User Manual, GD5C2 Rotary Indexer
Contents
1. oar ji 10 25 260 Dual Unit lt 16 25 387 Triple Unit 48 12 Others 22 97 583 Quad Unit gt mu 5 50 gt 140 Bottom View Quad Side View with Pneumatic High Force Collet Closer Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 01 19 BRS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 19 2 Set Up 2 1 General Setup Fill out the warranty information by visiting www hardinge com rotarywarranty on the internet 2 Place the indexer on the machine Route the cable from the head so that it avoids tool changers and table edges Cable slack must be provided for your machine s movements If the cable is cut the motor will fail prematurely Replace any damaged cable immediately Secure the indexer to the machine s T slot table as shown below upright or on its back T nut packages are available for purchase for various T slot tables Kit includes 2 T nuts 2 bolts and 2 flat washers Check to verify that all clearances are satisfied in full machine axes movements and that there is no possibility of a collision This mechanical Indexing head is configured to run in the horizontal position If a vertical running position is required spindle pointing up you must make alterations to the motor cover that are detailed as follows Located on the bottom of the motor cover when th2. Do not place the unit on top of other hot electronic controls 7a Connect the two cables from the indexer to the controller in the appropriate locations Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 01 19 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 9 CAUTION Never connect or disconnect these cables with the power on Instant failure will result 7b Connect the AC line cord to a 120V AC grounded receptacle The cord is a three wire ground type and the ground must be connected Power is 20VAC The power service must supply a minimum of 5 amps continuously Conduit wire must be 12 gauge or larger and fused for at least 20 amps If an extension cord is to be used use a three wire ground type and the ground line must be connected Avoid outlets that have large electric motors connected to them Use only heavy duty 2 gauge extension cords capable of 20 amp load Do not exceed a length of 30 feet Permanent installations should be hard wired or installed with locking plugs 7c Semi Fourth Axis Connect the remote interface cable See separate Hardinge Servo Control manual 8 Connect air to the quick disconnect fitting on top of the indexer if using a pneumatic collet closer Quick Disconnect Fitting CAUTION Never use more than 85 psi with the fail safe collet closer 9 Check the oil level If it is low add oil
3. 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 0119 BRS HARDINgE GD5C2 Rotary Indexing System User Manual B 9 Single Spindle GD5C2 Rotary Indexer for use as 4th Axis Unit 7 98 203 E 1 18 30 A thru hole Na Nag 171 4 00 3 26 83 101 6 025 y L Y LUI 3 0003 1 75 44 2 67 68 Cal 2 25 57 7640076 547 75 19 lt gt o lt 7 1789 gt 76 007 lt 7 62 193 FANUC 139 8 87 225 OKUMA 9 62 244 SIEMENS HEIDENHAIN Front View Side View Back View THE 5C DUAL TRIPLE AND QUAD UNITS CAN BE RUN IN THE HORIZONTAL POSITION ONLY 5 8 or 18mm Oil Drain locating pins Plug Bottom View Multiple Spindle GD5C2 02 03 and 04 Rotary Indexer as 4th Axis Unit m 9 64 245 lt 5 127 mes 127 lt 5 127 lt 7 98 203 Front View gt lt 72 18 EE EE 10 13 257 5 88 Sa 149 a 3 n VI 0 53 13 Dual Unit F 17 70 449 ag ee Okuma 1895 t481 seo IOB 850 216 gt Siemens Heidenhain 19 70 500 Triple Unit Fanuc 22 70 576 gt Okuma 23 95 608 Siemens Heidenhain 24 70 627 lt Quad Unit Fanuc 29 06 738 a Dual Triple Side View with Okuma 30 31 770 Pneumatic High Force Collet Closer Siemens Heidenhain 31 06 789 Dual Triple Plates Quad Plate
4. Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 0119 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 9 2 6 Tooling Locations The indexing system is equipped with tooling points in order to speed setups One of the most time consuming procedures in setup is aligning the head with the table On the mounting surfaces there are two 0 500 12 7mm bored holes on 3 000 76 2mm centers The holes on the bottom surface are parallel to the spindle within 0 001 0 25mm per 6 inches 152 4mm and on the center within 0 001 0 25mm By boring machine holes in your tooling plate setups become routine Using the tooling holes will also prevent the head from shifting on the mill table when the part is subjected to heavy cutting forces On CNC mills a machined stepped plug of 0 500 12 7mm diameter on one side and 0 625 15 87mm on the other comes with the Hardinge head The 0 625 15 87mm diameter fits into the T slot of the mill table This will give quick parallel alignment that will be close enough for most jobs NOTE 0 625 15 87mm and 18mm plugs are supplied as standard Plugs can be turned down to another diameter to accommodate tables with different slot dimensions 3 Backlash Adjustment 3 1 Measuring Backlash To measure backlash you need the use of a 0001 indicator and a small magnetic block or something with a flat on it such as the special
5. a greater available gripping force This force can be regulated by adjusting the air pressure but the force needs to be set according to levels below the maximum allowed for the workholding system Much SO 1381 like the Fail Safe Closer the total travel of this unit is 060 1 5mm but 6o 1670 the through hole is only 312 7 9mm This means that the high force closer can accommodate part variations of 0 015 4mm and can also 80 2228 be adjusted from the front of the indexer as well as from the back When 80 2805 using a Pneumatic High Force closer a mounting plate is required to mount 100 z783 O the unit on its back with the spindle in the vertical position Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 0119 BRS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 9 2 4 Use of Collets with Hardinge Collet Closers Collet Installation for High Force Collet Closer To install a collet align the collet keyway with the spindle key and insert the collet Insert a gt 16 hex wrench into the hex in the back of the draw tube and turn the draw tube to engage the collet Turn the draw tube until it grips the part and then back off approximately 4 turn This will be a good starting point for fine tuning the grip range If using a collet larger than the 2 16 hex wrench then the wrench can be inserted in the draw
6. each mechanical unit For these units an oil dipstick is provided to read the oil level Part No Cl 0001990 TDG Follow the guide below to properly check the oil fluid level Take care that no contamination is introduced to the inside of the mechanical indexing heads Allowing contamination such as chips and coolant to enter the mechanical head will void the warranty For dual axis tilting units follow the procedure below for orienting the units to check the oil level DIL FILL PORT ieee Ba INSURE AREA AROUND OIL FILL PORTS ARE FREE OF CHIPS AND COOLANT REMOVE PLUGS Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No B 0009500 01 19 24 BRS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 19 INSERT OIL DIPSTICK IN OIL FILL PORT INSURE THAT OIL DIPSTICK BOTTOMS OUT ON TOP U SURFACE OF INDEXER Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 01 19 BRS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 19 DIPSTICK PIN CT 001990JTOG REMOVE OIL DIPS TICK FROM INDEXER HOUSING AND CHECK READING OF OIL LEVEL OIL MUST BE ABOVE THE OIL FULL LINE IF NOT ADD OIL UNTIL LEVEL IS CORRECT OIL FULL HIE hy OM LEVEL AFTER CHECKING PROPER OIL LEVEL IN EACH INDEXER HEAD REPLACE OIL FILL PORT PLU
7. looped 999 times RS 232 INTERFACE With Hardinge Servo Control For computer control of sending and receiving programs and controlling indexer via the CNC control of host machine capable of RS 232 communication RESOLUTION Standard resolution of 001 degrees SIMPLE EDITING With Hardinge Servo Control Edit a program by simply writing over existing steps or inserting or deleting a line or several lines between steps with automatic program line renumbering SUBROUTINES With Hardinge Servo Control Allows repeated sequences up to 999 times saving programming time and memory space VARIABLE FEED RATES variable from 001 deg sec to 360 deg sec ZERO RETURN With Hardinge Servo Control An automatic home position can be programmed to return the spindle to its original starting position from any point ONE YEAR WARRANTY The Hardinge GD5C2 Rotary Indexing Table Systems are provided with a one year warranty against any defects in material and workmanship Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 0119 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 19 5 Specifications Spindle Torque ft Ib Nm Runout Maximum TIR Backlash arc sec Speed degrees sec RPM Maximum Load Support Spindle Nose Spindle center to base inch mm Indexing Accuracy arc sec Repeatability arc sec Resolution degree Ma
8. tube through the front of the collet for adjustment as well Collet Sticking NOTE To prevent excessive wear and collet sticking make sure collets are in good condition and free from burrs A light coat of Molybdenum grease on the collet wear surfaces will extend the life of the spindle and or collet and help prevent sticking Emergency collets are soft and are not recommended for long production runs These collets will stick after prolonged use When using the High Force Collet Closer releasing a collet is accomplished by removing the air supply It is then pushed out by a heavy spring inside the air collet The High Force Collet Closer uses shop air to pull the drawtube in and a heavy internal spring to push the draw tube out and release the collet If after repeated use the spring will not push the collet out use one of the following methods to remove the collet and lubricate the outside of the collet with a light coat of grease before reinserting If the optional three way air valve provided with the unit becomes clogged with contaminates the exhaust airflow may be restricted which may cause the collet to stick in the taper If this situation arises leave the valve in the clamped position then connect and disconnect the air supply several times in rapid succession 2 If the above procedure does not free the collet switch the valve to the unclamped position then gently tap the back end of the draw tube with a plastic faced m
9. BRS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 19 Setup and Operation for the Hardinge GD5C 2 Rotary Indexing System Original U S A Instructions Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No B 0009500 01 19 BRS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 19 Thank you for purchasing a Hardinge GD5C Rotary Indexing System This User s Manual is provided to assist you with setup procedures and to familiarize you with the features specifications and maintenance recommendations of your unit The mechanical indexing head can be maintained by the customer with proper cleaning lubrication and maintenance Any necessary repairs required during the warranty period will be made at Hardinge Inc or by a factory authorized representative Hardinge supplies a complete array of 5C workholding products including collets step chucks expanding collets chucks and fixture plates Custom manufacturing is also available Hardinge Inc One Hardinge Drive Elmira New York 14902 1507 U S A p 800 843 880 p 800 468 5946 Canada f 607 734 3886 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 01 19 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 9 Table of Contents Important Sa
10. GS Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No B 0009500 01 19 26 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 19 4 3 Collet Key Replacement Remove the pipe plug in the collet key access hole and then remove the collet key using a 3mm Allen wrench for both items A spare collet key can be found on the front face of the indexer housing Screw the new 5C collet key into the spindle until it begins to protrude into the inside diameter of the spindle Align the flat on the key to be parallel with the spindle centerline Slide a collet into the spindle to check the key fit Remove collet and adjust key until proper fit is achieved Loctite 242 can be used to secure key Replace the pipe plug back into the key access hole using pipe sealant COLLET KEY ACCESS HOLE COLLET KEY WITH FLAT SPARE KEY 44 Clean Up At the end of the workday or shift it is important to clean the indexer The head should be free of any chips or grime Clean with a chip brush and apply a coat of rust preventative Do not use an air gun around front or rear seals Chips may damage seal if blown in with an air gun 5 One Year Limited Warranty The Hardinge GD5C2 Rotary Indexin System is provided with a 2 month one year warranty against any defects in material and workmanship Specific details of the warranty can be found in the Hardinge Term
11. ON T OPEN THE CONTROL BOX without consulting with Hardinge Where Applicable DON T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a wet surface Where Applicable REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished Where Applicable ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters before restarting the machine Where Applicable KEEP THE AREA AROUND THE MACHINE well lit and dry Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 0119 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 19 Safety Recommendations continued KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating equipment HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combustible material and keep chips clear of the work area DON T USE a toxic or flammable substance as a solvent cleaner or coolant MAKE CERTAIN THAT PROPER GUARDING is in place and that all doors to the primary machine are closed and secured DON T OPEN GUARD DOORS of the primary machine while any machine component is in motion MAKE SURE chucks closers fixture plates and all other spindle mounted workholding devices are properly mounted and secured before starting the unit or the machine MAKE CERTAIN all tools are securely clamped in position before starting the unit or the
12. Tighten the two copper fittings SPINDLE NUT Never use hammer blows to remove or install the collet closers The shock will damage the precision bearings and gears inside the indexing head Part No B 0009500 01 19 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com 17 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 9 High Force Closer Removal Air collet closers fitted at the factory are not intended to be removed However if servicing is required remove the snap ring that holds the slip ring on the closer body Remove the valve assembly from the top of the indexer and pull the valve copper tubing and slip ring off of the collet closer as one assembly Use a woven strap wrench to remove the closer assembly with even pressure Do not use a hammer to remove the closer When reinstalling the closer use a strap wrench and tighten to about 30 ft lbs Installing the Fail Safe Collet Closer Insert the draw tube of the collet closer into the back of the indexer spindle and screw the main body onto the back of the spindle Insert 2 two dowel pins into the spanner holes on the back of the collet closer The pins should be long enough to put a wrench across them when installed in the holes Use a wrench to contact both dowel pins and turn the closer clockwise until tightened to about 30 ft lbs Mount the valve assembly to the top of the unit using one of t
13. U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 01 19 RS HARDINSE GD5C2 Rotary Indexing System User Manual B 1 9 Safety Recommendations READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE OPERATING THIS UNIT Note Equipment refers to the indexing system and or machine it is used with When this instruction book was printed the information given was current However since we are constantly improving the design of our products it is possible that the illustrations and descriptions may vary from the system you receive WARNING Occupational Safety and Health Administration OSHA Hazard Communication Standard 1910 1200 effective May 25 1986 and various state employee right to know laws require that information regarding chemicals used with this equipment be supplied to you Refer to the applicable section of the Material Safety Data Sheets supplied with your unit when handling storing or disposing of chemicals 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 ope
14. Use MOBILGEAR 600 XP 220 only 10 Save the packing materials in case you need to ship the unit 1 At the end of the workday or shift it is important to clean the indexer The indexer should be free of any chips or grime Clean with a chip brush and apply a coat of rust preventative CAUTION Do not use an air gun around the front or rear seals Chips may damage the seal if blown in with an air gun NOTE Prior to powering on the unit read and understand the entire control or 4th axis manual NOTE If using a tailstock always use Live Centers The use of Dead Centers could cause damage to the gear system 12 Turn on the mill and servo control if applicable and home the indexer by pressing the zero return button The indexer homes in the counterclockwise direction as viewed from the spindle Part No B 0009500 01 19 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com RS HARDINSE GD5C2 Rotary Indexing System User Manual B 1 19 2 2 Use of Collets Sure Grip Expanding Collets 3 Jaw Manual Chucks and Face Plates The unit accepts standard Hardinge 5C collets step chucks ID gripping collets chucks face plates and fixture plates When inserting the collet align the keyway on the collet with the key inside the spindle Push the collet in and turn the collet closer drawbar clockwise until proper collet tightness is obtained Chucks and face plates util
15. allet Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No B 0009500 01 19 RS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 19 Collet Installation for Fail Safe Collet Closer To install a collet align the collet keyway with the spindle key and insert the collet Use the provided knurled tool to turn the back of the collet closer draw tube Turn the draw tube several times to get the collet started in the draw tube Actuate the air valve to put air in the closer and move the draw tube to the forward position Continue to turn the draw tube until the collet grips the part and back the collet out of the draw tube 4 to 2 of a turn so that the part easily slips in and out of the collet Never try to turn the draw tube while the collet is gripping a part as the friction is too high inside the closer to allow the draw tube to turn Never under any circumstances should a wrench be put on the draw tube tool to aid in tightening or loosening a collet Any method of adjusting a collet other than by hand can break the closer and void any warranty by Hardinge Inc If at any time the draw tube is too hard to turn by hand call Hardinge for assistance DO NOT use other tools to try and break it free Knurled Tool 2 5 Replacing the Manual Collet Closer with a Pneumatic Collet Closer Removing the Manual Collet Closer Power down the indexer system so that ther
16. collet in the picture The magnetic block or flat on a fixture plate or collet should be as close to the spindle center line as possible Home the indexer as that is where backlash is checked at the Hardinge Factory Place the magnetic block on the indexer spindle face so that the top of the block is parallel to the machine bed or use a collet or fixture plate as shown in the picture Setup the indicator so that it is measuring the top of the flat item from the center of the spindle Use your hand to twist the spindle nose in one direction Move the spindle in that one direction until you measure approximately 0 0005 on your indicator Remove your hand from the spindle so that the spindle can spring back to a nominal position When the indicator shows that the spindle has sprung back some zero out the indicator at this position Twist the spindle in the opposite direction now Again you are going to want to move the spindle about 0 0005 and release the wrench or bar so the spindle can spring back Record the reading on your indicator as this will be used to calculate gear backlash Take the distance recorded by the indicator and take the inverse tangent tan of this measured distance and that will be how many degrees of backlash you have in your gears To figure out how many arc seconds that is simply multi ply the degrees you calculated by 3600 If you calculate your backlash to be 40 arc seconds or less then no backlash adjustments ar
17. d Tool spraying and splatter usually will not be detrimental to the motor but large amounts of pressurized coolant should be directed away from the head Some machining centers provide flood coolant at enormous rates so that the head is practically submerged Try to cut the flow down to match the job e Inspect the cables and gaskets for cuts or swelling Damage must be repaired immediately 4 2 Lubrication To check the lube level of the Hardinge indexer view the level of lube visible in the lubricant window when the unit is stopped The window is located on the side of the unit opposite the motor The lube level should reach the middle of the window If necessary add lubricant until the level reaches the midpoint of the window To add lubricant to the unit locate and remove the pipe plug from the lube fill port This is located behind the handle on top of the unit Add MOBILGEAR 600 XP 220 until the proper level is reached Replace the fill port pipe plug and tighten J Oil Fill Replace the oil every two years Drain oil using the drain location found on the bottom of the indexer unit Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 01 19 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 9 4 2 1 Lubrication of Multi Spindle Units For Multi spindle 5C indexer units the sight gage is not visible for checking the oil on
18. dure is not followed the warranty will be void for any contamination in the motor cover THE 5C DUAL TRIPLE AND QUAD UNITS CAN BE RUN IN THE HORIZONTAL POSITION ONLY The GD5C2 Rotary Indexing spindle is based on the industry standard threaded spindle design that has been used in Hardinge lathe production for over a century The Hardinge engineered mechanical elements guarantee the spindle will be accurate repeatable reliable and flexible to suit many different machining applications The spindle carries a center line from the machine bed of 4 00 101 6mm which is compatible with many other indexing products The spindle is hardened and ground for accuracy and has a rigid design with dual tapered roller bearings to support heavy cutting forces Positioning of the spindle is accomplished through a self locking gear set 2 High Stiffness Overall System The Hardinge GD5C2 Rotary Indexing System uses a high quality hardened gear system with a 60 1 ratio This type of gearing allows for an efficient forward driving capability motor side through the worm while at the same time preventing back driving from occurring by the applied cutting forces at the spindle side This is an important operating characteristic of the high ratio gear system since it adds stiffness into the machining operation Stiffness or rigidity is one of the more important features of any system employed in the activity of machining operations and is the driving force for Hardi
19. e indexer is in the horizontal position spindle pointing right or left are two drain holes If the indexer is to be mounted vertically drill and tap these holes for M5 set screws Seal the holes using M5 set screws and thread sealant Drill and tap a hole for a M5 set screw on the side of the motor cover parallel with the back mounting face of the indexer This will be the new drain hole for the indexer when it is mounted vertically If the indexer orientation is changed to horizontal mounting remove the two set screws and place one in the vertical mounting drain hole If this procedure is not followed the warranty will be void for any contamination in the motor cover 3 Place the indexer in an area free from chips and coolant where air can circulate freely Do not let chips pile up over the motor enclosure as this would prevent proper cooling 4 Connect the GD5C2 rotary indexer using one of the techniques as described in the Hardinge servo control or Hardinge 4th axis manual which will be included with the mechanical unit 5 Route the cable over the back of the mill sheet metal if using Hardinge Servo Control 6 If adding an indexer to a Hardinge mill using a remote CNC cable or as a true 4th axis refer to the instructions in the Hardinge 4th axis manual or call the Hardinge service department 7 If using the Hardinge servo control secure it in required placement Do not cover any surface of the control as it will quickly overheat
20. e is no possibility for the unit to index and unbolt the unit from the machine table Remove any spindle tooling before removing the manual collet closer Remove the top and bottom 2 13 mounting bolts that hold the collet closer handle in position and slide the handle off of the closer assembly The collet closer assembly will now slide out of the back of the spindle Unscrew and remove the spindle nut on the back of the spindle It may be necessary to use a wooden dowel and rubber mallet but be careful as excessive force may damage the gears Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 0119 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 9 Installing the High Force Collet Closer Insert the draw tube of the High Force Collet Closer into the back of the indexer spindle and screw the main body onto the back of the spindle where the spindle nut used to be Tighten with a strap wrench to approximately 30 ft lbs Mount the valve assembly to the top of the unit using one of the 2 13 SHCS from the manual collet closer and the two button head screws supplied Assemble the copper tubing in the fitting mounted to the closer slip ring and then slide the slip ring on to the closer inserting the other end of the tubing in the fitting on the valve at the same time Install the snap ring on the back of the closer to hold the slip ring in place
21. e necessary To compensate for the mechanical backlash electronically see the control manual A chart of various angles in arc seconds measured linearly at different radii along with a pictorial description of backlash follow below and on the next page Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No B 0009500 01 19 20 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 19 rete raas vaas vaas Pada vae 0 000096 0 00019 0 00029 0 00039 0 00048 0 00058 0 00014 0 00029 0 00044 0 00058 0 00073 0 00087 0 00019 0 00038 0 00058 0 00077 0 00097 0 0012 Jole BACKLASH J Ha SPACE BETWEEN GEAR AND WORM WORM teers ma A Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 01 19 BRS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 9 3 2 Adjusting Backlash NOTE A small amount of backlash is required for the gear set If it is determined that the backlash needs to be reduced Hardinge highly recommends that the unit be sent back to the factory if still within the warranty period If the customer decides to make the adjustments on their own Hardinge has included the following detailed instructions The eccentric that you will be adjusting is on the side of the indexer opposite of the motor cover Star
22. fety Recommendations X aaa 4 lo gera ME NAN PA BA AN 7 kal YS CI DEI ON maam EE NG aa tated 7 1 2 High Stiffness Overall System a Ama a GA NANANA KANG 7 ka Machinable Part S12 Cc aa ANA Naa 7 Na CACC CS anan katad kaka alec aa seit GE ee balaan pa 8 I 5 Specifications and General Requirements sesse se se see se ee Re Re Ge Re Rg 9 Lo DIMENSIONS se ccc T Namang eee el eas 10 2 Set Up 2 1 General SETUP se RE DE EED EE RE AG ee ee 12 2 2 Use of Collets Chucks and Face Plate sesse sesse se se ee Re ee ee Se ee gee ge 14 2 3 Hardinge Fail Safe and High Force CloserS uses sesse ese sesse se se see se ee se Ge eg ee ee I4 24 Use of Collets with the Hardinge Collet Closer sesse sesse se se ee Re Se ee 15 2 5 Replacing Collet Closefs sa RNEER KANA NAAN ANAN l6 ZG Tooling Loeations aaa a akan 29 3 Backlash Adjustment S l Measuring Backlash aste EE DE EE GE Aa 19 3 2 sAdjusting Backlas Meissie NN NANANA na Minana Ban Dn kabang baa a has Oda 21 4 Routine Maintenance 4 1 Use of Oil and Water Soluble Coolants esse ses sesse se se se ee Se Se Ge Ge ee ee ee se 22 42 IEubri ati n EE EG tet orn ty ee E O TEN 22 4 2 1 Lubrication of Multi Spindle Units 0 sesse se ee Re Se Re ee Ge Re 23 4 3 Collet Key Replacement ra ss se do DA EG Ee SE eg Ee 26 44 Cap aaa Ee aaa aka 26 VN T ARE Ee ae tents ee eer ate ce entra ner ae ED EE AE EE ME TE a 26 Hardinge Inc One Hardinge Drive Elmira New York
23. ges when handling a newly machined workpiece DON T REMOVE OR LOAD a workpiece while any part of the equipment is in motion DON T OPERATE ANY EQUIPMENT 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 equipment is running DON T LEAVE tools workpieces or other loose items where they can come in contact with a moving component of the equipment 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 equipment 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 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 01 19 RS HARDINSE GD5C2 Rotary Indexing System User Manual B 9 Safety Recommendations continued 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 tooling and fixtures DON T USE worn or broken tooling on machine MAKE CERTAIN that all tool mounting su
24. he 2 13 SHCS from the manual collet closer and the two button head screws supplied Assemble the copper tubing in the fitting mounted to the closer slip ring and then slide the slip ring on to the closer inserting the other end of the tubing in the fitting on the valve at the same time Install the snap ring on the back of the closer to hold the slip ring in place Tighten the two copper fittings The fitting on the slip ring should be tightened so that the flat on the fitting is parallel to the back face of the closer as shown in the picture on the next page Spanner Holes Slip ring fitting flat is aligned with back of closer Never use a hammer to remove or install a collet closer as the shock will damage the bearings and gears Fail Safe Closer Removal Air collet closers fitted at the factory are not intended to be removed However if servicing is required remove the snap ring that holds the slip ring on the closer body Remove the valve assembly from the top of the indexer and pull the valve copper tubing and slip ring off of the collet closer as one assembly Put 2 two long pins in the spanner holes on the back of the collet closer Put a wrench across the pins and with steady pressure turn the closer assembly in the counter clockwise direction and remove the closer from the spindle When reinstalling the collet closer use 2 two dowel pins and a wrench to tighten the closer to approximately 30 ft lbs Hardinge Inc One Hardinge
25. ith Hardinge Servo Control You can program a step that automatically divides a circle into any number of equal parts between 2 and 999 STOP FEED HOLD With Hardinge Servo Control You can use the STOP to feed hold spindle movement without losing position on restart FAST SETUPS With Hardinge Servo Control All connectors are quick disconnect ensuring fast and easy setups INTERFACING With Hardinge Servo Control Most CNC mills can be interfaced quickly and easily by using a spare M function which provides a switch closer as a signal between your mill and the control LINEAR amp SPIRAL MILLING With Hardinge Servo Control for semi fourth axis capability MEMORY With Hardinge Servo Control A nonvolatile memory retains your program even when power is turned OFF and remembers the current spindle position and step number PROGRAM STORAGE With Hardinge Servo Control Store and recall up to fifty different programs PROGRAMMABLE PARAMETERS With Hardinge Servo Control You can alter many of the basic features by performing basic programming PROGRAMMING With Hardinge Servo Control Program to rotate the spindle clockwise or counterclockwise with step sizes from OO1 to 9999 99 degrees Using G83 amp G84 continuous rotation is allowed Contact Hardinge for maximum speeds based on duty cycle ABSOLUTE OR INCREMENTAL PROGRAMMING With Hardinge Servo Control Up to 1000 different steps can be stored in memory and each step can be repeated
26. ize the 23 16 threaded nose on the spindle We recommend using chucks that are 5 127mm in diameter or smaller and weigh less than 20 pounds Pay special attention when installing chucks Always make sure that the thread and the outside diameter of the spindle are free of dirt and chips Apply a thin coating of oil to the spindle Screw the chuck on gently until it seats against the rear of the spindle Tighten the chuck to approximately 70 ft lb with a strap wrench Always use a firm steady pressure to remove or install chucks or face plates This is very important to prevent damage to the indexing head 2 3 Hardinge Pneumatic Fail Safe and High Force Collet Closers The Hardinge GD5C2 indexing head is provided with a manual collet closer as standard Additionally Hardinge offers two pneumatic collet closers the PFS Pneumatic Fail Safe and the PHF Pneumatic High Force Both of these closers provide an opportunity for operational improvements by reducing operator fatigue and allowing for possible automation arrangements Both closers utilize an original Hardinge concept of force amplification that has been historically proven to provide long life and effective operation even under demanding applications The Hardinge force amplifier which is an integral part of the design is a simple approach that allows high actuation forces with shop air pressure In the case of the High Force Pneumatic Closer air pressure is applied for gripping and is spring re
27. ll parts in machining operations such as milling drilling tapping contouring and spiral milling The Hardinge GD5C2 Rotary Indexing System is a fully integratable programmable rotary positioning device that saves on workspace without sacrificing performance The mechanical indexing head holds the workpiece which is positioned by programming angular movements into the all digital servo control as a slave to a CNC machine or directly into a CNC control in a true 4th axis setup The mechanical indexing head features a threaded spindle nose for spindle tooling compatibility with other 5C spindle CNC lathes The mechanical Indexing head is configured to run in the horizontal position If a vertical running position is required spindle pointing up you must make alterations to the motor cover that are detailed as follows Located on the bottom of the motor cover when the indexer is in the horizontal position spindle point ing right or left are two drain holes If the indexer is to be mounted vertically drill and tap these holes for M5 set screws Seal the holes using M5 set screws and thread sealant Drill and tap a hole for a M5 set screw on the side of the motor cover parallel with the back mounting face of the indexer This will be the new drain hole for the indexer when it is mounted vertically If the indexer orientation is changed to horizontal mounting remove the two set screws and place one in the vertical mounting drain hole If this proce
28. machine REMOVE ANY LOOSE PARTS OR TOOLS left on the unit or the machine or in the work area before operating the equipment 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 unit or 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 OIL LEVEL before operating the machine MAKE CERTAIN that all guards are in good condition and are functioning properly before operating the equipment INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good condition and are functioning properly before the cycle is started CHECK THE POSITION of any load unload automation before pressing the Cycle Start push button CHECK SETUP TOOLING AND SECURITY OF THE WORKPIECE if the machine has been OFF for any length of time DRY CYCLE a new setup to check for programming errors MAKE CERTAIN that you are clear of any pinch point created by moving slides before starting the machine DON T OPERATE any equipment while any part of the body is in the proximity of a potentially hazardous area DON T REMOVE CHIPS with hands Use a hook or similar device and make certain that all machine movements have ceased BE CAREFUL of sharp ed
29. nge engineered rotary systems The Hardinge Indexer provides the stiffness for the toughest applications through the spindle hard bearings the non backdriving worm gearing the servo holding mechanism and the stiffness of the 5C workholding system 1 3 Machinable Part Size The Hardinge GD5C2 Rotary Indexing System has been designed for those parts that can be conveniently gripped in any of the 5C gripping systems that Hardinge is noted for Typical parts are in the range of approximately 2 50 8mm in diameter and generally not longer than 6 152 4mm without the use of a tailstock It is typical to speak in terms of the L D Length Diameter ratio which is the length divided by the part diameter A 2 diameter part 6 long has an L D ratio of 3 1 Part pieces with larger L D ratios should be used with a tailstock up to a typical L D ratio of 6 1 Larger part sizes than those described above can be handled with certain restrictions and should not exceed 501b 22 7kg in weight Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 01 19 RS HARDINSE GD5C2 Rotary Indexing System User Manual B 1 19 4 Features RIGID DESIGN Increased distance between large bearings support heavy cutting forces on large or small parts HARDENED AND GROUND SPINDLE for higher accuracy DUAL TAPERED ROLLER BEARINGS support heavy cutting forces AUTOMATIC CIRCLE DIVISION W
30. ration 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 equipment Make certain that you understand all instructions DO NOT ALLOW the operation or repair of equipment by untrained personnel CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times When necessary wear respirator helmet gloves and ear muffs or plugs DON T OPERATE EQUIPMENT unless proper maintenance has been regularly performed and the equipment is known to be in good working order WARNING or INSTRUCTION TAGS are mounted on the unit for your safety and information Do not remove them or damage them DO NOT ALTER THE EQUIPMENT to bypass any interlock overload disconnect or other safety device DO NOT 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 LIFTING AND HANDLING OF THE UNIT should be done with full knowledge of the unit weight and using proper procedures MAKE CERTAIN that the equipment is properly grounded Consult National Electric Code and all local codes Remove power from the unit by unplugging the power cord before attempting repair or maintenance Where Applicable D
31. rfaces are clean before mounting tools INSPECT ALL CHUCKING 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 on the chuck Consider weight shape and balance of the workpiece DON T EXCEED the rated capacity of the equipment DON T LEAVE the equipment unattended while it is operating DON T CLEAN the equipment 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 equipment spindle without being adequately covered and properly supported UNLESS OTHERWISE NOTED all operating and maintenance procedures are to be performed by one person To avoid injury to yourself and others be sure that all personnel are clear of the equipment when opening or closing the coolant guard door and any access covers FOR YOUR PROTECTION WORK SAFELY DON T OPERATE THE EQUIPMENT with damaged or worn electrical cables VERIFY that the electrical cables are not restrained or pinched during full travel movement of the machine Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 0119 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 9 Introduction Description For accurate and dependable positioning of sma
32. s and Conditions document associated with the purchase agreement Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 01 19 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 9 NOTES Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BJ 0009500 01 19 27 Hardinge Inc One Hardinge Drive PO Box 1507 Elmira New York 14902 1507 USA USA 800 843 8801 Canada 800 468 5946 Fax 607 734 3886 To Order Online www shophardinge com Corporate Home Page www hardinge com E mail info shophardinge com All specifications subject to change without notice All marks indicated by or TM are trademarks of Hardinge Inc Insstruction Manual B 1 19 Litho in U S A Hardinge Inc 2013
33. t by removing the 2 two M5 bolts that hold the round black plug in the eccentric cavity M5 BOLTS 2 Remove the 4 four M4 bolts in the eccentric housing 3 Take note of the small dimple in the face of the eccentric The eccentricity of the eccentric goes towards this dimple Use a hex wrench to turn the eccentric to the next available hole in the direction that makes the dimple go towards the top of the indexer housing This may be either a clockwise or counterclockwise rotation 4 Replace the 4 four M4 bolts in the eccentric and measure the backlash again 5 Continue adjusting the eccentric one hole at a time and checking backlash until an acceptable backlash is REMOVE 4 achieved BOLTS NOTE Make sure when adjusting backlash that you have at least 10 arc seconds of backlash in the gear set or the gears may prematurely wear 6 Put the black round plug back in the eccentric cavity once finished adjusting backlash Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No B 0009500 01 19 22 BS HARDINgE GD5C2 Rotary Indexing System User Manual B 1 19 4 Routine Maintenance 4 1 Use of Oil and Water Soluble Coolants For the use of oil and water soluble coolants the following guidelines should be observed e DO NOT SUBMERGE THE UNIT IN COOLANTS Keep the coolant lines on the workpiece spraying away from the hea
34. tary Indexing System User Manual B 1 19 1 6 Dimensions Single Spindle GD5C2 Rotary Indexer for use with Hardinge Servo Control j 7 98 203 Na 51 13 ma if i ep 4 001 N i 7 101 6025 57h Yo Y 3 0003 Le e gt 175 44 7640076 547 75 19 mi 30003 6 7 178 gt 76 007 lt 15 40 391 gt 139 Front View Side View Back View THE 5C DUAL TRIPLE AND QUAD UNITS CAN BE RUN IN THE HORIZONTAL 3 0003 76 Sone POSITION ONLY 5 8 or 18mm Oil Drain locating pins Plug Bottom View Multiple Spindle GD5C2 02 03 and 04 Rotary Indexer for use with Hardinge Servo Control m2 9 64 245 lt 7 98 203 lt 5 127 lt 5 127 gt lt 5 127 gt m L72 18 1 88 8 CU d9 88 22 E RE 0 53 13 lt 15 88 403 Dual Unit 20 88 530 Triple Unit i 4 25 o lt 27 24 692 Quad Unit 8 50 216 gt Front View Dual Triple Side View with Pneumatic High Force Collet Closer Dual Triple Plates Sura Plate N N Ea Coo 3 3 951 242 Dual Triple 3 3 3 Y oa 10 25 260 Dual Unit 48 12 lt 16 25 387 Triple Unit Others lt 22 97 583 Quad Unit gt Bottom View Quad Side View with Pneumatic High Force Collet Closer Hardinge Inc One Hardinge Drive Elmira New York U S A 14902
35. turned for releasing The High Force Pneumatic Closer can be set for varying gripping force levels by simply adjusting the incoming air pressure within the specified operating range The following closers will accommodate the complete range of Hardinge 5C tooling including step chucks and internal Sure Grip systems Pneumatic Fail Safe Collet Closer The Pneumatic Fail Safe Collet Closer is spring close air to open for fail safe operation The part will remain clamped at an optimum 5C draw bar force of 1760 Ibs 7829 N even if loss of air occurs To release the part piece apply max air pressure of 85 psi A draw bar travel of 060 1 5mm allows varying part diameter of 015 4mm The 1 08 27 4mm through hole accommodates long parts and thru coolant The collet closer is designed so that the indexer can be positioned vertically without any use of a spacer Please contact Hardinge Inc if you plan to replace one of our other closers with a fail safe closer as older indexers may not accept the fail safe closer CAUTION Don t exceed 85 psi while operating the Fail Safe Collet Closer as it may cause fatal damage to the closer and may cause injury to the operator 5C High Force Gloser Increasing air pressure will not aid in gripping of part piece as gripping forces come from internal springs Air Pressure Drawbar Fores pail Ee Pneumatic High Force Collet Closer The Pneumatic High Force Collet Closer is designed with a dual cylinder for
36. x Rotation Step degree Gear Diameter inch mm Motor Type hp kW DC servo Gear Ratio gear set Operating Specifications Duty Cycle Operating Temperature Humidity Power Rating VAC Oil Requirements Weight Rotary Indexer Ib kg Servo Control Ib kg Workholding Collets Round max capacity inch mm Collets Hex max capacity inch mm Collets Square max capacity inch mm Step Chucks Regular Depth inch mm Step Chucks Extra Depth inch mm 3 Jaw Chucks diameter inch mm Sure Grip Expanding Collets inch mm Fixture Plates Spindle Mount dia inch mm Collet Style dia inch mm Slotted Face Plate dia inch mm Collet Stops for Part Positioning 54 73 0 0002 40 0 001 to 360 60 Dual Tapered Roller Bearings Threaded 2 3 16 10 4 000 101 6 0 001 025 25 5 0 001 9999 99 or Continuous Using G83 or G84 in the Hardinge Servo Control 2 8 71 0 78 0 58 With Hardinge Servo Control 60 90 at full speed without tailstock 120 F 49 C 85 Relative Humidity 115 5 10 amp MOBILGEAR 600 XP 220 48 22 10 4 5 16 26 98 29 32 23 01 3 4 19 05 Up to 6 152 4 Up to 6 152 4 5 127 6 152 4 g 3 3 17 76 2 3 5 76 2 127 33 8 43 s 85 72 1 11 12 71178 limited application Yes Part No BJ 0009500 01 19 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com RS HARDINSE GD5C2 Ro
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