Lubrication for Lathes

TM

Lube Point Fill Level or Condition Lubricant Typea

a Viscosity ranges are based on ambient temperatures.

Turret Oil Sight glass 1/2 full I.S.O. VG100-150

Chuck Grease Fill each of 3 plug points using

a grease gun

Moly Kote EP Grease

FRL Oil Between low and high markson the lubricator unit.

I.S.O. VG 32

Tool Release Cylinder Oil Maintain at 1/3 full, not to

exceed 1/2 full.

I.S.O. VG 32

Way Lube Oil Between high and low marks

on reservoir. Refer to

Autolube System, on page 3 -

5for more details.

I.S.O. VG 68

Way Lube Volume 2 liter

Way Lube Pump, voltage 115 VAC, 1 ph

Way Lube Pump, cycle 3cc/cycle

4 cycles/hour

Parts Catcher Between the high and low

marks on the plastic bowl.

I.S.O. V.G. 32

Hydraulic Tank I.S.O. V.G. 32


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Autolube System

The Autolube system automatically lubricates the slideways, guideways, and ballscrews.The pump cycles once every 15 minutes to send lube oil through the system when servosare On. The preset discharge rate is 3.0 cubic centimeters (cc) per pump cycle, and isadjustable. The way lube pressure should be set at 2.9 bar or 42 psi.

Here is a diagram of an Autolube system:

Figure 31. Autolube Pump and Tank Assembly

1 Set screw 9 Retaining ring 17 Motor cover

2 Discharge plunger 10 Reservoir 18 Grommet

3 Indicator rod 11 Screw 19 Thru coupling

4 Electric motor 12 Float switch

assembly

20 Reservoir gasket

5 Strainer, oil filter 13 O-ring 21 Mounting bracket,

reservoir

6 Reservoir worm and

gear lube

14 Suction filter group 22 Reservoir gasket

7 Screw, covermounting

15 Screw, covermounting

23 Outlet tube assembly

8 Screw, reservoir

mounting

16 Gasket, motor cover 24 Outlet check valve

assembly


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If the machine will be idle for 30 days or more, add a rust preventative to the systemlubrication. Initiate a manual lube cycle and move all axes for full travel several times to

allow delivery throughout the system.

The oil filter strainer prevents contamination from entering the system. The strainer mustbe checked periodically, and replaced if it becomes plugged.

Check Filler Screen and Fluid Level

Maintain the fluid level and check the filler screen:

1. Lift the oil filler cap and check that the screen is clean. Clean and dry thescreen before reinstalling it.

2. If needed, add oil to the tank. The level should be between the high and lowmarks (about 1/2 inch or 1.27 cm from top cover of tank). Replace the fill cap.

Activate System Manually

If the machine has been idle for a long time before powering up, or if the oil has just beenreplaced, follow these steps to manually activate the Autolube system:

1. Pull upward on the discharge plunger, then release it.

2. Stroke the plunger in this manner three to six times.

Adjust Autolube Discharge Rate

An indicator rod is located in the Autolube systems discharge chamber. The scalegraduations on the flat surface of the rod indicate the discharge rate in cubic centimeters(cc) per pump cycle. To adjust the discharge rate of the Autolube system, follow thesesteps:

1. Loosen (but do not remove) the setscrew in the center of the dischargeplunger body.

2. Turn the plunger body clockwise to increase or counterclockwise to decreasethe pump discharge rate.

3. Once the required discharge rate is obtained, align the setscrew with the flatsurface on the rod. Tighten the setscrew to secure the rod position.

Excess servo On time without table or head movement may cause oilto accumulate on the table and guideways. To eliminate excesslubrication, the Power Off Timer can be set to automatically shut off

power to a machine that has been idle for a specified time.


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Replace Oil and Suction Filter

To drain the reservoir and replace the oil and suction filter, follow these steps:

1. Shut off power to the machine.

2. Loosen and remove the two thumbscrews that secure the reservoir to itsmounting bracket.

3. Lower the reservoir downward from the threaded spacers.

4. Remove the suction filter group by first carefully prying out the retaining ring.

5. Remove the filter discs and screws. Note their order of assembly.

6. Insert the new coarse screen (filter disc support), fine screen (screen disc,filter disc), filter clamp ring and retaining ring.

7. Clean any contaminates from inside of the tank. Dry the inside with a clean,lint-free cloth.

8. Check that the strainer in the filler opening is clean and not damaged.

9. Make certain that the gasket is installed and is in good condition.

10. Place the tank on its mounting bracket, guiding it over the threaded spacers.

11.Carefully tighten the two thumb screws that secure the tank to its mounting

bracket.

12.Check that the screen is installed in the filler opening.

13. Fill the reservoir with the recommended oil.

14.Manually activate the system.

Turret

The turret is located inside the enclosure on the right side of the machine. Check the oillevel in the sight glass on the front of the turret oil tank. The tank should be at least 1/2full. Use the drain plug located in the front to fill the tank. Refer to Lubrication, on page 3- 4for information about turret lubrication.

Chuck

The chuck is located inside the enclosure on the left side of the machine. Grease thechuck daily. Refer to Lubrication, on page 3 - 4for information about chuck lubrication.

Over-tightening these thumbscrews can damage the tank.


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Hydraulic Pressure

The hydraulic pump provides power for the chuck, turret and optional tailstock. Thefollowing table contains hydraulic pump pressure settings for the three machine models.

Table 32. Hydraulic Pressure

Refer toChuck Hydraulic Pressure Gauge Settings, on page 4 - 10forinformation about setting the hydraulic pressure for the chuck.

Refer toTailstock Hydraulic Pressure Gauge Settings, on page 4 - 17forinformation about setting the hydraulic pressure for the optional tailstock.

Refer toTurret, on page 1 - 21for information about setting the hydraulicpressure for the turret.

Coolant System

The flood coolant system pumps coolant to the tool in the turret.

Used coolant is cleaned of chips and oil and recirculated into the coolant tank. Filters

remove contaminants from the coolant.

Selecting Coolant

Coolant should have these qualities:

Suitable for the work piece material and machining operation.

Soluble in water.

Mineral content of at least 35%. When synthetic coolants and coolants thatcontain too little mineral oil contact guideway lube oil, they can gum theguideways.

Adequate rust protection.

Anti-foam, anti-bacteria, and anti-fungi agents.

No skin irritation when prepared to the manufacturers specifications.

Penetrating lubrication oil should float on the surface of the coolant (insteadof dissolving in the coolant).

Hydraulic Pump Pressure Maximum 32 kg/cm2 455 psi

Hydraulic Pump Low Pressure Cut-off 15 kg/cm2 213 psi

The hydraulic pressure falling below the low pressure cut-off resultsin an error on the control.


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Use the recommended coolant to prevent damage to the machines oil,guideways, precision ballscrews, and painted surfaces. Use a non- or semi-synthetic water soluble coolant.

Failure of devices or performance problems related to coolant are not a defectin Hurcos material or workmanship, and will not be covered by Hurcoswarranty.

Preparing Coolant

Follow these guidelines when preparing coolant:

Mix the coolant according to the manufacturers instructions. Use deionized(preferred) or softened water for the coolant mixture. To prevent zinccontamination, do not store coolant in a galvanized container.

Check coolant concentration regularly with a refractometer, or by titration.

Screen off any residue floating in the coolant.

Use coolant additives, such as bactericides, and anti-foam corrosion agents,only if recommended by the manufacturer.

Do not allow foreign matter to mix with the coolant. Contaminated coolantcan damage machine parts.

Maintaining the Coolant

Check the coolant level every day at the start of operation. If the machine is used morethan 8 hours daily, check the coolant level every 8 hours. Find the level indicator on thecoolant tank and maintain the level as follows:

1. If the flood coolant pump is off, then fill the coolant to the H (High) mark. Note

that the machine should be off for at least 5 minutes before filling the tankwith coolant.

2. If the flood coolant pump is delivering coolant to the machine, then fill to the

MAX mark.

If the coolant level drops below the L (Low) level mark on the coolanttank, the coolant system may not operate properly.


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Replacing Coolant

To replace coolant, follow these steps:

1. Using a suitable brush, remove chips and other debris from the enclosure (andchip conveyor, if installed).

2. Drain used coolant from the system and tanks.

3. Clean, or change, pump filters and pick-up tubes.

4. Fill the coolant tank with a neutral aqueous cleaning agent and flushthoroughly.

5. Drain the cleaning agent.

6. Rinse the system thoroughly with a 1% coolant solution. If bacteria or fungicontaminate the system, use a cleaning agent recommended by the coolantmanufacturer.

7. Drain the rinsing solution.

8. Dispose of used coolant and cleaning solution in compliance with applicablepollution control regulations.

Limit Switches and Dogs

Limit switches and dogs are mounted on each axis. To determine end-of-travel and toestablish reference points for initial machine zeros,

1. Open the rear-access panel above the hydraulic pump so you can see the limitswitches and dogs.

2. Use the jog unit to position the axes at mid-travel.

3. Check the tightness of limit switch and dog fasteners.

Machine Electrical Ground

The machining centers ground is located inside the control cabinet, near the disconnectswitch. A licensed electrician should measure the ground impedance (resistance to trueearth) every three months.

Machine Level

Inspect the machines level every six months by placing a precision level (resolution0.0005 in/ft.) parallel and perpendicular to the leveling plate that bolts onto the turret.


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Touchscreen

The controls touchscreen can be calibrated if the cursor position does not follow thestylus accurately.

To calibrate the touchscreen,

1. Press the Menubutton.

2. Select Utilities.

3. Select SYSTEM CONFIGURATION F1.

4. Select HARDWARE CONFIGURATIONS F3.

5. Select TOUCH SCREEN CALIBRATION F1. A pop up control panel appears withseveral tabs containing options for adjusting the screen calibration settings.


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Troubleshooting

Failure conditions can be evident during power up and operation. Failure detection andprevention descriptions follow.

Power-Up Troubleshooting

No Response on the Console

? If a problem occurs during power up, look for one of the followingsymptoms: No messages appear on the console screen. The system may beep,

but does not start up.

Error messages appear during the initialization process before the

Input screen appears.

Error messages appear on the Input screen.

Before testing live circuits or attempting any repairs to electrical

connections, make sure that the power switch on the electrical

cabinet is in the Off position.Follow all established safety practices.

Remember that the power line from the source to the machine maybe live even though the machine tool is not receiving power.

? If no messages appear on the text screen after switching power on,make sure of the following: Power supply cord inside the electrical cabinet is properly

connected to the power source. Power switch on the computer and rack inside the

electrical cabinet is in the On position.

No floppy disk is in the floppy drive.


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Initialization Error Messages

After power has been switched on, initialization messages appear on the text screen.Errors indicated by the following error messages below can be easily remedied.

Other possible messages during initialization usually indicate missing or corrupted files.The usual solution for such problems is to restore or delete files. For help solving these

problems, contact you local Hurco service department.

Error Messages

If errors occur after power up, take careful note of any error messages on the screen.Note if the red beacon is on or flashing when the error occurs. Also, note if the controlresponds to any key, button, or touchscreen selection after the error occurs.

Corrective MeasuresOne or more of the following corrective measures may be necessary:

Swap Out a Printed Circui t Board

Sometimes, the printed circuit (PC) board is bad or has an intermittent problem, or theconnector on the board is not making sufficient contact. In this situation, the PC board issuspect. If possible, swap out the suspect PC board with a replacement.

If swapping out a board corrects the error, install the original PC board to see whether theerror returns. If not, the connector probably was not seated properly or the contacts needcleaning.

Non-system disk detected.Press any key.

There is a diskette in the floppy drive.Remove the diskette and turn the power

off and then back on.

Security device is invalid orhas failed.

The software security device has beenremoved, is broken, or is not properly

connected. Switch off the control and

remove the security device. If the device

is damaged, replace it. Reconnect the

device and switch on power.

? Before calling a Hurco service representative for assistance, alwaysswitch off the control at the power button, wait a few minutes, andthen power on again.


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Check Wiring

Perform these checks:

Trace the wiring as far as possible.

Wiggle connectors and ensure they are properly seated.

Test the connections with an ohmmeter.

Unplug and reseat circuit boards; sometimes connectors become tarnishedand do not conduct well. If the contact points on a PCB are dull looking,

polish them with a rubber eraser.

Perform a Reset

Technical assistance personnel may ask you to reset a circuit board or the machine.

To reset a PC board, press the boards reset button.

To reset the machine, switch the main power off and then back on.

Emergency Stop Condition

Pressing the Emergency Stop button removes all servo power and power to the waylubrication pumps, and resets the current program to the beginning. A message on thescreen indicates the Emergency Stop condition. The red icon appears in the status bar, inaddition to the red beacon lights. To remove the Emergency Stop condition, executethese steps:

1. If the Emergency Stop button is depressed, twist and lift it.

2. Press these console buttons in this order:

a. Manual

b. Power On

c. Start Cycle

Turn off machine power before checking the circuit boards.DO NOTperform this circuit board check with the power on.


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Common Problems

Common operator problems are listed below, with potential causes and solutions. Theseproblems are usually noticeable without the help of error messages, although errormessages may occur. More than one problem can result from a single cause.

Machine operation failures can be a programming or a hardware problem. Hardwareincludes electronic components, wiring, and electro-mechanical devices.

Power-on Self Test

Documents

Lathe Maintenance r0214-201.pdf